Manual de Taller KX 080 PDF

WORKSHOP MANUAL
KUBOTA EXCAVATOR
KX080-3
minor-change version
Code No.97899-61962
Record of Revisions
Symbol Date Main Revised Points & Corrective Measures Person-in-charge
Nov. 2008 1. Addition of ‘VII SUPER DOUBLE BOOM’. I. Okae
Mar. 2009 1. Engine oil specifications are corrected. I. Okae

2. Travel motor’s jig drawings are included.
Minor change version

Market
model name
KX080-3α EU-version (KE, KUK, KBM)
PP-version (KTC, KCL, KTA)
Note: In the following pages, model name is shown as
KX080-3AB KX080-3AB, which is not the official model name but
to indicate the minor change version with the serial
number starting from S/N 20001 and above.
ss CONTENTS
I GENERAL
(A) NEW PRODUCT FEATURE
(B) MACHINE MAINTENANCE
II MACHINE BODY
(A) SPECIFICATIONS
(B) UNDERCARRIAGE: TRACK
III ENGINE
• Mechanism section
(A) NEW EMISSIONS CONTROL ENGINE
• Service section
(A) TROUBLESHOOTING
(B) SERVICEING SPECIFICATIONS
(C) DISASSEMBLE AND REASSMBLE
(D) ENGINE WSM (V3307-DI-T-E3B)
IV HYDRAULIC SYSTEM
(A) GENERAL
(B) HYDRAULIC PUMP
(C) CONTROL VALVE
(D) CONTROL VALVE CIRCUIT
(E) CONTROL LEVER PILOT VALVE
(F) TRAVEL PILOT VALVE (WITH VISCOUS DAMPER)
(G) PILOT VALVE: DOZER AND ANGLE BLADE
(H) TRAVEL MOTOR (SGM-04D-S-09KT)
• Service section
(A) PERFORMANCE TEST
(B) SERVICING
V ELECTRICAL SYSTEM
(A) FEATURE AND MAIN FUNCTION
ss CONTENTS
VI. ANGLE BLADE
VII. SUPER DOUBLE BOOM

(A) GENERAL
(B) MACHINE BODY
(C) HYDRAULIC SYSTEM
(D) ELECTRICAL SYSTEM
WSM KX080-3AB I GENERAL
I. GENERAL
(A) NEW PRODUCT FEATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-3

a) Product Information, KX080-3AB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-3
b) Quick Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-3
c) Sales Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-4
d) List of Minor Change Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-9
(B) MACHINE MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-11
a) Maintenance Interval Chart: KTC, KCL-version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-11
b) Maintenance Interval Chart: KTA-version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-13
c) Maintenance Interval Chart: Air Conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-15
d) Greasing Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-16
e) Water and Oil Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-17
f) Recommended Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-18
Note: This minor change contains the changes and new adoptions only.
The other details are mostly the same in the previous WSM, Code No. 97899-61730.
I-1
I-2
(A) NEW PRODUCT FEATURE

a) Product Information, KX080-3AB
MINOR CHANGE Main points:
1. KX080-3’s engine has been changed to clear the

emissions control “Interim Tier 4”.
More competitiveness, durability & workability.
2. Travel motor is Mitsubishi-made.
3. Angle Blade-version has been newly introduced.
4. Control valve and hydraulic pump have been
minor-changed to upgrade the performance as
well as quality reliance.
5. New spiral-type rubber track.
6. New Iron Track, master pin.
b) Quick Chart
: Enhanced workability
13) New design of cab light : Enhanced durability
12) Guttering : New design
11) Rear view mirror
1) New engine type

(1) V3800DI → V3307DI-T
10) Wider outside mirror
(2) One side maintenance system
2) New place for SP pipe

8) New position for water separator
3) New material of bucket link

bushing
7) Traction force is increased by 9% 4) New position for bucket

pin grease nipple
SP: Service Port

6) Engine’s under cover 5) Longer dozer cylinder cover
I-3
c) Sales Features
1. New Engine
(1) New engine type(3800DI → V3307DI-T)
KX080-3 KX080-3AB Difference
Model V3800DI V3307DI-T -
One side maintenance system x Yes -
Output kW (HP) 47.8 (65) 52.2 (70.0) -
(Catalog value) Rated RPM 2000.0 2000.0 -
Number of cylinder/displacement /L 4/3.769 4/3.331 - / S0.438
The engine’s displacement is cut to clear the emissions control.

But, with the engine turbo system, the engine output is exactly same as the current model. It contributes to
keep the high performance of KX080-3 series.
(2) One side maintenance
(1)
current KX080-3 new KX080-3AB
(1) One side maintenance (Reposition of alternator)
2. New Installation for SP pipe

To avoid the outer pipe (SP2) being damaged by hitting, it is placed in parallel with the SP1 pipe
I-4
3. New material for the bucket link bushing

The material of the bucket link bushing is
changed from brass to steel. It increases dura-
bility of the bucket pin.
Steel (Iron) bushings are normally required for
daily greasing.
current KX080-3 4. New Installation of bucket pin grease

nipple
To avoid the grease nipple being damaged by
hitting and to grease up more easily, the nipple
is installed on the side of the arm
(Greasing interval)
1) Bucket and bucket link pins/bushings: Daily
2) Swivel gear: Every 50 hrs
3) Boom swing fulcrum: Every 100 hrs
4) Swivel bearing: Every 200 hrs
5) Others: 250 hrs
new KX080-3AB
5. Longer dozer cylinder cover

KX080-3α adopted the longer dozer cylinder
cover to increase more protection.
current KX080-3
new KX080-3AB
I-5
6. Engine’s under cover

To minimize possibility of the engine and other
components get damaged, KX080-3α/AB
adds the engine under cover.
Newly equipped
7. Increase of traction force by 9%

To meet customer needs, KX080-3α/AB is
increased the traction force by 9% at the low
speed.
8. New position of water separator

The water separator is positioned higher for
easy replacement.
I-6
9. Wider outside mirror

To increase the visibility, the wider outside mir-
ror is set up.
current KX080-3
new KX080-3AB
10. Rear view mirror

For more safety operation and better rear
visibility, the rear view mirror is equipped.
Newly equipped
11. Guttering
To avoid water on the cab easily drop into the
cab after rain when opening the front win-
dow, KX080-3α/AB is now equipped with the
guttering to prevent it.
Newly equipped
I-7
12. Others -appearance-

To clear the noise level control, the left side
bonnet and the counter-weight are newly
designed.
current KX080-3
new KX080-3AB
KTA-version
(1) Pre-cleaner
(1)
I-8
d) List of Minor Change Items

KX080-3α, KX080-3AB
No Mainly modified functions and components Detailed contents
1 New Emissions Control Engine Engine V3800DI → V3307DI-T, turbo charger with EGR
New engine of one-side-maintenance: Alternator, starter, oil filter
Engine oil cooler is adapted.
2 LS-pump and control valve: Horse power control Travel with less speed change at the simultaneous operation by modi-
performance improved. fying the control method of travel straight function.
Swap gear pumps, P3QP4 LS-pump: RD819-61111, Control valve: RD819-61131
3 Easier access to water separator Moved upward: 50mm
4 Additional engine bottom cover Improvement of S/F bottom protection cover: plate is made thicker and
distance between plate and bottom of rotary joint is increased.
Multi-perforated cover plate at the bottom of the swivel frame is
adopted. t=3~3.2mm
5 Structure for assembly of radiator net Additional net to the cover inside, same as KX121-3S, 161-3S
6 Traction force of low-speed is increased 9% up (15% up from the beginning)
7 Travel pilot valve with viscous damper Shock at the start / stop of driving reduced
RD819-61401
8 Improved horizontal leveling performance Related to Item 2 C/V (RD819-61131)
Arm regeneration function is deleted. Main spools of boom, arm,
bucket improved.
9 Improved durability of arm end Steel bush around the bucket linkages. Daily grease maintenance.
10 Key cover Key cover is adopted to prevent dust and dirt from intruding inside.
11 Improvement of cab Change of cab-light bracket design, improvement of water drain from
cab-roof
12 Improvement of rear visibility Rear mirror view enlarged
13 Smaller protrusion of S/P-pipe S/P-pipes are arranged in a row
14 New type seat belt Wire type → fixed type
15 Return line Return pipe as one part Hydr.hose changed to Yokohama-made
16 Cup holder (front) Additionally into the cab.
17 Bigger tool box Tool box to the center cover.
18 Additional net to the left cover Increased security
19 New fan shroud Fan shroud made of plastic
20 Adaption of quick reaction performance 14.7/12.7 → 12.7/9.8N
RD819-61711, 61721
21 Prevention of H/V-squeaking noise For boom cylinder relief condition
Improving the performance characteristic of piston (1) (2)
Drawing Change: RD809-64053
22 Improved performance of unload-valve Stabilizing of relief pressure
Relief valve set pressure: 3.92 +0.29/0 Mpa (40 +3/0 kgf/cm2) at 14.2 l/
min.
Cracking pressure: 3.43 Mpa (35kgf/cm2)
23 Label changed Model, Grease interval (bucket linkage pins greased every day)
Model name: KX080-3α (only EU)
24 Dozer cover enlarged Dozer hose to ORS All position to ORS-type
25 Enforcement of upper dozer plate Enforcement of metal sheet
t=4.0~4.5mm
26 FYI: Master pin of iron track (Running change) Installation method of master pin has already been changed prior to the
minor change. This is for your information.
LS-pump: Load Sensing pump, S/P: Service port (Auxilliary port), P/V: Pilot Valve,
H/V: Holding Valve, ORS: O-ring seal type
I-9
No.1 No.1 No.1
No.2, 8 No.9 No.3 No.4
No.2 No.10 No.12
No.13 No.15 No.18
No.24 No.26 No.26
I-10
(B) MACHINE MAINTENANCE

a) Maintenance Interval Chart: KTC, KCL-version
Hour meter indicator
No. Check points Intervals Consequently
50 100 150 200 250 300 350 400 450
check Daily check

1 Coolant
change every 2 years
2 Fuel check Daily check
check Daily check

3 Engine oil
change every 500 hrs
check Daily check

4 Hydraulic oil
Bucket and bucket
- Daily check
link pin
Grease front
5
attachments Boom swing fulcrum - every 100 hrs
Others - every 250 hrs
6 Radiator and oil cooler check Daily check
7 Washer liquid check Daily check
8 Engine and electrical wiring check Daily check every years
9 Fuel tank, Water separator drain every 50 hrs
10 Battery condition check every 50 hrs

11 Greasing swing bearing teeth - every 50 hrs
check Daily check

12 Fan belt tension
adjust every 200 hrs
check every 200 hrs
13 Radiator hoses and clamps
replace every 2 hrs
clean every 200 hrs
Air filter Outer element
14 replace every 1000 hrs
element
Inner element replace every 1000 hrs
15 Greasing swing ball bearing - every 200 hrs
16 Fuel filter cartridge replace every 500 hrs
17 Engine oil filter replace every 500 hrs
18 Drive unit oil change every 500 hrs
19 Hydraulic return filter cartridge replace every 500 hrs
20 Hydraulic suction filter element replace every 1000 hrs
21 Filter in the pilot hydraulic system replace every 1000 hrs
Fuel injection nozzle injection
22 check every 1500 hrs
pressure
23 Front idler and track roller oil change every 2000 hrs
24 Alternator and starter motor check every 2000 hrs
25 Injection pump check every 3000 hrs
26 Radiator system rinse every 2 hrs
check every 200 hrs
27 Fuel line and intake air line
replace every 2 hrs
* 500 thru 1000 continued to the following table.
I-11

500 550 600 650 700 750 800 1000
check Daily check

1 Coolant
check Daily check

3 Engine oil
check Daily check

4 Hydraulic oil
Bucket and bucket
Grease front link pin, Boom - every 100 hrs
5 swing fulcrum
attachments

check Daily check

12 Fan belt tension
check every 200 hrs
replace every 2 hrs
clean every 200 hrs
element
pressure
check every 200 hrs
replace every 2 hrs
I-12
b) Maintenance Interval Chart: KTA-version

Hour meter indicator Ref.
50 100 150 200 250 300 350 400 450 page
Check Daily check

1 Coolant
Change every 2 years
2 Fuel Check Daily check
Check Daily check

3 Engine oil
Change every 250 hrs
Check Daily check

4 Hydraulic oil
Bucket and
- Daily check
bucket link pin
Grease front
5 Boom swing
attachment - every 100 hrs
fulcrum
6 Radiator and oil cooler Check Daily check
7 Washer liquid Check Daily check
8 Pre-Cleaner Check Daily check
9 Engine and electrical wiring Check Daily check

Check Daily check

13 Fan belt tension
check every 200 hrs
replace every 2 hrs
clean every 200 hrs *2
15 replace every 1000 hrs *2 @
element
Inner element replace every 1000 hrs *2
17 Fuel filter cartridge replace every 500 hrs @
Filter in the pilot hydraulic
system
23 check every 1500 hrs *4 @
pressure
26 Injection pump check every 3000 hrs *4 @
check every 200 hrs
28 Fuel line and intake air line @
replace every 2 hrs *3
I-13

Hour meter indicator Ref.
500 550 600 650 700 750 800 1000 page
Check Daily check

1 Coolant
Change every 2 years
2 Fuel Check Daily check
Check Daily check

3 Engine oil
Check Daily check

4 Hydraulic oil
Change every 1000 hrs *1
Bucket and
- Daily check
bucket link pin
Grease front
5 Boom swing
attachment - every 100 hrs
fulcrum
6 Radiator and oil cooler Check Daily check
7 Washer liquid Check Daily check
8 Pre-Cleaner Check Daily check
9 Engine and electrical wiring Check Daily check

Check Daily check

13 Fan belt tension
check every 200 hrs
replace every 2 hrs
15 replace every 1000 hrs *2 @
element
Inner element replace every 1000 hrs *2
17 Fuel filter cartridge replace every 500 hrs @
Filter in the pilot hydraulic
system
23 check every 1500 hrs *4 @
pressure
26 Injection pump check every 3000 hrs *4 @
check every 200 hrs
28 Fuel line and intake air line @
replace every 2 hrs *3
I-14
c) Maintenance Interval Chart: Air Conditioner

Indication on hour meter Ref.
No. Items Period Since then
50 100 150 200 250 300 350 400 450 Page

1 Inner air filter
replace every 1000hrs *2
2 Air conditioner condenser clean every 200 hrs
3 Air conditioner drive belt check every 200 hrs
Air conditioner pipes and check every 1 year
4
hoses replace every 2 years
5 Refrigerant (gas) check Service as required
Indication on hour meter Ref.

No. Items Period Since then
500 550 600 650 700 750 700 800 1000 Page

1 Air filter
replace every 1000hrs *2
2 Air conditioner condenser clean every 200 hrs
3 Air conditioner drive belt check every 200 hrs
Air conditioner pipes and check every 1 year
4
hoses replace every 2 years
5 Refrigerant (gas) check Service as required
* The engine oil is gradually consumed with engine operation. The consumption depends on the type of
job and the model of engine. Before operation, make sure that the oil level is between the upper and
lower limits of the oil level gauge. Add oil as required. To avoid a shortened service life or burn-out of
the engine, use a Kubota-specified oil and genuine Kubota filter. Keep their specified replacement
intervals in mind.
IMPORTANT:
First operation
*1 When using a hydraulic breaker, change hydraulic oil and return filter according to the table on
“Hydraulic Oil Change (Including Exchange of the Suction Filter in the Hydraulic Tank) under
“EVERY 1000 SERVICE HOURS” in the chapter “REGULAR CHECKS AND MAINTENANCE
WORK”.
*2 Clean and replace the air filter more frequently if used under dusty conditions. When the filter is very
dirty from dusty conditions, replace the filter.
*3 Replace only if necessary.
*4 Consult your local KUBOTA Dealer for this service.
• The items listed above (@ marked) are registered as emission related critical parts by KUBOTA in
the U.S.EPA non-road emission regulation. As the engine owner, you are responsible for the
performance of the required maintenance on the engine according to the above instruction. Please
see the Warranty Statement in detail.
I-15
d) Greasing Intervals
Bushing material has been changed from metal (carbon steel) to copper alloy castings (high strength brass)
in certain locations.
High-strength brass is excellent in abrasion resistance.
1. Bucket, bucket link pin: Daily

2. Swivel bearing gear teeth: Every 50 hrs
3. Swivel bearing: Every 200 hrs
4. Boom swing fulcrum: Every 100 hrs
5. Others: 250 hrs
In each rotating area including cylinders, this new material bushing is installed.
In fixed areas, steel bushings are installed. (Materials used for main parts)
CA: Copper alloy casting
SC: Carbon steel
(1) RD809-6642-0 BUSH SC

(2) RD809-6643-0 BUSH SC
(3) RD809-6645-0 BUSH CA
(4) RD809-6648-0 BUSH SC
(5) RD809-6747-0 BUSH SC
(3)
(6) RD809-6746-0 BUSH SC
(1)
(6)
(3)
(5)
(5) (2)
(4)
(7) RD809-6659-0 BUSH CA

(7)
(7)
Note: Bushings around the bucket links have been changed back to steel bushings and are required a daily
greasing maintenance.
I-16
e) Water and Oil Quantity

Unit Remarks
L 10.5
Radiator
(gal) (2.77) Kubota LLC-N-50F
L 1.3 50%
Reserve tank
(gal) (0.34)
L 10.8 Engine Oil
Engine oil with filter
(gal) (2.85) SAE10W30 (CF or CI-4)
L 146 (38.6) STD, Angle blade
Hydraulic oil Full ISO 46
(gal) 159 (42.0) Super-Double Boom
L 75
Hydraulic oil Tank gauge center ISO 46
(gal) (19.8)
L 1.3 (0.34) EU-version Gear Oil
Wheel motor
(gal) 1.35 (0.36) KTC, KCL, KTA SAE90 (API GL-4)
cc 80 Engine Oil
Track roller
(cu.in.) (4.88) SAE30 (CD)
cc 60
Upper roller
(cu.in.) (3.66)
SAE30 (CD)
cc 80
Front idler
(cu.in.) (4.88)
L 115
Fuel tank Diesel Fuel JIS #3 (Initial)
(cu.in.) (30.4)
Note: Type of oil, fuel and coolant in the remarks are filled in the Factory.
Supply grease to such amount that it oozes

Grease
out of periphery of the rotating end. Ultra -pressure grease: EP2, Beacon Q2
Control levers and links Du-bushing Assemble after applying grease
Inspection of hydraulic oil

The hydraulic tank of KX080-3AB is pressurized type.
When checking the hydraulic oil level, satisfy the following conditions and make sure the oil level is above
the center the oil gauge.
1) Oil temp. should be between 10 ~ 30 °C

(50 ~ 86 °F)
2) Stance of front attachment:
Swing: Left end
Dozer blade: Down to the ground
Boom: The highest position
Arm: Crowd to end
Bucket: Crowd to end
Upper limit
25mm (0.98in.)
Lower limit
In this way, large amount of the hydraulic oil in the cylinders when checking and replenishing is supposed to
return back into the hydraulic tank in order to keep the tank pressurized.
I-17
f) Recommended Oils
IMPORTANT:
1. Before delivery the hydraulic oil used was an ISO 46 viscosity grade.
2. Use engine oil API service classification CF or CL-4.
3. Use SAE 90 (API, CLA/GL5) as drive unit oil for all seasons.
Application Viscosity KTC recommends Shell Mobil Exxon MIL-Standard
SAE Mobilube HD80W-90
In winter or at
75 Shell Oil S8643
low MIL-L-2105C
SAE Mobilube HD80W-90
temperatures
80 Shell Spirax HD80W
SAE Excavator Gear Oil 90 Mobilube 46 MIL-L-2105
In summer or
90 Part Number 70000-68700 (1 Quart) Shell Spirax HD90 Mobilube HD80W-90 MIL-L-2105C
at high ambient
SAE Mobilube HD85W-140 MIL-L-2105C
temperatures
140 Shell Spirax HD140 Mobilube HD80W-140 MIL-L-2105C
Gear Oil
All-weather Multi- Shell Spirax HD80W

Mobilube HD80W-90 GX80W-90 MIL-L-2105C
gear oil purpose Shell Spirax HD85W
Excavator Hydraulic Fluid 32

SAE
Part Number 70000-68720 (5 Gal Pail) Shell Tellus T32 Mobil DTE-Oil 13 NUTO H32
In winter or at 32
Part Number 70000-68740 (56 Gal Drum)
low
Excavator Hydraulic Fluid 46
temperatures SAE
Hydraulic Oil
Part Number 70000-68760 (5 Gal Pail) Shell Tellus T46 Mobil DTE-Oil 15 NUTO H46
46
Part Number 70000-68780 (55 Gal Drum)
In summer or
ISO
at high ambient Shell Tellus T68 Mobil DTE-Oil 16 NUTO H68
68
temperatures
Grease Shell Alvania EP2 Mobilux EP2 BEACON Q2

Fuel Light oil No. 2-D (ASTM D975/EN590)
Fuel-under -5C°
Light oil No. 1-D (ASTM D975/EN590)
(+23°F)
NOTE:
Engine Oil:
Above 25°C (77°F) SAE30, SAE 10W-30 or 15W-40
0 to 25°C (32 to 77°F) SAE20, SAE 10W-30 or 15W-40
Below 0°C (32°F) SAE10, SAE 10W-30 or 15W-40
• Oil used in the engine should have an American Petroleum institute (API) service classification CF or CI-4
and proper SAE Engine Oil according to the ambient temperature as shown above:
• As this engine is equipped with EGR (Exhaust Gas Re-circulation), the CF-4, CG-4, CH-4 engine oils
cannot be used.
• The CJ-4 engine oil is intended for DPF (Desel Particulate Filter) type engines, and cannot be used on
this excavator.
Fuel:
• Cetane number of 45 minimum. Cetane number greater than 50 is preferred, especially for temperatures
below -20°C (-4°F) or elevations above 1500 m (5000 ft).
• Diesel fuels specified to EN 590 or ASTM D975 are recommended.
• No.2-D is a distillate fuel of lower volatility for engines in industrial and heavy mobile service. (SAE J313 JUN87)
• DO NOT use diesel fuel with high sulfur content.
• This engine conforms to EPA interim Tier 4. The law specifies the use of low sulfur fuel or ultra low sulfur
fuel at EPA regulated area (North America). To comply with this law, use No.2-D S500 or S15 diesel fuel
as an alternative to No.2-D, or use No.1-D S500 or S15 diesel fuel as an alternative to No.1-D if temper-
ature is below -10°C (14°F).
I-18
WSM KX080-3AB II MACHINE BODY
II. MACHINE BODY

(A) SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-3
a) Machine Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-3
b) Major Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-4
c) Major Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-5
d) Quality Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-9
(B) UNDERCARRIAGE: TRACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-17
a) Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-17
b) Rubber Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-18
c) Comparison List and Interchangeability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-19
d) FYI (For Your Information) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-20
e) Iron Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-22
f) Iron Track Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-23
g) How to Use Jigs to Install Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-28
II-1
II-2
(A) SPECIFICATIONS
a) Machine Weight
Unit: kgf (lbs)
Track Arm KX080-3α: EU-version KX080-3AB: PP-version
STD. 8326 (18356) 8326 (18356)
Rubber
Short 8306 (18312) 8306 (18312)
Steel STD. 8376 (18460) 8376 (18460)

Mono-boom
(STD=450) Short 8356 (18422) 8356 (18422)
Steel STD. 8506 (18752) 8506 (18752)

(Wide=600) Short 8486 (18708) 8486 (18708)
STD.
Rubber
Two-piece Short
boom STD.
Steel
Short
STD. 8550 (18850)
Rubber
Mono-boom Short
+
Steel STD. 8600 (18960)
Angle blade
(STD=450) Short
Note:
1. PP-version: KTC, KCL, KTA-version
2. Arm length: STD=2100 mm (82.7 in.), Short=1750 mm (68.9 in.)
3. Machine weight values shown in the sales catalogue and operator’s manuals are slightly different from
above data due to changes without notice.
4. Machine weight is conditional as follows.
· Full fuel tank, hydraulic tank at the gauge center. Cooling water and other lubricants are to be
specified amount respectively.
5. Operator’s weight should be added when referring to a operating weight. Operator’s weight 80 kgf
(176 lbf)
6. Angle blade version doesn’t have a wide iron track due to its structural design limit.
II-3
b) Major Specifications
KUBOTA EXCAVATOR
Model name KX080-3AB
Type Cabin Angle Blade Type Cabin
Rubber Steel tracks Steel tracks Rubber Steel tracks
Operating weight tracks (450 width) (600 width) tracks (450 width)
(including operator's weight)
kg (lbs.) 8280 8330 8460 8630 8680
(18254) (18364) (18475) (19026) (19136)
Type Water cooled 4 cycle diesel engine with 4 cylinder
Model name KUBOTA V3307-DI-T
Total displacement
3331 (203.3)
cc (cu.in)
Engine SAE gross
52.2 (70.0)
Engine kW (Hp)
power SAE net
50.2 (67.3)
kW (Hp)
Rated speed rpm 2000
Swivel speed rpm 9.5
Travel Fast: S/R km/h (mph) 4.9 (3.1)
speed Slow S/R km/h (mph) 2.7 (1.7)
Ground contact kPa 36.0 36.2 27.6 37.5 37.7
Performance pressure (kgf/cm2) (0.367) (0.369) (0.281) (0.382) (0.384)
(With operator) [psi] [5.22] [5.25] [4.00] [5.44] [5.47]
Climbing angle % (deg) *36 (20)
Angle in case of
*27 (15)
crossing slope % (deg)
Width x Height mm (in.) 2200 x 500 (86.6 x 19.7) 2200 x 510 (86.6 x 20.1)
Dozer Max Left rad (deg) - 0.44 (25)
swing Right rad (deg) - 0.44 (25)
Left rad (deg) 1.22 (70)
Boom swing angle
Right rad (deg) 1.05 (60)
Max. discharge
Auxiliary (Theoretical) 100 (26.4)
port (SP1) L (US gal)/ min
for Max. pressure Mpa 20.6
attachments (kgf/cm2) (210)
[psi] [2987]
Fuel tank capacity L (US gal) 115 (30.4)
Note:
· Above dimensions are based on the machine with KUBOTA original bucket and 2100mm 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.
II-4
c) Main Dimensions
· Arm length
2100 Arm
mm (in.)
(A) (B) (C) (D) (E) (F) (G) (H) (I) (J)
590 770 2200 7300 5250 4600 3850 1460 4990 7330
KX080-3
(23.2) (30.3) (86.6) (287.4) (206.7) (181.1) (151.6) (57.5) (196.5) (288.6)
(K) (L) (M) (N) (O) (P) (Q) (R) (S)

500 500 2540 2200 7170 1460 6450 2150 2490
KX080-3
(19.7) (19.7) (100.0) (86.6) (282.3) (57.5) (253.9) (84.6) (98.0)
Note:
· Above dimensions are based on the machine with KUBOTA
original bucket.
· Above dimensions are based on the machine with rubber track.
II-5
Lifting Capacity
1. The lifting capacities are based on ISO 10567 and do not exceed 75% of the static tilt load of the
machine or 87% of the hydraulic lifting capacity of the machine.
2. The strokes are as follows.
(1) The load point corresponds to the front bolt part of the arm.
(2) The machine positions are; (i) over - front (Blade down), (ii) over - front (Blade up), and (iii) over -
side.
(3) The operating cylinder is the boom cylinder.
3. The bucket of the excavator, the hook, the sling and other lifting accessories are taken into consider-
ation for the loads.
Machine conditions:
No bucket, all others according to the standard regulations.
WARNING
To avoid personal injury or death:
· No loads greater than those values mentioned in the lifting capacity tables are to be lifted.
· The values mentioned in the table are valid only on even, hard grounds. When lifting on soft ground,
the machine can tip over due to the load being concentrated only on one side of the machine.
· The table values are calculated at the end of the arm without the bucket. In order to find the allow-
able loads for machines with bucket, the bucket weight must be subtracted from the values in the
table.
· Never lift the machine with the angle blade placed at an angle.
Lift radius Lift point
Lift point
height
Axis of rotation
II-6
Lifting Capacity Chart

KX080-3AB
2100 Arm Rubber tracks Steel tracks (450width)
kN
Lift point radius (m) (ton) Lift point radius (ft) 1000 lb
MIN. 3 4 5 MAX. MIN. 6 12 18 MAX.
14.2
+5 (1.45) 20
14.7 14.7 12.7
+4 (1.50) (1.50) (1.30) 16
Lift point height (m)
Lift Point Height (ft)

22.6 21.1 17.7 15.7 11.3
+3 (2.30) (2.15) (1.80) (1.60) (1.15) 12 3.6 3.1 2.7
38.2 32.4 21.6 15.2 10.3

+2 (3.90) (3.30) (2.20) (1.55) (1.05) 8 4.9 3.0 2.4
27.5 31.4 20.1 14.7 10.3

+1 (2.80) (3.20) (2.05) (1.50) (1.05) 4 5.3 2.9 2.3
19.1 30.4 19.6 14.2 10.3

0 (1.95) (3.10) (2.00) (1.45) (1.05) 0 5.0 2.8 2.3
18.6 29.9 19.1 13.7 11.3

-1 (1.90) (3.05) (1.95) (1.40) (1.15) -4 4.7 7.8 4.9 2.7 2.6
27.0 30.4 19.1 13.7 13.7

-2 (2.75) (3.10) (1.95) (1.40) (1.40) -8 11.1 11.6 5.0
49.5 23.5 15.7

-3 (5.05) (2.40) (1.60) -12
Over-front (Blade up) Over-front (Blade up)
kN
MIN. 3 4 5 MAX. MIN. 6 12 18 MAX.
14.2
+5 (1.45) 20
14.7 14.7 15.2
+4 (1.50) (1.50) (1.55) 16
22.6 21.1 17.7 15.7 15.2

+3 (2.30) (2.15) (1.80) (1.60) (1.55) 12 3.6 3.4 3.4
38.2 32.4 22.1 17.7 15.2

+2 (3.90) (3.30) (2.25) (1.80) (1.55) 8 4.9 3.6 3.4
27.5 40.2 26.0 19.6 15.7

+1 (2.80) (4.10) (2.65) (2.00) (1.60) 4 6.4 4.0 3.5
19.1 41.7 27.9 20.6 15.7

0 (1.95) (4.25) (2.85) (2.10) (1.60) 0 7.1 4.2 3.6
18.6 39.2 27.5 20.1 16.2

-1 (1.90) (4.00) (2.80) (2.05) (1.65) -4 4.7 7.8 6.8 3.9 3.7
27.0 33.8 24.0 17.2 16.7

-2 (2.75) (3.45) (2.45) (1.75) (1.70) -8 11.1 11.6 5.4
49.5 23.5 15.7

-3 (5.05) (2.40) (1.60) -12
Over-front (Blade down) Over-front (Blade down)
kN
MIN. 3 4 5 MAX. MIN. 6 12 18 MAX.
14.2
+5 (1.45) 20
14.7 12.3 9.8
+4 (1.50) (1.25) (1.00) 16
22.6 21.1 17.2 12.3 8.8

+3 (2.30) (2.15) (1.75) (1.25) (0.90) 12 3.6 2.4 2.1
28.9 25.0 16.2 11.8 7.8

+2 (2.95) (2.55) (1.65) (1.20) (0.80) 8 4.3 2.3 1.8
25.5 22.6 15.2 10.8 7.8

+1 (2.60) (2.30) (1.55) (1.10) (0.80) 4 3.9 2.2 1.7
19.1 21.6 14.2 10.3 7.8

0 (1.95) (2.20) (1.45) (1.05) (0.80) 0 3.7 2.1 1.8
18.6 21.6 14.2 10.3 8.3

-1 (1.90) (2.20) (1.45) (1.05) (0.85) -4 4.7 7.8 3.6 2.0 2.0
27.0 21.6 14.2 10.3 10.3

-2 (2.75) (2.20) (1.45) (1.05) (1.05) -8 11.1 11.6 3.6
49.5 22.1 14.7

-3 (5.05) (2.25) (1.50) -12
Over-side Over-side
II-7
KX080-3AB
2100 Arm Steel tracks (600width)t
kN
MIN. 3 4 5 MAX. MIN. 6 12 18 MAX.
14.2
+5 (1.45) 20
14.7 14.7 13.2
+4 (1.50) (1.50) (1.35) 16

22.6 21.1 17.7 15.7 11.8

+3 (2.30) (2.15) (1.80) (1.60) (1.20) 12 3.6 3.1 2.8
38.2 32.4 22.1 15.7 10.8

+2 (3.90) (3.30) (2.25) (1.60) (1.10) 8 4.9 3.1 2.5
27.5 32.4 20.6 14.7 10.3

+1 (2.80) (3.30) (2.10) (1.50) (1.05) 4 5.4 2.9 2.4
19.1 31.4 20.1 14.2 10.8

0 (1.95) (3.20) (2.05) (1.45) (1.10) 0 5.1 2.8 2.4
18.6 30.9 19.6 14.2 11.8

-1 (1.90) (3.15) (2.00) (1.45) (1.20) -4 4.7 7.8 5.0 2.8 2.7
27.0 31.4 19.6 14.2 13.7

-2 (2.75) (3.20) (2.00) (1.45) (1.40) -8 11.1 11.6 5.1
49.5 23.5 15.7

-3 (5.05) (2.40) (1.60) -12
Over-front (Blade up) Over-front (Blade up)
kN
MIN. 3 4 5 MAX. MIN. 6 12 18 MAX.
14.2
+5 (1.45) 20
14.7 14.7 15.2
+4 (1.50) (1.50) (1.55) 16
22.6 21.1 17.7 15.7 15.2

+3 (2.30) (2.15) (1.80) (1.60) (1.55) 12 3.6 3.4 3.4
38.2 32.4 22.1 17.7 15.2

+2 (3.90) (3.30) (2.25) (1.80) (1.55) 8 4.9 3.6 3.4
27.5 40.2 26.0 19.6 15.7

+1 (2.80) (4.10) (2.65) (2.00) (1.60) 4 6.4 4.0 3.5
19.1 41.7 27.9 20.6 15.7

0 (1.95) (4.25) (2.85) (2.10) (1.60) 0 7.1 4.2 3.6
18.6 39.2 27.5 20.1 16.2

-1 (1.90) (4.00) (2.80) (2.05) (1.65) -4 4.7 7.8 6.8 3.9 3.7
27.0 33.8 24.0 17.2 16.7

-2 (2.75) (3.45) (2.45) (1.75) (1.70) -8 11.1 11.6 5.4
49.5 23.5 15.7

-3 (5.05) (2.40) (1.60) -12
Over-front (Blade down) Over-front (Blade down)
kN
MIN. 3 4 5 MAX. MIN. 6 12 18 MAX.
14.2
+5 (1.45) 20
14.7 12.7 10.3
+4 (1.50) (1.30) (1.05) 16
22.6 21.1 17.7 12.3 8.8

+3 (2.30) (2.15) (1.80) (1.25) (0.90) 12 3.6 2.4 2.2
29.4 25.5 16.7 11.8 8.3

+2 (3.00) (2.60) (1.70) (1.20) (0.85) 8 4.4 2.4 1.9
26.0 23.0 15.7 11.3 7.8

+1 (2.65) (2.35) (1.60) (1.15) (0.80) 4 4.0 2.2 1.8
19.1 22.1 14.7 10.8 8.3

0 (1.95) (2.25) (1.50) (1.10) (0.85) 0 3.8 2.1 1.8
18.6 22.1 14.2 10.8 8.8

-1 (1.90) (2.25) (1.45) (1.10) (0.90) -4 4.7 7.8 3.7 2.1 2.0
27.0 22.1 14.7 10.8 10.3

-2 (2.75) (2.25) (1.50) (1.10) (1.05) -8 11.1 11.6 3.7
49.5 23.0 15.2

-3 (5.05) (2.35) (1.55) -12
Over-side Over-side
II-8
d) Quality Specifications
KX080-3α: KE, KUK, KBM version, KX080-3AB: KTC, KCL, KTA version
Machine specification: Auxiliary port, Wrist rest, Japan-cab, KBM-bucket, Rubber track, Heavy weight (1040 kgf, 2293 lbs),
No Specifications Items Unit KX080-3α/KX080-3AB Remarks
Q1 Main Speed JIS A8404 Arm=2100mm (82.7in.) Arm=1750mm (68.9in.)
1 1 Machine size mm 6410 ± 128 6365 ± 127
Total length (Transport)
inch 252.4 ± 5.0 250.5 ± 5.0
2 mm 2200 ± 22 ←
Total width
inch 86.6 ± 0.9 ←
3 mm - - Include grouser height
Total height (Canopy)
inch - -
4 mm 2540 ± 25 ←
Total height (Cabin)
inch 100.0 ± 25 ←
2 1 Weight kg - - Fuel tank: Full
Machine weight (Canopy)
lbs - -
2 kg 8326 ± 159 8306 ± 166
Machine weight (Cabin)
lbs 18356 ± 350 18312 ± 366
3 1 Performance L rpm 9.5 ± 1.0 ←
Swivel speed
2 R rpm 9.5 ± 1.0 ←
3 Rubber km/h 2.7 ± 0.3 ← Traveling stance:
F1 Engine Max.speed
mph 1.68 ± 0.19 ← Oil temp.: 50±5°C (122±9°F)
4 Rubber km/h 4.7 ± 0.5 ←
F2 mph 2.92 ± 0.31 ←
Travel speed
5 km/h 2.5 ± 0.3 ←
Iron F1
mph 1.55 ± 0.19 ←
6 km/h 4.5 ± 0.5 ←
Iron F2
mph 2.80 ± 0.31 ←
7 Gradeability deg 30 ←
4 1 Rear end min. turning radius mm 1460 ± 28 ←
inch 57.5 ± 1.1 ←
2 Swivel frame rear ground clearance mm 728 ± 15 ←
inch 28.7 ± 0.6 ←
3 Tumbler center distance mm 2296 ± 69 ←
inch 90.4 ± 2.7 ←
4 Crawler total length mm 2898 ± 87 ←
inch 114.1 ± 3.4 ←
5 Crawler total width mm 2200 ± 44 ←
inch 86.6 ± 1.7 ←
6 Min. ground clearance mm 386 ± 12 ←
inch 15.2 ± 0.5 ←
II-9

Arm=2100mm (82.7in.) Arm=1750mm (68.9in.)
5 1 Front attachment m3 ± ±
CECE 3
Bucket yd ± ±
heaped
2 capacity m3 0.162 ± 0.006 ←
SAE, JIS Slope angle: 1x1
yd3 0.216 ± 0.008 ←
2 m3 0.230 ± 0.009 ←
Bucket struck capacity 3
yd 0.307 ± 0.012 ←
3 mm 700 ± 14 ←
Bucket width Without side cutter
inch 27.6 ± 0.6 ←
4 Canopy L deg - -
5 Canopy R deg - -
Swing angle
6 Cabin L deg 67 ± 2 ←
7 Cabin R deg 60 ± 2 ←
8 mm 7332 ± 110 7007 ± 105
Max. digging radius
inch 288.7 ± 4.3 275.9 ± 4.1
9 Ground level Max. mm 7173 ± 108 6839 ± 103
digging radius inch 282.4 ± 4.3 269.3 ± 4.1
10 Ground level Min. mm 2091 ± 42 2312 ± 46
Bucket bottom horizontal
finish radius inch 82.3 ± 1.7 91.0 ± 1.8
11 mm 4602 ± 92 4252 ± 85
Max. digging depth
inch 181.2 ± 3.6 167.4 ± 3.4
12 Max. vertical digging mm 3674 ± 110 3507 ± 105
depth inch 144.6 ± 4.3 138.1 ± 4.1
13 mm - -
Canopy
Max. digging inch - -
14 height mm 7300 ± 146 7060 ± 141
Cabin
inch 287.4 ± 5.7 278.0 ± 5.6
15 mm - -
Canopy
Max. dump inch - -
16 height mm 5252 ± 105 5013 ± 100
Cabin
inch 206.8 ± 4.1 197.4 ± 3.9
17 mm - -
Canopy
Max. dump inch - -
height
18 (Arm vertical) mm 1774 ± 53 2114 ± 63
Cabin
inch 69.8 ± 2.1 83.2 ± 2.5
19 Front attachment mm - -
Canopy
Mini. turning inch - -
20 radius mm 2490 ± 75 2408 ± 72
Cabin
inch 98.0 ± 3.0 94.8 ± 2.8
21 mm - -
Canopy
Mini. turning inch - -
radius
22 (Left swing) mm 2050 ± 62 1922 ± 58
Cabin
inch 80.7 ± 2.4 75.7 ± 2.3
6 1 Blade mm 2200 ± 5 ←
Width
inch 86.6 ± 0.2 ←
2 mm 500 ± 10 ←
Height
inch 19.7 ± 0.4 ←
3 mm 491 ± 50 ←
Max. lift above GL
inch 19.3 ± 2.0 ←
4 mm 502 ± 50 ←
Max. down below GL
inch 19.8 ± 2.0 ←
II-10

Arm=2100mm (82.7in.) Arm=1750mm (68.9in.)
Q2 Main Specs JIS A8404
1 1 mm 40 Without shockless
Bucket tooth slaggish
inch 1.57 F=30 kgf (66 lbf)
2 mm 10 ←
Front boom lateral declination
inch 0.39 ←
3 mm 10 ←
Blade's lateral declination
inch 0.39 ←
2 1 Clearance between bucket crow and boom mm 199 ± 47 283 ± 19 From swivel center
cylinder cover inch 7.8 ± 1.85 11.1 ± 0.7
2 mm
(Min.value; reference)
inch
3 1 Approach angle deg 32 ± 3 ←
4 1 Crawler height mm 602 ± 12 ← Include grouser on the
spocket
inch 23.70 ± 0.47 ←
2 Max. crawler height mm 634 ± 13 ←
inch 24.96 ± 0.51 ←
Q3 Engine performance
1 1 Max, engine rpm no load rpm 2210 ←
2 1 pump relief rpm - -
3 2 pump relief rpm - -
4 3 pump relief rpm - - Boom, arm, swivel
5 2 pump relief rpm 2120 ←
6 Blade+2 pump relief rpm 2080 ←
2 1 Idling RPM Canopy rpm
2 Cabin rpm 1100 ± 50 ←
Q4 Travelling performance
1 1 Travel motor block L mm 0 0 20 deg. slope,
performance 10min engine stop.
inch 0 0 Hydraulic oil tempt: 50°±5°C
2 Travel motor block R mm 0 0
performance
inch 0 0
2 1 Max, Traction force F1 kgf 6633 ← KX080-3 F1: Slip. This value
is 70% of absolute traction
kN 65.0 ← force.
lbf 47976 ← KX080-3 F2: Relief. This value
is 60% of absolute traction
2 F2 kgf 6633 ← force.
kN 65.0 ← KX080-3α F1/F2: Slip. This
value is 70% of absolute
lbf 47976 ← traction force.
3 1 Travel straightness F1 mm 600 ← 10m distance
Engine Max. speed
inch 23.62 ←
2 F2 mm 600 ←
inch 23.62 ←
3 Blade F1 mm 600 ← Blade up & down 10m
distance
inch 23.62 ←
4 Blade R1 mm 600 ←
inch 23.62 ←
4 1 Track shoe sag Steel mm 40 - 55 ←
distance
inch 1.57 - 2.17 ←
2 Rubber mm 25 - 40 ←
inch 0.98 - 1.57 ←
II-11

Arm=2100mm (82.7in.) Arm=1750mm (68.9in.)
Q5 Work performance
1 1 Boom lifting capacity kgf 1534 2629, 2366 < Front end, Arm extend
bucket crowd, at tooth
kN 15.0 25.8, 23.2 <
lbf 3372 5799, 5216 <
1 2 Arm digging force kgf 3884 4396, 4182 < Bucket tooth root
kN 38.1 43.1 41 <
lbf 8565 9692, 9220 <
3 Bucket digging force kgf 6650 ← Machine stance to JIS
bucket tooth root
kN 65.2 ←
lbf 14657 ←
4 Blade force down kgf Cutting edge down force at
ground level
kN
lbf
2 1 Boom speed Canopy up 1st sec. - - Oil temp. 50±5°C (122±9°F)
Ground to max. height
2 up 2nd sec. - - (exclude cushioning)
3 down sec. - -
4 down sec. - -
5 Cabin up 1st sec. 3.4 ± 0.3 ←
6 up 2nd sec. - -
7 down sec. 3.6 ± 0.3 ←
8 down sec. - -
3 1 Arm speed crowd sec. 3.5 ± 0.3 ←
2 dump sec. 3.2 ± 0.3 ←
4 1 Bucket speed crowd sec. 3.1 ± 0.3 ← Oil temp. 50±5°C (122±9°F)
2 dump sec. 2.2 ± 0.3 ←
5 1 Blade speed up sec. ± ± Ground to max. up
2 up sec. 2.3 ± 0.3 ← Max. down to max. up
3 down sec. ± ± Max. up to ground
4 down sec. 3.0 ± 0.3 ← Max. up to max. down
6 1 Arm cylinder cavitation mm 5 > ← Oil temp. 95±5°C(203±9°F)
inch 0.20 > ← Engine speed: 1300 rpm
7 1 Max. digging height mm - -
radius Canopy
inch - -
2 mm 3388 ± 339 3132 ± 313
Cabin
inch 133.4 ± 13.4 123.3 ± 12.3
3 Max. dump height mm - - at bucket pin
radius Canopy
inch - -
4 mm 3260 ± 196 3004 ± 180
Cabin
inch 128.4 ± 7.7 118.3 ± 7.1
7 5 Bucket bottom height mm - - Bucket horizontal
at arm vertical Canopy
inch - -
6 mm 2271 ± 68 2612 ± 78
Cabin
inch 89.4 ± 2.7 102.8 ± 3.1
7 Bucket wrist angle deg. 178.6 +3.4,-2.6 ←
Q6 Swivel, swing performance
1 1 Swivel torque kgf.m 2104 ← Arm extend, Slow/Quick
operation
L kN.m 20.6 ←
ft.lbf 15218 ←
2 kgf.m 2104 ←
R kN.m 20.6 ←
ft.lbf 15218 ←
II-12

Arm=2100mm (82.7in.) Arm=1750mm (68.9in.)
2 1 Swivel capable slope angle L deg. 20 21 Bucket load=JIS heapedx1.8
2 R deg. 20 21
3 1 Swivel block deg. 0 ← Bucket loaded at heaped.
performance L Slope angle at 20°
Engine stop 1 min engine stop.
2 R deg. 0 ← Hydraulic oil tempt: 50°±5°C
3 Bucket loaded at heaped.
deg. 0 ←
Engine L Slope angle at 20°
1 min engine running.
4 running Lever lock released
R deg. 0 ←
Hydraulic oil tempt: 50°±5°C
4 1 Swivel start-up speed L sec. 2.9 ± 0.3 ← 0~90 deg. swivel
2 R sec. 2.9 ± 0.3 ←
5 1 Swing speed Canopy L sec. - -
2 R sec. - -
3 Cabin L sec. 7.5 ± 0.7 ←
4 R sec. 7.7 ± 0.7 ←
6 1 Swing Lock Swivel mm 10 > ← 90 deg-swivel, 100 times actual
R&L digging cylinder dislocation
inch 0.39 > ←
2 Reciprocating motion L / R Swing mm 90 deg-swivel,
inch 100 times
Q7 Hydraulic performance
1 1 Relief pressure setting P1 kgf/cm2 290 ± 5.0 ← At pump delivery
50±5°C(122±9°F)
MPa 28.4 ± 0.5 ←
bar 284 ± 5.0 ←
psi 4125 ± 71 ←
2 P2 kgf/cm2 290 ± 5.0 ←
MPa 28.4 ± 0.5 ←
bar 284 ± 5.0 ←
psi 4125 ± 71 ←
3 P3 kgf/cm2 220 ± 5.0 ←
MPa 21.6 ± 0.5 ←
bar 216 ± 5.0 ←
psi 3129 ± 71 ←
4 P4 kgf/cm2 40 ± 5.0 ←
MPa 3.9 ± 0.5 ←
bar 39.2 ± 5.0 ←
psi 569 ± 71 ←
2 1 Cylinder oil sealing Boom 50±5°C mm 20 ← Arm extend,
capacity (122±9°F) Bucket height 1m,
inch 0.79 ← 10 min.
2 mm 20 ← Bucket load=JIS heapedx1.8
95±5°C
(203±9°F) inch 0.79 ←
3 Arm 50±5°C mm 11 ←
(122±9°F) inch 0.43 ←
4 Bucket 50±5°C mm 10 ←
(122±°F) inch 0.39 ←
5 Blade 50±5°C mm 20 ← Arm vertical, blade cylinder
(122±9°F) inch 0.79 ← extended for 10 min. engine stop."
3 1 Boom cushioning 30°C Arm extended, bucket crowd
sec. 3 ←
performance (86°F) with no road. Engine Max.
speed."
2 50°C
sec. 0.4 - 1.3 ←
(122°F)
3 80°C
sec. 0.3 ←
(176°F)
4 Accumulator function time Waiting time for the boom to come down
50±5°C
(122±9°F) sec. 30 < ← to the ground after stopping the engine
with the boom up and the arm crowded.
II-13

Arm=2100mm (82.7in.) Arm=1750mm (68.9in.)
Q8 Lever operating force & stroke
1 1 Boom lever operating force UP kgf 1.3 -0.5,+0.5 ← Measuring point:
20 mm lower from the lever
N 12.7 -4.7,+5.3 ← top.
lbf 2.9 -1.1,+1.2 ← Pilot lever with engine Max.
speed.
2 down kgf 1.3 -0.5,+0.5 ←
N 12.7 -4.7,+5.3 ←
lbf 2.9 -1.1,+1.2 ←
1 3 Arm lever crowd kgf 1.3 -1.1,+2.1 ← Dump & crowd
N 12.7 -4.7,+5.3 ←
lbf 2.9 -1.1,+1.2 ←
4 dump kgf 1.3 -1.1,+2.1 ←
N 12.7 -4.7,+5.3 ←
lbf 2.9 -1.1,+1.2 ←
5 Bucket lever crowd kgf 1.0 -1.1,+2.1 ← Dump & crowd
N 9.8 -4.8,+5.2 ←
lbf 2.2 -1.1,+1.2 ←
6 dump kgf 1.0 -1.1,+2.1 ←
N 9.8 -4.8,+5.2 ←
lbf 2.2 -1.1,+1.2 ←
7 Swivel lever R kgf 1.0 -1.1,+2.1 ← Left & right
N 9.8 -4.8,+5.2 ←
lbf 2.2 -1.1,+1.2 ←
8 L kgf 1.0 -1.1,+2.1 ←
N 9.8 -4.8,+5.2 ←
lbf 2.2 -1.1,+1.2 ←
9 Blade lever up kgf 1.5 -0.5,+0.5 ← Up & down
Measuring point: 15 mm
N 14.7 -4.7,+5.3 ← lower from the lever top
lbf 3.3 -1.1,+1.2 ←
10 down kgf 2.5 -0.5,+0.6 ←
N 24.5 -4.5,+5.5 ←
lbf 5.5 -1.0,+1.2 ←
11 Travel lever L Forward kgf 1.8 -0.5,+0.6 ← Measuring point:
20 mm lower from the lever
N 17.7 -4.7,+5.3 ← top.
lbf 4.0 -1.0,+1.2 ←
12 Back kgf 1.8 -0.5,+0.6 ←
N 17.7 -4.7,+5.3 ←
lbf 4.0 -1.0,+1.2 ←
13 R Forward kgf 1.8 -0.5,+0.6 ←
N 17.7 -4.7,+5.3 ←
lbf 4.0 -1.0,+1.2 ←
14 Back kgf 1.8 -0.5,+0.6 ←
N 17.7 -4.7,+5.3 ←
lbf 4.0 -1.0,+1.2 ←
II-14

Arm=2100mm (82.7in.) Arm=1750mm (68.9in.)
1 15 Accelerator lever up kgf - - This machine has an accel
dial not a lever.
N - -
lbf - -
16 down kgf - -
N - -
lbf - -
17 Swing pedal R kgf 5.8 ± -1.0,+1.0 ← Pedal edge. 45 degree
inward
N 56.9 ± -9.9,+10.1 ←
lbf 12.8 ± -2.2,+2.3 ←
18 L kgf 5.8 ± -1.0,+1.1 ←
N 56.9 ± -9.9,+10.1 ←
lbf 12.8 ± -2.2,+2.3 ←
19 Safety lock lever R up kgf - - Up & down
N - -
lbf - -
20 down kgf - -
N - -
lbf - -
21 Safety lock lever L up kgf ± ± Up & down
N ± ±
lbf ± ±
22 down kgf ± ±
N ± ±
lbf ± ±
23 Travel Hi-Lo change kgf - - This machine has a switch
N - -
lbf - -
II-15

Arm=2100mm (82.7in.) Arm=1750mm (68.9in.)
2 1 Boom lever stroke up mm 78 ± 10 ←
inch 3.07 ± 0.39 ←
2 down mm 78 ± 10 ←
inch 3.07 ± 0.39 ←
3 Arm lever stroke crowd mm 78 ± 10 ←
inch 3.07 ± 0.39 ←
4 dump mm 78 ± 10 ←
inch 3.07 ± 0.39 ←
5 Bucket lever stroke crowd mm 78 ± 10 ←
inch 3.07 ± 0.39 ←
6 dump mm 78 ± 10 ←
inch 3.07 ± 0.39 ←
7 Swivel lever stroke R mm 78 ± 10 ←
inch 3.07 ± 0.39 ←
8 L mm 78 ± 10 ←
inch 3.07 ± 0.39 ←
9 Blade lever stroke up mm 73 ± 10 ←
inch 2.87 ± 0.39 ←
10 down mm 72 ± 10 ←
inch 2.83 ± 0.39 ←
11 Travel lever stroke L Forward mm 108 ± 10 ←
inch 4.25 ± 0.39 ←
12 Back mm 108 ± 10 ←
inch 4.25 ± 0.39 ←
13 R Forward mm 108 ± 10 ←
inch 4.25 ± 0.39 ←
14 Back mm 108 ± 10 ←
inch 4.25 ± 0.39 ←
Q9 Stability
1 1 Standard arm, Bucket load to Side, kgf.m - - Arm extend,
Dynamic operation 10 degrees blade up bucket crowd
load limit tipping N.m - - oil temp.50±5°C(122±9°F)
ft.lbf - -
2 Front, kgf.m - -
blade up
N.m - -
ft.lbf - -
3 Bucket load to Side, kgf.m -
tip fully blade up
N.m -
ft.lbf -
4 Front, kgf.m -
blade up
N.m -
ft.lbf -
5 Standard arm, static Side kgf.m 860 ← Front horizontal bucket
limited load crowd, load at arm tip end.
N.m 8434 ←
Bucket load to ft.lbf 6220 ←
6 tip fully Front kgf.m 1193 ←
N.m 11700 ←
ft.lbf 8629 ←
Q10 Comfortability
1 1 Noise level At operator's Canopy dB(A) - -
2 ear LPA Cabin dB(A) 75 , 77 > ← Cabin door close
3 Noise source; LWA 7m dB(A) 98 , 98.4 > ←
4 Sonic power level (JIS) dB(A)
II-16
(B) UNDERCARRIAGE: TRACK

1 2 3 (1)
a) Installation
Rubber track type
No. Part name
1 Idler assembly
2 Cylinder assembly
319mm(12.6inch)
25~40mm(1.0~1.6inch)
3 Spring assembly (rubber)
(3)
1 2 3 (2)
40~45mm(1.6~2.2inch)
334mm(13.1inch)
(4)
(Rubber track)
Iron track type

No. Part name
(1) Set the cotter pin into the hole inside.
(2) Set the cotter pin into the hole outside. 1 Idler assembly
(3) Rubber tr2ack 2 Cylinder assembly
(4) Iron track
3 Spring assembly (rubber)
(Iron track)
II-17
b) Rubber track
1. EU-version
Rubber track is identical to the KX080-3,
previous model.
(1) mark for indicating the overlap section.
(1)
2. KTC, KCL, KTA-version

SP-type rubber track
SP: Spiral
(1) Lug pattern is slightly different from the

conventional rubber track.
(2) As the overlap section dose not exist in SP-

type rubber tracks, there is no mark.
II-18
c) Comparison list and Interchangeability

Minor change: KX080-3α, KX080-3AB
Conventional model:
Rubber track KX080-3 From first unit
First 3 units only
in mass production
Part code RD809-22311 RD819-22311 RD819-22312
Part name Crawler (rubber) Crawler (rubber) Crawler (rubber)
Overlap type Overlap type
Structure Overlap type Weight increased Weight increased
(+25 kg/pc.) (+25 kg/pc.)
Europe-destined
mark Provided Provided Provided
Core Casting Casting (reinforced type) Casting (reinforced type)
Different from current one
Lug pattern - Same as current one (Same as with North
America-destined one)
Part code RD809-22311 RD819-22321
Part name Crawler (rubber) Crawler (rubber, SP)
North America- & Structure Overlap type Spiral type

Australia-destined mark Provided None
Core Casting Forging
Lug pattern - Different from current one
Note:
• Three different types (RD809-22311, RD819-22312 and RD819-22321) are all available. (BS)
(RD819-22311 is not available.)
• This rubber track modification has been designed to conform with the upgrade of the travel motor’s traction force.
Interchangeability
X
O
RD809-22311 X RD819-22311 X RD809-22312

Crawler (rubber) O Crawler (rubber) O Crawler (rubber)
X X X
RD809-22321
Crawler (rubber, SP) O: Interchangeable
X: Not interchangeable
II-19
d) FYI (For Your Information)

New Introduction of Spiral Rubber Track
Note: This SP-type rubber track is mounted on PP-version machines.
Major Improvements in Cutting and External Damage Resistances
1. Spiral steel cord
A single steel cord is coiled in spiral form

Steel cord construction
to get rid of conventional overlapping joint.
Current rubber crawler Tough track Thanks to the newly developed spiral
Overlap Spiral construction, the rubber track is free of
rigidity variations and better in fatigue-
from-flexing resistance. In this design, the
cutting problem can be greatly reduced,
which dramatically enhances the travel
durability of rubber tracks.
2. Stainless steel cord
With the stainless steel cord introduced,

Stainless steel cord evaluation
the strength degradation due to steel cord
corrosion is suppressed by 40%. The
Conventional Stainless steel cord
rubber track breakage from such cause
can be drastically cut down.
(2)
(1) If one of the cords gets corroded, the other
cords will also become eaten away.
(2) Rubber is sandwiched between the cords.
Even if one of the cords gets corroded, the
(1) other cords will not be affected.
Improvements in steel cord corrosion resistance

<7-day salt spray exposure test results>
Single-cord strength
retention factor (%)
Current cord
Stainless cord
Exposure days
II-20
3. Core configuration against core end cracks
The core ends have been rounded instead

FEM analysis of core configuration and its ends
of the straight form. This configuration has
been researched and developed to
Core configuration effectively deconcentrate and absorb
Current rubber crawler Tough track loads when the machine runs on the curb
or the like. FEM analysis reveals that the
pressure upon the core ends can be
dispersed through their roundness. The
durability against cracks that would occur
when running on the curb or the like can
therefore be improved more than 400%.
FEM analysis of core ends What’s more, external damages, such as
Tough track
edge damage, can also be cut down.
Current rubber crawler
FEM: Finite Element Method
4. New-type lug pattern and upgraded rubber

The new-type lug is up 20% in volume and upgraded in rubber quality. These improvements help
suppress external damages on the lugs, lessen wear and noticeably prolong the travel endurance
time. This also provides for comfortable ride with low vibrations.
FEM analysis: Finite Element Method analysis
The finite element method (FEM) (sometimes referred to as finite element analysis) is a numerical
technique for find approximate solutions of partial differential equations (PDE) as well as of integral
equations.
The Finite Element Method is a good choice for solving partial differential equations over complex
domains (like cars and oil pipelines), when the domain changes (as during a solid state reaction with a
moving boundary), when the desired precision varies over the entire domain, or when the solution
lacks smoothness.
The finite-element method originated from the needs for solving complex elasticity, structural analysis
problems in civil and aeronautical engineering.
In summary, virtual prototyping, fewer hardware prototypes, a faster and less expensive design cycle,
increased productivity, and increased revenue.
II-21
e) Iron Track
Shoe bolt tightening torque:
245 ± 25 N·m (25 ± 2.5kgf·m) 180.8 ± 18.1 ft·lbs
Standard 450 mm (17.7 in.) RD819-22201

Iron track
Wide 600mm (23.6 in) RD819-22401
(1) Link assy

(2) Shoe bolt
(3) Shue nut
(4) Shoe L=450
II-22
f) Iron Track Installation

f-1 Removing the old pin
1. Installation jig set
(1) Track pin

(2) Master pin
(2)
(1)
2. Attach the jig (1) on the outside of the track.
3. The outside jig (1) attached.
II-23
4. Attach the jig (2) on the inside of the track.
5. Insert the jig pin(4) (133L).
6. Install the jig (90L).

Hammer in the master pin or track pin.
If the pin weren’t come out, even with
hammering, take out the jig pin with a
magnet and check the jig center (90L)
alignment of jig (1) jig (2), and the track link.
(10) Magnet
(10)
II-24
7. Insert the long pin.

After the short pin jig (90L) (6) reached to
its end, replace with the long pin jig (189L)
(5).
8. Hammer in the old master pin or track pin.
9. The old pin is coming out.
II-25
f-2 Installing the new pin

1. Insert the jig pin (4) (133L) into the track
link.
This process is just for joining the track link
tentatively.
As the diameter of the jig pin (4) is 23.5
mm, it should be easy to insert by hand.
2. Set the jig (1) and the jig (2) with spring (7)
and plate (3).
3. Insert the master pin or link pin upon your

need.
Insert the jig pin (6) (90L)
Hammer in the pin to its end.
4. Take out the spring (7) after removing the

plate (3).
Replace the jig (5) (189L)
Hammer in the pin to its end.
II-26
f-3 Replacement of shoe plate

1. Removing the shoe bolts.
+25 +2.5
Tightening torque: 245 - 25 N·m (25 - 2.5 Kgf·m)
+18
181 - 18 ft·lbs
(1) Track pin

(2) Master pin
(1) (2)
f-4 Track link and pins

(1) Dust seal
(2) O-rings
(2) (1)
II-27
g) How to Use Jigs to Install Pins

1. Necessary jigs for removing & assembling the master pin / track pin
1 Jig (1)
2 Jig (2)
3 Plate
4 Pin (133L)
133
5 Jig (189L)
189
6 Jig (90L)
90
7 Spring
144
8 01133-61225 Bolt
x4
9 01774-51025 Flange bolt

x2
II-28
2. Jig drawing
1 Jig (1)
[Unit: mm]
Only 3 through thread.
Flame hardening
AT P-part
Surface hardness 45 HRC
Hardness
Material
229~269HB
Plating whole around Plating Ep-Fe/ Zn5/CMS

Plating whole around Plating Ep-Fe/ Zn5/CM2
Note:
1 No burrs at any corner.
2 Dimensions in the remarks below are your reference.
(Strict process control points for welding the member 2)
3 Use a solid wire for welding and make second layer beam immediately. Do slow-cooling to
avoid welding cracks. Make sure hardness on heat affected part must be below HV500.
II-29
2 Jig (2)
No excess welding
bead on this surface.
Only 3 through thread.

Note:
1. No burr at each corner.
2. Dimensions in the remarks are for your reference.
3 Plate

Note:
[Unit: mm]
II-30
4 Pin (133L)
Bright heat treatment

Whole (quenching and tempering)
Hardness 37~44HBC

Note:
5 Jig (189L)
Bright heat treatment

Hardness 37~44HBC

Note:
II-31
6 Jig (90L)
Bright heat treatment Note:

Hardness 37~44HBC

7 Spring
Note:
No. Specifications of Compression Spring

1 Coil wire diameter (mm) ø2.9
2 Coil average center diameter (mm) ø20
3 Total winding number 25
4 Effective winding number 25
5 End spring seat winding number 0
6 Winding direction clockwise
7 Free length (mm) 144
8 Length at setting (mm) (Free length) 144
9 At max. Length (mm) 109
10 setting Load (N) 106
11 condition Stress (N/mm2) 271
12 Fully compressed length (mm) 75.4
13 Spring constant (N/mm) 3.04
II-32
3. Dimensions of shoe plate and jig installation

(1) Shoe plate 450 mm width
1 8
190
(1)
350
450
133
125
A A
150
33.5
2 3 9 8
A–A
(2) Shoe plate 600 mm width
1 8
190
(1)
400
600
133
125
A A
150
33.5
2 3 9 8
II-33
4. Removing procedure for master pin / track pin

133
(1) Master pin / track
(1) pin
(2) (2) Shoe plate
A
600
B
8
1) Install the jig (1) 1 temporarily onto the shoe plate.

2) Fit position of the jig’s (1) 1 hole and the center of the master pin and tighten the bolt 8.
9 3 2
C
4) Tighten the plate 3 with the flange bolt 9.
4 37 6
5) Insert the pin (133L) 4.

6) Insert the jig (90L) 6.
7) Hammer in until the jig (90L) 6 touches the edge surface.

8) Use a large hammer 5.4 kg.
9) Pull out the jig (90L) 6.
II-34
99 5
10) Put the jig (189L) 5.
13) Remove all the jigs except the pin (133L) 4.

The pin (133L) 4 is one of the jigs.
14) Completed.
(1) Track pin

(2) Master pin
(1) (2)
II-35
5. Installation procedure for master pin / track pin

(1) Track link / Mas-
(1) ter pin
133
(2) (2) Pin (133L) 4
4
(3) Shoe plate
(3)
a
600
b
8
1) Install the jig (1) 1 temporarily onto the shoe plate.

7
9 3 2
c
3) Fit position of the jig’s (2) 2 hole and the center of the master pin (133L) and tighten the bolt 8.
4) Insert the spring 7 and tighten the plate 3 with the flange bolt 9.
(1) pin
37 6
5) Insert the master pin (1).


(4) Slide
f (4)
9) Pull out the jig (90L) 6.

10) Loosen the flange bolt 9, let the plate slide and remove the spring 7.
(Watch out for the spring’s jumping out)
11) Put the plate back to the original position and tighten the flange bolt 9.
II-36
99 5
13) Hammer in the jig (189L) 5 until it touches the edge surface.
133
(1) pin
15) Remove all the jigs.

16) Completed.
II-37
II-38
WSM KX080-3AB Mechanism III ENGINE
III. ENGINE
Mechanism Section
(A) NEW EMISSIONS CONTROL ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-M-3

a) Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-M-3
b) Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-M-4
c) Engine Electric Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-M-5
d) Performance Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-M-6
III-M-1
III-M-2
(A) NEW EMISSIONS CONTROL ENGINE

a) Outline
Tier 4 and Interim Tier 4 Engines for North American Market and Stage III A Engines for EU requirements
have been launched and mounted on Kubota Construction Machinery.
FEATURES and BENEFITS

Emissions
• Kubota Super Mini Series, the most compact multi-cylinder liquid cooled industrial diesel engines, com-
plies with EPA Tier 4 emissions regulations. These are the most stringent emissions regulations in the
world in this class.
• The 03-M Series engine complies with EPA Interim Tier 4 emissions regulations that are effective
through the end of 2012. This engine also complies with EU Stage III A requirements that are effective
through 2012 and beyond in the European market.
Durable Power
• The Kubota Super Mini Series has been chosen as a power source for a variety of applications since it
was first launched 25 years ago. It has become the benchmark in the compact diesel engine market.
• The D722 engine offers a seamless transition from Tier 2 to Tier 4 by totally maintaining the same perfor-
mance and physical characteristics of the previous Tier 2 engines.
• The Kubota 03-M Series is well recognized for industrial applications. With numerous features such as a
built-in solenoid, low fan position, and single side serviceability, this engine offers excellent performance
characteristics and application flexibility.
• The cooling water passages between the cylinder bores, using Kubota's original casting technology as a
countermeasure against heat load of high power density, provides both superior endurance and reliable
engine characteristics.
• The 03-M engine offers a seamless transition from Tier 2 to Interim Tier 4 by maintaining the same foot-
print and hard mounting points with only slight performance changes from the Tier 2 engine.
Clean and Quiet Power

• Kubota's original E-TVCS (Three Vortex Combustion System) has been improved. The airflow, combus-
tion chamber and piston recess were optimized to provide a 50% lower particulate matter (PM) level, the
same stringent level as above the 37kW class (EPA Interim Tier 4 Option 1).
• The half-float valve cover and MoS2 coated pistons lower noise levels by 1.0-2.0 dBA over conventional
diesel engines and provide reduced transmitted vibration from the valve area for better noise character-
istics.
III-M-3
b) Engine Specifications
Machine Model KX080-3AB Remarks
Engine Type V3307-DI-T-E3-BH
Engine Code No. 1J750-00000
No. of cylinder 4
mm 94 x 120
Bore x Stroke
in 3.70 x 4.72
cc 3331
Displacement
in3 203.27
SAE, Gross kW (HP) 52.2 (70.0)
Engine Output/Rated rpm
SAE, Net kW (HP) 50.2 (67.3)
Compression ratio 20
Max. torque N·m/rpm 267/1400

SAE 1349 Gross kgf·m/rpm 27.2/1400
(ISO3046-1) ft·lbf/rpm 197/1400
mm 787 x 553 x 747
Dimensions: LxWxH
in. 31.0 x 21.8 x 29.4
kgf 293
Dry weight
lbs 646
mm 0.13 - 0.17
Valve clearance
in. 0.0051 - 0.0067
Firing sequence 1-3-4-2
Mpa 3.73 - 3.92 / 2.90
Compression pressure
kgf/cm2 38 - 40 / 29.6
(A)/(B)
psi 540 - 569 / 421
Fuel injection timing rad (deg) 0.024 (1.4) After TDC
g/kWh 239
Fuel consumption ratio
g/PSh 176
(Engine unit only)
lbs/HPh 0.394
Fuel consumption amount l/h 13.4
(Fuel specific gravity =0.84, Load=100%) gal/h 3.54 239 x 47.2kW / 0.84
Max.speed without load rpm 2200
Speed with 2 pumps relief rpm 2120
Speed with idling rpm 1100+/-50
kPa 196 - 392 / 98
Engine oil pressure
kgf/cm2 2.0 - 4.0 / 1.0
with rated engine rpm
psi 28 - 57 / 14
MPa 18.6 / 22.6
Injection pressure
kgf/cm2 190 / 230
First/second injection
psi 2702 / 3278
Engine oil consumption ratio g/kWh 0.48
(Engine unit only) g/Psh 0.35
III-M-4
c) Engine Electric Components

Machine Model KX080-3AB Remarks
Fuel injection pump type Bosch P type mini-pump
Nozzle type Bosch P type
Mpa 18.6 / 22.6
Injection pressure kgf/cm2 190 / 230
psi 2702 / 3278
Dynomo 12V 960W
Manufacturer P/N 3R600-6401-0
Regulator adjusting voltage V 14.4 -15
Battery type 130E41R
Nominal capacity of 5hrs rating Ah 92
Specific gravity of electrolite 1.28
Starter motor 12V 2.7kW
Manufacturer P/N 1G524-6301-0
Glow plug Ω 0.95
III-M-5
d) Performance Curve
J V3307-DI-TE3-BH SAE J1995
ISO 3046-1 SAE J1349
Torque [N·m]
Engine output [kW]
Fuel consumption
ratio [g/kW·h]
Engine RPM [rpm]
III-M-6
WSM KX080-3AB Service III ENGINE
III. ENGINE
Service Section
(A) TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-3

(B) SERVICEING SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-4
(C) DISASSEMBLE AND REASSMBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-5
a) Pump Coupling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-5
b) Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-7
c) Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-10
d) Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-12
e) Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-14
f) Fuel Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-17
g) Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-21
h) Control Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-22
i) Fan Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-23
j) Engine Stop Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-24
k) Engine Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-25
l) Engine Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-27
m) Turbo Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-31
n) Engine Oil Cooler and Turbo Charger Lubrication Line . . . . . . . . . . . . . . . . . . . . . III-S-33
(D) ENGINE WSM (V3307-DI-T-E3B). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-35

• To the Reader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-37
• MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-M-45
• GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-G-67
• SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-115
III-S-1
III-S-2
(A) TROUBLESHOOTING
Refer to the following Engine WSM
III-S-3
(B) SERVICEING SPECIFICATIONS

Refer to the following Engine WSM
III-S-4
(C) DISASSEMBLE AND REASSMBLE

a) Pump Coupling
1. Disconnect the hoses and fit the plugs.
2. Hang the hydraulic pump with nylon

sling.
3. Dismount the pump assy.
4. Pump housing.
5. Pump coupling.
III-S-5
6. When reassembling
1) Applying grease to the spline
(1) Apply a proper amount of grease.
(Be careful not to allow it overflow.)
(2)
Be careful to keep the rubber free of grease.
Wipe off grease immediately, if on the rubber.
2) Fitting sequence of the coupling A

(A): Tighten up first.
*Set the coupling to the spring pin (a) and
(3)
tighten up.
(B): Tighten up second.

*Set the coupling to the spring pin (b) and
tighten up.
Tightening torque
210~230N.m (21.4~23.5kgf.m) 154.9~169.6ft.lbs
* Do not apply screw adhesive.
(1) Housing (pump)

(2) Coupling
(3) Apply grease to the spline.
(4) Parallel pin
III-S-6
b) Radiator
1. Overall view
(3) (1) Receiver

(2) (2) Condenser
(4) (1)
(3) Oil cooler (Hydraulic system)
(4) Radiator
(5) Oil cooler (Engine oil)
III-S-7
3. Stretch (A) of the fan out of the shroud (fan)

Around the fan
Reference dimension: 21 mm (0.83inch)
Minimum stretch: Over 15 mm (0.59inch)
Keep the entire stretch as small as possible.
4. Clearance (B) between fan and shroud (fan)

Around the fan
Reference dimension: 20 mm (0.79inch)
Minimum clearance: Over 16 mm (0.63inch)
Keep the entire clearance as small as possible.
5. Install the rubber (radiator mount) to the bracket.

Place the rubber's claws tight into position
.
(1)
(2) (3)
Over 16(0.63in)
Over 15(0.59in.)
430(16.9in.)
(4)
(1) Rubber (radiator mount)

(2) Make sure the claws are tight in their mating parts.
(3) Trim (625)
(4) Trim (430)
III-S-8
No. Part name Q'ty

1 Radiator assembly 1
2 Shroud (fan) 1
3 Cover (fan) 1
4 Bracket (1, oil cooler) 1
5 Bracket (2, oil cooler) 1
6 Rubber (radiator mount) 4
7 Hose (upper, WP) 1
8 Hose (lower, WP) 1
9 Base (drain) 1
10 Plug 1
11 Rubber-fitted washer 1
12 Hose (drain, 1) 1
13 Hose (drain, 2) 1
(1)
(2)
(3)
(1) Hose clamp (screw-in type 60)

(2) Hose clamp (screw-in type 14)
(3) Hose clamp (screw-in type)
III-S-9
c) Air Cleaner
1. Overall view, engine room.
(1) Air cleaner assy.
2. Air cleaner assy
3. Inlet hoses
4. Double elements
III-S-10
5. Laying the hose (1, inlet)
See the figure.

(2)(3)(4) (5)(6)(7)(8)
(1)
(9)(10)
(1) Bolt
(2) Hose (2, inlet)
(3) Hose clamp (66-88)
(4) Hose clip (58-75)
(5) Hose (1, inlet)
(6) Hose clip (58-75)
(7) Hose (3, inlet)
(8) Hose clip (58-75)
(9) Hose (3, inlet)
(10) Hose clip (58-75)
III-S-11
d) Muffler
1. Overall view
Note: After mounting the new muffler and starting

engine, some smoke may come out from the
engine room.
This smoke is resulted from the initial
burning of bandage around the muffler pipe.
III-S-12
2. Tightening the flange (muffler) clamp

Tightening torque
3.9~5.9N.m (0.4~0.6kgf.m) 28.2~42.7ft.lbs
3. Ensuring the clearance at the pipe

(muffler) outlet
Clearance: Over 25 mm(1.0inch)
(A)
(A) Front
4. Tightening sequence
* (A): Tighten up first.
Tightening torque
39.2~45.1N.m (4.0~4.6kgf.m) 28.9~33.3ft.lbs
* (B): Tighten up second.
* (C): Tighten up second.
Tightening torque
48.1~55.9N.m (4.9~5.7kgf.m) 35.5~41.2ft.lbs
* (D): Tighten up third.
* (E): Tighten up fourth.
(1) (2)(3)(4)(5)
(6) (7)
(8)
A
D B
(9) E
(1) Muffler assembly
(2) Cover (muffler)
(3) Bolt
(4) Plain washer
(5) Thermal insulation
(muffler cover)
(6) Flange (muffler)
(7) Face b
(8) Face c
(9) Face d
III-S-13
e) Fuel Tank
(3)(4) (1)(2)
(5)
(6)
(a)
1. Fitting the sensor assembly (fuel) (RD809-5114Δ)

Tightening torque
3~4N.m(0.3~0.4kgf.m)2.2~3.0ft.lbs
(7) Position the assembly so that the connector

(A)
socket faces the machine front.
2. Fitting the sensor assembly (fuel filler) (RD809-

5138Δ) and gauge (fuel) (RD809-5112Δ)
Do not force them into position. Apply some
(B)
cleaning agent for smooth fitting.
3. Fitting direction of the gauge (fuel) (RD809-5112Δ)

(1) Washer-fitted elbow
(2) O ring (P18) Position the gauge as shown at left. (F mark to
(3) Sensor assembly (fuel) face the machine front)
(4) Washer-fitted machine screw
(5) Sensor assembly (fuel filler)
(No specified fitting direction) 4. Fitting the cock (drain) (RD809-5125Δ)
(6) Gauge (fuel)
(7) Cock (drain) Position the cock as shown at left. (Drain port to
face downward)
(a) Connector socket direction (to face the machine front) After being fitted, close the cock.
(A) View A: Gauge (fuel) fitting direction
(B) Machine front
III-S-14
(1)(2)(3)
5. Fitting the washer-fitted elbow (68881-6446Δ)
Position the elbow as shown at left.
Note: Be careful not to confuse the O ring (fuel)
setup.
(Part code of O ring)
RD809-5128Δ
O ring (P18)
6. Adaptor tightening torque

G1/2 size
58.8~63.7N.m (6.0~6.5kgf.m) 43.4~47.0ft.lbs
7. Tightening the band assembly (fuel tank)

Shake the tank by hand and make sure it does
not wobble.
(4)
8. Fitting the plate assembly (fuel)

Tighten the assembly while holding the tank in
position.
Tightening torque
48.1~55.9N.m (4.9~5.7kgf.m) 35.5~41.2ft.lbs
(1) Band assembly (fuel tank)

(2) Plain washer
(3) Nut
(4) Plate assembly (fuel)
III-S-15
9. Attaching the cushions

(1) Attach the cushions as shown in the figure.
* Wipe clean the cushions beforehand.
(1) Cushion (9, fuel tank)

* (2) To be attached along this line
(5) Band assembly (fuel tank)
(6) Plain washer
(7) Bolt
(3) (11) Cushion (6, fuel tank)
(5)(6)(7)
(4)
(8)
(9)
(10)
(11)
III-S-16
f) Fuel Hose
Fuel tube Fuel tube length Protective tube length
1. Routing condition
A 800mm(31.5in.) 705mm(27.8in.)
Make sure the hoses are out of contact with
B 400mm(15.7in.) 300mm(11.8in.) sharp edges, hot zones and moving parts.
1650mm(65.0in.)
Do not clamp the fuel hose and electrical cable
C 1700mm(66.9in.)
together.
D 200mm(7.9in.) 150mm(5.9in.) See if the hoses are not too tight or locally
E 440mm(17.3in.) 350mm(13.8in.) sagging.
Be careful not to affect the hose diameter.
1450mm(57.1in.)
F 3800mm(149.6in.)
2100mm(82.7in.)
2. Installing the protective tubes
Strictly observe the dimensions specified in the
figure.
(1) Fuel tank

(2) Fuel assembly separator
(3) Fuel pump
(4) Fuel filter assembly
(5) Engine
Hose clamp (6) T joint (fuel filter assembly)
14911-4275Δ
Pipe clip
14971-4275Δ
Pipe clip
(1) (2) (4)

(3)
15(0.59in.)
25(1.0n.)
45(1.8in.) 45(1.8in.) 50(2.0in.) 50(2.0in.) 25(1.0n.) 25(1.0n.)
10(0.39in.) 45(1.8in.) 45(1.8in.)
25(1.0n.)
(6) (5)
III-S-17
3. Routes of the fuel feed and return hoses
(1)
(2)
(3)
(4)
(5)
(6) TO-Y490R-ADIATOR DŠë
AŒ¯
NC Rh’?
G?A
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A
EW e,nT‚v?@
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U h‚¯eIˆÓ
or‚é
tO‚È
p?B
N
en P
A
6-G
F30
0125-601
(7)
(8) ‚n
‚h
‚k
(15)
(12)
(14)
(13)
(9)
(10)
(16)
(11)
(17)
(1) Machine rear side

(2) Filter assembly (fuel)
(3) Fuel return hose
(4) Pass the fuel return hose below the fuel feed hose and
the engine’s injection pipe.
Then connect it to the engine.
(5) (Engine)
(6) Pump assembly (fuel)
(7) Pass the fuel return hose outside of the pump assembly
(fuel) (RD411-5135Δ), as shown in the figure.
Note: Lay the fuel return hose out of contact with the
pump.
(8) (Partition board)
(9) Pass through this notch of the partition board (RD809-
4153Δ).
(11) Fuel feed hose
(12) Filter assembly (separator)
(14) Fuel feed hose
(15) Lay the fuel return hose out of contact with the sensor
(fuel) connector.
(16) Pass through the oval hole of the swivel frame.
(17) (Battery mount of the swivel frame)
III-S-18
(1)
(5)
A-A A B
(6)
(2) (7)
(3) (8)
(4) (9)
(1) Cord band

(2) Pass both the fuel feed and return hoses through the
guide.
(3) Fuel feed hose
(6) Fuel feed hose
(7) Pass both the fuel feed and return hoses through the
guide.
(8) Fuel feed hose
III-S-19
(1)
(2)
(7)
(8)
(4) (9)
(5)
(6)
(1) Hose (1, fuel, filler)

(3) Swing hose
(4) Boom hose
(5) Hose (1, fuel, filler)
(7) Pump assembly (fuel, filler)
(8) Bolt
(9) Connect to the fuel tank.
III-S-20
g) Compressor
1. Fitting the bracket (compressor) and
(2)
bracket (pulley)
Fit the brackets in position as shown at left.
Tightening torque
17.7~20.6N.m (1.8~2.1kgf.m) 13.1~15.2ft.lbs
(1) M10
48.1~55.9N.m (4.9~5.7kgf.m) 35.5~41.2ft.lbs
2. Fitting the compressor

Fitting the bushing (compressor)
(3)
Fit the parts in position as shown at left.
Tighten the bolts from the pulley side first.
Set the bushing with its collar inside.
(5)
3. Tightening the bolts
(6) Tightening torque
17.7~20.6N.m (1.8~2.1kgf.m) 13.1~15.2ft.lbs
4. Adjusting the tension of V belt (FM59)

Adjust the tension at the arrow-marked position
as shown at left.
Belt deflection 12~15mm (0.47~0.59in.)
Pressing force
58.8~68.6N.m (6.0~7.0kgf.m) 43.4~50.6ft.lbs
5. Fitting the joint (heat takeout), pipe joint

(S, G1/4-G1/4), elbow joint (G4-13) and
(8) joint (water return) for the heater hoses
Fit the joints as shown at left.
Adaptor tightening torque
R3/8
68.6~73.5N.m (7.0~7.5kgf.m) 50.6~54.2ft.lbs
G1/4
24.5~29.4N.m (2.5~3.0kgf.m) 18.1~21.7ft.lbs
(7)
(4) (1) Tension pulley
Bolt
Bolt
(2) Joint (heat takeout)
Pipe joint (S, G1/4-G1/4)
O ring
Elbow joint (G4-13)
O ring
(3) Bracket (compressor)
Bolt
Bolt
(4) Bracket (pulley)
Bolt
Bolt
(5) Compressor
Bushing (compressor)
Bolt
Plain washer
(6) Details of A
(7) Joint (water return)
(9)
Elbow joint (G4-13)
O ring
(8) Check the compressor V belt tension here.
(9) V belt (FM59)
III-S-21
h) Control Cable
1. Connecting the cable (acceleration)
Connect the cable in the order as shown in the
figure.
2. Routing the cable (acceleration)

Lay the cable in the route as shown at left.
(6)
(1)
(7)
(3) (12)
(2) (8)
(4)
(13)
(9)
(10)
(5)
(11)
(15)
(16)
320
(14)
(17) (18)
(1) Connecting the cable (acceleration) (11) 3) Join the wire fixture and the cable together and
1) Install the wire fixture (36919-1033Δ) on the engine- tighten up the nut.
side acceleration lever. (12) Guide bar
(2) Wire fixture (13) Take the same route along the A/C hose in this arrow-
(3) Engine-side acceleration lever marked zone.
(4) Plain washer (14) Screw in until two threads or so (about 1 mm) stretch
Cotter pin out.
(5) 4) Connections and routing complete (15) A/C hose
(6) To AI motor (16) Pass the cable so that the sponge (EPDM material)
(7) Pass outside of the A/C hose. around the cable comes to these two guides (6 mm
(8) 2) Connect the cable’s outer adjuster along the near dia. round bars).
center of the bracket (acceleration cable). (17) A/C hose
(9) 32 (reference) (18) EPDM material (sponge)
(10) Cable (acceleration)
III-S-22
i) Fan Belt
1. Fitting the oil switch
Tightening the oil switch
Fit the oil switch in position as shown at left.
PT1/8 size
7.8~9.3N.m (0.8~0.95kgf.m) 5.8~6.9ft.lbs
2. Fitting the plate (clamp,2)

Fit the plate in position as shown at left.
3. Fan belt tension

Before mounting the engine, press on the
arrow-marked position in the figure to see if the
tension is proper.
(2)
(3)
(4)
(1)
(5)
(6)
(1) Water temperature sensor

(to be installed at Engineering staff before shipping)
(2) Used in connecting the alternator wire harness
(3) Spring washer
Nut
(4) Plate (clamp, 2)
Plain washer
Washer-fitted machine screw
(5) Press with a force of 10 kgf to make sure the deflection
is 6-8 mm.
(6) Oil switch
III-S-23
j) Engine Stop Lever

1. Fitting the sensor (rpm)
Tightening the flange bolt
Fit the sensor in position as shown at left.
Tightening torque
7.8~9.3N.m(0.8~0.95kgf.m)5.8~6.9ft.lbs
2. Fitting the plate (bus bar)

Install the plate between No. 1 and No. 2 nuts at
the air intake of the engine inlet, as shown at left.
Tightening torque
3. Fitting the engine stop lever

Fit the lever in position as shown at left.
A
(1)
(6)
(7)
(1)
(2)
A
(3) A-A (8)
(4) (8)
(4)
(9)
(5) (10)
(11)
(1)Lever grip (6)Plate (clamp, 1)

(2)Lever (engine stop) Bolt
Nut (7)Stay (wire harness clamp)
(3)Engine stop lever angle Bolt
10/Bracket (acceleration cable) (8)No. 1 nut
Grommet (engine stop) No. 2 nut
(4)Link (engine stop) (9)Sensor (rpm)
Headed pin Flange bolt
Plain washer (10)Details of B
Snap pin (11)10 (lever’s screw setting length)
(5)Plate (bus bar)
III-S-24
k) Engine Bracket
1. Overall view
III-S-25
2. Fitting the engine bracket

(1)
M12
(2) 77.5~90.2N.m (7.9~9.2kgf.m) 57.2~66.5ft.lbs
(7)
M16
196.1~225.6N.m (20.0~23.0kgf.m)
(3)
(8) 144.6~166.4ft.lbs
Apply screw adhesive (Loctite 271).
(4) (9)
3. Fitting the anti-vibration rubber
(5)
Fit the rubber as shown in the figure.
Double nut tightening torque
No. 1 nut
88.2~107.8N.m (9.0~11.0kgf.m) 65.1~79.5ft.lbs
No. 2 nut
166~191N.m (17.0~19.5kgf.m) 122.4~140.9ft.lbs
(1) (No. 2 nut)

(2) (No. 1 nut)
(3) Bolt
(4) Collar
(5) Washer
(6) Stud
(7) Washer
(8) Anti-vibration rubber
(9) (Right back) Bracket (1, engine)
(Right front) Bracket (2, engine)
Bolt
III-S-26
l) Engine Mount
1. Fly wheel
2. Install the coupling flange.
3. Install the fly wheel housing.
4. Mount the pump assy
III-S-27
5. Engine assy
6. Mount the engine assy on to the

machine.
7. Engine mount nuts

Left, rear
Left, front
III-S-28
Right, front
8. Engine oil cooler
9. Engine oil cooler hoses
10. Oil cooler support
III-S-29
11. Louver of the bonnet
12. Engine under cover
III-S-30
m) Turbo Charger
1. Engine outer view
2. Suction hose
3. Turbo charger
4. Breather hose
III-S-31
5. Gate valve
6. Lubrication pipes
III-S-32
n) Engine Oil Cooler and Turbo

Charger Lubrication Line
(1) (2)
(1) Turbo-charger
(3) (2) Engine oil pressure switch
(3) Oil filter
(4) Oil cooler
(4) (5) By-pass line
(6) Engine oil pressure relief
valve
49 N/cm2
(7) Engine
(5)
(7) (6) 1. By-pass line is incorporated as shown
in the Fig.
Bypass check valve cracking pressure
= 1 kgf/cm2 (0.1 Mpa) 14.2 psi
2. Engine oil pressure relief valve

Cracking pressure
= 4.5 kgf/cm2 (0.46 Mpa) 64 psi
3. Turbo charger lubrication

Required circulation pressure
At rated rpm = 2~5 kgf/cm2 (0.2~0.5 Mpa)
28~71 psi
At idling rpm = 0.8 kgf/cm2 (0.08 Mpa)
11.4 psi
(2) (3)
(1)
(1) Oil filter (2) Oil cooler

(3) By-pass check valve
III-S-33
III-S-34
WORKSHOP MANUAL
DIESEL-ENGINES
Series
Model
V3307-DI-T-E3B
TO THE READER
This Workshop Manual has been prepared to provide servicing personnel with
information on the mechanism, service and maintenance of 07-E3B series. It is divided
into three parts, “General”, “Mechanism” and “Servicing”.
General
Information on the engine identification, the general precautions, maintenance check
list, check and maintenance and special tools are described.
Mechanism
Information on the construction and function are included. This part should be
understood before proceeding with troubleshooting, disassembling and servicing.
Refer to Diesel Engine Mechanism Workshop Manual for the one which has not been
described to this workshop manual.
Servicing
Information on the troubleshooting, servicing specification lists, tightening torque,
checking and adjusting, disassembling and assembling, and servicing which cover
procedures, precautions, factory specifications and allowable limits.
All information illustrations and specifications contained in this manual are based on
the latest product information available at the time of publication.
The right is reserved to make changes in all information at any time without notice.
Due to covering many models of this manual, information or picture being used have
not been specified as one model.
July 2008
© KUBOTA Corporation 2008
This engine WSM has been compiled by Kubota Kikai Service Ltd. in Sakai and the
Engine Division. Kubota produces basic standard engine WSM per its series. Adding
this WSM to Construction Machinery WSM is to meet requests from the dealers in
overseas, which is required when they overhaul and assemble. Engine performance is
optimized for each use so that some main data, such as engine output, torque and RPM
may differ from basic specifications. About those main specifications, please refer to the
data regarding engines mounted on construction machinery at the Chapter III.
Thank you for you understanding and cooperation.
July 2008
III-S-37
III-S-38
SAFETY INSTRUCTIONS
SAFETY FIRST
This symbol, the industry’s “Safety Alert Symbol”, is used throughout this manual and on labels on
the machine itself to warn of the possibility of personal injury. Read these instructions carefully.
It is essential that you read the instructions and safety regulations before you attempt to repair or use
this unit.
DANGER : Indicates an imminently hazardous situation which, if not avoided, will result in
death or serious injury.
WARNING : Indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION : Indicates a potentially hazardous situation which, if not avoided, may result in
minor or moderate injury.
IMPORTANT : Indicates that equipment or property damage could result if instructions are not
followed.
NOTE : Gives helpful information.
BEFORE SERVICING AND REPAIRING

• Read all instructions and safety instructions in this
manual and on your engine safety decals.
• Clean the work area and engine.
• Park the machine on a firm and level ground.
• Allow the engine to cool before proceeding.
• Stop the engine, and remove the key.
• Disconnect the battery negative cable.
• Hang a “DO NOT OPERATE” tag in operator
station.
III-S-39
SAFETY STARTING
• Do not start the engine by shorting across starter
terminals or bypassing the safety start switch.
• Unauthorized modifications to the engine may impair
the function and / or safety and affect engine life.
SAFETY WORKING
• Do not work on the machine while under the influence
of alcohol, medication, or other substances or while
fatigued.
• Wear close fitting clothing and safety equipment
appropriate to the job.
• Use tools appropriate to the work. Makeshift tools,
parts, and procedures are not recommended.
• When servicing is performed together by two or more
persons, take care to perform all work safely.
• Do not touch the rotating or hot parts while the engine
is running.
• Never remove the radiator cap while the engine is
running, or immediately after stopping. Otherwise, hot
water will spout out from radiator. Only remove
radiator cap when cool enough to touch with bare
hands. Slowly loosen the cap to first stop to relieve
pressure before removing completely.
• Escaping fluid (fuel or hydraulic oil) under pressure
can penetrate the skin causing serious injury. Relieve
pressure before disconnecting hydraulic or fuel lines.
Tighten all connections before applying pressure.
• Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against objectionable
or uncomfortable loud noises.
• Do not open high-pressure fuel system.
High-pressure fluid remaining in fuel lines can cause
serious injury. Do not disconnect or attempt to repair
fuel lines, sensors, or any other components between
the high-pressure fuel pump and injectors on engines
with high pressure common rail fuel system.
• High voltage exceeding 100 V is generated in the
ECU, and is applied to the injector.
Pay sufficient caution to electric shock when
performing work activities.
III-S-40
AVOID FIRES
• Fuel is extremely flammable and explosive under
certain conditions. Do not smoke or allow flames or
sparks in your working area.
• To avoid sparks from an accidental short circuit,
always disconnect the battery negative cable first and
connect it last.
• Battery gas can explode. Keep sparks and open
flame away from the top of battery, especially when
charging the battery.
• Make sure that no fuel has been spilled on the engine.
VENTILATE WORK AREA

• If the engine must be running to do some work, make
sure the area is well ventilated. Never run the engine
in a closed area. The exhaust gas contains poisonous
carbon monoxide.
PREVENT ACID BURNS

• Sulfuric acid in battery electrolyte is poisonous. It is
strong enough to burn skin, clothing and cause
blindness if splashed into eyes. Keep electrolyte
away from eyes, hands and clothing. If you spill
electrolyte on yourself, flush with water, and get
medical attention immediately.
DISPOSE OF FLUIDS PROPERLY

• Do not pour fluids into the ground, down a drain, or
into a stream, pond, or lake. Observe relevant
environmental protection regulations when disposing
of oil, fuel, coolant, electrolyte and other harmful
waste.
III-S-41
PREPARE FOR EMERGENCIES

• Keep a first aid kit and fire extinguisher handy at all
times.
• Keep emergency numbers for doctors, ambulance
service, hospital and fire department near your
telephone.
III-S-42
DIMENSIONS
V3007-DI-T-E3B / V3307-DI-T-E3B
III-S-43
III-S-44
MECHANISM
1. FEATURE .................................................................................................. III-M-47

2. ENGINE BODY ......................................................................................... III-M-48
[1] CYLINDER BLOCK............................................................................. III-M-48
[2] COOLING JACKET............................................................................. III-M-49
[3] HALF-FLOATING HEAD COVER...................................................... III-M-49
[4] CYLINDER HEAD............................................................................... III-M-50
[5] 4 SCREWS PER EACH CYLINDER ASSEMBLING STRUCTURE .... III-M-51
[6] CENTER DIRECT INJECTION SYSTEM (E-CDIS) ........................ III-M-52
[7] GEAR TRAIN CONFIGURATION...................................................... III-M-53
[8] PISTON................................................................................................ III-M-53
[9] BUILT-IN DYNAMIC BALANCER (BALANCER MODEL ONLY).... III-M-53
3. LUBRICATING SYSTEM .......................................................................... III-M-54
[1] OIL COOLER ...................................................................................... III-M-54
4. COOLING SYSTEM.................................................................................. III-M-55
[1] THERMOSTAT .................................................................................... III-M-55
[2] BOTTOM BYPASS SYSTEM ............................................................ III-M-56
5. FUEL SYSTEM ......................................................................................... III-M-57
[1] GOVERNOR ........................................................................................ III-M-57
[2] 2 STAGE DI NOZZLE ....................................................................... III-M-60
[3] INJECTION PUMP WITH F.S.P. ...................................................... III-M-61
[4] CPV EQUIPPED DELIVERY VALVE................................................ III-M-62
6. EXHAUST GAS RECIRCULATION (EGR) SYSTEM ............................ III-M-63
[1] GENERAL............................................................................................ III-M-63
[2] External / Mechanical EGR.................................................................. III-M-63
(1) EGR Cooler ................................................................................... III-M-64
(2) Thermo Valve ................................................................................ III-M-64
(3) Mechanical EGR Valve .................................................................. III-M-65
(4) Reed Valve .................................................................................... III-M-65
III-M-45
III-M-46
1. FEATURE
The 07 series DI engine are the vertical type 4-cycle
diesel engine featuring the advanced performances
shown below.
J New Concept
• The Kubota 07 Series is a totally new concept in
engine design developed with various requirements
necessary for a wide range of industrial applications.
• Kubota’s unique cylinder block design was developed
using Kubota’s original casting technology allowing
for a larger displacement within the current 2.4 L
compact engine package.
• The improved cooling system with a main water
gallery and water passages between cylinder bores
as a countermeasure against heat load provides high
power density, superior endurance and a reliable
Kubota 07 Series.
• The Kubota 07 Series completes Kubota’s seamless
range up to 100 hp.
J Emissions
• The NEW Kubota 07 Series engines have been
designed to comply with EPA Interim Tier 4 (Option 1)
emissions regulations, which are the most stringent in
this size range. The Kubota 07 Series engines also
comply with EU Stage ΙΙΙA requirements. The Kubota
07 Series engines offer the benefit of one year longer
validity than Tier 3. Therefore, these engines are
good through the end of 2012 in both the North
American and European markets, which would save
engineering resources for the future Tier levels.
• Meeting emission regulations with minimal additional
required devices: NOx is reduced only by mechanical
means such as a compactly designed cooled exhaust
gas recirculation (EGR) system.
J Clean and Quiet Power
• Kubota’s original E-CDIS (Center Direct Injection
System) combustion system, renowned for clean
combustion in the Kubota V3 (DI) Series, has been
renovated. The fuel injection pressure was increased
and the combustion chamber was redesigned to
achieve a 25 % lower particulate matter (PM) level,
resulting in a better condition when compared to
engines that only meet EPA Tier 3 regulations in this
class.
• These new engines have been designed to reduce
transmitted vibrations and radiated sound, resulting in
lower noise levels. Operator and environmentally
friendly, the Kubota 07 Series begins a new era of
Kubota’s engine design.
W1012645
III-M-47
2. ENGINE BODY
[1] CYLINDER BLOCK
The 07 series DI engine employs ladder frame
structure type crankcases - the crankcase 1 (1) with
combustion part and the crankcase 2 (2) which supports
the crankcase 1 (1).
The following benefits are in the ladder frame
structure.
1. Minimizing parts.
2. Noise reduction.
3. Reduction of loss and dispersion on friction thanks to
accuracy of axial concentricity.
The cylinder is a linerless type which enables good
cooling operation, less strain and good abrasion
resistance.
(1) Crankcase 1 (3) Oil Pan
(2) Crankcase 2
W1012790
III-M-48
[2] COOLING JACKET

The 07 series DI engine employs coolant evenness
distribution type cooling jacket inside crankcase 1. The
coolant is evenly supplied to each cylinder through the
main gallery (3) in the jacket mold core (2).
(1) Coolant Passage between (2) Jacket Mold Core
Cylinder (3) Main Gallery
W1013000
[3] HALF-FLOATING HEAD COVER

The rubber packing (2) is fitted in to maintain the head
cover 0.5 mm (0.02 in.) or so off the cylinder head. This
arrangement helps reduce noise coming from the
cylinder head.
(1) Cylinder Head Cover (2) Rubber Packing
W1013327
III-M-49
[4] CYLINDER HEAD

This engine employs four valve system, the cylinder
head is provided with double intake passage in order to
ensure appropriate air suction and give an optimum swirl.
(1) Intake (2) Exhaust
W1013336
III-M-50
[5] 4 SCREWS PER EACH CYLINDER ASSEMBLING STRUCTURE

The 07 series DI engine employs 4 screws per each
cylinder assembling structure.
The cylinder head (2) and the crankcase 2 (4) are
assembled from the top and bottom to the crankcase 1
(3) with each of 10 screws.
The following objectives are in the 4 screws per each
cylinder assembling structure.
1. Reduce the load share rate of combustion pressure
on outer block surface wall.
2. Flexibility of cylinder head design.
(1) Cylinder Head Mounting (3) Crankcase 1
Screw (4) Crankcase 2
(2) Cylinder Head (5) Crankcase 2 Mounting Screw
W1013265
III-M-51
[6] CENTER DIRECT INJECTION SYSTEM (E-CDIS)

The 07 series DI engine adopts the Center Direct
Injection System (E-CDIS), in which the injection nozzle
(3) is positioned upright at the center of the cylinder.
This system serves to inject fuel directly at the center
of the cylinder. By so doing, injected fuel and suction air
can be mixed more uniformly, leading to more stable,
higher combustion performance. In other words, cleaner
emission, higher power output, lower fuel consumption,
lower operating noise and higher start-up performance.
(1) Exhaust Valves (3) Injection Nozzle
(2) Piston (4) Intake Valves
W11094950
The 07 series DI engine has two intake valves and

two exhaust valves per each cylinder.
The rocker arm (1) contacts a bridge arm (2) instead
of the valves stem tip.
The bridge arm (2) then contacts both intake valves or
both exhaust valves and results two valves to open
simultaneously.
(1) Rocker Arm (2) Bridge Arm
W1014724
III-M-52
[7] GEAR TRAIN CONFIGURATION

The 07 series DI engine employs gear train located at
flywheel side. The following benefits are in the rear gear
train configuration.
1. Flexibility of auxiliary parts arrangement.
2. Reduction of gear chattering noise from crankshaft of
torsional and bending vibration.
(1) Rear Gear Train (3) Balancer Shaft 2
(2) Balancer Shaft 1 (4) Flywheel
W1013611
[8] PISTON
Piston’s skirt is coated with molybdenum disulfideH,
which reduces the piston slap noise and thus the entire
operating noise.
Molybdenum disulfide (MoS2)

The molybdenum disulfide (1) serves as a solid
lubricant, like a Graphite or Teflon. This material helps
resist metal wears even with little lube oil.
(1) Molybdenum Disulfide
W1015665
[9] BUILT-IN DYNAMIC BALANCER (BALANCER MODEL ONLY)

Engine are sure to vibrate by piston’s reciprocation.
Theoretically, three-cylinder engines are much less
prone to cause vibration than four-cylinder ones (second
inertia, etc.). However, any engine has many moving
parts in addition to its pistons and cannot be completely
free from vibration.
The four cylinder engine is fitted with balance weight
on crankcase to absorb the second inertia mentioned
above and reduce vibration.
(1) Balancer Shaft 1 (2) Balancer Shaft 2
W1013617
III-M-53
3. LUBRICATING SYSTEM
[1] OIL COOLER
The 07 series engine has a coolant-cooled oil cooler
that not only cools hot oil, but also warms the cool engine
oil shortly after start up.
As shown in the figure, the oil flows inside the
connected cooler plate, whereas coolant is kept
circulating outside the cooler plate, thereby cooling down
or warming the oil.
(A) Oil Inlet Port (a) Coolant Inlet Port
(B) Oil Outlet Port (b) Coolant Outlet Port
W10344770
III-M-54
4. COOLING SYSTEM
[1] THERMOSTAT
Conventional thermostatically-controlled valves
(outlet water temperature control type) open against the
flow of coolant. In this design, the pressure (steam
pressure + water pump’s discharge pressure) affects the
open/close performance of such valve. In other words,
the valve may be delayed in opening at a preset opening
temperature opening suddenly, above the preset
temperature. This is called the overshoot phenomenon.
The overshoot problem invites the undershoot
phenomenon too. Too much water cooled by the radiator
flows through the water passage, which suddenly closes
the valve below the thermostat’s preset valve closing
temperature.
A repeated cycle of such overshoot (3) and
undershoot phenomena is called the water temperature
hunting. This hunting problem may adversely affect the
cooling system parts, and also the engine and its related
components.
To cope with this trouble, the 07 series engine is
equipped with the flow control thermostat. The valve has
a notch (4) to control the coolant flowrate smoothly in
small steps.
(1) Coolant Temperature (A) Valve Lift Versus Flowrate
(2) Time (B) Flowrate
(3) Overshoot (C) At Short Valve Lift
(4) Notch (D) At Medium Valve Lift
(E) At High Valve Lift
(F) Valve Lift
W1013684
III-M-55
[2] BOTTOM BYPASS SYSTEM

Bottom bypass system is introduced in the 07 series
for improving the cooling performance of the radiator.
While the temperature of coolant in the engine is low,
the thermostat (1) is held closed and the coolant is
allowed to flow through the bypass pipe and to circulate
in the engine.
When the temperature exceeds the thermostat (1)
valve opening level, the thermostat (1) fully opens itself
to prevent the hot coolant from flowing through the
bypass into the engine.
In this way, the radiator can increase its cooling
performance.
(1) Thermostat (A) Bypass Opened
(B) Bypass Closed
W1013406
III-M-56
5. FUEL SYSTEM
[1] GOVERNOR
The engine employs the separated fuel injection
pump in combination with Kubota’s own small multi-
function mechanical governor, which enables more
dependability.
It also employs the torque limiting mechanism to
control the maximum peak torque so that it complies with
the regulations of exhaust gas.
This mechanism maintains engine speed at a
constant level even under fluctuating loads, provides
stable idling and regulates maximum engine speed by
controlling the fuel injection rate.
This engine uses a mechanical governor that controls
the fuel injection rate at all speed ranges (from idling to
maximum speed) by utilizing the balance between the
flyweight’s centrifugal force and spring tension.
A governor shaft for monitoring engine speed is
independent of the injection pump shaft and rotates at
twice the speed of conventional types, providing better
response to load fluctuation and delivering greater
engine output.
W1013830
J At Start
The stop solenoid (energized-to-run type) is powered
to release the stop lever.
As no centrifugal force is applied to flyweight (2), low
tension of start spring (1) permits control rack to move
the starting position, supplying the amount of fuel
required to start the engine.
(1) Start Spring (2) Flyweight
W1013967
III-M-57
J At Idling
Turn the speed control lever (2) clockwise to idle the
engine. It tensions the governor spring (7) to pull the fork
lever 2 (1).
When the fork lever 2 (1) is pulled, it moves the torque
spring pin (3) and the fork lever 1 (5) in the direction of
the arrow A to restrain the weight. In combination with
the start spring tension, it is balanced with the centrifugal
force of flywheel weight to keep idling.
(1) Fork Lever 2 (5) Fork Lever 1
(2) Speed Control Lever (6) Flyweight
(3) Spring Pin (7) Governor Spring
(4) Start Spring
W1014034
J At rated speed with full load and overload

As the speed control lever is changed from the middle
speed to high speed, the governor spring tension
increases to compress the torque spring and move the
fork lever 1 in the direction of the arrow A.
The fork lever 2 moves until it reaches the output
limiting bolt (2) to keep rated rotation and rated output.
When the engine is overloaded, the engine rotating
speed decreases and the centrifugal force of flywheel
weight decreases. Then the torque spring moves the
fork lever 1 in the direction of arrow A.
The control rack moves in the direction that increases
fuel supply to increase the output. It is balanced with the
centrifugal force of the flywheel weight to produce low-
speed output (torque output).
(1) No-load Maximum Rotation (3) Torque Limiting Bolt
(2) Output Limiting Bolt
W1014276
III-M-58
J To stop engine
When the stop solenoid is turned off, the spring
tension of the solenoid is released, the rod extrudes and
the stop lever moves the control rack in the direction of
the arrow B which stops the engine.
To stop the engine manually, move the external stop
lever to the left.
W1014393
III-M-59
[2] 2 STAGE DI NOZZLE

Exhaust and noise regulations are becoming
increasingly strict, particularly in regard to the reduction
of NOx (nitrogen oxides) and particulates.
The two-spring nozzle holder has been developed to
reduce NOx (nitrogen oxides) and particulates from
direct injection diesel engine exhaust.
J Features
The two-spring nozzle holder limits needle valve lift at
initial valve opening to throttle the injection quantity.
Main injection occurs when the in-line pressure has
increased sufficiently to move the needle valve through
its full lift.
This gives the following features.
• Improved engine stability at low and intermediate
speeds.
• Decreased engine hunting and surge.
• Decreased noise at idling.
• Decreased idling speed because of improved engine
stability.
• Stabilized fuel injection characteristics from the
injection pump and nozzle system, and easier
matching of governor characteristics to engine
demand.
(1) Nozzle Holder Body (7) Second Spring
(2) 1st Stage Injection Pressure (8) Pre-lift Adjusting Spring Seat
Adjusting Shim (9) Chip-packing
(3) First Spring (10) Max-lift Adjusting Washer
(4) Pressure Pin (11) Retaining Nut
(5) Spring Seat (12) Nozzle
(6) 2nd Stage Injection Pressure
Adjusting Shim
W1014568
III-M-60
A-B : First Spring’s Set Force

B-C-D : Combined Force of
First and Second Springs
P1 : First Opening Pressure
P2 : Second Opening Pressure
L : Full Needle Valve Lift

l : Needle Valve Pre-lift
X1 : Cam Angle (°)

Y1 : Injection Rate (mm3/°)
X2 : Needle Valve Lift (mm)
Y2 : In-line Pressure
W1014795
J First opening pressure

The force of the high pressure fuel delivered by the injection pump acts to push the needle valve up. When this
force exceeds the set force of the first spring, the nozzle’s needle valve pushes the first pushrod up and the valve
opens. (First opening pressure is represented by point E in the bottom left hand figure, and point A in the above
figure.)
J Second opening pressure
When the first pushrod has been lifted through the pre-lift, it contacts the second pushrod. As the set force of the
second spring is acting on the second pushrod, the combined forces of both the first spring and the second spring then
act on the needle valve, which will not lift unless these forces are overcome.
[3] INJECTION PUMP WITH F.S.P.

