Page 1 WORKSHOP MANUAL K U B O T A E X C A V A T O R KX018-4 KiSC issued 06, 2012 A...
Page 2: Table Of Contents
CONTENTS TO THE READER 7. PILOT VALVE .......... 3-S61 TO THE READER 8. UNLOAD VALVE ........3-S66 9. PRESSURE SENSOR ......3-S67 I INFORMATION 10. ROUTING OF HYDRAULIC HOSES ..3-S68 CONTENTS 11. MEASURING THE PERFORMANCE INFORMATION OF HYDRAULIC DEVICES ..... 3-S89 1.
Page 3 • Refer to the information of the engine below. • Engine model : D782-E3B, D902-E3B • Web PDF-Code : No.9Y111-00133 • Hard Copy-Code : No.9Y121-00133 • CD-ROM-Code : No.9Y131-00133 June, 2012 © KUBOTA Corporation 2012 KiSC issued 06, 2012 A...
Page 4 INFORMATION KiSC issued 06, 2012 A...
Page 5 INFORMATION CONTENTS 1. SAFETY FIRST ..........................I-1 2. IN THE INTEREST OF WORK SAFETY ..................I-2 [1] WORKING SAFELY WITH THE EQUIPMENT MEANS ALWAYS FOLLOWING THESE INSTRUCTIONS:......................I-2 (1) Precautions Before Working on the Mini-excavator ............I-2 (2) Precautions Before Working on the Equipment..............I-3 3.
Page 6: Safety First
INFORMATION KX018-4, WSM 1. SAFETY FIRST SAFETY FIRST • This "Safety Alert Symbol" is used in this manual and on labels on equipment to indicate important issues and warn of the danger of personal injury. Read and follow these warnings carefully.
Page 7: In The Interest Of Work Safety
INFORMATION KX018-4, WSM 2. IN THE INTEREST OF WORK SAFETY [1] WORKING SAFELY WITH THE EQUIPMENT MEANS ALWAYS FOLLOWING THESE INSTRUCTIONS: (1) Precautions Before Working on the Mini-excavator Before starting any service or maintenance work, • Read all the general and safety instructions in this manual, as well as the decals on your equipment.
Page 8: Precautions Before Working On The Equipment
INFORMATION KX018-4, WSM (2) Precautions Before Working on the Equipment • Stop the machine on a hard and level location and make sure the area around the machine is free of obstacles and hazardous materials. When parking the machine indoors, select a spot that can be properly ventilated.
Page 9 INFORMATION KX018-4, WSM • The engine, muffler, radiator, hydraulic line, etc., have parts that remain very hot even after the engine has been stopped. Be sure to avoid these parts, as touching them can result in burns. Radiator coolant, hydraulic fluid and oil also remain hot. Therefore, do not attempt to remove caps and plugs, etc., before...
Page 10 INFORMATION KX018-4, WSM • Grease is under high pressure inside the hydraulic cylinder. It is very dangerous to loosen a grease nipple quickly as it may shoot off. Always loosen grease nipples slowly. • And never face a grease nipple while loosening it.
Page 11: Labels Displayed To Promote Work Safety
INFORMATION KX018-4, WSM 3. LABELS DISPLAYED TO PROMOTE WORK SAFETY [1] LOCATIONS RY9212190INI0002US0 KiSC issued 06, 2012 A...
Page 12 INFORMATION KX018-4, WSM RY9212190INI0003US0 KiSC issued 06, 2012 A...
Page 13 INFORMATION KX018-4, WSM RY9212190INI0004US0 KiSC issued 06, 2012 A...
Page 14 INFORMATION KX018-4, WSM RY9212190INI0005US0 KiSC issued 06, 2012 A...
Page 15 INFORMATION KX018-4, WSM RY9212190INI0006US0 I-10 KiSC issued 06, 2012 A...
Page 16: Label Maintenance
INFORMATION KX018-4, WSM RY9212190INI0007US0 [2] LABEL MAINTENANCE Thoroughly Read, Understand and Follow Safety Precautions on Labels • Always keep labels in a clean, undamaged state. • If labels get dirty, wipe them off with soapy water and a soft cloth.
Page 17: Main Specifications
INFORMATION KX018-4, WSM 4. MAIN SPECIFICATIONS KUBOTA EXCAVATOR Model name KX018-4 Type Canopy Cabin 1620 kg 1720 kg Machine weight 3571 lbs 3792 lbs 1695 kg 1795 kg Operating weight 3737 lbs 3957 lbs Volume (CECE) 0.040 m (0.24 cu.in.)
Page 18: Dimensions
INFORMATION KX018-4, WSM 5. DIMENSIONS 450 mm 510 mm 1300 mm 990 mm 1070 mm 990 mm 3450 mm 2480 mm KX018-4 17.7 in. 20.1 in. 51.2 in. 39.0 in. 42.1 in. 39.0 in. 135.8 in. 97.6 in. 2380 mm...
Page 19 GENERAL KiSC issued 06, 2012 A...
Page 20 6. OIL AND WATER CAPACITY TABLE ..................G-14 7. MAINTENANCE INTERVALS..................... G-15 [1] OPERATOR SERVICING..................... G-15 [2] SERVICING BY SKILLED PERSONAL OR KUBOTA DEALER .......... G-16 (1) For NA ..........................G-16 (2) For AU ..........................G-17 8. DESCRIPTION OF PARTS ......................G-18 [1] BUCKET ..........................
Page 21: General
GENERAL KX018-4, WSM 1. MACHINE INDENTIFICATION When consulting about this mini-excavator, please provide the model of the mini-excavator, its frame and engine numbers and the number of hours on the hour meter. (1) Mini-excavator Nameplate (Model, Model Nameplate frame number, engine number)
Page 22: Engine Indentification
GENERAL KX018-4, WSM 2. ENGINE INDENTIFICATION [1] MODEL AND ENGINE SERIAL NUMBER Be sure to check the engine nameplate and serial number when you wish to consult about the engine. The model and serial number of the engine need to be checked prior to servicing the engine or replacing any of its parts.
Page 23: General Precautions
Whenever a special tool is required, use the special tool that KUBOTA recommends. Make any special tools that are not used very frequently according to the diagrams in this manual. Always use genuine KUBOTA parts to maintain the performance and safety characteristics of the machine.
Page 24 GENERAL KX018-4, WSM Floating Seal • Be sure to wipe off any oil from the O-ring or surfaces that touch the O-ring. (For wheel motors, apply a light film) • When putting an O-ring into a floating seal, make sure the O-ring does not twist.
Page 25 GENERAL KX018-4, WSM Tightening Bolts and Nuts • Tighten bolts and nuts to their specified torque. • Tighten nuts and bolts alternately top/bottom (a) (b), left/right so the torque is distributed evenly. (A) Top/bottom alternately (C) Diagonally across the center...
Page 26 GENERAL KX018-4, WSM Installing and Removing Quick Couplings • To remove a quick hose coupling, push the fitting (2) in the direction of the arrow and pull on the plastic part (1) in the opposite direction. • To attach a quick coupler, push it in firmly in the direction of the arrow.
Page 27: Precautions When Handling Electrical Parts And Wiring
GENERAL KX018-4, WSM 4. PRECAUTIONS WHEN HANDLING ELECTRICAL PARTS AND WIRING Follow the precautions below for handling electrical parts and wiring to ensure safety and prevent damage to the machine and nearby equipment. IMPORTANT • Inspect electrical wiring for damage and/or loose connections.
Page 28 GENERAL KX018-4, WSM • Insert grommet securely. (1) Grommet (A) Correct (B) Incorrect RY9212001GEG0027US0 • Clamp wiring securely but do not damage wires with the clamp. (1) Clamp (Spiral clamp around wire) (3) Clamp (2) Wire (4) Welding Mark RY9212001GEG0028US0 •...
Page 29: Fuses
GENERAL KX018-4, WSM [2] FUSES • Always use fuses of the specified capacity. Never use over or undersized fuses. • Never use copper or steel wire in place of a fuse. • Do not install accessories such as work lights, radios, etc., if your machine does not have an auxiliary circuit.
Page 30: Washing The Mini-Excavator With A High-Pressure Washer
GENERAL KX018-4, WSM • The plastic covers of connectors must cover them completely. (1) Cover (A) Correct (B) Incorrect RY9212001GEG0037US0 [4] WASHING THE MINI-EXCAVATOR WITH A HIGH-PRESSURE WASHER Using a high-pressure washer incorrectly can lead to personal injury and/or damage, break or cause parts of the machine to fail, so use the power washer properly according to its operator's manual and labels.
Page 31: Torque Specification Table
GENERAL KX018-4, WSM 5. TORQUE SPECIFICATION TABLE [1] TORQUES FOR GENERAL USE NUTS AND BOLTS Screws, bolts and nuts whose tightening torques are not specified in this Workshop Manual should be tightened according to the table below. Indication on top of bolt...
Page 32: Torque For Hydraulic Hose Fittings
GENERAL KX018-4, WSM [3] TORQUE FOR HYDRAULIC HOSE FITTINGS (1) Torque for Hydraulic Hose Fittings Hose size Thread size Wrench size Torque 15 to 20 N·m DN 4 - 1 / 8 M12 × 1.5 14 mm 1.5 to 2.0 kgf·m 11.1 to 14.8 lbf·ft...
Page 33: Hose Clamp Screw Torque
GENERAL KX018-4, WSM [4] HOSE CLAMP SCREW TORQUE 2.5 to 3.5 N·m 10- 16 69741-72873 0.3 to 0.4 kgf·m 1.8 to 2.6 lbf·ft 2.5 to 3.5 N·m 13- 20 69481-11163 0.3 to 0.4 kgf·m 1.8 to 2.6 lbf·ft 4.0 to 5.0 N·m...
Page 34: Oil And Water Capacity Table
GENERAL KX018-4, WSM 6. OIL AND WATER CAPACITY TABLE Item Notes Shell Havella T10 W30 D10W30 Engine Oil (When changing filter) 3.6 L (0.95 U.S.gal) Super Canopy 2.7 L (0.71 U.S.gal) Coolant Cabin 2.9 L (0.77 U.S.gal) Anti-freeze Esso G03-11BVLK Reserve Tank 0.56 L (0.15 U.S.gal)
Page 35: Maintenance Intervals
GENERAL KX018-4, WSM 7. MAINTENANCE INTERVALS [1] OPERATOR SERVICING Hour meter indicator Check points Interval 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 1000 1 Coolant check Daily check 2 Fuel check...
Page 36: Servicing By Skilled Personal Or Kubota Dealer
• 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. • 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.
Page 37: For Au
When using a hydraulic breaker over 80 % → every 200 h (Hydraulic oil) / every 100 h (Return filter) • *2 : Replace only if necessary. • *3 : Consult your local KUBOTA Dealer for this service. • *4 : The maintenance identified with "*4" is appeared on the meter panel at each specified maintenance hours.
Page 38: Description Of Parts
GENERAL KX018-4, WSM 8. DESCRIPTION OF PARTS [1] BUCKET 452 mm 74 mm 2.8 mm 15 mm 34 mm (11) (16) (21) 18 in. 2.9 in. 0.1 in. 0.6 in. 1.3 in. 10 mm 182 mm 16.5 mm 30 mm...
Page 39: Bucket Installation Relevant Dimensions
GENERAL KX018-4, WSM [2] BUCKET INSTALLATION RELEVANT DIMENSIONS (A) Arm tip (B) Bucket, link 1 83 mm 759 mm 92 mm 125.5 mm (11) (16) 3.3 in. 29.9 in. 3.6 in. 4.94 in. 1007 mm 183 mm 125.5 mm 45.5 mm...
Page 40: Rubber Crawler
GENERAL KX018-4, WSM [4] RUBBER CRAWLER Identification mark (Core metal lapping position) 23 mm (1) Lug height 0.91 in. 15.5 mm (2) Link height 0.61 in. 230 mm (3) Crawler width 9.06 in. 10 to 15 mm (4) Crawler sag distance 0.39 to 0.59 in.
Page 41: Cylinder
GENERAL KX018-4, WSM [6] CYLINDER Boom Bucket Swing Blade Track 35 mm 30 mm 30 mm 30 mm 30 mm 30 mm 1.4 in. 1.2 in. 1.2 in. 1.2 in. 1.2 in. 1.2 in. 35 mm 30 mm 30 mm...
Page 42: Diagram And List Of Front Pins
GENERAL KX018-4, WSM [7] DIAGRAM AND LIST OF FRONT PINS (To be continued) G-22 KiSC issued 06, 2012 A...
Page 43 GENERAL KX018-4, WSM (Continued) Item 50 × 109 mm Pin Diameter and Length 2.0 × 4.3 in. 30 × 118 mm Pin Diameter and Length 1.2 × 4.6 in. 30 × 86.5 mm Pin Diameter and Length 1.2 × 3.4 in.
Page 44: List Of Front Bushing Dimensions
GENERAL KX018-4, WSM [8] LIST OF FRONT BUSHING DIMENSIONS Material Item Quality I.D. x O.D. x 50 × 60 × 37 mm S43C or S45C Length 2.0 × 2.4 × 1.5 in. I.D. x O.D. x 50 × 60 × 40 mm...
Page 45: Weights Of Parts
GENERAL KX018-4, WSM 9. WEIGHTS OF PARTS 100.5 kg 161 kg Track Frame (Center) Cabin 221.6 lbs 354.9 lbs 69.4 kg 60 kg Track Frame (Left) Canopy 153.0 lbs 132.3 lbs 69.4 kg 14 kg Track Frame (Right) Pump 153.0 lbs 30.9 lbs...
Page 46: Quality Specifications
GENERAL KX018-4, WSM 10. QUALITY SPECIFICATIONS Factory specification The condition of measurement or Item remarks Std. value Tolerance [Principal spec.] JIS, A8404 3725 mm ± 75 mm Transport length 146.7 in. ± 3.0 in. 1000/1300 mm ± 13 mm Overall width 39.4/51.2 in.
Page 47 +30, -40 psi 0.040 m ± 0.002 m CECE, Heapted With bucket recommended by 0.052 yd ± 0.002 yd Bucket KUBOTA with japanese standard capacity 0.040 m ± 0.002 m bucket SAE, Heapted 0.052 yd ± 0.002 yd 450 mm ±...
Page 48 GENERAL KX018-4, WSM Factory specification The condition of measurement or Item remarks Std. value Tolerance 990/1300 mm ± 5 mm Width 39/51.2 in. ± 0.2 in. Blade size 226 mm ± 5 mm Height 8.9 in. ± 0.2 in. Blade...
