Table Of Contents - Kubota KX080-3 Workshop Manual

Table of Contents

Table Of Contents3
General Information5
Body And Engine Identification Marks7
Safety Precautions For Servicing, Disassembly And Reassembly8
Preparation For Disassembly9
Precautions For Disassembly And Reassembly9
Important Safety Process And Critical Functional Process10
Important Inspection Items After Reassembling10
Essential Adhesives10
Servicing Fundamentals11
Items For Servicing11
O-Ring, Oil Seal, Circlip And Roll Pin13
Piping15
Hydraulic Hose15
Precautions In Tightening The Bolts And Nuts15
Hose Screw16
Metric Size Hose16
Joint Bodies16
Hose Clamp (Screw-In Type) Tightening Torque Chart17
Nuts For Piping17
Tightening Torque Of Bolts And Nuts18
Types And Materials Of Bolts And Nuts18
Washer-Equipped Elbow - Tightening Torque19
Face Sealing (Ors) Type20
Connecting The Face Sealing (Ors) Type Hose20
Hose Tightening Torque Chart21
Maintenance Intervals22
Maintenance Intervals Chart : Eu-Version22
Water And Oil Quantity25
Inspection Of Hydraulic Oil25
Recommended Oil26
Periodic Replacement Of Important Parts27
Check The Fuel And Hydraulic Hoses Too At The Following Periodic Inspections27
List Of Important Parts27
Machine Body29
Mechanism Section29
New Product Feature31
Feature, Quick Chart31
Feature Points32
Performance32
Kubota Original Engine32
Working Range And Stability32
Digging Force33
Lifting Capacity33
Load Sensing System34
Auto Idling System34
Saving Cost For Fuel34
Max. Hydraulic Flow Adjustor Auxiliary Circuit (Sp1)35
Functional Image Chart35
Durability And Service Ability36
Rubber Crawler36
Fuel Refilling Pump36
Triple Opening Bonnet37
Safety37
Rops/Fops Cabin37
Anti-Fall Valve (Holding Valve)38
Anti-Theft System38
Maintenence Components Layout39
Rubber Track Vs Iron Track41
Greasing Intervals42
Fyi (For Your Information)44
High-Strength Brass Castings (Jis H5102-1979)44
Machine Body - Service Section45
Specifications47
Machine Weight47
Major Specifications48
Lever Stroke And Operating Force49
Dimensions Of Parts50
Front Pins Dimensions50
Bucket Dimensions51
Bucket Installation Relevant Dimensions52
Rubber Crawler Dimensions53
Steel Crawler Dimensions53
Track Roller, Idler, Sprocket Dimensions54
Blade Dimensions55
Parts Weight56
Quality Specification58
Removing And Reassembling66
Front Attachment Removing66
Grease Nipple Set Up69
Grease Nipple Setup Direction69
Greasing Quantity69
Pin And Bushing Installation71
Fitting The Bushings71
Dust Seal Fitting Direction71
Bushing Setup Direction71
Shim Installation73
Clearance At The Front73
Vertical Clearance Between Swivel Frame And Swing Bracket73
Fitting The Thrust Collars73
Fitting The Control Lever75
Fitting The Grommets76
Travel Levers77
Adjusting The Lever Neutral Position77
Adjusting The Travel Levers77
Tightening Torque For The Pilot Valve77
Dozer Lever78
Adjusting The Dozer Lever Neutral Position78
Checking The Setup Condition78
Tightening Torque Of Bracket (Dozer Pilot Valve)78
Cab79
Anti-Vibration Rubber (Cab)79
Bonnet80
Sound Absorber And Insulator85
Counterweigt92
Attaching The Weight92
Fitting The Stay (Hook Lock), Cover (Weight) And Bracket (Left Cover)92
Attaching The Additional Weight93
Clearance Of Cover94
Level Difference Between Corners94
Dimensional Difference At Clearances94
List Of Labels95
M.labels95
Swivel Bearing105
Fitting The Bearing (Swivel)105
Greasing The Tooth Surface105
Swivel Bearing Mounting Bolt105
Undercarriage106
Upper Roller106
Track Roller107
Front Idler108
Track Adjustment109
Fitting To The Track Frame109
Spring Preset Length109
Adjusting The Crawler Tension109
Swivel Frame And Track Frame110
Engine - Mechanism Section111
Engine Specifications113
Engine Electric Components114
Performance Curve115
Different Installation From V3800 Basic Model117
