WORKSHOP MANUAL

KUBOTA EXCAVATOR

KX080-4

KiSC issued 08, 2015 A

 CONTENTS
TO THE READER SERVICING
TO THE READER 1. PUMP......................................................... 3-S1
I INFORMATION 2. CONTROL VALVE................................... 3-S17
CONTENTS 3. SWIVEL MOTOR ..................................... 3-S26
INFORMATION 4. SWIVEL JOINT ........................................ 3-S41
1. SAFETY FIRST ............................................ I-1 5. TRAVEL MOTOR..................................... 3-S49
2. IN THE INTEREST OF WORK 6. CYLINDER............................................... 3-S69
SAFETY........................................................ I-2 7. PILOT VALVE .......................................... 3-S71
3. LABELS DISPLAYED TO PROMOTE 8. SHOCKLESS VALVES .......................... 3-S106
WORK SAFETY............................................ I-6 9. SWIVEL SHUTTLE VALVE ................... 3-S107
4. MAIN SPECIFICATIONS............................ I-12 10. SOLENOID VALVE................................ 3-S108
5. DIMENSIONS ............................................. I-13 11. ROUTING OF HYDRAULIC HOSES ..... 3-S112
12. MEASURING HYDRAULIC DEVICE
G GENERAL
PERFORMANCE ................................... 3-S133
CONTENTS
13. HYDRAULIC DEVICE
GENERAL
PERFORMANCE STANDARDS............ 3-S158
1. CHECKING EXCAVATOR
14. TROUBLESHOOTING........................... 3-S165
IDENTIFICATION ........................................G-1
2. ENGINE IDENTIFICATION .........................G-2 4 ELECTRICAL SYSTEM
3. MUFFLER FULL ASSEMBLY CONTENTS
IDENTIFICATION ........................................G-5 SERVICING
4. GENERAL PRECAUTIONS.........................G-7 1. LAYOUT OF ELECTRICAL DEVICES
5. HANDLING PRECAUTIONS FOR AND WIRING ROUTING ........................... 4-S1
ELECTRICAL PARTS AND WIRING.........G-11 2. METER PANEL OPERATION ................. 4-S10
6. TIGHTENING TORQUES..........................G-16 3. INSPECTIONS......................................... 4-S44
7. OIL AND WATER CAPACITY TABLE .......G-20 4. TROUBLESHOOTING (START-UP
8. MAINTENANCE INTERVALS....................G-21 EQUIPMENT VERSION) ......................... 4-S50
5. METHODS FOR DIAGNOSING
1 MACHINE BODY
ERRORS.................................................. 4-S51
CONTENTS
6. TROUBLESHOOTING (METER
SERVICING
PANEL VERSION)................................... 4-S53
1. FRONT ...................................................... 1-S1
2. SWIVEL FRAME........................................ 1-S8 5 CABIN
3. TRACK FRAME ....................................... 1-S22 CONTENTS
4. MEASURING MACHINE MECHANISM
PERFORMANCE..................................... 1-S38 1. AIR CONDITIONING SYSTEM................. 5-M1
5. SWIVEL GEAR BACKLASH 2. WIPER .................................................... 5-M17
PERFORMANCE..................................... 1-S40 SERVICING
1. TROUBLESHOOTING............................... 5-S1
2 ENGINE
2. SERVICE SPECIFICATIONS .................... 5-S4
CONTENTS
3. TORQUE.................................................... 5-S5
GENERAL
4. PRECAUTIONS WHEN REPAIRING
1. SPECIFICATIONS.....................................2-G1
THE REFRIGERANT SYSTEM ................. 5-S6
2. DIMENSIONS ............................................2-G2
5. INSPECTING AND CHARGING THE
3. PERFORMANCE CURVES .......................2-G3
REFRIGERANT SYSTEM ....................... 5-S11
4. FAN DRIVE................................................2-G4
6. INSPECTION AND DISASSEMBLY ........ 5-S20
3 HYDRAULIC SYSTEM 7. WINDOW WASHER ................................ 5-S36
CONTENTS 8. CABIN GLASS REMOVAL AND
MECHANISM MOUNTING ............................................. 5-S38
1. DIAGRAM OF HYDRAULIC CIRCUIT...... 3-M1 9. REMOVAL AND INSTALLATION OF
2. HYDRAULIC DEVICE LAYOUT ............... 3-M3 GLASS ..................................................... 5-S52
3. PUMP ....................................................... 3-M4 10. FRONT WINDOW.................................... 5-S57
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

KiSC issued 08, 2015 A

 TO THE READER
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

January, 2013
© KUBOTA Corporation 2013

KiSC issued 08, 2015 A

Record of Revisions
Last digit of
the Code Date Main Revised Point and Corrective Measures Remarks
No.

• Add the contents of pump assembly and disassembly,

1 2015.08.05 S. M
the contents of cabin glass removal and mounting.

KiSC issued 08, 2015 A

I INFORMATION

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

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1. SAFETY FIRST
SAFETY FIRST
• This "Safety Alert Symbol" is used in this manual and on labels on equipment to indicate important
issues and warn of the danger of personal injury. Read and follow these warnings carefully.
• 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.
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2. IN THE INTEREST OF WORK SAFETY

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

• Stop the machine on a hard and level location and
make sure the area around the machine is free of
obstacles and hazardous materials. When parking
the machine indoors, select a spot that can be
properly ventilated.
• 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.
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• 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.
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• 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.
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• 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.
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• 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.
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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.
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• 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.
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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.
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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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3. LABELS DISPLAYED TO PROMOTE WORK

SAFETY
[1] LOCATIONS

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[2] LABEL MAINTENANCE

Thoroughly Read, Understand and Follow Safety Precautions on Labels
• Always keep labels in a clean, undamaged state.
• If labels get dirty, wipe them off with soapy water and a soft cloth.
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.
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4. MAIN SPECIFICATIONS
KUBOTA EXCAVATOR
Model name KX080-4
Type Cabin Angle Blade type Cabin
Rubber Steel tracks Steel tracks Rubber Steel tracks
Operating weight tracks (450 width) (600 width) tracks (450 width)
(including operator's weight) 8290 kg 8340 kg 8470 kg 8680 kg 8730 kg
18280 lbs 18390 lbs 18670 lbs 19140 lbs 19250 lbs
Type Water cooled 4 cycle diesel engine with 4 cylinder
Model name KUBOTA V3307-CRS-T4
Total displacement 3331 cc (203.3 cu.in.)
Engine Engine SAE gross 52.2 kW (70.0 Hp)
power SAE net 48.8 kW (65.5 Hp)
Rated speed 2000 rpm
Low idling speed 1000 rpm
Unit swing speed 9.5 rpm
Travel Fast 4.9 km / h (3.1 mph)
speed Slow 2.7 km / h (1.7 mph)
36.0 kPa 36.2 kPa 27.6 kPa 37.5 kPa 37.7 kPa
Performance Ground pressure (0.367 (0.369 (0.281 (0.382 (0.384
(With operator) kgf/cm2) kgf/cm2) kgf/cm2) kgf/cm2) kgf/cm2)
5.22 psi 5.25 psi 4.00 psi 5.44 psi 5.47 psi
Climbing angle *36 % (20 deg)
Angle in case of crossing
*27 % (15 deg)
slope
2200 x 500 mm 2200 x 510 mm
Width x Height
86.6 x 19.7 in. 86.6 x 20.1 in.
Blade
Max Left – 0.44 rad (25 deg)
swing Right – 0.44 rad (25 deg)
Left 1.22 rad (70 deg)
Boom swing angle
Right 1.05 rad (60 deg)
Max. displacement
100 L (26.4 U.S.gal) / min
Pressure (Theoretical)
connection for 20.6 MPa
attachments Max. pressure 210 kgf/cm2
2987 psi
Fuel tank capacity 115 L (30.4 U.S.gal)
NOTE
• Above dimensions are based on the machine with KUBOTA original bucket and 2100 arm.
• Specifications subject to change without notice.
• With unloaded digging bucket.
• Firm compacted soil.
• 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.
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5. DIMENSIONS

(1) Arm length (2100 Arm)

(A) (B) (C) (D) (E) (F) (G)

590 mm 770 mm 2200 mm 7300 mm 5250 mm 4600 mm 3850 mm
KX080-4
23.2 in. 30.3 in. 86.6 in. 287.4 in. 206.7 in. 181.1 in. 151.6 in.

(H) (I) (J) (K) (L) (M) (N)

1460 mm 4990 mm 7330 mm 500 mm 500 mm 2540 mm 2200 mm
KX080-4
57.5 in. 196.5 in. 288.6 in. 19.7 in. 19.7 in. 100.0 in. 86.6 in.

(O) (P) (Q) (R) (S)

7170 mm 1460 mm 6450 mm 2150 mm 2490 mm
KX080-4
282.3 in. 57.5 in. 253.9 in. 84.6 in. 98.0 in.

• Above dimensions are based on the machine with KUBOTA original bucket.
• Above dimensions are based on the machine with rubber track.
• Specifications subject to change without notice.
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G GENERAL

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 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

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KX080-4, WSM GENERAL

1. CHECKING EXCAVATOR IDENTIFICATION

When consulting with your local KUBOTA dealer about this
mini-excavator, please provide the model of the mini-excavator, its
frame and engine numbers and the number of hours on the hour
meter.
(1) Mini-excavator Nameplate (a) Model Nameplate
(Model, frame number, engine
number)
(2) Frame Number
(3) Engine Number
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2. ENGINE IDENTIFICATION
[1] MODEL NAME AND SERIAL NUMBER
Be sure to check the engine nameplate and serial number when
you wish to consult about the engine.
The model and serial number of the engine need to be checked
prior to servicing the engine or replacing any of its parts.
 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 Number or
Series Series
Alphabet Alphabet
GZ, OC, AC, EA,
1 05 (include: WG) 6
E
2 V3 7 03
3 08 8 07
4 SM (include: WG) A EA, RK
Air Cooled 03 (KET
5 B
Gasoline Production)

Production Year
Alphabet or Alphabet or
Year Year
Number Number
1 2001 F 2015
2 2002 G 2016
3 2003 H 2017
4 2004 J 2018
5 2005 K 2019
6 2006 L 2020
7 2007 M 2021
8 2008 N 2022
9 2009 P 2023
A 2010 R 2024
B 2011 S 2025
C 2012 T 2026
D 2013 V 2027
E 2014

(1) Engine Model Name and Serial

Number
(To be continued)

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KX080-4, WSM GENERAL
(Continued)
Production Month and Lot Number
Month Engine Lot Number
January A0001 to A9999 from B0001
February C0001 to C9999 from D0001
March E0001 to E9999 from F0001
April G0001 to G9999 from H0001
May J0001 to J9999 from K0001
June L0001 to L9999 from M0001
July N0001 to N9999 from P0001
August Q0001 to Q9999 from R0001
September S0001 to S9999 from T0001
October U0001 to U9999 from V0001
November W0001 to W9999 from X0001
December Y0001 to Y9999 from Z0001

* Alphabetical letters "I" and "O" are not used.

(a) (b)(c)(d) (e)
e.g. V2607 - 8 C L 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)
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[2] E4B ENGINE

[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) Engine output classification EPA regulation
Less than 19 kW Tier 4
From 19 to less than 56 kW Interim Tier 4
EF
From 56 to less than 75 kW Interim Tier 4
From 75 to less than 130 kW 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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[3] CYLINDER NUMBER

You can see the cylinder numbers of KUBOTA diesel engine in
the figure.
The sequence of cylinder numbers is No.1, No.2, No.3 and No.4
and it starts from the gear case side.
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3. MUFFLER FULL ASSEMBLY IDENTIFICATION

[1] PART NUMBER AND SERIAL NUMBER
Diesel Particulate Filter (hereinafter referred to as the "DPF")
Muffler Full Assembly Serial Number
The DPF muffler full assembly serial number is an identified
number for the DPF muffler full assembly.
It shows the month and year of manufacture as below.

Year of manufacture
Alphabet or Alphabet or
Year Year
Number Number
1 2001 F 2015
2 2002 G 2016
3 2003 H 2017
4 2004 J 2018
5 2005 K 2019
6 2006 L 2020
7 2007 M 2021
8 2008 N 2022
9 2009 P 2023
A 2010 R 2024
B 2011 S 2025
C 2012 T 2026
D 2013 V 2027
E 2014

Month of manufacture
Month DPF Muffler Full Assembly Lot Number
January A0001 to A9999 B0001 to BZ999
February C0001 to C9999 D0001 to DZ999
March E0001 to E9999 F0001 to FZ999
April G0001 to G9999 H0001 to HZ999
May J0001 to J9999 K0001 to KZ999
June L0001 to L9999 M0001 to MZ999
July N0001 to N9999 P0001 to PZ999
August Q0001 to Q9999 R0001 to RZ999
September S0001 to S9999 T0001 to TZ999
October U0001 to U9999 V0001 to VZ999
November W0001 to W9999 X0001 to XZ999
December Y0001 to Y9999 Z0001 to ZZ999

* Alphabetical letters "I" and "O" are not used.

(a)(b) (c)
e.g. C L 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)
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You must keep the records of the filter comp (DPF) part number
and serial number before you remove the DPF for cleaning.
(1) Body (DPF Outlet) Part Number and (3) Catalyst (DOC) Part Number and
Serial Number Serial Number
(2) Filter Comp (DPF) Part Number and
Serial Number
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4. GENERAL PRECAUTIONS
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 (4) Gap
(2) External Thread (5) Leave 1 to 2 Threads
(3) Internal Thread
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 (4) If the Ring Touches This Corner, It
(2) O-Ring Will Twist
(3) Check for Burrs
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 A : Air (Outside)
(2) Metal Ring B : Hydraulic Chamber (Inside)
(3) Spring
(4) Main Lip
(5) Grease
(6) Dust Lip
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 (A) External
Receives the Force (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) (a) Apply Here
(B) Pocket Bolt Hold (b) Do Not Apply
(Capsule Shape, etc.) (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 (C) Diagonally Across the Center
(B) Across Diagonally
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 (4) Wrench for Holding
(2) Washer (5) Hose
(3) Seal (O-Ring) (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

5. HANDLING PRECAUTIONS FOR ELECTRICAL

PARTS AND WIRING
Follow the precautions below for handling electrical parts and
wiring to ensure safety and prevent damage to the machine and
nearby equipment.
IMPORTANT
• Inspect electrical wiring for damage and/or loose
connections.
• 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

[1] WIRING
• Tighten wiring terminals securely.
(1) Correct (Tightened Securely) (2) Incorrect (Poor Contact if Loose)
RY9212001GEG0024US0

• Keep wiring away from hazards.

(1) Hazardous Positioning (3) Wiring Position (Right)
(2) Wiring Position (Wrong) (4) Hazardous Position
RY9212001GEG0025US0

• Immediately repair or replace old or damaged wiring.

(1) Damaged (3) Electrical Tape
(2) Torn
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) (3) Clamp
(2) Wire (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 (A) Correct
(2) Clamp (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 (a) Standard Wiring

(B) Diagram of Modification (b) Modified Wiring
RY9212038ELS0008US0

[2] FUSES
• 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 (3) Slow-Blow Fuse
(2) Fusible Link
RY9212001GEG0032US0

[3] CONNECTOR
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 (3) Sandpaper
(2) Bent Prong (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

[4] WASHING THE MACHINE WITH A HIGH-PRESSURE WASHER

Using a high-pressure washer incorrectly can lead to personal
injury and/or damage, break or cause parts of the machine to fail,
so use the power washer properly according to its operator's
manual and labels.

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 (A) Blasting
(2) Never Wash from Too Close (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

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

Indication on top of bolt No-grade or 4T 7T 9T

Indication on top of nut No-grade or 4T

6T
Material of opponent part Ordinariness Aluminum Steel Aluminum Steel
Unit 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 0.8 5.8 7.9 0.8 5.8 9.81 1.0 7.24 7.9 0.8 5.8 12.3 1.25 9.05
M6 to to to to to to to to to to to to to to to
9.3 0.95 6.8 8.8 0.9 6.5 11.2 1.15 8.31 8.8 0.9 6.5 14.2 1.45 10.4
18 1.8 13 17 1.7 13 24 2.4 18 18 1.8 13 30 3.0 22
M8 to to to to to to to to to to to to to to to
20 2.1 15 19 2.0 14 27 2.8 20 20 2.1 15 34 3.5 25
40 4.0 29 32 3.2 24 48 4.9 36 40 4.0 29 61 6.2 45
M10 to to to to to to to to to to to to to to to
45 4.6 33 34 3.5 25 55 5.7 41 44 4.5 32 70 7.2 52
63 6.4 47 78 7.9 58 63 6.4 47 103 10.5 76
M12 to to to – – – to to to to to to to to to
72 7.4 53 90 9.2 66 72 7.4 53 117 12 86.7
108 11 79.6 124 12.6 91.2 167 17 123
M14 to to to – – – to to to – – – to to to
125 12.8 92.5 147 15 108 196 20 144
167 17 123 197 20 145 260 26.5 192
M16 to to to – – – to to to – – – to to to
191 19.5 141 225 23 166 304 31 224
246 25 181 275 28 203 344 35 254
M18 to to to – – – to to to – – – to to to
284 29 209 318 32.5 235 402 41 296
334 34 246 368 37.5 272 491 50 362
M20 to to to – – – to to to – – – to to to
392 40 289 431 44 318 568 58 419
RY9212032GEG0001US0

G-16 KiSC issued 08, 2015 A

KX080-4, WSM GENERAL

[2] TORQUE FOR HYDRAULIC HOSE FITTINGS

(1) Torque for Hydraulic Hose Fittings
Union nut (metal seal type) Union nut (ORS type)
7.8 to 11.8 N·m
1/8 0.8 to 1.2 kgf·m – –
5.7 to 8.7 lbf·ft
24.5 to 29.2 N·m 35.2 to 43.1 N·m
1/4 2.5 to 3.0 kgf·m 9/16UNF 3.6 to 4.4 kgf·m
18.1 to 21.7 lbf·ft 26.0 to 31.8 lbf·ft
37.2 to 42.1 N·m 60.0 to 73.5 N·m
3/8 3.8 to 4.3 kgf·m 11/16UNF 6.1 to 7.5 kgf·m
27.5 to 31.1 lbf·ft 44.3 to 54.2 lbf·ft
58.8 to 63.7 N·m 70.6 to 86.2 N·m
1/2 6.0 to 6.5 kgf·m 13/16UNF 7.2 to 8.8 kgf·m
43.4 to 47.0 lbf·ft 52.1 to 63.6 lbf·ft
117.6 to 127.4 N·m 105.8 to 129.4 N·m
3/4 12.0 to 13.0 kgf·m 1-14UNS 10.8 to 13.2 kgf·m
86.8 to 94.0 lbf·ft 78.0 to 98.4 lbf·ft
220.5 to 230.3 N·m
1 - 1/4 22.5 to 23.5 kgf·m – –
162.7 to 169.8 lbf·ft

RY9212148GEG0006US0

(2) Torques of Lock-Nuts for Elbows with Male Seats and Adaptors with
O-rings (Straight Threads)
15.0 to 16.5 N·m
1/8 1.5 to 1.7 kgf·m
11.1 to 12.2 lbf·ft
24.5 to 29.4 N·m
1/4 2.5 to 3.0 kgf·m
18.1 to 21.7 lbf·ft
49.0 to 53.9 N·m
3/8 5.0 to 5.5 kgf·m
36.1 to 39.8 lbf·ft
58.8 to 63.7 N·m
Tightening torque 1/2 6.0 to 6.5 kgf·m
43.4 to 47.0 lbf·ft
117.6 to 127.4 N·m
3/4, 1 12.0 to 13.0 kgf·m
86.8 to 94.0 lbf·ft
220.5 to 230.3 N·m
1-1/4 22.5 to 23.5 kgf·m
162.8 to 170.0 lbf·ft
55.9 to 60.8 N·m
7/8 - 14UNF 5.7 to 6.2 kgf·m
41.2 to 44.8 lbf·ft

(1) Lock-nut (3) Seal (O-ring)

(2) Washer
RY9212148GEG0007US0

G-17 KiSC issued 08, 2015 A

KX080-4, WSM GENERAL

[3] HOSE CLAMP SCREW TORQUE

Type 1

2.5 to 3.4 N·m

10- 14 6C040-58721 25 to 35 kgf·cm
1.8 to 2.5 lbf·ft
2.5 to 3.4 N·m
12- 16 09318-89016 25 to 35 kgf·cm
1.8 to 2.5 lbf·ft
2.5 to 3.4 N·m
19- 25 09318-89024 25 to 35 kgf·cm
1.8 to 2.5 lbf·ft
2.5 to 3.4 N·m
31- 40 09318-89039 25 to 35 kgf·cm
1.8 to 2.5 lbf·ft
Tightening torque
2.5 to 3.4 N·m
36- 46 09318-89045 25 to 35 kgf·cm
1.8 to 2.5 lbf·ft
3.9 to 4.9 N·m
44- 53 09318-89052 40 to 50 kgf·cm
2.9 to 3.6 lbf·ft
3.9 to 4.9 N·m
51- 59 09318-89058 40 to 50 kgf·cm
2.9 to 3.6 lbf·ft
2.5 to 3.4 N·m
86- 96 RD809-42241 25 to 35 kgf·cm
1.8 to 2.5 lbf·ft
RY9212001GEG0045US0

G-18 KiSC issued 08, 2015 A

KX080-4, WSM GENERAL
Type 2

2.5 to 3.4 N·m

13- 20 RB101-63631 25 to 35 kgf·cm
1.8 to 2.5 lbf·ft
4.9 to 5.9 N·m
15- 25 RC101-64581 50 to 60 kgf·cm
3.6 to 4.3 lbf·ft
4.9 to 5.9 N·m
19- 28 R1401-63211 50 to 60 kgf·cm
3.6 to 4.3 lbf·ft
4.9 to 5.9 N·m
22- 32 R1401-63151 50 to 60 kgf·cm
3.6 to 4.3 lbf·ft
4.9 to 5.9 N·m
26- 38 68311-72821 50 to 60 kgf·cm
3.6 to 4.3 lbf·ft
4.9 to 5.9 N·m
32- 44 RD411-63821 50 to 60 kgf·cm
3.6 to 4.3 lbf·ft
Tightening torque
4.9 to 5.9 N·m
44- 56 35820-15181 50 to 60 kgf·cm
3.6 to 4.3 lbf·ft
4.9 to 5.9 N·m
50- 65 RC401-63191 50 to 60 kgf·cm
3.6 to 4.3 lbf·ft
4.9 to 5.9 N·m
58- 75 36919-04591 50 to 60 kgf·cm
3.6 to 4.3 lbf·ft
4.9 to 5.9 N·m
60- 80 RD809-63101 50 to 60 kgf·cm
3.6 to 4.3 lbf·ft
4.9 to 5.9 N·m
68- 85 RD809-63061 50 to 60 kgf·cm
3.6 to 4.3 lbf·ft
4.9 to 5.9 N·m
77- 95 69284-63171 50 to 60 kgf·cm
3.6 to 4.3 lbf·ft
RY9212001GEG0046US0

G-19 KiSC issued 08, 2015 A

KX080-4, WSM GENERAL

7. OIL AND WATER CAPACITY TABLE

Item KX080-4 Notes
Engine oil (when filter changed) 9.7 L (2.6 U.S.gal) API type, CJ-4
Coolant 10.5 L (2.77 U.S.gal) Antifreeze Kubota LLC-N-50F
Reserve tank 1.3 L (0.34 U.S.gal) Mixture ratio 50%

Fuel (full) 115 L (30.4 U.S.gal) JIS #3 diesel

Total volume (Std. spec.) 146 L (38.6 U.S.gal)
Hydraulic oil Tellus oil S2M46
Inside tank (gauge middle) 75 L (20.0 U.S.gal)
Travel motor 1.35 L (0.36 U.S.gal) Gear oil SAE#90 (API GL-4)
Idler assy 80 ml (4.88 cu.in.)
Track rollers 80 ml (4.88 cu.in.) Engine oil SAE #30CD (monograde)
Carrier rollers 80 ml (4.88 cu.in.)
Grease – EP2

RY9212158GEG0001US0

G-20 KiSC issued 08, 2015 A

KX080-4, WSM GENERAL

8. MAINTENANCE INTERVALS
Hour meter indication
No. Check points Measures Interval
50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 1000
check Daily check
1 Coolant every
change
2 years
2 Fuel check Daily check
check Daily check
3 Engine oil every
change  
500 hrs
check Daily check
4 Hydraulic oil every
change  *1
1000 hrs
Bucket and
bucket link pin
/ Dozer angle – Daily check
pin and angle
Grease front cylinder boss
5
attachments
Boom swing every
–         
fulcrum 100 hrs
every
Others –    
250 hrs
6 Radiator and oil cooler check Daily check
7 Washer liquid check Daily check
8 Engine and electrical wiring check Daily check
every
9 Water separator drain                 
50 hrs
every
10 Fuel tank drain                 
50 hrs
every
11 Battery condition check                 
50 hrs
Greasing swing bearing every
12 –                 
teeth 50 hrs
check Daily check
13 V-belt tension every
adjust     
200 hrs
every
check     
200 hrs
14 Radiator hoses and clamps
every
replace
2 years
every
clean      *2
Outer 200 hrs
Air filter element every
15 replace  *2 @
element 1000 hrs
every
Inner element replace  *2
1000 hrs
every
16 Greasing swing ball bearing –     
200 hrs
every
17 Fuel filter cartridge replace   @
500 hrs
every
18 Engine oil filter replace  
500 hrs
every
19 Drive unit oil change  
500 hrs
Hydraulic return filter every
20 replace  
cartridge 500 hrs
Hydraulic suction filter every
21 replace  *4
element 1000 hrs
Filter in the pilot hydraulic every
22 replace  *4
system 1000 hrs
every
23 Injector tip check *4 @
1500 hrs

G-21 KiSC issued 08, 2015 A

KX080-4, WSM GENERAL

Hour meter indication

No. Check points Measures Interval
50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 1000
every
24 Oil separator element replace *4 @
1500 hrs
every
25 EGR cooler check *4
1500 hrs
every
26 Front idler and track roller oil change *4
2000 hrs
every
27 Alternator and starter motor check *4
2000 hrs
every
28 EGR system check *4
3000 hrs
every
29 Turbo charger check *4
3000 hrs
every
30 DPF clean *4
3000 hrs
Boost sensor and AFS every
31 check *4
(Air flow sensor) 1 year
every
32 Condition of DPF muffler check *4
1 year
DPF differential pressure
every
33 sensor and piping for gas check *4
1 year
leak
DPF exhaust gas every
34 check *4
temperature sensor 1 year
every
35 EGR and piping for gas leak check *4
1 year
every
36 Radiator system rinse *4
2 years
every
check      @
200 hrs
37 Fuel line and intake air line
every
replace *3
2 years
Closed breather related every
38 replace *4
rubber piping 2 years
DPF differential pressure
every
39 sensor rubber piping (Front replace *4
2 years
and back)
Suction pipe downstream the every
40 replace *4
AFS 2 years
Boost sensor pressure every
41 replace *4
rubber piping 2 years
every
42 EGR cooler hose replace *4
2 years

G-22 KiSC issued 08, 2015 A

KX080-4, WSM GENERAL
Air conditioner
Hour meter indication
No. Check points Measures Interval
50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 1000
every
clean      *2
200 hrs
1 Air filter
every
replace  *2
1000 hrs
every
2 Air-conditioner condenser check     
200 hrs
every
check
Air-conditioner pipes and 1 year
3
hose every
replace
2 years
service as
4 Refrigerant (gas) check *4
required

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) SAE30 or SAE 10W-30, SAE 15W-40
0 to 25 °C (32 to 77 °F) SAE20 or SAE 10W-30, SAE 15W-40
Below 0 °C (32 °F) SAE10W or SAE 10W-30, SAE 15W-40

• Refer to the following table for the suitable API classification engine oil and the fuel.
Engine oil classification (API classification)
Fuel used
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 MACHINE BODY

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

1. FRONT
[1] BOOM ASSEMBLY/DISASSEMBLY
CAUTION
• Wear protective gear, such as a helmet, eye protection, etc., during assembly/disassembly.
• For group work, decide on signals for communication, make sure everyone understands and uses them
and be very careful about safety.
• 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 MACHINE BODY

[2] TABLE OF DIMENSIONS

(1) Bucket
NOTE
• Kubota Japan bucket

No. KX080-4 No. KX080-4 No. KX080-4 No. KX080-4

600 mm 105 mm 300 mm 462 mm
(1) (7) (13) (19)
23.62 in. 4.13 in. 11.81 in. 18.19 in.
620 mm 120 mm 205 mm 90 mm
(2) (8) (14) (20)
24.41 in. 4.72 in. 8.07 in. 3.54 in.
328 mm 60 mm 25 mm 22 mm
(3) (9) (15) (21)
12.91 in. 2.36 in. 0.98 in. 0.87 in.
200 mm 538 mm 37.5 mm 14 mm
(4) (10) (16) (22)
7.87 in. 21.18 in. 1.48 in. 0.55 in.
44 mm 902.5 mm 164.5 mm 222 mm
(5) (11) (17) (23)
1.73 in. 35.53 in. 6.48 in. 8.74 in.
20 mm 7.5 mm 82 mm 111 mm
(6) (12) (18) (24)
0.79 in. 0.30 in. 3.23 in. 4.37 in.

RY9212148MBS0033US0

1-S3 KiSC issued 08, 2015 A

KX080-4, WSM MACHINE BODY

(2) Front Pin

KX080-4
Item
(Pin dia. X length)
100 × 474 mm
(1)
3.94 × 18.66 in.
70 × 183 mm
(2)
2.76 × 7.20 in.
70 × 168 mm
(3)
2.76 × 6.61 in.
80 × 437 mm
(4)
3.15 × 17.20 in.
70 × 200 mm
(5)
2.76 × 7.87 in.
70 × 226 mm
(6)
2.76 × 8.90 in.
70 × 332 mm
(7)
2.76 × 13.07 in.
60 × 226 mm
(8)
2.36 × 8.90 in.
60 × 175 mm
(9)
2.36 × 6.89 in.
60 × 333 mm
(10)
2.36 × 13.11 in.
60 × 151 mm
(11)
2.36 × 5.94 in.
60 × 275 mm
(12)
2.36 × 10.83 in.
60 × 275 mm
(13)
2.36 × 10.83 in.
60 × 167 mm
(14)
2.36 × 6.57 in.
70 × 144 mm
(15)
2.76 × 5.67 in.
85 × 295 mm
(16)
3.35 × 11.61 in.
50 × 167 mm
(17)
1.97 × 6.57 in.
50 × 167 mm
(18)
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

1-S4 KiSC issued 08, 2015 A

KX080-4, WSM MACHINE BODY

(3) Front Bushings

KX080-4 KX080-4
Item Point used Item Point used
(I.D. X O.D. X Length) (I.D. X O.D. X Length)
100 × 115 × 64 mm 70 × 82 × 80 mm
Swing bracket top (7) Arm ends
3.94 × 4.53 × 2.52 in. 2.76 × 3.23 × 3.15 in.
100 × 115 × 110 mm 60 × 70 × 75 mm
(1) Swivel frame, vertical (8) Cylinder
3.94 × 4.53 × 4.33 in. 2.36 × 2.76 × 2.95 in.
100 × 115 × 61 mm 60 × 70 × 75 mm
Swing bracket bottom (9) Cylinder
3.94 × 4.53 × 2.40 in. 2.36 × 2.76 × 2.95 in.
70 × 82 × 65 mm 60 × 80 × 65 mm
(2) Cylinder (10) Arm ends
2.76 × 3.23 × 2.56 in. 2.36 × 3.15 × 2.56 in.
70 × 82 × 45 mm 60 × 70 × 60 mm
Swing bracket top (11) Bucket link
2.76 × 3.23 × 1.77 in. 2.36 × 2.76 × 2.36 in.
70 × 82 × 65 mm 60 × 70 × 65 mm
(3) Cylinder (12) Cylinder
2.76 × 3.23 × 2.56 in. 2.36 × 2.76 × 2.56 in.
70 × 82 × 36 mm 60 × 70 × 60 mm
Swing bracket bottom (13) Arm ends
2.76 × 3.23 × 1.42 in. 2.36 × 2.76 × 2.36 in.
80 × 95 × 80 mm 60 × 70 × 52 mm
Swing bracket ends Bucket link
3.15 × 3.74 × 3.15 in. 2.36 × 2.76 × 2.05 in.
(4) (14)
80 × 95 × 80 mm 60 × 70 × 65 mm
Boom ends Cylinder
3.15 × 3.74 × 3.15 in. 2.36 × 2.76 × 2.56 in.
70 × 82 × 49 mm 60 × 70 × 88 mm
Swing bracket right (15) Blade
2.76 × 3.23 × 1.93 in. 2.36 × 2.76 × 3.46 in.
70 × 82 × 75 mm 70 × 82 × 60 mm
(5) Cylinder (16) Blade
2.76 × 3.23 × 2.95 in. 2.76 × 3.23 × 2.36 in.
70 × 82 × 49 mm 50 × 60 × 60 mm
Swing bracket left (17) Cylinder
2.76 × 3.23 × 1.93 in. 1.97 × 2.36 × 2.36 in.
70 × 82 × 75 mm 85 × 100 × 60 mm
(6) Cylinder (18) Angle fulcrum, vertical
2.76 × 3.23 × 2.95 in. 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 MACHINE BODY
Bushing shape

(A) Flanged bushing

(B) Normal bushing

(a) I.D.
(b) O.D.
(c) Length
RY9212148MBS0036US0

(4) Arm

(A) Arm tip (B) Bucket link 1

No. KX080-4 No. KX080-4 No. KX080-4 No. KX080-4

260 mm 1745 mm 66 mm 70 mm
(1) (6) (11) (16)
10.24 in. 68.70 in. 2.60 in. 2.76 in.
1840 mm 403 mm 200 mm
(2) (7) (12) (17)
72.44 in. 15.87 in. 7.87 in. 200 mm
451 mm 428 mm 70 mm 7.87 in.
(3) (8) (13) (18)
17.76 in. 16.85 in. 2.76 in.
279 mm 13 mm 67 mm 76 mm
(4) (9) (14) (19)
10.98 in. 0.51 in. 2.64 in. 2.99 in.
370 mm 188 mm 80 mm 70 mm
(5) (10) (15) (20)
14.57 in. 7.40 in. 3.15 in. 2.76 in.

RY9212148MBS0037US0

1-S6 KiSC issued 08, 2015 A

KX080-4, WSM MACHINE BODY

(5) Blade
No. Item KX080-4
70 × 98 mm
(a) I.D. X Length
2.76 × 3.86 in.
70 × 28 mm
(b) I.D. X Length
2.76 × 1.10 in.
2200 mm
(c) Width
86.61 in.
500 mm
(d) Height
19.69 in.
1448 mm
(e) Length
57.01 in.
Tip height - plate 90 × t 16 mm
(f)
thickness 3.54 × t 0.63 in.
Distance between 698 mm
(g)
supports 27.48 in.
RY9212148MBS0038US0

No. Item KX080-4 No. Item KX080-4

70 × 98 mm 160 × t 15.9 mm
(a) I.D. X Length (g) Tip height - plate thickness
2.76 × 3.86 in. 6.30 × t 0.63 in.
70 × 28 mm 698 mm
(b) I.D. X Length (h) Distance between supports
2.76 × 1.10 in. 27.48 in.
85 × 289 mm 60 mm
(c) I.D. X Length (i) Cutting edge
3.35 × 11.38 in. 2.36 in.
2200 mm 153 mm
(d) Width (j) Cutting edge
86.61 in. 6.02 in.
510 mm 306 mm
(e) Height (k) Cutting edge
20.08 in. 12.05 in.
1754.5 mm 732 mm
(f) Length (l) Cutting edge
69.07 in. 28.82 in.

RY9212158MBS0003US0

1-S7 KiSC issued 08, 2015 A

KX080-4, WSM MACHINE BODY

2. SWIVEL FRAME
[1] WEIGHT ASSEMBLY/DISASSEMBLY
1. Remove the left and rear hoods.

CAUTION
It takes at least 2 people to remove the rear hood.
Rear hood weight Approx. 27 kg (60 lbs)

(1) Rear hood (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.
367.7 to 431.5 N·m
Tightening torque Weight 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

[2] CABIN REMOVAL AND MOUNTING

1. Remove the blower cover and AC panel, then remove the
blower hose, fuse box and AC connector.
(1) Blower cover (3) Fuse box
(2) AC panel
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).
259.9 to 304.0 N·m
Bolt 26.5 to 31.0 kgf·m
191.7 to 224.2 lbf·ft
Tightening torque
107.9 to 127.4 N·m
Nut 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 MACHINE BODY
Installation of cabin rubber vibration dampers

(1) Nut (3) Rubber vibration damper (5) Bolt (6) Rubber vibration damper
(2) Bolt (4) Nut

107.9 to 127.4 N·m

Nut (1) 11.0 to 13.0 kgf·m
79.6 to 94.0 lbf·ft
103.0 to 117.7 N·m
Bolt (2) 10.5 to 12.0 kgf·m
76.0 to 86.8 lbf·ft
Tightening torque
39.2 to 45.1 N·m
Nut (4) 4.0 to 4.6 kgf·m
28.9 to 33.3 lbf·ft
48.1 to 55.9 N·m
Bolt (5) 4.9 to 5.7 kgf·m
35.5 to 41.2 lbf·ft

RY9212148MBS0047US0

1-S10 KiSC issued 08, 2015 A

KX080-4, WSM MACHINE BODY

[3] FUEL TANK ASSEMBLY/DISASSEMBLY

1. Remove the cover.
(1) Cover
RY9212148MBS0048US0

2. After draining the fuel, remove the fuel hose.

(1) Water drain cock (2) Fuel hose
RY9212148MBS0049US0

3. Remove the electrical wiring and the fuel hose.

(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 MACHINE BODY
Fuel hose circuit

(1) Outside air (6) Fuel filter (a) 110 mm (4.3 in.) (f) 30 mm (1.2 in.)
(2) Strainer (Eur. only) (7) Engine (b) 45 mm (1.8 in.) (g) 75 mm (3.0 in.)
(3) Fuel tank (8) Fuel check valve (c) 65 mm (2.6 in.) (h) Drain (for bleeding water)
(4) Water separator (9) Fuel cooler (d) 50 mm (2.0 in.) (i) Air bleed
(5) Fuel pump (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.
Tube Protective tube Tube Protective tube
Length I.D. Length I.D. Length I.D. Length I.D.
850 mm 800 mm 15 mm 280 mm
A G – –
33.46 in. 8 mm 31.50 in. 0.59 in. 11.02 in. 8 mm
550 mm 0.31 in. 420 mm 16 mm 0.31 in.
B H Rubber cap – –
21.65 in. 16.54 in. 0.63 in.
1450 mm 1350 mm 260 mm 200 mm 10 mm
C M
57.09 in. 53.15 in. 10.24 in. 4 mm 7.87 in. 0.39 in.
320 mm 240 mm 15 mm 80 mm 0.16 in.
D N – –
12.60 in. 7 mm 9.45 in. 0.59 in. 3.15 in.
1650 mm 0.29 in. 1500 mm 480 mm 5 mm
E P – –
64.96 in. 59.06 in. 18.90 in. 0.20 in.
2360 mm
F – –
33.46 in.
900 mm
FA – –
35.43 in. 15 mm
1240 mm 0.59 in.
FB – –
48.82 in.

RY9212148MBS0148US0

1-S12 KiSC issued 08, 2015 A

KX080-4, WSM MACHINE BODY
Fuel Supply and Return Hose Routing

• (a): Fuel hose supply side

• (b): Fuel hose return side
• (c): Air bleed
• (d): Pass the return hose outside the electric pump. Install so the electric pump and hose do not interfere with
each other.
• (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 MACHINE BODY

[4] HYDRAULIC OIL TANK ASSEMBLY/DISASSEMBLY

1. After draining the hydraulic oil, remove the front, right and tank
covers.
(1) Front cover (3) Tank cover
(2) Right cover
RY9212148MBS0150US0

2. Remove the cover, electric fan, center cover and center frame.
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 (5) Top cover
(2) Electric fan (6) Fuel tank
(3) Center cover (7) Battery
(4) Center frame (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 (4) 2-way valve
(2) AUX mounting bracket (5) Bracket
(3) Manifold block adapter
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).
196.1 to 225.6 N·m
Tightening torque Bolt 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).
77.5 to 90.2 N·m
Tightening torque Bolt 7.9 to 9.2 kgf·m
57.2 to 66.5 lbf·ft

Approx. 19 kg
Hydraulic tank weight
Approx. 42 lbs

(1) Hydraulic oil tank

RY9212148MBS0156US0

1-S15 KiSC issued 08, 2015 A

KX080-4, WSM MACHINE BODY

[5] ASSEMBLY/DISASSEMBLY OF ENGINE RELATED

COMPONENTS
(1) DPF Muffler
1. Remove the rear and left hoods and the air cleaner.

CAUTION
• For hood removal, a minimum of 2 persons is needed.
Rear hood weight Approx. 27 kg (60 lbs)

(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 (3) DPF outlet temperature sensor
connector connector
(2) DOC outlet temperature sensor (4) Bracket
connector
RY9212148MBS0054US0

4. Disconnect the DPF pressure differential sensor connector and

remove the bracket.
(1) DPF pressure differential sensor (2) Bracket
connector
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)

48.1 to 55.9 N·m

Bolt (M10) 4.9 to 5.7 kgf·m
35.5 to 41.2 lbf·ft
77.5 to 90.2 N·m
Bolt (M12) 7.9 to 9.2 kgf·m
57.2 to 66.5 lbf·ft
Tightening torque
49.0 to 59.9 N·m
Flange nut 5.0 to 6.1 kgf·m
36.1 to 44.2 lbf·ft
16.0 to 23.0 N·m
Drain pipe 1.6 to2.3 kgf·m
11.8 to 17.0 lbf·ft

(1) Flange Nut (4) Drain Pipe

(2) Bracket Mounting Bolt (5) Gasket
(3) DPF Muffler Bracket (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.
48.1 to 55.9 N·m
Bolt (M10) 4.9 to 5.7 kgf·m
35.5 to 41.2 lbf·ft
9.8 to 11.3 N·m
Tightening torque Nut 1 1.0 to 1.2 kgf·m
7.2 to 8.3 lbf·ft
39.2 to 45.1 N·m
Nut 2 4.0 to 4.6 kgf·m
28.9 to 33.3 lbf·ft

(1) Muffler mounting band (a) 12 to 16 mm (0.5 to 0.6 in.)

(2) Bolt
(3) Nut 1
(4) Nut 2
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).
25.0 to 35.0 N·m
Exhaust temperature
Tightening torque 2.5 to 3.6 kgf·m
sensor
18.4 to 25.8 lbf·ft

(1) Exhaust Temperature Sensor (T0) (3) Exhaust Temperature Sensor (T2)
(2) Exhaust Temperature Sensor (T1)
RY9212148MBS0157US0

(2) Engine
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.
259.9 to 304.0 N·m
Tightening torque Bolt 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 (3) Heater hose
(2) AC 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 (3) Fuel cooler
(2) Supply pump
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.
88.2 to 107.8 N·m
First nut 9.0 to 11.0 kgf·m
65.1 to 79.5 lbf·ft
166.0 to 191.0 N·m
Second nut 16.9 to 19.5 kgf·m
122.4 to 140.9 lbf·ft
Tightening torque
196.1 to 225.6 N·m
Bolt (M16) 20.0 to 23.0 kgf·m
144.6 to 166.4 lbf·ft
123.6 to 147.1 N·m
Bolt (M14) 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 (5) Second nut

(2) Pump (6) Bolt (M16)
(3) Ground wire (7) Bolt (M14)
(4) First nut
RY9212148MBS0068US0

1-S20 KiSC issued 08, 2015 A

KX080-4, WSM MACHINE BODY

[6] ASSEMBLING OPERATING LEVERS

(1) Travel Lever
(1) Left travel lever (a) 260 ± 5 mm (10.2 ± 0.2 in.)
(2) Right travel lever (b) When in neutral
(3) Grip (c) 15 to 21 mm (0.59 to 0.83 in.)
(d) Fwd/rear deviation of l/r levers to
be within 2mm (0.08 in.)
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.
39.2 to 45.1 N·m
Tightening torque Left/right travel levers 4.0 to 4.6 kgf·m
28.9 to 33.3 lbf·ft

(1) Grip (5) Right pedal

(2) Bolt (6) Left pedal
(3) Right travel lever (7) Right damper
(4) Left travel lever (8) Left damper
RY9212148MBS0070US0

(2) Blade Lever

Neutral position

(a) 65.5 mm (2.6 in.)

RY9212148MBS0071US0

(3) Limit Switch

1. No clearance (a) when limit switch operated.
3.9 to 4.9 N·m
Tightening torque Bolt 0.4 to 0.5 kgf·m
2.9 to 3.6 lbf·ft

Apply thread lock compound ThreeBond TB1401B.

(1) Limit Switch (a) Clearance
(2) Damper (b) 16 mm (0.6 in.)
(3) Unload Lever
(4) Bolt
RY9212148MBS0072US0

1-S21 KiSC issued 08, 2015 A

KX080-4, WSM MACHINE BODY

3. TRACK FRAME
[1] SWIVEL BEARING ASSEMBLY/DISASSEMBLY
1. Remove the swivel frame.
RY9212148MBS0073US0

2. Suspend the swivel bearing with a crane, remove the swivel

bearing mounting bolts on the bottom side, then remove the
swivel bearing.
Swivel bearing weight (reference
110 kg (243 lbs)
value)

Component names
No. Name of part Qty
(1) Swivel bearing 1
(2) Bolt 36
(3) Diaphragm spring 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.
259.9 to 304.0 N·m
Tightening torque Swivel bearing 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 A: Front of machine
zone) B: Back of machine
(b) Tooth surface grease application C: Swivel frame side
zone D: Track frame side
(c) Port for applying grease to the
balls (mates with hole in swivel
frame)
(d) 'S' Mark
RY9212148MBS0075US0

1-S22 KiSC issued 08, 2015 A

KX080-4, WSM MACHINE BODY

[2] TRACK
WARNING
• The backhoe is equipped with an overload warning system.
When changing the rubber track to an iron track, or vice versa, it is necessary to change the preset code
in either case.
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) Assembly/Disassembly of the Rubber Track

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.
98.0 to 107.8 N·m
Tightening torque Grease nipple 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

(2) Assembly/Disassembly of Iron Tracks

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 (3) Block
(2) Master link
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 (3) Block
(2) Track
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 (d) Tool d
(b) Tool b (g) Tool g
(c) Tool c
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 MACHINE BODY

(3) Steel Track Removal/Installation Tools

No. in
Name of part
Figure
(a) Guide (outside)
(b) Guide (inside)
(c) Stopper plate
(d) Pin
(e) Pusher 1
(f) Pusher 2
(g) Spring
RY9212148MBS0088US0
(a)Guide (outside)

A 189.5 to 190.5 mm (7.46 to 7.50 in.) Q 21.0 mm (0.83 in.)

B 20.0 mm (0.79 in.) R 12.5 mm (0.49 in.)
C 5.0 mm (0.20 in.) S 24.5 to 25.5 mm (0.96 to 1.00 in.)
D 24.4 to 24.6 mm (0.96 to 0.97 in.) T 77.0 mm (3.03 in.)
E 45.0 mm (1.77 in.) U 25.0 mm (0.98 in.)
F 30.0 mm (1.18 in.) V 112.5 mm (4.43 in.)
G 43.5 mm (1.71 in.) W 67.0 mm (2.64 in.)
H 29.5 mm (1.16 in.) X 33.4 to 33.6 mm (1.31 to 1.32 in.)
I 150.0 mm (5.91 in.) Y 16.0 mm (0.63 in.)
J 10.5 mm (0.41 in.) Z 25.5 mm (1.00 in.)
K 57.5 to 58.5 mm (2.26 to 2.30 in.) C1 1.0 mm (0.04 in.) bevel
L 50.0 mm (1.97 in.) C2 2.0 mm (0.08 in.) bevel
M 29.0 mm (1.14 in.) a Ra=12.5a
N 30.0 mm (1.18 in.) b Ra=6.3a
O 100.0 mm (3.94 in.) c 2 x M12 x 1.25 / 10.8
P 19.0 mm (0.75 in.)

RY9212148MBS0089US0

1-S27 KiSC issued 08, 2015 A

KX080-4, WSM MACHINE BODY
(b)Guide (inside)

A 150.0 mm (5.91 in.) M 19.0 mm (0.75 in.)

B 3.2 mm (0.13 in.) N 15.5 mm (0.61 in.)
C 27.6 mm (1.09 in.) O 28.5 mm (1.12 in.)
D 34.0 mm (1.34 in.) P 39.5 to 40.5 mm (1.56 to 1.59 in.)
E 100.0 mm (3.94 in.) Q 48.5 mm (1.91 in.)
F 12.5 mm (0.49 in.) R 25.5 mm (1.00 in.)
G 24.5 to 25.5 mm (0.96 to 1.00 in.) S 16.0 mm (0.63 in.)
H 50.0 mm (1.97 in.) C0.5 0.5 mm (0.02 in.) bevel
I 67.0 mm (2.64 in.) a Ra=12.5a
J 33.0 to 34.0 mm (1.30 to 1.34 in.) b 2 x M12 x 1.25 / 10.8
K 43.5 mm (1.71 in.) c 2 x M10 x 1.25 x 20 / 8.8 x 25
L 57.5 to 58.5 mm (2.26 to 2.30 in.)

RY9212148MBS0090US0
(c)Stopper plate

A 9.0 mm (0.35 in.)

B 96.0 mm (3.78 in.)
C 70.0 mm (2.76 in.)
D 13.0 mm (0.51 in.)
E 5.5 mm (0.22 in.)
F 11.0 mm (0.43 in.)
G 16.0 mm (0.63 in.)
H 32.0 mm (1.26 in.)
a Ra=12.5a
RY9212148MBS0091US0

1-S28 KiSC issued 08, 2015 A

KX080-4, WSM MACHINE BODY
(d)Pin

A 2.0 mm (0.08 in.)

B 23.4 to 23.6 mm (0.92 to 0.93 in.)
C 132.7 to 133.3 mm (5.22 to 5.25 in.)
a 30°(0.52 rad)
RY9212148MBS0092US0

(e)Pusher 1

A 50.0 mm (1.97 in.)

B 2.0 mm (0.08 in.)
C 23.4 to 23.6 mm (0.92 to 0.93 in.)
D 65.0 mm (2.56 in.)
E 89.7 to 90.3 mm (3.53 to 3.56 in.)
F 155.0 mm (6.10 in.)
C1 1.0 mm (0.04 in.) bevel
a Ra=12.5a
b 30°(0.52 rad)
RY9212148MBS0093US0
(f)Pusher 2

A 50.0 mm (1.97 in.)

