Kubota KX080-4 Workshop Manual

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Page 1

WORKSHOP MANUAL

KiSC issued 08, 2015 A

KUBOTA EXCAVATOR

KX080-4

Page 2

KiSC issued 08, 2015 A

TO THE READER

I INFORMATION

CONTENTS INFORMATION

1. SAFETY FIRST ............................................ I-1

2. IN THE INTEREST OF WORK

SAFETY........................................................ I-2

3. LABELS DISPLAYED TO PROMOTE

WORK SAFETY............................................ I-6

4. MAIN SPECIFICATIONS ............................ I-12

5. DIMENSIONS ............................................. I-13

G GENERAL

CONTENTS GENERAL

1. CHECKING EXCAVATOR

IDENTIFICATION ........................................G-1

2. ENGINE IDENTIFICATION .........................G-2

3. MUFFLER FULL ASSEMBLY

IDENTIFICATION ........................................G-5

4. GENERAL PRECAUTIONS.........................G-7

5. HANDLING PRECAUTIONS FOR

ELECTRICAL PARTS AND WIRING.........G-11

6. TIGHTENING TORQUES ..........................G-16

7. OIL AND WATER CAPACITY TABLE .......G-20

8. MAINTENANCE INTERVALS....................G-21

1 MACHINE BODY

CONTENTS SERVICING

1. FRONT ...................................................... 1-S1

2. SWIVEL FRAME........................................ 1-S8

3. TRACK FRAME ....................................... 1-S22

4. MEASURING MACHINE

PERFORMANCE ..................................... 1-S38

5. SWIVEL GEAR BACKLASH

PERFORMANCE ..................................... 1-S40

2 ENGINE

CONTENTS GENERAL

1. SPECIFICATIONS.....................................2-G1

2. DIMENSIONS ............................................2-G2

3. PERFORMANCE CURVES .......................2-G3

4. FAN DRIVE................................................2-G4

3 HYDRAULIC SYSTEM

CONTENTS MECHANISM

1. DIAGRAM OF HYDRAULIC CIRCUIT...... 3-M1

2. HYDRAULIC DEVICE LAYOUT ............... 3-M3

3. PUMP ....................................................... 3-M4

4. CONTROL VALVE.................................. 3-M12

5. SWIVEL MOTOR.................................... 3-M29

6. TRAVEL MOTOR ................................... 3-M34

7. HYDRAULIC CYLINDER ........................ 3-M39

8. PILOT VALVE......................................... 3-M42

9. SHOCKLESS VALVES........................... 3-M52

10. SOLENOID VALVE................................. 3-M54

SERVICING

1. PUMP......................................................... 3-S1

2. CONTROL VALVE................................... 3-S17

3. SWIVEL MOTOR ..................................... 3-S26

4. SWIVEL JOINT ........................................ 3-S41

5. TRAVEL MOTOR..................................... 3-S49

6. CYLINDER............................................... 3-S69

7. PILOT VALVE .......................................... 3-S71

8. SHOCKLESS VALVES .......................... 3-S106

9. SWIVEL SHUTTLE VALVE ................... 3-S107

10. SOLENOID VALVE ................................ 3-S108

11. ROUTING OF HYDRAULIC HOSES .....3-S112

12. MEASURING HYDRAULIC DEVICE

PERFORMANCE ................................... 3-S133

13. HYDRAULIC DEVICE

PERFORMANCE STANDARDS............ 3-S158

14. TROUBLESHOOTING ........................... 3-S165

4 ELECTRICAL SYSTEM

CONTENTS SERVICING

1. LAYOUT OF ELECTRICAL DEVICES

AND WIRING ROUTING ........................... 4-S1

2. METER PANEL OPERATION ................. 4-S10

3. INSPECTIONS......................................... 4-S44

4. TROUBLESHOOTING (START-UP

EQUIPMENT VERSION) .........................4-S50

5. METHODS FOR DIAGNOSING

ERRORS.................................................. 4-S51

6. TROUBLESHOOTING (METER

PANEL VERSION)................................... 4-S53

5 CABIN

CONTENTS MECHANISM

1. AIR CONDITIONING SYSTEM................. 5-M1

2. WIPER .................................................... 5-M17

SERVICING

1. TROUBLESHOOTING............................... 5-S1

2. SERVICE SPECIFICATIONS .................... 5-S4

3. TORQUE.................................................... 5-S5

4. PRECAUTIONS WHEN REPAIRING

THE REFRIGERANT SYSTEM ................. 5-S6

5. INSPECTING AND CHARGING THE

REFRIGERANT SYSTEM ....................... 5-S11

6. INSPECTION AND DISASSEMBLY ........5-S20

7. WINDOW WASHER ................................ 5-S36

8. CABIN GLASS REMOVAL AND

MOUNTING ............................................. 5-S38

9. REMOVAL AND INSTALLATION OF

GLASS ..................................................... 5-S52

10. FRONT WINDOW .................................... 5-S57

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TO THE READER

NOTE

IMPORTANT

KiSC issued 08, 2015 A

This Workshop Manual provides service personnel with information about the mechanisms, service and maintenance of the construction machinery. This Workshop Manual is divided into 3 sections, General, Mechanisms and Service.

 General

This section contains information such as engine and equipment ID numbers, general precautions, maintenance schedules, inspections and maintenance items and special tools.

 Mechanisms

