Kubota KX080-4 Manuals

Kubota KX080-4 Workshop Manual (519 pages)

Brand: Kubota | Category: Excavators | Size: 36.54 MB

Workshop Manual Kubota Excavator

2
- Table of Contents
  2
Information

6
General

21
- 1 Checking Excavator Identification
  
  22
  - General
    22
- 2 Engine Identification
  
  23
  - Model Name and Serial Number
    23
  - E4B Engine
    24
  - Cylinder Number
    25
- 3 Muffler Full Assembly Identification
  
  26
  - Part Number and Serial Number
    26
- 4 General Precautions
  
  28
- 5 Handling Precautions for Electrical Parts and Wiring
  
  32
  - Wiring
    32
  - Fuses
    34
  - Connector
    34
  - Washing the Machine with a High-Pressure Washer
    36
- 6 Tightening Torques
  
  37
- 7 Oil and Water Capacity Table
  
  41
- 8 Maintenance Intervals
  
  42
  - Machine Body
    45
Servicing

46
- 1 Front
  
  48
  - Boom Assembly/Disassembly
    48
  - Table of Dimensions
    50
    
    Bucket
    50
    
    Front Pin
    51
    
    Front Bushings
    52
    
    Arm
    53
    
    Blade
    54
- 2 Swivel Frame
  
  55
  - Weight Assembly/Disassembly
    55
  - Cabin Removal and Mounting
    55
  - Fuel Tank Assembly/Disassembly
    58
  - Hydraulic Oil Tank Assembly/Disassembly
    61
  - Assembly/Disassembly of Engine Related Components
    63
    
    DPF Muffler
    63
    
    Engine
    65
  - Assembling Operating Levers
    68
    
    Travel Lever
    68
    
    Blade Lever
    68
    
    Limit Switch
    68
- 3 Track Frame
  
  69
  - Swivel Bearing Assembly/Disassembly
    69
  - Track
    70
    
    Assembly/Disassembly of the Rubber Track
    70
    
    Assembly/Disassembly of Iron Tracks
    71
    
    Steel Track Removal/Installation Tools
    74
  - Front Idler
    77
    
    Assembly/Disassembly of Front Idler
    77
    
    Assembly/Disassembly of the Front Idler
    77
  - Grease Cylinder
    79
    
    Assembly/Disassembly of the Grease Cylinder
    79
    
    Components
    79
  - Tensioner
    80
    
    Tensioner Assembly/Disassembly
    80
  - Track Rollers
    81
    
    Track Roller Assembly/Disassembly
    81
    
    Components
    81
  - Carrier Rollers
    82
    
    Carrier Roller Assembly/Disassembly
    82
    
    Components
    82
  - Table of Dimensions
    83
    
    Rubber Track
    83
    
    Steel Track
    83
    
    Idler Sprocket
    84
    
    Carrier Rollers and Track Rollers
    84
- 4 Measuring Machine Performance
  
  85
  - Measuring Front Performance
    85
    
    Measuring Swivel Gear Backlash
    85
    
    Measuring Swivel Bearing Play
    86
  - Swivel Gear Backlash Performance
    87
  - Engine
    88
    
    General
    89
    
    Dimensions ............................................2-G2
    89
    
    Specifications
    90
    
    Performance Curves
    92
    
    Fan Drive
    93
  - Hydraulic System
    94
Mechanism

95
- Shockless Valves........................... 3-M52
  96
- 1 Diagram of Hydraulic Circuit
  
  97
  - Diagram of Hydraulic Circuit (Kx080-4 Standard Specification)
    97
  - Diagram of Hydraulic Circuit (Kx080-4 Angle Blade Specification)
    98
- 2 Hydraulic Device Layout
  