B 2.0 mm (0.08 in.)
C 23.4 to 23.6 mm (0.92 to 0.93 in.)
D 65.0 mm (2.56 in.)
E 188.7 to 189.3 mm (7.43 to 7.45 in.)
F 254.0 mm (10.00 in.)
C1 1.0 mm (0.04 in.) bevel
a Ra=12.5a
b 30°(0.52 rad)
RY9212148MBS0094US0
(g)Spring

A 2.9 mm (0.11 in.)

B 20.0 mm (0.79 in.)
C 144.0 mm (5.67 in.)
D 109.0 mm (4.29 in.)
E 106.0 N (10.8 kgf, 23.8 lbs)
RY9212148MBS0095US0

1-S29 KiSC issued 08, 2015 A

KX080-4, WSM MACHINE BODY

[3] FRONT IDLER

(1) Assembly/Disassembly of Front Idler
1. Remove the track. (Refer to the chapter Assembly/Disassembly
of the Rubber Track.)
IMPORTANT
• Jack up the machine with the front-end and the blade and
place blocks under the frame.
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

(2) Assembly/Disassembly of the Front Idler

No. Name of part Qty Notes
123.6 to 147.1 N·m
(1) Bolt 4 12.6 to 15.0 kgf·m
91.2 to 108.5 lbf·ft
(2) Yoke 1
(3) Bracket 2
(4) Plug 2 R1/8
(5) Spring pin 2
(6) O-ring 2
(7) Shaft 1
(8) Floating seal 2
(9) Bushing 2
(10) Idler 1
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 (a) Pin Punch
(2) Bracket
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 (3) Floating Seal
(2) Bracket (4) Shaft
RY9212148MBS0007US0

Assembly Procedures
1. Mount the O-rings on the shaft.
IMPORTANT
• Apply engine oil to the O-rings.
(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.
Type SAE #30CD engine 80 cc
Lubricant
oil 4.88 cu.in

10.0 N·m
Tightening torque Plug 1.0 kgf·m
7.4 lbf·ft

Apply thread lock compound (Loctite 503 or equivalent)

RY9212148MBS0010US0

[4] GREASE CYLINDER

(1) Assembly/Disassembly of the Grease Cylinder
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

(2) Components
No. Name of part Qty Notes
(1) Rod 1
(2) Seal 1
(3) Backup ring 1
(4) O-ring 1
(5) Cylinder tube 1
98.0 to 107.8 N·m
(6) Grease nipple 1 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

[5] TENSIONER
(1) Tensioner Assembly/Disassembly
1. Remove the track front idler and grease cylinder. (Refer to the
the Track and Front Idler and Grease Cylinder sections for their
assembly/disassembly procedures.)
2. Remove the tensioner from the track frame.
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. Name of part Qty Notes

(1) Bolt 1
(2) Split pin 1
(3) Spring 1
(4) Retainer 1
(5) Washer 1
(6) Nut 1
RY9212148MBS0103US0

When switching from a rubber track to a steel one or vice versa,

set to the appropriate preset length.
334 mm
Steel Factory 13.1 in.
Preset length Specifica-
tion 319 mm
Rubber
12.6 in.

(a) Preset length

RY9212148MBS0104US0

1-S33 KiSC issued 08, 2015 A

KX080-4, WSM MACHINE BODY

[6] TRACK ROLLERS

(1) Track Roller Assembly/Disassembly
CAUTION
• As the grease cylinder is under high pressure, loosening the grease nipple all at once may cause the
nipple to go flying and/or grease to spray out.
• 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.
166.7 to 196.1 N·m
Tightening torque Bolt 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

(2) Components
(1) Spring pin (6) Bushing
(2) Bracket 1 (7) Roller
(3) Bolt (8) Shaft
(4) O-ring (9) Bracket 2
(5) Floating seal (10) Plug
RY9212148MBS0106US0

1-S34 KiSC issued 08, 2015 A

KX080-4, WSM MACHINE BODY

[7] CARRIER ROLLERS

(1) Carrier Roller Assembly/Disassembly
CAUTION
• As the grease cylinder is under high pressure, loosening the grease nipple all at once may cause the
nipple to go flying and/or grease to spray out.
• 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.
166.7 to 196.1 N·m
Tightening torque Bolt 17.0 to 20.0 kgf·m
123.0 to 144.6 lbf·ft

Apply a threadlock (ThreeBond 1305P).

Approx. 10.8 kg
Carrier roller weight
Approx. 23.8 lbs

(1) Block (2) Bolt

RY9212148MBS0146US0

(2) Components
(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 MACHINE BODY

[8] TABLE OF DIMENSIONS

(1) Rubber Track
No. Item KX080-4 KX080-4
Country sold CA USA
20 mm 20 mm
(1) Lug height
0.79 in. 0.79 in.
30 mm 30 mm
(2) Link height
1.18 in. 1.18 in.
450 mm 450 mm
(3) Track width
17.72 in. 17.72 in.
25 to 40 mm 25 to 40 mm
(4) Track tension
0.98 to 1.57 in. 0.98 to 1.57 in.
102.5 mm 102.5 mm
(5) Track height
4.04 in. 4.04 in.
No. of cored bars 76 76
6194 mm 6194 mm
Circumference in middle
243.86 in. 243.86 in.
81.5 mm 81.5 mm
Cored bar pitch
3.21 in. 3.21 in.
Endless ID mark –

(a) Track adjustment point

RY9212158MBS0006US0

(2) Steel Track

No. Item KX080-4
450 mm 600 mm
Track width
17.72 in. 23.62 in.
No. of links 39
616.0 / 632.0 mm
(1) 4 Link lengths (A)/(B)
24.25 / 24.88 in.
74.0 / 70.0 mm
(2) Height (A)/(B)
2.91 / 2.76 in.
26.0 / 16.0 mm
(3) Grouser height (A)/(B)
1.02 / 0.63 in.
41.26 / 40.26 mm
(4) Bushing O.D. (A)/(B)
1.62 / 1.59 in.
24.5 / 27.0 mm
(5) Bushing I.D. (A)/(B)
0.96 / 1.06 in.
24.0 / 21.0 mm
(6) Pin O.D. (A)/(B)
0.94 / 0.83 in.
40 to 55 mm
(7) Track tension
1.57 to 2.17 in.
(A): Factory spec. when new
(B): Recommended replacement values

(a) Track adjustment point

RY9212148MBS0109US0

1-S36 KiSC issued 08, 2015 A

KX080-4, WSM MACHINE BODY

(3) Idler Sprocket

No. Item KX080-4
Front Idler
390 / 384 mm
(1) O.D. (A)/(B)
15.35 / 15.12 in.
38 / 32 mm
(2) Guide width (A)/(B)
1.50 / 1.26 in.
98 mm
(3) Width
3.86 in.
Sprocket
493 / 481 mm
(4) O.D. (A)/(B)
19.41 / 18.94 in.
39 mm
(5) Wheel width
1.54 in.
(A): Factory spec. when new
(B): Recommended replacement values

(A) Front Idler (B) Sprocket

RY9212148MBS0110US0

(4) Carrier Rollers and Track Rollers

No. Item KX080-4
Carrier Rollers
80 / 76 mm
(1) O.D. (A)/(B)
3.15 / 2.99 in.
228.6 mm
(2) Roller width
9.00 in.
Track Rollers
104 / 96 mm
(3) Guide width (A)/(B)
4.09 / 3.78 in.
132 / 124 mm
(4) O.D. (A)/(B)
5.20 / 4.88 in.
228.6 mm
(5) Roller width
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

4. MEASURING MACHINE PERFORMANCE

[1] MEASURING FRONT PERFORMANCE
(1) Measuring Swivel Gear Backlash
Purpose
• Measure the degree of overall wear in the front and replace pins and/or bushings or add shims as needed.
• When there is a great deal of play, it may cause wear in the swivel bearing teeth, swivel motor pinion gear and
front pins and bushings.
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.) (3) 300 N (30 kgf, 67.4 lbs)
(2) 50 N (5.0 kgf, 11 lbs) (4) Amount of Play
RY9212148MBS0113US0

1-S38 KiSC issued 08, 2015 A

KX080-4, WSM MACHINE BODY

(2) Measuring Swivel Bearing Play

Purpose
• Assesses the degree of wear in the ball bearings and race surfaces of the swivel bearing according to the amount
of wear in the inner and outer races.
[Measurement preparation]
1. 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

5. SWIVEL GEAR BACKLASH PERFORMANCE

No. Item Factory specification Notes
≤ 70 mm
(1) Front play measurement
≤ 2.76 in.
Factory spec. 1.24 mm
when new 0.05 in.
(2) Swivel bearing play
2.48 mm
Usage limit
0.10 in.

RY9212158MBS0004US0

1-S40 KiSC issued 08, 2015 A

2 ENGINE

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

1. SPECIFICATIONS
KX080-4
Model V3307-CRS-T4
No. of cylinders 4
Cylinder Bore X Stroke 94.0 x 120 mm (3.70 x 4.72 in.)
Total displacement 3331 cm3 (203.3 cu.in.)
Idling RPM 1000 min-1
Rated RPM 2000 min-1
Maximum RPM 2220 min-1
Net 47.2 kW/2000 min-1 (63.3 kW/2000 min-1)
Rated output/RPM
Gross 49.7 kW/2000 min-1 (66.6 kW/2000 min-1)
258.9 N·m/1400 min-1
Net
(26.4 kgf·m/1400 min-1, 191.0 lbf·ft/1400 min-1 )
Max torque/RPM
267.0 N·m/1400 min-1
Gross
(27.73 kgf·m/1400 min-1, 196.9 lbf·ft/1400 min-1 )
Machine dimensions (LxWxH) 803 x 578 x 760 mm (31.61 x 22.76 x 29.92 in.)
Dry weight 310 kg (683 lbs)
Combustion type Re-entrant, direction injection type (E-CDIS)
Fuel injection pump type
Governor type
Nozzle type Denso common rail system
Fuel injection timing
Fuel injection pressure
Rotation direction Counterclockwise viewed from flywheel side
Firing sequence 1-3-4-2
Compression ratio 17.5
EGR External EGR
Compression pressure 3.1 MPa (32 kgf/cm2, 450 psi)
Fuel consumption (at Net 237.3 g/kW·h (177.0 g/HP·h, 0.390 lb/HP·h)
rated RPM) Gross 220 g/kW·h (164.1 g/HP·h, 0.362 lb/HP·h)
Engine oil consumption (at rated RPM) 0.54 g/kW·h (0.40 g/PS·h) or less
Alternator 12 V, 960 W
ETN 600 035 060
Battery name DIN 60035
JIS 12V92AH, 130E41R
Starter motor 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

2. DIMENSIONS

A 802.9 mm (31.57 in.) E 280 mm (11.02 in.) I 759.8 mm (29.91 in.)

B 321 mm (12.64 in.) F 578.1 mm (22.76 in.) J 233.6 mm (9.20 in.)
C 32.6 mm (1.28 in.) G 310.2 mm (12.21 in.) K 290 mm (11.42 in.)
D 113 mm (4.45 in.) H 5 mm (0.20 in.)

RY9212148END0002US0

2-G2 KiSC issued 08, 2015 A

KX080-4, WSM ENGINE

3. PERFORMANCE CURVES

(a) Engine RPM (e) Output (HP) A : SI unit

(b) Output (kW) (f) Torque (ft/lb) B : US units of work
(c) Torque (N·m) (g) Fuel consumption (g/HPh)
(d) Fuel consumption (g/kWh)
RY9212148END0003US0

2-G3 KiSC issued 08, 2015 A

KX080-4, WSM ENGINE

4. FAN DRIVE

(1) Bimetallic Strip (4) Feed Orifice (6) Collection Orifice A : At High Temperature
(2) Piston (5) Torque Transmission (7) Oil Collection Chamber B : At Low Temperature
(3) Flat Spring (Valve) Chamber

[At high temperature]

• 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 HYDRAULIC SYSTEM

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

1. DIAGRAM OF HYDRAULIC CIRCUIT

[1] DIAGRAM OF HYDRAULIC CIRCUIT (KX080-4 STANDARD SPECIFICATION)

3-M1 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

[2] DIAGRAM OF HYDRAULIC CIRCUIT (KX080-4 ANGLE BLADE SPECIFICATION)

3-M2 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

2. HYDRAULIC DEVICE LAYOUT

(1) Pump (7) Arm Cylinder (13) Travel Pilot Valve (19) Angle Solenoid Valve
(2) Control Valve (8) Bucket Cylinder (14) Blade Pilot Valves (20) Boom Shockless Valve
(3) Swivel Motor (9) Swing Cylinder (15) Swing Pilot Valve (21) Swivel Shuttle Valve
(4) Swivel Joint (10) Blade Cylinder (16) Unload Valve (22) EP Mode Solenoid Valve
(5) Travel Motor (11) Angle Cylinder (17) AUX1 Solenoid Valve (23) TPSS Valve
(6) Boom Cylinder (12) Control Pilot Valves (18) AUX2 Solenoid Valve
RY9212158HYM0030US0

3-M3 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

3. PUMP
[1] SPECIFICATIONS

P1,P2: Piston pump discharge PLS: Load pressure Pi : EP mode limit pressure PS: Suction pressure
pressure PPS: Valve inlet pressure Pave: average pressure CH: Air bleed
P3: Gear pump discharge
pressure
Pp : Pilot pump discharge
pressure

Maker KYB
Model
Rated RPM 2000 rpm
Rotation direction Right
Piston pump 36.0 + 36.0 cc/rev (2.2 cu.in./rev)
Pilot pump Max displacement 7.1 cc/rev (0.4 cu.in./rev)
Gear pump 33.3 cc/rev (2.0 cu.in./rev)
Standby flow amount 22 L/min (5.8 U.S.gals)

RY9212158HYM0010US0

3-M4 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

[2] PIST PUMP HORSEPOWER CONTROL CURVE

(1) P3 = At No Load (2 MPa)

(1) Pi = 3.6 MPa (P mode) (2) Pi = 0 MPa (E mode) (a) Discharge flow rate: Q (b) Discharge pressure: P
(L/min) (MPa)

Pump input RPM: 2000

Discharge pressure (MPa) Discharge flow rate (L/min) Discharge pressure (MPa) Discharge flow rate (L/min)
PA1 = 2.0 143.0 PB1 = 6.3 141.0
PA2 = 14.0 139.0 PB2 = 15.7 66.0
PA3 = 23.1 69.3 PB3 = 29.4 19.8
PA4 = 29.4 39.3

RY9212148HYM0064US0

(2) P3 = 20.6 MPa

(1) Pi = 3.6 MPa (P mode) (2) Pi = 0 MPa (E mode) (a) Discharge flow rate: Q (b) Discharge pressure: P
(L/min) (MPa)

Pump input RPM: 2000

Discharge pressure (MPa) Discharge flow rate (L/min) Discharge pressure (MPa) Discharge flow rate (L/min)
PA1 = 2.0 143.0 PB1 = 2.5 79.0
PA2 = 11.4 63.0 PB2 = 19.5 19.4
PA3 = 26.5 14.3 PB3 = 29.4 12.7
PA4 = 29.4 12.7

RY9212148HYM0065US0

3-M5 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

[3] FUNCTION AND STRUCTURE

(1) Operating Principles

(1) Piston (4) Swash-plate (7) Suction port A : Discharge side

(2) Retainer plate (5) Cylinder block (8) P1 discharge port B : Suction side
(3) Shoe (6) Valve plate (9) P2 discharge port

There are 10 pistons (1) built into the cylinder block (5) and it is coupled to the axle via a spline. 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

(2) Horsepower Control

Horsepower control is a matter of controlling the discharge flow of the piston pump in such a way that the total
consumed horsepower (torque) of the pump does not exceed the specified horsepower (torque) of the engine.
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 (3) Horsepower control valve
(2) Horsepower control spring (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 Pi : From E-mode limit
(2) Horsepower control spring pressure
(3) Horsepower control valve
(4) Horsepower control spool
(5) Reaction pin
RY9212148HYM0061US0

(3) Flow Control (LS Control)

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 (12) L/S Regulator
(11) Spool
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 (6) L/S Regulator
(2) Horsepower control spring (7) Spool
(3) Horsepower control valve (8) Compensator spool
(4) Horsepower control spool (9) Opening area
(5) Reaction pin
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 (4) L/S Regulator
(2) Horsepower control spring (5) Spool
(3) Horsepower control valve
RY9212148HYM0063US0

3-M10 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

(4) Gain Control

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

(5) Standby Flow Amount

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 (a) Discharge pressure

(2) Standby flow amount (b) Discharge flow
RY9212158HYM0011US0

3-M11 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

4. CONTROL VALVE
[1] SPECIFICATIONS

(1) Swivel right (Pbk5) (7) Travel left forward (Pbk2) (13) Bucket dump (Pb2) (18) Boom down (Pa4)
(2) Swivel left (Pak5) (8) Travel left reverse (Pak2) (14) Bucket crowd (Pa2) (19) Swing right (Pb5)
(3) Blade up (Pbk4) (9) Travel right forward (Pbk1) (15) AUX1 High (Pb3) (20) Swing left (Pa5)
(4) Blade down (Pak4) (10) Travel right reverse (Pak1) (16) AUX1 Low (Pb3) (21) Angle right (Pb6)
(5) AUX2 High (Pbk3) (11) Arm dump (Pb1) (17) Boom up (Pb4) (22) Angle left (Pa6)
(6) AUX2 Low (Pak3) (12) Arm crowd (Pa1)

Item Notes
Maker KYB
Model
2.7 MPa
Unload (aUN) 28 kgf/cm2 When 23 L/min., 6.1 U.S. gals
392 psi
27.4 MPa
Main LS (aLS) 279 kgf/cm2 When 48 L/min., 12.7 U.S. gals
Main relief valve setting 3974 psi
pressure 29.4 MPa
P1 (aTR)
300 kgf/cm2 When 43 L/min., 11.4 U.S. gals
P2 (aTL)
4264 psi
20.6 MPa
P3 (aP3) 210 kgf/cm2 When 66 L/min., 17.4 U.S. gals
2988 psi

3-M12 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

Item Notes
31.4 MPa
b1B
Boom 320 kgf/cm2
b1R
4554 psi
30.4 MPa
b2B 310 kgf/cm2
4409 psi
Arm
31.4 MPa
b2R 320 kgf/cm2
4554 psi
31.4 MPa
b3B
Bucket 320 kgf/cm2
b3R
4554 psi
27.4 MPa
Overload relief valve At 5 L/min
b4B 279 kgf/cm2
setting pressure (300 cu.in./min, 1.3 USGPM)
3974 psi
Blade
17.2 MPa
b4R 175 kgf/cm2
2495 psi
20.6 MPa
b6L
AUX1 210 kgf/cm2
b6R
2988 psi
19.0 MPa
b8B 194 kgf/cm2
2756 psi
Angle
31.4 MPa
b8R 320 kgf/cm2
4554 psi

RY9212158HYM0012US0

3-M13 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM
Hydraulic Circuit Diagram (Angle Spec.)

(1) P3 bypass valve (8) Independent travel valve A : Main spool pressure (a) Other
(2) Swivel (9) Arm receiver characteristics (b) Swing, angle
(3) Blade (10) Bucket B : Independent travel valve, (c) Blade Pa pressure
(4) AUX2 (11) AUX1 etc. pressure receiver (d) Blade Pb pressure
(5) Communication valve (12) Boom characteristics (e) Communication valve
(6) Travel left (13) Swing (f) Independent travel valve
(7) Travel right (14) Angle (A) Spool stroke (mm) (g) P3 bypass valve
(B) Pilot pressure (MPa)
RY9212158HYM0013US0

3-M14 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

[2] FUNCTION AND STRUCTURE

(1) Unload Valve Section
When in neutral

(1) Independent travel valve (3) Micro-orifice (4) PLS pressure passage (5) Notch
section
(2) LS drain plug
• Pump discharge pressure PPS and maximum load pressure PLS act on either end of the unload spool.
• 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 HYDRAULIC SYSTEM
During fine operation of LS section

(1) Independent travel valve (3) Micro-orifice (5) Notch (a) To each spool section
section (4) PLS pressure passage
(2) LS drain plug
• When the spool section is switched, the oil in the pump pressure passage passes through the main spool and is
discharged to the cylinder port. 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 HYDRAULIC SYSTEM
During operation of LS section

(1) Independent travel valve (3) Micro-orifice (5) Notch (a) To each spool section
section (4) PLS pressure passage
(2) LS drain plug
• When the spool section is switched, the oil in the pump pressure passage passes through the main spool and is
discharged to the cylinder port. 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 HYDRAULIC SYSTEM

(2) Mono-Block Section Operation (LS Control)

When in neutral

(1) Independent travel valve (5) Main spool (9) Pump pressure passage (a) From unload valve to tank
section (6) Compensator spool (10) Overload relief valve circuit
(2) LS drain plug (7) Load check valve (b) To pump
(3) Micro-orifice (8) Shuttle valve
(4) PLS pressure passage
• 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 HYDRAULIC SYSTEM
When Pb port pressurized

(1) Independent travel valve (5) Main spool (9) Pump pressure passage (a) From unload valve to tank
section (6) Compensator spool (10) Overload relief valve circuit
(2) LS drain plug (7) Load check valve (11) LS pressure guide orifice (b) To pump
(3) Micro-orifice (8) Shuttle valve
(4) PLS pressure passage
• 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

(3) Arm Regenerative Function

(1) Independent travel valve (5) Main spool (9) Pump pressure passage (13) LS pressure guide orifice
section (6) Compensator spool (10) Unload spool
(2) LS drain plug (7) Load check valve (11) Arm regenerative sleeve (a) To pump
(3) Micro-orifice (8) Shuttle valve (12) Regenerative poppet (b) Regenerative flow
(4) PLS pressure passage
• 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

(4) Swing Section Operation (LS Control)

(1) Independent travel valve
section
(2) LS drain plug
(3) Micro-orifice
(4) PLS pressure passage
(5) Main spool
(6) Compensator spool
(7) Load check valve
(8) Shuttle valve
(9) Pump pressure passage
(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

(5) Travel Section Operation (Open Center Control)

(1) Independent travel valve (3) Travel left section (5) PP2 signal pressure (a) To pump
section (4) Main spool (b) To unload valve
(2) Travel right section

[In neutral]
• 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

(6) Blade Section Operation (Open Center Control)

(1) Independent travel valve (4) Main spool (7) Bridge passage (9) AUX2
section (5) Load check valve (8) Center bypass passage (10) Swivel
(2) Blade section (6) Parallel passage
(3) Communication valve spool

[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

(7) Anti-Drift Function

(1) Independent travel valve (6) Compensator spool (11) Piston (a) From unload valve to tank
section (7) Load check valve (12) Spool circuit
(2) LS drain plug (8) Shuttle valve (13) Poppet A (b) To pump
(3) Micro-orifice (9) Pump pressure passage (14) Poppet B
(4) PLS pressure passage (10) Anti-drift valve
(5) Main spool

[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

(8) P3 Bypass Section Operation (Simultaneous Boom Up + Swivel

Operation)

(1) Boom section (4) Main spool (7) Switch spool (a) From P3 port
(2) P3 bypass section (5) Compensator spool (8) Check valve
(3) Swivel section (6) Pump pressure passage
• 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

(9) Signal Circuit

(1) Independent travel valve (7) Micro-orifice (13) Travel right (19) Main spool signal passage
section (8) Ring gap (14) Arm section
(2) Communication valve section (9) Swivel (15) Bucket (20) Area receiving pressure: A1
(3) P3 bypass section (10) Blade (16) AUX1 (21) Area receiving pressure: A2
(4) Independent travel valve (11) AUX2 (17) Boom
spool (12) Travel left (18) Swing (a) To pump
(5) Communication valve spool
(6) Filter

[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

5. SWIVEL MOTOR
[1] SPECIFICATIONS
(1) Port A
(2) Port B
(3) Port M
(4) Drain port
(5) Port SH
(6) Port PG
(7) Reverse check valve
(8) Hydraulic timer
(9) Swivel left relief valve (cSL)
(10) Swivel right relief valve
(cSR)

Item Notes
Maker KYB
Model MSG-44P-21-19
909 cm3/rev
Total displacement
55.5 cu.in./rev
44.1 cm3/rev
Motor displacement
2.7 cu.in./rev
Reduction ratio 20.615
21.6 MPa
cSR
220 kgf/cm2 At 66 L/min., 17.4 U.S. gals
cSL
3133 psi
Relief valve 8.3 ± 0.1 MPa
Shockless pressure 84.70 ± 1.02 kgf/cm2
1203.8 ± 14.5 psi
Shockless time 0.03 ± 0.05 sec
66 L/min
Useful flow
17.4 U.S.gals
1.5 to 4.9 MPa
PG 15.3 to 50.0 kgf/cm2
217.6 to 711.0 psi
Parking brake release
0.4 ± 0.1 MPa
pressure
SH 4.10 ± 1.02 kgf/cm2
58.0 ± 14.5 psi
Hydraulic timer 5.0 ± 1.5 sec

RY9212148HYM0030US0

3-M29 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

[2] FUNCTION AND STRUCTURE

(1) Operating Principles
[A] Motor
• The pressurized oil from port A (1) goes through
valve plate (3), enters piston (5) inside cylinder block
(4) and presses against the swash-plate (6). The
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 (5) Piston
(2) Port B (6) Swash Plate
(3) Valve Plate (7) Shaft
(4) Cylinder Block
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 (3) Poppet
(2) Port B (4) Port M
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[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 (a) Pressure
(2) Relief valve orifice (b) Time
(3) Body orifice (c) Primary relief pressure
(4) Piston chamber (d) Secondary relief pressure
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KX080-4, WSM HYDRAULIC SYSTEM

[D] Parking Brake

a)When the parking brake is operated
• When the brake release pressure is interrupted,
springs press the brake piston (1) against the disc (2)
that meshes with the spline on the circumference of
the cylinder block (3).
• Friction holds the cylinder block (3) to the case,
preventing it from turning.
(1) Brake piston (3) Cylinder block
(2) Disc
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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

[E] Hydraulic Timer

• 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 (a) ON
(2) Spring (b) OFF
(3) Drain port
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KX080-4, WSM HYDRAULIC SYSTEM

[F] Reverse Check Valve

• When the motor is stopped, the reverse check valve
prevents the swivel body from turning in reverse
when it is stopped due to accumulated pressure by
linking the motor's main line and makeup line for a
certain period of time.
(1) Sleeve (5) Orifice A
(2) Flow regulating valve (6) Orifice B
(3) Check valve (7) To high-pressure passage
(4) Damper chamber (8) To makeup
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a)In neutral
• The check valve is held in balance in the middle by
the spring. (Equal pressure on ports P1 and P2)
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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
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c)When braking
• Brake pressure shifts the check valve full stroke,
seating it.
(1) Brake pressure (2) Seat
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KX080-4, WSM HYDRAULIC SYSTEM
d)When reversing 1
• After valve unit braking makes it stop, the motor tries
to turn in reverse due to accumulated pressure in its
main line.
• This reverse pressure makes the shuttle valve
(sleeve) inside the check valve seat on the
low-pressure side of the check valve; 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
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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
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[G] Two-Stage Planetary Gear Decelerator

• 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 (6) Sun gear
(2) Drive gear (7) Planetary gear B
(3) Planetary gear A (8) Holder
(4) Housing (9) Pinion shaft
(5) Holder
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KX080-4, WSM HYDRAULIC SYSTEM

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

Item Notes
Maker Mitsubishi Heavy Industries
Model SGM-04D-S-09KT
Reduction ratio 54.8
10349 to 5322 N·m
Reduction ratio Output torque (1F/2F) 1055.6 to 542.8 kgf·m
7633.4 to 3925.5 lbf·ft
RPM (1F/2F) 26.6 /49.4 rpm
46.90 / 25.29 cm3/rev
Displacement (1F/2F)
2.86 / 1.54 cu.in./rev
72.0 L/min
Flow Rate
19.0 U.S.gals
29.4 MPa
Relief valve (cTF, cTR) 300 kgf/cm2
Hydraulic motor 4264 psi
4.0 MPa
2-speed switch pressure 40.8 kgf/cm2
580 psi
24.0 MPa
Auto 2-speed switch
245 kgf/cm2
pressure
3481 psi
0.98 MPa
Parking brake Release pressure 10.0 kgf/cm3
142.1 psi

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KX080-4, WSM HYDRAULIC SYSTEM

[2] FUNCTION AND STRUCTURE

(1) Operating Principles
[A] Motor
• Nine pistons (2) are built into the cylinder block (1),
and the end section of the block is in contact with a
valve plate (3), which has two half-moon shaped
ports (port C and port D for switching between high
and low pressure).
• 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 C : Port C
(2) Piston D : Port D
(3) Valve Plate
(4) Swash Plate
(5) Shaft
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KX080-4, WSM HYDRAULIC SYSTEM

[B] Brake Valve

a)During normal operation
• Oil supplied by the pump enters port A and opens the
check valve (1). The oil passes through the check
valve and goes from port C into the hydraulic motor,
providing rotary force to the motor.
• 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 (a) Line a
(2) Spool (b) Chamber b
(3) Parking brake
(4) Spring
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KX080-4, WSM HYDRAULIC SYSTEM

[C] Relief Valve

(A)At start up
• Until the shockless piston (1) reaches the end of its
stroke, the oil is released by the setting pressure (low
pressure relief) of the poppet (2).
• When the shockless piston (1) reaches the end of its
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 (a) Pressure
(2) Poppet (b) Time
(3) Chamber (c) Low-pressure relief
(primary relief pressure)
(d) Main relief
(e) Relief valve A release
timing
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KX080-4, WSM HYDRAULIC SYSTEM

[D] Parking Brake

• The parking brake is a negative brake composed of
a rotating disc (friction material) (4), an opposing
plate (5) a brake piston (3) and a spring (1).
• When the travel motor is stopped (the travel lever in
neutral), the parking brake takes effect.
• 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 (4) Disc (friction material)
(2) Brake piston chamber (5) Opposing plate (plate)
(3) Brake piston (6) Cylinder block
RY9212158HYM0001US0

[E] Auto-Decelerator Function

(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.
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KX080-4, WSM HYDRAULIC SYSTEM

7. HYDRAULIC CYLINDER
[1] SPECIFICATIONS

Boom Arm Bucket Blade Swing Angle

82 mm 70 mm 70 mm 82 mm 82 mm 60 mm
(1)
3.23 in. 2.76 in. 2.76 in. 3.23 in. 3.23 in. 2.36 in.
82 mm 70 mm 70 mm 82 mm 82 mm 60 mm
(2)
3.23 in. 2.76 in. 2.76 in. 3.23 in. 3.23 in. 2.36 in.
90 mm 85 mm 75 mm 75 mm 80 mm 60 mm
(3)
3.54 in. 3.35 in. 2.95 in. 2.95 in. 3.15 in. 2.36 in.
90 mm 85 mm 75 mm 75 mm 80 mm 60 mm
(4)
3.54 in. 3.35 in. 2.95 in. 2.95 in. 3.15 in. 2.36 in.
65 mm 60 mm 55 mm 65 mm 60 mm 45 mm
(5)
2.56 in. 2.36 in. 2.17 in. 2.56 in. 2.36 in. 1.77 in.
115 mm 100 mm 90 mm 125 mm 110 mm 80 mm
(6)
4.53 in. 3.94 in. 3.54 in. 4.92 in. 4.33 in. 3.15 in.
134 mm 118 mm 112 mm 146 mm 131 mm 96 mm
(7)
5.28 in. 4.65 in. 4.41 in. 5.75 in. 5.16 in. 3.78 in.
57 mm 55 mm 60 mm 65 mm 65 mm 40 mm
(8)
2.24 in. 2.17 in. 2.36 in. 2.56 in. 2.56 in. 1.57 in.
70 mm 58 mm 55 mm 65 mm 58 mm 40 mm
(9)
2.76 in. 2.28 in. 2.17 in. 2.56 in. 2.28 in. 1.57 in.
Max
1369 mm 1378 mm 1138 mm 689 mm 1165 mm 733 mm
compresse
53.90 in. 54.25 in. 44.80 in. 27.13 in. 45.87 in. 28.86 in.
d length
878 mm 912 mm 747 mm 250 mm 715 mm 455 mm
Stroke
34.57 in. 35.91 in. 29.41 in. 9.84 in. 28.15 in. 17.91 in.

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3-M39 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

[2] FUNCTION AND STRUCTURE

(1) Operating Principles
• Cushion Function
The device is equipped with a cushion to prevent spilling of earth or the like when it reaches the end of the
cylinder.
RY9212148HYM0050US0
Cushion function on the lift end of the boom

(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.
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KX080-4, WSM HYDRAULIC SYSTEM
Cushion function on dumping end of arm

(1) Port (3) Cushion Plunger A : Before Cushion Enters

(2) Cushion Chamber (4) Piston B : After Cushion Enters
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3-M41 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

8. PILOT VALVE
[1] CONTROL PILOT VALVES
(1) Specifications

(1) Port P (7) Independent operation torque (a) Secondary pressure (e) Pushrod stroke (mm)
(2) Port 1 (Left) (ports 1, 3) (kgf/cm2) (f) Operating angle (deg)
(3) Port 2 (Front) (8) Independent operation torque (b) Secondary pressure (MPa)
(4) Port 3 (Right) (port 2) (c) Operating torque (N·m)
(5) Port 4 (Rear) (9) Independent operation torque (d) Operating torque (kgf·cm)
(6) Port T (port 4)
(10) Secondary pressure

Maker Kawasaki Heavy Industries, Ltd.

Left PV48M2199
Model
Right PV48M2198

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KX080-4, WSM HYDRAULIC SYSTEM

(2) Function and Structure

[A] Function
The pilot valve is the valve that controls the direction and volume of the stroke of the control valve, and lowers the
primary pressure from the unload valve to a secondary pressure only as much as is necessary to move the control
valve spool.
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 (a) Output Port
(2) Spool (T) Port T
(3) Return Spring
(4) Return Spring
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 (a) Output Port
(2) Spring Seat (P) Port P
(3) Secondary Pressure Spring
(4) Spool
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KX080-4, WSM HYDRAULIC SYSTEM

[2] TRAVEL PILOT VALVE

(1) Specifications

(1) Port 1 (L Bwd) (5) Operating torque (a) Secondary pressure (e) Pushrod stroke (mm)
(2) Port 2 (L Fwd) (6) Secondary pressure (kgf/cm2) (f) Operating angle (deg)
(3) Port 3 (R Bwd) (P) Port P (b) Secondary pressure (MPa)
(4) Port 4 (R Fwd) (T) Port T (c) Operating torque (N·m)
(d) Operating torque (kgf·cm)

Maker Kawasaki Heavy Industries, Ltd.

Model PVD8PC6004A

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3-M44 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

(2) Function and Structure

[A] Function
The pilot valve is the valve that controls the direction and volume of the stroke of the control valve, and lowers the
primary pressure from the unload valve to a secondary pressure only as much as is necessary to move the control
valve spool.
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 (a) Port 1
(2) Pushrod (b) Port 2
(3) Spring seat (P) Port P
(4) Secondary pressure spring (T) Port T
(5) Spool A: Part A
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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 (a) Port 1
(2) Pushrod (b) Port 2
(3) Spool (P) Port P
(T) Port T
RY9212148HYM0009US0

3-M46 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

[3] SWING PILOT VALVE

(1) Specifications

(1) Port 1 (P) Port P (a) Secondary pressure (e) Pushrod stroke (mm)
(2) Port 2 (T) Port T (kgf/cm2) (f) Pedal operating angle (deg)
(3) Operating torque (b) Secondary pressure (MPa)
(4) Secondary pressure (c) Operating torque (N·m)
(d) Operating torque (kgf·cm)

• For Swing
Maker Kawasaki Heavy Industries, Ltd.
Model PV6P1005A

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3-M47 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

(2) Function and Structure

[A] Function
The pilot valve is the valve that controls the direction and volume of the stroke of the control valve, and lowers the
primary pressure from the unload valve to a secondary pressure only as much as is necessary to move the control
valve spool.
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 (a) Port 1
(2) Spool (b) Port 2
(3) Return spring (P) Port P
(4) Cam (T) Port T
(5) Pushrod
(6) Spring seat
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KX080-4, WSM HYDRAULIC SYSTEM

[4] BLADE PILOT VALVES

(1) Specifications

(1) Port 1 (P) Port P (a) Secondary Pressure (e) Pushrod stroke (mm)
(2) Port 2 (T) Port T (kgf/cm2) (f) Operating Angle (deg)
(b) Secondary Pressure (MPa) (g) Down
(c) Operating Torque (N·m) (h) Up
(d) Operating Torque (kgf·m)

Maker Kawasaki Heavy Industries, Ltd.

Model TH40P1048B

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3-M49 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

(2) Function and Structure

[A] Function
The pilot valve is the valve that controls the direction and volume of the stroke of the control valve, and lowers the
primary pressure from the unload valve to a secondary pressure only as much as is necessary to move the control
valve spool.
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 (a) Port 1
(2) Spool (b) Port 2
(3) Return Spring (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 (a) Port 1
(2) Spool (b) Port 2
(3) Secondary Pressure Spring (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 (a) Port 1
(2) Steel Ball (b) Port 2
(3) Spring (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 (a) Port 1
(2) Disc (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

9. SHOCKLESS VALVES
[1] SPECIFICATIONS
(1) Port 1 (Pilot valve side,
boom up)
(2) Port 2 (Pilot valve side,
boom down)

A : Port A (control valve side,

boom up)
B : Port B (control valve side,
boom down)
T: Port T
RY9212148HYM0052US0

[2] FUNCTION AND STRUCTURE

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 (A) Port A
(2) Port 2 (B) Port B
(3) Orifice (T) Port T
(4) Plunger
(5) Spring (a) Chamber a
(6) Spool (b) Chamber b
(7) Spring (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 (A) Port A
(2) Port 2 (B) Port B
(3) Orifice (T) Port T
(4) Plunger
(5) Spring (a) Chamber a
(b) Chamber b
(c) Orifice c
RY9212148HYM0055US0

3-M53 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

10. SOLENOID VALVE

[1] UNLOAD VALVE
(1) Specifications

(1) PAC Port (Accumulator) (3) Port B (Pilot Operation, Swivel (5) Port P (to Control Valve) (7) Pilot Primary Relief Valve
(2) Port A (2-Speed Travel Parking Brake) (6) Port C (from Pilot Pump) (aPP)
Switch) (4) Drain Port (to Hydraulic Oil (8) Check Valve
Tank)

Maker Nishina Industrial Notes

Rated Voltage 12 V
Relief Valve 3.92 + 0.29 MPa
at Temp. 50 °C (144 °F),
Pressure Setting 40.0 + 3.0 kgf/cm2
14.7 L/min (897 cu.in./min, 3.9 USGPM)
(aPP) 570 + 42 psi
130 ml/min
Leak volume port P
7.9 cu.in./min at 2.5 MPa (25.5 kgf/cm2, 363 psi)
→ port T
0.03 USGPM
90 ml/min
Leak volume port
5 cu.in./min at 3.9 MPa (40.0 kgf/cm2, 569 psi)
PAC → other ports
0.02 USGPM

RY9212148HYM0022US0

3-M54 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

(2) Function and Structure

[A] Function
The unload valve consists of two directional change valves operated by solenoid, a check valve and a relief valve;
it perform functions such as unloading control pressure from the pilot pump (returning oil to the hydraulic oil tank) and
supplying control pressures to pilot valves for operation and travel, as well as to the swivel motor (for the parking
brake) and the travel motor (for switching the two speeds).
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 A: Port A
(2) Plunger 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 A: Port A
(2) Spool C: Port C
(3) Spring P: Port P
(4) Plunger T: Port T
RY9212148HYM0024US0

3-M56 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

[2] AUX SOLENOID VALVE

(1) Specifications
Proportional Control Solenoid Valve
This valve is an electromagnetic solenoid valve. Normally a solenoid valve is turned off and on via 12V battery
voltage, but this valve is controlled via pulsed signals from the computer built into the ECU and the meter panel.
(Duty Control)
Item Specifications
3.9 MPa
Max operating pressure
40 kgf/cm2
(input pressure)
570 psi
1.0 MPa
Allowable back pressure
10 kgf/cm2
(pressure T)
100 psi
Maximum proportional valve
operating flow volume 15.6 L/min (4.1 GPM)
(input flow volume)
0.4 L/min ≥
Drain volume when solenoid off [at 20 cST, port P pressure =
4.9 MPa (50 kgf/cm2, 710 psi)]
Waterproof Standard JIS D 0203 S2 equivalent
Vibration Proof Standard JIS D 1601–1995
Hydraulic Oil Grade ISO VG32 to 68 equivalent
Hydraulic Oil Contamination
NAS Class 10 or less
Level
Rated Amperage: 1600 mA
Electrical Specifications Coil resistance: 3.2 ± 0.5 Ω
[at 20 deg C (68 deg F)]
0 to 2.7 MPa
Secondary pressure control
0 to 27 kgf/cm2
range
0 to 390 psi

(1) P port (a) Secondary Pressure (MPa)

(2) T port (b) Input Amperage (mA)
(3) A1 Port (Hi)
(4) A2 Port (Low)
RY9212148HYM0025US0

3-M57 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

(2) Function and Structure

The pressure from port P is supplied or cut off from port A or port B by the solenoid valve used when operating
the AUX.
RY9212095HYM0019US0
1. When the solenoid is off
When the solenoid is off, port P and port B are cut off
by the spool. Port B and port T are connected, so no
pressure is produced at port B.
(1) Spool A: Port A
(2) Solenoid 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 A: Port A
(2) Solenoid B: Port B
P: Port P
T: Port T
RY9212095HYM0021US0

3-M58 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

[3] ANGLE SOLENOID VALVE

(1) Specifications

A : Port A (Left) B : Port B (Right) P : Port P T : Port T

Maker Nishina Industrial

Rated Voltage DC 12 V
220 ml/min or less
Leak Volume at Temp. 50 °C (122 °F),
4.9 MPa (50 kgf/cm2, 3130 psi) pressure

RY9212158HYM0009US0

3-M59 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

[4] EP MODE SOLENOID VALVE

(1) Specifications
Item Specifications
3.9 MPa
Max operating pressure
40 kgf/cm2
(input pressure)
570 psi
1.0 MPa
Allowable back pressure
10 kgf/cm2
(pressure T)
100 psi
Maximum proportional valve
operating flow volume 10.0 L/min (2.64 U.S.gals./min)
(input flow volume)
0.6 L/min (0.2 U.S.gals../min) ≥
Drain volume when solenoid off [At 20 cST, port P pressure =
4.9 MPa (50 kgf/cm2, 710 psi)]
Rated Amperage: 1600 mA
Electrical Specifications Coil resistance: 3.3 Ω
[at 20 °C (68 °F)]

(1) Solenoid A : Port A

(2) Case 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

1. PUMP
[1] PUMP DISASSEMBLY / ASSEMBLY
CAUTION
• When removing a hydraulic device after operating the mini-excavator, lower the bucket and blade to the
ground and turn off the engine.
• Each of the devices and the hydraulic oil are hot right after stopping the mini-excavator. The oil is hot
enough to cause a burn, so always let it cool down before starting any work.
• 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.
196.1 to 225.6 N·m
Tightening torque Bolt 20.0 to 23.0 kgf·m
144.6 to 166.4 lbf·ft

Pump weight Approx. 50 kg (110 lbs)

(1) Pump
RY9212148HYS0207US0

Adapter angles

(1) P1 (a) 45°(0.79 rad)

(2) P2 (b) 30°(0.52 rad)
(3) P3
(4) P4
(5) Pps
(6) Pls
(7) Pi
RY9212148HYS0208US0

3-S2 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM
Pump Connector and Housing Assembly Diagram

(1) Connector (3) Pump housing (5) Parallel pin (6) Spring pin
(2) Connector mounting bolt (4) Housing mounting bolt
• (a) Apply grease to the spline.
IMPORTANT
• Align the spring pin before tightening the connector mounting bolts.
• 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.
210.0 to 230.0 N·m
Connector mounting bolt 21.4 to 23.5 kgf·m
154.9 to 169.6 lbf·ft
Tightening torque
48.1 to 55.9 N·m
Housing mounting bolt 4.9 to 5.7 kgf·m
35.5 to 41.2 lbf·ft

RY9212148HYS0371US0

3-S3 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

[2] PUMP DISASSEMBLY PROCEDURES

No. Part Name Q'ty No. Part Name Q'ty

(1) Plug 2 (17) Port block 1
(2) Orifice 1 (18) Gasket 1
(3) Swash plate 1 (19) Bolt 5
(4) Collar 1 (20) Bolt 2
(5) Shoe 10 (21) Bearing case 1
(6) Retainer plate 1 (22) Bolt 4
(7) Spring 10 (23) Pin 3
(8) Piston 10 (24) Case 1
(9) Cylinder block 1 (25) Plug 1
(10) Valve plate 1 (26) O-ring 1
(11) Collar 1 (27) Shaft 1
(12) Pin 4 (28) Roller bearing 1
(13) Needle bearing 1 (29) Cir-clip 1
(14) Piston assy 1 (30) Oil seal 1
(15) Spool guide 1 (31) Cir-clip 1
(16) O-ring 1

RY9212148HYS0382US0

3-S4 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

No. Part Name Q'ty No. Part Name Q'ty

(1) Holder 1 (17) Orifice 1
(2) Spring seat 1 (18) Orifice 1
(3) Spring 1 (19) Plug 1
(4) Spring 1 (20) O-ring 1
(5) Spring 1 (21) Spool 1
(6) Spring seat 1 (22) Bolt 4
(7) O-ring 1 (23) Bushing 1
(8) Valve sleeve 1 (24) Spring seat 1
(9) Spool 1 (25) Spring 1
(10) Pin 1 (26) O-ring 1
(11) O-ring 1 (27) Holder 1
(12) Plug 1 (28) Set screw 1
(13) Nut 1 (29) O-ring 1
(14) O-ring 1 (30) Nut 1
(15) Orifice 1 (31) Cap 1
(16) O-ring 1 (32) Nut 1

RY9212148HYS0383US0

3-S5 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

No. Part Name Q'ty No. Part Name Q'ty

(1) Socket head bolt 11 (10) Ball 2
(2) Plug 1 (11) Seat 2
(3) Orifice 1 (12) O-ring 2
(4) Plug 5 (13) O-ring 1
(5) O-ring 11 (14) Valve seat 1
(6) Orifice 3 (15) Oil pressure pump 1
(7) Plug 2 (16) Plain washer 2
(8) O-ring 1 (17) Bolt 2
(9) Collar 1

RY9212148HYS0384US0

3-S6 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

(1) Disassembly Procedures

1. Remove the hex socket bolts and then the gear pump.
• Tool to use: 10 mm hex socket

CAUTION
• Don't pinch your fingers between the port block and the
gear pump.
• 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 (3) Port Block
(2) Hex Socket Bolt M10 x 40 x 2
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 (3) Piston
(2) Spool Guide
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 HYDRAULIC SYSTEM
6. Remove the plug.
• Tool to use: 6 mm hex socket
(1) Plug
RY9212148HYS0390US0

7. Remove the collar and ball.

• Tool to use: Magnet
(1) Collar (2) Ball
RY9212148HYS0391US0

8. Remove the plug.

• Tool to use: 6 mm hex socket
(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 (8) Nut

(2) O-Ring (9) Set Screw
(3) Valve Body (10) Holder
(4) Spool (11) O-Ring
(5) Bushing (12) Nut
(6) Spring Seat (13) Orifice
(7) Spring (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 HYDRAULIC SYSTEM
Horsepower Control Valve Components

(1) Horsepower Control Valve (4) Pin

(2) Nut (5) Plug
(3) Spool
RY9212148HYS0400US0

16. Remove the gasket, spring ASSY and the cylinder block ASSY.

CAUTION
• Be careful not to cut your fingers on the gasket.
(1) Gasket (3) Cylinder Block ASSY
(2) Spring ASSY
RY9212148HYS0401US0

Spring ASSY Components

(1) Spring Seat (4) Inner Spring

(2) Assist Spring (5) Spring Seat
(3) Outer spring
RY9212148HYS0402US0

Cylinder Lock ASSY Components

(1) Piston (4) Spring

(2) Retainer Plate (5) Retainer Holder
(3) Cylinder Block
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 (3) Thrust Washer
(2) Bearing
RY9212148HYS0408US0

3-S11 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

(2) Assembly Procedures

1. Mount the thrust washer and bearing on the shaft.
2. Install the snap ring.

CAUTION
• Be careful not to hit your fingers with the hammer.
(1) Shaft (3) Bearing
(2) Thrust Washer (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
29.4 N·m
Tightening torque Plug (1) 3.0 kgf·m
21.7 lbf·ft

(1) Plug
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.
68.6 N·m
Nut (1) 6.70 kgf·m
50.6 lbf·ft
Tightening torque
57.0 N·m
Plug (3) 5.81 kgf·m
42.0 lbf·ft

(1) Nut (3) Plug

(2) Horsepower Control Valve
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
29.4 N·m
Tightening torque Plug (1) 3.0 kgf·m
21.7 lbf·ft

(1) Plug
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.
2.45 N·m
Tightening torque Orifice (1), (2) 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
12.65 N·m
Tightening torque Socket head bolt (2) 1.29 kgf·m
9.93 lbf·ft

(1) L/S Regulator (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.
51.0 N·m
Tightening torque Spool guide (2) 5.20 kgf·m
37.6 lbf·ft

(1) Valve Plate (3) Piston

(2) Spool Guide
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.
196.0 N·m
Socket head bolt (1) 19.99 kgf·m
144.6 lbf·ft
Tightening torque
106.9 N·m
Socket head bolt (2) 10.90 kgf·m
78.85 lbf·ft

(1) Hex Socket Bolt M16 x 40 x 5 (3) O-Ring

(2) Hex Socket Bolt M10 x 40 x 2 (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.
44.1 N·m
Tightening torque Socket head bolt (1) 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

2. CONTROL VALVE
[1] CONTROL VALVE REMOVAL
1. Remove the cover.
2. Attach a vacuum pump and depressurize the inside of the tank.
(1) Cover
RY9212158HYS0044US0

3. Disconnect all the hoses and wiring connected to the control

valve.
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 (a) Eye bolt mounting hole (M12,
(2) Bolt pitch 1.75)
RY9212158HYS0106US0

3-S17 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM
Control valve adapter angles (angle spec.)