The fuel injection pump with F.S.P. (Fine Spill Port)
mechanism is equipped with two functions: speed timer
function and injection rate control function.
The former function works like this. As the rpm is low,
the injection timing gets delayed. This helps cut down on
NOx and operating noise.
The latter function serves to keep down the initial
injection rate and keep up the later injection rate, which
cuts down on NOx and PM as well.
(1) Fine Spill Port (F.S.P.) (5) Plunger
(2) Plunger Chamber (6) F.S.P. Stroke
(3) Main Port (7) Leaking Fuel at Initial Fuel
(4) Cylinder Pressure-Feed Stage
W1014969
III-M-61
[4] CPV EQUIPPED DELIVERY VALVE

The Constant Pressure Valve (CPV) is a mechanism
that maintains uniform residual pressure in the high
pressure pipe. It stabilizes overall delivery quantity
characteristics and especially delivery quantity
characteristics at low speeds.
J At high fuel pressure
The delivery valve (1), the steel ball (4) and the
snapper valve (5) are moved up together. The delivery
valve seat surface (2) opens when the fuel pressure
becomes more than the delivery valve set pressure.
J At after injection
The delivery valve (1), the steel ball (4) and the
snapper valve (5) are moved down and the delivery valve
seat surface (2) closes. The steel ball still opens on the
way and the fuel returns to the injection pump side. The
steel ball (4) closes when the fuel pressure becomes less
than the snapper valve set pressure.
(1) Delivery Valve (7) Snapper Valve Spring
(2) Seat Surface (8) Snapper Valve Seat
(3) Valve Seat
(4) Orifice A : Current Delivery Valve
(5) Steel Ball B : CPV Equipped Delivery
(6) Snapper Valve Valve
W1015816
III-M-62
6. EXHAUST GAS RECIRCULATION (EGR) SYSTEM

[1] GENERAL
In order to meet with the strict emission regulations, Kubota has adopted the EGR on the V3007-DI-T-E3B and
V3307-DI-T-E3B. The nitrogen oxide (NOx) which is a hazardous component in exhaust gas is generated by oxidation
of nitrogen in the air, due to rise of the combustion temperature in cylinders. The EGR is a system in which the exhaust
gas with lean oxygen is cooled and returned to cylinders again in order to lower the combustion temperature. As a
result, NOx can be decreased.
[2] External / Mechanical EGR
(1) Thermo Valve (4) Reed Valve (a) Cooled EGR Gas (f) Cooled EGR Gas Merges
(2) Mechanical EGR Valve (5) EGR Cooler (b) Coolant Temperature with Fresh Air
(3) Cylinder Head (6) Intake Manifold (c) Boost Pressure (g) Exhaust Gas
(d) To The Intake Manifold (h) Coolant Inlet
(e) Fresh Air (i) Coolant Outlet
External / Mechanical EGR consists of water cooled EGR cooler (5), mechanical EGR valve (2), reed valve (4) and
thermo valve (1).
When the coolant temperature (b) is getting higher, thermo valve (1) is open and the boost pressure of intake
manifold (6) gets to reach the diaphragm of mechanical EGR valve (2).
If the coolant temperature (b) is high, but the boost pressure is low, the EGR valve (2) does not open. If coolant
temperature (b) is high, boost pressure is also high, EGR valve (2) is open and cooled EGR gas (a) through the water
cooled EGR cooler (5) flows into the intake manifold (6). And the reed valve (4) between EGR valve (2) and intake
manifold (6) prevents the fresh air flowing into EGR system.
III-M-63
(1) EGR Cooler

The EGR (Exhaust Gas Recirculation) cooler (3) is
used to lower combustion temperature and efficiently
cool EGR gas, with the aim of reducing the NOx that is in
the exhaust gas of diesel engine.
The EGR cooler (3) is placed between the cylinder
head (2) and the mechanical EGR valve (4) and returns
the cooled exhaust gases to the engine suction side.
The EGR cooler (3) has resistant to clogging up,
compact and efficient tubes (5) internally.
(1) Flange A : Coolant Inlet Port
(2) Cylinder Head B : Coolant Outlet Port
(3) EGR Cooler
(4) Mechanical EGR Valve
(5) Tube
W1175338
(2) Thermo Valve

Thermo valve (1) controls boost pressure “ON / OFF”
for the EGR valve.
If the coolant temperature (2) is low, thermo valve (1)
is closed, so that boost pressure does not reach to the
EGR valve.
If the coolant temperature (2) is high, thermo valve (1)
is open, so that boost pressure reaches to the EGR
valve.
(1) Thermo Valve (a) Boost Pressure From Intake
(2) Coolant Temperature Manifold
(3) Boost Pressure Flow (b) Boost Pressure To EGR
Valve
(c) Open
(d) Close
W1175753
III-M-64
(3) Mechanical EGR Valve

Mechanical EGR valve (2) controls the flow of cooled
EGR gas (c) to the intake manifold.
If the boost pressure (b) is low, EGR valve (2) is
closed, so cooled EGR gas (c) does not flow to the intake
manifold (e).
If the boost pressure (b) is getting higher, EGR valve
(2) is opening and cooled EGR gas (c) is flowing to the
intake manifold (e).
(1) Thermo Valve (a) Boost Pressure from Inlet
(2) Mechanical EGR Valve Manifold
(3) EGR Valve Lift (b) Boost Pressure from
(4) Boost Pressure Thermo Valve
(c) Cooled EGR Gas
(d) Coolant
(e) Cooled EGR Gas To The
Intake Manifold
(f) Close
(g) Open
W1176088
(4) Reed Valve

The reed valve (2) is provided at the confluence of
exhaust gas after passing the EGR valve (1), and intake
air. It operates by the pressure difference between inside
of the crankcase and the atmosphere, and prevents
backflow of the mixture of exhaust gas and intake air
generated by the piston and valves. It is used as the
secondary air introduction device for the
countermeasure against exhaust gas of four-cycle
engines.
(1) Mechanical EGR Valve (5) Valve
(2) Reed Valve (6) Case
(3) Reed Valve Housing (7) Stopper
(4) Intake Manifold (8) Screw
W1176594
III-M-65
III-M-66
WSM KX080-3AB General III ENGINE
GENERAL
1. ENGINE IDENTIFICATION....................................................................... III-G-69

[1] MODEL NAME AND ENGINE SERIAL NUMBER .......................... III-G-69
[2] E3B ENGINE ...................................................................................... III-G-70
[3] CYLINDER NUMBER ......................................................................... III-G-70
2. GENERAL PRECAUTIONS ...................................................................... III-G-71
3. MAINTENANCE CHECK LIST................................................................. III-G-72
4. CHECK AND MAINTENANCE................................................................. III-G-74
[1] DAILY CHECK POINTS..................................................................... III-G-74
[2] CHECK POINTS OF INITIAL 50 HOURS....................................... III-G-76
[3] CHECK POINT OF EVERY 50 HOURS ......................................... III-G-77
[4] CHECK POINTS OF EVERY 250 HOURS..................................... III-G-78
[5] CHECK POINTS OF EVERY 500 HOURS..................................... III-G-80
[6] CHECK POINT OF EVERY 1000 HOURS ..................................... III-G-83
[7] CHECK POINTS OF EVERY 1 OR 2 MONTHS........................... III-G-84
[8] CHECK POINTS OF EVERY 1500 HOURS................................... III-G-86
[9] CHECK POINTS OF EVERY 3000 HOURS................................... III-G-87
[10]CHECK POINTS OF EVERY 1 YEAR ............................................ III-G-90
[11]CHECK POINTS OF EVERY 2 YEARS.......................................... III-G-91
5. SPECIAL TOOLS...................................................................................... III-G-94
Important Note: Engine maintenance hours, if any difference, should be conformed to

I. General, B. Maintenance Intervals page I-11~14.
III-G-67
III-G-68
1. ENGINE IDENTIFICATION
[1] MODEL NAME AND ENGINE SERIAL NUMBER
When contacting the manufacture, always specify your engine
model name and serial number.
The engine model and its serial number need to be identified
before the engine can be serviced or parts replaced.
J Engine Serial Number
The engine serial number is an identified number for the engine.
It is marked after the engine model number.
It indicates month and year of manufacture as follows.
• Year of manufacture
Alphabet or Alphabet or
Year Year
Number Number
6 2006 H 2017
7 2007 J 2018
8 2008 K 2019
9 2009 L 2020
A 2010 M 2021
B 2011 N 2022
C 2012 P 2023
D 2013 R 2024
E 2014 S 2025
F 2015 T 2026
G 2016 V 2027
(1) Engine Model Name and Serial

Number
W1010477
• Month of manufacture
Month Engine Lot Number
January A0001 ~ A9999 B0001 ~ BZ999
February C0001 ~ C9999 D0001 ~ DZ999
March E0001 ~ E9999 F0001 ~ FZ999
April G0001 ~ G9999 H0001 ~ HZ999
May J0001 ~ J9999 K0001 ~ KZ999
June L0001 ~ L9999 M0001 ~ MZ999
July N0001 ~ N9999 P0001 ~ PZ999
August Q0001 ~ Q9999 R0001 ~ RZ999
September S0001 ~ S9999 T0001 ~ TZ999
October U0001 ~ U9999 V0001 ~ VZ999
November W0001 ~ W9999 X0001 ~ XZ999
December Y0001 ~ Y9999 Z0001 ~ ZZ999
* Alphabetical letters “I” and “O” are not used.
e.g. V3307-T - 7 V A001
(a) (b)(c) (d)
(a) Engine Model Name : V3307-DI-T
(b) Year : 7 indicates 2007
(c) Month : U or V indicates October
(d) Lot number : (0001 ~ 9999 or A001 ~ Z999)
W1024938
III-G-69
[2] E3B ENGINE

[Example : Engine Model Name V3307-DI-T-E3B-XXXX]
The emission controls previously implemented in various countries to prevent air pollution will be stepped up as
Non-Road Emission Standards continue to change. The timing or applicable date of the specific Non-Road 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 Non-Road Emission regulations. For Kubota Engines, E3B will be the designation
that identifies engine models affected by the next emission phase (See the table below).
When servicing or repairing ###-E3B series engines, use only replacement parts for that specific E3B engine,
designated by the appropriate E3B Kubota Parts List and perform all maintenance services listed in the appropriate
Kubota Operator's Manual or in the appropriate E3B Kubota Workshop Manual. Use of incorrect replacement parts
or replacement parts from other emission level engines (for example: E2B engines), may result in emission levels out
of compliance with the original E3B 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. E3B engines are
identified with "ET" at the end of the Model designation, on the US EPA label. Please note : E3B is not marked on the
engine.
Category (1) Engine output classification EU regulation

K From 19 to less than 37 kW STAGE ΙΙΙA
J From 37 to less than 75 kW STAGE ΙΙΙA
I From 75 to less than 130 kW STAGE ΙΙΙA
Category (2) Engine output classification EPA regulation

Less than 19kW Tier 4
From 19 to less than 56 kW Interim Tier 4
ET
From 56 to less than 75 kW Tier 3
From 75 to less than 130 kW Tier 3
(1) EU regulation engine output classification category

(2) “E3B” engines are identified with “ET” at the end of the Model designation, on
the US EPA label.
“E3B” designates Tier 3 and some Interim Tier 4 / Tier 4 models, depending on
engine output classification.
W1031971
[3] CYLINDER NUMBER

The cylinder numbers of kubota diesel engine are designated as
shown in the figure.
The sequence of cylinder numbers is given as No. 1, No. 2,
No. 3 and No. 4 starting from the front cover side.
W1011077
III-G-70
2. GENERAL PRECAUTIONS
• During disassembly, carefully arrange removed parts in a clean
area to prevent confusion later. Screws, bolts and nuts should be
replaced in their original position to prevent reassembly errors.
• When special tools are required, use KUBOTA genuine special
tools. Special tools which are not frequently used should be
made according to the drawings provided.
• Before disassembling or servicing live wires, make sure to
always disconnect the grounding cable from the battery first.
• Remove oil and dirt from parts before measuring.
• Use only KUBOTA genuine parts for parts replacement to
maintain engine performance and to ensure safety.
• Gaskets and O-rings must be replaced during reassembly.
Apply grease to new O-rings or oil seals before assembling.
• When reassembling external or internal snap rings, position them
so that the sharp edge faces against the direction from which
force is applied.
• Be sure to perform run-in the serviced or reassembled engine.
Do not attempt to give heavy load at once, or serious damage
may result to the engine.
(1) Grease (A) External Snap Ring
(2) Force (B) Internal Snap Ring
(3) Place the Sharp Edge against the
Direction of Force
W1011734
III-G-71
3. MAINTENANCE CHECK LIST

To maintain long-lasting and safe engine performance, make it a rule to carry out regular inspections by following
the table below.
Service Interval
Item Every Every Every Every 1 Every Every Every
Initial Every 250 500 1000 or 2 1500 3000 Every 2
50 hrs 50 hrs 1 year
hrs hrs hrs months hrs hrs years
Changing engine oil I I I
Replacing oil filter cartridge I I
*Checking fuel hoses and clamps I
*Cleaning air filter element
I
(Replace the element after 6 times cleanings)
*Cleaning fuel filter I
Checking battery electrolyte level I
Checking radiator hoses and clamps I
*Checking intake air line I
Checking fan belt tension and damage I I
*Replacing fuel filter cartridge I
Replacing fan belt I I
Cleaning radiator interior I
Checking valve clearance I
Recharging battery I
*Checking injection nozzle condition I
*Checking turbocharger I
Checking fuel injection pump I
*Checking injection timing (spill timing) I
*Replacing air filter element I
Changing radiator coolant (L.L.C.) I
Replacing radiator hoses and clamps I
*Replacing fuel hoses and clamps I
*Replacing intake air line I
Replacing battery I
* The items listed above (* marked) are registered as emission related critical parts by KUBOTA in the U.S.EPA
nonroad emission regulation.
As the engine owner, you are responsible for the performance of the required maintenance on the engine according
to the above instruction.
W1029462
CAUTION
• When changing or inspecting, be sure to level and stop the engine.
III-G-72
J NOTE
Engine Oil :
• Refer to the following table for the suitable American Petroleum Institute (API) classification of engine oil
according to the engine type (with internal EGR, external EGR or non-EGR) and the Fuel Type Used :
(Low Sulfur, Ultra Low Sulfur or High Sulfur Fuels).
Engine oil classification (API classification)
Fuel Type Engines with non-EGR
Engines with external EGR
Engines with internal EGR
CF
High Sulfur Fuel
(If the "CF-4, CG-4, CH-4, or CI-4" engine
[0.05 % (500 ppm) ≤
oil is used with a high-sulfur fuel, change –
Sulfur Content <
the engine oil at shorter intervals.
0.50 % (5000 ppm)]
(approximately half))
Low Sulfur Fuel
[Sulfur Content <
CF or CI-4
0.05 % (500 ppm)] or
CF, CF-4, CG-4, CH-4 or CI-4 (Class CF-4, CG-4 and CH-4 engine oils
Ultra Low Sulfur Fuel
cannot be used on EGR type engines.)
[Sulfur Content <
0.0015 % (15 ppm)]
EGR : Exhaust Gas Re-circulation
W1024941
• CJ-4 classification oil is intended for use in engines equipped with DPF (Diesel Particulate Filter) and is
Not Recommended for use in Kubota E3 specification engines.
• Oil used in the engine should have API classification and Proper SAE Engine Oil Viscosity according to
the ambient temperatures where the engine is operated.
• With strict emission control regulations now in effect, the CF-4 and CG-4 engine oils have been developed
for use with low sulfur fuels, for On-Highway vehicle engines. When a Non-Road engine runs on high
sulfur fuel, it is advisable to use a "CF or better" classification engine oil with a high Total Base Number
(a minimum TBN of 10 is recommended).
Fuel:
• Cetane Rating : The minimum recommended Fuel Cetane Rating is 45. A cetane rating greater than 50 is
preferred, especially for ambient temperatures below −20 °C (−4 °F) or elevations above 1500 m (5000 ft).
• Diesel Fuel Specification Type and Sulfur Content % (ppm) used, must be compliant with all applicable
emission regulations for the area in which the engine is operated.
• Use of diesel fuel with sulfur content less than 0.10 % (1000 ppm) is strongly recommended.
• If high-sulfur fuel (sulfur content 0.50 % (5000 ppm) to 1.0 % (10000 ppm)) is used as a diesel fuel, change
the engine oil and oil filter at shorter intervals. (approximately half)
• DO NOT USE Fuels that have sulfur content greater than 1.0 % (10000 ppm).
• Diesel fuels specified to EN 590 or ASTM D975 are recommended.
• No.2-D is a distillate fuel of lower volatility for engines in industrial and heavy mobile service. (SAE J313
JUN87)
• Since KUBOTA diesel engines of less than 56 kW (75 hp) utilize EPA Tier 4 and Interim Tier 4 standards,
the use of low sulfur fuel or ultra low sulfur fuel is mandatory for these engines, when operated in US EPA
regulated areas. Therefore, please use No.2-D S500 or S15 diesel fuel as an alternative to No.2-D, and use
No.1-D S500 or S15 diesel fuel as an alternative to No.1-D for ambient temperatures below −10 °C (14 °F).
1) SAE : Society of Automotive Engineers

2) EN : European Norm
3) ASTM : American Society of Testing and Materials
4) US EPA : United States Environmental Protection Agency
5) No.1-D or No.2-D, S500 : Low Sulfur Diesel (LSD) less than 500 ppm or 0.05 wt.%
No.1-D or No.2-D, S15 : Ultra Low Sulfur Diesel (ULSD) 15 ppm or 0.0015 wt.%
III-G-73
4. CHECK AND MAINTENANCE

[1] DAILY CHECK POINTS
Checking Engine Oil Level
1. Level the engine.
2. To check the oil level, draw out the dipstick (1), wipe it clean,
reinsert it, and draw it out again.
Check to see that the oil level lies between the two notches.
3. If the level is too low, add new oil to the specified level.
J IMPORTANT
• When using an oil of different maker or viscosity from the
previous one, drain old oil. Never mix two different types of
oil.
J NOTE
• Be sure to inspect the engine, locating it on a horizontal
place. If placed on gradients, accurately, oil quantity may
not be measured.
• Be sure to keep the oil level between upper and lower limits
of the dipstick (1). Too much oil may cause a drop in output
or excessive blow-by gas. On the closed breather type
engine in which mist is sucked through port, too much oil
may caused oil hammer. While too little oil, may seize the
engine’s rotating and sliding parts.
(1) Dipstick (a) Maximum
(b) Minimum
W1035676
III-G-74
Checking and Replenish Coolant

1. Without recovery tank (2) :
Remove the radiator cap (1) and check to see that the coolant
level is just below the port.
With recovery tank (2) :
Check to see that the coolant level lies between FULL (A) and
LOW (B).
2. If coolant level is too low, check the reason for decreasing
coolant.
(Case 1)
If coolant is decreasing by evaporation, replenish only fresh, soft
water.
(Case 2)
If coolant is decreasing by leak, replenish coolant of the same
manufacture and type in the specified mixture ratio (fresh, soft
water and L.L.C.). If the coolant brand cannot be identified, drain
out all of the remaining coolant and refill with a totally new brand
of coolant mix.
• Do not remove the radiator cap (1) until coolant temperature

is below its boiling point. Then loosen the cap slightly to
relieve any excess pressure before removing the cap
completely.
J IMPORTANT
• During filling the coolant, air must be vented from the engine
coolant passages. The air vents by jiggling the radiator
upper and lower hoses.
• Be sure to close the radiator cap (1) securely. If the cap is
loose or improperly closed, coolant may leak out and the
engine could overheat.
• Do not use an antifreeze and scale inhibitor at the same time.
Never mix the different type or brand of L.L.C..
(1) Radiator Cap A : FULL
(2) Recovery Tank B : LOW
W1035779
III-G-75
[2] CHECK POINTS OF INITIAL 50 HOURS

Changing Engine Oil
CAUTION
• Be sure to stop engine before changing engine oil.
1. Start and warm up the engine for approx. 5 minutes.
2. Place an oil pan underneath the engine.
3. To drain the used oil, remove the drain plug (1) at the bottom of
the engine and drain the oil completely.
4. Screw the drain plug (1).
5. Fill new oil up to upper line on the dipstick (2).
J IMPORTANT
previous one, remove all of the old oil.
• Never mix two different types of oil.
Engine oil should have properties of API classification CF
(See page G-5).
• Use the proper SAE Engine Oil according to ambient
temperature.
SAE 30 or SAE 10W-30
Above 25 °C (77 °F)
SAE 10W-40
0 °C to 25 °C (32 °F to 77 °F)
SAE 10W-40
SAE 10W or SAE 10W-30
Below 0 °C (32 °F)
SAE 10W-40
11.2 L
Engine oil capacity
2.96 U.S.gals
45 to 53 N·m
Tightening torque Drain plug 4.5 to 5.5 kgf·m
33 to 39 lbf·ft
(1) Drain Plug (a) Maximum

(2) Dipstick (b) Minimum
W1016604
Replacing Oil Filter Cartridge
CAUTION
• Be sure to stop the engine before changing filter cartridge.
1. Remove the oil filter cartridge (1) with the filter wrench.
2. Apply a slight coat of oil onto the new cartridge gasket.
3. To install the new cartridge, screw it in by hand. Over tightening
may cause deformation of rubber gasket.
4. After the new cartridge has been replaced, the engine oil
normally decrease a little. Thus see that the engine oil does not
leak through the seal and be sure to read the oil level on the
dipstick. Then, replenish the engine oil up to the specified level.
J IMPORTANT
• To prevent serious damage to the engine, replacement
element must be highly efficient. Use only a KUBOTA
genuine filter or its equivalent.
(1) Engine Oil Filter Cartridge
W1017137
III-G-76
Fan Belt Tension

1. Measure the deflection (A), depressing the fan belt (2) halfway
between the fan drive pulley and alternator pulley at specified
force 98 N (10 kgf, 22 lbf).
2. If the measurement is not within the factory specifications, loosen
the alternator mounting screws (1) and relocate the alternator to
adjust.
10.0 to 12.0 mm
Deflection (A) Factory spec.
0.394 to 0.472 in.
(1) Alternator Mounting Screws (A) Deflection

(2) Fan Belt
W1208957
[3] CHECK POINT OF EVERY 50 HOURS

Checking Fuel Hose and Clamp Bands
1. If the clamp (2) is loose, apply oil to the threads and securely
retighten it.
2. The fuel hose (1) is made of rubber and ages regardless of the
period service.
Change the fuel pipe together with the clamp (2) every two years.
3. However, if the fuel hose (1) and clamps (2) are found to be
damaged or deteriorate earlier than two years, then change or
remedy.
4. After the fuel hose (1) and the clamps (2) have been changed,
bleed the fuel system.
CAUTION
• Stop the engine when attempting the check and change
prescribed above.
(When bleeding fuel system)
1. Fill the tank with fuel and open the cock.
2. Loosen the air vent coupling bolt of fuel filter a few turns.
3. When there is no more air bubbles in the fuel coming out of this
coupling bolt, tighten the coupling bolt.
4. Open the air vent cock (3) on the top of fuel injection pump.
5. If equipped electrical fuel feed pump, turn the key on AC position
and pump the fuel up for 10 to 15 seconds.
If equipped mechanical fuel feed pump, set the stop lever on stop
position and crank the engine for 10 to 15 seconds.
6. Close securely the air vent cock (3) after air bleeding.
J IMPORTANT
• Except when venting the air, be sure to keep closed the air
vent coupling bolt of the fuel injection pump. Otherwise, the
engine may stall.
(1) Fuel Hose (3) Air Vent Cock
(2) Clamp
W1035921
III-G-77
[4] CHECK POINTS OF EVERY 250 HOURS

Fan Belt Tension
between the fan drive pulley and alternator pulley at specified
force 98 N (10 kgf, 22 lbf).
adjust.
10.0 to 12.0 mm
Deflection (A) Factory spec.
0.394 to 0.472 in.
(1) Alternator Mounting Screw (A) Deflection

(2) Fan Belt
W1014131
Fan Belt Damage and Wear
1. Check the fan belt for damage.
2. If the fan belt is damaged, replace it.
3. Check if the fan belt is worn and sunk in the pulley groove.
4. If the fan belt is nearly worn out and deeply sunk in the pulley
groove, replace it.
(A) Good (B) Bad
W1209480
Cleaning Air Cleaner Element

1. Remove the air cleaner element.
2. Use clean dry compressed air on the inside of the element.
Pressure of compressed air must be under 205 kPa (2.1 kgf/cm2,
30 psi).
Maintain reasonable distance between the nozzle and the filter.
J NOTE
• The air cleaner uses a dry element. Never apply oil to it.
• Do not run the engine with filter element removed.
• Change the element once a year or every 6th cleaning.
W1045746
III-G-78
Cleaning Fuel Filter (Element Type only)

1. Close the fuel cock (3).
2. Unscrew the retaining ring (6) and remove the filter cup (5), and
rinse the inside with kerosene.
3. Take out the element (4) and dip it in the kerosene to rinse.
4. After cleaning, reassemble the fuel filter, keeping out dust and
dirt.
5. Bleed the fuel system.
J IMPORTANT
• If dust and dirt enter the fuel, the fuel injection pump and
injection nozzle will wear quickly. To prevent this, be sure to
clean the filter cup (5) periodically.
(1) Cock Body (4) Filter Element
(2) Air Vent Plug (5) Filter Cup
(3) Fuel Cock (6) Retaining Ring
W1046058
Checking Radiator Hoses and Clamp Bands
1. Check to see if the radiator hoses are properly fixed every 250
hours of operation or every six months, whichever comes first.
2. If the clamp is loose, apply oil to the threads and retighten it
securely.
3. The water hose is made of rubber and tends to age. It must be
replaced every two years. Also replace the clamp and tighten it
securely.
(1) Upper Hose (2) Lower Hose
W1029518
Checking Battery Electrolyte Level

1. Check the battery electrolyte level.
2. If the level is below than lower level line (2), and the distilled water
to pour level of each cell.
(1) Upper Level Line (2) Lower Level Line
W1047154
Checking Intake Air Line

1. Check to see if the intake air hose(s) (1) are properly fixed every
250 hours of operation.
2. If the clamp is loose, apply oil to the threads and retighten it
securely.
3. The intake air hose(s) (1) is made of rubber and tends to age. It
must be change every two years. Also change the clamp (2) and
tighten it securely.
J IMPORTANT
• To prevent serious damage to the engine, keep out any dust
inside the intake air line.
(1) Intake Air Hose (2) Clamp
W1029631
III-G-79

Changing Engine Oil
CAUTION
J IMPORTANT
• Engine oil should have properties of API classification CF
(See page G-5).
temperature.
Above 25 °C (77 °F)
SAE 10W-40
0 °C to 25 °C (32 °F to 77 °F)
SAE 10W-40
Below 0 °C (32 °F)
SAE 10W-40
11.2 L
Engine oil capacity
2.96 U.S.gals
45 to 53 N·m
33 to 39 lbf·ft

W1014590
Replacing Oil Filter Cartridge
CAUTION
• Be sure to stop the engine before changing filter cartridge.
1. Remove the oil filter cartridge (1) with the filter wrench.
2. Apply a slight coat of oil onto the new cartridge gasket.
3. To install the new cartridge, screw it in by hand. Over tightening
may cause deformation of rubber gasket.
4. After the new cartridge has been replaced, the engine oil
normally decrease a little. Thus see that the engine oil does not
leak through the seal and be sure to read the oil level on the
dipstick. Then, replenish the engine oil up to the specified level.
J IMPORTANT
• To prevent serious damage to the engine, replacement
element must be highly efficient. Use only a KUBOTA
genuine filter or its equivalent.
(1) Engine Oil Filter Cartridge
W1015117
III-G-80
Replacing Fuel Filter Cartridge (Cartridge Type)

Water and dust in fuel are collected in the filter cartridge. So,
change the filter cartridge every 500 hours service.
1. Remove the used filter cartridge with filter wrench.
2. Apply a thin film of fuel to the surface of new filter cartridge gasket
before screwing on.
3. Then tighten enough by hand.
4. Loosen the air vent plug to let the air out.
5. Start engine and check for fuel leakage.
(1) Fuel Filter Cartridge
W1037062
Replacing Fan Belt

1. Remove the alternator (1).
2. Remove the fan belt (2).
3. Replace new fan belt.
4. Install the alternator.
5. Check the fan belt tension.
10.0 to 12.0 mm / 98 N
Deflection (A) Factory spec. 0.394 to 0.472 in. / 98 N
(10 kgf, 22 lbf)
(1) Alternator (A) Deflection

(2) Fan Belt
W1052220
Cleaning Water Jacket and Radiator Interior
CAUTION
• Do not remove the radiator cap (1) when the engine is hot.
Then loosen cap slightly to the stop to relieve any excess
pressure before removing cap completely.
1. Stop the engine and let cool down.
2. To drain the coolant, open the radiator drain plug (2) and remove
the radiator cap (1). Then radiator cap (1) must be removed to
completely drain the coolant. And open the drain cock of engine
body.
3. After all coolant is drained, close the drain plug (2).
4. Fill with clean water and cooling system cleaner.
5. Follow directions of the cleaner instruction.
6. After flushing, fill with clean water and anti-freeze until the coolant
level is just below the port. Install the radiator cap (1) securely.
7. Fill with coolant up to “FULL” (A) mark on the recovery tank (3).
8. Start and operate the engine for few minutes.
9. Stop the engine and let cool. Check coolant level of radiator and
recovery tank (3) and add coolant if necessary.
J IMPORTANT
• Do not start engine without coolant.
• Use clean, fresh, soft water and anti-freeze to fill the radiator
and recovery tank (3).
• When the anti-freeze is mixed with fresh, soft water, the anti-
freeze mixing ratio must be less than 50 %.
• Securely tighten radiator cap (1). If the cap is loose or
improperly fitted, water may leak out and the engine could
overheat.
(1) Radiator Cap A : Full
(2) Drain Plug B : Low
(3) Recovery Tank
W1038102
III-G-81
Anti-Freeze
• There are two types of anti-freeze available: use the permanent
type (PT) for this engine.
• Before adding anti-freeze for the first time, clean the radiator
interior by pouring fresh, soft water and draining it a few times.
• The procedure for mixing water and anti-freeze differs according
to the make of the anti-freeze and the ambient temperature.
Basically, it should be referred to SAE J1034 standard, more
specifically also to SAE J814c.
• Mix the anti-freeze with fresh, soft water, and then fill into the
radiator.
J IMPORTANT
Vol % Freezing point Boiling point*
anti-freeze °C °F °C °F
40 –24 –11 106 223
50 –37 –35 108 226
* At 1.013 × 100000 Pa (760 mmHg) pressure (atmospheric). A
higher boiling point is obtained by using a radiator pressure cap
which permits the development of pressure within the cooling
system.
J NOTE
• The above data represents industrial standards that
necessitate a minimum glycol content in the concentrated
anti-freeze.
• When the coolant level drops due to evaporation, add fresh,
soft water only to keep the anti-freeze mixing ratio less than
50 %. In case of leakage, add anti-freeze and fresh, soft
water in the specified mixing ratio.
• Anti-freeze absorbs moisture. Keep unused anti-freeze in a
tightly sealed container.
• Do not use radiator cleaning agents when anti-freeze has
been added to the coolant.
(Anti-freeze contains an anti-corrosive agent, which will
react with the radiator cleaning agent forming sludge which
will affect the engine parts.)
W1039218
III-G-82
[6] CHECK POINT OF EVERY 1000 HOURS

Checking Valve Clearance
J IMPORTANT
• Valve clearance must be checked and adjusted when engine
is cold.
1. Remove the high pressure pipes, glow lead, glow plugs and the
cylinder head cover.
2. Align the 1TC mark of flywheel and the convex of flywheel
housing timing windows so that the first piston (front cover side)
comes to the compression top dead center.
3. Before adjusting the valve clearance, adjust the bridge evenly to
the valve stem.
4. Loosen the lock nut (2) and adjust with screw (1).
5. Slightly push the rocker arm with your fingers and screw in the
adjusting screw (1) slowly until you feel the screw touch the top
of valve stem, then tighten the lock nut (2).
6. Loosen the lock nut (4) of adjusting screw (3) (push rod side) and
insert the feeler gauge between the rocker arm and the bridge
head. Set the adjusting screw (3) to the specified value, then
tighten the lock nut.
0.13 to 0.17 mm
Valve clearance Factory spec.
0.0052 to 0.0066 in.
J NOTE
• After adjusting, tighten the lock nut (4) securely.
Valve arrangement
Adjustment cylinder IN. EX
Location of piston
1st I I
When No.1 piston is at 2nd I

compression top dead center 3rd I
4th
1st

overlap position 3rd I
4th I I
6.87 to 11.2 N·m

Cylinder head cover screw 0.700 to 1.15 kgf·m
5.07 to 8.31 lbf·ft
Tightening torque
23 to 36 N·m
Injection pipe retaining nut 2.3 to 3.7 kgf·m
17 to 26 lbf·ft
(1) Adjusting Screw (3) Adjusting Screw

(2) Lock Nut (4) Lock Nut
W1047000
III-G-83
[7] CHECK POINTS OF EVERY 1 OR 2 MONTHS

Recharging
CAUTION
• When the battery is being activated, hydrogen and oxygen
gases in the battery are extremely explosive. Keep open
sparks and flames away from the battery at all times,
especially when charging the battery.
• When charging battery, remove battery vent plugs.
• When disconnecting the cable from the battery, start with
the negative terminal first. When connecting the cable to the
battery, start with the positive terminal first.
• Never check battery charge by placing a metal object across
the posts.
Use a voltmeter or hydrometer.
1) Slow Charging
1. Add distilled water if the electrolyte level is low. When charging,
the amount of electrolyte should be slightly lower than the
specified level to prevent overflow.
2. Connect the battery to the charging unit, following the
manufacture’s instructions.
3. As the electrolyte generates gas while charging, remove all port
caps.
4. The electrolyte temperature must not exceed 40 °C (104 °F)
during charging.
If it exceed 40 °C (104 °F), decrease the charging amperage or
stop charging for a while.
5. When charging several batteries in series, charge at the rate of
the smallest battery in the line.
2) Quick Charging
1. Determine the proper charging current and charging time with the
tester attached to the quick charger.
2. Determine the proper charging current as 1/1 of the battery
capacity. If the battery capacity exceeds 50 Ah, consider 50 A as
the maximum.
J Precaution for Operating a Quick Charger
• Operate with a quick charger differs according to the type.
Consult the instruction manual and use accordingly.
W1052658
III-G-84
Battery Specific Gravity

1. Check the specific gravity of the electrolyte in each cell with a
hydrometer.
2. When the electrolyte temperature differs from that at which the
hydrometer was calibrated, correct the specific gravity reading
following the formula mentioned in (Reference).
3. If the specific gravity is less than 1.215 (after it is corrected for
temperature), charge or replace the battery.
4. If the specific gravity differs between any two cells by more than
0.05, replace the battery.
J NOTE
• Hold the hydrometer tube vertical without removing it from
the electrolyte.
• Do not suck too much electrolyte into the tube.
• Allow the float to move freely and hold the hydrometer at eye
level.
• The hydrometer reading must be taken at the highest
electrolyte level.
(Reference)
• Specific gravity slightly varies with temperature. To be exact, the
specific gravity decreases by 0.0007 with an increase of 1 °C
(0.0004 with an increase of 1 °F) in temperature, and increases
by 0.0007 with a decreases of 1 °C (0.0004 with a decrease of 1
°F).
Therefore, using 20 °C (68 °F) as a reference, the specific gravity
reading must be corrected by the following formula :
- Specific gravity at 20 °C = Measured value + 0.0007 ×
(electrolyte temperature : 20 °C)
- Specific gravity at 68 °F = Measured value + 0.0004 ×
(electrolyte temperature : 68 °F)
Specific Gravity State of Charge
1.260 Sp. Gr. 100 % Charged
1.140 Sp. Gr. Very Little Useful Capacity
1.110 Sp. Gr. Discharged
At an electrolyte temperature of 20 °C (68 °F)
(a) Good (c) Bad
(b) Bad
W1012763
III-G-85

CAUTION
• Check the nozzle injection pressure and condition after confirming that there is nobody standing in the
direction the spray goes.
• If the spray from the nozzle directly contacts the human body, cells may be destroyed and blood poisoning
may be caused.
Nozzle Spraying Condition
1. Attach the injection nozzle to the nozzle tester, and check the
nozzle spraying condition.
2. If the spraying condition is defective, replace the injection nozzle
assembly or repair at Denso service shop.
(a) Good (b) Bad
W10371670
Checking Nozzle Injection Pressure

1. Attach the injection nozzle to the nozzle tester.
2. Slowly move the tester handle to measure the pressure at which
fuel begins jetting out from the nozzle.
3. If the measurement is not within the factory specifications,
replace the injection nozzle assembly or repair at Denso service
shop.
J NOTE
• Injection nozzle gasket must be replaced when the injection
nozzle is removed for checking.
18.64 to 19.61 MPa
Factory 1st
Injection pressure 190.0 to 200.0 kgf/cm2
spec. stage
2703 to 2844 psi
W1037280
Valve Seat Tightness
2. Raise the fuel pressure, and keep at 16.67 MPa (170.0 kgf/cm2,
2418 psi) for 10 seconds.
3. If any fuel leak is found, replace the injection nozzle assembly or
repair at Denso service shop.
No fuel leak at
16.67 MPa
Valve seat tightness Factory spec.
170.0 kgf/cm2
2418 psi
W10374150
III-G-86

Checking Turbocharger
(Turbine Side)
1. Check the exhaust port (2) and inlet port (4) side of turbine
housing (3) to see if there is no exhaust gas leak.
2. If any gas leak is found, retighten the bolts and nuts or replace
the gasket (1) / (5) with new one.
(Compressor Side)
1. Check the inlet hose (9) of the compressor cover (6) to see if
there is no air leak.
2. If any air leak is found, change the clamp (7) and / or inlet hoses
(9).
3. Check the intake hose (8) and the clamp (7) to see if there is not
loose or crack.
4. If any loose or crack is found, tighten the cramp or change the
hose to prevent dust from entry.
(Radial Clearance)
1. If the wheel contact to the housing, replace the turbocharger
assembly with new one.
(1) Gasket (6) Compressor Cover
(2) Exhaust Port (7) Clamp
(3) Turbine Housing (8) Intake Hose
(4) Inlet Port (9) Inlet Hose
(5) Gasket
W1022082
III-G-87
Injection Timing
1. Make sure of matching the injection timing align mark (1) of the
injection pump unit and the flywheel housing, as shown in the
illustration.
2. Remove the injection pipes.
3. Remove the stop solenoid.
4. Turn the flywheel counterclockwise (viewed from flywheel side)
until the fuel fills up to the hole of the delivery valve holder (3) for
No.1 cylinder.
5. After the fuel fills up to the hole of the delivery valve holder (3) for
No.1 cylinder, turn back (clockwise) the flywheel around 1.6 rad
(90 °).
6. Turn the flywheel counterclockwise to set at around 0.17 rad
(10 °) before T.D.C..
7. Slowly turn the flywheel counterclockwise and stop turning when
the fuel begins to come up, to get the present injection timing.
8. Check to see the degree on flywheel.
The flywheel has mark “1TC” for the crank angle before the top
dead center of No.1 piston.
9. If the injection timing is not within the specification, rotate the
injection pump unit to adjust the injection timing.
J IMPORTANT
• When installing the injection pump unit to the engine body,
follow the correct procedure.
See the “Injection Pump Unit”.
V3007-DI-T-E3B
0.00261 rad B.T.D.C. to
0.0235 rad A.T.D.C.
Injection timing Factory spec.
(0.150 ° B.T.D.C. to
1.35 ° A.T.D.C.)
V3307-DI-T-E3B
0.00960 rad B.T.D.C. to
0.0357 rad A.T.D.C.
(0.550 ° B.T.D.C. to
2.05 ° A.T.D.C.)
23 to 36 N·m
17 to 26 lbf·ft
Tightening torque
18 to 20 N·m
Injection pump unit
1.8 to 2.1 kgf·m
mounting nut
13 to 15 lbf·ft
(1) Injection Timing Align Mark (a) Injection Timing Advanced

(2) Injection Pump Unit Mounting Nut (b) Injection Timing Retarded
(3) Delivery Valve Holder
W1036105
III-G-88
Checking Injection Pump

(Fuel Tightness of Pump Element)
1. Remove the engine stop solenoid.
3. Install the injection pump pressure tester (1) to the injection
pump.
4. Install the injection nozzle (2) jetted with the proper injection
pressure to the injection pump pressure tester (1). (Refer to the
figure.)
5. Set the speed control lever to the maximum speed position.
6. Run the starter to increase the pressure.
7. If the pressure can not reach the allowable limit, replace the
pump with new one or repair with a Kubota-authorized pump
service shop.
(Fuel Tightness of Delivery Valve)
3. Install a pressure tester to the fuel injection pump.
pressure to the injection pump pressure tester (1).
6. Stop the starter when the fuel jets from the injection nozzle (2).
After that, turn the flywheel by the hand and raise the pressure to
approx. 18.63 MPa (190.0 kgf/cm2, 2702 psi).
7. Now turn the flywheel back about half a turn (to keep the plunger
free). Maintain the flywheel at this position and clock the time
taken for the pressure to drop from 18.63 to 17.65 MPa (from
190.0 to 180.0 kgf/cm2, from 2702 to 2560 psi).
8. Measure the time needed to decrease the pressure from 18.63 to
17.65 MPa (from 190.0 to 180.0 kgf/cm2, from 2702 to 2560 psi).
9. If the measurement is less than allowable limit, replace the pump
with new one or repair with a Kubota-authorized pump service
shop.
18.63 MPa
Fuel tightness of pump
Allowable limit 190.0 kgf/cm2
element
2702 psi
10 seconds
18.63 → 17.65 MPa
Factory spec.
190.0 → 180.0 kgf/cm2
Fuel tightness of 2702 → 2560 psi
delivery valve 5 seconds
18.63 → 17.65 MPa
Allowable limit
190.0 → 180.0 kgf/cm2
2702 → 2560 psi
J NOTE
• Never try to disassemble the injection pump assembly. For
repairs, you are strongly requested to contact a Kubota-
authorized pump service shop.
(1) Injection Pump Pressure Tester (3) Protection Cover for Jetted Fuel
(2) Injection Nozzle
W1022357
III-G-89
[10] CHECK POINTS OF EVERY 1 YEAR

Changing Engine Oil
CAUTION
J IMPORTANT
• Engine oil should have properties of API classification CF
(See page G-6).
temperature.
Above 25 °C (77 °F)
SAE 10W-40
0 °C to 25 °C (32 °F to 77 °F)
SAE 10W-40
Below 0 °C (32 °F)
SAE 10W-40
11.2 L
Engine oil capacity
2.96 U.S.gals

W1019006
Replacing Air Cleaner Element
1. Remove used air cleaner element.
2. Replace new air cleaner element.
J NOTE
• The air cleaner uses a dry element. Never apply oil to it.
• Do not run the engine with filter element removed.
W1020554
III-G-90
[11] CHECK POINTS OF EVERY 2 YEARS

Replacing Fan Belt
1. Remove the alternator (1).
2. Remove the fan belt (2).
3. Replace new fan belt.
4. Install the alternator.
5. Check the fan belt tension.
10.0 to 12.0 mm / 98 N
Deflection (A) Factory spec. 0.394 to 0.472 in. / 98 N
(10 kgf, 22 lbf)
(1) Alternator (A) Deflection

(2) Fan Belt
W1019333
Changing Radiator Coolant (L.L.C.)
CAUTION
• Do not remove the radiator cap (1) when the engine is hot.
Then loosen cap slightly to the stop to relieve any excess
1. Stop the engine and let cool down.
2. To drain the coolant, open the radiator drain plug (2) and remove
the radiator cap (1). Then radiator cap (1) must be removed to
completely drain the coolant. And open the drain cock of engine
body.
3. After all coolant is drained, close the drain plug (2).
4. Fill with clean water and cooling system cleaner.
5. Follow directions of the cleaner instruction.
6. After flushing, fill with clean water and anti-freeze until the coolant
level is just below the port. Install the radiator cap (1) securely.
7. Fill with coolant up to “FULL” (A) mark on the recovery tank (3).
8. Start and operate the engine for few minutes.
9. Stop the engine and let cool. Check coolant level of radiator and
recovery tank (3) and add coolant if necessary.
J IMPORTANT
• Do not start engine without coolant.
• Use clean, fresh, soft water and anti-freeze to fill the radiator
and recovery tank (3).
• Securely tighten radiator cap (1). If the cap is loose or
improperly fitted, water may leak out and the engine could
overheat.
(1) Radiator Cap A : Full
(2) Drain Plug B : Low
(3) Recovery Tank
W1024599
III-G-91
Changing Radiator Coolant (L.L.C.) (Continued)

(Anti-freeze)
• There are two types of anti-freeze available: use the permanent
type (PT) for this engine.
• Before adding anti-freeze for the first time, clean the radiator
interior by pouring fresh, soft water and draining it a few times.
• The procedure for mixing water and anti-freeze differs according
to the make of the anti-freeze and the ambient temperature.
Basically, it should be referred to SAE J1034 standard, more
specifically also to SAE J814c.
• Mix the anti-freeze with fresh, soft water, and then fill into the
radiator.
J IMPORTANT
Vol % Freezing point Boiling point*
anti-freeze °C °F °C °F
40 –24 –11 106 223
50 –37 –35 108 226
* At 1.013 × 100000 Pa (760 mmHg) pressure (atmospheric). A
higher boiling point is obtained by using a radiator pressure cap
which permits the development of pressure within the cooling
system.
J NOTE
• The above data represents industrial standards that
necessitate a minimum glycol content in the concentrated
anti-freeze.
• When the coolant level drops due to evaporation, add fresh,
soft water only to keep the anti-freeze mixing ratio less than
50 %. In case of leakage, add anti-freeze and fresh, soft
water in the specified mixing ratio.
• Anti-freeze absorbs moisture. Keep unused anti-freeze in a
tightly sealed container.
• Do not use radiator cleaning agents when anti-freeze has
been added to the coolant.
(Anti-freeze contains an anti-corrosive agent, which will
react with the radiator cleaning agent forming sludge which
will affect the engine parts.)
W1024852
Replacing Radiator Hoses and Clamp Bands
CAUTION
• Do not remove the radiator cap when the engine is hot. Then
loosen cap slightly to the stop to relieve any excess
1. Drain the coolant.
2. Loosen the clamp bands.
3. Remove the upper hose (1) and lower hose (2).
4. Replace new upper / lower hose (1), (2) and clamp bands.
5. Tighten the clamp bands.
6. Fill with clean water and anti-freeze until the coolant level is just
below the port. Install the radiator cap securely.
(1) Upper Hose (2) Lower Hose
W1024178
III-G-92
Replacing Fuel Hose and Clamp Bands

1. Loosen the clamp (2) and remove the fuel hose (1).
2. Replace new fuel hose (1) and new clamp (2).
3. Tighten the clamp (2).
CAUTION
• Stop the engine when attempting the check and change
prescribed above.
(When bleeding fuel system)
1. Fill the tank with fuel and open the cock.
2. Loosen the air vent coupling bolt of fuel filter a few turns.
3. When there is no more air bubbles in the fuel coming out of this
coupling bolt, tighten the coupling bolt.
4. Open the air vent cock (3) on the top of fuel injection pump.
5. If equipped electrical fuel feed pump, turn the key on AC position
and pump the fuel up for 10 to 15 seconds.
If equipped mechanical fuel feed pump, set the stop lever on stop
position and crank the engine for 10 to 15 seconds.
6. Close securely the air vent cock (3) after air bleeding.
J IMPORTANT
• Except when venting the air, be sure to keep closed the air
vent coupling bolt of the fuel injection pump. Otherwise, the
engine may stall.
(1) Fuel Hose (3) Air Vent Cock
(2) Clamp
W1020090
Replacing Intake Air Line
1. Loosen the clamp (2).
2. Remove the intake air hose (1) and clamp (2).
3. Replace new intake air hose (1) and new clamp (2).
4. Tighten the clamp (2).
J NOTE
• To prevent serious damage to the engine, keep out any dust
inside the intake air line.
(1) Intake Air Hose (2) Clamp
W1023867
Replacing Battery
CAUTION
• When the battery is being activated, hydrogen and oxygen
gases in the battery are extremely explosive. Keep open
sparks and flames away from the battery at all times,
especially when charging the battery.
• When charging battery, remove battery vent plugs.
• When disconnecting the cable from the battery, start with
the negative terminal first. When connecting the cable to the
battery, start with the positive terminal first.
• Never check battery charge by placing a metal object across
the posts.
1. Disconnect the negative terminal and positive terminal.
2. Remove the battery holder.
3. Remove the used battery.
4. Replace the new battery.
5. Tighten the battery holder.
6. Connect the positive terminal.
7. Connect the negative terminal.
W1023996
III-G-93
5. SPECIAL TOOLS
Diesel Engine Compression Tester
Code No: 07909-30208 (Assembly) 07909-31251 (G)
07909-30934 (A to F) 07909-31271 (I)
07909-31211 (E and F) 07909-31281 (J)
07909-31231 (H)
Application: Use to measure diesel engine compression and
diagnostics of need for major overhaul.
(1) Gauge (7) Adaptor F
(2) L Joint (8) Adaptor G
(3) Adaptor A (9) Adaptor H
(4) Adaptor B (10) Adaptor I
(5) Adaptor C (11) Adaptor J
(6) Adaptor E
W1024200
Oil Pressure Tester
Code No: 07916-32032
Application: Use to measure lubricating oil pressure.
(1) Gauge (5) Adaptor 2
(2) Cable (6) Adaptor 3
(3) Threaded Joint (7) Adaptor 4
(4) Adaptor 1 (8) Adaptor 5
W1024318
III-G-94
J NOTE
• The following special tools are not provided, make them referring to the figure.
Injection Pump Pressure Tester
Application: Use to check fuel tightness of injection pumps.
Pressure gauge full scale : More than 29.4 MPa
A
(300 kgf/cm2, 4270 psi)
B PF 1/2
C Copper gasket
D Flange (Material Steel)
E Hex. nut 27 mm (1.1 in.) across the plat
F Adhesive application
G Fillet welding on the enter circumference
H Retaining nut
I 17 mm dia. (0.67 in. dia.)
J 8.0 mm dia. (0.31 in. dia.)
K 1.0 mm (0.039 in.)
L 17 mm dia. (0.67 in. dia.)
M 6.10 to 6.20 mm dia. (0.241 to 0.244 in. dia.)
N 8.0 mm (0.31 in.)
O 4.0 mm (0.16 in.)
P 11.97 to 11.99 mm dia. (0.4713 to 0.4720 in. dia.)
Q PF 1/2
R 23 mm (0.91 in.)
S 17 mm (0.67 in.)
T 4.0 mm (0.16 in.)
U 12.00 to 12.02 mm dia. (0.4725 to 0.4732 in. dia.)
V 100 mm (3.94 in.)
W M12 × P1.5
X 5.0 mm (0.20 in.)
W10252400
III-G-95
Small End Bushing Replacing Tool

Application: Use to press out and to press fit the small end bushing.
[Press out]
A 157 mm (6.18 in.)
B 14.0 mm (0.551 in.)
C 120 mm (4.72 in.)
D 27.4 mm dia. (1.08 in. dia.)
E 30.950 mm dia. (1.218 in. dia.)
F 20 mm dia. (0.79 in. dia.)
a 6.3 μm (250 μin.)
b 6.3 μm (250 μin.)
C1 Chamfer 1.0 mm (0.039 in.)
[Press fit]
A 157 mm (6.18 in.)
B 14.0 mm (0.551 in.)
C 120 mm (4.72 in.)
D 27.4 mm dia. (1.08 in. dia.)
E 42.000 mm dia. (1.6535 in. dia.)
F 20 mm dia. (0.79 in. dia.)
a 6.3 μm (250 μin.)
b 6.3 μm (250 μin.)
W1040702
Idle Gear Bushing Replacing Tool
Application: Use to press out and to press fit the bushing.
A 196 mm (7.72 in.)
B 25.0 mm (0.984 in.)
C 150 mm (5.91 in.)
D 34.5 mm dia. (1.36 in. dia.)
E 38.075 to 38.100 mm dia. (1.4991 to 1.5000 in. dia.)
F 20 mm dia. (0.79 in. dia.)
a 6.3 μm (250 μin.)
b 6.3 μm (250 μin.)
W1040289
III-G-96
Valve Guide Replacing Tool

Application: Use to press out and press fit the valve guide.
A 225 mm (8.86 in.)
B 70 mm (2.8 in.)
C 45 mm (1.8 in.)
D 20 mm dia. (0.79 in dia.)
E 11.7 to 11.9 mm dia. (0.461 to 0.468 in. dia.)
F 6.50 to 6.60 mm dia. (0.256 to 0.259 in. dia.)
G 25 mm dia. (0.98 in. dia.)
H 6.70 to 7.00 mm dia. (0.264 to 0.275 in. dia.)
I 5.0 mm (0.20 in.)
J 20 mm dia. (0.79 in.dia.)
K 12.5 to 12.8 mm dia. (0.493 to 0.503 in. dia.)
L 8.50 to 8.90 mm (0.335 to 0.350 in.)
C0.3 Chamfer 0.30 mm (0.012 in.)
W1038887
Camshaft Cover Replacing Tool

Application: Use to press fit the camshaft cover.
A 30.0 mm (1.18 in.)
B 30.0 mm dia., 20.0 mm depth (1.18 in. dia., 0.79 in. depth)
C 47.975 to 48.000 mm (1.8888 to 1.8897 in.)
D 52.0 mm (2.05 in.)
E 80.0 mm (3.15 in.)
F 16.5 to 16.6 mm (0.650 to 0.653 in.)
G 80.0 mm (3.15 in.)
H 10.0 mm (0.394 in.)
I 26.0 mm (1.02 in.)
J 100 mm (3.94 in.)
K 6.0 mm (0.24 in.)
L 132 mm (5.20 in.)
M 1.0 mm (0.039 in.)
a 1.0 mm radius (0.039 in. radius)
b 2.0 mm radius (0.079 in. radius)
c Ra = 3.2a
d 0.40 mm radius (0.016 in. radius)
C0.5 Chamfer 0.50 mm (0.020 in.)
W1014056
III-G-97
Front Cover Oil Seal Replacing Tool

Application: Use to press fit the front cover oil seal.
A 120 mm (4.72 in.)

B 12.0 mm (0.472 in.)
C 2.90 to 3.00 mm (0.115 to 0.118 in.)
D 10.0 mm (0.394 in.)
E 80.0 mm (3.15 in.)
F 10.0 mm (0.394 in.)
G 95.0 mm dia. (3.74 in. dia.)
78.900 to 79.100 mm dia.
H
(3.1063 to 3.1141 in. dia.)
57.971 to 57.990 mm dia.
I
(2.2824 to 2.2830 in. dia.)
J 50.0 mm dia. (1.97 in. dia.)
K 15.0 mm dia. (0.591 in. dia.)
L 30.0 mm dia. (1.18 in. dia.)
M 15.0 mm (0.591 in.)
N 90.0 mm (3.54 in.)
O 2.50 mm (0.0984 in.)
P 0.35 rad (20 °)
0.15 to 0.25 mm
Q
(0.0059 to 0.0098 in.)
a Ra = 3.2 a
b Ra = 1.6 a
c 0.80 mm radius (0.031 in. radius)
C0.5 Chamfer 0.50 mm (0.020 in.)
W1014589
III-G-98
Flywheel Housing Oil Seal Replacing Tool

Application: Use to press fit the flywheel housing oil seal.
A 118 mm (4.65 in.)

B 12.0 mm (0.472 in.)
C 0.90 to 1.0 mm (0.036 to 0.039 in.)
D 10.0 mm (0.394 in.)
E 80.0 mm (3.15 in.)
F 10.0 mm (0.394 in.)
G 120 mm dia. (4.72 in. dia.)
100.90 to 101.10 mm dia.
H
(3.9725 to 3.9803 in. dia.)
86.966 to 86.988 mm dia.
I
(3.4239 to 3.4247 in. dia.)
J 79.0 mm dia. (3.11 in. dia.)
K 15.0 mm dia. (0.591 in. dia.)
L 30.0 mm dia. (1.18 in. dia.)
M 13.0 mm (0.512 in.)
N 90.0 mm (3.54 in.)
O 2.50 mm (0.0984 in.)
P 0.35 rad (20 °)
0.15 to 0.25 mm
Q
(0.0059 to 0.0098 in.)
a Ra = 3.2 a
b Ra = 1.6 a
c 0.80 mm radius (0.031 in. radius)
e 0.20 mm radius (0.0079 in. radius)
C0.3 Chamfer 0.30 mm (0.012 in.)
W1015151
III-G-99
Valve Bridge Shaft Replacing Tool

Application: Use to press fit the valve bridge shaft.
A 9.50 mm dia. (0.374 in. dia.) through hole
B 19.0 mm (0.748 in.)
C 23.2 mm (0.913 in.)
D 42.00 to 42.40 mm (1.654 to 1.669 in.)
E 12.5 mm dia. (0.492 in. dia.) through hole
F 61.0 mm (2.40 in.)
G 18.7 mm (0.736 in.)
H 30.90 to 31.70 mm (1.217 to 1.248 in.)
C0.5 Chamfer 0.50 mm (0.020 in.)
W1015898
III-G-100
Auxiliary Socket for Fixing Crankshaft Sleeve

Application: Use to fix the crankshaft sleeve of the diesel engine.
A 1.50 mm (0.0591 in.) Q 33.0 mm (1.30 in.)

B 0.52 rad (30 °) R 115 mm (4.53 in.)
C 34.925 to 34.950 mm dia. (1.3750 to 1.3759 in. dia.) S 43.0 mm (1.69 in.)
D 22 mm dia. (0.8661 in. dia.) T 120 mm (4.72 in.)
E 81.980 to 81.985 mm dia. (3.2276 to 3.2277 in. dia.) U 163 mm (6.42 in.)
F 6.0 mm (0.24 in.) V 8.0 mm dia. (0.31 in. dia.)
G 23.5 mm (0.925 in.) W 33.475 to 33.525 mm (1.3180 to 1.3198 in.)
H 29.5 mm (1.16 in.) a Ra = 1.6 a
I 58.0 mm (2.28 in.) b 0.50 mm radius (0.020 in. radius)
J 95.0 mm (3.74 in.) c Ra = 3.2 a
K 98.0 mm dia. (3.86 in. dia.) d 1.50 mm radius (0.0591 in. radius)
L 0.52 rad (30 °) e 10.0 mm radius (0.394 in. radius)
M 82.100 to 82.200 mm dia. (3.2323 to 3.2362 in. dia.) C1 Chamfer 1.0 mm (0.039 in.)
N 1.50 mm (0.0591 in.) C3 Chamfer 3.0 mm (0.12 in.)
O 15.0 mm dia. (0.591 in. dia.) C5 Chamfer 5.0 mm (0.20 in.)
P 30.0 mm dia. (1.18 in. dia.)
(1) Sleeve Guide (2) Auxiliary Socket for Pushing
III-G-101
Engine Stand
Application: Use to support engine.
A 107 mm (4.21 in.)
B 246 mm (9.68 in.)
C 21 mm (0.83 in.)
D 204 mm (8.03 in.)
E 102 mm (4.02 in.)
F 15 mm (0.59 in.)
G 59 mm (2.3 in.)
H 14 mm dia. (0.55 in. dia.)
I 80 mm radius (3.1 in. radius)
J 70 mm (2.8 in.)
K 460 mm (18.1 in.)
L 270 mm (10.6 in.)
M 6.0 mm (0.24 in.)
N 70 mm (2.8 in.)
C10 Chamfer 10 mm (0.39 in.)
W1033645
Tool for Aligning the Crankcase 1 and 2
Application: Use for aligning the crankcase 1 and 2.
A 126.6 mm (4.984 in.)
B 49.1 mm (1.93 in.)
C 37.5 mm (1.48 in.)
D 20 mm (0.79 in.)
E 14 mm dia. (0.55 in. dia.)
F 14 mm dia. (0.55 in. dia.)
G 14 mm dia. (0.55 in. dia.)
H 17.5 mm (0.689 in.)
I 17.5 mm (0.689 in.)
J 35 mm (1.4 in.)
K 19 mm (0.75 in.)
W1047882
III-G-102
Flywheel Housing Guide

Application: Use to install the flywheel housing to the crankcase.
A 70.0 mm (2.76 in.)

B 8.0 mm (0.31 in.)
C 22.0 mm (0.866 in.)
D 30.0 mm (1.18 in.)
E 87.0 mm dia. (3.43 in. dia.)
82.036 to 82.071 mm dia.
F
(3.2298 to 3.2311 in. dia.)
G 77.0 mm dia. (3.03 in. dia.)
H 57.0 mm dia. (2.24 in. dia.)
I 35.0 mm dia. (1.38 in. dia.)
J 30.0 mm dia. (1.18 in. dia.)
K 84.0 mm dia. (3.31 in. dia.)
L 3.5 mm (0.14 in.)
M 3.0 mm (0.12 in.)
N 6.60 to 6.80 mm (0.260 to 0.267 in.)
O 8.0 mm (0.31 in.)
P 67.0 mm dia. (2.64 in. dia.)
4.0 mm dia. (0.16 in. dia.)
Q
through hole
a Ra = 1.6 a
c Ra = 3.2 a
C0.5 Chamfer 0.50 mm (0.020 in.)
W1017819
III-G-103
Glow Plug Adapter

Application: Use to check compression pressure through glow plug hole.
A 3.0 mm dia. (0.12 in. dia.) through hole L 1.0 rad (60 °)
B 17.0 mm (0.669 in.) M 1.0 mm (0.039 in.)
C 16.0 mm dia. (0.630 in. dia.) P0.5 N 17.0 mm (0.669 in.)
D 13.0 mm dia. (0.512 in. dia.) O 61.5 mm (2.42 in.)
E 9.5 mm dia. (0.37 in. dia.) P 15.0 mm (0.591 in.)
F M8 x 1.0 Q 10.0 mm (0.394 in.)
G 6.50 to 6.70 mm dia. (0.256 to 0.263 in. dia.) R 100 mm (3.94 in.)
H 2.145 to 2.148 rad (122.9 to 123.1 °) S 79.5 mm (3.13 in.)
I 4.90 to 5.50 mm dia. (0.193 to 0.216 in. dia.) T 204.5 mm (8.051 in.)
J 0.52 rad (30 °) C1.5 Chamfer 1.5 mm (0.059 in.)
K 5.0 mm (0.20 in.)
III-G-104
Injection Pump Gear Puller

Application: Use for remove the injection pump gear from governor shaft.
M35 x P1.5, 6.0 mm depth

A
(0.24 in. depth)
35.0 mm dia., 12.0 mm depth
B
(1.38 in. dia., 0.472 in. depth)
30.0 mm dia., 27.5 mm depth
C
(1.18 in. dia., 1.08 in. depth)
40.00 to 40.20 mm dia.
D
(1.575 to 1.582 in. dia.)
35.90 to 36.10 mm dia.
E
(1.414 to 1.421 in. dia.)
F 2.09 rad (120 °)
G M8
H 9.0 mm dia. (0.35 in. dia.)
I 19.0 mm dia. (0.748 in. dia.)
J 12.0 mm (0.472 in.)
K 15.0 mm (0.591 in.)
L 27.5 mm (1.08 in.)
M 31.0 mm (1.22 in.)
N 57.5 mm (2.26 in.)
O 100 mm (3.94 in.)
3.75 to 4.00 mm
P
(0.148 to 0.157 in.)
Q 16.17 mm (0.6366 in.)
C0.2 Chamfer 0.20 mm (0.0079 in.)
C0.5 Chamfer 0.50 mm (0.020 in.)
W1018612
III-G-105
Jig for Governor Connecting Rod

Application: Use for connecting the governor connecting rod to the rack pin of the fuel injection pump assembly.
A 0.50 mm (0.020 in.) O 5.0 mm (0.20 in.)

B 12.7 to 13.0 mm (0.500 to 0.511 in.) P 4.0 mm (0.16 in.)
C 8.70 to 9.00 mm (0.343 to 0.354 in.) Q 2.955 to 2.965 mm dia. (0.1164 to 0.1167 in. dia.)
D 39.0 mm (1.54 in.) R 3.020 to 3.030 mm dia. (0.1189 to 0.1192 in. dia.)
E 10.0 mm (0.394 in.) S Ra = 1.6 a
F 7.0 mm (0.28 in.) AA Governor housing side
G 6.0 mm (0.24 in.) BB Press in side
H 80.0 mm (3.15 in.) a 0.60 mm radius (0.024 in. radius)
I 27.95 to 28.05 mm (1.101 to 1.104 in.) b 1.0 mm radius (0.039 in. radius)
J 5.0 mm (0.20 in.) C0.2 Chamfer 0.20 mm (0.0079 in.)
3.000 to 3.010 mm dia., 6.0 mm depth (0.1182 to 0.1185
K C0.4 Chamfer 0.40 mm (0.016 in.)
in. dia., 0.24 in. depth)
L 9.0 mm (0.35 in.) C0.5 Chamfer 0.50 mm (0.020 in.)
M 5.0 mm (0.20 in.) C1 Chamfer 1.0 mm (0.039 in.)
N 14.45 to 14.55 mm (0.5689 to 0.5728 in.) C2 Chamfer 2.0 mm (0.079 in.)
(1) Material : S43C-D (2) Permanent Magnet : (3) Pin

8.0 mm dia. (0.31 in. dia.)
Thickness : 3.0 mm (0.12 in.)
III-G-106
Pin for Balancer Shaft Bearing Replacing Tool (for Balancer

Model)
A 7.20 to 7.40 mm (0.284 to 0.291 in.)
B 4.0 mm dia. (0.16 in. dia.)
C Ra = 0.8 a
C0.1 Chamfer 0.10 mm (0.0039 in.)
C0.5 Chamfer 0.50 mm (0.020 in.)
W1020662
III-G-107
Balancer Shaft 1 Bearing A Replacing Tool (for Balancer Model)

Application: Use to press fit the bearing.
A 18.0 mm (0.709 in.) T 23.0 mm (0.906 in.)

B 130 mm (5.12 in.) U 0.35 rad (20 °)
C 1.2 mm (0.047 in.) V 24.0 mm (0.945 in.)
D 34.0 mm (1.34 in.) W 12.0 mm (0.472 in.)
E 99.0 mm (3.90 in.) X 12.0 mm (0.472 in.)
4.000 to 4.018 mm dia., 7.0 mm depth
F Y 12.0 mm (0.472 in.)
(0.1575 to 0.1581 in. dia., 0.28 in. depth)
G 53.0 mm dia. (2.09 in. dia.) Z 4.0 mm (0.16 in.)
H 48.80 to 48.90 mm dia. (1.922 to 1.925 in. dia.) a 3.0 mm (0.12 in.)
I 0.52 rad (30 °) b 35.0 mm (1.38 in.)
J 40.0 mm dia. (1.57 in. dia.) c 53.0 mm (2.09 in.)
K 20.0 mm dia. (0.787 in. dia.) d 3.0 mm (0.12 in.)
L 34.90 to 35.00 mm dia. (1.374 to 1.377 in. dia.) e 2.0 mm (0.079 in.)
M 1.5 mm (0.059 in.) f Ra = 3.2 a
N 5.5 to 6.5 mm (0.22 to 0.25 in.) g 0.80 mm radius (0.031 in. radius)
O 33.0 mm (1.30 in.) h 0.30 mm radius (0.012 in. radius)
P 134 mm (5.28 in.) i 7.0 mm radius (0.28 in. radius)
Q 167 mm (6.57 in.) j 0.40 mm radius (0.016 in. radius)
R 1.53 rad (87.5 °) C0.5 Chamfer 0.50 mm (0.020 in.)
S 35.0 mm dia. (1.38 in. dia.) C1 Chamfer 1.0 mm (0.039 in.)
(1) Shaft (2) Stopper
III-G-108
Balancer Shaft 1 Bearing C Replacing Tool (for Balancer Model)

A 52.5 mm dia. (2.07 in. dia.) V 0.86 rad (49 °)

B 48.40 to 48.50 mm dia. (1.906 to 1.909 in.) W 0.428 rad (24.5 °)
C 40.0 mm dia. (1.57 in. dia.) X 35.0 mm dia. (1.38 in. dia.)
D 0.52 rad (30 °) Y 23.0 mm (0.906 in.)
E 18.0 mm (0.709 in.) Z 0.35 rad (20 °)
F 1.2 mm (0.047 in.) a 24.0 mm (0.945 in.)
4.000 to 4.018 mm dia., 7.0 mm depth
G b 16.0 mm (0.630 in.)
(0.1575 to 0.1581 in. dia., 0.28 in. depth)
H 20.0 mm dia. (0.787 in. dia.) c 12.0 mm (0.472 in.)
I 46.0 mm dia. (1.81 in. dia.) d 12.0 mm (0.472 in.)
J 34.0 mm (1.34 in.) e 4.0 mm (0.16 in.)
K 99.0 mm (3.90 in.) f 35.0 mm (1.38 in.)
L 34.90 to 35.00 mm dia. (1.374 to 1.378 in. dia.) g 53.0 mm (2.09 in.)
M 1.5 mm (0.059 in.) h 2.0 mm (0.079 in.)
N 8.0 mm (0.31 in.) i 3.0 mm (0.12 in.)
O 193.5 mm (7.618 in.) j Ra = 3.2 a
P 10.0 mm (0.394 in.) k 0.80 mm radius (0.031 in. radius)
Q 6.0 mm (0.24 in.) l 0.30 mm radius (0.012 in. radius)
R 25.0 mm (0.984 in.) m 7.0 mm radius (0.28 in. radius)
S 211 to 212 mm (8.31 to 8.34 in.) n 0.40 mm radius (0.016 in. radius)
T 134 mm (5.28 in.) C0.5 Chamfer 0.50 mm (0.020 in.)
U 370.5 mm (14.59 in.) C1 Chamfer 1.0 mm (0.039 in.)
III-G-109
Balancer Shaft 1 Bearing D Replacing Tool (for Balancer Model)

A 34.5 mm dia. (1.36 in. dia.) V 35.0 mm dia. (1.38 in. dia.)
B 30.80 to 30.90 mm dia. (1.213 to 1.216 in. dia.) W 23.0 mm (0.906 in.)
C 24.0 mm dia. (0.945 in. dia.) X 0.35 rad (20 °)
D 0.52 rad (30 °) Y 24.0 mm (0.945 in.)
E 0.52 rad (30 °) Z 12.0 mm (0.472 in.)
4.000 to 4.018 mm dia., 7.0 mm depth
F a 12.0 mm (0.472 in.)
(0.1575 to 0.1581 in. dia., 0.28 in. depth)
G 26.0 mm dia. (1.02 in. dia.) b 12.0 mm (0.472 in.)
H 46.0 mm dia. (1.81 in. dia.) c 4.0 mm (0.16 in.)
I 34.0 mm (1.34 in.) d 3.0 mm (0.12 in.)
J 99.0 mm (3.90 in.) e 35.0 mm (1.38 in.)
K 34.90 to 35.00 mm dia. (1.374 to 1.377 in. dia.) f 53.0 mm (2.09 in.)
L 5.0 mm (0.20 in.) g 3.0 mm (0.12 in.)
M 1.5 mm (0.059 in.) h 2.0 mm (0.079 in.)
N 8.0 mm (0.31 in.) i Ra = 3.2 a
O 10.0 mm (0.394 in.) j 2.0 mm radius (0.079 in. radius)
P 29.5 mm (1.16 in.) l 0.30 mm radius (0.012 in. radius)
Q 24.5 mm (0.965 in.) k 0.80 mm radius (0.031 in. radius)
R 413.5 to 414.5 mm (16.28 to 16.31 in.) m 7.0 mm radius (0.28 in. radius)
S 134 mm (5.28 in.) n 0.40 mm radius (0.016 in. radius)
T 468 mm (18.4 in.) C0.5 Chamfer 0.50 mm (0.020 in.)
U 1.1 rad (65 °) C1 Chamfer 1.0 mm (0.039 in.)
III-G-110
Balancer Shaft 2 Bearing B Replacing Tool (for Balancer Model)

A 18.0 mm (0.709 in.) Q 0.52 rad (30 °)

B 125 mm (4.92 in.) R 35.0 mm dia. (1.38 in. dia.)
C 1.2 mm (0.047 in.) S 9.0 mm (0.35 in.)
4.000 to 4.018 mm dia., 7.0 mm depth
D T 0.52 rad (30 °)
(0.1575 to 0.1581 in. dia., 0.28 in. depth)
E 53.0 mm dia. (2.09 in.) U 84.5 to 85.5 mm (3.33 to 3.36 in.)
F 48.80 to 48.90 mm dia. (1.922 to 1.925 in. dia.) V 50.0 mm (1.97 in.)
G 40.0 mm dia. (1.57 in. dia.) W 0.70 rad (40 °)
H 0.52 rad (30 °) X 2.0 mm (0.079 in.)
I 1.5 mm (0.059 in.) Y 3.0 mm (0.12 in.)
J 20.0 mm dia. (0.787 in. dia.) a 0.80 mm radius (0.031 in. radius)
K 34.90 to 35.00 mm dia. (1.374 to 1.377 in. dia.) b Ra = 3.2 a
L 19.5 to 20.5 mm dia. (0.768 to 0.807 in. dia.) c 0.20 mm radius (0.0079 in. radius)
M 20.0 mm (0.787 in.) d 8.0 mm radius (0.31 in. radius)
N 99.0 mm (3.90 in.) e 0.40 mm radius (0.016 in. radius)
O 44.0 mm (1.73 in.) C0.5 Chamfer 0.50 mm (0.020 in.)
P 120 mm (4.72 in.) C1 Chamfer 1.0 mm (0.039 in.)
III-G-111
Balancer Shaft 2 Bearing C Replacing Tool (for Balancer Model)

A 52.5 mm dia. (2.07 in. dia.) V 9.0 mm (0.35 in.)

B 48.30 to 48.40 mm dia. (1.902 to 1.905 in.) W 84.5 to 85.5 mm (3.33 to 3.36 in.)
C 40.0 mm dia. (1.57 in. dia.) X 0.35 rad (20 °)
D 0.52 rad (30 °) Y 14.54 mm (0.5724 in.)
E 1.5 mm (0.059 in.) Z 39.94 mm (1.572 in.)
F 18.0 mm (0.709 in.) a 50.0 mm (1.97 in.)
G 1.2 mm (0.047 in.) b 0.87 rad (50 °)
4.000 to 4.018 mm dia., 7.0 mm depth
H c 18.0 mm (0.709 in.)
(0.1575 to 0.1581 in. dia., 0.28 in. depth)
I 20.0 mm dia. (0.787 in. dia.) d 4.0 mm (0.16 in.)
J 46.0 mm dia. (1.81 in. dia.) e 12.0 mm (0.472 in.)
K 34.90 to 35.00 mm dia. (1.374 to 1.378 in. dia.) f 15.0 mm (0.591 in.)
L 8.0 mm (0.31 in.) g 0.70 rad (40 °)
M 199.5 mm (7.854 in.) h 3.0 mm (0.12 in.)
N 15.0 mm (0.591 in.) i 2.0 mm (0.079 in.)
O 100 mm (3.94 in.) j Ra = 3.2 a
P 6.0 mm (0.24 in.) l 0.20 mm radius (0.0079 in. radius)
Q 25.0 mm (0.984 in.) k 0.80 mm radius (0.031 in. radius)
R 222 to 223 mm (8.74 to 8.77 in.) m 8.0 mm radius (0.31 in. radius)
S 120 mm (4.72 in.) n 0.40 mm radius (0.016 in. radius)
T 0.70 rad (40 °) C0.5 Chamfer 0.50 mm (0.020 in.)
U 35.0 mm dia. (1.38 in.) C1 Chamfer 1.0 mm (0.039 in.)
III-G-112
Balancer Shaft 2 Bearing D Replacing Tool (for Balancer Model)

A 34.5 mm dia. (1.36 in. dia.) T 120 mm (4.72 in.)

B 30.80 to 30.90 mm dia. (1.213 to 1.216 in.) U 479 mm (18.9 in.)
C 24.0 mm dia. (0.945 in. dia.) V 1.6 rad (92 °)
D 0.52 rad (30 °) W 35.0 mm dia. (1.38 in. dia.)
E 0.52 rad (30 °) X 9.0 mm (0.35 in.)
F 26.0 mm dia. (1.02 in. dia.) Y 0.52 rad (30 °)
G 46.0 mm dia. (1.81 in. dia.) Z 84.5 to 85.5 mm (3.33 to 3.36 in.)
H 34.90 to 35.00 mm dia. (1.374 to 1.377 in. dia.) a 50.0 mm (1.97 in.)
4.000 to 4.018 mm dia., 7.0 mm depth
I b 0.70 rad (40 °)
(0.1575 to 0.1581 in. dia., 0.28 in. depth)
J 1.2 mm (0.047 in.) c 2.0 mm (0.079 in.)
K 5.0 mm (0.20 in.) d 3.0 mm (0.12 in.)
L 1.5 mm (0.059 in.) e 2.0 mm radius (0.079 in. radius)
M 8.0 mm (0.31 in.) f Ra = 3.2 a
N 15.0 mm (0.591 in.) g 0.30 mm radius (0.012 in. radius)
O 20.0 mm (0.787 in.) h 0.80 mm radius (0.031 in. radius)
P 99.0 mm (3.90 in.) i 8.0 mm radius (0.31 in. radius)
Q 29.5 mm (1.16 in.) j 0.40 mm radius (0.016 in. radius)
R 24.5 mm (0.965 in.) C0.5 Chamfer 0.50 mm (0.020 in.)
S 424.5 to 425.5 mm (16.72 to 16.75 in.) C1 Chamfer 1.0 mm (0.039 in.)
III-G-113
III-G-114
SERVICING
1. TROUBLESHOOTING ..............................................................................III-S-117
2. SERVICING SPECIFICATIONS ..............................................................III-S-121
3. TIGHTENING TORQUES ........................................................................III-S-128
[1] TIGHTENING TORQUES FOR GENERAL USE SCREWS, BOLTS
AND NUTS.........................................................................................III-S-128
[2] TIGHTENING TORQUES FOR SPECIAL USE SCREWS, BOLTS
AND NUTS.........................................................................................III-S-129
4. CHECKING, DISASSEMBLING AND SERVICING ...............................III-S-131
[1] CHECKING AND ADJUSTING .........................................................III-S-131
(1) Engine Body .................................................................................III-S-131
(2) Lubricating System .......................................................................III-S-133
(3) Cooling System.............................................................................III-S-133
(4) Fuel System ..................................................................................III-S-136
(5) Electrical System ..........................................................................III-S-139
(6) Turbocharger ................................................................................III-S-143
(7) EGR System .................................................................................III-S-144
[2] DISASSEMBLING AND ASSEMBLING............................................III-S-146
(1) Draining Oil and Coolant...............................................................III-S-146
(2) External Components ...................................................................III-S-147
(3) Exhaust Gas Recirculation (EGR) ................................................III-S-149
(4) Cylinder Head and Valves ............................................................III-S-150
(5) Thermostat....................................................................................III-S-154
(6) Injection Pump Unit.......................................................................III-S-155
(7) Water Pump and Oil Cooler ..........................................................III-S-164
(8) Front Cover ...................................................................................III-S-165
(9) Flywheel and Timing Gears ..........................................................III-S-166
(10)Piston and Connecting Rod..........................................................III-S-170
(11)Crankshaft and Crankcase ...........................................................III-S-173
(12)Starter...........................................................................................III-S-175
(13)Alternator ......................................................................................III-S-175
[3] SERVICING ........................................................................................III-S-178
(1) Cylinder Head and Valves ............................................................III-S-178
(2) Timing Gears ................................................................................III-S-184
(3) Piston and Connecting Rod ..........................................................III-S-190
(4) Crankshaft ....................................................................................III-S-192
(5) Cylinder.........................................................................................III-S-196
(6) Oil Pump .......................................................................................III-S-196
(7) Starter ...........................................................................................III-S-197
(8) Alternator ......................................................................................III-S-199
III-S-115
III-S-116
1. TROUBLESHOOTING
Reference
Symptom Probable Cause Solution
Page
Engine Does Not Start No fuel Replenish fuel III-G-77
Air in the fuel system Vent air III-G-77
Water in the fuel system Change fuel and repair –
or replace fuel system
Fuel hose clogged Clean or replace III-G-77, 93
Fuel filter clogged Replace III-G-79, 81
Excessively high viscosity of fuel or engine oil at Use specified fuel or III-G-80
low temperature engine oil
Fuel with low cetane number Use specified fuel III-G-73
Fuel leak due to loose injection pipe retaining nut Tighten retaining nut III-S-150
Incorrect injection timing Adjust III-S-136
Fuel camshaft worn Replace III-S-160
Injection nozzle clogged Repair or replace III-S-138, 151
Injection pump malfunctioning Repair or replace III-S-137, 162
Seizure of crankshaft, camshaft, piston, cylinder or Repair or replace –
bearing
Compression leak from cylinder Replace head gasket, III-S-150 to
tighten cylinder head 154
screw, glow plug and
nozzle holder
Improper valve timing Correct or replace III-S-169
timing gear
Piston ring and cylinder worn Replace III-S-171,
172, 191, 196
Excessive valve clearance Adjust III-S-132
Stop solenoid malfunctioning Replace III-S-142
Starter Does Not Run Battery discharged Charge III-G-84, 85
Starter malfunctioning Repair or replace III-S-141,
175, 197
Key switch malfunctioning Replace –
Wiring disconnected Connect –
W1034445
III-S-117
Reference
Page
Engine Revolution Is Fuel filter clogged or dirty Replace III-G-79, 81
Not Smooth Air cleaner clogged Clean or replace III-G-78, 90
Fuel leak due to loose injection pipe retaining nut Tighten retaining nut III-S-150
Incorrect nozzle opening pressure Repair or replace III-S-138, 151
Injection nozzle stuck or clogged Repair or replace III-S-138, 151
Governor malfunctioning Repair III-S-157, 158
Turbocharger bearing worn out Replace the III-S-143, 147
turbocharger assembly
Turbocharger shaft bent Replace the III-S-143, 147
Turbocharger fin or other part damaged due to Replace the III-S-143, 147
foreign matters turbocharger assembly
Either White or Blue Excessive engine oil Reduce to specified III-G-74, 76
Exhaust Gas Is level
Observed Piston ring and cylinder worn or stuck Repair or replace III-S-171,
172, 191, 196
Oil Leak into Exhaust Waste oil pipe clogged or deformed Repair or replace III-S-147
Pipe or Suction Pipe Turbocharger’s piston ring seal faulty Replace the III-S-147
Either Black or Dark Overload Reduce the load –
Gray Exhaust Gas Is Low grade fuel used Use specified fuel III-G-73
Observed
Fuel filter clogged Replace III-G-79, 81
Air cleaner clogged Clean or replace III-G-78, 90
Deficient nozzle injection Repair or replace III-S-138, 151
nozzle
W1036076
III-S-118
Reference
Page
Deficient Output Incorrect injection timing Adjust III-S-136
Engine’s moving parts seem to be seizing Repair or replace –
Deficient nozzle injection Repair or replace III-S-138, 151
nozzle
Compression leak Check the III-S-131, 150
compression pressure to 154
and repair
Gas leak from exhaust system Repair or replace III-S-143, 147
Air leak from compressor discharge side Repair or replace III-S-143, 147
Air cleaner dirty or clogged Clean or replace III-G-78, 90
Compressor wheel turning heavily Replace the III-S-143, 147
Excessive Lubricant Piston ring’s gap facing the same direction Shift ring gap direction III-S-171, 172
Oil Consumption Oil ring worn or stuck Replace III-S-171,
172, 191
Piston ring groove worn Replace piston III-S-171,
172, 191
Valve stem and valve guide worn Replace III-S-154, 180
Crankshaft bearing and crank pin bearing worn Replace III-S-172,
173, 192, 194
Oil leaking due to defective seals or packing Replace –
Fuel Mixed into Injection pump’s plunger worn Repair or replace III-S-137, 162
Lubricant Oil Deficient nozzle injection Repair or replace III-S-138, 151
nozzle
Injection pump broken Replace III-S-137, 162
Water Mixed into Head gasket defective Replace III-S-152, 153
Lubricant Oil Cylinder block or cylinder head flawed Replace III-S-179
Low Oil Pressure Engine oil insufficient Replenish III-G-74, 76
Oil strainer clogged Clean III-S-170
Relief valve stuck with dirt Clean III-S-165
Relief valve spring weaken or broken Replace III-S-165
Excessive oil clearance of crankshaft bearing Replace III-S-173, 194
Excessive oil clearance of crankpin bearing Replace III-S-172, 193
Excessive oil clearance of rocker arm Replace III-S-151, 182
Oil passage clogged Clean –
Different type of oil Use specified type of III-G-73, 76
oil
Oil pump defective Replace III-S-133, 196
W1037777
III-S-119
Reference
Page
High Oil Pressure Different type of oil Use specified type of III-G-73, 76
oil
Relief valve defective Replace III-S-165
Engine Overheated Engine oil insufficient Replenish III-G-74, 76
Fan belt broken or elongated Replace or adjust III-G-78, 81
Coolant insufficient Replenish III-G-75, 82
Radiator net and radiator fin clogged with dust Clean –
Inside of radiator corroded Clean or replace III-G-81
Coolant flow route corroded Clean or replace III-G-81
Radiator cap defective Replace III-S-134
Overload running Reduce the load –
Head gasket defective Replace III-S-152, 153
Unsuitable fuel used Use specified fuel III-G-73
Battery Quickly Battery electrolyte insufficient Replenish distilled III-G-84, 85
Discharged water and charge
Fan belt slips Adjust belt tension or III-G-78, 81
replace
Wiring disconnected Connect –
Rectifier defective Replace III-S-142, 175
Alternator defective Replace III-S-142, 175
Battery defective Replace III-G-93,
III-S-139, 140
W1168623
III-S-120
2. SERVICING SPECIFICATIONS
ENGINE BODY
Item Factory Specification Allowable Limit
Compression Pressure 3.92 MPa / 2.90 MPa /
250 min−1 (rpm) 250 min−1 (rpm)
40.0 kgf/cm2 / 29.6 kgf/cm2 /
250 min−1 (rpm) 250 min−1 (rpm)
569 psi / 421 psi /
250 min−1 (rpm) 250 min−1 (rpm)
Variance Among Cylinders – 10 % or less
Valve Clearance (Cold) 0.13 to 0.17 mm –
0.0052 to 0.0068 in.
Top Clearance 0.60 to 0.80 mm –
0.024 to 0.031 in.
Cylinder Head Surface Flatness – 0.05 mm
0.002 in.
Valve Recessing (Intake and Exhaust) 0.65 to 0.85 mm 1.20 mm
0.026 to 0.033 in. 0.0472 in.
Valve Stem to Valve Guide (Intake and Clearance 0.055 to 0.085 mm 0.10 mm
Exhaust) 0.0022 to 0.0033 in. 0.0039 in.
Valve Stem O.D. 6.960 to 6.975 mm –

0.2741 to 0.2746 in.
Valve Guide I.D. 7.030 to 7.045 mm –

0.2768 to 0.2773 in.
Valve Face (Intake and Exhaust) Angle 0.79 rad –
(45 °)
Valve Seat (Intake and Exhaust) Angle 0.79 rad –
(45 °)
Width 3.3 to 3.6 mm –

0.13 to 0.14 in.
Intake Valve Timing Open 0.24 rad (14 °) –
before T.D.C.
Close 0.70 rad (40 °) –

after B.D.C.
Exhaust Valve Timing Open 0.87 rad (50 °) –
before B.D.C.
Close 0.24 rad (14 °) –

after T.D.C.
Valve Spring (Intake and Exhaust) Tilt – 1.0 mm
0.039 in.
Free Length 35.1 to 35.6 mm 34.6 mm

1.39 to 1.40 in. 1.36 in.
W1039573
III-S-121
ENGINE BODY (Continued)

Valve Spring (Intake and Exhaust) Setting Load / 63.5 N / 31.5 mm 45.9 N /
Setting Length 6.48 kgf / 31.5 mm 31.5 mm
14.3 lbf / 1.24 in. 4.68 kgf / 31.5 mm
10.3 lbf /
1.24 in.
Rocker Arm Shaft to Rocker Arm Oil Clearance 0.016 to 0.045 mm 0.15 mm
0.00063 to 0.0017 in. 0.0059 in.
Rocker Arm Shaft O.D. 14.973 to 14.984 mm –

0.58949 to 0.58992 in.
Rocker Arm I.D. 15.000 to 15.018 mm –

0.59056 to 0.59125 in.
Bridge Arm and Bridge Arm Shaft Oil Clearance 0.018 to 0.042 mm 0.15 mm
0.00071 to 0.0016 in. 0.0059 in.
Bridge Arm Shaft O.D. 9.023 to 9.032 mm –

0.3553 to 0.3555 in.
Bridge Arm I.D. 9.050 to 9.065 mm –

0.3563 to 0.3568 in.
Push Rod Alignment – 0.25 mm
0.0098 in.
Tappet to Tappet Bore Oil Clearance 0.020 to 0.050 mm 0.07 mm
0.00079 to 0.0019 in. 0.003 in.
Tappet O.D. 9.965 to 9.980 mm –

0.3924 to 0.3929 in.
Tappet Bore I.D. 10.000 to 10.015 mm –

0.39370 to 0.39429 in.
Timing Gear
Crank Gear to Cam Gear Backlash 0.0410 to 0.139 mm 0.22 mm
0.00162 to 0.00547 in. 0.0087 in.
Cam Gear to Balancer 1 Gear Backlash 0.0410 to 0.134 mm 0.22 mm

0.00162 to 0.00527 in. 0.0087 in.
Cam Gear to Idle Gear Backlash 0.0410 to 0.134 mm 0.22 mm

0.00162 to 0.00527 in. 0.0087 in.
Idle Gear to Injection Pump Gear Backlash 0.0410 to 0.134 mm 0.22 mm

0.00162 to 0.00527 in. 0.0087 in.
Idle Gear to Balancer 2 Gear Backlash 0.0410 to 0.129 mm 0.22 mm

0.00162 to 0.00507 in. 0.0087 in.
W1041245
III-S-122

Idle Gear Side Clearance 0.15 to 0.25 mm 0.90 mm
0.0059 to 0.0098 in. 0.035 in.
Idle Gear Shaft to Idle Gear Bushing Oil Clearance 0.050 to 0.091 mm 0.10 mm
0.0020 to 0.0036 in. 0.0039 in.
Idle Gear Shaft O.D. 34.959 to 34.975 mm –

1.3764 to 1.3769 in.
Idle Gear Bushing I.D. 35.025 to 35.050 mm –

1.3790 to 1.3799 in.
Camshaft Side Clearance – 0.10 mm
0.0039 in.
Camshaft Alignment – 0.01 mm
0.0004 in.
Cam Height Intake 37.50 mm 37.00 mm
1.476 in. 1.457 in.
Exhaust 37.90 mm 37.40 mm

1.492 in. 1.472 in.
Camshaft Oil Clearance 0.050 to 0.091 mm 0.15 mm
0.0020 to 0.0035 in. 0.0059 in.
Camshaft Journal 1 O.D. 34.934 to 34.950 mm –

1.3754 to 1.3759 in.
Camshaft Block Bore 1 I.D. 35.000 to 35.025 mm –

1.3780 to 1.3789 in.
Camshaft Journal 2 O.D. 43.934 to 43.950 mm –

1.7297 to 1.7303 in.
Camshaft Block Bore 2 I.D. 44.000 to 44.025 mm –

1.7323 to 1.7332 in.
Balancer Shaft
Balancer Shaft 1 Side Clearance 0.070 to 0.22 mm 0.30 mm
0.0028 to 0.0086 in. 0.012 in.
Balancer Shaft 2 Side Clearance 0.070 to 0.32 mm 0.34 mm

0.0028 to 0.012 in. 0.013 in.
Balancer Shaft 1, 2 Alignment – 0.02 mm
0.0008 in.
W1042752
III-S-123

Balancer Shaft 1 Journal Oil Clearance 0.0600 to 0.146 mm 0.20 mm
0.00237 to 0.00574 in. 0.0079 in.
Balancer Shaft 1 Journal O.D. 48.934 to 48.950 mm –

1.9266 to 1.9271 in.
Balancer Shaft 1 Bearing I.D. 49.010 to 49.080 mm –

1.9296 to 1.9322 in.
Balancer Shaft 2 Journal Oil Clearance 0.0500 to 0.136 mm 0.20 mm
0.00197 to 0.00535 in. 0.0079 in.
Balancer Shaft 2 Journal O.D. 48.934 to 48.950 mm –