This section describes the structure of mechanisms and explains their functions.Be sure that you fully understand this Mechanisms section prior to performing any service work, such as troubleshooting or when performing any disassembly or assembly work.

 Service

This section contains information and procedures for performing maintenance on the backhoe, such as troubleshooting, service specification tables, torque specifications, items to be inspected and adjusted, disassembly and assembly procedures, as well as precautions, maintenance standard values and usage limits.

All of the illustrations, specifications and other information in this manual were created based on the latest model at the time of publication.

Please be aware that changes to the content may be made without prior notice.

• Corresponding model list

Machine Model Engine Model

KX080-4 V3307-CRS-T4

• 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

Page 4

Record of Revisions

KiSC issued 08, 2015 A

Last digit of

the Code

No.

Date Main Revised Point and Corrective Measures Remarks

1 2015.08.05

• Add the contents of pump assembly and disassembly, the contents of cabin glass removal and mounting.

S. M

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I INFORMATION

KiSC issued 08, 2015 A

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INFORMATION

KiSC issued 08, 2015 A

CONTENTS

1. SAFETY FIRST .............................................................................................................................. I-1

2. IN THE INTEREST OF WORK SAFETY ........................................................................................ I-2

[1] WORKING SAFELY WITH THE EQUIPMENT MEANS ALWAYS FOLLOWING

THESE INSTRUCTIONS:......................................................................................................... I-2

(1) Precautions Before Working on the Machine ..................................................................... I-2

(2) Precautions Before Working on the Equipment.................................................................. I-3

3. LABELS DISPLAYED TO PROMOTE WORK SAFETY................................................................. I-6

[1] LOCATIONS ............................................................................................................................. I-6

[2] LABEL MAINTENANCE ......................................................................................................... I-11

4. MAIN SPECIFICATIONS.............................................................................................................. I-12

5. DIMENSIONS ............................................................................................................................... I-13

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KX080-4, WSM

SAFETY FIRST

DANGER

WARNING

CAUTION

IMPORTANT

NOTE

KiSC issued 08, 2015 A

INFORMATION

1. 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.

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

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

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

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

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

[NOTE]

• Indicates other supplementary information to take note of.

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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.

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• When performing maintenance on the equipment, hang the DO NOT OPERATE sign where it will be obvious from and around the driver's seat.

• When performing maintenance or repairs, always lower attachments to the ground, stop the engine and set the brake.

• When performing maintenance on the equipment, always disconnect the negative battery cable.

• Before using tools, make sure you understand how to use them correctly and use tools in good condition and of the right size for the job.

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Be Ready for an Emergency

• Keep a first-aid kit and fire extinguisher close at hand so you can use it when needed.

• Keep emergency contact information for doctors, hospitals and ERs handy.

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• Wear clothes appropriate for working on equipment. Do not wear loose-fitting clothes as they may catch on the machine controls.

• When working on the equipment, use all safety gear, such as a helmet, safety glasses and shoes, that are required by law or regulation.

• Never perform maintenance while drowsy or under the influence of alcohol or drugs.

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CAUTION

KiSC issued 08, 2015 A

(2) Precautions Before Working on the Equipment

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

• When performing work such as with a hammer, fragments may go flying, so make sure only authorized persons are around the machine.

• Before servicing the machine, clean it off so there is no mud, debris, oil or the like sticking to it.

• Before getting on/off of the machine, clean off around the steps so there is no mud on them. Always give yourself 3-point support when getting on/off the machine.