Starter Moter117
Oil Filter117
Engine - Service Section119
Troubleshooting121
Servicing Specifications122
Disassemble And Reassemble123
Pump Coupling123
When Reassembling124
Radiator Overall View125
B.radiator125
Air Cleaner - Overall View, Engine Room128
Air Cleaner Assy View128
Inlet Hoses View128
Double Elements View128
C.air Cleaner128
Laying The Hose (1, Inlet)129
Muffler Overall View130
D.muffler130
Tightening The Flange (Muffler) Clamp131
Ensuring The Clearance At The Pipe (Muffler) Outlet131
Fuel Tank132
Fitting The Sensor Assembly (Fuel) (Rd809-5114)132
Fitting Direction Of The Gauge (Fuel) (Rd809-5112)132
Fitting The Cock (Drain) (Rd809-5125)132
Fitting The Washer-Fitted Elbow (68881-6446)133
Adaptor Tightening Torque133
Tightening The Band Assembly (Fuel Tank)133
Fitting The Plate Assembly (Fuel)133
Attaching The Cushions134
Fuel Hose135
Routing Condition135
Installing The Protective Tubes135
Routes Of The Fuel Feed And Return Hoses136
Compressor139
Fitting The Bracket (Compressor) And Bracket (Pulley)139
Fitting The Compressor139
Fitting The Joint (Heat Takeout), Pipe Joint (S, G1/4-G1/4), Elbow Joint (G4-13) And Joint (Water Return) For The Heater Hoses139
Control Cable140
Connecting The Cable (Acceleration)140
Fan Belt141
Fitting The Oil Switch141
Fitting The Plate141
Fan Belt Tension141
Fitting The Sensor (Rpm)142
Fitting The Plate (Bus Bar)142
Fitting The Engine Stop Lever142
J .Engine Stop Lever142
Engine Bracket Overall View143
K.engine Bracket143
Fitting The Engine Bracket144
Fitting The Anti-Vibration Rubber144
L .Engine Assy145
Engine Wsm147
Engine Identification150
Model Name And Engine Serial Number150
Cylinder Number151
General Precautions152
Engine Maintenance Check List153
Lubricating Oil154
Engine Check And Maintenance155
Daily Check Points155
Checking Engine Oil Level155
Checking And Replenish Coolant156
Check Points Of Initial 50 Hours157
Changing Engine Oil157
Replacing Oil Filter Cartridge157
Engine: Fan Belt Tension157
Check Points Of Every 50 Hours158
Checking Fuel Hose And Clamp Bands158
Check Points Of Every 250 Hours159
Fan Belt Tension, Damage And Wear159
Cleaning Air Cleaner Element159
Cleaning Fuel Filter (Element Type Only)160
Checking Radiator Hoses And Clamp Bands160
Checking Battery Electrolyte Level160
Checking Intake Air Line160
Engine: Check Points Of Every 500 Hours161
Change Engine Oil161
Replace Oil Filter Cartridge161
Replacing Fuel Filter Cartridge (Cartridge Type)161
Replacing Fan Belt162
Cleaning Water Jacket And Radiator Interior162
Anti-Freeze163
Check Point Of Every 1000 Hours164
Checking Valve Clearance164
Check Point Of Every 1 Or 2 Months165
Recharging165
Battery Specific Gravity166
Check Points Of Every 1500 Hours167
Nozzle Spraying Condition167
Checking Nozzle Injection Pressure167
Valve Seat Tightness167
Check Points Of Every 3000 Hours168
Checking Turbocharger168
Injection Timing169
Checking Injection Pump170
Check Points Of Every 1 Year171
Engine Oil Change171
Replacing Air Cleaner Element171
Check Points Of Every 2 Years172
Fan Belt Replacement172
Changing Radiator Coolant (L.l.c.)172
Replacing Radiator Hoses And Clamp Bands173
Replacing Fuel Hose And Clamp Bands174
Replacing Intake Air Line174
Replacing Battery174
Special Tools175
Diesel Engine Compression Tester175
Oil Pressure Tester175
Injection Pump Pressure Tester176
Small End Bushing Replacing Tool177
Idle Gear Bushing Replacing Tool177
Gear Case Oil Seal Replacing Tool178
Valve Guide Replacing Tool178
Auxiliary Socket For Fixing Crankshaft Sleeve179
Balancer Bushing Replacing Tool 1 Assembly179
Balancer Bushing Replacing Tool 1 Components Parts180
Balancer Bushing Replacing Tool 2181
Balancer Replacing Tools 3, 4, 5182
Balancer Replacing Tool Components Parts182