  99
- 3 Pump
  
  100
  - Specifications
    100
  - Pist Pump Horsepower Control Curve
    101
    
    P3 = at no Load (2 Mpa)
    101
    
    P3 = 20.6 Mpa
    101
  - Function and Structure
    102
    
    Operating Principles
    102
    
    Horsepower Control
    103
    
    Flow Control (LS Control)
    104
    
    Gain Control
    107
    
    Standby Flow Amount
    107
- 4 Control Valve
  
  108
  - Specifications
    108
  - Function and Structure
    111
    
    Unload Valve Section
    111
    
    Mono-Block Section Operation (LS Control)
    114
    
    Arm Regenerative Function
    116
    
    Swing Section Operation (LS Control)
    117
    
    Travel Section Operation (Open Center Control)
    118
    
    Blade Section Operation (Open Center Control)
    120
    
    Anti-Drift Function
    121
    
    P3 Bypass Section Operation (Simultaneous Boom up + Swivel Operation)
    122
    
    Signal Circuit
    123
- 5 Swivel Motor
  
  125
  - Specifications
    125
  - Function and Structure
    126
    
    Operating Principles
    126
- 6 Travel Motor
  
  130
  - Specifications
    130
  - Function and Structure
    131
    
    Operating Principles
    131
- 7 Hydraulic Cylinder
  
  135
  - Specifications
    135
  - Function and Structure
    136
    
    Operating Principles
    136
- 8 Pilot Valve
  
  138
  - Control Pilot Valves
    138
    
    Specifications
    138
    
    Function and Structure
    139
  - Travel Pilot Valve
    140
    
    Specifications
    140
    
    Function and Structure
    141
  - Swing Pilot Valve
    143
    
    Specifications
    143
    
    Function and Structure
    144
  - Blade Pilot Valves
    145
    
    Specifications
    148
    
    Function and Structure
    148
- 10 Solenoid Valve
  
  150
  - Specifications
    150
  - Unload Valve
    150
    
    Function and Structure
    151
  - Aux Solenoid Valve
    153
    
    Specifications
    153
    
    Function and Structure
    154
  - Angle Solenoid Valve
    155
    
    Specifications
    155
  - Ep Mode Solenoid Valve
    156
    
    Specifications
    156
Servicing

157
- 1 Pump
  
  160
  - Pump Disassembly / Assembly
    160
  - Pump Disassembly Procedures
    163
    
    Disassembly Procedures
    166
    
    Assembly Procedures
    171
- 2 Control Valve
  
  176
  - Control Valve Removal
    176
  - Control Valve Assembly/Disassembly
    178
- 3 Swivel Motor
  
  185
  - Swivel Motor Removal and Installation
    185
  - Swivel Motor Disassembly/Assembly Procedures
    187
    
    Disassembly Procedures
    189
    
    Assembly Procedures
    193
    
    Special Tools
    199
- 4 Swivel Joint
  
  200
  - Removal and Installation of the Swivel Joint
    200
  - Swivel Joint Disassembly / Assembly Procedures
    203
    
    Disassembly Procedures
    204
    
    Assembly Procedures
    206
- 5 Travel Motor
  
  208
  - Removal and Installation of the Travel Motor
    208
  - Travel Motor Disassembly / Assembly Procedures
    209
    
    Disassembly Procedures
    211
    
    Assembly Procedures
    218
    
    Special Tools
    226
- 6 Cylinder
  
  228
  - Tightening Torque
    228
- 7 Pilot Valve
  
  230
  - Control Pilot Valves
    230
    
    Disassembly
    231
    
    Assembly
    234
    
    Special Tools
    238
  - Travel Pilot Valve
    239
    
    Disassembly
    240
    
    Assembly
    244
    
    Special Tools
    248
  - Swing Pilot Valve
    248
    
    Disassembly
    249
    
    Assembly
    252
    
    Disassembly
    259
    
    Assembly
    261
  - Shockless Valves
    265
- 9 Swivel Shuttle Valve
  
  266
- 10 Solenoid Valve
  
  267
  - Unload Valve
    267
  - Aux Proportional Control Solenoid Valve
    268
  - Angle Solenoid Valve
    269
  - Ep Mode Solenoid Valve
    270
- 11 Routing of Hydraulic Hoses
  
  271
  - High-Pressure Hoses
    272
    
    Deliver Hose Routing
    272
    
    PLS Hose Routing
    275
    
    Front Hose Routing
    276
    
    Boom Hose Routing
    279
    
    Undercarriage Hose Routing
    280
    
    Angle Blade Hose Routing
    281
  - Low-Pressure Hoses
    282
    
    Suction Pipe and Hose Routing
    282
    
    Drain Hose Routing
    283
  - Pilot Hoses
    284
    
    Deliver Hose Routing
    284
    
    Port P Hose Routing
    285
    
    Port T Hose Routing
    286
    
    Ports P and T Pilot Valve Hose Routing
    287
    
    Pilot Valve Hose Routing
    289
- 12 Measuring Hydraulic Device Performance
  
  292
  - Piston Pump Air Bleeding Procedure
    292
  - Release of Pressure in the Hydraulic System
    293
  - Manual Boom Lowering Procedure
    294
  - Measuring the Flow Rate
    295
    