• 3-point support means using both legs and one hand or both hands and one leg as you climb up/down.

INFORMATION

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Starting the Machine Safely

• Before starting the engine, always sit in the driver's seat and make sure the area is safe and clear.

• As it is dangerous, never start the engine from anywhere but the driver's seat.

• Always check and make sure control lever(s) are not engaged before starting the engine.

• Never start the engine by hot-wiring the starter circuit. This is not only dangerous, but may damage the machine.

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• Whenever it is necessary to open the engine covers or hood in order to service the machine, always prop them open.

• If it is absolutely necessary to run the engine while working on the machine, make sure you are clear of all rotating or moving parts. Also take care not to leave anything, such as tools or rags, near any moving parts.

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INFORMATION

• The engine, muffler, radiator, hydraulic line, etc., have parts that remain very hot even after the engine has been stopped. Be sure to avoid these parts, as touching them can result in burns. Radiator coolant, hydraulic fluid and oil also remain hot. Therefore, do not attempt to remove caps and plugs, etc., before these fluids have sufficiently cooled.

• Make sure the coolant temperature has dropped sufficiently before opening the radiator cap. Also, since the inside of the radiator is pressurized, when removing the cap, first loosen it to release the pressure before removing the cap completely.

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• The pressure in the hydraulic circuit stays at pressure even after the engine stops. Before removing parts, such as hydraulic devices from the machine, first release the pressure. Please note that when releasing residual pressure, the machine itself and/or implements may move without warning, so be very careful when releasing the pressure.

• Oil gushing out under pressure is extremely dangerous as it may pierce your skin or your eyes. Similarly, oil leaking out of pinholes is not visible. So when checking for oil leaks, always wear safety glasses and gloves and use a piece of cardboard or a wood block to shield yourself from oil.

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No Smoking or Open Flames while Fueling

• Fuel is extremely flammable and dangerous. Never smoke near fuel. If fuel is spilled on the machine, its engine, or electrical parts, it may cause a fire. If fuel is spilled, wipe it all up immediately.

• Never smoke while filling the machine with fuel. And always tighten the fuel cap securely and wipe up any spilled fuel.

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• Always wear safety glasses and gloves when handling the battery.

• The gas generated by the battery is flammable. Never weld or use tools like a grinder near the battery. And never smoke near it.

• When disconnecting the battery, always disconnect the negative cable first. When connecting the battery, always connect the positive cable first.

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INFORMATION

• Grease is under high pressure inside the hydraulic cylinder. It is very dangerous to loosen a grease nipple quickly as it may shoot off. Always loosen grease nipples slowly.

• And never face a grease nipple while loosening it.

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Dispose of Waste Fluids Properly

• Never dispose of waste fluids on the ground, in the gutter, a river, pond or lake. Always dispose of hazardous substances like waste oil, coolant and electrolytic fluid in accordance with the relevant environmental protection regulations.

• Keep the safety plates clean so they can be read. If a safety plate is damaged and comes off or becomes illegible, put a plate with the same warnings back in its place.

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3. LABELS DISPLAYED TO PROMOTE WORK SAFETY

[1] LOCATIONS

INFORMATION

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INFORMATION

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INFORMATION

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INFORMATION

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INFORMATION

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INFORMATION

[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.

• When using a pressure washer to clean the equipment, do not spray any labels directly as doing so may make

• 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

• When replacing a part that has a label on it, replace the label at the same time.

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If solvents such as paint thinner or engine oil are used, the text and or figures may fade away.

them peel off.

the same place.

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NOTE

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INFORMATION

4. MAIN SPECIFICATIONS

KUBOTA EXCAVATOR

Model name KX080-4

Type Cabin Angle Blade type Cabin

Rubber

Operating weight (including operator's weight)

tracks

8290 kg

18280 lbs

Type Water cooled 4 cycle diesel engine with 4 cylinder

Model name KUBOTA V3307-CRS-T4

Total displacement 3331 cc (203.3 cu.in.)