Injection Pump Gear Puller185
Engine Stand186
Flywheel Stopper (For Sae Flywheel And Housing)186
Tool For Aligning The Crankcase 1 And 2186
Nozzle Adaptor For Measuring Cylinder Compression Pressure187
Jig For Governor Connecting Rod188
Engine: Mechanism189
Engine: Feature191
Engine Body192
Cylinder Block192
Half-Floating Head Cover192
Cylinder Head193
Center Direct Injection System (E-Cdis)193
Piston194
Built-In Dynamic Balancer (Balancer Model Only)194
Lubrication System195
Oil Cooler195
Cooling System196
Thermostat196
Bottom Bypass System197
Fuel System198
Governor198
2 Stage Di Nozzle201
Injection Pump With F.s.p.202
Turbocharger System203
Boost Compensator203
Intake System204
Intake Air Filter204
Service205
Engine Troubleshooting207
Engine Does Not Start207
Starter Does Not Run207
Engine Revolution Is Not Smooth208
Either White Or Blue Exhaust Gas Is Observed208
Oil Leak Into Exhaust Pipe Or Suction Pipe208
Either Black Or Dark Gray Exhaust Gas Is Observed208
Deficient Output209
Excessive Lubricant Oil Consumption209
Fuel Mixed Into Lubricant Oil209
Low Oil Pressure209
High Oil Pressure210
Engine Overheated210
Battery Quickly Discharged210
Engine: Servicing Specifications211
Engine Body Servicing Specifications211
Lubricating System Servicing Specifications216
Cooling System Servicing Specifications216
Fuel System Servicing Specifications217
Electrical System Servicing Specifications217
Engine: Tightening Torques218
Tightening Torques For General Use Screws, Bolts And Nuts218
Tightening Torques For Special Use Screws, Bolts And Nuts219
Engine: Checking, Disassembling And Servicing221
Checking And Adjusting Engine Body221
Compression Pressure221
Check Of Valve Clearance222
Checking And Adjusting Lubricating System223
Engine Oil Pressure Check223
Checking And Adjusting Cooling System223
Fan Belt Tension Check223
Fan Belt Damage And Wear224
Radiator Cap Air Leakage224
Radiator Water Leakage224
Thermostat Valve Opening Temperature225
Checking And Adjusting The Fuel System226
Injection Timing Check226
Fuel Tightness Of Pump Element227
Fuel Tightness Of Delivery Valve227
Nozzle Spraying Condition Check228
Check Nozzle Injection Pressure228
Valve Seat Tightness Check228
Checking And Adjusting Electrical System229
Battery Specific Gravity Check230
Motor Test231
Magnetic Switch Test231
Magnet Switch Continuity Test231
Alternator On Unit Test232
Intake Air Heater232
Engine Stop Solenoid232
Checking And Adjusting The Tubrocharger233
Turbine Side Check233
Compressor Side Check233
Radial Clearance233
Engine Disassembling And Assembling234
Draining Oil And Coolant234
External Components234
Air Cleaner, Muffler And Others234
Oil Pipe235
Turbocharger235
Cylinder Head And Valves236
Cylinder Head Cover And Nozzle Holder236
Rocker Arm And Push Rod237
Injection Nozzle Oil Seal (If Necessary)237
Cylinder Head And Tappet238
Selecting Cylinder Head Gasket239
Replacing The Cylinder Head Gasket239
Valve239
Thermostat Assembly240
Removing The Fuel Injection Pump Unit241
Reassembling The Fuel Injection Pump Unit242
Governor Housing Assembly243
Governor Fork Lever Assembly244
Governor Lever245
Stop Lever245
Fuel Camshaft And Governor Weight246
Replacing Injection Pump Assembly248
Installing Procedure Of Injection Pump Assembly249
Fan Drive Pulley250
Water Pump251
Oil Cooler Removal251
Gear Case Cover252
Relief Valve252
Idle Gear And Camshaft252
Idle Gear 1 And Idle Gear 2 (For Balancer Model)253
Camshaft And Balancer Shaft (For Balancer Model)253
Plate (Gear Case)254
Piston And Connecting Rod254
Oil Pan And Oil Strainer254
Connecting Rod Cap255
Piston Removal255
Piston Ring And Connecting Rod256
Flywheel257
Bearing Case Cover257
Flywheel Housing258
Crankcase 2258
Crankcase 1 And Crankcase 2259
Crankshaft260
