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The Kubota Excavator KX080-4 Workshop Manual provides essential information on safety, servicing, and maintenance procedures for the machinery. It is divided into three main sections: General, Mechanisms, and Service, covering topics such as engine identification, hydraulic systems, and troubleshooting. The manual emphasizes the importance of following safety precautions and proper handling of equipment to prevent accidents and ensure efficient operation.

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0% found this document useful (0 votes)

37 views517 pages

WSM Kx080-4 - GB - Screen 3

Uploaded by

Lamch Dariusz

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Download as PDF, TXT or read online on Scribd

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WORKSHOP MANUAL

KUBOTA EXCAVATOR

KX080-4

KiSC issued 08, 2015 A

CONTENTS
TO THE READER 11. SOLENOID VALVE................................. 3-M57
TO THE READER SERVICING
I INFORMATION 1. PUMP......................................................... 3-S1
CONTENTS 2. CONTROL VALVE................................... 3-S17
INFORMATION 3. SWIVEL MOTOR ..................................... 3-S25
1. SAFETY FIRST ............................................ I-1 4. SWIVEL JOINT ........................................ 3-S40
2. IN THE INTEREST OF WORK 5. TRAVEL MOTOR..................................... 3-S47
SAFETY........................................................ I-2 6. CYLINDER............................................... 3-S68
3. LABELS DISPLAYED TO PROMOTE 7. PILOT VALVE .......................................... 3-S70
WORK SAFETY............................................ I-6 8. BOOM HOLDING VALVE ........................ 3-S99
4. MAIN SPECIFICATIONS............................ I-13 9. SHOCKLESS VALVES .......................... 3-S101
5. DIMENSIONS ............................................. I-14 10. SWIVEL SHUTTLE VALVE ................... 3-S102
11. SOLENOID VALVE................................ 3-S103
G GENERAL
12. ROUTING OF HYDRAULIC HOSES ..... 3-S106
CONTENTS
13. MEASURING HYDRAULIC DEVICE
GENERAL
PERFORMANCE ................................... 3-S128
1. CHECKING EXCAVATOR
14. HYDRAULIC DEVICE
IDENTIFICATION ........................................G-1
PERFORMANCE STANDARDS............ 3-S154
2. ENGINE IDENTIFICATION .........................G-2
15. TROUBLESHOOTING........................... 3-S161
3. MUFFLER FULL ASSEMBLY
IDENTIFICATION ........................................G-5 4 ELECTRICAL SYSTEM
4. GENERAL PRECAUTIONS.........................G-7 CONTENTS
5. HANDLING PRECAUTIONS FOR SERVICING
ELECTRICAL PARTS AND WIRING.........G-11 1. LAYOUT OF ELECTRICAL DEVICES
6. TIGHTENING TORQUES..........................G-16 AND WIRING ROUTING ........................... 4-S1
7. OIL AND WATER CAPACITY TABLE .......G-20 2. METER PANEL OPERATION ................. 4-S11
8. MAINTENANCE INTERVALS....................G-21 3. INSPECTIONS......................................... 4-S46
4. TROUBLESHOOTING (START-UP
1 MACHINE BODY
EQUIPMENT VERSION) ......................... 4-S52
CONTENTS
5. METHODS FOR DIAGNOSING
SERVICING
ERRORS.................................................. 4-S53
1. FRONT ...................................................... 1-S1
6. TROUBLESHOOTING (METER
2. SWIVEL FRAME...................................... 1-S10
PANEL VERSION)................................... 4-S55
3. TRACK FRAME ....................................... 1-S24
4. MEASURING MACHINE 5 CABIN
PERFORMANCE..................................... 1-S40 CONTENTS
5. SWIVEL GEAR BACKLASH MECHANISM
PERFORMANCE..................................... 1-S42 1. AIR CONDITIONING SYSTEM................. 5-M1
2. WIPER .................................................... 5-M17
2 ENGINE
SERVICING
CONTENTS
1. TROUBLESHOOTING............................... 5-S1
GENERAL
2. SERVICE SPECIFICATIONS .................... 5-S4
1. SPECIFICATIONS.....................................2-G1
3. TORQUE.................................................... 5-S5
2. DIMENSIONS ............................................2-G2
4. PRECAUTIONS WHEN REPAIRING
3. PERFORMANCE CURVES .......................2-G3
THE REFRIGERANT SYSTEM ................. 5-S6
4. FAN DRIVE................................................2-G4
5. INSPECTING AND CHARGING THE
3 HYDRAULIC SYSTEM REFRIGERANT SYSTEM ....................... 5-S11
CONTENTS 6. INSPECTION AND DISASSEMBLY ........ 5-S20
MECHANISM 7. WINDOW WASHER ................................ 5-S36
1. DIAGRAM OF HYDRAULIC CIRCUIT...... 3-M1 8. CABIN GLASS REMOVAL AND
2. HYDRAULIC DEVICE LAYOUT ............... 3-M3 MOUNTING ............................................. 5-S38
3. PUMP ....................................................... 3-M4 9. FRONT WINDOW.................................... 5-S52
4. CONTROL VALVE.................................. 3-M12
5. SWIVEL MOTOR.................................... 3-M28
6. TRAVEL MOTOR ................................... 3-M33
7. HYDRAULIC CYLINDER........................ 3-M39
8. PILOT VALVE......................................... 3-M42
9. BOOM HOLDING VALVE....................... 3-M49
10. SHOCKLESS VALVES........................... 3-M55

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-12
4. MAIN SPECIFICATIONS.............................................................................................................. I-13
5. DIMENSIONS ............................................................................................................................... I-14

KiSC issued 08, 2015 A

KX080-4(EU), WSM INFORMATION

1. SAFETY FIRST
SAFETY FIRST
• This "Safety Alert Symbol" is used in this manual and on labels on equipment to indicate important
issues and warn of the danger of personal injury. Read and follow these warnings carefully.
• It is important that you thoroughly read these instructions and safety rules prior to working on the
equipment and that you always follow them.

DANGER
• Indicates that failure to follow the warning will result in serious injury or death.

WARNING
• Indicates that failure to follow the warning may result in serious injury or death.

CAUTION
• Indicates that failure to follow the warning may result in injury.

IMPORTANT
• Indicates that failure to follow the warning may result in damage to or a breakdown of the equipment.

NOTE
• Indicates supplementary explanations that will be helpful when using the equipment.

[NOTE]
• Indicates other supplementary information to take note of.
RY9212001INI0001US0

I-1

KiSC issued 08, 2015 A

KX080-4(EU), WSM INFORMATION

2. IN THE INTEREST OF WORK SAFETY

[1] WORKING SAFELY WITH THE EQUIPMENT MEANS ALWAYS
FOLLOWING THESE INSTRUCTIONS:
(1) Precautions Before Working on the Machine
Before starting any service or maintenance work
• Read all the general and safety instructions in this
manual, as well as the decals on your equipment.
• Always stop the engine whenever you leave the
driver's seat to inspect or clean the machine or its
devices, or to inspect or adjust parts.
• Choose a safe spot for inspecting the equipment-on
flat, hard ground.
RY9212001INI0002US0

• When performing maintenance on the equipment,

KX080-4(EU), WSM INFORMATION

RY9212148INI0007US0

[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.
RY9212001INI0018US0

I-12

KiSC issued 08, 2015 A

KX080-4(EU), WSM INFORMATION

4. MAIN SPECIFICATIONS
KUBOTA Excavator
Model name KX080-4
Type (rubber crawler) with standard counterweight with heavy counterweight
Machine
(without operator) 7960 kg 8195 kg
weight
Bucket Volume (SAE/CECE) 0.25 / 0.21 m3
(KUBOTA) Width with side cutters attached 800 mm
Type Water-cooled 4-cylinder turbo-diesel engine
Model name V3307-CR-TE4
Engine Displacement 3331 cm3
Engine performance (ISO 9249) 47.8 kW
Rated speed 2000 min-1
Swivel speed (swivel frame) 9.5 min-1
2nd speed 4.9 km/h
Travel speed
1st speed 2.7 km/h

Performance Ground pressure

34.6 kPa (0.353 kgf/cm2) 35.6 kPa (0.363 kgf/cm2)
(without operator)
Climbing performance 36 % (20 degrees)
Max. swivel capability at slope
27 % (15 degrees)
angle
Dozer (width × height) 2200 × 500 mm
Swing angle Left 70 degrees
of the boom Right 60 degrees
Auxiliary Max. flow rate (theoretical) 100 L/min
port 1 Max. pressure 20.6 MPa (206 bar)
Auxiliary Max. flow rate (theoretical) 67 L/min
port 2 Max. pressure 20.6 MPa (206 bar)
Fuel tank capacity 115 L
Pulling capacity at the towing eyes 116900 N
Vertical load at the towing eyes 12100 N
LpA 75 dB (A)
Noise level
LwA (2000/14/EC) 96 dB (A)
Vibration at the drive levers * < 2.5 m/s2
Vibration at the control levers * < 2.5 m/s2
Vibration at the operator's seat * < 0.5 m/s2
Vibration at the bottom plate * < 0.5 m/s2
Vibration at the wrist rest * < 2.5 m/s2
* These values are measured under specific conditions at maximum engine speed and can deviate, depending on
the operating situation.
RY9212148INI0008US0

I-13

KiSC issued 08, 2015 A

KX080-4(EU), WSM INFORMATION

5. DIMENSIONS

(1) Arm Length (1750 mm) (2) Arm Length (2100 mm)

KX080-4(EU), 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
RY9212148GEG0012US0

G-1

KiSC issued 08, 2015 A

KX080-4(EU), WSM GENERAL

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

G-2

KiSC issued 08, 2015 A

KX080-4(EU), 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)
RY9212148GEG0002US0

[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.
RY9212148GEG0003US0

G-3

KiSC issued 08, 2015 A

KX080-4(EU), WSM GENERAL

[3] CYLINDER NUMBER

You can see the cylinder numbers of KUBOTA diesel engine in
the figure.
The sequence of cylinder numbers is No.1, No.2, No.3 and No.4
and it starts from the gear case side.
RY9212148GEG0013US0

G-4

KiSC issued 08, 2015 A

KX080-4(EU), WSM GENERAL

3. MUFFLER FULL ASSEMBLY IDENTIFICATION

[1] PART NUMBER AND SERIAL NUMBER
Diesel Particulate Filter (hereinafter referred to as the "DPF")
Muffler Full Assembly Serial Number
The DPF muffler full assembly serial number is an identified
number for the DPF muffler full assembly.
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)
RY9212148GEG0004US0

G-9

KiSC issued 08, 2015 A

KX080-4(EU), 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(EU), 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(EU), WSM GENERAL
• Insert grommet securely.
(1) Grommet (A) Correct
(B) Incorrect
RY9212001GEG0027US0

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(EU), 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

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) Diesel fuel, EN-590 and ASTM D975
Total volume (Std. spec.) 146 L (38.6 U.S.gal)
Total volume (2-piece boom
Hydraulic oil 159 L (42.0 U.S.gal) Tellus oil S2M46
spec.)
Inside tank (gauge middle) 75 L (20.0 U.S.gal)
Travel motor 1.3 L (0.34 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

RY9212148GEG0008US0

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

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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

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[2] 2-PIECE 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 equipment to the ground.
Remove the AUX lines from each bracket and disconnect the
bucket cylinder hoses.
(1) AUX line (2) Bucket cylinder hose
RY9212148MBS0024US0

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 2nd boom.
(1) Arm Cylinder (3) Block
(2) Pin
RY9212148MBS0025US0

3. Suspend the arm and bucket temporarily with the crane, then
remove the linkage pin between the arm and the 2nd boom and
then remove the bucket and the arm.
Weight Approx. 510 kg (1120 lbs)

(1) Pin
RY9212148MBS0026US0

4. Put the end of the 2nd boom onto the ground and disconnect the
wiring harness and the two-piece cylinder hoses.
(1) Wire harness (2) Two-piece cylinder hoses
RY9212148MBS0027US0

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5. Suspend the two-piece cylinder with the crane and remove the
stopper bolt, cover plate, spacer and two-piece cylinder in order.
Remove the two-piece cylinder on the other side in the same
way.
Weight Approx. 56 kg (120 lbs)

(1) Two-piece cylinder (3) Cover plate

(2) Stopper bolt (4) Spacer
RY9212148MBS0028US0

6. Disconnect the arm cylinder and bucket cylinder hoses and

suspend the 2nd boom with the crane.
Remove the linkage pin between the 1st and 2nd booms and
remove the 2nd boom.
Weight Approx. 342 kg (754 lbs)

(1) Pin (3) Bucket cylinder hose

(2) Arm cylinder hose
RY9212148MBS0029US0

7. Remove the boom cylinder cover and lower the boom cylinder
onto a stand.
Remove all of the front hose lines.
(1) Cylinder stand (2) Front hose lines
RY9212148MBS0030US0

8. Suspend the 1st boom and remove the pin on the boom cylinder
rod side and then the pin at the base of the 1st boom.
(1) Pin (2) Pin
RY9212148MBS0031US0

9. Operate the crane and remove the 1st boom.

Weight Approx. 318 kg (701 lbs)
RY9212148MBS0032US0

10. Perform the procedure in reverse for assembly.

RY9212148HYS0096US0

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[3] 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.

(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

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(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

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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 additional weight and open the right cover.

CAUTION
• Find its center of gravity and suspend it securely.
196.1 to 225.6 N·m
Tightening torque Additional weight 20.0 to 23.0 kgf·m
144.6 to 166.4 lbf·ft

During installation, apply a threadlock. (Loctite 271)

Weight of additional weight Approx. 215 kg (474 lbs)

(1) Additional weight (2) Right cover

RY9212148MBS0041US0
4. 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)

Heavy weight spec. Approx. 1040 kg (2293 lbs)
Weight of the weight
Light weight spec. Approx. 830 kg (1830 lbs)

KX080-4(EU), 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

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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

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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

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[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

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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

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[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

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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

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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

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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

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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

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[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

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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

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[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
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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-S26

KiSC issued 08, 2015 A

KX080-4(EU), 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

KX080-4(EU), 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-S31

KiSC issued 08, 2015 A

KX080-4(EU), 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-S32

KiSC issued 08, 2015 A

KX080-4(EU), 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-S33

KiSC issued 08, 2015 A

KX080-4(EU), 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-S34

KiSC issued 08, 2015 A

KX080-4(EU), 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-S35

KiSC issued 08, 2015 A

KX080-4(EU), 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-S36

KiSC issued 08, 2015 A

KX080-4(EU), 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

1-S40

KiSC issued 08, 2015 A

KX080-4(EU), 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

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(EU), 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(EU), WSM ENGINE

[1] BOOM HOLDING VALVE ................................................................................................... 3-M49
(1) Specifications................................................................................................................ 3-M49
(2) Function and Structure ................................................................................................. 3-M50
[2] 2-PIECE BOOM HOLDING VALVE .................................................................................... 3-M52
(1) Specifications................................................................................................................ 3-M52
(2) Function and Structure ................................................................................................. 3-M52
10. SHOCKLESS VALVES ............................................................................................................. 3-M55
[1] SPECIFICATIONS .............................................................................................................. 3-M55
[2] FUNCTION AND STRUCTURE ......................................................................................... 3-M55
11. SOLENOID VALVE................................................................................................................... 3-M57
[1] UNLOAD VALVE ................................................................................................................ 3-M57
(1) Specifications................................................................................................................ 3-M57
(2) Function and Structure ................................................................................................. 3-M58
[2] AUX SOLENOID VALVE .................................................................................................... 3-M60
(1) Specifications................................................................................................................ 3-M60
[3] EP MODE SOLENOID VALVE ........................................................................................... 3-M61
(1) Specifications................................................................................................................ 3-M61

KiSC issued 08, 2015 A

KX080-4(EU), 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(EU), WSM HYDRAULIC SYSTEM

[2] DIAGRAM OF HYDRAULIC CIRCUIT (KX080-4 2-PIECE BOOM SPECIFICATION)

[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(EU), 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

KiSC issued 08, 2015 A

KX080-4(EU), 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(EU), 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.
As oil always passes through the oil cooler, the oil
temperature can be kept down. The front (arm, bucket
AUX1, boom, swing, 2-piece boom) 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
RY9212148HYM0057US0

3-M11

KiSC issued 08, 2015 A

KX080-4(EU), 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) 2-piece boom crowd (Pb6)
(5) AUX2 High (Pbk3) (11) Arm dump (Pb1) (17) Boom up (Pb4) (22) 2-piece boom dump (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

(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(EU), 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(EU), 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(EU), 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(EU), 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(EU), 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 of each section (AUX2, blade, swivel), going through
the center bypass passage of each section (swivel, blade, AUX2) and returns to the hydraulic oil tank via the
communication valve spool 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 is pressurized]
• When the spool is shifted by pressure from the Pak4 port, it closes the PT notch of the main spool, cutting off the
connection between the center bypass passage 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 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 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.
RY9212148HYM0068US0

3-M24

KiSC issued 08, 2015 A

KX080-4(EU), WSM HYDRAULIC SYSTEM

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

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

(a) From P3 port

• Boom up operation pressurizes the Pb4 port and switches the boom section. At the same time, the Pbu1 port,
which is connected via external lines, is also pressurized and the switch spool of the P3 bypass valve is switched.
• The Pak5 (Pbk5) port is pressurized and when the swivel section is switched, the P3 pump pressure is guided to
the cylinder port of the swivel section, while simultaneously being guided to the switch spool of the P3 bypass
valve.

[Swivel section operating load pressure>boom section operating load pressure]

• The P3 pump pressure passes through the switch spool of the P3 bypass valve, presses up on the check valve
and flows together with oil from the PB1 port to the PB2 port.