Page 49 GENERAL KX018-4, WSM Factory specification The condition of measurement or Item remarks Std. value Tolerance 600 mm Low, forward Less than 23.6 in. Travelling 10 m (394 in.) at engine rated speed, oil temperature: 50 ± 5 °C (122 ± 9 °F)
Page 50 GENERAL KX018-4, WSM Factory specification The condition of measurement or Item remarks Std. value Tolerance Bucket wrist angle 184.0 ° ± 3 ° [Swivel, Swing performance] Left 254.9 kgf·m With max. reach at engine rated – 15 % Swivel torque 2.5 kN·m...
Page 51 GENERAL KX018-4, WSM Factory specification The condition of measurement or Item remarks Std. value Tolerance [Control lever load/stroke] 0.98 kgf ± 0.5 kgf Measurement under 20 mm (0.79 in.) Raise 9.6 N ± 4.9 N from the grip tip 2.2 lbf ±...
Page 52 ± 0.4 in. Shorten Right 16 mm ± 10 mm Auxiliary port pedal Measurement at the end of pedal 0.6 in. ± 0.4 in. Left Spec. shows with rubber crawler,std.arm,bucket recommended by KUBOTA RY9212190GEG0007US0 G-32 KiSC issued 06, 2012 A...
Page 53: Machine Body
MACHINE BODY KiSC issued 06, 2012 A...
Page 54: Servicing
SERVICING CONTENTS 1. FRONT EQUIPMENT ........................1-S1 [1] BUCKET INSTALLATION AND REMOVAL ................1-S1 [2] FRONT EQUIPMENT ATTACHMENT AND REMOVAL ............1-S2 [3] BLADE REMOVAL AND MOUNTING ...................1-S3 2. SWIVEL FRAME..........................1-S4 [1] WEIGHT DISASSEMBLY/ASSEMBLY .................1-S4 [2] CANOPY REMOVAL AND MOUNTING................1-S5 [3] FUEL TANK REMOVAL AND MOUNTING ................1-S6 [4] HYDRAULIC OIL TANK ......................1-S9 (1) Hydraulic Oil Tank Components..................1-S9 [5] ENGINE..........................1-S10...
Page 55: Front Equipment
MACHINE BODY KX018-4, WSM 1. FRONT EQUIPMENT [1] BUCKET INSTALLATION AND REMOVAL CAUTION • Wear safety equipment such as a helmet and safety glasses during mounting and removal. • When working with others, pay full attention to safety and make sure communication signals are completely clear to each other.
Page 56: Front Equipment Attachment And Removal
MACHINE BODY KX018-4, WSM [2] FRONT EQUIPMENT ATTACHMENT AND REMOVAL CAUTION • Each of the devices and the hydraulic and lubricating oils are hot and/or under high pressure immediately after operating the mini-excavator. If the hydraulic oil reached a high operating temperature, it may cause a burn.
Page 57: Blade Removal And Mounting
MACHINE BODY KX018-4, WSM [3] BLADE REMOVAL AND MOUNTING Removing the Blade 1. Put the mini-excavator on hard, level ground, swivel the frame to 90 ° and set the bucket and blade on the ground. 2. Set a block under the blade cylinder to support it and remove the bottom pin.
Page 58: Swivel Frame
MACHINE BODY KX018-4, WSM 2. SWIVEL FRAME [1] WEIGHT DISASSEMBLY/ASSEMBLY Removing the Right Engine Cover 1. Remove the four right engine cover mounting bolts, the fuel tank cap and then the right engine cover. (1) Cap ASSY (3) Engine cover...
Page 59: Canopy Removal And Mounting
MACHINE BODY KX018-4, WSM [2] CANOPY REMOVAL AND MOUNTING (1) ROPS Canopy (2) Grommet (3) Grommet (4) Trim (750, T5U) (5) Plug (6) Bolt (M14 x 1.5) (7) Flat Metal Washer (8) Collar (9) Bolt (M14 x 1.5) (10) Flat Metal Washer...
Page 60: Fuel Tank Removal And Mounting
MACHINE BODY KX018-4, WSM [3] FUEL TANK REMOVAL AND MOUNTING Removing the Right Engine Cover 1. Remove the four right engine cover mounting bolts, the fuel tank cap and then the right engine cover. (1) Cap ASSY (3) Engine cover...
Page 61 MACHINE BODY KX018-4, WSM Fuel Hose Routing (a) Water drain cock (c) Water separator (e) Fuel filter Engine (b) Fuel tank (d) Fuel pump Fuel Tube Length Protective Tube Length Fuel Tube Length Protective Tube Length 1500 mm 1450 mm...
Page 62 MACHINE BODY KX018-4, WSM Positions of Fuel Hose Clamps and Guides (a) Pass on the inside of guides (d) Pass through the notch (g) Clamp facing upwards (A) 45 ° and cables (e) Pass on the outside of pipe (h) Clamp facing downwards...
Page 63: Hydraulic Oil Tank
MACHINE BODY KX018-4, WSM [4] HYDRAULIC OIL TANK (1) Hydraulic Oil Tank Components Parts Name Q'ty Assy tank, oil Cover, Tank suction O-ring Bolt, Sems Filter, Suction Cover, Tank return O-ring Bolt, Sems Filter, Return (10) Plug (11) O-ring 2.0*129.5...
Page 64: Engine
MACHINE BODY KX018-4, WSM [5] ENGINE (1) Engine Removal and Mounting CAUTION • Remove the negative terminal of the battery before starting removal/mounting work. • Wear safety equipment such as a helmet and safety glasses during mounting and removal. • When working with others, pay full attention to safety and make sure communication signals are completely clear to each other.
Page 65 MACHINE BODY KX018-4, WSM 7. Remove the seat support mounting bolts, slide the seat support toward the front of the body and remove the cover. (1) Cover RY9212091MBS0039US0 8. Remove the fuel lines. (1) Fuel line RY9212091MBS0040US0 9. Loosen the hose clamp on the air cleaner and remove the intake hose from the intake manifold.
Page 66 MACHINE BODY KX018-4, WSM 13. Remove the pump mounting bolts and separate it from the pump coupling. 77.5 to 90.2 N·m Tightening torque Bolt (1) 7.9 to 9.2 kgf·m 57.2 to 66.5 lbf·ft (1) Bolt RY9212091MBS0044US0 14. Remove the mounting nut of the anti-vibration rubber. (4 places) 15.
Page 67: Engine Mounts
MACHINE BODY KX018-4, WSM (2) Engine Mounts (1) Engine, front bracket (3) Bolt (6) Cushion (8) Nut (2) Engine, rear bracket (4) Fuel tube (7) Spring washer (9) Cover (5) Fuel clamp 39.2 to 45.1 N·m Tightening torque Nut (8) 4.0 to 4.6 kgf·m...
Page 68: Muffler
MACHINE BODY KX018-4, WSM (3) Muffler (1) Muffler gasket (2) Muffler flange (3) Bolt (4) Muffler (5) Muffler flange clamp (6) Bolt (7) Flat metal washer (8) Spring washer (9) Nut (10) Muffler bracket (11) Bolt (12) Nut Muffler ASSY Installation Procedures 1.
Page 69: Arch
MACHINE BODY KX018-4, WSM (4) Arch Arch Assembly (1) Arch frame (2) Bolt (3) Support (4) Bolt (5) Bolt (6) Flat metal washer (7) Trim (8) Rubber seal (9) Grommet 77.5 to 90.2 N·m Tightening torque Bolt (2) 7.9 to 9.2 kgf·m 57.2 to 66.5 lbf·ft...
Page 70: Radiator, Oil Cooler
MACHINE BODY KX018-4, WSM (5) Radiator, Oil Cooler (1) Assy radiator (10) Bolt, w sems (phillips) (18) Hose (wp, drain) A : Cabin version (2) Shroud, fan (11) Cushion, radiator (19) Hose clamp 10 to 16 mm (a) 10 °...
Page 71: Operating Lever Assembly
MACHINE BODY KX018-4, WSM [6] OPERATING LEVER ASSEMBLY (1) Travel Lever Components (1) Grip (5) Travel lever, right 2 (9) Bolt (a) 15 to 25mm (0.59 to 0.98 in.) (2) Travel lever, left (6) Pin, spring (10) Bolt (b) 5 mm (0.2 in.)
Page 72: Blade Lever
MACHINE BODY KX018-4, WSM (2) Blade Lever Components (1) Blade Lever Assembly (2) Grip (3) Pan Head Machine Screw (4) Flat Metal Washer (5) Snap Pin (6) Flat Metal Washer (7) Snap Pin (8) Blade Cable (9) Cable Bracket (10) Bolt (a) 10 mm (0.39 in.)
Page 73: Adjustable Track Lever
MACHINE BODY KX018-4, WSM (3) Adjustable Track Lever Components (1) Adjustable Track Lever ASSY (2) Lever Grip (3) Flat Metal Washer (4) Snap Pin (5) Flat Metal Washer (6) Snap Pin (7) Adjustable Track Cable (a) The Gaps should be Uniform (b) White Tape (c) 146 mm (5.75 in.)
Page 74: Overall Routing Of Blade And Adjustable Track Cables
MACHINE BODY KX018-4, WSM (4) Overall Routing of Blade and Adjustable Track Cables Components (1) Accelerator cable (3) Adjustable track cable (5) Battery (a) No contact with the muffler (2) Blade cable (4) Delivery hose (b) Guide rod RY9212091MBS0054US0 1-S20...
Page 75: Accelerator Lever
MACHINE BODY KX018-4, WSM (5) Accelerator Lever Components (1) Accelerator Lever ASSY (7) Bolt (13) Accelerator Support (a) 10 mm (0.39 in.) (2) Grip (8) Bolt (14) Bolt (b) 12 mm (0.47 in.) (3) Spring (9) Nut (15) Pin (c) 111 mm (4.37 in.)
Page 76: Accelerator Cable Routing
MACHINE BODY KX018-4, WSM (6) Accelerator Cable Routing (1) Bonnet Front Cover (a) Hang the sponge of the (b) Do not allow it to touch the (c) Pass through the top hole (2) Accel Cable Bracket blade cable on the guide rod...
Page 77: Swing Pedal
MACHINE BODY KX018-4, WSM (7) Swing Pedal Components (1) Swing pedal (2) Bolt (3) Lever ASSY (4) Flat metal washer (5) Snap pin (6) Rod (7) Rod end, right (8) Bolt (9) Nut (10) Flat metal washer (11) Snap pin...
Page 78: Aux Pedal
MACHINE BODY KX018-4, WSM (8) AUX Pedal Components (1) AUX Pedal (2) Bolt (3) Lever ASSY (4) Flat metal washer (5) Snap pin (6) Bolt (7) Rod end, right screw (8) Nut (9) Rod end, screw (10) Spring washer (11) Nut...
Page 79: Track Frame
MACHINE BODY KX018-4, WSM 3. TRACK FRAME [1] SWIVEL BEARING ASSEMBLY (1) Swivel Bearing Assembly Procedure 1. Component names Parts Name Q'ty Bearing (swivel) Bolt (M12 x 40) Bolt (M12 x 40) 2. Assembly position Mount the inner tire soft zone ('S' mark) (d) on the left side of the body.
Page 80 MACHINE BODY KX018-4, WSM (3) Measuring Swivel Bearing Play 1. Attach a dial gauge and a clamp to hold the dial gauge to the front of the mini-excavator. (The point to measure depends on the model.) 2. Extend the arm completely and put the bucket in an extended position.
Page 81: Track Frame Assembly
MACHINE BODY KX018-4, WSM [2] TRACK FRAME ASSEMBLY Track Frame Assembly Procedures (1) Track frame, center (2) Track frame, left (3) Track frame, right (4) Stopper bolt (5) Spring washer 1. Stopper Bolt Torque 367.7 to 431.5 N·m Tightening torque Bolt (4) 37.5 to 44.0 kgf·m...
Page 82: Track
MACHINE BODY KX018-4, WSM [3] TRACK (1) Rubber Track Disassembly/Assembly CAUTION • The pressure in the grease cylinder is high so if loosened quickly, the nipple may pop off and the highly pressurized grease in the cylinder may fly out so do not get your face near the nipple nor place your body in front of the nipple and loosen the nipple gradually.
Page 83: Front Idler
MACHINE BODY KX018-4, WSM [4] FRONT IDLER (1) Front Idler Disassembly/Assembly Removing the Idler 1. Remove the track. (Refer to the chapter "Track Assembly/Disassembly.") Jack up the mini-excavator with the front and the blade and place timbers or the like under the frame.
Page 84: Cylinder Assembly
MACHINE BODY KX018-4, WSM [5] CYLINDER ASSEMBLY (1) Cylinder Assembly Disassembly/Assembly Removing the Cylinder ASSY 1. Remove the track and the front idler. (Refer to the "Front Idler" chapter for assembly/disassembly of the front idler.) After removing the spring ASSY, pull out the cylinder ASSY from the track frame.
Page 85: Track Roller
MACHINE BODY KX018-4, WSM [6] TRACK ROLLER (1) Track Roller Disassembly/Assembly Removing the Track Roller 1. Remove the track. (Refer to the chapter "Track Assembly/Disassembly".) Jack up the mini-excavator with the front and the blade and place timbers or the like under the frame.
Page 86: Engine
ENGINE KiSC issued 06, 2012 A...
Page 87 GENERAL CONTENTS 1. ENGINE ............................2-G1 [1] ENGINE SPECIFICATIONS ....................2-G1 [2] PERFORMANCE CURVE ....................2-G2 [3] DIMENSIONS ........................2-G4 KiSC issued 06, 2012 A...
Page 88: Engine
ENGINE KX018-4, WSM 1. ENGINE [1] ENGINE SPECIFICATIONS KX016-4 (For AU) KX018-4 (For NA) KX018-4 (For AU) Model D782-BH-5 D902-E3-BH-3 D902-BH-2 Number of cylinder 67 × 73.6 mm 72 × 73.6 mm Bore × Stroke 2.64 × 2.90 in. 2.83 × 2.91 in.
Page 89: Performance Curve
ENGINE KX018-4, WSM KX016-4 (For AU) KX018-4 (For NA) KX018-4 (For AU) Alternator 12 V (480 W) Charging current 40 A Regulation voltage 14.2 to 14.8 V 545 024 030 Battery 54524 12V45AH, 55B24R Electrolyte gravity 1.28 ± 0.01 Starter 12 V (1.2 kW)
Page 90 ENGINE KX018-4, WSM D902-BH-2 (1) Gross int. (a) Engine Speed (rpm × 100) (c) Brake Horsepower (2) Net int. (b) Torque (d) Specific Fuel Consumption RY9212095END0002US0 2-G3 KiSC issued 06, 2012 A...
Page 91: Dimensions
ENGINE KX018-4, WSM [3] DIMENSIONS 470.5 mm (18.5 in.) 186 mm (7.32 in.) 218 mm ( 8.58 in.) 18 mm (0.71 in.) 51.5 mm (2.03 in.) 564 mm (22.2 in.) 175 mm (6.89 in.) 199.6 mm (7.86 in.) 396 mm (15.6 in.) 174 mm (6.85 in.)