Intake Air Heater Disassembly261
Disassembling Motor261
Alternator261
Front Bracket261
Starter261
Pulley262
Rotor262
Brush262
Reassembling The Brush263
Bearing At Slip Ring Side263
Cylinder Head Servicing264
Top Clearance264
Cylinder Head Surface Flatness264
Cylinder Head Flaw265
Valve Recessing265
Valve Lapping265
Clearance Between Valve Stem And Valve Guide266
Replacing Valve Guide266
Correcting Valve And Valve Seat267
Free Length And Tilt Of Valve Spring268
Valve Spring Setting Load268
Oil Clearance Between Rocker Arm Shaft And Bearing268
Push Rod Alignment269
Oil Clearance Between Tappet And Tappet Guide Bore269
Timing Gears Servicing270
Timing Gear Backlash270
Idle Gear Side Clearance270
Camshaft Side Clearance271
Camshaft Alignment271
Cam Height271
Oil Clearance Of Camshaft Journal272
Oil Clearance Between Idle Gear Shaft 1, 2 And Idle Gear 1, 2272
Bushing272
Replacing Idle Gear Bushing272
Piston And Connecting Rod Servicing273
Balancer Shaft Side Clearance273
Balance Shaft Alignment273
Oil Clearance Of Balancer Shaft Journal273
Oil Clearance Between Piston Pin And Small End Bushing274
Replacing Small End Bushing274
Connecting Rod Alignment275
Piston Ring Gap275
Clearance Between Piston Ring And Groove275
Crankshaft Servicing276
Crankshaft Side Clearance276
Oversize Dimensions Of Crankshaft Journal276
Crankshaft Alignment276
Oil Clearance Between Crankpin And Crankpin Bearing277
Undersize Dimensions Of Crankpin278
Oil Clearance Between Crankshaft Journal And Crankshaft Bearing279
Undersize Dimensions Of Crankshaft Journal279
Replacing Crankshaft Sleeve279
Cylinder Servicing280
Oil Pump Servicing280
Cylinder Wear280
Correcting Cylinder (Oversize)280
Starter Servicing281
Clearance Between Outer Rotor And Pump Body281
Clearance Between Rotor And Cover281
Overrunning Clutch281
Commutator And Mica282
Brush Wear282
Brush Holder282
Alternator Servicing283
Armature Coil283
Field Coil283
Rotor Check284
Slip Ring284
Brush Wear Check284
Hydraulic System - Mechanism Section285
Features Of The Hydraulic System287
General287
Main Specifications Of Hydraulic Components288
Hydraulic Components Layout291
Hydraulic Circuit Diagram292
Pilot Pump Circuit293
Hydraulic Circuit Diagram (2)294
Hydraulic Pump Main Specifications295
Hydraulic Pump Outer View297
Hydraulic Pump Outer Structure - Diagrams298
Hydraulic Pump Functional Parts299
Functional Parts 1299
Functional Parts 2300
Pump Control Circuit301
Ls Control 1302
Ls Control 2303
Ls Control 3304
Horse Power Control Diagrams305
Ls Pump Swash Plate Control Mechanism Kx080-3308
Horse Power Control Mechanism309
Control Valve310
Hydraulic Circuit310
Feature310
Outline310
Flow Rate311
Overall View Of Control Valve313
Control Valve Specifications314
Tightening Torque For Aluminum Cap/Port Joint (Pipe)314
Pressure Receiving Characteristic Of Main Spoo314
Pressure Receiving Characteristic Of Travel Independent And Other Valves314
Swing Section Diagrams315
Control Valve: Uni-Block Section Assy Diagrams316
Boom Diagram318
S/P1 Diagram319
Bucket Diagram319
Arm Diagram320
Travel Independent Valve Diagram321
Travel, R Section Diagram322
Travel, L Section Diagram323
Combined Valve Diagram324
S/P2 Valve Diagram325
Dozer Section Diagram326
Swivel Section Diagram327
Outlet Section, P3 Bypass Valve328
Layout, Delivery Circuit And External Pipe Flow329
Inlet Section Of Mono-Block Valve Diagram330
Center Closed Valve Section (Bucket, S/P 1, Boom) Diagram331
Center Closed Valve Section (Arm) Diagram332
Arm Regenerative Flow Diagram333
Swing Section (Center Closed Valve) Diagram334
P1 And P2 Inlets And Travel Selector Valve Diagram335
Travel Section (Center Open Type) Diagram335
P3 Inlet And P3 Confluence Section Diagram336
Sp2 Section (Mechanical Flow Adjustment) Diagram337
Swivel Section337