[Swivel section operating load pressure<boom section operating load pressure]

• As the check valve of the P3 bypass valve does not open, the P3 pump pressure is not combined to the PB2 port
and operates independently.
RY9212148HYM0069US0

3-M25

KiSC issued 08, 2015 A

KX080-4(EU), WSM HYDRAULIC SYSTEM

(8) 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-M26

KiSC issued 08, 2015 A

KX080-4(EU), 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-M27

KiSC issued 08, 2015 A

KX080-4(EU), 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-M28

KiSC issued 08, 2015 A

KX080-4(EU), 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
RY9212148HYM0001US0

[C] Relief Valve

• The relief valve is the valve that determines the drive
and brake forces during swiveling and it's equipped
with main ports A/B lines for each.
• Oil that enters port B is guided to the piston chamber
(4) via the relief valve orifice (2) and the body orifice
(3). While the piston is moving to the left side, the
spring chamber is at low pressure, so it acts on the
piston with the low force provided by the spring.
(Primary relief pressure)
• When the piston in the diagram reaches the left side,
the pressure in the spring chamber rises, and acts on
the piston with the total force of the spring and the
pressure. (Secondary relief pressure)
• Because of this, the system can suppress dramatic
changes in pressure and can mitigate the shock of
starting up and stopping the equipment.
(1) Piston (a) Pressure
(2) Relief valve orifice (b) Time
(3) Body orifice (c) Primary relief pressure
(4) Piston chamber (d) Secondary relief pressure
RY9212148HYM0031US0

3-M29

KiSC issued 08, 2015 A

KX080-4(EU), 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
RY9212148HYM0032US0

b)When the parking brake is released

• When the brake release pressure is guided to the
brake piston chamber (1) via the PG port (P), the
release pressure acts against the resistance of the
brake piston's spring, eliminating the friction with the
disc and allowing the cylinder block to turn freely.
(1) Brake piston chamber P: Port PG
RY9212148HYM0033US0

[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
RY9212148HYM0034US0

3-M30

KiSC issued 08, 2015 A

KX080-4(EU), 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
RY9212148HYM0035US0

a)In neutral
• The check valve is held in balance in the middle by
the spring. (Equal pressure on ports P1 and P2)
RY9212148HYM0036US0

b)Acclerating to uniform RPM

• When swiveled, the check valve is pressed on the
high-pressure side, seating the check valve.
(1) Supply pressure (2) Seat
RY9212148HYM0037US0

c)When braking
• Brake pressure shifts the check valve full stroke,
seating it.
(1) Brake pressure (2) Seat
RY9212148HYM0038US0

3-M31

KiSC issued 08, 2015 A

KX080-4(EU), 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
RY9212148HYM0039US0
e)When reversing 2
• The reverse pressure pushes in the opposite
direction during check valve braking at the same
time.
• The flow regulating valve inside the check valve,
which is now on the low-pressure side, is open at a
certain flow rate to oil from inside the damper
chamber. As a result, the check valve is shifted at a
certain speed.
• The check valve eventually seats, so the passage
formed between the Pv2 and Cv ports is blocked.
(1) Reverse pressure
RY9212148HYM0040US0

[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
RY9212148HYM0041US0

3-M32

KiSC issued 08, 2015 A

KX080-4(EU), 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 Nabtesco
Model GM11VA
Reduction ratio 50.111
10720 / 5610 N·m
Decelerator Output torque (1F/2F) 1093.4 / 572.2 kgf·m
7907.1 / 4137.9 lbf·ft
RPM (1F/2F) 27.1 / 49.6 rpm
51.9 / 27.8 cm3/rev
Displacement (1F/2F)
3.17 / 1.70 cu.in./rev
RPM (1F/2F) 1360 / 2486 rpm
72.0 L/min
Flow Rate
19.0 U.S.gals
29.4 MPa
Hydraulic motor Relief valve (cTF, cTR) 300 kgf/cm2
4264 psi
4.0 MPa
2-speed switch pressure 40.8 kgf/cm2
580 psi
24.4 MPa
Auto 2-speed switch
249 kgf/cm2
pressure
3539 psi
0.63 MPa
Parking brake Release pressure 6.4 kgf/cm3
91.4 psi

RY9212148HYM0042US0

3-M33

KiSC issued 08, 2015 A

KX080-4(EU), 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
RY9212148HYM0002US0

[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, the oil enters port A, passes
through line 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.
• In addition, the shifting of the spool allows oil to enter
port E. The oil in port E flows to the parking brake (3)
and the 2-speed switch valve.
(1) Check valve (a) Line a
(2) Spool (b) Chamber b
(3) Parking brake
(4) Spring
RY9212148HYM0043US0

3-M34

KiSC issued 08, 2015 A

KX080-4(EU), WSM HYDRAULIC SYSTEM
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.
(1) Check valve (a) Line a
(2) Spool (b) Chamber b
RY9212148HYM0044US0
c) Runaway check function (for descending steep
slopes)
• Under normal operation, the pressure on the supply
side drops when the motor is driven by external
forces. When the pressure approaches that required
to start running away, the spool (2) starts moving
toward the neutral position in the middle.
• The surface area in the passage to port B from port
D on the motor outlet side drops in relation to the
distance the spool moves, limiting the amount of oil
discharged. At the same time, the pressure at port D
(back pressure) rises as well, preventing the
machine from running away down a hill.
(1) Check valve (2) Spool
RY9212148HYM0045US0

3-M35

KiSC issued 08, 2015 A

KX080-4(EU), WSM HYDRAULIC SYSTEM

[C] Relief Valve

a) At start up
• Until the position of piston h (2) of relief valve B (1)
reaches the end of its stroke, the oil from port C is
released at the pressure setting (low-pressure relief)
of valve e (4) and is guided to port D.
• When piston h (2) reaches the end of its stroke, the
pressure in chamber y (3) rises, and valve e (4)
closes and the main relief valve of the control valve
opens.
• These mechanisms raise the pressure at port C,
applying rotary force to the motor.
(1) Relief valve B (a) Pressure
(2) Piston h (b) Time
(3) Chamber y (c) Low-pressure relief
(4) Valve e (d) Main relief
RY9212148HYM0046US0

3-M36

KiSC issued 08, 2015 A

KX080-4(EU), WSM HYDRAULIC SYSTEM
b) When stopping
• Once the counterbalance valve returns to neutral, it
cuts off port D on the outlet side, and as the motor
keeps turning due to inertia, it increases the pressure
inside port D.
• The oil inside port D passes through the orifice inside
relief valve A (1) and is guided to chamber x (3). Until
the oil supplied to chamber x (3) shifts the position of
piston d (2) and it reaches the end of its stroke, the
oil from port D is released at the pressure setting
(low-pressure relief) of valve a (4) and is guided to
port C. The supply of oil to port C prevents cavitation.
• Once piston d (2) reaches the end of its stroke, the
pressure in chamber x (3) rises, closing valve a (4)
and acting with the total force of the spring and the
pressure inside chamber x. (Secondary relief
pressure)
The mechanisms above stop the motor.
(1) Relief valve A (a) Pressure
(2) Piston d (b) Time
(3) Chamber x (c) Low-pressure relief
(4) Valve a (primary relief pressure)
(d) Relief valve A release
timing
RY9212148HYM0047US0

3-M37

KiSC issued 08, 2015 A

KX080-4(EU), WSM HYDRAULIC SYSTEM

[D] Auto-decelerator Function

(1) 2-speed port
(2) Ridged spool
(3) Spring
(4) 2-speed switch piston
(5) S chamber
(6) Swash-plate

(a) Motor load pressure

(b) Drain
(c) Fulcrum

• 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.
RY9212148HYM0048US0

[E] 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
RY9212148HYM0003US0

3-M38

KiSC issued 08, 2015 A

KX080-4(EU), WSM HYDRAULIC SYSTEM

7. HYDRAULIC CYLINDER
[1] SPECIFICATIONS

Boom 2P boom Arm Bucket Blade Swing

82 mm 82 mm 70 mm 70 mm 82 mm 82 mm
(1)
3.23 in. 3.23 in. 2.76 in. 2.76 in. 3.23 in. 3.23 in.
82 mm 82 mm 70 mm 70 mm 82 mm 82 mm
(2)
3.23 in. 3.23 in. 2.76 in. 2.76 in. 3.23 in. 3.23 in.
90 mm 65 mm 85 mm 75 mm 75 mm 80 mm
(3)
3.54 in. 2.56 in. 3.35 in. 2.95 in. 2.95 in. 3.15 in.
90 mm 65 mm 85 mm 75 mm 75 mm 80 mm
(4)
3.54 in. 2.56 in. 3.35 in. 2.95 in. 2.95 in. 3.15 in.
65 mm 55 mm 60 mm 55 mm 65 mm 60 mm
(5)
2.56 in. 2.17 in. 2.36 in. 2.17 in. 2.56 in. 2.36 in.
115 mm 95 mm 100 mm 90 mm 125 mm 110 mm
(6)
4.53 in. 3.74 in. 3.94 in. 3.54 in. 4.92 in. 4.33 in.
134 mm 120 mm 118 mm 112 mm 146 mm 131 mm
(7)
5.28 in. 4.72 in. 4.65 in. 4.41 in. 5.75 in. 5.16 in.
57 mm 65 mm 55 mm 60 mm 65 mm 65 mm
(8)
2.24 in. 2.56 in. 2.17 in. 2.36 in. 2.56 in. 2.56 in.
70 mm 55 mm 58 mm 55 mm 65 mm 58 mm
(9)
2.76 in. 2.17 in. 2.28 in. 2.17 in. 2.56 in. 2.28 in.
Max
1369 mm 1050 mm 1378 mm 1138 mm 689 mm 1165 mm
compresse
53.90 in. 41.34 in. 54.25 in. 44.80 in. 27.13 in. 45.87 in.
d length
878 mm 578 mm 912 mm 747 mm 250 mm 715 mm
Stroke
34.57 in. 22.76 in. 35.91 in. 29.41 in. 9.84 in. 28.15 in.

RY9212148HYM0049US0

3-M39

KiSC issued 08, 2015 A

KX080-4(EU), 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.
RY9212148HYM0028US0

3-M40

KiSC issued 08, 2015 A

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

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

(2) Cushion Chamber (4) Piston B : After Cushion Enters
RY9212148HYM0029US0

3-M41

KiSC issued 08, 2015 A

KX080-4(EU), 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

RY9212148HYM0004US0

3-M42

KiSC issued 08, 2015 A

KX080-4(EU), 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
RY9212148HYM0006US0

3-M43

KiSC issued 08, 2015 A

KX080-4(EU), 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

RY9212148HYM0051US0

3-M44

KiSC issued 08, 2015 A

KX080-4(EU), WSM HYDRAULIC SYSTEM

(2) Function and Structure

[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
RY9212148HYM0008US0

3-M45

KiSC issued 08, 2015 A

KX080-4(EU), 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(EU), WSM HYDRAULIC SYSTEM

[3] BLADE, SWING AND 2-SPEED BOOM PILOT VALVES

(1) Specifications

(1) Port 1 A: Blade (a) Secondary pressure (e) Pushrod stroke (mm)
(2) Port 2 B: Swing, 2-speed boom (kgf/cm2) (f) Pedal operating angle (deg)
(3) Operating torque (P) Port P (b) Secondary pressure (MPa)
(4) Secondary pressure (T) Port T (c) Operating torque (N·m)
(d) Operating torque (kgf·cm)

• For blade
Maker Kawasaki Heavy Industries, Ltd.
Model PV6P1082A

• For swing, 2-speed boom

Maker Kawasaki Heavy Industries, Ltd.
Model PV6P1005A

RY9212148HYM0010US0

3-M47

KiSC issued 08, 2015 A

KX080-4(EU), WSM HYDRAULIC SYSTEM

(2) Function and Structure

[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
RY9212148HYM0011US0

3-M48

KiSC issued 08, 2015 A

KX080-4(EU), WSM HYDRAULIC SYSTEM

9. BOOM HOLDING VALVE

[1] BOOM HOLDING VALVE
(1) Specifications

(1) Relief valve (B1H) A1 : Port A1 PL : Pilot pressure port

B : Port B DR :Drain port

Maker Kawasaki Heavy Industries, Ltd. Notes

Model KHCV15G-A101-3.2
35 MPa
Relief valve pressure
360 kgf/cm2
setting
5100 psi
0.8 cc/min @Temp. 50 °C (122 °F), B Port : 8.3 MPa (85 kgf/cm2, 1200 psi)
Leak volume
0.05 cu.in./min pressure

KX080-4(EU), WSM HYDRAULIC SYSTEM

[2] 2-PIECE BOOM HOLDING VALVE

(1) Specifications

(1) Relief valve (B7H) A : Port A PL : Pilot pressure port

B : Port B DR :Drain port

Maker Kawasaki Heavy Industries, Ltd. Notes

Model KHV10N30/34
34.3 MPa
Relief valve pressure
350 kgf/cm2
setting
4970 psi
1.5 cc/min @Temp. 50 °C (122 °F), B Port : 8.3 MPa (85 kgf/cm2, 1200 psi)
Leak volume
0.09 cu.in./min pressure

RY9212148HYM0017US0

KX080-4(EU), WSM HYDRAULIC SYSTEM

10. 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-M55

KiSC issued 08, 2015 A

KX080-4(EU), 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-M56

KiSC issued 08, 2015 A

KX080-4(EU), WSM HYDRAULIC SYSTEM

11. 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-M57

KiSC issued 08, 2015 A

KX080-4(EU), WSM HYDRAULIC SYSTEM

(2) Function and Structure

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-S25
[1] REMOVAL AND INSTALLATION OF THE SWIVEL MOTOR.............................................3-S25
[2] SWIVEL MOTOR DISASSEMBLY/ASSEMBLY PROCEDURES .......................................3-S27
(1) Disassembly Procedures...............................................................................................3-S29
(2) Assembly Procedures....................................................................................................3-S33
(3) Special Tools .................................................................................................................3-S39
4. SWIVEL JOINT..........................................................................................................................3-S40
[1] REMOVAL AND INSTALLATION OF THE SWIVEL JOINT................................................3-S40
[2] SWIVEL JOINT DISASSEMBLY / ASSEMBLY PROCEDURES ........................................3-S42
(1) Disassembly Procedures...............................................................................................3-S43
(2) Assembly Procedures....................................................................................................3-S45
5. TRAVEL MOTOR ......................................................................................................................3-S47
[1] REMOVAL AND INSTALLATION OF THE TRAVEL MOTOR ............................................3-S47
[2] TRAVEL MOTOR DISASSEMBLY / ASSEMBLY PROCEDURES .....................................3-S48
(1) Disassembly Procedures...............................................................................................3-S50
(2) Assembly Procedures....................................................................................................3-S56
(3) Special Tools .................................................................................................................3-S64
6. CYLINDER.................................................................................................................................3-S68
[1] TIGHTENING TORQUE ......................................................................................................3-S68
7. PILOT VALVE............................................................................................................................3-S70
[1] CONTROL PILOT VALVES.................................................................................................3-S70
(1) Disassembly ..................................................................................................................3-S71
(2) Assembly .......................................................................................................................3-S74
(3) Special Tools .................................................................................................................3-S78
[2] TRAVEL PILOT VALVE.......................................................................................................3-S79
(1) Disassembly ..................................................................................................................3-S80
(2) Assembly .......................................................................................................................3-S84
(3) Special Tools .................................................................................................................3-S88
[3] BLADE, SWING AND 2-PIECE BOOM PILOT VALVES.....................................................3-S89
(1) Disassembly ..................................................................................................................3-S91
(2) Assembly .......................................................................................................................3-S94
8. BOOM HOLDING VALVE..........................................................................................................3-S99
[1] BOOM HOLDING VALVE....................................................................................................3-S99
[2] 2-PIECE BOOM HOLDING VALVE...................................................................................3-S100
9. SHOCKLESS VALVES............................................................................................................3-S101
10. SWIVEL SHUTTLE VALVE .....................................................................................................3-S102
11. SOLENOID VALVE..................................................................................................................3-S103
[1] UNLOAD VALVE ...............................................................................................................3-S103
[2] AUX PROPORTIONAL CONTROL SOLENOID VALVE ...................................................3-S104
[3] EP MODE SOLENOID VALVE ..........................................................................................3-S105
12. ROUTING OF HYDRAULIC HOSES.......................................................................................3-S106