Page 92: Hydraulic System
HYDRAULIC SYSTEM KiSC issued 06, 2012 A...
Page 93: Mechanism
MECHANISM CONTENTS 1. DIAGRAM OF HYDRAULIC CIRCUIT..................3-M1 [1] DIAGRAM OF HYDRAULIC CIRCUIT ................. 3-M1 2. HYDRAULIC DEVICE LAYOUT ....................3-M2 3. PUMP ............................3-M3 [1] SPECIFICATIONS........................ 3-M3 [2] COMPONENTS ........................3-M6 [3] FUNCTION AND STRUCTURE ................... 3-M7 (1) Pump Operating Principles..................... 3-M7 (2) Pump Horsepower Control Mechanism................
Page 94 (2) Components ......................... 3-M34 8. PILOT VALVE ........................... 3-M35 [1] PILOT VALVE (BOOM, ARM, BUCKET, SWIVEL) ............3-M35 (1) Specifications........................ 3-M35 9. UNLOAD VALVE ........................3-M37 [1] UNLOAD VALVE ........................ 3-M37 (1) Specifications........................ 3-M37 10. TPSS VALVE ..........................3-M38 [1] TPSS VALVE ........................3-M38 (1) Specifications........................
Page 96: Hydraulic Device Layout
HYDRAULIC SYSTEM KX018-4, WSM 2. HYDRAULIC DEVICE LAYOUT (1) Pump (5) Travel Motor (9) Swing Cylinder (13) Unload Valve (2) Control Valve (6) Boom Cylinder (10) Blade Cylinder (14) TPSS Valve (3) Swivel Motor (7) Arm Cylinder (11) Track Cylinder...
Page 97: Pump
HYDRAULIC SYSTEM KX018-4, WSM 3. PUMP [1] SPECIFICATIONS (1) P1 Discharge Port (3) P3 Discharge Port (5) Piston Pump (7) Suction Port (2) P2 Discharge Port (4) P4 Discharge Port (6) Gear Pump (8) Lubrication Port Item Notes Maker Fujikoshi (Ltd.)
Page 98 HYDRAULIC SYSTEM KX018-4, WSM (1) P3 = 0.5 MPa (5 kgf/cm (2) P3 = 20.6 MPa (210 kgf/cm (A) Horsepower Control Curve (a) Discharge Flow: q1 = q2 70 psi) 2990 psi) (Reference: Bench Test) (cc/rev) (b) Discharge Pressure: P1 + P2...
Page 99: Diagram Of Hydraulic Circuit
HYDRAULIC SYSTEM KX018-4, WSM Diagram of Hydraulic Circuit P1/P2 :Piston Pump Discharge E : Engine Pressure P3 : Gear Pump Discharge Pressure PP: Pilot Pump Discharge Pressure PS: Suction Pressure RY9212095HYM0003US0 3-M5 KiSC issued 06, 2012 A...
Page 100: Components
HYDRAULIC SYSTEM KX018-4, WSM [2] COMPONENTS Parts Name Q'ty Remarks Parts Name Q'ty Remarks Body-S (24) Bearing Body-H (25) Needle Bearing Shaft (26) Oil Seal Cylinder Barrel (27) Coned Disk Springs Valve Plate (28) Snap Ring JIS B 2804 42 Hole...
Page 101: Function And Structure
HYDRAULIC SYSTEM KX018-4, WSM [3] FUNCTION AND STRUCTURE (1) Pump Operating Principles (1) Suction Port (5) Cylinder Barrel (a) Intake Cycle (d) Bottom Dead Center (2) Discharge Port (P1) (6) Piston (b) Discharge Cycle (e) Tilt Angle (3) Discharge Port (P2)
Page 102: Pump Horsepower Control Mechanism
HYDRAULIC SYSTEM KX018-4, WSM (2) Pump Horsepower Control Mechanism (1) Swashplate (3) Rod G (5) P3 (a) Load F1 (2) Ball (4) Spring (b) Spring Force F2 Set Horsepower Control Mechanism Although the pump discharge quantity alters the swashplate angle, the swashplate angle regulates the fixed horsepower with a direct-acting variable mechanism that utilizes a simple spring.
Page 103: Control Valve
HYDRAULIC SYSTEM KX018-4, WSM 4. CONTROL VALVE [1] SPECIFICATIONS (1) Swing Rod (9) AUX (Pa6) (17) Boom Rod (Pa2) (25) T1 Port (2) Swing Bottom (10) AUX (Pb6) (18) Boom Bottom (Pb2) (26) Pp1 Port (3) Track EXT Rod (11) Arm Bottom (Pa5)
Page 104: Diagram Of Hydraulic Circuit
HYDRAULIC SYSTEM KX018-4, WSM [2] DIAGRAM OF HYDRAULIC CIRCUIT (1) Swing (9) Inlet (2) Track (10) Travel R (3) Blade (11) Boom (4) Swivel (12) Bucket (5) Communication (6) AUX (A) Spool Stroke (mm) (7) Arm (B) Pilot Pressure (MPa)
Page 105: Function And Structure
HYDRAULIC SYSTEM KX018-4, WSM [3] FUNCTION AND STRUCTURE (1) Cross-section of Each Section [A] P1 Line Inlet Section RY9212190HYM0006US0 Travel Right Section RY9212190HYM0007US0 Boom Section RY9212091HYM0025US0 Bucket Section RY9212091HYM0026US0 3-M11 KiSC issued 06, 2012 A...
Page 106 HYDRAULIC SYSTEM KX018-4, WSM [B] P2 Line Inlet Section RY9212190HYM0006US0 Travel Left Section RY9212190HYM0008US0 Arm Section RY9212190HYM0009US0 AUX Section RY9212190HYM0010US0 3-M12 KiSC issued 06, 2012 A...
Page 107 HYDRAULIC SYSTEM KX018-4, WSM [C] P3 Line Communication Valve Section Step 1 (Raises Unload Lever) Step 2 (Lowers Unload Lever) Step 3 (Travel + Front Operation) RY9212190HYM0011US0 3-M13 KiSC issued 06, 2012 A...
Page 108 HYDRAULIC SYSTEM KX018-4, WSM Swivel Section RY9212091HYM0031US0 Blade Section RY9212091HYM0032US0 Variable Track Section RY9212091HYM0033US0 Swing Section RY9212091HYM0034US0 3-M14 KiSC issued 06, 2012 A...
Page 109: Straight Travel Circuit
HYDRAULIC SYSTEM KX018-4, WSM (2) Straight Travel Circuit (1) Swing (4) Swivel (7) Arm (10) Travel R (2) Track (5) Communication (8) Travel L (11) Boom (3) Blade (6) AUX (9) Inlet (12) Bucket RY9212190HYM0012US0 The travel straight forward signal line is connected with the tank circuit by the left/right travel switch when it is in neutral, and the main spool of the communication valve remains in the neutral position.
Page 110: Travel Alarm
HYDRAULIC SYSTEM KX018-4, WSM (3) Travel Alarm (1) Swing (4) Swivel (7) Arm (10) Travel R (2) Track (5) Communication (8) Travel L (11) Boom (3) Blade (6) AUX (9) Inlet (12) Bucket RY9212190HYM0015US0 The travel alarm for signal line is connected with the tank circuit by the left/right travel switch when it is in neutral, ant the main spool of the communication valve remains in the neutral position.
Page 111: Swivel Motor
HYDRAULIC SYSTEM KX018-4, WSM 5. SWIVEL MOTOR [1] SWIVEL MOTOR (1) Specifications (1) Port A (3) Drain Port (4) Relief Valve (R) (5) Relief Valve (L) (2) Port B Item Notes Maker Eaton (Ltd.) Model 104-6445-005 195 cc/rev Total Displacement 11.9 cu.in./rev...
Page 112: Components
HYDRAULIC SYSTEM KX018-4, WSM (2) Components Name of part Notes Name of part Notes Bearing housing (24) Valve housing Includes nos. 31 to Pinion gear (25) Relief cartridge Ball bearing 6308 LLU (26) Steel ball Ball bearing 6207 (27) Plug...
Page 113: Function And Structure
HYDRAULIC SYSTEM KX018-4, WSM (3) Function and Structure [A] Operating Principles Pressurized oil from port A (1) flows into the rotor sub-assembly (10) via valve (3) and valve plate (4). The rotor sub-assembly (10) is made up of a stator (7) and seven rotors (6) and is secured by a housing.
Page 114: Travel Motor
HYDRAULIC SYSTEM KX018-4, WSM 6. TRAVEL MOTOR [1] SPECIFICATIONS (1) Counterbalance Valve (2) Travel 2-Speed (3) A Port (G3/8) (4) B Port (G3/8) (5) PP Port (G1/8) (2-Speed Travel Switch) (6) Drain Port (G1/4) (7) Lubricating Oil Fill/Drain Ports (G3/8)
Page 115: Components
HYDRAULIC SYSTEM KX018-4, WSM [2] COMPONENTS Parts Name Q'ty Remarks Parts Name Q'ty Remarks Body (12) Snap Ring 3 Pieces JIS B 2804 for Shaft Cover (13) Snap Ring Size 13 Gear (14) Plug Gear (15) Motor, Assy Ring (16)
Page 116 HYDRAULIC SYSTEM KX018-4, WSM (Continued) (b) Body assy (Motor 1) Parts Name Q'ty Remarks Parts Name Q'ty Remarks (32) Body 1 (45) Plug (33) Spool (46) Ring (34) Check Valve (47) Plug JIS B 2401 Class 1B (35) Spring Guide...
Page 117: Function And Structure
HYDRAULIC SYSTEM KX018-4, WSM [3] FUNCTION AND STRUCTURE (1) Operating Principles Nine pistons (2) are built into the cylinder block (1), and the end section of the block is in contact with a valve plate (3), which has two half-moon shaped ports (port B and port C for switching between high and low pressure).
Page 118: Brake Operation
HYDRAULIC SYSTEM KX018-4, WSM If pressurized oil flows to P1 The pressurized oil that passed through P1 flows through check valve L (2) to the motor (b) via the M1 port, thus turning the motor. The oil returning from the motor flows to the...
Page 119: 2-Speed Function
HYDRAULIC SYSTEM KX018-4, WSM (3) 2-Speed Function The swashplate has two surfaces, I and II, opposite the sliding surfaces of the shoes, and these are supported by the two balls mounted in the body 2. The balls are in an an eccentric position above the...
Page 120: Decelerator
HYDRAULIC SYSTEM KX018-4, WSM When the load is heavy The motor load pressure rises, so the motor load X 2-speed spool area (left) > pilot area under pressure X Ps + motor load X 2-speed spool area (right), thus moving the 2-speed spool to the right and switching to 1-speed (low).
Page 121: Hydraulic Cylinder
HYDRAULIC SYSTEM KX018-4, WSM 7. HYDRAULIC CYLINDER [1] BOOM CYLINDER (1) Specifications Maker LEDUC Tube outer diameter 70 mm (2.8 in.) Tube inner diameter 60 mm (2.4 in.) Rod diameter 30 mm (1.2 in.) Stroke 469 mm (18.5 in) Max compressed length 765 mm (30.1 in)
Page 122: Function And Structure
HYDRAULIC SYSTEM KX018-4, WSM (3) Function and Structure (1) Cylinder Tube (4) Cushion Ring (2) Cushion Tube (5) Piston (3) Screw Ring (6) Spiral RY9212095HYM0032US0 When cylinder is extended (boom lowered) The oil flowing from the bottom of the cylinder flows from inside the cushion tube→through the gap between...
Page 123 HYDRAULIC SYSTEM KX018-4, WSM When cylinder is compressed (cushioning function) • Cushion function on the lift end of the boom When the piston comes into the cushion tube, the hydraulic oil is expelled through the slit in the cushion tube and its passing through the spiral in the cushion ring...
Page 124: Arm Cylinder
HYDRAULIC SYSTEM KX018-4, WSM [2] ARM CYLINDER (1) Specifications Maker LEDUC Tube outer diameter 70 mm (2.8 in.) Tube inner diameter 60 mm (2.4 in.) Rod diameter 35 mm (1.4 in.) Stroke 362 mm (14.3 in) Max compressed length 609 mm (24.0 in)
Page 125: Specifications
HYDRAULIC SYSTEM KX018-4, WSM [3] BUCKET CYLINDER (1) Specifications Maker LEDUC Tube outer diameter 70 mm (2.8 in.) Tube inner diameter 60 mm (2.4 in.) Rod diameter 35 mm (1.4 in.) Stroke 291 mm (11.5 in) Max compressed length 545 mm (21.5 in)
Page 126: Specifications
HYDRAULIC SYSTEM KX018-4, WSM [4] SWING CYLINDER (1) Specifications Maker Roquet Tube outer diameter 65 mm (2.6 in.) Tube inner diameter 55 mm (2.2 in.) Rod diameter 30 mm (1.2 in.) Stroke 355 mm (14.0 in) Max compressed length 625 mm (24.6 in)
Page 127: Specifications
HYDRAULIC SYSTEM KX018-4, WSM [5] BLADE CYLINDER (1) Specifications Maker Roquet Tube outer diameter 75 mm (3.0 in.) Tube inner diameter 65 mm (2.6 in.) Rod diameter 30 mm (1.2 in.) Stroke 111 mm (4.4 in) Max compressed length 348 mm (13.7 in)
Page 128: Adjustable Track Cylinder
HYDRAULIC SYSTEM KX018-4, WSM [6] ADJUSTABLE TRACK CYLINDER (1) Specifications Maker Roquet Tube outer diameter 70 mm (2.8 in.) Tube inner diameter 60 mm (2.4 in.) Rod diameter 30 mm (1.2 in.) Stroke 310 mm (12.2 in) Max compressed length 528 mm (20.8 in)
Page 129: Pilot Valve
HYDRAULIC SYSTEM KX018-4, WSM 8. PILOT VALVE [1] PILOT VALVE (BOOM, ARM, BUCKET, SWIVEL) (1) Specifications 1. Pilot Valve Left (1) Port 1 (Arm Rake) (4) Port 4 (Swivel Right) (P) P Port (a) Secondary Pressure (MPa) (2) Port 2 (Swivel Left)
Page 130 HYDRAULIC SYSTEM KX018-4, WSM 2. Pilot Valve Right (1) Port 1 (Lift Boom) (4) Port 4 (Bucket Dump) (P) P Port (a) Secondary Pressure (MPa) (2) Port 2 (Dump Rake) (5) Secondary Pressure (T) T Port (b) Operating Torque (N·m)
Page 131: Unload Valve
HYDRAULIC SYSTEM KX018-4, WSM 9. UNLOAD VALVE [1] UNLOAD VALVE (1) Specifications (1) P Port (3) A2 Port (2-Speed Travel (5) Relief Valve (6) Check Valve (2) A1 Port (Pilot Operation) Switch) (4) T Port (To Hydraulic Oil Tank) Maker...