Engine

Engine power

SAE gross 52.2 kW (70.0 Hp)

SAE net 48.8 kW (65.5 Hp)

Rated speed 2000 rpm

Low idling speed 1000 rpm

Unit swing speed 9.5 rpm

Travel speed

Fast 4.9 km / h (3.1 mph)

Slow 2.7 km / h (1.7 mph)

36.0 kPa

Performance

Ground pressure (With operator)

(0.367

kgf/cm

5.22 psi

Climbing angle *36 % (20 deg)

Angle in case of crossing slope

Width x Height

Blade

Max swing

Left – 0.44 rad (25 deg)

Right – 0.44 rad (25 deg)

Left 1.22 rad (70 deg)

Boom swing angle

Right 1.05 rad (60 deg)

Max. displacement

Pressure

(Theoretical)

connection for attachments

Max. pressure

Fuel tank capacity 115 L (30.4 U.S.gal)

Steel tracks

(450 width)

8340 kg

18390 lbs

36.2 kPa (0.369

)

kgf/cm

5.25 psi

2200 x 500 mm

86.6 x 19.7 in.

Steel tracks

Rubber

(600 width)

8470 kg

18670 lbs

27.6 kPa (0.281

)

kgf/cm

4.00 psi

8680 kg

19140 lbs

37.5 kPa (0.382

kgf/cm

5.44 psi

*27 % (15 deg)

100 L (26.4 U.S.gal) / min

20.6 MPa

210 kgf/cm

2987 psi

tracks

)

2200 x 510 mm

86.6 x 20.1 in.

Steel tracks

(450 width)

8730 kg

19250 lbs

37.7 kPa (0.384

kgf/cm

5.47 psi

)

• Above dimensions are based on the machine with KUBOTA original bucket and 2100 arm.

• Specifications subject to change without notice.

• With unloaded digging bucket.

• Firm compacted soil.

• Operators must exercise extra caution and follow instructions in the operator's manual.

• Worse condition or heavier attachment to the above will decrease climbing angle.

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5. DIMENSIONS

INFORMATION

(1) Arm length (2100 Arm)

• Above dimensions are based on the machine with KUBOTA original bucket.

• Above dimensions are based on the machine with rubber track.

• Specifications subject to change without notice.

KX080-4

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

590 mm

23.2 in.

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

1460 mm

57.5 in.

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

7170 mm

282.3 in.

770 mm

30.3 in.

4990 mm

196.5 in.

1460 mm

57.5 in.

2200 mm

86.6 in.

7330 mm

288.6 in.

6450 mm

253.9 in.

7300 mm

287.4 in.

500 mm

19.7 in.

2150 mm

84.6 in.

5250 mm

206.7 in.

500 mm

19.7 in.

2490 mm

98.0 in.

4600 mm

181.1 in.

2540 mm

100.0 in.

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3850 mm

151.6 in.

2200 mm

86.6 in.

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G GENERAL

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GENERAL

KiSC issued 08, 2015 A

CONTENTS

1. CHECKING EXCAVATOR IDENTIFICATION .............................................................................. G-1

2. ENGINE IDENTIFICATION .......................................................................................................... G-2

[1] MODEL NAME AND SERIAL NUMBER ................................................................................ G-2

[2] E4B ENGINE .......................................................................................................................... G-3

[3] CYLINDER NUMBER ............................................................................................................. G-4

3. MUFFLER FULL ASSEMBLY IDENTIFICATION ......................................................................... G-5

[1] PART NUMBER AND SERIAL NUMBER .............................................................................. G-5

4. GENERAL PRECAUTIONS.......................................................................................................... G-7

5. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING .................................. G-11

[1] WIRING ................................................................................................................................ G-11

[2] FUSES.................................................................................................................................. G-13

[3] CONNECTOR ...................................................................................................................... G-13

[4] WASHING THE MACHINE WITH A HIGH-PRESSURE WASHER ..................................... G-15

6. TIGHTENING TORQUES........................................................................................................... G-16

[1] TORQUES FOR GENERAL USE NUTS AND BOLTS ........................................................ G-16

[2] TORQUE FOR HYDRAULIC HOSE FITTINGS ................................................................... G-17

(1) Torque for Hydraulic Hose Fittings ................................................................................. G-17

(2) Torques of Lock-Nuts for Elbows with Male Seats and Adaptors with O-rings

(Straight Threads)........................................................................................................... G-17

[3] HOSE CLAMP SCREW TORQUE ....................................................................................... G-18

7. OIL AND WATER CAPACITY TABLE ........................................................................................ G-20

8. MAINTENANCE INTERVALS..................................................................................................... G-21

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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

(Model, frame number, engine

number) (2) Frame Number (3) Engine Number

(a) Model Nameplate

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GENERAL

G-1

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2. ENGINE IDENTIFICATION

[1] MODEL NAME AND SERIAL NUMBER

Be sure to check the engine nameplate and serial number when

you wish to consult about the engine.

