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SHOP MANUAL

WEBM008601

PC80MR -3 HYDRAULIC EXCAVATOR

SERIAL NUMBER

PC80MR -3 F00003 and up

CONTENTS

CONTENTS Page

10. STRUCTURE AND FUNCTION................................................................................ 10-1 20. TESTING AND ADJUSTING .................................................................................... 20-1 30. DISASSEMBLY AND ASSEMBLY .......................................................................... 30-1 90. OTHER...................................................................................................................... 90-1

PC80MR-3

00-1 (1)

PAGE INTENTIONALLY LEFT BLANK

REVISED PAGES

REVISED PAGES The affected pages are indicated by the use of the following marks. It is requested that necessary actions be taken to these pages according to table below.

Mark

Indication

Action required

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Add

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Replace

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Discard

Pages having no marks are those previously revised or made additions. Mark

Page q 00-1 q 00-2 q 00-3 q 00-4 00-5 00-6 00-7 00-8 00-9 00-10 00-11 00-12 00-13 00-14 00-15 00-16 00-17 00-18 00-19 00-20 00-21 00-22 00-23 00-24

Time Mark of rev. (1) (1) (1) (1)

q 10-1 q 10-2 10-3 10-4 10-5 10-6 10-7 10-8 10-9 10-10 10-11 10-12 10-13 10-14 10-15 10-16 10-17 10-18 10-19 10-20 10-21 10-22 10-23 10-24 10-25 10-26 10-27 Q 10-27-1 (1) Q 10-27-2 (1)

PC80MR-3

Page

Time Mark of rev.

Q 10-27-3 (1) Q 10-27-4 (1) Q 10-27-5 (1) Q 10-27-6 (1) Q 10-27-7 (1) Q 10-27-8 (1) Q 10-27-9 (1) Q 10-27-10 (1) Q 10-27-11 (1) Q 10-27-12 (1) Q 10-27-13 (1) Q 10-27-14 (1) Q 10-27-15 (1) Q 10-27-16 (1) Q 10-27-17 (1) Q 10-27-18 (1) Q 10-27-19 (1) Q 10-27-20 (1) Q 10-27-21 (1) Q 10-27-22 (1) Q 10-27-23 (1) Q 10-27-24 (1) Q 10-27-25 (1) Q 10-27-26 (1) Q 10-27-27 (1) Q 10-27-28 (1) Q 10-27-29 (1) Q 10-27-30 (1) 10-28 10-29 10-30 10-31 10-32 10-33 10-34 10-35 10-36 10-37 10-38 10-39 10-40 10-41 10-42 10-43 10-44 10-45 10-46 10-47 10-48 10-49 10-50 10-51 10-52

Page Q 20-1 Q 20-2 Q 20-3 Q 20-4 Q 20-5 Q 20-6 Q 20-7 Q 20-8 Q 20-9 Q 20-10 Q 20-11 Q 20-12 Q 20-13 Q 20-14 Q 20-15 Q 20-16 Q 20-17 Q 20-18 Q 20-19 Q 20-20 Q 20-21 Q 20-22 Q 20-23 Q 20-24 Q 20-25 Q 20-26 Q 20-27 Q 20-28 Q 20-29 Q 20-30 Q 20-31 Q 20-32 Q 20-33 Q 20-34 Q 20-35 Q 20-36 Q 20-37 Q 20-38 Q 20-39 Q 20-40 Q 20-41 Q 20-42 Q 20-43 Q 20-44 Q 20-45 Q 20-46 Q 20-47 Q 20-48 Q 20-49 Q 20-50 Q 20-51 Q 20-52 Q 20-53 Q 20-54

Time Mark of rev. (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1)

Page

Time Mark of rev.

Q 20-55 Q 20-56 Q 20-57 Q 20-58 Q 20-59 Q 20-60 Q 20-61 Q 20-62 Q 20-63 Q 20-64 Q 20-65 Q 20-66

(1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1)

Q 30-1 Q 30-2 Q 30-3 Q 30-4 Q 30-5 Q 30-6 Q 30-7 Q 30-8 Q 30-9 Q 30-10 Q 30-11 Q 30-12 Q 30-13 Q 30-14 Q 30-15 Q 30-16 Q 30-17 Q 30-18 Q 30-19 Q 30-20 Q 30-21 Q 30-22 Q 30-23 Q 30-24 Q 30-25 Q 30-26 Q 30-27 Q 30-28 Q 30-29 Q 30-30 Q 30-31 Q 30-32 Q 30-33 Q 30-34 Q 30-35 Q 30-36 Q 30-37 Q 30-38 Q 30-39 Q 30-40 Q 30-41

(1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1)

Page Q 30-42 Q 30-43 Q 30-44 Q 30-45 Q 30-46 Q 30-47 Q 30-48 Q 30-49 Q 30-50 Q 30-51 Q 30-52 Q 30-53 Q 30-54 Q 30-55 Q 30-56 Q 30-57 Q 30-58 Q 30-59 Q 30-60 Q 30-61 Q 30-62 Q 30-63 Q 30-64 Q 30-65 Q 30-66 Q 30-67 Q 30-68 Q 30-69 Q 30-70 Q 30-71 Q 30-72 Q 30-73 Q 30-74 Q 30-75 Q 30-76 Q 30-77 Q 30-78 Q 30-79 Q 30-80 Q 30-81 Q 30-82 Q 30-83 Q 30-84 Q 30-85 Q 30-86 Q 30-87 Q 30-88 Q 30-89 Q 30-90 Q 30-91 Q 30-92 Q 30-93 Q 30-94 Q 30-95

Time of rev. (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1)

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REVISED PAGES

Mark

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(1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1)

90-1 90-2 90-3 90-4 90-5 90-6

00-4 (1)

PC80MR-3

k SAFETY

k IMPORTANT SAFETY NOTICE Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques recommended by Komatsu and describe in this manual are both effective and safe methods of operation. Some of these operations require the use of tools specially designed by Komatsu for the purpose. To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be carefully followed. If any danger arises or may possibly arise, first consider safety, and take necessary steps to face.

k SAFETY GENERAL PRECAUTIONS Mistakes in operation extremely dangerous. Read all the Operation and Maintenance Manual carefully BEFORE operating the machine.

PREPARATIONS FOR WORK 7. Before adding or making any repairs, park the machine on hard, level ground, and block the tracks to prevent the machine from moving.

1. Before carrying out any greasing or repairs, read all the precautions written on the decals which are suck on the machine.

8. Before starting work, lower outrigger, bucket or any other work equipment to the ground. If this is not possible, use blocks to prevent the work equipment from falling down. In addition, be sure to lock all the control levers and hang warning sign on them.

2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. • Always wear safety glasses when hitting parts with a hammer. • Always wear safety glasses when grinding parts with a grinder, etc. 3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work. 4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator’s compartment. 5. Keep all tools in good condition and learn the correct way to use them. 6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.

PC80MR-3

9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work. 10. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.

PRECAUTIONS DURING WORK 11. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the hydraulic circuit and engine cooling circuit, first remove the pressure completely from the circuit. 12. The water and oil in the circuits are not hot when the engine in stopped, so be careful not to get burned. Wait for the oil water to cool before carrying out any work on the cooling water circuits. 13. Before starting work, remove the leads from the battery. Always remove the lead from the negative ( – ) terminal first.

00-5

k SAFETY

14. When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 15. When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove. 16. When removing components, be careful not to break or damage the wiring. Damage wiring may cause electrical fires. 17. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires. 18. As a general rule, do not use gasoline to wash parts. In particular, use only the minimum of gasoline when washing electrical parts.

00-6

19. Be sure to assemble all parts again in their original places. Replace any damage parts with new parts. When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being operated. 20. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. Also, check that connecting parts are correctly tightened. 21. When assembling or installing parts, always use specified tightening torques. When installing the parts which vibrate violently or rotate at high speed, be particulary careful to check that they are correctly installed. 22. When aligning two holes, never insert your fingers or hand. 23. When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurement. 24. Take sure when removing or installing tracks. When removing tha track, the track separately suddenly, so never let anyone stand at either end of the track.

PC80MR-3

FOREWORD

FOREWORD This shop manual has been prepared as an aid to improve the quality of repairs by giving the operator an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This shop manual mainly contains the necessary technical information for operations performed in a service workshop. The manual is divided into chapters on each main group of components; these chapters are further divided into the following sections. STRUCTURE AND FUNCTION This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. TESTING AND ADJUSTMENTS This sections explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating «Problems» to «Causes» are also included in this section. REMOVAL AND INSTALLATION This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.

NOTE The specifications contained in this shop manual are subject to change at any time and without any notice. Contact your Komatsu distributor for the latest information.

PC80MR-3

00-7

HOW TO READ THE SHOP MANUAL

HOW TO READ THE SHOP MANUAL VOLUMES Shop manual are issued as a guide to carry out repairs. These various volumes are designed to avoid duplicating the same information.

SYMBOLS In order to make the shop manual greatly chelpful, important points about safety and quality are marked with the following symbols.

DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be sent to Komatsu distributors. Get the most up-to-date information before you start any work.

Symbol

FILING METHOD

Item

Special safety precautions are necessary when performing the work. Safety

1. See the page number on the bottom of the page. File the pages in correct order. 2. Following examples show you how to read the page number. Example:

Consecutive page number for each item

3. Additional pages: additional pages are indicated by a hyphen (–) and number after the page number. Fle as in the example. Example:

10-4 10-4-1

Caution

Weight

Weight of parts or systems. Caution necessary when selecting hoisting wire, or when working posture is important, etc.

Parts that require special attention for the tightening torque dur3 Tightening torque ing assembly.

2 5

Added pages

10-4-2 10-5

Extra special safety precautions are necessary when performing the work because it is under internal pressure. Special technical precautions or other precautions for preserving standards are necessary when performing the work.

10 - 3 Item number (10. Structure and Function)

Remarks

Coat

Parts to be coated with adhesives and lubricants etc.

Places where oil, water or fuel Oil, water must be added, and their quantity. Drain

Places where oil or water must be drained, and quantity to be drained.

REVISED EDITION MARK When a manual is revised, an edition mark is recorded on the bottom outside corner of the pages. REVISIONS Revised pages are shown on the LIST OF REVISED PAGES between the title page and SAFETY page.

00-8

PC80MR-3

HOISTING INSTRUCTIONS

Hooks have maximum strength at the middle portion.

k Heavy parts (25 kg or more) must be lifted with a hoist etc. In the Disassembly and Assembly section, every part weighing 25 kg or more is clearly indicated with the symbol 4

1. If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: • Check for removal of all bolts fastening the part to the relative parts. • Check for any part causing interference with the part to be removed.

Wire ropes 1) Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below: WIRE ROPES (Standard «S» or «Z» twist ropes without galvanizing) Rope diameter (mm)

Allowable load (tons)

10.0

1.0

11.2

1.4

12.5

1.6

14.0

2.2

16.0

2.8

18.0

3.6

20.0

4.4

22.4

5.6

30.0

10.0

40.0

18.0

50.0

28.0

60.0

40.0

3) Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound on to the load. k Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can cause dangerous accidents. 4)

Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load (kg) when hoisting is made with two ropes, each of which is allowed to sling up to 1000 kg vertically, at various handing angles. When two ropes sling a load vertically, up to 2000 kg of total weight can be suspended. This weight becomes 1000 kg when two ropes make a 120° hanging angle. On the other hand, two ropes are subjected to an excessive force as large as 4000 kg if they sling a 2000 kg load at a lifting angle of 150°.

The allowable load value is estimated to be onesixth or one-seventh of the breaking strength of the rope used. 2)

Sling wire ropes from the middle portion of the hook. Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result.

PC80MR-3

00-9

STANDARD TIGHTENING TORQUE

The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in section of «Disassembly and Assembly».

STANDARD TIGHTENING TORQUE OF BOLTS AND NUT Width across flat (mm)

Thread diameter of bolts (mm)

Pitch of bolts (mm)

1.25

kgm

0.96±0.1

9.5±1

1.3±0.15

13.5±1.5

2.3±0.2

23±2

3.2±0.3

32.2±3.5

1.5

4.6±0.5

45±4.9

6.5±0.6

63±6.5

1.75

7.8±0.8

77±8

11±1

108±11

12.5±1

122±13

17.5±2

172±18

19.5±2

191±21

27±3

268±29

2.5

27±3

262±28

37±4

366±36

2.5

38±4

372±40

53±6

524±57

2.5

52±6

511±57

73±8

719±80

66±7

644±70

92±10

905±98

96±10

945±100

135±15

1329±140

3.5

131±14

1287±140

184±20

1810±190

3.5

177±20

1740±200

250±27

2455±270

230±25

2250±250

320±35

3150±350

----

295±33

2900±330

410±45

4050±450

This torque table does not apply to bolts or nuts which have to fasten nylon or other parts non-ferrous metal washer.

a Nm (newton meter): 1 Nm = 0.102 kgm

00-10

PC80MR-3

STANDARD TIGHTENING TORQUE

TIGHTENING TORQUE FOR NUTS OF FLARED

Use these torques for nut part of flared. Thread diameter of nut part (mm)

Width across flats of nut part (mm)

TIGHTENING TORQUE kgm

1/2” - 20

2.6±0.5

25.5±4.9

9/16” - 18

4±0.5

39.2±4.9

3/4” - 16

6.7±2

65.7±19.6

7/8” - 14

8±2

78.5±19.6

1.1/16 - 12

9.7±3

95.15±29.4

1.5/16 - 12

17±3

166.7±29.4

1.5/8 - 12

20±5

196.2±49

8±2

78.5±19.6

20±5

196.2±49

Sealing surface

Thread diameter of nut part (mm)

Width across flats of nut part (mm)

kgm

9/16” - 18

2.3–2.5

23–25

11/16” - 16

3.4–3.9

33–38

13/16” - 16

5.2–5.8

51–57

1” - 14

8.2–9.2

80–90

1.3/16 - 12

12.2–13.3

120–130

1.7/16 - 12

15.3–17.3

150–170

1.11/16 - 12

18.4–20.4

180–200

2” - 12

20.4–24.4

200–240

PC80MR-3

TIGHTENING TORQUE

00-11

COATING MATERIALS

2 COATING MATERIALS

The recommended coating materials prescribed in Komatsu Shop Manuals are listed below: Nomenclature

Code

Applications

ASL800010 Used to apply rubber pads, rubber gaskets and cork plugs.

Adhesives

Gasket sealant

ASL800020

Used to apply resin, rubber, metallic and non-metallic parts when a fast, strong seal is needed.

Loctite 222

Used for low resistance locking of screws, check nuts and adjustment nuts.

Loctite 242

To prevent the loosening of bolts, nuts and plugs and the leakage of oil. Used for medium resistance locking of screws and nuts of every type, and for locking keys and bearings.

Loctite 262

Used for high resistant of threaded parts that can be removed with normal tools.

Loctite 270

Used for high resistant locking and for sealing threaded parts, bolts and stud bolts.

Loctite 542

Used for sealing the union threads for hydraulic tubes.

Loctite 573

Used for sealing rather exact plane surfaces when the option of possible future dismantling is required.

Loctite 601

Used for high resistant locking of mechanical components that can be removed only after heating

Loctite 675

Used to lock cylindrical couplings and for the permanent locking of threaded parts, and also to lock shafts to bearings, gears, pulleys, pins, bushings, etc.

ASL800060

Used by itself to seal grease fittings, tapered screw fittings and tapered screw fittings in hydraulic circuits of less than 50 mm in diameter.

Loctite 510

Used by itself on mounting flat surface (Clearance between surfaces within 0.2 mm)

Loctite 518

Used by itself on mounting flat surface (Clearance between surfaces within 0.5 mm

Antifriction compound Applied to bearings and taper shaft to facilitate press-fitting and to prevent (Lubricant including ASL800040 sticking, burning or rusting. Molybdenum disulfide) Grease (Lithium grease) Vaseline

00-12

ASL800050

-----

Applied to bearings, sliding parts and oil seals for lubrication, rust prevention and facilitation of assembling work. Used for protecting battery electrode terminals from corrosion

PC80MR-3

ELECTRIC

In the wiring diagrams various colour and symbols are employed to indicate the thickness of wires. This wire code table will help you understand WIRING DIAGRAMS. Example: R–N 1.5 indicates a cable having a nominal number 1.5 and red coating with black stripe.

CLASSIFICATION BY THICKNESS Nominal number

Copper wire Ø of strands (mm) 0.20 0.30 0.30 0.30 0.30 0.30 0.40 0.40

Number strands 16 14 21 35 56 84 84 399

0.5 1 1.5 2.5 4 6 10 50

Cross section (mm) 0.35 0.99 1.48 2.47 3.95 5.93 10.55 50.11

Cable O.D. (mm)

Current rating (A)

1.55 2.80 3.35 3.80 4.60 5.20 7.10 14

3.5 11 14 20 28 37 53 160

CLASSIFICATION BY COLOUR AND CODE Primary Code Colour

Auxiliary A–B

A/B

A–G

–

A–N

A/N

Light Blue Light Blue – White Light Blue–Yellow Light Blue–Black

Code

Colour

White

Code

Colour

Orange

Code

Colour

Yellow

B–G

–

B–N

B/N

B–R

B/R

White–Black

White–Red

White–Green

C–N

–

Orange–White

Orange–Blue

G–N

G–R

G/N

–

Yellow–Black

Yellow–Red

H–L

H–N

–

H/N

–

Orange–Black G–V

–

Code

Colour

Blue

Blue–White

Blue–Yellow

Blue–Black

Code

M–B

M–N

M–V

Colour

Brown

Grey–Blue

Grey–Black

L–B

L–G

L/B –

– M/N

Brown–White

Brown–Black

–

– –

–

– –

L/N – –

R–G

Red

Red–Yellow

Red–Black

Red–Green

Code

S–G

S–N

–

Colour

Pink

Pink–Yellow

Pink–Black

Code

V–B

V–N

Colour

Green

Code

Colour

Violet

– V/N

Green–White

Green–Black

Z–B

Z–N

Z/B

Violet–White

Z/N

Violet–Black

R–V

– –

–

– –

–

– – – –

– –

–

– –

–

– –

–

– –

–

– –

–

– –

–

Colour

–

R/N

–

– –

–

Brown–Green –

– –

–

– –

A/V

–

Code

–

R–N

–

– –

–

A–V

Light Blue–Green

–

Yellow–Green

B/V

C–L

C/B

Grey

Black

–

White–Yellow

Colour

A/R

C–B

Code

A–R

Light Blue–Red

–

– –

COMPOSITION OF THE COLOURS The coloration of two-colour wires is indicated by the composition of the symbol listed. Example: G–V = Yellow-Green with longitudinal colouring G/V = Yellow-Green with transversal colouring PC80MR-3

00-13

WEIGHT TABLE

k This weight table is a guide for use when transporting or handling components. Unit: kg Machine model

PC80MR-3

Engine group (without coolant and oil) Radiator group Hydraulic oil tank (empty) Fuel tank (empty) Revolving frame Counterweight Swing circle Swing machinery Swing motor Pump group Cab Seat Control valve Track frame, assy. (without tracks) • Idler • Idler cushion • Track roller • Final drive • Sprocket • Carrier roller Track, assy (L= 450 mm) Rubber shoe Track, assy (L= 600 mm) Track, assy (Road liner) Swivel joint Boom swing support 1-piece boom 1st boom 2nd boom Arm (L= 1650 mm) Arm (L= 1900 mm) Arm (L= 2250 mm) Blade, assy

00-14

PC80MR-3

TABLE OF OIL AND COOLANT QUANTITIES

TANK / RESERVOIR

CAPACITY’(l)

AMBIENT TEMPERATURE FLUID

-30 -22

-20 -4

-10 14

0 32

10 50

20 68

30 86

40 50°C 104 122°F

1st filling.

Change.

9.8

9.4

2.7

1.3

110

—

SAE 30

Engine oil pan

SAE 10W

OIL API CD

SAE 10W-30 SAE 15W-40 Travel reduction gear Final drive

OIL SAE 85W-90

API GL5

SAE 10W Hydraulic system

OIL

SAE 10W-30

API CD

SAE 15W-40

Hydraulic system with biodegradable oil

Fuel tank

DIESEL OIL

a ASTM D975 N. 2

Engine cooling system

PERMANENT COOLANT

(aa)

Articulation greasing Pinion/ball-bearing ring greasing

Lithium EP+MoS2 (NLGI 2) GREASE

Lithium EP (NLGI 2)

ASTM D975 N. 1

aaSpecial permanent antifreeze, biodegradable, ethylene glycol based with corrosion inhibitor and withno silicates, borates, nitrates, phosphates and amines.Red antifreeze suitable for aluminium radiators, diluted with water (50%) to ensure protection down to-36°C.

PC80MR-3

00-15

TABLE OF OIL AND COOLANT QUANTITIES

ASTM: America Society of Testing and Materials SAE: Society of Automotive Engineers API: American Petroleum Institute MIL: Military Specification CCMC: Common Market Constructors Committe First filling quantity: total quantity of oil, including the oil for the components and pipes. Oil change quantity: quantity of oil necessary to fill the system or unit during the normal inspection and maintenance operations. NOTE:

(1) When the diesel oil sulphur content is less then 0.5%, change the engine oil according to the periodic maintenance intervals indicated in the operation and maintenance manual. In the diesel oil sulphur content exceeds 0.5% change the engine oil according to the following table: Sulphur content from 0.5 to 1.0% over 1.0%

Engine oil change interval 1/2 of regular interval 1/4 of regular interval

(2) When starting the engine at temperatures below 0 °C, use engine oil SAE 10W, 20W-20, even if during the day the temperature increases by 10 °C. (3) Use engine oil with CD classification; if oil with CC classification is used, reduce the engine oil change interval by a half. (4) Use original products, which have characteristics specifically formulated and approved for the engine, the hydraulic circuit of equipment and for reductions.

00-16

PC80MR-3

CONVERSION TABLE

CONVERSION TABLE METHOD OF USING THE CONVERSION TABLE The conversion table in this section is provided to enable simple conversion of figures. For details of the method of using the conversion table, see the example given below. EXAMPLE • Method of using the conversion table to convert from millimeters to inches. 1.

Convert 55 mm into inches. 1 - Locate the number 50 in the vertical column at the left side, take this as A , then drow a horizontal line from

A. 2 - Locate the number 5 in the row across the top, take this as , then draw a perpendicular line down from B . 3 - Take the point where the two lines cross as C . This point C gives the value when converting from millimeters to inches. Therefore, 55 mm =2.165 in. 2.

Convert 550 mm into inches 1 - The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the left) to convert it to 55 mm. 2 - Carry out the same procedure as above to convert 55 mm to 2.165 in. 3 - The original value (550 mm) was divided by 10, so multiply 2.165 in. by 10 (move the decimal point one place to the right) to return to the original value. This gives 550 mm = 21.65 in.

From millimeters to inches

1 mm = 0.03937 in.