(1) P3 bypass (11) AUX1 (A) P1 (a) 5° (0.09 rad)

(2) Swivel (12) Boom (B) P2 (b) 6 ° (0.10 rad)
(3) Blade (13) Swing (C) P3 (c) 15 ° (0.26 rad)
(4) AUX2 (14) Angle (D) Pps (d) 20 ° (0.35 rad)
(5) Communication valve (E) Pls (e) 23 ° (0.40 rad)
(6) Travel left (F) T1 (f) 25 ° (0.44 rad)
(7) Travel right (G) T2 (g) 30 ° (0.52 rad)
(8) Independent travel valve (H) PP1 (h) 45 ° (0.79 rad)
(9) Arm (I) PP2 (i) 60 ° (1.05 rad)
(10) Bucket (J) PP3 (j) 75 ° (1.31 rad)
RY9212158HYS0031US0

3-S18 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

[2] CONTROL VALVE ASSEMBLY/DISASSEMBLY

Precautions during Disassembly / Assembly
Precautions during Disassembly
1. Generally, hydraulic devices are precision machined, and disassembly should therefore be conducted in a clean
environment to prevent entry of debris into the narrow interstices formed in the device structure.
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.
26.5 to 29.4 N·m
Tightening torque Nut (four locations) 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 (3) Spool
(2) Identification groove for spool
assembly orientation
RY9212148HYS0372US0

3-S19 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM
LS Section Components

No. Name of part Qty Torque

(1) Cap 4
8.8 to 11.0 N·m
(2) Hex socket bolt 8 0.9 to 1.1 kgf·m
6.5 to 8.1 lbf·ft
(3) Spring seat 4
(4) Spring 4
(5) Plate 4
(6) O-ring 4
(7) Spool 1
59.0 to 69.0 N·m
Relief valve
(8) 2 6.0 to 7.0 kgf·m
ASSY
43.5 to 50.9 lbf·ft
(9) O-ring 2
67.7 to 73.5 N·m
(10) Plug 2 6.9 to 7.5 kgf·m
49.9 to 54.2 lbf·ft
(11) O-ring 2
(12) Poppet 2
(13) Spool 2
(14) O-ring 2
(15) Spring 4
(16) Poppet 4
(17) O-ring 2
(18) Spool 1
59.0 to 69.0 N·m
(19) Shutoff valve 1 6.0 to 7.0 kgf·m
43.5 to 50.9 lbf·ft
(20) O-ring 1
(21) O-ring 1
59.0 to 69.0 N·m
(22) Anti-void valve 1 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 HYDRAULIC SYSTEM
Mono-block Section Components

A : Boom section C : Bucket section D : Arm section E : Emergency valve

B : AUX1 section
• In the N. Am. spec., part E is different as it has an anti-drift valve.
No. Name of part Qty Torque
(1) Cap 4
(2) Hex socket bolt 8 8.8 to 11.0 N·m (0.9 to 1.1 kgf·m, 6.5 to 8.1 lbf·ft)
(3) Spool stopper 4
(4) Spacer 2
(5) Backup ring 2

3-S21 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

No. Name of part Qty Torque

(6) O-ring 2
(7) Plate 8
(8) Spring 4
(9) Spool 4
(10) O-ring 4
(11) Plug 4
(12) Plug 8 106.0 to 141.0 N·m (10.8 to 14.4 kgf·m, 78.2 to 104.0 lbf·ft)
(13) O-ring 8
(14) Plug 8 106.0 to 141.0 N·m (10.8 to 14.4 kgf·m, 78.2 to 104.0 lbf·ft)
(15) Spring 8
(16) Poppet 8
(17) Plug assembly 1 28.0 to 30.0 N·m (2.9 to 3.1 kgf·m, 20.7 to 22.1 lbf·ft)
(18) Plug assembly 1 167.0 to 197.0 N·m (17.0 to 20.1 kgf·m, 123.2 to 145.3 lbf·ft)
(19) Plug assembly 3 61.8 to 82.4 N·m (6.3 to 8.4 kgf·m, 45.6 to 60.8 lbf·ft)
(20) Spring 1
(21) Poppet 1
(22) Plug assembly 1 28.0 to 30.0 N·m (2.9 to 3.1 kgf·m, 20.7 to 22.1 lbf·ft)
(23) Plug assembly 1 167.0 to 197.0 N·m (17.0 to 20.1 kgf·m, 123.2 to 145.3 lbf·ft)
(24) O-ring 1
(25) Backup ring 1
(26) Sleeve 1
(27) Cap 4
(28) Hex socket bolt 8 8.8 to 11.0 N·m (0.9 to 1.1 kgf·m, 6.5 to 8.1 lbf·ft)
(29) O-ring 4
(30) Poppet 4
(31) Spool 4
(32) Main relief valve (aLS) 1 49.0 to 54.0 N·m (5.0 to 5.5 kgf·m, 36.1 to 39.8 lbf·ft)
(33) Main relief valve (aUN) 1 167.0 to 197.0 N·m (17.0 to 20.1 kgf·m, 123.2 to 145.3 lbf·ft)
(34) Relief valve ASSY 1 59.0 to 69.0 N·m (6.0 to 7.0 kgf·m, 43.5 to 50.9 lbf·ft)
(35) O-ring 8
(36) Relief valve ASSY 2 59.0 to 69.0 N·m (6.0 to 7.0 kgf·m, 43.5 to 50.9 lbf·ft)
(37) Relief valve ASSY 5 59.0 to 69.0 N·m (6.0 to 7.0 kgf·m, 43.5 to 50.9 lbf·ft)
(38) Plug assembly 1 28.0 to 30.0 N·m (2.9 to 3.1 kgf·m, 20.7 to 22.1 lbf·ft)
(39) Plug assembly 1 106.0 to 141.0 N·m (10.8 to 14.4 kgf·m, 78.2 to 104.0 lbf·ft)
(40) Plug assembly 1 28.0 to 30.0 N·m (2.9 to 3.1 kgf·m, 20.7 to 22.1 lbf·ft)
(41) Valve ASSY 1 28.0 to 30.0 N·m (2.9 to 3.1 kgf·m, 20.7 to 22.1 lbf·ft)
(42) Plug 1 106.0 to 141.0 N·m (10.8 to 14.4 kgf·m, 78.2 to 104.0 lbf·ft)
(43) O-ring 1
(44) Metal plug 2
(45) Spacer 1
(46) Plug assembly 1 106.0 to 141.0 N·m (10.8 to 14.4 kgf·m, 78.2 to 104.0 lbf·ft)
(47) Orifice 1
(48) Plug assembly 1 11.2 to 12.4 N·m (1.1 to 1.3 kgf·m, 8.3 to 9.1 lbf·ft)
(49) Metal plug 1
(50) Anti-drift housing 1

RY9212158HYS0108US0

3-S22 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM
Independent Travel Valve and Travel Section Components

No. Name of part Qty Torque

28.0 to 30.0 N·m
(1) Plug 2 2.9 to 3.1 kgf·m
20.7 to 22.1 lbf·ft
(2) O-ring 2
(3) Filter 1
(4) Spring 1
(5) Body assembly 1
8.8 to 11.0 N·m
(6) Hex socket bolt 3 0.9 to 1.1 kgf·m
6.5 to 8.1 lbf·ft
28.0 to 30.0 N·m
(7) Plug 1 2.9 to 3.1 kgf·m
20.7 to 22.1 lbf·ft
(8) O-ring 1
(9) Spring 1
(10) Spring seat 1
(11) Plug 1
(12) O-ring 1
(13) Spool 1
28.0 to 30.0 N·m
(14) Plug assembly 1 2.9 to 3.1 kgf·m
20.7 to 22.1 lbf·ft
(15) Stopper 1
(16) Plate 2
(17) Spring 1
(18) Spool 1
(19) Plug 1
59.0 to 69.0 N·m
(20) Relief valve ASSY 2 6.0 to 7.0 kgf·m
43.5 to 50.9 lbf·ft
(21) O-ring 2
(22) O-ring 2
(23) O-ring 4
(24) Cap 1
8.8 to 11.0 N·m
(25) Hex socket bolt 10 0.9 to 1.1 kgf·m
6.5 to 8.1 lbf·ft
(26) Cap 4
(27) O-ring 4
(28) Spring seat 4
(29) Spring 4
(30) Plate 4
30.0 to 32.0 N·m
(31) Plug 3 3.1 to 3.3 kgf·m
22.1 to 23.6 lbf·ft
(32) O-ring 3
(33) Spool 1
(34) Spool 1

A : Independent travel valve

B : Travel right section
C : Travel left section
RY9212148HYS0375US0

3-S23 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM
Communication Valve and AUX2 Section Components

No. Name of part Qty Torque

(1) Cap 1
8.8 to 11.0 N·m
(2) Hex socket bolt 2 0.9 to 1.1 kgf·m
6.5 to 8.1 lbf·ft
(3) Spring seat 4
(4) Spring 1
(5) Plate 3
(6) O-ring 3
59.0 to 69.0 N·m
(7) Relief valve ASSY 1 6.0 to 7.0 kgf·m
43.5 to 50.9 lbf·ft
(8) O-ring 1
30.0 to 32.0 N·m
(9) Plug 2 3.1 to 3.3 kgf·m
22.1 to 23.6 lbf·ft
(10) O-ring 2
(11) Spring 2
(12) Poppet 1
(13) Spool 1
(14) Plug 1
(15) O-ring 1
(16) O-ring 1
(17) O-ring 1
28.0 to 30.0 N·m
(18) Plug 1 2.9 to 3.1 kgf·m
20.7 to 22.1 lbf·ft
(19) O-ring 1
(20) Spring 1
(21) Spring seat 1
(22) Spool 1
28.0 to 30.0 N·m
(23) Plug assembly 1 2.9 to 3.1 kgf·m
20.7 to 22.1 lbf·ft
8.8 to 11.0 N·m
(24) Hex socket bolt 2 0.9 to 1.1 kgf·m
6.5 to 8.1 lbf·ft
28.0 to 30.0 N·m
(25) Plug assembly 1 2.9 to 3.1 kgf·m
20.7 to 22.1 lbf·ft
(26) Body assembly 1
(27) Cap 2
(28) Spring 2
59.0 to 69.0 N·m
(29) Shut-off valve 2 6.0 to 7.0 kgf·m
43.5 to 50.9 lbf·ft
(30) Poppet 1
30.0 to 32.0 N·m
(31) Plug 1 3.1 to 3.3 kgf·m
22.1 to 23.6 lbf·ft
(32) O-ring 1
(33) O-ring 1
(34) Spool 1

3-S24 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

A : Communication valve
B : AUX2 section
RY9212148HYS0376US0
Blade, Swivel and P3 Bypass Section Components

No. Name of part Qty Torque

(1) Cap 4
8.8 to 11.0 N·m
(2) Hex socket bolt 8 0.9 to 1.1 kgf·m
6.5 to 8.1 lbf·ft
(3) Spring seat 4
(4) Spring 4
(5) Plate 4
(6) O-ring 4
59.0 to 69.0 N·m
(7) Relief valve ASSY 2 6.0 to 7.0 kgf·m
43.5 to 50.9 lbf·ft
(8) O-ring 2
30.0 to 32.0 N·m
(9) Plug 2 3.1 to 3.3 kgf·m
22.1 to 23.6 lbf·ft
(10) O-ring 2
(11) Spring 2
(12) Poppet 2
30.0 to 32.0 N·m
(13) Plug 2 3.1 to 3.3 kgf·m
22.1 to 23.6 lbf·ft
(14) O-ring 2
(15) O-ring 1
(16) Spool 1
(17) O-ring 2
(18) Spool 1
30.0 to 32.0 N·m
(19) Plug 1 3.1 to 3.3 kgf·m
22.1 to 23.6 lbf·ft
(20) O-ring 1
(21) Spring 1
(22) Poppet 1
28.0 to 30.0 N·m
(23) Plug 1 2.9 to 3.1 kgf·m
20.7 to 22.1 lbf·ft
(24) O-ring 1
(25) Spring seat 1
(26) Spring 1
(27) Spool 1
28.0 to 30.0 N·m
(28) Plug assembly 1 2.9 to 3.1 kgf·m
20.7 to 22.1 lbf·ft
28.0 to 30.0 N·m
(29) Plug assembly 1 2.9 to 3.1 kgf·m
20.7 to 22.1 lbf·ft

A : Blade section
B : Swivel section
C : P3 bypass section
RY9212148HYS0377US0

3-S25 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

3. SWIVEL MOTOR
[1] SWIVEL MOTOR REMOVAL AND INSTALLATION
CAUTION
• When removing a hydraulic device after operating the mini-excavator, lower the bucket and blade to the
ground and turn off the engine.
• Each of the devices and the hydraulic oil are hot right after stopping the mini-excavator. The oil is hot
enough to cause a burn, so always let it cool down before starting any work.
• 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 (3) Tank cover
(2) Electric fan (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 (3) Unload valve bracket
(2) Unload valve
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.
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3-S26 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM
5. Remove the 8 swivel motor mounting bolts and remove the
swivel motor.
259.9 to 304.0 N·m
Tightening torque Bolt 26.5 to 31.0 kgf·m
191.7 to 224.2 lbf·ft

Swivel motor weight Approx. 80 kg (180 lbs)

RY9212148HYS0216US0

Swivel motor adapter angles

(a) 90 ° (1.57 rad)

(b) 55 ° (0.96 rad)

A : Front side
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3-S27 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

[2] SWIVEL MOTOR DISASSEMBLY/ASSEMBLY PROCEDURES

(To be continued)

3-S28 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM
(Continued)
No. Part Name Qty No. Part Name Qty No. Part Name Qty
(1) Plug 2 (36) O-ring 2 (71) Spool 1
(2) O-ring 4 (37) Cover 1 (72) Spring 1
(3) Orifice 2 (38) Orifice 1 (73) O-ring 1
(4) Hex socket bolt 3 (39) Knock pin 1 (74) Plug 1
(5) Body 1 (40) Pin 2 (75) Housing 1
(6) Plug 2 (41) Pin 2 (76) Hex socket bolt 4
(7) Spring 2 (42) O-ring 1 (77) Plate 1
(8) Check valve 2 (43) Spring, small 8 (78) Drive gear 1
(9) Sleeve 1 (44) Spring, large 12 (79) Inner race 3
(10) O-ring 2 (45) Brake piston 1 (80) Needle bearing 3
(11) Plug 2 (46) O-ring 1 (81) Planetary gear A 3
(12) O-ring 3 (47) Collar 1 (82) Washer 3
(13) Plug 1 (48) O-ring 1 (83) Holder 1
(14) O-ring 1 (49) Disc 4 (84) Circlip 1
(15) Plug 2 (50) Plate A 1 (85) Sun gear 1
(16) O-ring 2 (51) Plate B 2 (86) Hex flange bolt 4
(17) Spring 2 (52) Ball bearing 1 (87) Plate 1
(18) Poppet 2 (53) Valve plate 1 (88) Inner race 4
(19) Hex socket bolt 4 (54) Circlip 1 (89) Needle bearing 4
(20) Nut 2 (55) Washer 2 (90) Planetary gear B 4
(21) Set screw 2 (56) Spring 1 (91) Washer 4
(22) Plug 2 (57) Cylinder block 1 (92) Holder 1
(23) Backup ring 4 (58) Pin 3 (93) Plate 2
(24) O-ring 2 (59) Piston ASSY 9 (94) Collar 1
(25) Piston 2 (60) Retainer holder 1 (95) Tapered roller bearing 1
(26) Spring guide 2 (61) Retainer plate 1 (96) Oil seal 1
(27) O-ring 2 (62) Swash-plate 1 (97) O-ring 1
(28) Spring 2 (63) Shaft 1 (98) Housing 1
(29) Spring seat 2 (64) Ball bearing 1 (99) O-ring 1
(30) Housing 2 (65) O-ring 1 (100) Plug 1
(31) Backup ring 2 (66) Plug 1 (101) Tapered roller bearing 1
(32) O-ring 2 (67) O-ring 1 (102) Collar 1
(33) Poppet 2 (68) O-ring 2 (103) Plate 1
(34) Poppet seat 2 (69) Hex socket bolt 2 (104) Plate 1
(35) Backup ring 2 (70) Valve body 1 (105) Shaft 1

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3-S29 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

(1) Disassembly Procedures

1. Mount the swivel motor on an assembly platform.
2. Remove the hex socket bolts and then the body.
• Tool to use: 6 mm hex socket
(1) Hex socket bolt (2) Body
RY9212148HYS0098US0

3. 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 (3) Poppet
(2) Spring
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 (3) Swash-plate
(2) Disc
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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 (3) Housing
(2) Hex socket bolt
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13. Remove the plate.

(1) Plate
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14. Remove the driver gear, planetary gear A, needle bearing, inner
race and washer and then remove the flange holder.
(1) Drive gear (4) Inner race
(2) Planetary gear A (5) Washer
(3) Needle bearing (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 (3) Plate
(2) Hex flange bolt
RY9212148HYS0111US0
16. Remove planetary gear B, needle bearing, inner race and
washer and then remove the flange holder.
(1) Planetary gear B (4) Washer
(2) Needle bearing (5) Flange holder
(3) Inner race
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
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3-S33 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

(2) Assembly Procedures

• Prior to assembly, clean all of the parts and make sure there is no dirt or other debris sticking to them.
• Always replace all of the O-rings, backup rings and oil seals with new ones.
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 (a) Plug installation position
(2) Housing
(3) Tapered roller bearing
RY9212148HYS0120US0

4. Use a press on the plate installation tool to install the plate.

11770 N
Press pressure Factory specification 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
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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.
15.7 ± 0.8 N·m
Tightening torque Plug 1.6 ± 0.1 kgf·m
11.6 ± 0.6 lbf·ft
• Tool to use: 5 mm hex socket
IMPORTANT
• Install with the rounded side of the washer down.
(1) Plug (3) Washer
(2) Holder
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 (3) Planetary gear B
(2) Needle bearing
RY9212148HYS0124US0

9. Install the plate and then the sun gear.

IMPORTANT
• Apply a thread lock (Loctite 242) to the hex flange bolts.
24.5 ± 4.9 N·m
Tightening torque Hex flange bolt 2.5 ± 0.5 kgf·m
18.1 ± 3.6 lbf·ft
• Tool to use: 5 mm hex socket
(1) Plate (3) Sun gear
(2) Hex flange bolt
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 (3) Planetary gear A
(2) Needle bearing (4) Drive gear
RY9212148HYS0127US0

3-S35 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM
12. Install the plate and O-ring.
IMPORTANT
• Apply grease to the O-ring.
(1) Plate (2) O-ring
RY9212148HYS0128US0

When parts inside the gear case have been replaced, take
measurement C between the inner race and the housing and then
select the correct plate.
• 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)
Less than Less than
Measure- 6.5 to 7.0 mm
5.3 to 5.8mm 5.3 to 5.8mm
ment C (0.26 to 0.28 in.)
(0.21 to 0.23 in.) (0.21 to 0.23 in.)
Plate to use 2.8 mm (0.11 in.) 2.3 mm (0.09 in.) 1.8 mm (0.07 in.)
RY9212148HYS0148US0

13. Install the housing.

177.0 ± 10.0 N·m
Tightening torque Hex socket bolt 18.0 ± 1.0 kgf·m
130.5 ± 7.5 lbf·ft
• Tool to use: 12 mm hex socket
(1) Housing
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
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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 (3) Plate A
(2) Plate B
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 (3) Housing
(2) O-ring
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 HYDRAULIC SYSTEM
Brake piston hole alignment positions
Install so the pin hole is at position .
(a) 0.393 rad (22.5 °)
RY9212148HYS0137US0

20. Install the large and small springs and the O-ring.
IMPORTANT
• Apply grease to the O-ring.
(1) Spring, large (3) O-ring
(2) Spring, small
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 (3) Plug
(2) Spring
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.
177.0 ± 10.0 N·m
Tightening torque Hex socket bolt 18.0 ± 1.0 kgf·m
130.5 ± 7.5 lbf·ft
• Tool to use: 12 mm hex socket
(1) Cover
RY9212148HYS0142US0

24. Install the plug and relief valve.

IMPORTANT
• Apply hydraulic oil to the relief valve.
157.0 ± 10.0 N·m
Plug 16.0 ± 1.0 kgf·m
115.5 ± 7.5 lbf·ft
Tightening torque
373.0 ± 20.0 N·m
Relief valve 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.
9.8 ± 1.0 N·m
Tightening torque Hex socket bolt 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.
32.4 ± 2.0 N·m
Tightening torque Hex socket bolt 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

(3) Special Tools

(a) Oil seal installation tool

A 150 mm (5.9 in.)

B 94.8 - 94.9 mm ( 3.73 - 3.74 in.)
C 30 mm ( 1.18 in.)
D 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 40 mm ( 1.57 in.)
B 40 mm (1.57 in.)
C 100 mm (3.93 in.)
D 40 mm (1.57 in.)
E 10 mm (0.39 in.)
F 50 mm (1.96 in.)
G 63.2 - 63.4 mm ( 2.48 - 2.49 in.)
H 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

4. SWIVEL JOINT
[1] REMOVAL AND INSTALLATION OF THE SWIVEL JOINT
CAUTION
• When removing a hydraulic device after operating the mini-excavator, lower the bucket and blade to the
ground and turn off the engine.
• Each of the devices and the hydraulic oil are hot right after stopping the mini-excavator. The oil is hot
enough to cause a burn, so always let it cool down before starting any work.
• 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 (3) Tank cover
(2) Electric fan (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 (3) Unload valve
(2) Hydraulic oil tank (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 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).
77.5 to 90.2 N·m
Swivel joint mounting
Tightening torque 7.9 to 9.2 kgf·m
bracket
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
Adapter angles

A : 2-speed pilot D : Left forward G : Right backward (a) 15 ° (0.26 rad)

B : Blade down E : Right forward H : Drain (b) 30 ° (0.52 rad)
C : Blade up F : Left backward (A) Blade side (c) 45 ° (0.79 rad)
RY9212148HYS0224US0

3-S42 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM
Adapter angle (angle spec.)

A: 2-speed pilot E: Right forward I : Angle Right (a) 15 ° (0.26 rad)

B: Blade down F: Left backward J : Angle Left (b) 30 ° (0.52 rad)
C: Blade up G: Right backward (c) 45 ° (0.79 rad)
D: Left forward H: Drain (A) Blade side
RY9212158HYS0032US0

3-S43 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

[2] SWIVEL JOINT DISASSEMBLY / ASSEMBLY PROCEDURES

Components

Qty
No. Part Name Angle Notes
Standard Spec
Specification
40.2 ± 3.9 N·m
(1) Plug (PT1/4) – 4 4.1 ± 0.4 kgf·m
29.6 ± 2.9 lbf·ft
71.1 ± 2.5 N·m
(2) Plug (PT3/8) 2 2 7.2 ± 0.2 kgf·m
52.4 ± 1.8 lbf·ft
85.9 ± 2.5 N·m
(3) Plug (PT1/2) 4 4 8.8 ± 0.2 kgf·m
63.3 ± 1.8 lbf·ft
(4) Shaft 1 1
(5) Collar 1 1
(6) Packing (U) 1 1
(7) O-ring 1 1
(8) Seal 7 9
(9) Body 1 1
(10) Bracket 2 2
84.0 ± 6.0 N·m
8.6 ± 0.6 kgf·m
(11) Bolt 4 4 62.0 ± 5.0 lbf·ft
Thread lock (Loctite 1324 or
equivalent)
84.0 ± 6.0 N·m
8.6 ± 0.6 kgf·m
(12) Bolt 4 4
62.0 ± 5.0 lbf·ft
Thread lock (Loctite 271)
(13) Collar 1 1
(14) Circlip 1 1
(15) O-ring 1 1
(16) Bottom cover 1 1
84.0 ± 6.0 N·m
8.6 ± 0.6 kgf·m
(17) Hex socket bolt 4 4 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) Disassembly Procedures

1. Prior to disassembly, mark the alignment of the shaft and body.
RY9212148HYS0002US0

2. Remove the hex socket bolts and then the bottom cover.
• Tool to use: 10 mm hex socket
(1) Bottom cover
RY9212148HYS0003US0

3. 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

(2) Assembly Procedures

• Prior to assembly, clean all of the parts and make sure they are not damaged and there is no dirt or other debris
sticking to them.
• After washing parts, blow them dry to remove any detergent. (Be particularly careful to remove any detergent
around port holes and bolt holes.)
• 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.

84.0 ± 6.0 N·m
Tightening torque Hex socket bolt 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

5. TRAVEL MOTOR
[1] REMOVAL AND INSTALLATION OF THE TRAVEL MOTOR
CAUTION
• Before removing hydraulic devices, lower the bucket and blade to the ground and stop the engine.
• Each of the devices and the hydraulic oil are hot right after stopping the mini-excavator. The oil is hot
enough to cause a burn, so always let it cool down before starting any work.
• 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).
282.0 ± 22.0 N·m
Tightening torque Travel motor 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).
181.4 ± 14.7 N·m
Tightening torque Sprocket 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

[2] TRAVEL MOTOR DISASSEMBLY / ASSEMBLY PROCEDURES

(To be continued)

3-S50 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM
(Continued)
No. Part Name Qty No. Part Name Qty No. Part Name Qty
(1) Wire 1 (32) Ball 2 (63) Poppet 2
(2) Plug 3 (33) Swash-plate 1 (64) Backup ring 2
(3) O-ring 3 (34) Piston ASSY 1 (65) O-ring 2
(4) Cover 1 (35) Retainer plate 1 (66) Seat 2
(5) O-ring 1 (36) Retainer holder 1 (67) Plug 2
(6) Bolt 8 (37) Cylinder block 1 (68) O-ring 2
(7) Plate 1 (38) Pin 3 (69) Spring 2
(8) Planetary gear B 3 (39) Plate A 1 (70) Poppet 2
(9) Needle bearing 3 (40) Spring 1 (71) Plug 2
(10) Holder 1 (41) Plate B 1 (72) O-ring 2
(11) Drive gear 1 (42) Circlip 1 (73) Spring 2
(12) Sun gear 1 (43) Valve plate 1 (74) Spring seat 2
(13) Gear case 1 (44) Knock pin 1 (75) Spool 1
(14) Plate 1 (45) Ball bearing 1 (76) Orifice 1
(15) Ring nut 1 (46) Disc 2 (77) Plug 4
(16) Angular bearing 2 (47) Plate 2 (78) Plug 6
(17) Planetary gear A 4 (48) Backup ring 1 (79) Hex socket bolt 8
(18) Collar 4 (49) O-ring 1 (80) Plug 1
(19) Needle bearing 4 (50) Backup ring 1 (81) O-ring 1
(20) Thrust washer 4 (51) O-ring 1 (82) Spring 1
(21) Floating seal 1 (52) Brake piston 1 (83) Spool 1
(22) Washer 1 (53) Spring 10 (84) O-ring 1
(23) Parallel pin 1 (54) Nut 2 (85) Plug 1
(24) Flange holder 1 (55) O-ring 2 (86) Nameplate 1
(25) Pin 2 (56) Body 2 (87) Plug 2
(26) O-ring 1 (57) Piston 2 (88) O-ring 2
(27) Oil seal 1 (58) Backup ring 2 (89) Plug 2
(28) Ball bearing 1 (59) O-ring 2 (90) O-ring 4
(29) Shaft 1 (60) Backup ring 2 (91) Ball 2
(30) Spring 1 (61) Rod 2 (92) Base plate 1
(31) 2-speed piston 1 (62) Spring 2

RY9212158HYS0001US0

3-S51 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

(1) Disassembly Procedures

[A] Gear Case
1. Mount the travel motor to the assembly platform and remove the
plug.
• Tool to use: 8 mm hex socket
(1) Plug
RY9212158HYS0002US0

2. Remove the wire.

• Tool to use: Slotted screwdriver
(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 (3) Needle bearing
(2) Planetary gear B (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 (3) Collar
(2) Needle bearing
RY9212158HYS0004US0

8. Remove the thrust washer, bolt and washer in order.

• Tool to use: Torx T40
(1) Thrust washer (3) Washer
(2) Bolt
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 (c) Removal bolts
(2) Flange holder
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 HYDRAULIC SYSTEM

[B] Motor
1. Remove the shockless valve.
• Tool to use: 22 mm socket
(1) Shockless valve
RY9212158HYS0006US0

2. Remove the plug, spring, spring seat and spool in order.

• Tool to use: 30 mm socket
(1) Plug (3) Spring seat
(2) Spring (4) Spool
RY9212158HYS0007US0

3. Remove the plug, spring and poppet in order.

• Tool to use: 10 mm hex socket
(1) Plug (3) Poppet
(2) Spring
RY9212158HYS0008US0

4. Remove the plug, spool and spring in order.

• Tool to use: 10 mm hex socket
(1) Plug (3) Spring
(2) Spool
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 (3) Shaft
(2) Swash-plate
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

(2) Assembly Procedures

[A] Motor
• Prior to assembly, clean all of the parts and make sure they are not damaged and there is no dirt or other debris
sticking to them.
• Always replace all of the O-rings, backup rings, oil seals and floating seals with new ones.
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 (3) Ball
(2) Spring
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 (3) Retainer holder
(2) Cylinder block
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 (3) Backup ring
(2) O-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.
129.4 ± 12.9 N·m
Tightening torque Hex socket bolt 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.
19.6 ± 1.0 N·m
Tightening torque Plug 2.0 ± 0.1 kgf·m
14.4 ± 0.7 lbf·ft
• Tool to use: 5 mm hex socket
(1) Ball (2) Plug
RY9212158HYS0057US0

15. Install the spring, spool and plug in order.

IMPORTANT
• Apply hydraulic oil to the spool.
78.5 ± 7.8 N·m
Tightening torque Plug 8.0 ± 0.8 kgf·m
57.9 ± 5.8 lbf·ft
• Tool to use: 8 mm hex socket
(1) Spring (3) Plug
(2) Spool
RY9212158HYS0024US0
16. Install the poppet, spring and plug in order.
IMPORTANT
• Apply hydraulic fluid to the spool.
65.7 ± 6.6 N·m
Tightening torque Plug 6.7 ± 0.7 kgf·m
48.2 ± 5.1 lbf·ft
• Tool to use: 10 mm hex socket
(1) Poppet (3) Plug
(2) Spring
RY9212158HYS0058US0
17. Install the spool spring seat, spring and plug in order.
IMPORTANT
• Apply hydraulic oil to the spool.
• The spool must slide smoothly.
176.4 ± 17.6 N·m
Tightening torque Plug 18.0 ± 1.8 kgf·m
130.0 ± 13.0 lbf·ft
• Tool to use: 30 mm socket
(1) Spool (3) Spring
(2) Spring seat (4) Plug
RY9212158HYS0025US0
18. Install the shockless valve.
142.1 ± 14.2 N·m
Tightening torque Shockless valve 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 HYDRAULIC SYSTEM

[B] Gear Case

1. Set one of the angular bearings in the gear case and use a
press to mount it.

Turn the gear case over and install the other angular bearing
with the press.
RY9212158HYS0027US0

2. 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.
117.5 ± 17.5 N·m
Tightening torque Factory specification 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.
35.3 ± 2.0 N·m
Tightening torque Bolt 3.6 ± 0.2 kgf·m
26.0 ± 1.5 lbf·ft
• Tool to use: Torx T40
(1) Thrust washer (3) Bolt
(2) Washer
RY9212158HYS0063US0
10. Install the collar, needle bearing and planetary gear A in order.
(1) Collar (3) Planetary gear A
(2) Needle bearing
RY9212158HYS0028US0

11. Install the sun gear and plate in order.

IMPORTANT
• Clean screw holes prior to installation.
• Apply a thread lock (ThreeBond 2403).
35.3 ± 2.0 N·m
Tightening torque Bolt 3.6 ± 0.2 kgf·m
26.0 ± 1.5 lbf·ft
• Tool to use: Torx T40
(1) Sun gear (3) Bolt
(2) Plate
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 (3) Planetary gear B
(2) Needle bearing (4) Drive gear
RY9212158HYS0065US0

13. Install the plate.

IMPORTANT
• Clean screw holes prior to installation.
• Apply a thread lock (ThreeBond 2403).
35.3 ± 2.0 N·m
Tightening torque Bolt 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.

58.8 ± 9.8 N·m
Tightening torque Plug 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 HYDRAULIC SYSTEM

(3) Special Tools

(a) Cover removal tool

A 80 mm (3.1 in.)
B 13 mm (0.51 in.)
C 60 mm (2.4 in.)
D R3/8
E 12.5 mm (0.492 in.)
F M12 x P1.25
G 25 mm (0.98 in.)
H 315 mm (12.4 in.)
C2 2 mm (0.08 in. bevel)
C5 5 mm (0.2 in. bevel)

(1) Tempered
RY9212148HYS0021US0

(b) Ring nut socket

A 800 mm (31.50 in.)

B 194 mm (7.64 in.)
C 230 mm (9.06 in.)
D 60 mm (2.36 in.)
E 100 mm (3.94 in.)
F 20 mm (0.79 in.)
G 6 mm (0.24 in.)
H 130 mm (5.12 in.)
I 12 mm (0.47 in.)
J 5 mm (0.20 in.)
K 184.5 mm (7.264 in.)
L 206 mm (8.11 in.)
M 222 mm (8.74 in.)
N 9 mm (0.35 in.)
Stud bolt
O
4 - M12 × 150 mm (5.91 in.)
Hex nut
P
12 - M12
Hex socket bolt
2 - M10 × 18 mm (0.71 in.)
Q
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)

A M14 x P2.0
B M14 nut
C 250 mm (9.84 in.)
D 5 mm (0.5 in.)
RY9212148HYS0020US0

3-S67 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM
(d)Tool for pressing cylinder block

A 27.8 to 28.2 mm (1.095 to 1.110 in.)

B 39.9 to 40.0 mm (1.571 to 1.574 in.)
C 11.9 to 12.0 mm (0.469 to 0.472 in.)
D 34.7 to 35.3 mm (1.366 to 1.390 in.)
E 2.9 to 3.1 mm (0.114 to 0.122 in.)
F 99.7 to 100.3 mm (3.926 to 3.949 in.)
G 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

A 30 mm (1.18 in.)
B 90 mm (3.54 in.)
C 235 mm (9.25 in.)
D 35 mm (1.38 in.)
E 15 mm (0.59 in.)
F 3 mm (0.12 in.)
G 29.8 to 30.0 mm (1.17 to 1.18 in.)
H 49.0 to 49.1 mm (1.92 to 1.93 in.)
I 0.52 rad (30 °)
C1 1 mm (0.04 in.) bevel
RY9212158HYS0069US0
(f) Floating seal installation tool

1 to 2 mm (0.039 to 0.079 in.)

A
1 notch in circumference
B 255 mm (10.04 in.)
C 239 mm (9.41 in.)
D 219 mm (8.62 in.)
E 20 mm (0.79 in.)
F 140 mm (5.51 in.)
G 10 mm (0.39 in.)
H 225 mm (8.86 in.)
I 3 mm (0.12 in.)
J 5.02 mm (0.198 in.)
K 5.71 mm (0.225 in.)
L 1.64 mm (0.065 in.)
M 2.6 mm (0.102 in.)
N 3.36 mm (0.132 in.)
O 0.79 rad (45°)
R0.5 Radius 0.5 mm (0.02 in.)
R1 Radius 1 mm (0.04 in.)
R4.25 Radius 4.25 mm (0.167 in.)
R5 Radius 5 mm (0.20 in.)
R8 Radius 8 mm (0.32 in.)
• Material: MC nylon
RY9212158HYS0070US0

3-S68 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

6. CYLINDER
[1] TIGHTENING TORQUE
KX080-4 Notes
Maker KYB
56.9 ± 10.7 N·m
Screw torque 5.8 ± 1.1 kgf·m
42.0 ± 7.9 lbf·ft
Screw size M12 × 1.75 Tap with punch in two places

Boom 3070 N·m

Piston torque 313.1 kgf·m
2264 lbf·ft
Width across hex-head. 80
950 N·m
Head torque 96.9 kgf·m Apply ThreeBond #1901
701 lbf·ft
Maker KYB
31.5 ± 5.88 N·m
Screw torque 3.2 ± 0.6 kgf·m
23.2 ± 4.3 lbf·ft
Screw size M10 × 1.5 Tap with punch in two places

Arm 3040 N·m

Piston torque 310.1 kgf·m
2242 lbf·ft
Width across hex-head. 70
950 N·m
Head torque 96.9 kgf·m Apply ThreeBond #1901
701 lbf·ft
Maker WIPRO
Screw size M10 × 1.5
1509 N·m
Piston torque 153.9 kgf·m
Bucket 1113 lbf·ft
Width across hex-head. 75
410 ± 25 N·m
Head torque 41.8 ± 2.6 kgf·m
302.4 ± 18.4 lbf·ft
Maker Koretsune Seiko
4000 ± 200 N·m
Piston torque 408.0 ± 20.4 kgf·m
Blade 2950.4 ± 147.5 lbf·ft
1200 ± 120 N·m
Head torque 122.4 ± 12.2 kgf·m
885.1 ± 88.5 lbf·ft
Maker Koretsune Seiko
2800 ± 140 N·m
Piston torque 285.6 ± 14.3 kgf·m
Swing 2065.3 ± 103.3 lbf·ft
650 ± 70 N·m
Head torque 66.3 ± 7.1 kgf·m
479.4 ± 51.6 lbf·ft

3-S69 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

KX080-4 Notes
Maker Koretsune Seiko
1500 ± 80 N·m
Piston torque 153.0 ± 8.2 kgf·m
Angle 1106.4 ± 59.0 lbf·ft
550 ± 60 N·m
Head torque 56.1 ± 6.1 kgf·m
405.7 ± 44.3 lbf·ft

RY9212158HYS0033US0

3-S70 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

7. PILOT VALVE
[1] CONTROL PILOT VALVES
No. Part Name Qty
(1) Handle 1
(2) Bellows 1
(3) Spring pin 1
(4) Lever 1
(5) Seal 4
(6) Plug 4
(7) O-ring 4
(8) Pushrod 4
(9) Spring seat 4
(10) Secondary pressure spring 4
(11) Shim 4
(12) Return spring (Ports 1 and 3) 2
(13) Return Spring (Port 2) 1
(14) Return Spring (Port 4) 1
(15) Spool 4
(16) Lock nut 1
(17) Adjusting nut 1
(18) Round plate nut 1
(19) U-joint 1
(20) Plate 1
(21) Bushing 1
(22) Casing 1
RY9212148HYS0226US0
Adapter angles

A Point used Tape color

(1) Swivel left Gray
(2) Arm dump Pea green
(3) Swivel right Light blue
(4) Arm crowd Blue
(5) P White
(6) T None

B Point used Tape color

(7) Bucket crowd Orange
(8) Boom down Yellow
(9) Bucket dump Red
(10) Boom up Green
(11) P White
(12) T None

A : Left pilot valve (a) 45 ° (0.79 rad)

B : Right pilot valve (b) 15 ° (0.26 rad)
(c) 30 ° (0.52 rad)
RY9212148HYS0227US0

3-S71 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

(1) Disassembly
CAUTION
• All of the parts are precision parts, so be very careful in handling them and take care not to drop or hit
parts against each other.
• If you hit a part too hard while working on it, it may result in burrs or other damage, thus preventing
installation as well as oil leaks and/or compromised performance, so be careful when handling parts.
• 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 (3) Adjusting Nut

(2) Round Plate 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 (3) Washer
(2) Secondary Pressure Spring (4) Spool
RY9212148HYS0157US0

9. Remove the plug from the pushrod.

(1) Plug (3) O-Ring

(2) Pushrod
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 (3) O-Ring
(2) Plug (4) Pushrod
RY9212148HYS0159US0

(2) Assembly
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 (3) Secondary Pressure Spring

(2) Washer (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 (3) Pushrod

(2) Seal (4) O-Ring
RY9212148HYS0164US0

3-S76 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM
7. Install the plug on the pushrod.

IMPORTANT
• Apply hydraulic oil to the pushrod.

(1) Pushrod (3) O-Ring

(2) Plug
RY9212148HYS0165US0

8. Install the plug ASSY into the case.

If the return spring is too stiff, use the plate to install the ASSY.

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.

47.0 ± 3.0 N·m

Tightening torque U-joint 4.8 ± 0.3 kgf·m
35.0 ± 2.0 lbf·ft
• Tool (a): U-joint clamping tool
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

70.0 ± 5.0 N·m
Tightening torque Adjusting nut 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 HYDRAULIC SYSTEM

(3) Special Tools

A 29 mm ( 1.142 in.)
B 26.5 mm ( 1.043 in.)
C 23.5 mm (0.925 in.) (nut width)
D 19 mm ( 0.748 in.)
E 13 mm (0.512 in.)
F 69 mm (2.717 in.)
G 54 mm (2.126 in.)
H 50 mm (1.968 in.)
I 46 mm (1.811 in.)
J 25 mm (0.984 in.)
K 17 mm (0.669 in.)
L 23 mm ( 0.906 in.)
M 27 mm ( 1.063 in.)
N 31 mm ( 1.220 in.)
O Hole H 6
P Axle n 6
Q 16 mm (0.6299 in.)
R 15.5 mm (0.6102 in.)
S 0.5 mm × 15 mm (0.0197 in. × 0.591 in.)
T 12.5 mm (0.492 in.)
U 9.5 mm (0.374 in.)
V 11.6 mm (0.457 in.)
W 6.5 mm (0.256 in.)
C1 0.5 mm (0.0197 in.) bevel
R1 R 13 mm (0.512 in.)
R2 R 5.8 mm (0.228 in.)
R3 R 4.5 mm (0.177 in.)

(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

[2] TRAVEL PILOT VALVE

No. Part Name Qty No. Part Name Qty No. Part Name Qty
(1) Bellows 2 (14) Plug 4 (27) Hex socket bolt 2
(2) Set screw 2 (15) O-ring 4 (28) Damper casing 1
(3) Cam 2 (16) Pushrod 4 (29) Plug 5
(4) Set screw 4 (17) Seat 4 (30) O-ring 4
(5) Lock nut 4 (18) Damping spring, small 4 (31) O-ring 2
(6) Hex socket bolt 2 (19) Damping spring, large 4 (32) Casing 1
(7) Bushing 4 (20) Spring seat 4 (33) Plug 3
(8) Camshaft 2 (21) Spring seat 4 (34) O-ring 3
(9) Cover 2 (22) Return spring 4 (35) Seat 3
(10) Hex socket bolt 2 (23) Secondary pressure spring 4 (36) Steel ball 3
(11) Cover 1 (24) Washer 4 (37) Plug 1
Secondary pressure
(12) Grease cap 4 (25) 4 (38) O-ring 1
adjustment shim
(13) Gasket 4 (26) Spool 4

RY9212148HYS0228US0

3-S80 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM
Travel pilot valve adapter angles

Point used Tape color

(1) Left backward Blue
(2) Left forward Red
(3) Right backward Green
(4) Right forward Yellow
(5) Pressure sensor None
(P) Port P White
(T) Port T None

(a) 20 ° (0.35 rad)

A : Front side
B : Standard Spec
C : Angle Specification
RY9212158HYS0034US0

(1) Disassembly
• 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 (3) Lock nut
(2) Set screw
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 (3) Damping spring, large
(2) Seat (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 (A) Reducing valve ASSY
(2) Return spring
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 (4) Washer
(2) Spring seat (5) Secondary pressure adjustment
(3) Secondary pressure spring 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 (4) Washer
(3) Secondary pressure spring (5) Secondary pressure adjustment
shim
RY9212148HYS0303US0

17. Remove the grease cap and O-ring from the plug.
(1) Plug (3) O-ring
(2) Grease cap
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 (A) Steel ball contact surface
(2) Seat
RY9212148HYS0248US0

21. Remove the steel ball from the casing.

• Tool to use: Magnet
(1) Steel ball
RY9212148HYS0249US0

(2) Assembly
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
11.8 ± 1.0 N·m
Tightening torque Hex socket bolt 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 (4) Secondary pressure spring
(2) Secondary pressure adjustment (5) Spring seat
shim
(3) Washer
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 (A) Reducing valve ASSY
(2) Casing (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.
8.8 ± 1.0 N·m
Tightening torque Hex socket bolt 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
20.6 ± 1.5 N·m
Tightening torque Hex socket bolt 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 (3) Seat
(2) Pushrod
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 (3) Damping spring, large
(2) Damping spring, small
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 (a) Special tool
(2) Bushing
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.
39.8 ± 4.0 N·m
Tightening torque Hex socket bolt 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.
6.9 ± 1.0 N·m
Tightening torque Set screw 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.
33.3 ± 3.4 N·m
Tightening torque Lock nut 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

(3) Special Tools

(a)Special tool

(1) Center hole OK [ 2mm (0.08 in.) (c) 20 mm (0.79 in.)

or less] (d) 2 mm (0.08 in.)
(e) 32 mm (1.26 in.)
(a) 12 (-0.25, -0.40) mm (0.42 in.) (f) 0.52 rad (30 °)
(b) 10 (-0.20, -0.25) mm (0.39 in.)
RY9212148HYS0267US0

[3] SWING PILOT VALVE

No. Part Name Qty
(1) Bellows 1
(2) Set screw 1
(3) Ball 2
(4) Cam 1
(5) Bushing 2
(6) Cam shaft 1
(7) Return spring 2
(8) Secondary pressure spring 2
(9) Metal washer 2
(10) Spring seat 2
(11) Spool 2
(12) Hex socket bolt 2
(13) O-ring 1
(14) Plug 1
(15) Shim 2
(16) Pushrod 2
(17) O-ring 2
(18) Gasket 2
(19) Plug 2
(20) Cover 1
(21) Casing 1
RY9212148HYS0170US0

3-S89 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM
Swing pilot valve adapter angles

Point used Tape color

(1) Left Pea green
(2) Right Orange
(P) Port P White
(T) Port T None

(A) Right swing

(B) Left swing

(a) 45 ° (0.79 rad)

RY9212148HYS0269US0

(1) Disassembly
1. Clamp the pilot valve in a vise.
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 (4) Plug

(2) Casing (5) O-ring
(3) Pushrod (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 (3) O-ring

(2) Pushrod
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 A : Reducing Valve ASSY

(2) Return Spring
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 (3) Shim
(2) Secondary Pressure Spring (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

(2) Assembly
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 (3) Secondary Pressure Spring

(2) Shim (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.

8.8 ± 0.8 N·m

Tightening torque Cover 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 HYDRAULIC SYSTEM
15. Install the hex socket bolt.

6.9 ± 1.0 N·m

Tightening torque Hex socket bolt 0.7 ± 0.1 kgf·m
5.1 ± 0.7 lbf·ft
• Tool to use: hex socket 3 mm
RY9212148HYS0199US0

16. Apply grease to the ends of the pushrods.

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

[4] BLADE PILOT VALVES

No. Part Name Qty No. Part Name Qty No. Part Name Qty
(1) Casing 1 (12) Spring seat 1 1 (23) Set screw 1
(2) Port plate 1 (13) Spring seat 2 1 (24) Detent plug 2
Select
(3) O-ring 1 (14) Washer 2 thick- (25) Holder 2
ness
(4) Hex socket bolt 2 (15) Return spring 2 (26) Steel ball 2
Secondary pressure
(5) Spool 2 (16) 1 (27) Spring 2
spring 1
Secondary pressure
(6) Plug 2 (17) 1 (28) Lock nut 2
spring 2
(7) Pushod 1 1 (18) Cover 1 (29) Adjusting nut 2
(8) Pushod 2 1 (19) Lever 1 (30) O-ring 2
(9) Seal 2 (20) Hex socket bolt 2 (31) Hex socket bolt 2
(10) O-ring 2 (21) Disc 1 (32) Bellows 1
(11) Washer 1 4 (22) Camshaft 1
• Thickness of washer 2 as per table below
Point used Thickness
Detent 0 to 2 mm (0 to 0.08 in.) or less
Reducing valve 0.4 mm (0.02 in.) One washer

RY9212158HYS0071US0

3-S98 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM
Adapter angles

Point used Tape color

(1) Down Brown
(2) Up Pink
(P) Port P White
(T) Port T None

(A) Front side

(a) 45 ° (0.79 rad)

RY9212158HYS0072US0

3-S99 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

(1) Disassembly
• To ensure parts that are reused are installed in the same place as before disassembly, mark the parts as needed
during disassembly.
RY9212158HYS0073US0
1. Clamp the pilot valve in a vise.
2. Remove the bellows from the cover.
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 (4) Adjusting Nut
(2) Detent Plug (5) Cover
(3) Lock Nut
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 (3) Disc
(2) Hex Socket Bolt
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 A : Reducing Valve
(2) Return Spring
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 (3) Spring Seat
(2) Secondary Pressure Spring (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

(2) Assembly
1. Assemble the reducing valve.
Install the secondary pressure setting spring and the spring seat
in that order on the spool, then press the spring seat down and
install the two half-circle shaped pieces of washer 1 on the
spring seat so they don't overlap.
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 (3) Spring Seat
(2) Secondary Pressure Spring (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
29.4 ± 2.0 N·m
Tightening torque Hex socket bolt 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 A : Reducing Valve
(2) Casing 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
11.8 ± 1.0 N·m
Tightening torque Hex socket bolt 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.
16.7 ± 1.0 N·m
Tightening torque Set screw 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
29.4 ± 2.0 N·m
Tightening torque Hex socket bolt 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
41.2 ± 2.9 N·m
Tightening torque Detent plug lock nut 4.2 ± 0.3 kgf·m
30.4 ± 2.1 lbf·ft

(1) Cover (a) 1.0 to 3.0 mm (0.04 to 0.12 in.)