KiSC issued 08, 2015 A

[1] HYDRAULIC HOSE SPECIFICATIONS ............................................................................3-S106
[2] HIGH-PRESSURE HOSES ...............................................................................................3-S107
(1) Deliver Hose Routing...................................................................................................3-S107
(2) PLS Hose Routing .......................................................................................................3-S110
(3) Front Hose Routing......................................................................................................3-S111
(4) Boom Hose Routing.....................................................................................................3-S114
(5) Undercarriage Hose Routing .......................................................................................3-S115
(6) 2-Piece Boom Hose Routing .......................................................................................3-S116
[3] LOW-PRESSURE HOSES ................................................................................................3-S117
(1) Suction Pipe and Hose Routing...................................................................................3-S117
(2) Drain Hose Routing .....................................................................................................3-S118
[4] PILOT HOSES...................................................................................................................3-S119
(1) Deliver Hose Routing...................................................................................................3-S119
(2) Port P Hose Routing ....................................................................................................3-S120
(3) Port T Hose Routing ....................................................................................................3-S121
(4) Ports P and T Pilot Valve Hose Routing ......................................................................3-S122
(5) Pilot Valve Hose Routing .............................................................................................3-S124
(6) 2-Piece Boom Hose Routing .......................................................................................3-S127
13. MEASURING HYDRAULIC DEVICE PERFORMANCE ..........................................................3-S128
[1] PISTON PUMP AIR BLEEDING PROCEDURE ................................................................3-S128
[2] RELEASE OF PRESSURE IN THE HYDRAULIC SYSTEM .............................................3-S129
[3] MANUAL BOOM LOWERING PROCEDURE ...................................................................3-S130
[4] MEASURING THE FLOW RATE .......................................................................................3-S131
(1) Measuring Main Pump Flow ........................................................................................3-S131
(2) Measuring the AUX Proportional Settings ...................................................................3-S133
(3) Measuring AUX Discharge Flow..................................................................................3-S134
[5] MEASURING PRESSURE ................................................................................................3-S135
(1) Measuring Main Relief Valve Pressure........................................................................3-S135
(2) Measuring Pilot Secondary Pressure ..........................................................................3-S137
(3) Measuring EP Proportional Solenoid Pressure ...........................................................3-S138
(4) Measuring the Overload Relief Valve Pressure...........................................................3-S139
(5) Measuring Holding Valve Relief Pressure ...................................................................3-S141
(6) Pressure Measuring Kit ...............................................................................................3-S142
(7) Adjusting Swivel Relief Valve Pressure .......................................................................3-S143
(8) Adjusting the LS Control Differential Pressure Adjusting Spring .................................3-S143
[6] MEASURING SWIVEL PERFORMANCE .........................................................................3-S144
(1) Measuring Swivel Motor Drain Volume........................................................................3-S144
(2) Measuring Swivel Block Performance .........................................................................3-S145
(3) Measuring Swivel Speed .............................................................................................3-S146
[7] MEASURING TRAVEL PERFORMANCE .........................................................................3-S147
(1) Measuring Travel Motor Drain Volume ........................................................................3-S147
(2) Measuring Travel Block Performance..........................................................................3-S148
(3) Measuring Travel Speed..............................................................................................3-S149
(4) Measuring Travel Drift .................................................................................................3-S149
[8] MEASURING CYLINDER SPEED.....................................................................................3-S150
(1) Measuring Hydraulic Cylinder Operating Time ............................................................3-S150
(2) Measuring Hydraulic Cylinder Drift ..............................................................................3-S152
(3) Measuring Swing Cylinder Deviation ...........................................................................3-S153
14. HYDRAULIC DEVICE PERFORMANCE STANDARDS..........................................................3-S154
[1] FLOW RATE......................................................................................................................3-S154
(1) Main Pump Discharge Flow Rate Data (Measured Values) ........................................3-S154
(2) Flow Rate Data for AUX Proportional Control (Measured Values) ..............................3-S156
(3) AUX Discharge Flow Rate Data (Measured Values) ...................................................3-S157
[2] RELIEF PRESSURE (MEASURED VALUES) ..................................................................3-S158
[3] SWIVEL PERFORMANCE ................................................................................................3-S159
[4] TRAVEL PERFORMANCE ................................................................................................3-S159
[5] CYLINDER SPEED ...........................................................................................................3-S160
15. TROUBLESHOOTING.............................................................................................................3-S161
[1] TROUBLESHOOTING ALL ACTUATORS ........................................................................3-S161

KiSC issued 08, 2015 A

[2] TROUBLESHOOTING FRONT SYSTEMS .......................................................................3-S161
[3] TRAVEL SYSTEM TROUBLESHOOTING........................................................................3-S163
[4] SWIVEL SYSTEM TROUBLESHOOTING ........................................................................3-S164
[5] TROUBLESHOOTING MULTIPLE OPERATIONS ...........................................................3-S165

KiSC issued 08, 2015 A

KX080-4(EU), 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(EU), 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(EU), 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(EU), WSM HYDRAULIC SYSTEM

KX080-4(EU), 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(EU), 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(EU), 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(EU), 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(EU), 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(EU), 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(EU), 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(EU), 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(EU), 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(EU), 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(EU), WSM HYDRAULIC SYSTEM

KX080-4(EU), WSM HYDRAULIC SYSTEM
Mono-block Section Components

A : Boom section B : AUX1 section C : Bucket section D : Arm section

3-S23

KiSC issued 08, 2015 A

KX080-4(EU), 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-S24

KiSC issued 08, 2015 A

KX080-4(EU), WSM HYDRAULIC SYSTEM

3. SWIVEL MOTOR
[1] REMOVAL AND INSTALLATION OF THE SWIVEL MOTOR
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.

(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-S29

KiSC issued 08, 2015 A

KX080-4(EU), 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
RY9212148HYS0107US0

3-S30

KiSC issued 08, 2015 A

KX080-4(EU), WSM HYDRAULIC SYSTEM
12. Remove the shaft. Remove the hex socket bolts and then the
housing.
• Tool to use: 12 mm hex socket
(1) Shaft (3) Housing
(2) Hex socket bolt
RY9212148HYS0108US0

13. Remove the plate.

(1) Plate
RY9212148HYS0109US0

14. 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-S31

KiSC issued 08, 2015 A

KX080-4(EU), WSM HYDRAULIC SYSTEM
17. Remove the housing from the assembly platform and then
remove the collar.

CAUTION
• If the plate comes off, the shaft may fall, so take care in
handling it.
• Always have the bottom of the shaft touching the ground
when removing the collar and plate.
(1) Collar (2) Plate
RY9212148HYS0113US0

18. Remove the plate and then the shaft.

• Tool to use: punch and hammer
(1) Plate (2) Shaft
RY9212148HYS0114US0

19. Remove the tapered roller bearing and the plug.

• Tool to use: 5 mm hex socket
(1) Tapered roller bearing (2) Plug
RY9212148HYS0115US0

20. Remove the oil seal.

• Tool to use: slotted screwdriver and hammer
(1) Oil seal
RY9212148HYS0116US0

3-S32

KiSC issued 08, 2015 A

KX080-4(EU), 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
RY9212148HYS0122US0

3-S33

KiSC issued 08, 2015 A

KX080-4(EU), 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.

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-S37

KiSC issued 08, 2015 A

KX080-4(EU), 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-S38

KiSC issued 08, 2015 A

KX080-4(EU), 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-S39

KiSC issued 08, 2015 A

KX080-4(EU), 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-S40

KiSC issued 08, 2015 A

KX080-4(EU), 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-S41

KiSC issued 08, 2015 A

KX080-4(EU), WSM HYDRAULIC SYSTEM

[2] SWIVEL JOINT DISASSEMBLY / ASSEMBLY PROCEDURES

Components

No. Part Name Qty Notes

71.1 ± 2.5 N·m
(1) Plug (PT3/8) 2 7.2 ± 0.2 kgf·m
52.4 ± 1.8 lbf·ft
85.9 ± 2.5 N·m
(2) Plug (PT1/2) 4 8.8 ± 0.2 kgf·m
63.3 ± 1.8 lbf·ft
(3) Shaft 1
(4) Collar 1
(5) Packing (U) 1
(6) O-ring 1
(7) Seal 7
(8) Body 1
(9) Bracket 2
84.0 ± 6.0 N·m
8.6 ± 0.6 kgf·m
(10) Bolt 4
62.0 ± 5.0 lbf·ft
Thread locking compound (Loctite 1324 or equivalent)
84.0 ± 6.0 N·m
8.6 ± 0.6 kgf·m
(11) Bolt 4
62.0 ± 5.0 lbf·ft
Thread locking compound (Loctite 271)
(12) Collar 1
(13) Circlip 1
(14) O-ring 1
(15) Bottom cover 1
84.0 ± 6.0 N·m
8.6 ± 0.6 kgf·m
(16) Hex socket bolt 4
62.0 ± 5.0 lbf·ft
Thread locking compound (Loctite 1324 or equivalent)
• During disassembly, always use a tap to clean the threads of any thread lock on them.
RY9212148HYS0090US0

3-S42

KiSC issued 08, 2015 A

KX080-4(EU), 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

KiSC issued 08, 2015 A

KX080-4(EU), 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-S47

KiSC issued 08, 2015 A

KX080-4(EU), WSM HYDRAULIC SYSTEM

[2] TRAVEL MOTOR DISASSEMBLY / ASSEMBLY PROCEDURES

(To be continued)

3-S48

KiSC issued 08, 2015 A

KX080-4(EU), WSM HYDRAULIC SYSTEM
(Continued)
No. Part Name Qty No. Part Name Qty No. Part Name Qty
(1) Plug 1 (32) O-ring 1 (63) Piston 2
(2) O-ring 3 (33) Oil seal 1 (64) Sleeve 2
(3) Wire 1 (34) Ball bearing 1 (65) O-ring 2
(4) Cover 1 (35) Shaft 1 (66) Backup ring 4
(5) Plug 2 (36) Parallel pin 2 (67) O-ring 2
(6) O-ring 1 (37) Pivot 2 (68) Collar 2
(7) Bolt 3 (38) Spring 1 (69) Valve 2
(8) Plate 3 (39) 2-speed piston 1 (70) Valve seat 2
(9) Planetary gear B 3 (40) Swash-plate 1 (71) Backup ring 4
(10) Needle bearing 3 (41) Piston ASSY 1 (72) O-ring 2
(11) Collar 3 (42) Retainer plate 1 (73) Plug 3
(12) Ball 1 (43) Retainer holder 1 (74) O-ring 3
(13) Drive gear 1 (44) Collar 1 (75) Spring 2
(14) Circlip 1 (45) Cylinder block 1 (76) Poppet 2
(15) Holder 1 (46) Pin 3 (77) Plug 2
(16) Sun gear 1 (47) Washer 2 (78) O-ring 2
(17) Collar 1 (48) Spring 1 (79) Spring 2
(18) Ring nut 1 (49) Circlip 1 (80) Spring seat 2
(19) Angular bearing 2 (50) Valve plate 1 (81) Spool 1
(20) Gear case 1 (51) Knock pin 1 (82) Plug 3
(21) Bolt 4 (52) Ball bearing 1 (83) Flanged plug 1
(22) Plate 4 (53) Disc 2 (84) Ball 1
(23) Planetary gear A 4 (54) Plate 3 (85) Orifice 1
(24) Needle bearing 4 (55) O-ring 1 (86) Orifice 1
(25) Collar 4 (56) O-ring 1 (87) Plug 4
(26) Thrust washer 4 (57) Brake piston 1 (88) Plug 1
(27) Floating seal 1 (58) Spring 10 (89) O-ring 1
(28) Set screw 2 (59) Plug 2 (90) Hex socket bolt 8
(29) Flange holder 1 (60) O-ring 2 (91) Spring 1
(30) O-ring 2 (61) Shim 2 (92) Spool 1
(31) Pin 2 (62) Spring 2 (93) Base plate 1

RY9212148HYS0034US0

3-S49

KiSC issued 08, 2015 A

KX080-4(EU), 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
RY9212148HYS0035US0

2. Remove the wire.

• Tool to use: Slotted screwdriver
(1) Wire
RY9212148HYS0036US0

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 ball and the drive gear.

(1) Ball (2) Drive gear
RY9212148HYS0037US0

3-S50

KiSC issued 08, 2015 A

KX080-4(EU), WSM HYDRAULIC SYSTEM
5. Remove the holder sub-assembly.
(1) Holder sub-assembly
RY9212148HYS0038US0

Holder sub-assembly components

(1) Sun gear (5) Planetary gear B
(2) Circlip (6) Needle bearing
(3) Plate (7) Collar
(4) Bolt (8) Holder

IMPORTANT
• Use a M8 X P1.25 tap to clean the threads of any thread lock
in the thread holes.
• Always replace removed bolts with new ones.
RY9212148HYS0039US0

6. Remove the bolts and plate in order.

• Tool to use: 17 mm socket
IMPORTANT
• Use a M10 X P1.5 tap to clean the threads of any thread lock
in the thread holes.
• Always replace removed bolts with new ones.
(1) Bolt (2) Plate
RY9212148HYS0040US0

7. Remove planetary gear A, the needle bearing and collar in

order.
(1) Planetary gear A (3) Collar
(2) Needle bearing
RY9212148HYS0041US0

8. Remove the thrust washer, collar and set screw.

• Tool to use: 4 mm hex socket
(1) Thrust washer (3) Set screw
(2) Collar
RY9212148HYS0042US0

3-S51

KiSC issued 08, 2015 A

KX080-4(EU), WSM HYDRAULIC SYSTEM
9. 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.
• Always replace removed ring nut with a new one.
(b) Ring nut socket
RY9212148HYS0043US0

10. 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

11. Remove the floating seal from the flange holder side.
• Tool to use: Slotted screwdriver
(1) Floating seal
RY9212148HYS0024US0

12. Remove the floating seal from the gear case side.
• Tool to use: Slotted screwdriver
(1) Floating seal
RY9212148HYS0025US0

13. Remove one of the angular bearing.

(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
RY9212148HYS0018US0

3. Install the 2-speed piston, spring, pivot and parallel pin.

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) Pivot
(2) Spring (4) Parallel pin
RY9212148HYS0055US0

3-S56

KiSC issued 08, 2015 A

KX080-4(EU), WSM HYDRAULIC SYSTEM
4. Install the shaft and swash-plate in order.
IMPORTANT
• Apply grease to the back of the swash-plate.
(1) Shaft (2) Swash-plate
RY9212148HYS0056US0

5. Install the washer, spring, washer and 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
RY9212148HYS0057US0

6. Install the 3 pins in the cylinder block and then install the collar
and retainer holder in order.
IMPORTANT
• Apply grease to the pins.
(1) Cylinder block (3) Collar
(2) Pin (4) Retainer holder
RY9212148HYS0058US0

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
RY9212148HYS0059US0

8. Install the sub-assy of the cylinder block to the flange holder.

IMPORTANT
• Turn the assembly platform 1.6 rad (90°) to install it and
then turn it back afterwards.
(1) Cylinder block sub-assembly
RY9212148HYS0060US0

3-S57

KiSC issued 08, 2015 A

KX080-4(EU), WSM HYDRAULIC SYSTEM
9. Install the plate and disc in order.
IMPORTANT
• Install the plates and discs alternately.
• Apply hydraulic oil to the plates.
(1) Plate (2) Disc
RY9212148HYS0061US0

10. Install the brake piston.

IMPORTANT
• Apply grease to the O-ring.
(1) Brake Piston (2) O-Ring
RY9212148HYS0019US0

11. Install the valve plate and springs.

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) Spring (2) Valve plate
RY9212148HYS0062US0

12. Install the O-ring and fill with hydraulic oil on the motor side.
IMPORTANT
• Apply grease to the O-ring.
Hydraulic oil 1.2 L (0.32 U.S. gals)

(1) O-ring
RY9212148HYS0063US0

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.
102.0 ± 15.7 N·m
Torque Hex socket bolt 10.4 ± 1.6 kgf·m
75.2 ± 11.6 lbf·ft
• Tool to use: 10 mm hex socket
(1) Hex socket bolt (2) Base plate
RY9212148HYS0064US0

KX080-4(EU), WSM HYDRAULIC SYSTEM
5. Set the floating seal installation tool on the gear case. Grease
the O-ring of the floating seal and set the floating seal on the
gear case.
• Tool to use: Floating seal installation tool (for gear case)
(1) Floating seal (i) Floating seal installation tool (for
gear case)]
RY9212148HYS0071US0

6. Install the floating seal in the gear case with the floating seal
installation tool.
• Tool to use: Floating seal installation tool (pusher), floating seal
installation tool (for gear case)
(h) Floating seal installation tool (i) Floating seal installation tool (for
(pusher) gear case)]
RY9212148HYS0072US0

7. 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

8. Install the gear case on the flange holder.

(1) Gear case (2) Flange holder
RY9212148HYS0033US0

3-S61

KiSC issued 08, 2015 A

KX080-4(EU), WSM HYDRAULIC SYSTEM
9. Install the ring nut.
588.0 ± 55.8 N·m
Torque Ring nut 63.0 ± 6.0 kgf·m
433.6 ± 41.1 lbf·ft
• Tool to use:Ring nut socket
IMPORTANT
• Apply a thread lock (Loctite #638) at 4 places, about 30 to
40mm (1.2 to 1.6 in.) wide on the threads (3 threads wide)
on the C bevel side around the circumference of the ring
nut.
• Be careful that the ring nut socket doesn't come off during
installation/removal.
• Install the side with a greater bevel to the angular bearing
side.
(b) Ring nut socket
RY9212148HYS0073US0
10. Install the thrust washer, collar and set screw.
11. After installing the set screw, swage the hole with a punch.
9.8 ± 1.6 N·m
Torque Set screw 1.0 ± 0.2 kgf·m
7.2 ± 1.2 lbf·ft
• Tool to use: 4mm hex socket, punch, hammer
(1) Thrust washer (3) Set screw
(2) Collar
RY9212148HYS0074US0

12. Install the collar, needle bearing and planetary gear A in order.
(1) Collar (3) Planetary gear A
(2) Needle bearing
RY9212148HYS0075US0

13. Install the plate and bolts in order.

57.9 ± 9.8 N·m
Torque Bolt 5.9 ± 1.0 kgf·m
42.7 ± 7.2 lbf·ft
• Tool to use: 17 mm socket
IMPORTANT
• Make sure the plate does not ride up on planetary gear A.
• Always replace bolts with new ones.
(1) Plate (2) Bolt
RY9212148HYS0076US0

3-S62

KiSC issued 08, 2015 A

KX080-4(EU), WSM HYDRAULIC SYSTEM
14. Mount the sun gear on the holder.
• Tool to use: circlip
IMPORTANT
• Install the circlip with the rounded side down.
(1) Holder (3) Sun gear
(2) Circlip
RY9212148HYS0077US0

15. Install the collar, needle bearing and planetary gear B on the
holder in order.
(1) Collar (3) Planetary gear B
(2) Needle bearing
RY9212148HYS0078US0

16. Install the plate and bolts in order.

IMPORTANT
• Use a cushioning plate when clamping in a vise.
• Make sure the plate does not ride up on planetary gear B.
• Always replace bolts with new ones.
33.3 ± 4.9 N·m
Torque Bolt 3.4 ± 0.5 kgf·m
24.5 ± 3.5 lbf·ft
• Tool to use: 14 mm socket
(1) Plate (2) Bolt
RY9212148HYS0079US0
17. Install the holder sub-assembly, drive gear and balls in order.
IMPORTANT
• When the holder sub-assembly is installed, turn the gear
case and make sure it turns smoothly. (Take the drive gear
out)
(1) Holder sub-assembly (3) Ball
(2) Drive gear
RY9212148HYS0080US0

18. Install the cover.

IMPORTANT
• Apply grease to the O-ring.
(1) Cover (2) O-ring
RY9212148HYS0081US0

3-S63

KiSC issued 08, 2015 A

KX080-4(EU), WSM HYDRAULIC SYSTEM
19. Install the wire and plug.
58.8 ± 9.8 N·m
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 the specified amount of gear oil (1.3 L,
0.34 US gal.) prior to mounting on the machine.
• After mounting the travel motor on the machine,
double-check the gear oil level.
(1) Plug (2) Wire
RY9212148HYS0082US0

(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

3-S64

KiSC issued 08, 2015 A

KX080-4(EU), WSM HYDRAULIC SYSTEM
(b) Ring nut socket

A 215.5 mm (8.48 in.)