    Measuring Main Pump Flow
    295
    
    Measuring the AUX Proportional Settings
    297
    
    Measuring AUX Discharge Flow
    298
  - Measuring Pressure
    299
    
    Main Relief Valve Measuring Procedure
    299
    
    Measuring Pilot Secondary Pressure
    301
    
    Measuring EP Proportional Solenoid Pressure
    302
    
    Measuring the Overload Relief Valve Pressure
    303
    
    Pressure Measuring Kit
    305
    
    Adjusting Swivel Relief Valve Pressure
    306
    
    Adjust the LS Control Differential Pressure Adjusting Spring Force
    306
  - Measuring Swivel Performance
    307
    
    Measuring Swivel Motor Drain Volume
    307
    
    Measuring Swivel Block Performance
    308
    
    Measuring Swivel Speed
    309
  - Measuring Travel Performance
    310
    
    Measuring Travel Motor Drain Volume
    310
    
    Measuring Travel Block Performance
    311
    
    Measuring Travel Speed
    312
    
    Measuring Travel Drift
    312
  - Measuring Cylinder Speed
    313
    
    Measuring Hydraulic Cylinder Operating Time
    313
    
    Measuring Hydraulic Cylinder Drift
    315
    
    Measuring Swing Cylinder Deviation
    316
- 13 Hydraulic Device Performance Standards
  
  317
  - Flow Rate
    317
    
    Main Pump Discharge Flow Rate Data (Measured Values)
    317
    
    Flow Rate Data for AUX Proportional Control (Measured Values)
    319
    
    AUX Discharge Flow Rate Data (Measured Values)
    320
  - Relief Pressure (Measured Values)
    321
  - Swivel Performance
    322
  - Travel Performance
    322
  - Cylinder Speed
    323
- 14 Troubleshooting
  
  324
  - Troubleshooting All Actuators
    324
  - Troubleshooting Front Systems
    324
  - Electrical System
    329
Servicing

330
- Contents
  330
- Inspections......................................... 4-S44
  330
- 1 Layout of Electrical Devices and Wiring Routing
  
  332
- 2 Meter Panel Operation
  
  341
  - Names and Functions of Meters
    341
  - User Settings Mode
    341
    
    Log Record
    342
    
    Periodic Check
    342
    
    Set Clock
    343
    
    Set AUX Flow Ctrl
    343
    
    Various Settings
    344
    
    Language Setting
    344
  - Service Dealer Setting
    344
    
    Crane Mode
    344
    
    Arm Control Mode (Only on Japan Spec.)
    344
  - Service/Dealer Mode
    345
    
    Diagnosis
    347
    
    Setting
    352
  - Settings When Replacing Electronic Devices
    365
    
    When Replacing the Meter or Main ECU
    365
    
    When the Battery Is Removed
    365
  - Table of Meter Panel Messages and Error History List
    366
    
    Red Warning Lamp Lit
    366
    
    Yellow Warning Lamp Lit
    368
    
    Other Screens
    369
    
    PM Clog Level and the State of the Machine
    371
    
    Table of Engine System Error Numbers
    374
  - Power and Ground
    375
  - Starting and Stopping Device
    378
  - Relay Layout
    379
- 4 Troubleshooting (Start-Up Equipment Version)
  
  381
- 5 Methods for Diagnosing Errors
  
  382
  - Guide to Diagnosing Errors
    382
  - Error Diagnosis Procedure
    382
  - Testing with a Circuit Tester
    383
- 6 Troubleshooting (Meter Panel Version)
  
  384
  - Machine Related System
    384
    
    Engine Oil Pressure Errors
    384
    
    Charging System Errors
    387
    
    Fuel Sensor Errors
    391
  - Front-End Systems
    394
    
    Lever Lock System Errors
    394
    
    Travel 2-Speed System Error
    398
    
    Angle System Errors
    402
  - Auto Idling (Ai) System
    405
    
    AI System Errors
    405
    
    Testing the AI Pressure Switch
    408
  - Testing the AI Switch
    411
  - Anti-Theft (At) System
    414
    
    Anti-Theft System Errors
    414
  - Power Supply System
    417
    
    Over Voltage
    417
    
    Short System Error
    418
  - Communication System
    419
    
    CAN Communication Errors
    419
  - Aux System
    425
    
    AUX1 / AUX2 (Thumb) System Errors
    425
  - Eco Mode System
    431
    
    EP System Errors
    431
  - Cabin
    436
Mechanism

437
- 1 Air Conditioning System
  
  438
  - Structure
    438
  - How the Mechanisms of the System Work
    439
  - Compressor
    440
  - Air Conditioning Unit
    443
  - Condenser
    448
  - Receiver
    449
  - Pressure Switch
    450
  - Electrical System
    451
    