(2) Detent plug
(3) Lock Nut
(4) Adjusting Nut
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

8. SHOCKLESS VALVES
Components

Name of
No. Qty Torque
part
44.2 to 54.0 N·m
(1) Plug 4 4.5 to 5.5 kgf·m
32.6 to 39.8 lbf·ft
(2) O-ring 4
(3) Spring 4
(4) Orifice 1
(5) Ring 2
(6) Spool 2
(7) Orifice 1
(8) Ball 6
(9) Body 1
23.8 to 29.2 N·m
(10) Plug 2 2.4 to 3.0 kgf·m
17.6 to 21.5 lbf·ft
(11) O-ring 2
(12) Spring 2
(13) Spring seat 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
Adapter angles

(1) Shockless Valves (a) 45 ° (0.79 rad)

(2) Swivel shuttle valve
RY9212158HYS0036US0

3-S106 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

9. SWIVEL SHUTTLE VALVE

Components

No. Name of part Q'ty Torque

(1) Body 1
23.8 to 29.2 N·m
(2) Plug 3 2.4 to 3.0 kgf·m
17.6 to 21.5 lbf·ft
(3) O-ring 3
13.2 to 16.2 N·m
1.4 to 1.7 kgf·m
(4) Seat 2 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 (a) 15 ° (0.26 rad) (b) 30 ° (0.52 rad) (c) 45 ° (0.79 rad)
(2) Shockless Valve
RY9212148HYS0276US0

3-S107 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

10. SOLENOID VALVE

[1] UNLOAD VALVE
Components

No. Name of part Qty Torque

15.7 ± 1.6 N·m
(1) Hex nut 1 1.6 ± 0.2 kgf·m
11.6 ± 1.2 lbf·ft
(2) Adjuster screw 1
3.9 N·m
(3) Hex socket bolt 2 0.4 kgf·m
2.9 lbf·ft
(4) Cover 1
(5) Plug 1
(6) O-ring 4
(7) Spring 1
(8) Plunger 1
(9) O-ring 1
(10) Rivet screw 2
(11) Nameplate 1
(12) Body 1
26.5 ± 2.7 N·m
(13) Plug 3 2.7 ± 0.3 kgf·m
19.5 ± 2.0 lbf·ft
(14) Plunger 1
(15) Spring 1
(16) O-ring 1
21.0 ± 2.1 N·m
(17) Plug 1 2.1 ± 0.2 kgf·m
15.5 ± 1.5 lbf·ft
(18) Spring 2
(19) Spool 2
(20) O-ring 2
(21) Solenoid 2
3.9 N·m
(22) Hex socket bolt 4 0.4 kgf·m
2.9 lbf·ft
RY9212148HYS0277US0
Adapter angles

(1) Travel 2-speed solenoid

(2) Pilot solenoid

(P) Port P
(T) Port T

(a) 45 ° (0.79 rad)

RY9212148HYS0278US0

3-S108 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

[2] AUX PROPORTIONAL CONTROL SOLENOID VALVE

Components

No. Name of part Qty Torque

7.0 ± 1.0 N·m
(1) Bolt 4 0.7 ± 0.1 kgf·m
5.2 ± 0.7 lbf·ft
(2) Solenoid 2
(3) O-ring 2
(4) O-ring 2
(5) O-ring 2
(6) O-ring 2
(7) Body 1
RY9212148HYS0279US0
Adapter angles

(1) AUX1 solenoid valve

(2) AUX2 solenoid valve

(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 HYDRAULIC SYSTEM

[3] ANGLE SOLENOID VALVE

Components

No. Name of part Qty Torque

26.5 ± 2.7 N·m
(1) Plug 2 2.7 ± 0.3 kgf·m
19.5 ± 2.0 lbf·ft
(2) O-ring 2
(3) Spring 2
(4) Spool 2
(5) Body 1
3.9 N·m
(6) Hex socket bolt 4 0.4 kgf·m
2.9 lbf·ft
(7) Solenoid 2
(8) O-ring 2
26.5 ± 2.7 N·m
(9) Plug 1 2.7 ± 0.3 kgf·m
19.5 ± 2.0 lbf·ft
(10) O-ring 1
RY9212148HYS0281US0
Adapter angles

(P) Port P
(T) Port T

(a) 20 ° (0.35 rad)

RY9212148HYS0282US0

3-S110 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

[4] EP MODE SOLENOID VALVE

Components

No. Name of part Qty Torque

7.0 ± 1.0 N·m
(1) Bolt 2 0.7 ± 0.1 kgf·m
5.2 ± 0.7 lbf·ft
(2) Solenoid 1
(3) O-ring 1
(4) O-ring 1
(5) O-ring 1
(6) O-ring 1
(7) Body 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 HYDRAULIC SYSTEM

11. ROUTING OF HYDRAULIC HOSES

[1] HYDRAULIC HOSE SPECIFICATIONS
(a) Total Length
RY9212004HYS0147US0

(1) C Type (Straight) (a) 45 °

(2) CR4 Type (45°) (b) 90 °
(3) CR9 Type (90°)
(4) QM Type (Quick)
(5) Q Type (Quick)
RY9212148HYS0202US0

3-S112 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

[2] HIGH-PRESSURE HOSES

(1) Deliver Hose Routing

(a) Pump (c) 3-way valve (d) Swivel motor (e) Swivel joint
(b) Control valve
(To be continued)

3-S113 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM
(Continued)
Hose Fitting
No. Function Point used
Total length Tape color Hose class Type Size
2890 mm White
(1) P1 PA2810 CR9·C 1-14UNS Pump (P1) to C/V (P1)
113.8 in. Red
2950 mm White
(2) P2 PA2810 CR9·C 1-14UNS Pump (P2) to C/V (P2)
116.1 in. Red
2520 mm White
(3) P3 PA2810 CR4·C 1-14UNS Pump (P3) to C/V (P3)
99.2 in. Red
2310 mm White
(4) PPS PFH04 C·C 9/16UNF Pump (PPS) to C/V (PPS)
90.9 in. Red
2880 mm White
(5) PLS PFH04 C·C 9/16UNF Pump (PLS) to C/V (PLS)
113.4 in. Red
910 mm C/V (PB1) to C/V (PB2)
(6) Boom union Black PFH06 C·C 11/16UN
35.8 in. (Boom union)
920 mm PA2808 C/V (Travel R-FWD) to R/J
(7) Travel right forward Yellow x 2 C·CR4 1-14UNS
36.2 in. equiv. (E)
1025 mm PA2808 C/V (Travel R-BWD) to R/J
(8) Travel right rear Green x 2 C·CR4 1-14UNS
40.4 in. equiv. (G)
950 mm PA2808 C/V - (Travel L-FWD) to R/J
(9) Travel left forward Red x 2 C·CR4 1-14UNS
37.4 in. equiv. (D)
1065 mm PA2808 C/V (Travel L-BWD) to R/J
(10) Travel left rear Blue x 2 C·CR4 1-14UNS
41.9 in. equiv. (F)
810 mm PA2808 C/V (Swivel left) to swivel
(11) Swivel left Gray C·CR4 13/16UN
31.9 in. equiv. motor (L)
670 mm PA2808 C/V (Swivel right) to swivel
(12) Swivel right Light blue C·CR4 13/16UN
26.4 in. equiv. motor (R)
1175 mm PA2808
(13) Blade down Brown C·CR4 13/16UN C/V (Blade down) to R/J (B)
46.3 in. equiv.
1065 mm PA2808
(14) Blade up Pink C·CR4 13/16UN C/V (Blade up) to R/J (C)
41.9 in. equiv.
465 mm PA2808 3-way valve to C/V (AUX1
(15) AUX1 (low-pressure) Brown C·CR9 1-14UNS
18.3 in. equiv. low pressure)
2170 mm C/V (L) to swing cylinder
(16) Swing left Orange PFH06 C·C 11/16UN
85.4 in. (bottom)
1940 mm C/V (R) to swing cylinder
(17) Swing right Pea green PFH06 C·C 11/16UN
76.4 in. (rod)

RY9212148HYS0285US0

3-S114 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM
Delivery Hose Clamp Positions

(1) Swing cylinder bottom side (4) P2 (6) P3 (9) PPS

(2) Swing cylinder rod side (5) EP mode solenoid valve port A (7) P4 (10) EP mode solenoid valve port P
(3) P1 (8) PLS

NOTE
• (a): So hoses to P1, P2 and P3 don't rub against each other.
• (b): Pass all hoses inside the rod.
RY9212148HYS0286US0

3-S115 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

(2) PLS Hose Routing

Hose Fitting
No. Function Point used
Total length Tape color Hose class Type Size
2880 mm White
(1) PLS PFH04 C·C 9/16UNF Pump (PLS) to C/V (PLS)
113.4 in. Red
750 mm P4 distribution block (tank
(2) Travel PLT04 CR9·Q 1/4·Q
29.5 in. 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

(3) Front Hose Routing

(a) Boom holding valve hose (Eur. only)

(To be continued)

3-S117 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM
(Continued)
Hose Fitting
No. Function Total Tape Hose Guard Point used
Type Size
length color class
2600 mm Green C/V (Boom up) to boom
(1) Boom up PA2810 C·C 1-14UNS
102.4 in. White cylinder (bottom)
3470 mm Colgate C/V (Boom down) to
(2) Boom down Yellow PFH08 CR9·C 13/16UN
136.6 in. tube boom cylinder (rod)
3280 mm C/V (arm crowd) to boom
(3) Blue PA2810 C·C 1-14UNS
129.1 in. back (pipe)
Arm crowd Boom back (pipe) (arm
720 mm PA2810
(4) Blue C·C 1-14UNS crowd) to arm cylinder
28.3 in. equiv.
(bottom)
3220 mm Colgate C/V (arm dump) to boom
(5) Pea green PFH08 C·C 13/16UN
126.8 in. tube back (pipe)
Arm dump Boom back (pipe) (arm
1955 mm PA2808
(6) Pea green C·C 13/16UN dump) to arm cylinder
77.0 in. equiv.
(rod)
3340 mm Colgate C/V (bucket crowd) to
(7) Bucket crowd Orange PA2810 C·C 1-14UNS
131.5 in. tube boom back (pipe)
Bucket crowd long 1150 mm
arm 45.3 in. Total spring Boom back (pipe) to
(8) PA2810 C·C 1-14UNS
Bucket crowd short 1350 mm length bucket cylinder
arm 53.1 in.
3280 mm Colgate C/V (bucket dump) to
(9) Bucket dump Red PFH08 C·C 13/16UN
129.1 in. tube boom back (pipe)
Bucket dump (long 1150 mm
arm) 45.3 in. Total spring Boom back (pipe) to
(10) PA2810 C·C 1-14UNS
Bucket dump (short 1350 mm length bucket cylinder
arm) 53.1 in.
3280 mm Colgate C/V (AUX1 Hi-press.) to
(11) Pink PA2810 C·C 1-14UNS
129.1 in. tube boom back (pipe)
540 mm PA2810
(12) AUX1 High pressure C·C 1-14UNS AUX middle (AUX1)
21.3 in. equiv.
980 mm PA2810 Total spring
(13) C·C 1-14UNS AUX end (AUX1)
38.6 in. equiv. length
465 mm C/V (AUX1 low pressure)
(14) Brown PA2810 CR9·C 1-14UNS
18.3 in. to 3-way valve
3-way valve (AUX1
3700 mm Colgate
(15) Brown PA2810 C·C 1-14UNS lo-press) to boom back
145.7 in. tube
AUX1 Low pressure (pipe)
540 mm PA2810
(16) C·C 1-14UNS AUX middle (AUX1)
21.3 in. equiv.
980 mm PA2810 Total spring
(17) C·C 1-14UNS AUX end (AUX1)
38.6 in. equiv. length
3390 mm Colgate C/V (AUX2 Hi-press.) to
(18) Pink PA2808 C·C 13/16UN
133.5 in. tube boom back (pipe)
605 mm
(19) AUX2 High pressure PA2808 C·C 13/16UN AUX middle (AUX2)
23.8 in.
1110 mm PA2810 Total spring
(20) C·C 1-14UNS AUX end (AUX2)
43.7 in. equiv. length
3590 mm Colgate C/V (AUX2 Lo-press.) to
(21) Brown PA2808 C·C 13/16UN
141.3 in. tube boom back (pipe)
605 mm
(22) AUX2 Low pressure PA2808 C·C 13/16UN AUX middle (AUX2)
23.8 in.
1110 mm PA2810 Total spring
(23) C·C 1-14UNS AUX end (AUX2)
43.7 in. equiv. length

RY9212158HYS0038US0

3-S118 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM
Front Hose Clamp Positions

(1) Brown (AUX1 Lo) (3) Orange (Bucket crowd) (5) Yellow (Arm dump) (7) Pink (AUX2 Hi)
(2) Red (Bucket dump) (4) Blue (Arm crowd) (6) Pink (AUX1 Hi) (8) Brown (P1 Lo)

NOTE
• (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

(4) Boom Hose Routing

(1) AUX2 (High) (4) Arm dump (7) Bucket crowd (10) AUX2 (Low)
(2) Boom up (5) Arm crowd (8) AUX1 (Low) (11) Velcro tape
(3) AUX1 (High) (6) Bucket dump (9) Boom down (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

(5) Undercarriage Hose Routing

(a) Blade Cylinder (c) Travel Motor L (e) Swivel Joint (f) 15 ° (0.3 rad)
(b) Blade Bulkhead Fitting (d) Travel Motor R

Hose Fitting
No. Function Total Tape Guard Point used
Hose class Type Size
length color
1415 mm Yellow x NWP280 15 S/J (E) to motor right
(1) Travel right forward CR4·C 1-14UNS
55.7 in. 2 equivalent down (A)
1355 mm Green x NWP280 15 S/J (G) to motor right up
(2) Travel right rear CR4·C 1-14UNS
53.3 in. 2 equivalent (B)
Spiral tube
1355 mm NWP280 15
(3) Travel left forward Blue x 2 CR4·C 1-14UNS S/J (E) to motor left up (A)
53.3 in. equivalent
1415 mm NWP280 15 S/J (G) to motor left down
(4) Travel left rear Red x 2 CR4·C 1-14UNS
55.7 in. equivalent (B)
1385 mm NWP105 6 S/J (A) to motor L/R
(5) Travel 2-speed C·C 1/4
54.5 in. equivalent 2-speed
1310 mm NWP35 9
(6) Drain CR4·C 3/8 S/J (H) to motor L/R drain
51.6 in. equivalent
430 mm NWP210 12
(7) Blade up Pink CR9·C 13/16UN S/J (C) to blade joint
16.9 in. equivalent
430 mm NWP210 12
(8) Blade down Brown CR9·C 13/16UN S/J (B) to blade joint
16.9 in. equivalent
795 mm NWP210 12 Blade joint to blade
(9) Blade up CR4·C 13/16UN
31.3 in. equivalent Total spring cylinder (rod)
795 mm NWP210 12 length Blade joint to blade
(10) Blade down CR4·C 13/16UN
31.3 in. equivalent cylinder (bottom)

RY9212148HYS0291US0

3-S121 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

(6) Angle Blade Hose Routing

(a) Control Valve (c) Travel Motor L (e) Blade Cylinder (g) Blade Bulkhead Fitting
(b) Swivel Joint (d) Travel Motor R (f) Angle Cylinder (h) 15 ° (0.3 rad)

Hose Fitting
No. Function Total Tape Hose Guard Point used
Type Size
length color class
1170 mm White PA2808
(1) C·CR9 13/16UN C/V (Angle left) to L/J (J)
46.1 in. Orange equiv.
440 mm White
(2) PFW08 C·CR9 13/16UN R/J (J) to blade joint
Angle Left 17.3 in. Orange
NWP280
800 mm Total spring Blade joint to angle
(3) 12 C·C 13/16UN
31.5 in. length cylinder (bottom)
equivalent
1170 mm Black PA2808
(4) C·CR9 13/16UN C/V (Angle right) to R/J (I)
46.1 in. Orange equiv.
610 mm Black
(5) PFW08 C·CR9 13/16UN R/J (I) to blade joint
Angle Right 24.0 in. Orange
NWP280
1290 mm Total spring Blade joint to angle
(6) 12 C·C 13/16UN
50.8 in. length cylinder (rod)
equivalent

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3-S122 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

[3] LOW-PRESSURE HOSES

(1) Suction Pipe and Hose Routing

(1) Suction hose 1 (2) Suction hose 2 (3) Suction pipe

NOTE
• (a): Tighten bands from the base plate side (bottom).

No. Function Point used

(1) Oil tank to suction pipe
Suction
(2) Pump to suction pipe

RY9212148HYS0293US0

3-S123 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

(2) Drain Hose Routing

(a) Return Pipe (c) 3-Way Valve (e) Swivel Motor (f) Oil Cooler
(b) Hydraulic Oil Tank (d) Control Valve

Hose Fitting
No. Function Total Tape Hose Guard Point used
Type Size
length color class
805 mm
(1) Return (T1) PA0320 C·C 1·1/4 C/V (T1) to return pipe
31.7 in.
560 mm C/V (T2) to swivel motor
(2) Swivel makeup Black PA0310 C·CR4 3/4
22.0 in. (M)
1180 mm Swivel motor (M) to oil
(3) PA0310 C·C 3/4
46.5 in. cooler
Return (T2) PVC tube
800 mm
(4) Black PA0310 C·C 3/4 Oil cooler to return pipe
31.5 in.
360 mm Swivel motor (Dr) to oil
(5) Swivel drain PLT04 CR4·C 1/4
14.2 in. tank
630 mm Center
(6) AUX1 return PA0310 C·C 3/4 3-way valve to return pipe
24.8 in. Pink x 2

RY9212148HYS0294US0

3-S124 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

[4] PILOT HOSES

(1) Deliver Hose Routing

(a) Pump (c) Collector Block (d) Unload Valve (e) Swivel Joint
(b) Line Filter

Hose Fitting
No. Function Point used
Total length Tape color Hose class Type Size
360 mm
(1) PF1406 C·C 3/8 Pump to line filter
14.2 in.
2080 mm
(2) P4 Red PF1406 C·C 3/8 Line filter to unload valve
81.9 in.
2010 mm Unload valve (B) to collector
(3) Red PLT06 C·C 3/8
79.1 in. block (P)
1350 mm Unload valve (A) to R/J travel
(4) Travel 2-speed Pea green PLT04 C·C 1/4
53.1 in. 2-speed boost

RY9212148HYS0295US0

3-S125 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

(2) Port P Hose Routing

(a) Control Valve (c) Swivel Motor (e) AUX2 Solenoid Valve (g) Unload Valve
(b) Swivel Shuttle Valve (d) AUX1 Solenoid Valve (f) P4 Distribution Block

Hose Fitting
No. Function Point used
Total length Tape color Hose class Type Size
350 mm Unload valve (B) to AUX1
(1) AUX1 P Blue PLT04 CR9·C 1/4
13.8 in. solenoid valve (P)
260 mm AUX1 solenoid valve (P) to
(2) AUX2 P PLT04 C·CR9 1/4
10.2 in. AUX2 solenoid valve (P)
380 mm Unload valve (P) to P4
(3) Distribution block P PLT04 CR9·C 1/4
15.0 in. distribution block (tank side)
220 mm P4 distribution block (tank
(4) AI Blue PLT04 Q·Q Q
8.7 in. side) to C/V (PP1)
240 mm P4 distribution block (tank
(5) Yellow PLT04 Q·Q Q
9.4 in. side) to C/V (PP2)
P3 union
400 mm P4 distribution block (tank
(6) Green PLT04 Q·Q Q
15.7 in. side) to C/V (PP3)
P4 distribution block (tank
480 mm
(7) Swivel brake P Light blue PLT04 Q·Q Q side) to swivel motor brake
18.9 in.
(PG)
1095 mm Light blue Shuttle valve to swivel motor
(8) Swivel brake signal PLT04 Q·CR9 Q·1/4
43.1 in. Gray brake (SH)
750 mm P4 distribution block (tank
(9) Travel PLT04 CR9·Q 1/4·Q
9.5 in. side) to C/V (PP4)

RY9212148HYS0296US0

3-S126 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

(3) Port T Hose Routing

Hose Fitting
No. Function Point used
Total length Tape color Hose class Type Size
610 mm
(1) Light blue PLT04 C·CR9 1/4 C/V (Dr2) to tank
24.0 in.
510 mm
(2) Center green PA0308 C·C 1/2 Unload valve (T) to tank
20.1 in.
1640 mm
(3) Center gray PLT06 C·C 3/8 Collector block (T) to tank
64.6 in.
990 mm
(4) Drain Orange PLT06 C·CR9 3/8 S/J (T) to tank
39.0 in.
410 mm Brown
(5) PLT04 C·CR9 1/4 AUX1 solenoid (T) to tank
16.1 in. Pink
330 mm
(6) PLT04 C·CR9 1/4 AUX2 solenoid (T) to tank
13.0 in.
740 mm
(7) PLT04 C·C 1/4 Anti-drift (T) to tank
29.1 in.

RY9212148HYS0297US0

3-S127 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

(4) Ports P and T Pilot Valve Hose Routing

(a) Boom Shockless Valve (d) Collector Block (g) Blade P/V (A) Angle Specification
(b) Travel P/V (e) Control P/V Left (h) EP Mode Solenoid Valve
(c) Swing P/V (f) Control P/V Right (i) Angle Solenoid Valve
(To be continued)

3-S128 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM
(Continued)
Hose Fitting
No. Function Point used
Total length Tape color Hose class Type Size
1495 mm Collector block (P) to blade
(1) Blade P White PLT04 C·Q 1/4·Q
58.9 in. P/V (P)
235 mm
(2) P/V right P White PLT04 Q·Q Q P/V (R) (P) to blade P/V (P)
9.3 in.
350 mm Collector block (P) to travel
(3) Travel P/V P White PLT04 C·C 1/4
13.8 in. P/V (P)
280 mm Travel P/V (P) to Swing P/V
(4) Swing P/V P White PLT04 C·Q 1/4·Q
11.0 in. (P)
1380 mm P/V (L) (T) to collector block
(5) PLT04 Q·C Q·1/4
54.3 in. (T)
330 mm
(6) PLT04 Q·Q Q P/V (R) (T) to blade P/V (T)
13.0 in.
1430 mm Blade P/V (T) to collector
(7) PLT04 Q·C Q·1/4
56.3 in. block (T)
Drain
330 mm Swing P/V (T) to Travel P/V
(8) White PLT04 Q·C Q·1/4
13.0 in. (T)
240 mm Travel P/V (T) to collector
(9) PLT04 C·C 1/4
9.4 in. block (T)
335 mm Collector block (T) to
(10) PLT04 C·C 1/4
13.2 in. shockless valve (T)
1300 mm
(11) Flow control PLT04 Q·C Q·1/4 E/P, solenoid to Pump (E/P)
51.2 in.
1300 mm
(12) E/P, SOL P White PLT04 C·C 1/4 Line filter to E/P, solenoid (P)
51.2 in.
285 mm E/P, solenoid (T) to collector
(13) Drain PLT04 C·CR9 1/4
11.2 in. block (T)
1280 mm E/P, solenoid (P) to P/V (L)
(14) P/V Left P White PLT04 C·Q 1/4·Q
50.4 in. (P)
2135 mm
(15) P/V right P White PLT04 Q·Q Q P/V (right) (P) to P/V (left) (P)
84.1 in.
280 mm Angle solenoid (P) to travel
(16) Angle solenoid P White PLT04 C·CR9 1/4
11.0 in. P/V (P)
360 mm Angle solenoid (T) to travel
(17) Drain PLT04 CR9·C 1/4
14.2 in. P/V (T)

RY9212158HYS0041US0

3-S129 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

(5) Pilot Valve Hose Routing

(a) Swivel Shuttle Valve (c) TPSS Valve (e) Control Right P/V (g) Blade P/V
(b) Boom Shockless Valve (d) Control Left P/V (f) Bulkhead Fitting

Hose Fitting
No. Function Point used
Total length Tape color Hose class Type Size
1410 mm P/V (swivel left) to shuttle
(1) Swivel left Gray PLT04 Q·C Q·1/4
55.5 in. valve
1415 mm P/V (swivel right) to shuttle
(2) Swivel right Light blue PLT04 Q·C Q·1/4
55.7 in. valve
1240 mm
(3) Blue PLT06 Q·C Q·3/8 P/V (arm crowd) to TPSS
48.8 in.
Arm crowd
530 mm TPSS to shuttle valve (arm
(4) Blue PLT06 C·C 3/8
20.9 in. crowd)
1210 mm
(5) Pea green PLT06 Q·C Q·3/8 P/V (arm dump) to TPSS
47.6 in.
Arm dump
505 mm TPSS to bulkhead fitting
(6) Pea green PLT06 C·C 3/8
19.9 in. (arm dump)
1655 mm P/V (bucket crowd) to
(7) Bucket crowd Orange PLT04 Q·QM Q
65.2 in. bulkhead fitting
1650 mm P/V (bucket dump) to
(8) Bucket dump Red PLT04 Q·QM Q
65.0 in. bulkhead fitting
1815 mm
(9) Green PLT06 Q·C Q·3/8 P/V (Boom up) to TPSS
71.5 in.
Boom up
505 mm TPSS to shockless valve
(10) Green PLT06 C·C 3/8
19.9 in. (Boom up)
1940 mm
(11) Yellow PLT06 Q·C Q·3/8 P/V (Boom down) to TPSS
76.4 in.
Boom down
485 mm TPSS to shockless valve
(12) Yellow PLT06 C·C 3/8
19.1 in. (Boom down)

3-S130 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

Hose Fitting
No. Function Point used
Total length Tape color Hose class Type Size
1400 mm Blade P/V (up) to bulkhead
(13) Blade up Pink PLT04 Q·QM Q
55.1 in. fitting
1400 mm Blade P/V (down) to
(14) Blade down Brown PLT04 Q·QM Q
55.1 in. bulkhead fitting

RY9212158HYS0042US0

(a) Control Valve (d) Travel P/V (f) Boom Shockless Valve (h) Blade P/V
(b) AUX1 Solenoid Valve (e) Bulkhead Fitting (g) Swivel Shuttle Valve (i) Angle Solenoid Valve
(c) AUX2 Solenoid Valve
(To be continued)

3-S131 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM
(Continued)
Hose Fitting
No. Function Point used
Total length Tape color Hose class Type Size
1845 mm Shuttle valve to C/V (swivel
(1) Swivel left Gray PLT04 Q·CR9 Q·1/4
72.6 in. left)
1405 mm Shuttle valve to C/V (swivel
(2) Swivel right Light blue PLT04 Q·Q Q
55.3 in. right)
1665 mm Shuttle valve to C/V (arm
(3) Arm crowd Blue PLT06 Q·CR9 Q·3/8
65.6 in. crowd)
1445 mm Bulkhead fitting to C/V (arm
(4) Arm dump Pea green PLT06 Q·Q Q
56.9 in. dump)
1885 mm Bulkhead fitting to C/V
(5) Bucket crowd Orange PLT04 Q·CR9 Q·1/4
74.2 in. (bucket crowd)
1355 mm Bulkhead fitting to C/V
(6) Bucket dump Red PLT04 Q·Q Q
53.3 in. (bucket dump)
1665 mm Shockless valve to C/V
(7) Boom union Green PLT06 Q·Q Q
65.6 in. (boom union Pbu)
860 mm C/V (boom union Pbu) to C/V
(8) Boom up Green PLT06 Q·Q Q
33.9 in. (boom up)
1785 mm Shockless valve to C/V
(9) Boom down Yellow PLT06 Q·CR4 Q·3/8
70.3 in. (boom down)
1660 mm Travel P/V (L-Fwd) to C/V
(10) Travel left forward Red x 2 PLT04 Q·Q Q·Q
65.4 in. (L-Fwd)
1950 mm Travel P/V (L-Bwd) to C/V
(11) Travel left rear Blue x 2 PLT04 Q·CR9 Q·1/4
76.8 in. (L-Bwd)
1550 mm Travel P/V (R-Fwd) to C/V
(12) Travel right forward Yellow x 2 PLT04 Q·Q Q
61.0 in. (R-Fwd)
1840 mm Travel P/V (R-Bwd) to C/V
(13) Travel right rear Green x 2 PLT04 Q·CR9 Q·1/4
72.4 in. (R-Bwd)
1850 mm
(14) Swing left Orange x 2 PLT04 Q·CR9 Q·1/4 Swing P/V (left) to C/V (left)
72.8 in.
1450 mm Swing P/V (right) to C/V
(15) Swing right Yellow x 2 PLT04 Q·Q Q
57.1 in. (right)
1545 mm Bulkhead fitting to C/V (blade
(16) Blade up Pink PLT04 Q·Q Q
60.8 in. up)
1795 mm Bulkhead fitting to C/V (blade
(17) Blade down Brown PLT04 Q·CR9 Q·1/4
70.7 in. down)
860 mm AUX1 solenoid (Hi) to C/V
(18) AUX1 High pressure Pink PLT04 C·Q 1/4·Q
33.9 in. (AUX1 Hi)
1050 mm AUX1 solenoid (Low) to C/V
(19) AUX1 Low pressure Brown PLT04 C·CR9 1/4
41.3 in. (AUX1 Low)
420 mm AUX2 solenoid (Hi) to C/V
(20) AUX2 High pressure Pink PLT04 Q·Q Q
16.5 in. (AUX2 Hi)
760 mm AUX2 solenoid (Low) to C/V
(21) AUX2 Low pressure Brown PLT04 Q·CR9 Q·1/4
29.9 in. (AUX2 Low)
345 mm Red
(22) P3 union PLT04 Q·Q Q C/V (PF1) to C/V (PF2)
13.6 in. Blue
495 mm
(23) Anti-drift PLT06 C·CR9 3/8 Boom rod P/V to anti-drift
19.5 in.
2070 mm White Angle solenoid (A) to C/V
(24) Angle Left PLT04 C·CR9 1/4
81.5 in. Orange (angle left)
1915 mm Black Angle solenoid (B) to C/V
(25) Angle Right PLT04 C·Q 1/4·Q
75.4 in. Orange (angle right)

RY9212158HYS0043US0

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KX080-4, WSM HYDRAULIC SYSTEM

12. MEASURING HYDRAULIC DEVICE

PERFORMANCE
[1] PISTON PUMP AIR BLEEDING PROCEDURE
Purpose
• When disassembling or replacing hydraulic equipment and/or hoses, etc., after changing the hydraulic fluid and
using the vacuum pump, and before operating the machine, always air bleed the pump to prevent pump scorching
or cavitation.
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 (3) Lock Section
(2) Hexagonal Plug (4) Clamp
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KX080-4, WSM HYDRAULIC SYSTEM

[2] RELEASE OF PRESSURE IN THE HYDRAULIC SYSTEM

Purpose
• It is necessary to release the pressure in the hydraulic system when removing/mounting hydraulic devices and
as preparation for taking measurements. Always release the pressure in such cases.
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
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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 (6) AUX port knob switch
(2) Right machine control lever (7) Swing pedal
(3) Travel lever left (8) Angle blade switch (angle spec.
(4) Travel lever right only)
(5) Blade control lever (9) AUX enable switch
RY9212158HYS0096US0

[3] MANUAL BOOM LOWERING PROCEDURE

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

[4] MEASURING THE FLOW RATE

(1) Measuring Main Pump Flow
Purpose
• Measuring the amount of oil discharged from the main pump allows an assessment of its performance.
• If the discharge volume is lower than the factory specification, something may be wrong with the main pump or
the engine.
RY9212148HYS0312US0

(1) Pump (3) Oil Cooler (5) Test Hose (7) Oil Receptacle
(2) Control Valve (4) Flow Meter (6) Pressure Gauge (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.
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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 Eco mode switch Auto-idle switch AC switch
Max RPM P mode OFF 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

(2) Measuring the AUX Proportional Settings

Purpose
• Measuring the maximum amount of oil flow at each step allows an assessment of solenoid valve performance.
• Prior to performing this test, make sure that each attachment is operating at the factory spec. speed and check
the amperage of each solenoid valve.
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.
Eco mode
Accelerator dial Auto-idle switch AC switch
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 (A) AUX High-Pressure Side
(2) Flow Meter (B) AUX Low-Pressure Side
RY9212148HYS0307US0

3-S138 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

(3) Measuring AUX Discharge Flow

Purpose
• Measuring the flow at the AUX discharge port allows you to confirm AUX port discharge while under load.
RY9212148HYS0349US0
[Measurement preparations]
1. Place the mini excavator on flat hard ground, lower the bucket
and the blade, and stop the engine.
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.
Eco mode
Accelerator dial Auto-idle switch AC switch
switch
Max RPM P mode 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 (A) AUX High-Pressure Side
(2) Flow Meter (B) AUX Low-Pressure Side
RY9212148HYS0308US0

3-S139 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

[5] MEASURING PRESSURE

(1) Main Relief Valve Measuring Procedure
Purpose
• Verification of correct pressure setting.
• If the measured value is low, there may be a problem with the relief valve and/or leaks in other hydraulic devices.
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.
Eco mode
Accelerator dial Auto-idle switch AC switch
switch
Max RPM P mode 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 (7) Main LS Valve (aLS)
(2) P2 Pressure Test Port (8) Main P3 Relief Valve (aP3)
(3) P3 Pressure Test Port (9) Unload LS Valve (aUN)
(4) P4 Pressure Test Port (10) Pilot Primary Pressure Relief Valve
(5) Travel Right Main Relief Valve (aPP)
(aTR)
(6) Travel Left Main Relief Valve (aTL)
RY9212158HYS0097US0

3-S140 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM
Adjusting the Main Relief Valve

CAUTION
• Only adjust the valve if the pressure setting of the main relief valve is lower than specification.
• If the pressure is raised above the setting value, it may cause damage to equipment, so never raise the
pressure above the setting value.
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 (a) Pressure Increase
(2) Adjuster Screw (b) Pressure Decrease
RY9212148HYS0319US0

Pressure Change/Turn for Main Relief Valve (Reference Values)

Amount adjuster screw turned 1/4 1/2 3/4 1
• Travel right main relief valve
4.4 MPa 8.9 MPa 13.3 MPa 17.7 MPa
• Travel left main relief valve
45.1 kgf/cm2 90.8 kgf/cm2 135.4 kgf/cm2 180.5 kgf/cm2
• Main LS valve
642 psi 1291 psi 1925 psi 2567 psi
• Main P3 relief valve
0.2 MPa 0.4 MPa 0.6 MPa 0.8 MPa
• Pilot primary pressure relief valve 2.0 kgf/cm2 4.1 kgf/cm2 6.1 kgf/cm2 8.2 kgf/cm2
29 psi 58 psi 87 psi 116 psi

RY9212148HYS0320US0

3-S141 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

(2) Measuring Pilot Secondary Pressure

Purpose
• Measure the pressure between the control valves and the oil from each pilot valve and solenoid and make sure
they are at specified values.
• If the pressure is lower than the factory specification, in general it indicates something may be wrong with the pilot
valve or solenoid valve.
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.
Eco mode
Accelerator dial Auto-idle switch AC switch
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 (3) Test Hose
(2) Pressure Gauge
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

(3) Measuring EP Proportional Solenoid Pressure

Purpose
• Measuring the pressure from the EP proportional solenoid valve to the pump allows assessment of the
performance of the EP solenoid valve.
RY9212148HYS0326US0
[Measurement preparations]
1. Place the mini excavator on flat hard ground, lower the bucket
and the blade, and stop the engine.
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.
Eco mode
Accelerator dial Auto-idle switch AC switch
switch
Max RPM P mode OFF OFF
Max RPM P mode OFF ON
Max RPM E mode OFF OFF
2. Position each of the switches as follows, and measure the
pressure when traveling or at boom up full stroke.
Eco mode
Accelerator dial Auto-idle switch AC switch
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 (3) Test Hose
(2) Pressure Gauge
RY9212148HYS0327US0

3-S143 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

(4) Measuring the Overload Relief Valve Pressure

IMPORTANT
• If it is necessary to check the overload relief pressure on this machine, measure the main relief pressure
of each circuit (boom, arm, bucket, blade, AUX and angle) and if the main relief pressures are within
factory specifications, the overload relief valve is judged to be normal.
• 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 HYDRAULIC SYSTEM
Angle Specification

(1) Blade rod

(2) Blade bottom
(3) Arm rod
(4) Arm bottom
(5) Bucket rod
(6) Bucket bottom
(7) AUX1. High
(8) AUX1. Low
(9) Boom bottom
(10) Boom rod
(11) Angle rod
(12) Angle bottom
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 (a) Pressure Increase
(2) Adjuster Screw (b) Pressure Decrease
RY9212148HYS0331US0

Pressure Change/Turn for Overload Relief Valves (Reference Values)

Amount adjuster screw turned 1/4 1/2 3/4 1
4.5 MPa 8.9 MPa 13.4 MPa 17.8 MPa
• Blade rod (b4R)
45.4 kgf/cm2 90.8 kgf/cm2 136.2 kgf/cm2 181.6 kgf/cm2
• Angle bottom (b8L)
645 psi 1291 psi 1936 psi 2582 psi
7.1 MPa 14.2 MPa 21.3 MPa 28.4 MPa
• Other 72.4 kgf/cm2 144.8 kgf/cm2 217.3 kgf/cm2 289.7 kgf/cm2
1030 psi 2060 psi 3089 psi 4119 psi

RY9212158HYS0102US0

3-S145 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

(5) Pressure Measuring Kit

No. Name of part Q'ty
(1) Support 1
(2) Pipe joint (M12-G1/4) 1
(3) Bolt (M10 x 35) 2
(4) Nut (M10) 2
(5) Test hose 1

CAUTION
• Use a test hose that can withstand pressure up to the
measurement pressure.
A : Nozzle Tester
RY9212148HYS0336US0
(1) Support
A 100 mm (3.94 in.)
B 50 mm (2.0 in.)
C t = 2.3 mm (0.09 in.)
D 70 mm (2.8 in.)
E 15 mm (0.59 in.)
F 600 mm (23.6 in.)
G 2–11 mm (2–0.43 in.)
Material std.: STKR400
RY9212148HYS0337US0
(2) Pipe joint (M12-G1/4)
A 47 mm (1.8 in.)
B 12 mm (0.47 in.)
C 15 mm (0.59 in.)
D 20 mm (0.79 in.)
E 10 mm (0.39 in.) ≤
F 12 mm (0.47 in.) ≤
G 8 mm (0.3 in.)
H 3 mm (0.1 in.)
I 18 mm (0.71 in.)
J 9.5 ± 0.2 mm (0.37 ± 0.01 in.)
K 19 +0, –0.35 mm (0.75 +0, –0.01 in.)
L 21.9 mm (0.86 in.)
M M12 × 1.5
N G1/4
O 0.52 rad (30 °)
RY9212148HYS0309US0

3-S146 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

(6) Adjusting Swivel Relief Valve Pressure

IMPORTANT
• When checking the relief pressure of the swivel motor on the machine, measure the main relief pressure
and if the main relief pressure is within factory specifications, the swivel relief valve is considered to be
normal.
• 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)
1/4 1/2 3/4 1
2.3 MPa 4.5 MPa 6.8 MPa 9.0 MPa
Amount adjuster
23.0 kgf/cm2 45.9 kgf/cm2 68.9 kgf/cm2 91.8 kgf/cm2
screw turned
326 psi 653 psi 979 psi 1305 psi

(1) Swivel Right Relief Valve (cSR) (2) Swivel Left Relief Valve (cSL)
RY9212148HYS0339US0

(7) Adjust the LS Control Differential Pressure Adjusting Spring Force

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.) (a) Increase Speed
(2) Lock Nut (b) Reduce Speed
(3) Adjuster Screw
RY9212148HYS0340US0

3-S147 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

[6] MEASURING SWIVEL PERFORMANCE

(1) Measuring Swivel Motor Drain Volume
Purpose
• Measuring the drain volume when operating allows an assessment of swivel motor performance.
IMPORTANT
• Swivel motor performance is used along with swivel block performance and measurement of swivel
speed to make a comprehensive assessment.
• 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.
Eco mode
Accelerator dial Auto-idle switch AC switch
switch
Max RPM P mode 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

(2) Measuring Swivel Block Performance

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.
Eco mode
Accelerator dial Auto-idle switch AC switch
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

(3) Measuring Swivel Speed

Purpose
• Measure how long it takes to swivel 3 times to assess the overall performance of the swivel drive system (main
and pilot lines).
[Measurement preparation]
1. Repeat swivel left and right operations to sufficiently warm up
the swivel motor.
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.
Eco mode
Accelerator dial Auto-idle switch AC switch
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

[7] MEASURING TRAVEL PERFORMANCE

(1) Measuring Travel Motor Drain Volume
Purpose
• Measuring the drain volume when operating and when locked allows an assessment of the travel motor
performance.
• Travel motor performance is used along with travel block performance, travel speed and travel drift to make a
comprehensive assessment.
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 (3) Swivel Joint
(2) Left Travel Motor (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 Accelerator Eco mode Auto-idle
AC switch
switch dial switch switch
1st Max RPM P mode OFF 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 Accelerator Eco mode Auto-idle
AC switch
switch dial switch switch
1st Max RPM P mode OFF OFF
2nd Max RPM P mode 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

(2) Measuring Travel Block Performance

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

(3) Measuring Travel Speed

Purpose
• Measure how long it takes to travel a distance to assess the overall performance of the travel drive system (main
and pilot lines).
[Measurement preparation]
1. Adjust the left and right crawlers to their specified dimensions
and operate the travel motor to thoroughly warm it up.
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.
Travel
Accelera- Eco mode Auto-idling
No. 2-speed AC switch
tor dial switch switch
switch
1 1st Max RPM P mode OFF OFF
2 2nd Max RPM P mode 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

(4) Measuring Travel Drift

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.
Travel
Accelera- Eco mode Auto-idling
No. 2-speed AC switch
tor dial switch switch
switch
1 1st Max RPM P mode OFF OFF
2 2nd Max RPM P mode 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

[8] MEASURING CYLINDER SPEED

(1) Measuring Hydraulic Cylinder Operating Time
Purpose
• Measure the amount of time it takes to operate each of the hydraulic cylinders to assess the overall performance
of the front drive system (main and pilot lines).
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 Eco mode switch Auto-idle switch AC switch
Max RPM P mode OFF 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

(2) Measuring Hydraulic Cylinder Drift

Purpose
• Measure how far a cylinder drops to asses leakage inside the cylinder, control valve and/or holding valve.
• When measuring a cylinder that has just been replaced, insure to purge any air prior to taking the measurements.
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

(3) Measuring Swing Cylinder Deviation

Purpose
• Measure how far the cylinder deviates to assess leakage inside the cylinder and/or control valve.
• When measuring a cylinder that has just been replaced, insure to purge any air prior to taking the measurements.
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.
Eco mode
Accelerator dial Auto-idle switch AC switch
switch
Max RPM P mode 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

13. HYDRAULIC DEVICE PERFORMANCE

STANDARDS
[1] FLOW RATE
(1) Main Pump Discharge Flow Rate Data (Measured Values)

(1) P Mode (Pi = 3.6 MPa, (2) E Mode (Pi = 0 MPa, (3) P Mode(P3 = 20.6 MPa) (a) Flow Rate L/min
37 kgf/cm2, 522 psi), 0 kgf/cm2, 0 psi), P3 = 2 MPa (4) E Mode(P3 = 20.6 MPa) (b) Pressure (MPa)
P3 = 2 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.
(To be continued)

3-S158 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM
(Continued)
MPa 1.5 5.0 7.5 10.0 12.5 15.0
Pressure kgf/cm2 15.3 51.0 76.5 102.0 127.5 153.0
psi 217.96 725.5 1087.8 1450.4 1813.0 2175.6
142.0 141.1 139.8 138.6 137.6 123.9
P mode
37.5 37.3 36.9 36.6 36.6 32.7
142.0 141.0 128.6 107.2 87.1 68.6
E mode
L/min 37.5 37.3 34.0 28.3 23.0 18.1
P mode U.S.gals 142.9 112.7 90.9 71.4 55.7 48.1
(P3 relief) 37.7 29.8 24.0 18.9 14.7 12.7
E mode 142.8 63.7 54.3 44.6 35.9 27.3
(P3 relief) 37.7 16.8 14.3 11.8 9.5 7.2

MPa 17.5 20.0 22.5 25.0 27.5 29.4

Pressure kgf/cm2 178.5 203.9 229.4 255.0 280.0 300.0
psi 2538.2 2900.8 3263.3 3630.0 3990.0 4260.0
103.4 82.9 63.0 49.2 40.5 29.9
P mode
27.3 21.9 16.6 13.0 10.7 7.9
53.4 44.8 37.2 28.6
E mode – –
L/min 14.1 11.8 9.8 7.6
P mode U.S.gals 39.3 31.4
– – – –
(P3 relief) 10.4 8.3
E mode 19.5
– – – – –
(P3 relief) 5.1

RY9212148HYS0370US0

3-S159 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

(2) Flow Rate Data for AUX Proportional Control (Measured Values)

(1) Left (Max) (1) Left (Idle) (A) AUX1 (a) Max Flow Setting
(2) Right (Max) (2) Right (Idle) (B) AUX2 (Limit Value)
(b) Flow Volume L/min

The relationship between pressure P, flow Q and lever knob operation (limit value) changes proportionally as
shown in the figures above.

CAUTION
• Measured values may vary with the machine.
RY9212148HYS0313US0

3-S160 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

(3) AUX Discharge Flow Rate Data (Measured Values)

(1) P Mode (a) Pressure (MPa) (A) AUX1

(2) E Mode (b) Flow Rate L/min (B) AUX2

CAUTION
• Measured values may vary depending on the machine.
• This measurement data is of the values set for the max discharge flow rate. (limit=max)
RY9212148HYS0353US0

3-S161 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

[2] RELIEF PRESSURE (MEASURED VALUES)

Item Notes

Travel right main pressure (aTR)

30.0 ± 0.5 MPa
306 ± 5 kgf/cm2
4351 ± 73 psi
Travel left main pressure (aTL)

27.5 ± 0.5 MPa

Main LS pressure (aLS) 281 ± 5 kgf/cm2
3989 ± 73 psi
21.5 ± 0.5 MPa
Main P3 pressure (aP3) 219 ± 5 kgf/cm2
3118 ± 73 psi
2.9 ± 0.2 MPa
Unload LS valve pressure (aUN) 30 ± 2 kgf/cm2
420 ± 29 psi
4.2 ± 0.2 MPa
Pilot primary pressure (aPP) 43 ± 2 kgf/cm2
610 ± 29 psi
3.6 ± 0.2 MPa
P mode 37 ± 2 kgf/cm2
522 ± 29 psi
2.8 ± 0.2 MPa
P mode (AC ON) 28.6 ± 2 kgf/cm2 Compressor: ON
EP proportional solenoid 406 ± 29 psi
pressure 0 MPa
E mode 0 kgf/cm2
0 psi
1.6 ± 0.2 MPa
E mode (during
16.3 ± 2 kgf/cm2
operation)
232 ± 29 psi

Bottom (b1B)
31.4 ± 1.0 MPa
Boom 320 ± 10 kgf/cm2
4554 ± 145 psi
Rod (b1R)

30.4 ± 1.0 MPa

Bottom (b2B) 310 ± 10 kgf/cm2
4409 ± 145 psi
Arm
31.4 ± 1.0 MPa
Rod (b2R) 320 ± 10 kgf/cm2
4554 ± 145 psi

Bottom (b3B)
31.4 ± 1.0 MPa
Bucket 320 ± 10 kgf/cm2
4554 ± 145 psi
Rod (b3R)

27.4 ± 1.0 MPa

Bottom (b4B) 279 ± 10 kgf/cm2
3974 ± 145 psi
Blade
19.5 ± 1.0 MPa
Measurement location: P3
Rod (b4R) 200 ± 10 kgf/cm2
pressure test port
2830 ± 145 psi

3-S162 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

Item Notes

Left (b6L)
22.5 ± 1.0 MPa
AUX1 230 ± 10 kgf/cm2
3260 ± 145 psi Measurement location: P1, P2
Right (b6R)
pressure test ports

22.5 ± 1.0 MPa

Bottom (b8B) 230 ± 10 kgf/cm2
3260 ± 145 psi
Angle
31.4 ± 1.0 MPa
Rod (b8R) 320 ± 10 kgf/cm2
4554 ± 145 psi

RY9212158HYS0103US0

[3] SWIVEL PERFORMANCE

Item Notes
315 ml/min Measured eference value for
Swivel motor drain volume When turning
19.22 cu.in./min new machines.
≤43.2 mm
When stopped
≤1.70 in.
Swivel block performance
≤43.2 mm
At idle
≤1.70 in.

Swivel speed 3 revs 17.1 to 20.9 sec

RY9212148HYS0348US0

[4] TRAVEL PERFORMANCE

Item Notes
75 ml/min
When turning (1st spd.)
4.58 cu.in./min
300 ml/min
When locked (1st spd.)
18.31 cu.in./min Measured eference value for
Travel motor
260 ml/min new machines.
When turning (2nd spd.)
15.87 cu.in./min
330 ml/min
When locked (2nd spd.)
20.14 cu.in./min
0 mm
Travel block performance
0 in.
1st 12.0 to 15.0 sec
Rubber
2nd 6.9 to 8.6 sec
Travel speed
1st 12.9 to 16.4 sec
Steel
2nd 7.2 to 9.0 sec
≤600 mm
Amount of travel drift
≤23.6 in.

RY9212148HYS0380US0

3-S163 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

[5] CYLINDER SPEED

Item Notes
Ground to max
3.1 ± 0.3 sec
Boom lift
Max lift to ground 3.4 ± 0.3 sec
Crowd 3.4 ± 0.3 sec
Arm
Dump 3.2 ± 0.3 sec
Crowd 3.1 ± 0.3 sec
Bucket
Hydraulic Dump 2.2 ± 0.3 sec
cylinder Left 7.5 ± 0.7 sec
operating time Swing
Right 7.7 ± 0.7 sec
Max down to
2.3 ± 0.3 sec
Max up
Blade
Max up to Max
3.0 ± 0.3 sec
down
Left 2.1 ± 0.3 sec
Angle (Angle spec.)
Right 2.3 ± 0.3 sec
Factory spec. ≤ 20.0 mm
when new ≤ 0.79 in.
Boom
≤ 100.0 mm
Usage limit
≤ 3.94 in.
Factory spec. ≤ 20.0 mm
when new ≤ 0.79 in.
Arm
≤ 100.0 mm
Usage limit
Hydraulic ≤ 3.94 in.
cylinder drift Factory spec. ≤ 10.0 mm
when new ≤ 0.39 in.
Bucket
≤ 50.0 mm
Usage limit
≤ 1.97 in.
Factory spec. ≤ 20.0 mm
when new ≤ 0.79 in.
Blade
≤ 100.0 mm
Usage limit
≤ 3.94 in.
Factory spec. ≤ 10.0 mm
when new ≤ 0.39 in.
Swing cylinder deviation
≤ 50.0 mm
Usage limit
≤ 1.97 in.

RY9212158HYS0110US0

3-S164 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM

14. TROUBLESHOOTING
[1] TROUBLESHOOTING ALL ACTUATORS
When all actuators are slow or fail to work
• Likely to be a problem in the pilot system and/or with the engine.
• Check for problems in hydraulic oil level and/or quality.
No. Cause Remedy Notes
Low engine RPM • Check the engine RPM
• Inspect fuel lines and air intake lines
1
• Test the accelerator dial
• Meter panel settings
Faulty limit switch • Check the operation of the limit switch
Move the unload lever up/down and check for continuity in the tester
2
mode.
(when locked: OFF, when released: ON)
Faulty unload valve • Check unload valve operation
3 1. Disconnect the unload valve connector and test for continuity.
2. Check for damage to the spool.
Pilot primary pressure relief valve (aPP) • Measure pilot primary pressure
4
faulty 1. Disassemble, clean and adjust or replace the relief valve
Pump fitting • Replace pump connector
5
Connector faulty
Pump drive shaft damaged • Replace shaft
6

RY9212148HYS0354US0

[2] TROUBLESHOOTING FRONT SYSTEMS

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 Remedy Notes
Defective pilot valve • Measure the pilot secondary pressure
1

• Leak inside a cylinder • Measure the hydraulic drift

• Leak inside a control valve 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
2. Test the hydraulic drift again.
[Assessment]
Within factory specs: control valve and/or overload relief valve faulty
Outside specs: replace cylinder seals
Overload relief valve faulty • Diagnose the overload relief valve
3 Temporarily replace with a known good overload relief valve and
determine whether faulty or not.
Main spool inside control valve sticking or • Inspect the main spool or replace the valve
damaged 1. Take the main spool out of the control valve and clean it.
4
2. After applying hydraulic oil, check whether it slides properly and
return to the control valve.
Pressure compensation valve sticking • Inspect the pressure compensation valve
1. Take the pressure compensation valve out of the control valve and
5 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 HYDRAULIC SYSTEM
Boom operation slow or jerky

No. Cause Remedy Notes

Anti-drop check valve sticking or • Inspect the anti-drop check valve
1 damaged 1. Remove the anti-drop check valve from the control valve.
2. Check the inside and inspect for abnormalities.
Shockless valve faulty • Clean or replace the shockless valve
2

P3 bypass spool sticking 1. Clean the spool

3
2. Replace the valve

RY9212158HYS0109US0
Arm operation slow or jerky

No. Cause Remedy Notes

Arm regenerative valve faulty • Inspect the arm regenerative valve
1 1. Take the spool out of the control valve and clean it.
2. Check the inside and inspect for abnormalities.