1.9266 to 1.9271 in.
Balancer Shaft 2 Bearing I.D. 49.000 to 49.070 mm –

1.9292 to 1.9318 in.
Piston Pin Bore I.D. 28.000 to 28.013 mm 28.05 mm
1.1024 to 1.1028 in. 1.104 in.
Piston Pin to Small End Bushing Oil Clearance 0.020 to 0.040 mm 0.15 mm
0.00079 to 0.0015 in. 0.0059 in.
Piston Pin O.D. 28.006 to 28.011 mm –

1.1026 to 1.1027 in.
Small End Bushing I.D. 28.031 to 28.046 mm –

1.1036 to 1.1041 in.
Connecting Rod Alignment – 0.05 mm
0.002 in.
Piston Ring Gap Top Ring 0.25 to 0.40 mm 1.25 mm
0.0099 to 0.015 in. 0.0492 in.
Second Ring 0.30 to 0.45 mm 1.25 mm

0.012 to 0.017 in. 0.0492 in.
Oil Ring 0.25 to 0.45 mm 1.25 mm

0.0099 to 0.017 in. 0.0492 in.
Piston Ring to Piston Ring Groove
Top Ring Clearance 0.050 to 0.090 mm 0.15 mm
0.0020 to 0.0035 in. 0.0059 in.
Second Ring Clearance 0.090 to 0.12 mm 0.20 mm

0.0035 to 0.0047 in. 0.0079 in.
Oil Ring Clearance 0.020 to 0.060 mm 0.15 mm

0.00079 to 0.0023 in. 0.0059 in.
W1044411
III-S-124

Crankshaft Side Clearance 0.15 to 0.35 mm 0.50 mm
0.0059 to 0.013 in. 0.020 in.
Crankshaft Alignment – 0.02 mm
0.0008 in.
Crank Pin to Crank Pin Bearing Oil Clearance 0.017 to 0.048 mm 0.20 mm
0.00067 to 0.0018 in. 0.0079 in.
Crank Pin O.D. 49.980 to 49.991 mm –

1.9678 to 1.9681 in.
Crankshaft Journal to Crankshaft Bearing Oil Clearance 0.030 to 0.073 mm 0.20 mm
0.0012 to 0.0028 in. 0.0079 in.
Crankshaft Journal O.D. 79.977 to 79.990 mm –

3.1487 to 3.1492 in.
Cylinder Bore I.D. 94.000 to 94.022 mm 94.15 mm
3.7008 to 3.7016 in. 3.707 in.
Cylinder Bore (Oversize) I.D. 94.500 to 94.522 mm 94.65 mm
3.7205 to 3.7213 in. 3.726 in.
W10138740
LUBRICATING SYSTEM
Engine Oil Pressure At Idle Speed – 49 kPa
0.50 kgf/cm2
7.1 psi
At Rated Speed 197 to 392 kPa 147 kPa

2.00 to 4.00 kgf/cm2 1.50 kgf/cm2
28.5 to 56.8 psi 21.3 psi
Engine Oil Pressure Switch Working Pressure 40 to 58 kPa –
0.40 to 0.60 kgf/cm2
5.7 to 8.5 psi
Inner Rotor to Outer Rotor Clearance 0.03 to 0.09 mm 0.30 mm
0.002 to 0.003 in. 0.012 in.
Outer Rotor to Pump Body Clearance 0.100 to 0.184 mm 0.30 mm
0.00394 to 0.00724 in. 0.012 in.
Rotor to Cover Clearance 0.025 to 0.075 mm 0.225 mm
0.00099 to 0.0029 in. 0.00886 in.
Relief Valve Working Pressure 887 kPa –
9.04 kgf/cm2
129 psi
W10139730
III-S-125
COOLING SYSTEM
Alternator Belt Tension 10.0 to 12.0 mm / 98 N –
0.394 to 0.472 in. / 98 N
(10 kgf, 22 lbf)
Radiator Cap Pressure Falling 10 seconds or more –
Time 88 → 59 kPa
0.90 → 0.60 kgf/cm2
13 → 8.5 psi
Radiator Water Leakage No leak at specified –
Test Pressure pressure
Thermostat Valve Opening 74.5 to 78.5 °C –
Temperature 166.1 to 173.3 °F
Valve Opening 90 °C –
Temperature 194 °F
(Opened
Completely)
W10135990
FUEL SYSTEM
Injection Timing V3007-DI-T-E3B 0.00261 rad B.T.D.C. to –
0.0235 rad A.T.D.C.
(0.150 ° B.T.D.C. to
1.35 ° A.T.D.C.)
V3307-DI-T-E3B 0.00960 rad B.T.D.C. to –

0.0357 rad A.T.D.C.
(0.550 ° B.T.D.C. to
2.05 ° A.T.D.C.)
Pump Element Fuel Tightness – 18.63 MPa
190.0 kgf/cm2
2702 psi
Delivery Valve Fuel Tightness 10 seconds 5 seconds
18.63 → 17.65 MPa 18.63 → 17.65 MPa
190.0 → 180.0 kgf/cm2 190.0 →
2702 → 2560 psi 180.0 kgf/cm2
2702 → 2560 psi
Fuel Injection Nozzle Injection Pressure 18.64 to 19.61 MPa –
(1st stage) 190.0 to 200.0 kgf/cm2
2703 to 2844 psi
Injection Pressure 22.56 to 23.53 MPa –

(2nd stage) 230.0 to 240.0 kgf/cm2
3272 to 3413 psi
Valve Seat When the pressure is –

Tightness 16.67 MPa
(170.0 kgf/cm2, 2418
psi), the valve seat must
be fuel tightness.
W10139730
III-S-126
ELECTRICAL SYSTEM
Glow Plug Resistance Approx. 0.95 Ω –
Starter
Commutator O.D. 32.0 mm 31.4 mm
1.26 in. 1.24 in.
Mica Undercut 0.50 mm 0.20 mm

0.020 in. 0.0079 in.
Brush Length 18.0 mm 11.0 mm

0.709 in. 0.433 in.
Brush Holder - Holder Support Resistance Infinity –
Commutator - Armature Coil Core Resistance Infinity –
Commutator - Segment Resistance 0Ω –
Field Coil Lead - Brush Resistance 0Ω –
Field Coil Brush - Yoke Resistance Infinity –

Alternator
No-load Voltage Output Voltage 13.8 to 14.8 V at –
25 °C (77 °F),
4000 min-1 (rpm)
Rotor Resistance 2.8 to 3.3 Ω –
Slip Ring O.D. 22.7 mm 22.1 mm

0.894 in. 0.870 in.
Brush Length 18.5 mm 5.0 mm

0.728 in. 0.20 in.
W1173869
III-S-127
3. TIGHTENING TORQUES
Screws, bolts and nuts must be tightened to the specified torque using a torque wrench, several screws, bolts and
nuts such as those used on the cylinder head must be tightened in proper sequence and the proper torque.
[1] TIGHTENING TORQUES FOR GENERAL USE SCREWS, BOLTS AND

NUTS
When the tightening torques are not specified, tighten the screws, bolts and nuts according to the table below.
Grade Standard Screw and Bolt Special Screw and Bolt
Nominal Unit
Diameter N·m kgf·m lbf·ft N·m kgf·m lbf·ft
M6 7.9 to 9.3 0.80 to 0.95 5.8 to 6.8 9.81 to 11.2 1.00 to 1.15 7.24 to 8.31
M8 18 to 20 1.8 to 2.1 13 to 15 24 to 27 2.4 to 2.8 18 to 20
M10 40 to 45 4.0 to 4.6 29 to 33 48 to 55 4.9 to 5.7 36 to 41
M12 63 to 72 6.4 to 7.4 47 to 53 78 to 90 7.9 to 9.2 58 to 66
W10371750
Screw and bolt material grades are shown by numbers punched on the screw and bolt heads. Prior to
tightening, be sure to check out the numbers as shown below.
Punched number Screw and bolt material grade
None or 4 Standard screw and bolt SS41, S20C
7 Special screw and bolt S43C, S48C (Refined)
W1012705
III-S-128
[2] TIGHTENING TORQUES FOR SPECIAL USE SCREWS, BOLTS AND

NUTS
J NOTE
• For “*” marked screws, bolts and nuts on the table, apply engine oil to their threads and seats before
tightening.
• The letter “M” in Size x Pitch means that the screw, bolt or nut dimension stands for metric. The size is the
nominal outside diameter in mm of the threads. The pitch is the nominal distance in mm between two
threads.
Item Size x Pitch N·m kgf·m lbf·ft
Glow lead mounting nut M4 x 0.7 0.98 to 1.7 0.10 to 0.18 0.73 to 1.3
Glow plug M8 x 1.0 7.7 to 9.3 0.78 to 0.95 5.7 to 6.8
Cylinder head cover screw M6 x 1.0 9.81 to 11.2 1.00 to 1.15 7.24 to 8.31
Injection pipe retaining nut M12 x 1.5 23 to 36 2.3 to 3.7 17 to 26
Oil switch taper screw R 1/8 15 to 19 1.5 to 2.0 11 to 14
Injection pump unit mounting nut M8 x 1.25 18 to 20 1.8 to 2.1 13 to 15
Drain plug M22 x 1.5 45 to 53 4.5 to 5.5 33 to 39
Oil pipe 1 mounting screw M10 x 1.25 16 to 19 1.6 to 2.0 12 to 14
Thermo valve R 3/8 30 to 39 3.0 to 4.0 22 to 28
Nozzle holder clamp screw M8 x 1.25 24 to 27 2.4 to 2.8 18 to 20
Overflow pipe assembly retaining screw M6 x 1.0 9.81 to 11.2 1.00 to 1.15 7.24 to 8.31
Rocker arm bracket screw M10 x 1.25 49 to 55 5.0 to 5.7 37 to 41
*Cylinder head mounting screw M14 x 1.5 187 to 196 19.0 to 20.0 138 to 144
*Lubricating oil pipe mounting screw M10 x 1.25 15 to 19 1.5 to 2.0 11 to 14
Governor housing mounting screw M6 x 1.0 9.81 to 11.2 1.00 to 1.15 7.24 to 8.31
Lock nut M5 x 0.8 2.9 to 4.0 0.29 to 0.41 2.1 to 2.9
Injection pump assembly mounting screw M8 x 1.25 24 to 27 2.4 to 2.8 18 to 20
Injection pump assembly mounting nut M8 x 1.25 18 to 20 1.8 to 2.1 13 to 15
Injection pump gear mounting nut (left-
M16 x 1.5 -LH 138 to 158 14.0 to 16.0 102 to 115
handed screw)
Governor weight mounting nut M12 x 1.25 63 to 72 6.4 to 7.4 47 to 53
Fuel camshaft stopper mounting screw M6 x 1.0 9.81 to 11.2 1.00 to 1.15 7.24 to 8.31
Fuel camshaft bearing stopper mounting
M6 x 1.0 3.9 to 4.2 0.39 to 0.43 2.9 to 3.1
screw
*Crankshaft screw M16 x 1.5 255 to 274 26.0 to 28.0 188 to 202
Oil cooler joint screw M20 x 1.5 40 to 44 4.0 to 4.5 29 to 32
Front cover mounting screw M8 x 1.25 24 to 27 2.4 to 2.8 18 to 20
Relief valve retaining screw M22 x 1.5 69 to 78 7.0 to 8.0 51 to 57
*Flywheel screw M12 x 1.25 98.1 to 107 10.0 to 11.0 72.4 to 79.5
Flywheel housing mounting screw M12 x 1.25 103 to 117 10.5 to 12.0 76.0 to 86.7
Camshaft set screw M8 x 1.25 24 to 27 2.4 to 2.8 18 to 20
Idle gear mounting screw M8 x 1.25 24 to 27 2.4 to 2.8 18 to 20
Balancer shaft set screw M8 x 1.25 24 to 27 2.4 to 2.8 18 to 20
*Connecting rod screw M9 x 1.0 69 to 73 7.0 to 7.5 51 to 54
*Crankcase 2 mounting screw M14 x 1.5 138 to 147 14.0 to 15.0 102 to 108
W1013236
III-S-129
J NOTE
• For “*” marked screws, bolts and nuts on the table, apply engine oil to their threads and seats before
tightening.
• The letter “M” in Size x Pitch means that the screw, bolt or nut dimension stands for metric. The size is the
nominal outside diameter in mm of the threads. The pitch is the nominal distance in mm between two
threads.
Item Size x Pitch N·m kgf·m lbf·ft
Crankcase 2 flange screw M10 x 1.25 59 to 63 6.0 to 6.7 44 to 47
Starter’s terminal B mounting nut M8 x 1.25 9.8 to 11 1.0 to 1.2 7.3 to 8.6
Alternator pulley nut M24 58.4 to 78.9 5.95 to 8.05 43.1 to 58.2
Oil pump cover screw – 7.9 to 9.3 0.80 to 0.95 5.8 to 6.8
W1159183
III-S-130
4. CHECKING, DISASSEMBLING AND SERVICING

[1] CHECKING AND ADJUSTING
(1) Engine Body
Compression Pressure
1. After warming up the engine, shut it down and remove the air
cleaner, the muffler, breather tube, glow lead and all glow plugs.
2. Install a compression tester (1) (Code No: 07909-30208) and
glow plug adaptor (2) for 07 series diesel engines to glow plug
hole. (Refer to “5. SPECIAL TOOLS” at “GENERAL” Section.)
3. After making sure that the stop lever is set at the stop position
(Non-injection), run the engine at 200 to 300 min−1 (rpm) with the
starter.
4. Read the maximum pressure. Measure the pressure more than
twice.
J NOTE
• Check the compression pressure with the specified valve
clearance.
• Always use a fully charged battery for performing this test.
• Variances in cylinder compression values should be under
10 %.
3.92 MPa / 250 min-1 (rpm)
Factory spec. 40.0 kgf/cm2 / 250 min-1 (rpm)
Compression 569 psi / 250 min-1 (rpm)
pressure 2.90 MPa / 250 min-1 (rpm)
Allowable limit 29.6 kgf/cm2 / 250 min-1 (rpm)
421 psi / 250 min-1 (rpm)
0.98 to 1.7 N·m

Glow lead mounting nut 0.10 to 0.18 kgf·m
0.73 to 1.3 lbf·ft
Tightening torque
7.7 to 9.3 N·m
Glow plug 0.78 to 0.95 kgf·m
5.7 to 6.8 lbf·ft
(1) Compression Tester (2) Glow Plug Adaptor

W1048776
III-S-131
Checking Valve Clearance

J IMPORTANT
• Valve clearance must be checked and adjusted when engine
is cold.
1. Remove the high pressure pipes, glow lead, glow plugs and the
cylinder head cover.
2. Align the 1TC mark of flywheel and the convex of flywheel
housing timing windows so that the first piston (front cover side)
comes to the compression top dead center.
3. Before adjusting the valve clearance, adjust the bridge evenly to
the valve stem.
4. Loosen the lock nut (2) and adjust with adjusting screw (1).
5. Slightly push the rocker arm with your fingers and screw in the
adjusting screw (1) slowly until you feel the screw touch the top
of valve stem, then tighten the lock nut (2).
6. Loosen the lock nut (4) of adjusting screw (3) (push rod side) and
insert the feeler gauge between the rocker arm and the bridge
head. Set the adjusting screw (3) to the specified value, then
tighten the lock nut (4).
0.13 to 0.17 mm
Valve clearance Factory spec.
0.0052 to 0.0066 in.
J NOTE
• After adjusting, tighten the lock nut (4) securely.
Valve arrangement
Adjustment cylinder IN. EX
Location of piston
1st I I

compression top dead center 3rd I
4th
1st

overlap position 3rd I
4th I I
9.81 to 11.2 N·m

7.24 to 8.31 lbf·ft
Tightening torque
23 to 36 N·m
17 to 26 lbf·ft
(1) Adjusting Screw (3) Adjusting Screw

(2) Lock Nut (4) Lock Nut
W1047000
III-S-132
(2) Lubricating System

Engine Oil Pressure
1. Remove the oil switch and set a pressure tester (Code No.
07916-32032).
2. Start the engine. After warming up, measure the oil pressure of
both idling and rated speeds.
3. If the oil pressure is less than the allowable limit, check the
following.
• Engine oil insufficient
• Oil pump defective
• Oil strainer clogged
• Oil filter cartridge clogged
• Oil gallery clogged
• Excessive oil clearance
• Foreign matter in the relief valve
(When reassembling)
• After checking the engine oil pressure, tighten the engine oil
pressure switch to the specified torque.
49 kPa
At idle Allowable
0.50 kgf/cm2
speed limit
7.1 psi
197 to 392 kPa
Factory
Engine oil pressure 2.00 to 4.00 kgf/cm2
spec.
At rated 28.5 to 56.8 psi
speed 147 kPa
Allowable
1.50 kgf/cm2
limit
21.3 psi
15 to 19 N·m
Tightening torque Oil switch taper screw 1.5 to 2.0 kgf·m
11 to 14 lbf·ft
W10349520
(3) Cooling System

Alternator Belt Tension
between the pulleys at specified force 98 N (10 kgf, 22 lbf).
adjust.
10.0 to 12.0 mm
Deflection (L) Factory spec.
0.394 to 0.472 in.
(1) Alternator Mounting Screw (A) Deflection

(2) Fan Belt
W1082347
III-S-133
Belt Damage and Wear

1. Check the belt for damage.
2. If the belt is damaged, replace it.
3. Check if the belt is worn and sunk in the pulley groove.
4. If the belt is nearly worn out and deeply sunk in the pulley groove,
replace it.
(A) Good (B) Bad
W1021108
CAUTION
• When removing the radiator cap, wait at least ten minutes after the engine has stopped and cooled down.
Otherwise, hot water may gush out, scalding nearby people.
Radiator Cap Air Leakage
1. Set a radiator tester (1) and an adaptor (2) on the radiator cap.
2. Apply the specified pressure of 88 kPa (0.90 kgf/cm2, 13 psi), and
measure the time for the pressure to fall to 59 kPa (0.60 kgf/cm2,
8.5 psi).
3. If the measurement is less than the factory specification, replace
the radiator cap.
More than 10 seconds
for pressure fall
Pressure falling time Factory spec. 88 → 59 kPa
(0.90 → 0.60 kgf/cm2,
13 → 8.5 psi)
(1) Radiator Tester (2) Adaptor

W1054156
Radiator Water Leakage
1. Pour a specified amount of water into the radiator.
2. Set a radiator tester (1) and an adaptor (2) and raise the water
pressure to the specified pressure.
3. Check the radiator for water leaks.
4. For water leak from the pinhole, replace the radiator or repair with
the radiator cement. When water leak is excessive, replace the
radiator.
Radiator water leakage No leak at specified
Factory spec.
test pressure pressure
J NOTE
• The pressure of the leak test is different from each radiator
specification.
Thus, do the leak test, refer to the test pressure of each
radiator specification.
(1) Radiator Tester (2) Adaptor
W1016903
III-S-134
Thermostat Valve Opening Temperature

1. Push down the thermostat valve and insert a string between the
valve and the valve seat.
2. Place the thermostat and a thermostat in a container with water
and gradually heat the water.
3. Hold the string to suspend the thermostat in the water. When the
water temperature rises, the thermostat valve will open, allowing
it to fall down from the string.
Read the temperature at this moment on the thermometer.
4. Continue heating the water and read the temperature when the
valve has risen by about 8 mm (0.3 in.).
5. If the measurement is not acceptable, replace the thermostat.
Thermostat’s valve 74.5 to 78.5 °C
Factory spec.
opening temperature 166.1 to 173.3 °F
Temperature at which
90 °C
thermostat completely Factory spec.
194 °F
opens
W1071639
III-S-135
(4) Fuel System

Injection Timing
1. Make sure of matching the injection timing align mark (1) of the
injection pump unit and the flywheel housing, as shown in the
illustration.
3. Remove the stop solenoid.
4. Turn the flywheel counterclockwise (viewed from flywheel side)
until the fuel fills up to the hole of the delivery valve holder (3) for
No.1 cylinder.
5. After the fuel fills up to the hole of the delivery valve holder (3) for
No.1 cylinder, turn back (clockwise) the flywheel around 1.6 rad
(90 °).
6. Turn the flywheel counterclockwise to set at around 0.17 rad
(10 °) before T.D.C..
7. Slowly turn the flywheel counterclockwise and stop turning when
the fuel begins to come up, to get the present injection timing.
8. Check to see the degree on flywheel.
The flywheel has mark “1TC” for the crank angle before the top
dead center of No.1 piston.
9. If the injection timing is not within the specification, rotate the
injection pump unit to adjust the injection timing.
J IMPORTANT
• When installing the injection pump unit to the engine body,
follow the correct procedure.
See the “Injection Pump Unit”.
V3007-DI-T-E3B
0.00261 rad B.T.D.C. to
0.0235 rad A.T.D.C.
(0.150 ° B.T.D.C. to
1.35 ° A.T.D.C.)
V3307-DI-T-E3B
0.00960 rad B.T.D.C. to
0.0357 rad A.T.D.C.
(0.550 ° B.T.D.C. to
2.05 ° A.T.D.C.)
23 to 36 N·m
17 to 26 lbf·ft
Tightening torque
18 to 20 N·m
Injection pump unit
1.8 to 2.1 kgf·m
mounting nut
13 to 15 lbf·ft
(1) Injection Timing Align Mark (a) Injection Timing Advanced

(2) Injection Pump Unit Mounting Nut (b) Injection Timing Retarded
(3) Delivery Valve Holder
W1089274
III-S-136
Fuel Tightness of Pump Element

3. Install the injection pump pressure tester (1) to the injection
pump.
pressure to the injection pump pressure tester (1). (Refer to the
figure.)
5. Set the speed control lever to the maximum speed position.
7. If the pressure can not reach the allowable limit, replace the
pump with new one or repair with a Kubota-authorized pump
service shop.
18.63 MPa
Fuel tightness of pump
Allowable limit 190.0 kgf/cm2
element
2702 psi
J NOTE
W1017430
Fuel Tightness of Delivery Valve

3. Install a pressure tester to the fuel injection pump.
pressure to the injection pump pressure tester (1).
6. Stop the starter when the fuel jets from the injection nozzle (2).
After that, turn the flywheel by the hand and raise the pressure to
approx. 18.63 MPa (190.0 kgf/cm2, 2702 psi).
7. Now turn the flywheel back about half a turn (to keep the plunger
free). Maintain the flywheel at this position and clock the time
taken for the pressure to drop from 18.63 to 17.65 MPa (from
190.0 to 180.0 kgf/cm2, from 2702 to 2560 psi).
8. Measure the time needed to decrease the pressure from 18.63 to
17.65 MPa (from 190.0 to 180.0 kgf/cm2, from 2702 to 2560 psi).
9. If the measurement is less than allowable limit, replace the pump
with new one or repair with a Kubota-authorized pump service
shop.
10 seconds
18.63 → 17.65 MPa
Factory spec.
190.0 → 180.0 kgf/cm2
Fuel tightness of 2702 → 2560 psi
delivery valve 5 seconds
18.63 → 17.65 MPa
Allowable limit
190.0 → 180.0 kgf/cm2
2702 → 2560 psi
J NOTE
W1017786
III-S-137
CAUTION
• Check the nozzle injection pressure and condition after confirming that there is nobody standing in the
direction the spray goes.
• If the spray from the nozzle directly contacts the human body, cells may be destroyed and blood poisoning
may be caused.
Nozzle Spraying Condition
1. Attach the injection nozzle to the nozzle tester, and check the
nozzle spraying condition.
2. If the spraying condition is defective, replace the injection nozzle
assembly or repair at Denso service shop.
(a) Good (b) Bad
W10371670
Checking Nozzle Injection Pressure

2. Slowly move the tester handle to measure the pressure at which
fuel begins jetting out from the nozzle.
3. If the measurement is not within the factory specifications,
replace the injection nozzle assembly or repair at Denso service
shop.
J NOTE
• Injection nozzle gasket must be replaced when the injection
nozzle is removed for checking.
18.64 to 19.61 MPa
Factory 1st
Injection pressure 190.0 to 200.0 kgf/cm2
spec. stage
2703 to 2844 psi
W1037280
Valve Seat Tightness
2. Raise the fuel pressure, and keep at 16.67 MPa (170.0 kgf/cm2,
2418 psi) for 10 seconds.
3. If any fuel leak is found, replace the injection nozzle assembly or
repair at Denso service shop.
No fuel leak at
16.67 MPa
Valve seat tightness Factory spec.
170.0 kgf/cm2
2418 psi
W10374150
III-S-138
(5) Electrical System
CAUTION
• To avoid accidental short circuit, be sure to attach the positive cable to the positive terminal before the
negative cable is attached to the negative terminal.
• Never remove the battery cap while the engine is running.
• Keep electrolyte away from eyes, hands and clothes. If you are spattered with it, wash it away completely
with water immediately.
• Keep open sparks and flames away from the battery at all times. Hydrogen gas mixed with oxygen
becomes very explosive.
J IMPORTANT
• If the machine is to be operated for a short time without battery (using a slave battery for starting), use
additional current (lights) while engine is running and insulate terminal of battery. If this advice is
disregarded, damage to alternator and regulator may result.
Battery Voltage
1. Stop the engine.
2. Measure the voltage with a circuit tester between the battery
terminals.
3. If the battery voltage is less than the factory specification, check
the battery specific gravity and recharge the battery.
Battery voltage Factory spec. More than 12 V
(1) Positive Terminal (2) Negative Terminal

W10125620
III-S-139
Battery Specific Gravity

1. Check the specific gravity of the electrolyte in each cell with a
hydrometer.
2. When the electrolyte temperature differs from that at which the
hydrometer was calibrated, correct the specific gravity reading
following the formula mentioned in (Reference).
3. If the specific gravity is less than 1.215 (after it is corrected for
temperature), charge or replace the battery.
4. If the specific gravity differs between any two cells by more than
0.05, replace the battery.
J NOTE
• Hold the hydrometer tube vertical without removing it from
the electrolyte.
• Do not suck too much electrolyte into the tube.
• Allow the float to move freely and hold the hydrometer at eye
level.
• The hydrometer reading must be taken at the highest
electrolyte level.
(Reference)
• Specific gravity slightly varies with temperature. To be exact, the
specific gravity decreases by 0.0007 with an increase of 1 °C
(0.0004 with an increase of 1 °F) in temperature, and increases
by 0.0007 with a decreases of 1 °C (0.0004 with a decrease of 1
°F).
Therefore, using 20 °C (68 °F) as a reference, the specific gravity
reading must be corrected by the following formula :
- Specific gravity at 20 °C = Measured value + 0.0007 ×
(electrolyte temperature : 20 °C)
- Specific gravity at 68 °F = Measured value + 0.0004 ×
(electrolyte temperature : 68 °F)
Specific Gravity State of Charge
1.140 Sp. Gr. Very Little Useful Capacity
1.110 Sp. Gr. Discharged
At an electrolyte temperature of 20 °C (68 °F)
(a) Good (c) Bad
(b) Bad
W1019017
III-S-140
Motor Test
CAUTION
• Secure the starter to prevent it from jumping up and down
while testing the motor.
1. Disconnect the battery negative cable from the battery.
2. Disconnect the battery positive cable from the battery.
3. Disconnect the leads from the starter B terminal.
4. Remove the starter from the engine.
5. Connect a jumper lead from the starter C terminal (1) to the
battery positive terminal (2).
6. Connect a jumper lead momentarily between the starter’s body
and the battery negative terminal (3).
7. If the motor does not run, starter is failure.
Repair or replace the starter.
J NOTE
• B terminal : It is the terminal which connects the cable from
the battery to the starter.
• C terminal : It is the terminal which connects the cable from
the motor to the magnet switch.
(1) C Terminal (3) Negative Terminal
(2) Positive Terminal
W1019297
Magnetic Switch Test
1. Disconnect the battery negative cable from the battery.
2. Disconnect the battery positive cable from the battery.
3. Disconnect the leads from the starter B terminal.
4. Remove the starter from the engine.
5. Connect a jumper lead from the starter S terminal (1) to the
battery positive terminal (2).
6. Connect a jumper lead momentarily between the starter’s body
and the battery negative terminal (3).
7. If the pinion gear does not pop out, the magnetic switch is failure.
Repair or replace the starter.
J NOTE
• B terminal : It is the terminal which connects the cable from
the battery to the starter.
• S terminal : It is the terminal which connects the cable from
the starter switch to the magnet switch.
(1) S Terminal (3) Negative Terminal
(2) Positive Terminal
0000010743E
Magnet Switch Continuity Test
1. Check the continuity across the C terminal (1) and the B terminal
(2) with a circuit tester, pushing in the plunger.
2. If not continuous or if a certain value is indicated, replace the
magnet switch.
(1) C Terminal (2) B Terminal
0000010771E
III-S-141
Alternator on Unit Test

(Before testing)
• Before alternator on unit test, check the battery terminal
connections, circuit connection, fan belt tension, charging
indicator lamp, fuses on the circuit, and abnormal noise from the
alternator.
• Prepare full charged battery for the test.
J NOTE
• Be careful not to touch the rotating engine parts while engine
is running.
Keep safety distance from the engine rotating parts.
1. Start the engine.
2. When the engine is operating measure the voltage between two
battery terminals. If the voltage is between 13.8 V and 14.8 V,
the alternator is operating normally.
3. If the results of alternator on unit test are not within the
specifications, disassemble the alternator and check the each
component part for finding out the failure. See the
“DISASSEMBLING AND ASSEMBLING” and “SERVICING” for
alternator.
Regulating voltage at no 13.8 to 14.8 V at 25 °C
Factory spec.
load (77 °F)
0000010745E
Glow Plug Continuity

1. Remove the glow plug (2).
2. Measure the resistance with a circuit tester between the glow
plug terminal and the glow plug housing.
3. If the factory specification is not indicated, glow plug (2) is faulty.
J NOTE
• Adjust the direction of the ditch to the terminal side when the
seal (1) is installed in the glow plug (2).
Resistance Factory spec. Approx. 0.95 Ω
(1) Seal (2) Glow Plug

W1036945
Engine Stop Solenoid
1. Remove the engine stop solenoid from the engine.
2. Connect the jumper leads from the pulling coil P terminal to the
switch (3), and from switch (3) to the battery positive terminal.
3. Connect the jumper leads from the holding coil H terminal to the
switch (4), and from switch (4) to the battery positive terminal.
4. Connect the jumper leads from the engine stop solenoid body to
the battery negative terminal.
5. When switch (4) is turn on, the plunger pull into the solenoid body
and then turn off the switch (4), the plunger comes out.
6. Turn on the switch (3) then turn on the switch (4), the plunger pull
into the solenoid body and it keep in holding position after turn off
the switch (4).
7. If the plunger is not attracted, the engine stop solenoid is faulty.
J IMPORTANT
• Never apply the current for pulling coil more than two
seconds when inspecting.
(1) Connector P : Terminal for Pulling Coil
(2) Battery H : Terminal for Holding Coil
(3) Switch for Holding Coil
(4) Switch for Pulling Coil
W1020600
III-S-142
(6) Turbocharger
Turbine Side
1. Check the exhaust port (2) and inlet port (4) side of turbine
housing (3) to see if there is no exhaust gas leak.
2. If any gas leak is found, retighten the bolts and nuts or replace
the gasket (1) / (5) with new one.
(1) Gasket (4) Inlet Port
(2) Exhaust Port (5) Gasket
(3) Turbine Housing
W1076917
Compressor Side
1. Check the inlet hose (4) of the compressor cover (1) to see if
there is no air leak.
2. Check for loose connections or cracks in the suction side of the
intake hose (3).
3. If any air leak is found, change the clamp (2) and or inlet / intake
hoses (3) / (4).
(1) Compressor Cover (3) Intake Hose
(2) Clamp (4) Inlet Hose
W1077032
Radial Clearance
1. If the wheel contact to the housing, replace the turbocharger
assembly with new one.
W1077353
III-S-143
(7) EGR System

Function of EGR System
1. Check the coolant temperature and monitor the coolant
temperature while checking 1) and 2).
2. If the coolant temperature is already 55 °C (131 °F), cool down
the engine.
3. Start the engine and go to check 1) immediately.
4. After completing checking 1), arrange the coolant temperature is
getting over 70 °C (158 °F).
5. If the coolant temperature is over 70 °C (158 °F), go to check 2).
(a) Measuring Place of EGR Pipe
Surface Temperature
W1177055
1) If the coolant temperature is under 55 °C (131 °F), the surface temperature of EGR pipe must be under
150 °C (302 °F).
III-S-144
2) If the coolant temperature is over 70 °C (158 °F), the surface temperature of EGR pipe must be over
150 °C (302 °F).
III-S-145
[2] DISASSEMBLING AND ASSEMBLING

(1) Draining Oil and Coolant
Draining Engine Oil
3. Remove the drain plug (1) to drain oil.
4. After draining, screw in the drain plug (1).
(When refilling)
• Fill the engine oil up to the upper line on the dipstick (2).
J IMPORTANT
temperature.
45 to 53 N·m
33 to 39 lbf·ft

W1023464
Draining Coolant
CAUTION
• Never remove radiator cap while operating or immediately
after stopping. Otherwise, hot water will spout out from the
radiator. Wait for more than ten minutes to cool the radiator,
before opening the cap.
1. Open the radiator drain plug and remove the radiator cap.
2. Remove the radiator hose (1) from engine body.
3. Remove the air vent hose (3).
(When refilling)
• Adjust the mark (5) of the air vent hose (3) to upward side near
the EGR valve (5).
• Fix the air vent hose (3) to the cylinder head cover (2) by using
clamp (4).
J NOTE
• Clamp the air vent hose (3) so as not to crush.
• Securely tighten clamps (4). If the clamp (4) is loose or
improperly fitted, coolant may leak out and the engine could
overheat.
(1) Radiator Hose (4) Clamp
(2) Cylinder Head Cover (5) Mark
(3) Air Vent Hose (6) EGR Valve
W1023496
III-S-146
(2) External Components

Air Cleaner, Muffler and Others
1. Remove the air cleaner and muffler.
2. Remove the fan (6), fan belt (5), cover (4), fuel filter cartridge (3),
fuel tubes (2), alternator (7) and starter (1).
(When reassembling)
• Check to see that there are no cracks on the belt surface.
• Mount the check valve with the ↓ mark toward the tank.
J IMPORTANT
• After reassembling the fan belt (5), be sure to adjust the fan
belt tension.
• Do not confuse the direction of the fan (6). Attach the fan (6)
with its marking facing frontward (toward the radiator).
(1) Starter (5) Fan Belt
(2) Fuel Tube (6) Fan
(3) Fuel Filter Cartridge (7) Alternator
(4) Cover
W1049622
CAUTION
• While the engine is running and or just after it stops, the turbocharger is hot, be careful not to touch the
turbocharger.
J NOTE
• When detaching and attaching the turbocharger assembly, be very careful not to allow dust, dirt and other
foreign matter in the oil pipes.
• When the turbocharger assembly has been replace, pour fresh engine oil through the oil filler port of the
turbocharger.
• Before starting the engine, make sure that air cleaner is in position.
Oil Pipe and Intake Hose
1. Remove the joint bolt (1), bolt (3) and clamp (4).
2. Disconnect the oil pipe 1 (2) and oil pipe 2 (5).
3. Remove the intake hose (6) and breather hose (7).
(When reassembling)
• Pour fresh engine oil through the oil filler port of the turbocharger.
• Replace the gasket with new one.
• Be careful not to allow dust, dirt and other foreign matters in the
oil pipes (2) / (5).
J NOTE
• Tape or plug all openings to prevent foreign matters from
damaging the oil cavities in the turbocharger.
(1) Joint Bolt (5) Oil Pipe 2
(2) Oil Pipe 1 (6) Intake Hose
(3) Bolt (7) Breather Hose
(4) Clamp
W1025983
III-S-147
Turbocharger Assembly and Exhaust Manifold

1. Remove the cover (1) and exhaust manifold mounting screws (3).
2. Take off the turbocharger assembly (4) with exhaust manifold (2).
3. Remove the oil pipe 1 (6) and oil pipe 2 (9). (If necessary)
4. Remove the exhaust port (5) and exhaust manifold (2). (If
necessary)
(When reassembling)
• Replace the gasket (8) with new one.
J NOTE
• Be careful not to damage the O-ring (10).
16 to 19 N·m
Tightening torque Oil pipe 1 mounting screw 1.6 to 2.0 kgf·m
12 to 14 lbf·ft
(1) Cover (6) Oil Pipe 1

(2) Exhaust Manifold (7) Oil Pipe Gasket
(3) Exhaust Manifold Mounting Screw (8) Gasket
(4) Turbocharger Assembly (9) Oil Pipe 2
(5) Exhaust Port (10) O-ring
W1078106
III-S-148
(3) Exhaust Gas Recirculation (EGR)

EGR System Assembly
1. Disconnect the EGR valve coolat hoses (2) and the boost
pressure hose 1 (3).
2. Disconnect boost the pressure hose 2 (4). (If necessary)
3. Remove the EGR system assembly (5).
4. Remove the thermo valve (1). (If necessary)
J NOTE
• If you drop the thermo valve (1), replace the thermo valve (1)
with new one.
(When reassembling)
• Securely connect the hoses.
• Replace the gasket (6) with new one.
30 to 39 N·m
Tightening torque Thermo valve 3.0 to 4.0 kgf·m
22 to 28 lbf·ft
(1) Thermo Valve (a) Boost Pressure from Intake

(2) EGR Valve Coolat Hose Manifold
(3) Boost Pressure Hose 1 (b) Boost Pressure to EGR Valve
(4) Boost Pressure Hose 2
(5) EGR System Assembly
(6) Gasket
W1103494
EGR Cooler and Flange (If necessary)

1. Remove the EGR cooler flange (2).
2. Remove the EGR cooler (4).
(When reassembling)
• Replace the gaskets (1) / (3) / (5) with new ones.
(1) Gasket (4) EGR Cooler
(2) EGR Cooler Flange (5) Gasket
(3) Gasket (6) EGR Valve
W1118406
III-S-149
EGR Valve and Reed Valve (If necessary)

1. Remove the EGR valve (1) from the EGR valve flange (5).
2. Remove the reed valve (3) from the EGR valve (1).
(When reassembling)
• Replace the gaskets (2) / (4) / (6) with new ones.
(1) EGR Valve (4) Gasket
(2) Gasket (5) EGR Valve Flange
(3) Reed Valve (6) Gasket
W1119991
(4) Cylinder Head and Valves

Cylinder Head Cover
1. Remove the glow lead (4) and the glow plugs (3).
2. Remove the injection pipes (1).
3. Remove the cylinder head cover (2).
(When reassembling)
• Check to see that the cylinder head cover gasket is not detective.
• Tighten the head cover mounting screws to specified torque.
• Check the position of the injection pipe clamps (5) to reduce the
vibration of the injection pipes (1). (See the figure.)
• Adjust the direction of the ditch to the terminal side when the seal
(6) is installed in the glow plug (3).
9.81 to 11.2 N·m
7.24 to 8.31 lbf·ft
23 to 36 N·m
Tightening torque Injection pipe retaining nut 2.3 to 3.7 kgf·m
17 to 26 lbf·ft
7.7 to 9.3 N·m
Glow plug 0.78 to 0.95 kgf·m
5.7 to 6.8 lbf·ft
(1) Injection Pipe (4) Glow Lead

(2) Cylinder Head Cover (5) Injection Pipe Clamp
(3) Glow Plug (6) Seal
W1021753
III-S-150
Nozzle Holder
1. Remove the overflow pipe (1).
2. Remove the nozzle holder clamps (2), nozzle holder assembly
(3) and nozzle gaskets.
(When reassembling)
• Be sure to place the nozzle gaskets and the O-rings (4).
24 to 27 N·m
Nozzle holder clamp screw 2.4 to 2.8 kgf·m
18 to 20 lbf·ft
Tightening torque
9.81 to 11.2 N·m
Overflow pipe assembly
1.00 to 1.15 kgf·m
retaining screw
7.24 to 8.31 lbf·ft
(1) Overflow Pipe (3) Nozzle Holder Assembly

(2) Nozzle Holder Clamp (4) O-ring
W1049737
Rocker Arm, Push Rod and Bridge Arm

1. Remove the rocker arm (1) as a unit.
2. Remove the push rods (2).
3. Remove the bridge arm (3).
(When reassembling)
• When putting the push rods (2) onto the tappets, check to see if
their ends are properly engaged with the grooves.
• When installing the bridge arm (3), apply engine oil to the bridge
arm shaft sufficiently and check whether to move smoothly.
J IMPORTANT
• After reassembling the rocker arm (1), be sure to adjust the
valve clearance.
49 to 55 N·m
Tightening torque Rocker arm bracket screw 5.0 to 5.7 kgf·m
37 to 41 lbf·ft
(1) Rocker Arm (3) Bridge Arm

(2) Push Rod
W1050212
III-S-151
Injection Nozzle Oil Seal (If necessary)

1. Remove the injection nozzle oil seal (2) from cylinder head cover
(1).
(When reassembling)
• When installing the injection nozzle oil seal (2), use new one.
(1) Cylinder Head Cover (2) Injection Nozzle Oil Seal
W1054100
Cylinder Head
1. Remove the cylinder head screw in the order of (10) to (1), and
remove the cylinder head.
2. Remove the cylinder head gasket.
(When reassembling)
• Replace the head gasket with a new one.
• When mounting the gasket, set it to the knock pin hole. Take
care not to mount it reversely.
• The cylinder head should be free of scratches and dust.
• Take care for handling the gasket not to damage it.
• Install the cylinder head.
• Tighten the cylinder head screw gradually in the order of (1) to
(10) after applying engine oil.
• Be sure to adjust the valve clearance. See the “Valve
Clearance”.
• It is not necessary to retighten the cylinder head screw after
running the engine for 30 minutes.
J IMPORTANT
• When replacing a piston, piston pin bush, connecting rod or
crankpin bearing, select the cylinder head gasket thickness
to meet with the top clearance refer to the “Selecting
Cylinder Head Gasket”.
187 to 196 N·m
Cylinder head mounting
Tightening torque 19.0 to 20.0 kgf·m
screw
138 to 144 lbf·ft
A : Front Cover Side B : Flywheel Housing Side

W1170923
III-S-152
Selecting Cylinder Head Gasket

J Replacing the Cylinder Head Gasket
1. Make sure to note the notch (a), (b) or (c) of cylinder head gasket
(1) in advance.
2. Replace the same notch (a), (b) or (c) as the original cylinder
head gasket (1).
J Selecting the Cylinder Head Gasket
• Select the cylinder head gasket (1) thickness to meet with the top
clearance when replacing the piston, piston pin bush, connecting
rod or crankpin bearing.
1. Measure the piston head’s protrusion or recessing from the
crankcase cylinder face 4 spots per each piston and (average of
four pistons) using the dial gauge as shown in figure.
2. Select the suitable cylinder head gasket (1) refer to the table
below.
Thickness of cylinder Piston Head’s
Notch of head gasket protrusion or recessing
Cylinder from the level of
Part Code
Head Before After crankcase cylinder
Gasket tightening tightening face.
(average of 4 pistons)
Without 1.10 mm 1.00 mm 0.2500 to 0.3425 mm
1G777-03610
notch (a) 0.0433 in. 0.0394 in. 0.009843 to 0.01348 in.
1.00 mm 0.900 mm 0.150 to 0.250 mm
1 notch (b) 1G777-03600
0.0394 in. 0.0354 in. 0.00591 to 0.00984 in.
2 notches 0.900 mm 0.800 mm 0.0775 to 0.150 mm
1G777-03310
(c) 0.0354 in. 0.0315 in. 0.00306 to 0.00590 in.
(1) Cylinder Head Gasket (a) Without Notch

(2) Measuring Point (b) 1 Notch
A: Notch of Cylinder Head Gasket (c) 2 Notches
B: Flywheel Housing Side
C: Front Cover Side
W1022965
III-S-153
Valve
1. Remove the valve spring collets (1) after compressing the valve
spring (3) with the valve spring retainer (2).
(When reassembling)
• Install the valve spring (3) with its smaller pitch (8) end downward
(at the cylinder head side (B)).
• Wash the valve stem and valve guide hole, and apply engine oil
sufficiently.
• After installing the valve spring collets (1), lightly tap the stem to
assure proper fit with a plastic hammer.
(1) Valve Spring Collet (7) Large Pitch
(2) Valve Spring Retainer (8) Smaller Pitch
(3) Valve Spring
(4) Valve Stem Seal A : Valve Spring Retainer Side
(5) Arm Bridge B : Cylinder Head Side
(6) Valve
W1053044
(5) Thermostat
Thermostat Assembly
1. Remove the thermostat cover mounting screws, and remove the
thermostat cover (1).
2. Remove the thermostat assembly (3).
(When reassembling)
• Attach assembly (3) facing toward the front cover side.
(1) Thermostat Cover (3) Thermostat Assembly
(2) Thermostat Cover Gasket (4) Hole
W1072747
III-S-154
(6) Injection Pump Unit

Injection Pump Unit
(Removing the fuel injection pump unit)
1. Detach the window cover (2) for the fuel injection pump unit from
the flywheel housing and remove the oil cap (3).
2. Place the piston of the 4th cylinder at the top dead center in the
compression stroke. Fix the flywheel with the flywheel stopper.
J IMPORTANT
• Look for the alignment mark (7) on the idle gear and the
injection pump gear. Using a white marking pen or the like,
put an alignment mark (7) on the engaged tooth of the both
gears. This helps to reassemble these gears in mesh later.
J NOTE
• When the already existing alignment marks (7) align with
each other, there is no need to put another alignment mark
(7).
3. Unscrew the two plugs (4) of the injection pump unit.
4. Tighten the upper fuel camshaft lock screw (8) until it comes into
contact with the fuel camshaft. Make sure the camshaft does not
move any longer.
5. Tighten the lower fuel camshaft lock screw (8) until it comes into
contact with the fuel camshaft.
J NOTE
• Never overtighten the lock screws when they have come into
contact with the camshaft. Otherwise the injection pump
itself may get damaged.
• Use of a socket set screw (dog point type) in recommended
for best results. Such screw can be constructed as shown
in figure (a).
6. Disconnect the lubricating oil pipe (5).
7. Loosen the three injection pump unit mounting nuts (1).
8. Remove the injection pump unit support (6) and take out the
injection pump unit.
A M8 × Pitch 1.25
B 0.79 rad (45 °)
C 5.0 mm dia. (0.20 in. dia.)
D 4.0 mm (0.16 in.)
E 45 mm (1.8 in.)
F 10 mm (0.39 in.) : Conspicuously Painted
G 5.0 mm (0.20 in.)
(1) Injection Pump Unit Mounting Nut (6) Injection Pump Unit Support
(2) Window Cover (7) Alignment Mark
(3) Oil Cap (8) Fuel Camshaft Lock Screw
(4) Plug (Socket Set Screw Dog Point Type)
(5) Lubricating Oil Pipe
W1175054
III-S-155
Injection Pump Unit (Continued)

(Reassembling the fuel injection pump unit)
1. Place the piston of the 4th cylinder at the top dead center in the
compression stroke. Fix the flywheel with the flywheel stopper.
2. Install the injection pump unit to the crankcase 1.
3. Make sure of aligning the alignment marks of the injection pump
gear (1) and the idle gear (2).
4. Take off the fuel camshaft lock screws (4) and tighten the plugs
(6) for plugging.
5. Moving the injection pump unit clockwise (viewed from front
cover side), align the injection timing marks (3) on the injection
pump unit and on the crankcase 1.
6. Tighten the injection pump unit mounting nut (5) to the specified
torque.
7. Reconnect the lubricating oil pipe (7) and place the injection
pump unit support (8) and the window cover of the injection pump
unit.
8. Remove the flywheel stopper.
9. Check the injection timing. (See the “Injection Timing”.)
10.If the injection timing is not within the specification, repeat “4.” to
“9.” again.
18 to 20 N·m
Injection pump unit
1.8 to 2.1 kgf·m
mounting nut
13 to 15 lbf·ft
Tightening torque
15 to 19 N·m
Lubricating oil pipe
1.5 to 2.0 kgf·m
mounting screw
11 to 14 lbf·ft
(1) Injection Pump Gear (5) Injection Pump Unit Mounting Nut
(2) Idle Gear (6) Plug
(3) Injection Timing Mark (7) Lubricating Oil Pipe
(4) Fuel Camshaft Lock Screw (8) Injection Pump Unit Support
(Socket Set Screw Dog Point Type)
W1176586
III-S-156
Governor Housing Assembly

1. Remove the injection pump unit from the engine. (See the
“Injection Pump Unit”.)
2. Remove the lubricating oil pipe (3).
3. Remove the stop solenoid (2).
4. Detach the sight cover (1) from the injection pump unit.
5. Unhook the start spring (7) from the rack pin (6) of injection pump
assembly.
6. Remove the lock nut (5).
J NOTE
• Be careful not to drop the nut inside.
7. Slide off the governor connecting rod (4) from the rack pin (6) of
injection pump assembly.
8. For convenient sake, temporarily hook the start spring (7) on the
rack pin (6) hole of the governor connecting rod (4).
9. Remove the governor housing mounting screws.
10.Detach the governor housing assembly (8) from the injection
pump unit.
(When reassembling)
• When reassembling the inside parts, put the oil on each inside
part slightly.
• After sliding on the governor connecting rod (4) to the rack pin
(6), tighten the nut with the specified torque with using the jig for
keeping the governor connecting rod (4) horizontal. (See the
“Replacing Injection Pump Assembly”.)
• After tightening the nut, hook the start spring (7) on the rack pin
(6).
• Check the movement of control rack of injection pump assembly
by the stop lever.
J NOTE
• When installing the governor housing assembly (8) to the
injection pump unit, be careful not to damage O-ring (9).
• When linking the governor connecting rod (4) to the rack pin
(6) of injection pump, use the jig for keeping the governor
connecting rod (4) horizontal. Otherwise the control rack
may be stuck, and causes to be difficult to start the engine
or hunting of governor. (See the “Replacing Injection Pump
Assembly”.)
9.81 to 11.2 N·m
Governor housing
1.00 to 1.15 kgf·m
mounting screw
7.24 to 8.31 lbf·ft
Tightening torque
2.9 to 4.0 N·m
Lock nut 0.29 to 0.41 kgf·m
2.1 to 2.9 lbf·ft
(1) Sight Cover (6) Rack Pin

(2) Stop Solenoid (7) Start Spring
(3) Lubricating Oil Pipe (8) Governor Housing Assembly
(4) Governor Connecting Rod (9) O-ring
(5) Lock Nut
W1137126
III-S-157
Governor Fork Lever Assembly

1. Pull off the governor fork lever shaft (2) with the extra bolt (Dia. :
4.0 mm (0.16 in.), Pitch : 0.7 mm (0.03 in.), Length : more than
25 mm (0.98 in.)) (1).
2. Unhook the governor spring (3) at the governor fork lever (4)
side.
3. Remove the governor fork lever assembly from the governor
housing (5).
(When reassembling)
• After reassembling the governor housing assembly, check the
movement of the governor fork lever assembly, the speed control
lever and the stop lever.
J NOTE
• When assembling the inside parts, put the oil on each inside
part slightly.
• Be careful not to deform the start spring.
(1) Extra Bolt (2) Governor Fork Lever Shaft
(Dia. : 4.0 mm (0.16 in.), (3) Governor Spring
Pitch : 0.7 mm (0.03 in.), (4) Governor Fork Lever
Length : more than 25 mm (0.98 in.)) (5) Governor Housing
W1139749
III-S-158
Governor Lever
1. Remove the spring pin (3).
2. Remove the speed control lever (2) and the return spring (1).
3. Remove the governor lever assembly (4) from the governor
housing.
4. Remove the start spring (6).
(1) Return Spring (4) Governor Lever Assembly
(2) Speed Control Lever (5) O-ring
(3) Spring Pin (6) Start Spring
W1142375
Stop Lever
1. Remove the spring pin (3).
2. Remove the stop lever (2) and the return spring (1).
3. Remove the stop lever shaft (4).
(1) Return Spring (4) Stop Lever Shaft
(2) Stop Lever (5) O-ring
(3) Spring Pin
W1143531
III-S-159
Fuel Camshaft and Governor Weight

1. Separate the governor housing assembly from the injection
pump unit. (See the “Injection Pump Unit”.)
2. Remove the governor sleeve (1).
3. Remove the injection pump assembly (4).
4. Remove the fuel camshaft lock screws.
5. Install the injection pump unit to the crankcase 1 again and
temporarily tighten unit.
6. Fix the flywheel with the flywheel stopper (6) and loosen the
injection pump gear mounting nut (5).
7. Remove the governor weight mounting nut (3) and the governor
weight (2).
8. Separate the injection pump unit from the crankcase 1.
J NOTE
• Do not use the fuel camshaft lock screws, when removing the
governor weight mounting nut (3). Otherwise, the lock
screws or injection pump housing might get damage.
J IMPORTANT
• This injection pump gear mounting nut (5) has left-handed
screw. To loose this nut, rotate clockwise (viewed from
flywheel side).
24 to 27 N·m
Injection pump assembly
2.4 to 2.8 kgf·m
mounting screw
18 to 20 lbf·ft
18 to 20 N·m
1.8 to 2.1 kgf·m
mounting nut
13 to 15 lbf·ft
Tightening torque
Injection pump gear 138 to 156 N·m
mounting nut (left-handed 14.0 to 16.0 kgf·m
screw) 102 to 115 lbf·ft
63 to 72 N·m
Governor weight mounting
6.4 to 7.4 kgf·m
nut
47 to 53 lbf·ft
(1) Governor Sleeve A : To Tighten

(2) Governor Weight B : To Loosen
(3) Governor Weight Mounting Nut
(4) Injection Pump Assembly
(5) Injection Pump Gear Mounting Nut
(6) Flywheel Stopper
W1144178
III-S-160
Fuel Camshaft and Governor Weight (Continued)

1. Pull out the injection pump gear using gear puller (1). (Refer to
“5. SPECIAL TOOLS” at “GENERAL” section.)
2. Loosen the fuel camshaft stopper mounting screws (2) and
remove the fuel camshaft stopper (3).
3. Pull out the fuel camshaft (8) and bearings (9) together.
4. Loosen the fuel camshaft bearing stopper mounting screws (5).
5. After removing the fuel camshaft bearing stopper (4), press out
the bearings (9).
J NOTE
• Do not use the fuel camshaft lock bolts, when removing the
governor weight mounting nut. Otherwise, the lock bolts or
injection pump housing might get damage.
(When reassembling)
• Press the bearings (9) into the fuel camshaft.
• Confirm that the oil path hole (7) set in position and attach the fuel
camshaft bearing stopper (4). Then tighten the fuel camshaft
bearing stopper mounting screws (5) with the specified torque.
• Install the fuel camshaft and bearings (9) to the injection pump
housing.
• Attach the fuel camshaft stopper (3) and tighten the fuel camshaft
stopper mounting screws (2) with the specified torque.
• Install the injection pump gear and mounting nut to the fuel
camshaft and temporarily tighten nut.
• Install the injection pump unit to the crankcase 1 and temporarily
tighten unit.
• Fix the flywheel with the flywheel stopper. Then tighten the
injection pump gear mounting nut and the governor weight
mounting nut with specified torque.
• Install the injection pump assembly to the injection pump
housing.
• Install the governor sleeve to the fuel camshaft.
• Check the movement of the governor sleeve.
J NOTE
• Be careful the direction of the governor sleeve.
• When reassembling the inside parts, put the oil on each
inside part slightly.
9.81 to 11.2 N·m
Fuel camshaft stopper
1.00 to 1.15 kgf·m
mounting screw
7.24 to 8.31 lbf·ft
Tightening torque
3.9 to 4.2 N·m
Fuel camshaft bearing
0.39 to 0.43 kgf·m
stopper mounting screw
2.9 to 3.1 lbf·ft
(1) Injection Pump Gear Puller (6) Key Way of Fuel Camshaft
(2) Fuel Camshaft Stopper Mounting (7) Oil Path Hole
Screw (8) Fuel Camshaft
(3) Fuel Camshaft Stopper (9) Bearing
(4) Fuel Camshaft Bearing Stopper (10) O-ring
(5) Fuel Camshaft Bearing Stopper
Mounting Screw
W1029456
III-S-161
Replacing Injection Pump Assembly (If necessary)

• The injection pump can be replaced with the crankshaft in
whatever position.
1. Disconnect all injection pipes (4).
2. Disconnect the fuel hose (2) and fuel overflow pipe (3).
3. Disconnect the connector from the stop solenoid (5). Then
remove the stop solenoid (5).
4. Detach the sight cover (1) from the injection pump unit.
5. Unhook the start spring (9), and remove the lock nut (7).
6. Slide off the governor connecting rod (6) from the rack pin (8) of
injection pump assembly (10).
7. Remove the injection pump mounting screws and nuts, and take
out the injection pump assembly (10).
J NOTE
• Be careful not to drop the lock nut (7).
• Be careful not to deform the start spring (9).
• When taking out the injection pump assembly (10), be careful
not to hit it against the governor connecting rod (6).
(When reassembling)
• Install the new injection pump according to the installing
procedure.
(1) Sight Cover (6) Governor Connecting Rod
(2) Fuel Hose (7) Lock Nut
(3) Fuel Overflow Pipe (8) Rack Pin
(4) Injection Pipe (9) Start Spring
(5) Stop Solenoid (10) Injection Pump Assembly
W1182379
III-S-162
Installing Procedure of Injection Pump Assembly

1. Install the fuel injection pump assembly (2) in its unit (1), and
tighten the mounting screws and nuts.
2. Hook the governor connecting rod (4) to the rack pin (5) of the
fuel injection pump assembly (2).
3. Tighten the mounting screws and nuts with the specified torque,
not to slide off the governor connecting rod (4) from the rack pin
(5).
4. Remove the top cover (3) and place the service jig (6) to the hole
of the fuel injection pump unit (1). (Refer to “5. SPECIAL
TOOLS” at “GENERAL” section.)
5. Make sure the permanent magnet at the tip of the service jig (6)
is attracted to the governor connecting rod (4).
6. Slightly tighten the lock nut (7) of the governor connecting rod (4).
7. Holding down the service jig (6) by hand, tighten up the lock nut
(7) to the specified torque.
8. Hook the start spring (8) to the rack pin (5).
(1) Fuel Injection Pump Unit (8) Start Spring
(2) Fuel Injection Pump Assembly (9) Sliding Point between Governor Fork
(3) Top Cover Lever and Governor Connecting Rod
(4) Governor Connecting Rod
(5) Rack Pin A : 27.95 to 28.05 mm
(6) Service Jig (1.100 to 1.104 in.)
(7) Lock Nut
W1069371
III-S-163
Installing Procedure of Injection Pump Assembly (Continued)

1. Move the stop lever (1) and visually check to see if the fuel
injection pump control rack comes smoothly back to the start
position by the counter force of the start spring.
2. If the control rack fails to move back smoothly, remove the start
spring and the lock nut, take the above steps from 2 of the former
page again.
3. Finally fit the sight cover and the stop solenoid back into place.
2.9 to 4.0 N·m
Lock nut 0.29 to 0.41 kgf·m
2.1 to 2.9 lbf·ft
24 to 27 N·m
mounting screw
18 to 20 lbf·ft
18 to 20 N·m
1.8 to 2.1 kgf·m
mounting nut
13 to 15 lbf·ft
(1) Stop Lever

W1069772
Fan Drive Pulley
1. Set the stopper to the flywheel.
2. Remove the crankshaft screw (2).
3. Draw out the fan drive pulley (1).
(When reassembling)
• Tighten the crankshaft screw (2) to specified torque after
applying engine oil.
255 to 274 N·m
Tightening torque Crankshaft screw 26.0 to 28.0 kgf·m
188 to 202 lbf·ft
(1) Fan Drive Pulley (2) Crankshaft Screw

W1185033
(7) Water Pump and Oil Cooler

Water Pump (If necessary)
1. Remove the water pump (1).
(When reassembling)
• When mounting the water pump (1), use the new water pump
gasket.
(1) Water Pump
W1187742
III-S-164
Oil Cooler
1. Remove the water pipe (2).
2. Remove the oil filter cartridge (1) and the oil cooler joint screw
(3).
3. Remove the oil cooler (4).
40 to 44 N·m
Tightening torque Oil cooler joint screw 4.0 to 4.5 kgf·m
29 to 32 lbf·ft
(1) Oil Filter Cartridge (3) Oil Cooler Joint Screw

(2) Water Pipe (4) Oil Cooler
W1032266
(8) Front Cover

Front Cover
1. Remove the front cover (1).
(When reassembling)
• Confirm that the front cover gasket (4) set in position.
• Confirm that the liquid gasket coating surface is free of water,
dust and oil in order to maintain sealing effect.
J NOTE
• Assemble the adhesive-applied parts within ten minutes.
• Apply a liquid gasket (Three Bond 1217D) (5) to the seam
between crankcase 1 (3) and crankcase 2 (2).
24 to 27 N·m
Front cover mounting
screw
18 to 20 lbf·ft
(1) Front Cover (4) Front Cover Gasket

(2) Crankcase 2 (5) Liquid Gasket
(3) Crankcase 1
W1189218
Relief Valve
1. Remove the relief valve retaining screw (5).
2. Remove the relief valve (2), the spring (3) and the packing (4).
69 to 78 N·m
Relief valve retaining
screw
51 to 57 lbf·ft
(1) Front Cover (4) Packing

(2) Relief Valve (5) Relief Valve Retaining Screw
(3) Spring
W1081251
III-S-165
(9) Flywheel and Timing Gears

Side PTO (Option)
1. Remove the PTO cover 2 (2) from the flywheel housing (1).
2. Remove the PTO cover 1 (3) with PTO gear assembly (5) from
the flywheel housing (1).
(When reassembling)
• Be sure to place the O-ring (4).
J NOTE
(1) Flywheel Housing (5) PTO Gear Assembly
(2) PTO Cover 2 (6) Snap Ring 1
(3) PTO Cover 1 (7) Snap Ring 2
(4) O-ring
W1124264
III-S-166
Flywheel
1. Install the stopper (1) to the flywheel (2) so that the flywheel (2)
does not turn.
J NOTE
• Do not use an impact wrench. Serious damage will occur.
• There is one positioning pin in the crankshaft gear and it is
installed in the flywheel (2).
2. Detach the flywheel screws (3) and set the flywheel guide screws
(4).
3. Remove the flywheel (2) using jack-up screws (5).
(When reassembling)
• Apply engine oil to the flywheel screws (3).
• Before fitting the flywheel (2) and the crankshaft gear together,
wipe oil, dust and other foreign substances off their mating faces.
• The flywheel (2) and the crankshaft gear are fitting together in
just one position. Make sure they are tightly fit and drive the
screws.
98.1 to 107 N·m
Tightening torque Flywheel screw 10.0 to 11.0 kgf·m
72.4 to 79.5 lbf·ft
(1) Stopper (4) Flywheel Guide Screw

(2) Flywheel (5) Jack-up Screw
(3) Flywheel Screw
W1060354
III-S-167
Flywheel Housing
1. Remove the outside flywheel housing mounting screws (2).
2. Remove the inside flywheel housing mounting screws (4).
3. Remove the flywheel housing (3).
(When reassembling)
• Apply engine oil to the flywheel housing oil seal (5).
• Set the flywheel housing guide jig (6) to the crankshaft gear (1).
(Refer to “5. SPECIAL TOOLS” at “GENERAL” section.)
• Apply a liquid gasket (Three Bond 1217D) (9) to the seam
between crankcase 1 (7) and crankcase 2 (8).
For Side PTO Model (Option)
• Install the inside roller bearing (11) of the camshaft (10) in the
outside roller bearing (12) of the flywheel housing (13).
103 to 117 N·m
Flywheel housing
mounting screw
76.0 to 86.7 lbf·ft
(1) Crankshaft Gear (7) Crankcase 1

(2) Flywheel Housing Mounting Screw (8) Crankcase 2
(Outside) (9) Liquid Gasket
(3) Flywheel Housing (10) Camshaft
(4) Flywheel Housing Mounting Screw (11) Roller Bearing (Inside)
(Inside) (12) Roller Bearing (Outside)
(5) Oil Seal (13) Flywheel Housing
(6) Jig
W1034007
III-S-168
Camshaft and Idle Gear

1. Rotate the cylinder head side of the engine crankcase to the
lower side.
2. Remove three camshaft set screws (7) and draw out the cam
gear (4).
3. Remove the idle gear mounting screws (8) and draw out the idle
gear (2).
J NOTE
• If the cylinder head side of the engine crankcase does not
become lower side, the tappets drop and become the trouble
to the camshaft. The camshaft will not be able to be drawn
out.
(When reassembling)
• When installing the idle gear (2) and cam gear (4), be sure to
place the 4th cylinder piston at the top dead center in
compression then, align all mating marks on each gear to
assemble the timing gears, set the cam gear last.
• Mount the injection pump gear (6) after installing the flywheel
housing.
24 to 27 N·m
Camshaft set screw 2.4 to 2.8 kgf·m
18 to 20 lbf·ft
Tightening torque
24 to 27 N·m
Idle gear mounting screw 2.4 to 2.8 kgf·m
18 to 20 lbf·ft
(1) Balancer 2 Gear (Option) (5) Balancer 1 Gear (Option)

(2) Idle Gear (6) Injection Pump Gear
(3) Crank Gear (7) Camshaft Set Screw
(4) Cam Gear (8) Idle Gear Mounting Screw
W1189797
Balancer Shaft (Option)

1. Remove the balancer shaft 1 set screws (1) and draw out the
balancer shaft 1 (3).
2. Remove the balancer shaft 2 set screws (2) and draw out the
balancer shaft 2 (4).
(When reassembling)
• When installing the balancer shaft 1 (3) and 2 (4), be sure to
place the 4th cylinders piston at the top dead center in
compression then, align all mating marks on each gear to
assemble the timing gears, set the cam gear last.
24 to 27 N·m
Tightening torque Balancer shaft set screw 2.4 to 2.8 kgf·m
18 to 20 lbf·ft
(1) Balancer Shaft 1 Set Screw (3) Balancer Shaft 1

(2) Balancer Shaft 2 Set Screw (4) Balancer Shaft 2
W1191037
III-S-169
(10) Piston and Connecting Rod

Oil Pan and Oil Strainer
1. Unscrew the oil pan mounting screws (1) and remove the oil pan
(2).
2. Unscrew the oil strainer mounting screws (4), and remove the oil
strainer (5).
(When reassembling)
• Install the oil strainer (5), using care not to damage the O-ring (3).
• Apply liquid gasket (Three Bond 1217D) (6) to the crankcase 2
(7) as shown in the figure.
• Carefully apply the adhesive evenly.
J NOTE
• When mounting the adhesive-applied parts, take care to fit
them to the mating parts.
• To avoid uneven tightening, tighten mounting screws (1) in
diagonal order from the center.
• After cleaning the oil strainer (5), install it.
• Attach the oil pan (2) so that the drain plugs (8) will approach
the flywheel housing side (B).
(1) Oil Pan Mounting Screw (6) Liquid Gasket
(2) Oil Pan (7) Crankcase 2
(3) O-ring (8) Drain Plug
(4) Oil Strainer Mounting Screw A: Front Cover Side
(5) Oil Strainer B: Flywheel Housing Side
W1057949
Tappet
1. Remove the tappets (1) from the tappet bore (2) of the crankcase
1 (3) using magnetic tool.
(When reassembling)
• Before installing the tappets (1), apply engine oil thinly around
them.
J NOTE
• Mark the cylinder number to the tappets (1) to prevent
interchanging.
(1) Tappet (3) Crankcase 1
(2) Tappet Bore
W1036026
III-S-170
Connecting Rod Cap

1. Remove the connecting rod screws (1) from connecting rod cap.
2. Remove the connecting rod caps.
(When reassembling)
• Align the marks (a) with each other. (Face the marks toward the
injection pump.)
• Apply engine oil to the connecting rod screws (1) and lightly
screw it in by hand, then tighten it to the specified torque.
If the connecting rod screw (1) won’t be screwed in smoothly,
clean the threads.
If the connecting rod screw (1) is still hard to screw in, replace it.
• When using the existing crank pin metal again, put tally marks on
the crank pin metal and the connecting rod in order to keep their
positioning.
• Fit the crank pin metal in place : its centrally groove side toward
the connecting rod, and the non-grooved side toward the cap.
69 to 73 N·m
Tightening torque Connecting rod screw 7.0 to 7.5 kgf·m
51 to 54 lbf·ft
(1) Connecting Rod Screw (a) Mark

W1058252
Piston
1. Completely clean carbon in the cylinders.
2. Turn the flywheel and set a piston to the top dead center.
3. Pull out the piston upward by lightly tapping it from the bottom of
the crankcase with the grip of a hammer.
(When reassembling)
• Before inserting the piston into the cylinder, apply enough engine
oil to the cylinder.
• When inserting the piston into the cylinder, face the mark (3) on
the connecting rod to the injection pump.
J NOTE
• Do not change the combination of cylinder and piston.
Make sure of the position of each piston by marking. For
example, mark “1” on the No. 1 position.
• When inserting the piston into the cylinder, place the gap of
each piston ring like the figure.
• Carefully insert the pistons using a piston ring compressor
(1). Otherwise, their chrome-plated section of piston rings
may be scratched, causing trouble inside the liner.
• When inserting the piston in place, be careful not to get the
molybdenum disulfide coating (2) torn off its skirt. This
coating is useful in minimizing the clearance with the
cylinder liner. Just after the piston pin has been press-fitted,
in particular, the piston is still hot and the coating is easy to
peel off. Wait until the piston cools down.
(1) Piston Ring Compressor (A) Top Ring Gap
(2) Molybdenum Disulfide Coating (B) Second Ring Gap
(3) Mark (C) Oil Ring Gap
(a) 0.79 rad (45 °) (D) Piston Pin Hole
(E) Injection Pump Side
W1058433
III-S-171
Piston Ring and Connecting Rod

1. Remove the piston rings using a piston ring tool.
2. Remove the piston pin (7), and separate the connecting rod (6)
from the piston (5).
(When reassembling)
• Be sure to fix the crankpin bearing and the connecting rod (6) are
same I.D. colors.
• When installing the ring, assemble the rings so that the
manufacture’s mark (12) near the gap faces the top of the piston
(5).
• When installing the oil ring (3) onto the piston (5), place the
expander joint (11) on the opposite side of the oil ring gap (10).
• Apply engine oil to the piston pin (7).
• When installing the piston pin (7), immerse the piston (5) in 80 °C
(176 °F) oil for 10 to 15 minutes and insert the piston pin (7) to
the piston (5).
• Assemble the piston (5) to the connecting rod (6) with the ↑ mark
(8) and the connecting rod numbering mark (9) facing same side.
• The end faces of the oil ring (3) are plated with hard chrome. In
putting the piston (5) into the cylinder, be careful not to get the oil
ring (3) scratched by the cylinder. Use the piston ring fitter to
tighten up the oil ring (3). If the ring’s planting is scratched, it may
get stuck on the cylinder wall, causing a serious trouble.
J IMPORTANT
• Mark the same number on the connecting rod (6) and the
piston (5) so as not to change the combination.
(1) Top Ring (10) Oil Ring Gap
(2) Second Ring (11) Expander Joint
(3) Oil Ring (12) Manufacture’s Mark
(4) Piston Pin Snap Pin
(5) Piston (A) Connecting Rod ID Color : Blue
(6) Connecting Rod or without Color
(7) Piston Pin (B) Crankpin Bearing ID Color : Blue
(8) Mark (↑) or without Color
(9) Numbering Mark
W1059589
III-S-172
(11) Crankshaft and Crankcase

Crankshaft and Crankcase
1. Remove the crankcase 2 mounting screw and crankcase 2 flange
screw in the order of Z to A.
2. Remove the crankcase 2 (1) from the crankcase 1 (2).
3. Remove the crankshaft (3).
(1) Crankcase 2 (a) Front Cover Side
(2) Crankcase 1 (b) Flywheel Housing Side
(3) Crankshaft A to J :Crankcase 2 Mounting Screw
K to Z :Crankcase 2 Flange Screw
W1037243
III-S-173
Crankshaft and Crankcase (Continued)

(When reassembling)
• Make sure the crankcase 1 (4) and 2 (1) are clean.
• Reassemble the crankshaft bearing (3) into crankcase 1 (4) and
2 (1).
• Reassemble the thrust bearing (2), with the oil groove facing
outside, into both flywheel housing edge journal side of the
crankcase 1 (4) and 2 (1).
• Apply oil to the thrust bearing and set the crankshaft (6).
• Apply liquid gasket (Three Bond 1217D) (5) to the crankcase 1
as shown in the figure.
• Carefully apply the adhesive evenly.
• Match the crankcase 1 (4) and 2 (1), referring to the flywheel
housing’s contoured face.
• Tighten the crankcase 2 mounting screws (A to J) and the
crankcase 2 flange screws (K to Z) loosely after applying engine
oil.
• Tighten up the jig (7) to the specified torque same as the flywheel
housing screw. (Refer to “5. SPECIAL TOOLS” at “GENERAL”
section.) This helps to minimize the level difference between the
crankcase 1 (4) and the crankcase 2 (1) (at the flywheel side).
Possible gap must be 0.05 mm (0.002 in.) or smaller.
• Tighten the crankcase 2 mounting screw and the crankcase 2
flange screw in the order of A to Z.
J NOTE
• When mounting the adhesive-applied parts, take care to fit
them to the mating parts.
138 to 147 N·m
Crankcase 2 mounting
14.0 to 15.0 kgf·m
screw (A to J)
102 to 108 lbf·ft
59 to 63 N·m
Crankcase 2 flange screw
(K to Z)
44 to 47 lbf·ft
103 to 117 N·m
Flywheel housing
10.5 to 12.0 kgf·m
mounting screw
76.0 to 86.7 lbf·ft
(1) Crankcase 2 (a) Front Cover Side

(2) Thrust Bearing (b) Flywheel Housing Side
(3) Crankshaft Bearing A to J : Crankcase 2 Mounting Screw
(4) Crankcase 1 K to Z : Crankcase 2 Flange Screw
(5) Liquid Gasket
(6) Crankshaft
(7) Jig
W1037643
III-S-174
(12) Starter
Disassembling Motor
1. Disconnect the solenoid switch (3).
2. Remove the 2 through screws (9) and the 2 brush holder lock
screws. Take out the rear end frame (13) and the brush holder
(12).
3. Disconnect the armature (10) and the yoke (11). Remove also
the ball (7) from the tip of the armature (10).
4. Remove the set of packing (8), the 4 planetary gears (6) and
another packing.
5. Take out the shaft assembly. Take note of the position of the
lever.
J IMPORTANT
• Before disconnecting the yoke (11), put tally marks on the
yoke (11) and the front bracket (2).
• Take note of the positions of the set of packing (8) and the
setup bolt.
• Apply grease to the gears, bearings, shaft’s sliding part and
ball (7).
J NOTE
• Do not damage to the brush and commutator.
(When reassembling)
• Apply grease (DENSO CO. No.50 or equivalent) to the parts
indicated in the figure.
9.8 to 11 N·m
Starter’s terminal B
mounting screw
7.3 to 8.6 lbf·ft
(1) Gear (8) Set of Packing

(2) Front Bracket (9) Through Screw
(3) Solenoid Switch (10) Armature
(4) Overrunning Clutch (11) Yoke
(5) Internal Gear (12) Brush Holder
(6) Planetary Gear (13) Rear End Frame
(7) Ball
W1074237
(13) Alternator
Front Bracket
1. Remove the 4 screws (3).
2. Separate the front bracket (1) and the rear bracket (2) from each
other.
J IMPORTANT
• Put a tally line on the front bracket (1) and the rear bracket (2)
for reassembling them later.
(1) Front Bracket (3) Screw
(2) Rear Bracket
W1074745
III-S-175
Pulley
1. Hold the rotor (base of the claw) in a vise. Loosen the lock nut
using a M24 box wrench.
58.4 to 78.9 N·m
Tightening torque Alternator pulley nut 5.95 to 8.05 kgf·m
43.1 to 58.2 lbf·ft
W1074849
Rotor
1. Remove the 4 screws and detach the bearing retainer.
2. Temporarily install the nut on the pulley screw, and detach the
rotor.
W1074920
Brush
1. When the rotor is detached, the 2 brushes are found to stretch
out of the shaft hole.
W1075045
III-S-176
Reassembling the Brush

1. Fit the brush with its sliding face in the clockwise direction when
viewed from front.
J IMPORTANT
• Be sure to keep the 2 brushes deep in the brush holder.
Otherwise the rotor and the rear section can not be fitted
into the position.
• Use a 4.0 mm (0.16 in.) hex. wrench to push the brushes into
place.
• Using a pin-pointed (2.0 mm (0.079 in.)) punch, keep the
brushes from popping out.
2. Match the tally line of the front section with that of the rear
section.
3. Tighten the 4 screws, and draw out the pin-pointed punch out of
the brush holder.
(1) Marking
W1075117
Bearing at Slip Ring Side

1. Lightly secure the rotor (1) with a vise to prevent damage, and
remove the bearing (2) with a puller (3).
(1) Rotor (3) Puller
(2) Bearing
W1019701
III-S-177
[3] SERVICING
(1) Cylinder Head and Valves
Top Clearance
1. Remove the cylinder head (remove the cylinder head gasket
completely).
2. Bring the piston to its top dead center, fasten fuse wires (dia. : 1.5
mm (0.059 in.), long : 5.0 to 7.0 mm (0.20 to 0.28 in.)) (1) to 3 to
4 spots on the piston top with grease so as to avoid the intake and
exhaust valves and the combustion chamber ports.
3. Bring the piston to its middle position, install the cylinder head,
and tighten the cylinder head screws to specification. (Head
gasket must be changed to new one).
4. Turn the crank shaft until the piston exceeds its top dead center.
5. Remove the cylinder head, and measure squeezed fuse wires (1)
for thickness.
6. If the measurement is not within the specified value, check the oil
clearance of the crankpin journal and the piston pin.
0.60 to 0.80 mm
Top clearance Factory spec.
0.024 to 0.031 in.
187 to 196 N·m

Cylinder head mounting
screw
138 to 144 lbf·ft
(1) Fuse Wire

W1049122
Cylinder Head Surface Flatness
1. Clean the cylinder head surface.
2. Place a straightedge on the cylinder head’s four sides (A), (B),
(C) and (D) and two diagonal (E) and (F) as shown in the figure.
Measure the clearance with a feeler gauge.
3. If the measurement exceeds the allowable limit, correct it with a
surface grinder.
J IMPORTANT
• Be sure to check the valve recessing after correcting.
Cylinder head surface 0.05 mm
Allowable limit
flatness 0.002 in.
W1061323
III-S-178
Cylinder Head Flaw

1. Prepare an air spray red check.
2. Clean the surface of the cylinder head with the detergent (2).
3. Spray the cylinder head surface with the red permeative liquid
(1). Leave it five to ten minutes after spraying.
4. Wash away the red permeative liquid on the cylinder head
surface with the detergent (2).
5. Spray the cylinder head surface with the white developer (3).
6. If flawed, it can be identified as red marks.
(1) Red Permeative Liquid (3) White Developer
(2) Detergent
W1076542
Valve Recessing
1. Clean the cylinder head, the valve face and seat.
2. Insert the valve into the valve guide.
3. Measure the valve recessing with a depth gauge.
4. If the measurement exceeds the allowable limit, replace the
valve.
If it still exceeds the allowable limit after replacing the valve,
replace the cylinder head.
(recessing)
Factory spec. 0.65 to 0.85 mm
Valve recessing 0.026 to 0.033 in.
(Intake and exhaust) (recessing)
Allowable limit 1.20 mm
0.0472 in.
(1) Cylinder Head Surface (A) Recessing

(B) Protrusion
W1061543
Valve Lapping
1. Apply compound evenly to the valve lapping surface.
2. Insert the valve into the valve guide. Lap the valve onto its seat
with a valve flapper or screwdriver.
3. After lapping the valve, wash the compound away and apply oil,
then repeat valve lapping with oil.
4. Apply prussian blue to the contact surface to check the seated
rate. If it is less than 70 %, repeat valve lapping again.
J IMPORTANT
• When valve lapping is performed, be sure to check the valve
recessing and adjust the valve clearance after assembling
the valve.
(1) Correct (3) Incorrect
(2) Incorrect
W1061709
III-S-179
Clearance between Valve Stem and Valve Guide

1. Remove carbon from the valve guide section.
2. Measure the valve stem O.D. with an outside micrometer.
3. Measure the valve guide I.D. of the cylinder head at the most
wear part as shown in the figure below with a small hole gauge.
And calculate the clearance.
4. If the clearance exceeds the allowable limit, replace the valves.
If it still exceeds the allowable limit, replace the valve guide.
0.055 to 0.085 mm
Clearance between Factory spec.
0.0022 to 0.0033 in.
valve stem and guide
(Intake and exhaust) 0.10 mm
Allowable limit
0.0039 in.
Valve stem O.D. 6.960 to 6.975 mm

Factory spec.
(Intake and exhaust) 0.2741 to 0.2746 in.
Valve guide I.D. 7.030 to 7.045 mm
Factory spec.
W1061883
Replacing Valve Guide

(When removing)
1. Using a valve guide replacing tool, press out the used valve
guide. (Refer to “5. SPECIAL TOOLS” at “GENERAL” section.)
(When installing)
1. Clean a new valve guide, and apply engine oil to it.
2. Using a valve guide replacing tool, press in a new valve guide
until it is flush with the cylinder head as shown in the figure.
3. Ream precisely the I.D. of the valve guide to the specified
dimension.
Valve guide I.D. 7.030 to 7.045 mm
Factory spec.
J IMPORTANT
• Do not hit the valve guide with a hammer, etc. during
replacement.
(A) When Removing (B) When Installing
W1062212
III-S-180
Correcting Valve and Valve Seat

J NOTE
• Before correcting the valve and seat, check the valve stem
and the I.D. of valve guide section, and repair them if
necessary.
• After correcting the valve seat, be sure to check the valve
recessing.
1) Correcting Valve
1. Correct the valve with a valve refacer.
Valve face angle 0.79 rad
Factory spec.
(Intake and exhaust) 45 °
2) Correcting Valve Seat
1. Slightly correct the seat surface with a 0.79 rad (45 °) valve seat
cutter.
2. Resurface the seat surface with a 0.26 rad (15 °) valve seat cutter
so that the width is close to specified valve seat width.
Valve seat width 3.3 to 3.6 mm
Factory spec.
3. After resurfacing the seat, inspect for even valve seating, apply a
thin film of compound between the valve face and valve seat, and
fit them with valve lapping tool.
4. Check the valve seating with prussian blue. The valve seating
surface should show good contact all the way around.
Valve seat angle 0.79 rad
Factory spec.
(Intake and exhaust) 45 °
(1) Valve Seat Width (A) Check Contact

(2) Identical Dimensions (B) Correct Seat Width
(C) Check Contact
(a) 0.26 rad (15 °)
(b) 0.79 rad (45 °)
(c) 0.52 rad (30 °)
W10283500
Free Length and Tilt of Valve Spring
1. Measure the free length (B) with vernier calipers. If the
measurement is less than the allowable limit, replace it.
2. Put the spring on a surface plate, place a square on the side of
the spring, and check to see if the entire side is contact with the
square. Rotate the spring and measure the maximum tilt (A). If
the measurement exceeds the allowable limit, replace.
3. Check the entire surface of the spring for scratches. Replace it,
if any.
1.0 mm
Tilt (A) Allowable limit
0.039 in.
35.1 to 35.6 mm
Factory spec.
1.39 to 1.40 in.
Free length (B)
34.6 mm
Allowable limit
1.36 in.
(A) Tilt (B) Free length

W1063303
III-S-181
Valve Spring Setting Load

1. Place the valve spring on a tester and compress it to the same
length it is actually compressed in the engine.
2. Read the compression load on the gauge.
3. If the measurement is less than the allowable limit, replace it.
63.5 N / 31.5 mm
Factory spec. 6.48 kgf / 31.5 mm
Setting load / setting 14.3 lbf / 1.24 in.
length 45.9 N / 31.5 mm
Allowable limit 4.68 kgf / 31.5 mm
10.3 lbf / 1.24 in.
W1063470
Oil Clearance between Rocker Arm Shaft and Bearing
1. Measure the rocker arm bearing I.D. with an inside micrometer.
2. Measure the rocker arm shaft O.D. with an outside micrometer,
and then calculate the oil clearance.
3. If the clearance exceeds the allowable limit, replace the rocker
arm and measure the oil clearance again. If it still exceeds the
allowable limit, replace also the rocker arm shaft.
0.016 to 0.045 mm
Factory spec.
Oil clearance of rocker 0.00063 to 0.0017 in.
arm shaft and bearing 0.15 mm
Allowable limit
0.0059 in.
14.973 to 14.984 mm
Rocker arm shaft O.D. Factory spec.
0.58949 to 0.58992 in.
15.000 to 15.018 mm
Rocker arm I.D. for shaft Factory spec.
0.59056 to 0.59125 in.
W1063697
Oil Clearance between Bridge Arm and Bridge Arm Shaft
1. Measure the bridge arm (1) I.D. with an inside micrometer.
2. Measure the bridge arm shaft O.D. with an outside micrometer,
and then calculate the oil clearance.
3. If the clearance exceeds the allowable limit, replace the bridge
arm (1) and measure the oil clearance again. If it still exceeds
the allowable limit, replace also the bridge arm shaft.
0.018 to 0.042 mm
Oil clearance between Factory spec.
0.00071 to 0.0016 in.
bridge arm and bridge
arm shaft 0.15 mm
Allowable limit
0.0059 in.
9.023 to 9.032 mm
Bridge arm shaft O.D. Factory spec.
0.3553 to 0.3555 in.
9.050 to 9.065 mm
Bridge arm I.D. Factory spec.
0.3563 to 0.3568 in.
(1) Bridge Arm

W1042581
III-S-182
Replacing Bridge Arm Shaft (If necessary)

1. Remove the used bridge arm shaft (2).
2. Clean the bridge arm shaft mounting hole.
3. Using bridge arm shaft replacing tool (3), press in the new shaft.
(1) Bridge Arm A : 31.1 to 31.7 mm (1.23 to 1.24 in.)
(2) Bridge Arm Shaft
(3) Bridge Arm Shaft Replacing Tool
W1042985
Push Rod Alignment

1. Place the push rod on V blocks.
2. Measure the push rod alignment.
3. If the measurement exceeds the allowable limit, replace the push
rod.
0.25 mm
Push rod alignment Allowable limit
0.0098 in.
(1) Push Rod

W10292900
Oil Clearance between Tappet and Tappet Bore

1. Measure the tappet O.D. with an outside micrometer.
2. Measure the I.D. of the tappet bore at the most wear part with a
small hole gauge.
3. If the oil clearance exceeds the allowable limit or the tappet is
damaged, replace the tappet.
0.020 to 0.050 mm
Factory spec.
OIl clearance between 0.00079 to 0.0019 in.
tappet and tappet bore 0.07 mm
Allowable limit
0.003 in.
9.965 to 9.980 mm
Tappet O.D. Factory spec.
0.3924 to 0.3929 in.
10.000 to 10.015 mm
Tappet bore I.D. Factory spec.
0.39370 to 0.39429 in.
(1) Tappet (2) Tappet Bore

W1043774
III-S-183
(2) Timing Gears

Timing Gear Backlash
1. Set a dial indicator (lever type) with its tip on the gear tooth.
2. Move the gear to measure the backlash, holding its mating gear.
3. If the backlash exceeds the allowable limit, check the oil
clearance of the shafts and the gear.
4. If the oil clearance is proper, replace the gear.
0.0410 to 0.139 mm
Factory spec.
Backlash between crank 0.00162 to 0.00547 in.
gear and cam gear 0.22 mm
Allowable limit
0.0087 in.
(for balancer model) 0.0410 to 0.134 mm

Factory spec.
Backlash between cam 0.00162 to 0.00527 in.
gear and balancer 1 0.22 mm
gear Allowable limit
0.0087 in.
0.0410 to 0.134 mm
Factory spec.
Backlash between cam 0.00162 to 0.00527 in.
gear and idle gear 0.22 mm
Allowable limit
0.0087 in.
0.0410 to 0.134 mm
Backlash between idle Factory spec.
0.00162 to 0.00527 in.
gear and injection pump
gear 0.22 mm
Allowable limit
0.0087 in.
(for balancer model) 0.0410 to 0.129 mm

Factory spec.
Backlash between idle 0.00162 to 0.00507 in.
gear and balancer 2 0.22 mm
gear Allowable limit
0.0087 in.
(1) Balancer 1 Gear (Option) (4) Injection Pump Gear

(2) Cam Gear (5) Balancer 2 Gear (Option)
(3) Idle Gear (6) Crank Gear
W1064048
Idle Gear Side Clearance
1. Set a dial indicator with its tip on the idle gear (1).
2. Measure the side clearance by moving the idle gear (1) to the
front and rear.
3. If the measurement exceeds the allowable limit, replace the idle
gear collars.
0.15 to 0.25 mm
Factory spec.
Side clearance of idle 0.0059 to 0.0098 in.
gear 0.90 mm
Allowable limit
0.035 in.
(1) Idle Gear (A) Side Clearance of Idle Gear

W1064208
III-S-184
Oil Clearance between Idle Gear Shaft and Idle Gear Bushing
1. Measure the idle gear shaft O.D. with an outside micrometer.
2. Measure the idle gear bushings I.D. with an inside micrometer,
and calculate the oil clearance.
3. If the oil clearance exceeds the allowable limit, replace the
bushing.
0.050 to 0.091 mm
0.0020 to 0.0035 in.
idle gear shaft and idle
gear bushing 0.10 mm
Allowable limit
0.0039 in.
34.959 to 34.975 mm
Idle gear shaft O.D. Factory spec.
1.3764 to 1.3769 in.
35.025 to 35.050 mm
Idle gear bushing I.D. Factory spec.
1.3790 to 1.3799 in.
W1064968
Replacing Idle Gear Bushing
(When removing)
1. Using an idle gear bushing replacing tool, press out the used
bushing. (Refer to “5. SPECIAL TOOLS” at “GENERAL”
section.)
(When installing)
1. Clean a new idle gear bushing and idle gear bore, and apply
engine oil to them.
2. Using an idle gear bushing replacing tool, press in a new bushing
(service parts) to the specified dimension. (See figure.)
(A) When Removing (B) When Installing
W10302410
Camshaft Side Clearance

1. Set a dial indicator with its tip on the camshaft.
2. Measure the side clearance by moving the cam gear (1) to the
front and rear.
camshaft bearing.
Side clearance of 0.10 mm
Allowable limit
camshaft 0.0039 in.
(1) Cam Gear (A) Side Clearance of Camshaft

W1064307
Camshaft Alignment
1. Support the camshaft (1) with V block on the surface plate and
set a dial indicator with its tip on the intermediate journal at right
angle.
2. Rotate the camshaft (1) on the V blocks and get the misalignment
(half of the measurement value).
3. If the misalignment exceeds the allowable limit, replace the
camshaft (1).
0.01 mm
Camshaft alignment Allowable limit
0.0004 in.
(1) Camshaft
W1064422
III-S-185
Cam Height
1. Measure the height of the cam (2) at its highest point with an
outside micrometer.
2. If the measurement is less than the allowable limit, replace the
camshaft (1).
Intake 37.50 mm
Factory valve 1.476 in.
spec. Exhaust 37.90 mm
Intake and exhaust cam valve 1.492 in.
height Intake 37.00 mm
Allowable valve 1.457 in.
limit Exhaust 37.40 mm
valve 1.472 in.
(1) Camshaft (2) Cam

W1064551
Oil Clearance of Camshaft Journal
1. Measure the camshaft journal O.D. with an outside micrometer.
2. Measure the cylinder block bore I.D. for camshaft with an inside
micrometer.
3. If the clearance exceeds the allowable limit, replace the
camshaft.
0.050 to 0.091 mm
Factory spec.
Oil clearance of 0.0020 to 0.0035 in.
camshaft journal 0.15 mm
Allowable limit
0.0059 in.
34.934 to 34.950 mm
Camshaft journal 1 O.D. Factory spec.
1.3754 to 1.3759 in.
Camshaft block bore 1 35.000 to 35.025 mm
Factory spec.
I.D. 1.3780 to 1.3789 in.
43.934 to 43.950 mm
Camshaft journal 2 O.D. Factory spec.
1.7297 to 1.7303 in.
Camshaft block bore 2 44.000 to 44.025 mm
Factory spec.
I.D. 1.7323 to 1.7332 in.
(1) Camshaft Journal 1 (2) Camshaft Journal 2

W1064798
Replacing Camshaft Cover (If necessary)
1. Remove the used camshaft cover and clean the hole.
2. Install the new camshaft cover (1) until bumping using camshaft
cover replacing tool. (Refer to “5. SPECIAL TOOLS” at
“GENERAL” section.)
(1) Camshaft Cover
W1048526
III-S-186
Balancer Shaft Side Clearance (for Balancer Model)

1. Set a dial indicator with tip on the balancer shaft.
2. Measure the side clearance by moving the balancer shaft to the
front and rear.
balancer shaft.
0.070 to 0.22 mm
Factory spec.
Side clearance of 0.0028 to 0.0086 in.
balancer shaft 1 0.30 mm
Allowable limit
0.012 in.
0.070 to 0.32 mm
Factory spec.
balancer shaft 2 0.34 mm
Allowable limit
0.013 in.
(A) Side Clearance of Balancer Shaft 2 (B) Side Clearance of Balancer Shaft 1
W1065273
Balancer Shaft Alignment (for Balancer Model)
1. Support the balancer shaft with V blocks on the surface plate and
set a dial indicator with its tip on the intermediate journal at high
angle.
2. Rotate the balancer shaft on the V block and get the
misalignment (half of the measurement value).
balancer shaft.
Balancer shaft 1, 2 0.02 mm
Allowable limit
alignment 0.0008 in.
(1) Balancer Shaft 1 (2) Balancer Shaft 2

W1065448
III-S-187
Oil Clearance of Balancer Shaft Journal (for Balancer Model)

1. Measure the balancer shaft journal O.D. with an outside
micrometer.
2. Measure the cylinder block bore I.D. (A), (B) for balancer shaft
with an inside micrometer.
3. If the clearance exceeds the allowable limit, replace the balancer
shaft bearing. If it still exceeds the allowable limit, replace also
the balancer shaft.
0.0600 to 0.146 mm
Factory spec.
balancer shaft 1 journal 0.20 mm
Allowable limit
0.0079 in.
Balancer shaft 1 journal 48.934 to 48.950 mm

Factory spec.
O.D. 1.9266 to 1.9271 in.
Balancer shaft 1 bearing 49.010 to 49.080 mm
Factory spec.
I.D. (A) 1.9296 to 1.9322 in.
0.0500 to 0.136 mm
Factory spec.
balancer shaft 2 journal 0.20 mm
Allowable limit
0.0079 in.
Balancer shaft 2 journal 48.934 to 48.950 mm

Factory spec.
O.D. 1.9266 to 1.9271 in.
Balancer shaft 2 bearing 49.000 to 49.070 mm
Factory spec.
I.D. (B) 1.9292 to 1.9318 in.
(1) Balancer Shaft 1 (A) Balancer Shaft 1 Bearing I.D.