The model and serial number of the engine need to be checked

prior to servicing the engine or replacing any of its parts.

 Engine Serial No.

The engine serial number is the numerical ID of the engine and

is printed after the engine's model number.

The year and month of manufacture are indicated as follows.

Engine Series

Number or

Alphabet

1 05 (include: WG) 6

2V3703

308807

4 SM (include: WG) A EA, RK

Air Cooled

Series

Gasoline

Number or

Alphabet

GENERAL

Series

GZ, OC, AC, EA,

03 (KET

Production)

Production Year

Alphabet or

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

E2014

(1) Engine Model Name and Serial

Number

Year

Alphabet or

Number

Year

(To be continued)

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NOTE

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(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)

e.g. V2607

(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)

(b)C(c)L(d)

- 8

(e)

A001

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GENERAL

[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

• "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.

From 19 to less than 56 kW Interim Tier 4

From 56 to less than 75 kW Interim Tier 4

From 75 to less than 130 kW Interim Tier 4

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[3] CYLINDER NUMBER

GENERAL

You can see the cylinder numbers of KUBOTA diesel engine in

the figure.

The sequence of cylinder numbers is No.1, No.2, No.3 and No.4

and it starts from the gear case side.

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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

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

Year

Alphabet or

Number

GENERAL

Yea r

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)L(b)

(c)

e.g. C

(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)

0019

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GENERAL

You must keep the records of the filter comp (DPF) part number

and serial number before you remove the DPF for cleaning.

(1) Body (DPF Outlet) Part Number and

Serial Number

(2) Filter Comp (DPF) Part Number and

Serial Number

(3) Catalyst (DOC) Part Number and

Serial Number

RY9212148GEG0005US0

G-6

Page 28

KX080-4, WSM

KiSC issued 08, 2015 A

4. GENERAL PRECAUTIONS

Whenever performing maintenance on the machine, always

read the Safety Precautions in this manual and the Operator's Manual carefully, become familiar with them and perform the work safely.

Before performing any maintenance on the machine, make sure

it is sufficiently clean and choose a sufficiently clean location to perform any disassembly.

Before performing maintenance on the machine, always

disconnect the negative battery cable first.

Whenever a special tool is required, use the special tool that

KUBOTA recommends. Make any special tools that are not used very frequently according to the diagrams in this manual.

Always use genuine KUBOTA parts to maintain the

performance and safety characteristics of the machine.

Plumber's Tape

• Wrap plumber's tape on the threads before tightening taper couplings. After wrapping (2 wraps) the plumber's tape, tighten to the specified torque. Once the coupling is tightened, do not loosen it as this will cause an oil leak.

(1) Plumber's Tape (2) External Thread (3) Internal Thread

GENERAL

RY9212001GEG0011US0

(4) Gap (5) Leave 1 to 2 Threads

RY9212001GEG0012US0

O-Ring

• Clean the groove the O-ring goes in and remove any burrs. Apply grease on the O-ring when inserting it in the groove. (Except floating seals)

• When putting the O-ring in the groove, be careful as it is easy at the very end to twist the O-ring against the inside of the groove. If it gets twisted, roll it gently with your fingertip to untwist it.

(1) O-Ring Groove (2) O-Ring (3) Check for Burrs

(4) If the Ring Touches This Corner, It

Will Twist

RY9212001GEG0013US0

Oil Seal

• Do not face the lip of the oil seal in the wrong direction. Face the main lip toward the material to be sealed.

• After oil seals are replaced, apply grease to the moving parts around the lip to prevent the dry surfaces from wearing against each other when the engine is started. If the seal has a dust lip, fill the gap between the lips with grease.

• As a general rule, use a press to insert the oil seal in place. If that is not possible, use an appropriate tool to gently and evenly tap it into place, taking care that it does not go in at a slant. Press the seal all the way so it seats in the boss.

(1) Gasket (2) Metal Ring (3) Spring (4) Main Lip (5) Grease (6) Dust Lip

A : Air (Outside) B : Hydraulic Chamber (Inside)

RY9212001GEG0014US0

G-7

Page 29

KX080-4, WSM

KiSC issued 08, 2015 A

GENERAL

Floating Seal

• Be sure to wipe off any oil from the O-ring or surfaces that touch the O-ring. (For wheel motors, apply a light film)

• When putting an O-ring into a floating seal, make sure the O-ring does not twist.

