The Kubota KX080-4 is a powerful and versatile mini-excavator designed for a variety of tasks. It features a robust engine, a spacious cabin, and a wide range of attachments to handle digging, lifting, and material handling applications. The KX080-4 is known for its maneuverability, making it ideal for tight spaces and demanding jobsites.
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KX080-4
KiSC issued 08, 2015 A
TO THE READER
TO THE READER
I INFORMATION
CONTENTS
INFORMATION
1. SAFETY FIRST ............................................ I-1
2. IN THE INTEREST OF WORK
SAFETY........................................................ I-2
3. LABELS DISPLAYED TO PROMOTE
WORK SAFETY............................................ I-6
4. MAIN SPECIFICATIONS............................ I-12
5. DIMENSIONS ............................................. I-13
G GENERAL
CONTENTS
GENERAL
1. CHECKING EXCAVATOR
IDENTIFICATION ........................................G-1
2. ENGINE IDENTIFICATION .........................G-2
3. MUFFLER FULL ASSEMBLY
IDENTIFICATION ........................................G-5
4. GENERAL PRECAUTIONS.........................G-7
5. HANDLING PRECAUTIONS FOR
ELECTRICAL PARTS AND WIRING.........G-11
6. TIGHTENING TORQUES..........................G-16
7. OIL AND WATER CAPACITY TABLE .......G-20
8. MAINTENANCE INTERVALS....................G-21
1 MACHINE BODY
CONTENTS
SERVICING
1. FRONT ...................................................... 1-S1
2. SWIVEL FRAME........................................ 1-S8
3. TRACK FRAME ....................................... 1-S22
4. MEASURING MACHINE
PERFORMANCE..................................... 1-S38
5. SWIVEL GEAR BACKLASH
PERFORMANCE..................................... 1-S40
2 ENGINE
CONTENTS
GENERAL
1. SPECIFICATIONS.....................................2-G1
2. DIMENSIONS ............................................2-G2
3. PERFORMANCE CURVES.......................2-G3
4. FAN DRIVE................................................2-G4
3 HYDRAULIC SYSTEM
CONTENTS
MECHANISM
1. DIAGRAM OF HYDRAULIC CIRCUIT...... 3-M1
2. HYDRAULIC DEVICE LAYOUT ............... 3-M3
3. PUMP ....................................................... 3-M4
4. CONTROL VALVE.................................. 3-M12
5. SWIVEL MOTOR.................................... 3-M29
6. TRAVEL MOTOR ................................... 3-M34
7. HYDRAULIC CYLINDER........................ 3-M39
8. PILOT VALVE......................................... 3-M42
9. SHOCKLESS VALVES........................... 3-M52
10. SOLENOID VALVE................................. 3-M54
CONTENTS
SERVICING
1. PUMP......................................................... 3-S1
2. CONTROL VALVE................................... 3-S17
3. SWIVEL MOTOR ..................................... 3-S26
4. SWIVEL JOINT ........................................ 3-S41
5. TRAVEL MOTOR..................................... 3-S49
6. CYLINDER............................................... 3-S69
7. PILOT VALVE .......................................... 3-S71
8. SHOCKLESS VALVES .......................... 3-S106
9. SWIVEL SHUTTLE VALVE ................... 3-S107
10. SOLENOID VALVE................................ 3-S108
11. ROUTING OF HYDRAULIC HOSES ..... 3-S112
12. MEASURING HYDRAULIC DEVICE
PERFORMANCE ................................... 3-S133
13. HYDRAULIC DEVICE
PERFORMANCE STANDARDS............ 3-S158
14. TROUBLESHOOTING........................... 3-S165
4 ELECTRICAL SYSTEM
CONTENTS
SERVICING
1. LAYOUT OF ELECTRICAL DEVICES
AND WIRING ROUTING ........................... 4-S1
2. METER PANEL OPERATION ................. 4-S10
3. INSPECTIONS......................................... 4-S44
4. TROUBLESHOOTING (START-UP
EQUIPMENT VERSION) ......................... 4-S50
5. METHODS FOR DIAGNOSING
ERRORS.................................................. 4-S51
6. TROUBLESHOOTING (METER
PANEL VERSION)................................... 4-S53
5 CABIN
CONTENTS
MECHANISM
1. AIR CONDITIONING SYSTEM................. 5-M1
2. WIPER .................................................... 5-M17
SERVICING
1. TROUBLESHOOTING............................... 5-S1
2. SERVICE SPECIFICATIONS .................... 5-S4
3. TORQUE.................................................... 5-S5
4. PRECAUTIONS WHEN REPAIRING
THE REFRIGERANT SYSTEM ................. 5-S6
5. INSPECTING AND CHARGING THE
REFRIGERANT SYSTEM ....................... 5-S11
6. INSPECTION AND DISASSEMBLY ........ 5-S20
7. WINDOW WASHER ................................ 5-S36
8. CABIN GLASS REMOVAL AND
MOUNTING ............................................. 5-S38
9. REMOVAL AND INSTALLATION OF
GLASS ..................................................... 5-S52
10. FRONT WINDOW.................................... 5-S57
KiSC issued 08, 2015 A
This Workshop Manual provides service personnel with information about the mechanisms, service and maintenance of the construction machinery. This Workshop Manual is divided into 3 sections,
General, Mechanisms and Service.
General
This section contains information such as engine and equipment ID numbers, general precautions, maintenance schedules, inspections and maintenance items and special tools.
Mechanisms
This section describes the structure of mechanisms and explains their functions.Be sure that you fully understand this Mechanisms section prior to performing any service work, such as troubleshooting or when performing any disassembly or assembly work.
Service
This section contains information and procedures for performing maintenance on the backhoe, such as troubleshooting, service specification tables, torque specifications, items to be inspected and adjusted, disassembly and assembly procedures, as well as precautions, maintenance standard values and usage limits.
All of the illustrations, specifications and other information in this manual were created based on the latest model at the time of publication.
Please be aware that changes to the content may be made without prior notice.
NOTE
• Corresponding model list
Machine Model Engine Model
KX080-4 V3307-CRS-T4
IMPORTANT
• 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
© KUBOTA Corporation 2013
January, 2013
KiSC issued 08, 2015 A
Record of Revisions
Last digit of the Code
No.
Date
1
Main Revised Point and Corrective Measures
2015.08.05
• Add the contents of pump assembly and disassembly, the contents of cabin glass removal and mounting.
2
Remarks
S. M
3
4
KiSC issued 08, 2015 A
I
KiSC issued 08, 2015 A
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. LABELS DISPLAYED TO PROMOTE WORK SAFETY................................................................. I-6
[1] LOCATIONS............................................................................................................................. I-6
[2] LABEL MAINTENANCE ......................................................................................................... I-11
4. MAIN SPECIFICATIONS.............................................................................................................. I-12
5. DIMENSIONS ............................................................................................................................... I-13
KiSC issued 08, 2015 A
KX080-4, WSM
INFORMATION
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.
• It is important that you thoroughly read these instructions and safety rules prior to working on the equipment and that you always follow them.
DANGER
• Indicates that failure to follow the warning will result in serious injury or death.
WARNING
• Indicates that failure to follow the warning may result in serious injury or death.
CAUTION
• Indicates that failure to follow the warning may result in injury.
IMPORTANT
• Indicates that failure to follow the warning may result in damage to or a breakdown of the equipment.
NOTE
• Indicates supplementary explanations that will be helpful when using the equipment.
[NOTE]
• Indicates other supplementary information to take note of.
RY9212001INI0001US0
I-1
KiSC issued 08, 2015 A
KX080-4, WSM
INFORMATION
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.
• Always stop the engine whenever you leave the driver's seat to inspect or clean the machine or its devices, or to inspect or adjust parts.
• Choose a safe spot for inspecting the equipment-on flat, hard ground.
RY9212001INI0002US0
• When performing maintenance on the equipment, hang the DO NOT OPERATE sign where it will be obvious from and around the driver's seat.
• When performing maintenance or repairs, always lower attachments to the ground, stop the engine and set the brake.
• When performing maintenance on the equipment, always disconnect the negative battery cable.
• Before using tools, make sure you understand how to use them correctly and use tools in good condition and of the right size for the job.
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Be Ready for an Emergency
• Keep a first-aid kit and fire extinguisher close at hand so you can use it when needed.
• Keep emergency contact information for doctors, hospitals and ERs handy.
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I-2
• Wear clothes appropriate for working on equipment.
Do not wear loose-fitting clothes as they may catch on the machine controls.
• When working on the equipment, use all safety gear, such as a helmet, safety glasses and shoes, that are required by law or regulation.
• Never perform maintenance while drowsy or under the influence of alcohol or drugs.
RY9212001INI0005US0
KiSC issued 08, 2015 A
KX080-4, WSM
INFORMATION
• 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.
• When performing work such as with a hammer, fragments may go flying, so make sure only authorized persons are around the machine.
• Before servicing the machine, clean it off so there is no mud, debris, oil or the like sticking to it.
RY9212001INI0006US0
• Before getting on/off of the machine, clean off around the steps so there is no mud on them.
Always give yourself 3-point support when getting on/off the machine.
CAUTION
• 3-point support means using both legs and one hand or both hands and one leg as you climb up/down.
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Starting the Machine Safely
• Before starting the engine, always sit in the driver's seat and make sure the area is safe and clear.
• As it is dangerous, never start the engine from anywhere but the driver's seat.
• Always check and make sure control lever(s) are not engaged before starting the engine.
• Never start the engine by hot-wiring the starter circuit. This is not only dangerous, but may damage the machine.
RY9212001INI0008US0
• Whenever it is necessary to open the engine covers or hood in order to service the machine, always prop them open.
• If it is absolutely necessary to run the engine while working on the machine, make sure you are clear of all rotating or moving parts. Also take care not to leave anything, such as tools or rags, near any moving parts.
RY9212001INI0009US0
I-3
KiSC issued 08, 2015 A
KX080-4, WSM
I-4
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 these fluids have sufficiently cooled.
• Make sure the coolant temperature has dropped sufficiently before opening the radiator cap.
Also, since the inside of the radiator is pressurized, when removing the cap, first loosen it to release the pressure before removing the cap completely.
RY9212001INI0016US0
• The pressure in the hydraulic circuit stays at pressure even after the engine stops.
Before removing parts, such as hydraulic devices from the machine, first release the pressure. Please note that when releasing residual pressure, the machine itself and/or implements may move without warning, so be very careful when releasing the pressure.
• Oil gushing out under pressure is extremely dangerous as it may pierce your skin or your eyes.
Similarly, oil leaking out of pinholes is not visible.
So when checking for oil leaks, always wear safety glasses and gloves and use a piece of cardboard or a wood block to shield yourself from oil.
RY9212001INI0011US0
No Smoking or Open Flames while Fueling
• Fuel is extremely flammable and dangerous.
Never smoke near fuel. If fuel is spilled on the machine, its engine, or electrical parts, it may cause a fire. If fuel is spilled, wipe it all up immediately.
• Never smoke while filling the machine with fuel.
And always tighten the fuel cap securely and wipe up any spilled fuel.
RY9212001INI0012US0
• Always wear safety glasses and gloves when handling the battery.
• The gas generated by the battery is flammable.
Never weld or use tools like a grinder near the battery. And never smoke near it.
• When disconnecting the battery, always disconnect the negative cable first. When connecting the battery, always connect the positive cable first.
RY9212001INI0013US0
KiSC issued 08, 2015 A
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.
RY9212001INI0014US0
Dispose of Waste Fluids Properly
• Never dispose of waste fluids on the ground, in the gutter, a river, pond or lake. Always dispose of hazardous substances like waste oil, coolant and electrolytic fluid in accordance with the relevant environmental protection regulations.
• Keep the safety plates clean so they can be read.
If a safety plate is damaged and comes off or becomes illegible, put a plate with the same warnings back in its place.
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I-5
KiSC issued 08, 2015 A
KX080-4, WSM
INFORMATION
I-6
RY9212158INI0003US0
KiSC issued 08, 2015 A
KX080-4, WSM
INFORMATION
I-7
RY9212158INI0004US0
KiSC issued 08, 2015 A
KX080-4, WSM
INFORMATION
I-8
RY9212158INI0005US0
KiSC issued 08, 2015 A
KX080-4, WSM
INFORMATION
I-9
RY9212158INI0006US0
KiSC issued 08, 2015 A
KX080-4, WSM
INFORMATION
I-10
RY9212158INI0007US0
KiSC issued 08, 2015 A
KX080-4, WSM
INFORMATION
RY9212158INI0008US0
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.
If solvents such as paint thinner or engine oil are used, the text and or figures may fade away.
• When using a pressure washer to clean the equipment, do not spray any labels directly as doing so may make them peel off.
• If a label is damaged or lost, order a new one from your dealer and affix it as before.
• Before affixing a new label, completely wipe off any dirt or grime on the surface, allow it to dry and then affix in the same place.
• When replacing a part that has a label on it, replace the label at the same time.
RY9212001INI0018US0
I-11
KiSC issued 08, 2015 A
KX080-4, WSM
INFORMATION
Model name
Type
Operating weight
(including operator's weight)
Engine
Performance
Type
Model name
Total displacement
Engine power
Rated speed
Low idling speed
Unit swing speed
Travel speed
SAE gross
SAE net
Fast
Slow
Ground pressure
(With operator)
Rubber tracks
8290 kg
18280 lbs
Cabin
KUBOTA EXCAVATOR
KX080-4
Angle Blade type Cabin
Steel tracks
(450 width)
8340 kg
18390 lbs
Steel tracks
(600 width)
8470 kg
18670 lbs
Rubber tracks
8680 kg
19140 lbs
Steel tracks
(450 width)
8730 kg
19250 lbs
Water cooled 4 cycle diesel engine with 4 cylinder
KUBOTA V3307-CRS-T4
3331 cc (203.3 cu.in.)
52.2 kW (70.0 Hp)
48.8 kW (65.5 Hp)
2000 rpm
36.0 kPa
(0.367 kgf/cm
2
5.22 psi
)
1000 rpm
9.5 rpm
36.2 kPa
(0.369 kgf/cm
2
)
5.25 psi
4.9 km / h (3.1 mph)
2.7 km / h (1.7 mph)
27.6 kPa
(0.281 kgf/cm
2)
4.00 psi
*36 % (20 deg)
37.5 kPa
(0.382 kgf/cm
2
)
5.44 psi
37.7 kPa
(0.384 kgf/cm
2
5.47 psi
)
Climbing angle
Angle in case of crossing slope
*27 % (15 deg)
Width x Height
Blade
Max swing
Left
Right
Pressure connection for attachments
Left
Boom swing angle
Right
Max. displacement
(Theoretical)
Max. pressure
2200 x 500 mm
86.6 x 19.7 in.
–
–
1.22 rad (70 deg)
1.05 rad (60 deg)
100 L (26.4 U.S.gal) / min
2200 x 510 mm
86.6 x 20.1 in.
0.44 rad (25 deg)
0.44 rad (25 deg)
20.6 MPa
210 kgf/cm
2
2987 psi
115 L (30.4 U.S.gal) Fuel tank capacity
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.
• Operators must exercise extra caution and follow instructions in the operator's manual.
• Worse condition or heavier attachment to the above will decrease climbing angle.
RY9212158INI0001US0
I-12
KiSC issued 08, 2015 A
KX080-4, WSM
INFORMATION
(1) Arm length (2100 Arm)
KX080-4
(A)
590 mm
23.2 in.
KX080-4
KX080-4
(H)
1460 mm
57.5 in.
(O)
7170 mm
282.3 in.
(B)
770 mm
30.3 in.
(I)
4990 mm
196.5 in.
(P)
1460 mm
57.5 in.
(C)
2200 mm
86.6 in.
(J)
7330 mm
288.6 in.
(Q)
6450 mm
253.9 in.
(D)
7300 mm
287.4 in.
(K)
500 mm
19.7 in.
(R)
2150 mm
84.6 in.
(E)
5250 mm
206.7 in.
(L)
500 mm
19.7 in.
(S)
2490 mm
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.
(F)
4600 mm
181.1 in.
(M)
2540 mm
100.0 in.
(G)
3850 mm
151.6 in.
(N)
2200 mm
86.6 in.
RY9212158INI0002US0
I-13
KiSC issued 08, 2015 A
G
KiSC issued 08, 2015 A
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. GENERAL PRECAUTIONS.......................................................................................................... G-7
5. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING .................................. G-11
[1] WIRING ................................................................................................................................ G-11
[2] FUSES.................................................................................................................................. G-13
[3] CONNECTOR ...................................................................................................................... G-13
[4] WASHING THE MACHINE WITH A HIGH-PRESSURE WASHER ..................................... G-15
6. TIGHTENING TORQUES........................................................................................................... G-16
[1] TORQUES FOR GENERAL USE NUTS AND BOLTS ........................................................ G-16
[2] TORQUE FOR HYDRAULIC HOSE FITTINGS ................................................................... G-17
(1) Torque for Hydraulic Hose Fittings ................................................................................. G-17
(2) Torques of Lock-Nuts for Elbows with Male Seats and Adaptors with O-rings
(Straight Threads)........................................................................................................... G-17
[3] HOSE CLAMP SCREW TORQUE ....................................................................................... G-18
7. OIL AND WATER CAPACITY TABLE ........................................................................................ G-20
8. MAINTENANCE INTERVALS..................................................................................................... G-21
KiSC issued 08, 2015 A
KX080-4, WSM
GENERAL
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
(Model, frame number, engine number)
(2) Frame Number
(3) Engine Number
(a) Model Nameplate
RY9212148GEG0001US0
G-1
KiSC issued 08, 2015 A
KX080-4, WSM
GENERAL
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.
Engine Serial No.
The engine serial number is the numerical ID of the engine and is printed after the engine's model number.
The year and month of manufacture are indicated as follows.
Engine Series
Number or
Alphabet
1
2
3
4
5
Production Year
Alphabet or
Number
1
6
7
8
9
2
3
4
5
C
D
E
A
B
Series
05 (include: WG)
V3
08
SM (include: WG)
Air Cooled
Gasoline
Year
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
2011
2012
2013
2014
Number or
Alphabet
6
7
8
A
B
Alphabet or
Number
F
G
H
J
K
L
M
N
P
R
S
T
V
Series
GZ, OC, AC, EA,
E
03
07
EA, RK
03 (KET
Production)
Year
2020
2021
2022
2023
2024
2025
2026
2027
2015
2016
2017
2018
2019
(1) Engine Model Name and Serial
Number
(To be continued)
G-2
KiSC issued 08, 2015 A
KX080-4, WSM
(Continued)
GENERAL
Production Month and Lot Number
Month Engine Lot Number
January
February
March
April
May
June
July
August
September
October
November
December
A0001 to A9999
C0001 to C9999
E0001 to E9999
G0001 to G9999
J0001 to J9999
L0001 to L9999
N0001 to N9999
Q0001 to Q9999
S0001 to S9999
U0001 to U9999
W0001 to W9999
Y0001 to Y9999 from B0001 from D0001 from F0001 from H0001 from K0001 from M0001 from P0001 from R0001 from T0001 from V0001 from X0001 from Z0001
* Alphabetical letters "I" and "O" are not used.
(a) e.g. V2607
(b) (c) (d)
- 8 C L
(e)
A001
(a)
V2607
: Engine Model Name
(b)
8
: Engine Series (07 series)
(c)
C
: Production Year (2012)
(d)
L
: Production Month (June)
(e)
A001
: Lot Number: (
0001 to 9999
or
A001 to Z999
)
RY9212148GEG0002US0
[Example: Engine Model Name V2607-CR-
TE4(C)B
-XXXX or V2607-CR-
TIE4(C)B
-XXXX]
The emission controls previously implemented in various countries to prevent air pollution will be stepped up as
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).
When servicing or repairing ###-E4B series engines, use only replacement parts for that specific E4B engine, designated by the appropriate KUBOTA Parts List and perform all maintenance services listed in the appropriate
KUBOTA Operator's Manual or in the appropriate KUBOTA Workshop Manual. Use of incorrect replacement parts or replacement parts from other emission level engines (for example: E3B engines), may result in emission levels out of compliance with the original E4B design and EPA or other applicable regulations.Please refer to the emission label located on the engine head cover to identify Output classification and Emission Control Information. E4B engines are identified with "EF" at the end of the Model designation, on the US EPA label. Please note: E4B is not marked on the engine.
Category (1)
EF
Engine output classification
Less than 19 kW
From 19 to less than 56 kW
From 56 to less than 75 kW
From 75 to less than 130 kW
EPA regulation
Tier 4
Interim Tier 4
Interim Tier 4
Interim Tier 4
NOTE
• "E4B" engines are identified with "EF" at the end of the
Model designation, on the US EPA label.
"E4B" designates some Interim Tier 4 / Tier 4 models, depending on engine output classification.
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G-3
KiSC issued 08, 2015 A
KX080-4, WSM
GENERAL
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.
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G-4
KiSC issued 08, 2015 A
KX080-4, WSM
GENERAL
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.
It shows the month and year of manufacture as below.
Year of manufacture
Alphabet or
Number
Year
C
D
E
8
9
A
B
4
5
6
7
1
2
3
2008
2009
2010
2011
2012
2013
2014
2001
2002
2003
2004
2005
2006
2007
Alphabet or
Number
F
J
K
G
H
L
M
N
P
R
S
T
V
Year
Month of manufacture
Month
January
February
March
April
May
June
July
August
September
October
November
December
DPF Muffler Full Assembly Lot Number
A0001 to A9999 B0001 to BZ999
C0001 to C9999
E0001 to E9999
G0001 to G9999
D0001 to DZ999
F0001 to FZ999
H0001 to HZ999
J0001 to J9999
L0001 to L9999
N0001 to N9999
Q0001 to Q9999
S0001 to S9999
U0001 to U9999
W0001 to W9999
Y0001 to Y9999
K0001 to KZ999
M0001 to MZ999
P0001 to PZ999
R0001 to RZ999
T0001 to TZ999
V0001 to VZ999
X0001 to XZ999
Z0001 to ZZ999
2022
2023
2024
2025
2026
2027
2015
2016
2017
2018
2019
2020
2021
* Alphabetical letters "I" and "O" are not used.
(a) (b) e.g. C L
(c)
0019
(1) DPF Muffler Full Assembly Part Number and Serial Number
(a) Year: C indicates 2012
(b) Month: L or M indicates June
(c) Lot Number: (
0001 to 9999
or
A001 to Z999
)
RY9212148GEG0004US0
G-5
KiSC issued 08, 2015 A
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
Serial Number
(2) Filter Comp (DPF) Part Number and
Serial Number
(3) Catalyst (DOC) Part Number and
Serial Number
RY9212148GEG0005US0
G-6
KiSC issued 08, 2015 A
KX080-4, WSM
GENERAL
Whenever performing maintenance on the machine, always read the Safety Precautions in this manual and the Operator's
Manual carefully, become familiar with them and perform the work safely.
Before performing any maintenance on the machine, make sure it is sufficiently clean and choose a sufficiently clean location to perform any disassembly.
Before performing maintenance on the machine, always disconnect the negative battery cable first.
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.
RY9212001GEG0011US0
Plumber's Tape
• Wrap plumber's tape on the threads before tightening taper couplings. After wrapping (2 wraps) the plumber's tape, tighten to the specified torque. Once the coupling is tightened, do not loosen it as this will cause an oil leak.
(1) Plumber's Tape
(2) External Thread
(3) Internal Thread
(4) Gap
(5) Leave 1 to 2 Threads
RY9212001GEG0012US0
O-Ring
• Clean the groove the O-ring goes in and remove any burrs.
Apply grease on the O-ring when inserting it in the groove.
(Except floating seals)
• When putting the O-ring in the groove, be careful as it is easy at the very end to twist the O-ring against the inside of the groove.
If it gets twisted, roll it gently with your fingertip to untwist it.
(1) O-Ring Groove
(2) O-Ring
(3) Check for Burrs
(4) If the Ring Touches This Corner, It
Will Twist
RY9212001GEG0013US0
Oil Seal
• Do not face the lip of the oil seal in the wrong direction. Face the main lip toward the material to be sealed.
• After oil seals are replaced, apply grease to the moving parts around the lip to prevent the dry surfaces from wearing against each other when the engine is started. If the seal has a dust lip, fill the gap between the lips with grease.
• As a general rule, use a press to insert the oil seal in place.
If that is not possible, use an appropriate tool to gently and evenly tap it into place, taking care that it does not go in at a slant. Press the seal all the way so it seats in the boss.
(1) Gasket
(2) Metal Ring
(3) Spring
(4) Main Lip
(5) Grease
(6) Dust Lip
A : Air (Outside)
B : Hydraulic Chamber (Inside)
RY9212001GEG0014US0
G-7
KiSC issued 08, 2015 A
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.
• Apply a light film of oil to surrounding surfaces when working to get the floating seal with O-ring in place; take care that the surrounding surfaces, O-ring and housing are parallel with each other.
• After getting the seal in place, turn the engine over 2 or 3 revolutions, to both create a film of oil on surrounding surfaces and to properly seat the face of the seal.
(1) Surrounding Surfaces (2) O-Ring
RY9212001GEG0015US0
Snap Ring Related
• When installing external or internal snap rings, orient them as shown in the diagram so the angled side faces the direction of force.
(1) Position so the Angled Part
Receives the Force
(A) External
(B) Internal
RY9212001GEG0016US0
Spring Pins
• When driving a spring pin, face the split in the direction that receives the force, as shown in the diagram.
(1) With Lateral Movement (2) With Rotational Movement
RY9212001GEG0017US0
Adhesive
• Clean and dry the area where adhesive will be applied with a solvent so it is free of moisture, oil and dirt.
• Apply adhesive all around the threads of the bolt except the first set of threads at the tip and fill the grooves between the threads.
If the threads or the grooves are large, adjust the amount of adhesive accordingly and apply it all around the bolt hole as well.
(A) Bolt Through-Hole (Nut)
(B) Pocket Bolt Hold
(Capsule Shape, etc.)
(a) Apply Here
(b) Do Not Apply
(c) Drip On
RY9212001GEG0018US0
G-8
KiSC issued 08, 2015 A
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
(B) Across Diagonally
(C) Diagonally Across the Center
RY9212001GEG0019US0
Assembling Hydraulic Hoses
• Tighten to their specified torque.
• Before assembling, wipe the inside of metal fittings clean of any dirt.
• After assembly, put the fitting under normal pressure and check that it does not leak.
RY9212001GEG0020US0
Elbow with Male Seat Assembly Procedure
When assembling an elbow with male seat, adhere to the following procedures to prevent deformation of O-rings and leaks.
1. Connecting to Valves
• Clean the blow with male seat and the surface of the seal opposite and mount with the lock-nut on top.
• Finger tighten till it touches the washer.
2. Positioning
• Turn the mouth of the elbow back so it faces the right direction. (not back over 1 turn)
3. Fasten
• Tighten the lock-nut to the specified torque with a wrench.
(1) Lock-Nut
(2) Washer
(3) Seal (O-Ring)
(4) Wrench for Holding
(5) Hose
(6) Torque Wrench for Tightening
RY9212001GEG0021US0
G-9
KiSC issued 08, 2015 A
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. Then check that it will not pull off.
(1) Plastic Part (2) Fitting
RY9212001GEG0022US0
Connecting the face sealing (ORS) type hose
1. Remove the protective cap from the adapter and make sure the
O-ring is installed in its groove. (If the O-ring is missing, fit the specified-size in position.)
2. Shift the hose's cap nut in the direction of arrow until the O-ring contact face stretched out of the cap nut.
3. Bring the hose's O-ring contact face in close contact with the joint's O-ring.
Make sure they do not come off each other.
4. Tighten up the cap nut to the specified torque.
(1) Protective cap
RY9212038GEG0005US0
G-10
KiSC issued 08, 2015 A
KX080-4, WSM
GENERAL
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.
• Do not alter or rewire any electrical parts or wiring.
• Always remove the negative battery cable first when disconnecting the battery and attach the positive cable first when connecting it.
(1) Battery Cable (-) Side (2) Battery Cable (+) Side
RY9212001GEG0023US0
• Tighten wiring terminals securely.
(1) Correct (Tightened Securely) (2) Incorrect (Poor Contact if Loose)
RY9212001GEG0024US0
• Keep wiring away from hazards.
(1) Hazardous Positioning
(2) Wiring Position (Wrong)
(3) Wiring Position (Right)
(4) Hazardous Position
RY9212001GEG0025US0
• Immediately repair or replace old or damaged wiring.
(1) Damaged
(2) Torn
(3) Electrical Tape
RY9212001GEG0026US0
G-11
KiSC issued 08, 2015 A
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)
(2) Wire
(3) Clamp
(4) Welding Mark
RY9212001GEG0028US0
• Clamp wiring so it is not twisted, pulled too tight or sag too much. However, moving parts may require play in the wiring.
(1) Wire
(2) Clamp
(A) Correct
(B) Incorrect
RY9212001GEG0029US0
• Do not pinch or bind wiring when installing parts.
(1) Wire
(A) Incorrect
RY9212001GEG0030US0
• After wiring, double-check terminal protectors and clamps before connecting battery cables.
(1) Cover (Install Covers Securely)
RY9212001GEG0031US0
G-12
KiSC issued 08, 2015 A
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
(B) Diagram of Modification
(a) Standard Wiring
(b) Modified Wiring
RY9212038ELS0008US0
• Always use fuses of the specified capacity.
Never use over or undersized fuses.
• Never use copper or steel wire in place of a fuse.
• Do not install accessories such as work lights, radios, etc., if your machine does not have an auxiliary circuit.
• Do not install accessories as they will exceed the capacity of fuses.
(1) Fuse
(2) Fusible Link
(3) Slow-Blow Fuse
RY9212001GEG0032US0
Connectors
The terminals of female connector are numbered from #1 on the top right when facing it.
Male terminals are numbered from #1 on the top left.
(A) Female connector terminals (B) Male connector terminals
RY9212038ELS0010US0
• Press the lock to disconnect locking connectors.
(A) Push
RY9212001GEG0033US0
G-13
KiSC issued 08, 2015 A
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 force)
(A) Pull (B) Loosened Crimping
RY9212038ELS0011US0
• Straighten bent prongs and make sure none are sticking out or missing.
• Remove corrosion from terminals with sandpaper.
(1) Missing Terminal
(2) Bent Prong
(3) Sandpaper
(4) Corrosion
RY9212001GEG0035US0
• Do not touch the terminals of connectors with bare hands.
(A) Do not touch
RY9212038ELS0012US0
• Female connectors must not be spread too far open
(A) Correct (B) Incorrect
RY9212001GEG0036US0
G-14
KiSC issued 08, 2015 A
KX080-4, WSM
GENERAL
• The plastic covers of connectors must cover them completely.
(1) Cover
(A) Correct
(B) Incorrect
RY9212001GEG0037US0
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.
CAUTION
• Stand at least 2.0 meters from the machine and adjust the nozzle for a wide spray so it does not cause any damage.
If you blast the machine with water or wash it from too close a distance,
1. It may cause a fire due to damaged or cuts in the insulation of electrical wiring.
2. An injury may result if hydraulic oil gushes out under high pressure, due to damaged hydraulic hoses.
3. It may damage, break or cause parts of the machine to fail.
(Ex.)
(1) Stickers or labels may come off
(2) Electrical parts or the engine may fail due to water in them.
(3) Damage glass, resins, etc. or the rubber of oil seals.
(4) Tear off paint or the film from plating
(1) Do Not Blast with Water
(2) Never Wash from Too Close
(A) Blasting
(B) Wide Spray
(C) Less Than 2.0 m (80 in.)
(D) Over 2.0 m (80 in.)
RY9212001GEG0038US0
G-15
KiSC issued 08, 2015 A
KX080-4, WSM
GENERAL
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
No-grade or 4T 7T 9T
Indication on top of nut
Material of opponent part
Unit
M6
M8
M10
M12
M14
M16
M18
M20
246 to
284
334 to
392
108 to
125
167 to
191
40 to
45
63 to
72
No-grade or 4T
Ordinariness Aluminum Steel Aluminum
6T
Steel
N·m kgf·m lbf·ft N·m kgf·m lbf·ft N·m kgf·m lbf·ft N·m kgf·m lbf·ft N·m kgf·m lbf·ft
7.9 to
9.3
18 to
20
0.8 to
0.95
1.8 to
2.1
5.8 to
6.8
13 to
15
7.9 to
8.8
17 to
19
0.8 to
0.9
1.7 to
2.0
5.8 to
6.5
13 to
14
9.81 to
11.2
24 to
27
1.0 to
1.15
2.4 to
2.8
7.24 to
8.31
18 to
20
7.9 to
8.8
18 to
20
0.8 to
0.9
1.8
to
2.1
5.8
to
6.5
13 to
15
12.3 to
14.2
30 to
34
1.25 to
1.45
3.0 to
3.5
9.05 to
10.4
22 to
25
4.0 to
4.6
6.4 to
7.4
11 to
12.8
17 to
19.5
29 to
33
47 to
53
79.6 to
92.5
123 to
141
32 to
34
–
–
–
3.2 to
3.5
–
–
–
24 to
25
–
–
–
48 to
55
78 to
90
124 to
147
197 to
225
4.9 to
5.7
7.9 to
9.2
12.6 to
15
20 to
23
36 to
41
58 to
66
91.2 to
108
145 to
166
40 to
44
63 to
72
–
–
4.0 to
4.5
6.4 to
7.4
–
–
29 to
32
47 to
53
–
–
61 to
70
103 to
117
167 to
196
260 to
304
6.2 to
7.2
10.5 to
12
17 to
20
26.5 to
31
123 to
144
192 to
224
45 to
52
76 to
86.7
25 to
29
34 to
40
181 to
209
246 to
289
–
–
–
–
–
–
275 to
318
368 to
431
28 to
32.5
37.5 to
44
203 to
235
272 to
318
–
–
–
–
–
–
344 to
402
491 to
568
35 to
41
50 to
58
254 to
296
362 to
419
RY9212032GEG0001US0
G-16
KiSC issued 08, 2015 A
KX080-4, WSM
GENERAL
Union nut (metal seal type)
1/8
7.8 to 11.8 N·m
0.8 to 1.2 kgf·m
5.7 to 8.7 lbf·ft
1/4
3/8
24.5 to 29.2 N·m
2.5 to 3.0 kgf·m
18.1 to 21.7 lbf·ft
37.2 to 42.1 N·m
3.8 to 4.3 kgf·m
27.5 to 31.1 lbf·ft
1/2
3/4
1 - 1/4
58.8 to 63.7 N·m
6.0 to 6.5 kgf·m
43.4 to 47.0 lbf·ft
117.6 to 127.4 N·m
12.0 to 13.0 kgf·m
86.8 to 94.0 lbf·ft
220.5 to 230.3 N·m
22.5 to 23.5 kgf·m
162.7 to 169.8 lbf·ft
–
Union nut (ORS type)
9/16UNF
11/16UNF
13/16UNF
1-14UNS
–
–
35.2 to 43.1 N·m
3.6 to 4.4 kgf·m
26.0 to 31.8 lbf·ft
60.0 to 73.5 N·m
6.1 to 7.5 kgf·m
44.3 to 54.2 lbf·ft
70.6 to 86.2 N·m
7.2 to 8.8 kgf·m
52.1 to 63.6 lbf·ft
105.8 to 129.4 N·m
10.8 to 13.2 kgf·m
78.0 to 98.4 lbf·ft
–
RY9212148GEG0006US0
Tightening torque
(1) Lock-nut
(2) Washer
1/8
1/4
3/8
1/2
3/4, 1
1-1/4
7/8 - 14UNF
15.0 to 16.5 N·m
1.5 to 1.7 kgf·m
11.1 to 12.2 lbf·ft
24.5 to 29.4 N·m
2.5 to 3.0 kgf·m
18.1 to 21.7 lbf·ft
49.0 to 53.9 N·m
5.0 to 5.5 kgf·m
36.1 to 39.8 lbf·ft
58.8 to 63.7 N·m
6.0 to 6.5 kgf·m
43.4 to 47.0 lbf·ft
117.6 to 127.4 N·m
12.0 to 13.0 kgf·m
86.8 to 94.0 lbf·ft
220.5 to 230.3 N·m
22.5 to 23.5 kgf·m
162.8 to 170.0 lbf·ft
55.9 to 60.8 N·m
5.7 to 6.2 kgf·m
41.2 to 44.8 lbf·ft
(3) Seal (O-ring)
RY9212148GEG0007US0
G-17
KiSC issued 08, 2015 A
KX080-4, WSM
Type 1
GENERAL
Tightening torque
10- 14
12- 16
19- 25
31- 40
36- 46
44- 53
51- 59
86- 96
6C040-58721
09318-89016
09318-89024
09318-89039
09318-89045
09318-89052
09318-89058
RD809-42241
2.5 to 3.4 N·m
25 to 35 kgf·cm
1.8 to 2.5 lbf·ft
2.5 to 3.4 N·m
25 to 35 kgf·cm
1.8 to 2.5 lbf·ft
2.5 to 3.4 N·m
25 to 35 kgf·cm
1.8 to 2.5 lbf·ft
2.5 to 3.4 N·m
25 to 35 kgf·cm
1.8 to 2.5 lbf·ft
2.5 to 3.4 N·m
25 to 35 kgf·cm
1.8 to 2.5 lbf·ft
3.9 to 4.9 N·m
40 to 50 kgf·cm
2.9 to 3.6 lbf·ft
3.9 to 4.9 N·m
40 to 50 kgf·cm
2.9 to 3.6 lbf·ft
2.5 to 3.4 N·m
25 to 35 kgf·cm
1.8 to 2.5 lbf·ft
RY9212001GEG0045US0
G-18
KiSC issued 08, 2015 A
KX080-4, WSM
Type 2
Tightening torque
GENERAL
13- 20
15- 25
19- 28
22- 32
26- 38
32- 44
44- 56
50- 65
58- 75
60- 80
68- 85
77- 95
RB101-63631
RC101-64581
R1401-63211
R1401-63151
68311-72821
RD411-63821
35820-15181
RC401-63191
36919-04591
RD809-63101
RD809-63061
69284-63171
2.5 to 3.4 N·m
25 to 35 kgf·cm
1.8 to 2.5 lbf·ft
4.9 to 5.9 N·m
50 to 60 kgf·cm
3.6 to 4.3 lbf·ft
4.9 to 5.9 N·m
50 to 60 kgf·cm
3.6 to 4.3 lbf·ft
4.9 to 5.9 N·m
50 to 60 kgf·cm
3.6 to 4.3 lbf·ft
4.9 to 5.9 N·m
50 to 60 kgf·cm
3.6 to 4.3 lbf·ft
4.9 to 5.9 N·m
50 to 60 kgf·cm
3.6 to 4.3 lbf·ft
4.9 to 5.9 N·m
50 to 60 kgf·cm
3.6 to 4.3 lbf·ft
4.9 to 5.9 N·m
50 to 60 kgf·cm
3.6 to 4.3 lbf·ft
4.9 to 5.9 N·m
50 to 60 kgf·cm
3.6 to 4.3 lbf·ft
4.9 to 5.9 N·m
50 to 60 kgf·cm
3.6 to 4.3 lbf·ft
4.9 to 5.9 N·m
50 to 60 kgf·cm
3.6 to 4.3 lbf·ft
4.9 to 5.9 N·m
50 to 60 kgf·cm
3.6 to 4.3 lbf·ft
RY9212001GEG0046US0
G-19
KiSC issued 08, 2015 A
KX080-4, WSM
Item
Engine oil (when filter changed)
Coolant
Reserve tank
Fuel (full)
Hydraulic oil
Total volume (Std. spec.)
Inside tank (gauge middle)
Travel motor
Idler assy
Track rollers
Carrier rollers
Grease
KX080-4
9.7 L (2.6 U.S.gal)
10.5 L (2.77 U.S.gal)
1.3 L (0.34 U.S.gal)
115 L (30.4 U.S.gal)
146 L (38.6 U.S.gal)
75 L (20.0 U.S.gal)
1.35 L (0.36 U.S.gal)
80 ml (4.88 cu.in.)
80 ml (4.88 cu.in.)
80 ml (4.88 cu.in.)
–
GENERAL
API type, CJ-4
Notes
Antifreeze Kubota LLC-N-50F
Mixture ratio 50%
JIS #3 diesel
Tellus oil S2M46
Gear oil SAE#90 (API GL-4)
Engine oil SAE #30CD (monograde)
EP2
RY9212158GEG0001US0
G-20
KiSC issued 08, 2015 A
KX080-4, WSM
GENERAL
No.
1 Coolant
2 Fuel
Check points
3 Engine oil
4 Hydraulic oil
5
Grease front attachments
Bucket and bucket link pin
/ Dozer angle pin and angle cylinder boss
Boom swing fulcrum
Others
Measures
check
Hour meter indication
50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 1000
Daily check
Interval
change check check
Daily check
Daily check every
2 years change check Daily check
every
500 hrs change
every
1000 hrs
*1
–
–
–
Daily check
every
100 hrs every
250 hrs
6 Radiator and oil cooler
7 Washer liquid check check
8 Engine and electrical wiring check
Daily check
Daily check
Daily check
9 Water separator
10 Fuel tank
11 Battery condition
12
Greasing swing bearing teeth drain drain check
– check
Daily check
every
50 hrs every
50 hrs every
50 hrs every
50 hrs
13 V-belt tension adjust
14 Radiator hoses and clamps
15
Air filter element
23 Injector tip
Outer element
Inner element replace
16 Greasing swing ball bearing
17 Fuel filter cartridge
18 Engine oil filter
19 Drive unit oil
20
21
22
Hydraulic return filter cartridge
Hydraulic suction filter element
Filter in the pilot hydraulic system check replace clean replace
– replace replace change replace replace replace check
every
500 hrs every
500 hrs every
500 hrs every
1000 hrs every
1000 hrs every
1500 hrs every
200 hrs every
200 hrs every
2 years every
200 hrs every
1000 hrs every
1000 hrs every
200 hrs every
500 hrs
*2
*2
*2
*4
*4
@
@
*4 @
G-21
KiSC issued 08, 2015 A
KX080-4, WSM
GENERAL
No.
24 Oil separator element
25 EGR cooler
26 Front idler and track roller oil change
27 Alternator and starter motor check
28 EGR system
29 Turbo charger
30 DPF
31
Check points
Boost sensor and AFS
(Air flow sensor)
32 Condition of DPF muffler
Measures
Hour meter indication
50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 1000
Interval
replace check check check clean check check every
1500 hrs every
1500 hrs every
2000 hrs every
2000 hrs every
3000 hrs every
3000 hrs every
3000 hrs every
1 year every
1 year
33
34
DPF differential pressure sensor and piping for gas leak
DPF exhaust gas temperature sensor check check every
1 year
35 EGR and piping for gas leak check
36 Radiator system
37 Fuel line and intake air line rinse check replace
every
1 year every
1 year every
2 years every
200 hrs every
2 years every
2 years
38
39
40
41
Closed breather related rubber piping
DPF differential pressure sensor rubber piping (Front and back) replace replace
Suction pipe downstream the
AFS replace
Boost sensor pressure rubber piping replace
42 EGR cooler hose replace every
2 years every
2 years every
2 years every
2 years
*4 @
*4
*4
*4
*4
*4
*4
*4
*4
*4
*4
*4
*4
*3
*4
*4
*4
*4
*4
@
G-22
KiSC issued 08, 2015 A
KX080-4, WSM
GENERAL
Air conditioner
No.
Check points Measures
Hour meter indication
50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 1000
Interval
1 Air filter
2 Air-conditioner condenser
3
Air-conditioner pipes and hose
4 Refrigerant (gas) clean replace check check replace check
every
200 hrs every
1000 hrs every
200 hrs every
1 year every
2 years service as required
*2
*2
*4
IMPORTANT
•
: First operation
• *1 : When using a hydraulic hammer, change hydraulic oil and return filter according to the table on
"Hydraulic Oil Change (Including Exchange of the Suction Filter in the Hydraulic Tank) under "EVERY
1000 SERVICE HOURS" in the chapter "REGULAR CHECKS AND MAINTENANCE WORK".
*2 : Clean and replace the air filter more frequently if used under dusty conditions. When the filter is very dirty from dusty conditions, replace the filter.
*3 : Replace only if necessary.
*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. Please see the Warranty
Statement in detail.
RY9212158GEG0002US0
NOTE
Engine Oil:
• Oil used in the engine should have an American Petroleum Institute (API) service classification and
Proper SAE Engine Oil according to the ambient temperatures.
Above 25 °C (77 °F)
0 to 25 °C (32 to 77 °F)
Below 0 °C (32 °F)
SAE30 or SAE 10W-30, SAE 15W-40
SAE20 or SAE 10W-30, SAE 15W-40
SAE10W or SAE 10W-30, SAE 15W-40
• Refer to the following table for the suitable API classification engine oil and the fuel.
Fuel used
Engine oil classification (API classification)
Oil class of engines except external DPF
Ultra Low Sulfur Fuel [< 0.0015 % (15 ppm)]
CJ-4
Fuel:
• Use the ultra low sulfur diesel fuel only [below 0.0015 % (15 ppm)] for these engines.
• Cetane number of 45 minimum. Cetane number greater than 50 is preferred, especially for temperatures below
-20 °C (-4 °F) or elevations above 1500 m (5000 ft).
• Diesel fuels specified to EN 590 or ASTM D975 are recommended.
• No. 2-D is a distillate fuel of lower volatility for engines in industrial and heavy mobile service. (SAE J313 JUN87)
• Indicated capacities of water and oil are manufacture's estimate.
IMPORTANT
• If you use different fuel or engine oil, the cleaning interval of the DPF (3000 hours) can't be secured and the DPF will be clogged for a shorter time than expected.
• Filters must trap fuel and lubricant sulfate additives (Zn, Pb, Na, K, Ca, Mg, Cu, Ba, P, etc.) as ash during combustion. Fuel must be controlled carefully to prevent the additives being mixed into fuel such as fuel tank anti-oxidants, water remover, anti-freeze and so on.
RY9212158GEG0003US0
G-23
KiSC issued 08, 2015 A
1
KiSC issued 08, 2015 A
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
(1) DPF Muffler ...................................................................................................................1-S16
(2) Engine ...........................................................................................................................1-S18
[6] ASSEMBLING OPERATING LEVERS................................................................................1-S21
(1) Travel Lever...................................................................................................................1-S21
(2) Blade Lever ...................................................................................................................1-S21
(3) Limit Switch ...................................................................................................................1-S21
3. TRACK FRAME .........................................................................................................................1-S22
[1] SWIVEL BEARING ASSEMBLY/DISASSEMBLY ...............................................................1-S22
[2] TRACK ................................................................................................................................1-S23
(1) Assembly/Disassembly of the Rubber Track.................................................................1-S23
(2) Assembly/Disassembly of Iron Tracks...........................................................................1-S24
(3) Steel Track Removal/Installation Tools .........................................................................1-S27
[3] FRONT IDLER.....................................................................................................................1-S30
(1) Assembly/Disassembly of Front Idler ............................................................................1-S30
(2) Assembly/Disassembly of the Front Idler ......................................................................1-S30
[4] GREASE CYLINDER ..........................................................................................................1-S32
(1) Assembly/Disassembly of the Grease Cylinder.............................................................1-S32
(2) Components ..................................................................................................................1-S32
[5] TENSIONER........................................................................................................................1-S33
(1) Tensioner Assembly/Disassembly.................................................................................1-S33
[6] TRACK ROLLERS...............................................................................................................1-S34
(1) Track Roller Assembly/Disassembly .............................................................................1-S34
(2) Components ..................................................................................................................1-S34
[7] CARRIER ROLLERS...........................................................................................................1-S35
(1) Carrier Roller Assembly/Disassembly ...........................................................................1-S35
(2) Components ..................................................................................................................1-S35
[8] TABLE OF DIMENSIONS ...................................................................................................1-S36
(1) Rubber Track.................................................................................................................1-S36
(2) Steel Track ....................................................................................................................1-S36
(3) Idler Sprocket ................................................................................................................1-S37
(4) Carrier Rollers and Track Rollers ..................................................................................1-S37
4. MEASURING MACHINE PERFORMANCE ..............................................................................1-S38
[1] MEASURING FRONT PERFORMANCE ............................................................................1-S38
(1) Measuring Swivel Gear Backlash..................................................................................1-S38
(2) Measuring Swivel Bearing Play .....................................................................................1-S39
KiSC issued 08, 2015 A
5. SWIVEL GEAR BACKLASH PERFORMANCE .........................................................................1-S40
KiSC issued 08, 2015 A
KX080-4, WSM
MACHINE BODY
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.
• Never put your finger in the pin hole when aligning the pin with the hole.
• When hoisting anything heavy, always determine its center of gravity before hoisting it.
• When working with a sling, use a cloth or the like in places that may be hit hard by the nylon sling.
RY9212148MBS0012US0
1. Lower the front to the ground.
Remove the AUX lines from each bracket and disconnect the bucket cylinder hoses.
(1) AUX line (2) Bucket cylinder hose
RY9212148MBS0017US0
2. Suspend the arm cylinder temporarily and remove the pin on the rod side.
Operate the crane and lower the arm cylinder onto a block on top of the boom.
(1) Arm Cylinder (2) Block
RY9212148MBS0018US0
3. Suspend the arm and bucket temporarily with the crane, then remove the linkage pin between the arm and the boom and then remove the bucket and the arm.
Weight Approx. 510 kg (1120 lbs)
(1) Pin
RY9212148MBS0019US0
4. Set the end of the boom on the ground.
Suspend the boom cylinder temporarily and remove the pin on the rod side.
Operate the crane and lower the boom cylinder onto a stand.
(1) Pin (2) Cylinder stand
RY9212148MBS0020US0
1-S1
KiSC issued 08, 2015 A
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. Operate the crane and remove the boom.
Boom weight Approx. 500 kg (1102 lbs)
RY9212148MBS0023US0
8. Perform the procedure in reverse for assembly.
RY9212148HYS0096US0
1-S2
KiSC issued 08, 2015 A
KX080-4, WSM
NOTE
• Kubota Japan bucket
MACHINE BODY
No.
(1)
(2)
(3)
(4)
(5)
(6)
KX080-4
600 mm
23.62 in.
620 mm
24.41 in.
328 mm
12.91 in.
200 mm
7.87 in.
44 mm
1.73 in.
20 mm
0.79 in.
No.
(7)
(8)
(9)
(10)
(11)
(12)
KX080-4
105 mm
4.13 in.
120 mm
4.72 in.
60 mm
2.36 in.
538 mm
21.18 in.
902.5 mm
35.53 in.
7.5 mm
0.30 in.
No.
(13)
(14)
(15)
(16)
(17)
(18)
KX080-4
300 mm
11.81 in.
205 mm
8.07 in.
25 mm
0.98 in.
37.5 mm
1.48 in.
164.5 mm
6.48 in.
82 mm
3.23 in.
No.
(19)
(20)
(21)
(22)
(23)
(24)
KX080-4
462 mm
18.19 in.
90 mm
3.54 in.
22 mm
0.87 in.
14 mm
0.55 in.
222 mm
8.74 in.
111 mm
4.37 in.
RY9212148MBS0033US0
1-S3
KiSC issued 08, 2015 A
KX080-4, WSM
1-S4
MACHINE BODY
Item
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
60 × 226 mm
2.36 × 8.90 in.
60 × 175 mm
2.36 × 6.89 in.
60 × 333 mm
2.36 × 13.11 in.
60 × 151 mm
2.36 × 5.94 in.
60 × 275 mm
2.36 × 10.83 in.
60 × 275 mm
2.36 × 10.83 in.
60 × 167 mm
2.36 × 6.57 in.
70 × 144 mm
2.76 × 5.67 in.
85 × 295 mm
3.35 × 11.61 in.
50 × 167 mm
1.97 × 6.57 in.
KX080-4
(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 × 17.20 in.
70 × 200 mm
2.76 × 7.87 in.
70 × 226 mm
2.76 × 8.90 in.
70 × 332 mm
2.76 × 13.07 in.
(18)
50 × 167 mm
1.97 × 6.57 in.
• The pin usage limit is when the wear exceeds 1.0mm (0.039 in.) from the factory spec. from new.
(a) Pin diameter
(b) Length
RY9212158MBS0001US0
KiSC issued 08, 2015 A
KX080-4, WSM
MACHINE BODY
Item
(1)
(2)
(3)
(4)
(5)
Cylinder
Cylinder
Cylinder
Point used
Swing bracket top
Swivel frame, vertical
Swing bracket bottom
Swing bracket top
Swing bracket bottom
Swing bracket ends
Boom ends
Swing bracket right
KX080-4
(I.D. X O.D. X Length)
100 × 115 × 64 mm
3.94 × 4.53 × 2.52 in.
100 × 115 × 110 mm
3.94 × 4.53 × 4.33 in.
100 × 115 × 61 mm
3.94 × 4.53 × 2.40 in.
70 × 82 × 65 mm
2.76 × 3.23 × 2.56 in.
70 × 82 × 45 mm
2.76 × 3.23 × 1.77 in.
70 × 82 × 65 mm
2.76 × 3.23 × 2.56 in.
70 × 82 × 36 mm
2.76 × 3.23 × 1.42 in.
80 × 95 × 80 mm
3.15 × 3.74 × 3.15 in.
80 × 95 × 80 mm
3.15 × 3.74 × 3.15 in.
70 × 82 × 49 mm
2.76 × 3.23 × 1.93 in.
70 × 82 × 75 mm
2.76 × 3.23 × 2.95 in.
Item
(7)
(8)
(9)
Arm ends
Cylinder
Cylinder
(10) Arm ends
(11) Bucket link
(12) Cylinder
(13) Arm ends
(14)
Bucket link
Cylinder
(15) Blade
(16) Blade
Point used
KX080-4
(I.D. X O.D. X Length)
70 × 82 × 80 mm
2.76 × 3.23 × 3.15 in.
60 × 70 × 75 mm
2.36 × 2.76 × 2.95 in.
60 × 70 × 75 mm
2.36 × 2.76 × 2.95 in.
60 × 80 × 65 mm
2.36 × 3.15 × 2.56 in.
60 × 70 × 60 mm
2.36 × 2.76 × 2.36 in.
60 × 70 × 65 mm
2.36 × 2.76 × 2.56 in.
60 × 70 × 60 mm
2.36 × 2.76 × 2.36 in.
60 × 70 × 52 mm
2.36 × 2.76 × 2.05 in.
60 × 70 × 65 mm
2.36 × 2.76 × 2.56 in.
60 × 70 × 88 mm
2.36 × 2.76 × 3.46 in.
70 × 82 × 60 mm
2.76 × 3.23 × 2.36 in.
(6)
Swing bracket left
Cylinder
70 × 82 × 49 mm
2.76 × 3.23 × 1.93 in.
70 × 82 × 75 mm
2.76 × 3.23 × 2.95 in.
(17) Cylinder
(18) Angle fulcrum, vertical
50 × 60 × 60 mm
1.97 × 2.36 × 2.36 in.
85 × 100 × 60 mm
3.35 × 3.94 × 2.36 in.
• The usage limit for bushings is when the wear exceeds 1.0 mm (0.039 in.) from the factory spec. from new.
RY9212158MBS0002US0
1-S5
KiSC issued 08, 2015 A
KX080-4, WSM
Bushing shape
MACHINE BODY
(A) Flanged bushing
(B) Normal bushing
(a) I.D.
(b) O.D.
(c) Length
RY9212148MBS0036US0
(A) Arm tip
No.
(1)
(2)
(3)
(4)
(5)
KX080-4
260 mm
10.24 in.
1840 mm
72.44 in.
451 mm
17.76 in.
279 mm
10.98 in.
370 mm
14.57 in.
(B) Bucket link 1
No.
(6)
(7)
(8)
(9)
(10)
KX080-4
1745 mm
68.70 in.
403 mm
15.87 in.
428 mm
16.85 in.
13 mm
0.51 in.
188 mm
7.40 in.
(13)
(14)
(15)
No.
(11)
(12)
KX080-4
66 mm
2.60 in.
200 mm
7.87 in.
70 mm
2.76 in.
67 mm
2.64 in.
80 mm
3.15 in.
No.
(16)
KX080-4
70 mm
2.76 in.
(17)
200 mm
7.87 in.
(18)
(19)
(20)
76 mm
2.99 in.
70 mm
2.76 in.
RY9212148MBS0037US0
1-S6
KiSC issued 08, 2015 A
KX080-4, WSM
MACHINE BODY
No.
(a)
Item
I.D. X Length
(b)
I.D. X Length
(c)
Width
(d)
Height
(e)
(f)
(g)
Length
Tip height - plate thickness
Distance between supports
70 × 98 mm
2.76 × 3.86 in.
70 × 28 mm
2.76 × 1.10 in.
2200 mm
86.61 in.
500 mm
19.69 in.
1448 mm
57.01 in.
90 × t 16 mm
3.54 × t 0.63 in.
698 mm
27.48 in.
KX080-4
RY9212148MBS0038US0
No.
(a)
Item
I.D. X Length
(b)
I.D. X Length
(c)
I.D. X Length
(d)
Width
(e)
Height
(f)
Length
KX080-4
70 × 98 mm
2.76 × 3.86 in.
70 × 28 mm
2.76 × 1.10 in.
85 × 289 mm
3.35 × 11.38 in.
2200 mm
86.61 in.
510 mm
20.08 in.
1754.5 mm
69.07 in.
No.
(g)
Item
Tip height - plate thickness
(h)
Distance between supports
(i)
Cutting edge
(j)
Cutting edge
(k)
Cutting edge
(l)
Cutting edge
KX080-4
160 × t 15.9 mm
6.30 × t 0.63 in.
698 mm
27.48 in.
60 mm
2.36 in.
153 mm
6.02 in.
306 mm
12.05 in.
732 mm
28.82 in.
RY9212158MBS0003US0
1-S7
KiSC issued 08, 2015 A
KX080-4, WSM
1. Remove the left and rear hoods.
MACHINE BODY
CAUTION
It takes at least 2 people to remove the rear hood.
Rear hood weight Approx. 27 kg (60 lbs)
(1) Rear hood (2) Left hood
RY9212148MBS0039US0
2. Remove the air cleaner.
(1) Air cleaner
RY9212148MBS0040US0
3. Remove the weight.
CAUTION
• Find its center of gravity and suspend it securely.
Tightening torque Weight
367.7 to 431.5 N·m
37.5 to 44.0 kgf·m
271.2 to 318.3 lbf·ft
During installation, apply a threadlock. (Loctite 271)
Weight of the weight Approx. 1040 kg (2293 lbs)
(1) Weight
RY9212148MBS0042US0
1. Remove the blower cover and AC panel, then remove the blower hose, fuse box and AC connector.
(1) Blower cover
(2) AC panel
(3) Fuse box
RY9212148MBS0043US0
1-S8
KiSC issued 08, 2015 A
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).
Tightening torque
Bolt
Nut
259.9 to 304.0 N·m
26.5 to 31.0 kgf·m
191.7 to 224.2 lbf·ft
107.9 to 127.4 N·m
11.0 to 13.0 kgf·m
79.6 to 94.0 lbf·ft
(1) Bolt (2) Nut
RY9212148MBS0045US0
4. Remove the cabin.
IMPORTANT
• Find its center of gravity and suspend it securely.
Cabin weight Approx. 230 kg (507 lbs)
(1) Cabin
RY9212148MBS0046US0
1-S9
KiSC issued 08, 2015 A
KX080-4, WSM
Installation of cabin rubber vibration dampers
MACHINE BODY
(1) Nut
(2) Bolt
Tightening torque
Nut (1)
Bolt (2)
Nut (4)
Bolt (5)
(3) Rubber vibration damper
(4) Nut
(5) Bolt
107.9 to 127.4 N·m
11.0 to 13.0 kgf·m
79.6 to 94.0 lbf·ft
103.0 to 117.7 N·m
10.5 to 12.0 kgf·m
76.0 to 86.8 lbf·ft
39.2 to 45.1 N·m
4.0 to 4.6 kgf·m
28.9 to 33.3 lbf·ft
48.1 to 55.9 N·m
4.9 to 5.7 kgf·m
35.5 to 41.2 lbf·ft
(6) Rubber vibration damper
RY9212148MBS0047US0
1-S10
KiSC issued 08, 2015 A
KX080-4, WSM
1. Remove the cover.
(1) Cover
MACHINE BODY
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.
(1) Electrical wiring (2) Fuel hose
RY9212148MBS0050US0
4. Remove the band for mounting the fuel tank and then remove the fuel tank.
(1) Fuel tank mounting band (2) Fuel tank
RY9212148MBS0051US0
1-S11
KiSC issued 08, 2015 A
KX080-4, WSM
Fuel hose circuit
MACHINE BODY
(1) Outside air
(2) Strainer (Eur. only)
(3) Fuel tank
(4) Water separator
(5) Fuel pump
(6) Fuel filter
(7) Engine
(8) Fuel check valve
(9) Fuel cooler
(a) 110 mm (4.3 in.)
(b) 45 mm (1.8 in.)
(c) 65 mm (2.6 in.)
(d) 50 mm (2.0 in.)
(e) 40 mm (1.6 in.)
NOTE
• (j): Install so the joint in the tube does not come to the edge of the fuel pump.
(f) 30 mm (1.2 in.)
(g) 75 mm (3.0 in.)
(h) Drain (for bleeding water)
(i) Air bleed
A
B
C
D
E
F
Length
850 mm
33.46 in.
550 mm
21.65 in.
1450 mm
57.09 in.
320 mm
12.60 in.
1650 mm
64.96 in.
2360 mm
33.46 in.
Tube
I.D.
8 mm
0.31 in.
7 mm
0.29 in.
Protective tube
Length I.D.
800 mm
31.50 in.
420 mm
16.54 in.
15 mm
0.59 in.
16 mm
0.63 in.
1350 mm
53.15 in.
240 mm
9.45 in.
1500 mm
59.06 in.
15 mm
0.59 in.
– –
G
H
M
N
P
Length
280 mm
11.02 in.
Rubber cap
260 mm
10.24 in.
80 mm
3.15 in.
480 mm
18.90 in.
Tube
I.D.
8 mm
0.31 in.
4 mm
0.16 in.
5 mm
0.20 in.
Protective tube
Length I.D.
–
–
200 mm
7.87 in.
–
–
–
–
10 mm
0.39 in.
–
–
FA
FB
–
–
–
–
900 mm
35.43 in.
1240 mm
48.82 in.
15 mm
0.59 in.
RY9212148MBS0148US0
1-S12
KiSC issued 08, 2015 A
KX080-4, WSM
Fuel Supply and Return Hose Routing
MACHINE BODY
• (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.
• (e): Pass through the long hole in the swivel frame.
• (g): Route the return hose so it does not touch the fuel sensor connector.
• (f): Install the return hose so it passes outside the band.
• (h): Pass both the supply and return hoses through the guide.
• (i): Pass through the hole in the bracket.
• (j): Drain
RY9212148MBS0149US0
1-S13
KiSC issued 08, 2015 A
KX080-4, WSM
(1) Front cover
(2) Right cover
MACHINE BODY
1. After draining the hydraulic oil, remove the front, right and tank covers.
(3) Tank cover
RY9212148MBS0150US0
2. Remove the cover, electric fan, center cover and center frame.
3. Remove the top cover, fuel tank, battery and control valve.
(Refer to sections on removing the fuel tank and control valve.)
[Work Tip]
• Move the condenser toward the rear of the machine with the AC hoses still installed.
(1) Cover
(2) Electric fan
(3) Center cover
(4) Center frame
(5) Top cover
(6) Fuel tank
(7) Battery
(8) Control valve
RY9212148MBS0151US0
4. Disconnect all the harnesses and the hydraulic hose connected to the hydraulic oil tank.
5. Remove the AUX mounting bracket, manifold block adapter and the 2-way valve from the hydraulic oil tank.
6. Remove the bracket from the battery support.
(1) Suction hose
(2) AUX mounting bracket
(3) Manifold block adapter
(4) 2-way valve
(5) Bracket
RY9212148MBS0152US0
7. Remove the hydraulic hoses.
IMPORTANT
• Plug the disconnected hoses and adapters.
(1) Hydraulic hose
RY9212148MBS0153US0
8. Remove the divider plates.
(1) Divider plate
RY9212148MBS0154US0
1-S14
KiSC issued 08, 2015 A
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).
Tightening torque Bolt
196.1 to 225.6 N·m
20.0 to 23.0 kgf·m
144.6 to 166.4 lbf·ft
(1) Battery support
RY9212148MBS0155US0
10. Suspend the hydraulic oil tank with a crane.
11. Remove the hydraulic tank mounting bolts, then lift with the crane and remove it.
IMPORTANT
• Apply a thread lock (Loctite 271).
Tightening torque
Hydraulic tank weight
Bolt
77.5 to 90.2 N·m
7.9 to 9.2 kgf·m
57.2 to 66.5 lbf·ft
Approx. 19 kg
Approx. 42 lbs
(1) Hydraulic oil tank
RY9212148MBS0156US0
1-S15
KiSC issued 08, 2015 A
KX080-4, WSM
MACHINE BODY
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)
(1) Air cleaner
RY9212148MBS0052US0
2. Remove the DPF muffler cover and the DPF exhaust pipe.
(1) DPF muffler cover (2) DPF exhaust pipe
RY9212148MBS0053US0
3. Remove the DOC intake temperature sensor, DOC outlet temperature sensor and DPF outlet temperature sensor connectors and then remove the bracket.
(1) DOC intake temperature sensor connector
(2) DOC outlet temperature sensor connector
(3) DPF outlet temperature sensor connector
(4) Bracket
RY9212148MBS0054US0
4. Disconnect the DPF pressure differential sensor connector and remove the bracket.
(1) DPF pressure differential sensor connector
(2) Bracket
RY9212148MBS0055US0
1-S16
KiSC issued 08, 2015 A
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.
• Refer to the DPF handling manual for cleaning DPF.
• During installation, first mount all the flange nuts and bracket mounting bolts loosely and then tilt the muffler itself in position, adjusting it so there is no stress on it and tighten the nuts/bolts.
Install the gasket so the protruding side faces the exhaust manifold side.
• Apply the anti-seize lube ("Pure Nickel Special" in
Never-Seez Anti-Seize and Lubricating Compounds) on the screw part when attaching the drain pipe.
DPF muffler weight Approx. 23 kg (51 lbs)
Tightening torque
Bolt (M10)
Bolt (M12)
Flange nut
Drain pipe
48.1 to 55.9 N·m
4.9 to 5.7 kgf·m
35.5 to 41.2 lbf·ft
77.5 to 90.2 N·m
7.9 to 9.2 kgf·m
57.2 to 66.5 lbf·ft
49.0 to 59.9 N·m
5.0 to 6.1 kgf·m
36.1 to 44.2 lbf·ft
16.0 to 23.0 N·m
1.6 to2.3 kgf·m
11.8 to 17.0 lbf·ft
(1) Flange Nut
(2) Bracket Mounting Bolt
(3) DPF Muffler Bracket
(4) Drain Pipe
(5) Gasket
(6) DPF Muffler
RY9212148MBS0056US0
6. Remove the DPF muffler bracket and muffler mounting band from the DPF muffler.
IMPORTANT
• During installation, tighten the bolts fully and then with the nuts mounted loosely, install onto the machine.
When fully tightening the nuts, tilt the muffler itself, adjusting it so it is not under stress.
Install the DPF mounting band so it fits within the specified dimensions at the location shown at left.
Tightening torque
Bolt (M10)
Nut 1
Nut 2
48.1 to 55.9 N·m
4.9 to 5.7 kgf·m
35.5 to 41.2 lbf·ft
9.8 to 11.3 N·m
1.0 to 1.2 kgf·m
7.2 to 8.3 lbf·ft
39.2 to 45.1 N·m
4.0 to 4.6 kgf·m
28.9 to 33.3 lbf·ft
(1) Muffler mounting band
(2) Bolt
(3) Nut 1
(4) Nut 2
(a) 12 to 16 mm (0.5 to 0.6 in.)
RY9212148MBS0057US0
1-S17
KiSC issued 08, 2015 A
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.
• When tightening the exhaust temperature sensor, apply the anti-seize lube ("Pure Nickel Special" in Never-Seez
Anti-Seize and Lubricating Compounds).
Tightening torque
Exhaust temperature sensor
25.0 to 35.0 N·m
2.5 to 3.6 kgf·m
18.4 to 25.8 lbf·ft
(1) Exhaust Temperature Sensor (T0)
(2) Exhaust Temperature Sensor (T1)
(3) Exhaust Temperature Sensor (T2)
RY9212148MBS0157US0
CAUTION
• Wear protective gear, such as a helmet, safety glasses, etc., during assembly/disassembly.
• Disconnect the negative terminal of the battery prior to any assembly/disassembly work.
• For group work, decide on signals for communication, make sure everyone understands and uses them and be very careful about safety.
RY9212148MBS0058US0
1. Remove the weight.
Refer to the section Weight Assembly/Disassembly for the weight removal/mounting procedure.
RY9212148MBS0059US0
2. Remove the cabin.
Refer to the section Cabin Removal and Mounting for the cabin removal/mounting procedure.
RY9212148MBS0060US0
3. Remove the pilot filter.
(1) Pilot filter
RY9212148MBS0061US0
1-S18
KiSC issued 08, 2015 A
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
• Find its center of gravity and suspend it securely.
• Be careful of the electrical wiring.
Tightening torque Bolt
259.9 to 304.0 N·m
26.5 to 31.0 kgf·m
191.7 to 224.2 lbf·ft
Apply thread lock compound (Loctite 271).
Arch weight Approx. 85 kg (187 lbs)
(1) Arch
RY9212148MBS0063US0
6. Remove the compressor.
7. Drain the coolant inside the radiator and disconnect the heater hose.
IMPORTANT
• Move the compressor across to the condenser side.
• Plug the disconnected heater hoses.
(1) Compressor
(2) AC hose
(3) Heater hose
RY9212148MBS0064US0
8. Disconnect the upper and lower hoses.
(1) Upper hose (2) Lower hose
RY9212148MBS0065US0
9. Disconnect the fuel hoses on the supply pump side.
IMPORTANT
• Between the fuel filter and supply pump
• Between the fuel cooler and the supply pump
• Plug the disconnected hoses.
(1) Fuel filter
(2) Supply pump
(3) Fuel cooler
RY9212148MBS0066US0
1-S19
KiSC issued 08, 2015 A
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.
13. Disconnect the ground and remove the engine.
CAUTION
• Find its center of gravity and suspend it securely.
• Make sure you have not forgotten to disconnect any electrical wiring before removing the engine.
Tightening torque
First nut
Second nut
Bolt (M16)
Bolt (M14)
88.2 to 107.8 N·m
9.0 to 11.0 kgf·m
65.1 to 79.5 lbf·ft
166.0 to 191.0 N·m
16.9 to 19.5 kgf·m
122.4 to 140.9 lbf·ft
196.1 to 225.6 N·m
20.0 to 23.0 kgf·m
144.6 to 166.4 lbf·ft
123.6 to 147.1 N·m
12.6 to 15.0 kgf·m
91.2 to 108.5 lbf·ft
Apply thread lock compound (Loctite 271).
Engine weight Approx. 350 kg (772 lbs)
(1) Engine
(2) Pump
(3) Ground wire
(4) First nut
(5) Second nut
(6) Bolt (M16)
(7) Bolt (M14)
RY9212148MBS0068US0
1-S20
KiSC issued 08, 2015 A
KX080-4, WSM
(1) Left travel lever
(2) Right travel lever
(3) Grip
MACHINE BODY
(a) 260 ± 5 mm (10.2 ± 0.2 in.)
(b) When in neutral
(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.)
RY9212148MBS0069US0
1. Install the left and right travel levers.
The pilot valve side is die cast aluminum so be careful not to over tighten; tighten to the torques indicated below.
Tightening torque Left/right travel levers
39.2 to 45.1 N·m
4.0 to 4.6 kgf·m
28.9 to 33.3 lbf·ft
(1) Grip
(2) Bolt
(3) Right travel lever
(4) Left travel lever
(5) Right pedal
(6) Left pedal
(7) Right damper
(8) Left damper
RY9212148MBS0070US0
Neutral position
(a) 65.5 mm (2.6 in.)
RY9212148MBS0071US0
1. No clearance
(a)
when limit switch operated.
Tightening torque Bolt
3.9 to 4.9 N·m
0.4 to 0.5 kgf·m
2.9 to 3.6 lbf·ft
Apply thread lock compound ThreeBond TB1401B.
(1) Limit Switch
(2) Damper
(3) Unload Lever
(4) Bolt
(a) Clearance
(b) 16 mm (0.6 in.)
RY9212148MBS0072US0
1-S21
KiSC issued 08, 2015 A
KX080-4, WSM
1. Remove the swivel frame.
MACHINE BODY
RY9212148MBS0073US0
2. Suspend the swivel bearing with a crane, remove the swivel bearing mounting bolts on the bottom side, then remove the swivel bearing.
Swivel bearing weight (reference value)
110 kg (243 lbs)
Component names
No.
(1)
(2)
(3)
Swivel bearing
Bolt
Diaphragm spring
Name of part Qty
1
36
36
RY9212148MBS0074US0
Mounting Procedure
1. Set the "S" mark on the right side of the machine and mount the swivel bearing mounting bolts finger tight.
Once they are all finger tight, tighten them in a diagonal pattern to the specified torque.
Tightening torque Swivel bearing
259.9 to 304.0 N·m
26.5 to 31.0 kgf·m
191.7 to 224.2 lbf·ft
Thread locking compound (Loctite 271)
IMPORTANT
• Make sure the diaphragm springs face the right way.
• After mounting the bearing, apply grease so that it covers the entire surface of bearing teeth.
(a) Ball insertion holes (outer soft zone)
(b) Tooth surface grease application zone
(c) Port for applying grease to the balls (mates with hole in swivel frame)
(d) 'S' Mark
A : Front of machine
B : Back of machine
C : Swivel frame side
D : Track frame side
RY9212148MBS0075US0
1-S22
KiSC issued 08, 2015 A
KX080-4, WSM
MACHINE BODY
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.
If the preset code is not set correctly, the overload warning will fail to work correctly, which presents the risk of serious injury or death.
After making the setting, always make sure the overload warning is working correctly as per the overload warning test procedure.
(Refer to the electrical part of the Overload Warning System section.)
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.
• Do not get your face or any body part right in front of the nipple while loosening it and loosen the nipple gradually.
RY9212148MBS0001US0
1. Remove the cover on the grease nipple.
2. Press a socket wrench onto the base of the grease nipple and loosen slowly.
If there are any rocks or the like caught in the sprocket, remove the rocks first.
• Tool to use: 22 mm socket
(1) Grease nipple
RY9212148MBS0002US0
3. Jack up the body using the front end and blade, expel grease from inside the grease cylinder, and fully loosen up the track.
When the track loosens up, attach the grease nipple.
Tightening torque Grease nipple
98.0 to 107.8 N·m
10.0 to 11.0 kgf·m
72.0 to 80.0 lbf·ft
RY9212148MBS0003US0
4. With the machine lifted slightly, wedge a steel pipe into the track and turn the sprocket backwards in direction
A
.
When the steel pipe reaches halfway up the idler and the track lifts off the idler, stop turning the sprocket and slide the track sideways in direction
B
to remove it.
• Weight of rubber track: approximately 405 kg (893 lbs)
A : Backwards B : Direction to slide
RY9212148MBS0004US0
1-S23
KiSC issued 08, 2015 A
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
. When a steel pipe reaches halfway up the idler, stop turning the sprocket. Slide the track sideways in direction
B
and set the track onto the idler. Lower the machine and drive it backwards to make sure the tracks are on securely.
Adjust the tension of the track.
CAUTION
• Make sure to assemble the rubber track facing the right way.
A : Backwards B : Direction to Slide
RY9212148MBS0013US0
Removal
1. Remove the cover on the grease nipple.
2. Press a socket wrench onto the base of the grease nipple and loosen slowly.
If there are any rocks or the like caught in the sprocket, remove the rocks first.
• Tool to use: 22 mm socket
(1) Cover
RY9212148MBS0005US0
3. Jack up the body using the front end and blade, expel grease from inside the grease cylinder, and fully loosen up the track.
When the track loosens up, attach the grease nipple.
RY9212148MBS0076US0
4. Rotate the track so the master pin comes to the front idler side and put a block under the track.
(1) Master pin
(2) Master link
(3) Block
RY9212148MBS0077US0
1-S24
KiSC issued 08, 2015 A
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
(c) Tool c
RY9212148MBS0078US0
6. After inserting tools d and e inside tool c, tap the side of tool e with a hammer.
(1) Master pin
(d) Tool d
(e) Tool e
RY9212148MBS0079US0
7. Switch tools e and f and tap with a hammer until the master pin comes out.
8. Once the master pin comes out, remove all of the mounted tools.
IMPORTANT
• Be careful when working because the moment tool d is removed, the master link will come off.
(1) Master pin
(d) Tool d
(f) Tool f
RY9212148MBS0080US0
9. Slowly operate the travel lever backwards on the side being removed and remove the track.
DANGER
• Do not get your feet under the mini-excavator.
RY9212148MBS0081US0
Mounting
1. Jack up the mini-excavator using the front end and blade and place the track so that the end of the track meshes with the sprocket under the mini-excavator.
IMPORTANT
• Take care to face the track in the correct direction.
(1) Master link
(a) Sprocket side
(b) Front idler side
RY9212148MBS0082US0
1-S25
KiSC issued 08, 2015 A
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.
(1) Front Idler
(2) Track
(3) Block
RY9212148MBS0084US0
4. Mount tools a and b on the track plate and insert tool d from the tool a side.
IMPORTANT
• Set tools c and g on tool b.
Align the holes of tools a and b with that of the master link and then install.
(a) Tool a
(b) Tool b
(c) Tool c
(d) Tool d
(g) Tool g
RY9212148MBS0085US0
5. Insert the master pin from the tool a side and use a hammer on tool e to insert the master pin.
6. After tapping tool e in to the end, remove tools b and g.
IMPORTANT
• When removing tool g, be careful that the spring doesn't make it go flying.
(1) Master pin
(b) Tool b
(d) Tool d
(e) Tool e
(g) Tool g
RY9212148MBS0086US0
7. After remounting tool b, tap tool f with a hammer until the master pin is all the way in.
(1) Master pin
(d) Tool d
(f) Tool f
RY9212148MBS0087US0
1-S26
KiSC issued 08, 2015 A
KX080-4, WSM
No. in
Figure
(a)
(b)
(c)
(d)
(e)
(f)
(g)
Guide (outside)
Guide (inside)
Stopper plate
Pin
Pusher 1
Pusher 2
Spring
(a)Guide (outside)
Name of part
MACHINE BODY
RY9212148MBS0088US0
N
O
P
L
M
H
I
J
K
D
E
F
G
A
B
C
189.5 to 190.5 mm (7.46 to 7.50 in.)
20.0 mm (0.79 in.)
5.0 mm (0.20 in.)
24.4 to 24.6 mm (0.96 to 0.97 in.)
45.0 mm (1.77 in.)
30.0 mm (1.18 in.)
43.5 mm (1.71 in.)
29.5 mm (1.16 in.)
150.0 mm (5.91 in.)
10.5 mm (0.41 in.)
57.5 to 58.5 mm (2.26 to 2.30 in.)
50.0 mm (1.97 in.)
29.0 mm (1.14 in.)
30.0 mm (1.18 in.)
100.0 mm (3.94 in.)
19.0 mm (0.75 in.)
1-S27
C2 a b c
X
Y
Z
C1
T
U
V
W
Q
R
S
21.0 mm (0.83 in.)
12.5 mm (0.49 in.)
24.5 to 25.5 mm (0.96 to 1.00 in.)
77.0 mm (3.03 in.)
25.0 mm (0.98 in.)
112.5 mm (4.43 in.)
67.0 mm (2.64 in.)
33.4 to 33.6 mm (1.31 to 1.32 in.)
16.0 mm (0.63 in.)
25.5 mm (1.00 in.)
1.0 mm (0.04 in.) bevel
2.0 mm (0.08 in.) bevel
Ra=12.5a
Ra=6.3a
2 x M12 x 1.25 / 10.8
RY9212148MBS0089US0
KiSC issued 08, 2015 A
KX080-4, WSM
(b)Guide (inside)
MACHINE BODY
D
E
F
G
A
B
C
J
K
L
H
I
150.0 mm (5.91 in.)
3.2 mm (0.13 in.)
27.6 mm (1.09 in.)
34.0 mm (1.34 in.)
100.0 mm (3.94 in.)
12.5 mm (0.49 in.)
24.5 to 25.5 mm (0.96 to 1.00 in.)
50.0 mm (1.97 in.)
67.0 mm (2.64 in.)
33.0 to 34.0 mm (1.30 to 1.34 in.)
43.5 mm (1.71 in.)