P3 Bypass Confluence Valve Diagram338
Ls Bleed Diagram339
Control Valve Circuit340
Control Valve Hydraulic Circuit Diagram340
Control Valve Hydraulic Circuit In Traveling341
Control Valve Hydraulic Circuit Under Ls System Control Without Traveling342
Control Valve P3 Hydraulic Circuit343
Control Valve P3 Confluence Hydraulic Circuit344
Control Valve P3 Bypass Circuit345
Control Valve High-Pressure Selection Function346
Control Valve Ai Signal Hydraulic Circuit347
Ls Load S Maximum Pressure Detection Method348
Sp2 Flow Control: Mechanical Oil Flow Adjustment349
S/P2 Flow Control Mechanism349
Travel Pilot Valve (With Damper) Outline And Specifications350
Travel Pilot Valve (With Damper) Structure - Diagrams351
Travel Pilot Valve (With Damper) Function353
Reducing Valve Section When The Pilot Valve Operating Section Is At The Neutral Position353
Reducing Valve Section When The Pilot Valve Operating Section Is Tilted From The Neutral Position353
Operation Section Damping Mechanism354
Shuttle Valve Section354
Operation When The Lever Is Tilted From The Neutral Position355
Lever Stroke State And The Operation When The Lever Is Tilted In Reverse Direction356
Swivel Motor General Information358
Swivel Motor Outer View358
Swivel Motor Structure - Diagrams359
Structure Of Reduction Gear Case360
Structure Of Brake Valve361
Function Of Swivel Motor362
Hydraulic Motor362
Relief Valve Functions362
Negative Brake Release363
Negative Brake Function364
Planetary Reduction Ratio364
Parking Brake And Hydraulic Timer365
Parking Brake (If Equipped With Parking Brake)365
Hydraulic Timer365
Anti Swivel Back Valve Ouline367
Anti Swivel Back Valve Structure367
Anti Swivel Back Valve Function369
Swivel Motor, Swivel Back Prevention Mechanism372
High-Pressure Selector Valve (For Swivel Brake Release Signal) Outline373
Release Function Of Negative Valve374
Travel Motor (Gm Motor)375
Travel Motor Specifications375
Motor Type375
Outer View376
Basic Structure Of Gm Motor377
Sectional View Of Gm Motor378
Gm Motor Parts List380
Gm Motor Function381
Reduction Gears381
First Reduction Section381
Second Reduction Section381
Entire Reduction Gears382
Hydraulic Drive383
Brake Valve, Relief Valve383
Two-Speed Select Mechanism383
Parking Brake383
Brake Valve384
Steady Running384
Stopping (Braking)385
Runaway Prevention Function385
Relief Mechanism Behavior386
Relief Mechanism Behavior - Stopping388
Two-Speed Select Mechanism (Manual Two-Speed Selection)390
Low-Speed Stage390
High-Speed Stage391
Parking Brake - Running392
Parking Brake - Braking392
Shockless Valve Of Boom Cylinder Pilot Line - Structure393
Shockless Valve Of Boom Cylinder Pilot Line - Function394
Port 1 To Port A: Free Flow395
Port A To Port 1: Flow Control Released395
Boom Cylinder Holding Valve Outline396
Boom Cylinder Holding Valve Specifications396
Boom Cylinder Holding Valve Circuit Diagram396
Holding Valve Installation397
Main Parts Function398
Holding Valve (Manual Open Type)398
Circuit Function - Neutral Position399
Curcuit Function - With Oil Flowing From A-Port To B-Port (From Main Control Valve To Cylinder)400
Curcuit Function - With Oil Flowing B-Port To A-Port (From Cylinder Bottom Side To Main Control Valve)401
Over-Pressure In The Cylinder (Relief Valve Activated)403
Manual Release Of Cylinder Bottom Oil404
Solenoid Valve405
Solenoid Proportional Control Valve405
Hydraulic System - Service Section409
Hydraulic System Troubleshooting411
Case Study: Abnormal Speed411
Case Study: The Power Is Weak413
Case Study: Poor Manipulation And Abnormal Operation414
Ls Control System Troubleshooting417
Procedures For Hydraulic Pilot System Troubleshooting417
Procedures For Ls Control Valve Troubleshooting418
Compensation Spool419
Procedures For Ls Control Pump Troubleshooting420