• Apply a light film of oil to surrounding surfaces when working to get the floating seal with O-ring in place; take care that the surrounding surfaces, O-ring and housing are parallel with each other.

• After getting the seal in place, turn the engine over 2 or 3 revolutions, to both create a film of oil on surrounding surfaces and to properly seat the face of the seal.

(1) Surrounding Surfaces (2) O-Ring

RY9212001GEG0015US0

Snap Ring Related

• When installing external or internal snap rings, orient them as shown in the diagram so the angled side faces the direction of force.

(1) Position so the Angled Part

Receives the Force

(A) External (B) Internal

RY9212001GEG0016US0

Spring Pins

• When driving a spring pin, face the split in the direction that receives the force, as shown in the diagram.

(1) With Lateral Movement (2) With Rotational Movement

RY9212001GEG0017US0

Adhesive

• Clean and dry the area where adhesive will be applied with a solvent so it is free of moisture, oil and dirt.

• Apply adhesive all around the threads of the bolt except the first set of threads at the tip and fill the grooves between the threads. If the threads or the grooves are large, adjust the amount of adhesive accordingly and apply it all around the bolt hole as well.

(A) Bolt Through-Hole (Nut) (B) Pocket Bolt Hold

(Capsule Shape, etc.)

(a) Apply Here (b) Do Not Apply (c) Drip On

RY9212001GEG0018US0

G-8

Page 30

KX080-4, WSM

KiSC issued 08, 2015 A

GENERAL

Tightening Bolts and Nuts

• Tighten bolts and nuts to their specified torque.

• Tighten nuts and bolts alternately top/bottom (a) (b), left/right so

the torque is distributed evenly.

(A) Top/Bottom Alternately (B) Across Diagonally

RY9212001GEG0019US0

Assembling Hydraulic Hoses

• Tighten to their specified torque.

• Before assembling, wipe the inside of metal fittings clean of any dirt.

• After assembly, put the fitting under normal pressure and check that it does not leak.

RY9212001GEG0020US0

Elbow with Male Seat Assembly Procedure

When assembling an elbow with male seat, adhere to the

following procedures to prevent deformation of O-rings and leaks.

1. Connecting to Valves

• Clean the blow with male seat and the surface of the seal opposite and mount with the lock-nut on top.

• Finger tighten till it touches the washer.

2. Positioning

• Turn the mouth of the elbow back so it faces the right direction. (not back over 1 turn)

3. Fasten

• Tighten the lock-nut to the specified torque with a wrench.

(1) Lock-Nut (2) Washer (3) Seal (O-Ring)

(4) Wrench for Holding (5) Hose (6) Torque Wrench for Tightening

RY9212001GEG0021US0

G-9

Page 31

KX080-4, WSM

KiSC issued 08, 2015 A

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

Page 32

KX080-4, WSM

IMPORTANT

KiSC issued 08, 2015 A

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.

• 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 (2) Wiring Position (Wrong)

(3) Wiring Position (Right) (4) Hazardous Position

RY9212001GEG0025US0

• Immediately repair or replace old or damaged wiring.

(1) Damaged (2) Torn

(3) Electrical Tape

RY9212001GEG0026US0

G-11

Page 33

KX080-4, WSM

KiSC issued 08, 2015 A

GENERAL

• Insert grommet securely.

(1) Grommet (A) Correct

(B) Incorrect

RY9212001GEG0027US0

• Clamp wiring securely but do not damage wires with the clamp.

(1) Clamp (Spiral Clamp Around Wire) (2) Wire

(3) Clamp (4) Welding Mark

RY9212001GEG0028US0

• Clamp wiring so it is not twisted, pulled too tight or sag too much. However, moving parts may require play in the wiring.

(1) Wire (2) Clamp

(A) Correct (B) Incorrect

RY9212001GEG0029US0

• Do not pinch or bind wiring when installing parts.

(1) Wire (A) Incorrect

RY9212001GEG0030US0

• After wiring, double-check terminal protectors and clamps before connecting battery cables.

(1) Cover (Install Covers Securely)

RY9212001GEG0031US0

G-12

Page 34

KX080-4, WSM

KiSC issued 08, 2015 A

GENERAL

• Do not modify harnesses. The diameter of wires in each harness is determined after calculating its capacity.

• Modifying harnesses may cause a malfunction or a fire.