B 198 mm (7.80 in.)
24.979 - 25.000 mm
C
( 0.98343 - 0.98425 in.)
25.000 - 25.021 mm
D
( 0.98425 - 0.98508 in.)
E 34.5 - 35.0 mm (1.36 - 1.38 in.)
F 45 mm (1.77 in.)
G 39 mm (1.54 in.)
H 26 mm (1.02 in.)
I 1 mm (0.04 in.)
J 14 mm (0.55 in.)
K 71 mm (2.80 in.)
L 9 mm (0.35 in.)
M 6- 30 mm (6 - 1.18 in.)
N 6 - 16 mm (6 - 0.63 in.)
O 4- 40 mm (4 - 1.57 in.)
P P.C.D. 120 mm (4.724 in.)
Q 35.7 - 35.9 mm (1.406 - 1.413 in.)
R 0.52 rad (30 °)
S 6 - 6.82 rad (6 - 360 °)
C1 1 mm (0.04 in.) bevel
C2 2 mm (0.08 in.) bevel
• Bold line indicates high-frequency
tempering
• If angle is not specified, there must not be
any burrs. Corner to be max of R0.4 mm
(0.016 in.)
RY9212148HYS0083US0
(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

(d) Tool for pressing cylinder block

A 24 mm (0.945 in.)
B 33.2 - 33.5 mm (1.31 - 1.32 in.)
C 5 mm (0.2 in.)
D 60 mm (2.362 in.)
E 125 mm (4.921 in.)
C1 1 mm (0.04 in.) bevel
C0.5 0.5 mm (0.02 in.) bevel
RY9212148HYS0084US0

3-S65

KiSC issued 08, 2015 A

KX080-4(EU), WSM HYDRAULIC SYSTEM
(a) Oil seal installation tool

A 30 mm (1.18 in.)
B 90 mm (3.54 in.)
C 235 mm (9.25 in.)
D 17 mm (0.67 in.)
E 18 mm (0.71 in.)
F 15 mm (0.59 in.)
G 3 mm (0.12 in.)
H 0.52 rad (30 °)
I 29.8 to 30.0 mm (1.17 to 1.18 in.)
J 49.1 to 49.0 mm (1.92 to 1.93 in.)
K 61 mm (2.4 in.)
C1 1 mm (0.04 in.) bevel
RY9212148HYS0085US0
(f) Angular bearing insertion tool

214.8 to 215.0 mm (8.457 to 8.464

A
in.)
B 208 mm (8.189 in.)
C 140 mm (5.512 in.)
175.3 to 175.5 mm (6.902 to 6.909
D
in.)
E 2 mm (0.08 in.)
F 14 mm (0.55 in.)
G 16 mm (0.63 in.)
H 31 mm (1.22 in.)
I 0.52 rad (30 °)
C1 1 mm (0.04 in.) bevel
C0.5 0.5 mm (0.02 in.) bevel
• Bold line indicates high-frequency
tempering
RY9212148HYS0086US0
(g) Floating seal installation tool (for
flange holder)

A 219.7 - 219.9 mm (8.650 - 8.657 in.)

B 228.5 - 228.6 mm (8.996 - 9.000 in.)
C 240 mm (9.45 in.)
D 290 mm (11.42 in.)
E 9.3 to 9.5 mm (0.366 to 0.374 in.)
F 1 mm (0.04 in.)
G 7.5 mm (0.30 in.)
H 13 mm (0.51 in.)
I 0.24 to 0.28 rad (14 to 16 °)
J 0.52 rad (30 °)
K Machined recess
L Light chamfering
C0.5 0.5 mm (0.02 in.) bevel
• Corner to be max of R0.4 mm (0.016 in.)
RY9212148HYS0087US0

3-S66

KiSC issued 08, 2015 A

KX080-4(EU), WSM HYDRAULIC SYSTEM
(h) Floating seal installation tool (pusher)

A 260 mm (10.24 in.)

B 197 to 200 mm (7.756 to 7.874 in.)
215.9 to 216.1 mm (8.500 to 8.508
C
in.)
218.9 to 219.1 mm (8.618 to 8.626
D
in.)
E 25.5 mm (1.00 in.)
F 10.5 to 10.7 mm (0.414 to 0.421 in.)
G 11.3 to 11.6 mm (0.445 to 0.457 in.)
H 0.24 to 0.28 rad (14 to 16 °)
R0.3 Radius 0.3 mm (0.012 in.)
R0.2 Radius 0.2 mm (0.008 in.)
C0.5 0.5 mm (0.02 in.) bevel
• Material: nylon
• Corner to be max of R0.4 mm (0.016 in.)
RY9212148HYS0088US0
(i) Floating seal installation tool (for gear
case)]

A 219.7 - 219.9 mm (8.650 - 8.657 in.)

B 218.8 - 218.9 mm (8.618 - 8.626 in.)
C 290 mm (11.42 in.)
D 1 mm (0.04 in.)
E 3.8 to 4.0 mm (0.150 to 0.157 in.)
F 9.3 to 9.5 mm (0.366 to 0.374 in.)
G 0.24 to 0.28 rad (14 to 16 °)
H 0.52 rad (30 °)
I Machined recess
J Light chamfering
C0.5 0.5 mm (0.02 in.) bevel
• Corner to be max of R0.4 mm (0.016 in.)
RY9212148HYS0089US0

3-S67

KiSC issued 08, 2015 A

KX080-4(EU), 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 N·m
Screw torque 3.2 kgf·m
23.2 lbf·ft
Screw size M10 × 1.5 Tap with punch in two places

2-piece boom 1980 N·m

Piston torque 202.0 kgf·m
1460 lbf·ft
Width across hex-head. 70
669 N·m
Head torque 68.2 kgf·m Apply ThreeBond #1901
493 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

3-S68

KiSC issued 08, 2015 A

KX080-4(EU), WSM HYDRAULIC SYSTEM

KX080-4 Notes
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

RY9212148HYS0225US0

3-S69

KiSC issued 08, 2015 A

KX080-4(EU), 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-S70

KiSC issued 08, 2015 A

KX080-4(EU), 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-S71

KiSC issued 08, 2015 A

KX080-4(EU), 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-S72

KiSC issued 08, 2015 A

KX080-4(EU), 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-S73

KiSC issued 08, 2015 A

KX080-4(EU), 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-S74

KiSC issued 08, 2015 A

KX080-4(EU), 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-S75

KiSC issued 08, 2015 A

KX080-4(EU), 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-S76

KiSC issued 08, 2015 A

KX080-4(EU), 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

(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-S82

KiSC issued 08, 2015 A

KX080-4(EU), 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-S83

KiSC issued 08, 2015 A

KX080-4(EU), 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
• Assembly is basically the reverse of disassembly.
RY9212148HYS0250US0
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-S84

KiSC issued 08, 2015 A

KX080-4(EU), 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-S85

KiSC issued 08, 2015 A

KX080-4(EU), 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-S86

KiSC issued 08, 2015 A

KX080-4(EU), 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-S87

KiSC issued 08, 2015 A

KX080-4(EU), 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-S88

KiSC issued 08, 2015 A

KX080-4(EU), WSM HYDRAULIC SYSTEM

[3] BLADE, SWING AND 2-PIECE BOOM PILOT VALVES

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

Blade pilot valve 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)

RY9212148HYS0268US0

3-S89

KiSC issued 08, 2015 A

KX080-4(EU), 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

2-Piece boom pilot valve adapter angles

Point used Tape color

(1) Dump Blue
(2) Crowd Green
(P) Port P White
(T) Port T None

(A) Dump
(B) Crowd

(a) 5° (0.09 rad)

(b) 10 ° (0.17 rad)
(c) 45 ° (0.79 rad)
RY9212148HYS0270US0

3-S90

KiSC issued 08, 2015 A

KX080-4(EU), WSM HYDRAULIC SYSTEM

(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

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

3-S91

KiSC issued 08, 2015 A

KX080-4(EU), WSM HYDRAULIC SYSTEM
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

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

3-S92

KiSC issued 08, 2015 A

KX080-4(EU), WSM HYDRAULIC SYSTEM
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
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

3-S93

KiSC issued 08, 2015 A

KX080-4(EU), WSM HYDRAULIC SYSTEM
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. 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

3-S94

KiSC issued 08, 2015 A

KX080-4(EU), WSM HYDRAULIC SYSTEM
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

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

3-S95

KiSC issued 08, 2015 A

KX080-4(EU), WSM HYDRAULIC SYSTEM
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
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

3-S96

KiSC issued 08, 2015 A

KX080-4(EU), WSM HYDRAULIC SYSTEM
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

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

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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

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8. BOOM HOLDING VALVE

[1] BOOM HOLDING VALVE

No. Part Name Qty Torque No. Part Name Qty Torque
98.0 to 120.0 N·m
(1) O-ring 1 (16) Plug 1 10.0 to 12.2 kgf·m
72.0 to 88.5 lbf·ft
(2) Bushing 1 (17) O-ring 1
(3) O-ring 1 (18) Needle bearing 1
110.0 to 130.0 N·m 27.0 to 31.0 N·m
(4) Plug 1 11.2 to 13.3 kgf·m (19) Lock nut 1 2.8 to 3.2 kgf·m
81.1 to 95.9 lbf·ft 20.0 to 23.0 lbf·ft
110.0 to 130.0 N·m
(5) O-ring 1 (20) Cap 1 11.2 to 13.3 kgf·m
81.1 to 95.9 lbf·ft
(6) Plug 1 (21) O-ring 1
(7) Valve body 1 (22) Spring 1
(8) O-ring 1 (23) Spring 1
29.0 to 39.0 N·m
(9) Relief valve 1 3.0 to 4.0 kgf·m (24) Spring seat 1
21.0 to 29.0 lbf·ft
(10) Poppet 1 (25) Bushing 1
(11) Spring 1 (26) O-ring 1
(12) O-ring 1 (27) Spool 1
130.0 to 150.0 N·m
(13) Plug 1 13.3 to 15.3 kgf·m (28) Ball 1
95.9 to 111.0 lbf·ft
(14) Piston 1 (29) Hex socket set screw 1
(15) O-ring 1 (30) Piston 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.
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[2] 2-PIECE BOOM HOLDING VALVE

No. Name of part Qty Torque
25.0 to 29.0 N·m
(1) Plug 1 2.5 to 3.0 kgf·m
18.0 to 21.0 lbf·ft
(2) O-ring 1
(3) Poppet 1
7.8 to 9.8 N·m
(4) Plug 5 0.8 to 1.0 kgf·m
5.8 to 7.2 lbf·ft
(5) Valve body 1
(6) Spool 1
(7) Spring 1
(8) O-ring 1
49.0 to 59.0 N·m
(9) Plug 1 5.0 to 6.0 kgf·m
36.0 to 44.0 lbf·ft
(10) O-ring 1
(11) Sleeve 1
(12) O-ring 1
(13) Poppet 1
(14) Spring 1
(15) O-ring 1
39.0 to 49.0 N·m
(16) Plug 1 4.0 to 5.0 kgf·m
29.0 to 36.0 lbf·ft
(17) O-ring 1
29.0 to 39.0 N·m
(18) Relief valve 1 3.0 to 4.0 kgf·m
21.0 to 29.0 lbf·ft
(19) O-ring 1
34.0 to 39.0 N·m
(20) Plug 1 3.5 to 4.0 kgf·m
25.0 to 29.0 lbf·ft
• 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.
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9. 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 valve

(2) Swivel shuttle valve

A : Standard Spec
B : 2-piece boom
specification

(a) 30 ° (0.52 rad)

(b) 45 ° (0.79 rad)
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10. SWIVEL SHUTTLE VALVE

Components

No. Name of part Q'ty Torque

KiSC issued 08, 2015 A

KX080-4(EU), WSM HYDRAULIC SYSTEM

12. 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)
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[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)

KX080-4(EU), WSM HYDRAULIC SYSTEM
(Continued)
Hose Fitting
No. Function Total Tape Hose Guard Point used
Type Size
length color class
2680 mm Green Colgate C/V (Boom up) to boom
(1) Boom up PA2810 C·C 1-14UNS
105.5 in. White tube 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 Colgate C/V (arm crowd) to boom
(3) Arm crowd Blue PA2810 C·C 1-14UNS
129.1 in. tube back (pipe)
Boom back (pipe) (arm
720 mm PA2810
(4) Arm crowd Blue C·C 1-14UNS crowd) to arm cylinder
28.3 in. equiv.
(bottom)
3220 mm Colgate C/V (arm dump) to boom
(5) Arm dump Pea green PFH08 C·C 13/16UN
126.8 in. tube back (pipe)
Boom back (pipe) (arm
1955 mm PA2808
(6) Arm dump 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

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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).
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(4) Boom Hose Routing

(1) AUX2 (High) (5) AUX1 (High) (9) Bucket crowd (13) Wire harness
(2) Boom H/V (signal) (6) Arm dump (10) AUX1 (Low) (14) White tape
(3) Boom H/V (drain) (7) Arm crowd (11) Boom down (15) Velcro tape
(4) Boom up (8) Bucket dump (12) AUX2 (Low)

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.
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(5) Undercarriage Hose Routing

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

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[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

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(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)

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(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.

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(4) Ports P and T Pilot Valve Hose Routing

(a) Boom Shockless Valve (d) Collector Block (g) Blade P/V A : 2-Piece Boom 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) 2P Boom P/V
(To be continued)

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KX080-4(EU), 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 Q·C Q·1/4
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)
330 mm Swing P/V (T) to Travel P/V
(8) White PLT04 Q·C Q·1/4
Drain 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)
Blue
2720 mm Boom H/V (Dr) to (P4, T)
(11) Yellow PLT04 C·C 1/4
107.1 in. collector block
Center white
1300 mm
(12) Flow control PLT04 Q·C Q·1/4 E/P, solenoid to Pump (E/P)
51.2 in.
1300 mm
(13) 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
(14) Drain PLT04 C·CR9 1/4
11.2 in. block (T)
1280 mm E/P, solenoid (P) to P/V (L)
(15) P/V Left P White PLT04 C·Q 1/4·Q
50.4 in. (P)
2135 mm
(16) P/V right P White PLT04 Q·Q Q P/V (right) (P) to P/V (left) (P)
84.1 in.
225 mm Travel P/V (P) to 2P boom
(17) 2P boom P/V P C·Q Q·C 1/4·Q
8.9 in. P/V (P)
225 mm 2P boom P/V (T) to Travel
(18) Drain Q·C Q·Q Q·1/4
8.9 in. P/V (T)

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(5) Pilot Valve Hose Routing

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

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
1420 mm P/V (arm crowd) to shuttle
(3) Arm crowd Blue PLT04 Q·C Q·3/8
55.9 in. valve
1315 mm P/V (arm dump) to bulkhead
(4) Arm dump Pea green PLT04 Q·C Q·3/8
51.8 in. fitting
1655 mm P/V (bucket crowd) to
(5) Bucket crowd Orange PLT04 Q·QM Q
65.2 in. bulkhead fitting
1650 mm P/V (bucket dump) to
(6) Bucket dump Red PLT04 Q·QM Q
65.0 in. bulkhead fitting
1815 mm P/V (boom up) to shockless
(7) Boom up Green PLT04 Q·C Q·3/8
71.5 in. valve
1840 mm P/V (boom down) to
(8) Boom down Yellow PLT04 Q·C Q·3/8
72.4 in. shockless valve
1400 mm Blade P/V (up) to bulkhead
(9) Blade up Pink PLT04 Q·QM Q
55.1 in. fitting
1400 mm Blade P/V (down) to
(10) Blade down Brown PLT04 Q·QM Q
55.1 in. bulkhead fitting

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

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(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)
Both edges
Boom anti-drop 2205 mm Shockless valve to H/V
(10) yellow X 2 PLT04 Q·C Q·1/4
release 86.8 in. (boom down signal)
Center white
1660 mm Travel P/V (L-Fwd) to C/V
(11) 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
(12) 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
(13) 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
(14) Travel right rear Green x 2 PLT04 Q·CR9 Q·1/4
72.4 in. (R-Bwd)
1850 mm
(15) 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
(16) Swing right Yellow x 2 PLT04 Q·Q Q
57.1 in. (right)
1545 mm Bulkhead fitting to C/V (blade
(17) Blade up Pink PLT04 Q·Q Q
60.8 in. up)
1795 mm Bulkhead fitting to C/V (blade
(18) Blade down Brown PLT04 Q·CR9 Q·1/4
70.7 in. down)
860 mm AUX1 solenoid (Hi) to C/V
(19) AUX1 High pressure Pink PLT04 C·Q 1/4·Q
33.9 in. (AUX1 Hi)
1050 mm AUX1 solenoid (Low) to C/V
(20) AUX1 Low pressure Brown PLT04 C·CR9 1/4
41.3 in. (AUX1 Low)
420 mm AUX2 solenoid (Hi) to C/V
(21) AUX2 High pressure Pink PLT04 Q·Q Q
16.5 in. (AUX2 Hi)
760 mm AUX2 solenoid (Low) to C/V
(22) AUX2 Low pressure Brown PLT04 Q·CR9 Q·1/4
29.9 in. (AUX2 Low)
345 mm Red
(23) P3 union PLT04 Q·Q Q C/V (PF1) to C/V (PF2)
13.6 in. Blue

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(6) 2-Piece Boom Hose Routing

(a) Control valve (b) Boom shockless valve (c) 2P boom P/V

Hose Fitting
No. Guard Point used
Total length Tape color Hose class Type Size
1950 mm Yellow 2P boom P/V (crowd) to C/V (2P
(1) PLT04 Q·Q Q
76.8 in. Gray crowd)
2350 mm Green 2P boom P/V (dump) to C/V (2P
(2) PLT04 Q·CR9 Q·1/4
92.5 in. Gray dump)
3310 mm 2P boom P/V (crowd) to boom
(3) PLT06 C·C 3/8
130.3 in. back pipe (lock release)
Colgate tube
2855 mm Boom back pipe (Dr) to
(4) PLT04 C·C 1/4
112.4 in. shockless valve (T)
540 mm Boom back pipe (lock release) to
(5) PLT06 C·CR9 3/8
21.3 in. Entire length 2P boom H/V (PL)
520 mm corrugated tube 2P boom H/V (Dr) to boom back
(6) PLT04 C·CR9 1/4
20.5 in. pipe (Dr)

RY9212148HYS0301US0

3-S127

KiSC issued 08, 2015 A

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13. 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
RY9212148HYS0304US0

3-S128

KiSC issued 08, 2015 A

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[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
RY9212001HYS0649US0

3-S129

KiSC issued 08, 2015 A

KX080-4(EU), 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-S136

KiSC issued 08, 2015 A

KX080-4(EU), 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
2-piece boom 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) 2-Piece Boom Crowd
(22) 2-Piece Boom Dump
RY9212148HYS0325US0

3-S137

KiSC issued 08, 2015 A

KX080-4(EU), 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-S138

KiSC issued 08, 2015 A

KX080-4(EU), 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 2-piece boom) 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
RY9212148HYS0328US0

[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-S139

KiSC issued 08, 2015 A

KX080-4(EU), WSM HYDRAULIC SYSTEM
2-piece boom 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) 2-Piece Rod
(12) 2-Piece Bottom
RY9212148HYS0330US0

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
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

RY9212148HYS0332US0

3-S140

KiSC issued 08, 2015 A

KX080-4(EU), WSM HYDRAULIC SYSTEM

(5) Measuring Holding Valve Relief Pressure

IMPORTANT
• If it is necessary to check the overload relief pressure on this machine, measure the main relief pressure
of each circuit (boom, 2-piece boom) 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.
RY9212148HYS0333US0
Holding Valve
[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 PL, A and Dr ports.
4. Disconnect the boom pressure sensor wiring and remove the
boom pressure sensor.
5. Attach the pressure measuring kit to the disconnected port.