(2) Balancer Shaft 2 (B) Balancer Shaft 2 Bearing I.D.
W1065581
III-S-188
Replacing Balancer Shaft Bearing (for Balancer Model)

1. Remove the used balancer shaft bearings (1), (2), (3) and (4).
2. Set the new bearing to the balancer shaft bearing replacing tools.
(Refer to “5. SPECIAL TOOLS” at “GENERAL” section.) Confirm
that the cut off position of the bearing (C) matched with the pin of
the replacing tool.
3. Install the new bearing from flywheel housing side keeping the
ditch (7) of the replacing tool horizontal.
(The installing order : bearing D (1) → bearing C (2) → bearing A
(4), B (3))
J IMPORTANT
• Be sure to align the oil hole of bearing and crankcase.
Otherwise the balancer shaft may be seized and engine may
get damaged.
• Apply engine oil to the bearing surface.
(Reference)
Bearing Code No. Quantity
Bearing A 1G772-26960 1
Bearing B 1G772-26970 1
Bearing C 1G772-26980 2
Bearing D 1G772-26990 2
(1) Bearing D A: Front Cover Side

(for Balancer Shaft 1 and 2) B: Flywheel Housing Side
(2) Bearing C C: Cut Off Position of Bearing
(for Balancer Shaft 1 and 2) D: Oil Hole Position of Bearing
(3) Bearing B (for Balancer Shaft 2) (a) 0.035 rad (2.0 °)
(4) Bearing A (for Balancer Shaft 1) (b) 0.44 rad (25 °)
(5) Balancer Shaft 1 Bearing Replacing (c) 0.72 rad (41 °)
Tool (3 kinds of tools available) (d) 1.6 rad (90 °)
(6) Balancer Shaft 2 Bearing Replacing (e) 0.393 rad (22.5 °)
Tool (3 kinds of tools available) (f) 1.6 rad (90 °)
(7) Ditch
W1010756
III-S-189
(3) Piston and Connecting Rod

Piston Pin Bore I.D.
1. Measure the piston pin bore I.D. in both the horizontal and
vertical directions with a cylinder gauge.
piston.
28.000 to 28.013 mm
Factory spec.
1.1024 to 1.1028 in.
Piston pin bore I.D.
28.05 mm
Allowable limit
1.104 in.
W1065759
Oil Clearance between Piston Pin and Small End Bushing

1. Measure the O.D. of the piston pin where it contacts the bushing
with an outside micrometer.
2. Measure the I.D. of the piston pin bushing at the connecting rod
small end with a cylinder gauge. Calculate the oil clearance.
connecting rod. If it still exceeds the allowable limit, replace the
piston pin.
0.020 to 0.040 mm
0.00079 to 0.0015 in.
piston pin and small end
bushing 0.15 mm
Allowable limit
0.0059 in.
28.006 to 28.011 mm
Piston pin O.D. Factory spec.
1.1026 to 1.1027 in.
28.031 to 28.046 mm
Small end bushing I.D. Factory spec.
1.1036 to 1.1041 in.
W1065897
Connecting Rod Alignment
J NOTE
• Since the I.D. of the connecting rod small end bushing is the
basis of this check, check the bushing for wear beforehand.
1. Remove the piston pin from the piston.
2. Install the piston pin in the connecting rod.
3. Install the connecting rod on the connecting rod alignment tool.
4. Put a gauge over the piston pin, and move it against the face
plate.
5. If the gauge does not fit squarely against the face plate, measure
the space between the pin of the gauge and the face plate.
connecting rod.
Connecting rod 0.05 mm
Allowable limit
alignment 0.002 in.
W1066581
III-S-190
Piston Ring Gap

1. Insert the piston ring into the lower part of the liner (the least worn
part).
2. Measure the ring gap with a feeler gauge.
3. If the gap exceeds the allowable limit, replace the piston ring.
0.25 to 0.40 mm
Factory spec.
0.0099 to 0.015 in.
Top ring
1.25 mm
Allowable limit
0.0492 in.
0.30 to 0.45 mm
Factory spec.
0.012 to 0.017 in.
Second ring
1.25 mm
Allowable limit
0.0492 in.
0.25 to 0.45 mm
Factory spec.
0.0099 to 0.017 in.
Oil ring
1.25 mm
Allowable limit
0.0492 in.
W1066430
Clearance between Piston Ring and Groove
1. Remove carbon from the ring grooves.
2. Measure the clearance between the ring and the groove with a
feeler gauge or depth gauge.
3. If the clearance exceeds allowable limit, check the new ring.
4. If clearance still exceeds the allowable limit after replacing the
ring, replace the piston.
0.050 to 0.090 mm
Top ring
0.0020 to 0.0035 in.
0.090 to 0.12 mm
Factory spec. Second ring
0.0036 to 0.0047 in.
0.020 to 0.060 mm
Oil ring
0.00079 to 0.0023 in.
0.15 mm
Top ring
0.0059 in.
0.20 mm
Allowable limit Second ring
0.0079 in.
0.15 mm
Oil ring
0.0059 in.
W1066183
III-S-191
(4) Crankshaft
Crankshaft Side Clearance
1. Set a dial indicator with its tip on the end of the crankshaft.
2. Measure the side clearance by moving the crankshaft to the front
and rear.
thrust bearings.
4. If the same size bearing is out of specifications because of the
crankshaft journal wear, replace it with an oversize one referring
to the table and figure.
0.15 to 0.35 mm
Factory spec.
crankshaft 0.50 mm
Allowable limit
0.020 in.
(Reference)
• Oversize dimensions of crankshaft journal.
0.20 mm 0.40 mm
Oversize
0.0079 in. 0.016 in.
41.10 to 42.10 mm 41.20 to 42.20 mm
Dimension A
1.619 to 1.657 in. 1.622 to 1.661 in.
28.20 to 28.25 mm 28.40 to 28.45 mm
Dimension B
1.111 to 1.112 in. 1.119 to 1.120 in.
2.8 to 3.2 mm radius 2.8 to 3.2 mm radius
Dimension C
0.11 to 0.12 in. radius 0.11 to 0.12 in. radius
(0.8S)
The crankshaft journal must be fine-finished to higher than ∇∇∇∇.
(A) Side Clearance of Crankshaft

W1066738
Crankshaft Alignment
1. Support the crankshaft with V block on the surface plate and set
a dial indicator with its tip on the intermediate journal at right
angle.
2. Rotate the crankshaft on the V block and get the misalignment
(half of the measurement value).
crankshaft.
0.02 mm
Crankshaft alignment Allowable limit
0.0008 in.
W1067285
III-S-192
Oil Clearance between Crankpin and Crankpin Bearing

1. Clean the crankpin and crankpin bearing (4).
2. Put a strip of plastigage on the center of the crankpin.
3. Install the connecting rod cap (1) and tighten the connecting rod
screws (2) to the specified torque, and remove the cap again.
4. Measure the amount of the flattening with the scale, and get the
oil clearance.
5. If the oil clearance exceeds the allowable limit, replace the
crankpin bearing (4).
6. If the same size bearing is useless because of the crankpin wear,
replace it with an undersize one referring to the table and figure.
J NOTE
• Never insert the plastigage into the crankpin oil hole.
• Be sure not to move the crankshaft while the connecting rod
screws (2) are tightened.
49.980 to 49.991 mm
Crankpin O.D. Factory spec.
1.9678 to 1.9681 in.
0.017 to 0.048 mm
0.00067 to 0.0018 in.
crankpin and crankpin
bearing 0.20 mm
Allowable limit
0.0079 in.
J IMPORTANT
• STD size crankpin bearing (4).
To replace it with a specific STD service part, make sure the
crankpin bearing (4) has the same ID color (3) as the
connecting rod.
Connecting rod Crankpin bearing
ID Color
Large-end in. dia. Class Part code Center wall thick
53.010 to 53.020 mm 1G772- 1.496 to 1.501 mm
Blue L
2.0870 to 2.0874 in. 22310 0.05890 to 0.05909 in.
Without 53.000 to 53.010 mm 1G772- 1.491 to 1.496 mm
S
color 2.0867 to 2.0870 in. 22330 0.05870 to 0.05889 in.
(Reference)
• Undersize dimensions of crankpin
0.20 mm 0.40 mm
Undersize
0.0079 in. 0.016 in.
Dimension A
1.0 to 1.5 mm relief 1.0 to 1.5 mm relief
*Dimension B
0.040 to 0.059 in. relief 0.040 to 0.059 in. relief
49.780 to 49.791 mm dia. 49.580 to 49.591 mm dia.
Dimension C
1.9599 to 1.9602 in. dia. 1.9520 to 1.9524 in. dia.
(0.8S)
The crankpin must be fine-finished to higher than ∇∇∇∇.
*Holes to be de-burred and edges rounded with 1.0 to 1.5 mm
(0.040 to 0.059 in.) relief.
(1) Connecting Rod Cap (4) Crankpin Bearing

(2) Connecting Rod Screw (5) Center Wall Thick
(3) ID Color
W1067389
III-S-193
Oil Clearance between Crankshaft Journal and Crankshaft

Bearing
1. Clean the crankshaft journal (2) and crankshaft bearing.
2. Put a strip of press gauge on the center of the journal.
J IMPORTANT
• Never insert the press gauge into the oil hole of the journal.
3. Install the crankcase 2 (1) and tighten the crankcase 2 mounting
screws to the specified torque, and remove the crankcase 2 (1)
again.
4. Measure the amount of the flattening with the scale and get the
oil clearance.
crankshaft bearing.
79.977 to 79.990 mm
Crankshaft journal O.D. Factory spec.
3.1487 to 3.1492 in.
0.030 to 0.073 mm
0.0012 to 0.0028 in.
crankshaft journal and
crankshaft bearing 0.20 mm
Allowable limit
0.0079 in.
(Reference)
• Undersize dimensions of crankshaft journal.
0.20 mm 0.40 mm
Undersize
0.0079 in. 0.016 in.
Dimension A
1.0 to 1.5 mm relief 1.0 to 1.5 mm relief
*Dimension B
0.040 to 0.059 in. relief 0.040 to 0.059 in. relief
79.777 to 79.790 mm dia. 79.577 to 79.590 mm dia.
Dimension C
3.1409 to 3.1413 in. dia. 3.1330 to 3.1334 in. dia.
(0.8S)
The crankshaft journal must be fine-finished to higher than ∇∇∇∇.
*Holes to be de-burred and edges rounded with 1.0 to 1.5 mm
(0.040 to 0.059 in.) relief.
(1) Crankcase 2 (3) Crankcase 1

(2) Crankshaft Journal
III-S-194
W1069159
Replacing Crankshaft Sleeve
1. Remove the used crankshaft sleeve (3).
2. Set the sleeve guide (2) to the crankshaft gear (4).
3. Heat a new crankshaft sleeve (3) to a temperature between 150
and 200 °C (302 and 392 °F), and fix the sleeve to the crankshaft
as shown in figure.
4. Press fit the sleeve using the auxiliary socket for pushing (1).
J NOTE
• Mount the sleeve with its largely chamfered surface facing
outward.
• Keep the space (A) between the edge of the crankshaft gear
(4) and the crankshaft sleeve (3).
(1) Auxiliary Socket for Pushing (4) Crankshaft Gear
(2) Sleeve Guide
(3) Crankshaft Sleeve A : More than 6.5 mm (0.26 in.)
W1069911
Replacing Flywheel Housing Oil Seal

1. Remove the used oil seal (2).
2. Clean the new flywheel housing oil seal (2) and apply engine oil
to it.
3. Install the new oil seal (2) to the specific position using the
flywheel housing oil seal replacing tool (1). (Refer to “5.
SPECIAL TOOLS” at “GENERAL” section.)
(1) Flywheel Housing Oil Seal Replacing (3) Flywheel Housing
Tool
(2) Oil Seal A : 1.0 mm (0.039 in.)
W1044329
Replacing Front Cover Oil Seal

1. Remove the used front cover oil seal (2).
2. Clean a new front cover oil seal (2) and apply engine oil to it.
3. Install the new oil seal (2) using the front cover oil seal replacing
tool (1). (Refer to “5. SPECIAL TOOLS” at “GENERAL” section.)
(1) Front Cover Oil Seal Replacing Tool (3) Front Cover
(2) Oil Seal
W1044902
III-S-195
(5) Cylinder
Cylinder Wear
1. Measure the I.D. of the cylinder at the six positions (see figure)
with a cylinder gauge to find the maximum and minimum I.D.’s.
2. Get the difference (Maximum wear) between the maximum and
the minimum I.D.’s.
3. If the wear exceeds the allowable limit, bore and hone to the
oversize dimension. (Refer to “Correcting Cylinder”.)
4. Visually check the cylinder wall for scratches. If deep scratches
are found, the cylinder should be bored. (Refer to “Correcting
Cylinder”.)
94.000 to 94.022 mm
Factory spec.
3.7008 to 3.7016 in.
Cylinder Bore I.D.
94.15 mm
Allowable limit
3.707 in.
(A) Top (a) Right-angled to piston pin

(B) Middle (b) Piston pin direction
(C) Bottom (Skirt)
W1070089
Correcting Cylinder (Oversize)

1. When the cylinder is worn beyond the allowable limit, bore and
hone it to the specified dimension.
94.500 to 94.522 mm
Cylinder I.D. (Oversize) Factory spec.
3.7205 to 3.7213 in.
94.65 mm
Maximum wear Allowable limit
3.726 in.
Hone to 2.2 to 3.0 μm Rz
Finishing
(0.000087 to 0.00011 in. Rz) ∇∇∇.
2. Replace the piston and piston rings with oversize 0.5 mm (0.02
in.) ones.
J NOTE
• When the oversize cylinder is worn beyond the allowable
limit, replace the cylinder block with a new one.
(1) Cylinder I.D. (Before Correction) (2) Cylinder I.D. (Oversize)
W10344480
(6) Oil Pump

Rotor Lobe Clearance
1. Measure the clearance between lobes of the inner rotor and the
outer rotor with a feeler gauge.
2. If the clearance exceeds the allowable limit, replace the oil pump
rotor assembly.
0.03 to 0.09 mm
0.002 to 0.003 in.
inner rotor and outer
rotor 0.30 mm
Allowable limit
0.012 in.
W1071254
III-S-196
Clearance between Outer Rotor and Pump Body

1. Measure the clearance between the outer rotor and the pump
body with a feeler gauge.
2. If the clearance exceeds the allowable limit, replace the oil pump
rotor assembly.
0.100 to 0.184 mm
0.00394 to 0.00724 in.
outer rotor and pump
body 0.30 mm
Allowable limit
0.012 in.
W1071334
Clearance between Rotor and Cover

1. Put a strip of plastigage onto the rotor face with grease.
2. Install the cover and tighten the screws with the specified torque.
3. Remove the cover carefully, and measure the amount of the
flattening with the scale and get the clearance.
4. If the clearance exceeds the allowable limit, replace oil pump
rotor assembly and the cover.
0.025 to 0.075 mm
Factory spec.
Clearance between rotor 0.00099 to 0.0029 in.
and cover 0.225 mm
Allowable limit
0.00886 in.
7.9 to 9.3 N·m

Tightening torque Oil pump cover screw 0.80 to 0.95 kgf·m
5.8 to 6.8 lbf·ft
W1148218
(7) Starter
Overrunning Clutch
1. Inspect the pinion for wear or damage.
2. If there is any defect, replace the overrunning clutch assembly.
3. Check that the pinion turns freely and smoothly in the
overrunning direction and does not slip in the cranking direction.
4. If the pinion slips or does not rotate in the both directions, replace
the overrunning clutch assembly.
W1075769
III-S-197
Commutator and Mica

1. Check the contact face of the commutator for wear, and grind the
commutator with emery paper if it is slightly worn.
2. Measure the commutator O.D. with an outside micrometer at
several points.
3. If the minimum O.D. is less than the allowable limit, replace the
armature.
4. If the difference of the O.D.’s exceeds the allowable limit, correct
the commutator on a lathe to the factory specification.
5. Measure the mica undercut.
6. If the undercut is less than the allowable limit, correct if with a saw
blade and chamfer the segment edges.
32.0 mm
Factory spec.
1.26 in.
Commutator O.D.
31.4 mm
Allowable limit
1.24 in.
0.50 mm
Factory spec.
0.020 in.
Mica under cut
0.20 mm
Allowable limit
0.0079 in.
(1) Segment (a) Good

(2) Depth of Mica (b) Bad
(3) Mica
W1075277
Brush Wear
1. If the contact face of the brush is dirty or dusty, clean it with emery
paper.
2. Measure the brush length (A) with vernier calipers.
3. If the length is less than the allowable limit, replace the yoke
assembly and brush holder.
18.0 mm
Factory spec.
0.709 in.
Brush length (A)
11.0 mm
Allowable limit
0.433 in.
(A) Brush Length

W1075476
Brush Holder
1. Check the continuity across the brush holder and the holder
support with an ohmmeter.
2. If it conducts, replace the brush holder.
Brush holder –
Resistance Infinity
Holder support
W1076066
III-S-198
Armature Coil
1. Check the continuity across the commutator and armature coil
core with an ohmmeter.
2. If it conducts, replace the armature.
3. Check the continuity across the segments of the commutator with
an ohmmeter.
4. If it does not conduct, replace the armature.
Commutator –
Infinity
Resistance Armature coil core
Commutator segment 0Ω
W1075693
Field Coil
1. Check the continuity across the lead (1) and brush (2) with an
ohmmeter.
2. If it does not conduct, replace the yoke assembly.
3. Check the continuity across the brush (2) and yoke (3) with an
ohmmeter.
4. If it conducts, replace the yoke assembly.
Lead (1) – Brush (2) 0Ω
Resistance
Brush (2) – Yoke (3) Infinity
(1) Lead (3) Yoke

(2) Brush
W1076156
(8) Alternator
Bearing
1. Check the bearing for smooth rotation.
2. If it does not rotate smoothly, replace it.
W1076281
III-S-199
Rotor
1. Measure the resistance across the slip rings with an ohmmeter.
2. If the resistance is not the factory specification, replace it.
3. Check the continuity across the slip and core with an ohmmeter.
4. If infinity is not indicated, replace it.
Resistance Factory spec. 2.8 to 3.3 Ω
W1076422
Slip Ring
1. Check the slip ring for score.
2. If scored, correct with an sand paper or on a lathe.
3. Measure the O.D. of slip ring with vernier calipers.
4. If the measurement is less than the allowable limit, replace it.
22.7 mm
Factory spec.
0.894 in.
Slip ring O.D.
22.1 mm
Allowable limit
0.870 in.
W1076592
Brush Wear
1. Measure the brush length (A) with vernier calipers.
2. If the measurement is less than allowable limit, replace it.
3. Make sure that the brush moves smoothly.
4. If the brush is defective, replace it.
18.5 mm
Factory spec.
0.728 in.
Brush length (A)
5.0 mm
Allowable limit
0.20 in.
(A) Brush Length

W1076714
III-S-200
WSM KX080-3AB Mechanism IV HYDRAULIC SYSTEM
IV. HYDRAULIC SYSTEM
Mechanism Section
(A) GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-M-3

a) Hydraulic Components Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-M-3
b) Hydraulic Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-M-4
(B) HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-M-13
a) Main Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-M-13
b) Outer View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-M-15
c) Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-M-16
d) Pump Control Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-M-17
f) FYI (For Your Information) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-M-25
(C) CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-M-27
a) Feature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-M-27
b) Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-M-27
c) New Minor-changed Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-M-30
(D) CONTROL VALVE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-M-47
a) Control Valve Hydraulic Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-M-47
b) Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-M-48
c) Control Valve Hydraulic Circuit in Traveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-M-49
d) Control Valve Hydraulic Circuit Under LS System Control Without Traveling . . . . IV-M-50
e) Control Valve P3 Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-M-51
f) Control Valve P3 Confluence Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-M-52
g) Control Valve P3 Bypass Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-M-53
h) Control Valve High-pressure Selection Function . . . . . . . . . . . . . . . . . . . . . . . . . . IV-M-54
i) Control Valve AI Signal Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-M-55
j) AI Function (Arm Crowd) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-M-56
k) Travel Function, Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-M-57
l) Travel Straight Function with Boom Down and Travel Reverse. . . . . . . . . . . . . . . IV-M-58
IV-M-1
(E) CONTROL LEVER PILOT VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IV-M-59

a) Structure & Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IV-M-59
(F) TRAVEL PILOT VALVE (WITH VISCOUS DAMPER) . . . . . . . . . . . . . . . . . . . . . . . . .IV-M-67
a) Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IV-M-67
b) Identification of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IV-M-68
c) Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IV-M-69
d) Control Diagram and Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IV-M-69
e) Outer View and Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IV-M-70
f) Inner Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IV-M-72
g) Comparison of sensing port for travel warning function . . . . . . . . . . . . . . . . . . . . . .IV-M-74
h) Performance Comparison . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IV-M-75
(G) PILOT VALVE: DOZER AND ANGLE BLADE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IV-M-77
a) General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IV-M-77
b) Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IV-M-77
c) Outer View and Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IV-M-78
d) Inner Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IV-M-80
(H) TRAVEL MOTOR (SGM-04D-S-09KT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IV-M-83
a) General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IV-M-83
b) Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IV-M-86
c) Outer View and Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IV-M-90
d) Cross-Sectional View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IV-M-93
e) Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IV-M-94
f) Outline of Travel Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IV-M-96
IV-M-2
(A) GENERAL
a) Hydraulic Components Layout
(10) (9)
(12) (1) Main pump
(8) (2) P1 delivery port
(13)
(3) P2 delivery port
(14) (3) (4) P3 pump
(11) (5) P3 delivery port
(2) (6) Pilot pump
(7) LS valve
(15) (1) (8) Unload valve & accumulator
(9) SP 1 proportional valve
(5) (10) SP 2 solenoid valve
(11) Suction filter
(12) Tank cap(pressure regulator)
(13) Return filter
(6) (14) Third line valve
(15) Control valve assy
(16) Holding valve
(4) (17) Pilot valve, dozer
(19) (18) Swivel joint
(19) Swivel motor
(20) Pilot valve. Swing
(21) Pilot valve, travel
(27) (22) Shuttle valve
(23) TPSS valve (PP-version)
(16) (24) Shock-absorbing valve
(25) Pilot control valve,L
(26) Travel motor
(27) SP 1 port, L
(28) (28) SP 2 port, L
(17)
(7)
(26)
(25)
(24)
(23)
(22)
(18) (21)
(20)
IV-M-3
b) Hydraulic Circuit Diagram

1. Hydraulic Circuit Diagram: KX080-3AB, PP standard-version
Swivel motor RD809-6128Δ Arm cylinder Boom cylinder
MSG-44P-21 Dozer cylinder Travel motor RD809-6760Δ RD809-6750Δ
Motor Disp. cm3/rev. 44.1 RD819-7510Δ (28) (29) RD819-6150Δ Bore φ100 Bucket cylinder Bore φ115
Swing cylinder Function
Bore φ125 SGM-04D-S-09KT Rod φ60 RD809-6780Δ RD809-6740Δ
Gear ratio 20.615
Motor Disp. 1F 46.9
Rod φ65
Bore φ110 (1) Swivel Right (8) Travel Right Forward (15) Boom Down
Bearing swivel/ Rod φ65 Stroke 912 Bore φ90 Stroke 878
100/13 φ55 Rod φ60 (2) Swivel Left (9) Arm Crowd (15-A) Boom H/V PL
piston Stroke 250 Dr Dr cm3/rev. 2F 25.29 Cushion bearing Rod Cushion bearing
Gear ratio 54.8 Cushion bearing Stroke 747 Stroke 715 (3) Dozer Up (10) Arm Dump (16) Boom Up
(4) Dozer Down (11) Bucket Crowd (17) Boom Swing Left
(21) (32) (5) Travel Left Rear (12) Bucket Dump (18) Boom Swing Right
B
Dr c3 (6) Travel Left Forward (13) SP1, Low pressure (19) SP2, Low pressure
2F 2F (7) Travel Right Rear (14) SP1, High pressure (20) SP2, High pressure
PL
SH
c2 c2
PG Dr
GA GB A Relief Pressure (MPa) (21) Swivel Motor (MSG-44P-21)
(22) (Right)
c1 c1 15A a1 29.4 Main (Travel (R)) c1 21.6 Swivel motor (23) (Left)
c2 c2 a2 29.4 Main (Travel (L)) c2 29.4 Travel motor (24) Lower (Forward)
a3 27.4 Main (LS) c3 30.4 Holding valve (25) Upper (Rear)
(26) Lower (Forward)
(31) a4 20.6 Main (P3) (27) Upper (Rear)
(22) A M B (23) B (24) A (25) A (26) B (27) (28) Travel Left
( 2F ) ( Dr ) ( 2F ) ( Dr ) a5 0.2 Line filter
d4 ( Dr ) C B D F A H E G A H Travel motor
H a6 3.9 Pump control (29) Travel Right
A Boom, Arm (rod) Travel motor
( 2F ) C B D F E G
(30) b1 31.4 Bucket (30) Swivel joint
(31) 2way valve
Dozer angle rod (32) Holding valve
b2 11.8 Dozer rod O/L d1 0.4 Back pressure (33) Swivel
( f r om PB1 ) (34) Dozer
b3 27.4 Dozer bottom O/L d2 1.5 Return filter (35) S/P 2
(39) b4 30.4 Arm (bottom) d3 0.07 Tank pressure (36) Travel (L)
(33) (34) (35) ( HIGH) ( LOW) (36) (37) (38) (40) ( ROD) ( BTM) (41) ( ROD) ( BTM) (42) ( HI GH) ( LOW) (43)( BTM) ( ROD) (44) ( ROD) ( BTM) b5 20.6 SP 1 d4 0.1 Oil cooler (37) Travel (R)
Bk 5 Ak 5 Bk 4 Ak 4 Bk 3 Ak 3 Bk 2 Ak 2 Bk 1 Ak 1 P B1 A1 B2 A2 B3 A3 PB2 B4 A4 B5 A5 (38) Travel independent
b6 1.96 Unload valve (39) Control valve
b6 b7 19.0 Dozer angle bottom (40) Arm
a2
(41) Bucket
a1 (42) S/P 1
(43) Boom
AI
PSVL2-36C-4 (44) Swing
Type P1 P2 P3 Pp (45) Oil tank
PAI b3 (46) P4 Signal devider
b2 Engine speed RPM 2000 2000 2000 2000 (47) Accumulator
Pp 1 b1 b1 b5 b1 (48) Solenoid/V (Unload)
Volume cc/rev 36.0 36.0 33.3 7.1
Dr 2 (49) Hydraulic pump
Delivery volume l/min 72.0 72.0 66.7 14.2 (50) P/V (Travel)
a4 a3 b4 b1 b5 b1
(51) Travel (L)
PB1 (52) Forward
Pbu 1 Pak 4 Pbk 4 Pak 3 Pbk 3 T2 P3 PF2 Pak 2 Pbk 2 Pak 1 Pbk 1 P1 P2 PPS Pp4 d1 PF1 Pa 1 Pb 1 Pa2 Pb2 Pa3 Pb3 Pa4 Pb4 PLS T3 Pa5 Pb5 (53) Rear
Pak 5 Pbk 5 T1 (54) Travel (R)
( f r om Pb4 )
Pp2 Pp3 17 18 (55) Forward

16 2 1 4 3 19 20 5 6 7 8 9 10 11 12 13 14 15 1 2 9 16 15A 15 10 12 11 3 4 (56) Rear
(57) P/V (Swing)
(62) (63) (58) Left
A B A B
( t o Pbu 1 ) (75) (76) (59) Right
(60) Shuttle valve
(77) (78) (79) (80) (81) (82) (83) (84)
(61) Plate
(50) (91) (92) (60) (62) Valve shockless
(57) (63) Adapter
(51) (52) (53) (54) (55) (56) 1 T 2 1 2
(58) (59)
(61) T T (64) Swivel left
P P (65) Swivel right
(85) (66) TPSS valve
(86) (87) (67) Arm crowd
(47) B A (48) T
P
T
(68) Arm dump
P (64)
6 5 8 7 17 18 (69) Boom down
(65)
(46) T
PLS PPS
(70) Boom up
A B C D (66) P T (71) Dozer down
a6 ISO JD
(72) Dozer up
PAC Pattern Pattern
(45) P
(49)
(ISO) 1 2 3 4 (JD) (B) (A)
(73) Bucket crowd
C (67)
d3 P3 P1 P2 (68)
(74) Bucket dump
d2 (69) (75) P/V (Left)
Pp (70) (76) P/V (Right)
(77) Left
a5 (78) Right
(71)
(72)
(79) Forward
(88) (73) (80) Rear
E (74) (81) Left
Ps (82) Right
CH2 (83) Forward
Pog P3s CH1 14 13 20 19 (84) Rear
(89) (90) (85) P/V (Dozer)
A B (86) Up
A H1 B
(87) Down
P
T (88) P4, T
P T H2 Flow Devider
(89) Solenoid/V (S/P 1)
(91) Damper
080MC_KQA_67_2_US_06 KX080-3AB 2008.2 (92) Damper
IV-M-4
2. Hydraulic Circuit Diagram: KX080-3AB, PP Angle blade-version

Swivel motor
MSG-44P-21
RD809-6128Δ
Dozer cylinder Angle cylinder Travel motor
Arm cylinder
RD809-6760Δ
Boom cylinder
RD809-6750Δ
Function
RD809-7510Δ RD819-7470Δ (28) (29) RD809-6150Δ Bore φ100 Bucket cylinder Bore φ115 Swing cylinder (1) Swivel Right (9) Arm Crowd (16) Boom Up
Motor Disp. cm3/rev. 44.1
Gear ratio 20.615 Bore φ125 Bore φ80 SGM-04D-S-09KT Rod φ60 RD809-6780Δ Rod φ65 RD809-6740Δ (2) Swivel Left (10) Arm Dump (17) Boom Swing Left
Motor Disp. 1F 46.9 Bore φ90 Stroke 878 Bore φ110 (11) Bucket Crowd (18) Boom Swing Right
Bearing swivel/ Rod φ65 Rod φ45 Dr Dr
Stroke 912 (3) Dozer Up
100/13 cm3/rev. 2F 25.29 Rod φ55 Cushion bearing Rod φ60
piston Stroke 250 Stroke 455 Cushion bearing
Stroke 715 (4) Dozer Down (12) Bucket Dump (19) SP2, Low pressure
Gear ratio 54.8 Cushion bearing Stroke 747
(5) Travel Left Rear (13) SP1, Low pressure (20) SP2, High pressure
(23) (32) (14) SP1, High pressure (21) Dozer angle left
B (6) Travel Left Forward
Dr c3 (7) Travel Right Rear (15) Boom Down (22) Dozer angle right
2F 2F (15-A) Boom H/V PL
PL
(8) Travel Right Forward
SH
c2 c2 (23) Swivel Motor (MSG-44P-21)

PG Dr
Relief Pressure (MPa) (24) Lower (Forward)
GA GB A
a1 29.4 Main (Travel (R)) c1 21.6 Swivel motor (25) Upper (Rear)
c1 c1 15A (26) Lower (Forward)
a2 29.4 Main (Travel (L)) c2 29.4 Travel motor (27) Upper (Rear)
c2 c2
a3 27.4 Main (LS) c3 30.4 Holding valve (28) Travel Left
Travel motor
a4 20.6 Main (P3) (29) Travel Right
(31) Travel motor
(99) A M B B (24) A (25) A (26) B (27) a5 0.2 Line filter (30) Swivel joint
(100) ( 2F ) ( Dr ) ( 2F ) ( Dr )
d4 ( Dr ) C B J I D F A H E G A H a6 3.9 Pump control (31) 2way valve
H (32) Holding valve
(30) Boom, Arm (rod) (33) Swivel
A
( 2F ) C B J I D F E G b1 31.4 Bucket (34) Dozer
Dozer angle rod (35) S/P 2
(36) Travel (L)
b2 17.2 Dozer rod O/L d1 0.4 Back pressure (37) Travel (R)
(38) Travel independent
( f r om PB1 ) b3 27.4 Dozer bottom O/L d2 1.5 Return filter (39) Control valve
b4 30.4 Arm (bottom) d3 0.07 Tank pressure (40) Arm
(39) (41) Bucket
( ROD) ( BTM) (41) ( ROD) ( BTM) (42) ( HI GH) ( LOW) b5 20.6 SP 1 d4 0.1 Oil cooler
(33) (34) (35) ( HI GH) ( LOW) (36) (37) (38) P (40) (43) ( BTM) ( ROD) (44) ( ROD) ( BTM) (98) ( ROD) ( BTM) (42) S/P 1
Bk 5 Ak 5 Bk 4 Ak 4 Bk 3 Ak 3 Bk 2 Ak 2 Bk 1 Ak 1 B1 A1 B2 A2 B3 A3 PB2 B4 A4 B5 A5 B6 A6 b6 1.96 Unload valve (43) Boom
(44) Swing
b6
b7 19.0 Dozer angle bottom (45) Oil tank
a2 (46) P4 Signal devider
a1 (47) Accumulator
PSVL2-36C-4 (48) Solenoid/V (Unload)
(49) Hydraulic pump
AI Type P1 P2 P3 Pp (50) P/V (Travel)
PAI (51) Travel (L)
b3 Engine speed RPM 2000 2000 2000 2000 (52) Forward
b2 b7
b1 Volume cc/rev 36.0 36.0 33.3 7.1 (53) Rear
Pp 1 b1 b1 b5 b1 (54) Travel (R)
Dr 2 Delivery volume l/min 72.0 72.0 66.7 14.2 (55) Forward
b4 b1 b5 b1 (56) Rear
a4 a3 (57) P/V (Swing)
PB1 (58) Left
(59) Right
Pbu 1 Pak 4 Pbk 4 Pak 3 Pbk 3 T2 P3 PF2 Pak 2 Pbk 2 Pak 1 Pbk 1 P1 P2 PPS Pp4 d1 PF1 Pa 1 Pb 1 Pa2 Pb2 Pa3 Pb3 Pa4 Pb4 PLS T3 Pa5 Pb5 Pa6 Pb6 (60) Shuttle valve
Pak 5 Pbk 5 T1 (61) Plate
( f r om Pb4 )
Pp2 Pp3 17 18 21 22
4 3 19 20 5 6 7 8 9 10 11 12 13 14 15
(62) Valve shockless
16 2 1 1 2 9 16 15A 15 10 21 22 12 11 3 4 (63) Adapter
(64) Swivel left
(62) (63) (65) Swivel right
A B A B
( t o Pbu 1 ) (79) (80) (66) Terminal adapter
(67) Pattern (B)
(81) (82) (83) (84) (85) (86) (87) (88)
(68) Pattern (A)
(50) (101) (102) (60) (69) Arm crowd
(57) (70) Arm dump
(51) (52) (53) (54) (55) (56)
(58) (59) 1 T 2 1 2 (71) Boom down
(61) T T
P P (72) Boom up
(89) (73) Dozer down
(92) (74) Dozer up
(47) (48) T T (90) (91) (93) (94) (75) Bucket crowd
B A P P (76) Bucket dump
(64)
6 5 8 7 17 18
(65) (77) Dozer angle right
(46) PLS PPS
T (78) Dozer angle left
A B C D (66) P T (79) P/V (Left)
a6 ISO JD (80) P/V (Right)
PAC (67) (68)
(45) P (49)
(ISO) 1 2 3 4 (JD) (81) Left
C (69) (82) Right
d3 P3 P1 P2 (70) (83) Forward
d2 (71)
(84) Rear
(72)
Pp (85) Left
(86) Right
a5 (87) Forward
(73)
(74) (88) Rear
(95) (75) (89) P/V (Dozer)
E (76) (90) Up
Ps
(77) (91) Down
CH2 (78) (92) Angle
Pog P3s CH1 14 13 20 19
(93) Left
(94) Right
(96) (97) (95) P4, T
A B
A H1 B Flow Devider
P (96) Solenoid/V (S/P 1)
T
P T H2 (97) Solenoid/V (S/P 2)
(98) Angle
(99) Right
(100) Left
KX080-3AB angle 2008.2 (101) Damper
(102) LDamper
080MC_KQA_67_3_ANG_06
IV-M-5
3. Main components location: KX080-3AB

Gear ratio 20.615
Motor Disp. 1F 46.9
Rod φ65
Rod φ65 Stroke 912 Bore φ90 Stroke 878
Bearing swivel/
B
Dr c3
(6) Travel Left Forward (13) SP1, Low pressure (19) SP2, Low pressure
PL
SH
c2 c2
PG Dr
(22) (Right)
( 2F ) C B D F E G
(31) 2way valve
a2
(41) Bucket
a1 (42) S/P 1
(43) Boom
AI
Volume cc/rev 36.0 36.0 33.3 7.1
a4 a3 b4 b1 b5 b1
(51) Travel (L)
PB1 (52) Forward
( f r om Pb4 )

16 2 1 4 3 19 20 5 6 7 8 9 10 11 12 13 14 15 1 2 9 16 15A 15 10 12 11 3 4 (56) Rear
(57) P/V (Swing)
(62) (63) (58) Left
A B A B
( t o Pbu 1 ) (75) (76) (59) Right
(60) Shuttle valve
(77) (78) (79) (80) (81) (82) (83) (84)
(61) Plate
(50) (91) (92) (60) (62) Valve shockless
(57) (63) Adapter
(51) (52) (53) (54) (55) (56) 1 T 2 1 2
(58) (59)
(86) (87) (67) Arm crowd
(47) B A (48) T
P
T
(68) Arm dump
P (64)
6 5 8 7 17 18 (69) Boom down
(65)
(46) T
PLS PPS
(70) Boom up
a6 ISO JD
(72) Dozer up
PAC Pattern Pattern
(45) P
(49)
(ISO) 1 2 3 4 (JD) (B) (A)
(73) Bucket crowd
C (67)
d3 P3 P1 P2 (68)
(74) Bucket dump
d2 (69) (75) P/V (Left)
Pp (70) (76) P/V (Right)
(77) Left
a5 (78) Right
(71)
(72)
(79) Forward
(88) (73) (80) Rear
E (74) (81) Left
Ps (82) Right
CH2 (83) Forward
Pog P3s CH1 14 13 20 19 (84) Rear
(89) (90) (85) P/V (Dozer)
A B (86) Up
A H1 B
(87) Down
P
T (88) P4, T
P T H2 Flow Devider
(91) Damper
IV-M-6
4. Pilot pump circuit

Gear ratio 20.615
Motor Disp. 1F 46.9
Rod φ65
Bearing swivel/
B
PL
SH
c2 c2
PG Dr
(22) (Right)
( 2F ) C B D F E G
(31) 2way valve
a2
(41) Bucket
a1 (42) S/P 1
(43) Boom
AI
Volume cc/rev 36.0 36.0 33.3 7.1
a4 a3 b4 b1 b5 b1
(51) Travel (L)
PB1 (52) Forward
( f r om Pb4 )

16 2 1 4 3 19 20 5 6 7 8 9 10 11 12 13 14 15 1 2 9 16 15A 15 10 12 11 3 4 (56) Rear
(57) P/V (Swing)
(62) (63) (58) Left
A B A B
( t o Pbu 1 ) (75) (76) (59) Right
(60) Shuttle valve
(77) (78) (79) (80) (81) (82) (83) (84)
(61) Plate
(50) (91) (92) (60) (62) Valve shockless
(57) (63) Adapter
(51) (52) (53) (54) (55) (56) 1 T 2 1 2
(58) (59)
(86) (87) (67) Arm crowd
(47) B A (48) T
P
T
(68) Arm dump
P (64)
6 5 8 7 17 18 (69) Boom down
(65)
(46) T
PLS PPS
(70) Boom up
a6 ISO JD
(72) Dozer up
PAC Pattern Pattern
(45) P
(49)
(ISO) 1 2 3 4 (JD) (B) (A)
(73) Bucket crowd
C (67)
d3 P3 P1 P2 (68)
(74) Bucket dump
d2 (69) (75) P/V (Left)
Pp (70) (76) P/V (Right)
(77) Left
a5 (78) Right
(71)
(72)
(79) Forward
(88) (73) (80) Rear
E (74) (81) Left
Ps (82) Right
CH2 (83) Forward
Pog P3s CH1 14 13 20 19 (84) Rear
(89) (90) (85) P/V (Dozer)
A B (86) Up
A H1 B
(87) Down
P
T (88) P4, T
P T H2 Flow Devider
(91) Damper
IV-M-7
5. Main pump circuit

Gear ratio 20.615
Motor Disp. 1F 46.9
Rod φ65
Bearing swivel/
B
PL
SH
c2 c2
PG Dr
(22) (Right)
( 2F ) C B D F E G
(31) 2way valve
a2
(41) Bucket
a1 (42) S/P 1
(43) Boom
AI
Volume cc/rev 36.0 36.0 33.3 7.1
a4 a3 b4 b1 b5 b1
(51) Travel (L)
PB1 (52) Forward
( f r om Pb4 )

16 2 1 4 3 19 20 5 6 7 8 9 10 11 12 13 14 15 1 2 9 16 15A 15 10 12 11 3 4 (56) Rear
(57) P/V (Swing)
(62) (63) (58) Left
A B A B
( t o Pbu 1 ) (75) (76) (59) Right
(60) Shuttle valve
(77) (78) (79) (80) (81) (82) (83) (84)
(61) Plate
(50) (91) (92) (60) (62) Valve shockless
(57) (63) Adapter
(51) (52) (53) (54) (55) (56) 1 T 2 1 2
(58) (59)
(86) (87) (67) Arm crowd
(47) B A (48) T
P
T
(68) Arm dump
P (64)
6 5 8 7 17 18 (69) Boom down
(65)
(46) T
PLS PPS
(70) Boom up
a6 ISO JD
(72) Dozer up
PAC Pattern Pattern
(45) P
(49)
(ISO) 1 2 3 4 (JD) (B) (A)
(73) Bucket crowd
C (67)
d3 P3 P1 P2 (68)
(74) Bucket dump
d2 (69) (75) P/V (Left)
Pp (70) (76) P/V (Right)
(77) Left
a5 (78) Right
(71)
(72)
(79) Forward
(88) (73) (80) Rear
E (74) (81) Left
Ps (82) Right
CH2 (83) Forward
Pog P3s CH1 14 13 20 19 (84) Rear
(89) (90) (85) P/V (Dozer)
A B (86) Up
A H1 B
(87) Down
P
T (88) P4, T
P T H2 Flow Devider
(91) Damper
IV-M-8
6. Hydraulic Circuit Diagram: KX080-3α, EU standard-version

Swivel motor RD809-6128Δ Arm cylinder
MSG-44P-21 Dozer cylinder Travel motor RD809-6760Δ
Motor Disp. cm3/rev. 44.1 RD809-7510Δ (28) (29) RD809-6130Δ Bore φ100 Bucket cylinder Swing cylinder Function
Bore φ125 GM11VA Rod φ60 RD809-6780Δ RD809-6740Δ
Gear ratio 20.615
Motor Disp. 1F 51.9 Bore φ110 (1) Swivel Right (8) Travel Right Forward (15) Boom Down
Rod φ65 Stroke 912 Bore φ90
Bearing swivel/
100/13 Dr Dr
φ55 Rod φ60 (2) Swivel Left (9) Arm Crowd (15-A) Boom H/V PL
piston FS 250 cm3/rev. 2F 27.8 Cushion bearing Rod
(21) (4) Dozer Down (11) Bucket Crowd (17) Boom Swing Left
(32)
B (5) Travel Left Rear (12) Bucket Dump (18) Boom Swing Right
2F 2F
Dr c3 (6) Travel Left Forward (13) SP1, Right port (19) SP2, Low pressure
PL (7) Travel Right Rear (14) SP1, Left port (20) SP2, High pressure
SH
c2 c2
PG Dr
GA GB A
Relief Pressure (MPa) (21) Swivel Motor (MSG-44P-21)
15A (22) (Right)
c1 c1
a1 29.4 Main (Travel (R)) c1 21.6 Swivel motor (23) (Left)
c2 c2 (24) Lower (Forward)
a2 29.4 Main (Travel (L)) c2 29.4 Travel motor
(25) Upper (Rear)
a3 27.4 Main (LS) c3 30.4 Holding valve (26) Lower (Forward)
(22) A M B (22) B (24) A (25) A (26) B (27)
( 2F ) ( Dr ) ( 2F ) ( Dr ) (28) Travel Left
d4 ( Dr ) C B D F A H E G A H a5 0.2 Line filter Travel motor
H
a6 3.9 Pump control (29) Travel Right
A
Boom, Arm (rod) Travel motor
( 2F ) C B D F E G
(30) (30) Swivel joint
b1 31.4 Bucket (31) 2way valve
( f r om PB1 ) b2 11.8 Dozer rod O/L d1 0.4 Back pressure (33) Swivel
(34) Dozer
(33) (34) (35) ( HIGH) (LOW) (36) (37) (38) (40) ( ROD) ( BTM) (41) ( ROD) ( BTM) (42) ( HI GH) ( LOW) (43) ( BTM) ( ROD) (44) ( ROD) ( BTM) (37) Travel (R)
Bk 5 Ak 5 Bk 4 Ak 4 Bk 3 Ak 3 Bk 2 Ak 2 Bk 1 Ak 1 P B1 A1 B2 A2 B3 A3 PB2 B4 A4 B5 A5 b5 20.6 SP 1 d4 0.1 Oil cooler (38) Travel independent
b6
a2 b7 19.0 Dozer angle bottom (40) Arm
a1 (41) Bucket
(42) S/P 1
(43) Boom
AI PSVL2-36CG (44) Swing
PAI b3 Type P1 P2 P3 Pp (45) Oil tank
b2 2 (46) P4 Signal devider
Pp 1 b1 Engine speed RPM 2000 2000 2000 2000 (47) Accumulator
b1 b5 b1
Volume cc/rev 36.0 36.0 33.3 7.1 (48) Solenoid/V (Unload)
a4 a3 b4 b1 b5 b1 Delivery volume l/min 72.0 72.0 66.7 14.2 (50) P/V (Travel)
PB1 (51) Travel (L)
(52) Forward
Pbu 1 Pak 4 Pbk 4 Pak 3 Pbk 3 T2 P3 PF2 Pak 2 Pbk 2 Pak 1 Pbk 1 P1 P2 PPS Pp4 d1 PF1 Pa 1 Pb 1 Pa2 Pb2 Pa3 Pb3 Pa4 Pb4 PLS T3 Pa5 Pb5
Pak 5 Pbk 5 (53) Rear
T1
(54) Travel (R)
( f r om Pb4 )
Pp2 Pp3 17 18
16 2 1 4 3 19 20 5 6 7 8 9 10 11 12 13 14 15 1 2 9 16 15A 15 10 12 11 3 4 (55) Forward
(56) Rear
(57) P/V (Swing)
A (62) B A (63) B (58) Left
( t o Pbu 1 ) (75) (76) (59) Right
(77) (78) (79) (80) (81) (82) (83) (84) (60) Shuttle valve
(50) (91) (92) (60) (61) Plate
(51)(52)
(57) (62) Valve shockless
(53) (54) (55) (56) 1 T 2 1 2 (63) Adapter
(58) (59) T T
(61) P P (64) Swivel left
(85)
(65) Swivel right
(86) (87)
(66) Terminal adapter
(47) B A (48) T T
(64) (67) Arm crowd
P P
6 5 8 7 17 18 (65) (68) Arm dump
(46) T
PLS PPS (69) Boom down
(70) Boom up
1
4
2
3
(66) P T
a6 (71) Dozer down
PAC
1
4
2
3
(45) P
(49) (67) (72) Dozer up
C
d3 P3 P1 P2
(68) (73) Bucket crowd
d2
(69) (74) Bucket dump
(70)
Pp
(75) P/V (Left)
(76) P/V (Right)
a5 (71) (77) Left
(72) (78) Right
(88) (73) (79) Forward
(74)
E (80) Rear
Ps
(81) Left
CH2 (82) Right
Pog P3s CH1 14 13 20 19 (83) Forward
(89) (90) (84) Rear
A B (85) P/V (Dozer)
A H1 B
P
(86) Up
T (87) Down
P T H2
(88) P4, T
Flow Devider
080MC_KQA_67_1_06 KX080-3α m/c 2008.2 (91) Damper
(92) Damper
IV-M-9
7. Hydraulic Circuit Diagram: KX080-3α, EU Two-Piece Boom-version

Arm cylinder Boom cylinder
Swivel motor RD809-6128Δ
Dozer cylinder
Travel motor RD809-6760Δ RD809-6750Δ (94)
Function
MSG-44P-21 RD809-6130Δ Bore φ100 Bucket cylinder
RD809-7510Δ Bore φ115 (1) Swivel Right (10) Arm Dump (18) Boom Swing Right
Motor Disp. cm3/rev. 44.1 (28) (29) GM11VA Rod φ60 RD809-6780Δ Rod φ65 2P boom cylinder
B
Gear ratio 20.615 Bore φ125 Motor Disp. 1F 51.9 Bore φ90 Swing cylinder L: RD809-6720Δ (2) Swivel Left (11) Bucket Crowd (19) SP2, Low pressure
Stroke 912 Stroke 878 Dr
Bearing swivel/ Rod φ65 cm3/rev. 2F 27.8 Rod φ55 RD809-6740Δ L: RD809-6730Δ (3) Dozer Up (12) Bucket Dump (20) SP2, High pressure
100/13 Cushion Inner Cushion Inner PL
piston Stroke 250 Dr Dr Gear ratio 50.11 Cushion Inner Stroke 747 Bore φ110 Bore φ95 (4) Dozer Down (13) SP1, Low pressure (21) 2 Piece boom crowd
23
Rod φ60 Rod φ55
c4 21A (5) Travel Left Rear (14) SP1, High pressure (21-A) 2 Piece boom H/V PL
Stroke 715 Stroke 578 (6) Travel Left Forward (15) Boom Down (22) 2 Piece boom dump
(95) (32) (15-A) Boom H/V PL (23) 2 Piece boom H/V Dr
B
A (7) Travel Right Rear
Dr c3 (8) Travel Right Forward (16) Boom Up
2F 2F
PL (9) Arm Crowd (17) Boom Swing Left
SH
c2 c2
PG Dr (24) Lower (Forward)
A
Relief Pressure (MPa) (25) Upper (Rear)
GA GB
a1 29.4 Main (Travel (R)) c1 21.6 Swivel motor (26) Lower (Forward)
c1 c1 15A (27) Upper (Rear)
B B a2 29.4 Main (Travel (L)) c2 29.4 Travel motor (28) Travel Left
c2 c2 H/ V H/ V
a3 27.4 Main (LS) c3 30.4 Holding valve Travel motor
A A (29) Travel Right
a4 20.6 Main (P3) c4 33.3 Holding valve Travel motor
Ri g h t ) A
( (96) M B (Lef t ) B A A ) (31) (30) Swivel joint
(97) (24) (25) (26) ) (27) a5 0.2 Line filter (31) 2way valve
( 2F ) ( Dr ) ( 2F ) ( Dr )
d4 ( Dr ) C B D F A H E G A H a6 3.9 Pump control (32) Holding valve
H
(33) Swivel
A
Boom, Arm (rod) (34) Dozer
( 2F ) C B D F E G
(30)
b1 31.4 Bucket (35) S/P 2
Dozer angle rod (36) Travel (L)
(37) Travel (R)
b2 11.8 Dozer rod O/L d1 0.4 Back pressure (38) Travel independent
( f r om PB1 )
b3 27.4 Dozer bottom O/L d2 1.5 Return filter (39) Control valve
(40) Arm
b4 30.4 Arm (bottom) d3 0.07 Tank pressure (41) Bucket
(39) ( ROD) ( BTM) (42) S/P 1
(33) (34) Bk 4 (35) HI GH) ( LOW) (36) (37) (38) (40) ( ROD) ( BTM) (41) ( ROD) ( BTM) (42) ( HI GH) ( LOW) (43) ( BTM) ( ROD) (44) ( ROD) ( BTM) (93) b5 20.6 SP 1 d4 0.1 Oil cooler
(43) Boom
Bk 5 Ak 5 Ak 4 Bk 3 Ak 3 DR1 Bk 2 Ak 2 Bk 1 Ak 1 P B1 A1 B2 A2 B3 A3 PB2 B4 A4 B5 A5 B6 A6
b6 1.96 Unload valve (44) Swing
b7 34.3 2 Peace boom (45) Oil tank
b6 (46) P4 Signal devider
a2
a1 (47) Accumulator
(48) Solenoid/V (Unload)
PSVL2-36CG-1 (49) Hydraulic pump
AI (50) P/V (Travel)
Type P1 P2 P3 Pp (51) Travel (L)
PAI b3 (52) Forward
b2 b7 Engine speed RPM 2000 2000 2000 2000 (53) Rear
Pp 1 b1 b7
b1 b5 b1 Volume cc/rev 36.0 36.0 33.3 7.1 (54) Travel (R)
(55) Forward
Dr 2 Delivery volume l/min 72.0 72.0 66.7 14.2 (56) Rear
a4 a3 b4 b1 b5 b1 (57) P/V (Swing)
PB1 (58) Left
(59) Right
( f r om Pb4 )
Pp2 Pp3 17 18 22 21
16 2 1 4 3 19 20 5 6 7 8 9 10 11 12 13 14 15 1 2 9 16 15A 15 10 12 11 3 4 (63) Adapter
(64) Swivel left
(63) (65) Swivel right
A (62) B A B (66) Terminal adapter
( t o Pbu 1 ) (75) (76)
(67) Arm crowd
(77) (78) (79) (80) (81) (82) (83) (84) (68) Arm dump
(69) Boom down
(60) (70) Boom up
(50) (98) (99)
(91) (51) (52) (53) (54) (55)
(57) 1 T 2 1 2
T T
(71) Dozer down
(56)
(91) (92) (58) (59) (61) P P (72) Dozer up
(73) Bucket crowd
(47) (48) (86) (87) (75) P/V (Left)
B A (64)
T T T
(65)
(76) P/V (Right)
P P P (77) Left
PLS PPS 6 5 8 7 17 18
(46) T 21A 21 22 (66) (78) Right
1
4
2
3
P T
(79) Forward
a6 (80) Rear
PAC
1
4
2
3
(45) 23 P
(49) (67) (81) Left
C (68) (82) Right
d3 P3 P1 P2 (69)
d2 (83) Forward
(70) (84) Rear
Pp
(85) P/V (Dozer)
a5 (71)
(86) Up
(72) (87) Down
(88) (73) (88) P4, T
(74) Flow Devider
E (89) Solenoid/V (S/P 1)
Ps (90) Solenoid/V (S/P 2)
CH2
(91) P/V (2 Piece boom)
Pog P3s CH1 14 13 20 19 Left: Boom crowd
(89) (90) Right: Boom dump
A B (91) Left
A H1 B
(92) Right
P (93) 2 Piece boom
T
P T H2 (94) Holding valve
(2 Piece boom cylinder)
(95) Swivel Motor (MSG-44P-21)
(96) Right
(97) Left
080MC_KQA_67_4_2PB_06 KX080-3α 2P 2008.2 (98) Damper
(99) Damper
IV-M-10
8. Hydraulic Circuit Diagram: KX080-3AB, PP standard-version

φ125 SGM-04D-S-09KT Rod φ60 RD809-6780Δ RD809-6740Δ
Gear ratio 20.615 Bore Rod φ65 (1) Swivel Right (8) Travel Right Forward (15) Boom Down
Motor Disp. 1F 46.9 Bore φ90 Bore φ110
Bearing swivel/ Rod φ65 Stroke 912 Stroke 878 (2) Swivel Left (9) Arm Crowd (15-A) Boom H/V PL
100/13 Dr Dr cm3/rev. 2F 25.29 Cushion bearing Rod φ55 Rod φ60
piston Stroke 250 Cushion bearing (10) Arm Dump (16) Boom Up
Gear ratio 54.8 Cushion bearing Stroke 747 Stroke 715 (3) Dozer Up
B
PL
SH
c2 c2
PG Dr
(22) (Right)
( 2F ) C B D F E G
(31) 2way valve
a2
(41) Bucket
a1 (42) S/P 1
(43) Boom
AI
Volume cc/rev 36.0 36.0 33.3 7.1
a4 a3 b4 b1 b5 b1
(51) Travel (L)
PB1 (52) Forward
( f r om Pb4 )

16 2 1 4 3 19 20 5 6 7 8 9 10 11 12 13 14 15 1 2 9 16 15A 15 10 12 11 3 4 (56) Rear
(57) P/V (Swing)
(62) (63) (58) Left
A B A B
( t o Pbu 1 ) (75) (76) (59) Right
(60) Shuttle valve
(77) (78) (79) (80) (81) (82) (83) (84)
(61) Plate
(50) (91) (92) (60) (62) Valve shockless
(57) (63) Adapter
(51) (52) (53) (54) (55) (56) 1 T 2 1 2
(58) (59)
T (86) (87) (67) Arm crowd
(47) B A (48) T
P (68) Arm dump
P (64)
6 5 8 7 17 18 (69) Boom down
(65)
(46) PLS PPS
T (70) Boom up
a6 ISO JD
(72) Dozer up
PAC Pattern Pattern
(45) P
(49)
(ISO) 1 2 3 4 (JD) (B) (A)
(73) Bucket crowd
C (67)
d3 P3 P1 P2 (68)
(74) Bucket dump
d2 (69) (75) P/V (Left)
Pp (70) (76) P/V (Right)
(77) Left
a5 (78) Right
(71)
(72)
(79) Forward
(88) (73) (80) Rear
E (74) (81) Left
Ps (82) Right
CH2 (83) Forward
Pog P3s CH1 14 13 20 19 (84) Rear
(89) (90) (85) P/V (Dozer)
A B (86) Up
A H1 B
(87) Down
P
T (88) P4, T
P T H2 Flow Devider
(91) Damper
IV-M-11
9. Hydraulic Circuit Diagram: KX080-3AB, PP Angle blade-version
Boom cylinder
Swivel motor
MSG-44P-21
RD809-6128Δ
Arm cylinder
RD809-6760Δ RD809-6750Δ
Function
φ45 Motor Disp. 1F 46.9 Bore φ90 Stroke 878 Bore φ110 (11) Bucket Crowd (18) Boom Swing Right
Bearing swivel/ Rod φ65 Rod Stroke 912 (3) Dozer Up
100/13 Dr Dr
cm3/rev. 2F 25.29 Cushion bearing Rod φ55 Cushion bearing Rod φ60
piston Stroke 250 Stroke 455
PL
SH

PG Dr
GA GB A
c2 c2
Travel motor
(31) Travel motor
(100) ( 2F ) ( Dr ) ( 2F ) ( Dr )
A
(36) Travel (L)
(39) (41) Bucket
( ROD) ( BTM) (41) ( ROD) ( BTM) (42) ( HI GH) ( LOW) b5 20.6 SP 1 d4 0.1 Oil cooler (42) S/P 1
(33) (34) (35) ( HI GH) ( LOW) (36) (37) (38) P (40) (43) ( BTM) ( ROD) (44) ( ROD) ( BTM) (98) ( ROD) ( BTM)
(44) Swing
b6
a1 (47) Accumulator
(49) Hydraulic pump
PAI (51) Travel (L)
b2 b7
b4 b1 b5 b1 (56) Rear
PB1 (58) Left
(59) Right
Pbu 1 Pak 4 Pbk 4 Pak 3 Pbk 3 T2 P3 PF2 Pa k 2 Pb k 2 Pa k 1 P b k 1 P1 P2 PPS Pp4 d1 PF 1 Pa 1 Pb 1 Pa 2 Pb 2 Pa 3 Pb 3 Pa4 Pb4 PLS T3 Pa5 Pb5 Pa6 Pb6 (60) Shuttle valve
( f r om Pb4 )
Pp2 Pp3 17 18 21 22
4 3 19 20 5 6 7 8 9 10 11 12 13 14 15
16 2 1 1 2 9 16 15A 15 10 21 22 12 11 3 4 (63) Adapter
(64) Swivel left
A B A B
(67) Pattern (B)
(81) (82) (83) (84) (85) (86) (87) (88)
(68) Pattern (A)
(50) (101) (102) (60) (69) Arm crowd
(57) (70) Arm dump
(51) (52) (53) (54) (55) (56)
(58) (59) 1 T 2 1 2 (71) Boom down
(61) T T
P P (72) Boom up
(92) (74) Dozer up
(47) (48) T T (90) (91) (93) (94) (75) Bucket crowd
(64)
6 5 8 7 17 18
(46) PLS PPS
A B C D (66) P T (79) P/V (Left)
PAC (67) (68)
(45) P (49)
(ISO) 1 2 3 4 (JD) (81) Left
C (69) (82) Right
d3 P3 P1 P2 (70) (83) Forward
d2 (71)
(84) Rear
(72)
Pp (85) Left
(86) Right
a5 (87) Forward
(73)
(74) (88) Rear
(95) (75) (89) P/V (Dozer)
E (76) (90) Up
Ps
(77) (91) Down
CH2 (78) (92) Angle
Po g P3 s CH1 14 13 20 19
(93) Left
(94) Right
(96) (97) (95) P4, T
A B
A H1 B Flow Devider
T
(98) Angle
(99) Right
(100) Left
(102) LDamper
080MC_KQA_67_3_ANG_06
IV-M-12
(B) HYDRAULIC PUMP

a) Main Specifications
1 Pump displacement (CC/rev) 36 x 2 + 33 + 8.1
Pump flow rate (L/min) 72 x 2 + 67 + 16 L/min (19.0 x 2 + 17.7 + 4.23 GPM)
2 Standby flow rate (L/min) 22 L/min (5.81 GPM)
3 Construction P1, P2 : Split flow of variable displacement piston pump
P3 : GP (Gear pump)
P4 : GP (Gear pump)
4 Rated speed 2000 rpm
5 LS flow control LS control valve: Differential pressure 1.5 MPa
Engine rpm proportional control at P4
Idling at rated flow rate: About 60 ~ 70%
6 Horsepower control PC horsepower control valve: With P3 horsepower shift
Without small-diameter piston (self-tilting moment)
P1 + P2 pressure: Average pressure by aperture
7 Construction Bearing: Cradle
Shoe plate: Spherical
Large-diameter piston (with shoe)
Piston pump power constant characteristics (KX080-3: before minor change)

Delivery flow : Q1 + Q2 [L/min]
P1 + P2 [MPa]
Pressure :
2
Shaft speed 2000 rpm

At gear pump pressure P3 = 2 MPa At gear pump pressure P3 = 20.6 MPa
Total input torque 192.4 N·m 0
-2.0
Total input torque 193.3 N·m 0
-2.0
Pressure [MPa] Delivery flow [MPa] Pressure [MPa] Delivery flow [MPa]
PA = 0.0 QA0 = 144.0 ± 4.3
PA1 = 11.8 QA1 = 140.9 PB1 = 0.0 QB1 = 141.0
PA2 = 24.6 QA2 = 40.0 PB2 = 11.9 QB2 = 45.3
PA3 = 29.4 QA3 = 24.8 PB3 = 21.8 QB3 = 16.8
PB4 = 29.4 QB4 = 10.1 ± 1.8
IV-M-13
Piston pump power constant characteristics (KX080-3AB: Minor change)

Delivery flow: Q 1 + Q 2 [L/min]
Pressure: P1=P2 [MPa]
Shaft speed 2000 rpm

At gear pump pressure P3 = 2 MPa At gear pump pressure P3 = 20.6 MPa
Total input torque 193 N·m 0

-3.0 Total input torque 208 N·m 0
-15
Pressure [MPa] Delivery flow [MPa] Pressure [MPa] Delivery flow [MPa]
PA = 0.0 QA0 = 144.0 ± 4.3
PA1 = 11.8 QA1 = 140.9 PB1 = 1.0 QB1 = 144.0
PA2 = 24.6 QA2 = 40.0 PB2 = 14.6 QB2 = 50.0
PA3 = 29.4 QA3 = 24.8 PB3 = 28.2 QB3 = 12.5
PB4 = 29.4 QB4 = 10.1 ± 1.8
IV-M-14
b) Outer View
IV-M-15
c) Structure
P1, P2
(Variable displacement pump + Horsepower control + LS control)
P3
Fixed gear pump (Swivel, dozer SP2)
P4 : Pilot pump
(Used also for LS engine rpm proportional control)
IV-M-16
d) Pump Control Circuit

(1) (18)
(1) PLS control pressure from CV
PLS PPS (2) LS differential pressure setting spring
(17) (3) Engine rpm proportional gain control piston
(4) Response improvement check valve at P3
P1 P2 under pressure
(2) (16) (5) Engine rpm proportional gain control aperture
(6) P3 pump horsepower shift piston
(3) (15) (7) P4 pilot pump
(8) P3 pump
(14) (9) Large-diameter tilt control piston
P3 P1 P2
(10) Tilting moment assist spring
(13) (11) P1, P2 pump
(12) Horsepower control spring
Pp (13) PC horsepower control spool
(12) (14) High-pressure selector check valve
(15) Aperture for P1 + P2 average pressure
(4) (16) LS control regulator
Basically common with L3
(5) (17) LS flow control spool
(18) PPS control pressure from CV
(6)
E a: Pmax
b: Tank
Ps c: P3
CH2
(7) P +P
d: P = 1 2
Pog P3s CH1 2
e: PC
(8) (9) (10) (11)
(Pump structure)
P1, P2 : Variable displacement pump + PC horsepower control + LS flow control (Q1 = Q2) (Travel, arm,
bucket, SP1, boom, swing, AUX)
: Split flow
: Spherical valve plate
: Cradle bearing
: No small-diameter piston provided (self-pressing moment used)
P3 : Gear pump (swivel, dozer, SP2) (Used for LS system in using the travel and LS control)
P4 : Gear pump ((Pilot pump) and to use also for LS engine rpm proportional control)
(Pump control)
1. Horsepower: Orifice-controlled P1 + P2 average pressure to make the power double, instead of gener-
ating the P1 + P2 horsepower with a stepped piston. P3 also controlled together.
2. Engine rpm gain control: P4 pilot pump' s discharge throttled, resulting in differential pressure. LS differ-
ential pressure modified accordingly. (Same mechanism as on KX121-3S/α and KX161-3S/α)
3. Introduction of response improvement check valve (LS flow control valve bypassed) at P3 under pres-
sure. In this way, swivel horsepower control response quicker and engine drop reduced. (4) Check valve
4. Tilting swash plate' s moment for larger flow rate controlled by repositioning the turning center of the
swash plate and generating the self-tilting moment. (The small-diameter piston on KX121-3S/α and
KX161-3S/α is abolished out.) Tilt moment assist spring also adopted to boost the tilting moment at low
pressure.
IV-M-17
1. LS control 1
PPS = PLS + PF + ΔPP
P3 Pav Pmax Pc
Pps
Pmax
Pc
Ppa
Pp
Ppb
PLS
LS-control valve
Control pin
When the machine is working under the stable load condition, load sensing pressure (PLS) and pump swash
plate angle are at certain stable values.
Therefore, LS control spool stays balancing according to the following equation.
PPS = PLS + PF + ΔPP (ΔPP = PPb - PPa)
Then the control pin stays at the stable position to keep the swash plate for required pump delivery.
(Note) When the system is within the horse power control, in other words, when LS control is functioning, Pc
port in the passage of the horse power control valve are always dump to tank pressure.
PPS-PLS 11~14 kgf/cm2 (1.12~1.43 MPa) 156~199 psi

(According to the LS control model, respectively.)
When an operator shifts the control lever, the pressure differential (PPs-PLs) varies.
Then the LS control valve spool automatically slides itself and induces or reduces pressure on the control
pin, adjusting the pump delivery flow in order to stable the pressure differential to the specified value.
IV-M-18
2. LS control 2
PPS > PLS + PF + ΔPP
P3 Pav Pmax Pc
Pps
Pmax
Pc
Ppa
Pp
Ppb
PLS
LS-control valve
Control pin
When an operator shifts the control lever to the inching movement of the front attachment, main spool notch
opening area of the control valve is regurated to limit the oil flow through.
Therefore, pressure value before the spool notch (PPS) becomes comparatively higher and the pressure dif-
ference between PPS (pressure before the spool notch) and PLS (pressure after the spool notch) increases
momentarily.
Thus, pressure balance changes to shift down the LS control spool, which leads the high pressure (Pmax) to
push the control pin and decrease the swash plate angle.
IV-M-19
3. LS control 3
PPS < PLS + PF + ΔPP
P3 Pav Pmax Pc
Pps
Pmax
Pc
Ppa
Pp
Ppb
PLS
LS-control valve
Control pin
When an operator shifts the control lever to full stroke, main spool notch area of the control valve opens fully.
Therefore, pressure value before the spool notch (PPS) becomes comparatively lower and the pressure dif-
ference between PPS (pressure before the spool notch) and PLS (pressure after the spool notch) decreases
momentarily.
Thus, pressure balance changes to shift up the LS control spool, which leads the control pressure (Pc) from
the control pin to dump and increase the swash plate angle.
IV-M-20
4. Horse power control 1
Operating condition :
Within the horsepower zone P3 Pav Pmax Pc
Low Pc pressure, LS control
zone, 0~100k
P1+P2
= 80k, P3 = 0
2
Pps
Pmax
Pc
Ppa
Pp
Ppb
PLS
LS-control valve
Control pin
Under this operating condition, average pressure ( P1+P2 ) is being applied the horse power spool to push
the spring to increase the swash plate angle. 2
The control spool notch is opened the Pc port from the control pin chamber to tank.
Note: In this condition, LS control spool chamber is in between or slightly opened to PC and drain to tank.
IV-M-21
MS
Within the horsepower zone P3 Pav Pmax Pc
Low Pc pressure, LS control
zone, 0~250k
P1+P2
= 200k, P3 = 0
2
Pps
Pmax
F2
Pc
Ppa
Pp
Ppb
PLS
LS-control valve
Control pin MP
Under this operating condition, average pressure ( P1+P2 ) is being applied the horse power spool to push in
2
the right direction and opens the oil passage of Pmax port to Pc port and block the drain to tank port.
This pressure oil is delivered to the control pin and push the swash plate, balancing against the horse power
spool via two springs.
P1+P2
Note: Average pressure ( ) pushes the spring by the following force to the right.
2
P1+P2 π
2 = 200k, F2 = 200 x x0.32 =14.13 kgf
4
And this average pressure, adjusted by itself, flows to the control pin and applied on the swash plate.
The swash plate keeps the balance between the two moments as shown in the arrows, MS and MP.
Finally, the horse power control pin returns to its original position, its Pc port is in between or slightly
opened to both Pmax and return to tank port.
On this condition, when the control lever is shifted, then the C/V main spool is shifted and the balance
between PPS and PLS changes to regulate the LS control spool to up and down, increasing or reducing
the control pin pressure.
IV-M-22
Horse power control zone P3 Pav Pmax Pc
P1+P2
= 150k
2
P3 = 200k
Pps
Pmax
F1
F2
Pc
Ppa
Pp
Ppb
PLS
LS-control valve
Control pin
Under this heavy load operating condition, average pressure ( P1+P2 ) and P3 pressure are being applied the
horse power spool to open the oil passage from Pmax to Pc. 2
This control pressure is also applied to the control pin to decrease the swash plate angle, preventing the
engine stall.
Note: Average pressure ( P1+P2 ) and P3 pressure are being applied the horse power spool to push the
2
springs and the swash plate to the right by the following forces.
π
F1 = 200 x (0.382 - 0.32) = 8.54 kgf
4
π
F2 = 150 x x 0.32 = 10.6 kgf
4
These sum of forces and the self-tilting moment are balancing the moment by the control pin force.
IV-M-23
7. LS control and Horse power control

Basically, LS control is a sort of pump flow control and regulated by LS control valve, detecting the pressure
differences of Pps and PLs.
On the other hand, horse power control is to maintain the hydraulic horse power, matching to the engine
torque and preventing the engine stall.
The P-Q performance curve below illustrates these functions.
a,b: LS control
c,d: Horse power control
e: LS control to Horse power control
a b c
IV-M-24
f) FYI (For Your Information)

1. LS pump swash plate control mechanism
KX080-3
Fc →
a
L3
Large-diameter piston F
for control
L2
Pc
θ
L1
M
Tilting
center
F
Fa: Assist spring (F = low pressure)

Counterclockwise moment of the cylinder block
= (L1 x F - L2 x F) x cosθ + Fa
= Fc x L3 cosθ (Moment by control pin)
Fc = π a2 x Pc Pc : Control pressure
4
From this equation, the small-diameter piston with a counterclockwise moment has been deleted.
Conventional type KX121-3/α, KX161-3/α
F
Large-diameter piston L2
for control = L2
L1
L1
Tilting center
Small-diameter piston
Clockwise moment of the cylinder block
= (L2 x F - L1 x F) x cosθ
Because L1 is equal to L2, the above equation produces 0.
The small-diameter piston has been needed in order to make for greater tilting. (On the variable dis-
placement type except for LS, a large spring has been employed instead of the small-diameter piston.)
IV-M-25
2. Horse power control mechanism
P3 P1 + P2 max(P1, P2) Pc
A1 Approx. φ3.8 2
← F3
F1
→ → ← F4
F2→ A3 Approx. φ9.0
→ →
A2 Approx. φ3.0 T
F4 F3
Pin Spool
P1 + P2
2
Pmax P F5
P3 c
(Independent of horse power control)
(Tilting moment assist spring)
π
F1 = P3 × (A1 − A2) F1 = 210 x (0.382-0.32)
4
P + P2
F2 = 1 × A2 =8.97 kgf
2
π
F1 + F2 = F3 + F4 F2 = 280 x x 0.32
4
F3 = K3 × χ + α =19.78 kgf
F4 = K4 × (χ − L4)
At Max. load condition:
F1 + F2 = 28.8 kgf
α: Initial spring force

L: Initial free length
Note : This is the information for those who require.
IV-M-26
(C) CONTROL VALVE

a) Feature
1 Section composition Center open valve (φ14): 3-gang; Swivel, dozer, SP2
P3 confluence valve (φ14)
Center open valve (φ14): 2-gang; Travel left and right
Travel selector valve (φ18)
Center closed valve (LS) (φ18): 4-gang monoblock; Arm, bucket, SP1, boom
Center closed valve (LS) (φ14): 1-gang; Swing
Center closed valve (LS) (other spec.) (φ14): 2-gang; Future option Angle blade, 2-piece boom
2 Maximum load pressure High pressure selection => Check valve + LS bleed orifice (φ0.5)
selection (system change)
3 Spare port SP1 maximum flow limit: By proportional valve
SP1 flow rate: 100 L/min, 26.4 GPM
SP2 maximum flow limit: Mechanical stopper
SP2 flow rate: 67 L/min, 17.7 GPM
4 Signal circuit AI signal: PP1
Travel control signal: PP2 (P1 and P2 to the left or right travel section)
LS control signal: PP3
P3 pump flow to join the LS system circuit by PP2 + PP3 (travel + LS front system control)
5 Travel speed change Similar to a variable displacement pump system (speed change by P3 horsepower shift)
when using the dozer
6 Traveling Left/right travel pumps acting independently
7 Others Boom' s anti-drift valve: None (Leak reduction thanks to the holding valve)
b. Outline
(1) Hydraulic circuit
1 Three-pump LS Front attachment (Boom, arm, bucket, swing, SP1) P1 + P2
Traveling P1, P2
Travel + Front attachment Travel: P1, P2
Front attachment: P3
Swivel: Dozer, SP2 P3
2 Pressure Travel 29.4 MPa, 300 kgf/cm2, 4267 psi
Front attachment 27.4 MPa, 280 kgf/cm2, 3983 psi
Swivel, dozer, SP2 (Service port 2) 20.6 MPa, 210 kgf/cm2, 2987 psi
Travel + Front attachment Travel: 29.4 MPa, 300 kgf/cm2, 4267 psi
Front attachment: 20.6 MPa, 210 kgf/cm2, 2987 psi
3 Checking the Main back-pressure check valve 0.4 MPa, 4.1 kgf/cm2, 58.0 psi
back pressure
Oil cooler back-pressure check valve 0.1 MPa, 1.0 kgf/cm2, 14.5 psi
4 Overload relief Arm (bottom) 30.4 MPa, 310 kgf/cm2, 4410 psi
Arm (R), boom (B/R), bucket (B/R) 31.4 MPa, 320 kgf/cm2, 4555 psi
Dozer (B) 27.5 MPa, 280 kgf/cm2, 3990 psi
Dozer (R) 11.8 MPa, 120 kgf/cm2, 1712 psi
SP1 (Service port 1) 20.6 Mpa, 210 kgf/cm2, 2987 psi
5 Others Swing (R) Anti-void
SP2, swing (B) Stop valve
IV-M-27
(2) Flow rate

Approx. flow rate: LPM (GPM)
Boom Up 102.3 (27.0)
Down 56.0 (14.8)
Arm Crowded 125.8 (33.2)
Dump 96.4 (25.5)
Bucket Crowded 95.3 (25.2)
Dump 91.6 (24.2)
SP1 89.4 (23.6) / 88.8 (23.5)
Swing Right 37.7 (9.96)
Left 53.9 (14.2)
Swivel 67 (17.7)
Travel R&L 72 (19.0) each
Dozer Up 67 (17.7)
Down 67 (17.7)
SP2 67 (17.7)
Note: Above flow amount varies according to the load pressure.

LS system flow amount shown above is based on the conditions that C port load pressure is 10MPa
(102 kgf/cm2, 1451 psi).
IV-M-28
(3) Location of the relief valve

(A)
18)
17)
6)
8)
7)
10)
9)
12)
11)
14) 13)
1)
(B)
2)
4) 3)
5)
16) 15)
(A) Machine front

(B) Cab side
ORV: Overload Relief valve
1) LS unload valve (b6)

2) LS main relief valve (a2)
3) Travel main relief valve (a1)
4) Travel main relief valve (a2)
5) Pump 3 main relief valve (a4)
6) Swing rod, anti-void valve
7) Boom rod, ORV (b1)
8) Boom bottom, ORV (b1)
9) Service port 1, ORV (b5)
10) Service port 1, ORV (b5)
11) Bucket bottom, ORV (b1)
12) Bucket rod, ORV (b1)
13) Arm bottom, ORV (b4)
14) Arm rod, ORV (b1)
15) Dozer bottom, ORV (b3)
16) Dozer rod, ORV (b2)
17) 2-P boom, ORV
18) 2-P boom, ORV
IV-M-29
c) New Minor-Changed Control Valve

1. Major change points of the control valve
1) Travel independent valve section
2) P3 confluence valve section
This modification is designed to achieve the smooth operation of travel straight function.
2. Structure of travel independent valve section

Continuous front attachment control has been upgraded for shifting the attachment smoothly with the
travel lever. To ensure such smooth operation, the following steps must be taken.
1) First turning on the P3 confluence valve
2) Then turning on the travel independent valve
For this purpose, the opening characteristics of the main and sub-spools of P3 confluence valve and
travel independent valve have been optimized with the springs. In the transient operating range,
however, the oil instantaneously flows through the LS circuit at the sum amount of Q1 + Q2 + Q3.
9
1 6 7 8 6
10
5
14
4 5 11 b. Travel independent valve 2 11 3
1. Valve housing By shifting up 4 mm maximum, the h This hole is

2. Main spool primary pilot pressure from PP4 located on the
3. Body assy flows through this opening into the g valve body
4. Cap main valve's spring chamber.
5. Socket head bolt Then the spool gets shifted. ø0.7
6. Spring seat
7. Spool end
12
8. Spring
9. O-ring
10. Plug PP4
11. O-ring 12
12. O-ring PP
13. Socket head bolt From confluence
14. Plug assy valve
IV-M-30
3. Structure of P3 confluence valve

No O-ring installed
on this side
Tightening torque No O-ring installed

(2 locations) on this side
8.8-10.8 N•m 14 B. Structure of P3 confluence valve
9 10 11 12
d
13 3
PF2
PP2
8 5 7 6
4 c 2 1
1. Valve housing 5. Spring seat 9. Plug (check valve) 13. Socket head bolt
2. Main spool 6. Spring seat 10. O-ring 14. Socket head bolt
3. Cap 7. Spring 11. Spring 15. Plug
4. Body assy 8. O-ring 12. Poppet (check valve)
3) Compare to circuit diagram

a. P3 Confluence valve b. Travel independent valve
a
b (39)
(35) ( HIGH) ( LOW) (36) (37) (38) (40) ( ROD)
4 Bk 3 Ak 3 Bk 2 Ak 2 Bk 1 Ak 1 P B1
b6
a2 (8) h This hole is
(7) a1 located on the
(2) g valve body
ø0.7
(2) d h
b1
g 12
a4 a3 PP4
Pak 3 Pbk 3 T2 P3 PF2 Pak 2 Pbk 2 Pak 1 Pbk 1 P1 P2 PPS Pp4 d1 PF1 Pa 1 Pb 1
12
PP
T1
Pp2 Pp3 From confluence
19 20 5 6 7 8 9 10
c valve
b. Travel independent valve
IV-M-31
4. Travel independent function

The pilot pressure at PP2 shifts up the sub-spool by 4 mm maximum, and the primary pilot pressure from
PP4 starts flowing through the valve body opening into the main spool's spring chamber. The spool gets
thus shifted.
Leading through Leading to the

the circular tank inside the
passage to the P1 P2 valve housing Shifting
tank
Filter
PP4
Shifting
Connected inside PP
the body ø0.7
Section A-A Section B-B
PP2
From P3 confluence valve
B (24) A (25) A (26) B (27)
( 2F ) ( Dr ) ( 2F ) ( Dr )
( Dr ) C B J I D F A H E G A H
H
(30) 3
A
( 2F ) C B J I D F E G MPa
Pilot pressure
2
1.85
(39)
1.63
(34) (35) ( HI GH) ( LOW) (36) (37) (38) (40) ( ROD) (B 1.4 Spool open
Bk 5 Ak 5 Bk 4 Ak 4 Bk 3 Ak 3 Bk 2 Ak 2 Bk 1 Ak 1 P B1 A1
1
b6
a2
a1
0
0 2 4
b3
b2 Spool stroke (mm)
b1 (Sub-spool)
a4 a3 b4
Pak 4 Pbk 4 Pak 3 Pbk 3 T2 P3 PF2 Pak 2 Pbk 2 Pak 1 Pbk 1 P1 P2 PPS Pp4 d1 PF1 Pa 1 Pb 1 3
Pbk 5 T1
Pp2 Pp3 MPa
1 4 3 19 20 5 6 7 8 9 10
Pilot pressure
2 Spool closed
1.45 1.6
1.2
1
(47) B A
(48)
0
(46) PLS PPS 0 2 4 5.5
T 3.5
PAC
a6 Spool stroke (mm)
P (49)
C (Main spool)
P3 P1 P2
Pp
a5
E
Ps
CH2
Pog P3s CH1
IV-M-32
5. P3 confluence valve function
When one of the travel levers is shifted, PP2 sensing pressure (pilot primary pressure) applies on the poppet
c shown above to push upward.
The pilot primary pressure PF2 passes through the sub-spool c and applies on the end surface of the spool
(2) to shift rightward.
Oil passage e is connected through two travel spool sections and to reach the travel independent sensing
sub-spool g.
IV-M-33
6. Travel straight function

(1) One of the travel section spools is being
Performance curves pushed by pilot secondary pressure.
(of P3 confluence valve) Travel straight sensing line will be
3 3 securely closed and sensing pressure to
MPa MPa be increased.
(2) P3 confluence valve sub-spool will be

2 2 Spool closed shifted by pilot primary pressure at 1.03
Pilot pressure
MPa as shown in the diagram

1.22 1.4
1.25
1 1.03 1 (3) At 1.22 MPa of the pilot primary
0.8 Spool closed pressure, main spool of the P3
confluence valve is to be shifted upward
0 0 on the circuit diagram.
0 2 4 0 2 3 4 5.5
Now P3 pump oil flows LS- control lines as
Spool stroke (mm) Spool stroke (mm)
confluence flow.
(Sub-spool) (Main spool)
During the transient period, after shifting the
P3 confluence spool and before shifting the
travel independence spool, all (Q1+Q2+Q3)
oil flows to LS control circuit instantaneously.
Sensing oil flows and shifting sequence of sub-spool
and mail spool for confluence flow (P1+P2+P3)
P3 flow (P3+P2) flow
(33) (34) (35) ( HI GH) ( LOW) (36) (37) (38) (39) (40) ( ROD) ( BTM) (41
b6
a2
a1
AI
PAI b3
b2 Blocked
Pp 1 b1
Dr 2
a4 a3 b4
PB1
Pbu 1 Pak 4 Pbk 4 Pak 3 Pbk 3 T2 P3 PF2 Pak 2 Pbk 2 Pak 1 Pbk 1 P1 P2 PPS Pp4 d1 PF1 Pa 1 Pb 1 Pa
Pak 5 Pbk 5 T1
( f r om Pb4 )
Pp2 Pp3
16 2 1 4 3 19 20 5 6 7 8 9 10
From P3
(47) B A
(48)
(46) PLS PPS

T
a6
PAC
P (49)
C
P3 P1 P2
IV-M-34
(4) Travel independence valve sub-spool

(Performance curve of travel independence valve) starts shifting upward on the circuit
3 diagram at 1.63 MPa.
3
MPa MPa
(5) While the poppet being shifted, travel
independent valve spool starts shifting
Pilot pressure
Pilot pressure
2 2 Spool closed upward to enable travel independent
1.85
1.63 1.45 1.6 function.
1.4 Spool open 1.2
1 1 (6) Then P3 flows to LS control front circuit
and P1 and P2 flows to travel R and L
respectively.
0 0 This is travel straight function.
0 2 4 0 2 4 5.5
3.5
Spool stroke (mm) Spool stroke (mm)
(Sub-spool) (Main spool)
(33) (34) (35) ( HI GH) ( LOW) (36) (37) (38) (39) (40) ( ROD) ( BTM)
To LS control
b6 front circuit
a2
a1
b3
b2
Blocked
2 b1
a4 a3 b4
Pak 4 Pbk 4 Pak 3 Pbk 3 T2 P3 PF2 Pak 2 Pbk 2 Pak 1 Pbk 1 P1 P2 PPS Pp4 d1 PF1 Pa 1 Pb 1
Pak 5 Pbk 5 T1
Pp2 Pp3
2 1 4 3 19 20 5 6 7 8 9 10
(47) B A
(48)
(46) PLS PPS

T
a6
PAC
IV-M-35
7. Control valve; Uni-block section assy
Section J-J
(2) (2)
(1)
Boom
S/P1
Arm
Bucket
(1) Tightening torque: 19-22 N.m

Section A-A Apply screw adhesive (Loctite #638)
(Class III specified in KES2237)
(2) (2) around the threads.
(2) Bleed-off orifice which works in the

transient stroke.
Section K-K
IV-M-36
Tightening torque
123.55 ±17.65 N.m
(8 locations)
Boom
S/P 1
Bucket
Arm
Unload valve
Section B-B
(1)
(2)
ID Part No.
No. Binary identification process 2 under-
Tightening torque digit
Tightening torque
(2 locations) Identification of the compensation spool
Section C-C Section L-L (1) Arm crowd

(2) Arm extend (Check valve block)
IV-M-37
Spool
notch
Spool
notch
Section B-B
IV-M-38
PLS
Tightening torque Tightening torque
(6 locations)
Two ID grooves without filter
Tightening torque
(4 locations)
Tightening torque
Section D-D
IV-M-39
8. Boom
(2) (2)
(1)
Tightening torque
123.55 ±17.65 N.m (3)
(8 locations)
Section E-E
(1) 1. Apply Class III screw adhesive (Loctite 638), specified in KES2237,
all around the 2-3 external threads of the plug (indicated //////////).
2. Tighten up the plug until it gets broken.
Breaking torque (M6): About 15 N.m (reference)
(2) Bleed off function in transient period
(3) Spool notch opening
Section E-E
IV-M-40
9. S/P1
Tightening torque
(2 locations)
Section F-F
IV-M-41
10.Bucket
Tightening torque
(2 locations)
Section G-G (1)

(1) Spool North
(1)
Tightening torque
(2 locations)
Section G-G
(1) Spool North
IV-M-42
11.Arm
(2) (2)
(1)
Tightening torque
123.55 ±17.65 N.m (1) 1. Apply Class III screw adhesive (Loctite 638),
(8 locations) specified in KES2237, all around the 2-3 external
threads of the plug (indicated //////////).
Section H-H 2. Tighten up the plug until it gets broken.
Breaking torque (M6): About 15 N.m (reference)
(2) Bleed-off orifice, working during the transient period.
Tightening torque Tightening torque
(2 locations)
One ID groove Tightening torque
Tightening torque
Tightening torque
Tightening torque
Section I-I
IV-M-43
IV-M-44
(33) Main spool stroke (mm)

(34) Others
(35) Swing, angle
(36) Blade Pb pressure
(24)
(37) Blade Pa pressure
(37) (38) Communicating valve
(34)
(39) Travel independent valve
(40) P3 bypass valve
(33) (41) Pilot pressure
(35) (42) Pilot pressure
(36)
(43) Fig. 1: Main spool pressure
(25) characteristics
(38) (39) (40) (44) Fig. 2: Travel independent
(27) valve and other pressure
(26)
characteristics
(2) (8) (41) (42)

(43) (44)
(1) Tightening torque: 8.8-11 N.m
(8 locations)
(2) Spool setup direction ID
(9) (blade, swing, angle)
(3) Tightening torque: 59-69 N.m
(10) (32) (4) Identification groove, 1 line
(5) 2-M10x1.5
Thread depth 19
(3) (30) (for lifting)
(11) (6) Identification groove, 1 line
(7) Identification groove, 1 line
(12) (8) Tightening torque: 29±1 N.m
(9) Angle
(13)
(10) Swing
(14) (11) Boom
(12) S/P1
(1) (31) (13) Bucket
(4)
(14) Arm
(15) Travel independent valve
(16) Travel
(5)
(15) (17) Travel
(18) Communicating valve
(19) S/P2
(16) (20) Blade
(21) Swivel
(17) (22) P3 bypass
(6)
(23) Tightening torque:
(18) 7.8~9.8 N.m (stroke adjust-
(19)
ing nut, both ends)
(24) 2-M12x1.75
(20) Thread depth 20
(25) Make sure the shorter
(23)
(21) threaded side faces the main
valve.
(22) [Main valve side: 13 mm]
(7) [Nut side: 18 mm]
(28) 26.5~29.4 N.m (4 locations)
(27) View Z
26.5~29.4 N.m (4 locations)
(29) 2-M12x1.75
Thread depth 20
(30) Identification groove, 2 lines
8.8-11 N.m (8 locations)
KX080-3AB Angle blade (32) 4xM12x1.75
(29) (Mainly PP-version) Thread depth 20
IV-M-45
ID No. Part name Q’ty Remarks ID No. Part name Q’ty Remarks 2. Control valve specifications
1 54 O-ring 1 JISB2401, 1A, G70 1. Maximum flow rate: P1, P2; 72 L/min, P3; 66 L/min
2 55 O-ring 1 JISB2401, 1A, G75 2. Maximum pressure: P1, P2; 29.4 MPa, P3; 20.6 MPa
3 Valve housing 1 56 O-ring 1 JISB2401, 1B, P7 3. Operating oil temperature range: 253 to 368 °K (-20 to 100°C)
4 Relief valve kit 1 A1 30.4±0.3MPa at 5L/min 57 Spring seat 1 4. Operating hydraulic oil type: ISO VG46 or equivalent
5 Spool 1 60 Tie-rod 4 5. Main relief vale pressure setting: P1, P2 (travel independent valve) 29.4 ± 0.3 MPa at 43 L/min
6 Spool 1 61 Tie-rod 4 P (LS) 27.4 ± 0.3 MPa at 48 L/min
7 Spool 1 62 Nut 8 P3 20.6 ± 0.3 MPa at 66 L/min
8 Spool 1 63 O-ring 2 6. Unload valve pressure setting: 2.35 ± 0.1 MPa at 23 L/min
9 Cap 4 64 Back-up ring 2 7. Overload relief valve pressure set- Arm A1: 30.4 ± 0.3 MPa at 5 L/min
10 Cap 4 65 Spacer 2 ting: B1: 31.4 ± 0.3 MPa at 5 L/min
11 Spool end 4 66 Plug 2 Bucket A2: 31.4 ± 0.3 MPa at 5 L/min
12 Spring 4 67 Spool section assembly 1 Swing B2: 31.4 ± 0.3 MPa at 5 L/min
13 Spring seat 8 68 Outlet housing 1 Outlet S/P A3: 20.6 ± 0.3 MPa at 5 L/min
14 Plug 8 69 Spool section assembly 1 Travel independent valve B3: 20.6 ± 0.3 MPa at 5 L/min
15 Spool 1 70 Spool section assembly 1 Travel Boom A4: 31.4 ± 0.3 MPa at 5 L/min
16 Spool 1 71 Spool section assembly 1 Travel B4: 31.4 ± 0.3 MPa at 5 L/min
17 Poppet 4 72 Spool section assembly 1 Confluence valve Angle blade A6: 19.0 ± 0.3 MPa at 5 L/min
18 Plug assembly 3 73 Spool section assembly 1 S/PS B6: 31.4 ± 0.3 MPa at 5 L/min
19 Poppet 1 74 Spool section assembly 1 Dozer Blade AK4: 27.4 ± 0.3 MPa at 5 L/min
20 Spring 1 75 Spool section assembly 1 Swivel BK4: 17.2 ± 0.3 MPa at 5 L/min
21 Plug assembly 1 76 Outlet section assembly 1 P3 bypass valve 8. Pressure Compensation valve S/P1: 12mm2 + None + ø0.8
22 Plug assembly 6 77 Relief valve kit 5 B1,A2,B2,A4,B4 (Underlap + LS orifice + Boom: 8mm2 + ø1.4 + ø0.6
23 O-ring 16 31.4±0.3MPa at 5L/min damper orifice)
24 Plug 8 78 Relief valve kit 3 A3,B3,AK4 Arm: 8mm2 + None + ø0.8
25 Poppet 8 20.6±0.3MPa at 5L/min Bucket: 6mm2 + None + ø0.8
26 Spring 8 79 Relief valve kit 2 P1,P2 Swing: 3mm2 + None + None
27 Spool 1 29.4±0.3MPa at 43L/min
Angle: 3mm2 + None + None
28 Spool 1 80 Relief valve kit 1 P3
Pilot air bleeding area ø0.5 orifice or equivalent Swivel, dozer, travel, swing, S/P2, arm, S/P1,
29 O-ring 8 JISB2401,1A, P26 20.6±0.3MPa at 66L/min
bucket, boom, angle
30 Plug assembly 1 81 Relief valve kit 1 AK4
9 Equipped with S/P2 spool stroke adjustment mechanism: Adjustable range; 2 ~ 8 mm
31 Relief valve kit 1 P(L5) 27.4±0.3MPa at 48L/min 27.4±0.3MPa at 5L/min
10 Pump LS control pressure difference setting: 1.5 MPa (15 kgf/cm2) 213 psi
32 Spool 1 82 Relief valve kit 1 BK4
33 Plug 1 17.2±0.3MPa at 5L/min 11. Genuine Kubota part code: RD819-74013 2
34 Stopper 1 83 Shut-off valve assembly 3 AK3, BK3, A5
35 Set-screw 1 JISB1177, M8x25L 84 Anti-void valve assembly 1 B5 Tightening torque for aluminum cap/port joint (pipe)
36 Nut 1 JISB1181, M8 Port size PF1/4 Port name Port size
37 Spring 1 Ports applied pa5, pb5, T1 PF1-1/4
38 O-ring 1 JISB2401,1B, P12 pak1 ~ 2, pak 4 ~ 5, pbk 1 ~ 2, pbk 4 ~ 5 P1, P2, T2, P PF3/4
39 Backup ring 1 JISB2407,P12, T2 Recommended tighten- 34.3 N·m A1 ~ A4, B1 ~ B4 7/8-14UNF
40 O-ring 1 JISB2401,1B, P24 P3, P4, A5, B5, PF1/2
ing torque
41 Sleeve 1 AK1 ~ AK5, BK1 ~ BK5, T3
42 Plug assembly 2
Maximum torque 39.2 N·m
Thread breaking torque 44.1 N·m [PB1], [PB2] PF3/8
43 O-ring 1 JISB2401,1B, P16 Pa1 ~ Pa5, Pb1 ~ Pb5, PF1/4
44 Backup ring 2 JISB2407,P16, T2 [Conditions] Standard-size joint (threaded-part length 12)
Pak1 ~ Pak5, Pbk1 ~ Pbk5,
45 Socket head bolt 16 JISB1176, M6x20L Remarks Be careful not to apply any torque over max-
PP1 ~ PP3, PPS, PLS, PAI,
46 Plug assembly 1 imum one.
PF1, PF2, PT, Dr1, Dr2, Pbu1
47 Plug assembly 2
Tightening torque list
( ROD) ( BTM) (9) ( ROD) ( BTM) (10) ( HI GH) ( LOW) (11) ( BTM) ( ROD) (12) ( ROD) ( BTM) (13) ( ROD) ( BTM) No. Thread size Tightening torque Spring size
(1) (2) (3) ( HI GH) ( LOW) (4) (5) (6) (7)
P (8)
Bk 5 Ak 5 Bk 4 Ak 4 Bk 3 Ak 3 Bk 2 Ak 2 Bk 1 Ak 1 B1 A1 B2 A2 B3 A3 PB2 B4 A4 B5 A5 B6 A6 45 M6x1 8.8~11 N·m L-size 5
(1) Swivel
b6 (2) Dozer 36 M8x1.25 8.8~11 N·m 13
a2 (3) S/P 2 21
a1 (4) Travel (L) PF1/4 28~30 N·m L-size 6
22
(5) Travel (R)
18 PF3/8 61.8~82.4 N·m L-size 8
AI (6) Travel independent
PAI
(7) Control valve 42 L-size 12
b3 (8) Arm PF3/4 167~197 N·m
b2 b7 33 32
Pp 1 b1 b1 (9) Bucket
b1 b5 b1 (10) S/P 1 4 59~69 N·m
Dr 2 (11) Boom
b4 b1 b5 b1 14 7/8 - 14UNF 24
a4 a3 (12) Swing 123.55±17.65 N·m
PB1 (13) Angle 24
Pbu 1 Pak 4 Pbk 4 Pak 3 Pbk 3 T2 P3 PF2 Pak 2 Pbk 2 Pak 1 Pbk 1 P1 P2 PPS Pp4 d1 PF1 Pa 1 Pb 1 Pa2 Pb2 Pa3 Pb3 Pa4 Pb4 PLS T3 Pa5 Pb5 Pa6 Pb6 47 PF1/2 106~141 N·m L-size 10
Pak 5 Pbk 5 T1
)
IV-M-46
(D) CONTROL VALVE CIRCUIT
a) Control Valve Hydraulic Circuit Diagram
( f r om PB1 )
(39)
(33) (34) (35) ( HIGH) ( LOW) (36) (37) (38) (40) ( ROD) ( BTM) (41) ( ROD) ( BTM) (42) ( HI GH) ( LOW) (43)( BTM) ( ROD) (44) ( ROD) ( BTM)
Bk 5 Ak 5 Bk 4 Ak 4 Bk 3 Ak 3 Bk 2 Ak 2 Bk 1 Ak 1 P B1 A1 B2 A2 B3 A3 PB2 B4 A4 B5 A5
WSM KX080-3AB Mechanism
b6
a2
a1
AI
PAI b3
b2
Pp 1 b1 b1 b5 b1
Dr 2
a4 a3 b4 b1 b5 b1
PB1
Pak 5 Pbk 5 T1
Pp2 Pp3 17 18
16 2 1 4 3 19 20 5 6 7 8 9 10 11 12 13 14 15
( f r om Pb4 )
1 2 9 16 15A 15
IV-M-47
A (62) B
(1) (2) (3)
(4) (5) (6)
(1) P3 pump (33) Swivel (39) Control valve

(2) Travel system (P1 or P2 pump) (34) Dozer (40) Arm
(3) LS system (P1 and P2 pumps) (35) S/P 2 (41) Bucket
(4) φ14 section (36) Travel (L) (42) S/P 1
(5) φ18 section monoblock section (37) Travel (R) (43) Boom
(6) φ14 section (38) Travel independent (44) Swing
IV HYDRAULIC SYSTEM
b) Neutral
( f r om PB1 )
(39)
(33) (35) HI GH) ( LOW) (36) (37) (38) (40) ( ROD) ( BTM) (41) ( ROD) ( BTM) (42) ( HI GH) ( LOW) (43) ( BTM) ( ROD)
Bk 5 Ak 5
(34) Bk 4 Ak 4 Bk 3 Ak 3 DR1 Bk 2 Ak 2 Bk 1 Ak 1 P B1 A1 B2 A2 B3 A3 PB2 B4 A4
b6
a2
a1
AI
PAI b3
b2
Pp 1 b1 b1 b5 b1
Dr 2
a4 a3 b4 b1 b5 b1
PB1
Pbu 1 Pak 4 Pbk 4 Pak 3 Pbk 3 T2 P3 PF2 Pak 2 Pbk 2 Pak 1 Pbk 1 P1 P2 PPS Pp4 d1 PF1 Pa 1 Pb 1 Pa2 Pb2 Pa3 Pb3 Pa4 Pb4 PLS
Pak 5 Pbk 5 T1
Pp2 Pp3
16 2 1 4 3 19 20 5 6 7 8 9 10 11 12 13 14 15
( f r om Pb4 )
1 2
( t o Pbu 1 )
(50) (98) (99)

(90) (51) (52) (53) (54) (55)
(57)
(56)
(91) (92) (58) (59)
IV-M-48
(47) B A (48)
T T T
P P P
PLS PPS 6 5 8 7 17 18
(46) T 21A 21 22
a6
PAC
(45) 23 P
C (49)
d3 P3 P1 P2
d2
Pp
a5
(88)
E
Ps
CH2
Pog P3s CH1 14 13 20 19
(33) Swivel (47) Accumulator (59) Right

(34) Dozer (48) Solenoid/V (Unload) (60) Shuttle valve
(35) S/P 2 (49) Hydraulic pump (61) Plate
(36) Travel (L) (50) P/V (Travel) (88) P4, T
(37) Travel (R) (51) Travel (L) Flow Devider
(38) Travel independent (52) Forward (89) Solenoid/V (S/P 1)
(39) Control valve (53) Rear (90) P/V (2 Piece boom)
(40) Arm (54) Travel (R) Left: Boom crowd
(41) Bucket (55) Forward Right: Boom dump
(42) S/P 1 (56) Rear (91) Left
(43) Boom (57) P/V (Swing) (92) Right
(45) Oil tank (58) Left (98) Damper
(46) P4 Signal devider (59) Right (99) Damper
(
IV HYDRAULIC SYSTEM
c) Control Valve Hydraulic Circuit in Traveling
(1)
(39)
(33) (34) (35) ( HI GH) ( LOW) (36) (37) (38) (40) ( ROD) ( BTM) (41) ( ROD) ( BTM)
Bk 5 Ak 5 Bk 4 Ak 4 Bk 3 Ak 3 Bk 2 Ak 2 Bk 1 Ak 1 P B1 A1 B2 A2
b6
a2
a1
PAI b3
b2
b1 b1
Dr 2
a4 a3 b4 b1
PB1
Pbu 1 Pak 4 Pbk 4 Pak 3 Pbk 3 T2 P3 PF2 Pak 2 Pbk 2 Pak 1 Pbk 1 P1 P2 PPS Pp4 d1 PF1 Pa 1 Pb 1 Pa2 Pb2
Pak 5 Pbk 5 T1
Pp2 Pp3
IV-M-49
16 2 1 4 3 19 20 5 6 7 8 9 10 11 12
( f r om Pb4 )
(5) (6)
(2) (3)(4)
Behavior
When the travel is selected, the travel selector valve switches on to supply oil from
the P1 or P2 pump. The PPS signal pressure becomes equal to the tank pressure.
When PLS >= PPS = Tank pressure, the pump flow rate gets maximized.
(1) Travel main relief valve (29.4 MPa) (33) Swivel

(2) Travel select signal detection pressure from P4 pump (34) Dozer
(3) P1 pump (35) S/P 2
(4) P2 pump (36) Travel (L)
(5) PPS signal (to pump) 0 (37) Travel (R)
(6) Travel selector valve (38) Travel independent
(7) Travel selector valve (39) Control valve
(40) Arm
(41) Bucket
IV HYDRAULIC SYSTEM
d) Control Valve Hydraulic Circuit Under LS System Control Without Traveling
(2) (3) (4)
(1)
( LOW) (39) ( ROD) ( LOW) ( ROD)

(36) (37) (38) P (40) ( BTM) (41) ( ROD) ( BTM) (42) ( HI GH) (43) ( BTM) (44) ( ROD)
Ak 3 Bk 2 Ak 2 Bk 1 Ak 1 B1 A1 B2 A2 B3 A3 PB2 B4 A4 B5
b6
a2
a1
b1 b1 b5 b1
a4 a3 b4 b1 b5 b1
3 T2 P3 PF2 Pak 2 Pbk 2 Pak 1 Pbk 1 P1 P2 PPS Pp4 d1 PF1 Pa 1 Pb 1 Pa2 Pb2 Pa3 Pb3 Pa4 Pb4 PLS T3 Pa5 Pb5
T1
Pp2 Pp3 17 18
IV-M-50
5 6 7 8 9 10 11 12 (9) 13 14 (10) 15 1 2
(11) (12)
9 16 15
(7)
(8) (1) Unload valve
(5) (6)
(2) PLS signal high-pressure select check valve
(3) Pressure compensating valve
(4) To cylinder
Behavior (5) P1 pump
When the travel is not selected, the travel selector valve does not switch on with (6) P2 pump
the LS system. The oil is supplied from the P1 and P2 pumps. The PPS signal (7) PPS signal (to pump)
pressure becomes equal to the delivery pressure and the pumps are controlled at (8) LS system main relief valve
(9) PLS signal
the LS flow rate. (10) Tank circuit
(11) PPS signal (to pump)
(12) PLS signal bleed aperture
(36) Travel (L)
(37) Travel (R)
(39) Control valve
(40) Arm
(41) Bucket
(42) S/P 1
(43) Boom
(44) Swing
IV HYDRAULIC SYSTEM
e) Control Valve P3 Hydraulic Circuit
(33) (34) (35) ( HIGH) ( LOW ) (36) (37) (38)
Bk 5 Ak 5 Bk 4 Ak 4 Bk 3 Ak 3 Bk 2 Ak 2 Bk 1 Ak 1
(1)
a2
a1
AI
PAI b3
b2
Pp 1
Dr 2
a4 a
PB1
IV-M-51
Pbu 1 Pak 4 Pbk 4 Pak 3 Pbk 3 T2 P3 PF2 Pak 2 Pbk 2 Pak 1 Pbk 1 P1 P2 PPS Pp4 d
Pak 5 Pbk 5 T1
Pp2
16 2 1 4 3 19 20 5 6 7 8
( f r om Pb4 )
(2)
(3)
(1) Tank circuit