[2] FUSES

[3] CONNECTOR

(A) Wiring Diagram (B) Diagram of Modification

(a) Standard Wiring (b) Modified Wiring

RY9212038ELS0008US0

• Always use fuses of the specified capacity. Never use over or undersized fuses.

• Never use copper or steel wire in place of a fuse.

• Do not install accessories such as work lights, radios, etc., if your machine does not have an auxiliary circuit.

• Do not install accessories as they will exceed the capacity of fuses.

(1) Fuse (2) Fusible Link

(3) Slow-Blow Fuse

RY9212001GEG0032US0

Connectors

The terminals of female connector are numbered from #1 on the

top right when facing it.

Male terminals are numbered from #1 on the top left.

(A) Female connector terminals (B) Male connector terminals

RY9212038ELS0010US0

• Press the lock to disconnect locking connectors.

(A) Push

RY9212001GEG0033US0

G-13

Page 35

KX080-4, WSM

KiSC issued 08, 2015 A

GENERAL

• Hold the connectors when separating them.

• Do not pull on the wire harness to separate the connectors.

(A) Correct (B) Incorrect

RY9212001GEG0034US0

Pull on the harness from the connector and make sure the harness does not come off. (Pull with 3 kgf (30 N, 7 lbf) or less of force)

(A) Pull (B) Loosened Crimping

RY9212038ELS0011US0

• Straighten bent prongs and make sure none are sticking out or missing.

• Remove corrosion from terminals with sandpaper.

(1) Missing Terminal (2) Bent Prong

(3) Sandpaper (4) Corrosion

RY9212001GEG0035US0

• Do not touch the terminals of connectors with bare hands.

(A) Do not touch

RY9212038ELS0012US0

• Female connectors must not be spread too far open

(A) Correct (B) Incorrect

RY9212001GEG0036US0

G-14

Page 36

KX080-4, WSM

CAUTION

KiSC issued 08, 2015 A

GENERAL

• The plastic covers of connectors must cover them completely.

(1) Cover (A) Correct

(B) Incorrect

RY9212001GEG0037US0

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

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

• Stand at least 2.0 meters from the machine and adjust the nozzle for a wide spray so it does not cause any damage. If you blast the machine with water or wash it from too close a distance,

1. It may cause a fire due to damaged or cuts in the insulation of electrical wiring.

2. An injury may result if hydraulic oil gushes out under high pressure, due to damaged hydraulic hoses.

3. It may damage, break or cause parts of the machine to fail.

(Ex.) (1) Stickers or labels may come off (2) Electrical parts or the engine may fail due to water in them. (3) Damage glass, resins, etc. or the rubber of oil seals. (4) Tear off paint or the film from plating

(1) Do Not Blast with Water (2) Never Wash from Too Close

(A) Blasting (B) Wide Spray (C) Less Than 2.0 m (80 in.) (D) Over 2.0 m (80 in.)

RY9212001GEG0038US0

G-15

Page 37

KX080-4, WSM

KiSC issued 08, 2015 A

GENERAL

6. TIGHTENING TORQUES

[1] TORQUES FOR GENERAL USE NUTS AND BOLTS

Screws, bolts and nuts whose tightening torques are not specified in this Workshop Manual should be

tightened according to the table below.