57.5 to 58.5 mm (2.26 to 2.30 in.)
1-S28
P
Q
R
S
M
N
O
C0.5
a b c
19.0 mm (0.75 in.)
15.5 mm (0.61 in.)
28.5 mm (1.12 in.)
39.5 to 40.5 mm (1.56 to 1.59 in.)
48.5 mm (1.91 in.)
25.5 mm (1.00 in.)
16.0 mm (0.63 in.)
0.5 mm (0.02 in.) bevel
Ra=12.5a
2 x M12 x 1.25 / 10.8
2 x M10 x 1.25 x 20 / 8.8 x 25
RY9212148MBS0090US0
(c)Stopper plate
D
E
F
G
H a
A
B
C
9.0 mm (0.35 in.)
96.0 mm (3.78 in.)
70.0 mm (2.76 in.)
13.0 mm (0.51 in.)
5.5 mm (0.22 in.)
11.0 mm (0.43 in.)
16.0 mm (0.63 in.)
32.0 mm (1.26 in.)
Ra=12.5a
RY9212148MBS0091US0
KiSC issued 08, 2015 A
KX080-4, WSM
1-S29
MACHINE BODY
(d)Pin
C a
A
B
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
E
F
C1 a
b
A
B
C
D
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.)
89.7 to 90.3 mm (3.53 to 3.56 in.)
155.0 mm (6.10 in.)
1.0 mm (0.04 in.) bevel
Ra=12.5a
30°(0.52 rad)
RY9212148MBS0093US0
(f)Pusher 2
C
D
A
B
E
D
E
F
C1 a
b
A
B
C
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.)
188.7 to 189.3 mm (7.43 to 7.45 in.)
254.0 mm (10.00 in.)
1.0 mm (0.04 in.) bevel
Ra=12.5a
30°(0.52 rad)
RY9212148MBS0094US0
(g)Spring
2.9 mm (0.11 in.)
20.0 mm (0.79 in.)
144.0 mm (5.67 in.)
109.0 mm (4.29 in.)
106.0 N (10.8 kgf, 23.8 lbs)
RY9212148MBS0095US0
KiSC issued 08, 2015 A
KX080-4, WSM
MACHINE BODY
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.
2. Use a crow bar to separate the front idler and the yoke from the track frame.
Front idler assembly weight Approx. 70 kg (150 lbs)
3. Use a crane during assembly.
IMPORTANT
• Wipe off any dirt, sand, etc. sticking to the inside of the track frame prior to inserting the component.
• Make sure it slides smoothly and insert it.
RY9212148MBS0096US0
No.
(1) Bolt
Name of part Qty
4
Notes
123.6 to 147.1 N·m
12.6 to 15.0 kgf·m
91.2 to 108.5 lbf·ft
(2)
(3)
(4)
(5)
(6)
(7)
Yoke
Bracket
Plug
Spring pin
O-ring
Shaft
(8)
(9)
Floating seal
Bushing
(10) Idler
2
2
1
2
2
1
2
2
1
R1/8
RY9212148MBS0097US0
Disassembly Procedures
1. Remove the plug from the bracket and drain the oil.
2. Use a pin punch to extract the left and right spring pins and then remove the bracket.
(1) Spring Pin
(2) Bracket
(a) Pin Punch
RY9212148MBS0006US0
1-S30
KiSC issued 08, 2015 A
KX080-4, WSM
MACHINE BODY
3. Remove the floating seal.
4. Remove the shaft.
(1) Spring Pin
(2) Bracket
(3) Floating Seal
(4) Shaft
RY9212148MBS0007US0
Assembly Procedures
1. Mount the O-rings on the shaft.
IMPORTANT
• Apply engine oil to the O-rings.
(1) Shaft (2) O-Ring
RY9212148MBS0008US0
2. After installing a floating seal on one side of the bracket, mount the shaft and fix it in place with a spring pin.
3. Install a floating seal on the idler.
IMPORTANT
• Face the split in the spring pin so it is perpendicular to the shaft and tap it in.
• Make sure there is no oil or debris on the O-ring or the
O-ring seat.
• Apply a thin film of oil to the sliding surfaces.
• Make sure there are no scratches in the sliding surfaces or the O-rings.
(1) Floating Seal
RY9212148MBS0098US0
4. Install a floating seal to the bracket on the other side of the idler.
IMPORTANT
• Make sure there is no oil or debris on the O-ring or the
O-ring seat.
• Apply a thin film of oil to the sliding surfaces.
• Make sure there are no scratches in the sliding surfaces or the O-rings.
(1) Floating Seal
RY9212148MBS0099US0
5. Align the holes in the shaft and the brackets, hold them in place with a clamp and tap in a spring pin.
IMPORTANT
• Face the split in the spring pin so it is perpendicular to the shaft and tap it in.
• After completing the assembly, turn the idler a little to form a film of oil on the sliding surface of the floating seals.
(1) Spring Pin
(a) Clamp
RY9212148MBS0009US0
1-S31
KiSC issued 08, 2015 A
KX080-4, WSM
MACHINE BODY
6. Fill with engine oil via the plug hole in the bracket.
7. Install the plug.
Lubricant
Type SAE #30CD engine oil
80 cc
4.88 cu.in
Tightening torque Plug
10.0 N·m
1.0 kgf·m
7.4 lbf·ft
Apply thread lock compound (Loctite 503 or equivalent)
RY9212148MBS0010US0
1. Remove the track and the front idler. (Refer to the the Track and
Front Idler chapters for assembly/disassembly of the track and front idler.)
2. Remove the grease cylinder from the track frame.
Grease cylinder weight Approx. 20 kg (44 lbs)
3. Use a crane during assembly.
IMPORTANT
• Wipe off any dirt, sand, etc. sticking to the inside of the track frame prior to inserting the component.
• Make sure it slides smoothly and insert it.
RY9212148MBS0100US0
No.
(1)
(2)
(3)
(4)
(5)
Name of part
Rod
Seal
Backup ring
O-ring
Cylinder tube
1
1
1
Qty
1
1
Notes
(6) Grease nipple 1
98.0 to 107.8 N·m
10.0 to 11.0 kgf·m
72.3 to 79.5 lbf·ft
RY9212148MBS0101US0
1-S32
KiSC issued 08, 2015 A
KX080-4, WSM
MACHINE BODY
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.
Tensioner weight Approx. 30 kg (66 lbs)
3. Use a crane during assembly.
IMPORTANT
• Wipe off any dirt, sand, etc. sticking to the inside of the track frame prior to inserting the component.
• Make sure it slides smoothly and insert it.
RY9212148MBS0102US0
No.
(1)
(2)
(3)
(4)
(5)
(6)
Bolt
Split pin
Spring
Retainer
Washer
Nut
Name of part Qty
1
1
1
1
1
1
Notes
RY9212148MBS0103US0
When switching from a rubber track to a steel one or vice versa, set to the appropriate preset length.
Preset length
Steel
Rubber
Factory
Specification
334 mm
13.1 in.
319 mm
12.6 in.
(a) Preset length
RY9212148MBS0104US0
1-S33
KiSC issued 08, 2015 A
KX080-4, WSM
MACHINE BODY
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.
• Do not get your face or any body part right in front of the nipple while loosening it and loosen the nipple gradually.
RY9212148MBS0016US0
1. Remove the track roller mounting bolts.
Tightening torque Bolt
166.7 to 196.1 N·m
17.0 to 20.0 kgf·m
123.0 to 144.6 lbf·ft
Apply a threadlock (ThreeBond 1305P).
(1) Bolt (2) Grease plug
RY9212148MBS0105US0
2. Jack up the body using the front end and blade, expel grease from inside the grease cylinder, and fully loosen up the track.
When the track is loose, attach the grease nipple and place a block under the track frame.
3. Remove the track roller(s).
Track roller weight Approx. 12.4 kg (27.3 lbs)
RY9212148MBS0011US0
(1) Spring pin
(2) Bracket 1
(3) Bolt
(4) O-ring
(5) Floating seal
(6) Bushing
(7) Roller
(8) Shaft
(9) Bracket 2
(10) Plug
RY9212148MBS0106US0
1-S34
KiSC issued 08, 2015 A
KX080-4, WSM
MACHINE BODY
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.
• Do not get your face or any body part right in front of the nipple while loosening it and loosen the nipple gradually.
RY9212148MBS0016US0
1. Jack up the body using the front end and blade, expel grease from inside the grease cylinder, and fully loosen up the track.
When the track is loose, attach the grease nipple and place a block under the track frame.
2. Insert a block between the track frame and the track and remove the carrier roller.
Tightening torque Bolt
166.7 to 196.1 N·m
17.0 to 20.0 kgf·m
123.0 to 144.6 lbf·ft
Apply a threadlock (ThreeBond 1305P).
Carrier roller weight
Approx. 10.8 kg
Approx. 23.8 lbs
(1) Block (2) Bolt
RY9212148MBS0146US0
(1) Roller
(2) Shaft
(3) Bracket 1
(4) Bracket 2
(5) Bushing
(6) Floating seal
(7) Spring pin
(8) O-ring
(9) Grease plug
RY9212148MBS0147US0
1-S35
KiSC issued 08, 2015 A
KX080-4, WSM
No.
(1)
Country sold
Item
Lug height
(2) Link height
(3) Track width
(4) Track tension
(5) Track height
No. of cored bars
Circumference in middle
Cored bar pitch
Endless ID mark
(a) Track adjustment point
MACHINE BODY
KX080-4
CA
20 mm
0.79 in.
30 mm
1.18 in.
450 mm
17.72 in.
25 to 40 mm
0.98 to 1.57 in.
102.5 mm
4.04 in.
76
6194 mm
243.86 in.
81.5 mm
3.21 in.
–
KX080-4
USA
20 mm
0.79 in.
30 mm
1.18 in.
450 mm
17.72 in.
25 to 40 mm
0.98 to 1.57 in.
102.5 mm
4.04 in.
76
6194 mm
243.86 in.
81.5 mm
3.21 in.
RY9212158MBS0006US0
No.
(1)
Item
Track width
No. of links
4 Link lengths (A)/(B)
(2) Height (A)/(B)
(3) Grouser height (A)/(B)
(4) Bushing O.D. (A)/(B)
(5) Bushing I.D. (A)/(B)
(6) Pin O.D. (A)/(B)
(7) Track tension
(A): Factory spec. when new
(B): Recommended replacement values
(a) Track adjustment point
KX080-4
450 mm
17.72 in.
600 mm
23.62 in.
39
616.0 / 632.0 mm
24.25 / 24.88 in.
74.0 / 70.0 mm
2.91 / 2.76 in.
26.0 / 16.0 mm
1.02 / 0.63 in.
41.26 / 40.26 mm
1.62 / 1.59 in.
24.5 / 27.0 mm
0.96 / 1.06 in.
24.0 / 21.0 mm
0.94 / 0.83 in.
40 to 55 mm
1.57 to 2.17 in.
RY9212148MBS0109US0
1-S36
KiSC issued 08, 2015 A
KX080-4, WSM
MACHINE BODY
No.
Front Idler
Item KX080-4
(1)
(2)
(3)
O.D. (A)/(B)
Guide width (A)/(B)
Width
390 / 384 mm
15.35 / 15.12 in.
38 / 32 mm
1.50 / 1.26 in.
98 mm
3.86 in.
Sprocket
(4)
(5)
O.D. (A)/(B)
Wheel width
493 / 481 mm
19.41 / 18.94 in.
39 mm
1.54 in.
(A): Factory spec. when new
(B): Recommended replacement values
(A) Front Idler (B) Sprocket
RY9212148MBS0110US0
No.
Carrier Rollers
Item KX080-4
(1)
(2)
O.D. (A)/(B)
Roller width
80 / 76 mm
3.15 / 2.99 in.
228.6 mm
9.00 in.
Track Rollers
(3)
(4)
(5)
Guide width (A)/(B)
O.D. (A)/(B)
Roller width
104 / 96 mm
4.09 / 3.78 in.
132 / 124 mm
5.20 / 4.88 in.
228.6 mm
9.00 in.
(A): Factory spec. when new
(B): Recommended replacement values
(A) Carrier rollers (B) Track rollers
RY9212148MBS0111US0
1-S37
KiSC issued 08, 2015 A
KX080-4, WSM
MACHINE BODY
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.
RY9212148MBS0112US0
Measurement preparation
1. To make the measurements, position the machine so the arm cylinder and bucket cylinder are fully compressed with the end of the arm at a height of 1.0 m (40 in.) off the ground.
2. Stop the engine.
[Left play measurement]
1. Push to the right with 50 N (5.0kgf, 11 lbs) of pressure, making that position the zero point; then press to the left with 300 N
(30 kgf, 67.4 lbs) of pressure and take a reading at that point.
2. Take three measurements, determine the average and take that as the measured value.
[Right play measurement]
1. Push to the left with 50 N (5.0 kgf, 11 lbs) of pressure, making that position the zero point; then press to the right with 300 N
(30 kgf, 67.4 lbs) of pressure and take a reading at that point.
2. Take three measurements, determine the average and take that as the measured value.
(1) 1.0 m (40 in.)
(2) 50 N (5.0 kgf, 11 lbs)
(3) 300 N (30 kgf, 67.4 lbs)
(4) Amount of Play
RY9212148MBS0113US0
1-S38
KiSC issued 08, 2015 A
KX080-4, WSM
MACHINE BODY
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. Make sure there is no looseness in the swivel bearing mounting bolts.
2. Operate the swivel and make sure there are no abnormal sounds and that it operates smoothly.
3. Fasten the dial gauge and the dial gauge stand to the track frame so the probe of the dial gauge touches the swivel frame.
[Measurement]
1. Arm cylinder fully compressed and bucket cylinder fully extended, keeping the boom base pin and the arm end pin at the same height.
2. Zero the dial gauge.
3. Use the front attachment to tilt the body of the machine upwards and take a reading on the dial gauge.
4. Take three measurements, determine the average and take that as the measured value.
(L) Measurement position 50 mm
(1.97 in.)
RY9212148MBS0132US0
1-S39
KiSC issued 08, 2015 A
KX080-4, WSM
MACHINE BODY
No.
(1)
(2)
Front play measurement
Swivel bearing play
Item
Factory spec. when new
Usage limit
Factory specification
≤ 70 mm
≤ 2.76 in.
1.24 mm
0.05 in.
2.48 mm
0.10 in.
Notes
RY9212158MBS0004US0
1-S40
KiSC issued 08, 2015 A
2
KiSC issued 08, 2015 A
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
KX080-4, WSM
ENGINE
Model
No. of cylinders
Cylinder Bore X Stroke
Total displacement
Idling RPM
Rated RPM
Maximum RPM
Rated output/RPM
Max torque/RPM
Net
Gross
Net
Gross
KX080-4
V3307-CRS-T4
4
94.0 x 120 mm (3.70 x 4.72 in.)
3331 cm
3
(203.3 cu.in.)
1000 min
-1
2000 min
-1
2220 min
-1
47.2 kW/2000 min
-1
(63.3 kW/2000 min
-1
)
49.7 kW/2000 min
-1
(66.6 kW/2000 min
-1
)
258.9 N·m/1400 min
-1
(26.4 kgf·m/1400 min
-1
, 191.0 lbf·ft/1400 min
-1
)
267.0 N·m/1400 min
-1
(27.73 kgf·m/1400 min
-1
, 196.9 lbf·ft/1400 min
-1
)
803 x 578 x 760 mm (31.61 x 22.76 x 29.92 in.)
310 kg (683 lbs)
Re-entrant, direction injection type (E-CDIS)
Machine dimensions (LxWxH)
Dry weight
Combustion type
Fuel injection pump type
Governor type
Nozzle type
Fuel injection timing
Fuel injection pressure
Rotation direction
Firing sequence
Compression ratio
EGR
Compression pressure
Fuel consumption (at rated RPM)
Net
Gross
Engine oil consumption (at rated RPM)
Alternator
Battery name
Starter motor
ETN
DIN
JIS
Denso common rail system
Counterclockwise viewed from flywheel side
1-3-4-2
17.5
External EGR
3.1 MPa (32 kgf/cm
2
, 450 psi)
237.3 g/kW·h (177.0 g/HP·h, 0.390 lb/HP·h)
220 g/kW·h (164.1 g/HP·h, 0.362 lb/HP·h)
0.54 g/kW·h (0.40 g/PS·h) or less
12 V, 960 W
600 035 060
60035
12V92AH, 130E41R
12 V, 2.7 kW
*As it is the fan drive specification, the net value noted is the same as for the E3.
RY9212148END0001US0
2-G1
KiSC issued 08, 2015 A
KX080-4, WSM
ENGINE
A
B
C
D
802.9 mm (31.57 in.)
321 mm (12.64 in.)
32.6 mm (1.28 in.)
113 mm (4.45 in.)
E
F
G
H
280 mm (11.02 in.)
578.1 mm (22.76 in.)
310.2 mm (12.21 in.)
5 mm (0.20 in.)
I
J
K
759.8 mm (29.91 in.)
233.6 mm (9.20 in.)
290 mm (11.42 in.)
RY9212148END0002US0
2-G2
KiSC issued 08, 2015 A
KX080-4, WSM
ENGINE
(a) Engine RPM
(b) Output (kW)
(c) Torque (N·m)
(d) Fuel consumption (g/kWh)
(e) Output (HP)
(f) Torque (ft/lb)
(g) Fuel consumption (g/HPh)
A : SI unit
B : US units of work
RY9212148END0003US0
2-G3
KiSC issued 08, 2015 A
KX080-4, WSM
ENGINE
(1) Bimetallic Strip
(2) Piston
(3) Flat Spring (Valve)
(4) Feed Orifice
(5) Torque Transmission
Chamber
(6) Collection Orifice
(7) Oil Collection Chamber
A : At High Temperature
B : At Low Temperature
[At high temperature]
• When the temperature rises, the bimetallic strip (1) bends slightly, opening the supply orifice (4) via the linkage of the piston (2) and the valve (3).
• Silicon oil flows from the supply orifice (4) into the torque transmission chamber (5), increasing the transmitted torque and increasing fan RPM.
[At low temperature]
• The supply orifice (4) closes and oil is not supplied to the torque transmission chamber (5).
• As the part colored in blue is directly coupled to the engine, it rotates at the same speed as the engine.
Conversely, the fan drive body turns at a lower RPM as there is little oil remaining in the torque transmission chamber (5). (The blue part turns at high RPM and the fan body turns at low speed.)
• The oil from the torque transmission chamber (5) returns to the oil collection chamber (7) via the collection orifice
(6).
RY9212148END0004US0
2-G4
KiSC issued 08, 2015 A
3
KiSC issued 08, 2015 A
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............................................................... 3-M5
(1) P3 = At No Load (2 MPa) ............................................................................................... 3-M5
(2) P3 = 20.6 MPa................................................................................................................ 3-M5
[3] FUNCTION AND STRUCTURE ........................................................................................... 3-M6
(1) Operating Principles ....................................................................................................... 3-M6
(2) Horsepower Control........................................................................................................ 3-M7
(3) Flow Control (LS Control) ............................................................................................... 3-M8
(4) Gain Control ................................................................................................................. 3-M11
(5) Standby Flow Amount .................................................................................................. 3-M11
4. CONTROL VALVE.................................................................................................................... 3-M12
[1] SPECIFICATIONS.............................................................................................................. 3-M12
[2] FUNCTION AND STRUCTURE ......................................................................................... 3-M15
(1) Unload Valve Section ................................................................................................... 3-M15
(2) Mono-Block Section Operation (LS Control) ................................................................ 3-M18
(3) Arm Regenerative Function.......................................................................................... 3-M20
(4) Swing Section Operation (LS Control).......................................................................... 3-M21
(5) Travel Section Operation (Open Center Control) ......................................................... 3-M22
(6) Blade Section Operation (Open Center Control) .......................................................... 3-M24
(7) Anti-Drift Function......................................................................................................... 3-M25
(8) P3 Bypass Section Operation (Simultaneous Boom Up + Swivel Operation) .............. 3-M26
(9) Signal Circuit ................................................................................................................ 3-M27
5. SWIVEL MOTOR...................................................................................................................... 3-M29
[1] SPECIFICATIONS.............................................................................................................. 3-M29
[2] FUNCTION AND STRUCTURE ......................................................................................... 3-M30
(1) Operating Principles ..................................................................................................... 3-M30
6. TRAVEL MOTOR ..................................................................................................................... 3-M34
[1] SPECIFICATIONS.............................................................................................................. 3-M34
[2] FUNCTION AND STRUCTURE ......................................................................................... 3-M35
(1) Operating Principles ..................................................................................................... 3-M35
7. HYDRAULIC CYLINDER.......................................................................................................... 3-M39
[1] SPECIFICATIONS.............................................................................................................. 3-M39
[2] FUNCTION AND STRUCTURE ......................................................................................... 3-M40
(1) Operating Principles ..................................................................................................... 3-M40
8. PILOT VALVE........................................................................................................................... 3-M42
[1] CONTROL PILOT VALVES................................................................................................ 3-M42
(1) Specifications ............................................................................................................... 3-M42
(2) Function and Structure ................................................................................................. 3-M43
[2] TRAVEL PILOT VALVE...................................................................................................... 3-M44
(1) Specifications ............................................................................................................... 3-M44
(2) Function and Structure ................................................................................................. 3-M45
[3] SWING PILOT VALVE ....................................................................................................... 3-M47
(1) Specifications ............................................................................................................... 3-M47
(2) Function and Structure ................................................................................................. 3-M48
KiSC issued 08, 2015 A
[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 ................................................................................................. 3-M55
[2] AUX SOLENOID VALVE .................................................................................................... 3-M57
(1) Specifications................................................................................................................ 3-M57
(2) Function and Structure ................................................................................................. 3-M58
[3] ANGLE SOLENOID VALVE ............................................................................................... 3-M59
(1) Specifications................................................................................................................ 3-M59
[4] EP MODE SOLENOID VALVE ........................................................................................... 3-M60
(1) Specifications................................................................................................................ 3-M60
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
3-M1
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
3-M2
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
(1) Pump
(2) Control Valve
(3) Swivel Motor
(4) Swivel Joint
(5) Travel Motor
(6) Boom Cylinder
(7) Arm Cylinder
(8) Bucket Cylinder
(9) Swing Cylinder
(10) Blade Cylinder
(11) Angle Cylinder
(12) Control Pilot Valves
(13) Travel Pilot Valve
(14) Blade Pilot Valves
(15) Swing Pilot Valve
(16) Unload Valve
(17) AUX1 Solenoid Valve
(18) AUX2 Solenoid Valve
(19) Angle Solenoid Valve
(20) Boom Shockless Valve
(21) Swivel Shuttle Valve
(22) EP Mode Solenoid Valve
(23) TPSS Valve
RY9212158HYM0030US0
3-M3
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
P1,P2: Piston pump discharge pressure
P3: Gear pump discharge pressure
Pp : Pilot pump discharge pressure
PLS: Load pressure
PPS: Valve inlet pressure
Maker
Model
Rated RPM
Rotation direction
Piston pump
Pilot pump
Gear pump
Standby flow amount
Max displacement
Pi : EP mode limit pressure
Pave: average pressure
PS: Suction pressure
CH: Air bleed
KYB
2000 rpm
Right
36.0 + 36.0 cc/rev (2.2 cu.in./rev)
7.1 cc/rev (0.4 cu.in./rev)
33.3 cc/rev (2.0 cu.in./rev)
22 L/min (5.8 U.S.gals)
RY9212158HYM0010US0
3-M4
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
(1) Pi = 3.6 MPa (P mode)
Discharge pressure (MPa)
PA1 = 2.0
PA2 = 14.0
PA3 = 23.1
PA4 = 29.4
(2) Pi = 0 MPa (E mode)
(a) Discharge flow rate: Q
(L/min)
Pump input RPM: 2000
Discharge flow rate (L/min)
143.0
Discharge pressure (MPa)
PB1 = 6.3
139.0
69.3
39.3
PB2 = 15.7
PB3 = 29.4
(b) Discharge pressure: P
(MPa)
Discharge flow rate (L/min)
141.0
66.0
19.8
RY9212148HYM0064US0
(1) Pi = 3.6 MPa (P mode)
Discharge pressure (MPa)
PA1 = 2.0
PA2 = 11.4
PA3 = 26.5
PA4 = 29.4
(2) Pi = 0 MPa (E mode)
(a) Discharge flow rate: Q
(L/min)
Pump input RPM: 2000
Discharge flow rate (L/min)
143.0
Discharge pressure (MPa)
PB1 = 2.5
63.0
14.3
12.7
PB2 = 19.5
PB3 = 29.4
(b) Discharge pressure: P
(MPa)
Discharge flow rate (L/min)
79.0
19.4
12.7
RY9212148HYM0065US0
3-M5
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
(1) Piston
(2) Retainer plate
(3) Shoe
(4) Swash-plate
(5) Cylinder block
(6) Valve plate
(7) Suction port
(8) P1 discharge port
(9) P2 discharge port
A : Discharge side
B : Suction side
There are 10 pistons (1) built into the cylinder block (5) and it is coupled to the axle via a spline. Also, one end of the cylinder block is in contact with a valve plate (6), which has two half-moon shaped ports (kidney ports); these two kidney ports are connected to suction and discharge ports respectively, so when the cylinder block rotates, the pistons are connected to the passage on the suction side for an interval of 180 degrees and to the discharge side for the remaining interval. There are shoes (3) crimped so they can rotate freely against the ball on the end of the piston and the retainer plate (2) presses them against the swash-plate(4). As a result, the shoes are always in contact with the swash-plate as it moves, so as the angle of the swash-plate changes, that translates into changes in the stroke of the piston and ultimately alters the amount of discharge from the pump. As a result of the cylinder block rotation, the side that is pressed into the cylinder block by the piston via the swash-plate is the discharge path. At this time the compressed chambers of the cylinder block are connected to the kidney ports on the discharge side A and the side where the pistons are being withdrawn become the suction path and are connected to the suction side kidney port.
As a consequence, during the interval of one revolution of the cylinder block, each piston alternately provides suction at the suction port and then discharge at the discharge port. Thus smooth pump operation is achieved by having 10 pistons constantly alternating between suction and discharge. The ports of the cylinder block are arranged alternately with different diameters; the discharge ports of the valve plate also has two kinds of ports arranged inside/outside to match, so the flow to be discharged can be split off to the inner/outer ports and consequently equivalent flow amounts can be obtained simultaneously.
RY9212148HYM0059US0
3-M6
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
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.
RY9212174HYM0005US0
1. When pressure P is low (when the load is low)
The horsepower control spool (4) is positioned at the far left, thus connecting the control pin (1) to the tank via the horsepower control spool (4). Consequently, there is no force on the control pin (1), which results in the maximum swash-plate tilt angle and discharge flow.
(1) Control pin
(2) Horsepower control spring
(3) Horsepower control valve
(4) Horsepower control spool
RY9212148HYM0060US0
3-M7
KiSC issued 08, 2015 A
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 discharge pressure P to the control pin (1), creating pressure on the control pin (1) and thus reducing the swash-plate tilt angle and reducing discharge flow.
When the swash-plate tilt angle is reduced, the horsepower control spring (2) returns the horsepower control spool (4) to the left, cutting off the connection between discharge pressure P and the control pin and this results in a balance of pressure.
Increasing pressure on the E-mode control pressure
(Pi) exerts a load on the horsepower control spool (4) pushing it to the left, so compared to when pressure is not applied to the E-mode control pressure (Pi), it allows an increase in the pump's effective horsepower.
(1) Control pin
(2) Horsepower control spring
(3) Horsepower control valve
(4) Horsepower control spool
(5) Reaction pin
Pi : From E-mode limit pressure
RY9212148HYM0061US0
LS control supplies the pressure and flow needed for a given load by controlling the pump's discharge pressure and flow so that pump discharge pressure PPS
= load pressure PLS + spring pressure.
(10) Spring
(11) Spool
(12) L/S Regulator
RY9212174HYM0006US0
3-M8
KiSC issued 08, 2015 A
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; this connects the control pin
(1) to the horsepower control valve (3). When this happens, the horsepower control spool (4) moves to the left, connecting the the control pin (1) to the tank, thus increasing the swash-plate tilt angle and increasing discharge flow. This equalizes the differential pressure and moves the L/S regulator spool back to the left.
(1) Control pin
(2) Horsepower control spring
(3) Horsepower control valve
(4) Horsepower control spool
(5) Reaction pin
(6) L/S Regulator
(7) Spool
(8) Compensator spool
(9) Opening area
RY9212148HYM0062US0
3-M9
KiSC issued 08, 2015 A
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. When this happens, it creates pressure on the control pin, thus reducing the swash-plate tilt angle and reducing the discharge flow.
(1) Control pin
(2) Horsepower control spring
(3) Horsepower control valve
(4) L/S Regulator
(5) Spool
RY9212148HYM0063US0
3-M10
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
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 pump discharge pressure and flows so that pump discharge pressure PPS = load pressure PLS + spring pressure + differential pressure. In other words, it changes the PPS and PLS differential pressure control from a constant control to a variable control and enables the proportional flow control of the engine RPM by how wide the same control valve is open.
(1) Orifice (2) Gear Pump (Pilot Pump)
RY9212174HYM0009US0
A standby flow volume is established so that oil is always flowing in the hydraulic system, even when idling.
By always passing through the oil cooler, the oil temperature can be kept down. The front (arm, bucket,
AUX1, boom, swing, angle) is in a center closed circuit, so when all the sections are in neutral, the hydraulic oil returns to the tank via an unload valve.
(1) Horsepower control curve
(2) Standby flow amount
(a) Discharge pressure
(b) Discharge flow
RY9212158HYM0011US0
3-M11
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
(1) Swivel right (Pbk5)
(2) Swivel left (Pak5)
(3) Blade up (Pbk4)
(4) Blade down (Pak4)
(5) AUX2 High (Pbk3)
(6) AUX2 Low (Pak3)
Maker
Model
Main relief valve setting pressure
(7) Travel left forward (Pbk2)
(8) Travel left reverse (Pak2)
(9) Travel right forward (Pbk1)
(10) Travel right reverse (Pak1)
(11) Arm dump (Pb1)
(12) Arm crowd (Pa1)
Item
(13) Bucket dump (Pb2)
(14) Bucket crowd (Pa2)
(15) AUX1 High (Pb3)
(16) AUX1 Low (Pb3)
(17) Boom up (Pb4)
KYB
Unload (aUN)
Main LS (aLS)
P1 (aTR)
P2 (aTL)
P3 (aP3)
2.7 MPa
28 kgf/cm
2
392 psi
27.4 MPa
279 kgf/cm
2
3974 psi
29.4 MPa
300 kgf/cm
2
4264 psi
20.6 MPa
210 kgf/cm
2
2988 psi
(18) Boom down (Pa4)
(19) Swing right (Pb5)
(20) Swing left (Pa5)
(21) Angle right (Pb6)
(22) Angle left (Pa6)
Notes
When 23 L/min., 6.1 U.S. gals
When 48 L/min., 12.7 U.S. gals
When 43 L/min., 11.4 U.S. gals
When 66 L/min., 17.4 U.S. gals
3-M12
KiSC issued 08, 2015 A
KX080-4, WSM
Bucket
Overload relief valve setting pressure
Blade
AUX1
Angle
Item
Boom
Arm b1B b1R b2B b2R b3B b3R b4B b4R b6L b6R b8B b8R
HYDRAULIC SYSTEM
Notes
31.4 MPa
320 kgf/cm
2
4554 psi
30.4 MPa
310 kgf/cm
2
4409 psi
31.4 MPa
320 kgf/cm
2
4554 psi
31.4 MPa
320 kgf/cm
2
4554 psi
27.4 MPa
279 kgf/cm
2
3974 psi
17.2 MPa
175 kgf/cm
2
2495 psi
20.6 MPa
210 kgf/cm
2
2988 psi
19.0 MPa
194 kgf/cm
2
2756 psi
31.4 MPa
320 kgf/cm
2
4554 psi
At 5 L/min
(300 cu.in./min, 1.3 USGPM)
RY9212158HYM0012US0
3-M13
KiSC issued 08, 2015 A
KX080-4, WSM
Hydraulic Circuit Diagram (Angle Spec.)
HYDRAULIC SYSTEM
(1) P3 bypass valve
(2) Swivel
(3) Blade
(4) AUX2
(5) Communication valve
(6) Travel left
(7) Travel right
(8) Independent travel valve
(9) Arm
(10) Bucket
(11) AUX1
(12) Boom
(13) Swing
(14) Angle
A : Main spool pressure receiver characteristics
B : Independent travel valve, etc. pressure receiver characteristics
(A) Spool stroke (mm)
(B) Pilot pressure (MPa)
(a) Other
(b) Swing, angle
(c) Blade Pa pressure
(d) Blade Pb pressure
(e) Communication valve
(f) Independent travel valve
(g) P3 bypass valve
RY9212158HYM0013US0
3-M14
KiSC issued 08, 2015 A
KX080-4, WSM
When in neutral
HYDRAULIC SYSTEM
(1) Independent travel valve section
(2) LS drain plug
(3) Micro-orifice (4) PLS pressure passage (5) Notch
• Pump discharge pressure PPS and maximum load pressure PLS act on either end of the unload spool.
• The PLS pressure passage (4) is connected to the tank circuit via the micro-orifice (3) in the LS drain plug (2).
• When the spool section is in neutral, no PLS pressure is generated, so PLS=tank pressure ≈ 0 and only spring pressure (unload valve setting pressure) acts on the right side of the unload spool.
• Hydraulic oil that flows in from the pump ports PP1 and PP2 is combined inside the independent travel valve section (1) and guided to the pump pressure passage, but when a spool section is in neutral, the pump pressure passage is stopped and pump discharge pressure PPS rises.
• When pump discharge pressure PPS rises to the unload valve setting pressure, the unload spool moves to the right side, and the pump pressure passage is connected to the tank circuit via the notch (5) in the unload spool.
This mechanism maintains the pump pressure passage PPS at the unload valve setting pressure.
• The unload valve is set at a pressure somewhat higher than the LS control differential pressure value set for the pump, so the pump maintains it at standby flow rate discharge status (fixed flow rate).
RY9212158HYM0014US0
3-M15
KiSC issued 08, 2015 A
KX080-4, WSM
During fine operation of LS section
HYDRAULIC SYSTEM
(1) Independent travel valve section
(2) LS drain plug
(3) Micro-orifice
(4) PLS pressure passage
(5) Notch
(a) To each spool section
• 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. The operating load pressure of the cylinder port is guided from inside the spool section to the PLS pressure passage (4) and becomes the PLS pressure. (Refer to the explanation of how the spool section operates.)
• As long as the amount switched from the spool section is small (fine operation), the open area of the spool section becomes also small, so it increases the pressure differential (PPS-PLS) between the pump pressure PPS and
PLS.
• Once the pressure differential (PPS-PLS) between the pump pressure PPS and PLS reaches the unload valve setting pressure, the unload spool moves to the right side, automatically adjusting the open area in the notch between the pump pressure passage and the tank passage, thus maintaining a steady pressure differential
(PPS-PLS) between the pump pressures PPS and PLS.
• The mechanism described above maintains a constant pressure differential (PPS-PLS) between the pump pressures PPS and PLS, even when there is a change in the spool section operating load pressure.
• The unload valve is set at a pressure somewhat higher than the LS control differential pressure value set for the pump, so the pump maintains it at standby flow rate discharge status (fixed flow rate).
RY9212158HYM0015US0
3-M16
KiSC issued 08, 2015 A
KX080-4, WSM
During operation of LS section
HYDRAULIC SYSTEM
(1) Independent travel valve section
(2) LS drain plug
(3) Micro-orifice
(4) PLS pressure passage
(5) Notch
(a) To each spool section
• 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. The operating load pressure of the cylinder port is guided from inside the spool section to the PLS pressure passage (4) and becomes the PLS pressure. (Refer to the explanation of how the spool section operates.)
• When the amount switched from the spool section is great, the area of the spool section that opens is large, so it reduces the pressure differential (PPS-PLS) between the pump pressure PPS and PLS.
• When the pressure differential (PPS-PLS) between the pump pressure PPS and PLS drops to the unload valve setting pressure, the unload spool moves to the left side, closing the opening at the notch between the pump pressure passage and the tank circuit, thus completely closing the unload spool.
• If the pressure differential (PPS-PLS) between the pump pressure PPS and PLS drops further to the LS limit pressure differential setting set for the pump, it increases the pump's swash-plate tilt angle, thus increasing the pump's discharge flow rate.
• The pump automatically changes the discharge flow rate according to the amount the spool section is switched and changes in the operating load pressure, thus limiting it to maintain a constant differential pressure (PPS-PLS) between the pump pressure PPS and PLS.
RY9212158HYM0016US0
3-M17
KiSC issued 08, 2015 A
KX080-4, WSM
When in neutral
HYDRAULIC SYSTEM
(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
(10) Overload relief valve
(a) From unload valve to tank circuit
(b) To pump
• Oil that flows in from P1 and P2 is combined inside the independent travel valve section (1) and guided to the pump pressure passage (9).
• The main spool PC notch, which opens/closes the pump pressure passage (9) and the compensator upstream passage, is closed.
• The PLS pressure passage (4) is connected to the tank circuit via the micro-orifice (3) in the LS drain plug (2), so
PLS=tank circuit pressure.
• Pump pressure PPS becomes the unload valve setting pressure and with the pump discharge flow rate at standby flow, the entire flow from the unload valve is returned to the tank circuit. (Refer to the explanation of the unload valve operation.)
• The main spool LSC and CT notches, which are connected to the cylinder port, are closed, keeping the actuator connected to the cylinder port in a stopped state.
RY9212158HYM0017US0
3-M18
KiSC issued 08, 2015 A
KX080-4, WSM
When Pb port pressurized
HYDRAULIC SYSTEM
(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
(10) Overload relief valve
(11) LS pressure guide orifice
(a) From unload valve to tank circuit
(b) To pump
• When the spool is shifted by the Pb port pressure, the pump pressure PPS flows to cylinder port B1 via the main spool PC notch, compensator spool C notch, the right load check and the main spool LSC notch.
• The pressure (load pressure) in the load check upstream passage is guided to the PLS pressure passage via the compensator spool LS pressure guide orifice (11), opening the shuttle poppet and becoming the PLS pressure; it is then guided to the pump as the PLS signal pressure from the PLS port.
• Part of the flow of oil in the PLS pressure passage passes through the micro-orifice (3) in the LS drain plug (2) and returns to the tank circuit.
• The pressure PPS in the pump pressure passage is guided to the pump from the independent travel valve's PPS port as the pump signal pressure.
• Part of the oil flowing back from the actuator returns from cylinder port A to the tank circuit via the main spool CT notch.
RY9212158HYM0018US0
3-M19
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
(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
(10) Unload spool
(11) Arm regenerative sleeve
(12) Regenerative poppet
(13) LS pressure guide orifice
(a) To pump
(b) Regenerative flow
• When the spool is shifted, the pump pressure PPS flows to cylinder port A1 via the main spool PC notch, compensator spool C notch, the right load check and the main spool LSC notch.
• The pressure (load pressure) in the load check upstream passage is guided to the PLS pressure passage via the compensator spool LS pressure guide orifice (13), opening the shuttle poppet and becoming the PLS pressure; it is then guided to the pump as the PLS signal pressure from the PLS port.
• Part of the flow of oil in the PLS pressure passage passes through the micro-orifice (3) in the LS drain plug (2) and returns to the tank circuit.
• The pressure PPS in the pump pressure passage is guided to the pump from the independent travel valve's PPS port as the pump signal pressure.
• Part of the oil flowing back from the actuator flows from cylinder port B2 via the CT notch in the main spool and the regenerative poppet to the upstream passage of the load check poppet and is combined as a regenerative flow. And part of the returning oil passes through the arm regenerative sleeve and returns to the tank circuit.
RY9212158HYM0019US0
3-M20
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
(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
(10) LS pressure guide orifice
(11) Anti-void valve
(a) To pump
(b) To unload valve
[In neutral]
• Oil that flows in from P1 and P2 is combined inside the independent travel valve section (1) and guided to the pump pressure passage (9).
• The main spool PC notch, which opens/closes the pump pressure passage (9) and the compensator upstream passage, is closed.
• The PLS pressure passage (4) is connected to the tank circuit via the micro-orifice (3) in the LS drain plug (2), so
PLS=tank circuit pressure.
• Pump pressure PPS becomes the unload valve setting pressure and with the pump discharge flow rate at standby flow, the entire flow from the unload valve is returned to the tank circuit. (Refer to the explanation of the unload valve operation.)
• The main spool LSC and CT notches, which are connected to the cylinder port, are closed, keeping the actuator connected to the cylinder port in a stopped state.
[When port is pressurized]
• When the spool is shifted by the Pa port pressure, the pump pressure PPS flows to cylinder port A via the main spool PC notch, compensator spool C notch, the right load check and the main spool LSC notch.
• The pressure (load pressure) in the load check upstream passage is guided to the PLS pressure passage via the compensator spool LS pressure guide orifice, opening the shuttle poppet and becoming the PLS pressure; it is then guided to the pump as the PLS signal pressure from the PLS port.
• Part of the flow of oil in the PLS pressure passage passes through the micro-orifice (3) in the LS drain plug (2) and returns to the tank circuit.
• The pressure PPS in the pump pressure passage is guided to the pump from the independent travel valve's PPS port as the pump signal pressure.
• Part of the oil flowing back from the actuator returns from cylinder port B to the tank circuit via the main spool CT notch.
RY9212158HYM0020US0
3-M21
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
(1) Independent travel valve section
(2) Travel right section
(3) Travel left section
(4) Main spool
(5) PP2 signal pressure
(a) To pump
(b) To unload valve
[In neutral]
• Oil that flows in from P1 and P2 is combined inside the independent travel valve section (1) and guided from the unload valve to the tank circuit.
• Pump pressure PPS becomes the unload valve setting pressure and with the pump discharge flow rate at standby flow, the entire flow from the unload valve is returned to the tank circuit. (Refer to the explanation of the unload valve operation.)
• Thus the pressure in the main spool spring chamber of the independent travel valve is PT pressure=tank circuit pressure.
• Cylinder ports AK1 (AK2), BK1 (BK2) are connected to the tank circuit via the CT notch in the main spool.
(To be continued)
3-M22
KiSC issued 08, 2015 A
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.
• By shifting the main spool of the independent travel valve, the pump pressure P1 (P2) is guided to the center bypass of the travel 1st (2nd) section and oil flows to the cylinder port AK1 (AK2) via the bridge passage and the
PC notch.
• At the same time, the pressure at the PPS port, which is connected to the pump, is connected to the tank circuit and the pump discharges a large volume of oil.
• The PT passage controls the volume of oil supplied to the cylinder port AK1 (AK2) according to how much the travel main spool is shifted, and varies the P1 (P2) pressure in line with the change, from fully open to fully closed.
• Oil flowing back from the actuator returns from cylinder port BK1 (BK2) to the tank circuit via the main spool CT notch.
RY9212158HYM0021US0
3-M23
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
(1) Independent travel valve section
(2) Blade section
(3) Communication valve spool
(4) Main spool
(5) Load check valve
(6) Parallel passage
(7) Bridge passage
(8) Center bypass passage
(9) AUX2
(10) Swivel
[In neutral]
• The oil flowing from P3 passes through the parallel passage (6) of each section (AUX2, blade, swivel), going through the center bypass passage (8) of each section (swivel, blade, AUX2) and returns to the hydraulic oil tank via the communication valve spool (3) of the communication section.
• The main spool PC and CT notches are closed, keeping the actuator connected to the cylinder ports AK4 and
BK4 in a stopped state.
[When port pressurized (6mm, 0.24in. stroke)]
• When the spool is shifted by pressure from the Pak4 port (6 mm, 0.24 in.), it closes the PT notch of the main spool, cutting off the connection between the center bypass passage (8) and the tank circuit.
• Pump pressure P3 presses up the load check poppet from the parallel passage and oil returns to the cylinder port
AK4 via the bridge circuit (7) and the PC notch.
• The PT passage controls the volume of oil supplied to the cylinder port AK4 according to how much the travel main spool (4) is shifted, and varies the P3 pressure in line with the change, from fully open to fully closed.
• Oil flowing back from the actuator returns from cylinder port BK4 to the tank circuit via the main spool CT notch.
[When port is pressurized (full stroke=float position)]
• When the main spool (4) is shifted by the Pak4 port pressure (full stroke), cylinder port AK4 and BK4 are connected to the tank circuit.
RY9212158HYM0022US0
3-M24
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
(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
(10) Anti-drift valve
(11) Piston
(12) Spool
(13) Poppet A
(14) Poppet B
(a) From unload valve to tank circuit
(b) To pump
[In neutral]
• The boom cylinder holding pressure (pressure from port B connected to the bottom side) acts on the spring chamber side of anti-drift valve poppet A, thus seating poppet A and contributing to reducing the amount leaked
(reducing boom drift).
[During boom down operation]
• When port Pa is pressurized, both port Pa and port Pi , which are connected to it externally, are pressurized, so the piston (11), spool (12) and poppet B are actuated and the spring chamber of poppet A is connected to DR1; this opens poppet A and the oil returning from the actuator passes from cylinder port B via main spool CT notch back to the tank circuit.
RY9212158HYM0025US0
3-M25
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
(1) Boom section
(2) P3 bypass section
(3) Swivel section
(4) Main spool
(5) Compensator spool
(6) Pump pressure passage
(7) Switch spool
(8) Check valve
(a) From P3 port
• Boom up operation pressurizes the Pb4 port and switches the boom section. At the same time, the Pbu1 port, which is connected via external lines, is also pressurized and the switch spool of the P3 bypass valve is switched.
• The Pak5 (Pbk5) port is pressurized and when the swivel section is switched, the P3 pump pressure is guided to the cylinder port of the swivel section, while simultaneously being guided to the switch spool of the P3 bypass valve.
[Swivel section operating load pressure>boom section operating load pressure]
• The P3 pump pressure passes through the switch spool of the P3 bypass valve, presses up on the check valve and flows together with oil from the PB1 port to the PB2 port.
[Swivel section operating load pressure<boom section operating load pressure]
• As the check valve of the P3 bypass valve does not open, the P3 pump pressure is not combined to the PB2 port and operates independently.
RY9212158HYM0023US0
3-M26
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
(1) Independent travel valve section
(2) Communication valve section
(3) P3 bypass section
(4) Independent travel valve spool
(5) Communication valve spool
(6) Filter
(7) Micro-orifice
(8) Ring gap
(9) Swivel
(10) Blade
(11) AUX2
(12) Travel left
(13) Travel right
(14) Arm
(15) Bucket
(16) AUX1
(17) Boom
(18) Swing
(19) Main spool signal passage section
(20) Area receiving pressure: A1
(21) Area receiving pressure: A2
(a) To pump
[In neutral]
• Pilot pump pressure is guided to the hydraulic supply ports PP1, PP2 and PP3 of the signal circuit.
• The pilot pump pressure supplied to port PP1 of the P3 bypass section returns to the tank circuit via the filter (6) and micro-orifice (7) and via the main spool signal passage switch (19) of all sections so port PAI port=tank pressure.
• The pilot pump pressure supplied to port PP2 of the communication valve section (2) returns to the tank circuit via the filter (6), micro-orifice (7) and the open center passage of the communication valve spool (5), and via the main spool signal passage switch of the travel section. And oil in the passage split at a point upstream of the travel section's main spool signal passage switch is guided to the independent travel valve section as well, and is connected to the PT port pressure chamber via the ring-shaped gap (8) of the independent travel valve spool (4).
• The pilot pump pressure supplied to port PP3 of the main valve returns to the tank circuit via the filter (6) and micro-orifice (7) and via the main spool signal passage switch of each of the arm → bucket → S/P1 → boom → swing section, so port PF1 port=tank pressure.
• The PF1 port is connected via external lines with the PF2 port of the communication valve section (2), so
PF1=PF2=tank pressure.
(To be continued)
3-M27
KiSC issued 08, 2015 A
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.
• This raises the PAI port pressure to the PP1 port pressure (that is, the pilot pump pressure).
• If the switched section above is the arm, bucket S/P1, boom or swing, the passage connecting the downstream side of the PP3 port micro-orifice and the tank circuit is cut off at the same time.
• This raises the PF1 port pressure, along with the PF2 port, which is connected by external lines, to the PP3 port pressure (in other words, the pilot pump pressure).
• Raising the PF2 port pressure pressurizes the pressure receiving chamber on the left side of the communication valve spool, and the pressure acts on the pressure receiving area A1, generating switching force toward the right; the communication valve spool does not move as it is configured with spring force so it switches when pressure receiving areas A1 and A are pressurized at the same time.
(communication valve spring pressure setting=pressure receiving area A1 switch force + pressure receiving area
A2 switching force)
[During independent travel operation]
• It switches the main spool of the travel section to either the A or the B port side and cuts off the passage that connects the PP2 port micro-orifice downstream and the tank circuit.
• This results in the pressure on the spring chamber, which is on the right side of the independent travel valve spool connected to the downstream of the PP2 micro-orifice, being equal to the PT port pressure, which rises to the
PP2 port pressure (in other words, the pilot pump pressure).
• When the PT port pressure rises, it shifts the independent travel valve spool and P1 and P2 pump pressure is supplied to the travel sections.
• Further, raising the PT port pressure pressurizes the pressure receiving chamber on the left side of the communication valve spool, and the pressure acts on the pressure receiving area A2, generating switching force toward the right; however, the communication valve spool does not move as it is configured with spring force that makes it switch when pressure receiving areas A1 and A2 are pressurized at the same time.
(communication valve spring pressure setting=pressure receiving area A1 switch force + pressure receiving area
A switching force)
[During travel + front operation]
• When the travel section is switched, as mentioned above, the actuation of the independent travel valve supplies
P1, P2 pump pressure independently to the section. (P1, P2 pump supply is cut off from the closed center section)
• In this situation, if one of the closed center sections (arm, bucket, S/P1, boom, swing) is switched, it pressurizes the PT port and PF2 port simultaneously.
• When pressure at the PT port and PF2 ports rises at the same time, the pressure receiving chamber on the left side of the communication valve spool is pressurized, exerting pressure on the receiving areas A1 and A2.
• As the communication valve spool is configured with spring pressure so it switches when receiving areas A1 and
A2 are pressurized at the same time, the communication valve spool shifts to the right.
(communication valve spring pressure setting=pressure receiving area A1 switch force + pressure receiving area
A2 switching force)
• Once the communication valve spool shifts, the passage that connects to the tank circuit via the communication valve spool is cut off, and the P3 pump pressure presses up on the check valve, communicating with the pump pressure passage of the closed center section. (operates the communication valve)
• Thus the travel section operates independently via P1 and P2 pumps and the closed center section operates using pump P3 pressure.
RY9212158HYM0024US0
3-M28
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
(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)
(10) Swivel right relief valve
(cSR)
Item
Maker
Model
Total displacement
Motor displacement
Reduction ratio
Relief valve cSR cSL
Shockless pressure
Shockless time
Useful flow
PG
Parking brake release pressure
SH
Hydraulic timer
Notes
KYB
MSG-44P-21-19
909 cm
3
/rev
55.5 cu.in./rev
44.1 cm
3
/rev
2.7 cu.in./rev
20.615
21.6 MPa
220 kgf/cm
2
3133 psi
8.3 ± 0.1 MPa
84.70 ± 1.02 kgf/cm
2
1203.8 ± 14.5 psi
0.03 ± 0.05 sec
66 L/min
17.4 U.S.gals
1.5 to 4.9 MPa
15.3 to 50.0 kgf/cm
2
217.6 to 711.0 psi
0.4 ± 0.1 MPa
4.10 ± 1.02 kgf/cm
2
58.0 ± 14.5 psi
5.0 ± 1.5 sec
At 66 L/min., 17.4 U.S. gals
RY9212148HYM0030US0
3-M29
KiSC issued 08, 2015 A
KX080-4, WSM
[A] Motor
HYDRAULIC SYSTEM
• 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 pistons receive the counterforce from the swash-plate, part of which becomes rotational force, and the block rotates due to the sum total of the rotational forces exerted by the pistons that the hydraulic oil entered.
• The cylinder block and the shaft (7) are linked via a spline, so rotation is transferred to the shaft.
• When in reverse, hydraulic oil flows in via port B (2) and is discharged via port A.
(1) Port A
(2) Port B
(3) Valve Plate
(4) Cylinder Block
(5) Piston
(6) Swash Plate
(7) Shaft
RY9212148HYM0056US0
[B] Make Up Circuit
• If the swivel is decelerated with pressurized oil supplied via port A (1), the motor rotates due to the inertia of the swiveling equipment, and the motor drives the pump.
• This results in load on the port A side; in order to prevent this, the oil on the return side passes through the poppet (3) in the make up circuit and is supplied to the port A side.
(1) Port A
(2) Port B
(3) Poppet
(4) Port M
RY9212148HYM0001US0
[C] Relief Valve
• The relief valve is the valve that determines the drive and brake forces during swiveling and it's equipped with main ports A/B lines for each.
• Oil that enters port B is guided to the piston chamber
(4) via the relief valve orifice (2) and the body orifice
(3). While the piston is moving to the left side, the spring chamber is at low pressure, so it acts on the piston with the low force provided by the spring.
(Primary relief pressure)
• When the piston in the diagram reaches the left side, the pressure in the spring chamber rises, and acts on the piston with the total force of the spring and the pressure. (Secondary relief pressure)
• Because of this, the system can suppress dramatic changes in pressure and can mitigate the shock of starting up and stopping the equipment.
(1) Piston
(2) Relief valve orifice
(3) Body orifice
(4) Piston chamber
(a) Pressure
(b) Time
(c) Primary relief pressure
(d) Secondary relief pressure
RY9212148HYM0031US0
3-M30
KiSC issued 08, 2015 A
KX080-4, WSM
[D] Parking Brake
[E] Hydraulic Timer
HYDRAULIC SYSTEM
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).
• Friction holds the cylinder block (3) to the case, preventing it from turning.
(1) Brake piston
(2) Disc
(3) Cylinder block
RY9212148HYM0032US0
b)When the parking brake is released
• When the brake release pressure is guided to the brake piston chamber (1) via the PG port
(P)
, the release pressure acts against the resistance of the brake piston's spring, eliminating the friction with the disc and allowing the cylinder block to turn freely.
(1) Brake piston chamber
P: Port PG
RY9212148HYM0033US0
• The hydraulic timer is a function for preventing drag on the parking brake when the swivel brake is used and it plays the role of ensuring delayed timing so the parking brake does not operate while hydraulic dynamic braking is absorbing inertial energy from the turning of the swivel; the delayed timing is achieved via flow control through an orifice that slows the discharge of oil from the brake piston chamber (1).
• From the state of the motor turning, when the pilot valve returns to neutral, the pilot valve switch signal and the linked timer valve switch pressure SH go to low pressure, and the brake piston chamber (1) and drain port (3) are linked by the spring (2).
• The pressure on the brake piston chamber (1) moves it in the direction to allow it to press against the disc via the force of the spring acting on the brake piston, but as flow is restricted by the timer valve orifice, until a certain amount of time passes, the brake piston does not touch the disc and the parking brake does not engage.
(1) Brake piston chamber
(2) Spring
(3) Drain port
(a) ON
(b) OFF
RY9212148HYM0034US0
3-M31
KiSC issued 08, 2015 A
KX080-4, WSM
[F] Reverse Check Valve
HYDRAULIC SYSTEM
• 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.
(1) Sleeve
(2) Flow regulating valve
(3) Check valve
(4) Damper chamber
(5) Orifice A
(6) Orifice B
(7) To high-pressure passage
(8) To makeup
RY9212148HYM0035US0
a)In neutral
• The check valve is held in balance in the middle by the spring. (Equal pressure on ports P1 and P2)
RY9212148HYM0036US0
b)Acclerating to uniform RPM
• When swiveled, the check valve is pressed on the high-pressure side, seating the check valve.
(1) Supply pressure (2) Seat
RY9212148HYM0037US0
c)When braking
• Brake pressure shifts the check valve full stroke, seating it.
(1) Brake pressure (2) Seat
RY9212148HYM0038US0
3-M32
KiSC issued 08, 2015 A
KX080-4, WSM
[G] Two-Stage Planetary Gear Decelerator
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; this forms a passage between the port (Pv2) pressurized by the reverse pressure and the port (Cv) linked by the main line, giving the reverse pressure access to the
Cv port.
(1) Reverse pressure (2) Seat
RY9212148HYM0039US0
e)When reversing 2
• The reverse pressure pushes in the opposite direction during check valve braking at the same time.
• The flow regulating valve inside the check valve, which is now on the low-pressure side, is open at a certain flow rate to oil from inside the damper chamber. As a result, the check valve is shifted at a certain speed.
• The check valve eventually seats, so the passage formed between the Pv2 and Cv ports is blocked.
(1) Reverse pressure
RY9212148HYM0040US0
• The motor shaft (1) is coupled to the drive gear (2) and the spline, so the drive force of the motor is transmitted to planetary gear A (3), which meshes with the drive gear (2).
• Planetary gear A (3) meshes with the ring gear of the decelerator housing (4). As a result, when it rotates, it turns around the ring gear.
• Planetary gear A (3) is held to holder (5) by the bearing and the holder (5) transmits the rotary motion of planetary gear A (3) to the sun gear (6), which is coupled to the spline.
• Sun gear (6) meshes with planetary gear B (7) and transmits the rotary motion to planetary gear B (7) in the same way as the first stage.
• As planetary gear B (7) meshes with the ring gear of the housing (4), it rotates around it as it turns.
• Planetary gear B (7) is held to holder (8) by the bearing and the holder (8) transmits the rotary motion of planetary gear B (7) to the pinion shaft, which is coupled to the spline.
(1) Motor shaft
(2) Drive gear
(3) Planetary gear A
(4) Housing
(5) Holder
(6) Sun gear
(7) Planetary gear B
(8) Holder
(9) Pinion shaft
RY9212148HYM0041US0
3-M33
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
(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)
Maker
Model
Reduction ratio
Hydraulic motor
Parking brake
Item
Reduction ratio
Output torque (1F/2F)
RPM (1F/2F)
Displacement (1F/2F)
Flow Rate
Relief valve (cTF, cTR)
2-speed switch pressure
Auto 2-speed switch pressure
Release pressure
Mitsubishi Heavy Industries
SGM-04D-S-09KT
54.8
10349 to 5322 N·m
1055.6 to 542.8 kgf·m
7633.4 to 3925.5 lbf·ft
26.6 /49.4 rpm
46.90 / 25.29 cm
3
/rev
2.86 / 1.54 cu.in./rev
72.0 L/min
19.0 U.S.gals
29.4 MPa
300 kgf/cm
2
4264 psi
4.0 MPa
40.8 kgf/cm
2
580 psi
24.0 MPa
245 kgf/cm
2
3481 psi
0.98 MPa
10.0 kgf/cm
3
142.1 psi
Notes
RY9212158HYM0026US0
3-M34
KiSC issued 08, 2015 A
KX080-4, WSM
[A] Motor
HYDRAULIC SYSTEM
• 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).
• If high-pressure oil is guided to port C, the pressurized oil passes through port C and presses on the swash-plate (4). The pistons receive the counterforce from the swash-plate, part of which is converted into rotational force, and the block rotates due to the sum total of the rotational forces exerted by pistons that the hydraulic oil entered.
• The cylinder block and the shaft (5) are linked via a spline, so the rotation is transferred to the shaft.
(1) Cylinder Block
(2) Piston
(3) Valve Plate
(4) Swash Plate
(5) Shaft
C : Port C
D : Port D
RY9212148HYM0002US0
3-M35
KiSC issued 08, 2015 A
KX080-4, WSM
[B] Brake Valve
HYDRAULIC SYSTEM
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.
• On the other hand, oil enters port A, passes through passage a from the small hole in the spool (2) and enters chamber b. The hydraulic force from chamber b shifts the spool from the center position to the left side.
• The shifting of the spool makes a link between port
D and port B, allowing the oil to return from the control valve to the tank and the motor turns.
• And by shifting the spool, oil enters port E and the oil in port E flows to the parking brake (3) and the
2-speed switch valve.
b)When stopping (brake operation)
• When the oil supplying port A is stopped, the pressure at port A and chamber b drops. As a result of the pressure drop, the spring starts pushing the spool (2) from left to right toward its neutral position.
At that time, the oil in chamber b tries to go out toward the port A side via line a inside the spool, but the effect of the orifice in line a creates back pressure, limiting the return speed of the spool.
• Conversely, even though the oil from port A is stopped, the inertial force tries to keep the motor turning, and the oil discharged from the motor tries to return to port B from port D.
Once the spool returns completely to neutral, the return passage from the spool to the motor is completely cut off and the motor stops.
The check valve (1) moves under the slightest of loads, opening a passage between the circuit on the port A side and port C of the motor intake, preventing motor cavitation.
c)Runaway check function (for descending steep slopes)
• Under normal operation, the pressure on the supply side drops when the motor is driven by external forces. When the pressure approaches that required to start running away, the spool (2) starts moving toward the neutral position in the middle.
• The surface area in the passage to port B from port
D on the motor outlet side drops in relation to the distance the spool moves, limiting the amount of oil discharged. At the same time, the pressure at port D
(back pressure) rises as well, preventing the machine from running away down a hill.
(1) Check valve
(2) Spool
(3) Parking brake
(4) Spring
(a) Line a
(b) Chamber b
RY9212158HYM0031US0
3-M36
KiSC issued 08, 2015 A
KX080-4, WSM
[C] Relief Valve
HYDRAULIC SYSTEM
(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 stroke, the pressure in the chamber (3) rises, and the poppet (2) closes and the main relief valve of the control valve opens.
These mechanisms raise the port pressure, applying rotary force to the motor.
(B)When stopping
• When the pressure on the motor outlet side rises, it is guided to the chamber (3) via the internal orifice.
• Until the oil supplied to the chamber (3) shifts the position of the shockless piston and it reaches the end of its stroke, the oil from the port is released at the pressure setting (low-pressure relief) of the shockless piston (1) and is guided to the port.
• Once the shockless piston (1) reaches the end of its stroke, the pressure in the chamber (3) rises, closing the poppet (2) and acting with the total force of the spring and the pressure inside the chamber.
(Secondary relief pressure)
The mechanisms above stop the motor.
(1) Shockless piston
(2) Poppet
(3) Chamber
(a) Pressure
(b) Time
(c) Low-pressure relief
(primary relief pressure)
(d) Main relief
(e) Relief valve A release timing
RY9212158HYM0032US0
3-M37
KiSC issued 08, 2015 A
KX080-4, WSM
[D] Parking Brake
[E] Auto-Decelerator Function
HYDRAULIC SYSTEM
• 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.
• The cylinder block (6) and the disc are linked via a spline and a friction material is applied to both sides of the disc. The disc is spring-loaded and friction is generated between the flange holder and the brake piston, and this limits the force with which the motor can turn, allowing it to function as a parking brake
• When pressurized oil is guided into the brake piston chamber (2), it generates an amount of thrust that matches the area of the brake piston that receives the pressure and overcomes the spring, thus moving the brake piston. The disk rotates freely between the flange holder and the brake piston, eliminating the parking brake function.
(1) Spring
(2) Brake piston chamber
(3) Brake piston
(4) Disc (friction material)
(5) Opposing plate (plate)
(6) Cylinder block
RY9212158HYM0001US0
(1) 2-speed port
(2) Ridged spool
(3) Spring
(4) 2-speed switch piston
(5) S chamber
(6) Swash-plate
(7) Ball
(a) Motor load pressure
(b) Drain
(c) High pressure selector valve
• This function gives priority to power for traveling and when the mini-excavator is traveling in the 2nd speed, if the travel load becomes great, such as when climbing or turning, it automatically decelerates to 1st speed
(low-speed). When the load is low, it returns to the 2nd speed (high-speed).
• When the speed button on top of the blade lever is pressed, it actuates the solenoid of the unload valve, thus guiding oil from the pilot pump to the 2-speed port (1). When pressure oil flows to the 2-speed port, it moves the ridged spool (2) to the right.
• Conversely, when the load
(a)
on the motor rises, pressure is guided against the small area of the ridged spool
(2), overcoming the pilot pressure and pressing the ridged spool (2) to the left, which releases the oil in chamber
S (5) to the drain via the ridged spool.
RY9212158HYM0027US0
3-M38
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
(4)
(5)
(6)
(7)
(1)
(2)
(3)
(8)
(9)
Max compresse d length
Stroke
Boom
82 mm
3.23 in.
82 mm
3.23 in.
90 mm
3.54 in.
90 mm
3.54 in.
65 mm
2.56 in.
115 mm
4.53 in.
134 mm
5.28 in.
57 mm
2.24 in.
70 mm
2.76 in.
1369 mm
53.90 in.
878 mm
34.57 in.
Arm
70 mm
2.76 in.
70 mm
2.76 in.
85 mm
3.35 in.
85 mm
3.35 in.
60 mm
2.36 in.
100 mm
3.94 in.
118 mm
4.65 in.
55 mm
2.17 in.
58 mm
2.28 in.
1378 mm
54.25 in.
912 mm
35.91 in.
Bucket
70 mm
2.76 in.
70 mm
2.76 in.
75 mm
2.95 in.
75 mm
2.95 in.
55 mm
2.17 in.
90 mm
3.54 in.
112 mm
4.41 in.
60 mm
2.36 in.
55 mm
2.17 in.
1138 mm
44.80 in.
747 mm
29.41 in.
Blade
82 mm
3.23 in.
82 mm
3.23 in.
75 mm
2.95 in.
75 mm
2.95 in.
65 mm
2.56 in.
125 mm
4.92 in.
146 mm
5.75 in.
65 mm
2.56 in.
65 mm
2.56 in.
689 mm
27.13 in.
250 mm
9.84 in.
Swing
82 mm
3.23 in.
82 mm
3.23 in.
80 mm
3.15 in.
80 mm
3.15 in.
60 mm
2.36 in.
110 mm
4.33 in.
131 mm
5.16 in.
65 mm
2.56 in.
58 mm
2.28 in.
Angle
60 mm
2.36 in.
60 mm
2.36 in.
60 mm
2.36 in.
60 mm
2.36 in.
45 mm
1.77 in.
80 mm
3.15 in.
96 mm
3.78 in.
40 mm
1.57 in.
40 mm
1.57 in.
1165 mm
45.87 in.
733 mm
28.86 in.
715 mm
28.15 in.
455 mm
17.91 in.
RY9212158HYM0002US0
3-M39
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
• 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
(a) Flow Via a Slit (b) Flow from Indentation
The discharge pressurized oil is automatically reduced on the lift end of the boom, slowing the operation of the cylinder and cushioning the shock on the lift end of the boom. An indentation and a split in the cushion bearing are provided as a means to reduce the pressure.
RY9212148HYM0027US0
Cushion function on the rake end of the arm
(a) Flow Via a Slit (b) Flow from Indentation
The discharge pressurized oil is automatically reduced on the rake end of the arm, slowing the operation of the cylinder and cushioning the shock on the rake end of the arm. An indentation and a split in the cushion bearing are provided as a means to reduce the pressure.
RY9212148HYM0028US0
3-M40
KiSC issued 08, 2015 A
KX080-4, WSM
Cushion function on dumping end of arm
HYDRAULIC SYSTEM
(1) Port
(2) Cushion Chamber
(3) Cushion Plunger
(4) Piston
A : Before Cushion Enters
B : After Cushion Enters
RY9212148HYM0029US0
3-M41
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
(1) Port P
(2) Port 1 (Left)
(3) Port 2 (Front)
(4) Port 3 (Right)
(5) Port 4 (Rear)
(6) Port T
Maker
Model
Left
Right
(7) Independent operation torque
(ports 1, 3)
(8) Independent operation torque
(port 2)
(9) Independent operation torque
(port 4)
(10) Secondary pressure
(a) Secondary pressure
(kgf/cm
2
)
(b) Secondary pressure (MPa)
(c) Operating torque (N·m)
(d) Operating torque (kgf·cm)
(e) Pushrod stroke (mm)
(f) Operating angle (deg)
Kawasaki Heavy Industries, Ltd.
PV48M2199
PV48M2198
RY9212148HYM0004US0
3-M42
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
[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.
RY9212001HYM0001US0
[B] Operation
1. When the control lever is in neutral
The force of the secondary pressure spring (1) does not press on the spool (2). As a result, the spool is held in a neutral position by the return spring (3) or (4). At such time, the output port (control valve port)
(a)
and port
T
(T)
are connected.
(1) Secondary Pressure Spring
(2) Spool
(3) Return Spring
(4) Return Spring
(a) Output Port
(T) Port T
RY9212148HYM0005US0
2. When the control lever has been actuated
When the control lever is actuated, the pushrod (1) presses down on the spool (4) via the spring seat (2) and the secondary pressure spring (3). In doing so, port P
(P)
and the output port
(a)
are connected, so the oil from the pilot pump flows through the output port to the control valve.
The pressure at the output port rises until it is equivalent to the force of the secondary pressure spring, thus balancing the hydraulic pressure on the spool with the tension of the secondary pressure spring and maintaining a fixed output port pressure.
(1) Pushrod
(2) Spring Seat
(3) Secondary Pressure Spring
(4) Spool
(a) Output Port
(P) Port P
RY9212148HYM0006US0
3-M43
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
(1) Port 1 (L Bwd)
(2) Port 2 (L Fwd)
(3) Port 3 (R Bwd)
(4) Port 4 (R Fwd)
Maker
Model
(5) Operating torque
(6) Secondary pressure
(P) Port P
(T) Port T
Kawasaki Heavy Industries, Ltd.
PVD8PC6004A
(a) Secondary pressure
(kgf/cm
2
)
(b) Secondary pressure (MPa)
(c) Operating torque (N·m)
(d) Operating torque (kgf·cm)
(e) Pushrod stroke (mm)
(f) Operating angle (deg)
RY9212148HYM0051US0
3-M44
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
[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.
RY9212001HYM0001US0
[B] Operation
1. When the control lever is in neutral
The oil from the pilot pump that flows into Port P
(P)
via the unload valve is cut off from port T
(T)
and port 1
(a)
by the spool (1).
And port 1 is connected to port T through the inside of the spool, so port 1 is at the tank pressure.
(1) Spool
(a) Port 1
(b) Port 2
(P) Port P
(T) Port T
RY9212148HYM0007US0
2. When the control lever has been actuated (when governing pressure)
When the cam (1) operating angle exceeds 1.9°, the pushrod (2) presses down on the spool (5) via the spring seat (3) and the secondary pressure spring (4).
At part A, port P
(P)
and port 1
(a)
are connected, while port 1 and port T
(T)
at part
A
are cut off, so the oil flows from port P to port 1.
When the pressure at port 1 gets high enough, it counters the secondary pressure spring and presses the spool up, thus cutting off port P and port 1 at part
A
and allowing port 1 and port T to be connected and lowering the pressure at port 1. The repetition of this process maintains a constant pressure equal to the secondary pressure spring load.
If the cam is depressed further, the position of the spool does not change and the pushrod and spring seat move downwards, compressing the secondary pressure spring and putting a large load on the spring; this generates pressure equivalent to this load at port 1.
(1) Cam
(2) Pushrod
(3) Spring seat
(4) Secondary pressure spring
(5) Spool
(a) Port 1
(b) Port 2
(P) Port P
(T) Port T
A : Part A
RY9212148HYM0008US0
3-M45
KiSC issued 08, 2015 A
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. As a result, part
A
is left open and the pressures of port P and port 1 equalize.
(1) Cam
(2) Pushrod
(3) Spool
(a) Port 1
(b) Port 2
(P) Port P
(T) Port T
RY9212148HYM0009US0
3-M46
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
(1) Port 1
(2) Port 2
(3) Operating torque
(4) Secondary pressure
• For Swing
Maker
Model
(P) Port P
(T) Port T
Kawasaki Heavy Industries, Ltd.
PV6P1005A
(a) Secondary pressure
(kgf/cm
2
)
(b) Secondary pressure (MPa)
(c) Operating torque (N·m)
(d) Operating torque (kgf·cm)
(e) Pushrod stroke (mm)
(f) Pedal operating angle (deg)
RY9212158HYM0003US0
3-M47
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
[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.
RY9212001HYM0001US0
[B] Operation
1. When the control lever or pedal is in neutral
The force of the secondary pressure spring (1) does not press on the spool (2). As a result, the spool is held in a neutral position by the return spring (3). At such time, the output ports (ports to the control valve port) port 1
(a)
and port 2
(b)
) and port T
(T)
are connected.
2. When a control lever or pedal has been actuated
The cam (4) is turned counterclockwise, the port 1 side pushrod (5) presses down on the spool (2) via the spring seat (6) and the secondary pressure spring (1).
When doing so, port P
(P)
and port 1
(a)
are connected, so the oil from the pilot pump flows through port 1 to the control valve.
The pressure at port 1 rises until it is equivalent to the force of the secondary pressure spring, thus balancing the hydraulic pressure on the spool with the tension of the secondary pressure spring and maintaining a fixed port 1 pressure.
(1) Secondary pressure spring
(2) Spool
(3) Return spring
(4) Cam
(5) Pushrod
(6) Spring seat
(a) Port 1
(b) Port 2
(P) Port P
(T) Port T
RY9212148HYM0011US0
3-M48
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
(1) Port 1
(2) Port 2
Maker
Model
(P) Port P
(T) Port T
Kawasaki Heavy Industries, Ltd.
TH40P1048B
(a) Secondary Pressure
(kgf/cm
2
)
(b) Secondary Pressure (MPa)
(c) Operating Torque (N·m)
(d) Operating Torque (kgf·m)
(e) Pushrod stroke (mm)
(f) Operating Angle (deg)
(g) Down
(h) Up
RY9212158HYM0004US0
3-M49
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
[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.
RY9212001HYM0001US0
[B] Operation
1. When the control lever is in neutral
The force of the secondary pressure spring (1) does not press on the spool (2). Consequently, spool (2) is pushed up by the return spring (3), and port 1
(a)
and port
T
(T)
are connected.
(1) Secondary Pressure Spring
(2) Spool
(3) Return Spring
(a) Port 1
(b) Port 2
(P) Port P
(T) Port T
RY9212158HYM0005US0
2.When the control lever has been actuated
When the control lever is tilted and pushrod (1) goes through its stroke, spool (2) moves downwards, port
P
(P)
and port 1
(a)
are connected, and oil from the pilot pump flows via port 1 to the control valve.
The pressure at the port rises until it is equivalent to the force of the secondary pressure spring (3), thus balancing the hydraulic pressure on the spool with the tension of the secondary pressure spring and maintaining a fixed port pressure.
(1) Pushrod
(2) Spool
(3) Secondary Pressure Spring
(a) Port 1
(b) Port 2
(P) Port P
(T) Port T
RY9212158HYM0006US0
3-M50
KiSC issued 08, 2015 A
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 change in operating torque, the operator knows he is close to the actuation angle of detent operation at a predetermined actuation angle.
(1) Disc
(2) Steel Ball
(3) Spring
(a) Port 1
(b) Port 2
(P) Port P
(T) Port T
RY9212158HYM0007US0
4. When detent is activated
At the detent operation activation angle before the end of stroke, the steel ball (1) slides into the V-shaped groove of the disc (2), which is detent operation status.
If the operator releases the lever during detent operation, the lever control angle is maintained and a fixed secondary pressure continues to be applied.
(1) Steel Ball
(2) Disc
(a) Port 1
(b) Port 2
(P) Port P
(T) Port T
RY9212158HYM0008US0
5. When detent is released
Detent can be released manually by applying a force greater than the release torque to the operating lever in the direction of neutral.
RY9212050HYM0022US0
3-M51
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
(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, boom down)
T: Port T
RY9212148HYM0052US0
The boom circuit is equipped with a shockless valve, which operates when stopping boom movement up or down.
RY9212148HYM0053US0
a) During boom up operation
• When pilot pressure enters port 1 (1), the oil passes through the orifice (3) and is discharged to port A
(A)
.
At such time the resistance to passing through the orifice (3) results in the pressure of chamber a
(a)
being less than that of chamber b
(b)
, so the plunger
(4) moves upwards.
• The movement of the plunger (4) causes the entire flow of the oil that connects port 1 and port A to be discharged to port A.
• Conversely, normally the spool (6) is held in the neutral position by the left/right spring (7), and the oil returning from port B is cut off at point X
(x)
from port
T.
• When the pilot oil from port 1 (1) generates enough pressure to overcome the spring (7), it moves the spool, connecting port B and port T and the oil returning from port B returns directly to the tank.
(1) Port 1
(2) Port 2
(3) Orifice
(4) Plunger
(5) Spring
(6) Spool
(7) Spring
(A) Port A
(B) Port B
(T) Port T
(a) Chamber a
(b) Chamber b
(x) Chamber X
RY9212148HYM0054US0
3-M52
KiSC issued 08, 2015 A
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 through the orifice (3) results in the pressure of chamber a
(a)
being greater than that of chamber b
(b)
, so the plunger (4) moves downwards.
• The movement of the plunger (4) closes orifice c
(c)
, raising the pressure in chamber b
(b)
.
• Once the pressures of chamber a
(a)
and chamber b
(b)
equalize, the plunger (4) is returned toward neutral by the spring (5). Repition of this dynamic keeps the plunger (4) at a balanced position. As a result, the pressure differential across the orifice (3) is fixed, allowing the flow of oil through the orifice (3) to be steady without maintaining the pilot pressure.
• When the pilot valve is returned to its neutral position, no oil comes from the pilot valve and the control valve tries to return to the neutral position.
• Return oil from port B flows to port 1 via the orifice
(3). The speed of the main spool of the control valve is limited by passing through the orifice (3).
(Shockless function)
(1) Port 1
(2) Port 2
(3) Orifice
(4) Plunger
(5) Spring
(A) Port A
(B) Port B
(T) Port T
(a) Chamber a
(b) Chamber b
(c) Orifice c
RY9212148HYM0055US0
3-M53
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
(1) PAC Port (Accumulator)
(2) Port A (2-Speed Travel
Switch)
(3) Port B (Pilot Operation, Swivel
Parking Brake)
(4) Drain Port (to Hydraulic Oil
Tank)
(5) Port P (to Control Valve)
(6) Port C (from Pilot Pump)
(7) Pilot Primary Relief Valve
(aPP)
(8) Check Valve
Maker
Rated Voltage
Relief Valve
Pressure Setting
(aPP)
Leak volume port P
→ port T
Leak volume port
PAC → other ports
Nishina Industrial
12 V
3.92 + 0.29 MPa
40.0 + 3.0 kgf/cm
2
570 + 42 psi
130 ml/min
7.9 cu.in./min
0.03 USGPM
90 ml/min
5 cu.in./min
0.02 USGPM at Temp. 50 °C (144 °F),
Notes
14.7 L/min (897 cu.in./min, 3.9 USGPM) at 2.5 MPa (25.5 kgf/cm at 3.9 MPa (40.0 kgf/cm
2
2
, 363 psi)
, 569 psi)
RY9212148HYM0022US0
3-M54
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
[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).
RY9212001HYM0124US0
[B] Operation
With this device, oil from the pilot pump enters port C and is supplied to the control valve from port P, but that is functionally identical to when oil from the pilot pump enters from port P and supplied to the control valve from port C.
Following is a description of when oil enters from port P from the pilot pump.
RY9212001HYM0125US0
1. When the solenoid is off
Oil from port P is cut off from passages to port A and port T by a spool (1) and plunger (2). Ports A and T are connected. And Port C and Port P are connected, so the pressures at port C and port P are always the same.
When the pressure from port P reaches the relief valve pressure setting, the oil from port P returns to the tank via the relief valve (pushes the plunger up).
(1) Spool
(2) Plunger
A : Port A
C : Port C
P : Port P
T : Port T
RY9212148HYM0023US0
3-M55
KiSC issued 08, 2015 A
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.
When port P pressure reaches a pressure at or greater than the spring (3), the plunger (4) moves to the right and pressure oil flows from port P to port PAC.
When the pressure at port P is low, the oil from port
PAC is cut off, preventing backflow.
(1) Solenoid
(2) Spool
(3) Spring
(4) Plunger
A : Port A
C : Port C
P : Port P
T : Port T
RY9212148HYM0024US0
3-M56
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
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.
(Duty Control)
Item
Max operating pressure
(input pressure)
Allowable back pressure
(pressure T)
Specifications
3.9 MPa
40 kgf/cm
2
570 psi
1.0 MPa
10 kgf/cm
2
100 psi
Maximum proportional valve operating flow volume
(input flow volume)
15.6 L/min (4.1 GPM)
Drain volume when solenoid off
Waterproof Standard
Vibration Proof Standard
Hydraulic Oil Grade
Hydraulic Oil Contamination
Level
0.4 L/min ≥
[at 20 cST, port P pressure =
4.9 MPa (50 kgf/cm
2
, 710 psi)]
JIS D 0203 S2 equivalent
JIS D 1601–1995
ISO VG32 to 68 equivalent
NAS Class 10 or less
Electrical Specifications
Secondary pressure control range
Rated Amperage: 1600 mA
Coil resistance: 3.2 ± 0.5 Ω
[at 20 deg C (68 deg F)]
0 to 2.7 MPa
0 to 27 kgf/cm
2
0 to 390 psi
(1) P port
(2) T port
(3) A1 Port (Hi)
(4) A2 Port (Low)
(a) Secondary Pressure (MPa)
(b) Input Amperage (mA)
RY9212148HYM0025US0
3-M57
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
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. Port B and port T are connected, so no pressure is produced at port B.