(2) P3 pump
(3) P3 line main relief vale (20.6 MPa)
(33) Swivel
(34) Dozer
(35) S/P 2
(36) Travel (L)
(37) Travel (R)
IV HYDRAULIC SYSTEM
f) Control Valve P3 Confluence Hydraulic Circuit
(39)
b6
a2
a1
AI
PAI b3
b2
Pp 1 b1 b1 b5 b1
Dr 2
a4 a3 b4 b1 b5 b1
PB1
Pak 5 Pbk 5 T1
Pp2 Pp3 17 18
16 2 1 4 3 19 20 5 6 7 8 9 10 11 12 13 14 15
( f r om Pb4 )
1 2 9 16 15A 15
(1)
(2) (3) (4)(5) (6) (7)
IV-M-52
Behavior (1) P3 confluence valve
When the travel is selected and the LS system is operated, the oil is sup- (2) P3 delivery port
plied from the P1 or P2 pump for the travel system (The P1 and P2 pumps (3) Travel select signal detection pressure from P4 pump
give their maximum flow rate within the horsepower range.) The P3 selec- (4) P1 pump
tor valve serves for the LS system in order to supply the oil from the P3 (5) P2 pump
pump. (The P3 pump is of fixed displacement type to provide a constant (6) CV internal signal detection pressure from P4 pump
flow rate. Extra oil is let out through the unload valve.) (7) LS system control detection signal
(33) Swivel
(34) Dozer
(35) S/P 2
(36) Travel (L)
(37) Travel (R)
(39) Control valve
(40) Arm
(41) Bucket
(42) S/P 1
(43) Boom
(44) Swing
IV HYDRAULIC SYSTEM
g) Control Valve P3 Bypass Circuit
( f r om PB1 )
(39)
b6
(1) a2
a1
AI
PAI b3
b2
Pp 1 b1 b1 b5 b1
Dr 2
a4 a3 b4 b1 b5 b1
PB1
Pak 5 Pbk 5 T1
(2) Pp2 Pp3 17 18
16 2 1 4 3 19 20 5 6 7 8 9 10 11 12 13 14 15
( f r om Pb4 )
1 2 9 16 15A 15
(4)
A (62) B
( t o Pbu 1 )
(3)
IV-M-53
Function (1) Check valve
When the swivel, boom, (arm) and (bucket) are activated at once, the boom-up pilot pressure works (2) P3 bypass confluence valve
(3) Confluence orifice
to switch the P3 bypass confluence valve. (The boom pilot pressure joins at 2.2 MPa.) The swivel P3 (4) Boom up signal
pump branches the flow for the boom to assist in moving up the boom. When the swivel pressure is (33) Swivel
greater than the boom operating pressure (at a start of swivel), the confluence occurs. (34) Dozer
As the swivel pump pressure drops, the variable displacement pump’s horsepower characteristic (35) S/P 2
varies accordingly, which increases the flow rate from this valve. With a drop in the swivel starting (36) Travel (L)
(37) Travel (R)
pressure, the swivel does not speed up too high. This way, the boom can be moved up speedily (38) Travel independent
compared with the swivel rate. (39) Control valve
(40) Arm
(41) Bucket
(42) S/P 1
(43) Boom
(44) Swing
IV HYDRAULIC SYSTEM
h) Control Valve High-pressure Selection Function
(4) (3) (2) (1)
(38) (39) (40) ( ROD) ( BTM) (41) ( ROD) ( BTM) (42) ( HI GH) ( LOW) (43)( BTM) ( ROD) (44) ( ROD) ( BTM)
P B1 A1 B2 A2 B3 A3 PB2 B4 A4 B5 A5
b6
a2
a1
b1 b1 b5 b1
a3 b4 b1 b5 b1
Pbk 1 P1 P2 PPS Pp4 d1 PF1 Pa 1 Pb 1 Pa2 Pb2 Pa3 Pb3 Pa4 Pb4 PLS T3 Pa5 Pb5
T1 (12)
IV-M-54
Pp3 (8) (9) 17 18
(7) (10)
(17) (11)
(5)(6)
(18)
φ18 (19)
(16) φ14
(14) (15) (20) (21) (22)
(1) To cylinder (10) PLS signal aperture (20) PLS signal high-pressure select
Changing the high-pressure select system (2) Pressure compensat- (11) PLS signal (to pump) check valve
ing valve (12) PLS signal bleed aperture (21) Swing section
Formerly, the high-pressure side was selected (3) PLS signal high-pres- (13) Pressure compensating valve (38) Travel independent
by a high-pressure selector valve ( ). On the sure select check valve (14) Boom section (39) Control valve
new system, the high pressure is introduced by (4) Unload valve (15) PLS signal high-pressure (40) Arm
(5) P1 pump select check valve (41) Bucket
the check valve that is incorporated in the pres- (6) P2 pump (16) PLS signal (to pump) (42) S/P 1
sure compensating valve. The LS bleeder lets (7) PPS signal (to pump) (17) PLS signal aperture (43) Boom
the high-pressure oil into the tank. (8) PLS signal (18) PLS signal bleed aperture (44) Swing
(9) Tank circuit (19) Pressure compensating valve
IV HYDRAULIC SYSTEM
i) Control Valve AI Signal Hydraulic Circuit
(39)
(1) b6
a2
a1
AI
PAI
b3
b2
Pp 1 b1 b1 b5 b1
(2)
Dr 2
a4 a3 b4 b1 b5 b1
PB1
Pak 5 Pbk 5 T1
(3) Pp2 Pp3 17 18
16 2 1 4 3 19 20 5 6 7 8 9 10 11 12 13 14 15
( f r om Pb4 )
1 2 9 16 15A 15
To tank To tank
(1) AI pressure switch

(2) AI signal detection aperture
(3) CV internal AI signal detection pressure from P4 pump
(33) Swivel
IV-M-55
(34) Dozer
(35) S/P 2
(36) Travel (L)
(37) Travel (R)
(39) Control valve
(40) Arm
(41) Bucket
(42) S/P 1
(43) Boom
(44) Swing
IV HYDRAULIC SYSTEM
j) AI Function (Arm Crowd)
AI pressure switch is turnd to OFF position by the pilot primary pressure.
(39) ( ROD) ( BTM)

(33) (35) HI GH) ( LOW) (36) (37) (38) (40) ( ROD) ( BTM) (41) ( ROD) ( BTM) (42) ( HI GH) ( LOW) (43) ( BTM) ( ROD) (44) ( ROD) ( BTM) (93)
(1) Bk 5 Ak 5
(34) Bk 4 Ak 4 Bk 3 Ak 3 DR1 Bk 2 Ak 2 Bk 1 Ak 1 P B1 A1 B2 A2 B3 A3 PB2 B4 A4 B5 A5 B6 A6
b6
a2
a1
AI
PAI b3
b2 b7
Pp 1 b1 b7
b1 b5 b1
Dr 2
a4 a3 b4 b1 b5 b1
PB1
Pbu 1 Pak 4 Pbk 4 Pak 3 Pbk 3 T2 P3 PF2 Pak 2 Pbk 2 Pak 1 Pbk 1 P1 P2 PPS Pp4 d1 PF1 Pa 1 Pb 1 Pa2 Pb2 Pa3 Pb3 Pa4 Pb4 PLS T3 Pa5 Pb5 Pa6 Pb6
Pak 5 Pbk 5 T1
Pp2 Pp3 17 18 22 21
16 2 1 4 3 19 20 5 6 7 8 9 10 11 12 13 14 15
( f r om Pb4 )
(2) 1 2 9 16 15A 15 10
A (62) B A (63)
( t o Pbu 1 )
(60)
(50) (98) (99)
(90) (57) 1 T 2 1
(51) (52) (53) (54) (55) (56)
(91) (92) (58) (59) (61)
IV-M-56
(47) B A (48) (64)
T T T
P P P (65)
PLS PPS 6 5 8 7 17 18
1
4
2
3
(46) T 21A 21 22 (66)

a6
1
4
2
3
PAC
(45) 23 P (67)
C (49) (68)
P3 P1 P2 (69)
(70)
Pp
a5
(88)
E
Ps
CH2
Pog P3s CH1 14 13 20 19
(1) AI pressure switch OFF. (41) Bucket (51) Travel (L) (61) Plate (91) Left
(2) Pilot primary pressure is blocked here. (42) S/P 1 (52) Forward (62) Valve shockless (92) Right
(33) Swivel (43) Boom (53) Rear (63) Adapter (93) 2 Piece boom
(34) Dozer (44) Swing (54) Travel (R) (66) Terminal adapter (98) Damper
(35) S/P 2 (45) Oil tank (55) Forward (88) P4, T (99) Damper
(36) Travel (L) (46) P4 Signal devider (56) Rear Flow Devider
(37) Travel (R) (47) Accumulator (57) P/V (Swing) (90) P/V (2 Piece boom)
(38) Travel independent (48) Solenoid/V (Unload) (58) Left Left: Boom crowd
(39) Control valve (49) Hydraulic pump (59) Right Right: Boom dump
(40) Arm (50) P/V (Travel) (60) Shuttle valve
IV HYDRAULIC SYSTEM
k) Travel Function, Forward
(39) ( ROD) ( BTM)

Bk 5 Ak 5
(1) b6
a2
a1
AI
PAI b3
b2 b7
Pp 1 b1 b7
b1 b5 b1
Dr 2
a4 a3 b4 b1 b5 b1
PB1
Pak 5 Pbk 5 T1
Pp2 Pp3 17 18 22 21
16 2 1 4 3 19 20 5 6 7 8 9 10 11 12 13 14 15
( f r om Pb4 )
1 2 9 16 15A 15 10
A (62) B A (63)
( t o Pbu 1 )
(60)
(50) (98) (99)
(90) (57) 1 T 2 1
(51) (52) (53) (54) (55) (56)
(91) (92) (58) (59) (61)
IV-M-57
(47) B A (48) (64)
T T T
P P P (65)
PLS PPS 6 5 8 7 17 18
1
4
2
3
(46) T 21A 21 22 (66)

a6
1
4
2
3
PAC
(45) 23 P (67)
C (49) (68)
P3 P1 P2 (69)
(70)
Pp
a5
(88)
E
Ps
CH2
Pog P3s CH1 14 13 20 19
(1) AI pressure switch OFF. (41) Bucket (51) Travel (L) (61) Plate (91) Left
(33) Swivel (42) S/P 1 (52) Forward (62) Valve shockless (92) Right
(34) Dozer (43) Boom (53) Rear (63) Adapter (93) 2 Piece boom
(35) S/P 2 (44) Swing (54) Travel (R) (66) Terminal adapter (98) Damper
(36) Travel (L) (45) Oil tank (55) Forward (88) P4, T (99) Damper
(37) Travel (R) (46) P4 Signal devider (56) Rear Flow Devider
(38) Travel independent (47) Accumulator (57) P/V (Swing) (90) P/V (2 Piece boom)
(39) Control valve (48) Solenoid/V (Unload) (58) Left Left: Boom crowd
(40) Arm (49) Hydraulic pump (59) Right Right: Boom dump
(50) P/V (Travel) (60) Shuttle valve
IV HYDRAULIC SYSTEM
l) Travel Straight Function with Boom Down and Travel Reverse
PL
(1) AI pressure switch OFF. (42) S/P 1 (53) Rear (66) Terminal adapter
(2) P3 oil flows to boom circuit (43) Boom c2 (54) Travel c2 (R) (88) P4, T
PG Dr
(33) Swivel (44) Swing (55) Forward Flow Devider A
GB
(34) Dozer (45) Oil tank (56) Rear (90) P/V (2 Piece boom)
15A
(35) S/P 2 c 1 c 1 (46) P4 Signal devider (57) P/V (Swing) Left: Boom crowd B B
(47) Accumulator c2 (58) Left c2 Right: Boom dump H/ V H/ V
(36) Travel (L)
(59) Right (91) Left A A
(37) Travel (R) (48) Solenoid/V (Unload)
M
(49) Hydraulic
B
pumpA (60)
A
Shuttle
)
valve (92) Right (31)
Ri g h t ) A
( (96) B (Lef t )
(24) (25) (26) )
Plate (27) (93) 2 Piece boom
(39) Control valve (97) (50) P/V (Travel) ( 2F ) ( Dr (61)
) ( 2F ) ( Dr )
d4 ( Dr ) C B A H (62) Valve E G shocklessA H (98) Damper
(40) Arm H (51) Travel (L) D F
(41) Bucket A
(52) Forward (63) Adapter (99) Damper
( 2F ) C B D F E G (2)
(30)
( f r om PB1 )
(39) ( ROD) ( BTM)

Bk 5 Ak 5
(1)
b6
a2
a1
AI
PAI b3
b2 b7
Pp 1 b1 b7
b1 b5 b1
Dr 2
a4 a3 b4 b1 b5 b1
IV-M-58
PB1
Pak 5 Pbk 5 T1
Pp2 Pp3 17 18 22 21
16 2 1 4 3 19 20 5 6 7 8 9 10 11 12 13 14 15
( f r om Pb4 )
1 2 9 16 15A 15 10
A (62) B A (63)
( t o Pbu 1 )
(60)
(50) (98) (99)
(90) (57) 1 T 2 1
(51) (52) (53) (54) (55) (56)
(91) (92) (58) (59) (61)
(47) B A (48) (64)

T T T
P P P (65)
PLS PPS 6 5 8 7 17 18
1
4
2
3
(46) T 21A 21 22 (66)

a6
1
4
2
3
PAC
(45) 23 P (67)
C (49) (68)
3 P3 P1 P2 (69)
(70)
Pp
a5
(88)
E
Ps
CH2
Pog P3s CH1 14 13 20 19
IV HYDRAULIC SYSTEM
(E) CONTROL LEVER PILOT VALVE

a) Structure & Specifications
(Right hand side)
PV48M2063B
Hydraulic symbol
(1)
(7)
(8)
(6)
(2)
(3)
(1) Screwing depth of lever (323) (4) (5)
(2) (Port 2) 221-2
(Port 4) 221-3
(3) Shim for adjusting secondary pressure: One sheet Note: Both right and left pilot valves have
with designed
Thickness t=0.4 been modified in the quick response
(4) Ports 2&4 performance compare to those of
(5) Ports 1&3 KX080-3.
(6) Ports 1&3
(7) Grease is applied on each rotational. Pay your attention to the push rod
Part of the universal joint. groove where the spool moves in,
Pay attention to the direction of assembling the making it short to generate the quick
universal joint.
(8) Grease is applied on each top part.
pressure rise.
IV-M-59
(Left hand side)

PV48M2089
(1)
(7)
(8)
(2)
(6)
(3)
(1) Screwing depth of lever (323)
(2) (Port 2) 221-2
(Port 4) 221-3
(3) Shim for adjusting secondary pressure: One sheet with designed
Thickness t=0.4mm (0.016in.)
(4) Ports 2&4
(5) Ports 1&3
(6) Port 1&3
(6) Ports 1&3
(7) Grease is applied on each rotational.
Part of the universal joint.
Pay attention to the direction of assembling the universal joint.
(8) Grease is applied on each top part.
IV-M-60
No. Part name Material Q’ty Remarks

101 Casing Al alloy 1
151 Plate Steel 1 Chromating
201 Spool Carbon steel 4
211 Plug Copper alloy 4
212 Rod, push Stainless steel 4
213 Seal NBR 4 HS70
214 O-ring NBR 4 JIS B2401 P20 HS90
216 Seat, spring Alloy steel 4 For 7 mm stroke
217 Washer 2 Steel 4
221-1 Spring Piano wire 2 For return 29.4 ~ 39.2 N (3.0 ~ 4.0 kgf) (For port 1 &3)
221-2 Spring Piano wire 1 For return 44.1 ~ 76.5 N (4.5 ~ 7.8 kgf) (For port 2)
221-3 Spring Piano wire 1 For return 33.3 ~ 59.0 N (3.4 ~ 6.0 kgf) (For port 4)
241 Spring Piano wire 4 For secondary pressure 0.83 ~ 65 MPa (8.5 ~ 27K)
301 Joint Alloy steel 1 Storong type
302 Plate, circular Alloy steel 1
312 Nut, adjusting Carbon steel 1 Phosphate coating
315 Nut, lock Carbon steel 1 Phosphate coating
323 Lever Steel 1 Chromating
402 Handle - 1 ERUH1-2.0-BH05-CA
434 Pin, spring Tool steel 1 JIS B 2808 SPV-5x28
457 Bush Synthetic rubber 1 HS70
501 Bellows Synthetic rubber 1

No. Screw size Tightening torque
47.1 ± 2.9 N·m
301 M14 (480 ± 30 kgf·cm)
(34.7 ± 2.2 ft·lbs)
68.6 ± 4.9 N·m
302, 312 M14 (700 ± 50 kgf·cm)
(50.6 ± 3.6 ft·lbs)
49 ± 3.4 N·m
315 M14 (500 ± 35 kgf·cm)
(36.2 ± 2.5 ft·lbs)
Pilot valve, left
IV-M-61
Specifications (Right hand side)

(1) MAX PRIMARY PRESSURE : 3.9 MPa (40 kgf/cm2) 569 psi
(2) MAX BACK PRESSURE : 0.3 MPa (3 kgf/cm2) 43 psi
(3) Max. Operating FLOW : 15 l/min 16.2 LPM (4.3 GPM)
(4) SECONDARY PRESSURE CHARACTRISTICS : Refer to the “Control Diagram“ shown below.
(5) OPRERATING TORQUE : Refer to the “Control Diagram“ shown below.
(6) MAX. ALLOWABLE EXTERNAL TORQUE : Refer to the “MAX. allowable external torque“ shown below.
(7) HYDRAULIC OIL : MINERAL HYDRAULIC OIL
(8) OIL TEMP. RANGE : -20°C ~ 90°C
(9) FILTER : A filter of 40 ~ mesh and ever should be applied at the entrance of port P for preventins
the spool stickine.
Operating specifications
(1) PRIMARY PRESSURE : 3.9 MPa (40 kgf/cm2) 569 psi
(1)
(5) (2)
Hydraulic symbol
8 : Gray 1 : Red
7 : yellow 2 : Black
(6) (3)
6 : Green 3 : White
5 : Blanking pin 4 : Blue
View C
(4)
(7)
(1) Tilting angle of handle

(2) Single-operating angle
(3) Lean center position
(4) Stamping of model name & serial No.
(5) Double-operating angle
(6) 4-φ7 Through
Insert washers (outer dia. is over dia. is over φ12 and
under φ13), or use flange sockets, when mounting (8)
flange of casing by the bolts M6 (Screw, hex, S, H, C)
(7) Deutch
Receptacle: DT04-8PA-CE02
Wedge: W8P
Pin: 0460-202-16141 (10)
Plug: 114017
(8) (Outer dia. of the port-part)
(9) Tilted direction of handle (no. 1 push-rod direction)
(10)6-G1/4 thread depth 12 (O-ring seal to JIS B 2351)
Spot fancing dia. φ24 depth 1
Tightening torque 29.4 ± 2.0 N·m (300 ± 20 kgf·cm)
21.7 ± 1.4 ft·lbs (9)
IV-M-62
(Right hand side)
(1) No.4 Push-rod (9) Switch motion range: ±11°

(2) No.3 Push-rod (10) View C
(3) No.1 Push-rod
(4) Switch 3
(5) Slide lever
(6) Switch 2
(7) No.2 Push-rod
(8) View B
(11) Red
(12) White
(13) Black
(14) Blank
(15) Blue
(16) Green
(17) Yellow
(18) Gray
(19) Proportional output
(20) Switch electric circuit
(21)83.5 ± 5.5% Vin

(22)50 ± 4.5% Vin
(23)16.5 ±8.5% Vin
Pilot valve, right
IV-M-63
(Left hand side)
(1) Double -operating angle

(2) 4- ø7 through
(3) Husing: M(6195-0024)

Terminal: M(8230-4472)
Wire seal: SS type(7165-0210)
(4) Single-operating angle
(5) Lean center position
(6) Stamping of model
Name & Serial No.
(7) Gray
(8) Yellow
(9) Green
(10) Brown
(11) Black
(12) Blue
(13) View C
(14) Tilter direction of handle

(No.3 push-rod direction)
(15) No.3 port
(16) P port
(17) 6-01/4 thread depth 12
(O-ring seal to JIS B 2351)
Spot facing dia. ø24 depth 1
Tightening torque 29.4 ± 2.1 N.m
300 ± 20 kgf.cm
(18) No.4 port
(19) No.2 port
(20) (Outer dia of the port-part)
(21) T port
(22) No.1 Port
(23) No.4 push-rod

(24) No.3 push-rod
(25) Switch 1
(26) Switch 2
(27) No.1 push-rod
(28) No.2 push-rod
(29) Switch 3
(30) View B(3D)
(31) Handle electric circuit
Handle specifications
1 Rated voltage DC30V 0.1A
current (At resistance load)
2 Operating quantity 1mm
3 Operating force 4N
4 Temp range -20~70°
IV-M-64
Pilot valve control diagram (L and R)

Ports 1, 3
Ports 2, 4
Control valve
IV-M-65
IV-M-66
(F) TRAVEL PILOT VALVE (WITH VISCOUS DAMPER)

a) Outline
This pilot valve is incorporated with a newly
developed viscous damper, different from a ori-
fice damper in the previous model.
One common sensing port is available for the

travel alarm system.
Type coding
Part code No: RD819-61401
PV V 7 P C4001
R&D number
Bank type
Spool dia. ø7.0
Viscous damper type
Pilot valve
IV-M-67
b) Identification of Parts
(1) Port 5 for travel alarm
(Secondary pilot pressure)
(2) Plug for check valves
(3) P-port (Pilot pump, primary pressure)
(4) T-port
(4)
(3)
(2)
(1)
(5) Check valve inside
(5)
(6) Port 1
(7) Port 2
(8) Port 3
(9) Port 4
(10) Plug, machined to make oil passage
(8)
(6) (10)
(7) (9)
IV-M-68
c) Specifications
Operating Torque (N·m) 7.2±1.0 1. Max.Primary pressure: 6.9 MPa (70 kgf / cm2)
996 psi
2. Max. Back pressure: 0.3 MPa (3 kgf / cm2)
43 psi
5.2±1.3 3. Rated flow: 10 l / min
4. Secondary pressure characteristics: Refer to the
‘Control diagram’ shown right.
5. Operating torque (valve): Refer to the ‘Control
diagram’ shown right.
30 60 6. Operating torque (damper): Refer to the damper
Angular speed (deg/s) torque shown above.
7. Hydraulic oil: Mineral hydraulic oil
Damper Torque 8. Oil temp range: -20°C ~ +90°C
9. Ambient temp. range: -30°C ~ +60°C
10. Filter: A filter of 40-mesh and over should be
applied at the entrance of port P.
d) Control Diagram and Hydraulic

System
HYDRAULIC SYMBOL
CONTROL DIAGRAM
IV-M-69
e) Outer View and Dimensions

(1)
(2)
(3)
(6)
(4) (7)
(5) (9)
(8)
(1) The pedal to be attached should have a flat surface (7) 3-G1/4 Depth 12 (port No.5 with plug)
(flatness tolerance 0.3 surface roughness 6.3a) of (O-ring seal to JIS B 2351)
more than 29x83 to be water proof and to be fixed Spot facing dia. ø24 depth 1
rate the upper edge of bellows. (Sharp edges of Tightening torque 29.4 ± 2.0 N·m (300 ± 20 kgf·cm)
corners should be removed.) 20 ± 1 ft·lbs
(2) Inclined less than ± 0.2 at neutral. Thread nipple depth should be less than 12.0.
(3) 4-M8 x P1.25 Thread depth 13 (8) 4- ø11 through
Tightening torque 16.7 ± 1.5 N·m (170 ± 15 kgf·cm) M10 x P1.5
12.3 ± 1.1 ft·lbs Max. Tightening torque 56.9 N·m (580 kgf·cm) 42 ft·lbs
(4) Location of port name (4 names): 1 2 3 4 Mounting flange area
(5) Stamping of model name 6 Serial No. Flatness: Below 0.5
(9) 4-G1/4 Depth 12
(6) Location of port name (3 names): T P 5 (O-ring seal to JIS B 2351)
Spot facing dia. ø24 depth 0.5
Tightening torque 29.4 ± 2.0 N·m (300 ± 20 kgf·cm)
20 ± 1 ft·lbs
Thread nipple depth should be less than 12.0.
IV-M-70
IV-M-71
f) Inner Structure
Hydraulic symbol
(6)
(1) (4)
(2)
(3) (7)
(5) (8)
No. Screw size Tightening torque
225 MG 8.8 ± 1.0 N·m (90 ± 10 kgf·cm) 6 ± 0.7 ft·lbs
251 G1/4 29.4 ± 2.0 N·m (300 ± 20 kgf·cm) 20 ± 1 ft·lbs
252 R1/8 9.8 ± 1.5 N·m (100 ± 15 kgf·cm) 7 ± 1.1 ft·lbs
253 G1/8 11.8 ± 1.0 N·m (120 ± 10 kgf·cm) 8.7 ± 0.7 ft·lbs
271 M8 20.6 ± 1.5 N·m (210 ± 15 kgf·cm) 15 ± 1.1 ft·lbs
IV-M-72
No. Part Name Material Q’ty Remarks

101 Casing Ai Allot 1
191-1 Sheet 1 Carbon Steel 2 Length 18mm
191-2 Sheet 2 Carbon Steel 2 Length 15.7mm
194 Steal ball Bearing Steel 3 JIS B 1501 DW-1/4
201 Cover Ai Allot 1
210 Packing Synthetic Rubber 4
211 O-ring Synthetic Rubber 4
214 Rod push Stainless Steel 4
217 Shim Ordinary Steel 4
224 Damper assy - 2
Hex. S.H.C.
225 Alloy Steel 4 JIS B 1176 MG-12
Screw
251 ROH plug Carbon Steel 1 G1/4
BP-1/8 (Capsule seal
252 Plug Carbon Steel 1
coated)
253 ROH plug Carbon Steel 3 G1/8
261 O-ring Synthetic Rubber 1 JIS B 2401 P11 Hs90
263 O-ring Synthetic Rubber 3 JIS B 2401 P8 Hs90
Screw, box
271 Alloy Steel 2 JIS B 1176 M8-35
S.H.C.
301 Spool Alloy Steel 4
311 Seat spring Carbon Steel 4
313 Washer Carbon Steel 4
324 Spring Piano Wire 4 For secondary pressure
335 Spring Piano Wire 4 For return
413 Cam shaft Stainless Steel 2
414 Bush - 4 Made by Daido
420 Cam Cast Iron 2 Phosphate coating
461 Steel ball Bearing Steel 4 JIS B 1501-1975 DW-5/16
471 Rollers Bearing Steel 2 6x40 JIS B 1506
501 Bellows Synthetic Resin 1
Seal kit sub 1st Elements
(1) Grease is applied on each parts

(2) Grease is applied on each top part
(3) Section C - C
(4) Grease is applied in each spot facing
(5) Section E - E
(6) Grease is applied on each spline part
(7) Section D - D
(8) Section F - F
IV-M-73
g) Comparison of sensing port for travel warning function

KX080-3
(1)
(3)
Hydraulic symbol
(2)
KX080-3α/KX080-3AB
(6)
(4)
Hydraulic symbol
(5)
(1) 4-ø11 Through

(2) Port 5 & 6 for travel alarm sensing
(3) 7mm
4 names
(4) 7mm
names
(5) Port 5 for travel alarm sensing
(6) Damper
IV-M-74
h) Performance comparison
KX080-3α/KX080-3AB
(1)
(4) (1) High Viscosity Liquid
(2) Fixed Plate
(3) Cam Shaft
(2) (4) Rotating Plate
Damper torque is generated by sharing force

of high viscosity liquid.
(3)
Viscous Damper
KX080-3
(6) (5) (5) Orifice
(6) Damper Piston
(7) Hydraulic Oil
(8) Casing
(8)
Damper torque is generated by passing drag
of hydraulic oil.
(7)
Orifice Damper
The viscous damper

gives damping force
at low-speed operation.
(9)
Damper Torque
(9) Viscous Damper

(10) Orifice Damper
(10)
Operating Speed
IV-M-75
IV-M-76
(G) PILOT VALVE: DOZER AND ANGLE BLADE

a) General
1. Outline
2. Type coding
Part code No: RD819-6144-1
RCV 8 C2015A
R&D number
Spool dia. ø8.0
Remote control valve
b) Specifications
1. Max. primary pressure: 9.8 MPa (100 kgf/cm2)
1420 psi
2. Max. back pressure: 0.3 MPa (3 kgf/cm2) 40 psi
3. Rated flow: 10 l/min. (2.64 gal/min.)
4. Hydraulic oil: mineral hydraulic oil
5. Oil temp range: -20°C ~ 90°C (-4°F ~ 194°F)
6. Painting (for casing and cover:
Phosphate coaing is applied to bellows inside)
7. Filter: A filter of 40-mesh and over should be
applied at the entrance of the port P to prevent
the spool from sticking
IV-M-77
c) Outer View and Dimensions

(1)
(1) M12 x P1.75 Thread depth 35
(2) The pedal to be attached should have a flat
surface (flatness tolerance 0.3 surface
roughness 6.3a) of more than 25x79 to be
(2) water proof and to be fixed at the upper
edge of bellows. (Sharp edges of corners
should be removed.)
(3) 2-M10 x 1.5 Thread depth 15
Tightening torque 33.3 ± 3.4 N·m (340 ± 35
kgf·cm) 25 ± 2.5 ft·lbs
(4) Port 1 operating angle
(5) Ports 1&2 lean enter position
(3) (6) Port 1 operating angle
(7) Stamping of model name & serial No.
(8) Stamping of ports name
(9) 2 x 2 - ø11 Through
(10) 4 - G1/4 Depth 12 JIS B 2351 O-ring seal
spot facing dia.
ø24 depth 0.5 tightening torque 36.3 ± 2.0
N·m (370 ± 20 kgf·cm) 27 ± 1 ft·lbs
(4) (6)
(7)
(5)
(8)
(9) (10)
IV-M-78
(2)
(5)
(6)
(7)
(3)
(8)
(9)
(4)
(1)
[Unit: mm]
(1) 2 - G1/4 Depth 12 JIS B 2351 O-ring seal spot facing dia.
ø24 depth 1.5
Tightening torque 36.3 ± 2.0 N·m (370 ± 20 kgf·cm) 26.8 ± 1.4 ft·lbs
(3) Adjustable stroke: 0~3 mm (0~0.12 in.)
(4) Location of port name P T
(6) Stroke-end detent angle
(7) Pre-detent angle
(8) Adjustable stroke: 0~3 mm (0~0.12 in.)
(9) Ports 1, 2 lean enter position
Detent Mode Hydraulic Symbol
IV-M-79
d) Inner Structure
(1) (2)
(20)
(11)
(9)

Screw
No. Tightening torque
size
(3) 113 M8 29.4 ± 2.9 N·m (300 ± 30 kgf·cm) 20 ± 2 ft·lbs
(10)
114 PT 1/8 9.8 ± 1.5 N·m (100 ± 15 kgf·cm) 7 ± 1.1 ft·lbs
271 M8 29.4 ± 2.9 N·m (300 ± 30 kgf·cm) 20 ± 2 ft·lbs
6.9 ± 1.0 N·m (70 ± 10 kgf·cm) 5 ± 0.7 ft·lbs
(4) 423 M6
(Apply loctite No. 241)
445 M8 29.4 ± 2.0 N·m (300 ± 20 kgf·cm) 20 ± 2 ft·lbs
16.7 1.0 N·m (170 ± 10 kgf·cm) 12 ± 0.7 ft·lbs
454 M8
(Apply loctite No. 241)
(5)
461
M16x1.5 41.2 ± 2.9 N·m (420 ± 30 kgf·cm) 30 ± 2 ft·lbs
465
472 M10 33.3 ± 3.4 N·m (340 ± 35 kgf·cm) 25 ± 2.5 ft·lbs
481 M6 11.8 ± 1.0 N·m (120 ± 10 kgf·cm) 8.7 ± 0.7 ft·lbs
(6) (7) (8)
(12)
(13)
(17) (18) (19)
(1) Shim for adjusting detente release force designed thickness 0 to 2 mm (11) Hydraulic symbol
(2) Grease is applied to each sliding surface (12) Grease is applied on each top part.
(3) Clearance should be 0 to 3 mm by adjusting with shim. (13) Grease is applied on each top part
(4) Grease is applied to each sliding surface (14) Ports 1&2
(5) Grease is applied on each top parts (15) Ports 1&2
(6) Port 3 (16) Ports 1, 2&4)
(7) Section B - B (17) Port 1
(8) Port 4 (18) Section A - A
(9) Grease is applied to each steel ball contacting face and both sliding side faces (19) Port 2
(10) Grease is applied on each top part. (20) Note: 1. Spray anti-rust oil to inside bellows
IV-M-80
No. Part Name Material Q’ty Remarks

101 Casing Cast lron 1
102 Casing Cast lron 1
111 Spacer Cast lron 1
112 O-ring Synthetic Rubber 4 JIS B 2401 P12 HS90
113 Screw, box S.H.C. Synthetic Rubber 4 JIS B 1176 SB-M8-35
JIS B 0203 BP-1/8
114 Plug Carbon Steel 2
With capsuled adhesive
201-1 Cover Cast lron 1 Phosphate coating
201-2 Cover Cast lron 1 Phosphate coating
202 Plug Copper Allot 4
210 Seal Synthetic Rubber 4 HS70
SER-10A HS90
211 Scraper Synthetic Rubber 4
Made by Sakagami
212 O-ring Synthetic Rubber 4 JIS B 2401 P20 HS90
214-1 Rod, push Stainless Steel 2 For ports 3&4
214-2 Rod, push Stainless Steel 2 For ports 1&2
215 Washer 1 Stainless Steel 8
217 Washer 2 Ordinary Steel 8
JIS B 1176 SB-M8-30
271 Screw, box S.H.C. Alloy Steel 2
Chromating
301 Spool Carbon Steel 4
311-1 Seat, spring Carbon Steel 2 For ports 1&2
311-2 Seat, spring Carbon Steel 1 For port 3
311-3 Seat, spring Carbon Steel 1 For port 4
313-1 Washer 3 Ordinary Steel 3 For ports1, 2&4
313-2 Washer 3 Ordinary Steel 1 For port 3
324-1 Spring Piano wire 2 For secondary pressure (For ports 1&2)
324-2 Spring Piano wire 1 For secondary pressure (For port 3)
324-3 Spring Piano wire 1 For secondary pressure (For port 4)
335 Spring Piano wire 4 98.0~125.5 N (10~12.8 kgf) For return
402 Lever Ordinary Steel 1
412 Bush PTFE, Bronze 2 Made by Daido metal
413 Shaft, cam Stainless Steel 1
420 Cam Cast lron 1 Phosphate coating
423 Screw, set Alloy Steel 1 JIS B 1177 SSS-M6-6
445 Screw, box S.H.C. Alloy Steel 2 JIS B 1176 SB-M8-16
452 Disk Alloy Steel 1 Half stroke - Stroke end
453 Shaft, cam Stainless Steel 1
454 Screw, box s.set Alloy Steel 1 JIS B 1177 SSS-M8-8
MB-14-10-DU
455 Bush BC, PTFE 1
Made by Daido metal
461 Plug, detent Carbon Steel 2
462 Holder Alloy Steel 2 For strong type detent
463 Ball, steal Bearing Steel 2 JIS B 1501 DW-3/16
464 Spring Piano wire 2 For strong type detent
465 Nut, lock Steel 2
467 Nut, adjusting Carbon Steel 2
471 O-ring NBR 2 JIS B 2401 P16 Hs70
472 Nut, lock Ordinary Steel 2 JIS B 1181 CN-M10 Chromating
473 Screw, set Alloy Steel 2
481 Screw, box S.H.C. Alloy Steel 2 JIS B 1176 SB-M6-69
501-1 Bellows PVC 1
501-2 Bellows Synthetic Rubber 1 HS50
Elements 217, 461, 462, 463, 464, 465,
Detent sub 1st
467, 471
Seal kit sub 1st Elements 112, 210, 211, 212, 471
IV-M-81
Ports 1, 2
Ports 3
Ports 4
IV-M-82
(H) TRAVEL MOTOR (SGM-04D-S-09KT)

a) General
1. Kubota’s travel motors have been four kinds of models since KX080-3 introduction.
To meet the market growth, however, their brands for the market are divided - Nabtesco for
Europe, and Mitsubishi for North America after the minor-change. The basic structure, function
and performance stay the same.
2. Change history
Machine model Travel motor assy code No. Type of travel motor Manufacturer Market
RD809-61291 GM09VN-B-21/36-3 NABTESCO EU-version ~ S/N10409
KX080-3 EU-version
RD809-61301 GM10VA-B-30/52-1 NABTECO PP-version
S/N10410~
EU-version
EU KX080-3α RD819-61301 GM11VA-C-28/52-1 NABTESCO
S/N20001~
Mitsubishi PP-version
NA KX080-3 (AB) RD819-61501 SGM-04D-S-09KT
Heavy Industry LTD S/N20001~
IV-M-83
3. Type coding
The motor type code is marked on the motor nameplate.
SGM - 04 D - S -09 KT
Abbreviation of Kubota
Output torque, rough valve = 9000 N·m
Automatic torque-speed change
Type of model
Motor capacity, rough value = 40 cc/rev
Shimonoseki Geared Motor
IV-M-84
4. Travel motor outer view

(PP-version)
Motor model: SGM-04D-S-09KT
Part No. : RD819-6150-1
1. Travel motor assy and sprocket
2. Motor valve, right side
3. Motor valve, left side
IV-M-85
b) Specifications
Unit KX080-3 KX080-3 Remarks
Manufacturer Nabtesco Corp. Nabtesco Corp.
Model GM09VN-B-21/36-3 GM10VA-B-30/52-1
Kubota part No. RD809-6129-1 RD809-6130-2
cc/rev 36.3 51.9
1st
cu.in./rev 2.22 3.17
Capacity
cc/rev 21.3 30.2
2nd
cu.in./rev 1.30 1.84
Reduction ratio 1/61.6 45.970
cc/rev 2236 2386
1st
cu.in./rev 136.5 146
Total displacement
cc/rev 1312 1388
2nd
cu.in./rev 80.07 84.7
L/min. 72 72
Rated oil flow
USGPM 19.02 19.02
N.m 9000 9830
1st kgf.m 918 1002
ft.lbf 6638 7250
Theoretical torque
N.m 5160 5590
2nd kgf.m 526 570
ft.lbf 3806 4123
1F 31.6 29.6
Theoretical speed rpm
2F 52.7 49.8
MPa 29.4 29.4
Relief valve pressure kgf/cm2 300 300
psi 4267 4267
MPa 0.20 0.20
Counter balance valve Peak 0.69MPa
kgf/cm2 2.0 2.0
operating pressure (7kgf/cm2, 99.6 psi)
psi 28 28
Climbing ability deg. 30 30
kN 55.2 55.2 Slip 70% theoretical torque
1F kgf 5633 5633 Oil temp.: 50 ± 5 °C
lbf 12421 12421 (122 ± 9 °F)
Max. traction force
kN 34.3 34.3
Relief 60% theoretical
2F kgf 3500 3500
torque
lbf 7718 7718
N.m 97.1 120.6
Parking brake; braking torque kgf.m 9.9 12.3
ft.lbf 71.6 88.9
MPa 0.47 0.63
Parking brake; release pressure kgf/cm2 4.79 6.42
psi 68 91
mm/10min. >
0, 300 = >
0, 300 = 10 min engine stop
Traveling block performance
in./10min. >
0.00, 11.81 = >
0.00, 11.81 = Testing slope angle: 20 deg.
km/h 2.7 / 2.5 2.7 / 2.5
1st
Traveling speed mph 1.68 / 1.55 1.68 / 1.55
(Rubber/Steel) km/h 4.7 / 4.5 4.7 / 4.5
2nd
mph 2.92 / 2.80 2.92 / 2.80
10m(32.8ft) traveling time 1F sec./10m 12.0 - 15.0 12.0 - 15.0
(Rubber crawler) 2F (32.8ft) 7.2 - 8.2 7.2 - 8.2
IV-M-86
Unit KX080-3 KX080-3 Remarks

Manufacturer Nabtesco Corp. Nabtesco Corp.
Model GM09VN-B-21/36-3 GM10VA-B-30/52-1
Straight travel perfor- mm/10m 600 => >
600 =
1F/2F
mance in./32.8ft 23.62 => >
23.62 =
L/min. >
4.0 = ←
Drain amount at lock 1F/2F
Gal./min. >
1.06 = ←
L/min. >
0.5 = ←
1F New machine
Drain amount while rotat- Gal./min. >
0.13 = ←
ing L/min. >
1.0 = ←
2F
Gal./min. >
0.26 = ←
MPa
Low 2
speed kgf/cm
Hi-speed change pres- psi
sure MPa >
2.0 = 4
Hi-Low 2 20 => 41
change kgf/cm
psi >
290 = 580
2F MPa 24
↓ kgf/cm2 249
Automatic Hi-Low torque 1F psi 3542 at PP=4.0MPa
change pressure 1F MPa (40.8kgf/cm2, 580 psi)
↓ kgf/cm2
2F psi
Hydraulic motor oil ISO VG32,VG46 ISO VG32,VG46
GL-4 #90 or GL-4 #90 or
Gearbox oil type
equivalent equivalent
L 1.3 ± 10% 1.3 ± 10%
Gearbox oil: quantity
US Gal 0.34 ± 10% 0.34 ± 10%
°C -20 - 90 -20 - 90
Oil temperature
°F -4 - 194 -4 - 194
kg 81 81
Total mass
lbs 178.6 178.6
mm 474.28 474.28
Sprocket P.C.D.
in 18.67 18.67
Applied machine 10001~10409 10410~
IV-M-87
Unit KX080-3α KX080-3AB Remarks

Mitsubishi
Manufacturer Nabtesco Corp. Heavy Indus-
tries LTD
Model GM11VA-C-28/52-1 SGM-04D-S-09KT
cc/rev 51.9 46.9
1st
cu.in./rev 3.17 2.86
Capacity
cc/rev 27.8 25.3
2nd
cu.in./rev 1.70 1.54
Reduction ratio 50.111 1/54.8
cc/rev 2601 2570
1st
cu.in./rev 159 157
Total displacement
cc/rev 1393.1 1386
2nd
cu.in./rev 85.0 84.6
L/min 72 72
Rated oil flow
USGPM 19.02 19.02
N.m 10720 10349
1st kgf.m 1093 1055
ft.lbf 7907 7633 at 29.4MPa(300kgf/cm2,
Theoretical torque 4264 psi)
N.m 5610 5322
27.0 L/min (7.13 USGPM)
2nd kgf.m 572 543
ft.lbf 4138 3925
1F 27.1 26.6 at 6.86MPa (70kgf/cm2,
Theoretical speed rpm 995 psi)
2F 49.6 49.4
72.0 L/min (19.02 USGPM)
MPa 29.4 29.4
Relief valve pressure kgf/cm2 300 300
psi 4267 4267
MPa 0.20 0.00
Counter balance valve
operating pressure kgf/cm2 2.0
psi 28
Climbing ability deg. 30 30
kN 55.2 55.2 Slip 70% theoretical torque
1F kgf 5633 5633 Oil temp.: 50 ± 5 °C
lbf 12421 12421 (122 ± 9 °F)
Max. traction force
kN 34.3 34.3
Relief 60% theoretical
2F kgf 3500 3500
torque
lbf 7718 7718
N.m 120.6 90.0
Parking brake; braking torque kgf.m 12.3 9.2
ft.lbf 88.9 66.4
MPa 0.63 1.0
Parking brake; release pressure kgf/cm2 6.42 9.99
psi 91 142
mm/10min. >
0, 300 = >
0, 300 = 10 min engine stop
Traveling block performance
in./10min. >
0.00, 11.81 = >
0.00, 11.81 = Testing slope angle: 20 deg.
km/h 2.7 / 2.5 2.7 / 2.5
1st
Traveling speed mph 1.68 / 1.55 1.68 / 1.55
(Rubber/Steel) km/h 4.7 / 4.5 4.7 / 4.5
2nd
mph 2.92 / 2.80 2.92 / 2.80
IV-M-88
Unit KX080-3α KX080-3AB Remarks

Mitsubishi
Manufacturer Nabtesco Corp. Heavy Indus-
tries LTD
Model GM11VA-C-28/52-1 SGM-04D-S-09KT
10m(32.8ft) traveling time 1F sec./10m 12.0 - 15.0 12.0 - 15.0
(Rubber crawler) 2F (32.8ft) 7.2 - 8.2 7.2 - 8.2
Straight travel perfor- mm/10m 600 => >
600 =
1F/2F
mance in./32.8ft 23.62 => >
23.62 =
L/min. >
4.0 = ←
Drain amount at lock 1F/2F
Gal./min. >
1.06 = ←
L/min. >
0.5 = ←
1F New machine
Drain amount while rotat- Gal./min. >
0.13 = ←
ing L/min. >
1.0 = ←
2F
Gal./min. >
0.26 = ←
>
MPa 1.0 =
Low 2
>
10.2 =
speed kgf/cm >
Hi-speed change pres- psi 145.0 =
sure MPa 4 >
2.0 =
Hi-Low 2 41 >
20 =
change kgf/cm
psi 580 290 =>
>
2F MPa 24 24.0 =
↓ kgf/cm2
>
249 245 =
1F psi 3542 3483 =
>
at PP=4.0MPa
Automatic Hi-Low torque
change pressure 1F MPa >
22.7 = (40.8kgf/cm2, 580 psi)
↓ kgf/cm2 >
232 =
2F psi 3294 =>
Hydraulic motor oil ISO VG32,VG46 ISO VG32,VG46
GL-4 #90 or GL-4 #90 or
Gearbox oil type
equivalent equivalent
L 1.3 ± 10% 1.3 ± 10%
Gearbox oil: quantity
US Gal 0.34 ± 10% 0.34 ± 10%
°C -20 - 90 -20 - 90
Oil temperature
°F -4 - 194 -4 - 194
kg 81 88
Total mass
lbs 178.6 194.0
mm 474.28 474.28
Sprocket P.C.D.
in 18.67 18.67
Applied machine 10001~10409 10410~
IV-M-89
c) Outer View and Dimensions

Model: SGM-04D-S-09KT
(1)
(2)
(3)
(4)
(1) G3/8 (When mounted at the machine

right side: Plug)
(2) G1/4
(3) 2xG1/2
(5) (4) G3/8 (When mounted at the machine
left side: Plug)
(6)
Shovel, viewed from machine back
Left-hand usage Right-hand usage
Plug at T1 Plug at T2
(5) 12-M14x2, through

(6) (M2)
(7) Counterbalance spool
maintenance space
(8) (8) (M1)
(9) 12-M16x2, depth 23
(10) G1/2 O-ring port
(7) (9) (14) PP, G1/4 O-ring port
(10) (12)
Shovel, viewed from machine back

(11) Left-hand usage Right-hand usage
(13)
Plug at T1 Plug at T2
(14)
IV-M-90
(1) Notes:
1. Turning in direction B when pressure oil flows from
port P1.
Turning in direction A when pressure oil flows from
port P2.
(2) 2. Low-speed fixed mode when port PP3 is connected
with the tank.
Automatic dual-speed mode when dual-speed
select signal pressure is applied to port PP3.
3. Before operation, fill the casing with hydraulic oil
(3) through the drain port (T).
4. Hydraulic oil cleanliness level to be above Class 10
of NAS1638.
5. Use Gear Oil: SAE #90, GL4, to keep the speed
reducer lubricated.
Check the oil level and cleanliness at regular
intervals. Add or replace as required.
6. Pour the lubricant up to the upper /////-marked level.
(Oil amount: About 1.35 liters, 0.36 US gal.)
(5) (4) 7. Approximate weight: About 88 kg
(1) Oil filler port G3/8
(2) Level check port G3/8
(3) Oil level
(4) Oil drain port G3/8
(5) View A
Hydraulic Circuit Symbol
IV-M-91
IV-M-92
d) Cross-Sectional View
IV-M-93
e) Parts List
No. Name Q’ty Remarks No. Name Q’ty Remarks

1 Travel Gear assy 1SET 21 Plate, Friction 2
-1 Body, Casing 1 22 Plate, Steel 2
-2 Seal, Floating 1 23 Spring 10
-3 Bearing, Angular ball 2 24 Plate 1
-4 Nut, Ring 1 25 Plug 2
-5 Gear, Casing Z=104T 1 26 Poppet 2
-6 Gear, Sun A Z=13T 1 27 Spring 2
-7 Gear, Planetary A Z=45T 3 28 O-ring 2 JIS B2401 1B P18
-8 Bearing, Needle A 3 29 -
-9 Carrier 1 30 O-ring 1 ø160.5, ø3.1 “Gs155”
-10 Gear, Sun B Z=20T 1 31 Ring, Back up 1
-11 Gear, Planetary B Z=42T 4 32 O-ring 1 JIS B2401 1B G130
-12 Bush 4 33 Ring, Back up 1
-12 Bearing, Needle B 4 34 O-ring 1 ø170.5, ø3.1 “Gs165”
-14 - 35 -
-15 Plate, Thrust (2) 1 36 -
-16 Plate, Thrust (3) 1 37 -
-17 Plate, Thrust (4) 4 38 -
-18 Screw 8 M8 x 20L 39 -
-19 Washer 1 40 -
-20 Pin, Snap 1 41 Pin 2
-21 Cover 1 42 Bolt 8 M12 x 35L
-22 O-ring 1 JIS B2401 G230 43 Cover, Motor 1
-23 Ring, Snap 1 44 Spool 1
-24 Plug 3 G3/8 45 Pusher 2
-25 O-ring 3 JIS B2401 1A P14 46 Spring 2
2 Shaft 1 47 Cover 2
3 Barrel, Cylinder 1 48 O-ring 2 JIS B2401 1B P28
4 Retainer, Ball 1 49 -
5 Retainer 1 50 Orifice 1
6 Cam 1 51 Spool 1
7 Piston assy 9SETS 52 -
-1 Piston 9 53 -
-2 Pusher 9 54 -
8 Plate, Valve 1 55 -
9 Plate 1 56 Orifice 1
10 Piston assy 1SET 57 Ball, Steel 2
-1 Piston 1 58 Plug 2 G1/8
-2 Slipper 1 59 O-ring 4 JIS B2401 1B P8
11 Bearing, Ball 1 60 Valve, Relief assy 2SETS
12 Bearing, Ball 1 -1 Body 2
13 Seal, Oil 1 -2 Poppet 2
14 Spring 1 -3 Rod 2
15 Spring 1 -4 Seat 2
16 Ball, Steel 2 -5 Piston 2
17 Pin 3 -6 -
18 Ring, Snap 1 -7 Cap, Nut 2
19 Pin, Spring 1 JIS B2808 ø5 x 14L AW -8 Spring 2
20 Piston, Brake 1 -9 -
IV-M-94
No. Name Q’ty Remarks

-10 -
-11 O-ring 2 JIS B2401 1B P20
-12 O-ring 2 AS568-016
-13 O-ring 2 AS568-021
-14 -
-15 Ring, Back up 2 JIS B2407 P20-T2
-16 Ring, Back up 4 SUN-2AS-016
-17 -
61 Plug 2 G1/4
62 O-ring 2 JIS B2401 1B P11
63 Plug 7 NPTF1/16
64 -
65 Plug 3 R1/8
66 -
67 Name plate 1
68 Rivet 2
69 -
70 -
71 -
72 -
73 Spring 1
74 Plug 1 7/8-14UNF-2A
75 O-ring 1 ARP568-910
76 -
77 -
78 -
79 -
80 Plug 1 G3/8
81 O-ring 1 JIS B2401 1A P14
D Seal kit 1SET
Tightening torque
Tightening
Size
N·m (kgf·m) ft·lbs
(1-18) M8 35.3 ± 2.0 (3.6 ± 0.2) 26 ± 1
(1-24) (80) G3/8 49.0 ± 4.9 (5.0 ± 0.5) 40 ± 4
(25) G1/2 65.7 ± 6.6 (6.7 ± 0.7) 48 ± 5
(42) M12 129.4 ± 12.9 (13.2 ± 1.3) 95.5 ± 9.4
(47) M30 x P1.5 176.4 ± 17.6 (18.0 ± 1.8) 130 ± 13
(50) (56) NPTF1/16 9.81 ± 1.0 (1.0 ± 0.1) 7 ± 0.7
(58) G1/8 19.6 ± 2.0 (2.0 ± 0.2) 10 ± 1
(60-1) M22 x P1.5 142.1 ± 14.2 (14.5 ± 1.4) 105 ± 10
(60-7) M30 x P1.5 142.1 ± 14.2 (14.5 ± 1.4) 105 ± 10
(61) G1/4 39.2 ± 3.9 (4.0 ± 0.4) 30 ± 3
(63) NPTF 1/16 14.7 ± 1.0 (1.5 ± 0.1) 11 ± 0.7
(65) R1/8 19.6 ± 2.0 (2.0 ± 0.2) 10 ± 1
(74) 7/8-14UNF 78.5 ± 7.8 (8.0 ± 0.8) 60 ± 6
IV-M-95
f) Outline of Travel Unit

SGM travel unit components
The SGM travel unit is composed mainly of three
components. The three components have their
following functions.
1. Hydraulic motor
1-1. Rotating function
1-2. Speed change function
1-3. Parking brake function
2. Brake valve
2-1. Counterbalance valve function
2-2. Crossover-relief valve function
2-3. Automatic dual-speed selector function
3. Reduction gears
(1) Reduction gears
(2) Hydraulic motor 3-1. Slow-down function
(3) Brake valve 3-2. Final power output function
(2)
(1) (3)
IV-M-96
1. Hydraulic motor
The hydraulic motor has the following three functions.

High-pressure oil is supplied to produce the turning
movement and torque. The turning movement and
torque are transmitted to the reduction gears.

The motor capacity (volume per revolution) is controlled
to switch the motor speed between high and low.

When no high-pressure oil is supplied to the motor and
the motor itself is at a stop, the parking brake activates
itself. Once the high-pressure oil is fed to get the motor
started, the parking brake releases itself.
(1) Hydraulic motor
(1)
IV-M-97

Suppose that high-pressure oil is being supplied
to the motor’s left port. The oil flows through the
valve plate into the cylinder barrel. The oil
pushes the piston to the left. The leftward-moving
piston slides over the cam (swash plate) surface
to turn the cylinder barrel.
The shaft is connected with the cylinder barrel,
whereas the sun gear (A) is coupled with the
shaft. As the sun gear (A) turns as shown above,
therefore, the turning movement is taken out.
Imagine that high-pressure oil is being supplied
to the motor’s opposite port. It produces the
opposite-direction turning, and the sun gear (A)
turns in the other direction.
(1) Sun gear (A)
The rotation of the sun gear (A) is transmitted to
(2) Shaft the reduction gears.
(3) (Spline) The torque and rpm produced by the hydraulic
(4) Piston motor depend on the motor capacity (volume per
(5) Cam (swash plate) revolution). The motor’s per-revolution volumetric
(6) Valve plate capacity varies depending on the cam (swash
(7) Cylinder barrel
(8) High pressure plate) angle (ø).
(9) Low pressure
Rotating function mechanism
(4) (6)
(1)
(2)
(3)
(5)
(8) (9)
(7)
IV-M-98

The torque and rpm produced by the hydraulic
motor depend on the motor capacity (volume per
(1) revolution). The motor’s per-revolution volumetric
capacity varies depending on the cam (swash
plate) angle (ø).
The larger the cam (swash plate) angle (ø) is, the
greater the torque is, and the lower the speed is.
To the contrary, the smaller the cam (swash
plate) angle (ø) is, the lesser the torque is, and
the higher the speed is.
(2) The SGM travel unit is equipped with a dual-
speed selector piston. With high-pressure oil
being supplied, the dual-speed selector piston
pushes the cam (swash plate), the angle of
which becomes smaller. In other words, the
motor switches from the low-speed mode to the
high-speed one.
(1) Dual-speed selector piston

(2) Low-speed mode (high torque)
(3) High-pressure oil being supplied
(3) (4) High-speed mode (low torque)
(4)
IV-M-99

The SGM travel unit is also provided with a
(1) (2)
parking brake. When no high-pressure oil is
supplied to the motor and the motor itself is at a
(3)
stop, the parking brake activates itself. Once the
high-pressure oil is fed to get the motor started,
the parking brake releases itself.
(4)
Just when the high-pressure oil flows to the
motor, the parking brake immediately gets
released and the motor starts running. Once the
high-pressure oil flow to the parking brake is
interrupted, the hydraulic motor stops running.
The brake piston is then slowly pressed to the left
by the spring force, which slowly activates the
parking brake.
Thanks to such gentle activation of the parking
brake, the friction disc and the iron sheet can be
protected against damage.
(1) Spined coupling

(2) Friction disc and iron sheet
(3) Brake piston
(4) Spring
IV-M-100
2. Brake valve
The brake valve has the following three 2-2. Shockless, crossover-relief valve function
functions. * The valve is designed to minimize jerks when
slowing down and stopping the machine.
2-1. Counterbalance valve function * The valve helps keep the motor against overload.
* The valve is intended to minimize jerks when * The valve makes up for short oil flow to the motor
starting and stopping the machine and to when slowing down and stopping the machine.
prevent downhill uncontrollability and * The shockless type valve is effective in
cavitation. suppressing jerks.
* Just before the travel unit starts running, high-
pressure oil is supplied to the parking brake 2-3. Automatic dual-speed selector function
releaser. The motor speed can be selected from the
following two levels.
1) Fixed low-speed mode: Always at low speed

2) Automatic dual-speed selector mode
2)-1: At high speed when a travel load is light
2)-2: At low speed when a travel load is heavy
(1 )Brake valve
(1)
IV-M-101
(1)
2-1. Counterbalance valve function
(2) (3) 1) Level ground travel
While high-pressure oil is not supplied to the brake
valve, the counterbalance spool stays in its middle
position by the two springs at both sides. In this
(5)
(4) state, the oil passage from the motor remains
closed.
When high-pressure oil is introduced into the right
port of the brake valve, the counterbalance spool
moves to the left under the pressure from the right
end. Accordingly, the oil passage from the motor
opens through the left shoulder of the
counterbalance spool. Now the oil starts flowing to
run the motor.
If the machine slows down or stops and the oil
being supplied to the right port decreases, the
pressure at the right end of the counterbalance
spool drops. Then the spring force at the spool’s
left side forces the spool toward the right. The
opening of the spool shoulder then gets narrow,
finally interrupting the high-pressure oil flow to the
(6) (7) brake valve. The opening will be fully closed. By
this “closed opening of the spool shoulder” action,
(1) “Stop status” (4) Relief valve (left) the motor outlet comes under pressure rise (back
High-pressure oil not (5) Relief valve (right) pressure).
supplied (6) Spring
(2) Parking brake (7) Counterbalance spool
(3) Gear (Neutral)
(1)
(2) (3)
(5)
(4)
(6) (7)
IV-M-102
2) Downhill travel
* Not equipped with the counterbalance valve
(8) (9) If not equipped with the counterbalance valve, the
machine may run downhill faster than expected by
gravity. The “over-running” cannot be prevented by
controlling the oil flow rate to the motor. The
hydraulic pump fails to maintain this oil flow rate,
which causes a negative pressure at the motor
(10) (11) inlet. It may prevent cavitation inside the motor.
* Counterbalance valve function and mechanism
During downhill run, the oil flow rate to the motor
becomes low and the pressure at the right port
drops. The pressure at the counterbalance valve’s
right side also becomes low, which moves the
counterbalance spool from the left to the right. At
this point, the opening at the spool’s shoulder gets
narrow, which causes a pressure rise (back
(12) pressure) at the motor outlet. This “back pressure”
prevent “over-running” or cavitation inside the
(13) (14) motor.
The counterbalance valve function works with
the counterbalance spool, two springs at both Hydraulic oil feed to release the parking brake
ends, and two check valves. Suppose that the oil from the pump is being
supplied to the right port of the brake valve in order
(8) “Running status” (12) Parking brake release to start running the travel unit. The counterbalance
High-pressure oil being oil passage spool moves to the left and the parking brake
supplied9) Gear (13) Low pressure
(10) Outlet (14) High pressure release oil passage opens.
(11) Inlet With the travel unit at a stop, the parking brake
release oil passage is closed. For detailed parking
brake function, refer to “1-3. Parking brake
function”.
(8) (9)
(Low speed)
(10) (11)
(12)
(13) (14)
IV-M-103
2-2. Cross-over relief valve function

The SGM travel unit is equipped with two * Not equipped with the crossover-relief valve
shockless crossover-relief valves. Here are their (Discussed below are two cases.)
functions.
* The valve is designed to minimize jerks when 1) When slowing down or stopping the machine,
slowing down and stopping the machine. the counterbalance valve functions, resulting in
* The valve helps keep the motor against pressure rise (back pressure) in the motor.
overload. (Refer back to “2-1”.) If the machine is stopped
* The valve makes up for short oil flow when suddenly without the crossover-relief valve in
slowing down and stopping the machine. place, the back pressure is quickly generated
* The shockless type valve is effective in and the operator feels jerks. In the worst
suppressing jerks. scenario, the machine may get damaged.
2) In getting the machine started, high-pressure oil
is supplied to the motor. If the travel start is too
quick without the crossover-relief valve in
place, a sudden pressure rise occurs in the
motor. This produces jerks.
The crossover-relief valves on the SGM travel
unit are designed to ease these pressure-
caused jerks, improve the operator comfort
and protect the machine.
1)
2)
3)
5)
4)
5) 5)
1) Crossover-relief valve
2) Shockless piston
3) Spring
4) Poppet
5) High pressure
IV-M-104
Shockless crossover-relief valve function

and mechanism
Refer back to the figure “2-1 Counterbalance Next, when the shockless piston is pushed
valve function” and the above figure on this down all the way to the stroke end (3), the
page. Discussed below is the relief valve relief pressure rises up to the final setting. This
(right). is because there is no more oil flow to move
Initially, the relief valve (right) is in the state the shockless piston and because the pressure
illustrated above (1). When a sudden pressure behind the poppet is high.
rise occurs in the motor outlet in slowing down Let’s suppose that the motor is stopped and
or stopping the machine, a shock by high- then restarted. The shockless piston is set up
pressure oil pushes down the shockless piston again, and it is pushed up by the high pressure
in the relief valve. At the same time, the poppet at the motor inlet.
gets activated to relieve the high pressure (2).
While the shockless piston is being pushed Oil replenishment
down, the pressure behind the poppet remains During relief, the relief valve serves to add oil
not too high. This is because there is an oil from the motor’s outlet to its inlet to make up
flow to move the shockless piston. In this way, for the oil blown out. This function helps
the relief pressure stays low. prevent an excessive loaded pressure in the
motor.
1)
2)
3)
5)
4)
5) 5)
1) Crossover-relief valve
2) Shockless piston
3) Spring
4) Poppet
5) High pressure
IV-M-105
2-3. Automatic dual-speed selector function

The automatic dual-speed selector function has the Functions
following two modes (1) and (2). Refer to the above figure (1).
(1) Fixed low-speed mode: Always at low speed When the pilot pressure is not applied,
(2) Automatic dual-speed selector mode the spool stays fixed at top by the spring
(2)-1: At high speed when the motor is lightly loaded force. The fixed low-speed mode is thus
(2)-2: At low speed when the motor is heavily loaded selected.
Refer to the above figure (2).
The above function is supported by the following two Under low loaded pressure, the pilot
component parts. pressure acts on the spool top, which
* Spool (mode selection and automatic speed change) moves downward to call the high-speed
Automatic selection mode (pilot pressure being supplied) mode. As the loaded pressure rises, it
High-speed mode when the loaded pressure is lower than affects the difference in spool pressure-
specified receiving area and gradually returns the
Low-speed mode when the loaded pressure is higher than spool top upward. At a specified loaded
specified pressure, the mode changes from high
Fixed low-speed mode (pilot pressure not being supplied) speed to low speed.
* High-pressure selector valve Changes in the cam (swash plate) angle
The pressure being supplied to the high-pressure port of are referred back to in “1-2. Speed
the motor is selected all the time. In whichever direction change function” of “1. Hydraulic motor”.
the motor is running, the dual-speed selector spool
receives high pressure.
2) 8)
3)
1)
4)
5)
6) 9)
7)
10)
13) 18)
11)
12) 15)
17)
16)
1) Pilot pressure ON/OFF 10) Pilot pressure ON/OFF

2) Spool 11) Spool pressure-receiving area, large
3) Spring 12) Spool pressure-receiving area, small
4) Spool pressure-receiving area, large 13) Loaded pressure
5) Spool pressure-receiving area, small 14) Dual-speed selector piston
6) Dual-speed selector piston 15) Steel ball
7) Cam (swash plate) 16) Closed
8) Pilot pressure inlet 17) Open
9) High-pressure selector valve 18) Dual-speed selector piston
IV-M-106
(1) Low speed

2)
3) 8)
1)
4)
5)
6)
9)
(2) High speed (Medium load pressure)
7)
18)
13)
10)
15)
17)
11) 16)
12)
1) Pilot pressure ON / OFF 10) Pilot pressure ON /OFF

2) Spool 11) Spool pressure-receiving area, large
3) Spring 12) Spool pressure-receiving area, small
4) Spool pressure-receiving area, large 13) Loaded pressure
5) Spool pressure-receiving area, small 14) Dual-speed selector piston
6) Dual-speed selector piston 15) Steel ball
7) Cam (swash plate) 16) Closed
8) Pilot pressure inlet 17) Open
9) High-pressure selector valve 18) Dual-speed selector piston
IV-M-107
(3) Automatic torque-up function

(High load pressure)
7)
10)
13) 18)
11)
12) 15)
17)
16)
10) Pilot pressure ON/OFF 15) Steel ball

11) Spool pressure-receiving area, large 16) Closed
12) Spool pressure-receiving area, small 17) Open
13) Loaded pressure 18) Dual-speed selector piston
14) Dual-speed selector piston
IV-M-108
(4) High speed (Medium load pressure)
Pilot pressure ON/OFF
(1)
PP
FP
(4)
(2)
(3)
(1) Pilot pressure ON/OFF

(2) Spool pressure-receiving area, large
(3) Spool pressure-receiving area, small
(4) Loaded pressure
IV-M-109
(5) Automatic torque-up function

(High load pressure)
(1) Pilot pressure ON/OFF
(2) Spool pressure-receiving area, large
Pilot primary pressure: PP (3) Spool pressure-receiving area, small
Pilot pressure ON/OFF (4) High oaded pressure: PH
(1) PP
d1
FP
(4)
d2
(2) PH
FH
d4
(3)
d3
PP= 40 kgf/cm2
PH = ?
d1 = ø1.9
d2 = ø0.845
d3 = ø0.800
π π
PP·(d12-d22) = PH·(d22-d32)
4 4
(d12-d22)
PH=PPx
(d22-d32)
(1.92-0.8452)
=PPx
0.8452-0.8002
a1 π π
a1= (d1 -d2 )
2 2
FP=PP x (d1 -d2 )
2 2
d1 4 4 (1.9+0.845)(1.9-0.845)
=PPx
FH=PH x (a1 - a2) (0.845+0.800)(0.845-0.800)
d2 (2.745x1.055)
π =PPx
a2 π =PH x (d22-d42-d32-d42)
1.645x0.045
a2= (d22-d32) 4
d2 4 π
=PH x (d22-d32)
4 PH=PPx39.13
d3
IV-M-110
2-4 Planetary reduction gears

The turning of the hydraulic motor shaft is (2) Star type
transmitted to the reduction gears. The function is Suppose that the carrier is fixed and the turning
as follows. force is taken out of the ring gear. This
mechanism is called “star type”. As the sun
(1) gear revolves clockwise, the planetary gears
(2) spin themselves. This makes the ring gear turn
counterclockwise.
In this way, the sun gear revolves clockwise,
whereas the ring gear turns counterclockwise.
The turning speed of the ring gear (output) is
different from the revolving speed of the sun
gear (input). The reduction ratio is given in the
following equation.
Reduction ratio (i) = Input / Output = Zr / Zs
(3) (5)
(3) Travel unit
The SGM travel unit is equipped with two-stage
(4) planetary reduction gears. The mixed
(1) Planetary reduction gears mechanism consists of planetary type and star
(2) Planetary gear type. The input is fed to the sun gear at the first
(3) Sun gear stage, and the output is taken out of the ring
(4) Carrier gear. The ring gear is commonly used at the
(5) Ring gear (gear casing)
first and second stages as well.
The reduction ratio is as follows.
The component parts of general planetary
reduction gears are as shown above. They include Reduction ratio (i) = Input / Output
the following four key parts. = (Zr/Zs1 + 1) x (Zr/Zs2 +1) - 1
Part name No. of teeth
Sun gear Zs where
Planetary gear Zp Zs1: No. of teeth of first-stage sun gear = 13
Carrier -- Zs2: No. of teeth of second-stage sun gear = 20
Ring gear Zr Zr: No. of teeth of ring gear - 104
(1) Planetary type

Suppose that the ring gear is fixed and the Final output
turning force is taken out of the sun gear. This The ring gear is provided with travel sprocket
mechanism is called “planetary type”. As the mounting flange. The final turning movement
sun gear revolves clockwise, the planetary and torque are taken out of the ring gear flange.
gears turn around the sun gear. This orbital
104 104
motion makes the carrier turn. Reduction ratio (i) = ( +1) ( +1) -1
13 20
In this way, the sun gear revolves clockwise,
whereas the carrier turns counterclockwise. = 9 x 6.2 - 1
The turning speed of the carrier (output) is =54.8
different from the revolving speed of the sun
gear (input). The input and output are
expressed as “reduction ratio (i)” in the
following equation.
Reduction ratio (i) = Input / Output = Zr / Zs + 1
IV-M-111
3. Reduction gears
The reduction gears have the following two
functions.
3-1. Slow-down function

The mechanism receives the turning force from
the hydraulic motor in the following manner.
Turning speed: Down
Turning torque: Up
(1) First stage 3-2. Final power output function

(2) Second stage
(3) Reduction gears The final turning output is given to the machine’s
(4) Sprocket mounting flange sprocket.
(1) (2)
(3) (4)
IV-M-112
2-5 FYI (For Your Information)

(1)
1. Application and example
1) Engagement between internal and pinion.
Center distance for the internal gear train is
shorter than the external gear train, but can
be obtained in the same direction.
a) Pinion is driver gear.

No. of teeth of piston
u= (Speed reducer)
No. of teeth of Internal gear
(2) b) Internal gear is driver gear.
No. of teeth of Internal gear
u= (Speed reducer)
No. of teeth of piston
(1) Piston
(2) Internal gear
(a) Planetary type

(b) Solar type
(c) Star type
2) Mechanism of planet gear train

Most mechanism of planet gear consist of sun, planet, internal
(3) (Annulus) gear and carrier which come with compact design and high
reductive gear ratio.
Type of Fixed Formulas of
Input Output Ratio
mechanism factor gear ratio
1
Planetary zC
Ring gear Sun gear Carrier +1 1/3~1/12
type zA
(z: Number of teeth)
(4) 1
Solar type Sun gear Ring gear Carrier zA 1/1.2~1/1.7
+1
(6) zC
(5)
1
-
zC
Star type Carrier Sun gear Ring gear zA 1/2~1/11
Input and output axis
have opposite rotation
z: Number of teeth, A&C: Expressed each sun internal gears.

[-]: Expressed output rotated direction against input rotation.
(3) Carrier
(4) Sun gear
(5) Internal gear
(6) Planet gear
IV-M-113
2. How to calculate the velocity ratio

(1) Planetary type
This type is used to fix the internal gear C.
Supposing that the sun gear A and the carrier D are the input and output shafts, respectively, the
velocity ratio is determined as follows with the mathematical table method.
Table 1 Planetary type’s velocity ratio calculation

Sun gear A Planetary Internal (1)
Carrier D
No. Description (input) gear B gear C
(output)
Zs Zp Zr
Carrier fixed and sun gear A Zs Zs

1 +1 - - 0
revolving one turn Zp Zr
Entire system starched
Zs Zs Zs Zs
2 Zs + + + +
and turned + Zr Zr Zr Zr
Zr
Zs Zs Zs Zs
3 Add (1) and (2). 1+ - 0 (fixed) + (a) Internal gear = fixed
Zr Zr Zp Zr
(1) C (fixed)
Zs
Output (Vc) Zr 1 Zs
Velocity ratio =
Zs
=
Zr
=
Input (Vs) 1+ +1 Zs + Z r
Zr Zs
Input (Ns) Zr Zr + Zs
Reduction ratio = +1=
Output (Nc) Zs Zs
The input and output shafts turn in the same direction.

When Zs=16, Zp=16 and Zr=48, for example, the velocity ratio will be 1: 4.
(2) Solar type

This type is used to fix the sun gear A.
Supposing that the internal gear C and the carrier D are the input and output shafts, respectively, the
velocity ratio is determined as follows.
Table 2 Solar type’s velocity ratio calculation

Sun gear A Planetary Internal
Carrier D
No. Description (input) gear B gear C
(output)
Zs Zp Zr
Carrier fixed and sun gear A Zs Zs

1 +1 - - 0
revolving one turn Zp Zp
Entire system starched and (2)
2 -1 -1 -1 -1
given one counterclockwise turn
Zs Zs
3 Add (1) and (2). 0 - -1 - -1 -1
Zp Zr (b) Sun gear = fixed
(1) A (fixed)
Output (Vc) 1 1
Velocity ratio = =
Zs Zs
Input (Vr) - -1 +1
Zr Zr
Input (Vr) Zs
Reduction ratio = +1
Output (Vc) Zr
The input and output shafts turn in the same direction.

When Zs=16, Zp=16 and Zr=48, for example, the velocity ratio will be 1: 1.33333.
IV-M-114
(3) Star type

This type is used to fix the carrier D.
With the star type, the planetary gear rotates on its axis, but does not go around in orbit. Strictly
speaking, therefore, this is not a planetary gear mechanism.
Supposing that the sun gear and the internal gear are the input and output shafts, respectively, the
velocity ratio is determined as follows.
Output (Vr) -Zs ZP Zs Zs
Velocity ratio = x =- -
Input (Vs) ZP Zr Zr Zr
Input (Vs) Zr (3)

Reduction ratio =-
Output (Vr) Zs
In other words, the planetary gear functions as idle gear.

The input and output shafts turn in the opposite direction.
When Zs=16, Zp=16 and Zr=48, for example, the velocity ratio will be minus 1: 3.
(c) Carrier = fixed

(3) D (fixed)
IV-M-115
3. Reduction ratio calculation method for dual-speed travel planetary speed reducer
Model R Various speeds
S1: 1st-stage sun gear turn = N
C1: 1st-stage carrier turn = 2nd-stage sun gear turn, S2
RQ: Drive gear turn = Nout
C2: 2nd-stage carrier turn
Numbers of gear teeth

Zs1: 1st-stage sun gear
Nin C1 C2 Nout Zp2: 1st-stage planetary gear
Zr1 = Zr2 = Zr: 1st-stage drive gear = 2nd-stage drive gear
Zs2: 2nd-stage sun gear
Zp2: 2nd-stage planetary gear
<Thinking steps>
(1) First consider the two-stage planetary gear (drive gear turn fixed)
(2) Take a negative amount to keep the 2nd-stage carrier fixed.
(3) Sum up.
(4) Take C = 1. (Divide the sum (3) by C.)
(5) Reduce a fraction.
D: 1st-stage carrier turn =

A: 1st-stage sun gear turn C: Drive gear turn = Nout E: 2nd-stage carrier turn
2nd-stage sun gear turn
1 N (ZS1/ (ZS1+Zr)) x N 0 (ZS1/ (ZS1+Zr)) x N X (ZC1/ (ZC1 + Zr))
2 -(ZS1/ (ZS1+Zr)) x N x (ZC1/ (ZC1+Zr)) -(ZS1/ (ZS1+Zr)) x N x (ZC1/ (ZC1+Zr)) -(ZS1/ (ZS1+Zr)) x N x (ZC1/ (ZC1+Zr)) -(ZS1/ (ZS1+Zr)) x N x (ZC1/ (ZC1+Zr))
(ZS1/ (ZS1+Zr)) x N
3 (1- (ZS1/ (ZS1+Zr)) x (ZC1/ ZC1+Zr))) x N -(ZS1/ (ZS1+Zr)) x (ZC1/ (ZC1+Zr)) x N 0
-(ZS1/ (ZS1+Zr)) x N x (ZC1/ (ZC1+Zr))
(1- (ZS1/ (ZS1+Zr)) x (ZC1/ (ZC1+Zr))) x N (ZS1/ (ZS1+Zr)) x N (1- (ZC1/ (ZC1+Zr))
4 -(ZS1/ (ZS1+Zr)) x (ZC1/ (ZC1+Zr)) x N -(ZS1/ (ZS1+Zr)) x (ZC1/ (ZC1+Zr)) x N 1 0
(1- (ZC1/ (ZC1+Zr))

5 -((ZS1+Zr) (ZC1+Zr) / (ZS1 x ZC1) -1) -(ZC1/ (ZC1+Zr)) 0
From the above table, the reduction ratio is obtained as follows.
Reduction ratio = C / A = -1 / ((ZA+ZC) (ZD+ZC) / (ZA+ZD) -1)
ef. SGM-04D-S-09KT
ZS1 13
ZP1 45
Zr 104
ZS2 20
ZP2 42
Reduction ratio = 1 / (54.80)
IV-M-116
4. Thinking procedure, step by step

1 First, start to think the planetary type reduction chain, that is, ring gear is fixed.
Zs1
Then turn the 1st sun gear by N rpm as shown 1-A and you’ll get x N for 1st carrier speed
Zs1+Zr
as shown 1-D by applying the tabular method as explained in 3-(1).
As the ring gear is fixed, the member of rotation is zero as shown in 1-C.
Second stage carrier rotation can be calculated as follows.
Zs1 Zs2
( x N) x as shown 1-E.
Zs1+Zr Zs1+Zr
2 In order to fix the rotation of 2nd stage carrier, input the reverse turn of 2nd stage carrier as shown
in 2-A to 2-E.
3 Calculate the simple sun of 1 and 2.
4 In order to obtain the reduction ratio of wheel motor, we need to set the ring gear rotation to 1 as
shown in 4-C.
In order to make C=1, column 4-A and 4-D should be divided by
-{ZS1 / (ZS1+Zr)} x {ZS2 / (ZS2+Zr)} x N.
Then you’ll get those complicated results in column 4-A and 4-D.
5 By calculating the column 4-A and 4-D to make them simple, you’ll get the result shown in column
5-A.
As this wheel motor is designed, Input is the 1st sun gear.
Out put is the ring gear.
The reduction ratio can be shown as follows.
R
Reduction ratio =
S1
ZS1 = 13 1
=
(ZS1+Zr)(ZS2+Zr)
ZP1 = 45 -{ - 1}
ZS1 x ZS2
Zr = 104
1
=
ZS2 = 20 (13+104)(20+104)
-1
T3 x 20
ZP2 = 42
1
=-
54.80
This final result means;

1
Reduction ratio is and the final rotating direction is the opposite of the 1st sun gear.
54.80
IV-M-117
IV-M-118
WSM KX080-3AB Service IV HYDRAULIC SYSTEM
IV. HYDRAULIC SYSTEM
Service Section
(A) PERFORMANCE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-3

a) One Pump Flow Test, Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-3
b) Hydraulic Test Data Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-4
c) Measuring the Main Pump's Stand-by Flow Rate . . . . . . . . . . . . . . . . . . . . . . . IV-S-5
d) LS Control Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-6
e) How to Test C3 Pressure of Boom Holding Valve . . . . . . . . . . . . . . . . . . . . . . . IV-S-7
(B) SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-9
a) Main Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-9
b) Gear Pump (P3, PP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-35
c) Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-39
d) Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-73
e) Pilot Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-105
f) Pilot Valve of Swing and Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-106
g) Travel Pilot Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-107
h) One-Two Way Change Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-113
IV-S-1
IV-S-2
(A) PERFORMANCE TEST

a) One Pump Flow Test Method
[Plumbing of hoses and flow
meter]
Hydraulic 1. Connect the P1 delivery
tank hose.
2. P2 delivery hose should be
directed to the tank.
4) 3. Plug the hoses at the control
2) valve sides of P1 and P2
hoses.
4. Swap the Pps and PLS sens-
ing lines.
(This hose-swapping is not
1) always necessary.)
To To
P2 Hydraulic Hydraulic
tank tank
P1 OUT
3)
1) Pump 1 pressure port
2) Pump 2 pressure port
IN 3) Pump 3 pressure port
4) Primary pilot pressure port
[Measurement]
(P) (CV) 1. Raise the engine speed to the maximum
rpm.
P 1 P 2 P 3 P P P PS P LS P LS P PS P 3 P2 P1 2. Gradurally close the flowmeter’s loading
valve and measure the flowrate and engine
rpm at each pressure point in the P-Q
curve.
3. Measure the pump flow 3 times.
Determine the averages and take them as
the final one.
Keep the oil temperature at 50 ± 5 °C (122
OUT ± 9°F) for the measurements.
[Test result]
IN (T) 1. One pump flow rate is just half of the two
pump flow.
(FM) 2. If needed, test the P2 pump flow as in the
same procedure.
(P ) : PumP
(CV) : Control Valve
(FM) : Flow Meter
(T) : Hydraulic Tank
: Plug
Note: As for “Two pump combined flow test”, refer to the previous WSM, code No.: 97899-61730.
IV-S-3
b) Hydraulic Test Data Sheet

HYDRAULIC TEST DATA SHEET
KX080-3, KX080-3α, KX080-3AB EXCAVATOR - FLOW TEST
CUSTOMER NAME: MODEL: HOURMETER:
SERVICING DEALER: SERIAL NUMBER: DATE:
PUMP FLOW TEST

-Warm hydraulic oil to 120F (50C) minimum
-Engine Lo-Idle: 1000~1100 RPM
-Pump flow tests are taken at 2000 engine RPM
-Engine Hi-Idle: 2000 RPM
-These specifications are for new machine
HYDRAULIC PUMP FLOW RATE Two Pump Combined Flow Test One Pump Flow Test (FYI)
Pump 1 and 2
Load sensing/Variable displacement Load pressure: Combined flow Load pressure Flow amount
(New Pump Test) ((P1+P2)/2 amount
Pump 1 & 2 0 PSI 38.0 GPM 140 PSI 19.0±1.3GPM

(WSM IV-M) (0 kgf/cm 2)
(144.01/min.) (10 kgf/cm2) (72±5LPM)
(WSM IV-M) (120kgf/cm 2)
(140.91/min.) (100 kgf/cm2) (70±5LPM)
(WSM IV-M) (250kgf/cm2) (40.01/min.) (200 kgf/cm2) (58±5LPM)
(WSM IV-M) (300kgf/cm 2)
(24.8/min.) (300 kgf/cm2) (33±5LPM)
Measuring the main pumps maximum flow rate: WSM page IV-S
Service port flow 1 and 2 Load Specifications Load Specifications
0 PSI 26.4 GPM 2133 PSI 21.7±1.3 GPM
Service port flow #1
(0 kgf/cm 2)
(100 l/min.) (150 kgf/cm2) (82±5 LPM)
0 PSI 17.6 GPM 2133 PSI 15.3±1.3GPM
Service port flow #2
(0 kgf/cm2) (66.6 l/min.) (150 kgf/cm2) (58±5LPM)
HYDRAULIC PUMP FLOW RATE Load Specification Load Specification

Pump 3 (Gear type) 0 PSI 17.6 GPM 2133 PSI 15.9±1.3 GPM
(WSM IV-M-4) (0 kgf/cm2) (67 l/min.) (150 kgf/cm2) (60±5 LPM)
Pump 4 (Gear type-Pilot circuit) 0 PSI 4.28 GPM 569 PSI 3.70±1.3 GPM
(WSM IV-M-4) (0 kgf/cm 2) (16 l/min.) (40 kgf/cm2) (14±2 LPM)
IV-S-4
c) Measuring the Main Pump’s Stand-by Flow Rate

Preparations are almost same as in pump’s Max. flow
rate.
1 ~ 5. Same as in pump’s Max. flowrate.
6. Disconnect hose PLS and attach plug (1/4) to

this hose’s end. Keep joint PLS (at the pump)
intact. (Place an oil pan to receive out-coming
oil.)
* This is because the pump’s swash plate is
fixed at its minimum tilt angle.
7 ~ 10. Same as in pump’s Max. flowrate.
Reference value: See the specifications
Q
LPM
N (RPM)
1000 2000
Engine Speed
IV-S-5
d) LS Control Pressure
The actual measurement of LS control differential pressure requires special equipment such as a dif-
ferential pressure instrument. General maintenance shops do not have such an expertise measuring
device. This section introduces a simple method that makes use of one of the LS functions, such as
the swing motion of an actual machine.
1. Place the machine on hard ground.
2. Warm up the machine to the oil temp. of 50 ± 5 °C
(122 ± 9 °F).
3. Raise up the engine speed at Max. rpm.
4. Measure the time for the constant boom swing function:
Right to left and left to right.
1)
Reference value: See the specifications
Machine condition: In case of boom swing speed test;

Refer to the Fig. in the left.
Boom raised, arm & bucket crowd without load.
Dozer-down on the ground.
5. Adjustment
2) 1) If actual measurement speed is slower than
specification, loosen the lock nut and screw in
the set screw.
2) If actual measurement speed is faster than
specification, loosen the lock nut and screw
back the set screw.
Note: Before loosening the nut, put alignment mark
on body, lock nut and set screw.
1) LS control valve
2) Set screw
(Swing cylinder speed)

KX080-3α/KX080-3AB Second
Left Right
6.8 ~ 8.2 7.0 ~ 8.4
(Cylinder full stroke)
IV-S-6
e. How to Test C3 Pressure of

Boom Holding Valve
1. Raise up LS main and b1 overload relief
pressure to 340 kgf/cm2 (33.2 MPa) 4836
psi.
Boom cylinder
RD809-6750Δ 2. Plumbing the hoses and pipes as shown in
Bore φ115 the diagram.
Rod φ65
Stroke 878
Cushion bearing (1) Plug
(2) Pressure gauge at warning sensor plug
(3) Remove plug and direct to drain. See photo.
(1) (4) Holding valve
(2)
B (4)
(3)
Dr c3
PL
A
(1)
15A
IV-S-7
IV-S-8
(B) SERVICING
a) Main Pump
1. Pump assy dismount
1. Disconnect the delivery hoses
2. Plug the joints.
3. Remove the suction hose from the pump.
4. Wind the nylon sling around the pump and

remove the mounting bolts.
5. Lift up the pump assy.
IV-S-9
6. The view after the pump was removed.
IV-S-10
2. Adaptor and joint

1) Fitting the adaptor
Place the adaptor in position as shown below.
2) Adaptor tightening torque

G1/4 size
24.5~29.4N.m (2.5~3.0kgf.m) 18.1~21.7ft.lbs
G3/8 size
37.2~42.1N.m (3.8~4.3kgf.m) 27.4~31.1ft.lbs
G1/2 size
58.8~63.7N.m (6.0~6.5kgf.m) 43.4~47.0ft.lbs
G3/4 size
117.6~127.4N.m (12.0~13.0kgf.m) 86.7~94.0
ft.lb
3) Bolt tightening torque: M16x1.5

196.1~225.6N.m(20.0~23.0kgf.m)144.6~166.4ft.lbs
(1) Pump assembly (piston)

(2) Bolt
(3) Pipe joint (LG4, 13/16U)
(4) Plug
(5) Adaptor
(6) Pipe joint (SG6, G6)
(7) Pipe joint (LG6, G4)
(8) Pipe joint (SG4, 1U)
(9) Plug
(12) Plug
(13) Flange (suction)
(14) O ring (1)(2)
(5)
(15) Bolt
(16) Pipe joint (L, G1/4-G1/4)
(17) O ring
(18) Pipe joint (SG2, 9/16U) (3)(4)
(19) Pipe joint (SG2, 9/16U)
(20) Straight pipe joint
(21) O ring
(6)(7)(8)(9) (10)(11)(12)
(16)(17)(18)
(20)(21) (19) (13)(14)(15)
IV-S-11
3. Disassembly and reassembly

P2 1) Outer view
Delivery port
P1
P2
P3
P3
P1
(1) Inlet port

(2) LS control valve
(1)
(2)
(1) (1) LS (Load sensing) control valve

(2) PC (Power control) valve
P2
P3
(2) P1
IV-S-12
P1
P1 P2
PLS
P2 P3
(1) Horse power control valve

(2) (2) Max. pressure sensing
(1) P1+P2
(3) Average pressure sensing
2
(3) (4) P3
(4)
Delivery port
P1
P1
P2
P3
P2
(1) Horse power control valve
(1)
(2) P3

(5) PLS port
(6) PPS port
(4)
(6)
IV-S-13
4. Remove gear pump

Bolt size: M10 x 22L
Wrench: 8 mm
Tightening torque:
44.1±4.4 N·m (32.5±3.2 ft·lbs) 4.5±0.45 kgf·m
(1) LS control valve.

(2) Section port for P3, Pp
(3) Delivery port of P3
(4) Horsepower sensing line of P3
(4)
(1)
(3) (2)
IV-S-14
5. Remove LS control valve

1) Remove the mounting bolts
Bolt size: M6 x16L
Wrench: 4 mm
Tightening torque:
12.65±1.3 N·m (9.3±1.0 ft·lbs) 1.3±0.13 kgf·m
2) LS control valve
1) 5 ports
1) Pump pressure sensing line
2) 2) HPC pilot line
3) HPC pilot line
3) 4) Pilot pump pressure after the fixed orifice
5) Pilot pump pressure before the fixed orifice
6) Pps port
4)
5)
3) Inner parts
IV-S-15
6. Remove horsepower control valve

1) Horsepower control valve punch the mating
mark before disassembling
2) Pull out the valve assy
3) Inner parts
4) Average pressure sensing puppet
IV-S-16
5) Max pump pressure selection check valve
6) Check valve for Pc bypass
IV-S-17
(1) 7. Servicing of PC valve

(PC valve: Power control valve)
Note:
Following pages instruct how to replace the PC
valve and relevant parts in the pump for
possible troubleshooting and/or flashing
contaminants.
Removing and readjusting are not
recommended by the original manufacturer;
follow the steps with care and at your own
expense.
(2)
P1 (1) PC valve
(2) LS control valve
P2
(1)
(2) P3
(3) Port block

(30) O-ring
(33) Spring
(36) Spring
(37) Spring seat
(40) Lock nut
(71) PC valve assy
IV-S-18
1) Put the alignment mark for reassembling work.

This alignment mark is vitally important for
reassembling of the PC valve assy.
Put the mark line on the port block, lock nut and
valve assy.
2) Loosen the lock-nut

* After loosening the nut, check to see if the
valve assembly (71) is not displaced
counterclockwise.
* If the valve assembly is displaced, turn it
clockwise and back into position.
3) Checking the valve assembly height

Using a depth gauge, take measurement from
the port block (3) to the valve assembly (71) and
record it.
4) Removal of the valve assembly
IV-S-19
5) Removal of the valve assembly

* Loosen the screw to draw the valve assembly
(71).
6) Removal of the spring seat

Use an antenna-type magnet.
7) Removal of the springs

Use an antenna-type magnet.
8) Removal of the spring seat

Clean up the spring seat and the spring (36) and
fit them together.
IV-S-20
9) Checking the spring seat

Clean up the spring (33) and fit it to the spring
seat.
10) Fitting the spring seat and the springs (1)

Fit the spring seat and the springs (33 and 36)
into the port block (3).
11) Fitting the spring seat and the springs

Make sure the spring seat comes deep
enough. (Press the spring seat with a finger
and make sure the springs are compressed.)
12) Replacing the valve assembly's O-ring

Remove the O-ring (30) and clean up the valve
assembly. Apply grease to a new O-ring (30)
and fit it to the valve assembly.
IV-S-21
13) Fitting the valve assembly

Fit the valve assembly to the port block.
14) Readjusting the valve assembly height

Using the depth gauge, readjust the height of
the valve assembly from the port block (3) to its
original level (measurement in Step 5 above).
15) Checking the mark

(1) Temporarily apply the nut (40).
(2) Using the marking tool, make sure that the
valve assembly (71) is in its original
position and that the marking (made in
Step 3 above) on the port block (3) is
aligned.
* If it is off of the position, turn the valve

assembly clockwise or counterclockwise to
get it in alignment with the marking.
16) Tightening the nut

Using a torque wrench, tighten up the nut.
Lock nut M30
* Tightening torque: 68.6 ± 6.9 N.m (7.0 ± 0.7
kgf.m, 50.6 ± 5 ft.lbs)
17) Checking
With the marking tool, make sure the valve
assembly (71) is not displaced.
18) Checking for oil leak

Test-run the machine and check for oil leak.
IV-S-22
8. How to Replace the Orifice

Following pages instruct how to replace the ori-
fice in the pump for machines which are not
renewed yet and/or future troubleshooting. The
B A new type of orifice is installed from S/N 10962
and above of KX080-3 and minor change mod-
C els.
1) Necessary Parts and Location

(11)
Parts code Parts Name Q'ty
A RD809-77482 Orifice 1
B RD809-77490 O-ring 1
C RD809-77510 O-ring 1
2) Tools required
(1) Spanner (32 mm)
(8) (7) (2) Ratchet wrench
(10) (3) Socket (14mm)
(4) Hexagon wrench socket (5mm)
(1) (3) (5) Hexagon wrench (5mm)
(6) Magnet
(7) Torque wrench CL180N
(9) (5) (4) (8) Torque wrench QL90N
(9) Special tool for orifice attachment
(10) Plug (5/8)
(2)
(6)
3) Removing the left cover

1) Remove the bolts (M10, 2 spots)
(A) Bolt position
(A)
Tools required
(2) Ratchet wrench
(3) 14mm Socket
2) Remove the left cover
IV-S-23
(B) 4) Removing the hydraulic hose

1) Vacuum the hydraulic line, with the vacuum
pump.
2) Remove the delivery hose (B) at the main

pump.
Attach plugs after removing the hose to avoid
oil leak.
Tools required:
(1) Spanner (32)
5) Removing the plug

1) Remove the plug at the main pump.
Tools required:
(5) Hexagon wrench (5mm)
6) Removing the spacer

Tools required:
(6) Magnet
7) Insert the special tool

Rotate the special tool and insert it to the screw
part of the orifice.
Tools required:
(4) Special tool
IV-S-24
• How the special tool was made:

(C) Insert the stud bolt (B) to the pipe (C) and
crimped.
(C) Pipe
(D) Stud bolt (M3 pitch 0.5)
(D)
8) Pull out the orifice
Tools required:
(9) Special tool
(C) 9) Attach O-rings to the new orifice

(B) (A) Orifice (RD809-77482)
(B) O-ring (RD809-77490)
(C) O-ring (RD809-77510)
(A)
10) Insert the special tool into the new orifice
IV-S-25
11) Insert the new orifice to the main pump
12) Insert the spacer

Note: Pay attention to the inserting direction of
spacer.
13) Install the plug and hose

1) Attach the plug.
Tightening torque: 48.0 ~ 56 N·m (4.9 ~ 5.7
kgf·m) 35.4 to 41.2 ft·lbf
Tools required:
(8) Torque wrench QL90N
2) Connect the delivery hose

Tightening torque: 106.0 ~ 129.4 N·m (10.8 ~
13.2 kgf·m) 78.04 to 95.44 ft·lbf
Tools required:
(7) Torque wrench CL180N
IV-S-26
9. Remove the valve block assy

Bolt size: M16 x 45L
Wrench:
Tightening torque:
196±2.0 N·m (145±1 ft·lbs) 20±0.2 kgf·m
2) Rear view of the valve block
3) Separate the valve block

(1)Gasket
(2)Knock pins
(1)
(2)
4) View from the top

(3)Valve plate
(4)Control plate
(5)Horsepower control pin
(4)
(5)
(3)
IV-S-27
5) Control pin
6) Control pin body
7) Off the valve plate
8) Off the spacer ring
IV-S-28
9) Hydraulic pump casing was modified from

KX080-3 S/N12176 and above.
The picture in the disassembling procedure is
the old one.
(1)
(2)
(1) View A
(2) Additional bolt hole (3)
(3) Additional bolt hole
New gasket
(Old) (Current)
RD809-77152 RD809-77541
t=0.45 t=0.38
IV-S-29
10. Removal of the cylinder block assy

1) Remove the gasket.
2) Remove the control spring assy.
3) Springs
(4)
(1) Inner control spring
(2) Outer control spring
(3) Assist spring
(4) Spring seat
(4)
(1)
(2) (3)
4) Remove the cylinder block assy.
5) Swash plate and cylinder block
IV-S-30
(4)
6) Inner parts of the cylinder block
(1) Pistons
(2) Cylinder
(3) Cone
(4) Springs
(2)
(1)
(3)
7) Springs
8) Piston
9) Spring seat
IV-S-31
11. Remove the main shaft

Bolt size: M6
Wrench: 4mm
Tightening torque:
12.65±1.3 N·m (9.3±1.0 ft·lbs) 1.3±0.13 kgf·m
This picture shows old pump.

The new pump does not have the mounting bolt.
2) Punch out the main shaft.
3) Remove the shaft and the flange.
4) Remove the shaft.
IV-S-32
5) Remove the snap ring.
6) Punch out the bearing.
7) Disassembled parts
(1) Main shaft

(2) Bearing
(3) Snap ring
(1)
(3)
(2)
IV-S-33
12. Reassembly
1) Install the snap ring
2) Install the flange
(1) Knock pin
3) Tighten the flange bolt
This picture shows old pump.

New pump does not have the mounting bolt.
4) Assemble the pistons and springs.

Each piston should be in the original cylinder
barrel.
One piston and one spring should be
remained for remembrance as a mark.
5) Assemble and inner parts and gasket.

The reassembling procedure reverses to the
disassembling.
(Photo shown the one of the previous model.)
IV-S-34
b) Gear Pump (P3, PP)

Disassemble and reassemble
(1)
1. Outer view
(1) Output shaft

(3) PP delivery port
(3) (2)
2. Remove mounting bolts.
Bolt: M12 × 1.5
Tightening torque:
106.9±10.7 N·m (78.9±7.9 ft·lbs) 10.9±1.1kgf·m
L-wrench: ¥ 10 mm
3. Remove the end cover.
(4) Knock pin

(5) Delivery chamber
(6) Suction chamber
(7) Drive gear
(8) Driven gear
Gear width = 9.35 mm (0.368 in.)
Important:
Gear pump is not recommended to be disassem-
bled and reassembled EXCEPT specific reasons.
The machine owner must take full responsibility for
the original manufacturers do not guarantee.
IV-S-35
(9) (5) Delivery chamber

(5)
(6) Suction chamber
(7) Drive gear
(8) Driven gear
(9) PP delivery passage
(8)
(6) (7)
(8)
(7)
3. Remove the pilot pump gear set.
(10) Pressure plate

Bronze metal surfaces to be inward.
(10)
(11) Bronze metal surface
(12) Delivery port side
(12)
(11)
IV-S-36
4. Separate the center housing.