0.039

0.079

0.118

0.157

0.197

0.236

0.276

0.315

0.354

0.394

0.433

0.472

0.512

0.551

0.591

0.630

0.669

0.709

0.748

0.787

0.827

0.866

0.906

0.945

0.984

1.024

1.063

1.102

1.142

1.181

1.220

1.260

1.299

1.339

1.378

1.417

1.457

1.496

1.536

1.575

1.614

1.654

1.693

1.732

1.772

1.811

1.850

1.890

1.929

C A

1.969

2.008

2.047

2.087

2.126

2.165

2.205

2.244

2.283

2.323

2.362

2.402

2.441

2.480

2.520

2.559

2.598

2.638

2.677

2.717

2.756

2.795

2.835

2.874

2.913

2.953

2.992

3.032

3.071

3.110

3.150

3.189

3.228

3.268

3.307

3.346

3.386

3.425

3.465

3.504

3.543

3.583

3.622

3.661

3.701

3.740

3.780

3.819

3.858

3.898

PC80MR-3

00-17

CONVERSION TABLE

From mm to in. 1 mm = 0.03937 in. 0

0.039

0.079

0.118

0.157

0.197

0.236

0.276

0.315

0.354

0.394

0.433

0.472

0.512

0.551

0.591

0.630

0.669

0.709

0.748

0.787

0.827

0.866

0.906

0.945

0.984

1.024

1.063

1.102

1.142

1.181

1.220

1.260

1.299

1.339

1.378

1.417

1.457

1.496

1.536

1.575

1.614

1.654

1.693

1.732

1.772

1.811

1.850

1.890

1.929

1.969

2.008

2.047

2.087

2.126

2.165

2.205

2.244

2.283

2.323

2.362

2.402

2.441

2.480

2.520

2.559

2.598

2.638

2.677

2.717

2.756

2.795

2.835

2.874

2.913

2.953

2.992

3.032

3.071

3.110

3.150

3.189

3.228

3.268

3.307

3.346

3.386

3.425

3.465

3.504

3.543

3.583

3.622

3.661

3.701

3.740

3.780

3.819

3.858

3.898

From kg to lb. 1 kg = 2.2046 lb. 0

2.20

4.41

6.61

8.82

11.02

13.23

15.43

17.64

19.84

22.05

24.25

26.46

28.66

30.86

33.07

35.27

37.48

39.68

41.89

44.09

46.30

48.50

50.71

51.91

55.12

57.32

59.53

61.73

63.93

66.14

68.34

70.55

72.75

74.96

77.16

79.37

81.57

83.78

85.98

88.18

90.39

92.59

94.80

97.00

99.21

101.41

103.62

105.82

108.03

110.23

112.44

114.64

116.85

119.05

121.24

123.46

125.66

127.87

130.07

132.28

134.48

136.69

138.89

141.10

143.30

145.51

147.71

149.91

152.12

154.32

156.53

158.73

160.94

163.14

165.35

167.55

169.76

171.96

174.17

176.37

178.57

180.78

182.98

185.19

187.39

189.60

191.80

194.01

196.21

198.42

200.62

202.83

205.03

207.24

209.44

211.64

213.85

216.05

218.26

00-18

PC80MR-3

CONVERSION TABLE

From liter to U.S. Gall. 0

1 ᐉ = 0.2642 U.S. Gall. 1

0.264

0.528

0.793

1.057

1.321

1.585

1.849

2.113

2.378

2.642

2.906

3.170

3.434

3.698

3.963

4.227

4.491

4.755

5.019

5.283

5.548

5.812

6.076

6.340

6.604

6.869

7.133

7.397

7.661

7.925

8.189

8.454

8.718

8.982

9.246

9.510

9.774

10.039

10.303

10.567

10.831

11.095

11.359

11.624

11.888

12.152

12.416

12.680

12.944

13.209

13.473

13.737

14.001

14.265

14.529

14.795

15.058

15.322

15.586

15.850

16.115

16.379

16.643

16.907

17.171

17.435

17.700

17.964

18.228

18.492

18.756

19.020

19.285

19.549

19.813

20.077

20.341

20.605

20.870

21.134

21.398

21.662

21.926

22.190

22.455

22.719

22.983

23.247

23.511

23.775

24.040

24.304

24.568

24.832

25.096

25.361

25.625

25.889

26.153

From liter to U.K. Gall. 0

1 ᐉ = 0.21997 U.K. Gall. 1

0.220

0.440

0.660

0.880

1.100

1.320

1.540

1.760

1.980

2.200

2.420

2.640

2.860

3.080

3.300

3.520

3.740

3.950

4.179

4.399

4.619

4.839

5.059

5.279

5.499

5.719

5.939

6.159

6.379

6.599

6.819

7.039

7.259

7.479

7.969

7.919

8.139

8.359

8.579

8.799

9.019

9.239

9.459

9.679

9.899

10.119

10.339

10.559

10.778

10.998

11.281

11.438

11.658

11.878

12.098

12.318

12.528

12.758

12.978

13.198

13.418

13.638

13.858

14.078

14.298

14.518

14.738

14.958

15.178

15.398

15.618

15.838

16.058

16.278

16.498

16.718

16.938

17.158

17.378

17.598

17.818

18.037

12.257

18.477

18.697

18.917

19.137

19.357

19.577

19.797

20.017

20.237

20.457

20.677

20.897

21.117

21.337

21.557

21.777

PC80MR-3

00-19

CONVERSION TABLE

From Nm to lb.ft. 1 Nm = 0.737 lb.ft. 0

0.737

1.474

2.211

2.948

3.685

4.422

5.159

5.896

6.633

7.370

8.107

8.844

9.581

10.318

11.055

11.792

12.529

13.266

14.003

14.740

15.477

16.214

16.951

17.688

18.425

19.162

19.899

20.636

21.373

22.110

22.847

23.584

24.321

25.058

25.795

26.532

27.269

28.006

28.743

29.480

30.217

30.954

31.691

32.428

33.165

33.902

34.639

35.376

36.113

36.850

37.587

38.324

39.061

39.798

40.535

41.272

42.009

42.746

43.483

44.220

44.957

45.694

46.431

47.168

47.905

48.642

49.379

50.116

50.853

51.590

52.327

53.064

53.801

54.538

55.275

56.012

56.749

57.486

58.223

58.960

59.697

60.434

61.171

61.908

82.645

63.382

64.119

64.856

65.593

66.330

67.067

67.804

68.541

69.278

70.015

70.752

71.489

72.226

72.963

100

73.700

74.437

75.174

75.911

76.648

77.385

78.122

78.859

79.596

80.333

110

81.070

81.807

82.544

83.281

84.018

84.755

85.492

86.229

86.966

87.703

120

88.440

89.177

89.914

90.651

91.388

92.125

92.862

93.599

94.336

95.073

130

95.810

96.547

97.284

98.021

98.758

99.495 100.232 100.969 101.706 102.443

140

103.180 103.917 104.654 105.391 106.128 106.865 107.602 108.339 109.076 109.813

150

110.550 111.287 112.024 112.761 113.498 114.235 114.972 115.709 116.446 117.183

160

117.920 118.657 119.394 120.131 120.868 121.605 122.342 123.079 123.816 124.553

170

125.290 126.027 126.764 127.501 128.238 128.975 129.712 130.449 131.186 131.923

180

132.660 133.397 134.134 134.871 135.608 136.345 137.082 137.819 138.556 139.293

190

140.030 140.767 141.504 142.241 142.978 143.715 144.452 145.189 145.926 146.663

00-20

PC80MR-3

CONVERSION TABLE

From Nm to kgm 1 Nm = 0.102 kgm 0

0.102

0.204

0.306

0.408

0.510

0.612

0.714

0.816

0.918

1.020

1.222

1.224

1.326

1.428

1.530

1.632

1.734

1.836

1.938

2.040

2.142

2.244

2.346

2.448

2.550

2.652

2.754

2.856

2.958

3.060

3.162

3.264

3.366

3.468

3.570

3.672

3.774

3.876

3.978

4.080

4.182

4.284

4.386

4.488

4.590

4.692

4.794

4.896

4.998

5.100

5.202

5.304

5.406

5.508

5.610

5.712

5.814

5.916

6.018

6.120

6.222

6.324

6.426

6.528

6.630

6.732

6.834

6.936

7.038

7.140

7.242

7.344

7.446

7.548

7.650

7.752

7.854

7.956

8.058

8.160

8.262

8.364

8.466

8.568

8.670

8.772

8.874

8.976

9.078

9.180

9.282

9.384

9.486

9.588

9.690

9.792

9.894

9.996

10.098

100

10.200

10.302

10.404

10.506

10.608

10.710

10.812

10.914

11.016

11.118

110

11.220

11.322

11.424

11.526

11.628

11.730

11.832

11.934

12.036

12.138

120

12.240

12.342

12.444

12.546

12.648

12.750

12.852

12.954

13.056

13.158

130

13.260

13.362

13.464

13.566

13.668

13.770

13.872

13.974

14.076

14.178

140

14.280

14.382

14.484

14.586

14.688

14.790

14.892

14.994

15.096

15.198

150

15.300

15.402

15.504

15.606

15.708

15.810

15.912

16.014

16.116

16.218

160

16.320

16.422

16.524

16.626

16.728

16.830

16.932

17.034

17.136

17.238

170

17.340

17.442

17.544

17.646

17.748

17.850

17.952

18.054

18.156

18.258

180

18.360

18.462

18.564

18.666

18.768

18.870

18.972

19.074

19.176

19.278

190

19.380

19.482

19.584

19.686

19.788

19.890

19.992

20.094

20.196

20.298

PC80MR-3

00-21

CONVERSION TABLE

From kgm to lb.ft. 1 kgm = 7.233 lb.ft. 0

7.2

14.5

21.7

28.9

36.2

43.4

50.6

57.9

65.1

72.3

79.6

86.8

94.0

101.3

108.5

115.7

123.0

130.2

137.4

144.7

151.9

159.1

166.4

173.6

180.8

188.1

195.3

202.5

209.8

217.0

224.2

231.5

238.7

245.9

253.2

260.4

267.6

274.9

282.1

289.3

296.6

303.8

311.0

318.3

325.5

332.7

340.0

347.2

354.4

361.7

368.9

376.1

383.4

390.6

397.8

405.1

412.3

419.5

426.8

434.0

441.2

448.5

455.7

462.9

470.2

477.4

484.6

491.8

499.1

506.3

513.5

520.8

528.0

535.2

542.5

549.7

556.9

564.2

571.4

578.6

585.9

593.1

600.3

607.6

614.8

622.0

629.3

636.5

643.7

651.0

658.2

665.4

672.2

679.9

687.1

694.4

701.6

708.8

716.1

100

723.3

730.5

737.8

745.0

752.2

759.5

766.7

773.9

781.2

788.4

110

795.6

802.9

810.1

817.3

824.6

831.8

839.0

846.3

853.5

860.7

120

868.0

875.2

882.4

889.7

896.9

904.1

911.4

918.6

925.8

933.1

130

940.3

947.5

954.8

962.0

969.2

876.5

983.7

990.9

998.2

1005.4

140

1012.6

1019.9

1027.1

1034.3

1041.5

1048.8

1056.0

1063.2

1070.5

1077.7

150

1084.9

1092.2

1099.4

1106.6

1113.9

1121.1

1128.3

1135.6

1142.8

1150.0

160

1157.3

1164.5

1171.7

1179.0

1186.2

1193.4

1200.7

1207.9

1215.1

1222.4

170

1129.6

1236.8

1244.1

1251.3

1258.5

1265.8

1273.0

1280.1

1287.5

1294.7

180

1301.9

1309.2

1316.4

1323.6

1330.9

1338.1

1345.3

1352.6

1359.8

1367.0

190

1374.3

1381.5

1388.7

1396.0

1403.2

1410.4

1417.7

1424.9

1432.1

1439.4

00-22

PC80MR-3

CONVERSION TABLE

From bar to psi (lb/in2) 1 bar = 14.503 psi 0

14.5

29.0

43.5

58.0

72.5

87.0

101.5

116.0

130.5

145.0

159.5

174.0

188.5

203.0

217.5

232.0

246.5

261.0

275.6

290.0

304.6

319.1

333.6

348.1

362.6

377.1

391.6

406.1

420.6

435.1

449.6

464.1

478.6

493.1

507.6

522.1

536.6

551.1

565.6

580.1

594.6

609.1

623.6

638.1

652.6

667.1

681.6

696.1

710.6

725.1

739.6

754.1

768.6

783.2

797.7

812.2

826.7

841.2

855.7

870.2

884.7

899.2

913.7

928.2

942.7

957.2

971.7

986.2

1000.7

1015.2

1029.7

1044.2

1058.7

1073.2

1087.7

1102.2

1116.7

1131.2

1145.7

1160.2

1174.7

1189.2

1203.7

1218.2

1232.7

1247.2

1261.8

1276.3

1290.8

1305.3

1319.8

1334.3

1348.8

1363.3

1377.8

1392.3

1406.8

1421.3

1435.8

100

1450.3

1464.8

1479.3

1493.8

1508.3

1522.8

1537.3

1551.8

1566.3

1580.8

110

1595.3

1609.8

1624.3

1638.8

1653.3

1667.8

1682.3

1696.8

1711.3

1725.8

120

1740.4

1754.9

1769.4

1783.9

1798.4

1812.9

1827.4

1841.9

1856.4

1870.8

130

1885.4

1899.9

1914.4

1928.9

1943.4

1957.9

1972.4

1986.9

2001.4

2015.9

140

2030.4

2044.9

2059.4

2073.9

2088.4

2102.9

1217.4

2131.9

2146.4

2160.9

150

2175.4

2189.9

2204.4

2218.9

2233.5

2248.0

2262.5

2277.0

2291.5

2306.0

160

2320.5

2335.0

2349.5

2364.0

2378.5

2393.0

2407.5

2422.0

2436.5

2451.0

170

2465.5

2480.0

2494.5

2509.0

2523.5

2538.0

2552.5

2567.0

2581.5

2596.0

180

2610.5

2625.0

2639.5

2654.0

2668.5

2683.0

2697.7

2712.1

2726.6

2641.1

190

2755.6

2770.0

2784.6

2799.1

2813.6

2828.1

2842.6

2857.1

2871.6

2886.1

200

2900.6

2915.1

2929.6

2944.1

2958.6

2973.1

2987.6

3002.1

3016.6

3031.1

210

3045.6

3060.1

3074.6

3089.1

3103.6

3118.1

3132.6

3147.1

3161.6

3176.1

220

3190.7

3205.2

3219.7

3234.2

3248.7

3263.2

3277.7

3192.2

3306.7

3321.2

230

3335.7

3350.2

3364.7

3379.2

3393.7

3408.2

3422.7

3437.2

3451.7

3466.2

240

3480.7

3495.2

3509.7

3524.2

3538.7

3553.2

3567.7

3582.2

3596.7

3611.2

PC80MR-3

00-23

CONVERSION TABLE

TEMPERATURE Fahrenheit-Centigrade conversion; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left. If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade values and read the corresponding Fahrenheit temperature on the right. 1 °C = 33.8°F °C

°F

°C

°F

°C

°F

°C

°F

–40.4 –37.2 –34.4 –31.7 –28.9

–40 –35 –30 –25 –20

–40.0 –31.0 –22.0 –13.0 –4.0

–11.7 –11.1 –10.6 –10.0 –9.4

11 12 13 14 15

51.8 53.6 55.4 57.2 59.0

7.8 8.3 8.9 9.4 10.0

46 47 48 49 50

144.8 116.6 118.4 120.2 122.0

27.2 27.8 28.3 28.9 29.4

81 82 83 84 85

117.8 179.6 181.4 183.2 185.0

–28.3 –27.8 –27.2 –26.7 –26.1

–19 –18 –17 –16 –15

–2.2 –0.4 1.4 3.2 5.0

–8.9 –8.3 –7.8 –7.2 –6.7

16 17 18 19 20

60.8 62.6 64.4 66.2 68.0

10.6 11.1 11.7 12.2 12.8

51 52 53 54 55

123.8 125.6 127.4 129.2 131.0

30.0 30.6 31.1 31.7 32.2

86 87 88 89 90

186.8 188.6 190.4 192.2 194.0

–25.6 –25.0 –24.4 –23.9 –23.3

–14 –13 –12 –11 –10

6.8 8.6 10.4 12.2 14.0

–6.1 –5.6 –5.0 –4.4 –3.9

21 22 23 24 25

69.8 71.6 73.4 75.2 77.0

13.3 13.9 14.4 15.0 15.6

56 57 58 59 60

132.8 134.6 136.4 138.2 140.0

32.8 33.3 33.9 34.4 35.0

91 92 93 94 95

195.8 197.6 199.4 201.2 203.0

–22.8 –22.2 –21.7 –21.1 –20.6

–9 –8 –7 –6 –5

15.8 17.6 19.4 21.2 23.0

–3.3 –2.8 –2.2 –1.7 –1.1

26 27 28 29 30

78.8 80.6 72.4 84.2 86.0

16.1 16.7 17.2 17.8 18.3

61 62 63 64 65

141.8 143.6 145.4 147.2 149.0

35.6 36.1 36.7 37.2 37.8

96 97 98 99 100

204.8 206.6 208.4 210.2 212.0

–20.0 –19.4 –18.9 –18.3 –17.8

–4 –3 –2 –1 0

24.8 26.6 28.4 30.2 32.0

–0.6 0.0 0.6 1.1 1.7

31 32 33 34 35

87.8 89.6 91.4 93.2 95.0

18.9 19.4 20.0 20.6 21.1

66 67 68 69 70

150.8 152.6 154.4 156.2 158.0

40.6 43.3 46.1 48.9 51.7

105 110 115 120 125

221.0 230.0 239.0 248.0 257.0

–17.2 –16.7 –16.1 –15.6 –15.0

1 2 3 4 5

33.8 35.6 37.4 39.2 41.0

2.2 2.8 3.3 3.9 4.4

36 37 38 39 40

96.8 98.6 100.4 102.2 104.0

21.7 22.2 22.8 23.3 23.9

71 72 73 74 75

159.8 161.6 163.4 165.2 167.0

54.4 57.2 60.0 62.7 65.6

130 135 140 145 150

266.0 275.0 284.0 2930 302.0

–14.4 –13.9 –13.3 –12.8 –12.2

6 7 8 9 10

42.8 44.6 46.4 48.2 50.0

5.0 5.6 6.1 6.7 7.2

41 42 43 44 45

105.8 107.6 109.4 111.2 113.0

24.4 25.0 25.6 26.1 26.7

76 77 78 79 80

168.8 170.6 172.4 174.2 176.0

68.3 71.1 73.9 76.7 79.4

155 160 165 170 175

311.0 320.0 329.0 338.0 347.0

00-24

PC80MR-3

10 STRUCTURE AND FUNCTION

POWER TRAIN...............................................................2 SWING CIRCLE..............................................................3 SWING MACHINERY .....................................................5 TRACK FRAME AND IDLER CUSHION.........................8 IDLER............................................................................10 TRACK ROLLER...........................................................11 CARRIER ROLLER.......................................................12 SPROCKET ..................................................................13 TRACK SHOE...............................................................14 SHOES..........................................................................17 RUBBER SHOE ............................................................18

PC80MR-3

SWIVEL JOINT ............................................................ 19 TRAVEL MOTOR ......................................................... 20 WORK EQUIPMENT CYLINDER................................. 22 SOLENOID VALVE GROUP ........................................ 26 CONTROL VALVE .................................................... 27-1 CLSS ....................................................................... 27-12 SWING MOTOR ........................................................... 28 ATTACHMENT ............................................................. 37 TRAVEL PPC VALVE .................................................. 42 BLADE, BOOM SWING, 2-PIECE BOOM PPC VALVES ....................................................................... 46 EQUIPMENT ................................................................ 50

10-1 (1)

STRUCTURE AND FUNCTION

POWER TRAIN

POWER TRAIN 1

5 6 7 8

15 14 13 12 11 10

4 16

RKP15700

1. Idler 2. Control valve 3. Center swivel joint 4. Swing motor 5. Travel motor 6. Control pump (for pilot control) 7. Hydraulic pump (for swing and blade) 8. Hydraulic pump (For travel and work equipment) 9. Engine

10-2

10. L.H. boom swing lock solenoid valve 11. R.H. boom swing lock solenoid valve 12. Equipment solenoid valve 13. Swing holding brake solenoid valve 14. Travel speed solenoid valve 15. Servocontrol solenoid valve 16. Swing machinery 17. Swing circle

PC80MR-3

STRUCTURE AND FUNCTION

SWING CIRCLE

SWING CIRCLE 2

a S

3 245 – 309 Nm

4 1,6

245 – 309 Nm

5 7

A-A

RKP15710

Unit: mm

No.

Control

Axial clearance of bearing

2. Greasing for swing circle bearing 3. Greasing for swing circle pinion 4. Outer race 5. Inner race 6. Ball 7. Seal

PC80MR-3

Criteria

Remedy

Standard clearance

Allowable clearance

0.20 – 0.80

2.0

Replace

a. Position of inner race soft zone b. Position of outer race soft zone SPECIFICATIONS Grease Quantity of grease Reduction ratio

G2-LI 5.5 l 80/10=8.0

10-3

PAGE INTENTIONALLY LEFT BLANK

STRUCTURE AND FUNCTION

SWING MACHINERY

13 A

9 10 6 5

2 14 1 RKP16560

1. Pinion (Number of teeth: 10) 2. Axle body 3. No. 2 planetary carrier 4. Ring gear 5. No. 2 planetary gear 6. No. 2 sun gear 7. No. 1 planetary carrier 8. Ring gear 9. No. 1 sun gear

PC80MR-3

10. No. 1 planetary gear 11. Swing motor 12. Oil filler pipe 13. Level gauge 14. Drain plug SPECIFICATIONS Reduction ratio Swing speed (rpm)

27.8 –

10-5

STRUCTURE AND FUNCTION

SWING MACHINERY

Loctite 242 .............. Nm Loctite 262

1 2 3

6 950 – 150 Nm Loctite 243

7 290 Nm Loctite 262

9 8 RKP16570

10-6

PC80MR-3

STRUCTURE AND FUNCTION

SWING MACHINERY

Unit: mm

No.

Control

Backlash between swing motor shaft and No. 1 sun gear

Backlash between No. 1 sun gear and No. 1 planetary gear

Backlash between No. 1 planetary gear and ring gear

Backlash between No. 1 planetary carrier and No. 2 sun gear

Backlash between No. 1 sun gear and No. 2 planetary gear

Backlash between No. 2 planetary gear and ring gear

Backlash between No. 2 planetary carrier and swing pinion

Backlash between pinion and swing circle

Wear of sliding surface of pinion collar against oil seal

PC80MR-3

Criteria Standard clearance

Clearance limit

Remedy

Replace

Basic dimension

Allowable

Limit size

Plating with hard chromium or replace

10-7

STRUCTURE AND FUNCTION

TRACK FRAME AND IDLER CUSHION

A-A

245 309 Nm Loctite 262

2 A

11a

10 11b

230 Nm Loctite 262

3,11c

9 11d 11e 59 74 Nm

11f

156,8 196 Nm

10-8

RKP15720

PC80MR-3

STRUCTURE AND FUNCTION

TRACK FRAME AND IDLER CUSHION

Unit: mm

No.

Control

Vertical width of idler guide

Lateral width of idler guide

Criteria Limit size

Track frame

Overlay

Idler support

Overlay or replace

Track frame

158

162

Overlay

Idler support

156

152

Overlay or replace

Basic dimension

Recoil spring

Limit size

Free length

Installed length

Installed load

Free length

Road liner

412

323

47.4 kN

402

42.2 kN Replace

Steel shoe

412

323

47.4 kN

402

42.2 kN

Rubber shoe

412

283

69.2 kN

402

61.6 kN

4. Idler 5. Track frame 6. Carrier roller 7. Travel motor 8. Sprocket 9. Track roller 10. Track shoe 11. Idler cushion 11a. Support 11b. Yoke 11c. Recoil spring 11d. Cylinder 11e. Disc 11f. Grease nipple 12. Idler guard (Road liner specification, steel shoe specification)

PC80MR-3

Remedy

Basic dimension

Installed load

SPECIFICATIONS Quantity of grease:96 cc (steel shoe, road liner) 233 cc (rubber shoe) Grease: G2-LI

10-9

STRUCTURE AND FUNCTION

IDLER

IDLER 3

5 4

1 2

RKP15730

Unit: mm

No.

Control

Criteria Basic dimension

Limit size

Outside diameter of projected part

Ø 460

–

Outside diameter of tread

Ø 415

Ø 407

Depth of tread

22.5

26.5

Width of projected part

Overall width

100

Width of tread

28.5

Clearance between idler shaft and bushing

Interference between idler and bushing

Side clearance of idler (Each side)

Thickness of tread (at cen-ter of width of tread)

–

Quantity of oil

10-10

Basic dimensi on

Allowable

Remedy

Standar d clearanc e

Standar d interfere nce

Shaft

Hole

Ø 44

-0.250 -0.290

+ 0.062 0

0.250– 0.352

1.5

Ø 50

+0.117 +0.087

+0.025 0

0.062– 0.117

–

Standard clearance

Allowable clearance

0.190 – 0.395

1.5

Basic dimension

Limit size

13.8

9.8

60 cc (Engine oil: SAE30CD)

Repair

Overlay or replace –

PC80MR-3

STRUCTURE AND FUNCTION

TRACK ROLLER

5 8

4 3

2 1

6 9

RKP16550

Unit: mm

No.

Control

Criteria Basic dimension

Limit size

Outer diameter of protrusion

Ø 139

–

Outside diameter of tread

Ø 110

Ø 103

Width of projected part

36.6

Overall width

136.6

–

Width of tread

46.8

51.1

Clearance between idler shaft and bushing

Interference between idler and bushing

Side clearance of track roller

Thickness of tread (at center of width of tread)

–

Quantity of oil

PC80MR-3

Basic dimensi on

Allowable

Remedy

Overlay or replace – Overlay or replace

Standar d clearanc e

Standar d interfere nce

Shaft

Hole

Ø 40

-0.250 -0.270

+ 0.165 – 0.020

0.230 – 0.435

1.5

Ø 44

+0.150 +0.110

+0.025 -0.020

0.075 – 0.170

–

Minimum clearance

Clearance limit

0.53 – 1.06

1.5

Basic dimension

Limit size

29.5

160 – 180 cc (Oil: G0140)

Replace

Overlay or replace –

10-11

STRUCTURE AND FUNCTION

CARRIER ROLLER

5 1 4 3 2

RKP15740

Unit: mm

No.

Control

1 2

Criteria Basic dimension

Limit size

Outside diameter of tread

Ø 82

Ø 72

Width of tread

100

–

Interference between shaft and bearing

Interference between roller and bearing

Thickness of tread

–

Quantity of oil

10-12

Basic dimensi on

Allowable

Standar d interfere nce

Remedy Overlay or replace

Allowabl e interfere nce

Shaft

Hole

Ø 30

+0.009 - 0.004

0 -0.010

-0.004 – 0.019

–

Ø 62

0 -0.013

+ 0.018 - 0.012

-0.031 – 0.012

–

Basic dimension

Limit size

47– 52 cc (Grease: ALVANIA EP-2)

Replace

Overlay or replace –

PC80MR-3

STRUCTURE AND FUNCTION

SPROCKET

SPROCKET 4 3

2 1

A-A

RKP15750

Unit: mm

No.

Control

Wear of root diameter

Criteria

Remedy

Basic dimension

Allowable

Limit size

Ø 433.004

+ 1.0 - 2.0

Ø 421

Wear of tip diameter

Ø 483.7

± 2.0

Ø 472

Wear of dip width

–

Wear of root width

+ 0.5 - 2.5

Thickness of root

84.002

+ 0.475 - 1.150

PC80MR-3

Overlay or replace

10-13

STRUCTURE AND FUNCTION

TRACK SHOE

TRACK SHOE ROAD LINER - STEEL SHOE - CITY PAD

22 21 16 6

24 11 14 13

[*1]

20a

1 20b

[*2]

26a

RKP15760

a Part P is the link on the press fitting side of bushing. [*1] City pad - Steel shoe [*2] Road liner

10-14

PC80MR-3

STRUCTURE AND FUNCTION

TRACK SHOE

Unit: mm

No.

Control

Criteria Basic dimension

Limit size

Link pitch

154.25

157.25

Outside diameter of bushing

41.2

37.2

Height of link

Thickness of link (Press fit-ting part of bushing)

5 6

Shoe bolt pitch

Repair or replace

Replace

8 Link

Inside width

Overall width

Width of tread

26.3

Projection of pin

Projection of regular bush-ing

3.15

Overall length of pin

131

Overall length of bushing (Master bushing)

74.6

Thickness of bushing

Thickness of spacer

17 18

Reverse or replace

Remedy

Press fitting pressure

*19

Repair or replace Adjust or replace

Basic dimension

Limit size

8.4

4.4 –

Bushing

19.6 -98.1 kN

Regular pin

49.0 -117.7 kN

Master pin

39.2 -78.5 kN

–

Items marked with * are for the dry track.

PC80MR-3

10-15

STRUCTURE AND FUNCTION

TRACK SHOE

Unit: mm

No.

Criteria

Control

Tightening torque

a. Regular link 20

Screw

b. Master link

• City pad • Steel shoe

117.7 ± 19.6 Nm

90° ± 10°

• Road liner

117.7 ± 19.6 Nm

60 ± 10 (Torque after retightening) Min. 343 Nm

Tightening torque

Lower limit torque

–

Number of shoes (Each side)

Clearance between regular pin and bushing

Interference between regular pin and link

Clearance between regular pin and bushing

Interference between master pin and link

Allowable Shaft

Hole

Standard interferenc e

+0.214 +0.174

+ 0.062 0

0.112 – 0.214

+0.150 0

- 0.198 - 0.250

0.198 – 0.400

Basic dimension

Allowable

Basic dimension

*25

Height of grouser

Road liner

Hole

+ 0.150 0

+0.830 +0.330

0.180 – 0.830

Shaft

Hole

Standard interferenc e

+ 0.020 - 0.020

-0.198 -0.250

0.178 – 0.270

Allowable

Basic dimension 24

Shaft

Standard clearance

Allowable

Basic dimension 24

Clearance between master pin and bushing

Remedy

Retighten

*24

Tightening torque

Shaft

Hole

Standard clearance

-0.150 -0.250

+0.630 +0.230

0.380 – 0.880

Basic dimension

Limit size

Adjust or replace

Replace

Items marked with * are for the dry track.

10-16

PC80MR-3

STRUCTURE AND FUNCTION

SHOES

SHOES STEEL SHOE - CITY PAD

A 1 A A-A

RKP15770

Unit: mm

No.

Control

Height of grouser

Overall height of shoe

Thickness of plate

4 5

Criteria

Remedy

Basic dimension

Limit size

18 6

Overlay or replace

14 Length of upper side of grouser

PC80MR-3

10 12

10-17

STRUCTURE AND FUNCTION

RUBBER SHOE

3 2 1 A-A

RKP15780

Unit: mm

No.

Control

1 2 3

Criteria Basic dimension

Limit size

Wear of lug height

Wear of roller guide

Wear of meshing part of sprocket

10-18

Standard dimension

Allowable

Limit size

22.5

±0.5

Remedy

Replace

PC80MR-3

STRUCTURE AND FUNCTION

SWIVEL JOINT

DR1

DR2

B2 B1

F1 3

11,8 14,7 Nm

1 5

A1: B1: C1: D1: E1 F1: G1 DR1: 1. 2. 3. 4.

A-A

From right travel control valve From right travel control valve From left travel control valve From left travel control valve From blade control valve From blade control valve From travel increment speed selector solenoid valve To tank

RKP16580

A2: B2: C2: D2: E2: F2: G2: DR2:

To right travel motor To right travel motor To left travel motor To left travel motor To blade cylinder (bottom side) To blade cylinder (head side) To travel increment speed From travel motor drain port

Cover Rotor Sealing ring Shaft Unit: mm

No. 5

Control Clearance between shaft and rotor

PC80MR-3

Criteria

Remedy

Basic dimension

Standard clearance

Allowable clearance

–

Replace

10-19

STRUCTURE AND FUNCTION

TRAVEL MOTOR

TRAVEL MOTOR PS T1

X P2 T2

RKP16930

P1: From control valve P2: From control valve T1: To tank PS From travel increment speed selector solenoid valve T2: To tank TECHNICAL DATA Theorical displacement: Max. engine speed: Min. pressure opening brake: Change displacement pressure: Reduction ratio

10-20

Fast: 29.1 (cm3/rev.) Slow: 48.6 (cm3/rev.) Fast: 2754 rpm Slow: 1646 rpm 13 bar 32 bar 53.0

PC80MR-3

STRUCTURE AND FUNCTION

TRAVEL MOTOR

290 310 Nm

128 ± 7 Nm

3 2

20 30 Nm

16 17 20 30 Nm

18 29,4 ± 2,0 Nm

19 24

1. Cover 2. Cover 3. Swash plate 4. Cylinder 5. Piston 6. Ring 7. Steel disk 8. Brake disk 9. Bearing 10. Ring nut 11. No. 2 planetary gear 12. Body 13. No. 1 planetary gear

PC80MR-3

21 23

20 RKP16920

14. No. 2 sun gear 15. No. 1 sun gear 16. Pad 17. Cover 18. Plug 19. No. 1 planetary 20. Piston spring 21. Piston 22. Swash plate 23. Floating seal 24. Shoe 25. Spring

10-21

STRUCTURE AND FUNCTION

WORK EQUIPMENT CYLINDER

WORK EQUIPMENT CYLINDER BOOM CYLINDER

RKP19460

ARM CYLINDER

RKP19470

BUCKET CYLINDER

RKP19480

10-22

PC80MR-3

STRUCTURE AND FUNCTION

WORK EQUIPMENT CYLINDER

BOOM SWING CYLINDER

RKP19490

BLADE CYLINDER

RKP16910

PC80MR-3

10-23

STRUCTURE AND FUNCTION

WORK EQUIPMENT CYLINDER

Unit: mm No. Control

Clearance between piston rod and bushing

Criteria Cylinder

Basic dimensio n

Shaft

Hole

Boom

-0.030 -0.076

+0.250 +0.055

0.085 – 0.326

0.654

Arm

-0.030 -0.067

+0.151 +0.006

0.036 – 0.218

0.567

Bucket

-0.030 -0.104

+0.163 +0.006

0.036 – 0.267

0.567

Boom swing

-0.030 -0.104

+0.163 +0.006

0.036 – 0.267

0.567

Blade

-0.030 -0.104

+0.250 +0.055

0.085 – 0.354

0.654

Boom

-0.030 -0.100

+0.174 +0.100

0.130 – 0.274

1.0

Arm

-0.025 -0.087

+0.142 +0.080

0.105 – 0.229

1.0

-0.030 -0.100

+0.142 +0.080

0.105 – 0.229

1.0

Boom swing

-0.025 -0.064

+0.142 +0.080

0.105 – 0.206

1.0

Blade

-0.030 -0.104

+0.174 +0.100

0.130 – 0.278

1.0

Boom

-0.030 -0.076

+0.174 +0.100

0.130 – 0.240

1.0

Arm

-0.025 -0.087

+0.142 +0.080

0.105 – 0.229

1.0

-0.030 -0.100

+0.142 +0.080

0.110 – 0.242

1.0

Boom swing

-0.025 -0.064

+0.142 +0.080

0.105 – 0.206

1.0

Blade

-0.030 -0.104

+0.174 +0.100

0.130 – 0.278

1.0

Clearance between piston rod support shaft Bucket and bushing

Clearance between cylinder bottom support Bucket shaft and bushing

10-24

Allowable

Remedy Standard Allowable clearance clearance

Replace bushing

Replace pin and bushing

PC80MR-3

STRUCTURE AND FUNCTION

No. Control

Criteria Boom

PC80MR-3

Remedy

961 ± 96.1 Nm

Arm

Procedure 1) Tighten at 1.11 -1.35 kNm 2) Loosen to 0 Nm 3) Tighten at 1.11 -1.35 kNm

Bucket

Procedure 1) Tighten at 1.16 -1.42 kNm 2) Loosen to 0 Nm 3) Tighten at 1.16 -1.42 kNm

Tightening torque of cylinder head

Tightening torque of cylinder piston

WORK EQUIPMENT CYLINDER

Boom swing

785 ± 78.5 Nm

Blade

1.030 ± 103.0 Nm

Boom

3.33 ± 0.33 kNm (Wrench: 70 mm).

Arm

3.33 ± 0.33 kNm (Wrench: 70 mm).

Bucket

2.16 ± 0.22 kNm (Wrench: 60 mm).

Boom swing

2.6 ± 0.26 kNm (Wrench: 70 mm).

Blade

3.14 ± 0.31 kNm (Wrench: 75 mm).

Retighten

10-25

STRUCTURE AND FUNCTION

SOLENOID VALVE GROUP

SOLENOID VALVE GROUP T

3 B1

SV4

SV3

1 B3

SV2 SV1

T RV1

CV1

35 bar

10-26

RKP19500

PC80MR-3

STRUCTURE AND FUNCTION

SOLENOID VALVE GROUP

A1: Accumulator B1: To servocontrol A2: From hydraulic pump (for servocontrol) B2: To travel motor (increment speed) B3: To swing motor (swing brake) A4: To control valve (per equipment) B4: To control valve (per equipment) T: Drain 1. 2. 3. 4. 5.

Equipment solenoid valve Swing holding brake solenoid valve Travel speed solenoid valve Servocontrol solenoid valve Main relief valve (32 kg/cm2)

PC80MR-3

10-27

STRUCTURE AND FUNCTION

CONTROL VALVE

CONTROL VALVE A1. A2. A3. A4. A5. A6. A7. A8. A9. B1. B2. B3. B4. B5. B6. B7. B8. B9. LS. P1. P2. PA1. PB1. PA2. PB2. PA3. PB3. PA4. PB4. PA5. PB5. PA6. PB6. PA7. PB7. PA8. PB8. PA9. PB9. PS: TB. TC. TS. TSW.