Fundamentals Of Ls Pump Troubleshooting (Defective Portions And Symptoms)421
Pump Component Trouble Causes And Remedy422
Control Valve Component Troubleshooting424
Control Valve In General Troubleshooting424
Relief Valve, Unload Valve And High Pressure Selector Valve Troubleshooting425
General Hydraulic System Troubleshooting425
Travel Motor Component Troubleshooting426
Counterbalance Valve Function Troubleshooting427
Hi-Low Speed Function Specifications428
Hydraulic System Specifications429
Specifications Of Pump429
Relief Valve Pressure Setting Specifications430
Main Relief Valve Specifications (Bench Data)430
Main Relief Valve Specifications (At The Measurement Port On The Machine)430
Overload Relief Valve Specifications (Bench Data)431
Overload Relief Valve (At The Measurement Port On The Machine)432
Pilot System Pressure433
Swivel Performance434
Traveling Performance435
Cylinder Speed437
Natural Fall437
Cylinder Specifications438
Cylinder Dimensions439
Boom Cylinder Tightening Torques441
Arm Cylinder Tightening Torques441
Bucket Cylinder Tightening Torques441
Swing Cylinder Tightening Torques442
Blade Cylinder Tightening Torques442
Hydraulic System Testing443
Testing Instruments & Special Tools443
Gauges And Special Tools For Pressure Testing443
Flow Meter And Special Tools For Flow Testing444
Precautions In Handling The Pump445
Points To Remember When Replacing The Pump Or Using A Vacuum Pump445
Air Bleeding Method In Case The Hydraulic Oil In The Tank Looks Cloudy With Air Bubbled446
Pilot Pressure447
Primary Pressure447
Secondary Pressure448
Main Relief Valve: Ls System449
Adjustment Of The Relief Valve449
Main Relief Valve: Travel System450
Unload Valve Measurement Method451
Unload Valve Adjustment451
Overload Relief Valve Measurement Method452
Overload Relief Valve Adjustment452
Location Of The Relief Valve453
Swivel Brake Valve Pressure454
Measuring The Main Pump Max. Flow Rate456
Measuring the Main Pump's Stand-By Flow Rate458
Ls Control Pressure459
Traveling Motor Drain Amount460
Swivel Motor Drain Amount461
Swivel Motor Block Performance462
Traveling Motor Block Performance463
Checking Each Operating Speed464
Boom Cylinder Speed464
Arm Cylinder Speed464
Bucket Cylinder Speed465
Swing Cylinder Speed465
Dozer Cylinder Speed465
Swivel Speed466
Traveling Speed466
Straight Travel Performance466
Coupling Flange Disassembling And Reassembling467
Pump Disassembling And Reassembling468
Pump Assy Dismount468
Adaptor And Joint Disassembling And Reassembling470
Disassembly And Reassembly472
Remove Gear Pump474
Remove Ls Control Valve475
Remove Horsepower Control Valve476
Remove The Valve Block Assy478
Remove The Cylinder Block Assy480
Inner Parts Of The Cylinder Block View481
Remove The Main Shaft482
Reassembling484
Gear Pump Disassembling And Reassembling485
Control Valve Disassembling And Reassembling490
Adaptor And Joint490
Fitting The Valve Assembly492
Valve Assy Disassembly495
Inlet Section (P1, P2) (Travel Independent Valve)501
Travel R Section502
Travel L Section503
P3 Inlet Section504
Sp2 Valve Section506
Dozer Section507
Swivel Section View508
P3 Confluence Valve509
Mono-Block Valve Assy510
Swing Valve Section512
End Plate513
Pilot Valve514
Dozer Pilot Valve515
Swing Pilot Valve516
Pilot Valve Disassemble (Dozer, Swing)518
Travel Pilot Valve519
Gm Motor: Troubleshooting And Corrective Measures520
Pilot Pressure: Disassembling Procedures521
Remove The Plugwith The Grease Cup (203),Nhu Packing (210) And O-Ring (212) Attached524
Gm Motor: Cleaning The Parts529
Gm Motor: Assembling Instructions530
Swivel Motor541
Travel Motor (Wheel Motor)542
Travel Motor Servicing (Gm090N, Nabtesco Make)544
Travel Motor Handling Precautions544
Travel Motor Positioning544
Travel Motor Piping544