(2)
(1) PP delivery passage
(2) Drive gear
(3) Driven gear
(4) Delivery pressure side
(4) (5) Suction side
(5) (6) Pilot pump passage
(3)
(1)
(6)
5. P3 gears assembly
Gear width = 43.60 mm
(7) Pressure plates
(7)
IV-S-37
6. Check the pump flange for scratch of gear.
7. Oil passage
(3) (1) PP delivery port

(2) Suction chamber
(3) Drain for ports
(4) PP port
(1) (2)
(4)
8. Pump flange
(8) PP delivery port
(8)
9. Reassembling
(9) PP internal passage

(10) PP port
• Before tightening the mounting bolts, securely

check to see if the pressure plates and the
knock pins are correctly installed.
• Gear pump should be replaced as pump
(9) (10) assembly if it is failed; the pump delivery
performance however can’t be assured.
IV-S-38
c) Control Valve
1. Adaptor and joint
1) Fitting the valve assembly (control), bracket (1,
valve), bracket (2, valve) and bracket (3, valve)
Set them up with the following steps.
a) Fit the three brackets (1, valve) (2, valve) and
(3, valve) onto the valve assembly (control).
Temporarily tighten the bolts.
b) Place the valve assembly (control) on the
base (valve).
c) Tighten up the bolts (1) specified in the figure
to fix the bracket (3, valve) onto the base
(valve).
d) Tighten up the bolts (2) specified in the figure
to fix the valve assembly (control) to the
bracket (3, valve).
e) Tighten up the bolts (3) specified in the figure
to fix the brackets (1, valve) and (2, valve)
onto the base (valve).
f) Tighten up the bolts (4) as shown at left to fix
the valve assembly (control).
2) Bolt tightening torque

77.5~90.2N.m(7.9~9.2kgf.m)57.2~66.5ft.lbs
3) Fitting the adaptor

Fit the adaptor referring to the instructions on
the next page.
(1) (2) (A) (Machine front)

L: (Left)
R: (Right)
D: (Down)
Lo: (LOW)
(a) B: (Backward)
L R (b) C: (Crowded)
(3) U: (Up)
D U (c)
Lo Hi (d) Hi: (HIGH)
(e) F: (Forward)
F
Du: (Dump)
Bo (f)
B F (g) (1) Bracket (1, valve)
(2) Bolt
(h) (3) Base (valve)
(4) Bracket (3, valve)
(i)
(5) Bolt
C Du (4) (5) (j) (6) Valve assembly (control)
C Du (k) (7) Bolt
Lo Hi (l) (8) Bracket (2, valve)
D U (m) (9) Bolt
(n) (a) (P3 confluence)
L R (o) (b) (Swivel)
(c) (Dozer)
(d) (SP2)
(e) (P3, T2)
(f) (Travel left)
(A) (g) (Travel right)
(h) (P1, P2)
(6)(7) (i) (T1)
(j) (Arm)
(k) (Bucket)
(l) (SP1)
(m) (Boom)
(n) (PLS)
(8) (9) (o) (Swing)
IV-S-39

G1/4 size
24.5~29.4N.m(2.5~3.0kgf.m)18.1~21.7ft.lbs
G3/8 size
37.2~42.1N.m(3.8~4.3kgf.m)27.4~31.1ft.lbs
G1/2 size
58.8~63.7N.m(6.0~6.5kgf.m)43.4~47.0ft.lbs
G3/4 size
117.6~127.4N.m(12.0~13.0kgf.m86.7~94.0ft.lbs
G1-1/4 size
220.5~230.3N.m(22.5~23.5kgf.m)
162.6~169.9ft.lbs
7/8-14UNF size
55.9~60.8N.m(5.7~6.2kgf.m)41.2~44.8ft.lbs
5) Tightening torque of the adaptor of port T1 Pipe

joint (SG12, G12) Valve assembly (return) Pipe
joint (LG12, G12)
G1-1/4 size
220.5~230.3N.m(22.5~23.5kgf.m)
162.6~169.9ft.lbs
G1-1/4 size
85.0~100.0N.m(8.7~10.2kgf.m)62.7~73.8ft.lbs
G1-1/4 size
(A)
85.0~100.0N.m(8.7~10.2kgf.m)62.7~73.8ft.lbs
(1)
6) Fitting direction of the valve assembly (return)

(RD809-6351Δ)
Fit the assembly in position.
(2)
(A) Adaptor at port T1

(B) Fitting direction of the valve assembly (return)
(a) (Control valve side)

(b) (Return pipe side)
(c) (Control valve side)

(3) (Tightening torque)
(a) 85.0~100.0N.m
(8.7~10.2kgf.m)62.7~73.8ft.lbs
(2) Valve assembly (return)
(Tightening torque)
(B) 85.0~100.0N.m
(b) (8.7~10.2kgf.m)62.7~73.8ft.lbs
(Tightening torque)
220.5~230.3N.m(22.5~23.5kgf.m)
162.6~169.9ft.lbs
(4) Set up the assembly with the outer arrow mark pointing
(4) upward.
(5) Look into the inside and make sure the nut head faces
toward the control valve.
(5)
(c)
IV-S-40
1. Fitting the valve assembly

Fit the assembly in position.
Tightening torque:
24.5~29.4N·m (2.5~3.0kgf·m) 18.1~21.7ft·lbs
(26)
(C/V)
(2) (25)
(3)
(4)
(1) (5) (6) (27) (28) (29)
(39) (38) (37) (36)
(7)
(22) (8)
(9) (35) (41)
(10) (42)
(57) (43)
(11)
(23) (58) (44)
(12) (59)
(44)
(12)
(30) (40) (45)
(13) (31)
(46)
(47)
(14) (48)
(49)
(24)
(32)
(15)
(50)
(16) (51)
(33)
(52)
(17) (53)
(34)
(19) (18)
(55) (54)
(20)
(21) (56)
(1) Pipe joint (15) Pipe joint (26) Groove (40)Pipe joint
(2) Pipe joint Pipe joint (27) Pipe joint (41)Elbow pipe joint
(3) O ring (16) Pipe joint O ring (42)Pipe joint
(4) Valve assembly (check) Pipe joint Pipe joint Pipe joint
Pipe joint (17) Pipe joint Adaptor (43)O ring
(5) Pipe joint Pipe joint O ring (44)Pipe joint
Pipe joint (18) Pipe joint Pipe joint Pipe joint
O ring (19) Pipe joint O ring Pipe joint
(6) Pipe joint Pipe joint (28) Pipe joint (45)O ring
Pipe joint (20) Pipe joint Pipe joint (46)Pipe joint
(7) Pipe joint (21) Pipe joint (29) Pipe joint Pipe joint
Pipe joint Pipe joint O ring Pipe joint
(8) O ring O ring Switch (47)Pipe joint
(9) Pipe joint (22) [PS bypass] O ring Pipe joint
Pipe joint (23) [Swivel] (left) (30) (Left forward) (48)Pipe joint
(10) Pipe joint [Dozer] (bottom) (31) (Right forward) (49)Pipe joint
Pipe joint [S/P2] (low) (32) (Rod) (50)Pipe joint
(11) Pipe joint [Confluence valve] (Rod) Pipe joint
Pipe joint [Travel] (left backward) (33)(Bottom) (51)Pipe joint
(12) Pipe joint [Travel] (right backward) (34)(Right) (52)Pipe joint
Pipe joint [Travel independent valve (35)Pipe joint Pipe joint
O ring (24) [Arm] (bottom) O ring (53)Pipe joint
Adaptor [Bucket] (bottom) Valve assembly (check) Pipe joint
O ring [S/P] (low) Pipe joint (54)Pipe joint
(13) Pipe joint [Boom] (rod) (36) Pipe joint (55)Pipe joint
Pipe joint [Swing] (left) (37) Pipe joint (56)Pipe joint
(14) Pipe joint (25) Set up the assembly with (38) Pipe joint (57) (Right)
Valve assembly (return) the groove toward the C/V (39) Pipe joint (58) (Rod)
Pipe joint as shown at left. Pipe join (59) (High)
IV-S-41
(a)
(b) (n)
(c) (o)
(d) (p)
(e)
(f) (q)
WSM KX080-3AB Service
(g) (r)
(h)
(s)
(i)
(t)
(j)
(u)
(k)
(v)
(l)
(m) (w)
IV-S-42
(a) [PS bypass]
(b) [Swivel] (left)
(c) [Dozer] (bottom)
(d) [S/P2] (low)
(e) [Confluence valve]
(f) [Travel] (left backward)
(g) [Travel] (right backward)
(h) [Travel independent valve]
(i) [Arm] (bottom)
(j) [Bucket] (bottom)
(k) [S/P] (low)
(l) [Boom] (rod)
(m) [Swing] (left)
(n) (Right)
(o) (Rod)
(p) (HIGH)
(q) (Left forward)
(r) (Right forward)
(s) (Rod)
(t) (Rod)
(u) (HIGH)
(v) (Bottom)
(w) (Right)
IV HYDRAULIC SYSTEM
IV-S-43

1. EU-standard version
(1) Swing section
(1)
2. KTC-Angle blade version
KTC-ANGLE BLADE VERSION

(2) Angle blade section
(2)
KTC-Angle blade version

(3) Overload relief valve
(2)
(3)
IV-S-44
KTC-Angle blade version

(4) Anti-void valve
(4)
(3)
3. Travel straight section
4. Secondary pilot control lines
5. PPS control line

(5) PPS control line
(5)
IV-S-45
6. Control valve assy
7. Hose relay block

(6) Relay block
(6)
8. Hose relay block for primary pilot control line
9. Change valve (Unload valve)

(7) Pilot system unload solenoid valve
(8) Travel high-low change solenoid
(8)
(7)
IV-S-46
10. S/P 2 solenoid valve

(1)
(2) (1) S/P 2 solenoid valve, R
(2) S/P 2 solenoid valve, L
(3) Pilot control unload solenoid valve
(4) Travel hi-low solenoid valve
(4)
(3)
11. Swivel motor and return lines
IV-S-47

(a) Valve assy disassembly
1. Lift down the control valve with the crane.
2. Lifting eye-bolt
M10x1.5
3. View from the top
PLS 4. View from the side
PF1 PP3 PPS PF2 PP2
5. Swing shut valve portion

(1) Shut valve for swing function
(2) Overload relief valve for two-piece boom type or
angle blade type.
(1)
(2)
IV-S-48
6. Anti-cavitation valve portion

(3) Anti-cavitation valve
(4) Overload relief valve for two-piece boom type or
angle blade type.
(3)
(4)
7. Around the unload valve

(1) LS main relief valve
(2) LS unload valve
(3) Travel function main relief valve
(1)
(3) (2)
8. Dozer, swivel section area

PP4: Pilot valve primary pressure is applied.
Screen and orifice are inside
Pbu1:
PB1: P3 pump oil partly joins to boom up function as
confluence flow.
PP4
Dr2
9. Around the AI pressure switch

PP4: Pilot valve primary pressure is applied.
PAI: AI pressure switch is installed
PAI
PP1
PLS 10. The side view
PF1 PP3 PPS PF2 PP2
IV-S-49
11. The side view, pilot port
PF1 12. The side view, mono block pilot port

PF1: Pilot valve primary pressure is applied.
PP3: AI pressure switch is installed
(4) Boom up confluence flow inlet from P3
PP3
(4)
13. The side view

Pilot port and S/P2 section
PP2: Pilot primary pressure for travel straight control
PF2: From PF1
S/P 2: Service port 2 section
PF2 PP2 SP 2
14. P3 confluence section

(1) P3 confluence section
(1)
15. PPS Port
(1)
IV-S-50
16. Screen and orifice (PP2)

PP2: Pilot primary pressure
PF2: From PF1
PF2 PP2 SP 2
17. LS main relief valve inside

(2) LS unload valve
(2)
(1)
16. P3 bypass spool
19. Compensation spool in the swing section
(1) Pressure compensation spool

(2) High pressure selection poppet
(2) (1)
20. Load check poppet and spring
IV-S-51
21. Swing section and end port plate

(Standard-version)
22. Swing section and boom section (Mono-

block)
23. Arm section (Mono-block) and inlet section

(2) (Travel independent valve)
(1) AI pressure sensing line
(2) Thread for valve assy lifting
(1)
24. Inlet section (Travel independent valve) and

travel R section

(2) PP2 internal line
(3) Travel straight sensing line
(3)
(2)
(1)

(1) (2) (3)
IV-S-52
25. Travel R and travel L section

26. Travel L and P3 inlet section
(2) (2)
27. P3 inlet section and SP2 section
IV-S-53
28. SP2 section and dozer section
29. Dozer section and swivel section
(4)
30. Swivel section and P3 confluence section
(5)
Pbu1
(9) (6)
(1) P3 neutral line
(2) Flow throught bypass spool
(3) Push check poppet
(3) (8) (4) To boom up confluence
(5) Check poppet
(1) (6) Boom-up pilot secondary line
(2) (7) PP1 from pilot primary line
(8) AI pressure switch
(9) Straight pipe joint, ø: 4.0 orifice
(7)
IV-S-54
(b) Each section and the inner parts

1. Inlet section (P1,P2) (Travel independent
valve)
1) Outer view
2) The other side

M
L-wrench = 5mm
4) Inner parts
(1) (1) Valve housing
(4) (2) Spool
(5)
(4) Valve body
(5) Cap
(3)
(3) (2)
IV-S-55
(6) Spool
(7) Spring retainer
(8) Spring
(8)
(7)
(4)
(6)
5) Oil passage
(9) PP2 sensing line
(10) To tank
(10)
(9)
• Tracing the PP2 line
• Tracing the tank line
IV-S-56
2. Travel R section
1) Outer view
2) Other side
3) Inner parts
4) Spiral notch-type drain groove of the spool
IV-S-57
3. Travel L section
1) Outer view
2) Other side
3) Inner parts
IV-S-58
4. P3 inlet section (P3 confluence)

1) Outer view
2) Other side
(2) 3) Inner parts

(1) (6) (1) Valve housing
(3)
(2) Check poppet
(3) P3 main relief valve: a4
(4) Spring
(5) Spool
(6) Valve body
(5)
(4)
IV-S-59
4) P3 confluence spool
(7) Spool
(8) Spring retainer
(9) Spring
PPS: Pilot primary pressure
5) Pilot port
PP2: Pilot sensing line for travel straight function

PF2: Pilot sensing line for P3 confluence function
(4) (5) 6) Inner parts

(1) Valve body
(2) Spool
(3) Spring retainer
(4) Spring
(5) Cap plug
(3)
(6) PP2 plug (Orifice and screen)
(6)
(2)
(1)
IV-S-60
7) Orifice (PP2)
8) Screen (PP2)
9) Two different parts

(1) Pilot spool for travel independent valve
(2) Pilot spool for P3 confluence valve
(1) (2)
(3) spring for travel independent valve

(4) spring for P3 confluence valve
(3)
(4)
IV-S-61
5. SP 2 valve section
1) Outer view
2) Other side
3) Adjusting bolt of SP2 spool
4) Inner parts
IV-S-62
6. Dozer section
1) Outer view
(1) Dozer section

(2) Check poppet inside
(3) Swivel section
(2)
(3) (1)
2) Mating surfaces of dozer and swivel section

(4) AI-pressure sensing line
(4)
3) Inner parts
IV-S-63
7. Swivel section
1) Outer view
2) Other side
3) Inner parts
IV-S-64
(4)
8. P3 bypass valve
(1) P3 bypass valve section
(2) Tie-rod nut, M8x1.25
Nut tightening torque:
26.5~29.4 N·m (2.7~3.0 kgf·m) 19.5~21.7 ft·lbs
(3) PB1, P3 by-pass to boom up. Pipe joint (S, G3/8-3/8)
ø4.0
(3) (4) Pbu1 To control boom-up main spool, connected
with Pb4
(5) PP1 from relay block
(6) AI-pressure switch port
(2) (7)Drain 2 to directly tank
(5)
(6) (1)
1) Outer view
2) Other side
(3)
3) Inner parts
(1) (1) Spool
(2) (2) Spring
(4) (5) (3) Spring retainer
(4) Check poppet
(5) PP1
IV-S-65
PF1
9. Mono-block valve assy
1) Outer view
PF1: To PF2 for activating P3 confluence valve
PP3: pilot primary pressure for AI sensing
PP3
(3) (4) (5) (6)

2) Other side
PL3 LS main relief valve Unload valve
(2) LS unload valve
(3) Arm section
(1) (4) Bucket section
(5) S/P 1 section
(6) Boom section
(2)
3) Boom valve section to swing section
PLS
4) Arm valve section mating face
(7) Return to tank
(7)
IV-S-66
5) Inner parts
(2) LS unload valve
(3) LS unload valve spool
(4) PP3
(2)
(4) (3) (1)
6) Inner parts Arm section

(1) Main spool
(2) Pressure compensation spool
(3) Check valve
(3)
(3)
(1) (2)
7) Side view
(4) LS unload valve
(4)
8) Side view, PP3
(4) PP3
(4)
IV-S-67
9) Plug with orifice (PLs)
IV-S-68
10. Swing valve section

(1)
1) Outer view
(1) Shut-off valve
(2) 2) Other side
(2) Anti-cavitation valve
3) Inner parts
4) Anti-void valve
(1) Anti-viod valve (Anti-cavitation valve)

(2) Spool ID mark
(1)
(2)
IV-S-69
11. End plate

1) Tie rod
2) Tightening method of tie rod

Tie-rod nut: M8x1.25
Tie rod nut tightening torque:

26.5~29.4 N·m (2.7~3.0kgf·m) 19.5~21.7 ft·lbs
12. PLS port, screen and orifice

(1) PLS port
(2) Screen and orifice
13. Pressure compensation spool for

mono-block section
IV-S-70
Tightening torque
123.55 ±17.65 N.m
(8 locations)
Section B-B
(1)
(2)
ID Part No.
Tightening torque
Tightening torque No. Binary identification process 2 under-
digit
(2 locations)
Identification of the compensation spool
Section C-C Section L-L

(1) Arm crowd
(2) Arm extend (Check valve block)
IV-S-71
14. Pressure compensation spool for

swing, angle blade and 2P-boom
15. Check valve for arm section

(Arm regeneration function is deleted from
minor change)
IV-S-72
WSM KX080-3AB Service IV Hydraulic system
d) Travel Motor
SGM-04D-S-09KT (Mitsubishi HI)
1. Disassembling
1. First of all, clean up the outer surface of the
(3) travel unit. In reassembling, be careful to install
the parts back in their original positions. For this
purpose, it is highly advisable to take notes of
the original positions of parts before and during
disassembling.
2. Disconnect the drain plug to let out the lube oil.

The SGM-04D travel unit has an oil capacity of
1.35 liters. Place the travel unit on a flat and
(1) clean floor.
(2)
3. Disconnect the relief valve (1) from the each

side.
TIP
(1) First disconnect the relief valve (1). It facilitates
removing the right bolts (2) and remove the
motor cover.
CAUTION
Be careful not to drop and damage the valve
plate. The valve plate is located on the inner
side face of the motor cover.
TIP
Slightly lift the motor cover and insert two
bladed screwdrivers between the cover and
the casing. Gently pry to detach the motor
cover in an easy way. (Be careful not to
damage the O-ring on the mating surfaces.)
4. Remove the eight bolts (2) and motor cover (3).
(4)
IV-S-73
5. Place the motor cover (3) on the wooden blocks

(5).
(5)
(3)
6. Detach the backup ring (6) and O-ring (7) from

the relief valve (1).
(6) (7)
WARNING
(8) The cover (8) is strongly spring-loaded. For
added safety and protection against damage,
pay special attention to loosening the cover.
Take the following procedure.
7. Detach the cover (8) from the motor cover.
8. Remove the spring (9), pusher (10) and spool

(11) (10) (9) (11) from the motor cover. These parts are
located below the cover (8).
IV-S-74
9. Disconnect the plug (12) from the motor cover

top.
(12)
10. Remove the spring (13) and spool (14) from

the motor cover. These parts are located
below the plug (12).
(13) (14) (12)
11. Detach the two plugs (15).
(15)
12. Take the O-ring (16) from each plug. Remove

the steel balls (17) from the motor cover.
(16) (17)
IV-S-75
13. Disconnect the plug (18) from the motor cover.
(18)
14. Remove the spring (15) and poppet (20) of the

(19) plug. Take the O-ring (21) from the plug (18).
(18)
(20) (21)
15. Put the motor cover upside down. Detach the

valve plate (22) from the motor cover.
(22)
16. Remove the bearing (23) as required.
(23)
IV-S-76
17. Remove the three O-rings (24 and 25) from the
(24) casing.
(25)
(24)
18. Remove the brake piston (26) of the casing.

Blow air through Point A, and the brake piston
will flow out of the casing.
(A) (26)
CAUTION
The brake piston may pop out when the air

blows and causes you get injured. Put a
protective cover or the like over the brake
piston.
19. Remove the O-rings (27 and 28) and backup

rings (29 and 30) from the brake piston.
(29)
(30)
(27) (28)
IV-S-77
20. Using a wire or magnet, remove the two

friction discs (31) and two steel plates (32) out
of the body casing. Keep the cylinder barrel
still in place.
(31)
(32)
(31) (32)
21. Place the travel unit on a wooden block as

shown below. set a wooden wedge to prevent
the unit from rolling. Remove the cylinder
barrel assembly (33) out of the body casing.
(33)
IV-S-78
22. Before removing the retainer (34), piston

assembly (35) and cylinder barrel (36), it is
highly advisable to take note of their original
positions. They must be placed back to their
specified original positions when
reassembling.
23. Detach the retainer (34) and piston assembly

(34) (35) from the cylinder barrel (36). Separate the
piston assembly from the retainer.
(35)
(36)
24. Remove the retainer ball (37) out of the

(37) cylinder barrel.
25. Pull the three pins (38) out of the cylinder

barrel.
(38)
IV-S-79
WARNING
The plate (39) is strongly spring-loaded. For
added safety and protection against damage,
hold the spring’s compressive force with a
press while disassembling the cylinder barrel.
26. Using a proper-diameter tool, apply a slight

(39) compressive force onto the plate (39) on the
press. Remove the snap ring (40). Detach the
plate (39), spring (41) and plate (42) from the
cylinder barrel (36).
(39)
(42)
(41)
(39)
(40)
(36)
IV-S-80
27. Remove the cam (swash plate) (43) from the

body casing.
(43)
(43)
28. Remove the two steel balls (44) and piston

(45) out of the body casing. Then remove the
(44) (45) spring (46) from the bottom of the piston.
(46)
(46) (45) (44)
IV-S-81
29. Place the travel unit on a wooden block.

1) 47
Be sure never to place the travel unit directly
on a flat ground because otherwise the shaft
may get damaged. Remove the three drain
48 plugs and snap ring (47).
(47)
1) Drain plug
2) Shaft
2)
30. Using a plastic hammer, gently tap the cover

(49) until it comes deep down to the bottom of
gear casing (50).
(49)
TIP
With the used travel motor, the cover (49) is
been pressed toward the outlet and against the
snap ring (47). Tap the cover and ease the snap
ring (47). This action is also helpful in inserting
smoothly the shim that is used to remove the
snap ring (47).
(50)
31. Insert the shim (0.1-0.3 mm 0.004~0.012 in.

thick), cut in rectangles, in between the gear
casing (50) and snap ring (47).
(47)
3) Shim
TIP
(50) If the shim is difficult to insert, try the following
steps.
3) * Tap the cover with a hammer and find out
where to insert the shim.
* Carefully look around to find out an easy
shim-in spot. Insert the shim first and then
slide it close to the snap ring end face.
IV-S-82
32. With the shim in place, lift the snap ring end
face with a needle to remove the snap ring
(47).
(47)
33. Apply the two eyebolts diagonally in the drain

1) holes of cover (49). With a crane, pull the
eyebolts and detach the cover. Be careful not
to allow the unit to go up and drop. Or pass a
lever through the eyebolts to remove the
G3/8 cover.
1) Eyebolts applied
2) Reference drawing
3) * Lifting with a crane
4) Cover
5) * Prying with a lever
6) Lever
2)
3)
4)
5)
6)
4)
IV-S-83
34. Remove the O-ring (48) from the cover (49).
7) Drain plug
(48)
(47) (48)
(49)
35. Remove the three bolts (51) and thrust plate

(52)
(51)
(52)
IV-S-84
36. Remove the sun gear (53), three planetary

(53) gears (54) and three bearings (55)
(55)
54
(53)
37. Remove the carrier (56)
(56)
38. When necessary, remove the three inner races

(55) (54) (57) from the carrier shaft.
(56)
(57)
IV-S-85
39. Remove the sun gear (58)
(58)
40. Remove the four bolts (59) and thrust plate

(59) (60)
(60)
41. Remove the four planetary gears (61), four

bearings (62), four bushings (63) and four
(61) plates (64) The plates (64) are located in the
back.
(62)
(63)
(64)
(61) (62) (63) (64)
IV-S-86
42. Remove the bolt (65) and washer (66)
(65)
(66)
43. Using a magnet, pull out the pin (67). If it is

difficult, take the following steps.
1) Cover the screw hole with adhesive tape
(68) and magnet plate.
(67)
2) Make a hole in the pin (67).
3) Cut threads in the hole of pin (67).
4) Drive a bolt halfway into the threaded hole.
Hold the bolt and pull out the pin.
44. Remove the ring nut (68) out of the body

casing.
a) a) Cover plate
45. Using a crane, detach the gear casing (50)

from the body casing.
(50)
46. Remove one angular bearing (69) from the

gear casing.
(69)
IV-S-87
47. Place the gear casing upside down. Remove

one floating seal (70) and the other angular
bearing (71) from the gear casing.
(70)
(71)
48. Remove the other floating seal (72) from the

(74) body casing (73). Take the shaft (74) and
(75) bearing (75) out of the body casing. To do this,
tap them in the arrow direction in the photo
(72)
using a plastic hammer and appropriate tool.
(73)
49. When necessary, take the bearing (75) out of

the body casing. Remove the oil seal (76) out
of the body casing.
(75)
(76)
50. When necessary, detach the bearing (75) from

the shaft (74).
(74)
(75)
Now the travel unit has been successfully

disassembled.
IV-S-88
2. Reassembling
51. Before reassembling, make sure all the parts
are clean and free of earth, sand and dust.
Check all the O-rings, backup rings and oil
seals, used for the travel unit, for anything
unusual. If any of them is unusual, replace it
with new one. Do not reuse the used floating
seal. Be sure to replace it with new one. Place
the body casing on a clean sheet spread on a
flat floor.
52. Attach the oil seal on the body casing. Install

(75) the bearing (75) onto the shaft (74). Set up the
(74)
shaft (74) in the body casing.
(75)
53. Place the body casing, with its shaft side

downward, on a wooden block or other
appropriate tool. Do not place the body casing
directly on the flat surface because otherwise
the shaft may get damaged.
1) Shaft
1)
IV-S-89
CAUTION
Before installing the floating seal, clean up the
O-ring (rubber-made) and seal ring
(metallic) and let them dry up. With the seal
in place, apply SAE30 engine oil or 80W-90
gear oil over the seal ring contact surface.
54. Using the “floating seal setup tool”, secure the

floating seal (72) to the body casing.
55. Apply fresh SAE30 engine oil or 80W-90 gear

oil over the contact surface (flat) of the seal
(72) ring (metallic).
56. Attach one angular bearing (69) in the gear

casing.
(69)
IV-S-90
57. Place the gear casing upside down as shown

below. Attach the other angular bearing (71) in
(71) the gear casing.
CAUTION
Before installing the floating seal, clean up the
O-ring (rubber-made) and seal ring (metallic)
and let them dry up. With the seal in place,
apply SAE30 engine oil or 80W-90 gear oil over
the seal ring contact surface.
58. Using the “floating seal setup tool”, secure the

other floating seal (70) to the body casing.
Then apply fresh SAE30 engine oil or 80W-90
gear oil over the contact surface (flat) of the
seal ring (metallic).
CAUTION
(70) In joining the two parts, be careful not to get
the floating seal scratched and otherwise
damaged.
59. Using a crane, lift the gear casing (50) over the
(73) body casing (73). Attach the gear casing onto
the body casing (73).
(50)
IV-S-91
TIP
With the ring gear placed on the body casing,
there is a clearance between them. This is
normal because of the function of the floating
seal. This clearance can be filled by applying
the ring nut (68).
60. In the following procedure, make a preload

adjustment for the bearings (69 and 71).
a) Tighten the ring nut (68) enough to get rid
of any minor gaps between the body
casing, two gearings, gear casing and ring
nut.
b) Turn the gear casing (50) a couple of times.
c) Using a spring balance, pull the body
casing tangentially. Tighten or loosen the
ring nut (68) until the rotating load reading
is somewhere between 100 and 135 N.
1) (10.2-13.8 kgf) 22.5-30.4 lbw. Keep the
ring nut in such tightness.
1) Spring balance
CAUTION
Before setting the pin in the ring nut, it is
necessary to make a new hole on the other
side of the existing hole. This is because if any
readjustment is made in Step 56, the ring nut
will not necessarily be back in the same
2) position.
61. Using adhesive tape or magnet plate, cover

the threaded hole. Drill a new hole in between
the body casing and ring nut.
Drilling specifications:
Hole diameter: 6.00-6.15 mm (0.236-0.242 in.)
Hole depth: 7.0-7.5 mm (0.276-0.295 in.)
3) 2) Drilling position
3) Cover plate
62. Clean up all cutting tips that are generated by

drilling. Insert the pin (67) in the new hole
(67) between the body casing (73) and ring nut
(68)
(68).
(73)
IV-S-92
63. Apply the “ThreeBond 2403” screw adhesive

to the bolt (65). Install the bolt (65) and washer
(66) in the body casing. Tighten up the bolt to
(65) the torque of 35.3 ± 2.0 N·m (3.6 ± 0.2 kgf·m)
26.0 ± 1.4 ft·lbs.
(66)
64. Place the travel unit. Install the two steel balls
(44), spring (45) and piston (46) in the body
(45) casing.
(44)
(46)
65. Install the cam (swash plate) (43) in the travel

unit body. Press the cam (swash plate) a
couple of times to make sure the cam (swash
plate) moves smoothly.
(43)
66. Install the plate (42), spring (41) and plate (39)
in the cylinder barrel (36).
(42)
(41) (39)
(40)
(36)
IV-S-93
67. Secure the plate (39) on a press and keep the

spring (41) compressed. Install the snap ring
(40) (40) in position.
(39)
(41)
(42)
68. Insert the three pins (38) in the cylinder barrel.
(38)
69. Insert the retainer ball (37) in the cylinder

barrel. Apply fresh hydraulic oil on the retainer
(37) ball (37).
70. Place the piston assembly (35) in its original

(34) position in the retainer (34). Apply fresh
hydraulic oil to the cylinder barrel hole and the
piston assembly (35). Put the retainer and
piston assembly together back into their
original position in the cylinder barrel (36).
(35)
(36)
IV-S-94
71. Apply fresh hydraulic oil to the cam (swash

plate), the surfaces of the nine piston shoes
(33) (sliding with the cam (swash plate)), and the
motor shaft spline. Place the travel unit body
sideways, and fit the entire cylinder barrel
assembly (33) onto the shaft.
72. Apply fresh hydraulic oil over the two friction

discs (31) and two steel plates (32).
1) 2)
1) Gear side
2) Brake valve side
(31) (32)
73. Place these plates alternately in the travel unit

body. The friction disc is located innermost
and the steel plate outermost.
(31)
(32)
74. Make sure the brake piston (26) is completely

(30) clean and free of sand and dust. Check the
backup rings (29 and 30) and O-rings (27 and
28) for anything unusual. If any of them is
(28) unusual or damaged, replace it with new one.
Install the backup rings (29 and 30) and O-
rings (27 and 28) on the brake piston (26).
(27) Apply a small amount of grease over all these
rings beforehand. Be careful not to confuse
the locations of these rings. (See the photo.)
(29)
(26)
IV-S-95
75. Apply fresh hydraulic oil over the body casing’s

surface over which the brake piston (26) slides
along. Using a plastic hammer, tap the brake
(26)
piston (26) into the travel unit body.
76. Install the three O-rings (24 and 25) to the

casing.
(24)
(25)
(24)
77. Install the bearing (23) on the motor cover.

(23)
78. Place the motor cover upside down on a

wooden block.
IV-S-96
79. Insert the spring (19) and poppet (20) in the

(19) (18) motor cover. Install the plug (18) and O-ring
(21) in position.
(20) (21)
80. Tighten the plug (18) to the torque of 65.7 ± 6.6

N·m (6.7 ± 0.67 kgf·m) 48.5 ± 4.8 ft·lbs.
(18)
81. Install the O-ring (16) each on the two plugs

(15) (17) (15). Insert the steel balls (17) in the motor
cover.
(16)

N·m (2.0 ± 0.1 kgf·m) 14.5 ± 0.7 ft·lbs.
(15)
IV-S-97
83. Install the spring (13) and spool (14) in the

motor cover.
(13) (14) (12)

N·m (8.0 ± 0.8 kgf·m) 57.9 ± 5.8 ft·lbs.
(12)
85. Apply a proper amount of hydraulic oil to the

(11) (10) (9) spool (11), and set it in the motor cover.
86. Tighten the cover (8) to the torque of 176.4 ±

(8) 17.6 N·m (18.0 ± 1.8 kgf·m) 130 ± 13 ft·lbs.
IV-S-98
87. Place the motor cover upside down. Install the

valve plate (22) back in position on the motor
(22) cover. Apply a proper amount of fresh
hydraulic oil over the valve plate surface.
88. Apply grease in the ten holes of the motor

cover. Fit the springs (76) into these holes.
(76) Greasing helps prevent the springs (76) from
dropping when mounting the motor cover to
the body casing.
89. Mount the motor cover (3) onto the body

casing. Make sure all the springs (76) are in
place. Fix the motor cover with the eight bolts
(2). Tighten these bolts to the torque of 129.4
± 12.9 N·m (13.2 ± 1.3 kgf·m) 95.5 ± 9.6 ft·lbs.
(3)
(2)
90. Install the backup ring (6) and O-ring (7) on the
relief valve (1).
(6) (7)
IV-S-99
91. Tighten the relief valve (1) to the torque of

(1) 142.1 ± 14.2 N·m (14.5 ± 1.5 kgf·m) 1.5 ± 10.5
ft·lbs.
92. Place the travel unit, as shown below, with the

brake valve side downward. Apply a torque to
the shaft (74) to check the parking brake
(74)
torque. Make sure the shaft’s rotational start-
up torque is 239 N·m (24.2 kgf·m) 176 ft·lbs or
higher.
93. Install the four plates (64), four bushings (63),

(61) four bearings (62) and four planetary gears
(61) in their specified positions.
(62)
CAUTION
To keep the needles of needle bearings (62) in
(63) place, first make subassemblies with the parts
(61), (62) and (63). Double-check that the
needles do not come out of these
(64) subassemblies.
94. Place the thrust plate (60) as shown below.

Prepare new bolts (59) on which the “Three
(59) Bond 2403” screw adhesive is already
applied. Clean up the bolt threads free of
foreign substance and grease, and apply the
four bolts (59) to the tightening torque of 35.3
± 2.0 N·m (3.6 ± 0.2 kgf·m) 26.0 ± 1.4 ft·lbs.
Next, fit the sun gear (58) in place.
(60) CAUTION
(58)
Be sure to use new bolts with screw adhesive
applied. Thoroughly keep the bolt hole threads
free of foreign substance and grease. Even if
slightly dirty, the screw adhesive will not be
effective enough and the bolts may come off.
IV-S-100
(55) 95. Fit the three inner races (57) onto the shafts of
(54)
(56) carrier (56).
(57)
96. Set the carrier (56).
(56)
97. Install the three bearings (55) and three

planetary gears (54) to the carrier (with the
(53) inner races already fitted). Next fit the sun
gear (53) in position.
CAUTION
To keep the needles of needle bearings (55) in
place, first make subassemblies with the parts
(54) and (55). Double-check that the needles do
(55) (54) not come out of these subassemblies.
98. Place the thrust plate (52) on the carrier.

Prepare new bolts (51) on which the “Three
(51) Bond 2403” screw adhesive is already
applied. Clean up the bolt threads free of
foreign substance and grease, and apply the
three bolts (51) to the tightening torque of 35.3
± 2.0 N·m (3.6 ± 0.2 kgf·m) 26.0 ± 1.4 ft·lbs to
secure the plate (52) to the carrier.
(52)
CAUTION
Be sure to use new bolts with screw adhesive
applied. Thoroughly keep the bolt hole threads
free of foreign substance and grease. Even if
slightly dirty, the screw adhesive will not be
effective enough and the bolts may come off.
IV-S-101
99. Apply grease to the gear casing and attach the

(49) (48) cover (49) on the gear casing. Be careful not
to damage the O-ring (48). Wipe off all excess
grease out of the groove.
100. Make sure the cover (49) is back in parallel

with the gear casing. Using a press, apply
compressive force upon the cover (49).
(49)
101. Fit the snap ring (47) in between the cover

(47) (49 and the gear casing.
(49)
102. Pour lube oil through the drain port. The

proper amount of lube oil for the SGM-04D’s
reduction gears is 1.35 liters (0.36 US gal.).
(77) Apply the three drain plugs (77) in place.
Now the travel unit is successfully reassembled.
CAUTION
To protect the motor, be sure to fill the motor
casing with hydraulic oil before getting started.
IV-S-102
3. Troubleshooting and Maintenance

The table below lists commonly experienced phenomena, their possible causes and corrections. If the
machine gets in trouble, its cause often is not attributable to just one defective part, but some relevant
parts involved. In other words, some troubles may require other corrective actions than listed in this
chart.
This table does not list up all possible causes and corrections. With this in mind, you are kindly
requested to discuss problems with your servicing supervisor and pinpoint their causes.
1) Travel motor (hydraulic motor and brake valve)

Trouble Possible causes Corrections
1. Equipment (pump, pressure controller, etc.) See if a specified oil pressure is applied at the
other than travel motor and reduction gears motor inlet. Check also other equipment. Repair
malfunctioning. as required.
Replace worn-out part with new one. Smoothen
2. Travel motor sliding section abnormally worn
the surface free of scratches, burrs, etc. Clean up
out, resulting in poor hydraulic effect.
all parts and put them together.
3. Motor’s major part damaged, resulting in
Motor failure to run malfunction. The following phenomena are
Check the drain oil. Disassemble the motor and
often found in such case.
replace defective part with new one. Clean up all
Running motor itself sounding unusual.
parts and put them together.
Abrasion powder (iron and copper alloy)
coming out of drain.
Check the sprocket for foreign matter deposits.
4. Motor overloaded, activating the crossover- Remove them as required. Check also the loading
relief valve. condition. Keep the load limit according to the
relief pressure setting.
1. Hydraulic pump, pressure control valve, etc. in See if a specified oil flow is provided at the motor
trouble, failing to supply a specified flow rate to inlet. Check also other equipment. Repair as
Motor rpm too low the motor. required. Disassemble the motor and check the
2. Motor volumetric efficiency lowered, failing to sliding section for unusual wear and tear. Repair
obtain a specified rpm. worn part or replace it with new one.
1. Motor’s sliding section worn out, inviting a large
leak of high-pressure oil at the drain port and Disassemble the motor and check all parts for
Motor rpm fluctuations causing remarkable drop in rpm. unusual wear. Replace as required. Clean up all
too much 2. Bearing worn out, causing violent rpm parts and put them together.
fluctuations.
1. Oil seal or O-ring damaged, resulting in oil leak. Replace the oil seal or O-ring with new one.
2. Drain pipe clogged with foreign matters. Too
long and/or too narrow piping, causing
Oil leak excessive back pressure, damaging the oil seal Clean up the drain pipe. Review the piping system
and resulting in oil leak. to lessen the piping resistance.
3. Unexpected pressure inside the motor casing,
damaging the oil seal and resulting in oil leak.
1. Difference in flow rate through the left and right Measure the motor drain oil amount. If out of spec,
travel units. repair the pump.
Oblique traveling 2. Relief valve degraded or damaged, resulting in
Replace the relief valve with new one.
oil leak.
3. Travel unit degraded or damaged. Replace the travel unit with new one.
1. Pilot pressure from the pilot pump out of spec. Set the correct pressure level.
Check the high-pressure selector valve. Repair as
Oblique traveling 2. High-pressure selector valve malfunctioning.
required. Replace the motor cover with new one.
(Trouble in automatic
dual-speed mode) 3. Automatic dual-speed selector spool
Replace the spool with new one.
malfunctioning
4. Dual-speed selector piston malfunctioning. Replace the piston with new one.
IV-S-103
2) Travel drive (reduction gears)

Trouble Possible causes Corrections
1. Motor valve in trouble.
2. Hydraulic motor in trouble. Refer back to the travel motor troubleshooting.
3. Brake valve (motor cover) in trouble.
4. Drive overloaded. Remove the overload.
5. Reduction gears in trouble. Check the reduction gears lube oil. Disassemble
The following phenomena are often found. the reduction gears and replace defective part
Travel drive failure to * Too much abrasion powder in lube oil. with new one.
run * Unusual noise from the reduction gears during Replace damaged gear with new one.
run. Replace damaged bearing with new one.
Gear in trouble Replace damaged shaft with new one.
Bearing damaged
Spline damaged
Replace the bolt with new one. Or repair the bolt’s
6. Sprocket mounting bolt broken.
threads.
7. Sprocket tooth missing. Replace the sprocket.
1. Too short lube oil. Add lube oil to specified level.
2. Too much lube oil. Check the lube oil level.
1) Reduce lube oil down to specified level.
Reduction gears 1) Too much lube oil added. 2) Replace the oil seal with new one. Add lube oil
overheated 2) Hydraulic oil flowing in reduction gears. to specified level.
3. Bearing damaged Replace the bearing with new one.
4. Tooth plane damaged Replace the gear with new one.
1. Mating surface scratched. Correct the surface with whetstone or sandpaper.
Oil leak at mating
2. Bolt loosened. Tighten up the bolt. Check again for oil leak.
surface
3. O-ring or packing damaged or degraded. Replace defective part with new one.
1. Plug loosened. Tighten up the plug and check again for oil leak.
Oil leak at hydraulic
2. O-ring damaged or degraded. Replace defective part with new one.
motor housing
3. Housing damaged. Replace the housing with new one.
1. Sliding surface worn out or corroded. Replace.
Oil leak at floating seal 2. O-ring damaged, twisted or degraded. Replace.
3. Seat cracked. Replace.
1. Travel unit damaged. Replace the travel unit with new one.
Unusual noise heard
2. Machine itself vibrating (piping, etc.) Secure the vibratory source.
4. Maintenance
<Change intervals for travel reduction gears lube oil >
Change the lube oil at the following intervals.
First replacement: 100 operating hours
Second replacement and thereafter: Every 500 operating hours
<Replacing the seals>

Check the seals for damage or degradation. Replace defective seal with new one.
Do not use any disassembled seals again. Be sure to replace them with new ones.
Handle the seals with enough care not to damage them.
(Keep in mind that damaged seals cause oil leak.)
IV-S-104
5. Jig
1. Ring nut tightening jig
Unit: mm
(1)
(1) SGP 20A

(2) Stud bolt
M12x150L-4PC
(3) M12, 1-12PC
(4) M10x18-2PC
ø9 for 6mm
(2)
(3)
(4)
IV-S-104-1
2. Floating seal fitting jig
Unit: mm
(1) One cutting notch at the circumference

(1)
3. Eyebolt JIS B 1169 M10
(1) Weld
(1)
IV-S-104-2
e) Pilot Valve
1.Fitting the adaptor
Port P
Filter
Pipe joint
Ports T, 1, 2, 3 and 4
Pipe joint
2.Adaptor tightening torque

G1/4 size
Left P/V
24.5~29.4N.m (2.5~3.0kgf.m) 18.1~21.7ft.lbs
Location Hose tape color
1 Swivel left Gray 3.Fitting direction of the valve

2 Arm dump Yellowish green
Position the valve with port (2) facing the
machine front.
3 Swivel right Sky-blue
4 Arm crowded Blue 4.Quick-coupling adaptor

P Port P White Pipe joint
T Port T None
Make sure the hose connection is free from
detrimental scratches.
Right P/V 5.Fitting the thermal insulation (21, cooler)

and valve assembly (pilot, R)
Tightening torque
1 Bucket crowded Orange
12.3~14.2N.m (1.3~1.5kgf.m) 9.1~10.5ft.lbs
2 Boom down Yellow
3 Bucket dump Red 6.Fitting the thermal insulation (21, cooler)

4 Boom up Green When winding the thermal insulation around the
valve, be careful not to wrap the wire harness
P Port P White
together.
T Port T None
(1) (View from the operator’s seat)

(1) (2) Left pilot valve
(2) (3)
(3) Right pilot valve
(4) Valve assembly (pilot, L)
Thermal insulation (21, cooler)
Inlet pipe band
Hex socket bolt (M6)
(4) (5) Wire harness
(10) (6) Port 4
Straight pipe joint (G2-G2)
O-ring
(7) Port P
Filter
O-ring
O-ring
(5) (8) Port 2
O-ring
(9) Ports T, 1 and 3
Pipe joint (S, G1/4-8.4)
(6) (10) Valve assembly (pilot, R)
Thermal insulation (21, cooler)
(11) Inlet pipe band
Hex socket bolt (M6)
(11) Ports T, 1, 2 and 3
(7) Pipe joint (S, G1/4-8.4)
(8) (9) (12) (12) Port P
Filter
(13) O-ring
(14) (14)
Pipe joint (S, G1/4-8.4)
(13) Port 4
Pipe joint (S, G1/4-G1/4)
O-ring
O-ring
(14) (Back)
(15) (Front)
(15) (15)
IV-S-105
f) Pilot Valve of Swing and Blade
(1) Swing pilot valve

(2) Dozer blade pilot valve
( )
( )
IV-S-106
g) Travel Pilot Valve

1. Main parts layout
040
090 010 Bracket, buzzer
060
020 Buzzer, back
010 /
070
040 Buzzer, back
020 060 Wire harness, alarm
070 Joint, pipe
090 Pilot pressure switch for travel alarm
(Port5)
040
010
010 Bracket, PV
030 Assy valve, PV
100 050 Filter
030
140 060 Joint, pipe
100
140 080 Joint, pipe
/
100 Joint, pipe
060
/ 120 Joint, pipe
120 050 080 140 Plug
/ 120
/
B
010 Assy valve, PV 150 Assy, damper
200
060 A
/
B A 220 020 Kit seal, PVS 170 Plug
250 / 030
200
240 020 030 Gasket 180 Plug
~
010
280 /
050 140
070 220
060 Boot 200 Seat, spring
~
280 /B
280
260 140
260
B/
070 Seat 220 Spring
270 230
250
130 250 240 080 Seat 230 Spring
250
190 230
030
110
080 090 Seat 240 Camshaft
270 040 070
150
130 180 100 Seat 250 Bush
030
080
110 Ball 260 Assy cam
B 180
/
120 Cover 270 Ball
120 070 290
110
/
130 Rod, push 280 Roller
180 A
A
150
110
100
140 Shim 290 Plug
090 170
080
010 Lever, travel LH

030 Pedal, drive LH
080
040
040 Lever, travel RH
070 070 Cover, drive pedal
080 Grip, travel
070
010
030
IV-S-107
2. Disassembly of travel pilot valve
1. The view from the top after taking off the

bellow boots.
2. Remove the damper assy
Important:
Following procedures with photo are FYI
only. Disassemble this with responsibility
for the manufacturer does not guarantee.
3. Remove the cover of the damper assy.
(1) Damper cover

(2) O-ring
(3) Damper body
(2)
(1) (3)
IV-S-108
4. Remove the outer-most cover.
5. Remove the spline yoke.

Inner metal plates mesh with the spline
yoke.
6. Inner parts
IV-S-109
7. Each block-colored has recess and

protrusion for exact fitting at reassembly.
8. remove the mounting bolts.
Bolt: M8 x 35
L-wench: 6 mm
Torque: 20.6±1.5 N·m (2.1±0.15 kgf·m)
15.2±1.1 ft·lbs
9. The view inside
IV-S-110
10. Remove the push rods.
11. Remove the control spool assy.
12. Inner parts

(5)
(1) Spool
(2) Control spring
(3) Shim, t=0.25mm
(4) Spring seat
(5) Spring retainer
(1)
(2)
(4)
(3)
13. Outer view
IV-S-111
14. Four pilot ports
15. Shuttle ball and seat
IV-S-112
(2) (3) h) One-Two Way Change Valve

(1) 1. Fitting the valve assembly (3-way)
Fit the assembly in position as shown at left.
No. 1 port
Pipe joint (SG6, 1U)
(4) (6) (RD809-6151D)
(5)
(7) No. 2 port
C/V Pipe joint (LG6, G6)
(RD809-6917D)
(8) No. 3 port
(10)
(RD809-6154D)
2. Adaptor tightening torque

G3/4 size
117.6~127.4N.m (12.0~13.0kgf.m)
86.7~94.0ft.lbs
3. Factory-setting the oil flow direction

Set the oil flow direction before shipping,
(11)
referring to the details given at left.
(Front pipe → C/V)
4. Fitting the bracket (selector, 3-way)

Tightening torque
48.1~55.9N.m (4.9~5.7kgf.m) 35.5~41.2ft.lbs
(12)
(1) Oil tank
(2) (Oil tank)
(3) Valve assembly (3-way)
Bolt
(4) No. 2 port
(5) No. 1 port
(13) C/V (6) No. 3 port
(7) Pipe joint (LG6, 1U)
(9) Front pipe
(11) Bracket (selector, 3-way)
(14) Bolt
(12) (Details of the selector lever)
The lever of this valve has grooves. The oil flows
along these grooves. In installing the lever, make sure
the grooves are positioned correctly.
(15) (13) Oil tank
(14) Groove
(15) Front pipe
IV-S-113
One-two way valve (Third line valve)
(Two way position)
(1) C-ring
(2) Plate
(3) Ball valve
(4) Body
(4)
(3)
(2)
(1)
IV-S-114
WSM KX080-3AB Mechanism V ELECTRICAL SYSTEM
V. ELECTRICAL SYSTEM
Mechanism Section
(A) FEATURE AND MAIN FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-M-3

a) Electrical System: Functional Comparison. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-M-3
b) New Starter Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-M-4
c) Travel Alarm System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-M-5
d) Electrical Circuit Diagram, KX080-3AB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-M-13
e) Electrical Wiring Diagram, KX080-3AB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-M-14
f) Electrical Circuit Diagram, KX080-3AB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-M-15
g) Electrical Wiring Diagram, KX080-3AB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-M-16
V-M-1
V-M-2
(A) FEATURE AND MAIN FUNCTION

a) Electrical System: Functional Comparison
:KX080-3AB
No. Function EU-version North America & Oceania
KICS; Kubota Intelligent Control System,
1 Yes Yes
LCD (liquid crystal display) with character and illustration
Yes (delete Yes (delete
2 Maintenance indication upon hour meter
method: manual) method: auto)
3 Anti-theft system Yes Yes
4 AI (Auto idle) function Yes Yes
5 Engine overheat warning Yes No
6 Starter motor auto release function Yes Yes
7 Travel high-low switch at dozer lever grip Yes Yes
8 Fuel feed assist sound Yes Yes
9 Heater Yes Yes

Harness and switch are Harness is
10 Rotating lamp
equipped as standard incorporated
11 Service port (thumb) finger - control Yes Yes
12 Air - conditioner idling control Yes Yes
13 Low temp. idle up control Yes Yes
14 Service port (1) discharge flow control (0 - 14 stage) Yes Yes
15 Fuel supply pump Yes Yes
16 Intake air heater control / Glow plug No / Yes No / Yes
17 Travel alarm system Yes (option) Yes
18 Boom overload sensor Yes Yes
19 Service port (2) solenoid ON-OFF control Yes Yes
V-M-3
b) New Starter Key

1. Key shutter
1.
2. Key inserted
3. Control console meter panel
V-M-4
c) Travel Alarm System

(KTA-standard version, others: Optional Kit)
1. Structure, main components
050
040
090
010 060 /
080
070
020
030
020: Back buzzer (32751-9686-0)

050: Wire harness, alarm
070: Pipe joint (RD809-6911-0)
090: Switch (RP421-5382-2)
RD819-211-10
2. Specifications of main components

1) Switch (RP421-5382-2)
(1) Terminal coupler

(2) Terminal
(3) Fix contact (Ag + Au plating)
(4) Moving plate (Ti.Cu)
(5) Moving contact (Ag + Au plating)
(6) Shaft
(7) O-ring
(8) Guide plate
(9) Spacer
(10) Stopper
(11) Bellowphram
(12) O-ring
(13) Cap
(14) Mounting joint (R 1/8)
Specifications
1) Detector: Metal diaphram
2) Rating voltage: 10 ~ 15.5 V
3) Rating current: Min. = 5 mA, Max. = 25 mA
4) Max. pressure: 3.92 MPa or less
5) Operating pressure: 0.44 ± 0.05 MPa → OFF
0.74 ± 0.05 MPa → ON
6) Switch logic: Normal open
7) Switch contact resistance: 1 Ω
8) Insulation resistance: 100 MΩ or more
9) Sensing cycle: 10 ms or less
10) Mounting torque: 9.8 ~ 14.7 N.m
V-M-5
2) Back buzzer (32751-9686-0)

(1) (3)
(2) (4) (1) - AV 0.75 f (RG)
(2) + AV 0.75 f (RG)
(5) (3) Heat-shrinkable tube
(4) Solderless male terminal
(CA-104)
(5) Transparent tube
(6) Solderless female terminal
(CB-104)
(7) High-frequency adhesion
(8) Black plastic tube
(6)
(7)
(8)
Specifications
Rated voltage DC12V
Current (consumption) 50 mA / max.
Fundamental frequency 2200 Hz ~ 3300 Hz
Sound pressure 90 dB ~ 100 dB / 2 m (A)
Operating voltage range 9 V ~ 15 V
Operating temperature -20 °C ~ 70 °C
Sound cycles Intermittent sound · 70 ~ 100 cycles / min.
Insulation resistance 3 MΩ / min. (500 V MEGGER)
Mass 45 g
Equipped with reverse voltage protective circuit
V-M-6
3. Function
1) When both of the travel levers are in neutral,
pressure switch (090) stays Off-position and
no current flows to the buzzer.
2) When one of the travel levers are shifted,

secondary pilot pressure applies to the pres-
sure switch to put it ON-position for the
warning buzzer.
(1) Port 5 for travel warning

(Pilot secondary pressure)
(1)
Wire harness (Travel alarm)

0.5-L
Buzzer(F)(+)
0.5-G/W CN783
Lever lock SW(L) 1 0.5-L
CN14 CN11 DL090-2pf 2
Key switch EU CN781-1 CB-1pf
5A 0.5f-L/W Lever lock 0.5f-G/W CN780 TravelSensor
st 2 1 ac 3-R/W
2 1 1 CN250-3pm
com3 2 3 090-2pf
Buzzer(F)(-)
fromTravelAlarmPower CN784
5-R
0.5-B
CA-1pm
CN336
1 312-1pm CN455
CN250-3pf
TravelAlarmPower
0.5-G/W
CN337 1
1 312-1pf 3 2
5-R/Y 0.5-L
0.5-B
CN101
AEX-8-R M8 GND
Travel Alarm
Battery terminal
GND
100A
SB-BOX-8p
30A
60A
AUX2-L 4 3
2 1 58-M-4pm
[main]_to_engine
SB-BOX-8p-2PF AUX2-R
Key SW
CN-14-3
off Lever Lock Lever lock,L SW Travel Alarm Power Travel Sensor
on CN-14-1 5A CN-11-2 CN455-1 CN-781-1-1 CN-781-1-2 CN-783
start CN-14-2 CN-784
Main to Engine Travel_Alarm_Buzzer(F)
CN(A)250-4p-3
CN-317-1
Travel_Alarm_Buzzer(R)
60A
58-M-4p-3 CN-317-2
Travel Alarm Power
100A
Battery
V-M-7
4. Adapter installation
(4) 1. Fitting of the adapters
(1) Ports P and T
Straight pipe joint (G2-G2) (RC441-6325Δ)
Pipe joint (cross, G1/4) (RP802-6193Δ)
Plug (68871-7359Δ)
T Ports 1, 2, 3 and 4
P Pipe joint (QL, G1/4-8.4) (RP821-6197Δ)
<Failure case>
5
Ports P and T
Failure to set up the plug

(2) (3) Oil leak
(5) (6)
2. Adapter tightening torque
G1/4 size 24.5~29.4 N.m (2.5~3.0 kgf.m)
<Failure case>
Insufficient tightness

Oil leak
3. Plug tightening torque (68871-7359Δ)

G1/4 size 24.5~29.4 N.m (2.5~3.0 kgf.m)
<Failure case>
(8) (7) Insufficient tightness

Oil leak
2 1 4. Fitting direction of the valve

Place the valve with Ports P and T toward the machine
front.
<Failure case>
Wrong fitting direction
4 3
(9) Difficult to connect the pilot hose
(10) 5. Quick-coupler adapter

Pipe joint (QL, G1/4-8.4) (RP821-6197Δ)
(1) (Machine front) Make sure the connections with the hoses are free of
(2) Remove the iron-made plugs from the pilot valve, detrimental scratches.
and connect the pipe joints.
(3) Pipe joint (L, G1/4-R1/8) <Failure hose>
Switch (pressure, 7.5K) Scratched
(4) Valve assembly (PV, travel), Bolt
(5) (Port T) Oil leak
(6) Straight pipe joint (G2-G2)
Pipe joint (cross, G1/4), O-ring, Plug 6. Fitting of the valve assembly (PV, travel)
(7) (Port P)
(8) Filter, O-ring, Straight pipe joint (G2-G2) (RD819-6140Δ)
Pipe joint (cross, G1/4), O-ring, Plug Tightening torque: M10
(9) Pipe joint (QL, G1/4-8.4) 48.1~55.9 N.m (4.9~5.7 kgf.m)
(10) Note: Make sure the hoses’ fixtures are out of
contact with each other. <Failure case>

Bolt loose
Come-off
1 Travel (left), backward Blue, double
2 Travel (left), forward Red, double 7. Switch (pressure, 7.5K) (RP421-5382Δ)
3 Travel (right), backward Green, double R1/8 size 9.8~14.7 N.m (1.0~1.5 kgf.m)
<Failure case>
4 Travel (right), forward Yellow, double Insufficient tightness
P Port P White
Oil leak
T Port T None
V-M-8
KX080-3 KX080-3α / KX080-3AB
(6)
5. Comparison of travel pilot valve
Hydraulic symbol Hydraulic symbol
V-M-9
(1)
(4)
(3)
(1) 4-ø11 Through

(2) Port 5 & 6 for travel alarm sensing
(3) 7mm
4 names
(4) 7mm
names
(5) Port 5 for travel alarm sensing
(2) (6) Damper
(5)
V ELECTRICAL SYSTEM
Front buzzer: Located below the step
(7)
6. Wire harness installation
(1)
(2) (4) (6)

(5)
(3)
Back buzzer: Located ahead of the radiator and at the oil tank partition
V-M-10
(9)
(10)
(8)
(1) Bracket (buzzer)

(3) Horn
(4) Buzzer (back)
(5) Clearance with the horn (to be
out of contact)
(6) Wire harness (travel alarm)
(7) Cord band: Clamp it to the wire
harness (main, anti-theft).
(8) Peel off the plastic tape and
take out the coupler.
(10) Buzzer (back)
V ELECTRICAL SYSTEM
Pre-cleaner (KTA-version)
1. Fitting of the cover (arch, top P)
Tightening torque
48.1-55.9 N·m (4.9-5.7 kgf·m) 35.4~41.2 ft·lbs
<Failure case>

Bolt loose

Come-off
2. Hose clip tightening torque

Tightening torque
4.9~5.9 N·m (0.5~0.6 kgf·m) 3.8~4.3 ft·lbs
<Failure case>

Air leak
3. Fitting of the cleaner assembly (pre-air)

(Clamp tightening torque)
Tightening torque
3.4~4.6 N·m (0.3~0.5 kgf·m) 2.2~3.8 ft·lbs
<Failure case>
(1) Clamp Insufficient tightness
(2) Bolt
(3) Hose clip (58-75) Air leak, come-off
(4) Cleaner assembly (pre-air)
(5) Cover (arch, top P)
(6) Hose (1, inlet P)
(1) (4)
(2)
(5)
40
(6)
(3)
V-M-11
V-M-12
d) Electrical Circuit Diagram, KX080-3AB
Lever Lock Lever lock,L SW Main to Engine Lever lock solenoid Main to Engine
5A CN-11-2 CN-11-1 SWP-16p-6
Key SW SWP-16p-8 CN-12-1 CN-12-2
CN-14-3
off
on CN-14-1
Starter
start CN-14-2 10A
Travel Hi-Low Lamp

CN-420-1 CN-420-2
Travel Hi-Low Main to Engine Travel hi-low solenoid Main to Engine
5A SWP-16p-4 SWP-16p-3
CN-13-1 CN-13-2
Glow relay Main to Engine Glow

AI motor 3 1 58-M-8p-1
15A CN-410-3 CN-410-1 CN-2-18 Motor Power supply
4 2
CN-410-4 CN-410-2
AI Self-hold relay
Meter Sub
5A CN-1-12 +B
Lever Lock sw CN-1-11

Meter Main CN-2-14 AI self-hold Relay
10A
Start SW CN-1-9 CN-34-3 CN-34-1
CN-1-1 AC-1
CN-34-4 CN-34-2
Fuel Supply Pump Main to Engine
Fuel sensor to Fuel 58-M-8p Auto release relay
CN-23-1 1 3 3 CN-2-2 Fuel Sensor Glow Relay
CN-23-2 2 2 4 5V CN-1-21
CN-2-15 +5V
CN-23-3 Engine to
Fuel supply pump CN-2-16 Analog-GND
Governor sensor Auto release Relay
AI Console CN-1-22
+5V CN-421-8 CN-4-1 CN-4-3 Main to Engine CN-32-1 CN-32-2 Main to Engine Water temp Sensor
SWP-16p-1 CN-2-1 Working lamp Relay
Accel. sensor CN-4-2 SWP-16p-2
CN-421-7 Water temp.sensor(auto glow) CN-1-13
GND CN-421-4
CN-2-4 Motor Pot Compressor crutch Relay
+12V CN-421-2 CN-1-14
AI operation LED CN-2-3 Accel pot
LED2 CN-421-1 AUX Control ON-OFF LED
LED1 CN-2-5 AUX. control pot CN-1-16
CN-421-5
AI operation SW Breaker Lock sw AI operation LED
SW2 CN-421-6 CN-1-4
CN-1-15
SW1 CN-421-3 CN-1-5 AUX. Control ON-OFF sw Travel Hi-Low Sol

Travel hi-low lock SW CN-2-10
CN-15-2 CN-15-1 CN-1-6 Travel Hi-Low sw
CN-1-7 AI operation sw
Main to Engine AI pressure SW Main to Engine
SWP-16p-11 CN-8-1 CN-8-2 SWP-16p-7 CN-1-8 AI pressure sw
JS Control(R)
GND
CN422-8 CN422-2 CN-1-10 Compressor crutch sw
pot
+5V CN422-3
CN422-1
V-M-13
HornSW-vcc HornSW Motor(+)
SWP-16p-14
CN422-7 CN422-4 CN-1-2 Spare sw
BrakerLockSW-vcc BrakerLockSW Motor(-) CN-2-20 CN-5-2 CN-5-1
M
Main to Engine
CN422-5 CN422-6
CN-2-19 AI Motor
CN-33-3
Power_Source(12V)
Engine speed sensor
5V 3
Main to Engine Eng. rpm Solenoid_Out_1 Main to Engine AUX. L solenoid
CN-33-2 SWP-16p-10 CN-1-17 AUX. sol(+)-L PMM_IN1 1
CN-1-18 5 CN-428-1
SWP-4p-1 CN-428-2
PMM_IN2 Main to Engine AUX. R solenoid
2 Solenoid_Out_2
AUX. sol(+)-R
CN-2-13 RS-485(+) CN-1-19 6 CN-427-1
AUX. sol(-) Power_Source(GND) SWP-4p-2 CN-427-2
Main to Engine CN-2-12 RS-485(-) 4
CN-33-1 SWP-16p-5 CN-1-20
Flash cnt
CN-2-9
CN-2-11 Txd-1
CN-2-8 Rxd-1 Charge sw CN-2-7
CN-1-3 Signal-GND oil sw CN-2-6 Engine oil SW

CN-28
Horn relay Horn 58-M-8p-7
Horn CN-46 Main to Engine
10A CN-306-3 CN-306-1
CN-2-17 Motor-GND
CN-306-2 CN-306-4
CN-45
CN-454-1
CN-454-2
CN-454-5
CN-454-6
CN-454-7
CN-454-3
CN-454-8
CN-454-4
CN-440-3 12V out(RF-unit)

Antithieft_sub
+B
RS-485-con
10A CN-440-7
CN-453-7
GND
CN-453-8
CN-453-3
CN-453-2
CN-453-4
CN-453-5
CN-453-6
CN-453-1
CN-440-6
CN-440-12 RF-GND
CN-440-8 Cont Power in

Antithieft_main Anti theft Relay
5A CN-440-9 AC Power in
CN-440-1
CN-441-5 Anti theft horn Relay
Starter relay
CN-440-2 RS-485-con
CN-441-2 CN-7-1 CN-5-1 CN-17-4 CN-17-3
CN-441-1 CN-440-5 CN-440-11
Txd(RF-unit) RS-485(+) CN-17-1 CN-17-2
CN-441-3 CN-7-2 CN-5-2 Starter
Rxd(RF-unit) RS-485(-) CN-37
CN-114
CN-441-4 CN-440-4 CN-440-10 58-M-2p-1
Anti theft RF Unit Anti-theft controller Anti theft Unit Main to Engine
Alternator
CN-113
Alternator Main to Engine

10A CN-25-1
58-M-8p-6
CN-25-2
58-M-8p-2
Work Light CN-302-2 CN-302-4 Main to Engine
20A CN-18-1 CN-100 Work lamp
CN-302-3 CN-302-1
CN-18-2 CN-100
60A
30A
Light relay
CN-36-2
58-M-2p-2
Main to Engine CN-36-1
Relay source
5A
100A
Fuel pump Engine stop solenoid
Battery
58-M-8p-8
CN-24-2
Auxiliary JSControl(L) Main to engine Engine to [Aux2-sol] 2pcs-Aux2(R)_solenoid 58-M-8p-5
15A 1 3 1 2 58-M-4p-1 CN(A)250-4p-1
2 4 3 CN-869-2
6 58-M-4p-2 CN(A)250-4p-2 CN-869-1
AUX2_LeverLock_relay 5 4 2pcs-Aux2(L)_solenoid
Fuel_Supply_Pump_Fuse
CN-871-2 Fuel_Supply_Pump
CN-871-1 30A 1 2
M
Cab relay
CN-308-3 CN-308-1
CN-308-2 CN-308-4 Fuel Supply Pump
Start relay
4 Fuel Level Sensor
1 1 1
2 Fuel_Supply_Pump_Fuse 3 2
Fuel Supply Pump Start SW
1 2 3 6 5A 2 4
Fuel Supply Pump 1 2
Stop Relay
Fuel Supply Punp Stop SW
Relay_Out_1
5
Relay_Out_2
Power_Source(12V) 6
3
4min Timer 1 Test_SW
Power_Source(GND)
4 2 Water_Temp._Sensor_SW
Main to Engine Main to Fuel Supply Pump

SWP-16p-13 SWP-3p-1
Travel Alarm Power Travel Sensor

CN455-1 CN-781-1-1 CN-781-1-2 CN-783
CN-784
2 1 Travel_Alarm_Buzzer(F)
Main to Engine
6 CN(A)250-4p-3
OverloadWarning Main to Cabin CN-317-1
10A CN-600-7 Main to Work Lamp 58-M-4p-3 Travel_Alarm_Buzzer(R)
4 3 Travel Alarm Power CN-317-2
Overload Worning SW CN-600-8 Overload_Warning_Buzzer
CN250-2p-1
Boom Rod Pressure sensor CN250-2p-2
-5V CN-765-1 -5V SWP-3p-1
Wiper Motor
Cabin Source(AUX) 2
CN-765-2 SWP-3P-2 GND
CN-601-1
CN-765-3 SWP-3p-3 M
CN-601-2 GND GND
+1 S +
CN-601-3
1
3
4
CN-601-4
Cab_Work_lamp_R
Cab power source CN-17-2
CN-600-1 CN-17-2
Cab Work Light relay Cab_Work_lamp_L
CN-600-2 CN-17-2
1
3
4
CN-841-2 CN-841-1
2
CN-821-1 CN-821-3 CN-17-2

Wiper/Washer CN-841-6 Work_lamp/Rear
CN-821-2 CN-821-4 CN-17-2
15A CN-600-6
CN-841-4 CN-841-3 CN-17-2
Cab Worklight SW
Wiper sw
off CN-609-5
CN-609-6
on CN-609-1
Washer Motor
Room Light room light CN-609-2 CN-609-3 CN-610-1
5A CN-600-5 CN-611 M
CN-610-2
CN-612
CN-103-1 Cab GND Radio
CN-317-1 CN-317-1 Frost_Sensor
CN-317-2 CN-317-2 Speaker (R) 2
CN-317-2 CN-317-2 7
3
CN-317-2 CN-317-1 4 6
Cigarette lighter CN-317-1 Speaker (L)
15A CN-317-2
CN-317-1 CN-317-1 5
Power source
CN-317-2 1
Electric Thermo Compressor Clutch relay
Main to Engine Compressor Clutch
CN-655-1 CN-655-3
Main to Engine DUAL_Pressure_SW Main to Engine
Beacon switch Beacon SWP-16p-15 CN-657-1 CN-655-4 CN-655-2 SWP-16p-16 CN-656-1
CN-472-5 CN-472-1 CN-600-4 CN-657-2 SWP-6p-12
CN-628-2 Blower Resisr
Cab Power Source CN-628-2
M
FT
CN-472-6 CN-472-3
Hi
Lo
Mi
Compressor
10A Air-conditioner sw
Blower Motor relay off
CN-652-3
CN-652-1
CN-652-4
CN-651-7 Lo Com
Blower Motor CN-655-2 CN-655-4 Blower Motor CN-651-3 Mi CN-651-2
20A CN-653-1 M CN-651-8 Hi
CN-655-1 CN-655-3 CN-653-2
CN-651-4
CN-651-1
CN-651-5
CN-800-1
CN-801-2
<KX080-3α/AB Export with anti-theft & AI & Air Conditioner & OverLoad Warning>
V ELECTRICAL SYSTEM
e) Electrical Wiring Diagram, KX080-3AB

0.5-R/Y 0.5-W/B
0.5-L
0.5-L/Y
0.5-B/Y
Horn-sw
EC/USA
pot
GND
0.75f-R/Y
4 3 2 1 +5V JSControl(R)
CN422
0.75f-Br
8 7 6 5 dewtsch-8pf
+5V
Br-lock-sw-Vcc
Br-lock-sw-sw
Blank
AnalogGND
Horn-sw-Vcc
0.75f-B/Y
MotorPot
OverLoadWarningSW
4 5 6 4t Room Lamp(GND) IC62
CN442 090MT-6pf 0.85-Y
0.5-L HM090-6pf 1 2 3 Anti theft Antenna unit(cap) CN612 WORK/L(+)
3 2 1 EU/USA M5
Room Lamp(+)
Travel hi-low Lock sw CN611 2 1 CB-1pf
E03F(BR) 0.5-Y/B CN15 0.5-Y CN441 0.85-B WORK/L(GND)
1 2 TNS-3pm Anti theft Antenna unit 2f-B 6 5 4 3
Motor_sensor 3 485+ 485- 1 2 3
4 5 6
HM090-6pm CA-1pm
CB-1pf
EU EU(with Anti theft)
Overload_Warning_Buzzer 8 7 6 5 0.5-W
CN250-2pf 0.5-R/B
JB-8pm
CN454 4 3 2 1 090II-2pf Harness (Wiper) 1.25-Lg/R
1 CN610 2f-Y CN613
Work lamp,R(+)
2 Washer motor
0.5-Br 0.5-B/Y
0.5-Br/W CN6 EU 3 2 1 CB-1pf CN614
1 0.5-Br/W HM090-4pf 090-4pm 090-4pf 0.85-B Work lamp,R(GND)
2 EU 7123-1347 6 5 4 CN609 2f-R
0.5-B/R 0.85-W Wiper SW
AUX-SW
Overload_Warning_Pressure_sw 0.5-R/B EU 485- 0.75(SoftVCTF-0.75*4core)-G
+12V
485+ 0.85-R CA-1pm
CN765 0.5-Br 1 0.5-L/B GND AI-LED 0.5-L/W CN453 4 3 2 1
US
2 JB-8pf 0.75(SoftVCTF-0.75*4core)-W NightLight(+) 0.85-Y
2 1
AMP090-JMk2-3pf
0.5-R/W
3 2 1 NightLight(GND)
0.5-Br
4 2f-B
2 1
8 7 6 5 US 0.5-L
0.5-R/Y
4 3
2 1
1.25f-R
4 3
2 1 CN615
4 3
2 1
2 1
8 7 6 5 485+ 485- 0.75(SoftVCTF-0.75*4core)-R 2 1
0.5-Br/W WorkLight 4 3 com 2-Y
coil contact Work lamp,L(+)
+5V 0.75(SoftVCTF-0.75*4core)-B Indicator(GND) 6 5 4 3
0.5-O
0.5-Br AUX-LED 0.85-G coil
Vcc
0.5-R 0.5-Br
pot
0.5-Br CN440 CN841
AI-SW
EU/USA
US
CN821
3 2 1
3 2 1
1.25f-G 0.5-L/B 0.85-B vcc 090MT-6pf CB-1pf

1
CN421 0.5-O CN1 EU 0.5-Br EU(with Anti theft) CabWorkLightRelay 0.85-B CN616
On-Off
6244-5061
0.5-B
8pf meter (big) Anti theft unit Work lamp,L(GND)
2
FW-L-8F SWP-12pf 0.5-B
0.5-R
(cap/antitheft) CabWorkLightSW
3
1.25f-Y AI console CA-1pm

com
SWP-3pf CN7 4 3 2 1 0.5-B

SWP-3pm 11 10 9 8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1 8 7 6 5
0.5-B/Y
22 21 20 19 18 17 16 15 14 13 12 20 19 18 17 16 15 14 13 12 11 meter(small) 090II-2pm 12 11 10 9
CN2
0.5-W 040_3-20pf Wire harness (Travel alarm) Harness(main,Cabin) 0.5-R RoomLight WorkLight
0.5-Br/W
4 3 2 1
1.25-Lg/R WiperMotor
8 7 6 5
2 1
EU EU 1.25-Lg/R etc
0.85-L/W
0.5-B/Y coil contact CN34
0.85-L/B
0.85-R
0.85-B
0.5-Br 4 3 com W-Boom-Ind.
coil Auto release relay OverloadWarningPower
0.85-B/R
0.85-R/B ST0-01T-187N CN628
Wire harness 0.85-B 0.5-B/R CN621 CN620 CB-1pf OverLoadWorning 1.25-L Beacon(+)
0.5-Y 0.5-R 1 CN628
2f-B 0.5-L Speaker,R(+) CN617
EU EU/USA
0.5-B/W
CA-1pm Radio(+B) CabPowersource CN628 1 Beacon(GND)
0.75f-Y CN5 1.25-L/W Battery direct Line CN250-8pm 2f-B
1 0.5-R/Y M6
1 AI motor 1.25-L/B CB-1pf CN600
2f-R
CN100 2 CN250-2pf 2 0.5-B/R Cabin,Source(Aux) Beacon(GND)
ST0-01T-110N CN622 Cap
coil
Buzzer(F)(+)
4coil
Working lamp(+) /EU CN623 0.5-Y/R
2 2f-Y
0.5-B CN601
1 2
0.5-Y/R
2 1 CN783 CN250-4pf
4 3
1
0.5-G/W Speaker,R(-)
4 3
2 1
Main to [work lamp]
0.5-R/Y
0.5-B/W
0.75f-B 0.5-B 4 3 com CN410
coil contact 1 0.5-L Radio(AC) CN250-4pm
contact3
CN603
com
2
0.5-R
coil AI Self holding relay CA-1pm
2f-Y CN618
CN100 1 0.5-B/W EU CN781-1 CB-1pf
Working lamp(-) 2 0.85-B Lever lock SW(L) TravelSensor 1.25-Lg/R
CN780
coil
2f-R/W 090-2pf
CN18
4coil
CN250-8pf CN11 DL090-2pf 1 CN250-3pm
1 2
CN455 2 3
ST0-01T-187N CN624 0.5-R
CabPowersource CN250-3pf Buzzer(F)(-) CN625 0.5-W
WorkLight
CN302
contact3
2 1 CN784 Speaker,L(+) CA-1pm Cabin,GND
com
coil contact Light relay 0.5f-G/W 0.5-G/W fromTravelAlarmPower
4 3 com 2 1 TravelAlarmPower 0.5-B 2f-B CN604
RoomLight coil CA-1pm 1 CN(A)250-1pf(B)
0.5-B
[main] to work lamp
0.5-G/W CN619
8 7 6 5
4 3 2 1 WiperMotor CA-1pm
etc
1 ST0-01T-110N Radio(GND)
0.5-G/W 3 2 CN627 CN626
0.5-W/B
OverLoadWorningPower Speaker,L(-) 1.25-B Cabin,GND(Aux)
OverLoadWorning CN605
0.5-B
CN18
CA-1pm
1 CN250-1pm
W-Boom-ind.
0.5-Y/R 3-B/W 10A Starter

Cab Power GND(cap) 1 CN103 Cap
coil
4coil
Cab GND CN14 Components(Speaker,Radio) should be connected Locally. CN606
1 2
CN104 Key switch 0.85-R 0.85-L 1 CN250-1pf
5A 20A 1 CN250-1pf
contact3
Blower_Motor(A/C)
EU/USA
Room_Light
com
st 2 1 ac 3-R/W 15A 2f-R Auxiliary 0.85-R EU/USA
20A 0.5-B com3 0.5-Y + - CN420
15A 15A 1.25-G/W Wiper/Washer CN317
coil
contact3 coi4 l
Work_Light AI_Motor 1 2 Travel hi-low lamp Radio(+B)_Battery_direct_Line

3-W/R 0.5-R
1 2
15A 1.25-G Cigarette lighter Power source 090-2pf-lamp Radio_Convert(CAP)

1 CN306 CA-1pm
com
0.5-R
Meter_Sub 5A 10A Horn relay AUX2_LeverLockRelay Radio_Convert
3-B
0.85-L
3-R
Antitheft_Sub 2 1.25-L MTW-9pf 0.5-R/Y Radio(AC)
CN308 2 1 2 1 MTW-9pm
Cab relay 5A 0.5-Br/W Room light coil contact
4 3 com coil contact
4 3 com CA-1pm
coil coil 3 2 1
10A 10A 20A 2f-R/W Work light 0.5-B Radio(GND)
1.25-B
Compressor(A/C) Alternator 6 5 4 3 2 1
0.85-R/B 9 8 7 CB-1pf
3-R 10A 0.5-L/W Horn 6 5 4
0.5-L 9 8 7 0.5-Y Speaker.R(+)
Cigarette_Lighter 15A 5A Lever_Lock 5A 0.5f-L/W Lever lock 0.5-W/R CB-1pf Harness(main,Cabin)
Light+
Lock
EU/USA
0.5-L/B
10A 0.5-Y/R Alternaator 0.5-Y/R NA

6 5 4 3
CN45 Speaker.R(-)
1
0.5-B
Lsw Rsw
com nc
15A 10A 5A 0.5-Y Travel Hi-Low 1 Horn(+) Rsw JSControl(L) CB-1pf

5-R
Horn 0.85-G
1
Auxiliary 3 2 1 DL090-6pf
5A 0.85-B/Y Meter Sub 0.5-W Speaker.L(+)
6 5 4
0.5-B/R
CB-1pf
2
10A
2
15A 1 Lsw Gsw Gsw
Free
Meter_Main 10A 0.85-R/B Meter Main 0.85-R/B EU/USA

Light-
Wiper/Washer 0.5-W/B Speaker.L(-)

CN472 CN46
0.5-B
Beacon sw EU 10A 1.25-R Anti theft sub 0.5-R Horn(-) CB-1pf
5A 5A Travel_Hi-Low 2.3II-6pf 5A 0.5-R/W Anti theft main
Antitheft_Main EU/USA EU
0.5-B
0.5-G EU 15A 2f-B/L AI Motor 0.5-R/G
10A 5A
0.5-B/W
Overload_Warning Relay_Source 5A relay source
0.5-Y/R
coil
4coil
1 2
0.5-L
contact3
10A
com
Starter 5-R/W 3-R/W
10A 0.5-R/W OverloadWarning
0.5-B
10A 1.25-R/W Compressor 3-R/W
20A 2-R Blower Motor
0.5-Lg
1.25-B
1.25-B
CN101
3-B
M8 GND
1.25-B CN102
0.85-Y
3-B
CN651 3-B
090-8pf air conditioner SW M8 GND
1.25-L/Y 0.5-L/B
3 2 1 1.25-R/W CN655 CN(A)250-4pf 0.5-R/B
8 7 6 5 4 clutch relay 0.5-B/R 0.5-B
0.5-B
1.25-R/W 0.5-W/R
2 1 0.5-L
0.85-R/B
coil contact
4 3 com
5-R
0.5-W coil 1.25-Y

2f-L
1.25-B 0.5-W
0.5-B
1 2
CN250-4pf
CN652 1 2 0.5-R/W 0.5-R/G
resistor CN655
0.5-L/W blower relay 0.5-W/R
Me 2 1
coil contact
2 1 0.5-L/W 4 3 com CN(A)250-4pf
4 3 coil
Lo Hi
3 2 1
1.25-Y
0.5-L/B
0.85-B
6 5 4
0.5-Y/R
0.5-R/B
1.25f-L
2f-L/W
FuelSupplyPumpDriveRelay
FW-L-6F
5-R/W
0.5-G/R
E.SpeedSensor-vcc
6pf
LeverLockSolenoid
AIPressu.SW
2f-B/Y CN17 AUX_Controller
2 1 Glow relay 3-B/R
coil coil
3-R 4 3
0.5-L/W com NO E.SpeedSensor-vout
0.5-G RefrigerantPress.SW
ChargeSW
TravelAlarm
FuelPump
GND
OilSW
CN658 E.SpeedSensor-gnd
3-R/W
Compressor
5 4 3 2 1 090II-5pf 16 15 14 13 WaterTemp.Sensor
GND
RefrigerantPress.SW +5V
Thermo_SW CN336 12 11 10 9 AUX2-L 4 3
LeverLockSol. SWP-16pm 8 7 6 5 Glow 2 1 58-M-4pm
1 312-1pm TravelHi-LowSorenoid 8 7 6 5 GND MotorPot 0.5-B FuelSensorGND [main]_to_engine
(LH) 4 3 2 1 4 3 4 3 2 1
2 1 58-M-8pm Alternator AUX2-R
CN653 AIPressu.SW 58-X-2pm 2 1 SWP-4pm AUX-L
WaterTemp.Sensor AUX-R FuelSensor
2f-L 1 blower motor TravelHi-LowSorenoid 0.5-B/Y
2 CN250-2pf
CN337 main_to_[engine]
1 312-1pf LeverLockSol.
FuelSensorGND
FuelSensor
AUX2-L 2 1 AUX2-R
Alternator
LeverLockSol.
0.5-L/B AIPress.SW TravelHi-LoSorenoid 58-M-2pf
4 3 58-M-4pf
TravelHi-LoSorenoid AUX-R AUX-L
2 1 2 1 SWP-4pf Glow TravelAlarm
SWP-16pf 4 3 4 3 2 1 58-M-8pf GND
4 3 2 1 GND 8 7 6 5 0.5-L
8 7 6 5 MotorPot
RefrigerantPress.SW 12 11 10 9 +5V
5-R/Y
GND
Compressor
ChargeSW
16 15 14 13
OilSW
FuelPump
Buzzer(R)(+)
0.5-G/W
WoterTemp.Sensor
WoterTemp.Sensor
0.5-R/B
0.5-B
3-R/W
AIPress.SW
CB-1pf
E.Speedsensor-vcc
1 RefrigerantPress.SW
E.Speedsensor-gnd
E.Speedsensor-vout
2 Buzzer(R)(-)
0.5-B
5-R/W
0.5-B/Y
EU/USA
0.5-Y
1 2 1.25f-B/W
AEX-8-R AEX-8-R CN8
0.5-R/G
CA-1pm
0.5-W/R
AI pressure SW
0.5-R/G
1 1 CN12
0.5-G/R
AEX-8-R 090-2pf
0.5-R/G
0.5-R
AVX-3-B/R
Lever lock solenoid
0.5-W/R
CN375-1pm
AVX-1.25f-B/Y
CN375-1pf
0.5-G
AVX-1.25f-W
AVX-1.25f-Y/R
AVX-1.25f-B/R
AVX-1.25f-Lg
AVX-1.25f-B
0.5-Y/R
AVX-1.25f-L
Battery + Terminal EU/USA - +
090-2pf 1 2 1 2 1
100A
SB-BOX-8p
30A
60A
refrigerant press SW 1 2
2f-R/W
2f-R/W
CN13 CN37-1
CN657 2 1 Travel hi-low solenoid Starter(+)
3 2 1 AUX.[R]control_SOL 1
Vcc Vout GND CN32 CN427 2
- +
60f-B/R
Water temp. senser 2 1 Fuel pump

CN33 store pull 2 1 CN28
AVX-1.25f-Y
E, speed sensor CN36 E. oil switch CN24

E. stop solenoid
EU/USA AUX.[L]control_SOL
CN656 CN428
Compressor(Aircon) 0.5-G/W
0.5-L
M4
0.5-R
M6 FC-250-1pm 1
M10 CN115 2
CN113
Alternator(+B) Battery (+)
CN114 1
SWP-3pm 3 2 1
Wire harness Glow plug CN25
Alternator
Startor(+B)
EU [main]_to_Fuel_supply_pump EU
1 2 1 2
main_to_[Fuel_supply_punp] FuelSensor 2pcs-Aux2(R)sol

SB-BOX-8p-2PF 3 2 1 SWP-3pf CN23 2pcs-Aux2(L)sol CN869
SWP-2pf CN871
SWP-2pm
Sonsor GND DUMMY

0.5-B 0.5-B
1 2 3
1 2
0.5-L
1 2
0.5-L
Fuel Supply Pump Starting SW
(Black)
HM090-2pm
0.5-R 0.5-L
1 2
3-W Harness(fuel)
EU
0.5-W
3-R 1 3-R Fuse

1 Fuse
5A
2
CN(A)250-1pf CN(A)250-1pm 30A

com
coil NO
1
3-R 1
3 2 1
6 5 4 CN250-6pf
0.5-G
coil null NC Fuel Supply Pump

2 1 dewtsch-2pf
0.5-L
Starting Relay
2 1
1 2 0.5-G
Ext. Fuel Supply Pump Ext. Fuel Pump
0.5-R
21
coil contact CN(A)250-4pf
4 3
coil com
Fuel Supply Pump Stop SW
Fuel Supply Pump Stop Relay
HM090-2pm
0.5-W 2 1 0.5-L
0.5-Br HM090-2pf
3-Br
Wire harness (Fuel pump) 1 2

0.5-Y
Fuel Level Sensor

EU
0.5-L
Y R B
FW-L-6F 3 2 1
6pf 6 5 4
0.5-Br
4min.Timer
0.5-L M8
GND KX080-3α/AB Export (theft),AI AUX A/C
V-M-14
f) Electrical Circuit Diagram, KX080-3AB
5A CN-11-2 CN-11-1 SWP-16p-6
CN-14-3
off
on CN-14-1
Starter
start CN-14-2 10A
Travel Hi-Low Lamp

CN-420-1 CN-420-2
CN-13-1 CN-13-2

4 2
CN-410-4 CN-410-2
AI Self-hold relay
Meter Sub
5A CN-1-12 +B

10A
CN-1-1 AC-1
CN-34-4 CN-34-2
CN-23-2 2 2 4 5V CN-1-21
CN-2-15 +5V
CN-23-3 Engine to
AI Console CN-1-22
GND CN-421-4
+12V CN-421-2 CN-1-14
CN-421-5
SW2 CN-421-6 CN-1-4
CN-1-15

JS Control(R)
GND
pot
+5V CN422-3
CN422-1
SWP-16p-14
M
Main to Engine
CN422-5 CN422-6
CN-2-19 AI Motor
CN-33-3
Power_Source(12V)
Engine speed sensor
5V 3
CN-1-18 5 CN-428-1
SWP-4p-1 CN-428-2
2 Solenoid_Out_2
AUX. sol(+)-R
CN-2-13 RS-485(+) CN-1-19 6 CN-427-1
CN-33-1 SWP-16p-5 CN-1-20
Flash cnt
CN-2-9
CN-2-11 Txd-1

CN-28
10A CN-306-3 CN-306-1
CN-2-17 Motor-GND
CN-306-2 CN-306-4
CN-45
CN-454-1
CN-454-2
CN-454-5
CN-454-6
CN-454-7
CN-454-3
CN-454-8
CN-454-4

Antithieft_sub
+B
RS-485-con
10A CN-440-7
CN-453-7
GND
CN-453-8
CN-453-3
CN-453-2
CN-453-4
CN-453-5
CN-453-6
CN-453-1
CN-440-6
CN-440-12 RF-GND

CN-440-1
CN-441-5 Anti theft horn Relay
Starter relay
CN-440-2 RS-485-con
CN-441-2 CN-7-1 CN-5-1 CN-17-4 CN-17-3
CN-441-1 CN-440-5 CN-440-11
Txd(RF-unit) RS-485(+) CN-17-1 CN-17-2
Rxd(RF-unit) RS-485(-) CN-37
CN-114
CN-441-4 CN-440-4 CN-440-10 58-M-2p-1
Anti theft RF Unit Anti-theft controller Anti theft Unit Main to Engine
Alternator
CN-113

10A CN-25-1
58-M-8p-6
CN-25-2
58-M-8p-2
CN-302-3 CN-302-1
CN-18-2 CN-100
60A
30A
Light relay
CN-36-2
58-M-2p-2
Relay source
5A
100A
Battery
58-M-8p-8
CN-24-2
15A 1 3 1 2 58-M-4p-1 CN(A)250-4p-1
2 4 3 CN-869-2
6 58-M-4p-2 CN(A)250-4p-2 CN-869-1
CN-871-1 30A 1 2
M
Cab relay
CN-308-3 CN-308-1
Start relay
4 Fuel Level Sensor
1 1 1
1 2 3 6 5A 2 4
Stop Relay
Relay_Out_1
5
Relay_Out_2
Power_Source(12V) 6
3
Power_Source(GND)

SWP-16p-13 SWP-3p-1

CN455-1 CN-781-1-1 CN-781-1-2 CN-783
CN-784
Main to Engine
6 CN(A)250-4p-3
CN250-2p-1
-5V CN-765-1 -5V SWP-3p-1
Wiper Motor
Cabin Source(AUX) 2
CN-601-1
CN-765-3 SWP-3p-3 M
CN-601-2 GND GND
+1 S +
CN-601-3
1
3
4
CN-601-4
Cab_Work_lamp_R
CN-600-1 CN-17-2
CN-600-2 CN-17-2
1
3
4
CN-841-2 CN-841-1
2
CN-821-1 CN-821-3 CN-17-2

CN-600-6 CN-821-2 CN-821-4 CN-17-2
15A
CN-841-4 CN-841-3 CN-17-2
Cab Worklight SW
Wiper sw
off CN-609-5
CN-609-6
on CN-609-1
Washer Motor
5A CN-600-5 CN-611 M
CN-610-2
CN-612
CN-317-2 CN-317-2 Speaker (R) 2
CN-317-2 CN-317-2 7
3
CN-317-2 CN-317-1 4 6
15A CN-317-2
CN-317-1 CN-317-1 5
Power source
CN-317-2 1
CN-655-1 CN-655-3
CN-472-5 CN-472-1 CN-600-4 CN-657-2 SWP-6p-12
M
FT
CN-472-6 CN-472-3
Hi
Lo
Mi
Compressor
CN-652-3
CN-652-1
CN-652-4
CN-651-7 Lo Com
20A CN-653-1 M CN-651-8 Hi
CN-655-1 CN-655-3 CN-653-2
CN-651-4
CN-651-1
CN-651-5
CN-800-1
CN-801-2
<KX080-3α/AB Export with anti-theft & AI & Air Conditioner & OverLoad Warning>
V-M-15
V ELECTRICAL SYSTEM
g) Electrical Wiring Diagram, KX080-3AB
0.5-R/Y 0.5-W/B
0.5-L
0.5-L/Y
0.5-B/Y
Horn-sw
EC/USA
pot
GND
0.75f-R/Y
CN422
0.75f-Br
8 7 6 5 dewtsch-8pf
+5V
Br-lock-sw-Vcc
Br-lock-sw-sw
Blank
AnalogGND
Horn-sw-Vcc
0.75f-B/Y
MotorPot
OverLoadWarningSW
4 5 6 4t Room Lamp(GND) IC62
CN442 090MT-6pf 0.85-Y
0.5-L HM090-6pf 1 2 3 Anti theft Antenna unit(cap) CN612 WORK/L(+)
3 2 1 EU/USA M5
Room Lamp(+)
Travel hi-low Lock sw CN611 2 1 CB-1pf
E03F(BR) 0.5-Y/B CN15 0.5-Y CN441 0.85-B WORK/L(GND)
1 2 TNS-3pm Anti theft Antenna unit 2f-B 6 5 4 3
Motor_sensor 3 485+ 485- 1 2 3
4 5 6
HM090-6pm CA-1pm
CB-1pf
EU EU(with Anti theft)
Overload_Warning_Buzzer 8 7 6 5 0.5-W
CN250-2pf 0.5-R/B
JB-8pm
CN454 4 3 2 1 090II-2pf Harness (Wiper) 1.25-Lg/R
1 CN610 2f-Y CN613
Work lamp,R(+)
2 Washer motor
0.5-Br 0.5-B/Y
0.5-Br/W CN6 EU 3 2 1 CB-1pf CN614
2 EU 7123-1347 6 5 4 CN609 2f-R
0.5-B/R 0.85-W Wiper SW
AUX-SW
Overload_Warning_Pressure_sw 0.5-R/B EU 485- 0.75(SoftVCTF-0.75*4core)-G
+12V
485+ 0.85-R CA-1pm
US
2 1
AMP090-JMk2-3pf
0.5-R/W
0.5-Br
4 2f-B
2 1
8 7 6 5 US 0.5-L
0.5-R/Y
4 3
2 1
1.25f-R
4 3
2 1 CN615
4 3
2 1
2 1
8 7 6 5 485+ 485- 0.75(SoftVCTF-0.75*4core)-R 2 1
0.5-Br/W WorkLight coil contact
4 3 com 2-Y Work lamp,L(+)
+5V 0.75(SoftVCTF-0.75*4core)-B Indicator(GND) 6 5 4 3
0.5-O
0.5-Br AUX-LED 0.85-G coil
Vcc
0.5-R 0.5-Br
pot
0.5-Br CN440 CN841
AI-SW
EU/USA
US
CN821
3 2 1
3 2 1

1
CN421 0.5-O CN1 EU 0.5-Br EU(with Anti theft) CabWorkLightRelay 0.85-B CN616
On-Off
6244-5061
0.5-B
8pf meter (big) Anti theft unit Work lamp,L(GND)
2
FW-L-8F SWP-12pf 0.5-B
0.5-R
(cap/antitheft) CabWorkLightSW
3

com
SWP-3pf CN7 4 3 2 1 0.5-B

SWP-3pm 11 10 9 8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1 8 7 6 5
0.5-B/Y
22 21 20 19 18 17 16 15 14 13 12 20 19 18 17 16 15 14 13 12 11 meter(small) 090II-2pm 12 11 10 9
CN2
0.5-W 040_3-20pf Wire harness (Travel alarm) Harness(main,Cabin) 0.5-R RoomLight WorkLight
0.5-Br/W
4 3 2 1
1.25-Lg/R WiperMotor
8 7 6 5
2 1
EU EU 1.25-Lg/R etc
0.85-L/W
0.85-L/B
0.85-R
0.85-B
0.85-B/R
0.85-R/B ST0-01T-187N CN628
0.5-Y 0.5-R 1 CN628
2f-B 0.5-L Speaker,R(+) CN617
EU EU/USA
0.5-B/W
1 0.5-R/Y M6
2f-R
ST0-01T-110N CN622 Cap
coil
Buzzer(F)(+)
4coil
2 2f-Y
0.5-B CN601
1 2
0.5-Y/R
2 1 CN783 CN250-4pf
4 3
1
0.5-G/W Speaker,R(-)
4 3
2 1
Main to [work lamp]
0.5-R/Y
0.5-B/W
0.75f-B 0.5-B coil contact
4 3 com CN410 1 0.5-L Radio(AC) CN250-4pm
contact3
CN603
com
2
0.5-R
2f-Y CN618
CN100 1 0.5-B/W EU CN781-1 CB-1pf
1 CN780
coil
2f-R/W 090-2pf
CN18
4coil
CN250-8pf CN11 DL090-2pf CN250-3pm
1 2
CN455 2 3
ST0-01T-187N CN624 0.5-R
WorkLight
CN302
contact3
2 1 CN784 Speaker,L(+) CA-1pm Cabin,GND
com
0.5f-G/W 0.5-G/W fromTravelAlarmPower
4 3 com Light relay
coil contact 2 1 TravelAlarmPower CA-1pm
0.5-B 2f-B 1 CN604
RoomLight coil CN(A)250-1pf(B)
0.5-B
[main] to work lamp
0.5-G/W CN619
8 7 6 5
4 3 2 1
WiperMotor CA-1pm
etc
0.5-G/W 3 2 CN627 CN626
0.5-W/B
0.5-B
CN18
CA-1pm
1 CN250-1pm
W-Boom-ind.
3-B/W 10A Starter

0.5-Y/R
coil
4coil
1 2
5A 20A 1 CN250-1pf
contact3
Blower_Motor(A/C)
EU/USA
Room_Light
com
st 2 1 ac 3-R/W 15A 2f-R Auxiliary 0.85-R EU/USA
20A 0.5-B com3 0.5-Y + - CN420
coil
contact3 coi4 l

3-W/R 0.5-R
1 2
15A 1.25-G Cigarette lighter Power source 090-2pf-lamp Radio_Convert(CAP)

1 CN306 CA-1pm
com
0.5-R
Meter_Sub 5A 10A Horn relay AUX2_LeverLockRelay Radio_Convert
3-B
0.85-L
3-R

CN308 2 1 2 1 MTW-9pm
4 3 com CA-1pm
coil coil 3 2 1
10A 10A 20A 2f-R/W Work light 0.5-B Radio(GND)
1.25-B
0.85-R/B 9 8 7 CB-1pf
3-R 10A 0.5-L/W Horn 6 5 4
0.5-L 9 8 7 0.5-Y Speaker.R(+)
Light+
Lock
EU/USA
0.5-L/B

6 5 4 3
CN45 Speaker.R(-)
1
0.5-B
Lsw Rsw Rsw
com nc
15A 10A 5A 0.5-Y Travel Hi-Low 1 Horn(+) JSControl(L) CB-1pf

5-R
Horn 0.85-G
1
Auxiliary 3 2 1 DL090-6pf
5A 0.85-B/Y Meter Sub 0.5-W Speaker.L(+)
6 5 4
0.5-B/R
CB-1pf
2
10A
2
15A 1 Lsw Gsw Gsw
Free

Light-

CN472 CN46
0.5-B
5A 5A Travel_Hi-Low 2.3II-6pf 5A 0.5-R/W Anti theft main
Antitheft_Main EU/USA EU
0.5-B
0.5-G EU 15A 2f-B/L AI Motor 0.5-R/G
10A 5A
0.5-B/W
0.5-Y/R
coil
4coil
1 2
0.5-L
contact3
10A
com
Starter 5-R/W 3-R/W
0.5-B
0.5-Lg
1.25-B
1.25-B
CN101
3-B
M8 GND
1.25-B CN102
0.85-Y
3-B
CN651 3-B
090-8pf air conditioner SW M8 GND
1.25-L/Y 0.5-L/B
3 2 1 1.25-R/W CN655 CN(A)250-4pf 0.5-R/B
8 7 6 5 4 clutch relay 0.5-B/R 0.5-B
0.5-B
1.25-R/W 0.5-W/R
2 1 0.5-L
0.85-R/B
coil contact
4 3 com
5-R
0.5-W coil 1.25-Y

2f-L
1.25-B 0.5-W
0.5-B
1 2
CN250-4pf
CN652 1 2 0.5-R/W 0.5-R/G
resistor CN655
Me 2 1
coil contact
2 1 0.5-L/W 4 3 com CN(A)250-4pf
4 3 coil
Lo Hi
3 2 1
1.25-Y
0.5-L/B
0.85-B
6 5 4
0.5-Y/R
0.5-R/B
1.25f-L
2f-L/W
FW-L-6F
5-R/W
0.5-G/R
E.SpeedSensor-vcc
6pf
LeverLockSolenoid
AIPressu.SW

coil coil
3-R 4 3
ChargeSW
TravelAlarm
FuelPump
GND
OilSW
E.SpeedSensor-gnd
CN658
3-R/W
Compressor
WaterTemp.Sensor
5 4 3 2 1 090II-5pf 16 15 14 13
GND
RefrigerantPress.SW +5V
Thermo_SW CN336 12 11 10 9 AUX2-L 4 3
(LH) 4 3 2 1 4 3 4 3 2 1
2 1 58-M-8pm Alternator AUX2-R
CN653 AIPressu.SW 58-X-2pm 2 1 SWP-4pm AUX-L
WaterTemp.Sensor AUX-R FuelSensor
2f-L 1 blower motor TravelHi-LowSorenoid 0.5-B/Y
2 CN250-2pf
FuelSensorGND
FuelSensor
AUX2-L 2 1 AUX2-R
Alternator
LeverLockSol.
4 3 58-M-4pf
TravelHi-LoSorenoid AUX-R AUX-L
SWP-16pf 4 3 4 3 2 1 58-M-8pf GND
4 3 2 1 GND 8 7 6 5 0.5-L
8 7 6 5 MotorPot
5-R/Y
GND
Compressor
ChargeSW
16 15 14 13
OilSW
FuelPump
Buzzer(R)(+)
0.5-G/W
WoterTemp.Sensor
WoterTemp.Sensor
0.5-R/B
0.5-B
3-R/W
AIPress.SW
CB-1pf
E.Speedsensor-vcc
1 RefrigerantPress.SW
E.Speedsensor-gnd
E.Speedsensor-vout
2 Buzzer(R)(-)
0.5-B
5-R/W
0.5-B/Y
EU/USA
0.5-Y
1 2
1.25f-B/W
AEX-8-R AEX-8-R CN8
0.5-R/G
CA-1pm
0.5-W/R
AI pressure SW
0.5-R/G
1 1 CN12
0.5-G/R
AEX-8-R 090-2pf
0.5-R/G
0.5-R
AVX-3-B/R
Lever lock solenoid
0.5-W/R
CN375-1pm
AVX-1.25f-B/Y
CN375-1pf
0.5-G
AVX-1.25f-W
AVX-1.25f-Y/R
AVX-1.25f-B/R
AVX-1.25f-Lg
AVX-1.25f-B
0.5-Y/R
AVX-1.25f-L
Battery + Terminal EU/USA - +
090-2pf 1 2 1 2 1
100A
SB-BOX-8p
30A
60A
2f-R/W
2f-R/W
CN13 CN37-1
CN657 2 1 Travel hi-low solenoid Starter(+)
3 2 1 AUX.[R]control_SOL 1
Vcc Vout GND CN32 CN427 2
- +
60f-B/R

CN33 store pull 2 1 CN28
AVX-1.25f-Y
E, speed sensor CN36 E. oil switch CN24

E. stop solenoid
CN656 CN428
0.5-L
M4
0.5-R
M6 FC-250-1pm 1
M10 CN115 2
CN113
CN114 1
SWP-3pm 3 2 1
Alternator
Startor(+B)
1 2 1 2
main_to_[Fuel_supply_punp] FuelSensor 2pcs-Aux2(R)sol

SWP-2pf CN871
SWP-2pm
0.5-B 0.5-B Sonsor GND DUMMY
1 2 3
1 2
0.5-L
1 2
0.5-L
(Black)
HM090-2pm
0.5-R 0.5-L
1 2
3-W Harness(fuel)
EU
0.5-W
3-R 1 3-R Fuse

1 Fuse
5A
2
CN(A)250-1pf CN(A)250-1pm 30A

com
coil NO
1
3-R 1
3 2 1
6 5 4 CN250-6pf
0.5-G
coil null NC Fuel Supply Pump

2 1 dewtsch-2pf
0.5-L
Starting Relay
2 1
1 2 0.5-G
0.5-R
21
4 3
coil com
Fuel Supply Pump Stop SW
Fuel Supply Pump Stop Relay
HM090-2pm
0.5-W 2 1 0.5-L
0.5-Br HM090-2pf
3-Br
Wire harness (Fuel pump) 1 2