Page 132: Tpss Valve
HYDRAULIC SYSTEM KX018-4, WSM 10. TPSS VALVE [1] TPSS VALVE (1) Specifications (1) A Port (P/V Side) (4) D Port (P/V Side) (7) c Port (C/V Side) (a) 90 ° (2) B Port (P/V Side) (5) a Port (C/V Side)
Page 133: Servicing
SERVICING CONTENTS 1. PUMP ............................3-S1 [1] PUMP DISASSEMBLY/ASSEMBLY ..................3-S1 [2] PUMP DISASSEMBLY PROCEDURES ................3-S3 (1) Disassembly Procedures....................3-S4 (2) Assembly Procedures......................3-S7 [3] SERVICE STANDARDS FOR PUMP PARTS..............3-S10 2. CONTROL VALVE........................3-S11 [1] CONTROL VALVE REMOVAL AND INSTALLATION............3-S11 [2] CONTROL VALVE DISASSEMBLY/ASSEMBLY PROCEDURES ........3-S13 3.
Page 134 (10)Pilot Hose Routing......................3-S82 (11)Pilot Hose Routing (Control Valve)................3-S84 (12)Entire Pilot Hose Routing ....................3-S85 (13)Pilot Hose Routing (Around the Driver's Seat) ..............3-S87 (14)TPSS Adapter .......................3-S88 11. MEASURING THE PERFORMANCE OF HYDRAULIC DEVICES ...........3-S89 12. TROUBLESHOOTING......................3-S103 KiSC issued 06, 2012 A...
Page 135: Pump
HYDRAULIC SYSTEM KX018-4, WSM 1. PUMP [1] PUMP DISASSEMBLY/ASSEMBLY CAUTION • When removing a hydraulic device after operating the mini-excavator, lower the bucket and blade to the ground and turn off the engine. • Each of the devices and the hydraulic oil are hot and under high pressure immediately after operating the mini-excavator.
Page 136 HYDRAULIC SYSTEM KX018-4, WSM Spline section grease application Apply the correct amount of grease to the spline section. IMPORTANT • Do not apply grease to the rubber section of the coupling. (1) Coupling (a) Spline Section (2) Bolt (Coupling) RY9212091HYS0031US0...
Page 137: Pump Disassembly Procedures
HYDRAULIC SYSTEM KX018-4, WSM [2] PUMP DISASSEMBLY PROCEDURES (A) Body S (C) Cylinder Barrel (D) Valve Plate (E) Needle Bearing (B) Body H Name of part Name of part Name of part Piston pump ASSY (A) to (16) O-ring (30)
Page 138: Disassembly Procedures
HYDRAULIC SYSTEM KX018-4, WSM (1) Disassembly Procedures After draining the pump of oil, wash off the pump and put a protector, such as clean paper, cloth, rubber mat, etc., on the work surface and proceed with disassembly and reassembly. Use any tools necessary and exercise caution so no parts are damaged and employ sufficient precautions to prevent any foreign matter from getting inside.
Page 139 HYDRAULIC SYSTEM KX018-4, WSM 4. Remove the upper two of the four bolts. Install two (M10 x 65) bolts in these positions temporarily and gently loosen the remaining two bolts. Next loosen the two temporary bolts and detach body S.
Page 140 HYDRAULIC SYSTEM KX018-4, WSM 8. Remove stopper pin A, stopper pin B, disc spring, rod and snap ring. (26) Rod (31) Disc Spring (27) Stopper Pin A (32) Internal Circlip (28) Stopper Pin B RY9212091HYS0009US0 9. Tap the shaft lightly with a plastic hammer and remove the seal holder (with oil seal and O-ring) and the shaft (w/ ball bearing) from body S.
Page 141: Assembly Procedures
HYDRAULIC SYSTEM KX018-4, WSM (2) Assembly Procedures 1. Use jig (a) to install the oil seal in body S. IMPORTANT • Apply grease to the lip of the oil seal. (30) Oil Seal (a) Jig 31.7 mm (1.25 in.) (A) Body S 19.8 mm (0.78 in.)
Page 142 HYDRAULIC SYSTEM KX018-4, WSM 4. Mount the balls on the swashplate and install it in body S. NOTE • If the balls fall out, apply grease when mounting them. (11) Swashplate (12) Ball RY9212091HYS0013US0 5. After mounting the springs in the cylinder barrel, install the three pins and the barrel holder, then carefully install the shoe holder with the pistons installed in it into body S.
Page 143 HYDRAULIC SYSTEM KX018-4, WSM 9. Mount body S to body H with the bolts. IMPORTANT • When installing the bolts, tighten them diagonally from each other. 53.9 to 63.7 N·m Tightening torque Bolt (33) 5.5 to 6.5 kgf·m 39.8 to 46.9 lbf·ft •...
Page 144: Service Standards For Pump Parts
HYDRAULIC SYSTEM KX018-4, WSM [3] SERVICE STANDARDS FOR PUMP PARTS Part Service Standard 1. No scratching, scoring or abnormal wear. (Especially sliding parts) 2. Check the clearance between the piston O.D. (D) and cylinder barrel I.D. (b). • (d) – (D) ≤ 0.05 mm (0.002 in.).
Page 145: Control Valve
HYDRAULIC SYSTEM KX018-4, WSM 2. CONTROL VALVE [1] CONTROL VALVE REMOVAL AND INSTALLATION CAUTION • When removing a hydraulic device after operating the mini-excavator, lower the bucket and blade to the ground and turn off the engine. • Each of the devices and the hydraulic oil are hot and under high pressure immediately after operating the mini-excavator.
Page 146 HYDRAULIC SYSTEM KX018-4, WSM 7. Remove the three bolts and then the control valve. IMPORTANT • Apply thread lock (Loctite AN302-71 equivalent). 23.5 to 27.5 N·m Tightening torque Bolt (3) 2.4 to 2.8 kgf·m 17.4 to 20.2 lbf·ft (1) Bolt...
Page 147: Control Valve Disassembly/Assembly Procedures
HYDRAULIC SYSTEM KX018-4, WSM [2] CONTROL VALVE DISASSEMBLY/ASSEMBLY PROCEDURES Precautions during Disassembly / Assembly Precautions during Disassembly 1. Generally, hydraulic devices are precision machined, and disassembly should therefore be conducted in a clean environment to prevent entry of debris into the narrow interstices formed in the device structure.
Page 148 HYDRAULIC SYSTEM KX018-4, WSM Spool Section (Swing) Components Name of part Tightening torque Notes in Fig. Valve housing O-ring Poppet Spring O-ring 40.0 N·m Plug 4.1 kgf·m 30.0 lbf·ft Spool O-ring Dust seal (10) Seat 5.0 N·m (11) Bolt 0.5 kgf·m 4.0 lbf·ft...
Page 149 HYDRAULIC SYSTEM KX018-4, WSM Spool Section (Track) Components Name of part Tightening torque Notes in Fig. Valve housing O-ring Poppet Spring O-ring 40.0 N·m Plug 4.1 kgf·m 30.0 lbf·ft Spool O-ring Dust seal (10) Seat 5.0 N·m (11) Bolt 0.5 kgf·m 4.0 lbf·ft...
Page 150 HYDRAULIC SYSTEM KX018-4, WSM Spool Section (Blade) Components Name of part Tightening torque Notes in Fig. Valve housing O-ring Poppet Spring O-ring 40.0 N·m Plug 4.1 kgf·m 30.0 lbf·ft Spool O-ring Dust seal (10) Seat 5.0 N·m (11) Bolt 0.5 kgf·m 4.0 lbf·ft...
Page 151 HYDRAULIC SYSTEM KX018-4, WSM Spool Section (Swivel) Components Name of part Tightening torque Notes in Fig. Valve housing O-ring Poppet Spring O-ring 40.0 N·m Plug 4.1 kgf·m 30.0 lbf·ft Spool O-ring Dust seal (10) Seat 5.0 N·m (11) Bolt 0.5 kgf·m 4.0 lbf·ft...
Page 152 HYDRAULIC SYSTEM KX018-4, WSM Spool Section (Communication Valve) Components Name of part Tightening torque Notes in Fig. Valve housing O-ring O-ring Poppet Spring O-ring 40.0 N·m Plug 4.1 kgf·m 30.0 lbf·ft Spool Plug ASSY (10) Spring seat (11) Spring (12)
Page 153 HYDRAULIC SYSTEM KX018-4, WSM Spool Section (AUX) Components Name of part Tightening torque Notes in Fig. Valve housing O-ring O-ring Poppet Spring O-ring 40.0 N·m Plug 4.1 kgf·m 30.0 lbf·ft Spool O-ring (10) Dust seal (11) Seat 5.0 N·m (12) Bolt 0.5 kgf·m...
Page 154 HYDRAULIC SYSTEM KX018-4, WSM Spool Section (Arm) Components Name of part Tightening torque Notes in Fig. Valve housing O-ring O-ring Poppet Spring O-ring 40.0 N·m Plug 4.1 kgf·m 30.0 lbf·ft Spool Spring seat A (10) Spring (11) Spring seat B 5.0 N·m...
Page 155 HYDRAULIC SYSTEM KX018-4, WSM Spool Section (Travel Left) Components Name of part Tightening torque Notes in Fig. Valve housing O-ring O-ring Poppet Spring O-ring 40.0 N·m Plug 4.1 kgf·m 30.0 lbf·ft Spool O-ring (10) Dust seal (11) Seat 5.0 N·m...
Page 156 HYDRAULIC SYSTEM KX018-4, WSM Spool Section (Inlet) Components Name of part Tightening torque Notes in Fig. Valve housing O-ring O-ring Spool Spring seat Spring O-ring Cap A 5.0 N·m Bolt 0.5 kgf·m 4.0 lbf·ft (10) Cap B Valve ASSY (Relief) Pressure Setting...
Page 157 HYDRAULIC SYSTEM KX018-4, WSM Spool Section (Travel Right) Components Name of part Tightening torque Notes in Fig. Valve housing O-ring O-ring Poppet Spring O-ring 40.0 N·m Plug 4.1 kgf·m 30.0 lbf·ft Spool Spring seat (10) Spring 5.0 N·m (11) Bolt 0.5 kgf·m...
Page 158 HYDRAULIC SYSTEM KX018-4, WSM Spool Section (Boom) Components Name of part Tightening torque Notes in Fig. Valve housing O-ring O-ring Poppet Spring O-ring 40.0 N·m Plug 4.1 kgf·m 30.0 lbf·ft Spool Spring seat A (10) Spring (11) Spring seat B 5.0 N·m...
Page 159 HYDRAULIC SYSTEM KX018-4, WSM Spool Section (Bucket) Components Name of part Tightening torque Notes in Fig. Valve housing O-ring O-ring Poppet Spring Poppet O-ring 40.0 N·m Plug 4.1 kgf·m 30.0 lbf·ft Spool (10) Spring seat A (11) Spring (12) Spring seat B 5.0 N·m...
Page 160: Swivel Motor
HYDRAULIC SYSTEM KX018-4, WSM 3. SWIVEL MOTOR [1] SWIVEL MOTOR REMOVAL AND INSTALLATION CAUTION • When removing a hydraulic device after operating the mini-excavator, lower the bucket and blade to the ground and turn off the engine. • Each of the devices and the hydraulic oil are hot and under high pressure immediately after operating the mini-excavator.
Page 161: Swivel Motor Disassembly/Assembly Procedures
HYDRAULIC SYSTEM KX018-4, WSM [2] SWIVEL MOTOR DISASSEMBLY/ASSEMBLY PROCEDURES (A) Bearing Housing (C) Valve Housing (D) Cartridge (E) Screw Guide (B) Pinion Gear Shaft Parts Name Q'ty Remarks Parts Name Q'ty Remarks (A), (B), (C) ~ (E), Assy Motor, Swivel...
Page 162: Disassembly Procedures
HYDRAULIC SYSTEM KX018-4, WSM (1) Disassembly Procedures Prior to disassembly, clean the work area and prepare plastic containers to hold parts. Prior to disassembly, clean the areas around motor ports and brush off the paint at each joint with a wire brush.
Page 163: Swivel Motor Disassembly/Assembly Procedures
HYDRAULIC SYSTEM KX018-4, WSM 6. Remove the pinion gear shaft with a press. RY9212091HYS0154US0 7. Remove the ball bearing. RY9212091HYS0155US0 8. Remove the X-ring. RY9212091HYS0156US0 (2) Assembly Procedures Inspect the mating surfaces of each part. Any scratches or burrs may cause a leak.
Page 164 HYDRAULIC SYSTEM KX018-4, WSM 2. Install the bearing in the bearing housing. (1) Bearing Housing (2) Bearing RY9212091HYS0159US0 3. Use a press to install the pinion shaft in the bearing housing. (1) Bearing Housing (2) Pinion Shaft RY9212091HYS0160US0 4. Install the retaining ring.
Page 165 HYDRAULIC SYSTEM KX018-4, WSM 6. Install the O-ring and and drive in the bearing housing. Install the O-rings in the wear plate. (1) Bearing Housing (4) O-Ring (2) Wear Plate (5) O-Ring (3) O-Ring RY9212091HYS0163US0 7. Install the geroler. Install the geroler so its drain hole and the drain hole of the wear plate line up.
Page 166 HYDRAULIC SYSTEM KX018-4, WSM Valve Timing Line up the tip of a spline tooth of the valve drive with the outside tooth of the geroler/star as in the diagram and mark the tip of the valve drive's tooth with a magic marker or the like. Install the parts so the marked spline tooth of the valve drive is 15°...
Page 167 HYDRAULIC SYSTEM KX018-4, WSM 14. Install the valve housing ASSY. Insert a tool such as a screwdriver through a port hole and hold the balancing plate while installing the ASSY to keep the balancing ring from coming out. (1) Valve Housing ASSY RY9212091HYS0172US0 15.
Page 168: Swivel Joint
HYDRAULIC SYSTEM KX018-4, WSM 4. SWIVEL JOINT [1] SWIVEL JOINT REMOVAL AND INSTALLATION CAUTION • When removing a hydraulic device after operating the mini-excavator, lower the bucket and blade to the ground and turn off the engine. • Each of the devices and the hydraulic oil are hot and under high pressure immediately after operating the mini-excavator.
Page 169 HYDRAULIC SYSTEM KX018-4, WSM Swivel Joint Assembly 1. Grease the D-ring and insert in the body. 2. Install backup rings on both sides of the D-ring 3. Grease the O-ring (5) and insert in the body. 4. Install a backup ring on the outside of the O-ring (5).