RY9212148HYS0357US0
Swing slow or fails to move

No. Cause Remedy Notes

Swing external orifice faulty • Clean swing external orifice
1
If same thing happens: problem with anti-void and/or shut-off valves

RY9212148HYS0358US0
Swing extends or contracts

No. Cause Remedy Notes

Anti-void faulty • Disassemble and clean or replace the anti-void valve
1 1. Seat NG: extends
2. Suction NG: makes it sway

RY9212148HYS0359US0
When lever operated, it goes down and then back up

No. Cause Remedy Notes

Load check valve inside the control valve • Inspect the load check valve.
1
faulty Remove and clean the load check valve.

RY9212148HYS0360US0
A great deal of hydraulic drift.

No. Cause Remedy Notes

1. Leak inside a cylinder • Measure the hydraulic drift
2. Leak inside a control valve If hydraulic drift is outside of factory specs, take the following steps.
1. Exchange hoses with a normally operating section (on control
valve side).
1
2. Test the hydraulic drift again.
[Assessment]
Within factory specs: control valve and/or overload relief valve faulty
Outside specs: cylinder seals faulty
Overload relief valve faulty • Diagnose the overload relief valve
2 Temporarily replace with a known good overload relief valve and
determine whether faulty or not.

RY9212148HYS0361US0

3-S166 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM
Slow during multiple operations

No. Cause Remedy Notes

Seat of unload LS valve (aUN) faulty • Measure unload LS valve pressure
1
1. Disassemble and clean or replace the relief valve
Seat of main LS valve (aLS) faulty • Measure main LS valve pressure
2
1. Disassemble, clean and adjust or replace the relief valve
Horsepower control valve faulty or loose Check and adjust for loose nuts
3

RY9212148HYS0362US0

[3] TRAVEL SYSTEM TROUBLESHOOTING

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. Cause Remedy Notes
1 Travel pilot valve filter blockage Clean the pilot valve filter
Pp2, Pp4 filters and/or orifices
2 Clean the filters and orifices
blocked
• 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
Independent travel valve's sub-spool
3 clean it.
and/or main spool sticking
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. Cause Remedy Notes

Defective travel pilot valve • Measure the pilot secondary pressure
1

Travel main relief valve faulty • Temporarily swap main relief valves forwards/backwards or left
right.
[Assessment]
2 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
Main spool inside control valve or • Swap the left-right travel hoses on the control valve side and see
travel section is sticking or damaged if the problem changes sides too.
3 [Assessment]
If problem switches sides: main spool is sticking or damaged
If problem doesn't change: swivel joint and/or travel motor are faulty
Defective travel motor • Measure the drain volume
[Assessment]
4
If within factory specs: swivel joint is faulty
If outside specs: travel motor is faulty
Swivel joint faulty • Swap the left/right travel hoses (swivel joint to travel motor) on the
5
swivel joint side and see if the problem changes sides too.

RY9212148HYS0365US0

3-S167 KiSC issued 08, 2015 A

KX080-4, WSM HYDRAULIC SYSTEM
Won't switch to high-speed travel
• Check whether the travel speed switch is switching in the tester mode.
No. Cause Remedy Notes
Faulty 2nd speed solenoid valve at • Check 2nd speed solenoid valve operation
1 unload unit 1. Check whether there is electricity to the unload valve.
2. Check whether the spool is switching inside.
• Defective travel motor • Measure the pressure at the travel motor 2-speed switch port.
• Swivel joint faulty [Assessment]
2
Rated pressure: travel motor faulty
Below rated pressure: swivel joint faulty

RY9212148HYS0366US0

[4] SWIVEL SYSTEM TROUBLESHOOTING

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 Remedy Notes
Defective pilot valve • Measure the pilot secondary pressure
1

Slow return valve faulty Clean or replace the slow return valve
2

Timer valve sticking or damaged Clean or replace the timer valve

3

Swivel shuttle valve faulty • Measure the timer valve release pressure
4 (When swivel left/right, or at arm crowd)
• Clean or replace the swivel shuttle valve
Swivel relief valve faulty • Temporarily swap the left/right swivel relief valves.
[Assessment]
5 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
Anticaviation valve faulty • Swap anticavitation valves
[Assessment]
6 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
Swivel motor faulty • Measure the drain volume
7

Main spool inside control valve • Inspect the main spool or replace the valve
sticking or damaged 1. Take the main spool out of the control valve and clean it.
8
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 HYDRAULIC SYSTEM
Swivel drifts
• Identify whether the fault is in the main system or the pilot system.
No. Cause Remedy Notes
Slow return valve faulty Clean or replace the slow return valve
1

Anti-void valve faulty Clean or replace the anti-void valve

2

Timer valve sticking or damaged Clean or replace the timer valve

3

Pilot valve spool damaged Check that the pilot valve spool returns to neutral.
4

Swivel relief valve faulty • Temporarily swap the left/right swivel relief valves.
[Assessment]
5 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
Anticaviation valve faulty • Clean or replace the anticavitation valve
[Assessment]
6
If problem is not resolved: the main spool is sticking or damaged or
the swivel motor is faulty
Swivel motor faulty • Measure the drain volume
7

Main spool inside control valve • Inspect the main spool or replace the valve
sticking or damaged 1. Take the main spool out of the control valve and clean it.
8
2. After applying hydraulic oil, check whether it slides properly and
return to the control valve.

RY9212148HYS0368US0

[5] TROUBLESHOOTING MULTIPLE OPERATIONS

Front fails to operate during multiple operations or while traveling

No. Cause Remedy Notes

• Communication valve sub-spool • Inspect the sub and main spools or replace the valve
sticking 1. Take the spool out of the control valve and clean it.
1
• Communication valve main spool 2. After applying hydraulic oil, check whether it slides properly and
sticking return to the control valve.

RY9212148HYS0369US0

3-S169 KiSC issued 08, 2015 A

4 ELECTRICAL SYSTEM

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. LAYOUT OF ELECTRICAL DEVICES AND WIRING

ROUTING
[1] PRECAUTIONS ON HOW TO CLAMP THE ELECTRICAL WIRING
1. Do not touch the wiring or the area around it.
Do not touch where uncovered.
2. Do not clamp to fuel hoses.
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 (A) Harness
(Insert Firmly Until it Catches.) (B) Clamp the Harness so It Stays in
(2) Screw Type Position and Does Not Move.
(Insert to the End of the Screw.) Insert the End of the Cable Tie
(3) and (4) Insert Type : Insert Until it Into the Hole on the Other Side to
Locks. Clamp the Harness.
RY9212001ELS0025US0

[2] PRECAUTIONS ON HANDLING ELECTRICAL CONNECTORS

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 ELECTRICAL SYSTEM
Colors of Wiring

Color of wiring Color code Color of wiring Color code

Black B Blue / Green L/G
Green G Blue / Orange L/Or
Blue L Blue / Red L/R
Pink P Blue / White L/W
Red R Blue / Yellow L/Y
White W Light Green / Blue Lg/B
Yellow Y Light Green / Red Lg/R
Brown Br Light Green / White Lg/W
Gray GY Light Green / Yellow Lg/Y
Light Green Lg Orange / White Or/W
Orange Or Pink / White P/W
Sky Blue Sb Pink / Blue P/L
Black / Green B/G Red / Black R/B
Black / Blue B/L Red / Green R/G
Black / Pink B/P Red / Blue R/L
Black / Violet B/V Red / White R/W
Black / Red B/R Red / Yellow R/Y
Black / White B/W Violet / White V/W
Black / Yellow B/Y White / Black B/W
Brown / Black Br/B White / Green W/G
Brown / Yellow Br/Y White / Blue W/L
Brown / Red Br/R White / Red W/R
Green / Black G/B White / Yellow W/Y
Green / Blue G/L Yellow / Black Y/B
Green / Red G/R Yellow / Green Y/G
Green / White G/W Yellow / Blue Y/L
Green / Yellow G/Y Yellow / Red Y/R
Blue / Black L/B

(Ex.)
1.25-Y/R means :
1.25 : Wire size (mm2)
Y : Base color (yellow)
R : Stripe color (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.

(a) Wire Size (mm2) (c) Stripe Color

(b) Insulation Base Color
RY9212038ELS0009US0

4-S2 KiSC issued 08, 2015 A

KX080-4, WSM ELECTRICAL SYSTEM

[3] LAYOUT AND WIRING ROUTING

(1) RPM sensor (5) Fuel level gauge (b) Must not interfere with hood (d) To starter relay
(2) Fuel filter heater (6) Ground cable lock bracket (e) To (+) battery terminal
(3) AC switch (7) Condenser fan (c) Fuel pump harness to pass
(4) Fuel pump (a) To main harness to the inside of the battery
cable.
RY9212158ELS0017US0

4-S3 KiSC issued 08, 2015 A

KX080-4, WSM ELECTRICAL SYSTEM

(1) DPF pressure differential (8) AC switch (13) Oil switch (a) To starter relay
sensor (9) Engine ECU (14) Water level switch (b) Be sure to install fuel pump
(2) Boost sensor (10) Travel alarm buzzer (optional) (15) NE sensor connector so it is vertical
(3) Air intake temperature sensor (11) Fuel pump (16) G sensor harness (c) To fuel supply pump
(4) EGR valve (12) (+) battery cable (17) Water temperature sensor (d) To main harness
(5) Air flow sensor (18) Air intake throttle valve
(6) Compressor
(7) Alternator
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 (3) DPF outlet temperature (5) DPF outlet temperature (7) Fuel temperature sensor
sensor 0 (black) sensor 2 (white) sensor connector 1 (dark
(2) DPF outlet temperature (4) DPF outlet temperature gray) (a) From engine harness
sensor 1 (dark gray) sensor connector 0 (black) (6) DPF outlet temperature
sensor connector 2 (white)

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 (b) To engine harness (d) Harness connector (f) To angle solenoid
(a) To front (c) To AC unit (e) Ground (g) To travel pressure sensor
RY9212158ELS0020US0

(1) Limit switch (2) Main ECU (a) To AC unit (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 (4) DPF inhibit switch (7) Worklight switch (10) Relay connector (12-pin)
(2) AI console (5) Engine stop knob (8) Relay connector (2-pin) (11) Relay connector (16-pin)
(3) EP switch (6) Beacon switch (9) Relay connector (8-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 (b) To main harness (c) Clamp wiring
clamps
RY9212158ELS0022US0

4-S9 KiSC issued 08, 2015 A

KX080-4, WSM ELECTRICAL SYSTEM

2. METER PANEL OPERATION

[1] NAMES AND FUNCTIONS OF METERS
Normal display

(1) User Setting Switch (Switch 1) (8) Hour Meter - Engine Tachometer
(2) Overload Warning Switch (Switch 2) (9) Fuel Gauge
(3) AUX Port Enable Switch (Switch 3) (10) Warning Lamp (Red, Yellow)
(4) Information Switch (Switch 4) (11) Oil Lamp
(5) Display Selector Switch (Switch 5) (12) Charge Lamp
(6) Clock Display (13) 2-Speed Indicator Lamp
(7) Water Temperature Gauge
RY9212148ELS0001US0

Display at menu-selection

(1) Direction cursor switch (Switch 1) (4) Cursor Move Switch (Switch 4)
Stop each setting and return to the (5) Save switch (Switch 5)
original screen. Decision of the Selection Item.
(2) Cursor move switches (Switch 2) Selecting the Item at the
Move Down the Selection Item. Menu-Selection Position.
Move Down the Menu-Selection
Position.
(3) Cursor Move Switches (Switch 3)
Move Up the Selection Item.
Move Up the Menu-Selection
Position.
RY9212007ELS0002US0

[2] USER SETTINGS MODE

• Turn the key from OFF to ON and press switch 1 to enter the user settings mode.
Item Description

(1) Log Record 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
(2) Periodic Check
conducting periodic inspections.

(3) Set Clock Sets the clock.

(4) Set AUX Flow Ctrl Sets the AUX flow control.

(5) Various Settings Allows you to change the order of the date display and the clock display method.

(6) Language Setting Changes the language of the meter panel display.

RY9212148ELS0002US0

4-S10 KiSC issued 08, 2015 A

KX080-4, WSM ELECTRICAL SYSTEM

(1) Log Record

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

(2) Days not in Use (5) Horizontal Axis (Day)
(3) Hours Used for Selected Date
RY9212148ELS0016US0

(2) Periodic Check

• 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.)

Hour meter indication

No. Check Item Interval Subsequently
50 100 250 500 600 750 1000
1 Engine oil (CJ-4)   Every 500 hrs
Change
2 Hydraulic oil  Every 1000 hrs
Outer element  Every 1000 hrs
3 Air cleaner element
Inner element  Every 1000 hrs
Replace
4 Fuel filter   Every 500 hrs
5 Engine oil filter   Every 500 hrs
6 Travel motor gear oil Change    Every 500 hrs
7 Hydraulic return filter   Every 500 hrs
8 Hydraulic suction filter Replace  Every 1000 hrs
9 Pilot filter  Every 1000 hrs
10 Grease idler and track rollers – Every 2000 hrs
11 DPF clean Every 3000 hrs
 First operation
RY9212158ELS0005US0

(3) Set Clock

• 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

(4) Set AUX Flow Ctrl

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

(5) Various Settings

• Allows you to change the order of the date display and the clock display method.
1. Select Various Settings and then Calendar.
2. Select the date and clock display methods as desired.

N.A. and Australia Specs MDY/AM-PM

When shipped Eur. spec. DMY/24 Hour
Japan spec YMD/AM-PM

(1) Select the Y/M/D Display Order (2) Select Either AM-PM or 24 Hour
Display
RY9212148ELS0023US0

(6) Language Setting

• 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

[3] SERVICE DEALER SETTING

• 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

(1) Crane Mode

• 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

(2) Arm Control Mode (Only on Japan Spec.)

• 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

[4] SERVICE/DEALER MODE

• Turning the key ON while holding down SW5 puts the machine in the service/dealer mode.
• Select a language. (Eur. spec.: 5 languages, US spec.:1 language, Canada spec.: 2 languages)
• There are 2 items in the service/dealer mode, namely "Diagnosis" and "Setting," which allow you to check/set the
content in the tables below.
Mode Item Description Notes
Checks the data from each sensor and
[A] Tester
switch.
(1) Diagnosis
[B] Retrieve Fail Record Checks the record of past failures.
[C] Delete Fail Record Deletes the record of past failures.
Make the setting when the AI motor,
accelerator dial or governor sensor is
[A] AI Set
touched. Also make the setting when
part(s) are replaced.
(A) Knob Set Set when the AUX1 knob is replaced.
Set when the AUX1 proportional valve
(B) (w/attach) Start Point Set and/or spool are replaced. (w/
attachment mounted)
[B] AUX1 Set Set when the AUX1 proportional valve
(C) (w/o attach) Start Point Set and/or spool are replaced. (w/ pressure
gauge mounted)
Make setting when the AUX1 start point
(D) Feeling Adj.
is inaccurate.
Make setting when the AUX2 knob is
(A) Knob Set
replaced.
Set when the AUX2 proportional valve,
(B) (w/attach) Start Point Set spool and/or ECU are replaced. (w/
attachment mounted)
[C] AUX2/Thumb Set
Set when the AUX2 proportional valve,
(C) (w/o attach) Start Point Set spool and/or ECU are replaced. (w/
pressure gauge mounted)
(2) Setting
Make setting when the AUX2 start point
(D) Feeling Adj.
is inaccurate.
Set when the AS position meter is
(A) Front Angle Set
replaced.
Set when the AS 4-way proportional
(B) Start Point Set
valve and/or control valve are replaced.
Only on RX series
[D] AS Set Set when you wish to change the (Japan)
(C) Feeling Adj. sensitivity of the AS cylinder end
cushion feel.
Set when using a bucket that is wider
(D) Bucket Set
than the standard bucket.
Set when the crane's position meter is
(A) Front Angle Set
replaced.
Make the setting when the AI motor, Crane spec. only
[E] Crane Set
accelerator dial or governor sensor is (Japan)
(B) Maximum Set
touched. Also make the setting when
part(s) are replaced.
Sets/changes the overload warning
[F] Over Load Warning Eur. spec. only
pressure.
Set when the ECU and/or meters are
[G] Model Set
replaced.

4-S14 KiSC issued 08, 2015 A

KX080-4, WSM ELECTRICAL SYSTEM

Mode Item Description Notes

Moves the AI motor position when the
(A) AI Motor Drive
accelerator dial is replaced.
Operates AUX2 via the AUX1 knob. Or
(B) Exchange (AUX1) (2/Thumb)
operates AUX1 via the AUX2 knob.
Changes the method of canceling the
(C) Periodic Check Selection periodic check guidance to automatic or
to manual.
Turns off the display of periodic check
(D) Periodic Check Display
guidance. Or turns it on.
Turns on the display of annual check
(E) Annual Guidance
guidance. Or turns it off.
When the meter is replaced, sets the
(2) Setting [H] Others periodic check time prior to
(F) Periodic Check Set
replacement to prevent a discrepancy
in the periodic check time.
Turns the message, "Set clock" to be
(G) Clock Set Warning (Y/N) displayed/not when the clock has the
wrong time.
Set when making fine adjustments to
(H) Arm Control Adj Japan spec. only
the stop position of the arm crowd limit.
Changes the operating conditions of the
(I) Multipurpose Mode
multi-purpose switch.
Checks all the fail records since the
(J) All Fail Record
machine was shipped.
(K) Opening Select Changes the opening display screen.

RY9212148ELS0028US0

4-S15 KiSC issued 08, 2015 A

KX080-4, WSM ELECTRICAL SYSTEM

(1) Diagnosis
[A] Tester
• Makes it possible to check the data from each sensor and switch.
• Determines when a setting is outside parameters and when a switch or solenoid is irregular in terms of continuity.
• Selecting Diagnosis → Tester puts it into this diagnosis mode.

(To be continued)

4-S16 KiSC issued 08, 2015 A

KX080-4, WSM ELECTRICAL SYSTEM
(Continued)
Scre
en Content displayed Description/std. value Notes
No.
Engine RPM • Current value (n/min)
Battery voltage • Battery voltage ± 0.5V
Oil switch • Prior to engine start: ON
1
• After engine start: OFF
Charge
• Key in the Start position: ON
Starter
• Key in any other position: OFF
• Current value (V) Common rail spec. voltage
Water temperature
• Current value (°C) (V) is dummy data
• Current value (V)
• Current value (Ω)
When cut off When shorted
Voltage 5.0 V 0V
Resistance 260Ω 0Ω
[NOTE]
2 Fuel
KX080
Full 5Ω or less
Showing 1/2 42.19 Ω
3 dots remaining 101.0 Ω
Empty 101.0Ω or higher
• Fuel low warning displayed when 3 dots remaining.
• Press switch: ON
Fuel supply switch
• Release switch: OFF
• Press switch: ON
2-speed switch
• Release switch: OFF
• With output signal from ECU: ON
2-speed solenoid
• No output signal from ECU: OFF
3 • Lever down: ON
Lever lock switch
• Lever up: OFF
• With output signal from ECU: ON
Lever lock solenoid
• No output signal from ECU: OFF
Oil temperature sensor • Dummy data
• Current value: 1.50 to 3.30 V
Accelerator POT
• Current value: idle, MAX
• Current value: 0.25 to 4.75 V
4 Governor POT
• Current value: idle, MAX Common rail spec. is dummy
• AI motor operating: 0.0 to 15.0A data
Motor amperage
• AI motor stopped: 0.0 to 2.0 A
• Not operating: ON
AI pressure switch
• Operating: OFF
• Press switch: ON
AI control switch
• Release switch: OFF
5
Compressor • Operating: ON
Water temperature • Current value (°C)
Common rail spec. is dummy
Idle up • Idle up setting value (V)
data
• Current value: 0.25 to 4.75 V
AUX1 • Setting value: left or right
• Setting value: neutral
Only for models equipped
6 • Operating: 0.5 to 2.0 A with AUX1 proportional
Amperage
• Stopped: 0 to 0.2A control (EU, N.A.)
• Press switch: ON
AUX hold switch
• Release switch: OFF

4-S17 KiSC issued 08, 2015 A

KX080-4, WSM ELECTRICAL SYSTEM

Scre
en Content displayed Description/std. value Notes
No.
• Current value: 0.25 to 4.75 V
AUX2 • Setting value: left or right
• Setting value: neutral
Only for models equipped
7 • Operating: 0.5 to 2.0 A with AUX2 proportional
Amperage
• Stopped: 0 to 0.2A control (EU, N.A.)
• Press switch: ON
AUX hold switch
• Release switch: OFF
AUX1 right setting
AUX1 left setting Only for models equipped
8 • Aux start point setting value with AUX proportional control
AUX2 right setting (EU, N.A.)
AUX2 left setting
Arm POT • Current value: 0.25 to 4.75 V
Arm limit setting value • Arm stop setting value Arm limit spec only Japanese
9
models
• With output signal from ECU: ON
Arm limit solenoid
• No output signal from ECU: OFF
• Antenna working normally: O
Anti-theft antenna
• Antenna malfunction: X
Have key: O Anti-theft mode: O
On/off enabled/cancelled
No key: X Anti-theft off: X
Same black key: O
Same red key: O
Red key, Black key Wrong red or black
Different red key: X If unknown or Anti-Theft
10 key: X
deactivated: –
Same yellow key: O Same green key: O
Yellow or green key Different yellow key: Different green key:
X X
Same yellow key: O Same green key: O
(Tag) yellow or green Different yellow key: Different green key:
X X
Angle right switch • Press switch: ON
Angle left switch • Release switch: OFF
Angle spec. only N.A.
11
Angle right solenoid models
• With output signal from ECU: ON
Angle left solenoid • No output signal from ECU: OFF

Tilt right switch • Press switch: ON

• Release switch: OFF
Tilt left switch
12 Tilt spec. only N.A. models
Tilt right solenoid • With output signal from ECU: ON
Tilt left solenoid • No output signal from ECU: OFF

Actual load • Current value (kg)

Rated load • Current value (kg)
13 Radius • Current value (mm)
Height • Current value (mm)
Travel pressure • Current value (MPa) Crane spec. only Japanese
• Current value: 0.25 to 4.75 V models
Arm POT
• Setting value: arm crowded, arm dump end
• Current value: 0.25 to 4.75 V
14 Boom POT
• Setting value: boom up end
Bottom pressure, rod
• Current value: 0.50 to 4.50 V
pressure
• Current value (V)
Boom bottom pressure
• Current value (MPa) Only EU models
15 Warning pressure • Current value (MPa)
• Current value (V)
Boom rod pressure Dummy data
• Current value (MPa)

4-S18 KiSC issued 08, 2015 A

KX080-4, WSM ELECTRICAL SYSTEM

Scre
en Content displayed Description/std. value Notes
No.
Multi-purpose1 switch 1 (AI
control dial) • Press switch: ON
Multi-purpose2 switch 2 • Release switch: OFF
16
(AUX left knob)
Multi-purpose switch • With output signal from ECU: ON
solenoid • No output signal from ECU: OFF
Compressor • Operating: ON
• Stopped or fine operation: ON
Boom up pressure switch
• Full stroke operations: OFF
• Press switch: ON
EP switch
• Release switch: OFF
• Current amperage (A)
KX080-4 (2-piece
17 KX080-4
boom spec.)
P mode (AC OFF) 0 mA
AC is Air Conditioner
EP solenoid P mode (AC ON) 600 mA
E mode (During
travel or full boom up 940 mA 840 mA
stroke operation)
E mode 1650 mA
• Current value (V)
Travel pressure sensor
• Current value (MPa)

18 DPF switch
• Press switch: ON
Worklight switch
• Release switch: OFF
Stop engine switch
Boom POT
Arm POT • Current value: 0.25 to 4.75 V
19 Offset POT
Setting Bo Ar • Setting value: boom up, arm crowded
Setting Of • Setting value: offset right
Boom solenoid
• Operating: 0.4 to 1.2 A
Arm dump/crowd
• Stopped: 0.0 to 0.6A
20 Offset solenoid Only on RX series (Japan)
Setting ArD ArC • Start point setting: arm dump, arm crowd
Setting Bo Of • Starting point setting: boom up, offset right
• Press switch: ON
Emergency switch
• Release switch: OFF
• During boom up operation: ON
21 Boom up pressure switch
• Not operating: OFF
• Normally: ON
Boom height limit
• At height limit: OFF
Meter • Normally: O [If the meter exists, then O]
ECU (main) • Normally: O [If the ECU (main) exists, then O]
22
ECU (AS) • Normally: O [If the ECU (AS) exists, then O] Only on RX series (Japan)
ECU (CRS) • Normally: O [If the ECU (CRS) exists, then O]
Meter
Ver • Program version
23
Rev • Program creation date (Y/M/D)
Serial No. • Serial no. (different number each machine)

4-S19 KiSC issued 08, 2015 A

KX080-4, WSM ELECTRICAL SYSTEM

Scre
en Content displayed Description/std. value Notes
No.
ECU (main)
Ver • Program version
24
Rev • Program creation date (Y/M/D)
Serial No. • Serial no. (different number each machine)
ECU (AS)
Ver • Program version
25 Only on RX series (Japan)
Rev • Program creation date (Y/M/D)
Serial No. • Serial no. (different number each machine)

RY9212148ELS0029US0

[B] Retrieve Fail Record

• Checks the record of past failures.
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 (3) Date and hour meter of initial
ECU (main or meter or AS) that occurrence and date and hour
detected it meter of last occurrence
(2) Number of occurrences (1 to 255)
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

(2) Setting
[A] AI Set
• Make the setting when the AI motor, accelerator dial or governor sensor is touched. Also make the setting when
part(s) are replaced.
1. Select Setting → AI set.
2. Follow the instructions on the meter panel.
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

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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 ELECTRICAL SYSTEM

[D] AS Set (Japan Spec. Only)

[Display when not the Japan spec.]
RY9212148ELS0042US0

[E] Crane Set (Japan Spec. Only)

[Display when not the Japan spec.]
RY9212148ELS0043US0

[F] Overload Warning (Eur. Spec. Only)

• Sets/changes the overload warning pressure.
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. Content displayed Notes

(1) Model name
(2) Destination
(3) AI
Eur. spec.: YES
(4) Overload Warning
N. Am. spec.: NO
(5) AUX1
(6) AUX2 / Thumb
(7) Arm Control Japan spec.: YES (Arm limit spec. only)
(8) Angle N. Am. spec.: YES (Angle spec. only)
(9) Tilt N. Am. spec.: YES (Tilt spec. only)
(10) Multipurpose Operating Has multi-purpose switch connector spec.: YES
2-piece boom spec.: 2
(11) Arm Type
Other specs.: 1
(12) Compartment
W/ eco mode spec.:1 (KX080-4)
(13) Force Mode W/AC mode spec.:2
No AC spec.: 0
(14) Common Rail System
(15) Setup Completed

RY9212158ELS0023US0

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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.
AUX1 AUX2
Normal Right control lever Left control lever
Reverse 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 Method for canceling periodic check guidance
Turn the key ON/OFF 10 times or operate the meter
Auto (N.A. spec.)
panel after making periodic checks.
Manual (Eur. spec.) 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

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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

(I) Multipurpose Mode

• Enabling the multi-purpose switch function on machines equipped with AUX1 and AUX2 makes 10 modes
available for use.
• Depending on the selected mode, it becomes necessary to add equipment to the machine, such as ON/OFF
switches, solenoid valves, wire harness, hydraulic hoses, etc.
• 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. Terminal Max rated amperage

<1> + Terminal 1A
<2> - Terminal –
RY9212148ELS0049US0

4-S29 KiSC issued 08, 2015 A

KX080-4, WSM ELECTRICAL SYSTEM

(b) Names of Parts

(1) Multi-Purpose Switch A (A) N.A. Spec.
(2) Indicator (B) Australia/Eur. Spec.
(3) Multi-Purpose Switch B
(4) AUX2/Thumb Hold Switch
(5) AUX2/Thumb Knob
RY9212148ELS0050US0

(c) Description of Each Mode

Mode No. 01: Enables the AUX2 hold switch.
• 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 (A) AUX2 signal
(2) Multi-Purpose Switch B
(3) AUX2/Thumb Hold Switch
(4) AUX2/Thumb Knob
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 (A) Multipurpose signal
(2) Multi-Purpose Switch B
(3) AUX2/Thumb Hold Switch
(4) AUX2/Thumb Knob
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 (A) Multipurpose signal
(2) Multi-Purpose Switch B
(3) AUX2/Thumb Hold Switch
(4) AUX2/Thumb Knob
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 (A) Multipurpose signal
(2) Multi-Purpose Switch B
(3) AUX2/Thumb Hold Switch
(4) AUX2/Thumb Knob
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

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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 (A) Multipurpose signal
(2) Multi-Purpose Switch B
(3) AUX2/Thumb Hold Switch
(4) AUX2/Thumb Knob
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 (A) Multipurpose signal
(2) Multi-Purpose Switch B
(3) AUX2/Thumb Hold Switch
(4) AUX2/Thumb Knob
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 (3) Date and hour meter of initial
ECU (main or meter or AS) that occurrence and date and hour
detected it meter of last occurrence
(2) Number of occurrences (1 to 255)
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

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KX080-4, WSM ELECTRICAL SYSTEM

(K) Opening Select

• Changes the opening display screen.
1. Select Setting → Others → Opening select.
2. Select the number of the desired display method.
3. Press SW5 to make the setting.

Number Screen display

(1) Silhouette of the excavator
(2) Kubota logo
• When shipped: 2
RY9212148ELS0063US0

4-S33 KiSC issued 08, 2015 A

KX080-4, WSM ELECTRICAL SYSTEM

[5] SETTINGS WHEN REPLACING ELECTRONIC DEVICES

(1) When Replacing the Meter or Main ECU

Content displayed Explanation

Press switch 5 "Yes" to overwrite data.
Press switch 1 "No" when checking whether another machine's meter or ECU
(1) Overwrite ECU with new data
that is temporarily installed is working or not.
If "No" is selected, the normal screen appears.
[Initializes saved settings.]
(2) Meter changed Press switch 5 "Yes" if the meter has been changed.
Press switch 1 "No" if the ECU has been changed.
(3) Need setup 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
(4) List of items that need to be set up
the settings.

IMPORTANT
• Never install an ECU from a previous model (spec. other than common rail) as doing so will damage the
ECU.
RY9212148ELS0064US0

(2) When the Battery is Removed

No. Content displayed Explanation

(A) STOP
(1) (B) RUN Install the battery and turn the key to [RUN].
(C) START
Press switch 5 "Yes" to set.
(2) Set Clock 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.
(3) Setting screen
• 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

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KX080-4, WSM ELECTRICAL SYSTEM

[6] TABLE OF METER PANEL MESSAGES AND ERROR HISTORY

LIST
(1) Red Warning Lamp Lit
When needed, pressing switch 4 displays a detailed description.
No. Screen display Pressing SW4 Message in fail record Reason detected/steps to take

a)Engine oil pressure low

[Meter]
1 – b)Oil switch always ON
Engine oil pressure error
c)Short in harness

[Meter] Engine overheated [118°C

2 –
Overheated (244°F)--automatically goes to idle]

Low alternator voltage detected

a)Alternator faulty
[Meter]
3 – b)Fan belt loose/off
Charging System Error
c)Break in harness
d)Fuse blown (10 A)

[Meter] a)Connector disconnected

4 –
Fuel Sensor Error b)Break in harness

a)Connector disconnected
[Meter]
CANSys (main) b)ECU (+B) fuse blown (5 A)
CAN Sys (Main)
c)Break or short in harness
5 a)Connector disconnected
[Meter] b)Slow blow fuse (CRS) blown (30 A)
CANSys (CRS)
CAN Sys (CRS) c)Engine ECU relay faulty
d)Break or short in harness

[Meter] Go through the model setup again. If this

6 –
Setup Data Error doesn't fix it, it's a faulty meter.

a) Water mixed with fuel in the fuel filter

[Main ECU] [Reference value:80 to 130 ml
7 –
Water mixed with fuel (0.07 to 0.11 lmp·qts, 0.08 to 0.14 U.S.qts)]
b)Short in the fuel filter line

[Main ECU]
8 2-speed solenoid a)2-speed solenoid line short
2-speed SOL

[Main ECU] a)AUX1 knob connector disconnected

AUX1 knob
AUX1 knob b)Break or short in harness
[Main ECU] a)AUX1 right solenoid connector disconnected
9 AUX1 right SOL
AUX1 right SOL b)Break or short in harness
[Main ECU] a)AUX1 left solenoid connector disconnected
AUX1 left SOL
AUX1 left solenoid b)Break or short in harness

4-S35 KiSC issued 08, 2015 A

KX080-4, WSM ELECTRICAL SYSTEM

No. Screen display Pressing SW4 Message in fail record Reason detected/steps to take
[Main ECU] a)AUX2 knob connector disconnected
AUX2/thumb knob
AUX2/thumb knob b)Break or short in harness
[Main ECU] a)AUX2 right solenoid connector disconnected
10 AUX2/thumb right SOL
AUX2/thumb right solenoid b)Break or short in harness
[Main ECU] a)AUX2 left solenoid connector disconnected
AUX2/thumb left SOL
AUX2/thumb left solenoid b)Break or short in harness

[Main ECU] a)Activated by 18V+

11 Over voltage
Over voltage b)Alternator faulty

[Main ECU]
Angle right solenoid a)Angle right solenoid line short
Angle right solenoid
12
[Main ECU]
Angle left solenoid a)Angle left solenoid line short
Angle left solenoid

[Main ECU] a)AI console connector disconnected

13 Accelerator sensor
Accelerator sensor b)Break or short in harness

a)Connector disconnected
[Main ECU]
14 Antenna b)Break in harness
Antenna
c)Antenna faulty

[Main ECU]
15 Lever lock solenoid a)Lever lock solenoid line short
Lever lock solenoid

[Main ECU]
16 Multipurpose SOL a)Multipurpose solenoid line short
Multipurpose solenoid

[Main ECU]
17 External 5V Short in 5V line
External 5V

18 1 to 64 – Engine system error

[Main ECU] a)Pressure sensor connector disconnected

Travel pressure
Travel pressure b)Break or short in harness
19
[Main ECU] a)EP solenoid connector disconnected
EP solenoid
EP solenoid b)Break or short in harness

RY9212158ELS0003US0

4-S36 KiSC issued 08, 2015 A

KX080-4, WSM ELECTRICAL SYSTEM

(2) Yellow Warning Lamp Lit

When needed, pressing switch 4 displays a detailed description.
No. Screen display Pressing SW4 Message in fail record Reason detected/steps to take

Fuel low
1 – –
Displayed at 6 minute intervals.

Water temperature rising.

2 – – Displayed at 6 minute intervals.
(110 to 117°C, 230 to 242°F)

Tried to start engine with an unregistered key

3 – –
(Anti-theft spec. only)

Tried to start engine with a red key (Anti-theft

4 – –
spec. only)

Suspended weight is over the rated load (Eur.

5 – –
overload warning spec. only)

6 Check location displayed – Displayed 10 hours before periodic check due

7 Check location displayed – Past time for periodic check

8 – – Annual check

9 – – The clock may have the wrong time.

RY9212148ELS0066US0

4-S37 KiSC issued 08, 2015 A

KX080-4, WSM ELECTRICAL SYSTEM

(3) Other Screens

No. Screen display Pressing SW4 Message in fail record Reason detected/steps to take

Switch 2 (crane) pressed on machine w/o

1 – –
overload warning

When meter or ECU replaced without doing

2 – –
setup

During setup after changing the meter or the

3 – – ECU, this screen comes up to confirm the
meter has been changed.

When neither the meter nor the ECU have

The setup item is
4 – been replaced, but some setting needs to be
displayed.
made.

If you attempt to start the engine with the lever

5 – –
lock still down.

If you press switch 3 (AUX) with the lever lock

6 – –
still up.

If you turned the key OFF but fail to take it out

7 – –
(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
8 – –
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.
9 – –
and press the AI switch.

If you press the multipurpose switch before

10 – –
registering it.

4-S38 KiSC issued 08, 2015 A

KX080-4, WSM ELECTRICAL SYSTEM

No. Screen display Pressing SW4 Message in fail record Reason detected/steps to take

During communication with the key (Anti-theft

11 – –
spec. only)

Displayed for 5 seconds when put in the E

12 – –
mode.

Displayed for 5 seconds when

13 – –
auto-regeneration of the DPF is inhibited.

Displayed for 5 seconds when the inhibition on

14 – –
DPF auto-regeneration is cancelled.

RY9212148ELS0067US0

4-S39 KiSC issued 08, 2015 A

KX080-4, WSM ELECTRICAL SYSTEM

(4) PM Clog Level and the State of the Machine

Inhibit switch ON
Clog Warning Engine
Buzzer Screen Content displayed Status and correction
Level lamp output
Level 0 OFF – – – – –
Level 1 OFF – – – – –

Regeneration of DPF is
Blinking ··PiPiPi··
Level 2 – inhibited. –
(Yellow) (Continue)
Allow regeneration.

··PiPiPi··
Regeneration of DPF is
(0 to 50 sec.)
inhibited.
50 % *2
Allow regeneration.
Pi-···Pi-
HP limited to low power.
(50 to 60 sec.)
Blinking
Level 3
(Red)

Engine forced to stop Turn and maximize the accelerator

Pi-···Pi-
– Increase RPM and dial and restart
(from 60 sec.)
restart *1

PiPiPiPi
Use the engine diagnosis tool and
(0 to 50 sec.)
Blinking DPF clogged up regenerate it manually
Level 4 50 %
(Red) Needs maintenance *1
Pi-···Pi-
*2
(from 50 sec.)

Blinking PiPiPiPi
Level 5 50 % Replace the DPF DPF is clogged. Needs replacement.
(Red) (Continue)

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 ELECTRICAL SYSTEM
Inhibit switch OFF
Clog Warning Engine Contents
Buzzer Engine RPM Screen Status and correction
Level lamp output displayed
Level 0 OFF – – – – – –
Exhaust More than 1900 engine RPM
temperature needed: DPF regenerates
··PiPiPi··
Blinking rising Less than 1900 engine RPM:
Level 1 (Every – –
(Yellow) Operate carefully DPF may not
60 sec.)
Can continue auto-regenerate due to open
working air and water temp.
Exhaust
temperature
More than rising
Being auto-regenerated
1900 rpm Operate carefully
Can continue
working
Exhaust
temperature
··PiPiPi··
Blinking rising
Level 2 (Every –
(Yellow) Operate carefully • When the engine RPM is
60 sec.)
Can continue low, DPF may not
Less than working auto-regenerate due to
1900 rpm open air and water temp.
• The screen changes
Increase engine every 3 sec.
RPM

Exhaust
temperature
rising
Operate carefully
Can continue
PiPiPi working • Being auto-regenerated
Blinking More than
(Every 50 % • The screen is changed
(Yellow) 1900 rpm
60 sec.) every 3 sec.

HP limited to low
power

Exhaust
temperature
rising
Level 3 • When the engine RPM is
Operate carefully
··PiPiPi·· Can continue low, DPF may not
(0-50 sec.) working auto-regenerate due to
50 % open air and water temp.
Pi-···Pi- • The screen changes
(50-60 sec.) Increase engine every 3 sec.
Blinking Less than RPM *2
(Red) 1900 rpm HP limited low
power

Engine forced to
Turn and maximize the
Pi-···Pi- stop
– accelerator dial and restart.
(from 60 sec.) Increase RPM
*1
and restart

PiPiPiPi Use the engine diagnosis

(0-50 sec.) DPF clogged up tool and regenerate it
Blinking
Level 4 50 % – Needs manually
(Red)
Pi-···Pi- maintenance *1
(from 50 sec.) *2

4-S41 KiSC issued 08, 2015 A

KX080-4, WSM ELECTRICAL SYSTEM

Clog Warning Engine Contents

Buzzer Engine RPM Screen Status and correction
Level lamp output displayed

Blinking PiPiPiPi DPF is clogged. Needs

Level 5 50 % – Replace the DPF
(Red) (Continue) replacement.

The engine rpm drops up to only 1900 rpm while pressing the AI switch.
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

KX080-4, WSM ELECTRICAL SYSTEM

(5) Table of Engine System Error Numbers

 Always happens
Symptom when error occurs
 May happen

Engine performance
No. Dis-
Error location Limited Limited Notes
played Won't start
RPM HP
1 RPM sensor system   
2 Fuel/rail pressure system    Fuel may run out.
3 SCV system error  
4 Intake temperature sensor system
5 Water temperature sensor system  
6 Fuel temperature sensor system
7 Injector system   
8 Intake pressure sensor system 
9 Battery voltage related   
10 Sensor voltage related   
11 Main relay related
12 Atmospheric pressure sensor related 
13 EGR valve related 
14 EGR starting to close warning
15 Emissions warning 
16 Air heater related
17 Engine ECU   
18 Communication error  
19 Mass airflow sensor related 
20 Intake throttle
21 Pressure differential sensor related
22 Exhaust temperature sensor (DOC intake)
23 Exhaust temperature sensor (DOC outlet)
24 Exhaust temperature sensor (DPF outlet)
25 Simultaneous break in all exhaust temperature sensors
26 DOC reaction  
27 DPF regeneration time up
28 Insufficient DPF regeneration water temperature rise
29 Regeneration too frequent 
30 Engine fuel system (P/L)  
31 Engine fuel system (rail pressure)  
32 Engine fuel system (fuel leak)   
33 Engine fuel system (SCV)   
34 Engine fuel system (Supply pump)  
35 Engine air intake system (Insufficient intake)  
36 Engine air intake system (Insufficient boost pressure)  
37 Engine exhaust temperature (DOC inlet temperature error) 
38 Engine exhaust temperature (DPF inlet temperature error) 
39 Engine exhaust temperature (DPF outlet temperature error) 
40 Starter relay start warning
60 Other errors   

RY9212148ELS0069US0

4-S43 KiSC issued 08, 2015 A

KX080-4, WSM ELECTRICAL SYSTEM

3. INSPECTIONS
[1] POWER AND GROUND
Battery
Check the voltage between the terminals
1. Connect a circuit tester between the (+) and (-) terminals of the
battery and measure the voltage across the terminals.
2. If the measurement is below factory specs, check the specific
gravity of the electrolyte.
Voltage between
Factory specification At least DC 12 V
terminals

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
Factory specification At least DC 0.1 V
terminals

(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

(1) A/C Controller (+B) (12) Cab Work Light

(2) Meter (+B) (13) Radio (AC)
(3) Blower Motor (14) Fuel Filter Heater
(4) Relay (15) ECU (+B)
(5) ECU (AC) (16) ECU (POWER)
(6) Room Light (17) Beacon
(7) Starter (18) Horn Switch
(8) Wiper/Washer (19) Horn
(9) Compressor (20) Lever Lock
(10) Electrical Outlet (21) Alternator
(11) Front Work Light (22) 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) Alternator (100 A)

(B) Engine ECU (30 A)
(C) Main Power (60 A)
(D) Engine Power (50 A)

(1) Slow-blow fuse box (2) Electric fan fuse (20 A)

RY9212148ELS0141US0

[2] STARTING AND STOPPING DEVICE

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 (3) Red

(2) Black / White
RY9212050ELS0027US0

4-S47 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

[3] RELAY LAYOUT

Relay Layout and Capacities

(1) Power relay (40A)

(2) Glow relay (40A)
(3) Horn relay (20A)
(4) Starter relay (20A)
(5) Beacon relay (20A)
(6) Worklight relay (20A)
(7) ECU (Power) relay (20 A)
(8) Blower relay (20A)
(9) Compressor relay (20A)
(10) Condenser relay (20 A)
(11) 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.
Mea-
Connector Name Connector Name
sure- Pin No. Pin No.
(+ terminal side) (+ terminal side)
ment
1 Starter relay <1> Starter relay <2>
2 Starter relay <1> Body GND –

Normal: 12V (battery voltage)

Irregular: Large discrepancy from 12V

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.
Mea-
Connector Name Connector Name
sure- Pin No. Pin No.
(+ terminal side) (+ terminal side)
ment
1 Starter relay <5> Starter relay <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.
Mea-
Connector Name Connector Name
sure- Pin No. Pin No.
(+ terminal side) (+ terminal side)
ment
1 Glow relay <1> Glow relay <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.
Mea-
Connector Name Connector Name
sure- Pin No. Pin No.
(+ terminal side) (+ terminal side)
ment
1 Glow relay <3> Glow relay <4>

Regular: Continuity
Irregular: No continuity
RY9212148ELS0144US0

4-S49 KiSC issued 08, 2015 A

KX080-4, WSM ELECTRICAL SYSTEM

4. TROUBLESHOOTING (START-UP EQUIPMENT

VERSION)
Engine does not start
Checkpoint Cause Solution
Check whether "Wrong
Key" is displayed when
it is in the start position. The engine was not started with the
Start the engine with the registered key.
Determine whether it is registered key.
the registered key or
not in the tester mode.
After determining the cause of
Check slow-blow and
Slow-blow and/or other fuses are blown. slow-blow and/or other fuses blowing,
other fuses.
replace them.
Check whether GND
wire(s) are securely Ground defective Tighten GND wire bolt(s).
connected to the body.
Check battery voltage
Battery fault Recharge or replace the battery.
and specific gravity.
Check continuity
between key switch Key switch faulty Replace the key switch.
terminals.
Measure the voltage at Repair the harness.
Break in continuity of the harness or starter
terminal B of the Replace the harness, starter relay
relay.
starter. and/or fuses.
Measure the voltage at Repair the harness.
Break in continuity in the harness, starter
terminal S of the Replace the harness, starter relay
relay and/or fuses.
starter. and/or fuses.

The engine fails to start sometimes.

Checkpoint Cause Solution
Is the key on a metal The key fob and/or keyring are interfering with
keyring or have a metal communication between the key and the Get rid of the key fob and/or ring.
fob? antenna.

Engine starts even with unregistered keys

Checkpoint Cause Solution
Check whether the
As the anti-theft function is not working, even
anti-theft system is Please contact Kubota service.
unregistered keys can start the engine.
"OFF" or not initialized.
RY9212148ELS0135US0

4-S50 KiSC issued 08, 2015 A

KX080-4, WSM ELECTRICAL SYSTEM

5. METHODS FOR DIAGNOSING ERRORS

The most important thing in diagnosing a malfunction is inferring the cause of the problem. It is important because
inferring the cause allows for a narrowing of the places that need to be inspected, and thus reducing wasted
inspection work. And the inference has to be supported by theory and practice--relying on intuition does not work.
RY9212038ELS0013US0

[1] GUIDE TO DIAGNOSING ERRORS

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.

• Accurately observe what the problem is. Check whether that problem is the only
1 Error Diagnosis Procedure
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.
2 Infer the Cause of the Error 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
Test Specified Locations and Find the
3 closer to the real cause. While making checks, you always have to be thinking,
Cause
which test can I make where to be more effective.
• After repairing a fault, always check and make sure the system is functioning
4 Check your Repairs
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

[2] ERROR DIAGNOSIS PROCEDURE

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.)
• Normal meter display
1 Observing the Malfunction
• Abnormal meter display
2 Checking the Faulty Line • Check in the meter's service mode. Checking for Breaks in Wiring
Specify the Faulty Circuit with a Circuit • Test related circuits with a circuit tester. Specify any faulty circuits in a harness.
3
Tester
Diagnose Sensors and Actuators with the • Judge sensors and actuators as normal or abnormal.
4
Tester
• Clear the history display after completing repairs. After clearing the history and
5 Final Operation Check
thoroughly checking operations, check for a history display again.