To swing motor MA To blade cylinder head To L.H. travel motor A To R.H. travel motor A To boom cylinder bottom To arm cylinder head To bucket cylinder head To boom swing cylinder bottom To attachment cylinder To swing motor MB To blade cylinder bottom To L.H. travel motor B To R.H. travel motor B To boom cylinder head To arm cylinder bottom To bucket cylinder bottom To boom swing cylinder head To attachment cylinder To pump LS valve From main pump From gear pump for swing, blade From right swing PPC valve From left swing PPC valve From blade RAISE PPC valve From blade LOWER PPC VALVE From L.H. travel FORWARD PPC valve From L.H. travel REVERSE PPC valve From R.H. travel FORWARD PPC valve From R.H. travel REVERSE PPC valve From boom RAISE PPC valve From boom LOWER PPC valve From arm OUT PPC valve From arm IN PPC valve From bucket DUMP PPC valve From bucket CURL PPC valve From boom swing PPC valve From boom swing PPC valve From attachment cylinder From attachment cylinder From boom raise PPC valve (only during boom raise + swing operation) To tank To oil cooler To tank To swing motor

10-27-1 (1)

PC80MR-3

STRUCTURE AND FUNCTION

CONTROL VALVE

9-SPOOL VALVE

LS A

PB9

PA9 AA

PA8 M

PA7 L

PA6 PA5

K J

B9 B8

PA4

PA3

PA2

A9 A8

PA1

PB8 PB7 PB6 PB5

PB4 PB3 PB2

F E

PB1

BB D

A B

TSW

P1 RKP19640

Z PC80MR-3

10-27-2 (1)

STRUCTURE AND FUNCTION

CONTROL VALVE

RKP19650

1. Stop plug (blade head) 2. Suction valve (L.H. travel A) 3. Suction valve (R.H. travel A) 4. Suction valve (boom bottom) 5. Suction valve (arm head) 6. Suction valve (bucket head) 7. Suction valve (boom swing head) 8. Check valve (attachment) 9. Check valve (attachment)

10-27-3 (1)

A- A

10. Suction valve (boom swing bottom) 11. Suction valve (bucket bottom) 12. Suction valve (arm bottom) 13. Suction valve (boom head) 14. Suction valve (R.H. travel B) 15. Suction valve (L.H. travel B) 16. Stop plug (Blade bottom) 17. Safety valve 18. Cooler bypass valve

PC80MR-3

STRUCTURE AND FUNCTION

CONTROL VALVE

RKP19660

1. Main relief valve 2. Spool (swing) 3. Spool (blade) 4. Spool (L.H. travel) 5. Spool (R.H. travel)

PC80MR-3

B- B

6. Spool (boom) 7. Spool (arm) 8. Spool (bucket) 9. Spool (boom swing) 10. Spool (attachment)

10-27-4 (1)

STRUCTURE AND FUNCTION

CONTROL VALVE

1 RKP19670

C- C

1. Spool (boom RAISE merge) 2. Gear pump relief valve for swing, blade 3. Pressure compensation valve F (L.H. travel) 4. Pressure compensation valve F (R.H. travel) 5. Pressure compensation valve F (Boom) 6. Pressure compensation valve F (Arm) 7. Pressure compensation valve F (bucket) 8. Pressure compensation valve F (boom swing) 9. Pressure compensation valve F (attachment) 10. Pump pressure detection plug

10-27-5 (1)

11. Pressure compensation valve R (attachment) 12. Pressure compensation valve R (boom swing) 13. Pressure compensation valve R (bucket) 14. Pressure compensation valve R (Arm) 15. Pressure compensation valve R (Boom) 16. Pressure compensation valve R (R.H. travel) 17. Pressure compensation valve R (L.H. travel)

a F: Flow control valve R: Reducing valve

PC80MR-3

STRUCTURE AND FUNCTION

CONTROL VALVE

2 3

4 5

6 7

RKP19680

D- D

1. Check valve (attachment) 2. Check valve (boom swing) 3. Check valve (bucket) 4. Check valve (arm)

PC80MR-3

5. Check valve (boom) 6. Check valve (blade RAISE) 7. Load check valve

10-27-6 (1)

STRUCTURE AND FUNCTION

CONTROL VALVE

BB- BB

6 5 AA- AA

7 N- N RKP19690

1. Main relief valve 2. Back pressure valve 3. Safety valve 4. Pressure release valve

10-27-7 (1)

5. LS bypass plug 6. Pump pressure detection plug 7. Unload valve

PC80MR-3

STRUCTURE AND FUNCTION

CONTROL VALVE

3 E- E

7 F- F

Swing valve 1. Load check valve 2. Spool 3. Spool (boom RAISE merge)

PC80MR-3

RKP19700

Blade valve 4. Stop plug (head) 5. Stop plug (bottom) 6. Spool 7. Gear pump relief valve for swing, blade

10-27-8 (1)

STRUCTURE AND FUNCTION

CONTROL VALVE

4 G- G

L.H., R.H. travel valve 1. Suction valve (A) 2. Suction valve (B) 3. Spool 4. Pressure compensation valve R 5. Pressure compensation valve F

10-27-9 (1)

H- H

RKP19710

Boom valve 6. Suction valve (bottom) 7. Suction valve (head) 8. Spool 9. Pressure compensation valve R 10. Pressure compensation valve F

PC80MR-3

STRUCTURE AND FUNCTION

CONTROL VALVE

4 G- G

Arm valve 1. Suction valve (head) 2. Suction valve (bottom) 3. Spool 4. Pressure compensation valve R 5. Pressure compensation valve F

PC80MR-3

K- K

RKP19720

Bucket valve 6. Suction valve (head) 7. Suction valve (bottom) 8. Spool 9. Pressure compensation valve R 10. Pressure compensation valve F

10-27-10 (1)

STRUCTURE AND FUNCTION

CONTROL VALVE

L- L

RKP19730

Boom swing valve 1. Suction valve (head) 2. Suction valve (bottom) 3. Spool 4. Pressure compensation valve R 5. Pressure compensation valve F

10-27-11 (1)

PC80MR-3

STRUCTURE AND FUNCTION

CLSS

CLSS OUTLINE OF CLSS Features CLSS stands for Closed center Load Sensing System, and has the following features. • Fine control not influenced by load. • Control enabling digging even with fine control. • Ease of compound operation ensured by flow divider function using area of opening of spool during compound operations. • Energy saving using variable pump control. Structure • The CLSS consists of a variable capacity single piston pump, control valve, and actuators. • The pump body consists of the main pump, PC valve and LS valve.

Actuator

PLS

Control valve

PC valve

LS valve PP

Servo piston RKP19760

PC80MR-3

10-27-12 (1)

STRUCTURE AND FUNCTION

CLSS

BASIC PRINCIPLE 1. •

Control of pump swash plate angle The pump swash plate angle (pump discharge amount) is controlled so that LS differential pressure DPLS (the difference between pump (discharge) pressure PP and control valve outlet port LS pressure PLS) (load pressure of actuator) is constant. (DPLS=Pump delivery pressure PP – LS – pressure PLS of delivery to the actuator). • If the differential pressure DPLS becomes lower than the set pressure of the LS valve LS (when the actuator load pressure is high), the angle of the swash plate increases. If the differential pressure DPLS increases (when the actuator load pressure is low), the angle of the swash plate decreases. a For details of the operation, see “HYDRAULIC PUMP”. Actuator

Control valve

PLS

Pump passage

LS passage

Main pump

Min.

Max.

Servo piston

DPLS

Differential pressure high

PC valve

Pump pressure high

Swash plate angle Q

LS valve

Differential pressure low

Pump pressure low RKP02921

10-27-13 (1)

Max.

Min.

LS differential pressure DPLS

Set differential pressure of LS valve RKP02931

PC80MR-3

STRUCTURE AND FUNCTION

2. •

CLSS

Pressure compensation control A pressure compensation valve is installed to the inlet port side of the control valve spool to balance the load. When two actuators are operated together, this valve acts to make pressure difference DP between the upstream (inlet port) and downstream (outlet port) the same, regardless of the size of the load (pressure). In this way, the flow of oil from the pump is divided (compensated) in proportion to the area of openings S1 and S2 of each valve when it is operated.

Load

W Actuator

Actuator

Pressure compensation valve

Pump

PC80MR-3

RKP19751

10-27-14 (1)

STRUCTURE AND FUNCTION

CLSS

OPERATION FOR EACH FUNCTION AND VALVE Hydraulic circuit diagram and name of valves LS

2 294 bar

Ls ø0,5

PA9

PA8

PA7

PA6

A6 B6 PB6

4 3

PA5

B5 PB5

PA4

R.H. travel

B4 PB4

PA3

Boom

4 3

Arm

4 3

Bucket

B7 PB7

4 3

Boom swing

B8 PB8

4 3

Attachment

B9 PB9

1. Unload valve (LS pressure + 32 kg/cm2) 2. Safety valve (300 kg/cm2) 3. Pressure compensation valve 4. Suction valve 5. Main relief valve (270 kg/cm2) 6. Relief valve for swing, blade (205 kg/cm2) 7. Cooler bypass valve (cracking pressure: 8.3 kg/cm2. 8. Boom RAISE boost merge valve 9. Back pressure valve (cracking pressure: 11.3 kg/cm2.

L.H. travel

B3 PB3

4 3

Blade

B2 PB2

PA2

200 bar

Swing

B1 PA1

PB1

31 bar

265 bar

9 P1

10-27-15 (1)

TSW TB TC

RKP19741

PC80MR-3

STRUCTURE AND FUNCTION

CLSS

UNLOAD VALVE 1. When control valve is at HOLD Function • When the control valve is at HOLD, pump discharge amount Q discharged by the minimum swash plate angle is released to the tank circuit. When this happens, pump discharge pressure PP is set at 32 kg/cm2 by spring (2) inside the valve. (LS pressure PLS 0 kg/cm2)

PLS

T 1

3 RKP02960

Operation • Pump discharge pressure PP is acting on the left end of spool (1) and LS pressure PLS is acting on the right end. • When the control valve is at HOLD, LS pressure PLS is not generated, so only pump discharge pressure PP has any effect, and PP is set only by the load of spring (2). • As pump discharge pressure PP rises and reaches the load of spring (2) 32 kg/cm2, spool (1) is moved to the right (o). The oil in the pump circuit is then connected to tank circuit T through the drill hole in sleeve (3). • In this way, pump discharge pressure PP is set to 32 kg/cm2.

PC80MR-3

10-27-16 (1)

STRUCTURE AND FUNCTION

CLSS

2. During fine control of control valve Function • During fine control of the control valve, when the demand flow for the actuator is within the amount discharged by the minimum swash plate angle of the pump, pump discharge pressure PP is set to LS pressure PLS + 32 kg/cm2. • When the difference in pressure between pump discharge pressure PP and LS pressure PLS reaches the load of spring (2) (32 kg/cm2), the unload valve opens, so LS differential pressure DPLS becomes 32 kg/cm2.

PLS

T 1

2 RKP02970

Operation • When fine control is carried out on the control valve, LS pressure PLS is generated and acts on the right end of spool (1). When this happens, the area of the opening of the control valve spool is small, so there is a big difference between LS pressure PLS and pump discharge pressure PP. • When the difference in pressure between pump discharge pressure PP and LS pressure PLS reaches the load of spring (2) (32 kg/cm2), spool (1) moves to the right (o), and pump circuit PP and tank circuit T are connected. • In other words, pump discharge pressure PP is set to a pressure equal to the spring force (32 kg/cm2) + LS pressure PLS, and LS differential pressure DPLS becomes 32 kg/cm2.

10-27-17 (1)

PC80MR-3

STRUCTURE AND FUNCTION

CLSS

3. Control valve operated Function • When the control valve is being operated and the demand flow for the actuator becomes greater than the pump discharge from the minimum swash plate angle, the flow of the oil out to tank circuit T is cut off, and all the pump discharge amount Q flows to the actuator circuit.

PLS

T 1

2 RKP02980

Operation • When the control valve is operated to a larger stroke, LS pressure PLS is generated and acts on the right end of spool (1). When this happens, the area of the opening of the control valve spool is large, so the difference between LS pressure PLS and pump discharge pressure PP is small. • For this reason, the difference in pressure between pump discharge pressure PP and LS pressure PLS does not reach the load of spring (2) (32 kg/cm2), so spool (1) is pushed to the left (i) by spring (2). • As a result, pump circuit PP and tank circuit T are shut off, and all the pump discharge amount Q flows to the actuator circuit.

PC80MR-3

10-27-18 (1)

STRUCTURE AND FUNCTION

CLSS

INTRODUCTION OF LS PRESSURE 1. Main control valve (boom, arm, bucket, boom swing) Function • The LS pressure is the actuator load pressure at the outlet port end of the control valve. • With the control valve, it reduces pump pressure PP at reducing valve (3) of the pressure compensation valve to the same pressure as actuator circuit pressure (A), and sends it to the LS circuit PLS. Furthermore, the orifice C is provided in the middle of the circuit from the pump circuit PP to the pressure reducing valve (3) for damper function. • With the travel valve, actuator circuit pressure A is taken directly to the LS circuit PLS.

A b

a d

PLS1

PLS

SLS

RKP02990

Operation • When spool (1) is operated, pump pressure PP flows from flow control valve (2) and notch a in the spool through bridge passage b to actuator circuit A. • At the same time, reducing valve (3) also moves to the right (o), so pump pressure PP brought from orifice c has its pressure reduced by the pressure loss at notch d. It goes to LS circuit PLS, and then goes to spring chamber PLS1. • At this point, the PLS circuit of the LS is connected to the tank circuit T by means of the by-pass plug (4). (See the description of the LS by-pass plug). • The area at both ends of reducing valve (3) is the same (SA = SLS), and actuator circuit pressure PA (=A) acts on the SA end. The reduced pump pressure PP acts on SLS at the other end. • As a result, reducing valve (3) is balanced at a position where actuator circuit pressure PA and the pressure of spring chamber PLS1 are the same. Pump pressure PP reduced at notch d becomes actuator circuit pressure A and is taken to LS circuit PLS.

10-27-19 (1)

PC80MR-3

STRUCTURE AND FUNCTION

CLSS

Travel valve

A b

a d

PLS RKP03000

Operation • When spool (1) is operated, pump pressure PP flows from flow control valve (2) and notch a in the spool through bridge passage b to actuator circuit A. • At the same time, reducing valve (3) is moved to the right (o) by actuator circuit pressure PA, and notch c and notch d are interconnected respectively with travel junction circuit e and LS circuit PLS. • As a result, actuator circuit pressure PA (= A) passes from notch c through notch d and goes to LS circuit PLS.

a The travel circuit is different from the work equipment circuit: actuator circuit pressure PA goes directly to LS circuit PLS.

PC80MR-3

10-27-20 (1)

STRUCTURE AND FUNCTION

CLSS

LS BYPASS PLUG Function • This releases the residual pressure of LS pressure PLS. • This makes the speed of the rise in pressure of LS pressure PLS more gentle. In addition, with this discarded throttled flow, it creates a pressure loss in the throttled flow of the spool or shuttle valve, and increases the stability by lowering the effective LS differential pressure.

PLS RKP03010

Operation • The pressurized oil for LS circuit PLS passes from clearance filter a (formed by the clearance between LS bypass plug (1) and the valve body) through orifice b and flows to the tank circuit.

10-27-21 (1)

PC80MR-3

STRUCTURE AND FUNCTION

CLSS

PRESSURE COMPENSATION VALVE Function • During compound operations, if the load pressure becomes lower than the other actuator and the oil flow is about to increase, compensation is received. (When this happens, the other actuator being used for compound operation (right side) is at a higher load than the actuator on this side (left side).)

PPA

PLS1

PPA

PP PLS

PP RKP03020

Operation • If the load pressure of the other actuator (right side) becomes higher during compound operations, the oil flow in actuator circuit A on this side (left side) tries to increase. • If this happens, the LS pressure PLS of the other actuator acts on spring chamber PLS1, and reducing valve (1) and flow control valve (2) are pushed to the left (i). • Flow control valve (2) throttles the area of opening between pump circuit PP and spool upstream PPA. Flow control valve (2) throttles the area of opening between pump circuit PP and spool upstream PPA. • Flow control valve (2) and reducing valve (1) are balanced in position where the difference in pressure between PLS and PA acting on both ends of reducing valve (2) and the pressure loss between PP and PPA on both sides of flow control valve (2) are the same. • In this way, the pressure difference between upstream pressure PPA and downstream pressure PA of both spools used during compound operations is the same, so the pump flow is divided in proportion to the area of opening of notch a of each spool.

PC80MR-3

10-27-22 (1)

STRUCTURE AND FUNCTION

CLSS

AREA RATIO OF PRESSURE COMPENSATION VALVE Function • The pressure compensation valve determines the compensation characteristics by carrying out fine adjustment of the area ratio (S2/S1) between area S2 of reducing valve (1) and area S1 of flow compensation valve (2) to match the characteristics of each actuator. S1: Area of flow control valve (2) – area of piston (3) S2: Area of reducing valve (1) – area of piston (3).

PPB

PLS RKP03030

Area ratio (S1 : S2) and compensation characteristics • When ratio is 1.00: [pump pressure PP – spool notch upstream pressure PPB] C [LS circuit pressure PLS – actuator circuit pressure PA (= A)]. Oil flow is divided in proportion to area of opening of spool. • When ratio is more than 1.00: PP – PPB > PLS – PA (= A). Delivery distribution is lower than the proportion of the opening surfaces of the spool. • When ratio is less than 1.00: PP – PPB < PLS – PA (= A). Delivery distribution is higher than the proportion of the opening surfaces of the spool.

10-27-23 (1)

PC80MR-3

STRUCTURE AND FUNCTION

CLSS

L.H., R.H. TRAVEL JUNCTION CIRCUIT 1. When traveling in a straight line Function • To compensate for any difference in the oil flow in the left and right travel circuits when traveling in a straight line, the junction circuit opens when the left and right travel spools are operated. In this way, the flow of oil to the left and right travel motors is almost the same when traveling in a straight line, so there is no travel deviation. • When steering the machine, the difference in the load pressure returns the reducing valve of the travel valve on the inside of the turn, so the junction circuit is closed and the machine can be steered.

R.H. travel

L.H. travel

Right A

Left PA

Left A

Right PA

PLS 3

PP b

c RKP03041

Operation • When left and right travel spools (1) are operated, the pump discharge flows from pump circuit PP and circuit PA to actuator circuit A. • When traveling in a straight line, to make actuator circuit PA equal, left and right reducing valves (2) are pushed to the right (o) by the same amount, and notch a and the travel junction circuit are opened. • In this way, the left and right travel actuator circuits are interconnected by the travel junction circuit, so if any difference occurs in the flow of oil to the left and right travel motors, the difference is compensated to prevent any deviation in travel.

PC80MR-3

10-27-24 (1)

STRUCTURE AND FUNCTION

CLSS

Steering when traveling

R.H. travel

L.H. travel

Right A

Left PA

Left A

Right PA

T PLS 3

PP b

c RKP03051

Operation • When traveling in a straight line, if left travel spool (left 1) is returned to the neutral position and the steering is operated, a difference (right A > left A) is generated in the load pressure of left and right travel actuator circuits PA, and LS pressure PLS becomes the same pressure as right A (the side with the high load pressure). • Questa azione spinge la valvola di controllo della portata (3) del lato sinistro verso sinistra (i ). Nell’esempio, la pressione A del circuito di traslazione destro fa aprire il passaggio a del lato destro e fa chiudere il passaggio a sinistro interrompendo il circuito di collegamento c e permettendo, la deviazione o sterzatura. • Damper b is provided in the circuit to dampen any excessive characteristics in the opening or closing of the travel junction circuit if the spool is operated suddenly.

10-27-25 (1)

PC80MR-3

STRUCTURE AND FUNCTION

CLSS

TRAVEL LS BYPASS CIRCUIT 1. Normal operation Function • When the travel and another actuator are operated at the same time, the amount of oil discarded by the throttle in LS circuit PLS increases and the pressure compensation precision of the travel circuit is relaxed to keep the drop in the travel speed to the minimum. • When the travel is operated independently or any other actuator is operated independently, the bypass circuit is closed.

PLS

PLS1 a

RKP03060

Operation • When boom spool (1) is operated, LS circuit PLS becomes the same pressure as boom circuit pressure A1. • At the same time, LS circuit pressure PLS also goes to spring chamber PLS1 of reducing valve (2) of the travel valve. • The travel spool is not being operated, so travel actuator circuit PA is closed, and check valve (4) inside reducing valve (4) is also closed. • As a result, when the boom is operated independently, the travel LS bypass circuit is closed.

PC80MR-3

10-27-26 (1)

STRUCTURE AND FUNCTION

CLSS

Travel + other actuator operated

PLS

PLS1 a

RKP03070

Operation • When boom spool (1) is operated, LS circuit PLS becomes the same pressure as boom circuit pressure A1. • With the actuator circuit pressure, the boom RAISE pressure is normally higher than the travel pressure (A1 > A2), so the pressure of spring chamber PLS1 inside reducing valve (2) of the travel valve is higher than travel circuit pressure PA. • As a result, reducing valve (2) moves to the left, LS pressure of spring chamber PLS1 goes from orifice a and pushes check valve (4) open, so oil flows from passage b and passage c to travel circuit PA. • For this reason, LS circuit pressure PLS (which is the same pressure as boom circuit pressure A1), flows to travel circuit A2 to reduce the pressure.

10-27-27 (1)

PC80MR-3

STRUCTURE AND FUNCTION

CLSS

BOOM, ARM REGENERATION CIRCUIT Function (of boom) 1. When the boom is being lowered, if bottom pressure A of cylinder (1) is higher than head pressure B, and there is hydraulic drift, this sends the return oil flow at the bottom end to the head end to increase the cylinder speed by that amount.

1 B A 4 2

T a PP

PLS RKP03080

Operation • If there is hydraulic drift when lowering the boom, pressure A at the bottom end of boom cylinder (1) becomes higher than pressure B at the head end. • When this happens, part of the return oil at the bottom end passes through regeneration passage a of boom spool (1), pushes check valve (3) open, and flows to the head end. • As a result, the boom lowering speed is increased.

PC80MR-3

10-27-28 (1)

STRUCTURE AND FUNCTION

CLSS

When lowering the boom, if head pressure B of cylinder (1) is greater than bottom pressure A, and the work equipment is in the load process, check valve (3) closes and shuts off the circuit between the head and bottom ends.

1 A

B 4

T a PP

PLS

RKP03090

Operation • When the boom is lowered, if the work equipment is in the load process, pressure B at the head end of boom cylinder (1) becomes higher than pressure A at the bottom end. • When this happens, check valve (3) is closed by spring (4) and pressure B at the head end, so the circuit between the head circuit and bottom circuit is shut off.

10-27-29 (1)

PC80MR-3

PAGE INTENTIONALLY LEFT BLANK

STRUCTURE AND FUNCTION

SWING MOTOR

SWING MOTOR B

1 B

B Z C

A T

Z RKP15890

B: From brake swing solenoid valve S: From the tank T: To tank MA: From control valve MB: From control valve

10-28

SPECIFICATIONS Type: LMF30AEL Displacement 31 cc/rev Safety valve set pressure: 210 bar Suction valve cracking pressure: 0.3 bar

PC80MR-3

STRUCTURE AND FUNCTION

SWING MOTOR

7 12

14 15 2

A-A

58,8 78,4 Nm

107,8 142,2 Nm

10 16 B-B

11 34,3 44,1 Nm

RKP15900

C-C

1. Output shaft 2. Body 3. Shoe 4. Piston 5. Cylinder 6. Valve plate 7. Spring 8. Plate

9. Safety valve 10. Check valve 11. Spring 12. Spring 13. Brake piston 14. Disk 15. Plate Unit: mm

Criteria Basic dimension No.

Control

Limit size Remedy

Free length x Outside diameter

Installed length

Installed load

Free length

Installed load

Check valve spring

15.5 x 9.0

11.5

0.9 N

–

0.69 N

Suction valve spring

33.0 x 13.8

19.5

1.8 N

–

1.41 N

PC80MR-3

If damaged or deformed

10-29

STRUCTURE AND FUNCTION

SWING MOTOR

BRAKE VALVE OUTLINE OF CLSS The brake valve consists of a check valve and a safety valve. FUNCTION • When swing operation is stopped, outlet circuit of the motor is closed by the control valve. However, the motor will run for a while by inertial force, so pressure at the outlet side of the motor will abnormally rise, which may cause damage to the motor. To avoid such danger, the safety valve releases the abnormally high pressure oil from the outlet side of the motor. OPERATION 1. •

PPC valve (swing) actuated When the swing control lever is operated to SWING LEFT, pressure oil from the pump will be sent to the Port MB through the control valve (1). By this, pressure in the Port MB rises, which generates starting force to the motor, and the motor starts to swing. Oil coming out of the outlet Port returns to the tank from the Port MA though the control valve.

2. •

•

When swing stops When the swing control lever is returned to the NEUTRAL position, pressure oil from the control valve is not sent to the Port MB. Since the return circuit for the oil from the motor outlet to the tank is closed by control valve, the pressure in port MA rises and revolution resistance is generated in the motor, then the motor is braked. The pressure in port MA rises to the set pressure of the safety valve. As a result, high braking torque is generated in the motor, then the motor stops. While the safety valve is operating, the oil discharged from the safety valve and the oil from port S are supplied through check valve CB to port MB so that cavitation will not occur in port.

RKP15910

RKP16120

10-30

PC80MR-3

STRUCTURE AND FUNCTION

SWING MOTOR

OPERATION OF THE MODULATING RELIEF VALVE FUNCTION The relief valve for the swing motor prevents the relief pressure from rising sharply to reduce shocks when the machine starts and stops swinging. P

Modulating relief valve Ordinary relief valve

RKP16140

t RKP16150

OPERATION 1. •

When circuit is > P0 The relief valve does not operate.

2. •

When circuit pressure rises sharply When circuit pressure rises to P1, the hydraulic pressure acts on the area difference between D1 and D3 (D1 > D3) and pushes spring (4) to open valve (3). At this time, pressure acts on the area difference between D1 and D2 (D2 > D1), so seat (1) follows valve (3). As seat (1) moves, the passage for the pressurized oil in chamber d to flow into port S is narrowed by ball (c). Accordingly, seat (1) does not move so fast as valve (3). As a result, the relief pressure rises gradually from P1 to P2 while seat (1) is moving to sleeve (5).

•

P1 P2

RKP16130

S RKP15920

PC80MR-3

10-31

STRUCTURE AND FUNCTION

SWING MOTOR

OPERATION OF SWING BRAKE 1.

When solenoid valve is de-energized

When solenoid valve is energized

OPERATION • When the solenoid valve of the swing brake is deenergized, the hydraulic oil from the self- pressure reducing valve is shut off and port B is connected to the tank circuit. • For this reason, brake piston (13) is pushed up by brake spring (12), and disc (14) and plate (15) are pushed together to apply the brake.

OPERATION • When the solenoid valve of the swing brake is energized, the valve is changed and hydraulic oil from the self-pressure reducing valve flows through port B into brake chamber A. • The hydraulic oil in chamber A pushes brake spring (12) and brake piston (13) moves down. As a result, disc (14) and plate (15) are separated and the brake is released.

Self-pressure reducing valve

De-energized

Energized Main pump

Swing brake solenoid valve

15 14 B A 13

RKP16170

10-32

Main pump

Swing brake solenoid valve

RKP15930

PC80MR-3

STRUCTURE AND FUNCTION

SWING MOTOR

REVERSE ROTATION PREVENTION LEVEL

A 1

MA: Port MB: Port T1: Port T2: Port

PC80MR-3

A-A

RKP15940

1. Body 2. Spool (MA Side) 3. Spring (MA Side) 4. Plug (MA Side) 5. Spool (MA Side) 6. Spring (MA Side) 7. Plug (MA Side)

10-33

STRUCTURE AND FUNCTION

SWING MOTOR

EFFECT EXPLANATION DRAWING

Reverse rotation pressure

With reverse rotation prevention valve Wihout reverse rotation prevention valve

MA pressure Containment pressure

MB pressure

Reverse rotation pressure

1st reverse rotation 2nd reverse rotation

Motor speed Start

Brake

Reverse rotation

Time t RKP15950

10-34

PC80MR-3

STRUCTURE AND FUNCTION

SWING MOTOR

FUNCTION • This valve reduces the swing back generated in the swing body by the inertia of the swing body, the backlash and rigidity of the machinery system, and the compression of the hydraulic oil when the swing is stopped. • This is effective in preventing spillage of the load when stopping the swing and reducing the cycle time. (the positioning ability is good and it is possible to move swiftly to the next job).

2. • •

After motor stops Operation The motor is reversed by the closing pressure generated at port MB. (1st reversal) When this happens, reversal pressure is generated at port MA. Pressure MA goes to chamber a, compresses spring (3), spool (2) moves to the right, and MA o b is connected.

MA MA

MB MB Notch K

1. •

•

RKP16240

f RKP15960

When brake pressure is being generated at port MB Pressure MB passes through the notch K and goes to chamber d, spool (5) compre sses spring (6) according to the difference in area D1 > D2, moves to the left, and MB and e are connected. When this happens, pressure MA is below the set pressure of spring (3), so spool (2) does not move. For this reason, the pressure oil is closed, and the braking force is ensured.

6 5

PC80MR-3

D1 D2

T e

f RKP16230

10-35

PAGE INTENTIONALLY LEFT BLANK

STRUCTURE AND FUNCTION

ATTACHMENT

E B

P1 RKP16450

Z L.H. PPC VALVE P1: Arm (open) P2: Arm (closes) P3: Swing (R.H.) P4: Swing (L.H.) P: Feed T: Drain

PC80MR-3

R.H. PPC VALVE P1: Boom (lower) P2: Boom (raise) P3: Bucket (Dump) P4: Bucket (Curl) P: Feed T: Drain

10-37

STRUCTURE AND FUNCTION

ATTACHMENT

5 4

11,6 14,7 Nm

8 9

14 10

B-B

34 44 Nm

98 127 Nm

39 49 Nm

D-D

6 11 Nm

4 9 Nm

C-C E-E

1. Spool 2. Adjusting screw (inner) 3. Adjusting screw (outer) 4. Piston 5. Disk 6. Nut

10-38

RKP16460

7. Joint 8. Cover 9. Retainer 10. Body 11. Filter

PC80MR-3

STRUCTURE AND FUNCTION

ATTACHMENT

Unit: mm

Criteria Basic dimension No.

Control

Limit size Remedy

Free length x Outside diameter

Installed length

Installed load

Free length

Installed load

Return spring (outer) (for ports P3 and P4)

42.48 x 15.5

34.0

17.65 N

–

14.1 N

Return spring (outer) (for ports P1 and P2)

44.45 x 15.5

34.0

29.42 N

–

23.5 N

Adjusting screw (inner)

26.47 x 8.20

24.9

16.66 N

–

13.3 N

PC80MR-3

If damaged or deformed

10-39

STRUCTURE AND FUNCTION

ATTACHMENT

PPC VALVES OPERATION

1. •

Control lever in neutral position Ports A and B of the control valve and Ports P1 and P2 of the PPC valve are connected to drain chamber D through fine control hole f in spool (1). •

as long as pressures at ports A and P1 are perfectly balanced;

until pressure in section A-P1 – i.e. the pressure acting on stem (1) – is enough to counteract the force of the spring (2). This ensures proportionality between control lever position, A-P1 circuit pressure, and main control valve stem displacement.

5 4

2 1

f P3 (P1)

2. •

•

Control valve

P4 (P2)

PP P1

RKP01090

During fine control (NEUTRAL o Actuator) When piston (4) starts to be pushed by disc (5), retainer (9) is pushed; spool (1) is also pushed by metering spring (2), and moves down. When this happens, fine control hole f is shut off from drain chamber D, and at almost the same time, it is connected to pump pressure chamber PP, so pilot pressure oil passes through fine control hole f and goes from port P1 to port A. When pressure P1 increases, stem (1) is pushed upwards, and calibrated hole f is connected back to drain chamber D thereby compressing the spring (2). The floating of the stem (1) will continue until calibrated f hole f is halfway between discharge chamber D and pressure chamber PP, in other words until the pressure in duct P1 – the pressure acting on the section of stem (1) – offsets the force applied by the spring (2). The spring (2) is compressed proportionally to the movement of the lever (5) and therefore, pressure at P1 increases in proportion to the travel of the lever (5). The equilibrium position is then kept until the position of piston (4) is changed, i.e.:

10-40

Control valve

B RKP01102

PC80MR-3

STRUCTURE AND FUNCTION

3. •

•

ATTACHMENT

During fine control (Actuator o NEUTRAL) When the disk (5) is released and moved to neutral position, the piston (4) is pushed upwards by the spring (3) acting on the retainer (9), and spool (1) is thrusted upwards both by the force of spring (2) and by the force that the pressure in section A-P1. applies against the stem. This movement moves the calibrated hole f of spool (1) into the discharge chamber D, thereby allowing pressure in section AP1 to be released. If pressure P1 drops too quickly, spool (1) is pushed downwards by spring (2) and the calibrated hole f becomes cut off from the discharge chamber D; at almost the same time, the calibrated hole f is put in connection with pressure chamber PP and starts supplying pressure to section P1 until the pressure corresponding to the control lever position is balanced. When the spool of the control valve returns, oil flows back into chamber D, through calibrated hole f’, and into chamber B of the control valve spool opposite the operating one. Oil flows through duct P2 and into chamber Bo ensure it is filled properly.

4. •

•

Control lever at full stroke (NEUTRAL o Full stroke) When the disk (5) pushes down on the piston (4), and the retainer (9) pushes down on the spool (1), calibrated hole f is put in direct connection with chamber PP, which is in turn connected to a constantly pressurised servocontrols circuit. Oil is then allowed to flow directly into section A-P1, thereby pushing the stem of the main control valve to the end of its travel. This causes the main control valve to send the oil contained in chamber B towards input P2, through calibrated hole f’ and into discharge chamber D.