(1) Spool
(2) Solenoid
A : Port A
B : Port B
P : Port P
T : Port T
RY9212095HYM0020US0
2. When the solenoid is on
When the solenoid is on, the spool is pressed down, connecting port P and port B. And as port B and port T are cut off, the oil from port P flows to port B.
(1) Spool
(2) Solenoid
A : Port A
B : Port B
P : Port P
T : Port T
RY9212095HYM0021US0
3-M58
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
A : Port A (Left)
Maker
Rated Voltage
Leak Volume
B : Port B (Right)
Nishina Industrial
DC 12 V
220 ml/min or less at Temp. 50 °C (122 °F),
4.9 MPa (50 kgf/cm
2
, 3130 psi) pressure
P : Port P T : Port T
RY9212158HYM0009US0
3-M59
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
Item
Max operating pressure
(input pressure)
Allowable back pressure
(pressure T)
Maximum proportional valve operating flow volume
(input flow volume)
Specifications
3.9 MPa
40 kgf/cm
2
570 psi
1.0 MPa
10 kgf/cm
100 psi
2
10.0 L/min (2.64 U.S.gals./min)
Drain volume when solenoid off
Electrical Specifications
0.6 L/min (0.2 U.S.gals../min) ≥
[At 20 cST, port P pressure =
4.9 MPa (50 kgf/cm
2
, 710 psi)]
Rated Amperage: 1600 mA
Coil resistance: 3.3 Ω
[at 20 °C (68 °F)]
(1) Solenoid
(2) Case
A : Port A
P : Port P
T : Port T
RY9212148HYM0026US0
3-M60
KiSC issued 08, 2015 A
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
(3) Special Tools .................................................................................................................3-S40
4. SWIVEL JOINT..........................................................................................................................3-S41
[1] REMOVAL AND INSTALLATION OF THE SWIVEL JOINT................................................3-S41
[2] SWIVEL JOINT DISASSEMBLY / ASSEMBLY PROCEDURES ........................................3-S44
(1) Disassembly Procedures...............................................................................................3-S45
(2) Assembly Procedures....................................................................................................3-S47
5. TRAVEL MOTOR ......................................................................................................................3-S49
[1] REMOVAL AND INSTALLATION OF THE TRAVEL MOTOR ............................................3-S49
[2] TRAVEL MOTOR DISASSEMBLY / ASSEMBLY PROCEDURES .....................................3-S50
(1) Disassembly Procedures...............................................................................................3-S52
(2) Assembly Procedures....................................................................................................3-S59
(3) Special Tools .................................................................................................................3-S67
6. CYLINDER.................................................................................................................................3-S69
[1] TIGHTENING TORQUE ......................................................................................................3-S69
7. PILOT VALVE............................................................................................................................3-S71
[1] CONTROL PILOT VALVES.................................................................................................3-S71
(1) Disassembly ..................................................................................................................3-S72
(2) Assembly .......................................................................................................................3-S75
(3) Special Tools .................................................................................................................3-S79
[2] TRAVEL PILOT VALVE.......................................................................................................3-S80
(1) Disassembly ..................................................................................................................3-S81
(2) Assembly .......................................................................................................................3-S85
(3) Special Tools .................................................................................................................3-S89
[3] SWING PILOT VALVE ........................................................................................................3-S89
(1) Disassembly ..................................................................................................................3-S90
(2) Assembly .......................................................................................................................3-S93
[4] BLADE PILOT VALVES ......................................................................................................3-S98
(1) Disassembly ................................................................................................................3-S100
(2) Assembly .....................................................................................................................3-S102
8. SHOCKLESS VALVES............................................................................................................3-S106
9. SWIVEL SHUTTLE VALVE .....................................................................................................3-S107
10. SOLENOID VALVE..................................................................................................................3-S108
[1] UNLOAD VALVE ...............................................................................................................3-S108
[2] AUX PROPORTIONAL CONTROL SOLENOID VALVE...................................................3-S109
[3] ANGLE SOLENOID VALVE ..............................................................................................3-S110
[4] EP MODE SOLENOID VALVE..........................................................................................3-S111
KiSC issued 08, 2015 A
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
[4] PILOT HOSES...................................................................................................................3-S125
(1) Deliver Hose Routing...................................................................................................3-S125
(2) Port P Hose Routing ....................................................................................................3-S126
(3) Port T Hose Routing ....................................................................................................3-S127
(4) Ports P and T Pilot Valve Hose Routing ......................................................................3-S128
(5) Pilot Valve Hose Routing .............................................................................................3-S130
12. MEASURING HYDRAULIC DEVICE PERFORMANCE ..........................................................3-S133
[1] PISTON PUMP AIR BLEEDING PROCEDURE................................................................3-S133
[2] RELEASE OF PRESSURE IN THE HYDRAULIC SYSTEM .............................................3-S134
[3] MANUAL BOOM LOWERING PROCEDURE ...................................................................3-S135
[4] MEASURING THE FLOW RATE.......................................................................................3-S136
(1) Measuring Main Pump Flow ........................................................................................3-S136
(2) Measuring the AUX Proportional Settings ...................................................................3-S138
(3) Measuring AUX Discharge Flow..................................................................................3-S139
[5] MEASURING PRESSURE ................................................................................................3-S140
(1) Main Relief Valve Measuring Procedure .....................................................................3-S140
(2) Measuring Pilot Secondary Pressure ..........................................................................3-S142
(3) Measuring EP Proportional Solenoid Pressure ...........................................................3-S143
(4) Measuring the Overload Relief Valve Pressure...........................................................3-S144
(5) Pressure Measuring Kit ...............................................................................................3-S146
(6) Adjusting Swivel Relief Valve Pressure .......................................................................3-S147
(7) Adjust the LS Control Differential Pressure Adjusting Spring Force............................3-S147
[6] MEASURING SWIVEL PERFORMANCE .........................................................................3-S148
(1) Measuring Swivel Motor Drain Volume........................................................................3-S148
(2) Measuring Swivel Block Performance .........................................................................3-S149
(3) Measuring Swivel Speed .............................................................................................3-S150
[7] MEASURING TRAVEL PERFORMANCE .........................................................................3-S151
(1) Measuring Travel Motor Drain Volume ........................................................................3-S151
(2) Measuring Travel Block Performance..........................................................................3-S152
(3) Measuring Travel Speed..............................................................................................3-S153
(4) Measuring Travel Drift .................................................................................................3-S153
[8] MEASURING CYLINDER SPEED.....................................................................................3-S154
(1) Measuring Hydraulic Cylinder Operating Time ............................................................3-S154
(2) Measuring Hydraulic Cylinder Drift ..............................................................................3-S156
(3) Measuring Swing Cylinder Deviation ...........................................................................3-S157
13. HYDRAULIC DEVICE PERFORMANCE STANDARDS..........................................................3-S158
[1] FLOW RATE......................................................................................................................3-S158
(1) Main Pump Discharge Flow Rate Data (Measured Values) ........................................3-S158
(2) Flow Rate Data for AUX Proportional Control (Measured Values) ..............................3-S160
(3) AUX Discharge Flow Rate Data (Measured Values) ...................................................3-S161
[2] RELIEF PRESSURE (MEASURED VALUES) ..................................................................3-S162
[3] SWIVEL PERFORMANCE ................................................................................................3-S163
[4] TRAVEL PERFORMANCE................................................................................................3-S163
[5] CYLINDER SPEED ...........................................................................................................3-S164
14. TROUBLESHOOTING.............................................................................................................3-S165
[1] TROUBLESHOOTING ALL ACTUATORS ........................................................................3-S165
[2] TROUBLESHOOTING FRONT SYSTEMS .......................................................................3-S165
KiSC issued 08, 2015 A
[3] TRAVEL SYSTEM TROUBLESHOOTING........................................................................3-S167
[4] SWIVEL SYSTEM TROUBLESHOOTING ........................................................................3-S168
[5] TROUBLESHOOTING MULTIPLE OPERATIONS ...........................................................3-S169
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
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.
• Oil gushing out under pressure has enough force to injure you by piercing your skin. Always relieve any pressure remaining in the system prior to working to remove any hydraulic equipment or lines.
RY9212148HYS0149US0
1. Remove the left and rear hoods.
IMPORTANT
• For hood removal, a minimum of 2 persons is needed.
(1) Rear hood (2) Left hood
RY9212148HYS0203US0
2. Remove the air cleaner.
(1) Air cleaner
RY9212148HYS0204US0
3. Attach a vacuum pump and depressurize the inside of the tank.
IMPORTANT
• Plug the breather hose.
(1) Vacuum pump
RY9212148HYS0205US0
4. Remove the bottom cover of the pump and disconnect all the hoses connected to the pump.
IMPORTANT
• Plug the disconnected hoses and adapters.
RY9212148HYS0206US0
3-S1
KiSC issued 08, 2015 A
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.
Tightening torque Bolt
196.1 to 225.6 N·m
20.0 to 23.0 kgf·m
144.6 to 166.4 lbf·ft
Pump weight Approx. 50 kg (110 lbs)
(1) Pump
RY9212148HYS0207US0
Adapter angles
(1) P1
(2) P2
(3) P3
(4) P4
(5) Pps
(6) Pls
(7) Pi
(a) 45°(0.79 rad)
(b) 30°(0.52 rad)
RY9212148HYS0208US0
3-S2
KiSC issued 08, 2015 A
KX080-4, WSM
Pump Connector and Housing Assembly Diagram
HYDRAULIC SYSTEM
(1) Connector
(2) Connector mounting bolt
(3) Pump housing
(4) Housing mounting bolt
(5) Parallel pin
• (a) Apply grease to the spline.
IMPORTANT
• Align the spring pin before tightening the connector mounting bolts.
• Do not use a thread lock on the connector mounting bolts.
• Do not apply grease to the connector rubber seal.
• Align the parallel pin before tightening the pump housing mounting bolts.
Tightening torque
Connector mounting bolt
Housing mounting bolt
210.0 to 230.0 N·m
21.4 to 23.5 kgf·m
154.9 to 169.6 lbf·ft
48.1 to 55.9 N·m
4.9 to 5.7 kgf·m
35.5 to 41.2 lbf·ft
(6) Spring pin
RY9212148HYS0371US0
3-S3
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
No.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Plug
Orifice
Swash plate
Collar
Shoe
Retainer plate
Spring
(8) Piston
(9) Cylinder block
(10) Valve plate
(11) Collar
(12) Pin
(13) Needle bearing
(14) Piston assy
(15) Spool guide
(16) O-ring
Part Name
1
10
10
1
1
Q'ty
2
1
10
1
1
1
4
1
1
1
1
No.
(17) Port block
(18) Gasket
(19) Bolt
(20) Bolt
(21) Bearing case
(22) Bolt
(23) Pin
(24) Case
(25) Plug
(26) O-ring
(27) Shaft
(28) Roller bearing
(29) Cir-clip
(30) Oil seal
(31) Cir-clip
Part Name
1
1
1
4
3
1
1
1
1
1
Q'ty
1
1
5
2
1
RY9212148HYS0382US0
3-S4
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
No.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
Holder
Spring seat
Spring
Spring
Spring
Spring seat
O-ring
Valve sleeve
Spool
(10) Pin
(11) O-ring
(12) Plug
(13) Nut
(14) O-ring
(15) Orifice
(16) O-ring
Part Name
1
1
1
1
1
1
Q'ty
1
1
1
1
1
1
1
1
1
1
No.
(17) Orifice
(18) Orifice
(19) Plug
(20) O-ring
(21) Spool
(22) Bolt
(23) Bushing
(24) Spring seat
(25) Spring
(26) O-ring
(27) Holder
(28) Set screw
(29) O-ring
(30) Nut
(31) Cap
(32) Nut
Part Name
4
1
1
1
1
1
Q'ty
1
1
1
1
1
1
1
1
1
1
RY9212148HYS0383US0
3-S5
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
(4)
(5)
(6)
(7)
(8)
(9)
No.
(1)
(2)
(3)
Socket head bolt
Plug
Orifice
Plug
O-ring
Orifice
Plug
O-ring
Collar
Part Name
3
2
1
1
5
11
Q'ty
11
1
1
No.
(10) Ball
(11) Seat
(12) O-ring
(13) O-ring
(14) Valve seat
(15) Oil pressure pump
(16) Plain washer
(17) Bolt
Part Name
1
2
2
1
1
Q'ty
2
2
2
RY9212148HYS0384US0
3-S6
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
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.
• If it is difficult to remove, tap lightly on it with a plastic hammer and remove.
(1) Hex Socket Bolt (with / washer)
M10 x 20 x 2
RY9212148HYS0385US0
2. Remove the O-rings.
IMPORTANT
• Take care not to scratch the surface of the port.
(1) O-Ring (2) O-Ring
RY9212148HYS0386US0
3. Remove the hex socket bolts and then the port block.
• Tool to use: 10, 16 mm hex socket
CAUTION
• Don't pinch your fingers between the port block and the case.
• If it is difficult to remove, tap lightly on it with a plastic hammer and remove.
(1) Hex Socket Bolt M16 x 40 x 5
(2) Hex Socket Bolt M10 x 40 x 2
(3) Port Block
RY9212148HYS0387US0
4. Remove the valve plate, spool guide and the piston.
• Tool to use: 24 mm wrench
IMPORTANT
• Take care not to scratch the valve plate.
(1) Valve Plate
(2) Spool Guide
(3) Piston
RY9212148HYS0388US0
5. Remove the collar and the needle bearing.
(1) Collar (2) Needle Bearing
RY9212148HYS0389US0
3-S7
KiSC issued 08, 2015 A
KX080-4, WSM
6. Remove the plug.
• Tool to use: 6 mm hex socket
(1) Plug
HYDRAULIC SYSTEM
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
(1) Plug
RY9212148HYS0392US0
9. Remove the seat and the ball.
• Tool to use: Magnet
(1) Seat (2) Ball
RY9212148HYS0393US0
10. Remove the hex socket bolts and then the L/S regulator.
• Tool to use: 5 mm hex socket
(1) L/S Regulator (2) Hex Socket Bolt M6 x 15 x 4
RY9212148HYS0394US0
3-S8
KiSC issued 08, 2015 A
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. After measuring the distance of
L
, loosen the nut and remove the set screw.
14. Remove the parts inside the L/S regulator.
• Tool to use: 13, 24 mm wrench, 4 mm hex socket
(1) Nut (2) Set Screw
RY9212148HYS0397US0
L/S Regulator Components
(1) Plug
(2) O-Ring
(3) Valve Body
(4) Spool
(5) Bushing
(6) Spring Seat
(7) Spring
(8) Nut
(9) Set Screw
(10) Holder
(11) O-Ring
(12) Nut
(13) Orifice
(14) Orifice
RY9212148HYS0398US0
15. After measuring the distance of
M
, loosen the nut and remove the horsepower control valve.
• Tool to use: 41 mm wrench, 8 mm hex socket
(1) Horsepower Control Valve (2) Nut
RY9212148HYS0399US0
3-S9
KiSC issued 08, 2015 A
KX080-4, WSM
Horsepower Control Valve Components
(1) Horsepower Control Valve
(2) Nut
(3) Spool
(4) Pin
(5) Plug
HYDRAULIC SYSTEM
RY9212148HYS0400US0
16. Remove the gasket, spring ASSY and the cylinder block ASSY.
CAUTION
• Be careful not to cut your fingers on the gasket.
(1) Gasket
(2) Spring ASSY
(3) Cylinder Block ASSY
RY9212148HYS0401US0
Spring ASSY Components
(1) Spring Seat
(2) Assist Spring
(3) Outer spring
(4) Inner Spring
(5) Spring Seat
RY9212148HYS0402US0
Cylinder Lock ASSY Components
(1) Piston
(2) Retainer Plate
(3) Cylinder Block
(4) Spring
(5) Retainer Holder
RY9212148HYS0403US0
17. Remove the swash-plate and the holder.
(1) Swash-Plate (2) Holder
RY9212148HYS0404US0
3-S10
KiSC issued 08, 2015 A
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
• Be careful not to hit your fingers with the hammer.
(1) Shaft (2) Bearing Case
RY9212148HYS0406US0
20. Remove the snap ring.
• Tool to use: Snap ring pliers
CAUTION
• Take care not to cut yourself, such as in the face, with the snap ring.
(1) Snap Ring
RY9212148HYS0407US0
21. Remove the bearing.
• Tool to use: punch and plastic hammer
CAUTION
• Be careful not to hit your fingers with the hammer.
(1) Snap Ring
(2) Bearing
(3) Thrust Washer
RY9212148HYS0408US0
3-S11
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
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
(2) Thrust Washer
(3) Bearing
(4) Snap Ring
RY9212148HYS0409US0
3. Mount the shaft in the bearing case.
• Tool to use: plastic hammer
CAUTION
• Be careful not to hit your fingers with the hammer.
(1) Bearing Case (2) Pin
RY9212148HYS0410US0
4. Mount the shaft in the case.
(1) Shaft (2) Case
RY9212148HYS0411US0
5. Mount the swash-plate and the holder.
IMPORTANT
• Mount so the surfaces of the swash-plate are not scratched.
(1) Swash-Plate (2) Holder
RY9212148HYS0412US0
6. Install the cylinder block ASSY.
IMPORTANT
• Do not scratch the pistons.
• Do not use a hammer.
• Apply hydraulic oil to the body and shoe face of the pistons.
(1) Cylinder Block ASSY
RY9212148HYS0413US0
3-S12
KiSC issued 08, 2015 A
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 (2) Gasket
RY9212148HYS0414US0
8. Install the seat and ball into the port block.
• Tool to use: Magnet
(1) Seat (2) Ball
RY9212148HYS0415US0
9. Install the plug.
• Tool to use: 6 mm hex socket
Tightening torque
(1) Plug
Plug (1)
29.4 N·m
3.0 kgf·m
21.7 lbf·ft
RY9212148HYS0416US0
10. Assemble the horsepower control valve and install it in the port block.
IMPORTANT
• Make sure the spool is facing the right way.
(1) Horsepower Control Valve (2) Port Block
RY9212148HYS0417US0
3-S13
KiSC issued 08, 2015 A
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.
Tightening torque
Nut (1)
Plug (3)
68.6 N·m
6.70 kgf·m
50.6 lbf·ft
57.0 N·m
5.81 kgf·m
42.0 lbf·ft
(1) Nut
(2) Horsepower Control Valve
(3) Plug
RY9212148HYS0418US0
12. Install the collar and ball.
• Tool to use: Magnet
(1) Collar (2) Ball
RY9212148HYS0419US0
13. Install the plug.
• Tool to use: 6 mm hex socket
Tightening torque
(1) Plug
Plug (1)
29.4 N·m
3.0 kgf·m
21.7 lbf·ft
RY9212148HYS0420US0
14. Assemble the L/S regulator.
IMPORTANT
• Make sure the spool is facing the right way.
• Pay attention to the sizes of the orifices and insert them in the right locations.
Tightening torque Orifice (1), (2)
2.45 N·m
0.250 kgf·m
1.81 lbf·ft
(1) Orifice (2) Orifice
RY9212148HYS0421US0
3-S14
KiSC issued 08, 2015 A
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
Tightening torque
(1) L/S Regulator
Socket head bolt (2)
12.65 N·m
1.29 kgf·m
9.93 lbf·ft
(2) Hex Socket Bolt M6 x 15 x 4
RY9212148HYS0423US0
17. Adjust the L/S regulator to the measurement prior to disassembly.
• Tool to use: ruler, 13, 24 mm wrench
(1) Nut (2) Set Screw
RY9212148HYS0424US0
18. Install the needle bearing and the collar.
IMPORTANT
• Install so the machined surface of the collar is facing the needle bearing.
(1) Needle Bearing (2) Collar
RY9212148HYS0425US0
19. Install the valve plate, spool guide and the piston.
• Tool to use: ruler, 24 mm wrench
IMPORTANT
• Position so the notch is aligned with the pin.
• Apply hydraulic oil to both faces of the valve plate.
Tightening torque Spool guide (2)
51.0 N·m
5.20 kgf·m
37.6 lbf·ft
(1) Valve Plate
(2) Spool Guide
(3) Piston
RY9212148HYS0426US0
3-S15
KiSC issued 08, 2015 A
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.
Tightening torque
Socket head bolt (1)
Socket head bolt (2)
196.0 N·m
19.99 kgf·m
144.6 lbf·ft
106.9 N·m
10.90 kgf·m
78.85 lbf·ft
(1) Hex Socket Bolt M16 x 40 x 5
(2) Hex Socket Bolt M10 x 40 x 2
(3) O-Ring
(4) O-Ring
RY9212148HYS0427US0
22. Install the gear pump.
• Tool to use: 10 mm hex socket
CAUTION
• Don't pinch your fingers between the port block and the gear pump.
Tightening torque Socket head bolt (1)
44.1 N·m
4.50 kgf·m
32.5 lbf·ft
(1) Hex Socket Bolt (w/washer)
M10 x 20 x 2
RY9212148HYS0428US0
3-S16
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
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.
4. Attach eye bolts to the base of the control valve and suspend the control valve with a crane.
IMPORTANT
• Plug the disconnected hoses and adapters.
• Label all of the disconnected hoses so you can identify them during assembly.
5. Remove the 4 base mounting bolts, then lift with the crane and remove it.
(1) Cover
(2) Bolt
(a) Eye bolt mounting hole (M12, pitch 1.75)
RY9212158HYS0106US0
3-S17
KiSC issued 08, 2015 A
KX080-4, WSM
Control valve adapter angles (angle spec.)
HYDRAULIC SYSTEM
(1) P3 bypass
(2) Swivel
(3) Blade
(4) AUX2
(5) Communication valve
(6) Travel left
(7) Travel right
(8) Independent travel valve
(9) Arm
(10) Bucket
(11) AUX1
(12) Boom
(13) Swing
(14) Angle
(A) P1
(B) P2
(C) P3
(D) Pps
(E) Pls
(F) T1
(G) T2
(H) PP1
(I) PP2
(J) PP3
(a) 5° (0.09 rad)
(b) 6 ° (0.10 rad)
(c) 15 ° (0.26 rad)
(d) 20 ° (0.35 rad)
(e) 23 ° (0.40 rad)
(f) 25 ° (0.44 rad)
(g) 30 ° (0.52 rad)
(h) 45 ° (0.79 rad)
(i) 60 ° (1.05 rad)
(j) 75 ° (1.31 rad)
RY9212158HYS0031US0
3-S18
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
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.
2. Always use clean tools and cleaning oil.
3. After removing from the machine, first wash the outside of the assembly.
4. Before starting work, prepare the necessary parts for the aims and extent of disassembly. Before reassembling, as a rule you should replace all seals and O-rings, etc. Also, since a subassembly is available with the required parts if parts cannot be supplied as single items, refer to the parts catalog beforehand in preparation.
Precautions on Assembly
1. Apply clean grease or hydraulic fluid to O-rings and their countersunk parts for mounting.
2. There should be no flaws in O-rings due to forming, and no marks or heat deformation incurred when handling.
3. If permanently deformed, O-rings will not straighten out. (Make sure that no flaws are incurred by an O-ring when passing it through sharp angled sections of a spool.)
4. Do not turn over O-rings on installation. (Fouled O-rings are difficult to re-install and can easily result in oil leakage.)
Before assembling, at the mating surface of each section, make sure no cleaning oil, hydraulic fluid, etc., is adhered to the outer surface of the O-ring groove. (If you assemble with oil adhered to a mating surface, this may be mistakenly recognized as oil leakage from that location when the machine is running.)
RY9212001HYS0140US0
Control Valve Disassembly / Assembly Procedures
1. Loosen the nuts on one side with a ring spanner.
Tightening torque Nut (four locations)
26.5 to 29.4 N·m
2.7 to 3.0 kgf·m
19.6 to 21.7 lbf·ft
2. Pull out each section with a tie rod, and arrange in order on a workbench.
CAUTION
• When removing each section, take care not to lose the load check valve and spring of the mating surface.
• Identify the load check valve and spring of each section so that they are not mismatched.
• Apply a location mark for each section.
• Excess torque on threads will cause defective spool operation. Therefore, be sure to use the specified torque.
• Take care over the direction of installation of each spool, align with the holes and insert slowly.
(1) Nut
(2) Identification groove for spool assembly orientation
(3) Spool
RY9212148HYS0372US0
3-S19
KiSC issued 08, 2015 A
KX080-4, WSM
LS Section Components
HYDRAULIC SYSTEM
No.
Name of part
(1) Cap
(2) Hex socket bolt
(3) Spring seat
(4) Spring
(5) Plate
(6) O-ring
(7) Spool
(8)
Relief valve
ASSY
(9) O-ring
(10) Plug
(11) O-ring
(12) Poppet
(13) Spool
(14) O-ring
(15) Spring
(16) Poppet
(17) O-ring
(18) Spool
(19) Shutoff valve
(20) O-ring
(21) O-ring
(22) Anti-void valve
2
2
2
2
4
4
2
1
2
2
4
4
4
4
1
Qty
4
8
Torque
8.8 to 11.0 N·m
0.9 to 1.1 kgf·m
6.5 to 8.1 lbf·ft
59.0 to 69.0 N·m
6.0 to 7.0 kgf·m
43.5 to 50.9 lbf·ft
2
67.7 to 73.5 N·m
6.9 to 7.5 kgf·m
49.9 to 54.2 lbf·ft
1
59.0 to 69.0 N·m
6.0 to 7.0 kgf·m
43.5 to 50.9 lbf·ft
1
1
1
59.0 to 69.0 N·m
6.0 to 7.0 kgf·m
43.5 to 50.9 lbf·ft
A : Angle section
B : Swing section
RY9212158HYS0107US0
3-S20
KiSC issued 08, 2015 A
KX080-4, WSM
Mono-block Section Components
HYDRAULIC SYSTEM
A : Boom section
B : AUX1 section
C : Bucket section D : Arm section
• In the N. Am. spec., part E is different as it has an anti-drift valve.
No.
(1)
(2)
(3)
(4)
(5)
Name of part
Cap
Hex socket bolt
Spool stopper
Spacer
Backup ring
4
2
2
Qty
4
8
Torque
E : Emergency valve
8.8 to 11.0 N·m (0.9 to 1.1 kgf·m, 6.5 to 8.1 lbf·ft)
3-S21
KiSC issued 08, 2015 A
KX080-4, WSM
No.
(6)
(7)
(8)
O-ring
Plate
Spring
(9) Spool
(10) O-ring
(11) Plug
(12) Plug
(13) O-ring
(14) Plug
Name of part
(15) Spring
(16) Poppet
(17) Plug assembly
(18) Plug assembly
(19) Plug assembly
(20) Spring
(21) Poppet
(22) Plug assembly
(23) Plug assembly
(24) O-ring
(25) Backup ring
(26) Sleeve
(27) Cap
(28) Hex socket bolt
(29) O-ring
(30) Poppet
(31) Spool
(32) Main relief valve (aLS)
(33) Main relief valve (aUN)
(34) Relief valve ASSY
(35) O-ring
(36) Relief valve ASSY
(37) Relief valve ASSY
(38) Plug assembly
(39) Plug assembly
(40) Plug assembly
(41) Valve ASSY
(42) Plug
(43) O-ring
(44) Metal plug
(45) Spacer
(46) Plug assembly
(47) Orifice
(48) Plug assembly
(49) Metal plug
(50) Anti-drift housing
HYDRAULIC SYSTEM
8
2
5
1
4
1
1
1
4
8
4
4
1
1
1
1
3
1
1
1
8
8
1
1
4
8
8
8
Qty
2
8
4
4
4
1
2
1
1
1
1
1
1
1
1
1
1
Torque
106.0 to 141.0 N·m (10.8 to 14.4 kgf·m, 78.2 to 104.0 lbf·ft)
106.0 to 141.0 N·m (10.8 to 14.4 kgf·m, 78.2 to 104.0 lbf·ft)
28.0 to 30.0 N·m (2.9 to 3.1 kgf·m, 20.7 to 22.1 lbf·ft)
167.0 to 197.0 N·m (17.0 to 20.1 kgf·m, 123.2 to 145.3 lbf·ft)
61.8 to 82.4 N·m (6.3 to 8.4 kgf·m, 45.6 to 60.8 lbf·ft)
28.0 to 30.0 N·m (2.9 to 3.1 kgf·m, 20.7 to 22.1 lbf·ft)
167.0 to 197.0 N·m (17.0 to 20.1 kgf·m, 123.2 to 145.3 lbf·ft)
8.8 to 11.0 N·m (0.9 to 1.1 kgf·m, 6.5 to 8.1 lbf·ft)
49.0 to 54.0 N·m (5.0 to 5.5 kgf·m, 36.1 to 39.8 lbf·ft)
167.0 to 197.0 N·m (17.0 to 20.1 kgf·m, 123.2 to 145.3 lbf·ft)
59.0 to 69.0 N·m (6.0 to 7.0 kgf·m, 43.5 to 50.9 lbf·ft)
59.0 to 69.0 N·m (6.0 to 7.0 kgf·m, 43.5 to 50.9 lbf·ft)
59.0 to 69.0 N·m (6.0 to 7.0 kgf·m, 43.5 to 50.9 lbf·ft)
28.0 to 30.0 N·m (2.9 to 3.1 kgf·m, 20.7 to 22.1 lbf·ft)
106.0 to 141.0 N·m (10.8 to 14.4 kgf·m, 78.2 to 104.0 lbf·ft)
28.0 to 30.0 N·m (2.9 to 3.1 kgf·m, 20.7 to 22.1 lbf·ft)
28.0 to 30.0 N·m (2.9 to 3.1 kgf·m, 20.7 to 22.1 lbf·ft)
106.0 to 141.0 N·m (10.8 to 14.4 kgf·m, 78.2 to 104.0 lbf·ft)
106.0 to 141.0 N·m (10.8 to 14.4 kgf·m, 78.2 to 104.0 lbf·ft)
11.2 to 12.4 N·m (1.1 to 1.3 kgf·m, 8.3 to 9.1 lbf·ft)
RY9212158HYS0108US0
3-S22
KiSC issued 08, 2015 A
KX080-4, WSM
Independent Travel Valve and Travel Section Components
HYDRAULIC SYSTEM
3-S23
No.
(1) Plug
(2) O-ring
(3) Filter
Name of part
(4) Spring
(5) Body assembly
(6) Hex socket bolt
(7) Plug
(8) O-ring
(9) Spring
(10) Spring seat
(11) Plug
(12) O-ring
(13) Spool
(14) Plug assembly
(15) Stopper
(16) Plate
(17) Spring
(18) Spool
(19) Plug
(20) Relief valve ASSY
(21) O-ring
(22) O-ring
(23) O-ring
(24) Cap
(25) Hex socket bolt
(26) Cap
(27) O-ring
(28) Spring seat
(29) Spring
(30) Plate
(31) Plug
(32) O-ring
(33) Spool
(34) Spool
A : Independent travel valve
B : Travel right section
C : Travel left section
3
1
1
4
4
4
4
4
4
1
2
2
1
2
1
1
1
1
1
1
1
1
1
2
1
1
1
Qty
2
Torque
28.0 to 30.0 N·m
2.9 to 3.1 kgf·m
20.7 to 22.1 lbf·ft
3
1
8.8 to 11.0 N·m
0.9 to 1.1 kgf·m
6.5 to 8.1 lbf·ft
28.0 to 30.0 N·m
2.9 to 3.1 kgf·m
20.7 to 22.1 lbf·ft
1
28.0 to 30.0 N·m
2.9 to 3.1 kgf·m
20.7 to 22.1 lbf·ft
2
59.0 to 69.0 N·m
6.0 to 7.0 kgf·m
43.5 to 50.9 lbf·ft
10
8.8 to 11.0 N·m
0.9 to 1.1 kgf·m
6.5 to 8.1 lbf·ft
3
30.0 to 32.0 N·m
3.1 to 3.3 kgf·m
22.1 to 23.6 lbf·ft
RY9212148HYS0375US0
KiSC issued 08, 2015 A
KX080-4, WSM
Communication Valve and AUX2 Section Components
3-S24
No.
(1) Cap
Name of part
(2) Hex socket bolt
(3) Spring seat
(4) Spring
(5) Plate
(6) O-ring
(7) Relief valve ASSY
(8) O-ring
(9) Plug
(10) O-ring
(11) Spring
(12) Poppet
(13) Spool
(14) Plug
(15) O-ring
(16) O-ring
(17) O-ring
(18) Plug
(19) O-ring
(20) Spring
(21) Spring seat
(22) Spool
(23) Plug assembly
(24) Hex socket bolt
(25) Plug assembly
(26) Body assembly
(27) Cap
(28) Spring
(29) Shut-off valve
(30) Poppet
(31) Plug
(32) O-ring
(33) O-ring
(34) Spool
HYDRAULIC SYSTEM
1
1
1
1
1
1
2
2
2
1
1
1
1
1
1
1
1
2
2
1
1
1
2
4
1
3
3
Qty
1
2
Torque
8.8 to 11.0 N·m
0.9 to 1.1 kgf·m
6.5 to 8.1 lbf·ft
1
59.0 to 69.0 N·m
6.0 to 7.0 kgf·m
43.5 to 50.9 lbf·ft
30.0 to 32.0 N·m
3.1 to 3.3 kgf·m
22.1 to 23.6 lbf·ft
1
28.0 to 30.0 N·m
2.9 to 3.1 kgf·m
20.7 to 22.1 lbf·ft
1
2
1
28.0 to 30.0 N·m
2.9 to 3.1 kgf·m
20.7 to 22.1 lbf·ft
8.8 to 11.0 N·m
0.9 to 1.1 kgf·m
6.5 to 8.1 lbf·ft
28.0 to 30.0 N·m
2.9 to 3.1 kgf·m
20.7 to 22.1 lbf·ft
59.0 to 69.0 N·m
6.0 to 7.0 kgf·m
43.5 to 50.9 lbf·ft
30.0 to 32.0 N·m
3.1 to 3.3 kgf·m
22.1 to 23.6 lbf·ft
KiSC issued 08, 2015 A
KX080-4, WSM
Blade, Swivel and P3 Bypass Section Components
3-S25
HYDRAULIC SYSTEM
(14) O-ring
(15) O-ring
(16) Spool
(17) O-ring
(18) Spool
(19) Plug
(20) O-ring
(21) Spring
(22) Poppet
(23) Plug
(24) O-ring
(25) Spring seat
(26) Spring
(27) Spool
(28) Plug assembly
No.
(1) Cap
Name of part
(2) Hex socket bolt
(3) Spring seat
(4) Spring
(5) Plate
(6) O-ring
(7) Relief valve ASSY
(8) O-ring
(9) Plug
(10) O-ring
(11) Spring
(12) Poppet
(13) Plug
(29) Plug assembly
A : Blade section
B : Swivel section
C : P3 bypass section
A : Communication valve
B : AUX2 section
RY9212148HYS0376US0
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
2
2
2
2
2
2
Qty
4
8
4
4
4
4
2
Torque
8.8 to 11.0 N·m
0.9 to 1.1 kgf·m
6.5 to 8.1 lbf·ft
59.0 to 69.0 N·m
6.0 to 7.0 kgf·m
43.5 to 50.9 lbf·ft
30.0 to 32.0 N·m
3.1 to 3.3 kgf·m
22.1 to 23.6 lbf·ft
30.0 to 32.0 N·m
3.1 to 3.3 kgf·m
22.1 to 23.6 lbf·ft
30.0 to 32.0 N·m
3.1 to 3.3 kgf·m
22.1 to 23.6 lbf·ft
28.0 to 30.0 N·m
2.9 to 3.1 kgf·m
20.7 to 22.1 lbf·ft
1
28.0 to 30.0 N·m
2.9 to 3.1 kgf·m
20.7 to 22.1 lbf·ft
28.0 to 30.0 N·m
2.9 to 3.1 kgf·m
20.7 to 22.1 lbf·ft
RY9212148HYS0377US0
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
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.
• Oil gushing out under pressure has enough force to injure you by piercing your skin. Always relieve any pressure remaining in the system prior to working to remove any hydraulic equipment or lines.
RY9212148HYS0149US0
1. Remove the cover, electric fan, tank cover and center cover.
[Work Tip]
• Move the condenser toward the rear of the machine with the AC hoses still installed.
(1) Cover
(2) Electric fan
(3) Tank cover
(4) Center cover
RY9212148HYS0212US0
2. Remove the center frame, unload valve and unload valve bracket in order.
IMPORTANT
• Disconnect the wire harness prior to removing the center frame.
• Plug the disconnected hoses and adapters.
(1) Center frame
(2) Unload valve
(3) Unload valve bracket
RY9212148HYS0213US0
3. Remove the AUX1 and AUX2 solenoid valves.
IMPORTANT
• Plug the disconnected hoses and adapters.
(1) AUX1 solenoid valve (2) AUX2 solenoid valve
RY9212148HYS0214US0
4. Disconnect all the hoses connected to the swivel motor.
IMPORTANT
• Plug the disconnected hoses and adapters.
RY9212148HYS0215US0
3-S26
KiSC issued 08, 2015 A
KX080-4, WSM
Swivel motor adapter angles
HYDRAULIC SYSTEM
5. Remove the 8 swivel motor mounting bolts and remove the swivel motor.
Tightening torque Bolt
259.9 to 304.0 N·m
26.5 to 31.0 kgf·m
191.7 to 224.2 lbf·ft
Swivel motor weight Approx. 80 kg (180 lbs)
RY9212148HYS0216US0
(a) 90 ° (1.57 rad)
(b) 55 ° (0.96 rad)
A : Front side
RY9212148HYS0217US0
3-S27
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
3-S28
(To be continued)
KiSC issued 08, 2015 A
KX080-4, WSM
(Continued)
(28)
(29)
(30)
(31)
(24)
(25)
(26)
(27)
(32)
(33)
(34)
(35)
(20)
(21)
(22)
(23)
(16)
(17)
(18)
(19)
(12)
(13)
(14)
(15)
(8)
(9)
(10)
(11)
(4)
(5)
(6)
(7)
No.
(1)
(2)
(3)
O-ring
Piston
Spring guide
O-ring
Spring
Spring seat
Housing
Backup ring
O-ring
Poppet
Poppet seat
Backup ring
Part Name
Plug
O-ring
Orifice
Hex socket bolt
Body
Plug
Spring
Check valve
Sleeve
O-ring
Plug
O-ring
Plug
O-ring
Plug
O-ring
Spring
Poppet
Hex socket bolt
Nut
Set screw
Plug
Backup ring
Part Name
O-ring
Cover
Orifice
Knock pin
Pin
Pin
O-ring
Spring, small
Spring, large
Brake piston
O-ring
Collar
O-ring
Disc
Plate A
Plate B
Ball bearing
Valve plate
Circlip
Washer
Spring
Cylinder block
Pin
Piston ASSY
Retainer holder
Retainer plate
Swash-plate
Shaft
Ball bearing
O-ring
Plug
O-ring
O-ring
Hex socket bolt
Valve body
(63)
(64)
(65)
(66)
(59)
(60)
(61)
(62)
(67)
(68)
(69)
(70)
(55)
(56)
(57)
(58)
(51)
(52)
(53)
(54)
(47)
(48)
(49)
(50)
(43)
(44)
(45)
(46)
(39)
(40)
(41)
(42)
No.
(36)
(37)
(38)
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
4
2
2
2
4
3
1
1
2
2
1
2
2
3
1
2
2
Qty
2
4
2
HYDRAULIC SYSTEM
1
1
1
1
9
1
1
1
1
2
2
1
2
1
1
3
2
1
1
1
1
1
4
1
8
12
1
1
1
2
2
1
Qty
2
1
1
(74)
(75)
(76)
(77)
No.
(71) Spool
(72) Spring
(73) O-ring
Part Name
Plug
Housing
Hex socket bolt
Plate
(78)
(79)
Drive gear
Inner race
(80) Needle bearing
(81) Planetary gear A
(82) Washer
(83) Holder
(84)
(85)
Circlip
Sun gear
(90)
(91)
(92)
(93)
(86)
(87)
(88)
(89)
Hex flange bolt
Plate
Inner race
Needle bearing
Planetary gear B
Washer
Holder
Plate
(94)
(95)
(96)
(97)
Collar
Tapered roller bearing
Oil seal
O-ring
(98)
(99)
Housing
O-ring
(100) Plug
(101) Tapered roller bearing
(102) Collar
(103) Plate
(104) Plate
(105) Shaft
RY9212148HYS0097US0
1
1
1
1
1
1
1
1
1
1
1
1
4
4
1
2
4
1
4
4
3
1
1
1
1
3
3
3
1
1
4
1
Qty
1
1
1
3-S29
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
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. Remove the hex socket bolts and then the valve body.
• Tool to use: 5 mm hex socket
(1) Hex socket bolt (2) Valve body
RY9212148HYS0099US0
4. Remove the relief valve and loosen the plug (both sides).
• Tool to use: 27mm box wrench, 12 mm hex socket
(1) Relief valve (2) Plug
RY9212148HYS0100US0
5. Remove the hex socket bolts and then the cover.
• Tool to use: 12 mm hex socket
(1) Hex socket bolt (2) Cover
RY9212148HYS0101US0
6. Remove the plug, spring and poppet in order.
• Tool to use: 12 mm hex socket
(1) Plug
(2) Spring
(3) Poppet
RY9212148HYS0102US0
3-S30
KiSC issued 08, 2015 A
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.
• Tool to use: air gun
CAUTION
• Be careful because if you blast air into the passage, the brake piston may come flying out.
(A) Brake release oil passage hole
RY9212148HYS0104US0
9. Remove the 1 disc and then the cylinder block ASSY.
(1) Disc (2) Cylinder block ASSY
RY9212148HYS0105US0
10. Remove the collar.
• Tool to use: Slotted screwdriver
CAUTION
• Be careful not to scratch the plate with the screwdriver.
(1) Collar
RY9212148HYS0106US0
11. Remove the plate, disc and swash-plate.
(1) Plate
(2) Disc
(3) Swash-plate
RY9212148HYS0107US0
3-S31
KiSC issued 08, 2015 A
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
(2) Hex socket bolt
(3) Housing
RY9212148HYS0108US0
13. Remove the plate.
(1) Plate
RY9212148HYS0109US0
14. Remove the driver gear, planetary gear A, needle bearing, inner race and washer and then remove the flange holder.
(1) Drive gear
(2) Planetary gear A
(3) Needle bearing
(4) Inner race
(5) Washer
(6) Flange holder
RY9212148HYS0110US0
15. Remove the sun gear, hex flange holder and then the plate.
• Tool to use: 5 mm hex socket
CAUTION
• If the bolts are tight and you can't loosen them, heat them with a heat gun or the like.
• Always use a tap to clean the threads of any thread lock on them..
(1) Sun gear
(2) Hex flange bolt
(3) Plate
RY9212148HYS0111US0
16. Remove planetary gear B, needle bearing, inner race and washer and then remove the flange holder.
(1) Planetary gear B
(2) Needle bearing
(3) Inner race
(4) Washer
(5) Flange holder
RY9212148HYS0112US0
3-S32
KiSC issued 08, 2015 A
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.
(1) Collar (2) Plate
RY9212148HYS0113US0
18. Remove the plate and then the shaft.
• Tool to use: punch and hammer
(1) Plate (2) Shaft
RY9212148HYS0114US0
19. Remove the tapered roller bearing and the plug.
• Tool to use: 5 mm hex socket
(1) Tapered roller bearing (2) Plug
RY9212148HYS0115US0
20. Remove the oil seal.
• Tool to use: slotted screwdriver and hammer
(1) Oil seal
RY9212148HYS0116US0
3-S33
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
• 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.
RY9212148HYS0117US0
1. Install the oil seal.
• Tool to use: hammer
• Tool to use: Oil seal installation tool
IMPORTANT
• Apply grease to the lip and circumference of the oil seal.
(a) Oil seal installation tool
RY9212148HYS0118US0
2. Apply grease to the pinion shaft's tapered roller bearing.
IMPORTANT
• Brand of grease: Shell Alvania Grease
• Amount of grease: Approx. 66 to 75 g (0.15 to 0.17 lbs)
(1) Pinion shaft
RY9212148HYS0119US0
3. Mount the housing on the pinion shaft and install the tapered roller bearing.
IMPORTANT
• Make sure the plug is not installed.
• If you mount the pinion shaft with the plug in place, the internal pressure rises and may blow the oil seals.
(1) Pinion shaft
(2) Housing
(3) Tapered roller bearing
(a) Plug installation position
RY9212148HYS0120US0
4. Use a press on the plate installation tool to install the plate.
Press pressure Factory specification
11770 N
1200 kgf
2646 lbs
• Tool to use: Plate installation tool
CAUTION
• If the plate comes off, the shaft may fall, so take care in handling it.
(1) Plate
(b) Plate installation tool
RY9212148HYS0121US0
5. Install the collar.
(1) Collar
RY9212148HYS0122US0
3-S34
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
6. Put the housing on the assembly platform and install the plug.
7. Install the holder and the washer.
Tightening torque Plug
15.7 ± 0.8 N·m
1.6 ± 0.1 kgf·m
11.6 ± 0.6 lbf·ft
• Tool to use: 5 mm hex socket
IMPORTANT
• Install with the rounded side of the washer down.
(1) Plug
(2) Holder
(3) Washer
RY9212148HYS0123US0
8. Install the inner race, needle bearing and planetary gear B in order.
IMPORTANT
• Take care to install the gear facing the right direction.
(1) Inner race
(2) Needle bearing
(3) Planetary gear B
RY9212148HYS0124US0
9. Install the plate and then the sun gear.
IMPORTANT
• Apply a thread lock (Loctite 242) to the hex flange bolts.
Tightening torque Hex flange bolt
24.5 ± 4.9 N·m
2.5 ± 0.5 kgf·m
18.1 ± 3.6 lbf·ft
• Tool to use: 5 mm hex socket
(1) Plate
(2) Hex flange bolt
(3) Sun gear
RY9212148HYS0125US0
10. Install the holder and the washer.
IMPORTANT
• Install with the rounded side of the washer down.
(1) Holder (2) Washer
RY9212148HYS0126US0
11. Install the inner race, needle bearing, planetary gear A and drive gear in order.
(1) Inner race
(2) Needle bearing
(3) Planetary gear A
(4) Drive gear
RY9212148HYS0127US0
3-S35
KiSC issued 08, 2015 A
KX080-4, WSM
12. Install the plate and O-ring.
IMPORTANT
• Apply grease to the O-ring.
(1) Plate (2) O-ring
HYDRAULIC SYSTEM
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.
• Tool to use: depth gauge
[Measurement Method]
Measurement A (Photo a) - measurement B (Photo b) = measurement C
• Housing height: measurement A (Photo
a
)
• Height between inner race and highest point of housing: measurement B (Photo
b
)
Measurement C
Plate to use
Less than
5.3 to 5.8mm
(0.21 to 0.23 in.)
2.8 mm (0.11 in.)
Less than
5.3 to 5.8mm
(0.21 to 0.23 in.)
6.5 to 7.0 mm
(0.26 to 0.28 in.)
2.3 mm (0.09 in.) 1.8 mm (0.07 in.)
RY9212148HYS0148US0
13. Install the housing.
Tightening torque Hex socket bolt
• Tool to use: 12 mm hex socket
(1) Housing
177.0 ± 10.0 N·m
18.0 ± 1.0 kgf·m
130.5 ± 7.5 lbf·ft
RY9212148HYS0130US0
14. Tap the ball bearing in and install the shaft.
IMPORTANT
• Face the ball bearing so the inscription is up.
• Apply grease to the circumference of the ball bearing.
(1) Ball bearing (2) Shaft
RY9212148HYS0131US0
3-S36
KiSC issued 08, 2015 A
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.
IMPORTANT
• After installing the part, turn the platform back.
(1) Cylinder block
RY9212148HYS0133US0
17. Install the disc, plate B and plate A.
IMPORTANT
• Install plates A and B with their rounded side up.
• Be careful to install the disc and plates in order.
• Plate A: thickness 3.0mm (0.063 in.)
• Plate B: thickness 1.6 mm (0.118 in.)
(1) Disc
(2) Plate B
(3) Plate A
RY9212148HYS0134US0
18. Mount the O-ring on the collar and install it in the housing.
IMPORTANT
• Apply grease to the collar and the O-ring.
(1) Collar
(2) O-ring
(3) Housing
RY9212148HYS0135US0
19. Mount the O-ring on the brake piston and install it in the housing.
IMPORTANT
• Apply grease to the O-ring.
• Take care to position the holes in the brake piston correctly.
(1) Brake piston (2) O-ring
RY9212148HYS0136US0
3-S37
KiSC issued 08, 2015 A
KX080-4, WSM
Brake piston hole alignment positions
Install so the pin hole is at position
.
(a) 0.393 rad (22.5 °)
HYDRAULIC SYSTEM
RY9212148HYS0137US0
20. Install the large and small springs and the O-ring.
IMPORTANT
• Apply grease to the O-ring.
(1) Spring, large
(2) Spring, small
(3) O-ring
RY9212148HYS0138US0
Small spring installation position
Install the small springs at position
.
(a) Pin hole position
RY9212148HYS0139US0
21. Insert the poppet and spring into the cover and mount the plug loosely (both sides).
IMPORTANT
• Apply hydraulic fluid to the spool.
(1) Poppet
(2) Spring
(3) Plug
RY9212148HYS0140US0
22. Install the ball bearing and valve plate on the cover.
IMPORTANT
• Take care to face the valve plate correctly.
• Apply grease to the back of the valve plate so it will not fall off.
(1) Ball bearing (2) Valve plate
RY9212148HYS0141US0
3-S38
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
23. Install the cover.
IMPORTANT
• Take care so the valve plate does not fall off.
Tightening torque Hex socket bolt
177.0 ± 10.0 N·m
18.0 ± 1.0 kgf·m
130.5 ± 7.5 lbf·ft
• Tool to use: 12 mm hex socket
(1) Cover
RY9212148HYS0142US0
24. Install the plug and relief valve.
IMPORTANT
• Apply hydraulic oil to the relief valve.
Plug
157.0 ± 10.0 N·m
16.0 ± 1.0 kgf·m
115.5 ± 7.5 lbf·ft
Tightening torque
Relief valve
373.0 ± 20.0 N·m
38.05 ± 2.05 kgf·m
275.0 ± 15.0 lbf·ft
• Tool to use: 12 mm hex wrench, 27 mm box wrench
(1) Plug (2) Relief valve
RY9212148HYS0143US0
25. Install the O-rings and valve body.
IMPORTANT
• Apply grease to the O-ring.
Tightening torque Hex socket bolt
9.8 ± 1.0 N·m
1.0 ± 0.1 kgf·m
7.2 ± 0.7 lbf·ft
• Tool to use: 5 mm hex socket
(1) O-ring (2) Valve body
RY9212148HYS0144US0
26. Install the O-rings and body.
IMPORTANT
• Apply grease to the O-ring.
Tightening torque Hex socket bolt
32.4 ± 2.0 N·m
3.3 ± 0.2 kgf·m
23.9 ± 1.5 lbf·ft
• Tool to use: 6 mm hex socket
(1) O-ring (2) Body
RY9212148HYS0145US0
3-S39
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
(a) Oil seal installation tool
A
B
C
D
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.)
C1
1 mm (0.04 in.) bevel
• If angle is not specified, there must not be any burrs. Corner to be max of R0.4 mm
(0.016 in.)
RY9212148HYS0146US0
(b) Plate installation tool
A
B
C
D
E
F
G
H
40 mm ( 1.57 in.)
40 mm (1.57 in.)
100 mm (3.93 in.)
40 mm (1.57 in.)
10 mm (0.39 in.)
50 mm (1.96 in.)
63.2 - 63.4 mm ( 2.48 - 2.49 in.)
53 mm (2.08 in.)
I
78.2 to 78.4 mm (3.07 to 3.08 in.)
• If angle is not specified, there must not be any burrs. Corner to be max of R0.4 mm
(0.016 in.)
RY9212148HYS0147US0
3-S40
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
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.
• Oil gushing out under pressure has enough force to injure you by piercing your skin. Always relieve any pressure remaining in the system prior to working to remove any hydraulic equipment or lines.
RY9212148HYS0149US0
1. Use the front and the blade to jack up the excavator.
CAUTION
• Always put stands under the track while the excavator is jacked up.
RY9212148HYS0218US0
2. Remove the cover, electric fan, tank cover and center cover.
[Work Tip]
• Move the condenser toward the rear of the machine with the AC hoses still installed.
(1) Cover
(2) Electric fan
(3) Tank cover
(4) Center cover
RY9212148HYS0219US0
3. Disconnect the 2-speed pilot hose and drain hose from the swivel joint.
4. Disconnect the R/L travel fwd/bwd hoses from the control valve side.
IMPORTANT
• Plug the disconnected hoses and adapters.
(1) Control valve
(2) Hydraulic oil tank
(3) Unload valve
(4) Swivel joint
RY9212148HYS0220US0
5. Remove the bottom cover of the track frame and disconnect all the hoses connected to the swivel joint body.
IMPORTANT
• Plug the disconnected hoses and adapters.
RY9212148HYS0221US0
3-S41
KiSC issued 08, 2015 A
KX080-4, WSM
Adapter angles
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).
Tightening torque
Swivel joint mounting bracket
77.5 to 90.2 N·m
7.9 to 9.2 kgf·m
57.2 to 66.5 lbf·ft
Swivel joint weight Approx. 45 kg (99 lbs)
(1) Swivel joint mounting bracket
RY9212148HYS0222US0
7. Perform the procedure in reverse for assembly.
RY9212148HYS0096US0
A : 2-speed pilot
B : Blade down
C : Blade up
D : Left forward
E : Right forward
F : Left backward
G : Right backward
H : Drain
(A) Blade side
(a) 15 ° (0.26 rad)
(b) 30 ° (0.52 rad)
(c) 45 ° (0.79 rad)
RY9212148HYS0224US0
3-S42
KiSC issued 08, 2015 A
KX080-4, WSM
Adapter angle (angle spec.)
HYDRAULIC SYSTEM
A : 2-speed pilot
B : Blade down
C : Blade up
D : Left forward
E : Right forward
F : Left backward
G : Right backward
H : Drain
I : Angle Right
J : Angle Left
(A) Blade side
(a) 15 ° (0.26 rad)
(b) 30 ° (0.52 rad)
(c) 45 ° (0.79 rad)
RY9212158HYS0032US0
3-S43
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
Components
Qty
No.
Part Name
Standard Spec
Angle
Specification
Notes
(1)
(2)
(3)
Plug (PT1/4)
Plug (PT3/8)
Plug (PT1/2)
–
2
4
4
2
4
40.2 ± 3.9 N·m
4.1 ± 0.4 kgf·m
29.6 ± 2.9 lbf·ft
71.1 ± 2.5 N·m
7.2 ± 0.2 kgf·m
52.4 ± 1.8 lbf·ft
85.9 ± 2.5 N·m
8.8 ± 0.2 kgf·m
63.3 ± 1.8 lbf·ft
(4)
(5)
(6)
(7)
Shaft
Collar
Packing (U)
O-ring
(8)
(9)
Seal
Body
(10) Bracket
7
1
2
1
1
1
1
9
1
2
1
1
1
1
(11) Bolt
(12) Bolt
4
4
4
4
84.0 ± 6.0 N·m
8.6 ± 0.6 kgf·m
62.0 ± 5.0 lbf·ft
Thread lock (Loctite 1324 or equivalent)
84.0 ± 6.0 N·m
8.6 ± 0.6 kgf·m
62.0 ± 5.0 lbf·ft
Thread lock (Loctite 271)
(13) Collar
(14) Circlip
(15) O-ring
(16) Bottom cover
1
1
1
1
1
1
1
1
(17) Hex socket bolt 4 4
84.0 ± 6.0 N·m
8.6 ± 0.6 kgf·m
62.0 ± 5.0 lbf·ft
Thread lock (Loctite 1324 or equivalent)
• During disassembly always tap out threads that have thread lock sticking to them.
RY9212148HYS0001US0
3-S44
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
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. Mount an eye bolt on the bottom cover and put a bar through the hole in the eye bolt. Knock upwards on both sides of the bar and remove the bottom cover.
(1) Bottom cover
RY9212148HYS0004US0
4. Remove the O-ring.
(1) O-ring
RY9212148HYS0005US0
5. Remove the circlip and then the collar.
IMPORTANT
• Be careful so the circlip does not go flying.
• Tool to use: snap ring pliers
(1) Circlip (2) Collar
RY9212148HYS0006US0
3-S45
KiSC issued 08, 2015 A
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.
(1) Swivel joint (2) Protective mat
RY9212148HYS0007US0
7. Remove the U packing and the collar in order.
• Tool to use: Slotted screwdriver
(1) Packing (U) (2) Collar
RY9212148HYS0008US0
8. Remove the O-ring and seal inside the body.
• Tool to use: awl
Work Tip
• Depending on the position where the seal is inserted, turn the body counterclockwise to remove it.
(1) O-ring (2) Seal
RY9212148HYS0009US0
3-S46
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
• 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.)
• Always replace all of the O-rings, seals and U packings with new ones.
RY9212174HYS0001US0
1. Install the seal and O-ring in the body.
IMPORTANT
• Apply grease uniformly to the O-ring and the seal.
• Manipulate the seal and O-ring until they seat perfectly into the groove.
Work Tip
• Depending on where the seal is being inserted, turn the body the opposite direction to mount it.
• If it is difficult to get the seal in, use a spatula with rounded edges to mount it.
(1) Seal (2) O-ring
RY9212148HYS0010US0
2. Mount the collar and U packing in order on the top of the shaft.
IMPORTANT
• Apply grease uniformly on the U packing.
• Make sure the collar and U packing stick to the head of the shaft.
(1) Collar (2) Packing (U)
RY9212148HYS0011US0
3. Apply grease uniformly onto the shaft.
RY9212148HYS0012US0
4. Check the positioning of the alignment mark and insert the shaft.
IMPORTANT
• Make sure there are no scratches or debris.
(1) Shaft (2) Body
RY9212148HYS0013US0
3-S47
KiSC issued 08, 2015 A
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.
IMPORTANT
• Apply grease to the O-ring.
(1) O-ring
RY9212148HYS0015US0
7. Mount the bottom cover.
Tightening torque Hex socket bolt
84.0 ± 6.0 N·m
8.6 ± 0.6 kgf·m
62.0 ± 5.0 lbf·ft
• Tool to use: 10 mm hex socket
IMPORTANT
• Apply thread lock (ThreeBond 1324 or equivalent) to the hex bolts.
(1) Bottom cover
RY9212148HYS0016US0
3-S48
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
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.
• When hydraulic oil is under pressure, it has enough force to pierce your skin or eyes. When working with hydraulic lines always relieve any residual pressure before starting work.
RY9212148HYS0091US0
1. Remove the track and cover.
• Tool to use: 14 mm socket
DANGER
• Always support the track frame with blocks.
(1) Cover (2) Bolt
RY9212148HYS0092US0
2. Use a vacuum pump to depressurize the hydraulic oil tank and then disconnect the hoses that are connected to the travel motor.
(1) Hose
RY9212148HYS0093US0
3. Suspend the travel motor with a nylon sling and remove the bolts.
IMPORTANT
• Apply a thread lock (Loctite 271).
Tightening torque Travel motor
282.0 ± 22.0 N·m
28.8 ± 2.3 kgf·m
208.0 ± 16.0 lbf·ft
(1) Bolt
RY9212148HYS0094US0
4. Use a crane to hoist and remove the travel motor.
IMPORTANT
• Apply a thread lock (Loctite 271).
Tightening torque Sprocket
181.4 ± 14.7 N·m
18.5 ± 1.5 kgf·m
133.8 ± 10.8 lbf·ft
(1) Travel motor
RY9212148HYS0095US0
5. Perform the procedure in reverse for assembly.
RY9212148HYS0096US0
3-S49
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
3-S50
(To be continued)
KiSC issued 08, 2015 A
KX080-4, WSM
(Continued)
(4)
(5)
(6)
(7)
No.
(1)
(2)
(3)
Wire
Plug
O-ring
Cover
O-ring
Bolt
Plate
Part Name
(8)
(9)
Planetary gear B
Needle bearing
(10) Holder
(11) Drive gear
(12) Sun gear
(13) Gear case
(14) Plate
(15) Ring nut
(16) Angular bearing
(17) Planetary gear A
(18) Collar
(19) Needle bearing
(20) Thrust washer
(21) Floating seal
(22) Washer
(23) Parallel pin
(24) Flange holder
(25) Pin
(26) O-ring
(27) Oil seal
(28) Ball bearing
(29) Shaft
(30) Spring
(31) 2-speed piston
No.
(32) Ball
Part Name
(33) Swash-plate
(34) Piston ASSY
(35) Retainer plate
(36) Retainer holder
(37) Cylinder block
(38) Pin
(39) Plate A
(40) Spring
(41) Plate B
(42) Circlip
(43) Valve plate
(44) Knock pin
(45) Ball bearing
(46) Disc
(47) Plate
(48) Backup ring
(49) O-ring
(50) Backup ring
(51) O-ring
(52) Brake piston
(53) Spring
(54) Nut
(55) O-ring
(56) Body
(57) Piston
(58) Backup ring
(59) O-ring
(60) Backup ring
(61) Rod
(62) Spring
1
1
1
1
1
2
1
1
4
1
1
1
2
4
4
4
1
1
1
1
3
3
1
1
1
1
8
1
Qty
1
3
3
HYDRAULIC SYSTEM
No.
(63) Poppet
Part Name
(64) Backup ring
(65) O-ring
(66) Seat
(67) Plug
(68) O-ring
(69) Spring
(70) Poppet
(71) Plug
(72) O-ring
(73) Spring
(74) Spring seat
(75) Spool
(76) Orifice
(77) Plug
(78) Plug
(79) Hex socket bolt
(80) Plug
(81) O-ring
(82) Spring
(83) Spool
(84) O-ring
(85) Plug
(86) Nameplate
(87) Plug
(88) O-ring
(89) Plug
(90) O-ring
(91) Ball
(92) Base plate
2
2
2
2
2
2
2
2
1
1
10
2
2
1
1
1
1
1
1
2
1
1
1
1
1
1
1
3
Qty
2
1
1
RY9212158HYS0001US0
4
2
1
1
2
2
2
1
1
1
1
6
8
1
1
2
1
1
4
2
2
2
2
2
2
2
2
Qty
2
2
2
3-S51
KiSC issued 08, 2015 A
KX080-4, WSM
[A] Gear Case
HYDRAULIC SYSTEM
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
(1) Wire
RY9212158HYS0003US0
3. Attach the cover removal tool and knock it up to remove the cover.
• Tool to use: Cover removal tool
If a cover removal tool is not available:
• Mount an eye bolt on the cover and put a bar through the hole in the eye bolt.
• Knock upwards on both sides of the bar and remove the cover.
(1) Cover
(a) Cover removal tool
RY9212148HYS0022US0
4. Remove the plate.
• Tool to use: Torx T40
(1) Plate
RY9212158HYS0045US0
3-S52
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
5. Remove the drive gear, planetary gear B, needle bearing, and the holder.
(1) Drive gear
(2) Planetary gear B
(3) Needle bearing
(4) Holder
RY9212158HYS0046US0
6. Remove the plate and the sun gear.
• Tool to use: Torx T40
(1) Plate (2) Sun gear
RY9212158HYS0047US0
7. Remove planetary gear A, the needle bearing and collar in order.
(1) Planetary gear A
(2) Needle bearing
(3) Collar
RY9212158HYS0004US0
8. Remove the thrust washer, bolt and washer in order.
• Tool to use: Torx T40
(1) Thrust washer
(2) Bolt
(3) Washer
RY9212158HYS0048US0
3-S53
KiSC issued 08, 2015 A
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.
• Tool to use: 4.2mm drill bit, M5 tap
IMPORTANT
• Be careful not to scratch the flange holder.
(1) Parallel pin
RY9212158HYS0049US0
10. Remove the ring nut.
• Tool to use: Ring nut socket
IMPORTANT
• Be careful that the ring nut socket doesn't come off during installation/removal.
(b) Ring nut socket
RY9212158HYS0005US0
11. Use removal bolts to raise the gear case up higher than the flange holder and remove the gear case.
• Tool to use: removal bolts
IMPORTANT
• Tighten the removal bolts equally.
(1) Gear case
(2) Flange holder
(c) Removal bolts
RY9212148HYS0023US0
12. Remove the floating seal from the flange holder side.
• Tool to use: Slotted screwdriver
(1) Floating seal
RY9212148HYS0024US0
3-S54
KiSC issued 08, 2015 A
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
• Tap and remove the outer race of the angular bearing.
• Tap evenly on the angular bearing with the pin punch.
(1) Angular bearing
RY9212148HYS0026US0
15. Turn the gear case over and remove the other angular bearing.
• Tool to use: pin punch and a hammer
IMPORTANT
• Tap and remove the outer race of the angular bearing.
• Tap evenly on the angular bearing with the pin punch.
(1) Angular bearing
RY9212148HYS0027US0
3-S55
KiSC issued 08, 2015 A
KX080-4, WSM
[B] Motor
HYDRAULIC SYSTEM
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
(1) Plug
(2) Spring
(3) Spring seat
(4) Spool
RY9212158HYS0007US0
3. Remove the plug, spring and poppet in order.
• Tool to use: 10 mm hex socket
(1) Plug
(2) Spring
(3) Poppet
RY9212158HYS0008US0
4. Remove the plug, spool and spring in order.
• Tool to use: 10 mm hex socket
(1) Plug
(2) Spool
(3) Spring
RY9212158HYS0009US0
5. Remove the plug and then the ball.
• Tool to use: 5 mm hex socket, magnet
(1) Ball (2) Plug
RY9212158HYS0050US0
3-S56
KiSC issued 08, 2015 A
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.
(1) Spring (2) Valve plate
RY9212158HYS0011US0
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.
CAUTION
• Be careful because if you blast air into the passage, the brake piston may come flying off.
(1) Brake Piston
(A) Brake Release Oil Passage Hole
(B) 2-Speed Switch Oil Passage Hole
RY9212158HYS0012US0
9. Remove the plates and discs.
(1) Plate (2) Disc
RY9212158HYS0051US0
3-S57
KiSC issued 08, 2015 A
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
(2) Swash-plate
(3) Shaft
RY9212158HYS0052US0
11. Use a press to press Plate A down inside the cylinder block and then remove the circlip. Remove the cylinder block from the press and remove Plate A, the springs and Plate B.
• Tool to use: snap ring pliers
• Tool to use: Tool for pressing cylinder block
(1) Circlip
(d) Tool for pressing cylinder block
RY9212158HYS0013US0
12. Turn the assembly platform back as it was and remove the
2-speed piston, springs and balls.
(1) 2-speed piston (2) Ball
RY9212158HYS0053US0
13. Remove the oil seal.
• Tool to use: slotted screwdriver and hammer
IMPORTANT
• When you removed the shaft, if the ball bearing had not been removed, remove them together now.
RY9212158HYS0014US0
3-S58
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
[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.
RY9212148HYS0028US0
1. Put the flange holder on the assembly platform and tap in the oil seal with an oil seal installation tool.
• Tool to use: Oil seal installation tool
IMPORTANT
• Take care to face the oil seal the right direction.
• Apply grease to its lip and circumference.
(1) Flange holder
(a) Oil seal lip
(e) Oil seal installation tool
RY9212148HYS0029US0
2. Tap the ball bearing in.
IMPORTANT
• Face the ball bearing so the inscription is up.
• Apply grease to the circumference of the ball bearing.
(1) Ball Bearing
RY9212158HYS0015US0
3. Install the 2-speed piston, springs and balls.
IMPORTANT
• The spring comes out easily, so apply some grease to it.
• Press the piston down and make sure it moves smoothly.
(1) 2-speed piston
(2) Spring
(3) Ball
RY9212158HYS0054US0
3-S59
KiSC issued 08, 2015 A
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.
• Tool to use: snap ring pliers
• Tool to use: Tool for pressing cylinder block
(1) Circlip
(d) Tool for pressing cylinder block
RY9212158HYS0017US0
6. Install the three pins in the cylinder block and mount the retainer holder.
IMPORTANT
• Apply grease to the pins.
• Apply hydraulic oil to the retainer holder.
(1) Pin
(2) Cylinder block
(3) Retainer holder
RY9212158HYS0055US0
7. Install the piston ASSY into the retainer plate and then install it into the cylinder block.
IMPORTANT
• Apply hydraulic oil to the pistons.
• Make sure the pistons move smoothly.
(1) Piston ASSY (2) Retainer plate
RY9212158HYS0018US0
8. Install the sub-assy of the cylinder block to the flange holder.
IMPORTANT
• Turn the assembly platform 1.6 rad (90°) to install them and then turn it back afterwards.
(1) Cylinder block sub-assembly
RY9212158HYS0019US0
3-S60
KiSC issued 08, 2015 A
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.
• Be careful of the installation position of O-ring and backup rings.
(1) Brake piston
(2) O-ring
(3) Backup ring
RY9212158HYS0056US0
11. Install the valve plate and springs.
IMPORTANT
• Take care to face the valve plate correctly.
• Apply grease to the back of the valve plates and springs so they will not fall off.
(1) Valve plate (2) Spring
RY9212158HYS0021US0
12. Install the O-rings.
IMPORTANT
• Apply grease to the O-ring.
(1) O-ring
RY9212158HYS0022US0
13. Install the base plate.
IMPORTANT
• Be careful so the base plate does not fall off.
• Tighten the hex socket bolts diagonal to each other.
Tightening torque Hex socket bolt
129.4 ± 12.9 N·m
13.2 ± 1.2 kgf·m
95.4 ± 9.5 lbf·ft
• Tool to use: 10 mm hex socket
(1) Base plate (2) Hex socket bolt
RY9212158HYS0023US0
3-S61
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
14. Install the ball and plug in order.
Tightening torque Plug
• Tool to use: 5 mm hex socket
(1) Ball (2) Plug
19.6 ± 1.0 N·m
2.0 ± 0.1 kgf·m
14.4 ± 0.7 lbf·ft
RY9212158HYS0057US0
15. Install the spring, spool and plug in order.
IMPORTANT
• Apply hydraulic oil to the spool.
Tightening torque Plug
78.5 ± 7.8 N·m
8.0 ± 0.8 kgf·m
57.9 ± 5.8 lbf·ft
• Tool to use: 8 mm hex socket
(1) Spring
(2) Spool
(3) Plug
16. Install the poppet, spring and plug in order.
RY9212158HYS0024US0
IMPORTANT
• Apply hydraulic fluid to the spool.
Tightening torque Plug
65.7 ± 6.6 N·m
6.7 ± 0.7 kgf·m
48.2 ± 5.1 lbf·ft
• Tool to use: 10 mm hex socket
(1) Poppet
(2) Spring
(3) Plug
RY9212158HYS0058US0
17. Install the spool spring seat, spring and plug in order.
IMPORTANT
• Apply hydraulic oil to the spool.
• The spool must slide smoothly.
Tightening torque Plug
176.4 ± 17.6 N·m
18.0 ± 1.8 kgf·m
130.0 ± 13.0 lbf·ft
• Tool to use: 30 mm socket
(1) Spool
(2) Spring seat
(3) Spring
(4) Plug
RY9212158HYS0025US0
18. Install the shockless valve.
Tightening torque Shockless valve
142.1 ± 14.2 N·m
14.5 ± 1.5 kgf·m
104.8 ± 10.5 lbf·ft
• Tool to use: 22 mm socket
(1) Shockless valve
RY9212158HYS0026US0
3-S62
KiSC issued 08, 2015 A
KX080-4, WSM
[B] Gear Case
HYDRAULIC SYSTEM
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. Grease the O-ring of the floating seal and set the floating seal on the flange holder with the floating seal installation tool.
• Tool to use: floating seal installation tool
(f) Floating seal installation tool
RY9212158HYS0059US0
3. Apply a little gear oil on the sliding surface of the floating seal.
[4 places, every 1.6 rad (90°)]
(1) Floating seal (2) Flange holder
RY9212148HYS0031US0
4. Grease the O-ring of the floating seal and use the floating seal installation tool to set the floating seal on the gear case.
• Tool to use: floating seal installation tool
(f) Floating seal installation tool
RY9212158HYS0060US0
3-S63
KiSC issued 08, 2015 A
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.
(1) Gear case (2) Flange holder
RY9212148HYS0033US0
7. Install the ring nut.
• Tool to use: Ring nut socket
IMPORTANT
• If the gear case is sticking up, use a clamp to press the gear case down.
• Be careful that the ring nut socket doesn't come off during installation/removal.
After turning the gear case several revolutions, mount the bolts in the mounting holes in the sprocket and pull on the bolt with a push/pull gauge to measure the rotational torque on the motor.
Tightening torque Factory specification
117.5 ± 17.5 N·m
12.0 ± 1.8 kgf·m
86.7 ± 12.9 lbf·ft
IMPORTANT
• If the torque is below the factory specification: tighten the ring nut and remeasure the torque.
• If the torque is higher than the factory specification: loosen the ring nut temporarily and then retighten the ring nut and recheck the torque.
(b) Ring nut socket
RY9212158HYS0061US0
3-S64
KiSC issued 08, 2015 A
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.
• Completely remove all the debris from drilling the hole.
[NOTE]
Hole diameter: 6.00 to 6.15mm (0.236 to 0.242 in.)
Depth: 7.5 to 8.0 mm (0.30 to 0.31 in.)
(1) Adhesive tape (2) Vacuum pump
RY9212158HYS0062US0
9. Install the thrust washer and bolt.
IMPORTANT
• Apply a thread lock (ThreeBond 2403).
• Clean screw holes prior to installation.
Tightening torque Bolt
35.3 ± 2.0 N·m
3.6 ± 0.2 kgf·m
26.0 ± 1.5 lbf·ft
• Tool to use: Torx T40
(1) Thrust washer
(2) Washer
(3) Bolt
RY9212158HYS0063US0
10. Install the collar, needle bearing and planetary gear A in order.
(1) Collar
(2) Needle bearing
(3) Planetary gear A
RY9212158HYS0028US0
11. Install the sun gear and plate in order.
IMPORTANT
• Clean screw holes prior to installation.
• Apply a thread lock (ThreeBond 2403).
Tightening torque Bolt
35.3 ± 2.0 N·m
3.6 ± 0.2 kgf·m
26.0 ± 1.5 lbf·ft
• Tool to use: Torx T40
(1) Sun gear
(2) Plate
(3) Bolt
RY9212158HYS0064US0
3-S65
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
12. Install the holder, needle bearing, planetary gear B and drive gear in order.
(1) Holder
(2) Needle bearing
(3) Planetary gear B
(4) Drive gear
RY9212158HYS0065US0
13. Install the plate.
IMPORTANT
• Clean screw holes prior to installation.
• Apply a thread lock (ThreeBond 2403).
Tightening torque Bolt
35.3 ± 2.0 N·m
3.6 ± 0.2 kgf·m
26.0 ± 1.5 lbf·ft
• Tool to use: Torx T40
(1) Plate (2) Bolt
RY9212158HYS0066US0
14. Install the cover.
IMPORTANT
• Apply grease to the O-ring.
(1) Cover (2) O-ring
RY9212158HYS0029US0
15. Install the wire and plug.
Tightening torque Plug
58.8 ± 9.8 N·m
6.0 ± 1.0 kgf·m
43.4 ± 7.2 lbf·ft
• Tool to use: 8 mm hex socket
IMPORTANT
• Be sure to fill with the specified amount of gear oil [1.35 L,
(0.36 US gal.)] prior to mounting on the machine.
• After mounting the travel motor on the machine, double-check the gear oil level.
(1) Wire (2) Plug
RY9212158HYS0030US0
3-S66
KiSC issued 08, 2015 A
KX080-4, WSM
3-S67
HYDRAULIC SYSTEM
(a) Cover removal tool
E
F
G
H
A
B
C
D
C2
C5
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. bevel)
(1) Tempered
RY9212148HYS0021US0
(b) Ring nut socket
L
M
N
H
I
J
K
D
E
F
G
A
B
C
O
P
Q
800 mm (31.50 in.)
194 mm (7.64 in.)
230 mm (9.06 in.)
60 mm (2.36 in.)
100 mm (3.94 in.)
20 mm (0.79 in.)
6 mm (0.24 in.)
130 mm (5.12 in.)
12 mm (0.47 in.)
5 mm (0.20 in.)
184.5 mm (7.264 in.)
206 mm (8.11 in.)
222 mm (8.74 in.)
9 mm (0.35 in.)
Stud bolt
4 - M12 × 150 mm (5.91 in.)
Hex nut
12 - M12
Hex socket bolt
2 - M10 × 18 mm (0.71 in.)
Machine the tip to 6 mm (0.24 in.) from the tip at 9 mm (0.35 in.).
RY9212158HYS0067US0
(c) Removal bolts (M14 × 2.0)
C
D
A
B
M14 x P2.0
M14 nut
250 mm (9.84 in.)
5 mm (0.5 in.)
RY9212148HYS0020US0
KiSC issued 08, 2015 A
KX080-4, WSM
3-S68
HYDRAULIC SYSTEM
(d)Tool for pressing cylinder block
C
D
A
B
E
F
G
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.)
99.7 to 100.3 mm (3.926 to 3.949 in.)
0.79 rad (45°)
C0.1
0.1 mm (0.004 in.) bevel
• Unspecified corners to be R0.4 mm
(0.016 in.)
RY9212158HYS0068US0
(a)Oil seal installation tool
G
H
I
C1
C
D
A
B
E
F
30 mm (1.18 in.)
90 mm (3.54 in.)
235 mm (9.25 in.)
35 mm (1.38 in.)
15 mm (0.59 in.)
3 mm (0.12 in.)
29.8 to 30.0 mm (1.17 to 1.18 in.)
49.0 to 49.1 mm (1.92 to 1.93 in.)
0.52 rad (30 °)
1 mm (0.04 in.) bevel
RY9212158HYS0069US0
(f) Floating seal installation tool
A
M
N
O
R0.5
I
J
K
L
R1
R4.25
R5
R8
E
F
G
H
B
C
D
• Material: MC nylon
1 to 2 mm (0.039 to 0.079 in.)
1 notch in circumference
255 mm (10.04 in.)
239 mm (9.41 in.)
219 mm (8.62 in.)
20 mm (0.79 in.)
140 mm (5.51 in.)
10 mm (0.39 in.)
225 mm (8.86 in.)
3 mm (0.12 in.)
5.02 mm (0.198 in.)
5.71 mm (0.225 in.)
1.64 mm (0.065 in.)
2.6 mm (0.102 in.)
3.36 mm (0.132 in.)
0.79 rad (45°)
Radius 0.5 mm (0.02 in.)
Radius 1 mm (0.04 in.)
Radius 4.25 mm (0.167 in.)
Radius 5 mm (0.20 in.)
Radius 8 mm (0.32 in.)
RY9212158HYS0070US0
KiSC issued 08, 2015 A
KX080-4, WSM
Boom
Arm
Bucket
Maker
Screw torque
Screw size
Piston torque
Width across hex-head.
Head torque
Maker
Screw torque
Screw size
Piston torque
Width across hex-head.
Head torque
Maker
Screw size
Piston torque
Width across hex-head.