Page 170: Travel Motor
HYDRAULIC SYSTEM KX018-4, WSM 5. TRAVEL MOTOR [1] TRAVEL MOTOR REMOVAL AND INSTALLATION CAUTION • When removing a hydraulic device after operating the mini-excavator, lower the bucket and blade to the ground and turn off the engine. • Each of the devices and the hydraulic oil are hot and under high pressure immediately after operating the mini-excavator.
Page 171: Travel Motor Disassembly/Assembly Procedures
HYDRAULIC SYSTEM KX018-4, WSM 5. Suspend the wheel motor ASSY from a crane and remove it. IMPORTANT • Apply thread lock (Loctite® AN302-71 equivalent). 60.7 to 70.6 N·m Tightening torque Sprocket (3) 6.2 to 7.2 kgf·m 44.8 to 52.0 lbf·ft...
Page 172 HYDRAULIC SYSTEM KX018-4, WSM (Continued) Name of part Name of part Wheel motor ASSY (25) Bearing Drive sprocket (26) O-ring Spring washer (27) Seal ring Hex socket bolt (28) Floating seal Spring washer (29) Body, ASSY (motor, 2) Hex socket bolt...
Page 173 HYDRAULIC SYSTEM KX018-4, WSM (1) Disassembly Procedures [A] Reduction Gear 1. Remove the two plugs (G3/8). 2. Remove the snap ring. 3. Remove the cover. • Tool to use : M8 hex socket (1) Plug (3) Cover (2) Snap Ring RY9212095HYS0014US0 4.
Page 174 HYDRAULIC SYSTEM KX018-4, WSM 9. Remove the gear from the holder and sub-assembly. (1) Holder and Sub-Assembly (2) Gear RY9212095HYS0019US0 10. Remove the four snap rings and the thrust plate. (1) Snap Ring (2) Thrust Plate RY9212095HYS0020US0 11. Remove the four gears, ninety-six needles, four thrust washers and four rings.
Page 175 HYDRAULIC SYSTEM KX018-4, WSM 13. Remove the steel balls with retainer and the internal ring of bearing from the speed reducer. IMPORTANT • Pay attention not to lose the balls from retainer. (1) Steel Balls with Retainer RY9212095HYS0023US0 14. Remove the speed reducer.
Page 176 HYDRAULIC SYSTEM KX018-4, WSM 17. Remove the floating seal with O-ring from the hydraulic motor. (1) Hydraulic Motor (3) Floating Seal (2) O-Ring RY9212095HYS0027US0 [B] Motor 1. Remove the seven hexagon socket head cap bolts. • Tool to use : M5 hex socket...
Page 177 HYDRAULIC SYSTEM KX018-4, WSM 5. Remove the nine piston-shoe assemblies, shoe holder, retainer holder and three pins. (1) Cylinder Barrel (4) Shoe Holder (2) Pin (5) Piston (3) Retainer Holder RY9212095HYS0032US0 6. Remove the shaft from the body-2. IMPORTANT • The bearing is not able to dissemble, because they are press-fitted.
Page 178 HYDRAULIC SYSTEM KX018-4, WSM 11. Remove the two plugs with O-rings from the body-1. • Tool to use : M8 hex socket RY9212095HYS0036US0 12. Remove the spring, two-speed spool, spool-B and spool-C. (1) Spool-B (3) Two-Speed Spool (2) Spring (4) Spool-C RY9212095HYS0037US0 13.
Page 179: Travel Motor Disassembly/Assembly Procedures
HYDRAULIC SYSTEM KX018-4, WSM (2) Assembly Procedures [A] Motor 1. Insert the spring ASSY, rings (both sides) and springs (both sides) into body 1 in order. IMPORTANT • The spool should slide smoothly on its own. • Apply hydraulic oil to the spool.
Page 180 HYDRAULIC SYSTEM KX018-4, WSM 5. Insert the shuttle spool and the needles (both sides) into body 1. IMPORTANT • The spool should slide smoothly on its own. • Apply hydraulic oil to the spool. RY9212095HYS0042US0 6. Screw the two plugs (1pc / side) with two O-rings (1pc / side).
Page 181 HYDRAULIC SYSTEM KX018-4, WSM 9. Install the parallel pin into body 2. (1) Parallel Pin RY9212095HYS0046US0 10. Place the control piston into the body-2. 11. Place the shaft into the body-2. IMPORTANT • Pay attention not to damage the oil seal with the shaft. A oil seal which damaged should be replaced.
Page 182 HYDRAULIC SYSTEM KX018-4, WSM 15. Install the valve plate into body 1. IMPORTANT • Take care to install the valve plate facing the right direction. • Apply grease to the back of the valve plate so it does not fall out.
Page 183 HYDRAULIC SYSTEM KX018-4, WSM 2. Install the ring inside the bearing and the retainer with steel balls on the body in that order. (1 set) IMPORTANT • Take care that the ring inside the bearing and the retainer face the right way. (See cross-section) •...
Page 184 HYDRAULIC SYSTEM KX018-4, WSM 4. Install the gear case onto the body. IMPORTANT • Use a vice or hydraulic press to press the hydraulic motor flange and the gear case flange together. RY9212091HYS0231US0 5. Install the the retainer with steel balls and the ring inside the bearing into the body in that order.
Page 185 HYDRAULIC SYSTEM KX018-4, WSM 7. Install the ring, flat washer, gear and needle in that order. (1) Ring (A) Thrust Plate Side (2) Flat Metal Washer (B) Washer Side (3) Gear (4) Needle RY9212091HYS0234US0 8. Install the thrust plate and secure it with snap rings.
Page 186 HYDRAULIC SYSTEM KX018-4, WSM 10. Install the holder ASSY and the gear in that order into the body. (1) Holder ASSY (2) Gear RY9212095HYS0053US0 11. Place the O-ring to the body. IMPORTANT • Apply grease to the O-ring. (1) O-Ring RY9212095HYS0054US0 12.
Page 187 HYDRAULIC SYSTEM KX018-4, WSM 14. Install the plug. IMPORTANT • Tighten the plug on the "DRAIN" side first and use the leverage on the snap ring to keep the cover from turning. 46 to 51 N·m Tightening torque Plug 4.7 to 5.2 kgf·m 34 to 38 lbf·ft...
Page 188: Hydraulic Cylinder
HYDRAULIC SYSTEM KX018-4, WSM 6. HYDRAULIC CYLINDER [1] HYDRAULIC CYLINDER DISASSEMBLY/ASSEMBLY PROCEDURES (1) Cylinder Components Boom Cylinder Name of part Name of part Bushing (12) O-ring Grease nipple (13) Grease nipple Plug (14) Cylinder rod Plug (15) Piston Cylinder tube...
Page 189: Disassembly Procedures
HYDRAULIC SYSTEM KX018-4, WSM (2) Disassembly Procedures Cylinder Disassembly 1. Drain the oil from inside the cylinder, and fasten the cylinder bottom in a vice across the bolt width. RY9212095HYS0004US0 2. Place an anti-rotation device in one position of the cylinder head.
Page 190 HYDRAULIC SYSTEM KX018-4, WSM 6. Remove the set screw. IMPORTANT • There is one set screw punched in place. • After removing it, use a hand tap to clean out the piston side. • If the set screw is damaged during removal, replace it with a new one.
Page 191: Assembly Procedures
HYDRAULIC SYSTEM KX018-4, WSM (3) Assembly Procedures Precautions on Assembly Replacing Seals All seals must be replaced when disassembling the cylinder. Replacing O-rings Thoroughly clean the mounting groove before fitting the backup ring and O-ring. Take care over the backup ring location.
Page 192 HYDRAULIC SYSTEM KX018-4, WSM 7. Install the piston. IMPORTANT • Tighten the piston to the specified torque. RY9212095HYS0062US0 8. Install the set screw. IMPORTANT • Tighten the set screw to the specified torque. • Apply Loctite 243. • After tightening the set screw, punch it in one spot to keep it from coming out.
Page 193 HYDRAULIC SYSTEM KX018-4, WSM Torque Notes 200 to 300 N·m Cylinder head 20.4 to 30.5 kgf·m 148 to 221 lbf/ft 230 to 340 N·m Boom Cylinder Piston 23.5 to 34.6 kgf·m 170 to 250 lbf/ft 20 N·m Set screw 2.0 kgf·m 15 lbf·ft...
Page 194: Cylinder Inspection
HYDRAULIC SYSTEM KX018-4, WSM Cylinder Inspection 1. Warping of the piston rod 1. Put the piston rod by itself on the V blocks. 2. Set a dial gauge on the center of the rod. 3. Rotate the piston rod and read the measurements on the dial gauge.
Page 195: Pilot Valve
HYDRAULIC SYSTEM KX018-4, WSM 7. PILOT VALVE [1] PILOT VALVE (CONTROL) DISASSEMBLY/ASSEMBLY PROCEDURES (1) Pilot Valve Components Name of part Valve, ASSY (A) (2) to (10) Handle Button Lever ASSY Rubber boot Nut (disc) Plate Plug Reducing valve ASSY (10)
Page 196: Disassembly Procedures
HYDRAULIC SYSTEM KX018-4, WSM (2) Disassembly Procedures CAUTION • All of the parts are precisely made, so be very careful in handling them and taking care not to drop or hit parts against each other. • If you hit a part too hard while working on it, it may result in burrs or other damage, thus preventing installation as well as oil leaks and/or compromised performance, so be careful when handling parts.
Page 197 HYDRAULIC SYSTEM KX018-4, WSM 5. Remove the four shims and the plates. CAUTION • When removing the plates, take care that the plug does not pop off. (7) Plate RY9212091HYS0263US0 6. Slip a slotted screwdriver in the groove around the plug to remove it.
Page 198: Assembly Procedures
HYDRAULIC SYSTEM KX018-4, WSM (3) Assembly Procedures CAUTION • Prepare your workbench in the same way as for disassembly. • Follow the same general precautions as in the disassembly. • When assembling the parts, remove all bits of metal or foreign matter from all the parts and make sure there aren't any burrs or dings on the parts.
Page 199 HYDRAULIC SYSTEM KX018-4, WSM 5. Install the nut (disc). 45 to 55 N·m Tightening torque Nut (6) 4.6 to 5.6 kgf·m 33 to 41 lbf·ft Apply thread lock (Loctite 262) • Tool to use: 8 mm hex socket (6) Nut (Disc) RY9212091HYS0268US0 6.
Page 200: Unload Valve
HYDRAULIC SYSTEM KX018-4, WSM 8. UNLOAD VALVE [1] UNLOAD VALVE ASSEMBLY PROCEDURES Name of part Tightening torque Notes Relief valve 20 to 30 N·m Valve 2.0 to 3.1 kgf·m 15 to 22 lbf·ft Check valve 4 to 6 N·m 0.4 to 0.6 kgf·m 3 to 4 lbf·ft...
Page 201: Pressure Sensor
HYDRAULIC SYSTEM KX018-4, WSM 9. PRESSURE SENSOR [1] PRESSURE SENSOR ASSEMBLY PROCEDURES (1) Pipe Joint (2) Pressure Sensor 30.0 to 34.0 N·m Tightening torque Pressure sensor (2) 3.1 to 3.4 kgf·m 23 to 25 lbf·ft RY9212190HYS0028US0 3-S67 KiSC issued 06, 2012 A...
Page 202: Routing Of Hydraulic Hoses
HYDRAULIC SYSTEM KX018-4, WSM 10. ROUTING OF HYDRAULIC HOSES [1] HYDRAULIC HOSE SPECIFICATIONS (1) Total Length of Hydraulic Hose (a) Total Length RY9212004HYS0147US0 (2) Types of Connector Fittings (Screw) (1) C Type (Straight) (a) 45 ° (2) CR4 Type (45°) (b) 90 °...
Page 203: Routing Of Hydraulic Hoses
HYDRAULIC SYSTEM KX018-4, WSM [2] ROUTING OF HYDRAULIC HOSES (1) Delivery Hose Routing (a) Pump (c) Rotary Joint (d) Swivel Motor (e) Swing Cylinder (b) Control Valve (To be continued) 3-S69 KiSC issued 06, 2012 A...
Page 204 HYDRAULIC SYSTEM KX018-4, WSM (Continued)  Table of Hydraulic Hoses Hose Fitting Function Guard Position Used Total Tape Size O.D. I.D. Type Size length color 1840 mm 17.4 mm 9.5 mm Pump (P1) to C/V C·C (72.4 in.) White (0.7 in.) (0.4 in.)
Page 205: Delivery Hose Clamp Positions
HYDRAULIC SYSTEM KX018-4, WSM (2) Delivery Hose Clamp Positions (a) Pass Inside the Guide (c) Pass on the Outside of (e) Pass through the Notch (g) Red (b) Mark Location Guide White (h) Blue (d) Hang on the Guide  Table of Hydraulic Hoses...
Page 206: Suction Hose Routing
HYDRAULIC SYSTEM KX018-4, WSM (3) Suction Hose Routing (a) Hose Clamp (c) 26.5 mm (1.0 in) (e) 43 mm (1.7 in) 10 ° (b) 15 mm (0.6 in) (d) 40 mm (1.6 in)  Table of Hydraulic Hoses Function Position Used...
Page 207: Front Hose Routing
HYDRAULIC SYSTEM KX018-4, WSM (4) Front Hose Routing (A) Parallel (B) Clamp Hoses (1) to (8) (C) 300 mm (11.8 in) (To be continued) 3-S73 KiSC issued 06, 2012 A...
Page 208 HYDRAULIC SYSTEM KX018-4, WSM (Continued)  Table of Hydraulic Hoses Hose Fitting Function Guard Position Used Total Tape Size O.D. I.D. Type Size length color 1380 mm CR9·C C/V (A2) to Hose (54.3 in.) 11.8 mm 6.4 mm Boom up Green (0.5 in.)
Page 209: Travel Hose Routing
HYDRAULIC SYSTEM KX018-4, WSM (5) Travel Hose Routing  Table of Hydraulic Hoses Hose Fitting Function Guard Position Used Total Tape Size O.D. I.D. Type Size length color Travel right 685 mm 17.4 mm 9.5 mm C·C C/V (A3) to R/J (I) forward (27.0 in.)
Page 210: Routing Of Swivel, Blade, Swing And Adjustable Track Hoses
HYDRAULIC SYSTEM KX018-4, WSM (6) Routing of Swivel, Blade, Swing and Adjustable Track Hoses (a) Clamp  Table of Hydraulic Hoses Hose Fitting Function Guard Position Used Total Tape Size O.D. I.D. Type Size length color 540 mm 11.8 mm 6.4 mm...