[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
• After measuring, the boom will be lifted, so lower it
according to the section Manual Boom Lowering
Procedure.
(1) Pressure Sensor (3) Straight Pipe Joint (G3/8-G1/4)
(2) Pressure Measuring Kit (4) O-Ring
RY9212148HYS0334US0
2-Piece Boom Holding Valve
[Measurement preparations]
1. Place the mini excavator on flat hard ground, lower the bucket
and the blade, and stop the engine.
• Position for measurement: 2-piece boom cylinder max
extended
2. Follow the chapter Releasing Pressure in the Hydraulic System
and release pressure in the hydraulic lines.
3. Disconnect the 2-piece cylinder hoses on the port A side and
plug the disconnected hoses.
4. Attach the pressure measuring kit to the disconnected port.

[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.
(1) Pressure Measuring Kit (3) Straight Pipe Joint (G3/8-G1/4)
(2) Straight (R1/8-G1/4) (4) Plug
RY9212148HYS0335US0

3-S141

KiSC issued 08, 2015 A

KX080-4(EU), WSM HYDRAULIC SYSTEM

(6) 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-S142

KiSC issued 08, 2015 A

KX080-4(EU), WSM HYDRAULIC SYSTEM

(7) 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

(8) Adjusting the LS Control Differential Pressure Adjusting Spring

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-S143

KiSC issued 08, 2015 A

KX080-4(EU), 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

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-S148

KiSC issued 08, 2015 A

KX080-4(EU), 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-S149

KiSC issued 08, 2015 A

KX080-4(EU), 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-S150

KiSC issued 08, 2015 A

KX080-4(EU), 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

Boom cylinder (2-piece boom spec. machines)

1. The position for measurement should be with the 2-piece boom
cylinder at maximum extension and at maximum compressed
length of the arm cylinder and bucket cylinder.
2. Operate the boom control lever at full stroke and measure the
time it takes the boom to go from having the tip of the arm on the
ground to the maximum lift position.
• Make this measurement without a bucket mounted.
• Do not include cushion operating time.
RY9212148MBS0122US0

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-S154

KiSC issued 08, 2015 A

[2] RELIEF PRESSURE (MEASURED VALUES)

Item Notes

Travel right main pressure (aTR) 30.0 ± 0.5 MPa

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

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 43 ± 2 kgf/cm2
610 ± 29 psi
2.8 ± 0.2 MPa
P mode (AC ON) 28.6 ± 2 kgf/cm2 Compressor: ON
406 ± 29 psi
0 MPa
EP proportional solenoid
E mode 0 kgf/cm2
pressure
0 psi
1.6 ± 0.2 MPa
16.3 ± 2 kgf/cm2 Mono-boom specification
E mode (during 232 ± 29 psi
operation) 2.2 ± 0.2 MPa
22.4 ± 2 kgf/cm2 2-piece boom specification
319 ± 29 psi

Bottom (b1B) 31.4 ± 1.0 MPa

320 ± 10 kgf/cm2
Rod (b1R) 4554 ± 145 psi
Boom
35.0 ± 1.0 MPa
HV (b1H) 5100 ± 10 kgf/cm2
4409 ± 145 psi
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
Rod (b3R) 4554 ± 145 psi

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

KX080-4(EU), WSM HYDRAULIC SYSTEM

15. 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-S161

KiSC issued 08, 2015 A

KX080-4(EU), WSM HYDRAULIC SYSTEM
Boom operation slow or jerky

No. Cause Remedy Notes

RY9212148HYS0361US0

3-S162

KiSC issued 08, 2015 A

KX080-4(EU), 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-S163

KiSC issued 08, 2015 A

KX080-4(EU), 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

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-S164

KiSC issued 08, 2015 A

KX080-4(EU), 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

Timer valve sticking or damaged Clean or replace the timer valve

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

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-S165

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-S11
[1] NAMES AND FUNCTIONS OF METERS ...........................................................................4-S11
[2] USER SETTINGS MODE ....................................................................................................4-S11
(1) Log Record ....................................................................................................................4-S12
(2) Periodic Check ..............................................................................................................4-S12
(3) Set Clock .......................................................................................................................4-S13
(4) Set AUX Flow Ctrl..........................................................................................................4-S13
(5) Various Settings ............................................................................................................4-S14
(6) Language Setting ..........................................................................................................4-S14
[3] SERVICE DEALER SETTING .............................................................................................4-S14
(1) Crane Mode...................................................................................................................4-S14
(2) Arm Control Mode (Only on Japan Spec.).....................................................................4-S14
[4] SERVICE/DEALER MODE..................................................................................................4-S15
(1) Diagnosis.......................................................................................................................4-S17
(2) Setting ...........................................................................................................................4-S22
[5] SETTINGS WHEN REPLACING ELECTRONIC DEVICES ................................................4-S36
(1) When Replacing the Meter or Main ECU ......................................................................4-S36
(2) When the Battery is Removed.......................................................................................4-S36
[6] TABLE OF METER PANEL MESSAGES AND ERROR HISTORY LIST............................4-S37
(1) Red Warning Lamp Lit...................................................................................................4-S37
(2) Yellow Warning Lamp Lit...............................................................................................4-S39
(3) Other Screens ...............................................................................................................4-S40
(4) PM Clog Level and the State of the Machine ................................................................4-S42
(5) Table of Engine System Error Numbers........................................................................4-S45
3. INSPECTIONS ..........................................................................................................................4-S46
[1] POWER AND GROUND .....................................................................................................4-S46
[2] STARTING AND STOPPING DEVICE ................................................................................4-S49
[3] RELAY LAYOUT .................................................................................................................4-S50
4. TROUBLESHOOTING (START-UP EQUIPMENT VERSION)..................................................4-S52
5. METHODS FOR DIAGNOSING ERRORS................................................................................4-S53
[1] GUIDE TO DIAGNOSING ERRORS ...................................................................................4-S53
[2] ERROR DIAGNOSIS PROCEDURE...................................................................................4-S53
[3] TESTING WITH A CIRCUIT TESTER.................................................................................4-S54
6. TROUBLESHOOTING (METER PANEL VERSION).................................................................4-S55
[1] MACHINE RELATED SYSTEM...........................................................................................4-S55
(1) Engine Oil Pressure Errors............................................................................................4-S55
(2) Charging System Errors ................................................................................................4-S58
(3) Fuel Sensor Errors ........................................................................................................4-S62
[2] FRONT-END SYSTEMS .....................................................................................................4-S66
(1) Lever Lock System Errors .............................................................................................4-S66
(2) Travel 2-speed System Error.........................................................................................4-S70
(3) Overload warning error..................................................................................................4-S74
[3] AUTO IDLING (AI) SYSTEM ...............................................................................................4-S77
(1) AI System Errors ...........................................................................................................4-S77
(2) Testing the AI Pressure Switch .....................................................................................4-S80

KiSC issued 08, 2015 A

(3) Testing the AI Switch .....................................................................................................4-S83
[4] ANTI-THEFT (AT) SYSTEM ................................................................................................4-S86
(1) Anti-Theft System Errors ...............................................................................................4-S86
[5] POWER SUPPLY SYSTEM ................................................................................................4-S89
(1) Over Voltage..................................................................................................................4-S89
(2) 5 V Short System Error..................................................................................................4-S90
[6] COMMUNICATION SYSTEM ..............................................................................................4-S91
(1) CAN Communication Errors ..........................................................................................4-S91
[7] AUX SYSTEM......................................................................................................................4-S97
(1) AUX1 / AUX2 (Thumb) System Errors...........................................................................4-S97
[8] ECO MODE SYSTEM .......................................................................................................4-S103
(1) EP System Errors ........................................................................................................4-S103

KiSC issued 08, 2015 A

KX080-4(EU), 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(EU), 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(EU), WSM ELECTRICAL SYSTEM

KX080-4(EU), 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(EU), WSM ELECTRICAL SYSTEM

KX080-4(EU), 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-S11

KiSC issued 08, 2015 A

KX080-4(EU), 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-S12

KiSC issued 08, 2015 A

KX080-4(EU), 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 & track rollers – Every 2000 hrs
11 DPF clean Every 3000 hrs
 First operation
RY9212148ELS0020US0

(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-S13

KiSC issued 08, 2015 A

KX080-4(EU), 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-S14

KiSC issued 08, 2015 A

KX080-4(EU), 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-S15

KiSC issued 08, 2015 A

KX080-4(EU), 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-S16

KiSC issued 08, 2015 A

KX080-4(EU), 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-S17

KiSC issued 08, 2015 A

KX080-4(EU), 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

KX080-4(EU), 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-S21

KiSC issued 08, 2015 A

[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)

(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-S31

KiSC issued 08, 2015 A

KX080-4(EU), 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

4-S32

KiSC issued 08, 2015 A

KX080-4(EU), WSM ELECTRICAL SYSTEM

(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

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

4-S33

KiSC issued 08, 2015 A

KX080-4(EU), WSM ELECTRICAL SYSTEM
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

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 (10A)

[Meter] a)Connector disconnected

4 –
Fuel Sensor Error b)Break in harness

a)Connector disconnected
[Meter]
CANSys (main) b)ECU (+B) fuse blown (10A)
CAN Sys (Main)
c)Break or short in harness
5 a)Connector disconnected
[Meter] b)Slow blow fuse (CRS) blown (30A)
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-S37

KiSC issued 08, 2015 A

KX080-4(EU), 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] a)Connector disconnected

12 Boom bottom
Boom bottom b)Break or short in harness

[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

RY9212148ELS0065US0

4-S38

KiSC issued 08, 2015 A

KX080-4(EU), 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-S39

KiSC issued 08, 2015 A

KX080-4(EU), 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-S40

KiSC issued 08, 2015 A

KX080-4(EU), 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-S41

KiSC issued 08, 2015 A

KX080-4(EU), 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-S42

KiSC issued 08, 2015 A

KX080-4(EU), 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-S43

KiSC issued 08, 2015 A

KX080-4(EU), 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.

4-S44

KiSC issued 08, 2015 A

KX080-4(EU), WSM ELECTRICAL SYSTEM

(5) Table of Engine System Error Numbers

METER PANEL OPERATION

 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

KX080-4(EU), 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
RY9212148ELS0140US0
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-S48

KiSC issued 08, 2015 A

KX080-4(EU), 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

4-S52

KiSC issued 08, 2015 A

KX080-4(EU), 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-S53

KiSC issued 08, 2015 A

KX080-4(EU), 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-S54

KiSC issued 08, 2015 A

KX080-4(EU), 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-S55

KiSC issued 08, 2015 A

KX080-4(EU), WSM ELECTRICAL SYSTEM

[B] Inspecting each device visually and physically

(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-S62

KiSC issued 08, 2015 A

KX080-4(EU), 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-S63

KiSC issued 08, 2015 A

KX080-4(EU), 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-S64

KiSC issued 08, 2015 A

KX080-4(EU), WSM ELECTRICAL SYSTEM

[E] Steps to Take after Completing Repairs

4-S65

KiSC issued 08, 2015 A

KX080-4(EU), WSM ELECTRICAL SYSTEM

[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

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

4-S66

KiSC issued 08, 2015 A

KX080-4(EU), WSM ELECTRICAL SYSTEM

[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

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

4-S67

KiSC issued 08, 2015 A

KX080-4(EU), WSM ELECTRICAL SYSTEM

[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-S68

KiSC issued 08, 2015 A

KX080-4(EU), 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

4-S69

KiSC issued 08, 2015 A

KX080-4(EU), 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-S70

KiSC issued 08, 2015 A

KX080-4(EU), 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-S71

KiSC issued 08, 2015 A

KX080-4(EU), 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-S72

KiSC issued 08, 2015 A

KX080-4(EU), 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

4-S73

KiSC issued 08, 2015 A

KX080-4(EU), WSM ELECTRICAL SYSTEM

(3) Overload warning 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.) Boom bottom

[Reason error screen displayed]

• Connector disconnected
• Break or short in harness
(1) Over load Sys Err (a) Warning lamp
(b) Info button
RY9212148ELS0161US0
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 unlock position and operate
the boom.
4. Check that the boom bottom pressure value changes.
Design Value Regular When cut off When shorted
Boom bottom
Current value 0V Not stable
pressure

(1) Boom Bottom Pres Alarm Press

Boom Rod
RY9212148ELS0162US0

[B] Inspecting each device visually and physically

1. Causes when a break in wiring
[Test Conditions]
1. Key switch : OFF
2. The boom pressure sensor connector CN765 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
boom pressure again in the tester mode.
(a) Boom Pressure Sensor
RY9212148ELS0102US0

4-S74

KiSC issued 08, 2015 A

KX080-4(EU), WSM ELECTRICAL SYSTEM
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
voltage of boom raise end point again in the tester mode.
RY9212148ELS0103US0

[C] Testing with a Circuit Tester

(a) Boom pressure sensor (b) Relay connector (front) (c) Relay connector (machine) (d) Main ECU connector
connector
RY9212148ELS0163US0
1. Voltage check
[Measurement Conditions]
1. Disconnect the boom pressure sensor connector.
2. Key switch: ON
3. Check the voltage based on the table below.
Meas
urem Connector Name (+ terminal side) Pin No. Connector Name (- terminal side) Pin No.
ent
(1) Boom pressure sensor <1> Boom pressure sensor <3>
(2) Boom pressure sensor <1> Body GND –

Regular: 5V
Irregular: Large discrepancy from 5V
RY9212148ELS0164US0

4-S75

KiSC issued 08, 2015 A

KX080-4(EU), 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.
Meas
urem Connector Name (+ terminal side) Pin No. Connector Name (- terminal side) Pin No.
ent
(1) Boom pressure sensor <1> Relay connector (front) <1>
(2) Boom pressure sensor <2> Relay connector (front) <2>
(3) Boom pressure sensor <3> Relay connector (front) <3>
(4) Relay connector (machine) <1> Main ECU <11>
(5) Relay connector (machine) <2> Main ECU <6>
(6) Relay connector (machine) <3> Main ECU <10>

Regular: Continuity
Irregular: No continuity
RY9212148ELS0165US0

[D] Testing the Equipment Itself

1. 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 Spec 22 kΩ
<3>

Regular: Within factory spec

Irregular: Outside factory spec.
RY9212148ELS0166US0
2. Settings after replacing device
1. Check that the overload alarm works.
RY9212148ELS0167US0

[E] Steps to Take after Completing Repairs

4-S76

KiSC issued 08, 2015 A

KX080-4(EU), 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-S77

KiSC issued 08, 2015 A

KX080-4(EU), 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-S78

KiSC issued 08, 2015 A

KX080-4(EU), 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

4-S79

KiSC issued 08, 2015 A

KX080-4(EU), 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-S80

KiSC issued 08, 2015 A

KX080-4(EU), 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-S81

KiSC issued 08, 2015 A

KX080-4(EU), 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

4-S82

KiSC issued 08, 2015 A

KX080-4(EU), 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-S83

KiSC issued 08, 2015 A

KX080-4(EU), WSM ELECTRICAL SYSTEM

[C] Testing with a Circuit Tester

Regular: 12V
Irregular: Large discrepancy from 12V
(a) Main ECU connector (b) AI console connector
RY9212148ELS0174US0