Selecting The Right Hydraulic Oil545
Gm Motor Maintenance And Inspection546
Changing The Hydraulic Oil546
Changing The Lube Oil546
Gear Oil Changing Procedure546
Mobilube546
Gm Motor Troubleshooting548
Hydraulic System Service Outline549
Standard Tools549
Xd-3549
Equipment And Materials550
Measuring Devices550
Manufacturing Tools551
Work Stand551
Fixture551
Retainers551
Bearing Pre-Load Adjuster552
Steel Rod552
Aluminum Rod553
Pf Eye Bolt553
Long Eye Bolt553
Flat Barand Steel Pipe553
F/S Installation Tools554
Gm Motor Tightening Torques555
Gm Motor Weight Table555
Gm Motor Disassembly556
General Suggestions When Working556
Gm Motor Disassembly Procedure557
Lubricating Oil Drain558
Cover Removal558
Disassembly Of Hydraulic Motor Parts567
Removal Of Spring Inside Cylinder Block569
Shaft Removal569
Removal Of Ball Bearing570
Removal Of Hold Flange571
Fixture Removal572
Spindle Removal572
Removal Of Ball Bearing, Rv Gear Assembly And Pin573
Ball Bearing Removal573
Removal Of Spindle Mounted Parts574
Disassembly Of Hold Flange Mounted Parts574
Rough Washing Of Various Parts575
Finish Washing575
Gm Motor Service Preparations577
Gm Motor Assembly578
Hub Section Assembly579
Spindle Section Assembly580
Mount The Rv Gear Assembly581
Hold Flange Mounting582
Reamer Bolt Fastening583
Fitting The Snap Ring583
Spur Gear Assembly584
Mounting On The Spindle585
Assembly Of Cylinder Block Interior587
Assembly Of Hydraulic Motor Parts588
Assembly Of Parking Brake Section588
Assembly Of Plugs In The Rear Flange589
Assembly Of Srv In The Rear Flange590
Assembly Of The Rear Flange Mounted Parts591
Connection Of Rear Flange With Spindle592
Assembly Of The Input Gear594
Cover Assembly595
Removal Of Travel Motor596
Pre-Load Adjustment Of Ball Bearing597
Ball Bearing Pre-Load Adjustment Procedure597
Shaft Direction Clearance Adjustment Of The Tapered Roller Bearing599
Gm Motor: Performance Confirmation Test601
Clearance Adjustment Parts - Dimensions Table602
Rotary Joint (Swivel Joint)604
Holding Valve605
Hydraulic Tank607
Filters609
Three Way Change Valve610
Pilot Primary Line And T Port Block611
Swivel Shuttle Valve612
Pilot Hose Relay Plate613
Pilot Hose Relay Adapter614
Unload Valve616
Sp1 And Sp2 Solenoid Valve617
Pilot Pump Relay Block618
Pilot Line Filter619
Cylinders620
Hydraulic Hose - Metallic Sealing Type622
Hydraulic Hose - Quick-Coupling Type622
Hose Route623
Pilot Hose 1623
Pilot Hose 2624
Pilot Hose 3625
Pilot Hose 4626
Pilot Hose 5627
High And Low Pressure Hose 1628
High And Low Pressure Hose 2629
Pump Delivery630
Suction631
Swivel Frame Partition632
Hose Route: Oil Cooler633
Front Hoses And Pipes634
List Of Pilot Hoses (Upper Structure) (Swivel Frame, C/V Side)637
List Of Pilot Hoses (Drain) (Upper Structure) (Hydraulic System)638
List Of Pilot Hoses (Upper Structure) (Platform, Control System)639
List Of Pilot Hoses (Drain) (Upper Structure) (Platform, Control System)639
List Of High-Pressure Hoses (Upper Structure) (Swivel Frame, C/V Side)640
List Of Low-Pressure Hoses (Upper Structure)641
Electrical System - Mechanism Section643
Electrical System Feature And Main Function645
Features Of Kx080-3 System645
Electrical System: Functional Comparison646
Service Port Speed Limit Control647
Background And Concept Of Rd647
Hand-Control System647
Speed Limit Function New Feature647
How To Operate Service Port 1648
Action Mode Of First Service Port Operation649
Setting Of Limited Flow Volume650
One Way Flow Operation652
Second Service Port Operation653
Instrument Panel, Switch View654
Theoretical Approach To Recognize The Principle Of Speed Limit Control655
Fuel Supply Pump656
Fuel Supply Pump: How To Use657
Electrical System Function - Circuit Diagram659
When The Start Switch Is Pushed660