5 4 9 D

T P

PP P1

3 2

T P

Control valve

B RKP01120

PP P1

Control valve

B RKP01110

PC80MR-3

10-41

STRUCTURE AND FUNCTION

TRAVEL PPC VALVE

TRAVEL PPC VALVE C

Z B

P3 RKP16470

P: Feed T: Drain P1: Left travel (reverse) P2: Left travel (forward) P3: Right travel (reverse) P4: Right travel (forward)

10-42

PC80MR-3

STRUCTURE AND FUNCTION

TRAVEL PPC VALVE

25 31 Nm

7,8 9,8 Nm

A-A

B-B

27 34 Nm

4 D

D C-C

4 9 Nm

6 11 Nm

D-D

3,9 4,9 Nm RKP16480

1. Piston 2. Cover 3. Gasket 4. Body

5. Spool 6. Adjusting screw (inner) 7. Adjusting screw (outer) 8. Screw Unit: mm

Criteria Basic dimension No.

Control

Limit size Remedy

Free length x Outside diameter

Installed length

Installed load

Free length

Installed load

Return spring (outer)

26.53 x 8.5

24.9

16.7 N

–

13.3 N

Adjusting screw (inner)

52.06 x 15.5

31.9

135.2 N

–

108 N

PC80MR-3

If damaged or deformed

10-43

STRUCTURE AND FUNCTION

1. •

TRAVEL PPC VALVE

Control lever in neutral position Ports A and B of the control valve and Ports P1 and P2 of the PPC valve are connected to drain chamber D through fine control hole f in spool (1).

P1 increases in proportion to the travel of the lever (5). The equilibrium position is then kept until the position of piston (4) is changed, i.e.: a)

as long as pressures at ports A and P1 are perfectly balanced;

•

D f

1 P1 A

4 9

Control valve

•

During fine control (NEUTRAL o fine control) When piston (4) starts to be pushed by lever (5), retainer (7) is pushed; spool (1) is also pushed by metering spring (2), and moves down. As a result of this action, the calibrated hole f will be isolated from the discharge chamber D and at almost at the same time it will be put in connection with the PP c hamb er, which is direct ly co nnec ted to th e servocontrols circuit. Pressure in the servocontrols circuit will flow through the calibrated hole f thereby increasing the pressure in duct P1-A. When pressure P1 increases, stem (1) is pushed upwards, and calibrated hole f is connected back to drain chamber D thereby compressing the spring (2). The floating of the stem (1) will continue until calibrated hole f is halfway between discharge chamber D and pressure chamber PP, in other words until the pressure in duct P1 – the pressure acting on the section of stem (1) – offsets the force applied by the spring (2). The spring (2) is compressed proportionally to the movement of the lever (5) and therefore, pressure at

10-44

RKP16490

1 P1 A

Control valve

10 B

RKP16500

PC80MR-3

STRUCTURE AND FUNCTION

3. •

•

TRAVEL PPC VALVE

During fine control (Actuator o NEUTRAL) When the control lever (5) is released and moved to neutral position, the piston (4) is pushed upwards by the spring (3) acting on the retainer (9), and stem (1) is thrust upwards both by the force of spring (2) and by the force that the pressure in section A-P1. applies against the stem. This movement moves the calibrated hole f of stem (1) into the drain chamber D, thereby allowing pressure in section A-P1 to be released. If pressure P1 drops too quickly, spool (1) is pushed downwards by spring (2) and the calibrated hole f becomes cut off from the discharge chamber D; at almost the same time, the calibrated hole f is put in connection with pressure chamber PP and starts supplying pressure to section P1 until the pressure corresponding to the control lever position is balanced. When the spool of the control valve returns, oil flows back into chamber D, through calibrated hole f’ , and into chamber B of the control valve spool opposite the operating one. Oil flows through duct P2 and into chamber B to ensure it is filled properly.

4. •

•

Control lever at full stroke (NEUTRAL o Full stroke) When the lever (5) pushes down on the piston (4), and the retainer (9) pushes down on the stem (1), calibrated hole f is put in direct connection with chamber PP, which is in turn connected to a constantly pressurised servocontrols circuit. Oil is then allowed to flow directly into section A-P1, thereby pushing the stem of the main control valve to the end of its travel. This causes the main control valve to send the oil contained in chamber B towards input P2, through calibrated holef and into discharge chamber D.

5 4

9 f

P1 D

3 2 f

1 P1 A

Control valve

RKP16520

Control valve

RKP16510

PC80MR-3

10-45

STRUCTURE AND FUNCTION

BLADE, BOOM SWING, 2-PIECE BOOM PPC VALVES

BLADE, BOOM SWING, 2-PIECE BOOM PPC VALVES A

P A

5 4

3 2 1 BLADE PPC VALVE P: Delivery T: Drain P1: Blade (raise) P2: Blade (lower) 1. Spool 2. Adjusting screw (inner) 3. Adjusting screw (outer) 4. Piston 5. Lever

10-46

11,76 Ð 14,7 Nm

9 BOOM SWING PPC VALVE P: Delivery T: Drain P1: Swing (R.H.) P2: Swing (L.H.)

8,8 Ð 11,8 Nm

A-A

RKP16540

2-PIECE BOOM PPC VALVE P: Delivery T: Drain P1: 2-piece boom (open) P2: 2-piece boom (closes)

6. Cover 7. Retainer 8. Body 9. Filter

PC80MR-3

STRUCTURE AND FUNCTION

BLADE, BOOM SWING, 2-PIECE BOOM PPC VALVES

BLADE PPC VALVE Unit: mm

Criteria Basic dimension No.

Control

Limit size Remedy

Free length x Outside diameter

Installed length

Installed load

Free length

Installed load

Return spring (outer)

42.4 x 32.5

32.5

147 N

–

118 N

Adjusting screw (inner)

22.7 x 8.10

22.0

16.7 N

–

13.3 N

If damaged or deformed

BOOM SWING, 2-PIECE BOOM PPC VALVE Unit: mm

Criteria Basic dimension No.

10 11

Control

Limit size Remedy

Free length x Outside diameter

Installed length

Installed load

Free length

Installed load

Return spring (outer)

33.9 x 15.3

28.4

125 N

–

100 N

Adjusting screw (inner)

22.7 x 8.10

22.0

16.7 N

–

13.3 N

PC80MR-3

If damaged or deformed

10-47

STRUCTURE AND FUNCTION

BLADE, BOOM SWING, 2-PIECE BOOM PPC VALVES

PPC VALVES OPERATION 1. •

The spring (2) is compressed proportionally to the movement of the lever (5) and therefore, pressure at P1 increases in proportion to the travel of the lever (5). The equilibrium position is then kept until the position of piston (4) is changed, i.e.:

Control lever in neutral position Ports A and B of the control valve and Ports P1 and P2 of the PPC valve are connected to drain chamber D through fine control hole f in spool (1).

as long as pressures at ports A and P1 are perfectly balanced;

•

1 P1

Control valve

7 B

During fine control (NEUTRAL o Actuator) When piston (4) starts to be pushed by lever (5), retainer (7) is pushed; spool (1) is also pushed by metering spring (2), and moves down. As a result of this action, the calibrated hole f will be isolated from the discharge chamber D and at almost at the same time it will be put in connection with the PP c hamb er, which is direct ly co nnec ted to th e servocontrols circuit. Pressure in the servocontrols circuit will flow through the calibrated hole f in the circuit thereby increasing the pressure in duct P1-A. When pressure P1 increases, stem (1) is pushed upwards, and calibrated hole f is connected back to drain chamber D thereby compressing the spring (2). The floating of the stem (1) will continue until calibrated hole f is halfway between discharge chamber D and pressure chamber PP, in other words until the pressure in duct P1 – the pressure acting on the section of stem (1) – offsets the force applied by the spring (2).

10-48

2 RKP13730

2. •

P2 PP

Control valve

B RKP13750

PC80MR-3

STRUCTURE AND FUNCTION

3. •

•

BLADE, BOOM SWING, 2-PIECE BOOM PPC VALVES

4. Control lever at full stroke (NEUTRAL o Full stroke) When the lever (5) pushes down on the piston (4), and the retainer (9) pushes down on the stem (1), calibrated hole f is put in direct connection with chamber PP, which is in turn connected to a constantly pressurised servocontrols circuit. Oil is then allowed to flow directly into section A-P1, thereby pushing the stem of the main control valve to the end of its travel. This causes the main control valve to send the oil contained in chamber B towards input P2, through calibrated holef and into discharge chamber D.

5 4

7 5

D T

1 7

D T

Control valve

RKP13770

1 PP

Control valve

B RKP13760

PC80MR-3

10-49

STRUCTURE AND FUNCTION

EQUIPMENT

EQUIPMENT E D

G C

F B

H J JK

M L

B R

L N

RKP16530

Unit: mm

Criteria No.

Control

Basic dimension Ø

Shaft

Hole

Standard Clearan ce clearance Limit

Allowable

Clearance betweenbushing and swingbracketrotating pin

110

-0.036 -0.090

+0.204 +0.125

0.161 – 0.294

1.0

Clearance between bushings and boom mounting pin

-0.030 -0.100

+0.174 +0.100

0.130 – 0.274

1.0

Clearance between bushings and arm mounting pin

-0.030 -0.100

+0.174 +0.100

0.130 – 0.274

1.0

Clearance between arm bushings and bucket mounting pin

-0.225 -0.285

+0.062 +0.120

0.105 – 0.223

1.0

Clearance between bushings and lever mounting pin

-0.225 -0.285

+0.062 +0.120

0.105 – 0.223

1.0

Clearance between bushings and lever mounting pin

-0.030 -0.100

+0.173 +0.100

0.130 – 0.273

1.0

Clearance between linkbushings and bucket mounting pin

-0.225 -0.285

+0.040 +0.094

0.131 – 0.245

1.0

Clearance between blade fulcrum pin and bushing

-0.025 -0.087

+0.142 +0.080

0.105– 0.229

1.0

10-50

Remedy

Replace

PC80MR-3

STRUCTURE AND FUNCTION

EQUIPMENT

A-A

F-F

B-B

C-C

D-D

E-E 3

G-G

H-H

J-J

K-K L-L

R-R

M-M

S-S

N-N

P-P

T -T RKP17500

PC80MR-3

10-51

PAGE INTENTIONALLY LEFT BLANK

20 TESTING AND ADJUSTMENTS

NORMAL OR STANDARD TECHNICAL DATA .................. 3

CHECKING PPC VALVE DELIVERY PRESSURE ........... 44

PUMP FEATURES ............................................................ 11

CHECKING SOLENOID VALVE OUTPUT PRESSURE ..... 45

CHECK POSITIONS ......................................................... 12

ADJUSTING BOOM SAFETY VALVE ............................... 46

SPECIAL TOOLS .............................................................. 17

SAFETY PRESSURE SWITCH CALIBRATION: ............... 47

MEASURING THE ENGINE SPEED................................. 19

ADJUSTING PPC VALVE CLEARANCE........................... 48

CHECKING THE EXHAUST SMOKE COLOUR ............... 21

MEASURING TRAVEL DEVIATION.................................. 49

REMOVAL OF VALVES COVER ...................................... 23

CHECKING TRAVEL SPEED............................................ 50

ADJUSTING VALVE CLEARANCE................................... 25

ANALYSIS OF THE CAUSES OF HYDRAULIC DRIFTS ........................................................ 51

MEASURING COMPRESSION PRESSURE .................... 28 TESTING AND ADJUSTING FUEL INJECTION TIMING .............................................................................. 30 CHECKING ENGINE OIL PRESSURE ............................. 34 CHECKING AND REGULATING PRESSURE IN THE HYDRAULIC CIRCUITS.................................................... 35 CHECKING AND CALIBRATING PRESSURE IN THE SECONDARY VALVES..................................................... 37 CHECKING AND ADJUSTING THE LS (Load Sensing) VALVE...................................................... 40

METHODS FOR TESTING FOR LEAKAGES INSIDE THE SWIVEL JOINT............................................. 57 ELIMINATING PRESSURES FROM CIRCUITS ............... 58 MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS .......................................................... 59 TESTING AND ADJUSTING TRACK SHOE TENSION .... 60 AIR BLEEDING FROM HYDRAULIC CIRCUITS .............. 61 TESTING THE AIR-CONDITIONING UNIT ....................... 64 EMPTYING THE AIR-CONDITIONING UNIT.................... 66

ADJUSTING PC VALVE.................................................... 42 CHECKING SERVO-CONTROL CIRCUIT PRESSURE ....................................................... 43

PC80MR-3

20-1 (1)

TESTING AND ADJUSTMENTS

NORMAL OR STANDARD TECHNICAL DATA

NORMAL OR STANDARD TECHNICAL DATA FOR THE ENGINE

Check item

Machine model

PC80MR-3

Engine

4D88E-5KFD

Test conditions

Unit

High idling (no-load) Engine speed (without load):

Low idling (no-load)

rpm

Max. power rating Sudden acceleration

Index Bosch

Exhaust gas colour At high idling speed Intake valve (20 °C) Valve clearance

Standard value

Permissible value

2250 +– 100 50

—

1100 ± 50

—

2000

—

Max. 3.5

6.0

Max. 1.0

2.0

0.35 ± 0.02

—

0.50 ± 0.02

—

mm Dump (20 °C)

Compression pressure (SAE15W-40 oil)

Oil temperature: 40-60°C Engine speed: 320 -360 rpm

kg/cm2

Min. 30

Blow-by pressure

Oil temperature: within range) At max. power rating

mmH2O

100

Engine oil pressure High idling

Oil temperature: within range

SAE 30

3.5 – 5.5

2.5

3.0 – 5.0

2.1

Engine oil pressure Low idling

Oil temperature: within range

SAE 30

1.8

1.5

1.3

engine oil temperature

Entire speed range

ºC

90 – 110

120

Fuel injection timing advance

BTDC

degrees

5 ± 0.75

Fan-belt tension

Deflection when pressed with finger force of approx. 6 kg

6 – 10

Belt tension air conditioner compressor

Deflection when pressed with finger force of approx. 6 kg

6 – 10

PC80MR-3

SAE 10W

kg/cm2

20-3 (1)

TESTING AND ADJUSTMENTS

NORMAL OR STANDARD TECHNICAL DATA

FOR MACHINE

Machine model Classifi cation

Check item

PC80MR-3

Test conditions

Unit

Standard value

Permissible value

rpm

2080±100

1980 – 2180

Engine

• Oil temperature 45 – 55°C

Engine speed with • Coolant circuit needed: at temperature. pump at max. • With boom raise in mode system P pressure

working

Operaring force for control of levers and pedals

Travel of levers and pedals

• With boom raise + swing in mode system P

20-4 (1)

Boom control lever

Neutral oRaise, Lower

76.5 – 93.5

Arm control lever

Neutral o Open Close

76.5 – 93.5

Bucket control lever

Neutral o Dump Curl

76.5 – 93.5

Neutral o Swing R.H. Swing L.H.

76.5 – 93.5

47.7 – 58.3

Neutral o Swing R.H. Swing L.H.

13.5 – 16.5

Travel control lever

Neutral o Forward Reverse

115

103.5 – 126.5

2-piece boom control pedal

Neutral o Open Close

20 30

18 – 22 27 – 33

Optional attachment pedal

Neutral o R.H. L.H.

–

Boom lever

1.75

1.4 – 2.1

Arm lever

1.75

1.4 – 2.1

Bucket lever

1.5

1.04 – 2.0

Revolving frame swing lever

1.5

1.04 – 2.0

2.6

2.08 – 3.12

Boom swing pedal

7.8

6.0 – 9.6

Travel levers

2.0

1.5 – 2.6

Revolving frame swing lever Blade control lever Boom swing pedal

• Equipment on the ground • Engine: switched off • At the end of the lever and at 90°. Reading at bottom of stroke, adding half freeplay

Neutral oRaise Lower

Blade lever

2nd boom pedal

Neutral o Open Close

3.8 1.8

3.04 – 4.56 1.44 – 2.16

Optional attachment pedal

Neutral o R.H. L.H.

2.3 3.7

1.8 – 2.8 3.2 – 4.2

PC80MR-3

TESTING AND ADJUSTMENTS

NORMAL OR STANDARD TECHNICAL DATA

Machine model

Standard value

Permissible value

General valve P1 (boom – arm - bucket) - Boom swing and travel

265

256 – 275

Main valve P2 (Blade - Swing)

211

201 – 215

With blade raise

196

196 – 201

Measured on the servocontrols outlet tube

31.4

31.4 – 33.3

Classific ation

Check item

Test conditions

Revolving frame secondary valve Hydraulic pressure

PC80MR-3

Servocontrols feed valve

• Hydraulic system oil temperature: 45-55 °C • Engine speed: Max.

Unit

bar

Secondary valve for optional attachment Load limiter with 1piece boom

Measure on the cylinder

115

110– 120

Load limiter with 2piece boom

Measure on the cylinder

110

105 – 115

Max. 20

sec.

0.7

0.7–2

sec.

90° : 2.2±0.3 180° : 3.7±0.3

90° : Max. 2.8 180° : Max. 4.3

Pressure drop

• Hydraulic system oil temperature: 45-55 °C • Pressure difference with engine under load at high idling and with engine at max. power rating

Measuring position: See Fig. A • Engine speed: Max. • Hydraulic system oil temperature: 45-55 °C • Swing the revolving frame 1 turn, and release the lever control. • Measure the delay between actuator release and stop.

Swing

Revolving frame inertia

Time needed to start swing motion (after command)

PC80MR-3

Measuring position: See Fig. A • Engine speed: Max. • Hydraulic system oil temperature: 45-55 °C • Time required to swing 90° and 180°, after command

20-5 (1)

TESTING AND ADJUSTMENTS

NORMAL OR STANDARD TECHNICAL DATA

Machine model Classifi cation

Check item

PC80MR-3

Test conditions

Unit

Standard value

Permissible value

sec.

26.4 – 32

mm (degre es)

0 (0)

Measuring position: See Fig. A

Time taken to swing

• Engine speed: Max. • Hydraulic system oil temperature: 45-55 °C • Mode system: P • Perform one turn to settle the machine and measure the time needed to perform the next 5 turns. • Check in both directions of rotation

Swing

Measuring position: See Fig. B

Mechanical drift of revolving frame

Internal leakage from swing motor

• Engine: switched off • Hydraulic system oil temperature: 45-55 °C • Revolving frame swung by 45° with vehicle on a 15° slope. • Blade lowered. • On the outer swing circle, mark the position between turret and track frame. • After 15 minutes measure the drift.

• Engine speed: Max. • Hydraulic system oil temperature: 45-55 °C • Revolving frame locked • Measure the leakage

l/ min.

Steel shoes

20-6 (1)

Travel speed:

• Engine speed: Max. • Mode system: P • Hydraulic system oil temperature: 4555 °C • Drive for at least 5 m, and then measure the time needed to cover 20 m

Normal

23.4 – 28.6 Rubber shoes

24.0

21.5 – 26.5

sec. Steel shoes With increment

Travel

Measuring position: see Fig. D

26.0

15.3

13.9 – 17.0 Rubber shoes

15.0

13.6 – 16.7

PC80MR-3

TESTING AND ADJUSTMENTS

NORMAL OR STANDARD TECHNICAL DATA

Machine model Classifi cation

Check item

Test conditions

PC80MR-3 Unit

Standard value

Max. 200

Permissible value

Measuring position: see Fig. D

Travel

Travel deviation

• Mode system: position P • Engine speed: Max. • Hydraulic system oil temperature: 45-55 °C • After driving for 5 metres and then covering another 20 metres. • Measure deviation “X” (see Fig. E)

Measuring position: see Fig. F • Engine: switched off

Hydraulic drift of travel • Hydraulic system oil temperature: 45-55 °C motors • Machine parked on sloping ground with blade

raised. • Measure the drift after 5 minutes • Engine speed: Max.

Inner leakage of travel • Hydraulic system oil temperature: 45-55 °C motor • Lock track and measure.

PC80MR-3

l/ min.

20-7 (1)

TESTING AND ADJUSTMENTS

NORMAL OR STANDARD TECHNICAL DATA

Machine model Classifi cation

Check item

PC80MR-3 Standard value

Permissible value

Max. 350

Max. 600

Max. 490

–

Max. 8

Max. 12

Max. 41

Max. 62

Max. 25

Max. 38

Max. 20

Max. 30

Standard boom

Max. 16

–

Long boom

Max. 16

–

Standard boom

Max. 16

–

Long boom

Max. 16

–

Max. 1.5

Max. 7.5

Test conditions

Unit

Total work equipment Standard (Standard boom) boom (Downward Measuring position: see Fig. G. mo veme nt buc ket • In this position, measure extension or Long boom teeth tips) retraction of each cylinder, and any

Work equipment (Hydraulic drifts)

Bomm cylinder (Retraction)

Arm cylinder (Extension)

Arm cylinder (Retraction)

Blade cylinder

leakages occurring when a load is applied to the tips of the bucket teeth. • Horizontal and level ground. • Load in the bucket: 620 kg • Levers: neutral • Engine: switched off • Hydraulic system oil temperature: 4555 °C • Safety valve disengaged • Take measurements as soon as the engine stops. • Measure the variations every 5 minutes and check the total variation after 15 mins.

• Engine: switched off • Hydraulic system oil temperature: 45-55 °C • Measure blade descent from max. height within a timeframe of 15 minutes.

Measuring position: see Fig. H. Boom swing (Standard boom)

Cylinder leankage

Boom swing (Boom + 2-piece boom)

20-8 (1)

All cylinders

• Engine: switched off • Hydraulic system oil temperature: 4555 °C • In the same position as above, park the machine on a 15° slope and bring the turret round to 135°. Measure the extension and retraction of the cylinder after 15 mins. • Repeat the procedure on the other side.

• Hydraulic system oil temperature: 45-55 °C • Pressurize the cylinder

cc/ min

PC80MR-3

TESTING AND ADJUSTMENTS

NORMAL OR STANDARD TECHNICAL DATA

Machine model Classifi cation

Check item Boom Bucket teeth on the ground Cylinders completely extended 2nd boom Cylinder completely retracted Cylinders completely extended

Work equipment (Speed)

Arm Cylinder completely retracted Cylinders completely extended Bucket Cylinder completely retracted Cylinders completely extended Boom swing Cylinder completely retracted Cylinders completely extended

PC80MR-3

Standard value

Permissible value

Raise

2.6 (2.5)

2.35–2.95 (2.2–2.8)

Lower

2.8 (2.55)

2.5–3.1 (2.1–3.0)

Closed

6.0

4.8–7.2

Inout

6.0

4.8–7.2

Closed

3.3 (3.4)

3.0–3.6 (3.1–3.7)

Inout

2.9 (3.5)

2.6–3.2 (2.8–3.4)

Closed

3.4

3.1–3.7

Inout

2.6

2.3–2.9

Left

6.7

6.0–7.4

Right

6.7

6.0–7.4

Raise

1.3

1.0–1.6

Lower

1.1

0.8–1.4

Test conditions

Measuring position: See Fig.I. • Engine speed: Max. • Hydraulic system oil temperature: 4555 °C • ( ): with long arm

Measuring position: See Fig. J. • Working Mode: P • Engine speed: Max. • Hydraulic system oil temperature: 4555 °C

Measuring position: See Fig. K. • Engine speed: Max. • Oil temperature 45 – 55°C • ( ) boom with safety valve

Unit

sec. Measuring position: See Fig. L. • Engine speed: Max. • Hydraulic system oil temperature: 45-55 °C

Measuring position: See Fig.M. • Engine speed: Max. • Hydraulic system oil temperature: 45-55 °C

Blade Measuring position: Blade on the ground See Fig. N. Blade at maximum height

PC80MR-3

• Engine speed: Max. • Hydraulic system oil temperature: 45-55 °C

20-9 (1)

TESTING AND ADJUSTMENTS

NORMAL OR STANDARD TECHNICAL DATA

Machine model Classifi cation

Check item

Test conditions

PC80MR-3 Unit

Standard value

Permissible value

Max. 2

Max. 3.9

Max. 2

Max. 3.9

Max. 1

Max. 2

Measuring position: See Fig. O. • Engine speed: low idling • Hydraulic system oil temperature: 45-55 °C • Retract fully the cylinders of the arm and bucket. Lower bucket to ground and measure time taken for chassis to rise from ground.

Boom

Measuring position: See Fig. P. Boom boom)

• Engine speed: low idling

( 2 - p i e c e • Hydraulic system oil temperature: 45-55 °C • Retract fully the cylinders of the arm and bucket. Extend the 2nd boom fully. Lower bucket to ground and measure time taken for chassis to rise from ground.

Work equipment (Time lags)

Measuring position: See Fig. Q. 2nd boom

• Engine speed: low idling • Hydraulic system oil temperature: 45-55 °C • Retract fully the cylinders of the arm and bucket. Extend the 2nd boom fully. Bring the boom into a vertical position. Close completely the 2nd boom and measure the time taken increase the pressure.

sec. Measuring position: See Fig. R. Arm

• Engine speed: low idling • Hydraulic system oil temperature: 45-55 °C • Bring the boom into a horizontal position. Retract the cylinder of the arm completely and then extend it. Amount of time when arm stops for a moment.

Measuring position: See Fig. S. Bucket

• Engine speed: low idling • Hydraulic system oil temperature: 45-55 °C • Bring the boom into a horizontal position. Retract the bucket cylinder completely, then extend it. Measure the time that elapses between the bucket stopping at dead centre and then starting to move again.

Measuring position: See Fig. T. Blade

20-10 (1)

• Engine speed: low idling • Hydraulic system oil temperature: 45-55 °C • Raise the blade to its max. height, then lower it. Measure the time it takes for the rear of the machine to be lifted off the ground, starting from the time the blade contacts the ground.

PC80MR-3

TESTING AND ADJUSTMENTS

PUMP FEATURES

Delivery of piston pumps

PC80MR-3

20-11 (1)

TESTING AND ADJUSTMENTS

CHECK POSITIONS

CHECK POSITIONS Fig. A

Fig. B

45° 15° RKP16600

Fig. C

RKP16610

Fig. D

45°

RKP16620 RKP16630

20-12 (1)

PC80MR-3

TESTING AND ADJUSTMENTS

CHECK POSITIONS

Fig. E

Fig. F

20 m

X 30° 10 m

RKP16650

RKP19950

Fig. G

Fig. H

15°

135° RKP16660

PC80MR-3

RKP16670

20-13 (1)

TESTING AND ADJUSTMENTS

CHECK POSITIONS

Fig. J

Fig. K

RKP16680

Fig. L

Fig. M

RKP16700

20-14 (1)

RKP16690

RKP16710

PC80MR-3

TESTING AND ADJUSTMENTS

CHECK POSITIONS

Fig. N

Fig. O

RKP16720

Fig. P

Fig. Q

RKP16730

PC80MR-3

RKP16770

RKP16740

20-15 (1)

TESTING AND ADJUSTMENTS

CHECK POSITIONS

Fig. R

Fig. S

RKP16750

RKP16760

Fig. T

RKP16780

20-16 (1)

PC80MR-3

TESTING AND ADJUSTMENTS

SPECIAL TOOLS

SPECIAL TOOLS Measurement points

check

Engine speed

Symbol

Coolant liquid temperature

6210-81-4111

Diverter

799-101-1500

Digital temperature gauge

-50 -1.200 °C

799-101-5002

Pressure gauge kit

Scale 25-60-400-600 bar

790-261-1203

Digital pressure gauge

Scale 600 bar

799-401-2320

Pressure gauge

Scale 10 bar

799-101-5160

Union

799-101-5220

Union

07002-11023

O-ring

799-401-2910

Union

02896-11008

O-ring

07043-00108

Union

799-401-2701

Differential pressure gauge

795-502-1590

Compression pressure 0–70 bar - (kit 795-502-1205) gauge

795-502-1370

Adapter

Blow-by pressure

799-201-1504

Pressure gauge

Valve clearance

Commercially available

Feeler gauge

790-201-9001

Probe

Commercially available

Readout device

Exhaust smoke

Digital display L: 60 -2000 rpm R: 60 -19999 rpm

Multi-scale tachometer

Compression pressure

Remarks

709-203-9000

Name

Hydraulic pressure

Code

Hexagonal hole

0–70% with standard colour (%x1/10= Bosch scale)

Force monitoring

Commercially available

Force gauge

Drift monitoring

Commercially available

Gauge

Attachment speed

Commercially available

Chronometer

YM15809051841

Adapter

YM23000013000

Dial gauge port

Commercially available

Dial gauge

Travel 30 mm

Commercially available

Dial gauge

Magnetic base

K Injection advance check

PC80MR-3

20-17 (1)

TESTING AND ADJUSTMENTS

Measurement points

check

SPECIAL TOOLS

Symbol 1 2

Connector monitoring

Code

Name

Remarks

790-601-9320

Connector

24 pins

790-601-9310

Plate

For 40-pole connector

799-601-8000

Full adapter

799-601-7310

Adapters

799-601-7050 3

799-601-7520 799-601-7360 799-601-7370

Fuel injection timing

20-18 (1)

799-601-9200

Adapters Kit

Commercially available

Dial gauge

PC80MR-3

TESTING AND ADJUSTMENTS

MEASURING THE ENGINE SPEED

MEASURING THE ENGINE SPEED a Check engine speed when the following conditions are met: • Coolant liquid temperature: within the acceptable range. • Hydraulic system oil temperature: 45-55 °C.

1. Measuring engine speed 1 -Remove the clamps (1) retaining the injection pipes, install and connect sensor (3) of speedometer A1 to the injection pipe (2).

1 RKPC7280

2 - Plug the connector of sensor (3) into the amplifier (4) an d con nect t he amplifier output connec tor to speedometer A1. 3 -Start the engine and turn the knob (a) on the amplifier (4) until the value displayed by speedometer A1 stabilizes; measure the number of revolutions.

a Min. and Max. speed with no load: measure speed when the accelerator lever is in the Min. and Max. positions. a Max. speed with piston pump in load condition: with Mode System P , operate the boom up. Bring the pump under load and rev up the engine to Max. speed, then measure stabilized speed.

RKPC0460

a Max. speed with piston pump and gear pump P3 in load condition: with Mode System P, boom up and rotate the revolving frame simultaneously. Rev up the engine to Max. speed, then measure stabilized speed. k To stop the revolving frame, fully extend the boom and drive the bucket teeth perpendicularly into the ground.

PC80MR-3

20-19 (1)

TESTING AND ADJUSTMENTS

MEASURING THE ENGINE SPEED

2. Measuring engine speed to check compression pressure 1

1 -Remove inspection cap (1) and apply a reflecting mark to the flywheel.

RKPC7290

2 -Disconnect engine stop solenoid connector (2) of fuel cut-off solenoid valve.

RKPC7300

3 -Using the starter, crank and run the engine. (For details, see "MEASURING COMPRESSION PRESSURE"). 4 -When RPM reaches a steady condition, read engine rotational speed.

RKPC7310

20-20 (1)

PC80MR-3

TESTING AND ADJUSTMENTS

CHECKING THE EXHAUST SMOKE COLOUR

CHECKING THE EXHAUST SMOKE COLOUR a When no compressed air is available, use tool G1 instead; if formal checks are to be performed, use tool G2. a Before checking the quality of the exhaust smoke, ensure that valve clearance is properly adjusted and that cooling liquid temperature is within the permitted range. k When installing or removing tools, pay attention not to touch hot parts.

1. Checking with tool G1

1 -Install a paper filter to tool G1. 2 -Introduce the tool's suction hose into the exhaust pipe; accelerate rapidly while simultaneously operating the plunger on tool G1 to allow the filter to absorb the exhaust smoke.

a Suction time 1.4±0.2 sec. 3 -Remove the paper filter and check the colour against the colour scale attached to the tool. a If the colour is between two colour samples in the scale, take the intermediate value.