Regular: Continuity
Irregular: No continuity
RY9212148ELS0175US0

[D] Testing the Equipment Itself

[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-S87

KiSC issued 08, 2015 A

KX080-4(EU), 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

4-S88

KiSC issued 08, 2015 A

KX080-4(EU), 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-S89

KiSC issued 08, 2015 A

KX080-4(EU), WSM ELECTRICAL SYSTEM

(2) 5 V Short System Error

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-S90

KiSC issued 08, 2015 A

KX080-4(EU), 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-S91

KiSC issued 08, 2015 A

KX080-4(EU), WSM ELECTRICAL SYSTEM

[B] Inspecting each device visually and physically

a) If a CAN system (main) error
1. Checking fuses
1. Check if the 10A ECU (+B) fuse is blown.
RY9212148ELS0176US0

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-S92

KiSC issued 08, 2015 A

KX080-4(EU), 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-S93

KiSC issued 08, 2015 A

KX080-4(EU), 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
RY9212148ELS0181US0

4-S94

KiSC issued 08, 2015 A

KX080-4(EU), 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.
Meas
urem Connector Name (+ terminal side) Pin No. Connector Name (- terminal side) Pin No.
ent
(1) 10 A fuse – Main (signal) <16>
(2) Engine (signal) <16> Main ECU <59>
(3) Main ECU <60> Joint connector <2>
(4) Main ECU <79> Joint connector <3>
(5) Joint connector <5> CAN connector <1>
(6) Joint connector <8> CAN connector <2>
(7) Joint connector <1> Meter panel <6>
(8) Joint connector <4> Meter panel <5>

Regular: Continuity
Irregular: No continuity
RY9212148ELS0183US0

4-S95

KiSC issued 08, 2015 A

KX080-4(EU), 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

4-S96

KiSC issued 08, 2015 A

KX080-4(EU), 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
RY9212148ELS0131US0

4-S97

KiSC issued 08, 2015 A

KX080-4(EU), 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
RY9212148ELS0133US0

[C] Testing with a Circuit Tester

Switch side

(a) Main ECU connector (b) Right control lever (c) Left control lever connector
connector
RY9212148ELS0186US0

4-S98

KiSC issued 08, 2015 A

KX080-4(EU), 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
RY9212148ELS0189US0

4-S99

KiSC issued 08, 2015 A

KX080-4(EU), 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.
RY9212148ELS0191US0

4-S100

KiSC issued 08, 2015 A

KX080-4(EU), 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

RY9212148ELS0134US0

4-S101

KiSC issued 08, 2015 A

KX080-4(EU), WSM ELECTRICAL SYSTEM

[E] Steps to Take after Completing Repairs

4-S102

KiSC issued 08, 2015 A

KX080-4(EU), 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.
RY9212032ELS0001US0

4-S103

KiSC issued 08, 2015 A

KX080-4(EU), 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
RY9212148ELS0197US0

4-S104

KiSC issued 08, 2015 A

KX080-4(EU), 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
RY9212148ELS0200US0

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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
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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
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[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
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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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[E] Steps to Take after Completing Repairs

4-S107

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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(EU), 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(EU), 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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(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(EU), 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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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
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KX080-4(EU), 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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KX080-4(EU), 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
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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

[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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KiSC issued 08, 2015 A

KX080-4(EU), 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)
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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. FRONT WINDOW......................................................................................................................5-S52
[1] ADJUSTING THE CLOSING LOCK OF THE FRONT WINDOW (TOP) .............................5-S52

KiSC issued 08, 2015 A

[2] ADJUSTING THE OPEN LOCK OF THE FRONT WINDOW (TOP) ...................................5-S53

KiSC issued 08, 2015 A

KX080-4(EU), 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

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KiSC issued 08, 2015 A

KX080-4(EU), 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

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KiSC issued 08, 2015 A

KX080-4(EU), 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(EU), 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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KX080-4(EU), 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
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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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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

(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.

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 resistance 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. 33 Ω (actual reference value)

Irregular: Large discrepancy from 33 Ω
4. Apply the battery voltage to terminals 1 and 2 of the servo motor
and check whether it drives the servo motor.
5. Measure the resistance between A and B in the diagram at left
according to the table below.
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 6 kΩ)

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
RY9212001CAS0047US0
When refrigerant pressure is rising (OFF)
1. Start the engine and set it at 1,500 rpms. Turn the AC switch on
the control panel on, set the fan switch to HI and set the
temperature control lever to the max cool position.
2. Cover the front of the condenser with cardboard or the like and
raise the pressure on the high-pressure side of the AC cycle.
3. Once the pressure on the high-pressure side rises, the
high-pressure switch operates, turning the magnetic clutch of
the compressor off. When it does so, read the HI
(high-pressure) gauge of the manifold gauge and if it reads
higher than the pressure setting, replace the pressure switch
(8).
• Pressure setting on the high-pressure side of the switch:
Switches off at approximately 3.14 MPa (32 kgf/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
RY9212148CAS0029US0
Filling the Compressor with Oil
When replacing the compressor
• The amount of oil required by the new compressor is enclosed
within the AC cycle. A certain amount of compressor oil
circulates along with the gas in the AC system.
• When replacing the compressor, remove the excess oil from the
new compressor.
• Compressor oil (ND-OIL8) readily absorbs moisture, so seal it
immediately.
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)
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
RY9212148CAS0020US0

(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
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4. Remove the wiper motor harness, the cap and then the cover.
(1) Harness (3) Cover
(2) Cap
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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-S45

KiSC issued 08, 2015 A

KX080-4(EU), WSM CABIN

[5] REMOVING OTHER PANES OF GLASS

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

CAUTION
• 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(EU), 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(EU), 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(EU), 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(EU), 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(EU), 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(EU), WSM CABIN

9. 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-S52

KiSC issued 08, 2015 A

KX080-4(EU), 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-S53

KiSC issued 08, 2015 A

W/H33 CORD,BATTERY(-)
CORD,BATTERY(-)(MAIN_FRAME) BASE: 3 B BASE: 3 B
BASE: 60.0 B/Y
CORD,BATTERY(-)(BATTERY) W/H33
GND1 GND1 GND2 GND3 GND4
W/H30 CORD,BATTERY(1,+) W/H33 BODYEARTH(MAIN_FRAME)
SWITCH(BATTERY_DISCONNECT) BI: 100.0 f B + GND2
W/H31 CORD,BATTERY(2,+) BATTERY_ISOLATOR
BASE: 60.0 B/Y
GND1:POWER(MAIN)
W/H31
CRSD&BI: 100.0 f B G H BI: 100.0 f B
BATTERY_TERMINAL,BI
BATTERY W/H34 GND3 GND2:ECU,SENSOR(MAIN)
2 1 BI: 3.00 R
BATTERY(POWER),BI MAIN(POWER),BI -
BI: 8.00 R
BATTERY_ISOLATOR
BI: 8.00 R
GND3:POWER,SHIELD(ENGINE)
W/H09 1 1 W/H32 W/H32 SWING_FRAME GND4:ECU,SENSOR(ENGINE)
RD459-53931
W/H32 CORD,BATTERY(3,+) ENGINE
BATTERY(ECU,+B),BI MAIN(ECU,+B),BI 1
BI: 3 R BI: 3.00 R W/H34 CORD,BODY EARTH BODYEARTH(ENGINE)
W/H09 1 1 W/H30

SBF,MAIN1-2
/Y
SBF(ENGINE) 3 R
FS:
AC: 5 R/Y Composition Specification Code Notes
50 2 2 W/H00 RD829-53410 W/H(MAIN,CRS)
Plug-in_type W/H05 RD809-53333 W/H(FUELSENSOR)
BASE ALL-USE
SBF(MAIN) MAIN(POWER) ENGINE(POWER) W/H06 RD829-53390 W/H(BLOWERMOTOR)
BASE: 5 R BASE: 5 R BASE: 5 R AI Auto Idle
60 1 1 1 1
SWITCH,STARTER W/H09 RD829-53340 W/H(ENGINE,CRS)

START
OFF
ON
BASE: 3 R
Plug-in_type W/H09 W/H00
AT Anti-Theft W/H10 1J770-65091 W/H(GS_INT)
SBF(CRS) SBF-BOX KEY_SWITCH
W/H12 RD829-53510 W/H(FRONT,OA)

5 R
5 R
5 R
AUX2: AUX1: 5 R

HT: AC: 5 R
HT: AC: 5 R
5 R
3 R
BCN: 5 R
CRSD: 5.00 R BASE: 3 R/W R/W BI Battery Isolator
30 3 3 1
RD809-53543 W/H(FRONT,2P)
Bolt-in_type BASE: 3 B/W
No.Battery Isolator

BASE:
BASE:
BASE:

BASE:
BASE:
2
B/W
N_BI
W/H19 RD829-49370 W/H(MAIN,CAB)

3 R/W
3 R/W
3 R/W
3 R/W
BASE: 3 R R
SBF-BOX SBF(ALTERNATOR) SBF-BOX 3 AT&BI Anti-Theft & Battery Isolator
BASE: 8.00 R BI: 8.00 R W/H20 RD829-49360 W/H(WIPER)
2 2 100 4 4

BASE:
BASE:
BASE:
BASE:
Bolt-in_type AT&N_BI Anti-Theft & No.Battery Isolator W/H28 RD829-49590 W/H(WORKLIGHT)
SBF_BOX RD451-54311 W/H30 RD829-53910 CORD,BATTERY(1,+)
ES Engine Stop

3 W

CAB: 3 W

HT: AC: 3 W
W/H31 RD829-53960 CORD,BATTERY(2,+)
RELAY(40A,ISO) BCN Beacon
W/H32 RD829-53970 CORD,BATTERY(3,+)

BASE:
RELAY(POWER) RELAY(POWER)
BASE: 5 R 30 87 BASE: 3 W OA Overload Alarm W/H33 RD809-53232 ORD,BATTERY(-)
C
3 4
BASE: 0.50 L 86 85 BASE: 0.30 B
TRB Travel Alarm W/H34 RD819-53241 CORD,BODY EARTH
1 2
GND2
HT Heater
AC A/C

EP Eco Power Mode

ASSY_ALTERNATOR AUX1 Grip (L)
BASE: 8.00 R B AUX2 Grip (R)
B-1
ALTERNATOR(+B)
AT&AUX1 Anti-Theft & Grip (R)
FUSE(ALTERNATOR) FUSE(ALTERNATOR) FUSE(ALTERNATOR)
BASE: 3 R/W BASE: 1.25 f Y/R
10 CAB CAB (8+4)
MiniFuses
IC
RD451-54101 RELAY(STARTER) W/H00 W/H09 NB Normal Blade
RELAY(STARTER) W/H00 W/H09 ALTERNATOR(IG,L)

FUSE(STARTER) FUSE(STARTER) FUSE(STARTER) RELAY(STARTER)

NULL
W/H09 W/H00
BASE: 0.50 W/R
ENGINE(OPEN) 8 8 MAIN(OPEN)
BASE: 0.75 f W/R L
FS Fuel Supply-pump
4 A-2
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 R
10 3 5 ENGINE(OPEN) 5 5 MAIN(OPEN) ENGINE(OPEN) 4 4 MAIN(OPEN) A-1 CRSD CRS-DENSO
BASE: 0.50 R/B 86 85
MiniFuses 1 2
GREASE GREASE GREASE GREASE
Y/B

Y/B

GREASE GREASE
RD451-54101 CRSD&BI CRS-DENSO & Battery Isolator
CRSD: 0.50

BASE: 0.50

COMMON ALL-USE
MAIN(SIGNAL) ENGINE(SIGNAL) STARTER(S),D
CRSD: 0.50 Y/B CRSD: 0.50 Y/B CRSD: 3 B/W S
15 15 A-1
W/H09 W/H00
CRSD&BI: 100.0 f B
4-Cylinder
30_+B
B-1 PLUG,GLOW
STARTER(+B),D GLOW,D
ASSY_STARTER CRSD: 3 R/B
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
GND2
CRSD: 0.30 G/O BASE: 0.30 L/O

RELAY(ECU_MAINPOWER)
RELAY(ECU_MAINPOWER)
NULL JOINT-AIM 232C 232C
FUSE(ECU_MAIN(POWER)) FUSE(ECU_MAIN(POWER)) FUSE(ECU_MAIN(POWER)) RELAY(ECU_MAINPOWER) 4 water-proof BI: 0.85 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
SWITCH,LIMIT SOLENOID(LEVER_LOCK) BASE: 0.50 B/O Rxd
1
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 ANTENNA(ANTITHEFT)
SWITCH(PRESSURE,25.0K)

G/W
RD451-54101
AI_PRESSURE_SW AI_PRESSURE_SW AT&BI: 0.85 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 10mA 6

BASE: 0.50
ENGINE(SIGNAL) 3 3 MAIN(SIGNAL) 1 2 MAIN(SIGNAL) 7 7 ENGINE(SIGNAL) AT: 0.30 LED R
W/H00 W/H09 W/H09 W/H00 3 10mA
AT: 0.50 W/B
SWITCH(PRESSURE,25.0K) 5
+12V
10mA
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 10mA INOUT
1 2 MAIN(SIGNAL) 12 12 ENGINE(SIGNAL) AT: 0.30 G RX RF
W/H09 W/H00 4 10mA
AT: 0.30 B GND
2 10mA
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
BASE: 2 f B
AT: 0.30 W TxD(RF-UNIT)
MAIN-POWER BASE: 2 f Y/R
49
3 GND1
AT:

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
AI: 0.50 G/W
1kohm,0.4W AI_POT
8
AI: 0.30 R
AI-PRESSURE-SW
50
1 W/H00 W/H09 SOLENOID(AUX1-L)
7 W/H00 W/H09 SOLENOID(AUX1-L) SOLENOID(AUX1-L)
B/Y BASE: 0.30 R/W WORKLIGHT-SW AUX1-SOL(R) AUX1: 0.50 W
GND AI: 0.50 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 AI: 0.30 W
5
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 AI: 0.30 L/W 63 19 SOLENOID(AUX2-R) SOLENOID(AUX2-R)
AI_LED
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
150ohm,2W AI_SW
3
AI: 0.30 O BASE: 0.30 L/O EP-MODE-SW 42 W/H00 W/H09 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
1 AI: 0.30 O AI-CHANGE-SW EP-SOL EP: 0.50 G
W/H00
W/H00
W/H09
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/B EP: 0.50 G SW1 SW2 EP: 0.50 G/B
TRAVEL-SPEED-SW EP-SOL-FEEDBACK
1 2
3 57 21
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)
CRSD: 0.30 G/O DPF-INHIBIT-SW
TRAVEL-SPEED-SOL
81 4 4 SOLENOID(TRAVEL_SPEED) SOLENOID(TRAVEL_SPEED)
70 BASE: 0.50 Y BASE: 0.50 B
W/H00 W/H09 (+) (-)
AUX2: AUX1: 0.30 Y/R AUX1-HOLD-SW MULITIPURPOSE-SOL 1 2
69 17 GND3
AUX2: AUX1: 0.30 L AUX2-HOLD-SW
ANGLE(R)-SOL
72
18
ANGLE(R)-SW
71 ANGLE(L)-SOL

ANGLE(L)-SW 20
68 ANTITHEFT-HORN-RELAY AT: 0.50 L/R
BASE: 0.50 G/W LEVER-LOCK-SW 13
67
SENSOR(PRESSURE,5MPA) LEVER-LOCK-SOL BASE: 0.50 G
GND BASE: 0.50 B/Y 62
1 CHARGE-INPUT
SENSOR Vout BASE: 0.50 L/B
TRAVEL-ALARM-BUZZER BASE: 0.50 B/Y
2
5MPA Vcc(+5V) BASE: 0.50 R/B OIL-SW 14
3 BUZZER-OUT BASE: 0.50 Y/B
TRAVEL_ALARM(FRONT,+)
TRAVEL_PRESSURE_SENSOR FUEL-SW 40
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
W/H12 W/H00 CRSD: 0.30 G/B
BOOM_BOTTOM_PRESSURE_SENSOR W/H12 W/H00 53 DPF-INHIBIT-INDICATOR

SENSOR(PRESSURE,35MPA) W/H12 W/H00 WATER-TEMP-SENSOR

48
Vcc(+5V) OA: 0.75 f R OA: 0.75 f R OA: 0.50 R/B ANTITHEFT-FLASHER-LED AT: 0.30 R ELECTRICAL_BUZZER
1 TO_MAIN(BOOM_PRESSURE) 1 1 TO_FRONT(BOOM_PRESSURE) JOINT-BUZ BI: 0.85 Y/R AV0.5R(+)
SENSOR Vout OA: 0.75 f G OA: 0.75 f G OA: 0.50 G
OIL-TEMP-SENSOR 37 water-proof 1 BUZZER,BACK
2 TO_MAIN(BOOM_PRESSURE) 2 2 TO_FRONT(BOOM_PRESSURE) BASE: 0.50 Y/B AV0.5B(-)
35MPA GND OA: 0.75 f Y OA: 0.75 f Y OA: 0.50 B/Y BOOM-ROD-PRESS-SENSOR
MULTI-PURPOSE-LED AI: 0.30 W
2
38
3 TO_MAIN(BOOM_PRESSURE) 3 3 TO_FRONT(BOOM_PRESSURE)
OA: 0.50 G 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

76 9
BASE: 0.50 W/R CHARGE_SW
BI: 0.85 Y/R +B(DIRECT)
10
59
AUX2: AUX1: 0.30

BASE: 0.50 B/W WAKEUP_OUT

BASE: 2 f B GND(POWER) 11
2 REMOTE_WAKE_UP
GND2 12

13
BASE: 0.50 B GND
AI: 0.50 R/B 14
GND2
OA: 0.50 R/B
BI: 0.85 Y/R
W/H00 W/H09
CRSD: 0.50 L CRSD: 0.75 f L
AUX2: AUX1: 0.30 R/B Y/R ENGINE(SOLENOID) 3 3 MAIN(SOLENOID)
AT&BI: 0.85

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
R/B

R/B
B/R

CRSD: 0.75 f L
R/B
R/B

OA: 0.50 B/Y 1

CRSD: 0.30
CRSD: 0.30
BASE: 0.30
BASE: 0.30
BASE: 0.50

BASE: 0.50
BASE: 0.50
0.50
0.50

AUX2: AUX1: 0.30 B/Y SENSOR,FUEL

AI:
AI:

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
0.30
CRSD: 0.50

ENGINE(SIGNAL) 8 8 MAIN(SIGNAL) 2 2 ENGINE(FUEL_SENSOR)

FUELSENSOR
GND2 W/H00 W/H09 W/H09 W/H05
BCN:

CAN CAN
W/H09 W/H,ENGINE 5 5
BASE: 0.50 Y CAN(H)
1
BASE: 0.50 G CAN(L)
8 8
2

FUSE(ECU-MAIN(+B)),BI FUSE(ECU-MAIN(+B)),BI FUSE(ECU-MAIN(+B)),BI ENGINE(SIGNAL)

VALVE,ASSY(PL,R,AX)
6 6
BI: 3 R BI: 0.85 Y/R BI: 0.85 Y/R 7 7
10 MAIN(SIGNAL) 16 16 JS_CONTROL(R) JS_CONTROL(R)
AUX2: AUX1: 0.30 R/B +5V(R) GND(B) AUX2: AUX1: 0.30 B/Y
MiniFuses W/H09 W/H00
R

1 2 1 1
7154-5845-30 OUTPUT(W) AUX2: AUX1: 0.30 W
0.50

8 3 4 4
AUX2: AUX1: 0.30 L Vcc_SW1(G) HORN_SW1(L) AUX2: AT&A
UX1: 0.30
7 4 L/W
BI:

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
JS_CONTROL(L) JS_CONTROL(L) to_J/C(CAN,MAIN)
MiniFuses AUX2: AUX1: 0.30 R/B +5V(R) GND(B) AUX2: AUX1: 0.30 B/Y
J/C(CAN,MAIN)
RELAY(HORN)
AUX2: AUX1: 0.30

RD451-54101 1 2
OUTPUT(W) AUX2: AUX1: 0.30 W RELAY(HORN)
8 3 NULL
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
AT: 0.50 L/R BASE: 0.50 B
5 6 DIODE(7321-9822) 1
86 85
2
FUSE(HORN-SW) FUSE(HORN-SW) FUSE(HORN-SW) DIODE(ANTITHEFT_HORN_PROTECT) D_7321-9822 DIODE(ANTITHEFT_HORN_PROTECT) L/R GND2
0
AUX2: AUX1: 5 R AUX2: AUX1: 0.30 L AUX2: AT&AUX1: 0.30 L/W A C AT: 0.50 L/R 0.5
5 2 400V 1 AT: BASE: 0.50 L HORN(+) ASSY_HORN
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

GND2
0.30 R/W

RD451-54101
0.50

RELAY(LIGHT)
OFF ON
BASE:

RELAY(LIGHT)
SWITCH(WORKLIGHT) LIGHT,WORK
BASE:

NULL
FUSE(RELAY) FUSE(RELAY) FUSE(RELAY) WORKLIGHT_SWITCH
RELAY(LIGHT)
4 FUSE(FRONT-WORKLIGHT) FUSE(FRONT-WORKLIGHT) FUSE(FRONT-WORKLIGHT) to_WORKLIGHT to_MAIN(WORKLIGHT) to_MAIN(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 9 1 2 MiniFuses FRONT_WORKLIGHT(+) FRONT_WORKLIGHT(-)
L

RD451-54101 ON BASE: 0.30 R GND2 RD451-54101

BCN: 0.50

6 W/H12 W/H(FRONT)
R/W

8 FUSE(CAB-WORKLIGHT) FUSE(CAB-WORKLIGHT) FUSE(CAB-WORKLIGHT)

BASE: 3 Y BASE: 2.00 Y
20
0.30

2 MiniFuses
HT: AC:

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 CAB RADIO
BCN: 0.30 R/B
3 5
BCN: 0.30 R/Y
W/H19 W/H28 LIGHT,WORK W/H28 W/H19
BASE: 0.50 O
R
R

86 85
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
0.85
0.85

BASE: 0.85 R 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)
BASE:
BASE:

RADIO(GND) C-1
OFF ON CAB_WORKLIGHT,B(+) CAB_WORKLIGHT,B(-) BASE: 0.50 W/B BASE: 1.25 B
SWITCH(BEACON) BASE: 0.85 R CA_R(+) CB_B(-) BASE: 0.85 B
(-)
1 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
7
Vcc
BEACON_SWITCH LAMP(BEACON) 2 SPEAKER(R-)
BASE: 0.50 W/B
E-1
SPEAKER(R-)
W/H00 W/H19 BEACON(+) BEACON(-)
OFF
9 BCN: 1.25 BR BASE: 1.25 BR BASE: 1.25 BR M5 M5 BASE: 0.85 B
SPEAKER,ASSY SPEAKER(R-)
BASE: 0.50 Y
F-1
ON BCN: 0.50 B
CAB
8 8 to_MAIN(CAB) 1 M 2
SPEAKER(L)
SPEAKER(L+)
SPEAKER(L+)
G-1 CAB_POWER_SOURCE
O

6 (-) BASE: 0.50 Y/B BASE: 0.50 Y/B SPEAKER(L-)

GND2 ASSY_LIGHT,ROOM SPEAKER(L-)
BR

1 H-1 GND(RADIO)
8 BASE: 0.50 Y BASE: 1.25 B
BASE: 0.50

(+) 1
W/H00 W/H19 ROOM_LIGHT ROOM_LIGHT 2
BASE: 1.25

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
BCN: 0.50 L BCN: 0.30 B BASE: 0.85 R
O

LED(+) LED(GND) 3 CAB_WORK_LIGHT

4 10 4
GND2
BASE: 0.50

BASE: 3 B GND(CAB)
1 5 5
FUSE(ROOM_LIGHT) FUSE(ROOM_LIGHT) FUSE(ROOM_LIGHT)
B
B

R BASE: 0.50 O 6
0.50 5 BASE: 1.25 Y
BASE: 0.50

FS: RADIO(AC)
BI:
0.85

0.85

MiniFuses 0.50
O W/H00 W/H19 BASE: 1.25 BR
7
BEACON
W/H00 W/H19 8
FUSE(RADIO(AC))
BASE:

BASE:

FUSE(RADIO(AC)) FUSE(RADIO(AC)) W/H00 BASE: 1.25 Y BASE: 3 B

W/H19 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: 214 AVS 3 B BASE: 3 B
MiniFuses 5 5 to_MAIN(CAB)
CAB
GND2 BASE: 0.85 B BASE: 1.25 B
1 1 to_MAIN(CAB)
B

BASE: 0.50 B
FUSE(WIPER/WASHER) FUSE(WIPER/WASHER) FUSE(WIPER/WASHER) GND(RADIO)
CAB BASE: 0.85 G
2 2 to_CAB(WIPER) 1
(+B)
MOTOR_WIPER
to_WIPER
BASE: 0.50

CAB: 3 W CAB: 1.25 G/W CAB: 1.25 G/W BASE: 0.85 G BASE: 0.50 W (S)
15 CAB(WIPER) 3 3 to_MAIN(CAB_WIPER) 4 WIPER,F
CAB: 1.25 R/W BASE: 0.85 W BASE: 0.85 W BASE: 0.50 R 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

CAB: 1.25 L/W BASE: 0.85 R BASE: 0.85 R

WIPER,F
CAB(WIPER) 2 2 to_MAIN(CAB_WIPER) 3 3 to_CAB(WIPER)
TANK(WASHER) to_WIPER
BASE: 1.25 B
WIPER_SWITCH WASHER_TANK WASHER_TANK BASE: 0.85 B BASE: 0.50 G
CAB: 1.25 W CAB: 1.25 W BASE: 0.50 W BASE: 0.50 W (+) (-) BASE: 0.50 B 1 1 to_CAB(WIPER)
WASHER(B)
3 CAB(WIPER) 4 4 to_MAIN(CAB_WIPER) 2 M 1
to_WIPER
W/H19 W/H20 GND(WIPER,F)
G/W
W/H19 W/H,CAB
Vcc_wash(Y/B) CAB: 1.25 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
30mA 6
S(G/W) CAB: 1.25 L/W

SERVO_MOTOR SERVO_MOTOR
5
Null
4 ASSY_SWITCH,AIR-CON HT: AC: 0.50 W MAXCOOL
M
1
HT: AC: 0.50 Y MAXHOT
2
CONSTANT OUT HT: AC: 0.50 BR/W Pt
A/C_HEATER_CONTROLER IN A/C_HEATER_CONTROLER
VOLTAGE A/C_SW 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
HT: AC: 0.50 W/R null
MiniFuses POT_GND
A/C_FAN_SWITCH
HT: AC: 0.50 W/R

7 CPU 3 6
HT: AC: 0.50 W/R Vz
FUSE(BLOWER) FUSE(BLOWER) FUSE(BLOWER)
RELAY(20A,MICRO-ISO) 14 12 7
HT: AC: 5 R HT: AC: 3 R AC: 0.50 G/B HT: AC: 0.50 Y OFF Lo Mi Hi
30 RELAY(BLOWER)
THERMO_SW
HOT_OUT SERVO_OUT2:HOT
11 6 A/C_FAN_SWITCH
Null HT: AC: 0.50 L HOT_IN COOL_IN HT: AC: 0.50 W
MiniFuses RELAY(BLOWER) 4 10
FAN
MOTOR
COOL_OUT SERVO_OUT1:COOL
5 HT: AC: 3 B HT: A com
HT: AC: 3 R 30 87 HT: AC: 3 L/W DRIVE ILL(-) HT: AC: 0.50 B C: 0 3
FUSE(COMPRESSOR) FUSE(COMPRESSOR) FUSE(COMPRESSOR) 3 5 13 CIRCUIT 0.5A 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
.50 L 6
10 1 2 15 4 HT: AC: 0.50 L LO
COMPRESSOR_CLUTCH(A/C) RD451-93901 GND1 W/H06 W/H,BLOWERMOTOR,AC
Y

2
MiniFuses 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)
AC: 0.50

ENGINE(SIGNAL) 1 1 MAIN(SIGNAL) 1 1
W/H00 W/H09 HT: AC: 3 L/B HI
RELAY(COMPRESSOR)
DIODE(6098-0061) 4
AC: 0.85
AC: 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 C A AC: 0.50 B GND1
3 5 1 2 HT: AC: 3 B
AC: 0.85 W/R 86 85 AC: 0.50 G/R GND1
1 2 GND1
DUAL_PRESSURE_SWITCH
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
THERMOSTAT
RELAY(CONDENSOR_FAN) 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 AC: 0.50 G/B
Plug-in_type ENGINE(SIGNAL) 5 5 MAIN(SIGNAL)
AC: 0.85 W/R
1
86 85
2
AC: 0.50 G/R
1
GND Null
5 RESISTOR_BLOWER
361897-0713 W/H00 W/H09 CONDENSOR_FAN THERMOSTAT HT: AC: 3 L/Y M1
CONDENSOR_FAN CONDENSOR_FAN BASE: 3 L/B BASE: 3 L/B
1
HI
221 ± 10
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
KIT_PUMP,FUEL_SUPPLY
FUEL_SUPPLY_PUMP FUEL_SUPPLY_PUMP
FUSE(HEATER,FUELFILTER) FUSE(HEATER,FUELFILTER) FUSE(HEATER,FUELFILTER) HEATER(FUEL_FILTER)
W/H00 W/H09 HEATER(FUEL_FILTER) HEATER(FUEL_FILTER) FS: 1.25 R/W AVX_2.0R(+) AVX_2.0B(-) FS: 1.25 B
BASE: 3 W BASE: 1.25 W BASE: 1.25 f W W W/B BASE: 1.25 f B 1 PTC
M 2
20 ENGINE(OPEN) 1 1 MAIN(OPEN) 1 2 GND3
GND3 RELAY(PTO)
MiniFuses GREASE GREASE FUSE(FUEL_SUPPLY) FUSE(FUEL_SUPPLY) FUSE(FUEL_SUPPLY)
7154-5845-30 RELAY(FUEL_SUPPLY_START) RELAY(FUEL_SUPPLY_START) FS: 3 R/W FS: 0.50 G
FS: 3 B NC null 5
4 6
SWITCH,DOWN (BLACK) GND3 FS: 3 R NO COM FS: 3 R/W MiniFuses
FUEL_SUPPLY_START_SW FUEL_SUPPLY_START_SW 5 3 7154-5845-30
FS: 0.50 O FS: 0.50 O R G FS: 0.50 L FS: 0.50 L COIL COIL FS: 0.50 L/R
ENGINE(SOLENOID) 11 11 MAIN(SOLENOID) 1 2 2 1
W/H00 W/H09 ASSY,SENSOR_FUEL_SUPPLY
L

RELAY,NC(FUEL_SUPPLY_STOP)
RELAY,NC(FUEL_SUPPLY_STOP)
FS: 0.50

FS: 0.50

FS:
0.50 RELAY,NC(FUEL_SUPPLY_STOP) FUEL_LEVEL_SENSOR FUEL_LEVEL_SENSOR
G
FS: 0.50 G NC NC FS: 0.50 Y FS: 0.50 Y P B FS: 0.50 L
1 3 2 1
FS: 3 R COIL COIL FS: 0.50 W FUEL_SUPPLY_STOP_SW SWITCH(PUSH_BUTTON) FUEL_SUPPLY_STOP_SW
2 4 R G FS: 0.50 B
1 RED 2
GND3

FUSE(FUEL_SUPPLY_PUMP) FUSE(FUEL_SUPPLY_PUMP) FUSE(FUEL_SUPPLY_PUMP) 4MIN._TIMER

FS: 3 R/Y
30
FS: 3 R DIODE(7321-9834-30) FS: 0.50 LG POWER_SOURCE
ECU(TIMMER,4MIN)
3
DIODE(FUEL_SUPPLY) D_7321-9834-30 FS: 0.50 B
MiniFuses FS: 0.50 L A DIODE(FUEL_SUPPLY)
POWER_SOURCE(GND)
4 4MIN._TIMER
7154-5845-30 1 C FS: 0.50 LG GND3 RELAY_OUT1 FS: 0.50 L/R
FS: 0.50 G A 400V 2 5
3 TEST_IN1 TEST_OUT2
2 6
RELAY(CRS_MAIN)
RELAY(CRS_MAIN) TEST_IN2
JOINT-CRS_RELAY1,D NULL 1
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

REGISTER(120ohm) REGISTER(120ohm) REGISTER(120ohm) CRSD: 0.50 G 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
R

CRSD: 0.50 R/B ENGINE-ECU(SS2intT4) CRANKSHAFT_SENSOR(NE),D SENSOR(NE)

CRSD: 0.75

S CRANKSHAFT_SENSOR(NE),D
CRSD: 0.50

SERVICE_TOOL 2 2 SERVICE_TOOL(CAP) CRSD: 0.50 B

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 +BP
B-5 A-43 SENSOR(G)
CAMSHAFT_SENSOR(G) CAMSHAFT_SENSOR(G)
B-6
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 S6 CRSD: 0.75 f B BASE: 0.5 f B S7
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
MicroComputer

1
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
SUCTION_CONTROL_VALVE
- CRSD: 0.5 f GR CRS-ECU(58pin)
CRSD: 0.75 f G
+
1
CRSD: 0.5 f L
EGR_Lft_SEN_Vcc
A-1
SCV
SUPPLY
2 CRS-ECU(96pin) EGR_Lft_SEN_GND VehicleSpeed CRSD: 0.75 f B/R +B CONTROL
VC CRSD: 0.5 f W/R A-2
AIR 3 EGR_lIFT_SEN
FUEL_TEMP_SENSOR VALVE
FLOW GND CRSD: 0.5 f W/B
4 CRSD: 0.75 f L CRSD: 0.75 f G
SENSOR CRSD: 0.50 R
EGR_Motor(-) PressDiffSensor_SIG
POWER 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 WATER_TEMP_SENSOR
THROTTLE_VALVE_ASSY(INTAKE) CRSD: 0.5 f W/B
A-30
MAF_GND SCV(+) CRSD: 0.75 f B/R 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
RAIL_PRESSURE_SENSOR
GND CRSD: 0.75 f L/B FuelTemp_SIG CRSD: 0.75 f G
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
CRS-ECU(96pin) CoolantTemp_GND CRSD: 0.75 f L 3
6
CRSD: 0.75 f L IntakeThrottleSensor_SIG
A-15 SENSOR_BOOST
SENSOR_BOOST
B-29
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 IntakeThrottleSensor_Vcc CRSD: 0.75 f W/R
CRS-ECU(58pin) B-9 2
Vout
PRESSURE
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)
CRS-ECU(96pin) FilterPlugged_SW
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
S CRSD: 0.50 B JOINT-INJ_021,D
A-3 A-38
Inlet_DOC_Temp_GND CRSD: 0.75 f L/B
water-proof
INJECTOR_2 INJECTOR_2 2 water-proof A-14
CRSD: 2.0 f B 2 1 CRSD: 2.0 f W CRSD: 1.25 f Y/B INJ2_DRV_TWV2 Outlet_DOC_Temp 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
A-12
Outlet_DPF_Temp CRSD: 0.75 f R/B
1 2
INJECTOR_3 INJECTOR_3 3 water-proof A-51 A-62
CRSD: 2.0 f B 2 1 CRSD: 2.0 f W 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
S CRSD: 0.50 B JOINT-INJ_041,D CRSD: 2 f B
B-3
CRSD: 2 f B
1 2
water-proof 4
POWER_GND SIGNAL_GND
INJECTOR_4 INJECTOR_4 water-proof B-4 B-1
CRSD: 2.0 f B 2 1 CRSD: 2.0 f W GND4 CRSD: 0.85 B CASE_GND SIGNAL_GND 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
GND4

Electrical Circuit Diagram (KX080-4 EU)