When Fuel Level Sensor Detects The Full Amount Of Fuel661
When Pushing The Stop Switch During Supplying The Fuel662
When Pushing The Start Switch After The Full Fuel Level663
Intake Air Heater Control View664
Outline Of Control System665
Control Points665
Air Intake Heater Diagram666
Air Intake Heater Relay (Code: No. N300-75211) Diagrams667
Electrical Components And Circuit Diagram669
Components Layout669
Electrical System: Main Components Diagram671
Electrical Circuit Diagram672
Service Mode Flow Chart673
Electrical Wiring Diagram674
Electrical System - Service Section675
Electrical System Troubleshooting677
Four Basic Checking Items For Electrical Diagnosis677
Electrical System: Troubleshooting Flow Chart678
Starter Motor Failure To Turn On678
Auto Release Malfunction679
Ai System Failure680
Wire Harness Installation - Precautions681
Wire Harness Installation - Engine Earth, Starter Switch682
Checking Cables, Wires And Battery683
Handling On-Vehicle Battery683
Wire Harness Route Diagrams684
Wire Harness Installation: Installation Of Main Parts, Couplers And Harnesses690
Around the Operator's Seat690
Front692
Work Lamp Harness View693
Fuel Tank View694
Starter, Alternator, Battery696
Fuses697
Fuse Capacities And Circuits Table697
Slow Blow Fuse697
Solenoid Valve Wiring698
Air Conditioner Wiring699
Cab Wire Harness700
Couplers Of Cab Harness700
Wire Harness For Woper Motor700
Wire Harness For Speaker And Antenna701
Wire Harness For Room Lamp701
Auxiliary Harness Outlet701
Circuit Diagram Of Cab Harness703
Air Conditioner (Mechanism)705
Air Conditioner System707
Principle Of Air Conditioner707
Change Of State Of Refrigerant708
Function And Construction709
Air Conditioner System Flow710
Refrigerant Cycle711
Evaporation711
Compression711
Condensation, Expansion711
Air Conditioner System Components: Kx080-3712
Air Conditioner Control Panel713
Air Conditioner Unit Exploded View713
Air Conditioning System Main Components714
Outline Of Sliding-Vane Type Compressor (Sv07 Type)714
Sliding-Vane Type Compressor Diagram715
Sliding-Vane Type Compressor Operation716
High Pressure Relief Valve717
Magnetic Clutch718
Condenser719
Receiver720
Dual Pressure Switch721
Air Conditioner Unit722
Box Type Expansion Valve722
Evaporator723
Heater Core723
Water Valve724
A/C Blower725
A/C Blower Resistor726
Relays727
Frost Control728
Kx080-3729
Frost Control: Electric Circuit Diagram730
Kx121-3, 161-3 Diagram730
Kx080-3 Diagram731
Air Conditioner (Service)733
Air Conditioning System Servicing Specifications735
Air Conditioning System Performance Specifications737
Ambient Temperature Vs Normal High-Low Pressure Range738
Air Conditioner Tightening Torques739
Air Conditioning System Regular Check And Service Points740
Air Conditioner Maintenance Intervals740
Air Conditioning System Troubleshooting741
Troubleshooting From Problem Symptoms (Except Refrigeration Cycle Troubles)742
Connecting The Pipes742
Replacing The O-Rings742
Charging Compressor Oil In Replacing The Functional Parts742
Checking The Refrigeration Cycle743
Checking The Refrigerant Amount743
Using A Gauge Manifold745
Normal Condition745
Refrigerant Shortage746
Too Much Refrigerant And Poor Condenser Cooling746
Water Mixed In The Circuit747
Poor Compressor Performance747
No Refrigerant Circulation (Clogged Circuit)748
Air Mixed In The Circuit748
Checking For Gas Leak749
Too Open Expansion Valve749
Gas Leak Checking Procedure In The Engine Room750
Gas Leak Checking Procedure In The Cabin (Cooler Unit)751
Efficient Use Of A Fluorescent Gas Leak Detector751
Precautions For Training (Charging Refrigerant)752
Precautions For Checking And Charging Air Conditioner Refrigerant Gas752
Training 1: Setting The Gauge Manifold753
Check Performance Of Air Conditioning System754
Conversion Table755