Page 211: Track Frame Hose Routing
HYDRAULIC SYSTEM KX018-4, WSM (7) Track Frame Hose Routing (a) Blade Cylinder (b) Rotary Joint (c) Wheel Motor Left Side (d) Wheel Motor Right Side (e) Blade Joint Track Cylinder R/J side Travel motor / cylinder side Variable track (compress)
Page 212 HYDRAULIC SYSTEM KX018-4, WSM  Table of Hydraulic Hoses Hose Fitting Function Guard Position Used Total Tape Size O.D. I.D. Type Size length color Travel right 920 mm 17.4 mm 9.5 mm R/J (i) to Travel CR9·C forward (36.2 in.) (0.7 in.)
Page 213: Return Hose Routing
HYDRAULIC SYSTEM KX018-4, WSM (8) Return Hose Routing (a) Control Valve (c) Swivel Motor (e) Pipe (g) Oil Cooler (b) Rotary Joint (d) Unload Valve Oil Tank  Table of Hydraulic Hoses Hose Fitting Function Guard Position Used Total Size O.D.
Page 214: Return Hose Clamp Position
HYDRAULIC SYSTEM KX018-4, WSM (9) Return Hose Clamp Position (a) Hose Clamp (b) 30 mm (1.2 in.) (c) Don't Contact the Swing (d) Move the Corrugate to Sides Cover of C/V After Assembling (To be continued) 3-S80 KiSC issued 06, 2012 A...
Page 215 HYDRAULIC SYSTEM KX018-4, WSM (Continued)  Table of Hydraulic Hoses Hose Fitting Function Guard Position Used Total Size O.D. I.D. Type Size length 800 mm 23.5 mm 15.9 mm Oil cooler IN C/V (T2) to oil cooler (Lower) (31.5 in.) (0.925 in.)
Page 216: Pilot Hose Routing
HYDRAULIC SYSTEM KX018-4, WSM (10) Pilot Hose Routing (a) Pump (d) Oil Tank (g) Rotary Joint (g) A : Front (b) Unload Valve (e) Pilot Valve (L) (h) TPSS B : Rear (c) Control Valve Pilot Valve (R) (To be continued)
Page 217 HYDRAULIC SYSTEM KX018-4, WSM (Continued)  Table of Hydraulic Hoses Hose Fitting Function Guard Position Used Total Tape Size O.D. I.D. Type Size length color 1080 mm 17.4 mm 9.5 mm CR4·C Pump (P4) to unload V (42.5 in.) (0.7 in.) (0.4 in.)
Page 218 HYDRAULIC SYSTEM KX018-4, WSM (11) Pilot Hose Routing (Control Valve) (A) Parallel (a) 35 ° (b) 14 ° (c) 65 ° (B) Don't Contact to the Bracket  Table of Hydraulic Hoses Hose Fitting Function Guard Position Used Total Tape Size O.D.
Page 219 HYDRAULIC SYSTEM KX018-4, WSM (12) Entire Pilot Hose Routing (a) Section A (e) Section E Control Valve Swing Cylinder Hoses (b) Section B TPSS Clamp (m) Return Hose (c) Section C (g) Unload Valve (k) Clamp from Above the (n) Pilot Valve...
Page 220 HYDRAULIC SYSTEM KX018-4, WSM (Continued)  Table of Hydraulic Hoses Hose Fitting Function Guard Position Used Total Tape Size O.D. I.D. Type Size length color 440 mm 11.8 mm 6.4 mm Unload V (A2) to R/J 2-speed signal C·C (17.3 in.) (0.5 in.)
Page 221: Pilot Hose Routing (Around The Driver's Seat)
HYDRAULIC SYSTEM KX018-4, WSM (13) Pilot Hose Routing (Around the Driver's Seat) (a) Clamp (b) Fasten the Bundle of Hoses to the Seat support with a Clamp. RY9212190HYS0020US0 3-S87 KiSC issued 06, 2012 A...
Page 222: Tpss Adapter
HYDRAULIC SYSTEM KX018-4, WSM (14) TPSS Adapter (1) Adapter (A) Back (C) Left (a) 10 ° (2) Adapter (B) Development Figure (D) Right (b) 5 ° (3) Pipe Joint 34.0 to 45.0 N·m Tightening torque M14 × 1.6 3.5 to 4.6 kgf·m 25.1 to 33.2 lbf·ft...
Page 223: Measuring The Performance Of Hydraulic Devices
HYDRAULIC SYSTEM KX018-4, WSM 11. MEASURING THE PERFORMANCE OF HYDRAULIC DEVICES Hydraulic System Pressure Release Procedure 1. Place the mini excavator on flat hard ground, lower the bucket and the blade, and stop the engine. RY9212091HYS0071US0 2. Without starting the engine, place the engine starter switch in the "RUN"...
Page 224 HYDRAULIC SYSTEM KX018-4, WSM Main Relief Valve Pressure Procedure for Measuring the Main Relief Valve 1. Place the mini excavator on flat, hard ground, lower the bucket and the blade and stop the engine. 2. Follow the chapter on "Releasing Pressure in the Hydraulic System"...
Page 225 HYDRAULIC SYSTEM KX018-4, WSM Main pump flow measurement Measurement preparation 1. Place the mini-excavator on hard, flat ground, lower the bucket and the blade and stop the engine. 2. Follow the chapter on "Releasing Pressure in the Hydraulic System" and release pressure in the hydraulic line.
Page 226 HYDRAULIC SYSTEM KX018-4, WSM Actual AUX PQ Value Measurement Measurement preparation 1. Place the mini excavator on flat, hard ground, lower the bucket and the blade and stop the engine. 2. Follow the chapter on "Releasing Pressure in the Hydraulic System"...
Page 227: Pilot Pressure
HYDRAULIC SYSTEM KX018-4, WSM Pilot Pressure Pilot Primary Pressure Measuring Procedure 1. Place the mini excavator on flat, hard ground, lower the bucket and the blade and stop the engine. 2. Follow the chapter on "Releasing Pressure in the Hydraulic System"...
Page 228 HYDRAULIC SYSTEM KX018-4, WSM Pilot Secondary Primary Pressure Measuring Procedure 1. Place the mini excavator on flat, hard ground, lower the bucket and the blade and stop the engine. 2. Follow the chapter on "Releasing Pressure in the Hydraulic System" and release pressure in the hydraulic lines.
Page 229: Measurement Preparation
HYDRAULIC SYSTEM KX018-4, WSM Overload Relief Valve Pressure Measurement Procedure A : Injection Pressure Tester B : Overload Relief Valve C : Control Valve Tested Parts Name Notes Support To hold the tester steady, fasten the tester to this support with Bolt (M10 x 35) bolts/nuts (2) and (3).
Page 230: Measurement Equipment
HYDRAULIC SYSTEM KX018-4, WSM Inspection Points Bench Data Measurement Values (Reference) 17.0 Mpa 17 ± 1 MPa Bottom (b1B) 170 kgf/cm 170 ± 10 kgf/cm 2500 psi 2500 ± 145 psi Boom 27.5 Mpa 27.5 ± 1 MPa Rod (b1R) 280 kgf/cm 280 ±...
Page 231 HYDRAULIC SYSTEM KX018-4, WSM Swivel Relief Valve Pressure 1. Place the mini excavator on flat, hard ground, lower the bucket and the blade and stop the engine. 2. Follow the chapter on "Releasing Pressure in the Hydraulic System" and release pressure in the hydraulic lines.
Page 232 HYDRAULIC SYSTEM KX018-4, WSM Swivel Motor Drain Volume 1. Before measuring, operate the swivel left and right repeatedly to sufficiently warm up the swivel motor. Hydraulic oil temperature of 50 ± 5 °C (122 ± 9 °F). 2. Place the mini excavator on flat, hard ground, lower the bucket and the blade and stop the engine.
Page 233 HYDRAULIC SYSTEM KX018-4, WSM Swivel Block Performance 1. Before measuring, operate the swivel left and right repeatedly to sufficiently warm up the swivel motor. Hydraulic oil temperature of 50 ± 5 °C (122 ± 9 °F). 2. Place dirt or a weight of the specified weight (JIS heap x specific gravity 1.8) in the bucket.
Page 234 HYDRAULIC SYSTEM KX018-4, WSM Hydraulic Cylinder Drift Amount 1. Before measuring, repeat front operations and fully warm up each cylinder. Hydraulic oil temperature of 50 ± 5 °C (122 ± 9 °F). 2. Place dirt or a weight of the specified weight (JIS heap x specific gravity 1.8) in the bucket.
Page 235 HYDRAULIC SYSTEM KX018-4, WSM Swing cylinder measurement 1. Before measuring, repeat front operations and fully warm up each cylinder. Set the hydraulic fluid temperature to 50 ± 5 °C (122 ± 9 °F). 2. The front attitude should be with arm cylinder fully compressed,...
Page 236 HYDRAULIC SYSTEM KX018-4, WSM Amount of travel drift 1. Before measuring, adjust the left and right crawlers to even tension, and operate the travel motor to thoroughly warm it up. Set the hydraulic fluid temperature to 50 ± 5 °C (122 ± 9 °F).
Page 237: Troubleshooting
HYDRAULIC SYSTEM KX018-4, WSM 12. TROUBLESHOOTING Front System Troubleshooting All front operations slow or not moving Reference Cause Inspection point Remedy page Defect of the engine itself Engine speed measurement Adjust each engine part Insufficient hydraulic fluid volume Check hydraulic tank oil level...
Page 238 HYDRAULIC SYSTEM KX018-4, WSM Reference Cause Inspection point Remedy page Defective seal(s) inside the Cylinder disassembly and Inspect applicable cylinder cylinder seal replacement Low power with certain implements Reference Cause Inspection point Remedy page Adjust, clean or replace pilot Pilot relief valve faulty operation or...
Page 239 HYDRAULIC SYSTEM KX018-4, WSM Swivel System Troubleshooting Swivel speed slow or no swivel Reference Cause Inspection point Remedy page Measure travel pilot valve Pilot valve disassembly, Defective pilot valve secondary pressure cleaning or replacement Inspect control valve swivel Swivel section spool sticks...
Page 240: Electrical System
ELECTRICAL SYSTEM KiSC issued 06, 2012 A...
Page 241: Contents
SERVICING CONTENTS 1. ELECTRONIC EQUIPMENT LAYOUT..................4-S1 2. WIRING CIRCUIT........................4-S2 [1] PRECAUTIONS ON HOW TO CLAMP THE ELECTRICAL WIRING ........4-S2 [2] PRECAUTIONS ON HANDLING ELECTRICAL CONNECTORS .........4-S2 [3] UNPLUGGING ELECTRICAL CONNECTORS AND WIRING LAYOUT ........................4-S3 3. TROUBLESHOOTING (START-UP EQUIPMENT VERSION)..........4-S14 4. CHECKS............................4-S15 [1] POWER AND GROUND .....................4-S15 [2] STARTING AND STOPPING DEVICES ................4-S18 5.
Page 243: Wiring Circuit
ELECTRICAL SYSTEM KX018-4, WSM 2. WIRING CIRCUIT [1] PRECAUTIONS ON HOW TO CLAMP THE ELECTRICAL WIRING 1. Do not touch the wiring or the area around it. Do not touch where uncovered. 2. Do not clamp to fuel hoses. 3. Connect connectors and terminals securely so they do not come unplugged when pulled on gently.
Page 244: Unplugging Electrical Connectors And Wiring Layout
ELECTRICAL SYSTEM KX018-4, WSM [3] UNPLUGGING ELECTRICAL CONNECTORS AND WIRING LAYOUT (1) Starter S-terminal connector (2) Engine oil switch connector RY9212091ELS0054US0 (1) Starter S-terminal Connector Connector No. Place Used CN37 Inside engine compartment (a) Press lock and unplug RY9212091ELS0002US0 (2) Engine oil switch connector Connector No.
Page 245 ELECTRICAL SYSTEM KX018-4, WSM (3) Alternator Connector Connector No. Place Used CN25 Inside engine compartment (a) Press lock and unplug RY9212091ELS0004US0 (4) Fuel Pump Connector Connector No. Place Used CN24 Inside engine compartment (a) Press lock and unplug RY9212091ELS0005US0 (5) Water Temperature Sensor Connector Connector No.
Page 246 ELECTRICAL SYSTEM KX018-4, WSM (7) Fuel sensor connector RY9212190ELS0021US0 (7) Fuel Sensor Connector Connector No. Place Used CN23 Swivel frame center RY9212091ELS0008US0 (8) Travel Alarm Connector RY9212190ELS0054US0 (8) Travel Alarm Connector Connector No. Place Used CN203, CN204 In front of the swivel frame...
Page 247 ELECTRICAL SYSTEM KX018-4, WSM (9) Rotation sensor connector RY9212091ELS0058US0 (9) Rotation Sensor Connector Connector No. Place Used CN33 Inside engine compartment (a) Press lock and unplug RY9212091ELS0010US0 (10) Key switch connector (12) Meter LCD buzzer connector (11) Horn switch connector...
Page 248 ELECTRICAL SYSTEM KX018-4, WSM (12) Meter LCD Buzzer Connector Connector No. Place Used CN250 Inside right control cover (b) Press lock and unplug RY9212091ELS0013US0 (13) Anti-theft Antenna Connector Connector No. Place Used CN441 Inside right control cover (b) Lift up on the lock and then...
Page 249 ELECTRICAL SYSTEM KX018-4, WSM (17) Lever lock switch connector RY9212091ELS0061US0 (17) Lever Lock Switch Connector Connector No. Place Used CN11 Inside left control cover (a) Press lock and unplug RY9212091ELS0017US0 (18) Horn connector RY9212091ELS0063US0 (18) Horn Connector Connector No. Place Used...
Page 250 ELECTRICAL SYSTEM KX018-4, WSM (19) Travel 2-speed switch connector RY9212091ELS0064US0 (19) Travel 2-speed Switch Connector Connector No. Place Used CN15 Rear of control panel (a) Press lock and unplug RY9212190ELS0067US0 (20) Lever lock solenoid connector (21) Travel 2-speed solenoid connector...
Page 251 ELECTRICAL SYSTEM KX018-4, WSM (22) Pressure Sensor Connector RY9212190ELS0056US0 (22) Pressure Sensor Connector Connector No. Place Used CN201 Under steps (a) Press lock and unplug RY9212190ELS0057US0 (23) LCD meter connector RY9212190ELS0045US0 (23) LCD Meter Connector Connector No. Place Used Inside meter panel box...
Page 252 ELECTRICAL SYSTEM KX018-4, WSM (24) CAN communication connector (26) Main ECU connector (25) Function expansion connector RY9212190ELS0047US0 (24) CAN Comm Connector Connector No. Place Used Under the seat (a) Press lock and unplug RY9212190ELS0048US0 (25) Function Expansion Connector Connector No.
Page 253 ELECTRICAL SYSTEM KX018-4, WSM (27) Work light harness connector RY9212190ELS0051US0 (27) Work Light Harness Connector Connector No. Place Used CN18 Swivel frame center (a) Press lock and unplug RY9212190ELS0052US0 (28) Panel switch connector RY9212190ELS0023US0 (28) Panel Switch Connector Connector No.