RY9212038ELS0015US0

4-S51 KiSC issued 08, 2015 A

KX080-4, WSM ELECTRICAL SYSTEM

[3] TESTING WITH A CIRCUIT TESTER

Testing Voltage and Continuity at a Connector
To prevent damage to the connector terminal contacts and/or
reducing the water-proofing of the connector when testing a
connector for voltage and/or continuity, follow the guidelines below.
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 (a) Measuring Harness

(B) Incorrect Example (b) 600 to 700 mm (23.7 to 27.5 in.)
(C) Using a Special Tool (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

6. TROUBLESHOOTING (METER PANEL VERSION)

[1] MACHINE RELATED SYSTEM
(1) Engine Oil Pressure Errors
[A] Checking the Meter Panel
1. Information displayed on the meter panel
1. When an error appears on the meter panel, stop the engine right
away.
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 (a) Warning Lamp
Press Err (b) Oil Lamp
Stop Engine
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 (c) The Last Breakdown Date (y/m/d)
(b) Number of Failure 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.
Regu- Oil When Oil When Oil
lar Lamp cut off Lamp shorted Lamp
Key Off Off Off Off
Key On Lit Off Lit
Key Start Off Off Lit

(1) Engine Speed

Battery V
Oil SW
Charging
Starter
RY9212148ELS0074US0

4-S53 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) (c) Main (solenoid) connector (d) Engine oil pressure switch
connector 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.
Mea-
sure- Connector Name (+ terminal side) Pin No. Connector Name (- terminal side) Pin No.
ment
(1) Engine oil pressure switch <1> Body GND –

Regular: 12V
Irregular: Large discrepancy from 12V
RY9212148ELS0146US0

4-S54 KiSC issued 08, 2015 A

KX080-4, WSM ELECTRICAL SYSTEM
2. Continuity check
[Measurement Conditions]
1. Key switch: OFF
2. Disconnect the connector to be tested.
3. Test the continuity based on the table below.
Mea-
sure- Connector Name (+ terminal side) Pin No. Connector Name (- terminal side) Pin No.
ment
(1) Engine oil pressure switch <1> Main (solenoid) <3>
(2) Engine (solenoid) <3> Meter panel <9>

Regular: Continuity
Irregular: No continuity
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.
50 kPa
Usage
At idle 0.51 kgf/cm2
limit
7.25 psi
Factory 200 to 390 kPa
Engine Oil Pressure specifica- 2.04 to 3.98 kgf/cm2
At Rated tion 29.01 to 56.56 psi
RPM 150 kPa
Usage
1.53 kgf/cm2
limit
21.76 psi

15 to 19 N·m
Oil switch tapering screw
Tightening torque 1.5 to 1.9 kgf·m
R1/8
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 ELECTRICAL SYSTEM

(2) Charging System Errors

[A] Checking the Meter Panel
1. Information displayed on the meter panel
1. Check whether or not the warning lamp (a) on the panel is
blinking red.
2. Check whether the charging lamp (b) is lit in red or off.
[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 (c) The Last Breakdown Date (y/m/d)
(b) Number of Failure and Hour Meter.
RY9212032ELS0001US0

3. Tester mode
1. Select the tester mode.
2. Check the operation of the charge according to the table below.
Regu- When When
Charge Charge Charge
lar cut off shorted
Key Off Off Off Off
Key On Lit Off Lit
Key Start Off Off 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

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

[C] Testing with a Circuit Tester

(a) Meter panel connector (b) Engine (open) connector (c) Main (open) connector (d) Alternator connector
• If connectors (b) (c) are removed, the engine will not start.
RY9212148ELS0149US0

4-S57 KiSC issued 08, 2015 A

KX080-4, WSM ELECTRICAL SYSTEM
1. Voltage check
[Measurement Conditions]
1. Disconnect the alternator connector.
2. Key switch: ON
3. Measure the voltage based on the table below.
Mea-
sure- Connector Name (+ terminal side) Pin No. Connector Name (- terminal side) Pin No.
ment
(1) Alternator <1> Body GND –
(2) Alternator <2> Body GND –

Regular: 12V
Irregular: Large discrepancy from 12V
RY9212148ELS0150US0
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.
Mea-
sure- Connector Name (+ terminal side) Pin No. Connector Name (- terminal side) Pin No.
ment
(1) Alternator <1> Main (open) <4>
(2) Alternator <2> Main (open) <8>
(3) Engine (open) <4> 10 A fuse –
(4) Engine (open) <8> Meter panel <10>

Regular: Continuity
Irregular: No continuity
RY9212148ELS0151US0

[D] Testing the Equipment Itself

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 ELECTRICAL SYSTEM

(3) Fuel Sensor Errors

[A] Checking the Meter Panel
1. Information displayed on the meter panel
Check whether or not the warning lamp (a) on the panel is
blinking red.
[Reason error screen displayed]
• Connector disconnected
• 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 (c) The Last Breakdown Date (y/m/d)
(b) Number of Failure 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.
Fuel voltage Resistance
When cut off 5.00 V 218 Ω
When shorted 0.00 V 0Ω

(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 (c) Fuel sensor connector (e) Engine (signal) connector (f) Meter panel connector
(b) Engine (fuel sensor) (d) Main (signal) connector
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 ELECTRICAL SYSTEM
1. Voltage check
[Measurement Conditions]
1. Disconnect the fuel sensor connector.
2. Key switch: ON
3. Measure the voltage based on the table below.
Mea-
sure- Connector Name (+ terminal side) Pin No. Connector Name (- terminal side) Pin No.
ment
(1) Sensor, Fuel <1> Sensor, Fuel <2>
(2) Sensor, Fuel <1> Body GND –

Regular: 12V
Irregular: Large discrepancy from 12V
RY9212148ELS0153US0
2. Continuity check
[Measurement Conditions]
1. Key switch: OFF
2. Disconnect the connector to be tested.
3. Test the continuity based on the table below.
Mea-
sure- Connector Name (+ terminal side) Pin No. Connector Name (- terminal side) Pin No.
ment
(1) Sensor, Fuel <1> Engine (fuel sensor) <1>
(2) Sensor, Fuel <2> Engine (fuel sensor) <2>
(3) Fuel sensor <1> Main (signal) <4>
(4) Fuel sensor <2> Main (signal) <8>
(5) Engine (signal) <4> Meter panel <1>
(6) Engine (signal) <8> Body GND –

Regular: Continuity
Irregular: No continuity
RY9212148ELS0154US0

[D] Testing the Equipment Itself

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 F (a) 1/2 (b) E (c)
Resistance value (Ω) 5≥ 42.19 101.0 ≤

(a) Full (c) Empty

(b) Half
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

[2] FRONT-END SYSTEMS

(1) Lever Lock System Errors
[A] Checking the Meter Panel
1. Information displayed on the meter panel
1. Check whether or not the warning lamp (a) on the panel is
blinking red.
2. Press the info button (b) and check the additional content.

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 (c) The Last Breakdown Date (y/m/d)
(b) Number of Failure 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.
Warn- Warn- When Warn-
Regu- When
ing ing shorte ing
lar cut off
lamp lamp d lamp
Lever lock
Off Off Off
switch ON
Lever lock
Off Off Off
switch OFF
Lever lock
Off Off Off
solenoid ON
Lever lock
Off Off Off
solenoid OFF

(1) 2 Speed SW (c) Unlock

2 Speed SOL (d) Lock
Lever Lock SW (e) Machinery Operation Lever Lock
Lever Lock SOL
Hydoil
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 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

[C] Testing with a Circuit Tester

(a) Main ECU connector (c) Engine (solenoid) (d) Main (solenoid) connector (e) Lever lock solenoid
(b) Lever lock switch connector connector 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.
Mea-
sure- Connector Name (+ terminal side) Pin No. Connector Name (- terminal side) Pin No.
ment
(1) Lever lock switch <2> Lever lock switch <1>
(2) Lever lock switch <2> Body GND –
(3) Lever lock solenoid <1> Lever lock solenoid <2>
(4) Lever lock solenoid <1> Body GND –
• To check the solenoid line, put the control lever lock in the [Unlock] position.
Regular: 12V
Irregular: Large discrepancy from 12V
RY9212148ELS0156US0

4-S65 KiSC issued 08, 2015 A

KX080-4, WSM ELECTRICAL SYSTEM
2. Continuity check
[Measurement Conditions]
1. Key switch: OFF
2. Disconnect the connector to be tested.
3. Test the continuity based on the table below.
Mea-
sure- Connector Name (+ terminal side) Pin No. Connector Name (- terminal side) Pin No.
ment
(1) 5A fuse – Lever lock switch <2>
(2) Lever lock switch connector <1> Engine (solenoid) <8>
(3) Lever lock switch <1> Main ECU <67>
(4) Main ECU <62> Engine (solenoid) <12>
(5) Main (solenoid) <8> Lever lock solenoid <1>
(6) Main (solenoid) <12> Lever lock solenoid <2>

Regular: Continuity
Irregular: No continuity
RY9212148ELS0157US0

[D] Testing the Equipment Itself

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 (c) Lever lock switch Connector
(b) 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

(2) Travel 2-Speed System Error

[A] Error from the Meter Panel
1. Information displayed on the meter panel
1. Check whether or not the warning lamp (a) on the panel is
blinking red.
2. Press the info button (b) and check the additional content.

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 (c) The Last Breakdown Date (y/m/d)
(b) Number of Failure 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.
2- 2- When 2-
Regu- When
speed speed shorte speed
lar cut off
lamp lamp d lamp
2-speed switch
Lit Lit Off
ON
2-speed switch
Off Off Off
OFF
2-speed
Lit Lit Off
solenoid ON
2-speed
Off Off Off
solenoid OFF

(1) 2 Speed SW (a) Angle Blade Version

2 Speed SOL (b) Standard Version
Lever Lock SW
Lever Lock SOL
Hydoil
(2) 2-Speed Switch
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 ELECTRICAL SYSTEM

[C] Testing with a Circuit Tester

(a) Main ECU connector (c) Engine (solenoid) (e) 2-speed solenoid connector A : Angle Specification
(b) 2-speed switch connector connector B : Standard Spec
(d) Main (solenoid) connector
• If connectors (c) (d) are removed, the engine will start but the machine will not operate.
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.
Mea-
sure- Connector Name (+ terminal side) Pin No. Connector Name (- terminal side) Pin No.
ment
(1) 2-speed switch <1> 2-speed switch <2>
(2) 2-speed switch <1> Body GND –
(3) 2-speed solenoid <1> 2-speed solenoid <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 ELECTRICAL SYSTEM
2. Continuity check
[Measurement Conditions]
1. Key switch: OFF
2. Disconnect the connector to be tested.
3. Test the continuity based on the table below.
Mea-
sure- Connector Name (+ terminal side) Pin No. Connector Name (- terminal side) Pin No.
ment
(1) 2-speed switch <2> Main ECU <57>
(2) 2-speed switch <1> Main ECU <41>
(3) Main ECU <81> Engine (solenoid) <4>
(4) Main (solenoid) <4> 2-speed solenoid <1>

Regular: Continuity
Irregular: No continuity
RY9212148ELS0160US0

[D] Testing the Equipment Itself

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 ELECTRICAL SYSTEM

(3) Angle System Errors

[A] Checking the Meter Panel
1. Information displayed on the meter panel
1. Check whether or not the warning lamp (a) on the panel is
blinking red.
2. Press the info button (b) and check the additional content.

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 (c) The Last Breakdown Date (y/m/d)
(b) Number of Failure 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
RY9212158ELS0012US0

[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.

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 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

[C] Testing with a Circuit Tester

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.
Mea-
Connector Name Connector Name
sure- Pin No. Pin No.
(+ terminal side) (- terminal side)
ment
(1) Left angle solenoid <1> Body GND –
(2) Right angle solenoid <1> Body GND –

Regular: 12V
Irregular: Large discrepancy from 12V
(a) Left angle solenoid connector (c) Main ECU connector
(b) Right angle solenoid connector
RY9212158ELS0013US0

2. Continuity check
[Measurement Conditions]
1. Key switch: OFF
2. Disconnect the connector to be tested.
3. Test the continuity based on the table below.
Mea-
Connector Name Connector Name
sure- Pin No. Pin No.
(+ terminal side) (- terminal side)
ment
(1) Left angle solenoid <1> Main ECU <20>
(2) Right angle solenoid <1> Main ECU <18>

Regular: Continuity
Irregular: No continuity
RY9212158ELS0014US0

[D] Testing the Equipment Itself

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

[3] AUTO IDLING (AI) SYSTEM

(1) AI System Errors
[A] Checking the Meter Panel
1. Information displayed on the meter panel
1. Check whether or not the warning lamp (a) on the panel is
blinking red.
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 (c) The Last Breakdown Date (y/m/d)
(b) Number of Failure 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 Accelerator When
Regular When cut off
Value POT shorted
Approx.
Idling 0.01 V
1.50 V Voltage fails to
Approx. stabilize
MAX 0.01 V
3.30 V

(1) Accel POT (b) Slow

Governor POT (c) Fast
Motor Current
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.
Mea-
Connector Name Connector Name
sure- Pin No. Pin No.
(+ terminal side) (- terminal side)
ment
(1) AI console <8> AI console <4>
(2) AI console <8> Body GND –

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.
Mea-
Connector Name Connector Name
sure- Pin No. Pin No.
(+ terminal side) (- terminal side)
ment
(1) AI console <7> Main ECU <7>
(2) AI console <8> Main ECU <11>
(3) AI console <4> Main ECU <10>

Regular: Continuity
Irregular: No continuity
RY9212148ELS0169US0

4-S75 KiSC issued 08, 2015 A

KX080-4, WSM ELECTRICAL SYSTEM

[D] Testing the Equipment Itself

1. Testing the accelerator sensor
[Measurement Conditions]
1. Key switch : OFF
2. Disconnect the accelerator sensor from the machine and test it
separately.
Factory specification Min. Max.
Accelerator sensor 4 to 8 1 kΩ ± 10 % 1 kΩ ± 10 %
Accelerator sensor 7 to 8 720 Ω 380 Ω
Accelerator sensor 4 to 7 380 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

(2) Testing the AI Pressure Switch

[A] Checking the Meter Panel
1. Tester mode
1. Select the tester mode.
2. Start the engine.
3. Check the operation of the AI pressure switch according to the
table below.
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 ELECTRICAL SYSTEM

[C] Testing with a Circuit Tester

(a) AI pressure switch (b) Main (signal) connector (c) Engine (signal) connector (d) Main ECU connector
connector
• If connectors (b) (c) are removed, the engine will crank but not start.
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.
Mea-
sure- Connector Name (+ terminal side) Pin No. Connector Name (- terminal side) Pin No.
ment
(1) AI pressure switch <1> AI pressure switch <2>
(2) AI pressure switch <1> Body GND –

Regular: 12V
Irregular: Large discrepancy from 12V
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.
Mea-
sure- Connector Name (+ terminal side) Pin No. Connector Name (- terminal side) Pin No.
ment
(1) AI pressure switch <1> Main (signal) <3>
(2) AI pressure switch <2> Main (signal) <7>
(3) Engine (signal) <3> Main ECU <76>
(4) Engine (signal) <7> Main ECU <50>

Regular: Continuity
Irregular: No continuity
RY9212148ELS0172US0

4-S78 KiSC issued 08, 2015 A

KX080-4, WSM ELECTRICAL SYSTEM

[D] Testing the Equipment Itself

1. Testing the AI pressure switch
[Test Conditions]
1. Key switch: OFF
2. Disconnect the AI pressure switch connector from the control
valve and attach the tester.
3. Start the engine and check continuity when it is operating and
when not operating.

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 ELECTRICAL SYSTEM

(3) Testing the AI Switch

[A] Checking the Meter Panel
1. Information displayed on the meter panel
1. When the AI switch (a) on the panel is pressed, check whether
the AI lamp (b) lights or is off.

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
RY9212148ELS0114US0

[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 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 ELECTRICAL SYSTEM

[C] Testing with a Circuit Tester

1. Voltage check
[Measurement Conditions]
1. Disconnect the AI console connector.
2. Key switch: ON
3. Measure the voltage based on the table below.
Mea-
Connector Name Connector Name
sure- Pin No. Pin No.
(+ terminal side) (- terminal side)
ment
(1) AI console <2> AI console <6>
(2) AI console <2> Body GND –

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.
Mea-
Connector Name Connector Name
sure- Pin No. Pin No.
(+ terminal side) (- terminal side)
ment
(1) AI console <6> Main ECU <75>
(2) AI console <2> Main ECU <76>

Regular: Continuity
Irregular: No continuity
RY9212148ELS0175US0

[D] Testing the Equipment Itself

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
AI switch released: no continuity
Regular
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

[4] ANTI-THEFT (AT) SYSTEM

(1) Anti-Theft System Errors
[A] Checking the Meter Panel
1. Information displayed on the meter panel
1. Check whether or not the warning lamp (a) on the panel is
blinking red.
2. Press the info button (b) and check the additional content.

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 (c) The Last Breakdown Date (y/m/d)
(b) Number of Failure and Hour Meter.
RY9212032ELS0001US0

3. Tester mode
1. Select the tester mode.
2. Check the anti-theft antenna.
Regular Irregular
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
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

RY9212148ELS0206US0
1. Voltage check
[Measurement Conditions]
1. Disconnect the anti-theft connector.
2. Key switch: ON
3. Measure the voltage based on the table below.
Mea-
sure- Connector Name (+ terminal side) Pin No. Connector Name (- terminal side) Pin No.
ment
(1) Anti-theft connector <5> Anti-theft connector <2>
(2) Anti-theft connector <5> Body GND –
(3) Anti-theft connector <6> Anti-theft connector <2>
(4) Anti-theft connector <6> Body GND –

Regular: 12V
Irregular: Large discrepancy from 12V
RY9212148ELS0122US0

4-S84 KiSC issued 08, 2015 A

KX080-4, WSM ELECTRICAL SYSTEM
2. Continuity check
[Measurement Conditions]
1. Key switch: OFF
2. Disconnect the connector to be tested.
3. Test the continuity based on the table below.
Mea-
sure- Connector Name (+ terminal side) Pin No. Connector Name (- terminal side) Pin No.
ment
(1) Anti-theft connector <1> Main ECU connector <49>
(2) Anti-theft connector <3> Main ECU connector <37>
(3) Anti-theft connector <4> Main ECU connector <51>
(4) Anti-theft connector <5> Main ECU connector <41>
(5) Anti-theft connector <6> Main ECU connector <59>

Regular: Continuity
Irregular: No continuity
RY9212148ELS0123US0

[D] Testing the Equipment Itself

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

[5] POWER SUPPLY SYSTEM

(1) Over Voltage
[A] Checking the Meter Panel
1. Information displayed on the meter panel
1. Check whether or not the warning lamp (a) on the panel is
blinking red.
2. Press the info button (b) and check the additional content.

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 (c) The Last Breakdown Date (y/m/d)
(b) Number of Failure 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 ELECTRICAL SYSTEM

(2) 5 V Short System Error

[A] Checking the Meter Panel
1. Information displayed on the meter panel
1. Check whether or not the warning lamp (a) on the panel is
blinking red.
2. Press the info button (b) and check the additional content.

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 (c) The Last Breakdown Date (y/m/d)
(b) Number of Failure and Hour Meter.
RY9212032ELS0001US0

Testing the 3.5V line

(a) Main ECU connector (d) AUX2/Thumb switch (e) Travel pressure sensor A : Eur. spec. only
(b) AI console connector connector connector
(c) AUX1 switch connector (f) Boom pressure sensor
connector

[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

[6] COMMUNICATION SYSTEM

(1) CAN Communication Errors
[A] Checking the Meter Panel
1. Information displayed on the meter panel
1. Check whether or not the warning lamp (a) on the panel is
blinking red.
2. Press the info button (b) and check the additional content.

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 (c) The Last Breakdown Date (y/m/d)
(b) Number of Failure and Hour Meter.
RY9212032ELS0001US0

3. Tester mode
1. Select the tester mode.
2. Confirm the ECU is O.
Regular Irregular
ECU (main)  ×
ECU (AS) × ×
ECU (CRS)  ×

(1) Meter
ECU (Main)
ECU (AS)
ECU (CRS)
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 ELECTRICAL SYSTEM

[C] Testing with a Circuit Tester

(a) Main ECU connector (d) Joint connector (f) Main (signal) connector (h) Engine ECU (58 pin)
(b) Meter panel connector (e) Engine (signal) connector (g) Engine ECU (96 pin) connector
(c) CAN comm connector connector (i) Engine relay
RY9212158ELS0009US0

4-S91 KiSC issued 08, 2015 A

KX080-4, WSM ELECTRICAL SYSTEM
CAN communication error (main)
1. Voltage check
[Measurement Conditions]
1. Disconnect the ECU connector.
2. Key switch: ON
3. Measure the voltage based on the table below.
Mea-
sure- Connector Name (+ terminal side) Pin No. Connector Name (- terminal side) Pin No.
ment
(1) Main ECU <59> Body GND –

Regular: 12V
Irregular: Large discrepancy from 12V
RY9212148ELS0182US0
2. Continuity check
[Measurement Conditions]
1. Key switch: OFF
2. Disconnect the connector to be tested.
3. Test the continuity based on the table below.
Mea-
sure- Connector Name (+ terminal side) Pin No. Connector Name (- terminal side) Pin No.
ment
(1) 5A fuse – Main ECU <59>
(2) Main ECU <60> Joint connector <2>
(3) Main ECU <79> Joint connector <3>
(4) Joint connector <5> CAN connector <1>
(5) Joint connector <8> CAN connector <2>
(6) Joint connector <1> Meter panel <6>
(7) Joint connector <4> Meter panel <5>

Regular: Continuity
Irregular: No continuity
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 Connector Name (+ terminal side) Pin No. Connector Name (- terminal side) Pin No.
ent
(1) Main ECU <5> Body GND –
(2) Main ECU <6> Body GND –
(3) Main ECU <33> Body GND –

Regular: 12V
Irregular: Large discrepancy from 12V
RY9212148ELS0184US0
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.
Meas
urem Connector Name (+ terminal side) Pin No. Connector Name (- terminal side) Pin No.
ent
(1) SBF (CRS) 30A – Engine ECU relay <1>
(2) SBF (CRS) 30A – Engine ECU relay <3>
(3) Engine ECU relay <5> Engine ECU <5>
(4) Engine ECU relay <5> Engine ECU <6>
(5) Engine ECU relay <2> Engine ECU <33>
(6) Joint connector <6> Engine (signal) <9>
(7) Joint connector <7> Engine (signal) <13>
(8) Main (signal) <13> Engine ECU <39>
(9) Main (signal) <9> Engine ECU <38>

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

4-S93 KiSC issued 08, 2015 A

KX080-4, WSM ELECTRICAL SYSTEM

[7] AUX SYSTEM

(1) AUX1 / AUX2 (Thumb) System Errors
[A] Checking the Meter Panel
1. Information displayed on the meter panel
1. Check whether or not the warning lamp (a) on the panel is
blinking red.
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 (a) Warning Lamp
(2) AUX2 Sys Err (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 (c) The Last Breakdown Date (y/m/d)
(b) Number of Failure 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.
Set value (ex.)
Indicated
Left Right Center At stop
value
(small) (large) (medium)
AUX1 knob
0.25 to 4.75 V 0.95 V 4.41 V 2.36 V 0V
switch
AUX2 /
Thumb knob 0.25 to 4.75 V 0.77 V 4.21 V 2.59 V 0V
switch
Output
0.5 to 2.0 A 0 to 0.2 A
current

Regular When cut off When shorted

Press the AUX one
way hold SW
Release the AUX
one way hold SW

(1) AUX1 Knob (4) Control Lever (Left)

Current (5) AUX One Way Hold SW
AUX Hold SW (6) AUX2 / Thumb knob
(2) Control Lever (Light) Current
(3) AUX One Way Hold SW AUX Hold SW
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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

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
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[C] Testing with a Circuit Tester

Switch side

(a) Main ECU connector (b) Right control lever (c) Left control lever connector
connector
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KX080-4, WSM ELECTRICAL SYSTEM
1. Voltage check (AUX hold switch)
[Measurement Conditions]
1. Disconnect the AUX1/AUX2 control lever connector.
2. Key switch: ON
3. Measure the voltage based on the table below.
Mea-
sure- Connector Name (+ terminal side) Pin No. Connector Name (- terminal side) Pin No.
ment
(1) Right control lever <5> Right control lever <6>
(2) Right control lever <5> Body GND –
(3) Left control lever <5> Left control lever <6>
(4) Left control lever <5> Body GND –

Regular: 12V
Irregular: Large discrepancy from 12V
RY9212148ELS0187US0
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.
Mea-
sure- Connector Name (+ terminal side) Pin No. Connector Name (- terminal side) Pin No.
ment
(1) Right control lever <1> Right control lever <2>
(2) Right control lever <1> Body GND –
(3) Left control lever <1> Left control lever <2>
(4) Left control lever <1> Body GND –

Regular: 5V
Irregular: Large discrepancy from 5V
RY9212148ELS0188US0
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.
Mea-
sure- Connector Name (+ terminal side) Pin No. Connector Name (- terminal side) Pin No.
ment
(1) Main ECU <41> Right control lever <5>
(2) Right control lever <6> Main ECU <69>
(3) Main ECU <41> Left control lever <5>
(4) Left control lever <6> Main ECU <72>

Regular: Continuity
Irregular: No continuity
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4-S96 KiSC issued 08, 2015 A

KX080-4, WSM ELECTRICAL SYSTEM
4. Continuity check (AUX1/AUX2 switch)
[Measurement Conditions]
1. Key switch: OFF
2. Disconnect the connector to be tested.
3. Test the continuity based on the table below.
Mea-
sure- Connector Name (+ terminal side) Pin No. Connector Name (- terminal side) Pin No.
ment
(1) Right control lever <3> Main ECU <28>
(2) Right control lever <1> Main ECU <11>
(3) Right control lever <2> Main ECU <10>
(4) Left control lever <3> Main ECU <29>
(5) Left control lever <1> Main ECU <11>
(6) Left control lever <2> Main ECU <10>

Regular: Continuity
Irregular: No continuity
RY9212148ELS0190US0
Solenoid side

(a) Main ECU connector (d) AUX1 (R) solenoid (f) AUX2 (R) solenoid (g) AUX2 (L) solenoid
(b) Engine (solenoid) connector connector connector
connector (e) AUX1 (L) solenoid
(c) Main (solenoid) connector connector
• If connectors (c) (d) are removed, the engine will start but the machine will not operate.
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4-S97 KiSC issued 08, 2015 A

KX080-4, WSM ELECTRICAL SYSTEM
1. Continuity check (AUX1 solenoid)
[Measurement Conditions]
1. Key switch: OFF
2. Disconnect the connector to be tested.
3. Test the continuity based on the table below.
Mea-
sure- Connector Name (+ terminal side) Pin No. Connector Name (- terminal side) Pin No.
ment
(1) AUX1 (right) solenoid <1> Main (solenoid) <1>
(2) AUX1 (right) solenoid <2> Main (solenoid) <5>
(3) AUX1 (left) solenoid <1> Main (solenoid) <9>
(4) AUX1 (left) solenoid <2> Main (solenoid) <5>
(5) Main ECU <24> Engine (solenoid) <1>
(6) Main ECU <23> Engine (solenoid) <9>
(7) Main ECU <19> Engine (solenoid) <5>

Regular: Continuity
Irregular: No continuity
RY9212148ELS0192US0
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.
Mea-
sure- Connector Name (+ terminal side) Pin No. Connector Name (- terminal side) Pin No.
ment
(1) AUX2 (right) solenoid <1> Main (solenoid) <2>
(2) AUX2 (right) solenoid <2> Main (solenoid) <6>
(3) AUX2 (left) solenoid <1> Main (solenoid) <10>
(4) AUX2 (left) solenoid <2> Main (solenoid) <6>
(5) Main ECU <42> Engine (solenoid) <2>
(6) Main ECU <43> Engine (solenoid) <10>
(7) Main ECU <16> Engine (solenoid) <6>

Regular: Continuity
Irregular: No continuity
RY9212148ELS0193US0

[D] Testing the Equipment Itself

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.
3.2 ± 0.5 Ω
AUX1 / AUX2 solenoid Factory specification
(at 20 °C, 68 °F )

(a) AUX1 / AUX2 Solenoid Terminals

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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
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4-S99 KiSC issued 08, 2015 A

KX080-4, WSM ELECTRICAL SYSTEM

[8] ECO MODE SYSTEM

(1) EP System Errors
[A] Checking the Meter Panel
1. Information displayed on the meter panel
1. Check whether or not the warning lamp (a) on the panel is
blinking red.
2. Press the info button (b) and check the additional content.

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 (c) The Last Breakdown Date (y/m/d)
(b) Number of Failure and Hour Meter.
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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

Mode Factory specification

P mode 0 to 0.6 A
EP solenoid
E mode 0.84 to 1.65 A

Design Value Regular When cut off When shorted

Travel pressure Current value 0V Not stable

(1) Compress (a) EP Switch

Boom Up SW
EP SW
Pump SOL
(2) 2Speed Press
2Speed Press
DPF SW
Light SW
Stop SW
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
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4-S101 KiSC issued 08, 2015 A

KX080-4, WSM ELECTRICAL SYSTEM

[C] Testing with a Circuit Tester

(a) EP Solenoid Connector (b) Travel Pressure Sensor (c) Main ECU Connector
Connector
RY9212148ELS0198US0
1. Voltage check (EP solenoid)
[Measurement Conditions]
1. Disconnect the EP solenoid connector.
2. Key switch: ON
3. EP switch: ON
4. Measure the voltage based on the table below.
Mea-
sure- Connector Name (+ terminal side) Pin No. Connector Name (- terminal side) Pin No.
ment
(1) EP solenoid <1> EP solenoid <2>
(2) EP solenoid <1> Body GND –

Regular: 12V
Irregular: Large discrepancy from 12V
RY9212148ELS0199US0
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.
Mea-
sure- Connector Name (+ terminal side) Pin No. Connector Name (- terminal side) Pin No.
ment
(1) EP solenoid <1> Main ECU <22>
(2) EP solenoid <2> Main ECU <21>

Regular: Continuity
Irregular: No continuity
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4-S102 KiSC issued 08, 2015 A

KX080-4, WSM ELECTRICAL SYSTEM
3. Voltage check (travel pressure sensor)
[Measurement Conditions]
1. Disconnect the travel pressure sensor connector.
2. Key switch: ON
3. Measure the voltage based on the table below.
Mea-
sure- Connector Name (+ terminal side) Pin No. Connector Name (- terminal side) Pin No.
ment
(1) Travel pressure sensor <3> Travel pressure sensor <1>
(2) Travel pressure sensor <3> Body GND –

Regular: 5V
Irregular: Large discrepancy from 5V
RY9212148ELS0201US0
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.
Mea-
sure- Connector Name (+ terminal side) Pin No. Connector Name (- terminal side) Pin No.
ment
(1) Travel pressure sensor <1> Main ECU <10>
(2) Travel pressure sensor <2> Main ECU <53>
(3) Travel pressure sensor <3> Main ECU <11>

Regular: Continuity
Irregular: No continuity
RY9212148ELS0202US0

[D] Testing the Equipment Itself

1. Testing the EP solenoid
[Measurement Conditions]
1. Key switch: OFF
2. Disconnect EP solenoid connector from the machine and test
the solenoid separately.
3.2 ± 0.5 Ω
EP solenoid Factory specification
[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> -
Factory specification 22 kΩ
<3>

Regular: Within factory spec

Irregular: Outside factory spec.
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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 CABIN

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. AIR CONDITIONING SYSTEM

[1] STRUCTURE

(1) Control panel (3) AC Unit (5) Condenser (7) Heater core
(2) External air intake (4) Compressor (6) Receiver (8) AC filter

The cabin is equipped with a high-capacity, low-profile air conditioner that can circulate cabin air or bring in fresh
air from outside. 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 3.4 kW ± 10 %
Heating capacity 4.1 kW ± 10 %
R134a
Type of refrigerant
950 g
(charge capacity)
2.09 lbs
Factory
specification 0.196 MPa
Pressure sensor (low) 2.0 kgf/cm2
28.4 psi
3.14 MPa
Pressure sensor (high) 32.0 kgf/cm2
455 psi

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KX080-4, WSM CABIN

[2] HOW THE MECHANISMS OF THE SYSTEM WORK

(1) Capillary Tube (Heat Sensitive (7) Condenser A : Cooled Air E : High Pressure/Temperature
Capillary Tube) (8) Receiver B : Low Pressure and Gas
(2) Expansion Valve (9) Dryer Temperature Vapor F : Hot Air
(3) Evaporator (10) Pressure Switch C, D : Air Passes Through G : Liquid
(4) Blower Motor (11) Heater Core In / Outside Air Filter
(5) Compressor (12) Hot Water Valve
(6) Engine Cooling Fan

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/cm2, 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).
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KX080-4, WSM CABIN

[3] COMPRESSOR
The vane type of compressor installed in this system
is composed of a cylinder (1) that is elliptical in
cross-section, along with five vanes (3) attached to the
rotor (2). This vane compressor has two each of intake
and discharge ports.
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 (3) Vane
(2) Rotor
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 (A) Compression Cycle
(2) Intake Port (B) Discharge Cycle
(3) Rotor (C) Intake Cycle
(4) Vane
(5) Discharge Port
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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.
Volume of Oil Product Name
110 to 120 cc
0.116 to 0.127 U.S.qts ND–OIL8 <PAG* oil>
0.098 to 0.106 lmp.qts
*PAG : Polyalkylene glycol (synthetic oil)
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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 (5) Rotor w/ Pulley
(2) Ball Bearing (6) Stator
(3) Snap Ring (7) Snap Ring
(4) Pulley
RY9212001CAM0006US0
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 : 113 L/min.

(27.2 U.S.gals./min.,
(A) Refrigerant Leak Route 24.86 lmp.gals./min.)
(B) Functional Characteristics b : 2.75 MPa
(C) Amount of Refrigerant (28.1 kgf/cm2, 399.7 psi)
Leaked c : 3.43 MPa
(D) Pressure (35.0 kgf/cm2, 497.8 psi)
d : 4.12 MPa
(42.0 kgf/cm2, 598.0 psi)
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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.
153 to 163 °C
OFF
307 to 325 °F
Operating Ranges
120 ± 5 °C
ON
248 ± 41 °F

11.8 ± 1.47 N·m

Temperature
Tightening torque 1.2 ± 0.15 kg·fm
Sensor
8.7 ± 1.08 lbf·ft

(1) Temperature Sensor A : Contact

(2) Compressor B : Bimetallic Strip
C : Rod
(a) To battery + Terminal
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5-M5 KiSC issued 08, 2015 A

KX080-4, WSM CABIN

[4] AIR CONDITIONING UNIT

(A) Diagram of Linkages and

Electrical Parts

The diagram above was created for general explanations of the air conditioning unit, so it may differ from the air
conditioning unit installed in the machine covered by this workshop manual. Similarly, this does not guarantee the
parts used inside the air conditioning unit are the same.
The air conditioning unit is composed of an evaporator, an expansion valve, a heater core, a blower, etc.
No. Name of part No. Name of part No. Name of part
(1) Upper case (10) Bolt (19) O-Ring
(2) Side cover (11) Fin thermistor (20) Servo motor
(3) Lower case (12) Clamp (21) Linkage lever
(4) Linkage cover (13) AC Amp (22) Blower resistor
(5) Intake cover (14) Heater core (23) Self-tapping screw
(6) Evaporator (15) Pipe (24) Self-tapping screw
(7) O-Ring (16) Hot water valve (25) Cap
(8) O-Ring (17) Pipe clip (26) Blower motor
(9) Expansion valve (18) Screw (27) Wire harness

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KX080-4, WSM CABIN
Evaporator
The evaporator takes the refrigerant, which has been
made liquid by the condenser and cooled and put under
low-pressure 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 (A) Inlet
(b) Tubes (B) Outlet
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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
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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.
Specifications (at 20 °C)
Model DC Ferrite
Rated Voltage 12 V
No load RPM 4300 ± 400 rpm
No load amperage 1 to 3 A
Direction of rotation
Left
(viewed from drive side)
Rated load torque 461 N·m, 47.0 kgf·m, 340 lbf·ft
RPM 2800 ± 280 rpm
Amperage 18.3 ± 1.8A

(1) Blower (A) Circuit Diagram

(a) (+) Terminal
(b) (-) Terminal
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5-M7 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 (A) Blower Resistor
(2) HI (B) Wiring Diagram
(3) LO
(4) Blank
RY9212148CAM0006US0

5-M8 KiSC issued 08, 2015 A

KX080-4, WSM CABIN
Expansion Valve
[Functions]
The expansion valve works in the following two
ways.
1. By spraying the liquid refrigerant, which is hot and
under high pressure, it makes it expand rapidly,
producing a low-temp, low-pressure refrigerant
vapor.
2. It adjusts the amount of refrigerant according to the
vaporized state of the refrigerant in the evaporator.
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.
Evaporator outlet temperature Operation
The pressure of the gas in the diaphragm chamber drops, reducing the volume and moving the
When low (when cooling load is low) 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
When high (when cooling load is high) heat-sensitive rod to the left, which opens the needle valve and supplies more refrigerant to the
evaporator.

(1) Evaporator A : Diaphragm D : Body (a) From Receiver

B : Heat-Sensitive Rod E : Needle Valve (Hi-Pressure)
C : Spring (b) To Compressor
(Lo-Pressure)
(c) To Evaporator
(d) From Evaporator
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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
Rated Voltage DC12 V
Measurement
DC13 ±0.2 V at 25 ± 5 °C (77 ± 9 °F)
Conditions
OFF R1 4383 ±131 Ω (2 °C, 36 °F)
Temperature
ON R2 (4095 Ω) (3.35 °C, 38 °F)
Detection
Hysteresis 215 ±5.0 Ω (1 °C, 34 °F)

Usage Conditions
Temperature
–30 to 80 °C (–22 to 176 °F)
Range
Voltage Range DC10 to 16 V
Operating Voltage
DC8 to 16 V (at 25 °C, 77 °F)
Range

Temperature 10 °C 15 °C 20 °C 25 °C 30 °C
Detection / 50 °F / 59 °F / 68 °F / 77 °F / 86 °F
2.96 2.34 1.87 1.50 1.22
Resistance Value
kΩ kΩ kΩ kΩ kΩ

(1) Fin Thermistor (a) Evaporator Fin

(2) Thermo-Amp 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) (c) Inlet

(b) Closed (MAX Cool) (d) Outlet
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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.
Specifications (at 20 °C, 68 °F)
Model DC Ferrite
Rated Voltage 12 V
Rated load torque 0.3 N·m, 0.03 kgf·m, 0.2 lbf·ft
RPM 3.5 to 5.5 rpm
Amperage 0.02 to 0.10 A
Potentiometer Linearity ±3%
Impressed Voltage Terminals 6 (POS.2) 7 (POS.1)

(1) Servo Motor (A) Potentiometer Output

(2) Linkage Lever Schematic
(3) Hot Water Valve (a) Voltage (V)
(b) Operating Angle 60 °
(c) MAXCOOL
(d) MAXHOT
(e) CW
RY9212001CAM0017US0

[5] CONDENSER
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 (a) Gaseous Refrigerant
(2) Fins (b) Liquid Refrigerant
(3) Vapor (c) Inlet (70 °C, 158 °F)
(4) Vapor/Liquid Mix (d) Outlet (50 °C, 122 °F)
(5) Liquid
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5-M11 KiSC issued 08, 2015 A

KX080-4, WSM CABIN

[6] RECEIVER
The receiver is composed of a receiver tank, dryer,
strainer and a receiver tube.
[Receiver Tank]
In the AC system, the rpm of the compressor
changes in response to changes in the engine rpm, so
the appropriate amount of refrigerant in the cooling
circuit also changes. 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 (A) Refrigerant Inlet
(2) Receiver Tube (B) Refrigerant Outlet
(3) Strainer
(4) Receiver Tank
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5-M12 KiSC issued 08, 2015 A

KX080-4, WSM CABIN

[7] PRESSURE SWITCH

This dual type of switch detects unusually high and
low pressures in the cooling cycle. If the pressure gets
abnormally high or, due to a leak, abnormally low, it may
damage the equipment or deteriorate the lubricating
ability of the compressor oil, leading to scorching and
breakdown. To prevent these kind of problems from
occurring, the switch cuts the power to the compressor
clutch and stops the compressor.
Refrigerant
Operation
pressure
No increase in
The refrigerant pressure becomes less
pressure state
than the force of the spring, so the spring
(A) (when
presses the plate up and the upper contact
abnormally
opens (OFF).
low)
The refrigerant pressure is greater than the
Contact ON
force of the spring, so the pressure plate is
(B) (normal
pressed down, which presses the upper
operation)
contact down, closing the contact (ON).
The refrigerant pressure becomes greater
Contact OFF than the force of the plate spring and the
(C) (abnormally plate spring pushes down on the pin, which
high pressure) press on the lower contact, opening it
(OFF).

(1) Diaphragm a : 0.19 MPa

(2) Plate Spring (2.0 kgf/cm2, 28.4 psi)
(3) Pin b : 3.14 MPa
(4) Plate (32 kgf/cm2, 455 psi)
(5) Contact D : OFF
(6) Spring E : ON
(7) Terminal P : Pressure
PS : Pressure Switch
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5-M13 KiSC issued 08, 2015 A

KX080-4, WSM CABIN

[8] ELECTRICAL SYSTEM

(1) Electrical Circuits

(1) Battery (13) Blower Switch (Shorting Type) (A) Fixed Voltage Circuit (h) (Free)
(2) Slow-Blow Fuse (80A) (14) Compressor Clutch Relay (B) Servo Motor Drive Circuit (i) Servo Motor Output1
(3) Slow-Blow Fuse (50A) (15) Pressure Switch (C) CPU (COOL Output)
(4) Fuse (5A) (16) Compressor Magnetic Clutch (D) Electronic Thermo Amp (j) (Free)
(5) Fuse (10A) (17) Fin Thermistor (Frost Sensor) (k) Servo Motor Output2
(6) Fuse (30A) (18) Indicator Lamp (a) Potentiometer Signal (HOT Output)
(7) Start Switch (19) AC switch (b) ILL– (l) (Free)
(8) Cab Relay (20) Volume (Temperature Setting) (c) Potentiometer Power (m) (Free)
(9) Headlight Switch (21) Servo Motor (d) Blower Motor (n) Headlight Switch
(10) Blower Motor Relay (e) Potentiometer GND (o) IG
(11) Blower Motor (f) Electronic thermo (p) +B Power
(12) Blower Resistor (g) GND

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)
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5-M14 KiSC issued 08, 2015 A

KX080-4, WSM CABIN

(2) Relays
Current flows in the components of the AC system to
the blower motor and compressor's magnetic clutch. If all
of the current were supplied via the main switch, the
current would be too much for the switch, so the contacts
of the main switch would be in danger of burning out.
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 (A) Connection Diagram
(2) Relay Terminal 2
(3) Relay Terminal 3
(5) Relay Terminal 5
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(3) Blower Switch

When the blower switch is in the LO, MI, or HI position

(1) Battery (9) Headlight Switch (16) Compressor Magnetic Clutch (A) Fixed Voltage Circuit
(2) Slow-Blow Fuse (80A) (10) Blower Motor Relay (17) Fin thermistor (Frost Sensor) (B) Servo Motor Drive Circuit
(3) Slow-Blow Fuse (50A) (11) Blower Motor (18) Indicator Lamp (C) CPU
(4) Fuse (5A) (12) Blower Resistor (19) AC Switch (D) Electronic Thermo Amp
(5) Fuse (10A) (13) Blower Switch (Shorting Type) (20) Volume (Temperature Setting)
(6) Fuse (30A) (14) Compressor Clutch Relay (21) Servo Motor
(7) Start Switch (15) Pressure Switch
(8) Cab Relay

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
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5-M16 KiSC issued 08, 2015 A

KX080-4, WSM CABIN

2. WIPER
[1] WIPER SWITCH
This switch has four positions, namely (a), (b), (c)
and (d) as indicated in the figure. When the starter key is
in its [RUN] position and the switch is pressed to its (b)
position, the wiper motor operates; 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 (a) Wash 1 Position
(2) Spring (Both Wiper Motor and
(3) Contact Window Washer Operate)
(4) Switch Body (b) On position (Only the
(5) Movable Contact Wiper Motor Operates)
(6) Insulator (c) Off Position
(d) Wash 2 Position (Only the
Window Washer Operates)
RY9212148CAM0005US0

[2] WIPER
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 (5) Wiper Blade
(2) Nut (6) Wiper Motor
(3) Wiper Arm (7) Wiper Motor Cover
(4) Nut (8) Flange Nut
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5-M17 KiSC issued 08, 2015 A

KX080-4, WSM CABIN

[3] WIPER MOTOR

A cylindrical ferrite magnet and an armature are
assembled inside the housing of the wiper motor.
A worm gear and a helical gear are attached to the end
of the armature and act as reduction gears and the rod
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 (8) Ferrite Magnet
(2) Arm's Axis (9) Helical Gear
(3) Rod (10) Breaker
(4) Worm Gear (11) Motor
(5) Armature Axle (12) Switch
(6) Brush
(7) Armature (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 CABIN

1. TROUBLESHOOTING
Compressor
Problem and/or
Possible Cause Solution
Situation
Wearing of or damage to the compressor's
Replace
bearings
Compressor valve damaged Replace
Noise (compressor on)
Belt slipping Adjust or replace
Compressor bracket mounting bolt(s) loose Tighten
Lines vibrating Tighten and/or add clamp(s)
Blower damaged Repair or replace
Noise (compressor off) Magnetic clutch, idler pulley and/or crank pulley
Replace
bearings damaged or wearing

Air Conditioning System

Problem and/or
Possible Cause Solution
Situation
Blown fuse Replace
Main AC relay defective Replace
Cooling not working
AC's blower motor damaged Replace
(air not blowing)
AC's blower switch broken Replace
Wiring harness unplugged or poor contact Fix
Blown fuse Replace

Cooling not working Magnetic clutch broken Repair or replace

(compressor not AC switch broken Replace
turning) Pressure switch broken Replace
Belt slipping Adjust or replace
Not enough refrigerant Check with a manifold gauge
Cooling not working
Expansion valve broken Replace
(other)
Compressor broken Replace
Filter clogged Clean or replace
Cooling not working Clean or replace the temperature
effectively Frost on the evaporator
switch
(not enough air
blowing) AC's blower motor damaged Replace
AC blower resistor broken Replace

Not cooling effectively Not enough refrigerant Check with a manifold gauge
(lots of foam visible in Refrigerant gas leaking from the cooling circuit Repair and/or recharge refrigerant
sight glass) Air got in Check with a manifold gauge
Too much refrigerant
Refrigerant overcharged Check with a manifold gauge
(no foam in sight glass)

Not cooling effectively Belt slipping Adjust or replace

(compressor not Magnetic clutch broken Repair or replace
rotating properly) Compressor broken Replace

5-S1 KiSC issued 08, 2015 A

KX080-4, WSM CABIN

Problem and/or
Possible Cause Solution
Situation
Thermistor broken Replace
Not cooling effectively Hot water valve damaged Replace
(other) Condenser clogged with dirt or debris Clean
Expansion valve broken Replace
Hot water valve damaged Replace
Not heating effectively
Servo motor broken Check and repair
Blower fan switch broken Check and repair

Not enough air flow AC main relay broken Replace

(blower motor not Brushes have poor contact Replace
turning) Blown fuse Replace
Miswiring or poor connections Check and repair

Not enough air flow Blower resistor damaged Replace

(air flow does not Relay damaged Replace
change to speed 3) Blower fan switch broken Replace
Blower not tight enough Check and repair
Blower deformed Replace
Blower hitting its casing Check and repair
Not enough air flow
Something blocking the inlet Check and repair
(other)
Frost on the evaporator Clean or replace
Filter clogged Clean or replace
Vent ducts clogged or detached Check and repair
Battery voltage too low Charge the battery
Rotor is hitting the stator Replace

Not cooling effectively Miswiring or loose connectors Check and repair

(compressor clutch not Relay damaged Replace
working) Coil shorted Replace
Ground defective Check and repair
Coil burned out Replace

Not cooling effectively Refrigerant overcharged Check with a manifold gauge

(high-pressure level Condenser clogged with dirt or debris Clean
too high) Air got in Check with a manifold gauge
Not enough refrigerant Check with a manifold gauge
Not cooling effectively Compressor discharge valve damaged Replace
(high-pressure level Compressor gasket damaged Replace
too low)
Error in the low-pressure line
Replace
(cracked or clogged)
Not cooling effectively Refrigerant overcharged Check with a manifold gauge
(low-pressure level too
high) Expansion valve too far open Replace

5-S2 KiSC issued 08, 2015 A

KX080-4, WSM CABIN

Problem and/or
Possible Cause Solution
Situation
Not enough refrigerant Check with a manifold gauge
Not cooling effectively Frost on the evaporator Clean or replace
(low-pressure level too Error in the low-pressure line
low) Replace
(cracked or clogged)
Expansion valve clogged Replace
Not cooling effectively
(both low and high
Refrigerant overcharged Check with a manifold gauge
pressure levels too
high)
Not cooling effectively
(both low and high
Not enough refrigerant Check with a manifold gauge
pressure levels too
low)
Cannot control Servo motor broken Replace
temperature Temperature control dial broken Replace
(servo motor and/or
temperature control Controller of the wire harness is off Repair or replace
dial defective)
Cannot control the Servo motor broken Replace
temperature
(hot water valve does Hot water valve damaged Replace
not open normally)
Cannot control the Heater hose is pinched Fix
temperature
(poor heater hose Heater hose is bent or broken Repair or replace
layout)
Water leak (water leak Drain hose bent or broken Check and repair
inside the cab) Drain hose clogged Clean
Wiper
Problem and/or
Possible Cause Solution
Situation
Fuse blown (a part inside the wiper motor or Pinpoint the cause of the damage
some other moving part is shorted or burned out) and replace
Wiper motor faulty (damaged armature, worn
Replace
motor brushes, motor shaft locked)
Wiper doesn't work
Wiper switch faulty Replace
Faulty operation of linkage mechanism due to
Fix
foreign matter
Wiper arm locked or rusted together Grease up or replace
Wiper motor faulty (damaged armature, poor
contact due to worn motor brushes, faulty Replace
operation of motor shaft)
Wiper moves too
slowly Battery voltage low Recharge or replace
Wiper arm shaft rusty, foreign matter stuck in it Grease up or replace
Poor contact in wiper switch Replace
Wiper motor faulty
Wiper fails to stop in
(Dirty or poor contact of the contacts at the Replace
the correct position
auto-stop position due to foreign matter)
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KX080-4, WSM CABIN

2. SERVICE SPECIFICATIONS
Allowable Limit
Item Factory specification
Value
0.30 to 0.65 mm
AC Compressor Magnetic Clutch Air Gap –
0.0118 to 0.0255 in.
Electrical
Magnetic Clutch Stator Coil 3.0 to 4.0 Ω –
Resistance
0.15 to 0.20 MPa
Pressure
1.5 to 2.0 kgf/cm2 –
(low-pressure side)
Cooling Cycle 21 to 28 psi
(cooling cycle when operating normally) Pressure 1.27 to 1.66 MPa
(high-pressure 13 to 17 kgf/cm2 –
side) 185 to 242 psi
Lower than the values
below
Pressure setting
About 0.196 MPa –
(low-pressure side)
2.0 kgf/cm2
Pressure switch 28.4 psi
(dual type) (when pressure switch is off) Higher than the values
Pressure setting below
(high-pressure About 3.14 MPa –
side) 32 kgf/cm2
455 psi
Deflects 20 to 25 mm
(0.79 to 0.98 in.) when
AC drive belt Tension 98.0 N (10.0 kgf, –
22.0 lbs) of forced is
applied
R134a
Type
Refrigerant 970 ± 50 g –
(recharge volume)
2.14 ± 0.11 lbs
ND-OIL8 <PAG*oil>
Type 110 to 120 cc
Compressor Oil –
(usage volume) 0.116 to 0.127 U.S.qts
0.097 to 0.106 Imp.qts
*PAG : Polyalkylene glycol (synthetic oil)
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5-S4 KiSC issued 08, 2015 A

KX080-4, WSM CABIN

3. TORQUE
The following table indicates the specified tightening torque for nuts.
Items N·m kgf·m lbf·ft
Condenser mounting M8 nut 17.7 to 20.6 1.8 to 2.1 13.0 to 15.2
Compressor mounting M8 bolt 16.7 to 19.6 1.7 to 2.0 12.3 to 14.5
Compressor bracket M12 bolt 77.5 to 90.2 7.9 to 9.2 57.1 to 66.5
mounting M8 bolt 16.7 to 19.6 1.7 to 2.0 12.3 to 14.5
Receiver mounting M8 bolt 17.7 to 20.6 1.8 to 2.1 13.0 to 15.2
High pressure line 1 M6 bolt 7.8 to 11.8 0.8 to 1.2 5.8 to 8.7
mounting
(on condenser side) M22 × 1.5 lock nut 19.6 to 24.5 2.0 to 2.5 14.5 to 18.1

Between condenser and M6 bolt 3.9 to 6.9 0.4 to 0.7 2.9 to 5.1
receiver M16 × 1.5 lock nut 11.8 to 14.7 1.2 to 1.5 8.7 to 10.8
High pressure line 2
mounting M16 × 1.5 lock nut 11.8 to 14.7 1.2 to 1.5 8.7 to 10.8
(on receiver side)
Low-pressure line M6 bolt 7.8 to 11.8 0.8 to 1.2 5.8 to 8.7
between AC and
compressor M24 × 1.5 lock nut 29.4 to 34.3 3.0 to 3.5 21.7 to 25.3

M6 bolt 3.9 to 6.9 0.4 to 0.7 2.9 to 5.1

AC mounting
M8 bolt 9.8 to 15.7 1.0 to 1.6 7.2 to 11.6
Magnetic clutch mounting M6 bolt 10.8 to 16.2 1.10 to 1.65 8.0 to 11.9
RY9212148CAS0002US0

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KX080-4, WSM CABIN

4. PRECAUTIONS WHEN REPAIRING

THE REFRIGERANT SYSTEM
[1] USE OF SERVICE TOOLS
(1) Manifold Gauge Set
Always follow the warnings and regulations below when inspecting or repairing the air conditioning system. It is
also extremely important that no one other than specially trained service personnel handles refrigerants.