RKPC0490

2. Checking with tool G2 1 -Introduce the probe (1) that is fitted on tool G2 into the exhaust pipe; lock into position using the clamp provided. 2 -Connect cable (2), throttle pedal (3) and hose (4) to tool G2.

RKPC0500

3 -Connect the power supply cable to a 100V (AC) socket.

a Before connecting the power cable, ensure that the instrument switch is in the “OFF”position. 4 -Loosen the plug (5) of the suction pump and introduce a paper filter.

a Ensure that the filter is properly seated, or the exhaust smoke will be unable to pass through it.

1 2

PC80MR-3

RKPC0510

20-21 (1)

TESTING AND ADJUSTMENTS

CHECKING THE EXHAUST SMOKE COLOUR

5 -Turn the switch of instrument G2 to the ON position. 6 -Accelerate rapidly while simultaneously operating the pedal (3) so as to allow the paper filter to absorb the exhaust smoke. 7 -Position the contaminated filter in the container, on top of a pile of at least 10 new filters and read the value displayed by the instrument. 8 -When the check is complete, remove the equipment.

20-22 (1)

PC80MR-3

TESTING AND ADJUSTMENTS

REMOVAL OF VALVES COVER

REMOVAL OF VALVES COVER 1 -Disconnect the connector (1) the temperature sensor.

RKPC7320

2 -Remove screws (2) and (3) and remove wiring harness tie straps and heating hose clamps.

2 3

RKPC7330

3 -Loosen nuts (4) and remove the clamp (5) retaining the fuel delivery pipes (6).

5 6

RKPC7340

4 -Disconnect pipes (6) from injectors and injector pump (7).

6 6

RKPC7350

PC80MR-3

20-23 (1)

TESTING AND ADJUSTMENTS

REMOVAL OF VALVES COVER

5 -Remove the fuel delivery pipe assembly (6).

RKPC7360

6 -Pry out seal (8) using a screwdriver placed in the seat at 3 o'clock.

RKPC7370

7 -Loosen and remove the valve cover retaining screws (9).

a Thoroughly check the O-rings.

RKPC7380

8 -Remove the valve cover (10) and its washer.

a Thoroughly check the valve cover seal and replace the seal at the slightest doubt about its integrity or proper working order.

RKPC7390

20-24 (1)

PC80MR-3

TESTING AND ADJUSTMENTS

ADJUSTING VALVE CLEARANCE

ADJUSTING VALVE CLEARANCE a The adjusting procedure should be performed with the engine at ambient temperature. NOTE: •

Cylinder no. 1 is the one on the flywheel side.

•

Ignition order: 1 - 3 - 4 - 2.

•

Rotation sense: clockwise as seen from flywheel side. 1 -Remove the valve cover. (For details, see "REMOVAL OF VALVES COVER"). RKPC7391

2 -Rotate the drive shaft in its normal direction of rotation until piston reaches top dead centre (TDC) in its compression stroke. (Intake valves closed and reference mark on the flywheel visible from the inspection hole). NOTE:When piston no. 1 is in its compression stroke, adjust the valves that are marked with q in the drawing shown to the side.

RKPC7400

N. Cylinder

Exhaust valve Intake valve

RKP19780

3 -Ensure that there is a clearance (1), (2) between valves (3) and bridge (4) and between bridge (4) and rocker arm (5).

4 1

RKP19790

PC80MR-3

20-25 (1)

TESTING AND ADJUSTMENTS

ADJUSTING VALVE CLEARANCE

4 -Loosen the lock nut (6) retaining the adjusting screw (7) while simultaneously holding the bridge into position with a wrench.

k Do not loosen or tighten the bridge adjusting screw lock nut without previously securing the bridge into position with a wrench to prevent it from rotating.

RKP19800

9 RKP19791

5 -After ensuring that the bridge (4) is resting on the rear valve (9), keep contact between bridge and rear valve by applying a light pressure “P” with your fingers on the bridge (4), and loosen the adjusting screw (7) until you notice a clearance (1) between bridge and front valve (3).

RKP19810

6 -Keep applying finger pressure “P” to the bridge and operate the adjusting screw (7) until clearance between screw and front valve (3) is zero.

RKP19820

20-26 (1)

PC80MR-3

TESTING AND ADJUSTMENTS

ADJUSTING VALVE CLEARANCE

7 -Tighten nut (6) while simultaneously holding the adjusting screw (7) into position and ensure that clearance (1) continues to be equal to zero while tightening.

a Clearance tends to increase as the nut is tightened. If necessary, resume the procedure from step 6.

RKP19830

8 -Loosen the lock nut (10) retaining the adjusting screw (11) for the rocker arm (12) and unscrew the adjusting screw (11) by approximately 1 turn.

11 10

9 -Insert a feeler gauge “F” (for proper feeler gauge size for this procedure see "NORMAL OR STANDARD TECHNICAL DATA") between the rocker arm (12) and bridge (4).

F 4 RKP19840

10 -Tighten the adjusting screw (11) until it rubs against gauge “F”. Secure this position with the nut (10). 11 - Check adjustment again and lubricate the contact surface between rocker arm (12) and bridge (4).

12 11 4

RKP19850

12 -Turn the drive shaft and adjust the clearance of valves that are marked with O. 13 -Reinstall valve cover and secure any removed parts.

PC80MR-3

20-27 (1)

TESTING AND ADJUSTMENTS

MEASURING COMPRESSION PRESSURE

MEASURING COMPRESSION PRESSURE k While measuring compression, take appropriate precautions to prevent parts of the body or clothing from being caught in the cooling fan, the alternator belt, or other rotating parts. Engine must reach normal temperature before you can start this measuring procedure. Use all precautions against burn injuries. a Check all cylinders. a Test conditions: • Engine: at working temperature. • Hydraulic oil: 55-60 °C. • Battery: fully charged • Valve clearance: adjusted (See "ADJUSTING VALVE CLEARANCE"). 1 -Remove the valve cover (1). (For details, see "REMOVAL OF VALVES COVER").

RKPC7392

2 -Close the fuel delivery cock (2) and disconnect the connector (3) of pump (4).

RKPC7410

3 -Remove the screws (5) and remove the fuel return line (6).

a Pay attention not to kink the line.

RKPC7420

4 -Remove the screw (7), bracket (8) and injector (9) of the cylinder being checked.

5 -Remove the injector guide (10) and seat (11).

10 7

9 8 RKPC7430

20-28 (1)

PC80MR-3

TESTING AND ADJUSTMENTS

MEASURING COMPRESSION PRESSURE

6 -Let the engine run for a few seconds to prevent fuel spillage during the compression test. 7 -Disconnect engine stop solenoid connector (12).

RKPC7301

8 -Install a seat for adapter D2 and plug in compression gauge D1.

9 -Crank the engine using the starter and read the pressure.

a Read the compression value compression gauge has stabilised.

when

the

a When measuring compression, also check the rotational speed of the engine using a stroboscopic tachometer C2. If rotational speed does not match check speed, then refer to the diagram. RKP19860

a Compression value: Normal: 34-36 bar at 250 rpm. Minimum permissible: 27.5±1 bar at 250 rpm

Compression pressure (bar)

a Difference between cylinders: 2–3 bar

Rotational speed (rpm)

RKP19870

10 -Rimontare le parti rimosse. 11 -Connect connectors (3) and (12), open the cock (2), bleed the air from the fuel lines and start the engine. 12- Check for leaks in the fuel supply lines.

PC80MR-3

20-29 (1)

TESTING AND ADJUSTMENTS

TESTING AND ADJUSTING FUEL INJECTION TIMING

TESTING AND ADJUSTING FUEL INJECTION TIMING a Directions of rotation are referred to the engine as seen from the fan side.

Test

1 -Close the fuel delivery cock (2). Disconnect and close the return hose (2). 2 -Thoroughly clean the cover to prevent contaminants from getting into the pump during the next steps.

RKPC7440

3 -Remove plug (3) from the pump cover.

RKPC7450

4 -Install adaptor K1 and dial gauge holder K2.

RKP19880

5 -Install a centesimal dial gauge K3 (30mm head travel) and lock into position at about half way of its working stroke.

RKP19890

20-30 (1)

PC80MR-3

TESTING AND ADJUSTMENTS

TESTING AND ADJUSTING FUEL INJECTION TIMING

6 -Using a wrench applied to the engine pulley screw, rotate the drive shaft clockwise until the TDC stamping becomes visible in the inspection hole (8).

6 5 4 8

RKP19900

7 -Align the TDC stamping (8) with the notch (9) in the inspection hole and mark out both reference marks.

RKP19910

8 -In the flywheel scale, also mark out the notch A relative to the injection advance that is specific to the engine. (Refer to "NORMAL OR STANDARD TECHNICAL DATA").

RKP19920

9 -Slowly rotate the flywheel counterclockwise until the dial gauge K3 completes its maximum stroke down.

a Slightly rotate the flywheel in both directions to confirm the position.

10 -Under this condition, set dial gauge K3 to the zero point.

RKP19890

PC80MR-3

20-31 (1)

TESTING AND ADJUSTMENTS

TESTING AND ADJUSTING FUEL INJECTION TIMING

11 -Slowly rotate the drive shaft clockwise until the dial gauge indicates an up stroke of about 2.5 mm. 12 -On the flywheel scale, check the previously marked A position for injection advance; if both marks (inspection hole notch and advance) match, advance is correct. If marks do not match, then injection advance needs adjusting.

RKP19920

Adjustment procedure 1 -Without attempting to move the dial gauge from its position, rotate the flywheel until the notch in the inspection hole (9) and the A mark for injection advance line up.

k DO NOT rotate the drive shaft during the steps below.

2 -Check reading on dial gauge K3. If it reads 2.5 mm, advance is correct. If reading is lower than 2.5 mm, injection is delayed. If reading is higher than 2.5 mm, injection is advanced. 3 -Loosen three nuts (10) retaining the injection pump to the timing cover and loosen screws (11) retaining the rear bracket (12).

RKP19920

11 10

RKPC7460

4 -Loosen the nuts on the bracket (13) retaining the fuel delivery lines.

14 13

5 -Loosen the fuel delivery lines (14) on the pump.

13 RKPC7470

20-32 (1)

PC80MR-3

TESTING AND ADJUSTMENTS

TESTING AND ADJUSTING FUEL INJECTION TIMING

6 -Rotate the pump until the dial gauge reads 2.5 mm. 7 -Secure the pump and the delivery lines. 8 -Remove the dial gauge and the adaptor and restore normal conditions. 9 -Start the engine and check the fuel system for leaks.

PC80MR-3

20-33 (1)

TESTING AND ADJUSTMENTS

CHECKING ENGINE OIL PRESSURE

CHECKING ENGINE OIL PRESSURE a Check pressure when the coolant liquid reaches operating temperature. 1 -Remove fuel pump assembly (1) and set it aside.

1 RKPC7480

2 -Disconnect the connector (2) and remove engine pressure sensor (3).

RKPC7490

3 -Install the nipple C3 and plug in the pressure gauge C2. 4 -Crank the engine and check pressure at Min. and at Max.

RKPC0590

20-34 (1)

PC80MR-3

TESTING AND ADJUSTMENTS

CHECKING AND REGULATING PRESSURE IN THE HYDRAULIC

CHECKING AND REGULATING PRESSURE IN THE HYDRAULIC CIRCUITS INTRODUCTION

•

The control valve is divided into two normally independent sections, supplied by pumps P1 e P2 respectively.

•

Each section is protected against overpressures by a main (or primary) relief valve with a regolable cartridge.

Each section is protected by safety valve with presetting cartridge. 1 - Main relief valve (Section 1) 2 - Main relief valve (Section 2) 3 - Safety valve

DIESEL

SECTION 2

SECTION 1

P2 TANK

2 P1

1 RKP19930

PC80MR-3

20-35 (1)

TESTING AND ADJUSTMENTS

•

CHECKING AND REGULATING PRESSURE IN THE HYDRAULIC

The sections consist of the spools that govern: Section 2

Control

Ports

Swing (Left-Right)

A1 - B1

Blade: (Lower - Raise)

A2 - B2

L.H. travel motor (Forward-Backward)

A3 - B3

R.H. travel motor (Backward-Forward)

A4 - B4

Boom (Raise-Lower)

A5 - B5

Arm (Open-Close)

A6 - B6

Bucket (Curl-Dump)

A7 - B7

Boom swing (Left-Right)

A8 - B8

10 9 8 7 6 5 4 3 2 1

* 2nd boom (Open-Close)

A9 - B9

PORTS

Attachment (L.H. side - R.H. side)

A10 - B10

10 9 8 7 6 5 4 3 2 1 A

RKP10592

* Opzional

20-36 (1)

PC80MR-3

TESTING AND ADJUSTMENTS

CHECKING AND CALIBRATING PRESSURE IN THE SECONDARY

CHECKING AND CALIBRATING PRESSURE IN THE SECONDARY VALVES a Test conditions: • Engine: at working temperature. • Engine idling Min. and Max.: within the permissible values • Hydraulic system oil temperature: 45-55°C. • Mode system: P

k Lower the equipment to the ground and stop the engine; slowly loosen the tank cap to relieve pressure, and move the safety engagement lever to locked position.

1. Preparing the machine 1 -Open the engine-hood. (1).

RKPC7500

2 -Remove plugs (2) from the delivery lines (3), (4) of pumps P1 or P2. Install a pressure tap and connect the digital pressure gauge C1 to one of the check points.

3 2

RKPC7510

2. Checking revolving frame rotational pressure 1 -Lock the revolving frame into position by fully extending the arm and driving the bucket teeth into the ground at a right angle. Rotate the revolving frame in both directions and, using pressure gauge C1, read pressure and ensure that it is within the range specified in “SPECIFICATIONS”.

a If the pressure values are lower than the value shown, check the safety valves of swing motor. RKPC7520

PC80MR-3

20-37 (1)

TESTING AND ADJUSTMENTS

CHECKING AND CALIBRATING PRESSURE IN THE SECONDARY

3. Adjusting general valve for revolving frame rotation and blade circuit k To make the valve setting, prepare the machine in the same way as for pressure testing.

1 -Loosen nut (1) and adjust the pressure using screw (2). • To INCREASE pressure, turn in a CLOCKWISE direction. • To DECREASE pressure, turn in an COUNTERCLOCKWISE direction.

1 2

k Adjusting amount for one turn of the screw: about 120 bar.

2 -Lock the position with nut.

3 Lock nut 39–49 Nm

RKPC7550

2 RKP10600

4. Checking boom, arm, bucket, boom swing and travel pressure k Prepare the machine for this check as you would do for the pressure checking procedure.

1 -Start and run the engine at Max. speed, force the boom up, and check for an out-of-specified range. • Max. pressure: 265 -+ 913 bar 2 -If the value displayed on the pressure gauge is not within range, adjust the upper valve (1). RKPC7530

RKPC7540

20-38 (1)

PC80MR-3

TESTING AND ADJUSTMENTS

CHECKING AND CALIBRATING PRESSURE IN THE SECONDARY

5. Adjusting secondary valve for boom, arm, bucket, boom swing and travel

k To make the valve setting, prepare the machine in the same way as for pressure testing.

a To pressurize the circuits, use the boom-up function. 1 -Loosen nut (1) and adjust the pressure using screw (2). • To INCREASE pressure, turn in a CLOCKWISE direction. • To DECREASE pressure, turn in an COUNTERCLOCKWISE direction.

2 RKP10600

k Adjusting amount for one turn of the screw: about 125 bar. 2 -Lock the position with nut (1).

3 Lock nut: 39-49 Nm

6. Checking Unloading pressure 1 - Open the upper hood (1).

RKPC7560

2 -Connect pressure tap C3 and pressure gauge C1 to the control valve. 3 -Start and run the engine at Max. speed and check pressure without load (unloading) with all control levers in neutral position.

C1 C3

a Normal pressure: Max. 29.4 bar

RKPC7570

PC80MR-3

20-39 (1)

TESTING AND ADJUSTMENTS

CHECKING AND ADJUSTING THE LS (Load Sensing) VALVE

CHECKING AND ADJUSTING THE LS (Load Sensing) VALVE 1. Measuring DPLS differential pressure 1

1 -Disconnect hose (1) and connect a “T” fitting. Fit a pressure tap C3to the "T" fitting, then reconnect the hose (1) to the "T" fitting.

RKPC7580

2 -Connect a differential pressure gauge C1 to pressure taps C3 for delivery hose LS and pump delivery line P1 (2). 3 -Measure the DPLS differential pressure according to the conditions shown in table 1.

RKPC7590

Table 1 Work mode

Accelerator lever position.

Operation

Differential pressure (bar)

Max.

Lever at NEUTRAL

–

Max.

Bucket curl (lever operated to full curl position)

RKPC0690

C1 C3

C4 RKPC0700

20-40 (1)

PC80MR-3

TESTING AND ADJUSTMENTS

CHECKING AND ADJUSTING THE LS (Load Sensing) VALVE

2. With analog pressure gauge

a Measure the pressure with the same pressure gauge. 1 -Remove the plug and connect a pressure tap to the delivery line (1) of pump P1. 2 -Connect the pressure gauge C1.

a Use a pressure gauge with an end scale value of 400 bar and 10-bar indexing.

3 -Measure pressure under the conditions listed in Table 1 and note it down.

a Be sure to take a correct reading from the pressure gauge by holding it frontally.

RKPC7600

4 -Connect the same pressure gauge to the LS pressure hose (2) with fittings C3 and C4, then measure the LS pressure under the conditions listed in table 1 and note it down.

C1 C3

5 -Calculate differential pressure using the following formula: differential pressure LS = (pump delivery pressure) – (LSpressure).

2 RKPC7610

3. Adjusting the valve If the values obtained during the measurement of the differential pressure according to the foregoing conditions are not in the standard value range, adjust the LS valve according to the following procedure.

a Before attempting to adjust the valve, mark the angle position of the adjusting nut (3) and screw (4). 1 -Loosen nut (3) and adjust the pressure using screw (4). • To INCREASE pressure, turn in a CLOCKWISE direction. • To DECREASE pressure, turn in an COUNTERCLOCKWISE direction.

a Adjusting amount for one turn of the screw: about 12.75 bar.

RKPC7620

2 -Block the screw (4) in position with the nut (3).

3 Nut: 31-38 Nm

a When tightening nut (3) to retain the screw, ensure that the screw retains the adjustment position. a After the adjustment, check the differential pressure using either procedure described in the paragraphs above.

PC80MR-3

20-41 (1)

TESTING AND ADJUSTMENTS

ADJUSTING PC VALVE

ADJUSTING PC VALVE a If the engine speed drops when a pressure or load increase is demanded, or if the attachment speed is low when the engine speed, delivery pressure, and LS differential pressure is normal, then the PC valve (1) needs adjusting. To adjust PC valve, use the following procedure. a Before loosening nut (2), mark the positions (a) between the adjusting nut and screw (3).

RKP19770

1 -Loosen the nut (2) and adjust the pump torque absorption with screw (3).

a The PC valve is an eccentric design valve, so the value of torque increase will never be known, whatever direction the screw is turned (3). On account of that, turn the screw (3) while at the same time checking the procedure on the engine speed monitor.

2 -Once the adjustment is completed, retain the position of the screw (3) and tighten the nut (2).

3 Nut: 27.4-34.3 Nm

20-42 (1)

RKPC7790

PC80MR-3

TESTING AND ADJUSTMENTS

CHECKING SERVO-CONTROL CIRCUIT PRESSURE

CHECKING SERVO-CONTROL CIRCUIT PRESSURE a Test conditions • Engine: at working temperature. • Engine idling Min. and Max.: within the permissible values • Hydraulic system oil temperature: 45-55°C.

k Lower the equipment to the ground and stop the engine; slowly loosen the tank cap to relieve pressure, and move the safety engagement lever to locked position.

1. Checking 1 -Remove the left side shield (1) and the front protective panel (2).

2 -Remove plug (3) and connect fitting C3; connect pressure gauge C1 (60 bar).

3 -Start and run the engine to Max. speed and check pressure. + 1.9

a Normal pressure: 31.4 0

RKPC7640

bar

C3 RKPC7650

2. Adjustment 1 -Remove plug (4) from valve (5) (8 mm hex wrench) and adjust the pressure by means of the inner screw (6) (6 mm hex wrench). • To INCREASE pressure, turn in a CLOCKWISE direction. • To DECREASE pressure, turn in an COUNTERCLOCKWISE direction.

a Adjusting amount for one turn of the screw: about 3.5 bar. 4 -Tighten plug (4).

3 Plug: 20-29 Nm

5 6 5 RKPC7660

PC80MR-3

20-43 (1)

TESTING AND ADJUSTMENTS

CHECKING PPC VALVE DELIVERY PRESSURE

CHECKING PPC VALVE DELIVERY PRESSURE a Test conditions • Engine: at working temperature. • Engine idling Min. and Max.: within the permissible values • Hydraulic system oil temperature: 45-55°C.

k Lower the equipment to the ground, stop the engine and operate the PPC valves several times. 1 -Disconnect hose (1) from the circuit to be checked.

RKPC7670

2 -Install fitting C4 between hose (1) and its fitting. 3 -Connect pressure gauge C1 (60 bar) with fitting C3.

4 -Start and run the engine to Max. speed, operate the control lever for the circuit under examination; check pressure.

a If pressure is low, check PPC input pressure; if the pressure is within normal values, then the PPC valve is faulty.

1 RKPC7680

a Measure pressure for: a - Revolving frame to the right b - Revolving frame to the left c - Blade lower d - Raise blade e - Left travel reverse f - Left travel forward g - Right travel reverse h - Right travel forward i - Raise boom j - Lower boom k - Arm open l - Arm closing m - Bucket dump n - Bucket curl o - Boom L.H. swing p - Boom right swing q - 2-piece boom closing r - 2-piece-boom deployment s - Equipment *: Optional

RKP19940

20-44 (1)

PC80MR-3

TESTING AND ADJUSTMENTS

CHECKING SOLENOID VALVE OUTPUT PRESSURE

CHECKING SOLENOID VALVE OUTPUT PRESSURE a Test conditions • Engine: at working temperature. • Engine idling Min. and Max.: within the permissible values • Hydraulic system oil temperature: 45-55°C. a Lower the equipment to the ground, stop the engine and operate the PPC valves several times. 1 -Remove the left side shield (1) and the front protective panel (2).

2 -Disconnect the outlet hose from the solenoid valve that is to be checked.

RKPC7640

C1 C3

3 -Connect pressure gauge C1 (60 bar) using fittings C3 and C4.

RKPC0791

4 -Measure the output pressures from the solenoid valve as per Table 2. Table 2 Name EV

PCC locking pressure Travel speed selector

Swing motor brake

Optional device selection

Operating mode

Pressure (bar)

PPC circuit under pressure

32±5

Lever in lock position

Pressure not applied

OFF

Selector on Hi

Speed increase engaged

32±5

Selector on Lo

Speed increase disabled

OFF

Perform one of the following procedures:

Brake is released

32±5

When moving the control back to NEUTRAL (Check after 5 sec.)

Brake is applied

OFF

Service enable selector

Services enabled

32±5

Measuring condition

Operating conditions

Safety lever in operating position

• Swing

NOTE:Solenoids function as follows: ON: Energized solenoid valve (pressure flowing) OFF: De-energized solenoid valve (no pressure)

PC80MR-3

20-45 (1)

TESTING AND ADJUSTMENTS

ADJUSTING BOOM SAFETY VALVE

ADJUSTING BOOM SAFETY VALVE a Test conditions: • Engine: at working temperature. • Hydraulic system oil temperature: 45-55 °C • WORKING MODE selector: position P • Secondary valves: set to normal values.

1 -Rest the work equipment on the ground, stop the engine and release any residual pressures. (For details see "ELIMINATING PRESSURES FROM CIRCUITS").

2 -Disconnect the connector (1) for the overload alarm.

3 -Remove clamps (2). 4 -Loosen fittings (3), (4) and (5). 5 -Loosen the screws retaining the valve collars, and remove pipe (6) from input C2.

a Plug the cylinder hole to prevent contamination.

5 6 4 2

6 -Disconnect hose (7) and connect it to input C2. 7 -Remove hose (8) from input V2.

8 -Remove the protection (9). 9 -Unscrew the nut (10) and remove the threaded rod (11) and the nut (12).

2 RKPC7690

10 -Start the engine and bring it up to high idling speed. 11 -Slowly bring boom raise to maximum pressure and check the valve for oil leaks. 12 -Maintaining pressure, adjust the valve with the screw (13), until a slight leakage of oil (just a few drops every minute) is seen coming from the flange V2. • To INCREASE pressure, turn in a CLOCKWISE direction. • To DECREASE pressure, turn in an COUNTERCLOCKWISE direction.

11 10 12 140 Nm

13 14 V2

a Every turn of the screw (13) changes the pressure by 110 bar. 13 -Block the screw (13) in position with the nut (12).

3 Lock nut: 70 Nm

14 -Screw the rod in (11) until it comes into contact with the retaining element (14) and then turn it back for 5-6 turns. Secure it in position with the nut (10).

15 -Rest the equipment on the ground, stop the engine, and release any residual pressures. 16 -Restore all connections and re-fasten the valve.

RKP07442

20-46 (1)

PC80MR-3

TESTING AND ADJUSTMENTS

SAFETY PRESSURE SWITCH CALIBRATION:

SAFETY PRESSURE SWITCH CALIBRATION: 1 -Stop the machine and park it safely with the bucket resting on its back on the ground.

RKPC7700

2 -Loosen the fitting (1), orientate the pressure switch (2) to the outside and lock into position.

3 -Remove connector (3) and middle bushing.

2 4

RKPC7710

4 -Remove plug (4), and install a pressure tap C3 connected to a pressure gauge C1.

a If an analogue pressure gauge is to be utilised, use a pressure gauge with an end scale value of 400 bar and 10-bar indexing.

RKPC7720

5 -Start the engine and raise the boom to the end of its travel; force the boom up so as to reach a pressure value of: 115-+ 510 bar (one-piece boom) 6 -Hold the pressure and, using a thin screwdriver A, adjust the centre screw until a chirp is heard.

RKPC7730

PC80MR-3

20-47 (1)

TESTING AND ADJUSTMENTS

ADJUSTING PPC VALVE CLEARANCE

ADJUSTING PPC VALVE CLEARANCE a If clearance in the equipment control levers is excessive, adjust clearance according to the following procedure. 1 -Remove the PPC valve (1) assembly. 2 -Loosen screw (2) and remove handle (3).

1 RKPC1020

3 -Remove the protection (4). 4 -Loosen nut (5) and screw in disc (6) until it touches the heads of pistons (7).

a Be careful not to move the pistons at this stage.

5 -Lock disc (6) into position with nut (5).

3 Nut 98–127 Nm

6 -Install boot (4), handle (3), and PPC valve.

4 6

RKP15170

20-48 (1)

PC80MR-3

TESTING AND ADJUSTMENTS

MEASURING TRAVEL DEVIATION

MEASURING TRAVEL DEVIATION a Test conditions • Flat, levelled, even ground. • Engine: at working temperature. • Engine idling Min. and Max.: within the permissible values • Hydraulic system oil temperature: 45-55°C.

1. Measuring the deviation

45°

2 -Position the machine as for travel, i.e. with the bucket and arm fully curled and the back of the boom at 45°.

RKP15580

3 -Run the engine to Max. speed and drive for 5 metres; measure the deviation “a” that occurs in the following 20 metres. • Max. deviation: 200 mm 5m

Theorichal travel line

Measuring the deviation a

RKP12593

a If deviation is higher than the permissible limit, check the following points in the sequence provided: • drainage travel motor • Pressure at servocontrol spool • Servocontrol spool opening • leaks from the swivel joint PC80MR-3

20-49 (1)

TESTING AND ADJUSTMENTS

CHECKING TRAVEL SPEED

CHECKING TRAVEL SPEED a Test conditions • Flat, levelled, even ground. • Engine at working temperature. • Engine idling Min. and Max.: within the permissible values • Hydraulic system oil temperature: 45-55 °C • Mod. System: P

45°

1 -Position the machine as for travel, i.e. with the bucket and arm fully curled and the back of the boom at 45°. 2 -Run the engine to Max. speed and drive for 5 metres; measure the time taken to cover an extra 20 metres.

RKP15580

3 -Check your measurements against the reference values in the table. Travel speed FORWARD-BACKWARD without increment (sec./20 m). Track type

Standard value

Min.

Max.

Steel

23.4

28.6

Rubber

21.5

26.5

Travel speed FORWARD-BACKWARD with increment (sec./20 m). Track type

Standard value

Min.

Max.

Steel

15.3

13.9

Rubber

13.6

16.7

NOTE:The 20 m distance remains unchanged regardless of deviations, providing deviations are within range (refer to "NORMAL OR STANDARD TECHNICAL DATA").

Theorichal travel line

Measuring the deviation a

RKP12593

20-50 (1)

PC80MR-3

TESTING AND ADJUSTMENTS

ANALYSIS OF THE CAUSES OF HYDRAULIC DRIFTS

ANALYSIS OF THE CAUSES OF HYDRAULIC DRIFTS a If hydraulic drift occurs in the work equipment, a check must be carried out to see if the cause is due to a cylinder gasket or to the control valve. a Conditions for all checks: • Engine: at working temperature. • Hydraulic system oil temperature: 45-55°C • Removal and connection of tubes only after relief of residual pressures. (See "ELIMINATING PRESSURES FROM CIRCUITS"). RKP16800

1. Boom test 1 -Position the machine with the arm vertical and the bucket on the ground, resting on its back. 2 -Stop the engine and release any residual hydraulic pressure.

3 -Disconnect the hose (1) that feeds the cylinder on the head side.

a Plug the hose to keep out impurity.

4 -Disconnect tube (2).

a Plug the hose to keep out impurity. 5 -Disconnect the connector (3) for overload control. 6 -Remove clamps (4).

7 -Loosen the screws on the retaining straps and rotate the safety valve (5) by 90°.

8 -Disconnect the feed hose (6).

a Plug the hose to keep out impurity. 9 -Start the engine and extend the arm completely. 10 -Stop the engine and check the position of the boom for 5 minutes. • If the boom drops, the drift is due to the cylinder gasket. • If the boom does not drop, the drift is due to the control valve.

PC80MR-3

RKPC7691

20-51 (1)

TESTING AND ADJUSTMENTS

ANALYSIS OF THE CAUSES OF HYDRAULIC DRIFTS

2. Arm test 1 -Position the machine with the arm completely extended and the bucket teeth on the ground. 2 -Stop the engine and release any residual hydraulic pressure.

RKP16810

3 -Disconnect lines (1) and (2) from the pipe and cylinder and plug them to avoid contamination. 4 -Plug the arm cylinder feed hose (1) – head end – and fit a provisional hose to fitting (3) in order to catch any leakage.

RKPC1050

5 -Start the engine and raise the boom. 6 -Stop the engine and check the position of the arm for 15 minutes. • If the arm drops, the drift is due to the cylinder gasket. • If the arm does not drop, the drift is due to the control valve.

RKP16820

20-52 (1)

PC80MR-3

TESTING AND ADJUSTMENTS

ANALYSIS OF THE CAUSES OF HYDRAULIC DRIFTS

3. Testing the functionality of the boom safety valve. a This test should be carried out after having checked that the drift is not due to the cylinder gasket. (see "1. Boom test") and after having checked the adjustment of the valves (see "ADJUSTING BOOM SAFETY VALVE").

1 -Disconnect the hose (1) that supplies the valve (port U2).

2 -Disconnect hose (2) – cylinder head side. 3 -Start the engine and extend the arm completely.

RKPC7740

4 -Stop the engine and check for leakages from the valve for 5 minutes. • If there is any leakage, the valve is defective.

4. Bucket test 1 - Position the machine with the arm in its upright position and the bucket resting on the ground, in its horizontal position, with a weight in it.

a If no weight is available, fill the bucket with soil. 2 - Stop the engine and release any residual hydraulic pressure.