0.5-Y
Fuel Level Sensor

EU
0.5-L
Y R B
FW-L-6F 3 2 1
6pf 6 5 4
0.5-Br
4min.Timer
0.5-L M8
GND KX080-3α/AB Export (theft),AI AUX A/C
V-M-16
WSM KX080-3AB Mechanism and Service VI ANGLE BLADE
VI ANGLE BLADE
Mechanism and Service Section
a) Specifications ..................................................................................................................... VI-3

b) Angle Blade Overview ....................................................................................................... VI-4
c) Installation .......................................................................................................................... VI-8
d) Swivel Joint ........................................................................................................................ VI-9
e) High Pressure Hose ......................................................................................................... VI-13
f ) Angle Blade Pilot valve .................................................................................................... VI-14
g) Control Valve ................................................................................................................... VI-19
h) Hydraulic Hose ................................................................................................................ VI-20
i ) Angle Cylinder ................................................................................................................. VI-25
j ) Control Lever ................................................................................................................... VI-26
k) Blade Bushings ................................................................................................................ VI-27
l) Swivel Frame ................................................................................................................... VI-28
m) Grease Point .................................................................................................................... VI-29
n) Decals .............................................................................................................................. VI-30
o) Hydraulic Circuit Diagram ................................................................................................ VI-35
VI-1
VI-2
VI. ANGLE BLADE

a) Specifications
Machine specification: Service port, TPSS, Arm rest, Long arm, 4-Post canopy, KTC-bucket
No Specifications Items Unit KX080-3AB KX121-3ST KX161-3ST U45ST Remarks
Q1 Main Speed JIS A8404
2 1 Weight Machine weight kg 8550 ± 171 4200 ± 85 5340 ± 107 5200 ± 107 Fuel tank: full, lub, oil,
(Cab, rubber track) lbs 18849 ± 377 9259.3 ± 187.4 11772.6 ± 235.9 11463.9 ± 235.9 coolant
2 Machine weight kg 8600 ± 172 4265 ± 85 5415 ± 107 5275 ± 107
(Cab, steel track) lbs 18960 ± 379.2 9402.6 ± 187.4 11937.9 ± 235.9 11629.3 ± 235.9
6 1 Blade Width mm 2200 ± 5 1700 ± 5 1960 ± 5 1960 ± 5
inch 86.6 ± 0.2 66.9 ± 0.2 77.2 ± 0.2 77.2 ± 0.2
2 Height mm 510 ± 10 395 ± 10 385 ± 10 385 ± 10
inch 20.1 ± 0.4 15.6 ± 0.4 15.2 ± 0.4 15.2 ± 0.4
3 Max. lift above GL mm 580 ± 50 425 ± 50 460 ± 50 460 ± 50
inch 22.8 ± 2.0 16.7 ± 2.0 18.1 ± 2.0 18.1 ± 2.0
4 Max. below GL mm 620 ± 50 500 ± 50 480 ± 50 480 ± 50
inch 24.4 ± 2.0 19.7 ± 2.0 18.9 ± 2.0 18.9 ± 2.0
5 Blade swing angle Left deg. 25 ± 5 25 ± 5 25 ± 5 25 ± 5
6 Right deg. 25 ± 5 25 ± 5 25 ± 5 25 ± 5
Q2 Main Specs JIS A8404
1 3 Declination of blade mm > 10 >
inch 10 > 0.39 >
3 1 Blade approach angle deg. 28 ± 3 26 ± 3
Q5 Work performance
5 1 Blade speed up (G→T) sec. - 1.3 ± 0.3 1.5 ± 0.3 1.5 ± 0.3 Ground to max. up
2 up (L→T) sec. 2.3 ± 0.3 2.6 ± 0.3 2.5 ± 0.3 2.5 ± 0.3 Max. down to max. up
3 down sec. Max. up to ground
- 1.5 ± 0.3 1.9 ± 0.3 1.9 ± 0.3
(T→G)
4 down sec. Max. up to max. down
3.0 ± 0.3 3.4 ± 0.3 3.8 ± 0.3 3.8 ± 0.3
(T→L)
8 1 Angle speed Left sec. 2.2 ± 0.3 1.6 ± 0.3 1.5 ± 0.3 1.5 ± 0.3 Side end to side end
Right sec. 2.2 ± 0.3 1.6 ± 0.3 2.5 ± 0.3 2.5 ± 0.3
2 5 Cylinder oil sealing Blade 50±5°C mm 20 20 Arm: vertical to GL,
capacity (122±9°F) inch Blade: Max. down,
0.79 Eng. stop: 10 min.
1 9 Blade lever up kgf 2.2 ± 0.5 2.9 ± 0.5 2.9 ± 0.5 2.9 ± 0.5 Measurement point:
N 22 ± 5 28.44 ± 4.9 28.44 ± 4.90 28.44 ± 4.90 Below 15 mm (0.6 in.)
from top of lever grip
lbf 4.9 ± 1.1 6.4 ± 1.1 6.4 ± 1.1 6.4 ± 1.1
10 down kgf 2.9 ± 0.5 2.9 ± 0.5 2.9 ± 0.5 2.9 ± 0.5
N 28 ± 5 28.44 ± 4.9 28.44 ± 4.90 28.44 ± 4.90
lbf 6.4 ± 1.1 6.4 ± 1.1 6.4 ± 1.1 6.4 ± 1.1
11 Float on kgf 10.0 ± 0.5 10.0 ± 0.5 10.0 ± 0.5 10.0 ± 0.5
N 98 ± 5 98.07 ± 4.90 98 .07 ± 4.90 98 .07 ± 4.90
lbf 22.0 ± 1.1 22.0 ± 1.1 22.0 ± 1.1 22.0 ± 1.1
Float off kgf 2.1 ± 0.5 4.0 ± 0.5 4.0 ± 0.5 4.0 ± 0.5
N 21 ± 5 39.23 ± 4.90 39 .23 ± 4.90 39.23 ± 4.90
lbf 4.6 ± 1.1 8.8 ± 1.1 8.8 ± 1.1 8.8 ± 1.1
24 Blade angle lever Left kgf 2.6 ± 0.5 4.8 ± 0.5 4.8 ± 0.5 4.8 ± 0.5
N 25 ± 5 47.07 ± 4.90 47.07 ± 4.90 47.07 ± 4.90
lbf 5.7 ± 1.1 10.6 ± 1.1 10.6 ± 1.1 10.6 ± 1.1
25 Right kgf 2.6 ± 0.5 4.8 ± 0.5 4.8 ± 0.5 4.8 ± 0.5
N 25 ± 5 47.07 ± 4.90 47 .07 ± 4.90 47.07 ± 4.90
lbf 5.7 ± 1.1 10.6 ± 1.1 10.6 ± 1.1 10.6 ± 1.1
2 9 Blade lever stroke up mm 60 ± 10 70 ± 15 60 ± 10 60 ± 10 Measurement point:
inch 2.4 ± 0.39 2.76 ± 0.59 2.4 ± 0.4 2.4 ± 0.4 top of lever grip
Exclude lever idle
10 down mm 60 ± 10 65 ± 15 60 ± 10 60 ± 10
inch 2.4 ± 0.39 2.56 ± 0.59 2.4 ± 0.4 2.4 ± 0.4
11 Float mm 95 ± 15 120 ± 15 95 ± 15 95 ± 15
inch 3.7 ± 0.6 4.72 ± 0.59 3.7 ± 0.6 3.7 ± 0.6
15 Angle lever stroke Left mm 35 ± 10 35 ± 10 35 ± 10 35 ± 10
inch 1.4 ± 0.4 1.38 ± 0.39 1.4 ± 0.4 1.4 ± 0.4
16 Right mm 35 ± 10 35 ± 10 35 ± 10 35 ± 10
inch 1.4 ± 0.4 1.38 ± 0.39 1.4 ± 0.4 1.4 ± 0.4
VI-3
b) Angle Blade Overview

1. Angle blade assy overview
2. Side view, angle blade
3. Cutting blades
Tightening bolt: RD819-74631

M14x1.5
Nut tightening torque: 12.0~14.0 kgf·m
VI-4
4. Standard blade
5. Angle blade cylinder
6. Grease points
7. Bushing
VI-5
8. Angle blade cylinder hoses
9. Angle blade cylinder hose ports
10. Standard blade cylinder hose
VI-6
11. Angle blade frame parts
290
300
250
230 070 060

030 340 010 Blade
200 330 020 Assy frame, Angle
180 030 Bush
280 140 040 Bush
060
080 050 Cir clip, Internal
280 170 040 070
200 160
290
300
060 Nipple, Grease
010 070 Seal, Dust
190 150
080 Seal, Dust
030 090 Blade, Cutting
/A 070
100 Bolt
130 130 Pin
140 Shim
330 150 Nipple, Grease
340
040
160 Plate
050 180 Pin, Angle, Cylinder
080 A 190 Pin, Angle, Cylinder
/
030 200 Nipple, Grease
020 230 Cover, Angle, Cylinder
~
100 050 250 Cover, Angle
RD819-153-10
090 290 Pin
300 Spacer
12. Control lever linkage

280 /
270
/
/
110 010
290 020
060
170 / 010 Assy lever angle
050
030
020 Bush
020 120
030 Screw, Rod-end RH
050 Braket, Angle lever
060 Pin, Joint
240
020 080 Pin, Snap
/ 100 Nut, Lock
150 110 Screw, Rod end
120 Nut, Lock
130 Bracket
220 200
080 150 Screw, Rod end
100 160 Nut, Lock
170 Assy rod, Blade
200 Bracket
220 Screw, Rod-end LH
240 Assy rod, Blade
140 130 270 Grip
280 Button, Switch green
160
RD819-173-10
290 Screw, Pan-head
VI-7
c) Installation
1. Tilt of the blade 3. Routes of the angle cylinder hose and dozer
cylinder rod-side hose
Less than 10 mm (0.39 in.)
No contact
<Failure case>
Poor appearance <Failure case>
2. Movement of the angle Contact
↓
Make sure there is no unusual noise. Hose damaged
↓
Apply molybdenum disulfide grease to the top Oil leak
and bottom faces of each support. (*-marked
locations shown below)
Make sure the backlash of each support is less
than 1.5 mm (0.06 in.)
Add shim (RD411-6639Δ) in case of unusual noise. (1) Cover (angle cylinder)
Note: Usually set up this component without any shim. Bolt
Plain washer
(2) Pipe joint (G2-G2)
Pipe joint (L, G1/4-G3/8)
O-ring
(3) Cover (1, angle)
Bolt
(4) Angle cylinder (rod side)
(5) Bracket (hydraulic, ANG)
Bolt
(6) Dozer cylinder (rod side)
(7) Angle cylinder (bottom side)
(8) The ANG cylinder bottom-
side hose cover is provided
with a slit marking to identify it
from the RD118-7494Δ one.
(9) Blade assembly (ANG, 1550)

Blade (ANG, 1550)
Bushing
Dust sealing (556542)
(10) Cylinder assembly (angle)
(11) Pin (1, angle cylinder)
Grease fitting
Bolt
Plain washer
(12) Pin (angle support)
Grease fitting
Bolt
Plain washer
(13) Frame (U, angle)
Grease fitting
(14) Frame (track, ANG)
VI-8
d) Swivel Joint
1. Fitting direction of the hydraulic adaptor 3. Fitting of the swivel joint assembly (ANG)
Position the adaptor as shown at the figure. (RD819-7550Δ) to the track frame
Tightening torque of the bolts
<Failure case>
Contact with hose and other parts
77.5 ~ 90.2 N·m (7.9 ~ 9.2 kgf·m)
↓ (Apply screw adhesive.)
Friction, oil leak (Loctite 271)
2. Tightening torque of the hydraulic adaptor <Failure case>
G1/4 24.5 ~ 29.4 N·m (2.5 ~ 3.0 kgf·m) 18.1 ~ 21.7 ft·lbs Looseness
G3/8 49.0 ~ 53.9 N·m (5.0 ~ 5.5 kgf·m) 36.2 ~ 39.8 ft·lbs ↓
Come-off
G1/2 58.8 ~ 63.7 N·m (6.0 ~ 6.5 kgf·m) 43.4 ~ 47.0 ft·lbs ↓
Oil leak
<Failure case>
Insufficient tightening
↓ The *-marked parts have been modified for the
Looseness, oil leak, damage angle dozer type.
(1) Elbow pipe joint (G1/2-2), 4 pcs. (15) I (angle right) (26) Straight pipe joint, 2 pcs.
Pipe joint (SG4, 1U), 4 pcs. (16) Machine front (dozer side) O-ring, 2 pcs.
Ports D, E, F and G (17) Pipe joint (S, G3/8-G3/8) Port H (both sides)
(2) Elbow pipe joint (G1/2-2) Pipe joint (LG3, 13/16U) (27) Pipe joint (SG4, 1U), 2 pcs.
Pipe joint (SG4, 13/16U) Port J Port I
Port C (18) Pipe joint (LG3, 13/16U) (28) Pipe joint (LG3, 13/16U)
(3) Elbow pipe joint (G1/2-2) Port I Port I
Pipe joint (SG4, 13/16U) (19) (Dozer side)
Port B (20) Bracket (swivel joint) (5)
(4) Pipe joint (SG2, G2) Bolt, 4 pcs. D (6) B (7)
Pipe joint (L,G1/4-G1/4) (21) Pipe joint (bushing, 1/2) (3)
(1) F (8)
Port A Pipe joint (L, F1/2-F3/8)
(5) Machine back O-ring *(15)
(6) D (left forward) Port H
(7) B (dozer down) (22) Pipe joint (L, G1/4-G1/4), 2 pcs. A (14)
(8) F (left backward) Port A (both sides)
(9) G (right forward) (23) Pipe joint (SG4, 13/16U), 2 pcs. (4)
(2)
(10) E (right backward) Ports B and C G (9) J *(13)
(11) C (dozer up) (24) Pipe joint (SG4, 1U), 2 pcs.
(12) H (drain) Ports E and G E (10) C (11) H (12)
(13) J (angle left) (25) Pipe joint (LG3, 13/16U)
(14) A (dual-speed) Port J
(16)
(21)
*(17)
(22)
*(18)
A (29) (23) (20) (19) A

B
C
F
G (24) (27)
*(28)
D
*(25)
E
I
J
(26)
H H
The *-marked parts are additionally employed for the angle dozer type.
The figure shows the top view of the swivel joint assembly.
The swivel frame is shown to be facing frontward.
VI-9
1. Control valve section: Angle blade
(1)
(5)
(6)
(2)
(3)
(4)
No. Name Q’ty Remarks

1 Valve housing 1
2 Spool 1
3 Cap 2 (1) Tightening torque: 70.6±2.9N·m
(2) Tightening torque: 8.8~10.8N·m
4 Spring sheet 2 (3) One ID-mark for spool insert direction
5 Spring sheet 2 (4) 2-PF1/4
(5) Identification mark, 4pcs
6 Spring 2 (6) 2-PF1/2
7 Socket head bolt 4 JISB1176, M6x18L
8 O-ring 2 JISB2401, 1A, S24
9 Spool (Corupe) 1
10 Poppet (Check valve) 2
11 Spring (Check valve) 2
12 Plug 1
13 Poppet 1
14 O-ring 1 JISB2401, 1B, P7
15 O-ring 1 JISB2401, 1A, G75
16 O-ring 1 JISB2401, 1B, P18
VI-10
2. Control valve section: Dozer blade with float function
T. T.
(18) (17)
T. T.
No. Parts Name

(1) Valve housing
(2) Spool
(3) Cap
(4) Spring sheet
(5) Spring sheet
(6) Spring
(7) Spring
(8) Poppet
(9) Spring
(10) Plug
(11) O-ring
(12) O-ring
(13) Socket head bolt
(14) O-ring
(15) Spacer
(16) O-ring
(17) Cylinder rod side
(18) Cylinder bottom side
VI-11
3. Angle cylinder hose

(7) 1. Routing of the hoses
Connect the hoses. (as shown at left)
Make sure there is no excess twist,
crossover and tight contact inside the
track frame.
<Failure case>
Wrong routing
(6) (8)
Contact, twist
(9)
(10) Hose durability degraded
Swivel joint side Travel motor cylinder side

A Dual-speed pilot Left/right travel dual-speed 2. Connecting direction of the dozer hoses
B Dozer down Dozer cylinder bottom Position the hoses. (as shown at left)
C Dozer up Dozer cylinder rod Orient the dozer hoses (crane-necked)
D Left forward Left B face downward and 15° outward at the
E Right forward Right A track frame.
F Left backward Left A
G Right backward Right B <Failure case>
H Drain Left/right drain port (upper) Wrong fitting angle
I Angle dozer right Angle cylinder rod
J Angle dozer left Angle cylinder bottom Contact with other parts
Hose damaged
(2) (1)
(1) Fitting the dozer and angle hoses

(2) Angle cylinder (rod side)
(3) Angle cylinder (bottom side)
(4) Dozer cylinder (rod side)
(5) Dozer cylinder (bottom side)
(6) Left track
(7) Dozer
(8) Right track
(9) Angle
(10) Hose routes
(3) (4) (5)
Route Part name Tape color

Swivel joint (E) ~ Motor right bottom (A) Hydraulic hose (5/8) Yellow, double (right front) RD819-6371Δ 1415
Swivel joint (G) ~ Motor right top (B) Hydraulic hose (5/8) Green, double (right back) RD809-6372Δ 1355
Swivel joint (F) ~ Motor left bottom (A) Hydraulic hose (5/8) Red, double (left back) RD809-6373Δ 1355
Swivel joint (D) ~ Motor left top (B) Hydraulic hose (5/8) Green, double (left front) RD819-6374Δ 1415
Swivel joint (A) ~ Motor left/right dual-speed Hydraulic hose (1/4) - RD809-6375Δ 1385
Swivel joint (H) ~ Motor left/right drain Hydraulic hose (3/8) - RD809-6378Δ 1310
Swivel joint (C) ~ Dozer relay Hydraulic hose (1/2) Violet RD819-6379Δ 430
Swivel joint (B) ~ Dozer relay Hydraulic hose (1/2) Brown RD819-6380Δ 430
Dozer relay ~ Dozer cylinder (rod) Hydraulic hose (1/2) - RD819-6377Δ 790
Dozer relay ~ Dozer cylinder (bottom) Hydraulic hose (1/2) - RD819-6377Δ 790
Swivel joint (I) ~ Dozer relay Hydraulic hose (1/2, angle, R) Black outside, orange inside RD819-7428Δ 610
Swivel joint (J) ~ Dozer relay Hydraulic hose (1/2, angle, L) White outside, orange inside RD819-7427Δ 440
Dozer relay ~ Angle cylinder (bottom) Hydraulic hose (1/2, angle, L) - RD819-7488Δ 800
Dozer relay ~ Angle cylinder (rod) Hydraulic hose (1/2, angle, R) - RD819-7487Δ 1290
VI-12
e) High Pressure Hose
For the angle dozer type, only additional hoses are listed below
List of pilot hoses (upper structure) (platform, control system)

Part code Size
No. Part name Q’ty Tape color Hose configuration Remarks
(EU) KX080-3 (US) (AU) (mm)
Hydraulic hose White outside,

27 Pilot valve (angle left) ~ Relay plate - RD819-7424Δ - 1 1400 Quick-on PLT04 Quick-on
(1/4, angle, L) orange inside
Hydraulic hose Black outside,

28 Pilot valve (angle right) ~ Relay plate - RD819-7423Δ - 1 1290 Quick-on PLT04 Quick-on
(1/4, angle, R) orange inside
WSM KX080-3AB Mechanism and Service
List of pilot hoses (upper structure) (swivel frame, control valve)

Part code Size
No. Location Part name Q’ty Tape color Hose configuration Remarks
(EU) KX080-3 (US) (AU) (mm)

36 Relay plate ~ Control valve (angle left) - RD819-7422Δ - 1 1940 Quick-on PLT04 G1/4

37 Relay plate ~ Control valve (angle right) - RD819-7421Δ - 1 1570 Quick-on PLT04 Quick-on
VI-13
List of high-pressure hoses (upper structure) (swivel frame, control valve)
Part code Size
No. Location Part name Q’ty Tape color Hose configuration Remarks
(EU) KX080-3 (US) (AU) (mm)
35 Control valve (angle left) ~ Rotary joint (J) - RD819-7418Δ - 1 1170 13/16UN PA2808 13/16UN

36 Control valve (angle right) ~ Rotary joint (I) - RD819-7419Δ - 1 1170 13/16UN PA2808 13/16UN
VI ANGLE BLADE
f) Angle Blade Pilot Valve

1. Installation 4. Quick-on coupler adapter
1. Fitting of the adapters Pipe joint (QL, G1/4-8.4) (RP821-6197Δ)
Make sure there is no detrimental scratch at
Port P
the fitting with the hose.
Filter (68499-8374Δ)
Pipe joint (L, G1/4-G1/4) (RP201-6189Δ) <Failure case>
Pipe joint (QL, G1/4-8.4) (RP821-6197Δ) Detrimental scratch
Fit Ports T, 1, 2, 3 and 4 in position as Oil leak
shown at left.
<Failure case> 5. Fitting of the valve assembly
Port P (RD819-6144Δ)
Failure to install the filter Tightening torque
Dust deposit in valve 48.1~55.9 N·m (4.9~5.7 kgf·m)
<Failure case>
Malfunction Poor tightness
2. Tightening torque of the adapter Bolt loose

G1/4 size 24.5~29.4 N·m (2.5~3.0 kgf·m)
Come-off
<Failure case> Contact with other parts
Poor tightness
Hose damaged
Oil leak
3. Fitting direction of the valve

Place the valve with Ports P and T facing
the machine bottom.
(1) Ports 1 and 3
<Failure case> Straight pipe joint (G2-G2)
Wrong fitting direction Pipe joint (QL, G1/4-8.4)
(2) Ports 2 and 4
Pipe joint (QL, G1/4-8.4)
Poor pilot hose coupling (3) Filter
O-ring
Pipe joint (L, G1/4-G1/4)
Angle dozer pilot valve O-ring
Pipe joint (QL, G1/4-8.4)
(4) Kawasaki remote-controlled valve
Location Hose tape color RCV8C2015-EV1
White (outside), Valve assembly (PV, DZ, ANG)
1 Dozer (left) Bolt
orange (inside)
(5) Pipe joint (T, G2-G2-G2)
Black (outside), Straight pipe joint (G2-G2)
2 Dozer (right)
orange (inside) Pipe joint (QL, G1/4-8.4) (6)
(6) Plate (PV, ANG)
3 Dozer (down) Brown Bolt
4 Dozer (up) Peach
T Port P White
P Port T None
(1)
(2) (5) (4)

(3)
VI-14

1. Outer view
Fit the adapters in their specified angles.
(1) Cover
(3) (2) Body
(3) (3) Detent assy
(4)
(1) (5) Gozer, pilot secondary
control pressure ports
(6) Mounting bolt
(2)
(2)
(6)
(4)
(5)
2. The view from the top after removing the

bolts.
(3) 3. Separate the two pilot valve

(1) Pilot valve for angle blade
(2) Pilot valve for dozer blade
(3) Lever
(6)
(1) (2)
VI-15
4. Remove the detent assy.
5. Remove the lever
6. Inner parts
(1) Detent holder
(2) Shim
(3) Spring
(4) Cap plug, lock nut
(1) (2) (3) (4)
7. Separated view
VI-16
8. Disassembly the push rod, control spool

(1)
and spring.
(1) Push rod
(3) (2) Spool
(3) Control spring
(4) Return spring
(4)
(2)
9. Inner parts
(1) Spool
(2) Control spring
(3) Control shim, t=0.35 mm (0.014 in.)
(2) (4) Spacer
(5) Spring seat
(6) Spilit washer
(3)
(1)
(6)
(5)
(4)
(3)
(2)
(1)
VI-17
10. Parts identification

B 010 Assy valve
400 / 020 Assy spring
410 030 Ball
330 110 040 O-ring
310 050 Kit seal
440 100 060 O-ring
C
290 / 070 Seal
320 190 A 080 Scraper
140 240 / 090 O-ring
060 100 Spacer
260
340 310 200 210 120 060 110 Bolt, HEX-SOC-HD
180 120 Plug
170 290 C/ 130 Cover
090 250
070 / 270 140 Cover
080 / 220 150 Plug
150 180 160 Push rod
A / 160 /C 110 170 Push rod
/
020 040 090 290 180 Washer
B / 070 190 190 Washer
/
190 080 240
C 150 280 200 Bolt, HEX-SOC-HD
010 / / 210 Seat, Spring
020 040 030 230
/ / 180 220 Seat, Spring
050 060 420 160 230 Washer
/
390 090 240 Washer
~
100 090 070 250 Spring

080 030
350 260 Spring
~
150 /
440 430 190 270 Spring
370 / 280 Spring
130 040 020 290 Spring
360 / 300 Lever
380 310 Bush
300 / 320 Camshaft
RD819-146-10
/ 330 Cam
340 Screw
350 Bolt, HEX-SOC-HD
360 Disk
370 Camshaft
380 Screw, Set
390 Bush
400 Nut, Lock
410 Screw, Set
420 Screw, Set
430 Boot
440 Bellows
010 Assy valve

190 020 Bolt
/ 030 Plate
170 200 040 Bolt
190 050 Filter
/ / 060 O-ring
200 180 070 Joint, Pipe
080 O-ring
/ 090 Joint, Pipe
A 200 100 O-ring
/ 190 110 Joint, Pipe (TG-G-G)
180 120 O-ring
170 060 130 Joint, Pipe
140 O-ring
/ 090 050 150 Joint, Pipe
200 / 160 O-ring
190 080 170 Joint, Pipe
100
180 O-ring
040 020 190 Joint, Pipe
200 O-ring
/
010 100
120 130
090
110 140 070
/ / 150
020 030 160
/
A 160
150
/
RD819-145-10
VI-18
g) Control Valve
1. Fitting of the valve assembly (RD819-7401)
Fit the assembly.
Tightening torque: (1) Pipe joint (LG3, 11/16U) (37) (high)
24.5~29.4 N·m (2.5~3.0 kgf·m) Pipe joint (S, G3/8-G3/8) (38) (left forward)
(2) Pipe joint (LG4, 13/16U) (39) (right forward)
Pipe joint (S, G1/2-G1/2) (40) (rod)
<Failure case> (74) O-ring (41) (rod)
Poor tightness (3) Pipe joint (LG4, 13/16U) (42) (high)
Pipe joint (SG4, G4) (43) (bottom)
Adapter loose (73) (75) (4) Pipe joint (LG4, 13/16U) (44) (right)
Pipe joint (SG4, G4) (45) (rod)
(5) Pipe joint (LG4, 13/16U) (46) Pipe joint (L, G1/4-G1/4)
Come-off joint (SG4, G4) O-ring
(6) Pipe joint (LG4, 1U) Straight pipe joint
Pipe joint (bushing, 1/2) (47) Pipe joint (L, G2, G2-G2)
Note: The *-marked parts are added or modified for the angle dozer type. (7) Pipe joint (LG4, 1U) Pipe joint (S, G1/4-8.4)
Pipe joint (S, G1/2-G1/2) (48) Pipe joint (L, G1/4-M10)
O-ring O-ring
(8) Pipe joint (LG6, 1U) Switch (pressure, 25.OK)
Pipe joint (SG5, G6) O-ring
(46) (47) (60) (59) (58) (9) Pipe joint (LG12, G8) (49) Pipe joint (S, G1/4-G1/4)
(48) Valve assembly (return) O-ring
(1) (2) Pipe joint (SG12, G12) Valve assembly (check)
(3) (17) (10) Pipe joint (L7/8U,1U) Pipe joint (To Q, G1/4-8.4)
(61)
(49) Pipe joint (S7/8U, 7/8U) (50) Pipe joint (S, G1/4-8.4)
(4) (62) (11) Pipe joint (L7/8U, 1U) (51) Pipe joint (SG2, 9/16U)
(18) Pipe joint (S7/8U, 7/8U) Pipe joint (SG2, G2)
(50)
(63) (12) Pipe joint (L7/8U, 1U) (52) Pipe joint (S, G1/4-G1/4)
(5) (21) Pipe joint (S7/8U, 7/8U) (53) Pipe joint (QL, G1/4-8.4)
(22) (35) Adapter (gauge) 612 351 (54) Pipe joint (To Q, G1/4-8.4)
(6) (13) Pipe joint (L7/8U, 13/16U) (55) Pipe joint (LG3, 11/16U)
(64) Pipe joint (S7/8U, 7/8U) Pipe joint (S, G3/8-G3/8)
(23) (36)
(14) Pipe joint (LG2, 9/16U) (56) Pipe joint (To Q, G1/4-8.4)
(24) (37) (65) (15) Pipe joint (LG4, 11/16U) (57) Pipe joint (To Q, G1/4-8.4)
(7)
Pipe joint (S, G1/2-1/2) (58) Pipe joint (QL, G1/4-8.4)
(25) O-ring (59) Pipe joint (S, G1/4-8.4)
(16) Pipe joint (SG4, 13/16U) (60) Pipe (LG4, 13/16U)
(26) (51) Pipe joint (L, G1/2-G1/2) (61) Pipe joint (LG4, 13/16U)
(38)
Pipe joint (S, G1/2-1/2) Pipe joint (SG4, G4)
(8) (27) (39) O-ring (62) Elbow pipe joint
(52)
(17) Pipe joint (S, G1/4-G1/4) (63) Pipe joint (S, G1/2-1/2)
(66) O-ring O-ring
(28)
Valve assembly (check) (64) Pipe joint (LG4, 1U)
(9) (53) Pipe joint (L, G1/4-G1/4) (65) Pipe joint (LG4, 1U)
(18) Pipe joint (L, G1/4-G1/4) Pipe joint (S, G1/2-G1/2)
(67) Straight pipe joint (G2-G2) O-ring
(19) Pipe joint (L, G1/4-G1/4) (66) Pipe joint (LG6, 1U)
(68) (20) Pipe joint (L, G1/4-G1/4) Pipe joint (SG6, G5)
(29) (40) (21) P3 bypass (67) Pipe joint (L7/8U, 13/16U)
(10) (22) Swivel (left) (68) Pipe joint (L7/8U, 13/16U)
(30) (41) (23) Dozer (bottom) Pipe joint (S7/8U, 7/8U)
(69) (24) S/P2 (low) (69) Pipe joint (L7/8U, 1U)
(11)
(31) (42) (25) Communication valve (70) Pipe joint (L7/8U, 1U)
(26) Travel (left backward) Pipe joint (S7/8U, 7/8U)
(54)
(32) (43) (27) Travel (right backward) (71) Pipe joint (LG4, 11/16U)
(12) (28) Travel independent valve (72) Pipe joint (SG4, 13/16U)
(70) (29) Arm (bottom) Pipe joint (L, G1/2,-G1/2)
(30) Bucket (bottom) (73) Make sure the groove is
(19) (31) S/P1 (low) positioned as shown here
(13) (55)
(33) (44) (32) Boom (rod) (toward the control valve).
(33) Swing (left) (The same is true with the
(14) (34) (45) (34) Angle dozer (bottom) other side.)
(56) (71) (35) (right) (74) Groove
(15)
(36) (rod) (75) (Control valve)
*(16) *(20)
*(57) *(72)
VI-19
h) Hydraulic Hoses
1. Pilot hose 1
Pilot hoses
(3) (4) Tape
No. Location Part code Q’ty
color
(1)
1 P4, T assembly block ~ Pilot valve (left) (P) Pilot valve boost White RD809-6333Δ 1
2 P4, T assembly block ~ Dozer pilot valve (P) Dozer pilotvalve boost White RD809-6334Δ 1
(2) 3 Dozer pilot valve (P) ~ Pilot valve (right) (P) Pilot valve boost White RD809-6332Δ 1
(5)
4 P4, T assembly block ~ Travel pilot valve (P) Travel pilot valve boost White RD809-6335Δ 1
5 Travel pilot valve (P) ~ Swing pilot valve (P) Swing pilot valve boost White RD809-6336Δ 1
20 Pilot valve (left) (T) ~ (P4, T) assembly block Drain RD809-6343Δ 1
21 Pilot valve (right) (T) ~ Dozer pilot valve (T) Drain RD809-6342Δ 1
22 Dozer pilot valve (T) ~ (P4, T) assembly block Drain RD809-6344Δ 1
23 Swing pilot valve (T) ~ Travel pilot valve (T) Drain RD809-6346Δ 1
24 Travel pilot valve (T) ~ (P4, T) assembly block Drain RD809-6345Δ 1
25 P4, T assembly block ~ Shock-less valve (T) Drain RD809-6349Δ 1
26 Boom H/V (Dr) ~ (P4, T) assembly block Drain RD809-6358Δ 1
(7) (8)
(15)
(9) (11)
(6)
(10) (12)
(1) Valve assembly (shock-less)
(13) (2) (Control valve)
(3) Valve assembly (PV, travel)
(4) Attention to the fitting angle of the crane-
necked hose at Port P.
(5) Machine front
(6) Adapter (pilot hose, 1)
(8) Valve assembly (pilot, R)
(9) (Front)
(14) (10) (Back)
(11) (Front)
(12) (Back)
(13) (Port locations viewed from the valve top)
(14) (Used for the angle dozer lever)
Valve assembly (pilot, OFF)
(15) (Used for the swing pedal)
VI-20
2. Pilot hose 2
(6) Pilot hoses

(1) (4) (7) No. Location tape color Parts No. Q'ty
(3) 6 Pilot valve (swivel left) ~ Shuttle valve Swivel (left) Gray RD809-6249Δ 1
(8)
7 Pilot valve (swivel right) ~ Shuttle valve Swivel (right) Light blue RD809-6248Δ 1
(9) (10) (11)
8 Pilot valve (arm crowded) ~ Relay adapter Arm (crowded) Blue RD819-6244Δ 1
9 Relay adapter ~ Shockless valve (arm crowded) Arm (crowded) Blue RD819-6294Δ 1
(2)
(5) (14) 9-1 Arm shockless valve ~ Shuttle valve (arm crowded) Arm (crowded) Blue RD819-6277Δ 1
(12) (13) (15)
10 Pilot valve (arm dump) ~ Relay adapter Arm (dump) Yellowish green RD819-6245Δ 1
11 Relay adapter ~ Shockless valve (arm dump) Arm (dump) Yellowish green RD819-6295Δ 1
12 Pilot valve (bucket crowded) ~ Relay plate Bucket (crowded) Orange RD819-6246Δ 1
13 Pilot valve (bucket dump) ~ Relay plate Bucket (dump) Red RD819-6247Δ 1
14 Pilot valve (boom up) ~ Relay adapter Boom (up) Green RD819-6242Δ 1
15 Relay adapter ~ Shockless valve (boom up) Boom (up) Green RD819-6292Δ 1
16 Pilot valve (boom down) ~ Relay adapter Boom (down) Yellow RD819-6243Δ 1
17 Relay adapter ~ Shockless valve (boom down) Boom (down) Yellow RD819-6293Δ 1
18 Dozer pilot valve (up) ~ Relay plate Dozer (up) Pink RD809-6271Δ 1
19 Dozer pilot valve (down) ~ Relay plate Dozer (down) Brown RD809-6272Δ 1
(16)
(1) Valve assembly (shockless)

(2) Valve assembly (swivel shuttle)
(26) (3) H/V
(4) Adaptors for arm
(26) (5) Arm (crowded)
(6) Bracket (pilot hose)
(7) (View A)
(8) Shockless valve (drain)
(9) Bucket (dump)
(10) Dozer (up)
(11) Dozer (down)
(27) (12) Boom (up)
(28)
(13) Boom (down)
(22) (23) (27) (14) Bucket (crowded)
(15) Arm (dump)
(17) (19) (17) Arm (crowded)
(18) Boom (up)
(19) Boom (down)
(20) Arm (dump)
(29) (21) Adapter (pilot hose, 2)
(24) (25) (22) Boom (down)
(18) (20) (23) Arm (crowded)
(24) Arm (dump)
(21) (25) Boom (up)
(26) (Front)
(27) (Back)
(28) Valve assembly (pilot, R)
(29) (Used for dozer lever)
VI-21
3. Pilot hose 3
(1)
(23) No. Location Tape color Part code Q’ty
13 Shuttle valve ~ Control valve (swivel left) Swivel (left) Gray RD819-6259Δ 1
(2) (24) (25)
14 Shuttle valve ~ Control valve (swivel right) Swivel (right) Light blue RD819-6258Δ 1
15 Shuttle valve ~ Control valve (arm crowded) Arm (crowded) Blue RD819-6254Δ 1
Yellowish
16 Relay plate ~ Control valve (arm dump) Arm (dump) RD819-6255Δ 1
green
17 Relay plate ~ Control valve (arm crowded) Bucket (crowded) Orange RD819-6256Δ 1
18 Relay plate ~ Control valve (bucket dump) Bucket (dump) Red RD819-6257Δ 1
19 Shock-less valve ~ Control valve (boom confluence Pbu) Boom (up) Green RD819-6252Δ 1
Control valve (boom confluence Pbu) ~ Control valve Boom
(3) 20 Green RD809-6297Δ 1
(boom up) (confluence, up)
21 Shock-less valve ~ Control valve (boom down) Boom (down) Yellow RD819-6253Δ 1
Boom Both ends: Yellow
22 Shock-less valve ~ Boom H/V (boom down signal) RD809-6298Δ 1
(anti-fall release) Center: White
Travel pilot valve (left forward) ~ Control valve (left Travel
23 Red RD809-6263Δ 1
forward) (left, forward)
Travel pilot valve (left backward) ~ Control valve (left Travel
24 Blue RD809-6264Δ 1
backward) (left, backward)
Travel pilot valve (right forward) ~ Control valve (right Travel
25 Yellow RD809-6261Δ 1
forward) (right, forward)
Travel pilot valve (right backward) ~ Control valve Travel
26 Green RD809-6262Δ 1
(right backward) (right, backward)
27 Swing pilot valve (left) ~ Control valve (swing left) Swing (left) Orange RD809-6266Δ 1
Yellowish
28 Swing pilot valve (right) ~ Control valve (swing right) Swing (right) RD809-6265Δ 1
green
29 Relay plate ~ Control valve (dozer up) Dozer (up) Violet RD819-6273Δ 1
(4)
30 Relay plate ~ Control valve (dozer down) Dozer (down) Brown RD819-6274Δ 1
(5) SP1 SOL (high-pressure) ~ Control valve (SP1, high- SP1
(6) 31 Violet RD809-6267Δ 1
pressure) (high-pressure)
(7) SP1 SOL (low-pressure) ~ Control valve (SP1, low- SP1
(8) 32 Brown RD809-6268Δ 1
pressure) (low-pressure)
(12) SP2 SOL (high-pressure) ~ Control valve (SP1, high- SP2
33 Violet RD809-6275Δ 1
(9) pressure) (high-pressure)
SP2 SOL (low-pressure) ~ Control valve (SP1, low- SP2
34 Brown RD809-6276Δ 1
(10) pressure) (low-pressure)
(11) 35 Control valve (PF1) ~ Control valve (PF2) P3 confluence Blue, red RD809-6296Δ 1
White outside,
36 Relay plate ~ Control valve (dozer left) Dozer (left) RD819-7422Δ 1
orange inside
Black outside,
37 Relay plate ~ Control valve (dozer right) Dozer (right) RD819-7421Δ 1
orange inside
(13)
) (1) Control valve assembly (ANG) (14) Valve assembly (shock-less)

(18 (14)
(20) (2) Valve assembly (unload) (15) Swivel (left)
(3) Valve assembly (proportional) (16) Swivel (right)
(19) (21) (22) (17) Valve assembly (swivel shuttle)
(15) (4) Bracket (pilot hose)
(5) (View A) (18) H/V
(16) (6) Dozer (down) (19) Arm (crowded)
(7) Dozer (up) (20) (Used for the swing pedal)
(17) (8) Bucket (crowded) Valve assembly (pilot, OFF)
(9) Bucket (dump) (21) (Left)
(10) Dozer (right) (22) (Right)
(11) Dozer (left) (23) Valve assembly (PV, travel)
(12) Arm (dump) (24) (Left)
(13) Adapter (pilot hose, 3) (25) (Right)
VI-22
4. High & low pressure hose
No. Location Tape color Part code Q’ty
1 Pump (P1) ~ Control valve (P1) Delivery (P1) Red, white RD809-6321Δ 1
2 Pump (P2) ~ Control valve (P2) Delivery (P2) Red, white RD809-6322Δ 1
(2) 3 Pump (P3) ~ Control valve (P3) Delivery (P3) Red, white RD809-6323Δ 1
(1)
4 Pump (PPS) ~ Control valve (PPS) LS signal Red, white RD809-6324Δ 1
5 Pump (PLS) ~ Control valve (PLS) LS signal Red, white RD809-6325Δ 1

Boom
12 Pump (PB1) ~ Control valve (PB2) Green RD809-6417Δ 1
confluence
Control valve (travel right forward) Travel (right)
15 Yellow, double RD809-6441Δ 1
~ Rotary joint (E) forward
Control valve (travel right Travel (right)
16 Green, double RD809-6442Δ 1
backward) ~ Rotary joint (G) backward
Control valve (travel left forward) ~ Travel (left)
17 Red, double RD809-6443Δ 1
Rotary joint (D) forward
Control valve (travel left backward) Travel (left) Yellowish
18 RD809-6444Δ 1
~ Rotary joint (F) backward green, double
Control valve (swivel left) ~ Swivel
19 Swivel (left) Gray RD809-6451Δ 1
motor (B)
Control valve (swivel right) ~
20 Swivel (right) Light blue RD809-6452Δ 1
Swivel motor (A)
(3) Control valve (dozer down) ~
23 Dozer (down) Brown RD809-6471Δ 1
Dozer cylinder (bottom)
Control valve (dozer up) ~ Dozer
24 Dozer (up) Violet RD809-6472Δ 1
cylinder (rod)
3-way valve ~ Control valve (SP1, SP1
30 Brown RD809-9256Δ 1
low-pressure) (low-pressure)
Control valve (angle left) ~ Rotary Angle dozer White outside,
35 RD819-7418Δ 1
joint (J) (left) orange inside
Control valve (angle right) ~ Rotary Angle dozer Black outside,
36 RD819-7419Δ 1
joint (I) (right) orange inside
(4)
(5)
(1) Pump assembly (piston)

(2) Tank assembly (3-way)
(3) Motor assembly (swivel)
(4) Control valve assembly (ANG)
(5) Swivel joint assembly (ANG)
VI-23
5. Hose installation
C A 1) Angle blade valve 3) Angle blade cylinder
A 010~100: Hydraulic hose A 010~040: Hydraulic hose

090: Nut B 050: Joint, Pipe (SG/U)
100 040 A
B 060: O-ring
030
D B 040 070: O-ring
100 080: Joint, Pipe
B 120
/ 090: O-ring
C 110 100: Joint, Pipe (LG/U)
030 110: O-ring
/ 120: O-ring
080 080 090
010 130: Hydraulic hose
050 050 140: Hydraulic hose
D 070
060 090 /
070 060
140 020
020
090
010
130
RD819-148-10
RD819-150-10
2) Dozer blade cylinder

A
010: Cover
B
030: Hydraulic hose
A 110 040: Hydraulic pipe
B 120
050: O-ring
100 060: Pipe
070: O-ring
090~120: Hydraulic hose
060
070
/
070
010
030 090
080 050
/
050
040
030
RD819-149-10
VI-24
i) Angle Cylinder
1. Fitting of the cylinder adapters
Fit the adapters in their specified angles.
<Failure Case>
Wrong fitting angle
Difficult to connect the hoses
2. Tightening torque of the adapter

G1/2 size
58.8~63.7 N·m (6.0~6.5 kgf·m) 43.4~47.0 ft·lbs
(2)
<Failure Case>
(1) Poor tightness
(Angle cylinder) RD819-7470Δ Oil leak
(1) Pipe joint (SG4, 13/16U)

(2) Pipe joint (bushing, 1/2)
Pipe joint (LG4, 13/16U)
010 Assy cylinder

170 020 Assy tube, Angle
180
100
030 Bush
010 040 Assy rod, Angle
090
190 050 Bush
060 Piston
080
070 Nut, Lock
140 080 Cylinder head
150 090 Bush
160 100 Ring, Snap
100 Kit seal
120 Assy seal
130 Ring
140 U-ring
150 Ring, Back up
160 Ring, Wiper
170 O-ring
/ 180 Ring, Back up
030
070 190 O-ring
020
130
020
/ 060 /
040 040
050 120 010 /
130 060
120
~
110
~
190
RD819-151-10
VI-25
j) Control Lever
1. Adjusting of the dozer lever neutral position 3. Location of the DU bushing
Position the lever Apply grease.
<Failure case> <Failure case>
Malpositioned Failure to grease
↓ ↓
Malfunction Bigger rotation resistance
2. Check points after fitting Excessive grease
↓
Make sure the valve spool moves over its full Poor appearance
stroke.
Make sure the valve spool moves smoothly.
<Failure case>
Insufficient dimensions
↓
Dust sealing stretched out, damage
(1) Plain washer (8) Bracket assembly (control R1, ANG)

Anti-rotation nut Bracket (control, R, 1, ANG)
(2) Bracket (lever, ANG) Bushing
(3) Headed pin Bolt
Plain washer (9) Lever assembly (dozer, ANG)
Snap pin Lever (dozer, ANG)
(4) Rod-end right-hand female screw Bushing
Bolt (10) Grip (dual-speed) (12)
(5) Rod-end right-hand screw Pan-head machine screw
Anti-rotation nut (11) 41 (neutral)
(6) Bracket (PV, ANG) (12) Up
Bolt (13) Down (10)
Rod-end left-hand female screw (14) Float (13)
Bolt (15) 15 (neutral)
Rod assembly (blade) (14)
Rod (M8-142)
Nut
Nut left-hand screw 8
(7) Fixture (PV, ANG) (9)
Bolt
Rod-end left-hand screw
Anti-rotation nut
Rod assembly (blade) (11)
Rod (M8-142)
Nut (8)
Nut left-hand screw 8
(15)
(1)
(2)
(3)
(4)
(6) (7)
(5)
Move the lever over the full stroke (*-marked range) to make sure it
does not hit against the cover (right top).
VI-26
k) Blade Bushings
1. Inserting of the bushing 3. Fitting direction of the dust sealing
Using a contact block or the like, set the bush- Fit the sealing
ing in position.
<Failure case>
* Do not hit directly upon the bushing. Wrong direction
↓
<Failure case> No greasing possible, pins unusually worn out
Bushing damaged
2. Dimensions of the bushing in place
Ensure the dimensions of the dust sealing on
both sides.
(It is acceptable to check the press-fitting
dimensions only.)
<Failure case>
Insufficient dimensions
↓
Dust sealing stretched, damage
(1)
(8)
(2) (3)
(10)
(7)
(11)
(5) (6)
(10)
(4)
(9)
(1) (Enlarged view of the dust sealing)

(2) Bushing side
(3) Outside
(4) Bushing
(5) Insert down.
(6) Contact block
(7) Bushing
(8) Inserting direction of the bushing and dust sealing
(9) Inserting direction of the bushing, circlip and dust sealing
(10) Dust sealing
(11) Circlip
VI-27
l) Swivel Frame
1. Fitting of the grommets
(RD809-4143Δ)
(RD809-4144Δ)
(RD809-4145Δ)
Secure the grommets as shown bellow.
Apply instantaneous adhesive.
<Failure case>
Failure to apply instantaneous adhesive
Come-off
Hose worn-out
(1) View A
(2) Grommet (2, swivel)
(3) View B
(5) Guide (hose, swing)
Bolt
Note: The *-marked parts have been added for the
angle dozer type.
(7) View C
(1)
(5) (2)
(3)
(4)
(6) C
(8)
(7)
95
VI-28
m) Grease Points
1. Fitting direction of grease fittings 2. Greasing quantity
Type A: Straight (06611-15010) Feed grease until it comes out of the other face
Type B: 67° (06616-25010) of the turning part.
Fit them as shown bellow.
<Failure case>
<Failure case> Too much grease
Wrong direction ↓
↓ Grease dripping from the turning face
No greasing possible ↓
Poor appearance
* The *-marked grease fittings are additionally employed for the angle dozer type.
*(1)
*(1)
(2)
*(1)
(1)
(2)
(2)
(1) Type A
(2) Type B
VI-29
n) Decals
(1)
(2) (4)
(3)
(7) (5)
(6)
(1) Marking (float angle blade)

* Adjust the stick-on position referring to the surface protective sheet's edge.
(2) Dozer blade back
(3) Label (lifting)
* Apply on the other side too.
(4) Right control box and angle dozer control lever
(5) Stick on along this line.
(6) Label (dozer, caution)
(7) D (details)
VI-30
(14)
(3) (12) (15)

(4)
(13)
(2)
(1)
(16)
(11)
(1) Align with this line.
(2) Label (dozer, caution)
(3) Label (operation pattern)
VI-31
(17) (4) Apply at the center.
(5) Label (inspection, US, 1)
(18) (6) Nameplate (serial number)
(7) Label (barcode)
(5) (8) Label (new-vehicle sticker)
(9) Cover seam
(10) Label (inner/outer attachment
(19) switching)
(11) Label (lever lock)
(12) Label (KUBOTA)
(10) (13) Marking (model number, right,
US)
(14) Label (INT, TIER4)
(15) Marking (floating angle blade)
(16) Marking (Auto Idle)
(9) (17) End of R50
(18) Label (get-on/get-off caution)
(Move up the lever and make
(6) (8) sure it positions itself at level.)
(19) Label (fuse)
(20) Marking (model number, left,
US)
(7) (20) (21)
(21) Label (crawler adjustment)
VI ANGLE BLADE
(1) (1) Tag (anti-theft key, US)
Destined for KTC
(No need for KTA-destined machines)
(2) Label (lifting prohibited, EU)
(4 locations)
(3) Marking (floating angle blade)
(2) (4) Label (INT, TIER4)
(5) Marking (KUBOTA)
(3)
(4)
VI-32
(5)
VI ANGLE BLADE
(1)
50
25 (3)
150
18
0
24
(2) 30
(4) 56 (6)
(7)
27 (8)
300
28 26 30
VI-33
(5)
100
80
45 (9) 200
30
(1) Apply the same one on the other side too.

(2) Marking (KUBOTA, US)
(one each on both sides)
(3) Label (lifting)
2 (one each on both sides)
10
(4) Label (lubrication, ANG)
Apply this one on the other side only.
(5) Label (caution)
(8) Label (lifting)
(9) Label (tie-down)
VI ANGLE BLADE
VI-34
o) Hydraulic Circuit Diagram

1. KX080-3AB: Angle Blade
Swivel motor
MSG-44P-21
RD809-6128Δ
Arm cylinder
RD809-6760Δ
Boom cylinder
RD809-6750Δ
Function
PL
SH

PG Dr
GA GB A
c2 c2
Travel motor
(31) Travel motor
(100) ( 2F ) ( Dr ) ( 2F ) ( Dr )
A
(36) Travel (L)
(39) (41) Bucket
(44) Swing
b6
a1 (47) Accumulator
PSVL2-36C-4 (49) Hydraulic pump
PAI (51) Travel (L)
b2 b7
b4 b1 b5 b1 (56) Rear
PB1 (58) Left
(59) Right
( f r om Pb4 )
Pp2 Pp3 17 18 21 22
4 3 19 20 5 6 7 8 9 10 11 12 13 14 15
16 2 1 1 2 9 16 15A 15 10 21 22 12 11 3 4 (63) Adapter
(64) Swivel left
A B A B
(67) Pattern (B)
(81) (82) (83) (84) (85) (86) (87) (88)
(68) Pattern (A)
(50) (101) (102) (60) (69) Arm crowd
(57) (70) Arm dump
(51) (52) (53) (54) (55) (56)
(58) (59) 1 T 2 1 2 (71) Boom down
(61) T T
P P (72) Boom up
(92) (74) Dozer up
(47) (48) T T (90) (91) (93) (94) (75) Bucket crowd
(64)
6 5 8 7 17 18
(46) PLS PPS
A B C D (66) P T (79) P/V (Left)
PAC (67) (68)
(45) P (49)
(ISO) 1 2 3 4 (JD) (81) Left
C (69) (82) Right
d3 P3 P1 P2 (70) (83) Forward
d2 (71)
(84) Rear
(72)
Pp (85) Left
(86) Right
a5 (87) Forward
(73)
(74) (88) Rear
(95) (75) (89) P/V (Dozer)
E (76) (90) Up
Ps
(77) (91) Down
CH2 (78) (92) Angle
Pog P3s CH1 14 13 20 19
(93) Left
(94) Right
(96) (97) (95) P4, T
A B
A H1 B Flow Devider
T
(98) Angle
(99) Right
(100) Left
(102) LDamper
080MC_KQA_67_3_ANG_06
VI-35
2. KX080-3AB: Angle Blade

Dozer cylinder: Float position
Angle cylinder: Left-ward
Swivel motor
MSG-44P-21
RD809-6128Δ
Arm cylinder
RD809-6760Δ
Boom cylinder
RD809-6750Δ
Function
PL
SH

PG Dr
GA GB A
c2 c2
Travel motor
(31) Travel motor
(99) A M B
(100)
B (24) A (25) A (26) B (27) C/V a5 0.2 Line filter (30) Swivel joint
d4 ( Dr ) C B J I D F
( 2F )
A
( Dr )
H E G
( 2F )
A
( Dr )
H Angle section a6 3.9 Pump control (31) 2way valve
A
(36) Travel (L)
(39) (41) Bucket
(44) Swing
b6
a1 (47) Accumulator
(49) Hydraulic pump
PAI (51) Travel (L)
b2 b7
b4 b1 b5 b1 (56) Rear
PB1 (58) Left
(59) Right
( f r om Pb4 )
Pp2 Pp3 17 18 21 22
4 3 19 20 5 6 7 8 9 10 11 12 13 14 15
16 2 1 1 2 9 16 15A 15 10 21 22 12 11 3 4 (63) Adapter
(64) Swivel left
A B A B
(79) (80) (66) Terminal adapter
( t o Pbu 1 ) Angle blade (67) Pattern (B)
(81) (82) (83) (84) (85) (86) (87) (88)
pilot valve (68) Pattern (A)
(50) (101) (102) (60) (69) Arm crowd
(57) (70) Arm dump
(51) (52) (53) (54) (55) (56)
(58) (59) 1 T 2 1 2 (71) Boom down
(61) T T
P P (72) Boom up
(92) (74) Dozer up
(47) (48) T T (90) (91) (93) (94) (75) Bucket crowd
(64)
6 5 8 7 17 18
(46) PLS PPS
A B C D (66) P T (79) P/V (Left)
PAC (67) (68)
(45) P (49)
(ISO) 1 2 3 4 (JD) (81) Left
C (69) (82) Right
d3 P3 P1 P2 (70) (83) Forward
d2 (71)
(84) Rear
(72)
Pp (85) Left
(86) Right
a5 (87) Forward
(73)
(74) (88) Rear
(95) (75) (89) P/V (Dozer)
E (76) (90) Up
Ps
(77) (91) Down
CH2 (78) (92) Angle
Pog P3s CH1 14 13 20 19
(93) Left
(94) Right
(96) (97) (95) P4, T
A B
A H1 B Flow Devider
T
(98) Angle
(99) Right
(100) Left
(102) LDamper
080MC_KQA_67_3_ANG_06
VI-36
3. KX080-3AB: Angle Blade-version
Swivel motor RD809-6128 Arm cylinder Boom cylinder

MSG-44P-21 Dozer cylinder Angle cylinder Travel motor RD809-6760 RD809-6750
Function
RD809-7510 RD819-7470 (28) (29) RD809-6150 Bore 100 Bucket cylinder Bore 115 Swing cylinder (1) Swivel Right (9) Arm Crowd (16) Boom Up
Gear ratio 20.615 Bore 125 Bore 80 SGM-04D-S-09KT Rod 60 RD809-6780 Rod 65 RD809-6740 (2) Swivel Left (10) Arm Dump (17) Boom Swing Left
Motor Disp. 1F 46.9 Bore 90 Stroke 878 Bore 110 (11) Bucket Crowd (18) Boom Swing Right
Bearing swivel/ Rod 65 Rod 45 Dr Dr
100/13 cm3/rev. 2F 25.29 Rod 55 Cushion bearing Rod 60
2F 2F
PL
(8) Travel Right Forward (15-A) Boom H/V PL
SH

PG Dr
GA GB A
c2 c2
Travel motor
(31) Travel motor
(100) ( 2F ) ( Dr ) ( 2F ) ( Dr )
A
(36) Travel (L)
(39) (41) Bucket
(33) (34) (35) ( HI GH) ( LOW) (36) (37) (38) (40) (43) ( BTM) ( ROD) (44) ( ROD) ( BTM) (98) ( ROD) ( BTM) (42) S/P 1
Bk 5 Ak 5 Bk 4 Ak 4 Bk 3 Ak 3 Bk 2 Ak 2 Bk 1 Ak 1 P B1 A1 B2 A2 B3 A3 PB2 B4 A4 B5 A5 B6 A6 b6 1.96 Unload valve (43) Boom
(44) Swing
b6
a1 (47) Accumulator
PSVL2-36C-4 (49) Hydraulic pump
PAI (51) Travel (L)
b2 b7
b4 b1 b5 b1 (56) Rear
PB1 (58) Left
(59) Right
( f r om Pb4 )
Pp2 Pp3 17 18 21 22
4 3 19 20 5 6 7 8 9 10 11 12 13 14 15
16 2 1 1 2 9 16 15A 15 10 21 22 12 11 3 4 (63) Adapter
(64) Swivel left
A B A B
(67) Pattern (B)
(81) (82) (83) (84) (85) (86) (87) (88)
(68) Pattern (A)
(50) (101) (102) (60) (69) Arm crowd
(57) (70) Arm dump
(51) (52) (53) (54) (55) (56)
(58) (59) 1 T 2 1 2 (71) Boom down
(61) T T
P P (72) Boom up
(92) (74) Dozer up
(47) (48) T T (90) (91) (93) (94) (75) Bucket crowd
(64)
6 5 8 7 17 18
(46) PLS PPS
A B C D (66) P T (79) P/V (Left)
PAC (67) (68)
(45) P (49)
(ISO) 1 2 3 4 (JD) (81) Left
C (69) (82) Right
d3 P3 P1 P2 (70) (83) Forward
d2 (71)
(84) Rear
(72)
Pp (85) Left
(86) Right
a5 (87) Forward
(73)
(74) (88) Rear
(95) (75) (89) P/V (Dozer)
E (76) (90) Up
Ps
(77) (91) Down
CH2 (78) (92) Angle
Pog P3s CH1 14 13 20 19
(93) Left
(94) Right
(96) (97) (95) P4, T
A B
A H1 B Flow Devider
T
(98) Angle
(99) Right
(100) Left
(102) LDamper
080MC_KQA_67_3_ANG_06
VI-37
Dozer cylinder: Float position

Swivel motor RD809-6128
Angle cylinder: Left-ward Arm cylinder Boom cylinder
MSG-44P-21 Dozer cylinder Angle cylinder Travel motor RD809-6760 RD809-6750
Function
RD809-7510 RD819-7470 (28) (29) RD809-6150 Bore 100 Bucket cylinder Bore 115 Swing cylinder (1) Swivel Right (9) Arm Crowd (16) Boom Up
Gear ratio 20.615 Bore 125 Bore 80 SGM-04D-S-09KT Rod 60 RD809-6780 Rod 65 RD809-6740 (2) Swivel Left (10) Arm Dump (17) Boom Swing Left
Motor Disp. 1F 46.9 Bore 90 Stroke 878 Bore 110 (11) Bucket Crowd (18) Boom Swing Right
Bearing swivel/ Rod 65 Rod 45 Dr Dr
100/13 cm3/rev. 2F 25.29 Rod 55 Cushion bearing Rod 60
2F 2F
PL
(8) Travel Right Forward (15-A) Boom H/V PL
SH

PG Dr
GA GB A
c2 c2
Travel motor
(31) Travel motor
(99) A M B
(100)
B (24) A (25) A (26) B (27) C/V a5 0.2 Line filter (30) Swivel joint
d4 ( Dr ) C B J I D F
( 2F )
A
( Dr )
H E G
( 2F )
A
( Dr )
H Angle section a6 3.9 Pump control (31) 2way valve
A
(36) Travel (L)
(39) (41) Bucket
(33) (34) (35) ( HI GH) ( LOW) (36) (37) (38) (40) (43) ( BTM) ( ROD) (44) ( ROD) ( BTM) (98) ( ROD) ( BTM) (42) S/P 1
Bk 5 Ak 5 Bk 4 Ak 4 Bk 3 Ak 3 Bk 2 Ak 2 Bk 1 Ak 1 P B1 A1 B2 A2 B3 A3 PB2 B4 A4 B5 A5 B6 A6 b6 1.96 Unload valve (43) Boom
(44) Swing
b6
a1 (47) Accumulator
(49) Hydraulic pump
PAI (51) Travel (L)
b2 b7
b4 b1 b5 b1 (56) Rear
PB1 (58) Left
(59) Right
( f r om Pb4 )
Pp2 Pp3 17 18 21 22
4 3 19 20 5 6 7 8 9 10 11 12 13 14 15
16 2 1 1 2 9 16 15A 15 10 21 22 12 11 3 4 (63) Adapter
(64) Swivel left
A B A B
(66) Terminal adapter
( t o Pbu 1 ) (79) (80) Angle blade (67) Pattern (B)
(81) (82) (83) (84) (85) (86) (87) (88)
pilot valve (68) Pattern (A)
(50) (101) (102) (60) (69) Arm crowd
(57) (70) Arm dump
(51) (52) (53) (54) (55) (56)
(58) (59) 1 T 2 1 2 (71) Boom down
(61) T T
P P (72) Boom up
(92) (74) Dozer up
(47) (48) T T (90) (91) (93) (94) (75) Bucket crowd
(64)
6 5 8 7 17 18
(46) PLS PPS
A B C D (66) P T (79) P/V (Left)
PAC (67) (68)
(45) P (49)
(ISO) 1 2 3 4 (JD) (81) Left
C (69) (82) Right
d3 P3 P1 P2 (70) (83) Forward
d2 (71)
(84) Rear
(72)
Pp (85) Left
(86) Right
a5 (87) Forward
(73)
(74) (88) Rear
(95) (75) (89) P/V (Dozer)
E (76) (90) Up
Ps
(77) (91) Down
CH2 (78) (92) Angle
Pog P3s CH1 14 13 20 19
(93) Left
(94) Right
(96) (97) (95) P4, T
A B
A H1 B Flow Devider
T
(98) Angle
(99) Right
(100) Left
(102) LDamper
080MC_KQA_67_3_ANG_06
VI-38
WSM KX080-3AB Mechanism and Service VII SUPER DOUBLE BOOM
VII SUPER DOUBLE BOOM
Mechanism and Service Section
(A) GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII-3

a) Main Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII-3
b) Feature of Super Double Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII-5
c) Maintenance Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII-11
d) Quality Specifications, Super Double Boom-version. . . . . . . . . . . . . . . . . . . . . . . . . . . VII-16
e) Lifting Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII-19
(B) MACHINE BODY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII-23

a) Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII-23
b) Front pins, Bushings and Shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII-26
c) Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII-39
d) Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII-42
(C) HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .VII-45

a) Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII-45
b) Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII-46
c) Hydraulic Circuit Diagram: Super Double Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII-47
d) Super Double Boom Crowding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII-48
e) Hydraulic Components on the Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII-49
f) Second Boom Pilot Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII-51
g) Travel Pilot Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII-52
h) Shockless Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII-54
i) Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII-55
j) Second Boom Holding Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII-59
k) Second Boom Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII-74
l) Hoses and Pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII-83
(D) ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII-103

a) Wire Harness Route . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .VII-103
b) Boom Cylinder Overload Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .VII-105
c) Electrical Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .VII-107
d) Electrical Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .VII-108
VII-1
VII-2
(A) GENERAL
a) Main Specifications
1. Machine Specifications
KUBOTA EXCAVATOR, KX080-3AB/KX080-3
Model name Super Double boom Mono-boom
Type Cab
Operating weight Steel track Rubber track Rubber track Steel track Steel track
(including operator's weight) (450 width) (450 width) (450 width) (450 width) (600 width)
kg (lbs.) 8840 (19489) 8790 (19379) 8280 (18254) 8330 (18364) 8460 (18475)
Type Water cooled 4 cycle diesel engine with 4 cylinder
Model name KUBOTA V3307-DI-T-E3-BH
Total displacement
3331 (203.27)
cc (cu.in)
Engine
Engine power
52.2 (70.0) / 49.6 (66.5)
SAE gross / net kW (Hp)
Rated speed rpm 2000
Low idling speed rpm 1050 ~ 1150
Swivel speed rpm 9.5
Travel Low: km/h (mph) 2.7 (1.7)
speed High: km/h (mph) 4.9 (3.1)
Ground contact Steel track Rubber track Rubber track Steel track Steel track
pressure (450 width) (450 width) (450 width) (450 width) (600 width)
Performance (With operator) kPa 38.1 38.3 36.0 36.2 27.6
(kgf/cm2) (0.389) (0.391) (0.367) (0.369) (0.281)
[psi] [5.53] [5.56] [5.22] [5.25] [4.00]
Climbing angle % (deg) *36 (20)
Angle in case of
*27 (15)
crossing slope % (deg)
2400 x 500
Dozer Width x Height mm (in.) 2200 x 500 (86.6 x 19.7)
(94.5 x 19.7)
Left rad (deg) 1.22 (70)
Boom swing angle
Right rad (deg) 1.05 (60)
Max.displacement
Pressure (Theoretical) 100 (26.4) / 67 (17.7)
connection SP1 / SP2 L(US gal)/ min
for Max. pressure Mpa 20.6
attachments (kgf/cm2) (210)
SP1, SP2 [psi] [2987]
Fuel tank capacity L (US gal) 115 (30.4)
Note: Above date are identical to specifications in the Operator’s Manual.
· Above dimensions are based on the machine with KUBOTA original bucket and 2100mm (82.7in.) length arm.
* 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.
VII-3
2. Operating Space
1) Super Double boom
· Arm length
2100 Arm
mm (in.)
(A) (B) (C) (D) (E) (F) (G) (H) (I) (J)
KX080-3 590 770 2200 8240 6210 4590 4120 1500 5440 7820
Super Double Boom (23.2) (30.3) (86.6) (324.4) (244.4) (180.7) (162.2) (59.0) (214.1) (307.8)
(K) (L) (M) (N) (O) (P) (Q) (R) (S)

KX080-3 500 500 2540 2200 7670 1500 6940 2150 2420
Super Double Boom (19.7) (19.7) (100.0) (86.6) (301.9) (59.0) (273.2) (84.6) (95.2)
Note:
Above dimensions are based on the machine with KUBOTA original bucket.
Above dimensions are based on the machine with rubber crawler.
Specifications subject to change without notice.
VII-4
b) Feature of Super Double Boom

1. Operational Feature
1) Better workability in narrow space
1-1. Work closer
* The machine performs better in deep digging at near side than standard machines.
* The machine can easily do the lifting at near side.
1-2. Minimum front turning radius
* The machine can swivel with the second boom folded.
2) Loading onto dump truck

2-1. Earth can be loaded from a wide area onto a dump truck without running the machine.
2-2. Earth can be loaded deep onto a dump truck without running the machine.
3) Expanded work zone

* The machine reaches enough farther and work closer.
4) Horizontal digging and leveling off

The machine reaches long with the arm and second boom. Earth can be easily horizontally dug and
leveled off.
2. Working Space Comparison: Mono-boom vs Super Double Boom

Arm length = 2100 mm (82.7 inch)
SDB
1) Overall working space
SDB: Super Double boom
+ 2100 (82.7 in.) arm
MB: Mono-boom
+ 2100 (82.7 in.) arm
MB
Unit: mm
VII-5
SDB 2) Dumping height and loading

height on to truck
Unit: mm (inch)
MB
SDB: Super Double Boom
MB: Mono-boom
5250 (207)
6210 (244)
SDB
MB
2500 (98.4)
SD Boom Mono-boom
VII-6
3) Max. digging reach on the ground
2540 (100)
SDB
7170 (282) 1490 (59)
7670 (302)
4) Ditch digging length

Ditch depth = 1000 mm (39 inch)
SDB
1000 (39)
1490 (59)
MB
MB
SDB
SDB
VII-7
5) Approach digging distance
SDB: Super Double Boom

MB: Mono-boom
SDB
MB
6) Turning radius: front and rear

MB : 2490 (98) SDB: Super Double Boom
MB: Mono-boom
SDB : 2420 (95) RT: Rear tail turning radius
MB=1420 mm (55.9 in.)

1460 mm (57.5 in.)
SDB=1500 mm (59.0in.)
RT
2540 (102)
VII-8
3. Main Performance Comparison

1) Working range and stability equal to or better than the competitors
Kubota Takeuchi Komatsu Neuson Kubota
KX080-3/KX080-3AB TB175 PC75-2 8003 KX251
Weight kg 8700 7940 *8140 7600 *8180 8000 *8910 7860
Overall width mm 2200 2245 2050 2250
Rear over hang mm 380 645 475 485
Maximum dumping height mm 6210 5255 6135 5882 5820
Maximum digging depth mm 4590 4440 4210 4560 4200
Maximum digging radius mm 7810 7650 7770 7778 7410
Front kg *1058 *879 *867 *932 850
Static stability
Sideways kg *736 *686 *562 *838 *678
*marked values are actual measurements. The stability values were converted, as with the 191-kg Kubota bucket attached, for the
same conditions.
2) Improvements in second boom holding power, simultaneous controllability and swivel angle
Kubota Takeuchi Komatsu Neuson Kubota
KX080-3/KX080-3AB TB175 PC75-2 8003 KX251
Second boom cylinder off-
mm 8 167 163 10 -
set amount (10 diggings)
Second boom speed,
sec 4.3/5.3 6.8/8.0 4.7/5.5 4.7/8.4 10.6/11.8
crowd / dump
Swivel angle, left/right degrees 17.5/19 15/15.5 14.5/14 17/19 (16.4/15.9)
*: The KX251 swivel angle is for the single-boom type.
Some of the above data are the actually measured values from one machine each for the purpose of comparison.
Therefore, these are not machine's specifications.
FYI (For Your Information)

1. Super Double Boom machine does not fit in the arm with the thumb-attachment due to its stability.
2. Super Double Boom machine does not have the Angle-Blade version due to the arrangement of
the control valve section
VII-9
4. Operation of the Second Boom

(Super Double Boom)
1. Flip the left pedal lock up to unlock the pedal.

2. Step on the right side of the pedal ( ) to raise
the second boom.
3. Step on the left side of the pedal ( ) to lower
the second boom.
(1) Second boom control pedal

(2) Pedal lock
IMPORTANT:
· Note that the attachment might come in contact
with the boom cylinder, the swing bracket or the
hydraulic hoses when the arm and the bucket are
operated with the second boom crowded.
VII-10
c) Maintenance Specifications
1. Water and Oil Quantity
Unit Mono-boom Super Double Boom Remarks
L 10.5
Radiator ←
gal (2.79) Kubota LLC-N-50F
L 1.3 50%
Reserve tank ←
gal (0.34)
L 10.8 Engine Oil
Engine oil with filter ←
gal (2.83) SAE10W30(CF-4)
L 146
Hydraulic oil Full 159(42.0) ISO 46
gal (38.6)
L 75
Hydraulic oil Tank gauge center ← ISO 46
gal (19.8)
L 1.3 Gear Oil
Wheel motor ←
gal (0.34) SAE90 (API GL-4)
cc 80 Engine Oil
Track roller ←
cu.in. (4.88) SAE30(CD)
cc 60
Upper roller ←
cu.in. (3.66)
SAE30(CD)
cc 80
Front idler ←
cu.in. (4.88)
L 115 Diesel Fuel JIS #3
Fuel tank ←
cu.in. (30.4) (Initial)
Note: Type of oil, fuel and coolant in the remarks are filled in the factory.
Supply grease to such amount that it oozes

Grease
out of periphery of the rotating end. Ultra -pressure grease: EP2, Beacon Q2
Control levers and links Du-bushing Assemble after applying grease
2. Inspection of hydraulic oil

The hydraulic tank of KX080-3, KX080-3AB is pressurized type.
When checking the hydraulic oil level, meet the following conditions and make sure the oil level is above the
center the oil gauge.
1) Oil temp. should be between 10 ~ 30 °C

(50 ~ 86 °F)
2) Stance of front attachment:
Swing: Left end
Dozer blade: Down to the ground
Boom: The highest position
Arm: Crowd to end
Bucket: Crowd to end
Upper limit
25mm (0.98in.)
Lower limit
In this way, large amount of the hydraulic oil in the cylinders is supposed to return back into the hydraulic
tank and result in getting the tank pressurized during the normal operation.
VII-11
3. Maintenance Intervals Chart: KTC, KCL-version

50 100 150 200 250 300 350 400 450
check Daily check

1 Coolant
check Daily check

3 Engine oil
check Daily check

4 Hydraulic oil
Bucket and bucket
- Daily check
link pin
Grease front
5
attachments Boom swing fulcrum - every 100 hrs

check Daily check

12 Fan belt tension
check every 200 hrs
replace every 2 hrs
clean every 200 hrs
element
pressure
check every 200 hrs
replace every 2 hrs
VII-12

500 550 600 650 700 750 800 1000
check Daily check

1 Coolant
check Daily check

3 Engine oil
check Daily check

4 Hydraulic oil
Bucket and bucket
Grease front link pin, Boom - every 100 hrs
5 swing fulcrum
attachments

check Daily check

12 Fan belt tension
check every 200 hrs
replace every 2 hrs
clean every 200 hrs
element
pressure
check every 200 hrs
replace every 2 hrs
VII-13
4. Greasing Front Attachments (without

bucket pin and boom swing fulcrum)
Every 250 hrs
CAUTION
To avoid personal injury:
(1)
· First lower all attachments on the ground
then stop the engine and remove the key.
· While greasing, not to step on the bucket
teeth.
(2)
INPORTANT:
· When doing excavating work in water, generously
grease the following points. After the job, grease
them again.
B (1) Grease the marked grease nipples shown by
(3) P arrows in the illustration below.
(4) B P (7)
(1) 2nd boom bottom linkage (1)
B (2) 2nd boom cylinder boss, rod and bottom sides (4)
(3) 1st boom cylinder rod pin (1)
(4) Boom bottom linkage (1)
B (2) (5) Arm bottom linkage (1)
(6) 1st boom cylinder boss, bottom side (1)
B (2) (7) Arm cylinder pin, rod and bottom sides (2)
(5) B
(8) Bucket cylinder pin, bottom side (1)
Fig. in the left shows the machine stance for applying
grease to the 1st boom cylinder rod pin (3).
(9) B (6) B
(9) B B B P
SB
ST P (9)
(8) P (7) P
(9)
(3) P
(1) B
B (2) (7) P
(2) B
(5) B
(11)
(11)
P
B B P (8) P (7) P
(10)
P: Pin-grease type (10)
B: Boss-grease type
SB: Swivel Bearing Ball
ST: Swivel Bearing Teeth
(9) Swing cylinder boss, rod and bottom sides (2)
(10) Dozer cylinder boss, rod and bottom sides (2)
(11) Dozer arm linkage boss (2)
VII-14
5. Front Attachment (Greasing)

1) Fitting direction of the grease fittings
The grease fittings
Type A: Straight (06611-15010)
Fit them as shown at left.
(1) Details of Section F
(2) Position the grease fitting so that it does not <Failure case>
come in contact with the bucket hose and Wrong direction
SP hose with the 2P cylinder retracted most.
(3) Connector Impossible to grease up
(4) Type A (boss to be greased)
(5) Type A (pin to be greased)
(6) Tube (grease, 900) 2) Greasing amount
(7) Type A (boss to be greased) Apply grease until it flows out of the other side of
(8) Connector the rotating end face.
(9) Tube (grease, 490)
(10) Details of Section E <Failure case>
(11) Connector Over-greasing
(12) Type A
(13) Details of Section G Poor appearance
(10)
(11)
(13)
(12)
(1) (9)
(3)
(8)
(2)
(7)
(6)
(4)
(5)
VII-15
d) Quality Specifications, Super Double Boom-version

Machine specification: Rubber track, Auxiliary port (SP1, SP2), Wrist rest, 2100mm arm, Japan-cab, bucket, AI
(Data listed below are major different values from standard-version.
No Specifications Items Unit KX080-3/KX080-3AB Remarks
Q1 Main Speed JIS A8404
1 1 Machine size mm 6930 ± 139
Total length (Transport)
inch 272.8 ± 5.47
2 mm 2200 ± 22
Total width
inch 86.6 ± 0.9
4 mm 2540 ± 25
Total height (Cabin) Include grouser height
inch 100.0 ± 25
2 2 Weight kg 8800 ± 176 Fuel tank: Full
Lub oil and hydraulic tank
coolant to be specified.
Machine weight (Cabin)
lbs 19401 ± 388 Additional weight: 200kgf (441
lbs)
4 1 Rear end min. turning radius mm 1490 ± 30

inch 58.7 ± 1.2
5 8 Front attachment mm 7820 ± 117
Max. digging radius
inch 307.9 ± 4.6 Swing angle = 0 degree
9 Ground level Max. mm 7673 ± 115 Second boom = Extended
digging radius inch 302.1 ± 4.5
10 Ground level Min. mm 2684 ± 54
Bucket bottom horizontal
finish radius inch 105.7 ± 2.1
11 mm 4588 ± 10.8
Max. digging depth
inch 180.6 ± 4.3
12 mm 4122 ± 124
Max. vertical digging depth
inch 162.3 ± 4.9
14 Max. digging mm 8236 ± 165
height Cabin
inch 324.3 ± 6.5
16 Max. dump mm 6208 ± 124
height Cabin
inch 244.4 ± 4.9
18 Max. dump mm 2550 76
height (Arm Cabin
vertical) inch 100.4 3.0
20 Mini. turning mm 2421 ± 73
radius Cabin
inch 95.3 ± 2.9
22 Mini. turning mm 1984 ± 60
radius Cabin
(Left swing) inch 78.5 ± 22.4
Q5 Work performance
2 5 Boom speed Cabin up 1st sec. 4.0 ± 0.3
6 up 2nd sec. - Oil temp. 50±5°C (122±9°F)
Ground to max. height
7 down sec. 4.4 ± 0.3 (exclude cushioning)
8 down sec. -
2-2 1 Second boom speed crowd sec. 4.7 ± 0.3 Arm extended, bucket dump
2 dump sec. 5.5 ± 0.3 without load.
7 2 Max. digging height mm 1987 ± 199 Second boom extended,
radius Cabin
inch 78.2 ± 7.8 Distance from swivel center
4 Max. dump height mm 2229 ± 134 at bucket pin
radius Cabin
inch 87.9 ± 5.3 Second boom extended
6 Bucket bottom mm 3048 ± 91 Bucket horizontal
height at arm vertical Cabin Second boom extended
inch 120.0 ± 3.6
VII-16

Q6 Swivel, swing performance
2 1 Swivel capable slope angle L deg. 14, 12< Bucket load=JIS heapedx1.8
2 R deg. 14, 12< Second boom extended
3 1 Swivel block L Bucket loaded at heaped.
deg. 0
performance Slope angle at 20°
Engine stop
2 1 min engine stop.
R deg. 0 Hydraulic oil temp: 50°±5°C
3 L Bucket loaded at heaped.
deg. 0 Slope angle at 20°
4 Engine running 1 min engine running.
R deg. 0 Lever lock released
Hydraulic oil temp: 50°±5°C
1 1 Relief pressure setting P1 kgf/cm2 290 ± 10 At pump delivery port
MPa 28.4 ± 1.0 50±5°C(122±9°F)
Engine Max. speed
bar 284 ± 10
psi 4125 ± 142
2 P2 kgf/cm2 290 ± 10
MPa 28.4 ± 1.0
bar 284 ± 10
psi 4125 ± 142
3 P3 kgf/cm2 220 ± 10
MPa 21.6 ± 1.0
bar 216 ± 10
psi 3129 ± 142
4 P4 kgf/cm2 40 ± 10
MPa 3.9 ± 1.0
bar 39 ± 10
psi 569 ± 142
2 1 Cylinder oil sealing Boom 50±5°C mm 20 Arm extended,
capacity (122±9°F) inch 0.79 Bucket height 1m,
10 min.
2 95±5°C mm 20 Bucket load=JIS heapedx1.8
(203±9°F) inch 0.79
3 Arm 50±5°C mm 11
(122±9°F) inch 0.43
4 Bucket 50±5°C mm 10
(122±°F) inch 0.39
5 Blade 50±5°C mm 20 Arm vertical, blade cylinder
extended for 10 min. engine
(122±9°F) inch 0.79 stop."
6 Second boom mm 10, 10>
inch 0.4, 0.4>
VII-17

1 19 Second boom pedal R kgf 5.8 -1.0,+1.0 Pedal edge
N 56.9 -9.9,+10.1
lbf 12.8 -2.2,+2.3
20 L kgf 5.8 -1.0,+1.1
N 56.9 -9.9,+10.1
lbf 12.8 -2.2,+2.3
Q9 Stability
1 5 STD arm, static Bucket load to tip Side kgf 709 Front horizontal, bucket crowd.
limited load fully N 6953 Load at arm tip end.
Arm length = Second boom extended.
2100mm (82.7inch) lbf 1563 Oil temp.50±5°C (122±9°F)
6 Front kgf 1033
N 10131
lbf 2277
VII-18
e) Lifting Capacity
1. Lifting Capacity Chart
KX080-3 Super Double Boom

Rubber tracks
Steel tracks (450 width)
Arm: 2100 mm (82.7 in.)
Lift point radius (ft) 1000lb
MIN. 6 12 18 MAX.
20 4.3
16 4.2 3.2 3.0
Lift point height (ft)
12 4.8 3.1 2.4

8 5.7 3.0 2.1
4 5.2 2.9 2.0
0 5.0 2.7 2.1
-4 5.3 5.4 4.9 2.7 2.3
-8 3.9
-12
Over-front (Blade up)

MIN. 6 12 18 MAX.
20 4.3
16 4.2 3.5 3.5
12 4.8 3.6 3.2

8 5.9 3.8 3.1
4 6.7 3.9 3.0
0 6.5 3.9 2.8
-4 5.3 5.4 5.6 3.4 2.5
-8 3.9
-12
Over-front (Blade down)

MIN. 6 12 18 MAX.
20 4.3
16 4.2 2.4 2.3
12 4.7 2.4 1.8

8 4.2 2.3 1.6
4 3.8 2.1 1.5
0 3.5 2.0 1.5
-4 5.3 5.4 3.5 2.0 1.7
-8 3.6
-12
Over-side
VII-19
2. Safety Precautions About Object Handling Application

1. Don’t use of the excavator to lift loads without suitable load lifting attachments.
Object handing application is prohibited unless otherwise a hydraulic excavator meet the safety
requirements of ISO 8643. 1987, ISO 10567 (1992) and EN474 (2006).
2. If you do the object handling application, the suitable device should be equipped.
The lifting device (Example: Hook) which accorded to EN474-1 should be equipped as follows.
2-1. Lifting Device

The lifting device has to be safely mounted to the attachment or other parts of the excavator to prevent
the rope from unhooking.
When mounting the device to an attachment or the equipment, ensure visibility between the operator
and the guide [person who attaches the rope to the lifting device].
Position the lifting device to make sure that the rope will not be deflected in its vertical direction by other
machine parts.
The lifting device's shape and position should guarantee that the rope can not be deflected.
When positioning the lifting device, make sure that no restrictions (such as jamming) occur during nor-
mal operation or when working with objects.
Trained personnel may attach load support devices (such as hooks) by welding. For such tasks, contact
your authorized KUBOTA dealer.
At any attachment or boom part of the lifting device should be firm enough to with hold 250% of the
nominal lifting capacity.
3. When lifting loads using the excavator with a lifting capacity (acc.to ISO 10567) of more than 1000kg
or tipping moment equal/more than 40000N·m, the excavator should be equipped with additional
devices described in EN474-5, like the followings.
3-1. Load safety device

An overload warning device.
Acoustic or visual warning device for the operator when the rated load or the corresponding tilting
moment has been exceeded.
A boom lowering control device shall conform to ISO 8643:1997.
4. If you do object handling application:

Even with the all above conditions satisfied, do not lift loads exceeding the values given in the lifting capacity
tables.
VII-20
3. Safety Precautions About Lifting Capacity

1. The lifting capacities are based on ISO 10567 and do not exceed 75% of the static tilt load of the machine
or 87% of the hydraulic lifting capacity of the machine.
2. The conditions are:
- The load point corresponds to the front pin part of the arm that is fully extended.
- The machine positions - (i) over - front (Blade down), (ii) over - front (Blade up), and (iii) over - side.
- The operating cylinder is the boom cylinder.
3. The bucket of the excavator, the hook, the sling and other lifting accessories should be included for the
loads.
Machine conditions:
No bucket, all others according to the standard regulations.
WARNING
To avoid personal injury or death:
· No loads greater than those values mentioned in the lifting capacity tables are to be lifted.
· No loads greater than 1 ton are to be lifted when no safety devices are not attached to boom and dozer
blade cylinders.
· The values mentioned in the table are valid only on level and hard grounds. When lifting on soft
ground, the machine can tip over due to the load being concentrated on only one side of the machine.
· The table values are calculated at the end of the arm without the bucket. In order to find the allowable
loads for machines with bucket, the bucket weight must be subtracted from the values in the table.
Lift point
Lift point radius
Lift point
height
Axis of swivelling
VII-21
4. FYI (For Your Information): Relevant Safety Regulations
EN474-1(2006) - safety, general requirement -

5 Safety requirements and/or measures
5.12 Object handling
5.12.1 Lifting device for object handling
The lifting device may be either fixed or removable.
The device may be located on a bucket, on an arm or any other part of the machine or may
be a separate device and shall be;
(1)so located and designed that the risk of being damaged during normal earth moving
operations is minimized;
(2)Designed so that hooking device prevents unintentional unhooking of the load.
(3)The lifting device shall meet the requirements of Annex E.
Annex E
Shows strength, assembly and operation about lifting device test methods. Operator's manual
shall be supplied by the manufacturer of the lifting device and shall include the following infor-
mation for use of the lifting device.
5.12.2 Lowering control device

Machine used in object handling application, which require a boom lowering control device,
shall conform with ISO 8643;1997.
7.2 Operator's manual

7.2.3 Instruction and information for use and maintenance of the machine
18)safety instructions for object handling application
EN474-5(2006) - safety requirement for hydraulic excavator -

5 Safety requirements and/or measures
5.6 Stability and safety devices
5.6.4 Object handling application
5.6.4.3 Rated lift capacity table in object handling
The table shall be available at the operator's station for each object-handling configula-
tion specified in OPM. This capacity should be determined according to ISO10567(1992).
5.6.4.3 Load safety devices

In case that either 1000kg or 40000Nm, shall be equiped with
(1)acoustic or visual warning device...............
(2)boom lowering control device in accordance with ISO8643;1997
While doing object handling by earth moving machinery, lifting device (hook, etc.) shall be in
accordance with EN and safety instruction for object handling shall be noted in OPM.
While doing object handling by hydraulic excavator, preparation of lifting capacity infor-
mation on operator's space as well as observance the above EN474-1. In case that either
lifting capacity is 1000kg or tilting momentum is 40000Nm, acoustic or visual warn-
ing device shall be equipped and boom lowering device (followed ISO8643) shall be
equipped.
VII-22
(B) MACHINE BODY

a) Specifications
1. Location and size of front pins and
bushing
3 2 4 7 5 6
1 10 9
(1)
18
14
16 (2)
17
13
15
(3)
19
20
23
21 23
22
VII-23
(Unit: mm (inch)
Pin size Bush size Dust seal size

No. Location
Dia. x Length Inner x Outer x Length S.D. x Outer x Width
65 x 151
1 Arm assy-Bucket cylinder bottom Cylinder
(2.56 x 5.94)
70 x 332 70 x 82 x 80 (CAC) 70 x 82 x 06
2 Arm assy-boom assy
(2.76 x 13.1) (2.76 x 3.23 x 3.15) (2.76 x 3.23 x 0.24)
60 x 175
3 Arm assy-arm cylinder rod Cylinder
(2.37 x 6.89)
60 x 226
4 Boom assy-boom cylinder bottom Cylinder
(2.37 x 8.90)
70 x 82 x 36 (SC)
70 x 168 (2.76 x 3.23 x 1.42)
5 Swing bracket-swing cylinder rod Cylinder
(2.76 x 6.61) 70 x 82 x 45 (SC)
(2.76 x 3.23 x 1.78)
70 x 183
6 Swivel frame-swing cylinder bottom Cylinder
(2.76 x 7.21)
80 x 437 80 x 95 x 80 (CAC) 80 x 95 x 08
7 Swing bracket-boom assy
(3.15 x 17.2) (3.15 x 3.74 x 3.15) (3.15 x 4.53 x 0.31)
100 x 115 x 64 (SC)
100 x 474 (3.94 x 4.53 x 2.52) 100 x 115 x 08 (2)
8 Swing bracket-swivel frame
(3.94 x 18.7) 100 x 115 x 61 (SC) (3.94 x 4.53 x 0.31)
(3.94 x 4.53 x 2.40)
70 x 200 70 x 82 x 49
9 Swing bracket-boom cylinder bottom Cylinder
(2.76 x 7.87) (2.76 x 3.23 x 1.93)
70 x 226
10 Boom assy-boom cylinder rod Cylinder
(2.76 x 8.90)
60 x 284 60 x 70 x 52 (CAC) 60 x 70 x 04
13 Bucket link 1, 2, 3-bucket cylinder
(2.37 x 11.2) (2.37 x 2.76 x 2.05) (2.37 x 2.76 x 0.16)
60 x 284 60 x 70 x 60 (CAC) 60 x 70 x 04
14 Bucket link 2, 3-arm assy
(2.37 x 11.2) (2.37 x 2.76 x 2.37) (2.37 x 2.76 x 0.16)
60 x 333 60 x 70 x 60 (CAC) 60 x 70 x 04
15 Bucket link 1-bucket
(2.37 x 13.1) (2.37 x 2.76 x 2.37) (2.37 x 2.76 x 0.16)
60 x 333 60 x 70 x 60 (CAC) 60 x 70 x 04
16 Arm assy-bucket
(2.37 x 13.1) (2.37 x 2.76 x 2.37) (2.37 x 2.76 x 0.16)
60 x 167
17 Blade arm-track frame - Cylinder
(2.37 x 6.57)
70 x 147
18 Blade cylinder Cylinder
(2.76 x 5.79)
60 x 226
19 Boom 2 assy-arm cylinder bottom
(2.37 x 8.90)
70 x 232 70 x 82 x 80 70 x 82 x 06 (2)
20 Boom 1 assy-boom 2 assy
(2.76 x 9.13) (2.76 x 3.23 x 3.15) (2.76 x 3.23 x 0.24)
70 x 332
21 Boom 2 assy-arm assy
(2.76 x 13.1)
70 x 258
22 Boom 1 assy-boom cylinder rod
(2.76 x 10.2)
70 x 520 70 x 82 x 52 70 x 82 x 06 (4)
23 Boom 1 assy-boom 2 cylinder bottom
(2.76 x 20.5) (2.76 x 3.23 x 2.05) (2.76 x 3.23 x 0.24)
70x 520 70 x 82 x 52 70 x 82 x 06 (4)
23 Boom 2 assy-boom 2 cylinder rod
(2.76 x 20.5) (2.76 x 3.23 x 2.05) (2.76 x 3.23 x 0.24)
CAC = Copper alloy castings, SC = Carbon steel, SD = Shaft diameter
VII-24
2. Main Parts Weight

No. Name Weight: kgf (lbs) Code No. Application
1 Standard weight 830 (1830) RD819-48133 Standard machine
+
2 Heavy weight 1040 (2293) RD819-48143 attachment
To be added upon
3 Additional weight 200 (441) RD809-48214
attachment
RD819-48143 (1040k)
1240 (2734)
4 Heavy + additional weight + Super Double Boom
(1040 + 200)
RD809-48211 (200k)
5 First boom assy 300 (661) RD809-66111
6 Second boom assy 205 (452) RD809-66211
7 First boom cylinder 100 (220) RD809-67503
RD809-67201
8 Second boom cylinder 56 (123)
RD809-67301
9 Second boom pin 10.6 (23.4) RD809-66562
10 Rubber track, 450 mm 440 (882) RD809-22310
11 Iron track, 450 mm 428 (945) RD809-22201
12 Iron track, 600 mm 941 (1082) RD809-22401
13 Arm assy (1750) 163 (359) RD809-66604
14 Arm assy (2100) 184 (406) RD809-67104
15 STD bucket (KBT) 177 (390)
VII-25
(A) (1)
b) Front Pins, Bushings and Shims
1. Installation Method
(2) 1) Fitting the bushings
Using a block or the like, fit the bushings into
position.
* Do not hit the bushings directly.
2) Bushing setup dimensions
(1) Without the dust seals
Make sure the bushings do not stretch out of
both sides.
(B) (2) With the dust seals
Ensure the dust seal setup space at both
(3) sides.
(4)
(It is possible to control the press-fitting
dimension instead.)
3) Dust seal fitting direction
Fit the dust seals as specified in the figure.
4) Bushing setup direction
(C)
Insert the bushings from the 15°-chamfered
side.
(3) (4) Installing direction
No. With the dust seals Seal width, S
of dust seal
11 * Bucket link 1, 6 pcs. 5.0mm(0.20in.) (B)

RD809-6667 * Swing bracket, 2 pcs.
12 10.0mm(0.39in.) (B)
Boom support
13 * Arm end, 4 pcs. 4.5mm(0.18in.) (C)
14 * Arm support, 2 pcs. 6.5mm(0.26in.) (B)
15 * Cylinder protector
(A) Insert in this direction.

(B) Enlarged view of dust seal (Most of the front links)
15 (C) Enlarged view of dust seal (Arm end boss L & R only)
(1) Block
(2) Bushing
(3) Bushing side
(4) Outside
(5) Dust seal
14 (6) Bushing
(7) Dust seal
(8) Bushing setup direction
12 13 (9) Bushing setup direction
11 (10) More than S
(6)
(10)
(10) )
3(0.12in.) 3(0.12in.) n.
(5) 02i (7)
( 0.
5
0.
C
(8) (9)
n .)
2i
0.0
5(
0.
C
VII-26
2. Pins and Bushings: Mono-boom
3 2 4 7 5 6
1 Arm assembly - Bucket

cylinder bottom
2 Boom assembly - Arm
1 10 9 assembly
3 Arm assembly - Arm
cylinder rod
4 Boom assembly - Arm
cylinder bottom
5 Swing bracket - Swing
cylinder rod
6 Swivel frame ~Swing
cylinder bottom
7 Boom assembly - Swing
bracket
8 Swing bracket -Swivel
frame
9 Swing bracket - Boom
cylinder bottom
10 Boom assembly-Boom
cylinder rod
(1) Pin (anti-rotation)

(2) Bolt
(3) Bushing
(4) Bushing
(5) Pin: ø70x200
(40)(41) (6) Spacer
(7) Bolt
(8) Plain washer
(9) Plate
(10) Bolt
(57) (11) Dust seal (10011508)
(42)
(12) Bushing (100115110)
(13) Bushing
(14) Grease fitting (Type C)
(15) Bushing
(16) Pin: ø100x474
(17) Grease fitting (Type B)
(18) Spacer
(19) Bolt
(20) Spring washer
(21) Plain washer
(22) Dust seal(809508)
(23) Bushing(809580)
(24) Collar
(25) Grommet
(26) Pin: ø80x437
(27) Bushing
(28) Bolt (anti-rotation)
(29) Pin: ø70x183
(30) Bolt
(31) Plain washer
(32) Pin: ø70x226
(33) Grease fitting (Type A)
(34) Bolt (anti-rotation)
(35) Bushing
(36) Bushing
(37) Washer
(38) Bolt
(39) Pin: ø70x168
(40) Bolt
(41) Plain washer
(42) Pin: ø60x226
(43) Pin: ø60x175
(44) Bolt
(45) Plain washer
(47) Bolt
(48) Plain washer
(49) Bushing(708280)
(50) Pin: ø70x332
(51) Dust seal (708206)
(52) Grease fitting (Type B)
(53) Bolt
(54) Plain washer
(55) Pin: ø60x151
(57) Connector
VII-27
3. Pins and Bushings: Super Double Boom
(1) Connector
(21) (2) Bolt
Plain washer
(3) Pin
(4) Bolt
Spring washer
(7) (8) Plain washer
(5) Pin
(6) Connector
(7) Pin
(8) Bolt
Spring washer
Plain washer
(22) (9) Grease fitting (Type A)
(10) Bolt
Plain washer
(11) Pin
(9) (12) Pin
(10) (13) Bolt
Anti-rotation nut
(11) (14) Washer
(15) Bolt
(16) Collar
VII-28
(17) Enlarged view of Section A
(19) (18) * Insert the shim between the cylinder
and collar as shown above.
(19) Boom 2 assembly - Arm cylinder

(2) RD809-6695Δ shim (1.0, 110-61)
RD809-6694Δ shim (0.5, 110-61)
selective
(1) (20) Boom 1 assembly - Boom 2 assembly
(3) (23) RD809-6697Δ shim (1.0, 140-71)
RD809-6696Δ shim (0.5, 140-71)
selective
(20) (17) (12) (21) Boom 2 assembly - Arm assembly
(14) RD809-6697Δ shim (1.0, 140-71)
(5) RD809-6696Δ shim (0.5, 140-71)
A selective
(15) (22) Boom 1 assembly - Boom cylinder
(13) (16) RD809-6758Δ shim (1.0, 110-75)
RD809-6757Δ shim (0.5, 110-75)
(4) selective
(6)
(23) Boom 1 and 2 assemblies - 2P boom
(24) cylinder
RD809-6758Δ shim (1.0, 110-75)
(18) RD809-6757Δ shim (0.5, 110-75)
selective
(24) Shim
10 (1) 4. Shim and Thrust Collar Installation

Boom assembly -
Boom cylinder
1. Clearance at the front
Shim (1.0, 110-75)
Shim (0.5, 110-75)
*Gap in thrust direction at each support pin:
To be selected Less than 0.6 mm(0.02inch)
*If over 0.6 mm(0.02inch), add a shim to readjust
9 (1)
the gap. (See the figure for proper shims.)
Swing bracket -
Boom cylinder Shim (1.0, 140-71)
Shim (0.5, 140-71)
To be selected 2. Vertical clearance between swivel frame
8
and swing bracket
(1)
Swing bracket - +0.1~+1.1mm(0.004~0.04inch)
Swivel frame
3. Pin lock bolt applying direction

Top Bottom Apply the bolts as shown at left.
Thrust collar (3,2) Thrust collar (3.5)
Thrust collar (3.2)
Fit with the groove To be selected
downward. 4. Direction of the thrust collar on top of the
7 (1)
swing support
Face the groove toward the swivel frame.
Boom assembly -
Swing bracket
Shim (1.0, 150-81) 5. Fitting the thrust collars

Shim (0.5, 150-81)
To be selected
5 (1)
Swing bracket - Shim (1.0, 120-71)

Swing cylinder Shim (0.5, 120-71)
To be selected (2)
4 (1)
Fig. A
Boom assembly - Shim (1.0, 110-61)
Arm cylinder Shim (0.5, 110-61) 1) Install the grooved thrust collar (with the groove
To be selected downward) at the top. Apply grease at 8
locations on both sides. (See Fig. A.)
3 (1)
(Molybdenum anti-seizure compound may be
Shim (1.0, 110-61) used instead.)
Arm assembly - Shim (0.5, 110-61)
Arm cylinder To be selected
2) Prepare two different-thickness thrust collars
for the bottom. Try the 3.5 mm thick one first to
2 (1) see if it fits on smoothly. If not, use the 3.2 mm
thick one.
Boom assembly - Shim (1.0, 140-71) (Be sure to select a suitable thrust collar.)
Arm assembly Shim (0.5, 140-71)
To be selected
1 (1)
(1) Pin
Shim (1.0, 110-61) (2) Apply grease
Arm assembly - Shim (0.5, 110-61)
Bucket cylinder To be selected
VII-29
5. Front Attachment: Super Double Boom

(Bushing, Pin and Shim)
19
(2) 19 Boom 2 assembly - Arm cylinder bottom
20 Boom 1 assembly - Boom 2 assembly
(1) (3) 21 Boom 2 assembly - Arm assembly
22 Boom 1 assembly - Boom cylinder rod
23 Boom 1 & 2 assemblies - 2P boom cylinder
(4)
20 (1) Connector
(2) Bolt
Plain washer
(6) (3) Pin: ø60 x L266
(5) Shim: t=1.0, 0.5 ø110-ø61
(4) Pin: ø70 x L332
(5) Connector
21 (6) Bolt
Spring washer
Plain washer
(7) (8) Shim: t=1.0, 0.5 ø140-ø71
(7) Pin: ø70 x L332
(8) Bolt
Spring washer
Plain washer
22 Shim: t=1.0, 0.5 ø140-ø71
(10) (9) Grease nipple (type A)
(10) Bolt
(9) Plain washer
(11) Pin: ø70 x L258
(11) Shim: t=1.0, 0.5 ø110-ø75
(12) Pin: ø70 x L520
23 (13) Bolt
Anti-rotation nut
(12) (14) Washer
(14) (15) Bolt
(16) Collar: t=9.0, ø70-110
(15) Shim: t=1.0, 0.5 ø110-ø75
(13) Note: Shims are to be inserted selectively to readjust

(16) the gap less then 0.6 mm (0.02 inch)
19
20
23
21 23
22
(Pin specifications)
New pin's tolerance: ø60 -0.05 -0.05
-0.09 , ø70 -0.09
Pin's material: S45C-D
Surface treatment: High frequency electro-induction heat surface hardening
Effective hardeness depth: 2~4 mm (0.08~0.16 in.)
Surface hardness: 52~59 HRC
VII-30
6. Arm Assy
VII-31
Arm assembly Arm assembly Weight (2) 59.95 dia. shaft to be smoothly passed
Part No. No. Name of parts Material Q’ty (3) 59.95 dia. shaft to be smoothly passed
(2100) (1750) kgf (lbs)
(4) Over 4.5
O O RD809-66651 3 Bush (607060) CAC304C 4 0.378 (0.83) (5) Over 4.5
(6) 59.95 dia. shaft to be smoothly passed
O O RD809-66621 2 Bush (708280) CAC304C 2 0.716 (1.58) (7)Over 6.5
O RD809-66614 1 Arm (2100) SM570*ETC 1 161.1 (355) (8)Over 6.5
O RD809-67114 1 Arm (1750) SM570*ETC 1 182.7 (403)

7. Grease Nipple Installation
VII-32
8. Super Double Boom Mounting Procedure

1) Arm assy
2) Bucket link and dust seal
3) Second boom (Boom 2)
4) Boom 1 and Boom 2
VII-33
5) Holding valve
6) Boom 2 cylinder
7) Pin and dust seal
8) Boom 1 and 2 assy

Mount the support bar for safety.
(1)Support bar
(1)
VII-34
9) Install the boom 1 cylinder
10) Connect the hoses of boom 1 cylinder and

holding valve
11) Boom 1 cylinder assembled.
12) Lifting Super Double Boom assy.
VII-35
13) Bushing and dust seal in the swing bracket.
14) Install boom pin and shim.
15) Install boom 2 cylinder.
16) Lifting arm assy.
VII-36
17) Mount arm assy to boom 2.
18) Install the pin and shim between arm and

boom 2.
19) Install arm cylinder.
20) Super Double Boom assy is crowded.
VII-37
21) Super Double Boom assy extended.
22) Super Double Boom machine stance for

hydraulic oil level check.
(1) Boom 1 cylinder extended

(2) Boom 2 cylinder extended
(3) Arm cylinder extended
(4) Bucket cylinder extended
(5) Swing cylinder extended
23) Boom 1 cylinder seal leak test.
Standard bucket = 177 kgf (390 lbs)

Weight added = 430 kgf (948 lbs)
· Arm tip end load = 607 kgf (1338 lbs)

· Arm tip end hight =1 m (39.4 in.)
· Boom cylinder rod dislocation
for 10 min. 20 mm (0.78 in.)
· Oil temp. = 50°C (122°F)
Note: Above machine condition is the one

tested in the factory’s inspection
section.
VII-38
c) Counterweight
Type of Super Double Boom

STD-version
weight version
EU 830 or 1040 1040 and 200
NA 1040 1040 and 200
(1) Stay (hood lock)
Light-duty weight: 830 kgf (1830 lbs) (2) Shim (T2)
Heavy-duty weight: 1040 kgf (2293 lbs) (3) Bolt
Additional weight: 200 kgf (441 lbs) (4) Plug (M24)
EU = European-version (5) Weight (830) or (5’) weight (1040)
NA = North American-version (6) Bolt
(7) Washer
(8) Spring washer
1. Attaching the Weight (9) Cover (weight)
(10) Bolt
Tightening torque (11) Plain washer
Three M20 bolts at the back (12) Plug
367.7~431.5 N.m (37.5~44.0 kgf.m) (13) Bracket (left cover)
(14) Bolt
271.2~318.3 ft.lbs (15) Weight
2. Fitting the Stay (Hook Lock), Cover (Weight)

and Bracket (Left Cover)
Tightening torque
48.1~55.9 N.m (4.9~5.7 kgf.m) 35.5~41.2 ft.lbs
(1)(2)(3)
Standard version
(4)
(5)
(5')
(6)(7)(8)
(13)(14)
(9)(10)(11)
(12)
VII-39
3. Attaching the Additional Weight

Tightening torque
Three M16 bolts
196.1~225.6 N.m (20.0~23.0 kgf.m)
144.6~166.4 ft.lbs
Super Double Boom version
(5)
(1)
(2)
(3)
(4)
14
15
85 85
(1) Before attaching the weight (200, additional), peel the

Weight (1040) RD819-4813Δ label (reflector, red, EU) off the weight.
Additional weight RD809-4821Δ (2) Weight (200, additional)
Bolt (M16x60-9T)
Spring washer
Plain washer
(3) Plug (M24)
(4) Label (reflector, red, EU)
(5) Weight (1040)
VII-40
4. Modification of Counterweight
Following the introduction of Super Double Boom type, the counterweight combinations on standard-version
machine has also been modified as below.
2008/02~
~2007/05 2007/05~ From minor change: Main market
S/N 20001~
RD809-4811Δ Weight (870) RD809-4811Δ Weight (870)
Turning radius: 1420 mm (55.9 in.) Turning radius: 1420 mm (55.9 in.)
(Light-duty weight)
RD819-48133
830 kgf (1830 lbs) EU-nations, mainly
Germany and Italy
Turning radius:
1460 mm (57.5 in.)
Standard-version
RD809-4811Δ Weight (870) New-type part (integrated)

+ RD809-4821Δ Weight (200, added) RD809-4847Δ Weight (1100)
Turning radius: 1460 mm (57.5 in.) Turning radius: 1460mm (57.5 in.)
(Heavy-duty weight)
World-wide except
RD819-48143
Germany and Itary
1040 kgf (2293 lbs)
North American
Turning radius:
version
1460 mm (57.5 in.)
New-type part (integrated)

RD809-4847Δ Weight (1100)
+ RD809-4821Δ Weight (200, added)
Super Double Boom-version
Turning radius: 1490 mm (58.7 in.) (Combined-type)

Two-piece Boom-version
RD819-48133
1040 kgf (2293 lbs)
+
RD809-48214
EU-nations
- 200 kgf (441 lbs)
and the US
= total 1240kgf (2734
lbs)
Turning radius:
1500 mm (59.0 in.)
* The counterweight lock bolts and other related parts remain the same
VII-41
d) Labels
EU-version
(1)
(4)
(2)
(5)
(1) To be applied in the same way.