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 (4) Valve Core
(2) High-Pressure Gauge (5) Low-Pressure Valve
(3) High-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
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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

(2) Refrigerant Charging Hoses

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 (7) Sleeve
(2) High Pressure Valve (8) Pusher
(3) Red Hose
(4) Quick Disconnect Adapter a : Makes a catching sound
(5) Green Hose
(6) Blue Hose
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(3) Vacuum Pump Adapter

Purpose of the Vacuum Pump Adapter
1. After the AC cooling system is vacuumed, when the vacuum
pump is stopped, there is a vacuum inside the hoses of the
manifold gauge, so the oil of the vacuum pump flows back into
the refrigerant charging hose. 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 (5) Air
(2) Vacuum Pump (6) For R12
(3) For R134a (7) Plug Cap
(4) Solenoid Valve
RY9212001CAS0011US0

(4) Electric Gas Leak Tester

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

(5) Canister Tap Valve

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 (3) Disc
(2) Connector (4) Needle
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(6) T-Joint
A T-joint (2) is used when using two refrigerant canisters (4) at
the same time to make gas recharging more efficient.
1. Attach a refrigerant canister service valve on each side of the
T-joint (2) and connect a refrigerant charging hose (1) to the
T-joint.
(1) Refrigerant Charging Hose (Green) (3) Canister Tap Valve
(2) T-Joint (4) Refrigerant Canister
RY9212001CAS0014US0

(7) R134a Refrigerant Collection/Recycling Device

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.
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KX080-4, WSM CABIN

5. INSPECTING AND CHARGING THE REFRIGERANT

SYSTEM
[1] CHECKING THE SYSTEM WITH A MANIFOLD GAUGE
IMPORTANT
• Be aware that the gauge pressure values noted in the following test are measured under identical
conditions and they may vary somewhat from your gauge pressure values, depending on the prevailing
conditions.
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 (5) Manifold gauge
(blue or yellow) (6) Low-pressure side charge valve
(2) Refrigerant charging hose (red) (7) High-pressure side charge valve
(3) High-pressure valve
(4) Low-pressure valve
RY9212148CAS0005US0

When operating normally

If the refrigerant cycle is operating normally, readings will be
around the factory specifications in the table below.
Low 0.15 to 0.20 MPa
pressure 1.5 to 2.0 kgf/cm2
Factory side 21 to 28 psi
Gas Pressure specifica-
tion High 1.27 to 1.66 MPa
pressure 13 to 17 kgf/cm2
side 185 to 242 psi

(1) Low Pressure Side (2) High Pressure Side

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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/cm2,
7.1 to 14.2 psi)
High-pressure side (2) : 0.69 to 0.98 MPa (7 to 10 kgf/cm2,
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/cm2,
28.4 to 49.8 psi)
High-pressure side (2) : 1.96 to 2.45 MPa (20 to 25 kgf/cm2,
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

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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/cm2,
28.4 to 49.8 psi)
High-pressure side (2) : 1.96 to 2.45 MPa (20 to 25 kgf/cm2,
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/cm2,
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
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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/cm2,
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/cm2,
42.7 to 56.9 psi)
High-pressure side (2) : 1.96 to 2.45 MPa (20 to 25 kgf/cm2,
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/cm2,
56.9 to 85.3 psi)
High-pressure side (2) : 0.69 to 0.98 MPa (7 to 10 kgf/cm2,
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 (2) High Pressure Side
RY9212001CAS0025US0
5-S14 KiSC issued 08, 2015 A
KX080-4, WSM CABIN

[2] COLLECTION, VACUUMING AND CHARGING

IMPORTANT
• Follow 4. Precautions when Repairing the Refrigerant Cycle when discharging, vacuuming and charging
the refrigerant system.
RY9212001CAS0026US0

(1) Collecting Refrigerant

Get a R134a refrigerant collection/recycling device ready to
use.
1. Connect the low-pressure hose (blue) (4) from the refrigerant
collection/recycling machine to the low-pressure side charge
valve (1). 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.

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 (5) Manifold gauge
(blue or yellow) (6) Low-pressure side charge valve
(2) Refrigerant charging hose (red) (7) High-pressure side charge valve
(3) High-pressure valve
(4) Low-pressure valve
RY9212148CAS0006US0

(2) Vacuuming Out the System

No. Description of Work Remarks
(1) Check the connected parts and correct any problems
(2) Start vacuuming Approx 15 minutes, 750 mmHg (229 in.Hg) or greater
(3) Stop vacuuming Leave for five minutes
(4) Check the concentration If the gauge indicates abnormally, return to (1)
(5) Charge with refrigerant 98 kPa (1.0 kgf/cm2, 14 psi)
(6) Check for gas leaks
(7) Charge with refrigerant

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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.
Low-pressure side
Blue hose
(L mark)
High-pressure side
Red hose
(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 (A) Inspection Line Connections
(2) High-Pressure Valve (B) Low-Pressure Gauge
(3) Low-Pressure Valve
(4) High-Pressure Side (H Mark) (a) Valve Settings
(5) Low-Pressure Side (L Mark) (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 (a) Press Valve Core to Expel Air
(2) High-Pressure Valve
(3) Low-Pressure Valve
(4) High-Pressure Side (H Mark)
(5) Low-Pressure Side (L Mark)
RY9212001CAS0030US0

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(3) Charging from the High-Pressure Side

Charging from the High-pressure Side

CAUTION
• Important : do not start the engine. If the engine is running,
the gas will flow back and burst either the service canister
or a hose.
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/cm2), 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 (a) Press Valve Core to Expel Air
(2) High-Pressure Valve
(3) Low-Pressure Valve
RY9212001CAS0031US0

(4) Charging from the Low-Pressure Side

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 (a) Press Valve Core to Expel Air
(2) High-Pressure Valve
(3) Low-Pressure Valve
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(5) Inspections and Troubleshooting

[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 All open
Inside/outside air switch Inside
Ambient air temperature 30 to 35 °C (86 to 95 °F)
Engine RPM About 1,500
Temperature control 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.
Factory Low 0.15 to 0.20 MPa
specifica- pressure 1.5 to 2.0 kgf/cm2
tion side 21 to 28 psi
When Normal
Factory High 1.27 to 1.66 MPa
specifica- pressure 13 to 17 kgf/cm2
tion side 185 to 242 psi

(1) High-Pressure Gauge (a) High-Pressure Side

(2) Low-Pressure Gauge (Compressor's H-Mark Side)
(3) High-Pressure Valve (b) Low-Pressure Side
(4) Low-Pressure Valve (Compressor's L-Mark Side)
(5) Valve Core
(6) Red
(7) Blue
(8) Quick Joint
(9) Green
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Checking with the sight glass
Conditions
Doors All open
Inside/outside air switch Inside
Ambient air temperature 30 to 35 °C (86 to 95 °F)
Engine RPM About 1500 rpm
Temperature control Max cooling position
Blower switch HI

Criteria
No air bubbles at all in the flow. In this case, both high
(a) Overcharged 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
Normal
(b) raised gradually from idle to 1500 rpm, the air bubbles
amount
disappear and the flow becomes transparent.
(c) Undercharged Air bubbles flow past constantly.

(1) Sight Glass

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6. INSPECTION AND DISASSEMBLY

[1] CHECKS AND ADJUSTMENTS
(1) Compressor
Magnetic clutch
1. Start the engine.
2. With the AC switch on the AC control panel off, check and make
sure that no scraping sounds or other noise comes from the
pulley as it turns.
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 Factory specification 3 to 5 Ω
coil
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Adjusting clearance
1. Use a feeler gauge to check the clearance.
2. If the measurement is outside the factory specification, adjust
the clearance.
0.30 to 0.65 mm
Clearance Factory specification
0.0118 to 0.0255 in.

[NOTE]
Shim Thickness Part No.
0.10 mm (0.0039 in.) T1065-87340
0.15 mm (0.0059 in) T1065-87350
0.40 mm (0.016 in.) T1065-87360
0.60 mm (0.024 in.) T1065-87370
1.0 mm (0.0394 in.) T1065-87380

(1) Magnetic Clutch Mounting Screw (6) Snap Ring

(2) Hub Plate (7) Stator
(3) Shim (8) Compressor Body
(4) Snap Ring
(5) Rotor L : Clearance
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(2) Relays
Blower motor inspection
1. Key switch: STOP
2. Check whether the blower motor fuse (30A) is blown.
Criteria
Regular: no break
Irregular: has a break
3. Switch the blower motor and horn relays.
4. Start the engine, then turn the fan switch to [3] and check if it
works.
Criteria
Regular: it works
Irregular: it does not work

(1) Blower motor fuse (30A) (3) Horn relay

(2) Blower motor 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.
Mea-
Connector name Connector name
sure- Pin No. Pin No.
(+ terminal side) (- terminal side)
ment
(a) Blower motor relay <1> Body GND –
(b) Blower motor relay <3> Body GND –

Regular: 12 V
Irregular: Large discrepancy from 12 V
(1) Blower Motor Relay (A) Fuse Box Terminals
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Blower motor inspection
1. Key switch: STOP
2. Take out the blower motor relay.
3. Measure the resistance based on the table below.
Mea-
Relay terminal Relay terminal
sure-
(+ terminal side) (- terminal side)
ment
(a) (3) (5)

Factory spec: 92 to 112 Ω

Outside factory spec: NG

4. Test the continuity based on the table below.

Mea-
Relay terminal Relay terminal
sure-
(+ terminal side) (- terminal side)
ment
(a) (1) (2)

Regular: No continuity
Irregular: Continuity
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(3) Blower Motor

Checking the Voltage
1. Remove the blower motor connector.
2. After starting the engine, set the fan switch on [3].

Measure the voltage based on the table below.

Mea-
sure-
Connector Name Connector Name
ment Pin No. Pin No.
(+terminal side) (- terminal side)
Point
s
Blower motor
(a) <1> Body GND –
connector

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
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(4) Blower Resistor

Checking the Voltage
1. Remove the blower motor connector.
2. After starting the engine, set the fan switch off.
3. Measure the voltage based on the table below.
Mea-
Connector Name Pin Connector Name Pin
sure-
(+terminal side) No. (- terminal side) No.
ment
Blower resistor motor
(a) <2> Body GND –
connector

Normal: 12 V
Irregular: Large discrepancy from 12 V
(1) Blower Resistor (3) Fan Switch
(2) Blower Resistor Motor Connector
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.
Mea-
Factory Assessment
sure- Between terminals
specification Results
ment
(a) 1–3 Approx. 1.0 Ω
(b) 1–2 Approx. 0.7 Ω
(c) 2–3 Approx. 1.7 Ω

Regular: Within factory specification

Irregular: Outside factory specification
(1) MI (A) Blower Resistor
(2) HI (B) Wiring Diagram
(3) LO
(4) Blank
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(5) Blower Switch

Voltage check
1. Disconnect the blower switch connector.
2. Turn the key switch to the RUN position.
3. Measure the voltage based on the table below.
Mea- Connector terminal
Pin Connector terminal Pin
sure- name (+ terminal
No. name (- terminal side) No.
ment side)
Blower switch Blower switch
(a) <6> <3>
connector connector
Blower switch
(b) <6> Body GND –
connector

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

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(6) Servo Motor (for Temp Control)

Voltage check
1. Disconnect the servo motor connector.
2. Turn the key switch to the RUN position.
3. Measure the voltage based on the table below.
Mea- Connector terminal
Pin Connector terminal Pin
sure- name (+ terminal
No. name (- terminal side) No.
ment side)
(a) Servo motor connector <5> Servo motor connector <7>
(b) Servo motor connector <5> Body GND –

Regular: 5V
Irregular: Large discrepancy from 5V
(1) Servo motor connector
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.
Mea- Connector terminal
Pin Connector terminal Pin
sure- name (+ terminal
No. name (- terminal side) No.
ment side)
(a) Servo motor <1> Servo motor <2>

Regular: Approx. 33Ω (actual reference value)

Irregular: Large discrepancy from 33Ω
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.
Mea- Connector terminal
Pin Connector terminal Pin
sure- name (+ terminal
No. name (- terminal side) No.
ment side)
(b) Servo motor <3> Servo motor <5>

Regular: Gradual change in resistance (0 to within 6kΩ)

Irregular: No change in resistance
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(7) Pressure Switch

When a pressure switch (inside the high-pressure/low-pressure
switch) is operating normally, electricity is conducted (ON) and
when an abnormal pressure occurs, it trips the switch, blocking the
electricity (OFF).
RY9212001CAS0046US0
Manifold gauge connections
1. Close the HI (high-pressure side) valve (3) and the LO
(low-pressure side) valve (2) of the manifold gauge (1) securely.
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 (4) Red Charging Hose
(2) Low-Pressure Valve (5) Blue Charging Hose
(3) High-Pressure Valve
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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/cm2, 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/cm2, 28 psi)
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[2] DISASSEMBLY AND ASSEMBLY

(1) AC Unit Assembly/Disassembly

(1) AC Unit (3) Filter (5) Collar (a) To rear duct

(2) AC step (4) Bolt
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(2) Mounting and Removing the Compressor

(1) Compressor ASSY (3) V belt (5) Compressor bushing (a) Point to measure
(2) Compressor bracket (4) Bolt compressor belt tension
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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.
Capacity (reference
Compressor Oil Type: ND-OIL8
value): 60 cc

(1) New Compressor A : Amount of Oil for New

(2) Compressor Being Replaced Compressor
B : Amount of Oil from Old
Compressor

(a) Remove Excess Oil (A-B)

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When replacing the compressor, press at point (a) on the drive
belt and adjust the tension.
IMPORTANT
• Be careful that the compressor bushing faces the right
direction.
98 N
20 to 25 mm
Belt tension adjustment 10.0 kgf
0.79 to 0.98 in.
22 lbf
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(3) AC and Heater Hose Routing

[A] AC Hose

(1) Discharge hose (4) Liquid hose P2 (a) Compressor side (A) M24X1.5 connection
(2) Suction hose 2 (5) Liquid hose P1 (b) Condenser side (B) M16X1.5 connection
(3) Suction hose 1 (6) Liquid hose (c) AC unit side
(d) Receiver side

7.9 to 11.8 N·m

Discharge hose (1) (M6
0.8 to 1.2 kgf·m
bolt)
5.8 to 8.7 lbf·ft
29.4 to 34.3 N·m
Suction hose (2), (3)
3.0 to 3.5 kgf·m
(M24X1.5)
21.7 to 25.3 lbf·ft
11.8 to 14.7 N·m
Liquid hose (4), (5)
Tightening torque 1.2 to 1.5 kgf·m
(M16X1.5)
8.7 to 10.8 lbf·ft
7.9 to 11.8 N·m
Liquid hose (6) (Condenser
0.8 to 1.2 kgf·m
side M6 bolt)
5.8 to 8.7 lbf·ft
3.9 to 6.9 N·m
Liquid hose (6) (Receiver
0.4 to 0.7 kgf·m
side M6 bolt)
2.9 to 5.1 lbf·ft

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.)
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[B] Hose Routing

(1) Discharge hose (3) Liquid hose (a) 25 ° (0.44 rad)

(2) Suction hose 2 (4) Liquid hose P2
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(4) Electric Condenser/Fan Mounting and Removal

(1) Condenser cover (4) Liquid hose (6) Cushion (a) Electrical wiring
(2) Electric fan (5) Discharge hose (7) Condenser
(3) Condenser base
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(1) Heater hose 3 (6) Heater hose 2 (a) Engine side discharge (e) To engine side
(2) Liquid hose P1 (7) Liquid hose (b) Engine side return (f) To AC unit side
(3) Suction hose 1 (8) Discharge hose (c) AC unit return (g) Take care to face clamps
(4) Liquid hose P2 (9) Heater hose 1 (d) AC unit supply correctly.
(5) Suction hose 2
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7. WINDOW WASHER
[1] WIPER SWITCH
Connector voltage
1. Remove the 6P connector from the wiper switch.
2. Switch the starter switch to [RUN] and the wiper switch to ON.
3. Measure the voltage between terminal 1of the connector on the
harness side and ground on the body.
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)

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[2] WIPER MOTOR

Checking the Voltage
1. Remove the wiper motor connector.
2. Start the engine and turn the wiper switch ON.

Measure the voltage based on the table below.

Mea-
sure-
Connector Name Connector Name
ment Pin No. Pin No.
(+terminal side) (- terminal side)
Point
s
(a) Wiper motor connector <1> Wiper motor connector <2>
(b) Wiper motor connector <3> Wiper motor connector <2>

Regular: 12 V
Irregular: Large discrepancy from 12 V
(1) Wiper Motor A : Wiper Motor Connector
RY9212148CAS0019US0

[3] WASHER MOTOR

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.

Mea-
sure-
Connector Name Connector Name
ment Pin No. Pin No.
(+terminal side) (- terminal side)
Point
s
Washer motor Washer motor
(a) <2> <1>
connector connector

Regular: 12 V
Irregular: Large discrepancy from 12 V
(1) Washer Tank (2) Washer Motor Connector
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8. CABIN GLASS REMOVAL AND MOUNTING

[1] COMPONENT SCHEMATIC

No. Part Name Q'ty No. Part Name Q'ty

(1) Striker (door) 1 (16) Bolt 4
(2) Toothed washer 2 (17) Bolt 4
(3) Screw 2 (18) Screw 2
(4) Knob 1 (19) Handle 1
(5) Screw 2 (20) Spring nut 2
(6) Bolt 5 (21) Seal 1
(7) Handle ASSY (inner) 1 (22) Washer 2
(8) Cover 1 (23) U bolt 1
(9) Fastener 4 (24) Seal 1
(10) Door lock ASSY 1 (25) Handle ASSY (Outer) 1
(11) Joint 1 (26) Spacer 3
(12) Screw 3 (27) Upper glass 1
(13) Trim 1 (28) Spacer 6
(14) Doors 1 (29) Lower glass 1
(15) Hinge 2

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No. Part Name Q'ty No. Part Name Q'ty

(1) Spacer 8 (7) Roof 1
(2) Front glass 1 (8) Glass 1
(3) Rear glass 1 (9) Cushion 1
(4) Hook 2 (10) Glass 1
(5) Sash 1 (11) Spacer 2
(6) Spacer 5

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No. Part Name Q'ty No. Part Name Q'ty

(1) Stopper 2 (11) Lever 1
(2) Linkage 2 (12) Bolt 4
(3) Bolt 4 (13) Cover 1
(4) Bushing 4 (14) Cover 2
(5) Snap ring 4 (15) Clip 5
(6) Linkage 1 (16) Striker 1
(7) Snap ring 2 (17) Bolt 4
(8) Damper 1 (18) Stopper (rubber) 2
(9) Washer 2 (19) Nut 2
(10) Lever 1

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No. Part Name Q'ty No. Part Name Q'ty

(1) Nut 1 (11) Cover 1
(2) Arm (wiper) 1 (12) Clip 3
(3) Cap 1 (13) Screw 2
(4) Blade (wiper) 1 (14) Nozzle 1
(5) Nut 1 (15) Clamp 4
(6) Washer 1 (16) Bolt 2
(7) Gasket 1 (17) Hose 1
(8) Holder 1 (18) Flange 1
(9) Wiper Motor 1 (19) Washer tank 1
(10) Bolt 3

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No. Part Name Q'ty No. Part Name Q'ty

(1) Spacer 8 (7) Roof 1
(2) Front glass 1 (8) Glass 1
(3) Rear glass 1 (9) Cushion 1
(4) Hook 2 (10) Glass 1
(5) Sash 1 (11) Spacer 2
(6) Spacer 5

RY9212148CAS0080US0

[2] NECESSARY TOOLS

(1) Piano Wire (7) Torx (T50)
(2) Scraper (8) Wrench (10 mm)
(3) Slotted Screwdriver (9) Wrench (27 mm)
(4) Needle-Nose Pliers (10) Socket (M12),Ratchet
(5) Utility Knife (11) Suction Pads
(6) Slotted Screwdriver
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[3] REMOVING THE GLASS ON THE RIGHT

1. Protect inside cabin from possible glass debris.

CAUTION
• Take care not to get hurt from shards of glass.
(1) Cover
RY9212148CAS0037US0

2. Insert the utility knife between the frame of the cabin and the
right sash to make an opening to pass the piano wire through.

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
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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
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8. Expand the frame of the right sash in direction A and remove the
glass in direction B.
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[4] REMOVING THE FRONT GLASS

1. Remove the bolts and then the wiper.
2. Remove the cap.
(1) Nut (3) Cap
(2) Wiper
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 (3) Cover
(2) Cap
RY9212148CAS0045US0

5. Remove the three bolts and the wiper motor.

(1) 3 × Bolt (M6 × 25) (2) Wiper Motor
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6. Remove the cap and the cover. (LH/RH 2 places each)
(1) Cap (2) Cover
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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
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[5] REMOVING OTHER PANES OF GLASS

1. Protect inside cabin from possible glass debris.
2. Insert the utility knife between the cabin frame and the glass to
make an opening to pass the piano wire through.

CAUTION
• 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

[6] INSTALLING THE GLASS ON THE RIGHT

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 15°C or higher 10 minutes
temperature Below 15°C 30 minutes

(1) Cabin frame (a) No less than 20 mm (0.79 in.)

(2) Primer
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) (a) No less than 10 mm (0.39 in.)
(2) Nozzle (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

[7] INSTALLING THE FRONT GLASS

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 15°C or higher 10 minutes
temperature Below 15°C 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) (a) No less than 8 mm (0.31 in.)
(2) Nozzle (b) No less than 12 mm (0.47 in.)
(3) Trim
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)
9.0 to 15.0 N·m
Tightening torque Bolt (1) 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 CABIN
10. Install the wiper motor.
3.5 to 6.5 N·m
Tightening torque Bolt (2) 0.36 to 0.66 kgf·m
2.58 to 4.79 lbf·ft

(1) Wiper Motor (2) 3 × Bolt (M6 × 25)

RY9212148CAS0069US0

11. Install the wiper motor harness, cover and cap.

(1) Harness (3) Cap
(2) Cover
RY9212148CAS0070US0

12. Install the nut.

IMPORTANT
• Take care not to crack the glass.
2.5 to 3.5 N·m
Tightening torque Nut (1) 0.26 to 0.36 kgf·m
1.84 to 2.58 lbf·ft

(1) Nut
RY9212148CAS0071US0

13. Install the cap, wiper and nuts.

6.5 to 9.5 N·m
Tightening torque Nut (3) 0.66 to 0.97 kgf·m
4.79 to 7.01 lbf·ft

(1) Cap (3) Nut

(2) Wiper
RY9212148CAS0072US0

5-S50 KiSC issued 08, 2015 A

KX080-4, WSM CABIN

[8] INSTALLING OTHER PANES OF GLASS

1. Use the scraper and the cleaning agent to remove any
remaining adhesive, grime or oil on the frame and then apply
the trim to the frame.
2. Apply primer and allow to dry for the indicated time.
Ambient 15°C or higher 10 minutes
temperature Below 15°C 30 minutes

(1) Cabin Frame (a) No less than 18 mm (0.71 in.)

(2) Trim
(3) Primer
RY9212148CAS0073US0
3. Apply the adhesive.
(1) Nozzle (a) No less than 7 mm (0.31 in.)
(2) Trim (b) No less than 12 mm (0.47 in.)
(3) Adhesive (Sikaflex - 265)
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

9. REMOVAL AND INSTALLATION OF GLASS

[1] PREPARATION
Items required
• Cleaner : Equivalent of Seeker Cleaner 205
• Adhesive : Equivalent of Seeker Flex 250PC-JM
• Primer : Equivalent of Seeker Primer 206
• Scraper
• Awl
• 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

[2] REMOVING GLASS

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 (5) Piano Wire
(2) Glass (6) Wood
(3) Awl (7) Adhesive Cutter
(4) Adhesive
RY9212001CAS0086US0

5-S52 KiSC issued 08, 2015 A

KX080-4, WSM CABIN

[3] INSTALLING GLASS

1. Completely eliminate all old adhesive on the frame of the cab.
2. Use the cleaner to clean the cab frame and the surface of the
new glass where adhesive will be applied to get rid of any dirt or
oil.
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 (a) At Least 7 mm (0.28 in.)
(2) Windshield Dam (W/Adhesive) (b) At Least 12 mm (0.47 in.)
(3) Primer (Apply) (c) 12 mm (0.47 in.)
(4) Adhesive (Apply) (A) Start Affixing Dam Here
RY9212001CAS0087US0
• For the front window
(1) Glass (a) At Least 7 mm (0.28 in.)
(2) Windshield Dam (W/Adhesive) (b) At Least 12 mm (0.47 in.)
(3) Adhesive (Apply)
(4) Fastener (Affix as Male/Female Set) (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 (a) At Least 8 mm (0.31 in.)
(2) Windshield Dam (W/Adhesive) (b) At Least 12 mm (0.47 in.)
(3) Adhesive (Apply)
RY9212001CAS0089US0

5-S53 KiSC issued 08, 2015 A

KX080-4, WSM CABIN

[4] GLASS TRIM TYPE

(When removing)
1. Lift the rubber core by its seam and remove it.
2. Remove the glass to the outside.
(When attaching)
1. From the outside, insert the glass into the glass trim.
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 (a) Inside
(2) Glass Trim (b) Start Here
(3) Rubber Core
(4) Glass
RY9212001CAS0090US0

[5] HOW TO REPLACE THE GLASS OF THE RIGHT-SIDE WINDOW

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 (A) Push down to widen up the
(2) Window 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) (a) 12 mm (0.47 in.)
(2) Primer (Apply) (b) 12 mm (0.47 in.) or more
(3) Adhesive (Apply) (c) 7 mm (0.27 in.) or more

(A) Starting Point of Installation

RY9212032CAS0016US0
5-S55 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

10. FRONT WINDOW

[1] ADJUSTING THE CLOSING LOCK OF THE FRONT WINDOW
(TOP)
When water leaks in the cabin or it rattles
1. Close the front window (top) and lock it securely.
2. Remove the trim on the top edge of the front window (top) about
half way along the frame and measure the clearance between
the glass and the cab frame.
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 (a) Clearance
(2) Front Window (Top)
(3) Trim
(4) Cab Frame
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 (3) Bolt (Rear)
(2) Bolt (Front)
RY9212001CAS0093US0

5-S57 KiSC issued 08, 2015 A

KX080-4, WSM CABIN

[2] ADJUSTING THE OPEN LOCK OF THE FRONT WINDOW (TOP)

When it rattles on the cabin
1. Lift the front window (top) and lock it securely to the ceiling.
2. While pulling down on the handle, check whether there is a gap
between the glass and the cushion.
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 (3) Cushion
(2) Nut (4) Handle
RY9212001CAS0094US0

5-S58 KiSC issued 08, 2015 A

 W/H33 CORD,BATTERY(-)
W/H30 CORD,BATTERY(+) CORD,BATTERY(-)(MAIN_FRAME) BASE: 3 B BASE: 3 B
CRSD&N_BI: 100.0 f B BASE: 60.0 B/Y
CORD,BATTERY(-)(BATTERY) W/H33
W/H33 GND1 GND1 GND2 GND3 GND4
BODYEARTH(MAIN_FRAME)
+ BASE: 60.0 B/Y GND2
BATTERY W/H34
GND1:POWER(MAIN)
-
BATTERY_TERMINAL,N_BI
GND2:ECU,SENSOR(MAIN)
N_BI: 8.00 R SWING_FRAME GND3:POWER,SHIELD(ENGINE)
ENGINE GND4:ECU,SENSOR(ENGINE)
1
W/H34 CORD,BODY EARTH BODYEARTH(ENGINE)
BATTERY(POWER),N_BI MAIN(POWER),N_BI
N_BI: 8.00 R N_BI: 8.00 R
1 1
W/H09 W/H30

SBF,MAIN1-2
SBF(ENGINE)
AC: 5 R/Y
50 2 2
Plug-in_type Composition Specification Code Notes W/H00 RD828-53410 W/H(MAIN,CRS,CA,ANG)
RD828-53420 W/H(MAIN,CRS,CA,ANG)
SBF(MAIN) MAIN(POWER) ENGINE(POWER) BASE ALL-USE
BASE: 5 R BASE: 5 R BASE: 5 R W/H05 RD809-53333 W/H(FUELSENSOR)
60 1 1 1 1
SWITCH,STARTER AI Auto Idle

START
OFF
W/H06 RD829-53390 W/H(BLOWERMOTOR)

ON
BASE: 3 R
Plug-in_type W/H09 W/H00

SBF(CRS) SBF-BOX
KEY_SWITCH AT Anti-Theft W/H09 RD828-53340 W/H(ENGINE,CRS,US,ANG)

BASE: 5 R
BASE: 5 R
BASE: 5 R
AUX2: AUX1: 5 R
N_BI: 5 R
N_BI: 5 R

HT: AC: 5 R
HT: AC: 5 R
BASE: 5 R
BASE: 3 R
BCN: 5 R
CRSD: 5.00 R BASE: 3 R/W
30 3 3 1
R/W
N_AT No.Anti-Theft W/H10 1J770-65091 W/H(GS_INT)
BASE: 3 B/W
Bolt-in_type 2
B/W
W/H12 RD828-53510 W/H(FRONT)
No.Battery Isolator

BASE: 3 R/W
BASE: 3 R/W
BASE: 3 R/W
BASE: 3 R/W
BASE: 3 R R N_BI
SBF(ALTERNATOR)
SBF-BOX SBF-BOX 3 W/H19 RD829-49370 W/H(MAIN,CAB)
BASE: 8.00 R N_B
2 2 100 4 4 I: 8
.00
AT&BI Anti-Theft & Battery Isolator W/H20 RD829-49360 W/H(WIPER)
Bolt-in_type R
AT&N_BI Anti-Theft & No.Battery Isolator W/H21 RD828-47030 W/H(CAB,RADIO)
SBF_BOX RD451-54311
Engine Stop W/H28 RD829-49590 W/H(WORKLIGHT)
ES

BASE: 3 W

CAB: 3 W

CAB: 3 W

HT: AC: 3 W
RELAY(40A,ISO) W/H30 RD828-53220 CORD,BATTERY(+)
BCN Beacon
RELAY(POWER) RELAY(POWER) W/H33 RD809-53232 CORD,BATTERY(-)
BASE: 5 R 30 87 BASE: 3 W
3 4 TRB Travel Alarm W/H34 RD819-53241 CORD,BODY EARTH
BASE: 0.50 L 86 85 BASE: 0.30 B
1 2
GND2 HT Heater
AC A/C

EP Eco Power Mode

AUX1 Grip (L)
ASSY_ALTERNATOR
AUX2 Grip (R)
BASE: 8.00 R B
B-1 AT&AUX1 Anti-Theft & Grip (R)
ALTERNATOR(+B)
FUSE(ALTERNATOR) FUSE(ALTERNATOR) FUSE(ALTERNATOR)
CAB CAB (8+4)
BASE: 3 R/W BASE: 1.25 f Y/R
10
MiniFuses NB Normal Blade

IC
RD451-54101 RELAY(STARTER) W/H00 W/H09
RELAY(STARTER) W/H00 W/H09 ALTERNATOR(IG,L) AB Angel Blade
NULL BASE: 0.50 W/R BASE: 0.75 f W/R
FUSE(STARTER)
FUSE(STARTER) L
FUSE(STARTER) RELAY(STARTER) 4 W/H09 W/H00 ENGINE(OPEN) 8 8 MAIN(OPEN)
BASE: 3 B/W BASE: 3 B/W 30 87 CRSD: 3 B/W CRSD: 3 B/W BASE: 1.25 f Y/R BASE: 1.25 f Y/R
A-2
R BC Blade Cap
10 3 5 ENGINE(OPEN) 5 5 MAIN(OPEN) ENGINE(OPEN) 4 4 MAIN(OPEN) A-1
MiniFuses BASE: 0.50 R/B
1
86 85
2
GREASE GREASE GREASE GREASE N_FS No.Fuel Supply-pump
GREASE GREASE
Y/B

Y/B

RD451-54101
CRSD CRS-DENSO
CRSD: 0.50

0.50

MAIN(SIGNAL) ENGINE(SIGNAL) STARTER(S),D CRSD&N_BI CRS-DENSO & No.Battery Isolator

CRSD: 0.50 Y/B CRSD: 0.50 Y/B CRSD: 3 B/W
BASE:

S
15 15 A-1
COMMON ALL-USE
W/H09 W/H00 4-Cylinder
f B
30_+B

100.0 B-1 PLUG,GLOW

_BI: STARTER(+B),D GLOW,D
D&N
CRS CRSD: 3 R/B
ASSY_STARTER
M 1

RELAY(40A,ISO)
RELAY(GLOW) RELAY(GLOW) W/H00 W/H09
BASE: 5 R 30 87 CRSD: 3 R/B
3 4 ENGINE(OPEN) 2 2 MAIN(OPEN)
BASE: 0.50 B/R 86 85 BASE: 0.50 B/R GREASE GREASE
1 2

(V0511-53822)
ON OFF SW(DPF,INHIBIT) OFF ON
SWITCH(DPF,INHIBIT) SWITCH(E/P,CHANGE)
CRSD: 0.30 R/B Vcc(12V) E/F_CHANGE_SWITCH
7 SWITCH(DPF,INHIBIT) BASE: 0.30 R/B AC
OFF 7 E/F_CHANGE_SWITCH
9 OFF
SIGNAL CRSD: 0.30 G/O 9
6 ON BASE: 0.30 L/O
Null 6
8
Null 8
3
Null 3
2
CRSD: 0.30 R/B LED(AMBER) 680 LED(AMBER_GND) CRSD: 0.30 G/B 2
4 10 BASE: 0.30 R/B LED(+) LED(GND) BASE: 0.30 L/W
CRSD: 0.30 G/O RESISTANCE(GND) 620 RESISTANCE CRSD: 0.30 B 4 10
1 5 BASE: 0.30 L/O RESISTOR RESISTOR BASE: 0.30 B
GND2 1 620ohm 620ohm 5
CRSD: 0.30 G/O
GND2
BASE: 0.30 L/O

RELAY(ECU_MAINPOWER)
RELAY(ECU_MAINPOWER) N_BI:
NULL JOINT-AIM 0.50 232C 232C
FUSE(ECU_MAIN(POWER)) FUSE(ECU_MAIN(POWER)) FUSE(ECU_MAIN(POWER)) RELAY(ECU_MAINPOWER) 4 water-proof
Y/R
+B
BASE: 5 R BASE: 3 Y/R BASE: 3 Y/R 30 87 BASE: 3 Y/R 4
30 3 5 BASE: 0.50 B GND
BASE: 2 Y/R 86 85 BASE: 0.30 Y/G
MiniFuses 1 2 GND2 BASE: 0.50 L
3
Txd
RD451-54101 2
BASE: 0.50 B/O
SWITCH,LIMIT SOLENOID(LEVER_LOCK) 1
Rxd

FUSE(LEVER_LOCK) FUSE(LEVER_LOCK) FUSE(LEVER_LOCK) SWITCH(LEVER_LOCK) SWITCH(LEVER_LOCK) SOLENOID(LEVER_LOCK) SOLENOID(LEVER_LOCK)

BASE: 3 R/W BASE: 0.50 f L/W BASE: 0.50 f L/W B B BASE: 0.50 f G/W BASE: 0.50 f G/W BASE: 0.50 G/W BASE: 0.50 G/W (+) (-) BASE: 0.50 G BASE: 0.50 G
5 2 1 ENGINE(SOLENOID) 8 8 MAIN(SOLENOID) 1 2 MAIN(SOLENOID) 12 12 ENGINE(SOLENOID)
MiniFuses W/H00 W/H09 W/H09 W/H00 AT&N ANTENNA(ANTITHEFT)

G/W
_
RD451-54101 SWITCH(PRESSURE,25.0K) BI: 0.30
AI_PRESSURE_SW AI_PRESSURE_SW Y/R
LED+
AI: 0.50 R/B AI: 0.50 R/B NC NC AI: 0.50 G/W AI: 0.50 G/W 6

0.50
ENGINE(SIGNAL) 3 3 MAIN(SIGNAL) 1 2 MAIN(SIGNAL) 7 7 ENGINE(SIGNAL) AT: 0.30 R LED
W/H00 W/H09 W/H09 W/H00 3

BASE:
SWITCH(PRESSURE,25.0K) AT: 0.50 W/B
5
+12V
BOOM_RAISE_SW BOOM_RAISE_SW AT: 0.30 W TX
EP: 0.50 R/B NC NC EP: 0.50 G/R EP: 0.50 G/R 1 INOUT
1 2 MAIN(SIGNAL) 12 12 ENGINE(SIGNAL) AT: 0.30 G RX RF
W/H09 W/H00 4
AT: 0.30 B GND
2
GND2 ANTITHEFT_ANTENNA
ECU(MAIN) ECU(MAIN) ECU(MAIN)
BASE: 0.50 L BASE: 0.50 Y
W/B

TxD(MAIN-ECU) CAN-H
61 60
BASE: 0.50 B/O RxD(MAIN-ECU) CAN-L BASE: 0.50 G
SWITCH,ASSY.ENGINE_STOP
0.50

80 79
MAIN-POWER BASE: 2 f Y/R BASE: 2 f B
AT: 0.30 W TxD(RF-UNIT)
3 GND1
AT:

49
STOP_SWITCH STOP_SWITCH
AI-MOTOR(+)
ES: 0.50 W/B R G ES: 0.50 R/L
AT: 0.30 G
1 2 RxD(RF-UNIT)
SOLENOID(AUX1-R)
PANEL,ASSY(AI) 51 AI-MOTOR(-)
SOLENOID(AUX1-R) SOLENOID(AUX1-R)
AI_CONSOLE AC: 0.50 Y COMPRESSOR-CRUTCH-SW
AUX1: 0.50 W AUX1: 0.50 W SW1 SW2 AUX1: 0.50 W/B
+5V AI: 0.50 R/B 45 BASE: 2 f B 1 1 MAIN(SOLENOID)
MOTOR-GND ENGINE(SOLENOID) 1 2
8 AI: 0.50 G/W AI-PRESSURE-SW 1 W/H00 W/H09
1kohm,0.4W AI_POT AI: 0.30 R 50 SOLENOID(AUX1-L)
7 W/H00 W/H09 SOLENOID(AUX1-L) SOLENOID(AUX1-L)
BASE: 0.30 R/W WORKLIGHT-SW AUX1-SOL(R) AUX1: 0.50 W
GND AI: 0.50 B/Y AUX1: 0.50 R/W AUX1: 0.50 R/W SW1 SW2 AUX1: 0.50 W/B
4 44 24 9 9 MAIN(SOLENOID)
ENGINE(SOLENOID) 1 2
+12V AI: 0.50 R/B BASE: 0.50 Y/B STARTER-SW AUX1-SOL(L) AUX1: 0.50 R/W AUX1: 0.50 W/B AUX1: 0.50 W/B
750ohm,0.5W 2 46 23 ENGINE(SOLENOID) 5 5 MAIN(SOLENOID)
AUX_LED
5
AI: 0.30 W ES: 0.50 R/L ENGINE-STOP-SW AUX1-SOL-FEEDBACK AUX1: 0.50 W/B W/H00 W/H09 SOLENOID(AUX2-R)
750ohm,0.5W 63 19 SOLENOID(AUX2-R) SOLENOID(AUX2-R)
AI_LED AI: 0.30 L/W
1 WATERSEPARATOR-SW AUX2: 0.50 O AUX2: 0.50 O SW1 SW2 AUX2: 0.50 O/B
150ohm,2W AUX_SW AI: 0.30 B/R 2 2 MAIN(SOLENOID)
AUX2-SOL(R) AUX2: 0.50 O ENGINE(SOLENOID) 1 2
3 W/H00 W/H09
150ohm,2W AI_SW AI: 0.30 O
BASE: 0.30 L/O EP-MODE-SW 42 SOLENOID(AUX2-L)
6 65 AUX2-SOL(L) AUX2: 0.50 P AUX2: 0.50 P SOLENOID(AUX2-L) SOLENOID(AUX2-L)
EP: 0.50 G/R BOOM-RAISE-SW 43 AUX2: 0.50 P SW1 SW2 AUX2: 0.50 O/B
66 ENGINE(SOLENOID) 10 10 MAIN(SOLENOID) 1 2
AUX2-SOL-FEEDBACK AUX2: 0.50 O/B
AUX2: 0.50 O/B AUX2: 0.50 O/B
GRIP(2SPEED) TRAVEL_SPEED_SW AI: 0.30 B/R MULTIPURPOSE-SW 16
ENGINE(SOLENOID) 6 6
MAIN(SOLENOID)
Vcc(W) NB: 0.50 W/B 74
W/H00 W/H09
1 AI: 0.30 O AI-CHANGE-SW EP-SOL EP: 0.50 G W/H00 W/H09 SOLENOID
PUSH_SW(B) NB: 0.50 Y/B 75 22 SOLENOID(E/P) SOLENOID(E/P)
2 NB: 0.50 Y/B EP: 0.50 G SW1 SW2 EP: 0.50 G/B
TRAVEL-SPEED-SW EP-SOL-FEEDBACK EP: 0.50 G/B
Y/B 1 2
.50 57 21
3 AB: 0
AUX2: AUX1: 0.30 L/W MULTIPURPOSE-LEVER-SW
ENGINE(SOLENOID) MAIN(SOLENOID)
73
BASE: 0.50 Y BASE: 0.50 Y
SOLENOID(TRAVEL_SPEED)
GRIP(ANGLE)
TRAVEL-SPEED-SOL
TRAVEL_SPEED&ANGLE_BLADE_CONTROL_SW CRSD: 0.30 G/O DPF-INHIBIT-SW 4 4 SOLENOID(TRAVEL_SPEED) SOLENOID(TRAVEL_SPEED)
81
Vcc(B) AB: 0.50 W/B 70 BASE: 0.50 Y BASE: 0.50 B
W/H00 W/H09 (+) (-)
1 AUX2: AUX1: 0.30 Y/R AUX1-HOLD-SW MULITIPURPOSE-SOL 1 2
PUSH_SW(W) AB: 0.50 Y/B
2
69 17 GND3
AUX2: AUX1: 0.30 L AUX2-HOLD-SW
LEFT_SW(Y) AB: 0.50 R/Y ANGLE(R)-SOL AB: 0.50 G/W
3 72
18
RIGHT_SW(Y) AB: 0.50 L/Y AB: 0.50 L/Y ANGLE(R)-SW
4 71 AB: 0.50 R/B
R/Y
ANGLE(L)-SOL
20 SOLENOID(ANGLE-R)
AB: 0.50 ANGLE(L)-SW
SOLENOID(ANGLE-R) SOLENOID(ANGLE-R)
68 ANTITHEFT-HORN-RELAY AT: 0.50 L/R AB: 0.50 G/W (+) (-) AB: 0.50 B
BASE: 0.50 G/W LEVER-LOCK-SW 13 1 2
SENSOR(PRESSURE,5MPA) 67
SOLENOID(ANGLE-L) GND1
LEVER-LOCK-SOL BASE: 0.50 G
GND BASE: 0.50 B/Y 62 SOLENOID(ANGLE-L) SOLENOID(ANGLE-L)
1 CHARGE-INPUT AB: 0.50 R/B (+) (-) AB: 0.50 B
SENSOR Vout
2
BASE: 0.50 L/B
TRAVEL-ALARM-BUZZER BASE: 0.50 B/Y 1 2
GND1
5MPA Vcc(+5V) BASE: 0.50 R/B OIL-SW 14
3 BUZZER-OUT BASE: 0.50 Y/B
TRAVEL_PRESSURE_SENSOR FUEL-SW 40 TRAVEL_ALARM(FRONT,+)
BASE: 0.50 R/B 0.5R(+)
A-1 BUZZER,BACK
ANTITHEFT-RELAY BASE: 0.50 B/Y 0.5B(-)
DISPLAY-CHANGE-SW B-1
TRAVEL_ALARM(FRONT,GND)
STARTER-RELAY
USER-CHANGE-SW
BUZZER,BACK

water-proof
BASE: 0.50 R/B +5V-OUT GLOW-RELAY BASE: 0.50 B/R W/H00 W/H09
11 33 W/H00 W/H09 TRAVEL_ALARM(REAR,+)
BASE: 0.50 B/Y BASE: 0.50 R/B BASE: 0.50 R/B 0.5R(+)
GND(Sensor-Use)
BACKETLOCK-SOL-RELAY ENGINE(OPEN) 3 3 MAIN(OPEN) A-1
10 BASE: 0.50 B/Y BASE: 0.50 B/Y 0.5B(-)
FUEL-SENSOR ENGINE(OPEN) 7 7 MAIN(OPEN) B-1
EF-MODE-INDICATOR BASE: 0.30 L/W GREASE GREASE TRAVEL_ALARM(REAR,GND)
BASE: 0.50 L/B 47 GREASE GREASE
TRAVEL-PRESSURE-SENSOR
53 DPF-INHIBIT-INDICATOR CRSD: 0.30 G/B
N_B
WATER-TEMP-SENSOR
48 I: 0
.85
ANTITHEFT-FLASHER-LED AT: 0.30 R Y/R ELECTRICAL_BUZZER
JOINT-BUZ AV0.5R(+)
OIL-TEMP-SENSOR 37 water-proof 1 BUZZER,BACK
BASE: 0.50 Y/B AV0.5B(-)
MULTI-PURPOSE-LED AI: 0.30 W
BOOM-ROD-PRESS-SENSOR 2
38
BOOM-BOT-PRESS-SENSOR AI-MODE-LED AI: 0.30 L/W
6 39
BOOM-POT
AI-SELFHOLD-RELAY BASE: 0.30 Y/G
12
AI: 0.30 R ACCEL-POT
7
AI-MOTOR-POT

ARM-POT

AUX2: AUX1: 0.30 W AUX1-POT1

28
ASSY_METER
LCD_METER
AUX1-POT2 BASE: 0.50 R +B
7
AUX2: AUX1: 0.30 W AUX2-POT1 BASE: 0.50 G CAN(L)
29 5
BASE: 0.50 Y CAN(H)
AUX2-POT2
6
BASE: 0.50 R/B AC_SW
8
BASE: 0.50 L FUEL_SENSOR
ENGINE-REV-SIGNAL
1
WATER_TEMP_SENSOR
BASE: 0.50 B/W WAKEUP-SIGNAL 2
31 ANALOG_GND
ES: 0.50 W/B +12V-OUT
3
CN_VSS
41
4
BASE: 0.50 R/B AC-SW(KEY-SW) CRSD: 0.50 L OLS_SW
W/B

N_BI: 76 9
0.50 Y/R BASE: 0.50 W/R CHARGE_SW
+B(DIRECT)
B/W 10
59
0.30

BASE: 0.50 WAKEUP_OUT

BASE: 2 f B GND(POWER) 11
2 REMOTE_WAKE_UP
AUX2: AUX1:

GND2 12

13
BASE: 0.50 B GND
AI: 0.50 R/B 14
GND2
N_BI: 0.50 Y/R
W/H00 W/H09
AT&N_BI: 0.30 Y/R CRSD: 0.50 L CRSD: 0.75 f L
ENGINE(SOLENOID) 3 3 MAIN(SOLENOID)
AUX2: AUX1: 0.30 R/B
N_BI: 0.85 Y/R

AI: 0.50 B/Y BASE: 0.50 R/B water-proof SWITCH,OIL

JOINT-OIL-SW OIL-SW,D
R/B
R/B
R/B
R/B
BASE: 0.50 R/B

R/B
B/R

CRSD: 0.75 f L
AI: 0.50 R/B
AI: 0.50 R/B

1
CRSD: 0.30
CRSD: 0.30
BASE: 0.30
BASE: 0.30

BASE: 0.50
BASE: 0.50

B/Y
AUX2: AUX1: 0.30 SENSOR,FUEL
FUSE(ECU-MAIN(AC)) FUSE(ECU-MAIN(AC)) FUSE(ECU-MAIN(AC)) SENSOR,FUEL SENSOR,FUEL
BASE: 3 R/W BASE: 0.50 R/B BASE: 0.50 L BASE: 0.50 L BASE: 0.50 L FUEL_SENSOR EARTH BASE: 0.50 B
5 ENGINE(SIGNAL) 4 4 MAIN(SIGNAL)
FUELSENSOR
1 1 ENGINE(FUEL_SENSOR) 1 2
MiniFuses W/H00 W/H09 W/H09 W/H05
3
DUMMY
R/B

R/B

RD451-54101
BASE: 0.50 B BASE: 0.50 B BASE: 0.50 B
W/H05 W/H,FUEL_SENSOR
CRSD: 0.50

BCN: 0.30

ENGINE(SIGNAL) 8 8 MAIN(SIGNAL) 2 2 ENGINE(FUEL_SENSOR)

FUELSENSOR
GND2 W/H00 W/H09 W/H09 W/H05
FUSE(ECU-MAIN(+B)) FUSE(ECU-MAIN(+B)) FUSE(ECU-MAIN(+B)) CAN CAN
N_BI: 5 R N_BI: 0.50 Y/R W/H09 W/H,ENGINE 5 5 BASE: 0.50 Y CAN(H)
5 1
BASE: 0.50 G
MiniFuses 8 8
2
CAN(L)