RKP16850

3 - Disconnect the pipes (1 and 2) of the bucket cylinder and cap them to prevent entry of impurities.

a If an optional system is equipped for the attachments, disconnect valve (3). 4 - Plug bucket cylinder hole on base side and fit a temporary pipe on fitting (4) to catch any oil leakage.

4 1 2 RKPC7800

PC80MR-3

20-53 (1)

TESTING AND ADJUSTMENTS

ANALYSIS OF THE CAUSES OF HYDRAULIC DRIFTS

5 -Start the engine and raise the boom. 6 -Stop the engine and check the position of the bucket for 5 minutes. • If the bucket tends to open, the drift is due to the cylinder gasket. • If the bucket does not tend to open, the drift is due to the control valve. 50 cm

RKP16830

5. Boom swing test 1 - Position the machine with the boom, arm and bucket raised and with the revolving frame turned 135° to the right. 2 - Stop the engine and release any residual hydraulic pressure.

15°

135° RKP16840

3 - Disconnect the pipes (1 and 2) of the boom swing cylinder and cap them. 4 - Cap the hole in the boom swing cylinder on the bottom side and attach a provisional hose to the head side to collect any oil leakages.

5 - Start the engine and move the machine onto a 15° slope. 6 -Stop the engine and check the position of the boom for 5 minutes. • If the boom tends to swing, the drift is due to the cylinder gasket. • If the boom does not tend to swing, the drift is due to the control valve.

RKPC7750

RKPC7760

20-54 (1)

PC80MR-3

TESTING AND ADJUSTMENTS

ANALYSIS OF THE CAUSES OF HYDRAULIC DRIFTS

8. Blade test 1 - Position the machine with the arm vertical and resting on the ground, and with the bucket resting on its back. 2 - Bring the blade to roughly half its potential stroke and rest it on a centrally placed block. 3 - Stop the engine and release any residual hydraulic pressure.

27 cm

RKP16860

4 -Remove the protection (1).

RKPC7770

5 - Disconnect hoses (2) and (3) from blade cylinder and plug them to prevent contamination from dust or foreign matter.

6 -Remove the safety valve (4) and set it aside. 7 -Cap the hole in the blade cylinder on the head side and attach a provisional hose to the bottom side of the cylinder to collect any oil leakages. 8 - Start the engine, push down with the boom to raise the machine in order to remove the block on which the blade is resting.

3 RKPC7780

9 - Lower the machine and stop the engine. 10 -Check the position of the blade for 5 minutes. • If the blade tends to sink, the drift is due to the cylinder. • If the blade does not tend to sink, the drift is due to the safety valve group.

a To discover whether or not the drift is due to the swivel joint, see "METHODS FOR TESTING FOR LEAKAGES INSIDE THE SWIVEL JOINT".

RKP07320

PC80MR-3

20-55 (1)

TESTING AND ADJUSTMENTS

ANALYSIS OF THE CAUSES OF HYDRAULIC DRIFTS

9. Swing motor test k

1 -Drive bucket teeth into the ground to stop the swing motion of the revolving frame and stop the engine.. 2 -Loosen the tank cap to relieve pressure and connect a vacuum pump.

3 -Disconnect the motor drain hose (1) from the oil tank.

a Cap the tank and the hose RKPC7810

4 -Disconnect the swivel joint drain hose (3) from fitting (2). 5 -Connect a provisional hose to fitting (2) to collect any leaks from the swing motor. 6 -Start the engine, run the engine at Max. speed and perform a swing.

7 -After 30 seconds, measure leakages for 1 minute.

a After the first measurement, swing the revolving frame by 180° and repeat the test.

3 RKPC7820

10. Travel motors 1 -Disconnect the drain hose (1) from the motor during the test; plug the hose.

2 -Introduce a block “A” between the teeth of the drive wheel (2) and the frame (3), so as to lock the track. 3 -Start the engine, run it at Max. speed and slowly pressurize the circuit.

k Ensure that the block is strong enough not to be ejected out.

RKPC0843

4 -After 30 seconds, measure leakages for 1 minute.

a Take several measurements of the drive wheel in different positions.

RKP15601

20-56 (1)

PC80MR-3

TESTING AND ADJUSTMENTS

METHODS FOR TESTING FOR LEAKAGES INSIDE THE SWIVEL

METHODS FOR TESTING FOR LEAKAGES INSIDE THE SWIVEL JOINT a Test conditions: • Engine: at working temperature. • Hydraulic system oil temperature: 45-55 °C

1. Functionality test 1 -When a lower actuator (blade, travel motor, travel increment) is found to be defective, one of the possible causes of failure is the swivel joint. 2 -To confirm the defect it is sufficient to by-pass the joint by connecting (using an additional length of tubing) the input and output hoses of the joint of the branch to be checked. If the defect disappears, it is certainly due to the swivel joint. If the defect remains, it can be due to other causes, but not to the swivel joint.

G E

F D

C B A

2. Identification of defective seal

k These checks are to be carried out only on those lines subjected to working pressures. The drainage line is therefore not included in these tests. The test method consists in pressurising the branch under examination and measuring any leakage from adjacent branches, as set out in the following table:

RKP16870

TABLE A Mark

Branch to be tested (under pressure)

R.H. travel motor - Backwards

R.H. travel motor - Forwards

L.H. travel motor - Backwards

L.H. travel motor - Forwards

Blade cylinder head side - (rise)

Blade cylinder bottom side (descent)

Speed increment

Drainage travel motor

k The symbols correspond to the symbols stamped onto the input and output ports of the swivel joint PC80MR-3

Adjacent parts (Leakages)

Mark

External leakage (visible)

R.H. travel motor - Forwards

–

L.H. travel motor - Backwards

R.H. travel motor - Backwards

L.H. travel motor - Forwards

R.H. travel motor - Forwards

Blade cylinder head side - (rise)

L.H. travel motor - Backwards

Blade cylinder bottom side (descent)

L.H. travel motor - Forwards

Speed increment

Blade cylinder head side - (rise)

External leakage (visible)

–

Blade cylinder bottom side (descent)

–

20-57 (1)

TESTING AND ADJUSTMENTS

ELIMINATING PRESSURES FROM CIRCUITS

ELIMINATING PRESSURES FROM CIRCUITS a Residual pressures in lines, control valve, cylinders and swing motor are relieved by moving the control levers in all directions after the engine is stopped. Before disconnecting any hose, make sure to adhere to the following instructions. 1 -With the engine at Min. speed, lower the equipment to the ground and ensure that the cylinders are not pressurized when they reach end of stroke. Stop the engine.

a If cylinders are pressurized when they reach end of stroke, allow 5-10 minutes after the engine is stopped before disconnecting the lines. 2 -Slowly loosen the plug (1) to gradually relieve residual pressures from circuits.

RKPC7830

20-58 (1)

PC80MR-3

TESTING AND ADJUSTMENTS

MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS

MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS k Be careful not to put a hand or foot under the undercarriage, while taking measurement. 1 -Secure magnetic dial gauge L1 to track frame and apply the probe to the underside of outer race (1), perpendicularly.

a Set dial gauge at the track frame rear.

L1 RKP15611

2 -Fully extend the equipment, raise bucket teeth up to the lower table of the upper frame; swing the revolving frame until it is parallel with the tracks, with the equipment on the blade side.

a This will lower the front side of the upper structure and raise the rear side. 3 -Set the dial gauge to the zero point L1.

RKP15620

4 -Hold the arm perpendicular to the ground, with the bucket resting on its back. Lower the boom until the track shoes will be lifted.

a This will reverse the load pattern on the swing circle. 5 -Read off the value on dial gauge L1in this condition.

a The measured value is the clearance in swing circle bearing. 6 -Return the machine to the position in Item 2 above, and confirm that reading of dial gauge L1 is zero.

a If a value other than zero is displayed, repeat steps from 3 through 5.

PC80MR-3

150 ~ 200 mm

RKP15630

20-59 (1)

TESTING AND ADJUSTMENTS

TESTING AND ADJUSTING TRACK SHOE TENSION

TESTING AND ADJUSTING TRACK SHOE TENSION 1. Checking a Perform the test on both tracks.

1 -Run the engine at low idling and move the machine by the length of track on ground, then stop slowly. 2 -Slowly stop the machine. Place bar “H” on the track shoe between the idler and the shoe plate.

a Ensure that bar “H” is perfectly straight. 3 -Measure maximum clearance (a) between bar “H” and track shoe. • Standard maximum clearance: steel shoe specification: 5 – 15 mm rubber shoe specification: 1-3 mm

RKP15640

2. Adjustment •

To heighten tension 1 -Supply grease through grease fitting (1).

2 1

2 -To check for normal tension, start and run the engine at MIN speed andmove the machine forward by the length of track on ground, then stop slowly and check tension. •

To lower tension 1 -Loosen valve (2) to bleed grease.

k The grease contained in the track shoe stretching cylinder is under pressure and could cause serious injury to the operator. For this reason the valve should not be loosened by more than one turn.

RKPC0860

a If the grease does not run out easily, slowly move the machine backwards and forwards. 2 -Tighten the valve and check track tension using the procedure described in paragraph 1.

20-60 (1)

PC80MR-3

TESTING AND ADJUSTMENTS

AIR BLEEDING FROM HYDRAULIC CIRCUITS

AIR BLEEDING FROM HYDRAULIC CIRCUITS Order for operations Air bleeding item Task

• Oil change • Filter replacement

–

From pump

Start engine

From pump to tank circuit

From LS circuit

From cylinders

From swing motor

From travel motors

From swing circuits

Task start

• Replace return filter element • Pump replacement or overhauling

Q Q

• Suction tube removal • Control valve replacement/ repair

• Replace cylinder

• Remove cylinder piping • Replace swing motor • Remove swing motor piping • Travel motor and swivel joint replacement • Travel motor and swivel joint removal • Swing circuit part replacement and removal (PPC valve, lines, pressure switch, etc.)

Q Q

NOTA: Bleed the air from the swing motors or travel motors only when the oil inside the motor case has been drained

1. Bleeding air from pump a The pump is highly likely to become damaged if it is operated without filling the casing. Before starting the engine, fill the casing as follows: 1 -Loosen the plug (1) that is fitted on the pump bleeding port and wait until oil comes out. 2 -Tighten plug (1).

3 Plug: 7.8-9.8 Nm

RKPC7840

PC80MR-3

20-61 (1)

TESTING AND ADJUSTMENTS

AIR BLEEDING FROM HYDRAULIC CIRCUITS

2. Bleeding air from tank 1 -Start the engine and operate it at medium speed (about 1650 RPM). 2 -Slowly move all the attachments for about 5 minutes to bleed the air.

3. Bleeding air from LS circuits a The air bleeding procedure should only be carried out after a pump hose, a valve or an LS circuit hose has been removed or replaced.

a Failure to bleed air from the LS circuit will result in abnormal attachment operation and incorrect machine motion. 1 -Loosen the bleed screw (1) on the fitting at the pump LS port. 2 -Start the engine and operate it at Min. speed for 2 minutes.

RKPC7840

3 -Move the bucket to end of travel and in both directions for an extra 2 minutes. 4 -Tighten the bleed screw.

4. Bleeding air from hydraulic cylinders a Bleed air from cylinders when a hose is disconnected or when one or several cylinders are replaced. 1 -Start the engine, operate it at average speed (approx. 1650 RPM) and slowly move the piston 4 to 5 times to within approximately 100 mm of bottom of stroke. 2 -Send piston to bottom of stroke in 3 - 4 moves. 3 -Perform 4 - 5 full displacements by pressurizing the piston.

20-62 (1)

PC80MR-3

TESTING AND ADJUSTMENTS

AIR BLEEDING FROM HYDRAULIC CIRCUITS

5. Bleeding air from swing motors a Bleed air from the motor each time that the oil is drained from the casing. 1 -Start the engine at Min. speed and perform a slow, continuous swing. 2 -With the engine at Min. speed, perform 2 continuous swings in both directions.

RKPC7850

6. Air bleeding from travel motors a Bleed air from the motors each time that the oil is drained from the casing.

1 -Start and run the engine at Min. speed and loosen the drain hose (1); when oil escapes from the fitting, tighten the hose. 2 -Keep the engine running at Min. speed and swing the revolving frame by 90° towards the motor to be bled.

RKPC0843

3 -Force the boom to lift the track as shown and swing the boom for 2 minutes. 4 -Repeat the same procedure for the other track.

7. Bleeding air from the revolving frame servocontrol circuit RKP15650

1 -Drive bucket teeth into the ground to stop the swing motion of the revolving frame. 2 -Operate the engine at Min. speed. 3 -Loosen the bleed screws (2) of the pressure switches installed to the frame rotation element. 4 -Move the swing control lever to end of travel several times and in both directions until air-free oil flows from the bleed screws (2).

5 -Tighten the bleed screws.

3 Bleed screws: 7.8-9.8 Nm RKPC7860

PC80MR-3

20-63 (1)

TESTING AND ADJUSTMENTS

TESTING THE AIR-CONDITIONING UNIT

TESTING THE AIR-CONDITIONING UNIT a Test conditions: • Machine on flat level ground, with the attachments on the ground and the safety devices engaged

RKPC1100

1. Testing the working temperature 1 -Connect the maintenance station L1 to the high pressure valve (H.P.) and the low pressure valve (L.P.) 2 -Start the engine and bring it up to a speed of 1500 rpm. 3 -Switch on the A/C unit using the switch in the cab. 4 -Select an intermediate ventilation speed inside the cab. 5 -Use the thermometer/hygrometer to check that the temperature inside the cab is equal to or lower than the ambient temperature.

a If the temperature of the cab is higher than the ambient temperature, open the doors and widows and wait until the cab temperature stabilizes at the outside value. 6 -Close the doors and let the A/C unit operate in these conditions for 5 - 10 minutes. 7 -Use the thermometer to check the temperature of the air at the central outlets.

a Position the probe as close as possible to the air outlets. 8 -Compare the average value of the measured temperatures using the following table: Ambient temperature (°C)

Air outlet temperature (°C)

6 -- 8

8 -- 10

8 -- 12

9 -- 14

9 -If the average value of the temperature measured does not fall within the values given in the table, it will be necessary to thoroughly check the unit.

20-64 (1)

PC80MR-3

TESTING AND ADJUSTMENTS

TESTING THE AIR-CONDITIONING UNIT

2. Checking the unit Check the unit after the point 1, 2, 3, 4, and 6. of the precedent paragraph. A diagnosis of faults in the unit is based on the working pressures. When the pressures do not fall within the values given in the following table, the causes must be sought by checking the high-pressure (H.P.) and low pressure (L.P.) pressure gauges. Unit with R134a Outer temperature (°C)

L.P. (kg/cm²)

H.P. (kg/cm²)

Min.

Max.

Min.

Max.

1.2

2.5

6.0

9.0

1.0

2.5

7.5

10.5

1.1

2.4

9.5

13.0

1.3

2.4

12.0

15.5

1.5

1.8

18.0

18.8

1.8

1.9

21.5

22.0

The following conditions may be found: Conditions

Causes - Faults

L.P. high - H.P. normal or low

• • •

Electromagnetic pulley that slips or does not engage correctly Expansion valve blocked in open position Compressor damaged

• • •

Expansion valve blocked in closed position or obstructed Filter saturated with moisture Obstruction in the L.P. line or in the H.P. line between the filter and the evaporator L.P.

• • •

Infiltration of hot air into the evaporator group, the pipes or the cab Hot air circulating in the heating group Formation of ice on the evaporator

• • • • •

Normal condition with very high ambient temperature (higher than 43 °C) Excess coolant (30÷35% more) Overheating of condenser Air present in the unit Obstruction in the H.P. line between the compressor and the condenserfilter tube, behind the measurement point of the H.P.

• • • •

Normal condition with very low temperature (lower than 5°C) Lack of coolant (70÷75% less) (probable leakages) Obstruction in the H.P. line between the compressor and the condenserfilter tube, before the measurement point of the H.P. Compressor damaged

• • •

Compressor belt missing Electromagnetic pulley that slips or does not engage Compressor damaged

L.P. low - A.P. high or normal

L.P. normal - H.P. normal

L.P. high - H.P. high

L.P. normal or low - H.P. low

L.P. roughly equal to H.P.

PC80MR-3

20-65 (1)

TESTING AND ADJUSTMENTS

EMPTYING THE AIR-CONDITIONING UNIT

EMPTYING THE AIR-CONDITIONING UNIT 1 -Connect the maintenance station to the service valves (1) and (2) and follow the specific maintenance station instructions relative to the drainage of the unit.

2 -Disconnect the group to be substituted or reconditioned immediately after switching off the maintenance station. Plug the removed or disconnected connection tubes tightly and with a minimum of delay. 3 -Carefully check the quantity of anti-freeze oil recovered and contained in the disassembled parts, since the same quantity must be replaced when the airconditioning unit is refilled.

20-66 (1)

1 RKPC7870

PC80MR-3

30 REMOVAL AND INSTALLATION HOW TO READ THE MANUAL .....................................3 PRECAUTIONS TO BE TAKEN WHILE WORKING .....4 SPECIAL TOOLS ...........................................................5 COUNTERWEIGHT ........................................................9 • Removal ....................................................................9 • Installation ...............................................................10 INJECTION PUMP........................................................11 • Removal ..................................................................11 • Installation ...............................................................13 ENGINE HEAD .............................................................14 • Removal ..................................................................14 • Installation ...............................................................18 PUMP GROUP..............................................................19 • Removal ..................................................................19 • Installation ...............................................................21 GEAR-PUMP ................................................................22 • Installation ...............................................................22 ENGINE - PUMPS ........................................................23 • Installation ...............................................................27 COMPLETE RADIATOR AND AIR CONDITIONING CONDENSER ...............................................................28 • Removal ..................................................................28 • Installation ...............................................................30 SWING MOTOR AND REDUCTION GEAR .................31 • Removal ..................................................................31 • Installation ...............................................................32 SWING MOTOR............................................................33 • Removal ..................................................................33 • Installation ...............................................................33 SWING REDUCTION GEAR ........................................34 • Disassembly ............................................................34 • Assembly .................................................................40 SWIVEL JOINT.............................................................47 • Removal ..................................................................47 • Installation ...............................................................48 • Disassembly ............................................................49 • Assembly .................................................................49 CONTROL VALVE .......................................................50 • Removal ..................................................................50 • Installation ...............................................................52 LH PPC VALVE ............................................................53 • Removal ..................................................................53 • Installation ...............................................................54 R.H. PPC VALVE..........................................................55 • Removal ..................................................................55 • Installation ...............................................................55

PC80MR-3

EQUIPMENT PPC VALVES ........................................ 56 • Assembly ................................................................ 56 TRAVEL PPC VALVE.................................................. 57 • Removal.................................................................. 57 • Installation............................................................... 58 • Assembly ................................................................ 59 ADDITIONAL EQUIPMENT AND BOOM SWING PPC VALVE ......................................................................... 60 • Removal.................................................................. 60 • Installation............................................................... 60 BLADE PPC VALVE.................................................... 61 • Removal.................................................................. 61 • Installation............................................................... 61 ACCELERATOR POTENTIOMETER .......................... 62 • Removal.................................................................. 62 • Installation............................................................... 62 CONTROLLER ............................................................ 63 • Removal.................................................................. 63 • Installation............................................................... 63 SAFETY MICROSWITCH ............................................ 64 • Removal.................................................................. 64 • Installation............................................................... 65 HYDRAULIC OIL TANK .............................................. 66 • Removal.................................................................. 66 • Installation............................................................... 67 FUEL TANK ................................................................. 68 • Installation............................................................... 70 CONTROL MODULES (MACHINE - ENGINE - KOMTRAX) ............................ 71 • Removal.................................................................. 71 • Installation............................................................... 71 EVAPORATOR UNIT................................................... 72 • Removal.................................................................. 72 • Installation............................................................... 76 CABIN .......................................................................... 77 • Removal.................................................................. 77 • Installation............................................................... 81 SWING CIRCLE........................................................... 82 • Removal.................................................................. 82 • Installation............................................................... 82 REVOLVING FRAME .................................................. 83 • Removal.................................................................. 83 • Installation............................................................... 85 EQUIPMENT (1-piece boom version)........................ 86 • Removal.................................................................. 86 • Installation............................................................... 88

30-1 (1)

BOOM CYLINDER (For 1-piece boom)...................... 89 • Removal.................................................................. 89 • Installation............................................................... 90

STEEL SHOES...........................................................106 • Removal ................................................................106 • Installation .............................................................106

ARM CYLINDER .......................................................... 91 • Removal.................................................................. 91 • Installation............................................................... 92

RUBBER SHOES .......................................................107 • Removal ................................................................107 • Installation .............................................................107

BUCKET CYLINDER ................................................... 93 • Removal.................................................................. 93 • Installation............................................................... 94

SPROCKET ................................................................108 • Removal ................................................................108 • Installation .............................................................108

BOOM SWING CYLINDER.......................................... 95 • Removal.................................................................. 95 • Installation............................................................... 96

COMPLETE TRAVEL ASSEMBLY............................109 • Removal ................................................................109 • Installation .............................................................110

BLADE CYLINDER...................................................... 97 • Removal.................................................................. 97 • Installation............................................................... 97

TRACK SHOE IDLER ................................................111 • Assembly...............................................................111

CYLINDERS................................................................. 98 • Disassembly............................................................ 98 • Assembly .............................................................. 100 SWING SUPPORT ..................................................... 103 • Removal................................................................ 103 • Installation............................................................. 105

30-2 (1)

BUMPER SPRING......................................................114 • Disassembly ..........................................................114 • Assembly...............................................................115 LOWER IDLER ROLLERS.........................................117 • Disassembly ..........................................................117 • Assembly...............................................................118

PC80MR-3

REMOVAL AND INSTALLATION

HOW TO READ THE MANUAL

HOW TO READ THE MANUAL 1.

Removal and Installation of the groups (1) The procedures and information needed to carry out the work of removing or Installing units or groups are given in the removal procedure. The sequence of operations is not repeated in the installation procedure. (2) Information needed for installation is marked with the symbol [*1]. The same symbol is repeated at the end of each removal procedure for the same item, to indicate to which installation item it refers. (Example) REMOVAL GROUP ● ● ● : .......................................................Title of operation.

k: ............................................................................................Safety precautions to be followed when carrying out the operation. 1 - Remove XXXX (1): ..............................................................Step in removal procedure. a: ........................................................................................Technique or important point to remember when removing XXXX (1) 2 - eee (2): ...................................................................... [*1] This sign means that information is given for the installation procedure 3 - Remove ttt (3):

6........... l: ....................................................................Recovery of oil or water, and the quantity to be recovered.

INSTALLATION GROUP ● ● ● : ...............................................Title of operation

To install, reverse the removal procedure.

[*1]: .............................................................................................To install, reverse the removal procedure a: ........................................................................................Technique or important point to remember when removing eee (2) q

Addition of water or oil: ........................................................Step in removal procedure.

a: Point to remember when adding water or oil. 2.

To the precautions to be taken during the removal or installation of the groups, must be added the specific "PRECAUTIONS TO BE TAKEN WHILE WORKING". . Always make sure that these precautions are taken.

List of special tools. (1) For details of the descriptions, codes and quantities of each tool (A1; A2 etc.) mentioned in the operational procedures, see the list "SPECIAL TOOLS" supplied in this section.

List of the tightening torques and weights, and the quantities oil, liquids or grease needed to fill tanks and containers (1) In the operating procedures, you will find the symbols 3 , 4, 5,6,2; in the following order, these represent the values of "TIGHTENING TORQUES", "WEIGHT OF PARTS OR GROUPS", "QUANTITIES OF OIL OR LIQUIDS TO BE INTRODUCED", "SCREW LOCKING MATERIAL, SEALANTS AND LUBRICATION", "LUBRICATING GREASE" and LIQUID DRAINING.

NOTE If no symbol is indicated, the values to be used are those given in the introductory sections of this manual.

PC80MR-3

30-3 (1)

REMOVAL AND INSTALLATION

PRECAUTIONS TO BE TAKEN WHILE WORKING

PRECAUTIONS TO BE TAKEN WHILE WORKING a When dismantling or installing a part, always take the following general precautions. 1.

Precautions for removal operations • If not otherwise indicated, lower the work equipment until it rests on the ground • Always use the safety devices when working with the working equipment raised. • If the coolant liquid contains an anti-freeze substance, follow the instructions given for drainage • After having removed flanges and tubes, insert plugs to prevent impurities from entering. • Before removing a cylinder, fully retract the piston and tie it with wire. • Drain the oil before removing any mechanical assemblies • Use a sufficiently large container to collect the oil • Before removing a part from the machine, check the alignment reference marks which show the correct installation position. If necessary add further marks to avoid incorrect installation. • While dismantling the connectors, always grasp them firmly to avoid undue strain on the wiring. • If necessary, attach markers to the wires and tubes to avoid muddling them up during installation. • Check the number and height of the adjustments to a given clearance and store them in a safe place. • When raising the machine or some parts of it, use adequate equipment for the weight of the part concerned. • When using screws or eyebolts to remove items of the machinery, screw them alternately, and as deeply as they will go. • Before removing a piece, clean the surrounding area and, after removal, cover the area to prevent dirt or dust from gaining entrance.

Precautions to be taken during installation • Tighten nuts and screws with the specified tightening torques. • Install the flexible hoses, taking care not to entangle or twist them. • Replace O-ring seals, cotter pins and retainer rings with new ones. • Bend the cotter pins and retainers in such a way as to secure them. • When coating the threads with adhesives, clean the piece to remove oil and grease, then apply just enough adhesive to cover the threading in a uniform manner. • When applying a liquid sealant, clean the surface involved, remove residual oil and grease, check that there are no dents or dirt, then apply the liquid sealant in a uniform manner. • Clean all the parts, remove dirt, rust, burrs, or dents. • Apply a film of engine oil over all the moving parts. • Apply a film of anti-friction grease (ASL800040) over all surfaces assembled with pressure, to avoid sticking. • After having mounted the snap-rings, check that they are firmly positioned in their seatings. • When installing electrical system jacks, remove any oil, dust or water that may have penetrated into them, then connect them firmly. • If using eyebolts, check that they are not distorted, screw them in fully, and then align the eye with the hoisting hook. • Mount the flanges in a uniform manner, and tighten the screws in criss-cross sequence, to avoid excessive pull on one side only.

Precautions to be taken on completion of removal and installation operations. • If the coolant liquid has been drained away, close the drainage plug and add new liquid up to normal level. Start the engine to circulate the liquid throughout the cooling system and then top up the level once more. • When the hydraulic equipment has been dismantled, add engine oil to the indicated level. Start up the engine to circulate the oil in the hydraulic circuits, and then top up to the indicated level. • Fill with lubricant when installing mechanical assemblies. • If hoses or hydraulic equipment, such as hydraulic cylinders, pumps, motors, solenoid valves and valves, are removed for repairs or substitution, bleed air from the hydraulic circuits after having re-assembled the machine. a For details, see «20. TESTING AND ADJUSTMENTS». • After having re-assembled cylinder joints or cylinders, or work equipment articulations, lubricate thoroughly.

30-4 (1)

PC80MR-3

REMOVAL AND INSTALLATION

SPECIAL TOOLS

SPECIAL TOOLS Nature of work

Disassembly/Assembly of swing machinery

Mark

L Assembly of lower idler rollers

Disassembly – assembly of recoil spring

Q.ty

Wrench

To remove and mount lock-nut

Plunger

To remove inside ring from pinion bearing

Plunger

To assemble inside bearing ring

Plunger

To mount outside bearing ring

790-101-5001

Full piston

Bushing assembly

796-230-1110

Tool

Floating seal installation

790-101-5001

Full piston

Bushing assembly

796-230-1120

Tool

Floating seal installation

791-685-8005

Tool

790-201-2860

Spacer

791-365-3160

Extension

790-101-1600

Cylinder (686 kN)

790-101-1102

Pump

791-616-1030

Tool

790-105-1100

Cylinder (294 kN)

790-101-1102

Pump

790-101-2501

Full puller

790-502-1003

Cylinder repair bench

790-101-1102

Pump

Swivel joint disassembly

Remarks

Removal of steel shoes

T 1

790-102-3802

Spanner with torque amplifier

790-330-1100

PC80MR-3

Name

Assembly of track shoe idler

Disassembly - Cylinder assembly

Code

Spring compression

Connecting pin removal

Rotor and ring removal All cylinders

Boom, blade and boom swing cylinders

Arm and bucket cylinders

790-102-1330

Wrench (75 mm)

Blade cylinders

790-102-1470

Wrench (70 mm)

Boom, arm and boom swing cylinders

790-302-1290

Wrench (60 mm)

Bucket

790-720-1000

Expander

30-5 (1)

REMOVAL AND INSTALLATION

Nature of work

Mark

Disassembly - Cylinder assembly

U 6

Swing bracket removal

30-6 (1)

SPECIAL TOOLS

Code

Name

Q.ty

Remarks

796-720-1660

Calibrator

07280-01279

Clamps

796-720-1650

Calibrator

796-720-1660

Calibrator

07281-01159

Clamps

796-720-1650

Calibrator

07281-01029

Clamps

796-720-1670

Calibrator

07281-01279

Clamps

790-201-1702

Driver kit

790-101-5021

. Handle

01010-50816

. Screw:

790-201-1791

. Plunger

Blade and boom cylinder

790-201-1781

. Plunger

Boom and arm swing cylinders

790-201-1771

. Plunger

Arm cylinder

790-201-1500

Driver kit

790-101-5021

. Handle

01010-50816

. Screw:

790-201-1620

. Plunger

Boom and blade cylinders

790-201-1610

. Plunger

Arm and boom swing cylinders

790-201-1580

. Plunger

Arm cylinder

790-101-2102

Puller

790-101-1102

Pump

Boom cylinder

Arm and boom swing cylinders

Arm cylinder

Blade cylinder

All cylinders

PC80MR-3

REMOVAL AND INSTALLATION

SPECIAL TOOLS

40 31 3.2

3/4

20 8

3.2

Ø65

Ø76 ±0.01 Ø63

3.2

N°4 SPINE A 90° Nos 4 PINS AT 90°

1x45°

Ø4

1x45°

Ø90

Ø6.5 H7/m6

Particular «A» RKP13300

125

14 3.2

3.2

R2 RKP13310

Ø84.5 ± 0.1

Ø78.5 ± 0.1

8 1x45°

Ø35

1 x45°

Ø74 ± 0.1

Ø90

Ø76

Ø62

3.2

R2 RKP13330

3.2

Ø40

Ø130 ±0.01

3.2

Ø124 ±0.01

RKP13320

PC80MR-3

30-7 (1)

PAGE INTENTIONALLY LEFT BLANK

REMOVAL AND INSTALLATION

COUNTERWEIGHT

COUNTERWEIGHT Removal

k Stop the machine on a level surface; rest the equipment on the ground, stop the engine.

1 -Mark the position of the non-removable part of hinges (1) and remove the engine hood (2).

RKPC7880

2 -Remove lower (3), (4) protective covers.

RKPC7890

3 -Remove the side shield (5), (6).

6 RKPC7900

4 -Remove screws (7), (8) and cover (9).

RKPC7910

PC80MR-3

30-9 (1)

REMOVAL AND INSTALLATION

COUNTERWEIGHT

5 -Disconnect surge tank (11) and hose (10) from radiator. Remove the surge tank and place it aside.

6 -Remove bulkhead (12).

11 RKPC7920

7 -Remove the plugs from the removal holes and thread two lifting eyes (13) into the holes; connect some hoisting tackle to the lifting eyes and slightly tension the cables.