Head torque
Maker
Piston torque
Blade
Head torque
Maker
Piston torque
Swing
Head torque
HYDRAULIC SYSTEM
KX080-4
KYB
56.9 ± 10.7 N·m
5.8 ± 1.1 kgf·m
42.0 ± 7.9 lbf·ft
M12 × 1.75
3070 N·m
313.1 kgf·m
2264 lbf·ft
80
950 N·m
96.9 kgf·m
701 lbf·ft
KYB
31.5 ± 5.88 N·m
3.2 ± 0.6 kgf·m
23.2 ± 4.3 lbf·ft
M10 × 1.5
3040 N·m
310.1 kgf·m
2242 lbf·ft
70
950 N·m
96.9 kgf·m
701 lbf·ft
WIPRO
M10 × 1.5
1509 N·m
153.9 kgf·m
1113 lbf·ft
75
410 ± 25 N·m
41.8 ± 2.6 kgf·m
302.4 ± 18.4 lbf·ft
Koretsune Seiko
4000 ± 200 N·m
408.0 ± 20.4 kgf·m
2950.4 ± 147.5 lbf·ft
1200 ± 120 N·m
122.4 ± 12.2 kgf·m
885.1 ± 88.5 lbf·ft
Koretsune Seiko
2800 ± 140 N·m
285.6 ± 14.3 kgf·m
2065.3 ± 103.3 lbf·ft
650 ± 70 N·m
66.3 ± 7.1 kgf·m
479.4 ± 51.6 lbf·ft
Notes
Tap with punch in two places
Apply ThreeBond #1901
Tap with punch in two places
Apply ThreeBond #1901
3-S69
KiSC issued 08, 2015 A
KX080-4, WSM
Angle
Maker
Piston torque
Head torque
KX080-4
Koretsune Seiko
1500 ± 80 N·m
153.0 ± 8.2 kgf·m
1106.4 ± 59.0 lbf·ft
550 ± 60 N·m
56.1 ± 6.1 kgf·m
405.7 ± 44.3 lbf·ft
HYDRAULIC SYSTEM
Notes
RY9212158HYS0033US0
3-S70
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
Adapter angles
A
(1)
(2)
(3)
(4)
(5)
(6)
P
T
Swivel left
Arm dump
Swivel right
Arm crowd
Point used
B
(7)
(8)
(9)
Bucket crowd
Boom down
Bucket dump
(10) Boom up
(11) P
(12) T
Point used
A : Left pilot valve
B : Right pilot valve
(4)
(5)
(6)
(7)
No.
(1)
(2)
(3)
Handle
Bellows
Spring pin
Lever
Seal
Plug
O-ring
Part Name
(8)
(9)
Pushrod
Spring seat
(10) Secondary pressure spring
(11) Shim
(12) Return spring (Ports 1 and 3)
(13) Return Spring (Port 2)
(14) Return Spring (Port 4)
(15) Spool
(16) Lock nut
(17) Adjusting nut
(18) Round plate nut
(19) U-joint
(20) Plate
(21) Bushing
(22) Casing
1
1
1
1
1
1
1
RY9212148HYS0226US0
2
1
1
4
4
4
4
4
1
4
4
4
Qty
1
1
1
Tape color
Gray
Pea green
Light blue
Blue
White
None
Tape color
Orange
Yellow
Red
Green
White
None
(a) 45 ° (0.79 rad)
(b) 15 ° (0.26 rad)
(c) 30 ° (0.52 rad)
RY9212148HYS0227US0
3-S71
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
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.
• If parts are left disassembled or left partway disassembled, humidity or foreign matter may cause rust, so if interrupting the work is unavoidable, take precautions to protect the parts from rust and dust.
RY9212148HYS0150US0
1. Clamp the pilot valve in a vise.
IMPORTANT
• When clamping it in a vise, use a sheet of copper to prevent scratching the pilot valve.
(1) Casing
(2) Round Plate Nut
(3) Adjusting Nut
RY9212148HYS0151US0
2. Use wrenches to remove the adjusting nut and round plate nut.
• Tools to use: 22 mm and 32 mm wrenches
(1) Adjusting Nut
RY9212148HYS0152US0
3. Mark the relationship of holes to the casing.
RY9212001HYS0479US0
3-S72
KiSC issued 08, 2015 A
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.
(1) U-Joint (2) Plug
RY9212148HYS0153US0
5. Remove the plate.
(1) Plate
RY9212148HYS0154US0
6. Slip a slotted screwdriver in the groove in the plug to remove the plug.
CAUTION
• Take care so the plug does not go flying.
• Take care not to damage it by exerting force unevenly.
• If a burr is formed, use a whetstone to remove it.
(1) Plug
RY9212148HYS0155US0
3-S73
KiSC issued 08, 2015 A
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 to.
(1) Return Spring
(a) Reducing Valve ASSY
RY9212148HYS0156US0
8. To disassemble a reducing valve, press the spring seat in and while compressing the secondary pressure spring, shift the spring seat to the side and remove it from the spool via the larger hole.
IMPORTANT
• Be careful not to scratch the surface of the spool.
• Do not depress the spring seat more than 6mm (0.24 in.).
• Do not disassemble the reducing valve unless there is a problem with it.
Components of the reducing valve
(1) Spring Seat
(2) Secondary Pressure Spring
(3) Washer
(4) Spool
RY9212148HYS0157US0
9. Remove the plug from the pushrod.
(1) Plug
(2) Pushrod
(3) O-Ring
RY9212148HYS0158US0
3-S74
KiSC issued 08, 2015 A
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
(2) Plug
(3) O-Ring
(4) Pushrod
RY9212148HYS0159US0
CAUTION
• Prepare your workbench in the same way as for disassembly.
• Follow the same general precautions as in the disassembly.
• When assembling the parts, remove all bits of metal or foreign matter from all the parts and make sure there aren't any burrs or dings on the parts.
• Replace used O-rings with new ones.
• Take care not to damage the O-rings when installing them.
RY9212148HYS0160US0
1. Make sure there aren't any burrs or scratches inside the casing.
RY9212001HYS0487US0
2. Install the return spring in the casing.
IMPORTANT
• Install it in the same position as before disassembly.
(1) Return Spring
RY9212148HYS0161US0
3-S75
KiSC issued 08, 2015 A
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.
(1) Spool
(2) Washer
(3) Secondary Pressure Spring
(4) Spring Seat
RY9212148HYS0162US0
4. Install the reducing valve ASSY.
After installing it, make sure the spool moves smoothly.
IMPORTANT
• Install it in the same position as before disassembly.
RY9212001HYS0490US0
5. Install the O-ring on the plug.
(1) Plug (2) O-Ring
RY9212148HYS0163US0
6. Install the seal on the plug.
IMPORTANT
• Be careful that the seal faces the right direction.
• Apply hydraulic oil on the circumference and lip of the seal.
(1) Plug
(2) Seal
(3) Pushrod
(4) O-Ring
RY9212148HYS0164US0
3-S76
KiSC issued 08, 2015 A
KX080-4, WSM
7. Install the plug on the pushrod.
IMPORTANT
• Apply hydraulic oil to the pushrod.
(1) Pushrod
(2) Plug
(3) O-Ring
HYDRAULIC SYSTEM
RY9212148HYS0165US0
8. Install the plug ASSY into the case.
If the return spring is too stiff, use the plate to install the ASSY.
IMPORTANT
• Be careful not to scratch the hole of the casing by prying on the spool.
• Take care so the plug ASSY does not go flying.
RY9212001HYS0494US0
9. Install the plate.
(1) Plate
RY9212148HYS0166US0
10. Install the U-joint.
Tightening torque U-joint
• Tool
(a)
: U-joint clamping tool
47.0 ± 3.0 N·m
4.8 ± 0.3 kgf·m
35.0 ± 2.0 lbf·ft
RY9212148HYS0167US0
11. Install the round plate nut on the U-joint.
Tighten it until it touches all four pushrods equally.
CAUTION
• If you tighten it too far, the mechanism will not function properly when the lever is in neutral, so be careful to adjust the round plate nut to the correct position.
IMPORTANT
• Apply Loctite 262 to the top threads of the U-joint.
(1) Round Plate Nut
RY9212148HYS0168US0
3-S77
KiSC issued 08, 2015 A
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
Tightening torque Adjusting nut
70.0 ± 5.0 N·m
7.0 ± 0.5 kgf·m
51.6 ± 4.0 lbf·ft
RY9212148HYS0169US0
13. Apply grease to the rotating parts of the universal joint and to the ends of the pushrods.
RY9212001HYS0499US0
3-S78
KiSC issued 08, 2015 A
KX080-4, WSM
U
V
W
C1
Q
R
S
T
R1
R2
R3
M
N
O
P
I
J
K
L
E
F
G
H
A
B
C
D
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.)
46 mm (1.811 in.)
25 mm (0.984 in.)
17 mm (0.669 in.)
23 mm ( 0.906 in.)
27 mm ( 1.063 in.)
31 mm ( 1.220 in.)
Hole H 6
Axle n 6
16 mm (0.6299 in.)
15.5 mm (0.6102 in.)
0.5 mm × 15 mm (0.0197 in. × 0.591 in.)
12.5 mm (0.492 in.)
9.5 mm (0.374 in.)
11.6 mm (0.457 in.)
6.5 mm (0.256 in.)
0.5 mm (0.0197 in.) bevel
R 13 mm (0.512 in.)
R 5.8 mm (0.228 in.)
R 4.5 mm (0.177 in.)
HYDRAULIC SYSTEM
(1) Bushing
(a) U-Joint Tightening Tool, Detailed
Schematic
(b) Bushing, Detailed Schematic
(c) Assembled U-Joint
RY9212001HYS0500US0
3-S79
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
No.
(1)
(2)
(3)
(4)
(5)
(6)
Bellows
Part Name
Set screw
Cam
Set screw
Lock nut
Hex socket bolt
(7)
(8)
Bushing
Camshaft
(9) Cover
(10) Hex socket bolt
(11) Cover
(12) Grease cap
(13) Gasket
2
4
4
2
Qty
2
2
2
2
1
4
2
4
4
No.
(14) Plug
(15) O-ring
Part Name
(16) Pushrod
(17) Seat
(18) Damping spring, small
(19) Damping spring, large
(20) Spring seat
(21) Spring seat
(22) Return spring
(23) Secondary pressure spring
(24) Washer
(25)
Secondary pressure adjustment shim
(26) Spool
4
4
4
4
Qty
4
4
4
4
4
4
4
4
4
No.
Part Name
(27) Hex socket bolt
(28) Damper casing
(29) Plug
(30) O-ring
(31) O-ring
(32) Casing
(33) Plug
(34) O-ring
(35) Seat
(36) Steel ball
(37) Plug
(38) O-ring
RY9212148HYS0228US0
5
4
2
1
Qty
2
1
3
3
1
3
3
1
3-S80
KiSC issued 08, 2015 A
KX080-4, WSM
(1)
(2)
(3)
(4)
(5)
(P)
(T)
HYDRAULIC SYSTEM
Travel pilot valve adapter angles
Point used
Left backward
Left forward
Right backward
Right forward
Pressure sensor
Port P
Port T
Tape color
Blue
Red
Green
Yellow
None
White
None
(a) 20 ° (0.35 rad)
A : Front side
B : Standard Spec
C : Angle Specification
RY9212158HYS0034US0
• To ensure parts that are reused are installed in the same place as before disassembly, mark the parts as needed during disassembly.
RY9212148HYS0230US0
1. Clamp the pilot valve in a vise.
2. Remove the bellows from the cover.
IMPORTANT
• Use a copper plate when clamping the pilot valve.
(1) Bellows (2) Cover
RY9212148HYS0231US0
3. Loosen the hex socket set screws.
• Tool to use: 7 mm hex socket
IMPORTANT
• The set screw is held with a thread lock, so be careful when removing it.
RY9212148HYS0232US0
3-S81
KiSC issued 08, 2015 A
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.
IMPORTANT
• Be careful as a pushrod may pop out.
(1) Cam
(2) Set screw
(3) Lock nut
RY9212148HYS0234US0
6. Remove the hex bolts.
• Tool to use: 7 mm hex socket
(1) Hex socket bolt (2) Cover
RY9212148HYS0235US0
7. Remove the cover.
IMPORTANT
• Be careful as the pushrod and/or the plug may pop out due to the force of the spring.
(1) Cover
RY9212148HYS0236US0
8. Take the pushrod off the plug.
IMPORTANT
• Be careful not to scratch the pushrod.
• Be careful as the plug may pop out due to the force of the spring.
(1) Plug (2) Pushrod
RY9212148HYS0237US0
3-S82
KiSC issued 08, 2015 A
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.
(1) Plug
(2) Seat
(3) Damping spring, large
(4) Damping spring, small
RY9212148HYS0238US0
11. Remove the spring seat from the casing.
(1) Spring seat
RY9212148HYS0239US0
12. Remove the hex socket bolts and then the cover.
• Tool to use: 7 mm hex socket
(1) Hex socket bolt (2) Cover
RY9212148HYS0240US0
13. Remove the hex bolts.
• Tool to use: 7 mm hex socket
IMPORTANT
• Loosen the 2 hex socket bolts evenly to keep the damper casing level.
RY9212148HYS0241US0
14. Remove the damper casing, reducing valve ASSY and the return spring.
IMPORTANT
• Be careful as the reducing valve ASSY may pop out due to the force of the spring.
(1) Damper casing
(2) Return spring
(A) Reducing valve ASSY
RY9212148HYS0242US0
3-S83
KiSC issued 08, 2015 A
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.
IMPORTANT
• Be careful not to scratch the surface of the spool.
• Do not disassemble the reducing valve unless there is a problem with it.
• Do not depress the spring seat more than 4 mm (0.16 in.).
Reducing valve ASSY
(1) Spool
(2) Spring seat
(3) Secondary pressure spring
(4) Washer
(5) Secondary pressure adjustment shim
RY9212148HYS0243US0
16. Disassemble the spool, secondary pressure spring, washer, and secondary pressure adjusting shim.
IMPORTANT
• The thickness of the secondary pressure adjusting shim varies for each spool due to the preset adjustment of the secondary pressure spring.
(1) Spool
(3) Secondary pressure spring
(4) Washer
(5) Secondary pressure adjustment shim
RY9212148HYS0303US0
17. Remove the grease cap and O-ring from the plug.
(1) Plug
(2) Grease cap
(3) O-ring
RY9212148HYS0244US0
18. Remove the gasket from the plug.
• Tool to use: plastic spatula
IMPORTANT
• Be careful not to scratch the inside surface of the plug.
(1) Gasket
RY9212148HYS0245US0
19. Put the casing in a vise and remove the plug.
• Tool to use: 7 mm hex socket
RY9212148HYS0246US0
3-S84
KiSC issued 08, 2015 A
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
(2) Seat
(A) Steel ball contact surface
RY9212148HYS0248US0
21. Remove the steel ball from the casing.
• Tool to use: Magnet
(1) Steel ball
RY9212148HYS0249US0
1. Install the steel ball and the seat in that order in the casing and mount and tighten the plug.
• Tools to use: Magnet, torque wrench
Tightening torque Hex socket bolt
11.8 ± 1.0 N·m
1.2 ± 0.1 kgf·m
8.7 ± 0.7 lbf·ft
RY9212148HYS0251US0
2. Install the secondary pressure adjusting shim, washer, secondary pressure spring and spring seat on the spool in order.
(1) Spool
(2) Secondary pressure adjustment shim
(3) Washer
(4) Secondary pressure spring
(5) Spring seat
RY9212148HYS0252US0
3-S85
KiSC issued 08, 2015 A
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.
(1) Return spring
(2) Casing
(A) Reducing valve ASSY
(B) Corner of casing
RY9212148HYS0253US0
4. Install the O-ring in the casing and mount the damper casing to the casing with hex socket bolts.
• Tool to use: torque wrench
IMPORTANT
• Apply hydraulic oil to the O-ring.
• Tighten the hex socket bolts alternately so the casing stays level during assembly.
Tightening torque Hex socket bolt
8.8 ± 1.0 N·m
0.9 ± 0.1 kgf·m
6.5 ± 1.0 lbf·ft
(1) Hex socket bolt
RY9212148HYS0254US0
5. Mount the cover to the damper casing with hex socket bolts.
• Tool to use: torque wrench
Tightening torque Hex socket bolt
20.6 ± 1.5 N·m
2.1 ± 0.2 kgf·m
15.2 ± 1.0 lbf·ft
(1) Cover (2) Hex socket bolt
RY9212148HYS0255US0
6. Install the gasket, grease cap and O-ring on the plug.
IMPORTANT
• Make sure to face the gasket the correct way.
• Apply grease to the gasket prior to assembly.
(1) Gasket
RY9212148HYS0256US0
3-S86
KiSC issued 08, 2015 A
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
(2) Pushrod
(3) Seat
RY9212148HYS0257US0
9. Install the spring seat and damping springs into the casing.
IMPORTANT
• Install them in the same position as before disassembly.
• Make sure the springs don't get tangled with each other.
(1) Spring seat
(2) Damping spring, small
(3) Damping spring, large
RY9212148HYS0258US0
10. Install the pushrod ASSY into the casing.
(1) Pushrod ASSY
RY9212148HYS0259US0
11. Use special tool
(a)
to insert the bushing into the cover.
• Tool to use: hammer
IMPORTANT
• Take care so the bushing doesn't protrude inside the cover.
(1) Cover
(2) Bushing
(a) Special tool
RY9212148HYS0260US0
12. Mount the cover with hex socket bolts.
• Tool to use: torque wrench
IMPORTANT
• Tighten the hex socket bolts alternately so the cover stays level during assembly.
Tightening torque Hex socket bolt
39.8 ± 4.0 N·m
4.1 ± 0.4 kgf·m
29.4 ± 3.0 lbf·ft
RY9212148HYS0261US0
3-S87
KiSC issued 08, 2015 A
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.
• Apply a thread lock (Loctite 241) to the set screws.
Tightening torque Set screw
6.9 ± 1.0 N·m
0.7 ± 0.1 kgf·m
5.1 ± 0.7 lbf·ft
RY9212148HYS0263US0
15. Adjust the height of the set screws so the top of the cam and the bottom of the cam are level.
Make sure there isn't any play in the middle and tighten the lock nuts.
• Tool to use: 7 mm hex socket, torque wrench
IMPORTANT
• Be careful because overtightening the set screws can also result in play in the middle and when the engine starts up, it may cause it to move suddenly.
Tightening torque Lock nut
33.3 ± 3.4 N·m
3.4 ± 0.3 kgf·m
24.6 ± 2.5 lbf·ft
RY9212148HYS0264US0
16. Tilt the cam and grease the head of the pushrods and inside the grease cap.
• Tool to use: 7 mm hex socket, spatula
IMPORTANT
• Apply grease with a spatula shaped tool made of a soft material so you don't scratch the pushrods or the plug.
(1) Cam
RY9212148HYS0265US0
17. Apply an anti-rust oil to the parts inside the cover.
Install the bellows on top of the cover.
(1) Cover (2) Bellows
RY9212148HYS0266US0
3-S88
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
(a)Special tool
(1) Center hole OK [ 2mm (0.08 in.) or less]
(a)
(b)
12 (-0.25, -0.40) mm (0.42 in.)
10 (-0.20, -0.25) mm (0.39 in.)
(c) 20 mm (0.79 in.)
(d) 2 mm (0.08 in.)
(e) 32 mm (1.26 in.)
(f) 0.52 rad (30 °)
RY9212148HYS0267US0
(4)
(5)
(6)
(7)
No.
(1)
(2)
(3)
Bellows
Set screw
Ball
Cam
Bushing
Cam shaft
Part Name
Return spring
(8)
(9)
Secondary pressure spring
Metal washer
(10) Spring seat
(11) Spool
(12) Hex socket bolt
(13) O-ring
(14) Plug
(15) Shim
(16) Pushrod
(17) O-ring
(18) Gasket
(19) Plug
(20) Cover
(21) Casing
2
2
1
1
2
2
2
1
1
RY9212148HYS0170US0
1
2
1
2
Qty
1
1
2
2
2
2
2
2
3-S89
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
Swing pilot valve adapter angles
Point used
(1)
(2)
Left
Right
(P)
Port P
(T)
Port T
(A) Right swing
(B) Left swing
(a) 45 ° (0.79 rad)
Tape color
Pea green
Orange
White
None
RY9212148HYS0269US0
1. Clamp the pilot valve in a vise.
2. Remove the bellows from the cover.
IMPORTANT
• Use a copper plate when clamping the part.
(1) Bellows (2) Cover
RY9212148HYS0171US0
3. Remove the set screw.
IMPORTANT
• The set screw is held with a thread lock, so be careful when removing it.
• Tool to use: 3 mm hex socket
RY9212148HYS0172US0
4. Put a pin punch against the edge of the cam shaft and tap it lightly with a hammer to remove it.
• Tool to use: Hammer and pin punch ( 7 mm, 0.3 in. ≥ )
(1) Cam Shaft
RY9212148HYS0173US0
3-S90
KiSC issued 08, 2015 A
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.
• Tool to use: hex socket 5 mm
(1) Hex Socket Bolt
RY9212148HYS0175US0
7. Remove the cover.
CAUTION
• Mark the relationship between the cover and the casing.
• Be careful so the pushrod and the plug don't pop out.
(1) Cover
(2) Casing
(3) Pushrod
(4) Plug
(5) O-ring
(6) Return Spring
RY9212148HYS0176US0
8. Take the plug out with the pushrod still in place.
IMPORTANT
• Mark the relationship between the plug and the casing.
(1) Plug
(2) Pushrod
(3) O-ring
RY9212148HYS0177US0
3-S91
KiSC issued 08, 2015 A
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
(2) Return Spring
A : Reducing Valve ASSY
RY9212148HYS0178US0
10. Put the cover on its side, put a pin punch against the bushing and lightly tap it with a hammer to remove it.
• Tools to use : Hammer and pin punch ( 10 mm, 0.39 in. ≥ )
(1) Bushing (2) Cover
RY9212148HYS0179US0
11. To disassemble the reducing valve, compress the secondary pressure spring, shift the spring seat to the side and remove the spool via the large hole.
IMPORTANT
• Be careful not to scratch the spool.
• Do not depress the spring seat more than 4 mm (0.16 in.).
• Do not disassemble the reducing valve unless there is a problem with it.
(1) Spring Seat
RY9212148HYS0180US0
12. Remove the spool, secondary pressure spring shim(s) and washer.
IMPORTANT
• Treat as an assembly until reassembly.
• The thickness of the metal washers is different for each spool ASSY due to the preset adjustment of the secondary pressure spring.
• A metal washer is not used in the figure.
(1) Spool
(2) Secondary Pressure Spring
(3) Shim
(4) Spring Seat
RY9212148HYS0181US0
3-S92
KiSC issued 08, 2015 A
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.
• Tool to use: Slotted screwdriver
(1) Plug (2) Gasket
RY9212148HYS0183US0
15. Remove the O-ring from the plug.
(1) Plug (2) O-Ring
RY9212148HYS0184US0
1. Install the metal washer, shim, secondary pressure spring and spring seat in order on the spool.
IMPORTANT
• The thickness of the metal washers is different for each spool ASSY due to the preset adjustment of the secondary pressure spring.
(1) Spool
(2) Shim
(3) Secondary Pressure Spring
(4) Spring Seat
RY9212148HYS0185US0
2. Pass the end of the spool through the larger part of the hole in the spring seat (10), compressing the spring and shifting the spring seat to the side to install it.
IMPORTANT
• Be careful not to scratch the spool.
• Do not depress the spring seat 4 mm (0.16 in.) ≤
(1) Spring seat
RY9212148HYS0186US0
3-S93
KiSC issued 08, 2015 A
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.
IMPORTANT
• Install it in the same position as before disassembly.
• When installing the reducing valve ASSY, take care not to hit the bottom edge of the spool hard against the corner B or the casing.
(1) Casing
A : Reducing Valve ASSY
B : Corner of Casing
RY9212148HYS0188US0
5. Install the O-ring on the plug.
IMPORTANT
• Apply hydraulic oil to the O-ring.
(1) Plug (2) O-Ring
RY9212148HYS0189US0
3-S94
KiSC issued 08, 2015 A
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.
(2) Gasket (1) Plug
RY9212148HYS0190US0
7. Install the pushrod into the plug.
IMPORTANT
• Apply hydraulic oil to the pushrod.
• Do not force the gasket in as it may damage its lip.
(1) Pushrod (2) Plug
RY9212148HYS0191US0
8. Install the pushrod and plug ASSY in the casing.
(1) Plug (2) Casing
RY9212148HYS0192US0
9. Turn the cover on its side and tap lightly on the bushing with a hammer to install it.
IMPORTANT
• Take care not to knock the bushing so it sticks out from the inside of the cover.
• Tool to use: hammer
(1) Bushing
RY9212148HYS0193US0
3-S95
KiSC issued 08, 2015 A
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.
IMPORTANT
• Install them so the cover sits flat.
Tightening torque Cover
8.8 ± 0.8 N·m
0.90 ± 0.08 kgf·m
6.5 ± 0.6 lbf·ft
• Tool to use: hex socket 5 mm
(1) Hex Socket Bolt
RY9212148HYS0195US0
12. Install the cam on the cover.
IMPORTANT
• Install it in the same position as before disassembly.
(1) Cam (2) Cover
RY9212148HYS0196US0
13. Install the camshaft.
IMPORTANT
• Grease the sliding part that holds the camshaft.
• Install the indentation in the cam faces up.
(1) Cam Shaft (2) Cam
RY9212148HYS0197US0
14. Apply Loctite to the threads of the hex socket bolt.
• Loctite #241
RY9212148HYS0302US0
3-S96
KiSC issued 08, 2015 A
KX080-4, WSM
15. Install the hex socket bolt.
Tightening torque Hex socket bolt
• Tool to use: hex socket 3 mm
HYDRAULIC SYSTEM
6.9 ± 1.0 N·m
0.7 ± 0.1 kgf·m
5.1 ± 0.7 lbf·ft
RY9212148HYS0199US0
16. Apply grease to the ends of the pushrods.
IMPORTANT
• Use a soft spatula to apply the grease so you don't scratch the surfaces of the pushrods or the plugs.
(1) Pushrod (2) Cam
RY9212148HYS0200US0
17. After fitting the top of the bellows onto the cam, fit the bottom edge into the groove in the cover.
IMPORTANT
• Before fitting the bottom edge of the bellows into the groove of the cover, apply an anti-rust oil to the parts inside the bellows.
(1) Bellows (2) Cover
RY9212148HYS0201US0
3-S97
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
No.
(1)
(2)
Casing
Part Name
Port plate
(3) O-ring
Qty
1
1
1
No.
Part Name
(12) Spring seat 1
(13) Spring seat 2
(14) Washer 2
(4)
(5)
(6)
Hex socket bolt
Spool
Plug
(7)
(8)
(9)
Pushod 1
Pushod 2
Seal
(10) O-ring
2
2
2
1
1
2
2
(15) Return spring
(16)
Secondary pressure spring 1
(17)
Secondary pressure spring 2
(18) Cover
(19) Lever
(20) Hex socket bolt
(21) Disc
(11) Washer 1 4 (22) Camshaft
• Thickness of washer 2 as per table below
Point used
Detent
Reducing valve
Thickness
0 to 2 mm (0 to 0.08 in.) or less
0.4 mm (0.02 in.) One washer
1
1
1
2
1
1
Qty
1
1
Select thickness
2
1
No.
Part Name
(23) Set screw
(24) Detent plug
(25) Holder
(26) Steel ball
(27) Spring
(28) Lock nut
(29) Adjusting nut
(30) O-ring
(31) Hex socket bolt
(32) Bellows
RY9212158HYS0071US0
2
2
2
2
1
2
2
Qty
1
2
2
3-S98
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
Adapter angles
Point used
(1)
(2)
(P)
(T)
Down
Up
Port P
Port T
(A) Front side
(a) 45 ° (0.79 rad)
Tape color
Brown
Pink
White
None
RY9212158HYS0072US0
3-S99
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
• 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.
3. Remove the detent parts from the outwards in and remove the ball, holder, washer 2 and the spring that are inside it.
• Tool to use: 22 mm socket
IMPORTANT
• Use a copper plate when clamping the pilot valve.
(1) Bellows
(2) Detent Plug
(3) Lock Nut
(4) Adjusting Nut
(5) Cover
RY9212158HYS0074US0
4. Remove the hex socket bolts and then the lever.
• Tool to use: 6 mm hex socket
(1) Hex Socket Bolt (2) Lever
RY9212158HYS0075US0
5. Remove the set screw and camshaft.
• Tool to use: 4 mm hex socket
IMPORTANT
• The set screw is held with a thread lock, so be careful when removing it.
(1) Set Screw (2) CamShaft
RY9212158HYS0076US0
6. Use the lever and the hex bolts to take the disc out.
(1) Lever
(2) Hex Socket Bolt
(3) Disc
RY9212158HYS0077US0
7. Remove the hex socket bolts and then the cover.
• Tool to use: 5 mm hex socket
IMPORTANT
• If the return spring is strong, when you loosen a hex socket bolt, the cover, plug and pushrod will lift up at the same time, so loosen the bolts alternately so the cover stays level.
(1) Hex Socket Bolt (2) Cover
RY9212158HYS0078US0
3-S100
KiSC issued 08, 2015 A
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.
• Also note that the plug may pop out due to the force of the spring.
(1) Plug
RY9212158HYS0079US0
9. Remove the reducing valve and the return spring.
IMPORTANT
• Be careful not to scratch the spool.
• Do not disassemble the reducing valve unless there is a problem with it.
(1) Casing
(2) Return Spring
A : Reducing Valve
RY9212158HYS0080US0
Reducing valve
IMPORTANT
• Do not depress the spring seat more than 4 mm (0.16 in.).
• The metal washer 2 is not used in the photo at left.
• The thickness of washer 2 varies for each spool due to the preset adjustment of the secondary pressure spring.
(1) Spool
(2) Secondary Pressure Spring
(3) Spring Seat
(4) Washer 1
RY9212158HYS0081US0
10. Flip the casing over in the vise and remove the hex socket bolts and the port plate.
• Tool to use: 6 mm hex socket
(1) Hex Socket Bolt (2) Port Plate
RY9212158HYS0082US0
11. Remove the O-ring from the casing.
(1) O-ring (2) Casing
RY9212158HYS0083US0
3-S101
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
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.
NOTE
• Face washers 1 edge side up so they catch the head of the spool.
• Do not depress the spring seat more than 4 mm (0.16 in.).
• The metal washer 2 is not used in the photo at left.
• The thickness of washer 2 varies for each spool due to the preset adjustment of the secondary pressure spring.
(1) Spool
(2) Secondary Pressure Spring
(3) Spring Seat
(4) Washer 1
RY9212158HYS0084US0
2. Install the O-ring on the casing.
IMPORTANT
• Apply hydraulic oil to the O-ring.
(1) O-ring (2) Casing
RY9212158HYS0085US0
3. Install the port plate on the casing and tighten it with the hex socket bolts.
• Tool to use: 6 mm hex socket
Tightening torque Hex socket bolt
29.4 ± 2.0 N·m
3.0 ± 0.2 kgf·m
21.7 ± 1.5 lbf·ft
(1) Port Plate (2) Hex Socket Bolt
RY9212158HYS0086US0
3-S102
KiSC issued 08, 2015 A
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
(2) Casing
A : Reducing Valve
B : Corner of Casing
RY9212158HYS0087US0
5. Apply grease to the ends of the pushrods and install them in the casing.
NOTE
• If the force of the return springs is weak, the plug may be stuck to the casing by the O-ring's resistance to sliding.
• If the force of the return springs is strong, put the top cover on and tighten the hex socket bolts alternately so the top cover is installed evenly.
• Apply hydraulic oil to the O-ring.
(1) Pushrod (2) Casing
RY9212158HYS0088US0
6. Install the cover on the casing and tighten it with the hex socket bolts.
• Tool to use: 5 mm hex socket
Tightening torque Hex socket bolt
11.8 ± 1.0 N·m
1.2 ± 0.1 kgf·m
8.7 ± 0.7 lbf·ft
(1) Cover (2) Hex Socket Bolt
RY9212158HYS0089US0
7. Wipe off any thread lock compound remaining on the screw holes on the top of the disc.
IMPORTANT
• Apply grease to the surface of the disc where the steel ball rides.
(1) Disc
RY9212158HYS0090US0
3-S103
KiSC issued 08, 2015 A
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.
Tightening torque Set screw
16.7 ± 1.0 N·m
1.7 ± 0.1 kgf·m
12.3 ± 0.7 lbf·ft
(1) Camshaft (2) Set Screw
RY9212158HYS0091US0
9. Mount the lever on top of the disc and tighten the hex socket bolts.
• Tool to use: 6 mm hex socket
Tightening torque Hex socket bolt
29.4 ± 2.0 N·m
3.0 ± 0.2 kgf·m
21.7 ± 1.5 lbf·ft
(1) Lever (2) Hex Socket Bolt
RY9212158HYS0092US0
10. Assemble the steel ball, the holder, washer 2 and the spring inside the detent plug and test fit the lock nut and the adjusting nut.
IMPORTANT
• Apply plenty of grease to the area around the steel ball.
(1) Detent plug
RY9212158HYS0093US0
11. Install the detent plug in the cover and tighten.
12. Turn the adjusting plug to adjust the force required to release the detent and tighten the lock nut.
• Tool to use: 22 mm socket
Tightening torque Detent plug lock nut
41.2 ± 2.9 N·m
4.2 ± 0.3 kgf·m
30.4 ± 2.1 lbf·ft
(1) Cover
(2) Detent plug
(3) Lock Nut
(4) Adjusting Nut
(a) 1.0 to 3.0 mm (0.04 to 0.12 in.)
RY9212158HYS0094US0
3-S104
KiSC issued 08, 2015 A
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
KX080-4, WSM
HYDRAULIC SYSTEM
Adapter angles
(1) Shockless Valves
(2) Swivel shuttle valve
Components
No.
Name of part
Qty Torque
(1) Plug 4
44.2 to 54.0 N·m
4.5 to 5.5 kgf·m
32.6 to 39.8 lbf·ft
(6)
(7)
(8)
(9)
(2)
(3)
(4)
(5)
O-ring
Spring
Orifice
Ring
Spool
Orifice
Ball
Body
2
1
6
1
4
4
1
2
(10) Plug 2
23.8 to 29.2 N·m
2.4 to 3.0 kgf·m
17.6 to 21.5 lbf·ft
(11) O-ring
(12) Spring
(13) Spring seat
2
2
2
(14) Spool 1
• Prior to assembly, clean all of the parts and make sure they are not damaged and there is no dirt or other debris on them.
• Always replace all of the O-rings with new ones.
• During assembly, apply hydraulic oil to the spool.
RY9212148HYS0273US0
(a) 45 ° (0.79 rad)
RY9212158HYS0036US0
3-S106
KiSC issued 08, 2015 A
KX080-4, WSM
Components
HYDRAULIC SYSTEM
No.
(1) Body
Name of part Q'ty
1
Torque
(2) Plug 3
23.8 to 29.2 N·m
2.4 to 3.0 kgf·m
17.6 to 21.5 lbf·ft
(3) O-ring 3
(4) Seat 2
13.2 to 16.2 N·m
1.4 to 1.7 kgf·m
9.74 to 11.90 lbf·ft
Apply thread lock (Loctite
262 or equivalent)
(5) Ball 2
• During disassembly, always use a tap to clean the threads of any thread lock on them.
• Prior to assembly, clean all of the parts and make sure they are not damaged and there is no dirt or other debris on them.
• Always replace all of the O-rings with new ones.
RY9212148HYS0275US0
Adapter angles
(1) Swivel Shuttle Valve
(2) Shockless Valve
(a) 15 ° (0.26 rad) (b) 30 ° (0.52 rad) (c) 45 ° (0.79 rad)
RY9212148HYS0276US0
3-S107
KiSC issued 08, 2015 A
KX080-4, WSM
Components
HYDRAULIC SYSTEM
No.
(1)
(2)
(3)
Hex nut
Adjuster screw
Hex socket bolt
(4)
(5)
(6)
(7)
Cover
Plug
O-ring
Spring
(8)
(9)
Plunger
O-ring
(10) Rivet screw
(11) Nameplate
(12) Body
(13) Plug
(14) Plunger
(15) Spring
(16) O-ring
(17) Plug
(18) Spring
(19) Spool
(20) O-ring
(21) Solenoid
Name of part
(22) Hex socket bolt
Qty
1
Torque
15.7 ± 1.6 N·m
1.6 ± 0.2 kgf·m
11.6 ± 1.2 lbf·ft
1
2
3.9 N·m
0.4 kgf·m
2.9 lbf·ft
2
1
1
1
1
1
1
4
1
3
26.5 ± 2.7 N·m
2.7 ± 0.3 kgf·m
19.5 ± 2.0 lbf·ft
1
1
1
1
21.0 ± 2.1 N·m
2.1 ± 0.2 kgf·m
15.5 ± 1.5 lbf·ft
2
2
2
2
4
Adapter angles
(1) Travel 2-speed solenoid
(2) Pilot solenoid
3.9 N·m
0.4 kgf·m
2.9 lbf·ft
RY9212148HYS0277US0
(P) Port P
(T) Port T
(a) 45 ° (0.79 rad)
RY9212148HYS0278US0
3-S108
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
Components
No.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Bolt
Solenoid
O-ring
O-ring
O-ring
O-ring
Body
Name of part Qty
4
Torque
7.0 ± 1.0 N·m
0.7 ± 0.1 kgf·m
5.2 ± 0.7 lbf·ft
2
2
2
2
2
1
Adapter angles
(1) AUX1 solenoid valve
(2) AUX2 solenoid valve
RY9212148HYS0279US0
(P) Port P
(T) Port T
(a) 35 ° (0.61 rad)
(b) 45 ° (0.79 rad)
RY9212148HYS0280US0
3-S109
KiSC issued 08, 2015 A
KX080-4, WSM
Components
No.
Name of part
(1) Plug
(2)
(3)
(4)
(5)
O-ring
Spring
Spool
Body
(6) Hex socket bolt
(7)
(8)
Solenoid
O-ring
(9) Plug
(10) O-ring
Adapter angles
(P) Port P
(T) Port T
(a) 20 ° (0.35 rad)
4
2
2
2
1
2
2
Qty
2
1
1
HYDRAULIC SYSTEM
Torque
26.5 ± 2.7 N·m
2.7 ± 0.3 kgf·m
19.5 ± 2.0 lbf·ft
3.9 N·m
0.4 kgf·m
2.9 lbf·ft
26.5 ± 2.7 N·m
2.7 ± 0.3 kgf·m
19.5 ± 2.0 lbf·ft
RY9212148HYS0281US0
RY9212148HYS0282US0
3-S110
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
Components
No.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Bolt
Solenoid
O-ring
O-ring
O-ring
O-ring
Body
Name of part Qty
2
Torque
7.0 ± 1.0 N·m
0.7 ± 0.1 kgf·m
5.2 ± 0.7 lbf·ft
1
1
1
1
1
1
RY9212148HYS0283US0
Adapter angles
(A) Port A (to tank)
(P1) Port P1 (to pilot valve)
(P2) Port P2 (from pilot filter)
(T) Port T
RY9212148HYS0284US0
3-S111
KiSC issued 08, 2015 A
KX080-4, WSM
(a) Total Length
HYDRAULIC SYSTEM
RY9212004HYS0147US0
(1) C Type (Straight)
(2) CR4 Type (45°)
(3) CR9 Type (90°)
(4) QM Type (Quick)
(5) Q Type (Quick)
(a) 45 °
(b) 90 °
RY9212148HYS0202US0
3-S112
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
(a) Pump
(b) Control valve
(c) 3-way valve (d) Swivel motor (e) Swivel joint
(To be continued)
3-S113
KiSC issued 08, 2015 A
KX080-4, WSM
(Continued)
No.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
P1
P2
P3
PPS
PLS
Function
Boom union
Travel right forward
Travel right rear
Travel left forward
Travel left rear
Swivel left
Swivel right
Blade down
Blade up
(15) AUX1 (low-pressure)
(16)
(17)
Swing left
Swing right
920 mm
36.2 in.
1025 mm
40.4 in.
950 mm
37.4 in.
1065 mm
41.9 in.
810 mm
31.9 in.
670 mm
26.4 in.
1175 mm
46.3 in.
1065 mm
41.9 in.
Total length
2890 mm
113.8 in.
2950 mm
116.1 in.
2520 mm
99.2 in.
2310 mm
90.9 in.
2880 mm
113.4 in.
910 mm
35.8 in.
465 mm
18.3 in.
2170 mm
85.4 in.
1940 mm
76.4 in.
Hose
Tape color
White
Red
White
Red
White
Red
White
Red
White
Red
Black
Yellow x 2
Green x 2
Red x 2
Blue x 2
Gray
Light blue
Brown
Pink
Brown
Orange
Pea green
Hose class
PA2810
PA2810
PA2810
PFH04
PFH04
PFH06
PA2808 equiv.
PA2808 equiv.
PA2808 equiv.
PA2808 equiv.
PA2808 equiv.
PA2808 equiv.
PA2808 equiv.
PA2808 equiv.
PA2808 equiv.
PFH06
PFH06
HYDRAULIC SYSTEM
C·CR4
C·CR4
C·CR4
C·CR4
C·CR4
C·CR4
C·CR9
C·C
C·C
Type
CR9·C
Fitting
Size
1-14UNS
CR9·C 1-14UNS
CR4·C
C·C
C·C
C·C
C·CR4
C·CR4
1-14UNS
9/16UNF
9/16UNF
11/16UN
1-14UNS
1-14UNS
1-14UNS
1-14UNS
13/16UN
13/16UN
13/16UN
13/16UN
1-14UNS
11/16UN
11/16UN
Point used
Pump (P1) to C/V (P1)
Pump (P2) to C/V (P2)
Pump (P3) to C/V (P3)
Pump (PPS) to C/V (PPS)
Pump (PLS) to C/V (PLS)
C/V (PB1) to C/V (PB2)
(Boom union)
C/V (Travel R-FWD) to R/J
(E)
C/V (Travel R-BWD) to R/J
(G)
C/V - (Travel L-FWD) to R/J
(D)
C/V (Travel L-BWD) to R/J
(F)
C/V (Swivel left) to swivel motor (L)
C/V (Swivel right) to swivel motor (R)
C/V (Blade down) to R/J (B)
C/V (Blade up) to R/J (C)
3-way valve to C/V (AUX1 low pressure)
C/V (L) to swing cylinder
(bottom)
C/V (R) to swing cylinder
(rod)
RY9212148HYS0285US0
3-S114
KiSC issued 08, 2015 A
KX080-4, WSM
Delivery Hose Clamp Positions
HYDRAULIC SYSTEM
(1) Swing cylinder bottom side
(2) Swing cylinder rod side
(3) P1
(4) P2
(5) EP mode solenoid valve port A
(6) P3
(7) P4
(8) PLS
NOTE
• (a): So hoses to P1, P2 and P3 don't rub against each other.
• (b): Pass all hoses inside the rod.
(9) PPS
(10) EP mode solenoid valve port P
RY9212148HYS0286US0
3-S115
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
Hose
Tape color
White
Red
Fitting
No.
(1)
(2)
PLS
Travel
Function
Total length
2880 mm
113.4 in.
750 mm
29.5 in.
Hose class
PFH04
PLT04
Type
C·C
CR9·Q
Size
9/16UNF
1/4·Q
Point used
Pump (PLS) to C/V (PLS)
P4 distribution block (tank side) to C/V (PP4)
NOTE
• (a): Install so the hoses and joint of the arm crowd point do not hit each other hard.
• (b): Arm section
RY9212158HYS0037US0
3-S116
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
(a) Boom holding valve hose (Eur. only)
3-S117
(To be continued)
KiSC issued 08, 2015 A
KX080-4, WSM
(Continued)
No.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
Function
Boom up
Boom down
Arm crowd
Arm dump
Bucket crowd
Bucket crowd long arm
Bucket crowd short arm
Bucket dump
Bucket dump (long arm)
Bucket dump (short arm)
(12) AUX1 High pressure
(13)
(14)
(15)
(16)
(17)
(18)
(19) AUX2 High pressure
(20)
(21)
(22)
(23)
AUX1 Low pressure
AUX2 Low pressure
3220 mm
126.8 in.
1955 mm
77.0 in.
1350 mm
53.1 in.
3280 mm
129.1 in.
540 mm
21.3 in.
980 mm
38.6 in.
465 mm
18.3 in.
3340 mm
131.5 in.
1150 mm
45.3 in.
1350 mm
53.1 in.
3280 mm
129.1 in.
1150 mm
45.3 in.
3700 mm
145.7 in.
540 mm
21.3 in.
980 mm
38.6 in.
3390 mm
133.5 in.
605 mm
23.8 in.
1110 mm
43.7 in.
3590 mm
141.3 in.
605 mm
23.8 in.
1110 mm
43.7 in.
Total length
2600 mm
102.4 in.
3470 mm
136.6 in.
3280 mm
129.1 in.
720 mm
28.3 in.
Hose
Tape color
Green
White
Yellow
Blue
Blue
Pea green
Pea green
Orange
Red
Pink
Brown
Brown
Pink
Brown
PA2810
PFH08
PA2810
PA2810
PA2810 equiv.
PA2810 equiv.
PA2810
PA2810
PA2810 equiv.
PA2810 equiv.
PA2808
PA2808
PA2810 equiv.
PA2808
PA2808
PA2810 equiv.
Hose class
PA2810
PFH08
PA2810
PA2810 equiv.
PFH08
PA2808 equiv.
PA2810
HYDRAULIC SYSTEM
3-S118
C·C
C·C
C·C
CR9·C
C·C
C·C
C·C
C·C
C·C
C·C
C·C
C·C
Type
Fitting
C·C
CR9·C
C·C
C·C
C·C
C·C
C·C
C·C
C·C
C·C
C·C
Size
1-14UNS
13/16UN
1-14UNS
1-14UNS
13/16UN
13/16UN
1-14UNS
Guard Point used
Colgate tube
Colgate tube
Colgate tube
C/V (Boom up) to boom cylinder (bottom)
C/V (Boom down) to boom cylinder (rod)
C/V (arm crowd) to boom back (pipe)
Boom back (pipe) (arm crowd) to arm cylinder
(bottom)
C/V (arm dump) to boom back (pipe)
Boom back (pipe) (arm dump) to arm cylinder
(rod)
C/V (bucket crowd) to boom back (pipe)
1-14UNS
Total spring length
Boom back (pipe) to bucket cylinder
13/16UN
Colgate tube
C/V (bucket dump) to boom back (pipe)
1-14UNS
Total spring length
Boom back (pipe) to bucket cylinder
1-14UNS
1-14UNS
1-14UNS
1-14UNS
1-14UNS
1-14UNS
1-14UNS
13/16UN
13/16UN
1-14UNS
13/16UN
13/16UN
1-14UNS
Colgate tube
C/V (AUX1 Hi-press.) to boom back (pipe)
AUX middle (AUX1)
Total spring length
AUX end (AUX1)
Colgate tube
C/V (AUX1 low pressure) to 3-way valve
3-way valve (AUX1 lo-press) to boom back
(pipe)
AUX middle (AUX1)
Total spring length
Colgate tube
AUX end (AUX1)
C/V (AUX2 Hi-press.) to boom back (pipe)
AUX middle (AUX2)
Total spring length
Colgate tube
AUX end (AUX2)
C/V (AUX2 Lo-press.) to boom back (pipe)
AUX middle (AUX2)
Total spring length
AUX end (AUX2)
RY9212158HYS0038US0
KiSC issued 08, 2015 A
KX080-4, WSM
Front Hose Clamp Positions
HYDRAULIC SYSTEM
(1) Brown (AUX1 Lo)
(2) Red (Bucket dump)
(3) Orange (Bucket crowd)
(4) Blue (Arm crowd)
(5) Yellow (Arm dump)
(6) Pink (AUX1 Hi)
(7) Pink (AUX2 Hi)
(8) Brown (P1 Lo)
NOTE
• (a): Use a cushion when clamping on the boom rod side (opposite that in the illustration).
RY9212148HYS0289US0
3-S119
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
(1) AUX2 (High)
(2) Boom up
(3) AUX1 (High)
(4) Arm dump
(5) Arm crowd
(6) Bucket dump
(7) Bucket crowd
(8) AUX1 (Low)
(9) Boom down
(10) AUX2 (Low)
(11) Velcro tape
(12) White tape
NOTE
• (a):Install the cover with the urethane coated side (slippery side) on the inside (hose side).
• (b):Put the white tape in place and install the cover from the end of the tape.
• (c):Insert the end of the cover securely inside the swivel frame.
• (d):Install so you cannot see the joint in the velcro as viewed from the arrow.
RY9212158HYS0039US0
3-S120
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
(a) Blade Cylinder
(b) Blade Bulkhead Fitting
No.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
Travel right forward
Travel right rear
Travel left forward
Travel left rear
Travel 2-speed
Drain
Function
Blade up
Blade down
Blade up
Blade down
1310 mm
51.6 in.
430 mm
16.9 in.
430 mm
16.9 in.
795 mm
31.3 in.
795 mm
31.3 in.
Total length
1415 mm
55.7 in.
1355 mm
53.3 in.
1355 mm
53.3 in.
1415 mm
55.7 in.
1385 mm
54.5 in.
(c) Travel Motor L
(d) Travel Motor R
Hose
Tape color
Yellow x
2
Green x
2
Blue x 2
Red x 2
Pink
Brown
Hose class
NWP280 15 equivalent
NWP280 15 equivalent
NWP280 15 equivalent
NWP280 15 equivalent
NWP105 6 equivalent
NWP35 9 equivalent
NWP210 12 equivalent
NWP210 12 equivalent
NWP210 12 equivalent
NWP210 12 equivalent
(e) Swivel Joint
Type
CR4·C
CR4·C
CR4·C
CR4·C
C·C
CR4·C
CR9·C
CR9·C
CR4·C
CR4·C
Fitting
Size
1-14UNS
1-14UNS
1-14UNS
1-14UNS
1/4
3/8
13/16UN
13/16UN
13/16UN
13/16UN
(f)
Guard
Spiral tube
15 ° (0.3 rad)
Point used
S/J (E) to motor right down (A)
S/J (G) to motor right up
(B)
S/J (E) to motor left up (A)
S/J (G) to motor left down
(B)
S/J (A) to motor L/R
2-speed
S/J (H) to motor L/R drain
S/J (C) to blade joint
S/J (B) to blade joint
Total spring length
Blade joint to blade cylinder (rod)
Blade joint to blade cylinder (bottom)
RY9212148HYS0291US0
3-S121
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
(a) Control Valve
(b) Swivel Joint
No.
Function
(1)
(2)
Angle Left
(3)
(4)
(5)
Angle Right
(6)
(c) Travel Motor L
(d) Travel Motor R
Total length
1170 mm
46.1 in.
440 mm
17.3 in.
Hose
Tape color
White
Orange
White
Orange
800 mm
31.5 in.
1170 mm
46.1 in.
610 mm
24.0 in.
1290 mm
50.8 in.
Black
Orange
Black
Orange
Hose class
PA2808 equiv.
PFW08
(e) Blade Cylinder
(f) Angle Cylinder
Fitting
Type Size
C·CR9
C·CR9
13/16UN
13/16UN
NWP280
12 equivalent
PA2808 equiv.
PFW08
NWP280
12 equivalent
C·C
C·CR9
C·CR9
C·C
13/16UN
13/16UN
13/16UN
13/16UN
(g) Blade Bulkhead Fitting
(h) 15 ° (0.3 rad)
Guard
Total spring length
Blade joint to angle cylinder (bottom)
Total spring length
Point used
C/V (Angle left) to L/J (J)
R/J (J) to blade joint
C/V (Angle right) to R/J (I)
R/J (I) to blade joint
Blade joint to angle cylinder (rod)
RY9212158HYS0040US0
3-S122
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
(1) Suction hose 1 (2) Suction hose 2 (3) Suction pipe
NOTE
• (a): Tighten bands from the base plate side (bottom).
No.
(1)
(2)
Suction
Function Point used
Oil tank to suction pipe
Pump to suction pipe
RY9212148HYS0293US0
3-S123
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
(a) Return Pipe
(b) Hydraulic Oil Tank
No.
Function
(1) Return (T1)
(2) Swivel makeup
(3)
(4)
Return (T2)
(5) Swivel drain
(6) AUX1 return
(c) 3-Way Valve
(d) Control Valve
Total length
805 mm
31.7 in.
560 mm
22.0 in.
1180 mm
46.5 in.
800 mm
31.5 in.
360 mm
14.2 in.
630 mm
24.8 in.
Hose
Tape color
Black
Black
Center
Pink x 2
Hose class
PA0320
PA0310
PA0310
PA0310
PLT04
PA0310
(e) Swivel Motor
Type
C·C
C·CR4
C·C
C·C
CR4·C
C·C
Fitting
Size
1·1/4
3/4
3/4
3/4
1/4
3/4
(f) Oil Cooler
Guard Point used
PVC tube
C/V (T1) to return pipe
C/V (T2) to swivel motor
(M)
Swivel motor (M) to oil cooler
Oil cooler to return pipe
Swivel motor (Dr) to oil tank
3-way valve to return pipe
RY9212148HYS0294US0
3-S124
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
(a) Pump
(b) Line Filter
No.
Function
(1)
(2) P4
(3)
(4) Travel 2-speed
(c) Collector Block (d) Unload Valve
Total length
360 mm
14.2 in.
2080 mm
81.9 in.
2010 mm
79.1 in.
1350 mm
53.1 in.
Hose
Tape color
Red
Red
Pea green
Hose class
PF1406
PF1406
PLT06
PLT04
Type
C·C
Fitting
Size
3/8
C·C 3/8
C·C
C·C
3/8
1/4
(e) Swivel Joint
Point used
Pump to line filter
Line filter to unload valve
Unload valve (B) to collector block (P)
Unload valve (A) to R/J travel
2-speed boost
RY9212148HYS0295US0
3-S125
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
(a) Control Valve
(b) Swivel Shuttle Valve
No.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Function
AUX1 P
AUX2 P
Distribution block P
AI
P3 union
Swivel brake P
(8) Swivel brake signal
(9) Travel
(c) Swivel Motor
(d) AUX1 Solenoid Valve
Hose
Tape color
(e) AUX2 Solenoid Valve
(f) P4 Distribution Block
Fitting
Hose class Type Size Total length
350 mm
13.8 in.
260 mm
10.2 in.
380 mm
15.0 in.
220 mm
8.7 in.
240 mm
9.4 in.
400 mm
15.7 in.
Blue
Blue
Yellow
Green
PLT04
PLT04
PLT04
PLT04
PLT04
PLT04
CR9·C
C·CR9
CR9·C
Q·Q
Q·Q
Q·Q
1/4
1/4
1/4
Q
Q
Q
480 mm
18.9 in.
1095 mm
43.1 in.
750 mm
9.5 in.
Light blue
Light blue
Gray
PLT04
PLT04
PLT04
Q·Q
Q·CR9
CR9·Q
Q
Q·1/4
1/4·Q
(g) Unload Valve
Point used
Unload valve (B) to AUX1 solenoid valve (P)
AUX1 solenoid valve (P) to
AUX2 solenoid valve (P)
Unload valve (P) to P4 distribution block (tank side)
P4 distribution block (tank side) to C/V (PP1)
P4 distribution block (tank side) to C/V (PP2)
P4 distribution block (tank side) to C/V (PP3)
P4 distribution block (tank side) to swivel motor brake
(PG)
Shuttle valve to swivel motor brake (SH)
P4 distribution block (tank side) to C/V (PP4)
RY9212148HYS0296US0
3-S126
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
No.
(5)
(6)
(7)
(1)
(2)
(3)
(4) Drain
Function
Total length
610 mm
24.0 in.
510 mm
20.1 in.
1640 mm
64.6 in.
990 mm
39.0 in.
410 mm
16.1 in.
330 mm
13.0 in.
740 mm
29.1 in.
Hose
Tape color
Light blue
Center green
Center gray
Orange
Brown
Pink
Hose class
PLT04
PA0308
PLT06
PLT06
PLT04
PLT04
PLT04
Type
C·CR9
Fitting
Size
1/4
C·C 1/2
C·C
C·CR9
C·CR9
C·CR9
C·C
3/8
3/8
1/4
1/4
1/4
Point used
C/V (Dr2) to tank
Unload valve (T) to tank
Collector block (T) to tank
S/J (T) to tank
AUX1 solenoid (T) to tank
AUX2 solenoid (T) to tank
Anti-drift (T) to tank
RY9212148HYS0297US0
3-S127
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
(a) Boom Shockless Valve
(b) Travel P/V
(c) Swing P/V
(d) Collector Block
(e) Control P/V Left
(f) Control P/V Right
(g) Blade P/V
(h) EP Mode Solenoid Valve
(i) Angle Solenoid Valve
(A) Angle Specification
(To be continued)
3-S128
KiSC issued 08, 2015 A
KX080-4, WSM
(Continued)
No.
Function
(1) Blade P
(2) P/V right P
(3) Travel P/V P
(4) Swing P/V P
(5)
(6)
(7)
(8)
Drain
(9)
(10)
(11) Flow control
(12) E/P, SOL P
(13) Drain
(14) P/V Left P
(15) P/V right P
(16) Angle solenoid P
(17) Drain
HYDRAULIC SYSTEM
Total length
1495 mm
58.9 in.
235 mm
9.3 in.
350 mm
13.8 in.
280 mm
11.0 in.
1380 mm
54.3 in.
330 mm
13.0 in.
1430 mm
56.3 in.
330 mm
13.0 in.
240 mm
9.4 in.
335 mm
13.2 in.
1300 mm
51.2 in.
1300 mm
51.2 in.
285 mm
11.2 in.
1280 mm
50.4 in.
2135 mm
84.1 in.
280 mm
11.0 in.
360 mm
14.2 in.
Hose
Tape color
White
White
White
White
White
White
White
White
White
Hose class
PLT04
PLT04
PLT04
PLT04
PLT04
PLT04
PLT04
PLT04
PLT04
PLT04
PLT04
PLT04
PLT04
PLT04
PLT04
PLT04
PLT04
C·CR9
C·Q
Q·Q
C·CR9
CR9·C
C·C
C·C
Q·C
C·C
C·C
C·Q
Q·C
Q·Q
Q·C
Q·C
Type
C·Q
Fitting
Size
1/4·Q
Q·Q Q
1/4
1/4·Q
Q·1/4
Q
Q·1/4
Q·1/4
1/4
1/4·Q
Q
1/4
1/4
1/4
1/4
Q·1/4
1/4
Point used
Collector block (P) to blade
P/V (P)
P/V (R) (P) to blade P/V (P)
Collector block (P) to travel
P/V (P)
Travel P/V (P) to Swing P/V
(P)
P/V (L) (T) to collector block
(T)
P/V (R) (T) to blade P/V (T)
Blade P/V (T) to collector block (T)
Swing P/V (T) to Travel P/V
(T)
Travel P/V (T) to collector block (T)
Collector block (T) to shockless valve (T)
E/P, solenoid to Pump (E/P)
Line filter to E/P, solenoid (P)
E/P, solenoid (T) to collector block (T)
E/P, solenoid (P) to P/V (L)
(P)
P/V (right) (P) to P/V (left) (P)
Angle solenoid (P) to travel
P/V (P)
Angle solenoid (T) to travel
P/V (T)
RY9212158HYS0041US0
3-S129
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
(a) Swivel Shuttle Valve
(b) Boom Shockless Valve
No.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
Function
Swivel left
Swivel right
Arm crowd
Arm dump
Bucket crowd
Bucket dump
Boom up
Boom down
(c) TPSS Valve
(d) Control Left P/V
Hose
Tape color Total length
1410 mm
55.5 in.
1415 mm
55.7 in.
1240 mm
48.8 in.
530 mm
20.9 in.
1210 mm
47.6 in.
505 mm
19.9 in.
1655 mm
65.2 in.
1650 mm
65.0 in.
1815 mm
71.5 in.
505 mm
19.9 in.
1940 mm
76.4 in.
485 mm
19.1 in.
Gray
Light blue
Blue
Blue
Pea green
Pea green
Orange
Red
Green
Green
Yellow
Yellow
(e) Control Right P/V
(f) Bulkhead Fitting
Fitting
Hose class Type Size
(g) Blade P/V
Point used
PLT04
PLT04
Q·C
Q·C
Q·1/4
Q·1/4
P/V (swivel left) to shuttle valve
P/V (swivel right) to shuttle valve
PLT06 Q·C Q·3/8
PLT06 C·C 3/8
P/V (arm crowd) to TPSS
TPSS to shuttle valve (arm crowd)
PLT06
PLT06
PLT04
PLT04
Q·C
C·C
Q·QM
Q·QM
Q·3/8
3/8
Q
Q
P/V (arm dump) to TPSS
TPSS to bulkhead fitting
(arm dump)
P/V (bucket crowd) to bulkhead fitting
P/V (bucket dump) to bulkhead fitting
PLT06
PLT06
PLT06
PLT06
Q·C
C·C
Q·C
C·C
Q·3/8
3/8
Q·3/8
3/8
P/V (Boom up) to TPSS
TPSS to shockless valve
(Boom up)
P/V (Boom down) to TPSS
TPSS to shockless valve
(Boom down)
3-S130
KiSC issued 08, 2015 A
KX080-4, WSM
No.
Function
(13) Blade up
(14) Blade down
Total length
1400 mm
55.1 in.
1400 mm
55.1 in.
Hose
Tape color
Pink
Brown
Hose class
PLT04
PLT04
Type
Q·QM
Fitting
Size
Q
Q·QM Q
HYDRAULIC SYSTEM
Point used
Blade P/V (up) to bulkhead fitting
Blade P/V (down) to bulkhead fitting
RY9212158HYS0042US0
(a) Control Valve
(b) AUX1 Solenoid Valve
(c) AUX2 Solenoid Valve
(d) Travel P/V
(e) Bulkhead Fitting
(f) Boom Shockless Valve
(g) Swivel Shuttle Valve
(h) Blade P/V
(i) Angle Solenoid Valve
(To be continued)
3-S131
KiSC issued 08, 2015 A
KX080-4, WSM
(Continued)
No.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
Function
Swivel left
Swivel right
Arm crowd
Arm dump
Bucket crowd
Bucket dump
Boom union
Boom up
Boom down
Travel left forward
Travel left rear
Travel right forward
Travel right rear
Swing left
Swing right
Blade up
Blade down
(18) AUX1 High pressure
(19)
(20) AUX2 High pressure
(21)
(22)
(23)
(24)
(25)
AUX1 Low pressure
AUX2 Low pressure
P3 union
Anti-drift
Angle Left
Angle Right
Total length
1845 mm
72.6 in.
1405 mm
55.3 in.
1665 mm
65.6 in.
1445 mm
56.9 in.
1885 mm
74.2 in.
1355 mm
53.3 in.
1665 mm
65.6 in.
860 mm
33.9 in.
1785 mm
70.3 in.
1660 mm
65.4 in.
1950 mm
76.8 in.
1550 mm
61.0 in.
1840 mm
72.4 in.
1850 mm
72.8 in.
1450 mm
57.1 in.
1545 mm
60.8 in.
1795 mm
70.7 in.
860 mm
33.9 in.
1050 mm
41.3 in.
420 mm
16.5 in.
760 mm
29.9 in.
345 mm
13.6 in.
495 mm
19.5 in.
2070 mm
81.5 in.
1915 mm
75.4 in.
Hose
Tape color
Gray
Light blue
Blue
Pea green
Orange
Red
Green
Green
Yellow
Red x 2
Blue x 2
Yellow x 2
Green x 2
Orange x 2
Yellow x 2
Pink
Brown
Pink
Brown
Pink
Brown
Red
Blue
White
Orange
Black
Orange
Hose class
PLT04
PLT04
PLT06
PLT06
PLT04
PLT04
PLT06
PLT06
PLT06
PLT04
PLT04
PLT04
PLT04
PLT04
PLT04
PLT04
PLT04
PLT04
PLT04
PLT04
PLT04
PLT04
PLT06
PLT04
PLT04
HYDRAULIC SYSTEM
Q·CR4
Q·Q
Q·CR9
Q·Q
Q·CR9
Q·CR9
Q·Q
Q·Q
Q·CR9
C·Q
C·CR9
Q·Q
Q·CR9
Q·Q
C·CR9
C·CR9
C·Q
Type
Q·CR9
Fitting
Size
Q·1/4
Q·Q Q
Q·CR9
Q·Q
Q·CR9
Q·Q
Q·Q
Q·Q
Q·3/8
Q
Q·1/4
Q
Q
Q
1/4
Q
Q·1/4
Q
3/8
1/4
1/4·Q
Q·1/4
Q·1/4
Q
Q
Q·1/4
1/4·Q
Q·3/8
Q·Q
Q·1/4
Q
Point used
Shuttle valve to C/V (swivel left)
Shuttle valve to C/V (swivel right)
Shuttle valve to C/V (arm crowd)
Bulkhead fitting to C/V (arm dump)
Bulkhead fitting to C/V
(bucket crowd)
Bulkhead fitting to C/V
(bucket dump)
Shockless valve to C/V
(boom union Pbu)
C/V (boom union Pbu) to C/V
(boom up)
Shockless valve to C/V
(boom down)
Travel P/V (L-Fwd) to C/V
(L-Fwd)
Travel P/V (L-Bwd) to C/V
(L-Bwd)
Travel P/V (R-Fwd) to C/V
(R-Fwd)
Travel P/V (R-Bwd) to C/V
(R-Bwd)
Swing P/V (left) to C/V (left)
Swing P/V (right) to C/V
(right)
Bulkhead fitting to C/V (blade up)
Bulkhead fitting to C/V (blade down)
AUX1 solenoid (Hi) to C/V
(AUX1 Hi)
AUX1 solenoid (Low) to C/V
(AUX1 Low)
AUX2 solenoid (Hi) to C/V
(AUX2 Hi)
AUX2 solenoid (Low) to C/V
(AUX2 Low)
C/V (PF1) to C/V (PF2)
Boom rod P/V to anti-drift
Angle solenoid (A) to C/V
(angle left)
Angle solenoid (B) to C/V
(angle right)
RY9212158HYS0043US0
3-S132
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
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.
RY9212148HYS0310US0
Work Tip
To prevent cavitation, never relieve pressure during air bleeding.
1. With the engine stopped, remove the hose at the top of the pump from its clamp.
2. Press the hexagonal plug and the black plastic lock section as well. Then hold the black plastic lock section and pull out the hexagonal plug.
3. Drape the hose on the front of the weight, and leave for 30 seconds.
4. Fit a hexagonal plug to the hose, start and idle the engine, and check whether there is any cavitation noise from the pump.
5. Repeat operations 2, 3 and 4 until pump cavitation noise subsides.
6. When cavitation noise subsides, raise the engine speed to
1500 rpm, slowly operate the arm and check whether any cavitation noise is produced.
7. If there is no cavitation noise, raise the engine speed to
2000 rpm, slowly operate the arm, and check again for cavitation noise. If cavitation noise is produced, stop the engine and carry out steps 2, 3 and 4.
8. Take the engine to max RPM, slowly operate the arm and check for cavitation noise. If cavitation noise is produced, stop the engine and carry out steps 2, 3 and 4.
9. Clamp the air bleed hose in its original position.
(1) Air Bleed Hose
(2) Hexagonal Plug
(3) Lock Section
(4) Clamp
RY9212148HYS0304US0
3-S133
KiSC issued 08, 2015 A
KX080-4, WSM
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.
RY9212148HYS0311US0
Hydraulic System Pressure Release Procedure
1. Place the machine on firm, level ground, lower the bucket and blade to ground level, and stop the engine.
RY9212032HYS0060US0
2. Without starting the engine, place the engine starter switch in the "RUN"
(B)
position.
(1) Starter Switch
(A) STOP
(B) RUN
(C) START
RY9212001HYS0648US0
3. Place the machine lock lever in the release position.
(1) Machine Lock Lever
(A) Release
(B) Lock
RY9212001HYS0649US0
3-S134
KiSC issued 08, 2015 A
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.
7. Place the machine's lock lever in the "Lock" position, and the engine starter switch to the "STOP" position.
8. Loosen the filler port on top of the hydraulic oil tank one half to a full turn to relieve pressure.
(1) Left machine control lever
(2) Right machine control lever
(3) Travel lever left
(4) Travel lever right
(5) Blade control lever
(6) AUX port knob switch
(7) Swing pedal
(8) Angle blade switch (angle spec. only)
(9) AUX enable switch
RY9212158HYS0096US0
Purpose
• This procedure is used in cases where the accumulator stops working and you have an urgent need to lower the boom.
RY9212148HYS0350US0
(1) Nut
(2) Screw
(A) Boom lock valve
Work Procedure
1. With the engine stopped, loosen the shut-off valve nut on the boom lock valve.
2. Loosen the boom lock valve screw 45 degrees (0.79 rad).
CAUTION
• Never get under the boom.
• After lowering the boom, be sure to retighten the screw and nut to their original positions.
• If you overloosen the screw and it comes off, oil will leak out and the boom will drop quickly.
RY9212158HYS0105US0
3-S135
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
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.
RY9212148HYS0312US0
(1) Pump
(2) Control Valve
(3) Oil Cooler
(4) Flow Meter
(5) Test Hose
(6) Pressure Gauge
(7) Oil Receptacle
(8) EP Solenoid Valve
RY9212148HYS0314US0
[Measurement preparations]
If measuring the flow rates for P1 and/or P2 (piston 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.
3. Use the vacuum pump and attach a pressure gauge to the pressure test port and the Pi port.
4. Disconnect the P1 and P2 delivery hoses on the pump side and plug the disconnected hoses.
5. Connect a test hose to the P1, P2 discharge ports and connect the flow meter on the IN side. (Use an adapter to combine the flows.)
6. Disconnect the return hose from the oil cooler OUT side on the return pipe side and plug the disconnected hose.
7. Use a test hose to connect the return pipe and the OUT side of the flow meter.
8. Disconnect the PPS hose on the control valve side and plug port PPS of the control valve.
9. Set the PPS hose in the oil receptacle to collect oil.
10. Remove the vacuum pump and bleed air from the pump and make sure there are not any oil leaks in any of the lines.
RY9212148HYS0315US0
3-S136
KiSC issued 08, 2015 A
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.
3. Use the vacuum pump and attach a pressure gauge to the pressure test port.
4. Disconnect the P3 delivery hose on the pump side and plug the disconnected hose.
5. Connect a test hose to the P3 discharge port and connect to the flow meter on the IN side.
6. Disconnect the return hose from the oil cooler OUT side on the return pipe side and plug the disconnected hose.
7. Use a test hose to connect the return pipe and the OUT side of the flow meter.
8. Remove the vacuum pump and bleed air from the pump and make sure there are not any oil leaks in any of the lines.
RY9212148HYS0316US0
[Measurement]
1. Open the loading valve of the flow meter all the way and start the engine.
2. Bring the hydraulic oil temperature to 50 ± 5 °C (122 ± 9 °F).
3. Position each of the switches as follows.
Accelerator dial
Max RPM
Eco mode switch
P mode
Auto-idle switch
OFF
AC switch
OFF
4. Gradually close the flow meter's loading valve until it reaches the main LS relief pressure, then measure the oil flow and engine RPM at each pressure.
5. Take three measurements of the oil flow, determine the average and take that as the measured value.
6. Convert the measured value to what it would be with the engine at its rated RPM.
RY9212148HYS0317US0
3-S137
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
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.
RY9212148HYS0318US0
[Measurement preparations]
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.
3. Connect a vacuum pump.
4. Connect the AUX discharge (high-pressure side) and the IN side of the flow meter with a test hose.
5. Connect the OUT side of the flow meter and the AUX discharge
(low-pressure side) with a test hose.
6. Remove the vacuum pump.
[Measurement]
1. Open the loading valve of the flow meter all the way and start the engine.
2. Hydraulic oil temperature of 50 ± 5 °C (122 ± 9 °F).
3. Position each of the switches as follows.
Accelerator dial
Eco mode switch
Auto-idle switch AC switch
Max RPM P mode OFF OFF
4. Operate the meter panel and measure the flow when at each
AUX flow setting step by step.
5. Take three measurements of the oil flow, determine the average and take that as the measured value.
IMPORTANT
• Do not make a mistake in the oil flow direction or the direction oil flows into the flow meter.
• Refer to the Operator's Manual for how to set the flow limit values.
(1) Test Hose
(2) Flow Meter
(A) AUX High-Pressure Side
(B) AUX Low-Pressure Side
RY9212148HYS0307US0
3-S138
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
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.
2. Follow the chapter Releasing Pressure in the Hydraulic System and release pressure in the hydraulic lines.
3. Connect a vacuum pump.
4. Connect the AUX discharge (high-pressure side) and the IN side of the flow meter with a test hose.
5. Connect the OUT side of the flow meter and the AUX discharge
(low-pressure side) with a test hose.
6. Remove the vacuum pump.
[Measurement]
1. Open the loading valve of the flow meter all the way and start the engine.
2. Hydraulic oil temperature of 50 ± 5 °C (122 ± 9 °F).
3. Position each of the switches as follows.
Accelerator dial
Eco mode switch
P mode
Auto-idle switch AC switch
Max RPM OFF OFF
Max RPM E mode OFF OFF
4. Gradually close the flow meter's loading valve until it reaches the relief pressure, then measure the oil flow at each pressure.
5. Take three measurements of the oil flow, determine the average and take that as the measured value.
IMPORTANT
• Do not make a mistake in the oil flow direction or the direction oil flows into the flow meter.
(1) Test Hose
(2) Flow Meter
(A) AUX High-Pressure Side
(B) AUX Low-Pressure Side
RY9212148HYS0308US0
3-S139
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
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.
RY9212148HYS0321US0
[Measurement preparations]
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.
3. Use the vacuum pump and attach a pressure gauge to the pressure test port to be measured.
4. Remove the vacuum pump.
5. Start and idle the engine, and check that there is no oil leakage.
6. Hydraulic oil temperature of 50 ± 5 °C (122 ± 9 °F).
[Measurement]
1. Position each of the switches as follows.
Accelerator dial
Eco mode switch
P mode
Auto-idle switch AC switch
Max RPM OFF OFF
2. Slowly operate the control lever of the front equipment to be measured, operating it until the cylinder reaches the end of its stroke, then relieve.
3. When measuring the travel main relief pressure, lock the travel section, gradually operate the travel lever, then relieve.
4. When testing the unload LS pressure, check the discharge pressure of P1 or P2 without operating any of the control levers.
5. When testing the Pilot Primary Pressure, check the discharge pressure of P4 without operating any of the control levers.
6. Measure the pressure three times, determine the average and take that as the measured value.
(1) P1 Pressure Test Port
(2) P2 Pressure Test Port
(3) P3 Pressure Test Port
(4) P4 Pressure Test Port
(5) Travel Right Main Relief Valve
(aTR)
(6) Travel Left Main Relief Valve (aTL)
(7) Main LS Valve (aLS)
(8) Main P3 Relief Valve (aP3)
(9) Unload LS Valve (aUN)
(10) Pilot Primary Pressure Relief Valve
(aPP)
RY9212158HYS0097US0
3-S140
KiSC issued 08, 2015 A
KX080-4, WSM
Adjusting the Main Relief Valve
HYDRAULIC SYSTEM
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.
1. Loosen the relief valve lock nut.
2. Use a hexagonal wrench to turn the adjuster screw, and tighten the lock nut.
3. After setting the pressure, always check the setting according to the section Measuring the Main Relief Valve Pressure.
(1) Lock Nut
(2) Adjuster Screw
(a) Pressure Increase
(b) Pressure Decrease
RY9212148HYS0319US0
Pressure Change/Turn for Main Relief Valve (Reference Values)
Amount adjuster screw turned
• Travel right main relief valve
• Travel left main relief valve
• Main LS valve
• Main P3 relief valve
1/4
4.4 MPa
45.1 kgf/cm
2
642 psi
1/2
8.9 MPa
90.8 kgf/cm
2
1291 psi
• Pilot primary pressure relief valve
0.2 MPa
2.0 kgf/cm
2
29 psi
0.4 MPa
4.1 kgf/cm
2
58 psi
3/4
13.3 MPa
135.4 kgf/cm
2
1925 psi
1
17.7 MPa
180.5 kgf/cm
2
2567 psi
0.6 MPa
6.1 kgf/cm
2
87 psi
0.8 MPa
8.2 kgf/cm
2
116 psi
RY9212148HYS0320US0
3-S141
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
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.
RY9212148HYS0323US0
[Measurement preparations]
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.
3. Use the vacuum pump and then fit an adapter and test hose to the pilot port on the control valve side to be measured and attach a pressure gauge.
4. Remove the vacuum pump.
5. Start and idle the engine, and check that there is no oil leakage.
6. Hydraulic oil temperature of 50 ± 5 °C (122 ± 9 °F).
[Measurement]
1. Position each of the switches as follows.
Accelerator dial
Eco mode switch
Auto-idle switch AC switch
Max RPM P mode OFF OFF
2. Operate the lever to be tested and measure the secondary pilot pressure at full stroke.
• When measuring cylinder secondary pressure, take the measurement when at the cylinder end.
• When measuring motor secondary pressure, take the measurement with it locked.
3. Measure the pressure three times, determine the average and take that as the measured value.
(1) Adapter
(2) Pressure Gauge
(3) Test Hose
RY9212148HYS0324US0
Angle Specification
(1) Swivel right
(2) Swivel left
(3) Blade up
(4) Blade down
(5) AUX2, High
(6) AUX2, Low
(7) Travel left forward
(8) Travel left rear
(9) Travel right forward
(10) Travel right rear
(11) Arm dump
(12) Arm crowd
(13) Bucket dump
(14) Bucket crowd
(15) AUX1. High
(16) AUX1. Low
(17) Boom up
(18) Boom down
(19) Swing right
(20) Swing left
(21) Angle Right
(22) Angle Left
RY9212158HYS0099US0
3-S142
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
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.
2. Follow the chapter Releasing Pressure in the Hydraulic System and release pressure in the hydraulic lines.
3. Connect a vacuum pump.
4. Disconnect the hose from the EP proportional solenoid valve to the pump from the EP proportional solenoid valve side and attach an adapter and test hose and then attach a pressure gauge.
5. Remove the vacuum pump.
6. Start and idle the engine, and check that there is no oil leakage.
7. Hydraulic oil temperature of 50 ± 5 °C (122 ± 9 °F).
[Measurement]
1. Position each of the switches as follows and measure the pressure.
Accelerator dial
Max RPM
Max RPM
Max RPM
Eco mode switch
P mode
P mode
E mode
Auto-idle switch
OFF
OFF
OFF
AC switch
OFF
ON
OFF
2. Position each of the switches as follows, and measure the pressure when traveling or at boom up full stroke.
Accelerator dial
Eco mode switch
Auto-idle switch AC switch
Max RPM E mode OFF OFF
3. Measure the pressure three times, determine the average and take that as the measured value.
(1) Adapter
(2) Pressure Gauge
(3) Test Hose
RY9212148HYS0327US0
3-S143
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
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.
• If there is a problem, we recommend replacing the overload relief valve as an assembly.
• If a measurement has to be made for some reason, the procedures is as follows.
(1) Pressure measuring kit
(2) Pipe joint (R1/8-G1/4)
(3) Straight pipe joint (13/16U)
(4) Straight pipe joint (1/14U)
(5) Plug
RY9212158HYS0100US0
[Measurement preparations]
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.
3. Use the vacuum pump and disconnect the high pressure hose from the port where the overload relief valve to be measured is mounted and plug the hose.
4. Attach the pressure measuring kit to the disconnected port.
5. Remove the vacuum pump.
[Measurement]
1. Increase pressure until the overload relief valve opens.
2. Measure the pressure three times, determine the average and take that as the measured value.
CAUTION
• When disconnecting the pressure measuring kit, take appropriate care in removing it as the line is pressurized.
RY9212148HYS0329US0
3-S144
KiSC issued 08, 2015 A
KX080-4, WSM
Angle Specification
HYDRAULIC SYSTEM
(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
RY9212158HYS0101US0
Adjusting the overload relief valve
CAUTION
• Only adjust the valve if the pressure setting of the overload relief valve is low.
• If the pressure is raised above the setting value, it may cause damage to equipment, so never raise the pressure above the setting value.
1. Loosen the relief valve lock nut.
2. Use a hexagonal wrench to turn the adjuster screw and then tighten the lock nut.
3. After setting the pressure, always check the setting according to the section Measuring the Main Overload Valve Pressure.
(1) Lock Nut
(2) Adjuster Screw
(a) Pressure Increase
(b) Pressure Decrease
RY9212148HYS0331US0
Pressure Change/Turn for Overload Relief Valves (Reference Values)
Amount adjuster screw turned
• Blade rod (b4R)
• Angle bottom (b8L)
• Other
1/4
4.5 MPa
45.4 kgf/cm
2
645 psi
7.1 MPa
72.4 kgf/cm
2
1030 psi
1/2
8.9 MPa
90.8 kgf/cm
2
1291 psi
14.2 MPa
144.8 kgf/cm
2
2060 psi
3/4
13.4 MPa
136.2 kgf/cm
2
1936 psi
21.3 MPa
217.3 kgf/cm
2
3089 psi
1
17.8 MPa
181.6 kgf/cm
2
2582 psi
28.4 MPa
289.7 kgf/cm
2
4119 psi
RY9212158HYS0102US0
3-S145
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
No.
(1)
(2)
(3)
(4)
(5)
Name of part
Support
Pipe joint (M12-G1/4)
Bolt (M10 x 35)
Nut (M10)
Test hose
Q'ty
1
1
2
2
1
CAUTION
• Use a test hose that can withstand pressure up to the measurement pressure.
A : Nozzle Tester
RY9212148HYS0336US0
(1) Support
A
B
C
D
E
F
G
Material std.: STKR400
100 mm (3.94 in.)