Page 254 ELECTRICAL SYSTEM KX018-4, WSM Names of the Terminal Signals of the Main ECU Connector (Harness Side) Connector Connector Terminal Signal Name Terminal Signal Name – CAN H0 – CAN L0 Engine revolution in CAN H1 RXD (Main CPU) CAN L1 TXD (Main CPU) –...
Page 255: Troubleshooting (Start-Up Equipment Version)
ELECTRICAL SYSTEM KX018-4, WSM 3. TROUBLESHOOTING (START-UP EQUIPMENT VERSION) Engine does not start Inspection point Cause Remedy Check whether "Remove key lamp" has blinked when it is in The engine was not started with the registered Start the engine with the the start position.
Page 256: Checks
ELECTRICAL SYSTEM KX018-4, WSM 4. CHECKS [1] POWER AND GROUND Slow-blow fuses IMPORTANT • When replacing a slow-blow fuse, always use the same capacity fuse and replace it after determining why it blew. (1) Slow-blow fuses RY9212091ELS0047US0 Inspecting slow-blow fuses...
Page 257 ELECTRICAL SYSTEM KX018-4, WSM Precautions when a fuse blows When a fuse blows, there are 2 potential causes. The first is when an overload of current exceeds the rated amperage of the fuse, blowing it; the other is when it blows due to a repetitive, intermittent current.
Page 258 ELECTRICAL SYSTEM KX018-4, WSM Ground Check whether GND wire(s) are securely connected to the body. RY9212091ELS0029US0 Battery Check the voltage between the terminals 1. Connect a circuit tester between the (+) and (-) terminals of the battery and measure the voltage across the terminals.
Page 259: Starting And Stopping Devices
ELECTRICAL SYSTEM KX018-4, WSM [2] STARTING AND STOPPING DEVICES Key switch Checks 1. Remove the key switch's 3P connector. 2. Turn the key switch to the RUN position and then check the continuity between the red / white wire terminal of the connector on the key switch side and the red wire terminal on the connector.
Page 260 ELECTRICAL SYSTEM KX018-4, WSM Relay capacities and circuits (1) Beacon (20 A) (5) Horn (20 A) (2) Work light (20 A) (6) Glow (20 A) (3) Cab (20 A) (7) Engine stop (20 A) (4) Auto release (20 A) (8) Heater (20 A)
Page 261 ELECTRICAL SYSTEM KX018-4, WSM Glow Relay Voltage Test 1. Remove the glow relay. 2. Key Switch: RUN 3. Measure the voltage based on the table below. Connector Connector Assess- Measure Name Name ment ment (+ terminal (- terminal side) Results...
Page 262 ELECTRICAL SYSTEM KX018-4, WSM Engine Stop Relay Voltage Test 1. Remove the engine stop relay. 2. Key Switch: RUN 3. Measure the voltage based on the table below. Connector Connector Assess- Measure Name Name ment ment (+ terminal (- terminal side)
Page 263 ELECTRICAL SYSTEM KX018-4, WSM Switch (limit) connector voltage 1. Remove the 2P connector of the lever lock switch (limit). 2. Turn the key switch to RUN and measure the voltage between the connector terminal (blue/white) on the wire harness side and the body.
Page 264: Meter Panel
ELECTRICAL SYSTEM KX018-4, WSM 5. METER PANEL [1] NAMES AND FUNCTIONS OF METERS AND SWITCHES Name Function Travel 2-speed lamp Lights when in 2nd Blinks during key registration when Insert key lamp the key is to be inserted Blinks during key registration when...
Page 265: User Settings Mode
ELECTRICAL SYSTEM KX018-4, WSM 2. Pressing SW2 toggles the item displayed on the LCD screen (3) in a loop. (1) User switch (SW1) (a) Clock (2) Toggle display switch (SW2) (b) Engine RPM (3) LCD screen (c) Hour meter (A) Error message (Only displays to show a warning.
Page 266 ELECTRICAL SYSTEM KX018-4, WSM Switching to the Periodic Inspection Item Display Screen 1. After switching to the user settings mode, press SW2 and select the periodic inspection mode. 2. After turning the work light switch ON/OFF once, pressing and holding SW2 switches the display to the periodic inspection item display screen.
Page 267 ELECTRICAL SYSTEM KX018-4, WSM Table of Periodic Inspection Items When the hour meter has counted up to the hours circled in the maintenance list below, the message appears. The message shows up as follows. Check points C: _ _ 1...
Page 268: Service Dealer Mode
ELECTRICAL SYSTEM KX018-4, WSM [4] SERVICE DEALER MODE (1) Table of Diagnostic / Setting Items Number Item Display Remarks Engine RPM 1:OOOO Battery voltage 2:OO.O Engine oil 3:ON OFF Charge 4:ON OFF Starter position 5:ON OFF Worklight 6:ON OFF Water temperature voltage 7:O.OO...
Page 269 ELECTRICAL SYSTEM KX018-4, WSM Number Item Display Remarks no-01 AUX knob setting nob-R AUX activation point setting (with no-02 2:– – – – attachment) AUX activation point setting (no no-03 3:– – – – attachment) no-04 AUX feeling adjustment 4:– – – –...
Page 270 ELECTRICAL SYSTEM KX018-4, WSM [A] Tester (SET-1) Guide to Using the Tester Mode, Check to See the Conditions of the Various Sensors and the Information of Switches 1. With SW2 pressed down, turn the starter key to the [RUN] position to enter the service dealer mode. "SET-1" is displayed on the LCD screen.
Page 271 ELECTRICAL SYSTEM KX018-4, WSM SET-1 Tester Content Description NOTE • Press SW1: Back • Press SW2: Forward, switch • Press and hold SW1: Back all the way (Return to SET-1) • Press and hold SW2: Set Displayed Item Description Ex.: 2086 rpm 1.
Page 272 ELECTRICAL SYSTEM KX018-4, WSM Displayed Item Description Press switch: ON 12. Travel 2-speed switch Release switch: OFF Solenoid on: ON 13. Travel 2-speed solenoid Solenoid off: OFF (when lever lock is released) Lever lock switch on: ON 14. Lever lock switch...
Page 273 ELECTRICAL SYSTEM KX018-4, WSM Displayed Item Description Ex.: 2 (black key) 25. Key type Unknown: 0, red:1, black:2, yellow:3, green:4 Key matches: ON 26. Key matching Key does not match: ON (when keys are registered) Set to anti-theft mode: OFF 27.
Page 274 ELECTRICAL SYSTEM KX018-4, WSM [B] Read Error History (SET-2) [C] Read Entire Error History (SET-5) Guide to Checking the History of Errors in the Past 1. With SW2 pressed down, turn the starter key to the [RUN] position to enter the service dealer mode. "SET-1" is displayed on the LCD screen.
Page 275 ELECTRICAL SYSTEM KX018-4, WSM Guide to SET-2 Reading Error History Guide to SET-5 Reading Entire Error History NOTE • Press SW1: Back • Press SW2: Forward, switch • Press and hold SW1: Back all the way (Return to SET-2 or SET-5) •...
Page 276 ELECTRICAL SYSTEM KX018-4, WSM Displayed Item Description After the error history is cleared, hour meter when the Ex.: 130h first error occurred After the error history is cleared, year when the first Ex.: 2009 error occurred After the error history is Ex.: 2009/11/08...
Page 277 ELECTRICAL SYSTEM KX018-4, WSM [D] Clear Error History (SET-3) Guide to Clearing the History of Errors in the Past 1. With SW2 pressed down, turn the starter key to the [RUN] position to enter the service dealer mode. "SET-1" is displayed on the LCD screen.
Page 278 ELECTRICAL SYSTEM KX018-4, WSM Method for Storing Error History Data E.g.) Occurrence of engine oil pressure error (E:014) 1. The following content is displayed when either the SET-2 error history is read or the SET-5 entire error history is read.
Page 279 ELECTRICAL SYSTEM KX018-4, WSM (Continued) After the error history is cleared, hour meter when first error 100 h occurred After the error history is cleared, No error history 2009 year when first error occurred After the error history is cleared, month &...
Page 280 ELECTRICAL SYSTEM KX018-4, WSM Guide to SET-3 Clearing of Error History NOTE • Press SW1: Back • Press SW2: Forward, switch • Press and hold SW1: Back all the way (Return to SET-3) • Press and hold SW2: Set Explanation of Display...
Page 281 ELECTRICAL SYSTEM KX018-4, WSM [E] Dealer Settings (SET-4) Guide to Making Various Settings, such as Model and AUX Settings 1. With SW2 pressed down, turn the starter key to the [RUN] position to enter the service dealer mode. "SET-1" is displayed on the LCD screen.
Page 282 ELECTRICAL SYSTEM KX018-4, WSM SET-4 Table of Dealer Settings NOTE • Press SW1: Back • Press SW2: Forward, switch • Press and hold SW1: Back all the way (Return to SET-4) • Press and hold SW2: Set Display Item Description...
Page 283 ELECTRICAL SYSTEM KX018-4, WSM Guide to No-01 AUX Knob Settings Readjusting the modified AUX knob setting Explanation of Display Operation With the slide lever of the AUX knob all AUX knob right end setting the way to the right, press and hold...
Page 284 ELECTRICAL SYSTEM KX018-4, WSM Guide to No-03 AUX Activation Point Setting (no Attachment) When the AUX proportional valve or spool has been replaced by new one: Explanation of Display Operation The display screen is switched 3:---- : Standing by for lever lock...
Page 285 ELECTRICAL SYSTEM KX018-4, WSM Guide to No-05 Model Setting Settings required when the main ECU or meter has been replaced by new one: Explanation of Display Operation 51: No-05 Model, step 1 024: KX015-4 025: KX016-4 026: KX018-4 Model setting...
Page 286 ELECTRICAL SYSTEM KX018-4, WSM Guide to No-08 Periodic Inspection Offset Time Adjustment Entering the previous main ECU operating hours when the main ECU has been replaced by new one: Explanation of Display Operation Pressing and holding SW2 shift the digit right...
Page 287 ELECTRICAL SYSTEM KX018-4, WSM Navigation list of messages LCD display Problem / Error Preliminary Measure CAN system error The Controller Area Network (CAN) has The machine can be started and driven. developed a fault. Measured values may Do not perform any work with the be incorrect and switches may not machine.
Page 288 ELECTRICAL SYSTEM KX018-4, WSM LCD display Problem / Error Preliminary Measure Oil pressure too low (red) Stop the engine immediately. (Blinking) The engine oil pressure is too low. The engine may have developed a fault. (Lighting) Overheat Allow the machine to cool off by idling.
Page 289 ELECTRICAL SYSTEM KX018-4, WSM LCD display Problem / Error Preliminary Measure External 5-V system error The 5-V sensor supply line has The machine can be started and driven. developed a system fault. Do not perform any work with the The main functions are not available.
Page 290: Troubleshooting (Meter Panel)
ELECTRICAL SYSTEM KX018-4, WSM 6. TROUBLESHOOTING (METER PANEL) [1] ENGINE RELATED SYSTEM (1) Engine Oil Pressure Error (E:014) [A] Checking Via the LCD Panel Display 1. LCD Panel Display 1. Check if the warning lamp (a) on the LCD panel is blinking in red.
Page 291 ELECTRICAL SYSTEM KX018-4, WSM 3. Tester Mode 1. Select the tester mode. 2. Check the operation of the engine oil switch as per the table below. Discon- Normal Shorted lamp nected lamp lamp Key Off Not lit Not lit Not lit...
Page 292 ELECTRICAL SYSTEM KX018-4, WSM [C] Testing with a Circuit Tester 1. Checking the Voltage [Test Conditions] 1. Disconnect engine oil switch connector CN28. 2. Key switch: RUN 3. Test the voltage as per the table below. Connector Connector Mea- Assess-...
Page 293 ELECTRICAL SYSTEM KX018-4, WSM 3. Clearing the Error History 1. After fixing the problem, select Clear Error History and clear the history. 2. After clearing the history, read the error history again and make sure the error does not exist anymore.
Page 294: Charging System Error (E:016)
ELECTRICAL SYSTEM KX018-4, WSM (2) Charging System Error (E:016) [A] Checking Via the LCD Panel Display 1. LCD Panel Display 1. Check if the warning lamp (a) on the LCD panel is blinking in red. 2. Check if the charging lamp (b) is lit in red or is off.
Page 295 ELECTRICAL SYSTEM KX018-4, WSM 3. Tester Mode 1. Select the tester mode. 2. Check the operation of the charging switch as per the table below. Charg- Dis- Charg- Charg- Nor- con- Shorted lamp nected lamp lamp Key Off Not lit...
Page 296 ELECTRICAL SYSTEM KX018-4, WSM 4. Cause of Short [Inspection Conditions] 1. Key switch: STOP 2. One of the wires of the charging switch connector CN25 is pinched against or is touching the body. If the insulation is stripped, repair it properly and check the operation of the charging switch again in the tester mode.
Page 297 ELECTRICAL SYSTEM KX018-4, WSM [D] Testing the Equipment Itself 1. Inspecting the alternator 1. Check for a cut, loose or slipping fan belt. 2. Measure the voltage between terminal B of the alternator and body GND. If the measured voltage is about 12V, it is normal. If...
Page 298: Fuel Sensor Error (E:017)
ELECTRICAL SYSTEM KX018-4, WSM (3) Fuel Sensor Error (E:017) [A] Checking Via the LCD Panel Display 1. LCD Panel Display Check if the warning lamp (a) on the LCD panel is blinking in red. (a) Warning lamp (b) Error message E:017...
Page 299 ELECTRICAL SYSTEM KX018-4, WSM 3. Tester Mode 1. Select the tester mode. 2. Start the engine. 3. Check the display of fuel resistance values as per the following table. • Judge what the fuel sensor error is by looking at the resistance values.
Page 300 ELECTRICAL SYSTEM KX018-4, WSM 4. Causes when a short [Test Conditions] 1. Key switch : STOP 2. The fuel sensor wire is pinched against or touching the body. If the insulation is damaged, repair it properly and check the voltage and resistance for the fuel again in the tester mode.
Page 301 ELECTRICAL SYSTEM KX018-4, WSM [D] Checking the Equipment Itself 1. Inspecting the Fuel Sensor [Test Conditions] 1. Key switch: STOP 2. Disconnect connector CN23 from the fuel sensor and test the sensor. 3. Refer to the table below for the resistance at given float positions.
Page 302: Water Temperature Sensor Error (E:018)
ELECTRICAL SYSTEM KX018-4, WSM (4) Water Temperature Sensor Error (E:018) [A] Checking Via the LCD Panel Display 1. LCD Panel Display Check if the warning lamp (a) on the LCD panel is blinking in red. (a) Warning lamp (b) Error message E:018 (Water...