J/C-SLD-GND
ELECTRICAL_ ENGINE FUEL_SUPPLY FUSE FUSE(HEATER,
4MIN._TIMER ALTERNATOR BATTERY_ISOLATOR CAB(CAB_ CAB(WIPER) CAMSHAFT_SENSOR(G) DOC_INLET_TEMP_SENSOR BUZZER (SOLENOID) _PUMP (COMPRESSOR) FUELFILTER)
(IG,L) WORKLIGHT,
FL(+))
3 2 1 1 2 1 3 2 1 2 1 2 1
1 1 1 2 3 4 2 1 2 1
6 5 4 M8 4 3
2 1 2
C_WF03_6189-1130_1 C_WF02_7283-7026-30_1 5 6 7 8 C_OF02_M
C_WF02_D
iniFuses C_OF02_M
C_WF06_FW-C-6F_1 C_OF04_7123 9 10 11 12 T06-2S-C
_1 iniFuses
C_OF02_71 C_LAF01_M8_1 -6040_1 C_OF02_7123 E05_1
23-2820_1 -2820_1 _1
CAN DOC_OUTLET_TEMP_SENSOR
C_CAM01 C_WM12_7222
232C _1 -7923-40_1
to_MAIN(CAB FUSE
ANTITHEFT_ BATTERY_TERMINAL,BI _WIPER) 2 1 2 1 FUEL_SUPPLY_ FUSE
ANTENNA START_SW (HORN-MAIN)
2 1 ELECTRICAL_ (CONDENSOR
to_CAB_ C_WF02_7123-8520-40_1 C_WF02_7283-7028-10_1 OUTLET MAIN(SOLENOID) _FAN)
4 3 1 WORKLIGHT, 1 2 2 1
1
1 2 3 M8 FL(+) 1 2
3 4 2 2 1
C_WF04_7123-7740-40_1 4 5 6 COMPRESSOR_CLUTCH(A/C) DPF_DIFF_PRESSURE_SENSOR 4 3 2 1 C_OF02_M
iniFuses
1 C_OM04_7122 8 7 6 5
C_WM02_6 C_OF02_P _1
C_OF02_7123 187-2802 lug-in_t
A/C_FAN_SWITCH C_WM06_61 C_LAF01_M8_1 -6040_1 1 3 2 1 _1
89-6171_1
-8322_1 12 11 10 9 ype_1
FUSE(HORN-
C_WF01_FW-C-1F_1 C_WF03_1813271-1_1
BEACON(+) C_CBF01 C_WF12_7123 FUEL_SUPPLY_ FUSE(ECU- SW)
CAB_POWER_
BATTERY _1 -7923-40_1
3 2 1 SOURCE ENGINE STOP_SW MAIN(+B)),BI
(ECU,+B),BI
1 CONDENSOR_FAN DPF_OUTLET_TEMP_SENSOR (FUEL_SENSOR) 2 1
6 5 4
M3 CAB(CAB_
4 3 2 1
1 1 2 ENGINE(SYGNAL) 2 1 C_OF02_M
WORKLIGHT, 8 7 6 5 2 1 2 1 1 2 iniFuses
C_OF06_7123-2865-30_1 FL(-)) _1
C_WM02_7222 C_OF02_M
C_OM01_71
22-2810_1
C_LEF01_M3_1 C_OF08_7123 C_WF02_DT06-2S-CE05_1 C_WF02_7283-7023_1 -1424-40_1 1 2 3 4 C_WM02_6 iniFuses
-6083-30_1 187-2801 _1
1 5 6 7 8 _1

BEACON_SWITCH CRANKSHAFT_SENSOR(NE),D 9 10 11 12 FUSE(LEVER_

MAIN(ECU,+B) DUAL_PRESSURE_SWITCH FUELSENSOR
A/C_HEATER_CONTROLER CAB_WORKLIGHT FUEL_TEMP_ FUSE(ECU- LOCK)
,BI ,B(+) 13 14 15 16
SENSOR MAIN(AC))
4 3 2 1 C_CBF01
_1
3 2 1 2 1 2 1 2 1
1 10 9 8 7 6 5 1 C_WM16_7222
C_WF03_7283-8852-30_1 C_WF02_6189-0094_1 C_WF02_7123
-7564-40_1 2 1 2 1
1 2 3 4 5 6 7 8 -1424-40_1
C_OF02_M
C_OF01_71 C_OF10_7123-8307 to_CAB_ iniFuses
9 10 11 12 13 14 15 16 23-2810_1 _1 WORKLIGHT, C_WF02_1 C_OF02_M _1
C_CBF01_1 CRS-ECU(58pin) E/F_CHANGE_SWITCH 78392-6_ iniFuses
FL(-) _1
1
MAIN(SYGNAL)
BATTERY ENGINE(OPEN) FUSE(METER
C_OF16_MX34016SF1_1 BLOWER_MOTOR 1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 4 3 2 1
(POWER),BI 1 CAB_WORKLIGHT, (+B))
B(-) 20 21 22 23 24 25 26 27 28 29 30 31 32 10 9 8 7 6 5 FUSE(A/C_ FUSE(ECU_
2 1 1 2 3 4 4 3 2 1 CONTROLLER) MAIN(POWER))
3 4 2 1
1 5 6 7 8 8 7 6 5
1 C_OF10_7123-8307_1
C_OF02_6098-0325 C_CAM01 33 34 35 36 37 38 39 40 41 42 43 44 45
_1 _1
12 11 10 9 2 1 2 1 C_OF02_M
C_OM01_71 iniFuses
22-4113-3 5 6 46 47 48 49 50 51 52 53 54 55 56 57 58 C_OM08_7122
16 15 14 13 _1
-6080_1
0_1 ECU(MAIN) C_OF02_M C_OF02_M
AIR_FLOW_SENSOR
C_CAM01_1 iniFuses iniFuses
BOOM_BOTTOM_ CAB(CAB_ C_WF58_9-1452415-9_1 C_WF16_7123 _1
_1 FUSE(RADIO
RESSURE_SENSOR WORKLIGHT, -7564-40_1
5 4 3 2 1 MAIN(OPEN) (AC))
MAIN(POWER), FR(+))
BI CAB_WORKLIGHT, 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 5 4 FUSE
3 2 1 CRS-ECU(96pin)
FL(+) 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 (ELECTRICAL_
C_WF05_6189-1046_1 4 3 2 1 2 1
1 FRONT_ FUSE OUTLET)
1 1 3 8 7 6 5 (ALTERNATOR)
C_WF03_173091-2_
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 WORKLIGHT(+)
1 C_OF02_M
AI_CONSOLE 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 2 1
C_OF01_71 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 iniFuses
C_OF08_7123
23-4113-3 25 26 27 28 29 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 2 1 -6080_1 1
2 1 _1
0_1 C_CAM01
4 3 2 1 BOOM_RAISE_SW _1 C_OF02_M
C_CBF01_1 49 50 51 52 53 iniFuses
C_OF02_M
8 7 6 5 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 iniFuses _1 FUSE(RELAY)
BATTERY_ 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_WF81_1473244-1_1 ENGINE(POWER) _1
1 to_CAB_
ISOLATOR CAB_WORKLIGHT, C_CBF01_1
C_WF08_FW-C-8F_1
2 WORKLIGHT, FL(-) 2 1
FR(+) FUSE(FRONT-
1 C_WF96_9-1452423-9_1 1 FRONT_ FUSE(BEACON) WORKLIGHT)
AI_PRESSURE_SW
C_WF02_6189-0156 1 WORKLIGHT(-) C_OF02_M
M8 _1 2 iniFuses
1
DIODE(COMPRESSOR) EGR_VALVE 2 1 2 1 _1
1 C_OM02_7122 1
C_LAF01_M CAB -4123-30_1 C_OF02_M C_OF02_M
2 8_1
C_CAM01_1
2 1 4 3 2 1 iniFuses iniFuses FUSE(ROOM_
C_CBF01 _1 _1 LIGHT)
C_WF02_6189-0156_1 4 3 2 1 _1
C_WF04_6195-0030_1 MAIN(POWER)
CAB_WORKLIGHT, C_OF02_6098-0017_1 C_CAM01_1
8 7 6 5 FR(+) 2 1
FUSE(BLOWER) FUSE(FUEL_
CAB(CAB_ PUMP)
ALTERNATOR(+B) C_OF08_7123-6083 WORKLIGHT,
1 FUEL_LEVEL_ C_OF02_M
-30_1 1 SENSOR
FR(-)) 2 iniFuses
1 2 1 2 1 _1

C_OF02_7123
M6 to_MAIN(CAB) 1 -4123-30_1 2 1 C_OF02_M C_OF02_M
C_CBF01_1 iniFuses iniFuses
_1 _1 FUSE
C_WF02_6180
(STARTER)
C_LAF01_M6_1 1 2 3 4 -2452_1
CAB_WORKLIGHT,
5 6 7 8 C_CBF01
FUSE(FUEL_ 2 1
_1 FR(-)
FUEL_PUMP FUSE(CAB- SUPPLY)
C_OM08_7122-6083 1 WORKLIGHT) C_OF02_M
-30_1 iniFuses
to_CAB_
WORKLIGHT, 1 2 1 _1

FR(-) 2 2 1
C_OF02_M
C_CAM01_1 iniFuses FUSE(WIPER/
C_OF02_7123 C_OF02_M _1 WASHER)
1 -2820_1 iniFuses
_1

FUSE(FUEL_ 2 1
SUPPLY_PUMP)
C_CAM01
_1 C_OF02_M
iniFuses
2 1 _1

C_OF02_M
iniFuses
_1

CONNECTOR CHART 1 (KX080-4 EU)

GLOW,D GND4 INJECTOR_4 RADIO(+B) RELAY RELAY,NC(FUEL_ SERVICE_TOOL SOLENOID STARTER(+B),D TO_FRONT WATER_TEMP_SENSOR to_J/C(CAN,EGR,SERVICE) to_MAIN
(CONDENSOR_ SUPPLY_STOP) (LEVER_ (BOOM_ (WORKLIGHT)
FAN) LOCK) PRESSURE)
1 1 2 1 1
1 1 2 1 2 1 6 5 4 3 2 1
M4 M8 2 3 4 3 2 1 M10 3 2 1
5 4 3 1
C_WF02_178392-6_
C_WF04_174257-2_1 C_WF06_7283-8850-
C_WF02_6189-0611_1
1 4 2 C_WF02_ C_WF03_71 1
30_1 2
C_LEF01 C_LAF01 C_CBF01_ C_OF04_7123-28 7283-20 C_BAF01_M10_1 23-7434-4
_M4_1 _7009-1 1 40-90_1 90-30_1 0_1
836_1 C_OF05_M C_OM
-ISO_1 WIPER,F 02_7
INLET_AIR_TEMP_SENSOR TO_MAIN 122-
GND SOLENOID STARTER(S),D
(CABFRAME) RADIO(AC) RESISTOR_BLOWER SERVICE_TOOL(CAP) (BOOM_ J/C(CAN,EGR,SERVICE) 2820
(TRAVEL_ 2 1 _1
2 1 RELAY(CRS_ PRESSURE)
SPEED)
MAIN) 1 4 3
1 1 1 2 3 4 5 6
1 2
HEATER C_WF02_7283-7027-40 2 1 1 2 3
M8 (FUEL_FILTER) _1 3 3 4 2 1 C_OF01_172320-1_ C_OF04_6090-1011 to_
4 3 1 _1 WORKLIGHT
5 C_WM06_7182-9630-
C_WF02_ C_WM03_72 30_1
C_CBF01_ 1 4 2 C_OF04_6098-05 C_WM04_174259-2_1 22-7434-4
C_LAF01 INTAKE_THROTTLE_MOTOR 7283-20
1 14_1 0_1
_M8_1 2 1 90-30_1 STOP_SWITCH WIPER_SWITCH
1
C_OF05_M to_J/C(CAN,MAIN)
-ISO_1 TRAVEL_ 2
C_WF02_ 6 5 4 3 2 1 3 2 1
GND(RADIO) 6-17614 RADIO(GND)
SERVO_MOTOR SPEAKER(L) 1 2 ALARM
6-6_1 ROOM_LIGHT (FRONT,+) 6 5 4 4 3 2 1 C_OF
C_WF06_7283-1968-30 02_7
C_WM02_6187-2801 8 7 6 5
_1 1 _1
123-
1 3 2 1 7 6 5 4 3 2 1 1 1
C_OF06_7123-2860 2820
HORN(+) RELAY(ECU_ _1 _1
C_WF08_7283-1081-
M8 MAINPOWER) 2 10_1
C_OF03_6130-23
1 JS_CONTROL(L)
30_1
C_CAM01_ C_OF07_IL-AG5-7S-S3 C_OF02_ SUCTION_CONTROL_ WORKLIGHT_SWITCH
1
3 C1_1 C_CBF01_1
7123-28 VALVE
C_LAF01 J/C(CAN,MAIN)
_M8_1 5 20_1
4 3 2 1 SBF,MAIN1-2 2 1
1 4 2 4 3 2 1
C_OF01_ RADIOFRAME TRAVEL_ 1 2 3 4
7123-20 8 7 6 5 (GND) ALARM
10 9 8 7 6 5
GND(RADIO, 10_1 SPEAKER(L+) C_WF02_6189-0039
CAB)
C_OF05_M 2 1 SOLENOID(AUX1-L) _1 (FRONT,GND)
C_WF08_6195-0051_1 -ISO_1 C_OF10_7123-8307
5 6 7 8
1 _1
C_OF02_7323-32 1
1 HORN(-) 1
RELAY(FUEL_
20_1 2 1 C_WM08_7382-1481-
10_1
M5 SUPPLY_ SWITCH(DPF,INHIBIT) to_CAB(WIPER)
1 START) C_WF02_174352-2_1
C_CAM01_
1 SBF-BOX C_CAM01 C_CAM01_1
_1
C_LEF01 1 3 5 M5 M5 SOLENOID(AUX1-R)
1 2 to_J/C-INJ/SLD-GND
_M5_1 JS_CONTROL(R) RAIL_ 4 3 2 1
C_OF01_ TRAVEL_ 3 4
PRESSURE_ 2 6 4 2 1
7123-20
SONSOR 10 9 8 7 6 5 ALARM
4 3 2 1
10_1 4 3 2 1 SPEAKER(L-) (REAR,+)
GND(WIPER, C_OF06_6 C_OM04_7122-1347
F) M6 M5 8 7 6 5
4 3 2 1 020-6161
C_OF10_7123-8307
_1
_1 C_WF02_174352-2_1
3 2 1 1 _1 1
INJECTOR_1 8 7 6 5 C_OF06_7357-51 C_WF08_7283-7080-
1 55-30_1 to_WIPER 40_1
C_WF03_1
M8 C_WF08_6195-0051_1
74357-2_
SOLENOID(AUX2-L)
1 RELAY(GLOW)
1 C_CAM01 C_CBF01_1
SENSOR,FUEL 2 1 J/C-INJ/SLD-GND
2 2 1 _1
SWITCH(LEVER_LOCK)
C_LAF01 4 3
_M8_1 REGISTER 3 TRAVEL_ 1 2 3 4
C_WF02_ 3 2 1
(120ohm) 1 2 C_WF02_174352-2_1 ALARM
6189-06 SPEAKER(R) C_OF04_7123-1347
11_1 2 1 (REAR,GND) _1 5 6 7 8
KEY_SWITCH 4 C_WF03_7283-87
GND1 2 1 30-30_1
SOLENOID(AUX2-R) C_WF02_6195-0003
1 1
INJECTOR_2 2 1 C_OF04_P _1
to_CAMSHAFT_SENSOR C_WM08_7382-1480-
C_WF02_7 -ISO_1 40_1
1 3 123-6423 SENSOR_BOOST 2 1 2
-30_1 C_CAM01_1
M8 C_OF02_ SWITCH(WATER_LEVEL)
1 C_WF03_7123-6234-40 RELAY(HORN) C_WF02_174352-2_1 2 1 to_J/C-SLD-GND
_1 3 2 1 7123-28
2 20_1 4 3
C_LAF01 RELAY C_WF03_6189-00 2 1 TRAVEL_ 2 1
_7009-1
3 99_1 SOLENOID(E/F) PRESSURE_
C_WF02_ LCD_METER (BEACON) C_WF04_33472-040
836_1 6189-06 5 SENSOR
SPEAKER(R-) C_WF02_6189-0176
1_1
11_1 C_WF02_7283-7020-
1 4 2 2 1 _1 10_1
7 6 5 4 3 2 1 3
1 3 2 1 to_MAIN(CAMSHAFT_
14 13 12 11 10 9 8 5 C_OF05_M C_WF02_174352-2_1
INJECTOR_3 THERMOSTAT SENSOR)
-ISO_1 J/C-SLD-GND
GND2 1 4 2 C_WF03_71
C_OF14_7283-5832_1 83-7874-3
5 4 3 2 1
0_1 1 2 1 2
1 C_OF05_M C_CAM01
-ISO_1
RELAY(LIGHT) _1 3 4
1 2 OIL-SW,D TRAVEL_
C_OF05_7283-1050
_1 SPEED_SW C_WM02_7382-8924-
M8 RELAY 10_1
C_WF02_ C_WM04_33482-040
1 (BLOWER) 3 SPEAKER(R-) 6_1
6189-06
11_1
5 1 2
C_LAF01 C_OF01_172320-2_1 3 1 4 2 1
_7009-1 3
836_1 5
C_OF05_M
1 4 2 -ISO_1 C_WM03_60
92-0013_1
C_CAM01
C_OF05_M _1
-ISO_1
RELAY
WASHER_TANK
(POWER)

GND3
1
RELAY 1 2 2
1 (COMPRESSOR)
4
M8 C_OF02_71
C_OF04_P 23-2820_1
3 -ISO_1

C_LAF01
5
_7009-1 1 4 2 RELAY
836_1
(STARTER)
C_OF05_M
-ISO_1
3
5
1 4 2

C_OF05_M
-ISO_1
CONNECTOR CHART 2 (KX080-4 EU)
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 : kbt_g.ce-sv@kubota.com

Printed in Japan 2015. 08, H, EI, EI, engusa Code No.RY911-21491

KUBOTA Corporation Printed in Japan 2013. 02, H, EI, EI, engusa Code No.RY921-21490

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