50 mm (2.0 in.) t = 2.3 mm (0.09 in.)
70 mm (2.8 in.)
15 mm (0.59 in.)
600 mm (23.6 in.)
2–11 mm (2–0.43 in.)
RY9212148HYS0337US0
(2) Pipe joint (M12-G1/4)
J
K
L
M
N
O
F
G
H
I
C
D
E
A
B
47 mm (1.8 in.)
12 mm (0.47 in.)
15 mm (0.59 in.)
20 mm (0.79 in.)
10 mm (0.39 in.) ≤
12 mm (0.47 in.) ≤
8 mm (0.3 in.)
3 mm (0.1 in.)
18 mm (0.71 in.)
9.5 ± 0.2 mm (0.37 ± 0.01 in.)
19 +0, –0.35 mm (0.75 +0, –0.01 in.)
21.9 mm (0.86 in.)
M12 × 1.5
G1/4
0.52 rad (30 °)
RY9212148HYS0309US0
3-S146
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
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.
• If there is a problem, we recommend replacing the swivel relief valve as an assembly.
RY9212148HYS0338US0
Change/turn for the swivel relief valve (reference values)
Amount adjuster screw turned
1/4
2.3 MPa
23.0 kgf/cm
2
326 psi
1/2
4.5 MPa
45.9 kgf/cm
2
653 psi
3/4
6.8 MPa
68.9 kgf/cm
2
979 psi
1
9.0 MPa
91.8 kgf/cm
2
1305 psi
(1) Swivel Right Relief Valve (cSR) (2) Swivel Left Relief Valve (cSL)
RY9212148HYS0339US0
CAUTION
• Perform this adjustment procedure only when the LS regulator has been disassembled or when readjustment is necessary.
• Increasing the speed above the factory specification may damage the machine so never raise the speed above the factory specification.
• If it is out of adjustment, matching for the entire machine will be off and the operating speed of each device, including the boom, arm, etc. will be altered.
[Measurement]
1. Measure the speed of the swing according the section
Measuring Hydraulic Cylinder Operating Time.
2. If a value within factory specifications is not obtained, loosen the
LS regulator lock nut.
3. Turn the adjuster screw with a hex wrench to adjust the spring tension.
After setting the pressure, always check the swing speed according to the section Measuring Hydraulic Cylinder
Operating Time.
4. Tighten the lock nut.
5. Measure each operating time and make sure they are within specifications.
(1) 1.0 m (40 in.)
(2) Lock Nut
(3) Adjuster Screw
(a) Increase Speed
(b) Reduce Speed
RY9212148HYS0340US0
3-S147
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
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.
• When using this procedure to make measurements, the movement is in one direction.
(1) Plug
(2) Graduated Cylinder
(3) Test Hose
(4) Adapter
RY9212148HYS0341US0
[Measurement preparations]
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.
3. Attach a vacuum pump.
4. Disconnect the hose that connects the oil cooler and the return filter on the return filter side and plug the disconnected hose and adapter.
5. Disconnect the return hose that connects the control valve and the swivel motor on the swivel motor side and plug the disconnected hose and adapter.
6. Disconnect one of the high-pressure hoses that connects the control valve and the swivel motor on the control valve side and split the unload valve and port T so it returns directly to the tank. Plug the hose with the disconnected adapter.
7. Disconnect the swivel motor's drain hose from the swivel motor side, and plug the disconnected hose.
8. Swap out the swivel motor drain hose with a test hose.
9. Remove the vacuum pump.
10. Operate the swivel and allow the swivel motor to warm up fully. However, operate the swivel slowly as cavitation may occur.
• Hydraulic oil temperature of 50 ± 5 °C (122 ± 9 °F).
CAUTION
• Before commencing measurement, make sure there are no persons or obstacles within the swivel range.
• To measure the opposite direction, swap the swivel motor's high pressure hose.
RY9212148HYS0342US0
3-S148
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
[Measurement when turning]
1. Position each of the switches as follows.
Accelerator dial
Eco mode switch
P mode
Auto-idle switch AC switch
Max RPM OFF OFF
2. The position for measurement should be with maximum extension of the boom cylinder, arm cylinder and bucket cylinder.
3. Operate the swivel lever with full stroke and while maintaining a uniform swivel speed, measure the drain volume coming from the test hose in 1 minute.
4. Measure the drain volume 3 times each left and right, determine the average and take that as the measured value.
RY9212148HYS0343US0
Purpose
• Measure how much the machine slips on sloping ground to asses the performance of the swivel parking brake.
[Measurement preparation]
1. Repeat swivel left and right operations to sufficiently warm up the swivel motor.
Hydraulic oil temperature 50 ± 5 °C (122 ± 9 °F)
2. Place dirt or a weight of the specified weight (JIS heap x specific gravity 1.8) in the bucket.
Specified weight 414 kg (913 lbs)
3. Climb onto a slope of 0.35 rad (20 °) but whose surface is even and swivel the machine so the top is at 1.6 rad (90 °) to the slope.
4. The front position should be with the arm cylinder fully compressed and bucket cylinder fully extended, keeping the boom base pin and the arm end pin at the same height.
5. Place marks on the circumference of the swivel bearing and the track frame.
CAUTION
• Before commencing measurement, make sure there are no persons or obstacles within the swivel range.
[Measurement]
1. Position each of the switches as follows.
Accelerator dial
Eco mode switch
Auto-idle switch AC switch
Idling P mode OFF OFF
2. Start the engine, release the safety lock lever (lower) and after
1 minute, measure any deviation between the marks on the swivel bearing and the track frame.
3. Measure the swing 3 times each right/left with the engine stopped and at idle and take the average as the measured value.
RY9212148MBS0128US0
3-S149
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
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.
Hydraulic oil temperature 50 ± 5 °C (122 ± 9 °F)
2. The position for measurement should be with maximum extension of the boom cylinder, arm cylinder and bucket cylinder.
CAUTION
• Before commencing measurement, make sure there are no persons or obstacles within the swivel range.
[Measurement]
1. Position each of the switches as follows.
Accelerator dial
Eco mode switch
Auto-idle switch AC switch
Max RPM P mode OFF OFF
2. Operate the swivel control lever at full stroke, and once it reaches a uniform speed, measure the time taken for three turns of the swivel unit.
3. Take three measurements each swiveling left and right, determine the average and take that as the measured value.
RY9212148MBS0130US0
3-S150
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
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.
RY9212148HYS0344US0
[Measurement preparations]
1. Repeat left and right travel operations to sufficiently warm up the travel motor.
• Hydraulic oil temperature of 50 ± 5 °C (122 ± 9 °F).
2. Place the mini excavator on flat hard ground, lower the bucket and the blade, and stop the engine.
3. Follow the chapter Releasing Pressure in the Hydraulic System and release pressure in the hydraulic lines.
4. Use a vacuum pump and disconnect the travel motor's drain hose from the travel motor side, and insert a plug in the disconnected hose.
5. Connect a test hose to the travel motor drain port and remove the vacuum pump.
6. Start the engine and jack up the machine.
CAUTION
• Place safety blocks and supports under the jacked up machine to prevent it from dropping.
• When working near rotating parts, take care not to get your gloves/clothes caught in them.
(1) Right Travel Motor
(2) Left Travel Motor
(3) Swivel Joint
(4) Graduated Cylinder
RY9212148HYS0345US0
3-S151
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
[Measurement when turning]
1. Position each of the switches as follows.
Travel speed switch
1st
Accelerator dial
Max RPM
Eco mode switch
P mode
Auto-idle switch
OFF
AC switch
OFF
2nd Max RPM P mode OFF OFF
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.
3. Measure the drain volume 3 times each in 1st and 2nd speeds, determine the average and take that as the measured value.
[Measurement when locked]
1. Position each of the switches as follows.
Travel speed switch
1st
2nd
Accelerator dial
Max RPM
Max RPM
Eco mode switch
P mode
P mode
Auto-idle switch
OFF
OFF
AC switch
OFF
OFF
2. Lock the travel, slowly operate the travel lever forwards and backwards full stroke and measure the drain volume from the test hose in 1 minute.
3. Measure the drain volume 3 times each in 1st and 2nd speeds, determine the average and take that as the measured value.
IMPORTANT
• The drain volume can vary greatly depending on the position of the internal parts (pistons and barrel), so adjust the motor position and take the measurement where it drains the least.
RY9212148HYS0379US0
Purpose
• Measure how much the machine slips on sloping ground to asses the performance of the parking brake.
[Measurement preparation]
1. Repeat left and right travel operations to sufficiently warm up the travel motor.
Hydraulic oil temperature 50 ± 5 °C (122 ± 9 °F)
2. Climb onto a slope of 0.35 rad (20°) but whose surface is even.
3. Stop the machine on the slope, and set the front to travel position.
[Measurement]
1. Place the travel lever in neutral and stop the engine.
2. Make marks in the track frame and crawler, and measure the slippage after ten minutes.
RY9212148MBS0134US0
3-S152
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
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.
Hydraulic oil temperature 50 ± 5 °C (122 ± 9 °F)
2. Set a level course on flat, hard ground of 10 m (390 in.) for the measurement with a run up course of 5.0 m (200 in.).
3. Measure travel performance in the travel position.
[Measurement]
1. Position each of the switches as follows.
No.
1
2
Travel
2-speed switch
1st
2nd
Accelerator dial
Max RPM
Max RPM
Eco mode switch
P mode
P mode
Auto-idling switch
OFF
OFF
AC switch
OFF
OFF
2. Measure travel speed forwards/backwards three times each in
1st and 2nd and take the average as the measured value.
(a) Run-up 5.0 m (200 in.) (b) Measurement distance 10 m
(390 in.)
RY9212148MBS0136US0
Purpose
• Measure travel drift to assess left/right balance in 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.
Hydraulic oil temperature 50 ± 5 °C (122 ± 9 °F)
2. Determine a 10 m (390 in.) travel course on hard, flat ground, and put the machine in travel position for the measurement.
[Measurement]
1. Position each of the switches as follows.
No.
1
2
Travel
2-speed switch
1st
2nd
Accelerator dial
Max RPM
Max RPM
Eco mode switch
P mode
P mode
Auto-idling switch
OFF
OFF
AC switch
OFF
OFF
2. Measure travel drift forwards/backwards three times each in 1st and 2nd and take the average as the measured value.
(a) Drift (b) 10 m (390 in.)
RY9212148MBS0138US0
3-S153
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
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).
RY9212148MBS0114US0
Measurement preparation
1. Stop the machine on hard, level ground.
2. Repeat front operations and fully warm up each cylinder.
• Hydraulic oil temperature of 50 ± 5 °C (122 ± 9 °F).
RY9212148MBS0115US0
Measurement
1. Position each of the switches as follows.
Accelerator dial
Max RPM
Eco mode switch
P mode
Auto-idle switch
OFF
AC switch
OFF
2. Measure the speed of each cylinder three times and take the average as the measured value.
3. Make the measurements for each cylinder in the position given below.
RY9212148MBS0116US0
Boom Cylinder
1. Arm and bucket cylinder fully compressed.
2. Operate the boom control lever at full stroke and measure the time it takes the boom to go from having the bucket on the ground to the maximum lift position.
• Do not include cushion operating time.
RY9212148MBS0117US0
Arm Cylinder
1. Boom cylinder fully extended and bucket cylinder fully compressed.
2. Operate the arm control lever at full stroke and measure the time it takes the arm to go full stroke from dump to crowd.
• Do not include cushion operating time.
RY9212148MBS0118US0
Bucket Cylinder
1. Adjust the arm and the boom to positions in which the bucket will not hit the machine when the bucket is operated through its full stroke.
2. Operate the bucket control lever at full stroke and measure the time it takes the bucket to go full stroke from dump to crowd.
RY9212148MBS0119US0
3-S154
KiSC issued 08, 2015 A
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.
(a) 1.0 m (40 in.)
RY9212148MBS0120US0
Blade cylinder
1. Jack up the machine with the front to ensure the blade can move through its entire stroke top to bottom.
2. Operate the blade control lever full stroke and measure the time it takes the blade to go full stroke up and down.
RY9212148MBS0121US0
Angle Cylinder (Excavators with Angle Specification)
1. Jack up the machine with the front.
2. Operate the angle control switch full stroke and measure the time it takes the arm to go full stroke angle right and angle left.
RY9212158MBS0005US0
3-S155
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
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.
Slowly operate the cylinder repeatedly to end stroke and full retraction.
RY9212148MBS0124US0
Measuring drift of the boom, arm and bucket cylinders
[Measurement preparation]
1. Repeat front operations and fully warm up each cylinder.
Hydraulic oil temperature 50 ± 5 °C (122 ± 9 °F)
2. Place dirt or a weight of the specified weight (JIS heap x specific gravity 1.8) in the bucket and position the machine on flat, hard ground.
Specified weight 414 kg (913 lbs)
3. Arm cylinder fully compressed, bucket cylinder fully extended, and bucket bottom approximately 1.0 m (40 in.) above ground level. Note that the arm cylinder should return about 50 mm
(2.0 in.) from the stroke end, and be outside the cushion range.
[Measurement]
1. Stop the engine, and place marks on the boom, arm and bucket cylinder rods.
2. After ten minutes has elapsed, measure the boom cylinder compression, arm cylinder extension and bucket cylinder compression.
(a) 1.0 m (40 in.)
RY9212148MBS0125US0
Measuring blade cylinder drift
[Measurement preparation]
1. Repeat blade operations and fully warm up the cylinders.
Hydraulic oil temperature 50 ± 5 °C (122 ± 9 °F)
2. Use the blade and front to jack up the machine so blade cylinder is fully extended, the arm is perpendicular to the ground and the excavator is level.
[Measurement]
1. Stop the engine and mark the rod of the blade cylinder.
2. After 10 minutes, measure how much the blade cylinder is compressed.
CAUTION
• Never allow your feet or any body part to be under the machine when it is jacked up.
RY9212148MBS0126US0
3-S156
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
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.
Slowly operate the cylinder repeatedly to end stroke and full retraction.
[Measurement preparation]
1. Repeat swing operations through their full stroke and fully warm up the cylinders.
Hydraulic oil temperature 50 ± 5 °C (122 ± 9 °F)
2. Place dirt or a weight of the specified weight (JIS heap x specific gravity 1.8) in the bucket and position the machine on flat, hard ground.
Specified weight 414 kg (913 lbs)
3. Arm cylinder fully compressed, bucket cylinder fully extended, and bucket bottom approximately 1.0 m (40 in.) above ground level.
4. Put the arm in its central swing position and then swing it back and forth 5 times and stop.
[Measurement]
1. Stop the engine and mark the rod of the swing cylinder.
2. Position each of the switches as follows.
Accelerator dial
Eco mode switch
P mode
Auto-idle switch AC switch
Max RPM OFF OFF
3. Swing the front through 1.6 rad (90 °) and stop 100 times and then measure the deviation.
IMPORTANT
• When you stop after swinging the front, let the wobbling of the front stabilize and then perform the following operation.
(a) 1.0 m (40 in.) (b) 1.6 rad (90 °)
RY9212148MBS0144US0
3-S157
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
(1) P Mode (Pi = 3.6 MPa,
37 kgf/cm
2
, 522 psi),
P3 = 2 MPa
(2) E Mode (Pi = 0 MPa,
0 kgf/cm
2
, 0 psi), P3 = 2 MPa
(3) P Mode(P3 = 20.6 MPa)
(4) E Mode(P3 = 20.6 MPa)
CAUTION
• Measured values may vary depending on the machine.
• This data is of values converted to the rated RPM.
• The usage limit is 80% of the discharge volume.
(a) Flow Rate L/min
(b) Pressure (MPa)
(To be continued)
3-S158
KiSC issued 08, 2015 A
KX080-4, WSM
(Continued)
Pressure
P mode
E mode
P mode
(P3 relief)
E mode
(P3 relief)
Pressure
P mode
E mode
P mode
(P3 relief)
E mode
(P3 relief)
MPa kgf/cm
2 psi
L/min
U.S.gals
MPa kgf/cm
2 psi
L/min
U.S.gals
17.5
178.5
2538.2
103.4
27.3
53.4
14.1
39.3
10.4
19.5
5.1
1.5
15.3
217.96
142.0
37.5
142.0
37.5
142.9
37.7
142.8
37.7
20.0
203.9
2900.8
82.9
21.9
44.8
11.8
31.4
8.3
–
5.0
51.0
725.5
141.1
37.3
141.0
37.3
112.7
29.8
63.7
16.8
22.5
229.4
3263.3
63.0
16.6
37.2
9.8
–
7.5
76.5
1087.8
139.8
36.9
128.6
34.0
90.9
24.0
54.3
14.3
–
25.0
255.0
3630.0
49.2
13.0
28.6
7.6
–
10.0
102.0
1450.4
138.6
36.6
107.2
28.3
71.4
18.9
44.6
11.8
–
HYDRAULIC SYSTEM
12.5
127.5
1813.0
137.6
36.6
87.1
23.0
55.7
14.7
35.9
9.5
27.5
280.0
3990.0
40.5
10.7
–
–
– –
RY9212148HYS0370US0
15.0
153.0
2175.6
123.9
32.7
68.6
18.1
48.1
12.7
27.3
7.2
29.4
300.0
4260.0
29.9
7.9
–
–
3-S159
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
(1) Left (Max)
(2) Right (Max)
(1) Left (Idle)
(2) Right (Idle)
(A) AUX1
(B) AUX2
(a) Max Flow Setting
(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.
CAUTION
• Measured values may vary with the machine.
RY9212148HYS0313US0
3-S160
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
(1) P Mode
(2) E Mode
(a) Pressure (MPa)
(b) Flow Rate L/min
(A) AUX1
(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)
RY9212148HYS0353US0
3-S161
KiSC issued 08, 2015 A
KX080-4, WSM
Item
Travel right main pressure (aTR)
30.0 ± 0.5 MPa
306 ± 5 kgf/cm
2
4351 ± 73 psi
Travel left main pressure (aTL)
Main LS pressure (aLS)
Main P3 pressure (aP3)
Unload LS valve pressure (aUN)
Pilot primary pressure (aPP)
EP proportional solenoid pressure
P mode
P mode (AC ON)
E mode
E mode (during operation)
27.5 ± 0.5 MPa
281 ± 5 kgf/cm
2
3989 ± 73 psi
21.5 ± 0.5 MPa
219 ± 5 kgf/cm
2
3118 ± 73 psi
2.9 ± 0.2 MPa
30 ± 2 kgf/cm
2
420 ± 29 psi
4.2 ± 0.2 MPa
43 ± 2 kgf/cm
2
610 ± 29 psi
3.6 ± 0.2 MPa
37 ± 2 kgf/cm
2
522 ± 29 psi
2.8 ± 0.2 MPa
28.6 ± 2 kgf/cm
2
406 ± 29 psi
0 MPa
0 kgf/cm
2
0 psi
1.6 ± 0.2 MPa
16.3 ± 2 kgf/cm
2
232 ± 29 psi
Bottom (b1B)
Boom
31.4 ± 1.0 MPa
320 ± 10 kgf/cm
2
4554 ± 145 psi
Rod (b1R)
Arm
Bottom (b2B)
Rod (b2R)
30.4 ± 1.0 MPa
310 ± 10 kgf/cm
2
4409 ± 145 psi
31.4 ± 1.0 MPa
320 ± 10 kgf/cm
2
4554 ± 145 psi
Bottom (b3B)
Bucket
31.4 ± 1.0 MPa
320 ± 10 kgf/cm
2
4554 ± 145 psi
Rod (b3R)
Blade
Bottom (b4B)
Rod (b4R)
27.4 ± 1.0 MPa
279 ± 10 kgf/cm
2
3974 ± 145 psi
19.5 ± 1.0 MPa
200 ± 10 kgf/cm
2
2830 ± 145 psi
HYDRAULIC SYSTEM
Notes
Compressor: ON
Measurement location: P3 pressure test port
3-S162
KiSC issued 08, 2015 A
KX080-4, WSM
AUX1
Angle
Item
Left (b6L)
Right (b6R)
Bottom (b8B)
Rod (b8R)
Item
Swivel motor drain volume When turning
Swivel block performance
Swivel speed
When stopped
At idle
3 revs
Item
When turning (1st spd.)
Travel motor
When locked (1st spd.)
When turning (2nd spd.)
When locked (2nd spd.)
Travel block performance
Travel speed
Rubber
Steel
1st
2nd
1st
2nd
Amount of travel drift
22.5 ± 1.0 MPa
230 ± 10 kgf/cm
2
3260 ± 145 psi
22.5 ± 1.0 MPa
230 ± 10 kgf/cm
2
3260 ± 145 psi
31.4 ± 1.0 MPa
320 ± 10 kgf/cm
2
4554 ± 145 psi
315 ml/min
19.22 cu.in./min
≤ 43.2 mm
≤ 1.70 in.
≤ 43.2 mm
≤ 1.70 in.
17.1 to 20.9 sec
75 ml/min
4.58 cu.in./min
300 ml/min
18.31 cu.in./min
260 ml/min
15.87 cu.in./min
330 ml/min
20.14 cu.in./min
0 mm
0 in.
12.0 to 15.0 sec
6.9 to 8.6 sec
12.9 to 16.4 sec
7.2 to 9.0 sec
≤ 600 mm
≤ 23.6 in.
HYDRAULIC SYSTEM
Notes
Measurement location: P1, P2 pressure test ports
RY9212158HYS0103US0
Notes
Measured eference value for new machines.
RY9212148HYS0348US0
Notes
Measured eference value for new machines.
RY9212148HYS0380US0
3-S163
KiSC issued 08, 2015 A
KX080-4, WSM
Item
Hydraulic cylinder operating time
Boom
Arm
Bucket
Swing
Blade
Angle (Angle spec.)
Boom
Ground to max lift
Max lift to ground
Crowd
Dump
Crowd
Dump
Left
Right
Max down to
Max up
Max up to Max down
Left
Right
Factory spec. when new
Usage limit
Factory spec. when new
Arm
Hydraulic cylinder drift
Bucket
Blade
Usage limit
Factory spec. when new
Usage limit
Factory spec. when new
Swing cylinder deviation
Usage limit
Factory spec. when new
Usage limit
3.1 ± 0.3 sec
3.4 ± 0.3 sec
3.4 ± 0.3 sec
3.2 ± 0.3 sec
3.1 ± 0.3 sec
2.2 ± 0.3 sec
7.5 ± 0.7 sec
7.7 ± 0.7 sec
2.3 ± 0.3 sec
3.0 ± 0.3 sec
2.1 ± 0.3 sec
2.3 ± 0.3 sec
≤ 20.0 mm
≤ 0.79 in.
≤ 100.0 mm
≤ 3.94 in.
≤ 20.0 mm
≤ 0.79 in.
≤ 100.0 mm
≤ 3.94 in.
≤ 10.0 mm
≤ 0.39 in.
≤ 50.0 mm
≤ 1.97 in.
≤ 20.0 mm
≤ 0.79 in.
≤ 100.0 mm
≤ 3.94 in.
≤ 10.0 mm
≤ 0.39 in.
≤ 50.0 mm
≤ 1.97 in.
HYDRAULIC SYSTEM
Notes
RY9212158HYS0110US0
3-S164
KiSC issued 08, 2015 A
KX080-4, WSM
HYDRAULIC SYSTEM
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.
No.
Cause
1
2
3
4
Low engine RPM
Faulty limit switch
Faulty unload valve
Remedy
• Check the engine RPM
• Inspect fuel lines and air intake lines
• Test the accelerator dial
• Meter panel settings
• Check the operation of the limit switch
Move the unload lever up/down and check for continuity in the tester mode.
(when locked: OFF, when released: ON)
• Check unload valve operation
1. Disconnect the unload valve connector and test for continuity.
2. Check for damage to the spool.
• Measure pilot primary pressure
1. Disassemble, clean and adjust or replace the relief valve
• Replace pump connector
5
Pilot primary pressure relief valve (aPP) faulty
Pump fitting
Connector faulty
Pump drive shaft damaged
6
• Replace shaft
Notes
RY9212148HYS0354US0
When just certain cylinder(s) fail to work, are slow or jerky
• Identify whether the fault is in the main system or the pilot system.
• If a circuit lacks power, test the pressure of the corresponding main relief valve or the overload relief valve.
No.
Cause
Defective pilot valve
Notes
1
Remedy
• Measure the pilot secondary pressure
2
3
4
5
• Leak inside a cylinder
• Leak inside a control valve
Overload relief valve faulty
Main spool inside control valve sticking or damaged
Pressure compensation valve sticking
• Measure the hydraulic drift
If hydraulic drift is outside of factory specs, take the following steps.
1. Exchange hoses with a normally operating section (on control valve side).
2. Test the hydraulic drift again.
[Assessment]
Within factory specs: control valve and/or overload relief valve faulty
Outside specs: replace cylinder seals
• Diagnose the overload relief valve
Temporarily replace with a known good overload relief valve and determine whether faulty or not.
• Inspect the main spool or replace the valve
1. Take the main spool out of the control valve and clean it.
2. After applying hydraulic oil, check whether it slides properly and return to the control valve.
• Inspect the pressure compensation valve
1. Take the pressure compensation valve out of the control valve and clean it.
2. After applying hydraulic oil, check whether it slides properly and return to the control valve.
RY9212148HYS0355US0
3-S165
KiSC issued 08, 2015 A
KX080-4, WSM
Boom operation slow or jerky
No.
1
Cause
Anti-drop check valve sticking or damaged
2
Shockless valve faulty
3
P3 bypass spool sticking
Remedy
• Inspect the anti-drop check valve
1. Remove the anti-drop check valve from the control valve.
2. Check the inside and inspect for abnormalities.
• Clean or replace the shockless valve
1. Clean the spool
2. Replace the valve
HYDRAULIC SYSTEM
Notes
RY9212158HYS0109US0
Arm operation slow or jerky
No.
Cause
Arm regenerative valve faulty
1
Remedy
• Inspect the arm regenerative valve
1. Take the spool out of the control valve and clean it.
2. Check the inside and inspect for abnormalities.
Notes
RY9212148HYS0357US0
Swing slow or fails to move
No.
1
Cause
Swing external orifice faulty
Remedy
• Clean swing external orifice
If same thing happens: problem with anti-void and/or shut-off valves
Notes
RY9212148HYS0358US0
Swing extends or contracts
No.
1
Cause
Anti-void faulty
1. Seat NG: extends
2. Suction NG: makes it sway
Remedy
• Disassemble and clean or replace the anti-void valve
Notes
When lever operated, it goes down and then back up
No.
1
Cause
Load check valve inside the control valve faulty
Remedy
• Inspect the load check valve.
Remove and clean the load check valve.
A great deal of hydraulic drift.
No.
Cause
1. Leak inside a cylinder
2. Leak inside a control valve
1
2
Overload relief valve faulty
RY9212148HYS0359US0
Notes
RY9212148HYS0360US0
Remedy
• Measure the hydraulic drift
If hydraulic drift is outside of factory specs, take the following steps.
1. Exchange hoses with a normally operating section (on control valve side).
2. Test the hydraulic drift again.
[Assessment]
Within factory specs: control valve and/or overload relief valve faulty
Outside specs: cylinder seals faulty
• Diagnose the overload relief valve
Temporarily replace with a known good overload relief valve and determine whether faulty or not.
Notes
RY9212148HYS0361US0
3-S166
KiSC issued 08, 2015 A
KX080-4, WSM
Slow during multiple operations
No.
1
Cause
Seat of unload LS valve (aUN) faulty
2
Seat of main LS valve (aLS) faulty
3
Horsepower control valve faulty or loose
Remedy
• Measure unload LS valve pressure
1. Disassemble and clean or replace the relief valve
• Measure main LS valve pressure
1. Disassemble, clean and adjust or replace the relief valve
Check and adjust for loose nuts
HYDRAULIC SYSTEM
Notes
RY9212148HYS0362US0
Fails to travel right and left or is slow
• It is unlikely that the right and left pilot valve, travel motor, control valves (travel section), etc. would become faulty at the same time.
• If neither right nor left will travel, it is likely a common pilot system is faulty.
• Adjust the left/right track tension and get rid of any clumps of mud.
No.
1
2
Cause
Travel pilot valve filter blockage
Pp2, Pp4 filters and/or orifices blocked
Clean the pilot valve filter
Clean the filters and orifices
Remedy Notes
3
Independent travel valve's sub-spool and/or main spool sticking
• Inspect and replace the sub-spool and/or main spool
1. Take the sub-spool and/or main spool out of the control valve and clean it.
2. After applying hydraulic oil, check whether it slides properly and return to the control valve.
RY9212148HYS0364US0
One side fails to travel, is slow or meanders
No.
1
Cause
Defective travel pilot valve
Remedy
• Measure the pilot secondary pressure
Notes
2
3
4
5
Travel main relief valve faulty
Main spool inside control valve or travel section is sticking or damaged
Defective travel motor
Swivel joint faulty
• Temporarily swap main relief valves forwards/backwards or left right.
[Assessment]
If problem swaps forwards/backwards or left-right: travel main relief valve is faulty
If problem is the same: the main spool is sticking or damaged or the swivel joint and/or travel motor are faulty
• Swap the left-right travel hoses on the control valve side and see if the problem changes sides too.
[Assessment]
If problem switches sides: main spool is sticking or damaged
If problem doesn't change: swivel joint and/or travel motor are faulty
• Measure the drain volume
[Assessment]
If within factory specs: swivel joint is faulty
If outside specs: travel motor is faulty
• Swap the left/right travel hoses (swivel joint to travel motor) on the swivel joint side and see if the problem changes sides too.
RY9212148HYS0365US0
3-S167
KiSC issued 08, 2015 A
KX080-4, WSM
Won't switch to high-speed travel
• Check whether the travel speed switch is switching in the tester mode.
No.
1
2
Cause
Faulty 2nd speed solenoid valve at unload unit
• Defective travel motor
• Swivel joint faulty
Remedy
• Check 2nd speed solenoid valve operation
1. Check whether there is electricity to the unload valve.
2. Check whether the spool is switching inside.
• Measure the pressure at the travel motor 2-speed switch port.
[Assessment]
Rated pressure: travel motor faulty
Below rated pressure: swivel joint faulty
HYDRAULIC SYSTEM
Notes
RY9212148HYS0366US0
When the swivel is slow, fails to work or is jerky.
• Identify whether the fault is in the main system or the pilot system.
No.
Cause
Defective pilot valve
1
Remedy
• Measure the pilot secondary pressure
Notes
Slow return valve faulty Clean or replace the slow return valve
2
Timer valve sticking or damaged Clean or replace the timer valve
3
4
5
6
Swivel shuttle valve faulty
Swivel relief valve faulty
Anticaviation valve faulty
• Measure the timer valve release pressure
(When swivel left/right, or at arm crowd)
• Clean or replace the swivel shuttle valve
• Temporarily swap the left/right swivel relief valves.
[Assessment]
If the problem changes sides: swivel relief valve faulty
If problem is the same: the main spool is sticking or damaged or the anticavitation valve and/or swivel motor are faulty
• Swap anticavitation valves
[Assessment]
If the problem changes sides: anticavitation valve faulty
If problem is the same: the main spool is sticking or damaged or the swivel motor is faulty
• Measure the drain volume
7
Swivel motor faulty
8
Main spool inside control valve sticking or damaged
• Inspect the main spool or replace the valve
1. Take the main spool out of the control valve and clean it.
2. After applying hydraulic oil, check whether it slides properly and return to the control valve.
RY9212148HYS0367US0
3-S168
KiSC issued 08, 2015 A
KX080-4, WSM
Swivel drifts
• Identify whether the fault is in the main system or the pilot system.
No.
1
Cause
Slow return valve faulty
Remedy
Clean or replace the slow return valve
2
Anti-void valve faulty Clean or replace the anti-void valve
3
Timer valve sticking or damaged Clean or replace the timer valve
4
Pilot valve spool damaged Check that the pilot valve spool returns to neutral.
5
6
7
Swivel relief valve faulty
Anticaviation valve faulty
Swivel motor faulty
HYDRAULIC SYSTEM
• Temporarily swap the left/right swivel relief valves.
[Assessment]
If the problem changes sides: swivel relief valve faulty
If problem is the same: the main spool is sticking or damaged or the anticavitation valve and/or swivel motor are faulty
• Clean or replace the anticavitation valve
[Assessment]
If problem is not resolved: the main spool is sticking or damaged or the swivel motor is faulty
• Measure the drain volume
Notes
8
Main spool inside control valve sticking or damaged
• Inspect the main spool or replace the valve
1. Take the main spool out of the control valve and clean it.
2. After applying hydraulic oil, check whether it slides properly and return to the control valve.
RY9212148HYS0368US0
Front fails to operate during multiple operations or while traveling
No.
1
Cause
• Communication valve sub-spool sticking
• Communication valve main spool sticking
Remedy
• Inspect the sub and main spools or replace the valve
1. Take the spool out of the control valve and clean it.
2. After applying hydraulic oil, check whether it slides properly and return to the control valve.
Notes
RY9212148HYS0369US0
3-S169
KiSC issued 08, 2015 A
4
KiSC issued 08, 2015 A
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
(3) Set Clock .......................................................................................................................4-S12
(4) Set AUX Flow Ctrl..........................................................................................................4-S12
(5) Various Settings ............................................................................................................4-S13
(6) Language Setting ..........................................................................................................4-S13
[3] SERVICE DEALER SETTING.............................................................................................4-S13
(1) Crane Mode...................................................................................................................4-S13
(2) Arm Control Mode (Only on Japan Spec.).....................................................................4-S13
[4] SERVICE/DEALER MODE..................................................................................................4-S14
(1) Diagnosis.......................................................................................................................4-S16
(2) Setting ...........................................................................................................................4-S21
[5] SETTINGS WHEN REPLACING ELECTRONIC DEVICES ................................................4-S34
(1) When Replacing the Meter or Main ECU ......................................................................4-S34
(2) When the Battery is Removed.......................................................................................4-S34
[6] TABLE OF METER PANEL MESSAGES AND ERROR HISTORY LIST............................4-S35
(1) Red Warning Lamp Lit...................................................................................................4-S35
(2) Yellow Warning Lamp Lit...............................................................................................4-S37
(3) Other Screens ...............................................................................................................4-S38
(4) PM Clog Level and the State of the Machine ................................................................4-S40
(5) Table of Engine System Error Numbers........................................................................4-S43
3. INSPECTIONS ..........................................................................................................................4-S44
[1] POWER AND GROUND .....................................................................................................4-S44
[2] STARTING AND STOPPING DEVICE................................................................................4-S47
[3] RELAY LAYOUT .................................................................................................................4-S48
4. TROUBLESHOOTING (START-UP EQUIPMENT VERSION)..................................................4-S50
5. METHODS FOR DIAGNOSING ERRORS................................................................................4-S51
[1] GUIDE TO DIAGNOSING ERRORS...................................................................................4-S51
[2] ERROR DIAGNOSIS PROCEDURE...................................................................................4-S51
[3] TESTING WITH A CIRCUIT TESTER.................................................................................4-S52
6. TROUBLESHOOTING (METER PANEL VERSION).................................................................4-S53
[1] MACHINE RELATED SYSTEM...........................................................................................4-S53
(1) Engine Oil Pressure Errors............................................................................................4-S53
(2) Charging System Errors ................................................................................................4-S56
(3) Fuel Sensor Errors ........................................................................................................4-S60
[2] FRONT-END SYSTEMS .....................................................................................................4-S63
(1) Lever Lock System Errors .............................................................................................4-S63
(2) Travel 2-Speed System Error ........................................................................................4-S67
(3) Angle System Errors......................................................................................................4-S71
[3] AUTO IDLING (AI) SYSTEM ...............................................................................................4-S74
(1) AI System Errors ...........................................................................................................4-S74
(2) Testing the AI Pressure Switch .....................................................................................4-S77
KiSC issued 08, 2015 A
(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
KiSC issued 08, 2015 A
KX080-4, WSM
ELECTRICAL SYSTEM
1. Do not touch the wiring or the area around it.
Do not touch where uncovered.
2. Do not clamp to fuel hoses.
3. Connect connectors and terminals securely so they do not come unplugged when pulled on gently.
4. Be sure to clamp the harness at the clamp position.
5. Clamps for securing harnesses
(1) Anchor Type
(Insert Firmly Until it Catches.)
(2) Screw Type
(Insert to the End of the Screw.)
(3) and (4) Insert Type : Insert Until it
Locks.
(A) Harness
(B) Clamp the Harness so It Stays in
Position and Does Not Move.
Insert the End of the Cable Tie
Into the Hole on the Other Side to
Clamp the Harness.
RY9212001ELS0025US0
1. When disconnecting connectors, grasp the body of the connector and pull it out; do not pull on the wiring harness.
If the connector is the locking type, release the lock and then pull to disconnect.
2. When removing a connector's plastic cover (for water protection) to inspect it, be careful not to let any water get in the connector. If water does get in, dry it thoroughly before reassembling the connector and putting its plastic cover securely in place.
3. Straighten any bent connector terminals and make sure none are sticking out or missing. Also make sure there is no corrosion on the connector's terminals before connecting it.
4. When connecting a locking connector, be sure to press it in until you hear it click and then pull gently on the harness close to the connector and make sure the harness does not come out.
RY9212001ELS0224US0
4-S1
KiSC issued 08, 2015 A
KX080-4, WSM
Colors of Wiring
Color of wiring
Black
Green
Blue
Pink
Red
White
Yellow
Brown
Gray
Light Green
Orange
Sky Blue
Black / Green
Black / Blue
Black / Pink
Black / Violet
Black / Red
Black / White
Black / Yellow
Brown / Black
Brown / Yellow
Brown / Red
Green / Black
Green / Blue
Green / Red
Green / White
Green / Yellow
Blue / Black
ELECTRICAL SYSTEM
B/W
B/Y
Br/B
Br/Y
Br/R
G/B
G/L
G/R
G/W
G/Y
L/B
B/L
B/P
B/V
B/R
Lg
Or
Sb
B/G
Color code
B
G
L
P
R
W
Y
Br
GY
(Ex.)
1.25-Y/R means :
1.25 : Wire size (mm
2
)
Y : Base color (yellow)
R : Stripe color (red)
Color of wiring
Blue / Green
Blue / Orange
Blue / Red
Blue / White
Blue / Yellow
Light Green / Blue
Light Green / Red
Light Green / White
Light Green / Yellow
Orange / White
Pink / White
Pink / Blue
Red / Black
Red / Green
Red / Blue
Red / White
Red / Yellow
Violet / White
White / Black
White / Green
White / Blue
White / Red
White / Yellow
Yellow / Black
Yellow / Green
Yellow / Blue
Yellow / Red
• Do not pull on or step on wires. Also, do not cut wires on burred edges or the like.
• Do not twist or pinch wiring when installing it.
Or/W
P/W
P/L
R/B
R/G
R/L
R/W
R/Y
Color code
L/G
L/Or
L/R
L/W
L/Y
Lg/B
Lg/R
Lg/W
Lg/Y
V/W
B/W
W/G
W/L
W/R
W/Y
Y/B
Y/G
Y/L
Y/R
(a) Wire Size (mm
2
)
(b) Insulation Base Color
(c) Stripe Color
RY9212038ELS0009US0
4-S2
KiSC issued 08, 2015 A
KX080-4, WSM
ELECTRICAL SYSTEM
(1) RPM sensor
(2) Fuel filter heater
(3) AC switch
(4) Fuel pump
(5) Fuel level gauge
(6) Ground cable
(7) Condenser fan
(a) To main harness
(b) Must not interfere with hood lock bracket
(c) Fuel pump harness to pass to the inside of the battery cable.
(d) To starter relay
(e) To (+) battery terminal
RY9212158ELS0017US0
4-S3
KiSC issued 08, 2015 A
KX080-4, WSM
ELECTRICAL SYSTEM
(1) DPF pressure differential sensor
(2) Boost sensor
(3) Air intake temperature sensor
(4) EGR valve
(5) Air flow sensor
(6) Compressor
(7) Alternator
(8) AC switch
(9) Engine ECU
(10) Travel alarm buzzer (optional)
(11) Fuel pump
(12) (+) battery cable
(13) Oil switch
(14) Water level switch
(15) NE sensor
(16) G sensor harness
(17) Water temperature sensor
(18) Air intake throttle valve
(a) To starter relay
(b) Be sure to install fuel pump connector so it is vertical
(c) To fuel supply pump
(d) To main harness
RY9212158ELS0018US0
4-S4
KiSC issued 08, 2015 A
KX080-4, WSM
ELECTRICAL SYSTEM
(a) To main harness (b) To fuel sensor
RY9212158ELS0019US0
4-S5
KiSC issued 08, 2015 A
KX080-4, WSM
ELECTRICAL SYSTEM
(1) DPF outlet temperature sensor 0 (black)
(2) DPF outlet temperature sensor 1 (dark gray)
(3) DPF outlet temperature sensor 2 (white)
(4) DPF outlet temperature sensor connector 0 (black)
(5) DPF outlet temperature sensor connector 1 (dark gray)
(6) DPF outlet temperature sensor connector 2 (white)
(7) Fuel temperature sensor
(a) From engine harness
IMPORTANT
• When attaching sensors, match the color of the connectors to those of the harness.
RY9212148ELS0210US0
4-S6
KiSC issued 08, 2015 A
KX080-4, WSM
ELECTRICAL SYSTEM
(1) Horn
(a) To front
(b) To engine harness
(c) To AC unit
(d) Harness connector
(e) Ground
(f) To angle solenoid
(g) To travel pressure sensor
RY9212158ELS0020US0
(1) Limit switch (2) Main ECU
(a) To AC unit (b) To fuse box
RY9212148ELS0212US0
4-S7
KiSC issued 08, 2015 A
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
(2) AI console
(3) EP switch
(4) DPF inhibit switch
(5) Engine stop knob
(6) Beacon switch
(7) Worklight switch
(8) Relay connector (2-pin)
(9) Relay connector (8-pin)
(10) Relay connector (12-pin)
(11) Relay connector (16-pin)
RY9212148ELS0214US0
4-S8
KiSC issued 08, 2015 A
KX080-4, WSM
ELECTRICAL SYSTEM
(1) Relay box (2) Fuse box (condenser fan) (3) Slow-blow fuse box
RY9212148ELS0216US0
(a) Arm bottom hoses and clamps
(b) To main harness (c) Clamp wiring
4-S9
RY9212158ELS0022US0
KiSC issued 08, 2015 A
KX080-4, WSM
Normal display
ELECTRICAL SYSTEM
(1) User Setting Switch (Switch 1)
(2) Overload Warning Switch (Switch 2)
(3) AUX Port Enable Switch (Switch 3)
(4) Information Switch (Switch 4)
(5) Display Selector Switch (Switch 5)
(6) Clock Display
(7) Water Temperature Gauge
(8) Hour Meter - Engine Tachometer
(9) Fuel Gauge
(10) Warning Lamp (Red, Yellow)
(11) Oil Lamp
(12) Charge Lamp
(13) 2-Speed Indicator Lamp
RY9212148ELS0001US0
Display at menu-selection
(1) Direction cursor switch (Switch 1)
Stop each setting and return to the original screen.
(2) Cursor move switches (Switch 2)
Move Down the Selection Item.
Move Down the Menu-Selection
Position.
(3) Cursor Move Switches (Switch 3)
Move Up the Selection Item.
Move Up the Menu-Selection
Position.
(4) Cursor Move Switch (Switch 4)
(5) Save switch (Switch 5)
Decision of the Selection Item.
Selecting the Item at the
Menu-Selection Position.
RY9212007ELS0002US0
• Turn the key from OFF to ON and press switch 1 to enter the user settings mode.
Item
(1)
(2)
(3)
(4)
(5)
(6)
Log Record
Periodic Check
Set Clock
Set AUX Flow Ctrl
Various Settings
Language Setting
Description
Allows you to check the hours in use for each day for up to 3 months prior.
Allows you to check the periodic check items and operate the meter panel after conducting periodic inspections.
Sets the clock.
Sets the AUX flow control.
Allows you to change the order of the date display and the clock display method.
Changes the language of the meter panel display.
RY9212148ELS0002US0
4-S10
KiSC issued 08, 2015 A
KX080-4, WSM
ELECTRICAL SYSTEM
• 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.
3. If you press switch 5, you can check the hours in operation for one month.
[Sample screenshot using switch 5]
(1) Days in Use (B/W reversed)
(2) Days not in Use
(3) Hours Used for Selected Date
(4) Selected Date
(5) Horizontal Axis (Day)
RY9212148ELS0016US0
• Allows you to check the periodic check items and operate the meter panel after conducting periodic inspections.
1. Select Periodic Check and check the periodic check items.
IMPORTANT
• Once an item is within 10 hours of its periodic check time, switches 4 and 5 can be selected.
(1) Check Item
(2) Hours Until Service (Next check time - service hour meter)
Service Hour Meter : hour meter + offset time
(3) Next Check Time
RY9212148ELS0017US0
Operation after making a periodic check
1. Select Periodic Check and select the periodic check item that was performed.
2. Press switch 4 and make sure the check mark is displayed in the upper left of the meter panel.
3. Press switch 5.
IMPORTANT
• When "Periodic Check Selection" is set to Manual, switch 4 cannot be selected unless the worklight is pressed "ON".
(Std. for European spec)
• When the "Periodic Check Selection" is set to Auto, turning the key ON/OFF 10 times means the periodic check has been done. (Std. for other than European specs)
4. To perform the check, press switch 5. To return, press switch 1.
IMPORTANT
• Once you initiate a check (switch 5), you cannot go back.
(1) Hours Until Service (5 hours until periodic check time)
RY9212148ELS0018US0
4-S11
KiSC issued 08, 2015 A
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.)
No.
Check Item
1
2
Engine oil (CJ-4)
Hydraulic oil
3 Air cleaner element
Outer element
Inner element
6
7
8
4
5
Fuel filter
Engine oil filter
Travel motor gear oil
Hydraulic return filter
Hydraulic suction filter
9
10
Pilot filter
Grease idler and track rollers
11 DPF
First operation
Interval
Change
Replace
Change
Replace
– clean
50
100
Hour meter indication
250 500 600
750 1000
Subsequently
Every 500 hrs
Every 1000 hrs
Every 1000 hrs
Every 1000 hrs
Every 500 hrs
Every 500 hrs
Every 500 hrs
Every 500 hrs
Every 1000 hrs
Every 1000 hrs
Every 2000 hrs
Every 3000 hrs
RY9212158ELS0005US0
• Sets the clock.
1. Select "Set Clock" and set the clock.
[NOTE]
• Clock precision: 2 seconds/day
NOTE
• Clock settings can be made with the display methods in the
"Various Settings" mode.
(1) Clock Setting Screen
RY9212148ELS0021US0
1. Select "Set AUX Flow Ctrl" and set the auxiliary flow control.
NOTE
• When shipped only icons 1 and 2 are recorded.
(N.A. spec.)
• When shipped only icons 1, 2 and 3 are recorded.
(Eur. spec.)
(1) Icons (1 to 5) (2) Cursor
RY9212148ELS0022US0
4-S12
KiSC issued 08, 2015 A
KX080-4, WSM
ELECTRICAL SYSTEM
• 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.
When shipped
N.A. and Australia Specs
Eur. spec.
Japan spec
MDY/AM-PM
DMY/24 Hour
YMD/AM-PM
(1) Select the Y/M/D Display Order (2) Select Either AM-PM or 24 Hour
Display
RY9212148ELS0023US0
• Changes the language of the meter panel display.
1. Select "Language Setting" and select a language.
IMPORTANT
• In Eur. ver., 11 languages are available.
• In US ver., English only.
• In Canada ver., English and French only.
(1) Language selection screen
RY9212148ELS0024US0
• Turning the key ON while holding SW1 down, allows you to enter the hide user mode.
• There are two items in the hide user mode, the crane mode and the arm control mode.
RY9212148ELS0025US0
• Disables the overload alarm on excavators that have the overload alarm. (Eur. spec.)
• Disables the crane function on excavators with the crane specification. (Japan spec.)
1. Select the crane mode.
2. Select the desired setting.
3. Press SW5 to make the setting.
• When shipped: enabled
IMPORTANT
• The setting is displayed and can be made on the N.A.
specification as well (Does not affect this machine).
RY9212148ELS0026US0
• Disables the ability to switch the arm control on machines with the arm control specification.
1. Select the arm control mode.
2. Select the desired setting.
3. Press SW5 to make the setting.
• When shipped: enabled
IMPORTANT
• The setting is displayed and can be made on the Japan specification as well (Does not affect this machine).
RY9212148ELS0027US0
4-S13
KiSC issued 08, 2015 A
KX080-4, WSM
ELECTRICAL SYSTEM
• 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.
Mode Item Notes
(1) Diagnosis
(2) Setting
[A] Tester
[B] Retrieve Fail Record
[C] Delete Fail Record
[A] AI Set
[B] AUX1 Set
[C] AUX2/Thumb Set
[D] AS Set
[E] Crane Set
[F] Over Load Warning
[G] Model Set
(A) Knob Set
(B) (w/attach) Start Point Set
(C) (w/o attach) Start Point Set
(D) Feeling Adj.
(A) Knob Set
(B) (w/attach) Start Point Set
(C) (w/o attach) Start Point Set
(D) Feeling Adj.
(A) Front Angle Set
(B) Start Point Set
(C) Feeling Adj.
(D) Bucket Set
(A) Front Angle Set
(B) Maximum Set
Description
Checks the data from each sensor and switch.
Checks the record of past failures.
Deletes the record of past failures.
Make the setting when the AI motor, accelerator dial or governor sensor is touched. Also make the setting when part(s) are replaced.
Set when the AUX1 knob is replaced.
Set when the AUX1 proportional valve and/or spool are replaced. (w/ attachment mounted)
Set when the AUX1 proportional valve and/or spool are replaced. (w/ pressure gauge mounted)
Make setting when the AUX1 start point is inaccurate.
Make setting when the AUX2 knob is replaced.
Set when the AUX2 proportional valve, spool and/or ECU are replaced. (w/ attachment mounted)
Set when the AUX2 proportional valve, spool and/or ECU are replaced. (w/ pressure gauge mounted)
Make setting when the AUX2 start point is inaccurate.
Set when the AS position meter is replaced.
Set when the AS 4-way proportional valve and/or control valve are replaced.
Set when you wish to change the sensitivity of the AS cylinder end cushion feel.
Set when using a bucket that is wider than the standard bucket.
Set when the crane's position meter is replaced.
Make the setting when the AI motor, accelerator dial or governor sensor is touched. Also make the setting when part(s) are replaced.
Sets/changes the overload warning pressure.
Set when the ECU and/or meters are replaced.
Only on RX series
(Japan)
Crane spec. only
(Japan)
Eur. spec. only
4-S14
KiSC issued 08, 2015 A
KX080-4, WSM
Mode
(2) Setting [H] Others
ELECTRICAL SYSTEM
Item
(A) AI Motor Drive
(B) Exchange (AUX1) (2/Thumb)
(C) Periodic Check Selection
(D) Periodic Check Display
(E) Annual Guidance
(F) Periodic Check Set
(G) Clock Set Warning (Y/N)
(H) Arm Control Adj
(I) Multipurpose Mode
(J) All Fail Record
(K) Opening Select
Description
Moves the AI motor position when the accelerator dial is replaced.
Operates AUX2 via the AUX1 knob. Or operates AUX1 via the AUX2 knob.
Changes the method of canceling the periodic check guidance to automatic or to manual.
Turns off the display of periodic check guidance. Or turns it on.
Turns on the display of annual check guidance. Or turns it off.
When the meter is replaced, sets the periodic check time prior to replacement to prevent a discrepancy in the periodic check time.
Turns the message, "Set clock" to be displayed/not when the clock has the wrong time.
Set when making fine adjustments to the stop position of the arm crowd limit.
Changes the operating conditions of the multi-purpose switch.
Checks all the fail records since the machine was shipped.
Changes the opening display screen.
Notes
Japan spec. only
RY9212148ELS0028US0
4-S15
KiSC issued 08, 2015 A
KX080-4, WSM
ELECTRICAL SYSTEM
[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.
• Selecting Diagnosis → Tester puts it into this diagnosis mode.
4-S16
(To be continued)
KiSC issued 08, 2015 A
KX080-4, WSM
(Continued)
Scre en
No.
Content displayed
1
Engine RPM
Battery voltage
Oil switch
Charge
Starter
Water temperature
2 Fuel
3
4
5
Fuel supply switch
2-speed switch
2-speed solenoid
Lever lock switch
Lever lock solenoid
Oil temperature sensor
Accelerator POT
Governor POT
Motor amperage
AI pressure switch
AI control switch
Compressor
Water temperature
Idle up
AUX1
6
Amperage
AUX hold switch
ELECTRICAL SYSTEM
Description/std. value
• Current value (n/min)
• Battery voltage ± 0.5V
• Prior to engine start: ON
• After engine start: OFF
• Key in the Start position: ON
• Key in any other position: OFF
• Current value (V)
• Current value (°C)
• Current value (V)
• Current value ( Ω )
Voltage
Resistance
[NOTE]
When cut off
5.0 V
260 Ω
When shorted
Full
Showing 1/2
3 dots remaining
KX080
5 Ω or less
42.19 Ω
101.0 Ω
Empty 101.0
Ω or higher
• Fuel low warning displayed when 3 dots remaining.
• Press switch: ON
• Release switch: OFF
• Press switch: ON
• Release switch: OFF
0 V
0 Ω
• With output signal from ECU: ON
• No output signal from ECU: OFF
• Lever down: ON
• Lever up: OFF
• With output signal from ECU: ON
• No output signal from ECU: OFF
• Dummy data
• Current value: 1.50 to 3.30 V
• Current value: idle, MAX
• Current value: 0.25 to 4.75 V
• Current value: idle, MAX
• AI motor operating: 0.0 to 15.0A
• AI motor stopped: 0.0 to 2.0 A
• Not operating: ON
• Operating: OFF
• Press switch: ON
• Release switch: OFF
• Operating: ON
• Current value (°C)
• Idle up setting value (V)
• Current value: 0.25 to 4.75 V
• Setting value: left or right
• Setting value: neutral
• Operating: 0.5 to 2.0 A
• Stopped: 0 to 0.2A
• Press switch: ON
• Release switch: OFF
4-S17
Notes
Common rail spec. voltage
(V) is dummy data
Common rail spec. is dummy data
Common rail spec. is dummy data
Only for models equipped with AUX1 proportional control (EU, N.A.)
KiSC issued 08, 2015 A
KX080-4, WSM
Scre en
No.
Content displayed
AUX2
7
8
9
Amperage
AUX hold switch
AUX1 right setting
AUX1 left setting
AUX2 right setting
AUX2 left setting
Arm POT
Arm limit setting value
Arm limit solenoid
Anti-theft antenna
On/off enabled/cancelled
10
Red key, Black key
Yellow or green key
(Tag) yellow or green
11
12
13
Angle right switch
Angle left switch
Angle right solenoid
Angle left solenoid
Tilt right switch
Tilt left switch
Tilt right solenoid
Tilt left solenoid
Actual load
Rated load
Radius
Height
Travel pressure
Arm POT
14
15
Boom POT
Bottom pressure, rod pressure
Boom bottom pressure
Warning pressure
Boom rod pressure
Description/std. value
• Current value: 0.25 to 4.75 V
• Setting value: left or right
• Setting value: neutral
• Operating: 0.5 to 2.0 A
• Stopped: 0 to 0.2A
• Press switch: ON
• Release switch: OFF
• Aux start point setting value
• Current value: 0.25 to 4.75 V
• Arm stop setting value
• With output signal from ECU: ON
• No output signal from ECU: OFF
• Antenna working normally: O
• Antenna malfunction: X
Have key: O
No key: X
Same red key: O
Different red key: X
Anti-theft mode: O
Anti-theft off: X
Same black key: O
Wrong red or black key: X
Same yellow key: O
Different yellow key:
X
Same yellow key: O
Different yellow key:
X
Same green key: O
Different green key:
X
Same green key: O
Different green key:
X
• Press switch: ON
• Release switch: OFF
• With output signal from ECU: ON
• No output signal from ECU: OFF
• Press switch: ON
• Release switch: OFF
• With output signal from ECU: ON
• No output signal from ECU: OFF
• Current value (kg)
• Current value (kg)
• Current value (mm)
• Current value (mm)
• Current value (MPa)
• Current value: 0.25 to 4.75 V
• Setting value: arm crowded, arm dump end
• Current value: 0.25 to 4.75 V
• Setting value: boom up end
• Current value: 0.50 to 4.50 V
• Current value (V)
• Current value (MPa)
• Current value (MPa)
• Current value (V)
• Current value (MPa)
4-S18
ELECTRICAL SYSTEM
Notes
Only for models equipped with AUX2 proportional control (EU, N.A.)
Only for models equipped with AUX proportional control
(EU, N.A.)
Arm limit spec only Japanese models
If unknown or Anti-Theft deactivated: –
Angle spec. only N.A. models
Tilt spec. only N.A. models
Crane spec. only Japanese models
Only EU models
Dummy data
KiSC issued 08, 2015 A
KX080-4, WSM
Scre en
No.
Content displayed
16
17
18
19
20
21
22
23
Description/std. value
ELECTRICAL SYSTEM
Notes
Multi-purpose1 switch 1 (AI control dial)
Multi-purpose2 switch 2
(AUX left knob)
Multi-purpose switch solenoid
Compressor
Boom up pressure switch
EP switch
EP solenoid
• Press switch: ON
• Release switch: OFF
• With output signal from ECU: ON
• No output signal from ECU: OFF
• Operating: ON
• Stopped or fine operation: ON
• Full stroke operations: OFF
• Press switch: ON
• Release switch: OFF
• Current amperage (A)
KX080-4
P mode (AC OFF)
P mode (AC ON)
E mode (During travel or full boom up stroke operation)
E mode
• Current value (V)
• Current value (MPa)
940 mA
0 mA
KX080-4 (2-piece boom spec.)
600 mA
1650 mA
840 mA
AC is Air Conditioner
Travel pressure sensor
DPF switch
Worklight switch
Stop engine switch
Boom POT
Arm POT
Offset POT
Setting Bo Ar
Setting Of
Boom solenoid
Arm dump/crowd
Offset solenoid
Setting ArD ArC
Setting Bo Of
Emergency switch
• Press switch: ON
• Release switch: OFF
• Current value: 0.25 to 4.75 V
• Setting value: boom up, arm crowded
• Setting value: offset right
• Operating: 0.4 to 1.2 A
• Stopped: 0.0 to 0.6A
Only on RX series (Japan)
Boom up pressure switch
Boom height limit
Meter
ECU (main)
ECU (AS)
ECU (CRS)
Meter
Ver
Rev
Serial No.
• Start point setting: arm dump, arm crowd
• Starting point setting: boom up, offset right
• Press switch: ON
• Release switch: OFF
• During boom up operation: ON
• Not operating: OFF
• Normally: ON
• At height limit: OFF
• Normally: O [If the meter exists, then O]
• Normally: O [If the ECU (main) exists, then O]
• Normally: O [If the ECU (AS) exists, then O]
• Normally: O [If the ECU (CRS) exists, then O]
• Program version
• Program creation date (Y/M/D)
• Serial no. (different number each machine)
Only on RX series (Japan)
4-S19
KiSC issued 08, 2015 A
KX080-4, WSM
Scre en
No.
Content displayed
24
25
ECU (main)
Ver
Rev
Serial No.
ECU (AS)
Ver
Rev
Serial No.
[B] Retrieve Fail Record
• Checks the record of past failures.
Description/std. value
• Program version
• Program creation date (Y/M/D)
• Serial no. (different number each machine)
• Program version
• Program creation date (Y/M/D)
• Serial no. (different number each machine)
ELECTRICAL SYSTEM
Notes
Only on RX series (Japan)
RY9212148ELS0029US0
1. Select Diagnosis → Retrieve Fail Record.
2. If there are more than one failure records, you can toggle the display each time you press switch 2 or 3.
[Display when fail record exists]
(1) Content of Failure detected by the
ECU (main or meter or AS) that detected it
(2) Number of occurrences (1 to 255)
(3) Date and hour meter of initial occurrence and date and hour meter of last occurrence
RY9212148ELS0030US0
[Display when no fail record exists]
RY9212148ELS0031US0
[C] Delete Fail Record
• Deletes the record of past failures.
1. Select Diagnosis → Delete Fail Record.
[Display when fail record deleted]
IMPORTANT
• Even when fail records are deleted, they are still recorded in the all fail record.
RY9212148ELS0032US0
4-S20
KiSC issued 08, 2015 A
KX080-4, WSM
ELECTRICAL SYSTEM
[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.
3. Press SW5 to make the setting.
4. Follow the instructions on the meter panel and repeat steps 2 and 3.
[Work flow]
Accel to MAX → Accel to Idling
RY9212148ELS0033US0
[B] AUX1 Set
(A) Knob Set
• Set when the knob is replaced.
1. Select Setting → AUX1 Set → Knob set.
2. Follow the instructions on the meter panel.
3. Press SW5 to make the setting.
4. Follow the instructions on the meter panel and repeat steps 2 and 3.
[Work flow]
AUX Knob R END → AUX Knob L END → Knob to Neutral
RY9212148ELS0034US0
(B) (w/attach) Start Point Set
• Make setting when the AUX1 proportional valve, spool and/or AUX1 knob is replaced.
• Mount an attachment on the AUX1 port and make the setting.
1. Select Setting → AUX1 Set → (w/attach) Start Point Set.
2. Follow the instructions on the meter panel.
3. Press SW5 to make the setting.
4. Follow the instructions on the meter panel and repeat steps 2 and 3.
[Work flow]
Accel to MAX → Measure L when attachment moves →
Measure R when attachment moves
RY9212148ELS0035US0
4-S21
KiSC issued 08, 2015 A
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.
2. Follow the chapter Releasing Pressure in the Hydraulic System and release pressure in the hydraulic line.
3. Attach a pressure gauge at the end of the AUX1 discharge (high pressure side, low pressure side).
4. Select Setting → AUX1 Set → (w/o attach) Start Point Set.
5. Follow the instructions on the meter panel.
6. Press SW5 to make the setting.
7. Follow the instructions on the meter panel and repeat steps 2 and 3.
[Work flow]
Accel to MAX → Measure L when pressure rises → Measure R when pressure rises
RY9212148ELS0036US0
(D) Feeling Adj.
• Adjust the AUX1 start point to customer's specification.
1. Select Setting → AUX1 Set → Feeling Adj.
2. Follow the instructions on the meter panel and change the number while monitoring the feel.
3. Press SW5 to make the setting.
CAUTION
• Only use if it does not work properly even after making the start point setting.
(1) Right Fine Adjustment Value (2) Left Fine Adjustment Value
RY9212148ELS0037US0
[C] AUX2/Thumb Set
(A) Knob Set
• Set when the AUX2 knob is replaced.
1. Select Setting → AUX2/Thumb Set → Knob set.
2. Follow the instructions on the meter panel.
3. Press SW5 to make the setting.
4. Follow the instructions on the meter panel and repeat steps 2 and 3.
[Work flow]
AUX Knob R END → AUX Knob L END → Knob to Neutral
RY9212148ELS0038US0
4-S22
KiSC issued 08, 2015 A
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.
2. Follow the instructions on the meter panel.
3. Press SW5 to make the setting.
4. Follow the instructions on the meter panel and repeat steps 2 and 3.
[Work flow]
Accel to MAX → Measure L when attachment moves →
Measure R when attachment moves
RY9212148ELS0039US0
(C) (w/o attach) Start Point Set
• Make setting when the AUX2 proportional valve, spool and/or AUX2 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.
2. Follow the chapter Releasing Pressure in the Hydraulic System and release pressure in the hydraulic line.
3. Attach a pressure gauge at the end of the AUX2 discharge (high pressure side, low pressure side).
4. Select Setting → AUX2/Thumb Set → (w/o attach) Start Point
Set.
5. Follow the instructions on the meter panel.
6. Press SW5 to make the setting.
7. Follow the instructions on the meter panel and repeat steps 2 and 3.
[Work flow]
Accel to MAX → Measure L when pressure rises → Measure R when pressure rises
RY9212148ELS0040US0
(D) Feeling Adj.
• Adjust the AUX2 start point to customer's specification.
1. Select Setting → AUX2/Thumb Set → Feeling Adj.
2. Follow the instructions on the meter panel and change the number while monitoring the feel.
3. Press SW5 to make the setting.
CAUTION
• Only use when it does not work properly even after making the start point setting.
(1) Right fine adjustment value (2) Left fine adjustment value
RY9212148ELS0041US0
4-S23
KiSC issued 08, 2015 A
KX080-4, WSM
[D] AS Set (Japan Spec. Only)
ELECTRICAL SYSTEM
[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.
1. Select Setting → Overload warning.
2. Enter a pressure warning value appropriate for the specification.
RY9212158ELS0002US0
[Display when not overload warning spec.]
(1) Not the crane spec. or the overload warning spec.
RY9212148ELS0045US0
4-S24
KiSC issued 08, 2015 A
KX080-4, WSM
ELECTRICAL SYSTEM
[G] Model Set
• Set when the ECU and/or meters are replaced.
• Select Diagnosis → Model Set to make this setting.
• After setting the model, it is necessary to make the AI, AUX1 knob and AUX2 knob settings.
Screen No.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
Content displayed
Model name
Destination
AI
Overload Warning
AUX1
AUX2 / Thumb
Arm Control
Angle
Tilt
Multipurpose Operating
Arm Type
Compartment
(13)
(14)
(15)
Force Mode
Common Rail System
Setup Completed
Notes
4-S25
Eur. spec.: YES
N. Am. spec.: NO
Japan spec.: YES (Arm limit spec. only)
N. Am. spec.: YES (Angle spec. only)
N. Am. spec.: YES (Tilt spec. only)
Has multi-purpose switch connector spec.: YES
2-piece boom spec.: 2
Other specs.: 1
W/ eco mode spec.:1 (KX080-4)
W/AC mode spec.:2
No AC spec.: 0
RY9212158ELS0023US0
KiSC issued 08, 2015 A
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.
• Switch 2: Counterclockwise
• Switch 3: Clockwise
IMPORTANT
• The common rail spec. does not have an AI motor, so this does not function.
RY9212148ELS0003US0
(B) Exchange (AUX1) (2/Thumb)
• Operates AUX2 via the AUX1 knob. Or operates AUX1 via the AUX2 knob.
1. Select Setting → Others → Exchange (AUX1) (2/Thumb).
2. Select the desired operating method.
3. Press SW5 to make the setting.
Normal
Reverse
AUX1
Right control lever
Left control lever
AUX2
Left control lever
Right control lever
RY9212148ELS0004US0
(C) Periodic Check Selection
• Changes the method of canceling the periodic check guidance to automatic or to manual.
1. Select Setting → Others → Periodic Check Selection.
2. Select the desired operating method.
3. Press SW5 to make the setting.
Selection mode
Auto (N.A. spec.)
Manual (Eur. spec.)
Method for canceling periodic check guidance
Turn the key ON/OFF 10 times or operate the meter panel after making periodic checks.
Operate meter panel after making periodic check.
RY9212148ELS0005US0
(D) Periodic Check Display
• Turns off the display of periodic check guidance. Or turns it on.
1. Select Setting → Others → Periodic Check Display.
2. Select the desired operating method.
3. Press SW5 to make the setting.
• When shipped: displays
RY9212148ELS0006US0
4-S26
KiSC issued 08, 2015 A
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.
• When shipped: does not display
RY9212148ELS0007US0
[When display is selected]
1. Set the year and month to be displayed.
2. Press SW5 to make the setting.
(1) Annual check guidance display period (Y/M)
RY9212148ELS0008US0
[Display when the set month is reached]
IMPORTANT
• Each time the key is turned ON, the message is displayed for 10 seconds on the normal screen.
• Use Periodic Check in the user setting mode to turn it off.
RY9212148ELS0009US0
[Display from Periodic Check in the user setting mode]
(1) Selected year and month
(2) Minus 1 month (Ex.: one month past the period set for the check.)
RY9212148ELS0010US0
4-S27
KiSC issued 08, 2015 A
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.
2. Enter the service hour meter prior to replacing the meter.
3. Press SW5 to make the setting.
RY9212148ELS0011US0
(G) Clock Set Warning (Y/N)
• Sets whether to display the message, "Set clock" or not.
1. Select Setting → Others → Clock Set Warning (Y/N).
2. Select the desired operating method.
3. Press SW5 to make the setting.
• When shipped: prompts to set the clock
RY9212148ELS0012US0
(H) Arm Control Adj (Japan spec. only)
• Set when making fine adjustments to the stop position of the arm crowd limit.
1. Select Setting → Others → Arm control Adj.
2. Change to the desired value (0 to 250ms).
3. Press SW5 to make the setting.
• When shipped: 150ms
Increasing the value: stops closer to the dump side than the original stop position
Reducing the value: stops closer to the near side than the original stop position
IMPORTANT
• The setting is displayed and can be made on the Japan specification as well. (Does not affect this machine.)
RY9212148ELS0013US0
4-S28
KiSC issued 08, 2015 A
KX080-4, WSM
ELECTRICAL SYSTEM
• 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.
• The multi-purpose switch allows you to control added solenoid valves and to operate hydraulic devices.
1. Select Setting → Model Set.
2. Make sure the multi-purpose specification is set to "YES."
IMPORTANT
• If the multi-purpose specification is set to "NO," the multi-purpose mode will not work, so select "YES" and redo the setting.
3. Select Setting → Others → Multi-purpose mode.
4. Enter the number of the mode you wish to use.
5. Press SW5 to make the setting.
• Available mode numbers: 00 to 10
Mode number when shipped: 00
(Multi-purpose switch function disabled and AUX2 hold function disabled)
RY9212148ELS0014US0
(a) Position of Connector for Operating Added Solenoid Valve
IMPORTANT
• Available from serial number: 030546
(1) Multi-purpose connector
RY9212148ELS0048US0
Pin No.
<1>
<2>
Terminal
+ Terminal
- Terminal
Max rated amperage
1 A
–
RY9212148ELS0049US0
4-S29
KiSC issued 08, 2015 A
KX080-4, WSM
(b) Names of Parts
(1) Multi-Purpose Switch A
(2) Indicator
(3) Multi-Purpose Switch B
(4) AUX2/Thumb Hold Switch
(5) AUX2/Thumb Knob
ELECTRICAL SYSTEM
(A) N.A. Spec.
(B) Australia/Eur. Spec.
RY9212148ELS0050US0
(c) Description of Each Mode
Mode No. 01: Enables the AUX2 hold switch.
• Pressing the AUX2/Thumb hold switch turns the AUX2 signal ON. Pressing the switch again turns the AUX2 signal OFF.
• The AUX2/Thumb knob signal takes priority over the AUX2/thumb hold switch signal.
Example of Usage: Attachment that is not influenced by the operation of the front, such as a mower (rotary type)
(1) Multi-Purpose Switch A
(2) Multi-Purpose Switch B
(3) AUX2/Thumb Hold Switch
(4) AUX2/Thumb Knob
(A) AUX2 signal
RY9212148ELS0051US0
4-S30
KiSC issued 08, 2015 A
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
(2) Multi-Purpose Switch B
(3) AUX2/Thumb Hold Switch
(4) AUX2/Thumb Knob
(A) Multipurpose signal
RY9212148ELS0052US0
Mode No. 03: Mode No. 01 + Mode No. 02
• Enables the AUX2 hold switch.
• Pressing multipurpose switch A or multipurpose switch B switches the operation of swivel/swing ON/OFF.
RY9212148ELS0053US0
Mode No. 04: Turns the water sprinkler for asphalt planer, etc. ON/OFF.
• The multi-purpose signal is ON only while multipurpose switch A or B is pressed.
(1) Multi-Purpose Switch A
(2) Multi-Purpose Switch B
(3) AUX2/Thumb Hold Switch
(4) AUX2/Thumb Knob
(A) Multipurpose signal
RY9212148ELS0054US0
Mode No. 05: Mode No. 01 + Mode No. 04
• Enables the AUX2 hold switch.
• The multi-purpose signal is ON only while multipurpose switch A or B is pressed.
RY9212148ELS0055US0
Mode No. 06: Operates the hydraulic quick hitch (operation of blade, swing, etc.)
• Turns the multipurpose switch signal ON while multipurpose switch A is pressed.
• Operating the actuator while multipurpose switch A is pressed operates the quick hitch.
• Enables the hydraulic quick hitch for single or multi-operation
(1) Multi-Purpose Switch A
(2) Multi-Purpose Switch B
(3) AUX2/Thumb Hold Switch
(4) AUX2/Thumb Knob
(A) Multipurpose signal
RY9212148ELS0056US0
Mode No. 07: Mode No. 01 + Mode No. 06
• Enables the AUX2 hold switch.
• Operating the swing while multipurpose switch A is pressed operates the quick hitch.
RY9212148ELS0057US0
4-S31
KiSC issued 08, 2015 A
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
(2) Multi-Purpose Switch B
(3) AUX2/Thumb Hold Switch
(4) AUX2/Thumb Knob
(A) Multipurpose signal
RY9212148ELS0058US0
Mode No. 09: Mode No. 01 + Mode No. 08
• Enables the AUX2 hold switch.
• Operates a hydraulic quick hitch or for using Tiltrotator.
RY9212148ELS0059US0
Mode No. 10: Operates a hydraulic quick hitch (Assigns AUX2 to the dedicated quick hitch port)
• While pressing multipurpose switch A, operating the AUX2/thumb knob turns the multipurpose switch signal ON.
• Enables the hydraulic quick hitch for single or multi-operation
(1) Multi-Purpose Switch A
(2) Multi-Purpose Switch B
(3) AUX2/Thumb Hold Switch
(4) AUX2/Thumb Knob
(A) Multipurpose signal
RY9212148ELS0060US0
(J) All Fail Record
• Checks all the fail records since the machine was shipped.
1. Select Setting → Others → All Fail Record.
2. If more than one failure record exists, each press of switch 2 or
3 toggles the display.
[Display when fail record exists]
IMPORTANT
• The content displayed when retrieving all fail records is not deleted even if you delete individual fail records.
(1) Content of failure detected by the
ECU (main or meter or AS) that detected it
(2) Number of occurrences (1 to 255)
(3) Date and hour meter of initial occurrence and date and hour meter of last occurrence
RY9212148ELS0061US0
[Display when no fail record exists]
IMPORTANT
• As the failures governed by the engine ECU are not left on this machine (all fail record), use the engine diagnosis tool.
(1) No fail records
RY9212148ELS0062US0
4-S32
KiSC issued 08, 2015 A
KX080-4, WSM
(K) Opening Select
• Changes the opening display screen.
ELECTRICAL SYSTEM
1. Select Setting → Others → Opening select.
2. Select the number of the desired display method.
3. Press SW5 to make the setting.
Number
(1)
(2)
• When shipped: 2
Screen display
Silhouette of the excavator
Kubota logo
RY9212148ELS0063US0
4-S33
KiSC issued 08, 2015 A
KX080-4, WSM
ELECTRICAL SYSTEM
(1)
(2)
(3)
(4)
Overwrite ECU with new data
Meter changed
Need setup
Content displayed
List of items that need to be set up
Explanation
Press switch 5 "Yes" to overwrite data.
Press switch 1 "No" when checking whether another machine's meter or ECU that is temporarily installed is working or not.
If "No" is selected, the normal screen appears.
[Initializes saved settings.]
Press switch 5 "Yes" if the meter has been changed.
Press switch 1 "No" if the ECU has been changed.
Pressing switch 4 allows you to check the items that need to be set up.
After checking the items that need to be set up, turn the key to OFF to make the settings.
IMPORTANT
• Never install an ECU from a previous model (spec. other than common rail) as doing so will damage the
ECU.
RY9212148ELS0064US0
No.
(1)
Content displayed
(A) STOP
(B) RUN
(C) START
Explanation
Install the battery and turn the key to
[RUN]
.
(2)
(3)
Set Clock
Setting screen
Press switch 5 "Yes" to set.
Press switch 1 "No" to skip setting it.
If "No" is selected, the normal screen appears.
[Clock setting guide]
• Pressing switch 4 ( ) changes the setting item from Yr → Mo → Day → Hr → Min → Yr.
• Pressing switch 2 ( ) reduces the number.
• Pressing switch 2 ( ) increases the number.
• Pressing switch 1 while on the clock setting screen takes the screen back without changing the time.
(4) Setup complete
• When in the dealer mode, it is also possible to disable the warning via "Clock Set Warning (Y/N)." (Set to display when shipped)
• After removing the battery, the condenser inside the meter holds its charge for about 2 days.
RY9212148ELS0015US0
4-S34
KiSC issued 08, 2015 A
KX080-4, WSM
ELECTRICAL SYSTEM
When needed, pressing switch 4 displays a detailed description.
No.
Screen display Pressing SW4 Message in fail record Reason detected/steps to take
1 –
[Meter]
Engine oil pressure error a)Engine oil pressure low b)Oil switch always ON c)Short in harness
2 –
[Meter]
Overheated
3
4
5
6
7
–
–
CANSys (main)
CANSys (CRS)
–
–
[Meter]
Charging System Error
[Meter]
Fuel Sensor Error
[Meter]
CAN Sys (Main)
[Meter]
CAN Sys (CRS)
[Meter]
Setup Data Error
[Main ECU]
Water mixed with fuel
Engine overheated [118°C
(244°F)--automatically goes to idle]
Low alternator voltage detected a)Alternator faulty b)Fan belt loose/off c)Break in harness d)Fuse blown (10 A) a)Connector disconnected b)Break in harness a)Connector disconnected b)ECU (+B) fuse blown (5 A) c)Break or short in harness a)Connector disconnected b)Slow blow fuse (CRS) blown (30 A) c)Engine ECU relay faulty d)Break or short in harness
Go through the model setup again. If this doesn't fix it, it's a faulty meter.
a) Water mixed with fuel in the fuel filter
[Reference value:80 to 130 ml
(0.07 to 0.11 lmp·qts, 0.08 to 0.14 U.S.qts)] b)Short in the fuel filter line
8
9
2-speed solenoid
AUX1 knob
AUX1 right SOL
AUX1 left SOL
[Main ECU]
2-speed SOL
[Main ECU]
AUX1 knob
[Main ECU]
AUX1 right SOL
[Main ECU]
AUX1 left solenoid a)2-speed solenoid line short a)AUX1 knob connector disconnected b)Break or short in harness a)AUX1 right solenoid connector disconnected b)Break or short in harness a)AUX1 left solenoid connector disconnected b)Break or short in harness
4-S35
KiSC issued 08, 2015 A
KX080-4, WSM
No.
Screen display
10
Pressing SW4
AUX2/thumb knob
AUX2/thumb right SOL
AUX2/thumb left SOL
Message in fail record
[Main ECU]
AUX2/thumb knob
[Main ECU]
AUX2/thumb right solenoid
[Main ECU]
AUX2/thumb left solenoid
11 Over voltage
[Main ECU]
Over voltage
ELECTRICAL SYSTEM
Reason detected/steps to take
a)AUX2 knob connector disconnected b)Break or short in harness a)AUX2 right solenoid connector disconnected b)Break or short in harness a)AUX2 left solenoid connector disconnected b)Break or short in harness a)Activated by 18V+ b)Alternator faulty
12
Angle right solenoid
Angle left solenoid
[Main ECU]
Angle right solenoid
[Main ECU]
Angle left solenoid a)Angle right solenoid line short a)Angle left solenoid line short
13 Accelerator sensor
[Main ECU]
Accelerator sensor a)AI console connector disconnected b)Break or short in harness
14 Antenna
[Main ECU]
Antenna a)Connector disconnected b)Break in harness c)Antenna faulty
15 Lever lock solenoid
[Main ECU]
Lever lock solenoid a)Lever lock solenoid line short
16
17
Multipurpose SOL
[Main ECU]
Multipurpose solenoid
External 5V
[Main ECU]
External 5V a)Multipurpose solenoid line short
Short in 5V line
18
19
1 to 64
Travel pressure
EP solenoid
[Main ECU]
Travel pressure
[Main ECU]
EP solenoid
– Engine system error a)Pressure sensor connector disconnected b)Break or short in harness a)EP solenoid connector disconnected b)Break or short in harness
RY9212158ELS0003US0
4-S36
KiSC issued 08, 2015 A
7
8
9
KX080-4, WSM
When needed, pressing switch 4 displays a detailed description.
No.
Screen display Pressing SW4 Message in fail record
1 – –
ELECTRICAL SYSTEM
Reason detected/steps to take
Fuel low
Displayed at 6 minute intervals.
2
3
–
–
–
–
Water temperature rising.
Displayed at 6 minute intervals.