RD451-54101
6 6
VALVE,ASSY(PL,R,AX)
JS_CONTROL(R) JS_CONTROL(R) 7 7
AUX2: AUX1: 0.30 R/B +5V(R) GND(B) AUX2: AUX1: 0.30 B/Y
1 2 1 1
OUTPUT(W) AUX2: AUX1: 0.30 W
8 3 N_AT: 0.50 L/W 4 4
AUX2: AUX1: 0.30 L Vcc_SW1(G) HORN_SW1(L) AUX2: AT&AUX1: 0.30 L/W
7 4
AUX2: AUX1: 0.30 W/B Vcc_SW2(Gy) TRIG_SW2(Y) AUX2: AUX1: 0.30 Y/R 3 3
5 6
FUSE(METER(+B)) FUSE(METER(+B)) FUSE(METER(+B))
2 2
BASE: 5 R BASE: 0.50 R VALVE,ASSY(PL,L,AX)
W/B

10 to_J/C(CAN,MAIN)
JS_CONTROL(L) JS_CONTROL(L)
MiniFuses AUX2: AUX1: 0.30 R/B +5V(R) GND(B) AUX2: AUX1: 0.30 B/Y
J/C(CAN,MAIN)
RELAY(HORN)
0.30

RD451-54101 1 2
OUTPUT(W) AUX2: AUX1: 0.30 W RELAY(HORN)
8 3 NULL
AUX2: AUX1:

AUX2: AUX1: 0.30 W/B Vcc_SW1(G) PUSH_SW1(L) AUX2: AUX1: 0.30 L/W RELAY(HORN) 4
7 4 BASE: 0.50 L/W 30 87 BASE: 1.25 L
AUX2: AUX1: 0.30 W/B Vcc_SW2(Gy) TRIG_SW2(Y) AUX2: AUX1: 0.30 L 3 5
L/R
5 6 DIODE(7321-9822) AT: 0.50
L/W 1
86 85
2
BASE: 0.50 B
FUSE(HORN-SW) FUSE(HORN-SW) FUSE(HORN-SW) DIODE(ANTITHEFT_HORN_PROTECT) D_7321-9822 DIODE(ANTITHEFT_HORN_PROTECT) 0 .50 L/R
GND2
AUX2: AUX1: 5 R AUX2: AUX1: 0.30 L AUX2: AT&AUX1: 0.30 L/W A C AT: 0.50 L/R N_AT:
5 2 400V 1 : 0 . 5 0
BASE: 0.50 L HORN(+) ASSY_HORN
AT BASE: 1.25 L
MiniFuses A-1
T1

BASE: 1.25 B
FUSE(HORN-MAIN) FUSE(HORN-MAIN) FUSE(HORN-MAIN) DIODE(7321-9822) B-1
T2

BASE: 5 R BASE: 0.50 L/W DIODE(HORN) D_7321-9822 DIODE(HORN)

HORN(-)
10 BASE: 0.50 L C A BASE: 0.50 B
MiniFuses 1 400V 2
L

RD451-54101 GND2
R/W
0.50

RELAY(LIGHT)
0.30

OFF ON
BASE:

RELAY(LIGHT)
SWITCH(WORKLIGHT) NULL LIGHT,WORK
FUSE(RELAY) FUSE(RELAY) FUSE(RELAY) RELAY(LIGHT) FUSE(FRONT-WORKLIGHT) FUSE(FRONT-WORKLIGHT) FUSE(FRONT-WORKLIGHT) to_MAIN(WORKLIGHT) to_MAIN(WORKLIGHT)
BASE:

WORKLIGHT_SWITCH 4 to_WORKLIGHT to_WORKLIGHT

BASE: 3 R/W BASE: 0.50 L BASE: 0.50 L Vcc BASE: 3 R 30 87 BASE: 3 Y BASE: 3 Y BASE: 1.25 Y BASE: 1.25 Y CA_R(+) CB_B(-) BASE: 1.25 f B BASE: 1.25 B
5 7 WORKLIGHT_SWITCH 3 5 15 W/H00 1 1 W/H12 1 2 W/H12 2 2 W/H00
OFF BASE: 0.30 R 86 85 BASE: 0.50 B GND2
MiniFuses MiniFuses FRONT_WORKLIGHT(+) FRONT_WORKLIGHT(-)
L

9 1 2
RD451-54101 ON BASE: 0.30 R GND2 RD451-54101
0.50

W/H12 W/H(FRONT)
R/W

8 FUSE(CAB-WORKLIGHT) FUSE(CAB-WORKLIGHT) FUSE(CAB-WORKLIGHT)

BCN:

BASE: 3 Y BASE: 2.00 Y

HT: AC: 0.30

3 20
2 MiniFuses
BASE: 0.50 L LED(+) LED(GND) BASE: 0.30 B RD451-54101
4 10
GND1
1 5

RELAY(BEACON)
RELAY(BEACON) LIGHT,WORK
NULL W/H00 W/H19 to_CAB_WORKLIGHT,FR(+) CAB_WORKLIGHT,FR(+) CAB_WORKLIGHT,FR(-) to_CAB_WORKLIGHT,FR(-)
FUSE(BEACON) FUSE(BEACON) FUSE(BEACON) RELAY(BEACON) 4 BASE: 2.00 Y BASE: 0.85 R BASE: 0.85 R CA_R(+) CB_B(-) BASE: 0.85 B BASE: 0.85 B
BCN: 5 R BCN: 1.25 W BCN: 1.25 W 30 87 BCN: 1.25 BR 4 4 to_MAIN(CAB) 1 1 CAB(CAB_WORKLIGHT,FR(+)) A-1 B-1 CAB(CAB_WORKLIGHT,FR(-)) 1 1
15 3 5
CAB
W/H19 W/H28 LIGHT,WORK W/H28 W/H19 RADIO
R
R

BCN: 0.30 R/B 86 85 BCN: 0.30 R/Y BASE: 0.50 O

MiniFuses 1 2 to_CAB_WORKLIGHT,FL(+) CAB_WORKLIGHT,FL(+) CAB_WORKLIGHT,FL(-) to_CAB_WORKLIGHT,FL(-) RADIO(+B) A-1
RADIO(+B)

RD451-54101 BASE: 0.85 R

0.85
0.85

BASE: 0.85 R CA_R(+) CB_B(-) BASE: 0.85 B BASE: 0.85 B BASE: 1.25 Y RADIO(AC)
1 1 CAB(CAB_WORKLIGHT,FL(+)) 1 1 RADIO(AC)
A-1 B-1 CAB(CAB_WORKLIGHT,FL(-)) SPEAKER,ASSY BASE: 0.50 B
B-1
W/H19 W/H28 LIGHT,WORK W/H28 W/H19 SPEAKER(R) RADIO(GND)
RADIO(GND)
C-1
BASE:
BASE:

OFF ON CAB_WORKLIGHT,B(+) CAB_WORKLIGHT,B(-) BASE: 1.25 B

SWITCH(BEACON) BASE: 0.85 R CA_R(+) CB_B(-) BASE: 0.85 B
(-)
1
BASE: 0.50 W/B
RADIOFRAME(GND)
RADIOFRAME(GND)
D-1
BEACON_SWITCH A-1 B-1 (+) BASE: 0.50 W BASE: 0.50 W SPEAKER(R+)
BCN: 0.30 R/Y SPEAKER(R-)
7
Vcc
BEACON_SWITCH LAMP(BEACON) 2
BASE: 0.50 W/B
E-1
SPEAKER(R-)
W/H00 W/H19 BEACON(+) BEACON(-) SPEAKER(R-)
OFF
9 BCN: 1.25 BR BASE: 1.25 BR BASE: 1.25 BR M5 M5 BASE: 0.85 B
SPEAKER,ASSY BASE: 0.50 Y
F-1
ON BCN: 0.50 B 8 8 to_MAIN(CAB) 1 M 2 SPEAKER(L) SPEAKER(L+)
SPEAKER(L+)
G-1
6
CAB
(-) BASE: 0.50 Y/B BASE: 0.50 Y/B SPEAKER(L-) CAB_POWER_SOURCE
O

GND2
BASE: 1.25 BR

8
ASSY_LIGHT,ROOM (+)
1
BASE: 0.50 Y
SPEAKER(L-) H-1
BASE: 1.25 B
GND(RADIO)
1
BASE: 0.50

W/H00 W/H19 ROOM_LIGHT 2

3 BASE: 0.50 O BASE: 0.50 O BASE: 0.50 O com DOOR GND(RADIO,CAB) 2
3 3 to_MAIN(CAB) 2 1 BASE: 0.50 O ROOM_LIGHT(+B)
CAB
2 ON BASE: 1.25 B 3
O

BCN: 0.50 L LED(+) LED(GND) BCN: 0.30 B 3 BASE: 0.85 R CAB_WORK_LIGHT

4 10 4
GND2
BASE: 0.50

BASE: 3 B GND(CAB)
B

1 5 5
FUSE(ROOM_LIGHT) FUSE(ROOM_LIGHT) FUSE(ROOM_LIGHT)
0.50

N_BI: 5 R BASE: 0.50 O

B

6
5 BASE: 1.25 Y RADIO(AC)
BASE: 0.85

BASE: 0.85

BASE: 0.85

BASE: 0.85

MiniFuses 7
BASE:

W/H00 W/H19 BASE: 1.25 BR BEACON

W/H00 W/H19 8
FUSE(RADIO(AC)) FUSE(RADIO(AC)) FUSE(RADIO(AC)) W/H00 W/H19 BASE: 1.25 Y BASE: 3 B
CAB_POWER_SOURCE
CAB: 3 W CAB: 1.25 Y CAB: 1.25 Y BASE: 1.25 Y
15 CAB
7 7 to_MAIN(CAB) GND(CABFRAME)
BASE: 3 B BASE: 3 B
MiniFuses 5 5 to_MAIN(CAB)
GND2 BASE: 0.85 B CAB
BASE: 1.25 B
1 1 to_MAIN(CAB)
B

FUSE(WIPER/WASHER) FUSE(WIPER/WASHER) FUSE(WIPER/WASHER) GND(RADIO) CAB BASE: 0.85 G

2 2 to_CAB(WIPER)
BASE: 0.50 B
1
(+B)
MOTOR_WIPER
to_WIPER
CAB: 1.25 G/W
BASE: 0.50

CAB: 3 W CAB: 1.25 G/W BASE: 0.85 G BASE: 0.50 W (S)

15 3 3 to_MAIN(CAB_WIPER) WIPER,F
CAB(WIPER)
CAB: 1.25 R/W BASE: 0.85 W BASE: 0.85 W BASE: 0.50 R
4
M BASE: 0.50 G
MiniFuses CAB(WIPER) 1 1 to_MAIN(CAB_WIPER) to_WIPER 4 4 to_CAB(WIPER) 3
(+1) (-)
2
SWITCH,ASSY(WIPER)
WASH2

WASH1

RD451-54101
OFF
ON

CAB: 1.25 L/W BASE: 0.85 R BASE: 0.85 R WIPER,F

2 2 to_MAIN(CAB_WIPER) 3 3 to_CAB(WIPER)
CAB(WIPER) TANK(WASHER) to_WIPER
BASE: 1.25 B
WIPER_SWITCH WASHER_TANK WASHER_TANK BASE: 0.85 B BASE: 0.50 G
WASHER(B)
3
CAB: 1.25 W CAB: 1.25 W
CAB(WIPER) 4
BASE: 0.50 W
4 to_MAIN(CAB_WIPER)
BASE: 0.50 W
2
(+)
M (-)
1
BASE: 0.50 B to_WIPER 1
W/H19
1 to_CAB(WIPER)
W/H20
GND(WIPER,F)
W/H19 W/H,CAB
Vcc_wash(Y/B) CAB: 1.25 G/W W/H00 W/H19 W/H19 W/H20
2 W/H00 W/H19 W/H19 W/H20
Vcc(R)

mo(+1)(G/R)
1
CAB:

CAB:
1.25

1.25
G/W

R/W
W/H00
W/H00
W/H19
W/H19
W/H19 W/H20
W/H20 W/H,WIPERCODE
6
S(G/W) CAB: 1.25 L/W
5
Null SERVO_MOTOR SERVO_MOTOR
4 ASSY_SWITCH,AIR-CON HT: AC: 0.50 W MAXCOOL
M
1
HT: AC: 0.50 Y                
2
CONSTANT OUT HT: AC: 0.50 BR/W Pt
A/C_HEATER_CONTROLER IN VOLTAGE A/C_SW A/C_HEATER_CONTROLER 3
HT: AC: 0.50 R CIRCUIT POT_Vcc HT: AC: 0.50 R/Y null
FUSE(A/C_CONTROLLER)
+B
FUSE(A/C_CONTROLLER) FUSE(A/C_CONTROLLER) 16 2 4
HT: AC: 5 R HT: AC: 0.50 R HT: AC: 0.50 W/R IG POT_Vout HT: AC: 0.50 BR/W HT: AC: 0.50 R/Y GND
5 8 1 5
MiniFuses HT: AC: 0.50 W/R null A/C_FAN_SWITCH
W/R

POT_GND
7 CPU 3 6
HT: AC: 0.50 W/R Vz
FUSE(BLOWER) FUSE(BLOWER) FUSE(BLOWER)
RELAY(20A,MICRO-ISO) 14 12 7
OFF Lo Mi Hi
HT: AC: 0.50

HT: AC: 5 R HT: AC: 3 R AC: 0.50 G/B HT: AC: 0.50 Y
30 RELAY(BLOWER)
THERMO_SW
HOT_OUT SERVO_OUT2:HOT
11 6
Null HT: AC: 0.50 L HOT_IN COOL_IN HT: AC: 0.50 W A/C_FAN_SWITCH
MiniFuses RELAY(BLOWER) 4 10
FAN
COOL_OUT SERVO_OUT1:COOL
5 HT: AC: 3 B com
HT: AC: 3 L/W
MOTOR HT: A
C: 0
HT: AC: 3 R 30 87 DRIVE ILL(-) HT: AC: 0.50 B 3
FUSE(COMPRESSOR) FUSE(COMPRESSOR) FUSE(COMPRESSOR) 3 5 13 CIRCUIT 9 HT: AC: 0.50 L HT: A
.50 L
P-ON
HT: AC: 3 W HT: AC: 0.85 W/R HT: AC: 0.85 W/R 86 85 HT: AC: 0.50 L
COMPRESSOR_ASSY HT: AC: 0.30 R/W ILL(+) GND HT: AC: 0.50 B GND1 C: 0.5 6
10 1 2 15 4 HT: AC: 0.50 L
0 L
LO
COMPRESSOR_CLUTCH(A/C) RD451-93901 GND1 W/H06 W/H,BLOWERMOTOR,AC 2
MiniFuses
Y

AC: 0.85 Y AC: 1.25 f Y HT: AC: 3 L/Y MID

W/R
W/R

RD451-54101 RELAY(20A,MICRO-ISO) ENGINE(SIGNAL) 1 1 MAIN(SIGNAL) 1 1

AC: 0.50

W/H00 W/H09 HT: AC: 3 L/B HI

RELAY(COMPRESSOR)
DIODE(6098-0061) 4 19.6A
0.85
0.85

Null HT: AC: 3 B

RELAY(COMPRESSOR) 4 DIODE(COMPRESSOR) D_6098-0061 DIODE(COMPRESSOR) 5
AC: 0.85 W/R 30 87 AC: 0.85 Y AC: 0.50 Y AC: 0.50 B GND1
AC:
AC:

C A
3 5 1 3A 2 HT: AC: 3 B
AC: 0.85 W/R 86 85 AC: 0.50 G/R GND1
1 2
DUAL_PRESSURE_SWITCH GND1
DUAL_PRESSURE_SWITCH DUAL_PRESSURE_SWITCH
AC: 0.50 G/R AC: 0.50 G AC: 0.50 G
ENGINE(SIGNAL) 2 2 MAIN(SIGNAL) 1 2 MAIN(SIGNAL) 6 6 ENGINE(SIGNAL)
W/H00 W/H09 W/H09 W/H00
THERMOSTAT
RELAY(CONDENSOR_FAN) THERMOSTAT
AC: 0.85 W/R A/C THERMISTOR
RELAY(CONDENSOR_FAN)
Null AC: 0.50 G
2 6 THERMISTOR
SBF(CONDENSOR_FAN)
MGC THERMISTOR
FUSE(CONDENSOR_FAN) FUSE(CONDENSOR_FAN) RELAY(CONDENSOR_FAN) 4 3 7
AC: 5 R/Y AC: 3 R/L AC: 3 R/L 30 87 AC: 2 f R/G Null GND
20 3 5 4 1 2 RESISTOR_BLOWER
AC: 0.85 W/R
Plug-in_type ENGINE(SIGNAL) 5
AC:
5 MAIN(SIGNAL)
0.85 W/R
1
86 85
2
AC: 0.50 G/R AC: 0.50 G/B
1
GND Null
5 RESISTOR_BLOWER
361897-0713 W/H00 W/H09 CONDENSOR_FAN THERMOSTAT HT: AC: 3 L/Y M1
1 221 ℃± 10 ℃
CONDENSOR_FAN CONDENSOR_FAN BASE: 3 L/B BASE: 3 L/B HI
AC: 2 f R/G (+)L (-)B AC: 2 f B 2
2 M 1 HT: AC: 3 B LO
GND3 3
M2
[MAIN]to_BLOWER_MOTOR MAIN_to[BLOWER_MOTOR] 4
HT: AC: 3 L/B BASE: 3 L/B
W/H00 2 2 W/H06
BLOWER_MOTOR
[MAIN]to_BLOWER_MOTOR MAIN_to[BLOWER_MOTOR] BLOWER_MOTOR BLOWER_MOTOR
CigaretteSocket HT: AC: 3 L/W BASE: 3 L/W BLOWER BLOWER BASE: 3 L/B
FUSE(ELECTRICAL_OUTLET) FUSE(ELECTRICAL_OUTLET) FUSE(ELECTRICAL_OUTLET) ELECTRICAL_OUTLET W/H00 1 1 W/H06 1 M 2
BASE: 3 W
15
BASE: 1.25 G BASE: 1.25 G (+) (+)
1
BASE: 2 B
MiniFuses (-) GND W/H06 W/H,BLOWERMOTOR,AC
2
RD451-54101 GND2
ASSY_PUMP,FUEL_BOOT
FUSE(FUEL_PUMP) FUSE(FUEL_PUMP) FUSE(FUEL_PUMP) W/H00 W/H09 FUEL_PUMP
BASE: 3 R/W BASE: 0.50 Y/R BASE: 0.50 Y/R +
5 ENGINE(OPEN) 6 6 MAIN(OPEN) 1
BASE: 0.50 B
MiniFuses GREASE GREASE
2
-

RD451-54101 GND3

FUSE(HEATER,FUELFILTER) FUSE(HEATER,FUELFILTER) FUSE(HEATER,FUELFILTER) W/H09 HEATER(FUEL_FILTER)

W/H00 HEATER(FUEL_FILTER) HEATER(FUEL_FILTER)
BASE: 3 W BASE: 1.25 W BASE: 1.25 f W W W/B BASE: 1.25 f B
20 ENGINE(OPEN) 1 1 MAIN(OPEN) 1 2
MiniFuses GREASE GREASE GND3
7154-5845-30

RELAY(CRS_MAIN)
RELAY(CRS_MAIN)
JOINT-CRS_RELAY1,D NULL
water-proof RELAY(CRS_MAIN) 4
CRSD: 3.00 R 30 87 CRSD: 3.00 R
3 5
CRSD: 2.00 R 86 85 CRSD: 0.50 L
1 2
W/H09 W/H00
W/H09 W/H00

CRSD: 0.50 G
REGISTER(120ohm) REGISTER(120ohm) REGISTER(120ohm) CRSD: 0.50 G
CRSD: 0.50 Y REGISTER REGISTER CRSD: 0.50 G MAIN(SIGNAL) 13 13 ENGINE(SIGNAL)
2 120ohm 120ohm 1 CRSD: 0.50 Y CRSD: 0.50 Y
J/C(CAN,EGR,SERVICE) MAIN(SIGNAL) 9 9 ENGINE(SIGNAL)

to_J/C(CAN,EGR,SERVICE)
4

W/H09 W/H00
W/H09 W/H00
CRSD: 0.50 Y CRSD: 0.50 Y
MAIN(SIGNAL) 10 10 ENGINE(SIGNAL) SERVICE_TOOL 1 1 SERVICE_TOOL(CAP)
CRSD: 0.50 G CRSD: 0.50 G CRSD: 0.50 G
MAIN(SIGNAL) 14 14 ENGINE(SIGNAL) SERVICE_TOOL 3 3 SERVICE_TOOL(CAP)
f R

f R

CRSD: 0.50 B SHIELD-NE,D

SERVICE_TOOL 4 4 SERVICE_TOOL(CAP)
water-proof
GND2
CRSD: 0.50 R

CRSD: 0.50 R/B SENSOR(NE)

CRSD: 0.75

CRSD: 0.75

SERVICE_TOOL 2 2 SERVICE_TOOL(CAP) ENGINE-ECU(SS2intT4) CRSD: 0.50 B S CRANKSHAFT_SENSOR(NE),D CRANKSHAFT_SENSOR(NE),D

NE_Vcc CRSD: 0.75 f G 5 CRSD: 0.75 f G Vcc OUT CRSD: 0.75 f R
A-22 1 3
JOINT-CRS_POWER,D NE_GND CRSD: 0.75 f B CRSD: 0.75 f B GND
water-proof A-19 2
CRSD: 2 f R +BP NE_SIG CRSD: 0.75 f R
CRSD: 2 f R
B-5
+BP
A-43 SENSOR(G)
B-6 CAMSHAFT_SENSOR(G) CAMSHAFT_SENSOR(G)
CRS-ECU(58pin) G_Vcc CRSD: 0.75 f G CRSD: 0.75 f G BASE: 0.5 f R BASE: 0.5 f R VCC OUT BASE: 0.5 f W
A-44 to_CAMSHAFT_SENSOR 3 3 to_MAIN(CAMSHAFT_SENSOR) 1 3
G_GND CRSD: 0.75 f Y CRSD: 0.75 f Y BASE: 0.5 f B BASE: 0.5 f B GND
A-18 to_CAMSHAFT_SENSOR 2 2 to_MAIN(CAMSHAFT_SENSOR) 2
G_SIG CRSD: 0.75 f L CRSD: 0.75 f L BASE: 0.5 f W
to_CAMSHAFT_SENSOR 1 1 to_MAIN(CAMSHAFT_SENSOR)
A-42
CRSD: 0.50 B S 6 CRSD: 0.75 f B BASE: 0.5 f B S 7
VALVE,ASSY(EGR) water-proof to_CAMSHAFT_SENSOR 4 4 to_MAIN(CAMSHAFT_SENSOR)
SHIELD-G1,D GND4
W/H09 W/H10 water-proof W/H10 W/H,GS
W/H09 W/H10 SHIELD-G2,D
EGR_VALVE W/H09 W/H10
CRS-ECU(96pin) CRS-ECU(96pin)
CRSD: 0.75 f Y CAN_H W/H09 W/H10
1
MicroComputer

CRSD: 0.75 f G CAN_L

2 M EngineWarning_Lamp
CRSD: 0.75 f B GND
3 EngineStop_Lamp
GND4 CRSD: 0.75 f R POWER(12V)
4 CRSD: 0.50 L MainRelay OIL_Lamp
B-33
Heater_Lamp

OverHeat_Lamp

ForceRegenReq_Lamp

Regen_Lamp

CRSD: 0.50 Y CAN1-H

B-51
CRSD: 0.50 G CAN1-L
B-52
CRS-ECU(58pin) AccelSensor1_Vcc

AccelSensor1_SIG
SENSOR
CRS-ECU(58pin) DPF_DIFF_PRESSURE_SENSOR
CRSD: 0.50 Y CAN2-H AccelSensor1_GND CRSD: 0.75 f L/R VDD
B-38 3
CRSD: 0.50 G CRSD: 0.75 f L/B
CAN2-L
CRS-ECU(96pin)
GND
ASIC
B-39
AccelSensor2_Vcc CRSD: 0.75 f L
2
VOUT
4.7ohm
1
SENSOR_AIR_FLOW AccelSensor2_SIG

AIR_FLOW_SENSOR TAC AccelSensor2_GND

PUMP_ASSY_SUPPLY
- CRSD: 0.5 f GR SUCTION_CONTROL_VALVE
CRS-ECU(58pin)
CRSD: 0.75 f G
+
1
CRSD: 0.5 f L
EGR_Lft_SEN_Vcc
A-1
SCV
SUPPLY
2
CRSD: 0.5 f W/R
CRS-ECU(96pin) EGR_Lft_SEN_GND VehicleSpeed CRSD: 0.75 f B/R +B CONTROL
A-2
AIR_ VC
3 EGR_lIFT_SEN VALVE
FUEL_TEMP_SENSOR
FLOW_ GND CRSD: 0.5 f W/B
CRSD: 0.75 f L CRSD: 0.75 f G
4 EGR_Motor(-) PressDiffSensor_SIG
SENSOR POWER CRSD: 0.50 R A-66 B-1
5 EGR_Motor(+) PressDiffSensor_GND CRSD: 0.75 f L/B CRSD: 0.75 f G/W
CRS-ECU(58pin) A-59 B-2
PressDiffSensor_Vcc CRSD: 0.75 f L/R
A-23
CRSD: 0.5 f W/R MAF_SEN_SIG CRS-ECU(96pin) SENSOR,WATER_TEMP.
WATER_TEMP_SENSOR
THROTTLE_VALVE_ASSY(INTAKE) CRSD: 0.5 f W/B
A-30
MAF_GND SCV(+) CRSD: 0.75 f B/R
WATER_TEMP_SENSOR
CRSD: 0.75 f L/R GND CRSD: 0.75 f L
INTAKE_THROTTLE_MOTOR A-7 B-20 1 2
M1(OPEN) CRSD: 0.75 f B/R CRSD: 0.5 f L IntakeAirTemp(AFS) SCV(-) CRSD: 0.75 f G
M 1 A-34 B-7 CRS-ECU(58pin)
M2(CLOSE) CRSD: 0.75 f R/B CRSD: 0.5 f GR
2 CRS-ECU(96pin)
IntakeAirTemp(AFS)_GND
A-10
RAIL_ASSY_COMMON
GND CRSD: 0.75 f L/B FuelTemp_SIG CRSD: 0.75 f G RAIL_PRESSURE_SENSOR
3 A-31 CRSD: 0.5 f L A-VCC

Hall IC
TPS CRSD: 0.75 f L CRSD: 0.75 f R/B IntakeThrottleMotor(+) FuelTemp_GND CRSD: 0.75 f G/W
CRSD: 0.5 f Y
1 Pressure
4 B-57 A-8
5V CRSD: 0.75 f G/W CRSD: 0.75 f B/R IntakeThrottleMotor(-) CoolantTemp_SIG CRSD: 0.75 f L/R 2
PFUEL
Sensor
5 CRS-ECU(58pin) B-44 A-39 CRSD: 0.5 f G A-GND
CoolantTemp_GND CRSD: 0.75 f L 3
CRS-ECU(96pin)
6
CRSD: 0.75 f L IntakeThrottleSensor_SIG
A-15 SENSOR_BOOST
B-29 SENSOR_BOOST
CRSD: 0.75 f L/B IntakeThrottleSensor_GND SLD_GND CRS-ECU(96pin) CRSD: 0.75 f G/W Vcc
B-16 1 BOOST
CRSD: 0.75 f G/W CRSD: 0.75 f W/R
PRESSURE
IntakeThrottleSensor_Vcc Vout
CRS-ECU(58pin) B-9 2
PFuel_SIG
A-40
CRSD: 0.5 f Y
CRSD: 0.50 B S SHIELD-RAIL CRSD: 0.75 f W/B
3
GND
SENSOR
CRS-ECU(96pin) water-proof
PFuel_SIG CRSD: 0.5 f Y 8
A-41 SENSOR_INLET_AIR_TEMP.
PFuel_Vcc CRSD: 0.5 f L INLET_AIR_TEMP_SENSOR INLET_AIR_TEMP_SENSOR
CRS-ECU(58pin)
A-24 CRSD: 0.5 f W CRSD: 0.5 f R
PFuel_GND CRSD: 0.5 f G 1 2
A-16
ExtShutterPull_Relay BoostSEN_Vcc CRSD: 0.75 f G/W
A-46
ExtShutterHold_Relay BoostSEN_SIG CRSD: 0.75 f W/R
CRS-ECU(96pin) A-61
BoostSEN_GND CRSD: 0.75 f W/B
A-57
Starter_Relay

ExtAirTempSEN_SIG CRSD: 0.5 f W

B-28
CRSD: 0.50 Y/B ST_SW ExtAirTempSEN_GND CRSD: 0.5 f R
B-54
IG_SW
B-15 CRS-ECU(58pin)
CRS-ECU(96pin)
CRSD: 0.50 B S 9

IG_SW water-proof SWITCH(WATER_LEVEL)

CRS-ECU(58pin) SHIELD-AIR-TEMP
CRS-ECU(58pin)
STOP_SW
SWITCH(WATER_LEVEL) SWITCH(WATER_LEVEL)
Parking_SW CRSD: 0.75 f W W W/B CRSD: 0.75 f R
1 2
ForceRegen_SW

Heater_Relay Regenlnhibit_SW

WaterLevel_SW CRSD: 0.75 f W

A-85 CRS-ECU(96pin)
FilterPlugged_SW
CRS-ECU(96pin)
CRS-ECU(58pin)
CRSD: 1.25 f B/W INJ_Common1 CAN_SEL_SW
A-49
CRSD: 1.25 f R/W INJ_Common1 BGmode_SW
CRS-ECU(96pin)
A-73
CRSD: 1.25 f L/R INJ-Common2 RatedSpeedSel_SW(BG)
JOINT-INJ_012,D A-1
water-proof CRSD: 1.25 f B/R INJ-Common2 Neutral_SW

INJECTOR,ASSY SHIELD-01
water-proof S CRSD: 0.50 B JOINT-INJ_011,D CRSD: 1.25 f Y
A-25
INJ_DRV_TWV1 OIL_SW
CRS-ECU(58pin)
INJECTOR_1 INJECTOR_1 1 water-proof A-74
CRSD: 2.0 f B 2 1 CRSD: 2.0 f W CRS-ECU(96pin)
2 1 JOINT-INJ_022,D
water-proof CRSD: 1.25 f W/B INJ4_DRV_TWV4 Inlet_DOC_Temp CRSD: 0.75 f LG
INJECTOR,ASSY SHIELD-02
water-proof S CRSD: 0.50 B JOINT-INJ_021,D
A-3 A-38
Inlet_DOC_Temp_GND CRSD: 0.75 f L/B
INJECTOR_2 INJECTOR_2 2 water-proof
CRSD: 2.0 f B 2 1 CRSD: 2.0 f W CRSD: 1.25 f Y/B INJ2_DRV_TWV2 Outlet_DOC_Temp
A-14
CRSD: 0.75 f B/R SENSOR(THERMO,0)
DOC_INLET_TEMP_SENSOR DOC_INLET_TEMP_SENSOR
2 1 JOINT-INJ_032.D A-26 A-36
water-proof Outlet_DOC_Temp_GND CRSD: 0.75 f L CRSD: 0.75 f L/B CRSD: 0.75 f LG
INJECTOR,ASSY SHIELD-03
water-proof S CRSD: 0.50 B JOINT-INJ_031,D CRSD: 1.25 f R/L INJ3_DRV_TWV3 Outlet_DPF_Temp
A-12
CRSD: 0.75 f R/B
1 2
INJECTOR_3 INJECTOR_3 3 water-proof
CRSD: 2.0 f B 2 1 CRSD: 2.0 f W
A-51 A-62
Outlet_DPF_Temp_GND CRSD: 0.75 f L/R SENSOR(THERMO,1)
DOC_OUTLET_TEMP_SENSOR DOC_OUTLET_TEMP_SENSOR
2 1 JOINT-INJ_042,D A-58
water-proof CRSD: 2 f B POWER_GND CRSD: 0.75 f L CRSD: 0.75 f B/R
INJECTOR,ASSY SHIELD-04
water-proof S CRSD: 0.50 B JOINT-INJ_041,D CRSD: 2 f B
B-3
POWER_GND SIGNAL_GND CRSD: 2 f B
1 2
INJECTOR_4 INJECTOR_4 4 water-proof
CRSD: 2.0 f B 2 1 CRSD: 2.0 f W GND4 CRSD: 0.85 B
B-4
CASE_GND SIGNAL_GND
B-1
CRSD: 2 f B SENSOR(THERMO,2)
DPF_OUTLET_TEMP_SENSOR DPF_OUTLET_TEMP_SENSOR
2 1 GND4 CRS-ECU(58pin) B-18 B-2 CRS-ECU(58pin) GND4 CRSD: 0.75 f L/R CRSD: 0.75 f R/B
GND4 GND4 1 2

to_J/C-INJ/SLD-GND 5 5 4 4 to_J/C-INJ/SLD-GND

to_J/C-INJ/SLD-GND 6 6 3 3 to_J/C-INJ/SLD-GND

to_J/C-INJ/SLD-GND 7 7 2 2 to_J/C-INJ/SLD-GND
CRSD: 0.50 B
to_J/C-INJ/SLD-GND 8 8 1 1 to_J/C-INJ/SLD-GND
J/C-INJ/SLD-GND
GND3
2 2 to_J/C-SLD-GND
CRSD: 0.50 B
1 1 to_J/C-SLD-GND
J/C-SLD-GND
GND4

Electrical Circuit Diagram (KX080-4 US, CA)

 232C ALTERNATOR BEACON_SWITCH CAB(CAB_ CAB_ CRANKSHAFT_SENSOR(NE),D DUAL_PRESSURE_SWITCH ENGINE(OPEN) FRONT_ FUSE FUSE(HEATER, GND
(IG,L) WORKLIGHT,FR(+)) WORKLIGHT, WORKLIGHT(+) (COMPRESSOR) FUELFILTER) (CABFRAME)
FL(+)
2 1 4 3 2 1 3 2 1 2 1 2 1 1
1 1 1 2 3 4 2 1
4 3 10 9 8 7 6 5 1 1
2 C_WF03_7283-8852-30_1 C_WF02_6189-0094_1 5 6 7 8 M8
C_OF02_M
C_WF04_7123-7740-40_1 C_OF10_7123-8307 iniFuses C_OF02_M
C_OF02_71 _1 _1 iniFuses
C_OM08_7122 *1 279 _1
23-2820_1 C_CAM01_1 C_CBF01_ CRS-ECU(58pin) E/F_CHANGE_SWITCH -6080_1 C_CBF01_ *2 351 C_LAF01
1 1 _M8_1
A/C_FAN_SWITCH BLOWER_MOTOR 7 8 9 10 11 12 13 14 15 16 17 18 19 FUSE(HORN-
ANTITHEFT_ to_CAB_WORK 1 2 4 3 2 1
ANTENNA CAB_WORK MAIN(OPEN) FUSE MAIN)
LIGHT,FR(+) 20 21 22 23 24 25 26 27 28 29 30 31 32 10 9 8 7 6 5 GND(RADIO)
LIGHT,FL (CONDENSOR_
2 1 (-) FRONT_ FAN)
3 2 1 3 4 WORKLIGHT(-) 2 1
4 3 2 1
6 5 4 1 2 3 1 C_OF10_7123-8307_1
1
C_OF02_6098-0325 33 34 35 36 37 38 39 40 41 42 43 44 45 8 7 6 5 2 1
4 5 6 _1 1 1 C_OF02_M
5 6 46 47 48 49 50 51 52 53 54 55 56 57 58 iniFuses M8
C_OF06_7123-2865-30_1 C_OF08_7123 C_OF02_P _1
C_WM06_61 C_CBF01_1 ECU(MAIN) -6080_1 lug-in_t
BOOM_RAISE_SW C_WF58_9-1452415-9_1 ype_1
89-6171_1
C_CAM01_ C_CAM01_ FUSE(HORN- C_LAF01
1 1 _M8_1
CAB(CAB_ SW)
BATTERY 1 FUSE(ECU-
WORKLIGHT,FR(-)) CRS-ECU(96pin) 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 5 4 ENGINE(POWER)
(POWER),N_BI 2 MAIN(+B))
A/C_HEATER_CONTROLER CAB_ 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 2 1 GND(RADIO
WORKLIGHT, FUEL_PUMP ,CAB)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 3
C_WF02_6189-0156 FR(+) 1
_1 1 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 2 1 C_OF02_M
1 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 2
25 26 27 28 29 1
iniFuses 1
1 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 2 1 _1
1 2 3 4 5 6 7 8 2
C_OF02_M
M5
C_OM01_71 CAB 49 50 51 52 53 C_OM02_7122 iniFuses
9 10 11 12 13 14 15 16 22-4113-3
C_CBF01_1 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 -4123-30_1 _1
0_1 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 C_OF02_7
4 3 2 1 C_WF81_1473244-1_1 123-2820 FUSE(LEVER_ C_LEF01
C_CBF01_
to_CAB_ 1 _1 LOCK) _M5_1
C_OF16_MX34016SF1_1 8 7 6 5 MAIN(POWER) FUSE(ECU-
MAIN(POWER), WORKLIGHT,FR(-)
C_WF96_9-1452423-9_1 MAIN(+B)),BI
N_BI
CAB_ FUEL_TEMP_ 2 1 GND(WIPER,
C_OF08_7123-6083
1 1
-30_1 WORKLIGHT, SENSOR 2 1 F)
1 FR(-) DIODE(COMPRESSOR)
EGR_VALVE 2 C_OF02_M
iniFuses
to_MAIN(CAB) 2 1 C_OF02_M _1 1
AIR_FLOW_SENSOR
C_OF01_71 1 2 1 C_OF02_7123 iniFuses
23-4113-3 C_CAM01_1 4 3 2 1 -4123-30_1 _1 M8
0_1 C_WF02_1
C_OF02_6098-0017_1
FUSE(METER
1 2 3 4 C_WF04_6195-0030_1
78392-6_
(+B))
5 4 3 2 1 CAB(WIPER) ENGINE 1
5 6 7 8 FUSE(ECU-
BATTERY_ C_CAM01_ (SOLENOID) C_LAF01
MAIN(AC)) _M8_1
TERMINAL,BI 1
DOC_INLET_TEMP_SENSOR ELECTRICAL_BUZZER 2 1
C_WF05_6189-1046_1
C_OM08_7122-6083 2 1 FUSE(A/C_
-30_1
4 3 1 2 3 4 CONTROLLER) 2 1 C_OF02_M
1 CAMSHAFT_
2 1 GND1
AI_CONSOLE 1 5 6 7 8 iniFuses
SENSOR(G) _1
M8 CAB(CAB_WORKLIGHT, C_OF04_7123 C_WF02_7283-7026-30_1 2 9 10 11 12 2 1 C_OF02_M
FL(+)) -6040_1 iniFuses
4 3 2 1 _1 FUSE(RADIO 1
8 7 6 5 3 2 1 C_OF02_7123-2820_1
C_WM12_7222 C_OF02_M
(AC))
C_LAF01_M 1 to_MAIN(CAB_ DOC_OUTLET_TEMP_SENSOR -7923-40_1 iniFuses M8
8_1 WIPER) _1 FUSE(ECU_
C_WF03_6
C_WF08_FW-C-8F_1 189-1130
ELECTRICAL_OUTLET MAIN(POWER)) 2 1
_1 2 1
MAIN(SOLENOID) C_LAF01
BATTERY_ 1 2
AI_PRESSURE_SW TERMINAL,N_BI C_CAM01_1 1 FUSE
C_OF02_M _7009-1
C_WF02_7283-7028-10_1 2 1 iniFuses 836_1
3 4 2 (ALTERNATOR) _1
CAN
4 3 2 1
1 to_CAB_WORKLIGHT,FL(+) C_OF02_M
1 C_OM04_7122 DPF_DIFF_PRESSURE_SENSOR 8 7 6 5 2 1 iniFuses
2 -6040_1 2 1 C_OF02_7123-8322_1
_1
FUSE(RELAY)
M8 12 11 10 9
1 C_WF02_7 3 2 1 C_OF02_M
C_WF02_6189-0156_1 ENGINE(FUEL_SENSOR) iniFuses FUSE
CAB_POWER_ 123-8520 C_WF12_7123 2 1 GND2
_1
C_LAF01_M SOURCE -40_1 -7923-40_1 (ELECTRICAL_
C_WF03_1813271-1_1
8_1 OUTLET)
ALTERNATOR(+B) 1 2 C_OF02_M
C_CBF01_1 iniFuses
4 3 2 1 COMPRESSOR_ ENGINE(SYGNAL) FUSE(BEACON)
2 1 _1 1
BEACON(+) CLUTCH(A/C) DPF_OUTLET_TEMP_SENSOR
1 8 7 6 5 C_WM02_7222-1424-40_1
CAB(CAB_WORKLIGHT, M8
M6 2 1 C_OF02_M
FUSE(ROOM_
1 FL(-)) 2 1 iniFuses
C_OF08_7123
1 1 2 3 4 _1 LIGHT)
-6083-30_1 FUELSENSOR
M3 C_WF02_7283-7023_1 5 6 7 8 C_OF02_M C_LAF01
1 iniFuses _7009-1
C_LAF01_M6_1 C_WF01_F 9 10 11 12 _1 2 1 836_1
CAB_WORKLIGHT, W-C-1F_1 2 1 FUSE(FRONT-
B(+) 13 14 15 16 WORKLIGHT)
C_LEF01_M C_OF02_M
3_1 C_WF02_7123-1424-40_1 iniFuses
C_CBF01_1 CONDENSOR_ FUSE(BLOWER)
C_WM16_7222 _1
1 FAN 2 1
-7564-40_1
2 1 FUSE
to_CAB_WORKLIGHT,FL(-) C_OF02_M
2 1 iniFuses (STARTER)
C_CBF01_1 C_OF02_M _1 GND3
1 C_WF02_D MAIN(SYGNAL) iniFuses
2 1
T06-2S-C _1
CAB_WORKLIGHT, E05_1 FUSE(FUEL_ 1
B(-) PUMP) C_OF02_M
4 3 2 1 iniFuses M8
C_CAM01_1 _1
1 8 7 6 5 FUSE(CAB- 2 1
WORKLIGHT)
12 11 10 9
C_LAF01
C_OF02_M
16 15 14 13 iniFuses
FUSE(WIPER/ _7009-1
WASHER) 836_1
C_CAM01_1
2 1 _1
C_WF16_7123
-7564-40_1
C_OF02_M
FUSE(FUEL_ 2 1
iniFuses
_1 SUPPLY_PUMP) GND4
C_OF02_M
iniFuses
_1
2 1 1

C_OF02_M GLOW,D M8
iniFuses
_1
1
C_LAF01
M4 _7009-1
836_1

CONNECTOR CHART 1 (KX080-4 US, CA) C_LEF01_

M4_1
HEATER INLET_AIR_TEMP_SENSOR RADIO(AC) RELAY SBF,MAIN1-2 SOLENOID SPEAKER(L) SUCTION_CONTROL_ TRAVEL_PRESSURE_ to_CAB(WIPER) to_J/C-INJ/SLD-GND
(FUEL_ (CRS_MAIN) (AUX1-L) VALVE SENSOR
IFILTER)
2 1 1 2
2 1 1 3 1 2 1 3 2 1 4 3 2 1
2 1 5 3 4
C_OF02_7323-3220_1 2 1 2 8 7 6 5
C_WF02_7283-7027-40 C_WF02_6189-0039 C_WF03_7183-7874
C_WF02_ _1
1 4 2 _1 -30_1
C_OF02_ C_OM04_7122-1347_ C_WF08_7283
6-17614 C_CBF01_ C_WF0
6-6_1
SBF-BOX 2_174 7123-28 1 -7080-40_1
1 C_OF05_M
-ISO_1 352-2 20_1
M5 M5 _1 SWITCH(DPF,INHIBIT) TRAVEL_SPEED&ANGLE_
INTAKE_THROTTLE_MOTOR
HORN(+) 2 1 BLADE_CONTROL_SW to_WIPER
SPEAKER(L+) J/C-INJ/SLD-GND
RADIO(GND) 4 3
6 5 4 3 2 1 SOLENOID
1 2 1 2 1
1
RELAY(ECU_ M6 M5 (AUX1-R) 1 2 3 4
MAINPOWER) 1 4 3 2 1 4 3
C_WF06_7283-1968-30 4 3
_1
C_OF06_7357-5155-30 10 9 8 7 6 5
_1 5 6 7 8
3 C_OF04_7123-1347_
C_OF01_ 2 1 C_WF04_6180-4181
1
7123-20 _1
10_1
C_CAM01_ 5 C_CAM01 C_OF10_7123-8307 C_WM08_7382
1 SENSOR,FUEL C_WF0 _1 -1480-40_1
JS_CONTROL(L) 1 4 2 _1
2_174
TRAVEL_SPEED_SW to_CAMSHAFT_SENSOR
352-2
HORN(-) RADIOFRAME C_OF05_M
3 2 1 _1
(GND) -ISO_1 SPEAKER(L-) to_J/C-SLD-GND
4 3 2 1 C_WF03_7283-8730-30 1 2 2 1
1 8 7 6 5 _1 SWITCH(LEVER_LOCK)
1 SOLENOID 3 4 3
(AUX2-L)
1 2 1
RELAY(GLOW)
SENSOR_BOOST C_WM03_6092-0013 C_WF04_33472-0401
C_OF01_
C_WF08_6195-0051_1 2 1 _1 _1 C_WF02_7283
7123-20 -7020-10_1
C_CAM01_ 3
10_1 2 1 C_CAM01
1 3 2 1 _1
C_WF02_6195-0003
1 2 _1 WASHER_TANK to_MAIN(CAMSHAFT_
C_WF0 SENSOR) J/C-SLD-GND
RAIL_ 4 C_WF03_6189-0099_1 2_174
INJECTOR_1 PRESSURE_ 352-2 SPEAKER(R)
JS_CONTROL(R) _1 SWITCH(WATER_LEVEL) 1 1 2
SENSOR C_OF04_P 1 2
-ISO_1 SERVICE_TOOL 2
1 3 4
3 2 1 1 2 1 C_WM02_7382
2 4 3 2 1 SOLENOID C_OF02_7123-2820 -8924-10_1
(AUX2-R) 2 _1
8 7 6 5 RELAY(HORN) 2 1 C_WM04_33482-0406
C_WF03_1 C_WF02_6189-0176 _1
C_WF02_
6189-06
74357-2_ 4 3 C_OF02_ _1
to_MAIN
1
11_1 C_WF08_6195-0051_1 3 7123-28 WATER_TEMP_SENSOR (WORKLIGHT)
2 1 20_1
5 C_WF04_174257-2_1 to_J/C(CAN,EGR,SERVICE)
THERMOSTAT
REGISTER 1 4 2 C_WF0
(120ohm) 2 1 1
INJECTOR_2 2_174 SPEAKER(R-)
352-2 5 4 3 2 1 6 5 4 3 2 1 2
C_OF05_M _1
2 1 -ISO_1 SERVICE_TOOL(CAP) C_WF02_178392-6_
1 KEY_SWITCH 1 C_OF05_7283-1050
1
C_WF06_7283-8850- C_OM02_7122
2 _1 30_1 -2820_1
C_WF02_7 SOLENOID
2 1 123-6423 1 2 (E/F)
-30_1 WIPER,F
C_WF02_ 3 RELAY(LIGHT)
6189-06 3 4 C_CAM01
TRAVEL_ALARM to_WORKLIGHT
11_1 _1
(FRONT,+)
2 1 2 1 J/C(CAN,EGR,SERVICE)
C_WF03_7123-6234-40 3 C_WM04_174259-2_1
_1
RELAY 4 3
5 1 1
(BEACON) C_WF0 SPEAKER(R-)
INJECTOR_3 1 4 2 2_174 1 2 3 4 5 6
352-2
C_OF04_6090-1011 2
LCD_METER _1
_1
3 SERVO_MOTOR
1 C_OF05_M 1 C_CBF01_1 C_WM06_7182-9630- C_OF02_7123
7 6 5 4 3 2 1 5 -ISO_1
30_1 -2820_1
2 WIPER_SWITCH
14 13 12 11 10 9 8 1 4 2 SOLENOID TRAVEL_ALARM
7 6 5 4 3 2 1 (LEVER_ (FRONT,GND)
C_WF02_ LOCK) to_J/C(CAN,MAIN)
6189-06 C_OF05_M RELAY(POWER) C_CAM01 3 2 1
C_OF14_7283-5832_1 _1
11_1 -ISO_1
C_OF07_IL-AG5-7S-S3 1 6 5 4
C1_1 2 1 4 3 2 1
RELAY 3
OIL-SW,D STARTER(S),D C_OF06_7123-2860 8 7 6 5
(BLOWER) 1 2 _1
INJECTOR_4 C_WF0
2_728
1 4 3-209 C_CAM01_1 C_WF08_7283-1081-
3 SOLENOID(ANGLE-L) 0-30_ 1 10_1
1 1
WORKLIGHT_SWITCH
C_OF01_172320-2_1 5 C_OF04_P
2 -ISO_1
C_OF01_ TRAVEL_ALARM(REAR,+)
1 4 2 2 1 172320- 4 3 2 1 J/C(CAN,MAIN)
C_WF02_ SOLENOID 1_1
6189-06
RADIO(+B) RELAY (MULTI) 10 9 8 7 6 5
C_WF02_7283-2090-30 1 2 3 4
11_1 C_OF05_M (STARTER) _1 1
-ISO_1
STOP_SWITCH C_OF10_7123-8307
1 _1 5 6 7 8
3 2 1
SOLENOID(ANGLE-R)
5 C_CBF01_1
C_WM08_7382-1481-
1 4 2
C_WF0 1 2 10_1
C_CBF01_1 2_728
RELAY 2 1 3-209
(COMPRESSOR) 0-30_
TRAVEL_ALARM
C_OF05_M C_WM02_ (REAR,GND)
1
-ISO_1 C_WF02_7283-2090-30 6187-28
_1 01_1
3 1
RESISTOR_ SOLENOID
5 (TRAVEL_
BLOWER
1 4 2 SPEED)
C_CAM01_1
C_OF05_M 2 1
-ISO_1 2 1
4 3

RELAY C_OF04_6 C_WF0

(CONDENSOR_ 098-0514 2_728
_1 3-209
FAN)
0-30_
1
3
5 ROOM_LIGHT
1 4 2

C_OF05_M
3 2 1
-ISO_1

CONNECTOR CHART 2 (KX080-4 US, CA)

C_OF03_6
130-2330
_1
 EDITOR:
KUBOTA CORPORATION
CONSTRUCTION MACHINERY
SERVICE TECHNICAL SUPPORT DEPARTMENT
1-1 NAKAMIYA-OHIKE 1-CHOME, HIRAKATA-CITY, OSAKA, 573-8573, JAPAN
PHONE : (81)72-840-1195
FAX : (81)72-890-2883
E-mail : [email protected]

Printed in Japan 2015. 08, H, EI, EI, engusa Code No. RY911-21601
KUBOTA Corporation Printed in Japan 2013. 02, H, EI, EI, engusa Code No. RY911-21600