(2) Marking (Kubota 1)
(2 pcs., on both sides) (3)
(3) Label (attention to swing)
(2 pcs., on both sides)
(4) Label (lifting)
(2 pcs., on both sides)
(5) To be applied in the same way.
PP-version (7)
(5)
* 20
20
*110 *
60
*(1) *
110
40
20
(7)
(8)
6.6
*
(2) 40
90
20
90
60
(2-piece boom type) (3) *

(6)
Note: 1. The *-marked parts alone are different from those of the * 30
Europe-destined model (2-piece boom).
* 80
20
(1) Mark (KUBOTA, US) (5) Mark (Super Double Boom)

(On both sides each) (On both sides each)
(2) Label (lifting) (6) To be applied on the other side too.
*
10
(On both sides each) (7) When viewed from the other side
0
(3) Label (lubrication chart) (8) Make sure the mark does not get onto
To be applied on the other side only. the bending part of the boom. *(4)
(4) Label (warning)
(On both sides each)
VII-42
(1) For Super Double Boom type

Label (Super Double Boom operation)
RD809-5767Δ
(2) Label (swing, EU)
RD809-5757Δ
(3) Label (emergency exit)
(to be applied on the inner face of window pane)
RD809-5714Δ
(4) Label (inspection)
RD809-5746Δ
VII-43
(1) Label (ROPS, cabin)

(Data marked on RC448-5855Δ)
RD809-5802Δ
(2) Label (windshield lock, EU)
(2 pcs.)
RB419-5793Δ
(3) Label (manual)
69198-5784Δ
(4) Label (anti-theft)
(2 pcs.)
(to be applied on the outer face of window pane)
RA228-9338Δ
(5) Label (seat belt)
RD809-5743Δ
(6) Label (adjustment, SP)
RD809-5748Δ
(7) For two-boom type
Label (lifting load, 2P)
RD809-5761Δ
(8) Label (lifting load, EU)
RD809-5747Δ
(9) Label (operation, SP)
RD809-5744Δ
VII-44
(C) HYDRAULIC SYSTEM

a) Specifications
No. Specifications items Unit Specifications value
mm ø95 x ø55 x ø578
1 Second boom cylinder size
(inch) (ø3.74 x ø2.17 x ø22.96)
2 Second boom cylinder speed: crowd / dump sec. 4.7 ± 0.3 / 5.5 ± 0.3
mm 10>
3 Second boom cylinder oil sealing capacity
(inch) (0.4>)
MPa 27.4 ± 0.3
Main relief pressure, a3
4 (kgf/cm2) (280 ± 3)
(LS main) at bench
psi 3983 ± 44
Main relief pressure, a3 MPa 27.9 ± 1.0
5 (LS main) on machine (kgf/cm2) (285 ± 10)
at Max. speed. psi 4047 ± 145
MPa 34.3 ± 0.3
Overload relief pressure: b7
6 (kgf/cm2) (350 ± 3)
(2-P boom cylinder) at bench
psi 4978 ± 44
Overload relief pressure: b7 MPa 34.8 ± 1.5
7 (2-P boom cylinder) on machine (kgf/cm2) (355 ± 15)
at 1500 rpm psi 5050 ± 213
MPa 33.3
Second boom holding valve
8
overload relief pressure at bench (kgf/cm2) (340)
psi 4836
MPa 12.9
First boom overload
9
warning pressure at bench (kgf/cm2) (132)
psi 1872
N 56.9 ± 10
10 Second boom pedal operating force (kgf) (5.8 ± 1.0)
lbs 12.8 ± 2.2
11
12
VII-45
b) Troubleshooting
No. Trouble symptom Suspected causes Remedies to be taken
a. Second boom does not 1.Not enough pilot secondary pressure. 1.Check pilot secondary pressure.
move to both directions. 2.Main control valve spool is stuck. 2.Check main control valve spool.
3.Pressure compensation spool is stuck. 3.Check the P.C spool.
4.Second boom pilot valve malfunction 4.Check the pilot valve.
b. Second boom does not 1.Overload relief valve malfunction. 1.Check O.R. valve.
move either one direction. 2.Main control valve spool is stuck. 2.Check main control valve spool.
c. Second boom does not 1.Not enough pilot secondary pressure at 1.Check pilot secondary pressure.
move to crowd direction. main control valve and holding valve.
2.Second boom holding valve malfunc- 2.Check the second boom holding
tion. (Poppet, spool, sleeve) valve.
d. Second boom speed is 1.Not enough pilot secondary pressure. 1.Check pilot secondary pressure.
slow. 2.Second boom cylinder inner leakage. 2.Check the pilot second boom
cylinder.
3.Main control valve spool doesn’t shift 3.Check the control valve spool.
fully.
e. A natural-fall of the second 1.Cylinder piston seal is defective. 1.Check the piston seal.
boom cylinder is excessive. 2.Oil leaks through main spool. 2.Check main spool sealing capacity.
VII-46
c) Hydraulic Circuit Diagram: Super Double Boom

Dozer cylinder
Function
MSG-44P-21 RD809-6130Δ Bore φ100 Bucket cylinder Super Double
Motor Disp. cm3/rev. 44.1 (28) (29) GM11VA Rod φ60 RD809-6780Δ Rod φ65 Boom cylinder B
piston Stroke 250 Dr Dr Gear ratio 50.11 Cushion Inner Stroke 747 Bore φ110 Bore φ95 (4) Dozer Down (13) SP1, Low pressure (21) Super Double Boom crowd
23
Rod φ60 Rod φ55
c4 21A (5) Travel Left Rear (14) SP1, High pressure (21-A) Super Double Boom H/V PL
Stroke 715 Stroke 578 (6) Travel Left Forward (15) Boom Down (22) Super Double Boom dump
(95) (32) (15-A) Boom H/V PL (23) Super Double Boom H/V Dr
B
2F 2F
SH
c2 c2
A
GA GB
c2 c2 H/ V H/ V
Ri g h t ) A
( 2F ) ( Dr ) ( 2F ) ( Dr )
H
(33) Swivel
A
( 2F ) C B D F E G
(30)
b1 31.4 Bucket (35) S/P 2
(37) Travel (R)
( f r om PB1 )
(40) Arm
(39) ( ROD) ( BTM) (42) S/P 1
(43) Boom
b7 34.3 Super Double Boom (45) Oil tank
a2
a1 (47) Accumulator
PAI b3 (52) Forward
Pp 1 b1 b7
(55) Forward
a4 a3 b4 b1 b5 b1 (57) P/V (Swing)
PB1 (58) Left
(59) Right
( f r om Pb4 )
Pp2 Pp3 17 18 22 21
16 2 1 4 3 19 20 5 6 7 8 9 10 11 12 13 14 15 1 2 9 16 15A 15 10 12 11 3 4 (63) Adapter
(64) Swivel left
( t o Pbu 1 ) (75) (76)
(67) Arm crowd
(77) (78) (79) (80) (81) (82) (83) (84) (68) Arm dump
(69) Boom down
(60) (70) Boom up
(50) (98) (99)
(91) (51) (52) (53) (54) (55)
(57) 1 T 2 1 2
T T
(71) Dozer down
(56)
(91) (92) (58) (59) (61) P P (72) Dozer up
(73) Bucket crowd
(47) (48) (86) (87) (75) P/V (Left)
B A (64)
T T T
(65)
(76) P/V (Right)
P P P (77) Left
PLS PPS 6 5 8 7 17 18
(46) T 21A 21 22 (66) (78) Right
1
4
2
3
P T
(79) Forward
a6 (80) Rear
PAC
1
4
2
3
(45) 23 P
(49) (67) (81) Left
C (68) (82) Right
d3 P3 P1 P2 (69)
d2 (83) Forward
(70) (84) Rear
Pp
(85) P/V (Dozer)
a5 (71)
(86) Up
(72) (87) Down
(88) (73) (88) P4, T
(74) Flow Devider
CH2
(91) P/V (Super Double Boom)
A B (91) Left
A H1 B
(92) Right
P (93) Super Double Boom
T
(Super Double Boom cylinder)
(95) Swivel Motor (MSG-44P-21)
(96) Right
(97) Left
(99) Damper
VII-47
d) Super Double Boom Crowding

Dozer cylinder
Function
MSG-44P-21 RD809-6130Δ Bore φ100 Bucket cylinder Super Double
Motor Disp. cm3/rev. 44.1 (28) (29) GM11VA Rod φ60 RD809-6780Δ Rod φ65 Boom cylinder B
piston Stroke 250 Dr Dr Gear ratio 50.11 Cushion Inner Stroke 747 Bore φ110 Bore φ95 (4) Dozer Down (13) SP1, Low pressure (21) Super Double Boom crowd
23
Rod φ60 Rod φ55 c4 21A (5) Travel Left Rear (14) SP1, High pressure (21-A) Super Double Boom H/V PL
Stroke 715 Stroke 578 (6) Travel Left Forward (15) Boom Down (22) Super Double Boom dump
(95) (32) (15-A) Boom H/V PL (23) Super Double Boom H/V Dr
B
2F 2F
SH
c2 c2
A
GA GB
c2 c2 H/ V H/ V
Ri g h t ) A
( 2F ) ( Dr ) ( 2F ) ( Dr )
H
(33) Swivel
A
( 2F ) C B D F E G
(30)
b1 31.4 Bucket (35) S/P 2
(37) Travel (R)
( f r om PB1 )
(40) Arm
(39) ( ROD) ( BTM) (42) S/P 1
(43) Boom
b7 34.3 Super Double Boom (45) Oil tank
a2
a1 (47) Accumulator
PAI b3 (52) Forward
Pp 1 b1 b7
(55) Forward
a4 a3 b4 b1 b5 b1 (57) P/V (Swing)
PB1 (58) Left
(59) Right
( f r om Pb4 )
Pp2 Pp3 17 18 22 21
16 2 1 4 3 19 20 5 6 7 8 9 10 11 12 13 14 15 1 2 9 16 15A 15 10 12 11 3 4 (63) Adapter
(64) Swivel left
( t o Pbu 1 ) (75) (76)
(67) Arm crowd
(77) (78) (79) (80) (81) (82) (83) (84) (68) Arm dump
(69) Boom down
(60) (70) Boom up
(50) (98) (99)
(91) (51) (52) (53) (54) (55)
(57) 1 T 2 1 2
T T
(71) Dozer down
(56)
(91) (92) (58) (59) (61) P P (72) Dozer up
(73) Bucket crowd
(47) (48) (86) (87) (75) P/V (Left)
B A (64)
T T T
(65)
(76) P/V (Right)
P P P (77) Left
PLS PPS 6 5 8 7 17 18
(46) T 21A 21 22 (66) (78) Right
1
4
2
3
P T
(79) Forward
a6 (80) Rear
PAC
1
4
2
3
(45) 23 P
(49) (67) (81) Left
C (68) (82) Right
d3 P3 P1 P2 (69)
d2 (83) Forward
(70) (84) Rear
Pp
(85) P/V (Dozer)
a5 (71)
(86) Up
(72) (87) Down
(88) (73) (88) P4, T
(74) Flow Devider
CH2
(91) P/V (Super Double Boom)
A H1 B
A B
P1,P2 high pressure (91) Left
(92) Right
P
T Pilot primary presuure (93) Super Double Boom
Pilot secondary presuure (Super Double Boom cylinder)
Return oil (95) Swivel Motor (MSG-44P-21)
(96) Right
(97) Left
(99) Damper
VII-48
e) Hydraulic Components on the Platform

(EU-version)
(2) (1) (9)
(3)
(4)
(5) (10)
(6)
(7)
(8)
(1) Adapter (pilot hose)

(For the arm)
(Shockless valve for the boom)
(Swivel shuttle valve)
(4) Valve assembly (pilot, OFF)
(Swing P/V)
(5) Machine front
(Travel P/V)
(Super Double Boom P/V)
(Pilot relay adapter)
(Relay plate)
(P4, T collective block)
VII-49
(PP-version)
(2) (1) (9)
(3)
(4)
(5) (10)
(6)
(7)
(8)
(1) Adapter (pilot hose)
(For the arm)
(Shockless valve for the boom)
(Swivel shuttle valve)
(Swing P/V)
(5) Machine front
(Travel P/V)
(Super Double Boom P/V)
(8) TPSS valve
(Relay plate)
(P4, T collective block)
VII-50
f) Second Boom Pilot Valve

(1) (2) (1) Fitting the valve assembly (pilot, boom 2)
(RD809-6551Δ)
Tightening torque
(2) Applying the anti-slip sheet (swing pedal)
(RD809-6552Δ)
Apply the sheets as shown at left.
(6) (1) Anti-slip sheet (swing pedal)

(9) (12) (2) Anti-slip sheet (Boom 2 pedal)
(3) Cover (swing pedal)
(10) (11) (13) (14) Cover (rubber, swing cover)
Pin (rubber, swing cover)
Plain washer
Cotter pin
(4) Valve assembly (pilot, boom 2)
(5) Bolt
(5) Pedal (swing)
Bolt
Anti-slip sheet (swing pedal)
(6) Pedal (Boom 2)
Bolt
Anti-slip sheet (Boom 2 pedal)
(7) Cover (Boom 2 pedal)
Cover (rubber, Boom 2)
Pin (rubber, Boom 2)
Plain washer
Cotter pin
(8) Valve assembly (pilot, boom 2)
(3) (7) Bolt
(9) (View from machine front)
(10) (Right swing)
(11) (Left swing)
(12) (View from machine front)
(13) (Boom 2 dump)
(14) (Boom 2 crowded)
(4)
(8)
VII-51
g) Travel Pilot Valve

1. Fitting of the adapters
(2)
(1) Ports P and T
Straight pipe joint (G2-G2) (RC441-6325Δ)
Pipe joint (cross, G1/4) (RP802-6193Δ)
Plug (68871-7359Δ)
Ports 1, 2, 3 and 4
<Failure case>
Ports P and T
Failure to set up the plug

Oil leak
(3) (4) 2. Adapter tightening torque

G1/4 size
24.5~29.4 N·m (2.5~3.0 kgf·m) 18.1~21.7 ft·lbs
<Failure case>

Oil leak
3. Fitting direction of the valve

Place the valve with Ports P and T toward the machine front.
<Failure case>
(5) (6) Wrong fitting direction

Difficult to connect the pilot hose
4. Quick-coupler adapter
Make sure the connections with the hoses are free of detri-
mental scratches.
<Failure hose>
Scratched

Oil leak
(7)
5. Fitting of the valve assembly (PV, travel)
(9)
(8) (RD819-6140Δ)
Tightening torque: M10
(10) 48.1~55.9 N·m (4.9~5.7 kgf·m) 35.4~41.2 ft·lbs
(1) (Machine front)
(2) Valve assembly (PV, travel) <Failure case>
Bolt Insufficient tightness
(3) (Port T)
(4) Straight pipe joint (G2-G2) Bolt loose
Pipe joint (cross, G1/4)
O-ring Come-off
(5) (Port P)
(6) Filter Travel pilot valve
O-ring
Straight pipe joint (G2-G2) No. Location Hose tape color
Pipe joint (cross, G1/4) 1 Travel (left), backward Blue, double
O-ring
2 Travel (left), forward Red, double
(7) Pipe joint (QL, G1/4-8.4)
(8) Note: Make sure the hoses’ fixtures are out 3 Travel (right), backward Green, double
of contact with each other. 4 Travel (right), forward Yellow, double
(9) (Section D on standard type) P Port P White
(10) Standard type: Plug provided
Super Double Boom: No plug provided T Port T None
VII-52
(A) 1. Fitting the Adaptor

E C Port P
(1) Pilot valve
(2) Bolt
(3) Pipe joint (S, G1/4-8, 4)
Ports 1 and 2
(4) Filter
(1)(2) (5) Pipe joint (S, G1/4-8, 4)
(3) Port T
(6) Pipe joint (QL, G1/4-8, 4)
(7) Pipe joint
2. Adaptor Tightening Torque

(4)(5) G1/4 size
24.5~29.4 N·m(2.5~3.0 kgf·m)18.1~21.7 ft·lbs
(7)
3. Fitting Direction of the Valve
(8)
Position the valve with ports P and T facing the
machine’s left side.
(9)
4. Quick-coupling Adaptor
Pipe joint (S, G1/4-8, 4), (QL, G1/4-8, 4)
(10) Make sure the hose connection is free from any
(12)
scratches.
(11)
5. Fitting the Valve Assembly (Pilot, Boom2)
(13) (RD809-6551Δ)
(6)
48.1~55.9 N·m (4.9~5.7 kgf·m) 35.5~41.2 ft·lbs
Super Double Boom: Boom 2 P/V

1 Boom 2 extend (right) Blue, double
2 Boom 2 crowd (left) Green, double
P Port P White
T Port T None
(3) (A) (Viewed from the machine front)
(1) E: Boom 2 extend

C: Boom 2 crowd
(4) (1) Valve assembly (pilot, boom 2)
(5) (2) Bolt
(3) Pipe joint (S, G1/4-8.4)
(7) (4) Filter, O-ring
(5) Pipe joint (S, G1/4-8.4)
(7) Pipe joint (S, G1/4-G1/4)
(8) To C/V bottom side
(9) Back side of the boom
(10) Pipe joint (L, G1/4-G1/4), O-ring
(11) Pipe joint (S, G2-G2)
(12) Pipe joint (G2-G3), O-ring
(13) To C/V rod side
(6)
VII-53
h) Shockless Valve
(2) (1) 1) Fitting the adaptor
(8)
(3) Fit the adaptor as shown on the left.
(9)
G1/4 size: 24.5~29.4 N·m (2.5~3.0 kgf·m)
18.1~21.7 ft·lbs
G3/8 size: 37.2~42.1 N·m (3.8~4.3 kgf·m)
27.5~31.1 ft·lbs
(17) (10) (11) 3) Quick coupler adaptor

(4) Pipe joint (Q, G1/4-8.4) (RP821-6198Δ)
No scratches on the fitting with the hose.
4) Valve assembly (shock-less) installation

direction
Set up the valve with nameplate facing
the machine’s back. (RD809-6135Δ)
5) Valve assembly (shock-less) bolt

tightening torque. (RD809-6135Δ)
M10x1.5
(5) 48.1~55.9 N·m (4.9~5.7 kgf·m)
35.4~41.2 ft·lbs
(12) 6) Fitting the bracket (pilot hose, 2)
(6)
Fit the bracket as shown on the left.
(7) (16) (RD809-4413Δ)
(13)
(14) 7) Bracket (pilot hose, 2) bolt tightening
(15) torque. (RD809-4413Δ)
M10x1.25
48.1~55.9 N·m (4.9~5.7 kgf·m)
35.4~41.2 ft·lbs
(1) Section A-A

(2) Bracket (pilot hose, 2)
(3) Bolt
(4) Pip joint
O-ring
(5) Pip joint
(7) Pipe joint
O-ring
Pipe joint
Pipe joint
(8) Bolt
(9) Valve assembly (shock-less)
(11) Pipe joint
(13) Pipe joint
(14) Pipe joint
(15) Pipe joint
VII-54
i) Control Valve
1. Fitting of the following parts
Control valve assembly (2P) (RD819-6133Δ)
Bracket (1, valve) (RD809-6115Δ)
(1) 4
Bracket (2, valve, 2P) (RD809-6136Δ)
Bracket (3, valve) (RD809-6117Δ)
4
Fit the parts in the following procedure.
3 1) Fit the bracket (1, valve), bracket (2, valve, 2P) and
Pbu 1
bracket (3, valve) to the control valve assembly (2P).
PB1 PAI
Temporarily tighten the bolts.
(8) (20)
AK5 BK5
(2)
2) Set the control valve assembly (2P) onto the base
(9) AK4 BK4 (21) (valve).
(10) AK3 BK3 (22) 3) Tighten up the bolts (1), as shown at left, to fix the
Dr 1
P3 T2 bracket (3, valve) to the base (valve).
(11) AK2 BK2
(23) 4) Tighten up the bolts (2), as shown at left, to fix the
(12) AK1 BK1 (24) control valve assembly (2P) to the bracket (3, valve).
P2 P1
5) Tighten up the bolts (3), as shown at left, to fix the
1
bracket (1, valve) and bracket (2, valve, 2P) to the
base (valve).
T1 P 4) Finally tighten up the bolts (4) and (5), as shown at
(3) 1
left, to fix the control valve assembly (2P) in position.
(13) A1 B1 (25)
(14) A2 B2 (26) <Failure case>
(15) A3 B3 (27) Wrong fitting procedure
A4 (4) Wrong bolt tightening-up order
(16) (28)
PLS
Bending force upon control valve
(17) (29)

A5 B5
(18) A6 B6 (30) (5) Oil leak from valve block
2. Bolt tightening torque

(1) and (3): M12x1.25
3 (2), (4) and (5): M12x1.75
(19) 5 77.5~90.2 N·m (7.9~9.2 kgf·m) 57.1~66.5 ft·lbs
<Failure case>

Bolt loose

(7) 3 Come-off
3. Fitting of the adapters

(31) PP1
Fit the adapters as specified on the next page.
Pbk 5
(32)
(33)
Pbk 4
<Failure case>
(34)
Pbk 3
Wrong fitting
(35) PP2
Poor hose coupling
PF2
(36) Pbk 2
(37) Pbk 1
(1) Bracket (1, valve) (9) (Down) (28) (Up)
PPS Bolt (3) (10) (Low) (29) (Right)
(38) (11) (Backward) (30) (Crowded)
(2) Base (valve)
(3) Bracket (3, valve) (12) (Backward) (31) (P3 confluence)
(39) Bolt (1) (13) (Crowded) (32) (Swivel)
PF1 PP3
(4) Insert the plugs (67111-5187Δ) into (14) (Crowded) (33) (Dozer)
(40)
Pb 1
these two unused holes. (15) (Low) (34) (SP2)
Pb2 (5) With the Super Double Boom type, the (16) (Down) (35) (P3, T2)
(41) 2 parts within this chain-double-dashed- (17) (Left) (36) (Travel left)
(42) Pb3
lined box have been modified. (18) (Dump) (37) (Travel right)
1) Control valve section added (19) Machine front (38) (P1, P2)
(43) Pb4
(20) (Right) (39) (T1)
2) Valve mounting bracket modified
(44)
PB2
(marked with *) (21) (Up) (40) (Arm)
Pb5 (6) Control valve assembly (2P) (22) (High) (41) (Bucket)
(45) Bolt (2), Bolt (4), Bolt (5) (23) (Forward) (42) (SP1)
(46)
Pb6
(7) (For the Super Double Boom type only) (24) (Forward) (43) (Boom)
Bracket (2, valve, 2P) (25) (Dump) (44) (PLS)
Bolt (3) (26) (Dump) (45) (Swing)
(8) (Left) (27) (High) (46) (Super Double Boom)
2 4 5 (6)
VII-55
4. Install the Control Valve Adaptors

(26)
(1)
(2) (15)
(3) (16)
(4) (17)
(5)
(6) (18)
(7) (19)
(8)
(9) (20)
(10) (21)
(11) (22)
(12)
(23)
(13) (24)
(14) (25)
(27)
(28)
(1) P3 bypass (15) (Right)

(2) Swivel (left) (16) (Rod)
(3) Dozer (bottom) (17) (High)
(4) S/P2 (low) (18) (Left forward)
(5) Communicating valve (19) (Right forward)
(6) Travel (left backward) (20) (Rod)
(7) Travel (right backward) (21) (Rod)
(8) Travel independent valve (22) (High)
(9) Arm (bottom) (23) (Bottom)
(10) Bucket (bottom) (24) (Right)
(11) S/P1 (low) (25) (Crowded)
(12) Boom (rod) (26) See Note (40°)
(13) Swing (left) (27) Details of Section A
(14) Super Double Boom (dump)
(28) Note: Fit the pipe joint with care to keep the hose and
the bolt head out of contact with each other.
5. Adjusting the angles of the swing and Super Double Boom adapters
First set the Super Double Boom (dump) adapter to the center of the swing (right) port (marked with *
above). Then reposition the other adapters in parallel with the Super Double Boom (dump) adapter.
VII-56
1. Fitting of the valve assembly (RD401-6378Δ) (1) P3 bypass (26) Pipe joint (LG3, 11/16U) (35) Pipe joint (L7/8U, 1U) (42) Pipe joint (S, G1/4-G1/4)
(2) Swivel (left) Pipe joint (S, G3/8-3/8) Pipe joint (S7/8U, 7/8U) O-ring
Fit the assembly as shown at left. (3) Dozer (bottom) (27) Pipe joint (LG4, 13/16U) (36) Pipe joint (L7/8U, 1U) Valve assembly (check)
(4) S/P2 (low) Pipe joint (S, G1/2-G1/2) Pipe joint (S7/8U, 7/8U) Pipe joint (L, G1/4-G1/4)
Tightening torque (5) Communicating valve O-ring (37) Pipe joint (L7/8U, 1U)
(6) Travel (left backward) (28) Pipe joint (LG4, 13/16U) Pipe joint (S7/8U, 7/8U) (43) Pipe joint (L, G1/4-G1/4)
24.5~29.4 N·m (2.5~3.0 kgf·m) (7) Travel (right backward) Pipe joint (SG4, G4) Adapter (gauge) Straight pipe joint (G2-G2)
(8) Travel independent valve (29) Pipe joint (LG4, 13/16U) (38) Pipe joint (L7/8U, 13/16U) (44) Pipe joint (L, G1/4-G1/4)
(9) Arm (bottom) Pipe joint (SG4, G4) Pipe joint (S7/8U, 7/8U) (45) Pipe joint (L, G1/4-G1/4)
<Failure case> (10) Bucket (bottom) (30) Pipe joint (LG4, 13/16U) (39) Pipe joint (LG2, 9/16U) (46) Pipe joint (L, G1/4-G1/4)
(11) S/P1 (low) Pipe joint (SG4, G4) (40) Pipe joint (LG4, 11/16U) O-ring
Insufficient tightness (12) Boom (rod) (31) Pipe joint (LG4, 1U) Pipe joint (S, G1/2-1/2) Straight pipe joint
(13) Swing (left) Pipe joint (bushing, 1/2) O-ring
(14) Super Double Boom (bottom) (32) Pipe joint (LG4, 1U) (41) Pipe joint (SG4, 11/16U) (47) Pipe joint (L, G2, G2-G2)
Adapter loose (15) (Right) Pipe joint (S, G1/2-G1/2) Pipe joint (L, G1/2-G1/2) Pipe joint (S, G1/4-8.4)
(16) (Rod) O-ring Pipe joint (S, G1/2-1/2) (48) Pipe joint (L, G1/4-M10)
Come-off (17) (High) (33) Pipe joint (LG6, 1U) O-ring O-ring
(18) (Left forward) Pipe joint (SG6, G6) Switch (pressure, 25.0K)
(19) (Right forward) (34) Pipe joint (LG12, G8) O-ring
Make sure the groove faces toward the control valve (20) (Rod) Valve assembly (return) (49) Pipe joint (S, G1/4-G1/4)
(21) (Rod) Pipe joint (SG12, G12)
as shown here. (The same is true with the opposite (22) (High) O-ring
side.) (23) (Bottom) Valve assembly (check)
(73) Pipe joint (To Q, G1/4-8.4)
(24) (Right)
(25) (Rod) (75) (50) Pipe joint (S, G1/4-8.4)
(74) (51) Pipe joint (SG2, 9/16U)
Pipe joint (SG2, G2)
(52) Pipe joint (S, G1/4-G1/4)
(54) Pipe joint (To Q, G1/4-8.4)
(55) Pipe joint (LG3, 11/16U)
Pipe joint (S, G3/8-3/8)
(26) (27) (43) (42) (46) (47) (48) (56) Pipe joint (To Q, G1/4-8.4)
(61) (60) (59) (58) (57) Pipe joint (To Q, G1/4-8.4)
(28) (49) (58) Pipe joint (QL, G1/4-8.4)
(62)
VII-57
(50) (59) Pipe joint (S, G1/4-8.4)
(1) (60) Pipe joint (LG4, 13/16U)
(29) (63) (61) Pipe joint (LG4, 13/16U)
(2) (15) Pipe joint (SG4, G4)
(3) (62) Elbow pipe joint
(16)
(64) (63) Pipe joint (S, G1/2-1/2)
(30) (4) (17) O-ring
(31) (65) (64) Pipe joint (LG4, 1U)
(5) (65) Pipe joint (LG4, 1U)
(32) (6) (18) Pipe joint (S, G1/2-G1/2)
(7) (19) O-ring
(33) (51) (66) Pipe joint (LG6, 1U)
(8) (66) Pipe joint (SG6, G6)
(52) (67) Pipe joint (L7/8U, 13/16U)
(34) (68) Pipe joint (L7/8U, 13/16U)
(53) (67) Pipe joint (S7/8U, 7/8U)
(69) Pipe joint (L7/8U, 1U)
(20) (68) (70) Pipe joint (L7/8U, 1U)
(35) (9) Pipe joint (S7/8U, 7/8U)
(21) (71) Pipe joint (LG4, 11/16U)
(10) (22) (69) (72) Pipe joint (SG4, 11/16U)
(36) (11) Pipe joint (LG4, 11/16U)
(54) (73) Groove
(12) (23) (74) (Control valve)
(37)
(70) (75) Note: The *-marked parts
have been added or modified
(38) (44) (24) (55) for the Super Double Boom
(13)
type.
(14) (25) (56) (71)
(39)
(45)* (57)
(40) (72)*
(41)*
(1) Control valve section, Super Double Boom.

(2) (2) Overload relief valve, dump.
(3) Pilot secondary pressure port, Pa6.
(3) (1)
(4) Overload relief valve, crowd, Pb6.

(5) B6 port: Boom 2, crowd.
(6) A6 port: Boom 2, dump.
(4)
(6) (5)
VII-58
j) Second Boom Holding Valve

1. Outline
This valve is installed between the hydraulic sec-
ond boom cylinder and the control valve. The grav-
ity fall of the cylinder due to leak from the control
valve can be minimized.
KHV 10 N 30 / *
Own pressure relief valve
pressure setting
Series No.
Size
Holding valve
(1)
(2)
(5)
(7)
(4)
(6)
(3)
2. Installation
1) Adaptors
(1) Pipe joint (FG4, 13/16V)

(2) Pipe joint (FG4, 13/16V)
(3) Pipe joint (LG4,13/16 U)
(4) Pipe joint (L, G1/4 - G3/8)
(5) Pipe joint (L, G1/4 - G1/4)
(6) Mounting bolt
VII-59

G1/4 size
24.5~29.4N·m (2.5~3.0kgf·m) 18.1~21.7ft·lbs
G1/2 size
58.8~63.7N·m (6.0~6.5kgf·m) 43.4~47.0ft·lbs
4) Fitting procedure (explained here for the left-side

cylinder)
(1) Temporarily fix the valve assembly (holding) to
the bracket (left, holding valve).
(2) Screw the pipe joint (6) (FG4, 13/16U) to the pipe
joint (A). Temporarily fix the bracket (8) (left,
holding valve) to the cylinder.
(3) Tighten up the joint unit for the pipe joint (6)
(FG4, 13/16U).
(4) Tighten up the bolts (B and C).
* The valve assembly (holding) is fitted in a different

direction on the right-side cylinder. Refer to the
figure.
5) Bolt tightening torque

70.6~86.2 N·m (7.2~8.8 kgf.m) 52.1~63.7 ft·lbs
(B) M8 x 55
23.5~27.5 N·m (2.4~2.8 kgf.m) 17.4~20.3 ft·lbs
(C) M10 x 20
48.1~55.9 N·m (4.9~5.7 kgf.m) 35.4~41.2 ft·lbs
VII-60
1. Fitting of the adapters (1) The fitting direction of the valve assembly (holding) is dif-
Fit the adapters as shown at left. ferent between the right and left cylinders: vertically
reversed.
The port of Type L pipe joint should face upward.
<Failure case> (2) Bracket (right, H/V)
Wrong positioning Bolt
(3) Pipe joint (L, G1/4-G1/4)
Difficult to connect the hoses (4) Pipe joint (L, G1/4-G3/8)
(5) Valve assembly (holding)
2. Adapter tightening torque Bolt
(6) Pipe joint (FG4, 13/16U)
G1/4 size (7) Pipe joint (LG4, 13/16U)
24.5~29.4 N·m (2.5~3.0 kgf·m) 18.1~21.7 ft·lbs (8) Bracket (left, H/V)
G1/2 size Bolt
58.8~63.7 N·m (6.0~6.5 kgf·m) 43.4~47.0 ft·lbs (9) (Fitting to the right cylinder)
(10) Super Double Boom cylinder (Fitting to the left cylinder)
<Failure case> (3) (4) (5)

(10)
(6)
Oil leak
3. Fitting procedure (discussed here for the left

cylinder)
1. Temporarily tightening the bolt B, attach the valve
assembly (holding) to the bracket (left, H/V).
VII-61
2. Screw the pipe joint (FG4, 13/16U) into the pipe (7)
joint A. Temporarily tightening the bolt C, attach
the bracket (left, H/V) to the cylinder.
3. Tighten up the pipe joint (FG4, 13/16U).
4. Tighten up the bolts B and C.
* In fitting at the right cylinder, the valve assembly
(holding) must be oriented in a different direction.
See the figure.
Bolt tightening torque (9)
-> 70.6~86.2 N·m (7.2~8.8 kgf·m) (1)
52.1~63.7 ft·lbs
B: 23.5~27.5 N·m (2.4~2.8 kgf·m)
17.4~20.3 ft·lbs
C: 48.1~55.9 N·m (4.9~5.7 kgf·m)
35.4~41.2 ft·lbs
<Failure case>
(2)
Come-off
Wrong fitting procedure

Damage
(8)
4. Circuit Diagram
Port size
G1/2: A, B
G1/4: PL, DR
(2)
(1) ø9 Through
Tightening torque: 27~31 N·m (2.75~3.16 kgf·m) 19.9~22.9 ft·lbs
VII-62
5. Main Parts
Tighting torque
A, B port:
98~120 N·m (10.0~12.2 kgf·m)
72.3~88.2 ft·lbs
PL, Dr, (PB) port:
34~39 N·m (3.47~3.98 kgf·m)
25.1~28.8 ft·lbs
101 Casing 311 poppet

162 O-ring 321 spring
163 O-ring 322 spring
164 O-ring 511 spool
165 O-ring 541 sleeve
166 O-ring 601 relief valve
167 O-ring 631 piston
201 plug 901 name plate
203 plug 902 pin
205 plug
206 plug
212 plug
6. Specifications
1. Max pressure: 34.3 MPa (350 kgf/cm2) 4798 psi
2. Rated flow: 100 L/min. (A→B)
3. Cracking pressure
Opening pressure is action at A port: PA = 0.1 MPa
(1.0kgf/cm2)
14.2 psi
Opening pressure is action at PL port: PPL = 0.35~0.5 Mpa
(3.6~5.1kgf/cm2)
51~73 psi
4. Leakage flow rate: 1.5cc/min or less
ISO VG 46, Temp: 50°C
Rated pressure is activated at B port.
5. Overload relief pressure 33.3 MPa (340 kgf/cm2) 4830 psi
VII-63
7. Structure
The structure of the KHV10N30/* holding valve is shown in Fig. 1.
The holding valve and the relief valve are housed in the casing (101) that also has the control valve, cylinder
and connection ports (PF threaded type).
Inside the casing (101), the relief valve is connected upstream with the port that leads to the cylinder and is
connected downstream with the DR port through the orifice of spool (511).
In the holding valve, the poppet (311) that controls the hydraulic oil flow is kept pressed by the spring (322)
against the seat of casing (101).
On the other hand, the spool (511) is incorporated in the sleeve (541). The circular conical surface of spool
(511) is kept pushed by the spring (321) against the seat of sleeve (541). The sleeve (541) is provided with a
cylinder hold pressure lead-in opening.
(631) (311) (101)
(601)
(541)
(511) (321) (322)
Fig. 1
101: Casing A: Port to control valve

311: Poppet B: Port to boom 2 cylinder bottom side
321: Spring PL: Pilot secondary pressure from boom 2 pilot valve
322: Spring Dr: Drain line to tank
511: Spool
541: Sleeve
601: Relief valve
631: Piston
VII-64
8. Function
8-1. With the cylinder being held
In Fig. 2, the cylinder’s hold pressure is fed through the B port and around the spool (511) into the spring
chamber (a) of poppet (311). This hold pressure pushes the poppet (311) against the casing (101), which
closes the return oil passage at the head and prevents the cylinder from falling by gravity.
(311)
(101)
(511) (a)
Fig. 2
a: Spring chamber
A: Port to control valve

A B: Port to boom 2 cylinder bottom side
PL PL: Pilot secondary pressure from boom 2 pilot valve
Dr: Drain line to tank
101: Casing
311: Poppet
511: Spool
DR B
VII-65
8-2. Oil flow from A to B (From control valve to cylinder: Free flow)
Boom 2 cylinder extending:

In Fig. 3, the control valve is activated for hydraulic oil to flow toward side A.
The poppet (311) gets activated at 0.1 MPa (1 kgf/cm2) 14.2psi and lifted to let hydraulic oil flow from A to B.
(311)
Fig. 3
311: Poppet A: Port to control valve

B: Port to boom 2 cylinder bottom side
PL: Pilot secondary pressure from boom 2 pilot valve
VII-66
8-3. Oil flow from B to A (From cylinder to control valve: with the cylinder released)
In Fig. 4, the cylinder is still held (in the state 6-1) and the PL pilot port gets pressurized.
When a pressure of over 0.33 MPa (about 3.4 kgf/cm2) 48.4psi is applied to the PL port, the piston (631)
gets activated to move the spool (511) over its stroke against the preset load of spring (321).
As the spool (511) starts over its stroke, the land of spool (511) closes the B opening of sleeve (541), which
shuts off the cylinder hold pressure as well as the pressure in the spring chamber of poppet (311).
As the spool (511) moves further full-stroke, the notch of spool (511) opens. The pressure in the spring
chamber of poppet (311) is fed through the C opening of sleeve (541) and the notch of spool (511) to the DR
drain port.
As a result, the pressure in the spring chamber of poppet (311) becomes equal to the drain pressure. The
poppet (311) receives the cylinder hold pressure upon a ring-shaped area that is formed from the difference
in diameter at the seat of casing (101). The poppet then overcomes the spring (322) and lifts itself, which lets
hydraulic oil flow from B to A.
When the pressure at the PL pilot port comes back to 0 MPa, the spool (511) returns to the neutral position
by the force of spring (321).
Therefore, the spring chamber of poppet (311) and the DR drain port are shut off from each other, and the
cylinder pressure is led in again. The poppet (311) is then pushed against the seat of casing (101), which
holds hydraulic oil from the cylinder.
(631) (311) (101)
PSP
C (541)
(511) (321) (322)
Fig. 4
101: Casing A: Port to control valve

311: Poppet B: Port to boom 2 cylinder bottom side
321: Spring PL: Pilot secondary pressure from boom 2 pilot valve
322: Spring Dr: Drain line to tank
511: Spool PSP: Pilot secondary pressure
541: Sleeve
631: Piston
VII-67
8-4. In case of overload
As shown in Fig. 5, the relief valve is built in to protect the machine if the cylinder gets held and overloaded.
The hold pressure from the cylinder bottom side is introduced into the D chamber. If this pressure exceeds
the relief valve’s pressure setting, the relief valve’s poppet lifts itself and the hold pressure from the cylinder
bottom side is applied via the relief valve into the E chamber. The oil in the E chamber passes through the
orifice of spool (511) to the DR drain port. Now the pressure in the E chamber rises because of a pressure
difference of the oil passing through the orifice of spool (511). The spool (511) then acts against the spring
(321) and shifts downward. The F section is connected with the spring chamber (a) of poppet (311). A down-
ward shift in the spool (511) makes for a passage to the DR drain port and reduces the pressure in the spring
chamber (a). In this way, the poppet (311) gets released from the casing (101) and moves down. The return
oil at the cylinder bottom side now flows toward the A port, preventing an unusual rise in the hold pressure.
F
Or a (322) (311)
(511)
Fig. 5
a: Spring chamber of poppet

Or: Orifice
A: Port to control valve

B: Port to boom 2 cylinder bottom side
PL A PL: Pilot secondary pressure from boom 2 pilot valve
D: Chamber D
E: Chamber E
F: Section F
311: Poppet
322: Spring
511: Spool
DR B
VII-68
9. Maintenance Procedures
9-1. Tools required and tightening torques
Tool Size Fig No. Part name Screw size Tightening torque: N·m (kgf·m) ft·lbs
Allen wrench 4mm 206 Plug NPTF 1/16 7.8~9.8 (0.8~1.0) 5.8~7.2
6mm 205 Plug PF 1/4 34~39 (3.5~4.0) 25.3~29.0
212 Plug M12 25~29 (2.6~3.0) 18.8~21.7
8mm 203 Plug M16 39~49 (4.0~5.0) 29.0~36.2
Wrench 24mm 201 Plug M18 49~59 (5.0~6.0) 36.2~43.5
Torque wrench 7.8~59.0 N·m (0.8~6.0 kgf·m) 5.8~43.5 ft·lbs
Others: Grease, vapor-phase inhibitor
9-2. Relief valve adjustment

The relief valve pressure setting is made using the adjusting screw. In this adjustment, be sure to connect a
pressure gauge to the pressure port and monitor the pressure.
One turn of the adjusting screw: About 24.1 MPa (about 245.7 kgf/cm2) 3495 psi
VII-69
9-3. Disassembling procedure

1) Preparations
* Prepare a workbench that is large enough to place removed parts, as well as stable and solid enough to
keep them during the job.
* Prepare the tools and materials.
2) General precautions for disassembling

* All the parts are of high precision. Handle them with enough care. Be very careful not to hit or drop them.
* Even if any of the parts is tough to remove, be very careful not to hit it hard or twist it. Otherwise, the part
may get burred or damaged, resulting in fitting failure, oil leak or poor performance.
* Do not leave the removed parts or stop the disassembling halfway. Wetness and dust cause rust. During
and after the work, take measures to avoid rust and dust.
3) Disassembling procedure
A
101 1. Clean the holding valve with white kerosene.
601 PL Before cleaning, cover the ports to avoid dust by
applying blank caps and sealings.
B
101: Holding valve assy
601: Overload relief valve
Dr
A: A-port, to or from the control valve
B: B-port, to or from the second boom cylinder bottom
side
PL: PL-port, to or from the boom 2 pilot valve
Dr: Drain port
203 2. Take out the relief poppet.

1) Secure the casing (101) in a vise or the like.
Preferably fix the casing (101) upward for
easier disassembling.
163 2) Using a wrench, loosen the plug (203) and
take it out of the poppet (311) and spring
(322).
311 322
163: O-ring
203: Plug
322: Spring
311: Poppet
3. Remove the overload relief valve.

1) Loosen the lick nut
2) Using an Allen wrench, loosen the adjusting
screw.
3) Remove the valve assy.
601
601: Relief valve assy
601-1: Adjust screw
601-2: Spring
601-3: Needle poppet
601-1
601-3
601-2
VII-70
4. Removing the piston (631), sleeve (541) and

spool (511)
(Taking out the piston (631))
1) Loosen the plug (201) and take it out of the

casing (101).
2) Take the spring (321) out of the casing (101).
3) Take the spool (511) and sleeve (541) out of
the casing (101).
4) Remove the O-ring (164) from the plug (201).
511 321 201

201: Plug
321: Spring
511: Spool
631: Piston
Securely check the fitting direction
541: Sleeve
631
5. Cleaning the parts

1) Put the parts in a rough-washing container
with white kerosene and wash them lightly.
2) Then put the parts in a finish-washing con-
tainer with white kerosene. Slowly turn
around the container to wash the inside of the
parts as well. (Finish cleaning)
Using clean waste cloth, wipe white kerosene
off the parts.
* Do not wash dirty parts in kerosene just after
soaking them. They may get scratched. Keep
511 321 201 them in kerosene until dust, fat and oil
631 become loose and floating.
* Carefully maintain the cleanliness of white ker-
osene. Unclean white kerosene may cause
damage on the parts, resulting in poor perfor-
mance after reassembling.
* Do not compressed air to dry up the parts.
Dust and moisture in the air may damage the
parts or gather dust.
6. Rust-preventing method
Spray vapor-phase inhibitor over the parts.
Do not leave the cleaned parts as they are. They
may get rusty and function poorly after reassem-
bling.
321
541 511
VII-71
311 322 203
212 631
541 511 321 201
601
201, 203, 212 : Plug 511: Spool 601: Relief valve

321, 322 : Spring 541: Sleeve
311 : Poppet 631: Piston
9-4. Reassembling procedure

1) Preparations
(1) Prepare the workbench, tools and materials in the same way when disassembling.
2) General precautions for reassembling

(1) Take the same general precautions when disassembling.
(2) In reassembling, remove metallic chips and foreign substance off the parts. Make sure the parts are
free of burr, hit marks and the like. Remove such defects, if any, with an oil stone.
(3) As a rule, replace all the existing O-rings with new ones.
(4) When installing the O-rings, be careful not to damage them. (Preferably apply a small amount of
grease on them for smooth fitting.)
(5) When fitting the parts, preferably apply grease on them to avoid dropping.
(6) Tighten the plugs and other threaded parts to their respective torques listed in “6-1 Tightening Torque
Table”. Use a torque wrench to monitor the tightening torque.
(7) With all the parts in place, apply plugs to all the ports to keep off dust.
VII-72
3) Reassembling procedure
1. Reassemble the sleeve (541), spool (511) and
piston (631)
1) Secure the casing (101) in a vise or the like.
2) Install the O-ring (164) on the sleeve (541).
3) Fit the sleeve (541) to the casing (101).
In fitting the sleeve (541), be careful not to
scratch its seat.
4) Place the spool (511) in the sleeve (541).
Make sure the spool (511) moves smoothly
inside the sleeve (541).
5) Install the O-ring (161) on the plug (201).
321 6) Place the spring (321) in the spool (511), fit
541 511
the plug (201) to the casing (101), and tighten
them up to the specified torque with a wrench.
7) Fit the piston (631) in the casing (101).
8) Finally install the O-ring (164) on the plug
(204), fit them to the casing (101), and tighten
them up to the specified torque with an Allen
wrench.
631
2. Reassemble the poppet.

203
1) Fit the poppet (311) and spring (322) to the
casing (101).
2) Install the O-ring (163) on the plug (203), fit
them to the casing (101), and tighten them up
to the specified torque with an Allen wrench.
163
3. Reassemble the relief valve
311 322 1) Fit the relief valve (601) to the casing (101),
and tighten them up to the specified torque
with a wrench.
4. Fit the O-ring (165) to the blind plug (205).

Tighten them in position, specified in the Assem-
bly Sectional View, to the specified torque.
601-1 5. Rust-preventing the inside

601-3 To prevent rust due to dew condensation, fill the
601-2 casing (101) with vapor-phase inhibitor and seal
all the ports with blind plugs.
VII-73
k. Second Boom Cylinder

1. Adaptors
Adaptor tightening torque
RD809-6823
RD809-68771
G1/2 size
58.8~63.7 N·m (6.0~6.5kgf·m) 43.4~47.0 ft·lbs
(1)
(3)
(4)
(5)
(6)
(2)
(6)
(7)
(5) (8)
(1) (Boom 2 cylinder L) RD809-6720Δ
(2) (Boom 2 cylinder R) RD809-6730Δ
Different from RD809-6720Δ for left- and right
hand setup, but with same adaptor
(3) Pipe joint
(4) Pipe joint
(5) Dust seal (708260)
(6) Dust seal (708260)
(7) Dust seal (708260)
(8) Pipe joint
(9) Pipe joint
(10) Dust seal (708260)
VII-74
2. Second-boom cylinder cover (1) Section A-A
(2) Band (3, cover)
(3) Target distance between the top of the upper
Fitting of the cover (cylinder tube) (RD819-6773Δ) and nut and the tip of the bolt (for all 6 locations)
cover (cylinder pipe) (RD819-6759Δ) (4) Band (2, cover), Plain washer, Nut
(5) Cover (cylinder tube), Bolt
Mounting bolt tightening torque (6) Bracket (2, H/V)
(7) Section B-B
M8 tightening torque (8) Section C-C
23.5~27.5 N·m (2.4~2.8 kgf·m) 17.4~20.3 ft·lbs (9) Band (3, cover)
(10) Band (1, cover), Plain washer, Nut
<Failure case> (11) Cover (cylinder pipe), Bolt
Insufficient tightness (12) In positioning, adjust the angle so that this
part is kept out of contact with the pipe.
Bolt loose
A B A C
Come-off
A B A C
VII-75
153
(12)
(1) (6) (7) (8)
(2) (9)
8
8
(3)
(10)
(4)
(5)
(5) (11)
Fitting of the cover (cylinder, Super Double Boom) (RD819-6731Δ) (1) Cover (cylinder , 2PB)
Bolt
Mounting bolt tightening torque (2) Details A
M10 tightening torque (3) Stay (cylinder cover, 2PB)
48.1~55.9 N·m (4.9~5.7 kgf·m) 35.4~41.2 ft·lbs (4) Section B-B
(5) Band (1, cover, 2PB)
(6) Apply grease here.
<Failure case> (7) Cap (cylinder cover)
Insufficient tightness (8) Band (2, cover, 2PB)
Nut
Bolt loose Plain washer

Come-off
(2) (1)
VII-76
(3)
(4) B
(5)
A
(6)
(7)
(8)
3. Boom 2 Cylinder Dismounting.

1) Remove the stopper bolt and cover plate.
2) Take out the spacer.
3) Check the dust seal.
4) Loosen the adapter of the L-joint.
VII-77
5) Remove the mounting bolts.
6) Disconnect the adapter and plug them.
7) Remove the stopper bolt and cover plate in

the cylinder rod side.
8) Tap in the pin with copper hammer.
VII-78
9) Hang the cylinder assy with nylon sling and

pull it out.
10) Dismount the other side of cylinder assy.
11) Pull out the pin.

Pin weight is approx. 20 kgf (44 lbs).
VII-79
4. Boom 2 Cylinder Remounting

1) Lift up the cylinder assy with nylon sling.
2) Insert the cylinder bottom side first.
3) Place the spacer and cover and tighten the

stopper bolt.
4) Tighten the mounting bolts by hand.

Tighten all the hose adaptors to torque.
VII-80
5) Tighten the mounting bolts to torque.
M10 x 20
Tightening torque: 48.1~55.9 N·m (4.9~5.7
kgf·m) 35.4~41.2 ft·lbs
6) Start engine and operate the cylinder.
7) Align the pin and the cylinder boss at rod

side.
8) Tap in the pin with a copper hammer.
VII-81
9) Install the dust seal.

Be sure of the direction.
10) Place the spacer and cover and tighten the

stopper bolt.
VII-82
l) Hose and Pipes

1. Hoses in the Swing Bracket
(8) (1) Bracket (swing)
(9) (2) Bracket (hose guide)
(3) Stay (1, harness clamp)
(10)
(4) Bolt
(4) (5) Cushion
(6) Plate
(3)
(7) Bolt
(8) Cushion (hose, front)
(2) (9) Clamp (2P, front)
(10) Bolt
(5)
(6)
(7)
(1)
VII-83
2. Hoses and Pipes of the Super Double Boom
[Boom assembly 1, rear pipe locations]
(2)
(3)
(1) (14)
(15)
(16)
(6) (17)
(5)
(4)
(18)
(10)
(19)
(11)
(12)
VII-84
(13)
(7)
(8)
(1) Pipe (right, F, SP, 2P) (7) Pipe joint (SG4, 1U)
O-ring (1UNF) (8) Boom assembly 2
Bolt (9) Boom assembly 1
(2) Pipe (right, F, SP2, 2P) (10) Pipe (hydraulic) (9)
O-ring (13/16UNF) (11) Pipe (hydraulic)
(3) Pipe (hydraulic) (12) Pipe (left, R, SP2, 2P)
O-ring (13/16UNF) (13) Pipe (left, R, SP, 2P)
O-ring (1UNF) (14) Pipe (P, H/V, 2P)
(4) Pipe (left, F, SP, 2P) (15) Pipe (T, H/V, 2P)
O-ring (1UNF) (16) Pipe (right, R, SP2, 2P)
Bolt (17) Pipe (right, R, SP, 2P)
(5) Pipe (left, F, SP2, 2P) (18) Pipe (hydraulic)
(6) Pipe (hydraulic)
O-ring (1UNF)
3. Hoses List
List of pilot hoses (upper) (platform, control system)
Part code Size Tape
No. Location Part name Q'ty Hose configuration Remarks
KX080-3 (EU) (mm) color
1 Travel P/V (P) ~ Super Double Boom P/V (P) RD809-6336Δ Hydraulic hose (1/4P, swing PV) 1 190 White Quick PLT04 G1/4 Common with Travel P/V ~
Swing P/V, 90° long-neck type
at travel P/V side
List of pilot hoses (drain) (upper) (platform, control system)

2 Super Double Boom P/V (T) ~ Travel P/V (T) RD809-6346Δ Hydraulic hose (1/4P, swing PV) 1 210 Quick PLT04 G1/4 Common with Travel P/V ~
Swing P/V, 90° long-neck type
at travel P/V side
List of pilot hoses (upper) (control valve, front attachment)

3 Super Double Boom P/V (crowded) ~ C/V (2P crowded) RD809-6896Δ Hydraulic hose (1/4, boom 2, P) 1 1950 Green, double Quick PLT04 Quick With corrugated tube
With corrugated tube, 90°
4 Super Double Boom P/V (dump) ~ C/V (dump) RD809-6897Δ Hydraulic hose (1/4, boom 2, T) 1 2350 Blue, double Quick PLT04 G1/4 long-neck type at travel P/V side
5 Super Double Boom P/V (crowded) ~ Boom back pipe (unlock) RD809-6813Δ Hydraulic hose (3/8) 1 3310 G3/8 PLT06 G3/8 With corrugated tube
With corrugated tube, quick type
6 Boom back pipe (drain) ~ Shockless valve (T) RD809-6814Δ Hydraulic hose (1/4) 1 3000 G1/4 PLT04 Quick at shockless valve side
VII-85
7 Boom back pipe (unlock) ~ Super Double Boom boom H/V (PL) RD809-6833Δ Hydraulic hose (3/8) 2 540 G3/8 PLT06 G3/8 Overall with corrugated tube
8 Super Double Boom H/V (Dr) ~ Boom back pipe (drain) RD809-6834Δ Hydraulic hose (1/4) 2 520 G1/4 PLT04 G1/4 Overall with corrugated tube
List of high-pressure hoses (upper) (control valve, front)

Part code Size Tape
No. Location Part name Q'ty Hose configuration Remarks
KX080-3 (EU) - (mm) color
9 C/V (2P crowded) ~ Boom back pipe RD809-6811Δ - Hydraulic hose (1/2) 1 3040 Green, double 13/16UN PF2108 13/16UN With corrugated tube
10 C/V (2P dump) ~ Boom back pipe RD809-6812Δ - Hydraulic hose (1/2) 1 3020 Blue, double 13/16UN PF2108 13/16UN With corrugated tube
11 Boom back pipe ~ Super Double Boom H/V (A) (bottom) RD809-6819Δ - Hydraulic hose (1/2) 2 560 13/16UN PF2108 13/16UN With corrugated tube
12 Boom back pipe ~ Super Double Boom CYL port (rod) RD809-6819Δ - Hydraulic hose (1/2) 2 560 13/16UN PF2108 13/16UN With corrugated tube
13 Boom back pipe (crowded) ~ Arm CYL (bottom) RD809-6835Δ - Hydraulic hose (5/8) 1 1010 Blue 1-14UNS PA2810 1-14UNS (Yokohama-made)
14 Boom back pipe (dump) ~ Arm CYL (rod) RD809-6836Δ - Hydraulic hose (1/2) 1 2195 13/16UN PF2108 13/16UN (Yokohama-made)
15 Boom back pipe (crowded) ~ Bucket CYL (bottom) RD809-6844Δ - Hydraulic hose (5/8) 1 890 1-14UNS PA2810 1-14UNS (Yokohama-made)
16 Boom back pipe (dump) ~ Bucket CYL (rod) RD809-6846Δ - Hydraulic hose (1/2) 1 890 13/16UN PF2108 13/16UN (Yokohama-made)
17 S/P intermediate (SP1) RD809-6844Δ - Hydraulic hose (5/8) 2 890 1-14UNS PA2810 1-14UNS (Yokohama-made)
18 S/P intermediate (SP2) RD809-6846Δ - Hydraulic hose (1/2) 2 890 13/16UN PFH08 13/16UN (Yokohama-made)
(2)
(1)
(3)
(4)
(5)
(1) Stay (wire harness clamp)

O-ring (13/16UNF)
Bolt
O-ring (13/16UNF)
Bolt
O-ring (13/16UNF)
O-ring (1UNF)
VII-86
(3)
(4)
(1)
(2)
(5)
(1) Pipe (left, R, SP, 2P)

O-ring (1UNF)
Bolt
(2) Pipe (left, R, SP2, 2P)
O-ring (13/16UNF)
Bolt
(3) Pipe (right, R, SP, 2P)
O-ring (1UNF)
Bolt
(4) Pipe (right, R, SP2, 2P)
O-ring (13/16UNF)
Bolt
(5) Plug
O-ring
VII-87
(1)
(2)
(1) Pipe (P, H/V, 2P)

Bolt
(2) Pipe (T, H/V, 2P)
Bolt
VII-88
4. Hose Connection
Pilot hoses
No. Location Tape color Part code Q'ty
1 Travel P/V (P) ~ Super Double Boom P/V (P) 2P boom P/V boost White RD819-6336Δ 1
2 2P boom P/V (T) ~ Travel P/V (T) Drain RD819-6346Δ 1
The dashed circuit lines are the same as for the standard machine.
(2) (3)
(1) (4)
(5)
(8) (9)
(16)
(10) (12)
(6) (11) (13)

(14)
(15)
(17)
(7)
(1) Machine front (12) (Front)

(2) Valve assembly (PV, travel) (13) (Back)
(3) Attention to the fitting angle of the (14) (Port locations when viewed from
crane-neck-shaped hose at Port P. above the valve top)
(4) Machine front (15) (Used for the dozer lever)
(5) Valve assembly (shockless) Valve assembly (pilot, OFF)
(6) Adapter (pilot hose, 1) (16) (Used for the swing pedal)
(7) Boom H/V (Dr) Valve assembly (pilot, OFF)
(8) Valve assembly (pilot, L) (17) (Used for the Super Double Boom
(9) Valve assembly (pilot, R) pedal)
(10) (Front) Valve assembly (pilot, OFF)
(11) (Back)
VII-89
5. Hose Connection 2
Connecting the front hoses (high-pressure hoses) and holding valve hoses (low-pressure hoses)
Connect these hoses to the control valve according to the procedural instructions in the figure. Pay special
attention in connecting the holding valve hoses (signal and drain) of the booms (bottom and rod).
(4) (5)
(57)(58)(59)(60)(61)(62)
(53)(54) (55)(56)
(6)
(63)
(45)(46)(47)(48) (49)(50)(51)(52)
(32) (21)
(31) (20)
(30) (19)
(29) (18)
(37) (38) (39) (40) (41) (42) (43) (44)
(28) (17)
(27) (16)
(2) (3)
(33) (34) (35)(36) (15)

(26) (14)
(25) (13)
(12)
(24) (11)
(23) (10)
(9)
(22)
(8)
VII-90
(1) Connecting the front hoses

1) Pass the hoses from the swing bracket. Clamp them at the swing bracket.
2) Arrange the hoses as shown below. (Pass the boom holding valve hoses above the boom (up) and S/P1 (high)
hoses.) Check the hoses from the clamp to their sockets to make sure that the hoses are not twisted and do not
cross each other.
3) Connect the hoses to the control valve in the numerical order shown below. Note that the six hoses (marked A)
should be passed above the S/P2 (low) hose and the two hoses (marked B) above the S/P2 (high) hose.
(2) Super Double Boom holding valve hose
(3) Boom holding valve hose
(4) Super Double Boom holding valve unlock (signal) hose
(5) Super Double Boom holding valve drain hose
(6) In this dashed-line-circled zone, arrange the hoses not twisted or crossed each other. Pass the two boom holding
valve hoses above the boom (up) and S/P1 (high) hoses.
(7) Connecting the front hoses for the Super Double Boom type
1) Connect all the standard-type hoses in the same way.
2) The additional hoses for the Super Double Boom type should be connected in the procedure below.
Pass the two high-pressure hoses, between the control valve and the cylinder, above all the other high-pressure
hoses. Pass the lock valve unlock (signal) hose of the two holding valve pilot hoses along the boom holding
valve hoses.
The drain hose crosses the Super Double Boom high-pressure hose in the frame. Pass the drain hose above the
high-pressure hose and along the boom holding valve hoses.
(8) P3 bypass (31) (Right) (52) Boom (down)

(9) Swivel (left) (32) (Rod) (53) S/P2 (high)
(10) Dozer (down) (33) (Pink) S/P2 (high) (54) Super Double Boom (dump)
(11) S/P2 (low) (34) (Green, gray) (55) Super Double Boom (crowded)
(12) Confluence valve Super Double Boom (dump) (56) S/P2 (low)
(13) Travel (backward) (35) (Yellow, gray) (57) S/P1 (high)
(14) Travel (backward) Super Double Boom (crowded) (58) Arm (dump)
(15) Travel independent valve (36) (Brown) S/P2 (low) (59) Arm (crowded)
(16) Arm (crowded) (37) (Blue) (60) Bucket (crowded)
(17) Bucket (crowded) (38) (Pink) (61) Bucket (dump)
(18) S/P1 (low) (39) (Yellowish green) (62) S/P1 (low)
(19) Boom (down) (40) (Blue) (63) Swivel frame inlet
(20) Swing (left) (41) (Orange)
(21) Super Double Boom (bottom) (42) (Red)
(22) (Right) (43) (Brown)
(23) (Up) (44) (Yellow)
(24) (High) (45) Boom (up)
(25) (Forward) (46) S/P1 (high)
(26) (Forward) (47) Arm (dump)
(27) (Dump) (48) Arm (crowded)
(28) (Dump) (49) Bucket (crowded)
(29) (High) (50) Bucket (dump)
(30) (Up) (51) S/P1 (low)
VII-91
1. Fitting of the cover (hose, 2-600)
(RD809-6466Δ)
Bundle the hoses with their white tape in align-
ment as shown at left. Install the cover from the
ends of the tape as shown at left.
<Failure case>
Cover (hose, 2-600) wrongly installed

Hose malfunctioning at swing operation

Hose damaged
(46)
(47)
(1)
(3) (2) (5)
(14) (17)
(15) (18)
(25) (16) (19)

(24)
(4) (20)
(6) (22)
(26) (21)
(28)
(27)
(24)
(36) (38)
(29) (44) (37)
(30)
(31) (13)
(32) (7)
(39) (23)
(40)
(8)
(33) (34) (35) (43) (42) (41)
(9)
(10) (11) (12)
(1) Section A-A (when viewed from the (15) (When viewed from the arrow) (33) S/P1 (low)
machine front) (16) (Operator’s seat) (34) Bucket (crowded)
(2) (Top) (17) (Wrong setup) (35) Bucket (dump)
(3) Boom H/V hoses (signal and drain) (18) (When viewed from the arrow) (36) S/P2 (low)
(4) Boom (up) hose (19) (Operator’s seat) (37) Super Double Boom H/V (signal)
(5) Velcro fastener (20) View B (38) Boom H/V (signal)
(6) (Bottom) (21) Super Double Boom H/V hose (signal) (39) Boom H/V (drain)
(7) Cover (hose, 3-670) White tape (40) Boom (up)
This cover has its front and back. (22) Super Double Boom H/V hose (drain) (41) S/P1 (high)
Install it with its urethane-coated (23) Lay the Super Double Boom H/V (42) Arm (dump)
(smooth) face inward (toward the hoses with the white tape on this side (43) Arm (crowded)
hoses). of the round bar, as shown above. (44) Super Double Boom (dump)
(8) Green tape (24) Section C-C (when viewed from the (45) Layout of the front hose outlets at the
(9) White tape machine front) swivel frame
(10) Boom (up) hose (25) Boom H/V hoses (signal and drain) (46) Detail view of the clamping position of
(11) Cover (hose, 2-600) (26) Boom cylinder boom H/V hoses (signal and drain)
This cover has its front and back. (27) Velcro fastener (47) Place the two thin hoses atop the
Install it with its urethane-coated Place the fastener toward the boom thick hose as shown at left (Section
(smooth) face inward (toward the cylinder. A-A). Then wrap them all with the
hoses). (28) Wire harness cover. Make sure the Velcro fastener
(12) Make sure the cover edge is placed (29) Super Double Boom H/V (drain) is on the top (thin hoses).
behind the swivel frame. (30) Super Double Boom (crowded) When viewed from the side of the
(13) Boom H/V hoses (signal and drain) (31) S/P2 (low) swing bracket, make sure the Velcro
(14) (Correct setup) (32) Boom (down) fastener is invisible at Point B. (See
below.)
VII-92
(1) (15)
(2)
(14)
(3)
(13)
(4)
(5) (12)
(16)
(6)
(17) (11)
(7) (10)
(9)
(8)
(18)
(19)
(16) Stay (harness clamp)

(1) S/P1 (brown) (17) Clamp assembly
(2) Bucket (red) 01133-61060
(3) Bucket (orange) Bolt
(4) Arm (blue) (Behind)
(5) Arm (yellowish green) Clamp assembly
(6) S/P1 (pink) Cushion
(7) Cushion 01133-61060
(8) Clamp (2P, front) Bolt
01135-61025 x 2 pcs. (18) Bracket (hose guide)
Bolt 01135-61025 x 2 pcs.
(9) RC411-6421Δ x 2 pcs. Bolt
Cushion (hose, front) (19) Plate
(10) Super Double Boom H/V (unlock) 01135-61025 x 2 pcs.
(11) S/P2 (pink) Bolt
(12) Super Double Boom (green, grey)
(13) Super Double Boom (yellow, grey)
(14) S/P2 (brown)
(15) Super Double Boom H/V (Dr)
VII-93
8. Pipe Installation 1
(1)
(2)
(5)
1 (3)
A
(6)
B
T
2
(7)
(4)
(1) Control valve assembly (2P)

(4) (Crowded)
(5) (Dump) Super Double Boom
(6) P/T collective block
No. Location Tape color

3 Super Double Boom P/V (crowded) ~ C/V (2P crowded) 2nd boom (crowded) Green, double
4 Super Double Boom P/V (dump) ~ C/V (2P dump) 2nd boom (dump) Blue, double
5 Super Double Boom P/V (crowded) ~ Boom back pipe (unlock) Anti-fall valve unlock
6 Boom back pipe (drain) ~ Shockless valve (T) Drain
7 Boom back pipe (unlock) ~ Super Double Boom H/V (PL) Anti-fall valve unlock
8 Super Double Boom H/V (Dr) ~ Boom back pipe (drain) Drain
VII-94
(1)
(3)
(2)
(1) Control valve assembly (2P)

(2) Super Double Boom (dump)
(3) (Crowded)
No. Location Tape color Parts No. Q’ty

9 Control valve (2P crowded) ~ Boom rear pipe No. 2 boom (crowded) Yellow, gray RD809-6811Δ 1
10 Control valve (2P dump) ~ Boom rear pipe No. 2 boom (dump) Green, gray RD809-6812Δ 1
11 Boom rear pipe ~ H/V (A) (bottom) No. 2 boom (dump) RD809-6819Δ 2
12 Boom rear pipe ~ Super Double Boom cylinder port (rod) No. 2 boom (crowded) RD809-6819Δ 2
13 Boom rear pipe (crowded) ~ Arm cylinder (bottom) Arm (crowded) Blue RD809-6835Δ 1
14 Boom rear pipe (dump) ~ Arm cylinder (rod) Arm (dump) RD809-6836Δ 1
15 Boom rear pipe (crowded) ~ Bucket cylinder (bottom) Bucket (crowded) RD809-6844Δ 1
16 Boom rear pipe (dump) ~ Bucket cylinder (rod) Bucket (dump) RD809-6846Δ 1
17 S/P intermediate (SP1) SP1 RD809-6844Δ 2
18 S/P intermediate (SP2) SP2 RD809-6846Δ 2
VII-95
(2)
(3)
(1) (14)
(15)
(16)
(6) (17)
(5)
(4)
(18)
(10)
(19)
(11)
(12)
VII-96
(13)
(7)
(8)
(1) Pipe (right, F, SP, 2P) (7) Pipe joint (SG4, 1U)
O-ring (1UNF) (8) Boom assembly 2
Bolt (9) Boom assembly 1
(2) Pipe (right, F, SP2, 2P) (10) Pipe (hydraulic) (9)
(3) Pipe (hydraulic) (12) Pipe (left, R, SP2, 2P)
O-ring (13/16UNF) (13) Pipe (left, R, SP, 2P)
O-ring (1UNF) (14) Pipe (P, H/V, 2P)
(4) Pipe (left, F, SP, 2P) (15) Pipe (T, H/V, 2P)
O-ring (1UNF) (16) Pipe (right, R, SP2, 2P)
Bolt (17) Pipe (right, R, SP, 2P)
(5) Pipe (left, F, SP2, 2P) (18) Pipe (hydraulic)
O-ring (1UNF)
(2)
(1)
(3)
(4)
(5)

O-ring (13/16UNF)
Bolt
O-ring (13/16UNF)
Bolt
O-ring (13/16UNF)
O-ring (1UNF)
VII-97
(3)
(4)
(1)
(2)
(5)
(1) Pipe (left, R, SP, 2P)

O-ring (1UNF)
Bolt
(2) Pipe (left, R, SP2, 2P)
O-ring (13/16UNF)
Bolt
(3) Pipe (right, R, SP, 2P)
O-ring (1UNF)
Bolt
(4) Pipe (right, R, SP2, 2P)
O-ring (13/16UNF)
Bolt
(5) Plug
O-ring
VII-98
11. Clamp
(1) (2) Bracket (pipe, H/V, 2P)
Clamp (front)
Bolt
(2) (3) Clamp (4, front)
Clamp (front)
Bolt
Bolt
(3) (5) Clamp (front)
Bolt
(6) Clamp
Bolt
(7) Clamp (T)
Bolt
(8) Clamp
Bolt
Bolt
(10) Clamp (4, front)
Clamp (front)
(5) Bolt
(11) Clamp
Bolt
(12) Bracket (SP)
(6) Bolt
(13) Clamp (pipe, front)
Bolt
(14) Bracket (clamp)
Bolt
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
VII-99
Clamp (front)
(2) Bolt
(4) Clamp (front)
Bolt
Bolt
(3) (5) Clamp (front)
Bolt
(6) Clamp
Bolt
(7) Clamp (T)
(5) (12) Bolt
(8) Clamp
(7) Bolt
(9) Bracket (pipe, H/V, 2P)
(13) Bolt
Clamp (front)
Bolt
(11) Clamp
Bolt
(12) Bracket (SP)
Bolt
(13) Clamp (pipe, front)
Bolt
(14) Bracket (clamp)
VII-100
(6) Bolt
(11)
(10)
(8) (9)
12. Reference Photo- Pipes and Hoses
VII-101
VII-102
(D) ELECTRICAL SYSTEM

a) Wire Harness Route
(1)
(21) (23) (24)

(2)
(22)
(3)
(25)
(20)
(4) (19)
(5)
(6)
(18)
(7)
(17)
(8)
(9) (16)
(10)
(15)
(11) (12) (13) (14)
(1) Details of Location A (7 locations) (16) Feed sensor

(2) Wire harness (17) Fuel level gauge
(3) Insert cable clamp (18) Ground cable
(4) Stator relay (19) To main wire harness
(5) Stay (harness clamp) (20) Fuel feed pump
(6) Plate (clamp, 1) (21) Details of Location B (19 locations)
(7) Engine stop solenoid (22) Wire harness
(8) Air intake heater (23) Location C (6 locations)
(9) A/C sensor (24) Coupler
(10) A/C compressor switch wire harness rerouted (25) Wire harness
(11) Fuel pump
(12) Stay (1, wire harness)
(13) Fuel feed switch box
(14) Fuel level gauge
(15) Feed sensor
VII-103
(1)
(4) (6)
(5) (7)
(2)
(3)
(8)
P
LA
R B
D
B A A A A A A A
(9)
30
(11) (12)
(10) 30 (13)
(14)
A A
C C
(15)
(16)
(1) Details of Section A (8 locations)

(2) Wire harness
(4) Details of Section B (1 location)
(5) Wire harness
(6) Details of Section C (2 locations)
(7) Wire harness
(8) S/P2 (high) hose and clamp
(9) Using the 2 quick clamps, bundle the wire
harnesses 30 mm away from the wire
harness clamp center.
(10) Bending location of S/P2 (high) pipe
(11) Cord band (SP2 pipe and clamp)
(12) Cord band (2 pcs.)
(13) To main wire harness
(14) Grommet (attached on the wire harness)
(15) To main wire harness
(16) Cord band (3 pcs.)
VII-104
b) Boom Cylinder Overload Sensor

(1) 1. Location
(1) Boom 1 cylinder holding valve:
RD 809-64052
(2) (2) Pressure switch: RD 809-64091
2. Specifications
1. Code. No: RD809-64091
2. Screw size: G 3/8 A (PF)
3. Pressure range: 0~35 MPa (~357 kgf/cm2)
0~5078 psi
4. Output: Open collector type (30V, 150mA)
5. Source: 12V DC
6. Sensing pressure: 12.9 MPa ON
(132 kgf/cm2)
1872 psi
(1) 3. Comparison
Boom Mono-boom: Super Double Boom:
Boom 1 boom cylinder boom 1 cylinder
Holding valve
RD 809-64052 ←
assy
Pressure switch RD 809-64081 RD 809-64091
11.8 MPa 12.9MPa
Sensing
(2)
pressure (120 kgf / cm2) (132 kgf / cm2)
1712 psi 1872 psi
30.4 MPa
Overload relief
(310 kgf / cm2) ←
pressure, c3
4409 psi
Arm tip end
load
4. Parts Name
1) Power (+)
2) Output (+)
3) Common
4) Wrench size: 22 x 25.4
5) O-ring P14 (JIS 1-B,NBR)
6) G 3/8 A (PF)
7) Orifice ø0.7
VII-105
VII-106
5A CN-11-2 CN-11-1 SWP-16p-6
CN-14-3
off
on CN-14-1
Starter
start CN-14-2 10A
Travel Hi-Low Lamp

CN-420-1 CN-420-2
CN-13-1 CN-13-2

4 2
CN-410-4 CN-410-2
AI Self-hold relay
Meter Sub
5A CN-1-12 +B

10A
CN-1-1 AC-1
CN-34-4 CN-34-2
CN-23-2 2 2 4 5V CN-1-21
CN-2-15 +5V
CN-23-3 Engine to
AI Console CN-1-22
c) Electrical Circuit Diagram: Super Double Boom
GND CN-421-4
+12V CN-421-2 CN-1-14
CN-421-5
SW2 CN-421-6 CN-1-4
CN-1-15

JS Control(R)
GND
pot
+5V CN422-3
CN422-1
SWP-16p-14
M
Main to Engine
CN422-5 CN422-6
CN-2-19 AI Motor
CN-33-3
Power_Source(12V)
Engine speed sensor
5V 3
CN-1-18 5 CN-428-1
SWP-4p-1 CN-428-2
2 Solenoid_Out_2
AUX. sol(+)-R
CN-2-13 RS-485(+) CN-1-19 6 CN-427-1
CN-33-1 SWP-16p-5 CN-1-20
Flash cnt
CN-2-9
CN-2-11 Txd-1

CN-28
10A CN-306-3 CN-306-1
CN-2-17 Motor-GND
CN-306-2 CN-306-4
CN-45
CN-454-1
CN-454-2
CN-454-5
CN-454-6
CN-454-7
CN-454-3
CN-454-8
CN-454-4

Antithieft_sub
+B
RS-485-con
10A CN-440-7
CN-453-7
GND
CN-453-8
CN-453-3
CN-453-2
CN-453-4
CN-453-5
CN-453-6
CN-453-1
CN-440-6
CN-440-12 RF-GND

CN-440-1
CN-441-5 AC Power in Anti theft horn Relay
Starter relay
CN-440-2 RS-485-con
CN-441-2 GND CN-7-1 CN-5-1 CN-17-4 CN-17-3
CN-441-1 CN-440-5 CN-440-11
Txd(RF-unit) Txd(RF-unit) RS-485(+) CN-17-1 CN-17-2
Rxd(RF-unit) Rxd(RF-unit) RS-485(-) CN-37
unti thieft LED CN-114
CN-441-4 CN-440-4 CN-440-10 58-M-2p-1
Anti theft RF Unit Anti theft Unit Main to Engine
Alternator
CN-113

10A CN-25-1
58-M-8p-6
CN-25-2
58-M-8p-2
CN-302-3 CN-302-1
CN-18-2 CN-100
60A
30A
Light relay
CN-36-2
58-M-2p-2
Relay source
5A
100A
Battery
58-M-8p-8
CN-24-2
15A 1 3 1 2 58-M-4p-1 CN(A)250-4p-1
2 4 3 CN-869-2
6 58-M-4p-2 CN(A)250-4p-2 CN-869-1
CN-871-1 30A 1 2
M
Cab relay
CN-308-3 CN-308-1
Start relay
4 Fuel Level Sensor
1 1 1
1 2 3 6 5A 2 4
Stop Relay
Relay_Out_1
5
Relay_Out_2
Power_Source(12V) 6
3
Power_Source(GND)

SWP-16p-13 SWP-3p-1

CN455-1 CN-781-1-1 CN-781-1-2 CN-783
CN-784
Main to Engine
6 CN(A)250-4p-3
CN250-2p-1
-5V CN-765-1 -5V SWP-3p-1
Wiper Motor
Cabin Source(AUX) 2
CN-601-1
CN-765-3 SWP-3p-3 M
CN-601-2 GND GND
+1 S +
CN-601-3
1
3
4
CN-601-4
Cab_Work_lamp_R
CN-600-1 CN-17-2
CN-600-2 CN-17-2
1
3
4
CN-841-2 CN-841-1
2
CN-821-1 CN-821-3 CN-17-2

CN-600-6 CN-821-2 CN-821-4 CN-17-2
15A
CN-841-4 CN-841-3 CN-17-2
Cab Worklight SW
Wiper sw
off CN-609-5
CN-609-6
on CN-609-1
Washer Motor
5A CN-600-5 CN-611 M
CN-610-2
CN-612
CN-317-2 CN-317-2 Speaker (R) 2
CN-317-2 CN-317-2 7
3
CN-317-2 CN-317-1 4 6
15A CN-317-2
CN-317-1 CN-317-1 5
Power source
CN-317-2 1
CN-655-1 CN-655-3
CN-472-5 CN-472-1 CN-600-4 CN-657-2 SWP-6p-12
M
FT
CN-472-6 CN-472-3
Hi
Lo
Mi
Compressor
CN-652-3
CN-652-1
CN-652-4
CN-651-7 Lo Com
20A CN-653-1 M CN-651-8 Hi
CN-655-1 CN-655-3 CN-653-2
CN-651-4
CN-651-1
CN-651-5
CN-800-1
CN-801-2
<KX080-3 Export with anti-theft & AI & AirConditioner & Overload Warning>
VII-107
d) Electrical Wiring Diagram: Super Double Boom
0.5-R/Y 0.5-W/B
0.5-L
0.5-L/Y
0.5-B/Y
Horn-sw
EC/USA
pot
GND
0.75f-R/Y
CN422
0.75f-Br
8 7 6 5 dewtsch-8pf
DT06-08SA-CE05
+5V
Br-lock-sw-Vcc
Br-lock-sw-sw
Blank
AnalogGND
Horn-sw-Vcc
0.75f-B/Y 0.5-W
MotorPot
OverLoadWarningSW
4 5 6 Room Lamp(GND) IC62
6180-6181 090MT-6pf 0.85-Y
0.5-L HM090-6pf 1 2 3 CN612 6244-5061 WORK/L(+)
3 2 1 EU/USA M5
Room Lamp(+)
Travel ho-low Lock sw CN611 2 1 CB-1pf
E03F(BR) 0.5-Y/B CN15 0.5-Y 0.85-B WORK/L(GND)
6098-0142 1 2 TNS-3pm 2f-B 6 5 4 3
3 6092-0013 485+ 485- 1 2 3
Motor_sensor CA-1pm
4 5 6
CB-1pf
EU
Overload_Warning_Buzzer 7382-1481-10 8 7 6 5 7283-4421-30 0.5-W
Harness (Wiper) CN613
0.5-R
CN250-2pf JB-8pm 4 3 2 1 090II-2pf 1 CN610 2f-Y Work lamp,R(+)
0.5-R/B CN454 1.25-Lg/R 2 Washer motor
0.5-G
7123-2820
0.5-Br 0.5-B/Y
0.5-Br/W CN6 EU 3 2 1 CB-1pf CN614
2 EU 6090-1011 7122-1347 7123-1347 6 5 4 CN609 2f-R
7323-7729-40 0.5-B/R 0.85-W Wiper SW
AUX-SW
Overload_Warning_Pressure_sw 7321-9822 0.5-R/B EU 485- 0.75(SoftVCTF-0.75*4core)-G
+12V
485+ 0.85-R CA-1pm
US
2 1
AMP090-JMk2-3pf
0.5-R/W
0.5-Br
4 2f-B
2 1
7383-1081 8 7 6 5 US 0.5-L
0.5-R/Y
4 3
2 1
1.25f-R
4 3
174357-2 2 1 CN615
4 3
2 1
2 1
8 7 6 5 485+ 485- 0.75(SoftVCTF-0.75*4core)-R 2 1
0.5-Br/W coil contact 2-Y Work lamp,L(+)
+5V 0.75(SoftVCTF-0.75*4core)-B 6 5 4 3 WorkLight 4 3 com
0.5-O
7147-5955-10 0.5-Br AUX-LED 0.85-G Indicator(GND) coil
Vcc
0.5-R 0.5-Br
pot
0.5-Br CN841
AI-SW
EU/USA
US
CN821
3 2 1
3 2 1

1
CN421 0.5-O CN1 EU 0.5-Br CabWorkLightrelay 0.85-B CN616

On-Off
6244-5061
0.5-B
8pf meter (big) Work lamp,L(GND)
2
FW-L-8F 7283-5834 0.5-B
0.5-R
CabWorkLightSW
3

com
SWP-3pf 4 2 3 1 0.5-B
SWP-3pm 7123-7434-40 11 10 9 8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1 8 7 6 5
0.5-B/Y
7122-7434-40 22 21 20 19 18 17 16 15 14 13 12 20 19 18 17 16 15 14 13 12 11 meter(small) 12 11 10 9
CN2
0.5-W 040_3-20pf
7383-5847 Wire harness (Travel alarm) Harness(main,Cabin) 0.5-R RoomLight WorkLight
0.5-Br/W
4 3 2 1
1.25-Lg/R
8 7 6 5
2 1
EU EU 1.25-Lg/R WiperMotor etc
0.85-L/W
0.85-L/B
0.85-R
0.85-B
0.85-B/R
0.85-R/B ST0-01T-187N CN628
0.5-B 0.5-Y 0.5-R 1 CN628
2f-B 0.5-L Speaker,R(+) CN617 7323-2010
EU 7122-2820 EU/USA
0.5-B/W
7323-2010
1 0.5-R/Y 7122-2885-60 M6
2f-R
7123-2825 ST0-01T-110N CN622 Cap
coil
Buzzer(F)(+)
4coil
2 2f-Y
0.5-B CN601
1 2
7122-2845-60
0.5-Y/R
2 1 7123-2840-30 CN783 CN250-4pf
4 3
1
7115-1050-02 0.5-G/W Speaker,R(-)
4 3
2 1
Main to [work lamp]
0.5-R/Y
0.5-B/W
0.75f-B 0.5-B coil contact
4 3 com CN410 1 0.5-L Radio(AC) CN250-4pm 7123-2840-60
contact3
CN603
com
2
0.5-R
2f-Y 6189-0156 CN618
CN100 1 0.5-B/W EU CN781-1 CB-1pf
7123-2885-60 CN780
coil
2f-R/W 090-2pf
CN18
4coil
7113-1020-02 CN250-8pf CN11 DL090-2pf 1 CN250-3pm
1 2
7123-2820 6195-0003 CN455 2 3 7122-2835-30
ST0-01T-187N CN624 0.5-R
WorkLight
CN302
contact3
2 1 7123-2835-30 CN784 Speaker,L(+) CA-1pm Cabin,GND
com
coil contact Light relay 0.5f-G/W 0.5-G/W fromTravelAlarmPower
4 3 com 2 1 TravelAlarmPower 0.5-B 2f-B CN604
RoomLight coil CA-1pm 1 CN(A)250-1pf(B)
0.5-B
[main] to work lamp
7147-5955-10 0.5-G/W CN619 7123-2810-30

8 7 6 5
4 3 2 1
WiperMotor CA-1pm
etc
0.5-G/W 3 2 CN627 CN626
0.5-W/B
0.5-B
CN18
CA-1pm
1 CN250-1pm
W-Boom-ind.
7122-2810-30
3-B/W 10A Starter
0.5-Y/R
coil
4coil
1 2
5A 20A 1 CN250-1pf 7122-2810-30 7123-2815
contact3
Blower_Motor(A/C) 7123-2810-30 7123-6234-40
EU/USA
Room_Light
com
15A Auxiliary 7123-2840-30
st 2 1 ac 3-R/W 2f-R 0.85-R EU/USA
20A 0.5-B 3
com 0.5-Y + - CN420
coil
contact3 coi4 l

3-W/R 0.5-R
1 2
1.25-G Cigarette lighter Power source 7123-2840-30 090-2pf-lamp 7123-2840-30 Radio_Convert(CAP)

15A CN306
1 7123-8322 7323-1520-80 6130-2390(7123-1090) CA-1pm
com
0.5-R
Meter_Sub 5A 10A Horn relay AUX2_LeverLockrelay Radio_Convert
3-B
0.85-L
3-R

CN308 2 1 2 1 MTW-9pm
4 3 com 6130-0590(7322-1090) CA-1pm
7123-2840-30 coil coil 3 2 1
0.5-B
10A 10A 20A 2f-R/W Work light Radio(GND)
1.25-B
0.85-R/B 9 8 7 CB-1pf
3-R 10A 0.5-L/W Horn 6 5 4
0.5-L 9 8 7 0.5-Y Speaker.R(+)
Light+
Lock
EU/USA
0.5-L/B

6 5 4 3
CN45 Speaker.R(-)
1
0.5-B
Lsw Rsw Rsw
com nc
15A 10A 5A 0.5-Y Travel Hi-Low 1 Horn(+) JSControl(L) CB-1pf

5-R
Horn 0.85-G 7323-2010
1
Auxiliary 2 1 DL090-6pf
7323-7729-40
3
7321-9822
0.5-W Speaker.L(+)
5A 0.85-B/Y Meter Sub 6 5 4 6195-0021
0.5-B/R
CB-1pf
2
10A
2
15A 1 Lsw Gsw Gsw
Free

Light-

CN472 CN46
0.5-B
5A 5A 4F0670-000 Anti theft main 7323-2010
Antitheft_Main Travel_Hi-Low EU 5A 0.5-R/W
2.3II-6pf
0.5-B
EU/USA AI Motor 7123-2840-30 0.5-R/G
0.5-G EU 15A 2f-B/L
10A 5A
0.5-B/W
0.5-Y/R
coil
4coil
1 2
0.5-L
contact3
10A
com
Starter 5-R/W 3-R/W
0.5-B
0.5-Lg
1.25-B
1.25-B
CN101
3-B
M8 GND
1.25-B CN102
0.85-Y
3-B
090-8pf CN651 3-B
7383-1080 air conditioner SW M8 GND
1.25-L/Y 0.5-L/B
3 2 1 1.25-R/W CN655 CN(A)250-4pf 0.5-R/B
8 7 6 5 4 crutch relay 7123-2840-90 0.5-B/R 0.5-B
2 1
1.25-R/W 0.5-B 0.5-W/R
0.5-L
0.85-R/B
coil contact
4 3 com 7321-9822
7323-7729-40
5-R
0.5-W coil 1.25-Y

2f-L
1.25-B 0.5-W
0.5-B
1 2
CN250-4pf 7321-9822
7123-2840 7323-7729-40
CN652 1 2 0.5-R/W 0.5-R/G
resistor CN655
Me 2 1
coil contact
2 1 0.5-L/W 4 3 com CN(A)250-4pf
4 3 coil 7123-2840
Lo Hi
3 2 1
1.25-Y
0.5-L/B
0.85-B
6 5 4
0.5-Y/R
0.5-R/B
1.25f-L
2f-L/W
FW-L-6F(7323-8969)
5-R/W
0.5-G/R
E.SpeedSensor-vcc
6pf
LeverLockSolenoid
AIPressu.SW

coil coil 7123-9246
3-R 4 3
ChargeSW
TravelAlarm
FuelPump
GND
7147-5846-40
OilSW
E.SpeedSensor-gnd
CN658 7047-4988
3-R/W
Compressor
WaterTemp.Sensor
5 4 3 2 1 090II-5pf 16 15 14 13 7147-5846-40 7047-4988
GND
7283-1050 RefrigerantPress.SW +5V 7222-7564-40 7122-6040
Thermo_SW CN336 12 11 10 9 AUX2-L 4 3
7282-3013-10 4 3 2 1 7047-4988 4 3 4 3 2 1
7122-6083 AUX2-R
7147-5887-90(LH) 7222-6423-30 SWP-4pm 2 1 AUX-L 58-M-8pm Alternator
CN653 AIPressu.SW WaterTemp.Sensor 58-X-2pm 2 1 7222-7444-40 AUX-R
2f-L 1 blower motor TravelHi-LowSorenoid 0.5-B/Y FuelSensor
2 CN250-2pf
7123-2820
FuelSensorGND
7123-6423-30
FuelSensor
7283-3013-10 AUX2-L 2 1 AUX2-R
Alternator
LeverLockSol.
TravelHi-LoSorenoid AUX-R AUX-L 58-M-4pf
4 3 7123-6040
SWP-16pf 4 3 7123-7444-40 4 3 2 1 58-M-8pf GND
7123-7564-40 4 3 2 1 GND 8 7 6 5 7123-6083 0.5-L
8 7 6 5 MotorPot
5-R/Y
GND
Compressor
ChargeSW
16 15 14 13
OilSW
FuelPump
Buzzer(R)(+)
WoterTemp.Sensor
WoterTemp.Sensor
0.5-G/W
0.5-R/B
0.5-B
3-R/W
AIPress.SW
CB-1pf
E.Speedsensor-vcc
1 RefrigerantPress.SW 7147-5955-10
E.Speedsensor-gnd
E.Speedsensor-vout
2 Buzzer(R)(-)
0.5-B
5-R/W
0.5-B/Y
EU/USA
0.5-Y
1 2
1.25f-B/W
AEX-8-R AEX-8-R CN8

0.5-R/G
CA-1pm
0.5-W/R
AI pressure SW
0.5-R/G
1 1 CN12 7323-8321
0.5-G/R
AEX-8-R 090-2pf
0.5-R/G
AVX-3-B/R
0.5-R
Lever lock solenoid
0.5-W/R
AVX-1.25f-B/Y
CN375-1pm CN375-1pf 6189-0156

0.5-G
AVX-1.25f-W
AVX-1.25f-Y/R
7122-4113-30 7147-5955-10
AVX-1.25f-B/R
7123-4113-30
AVX-1.25f-Lg
AVX-1.25f-B
EU/USA
0.5-Y/R
AVX-1.25f-L
7323-1223-40 - +
090-2pf 1 2 1 2 1
100A
SB-BOX-8p
30A
60A
2f-R/W
2f-R/W
7257-5155-30 CN657 CN37-1

CN13 Starter(+) 174352-2(7323-8321)
2 1 Travel hi-low solenoid
3 2 1 7323-2010 AUX.[R]control_SOL 1
CN32 7323-8321 CN427 2
Vcc Vout GND - +
60f-B/R

CN33 store pull 2 1 CN28 7123-2820-30
AVX-1.25f-Y
E, speed sensor CN36

174352-2(7323-8321) E. oil switch CN24
E. stop solenoid
CN656 CN428
0.5-L
M4
0.5-R
M6 FC-250-1pm 1
M10 12645-5201-02 2
CN115 7147-5955-10
CN113
CN114 1 7122-7434-40
SWP-3pm 3 2 1
Alternator 7147-5955-10
Startor(+B)
1 2 1 2
7323-8321
main_to_[Fuel_supply_punp] FuelSensor 7323-8321 2pcs-Aux2(R)sol
7123-7434-40 7123-1424-40 7122-1424-40 CN871
7323-3220 SWP-2pf SWP-2pm
Sonsor GND DUMMY
0.5-B 0.5-B
1 2 3
1 2
0.5-L
1 2
0.5-L
6187-2801(Black)
HM090-2pm
0.5-R 0.5-L
1 2
3-W Harness(fuel)
EU
0.5-W
3-R 3-R 361897-0313

1 1 Fuse
5A Fuse
361897-0313
2
CN(A)250-1pf CN(A)250-1pm 30A

7123-2810 7122-2810 coil
com
NO
1
3-R 1
3 2 1
6 5 4 CN250-6pf
7323-5365
0.5-G
7321-9834-30 coil null NC Fuel Supply Pump

2 1 dewtsch-2pf
0.5-L
Starting Relay
2 1
1 2 0.5-G 1062-16-0622
0.5-R
21
4 3
Fuel Supply Pump Stop SW coil com 7123-2840-90
6187-2801 Fuel Supply Pump Stop Relay
HM090-2pm
0.5-W 2 1 0.5-L
0.5-Br HM090-2pf
3-Br
Wire harness (Fuel pump) 1 2 6180-2451

0.5-Y
Fuel Level Sensor

EU
0.5-L
Y R B
FW-L-6F 3 2 1
6pf 6 5 4
0.5-Br
4min.Timer
GND
0.5-L M8
KX080-3 Export (Anti-theft), AI AUX A/C
VII-108
ss
Conversion Tables
KUBOTA Corporation
CONSTRUCTION MACHINERY DIVISION
1-1-1 NAKAMIYA-OHIKE, HIRAKATA, OSAKA, JAPAN
EDITOR:
CONSTRUCTION MACHINERY DIVISION
CUSTOMER TECHNICAL SUPPORT DEPT.
HIRAKATA PLANT
1-1-1 NAKAMIYA-OHIKE, HIRAKATA, OSAKA, JAPAN
PHONE: +81-72-890-2888
FAX: +81-72-890-2886
PP (Pan-Pacific: KTC, KCL, KTA)-version
KUBOTA Corporation Printed in Japan Jul./Nov./Mar. 2009 800 CMC.e. KISO Code No.97899-61962

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WORKSHOP MANUAL

Mar. 2009 1. Engine oil specifications are corrected. I. Okae

Minor change version

VII. SUPER DOUBLE BOOM

(A) NEW PRODUCT FEATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-3

(A) NEW PRODUCT FEATURE

1. KX080-3’s engine has been changed to clear the

12) Guttering : New design

11) Rear view mirror

1) New engine type

2) New place for SP pipe

3) New material of bucket link

7) Traction force is increased by 9% 4) New position for bucket

SP: Service Port

The engine’s displacement is cut to clear the emissions control.

(2) One side maintenance

current KX080-3 new KX080-3AB

(1) One side maintenance (Reposition of alternator)

2. New Installation for SP pipe

current KX080-3 new KX080-3AB

3. New material for the bucket link bushing

current KX080-3 4. New Installation of bucket pin grease

5. Longer dozer cylinder cover

6. Engine’s under cover

7. Increase of traction force by 9%

8. New position of water separator

current KX080-3 new KX080-3AB

9. Wider outside mirror

10. Rear view mirror

12. Others -appearance-

d) List of Minor Change Items

No.1 No.1 No.1

No.2, 8 No.9 No.3 No.4

No.2 No.10 No.12

No.13 No.15 No.18

No.24 No.26 No.26

(B) MACHINE MAINTENANCE

check Daily check

2 Fuel check Daily check

check Daily check

check Daily check

6 Radiator and oil cooler check Daily check

7 Washer liquid check Daily check

8 Engine and electrical wiring check Daily check every years

9 Fuel tank, Water separator drain every 50 hrs

10 Battery condition check every 50 hrs

check Daily check

* 500 thru 1000 continued to the following table.

Hour meter indicator

check Daily check

2 Fuel check Daily check

check Daily check

check Daily check

6 Radiator and oil cooler check Daily check

7 Washer liquid check Daily check

8 Engine and electrical wiring check Daily check every years

9 Fuel tank, Water separator drain every 50 hrs

10 Battery condition check every 50 hrs

check Daily check

b) Maintenance Interval Chart: KTA-version

Check Daily check

2 Fuel Check Daily check

Check Daily check