(110 to 117°C, 230 to 242°F)
Tried to start engine with an unregistered key
(Anti-theft spec. only)
4
5
–
–
–
–
Tried to start engine with a red key (Anti-theft spec. only)
Suspended weight is over the rated load (Eur. overload warning spec. only)
6 Check location displayed – Displayed 10 hours before periodic check due
Check location displayed
–
–
–
–
–
Past time for periodic check
Annual check
The clock may have the wrong time.
RY9212148ELS0066US0
4-S37
KiSC issued 08, 2015 A
KX080-4, WSM
No.
Screen display Pressing SW4
1 –
2
3
4
5
6
7
8
9
10
–
–
The setup item is displayed.
–
–
–
–
–
–
ELECTRICAL SYSTEM
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
ECU, this screen comes up to confirm the meter has been changed.
When neither the meter nor the ECU have been replaced, but some setting needs to be made.
If you attempt to start the engine with the lever lock still down.
If you press switch 3 (AUX) with the lever lock still up.
If you turned the key OFF but fail to take it out
(Anti-theft spec. only)
• If you press switch 3 (AUX) on a machine w/o AUX1/AUX2/thumb spec.
• If you setup the model as AUX1 (w/o) and press switch 3 (AUX).
• If you press the AI switch on a machine w/o the AI spec.
• If you set up the model as AI (w/o) spec. and press the AI switch.
If you press the multipurpose switch before registering it.
4-S38
KiSC issued 08, 2015 A
KX080-4, WSM
No.
Screen display Pressing SW4
11 –
12
13
14
–
–
–
Message in fail record
–
ELECTRICAL SYSTEM
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 auto-regeneration of the DPF is inhibited.
Displayed for 5 seconds when the inhibition on
DPF auto-regeneration is cancelled.
RY9212148ELS0067US0
4-S39
KiSC issued 08, 2015 A
KX080-4, WSM
Inhibit switch ON
Clog
Level
Warning lamp
Buzzer
Engine output
Screen Content displayed
Level 0
Level 1
OFF
OFF
–
–
–
–
–
–
–
–
Level 2
Blinking
(Yellow)
··PiPiPi··
(Continue)
–
Regeneration of DPF is inhibited.
Allow regeneration.
Level 3
··PiPiPi··
(0 to 50 sec.)
Blinking
(Red)
Pi-···Pi-
(50 to 60 sec.)
Pi-···Pi-
(from 60 sec.)
50 %
–
Regeneration of DPF is inhibited.
Allow regeneration.
HP limited to low power.
*2
ELECTRICAL SYSTEM
Status and correction
–
–
–
Engine forced to stop
Increase RPM and restart
Turn and maximize the accelerator dial and restart
*1
Level 4
Blinking
(Red)
PiPiPiPi
(0 to 50 sec.)
Pi-···Pi-
(from 50 sec.)
50 %
DPF clogged up
Needs maintenance
Use the engine diagnosis tool and regenerate it manually
*1
*2
Level 5
Blinking
(Red)
PiPiPiPi
(Continue)
50 % Replace the DPF DPF is clogged. Needs replacement.
The engine rpm drops up to only 1900 rpm while pressing the AI switch.
PM clog level does not change when the key is turned OFF. The level stays the same when the engine restarts.
*1 : If the lever lock is up, the engine stops forcibly in 60 seconds.
*2 : If the lever lock is down, the engine does not stop. The same buzzer from 0 to 50 sec. keeps sounding.
RY9212148ELS0221US0
4-S40
KiSC issued 08, 2015 A
KX080-4, WSM
Inhibit switch OFF
Clog
Level
Warning lamp
Level 0 OFF
Buzzer
–
Level 1
Blinking
(Yellow)
··PiPiPi··
(Every
60 sec.)
Engine output
–
Engine RPM
–
– –
Screen
–
Level 2
Blinking
(Yellow)
··PiPiPi··
(Every
60 sec.)
–
Pi-···Pi-
(from 60 sec.)
–
Level 4
Blinking
(Red)
PiPiPiPi
(0-50 sec.)
Pi-···Pi-
(from 50 sec.)
50 %
More than
1900 rpm
Less than
1900 rpm
Blinking
(Yellow)
PiPiPi
(Every
60 sec.)
50 %
More than
1900 rpm
Level 3
Blinking
(Red)
··PiPiPi··
(0-50 sec.)
Pi-···Pi-
(50-60 sec.)
50 %
Less than
1900 rpm
–
ELECTRICAL SYSTEM
Contents displayed
–
Exhaust temperature rising
Operate carefully
Can continue working
Exhaust temperature rising
Operate carefully
Can continue working
Exhaust temperature rising
Operate carefully
Can continue working
Increase engine
RPM
Status and correction
–
More than 1900 engine RPM needed: DPF regenerates
Less than 1900 engine RPM:
DPF may not auto-regenerate due to open air and water temp.
Being auto-regenerated
• When the engine RPM is low, DPF may not auto-regenerate due to open air and water temp.
• The screen changes every 3 sec.
Exhaust temperature rising
Operate carefully
Can continue working
• Being auto-regenerated
• The screen is changed every 3 sec.
HP limited to low power
Exhaust temperature rising
Operate carefully
Can continue working
Increase engine
RPM
HP limited low power
• When the engine RPM is low, DPF may not auto-regenerate due to open air and water temp.
• The screen changes every 3 sec.
*2
Engine forced to stop
Increase RPM and restart
Turn and maximize the accelerator dial and restart.
*1
DPF clogged up
Needs maintenance
Use the engine diagnosis tool and regenerate it manually
*1
*2
4-S41
KiSC issued 08, 2015 A
KX080-4, WSM
Clog
Level
Warning lamp
Buzzer
Engine output
Engine RPM
Level 5
Blinking
(Red)
PiPiPiPi
(Continue)
50 % –
Screen
Contents displayed
ELECTRICAL SYSTEM
Status and correction
Replace the DPF
DPF is clogged. Needs replacement.
The engine rpm drops up to only 1900 rpm while pressing the AI switch.
PM clog level does not change when the key is turned OFF. The level stays the same when the engine restarts.
*1 : If the lever lock is up, the engine stops forcibly in 60 seconds.
*2 : If the lever lock is down, the engine does not stop. The same buzzer from 0 to 50 sec. keeps sounding.
RY9212148ELS0222US0
4-S42
KiSC issued 08, 2015 A
29
30
31
32
25
26
27
28
21
22
23
24
17
18
19
20
37
38
39
40
60
33
34
35
36
13
14
15
16
9
10
11
12
5
6
7
8
1
2
3
4
KX080-4, WSM
Symptom when error occurs
Always happens
May happen
No. Displayed
Error location
ELECTRICAL SYSTEM
Engine performance
Limited
RPM
Limited
HP
Won't start
Notes
Fuel may run out.
RPM sensor system
Fuel/rail pressure system
SCV system error
Intake temperature sensor system
Water temperature sensor system
Fuel temperature sensor system
Injector system
Intake pressure sensor system
Battery voltage related
Sensor voltage related
Main relay related
Atmospheric pressure sensor related
EGR valve related
EGR starting to close warning
Emissions warning
Air heater related
Engine ECU
Communication error
Mass airflow sensor related
Intake throttle
Pressure differential sensor related
Exhaust temperature sensor (DOC intake)
Exhaust temperature sensor (DOC outlet)
Exhaust temperature sensor (DPF outlet)
Simultaneous break in all exhaust temperature sensors
DOC reaction
DPF regeneration time up
Insufficient DPF regeneration water temperature rise
Regeneration too frequent
Engine fuel system (P/L)
Engine fuel system (rail pressure)
Engine fuel system (fuel leak)
Engine fuel system (SCV)
Engine fuel system (Supply pump)
Engine air intake system (Insufficient intake)
Engine air intake system (Insufficient boost pressure)
Engine exhaust temperature (DOC inlet temperature error)
Engine exhaust temperature (DPF inlet temperature error)
Engine exhaust temperature (DPF outlet temperature error)
Starter relay start warning
Other errors
RY9212148ELS0069US0
4-S43
KiSC issued 08, 2015 A
KX080-4, WSM
ELECTRICAL SYSTEM
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.
Voltage between terminals
Factory specification At least DC 12 V
Check the condition of terminal connections
1. Put an electrical load on the battery. (E.g.: Turn the key switch to RUN and turn a worklight on.
2. Connect the (+) side if the circuit tester to the (+) terminal of the battery and the (-) side of the circuit tester to the (+) battery cable. Measure the voltage.
3. Connect the (-) side if the circuit tester to the (-) terminal of the battery and the (+) side of the circuit tester to the (-) battery cable. Measure that voltage.
4. If the measurements are greater than factory specs, check the condition of the contacts at the terminals.
Voltage between terminals
Factory specification At least DC 0.1 V
(1) (-) Terminal (2) (+) Terminal
RY9212001ELS0034US0
4-S44
KiSC issued 08, 2015 A
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
RY9212148ELS0138US0
Inspecting fuses
• Measurement parameter: check continuity across its terminals
RY9212001ELS0031US0
4-S45
KiSC issued 08, 2015 A
KX080-4, WSM
ELECTRICAL SYSTEM
Fuse Layout and Capacities
(7)
(8)
(9)
(10)
(11)
(1)
(2)
(3)
(4)
(5)
(6)
A/C Controller (+B)
Meter (+B)
Blower Motor
Relay
ECU (AC)
Room Light
Starter
Wiper/Washer
Compressor
Electrical Outlet
Front Work Light
(18)
(19)
(20)
(21)
(22)
(12)
(13)
(14)
(15)
(16)
(17)
Cab Work Light
Radio (AC)
Fuel Filter Heater
ECU (+B)
ECU (POWER)
Beacon
Horn Switch
Horn
Lever Lock
Alternator
Fuel Pump
RY9212158ELS0016US0
Precautions when a Fuse Blows
When a fuse blows, there are 2 potential causes. The first is when an overload of current exceeds the rated amperage of the fuse, blowing it; the other is when it blows due to a repetitive, intermittent current.
These two cases can be readily recognized visually, so when a fuses blows, take note of the following points.
1. When a fuse blows due to an overload of current exceeding its rated capacity.
An overload current produces a blown fuse such as shown at left
(A)
.
You should not immediately replace a fuse that blows in this way with a new one.
The fuse will just blow again when subjected to the overload current, so first inspect the circuit for a short or a problem with a device, then after fixing the problem, install a fuse of the same capacity.
The purpose of the original fuse is to provide a margin of safety, so never replace a fuse with one of a higher capacity.
If you replace a fuse with one of a higher capacity, it presents the danger of a current overload damaging the electrical device(s) and/or the wiring in the circuit before blowing the fuse.
2. When a fuse blows due to a repetitive, intermittent current.
A repetitive, intermittent current produces a blown fuse such as shown at left
(B)
. In general, this kind of blown fuse occurs after a relatively long period of time, so it does not happen very often.
With this kind of blown fuse, it is OK to replace it with a fuse of the same capacity.
(A) Fuse Blown by Current Overload (B) Fuse Blown by Thermal Fatigue
RY9212001ELS0032US0
4-S46
KiSC issued 08, 2015 A
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
RY9212001ELS0028US0
Slow Blow Fuse Layout and Capacities
(A)
(B)
(C)
(D)
Alternator (100 A)
Engine ECU (30 A)
Main Power (60 A)
Engine Power (50 A)
(1) Slow-blow fuse box (2) Electric fan fuse (20 A)
RY9212148ELS0141US0
Key switch
Checks
1. Remove the key switch's 3P connector.
2. Turn the key switch to the RUN position and then check the continuity between the red / white wire terminal of the connector on the key switch side and the red wire terminal on the connector.
3. Turn the key switch to the START position and then check the continuity between the black/white wire terminal of the connector on the key switch side and the red wire terminal on the connector.
Key switch circuit table
(1) Red / White
(2) Black / White
4-S47
(3) Red
RY9212050ELS0027US0
KiSC issued 08, 2015 A
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.
2. If the measurement meets the factory spec, the harness between the battery and terminal B is OK.
3. If the measurement is outside of factory specs, check the condition of the battery cable (+) contact and that of the GND (–) cable and the body.
Measured voltage Factory specification 11 to 14 V (battery voltage)
2. Power supply to starter's pull-in and holding coils
1. Remove the connector from the starter's S terminal.
2. Connect the (+) of the circuit tester to the connector on the harness side and the (–) to the body.
3. Put the machinery operation lock lever in the lock position and measure the voltage with the key switch held in the START position.
If the measurement meets factory specs, the circuit from the battery to the S terminal is OK (harness, key switch, auto-release relay).
Measured voltage Factory specification 11 to 14 V (battery voltage)
(1) Terminal B (2) Terminal S
RY9212148ELS0137US0
Relay Layout and Capacities
(6)
(7)
(8)
(9)
(10)
(11)
(1)
(2)
(3)
(4)
(5)
Power relay (40A)
Glow relay (40A)
Horn relay (20A)
Starter relay (20A)
Beacon relay (20A)
Worklight relay (20A)
ECU (Power) relay (20 A)
Blower relay (20A)
Compressor relay (20A)
Condenser relay (20 A)
Engine ECU relay (20A)
RY9212148ELS0142US0
4-S48
KiSC issued 08, 2015 A
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.
Measurement
1
2
Connector Name
(+ terminal side)
Pin No.
Connector Name
(+ terminal side)
Starter relay
Starter relay
<1>
<1>
Starter relay
Body GND
Normal: 12V (battery voltage)
Irregular: Large discrepancy from 12V
Pin No.
<2>
–
2. Continuity check
[Measurement Conditions]
1. Key switch: OFF
2. Remove the starter relay.
3. Apply battery voltage across relay terminals 1 and 2.
4. Check for continuity based on the table below.
Measurement
1
Connector Name
(+ terminal side)
Starter relay
Pin No.
<5>
Connector Name
(+ terminal side)
Starter relay
Pin No.
<3>
Regular: Continuity
Irregular: No continuity
RY9212148ELS0143US0
Glow relay inspection
1. Voltage check
[Measurement Conditions]
1. Remove the glow relay.
2. Key switch: ON
3. Measure the voltage based on the table below.
Measurement
1
Connector Name
(+ terminal side)
Glow relay
Pin No.
<1>
Connector Name
(+ terminal side)
Glow relay
Pin No.
<2>
Normal: 12V (battery voltage)
Irregular: Large discrepancy from 12V
2. Continuity check
[Measurement Conditions]
1. Key switch: OFF
2. Remove the glow relay.
3. Apply battery voltage across relay terminals 1 and 2.
4. Check for continuity based on the table below.
Measurement
1
Connector Name
(+ terminal side)
Glow relay
Regular: Continuity
Irregular: No continuity
Pin No.
<3>
Connector Name
(+ terminal side)
Glow relay
Pin No.
<4>
RY9212148ELS0144US0
4-S49
KiSC issued 08, 2015 A
KX080-4, WSM
ELECTRICAL SYSTEM
Engine does not start
Checkpoint Cause Solution
Check whether "Wrong
Key" is displayed when it is in the start position.
Determine whether it is the registered key or not in the tester mode.
The engine was not started with the registered key.
Start the engine with the registered key.
Check slow-blow and other fuses.
Slow-blow and/or other fuses are blown.
After determining the cause of slow-blow and/or other fuses blowing, replace them.
Check whether GND wire(s) are securely connected to the body.
Check battery voltage and specific gravity.
Check continuity between key switch terminals.
Measure the voltage at terminal B of the starter.
Measure the voltage at terminal S of the starter.
Ground defective
Battery fault
Key switch faulty
Break in continuity of the harness or starter relay.
Break in continuity in the harness, starter relay and/or fuses.
Tighten GND wire bolt(s).
Recharge or replace the battery.
Replace the key switch.
Repair the harness.
Replace the harness, starter relay and/or fuses.
Repair the harness.
Replace the harness, starter relay and/or fuses.
The engine fails to start sometimes.
Is the key on a metal keyring or have a metal fob?
Checkpoint Cause
The key fob and/or keyring are interfering with communication between the key and the antenna.
Engine starts even with unregistered keys
Checkpoint
Check whether the anti-theft system is
"OFF" or not initialized.
Cause
As the anti-theft function is not working, even unregistered keys can start the engine.
Solution
Get rid of the key fob and/or ring.
Solution
Please contact Kubota service.
RY9212148ELS0135US0
4-S50
KiSC issued 08, 2015 A
KX080-4, WSM
ELECTRICAL SYSTEM
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. And the inference has to be supported by theory and practice--relying on intuition does not work.
RY9212038ELS0013US0
When diagnosing errors if you fail to go through the proper procedures, it clouds the view of the actual problem and conversely, in the end you are liable to make an incorrect guess about the cause and repair. For that reason, it is necessary to think through the following 4 steps when diagnosing errors.
1
Error Diagnosis Procedure
2
Infer the Cause of the Error
3
4
Test Specified Locations and Find the
Cause
Check your Repairs
• Accurately observe what the problem is. Check whether that problem is the only one or whether there are other problems.
• When inferring the cause of an error, it is important to grasp the circuits in the wiring diagram as a system. Of course you have to know how switches, relays, etc. function, but having a broader view of the causes of errors, such as from experience of what caused past errors that you repaired, is necessary to making inferences.
• Error diagnosis is a matter of building up facts from tests and step by step getting closer to the real cause. While making checks, you always have to be thinking, which test can I make where to be more effective.
• After repairing a fault, always check and make sure the system is functioning normally. And make sure no new problem has arisen.
These materials provide information necessary for diagnosing errors and the overall wiring diagram and circuit diagrams for each system were compiled with a view to simplifying error diagnosis.
1. The circuit diagrams show the layout of connectors and wiring routing on the machine.
2. The circuit diagrams show the structure of circuits in the system and indicate the normal (not operating) state of all of the kinds of switches.
3. The flow of electricity when switches are operated is explained based on the circuit diagrams and how each device operates is indicated.
4. Troubleshooting tips are provided to help identify the causes of errors from multiple pieces of information and using common sense.
If you cannot pinpoint the cause based on these tips, follow the circuit for each system to diagnose the error.
RY9212148ELS0071US0
All diagnoses of malfunctions should narrow down the cause via the following procedures and specify the faulty location.
(Not following the procedures results in not knowing the cause of the fault.)
1
2
3
4
Observing the Malfunction
Checking the Faulty Line
Specify the Faulty Circuit with a Circuit
Tester
Diagnose Sensors and Actuators with the
Tester
• Normal meter display
• Abnormal meter display
• Check in the meter's service mode. Checking for Breaks in Wiring
• Test related circuits with a circuit tester. Specify any faulty circuits in a harness.
• Judge sensors and actuators as normal or abnormal.
5
Final Operation Check
• Clear the history display after completing repairs. After clearing the history and thoroughly checking operations, check for a history display again.
RY9212038ELS0015US0
4-S51
KiSC issued 08, 2015 A
KX080-4, WSM
ELECTRICAL SYSTEM
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.
RY9212038ELS0016US0
1. General (not waterproof) connectors
• Insert the test lead from the harness side. Female terminals are particularly prone to damage so always insert the test leads from the harness side.
• ECU connector terminal pins are extremely small, so do not try and force a test lead in; use the special tool.
2. Waterproof connectors
• If you try to test the circuit when it is in a closed state and force the test leads in from the harness side, it will reduce the effectiveness of its waterproofing, leading to corrosion, so never do this.
• When testing a male pin, touch the test lead directly to the pin. In this situation, be very careful not to short circuit across connector terminals.
3. Special tools
• When the connector pin holes are smaller than the test leads, use thin wires.
(A) Correct Example
(B) Incorrect Example
(C) Using a Special Tool
(a) Measuring Harness
(b) 600 to 700 mm (23.7 to 27.5 in.)
(c) 10 mm (0.39 in.)
(d) 0.6 mm (0.02 in.)
(e) Clip
(f) Tape
RY9212038ELS0017US0
4-S52
KiSC issued 08, 2015 A
KX080-4, WSM
ELECTRICAL SYSTEM
[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.
2. Check the level of the engine oil.
3. Check whether or not the warning lamp
(a)
on the panel is blinking red.
4. Check whether the oil lamp
(b)
is lit in red or off.
[Reason error screen displayed]
• Engine oil pressure low
• Oil switch always ON
• Short in harness
(1) Engine Oil
Press Err
Stop Engine
(a) Warning Lamp
(b) Oil Lamp
RY9212148ELS0072US0
[Test Conditions]
1. Key switch : ON
(a)
If the oil lamp is lit : caused by a short
(b)
If the oil lamp is off : caused by break in wiring
RY9212148ELS0073US0
2. Reading the failure history
1. Select the failure history read mode.
2. Read the failure history and check the date (y/m/d) and hour meter of the last occurrence.
Ex.) The last failure record was February 6, 2009 at 37 hours.
(a) Failure
(b) Number of Failure
(c) The Last Breakdown Date (y/m/d) and Hour Meter.
RY9212032ELS0001US0
3. Tester mode
1. Select the tester mode.
2. Check the operation of the oil switch according to the table below.
Key Off
Key On
Key Start
Regular
Oil
Lamp
Off
Lit
Off
When cut off
Oil
Lamp
Off
Off
Off
When shorted
Oil
Lamp
Off
Lit
Lit
(1) Engine Speed
Battery V
Oil SW
Charging
Starter
4-S53
RY9212148ELS0074US0
KiSC issued 08, 2015 A
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.
Pull on the harness and make sure the connector/harness does not come off. (pull with a max of 3 kgf (30 N, 7 lbf) of force) If it comes off, plug the connector back in securely and check the operation of the oil switch again in the tester mode.
RY9212148ELS0075US0
2. Causes when a short
[Test Conditions]
1. Key switch : OFF
2. The oil switch wire is pinched against or touching the body.
If the insulation is damaged, repair it properly and check the operation of the oil switch again in the tester mode.
RY9212148ELS0076US0
[C] Testing with a Circuit Tester
(a) Meter panel connector (b) Engine (solenoid) connector
(c) Main (solenoid) connector (d) Engine oil pressure switch connector
• If connectors
(b) (c)
are removed, the engine will start but the machine will not operate.
RY9212148ELS0145US0
1. Voltage check
[Measurement Conditions]
1. Disconnect the engine oil pressure switch connector.
2. Key switch: ON
3. Measure the voltage based on the table below.
Measurement
(1)
Connector Name (+ terminal side)
Engine oil pressure switch
Pin No.
<1>
Connector Name (- terminal side)
Body GND
Pin No.
–
Regular: 12V
Irregular: Large discrepancy from 12V
RY9212148ELS0146US0
4-S54
KiSC issued 08, 2015 A
KX080-4, WSM
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.
Measurement
(1)
(2)
Connector Name (+ terminal side)
Engine oil pressure switch
Engine (solenoid)
Regular: Continuity
Irregular: No continuity
Pin No.
<1>
<3>
Connector Name (- terminal side)
Main (solenoid)
Meter panel
ELECTRICAL SYSTEM
Pin No.
<3>
<9>
RY9212148ELS0147US0
[D] Testing the Equipment Itself
1. Measuring engine pressure
[Measurement Conditions]
1. Remove the engine oil switch, attach a pressure gauge and measure the pressure.
Engine Oil Pressure
At idle
At Rated
RPM
Usage limit
Factory specification
Usage limit
50 kPa
0.51 kgf/cm
2
7.25 psi
200 to 390 kPa
2.04 to 3.98 kgf/cm
2
29.01 to 56.56 psi
150 kPa
1.53 kgf/cm
2
21.76 psi
Tightening torque
Oil switch tapering screw
R1/8
15 to 19 N·m
1.5 to 1.9 kgf·m
11.1 to 14.0 lbf·ft
RY9212148ELS0077US0
[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.
(1) No Fail Record
RY9212148ELS0148US0
4-S55
KiSC issued 08, 2015 A
KX080-4, WSM
[A] Checking the Meter Panel
ELECTRICAL SYSTEM
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.
[Reason error screen displayed]
• Alternator faulty
• Fan belt loose/off
• Break in the harness
• Fuse blown (10A)
(1) Charging Sys Err
(a) Warning Lamp
(b) Charging Lamp
RY9212148ELS0078US0
[Test Conditions]
1. Key switch : ON
(a)
If the charging lamp is lit : caused by a short
(b)
If the charging lamp is off : caused by break in wiring
RY9212148ELS0079US0
2. Reading the failure history
1. Select the failure history read mode.
2. Read the failure history and check the date (y/m/d) and hour meter of the last occurrence.
Ex.) The last failure record was February 6, 2009 at 37 hours.
(a) Failure
(b) Number of Failure
(c) The Last Breakdown Date (y/m/d) and Hour Meter.
RY9212032ELS0001US0
3. Tester mode
1. Select the tester mode.
2. Check the operation of the charge according to the table below.
Regular
Charge
When cut off
Charge
When shorted
Charge
Key Off
Key On
Key Start
Off
Lit
Off
Off
Off
Off
Off
Lit
Lit
(1) Engine Speed
Battery V
Oil SW
Charging
Starter
RY9212148ELS0080US0
4-S56
KiSC issued 08, 2015 A
KX080-4, WSM
ELECTRICAL SYSTEM
[B] Inspecting each Device Visually and Physically
1. Checking fuses
Check whether the alternator fuse (10A) is blown.
RY9212001ELS0064US0
[C] Testing with a Circuit Tester
2. Causes when a break in wiring
[Test Conditions]
1. Key switch : OFF
2. The alternator connector is disconnected.
3. There is a break somewhere in the wiring.
Pull on the harness and make sure the connector/harness does not come off. (pull with a max of 3 kgf (30 N, 7 lbf) of force) If it comes off, plug the connector back in securely and check the operation of the charging switch again in the tester mode.
RY9212148ELS0081US0
3. Causes when a short
[Test Conditions]
1. Key switch : OFF
2. The alternator connector wire is pinched against or touching the body.
If the insulation is damaged, repair it properly and check the operation of the charging switch again in the tester mode.
RY9212148ELS0082US0
(a) Meter panel connector (b) Engine (open) connector (c) Main (open) connector
• If connectors
(b) (c)
are removed, the engine will not start.
(d) Alternator connector
RY9212148ELS0149US0
4-S57
KiSC issued 08, 2015 A
KX080-4, WSM
1. Voltage check
[Measurement Conditions]
1. Disconnect the alternator connector.
2. Key switch: ON
3. Measure the voltage based on the table below.
Measurement
(1)
(2)
Connector Name (+ terminal side)
Alternator
Alternator
Regular: 12V
Irregular: Large discrepancy from 12V
Pin No.
<1>
<2>
2. Continuity check
[Measurement Conditions]
1. Key switch: OFF
2. Disconnect the connector and fuse to be tested.
3. Test the continuity based on the table below.
Measurement
(1)
(2)
(3)
(4)
Connector Name (+ terminal side)
Alternator
Alternator
Engine (open)
Engine (open)
Regular: Continuity
Irregular: No continuity
Pin No.
<1>
<2>
<4>
<8>
[D] Testing the Equipment Itself
ELECTRICAL SYSTEM
Connector Name (- terminal side)
Body GND
Body GND
Connector Name (- terminal side)
Main (open)
Main (open)
10 A fuse
Meter panel
Pin No.
–
–
RY9212148ELS0150US0
Pin No.
<4>
<8>
–
<10>
RY9212148ELS0151US0
1. Inspecting the alternator
1. Check for a cut, loose or slipping fan belt.
2. Measure the voltage between terminal B of the alternator and body GND. If the measured voltage is about 12V, it is normal. If the measured voltage is low, it may indicate insufficient battery capacity or looseness in connections somewhere before the alternator.
3. Next, start the engine and measure the voltage generated when the alternator is operating. Take the measurement between terminal B on the alternator side and the body GND. If the measured voltage is about 14V, it is normal. If the measured voltage does not vary from the battery voltage (about 12V), then the alternator itself or the regulator is faulty.
(A) Displacement 12 to 15 mm
(0.47 to 0.59 in.)
RY9212148ELS0083US0
4-S58
KiSC issued 08, 2015 A
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.
(1) No Fail Record
RY9212148ELS0148US0
4-S59
KiSC issued 08, 2015 A
KX080-4, WSM
[A] Checking the Meter Panel
ELECTRICAL SYSTEM
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
• Break in the harness
(1) Fuel Sensor Err
(a) Warning Lamp
RY9212148ELS0084US0
[Test Conditions]
1. Key switch : ON
(a)
If the fuel level is at the top : caused by a short
(b)
If the fuel level is blank : caused by a break
RY9212148ELS0085US0
2. Reading the failure history
1. Select the failure history read mode.
2. Read the failure history and check the date (y/m/d) and hour meter of the last occurrence.
Ex.) The last failure record was February 6, 2009 at 37 hours.
(a) Failure
(b) Number of Failure
(c) The Last Breakdown Date (y/m/d) and Hour Meter.
RY9212032ELS0001US0
3. Tester mode
1. Select the tester mode.
2. Start the engine.
3. Check the display for the voltage and resistance of the fuel based on the following table.
When cut off
When shorted
Fuel voltage
5.00 V
0.00 V
Resistance
218 Ω
0 Ω
(1) Water Temp.
Fuel
Refueling SW
RY9212148ELS0086US0
4-S60
KiSC issued 08, 2015 A
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. (pull with a max of 3 kgf (30 N, 7 lbf) of force) If it comes off, plug the connector back in securely and check the voltage and resistance for the fuel again in the tester mode.
RY9212148ELS0087US0
2. Causes when a short
[Test Conditions]
1. Key switch : OFF
2. The fuel sensor wire is pinched against or touching the body.
If the insulation is damaged, repair it properly and check the voltage and resistance for the fuel again in the tester mode.
RY9212148ELS0088US0
[C] Testing with a Circuit Tester
(a) Sensor, fuel connector
(b) Engine (fuel sensor) connector
(c) Fuel sensor connector
(d) Main (signal) connector
(e) Engine (signal) connector (f) Meter panel connector
• If connectors
(d) (e)
are removed, the engine will crank but not start.
Further, "CAN comm error" and "fuel sensor error" are displayed on the meter panel.
RY9212148ELS0152US0
4-S61
KiSC issued 08, 2015 A
KX080-4, WSM
1. Voltage check
[Measurement Conditions]
1. Disconnect the fuel sensor connector.
2. Key switch: ON
3. Measure the voltage based on the table below.
Measurement
(1)
(2)
Connector Name (+ terminal side)
Sensor, Fuel
Sensor, Fuel
Regular: 12V
Irregular: Large discrepancy from 12V
Pin No.
<1>
<1>
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.
(3)
(4)
(5)
(6)
Measurement
(1)
(2)
Connector Name (+ terminal side)
Sensor, Fuel
Sensor, Fuel
Fuel sensor
Fuel sensor
Engine (signal)
Engine (signal)
Regular: Continuity
Irregular: No continuity
Pin No.
<1>
<2>
<1>
<2>
<4>
<8>
[D] Testing the Equipment Itself
ELECTRICAL SYSTEM
Connector Name (- terminal side)
Sensor, Fuel
Body GND
Connector Name (- terminal side)
Engine (fuel sensor)
Engine (fuel sensor)
Main (signal)
Main (signal)
Meter panel
Body GND
Pin No.
<2>
–
RY9212148ELS0153US0
Pin No.
<1>
<2>
<4>
<8>
<1>
–
RY9212148ELS0154US0
1. Inspecting the fuel sensor
[Measurement Conditions]
1. Key switch : OFF
2. Disconnect the connector from the fuel sensor and take measurements.
3. Refer to the following table for the resistance at different float positions.
Factory Spec
Float position
Resistance value ( Ω )
(a) Full
(b) Half
F (a)
5 ≥
(c) Empty
1/2 (b)
42.19
E (c)
101.0 ≤
RY9212148ELS0089US0
4-S62
KiSC issued 08, 2015 A
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.
(1) No Fail Record
RY9212148ELS0148US0
[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.
Ex.) Lever lock solenoid
[Reason error screen displayed]
• Lever lock solenoid line short
(1) Lever Lock Sys Err
(a) Warning Lamp
(b) Info Button
RY9212148ELS0090US0
2. Reading the failure history
1. Select the failure history read mode.
2. Read the failure history and check the date (y/m/d) and hour meter of the last occurrence.
Ex.) The last failure record was February 6, 2009 at 37 hours.
(a) Failure
(b) Number of Failure
(c) The Last Breakdown Date (y/m/d) and Hour Meter.
RY9212032ELS0001US0
4-S63
KiSC issued 08, 2015 A
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.
Regular
Warning lamp
When cut off
Warning lamp
When shorte d
Warning lamp
Lever lock switch ON
Lever lock switch OFF
Lever lock solenoid ON
Lever lock solenoid OFF
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
(1) 2 Speed SW
2 Speed SOL
Lever Lock SW
Lever Lock SOL
Hydoil
(c) Unlock
(d) Lock
(e) Machinery Operation Lever Lock
RY9212148ELS0091US0
[B] Inspecting each Device Visually and Physically
1. Checking fuses
1. Check whether the 5A lever lock fuse is blown.
RY9212001ELS0088US0
2. Causes when a break in wiring
[Test Conditions]
1. Key switch : OFF
2. The lever lock switch connector is disconnected.
3. The lever lock solenoid connector is disconnected.
4. There is a break somewhere in the wiring.
Pull on the harness and make sure the connector/harness does not come off. (pull with a max of 3 kgf (30 N, 7 lbf) of force) If it comes off, plug the connector back in securely and check the lever lock switch and lever lock solenoid in the tester mode.
(a) Lever Lock Solenoid Connector (b) Lever Lock Switch Connector
RY9212148ELS0092US0
4-S64
KiSC issued 08, 2015 A
KX080-4, WSM
[C] Testing with a Circuit Tester
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.
RY9212148ELS0093US0
(a) Main ECU connector
(b) Lever lock switch connector
(c) Engine (solenoid) connector
(d) Main (solenoid) connector (e) Lever lock solenoid connector
• If connectors
(c) (d)
are removed, the engine will start but the machine cannot be operated.
RY9212148ELS0155US0
1. Voltage check
[Measurement Conditions]
1. Disconnect the connector to be tested.
2. Key switch: ON
3. Measure the voltage based on the table below.
Measurement
(1)
(2)
Connector Name (+ terminal side)
Lever lock switch
Lever lock switch
Pin No.
<2>
<2>
Connector Name (- terminal side)
Lever lock switch
Body GND
(3)
(4)
Lever lock solenoid
Lever lock solenoid
<1>
<1>
Lever lock solenoid
Body GND
• To check the solenoid line, put the control lever lock in the [Unlock] position.
Regular: 12V
Irregular: Large discrepancy from 12V
Pin No.
<1>
–
<2>
–
RY9212148ELS0156US0
4-S65
KiSC issued 08, 2015 A
KX080-4, WSM
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.
Measurement
(1)
(2)
(3)
(4)
(5)
(6)
Connector Name (+ terminal side)
5A fuse
Lever lock switch connector
Lever lock switch
Main ECU
Main (solenoid)
Main (solenoid)
Regular: Continuity
Irregular: No continuity
[D] Testing the Equipment Itself
Pin No.
–
<1>
<1>
<62>
<8>
<12>
Connector Name (- terminal side)
Lever lock switch
Engine (solenoid)
Main ECU
Engine (solenoid)
Lever lock solenoid
Lever lock solenoid
ELECTRICAL SYSTEM
Pin No.
<2>
<8>
<67>
<12>
<1>
<2>
RY9212148ELS0157US0
1. Inspecting the lever lock switch
[Test Conditions]
1. Key switch: OFF
2. Disconnect the lever lock switch connector from the machine and press the switch and check for continuity.
Regular: Continuity
Irregular: No continuity
(a) Lever lock switch
(b) Lever lock switch Connector
(c) Lever lock switch Connector terminals
RY9212148ELS0094US0
2. Testing the lever lock solenoid
[Test Conditions]
1. Key switch : OFF
2. Disconnect lever lock solenoid connector from the machine and test the solenoid separately.
Lever lock solenoid Factory specification 12 Ω ±10 %
(a) Lever Lock Solenoid Terminals
RY9212148ELS0095US0
[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.
(1) No Fail Record
RY9212148ELS0148US0
4-S66
KiSC issued 08, 2015 A
KX080-4, WSM
ELECTRICAL SYSTEM
[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.
Ex.) 2-speed solenoid
[Reason error screen displayed]
• 2-speed solenoid line short
(1) Travel2 Speed Sys Err
(a) Warning Lamp
(b) Info Button
RY9212148ELS0096US0
2. Reading the failure history
1. Select the failure history read mode.
2. Read the failure history and check the date (y/m/d) and hour meter of the last occurrence.
Ex.) The last failure record was February 6, 2009 at 37 hours.
(a) Failure
(b) Number of Failure
(c) The Last Breakdown Date (y/m/d) and Hour Meter.
RY9212032ELS0001US0
3. Tester mode
1. Select the tester mode.
2. Start the engine.
3. Put the machinery operation lever lock in the [Unlock] position and press the 2-speed switch.
4. Operate the 2-speed switch and check the 2-speed switch and
2-speed solenoid based on the following table.
Regular
2- speed lamp
When cut off
2- speed lamp
When shorte d
2- speed lamp
2-speed switch
ON
2-speed switch
OFF
2-speed solenoid ON
2-speed solenoid OFF
Lit
Off
Lit
Off
Lit
Off
Lit
Off
Off
Off
Off
Off
(1) 2 Speed SW
2 Speed SOL
Lever Lock SW
Lever Lock SOL
Hydoil
(2) 2-Speed Switch
(a) Angle Blade Version
(b) Standard Version
RY9212148ELS0097US0
4-S67
KiSC issued 08, 2015 A
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.
Pull on the harness and make sure the connector/harness does not come off. (pull with a max of 3 kgf (30 N, 7 lbf) of force) If it comes off, plug the connector back in securely and check the
2-speed solenoid and the 2-speed switch in the tester mode.
(a) 2-Speed Solenoid Connector (b) 2-Speed Switch Connector
RY9212148ELS0098US0
2. Causes when a short
[Test Conditions]
1. Key switch : OFF
2. The wiring of the 2-speed solenoid connector and/or the
2-speed switch connector are pinched against or touching the body
If the insulation is damaged, repair it properly and check the
2-speed solenoid and the 2-speed switch again in the tester mode.
RY9212148ELS0099US0
4-S68
KiSC issued 08, 2015 A
KX080-4, WSM
[C] Testing with a Circuit Tester
ELECTRICAL SYSTEM
(a) Main ECU connector
(b) 2-speed switch connector
(c) Engine (solenoid) connector
(d) Main (solenoid) connector
(e) 2-speed solenoid connector A : Angle Specification
B : Standard Spec
• If connectors
(c) (d)
are removed, the engine will start but the machine will not operate.
RY9212148ELS0158US0
1. Voltage check
[Measurement Conditions]
1. Disconnect the connector to be tested.
2. Key switch: ON
3. Measure the voltage based on the table below.
Measurement
(1)
(2)
(3)
Connector Name (+ terminal side)
2-speed switch
2-speed switch
2-speed solenoid
Pin No.
<1>
<1>
<1>
Connector Name (- terminal side)
2-speed switch
Body GND
2-speed solenoid
Pin No.
<2>
–
<2>
(4) 2-speed solenoid <1> Body GND –
• To check the solenoid line, put the machinery operation lever lock in the [Unlock] position and press the 2-speed switch.
Regular: 12V
Irregular: Large discrepancy from 12V
RY9212148ELS0159US0
4-S69
KiSC issued 08, 2015 A
KX080-4, WSM
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.
Measurement
(1)
(2)
(3)
(4)
Connector Name (+ terminal side)
2-speed switch
2-speed switch
Main ECU
Main (solenoid)
Regular: Continuity
Irregular: No continuity
[D] Testing the Equipment Itself
Pin No.
<2>
<1>
<81>
<4>
Connector Name (- terminal side)
Main ECU
Main ECU
Engine (solenoid)
2-speed solenoid
ELECTRICAL SYSTEM
Pin No.
<57>
<41>
<4>
<1>
RY9212148ELS0160US0
1. Testing the 2-speed switch
[Test Conditions]
1. Key switch: OFF
2. Disconnect the 2-speed switch connector from the machine and press the switch and check for continuity.
Regular: Continuity
Irregular: No continuity
(a) 2-speed switch A : Angle Specification
B : Standard Specification
RY9212148ELS0100US0
2. Testing the 2-speed solenoid
[Test Conditions]
1. Key switch : OFF
2. Disconnect 2-speed solenoid connector from the machine and test the solenoid separately.
2-speed solenoid Factory specification 12 Ω ±10 %
(a) 2-Speed Solenoid Terminals
RY9212148ELS0101US0
[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.
(1) No Fail Record
RY9212148ELS0148US0
4-S70
KiSC issued 08, 2015 A
KX080-4, WSM
[A] Checking the Meter Panel
ELECTRICAL SYSTEM
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.
Ex.)
• Angle right solenoid
• Angle left solenoid
[Reason error screen displayed]
• Short in solenoid line
(1) Angle Sys Err
(a) Warning lamp
(b) Info button
RY9212158ELS0011US0
2. Reading the failure history
1. Select the failure history read mode.
2. Read the failure history and check the date (y/m/d) and hour meter of the last occurrence.
Ex.) The last failure record was February 6, 2009 at 37 hours.
(a) Failure
(b) Number of Failure
(c) The Last Breakdown Date (y/m/d) and Hour Meter.
RY9212032ELS0001US0
3. Tester mode
1. Select the tester mode.
2. Start the engine.
3. Put the machine's lever lock in the release position and operate the angle control.
4. Check the angle operation.
(1) Angle R SW
Angle L SW
Angle R SOL
Angle L SOL
[B] Inspecting each Device Visually and Physically
1. Causes when a break in wiring
[Test Conditions]
1. Key switch: OFF
2. Angle solenoid connector disconnected.
3. There is a break somewhere in the wiring.
RY9212158ELS0012US0
Pull on the harness and make sure the connector/harness does not come off. (pull w/3kgf or less force)
If it comes off, plug the connector back in and check the angle solenoid again in the tester mode.
(a) Left angle solenoid valve (b) Right angle solenoid valve
RY9212158ELS0006US0
4-S71
KiSC issued 08, 2015 A
KX080-4, WSM
[C] Testing with a Circuit Tester
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.
RY9212158ELS0007US0
1. Voltage check
[Measurement Conditions]
1. Disconnect the angle solenoid connector.
2. Key switch: ON
3. Put the machinery operation lever lock in the [Unlock] position and press the angle control button.
4. Check the voltage based on the table below.
Measurement
(1)
(2)
Connector Name
(+ terminal side)
Left angle solenoid
Right angle solenoid
Pin No.
<1>
<1>
Connector Name
(- terminal side)
Body GND
Body GND
Pin No.
–
–
Regular: 12V
Irregular: Large discrepancy from 12V
(a) Left angle solenoid connector
(b) Right angle solenoid connector
(c) Main ECU connector
RY9212158ELS0013US0
[D] Testing the Equipment Itself
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.
Measurement
(1)
(2)
Connector Name
(+ terminal side)
Left angle solenoid
Right angle solenoid
Regular: Continuity
Irregular: No continuity
Pin No.
<1>
<1>
Connector Name
(- terminal side)
Main ECU
Main ECU
Pin No.
<20>
<18>
RY9212158ELS0014US0
1. Test the angle solenoid
[Test Conditions]
1. Key switch: OFF
2. Disconnect the angle solenoid connector from the machine and test the solenoid independently.
Angle solenoid Factory specification 12 Ω ± 10 %
(a) Angle solenoid terminals
RY9212158ELS0015US0
4-S72
KiSC issued 08, 2015 A
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.
(1) No Fail Record
RY9212148ELS0148US0
4-S73
KiSC issued 08, 2015 A
KX080-4, WSM
ELECTRICAL SYSTEM
[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.
Ex.)Accelerator sensor
[Reason error screen displayed]
• AI console connector disconnected
• Break or short in harness
(1) AI Sys Err
(a) Warning Lamp
(b) Info Button
RY9212148ELS0104US0
2. Reading the failure history
1. Select the failure history read mode.
2. Read the failure history and check the date (y/m/d) and hour meter of the last occurrence.
Ex.) The last failure record was February 6, 2009 at 37 hours.
(a) Failure
(b) Number of Failure
(c) The Last Breakdown Date (y/m/d) and Hour Meter.
RY9212032ELS0001US0
3. Tester mode
1. Select the tester mode.
2. Start the engine.
3. Turn the accelerator dial to the right (hi-speed) and to the left
(lo-speed) and check the accelerator POT voltage based on the following table.
Design
Value
Accelerator
POT
Regular When cut off
When shorted
Idling
MAX
Approx.
1.50 V
Approx.
3.30 V
0.01 V
0.01 V
Voltage fails to stabilize
(1) Accel POT
Governor POT
Motor Current
(b) Slow
(c) Fast
RY9212148ELS0105US0
4-S74
KiSC issued 08, 2015 A
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. (pull with a max of 3 kgf (30 N, 7 lbf) of force) If it comes off, plug the connector back in securely, turn the accelerator dial to the right (hi-speed) and the left (lo-speed) and check the voltage of the accelerator sensor again in the tester mode.
RY9212148ELS0106US0
2. Causes when a short
[Test Conditions]
1. Key switch : OFF
2. The wiring of the AI console connector is pinched against or touching the body.
If the insulation is damaged, repair it properly, turn the accelerator dial to the right (hi-speed) and the left (lo-speed) and check the voltage of the accelerator sensor again in the tester mode.
RY9212148ELS0107US0
[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.
Measurement
(1)
(2)
Connector Name
(+ terminal side)
AI console
AI console
Pin No.
<8>
<8>
Connector Name
(- terminal side)
AI console
Body GND
Pin No.
<4>
–
Regular: 5V
Irregular: Large discrepancy from 5V
(a) Main ECU Connector (b) AI console Connector
RY9212148ELS0168US0
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.
Measurement
(1)
(2)
(3)
Connector Name
(+ terminal side)
AI console
AI console
AI console
Pin No.
<7>
<8>
<4>
Connector Name
(- terminal side)
Main ECU
Main ECU
Main ECU
Regular: Continuity
Irregular: No continuity
Pin No.
<7>
<11>
<10>
RY9212148ELS0169US0
4-S75
KiSC issued 08, 2015 A
KX080-4, WSM
[D] Testing the Equipment Itself
ELECTRICAL SYSTEM
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
Accelerator sensor 4 to 8
Accelerator sensor 7 to 8
Accelerator sensor 4 to 7
Min.
1 k Ω ± 10 %
720 Ω
380 Ω
Max.
1 k Ω ± 10 %
380 Ω
720 Ω
(a) Accelerator Dial Terminal
Numbers
RY9212148ELS0108US0
2. Settings after replacing device
1. Make AI settings.
(1) AI Set
AUX Set
AUX2/Thumb Set
RY9212148ELS0109US0
[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.
(1) No Fail Record
RY9212148ELS0148US0
4-S76
KiSC issued 08, 2015 A
KX080-4, WSM
ELECTRICAL SYSTEM
[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.
Regular When cut off When shorted
Operating
Not operating
(1) AI Press SW
AI operation SW
Compressor
Water Temp.
Idling Up Set
RY9212148ELS0110US0
[B] Inspecting each Device Visually and Physically
1. Causes when a break in wiring
[Test Conditions]
1. Key switch : OFF
2. The AI pressure switch connector is disconnected.
3. There is a break somewhere in the wiring.
Pull on the harness and make sure the connector/harness does not come off. (pull with a max of 3 kgf (30 N, 7 lbf) of force) If it comes off, plug the connector back in securely and check the operation of the auto-idle switch again in the tester mode.
RY9212148ELS0111US0
2. Causes when a short
[Test Conditions]
1. Key switch : OFF
2. The wire of the auto-idle pressure switch connector is pinched against or touching the body.
If the insulation is damaged, repair it properly and check the operation of the auto-idle switch again in the tester mode.
RY9212148ELS0112US0
4-S77
KiSC issued 08, 2015 A
KX080-4, WSM
[C] Testing with a Circuit Tester
ELECTRICAL SYSTEM
(a) AI pressure switch connector
(b) Main (signal) connector (c) Engine (signal) connector (d) Main ECU connector
• If connectors
(b) (c)
are removed, the engine will crank but not start.
Further, "CAN comm error" and "fuel sensor error" are displayed on the meter panel.
RY9212148ELS0170US0
1. Voltage check
[Measurement Conditions]
1. Disconnect the AI pressure switch connector.
2. Key switch: ON
3. Measure the voltage based on the table below.
Measurement
(1)
(2)
Connector Name (+ terminal side)
AI pressure switch
AI pressure switch
Regular: 12V
Irregular: Large discrepancy from 12V
Pin No.
<1>
<1>
Connector Name (- terminal side)
AI pressure switch
Body GND
Pin No.
<2>
–
RY9212148ELS0171US0
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.
Measurement
(1)
(2)
(3)
(4)
Connector Name (+ terminal side)
AI pressure switch
AI pressure switch
Engine (signal)
Engine (signal)
Regular: Continuity
Irregular: No continuity
Pin No.
<1>
<2>
<3>
<7>
Connector Name (- terminal side)
Main (signal)
Main (signal)
Main ECU
Main ECU
Pin No.
<3>
<7>
<76>
<50>
RY9212148ELS0172US0
4-S78
KiSC issued 08, 2015 A
KX080-4, WSM
[D] Testing the Equipment Itself
ELECTRICAL SYSTEM
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.
When operating: No continuity
When not operating: Continuity
The AI switch is normally closed (normally ON)
RY9212148ELS0173US0
2. Settings after replacing device
1. Make AI settings.
(1) AI Set
AUX Set
AUX2/Thumb Set
RY9212148ELS0205US0
[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.
(1) No Fail Record
RY9212148ELS0148US0
4-S79
KiSC issued 08, 2015 A
KX080-4, WSM
[A] Checking the Meter Panel
ELECTRICAL SYSTEM
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.
Regular: lamp lights
Irregular: lamp off
(a) AI switch (b) AI Lamp
RY9212148ELS0113US0
2. Tester mode
1. Select the tester mode.
2. Check the operation of the AI switch according to the table below.
Regular When cut off When shorted
With AI SW pressed
With AI SW released
(1) AI Press SW
AI operation SW
Compressor
Water Temp.
Idling Up Set
[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.
RY9212148ELS0114US0
Pull on the harness and make sure the connector/harness does not come off. (pull with a max of 3 kgf (30 N, 7 lbf) of force) If it comes off, plug the connector back in securely and check the operation of the AI switch again in the tester mode.
RY9212148ELS0115US0
2. Causes when a short
[Test Conditions]
1. Key switch : OFF
2. The wiring of the AI console connector is pinched against or touching the body.
If the insulation is damaged, repair it properly and check the operation of the AI switch again in the tester mode.
RY9212148ELS0116US0
4-S80
KiSC issued 08, 2015 A
KX080-4, WSM
[C] Testing with a Circuit Tester
[D] Testing the Equipment Itself
ELECTRICAL SYSTEM
1. Voltage check
[Measurement Conditions]
1. Disconnect the AI console connector.
2. Key switch: ON
3. Measure the voltage based on the table below.
Measurement
(1)
(2)
Connector Name
(+ terminal side)
AI console
AI console
Pin No.
<2>
<2>
Connector Name
(- terminal side)
AI console
Body GND
Pin No.
<6>
–
Regular: 12V
Irregular: Large discrepancy from 12V
(a) Main ECU connector (b) AI console connector
RY9212148ELS0174US0
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.
Measurement
(1)
(2)
Connector Name
(+ terminal side)
AI console
AI console
Pin No.
<6>
<2>
Connector Name
(- terminal side)
Main ECU
Main ECU
Regular: Continuity
Irregular: No continuity
Pin No.
<75>
<76>
RY9212148ELS0175US0
1. Testing the AI switch
[Measurement Conditions]
1. Key switch: OFF
2. Remove the AI console from the machine and replace with a new AI console.
3. Select the tester mode and check the operation of the AI switch.
Criteria
Regular
AI switch released: no continuity
AI switch pressed: continuity
Irregular Other than above
RY9212148ELS0117US0
2. Settings after replacing device
1. Make AI settings.
(1) AI Set
AUX Set
AUX2/Thumb Set
RY9212148ELS0118US0
4-S81
KiSC issued 08, 2015 A
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.
(1) No Fail Record
RY9212148ELS0148US0
4-S82
KiSC issued 08, 2015 A
KX080-4, WSM
ELECTRICAL SYSTEM
[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.
Ex.) Antenna
[Reason error screen displayed]
• Anti-theft connector disconnected
• Break in the harness
• Antenna faulty
(1) Ant-theft Sys Err
(a) Warning Lamp
(b) Info Button
RY9212148ELS0119US0
[Test Conditions]
1. Key switch : OFF
2. Check whether the anti-theft indicator is blinking or not.
(a) Anti-Theft Indicator
RY9212001ELS0198US0
2. Reading the failure history
1. Select the failure history read mode.
2. Read the failure history and check the date (y/m/d) and hour meter of the last occurrence.
Ex.) The last failure record was February 6, 2009 at 37 hours.
(a) Failure
(b) Number of Failure
(c) The Last Breakdown Date (y/m/d) and Hour Meter.
RY9212032ELS0001US0
3. Tester mode
1. Select the tester mode.
2. Check the anti-theft antenna.
Regular
Anti-theft antenna
On/off Valid cancel
Red key Black key
–
(1) AT Anten
AT Mode
Key : Red Black
Key : Yellow Green
Tag : Yellow Green
×
×
–
Irregular
–
RY9212032ELS0026US0
4-S83
KiSC issued 08, 2015 A
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. (pull with a max of 3 kgf (30 N, 7 lbf) of force) If it comes off, plug the connector back in securely and check the anti-theft antenna again in the tester mode.
RY9212148ELS0120US0
2. Causes when a short
[Measurement Conditions]
1. Key switch : OFF
2. The anti-theft connector wire is pinched against or touching the body.
If the insulation is damaged, repair it properly and check the operation of the anti-theft antenna again in the tester mode.
(a) Anti-Theft Connector
RY9212148ELS0121US0
[C] Testing with a Circuit Tester
(a) Main ECU (b) Anti-theft connector
1. Voltage check
[Measurement Conditions]
1. Disconnect the anti-theft connector.
2. Key switch: ON
3. Measure the voltage based on the table below.
Measurement
(1)
(2)
(3)
(4)
Connector Name (+ terminal side)
Anti-theft connector
Anti-theft connector
Anti-theft connector
Anti-theft connector
Regular: 12V
Irregular: Large discrepancy from 12V
Pin No.
<5>
<5>
<6>
<6>
RY9212148ELS0206US0
Connector Name (- terminal side)
Anti-theft connector
Body GND
Anti-theft connector
Body GND
Pin No.
<2>
–
<2>
–
RY9212148ELS0122US0
4-S84
KiSC issued 08, 2015 A
KX080-4, WSM
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.
Measurement
(1)
(2)
(3)
(4)
(5)
Connector Name (+ terminal side)
Anti-theft connector
Anti-theft connector
Anti-theft connector
Anti-theft connector
Anti-theft connector
Regular: Continuity
Irregular: No continuity
[D] Testing the Equipment Itself
Pin No.
<1>
<3>
<4>
<5>
<6>
Connector Name (- terminal side)
Main ECU connector
Main ECU connector
Main ECU connector
Main ECU connector
Main ECU connector
ELECTRICAL SYSTEM
Pin No.
<49>
<37>
<51>
<41>
<59>
RY9212148ELS0123US0
1. Inspecting the anti-theft antenna
[Measurement Conditions]
1. Key switch : OFF
2. Replace with a new antenna.
3. Select the tester mode and check the anti-theft antenna.
RY9212001ELS0205US0
[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.
(1) No Fail Record
RY9212148ELS0148US0
4-S85
KiSC issued 08, 2015 A
KX080-4, WSM
ELECTRICAL SYSTEM
[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.
Ex.) Over voltage
[Reason error screen displayed]
• Activated by 18V+
• Alternator faulty
(1) Over voltage Sys Err
(a) Warning Lamp
(b) Info Button
RY9212148ELS0124US0
Check whether the machine has been jump started with a 24 V battery.
Ex.) Whether switched to 24V
(a) 12 V (b) 24 V
RY9212001ELS0207US0
2. Reading the failure history
1. Select the failure history read mode.
2. Read the failure history and check the date (y/m/d) and hour meter of the last occurrence.
Ex.) The last failure record was February 6, 2009 at 37 hours.
(a) Failure
(b) Number of Failure
(c) The Last Breakdown Date (y/m/d) and Hour Meter.
RY9212032ELS0001US0
An alternator recharging error is also possible.
Refer to the pages on the recharging system errors.
RY9212001ELS0209US0
4-S86
KiSC issued 08, 2015 A
KX080-4, WSM
[A] Checking the Meter Panel
ELECTRICAL SYSTEM
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.
Ex.) External 5V
[Reason error screen displayed]
• Short in 5 V line
(1) External 5 V Sys Err
(a) Warning Lamp
(b) Info Button
RY9212148ELS0125US0
2. Reading the failure history
1. Select the failure history read mode.
2. Read the failure history and check the date (y/m/d) and hour meter of the last occurrence.
Ex.) The last failure record was February 6, 2009 at 37 hours.
(a) Failure
(b) Number of Failure
(c) The Last Breakdown Date (y/m/d) and Hour Meter.
RY9212032ELS0001US0
Testing the 3.5V line
(a) Main ECU connector
(b) AI console connector
(c) AUX1 switch connector
(d) AUX2/Thumb switch connector
(e) Travel pressure sensor connector
(f) Boom pressure sensor connector
A : Eur. spec. only
[Test Conditions]
1. Check whether each line is pinched against or touching the body. If the insulation is damaged, repair it properly and check the meter display again.
RY9212148ELS0126US0
4-S87
KiSC issued 08, 2015 A
KX080-4, WSM
ELECTRICAL SYSTEM
[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.
Ex.)
• CAN system (main)
• CAN Sys (CRS)
[Reason error screen displayed]
• ECU connector disconnected
• Fuse blown
• Break or short in harness
• Engine ECU relay faulty
(1) CAN Sys Err
(a) Warning Lamp
(b) Info Button
(c) Oil Lamp
(d) Charging Lamp
RY9212148ELS0127US0
2. Reading the failure history
1. Select the failure history read mode.
2. Read the failure history and check the date (y/m/d) and hour meter of the last occurrence.
Ex.) The last failure record was February 6, 2009 at 37 hours.
(a) Failure
(b) Number of Failure
(c) The Last Breakdown Date (y/m/d) and Hour Meter.
RY9212032ELS0001US0
3. Tester mode
1. Select the tester mode.
2. Confirm the ECU is O.
ECU (main)
ECU (AS)
ECU (CRS)
(1) Meter
ECU (Main)
ECU (AS)
ECU (CRS)
Regular
×
Irregular
×
×
×
RY9212148ELS0128US0
4-S88
KiSC issued 08, 2015 A
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.
3. Check whether the machine's ECU connector is disconnected.
(a) Joint connector
RY9212148ELS0177US0
3. Causes when a short
[Test Conditions]
1. Key switch: OFF
2. The CAN connector wire is pinched against or touching the body.
If the insulation is damaged, repair it properly and check the
ECU (main) again in the tester mode.
(a) CAN communication (2 wires)
RY9212148ELS0129US0
1. Checking fuses
1. Check if the 30A ECU (CRS) slow blow fuse is blown.
RY9212148ELS0178US0
2. Checking relays
1. Replace the engine ECU and condenser motor relays.
After replacing them, check for normal operation.
(a) Engine ECU relay (b) Condenser motor relay
RY9212148ELS0179US0
4-S89
KiSC issued 08, 2015 A
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) (b) Engine ECU
RY9212148ELS0180US0
4-S90
KiSC issued 08, 2015 A
KX080-4, WSM
[C] Testing with a Circuit Tester
ELECTRICAL SYSTEM
(a) Main ECU connector
(b) Meter panel connector
(c) CAN comm connector
(d) Joint connector
(e) Engine (signal) connector
(f) Main (signal) connector
(g) Engine ECU (96 pin) connector
(h) Engine ECU (58 pin) connector
(i) Engine relay
RY9212158ELS0009US0
4-S91
KiSC issued 08, 2015 A
KX080-4, WSM
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.
Measurement
(1)
Connector Name (+ terminal side)
Main ECU
Pin No.
<59>
Regular: 12V
Irregular: Large discrepancy from 12V
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.
Measurement
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Connector Name (+ terminal side)
5A fuse
Main ECU
Main ECU
Joint connector
Joint connector
Joint connector
Joint connector
Regular: Continuity
Irregular: No continuity
Pin No.
–
<60>
<79>
<5>
<8>
<1>
<4>
ELECTRICAL SYSTEM
Connector Name (- terminal side)
Body GND
RY9212148ELS0182US0
Connector Name (- terminal side)
Main ECU
Joint connector
Joint connector
CAN connector
CAN connector
Meter panel
Meter panel
Pin No.
–
Pin No.
<59>
<2>
<3>
<1>
<2>
<6>
<5>
RY9212158ELS0010US0
4-S92
KiSC issued 08, 2015 A
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 ent
(1)
(2)
(3)
Connector Name (+ terminal side)
Main ECU
Main ECU
Main ECU
Regular: 12V
Irregular: Large discrepancy from 12V
Pin No.
<5>
<6>
<33>
Connector Name (- terminal side)
Body GND
Body GND
Body GND
Pin No.
–
–
–
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.
(6)
(7)
(8)
(9)
Meas urem ent
(1)
(2)
(3)
(4)
(5)
Connector Name (+ terminal side)
SBF (CRS) 30A
SBF (CRS) 30A
Engine ECU relay
Engine ECU relay
Engine ECU relay
Joint connector
Joint connector
Main (signal)
Main (signal)
Pin No.
–
–
<5>
<5>
<2>
<6>
<7>
<13>
<9>
Engine ECU relay
Engine ECU relay
Engine ECU
Engine ECU
Engine ECU
Engine (signal)
Engine (signal)
Engine ECU
Engine ECU
RY9212148ELS0184US0
Connector Name (- terminal side) Pin No.
Regular: Continuity
Irregular: No continuity
RY9212148ELS0185US0
[D] 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.
(1) No Fail Record
RY9212148ELS0148US0
<1>
<3>
<5>
<6>
<33>
<9>
<13>
<39>
<38>
4-S93
KiSC issued 08, 2015 A
KX080-4, WSM
ELECTRICAL SYSTEM
[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.
Ex.)
• AUX1/AUX2 (thumb) knob
• AUX1/AUX2 (thumb) right SOL
• AUX1/AUX2 (thumb) left SOL
[Reason error screen displayed]
• AUX1/AUX2 (thumb) control lever connector disconnected
• AUX1/AUX2 (thumb) solenoid connector disconnected
• Break or short in harness
(1) AUX1 Sys Err
(2) AUX2 Sys Err
(a) Warning Lamp
(b) Info Lamp
RY9212148ELS0130US0
2. Reading the failure history
1. Select the failure history read mode.
2. Read the failure history and check the date (y/m/d) and hour meter of the last occurrence.
Ex.) The last failure record was February 6, 2009 at 37 hours.
(a) Failure
(b) Number of Failure
(c) The Last Breakdown Date (y/m/d) and Hour Meter.
RY9212032ELS0001US0
3. Tester mode
1. Select the tester mode.
2. Start the engine.
3. Measure the voltage of AUX switch based on the table below.
Indicated value
Left
(small)
Set value (ex.)
Right
(large)
Center
(medium)
At stop
AUX1 knob switch
AUX2 /
Thumb knob switch
Output current
0.25 to 4.75 V
0.25 to 4.75 V
0.95 V
0.77 V
4.41 V
4.21 V
0.5 to 2.0 A
2.36 V
2.59 V
0 V
0 V
0 to 0.2 A
Regular When cut off When shorted
Press the AUX one way hold SW
Release the AUX one way hold SW
(1) AUX1 Knob
Current
AUX Hold SW
(2) Control Lever (Light)
(3) AUX One Way Hold SW
(4) Control Lever (Left)
(5) AUX One Way Hold SW
(6) AUX2 / Thumb knob
Current
AUX Hold SW
RY9212148ELS0131US0
4-S94
KiSC issued 08, 2015 A
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.
Pull on the harness and make sure the connector/harness does not come off. (Pull with a max of 3kgf of force) If it comes off, plug the connector back in securely and check the AUX1 and 2 solenoids in the tester mode.
(a) AUX1 SOL (b) AUX2 SOL
RY9212148ELS0132US0
[C] Testing with a Circuit Tester
Switch side
2. Causes when a short
[Test Conditions]
1. Key switch: OFF
2. The AUX1, AUX2 solenoid connector and/or AUX control lever connector wiring is pinched and touching the body, or if the insulation is damaged, repair it properly and check the AUX solenoids again in the tester mode.
(c) AUX control lever connector
RY9212148ELS0133US0
(a) Main ECU connector (b) Right control lever connector
(c) Left control lever connector
RY9212148ELS0186US0
4-S95
KiSC issued 08, 2015 A
KX080-4, WSM
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.
Measurement
(1)
(2)
(3)
(4)
Connector Name (+ terminal side)
Right control lever
Right control lever
Left control lever
Left control lever
Regular: 12V
Irregular: Large discrepancy from 12V
Pin No.
<5>
<5>
<5>
<5>
2. Voltage check (AUX1/AUX2 switch)
[Measurement Conditions]
1. Disconnect the AUX1/AUX2 control lever connector.
2. Key switch: ON
3. Test the continuity based on the table below.
Measurement
(1)
(2)
(3)
(4)
Connector Name (+ terminal side)
Right control lever
Right control lever
Left control lever
Left control lever
Pin No.
<1>
<1>
<1>
<1>
Regular: 5V
Irregular: Large discrepancy from 5V
3. Continuity check (AUX hold switch)
[Measurement Conditions]
1. Key switch: OFF
2. Disconnect the connector to be tested.
3. Test the continuity based on the table below.
Measurement
(1)
(2)
(3)
(4)
Connector Name (+ terminal side)
Main ECU
Right control lever
Main ECU
Left control lever
Regular: Continuity
Irregular: No continuity
Pin No.
<41>
<6>
<41>
<6>
ELECTRICAL SYSTEM
Connector Name (- terminal side)
Right control lever
Body GND
Left control lever
Body GND
RY9212148ELS0187US0
Connector Name (- terminal side)
Right control lever
Body GND
Left control lever
Body GND
Pin No.
<2>
–
<2>
–
RY9212148ELS0188US0
Connector Name (- terminal side)
Right control lever
Main ECU
Left control lever
Main ECU
Pin No.
<6>
–
<6>
–
Pin No.
<5>
<69>
<5>
<72>
RY9212148ELS0189US0
4-S96
KiSC issued 08, 2015 A
KX080-4, WSM
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.
Measurement
(1)
(2)
(3)
(4)
(5)
(6)
Connector Name (+ terminal side)
Right control lever
Right control lever
Right control lever
Left control lever
Left control lever
Left control lever
Regular: Continuity
Irregular: No continuity
Solenoid side
Pin No.
<3>
<1>
<2>
<3>
<1>
<2>
ELECTRICAL SYSTEM
Connector Name (- terminal side)
Main ECU
Main ECU
Main ECU
Main ECU
Main ECU
Main ECU
Pin No.
<28>
<11>
<10>
<29>
<11>
<10>
RY9212148ELS0190US0
(a) Main ECU connector
(b) Engine (solenoid) connector
(c) Main (solenoid) connector
(d) AUX1 (R) solenoid connector
(e) AUX1 (L) solenoid connector
(f) AUX2 (R) solenoid connector
(g) AUX2 (L) solenoid connector
• If connectors
(c) (d)
are removed, the engine will start but the machine will not operate.
RY9212148ELS0191US0
4-S97
KiSC issued 08, 2015 A
KX080-4, WSM
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.
Measurement
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Connector Name (+ terminal side)
AUX1 (right) solenoid
AUX1 (right) solenoid
AUX1 (left) solenoid
AUX1 (left) solenoid
Main ECU
Main ECU
Main ECU
Regular: Continuity
Irregular: No continuity
2. Continuity check (AUX2 solenoid)
[Measurement Conditions]
1. Key switch: OFF
2. Disconnect the connector to be tested.
3. Test the continuity based on the table below.
Measurement
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Connector Name (+ terminal side)
AUX2 (right) solenoid
AUX2 (right) solenoid
AUX2 (left) solenoid
AUX2 (left) solenoid
Main ECU
Main ECU
Main ECU
Regular: Continuity
Irregular: No continuity
[D] Testing the Equipment Itself
Pin No.
<1>
<2>
<1>
<2>
<24>
<23>
<19>
Pin No.
<1>
<2>
<1>
<2>
<42>
<43>
<16>
ELECTRICAL SYSTEM
Connector Name (- terminal side)
Main (solenoid)
Main (solenoid)
Main (solenoid)
Main (solenoid)
Engine (solenoid)
Engine (solenoid)
Engine (solenoid)
Main (solenoid)
Main (solenoid)
Main (solenoid)
Main (solenoid)
Engine (solenoid)
Engine (solenoid)
Engine (solenoid)
<2>
<6>
<10>
<6>
<2>
<10>
<6>
<1>
<5>
<9>
<5>
<1>
<9>
<5>
RY9212148ELS0192US0
Connector Name (- terminal side)
Pin No.
Pin No.
RY9212148ELS0193US0
1. Testing the AUX1 / AUX2 solenoid
[Test Conditions]
1. Key switch : OFF
2. Disconnect AUX1 / AUX2 solenoid connector from the machine and test the solenoid separately.
AUX1 / AUX2 solenoid Factory specification
3.2 ± 0.5 Ω
(at 20 °C, 68 °F )
(a) AUX1 / AUX2 Solenoid Terminals
RY9212148ELS0134US0
4-S98
KiSC issued 08, 2015 A
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.
(1) No Fail Record
RY9212148ELS0148US0
4-S99
KiSC issued 08, 2015 A
KX080-4, WSM
[A] Checking the Meter Panel
ELECTRICAL SYSTEM
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.
Ex) EP solenoid travel pressure
[Reason error screen displayed]
• Pressure sensor connector disconnected
• EP solenoid connector disconnected
• Break or short in harness
(1) EP Sys Err
(a) Warning Lamp
(b) Info Button
RY9212148ELS0194US0
2. Reading the failure history
1. Select the failure history read mode.
2. Read the failure history and check the date (y/m/d) and hour meter of the last occurrence.
Ex.) The last failure record was February 6, 2009 at 37 hours.
(a) Failure
(b) Number of Failure
(c) The Last Breakdown Date (y/m/d) and Hour Meter.
RY9212032ELS0001US0
4-S100
KiSC issued 08, 2015 A
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.
5. Put the excavator in travel and check the travel pressure sensor operation.
Regular When cut off When shorted
EP SW ON
EP SW OFF
EP solenoid
Design Value
Travel pressure
(1) Compress
Boom Up SW
EP SW
Pump SOL
(2) 2Speed Press
2Speed Press
DPF SW
Light SW
Stop SW
Mode
P mode
E mode
Regular
Current value
When cut off
0 V
(a) EP Switch
Factory specification
0 to 0.6 A
0.84 to 1.65 A
When shorted
Not stable
RY9212148ELS0195US0
[B] Inspecting each Device Visually and Physically
1. Causes when a break in wiring
[Test Conditions]
1. Key switch: OFF
2. EP solenoid connector disconnected.
3. Travel pressure sensor connector disconnected.
4. There is a break somewhere in the wiring.
Pull on the harness and make sure the connector/harness does not come off. (pull w/3kgf or less force)
If it comes off, plug the connect or back in and check again in the tester mode.
(1) EP solenoid connector
RY9212148ELS0196US0
2. Causes when a short
[Test Conditions]
1. Key switch: OFF
2. The EP solenoid connector and/or travel pressure sensor connector wires are pinched against or touching the body.
If the insulation is damaged, repair it properly and check the EP solenoid and travel pressure sensor again in the tester mode.
(2) Travel pressure sensor connector
RY9212148ELS0197US0
4-S101
KiSC issued 08, 2015 A
KX080-4, WSM
[C] Testing with a Circuit Tester
ELECTRICAL SYSTEM
(a) EP Solenoid Connector (b) Travel Pressure Sensor
Connector
1. Voltage check (EP solenoid)
[Measurement Conditions]
1. Disconnect the EP solenoid connector.
2. Key switch: ON
3. EP switch: ON
4. Measure the voltage based on the table below.
Measurement
(1)
(2)
Connector Name (+ terminal side)
EP solenoid
EP solenoid
Regular: 12V
Irregular: Large discrepancy from 12V
Pin No.
<1>
<1>
2. Continuity check (EP solenoid)
[Measurement Conditions]
1. Key switch: OFF
2. Disconnect the connector to be tested.
3. Test the continuity based on the table below.
Measurement
(1)
(2)
Connector Name (+ terminal side)
EP solenoid
EP solenoid
Regular: Continuity
Irregular: No continuity
Pin No.
<1>
<2>
(c) Main ECU Connector
RY9212148ELS0198US0
Connector Name (- terminal side)
EP solenoid
Body GND
RY9212148ELS0199US0
Connector Name (- terminal side)
Main ECU
Main ECU
Pin No.
<2>
–
Pin No.
<22>
<21>
RY9212148ELS0200US0
4-S102
KiSC issued 08, 2015 A
KX080-4, WSM
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.
Measurement
(1)
(2)
Connector Name (+ terminal side)
Travel pressure sensor
Travel pressure sensor
Regular: 5V
Irregular: Large discrepancy from 5V
Pin No.
<3>
<3>
4. Continuity check (travel pressure sensor)
[Measurement Conditions]
1. Key switch: OFF
2. Disconnect the connector to be tested.
3. Test the continuity based on the table below.
Measurement
(1)
(2)
(3)
Connector Name (+ terminal side)
Travel pressure sensor
Travel pressure sensor
Travel pressure sensor
Regular: Continuity
Irregular: No continuity
Pin No.
<1>
<2>
<3>
[D] Testing the Equipment Itself
ELECTRICAL SYSTEM
Connector Name (- terminal side)
Travel pressure sensor
Body GND
Connector Name (- terminal side)
Main ECU
Main ECU
Main ECU
Pin No.
<1>
–
RY9212148ELS0201US0
Pin No.
<10>
<53>
<11>
RY9212148ELS0202US0
1. Testing the EP solenoid
[Measurement Conditions]
1. Key switch: OFF
2. Disconnect EP solenoid connector from the machine and test the solenoid separately.
EP solenoid Factory specification
3.2 ± 0.5 Ω
[20 °C (68 °F )]
Regular: Within factory spec
Irregular: Outside factory spec.
(a) EP Solenoid Terminal
RY9212148ELS0203US0
2. Testing the pressure sensor
[Measurement Conditions]
1. Key switch: OFF
2. Disconnect the pressure sensor connector from the machine and test the pressure sensor independently.
Load resistance <2> -
<3>
Factory specification
Regular: Within factory spec
Irregular: Outside factory spec.
22 k Ω
RY9212148ELS0204US0
4-S103
KiSC issued 08, 2015 A
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.
(1) No Fail Record
RY9212148ELS0148US0
4-S104
KiSC issued 08, 2015 A
5
KiSC issued 08, 2015 A
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...................................................................................................... 5-M14
(1) Electrical Circuits .......................................................................................................... 5-M14
(2) Relays........................................................................................................................... 5-M15
(3) Blower Switch ............................................................................................................... 5-M16
2. WIPER ...................................................................................................................................... 5-M17
[1] WIPER SWITCH................................................................................................................. 5-M17
[2] WIPER................................................................................................................................ 5-M17
[3] WIPER MOTOR ................................................................................................................. 5-M18
KiSC issued 08, 2015 A
KX080-4, WSM
CABIN
(1) Control panel
(2) External air intake
(3) AC Unit
(4) Compressor
(5) Condenser
(6) Receiver
(7) Heater core
(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. Cabin air and outside air are directed through the AC filter to the AC unit. The cabin or outside air that is sucked into the AC unit is cooled and dehumidified by the cooler of the AC unit. When the system is used for heating, the air is heated by the heater core and then expelled from the air vents. The air vents can be opened and closed and the direction of the airflow can be adjusted.
Cooling capacity
Heating capacity
Type of refrigerant
(charge capacity)
Pressure sensor (low)
Pressure sensor (high)
Factory specification
3.4 kW ± 10 %
4.1 kW ± 10 %
R134a
950 g
2.09 lbs
0.196 MPa
2.0 kgf/cm
2
28.4 psi
3.14 MPa
32.0 kgf/cm
2
455 psi
RY9212148CAM0004US0
5-M1
KiSC issued 08, 2015 A
KX080-4, WSM
CABIN
(1) Capillary Tube (Heat Sensitive
Capillary Tube)
(2) Expansion Valve
(3) Evaporator
(4) Blower Motor
(5) Compressor
(6) Engine Cooling Fan
(7) Condenser
(8) Receiver
(9) Dryer
(10) Pressure Switch
(11) Heater Core
(12) Hot Water Valve
A : Cooled Air
B : Low Pressure and
Temperature Vapor
C, D : Air Passes Through
In / Outside Air Filter
E : High Pressure/Temperature
Gas
F : Hot Air
G : Liquid
This air conditioning system works as follows.
1. Refrigerant passes through the evaporator (3), is vaporized and then is compressed by the compressor (5) to approximately 1.47 MPa (15 kgf/cm
2
, 210 psi) and raised to a temperature of approximately 70 °C (158 °F) the refrigerant is then sent in this state to the condenser (7).
2. The vaporized refrigerant passes through the condenser (7), where it is cooled down to approximately 50 °C
(122 °F) and the refrigerant changes back from a vapor to a liquid; it is then sent on to the receiver (8).
Then the heat from inside the cabin that is captured by the condenser (7) is released outside the cabin.
3. The liquid refrigerant collects in the receiver (8) and any moisture is removed from the refrigerant by the dryer (9).
4. The liquid refrigerant then passes on to the expansion valve (2), where it is sprayed through the small holes in the valve into the evaporator (3), which produces a mist of the refrigerant; its pressure and temperature drop and the refrigerant evaporates.
5. The refrigerant simultaneously captures heat from the surface of the evaporator's (3) pipes and evaporates vigorously at 0 °C (32 °F).
6. As this happens, warm air from inside the cabin is drawn into the evaporator (3) by the blower motor (4) and the refrigerant captures the heat and evaporates. In this way the air in the cabin is cooled.
[NOTE]
• Because the warm air inside the cabin is cooled quickly, the moisture in the air condenses. In other words, the air in the cabin can be dehumidified.
7. The refrigerant vaporized in the evaporator (3) is returned to the compressor (5) and compressed, changing it back into a liquid. In doing so, the refrigerant is put under high pressure and temperature.
8. The air that passed through the evaporator (3) can be adjusted to the desired temperature by then passing it through the heater core (11). Engine coolant is heated by the engine and the amount of the coolant that flows into the heater core (11) is controlled by the hot water valve (12), and this adjusts the temperature of the air that flows through the heater core (11).
RY9212001CAM0002US0
5-M2
KiSC issued 08, 2015 A
KX080-4, WSM
CABIN
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.
The five vanes (3) are attached to the rotor (2) and as it rotates, the tips of the vanes come in contact with the walls of the cylinder (1) and an airtight compression space is maintained both by the centrifugal force exerted by the rotor (2) along with the back pressure on the vanes (3), which is in proportion to the rpms of the rotor
(2).
As a result, the volume changes in each of the five segments of the cylinder, which are divided by the five vanes (3) in the cylinder (1).
Each time that the rotor (2) rotates, each of the five segments of the cylinder goes through two cycles of intake, compression and discharge.
(1) Cylinder
(2) Rotor
(3) Vane
RY9212001CAM0003US0
How it Works
As the rotor (3) turns, the volume of space in a segment, as divided by the cylinder (1) and vanes (4), increases, sucking refrigerant gas from the intake port
(2) into the cylinder space.
As the rotor (3) turns further, the volume of the space created between the cylinder (1) and vanes (4) decreases, compressing the refrigerant gas. As the rotor
(3) continues to turn, the refrigerant gas is compressed further, putting it under a great deal of pressure, pressing on the discharge valve and opening it. The refrigerant gas is then expelled via the discharge port (5).
(1) Cylinder
(2) Intake Port
(3) Rotor
(4) Vane
(5) Discharge Port
(A) Compression Cycle
(B) Discharge Cycle
(C) Intake Cycle
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Compressor Oil
The compressor oil is dissolved in the refrigerant and circulates throughout the entire cooling system acting as the lubricating oil for the compressor. However, because the previously used R12 compressor oil does not dissolve in R134a, it does not circulate through the cooling cycle. So it drastically reduces the working life of the compressor.
As a result, it is imperative that the right compressor oil is always used. The mineral oil that is used in an R12 cooling system cannot be used in an R134a cooling system. A synthetic PAG oil has to be used in an R134a cooling system. This oil mixes extremely well with refrigerant gas and provides the entire system with the optimum lubrication.