Indication on top of bolt

Indication on top of nut

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

M10

M12

M14

M16

M18

M20

9.3

108

125

191

246

284

334

392

0.95

1.8 to

2.1

4.0 to

4.6

6.4 to

7.4

12.8

19.5

No-grade or 4T 7T 9T

No-grade or 4T

5.8

7.9

0.8

5.8

9.81

1.0

7.24

7.9

0.8

5.8

12.3

6.8

8.8

0.9

6.5

1.7

to 53–––

79.6 to

–––

92.5

123

–––

141

181

–––

209

246

–––

289

2.0

3.2 to

3.5

11. 2

124

147

197

225

275

318

368

431

1.15

2.4 to

2.8

4.9 to

5.7

7.9 to

9.2

12.6 to

32.5

37.5 to

8.31

91.2 to

108

145

166

203

235

272

318

8.8

0.9

1.8

2.1

4.0

4.5

6.4

7.4

––

–––

6.5

14.2

103

117

167

–

196

260

304

344

402

491

568

RY9212032GEG0001US0

1.25 to

1.45

3.0 to

3.5

6.2 to

7.2

10.5 to

26.5 to

9.05 to

10.4

86.7

123

144

192

224

254

296

362

419

G-16

Page 38

KX080-4, WSM

KiSC issued 08, 2015 A

[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

1/4

3/8

1/2

3/4

1 - 1/4

0.8 to 1.2 kgf·m

5.7 to 8.7 lbf·ft

24.5 to 29.2 N·m

2.5 to 3.0 kgf·m

18.1 to 21.7 lbf·ft

37.2 to 42.1 N·m

3.8 to 4.3 kgf·m

27.5 to 31.1 lbf·ft

58.8 to 63.7 N·m

6.0 to 6.5 kgf·m

43.4 to 47.0 lbf·ft

117.6 to 127.4 N·m

12.0 to 13.0 kgf·m

86.8 to 94.0 lbf·ft

220.5 to 230.3 N·m

22.5 to 23.5 kgf·m

162.7 to 169.8 lbf·ft

––

35.2 to 43.1 N·m

9/16UNF

11/16UNF

13/16UNF

1-14UNS

––

3.6 to 4.4 kgf·m

26.0 to 31.8 lbf·ft

60.0 to 73.5 N·m

6.1 to 7.5 kgf·m

44.3 to 54.2 lbf·ft

70.6 to 86.2 N·m

7.2 to 8.8 kgf·m

52.1 to 63.6 lbf·ft

105.8 to 129.4 N·m

10.8 to 13.2 kgf·m

78.0 to 98.4 lbf·ft

GENERAL

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

Tightening torque

(1) Lock-nut (2) Washer

1/8

1/4

3/8

1/2

3/4, 1

1-1/4

7/8 - 14UNF

(3) Seal (O-ring)

1.5 to 1.7 kgf·m

11.1 to 12.2 lbf·ft

24.5 to 29.4 N·m

2.5 to 3.0 kgf·m

18.1 to 21.7 lbf·ft

49.0 to 53.9 N·m

5.0 to 5.5 kgf·m

36.1 to 39.8 lbf·ft

58.8 to 63.7 N·m

6.0 to 6.5 kgf·m

43.4 to 47.0 lbf·ft

117.6 to 127.4 N·m

12.0 to 13.0 kgf·m

86.8 to 94.0 lbf·ft

220.5 to 230.3 N·m

22.5 to 23.5 kgf·m

162.8 to 170.0 lbf·ft

55.9 to 60.8 N·m

5.7 to 6.2 kgf·m

41.2 to 44.8 lbf·ft

RY9212148GEG0007US0

G-17

Page 39

KX080-4, WSM

KiSC issued 08, 2015 A

[3] HOSE CLAMP SCREW TORQUE

Type 1

GENERAL

Tightening torque

10- 14 6C040-58721

12- 16 09318-89016

19- 25 09318-89024

31- 40 09318-89039

36- 46 09318-89045

44- 53 09318-89052

51- 59 09318-89058

86- 96 RD809-42241

2.5 to 3.4 N·m 25 to 35 kgf·cm

1.8 to 2.5 lbf·ft

2.5 to 3.4 N·m 25 to 35 kgf·cm

1.8 to 2.5 lbf·ft

2.5 to 3.4 N·m 25 to 35 kgf·cm

1.8 to 2.5 lbf·ft

2.5 to 3.4 N·m 25 to 35 kgf·cm

1.8 to 2.5 lbf·ft

2.5 to 3.4 N·m 25 to 35 kgf·cm

1.8 to 2.5 lbf·ft

3.9 to 4.9 N·m 40 to 50 kgf·cm

2.9 to 3.6 lbf·ft

3.9 to 4.9 N·m 40 to 50 kgf·cm

2.9 to 3.6 lbf·ft

2.5 to 3.4 N·m 25 to 35 kgf·cm

1.8 to 2.5 lbf·ft

RY9212001GEG0045US0

G-18

Page 40

KX080-4, WSM

KiSC issued 08, 2015 A

GENERAL

Type 2

Tightening torque

13- 20 RB101-63631

15- 25 RC101-64581

19- 28 R1401-63211

22- 32 R1401-63151

26- 38 68311-72821

32- 44 RD411-63821

44- 56 35820-15181

50- 65 RC401-63191

58- 75 36919-04591

60- 80 RD809-63101

68- 85 RD809-63061

77- 95 69284-63171

2.5 to 3.4 N·m 25 to 35 kgf·cm

1.8 to 2.5 lbf·ft