RKPC7930

8 -Loosen and remove the counterweight retaining screws (14) and remove the counterweight (15). [*1]

4 Counterweight: approx. 965 kg

RKPC7891

Installation • [*1]

To install, reverse the removal procedure.

3 Counterweight screws: Loctite 265 Counterweight screws: 3320 Nm

30-10 (1)

PC80MR-3

REMOVAL AND INSTALLATION

INJECTION PUMP

INJECTION PUMP Removal

k Lower the work equipment until it is resting on the ground and switch off the engine. k Release all residual pressure.

k Cycle the battery main switch to the O (OFF) position and remove the handle. a Remove the engine hood and counterweight. (For details see "COUNTERWEIGHT"). a Drain the air conditioning unit. (For details see "20 TESTING AND ADJUSTMENTS").

RKPC7940

a Drain the hydraulic oil.

6 Hydraulic oil: approx 65 l a Drain the engine cooling liquid.

6 Coolant liquid needed: approx 18 l

1 -Disconnect the delivery hose (2) from the compressor (1) and release the hose (3) from the hose clamps.

a Plug all pipe to keep out moisture. 2 -Secure hoses (2) and (3) separately.

3 2

RKPC7950

3 -Close the separator cock (4). 4 -Remove the separator (5) and set it aside.

RKPC7960

PC80MR-3

30-11 (1)

REMOVAL AND INSTALLATION

5 -Disconnect the fuel feed hose (7) and fuel return hoses (8), (9) from the injection pump (6).

a Plug the hoses tight to avoid fuel leakage.

INJECTION PUMP

7 6

9 RKPC7970

6 -Disconnect the actuator and rev sensor connectors (10), (11). 7 -Disconnect engine stop solenoid connector (12).

RKPC7980

8 -Disconnect from the engine the hose (13) connecting to the engine oil cooler.

RKPC7990

9 -Remove the radiator assembly (14). (For details, see "COMPLETE RADIATOR AND AIR CONDITIONING CONDENSER"). 10 -Remove the injection pump assembly in accordance with the instructions given in the engine workshop manual (code no. 0BTNV-G00101).

RKPC8001

30-12 (1)

PC80MR-3

REMOVAL AND INSTALLATION

INJECTION PUMP

Installation •

To install, reverse the removal procedure.

•

Perform all fills, start the engine and let it run at Min. speed for a couple of minutes. Stop the engine and check for leaks and incorrect levels.

•

Bleed and pressurize the hydraulic system.

PC80MR-3

30-13 (1)

REMOVAL AND INSTALLATION

ENGINE HEAD

ENGINE HEAD Removal

k Lower the work equipment until it is resting on the ground and switch off the engine. k Release all residual pressure.

RKPC7940

a Drain the coolant liquid and the hydraulic oil. 6 Coolant liquid needed: approx 18 l

6 Hydraulic oil: approx 65 l

1 -Disconnect hoses (2), (3) from compressor (1) and release hose (3) from the hose clamps.

a Plugs all pipes to keep out moisture. 2 -Secure the hoses to a side.

3 2

RKPC7950

3 -Close the separator cock (4). 4 -Remove the separator (5) and set it aside.

RKPC7960

30-14 (1)

PC80MR-3

REMOVAL AND INSTALLATION

ENGINE HEAD

5 -Disconnect cab heating hoses (6) and engine oil cooler hose (7). 6 -Remove the hose clamps and place the hoses to a side.

RKPC7991

7 -Remove the straps (8) retaining the wiring harness (9). 8 -Remove the guard (10) the thermal starter.

RKPC8010

9 -Remove the air intake lines (11), (12), (13).

13 RKPC8021

10 -Take out screws (14) and remove cover (15). 11 -Loosen retaining nuts (16) and the screws (17).

12 -Loosen the nuts (18) on the tie bar (19) and disengage the compressor drive belt (20).

15 19 20 17 RKPC8030

PC80MR-3

30-15 (1)

REMOVAL AND INSTALLATION

ENGINE HEAD

13 -Disconnect connectors (21) for compressor (20).

RKPC8040

14 -Take out compressor screws (22) and remove compressor (20) together with its mount (23).

20 22

22 23 RKPC9140

15 -Remove the radiators assembly (24). (For details, see "COMPLETE RADIATOR AND AIR CONDITIONING CONDENSER").

RKPC8002

16 -Disconnect engine coolant temperature sensor connector (25) and engine pressure sensor connectors (26). Release the wiring harnesses from the tie straps and place them aside.

26 25

RKPC8050

30-16 (1)

PC80MR-3

REMOVAL AND INSTALLATION

ENGINE HEAD

17 -Disconnect connector (27), disconnect hoses (28) and remove the EGR assembly (29).

28 27

RKPC8060

18 -Remove the screws (9), remove the fuel filter (30) and place it to a side.

RKPC9130

19 -Disconnect the fuel return hose (31) from the engine head.

a Plug the hose tight to avoid leakage.

RKPC7971

20 -Remove cover (32).

RKPC8080

PC80MR-3

30-17 (1)

REMOVAL AND INSTALLATION

ENGINE HEAD

21 -Remove the cover (33) blocking out access to the starter.

RKPC8070

22 -Remove muffler nuts (34) and screws (35) and remove muffler (36).

RKPC8090

23 -Disconnect wiring harness (37). 24 -Loosen screws (38), (39), disengage belt (40) and remove bracket (41).

25 -Continue with the engine head removal procedure by removing the valve cover and the rocker arm supports in accordance with the instructions provided in the engine workshop manual, code no. 0BTNV-G00101.

RKPC8100

Installation •

To install, reverse the removal procedure.

•

Perform all fills, start the engine and let it run at Min. speed for a couple of minutes. Stop the engine and check for leaks and incorrect levels.

•

Bleed and pressurize the hydraulic system.

30-18 (1)

PC80MR-3

REMOVAL AND INSTALLATION

PUMP GROUP

PUMP GROUP Removal a Remove the engine hood and counterweight. (For details see "COUNTERWEIGHT").

k Allow the attachments to settle on the ground and stop the engine. k Cycle the battery main switch to the O (OFF) position and remove the handle. k Relieve pressure from tank by slowly loosening the fill cap.

RKPC7700

1 -Drain the hydraulic oil.

6 Hydraulic oil: approx 65 l

2 -Remove the intake lines (11) and the air filter (2).

a Cap the hole on the suction manifold. 3 -Remove the lower left-hand protective casin (3).

RKPC9150

4 -Disconnect hoses (5) from pumps (4).

a Flanges the hose to keep out impurity.

5 4

6 RKPC8121

5 -Disconnect the outlet hoses (7), (8) and (9).

a Plug all pipes to keep out impurity.

RKPC7511

PC80MR-3

30-19 (1)

REMOVAL AND INSTALLATION

PUMP GROUP

6 -Disconnect the LS, pressure signal and drain hoses (10), (11), (12).

11 10

12 RKPC8130

7 -Disconnect connector (13).

RKPC7581

8 -Connect a hoisting device to the pump assembly lifting eye and apply a slight tension to the cable. 9 -Loosen and remove three screws (14) (nr. 2) and remove the pump group (15). [*1]

15 14

RKPC8140

30-20 (1)

PC80MR-3

REMOVAL AND INSTALLATION

PUMP GROUP

Installation •

To install, reverse the removal procedure.

[*1]

2 Lubricate the shaft with G2 – LI grease 2 Loctite 243

1 -Fill the hydraulic oil tank to maximum level.

Hydraulic oil: approx 65 l

2 -Loosen the pump bleed screw (16) until bubble-free oil comes out.

RKPC8150

3 -Start the engine and operate it at Min. speed for few minutes. 4 -Stop the engine, check levels again and inspect for leaks. 5 -Pressurize the system.

PC80MR-3

30-21 (1)

REMOVAL AND INSTALLATION

GEAR-PUMP

GEAR-PUMP k Lower the work equipment until it is resting on the ground and switch off the engine. k Release all residual pressure.

a Drain the hydraulic oil.

6 Hydraulic oil: approx 65 l 1 -Remove the lower left-hand protective casin.

RKPC8111

2 -Loosen the hose clamp (1) and disconnect the pump intake line (2).

3 -Disconnect the outlet hoses (3) and (4). 4 -Loosen and remove screws (5) and remove the pump group (6).

3 2

6 RKPC8160

Installation •

To install, reverse the removal procedure. 1 -Fill the hydraulic oil tank to maximum level. 2 -Start and run the engine at Min. speed and slowly operate all controls to bleed air from the circuits. 3 -Pressurize the system.

30-22 (1)

PC80MR-3

REMOVAL AND INSTALLATION

ENGINE - PUMPS

ENGINE - PUMPS k Allow the attachments to settle on the ground and stop the engine. k Relieve pressure from tank by slowly loosening the fill cap.

k Cycle the battery main switch to the O (OFF) position and remove the handle. k Drain the air conditioning unit. (For details see "20 TESTING AND ADJUSTMENTS").

RKPC7940

1 -Drain the hydraulic oil.

6 Hydraulic oil: approx 65 l

2 -Drain the coolant liquid.

6 Coolant liquid needed: approx 18 l

3 -Remove the counterweight . (For details, see "COUNTERWEIGHT"). 4 -Remove lower guards (1), (2) (3). RKPC7892

5 - Remove the engine air intake lines (4), (5), (6).

6 RKPC8020

6 -Disconnect cab heating hoses (7), (8) and engine oil cooler hose (9).

9 RKPC8170

PC80MR-3

30-23 (1)

REMOVAL AND INSTALLATION

ENGINE - PUMPS

7 -Disconnect the fuel feed hose (12) and fuel return hose (13), from the separator filter (10) and fuel filter (11).

a Plug lines and holes to prevent hose contamination and fuel leakage.

12 10

RKPC8180

8 -Disconnect the ground plait (14).

RKPC8190

9 -Remove the radiator-oil cooler assembly (15). (For details, see "COMPLETE RADIATOR AND AIR CONDITIONING CONDENSER").

RKPC8000

10 -Disconnect the intake lines (16), (17) from the pumps.

a Plug all pipes to keep out impurity.

17 RKPC8120

30-24 (1)

PC80MR-3

REMOVAL AND INSTALLATION

ENGINE - PUMPS

11 -Disconnect LS hoses (18) and (19), drain hoses (20), and delivery hoses (21), (22), (23).

a Plug all pipes to keep out impurity.

12 -Remove the tie straps and disconnect from engine all connectors and wiring harnesses that are accessible from the rear.

a Check to ensure that the connectors have marks scribbled on and that they are completely disengaged from the engine.

20 RKPC8131

RKPC7512

13 -Remove upper guard (24).

RKPC8081

14 -Remove the cover (25) that provides access to the starter.

RKPC8071

PC80MR-3

30-25 (1)

REMOVAL AND INSTALLATION

ENGINE - PUMPS

15 -Disconnect connector (27) and wiring harnesses (28), (29) from alternator (26).

27 28

RKPC8101

16 -Disconnect wiring harnesses (31), (32) from starter (30). 17 -Remove tie strap (33) and ground wire to release the wiring harnesses.

RKPC8200

18 -Using the brackets provided, connect the engine (34) to some hoisting tackle and slightly tension the cables or chains.

RKPC8210

19 -Loosen and remove the screws (35) securing the engine. [*1].

20 -Lift the engine by about 10 mm and remove the vibration dampers (36). 21 -Lower the engine and slide it towards the machine rear and out.

RKPC8220

30-26 (1)

PC80MR-3

REMOVAL AND INSTALLATION

ENGINE - PUMPS

Installation •

To install, reverse the removal procedure.

[*1]

3 Motor screws: 200±10 Nm

1 -Perform all fills and start the engine at Min. to allow fluids to be circulated and systems to be bled. 2 -Stop the engine and check for leaks. 3 -Pressurize the hydraulic oil tank.

PC80MR-3

30-27 (1)

REMOVAL AND INSTALLATION

COMPLETE RADIATOR AND AIR CONDITIONING CONDENSER

COMPLETE RADIATOR AND AIR CONDITIONING CONDENSER Removal a Remove the engine hood and counterweight. (For details see, "COUNTERWEIGHT").

6 Drain the air conditioning unit. (For details see "20 TESTING AND ADJUSTMENTS"). a Drain the engine cooling liquid.

6 Coolant liquid needed: approx 18 l

1 -Disconnect the expansion tank hose (1) from the radiator.

2 -Remove the screws and remove the tank (2).

2 RKPC8003

3 -Take out screws (3) and fan guard (4).

4 3 RKPC8230

4 -Disconnect the intake line (6) from the bulkhead (5).

5 -Remove four screws (7) and remove bulkhead (5).

5 6

RKPC7921

30-28 (1)

PC80MR-3

REMOVAL AND INSTALLATION

COMPLETE RADIATOR AND AIR CONDITIONING CONDENSER

6 -Disconnect hoses (9), (10) from radiator (8) connecting to the engine.

RKPC8240

8 -Loosen the lower hose (11) and drain the oil from the oil cooler (12); disconnect the input (13) and output (11) hoses.

6 Hydraulic oil: approx 5 l

12 11

RKPC8250

9 -Remove the screws (14) and place the air conditioning filter (15) to a side.

RKPC8260

10 -Disconnect the input and output hoses (17) and (18) from the condenser (16).

16 17

18 RKPC8270

PC80MR-3

30-29 (1)

REMOVAL AND INSTALLATION

COMPLETE RADIATOR AND AIR CONDITIONING CONDENSER

11 -Take out the screws (19) securing the upper bracket (20).

RKPC8280

12 -Remove screws (21) from the lower anchoring device retaining the radiators assembly (22). 13 -Take out the vibration dampeners (23) and remove assembly (22).

22 23

RKPC8290

Installation •

To install, reverse the removal procedure. 1 -Perform all fills, start the engine and let it run at Min. speed for a couple of minutes, then check for leaks and incorrect levels.

30-30 (1)

PC80MR-3

REMOVAL AND INSTALLATION

SWING MOTOR AND REDUCTION GEAR

SWING MOTOR AND REDUCTION GEAR Removal a Fully extend the attachments, drive the bucket teeth into the ground and stop the engine. k Slowly loosen the tank cap to relieve pressure.

1 -Remove upper hood (1) and side fixed hood (2).

RKPC8300

2 -Mark hose positions and disconnect hoses (4), (5), (6), (7) and (8) from motor (3).

a Plug all pipes to keep out impurity.

6 3 7 8

RKPC7851

3 -Apply a vacuum pump to the tank and disconnect the drain hose (9).

a Plug hose and tank tight to prevent oil spillage and contamination.

RKPC7812

4 -Loosen and remove reduction gear screws (10). 5 -Remove both plugs (11) protecting the reduction gear removal holes. 6 -Install two screws and push them in in an alternate manner to separate the reduction gear from the frame. 7 -Attach a lifting device to the reduction gear assembly (12) and remove the assembly.

a Take care to not damage the cage of drain pipe (9). [*1]

4 Complete group: 77 kg PC80MR-3

RKPC7821

30-31 (1)

REMOVAL AND INSTALLATION

SWING MOTOR AND REDUCTION GEAR

Installation • [*1]

To install, reverse the removal procedure.

2 Coat the contacting surface with LG6 sealant (silicone base). 3 Attachment screws: 245-308 Nm

a When installing the assembly, pay attention not the damage the reduction gear drain hose. a Fill motor and reduction gear with oil. Crank the engine to circulate the oil in the hoses. Stop the engine and check the oil level in the tank. If necessary, top it up. a Introduce the plugs into the removal holes having care to coat the threads with grease beforehand.

30-32 (1)

PC80MR-3

REMOVAL AND INSTALLATION

SWING MOTOR

SWING MOTOR Removal a Disconnect the lines from the motor. (For details, see "SWING MOTOR AND REDUCTION GEAR").

1 -Loosen and remove 8 retaining screws (1) and remove the motor (2).

a When motor has been removed, cover the final drive to prevent letting in dust or contaminants.

RKPC8310

Installation •

To install, reverse the removal procedure.

a Fill the housing with hydraulic oil, then bleed the air. (For details, see "20 TESTING AND ADJUSTMENTS").

PC80MR-3

30-33 (1)

REMOVAL AND INSTALLATION

SWING REDUCTION GEAR

SWING REDUCTION GEAR Disassembly a Before dismantling the swing machinery mark the position of the hydraulic motor (1) in relation to the flange (2), in relation to the flange (2), in relation to the flange (2) and ring gear (3) and gear housing (4). a Remove the oil drain pipe (5).

RKP17440

1 -Remove the screw (6) and hydraulic motor (1).

RKPC1640

2 -Remove the oil drain plug (7) and the union (8).

RKPB6980

3 -Remove tha pinion (9) and the snap ring (10).

9 9

RKPB6990

30-34 (1)

PC80MR-3

REMOVAL AND INSTALLATION

SWING REDUCTION GEAR

4 -Remove the planetary carrier (11).

RKPB7000

5 -Remove the ten screw (12) fixing the snap ring (2).

RKPB7010

6 -Remove the snap ring (2).

RKPB7020

7 -Remove from gear ring (2) the O-ring (13).

13 2

RKPB7030

PC80MR-3

30-35 (1)

REMOVAL AND INSTALLATION

SWING REDUCTION GEAR

8 -Remove the pinion (14).

RKPB7040

9 -Using an extractor remove the planetary carraier (15).

RKPB7050

10 -Remove the ring gear (3) from gearbox housing (4).

4 RKPB7060

11 -Remove the O-ring (16) from gearbox housing (4).

RKPB7070

30-36 (1)

PC80MR-3

REMOVAL AND INSTALLATION

SWING REDUCTION GEAR

12 -Lift the staking of the ring nut (17).

17 18

RKPB7080

13 -Using the special tool C1 and a dynamometric wrench, remove the ring nut (17).

RKPB7090

14 -Remove the spacer (19).

RKPB7100

15 - Using a puller, remove the swing pinion shaft (18) from gearbox housing (4).

18 4 RKPB7110

PC80MR-3

30-37 (1)

REMOVAL AND INSTALLATION

SWING REDUCTION GEAR

16 -Remove the bearing inner ring (20).

RKPB7120

17 -Remove the gearbox housing (4) from swing pinion shaft (18).

RKPB7130

18 -Using a puller, remove the bearing outer ring (20) from gearbox housing (4).

20 4

RKPB7140

19 -Using the special tool C2 and a press, remove the bearing inner ring (21), the seal ring (22) and the spacer (23) from swing pinion shaft (18).

18 22 21

23 RKPB2272

30-38 (1)

PC80MR-3

REMOVAL AND INSTALLATION

SWING REDUCTION GEAR

20 -Overturn the gearbox housing (4) and remove the seal ring (24).

RKPB7150

21 -Using a puller, remove the bearing outer ring (21) from gearbox housing (4).

RKPB7160

PC80MR-3

30-39 (1)

REMOVAL AND INSTALLATION

SWING REDUCTION GEAR

Assembly REMARKS When installing the swing machinery, some fundamental rules must be followed: a - In the case of a damaged sun gear, the entire reduction unit must be substituted, not just the single sun gear. b - Always fit a new O-ring with the part to be replaced, after thoroughly cleaning the installation seating and after having spread a film of grease (ASL800050) over the seatings and the seals to facilitate installation.

1 -Mount the spacer (23) on the swing pinion (18).

a Check that the chamfered part rests on the pinion.

18 RKPB2282

2 -Mount the metal sealing ring (22).

RKPB2292

3 -Fill the metal sealing ring (22) with grease (ASL800050).

RKPB2302

30-40 (1)

PC80MR-3

REMOVAL AND INSTALLATION

SWING REDUCTION GEAR

4 -Apply a layer of grease over the inside bearing ring (21).

2 Bearing: ASL800050

21 RKPB2312

5 -Using the tool C3 and a press, drive the inside bearing ring (21) down over the spacer (22).

21 22 RKPB2322

6 -Using the tool C4 and a press, drive the outside bearing ring (21) down over the gearbox housing (4).

C4 4

RKPB7220

7 -Using the same method as above, mount the outside ring of the other bearing (29) in the gearbox housing.

RKPB7230

PC80MR-3

30-41 (1)

REMOVAL AND INSTALLATION

SWING REDUCTION GEAR

8 -Mount the sealing ring (24) in the gearbox housing (4).

RKPB7170

9 -Fill with grease the bearing (21) seat and position the gearbox housing (4) over the swing pinion (18).

RKPB7130

10 -Mount the inside bearing ring (20) on the swing pinion (18).

RKPB7121

11 -Mount the spacer (19) on the swing pinion (18).

18 19

RKPB7101

30-42 (1)

PC80MR-3

REMOVAL AND INSTALLATION

SWING REDUCTION GEAR

12 -Tighten the lock-nut (17).

a Use a new lock-nut.

2 Shaft nut: Loctite 242

RKPB7180

13 -Use the special wrench C1 and a dynamometric wrench to tighten the lock-nut (17).

3 Shaft nut: 1000±50 Nm

a If the bearings (20-21), the pinion (18) or the gearbox housing (4) are replaced check the rotation torque of the pinion (18).

3 Rotation torque: 50-60 Nm

a If the torque is higher, increase the thickness of shim (19). a If the torque is lower, decrease the thickness of shim (19).

RKPB7091

14 -Lock the position of the lock-nut (17) with 6 safety caulkings, corresponding to the grooves in the pinion shaft (18).

17 RKPB2402

15 -Lubricate the O-ring seating of the gearbox housing (4) and mount the seal (16).

2 Seat: ASL800050

RKPB7070

PC80MR-3

30-43 (1)

REMOVAL AND INSTALLATION

SWING REDUCTION GEAR

16 -Install the 2nd sun gear groups (15).

RKPB7210

17 -Mount the toothed ring (3).

a Check the position.

RKPB7240

18 -Install 2nd reduction pinion (14).

RKPB7040

19 -Lubricate the O-Ring seat and mount the O-Ring (13) in the flange (2).

2 Seat: ASL800050

RKPB7030

30-44 (1)

PC80MR-3

REMOVAL AND INSTALLATION

SWING REDUCTION GEAR

20 -Position the gear ring (2) on the gearbox housing (4).

a Check the position.

RKPB7190

21 -Tighten the ten screws (12).

3 Bolt: 85 Nm

RKPB7200

22 -Mount the planetary carrier (11).

RKPB7000

23 -Mount the snaqp ring (10) on the pinion (9) and insert it on the 1st sun gear group (11).

9 9

10 11 RKPB7250

PC80MR-3

30-45 (1)

REMOVAL AND INSTALLATION

SWING REDUCTION GEAR

24 -Using a caliper verify the correct assembly of the gearbox checking the axial quota.

28,9-29,5

a Axial quota: 28.9-29.5 mm a If the value is higher, reduce the sun gear (9) width in the axial direction flattening the support plane (reduction side). a If the value is lower, insert adjusting spacer between sun gear (9) and planetary carrier (11).

RKP12790

25 -Install fitting (8) to the reduction gear housing (4).

2 Union: Loctite 243

RKPB7260

26 -Mount the plug (7).

3 Plug: 20-30 Nm

7 RKPB7270

27 -Place the swing machinery (1), tighten the screws (6).

a Check the position.

30-46 (1)

RKPC1640

PC80MR-3

REMOVAL AND INSTALLATION

SWIVEL JOINT

SWIVEL JOINT Removal a Fully extend the attachments, allow them to settle on the ground and stop the engine. k Slowly loosen the hydraulic oil tank cap to relieve pressure.

1 2

1 -Remove upper guard (1) and side fixed guard (2).

RKPC8300

2 -Disconnect the travel motors drain hose (3). 3 -Mark and then disconnect seven hoses (4) coming from the control valve and reserved for travel, blade and speed increase.

3 4

a Plug all pipes to keep out impurity.

RKPC8320

4 -Remove the cotter pins, washers, retaining pins (5), and remove the anti-rotation bracket (6).

a Replace cotter pins at each disassembly.

6 5

RKPC8330

5 -Remove the lower guard (7).

RKPC8350

PC80MR-3

30-47 (1)

REMOVAL AND INSTALLATION

SWIVEL JOINT

6 -Disconnect all travel, speed increase, blade and travel motor drain radial hoses (8).

a Mark the position of lines to avoid mixing them during installation. a Plug all pipes to keep out impurity.

8 8 RKPC8340

7 -Disconnect lower hoses (9) and remove fitting (10). 8 -Connect swivel joint to a hoist and slightly tension the cable. Loosen and remove four screws (11) (n°4) retaining joint to bracket (12).

11 9

RKPC8360

9 -Remove swivel joint (13).

4 Swivel joint: approx. 18.5 kg

RKPC1691

Installation •

To install, reverse the removal procedure.

a Pay attention not to mix the lines. a Bleed the air from the travel circuits. (For details, see "20 TESTING AND ADJUSTMENTS").

30-48 (1)

PC80MR-3

REMOVAL AND INSTALLATION

SWIVEL JOINT

Disassembly

1 -Remove flange (1). 2 -Remove snap ring (2).

3 -Using tool “T”, remove rotor (4) and rings (3) from stator (5).

4 -Remove O-rings (6) and sealing rings (7).

Assembly 1 -Fit sealing rings (7) and O-rings (6) to stator (5). 2 -Introduce rotor (5) into stator (4) using a plastic hammer.

a Coat sealing rings and shoes with grease. 2 Rings and shoes: G2 - LI

a Take care not to damage the sealing rings.

3 -Install ring (3) and snap ring (2). 4 -Install O-ring and flange (1).

3 Flange screws: 32±3 Nm

RKP17010

RKP17020

PC80MR-3

30-49 (1)

REMOVAL AND INSTALLATION

CONTROL VALVE

CONTROL VALVE Removal

k Lower the equipment to the ground and stop the engine. Slowly loosen the tank cap to relieve any residual pressure. k Cycle the battery main switch to O (OFF). a Remove the hydraulic oil.

6 Hydraulic oil: approx 65 l

a Remove the fuel tank. (For details, see "FUEL TANK").

RKPC7940

1-Disconnect the connectors (1) attached to the revolving frame rotation and travel pressure-switches (2).

a Ensure that all connectors are marked as follows: R.H. SIDE Mark

X381 4th element X380 3rd element X199 1st element

L.H. SIDE X383 4th element X382 3rd element X200 1st element

1 2 RKPC7541

2 -Disconnect the servocontrol hoses (3) (right and left).

a Note down the hose codes and colours as well as their connecting locations (from “A” to “R”).

a Plug all pipes to keep out impurity.

RKPC8370

3 -Remove the U bolt (4) and reinforcement bracket (5) supporting the delivery hose leading to the optional attachments.

4 RKPC8380

30-50 (1)

PC80MR-3

REMOVAL AND INSTALLATION

CONTROL VALVE

4 -Disconnect the actuator front hoses (6) and the special attachment hose.

a Note down hose codes and colours as well as their connecting positions.

a Plug all pipes to keep out impurity.

RKPC8390

5 -Disconnect the exhaust pipes (7) and (8).

RKPC8400

6 -Disconnect delivery hoses (9), (10) and pilot system hose (11).

RKPC8410

7 -Disconnect the engine upper valve discharge hose (12).

RKPC8420

PC80MR-3

30-51 (1)

REMOVAL AND INSTALLATION

CONTROL VALVE

8 -Thread a lifting eye into the head of the control valve (13) and connect it to a hoisting device.

RKPC8430

9 -Loosen and remove screws (14) and remove vibration dampeners and control valve (15).

14 RKPC8440

Installation •

To install, reverse the removal procedure. 1 -Start the engine to circulate the oil and check the seals. 2 -Bleed the air from the revolving frame rotation servocontrol circuit. 3 -Stop the engine and check the hydraulic oil level.

30-52 (1)

PC80MR-3

REMOVAL AND INSTALLATION

LH PPC VALVE

LH PPC VALVE Removal

k Lower the work equipment until it is resting on the ground and switch off the engine. 1 -Release residual pressures from all circuits. (For details see "20 TESTING AND ADJUSTMENTS").

2 -Remove the radio compartment close-out panel (1) and button strip (2).

RKPC1750

3 -Slide the boot (3) up. 4 -Remove the collar (4) retaining the boot.

4 RKPC1760

5 -Remove the rear storage bin (5).

RKPC8450

PC80MR-3

30-53 (1)

REMOVAL AND INSTALLATION

LH PPC VALVE

6 -Loosen and remove front and rear screws (6) and remove casing (7).

7 RKPC1780

7 -Disconnect connector (8), remove the screws and lift the PPC valve (9). 8 -Note down positions, disconnect the lines and remove the fittings. [1*][2*]

9 8

RKPC1790

Installation •

To install, reverse the removal procedure.

[*1]

a Location for hose connection:

M white

S white

F yellow

F green

A yellow

A green

[*2]

3 Actuator fittings (1-2-3-4): 34-35 Nm

3 4 2 RKPC1800

3 Feed and discharge fittings (P-T): 34 – 44 Nm 1 -Start the engine at low idling and perform all the manoeuvres enabled by the PPC valve. Switch off the engine and check level of the hydraulic oil.

30-54 (1)

PC80MR-3

REMOVAL AND INSTALLATION

R.H. PPC VALVE

R.H. PPC VALVE Removal 1 -Fully raise the boot and remove the boot collar according to the procedures described for the LH PPC valve.

2 -Loosen and remove front (1) and rear (2) screws; lift out the control dashboard (3) and set it aside.

1 3 RKPC8460

3 -Disconnect connector (4), remove the screws and lift the PPC valve (5). 4 -Note down positions, disconnect the lines and remove the fittings. [1*][2*]

RKPC1820

Installation •

To install, reverse the removal procedure.

[*1]

a Location for hose connection:

S white

M white

E green

E yellow

G yellow

G green

3 4 2

[*2]

3 Usable fittings (1-2-3-4): 34-35 Nm

RKPB9270

PC80MR-3

30-55 (1)

REMOVAL AND INSTALLATION

EQUIPMENT PPC VALVES

EQUIPMENT PPC VALVES Assembly a Cleanliness is of the essence when assembling PPC valves.

5 7 mm

1 -When installing pistons (1), lubricate seats and pistons with grease (G2 - LI). 2 -When installing disk (2), adjust gap to achieve a lever travel of 0.5 - 3 mm (within 200 mm of the lever rotation centre). 3 -When installing joint (3) to body (4), degrease threads and apply a drop of adhesive to the female thread, 5 -7 mm away from the edge

2 Thread: Loctite 262

RKP17080

4 -Install smaller diameter springs (5) to shims (6).

a Spring inner diameter: • Inner spring: 4.9 mm • Outer spring: 5.55 mm

2 3

5 -When installing plug (7) into body (4), make sure that plug does not bottom out on the 20 mm diameter hole.

6 -Apply grease to the articulation on joint (3) and to the contact surface of disk (2) and pistons (1).

2 Grease G2 - LI

a Amount of grease: • Joint articulation: 2 -4 cm3 • Disk and pistons: 0.3 -0.8 cm3 7 -Tighten each part to the following torques: • Swivel joint (3): 39-49 Nm • Swivel joint (8): 11.8-14.7 Nm • Nut (9): 98-127 Nm • Plug (10): 6-11 Nm

1 1 5 6

5 6

4 10 7

30-56 (1)

RKP17070

PC80MR-3

REMOVAL AND INSTALLATION

TRAVEL PPC VALVE

TRAVEL PPC VALVE Removal

k Lower the work equipment until it is resting on the ground and switch off the engine. Release residual pressures from all circuits. (For details see "20 TESTING AND ADJUSTMENTS"). 1 -Remove the left side shield (1) and the front protective panel (2).

RKPC7640

2 -Disconnect six hoses (4) from PPC valve (3).

a Mark the position of lines to avoid mixing them during installation.

a Plug all pipes to keep out impurity.

4 RKPC8470

3 -Remove screws (5) and remove travel control levers (6) and pedals (7). [*1]

6 5 RKPC1840

4 -Remove the retaining screws and remove the PPC valve unit (8) together with the mounting plate (9).