Page 303 ELECTRICAL SYSTEM KX018-4, WSM 3. Tester Mode 1. Select the tester mode. 2. Start the engine. 3. Check the display of water temperature sensor voltage and temperature in the tester mode as per the following table. Water temperature Temperature voltage Normal 2.34 V...
Page 304 ELECTRICAL SYSTEM KX018-4, WSM 4. Cause of Short [Inspection Conditions] 1. Key switch: STOP 2. One of the water temperature sensor wires is pinched against or is touching the body. If the insulation is stripped, repair it properly and check the water temperature sensor voltage and temperature again in the tester mode.
Page 305 ELECTRICAL SYSTEM KX018-4, WSM [D] Checking the Equipment Itself 1. Inspecting the Water Temperature Sensor [Test Conditions] 1. Key switch: STOP 2. Disconnect connector CN32 from the water temperature sensor and test the sensor. 3. Refer to the table below for the resistance at given water temperatures.
Page 306: Machine Related System
ELECTRICAL SYSTEM KX018-4, WSM [2] MACHINE RELATED SYSTEM (1) Lever Lock System Error (E:020) [A] Checking Via the LCD Panel Display 1. LCD Panel Display Content 1. Check if the warning lamp (a) on the LCD panel is blinking in red.
Page 307 ELECTRICAL SYSTEM KX018-4, WSM [B] Inspecting Each Device Visually and Physically 1. Checking fuses 1. Check whether the 5A lever lock fuse is blown. RY9212001ELS0088US0 2. Checking relays 1. Checking relays is not necessary. RY9212001ELS0009US0 3. Cause of Disconnects [Inspection Conditions] 1.
Page 308 ELECTRICAL SYSTEM KX018-4, WSM [C] Testing with a Circuit Tester 1. Checking the Voltage (Lever Lock Switch) [Test Conditions] 1. Disconnect the lever lock switch connector CN11. 2. Key switch: RUN 3. Test the voltage as per the table below.
Page 309 ELECTRICAL SYSTEM KX018-4, WSM 4. Checking Continuity (Lever Lock Solenoid) [Test Conditions] 1. Key switch: STOP 2. Disconnect the main ECU connector CN1. 3. Disconnect the lever lock solenoid connector CN12. 4. Test continuity as per the table below. Connector...
Page 310 ELECTRICAL SYSTEM KX018-4, WSM 4. Clearing the Error History 1. After fixing the problem, select Clear Error History and clear the history. 2. After clearing the history, read the error history again and make sure the error does not exist anymore.
Page 311 ELECTRICAL SYSTEM KX018-4, WSM (2) Travel 2-Speed System Error (E:021) [A] Checking Via the LCD Panel Display 1. LCD Panel Display Content 1. Check if the warning lamp (a) on the LCD panel is blinking in red. (a) Warning lamp...
Page 312 ELECTRICAL SYSTEM KX018-4, WSM 3. Tester Mode 1. Select the tester mode. 2. Start the engine. 3. Put the equipment operating lever lock in the [Release] position and press the 2-speed switch. 4. Operate the 2-speed switch and check the operation of the 2-speed switch and 2-speed solenoid as per the table below.
Page 313 ELECTRICAL SYSTEM KX018-4, WSM 4. Cause of Short [Inspection Conditions] 1. Key switch: STOP 2. One of the wires of the 2-speed switch connector CN15 and/or 2-speed solenoid connector CN13 is pinched against or is touching the body If the insulation is stripped, repair it properly and check the 2-speed solenoid and switch again in the tester mode.
Page 314 ELECTRICAL SYSTEM KX018-4, WSM 3. Checking the Voltage (2-Speed Switch) [Test Conditions] 1. Disconnect the 2-speed switch connector CN15. 2. Key switch: RUN 3. Test the voltage as per the table below. Connector Connector Mea- Assess- Name Name sure- Pin No.
Page 315 ELECTRICAL SYSTEM KX018-4, WSM 2. Inspecting the 2-Speed Solenoid [Inspection Conditions] 1. Key switch: STOP 2. Disconnect 2-speed solenoid connector CN13 from the equipment and test the solenoid independently. 2-speed solenoid Factory Specification 8 Ω ± 15 % Assessment Assessment Criteria...
Page 316: Power Supply System
ELECTRICAL SYSTEM KX018-4, WSM [3] POWER SUPPLY SYSTEM (1) Over-Voltage (E:025) [A] LCD Panel Display Content 1. LCD Panel Display Content 1. Check if the warning lamp (a) on the LCD panel is blinking in red. (a) Warning lamp (b) Error message E:025...
Page 317 ELECTRICAL SYSTEM KX018-4, WSM The alternator's charging system may be faulty. Refer to the page on charging system errors. RY9212091ELS0157US0 4-S76 KiSC issued 06, 2012 A...
Page 318: External 5 V Short Error (E:027)
ELECTRICAL SYSTEM KX018-4, WSM (2) External 5 V Short Error (E:027) [A] LCD Panel Display Content 1. LCD Panel Display Content 1. Check if the warning lamp (a) on the LCD panel is blinking in red. (a) Warning lamp (b) Error message E:027...
Page 319: External 12 V Short Error (E:028)
ELECTRICAL SYSTEM KX018-4, WSM (3) External 12 V Short Error (E:028) [A] LCD Panel Display Content 1. LCD Panel Display Content 1. Check if the warning lamp (a) on the LCD panel is blinking in red. (a) Warning lamp (b) Error message E:028...
Page 320: Communication System
ELECTRICAL SYSTEM KX018-4, WSM [4] COMMUNICATION SYSTEM (1) CAN Communication Error (E:001) [A] LCD Panel Display Content 1. LCD Panel Display Content 1. Check if the warning lamp (a) on the LCD panel is blinking in red. (a) Warning lamp...
Page 321 ELECTRICAL SYSTEM KX018-4, WSM 3. Cause of Disconnects [Test Conditions] 1. Key switch: STOP 2. LCD meter connector CN2 disconnected. 3. Break of wiring continuity somewhere in the middle. Pull on the harness bundle and make sure the harness does not come unplugged.
Page 322 ELECTRICAL SYSTEM KX018-4, WSM [D] Testing the Equipment Itself 1. Clearing the Error History 1. After fixing the problem, select Clear Error History and clear the history. 2. After clearing the history, read the error history again and make sure the error does not exist anymore.
Page 323: Travel Alarm
ELECTRICAL SYSTEM KX018-4, WSM [5] TRAVEL ALARM (1) Travel Alarm Error [A] LCD Panel Display Content 1. Service Dealer Mode 1. Select the service dealer mode. 2. Start the engine. 3. Check the travel alarm function as per the following table.
Page 324 ELECTRICAL SYSTEM KX018-4, WSM [B] Inspecting Each Device Visually and Physically 1. Checking fuses 1. Checking fuses is not necessary. RY9212001ELS0008US0 2. Checking relays 1. Checking relays is not necessary. RY9212001ELS0009US0 3. Cause of Disconnects [Inspection Conditions] 1. Key switch: STOP 2.
Page 325 ELECTRICAL SYSTEM KX018-4, WSM 2. Checking Continuity [Test Conditions] 1. Key switch: STOP 2. Disconnect the pressure sensor connector CN203, 204. 3. Test continuity as per the table below. Assessment Criteria Normal: Continuous (OK) Error: Not continuous (NG) RY9212190ELS0064US0 3. Checking Continuity [Test Conditions] 1.
Page 329: Cabin
CABIN KiSC issued 06, 2012 A...
Page 330: Servicing
SERVICING CONTENTS 1. CABIN REMOVAL AND MOUNTING ..................5-S1 2. HEATER REMOVAL AND INSTALLATION ................5-S3 3. CHECKS............................5-S5 [1] HEATER RELATED ......................5-S5 (1) Blower Switch ........................5-S5 (2) Blower Motor ........................5-S6 [2] WINDOW WASHER RELATED ....................5-S7 (1) Wiper Switch........................5-S7 (2) Wiper Motor ........................5-S8 (3) Washer Motor ........................5-S9 [3] LIGHTING EQUIPMENT RELATED..................5-S10 4.
Page 331: Cabin Removal And Mounting
CABIN KX018-4, WSM 1. CABIN REMOVAL AND MOUNTING CAUTION • Always disconnect the battery terminals prior to cabin removal or mounting. RY9212091CAS0031US0 1. Put the bucket on the ground and stop the engine. Slide the seat toward the front of the mini-excavator and disconnect the two connectors of the cabin harness and the excavator's main harness.
Page 332 CABIN KX018-4, WSM • Stud Bolt Installation 107.9 to 125.5 N·m Stud (front) Tightening torque 11.0 to 12.8 kgf·m Stud (rear) 59.6 to 92.5 lbf·ft Apply thread lock (Loctite AN320-72 equivalent). (1) Nut (cab) (A) 2 places at front of excavator...
Page 333: Heater Removal And Installation
CABIN KX018-4, WSM 2. HEATER REMOVAL AND INSTALLATION 1. Remove the bolts and then the cover. (1) Bolt (2) Cover RY9212091CAS0027US0 2. Remove the 3P connector from the blower motor. 3. Loosen the hose clamp and remove the hose. CAUTION •...
Page 334 CABIN KX018-4, WSM Heater Hose Routing (1) Heater Valve (a) 65 ° (2) Heater Hose (b) 15 ° (3) Inlet Hose (c) Don't contact with the engine in the swivel frame (d) Go under the inlet hose Don't contact with the inlet hose over 20 N·m...
Page 335: Checks
CABIN KX018-4, WSM 3. CHECKS [1] HEATER RELATED (1) Blower Switch Connector Voltage 1. Remove the 4P connector from the blower switch. 2. Turn the starter switch to [RUN]. 3. Measure the voltage between terminals 1 & 2 of the connector on the harness side.
Page 336: Blower Motor
CABIN KX018-4, WSM (2) Blower Motor Connector Voltage 1. Remove the 3P connector from the blower motor. 2. Switch the starter switch to [RUN] and the blower switch to HI. 3. Measure the voltage between terminals 3 & 4 of the connector on the switch side.
Page 337: Window Washer Related
CABIN KX018-4, WSM [2] WINDOW WASHER RELATED (1) Wiper Switch This switch has four positions, namely (a), (b), (c), and (d) as indicated in the figure. Turn the starter key to the [RUN] position and press the knob to position (b) to operate the wiper motor.If you...
Page 338: Wiper Motor
CABIN KX018-4, WSM Checking the Wiper Switch 1. Test the continuity between each of the terminals according to the table below. 2. If continuity exists, it is normal. A : 6P connector (switch side) RY9212091CAS0011US0 Checking the Cab Wiper Power Harness 1.
Page 339: Washer Motor
CABIN KX018-4, WSM Testing the Motor Separately 1. Raise the wiper blade so there is no load on it. 2. Switch the starter switch to [RUN] and the wiper switch to ON. 3. If the wiping angle is as in the table, it is normal.
Page 340: Lighting Equipment Related
CABIN KX018-4, WSM [3] LIGHTING EQUIPMENT RELATED Connector Voltage 1. Disconnect the cab power 8P connector from the wiring harness (cabin). 2. Measure the voltage between terminal 3 of the connector on the cabin power harness side and ground on the body. (Interior light) 3.
Page 341 CABIN KX018-4, WSM Terminal Voltage (Interior Light) 1. Remove the interior light cover. 2. Remove the bulb. (pull it out) 3. Switch the interior light switch to [ON]. 4. Measure the voltage between GND and the interior light terminal (+).
Page 342: Removal And Installation Of Glass
CABIN KX018-4, WSM 4. REMOVAL AND INSTALLATION OF GLASS [1] PREPARATION Items required • Cleaner : Equivalent of Seeker Cleaner 205 • Adhesive : Equivalent of Seeker Flex 250PC-JM • Primer : Equivalent of Seeker Primer 206 • Scraper • Awl •...
Page 343: Installing Windows
CABIN KX018-4, WSM [3] INSTALLING WINDOWS 1. Completely eliminate all old adhesive on the frame of the cab. 2. Use the cleaner to clean the cab frame and the surface of the new glass where adhesive will be applied to get rid of any dirt or oil.
Page 344: Glass Trim Type
CABIN KX018-4, WSM [4] GLASS TRIM TYPE (When removing) 1. Lift the rubber core by its seam and remove it. 2. Remove the glass to the outside. (When attaching) 1. From the outside, insert the glass into the glass trim.
Page 345: Troubleshooting
CABIN KX018-4, WSM 5. TROUBLESHOOTING Air Conditioning System Problem &/or Possible Causes Remedy Situation Noise Blower damaged Repair or replace Hot water valve damaged Replace Not heating effectively Servo motor broken Check and repair Blower fan switch broken Check and repair...
Page 346 CABIN KX018-4, WSM (Continued) Wiper Problem &/or Possible Causes Remedy Situation Fuse blown (a part inside the wiper motor or Pinpoint the cause of the damage some other moving part is shorted or burned out) and replace Wiper motor faulty (damaged armature, worn...
Page 347 SBF(main) 361897-0713 3-B/W 0.3-B RoomLight(+B) mo(+1) s(com) 0.5-BR 0.5-BR Vcc(AC) 1-BR 0.5-BR 0.5-L 0.5-Br 0.5-B 1-Br 250-1pf_with_sleeve Beacon(+) 1-R/B 12607900A 0.5-B 250-1pf_with_sleeve Beacon(GND) 1-Br 1-Br 12607900A 0.3-R/L 2f-B 1.25-Br Beacon 1.25-Y Radio(AC) 0.85-B 1.25-B 1.25-B 1.25-Y 0.5-L/W 0.5-B 0.5-Lg 0.5-B 1.25-B +B(Direct) 1.25f-W/R(AVSSX)
Page 348 Key SW CN-14-3 CN-14-1 CN-14-2 start CN-2-1 Meter +B CN-2-11 Relay source Front Light SW CN-830-8 CN-830-2 CN-830-10 CN-830-4 Front Work Light CN-18-1 CN-55-1 CN-100 Work lamp CN-55-2 CN-18-2 Front Light Relay CN-100 Wake Up Out CN-2-12 Work lamp CN-16-4 Sub Work Light Work lamp Fuel pump...
Page 349 EDITOR: KUBOTA CORPORATION CONSTRUCTION MACHINERY DIVISION CUSTOMER TECHNICAL SUPPORT DEPARTMENT 1-1 NAKAMIYA-OHIKE 1-CHOME, HIRAKATA-CITY, OSAKA, 573-8573, JAPAN PHONE : (81)72-840-1195 : (81)72-890-2883 E-mail : ce-sv@kubota.co.jp KUBOTA Corporation Printed in Japan 2012. 06, H, EI, EI, engusa Code No. RY911-21920...

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