Product Name Volume of Oil
110 to 120 cc
0.116 to 0.127 U.S.qts
0.098 to 0.106 lmp.qts
*PAG : Polyalkylene glycol (synthetic oil)
ND–OIL8 <PAG* oil>
RY9212001CAM0005US0
5-M3
KiSC issued 08, 2015 A
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 when the temperature reaches the temperature set with the temperature control switch, or when the cabin gets hot, the clutch works to stop or to drive the compressor, respectively.
The hub of the magnetic clutch is attached to the compressor shaft and when it is not driving the compressor, it is separate from the rotor and just the pulley turns. When the AC switch is turned on, current flows into the stator coil, making the stator into a magnet, which then holds onto the hub and the pulley turns along with the compressor.
(1) Pressure Plate
(2) Ball Bearing
(3) Snap Ring
(4) Pulley
(5) Rotor w/ Pulley
(6) Stator
(7) Snap Ring
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B. Safety Valve
The valve opens when the refrigerant pressure reaches the specified pressure, thus relieving the pressure. When the pressure becomes abnormally high, it overcomes the force of the spring, allowing refrigerant to leak out of the relief port; when the pressure drops the reverse happens--the spring overcomes the pressure and the safety valve closes. When an error occurs, this also keeps the discharge of refrigerant to a minimum.
(1) Safety Valve
(A) Refrigerant Leak Route
(B) Functional Characteristics
(C) Amount of Refrigerant
Leaked
(D) Pressure a : 113 L/min.
(27.2 U.S.gals./min.,
24.86 lmp.gals./min.) b : 2.75 MPa
(28.1 kgf/cm
2
, 399.7 psi) c : 3.43 MPa
(35.0 kgf/cm
2
, 497.8 psi) d : 4.12 MPa
(42.0 kgf/cm
2
, 598.0 psi)
RY9212001CAM0007US0
5-M4
KiSC issued 08, 2015 A
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. The temperature sensor is composed of a bimetallic strip and contacts. A bimetallic strip is a sandwich of two metals with different rates of expansion and it bends when heated due to these different rates of expansion. This characteristic is exploited when there is an excessive temperature via the rod, which breaks the contact and switches the magnetic clutch off.
Operating Ranges
OFF
ON
153 to 163 °C
307 to 325 °F
120 ± 5 °C
248 ± 41 °F
Tightening torque
(1) Temperature Sensor
(2) Compressor
Temperature
Sensor
11.8 ± 1.47 N·m
1.2 ± 0.15 kg·fm
8.7 ± 1.08 lbf·ft
A : Contact
B : Bimetallic Strip
C : Rod
(a) To battery + Terminal
RY9212001CAM0008US0
5-M5
KiSC issued 08, 2015 A
KX080-4, WSM
CABIN
(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.
The air conditioning unit is composed of an evaporator, an expansion valve, a heater core, a blower, etc.
No.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
Upper case
Side cover
Name of part
Lower case
Linkage cover
Intake cover
Evaporator
O-Ring
O-Ring
Expansion valve
No.
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
Name of part
Bolt
Fin thermistor
Clamp
AC Amp
Heater core
Pipe
Hot water valve
Pipe clip
Screw
No.
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
Name of part
O-Ring
Servo motor
Linkage lever
Blower resistor
Self-tapping screw
Self-tapping screw
Cap
Blower motor
Wire harness
RY9212148CAM0001US0
5-M6
KiSC issued 08, 2015 A
KX080-4, WSM
5-M7
CABIN
Evaporator
The evaporator takes the refrigerant, which has been made liquid by the condenser and cooled and put under low-pressure by the expansion valve, and by evaporating it, the heat and humidity of the air passing through the evaporator is removed, thus producing cool, dehumidified air.
(a) Fins
(b) Tubes
(A) Inlet
(B) Outlet
RY9212001CAM0010US0
Heater Core
The heater core dissipates the heat of the heated engine coolant. So, the air that is blown through it by the blower motor passes through the fins of the heater core and the air takes on the heat of the coolant.
(1) Heater Core
(A) Inlet
(B) Outlet
RY9212001CAM0011US0
Blower
The blower is built into the right side of the AC unit.
The blower forces cool, warm or fresh outside air through the vents into the cabin.
The rpm of the blower motor can be adjusted to three levels with the blower resistor. The blower fan is the type that uses centrifugal force and it sucks in air parallel to its axis of rotation and blows it out perpendicular to the centrifugal force, or in other words, perpendicular to the axis of rotation.
Model
Rated Voltage
No load RPM
No load amperage
Direction of rotation
(viewed from drive side)
Rated load torque
RPM
Amperage
Specifications (at 20 °C)
DC Ferrite
12 V
4300 ± 400 rpm
1 to 3 A
Left
461 N·m, 47.0 kgf·m, 340 lbf·ft
2800 ± 280 rpm
18.3 ± 1.8A
(1) Blower
(A) Circuit Diagram
(a) (+) Terminal
(b) (-) Terminal
RY9212001CAM0012US0
KiSC issued 08, 2015 A
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.
(1) MI
(2) HI
(3) LO
(4) Blank
(A) Blower Resistor
(B) Wiring Diagram
RY9212148CAM0006US0
5-M8
KiSC issued 08, 2015 A
KX080-4, WSM
Evaporator outlet temperature
When low (when cooling load is low)
When high (when cooling load is high)
(1) Evaporator
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.
In order to take full advantage of the capabilities of the evaporator, a state must always be maintained in which the liquid refrigerant takes on the ambient heat, then it is completely vaporized at the outlet of the evaporator. In order to do so, the expansion valve automatically adjusts the volume of refrigerant in response to changes in the cabin temperature
(cooling load) and changes in the compressor RPM.
[Structure (box type)]
• The expansion valve is composed of a diaphragm, heat-sensing rod, and a needle valve (ball) and the refrigerant gas is enclosed upstream of the diaphragm. The downstream side of the diaphragm is pressurized by the evaporator outlet pressure.
[How it Works]
• The heat-sensitive rod senses the temperature of the refrigerant passing to the evaporator and the temperature at that point is communicated to the refrigerant gas on the upstream side of the diaphragm via the heat-sensitive rod. As such, the pressure of the gas varies with the temperature, thus moving the heat-sensitive rod directly connected to the diaphragm and adjusting the opening of the needle valve.
Operation
The pressure of the gas in the diaphragm chamber drops, reducing the volume and moving the heat-sensitive rod to the right, which constricts the needle valve and reduces the flow of refrigerant to the evaporator.
The pressure of the gas in the diaphragm chamber rises, increasing the volume and moving the heat-sensitive rod to the left, which opens the needle valve and supplies more refrigerant to the evaporator.
A : Diaphragm
B : Heat-Sensitive Rod
C : Spring
D : Body
E : Needle Valve
(a) From Receiver
(Hi-Pressure)
(b) To Compressor
(Lo-Pressure)
(c) To Evaporator
(d) From Evaporator
RY9212001CAM0014US0
5-M9
KiSC issued 08, 2015 A
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 evaporator's fin temperature and if the resistance inside the sensor exceeds the thermo-amp resistance setting, its internal circuit shuts off the power to the compressor clutch.
Specifications
DC12 V Rated Voltage
Measurement
Conditions
DC13 ±0.2 V at 25 ± 5 °C (77 ± 9 °F)
Temperature
Detection
OFF R1
ON R2
Hysteresis
4383 ±131 Ω (2 °C, 36 °F)
(4095 Ω ) (3.35 °C, 38 °F)
215 ±5.0 Ω (1 °C, 34 °F)
Temperature
Range
Voltage Range
Operating Voltage
Range
Usage Conditions
–30 to 80 °C (–22 to 176 °F)
DC10 to 16 V
DC8 to 16 V (at 25 °C, 77 °F)
Temperature
Detection
Resistance Value
10 °C
/ 50 °F
2.96 k Ω
15 °C
/ 59 °F
2.34 k Ω
20 °C
/ 68 °F
1.87 k Ω
25 °C
/ 77 °F
1.50 k Ω
30 °C
/ 86 °F
1.22 k Ω
(1) Fin Thermistor
(2) Thermo-Amp
(a) Evaporator Fin
Temperature Detector
RY9212001CAM0015US0
Hot Water Valve
The hot water valve is the valve that adjusts the volume of engine coolant that flows into the heater core, and this adjustment changes the temperature of the heater core and thus controls the temperature of air flowing through it.
(a) Open (MAX Hot)
(b) Closed (MAX Cool)
(c) Inlet
(d) Outlet
RY9212001CAM0016US0
5-M10
KiSC issued 08, 2015 A
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. Its potentiometer also uses variable resistance and changes the resistance value according to the operating angle.
The servo motor and the hot water valve are linked via a linkage lever and turning the temperature control dial on the control panel opens/closes the hot water valve and adjusts the temperature of air vented inside the cabin.
Model
Rated Voltage
Rated load torque
RPM
Amperage
Specifications (at 20 °C, 68 °F)
DC Ferrite
12 V
0.3 N·m, 0.03 kgf·m, 0.2 lbf·ft
3.5 to 5.5 rpm
0.02 to 0.10 A
Potentiometer Linearity
Impressed Voltage Terminals
± 3 %
6 (POS.2) 7 (POS.1)
(1) Servo Motor
(2) Linkage Lever
(3) Hot Water Valve
(A) Potentiometer Output
Schematic
(a) Voltage (V)
(b) Operating Angle 60 °
(c) MAXCOOL
(d) MAXHOT
(e) CW
RY9212001CAM0017US0
The hot, compressed refrigerant is under high pressure and in a gaseous state; the condenser cools it and returns it to a liquid state. In the interval between entering and passing through the condenser, the refrigerant is cooled and becomes liquid refrigerant again. At this point, it is necessary to be sure the refrigerant is liquid at the outlet of the condenser. If the refrigerant is not condensed enough in the condenser some refrigerant would be in a gaseous state and that would reduce the AC's cooling efficiency.
(1) Tubes
(2) Fins
(3) Vapor
(4) Vapor/Liquid Mix
(5) Liquid
(a) Gaseous Refrigerant
(b) Liquid Refrigerant
(c) Inlet (70 °C, 158 °F)
(d) Outlet (50 °C, 122 °F)
RY9212001CAM0018US0
5-M11
KiSC issued 08, 2015 A
KX080-4, WSM
CABIN
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. The receiver tank is the part that reacts to those changes; when a lot of refrigerant is not required in the cooling circuit, excess refrigerant is stored temporarily in the tank and when more coolant is needed, it is supplied to the circuit via the receiver tube.
It also acts to store the balance of refrigerant charges and for extra refrigerant to counteract the leak of small amounts of refrigerant, such as via permeation of rubber hoses.
[Dryer]
If any moisture exists in the cooling circuit, it damages the system by deteriorating the valves of the compressor, its oil, by corroding metal parts in the circuit, and/or freezes in the expansion valve and blocks the circuit. The AC system uses synthetic zeolite as a dryer that is compatible with the circuit, and it absorbs any moisture that gets mixed into the circuit during installation or charging of refrigerant.
If the expansion valve freezes up frequently due to moisture (icing), it means the dryer has lost its ability to absorb it, so the receiver has to be replaced.
[Strainer]
If dirt gets into the cooling circuit, it blocks the expansion valve, damages the compressor and otherwise hampers its cooling function. The strainer works to prevent any dirt flowing in the refrigerant from going any further. The strainer cannot be cleaned, so when it becomes severely clogged up, (in which case the high pressure gets high, low pressure gets low), the receiver has to be changed.
[Sight Glass]
The sight glass is mounted at the receiver joint on top of the receiver and it is the only place in the circuit where the amount of refrigerant can be visually inspected.
(1) Dryer
(2) Receiver Tube
(3) Strainer
(4) Receiver Tank
(A) Refrigerant Inlet
(B) Refrigerant Outlet
RY9212001CAM0019US0
5-M12
KiSC issued 08, 2015 A
KX080-4, WSM
CABIN
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. To prevent these kind of problems from occurring, the switch cuts the power to the compressor clutch and stops the compressor.
(A)
Refrigerant pressure
No increase in pressure state
(when abnormally low)
Operation
The refrigerant pressure becomes less than the force of the spring, so the spring presses the plate up and the upper contact opens (OFF).
(B)
(C)
Contact ON
(normal operation)
Contact OFF
(abnormally high pressure)
The refrigerant pressure is greater than the force of the spring, so the pressure plate is pressed down, which presses the upper contact down, closing the contact (ON).
The refrigerant pressure becomes greater than the force of the plate spring and the plate spring pushes down on the pin, which press on the lower contact, opening it
(OFF).
(1) Diaphragm
(2) Plate Spring
(3) Pin
(4) Plate
(5) Contact
(6) Spring
(7) Terminal
a : 0.19 MPa
(2.0 kgf/cm
2
, 28.4 psi) b : 3.14 MPa
(32 kgf/cm
2
, 455 psi)
D : OFF
E : ON
P : Pressure
PS : Pressure Switch
RY9212001CAM0020US0
5-M13
KiSC issued 08, 2015 A
KX080-4, WSM
CABIN
(1) Battery
(2) Slow-Blow Fuse (80A)
(3) Slow-Blow Fuse (50A)
(4) Fuse (5A)
(5) Fuse (10A)
(6) Fuse (30A)
(7) Start Switch
(8) Cab Relay
(9) Headlight Switch
(10) Blower Motor Relay
(11) Blower Motor
(12) Blower Resistor
(13) Blower Switch (Shorting Type)
(14) Compressor Clutch Relay
(15) Pressure Switch
(16) Compressor Magnetic Clutch
(17) Fin Thermistor (Frost Sensor)
(18) Indicator Lamp
(19) AC switch
(20) Volume (Temperature Setting)
(21) Servo Motor
(A) Fixed Voltage Circuit
(B) Servo Motor Drive Circuit
(C) CPU
(D) Electronic Thermo Amp
(a) Potentiometer Signal
(b) ILL–
(c) Potentiometer Power
(d) Blower Motor
(e) Potentiometer GND
(f) Electronic thermo
(g) GND
(h) (Free)
(i) Servo Motor Output1
(COOL Output)
(j) (Free)
(k) Servo Motor Output2
(HOT Output)
(l) (Free)
(m) (Free)
(n) Headlight Switch
(o) IG
(p) +B Power
The processes up to the compressor's magnetic clutch engaging are indicated below.
1. Start switch → cab relay ON → blower motor relay ON → blower switch ON (LO, MI or HI) → blower motor ON
2. AC switch ON (indicator lamp lights up) → pressure switch ON → fin thermistor ON → compressor clutch relay ON → compressor magnetic clutch ON (compressor operates)
RY9212001CAM0024US0
5-M14
KiSC issued 08, 2015 A
KX080-4, WSM
CABIN
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.
Similarly, if this current flowed directly from the battery and the operator forget to turn the blower motor off, the battery would discharge.
The system is equipped with relays in order to prevent these kind of problems. When the current flows through the coils of these relays, their contacts close, allowing electricity to be supplied from the battery. By adopting these relays, only a tiny amount of current is needed to operate the relays, so very little current flows through the main switch. As a result, the concern over its contacts burning out is eliminated and when the main switch is open, the relays' contacts open at the same time. When this occurs, the flow of electricity in the AC circuit ceases and the possibility of the battery discharging is also eliminated.
(1) Relay Terminal 1
(2) Relay Terminal 2
(3) Relay Terminal 3
(5) Relay Terminal 5
(A) Connection Diagram
RY9212148CAM0007US0
5-M15
KiSC issued 08, 2015 A
KX080-4, WSM
When the blower switch is in the LO, MI, or HI position
CABIN
(1) Battery
(2) Slow-Blow Fuse (80A)
(3) Slow-Blow Fuse (50A)
(4) Fuse (5A)
(5) Fuse (10A)
(6) Fuse (30A)
(7) Start Switch
(8) Cab Relay
(9) Headlight Switch
(10) Blower Motor Relay
(11) Blower Motor
(12) Blower Resistor
(13) Blower Switch (Shorting Type)
(14) Compressor Clutch Relay
(15) Pressure Switch
(16) Compressor Magnetic Clutch
(17) Fin thermistor (Frost Sensor)
(18) Indicator Lamp
(19) AC Switch
(20) Volume (Temperature Setting)
(21) Servo Motor
(A) Fixed Voltage Circuit
(B) Servo Motor Drive Circuit
(C) CPU
(D) Electronic Thermo Amp
When the starter switch and the blower switch are turned on, electricity flows from the battery to the coil of the blower motor relay, turning the blower motor relay on. With the blower motor relay on, the electricity flows to the blower motor as indicated below.
Lo Position
• Battery → slow-blow fuse (80A) → slow-blow fuse (50A) → fuse (30A) → blower motor relay → blower motor → blower resistor → ground
Mi Position
• Battery → slow-blow fuse (80A) → slow-blow fuse (50A) → fuse (30A) → blower motor relay → blower motor → blower resistor → blower switch (E → A) → ground
Hi Position
• Battery → slow-blow fuse (80A) → slow-blow fuse (50A) → fuse (30A) → blower motor relay → blower motor → blower resistor → blower switch (F → A) → ground
RY9212001CAM0026US0
5-M16
KiSC issued 08, 2015 A
KX080-4, WSM
CABIN
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; pressing it in further to its
(a)
position operates the window washer. When the operator releases the switch, it automatically returns from position
(a)
to position
(b)
.
The window washer also operates if it is pressed in to position
(d)
on the [OFF] side. When it is released, it automatically returns in the same way to position
(c)
.
(1) Switch
(2) Spring
(3) Contact
(4) Switch Body
(5) Movable Contact
(6) Insulator
(a) Wash 1 Position
(Both Wiper Motor and
Window Washer Operate)
(b) On position (Only the
Wiper Motor Operates)
(c) Off Position
(d) Wash 2 Position (Only the
Window Washer Operates)
RY9212148CAM0005US0
The wiper is composed of a motor, wiper arm, wiper blade, etc.
The motor is fixed speed and automatically returns to a set position.
(1) Washer
(2) Nut
(3) Wiper Arm
(4) Nut
(5) Wiper Blade
(6) Wiper Motor
(7) Wiper Motor Cover
(8) Flange Nut
RY9212001CAM0028US0
5-M17
KiSC issued 08, 2015 A
KX080-4, WSM
CABIN
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 and a segmented arm provide reciprocating motion, which is communicated to the wiper arm via the arms axis.
The motor is a 2-brush specification model and its rpm cannot be altered.
(1) Segmented Arm
(2) Arm's Axis
(3) Rod
(4) Worm Gear
(5) Armature Axle
(6) Brush
(7) Armature
(8) Ferrite Magnet
(9) Helical Gear
(10) Breaker
(11) Motor
(12) Switch
(A) Wiring Diagram
(Motor Stop Position)
RY9212001CAM0029US0
5-M18
KiSC issued 08, 2015 A
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
5. INSPECTING AND CHARGING THE REFRIGERANT SYSTEM .............................................5-S11
[1] CHECKING THE SYSTEM WITH A MANIFOLD GAUGE...................................................5-S11
[2] COLLECTION, VACUUMING AND CHARGING.................................................................5-S15
(1) Collecting Refrigerant ....................................................................................................5-S15
(2) Vacuuming Out the System...........................................................................................5-S15
(3) Charging from the High-Pressure Side..........................................................................5-S17
(4) Charging from the Low-Pressure Side ..........................................................................5-S17
(5) Inspections and Troubleshooting...................................................................................5-S18
6. INSPECTION AND DISASSEMBLY..........................................................................................5-S20
[1] CHECKS AND ADJUSTMENTS .........................................................................................5-S20
(1) Compressor ...................................................................................................................5-S20
(2) Relays............................................................................................................................5-S22
(3) Blower Motor .................................................................................................................5-S24
(4) Blower Resistor .............................................................................................................5-S25
(5) Blower Switch ................................................................................................................5-S26
(6) Servo Motor (for Temp Control).....................................................................................5-S27
(7) Pressure Switch.............................................................................................................5-S28
[2] DISASSEMBLY AND ASSEMBLY ......................................................................................5-S29
(1) AC Unit Assembly/Disassembly ....................................................................................5-S29
(2) Mounting and Removing the Compressor .....................................................................5-S30
(3) AC and Heater Hose Routing ........................................................................................5-S32
(4) Electric Condenser/Fan Mounting and Removal ...........................................................5-S34
7. WINDOW WASHER ..................................................................................................................5-S36
[1] WIPER SWITCH..................................................................................................................5-S36
[2] WIPER MOTOR ..................................................................................................................5-S37
[3] WASHER MOTOR ..............................................................................................................5-S37
8. CABIN GLASS REMOVAL AND MOUNTING ...........................................................................5-S38
[1] COMPONENT SCHEMATIC ...............................................................................................5-S38
[2] NECESSARY TOOLS .........................................................................................................5-S42
[3] REMOVING THE GLASS ON THE RIGHT .........................................................................5-S43
[4] REMOVING THE FRONT GLASS ......................................................................................5-S44
[5] REMOVING OTHER PANES OF GLASS ...........................................................................5-S46
[6] INSTALLING THE GLASS ON THE RIGHT........................................................................5-S46
[7] INSTALLING THE FRONT GLASS .....................................................................................5-S48
[8] INSTALLING OTHER PANES OF GLASS..........................................................................5-S51
9. REMOVAL AND INSTALLATION OF GLASS ...........................................................................5-S52
[1] PREPARATION...................................................................................................................5-S52
KiSC issued 08, 2015 A
[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
KX080-4, WSM
Compressor
Problem and/or
Situation
Possible Cause
Noise (compressor on)
Noise (compressor off)
Wearing of or damage to the compressor's bearings
Compressor valve damaged
Belt slipping
Compressor bracket mounting bolt(s) loose
Lines vibrating
Blower damaged
Magnetic clutch, idler pulley and/or crank pulley bearings damaged or wearing
Air Conditioning System
Problem and/or
Situation
Cooling not working
(air not blowing)
Cooling not working
(compressor not turning)
Cooling not working
(other)
Possible Cause
Blown fuse
Main AC relay defective
AC's blower motor damaged
AC's blower switch broken
Wiring harness unplugged or poor contact
Blown fuse
Magnetic clutch broken
AC switch broken
Pressure switch broken
Belt slipping
Not enough refrigerant
Expansion valve broken
Compressor broken
Filter clogged
Cooling not working effectively
(not enough air blowing)
Frost on the evaporator
Not cooling effectively
(lots of foam visible in sight glass)
AC's blower motor damaged
AC blower resistor broken
Not enough refrigerant
Refrigerant gas leaking from the cooling circuit
Air got in
Too much refrigerant
(no foam in sight glass)
Refrigerant overcharged
Not cooling effectively
(compressor not rotating properly)
Belt slipping
Magnetic clutch broken
Compressor broken
Solution
Replace
Replace
Adjust or replace
Tighten
Tighten and/or add clamp(s)
Repair or replace
Replace
CABIN
Solution
Replace
Replace
Replace
Replace
Fix
Replace
Repair or replace
Replace
Replace
Adjust or replace
Check with a manifold gauge
Replace
Replace
Clean or replace
Clean or replace the temperature switch
Replace
Replace
Check with a manifold gauge
Repair and/or recharge refrigerant
Check with a manifold gauge
Check with a manifold gauge
Adjust or replace
Repair or replace
Replace
5-S1
KiSC issued 08, 2015 A
KX080-4, WSM
Problem and/or
Situation
Possible Cause
Not cooling effectively
(other)
Not heating effectively
Not enough air flow
(blower motor not turning)
Not enough air flow
(air flow does not change to speed 3)
Not enough air flow
(other)
Not cooling effectively
(compressor clutch not working)
Not cooling effectively
(high-pressure level too high)
Not cooling effectively
(high-pressure level too low)
Not cooling effectively
(low-pressure level too high)
Thermistor broken
Hot water valve damaged
Condenser clogged with dirt or debris
Expansion valve broken
Hot water valve damaged
Servo motor broken
Blower fan switch broken
AC main relay broken
Brushes have poor contact
Blown fuse
Miswiring or poor connections
Blower resistor damaged
Relay damaged
Blower fan switch broken
Blower not tight enough
Blower deformed
Blower hitting its casing
Something blocking the inlet
Frost on the evaporator
Filter clogged
Vent ducts clogged or detached
Battery voltage too low
Rotor is hitting the stator
Miswiring or loose connectors
Relay damaged
Coil shorted
Ground defective
Coil burned out
Refrigerant overcharged
Condenser clogged with dirt or debris
Air got in
Not enough refrigerant
Compressor discharge valve damaged
Compressor gasket damaged
Error in the low-pressure line
(cracked or clogged)
Refrigerant overcharged
Expansion valve too far open
Solution
Replace
Replace
Clean
Replace
Replace
Check and repair
Check and repair
Replace
Replace
Replace
Check and repair
Replace
Replace
Replace
Check and repair
Replace
Check and repair
Check and repair
Clean or replace
Clean or replace
Check and repair
Charge the battery
Replace
Check and repair
Replace
Replace
Check and repair
Replace
Check with a manifold gauge
Clean
Check with a manifold gauge
Check with a manifold gauge
Replace
Replace
Replace
Check with a manifold gauge
Replace
CABIN
5-S2
KiSC issued 08, 2015 A
KX080-4, WSM
CABIN
Problem and/or
Situation
Not cooling effectively
(low-pressure level too low)
Not enough refrigerant
Frost on the evaporator
Error in the low-pressure line
(cracked or clogged)
Expansion valve clogged
Not cooling effectively
(both low and high pressure levels too high)
Not cooling effectively
(both low and high pressure levels too low)
Cannot control temperature
(servo motor and/or temperature control dial defective)
Cannot control the temperature
(hot water valve does not open normally)
Cannot control the temperature
(poor heater hose layout)
Water leak (water leak inside the cab)
Wiper
Problem and/or
Situation
Possible Cause
Refrigerant overcharged
Not enough refrigerant
Servo motor broken
Temperature control dial broken
Controller of the wire harness is off
Servo motor broken
Hot water valve damaged
Heater hose is pinched
Heater hose is bent or broken
Drain hose bent or broken
Drain hose clogged
Possible Cause
Wiper doesn't work
Wiper moves too slowly
Wiper fails to stop in the correct position
Fuse blown (a part inside the wiper motor or some other moving part is shorted or burned out)
Wiper motor faulty (damaged armature, worn motor brushes, motor shaft locked)
Wiper switch faulty
Faulty operation of linkage mechanism due to foreign matter
Wiper arm locked or rusted together
Wiper motor faulty (damaged armature, poor contact due to worn motor brushes, faulty operation of motor shaft)
Battery voltage low
Wiper arm shaft rusty, foreign matter stuck in it
Poor contact in wiper switch
Wiper motor faulty
(Dirty or poor contact of the contacts at the auto-stop position due to foreign matter)
Solution
Check with a manifold gauge
Clean or replace
Replace
Replace
Check with a manifold gauge
Check with a manifold gauge
Replace
Replace
Repair or replace
Replace
Replace
Fix
Repair or replace
Check and repair
Clean
Replace
Solution
Pinpoint the cause of the damage and replace
Replace
Fix
Grease up or replace
Replace
Recharge or replace
Grease up or replace
Replace
Replace
5-S3
RY9212001CAS0001US0
KiSC issued 08, 2015 A
KX080-4, WSM
Item
AC Compressor Magnetic Clutch
Magnetic Clutch Stator Coil
Cooling Cycle
(cooling cycle when operating normally)
Pressure switch
(dual type) (when pressure switch is off)
AC drive belt
Refrigerant
Compressor Oil
Air Gap
Electrical
Resistance
Pressure
(low-pressure side)
Pressure
(high-pressure side)
Pressure setting
(low-pressure side)
Pressure setting
(high-pressure side)
Tension
Type
(recharge volume)
Type
(usage volume)
Factory specification
0.30 to 0.65 mm
0.0118 to 0.0255 in.
3.0 to 4.0 Ω
0.15 to 0.20 MPa
1.5 to 2.0 kgf/cm
2
21 to 28 psi
1.27 to 1.66 MPa
13 to 17 kgf/cm
2
185 to 242 psi
Lower than the values below
About 0.196 MPa
2.0 kgf/cm
2
28.4 psi
Higher than the values below
About 3.14 MPa
32 kgf/cm
2
455 psi
Deflects 20 to 25 mm
(0.79 to 0.98 in.) when
98.0 N (10.0 kgf,
22.0 lbs) of forced is applied
R134a
970 ± 50 g
2.14 ± 0.11 lbs
ND-OIL8 <PAG*oil>
110 to 120 cc
0.116 to 0.127 U.S.qts
0.097 to 0.106 Imp.qts
*PAG : Polyalkylene glycol (synthetic oil)
Allowable Limit
Value
–
–
–
–
–
–
–
–
–
CABIN
RY9212148CAS0001US0
5-S4
KiSC issued 08, 2015 A
KX080-4, WSM
The following table indicates the specified tightening torque for nuts.
Items
Condenser mounting
Compressor mounting
Compressor bracket mounting
M8 nut
M8 bolt
M12 bolt
M8 bolt
M8 bolt
M6 bolt
Receiver mounting
High pressure line 1 mounting
(on condenser side)
M22 × 1.5 lock nut
Between condenser and receiver
M6 bolt
M16 × 1.5 lock nut
High pressure line 2 mounting
(on receiver side)
Low-pressure line between AC and compressor
M16 × 1.5 lock nut
M6 bolt
M24 × 1.5 lock nut
AC mounting
M6 bolt
M8 bolt
Magnetic clutch mounting M6 bolt
N·m
17.7 to 20.6
16.7 to 19.6
77.5 to 90.2
16.7 to 19.6
17.7 to 20.6
7.8 to 11.8
19.6 to 24.5
3.9 to 6.9
11.8 to 14.7
11.8 to 14.7
7.8 to 11.8
29.4 to 34.3
3.9 to 6.9
9.8 to 15.7
10.8 to 16.2
CABIN
kgf·m
1.8 to 2.1
1.7 to 2.0
7.9 to 9.2
1.7 to 2.0
1.8 to 2.1
0.8 to 1.2
2.0 to 2.5
0.4 to 0.7
1.2 to 1.5
lbf·ft
13.0 to 15.2
12.3 to 14.5
57.1 to 66.5
12.3 to 14.5
13.0 to 15.2
5.8 to 8.7
14.5 to 18.1
2.9 to 5.1
8.7 to 10.8
1.2 to 1.5
8.7 to 10.8
0.8 to 1.2
3.0 to 3.5
0.4 to 0.7
1.0 to 1.6
1.10 to 1.65
5.8 to 8.7
21.7 to 25.3
2.9 to 5.1
7.2 to 11.6
8.0 to 11.9
RY9212148CAS0002US0
5-S5
KiSC issued 08, 2015 A
KX080-4, WSM
CABIN
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.
CAUTION
• If the liquid refrigerant comes in contact with skin, it results in frostbite, so always be careful when handling refrigerants. Always wear goggles when working on this system in order to protect your eyes.
• Refrigerant service containers are made very sturdy for safety. However, they can explode if handled improperly. Always follow the instructions printed on their labels. In particular, never heat a refrigerant container above 40 °C (104 °F). Also, never drop one from any height.
• Do not steam clean this system. In particular, this system is under extremely high pressure, so do not steam clean the condenser as it may cause the system to explode.
• If an error is made in handling the service valve or in connecting a hose between the compressor's service valve and a manifold gauge, it may cause the refrigerant service container or the charging hose to explode. When connecting hoses or handling service valves, always check the pressure on the high-pressure side or on the low-pressure side.
• When recharging refrigerant with the compressor operating, do not open the high-pressure valve of the manifold gauge.
• Be careful of gas toxicity. The refrigerant gas in its natural state is harmless and is not toxic. However, when it comes in contact with very hot parts, it can break down chemically, producing hazardous materials.
• Do not heat service canisters unless absolutely necessary. When necessary to heat a canister, use water at or below 40 °C (104 °F). Never use boiling water to heat a canister.
• Take care with the following points on storing and handling service canisters.
• Store in a cool, dry place.
• Never drop or strike a canister.
• Do not use service canisters that are deformed, have unusable screws or are otherwise damaged.
• Never heat a service canister unless necessary. If one must be heated for some reason, use water at or below 40 °C (In such cases, never warm the canister while heating the water.) Do not immerse the valve of the service canister in water. Do not turn the service canister upside down. Turning it upside down allows liquid refrigerant into the compressor, which damages the valve.
• Do not shake hard. (If the mounting of the valve is not secure, it may come off.)
• Use ND-OIL8 (made by DENSO (Co. Ltd.)) compressor oil. (ND-OIL6 is designated for use with R12, so do not mistakenly use ND-OIL6.)
• Precautions on Inspecting and Charging A/C Gas
• Perform all work in a well-ventilated location.
• Be careful when handling high-pressure valves. When recharging refrigerant with the engine running, do not open the high-pressure valve (HI) of the manifold gauge. Overcharging refrigerant may cause problems such as poor cooling and overheating.
IMPORTANT
• Using R12 refrigerant in an R134a A/C system may cause problems to result, such as leaks of refrigerant at O-rings and fogging of the sight glass. Consequently, the shapes of line joints, service valves and service tools are different in order to prevent mistakes in connecting or recharging the wrong system.
• Always keep the work area clean, dry and free of any dirt or dust. Always wipe off any water from line fittings with a clean cloth before opening the fitting.
• Only use R134a refrigerant service tools.
• When discharging refrigerant, use an R134a refrigerant collection/recycling machine.
• Prior to connecting a charging hose to the tap valve of a refrigerant canister, check each seal and make sure it is not clogged up.
• When disconnecting charging hoses from compressor and receiver valves, do so as quickly as possible to minimize the leakage of gas.
• Be careful to only charge with the specified amount of refrigerant; never overcharge the system. This is important because overcharging the refrigerant can cause poor cooling performance among other things.
5-S6
KiSC issued 08, 2015 A
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.
• R134a compressor oil readily absorbs moisture, so always seal any parts after disconnecting them.
• Do not use any of the old style R12 refrigerant or previous kinds of refrigerant compressor oil.
RY9212079CAS0001US0
The manifold gauge set has a valve handle for opening and closing valves. The valve handle marked LO is for use on the low-pressure valve (5) and the valve handle marked HI is for use on the high-pressure valve (3). The following circuits can be achieved by variously opening and closing the high and low pressure valves.
(1) Low-Pressure Gauge
(2) High-Pressure Gauge
(3) High-Pressure Valve
(4) Valve Core
(5) Low-Pressure Valve
RY9212001CAS0005US0
When low and high pressure valves are closed
The following 2 circuits are formed.
Port (C) → Low-pressure gauge (1)
Port (A) → High-pressure gauge (2)
CAUTION
• Be sure to open the valve core (d).
(1) Low-Pressure Gauge (2) High-Pressure Gauge
RY9212001CAS0006US0
With the low-pressure valve open and the high-pressure valve closed
The following circuits are formed.
Port (C) → Low-pressure gauge (1)
Port (C) → Port (B)
Port (C) → Port (D)
Port (A) → High-pressure gauge (2)
CAUTION
• Be sure to open the valve core (D).
(1) Low-Pressure Gauge (2) High-Pressure Gauge
RY9212001CAS0007US0
With the low-pressure valve closed and the high-pressure valve open
The following circuits are formed.
Port (C) → Low-pressure gauge (1)
Port (A) → Port (B)
Port (A) → Port (D) (Be sure to open the valve core.)
Port (A) → High-pressure gauge (2)
CAUTION
• Be sure to open the valve core (D).
(1) Low-Pressure Gauge (2) High-Pressure Gauge
RY9212001CAS0008US0
5-S7
KiSC issued 08, 2015 A
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
• Be sure to open the valve core (D).
(1) Low-Pressure Gauge (2) High-Pressure Gauge
RY9212001CAS0009US0
The three kinds of refrigerant charging hoses can be identified by color. Each of the refrigerant charging hoses is to be used as follows.
• In line with the AC manufacturer's recommendation, the blue hose (6) is to be used on the low-pressure side (intake side), the green hose (5) on the cooling side (center connection port) and the red hose (3) on the high-pressure side (discharge side).
(When connecting)
• Press the quick disconnect adapter (4) into the recharge valve and push in on part
A
until you hear it catch.
CAUTION
• While pressing in to make a connection, be careful not to bend any lines.
• If the sleeve (7) moves prior to connecting the quick disconnect adapter to the recharge valve, move the sleeve back to its original position and try again to make the connection.
• If there is any refrigerant remaining in the refrigerant recharge hose, it makes it difficult to connect the quick disconnect adapter. In this case, relieve the pressure in the refrigerant recharge hose and then connect the adapter.
(Pressing on the plunger (8) eliminates any residual pressure.)
(When disconnecting)
• With part
A
of the quick-disconnect adaptor held in place, slide part
B
up.
CAUTION
• After removing the quick-disconnect adapter, be sure to put a cap on the service valve of the adapter.
(1) Low Pressure Valve
(2) High Pressure Valve
(3) Red Hose
(4) Quick Disconnect Adapter
(5) Green Hose
(6) Blue Hose
(7) Sleeve
(8) Pusher
a : Makes a catching sound
RY9212148CAS0003US0
5-S8
KiSC issued 08, 2015 A
KX080-4, WSM
CABIN
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. If the refrigerant system is charged in this state, the vacuum pump oil remaining in the refrigerant charging hose will go into the AC refrigerant system along with the refrigerant. A vacuum pump adaptor equipped with a solenoid valve is used to prevent this backflow of oil from the vacuum pump. The role of the solenoid valve is to close when electricity is flowing to the solenoid valve, cutting it off from outside air and maintaining the vacuum; when the electricity is cut off, the valve opens, bringing in outside air and relieving the vacuum.
2. If this adapter is connected to the currently used R12 vacuum pump, it enables the vacuum pump to be used for both R134a and R12.
(1) Vacuum Pump Adapter
(2) Vacuum Pump
(3) For R134a
(4) Solenoid Valve
(5) Air
(6) For R12
(7) Plug Cap
RY9212001CAS0011US0
The old style R12 gas leak tester are not sensitive enough for
R134a and cannot be used. Consequently a new and very sensitive electrical gas leak tester has been designed that can be used with both R134a and R12.
[NOTE]
Halogenated Torch Gas Leak Testers
• Because this tester detects gas leaks based on the reaction of chlorine in the refrigerant, it cannot detect R134a because it does not contain chlorine.
(1) Electrical Gas Leak Tester
RY9212001CAS0012US0
The canister tap valve used in recharging the refrigerant of the
AC system has to be used as follows.
1. Before attaching the canister tap valve to the refrigerant container, rotate the handle (1) counterclockwise until the needle of the valve is completely retracted.
2. Rotate the plate nut (disk) (3) counterclockwise to its highest position and then screw the canister tap valve into the sealed tap.
3. Rotate the plate nut clockwise as far as you can and fasten the center charging hose to the canister tap valve.
4. Tighten the plate nut securely by hand.
5. Rotate the handle (1) clockwise to open a hole in the sealed tap.
6. To charge the system with refrigerant, turn the handle (1) counterclockwise. To stop charging, turn the handle clockwise.
(1) Butterfly Handle
(2) Connector
(3) Disc
(4) Needle
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5-S9
KiSC issued 08, 2015 A
KX080-4, WSM
CABIN
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.
(1) Refrigerant Charging Hose (Green)
(2) T-Joint
(3) Canister Tap Valve
(4) Refrigerant Canister
RY9212001CAS0014US0
When it is necessary to discharge the refrigerant in order to work on the machine, a collection / recycling device must be used.
(Never release refrigerant into the atmosphere.)
IMPORTANT
• Use a dedicated R134a refrigerant collection/recycling device.
• To prevent any damage to the compressor, use neither R12 system refrigerant nor cooling system oil in R134a equipment.
RY9212001CAS0015US0
5-S10
KiSC issued 08, 2015 A
KX080-4, WSM
CABIN
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.
Conditions
• Ambient temperature : 30 to 35 °C (86 to 95 °F)
• Engine RPM : Approx. 1,500
• Temperature control lever : Max cooling position
• Blower switch : HI Position
RY9212001CAS0016US0
Manifold connections and test preparations
1. Close the manifold gauge's high (3) and low (4) pressure valves tightly.
2. Connect the red (2) refrigerant charging hose to the high-pressure charge valve (7) and the blue or yellow (1) refrigerant charging hose to the low-pressure charge valve (6).
CAUTION
• Use the refrigerant pressure in the refrigerant cycle to completely flush out the air in the refrigerant charging hose from the end of the manifold gauge's connection.
3. Start up the engine and set it at approximately 1,500 rpms.
4. Turn the AC switch on and set the temperature control dial to the max cooling position.
5. Set the blower switch to its HI position.
(1) Refrigerant charging hose
(blue or yellow)
(2) Refrigerant charging hose (red)
(3) High-pressure valve
(4) Low-pressure valve
(5) Manifold gauge
(6) Low-pressure side charge valve
(7) High-pressure side charge valve
RY9212148CAS0005US0
When operating normally
If the refrigerant cycle is operating normally, readings will be around the factory specifications in the table below.
Gas Pressure
Factory specification
Low pressure side
High pressure side
0.15 to 0.20 MPa
1.5 to 2.0 kgf/cm
2
21 to 28 psi
1.27 to 1.66 MPa
13 to 17 kgf/cm
2
185 to 242 psi
(1) Low Pressure Side (2) High Pressure Side
RY9212001CAS0018US0
5-S11
KiSC issued 08, 2015 A
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
2
,
7.1 to 14.2 psi)
High-pressure side (2) : 0.69 to 0.98 MPa (7 to 10 kgf/cm
2
,
99.6 to 142.2 psi)
• Foam visible in the sight glass.
• Air output by the A/C appears to be cooled.
2. Possible Cause
• Gas leaking from the circuit of the refrigerant cycle.
3. Solution Methods
• Use an electric gas leak tester to check for leaks and repair any found.
• Recharge the system with an appropriate amount of refrigerant.
(1) Low Pressure Side (2) High Pressure Side
RY9212001CAS0019US0
Excess refrigerant or insufficient condenser cooling
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
2
,
28.4 to 49.8 psi)
High-pressure side (2) : 1.96 to 2.45 MPa (20 to 25 kgf/cm
2
,
284.5 to 355.6 psi)
2. Possible Causes
• Cycle charged with too much refrigerant.
• Poor condenser cooling.
3. Solution Methods
• Clean the condenser.
• Adjust the tension of the A/C drive belt to the appropriate tension.
• If the 2nd item above is normal, check the amount of refrigerant.
CAUTION
• To discharge excess refrigerant, loosen the manifold's gauge's low-pressure valve and slow discharge it.
(1) Low Pressure Side (2) High Pressure Side
RY9212001CAS0020US0
5-S12
KiSC issued 08, 2015 A
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
2
,
28.4 to 49.8 psi)
High-pressure side (2) : 1.96 to 2.45 MPa (20 to 25 kgf/cm
2
,
284.5 to 355.6 psi)
• The line on the low-pressure side (1) feels cold to the touch.
2. Possible Causes
• Air is mixed in the refrigerant cycle
3. Solution Methods
• Replace the receiver.
• Check the amount of compressor oil and whether it is contaminated.
• Vacuum it out and charge the cycle again with fresh refrigerant.
CAUTION
• If you fail to vacuum out a refrigerant cycle like that mentioned above and simply charge the cycle with refrigerant, the problem may recur.
(1) Low Pressure Side (2) High Pressure Side
RY9212001CAS0021US0
Moisture mixed into the cycle
1. Symptoms that appear in the refrigerant cycle
• At first the A/C works normally, but after some time, the pressure on the low-pressure side (1) becomes a vacuum and the high-pressure side (2) is at a low pressure.
Low-pressure side (1) : Vacuum;
High-pressure side (2) : 0.69 to 0.98 MPa (7 to 10 kgf/cm
2
,
99.6 to 142.2 psi)
2. Possible Causes
• Moisture in the refrigerant cycle freezes up in the expansion valve orifice, creating a temporary blockage. As time elapses, the ice thaws and it returns to normal.
3. Solution Methods
• Replace the receiver.
• Eliminate the moisture in the refrigerant cycle by repeatedly vacuuming it out.
• Recharge the system with an appropriate amount of refrigerant.
(1) Low Pressure Side (2) High Pressure Side
RY9212001CAS0022US0
5-S13
KiSC issued 08, 2015 A
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
2
,
71.2 to 85.3 psi)
2. Possible Causes
• The line above the expansion valve orifice is frozen up and the refrigerant cannot flow due to moisture and/or dirt stuck in the refrigerant cycle.
3. Solution Methods
Wait for some time to elapse and determine whether it is dirt or moisture blocking the line by whether A/C operation recovers or not.
• If the problem is moisture, the problem resolves itself, as indicated in the previous section.
• If the cause is dirt, remove the expansion valve and blow out any dirt with compressed air.
• If the dirt cannot be eliminated, replace the expansion valve and the receiver. Vacuum out the line and charge the cycle with an appropriate amount of fresh refrigerant.
• If the problem is caused by a gas leak in the heat-sensitive tube, replace the expansion valve.
(1) Low Pressure Side (2) High Pressure Side
RY9212001CAS0023US0
Expansion valve too far open
1. Symptoms that appear in the refrigerant cycle
• Both high (2) and low (1) side pressures are too high.
Low-pressure side (1) : 0.29 to 0.39 MPa (3 to 4 kgf/cm
2
,
42.7 to 56.9 psi)
High-pressure side (2) : 1.96 to 2.45 MPa (20 to 25 kgf/cm
2
,
284.5 to 355.6 psi)
• Either frost or heavy condensation on the low-pressure side line
2. Possible Causes
• Problem with the expansion valve.
• The flow volume adjustment is set improperly.
3. Solution Methods
• Replace the expansion valve.
(1) Low Pressure Side (2) High Pressure Side
RY9212001CAS0024US0
Faulty compression from compressor
1. Symptoms that appear in the refrigerant cycle
• Low-pressure side (1) : 0.39 to 0.59 MPa (4 to 6 kgf/cm
2
,
56.9 to 85.3 psi)
High-pressure side (2) : 0.69 to 0.98 MPa (7 to 10 kgf/cm
2
,
99.6 to 142.2 psi)
2. Possible Causes
• Compressor is leaking.
3. Solution Methods
• Replace the compressor.
CAUTION
• When the compressor is producing a faulty compression, it can be detected with a manifold gauge (figure at left).
(1) Low Pressure Side
5-S14
(2) High Pressure Side
RY9212001CAS0025US0
KiSC issued 08, 2015 A
KX080-4, WSM
CABIN
IMPORTANT
• Follow 4. Precautions when Repairing the Refrigerant Cycle when discharging, vacuuming and charging the refrigerant system.
RY9212001CAS0026US0
use.
Get a R134a refrigerant collection/recycling device ready to
1. Connect the low-pressure hose (blue) (4) from the refrigerant collection/recycling machine to the low-pressure side charge valve (1). Connect the high-pressure hose (red) (5) to the high-pressure charge valve (2).
2. Follow the instructions of the manufacturer and discharge the refrigerant from the cooling system.
IMPORTANT
• Do not use device except an R134a refrigerant collection and recycling machine. In order to prevent damage to the compressor, do not mix R134a equipment, refrigerant or compressor oil into an R12 system.
(4)
(5)
(6)
(7)
No.
(1)
(2)
(3)
Description of Work
Check the connected parts and correct any problems
Start vacuuming
Stop vacuuming
Check the concentration
Charge with refrigerant
Check for gas leaks
Charge with refrigerant
CAUTION
• When removing the charge valve hose, cover it with a rag to protect your fingers and eyes from frost bite from the refrigerant.
(1) Refrigerant charging hose
(blue or yellow)
(2) Refrigerant charging hose (red)
(3) High-pressure valve
(4) Low-pressure valve
(5) Manifold gauge
(6) Low-pressure side charge valve
(7) High-pressure side charge valve
RY9212148CAS0006US0
Remarks
Approx 15 minutes, 750 mmHg (229 in.Hg) or greater
Leave for five minutes
If the gauge indicates abnormally, return to (1)
98 kPa (1.0 kgf/cm
2
, 14 psi)
RY9212001CAS0028US0
5-S15
KiSC issued 08, 2015 A
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.
Blue hose
Red hose
Low-pressure side
(L mark)
High-pressure side
(H mark)
3. Connect the charging hose (green) in the middle of the manifold gauge to the vacuum pump.
4. Open the high and low pressure valves of the manifold gauge.
5. Turn the vacuum pump switch on and vacuum the line until the low-pressure gauge reaches a reading of approximately
–0.1 MPa (–750 mmHg). (about 15 minutes)
6. Once about –0.1 MPa (–750 mmHg) is reached, close the high and low pressure valves of the manifold gauge and stop the vacuum pump.
7. Let it set for at least five minutes and check to make sure the indicator needle of the low-pressure gauge does not approach
0.
8. If the needle of the gauge approaches 0, the system's airtightness is compromised somewhere, so after inspecting and repairing the line connections, run the vacuum again and check to make sure there are not any places that are not airtight.
(1) Vacuum Pump
(2) High-Pressure Valve
(3) Low-Pressure Valve
(4) High-Pressure Side (H Mark)
(5) Low-Pressure Side (L Mark)
(A) Inspection Line Connections
(B) Low-Pressure Gauge
(a) Valve Settings
(L: Closed, H: Closed)
(b) Leave for at Least Five Minutes
(c) If the Needle Approaches 0,
Inspecting and Repairing the Line
Connections.
RY9212001CAS0029US0
Connections with a refrigerant collector or service canister
1. Close the high-pressure (HI) and low-pressure (LO) valves of the manifold gauge.
2. Connect the charging hose (green) connected to the vacuum pump to the collector or service canister. (Air is in the charging hose, so do not open the high or low pressure valves.)
3. Discharge from the collector or open the service canister's valve.
4. Press on the valve core of the manifold gauge for three to five seconds to discharge any air from the hose.
(1) Service Canister Valve
(2) High-Pressure Valve
(3) Low-Pressure Valve
(4) High-Pressure Side (H Mark)
(5) Low-Pressure Side (L Mark)
(a) Press Valve Core to Expel Air
RY9212001CAS0030US0
5-S16
KiSC issued 08, 2015 A
KX080-4, WSM
Charging from the High-pressure Side
CABIN
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.
IMPORTANT
• Do not open the low-pressure valve of the manifold gauge.
• If the service canister has been changed, be sure to expel any air out of the charging hose (green).
1. Without starting the engine, open the high-pressure valve and charge with approx 500 g of gas.
2. While charging, once the low-pressure gauge indicates approx
0.10 MPa (approx 1.0 kgf/cm
2
), close the high-pressure valve and the service canister valve for the time being.
3. Use a gas detector to check the hoses and pipe connections for gas leaks; if any exist, repair them. If there are no leaks, continue charging the refrigerant.
4. When charging on the high-pressure side stops, close the high-pressure valve on the manifold gauge and the service canister valve, and then charge from the low-pressure side.
(1) Service Canister Valve
(2) High-Pressure Valve
(3) Low-Pressure Valve
(a) Press Valve Core to Expel Air
RY9212001CAS0031US0
Charging from the Low-Pressure Side
CAUTION
• Never open the manifold gauge's high-pressure valve when charging refrigerant while the engine is running. (If the high-pressure valve is opened, high-pressure gas will flow back up the line and rupture the service canister or a charging hose.)
• Always keep the service canister upright when charging.
IMPORTANT
• If the service canister has been changed, be sure to expel any air out of the charging hose (green).
1. Check and make sure the manifold gauge's high-pressure valve is closed.
2. After starting the engine, set it to approx 1500 rpms and open all of the doors.
3. Turn the AC switch on and set the temperature control to maximum cooling.
4. Open the manifold gauge's low-pressure valve and the service canister valve and charge with the specified amount of gas.
5. After completing refrigerant charging, close the manifold gauge's low-pressure valve and the service canister valve and stop the engine.
6. Check for any gas leaks with the gas leak tester.
(1) Service Canister Valve
(2) High-Pressure Valve
(3) Low-Pressure Valve
(a) Press Valve Core to Expel Air
RY9212148CAS0022US0
5-S17
KiSC issued 08, 2015 A
KX080-4, WSM
CABIN
[A] Checking the Quantity of AC Gas
Checking with a manifold gauge
All the manifold gauge values indicated below are measurements taken under the specified conditions. Please note that the measurements you take will vary depending on the prevailing conditions.
Conditions
Doors
Inside/outside air switch
Ambient air temperature
Engine RPM
Temperature control
All open
Inside
30 to 35 °C (86 to 95 °F)
About 1,500
Max cooling position
Blower switch HI
1. After closing both the high and low-pressure valves of the manifold gauge, connect charging hoses (red/blue) to the compressor and the service canister valve of the receiver tank.
2. Loosen the low-pressure valve slightly to expel any air from the charging hose. After expelling the air, close the low-pressure valve again.
3. Expel air from the charging hose on the high-pressure side in the same way.
4. Start the engine and set it at approximately 1500 rpms.
5. Turn the AC switch ON and set the temperature control to maximum cooling and the blower switch to HI.
6. Read the values on the low-pressure and high-pressure gauges.
When Normal
Factory specification
Factory specification
Low pressure side
High pressure side
0.15 to 0.20 MPa
1.5 to 2.0 kgf/cm
2
21 to 28 psi
1.27 to 1.66 MPa
13 to 17 kgf/cm
2
185 to 242 psi
(1) High-Pressure Gauge
(2) Low-Pressure Gauge
(3) High-Pressure Valve
(4) Low-Pressure Valve
(5) Valve Core
(6) Red
(7) Blue
(8) Quick Joint
(9) Green
(a) High-Pressure Side
(Compressor's H-Mark Side)
(b) Low-Pressure Side
(Compressor's L-Mark Side)
RY9212001CAS0033US0
5-S18
KiSC issued 08, 2015 A
KX080-4, WSM
CABIN
Checking with the sight glass
Conditions
Doors
Inside/outside air switch
Ambient air temperature
Engine RPM
Temperature control
Blower switch
All open
Inside
30 to 35 °C (86 to 95 °F)
About 1500 rpm
Max cooling position
HI
Criteria
(a)
(b)
(c)
Overcharged
Normal amount
No air bubbles at all in the flow. In this case, both high and low-pressure sides are at high pressure and the cooling is ineffective.
Almost no air bubbles in the flow. If the engine rpm is raised gradually from idle to 1500 rpm, the air bubbles disappear and the flow becomes transparent.
Undercharged Air bubbles flow past constantly.
(1) Sight Glass
RY9212001CAS0034US0
5-S19
KiSC issued 08, 2015 A
KX080-4, WSM
CABIN
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.
3. Turn the AC switch and the fan switch on to make the AC system operate. With the AC working, check and make sure the magnetic clutch is not slipping.
4. If there is any noise, repair or replace it.
(1) Magnetic Clutch
RY9212148CAS0008US0
Stator coil
1. Remove the magnetic clutch's 1P connector.
2. Measure the resistance between the 1P connector on the magnetic clutch side and the body of the stator.
3. If the measurement falls outside of the factory specification, replace the stator coil.
Between stator body and harness side of stator coil
Factory specification 3 to 5 Ω
RY9212148CAS0009US0
5-S20
KiSC issued 08, 2015 A
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.
Clearance Factory specification
0.30 to 0.65 mm
0.0118 to 0.0255 in.
[NOTE]
Shim Thickness
0.10 mm (0.0039 in.)
0.15 mm (0.0059 in)
0.40 mm (0.016 in.)
0.60 mm (0.024 in.)
1.0 mm (0.0394 in.)
Part No.
T1065-87340
T1065-87350
T1065-87360
T1065-87370
T1065-87380
(1) Magnetic Clutch Mounting Screw
(2) Hub Plate
(3) Shim
(4) Snap Ring
(5) Rotor
(6) Snap Ring
(7) Stator
(8) Compressor Body
L : Clearance
RY9212148CAS0010US0
5-S21
KiSC issued 08, 2015 A
KX080-4, WSM
CABIN
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.
Criteria
Regular: it works
Irregular: it does not work
(1) Blower motor fuse (30A)
(2) Blower motor relay
(3) Horn relay
(4) Fan switch
RY9212148CAS0011US0
Blower motor relay voltage check
1. Take out the blower motor relay.
2. Key switch: RUN
3. Measure the voltage based on the table below.
Measurement
(a)
(b)
Connector name
(+ terminal side)
Blower motor relay
Blower motor relay
Pin No.
<1>
<3>
Connector name
(- terminal side)
Body GND
Body GND
Pin No.
–
–
Regular: 12 V
Irregular: Large discrepancy from 12 V
(1) Blower Motor Relay
(A) Fuse Box Terminals
RY9212148CAS0012US0
5-S22
KiSC issued 08, 2015 A
KX080-4, WSM
Blower motor inspection
1. Key switch: STOP
2. Take out the blower motor relay.
3. Measure the resistance based on the table below.
Measurement
(a)
Relay terminal
(+ terminal side)
(3)
Factory spec: 92 to 112 Ω
Outside factory spec: NG
Relay terminal
(- terminal side)
(5)
CABIN
4. Test the continuity based on the table below.
Measurement
(a)
Relay terminal
(+ terminal side)
(1)
Relay terminal
(- terminal side)
(2)
Regular: No continuity
Irregular: Continuity
RY9212148CAS0013US0
5-S23
KiSC issued 08, 2015 A
KX080-4, WSM
CABIN
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.
Measurement
Point s
Connector Name
(+terminal side)
Pin No.
Connector Name
(- terminal side)
(a)
Blower motor connector
<1> Body GND
Pin No.
–
Normal: 12 V
Irregular: Large discrepancy from 12 V
(1) Blower Motor Connector (2) Fan Switch
RY9212148CAS0014US0
Blower motor test
1. Remove the blower resistor.
2. Turn the blower motor by hand and check whether it turns smoothly.
3. If the blower motor fails to turn, check the motor.
(1) Blower Motor
(A) Circuit Diagram
(a) (+) Terminal
(b) (–) Terminal
RY9212148CAS0015US0
5-S24
KiSC issued 08, 2015 A
KX080-4, WSM
CABIN
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.
Measurement
Connector Name
(+terminal side)
Pin
No.
Connector Name
(- terminal side)
(a)
Blower resistor motor connector
<2> Body GND
Pin
No.
–
Normal: 12 V
Irregular: Large discrepancy from 12 V
(1) Blower Resistor
(2) Blower Resistor Motor Connector
(3) Fan Switch
RY9212148CAS0016US0
Inspecting the Blower Resistor
1. Put the key switch in its STOP position.
2. Disconnect the blower resistor connector from the machine and test the resistor on its own.
3. Measure the resistance based on the table below.
Measurement
(a)
(b)
(c)
Between terminals
1 – 3
1 – 2
2 – 3
Factory specification
Approx. 1.0 Ω
Approx. 0.7 Ω
Approx. 1.7 Ω
Assessment
Results
Regular: Within factory specification
Irregular: Outside factory specification
(1) MI
(2) HI
(3) LO
(4) Blank
(A) Blower Resistor
(B) Wiring Diagram
RY9212148CAS0017US0
5-S25
KiSC issued 08, 2015 A
KX080-4, WSM
CABIN
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.
Measurement
(a)
(b)
Connector terminal name (+ terminal side)
Blower switch connector
Blower switch connector
Pin
No.
<6>
<6>
Connector terminal name (- terminal side)
Blower switch connector
Body GND
Pin
No.
<3>
–
Regular: 12V
Irregular: Large discrepancy from 12V
(1) Control panel (2) Blower switch connector
RY9212158CAS0001US0
1. Turn the key switch to the STOP position.
2. Remove the control panel from the machine and test the blower switch independently.
(1) Control panel (2) Blower switch
RY9212158CAS0002US0
5-S26
KiSC issued 08, 2015 A
KX080-4, WSM
CABIN
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.
Measurement
(a)
(b)
Connector terminal name (+ terminal side)
Servo motor connector
Servo motor connector
Pin
No.
<5>
<5>
Connector terminal name (- terminal side)
Servo motor connector
Body GND
Regular: 5V
Irregular: Large discrepancy from 5V
(1) Servo motor connector
Pin
No.
<7>
–
RY9212158CAS0003US0
Servo motor inspection
1. Turn the key switch to the STOP position.
2. Disconnect the servo motor connector from the machine and test the servo motor independently.
3. Measure the voltage based on the table below.
Measurement
(a)
Connector terminal name (+ terminal side)
Servo motor
Pin
No.
<1>
Connector terminal name (- terminal side)
Servo motor
Pin
No.
<2>
Regular: Approx. 33 Ω (actual reference value)
Irregular: Large discrepancy from 33 Ω
4. Apply the battery voltage to terminals 1 and 2 of the servo motor and check whether it drives the servo motor.
5. Measure the resistance between A and B in the diagram at left according to the table below.
Measurement
(b)
Connector terminal name (+ terminal side)
Servo motor
Pin
No.
<3>
Connector terminal name (- terminal side)
Servo motor
Pin
No.
<5>
Regular: Gradual change in resistance (0 to within 6k Ω )
Irregular: No change in resistance
RY9212158CAS0004US0
5-S27
KiSC issued 08, 2015 A
KX080-4, WSM
CABIN
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.
2. Connect the red charging hose (4) to the HI (high-pressure side) charge valve (1) and the blue charging hose (5) to the LO
(low-pressure side) charge valve (2).
3. Open the manifold gauge's HI (high-pressure side) valve (3) a little and press on the valve core to expel any air inside its charging hose (4). Then close the HI (high-pressure side) valve
(3) tightly.
4. Open the manifold gauge's LO (low-pressure side) valve (2) a little and press on the valve core to expel any air inside its charging hose (5). Then close the LO (low-pressure side) valve
(2) tightly.
(1) Manifold Gauge
(2) Low-Pressure Valve
(3) High-Pressure Valve
(4) Red Charging Hose
(5) Blue Charging Hose
RY9212001CAS0047US0
When refrigerant pressure is rising (OFF)
1. Start the engine and set it at 1,500 rpms. Turn the AC switch on the control panel on, set the fan switch to HI and set the temperature control lever to the max cool position.
2. Cover the front of the condenser with cardboard or the like and raise the pressure on the high-pressure side of the AC cycle.
3. Once the pressure on the high-pressure side rises, the high-pressure switch operates, turning the magnetic clutch of the compressor off. When it does so, read the HI
(high-pressure) gauge of the manifold gauge and if it reads higher than the pressure setting, replace the pressure switch
(8).
• Pressure setting on the high-pressure side of the switch:
Switches off at approximately 3.14 MPa (32 kgf/cm
2
, 460 psi) or higher
RY9212148CAS0018US0
When refrigerant pressure is dropping (OFF)
1. Remove the connector of the pressure switch (1).
2. Measure the resistance between the terminals of the pressure switch with a circuit tester. It should register 0 Ω unless there is insufficient gas due to a leak or unless the pressure switch is faulty.
• Pressure setting on the low-pressure side of the switch:
Switches off at approximately 0.196 MPa (2.0 kgf/cm
2
, 28 psi)
RY9212001CAS0049US0
5-S28
KiSC issued 08, 2015 A
KX080-4, WSM
CABIN
(1) AC Unit
(2) AC step
(3) Filter
(4) Bolt
(5) Collar
(a) To rear duct
RY9212158CAS0005US0
5-S29
KiSC issued 08, 2015 A
KX080-4, WSM
CABIN
(1) Compressor ASSY
(2) Compressor bracket
(3) V belt
(4) Bolt
(5) Compressor bushing
(a) Point to measure compressor belt tension
RY9212148CAS0029US0
Filling the Compressor with Oil
When replacing the compressor
• The amount of oil required by the new compressor is enclosed within the AC cycle. A certain amount of compressor oil circulates along with the gas in the AC system.
• When replacing the compressor, remove the excess oil from the new compressor.
• Compressor oil (ND-OIL8) readily absorbs moisture, so seal it immediately.
Compressor Oil Type: ND-OIL8
Capacity (reference value): 60 cc
(1) New Compressor
(2) Compressor Being Replaced
A : Amount of Oil for New
Compressor
B : Amount of Oil from Old
Compressor
(a) Remove Excess Oil (A-B)
RY9212079CAS0037US0
5-S30
KiSC issued 08, 2015 A
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.
Belt tension adjustment
98 N
10.0 kgf
22 lbf
20 to 25 mm
0.79 to 0.98 in.
RY9212148CAS0030US0
5-S31
KiSC issued 08, 2015 A
KX080-4, WSM
[A] AC Hose
CABIN
(1) Discharge hose
(2) Suction hose 2
(3) Suction hose 1
Tightening torque
(4) Liquid hose P2
(5) Liquid hose P1
(6) Liquid hose
Discharge hose (1) (M6 bolt)
Suction hose (2), (3)
(M24X1.5)
Liquid hose (4), (5)
(M16X1.5)
Liquid hose (6) (Condenser side M6 bolt)
Liquid hose (6) (Receiver side M6 bolt)
7.9 to 11.8 N·m
0.8 to 1.2 kgf·m
5.8 to 8.7 lbf·ft
29.4 to 34.3 N·m
3.0 to 3.5 kgf·m
21.7 to 25.3 lbf·ft
11.8 to 14.7 N·m
1.2 to 1.5 kgf·m
8.7 to 10.8 lbf·ft
7.9 to 11.8 N·m
0.8 to 1.2 kgf·m
5.8 to 8.7 lbf·ft
3.9 to 6.9 N·m
0.4 to 0.7 kgf·m
2.9 to 5.1 lbf·ft
(a) Compressor side
(b) Condenser side
(c) AC unit side
(d) Receiver side
(A) M24X1.5 connection
(B) M16X1.5 connection
CAUTION
• Always collect the refrigerant before disconnecting any hoses and promptly seal the AC system so no moisture or water gets into it.
• Disconnect the negative battery terminal before disconnecting any connectors.
• Be careful not to mix up the high and low-pressure hoses or the charge/discharge hoses.
• Apply compressor oil (ND-OIL8) to pipes with O-rings and push the tip in to the ridged surface.
• Install so pipes and hoses are not twisted.
• Use two wrenches on aluminum pipe nuts and fasten to keep the companion nut from turning. (The material of the companion nut is softer, so be careful when tightening it.)
RY9212158CAS0006US0
5-S32
KiSC issued 08, 2015 A
KX080-4, WSM
[B] Hose Routing
CABIN
(1) Discharge hose
(2) Suction hose 2
(3) Liquid hose
(4) Liquid hose P2
(a) 25 ° (0.44 rad)
RY9212158CAS0007US0
5-S33
KiSC issued 08, 2015 A
KX080-4, WSM
CABIN
(1) Condenser cover
(2) Electric fan
(3) Condenser base
(4) Liquid hose
(5) Discharge hose
(6) Cushion
(7) Condenser
(a) Electrical wiring
RY9212158CAS0008US0
5-S34
KiSC issued 08, 2015 A
KX080-4, WSM
CABIN
(1) Heater hose 3
(2) Liquid hose P1
(3) Suction hose 1
(4) Liquid hose P2
(5) Suction hose 2
(6) Heater hose 2
(7) Liquid hose
(8) Discharge hose
(9) Heater hose 1
(a) Engine side discharge
(b) Engine side return
(c) AC unit return
(d) AC unit supply
(e) To engine side
(f) To AC unit side
(g) Take care to face clamps correctly.
RY9212158CAS0009US0
5-S35
KiSC issued 08, 2015 A
KX080-4, WSM
CABIN
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.
4. If is the same as the battery voltage (DC 11 to 14 V), it is normal.
(1) Wiper Switch
A : 6P Connector (Harness Side)
RY9212001CAS0071US0
Checking the wiper switch
1. Check the continuity between each of the terminals according to the table below.
2. If continuity exists, it is normal.
A : 6P Connector (Switch Side)
RY9212001CAS0072US0
5-S36
KiSC issued 08, 2015 A
KX080-4, WSM
CABIN
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.
Measurement
Point s
(a)
(b)
Connector Name
(+terminal side)
Wiper motor connector
Wiper motor connector
Pin No.
<1>
<3>
Connector Name
(- terminal side)
Wiper motor connector
Wiper motor connector
Pin No.
<2>
<2>
Regular: 12 V
Irregular: Large discrepancy from 12 V
(1) Wiper Motor
A : Wiper Motor Connector
RY9212148CAS0019US0
Checking the Voltage
1. Remove the washer motor connector.
2. Start the engine and turn the wiper switch ON.
Measure the voltage based on the table below.
Measurement
Point s
Connector Name
(+terminal side)
Pin No.
Connector Name
(- terminal side)
(a)
Washer motor connector
<2>
Washer motor connector
Pin No.
<1>
Regular: 12 V
Irregular: Large discrepancy from 12 V
(1) Washer Tank (2) Washer Motor Connector
RY9212148CAS0020US0
5-S37
KiSC issued 08, 2015 A
KX080-4, WSM
CABIN
(5)
(6)
(7)
(8)
(9)
No.
(1)
(2)
(3)
(4)
Striker (door)
Toothed washer
Screw
Knob
Screw
Bolt
Part Name
Handle ASSY (inner)
Cover
Fastener
(10) Door lock ASSY
(11) Joint
(12) Screw
(13) Trim
(14) Doors
(15) Hinge
2
5
1
1
4
Q'ty
1
2
2
1
1
1
2
1
1
3
No.
(16) Bolt
(17) Bolt
(18) Screw
(19) Handle
(20) Spring nut
(21) Seal
(22) Washer
(23) U bolt
(24) Seal
Part Name
(25) Handle ASSY (Outer)
(26) Spacer
(27) Upper glass
(28) Spacer
(29) Lower glass
2
1
2
1
1
Q'ty
4
4
2
1
1
3
1
6
1
RY9212148CAS0076US0
5-S38
KiSC issued 08, 2015 A
KX080-4, WSM
CABIN
No.
(1)
(2)
(3)
(4)
(5)
(6)
Spacer
Front glass
Rear glass
Hook
Sash
Spacer
Part Name
1
5
1
2
Q'ty
8
1
No.
(7)
(8)
Roof
Glass
(9) Cushion
(10) Glass
(11) Spacer
Part Name
1
1
2
Q'ty
1
1
RY9212148CAS0077US0
5-S39
KiSC issued 08, 2015 A
KX080-4, WSM
CABIN
No.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Stopper
Linkage
Bolt
Bushing
Snap ring
Linkage
Snap ring
Damper
(9) Washer
(10) Lever
Part Name
4
1
4
4
2
1
Q'ty
2
2
2
1
No.
(11) Lever
(12) Bolt
(13) Cover
(14) Cover
(15) Clip
(16) Striker
(17) Bolt
(18) Stopper (rubber)
(19) Nut
Part Name
5
1
1
2
Q'ty
1
4
4
2
2
RY9212148CAS0078US0
5-S40
KiSC issued 08, 2015 A
KX080-4, WSM
CABIN
No.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Nut
Arm (wiper)
Cap
Blade (wiper)
Nut
Washer
Gasket
Holder
(9) Wiper Motor
(10) Bolt
Part Name
1
1
1
1
1
1
Q'ty
1
1
1
3
No.
(11) Cover
(12) Clip
(13) Screw
(14) Nozzle
(15) Clamp
(16) Bolt
(17) Hose
(18) Flange
(19) Washer tank
Part Name
4
2
2
1
Q'ty
1
3
1
1
1
RY9212148CAS0079US0
5-S41
KiSC issued 08, 2015 A
KX080-4, WSM
CABIN
No.
(1)
(2)
(3)
(4)
(5)
(6)
Spacer
Front glass
Rear glass
Hook
Sash
Spacer
Part Name
1
5
1
2
Q'ty
8
1
No.
(7)
(8)
Roof
Glass
(9) Cushion
(10) Glass
(11) Spacer
(1) Piano Wire
(2) Scraper
(3) Slotted Screwdriver
(4) Needle-Nose Pliers
(5) Utility Knife
(6) Slotted Screwdriver
Part Name
1
1
2
Q'ty
1
1
RY9212148CAS0080US0
(7) Torx (T50)
(8) Wrench (10 mm)
(9) Wrench (27 mm)
(10) Socket (M12),Ratchet
(11) Suction Pads
RY9212148CAS0036US0
5-S42
KiSC issued 08, 2015 A
KX080-4, WSM
1. Protect inside cabin from possible glass debris.
CABIN
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.
CAUTION
• Take care not to cut your hands or fingers on the blade of the utility knife.
(1) Utility Knife (2) Sash
RY9212148CAS0038US0
3. Pass the piano wire between the frame of the cabin and the right sash.
4. Wind the ends of piano wire on with wood-block or something like handle, and cut the seal between the frame and glass with moving the piano wire alternately.
CAUTION
• The piano wire may break due to the heat from the friction, so take care not to cut your hand/fingers.
(1) Piano Wire (2) Wood Block
RY9212148CAS0039US0
5. Remove the right sash from the cabin.
(1) Seal
RY9212148CAS0040US0
6. A coating was applied to the right sash, so use the scraper to scrape it off. (2 places)
7. Lift up the end of the seal with a slotted screwdriver from the direction of
X
. (2 places)
(1) Seal
(a) Coating
RY9212148CAS0041US0
5-S43
KiSC issued 08, 2015 A
KX080-4, WSM
CABIN
8. Expand the frame of the right sash in direction
A
and remove the glass in direction
B
.
RY9212148CAS0042US0
1. Remove the bolts and then the wiper.
2. Remove the cap.
(1) Nut
(2) Wiper
(3) Cap
RY9212148CAS0043US0
3. Remove the nut.
IMPORTANT
• Take care not to crack the glass.
(1) Nut
RY9212148CAS0044US0
4. Remove the wiper motor harness, the cap and then the cover.
(1) Harness
(2) Cap
(3) Cover
RY9212148CAS0045US0
5. Remove the three bolts and the wiper motor.
(1) 3 × Bolt (M6 × 25) (2) Wiper Motor
RY9212148CAS0046US0
5-S44
KiSC issued 08, 2015 A
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. Remove the front frame.
IMPORTANT
• Take care not to crack the glass.
• Take care not to lose the roller.
(1) Front Frame (2) Roller
RY9212148CAS0049US0
9. Insert the utility knife between the front frame and the glass to make an opening to pass the piano wire through.
CAUTION
• Take care not to cut your hands or fingers on the blade of the utility knife.
• Take care not to get hurt from shards of glass.
(1) Utility Knife
RY9212148CAS0050US0
10. Pass the piano wire between the front frame and the glass.
11. Wrap both ends of the piano wire around blocks of wood or the like and move them back and forth.
CAUTION
• The piano wire may break due to the heat from the friction, so take care not to cut your hand/fingers.
(1) Piano Wire (2) Wood Block
RY9212148CAS0051US0
5-S45
KiSC issued 08, 2015 A
KX080-4, WSM
CABIN
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
• Take care not to cut your hands or fingers on the blade of the utility knife.
• Take care not to get hurt from shards of glass.
(1) Cover (2) Utility Knife
RY9212148CAS0052US0
3. Pass the piano wire between the cabin frame and the glass.
4. Wind the ends of piano wire on with wood-block or something like handle, and cut the seal between the frame and glass with moving the piano wire alternately.
CAUTION
• The piano wire may break due to the heat from the friction, so take care not to cut your hand/fingers.
(1) Piano Wire (2) Wood Block
RY9212148CAS0053US0
1. Remove any adhesive remaining on the cabin frame.
CAUTION
• Take care not to cut your hands or fingers on the blade of the scraper.
RY9212148CAS0054US0
2. Use the cleaning agent to remove any grime or oil remaining on the cabin frame.
3. Apply primer and allow to dry for the indicated time.
• Cleaning agent (Sika Aktivator-205)
• Primer (Sika Primer-206 G + P)
CAUTION
• Take care not to get the cleaner or the primer in your eyes.
Ambient temperature
15°C or higher
Below 15°C
10 minutes
30 minutes
(1) Cabin frame
(2) Primer
(a) No less than 20 mm (0.79 in.)
RY9212148CAS0055US0
5-S46
KiSC issued 08, 2015 A
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.
(2 places)
6. Apply the coating.
IMPORTANT
• Apply the coating so there are no gaps and water cannot leak.
(1) Seal
(a) Coating (Sikaflex - 265)
RY9212148CAS0057US0
7. Stick the new spacers at the set locations.
(1) Spacer
(a) 100 mm (3.9 in.)
RY9212148CAS0058US0
8. Apply the adhesive around the entire cabin frame.
(1) Adhesive (Sikaflex - 265)
(2) Nozzle
(a) No less than 10 mm (0.39 in.)
(b) No less than 12 mm (0.47 in.)
RY9212148CAS0059US0
5-S47
KiSC issued 08, 2015 A
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.
RY9212148CAS0060US0
1. Use the scraper and the cleaning agent to remove any remaining adhesive, grime or oil on the front frame and then apply the trim to the frame.
CAUTION
• Take care not to cut your hands or fingers on the blade of the scraper.
• Take care not to get the cleaner or the primer in your eyes.
(1) Front Frame (2) Trim
RY9212148CAS0061US0
2. Apply primer and allow to dry for the indicated time.
Ambient temperature
15°C or higher
Below 15°C
10 minutes
30 minutes
(a) No less than 12 mm (0.47 in.)
RY9212148CAS0062US0
3. Apply the adhesive only to the bottom of the front frame (round frame).
4. Use suction pads to mount the front glass to the frame.
IMPORTANT
• Take care not to drop the glass.
(1) Adhesive (Sikaflex - 265)
(2) Nozzle
(3) Trim
(a) No less than 8 mm (0.31 in.)
(b) No less than 12 mm (0.47 in.)
RY9212148CAS0063US0
5-S48
KiSC issued 08, 2015 A
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
• Take care not to crack the glass.
RY9212148CAS0065US0
7. Install the front frame.
IMPORTANT
• Take care not to crack the glass.
• Apply grease to the roller to prevent them to come lose.
(LH/RH 2 places each)
CAUTION
• Take care not to get your fingers caught between the glass and the frame.
(1) Roller (2) Front Frame
RY9212148CAS0066US0
8. With the front glass closed, install the 4 bolts. (LH/RH 2 places each)
Tightening torque Bolt (1)
9.0 to 15.0 N·m
0.92 to 1.53 kgf·m
6.64 to 11.10 lbf·ft
(1) 4 × Bolt (M6 × 12)
RY9212148CAS0067US0
9. Install the cover and the cap. (LH/RH 2 places each)
(1) Cover (2) Cap
RY9212148CAS0068US0
5-S49
KiSC issued 08, 2015 A
KX080-4, WSM
10. Install the wiper motor.
Tightening torque Bolt (2)
(1) Wiper Motor
CABIN
3.5 to 6.5 N·m
0.36 to 0.66 kgf·m
2.58 to 4.79 lbf·ft
(2) 3 × Bolt (M6 × 25)
RY9212148CAS0069US0
11. Install the wiper motor harness, cover and cap.
(1) Harness
(2) Cover
(3) Cap
RY9212148CAS0070US0
12. Install the nut.
IMPORTANT
• Take care not to crack the glass.
Tightening torque Nut (1)
(1) Nut
2.5 to 3.5 N·m
0.26 to 0.36 kgf·m
1.84 to 2.58 lbf·ft
RY9212148CAS0071US0
13. Install the cap, wiper and nuts.
Tightening torque Nut (3)
(1) Cap
(2) Wiper
(3) Nut
6.5 to 9.5 N·m
0.66 to 0.97 kgf·m
4.79 to 7.01 lbf·ft
RY9212148CAS0072US0
5-S50
KiSC issued 08, 2015 A
KX080-4, WSM
CABIN
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.
Ambient temperature
15°C or higher
Below 15°C
10 minutes
30 minutes
(1) Cabin Frame
(2) Trim
(3) Primer
(a) No less than 18 mm (0.71 in.)
RY9212148CAS0073US0
3. Apply the adhesive.
(1) Nozzle
(2) Trim
(3) Adhesive (Sikaflex - 265)
(a) No less than 7 mm (0.31 in.)
(b) No less than 12 mm (0.47 in.)
RY9212148CAS0074US0
Check for Water Leaks
1. After mounting the glass, sprinkle water to test the seal.
IMPORTANT
• Make sure there are no water leaks.
RY9212148CAS0075US0
5-S51
KiSC issued 08, 2015 A
KX080-4, WSM
CABIN
Items required
• Cleaner : Equivalent of Seeker Cleaner 205
• Adhesive : Equivalent of Seeker Flex 250PC-JM
• Primer : Equivalent of Seeker Primer 206
• Scraper
• Awl
• Adhesive cutter
• Glass suction cups (use if needed)
NOTE
• The cleaner and adhesive have a short shelf-life (9 to 12 months), so obtain them immediately before use from a nearby manufacturer or a shop that handles auto glass products.
(1) Glass Suction Cups (2) Adhesive Cutter
RY9212001CAS0085US0
CAUTION
• The section on removing and installing glass was created as a general explanation of the work method and it may differ from the removal/installation methods for glass installed on the machine covered by this workshop manual. Further, there is no guarantee on the glass or parts used around the glass.