    Electrical Circuits
    451
    
    Relays
    452
    
    Blower Switch
    453
- 2 Wiper
  
  454
  - Wiper Switch
    454
  - Wiper Motor
    455
Servicing

456
- 1 Troubleshooting
  
  458
- 2 Service Specifications
  
  461
- 3 Torque
  
  462
- 4 Precautions When Repairing the Refrigerant System
  
  463
  - Use of Service Tools
    463
    
    Manifold Gauge Set
    463
  - Refrigerant Charging Hoses
    465
  - Vacuum Pump Adapter
    466
  - Electric Gas Leak Tester
    466
  - Canister Tap Valve
    466
  - T-Joint
    467
  - R134A Refrigerant Collection/Recycling Device
    467
- 5 Inspecting and Charging the Refrigerant System
  
  468
  - Checking the System with a Manifold Gauge
    468
  - Collection, Vacuuming and Charging
    472
    
    Collecting Refrigerant
    472
    
    Vacuuming out the System
    472
    
    Charging from the High-Pressure Side
    474
    
    Charging from the Low-Pressure Side
    474
    
    Inspections and Troubleshooting
    475
- 6 Inspection and Disassembly
  
  477
  - Checks and Adjustments
    477
    
    Compressor
    477
  - Relays
    479
  - Blower Motor
    481
  - Blower Resistor
    482
  - Blower Switch
    483
  - Servo Motor (for Temp Control)
    484
  - Pressure Switch
    485
  - Disassembly and Assembly
    486
    
    AC Unit Assembly/Disassembly
    486
    
    Mounting and Removing the Compressor
    487
    
    AC and Heater Hose Routing
    489
    
    Electric Condenser/Fan Mounting and Removal
    491
- 7 Window Washer
  
  493
  - Wiper Switch
    493
  - Washer Motor
    494
  - Wiper Motor
    494
  - Cabin Glass Removal and Mounting
    495
    
    Component Schematic
    495
  - Necessary Tools
    499
  - Removing the Glass on the Right
    500
  - Removing the Front Glass
    501
  - Installing the Glass on the Right
    503
  - Removing Other Panes of Glass
    503
  - Installing the Front Glass
    505
  - Installing Other Panes of Glass
    508
- 9 Removal and Installation of Glass
  
  509
  - Preparation
    509
  - Removing Glass
    509
  - Installing Glass
    510
  - Glass Trim Type
    511
  - How to Replace the Glass of the Right-Side Window
    511
- 10 Front Window
  
  514
  - Adjusting the Closing Lock of the Front Window (Top)
    514
  - Adjusting the Open Lock of the Front Window (Top)
    515

Kubota KX080-4 Manuals

Kubota KX080-4 Workshop Manual (519 pages)

Table of Contents

Workshop Manual Kubota Excavator

Information

1 Safety First

2 In the Interest of Work Safety

3 Labels Displayed to Promote Work Safety

4 Main Specifications

5 Dimensions

General

1 Checking Excavator Identification

2 Engine Identification

3 Muffler Full Assembly Identification

4 General Precautions

5 Handling Precautions for Electrical Parts and Wiring

6 Tightening Torques

7 Oil and Water Capacity Table

8 Maintenance Intervals

Servicing

1 Front

2 Swivel Frame

3 Track Frame

4 Measuring Machine Performance

Mechanism

1 Diagram of Hydraulic Circuit

2 Hydraulic Device Layout

3 Pump

4 Control Valve

5 Swivel Motor

6 Travel Motor

7 Hydraulic Cylinder

8 Pilot Valve

10 Solenoid Valve

Servicing

1 Pump

2 Control Valve

3 Swivel Motor

4 Swivel Joint

5 Travel Motor

6 Cylinder

7 Pilot Valve

9 Swivel Shuttle Valve

10 Solenoid Valve

11 Routing of Hydraulic Hoses

12 Measuring Hydraulic Device Performance

13 Hydraulic Device Performance Standards

14 Troubleshooting

Servicing

1 Layout of Electrical Devices and Wiring Routing

2 Meter Panel Operation

4 Troubleshooting (Start-Up Equipment Version)

5 Methods for Diagnosing Errors

6 Troubleshooting (Meter Panel Version)

Mechanism

1 Air Conditioning System

2 Wiper

Servicing

1 Troubleshooting

2 Service Specifications

3 Torque

4 Precautions When Repairing the Refrigerant System

5 Inspecting and Charging the Refrigerant System

6 Inspection and Disassembly

7 Window Washer

9 Removal and Installation of Glass

10 Front Window

Kubota KX080-4 Operator's Manual (138 pages)

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