RY9212158CAS0010US0
1. Mask off painted surface around the glass to protect them from scratching while removing/installing glass.
2. Remove the glass.
[When using piano wire (damages parts of the glass)]
• Pierce and make a hole in the adhesive with an awl (or knife of glass cutter, etc.).
• Pass the piano wire (or steel wire) through the hole.
• Wrap both ends of the piano wire around a wood block or the like.
• Pull the piano wire along the edge of the window, sawing through the adhesive between the cab and the glass; then remove the glass from the cab.
[When using an adhesive cutter (completely ruins the glass)]
• Insert the adhesive cutter into the adhesive.
• Pull on part
(a)
of the cutter and cut the glass out.
CAUTION
• If the piano wire gets very hot in one place, it may break.
Avoid rubbing it with much force against the edge of the glass.
• Be careful not to cut yourself on fragments of glass or the blade of the cutter.
(1) Cab Frame
(2) Glass
(3) Awl
(4) Adhesive
(5) Piano Wire
(6) Wood
(7) Adhesive Cutter
RY9212001CAS0086US0
5-S52
KiSC issued 08, 2015 A
KX080-4, WSM
CABIN
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.
3. Affix the windshield dam to the surface of the new glass where the adhesive will be applied.
4. Apply primer uniformly around the circumference of the windshield dam.
5. Apply adhesive uniformly along the outer circumference of the windshield dam.
6. Apply primer uniformly around the entire circumference of the flange of the cab frame. (Application width: 18 mm (0.71 in.) or more)
7. Make and install a spacer for in between the edge of the glass and the cab's frame so that the glass does not slide down during installation. (holds position and prevents slipping)
8. Press lightly all the way around the edge of the glass from the outside, so the glass touches the shield dam and they stick together.
9. Hold the glass in place with packing tape until the adhesive hardens so the glass does not shift or come off.
(1) Glass
(2) Windshield Dam (W/Adhesive)
(3) Primer (Apply)
(4) Adhesive (Apply)
(a) At Least 7 mm (0.28 in.)
(b) At Least 12 mm (0.47 in.)
(c) 12 mm (0.47 in.)
(A) Start Affixing Dam Here
RY9212001CAS0087US0
• For the front window
(1) Glass
(2) Windshield Dam (W/Adhesive)
(3) Adhesive (Apply)
(4) Fastener (Affix as Male/Female Set)
(a) At Least 7 mm (0.28 in.)
(b) At Least 12 mm (0.47 in.)
(A) Line Up with the Edge of the
Frame
RY9212001CAS0088US0
• Recommended shape of triangular bead
NOTE
• Cut the tip of the nozzle of the adhesive cartridge in the shape of a V.
• Apply the adhesive to the glass so it forms a uniform triangular bead.
(1) Nozzle Tip
(2) Windshield Dam (W/Adhesive)
(3) Adhesive (Apply)
(a) At Least 8 mm (0.31 in.)
(b) At Least 12 mm (0.47 in.)
RY9212001CAS0089US0
5-S53
KiSC issued 08, 2015 A
KX080-4, WSM
CABIN
(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.
2. Insert the rubber core into the groove all the way around the trim.
3. Start inserting the rubber core at the bottom center. (to prevent rain from getting in)
(1) Panel
(2) Glass Trim
(3) Rubber Core
(4) Glass
(a) Inside
(b) Start Here
RY9212001CAS0090US0
Put something like a piano wire into the outer window frame, pull it along the frame, remove the adhesive agent and cut it off from the cab frame. Replace the window glass followed by the next procedure.
RY9212032CAS0012US0
How to replace the glass
1. Lift the pin up with a flat-head driver.
Remove the sealant first and lift the pin.
2. Open the window to the point as shown in the figure.
3. Push down to widen up the window frame within elastic deflection not enough to deform itself permanently and replace the glass.
And the same way when you install the glass.
4. Put the pin back and apply sealant.
NOTE
• Use same brand of an adhesive agent and a primer
E.g.)
– Cleaner: TK cleaner made in Daishin Chemistry
– Adhesive agent: Sikaflex-260AP (SikaTack-Go!) or MSI made Sunrise U90
– Primer: Sika Coating Activator or MSI made Sunrise
Primer 24
(1) Pin
(2) Window
(A) Push down to widen up the window frame
RY9212148CAS0023US0
5-S54
KiSC issued 08, 2015 A
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.
NOTE
• You have to finish the glass installation within 3 min. to
6 hours after coating the primer.
(1) Primer (Apply)
(a) 18 mm (0.71 in.) or more
RY9212032CAS0014US0
How to install the glass spacer
1. Remove dirt and grease on the surface of glass spacer with a cleaner such as white gasoline.
2. Apply the primer to the glass spacer.
3. Install the glass spacer in the glass sash. (4 spots)
(1) Glass Spacer
(a) 100 mm (3.9 in.)
(b) Cross Section of the Spacer
(c) Install in the Sash
(d) Inclined Surface
(e) Cab Side
RY9212032CAS0015US0
How to install the sealant dam and apply the primer
1. Remove dirt and grease on the surface of the circumference at the back of the sash glass to apply an adhesive agent and on the surface of applying a sealant dam with a cleaner such as white gasoline. Avoid using an alcoholic cleaner.
2. Put a sealant dam on the position as shown in the figure and evenly apply the primer peripherally.
[ How to apply adhesive ]
1. Apply the adhesive along the circumference of the sealant dam.
NOTE
• You have to finish the glass installation within 3 min. to
6 hours after coating the primer.
• In order to keep water-tightness, the adhesive must be applied unbrokenly.
• Installation of glass needs to be done within 3 min. after the adhesive is applied.
(1) Sealant Dam (W/Adhesive)
(2) Primer (Apply)
(3) Adhesive (Apply)
(a) 12 mm (0.47 in.)
(b) 12 mm (0.47 in.) or more
(c) 7 mm (0.27 in.) or more
5-S55
(A) Starting Point of Installation
RY9212032CAS0016US0
KiSC issued 08, 2015 A
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.
• Need to maintain that state for about 24 hours after the glass sash is set.
(1) Glass Sash
RY9212032CAS0017US0
5-S56
KiSC issued 08, 2015 A
KX080-4, WSM
CABIN
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.
NOTE
• If you remove the trim too far, the glass may shift out of position, preventing a reliable measurement of the clearance.
(1) Cab ASSY
(2) Front Window (Top)
(3) Trim
(4) Cab Frame
(a) Clearance
RY9212001CAS0091US0
3. Remove the clip and then the lock cover.
(1) Lock Cover (2) Clip
RY9212001CAS0092US0
4. Remove the lock of the front window (top) and loosen the lock's mounting bolts.
5. Leave the rear bolt as is and lift up the front bolt 1.0 to 1.5 mm
(0.04 to 0.06 in.).
NOTE
• Lifting the bolt more than 1.5 mm (0.06 in.) may prevent the lock from working.
6. Re-tighten the bolts to the specified torque.
7. Close the front window (top) and lock it securely.
8. Recheck the clearance between the glass and the cab frame and make sure the clearance is smaller.
9. Operate the mini-excavator and make sure the rattling has stopped while driving.
10. Spray some water on the window and make sure it does not leak.
(1) Lock
(2) Bolt (Front)
(3) Bolt (Rear)
RY9212001CAS0093US0
5-S57
KiSC issued 08, 2015 A
KX080-4, WSM
CABIN
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.
3. If the glass is up against the cushion without a gap, it is OK.
4. If there is a gap between the glass and the cushion, it causes the rattling. Loosen the nut and stretch the cushion until it is against the surface of the glass.
5. After adjusting the cushion, re-tighten the nut.
6. Lift the front window (top) and lock it securely to the ceiling.
7. Operate the mini-excavator and make sure the rattling has stopped while driving.
(1) Cabin
(2) Nut
(3) Cushion
(4) Handle
RY9212001CAS0094US0
5-S58
KiSC issued 08, 2015 A
W/H30 CORD,BATTERY(+)
CRSD&N_BI: 100.0
f B
BATTERY_TERMINAL,N_BI
N_BI: 8.00
R
+
BATTERY
-
W/H33 CORD,BATTERY(-)
CORD,BATTERY(-)(MAIN_FRAME)
BASE: 60.0
B/Y
CORD,BATTERY(-)(BATTERY)
W/H33
W/H33
BODYEARTH(MAIN_FRAME)
BASE: 60.0
B/Y
W/H34
W/H34 CORD,BODY EARTH
SWING_FRAME
ENGINE
1
BODYEARTH(ENGINE)
GND1
GND2
BASE: 3 B
GND1 GND2 GND3
BASE: 3 B
GND4
GND1:POWER(MAIN)
GND2:ECU,SENSOR(MAIN)
GND3:POWER,SHIELD(ENGINE)
GND4:ECU,SENSOR(ENGINE)
BATTERY(POWER),N_BI
N_BI: 8.00 R
W/H09
1
MAIN(POWER),N_BI
1
N_BI: 8.00 R
W/H30
SBF-BOX
BASE: 8.00
R
2
SBF_BOX
SBF(ENGINE)
50
Plug-in_type
SBF(MAIN)
60
Plug-in_type
SBF(CRS)
Bolt-in_type
30
1
2
SBF(ALTERNATOR)
100
Bolt-in_type
RD451-54311
4
3
2
SBF,MAIN1-2
2
AC: 5 R/Y
1
BASE: 5 R
SBF-BOX
CRSD: 5.00
R
3
SBF-BOX
4
N_BI:
8.00
R
FUSE(ALTERNATOR)
BASE: 3 R/W
FUSE(STARTER)
BASE: 3 B/W
FUSE(ALTERNATOR)
10
MiniFuses
RD451-54101
FUSE(STARTER)
10
MiniFuses
RD451-54101
MAIN(SIGNAL)
CRSD: 0.50
Y/B
15
W/H09
ENGINE(SIGNAL)
15
CRSD: 0.50
Y/B
W/H00
FUSE(ECU_MAIN(POWER))
BASE: 5 R
FUSE(LEVER_LOCK)
BASE: 3 R/W
FUSE(ECU_MAIN(POWER))
30
MiniFuses
RD451-54101
FUSE(LEVER_LOCK)
MiniFuses
RD451-54101
5
FUSE(ECU-MAIN(AC))
BASE: 3 R/W
FUSE(ECU-MAIN(AC))
MiniFuses
RD451-54101
5
FUSE(ECU-MAIN(+B))
N_BI: 5 R
FUSE(ECU-MAIN(+B))
MiniFuses
RD451-54101
5
FUSE(METER(+B))
BASE: 5 R
FUSE(METER(+B))
10
MiniFuses
RD451-54101
FUSE(HORN-SW)
AUX2: AUX1: 5 R
FUSE(HORN-MAIN)
BASE: 5 R
FUSE(HORN-SW)
MiniFuses
5
FUSE(HORN-MAIN)
10
MiniFuses
RD451-54101
FUSE(RELAY)
BASE: 3 R/W
FUSE(RELAY)
MiniFuses
RD451-54101
5
MAIN(POWER)
BASE: 5 R
1
W/H09
ENGINE(POWER)
BASE: 5 R
1
W/H00
FUSE(ECU_MAIN(POWER))
BASE: 3 Y/R
FUSE(LEVER_LOCK)
BASE: 0.50
f L/W
FUSE(ECU-MAIN(AC))
BASE: 0.50
R/B
FUSE(ECU-MAIN(+B))
N_BI: 0.50
Y/R
FUSE(METER(+B))
BASE: 0.50
R
FUSE(HORN-SW)
AUX2: AUX1: 0.30
L
FUSE(HORN-MAIN)
BASE: 0.50
L/W
FUSE(RELAY)
BASE: 0.50
L
BASE: 3 R
FUSE(ALTERNATOR)
BASE: 1.25
f Y/R
FUSE(STARTER)
BASE: 3 B/W
RELAY(STARTER)
BASE: 0.50
R/B
RELAY(STARTER)
30
3
86
1
NULL
4
87
5
85
2
RELAY(STARTER)
CRSD: 3 B/W
W/H00
ENGINE(OPEN)
5
GREASE
W/H09
5
CRSD: 3 B/W
MAIN(OPEN)
GREASE
BASE: 8.00
R
B
B-1
ALTERNATOR(+B)
ASSY_ALTERNATOR
ALTERNATOR(IG,L)
BASE: 0.75
f W/R
BASE: 1.25
f Y/R
A-2
L
A-1
R
IC
CRSD: 3 B/W
STARTER(S),D
A-1
S
: 100.0
f B
30_+B
B-1
STARTER(+B),D
CRSD&N_BI
ASSY_STARTER
SWITCH(DPF,INHIBIT)
CRSD: 0.30
R/B
7
Vcc(12V)
8
Null
ON OFF
SW(DPF,INHIBIT)
SWITCH(DPF,INHIBIT)
OFF
SIGNAL
9
6
CRSD: 0.30
G/O
CRSD: 0.30
R/B
CRSD: 0.30
G/O
LED(AMBER)
4
RESISTANCE(GND)
1
680
620
Null
3
Null
2
LED(AMBER_GND)
10
RESISTANCE
5
CRSD: 0.30
G/B
CRSD: 0.30
B
GND2
CRSD: 0.30 G/O
AI: 0.50
R/B
ENGINE(SIGNAL)
3
W/H00
RELAY(ECU_MAINPOWER)
RELAY(ECU_MAINPOWER)
NULL
RELAY(ECU_MAINPOWER)
BASE: 3 Y/R
BASE: 2 Y/R
3
30
1
86
87
85
4
5
2
BASE: 3 Y/R
BASE: 0.30
Y/G
3
MAIN(SIGNAL)
W/H09
SWITCH,LIMIT
SWITCH(LEVER_LOCK)
BASE: 0.50
f L/W
2
B B
1
SWITCH(LEVER_LOCK)
BASE: 0.50
f G/W
SWITCH(PRESSURE,25.0K)
AI_PRESSURE_SW
AI: 0.50
R/B
1
NC NC
2
AI_PRESSURE_SW
AI: 0.50
G/W
SWITCH(PRESSURE,25.0K)
BOOM_RAISE_SW
EP: 0.50
R/B
1
NC NC
2
BOOM_RAISE_SW
EP: 0.50
G/R
M
RELAY(GLOW)
BASE: 5 R
BASE: 0.50
B/R
E/F_CHANGE_SWITCH
BASE: 0.30
R/B
7
AC
GLOW,D
CRSD: 3 R/B
1
4-Cylinder
PLUG,GLOW
RELAY(40A,ISO)
1
3
30
86
87
85
4
2
RELAY(GLOW)
CRSD: 3 R/B
BASE: 0.50 B/R
W/H00
ENGINE(OPEN)
2
GREASE
W/H09
2
MAIN(OPEN)
GREASE
OFF ON
(V0511-53822)
SWITCH(E/P,CHANGE)
E/F_CHANGE_SWITCH
OFF
9
ON BASE: 0.30
L/O
6
8
BASE: 0.30
R/B
BASE: 0.30
L/O
4
LED(+)
RESISTOR
1 620ohm
3
2
LED(GND)
10
RESISTOR
620ohm 5
BASE: 0.30
L/W
BASE: 0.30
B
GND2
BASE: 0.30
L/O
BASE: 0.50
f G/W
ENGINE(SOLENOID)
8
W/H00
8
BASE: 0.50
G/W
MAIN(SOLENOID)
W/H09
MAIN(SIGNAL)
7
W/H09
7
AI: 0.50
G/W
ENGINE(SIGNAL)
W/H00
MAIN(SIGNAL)
12
W/H09
12
EP: 0.50
G/R
ENGINE(SIGNAL)
W/H00
JOINT-AIM water-proof
SOLENOID(LEVER_LOCK)
SOLENOID(LEVER_LOCK)
BASE: 0.50 G/W
1
(+) (-)
SOLENOID(LEVER_LOCK)
BASE: 0.50
G
2 MAIN(SOLENOID)
12
W/H09
12
BASE: 0.50
G
ENGINE(SOLENOID)
W/H00
PANEL,ASSY(AI)
1kohm,0.4W
750ohm,0.5W
750ohm,0.5W
150ohm,2W
150ohm,2W
+5V
AI_POT
8
7
GND
4
+12V
2
AUX_LED
5
AI_LED
1
AUX_SW
3
AI_SW
6
AI_CONSOLE
AI: 0.50
R/B
AI: 0.30
R
AI: 0.50
B/Y
AI: 0.50
R/B
AI: 0.30
W
AI: 0.30
L/W
AI: 0.30
B/R
AI: 0.30
O
GRIP(2SPEED)
Vcc(W)
1
PUSH_SW(B)
2
3
TRAVEL_SPEED_SW
NB: 0.50
W/B
NB: 0.50
Y/B
GRIP(ANGLE)
Vcc(B)
1
PUSH_SW(W)
2
LEFT_SW(Y)
3
RIGHT_SW(Y)
4
TRAVEL_SPEED&ANGLE_BLADE_CONTROL_SW
AB: 0.50
W/B
AB: 0.50
Y/B
AB: 0.50
R/Y
AB: 0.50
L/Y
SENSOR(PRESSURE,5MPA)
SENSOR
5MPA
GND
BASE: 0.50
B/Y
1
Vout
BASE: 0.50
L/B
2
Vcc(+5V)
BASE: 0.50
R/B
3
TRAVEL_PRESSURE_SENSOR
WORKLIGHT_SWITCH
BASE: 0.50
L
7
Vcc
OFF ON
SWITCH(WORKLIGHT)
WORKLIGHT_SWITCH
OFF
9
ON BASE: 0.30
R
6
8
BASE: 0.50
L
4
LED(+)
1
3
2
LED(GND)
10
5
BASE: 0.30
B
GND1
SWITCH,STARTER
KEY_SWITCH
BASE: 3 R/W
BASE: 3 B/W
BASE: 3 R
1
2
3
R/W
B/W
R
RELAY(POWER)
BASE: 5 R
BASE: 0.50
L
RELAY(40A,ISO)
1
3
30
86
87
85
4
2
RELAY(POWER)
BASE: 3 W
BASE: 0.30
B
GND2
W/H00
W/H00
BASE: 0.50
W/R
ENGINE(OPEN)
BASE: 1.25
f Y/R
ENGINE(OPEN)
8
4
GREASE
GREASE
W/H09
W/H09
8
MAIN(OPEN)
4
MAIN(OPEN)
GREASE
GREASE
SWITCH,ASSY.ENGINE_STOP
ES: 0.50
W/B
STOP_SWITCH
1
R
STOP_SWITCH
G
2
ES: 0.50
R/L
AI: 0.50
R/B
AUX2: AUX1: 0.30 R/B
AI: 0.50
B/Y
AUX2: AUX1: 0.30
B/Y
JS_CONTROL(R)
AUX2: AUX1: 0.30
R/B
1
+5V(R)
AUX2: AUX1: 0.30
L
AUX2: AUX1: 0.30
W/B
VALVE,ASSY(PL,R,AX)
8
Vcc_SW1(G)
7
Vcc_SW2(Gy)
5
GND(B)
2
JS_CONTROL(R)
AUX2: AUX1: 0.30
OUTPUT(W)
3
HORN_SW1(L)
4
TRIG_SW2(Y)
6
AUX2: AUX1: 0.30
B/Y
AUX2: AUX1: 0.30 Y/R
W
N_AT: 0.50 L/W
AUX2: AT&AUX1: 0.30
L/W
JS_CONTROL(L)
AUX2: AUX1: 0.30
R/B
1
+5V(R)
AUX2: AUX1: 0.30
W/B
AUX2: AUX1: 0.30
W/B
VALVE,ASSY(PL,L,AX)
8
Vcc_SW1(G)
7
Vcc_SW2(Gy)
5
GND(B)
2
JS_CONTROL(L)
AUX2: AUX1: 0.30
B/Y
AUX2: AUX1: 0.30
W OUTPUT(W)
3
PUSH_SW1(L)
4
TRIG_SW2(Y)
6
AUX2: AUX1: 0.30
AUX2: AUX1: 0.30
L/W
L
BASE:
RELAY(LIGHT)
BASE: 3 R
3
0.30
R
1
RELAY(LIGHT)
30
86
NULL
4
87
5
85
2
RELAY(LIGHT)
BASE: 3 Y
BASE: 0.50
B
GND2
BASE: 0.30 L/O
EP: 0.50 G/R
AI: 0.30 B/R
AI: 0.30
O
NB: 0.50
Y/B
AUX2: AUX1: 0.30 L/W
AB: 0.50
Y/B
CRSD: 0.30
G/O
AUX2: AUX1: 0.30
Y/R
AUX2: AUX1: 0.30
L
L/Y
AB: 0.50
AB: 0.50
R/Y
BASE: 0.50 G/W
ECU(MAIN)
BASE: 0.50
L
BASE: 0.50 B/O
AT: 0.30
W
TxD(MAIN-ECU)
61
RxD(MAIN-ECU)
80
TxD(RF-UNIT)
49
AT: 0.30
G
AC: 0.50
Y
AI: 0.50 G/W
BASE: 0.30 R/W
BASE: 0.50 Y/B
ES: 0.50 R/L
RxD(RF-UNIT)
51
COMPRESSOR-CRUTCH-SW
45
AI-PRESSURE-SW
50
WORKLIGHT-SW
44
STARTER-SW
46
ENGINE-STOP-SW
63
WATERSEPARATOR-SW
EP-MODE-SW
65
BOOM-RAISE-SW
66
MULTIPURPOSE-SW
74
AI-CHANGE-SW
75
TRAVEL-SPEED-SW
57
MULTIPURPOSE-LEVER-SW
73
DPF-INHIBIT-SW
70
AUX1-HOLD-SW
69
AUX2-HOLD-SW
72
ANGLE(R)-SW
71
ANGLE(L)-SW
68
LEVER-LOCK-SW
67
CHARGE-INPUT
OIL-SW
FUEL-SW
BASE: 0.50 R/B
BASE: 0.50 B/Y
BASE: 0.50 L/B
AI: 0.30
R
AUX2: AUX1: 0.30
W
AUX2: AUX1: 0.30 W
DISPLAY-CHANGE-SW
USER-CHANGE-SW
+5V-OUT
11
GND(Sensor-Use)
10
FUEL-SENSOR
TRAVEL-PRESSURE-SENSOR
53
WATER-TEMP-SENSOR
OIL-TEMP-SENSOR
BOOM-ROD-PRESS-SENSOR
BOOM-BOT-PRESS-SENSOR
6
BOOM-POT
ACCEL-POT
7
AI-MOTOR-POT
ARM-POT
AUX1-POT1
28
AUX1-POT2
AUX2-POT1
29
AUX2-POT2
BASE: 0.50
B/W
ES: 0.50
W/B
BASE: 0.50
R/B
N_BI: 0.50 Y/R
BASE: 2 f B
GND2
ENGINE-REV-SIGNAL
WAKEUP-SIGNAL
31
+12V-OUT
41
AC-SW(KEY-SW)
76
+B(DIRECT)
59
GND(POWER)
2
N_BI: 0.50
Y/R
AT&N_BI: 0.30
Y/R
N_BI: 0.85
Y/R
BASE: 0.50
R/B
ECU(MAIN)
DIODE(ANTITHEFT_HORN_PROTECT)
AUX2: AT&AUX1: 0.30
L/W
2
DIODE(7321-9822)
A
D_7321-9822
400V
C
DIODE(ANTITHEFT_HORN_PROTECT)
AT: 0.50
L/R
1
FUSE(FRONT-WORKLIGHT)
BASE: 3 Y
FUSE(CAB-WORKLIGHT)
BASE: 3 Y
FUSE(FRONT-WORKLIGHT)
15
MiniFuses
RD451-54101
FUSE(CAB-WORKLIGHT)
20
MiniFuses
RD451-54101
CAN-H
60
CAN-L
79
MAIN-POWER
3
AI-MOTOR(+)
AI-MOTOR(-)
ECU(MAIN)
BASE: 0.50
BASE: 0.50
Y
G
BASE: 2 f Y/R
MOTOR-GND
1
AUX1-SOL(R)
24
AUX1-SOL(L)
23
AUX1-SOL-FEEDBACK
19
BASE: 2 f B
AUX1: 0.50 W
AUX1: 0.50 R/W
AUX1: 0.50 W/B
AUX2-SOL(R)
42
AUX2-SOL(L)
43
AUX2-SOL-FEEDBACK
16
EP-SOL
22
EP-SOL-FEEDBACK
21
AUX2: 0.50 O
AUX2: 0.50 P
AUX2: 0.50
O/B
EP: 0.50 G
EP: 0.50 G/B
TRAVEL-SPEED-SOL
81
MULITIPURPOSE-SOL
17
ANGLE(R)-SOL
18
ANGLE(L)-SOL
20
ANTITHEFT-HORN-RELAY
13
LEVER-LOCK-SOL
62
TRAVEL-ALARM-BUZZER
14
BUZZER-OUT
40
BASE: 0.50
Y
AB: 0.50 G/W
AB: 0.50 R/B
AT: 0.50 L/R
BASE: 0.50
G
BASE: 0.50
BASE: 0.50
B/Y
Y/B
ANTITHEFT-RELAY
STARTER-RELAY
GLOW-RELAY
33
BACKETLOCK-SOL-RELAY
BASE: 0.50
B/R
EF-MODE-INDICATOR
47
48
ANTITHEFT-FLASHER-LED
37
MULTI-PURPOSE-LED
38
AI-MODE-LED
39
AI-SELFHOLD-RELAY
12
BASE: 0.30
L/W
CRSD: 0.30
G/B
AT: 0.30
AI:
AI:
0.30
0.30
BASE: 0.30
R
W
L/W
Y/G
FUSE(FRONT-WORKLIGHT)
BASE: 1.25
Y
FUSE(CAB-WORKLIGHT)
BASE: 2.00
Y
Composition Specification Code
BASE
AI
AT
N_AT
N_BI
AT&BI
AT&N_BI
ES
BCN
TRB
HT
AC
EP
AUX1
AUX2
AT&AUX1
CAB
NB
AB
BC
N_FS
CRSD
CRSD&N_BI
COMMON
Notes
ALL-USE
Auto Idle
Anti-Theft
No.Anti-Theft
No.Battery Isolator
Anti-Theft & Battery Isolator
Anti-Theft & No.Battery Isolator
Engine Stop
Beacon
Travel Alarm
Heater
A/C
Eco Power Mode
Grip (L)
Grip (R)
Anti-Theft & Grip (R)
CAB (8+4)
Normal Blade
Angel Blade
Blade Cap
No.Fuel Supply-pump
CRS-DENSO
CRS-DENSO & No.Battery Isolator
ALL-USE
W/H00
W/H05
W/H06
W/H09
W/H10
W/H12
W/H20
W/H21
W/H28
W/H30
W/H33
W/H34
RD828-53410
RD828-53420
RD809-53333
RD829-53390
RD828-53340
1J770-65091
RD828-53510
RD829-49370
RD829-49360
RD828-47030
RD829-49590
RD828-53220
RD809-53232
RD819-53241
W/H(MAIN,CRS,CA,ANG)
W/H(MAIN,CRS,CA,ANG)
W/H(FUELSENSOR)
W/H(BLOWERMOTOR)
W/H(ENGINE,CRS,US,ANG)
W/H(GS_INT)
W/H(FRONT)
W/H(MAIN,CAB)
W/H(WIPER)
W/H(CAB,RADIO)
W/H(WORKLIGHT)
CORD,BATTERY(+)
CORD,BATTERY(-)
CORD,BODY EARTH
GND2
BASE: 0.50
B
N_BI:
0.50
BASE: 0.50
L
BASE: 0.50 B/O
1
2
3
4
232C
+B
GND
Txd
Rxd
AT&N_BI:
AT: 0.30
AT: 0.30
AT: 0.50 W/B
AT: 0.30
W
AT:
B
GND2
0.30
0.30
Y/R
R
ANTENNA(ANTITHEFT)
6
3
5
LED+
LED
+12V
TX
1
G RX
4
GND
2
ANTITHEFT_ANTENNA
INOUT
RF
BASE: 2 f B
GND1
AUX1: 0.50 W
ENGINE(SOLENOID)
1
W/H00
W/H00
AUX1: 0.50 R/W
ENGINE(SOLENOID)
9
AUX1: 0.50 W/B
ENGINE(SOLENOID)
5
W/H00
AUX2: 0.50 O
ENGINE(SOLENOID)
2
W/H00
AUX2: 0.50 P
ENGINE(SOLENOID)
AUX2: 0.50 O/B
ENGINE(SOLENOID)
10
6
W/H00
W/H00
1
SOLENOID(AUX1-R)
AUX1: 0.50 W
MAIN(SOLENOID) 1
W/H09
SOLENOID(AUX1-R)
SW1
SOLENOID(AUX1-L)
SW2
W/H09
SOLENOID(AUX1-L)
AUX1: 0.50 R/W
9
5
MAIN(SOLENOID)
AUX1: 0.50
W/B
MAIN(SOLENOID)
W/H09
1
SW1
2
SOLENOID(AUX2-R)
AUX2: 0.50 O
MAIN(SOLENOID) 1
W/H09
SOLENOID(AUX2-R)
SW1
SOLENOID(AUX2-L)
10
6
SOLENOID(AUX2-L)
AUX2: 0.50
P
MAIN(SOLENOID)
AUX2: 0.50
O/B
MAIN(SOLENOID)
1
W/H09
W/H09
EP:
SOLENOID(E/P)
0.50 G
SW1
1
SW1
SOLENOID
SW2
SW2
SW2
SOLENOID(AUX1-R)
AUX1: 0.50
W/B
2
SOLENOID(AUX1-L)
2
AUX1: 0.50 W/B
SOLENOID(AUX2-R)
AUX2: 0.50
O/B
2
SOLENOID(AUX2-L)
AUX2: 0.50
O/B
2
SW2
SOLENOID(E/P)
EP: 0.50
G/B
2
ENGINE(SOLENOID)
BASE: 0.50 Y
4
W/H00
MAIN(SOLENOID)
4
W/H09
SOLENOID(TRAVEL_SPEED)
SOLENOID(TRAVEL_SPEED)
BASE: 0.50 Y
1
(+) (-)
2
SOLENOID(TRAVEL_SPEED)
BASE: 0.50
B
GND3
SOLENOID(ANGLE-R)
SOLENOID(ANGLE-R)
AB: 0.50
G/W
1
(+) (-)
SOLENOID(ANGLE-L)
SOLENOID(ANGLE-L)
AB: 0.50
R/B
1
(+) (-)
SOLENOID(ANGLE-R)
AB: 0.50
B
2
SOLENOID(ANGLE-L)
AB: 0.50
B
2
GND1
GND1
BASE: 0.50
R/B
ENGINE(OPEN)
BASE: 0.50
B/Y
ENGINE(OPEN)
W/H00
W/H00
3
7
GREASE
GREASE
TRAVEL_ALARM(FRONT,+)
BASE: 0.50
R/B
BASE: 0.50
B/Y
0.5R(+)
A-1
0.5B(-)
B-1
TRAVEL_ALARM(FRONT,GND)
BUZZER,BACK
BUZZER,BACK
W/H09
W/H09
3
7
MAIN(OPEN)
GREASE
GREASE
TRAVEL_ALARM(REAR,+)
BASE: 0.50
R/B
BASE: 0.50
B/Y
0.5R(+)
A-1
0.5B(-)
B-1
TRAVEL_ALARM(REAR,GND)
N_BI:
0.85
Y/R
BASE: 0.50 Y/B
ELECTRICAL_BUZZER
AV0.5R(+)
1
AV0.5B(-)
2
BUZZER,BACK
BASE: 0.50
B
GND2
ASSY_METER
LCD_METER
BASE: 0.50
R
BASE: 0.50
G
BASE: 0.50
Y
BASE: 0.50 R/B
BASE: 0.50
L
CRSD: 0.50
BASE:
BASE:
0.50 W/R
0.50 B/W
L
+B
7
CAN(L)
5
CAN(H)
6
AC_SW
8
FUEL_SENSOR
1
WATER_TEMP_SENSOR
2
ANALOG_GND
3
CN_VSS
4
OLS_SW
9
CHARGE_SW
10
WAKEUP_OUT
11
REMOTE_WAKE_UP
12
13
14
GND
W/H00
CRSD: 0.50
L
ENGINE(SOLENOID)
3
W/H09
3
CRSD: 0.75
f L
MAIN(SOLENOID) water-proof
JOINT-OIL-SW
OIL-SW,D
CRSD: 0.75 f L
1
SWITCH,OIL
GND2
BASE: 0.50
L
ENGINE(SIGNAL)
4
W/H00
4
BASE: 0.50
L
MAIN(SIGNAL)
W/H09
BASE: 0.50
B
ENGINE(SIGNAL)
8
W/H00
8
BASE: 0.50
B
MAIN(SIGNAL)
W/H09
W/H09 W/H,ENGINE
1
2
SENSOR,FUEL
1
BASE: 0.50
L
ENGINE(FUEL_SENSOR)
W/H05
SENSOR,FUEL
FUEL_SENSOR
1
DUMMY
3
EARTH
2
SENSOR,FUEL
BASE: 0.50
B
W/H05 W/H,FUEL_SENSOR
2
BASE: 0.50
B
ENGINE(FUEL_SENSOR)
W/H05
5 5
CAN
BASE: 0.50 Y
8 8
BASE: 0.50 G
1
4
6
7
1
4
6
7
CAN
CAN(H)
1
2
CAN(L)
3
2
3
2 to_J/C(CAN,MAIN)
BASE: 0.50
L/W
AT: 0.50
N_AT:
0.50
L/R
L/W
L/R
AT:
0.50
RELAY(HORN)
30
3
86
1
RELAY(HORN)
NULL
4
87
RELAY(HORN)
BASE: 1.25
L
5
85
2
BASE: 0.50
GND2
B
BASE: 0.50
L
J/C(CAN,MAIN)
DIODE(7321-9822)
DIODE(HORN)
BASE: 0.50
L
1
C
D_7321-9822
400V
A
DIODE(HORN)
BASE: 0.50
B
2
HORN(+)
BASE: 1.25
L
A-1
BASE: 1.25
B
B-1
HORN(-)
GND2
ASSY_HORN
T1
T2 to_WORKLIGHT
W/H00
1 to_MAIN(WORKLIGHT)
BASE: 1.25
Y
1 W/H12
LIGHT,WORK
CA_R(+)
1
FRONT_WORKLIGHT(+)
CB_B(-)
2
FRONT_WORKLIGHT(-) to_MAIN(WORKLIGHT)
BASE: 1.25
f B
W/H12
2
W/H12 W/H(FRONT) to_WORKLIGHT
BASE: 1.25
B
2 W/H00
GND2
FUSE(BEACON)
BCN: 5 R
FUSE(BEACON)
15
MiniFuses
RD451-54101
FUSE(ROOM_LIGHT)
N_BI: 5 R
FUSE(RADIO(AC))
CAB: 3 W
FUSE(WIPER/WASHER)
CAB: 3 W
FUSE(ROOM_LIGHT)
MiniFuses
5
FUSE(RADIO(AC))
15
MiniFuses
FUSE(WIPER/WASHER)
15
MiniFuses
RD451-54101
FUSE(A/C_CONTROLLER)
HT: AC: 5 R
FUSE(BLOWER)
HT: AC: 5 R
FUSE(COMPRESSOR)
HT: AC: 3 W
FUSE(A/C_CONTROLLER)
MiniFuses
5
FUSE(BLOWER)
30
MiniFuses
FUSE(COMPRESSOR)
10
MiniFuses
RD451-54101
FUSE(CONDENSOR_FAN)
AC: 5 R/Y
SBF(CONDENSOR_FAN)
20
Plug-in_type
361897-0713
FUSE(ELECTRICAL_OUTLET)
BASE: 3 W
FUSE(FUEL_PUMP)
BASE: 3 R/W
FUSE(HEATER,FUELFILTER)
BASE: 3 W
FUSE(ELECTRICAL_OUTLET)
15
MiniFuses
RD451-54101
FUSE(FUEL_PUMP)
MiniFuses
RD451-54101
5
FUSE(HEATER,FUELFILTER)
20
MiniFuses
7154-5845-30
FUSE(BEACON)
BCN: 1.25
W
FUSE(ROOM_LIGHT)
BASE: 0.50
O
FUSE(RADIO(AC))
CAB: 1.25
Y
FUSE(WIPER/WASHER)
CAB: 1.25
G/W
FUSE(A/C_CONTROLLER)
HT: AC: 0.50
R
FUSE(BLOWER)
HT: AC: 3 R
FUSE(COMPRESSOR)
HT: AC: 0.85
W/R
FUSE(CONDENSOR_FAN)
AC: 3 R/L
FUSE(ELECTRICAL_OUTLET)
BASE: 1.25
G
FUSE(FUEL_PUMP)
BASE: 0.50
Y/R
FUSE(HEATER,FUELFILTER)
BASE: 1.25
W
RELAY(BEACON)
BCN: 1.25
W
RELAY(BEACON)
3
30
BCN: 0.30 R/B 86
1
NULL
4
87
5
85
2
RELAY(BEACON)
BCN: 1.25
BCN: 0.30
BR
R/Y
BCN: 0.30
BEACON_SWITCH
R/Y
7
Vcc
BCN: 0.50
L
8
4
LED(+)
1
OFF ON
SWITCH(BEACON)
BEACON_SWITCH
OFF
9
ON BCN: 0.50
B
6
GND2
3
2
LED(GND)
10
5
BCN: 0.30
B
GND2
ELECTRICAL_OUTLET
BASE: 1.25
G
BASE: 2 B
CigaretteSocket
1
(+)
(+)
GND
GND2
2
(-)
W/H00
ENGINE(OPEN)
6
GREASE
W/H09
6
MAIN(OPEN)
GREASE
GND3
ASSY_PUMP,FUEL_BOOT
FUEL_PUMP
BASE: 0.50 Y/R
1
+
BASE: 0.50
B
-
2
W/H00
ENGINE(OPEN)
1
GREASE
W/H09
1
HEATER(FUEL_FILTER)
MAIN(OPEN)
BASE: 1.25
f W
GREASE
HEATER(FUEL_FILTER)
W
W/B
1 2
HEATER(FUEL_FILTER)
BASE: 1.25
f B
GND3
W/H00
BASE: 2.00
Y
CAB
4
W/H19
4
BASE: 0.85
R to_MAIN(CAB)
W/H00
BCN: 1.25 BR
CAB
8
W/H19
8
BASE: 1.25 BR to_MAIN(CAB)
W/H00
BASE: 0.50 O
CAB
3
W/H19
3
BASE: 0.50 O to_MAIN(CAB) to_CAB_WORKLIGHT,FR(+)
1
W/H19 to_CAB_WORKLIGHT,FL(+)
BASE: 0.85
R
1
W/H19
LIGHT,WORK
1
W/H28
CAB_WORKLIGHT,FR(+)
BASE: 0.85
R
CAB(CAB_WORKLIGHT,FR(+))
CA_R(+)
A-1
CB_B(-)
LIGHT,WORK
1
CAB_WORKLIGHT,FL(+)
BASE: 0.85
R
CAB(CAB_WORKLIGHT,FL(+))
W/H28
CA_R(+)
A-1
LIGHT,WORK
CAB_WORKLIGHT,B(+)
BASE: 0.85
R
CA_R(+)
A-1
LAMP(BEACON)
CB_B(-)
BEACON(+)
BASE: 1.25
BR
1
M5 M
CB_B(-)
M5
2
B-1
B-1
B-1
CAB_WORKLIGHT,FR(-)
BASE: 0.85
B
CAB(CAB_WORKLIGHT,FR(-))
CAB_WORKLIGHT,FL(-)
BASE: 0.85
B
CAB(CAB_WORKLIGHT,FL(-))
CAB_WORKLIGHT,B(-)
BASE: 0.85
B
BEACON(-)
BASE: 0.85
B
ASSY_LIGHT,ROOM
ROOM_LIGHT
BASE: 0.50
O
2 com DOOR
1
ON
3
1
W/H28
1
W/H28
BASE: 1.25
B to_CAB_WORKLIGHT,FR(-)
1
BASE: 0.85
W/H19
B to_CAB_WORKLIGHT,FL(-)
1
BASE: 0.85
B
W/H19
SWITCH,ASSY(WIPER)
WIPER_SWITCH
WASHER(B)
3
CAB: 1.25
W
CAB: 1.25
G/W
Vcc_wash(Y/B)
2
Vcc(R)
1 mo(+1)(G/R)
S(G/W)
6
5
CAB: 1.25
CAB: 1.25
CAB: 1.25
G/W
R/W
L/W
Null
4
BASE: 3 B
GND2
BASE: 0.85
B
GND(RADIO)
W/H00
W/H00
W/H00
CAB: 1.25
Y
CAB
7
CAB
5
CAB
1
CAB: 1.25 G/W
CAB(WIPER)
CAB: 1.25 R/W
CAB(WIPER)
CAB: 1.25 L/W
CAB(WIPER)
3
1
2
CAB: 1.25
CAB(WIPER)
W
4
W/H00
W/H00
W/H00
W/H00
W/H19
W/H19
7
5
1 to_MAIN(CAB)
BASE: 3 to_MAIN(CAB)
BASE: 1.25
to_MAIN(CAB)
Y
B
B
3
1
2
BASE: 0.85
G to_MAIN(CAB_WIPER)
BASE: 0.85
W to_MAIN(CAB_WIPER)
BASE: 0.85
R to_MAIN(CAB_WIPER)
4
BASE: 0.50
W/H19
W to_MAIN(CAB_WIPER)
W/H19
W/H19
W/H19
RELAY(20A,MICRO-ISO)
RELAY(BLOWER)
Null
RELAY(BLOWER)
HT: AC: 3 R
3
30
HT: AC: 0.85 W/R
86
1
87
85
4
5
2
HT: AC: 3 L/W
HT: AC: 0.50
L
RELAY(20A,MICRO-ISO)
RELAY(COMPRESSOR)
Null
RELAY(COMPRESSOR)
AC: 0.85 W/R
AC: 0.85 W/R
3
30
1
86
87
85
4
5
2
AC: 0.85
Y
AC: 0.50
G/R
ENGINE(SIGNAL)
W/H00
2
AC: 0.85 Y
ENGINE(SIGNAL)
1
W/H00
DIODE(COMPRESSOR)
AC: 0.50 Y
1
MAIN(SIGNAL)
W/H09
DIODE(6098-0061)
D_6098-0061
1
COMPRESSOR_CLUTCH(A/C)
COMPRESSOR_ASSY
RD451-93901
C
3A
AC: 1.25
f Y
A
1
2
DIODE(COMPRESSOR)
AC: 0.50 B
GND1
DUAL_PRESSURE_SWITCH
2
MAIN(SIGNAL)
W/H09
DUAL_PRESSURE_SWITCH
AC: 0.50
G/R
1 2
DUAL_PRESSURE_SWITCH
AC: 0.50
G
MAIN(SIGNAL)
6
W/H09
AC: 0.85
W/R
ENGINE(SIGNAL)
5
W/H00
RELAY(CONDENSOR_FAN)
RELAY(CONDENSOR_FAN)
Null
5
RELAY(CONDENSOR_FAN)
AC: 3 R/L
3
30
AC: 0.85
MAIN(SIGNAL)
W/H09
W/R
1
86
87
85
4
5
2
AC: 2 f R/G
AC: 0.50 G/R
CONDENSOR_FAN
AC: 2 f R/G
CONDENSOR_FAN
2
(+)L
M
(-)B
1
6
AC: 0.50
G
ENGINE(SIGNAL)
W/H00
CONDENSOR_FAN
AC: 2 f B
A/C_HEATER_CONTROLER
HT: AC: 0.50
R
HT: AC: 0.50 W/R
16
+B
8
IG
AC: 0.50 G/B
HT: AC: 0.50
L
HT: AC: 0.30 R/W
7
14
THERMO_SW
11
FAN
10
13
15
ILL(+)
GND3
THERMOSTAT
AC: 0.85 W/R
AC: 0.50
G
AC: 0.50 G/B
TANK(WASHER)
WASHER_TANK
BASE: 0.50
W
2
(+)
M
(-)
WASHER_TANK
BASE: 0.50
B
1
ASSY_SWITCH,AIR-CON
IN
CONSTANT
VOLTAGE
CIRCUIT
OUT
A/C_SW
HOT_IN
CPU
COOL_IN
HOT_OUT
COOL_OUT
A/C_HEATER_CONTROLER
POT_Vcc
2
HT: AC: 0.50
R/Y
HT: AC: 0.50
BR/W
POT_Vout
1
POT_GND
3
HT: AC: 0.50
W/R
12
SERVO_OUT2:HOT
6
SERVO_OUT1:COOL
5
ILL(-)
9
GND
4
HT: AC: 0.50
HT: AC: 0.50
HT: AC: 0.50
Y
W
B
HT: AC: 0.50
B
GND1
GND1
2
3
A/C
MGC
1
GND
THERMOSTAT
THERMISTOR
6
THERMISTOR
7
Null
4
Null
5
THERMOSTAT
1
THERMISTOR
GND
2
SPEAKER,ASSY
(-)
1
(+)
2
SPEAKER,ASSY
(-)
(+)
1
2
SPEAKER(R)
BASE: 0.50
W/B
BASE: 0.50
W
SPEAKER(L)
BASE: 0.50
Y/B
BASE: 0.50
Y
BASE: 1.25
Y
BASE: 0.85 G to_WIPER
2
BASE: 0.85 W to_WIPER
BASE: 0.85 R to_WIPER
4
3
BASE: 0.85 B to_WIPER
1
W/H19
W/H19
W/H19
W/H19
2 to_CAB(WIPER)
4 to_CAB(WIPER)
3 to_CAB(WIPER)
1
BASE: 0.50
W/H20
G to_CAB(WIPER)
W/H20
W/H20
W/H20
BASE: 0.50
RADIO(+B)
BASE: 1.25
RADIO(AC)
BASE: 0.50
RADIO(GND)
O
Y
B
BASE: 1.25
RADIOFRAME(GND)
BASE: 0.50
SPEAKER(R-)
B
W
BASE: 0.50 W/B
SPEAKER(R-)
Y BASE: 0.50
SPEAKER(L+)
BASE: 0.50 Y/B
SPEAKER(L-)
RADIO
RADIO(+B)
A-1
RADIO(AC)
B-1
RADIO(GND)
C-1
RADIOFRAME(GND)
D-1
SPEAKER(R+)
E-1
SPEAKER(R-)
F-1
SPEAKER(L+)
G-1
SPEAKER(L-)
BASE: 1.25
B
GND(RADIO,CAB)
BASE: 3 B
CAB_POWER_SOURCE
GND(RADIO)
1
BASE: 0.50 O
BASE: 0.85 R
BASE: 3 B
2
ROOM_LIGHT(+B)
3
CAB_WORK_LIGHT
4
5
GND(CAB)
BASE: 1.25
Y
BASE: 1.25 BR
6
RADIO(AC)
7
BEACON
8
CAB_POWER_SOURCE
GND(CABFRAME)
BASE: 0.50 B
BASE: 0.50 W
BASE: 0.50 R
WIPER,F
1
4
3
(+B)
(S)
(+1)
M
MOTOR_WIPER
(-)
2
WIPER,F
BASE: 0.50
G
BASE: 1.25
B
GND(WIPER,F)
HT: AC: 0.50
HT: AC: 0.50
SERVO_MOTOR
W MAXCOOL
1
Y
HT: AC: 0.50 BR/W
2
Pt
3 null
4
HT: AC: 0.50
R/Y GND
5 null
HT: AC: 0.50
W/R
6
7
Vz
SERVO_MOTOR
M
W/H06 W/H,BLOWERMOTOR,AC
HT: AC: 3 B
HT: AC: 0.50 L
A/C_FAN_SWITCH
HT: AC:
HT: AC: 0.50 L
L
HT: AC: 3 L/Y
HT: AC: 3 L/B
HT: AC: 3 B
GND1
HT: AC: 3 B
GND1
A/C_FAN_SWITCH
OFF Lo Mi Hi
1 com
3
6
P-ON
LO
2
MID
4
HI
19.6A
5
BASE: 3 L/B
[MAIN]to_BLOWER_MOTOR
HT: AC: 3 L/B
W/H00
2
[MAIN]to_BLOWER_MOTOR
HT: AC: 3 L/W
W/H00
1
RESISTOR_BLOWER
MAIN_to[BLOWER_MOTOR]
RESISTOR_BLOWER
HT: AC: 3 L/Y
BASE: 3 L/B
HT: AC: 3 B
3
4
1
2
M1
HI
LO
M2
BLOWER_MOTOR
MAIN_to[BLOWER_MOTOR]
BLOWER_MOTOR
BASE: 3 L/W
1 W/H06
1
BLOWER
M
BLOWER
2
221 ℃ ± 10 ℃
BLOWER_MOTOR
BASE: 3 L/B
W/H06 W/H,BLOWERMOTOR,AC
RELAY(CRS_MAIN)
RELAY(CRS_MAIN)
CRSD: 3.00
R
3
30
CRSD: 2.00
R
86
1
NULL
4
87
RELAY(CRS_MAIN)
CRSD: 3.00
R
5
85 CRSD: 0.50
L
2
J/C(CAN,EGR,SERVICE) to_J/C(CAN,EGR,SERVICE)
W/H09
W/H09
CRSD: 0.50
Y
MAIN(SIGNAL)
CRSD: 0.50
G
MAIN(SIGNAL)
10
14
W/H00
W/H00
10
14
CRSD: 0.50
Y
ENGINE(SIGNAL)
CRSD: 0.50
G
ENGINE(SIGNAL)
CRSD: 0.50 B
GND2
SERVICE_TOOL
SERVICE_TOOL
SERVICE_TOOL
CRSD: 0.50
R/B
SERVICE_TOOL
1
3
4
2
1
3
SERVICE_TOOL(CAP)
CRSD: 0.50
G
SERVICE_TOOL(CAP)
4
SERVICE_TOOL(CAP)
2
SERVICE_TOOL(CAP)
REGISTER(120ohm)
CRSD: 0.50
Y
REGISTER(120ohm)
REGISTER
2 120ohm
REGISTER
120ohm 1
REGISTER(120ohm)
CRSD: 0.50
G
GND4
EGR_VALVE
CRSD: 0.75 f Y
CRSD: 0.75 f G
CRSD: 0.75
f B
CRSD: 0.75 f R
VALVE,ASSY(EGR)
CAN_H
1
CAN_L
2
GND
3
POWER(12V)
4
M
SENSOR_AIR_FLOW
AIR_
FLOW_
SENSOR
-
1
+
2
VC
3
GND
POWER
4
5
AIR_FLOW_SENSOR
CRSD: 0.5
f GR
CRSD: 0.5
f L
CRSD: 0.5
f W/R
CRSD: 0.5
f W/B
CRSD: 0.50
R
THROTTLE_VALVE_ASSY(INTAKE)
M
Hall IC
M1(OPEN)
1
M2(CLOSE)
2
GND
3
TPS
4
5V
5
INTAKE_THROTTLE_MOTOR
CRSD: 0.75
f B/R
CRSD: 0.75
f R/B
CRSD: 0.75
f L/B
CRSD: 0.75
f L
CRSD: 0.75
f G/W
6
INJECTOR,ASSY
INJECTOR_1
CRSD: 2.0 f B
2
2
INJECTOR,ASSY
INJECTOR_2
CRSD: 2.0 f B
2
2
INJECTOR,ASSY
INJECTOR_3
CRSD: 2.0 f B
2
2
INJECTOR_4
CRSD: 2.0 f B
2
INJECTOR,ASSY
2 1
1
1
1
1
INJECTOR_1
CRSD: 2.0 f W
1
INJECTOR_2
CRSD: 2.0 f W
1
INJECTOR_3
CRSD: 2.0 f W
1
INJECTOR_4
CRSD: 2.0 f W
1
S
CRSD: 0.50
B
2
S
CRSD: 0.50
B
3
S
CRSD: 0.50
B
4
S
CRSD: 0.50
B
JOINT-INJ_012,D water-proof
JOINT-INJ_022,D water-proof
JOINT-INJ_032.D
water-proof
JOINT-INJ_042,D water-proof
JOINT-INJ_011,D water-proof
JOINT-INJ_021,D water-proof
JOINT-INJ_031,D water-proof
JOINT-INJ_041,D water-proof
W/H09
W/H09
CRSD: 0.50
G
MAIN(SIGNAL)
CRSD: 0.50
Y
MAIN(SIGNAL)
13
9
W/H00
W/H00
13
9
CRSD: 0.50
G
ENGINE(SIGNAL)
CRSD: 0.50
Y
ENGINE(SIGNAL)
CRSD: 2 f R
CRSD: 2 f R
CRS-ECU(58pin)
+BP
B-5
+BP
B-6
CRS-ECU(96pin)
CRSD: 0.50
L
MainRelay
B-33
CRSD: 0.50 Y
CRSD: 0.50 G
CRS-ECU(58pin)
CAN1-H
B-51
CAN1-L
B-52
CRSD: 0.50 Y
CRSD: 0.50 G
CAN2-H
B-38
CAN2-L
B-39
CRS-ECU(96pin)
TAC
EGR_Lft_SEN_Vcc
EGR_Lft_SEN_GND
EGR_lIFT_SEN
EGR_Motor(-)
EGR_Motor(+)
CRS-ECU(58pin)
CRSD: 0.5 f W/R
CRSD: 0.5 f W/B
CRSD: 0.5 f L
CRSD: 0.5 f
CRS-ECU(96pin)
GR
CRSD: 0.75 f R/B
CRSD: 0.75 f B/R
CRS-ECU(58pin)
CRS-ECU(96pin)
CRSD: 0.75 f L
CRSD: 0.75 f L/B
CRSD: 0.75 f G/W
CRS-ECU(58pin)
CRS-ECU(96pin)
CRS-ECU(58pin)
MAF_SEN_SIG
A-30
MAF_GND
A-7
IntakeAirTemp(AFS)
A-34
IntakeAirTemp(AFS)_GND
A-10
IntakeThrottleMotor(+)
B-57
IntakeThrottleMotor(-)
B-44
IntakeThrottleSensor_SIG
B-29
IntakeThrottleSensor_GND
B-16
IntakeThrottleSensor_Vcc
B-9
ExtShutterPull_Relay
ExtShutterHold_Relay
CRS-ECU(96pin)
Starter_Relay
CRSD: 0.50
Y/B
ST_SW
B-54
IG_SW
IG_SW
CRS-ECU(58pin)
Heater_Relay
CRS-ECU(96pin)
CRSD: 1.25
f B/W
CRSD: 1.25
f R/W
CRSD: 1.25
f L/R
CRSD: 1.25
f B/R
CRSD: 1.25
f Y
INJ_Common1
A-49
INJ_Common1
A-73
INJ-Common2
A-1
INJ-Common2
A-25
INJ_DRV_TWV1
A-74
CRSD: 1.25
f W/B
CRSD: 1.25
f Y/B
INJ4_DRV_TWV4
A-3
INJ2_DRV_TWV2
A-26
CRSD: 1.25
f R/L
INJ3_DRV_TWV3
A-51
CRSD: 2 f B
CRSD: 2 f B
GND4
GND4
CRSD: 0.85
B
CRS-ECU(58pin)
GND4
POWER_GND
B-3
POWER_GND
B-4
CASE_GND
B-18
ENGINE-ECU(SS2intT4)
NE_Vcc
NE_GND
NE_SIG
A-22
A-19
A-43
G_Vcc
G_GND
G_SIG
A-44
A-18
A-42
CRSD: 0.75
f G
CRSD: 0.75
f B
CRSD: 0.75
f R
CRSD: 0.75
f G
CRSD: 0.75
f Y
CRSD: 0.75
f L
CRSD: 0.50
B water-proof
SHIELD-G1,D
S
CRS-ECU(96pin)
6
CRSD: 0.50
B
SHIELD-NE,D water-proof
S
5
CRSD: 0.75
f G to_CAMSHAFT_SENSOR
CRSD: 0.75
f Y
CRSD: 0.75
f L
1
3
2 to_CAMSHAFT_SENSOR
GND4
4
W/H09
W/H09
W/H09
W/H09
CRANKSHAFT_SENSOR(NE),D
CRSD: 0.75
f G
CRSD: 0.75
f B
1
2
Vcc
GND
SENSOR(NE)
1
3
2
4
W/H10
W/H10
W/H10
W/H10
BASE: 0.5 f R to_MAIN(CAMSHAFT_SENSOR)
BASE: 0.5 f B to_MAIN(CAMSHAFT_SENSOR)
BASE: 0.5 f W to_MAIN(CAMSHAFT_SENSOR) to_MAIN(CAMSHAFT_SENSOR)
S
7 water-proof
SHIELD-G2,D
OUT
CRANKSHAFT_SENSOR(NE),D
CRSD: 0.75
f R
3
CAMSHAFT_SENSOR(G)
BASE: 0.5 f R
1
BASE: 0.5 f B
2
VCC
GND
SENSOR(G)
W/H10 W/H,GS
OUT
CAMSHAFT_SENSOR(G)
BASE: 0.5 f W
3
EngineWarning_Lamp
EngineStop_Lamp
OIL_Lamp
Heater_Lamp
OverHeat_Lamp
ForceRegenReq_Lamp
Regen_Lamp
AccelSensor1_Vcc
AccelSensor1_SIG
AccelSensor1_GND
CRS-ECU(58pin)
CRS-ECU(96pin)
AccelSensor2_Vcc
AccelSensor2_SIG
AccelSensor2_GND
CRS-ECU(58pin)
VehicleSpeed
PressDiffSensor_SIG
A-66
PressDiffSensor_GND
A-59
PressDiffSensor_Vcc
A-23
SCV(+)
SCV(-)
B-20
B-7
FuelTemp_SIG
A-31
FuelTemp_GND
A-8
CoolantTemp_SIG
A-39
CoolantTemp_GND
A-15
CRSD: 0.75
f L
CRSD: 0.75
f L/B
CRSD: 0.75
f L/R
CRS-ECU(96pin)
CRSD: 0.75
f B/R
CRSD: 0.75
f G
CRS-ECU(58pin)
CRSD: 0.75
f G
CRSD: 0.75
f G/W
CRSD: 0.75
f L/R
CRSD: 0.75
f L
SLD_GND
CRS-ECU(96pin)
PFuel_SIG
A-40
PFuel_SIG
A-41
PFuel_Vcc
A-24
PFuel_GND
A-16
BoostSEN_Vcc
A-46
BoostSEN_SIG
A-61
BoostSEN_GND
A-57
ExtAirTempSEN_SIG
B-28
ExtAirTempSEN_GND
B-15
CRSD: 0.5 f Y
CRSD: 0.5 f Y
CRSD: 0.5 f L
CRSD: 0.5 f G
CRSD: 0.75
f G/W
CRSD: 0.75
f W/R
CRSD: 0.75
f W/B
CRSD: 0.5 f W
CRSD: 0.5 f R
CRS-ECU(58pin)
CRS-ECU(96pin)
CRS-ECU(58pin)
STOP_SW
Parking_SW
ForceRegen_SW
Regenlnhibit_SW
WaterLevel_SW
A-85
FilterPlugged_SW
CAN_SEL_SW
BGmode_SW
RatedSpeedSel_SW(BG)
Neutral_SW
OIL_SW
CRSD: 0.75
f W
CRS-ECU(96pin)
CRS-ECU(58pin)
CRS-ECU(96pin)
Inlet_DOC_Temp
A-38
Inlet_DOC_Temp_GND
A-14
Outlet_DOC_Temp
A-36
Outlet_DOC_Temp_GND
A-12
Outlet_DPF_Temp
A-62
Outlet_DPF_Temp_GND
A-58
SIGNAL_GND
B-1
SIGNAL_GND
B-2
CRS-ECU(58pin)
CRS-ECU(96pin)
CRSD: 0.75
f LG
CRSD: 0.75
f L/B
CRSD: 0.75
f B/R
CRSD: 0.75
f L
CRSD: 0.75
f R/B
CRSD: 0.75
f L/R
CRSD: 2 f B
CRSD: 2 f B
CRS-ECU(58pin)
GND4
GND4
CRSD: 0.50 B
CRSD: 0.50 B
S
8
SHIELD-RAIL water-proof
S
9 water-proof
SHIELD-AIR-TEMP
SENSOR
DPF_DIFF_PRESSURE_SENSOR
CRSD: 0.75
f L/R
CRSD: 0.75
f L/B
CRSD: 0.75
f L
VDD
3
1
2
GND
VOUT
4.7ohm
ASIC
PUMP_ASSY_SUPPLY
SUCTION_CONTROL_VALVE
CRSD: 0.75 f G
A-1
SCV
CRSD: 0.75
f B/R
A-2
+B
SUPPLY
CONTROL
VALVE
FUEL_TEMP_SENSOR
CRSD: 0.75 f G
B-1
CRSD: 0.75 f G/W
B-2
SENSOR,WATER_TEMP.
1
GND
WATER_TEMP_SENSOR
CRSD: 0.75
f L
2
RAIL_ASSY_COMMON
RAIL_PRESSURE_SENSOR
CRSD: 0.5 f L
CRSD: 0.5 f Y
1
A-VCC
PFUEL
Pressure
Sensor
CRSD: 0.5 f G
2
A-GND
3
SENSOR_BOOST
CRSD: 0.75
f G/W
CRSD: 0.75
f W/R
1
1
2
SENSOR_BOOST
Vcc
Vout
CRSD: 0.75
f W/B
INLET_AIR_TEMP_SENSOR
CRSD: 0.5 f W
GND
3
SENSOR_INLET_AIR_TEMP.
2
BOOST
PRESSURE
SENSOR
INLET_AIR_TEMP_SENSOR
CRSD: 0.5 f R
SWITCH(WATER_LEVEL)
SWITCH(WATER_LEVEL)
CRSD: 0.75
f W
1
W
SWITCH(WATER_LEVEL)
W/B
2
CRSD: 0.75
f R
DOC_INLET_TEMP_SENSOR
CRSD: 0.75
f L/B
DOC_OUTLET_TEMP_SENSOR
CRSD: 0.75
f L
SENSOR(THERMO,0)
1
SENSOR(THERMO,1)
2
1
SENSOR(THERMO,2)
2
DPF_OUTLET_TEMP_SENSOR
CRSD: 0.75
f L/R
1 2
DOC_INLET_TEMP_SENSOR
CRSD: 0.75
f LG
DOC_OUTLET_TEMP_SENSOR
CRSD: 0.75
f B/R
DPF_OUTLET_TEMP_SENSOR
CRSD: 0.75
f R/B to_J/C-INJ/SLD-GND to_J/C-INJ/SLD-GND to_J/C-INJ/SLD-GND to_J/C-INJ/SLD-GND
5
6
5
6
4
3
7 7 2
8 8 1
J/C-INJ/SLD-GND
1
2
4
3 to_J/C-INJ/SLD-GND to_J/C-INJ/SLD-GND to_J/C-INJ/SLD-GND
CRSD: 0.50
B to_J/C-INJ/SLD-GND
GND3
2
1
J/C-SLD-GND
1
2 to_J/C-SLD-GND
CRSD: 0.50
B to_J/C-SLD-GND
GND4
232C
2 1
4 3
C_WF04_7123-7740-40_1
A/C_FAN_SWITCH
3
6
2
5
1
4
C_OF06_7123-2865-30_1
A/C_HEATER_CONTROLER
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
C_OF16_MX34016SF1_1
AIR_FLOW_SENSOR
5 4 3 2 1
C_WF05_6189-1046_1
AI_CONSOLE
4 3
8 7
2
6
1
5
C_WF08_FW-C-8F_1
AI_PRESSURE_SW
1
2
C_WF02_6189-0156_1
ALTERNATOR(+B)
1
M6
C_LAF01_M6_1
ALTERNATOR
(IG,L)
1
2
C_OF02_71
23-2820_1
BEACON_SWITCH
4
10
3
9 8 7
2
6
1
5
C_OF10_7123-8307
_1
CAB(CAB_
WORKLIGHT,FR(+))
CAB_
WORKLIGHT,
FL(+)
1
1
C_CAM01_1 C_CBF01_
1
ANTITHEFT_
ANTENNA
1 2 3
4 5 6
BLOWER_MOTOR
2 1
C_OF02_6098-0325
_1 to_CAB_WORK
LIGHT,FR(+)
1
CAB_WORK
LIGHT,FL
(-)
1
C_WM06_61
89-6171_1
BOOM_RAISE_SW
C_CBF01_1
BATTERY
(POWER),N_BI
1
2
C_WF02_6189-0156
_1
CAB(CAB_
WORKLIGHT,FR(-))
1
C_CAM01_
1
CAB_
WORKLIGHT,
FR(+)
1
1
C_OM01_71
22-4113-3
0_1
CAB
C_CBF01_1
MAIN(POWER),
N_BI
1
C_OF01_71
23-4113-3
0_1
4
8
3
7
2
6
C_OF08_7123-6083
-30_1 to_MAIN(CAB)
1
5 to_CAB_
WORKLIGHT,FR(-)
1
C_CAM01_1
C_CBF01_
1
CAB_
WORKLIGHT,
FR(-)
1
1 2 3
5 6
4
7 8
CAB(WIPER)
BATTERY_
TERMINAL,BI
C_CAM01_
1
1
M8
C_OM08_7122-6083
-30_1
2
4
1
3
C_OF04_7123
-6040_1 to_MAIN(CAB_
WIPER)
CAMSHAFT_
SENSOR(G)
C_LAF01_M
8_1
CAB(CAB_WORKLIGHT,
FL(+))
1
3 2 1
C_WF03_6
189-1130
_1
BATTERY_
TERMINAL,N_BI
1
M8
C_CAM01_1
1 2
3 4 to_CAB_WORKLIGHT,FL(+)
C_OM04_7122
-6040_1
1
C_LAF01_M
8_1
CAB_POWER_
SOURCE
C_CBF01_1
BEACON(+)
1
M3
CAB(CAB_WORKLIGHT,
FL(-))
1
4
8
3
7
2
6
1
5
C_OF08_7123
-6083-30_1
C_LEF01_M
3_1
C_CBF01_1
CAB_WORKLIGHT,
B(+)
1
CAN
2 1
C_WF02_7
123-8520
-40_1
COMPRESSOR_
CLUTCH(A/C)
1
C_WF01_F
W-C-1F_1
CONDENSOR_
FAN to_CAB_WORKLIGHT,FL(-)
1
C_CBF01_1
2 1
C_WF02_D
T06-2S-C
E05_1
C_CAM01_1
CAB_WORKLIGHT,
B(-)
1
C_CAM01_1
CRANKSHAFT_SENSOR(NE),D
3 2 1
C_WF03_7283-8852-30_1
CRS-ECU(58pin)
1 2
7 8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28 29 30 31 32
3 4
5 6
33 34 35 36 37 38 39 40 41 42 43 44 45
46 47 48 49 50 51 52 53 54 55 56 57 58
C_WF58_9-1452415-9_1
CRS-ECU(96pin)
1 2 3 4 5
25 26 27 28 29
6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
49 50 51 52 53
73 74 75 76 77
54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
C_WF96_9-1452423-9_1
DIODE(COMPRESSOR)
2 1
C_OF02_6098-0017_1
DOC_INLET_TEMP_SENSOR
2 1
C_WF02_7283-7026-30_1
DOC_OUTLET_TEMP_SENSOR
2 1
C_WF02_7283-7028-10_1
DPF_DIFF_PRESSURE_SENSOR
3 2 1
C_WF03_1813271-1_1
DPF_OUTLET_TEMP_SENSOR
2 1
C_WF02_7283-7023_1
DUAL_PRESSURE_SWITCH
2 1
C_WF02_6189-0094_1
E/F_CHANGE_SWITCH
4
10
3
9 8 7
2
6
1
5
C_OF10_7123-8307_1
ECU(MAIN)
6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43
5
3
44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62
63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81
2
4
1
C_WF81_1473244-1_1
EGR_VALVE
4 3 2 1
C_WF04_6195-0030_1
ELECTRICAL_BUZZER
2
1
2
C_OF02_7123-2820_1
ELECTRICAL_OUTLET
1
C_OF02_7123-8322_1
ENGINE(FUEL_SENSOR)
1 2
C_WM02_7222-1424-40_1
FUELSENSOR
2 1
C_WF02_7123-1424-40_1
ENGINE(OPEN)
1 2 3
5 6
C_OM08_7122
-6080_1
MAIN(OPEN)
4
8
3
7
C_OF08_7123
-6080_1
ENGINE(POWER)
1
2
7 8
2
6
C_OM02_7122
-4123-30_1
MAIN(POWER)
1
2
C_OF02_7123
-4123-30_1
ENGINE
(SOLENOID)
1 2 3 4
5 6 7 8
9 10 11 12
C_WM12_7222
-7923-40_1
4
1
5
FRONT_
WORKLIGHT(+)
FUSE
(COMPRESSOR)
FUSE(HEATER,
FUELFILTER)
GND
(CABFRAME)
1
C_CBF01_
1
FRONT_
WORKLIGHT(-)
1
C_CAM01_
1
FUEL_PUMP
1
2
C_OF02_7
123-2820
_1
FUEL_TEMP_
SENSOR
2 1
C_WF02_1
78392-6_
1
FUSE(A/C_
CONTROLLER)
2
C_OF02_M iniFuses
_1
1
2 1
2 1
C_OF02_M iniFuses
_1
*1 279
*2 351
C_OF02_M iniFuses
_1
FUSE
(CONDENSOR_
FAN)
FUSE(HORN-
MAIN)
2 1
2 1
C_OF02_P lug-in_t ype_1
C_OF02_M iniFuses
_1
FUSE(HORN-
SW)
FUSE(ECU-
MAIN(+B))
2 1
2 1
C_OF02_M iniFuses
_1
C_OF02_M iniFuses
_1
FUSE(LEVER_
LOCK)
FUSE(ECU-
MAIN(+B)),BI
2 1
2 1
C_OF02_M iniFuses
_1
C_OF02_M iniFuses
_1
FUSE(METER
(+B))
FUSE(ECU-
MAIN(AC))
2 1
2 1
C_OF02_M iniFuses
_1
C_OF02_M iniFuses
_1
FUSE(RADIO
(AC))
FUSE(ECU_
MAIN(POWER))
2 1
MAIN(SOLENOID)
FUSE
(ALTERNATOR)
2 1
4
8
12
3
7
2
6
11 10
1
5
9
2 1
C_OF02_M iniFuses
_1
C_WF12_7123
-7923-40_1
C_OF02_M iniFuses
_1
ENGINE(SYGNAL)
FUSE(BEACON)
FUSE
(ELECTRICAL_
OUTLET)
2 1
2 1
C_OF02_M iniFuses
_1
C_OF02_M iniFuses
_1
FUSE(RELAY)
2
C_OF02_M iniFuses
_1
1
FUSE(ROOM_
LIGHT)
1
M8
C_LAF01
_M8_1
GND(RADIO)
1
M8
C_LAF01
_M8_1
GND(RADIO
,CAB)
1
M5
C_LEF01
_M5_1
GND(WIPER,
F)
1
M8
C_LAF01
_M8_1
GND1
1
M8
C_LAF01
_7009-1
836_1
GND2
1
M8
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
C_WM16_7222
-7564-40_1
C_OF02_M iniFuses
_1
FUSE(BLOWER)
FUSE(FRONT-
WORKLIGHT)
2 1
2
C_OF02_M iniFuses
_1
1
C_LAF01
_7009-1
836_1
MAIN(SYGNAL)
2
C_OF02_M iniFuses
_1
1
C_OF02_M iniFuses
_1
FUSE
(STARTER)
2 1
GND3
4
8
12
3
7
11
2
6
10
16 15 14
1
5
9
13
FUSE(CAB-
WORKLIGHT)
2 1
FUSE(FUEL_
PUMP)
2
C_OF02_M iniFuses
_1
1
C_OF02_M iniFuses
_1
FUSE(WIPER/
WASHER)
1
M8
C_LAF01
_7009-1
836_1
C_WF16_7123
-7564-40_1
C_OF02_M iniFuses
_1
FUSE(FUEL_
SUPPLY_PUMP)
2
C_OF02_M iniFuses
_1
1
GND4
2 1
1
M8
C_OF02_M iniFuses
_1
GLOW,D
1
M4
C_LAF01
_7009-1
836_1
C_LEF01_
M4_1
HEATER
(FUEL_
IFILTER)
2 1
C_WF02_
6-17614
6-6_1
HORN(+)
1
C_OF01_
7123-20
10_1
HORN(-)
1
C_OF01_
7123-20
10_1
INJECTOR_1
1
2
C_WF02_
6189-06
11_1
INJECTOR_2
1
2
C_WF02_
6189-06
11_1
INJECTOR_3
1
2
C_WF02_
6189-06
11_1
INJECTOR_4
1
2
C_WF02_
6189-06
11_1
INLET_AIR_TEMP_SENSOR
6 5 4 3 2 1
C_WF06_7283-1968-30
_1
4
8
2
6
C_WF08_6195-0051_1
JS_CONTROL(R)
4
8
2
3
7
3
7
2
3
1
C_WF02_7283-7027-40
_1
INTAKE_THROTTLE_MOTOR
JS_CONTROL(L)
1
C_WF03_7123-6234-40
_1
LCD_METER
7 6
14 13
5
12
4
11
3
10
2
9
1
8
C_OF14_7283-5832_1
1
2
6
C_OF01_172320-2_1
1
5
C_WF08_6195-0051_1
1
5
KEY_SWITCH
OIL-SW,D
RADIO(+B)
1
C_CBF01_1
RADIO(AC)
1
RELAY
(CRS_MAIN)
1
3
5
4 2
C_OF05_M
-ISO_1
SBF,MAIN1-2
2 1
C_OF02_7323-3220_1
C_CBF01_
1
RADIO(GND)
1
RELAY(ECU_
MAINPOWER)
C_CAM01_
1
1
3
5
4 2
RADIOFRAME
(GND)
1
C_OF05_M
-ISO_1
RELAY(GLOW)
SBF-BOX
M5 M5
2
4
1
3
M6 M5
C_OF06_7357-5155-30
_1
SENSOR,FUEL
3 2 1
C_WF03_7283-8730-30
_1
SENSOR_BOOST
C_CAM01_
1
RAIL_
PRESSURE_
SENSOR
1
3
4
2
C_OF04_P
-ISO_1
3 2 1
C_WF03_6189-0099_1
SERVICE_TOOL
3 2 1
C_WF03_1
74357-2_
1
REGISTER
(120ohm)
2 1
RELAY(HORN)
1
3
5
4 2
C_OF05_M
-ISO_1
2 1
4 3
C_WF04_174257-2_1
SERVICE_TOOL(CAP)
C_WF02_7
123-6423
-30_1
RELAY
(BEACON)
RELAY(LIGHT)
1
3
5
4 2
1 2
3 4
C_WM04_174259-2_1
1
3
5
4 2
C_OF05_M
-ISO_1
C_OF05_M
-ISO_1
RELAY(POWER)
RELAY
(BLOWER) 1
3
2
1
3
5
4 2
4
C_OF04_P
-ISO_1
C_OF05_M
-ISO_1
RELAY
(STARTER)
1
3
5
4 2
RELAY
(COMPRESSOR)
C_OF05_M
-ISO_1
1
3
5
4 2
RESISTOR_
BLOWER
C_OF05_M
-ISO_1
2
4
1
3
RELAY
(CONDENSOR_
FAN)
1
3
5
4 2
C_OF04_6
098-0514
_1
ROOM_LIGHT
3 2 1
C_OF05_M
-ISO_1
C_OF03_6
130-2330
_1
7 6
SERVO_MOTOR
5
2
2
4
1
1
3
C_OF07_IL-AG5-7S-S3
C1_1
C_WF02_7283-2090-30
_1
C_WF02_7283-2090-30
_1
2
SOLENOID(ANGLE-L)
SOLENOID(ANGLE-R)
1
SOLENOID
(AUX1-L)
SPEAKER(L)
SUCTION_CONTROL_
VALVE
2 1
1
2
C_WF0
2_174
352-2
_1
C_OF02_
7123-28
20_1
SOLENOID
(AUX1-R)
SPEAKER(L+)
1
C_WF02_6189-0039
_1
SWITCH(DPF,INHIBIT)
4
10
3
9 8
2
7
1
2
6
1
5
2 1
C_CAM01
_1
C_OF10_7123-8307
_1
C_WF0
2_174
352-2
_1
SPEAKER(L-)
SWITCH(LEVER_LOCK)
SOLENOID
(AUX2-L)
1
2 1
2 1
C_CAM01
_1
C_WF02_6195-0003
_1
C_WF0
2_174
352-2
_1
SPEAKER(R)
SWITCH(WATER_LEVEL)
SOLENOID
(AUX2-R)
2 1
C_WF0
2_174
352-2
_1
SOLENOID
(E/F)
2
C_WF0
2_174
352-2
_1
SOLENOID
(LEVER_
LOCK)
2
1
1
C_WF0
2_728
3-209
0-30_
1
SOLENOID
(MULTI)
1
2
C_OF02_
7123-28
20_1
SPEAKER(R-)
1
C_CAM01
_1
SPEAKER(R-)
1
C_CAM01
_1
STARTER(S),D
1
C_OF01_
172320-
1_1
STOP_SWITCH
2 1
C_WF02_6189-0176
_1
THERMOSTAT
5 4 3 2 1
C_OF05_7283-1050
_1
TRAVEL_ALARM
(FRONT,+)
1
C_CBF01_1
TRAVEL_ALARM
(FRONT,GND)
1
C_CAM01_1
TRAVEL_ALARM(REAR,+)
1
TRAVEL_PRESSURE_
SENSOR to_CAB(WIPER) to_J/C-INJ/SLD-GND
3 2 1
1 2
3 4
4 3
8 7
2
6
1
5
C_WF03_7183-7874
-30_1
C_OM04_7122-1347_
1
C_WF08_7283
-7080-40_1
TRAVEL_SPEED&ANGLE_
BLADE_CONTROL_SW
2
1
2
1
4 3
C_WF04_6180-4181
_1
TRAVEL_SPEED_SW
1 2
C_WM03_6092-0013
_1
WASHER_TANK
C_OF02_7123-2820
_1
WATER_TEMP_SENSOR
2
3
1 to_WIPER
J/C-INJ/SLD-GND
2
4
1
3
1 2 3 4
5 6 7 8
C_OF04_7123-1347_
1
C_WM08_7382
-1480-40_1 to_CAMSHAFT_SENSOR to_J/C-SLD-GND
2 1
4 3
2 1
C_WF04_33472-0401
_1
C_WF02_7283
-7020-10_1 to_MAIN(CAMSHAFT_
SENSOR)
J/C-SLD-GND
1 2
3 4
1 2
C_WM02_7382
-8924-10_1
C_WM04_33482-0406
_1 to_J/C(CAN,EGR,SERVICE) to_MAIN
(WORKLIGHT)
6 5 4 3 2 1
1
2
C_WF02_178392-6_
1
C_WF06_7283-8850-
30_1
C_OM02_7122
-2820_1
WIPER,F to_WORKLIGHT
2
4
1
3
J/C(CAN,EGR,SERVICE)
C_OF04_6090-1011
_1
1
2
C_WM06_7182-9630-
30_1
C_OF02_7123
-2820_1
WIPER_SWITCH to_J/C(CAN,MAIN)
3
6
2
5
1
4
C_OF06_7123-2860
_1
4 3
8 7
2
6
1
5
C_WF08_7283-1081-
10_1
WORKLIGHT_SWITCH
J/C(CAN,MAIN)
4
10
3
9 8 7
2
6
1
5
C_OF10_7123-8307
_1
1 2 3 4
5 6 7 8
2 1
C_WF0
2_728
3-209
0-30_
1
1 2
C_WM02_
6187-28
01_1
C_CBF01_1
TRAVEL_ALARM
(REAR,GND)
1
C_WM08_7382-1481-
10_1
SOLENOID
(TRAVEL_
SPEED)
C_CAM01_1
2 1
C_WF0
2_728
3-209
0-30_
1
Printed in Japan 2015. 08, H, EI, EI, engusa Code No. RY911-21601
Printed in Japan 2013. 02, H, EI, EI, engusa Code No. RY911-21600
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Advanced hydraulic system for smooth and powerful operation
Durable construction for demanding applications
Comfortable cabin with excellent visibility
Intuitive controls and advanced monitoring system
Spacious cabin with excellent visibility
Reliable, durable, and high-performance
The key features include an advanced hydraulic system, durable construction, comfortable cabin, intuitive controls, and advanced monitoring system.
The KX080-4 is ideal for demanding tasks in construction, landscaping, and other industries.
It features a spacious cabin with excellent visibility, providing operators with a comfortable and safe working environment.
It provides smooth and powerful operation, enhancing productivity and efficiency.
Yes, the KX080-4 is known for its reliability, durability, and high performance, ensuring longevity and minimizing downtime.
What should I do if a system error occurs?
Please provide details about the error message and the actions preceding its appearance. This information will help in identifying the problem and finding a solution within the viewed workshop manual.
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