8 9 RKPC1850

PC80MR-3

30-57 (1)

REMOVAL AND INSTALLATION

TRAVEL PPC VALVE

5 -Remove screws, washers, spacers and casing (10).

RKPC1860

6 -Remove seals (11) and springs (12); loosen screws (13) and remove PPC valve (8).

RKPC1870

Installation •

To install, reverse the removal procedure.

[*1]

3 Pedal and lever screws: _____ Nm

1 -Start and run engine at low idling speed; stop the engine and check the oil level in the tank. 2 -Perform a few travel manoeuvres in both directions to bleed the air from the servo-control circuit.

30-58 (1)

PC80MR-3

REMOVAL AND INSTALLATION

TRAVEL PPC VALVE

Assembly

a Cleanliness is of the essence when assembling PPC valves. 1 -When installing pistons (1), lubricate seats and pistons with grease (G2 - LI).

2 1

2 -Install smaller diameter springs (2) to shims (3).

a Spring inner diameter: • Inner spring: 4.9 mm • Outer spring: 5.55 mm

3 11

3 -Use the specific installation equipment to install bushings (4) and pins (5).

k Do not use hammers but push in the bushings and pins by applying consistent thrust (no blows should be applied).

4 -Apply grease to the shafts of levers (6), to the contact surfaces on levers (7), to pistons (1), to the surfaces on shoes (8) and to the pins of lever (9).

2 Grease G2 - LI

a Amount of grease: • Bushings (4) and shoes (8): 4 -8 cm3 • Contact surfaces: 0.3 -0.8 cm3

12 c

10 4

5 6 15

5 9

RKP17090

5 -Install 1.6 mm thick washers (10); if difference between levers at end of travel exceeds 0.7°, replace the washers until the difference is within the 0.7° tolerance. A 0.3 mm reduction in thickness will increase the angle by 0.39°.

a Available shims: 1 - 1.3 - 1.6 mm 6 -Tighten each part to the following torques:

3 Plug (11): 6 – 11 Nm Bolt (12): 3.9 – 4.9 Nm (con Loctite 262) Bolt (13): 7.8 – 9.8 Nm Plug (14): 4 -9 Nm Bolt (15): 25 -30 Nm Bolt (16): 27-34 Nm

PC80MR-3

30-59 (1)

REMOVAL AND INSTALLATION

ADDITIONAL EQUIPMENT AND BOOM SWING PPC VALVE

ADDITIONAL EQUIPMENT AND BOOM SWING PPC VALVE Removal

k Lower the work equipment until it is resting on the ground and switch off the engine. 1 -Release residual pressures from all circuits. (For details, see "20 TESTING AND ADJUSTMENTS"). 2 -Remove the left side shield (1) and the front protective panel (2).

3 -Disconnect lower hoses (3), side hoses (4) and side fittings (5) from the PPC valve that is being removed.

RKPC7640

5 4

3 RKPC8480

4 -Remove screws (6) and remove PPC valve (7).

6 RKPC1890

Installation •

To install, reverse the removal procedure. 1 -Start and run engine at low idling speed and perform the manoeuvres controlled by the PPC valve; stop the engine and check the oil level in the tank.

30-60 (1)

PC80MR-3

REMOVAL AND INSTALLATION

BLADE PPC VALVE

BLADE PPC VALVE Removal

k Fully lower the attachments until they are resting on the ground; stop the engine and turn the battery main switch key to the O (OFF) position.

1 2

1 -Release residual pressures from all circuits. (For details see "20 TESTING AND ADJUSTMENTS"). 2 -Remove seat.

3 -Loosen three screws (1) and move box (2) away from the cab right wall. RKPC1900

4 -Loosen and remove screws (3) and lift PPC valve (4).

4 3

RKPC8490

5 -Disconnect hoses (5) and hoses (6) in the sequence given.

6 RKPC8500

Installation •

To install, reverse the removal procedure. 1 -Start the engine to circulate the oil. 2 -Make a few manoeuvres with the blade to bleed air from servo-control circuit.

PC80MR-3

30-61 (1)

REMOVAL AND INSTALLATION

ACCELERATOR POTENTIOMETER

ACCELERATOR POTENTIOMETER Removal

k Position the machine on firm level ground, with the attachments to the ground, and the safety devices engaged.

k Cycle the battery main switch to the O (OFF) position and remove the key.

RKPC7940

1 -Lift up the boot (1) on the RH PPC valve and remove the boot collar. 2 -Loosen and remove front and rear screws and lift out the control dashboard (2).

1 RKPC8510

3 -Remove control knob (3) and disconnect connector (4). Take out screws (5) and remove potentiometer (6).

6 5 5 4

RKPC8520

Installation •

To install, reverse the removal procedure.

30-62 (1)

PC80MR-3

REMOVAL AND INSTALLATION

CONTROLLER

CONTROLLER Removal

k Stop the machine on firm level ground, with the attachment to the ground.

k Cycle the battery main switch to the O (OFF) position.

1 -Remove screw (1) and remove the dashboard (2) of controller (3).

2 2 RKPC8530

2 -Loosen and remove three retaining screws (4) and lift the controller.

a Note down shim position and quantity (5). 3 -Disconnect the connectors and remove the controller (3).

4 RKPC8540

Installation •

To install, reverse the removal procedure.

PC80MR-3

30-63 (1)

REMOVAL AND INSTALLATION

SAFETY MICROSWITCH

SAFETY MICROSWITCH Removal

k Position the machine on firm level ground, with the attachments to the ground, and the safety devices engaged.

k Cycle the battery main switch to the O (OFF) position.

1 -Remove the radio compartment close-out panel (1) and button strip (2).

RKPC8550

2 -Remove the rear storage bin (3).

RKPC8451

3 -Loosen and remove front and rear screws (4) and remove casing (5).

5 RKPC1781

4 -Using a thin-bladed screwdriver, remove screw covers (7) (LH side) from lower hood (6).

7 6

30-64 (1)

RKPC1970

PC80MR-3

REMOVAL AND INSTALLATION

SAFETY MICROSWITCH

5 -Take out screws (8), (9).

9 8

RKPC1980

6 -Lift hood (10), remove screws (11) and remove the safety engagement lever (12). [*1]

RKPC1990

7 -Lower hood (10) and disengage microswitch wiring harness from tie straps. 8 -Disconnect the connector, remove screws (13) and remove microswitch (14).

13 10 RKPC2000

Installation • [*1]

To install, reverse the removal procedure.

3 Bolt: ___ Nm

PC80MR-3

30-65 (1)

REMOVAL AND INSTALLATION

HYDRAULIC OIL TANK

HYDRAULIC OIL TANK Removal a Turn the revolving frame 90° to the right in order to drain the hydraulic oil; rest the attachments on the ground and stop the engine, then turn the battery main switch to the O (OFF) position.

k Slowly loosen the tank cap to relieve any residual pressure.

1 -Drain the hydraulic oil.

6 Oil: approx 65 l

2 -Remove upper hood (1) and side hood right (2).

RKPC8560

3 -Remove the lower right guard (3).

RKPC8570

4 -Disconnect connector (4) and cables (5).

4 5

RKPC8580

5 -Disconnect the hoses (6), (7), (8) from the upper filter.

a Plug all pipes to keep out impurity.

8 6 RKPC8590

30-66 (1)

PC80MR-3

REMOVAL AND INSTALLATION

HYDRAULIC OIL TANK

6 -Loosen the clamps and remove the pump suction line (9).

a Plug all pipe to keep out impurity.

RKPC8600

7 -Disconnect the discharge and drain side hoses (11) from tank (10).

a Plug all pipes to keep out impurity.

a Mark the hoses to prevent incorrect connections during installation.

RKPC7811

8 -Connect the upper eye on tank (10) to a hoist "D” and slightly tension the cable. 9 -Loosen and remove the lower screws and remove tank.

4 Oil tank: 70 kg

RKPC8610

Installation •

To install, reverse the removal procedure.

a Do not mix the lines. 1 -Fill tank. 2 -Start the engine to let the oil flow through the system; stop the engine, check the oil level and top up if necessary. 3 -Pressurize the tank.

PC80MR-3

30-67 (1)

REMOVAL AND INSTALLATION

FUEL TANK

FUEL TANK 1 -Swing the revolving frame by 90° to the right.

k Stop the engine and cycle the battery main switch to the O (OFF) position.

2 -Lift the upper hood (1).

RKPC8561

3 -Remove the right side shield (2).

RKPC8620

4 -Remove the lower hand protective casin (3).

RKPC8650

5 -Open the cock (4) and drain the fuel from the tank.

RKPC8640

30-68 (1)

PC80MR-3

REMOVAL AND INSTALLATION

FUEL TANK

6 -Remove washer tank (5) and set it aside. 7 -Remove the washer tank support (6).

RKPC8630

8 -Disconnect the connector (7) of the level gauge. 9 -Loosen the hose clamp and disconnect the fuel return hose (9) from tank (8).

a Plug the hose to keep out impurity.

RKPC8660

10 -Close the cock (4), loosen the hose clamp and disconnect the fuel feed hose (10) from tank (8).

a Plug the hose to keep out impurity.

10 RKPC8641

11 -Loosen the nuts (11) holding the retaining straps (12) and remove the tank (8). [*1]

12 RKPC8670

PC80MR-3

30-69 (1)

REMOVAL AND INSTALLATION

FUEL TANK

Installation •

To install, reverse the removal procedure.

[*1]

3 Strap tensioning bottom nut: 5±2 Nm

3 Strap tensioning superior nut: 60±6 Nm 1 -Fill the fuel tank, bleed the air from the fuel system and start the engine.

30-70 (1)

PC80MR-3

REMOVAL AND INSTALLATION

CONTROL MODULES (MACHINE - ENGINE - KOMTRAX)

CONTROL MODULES (MACHINE - ENGINE - KOMTRAX) Removal

k Stop the machine on firm level ground, with the attachments to the ground and the safety devices engaged.

k Cycle the battery main switch to the O (OFF) position.

RKPC7940

1 -Remove screws (1) and remove protective hood (2).

1 RKPC2120

2 -Disconnect the connectors attached to the control module to be removed: - Machine control module (3). - Engine control module (4). - Komtrax control module (5).

5 3 4

3 -Remove the screws and remove the control module.

RKPC8680

Installation •

To install, reverse the removal procedure.

PC80MR-3

30-71 (1)

REMOVAL AND INSTALLATION

EVAPORATOR UNIT

EVAPORATOR UNIT Removal

k Lower the work equipment until it is resting on the ground and switch off the engine.

k Cycle the battery main switch to the O (OFF) position. 1 -Drain the air conditioning unit. (For details see "20 TESTING AND ADJUSTMENTS"). 2 -Drain the coolant liquid.

6 Liquid: approx 8 l RKPC7940

3 -Remove seat (1) and evaporator cover (2).

2 RKPC2140

4 -Remove screw (3) and remove the controller dashboard (4).

4 4 RKPC8531

5 -Remove two screws (5) (n° 2), remove right box lower protective cover (6); disconnect lighter connector.

RKPC2150

30-72 (1)

PC80MR-3

REMOVAL AND INSTALLATION

EVAPORATOR UNIT

6 -Remove two screws (7) and remove cover (8).

RKPC2160

7 -Remove screws (9), lower sleeve (10) and remove the top part (11) of the air duct.

9 11 10 9 RKPC2170

8 -Remove screws (12), disconnect connector (13) and slide off the centre (shutting) part (14) of the air duct.

12 RKPC2180

9 -Remove screws (15) and (16) and remove duct (17) from evaporator.

15 RKPC2190

PC80MR-3

30-73 (1)

REMOVAL AND INSTALLATION

EVAPORATOR UNIT

10 -Remove wiring harness clamps (18), (19).

18 19

RKPC2200

11 -Loosen straps and disconnect heating hoses (20) and (21).

RKPC8690

12 -Disconnect connectors (22), (23), (24).

22 24

23 RKPC2220

13 -Disconnect the connector (25) for the rear shutter (22).

RKPC2230

30-74 (1)

PC80MR-3

REMOVAL AND INSTALLATION

EVAPORATOR UNIT

14 -Disconnect feed hose (28), discharge hose (29) and pressure switch connector (30) from evaporator.

a Plug all holes and protect hoses and sealing rings. 15 -Remove feedthrough seal (31) and route hoses under the cab floor.

28 31

RKPC2240

16 -Remove the retaining screws and lift the seat holder (32) by 6 cm by threading 70-80 mm long screws “A” into the holes provided.

17 -Remove the front screws (33) retaining the unit.

RKPC2250

18 -Loosen the rear screws (34).

RKPC2221

19 -Lift the front part of the evaporator unit (27) and slide it out towards the machine front.

RKPC2260

PC80MR-3

30-75 (1)

REMOVAL AND INSTALLATION

EVAPORATOR UNIT

Installation •

To install, reverse the removal procedure. 1 -Refill the coolant liquid tank.

Coolant liquid needed: approx 8 l

2 -Refill the air-conditioning unit. (For details see "20 TESTING AND ADJUSTMENTS"). 3 -Start and run the engine for a couple of minutes, allow the liquid to flow through the heating system and check the air conditioning unit for proper operation. 4 -Stop the engine and top up the coolant liquid.

30-76 (1)

PC80MR-3

REMOVAL AND INSTALLATION

CABIN

CABIN Removal

k Lower the work equipment until it is resting on the ground and switch off the engine.

k Cycle the battery main switch to the O (OFF) position. 1 -Eliminate residual pressure from all circuits. (For details, see "20 TESTING AND ADJUSTMENTS"). 2 - Disconnect the ground cable (1).

RKPC8700

3 -Loosen plug (2) and drain the coolant liquid.

6 Coolant liquid needed: approx 18 l

4 -Drain the air conditioning unit. (For details see "20 TESTING AND ADJUSTMENTS").

RKPC8710

5 -Remove the left side shield (3) and the front protective panel (4).

3 RKPC7641

6 -Remove the side fixed hood (5).

RKPC8082

PC80MR-3

30-77 (1)

REMOVAL AND INSTALLATION

CABIN

7 -Disconnect the standard servocontrol delivery hoses (8) (M) and discharge hoses (9) (S) plus the optional 2piece-boom hoses (10), (11) from the distribution units (6), (7).

k To avoid oil spillage, DO NOT disconnect hoses (12) and (13).

a Check to ensure that all hoses have marks scribbled on, so that delivery and discharge are not mixed up.

13 12

a Plug all pipes to keep out impurity. [*1]

RKPC8720

8 -Disconnect all quick-coupling lines (14).

a Ensure that all hoses are marked with the correct codes and colours as shown in the drawing.

RKPC8730

Green

Yellow RKP19960

9 -Disconnect connectors (15), (16), (17).

RKPC8740

30-78 (1)

PC80MR-3

REMOVAL AND INSTALLATION

CABIN

10 -Disconnect the heating hoses (18) from the cab.

RKPC8691

11 -Remove the right box covers and the front evaporator shield (19). (For details, see "EVAPORATOR UNIT").

19 RKPC2311

12 -Remove the retaining bracket and disconnect air conditioning hoses (20), (21) from evaporator; remove feedthrough plate (22) and route the hoses under the cab floor. Disconnect connector (23). [*2]

13 -Release from the straps all the hoses and wiring harnesses secured to the lower frame.

21 22

14 -Loosen and remove the inner cab retaining screw (24) on the right rear side. [*3]

RKPC2243

15 -Loosen and remove the outer cab retaining screws (25). [*3]

25 RKPC8750

PC80MR-3

30-79 (1)

REMOVAL AND INSTALLATION

CABIN

16 -Disconnect hose (27) from the washer tank (26).

27 RKPC8631

17 -Remove plugs and thread some lifting eyes “A” into the cab roof. [*4]

RKPC2330

18 -Connect to a hoist and start lifting the cab.

k Support the hoses and wiring harnesses while lifting the cab. 4 Full cab: approx. 400 kg

RKPC8760

30-80 (1)

PC80MR-3

REMOVAL AND INSTALLATION

Installation •

To install, reverse the removal procedure.

CABIN

[*1] •

Connect the hoses according to the following pattern:

Section M (delivery) 1 - Boom swing pedal 2 -Travel PPC valves 3 - Blade PPC valve 4 - Already connected 5 - R.H. PPC valve 6 - L.H. PPC valve

RKPC8721

Section S (discharge) 1 - Blade PPC valve 2 - Boom swing pedal 3 - Already connected 4 -Travel PPC valves 5 - R.H. PPC valve 6 - L.H. PPC valve OPTIONAL 10-11 - To the 2-piece boom pedal

[*2]

[*3]

3 Bracket bolt: ___ Nm 3 Cab mounting screws: ___ Nm

[*4]

a When the lifting eyes are removed, apply grease to the thread and re-install the plugs in the holes 1 -Fill with coolant liquid and fill the air conditioning system; start the engine at low idling speed and let it run for about 5 minutes.

Coolant liquid needed: approx 8 l

2 -Stop the engine, check the coolant liquid level and the oil level in the tank.

PC80MR-3

30-81 (1)

REMOVAL AND INSTALLATION

SWING CIRCLE

SWING CIRCLE Removal 1 -Remove the revolving frame. (For deta ils, se e"EQ UI PMENT (1-piece b oom version)").

2 -Connect a hoist to the swing circle (1) and slightly tension the cables. 3 -Loosen and remove 24 retaining screws (2). [*1]

4 -Remove the swing circle (1).

4 Swing circle: 105 kg

RKPC9120

[*2]

Installation • [*1]

To install, reverse the removal procedure.

2 Bolt: Loctite 262

3 Bolt: 280±30 Nm [*2]

a When positioning the swing circle, orientate the inner ring area marked with “S” to the right side of the frame as shown.

RKPC8770

2 Lubricate swing circle teeth with G2 – LI grease and introduce grease in the pinion compartment. 2 Grease: approx. 4.5 kg

a Lubricate the seal rim (3) as well.

RKPC8780

30-82 (1)

PC80MR-3

REMOVAL AND INSTALLATION

REVOLVING FRAME

REVOLVING FRAME Removal

k Cycle the battery main switch to the O (OFF) position. a Remove the equipment. ( F or d et ai l s s ee "EQ U IPM E N T ( 1- pi ec e b oo m version)"). a Remove the complete cab. (For details, see "CABIN"). a Move the hoses for the removed equipment inside the revolving frame and secure them. RKPC7940

1 -Remove engine hood (1), upper and front hood, side hood (2) and front hood (3).

RKPC8820

2 RKPC7642

2 -Remove the side fixed hood (4).

RKPC8083

PC80MR-3

30-83 (1)

REMOVAL AND INSTALLATION

REVOLVING FRAME

3 -Disconnect the travel, blade, travel motor drain and speed increase hoses (6) from the swivel joint (5).

6 5

RKPC8321

4 -Remove pins (7) and bracket (8).

7 8 7

RKPC8331

5 -Remove lines (9), (10) and the complete air filter (11).

RKPC8022

6 -Sling boom cylinder (12), disconnect hoses, remove fulcrum pin (13), (6) and cylinder.

13 RKPC8790

30-84 (1)

PC80MR-3

REMOVAL AND INSTALLATION

REVOLVING FRAME

7 -Loosen and remove the screws retaining the swing circle outer ring (14) to the revolving frame.

a Leave three screws in place for safety.

RKPC8800

8 -Connect a hoisting device to boom-swing bracket and counterweight (15).

RKPC8810

9 -Lift the complete revolving frame. [*1]

RKPC9160

Installation • [*1]

To install, reverse the removal procedure.

2 Lubricate swing circle teeth with G2 – LI grease.

PC80MR-3

30-85 (1)

REMOVAL AND INSTALLATION

EQUIPMENT (1-piece boom version)

EQUIPMENT (1-piece boom version) Removal a Fully extend the equipment, allow it to settle on the ground and stop the engine.

k Slowly loosen the tank cap to relieve any residual pressure.

1 -Remove the upper hood (1) giving access to the tank.

RKPC8820

2 -Disconnect boom beacon connector (2).

2 RKPC8830

3 -Mark the positions of and disconnect the attachment and optional attachment hoses (3).

k Slowly loosen the hoses in a gradual manner to relieve any residual pressure; disconnect the hoses when oil stops coming out. a Plug all holes so as to keep out impurities. a Route the hoses to the rear of the machine.

3 3 RKPC8840

4 -Support the boom cylinder (4) by means of a hoist, remove piston pin (5). [*1]

a Note down shim position and quantity.

RKPC8850

30-86 (1)

PC80MR-3

REMOVAL AND INSTALLATION

EQUIPMENT (1-piece boom version)

5 -Lower cylinder (4) and rest it on a stand “A”.

RKPC8860

6 -Introduce a bar “B” into boom piston connecting hole. Connect the equipment to a hoist and slightly tension the cables.

RKPC8870

7 -Remove the pin (7) and remove the attachments (8). [*2]

a Note down shim position and quantity.

4 Attachment control valve approx. 1.100 kg

RKPC8880

PC80MR-3

30-87 (1)

REMOVAL AND INSTALLATION

EQUIPMENT (1-piece boom version)

Installation •

To install, reverse the removal procedure.

k When aligning the positions between holes and pin, let the engine run at minimum idling. Do not insert fingers in the holes to check the alignment. [*1] •

Lubricate pins and bushings with grease.

•

Adjust clearance between cylinder rod and boom using shims.

2 Pins and bushings: Molikote

a Standard clearance: Max. 1 mm [*2] •

Lubricate pins and bushings with grease

2 Pins and bushings: Molikote

•

Adjust clearance between boom and support using shims.

a Standard clearance: Max. 1 mm 1 -Lubricate previously removed pins; inject grease until it bottoms out on the side rings. 2 -Check the oil level in the tank. Start engine at low idling speed to allow the oil to flow. Bleed air from cylinders for arm, bucket and additional equipment (if applicable). For details, see "20 TESTING AND ADJUSTMENTS").

30-88 (1)

PC80MR-3

REMOVAL AND INSTALLATION

BOOM CYLINDER (For 1-piece boom)

BOOM CYLINDER (For 1-piece boom) Removal

k Extend the arm fully and open the bucket completely. Lower the work equipment until it is resting on the ground.

1 -Put a sling around the cylinder (1). 2 -Switch off the engine, release pressure in the cylinder by moving the RH PPC valve lever several times.

3 -Take out screws (2) and remove pin (3). [3*][4*] 4 -Start the engine to retract the piston (4).

RKPC8930

[*2] 5 -Lower the cylinder (1) until it comes to rest on blocks “A”. 6 -Stop the engine and release any residual hydraulic p r e ss u r e . ( F or d et ai l s s e e " 20 T E S T I N G A N D ADJUSTMENTS").

A RKPC8940

7 -Disconnect hoses (5) and (6) and unplug connector (7).

a Plug all pipes to keep out impurity.

5 RKPC8950

8 -Take out screws (8) and remove pin (9). [1*][2*][*3] 9- Remove cylinder (1).

RKPC8960

PC80MR-3

30-89 (1)

REMOVAL AND INSTALLATION

BOOM CYLINDER (For 1-piece boom)

Installation •

To install, reverse the removal procedure.

[*1]

a Insert the spacers to a given clearance (distributed on both sides of the cylinder rod) until a clearance of 0.5 – 1 mm is obtained. [*2]

[*3]

k When aligning the positions between hole and pin, run the engine at minimum idling. Do not insert fingers in the holes to check the alignment. 2 Inside bushings: ASL800050

[*4]

a Insert the spacers to a given clearance (distributed on both sides of the top of the piston rod) until a clearance of 0.5 – 1 mm is obtained. •

Start the engine to circulate the oil, and bleed air from the cylinder. (For details see "20 TESTING AND ADJUSTMENTS").

a After bleeding the air, switch off the engine and check the oil level in the tank.

30-90 (1)

PC80MR-3

REMOVAL AND INSTALLATION

ARM CYLINDER

ARM CYLINDER Removal

k Fully dump the bucket (1). Open the arm (2) to within 8 cm of the bottom of stroke.

1 -Operate the boom (3) until the arm touches the ground and swing the bucket until the teeth touch the ground.

2 1

2 -Place a safety jack “A” and a non-slip block under the boom (3).

a In machine models with 2-piece boom, the jack should be applied under the 2-piece boom.

RKPC2610

3 -Stop the engine and relieve all residual pressure from the arm cylinder by operating the PPC valve several times.

4 -Position a safety block “B” under cylinder (4). [1*][3*] 5 -Take out screws (5) and remove pin (6). 6 -Start the engine and fully retract the piston.

7 -Stop the engine and release any residual hydraulic p r e ss u r e . ( F or d et ai l s s e e " 20 T E S T I N G A N D ADJUSTMENTS").

RKPC8970

8 -Disconnect the tubes (7) and plug them.

RKPC8980

9 -Connect the cylinder to a hoist, remove screws (8) and remove pin (9). [2*][3*][*4] 10 -Remove cylinder (4).

8 RKPC8990

PC80MR-3

30-91 (1)

REMOVAL AND INSTALLATION

ARM CYLINDER

Installation •

To install, reverse the removal procedure.

[*1]

a Insert the spacers to a given clearance (distributed on both sides of the eyes piston) until a clearance of 0.5 – 1 mm is obtained. [*2]

[*3]

k When aligning the positions between hole and pin, run the engine at minimum idling. Do not insert fingers in the holes to check the alignment. 2 Inside bushings: ASL800050

[*4]

a Insert the spacers to a given clearance (distributed on both sides of the cylinder rod) until a clearance of 0.5 – 1 mm is obtained. •

Start the engine to circulate the oil, and bleed air from the cylinder. (For details see "20 TESTING AND ADJUSTMENTS").

a After bleeding the air, switch off the engine and check the oil level in the tank.

30-92 (1)

PC80MR-3

REMOVAL AND INSTALLATION

BUCKET CYLINDER

BUCKET CYLINDER Removal 1 -Fully extend the arm (1). 2 -Operate the boom and bucket (2) until bottom of bucket sits level.

3 -Lower the blade.

RKPC9000

4 -Sling the cylinder (3) in a strap and connect it to a hoisting device; apply a slight tension.

a Do not engage the hoses with the strap.

RKPC9170

5 -Remove the nuts (4), remove the screw and remove the pin (5). [1*][2*][*3]

6 -Start the engine and fully retract the piston.

k Stop the engine and release any residual pressures.

RKPC9010

7 -Disconnect hoses (6) and (7).

a Plug all pipes to keep out impurity. 8 -Take out screws (8) and remove pin (9). [1*][2*][*4] 9 -Remove cylinder.

9 6

RKPC9020

PC80MR-3

30-93 (1)

REMOVAL AND INSTALLATION

BUCKET CYLINDER

Installation •

To install, reverse the removal procedure.

[*1]

a Insert the spacers to a given clearance (distributed on both sides of the eyes piston) until a clearance of 0.5 – 1 mm is obtained. [*2]

[*3]

k When aligning the positions between hole and pin, do not insert fingers into the hole to check the alignment. 2 Inside bushings: ASL800050

[*4]

a Insert the spacers to a given clearance (distributed on both sides of the cylinder rod) until a clearance of 0.5 – 1 mm is obtained. •

Start the engine to circulate the oil, and bleed air from the cylinder. (For details, see "20 TESTING AND ADJUSTMENTS").

a After bleeding the air, switch off the engine and check the oil level in the tank.

30-94 (1)

PC80MR-3

REMOVAL AND INSTALLATION

BOOM SWING CYLINDER

BOOM SWING CYLINDER Removal 1 -Swing the boom to the left to extend the cylinder fully. 2 -Switch off the engine and move the PPC valve several times to release all residual pressures.

3 -Remove right guard (1) from revolving frame.

RKPC8820

4 -Disconnect hoses (2), (3) from the cylinder and plug them. Also disconnect hose (4) for lubrication.

4 2 RKPC9030

5 -Apply a block under the cylinder to prevent kinking the cylinder rod against the edge of the frame. 6 -Remove the screw (5), draw out the pin (6) and detach the piston rod from its support (7).

[1*][2*]

RKPC9040

7 -Remove the screws (8) and draw out the stop (9) and the pin (10). [2*][3*][*4]

8 -Release from the straps all the hoses; slide the cylinder out partially from the front and, as soon as possible, put it in a sling and lift it off.

a During this operation take great care not to dent the piston rod.

8 RKPC9050

PC80MR-3

30-95 (1)

REMOVAL AND INSTALLATION

BOOM SWING CYLINDER

Installation •

To install, reverse the removal procedure.

[*1]

a Insert the spacers to a given clearance (distributed on both sides of the eyes piston) until a clearance of 0.5 – 1 mm is obtained. [*2]

[*3]

k When aligning the positions between hole and pin, run the engine at minimum idling. Do not insert fingers in the holes to check the alignment. 2 Inside bushings: ASL800050

[*4]

a Insert the spacers to a given clearance (distributed on both sides of the cylinder rod) until a clearance of 0.5 – 1 mm is obtained. •

Start the engine to circulate the oil, and bleed air from the cylinder. (For details see "20 TESTING AND ADJUSTMENTS").

30-96 (1)

PC80MR-3

REMOVAL AND INSTALLATION

BLADE CYLINDER

BLADE CYLINDER Removal

k Swing the revolving frame 90° to the right and lower the blade and attachments to the ground, with the safety devices engaged.

1 -Remove the protection (1). 2 -Put the blade cylinder (2) in a sling and put the cable under slight tension. 3 -Switch off the engine and release pressures in the cylinder by moving the lever of the blade PPC valves several times in both directions.

RKPC7770

4 -Remove the screws and remove pin (3). [1*][3*] 5 -Start the engine to retract the piston (4). [*2] 6 -Stop the engine and release any residual hydraulic pressure. (For details see "20 TESTING AND ADJUSTMENTS").

4 8 2

7 -Disconnect hoses (5) and (6): plug holes and hoses to prevent contamination from impurities.

8 -Remove the screws and remove pin (7). [2*][3*]

5 RKPC9060

9 -Remove the blade cylinder (2) together with the safety valve (8).

Installation • To install, reverse the removal procedure. [*1]

a Insert the spacers to a given clearance on both sides of the piston. [*2]

[*3]

k When aligning the positions between hole and pin, run the engine at minimum idling. Do not insert fingers in the holes to check the alignment. 2 Inside bushings: ASL800050

[*4]

a Insert the spacers to a given clearance on both sides of the piston. •

Start the engine to circulate the oil, and bleed air from the cylinder. (For details see "20 TESTING AND ADJUSTMENTS").

PC80MR-3

30-97 (1)

REMOVAL AND INSTALLATION

CYLINDERS

CYLINDERS Disassembly 1. CYLINDER

U2 2

1 -Position cylinder (1) to equipment U1.

2 -Using wrench U2 with torque amplifier, loosen the head (2).

RKP17100

3 -Extract the entire piston (3).

RKP17110

2. PISTON ROD 1 -Position piston rod (3) to equipment U1.

2 -Using a wrench with torque amplifier and tool U3, remove nut (4) from piston (5).

3 Width across flats of socket:

U1 Unit: mm

Cylinder

Boom

Arm

Wrench

Bucket Boom swing 60

Blade 75

RKP17120

3 -Remove the entire piston (6). 4 -Remove head (2).

2 RKP17130

30-98 (1)

PC80MR-3

REMOVAL AND INSTALLATION

CYLINDERS

Only for arm cylinder: 5 - Remove dowel (6), nine balls (7) and remove braking end (8).

RKP17140

3. PISTON 1 -Remove wear ring (9) 2 -Remove gaskets (10).

a Use a screwdriver and a hammer to remove ring from gasket.

RKP17150

4. CYLINDER HEAD ASSEMBLY 1 -Remove O-ring (11) and backup ring. 2 -Remove O-ring (12). 3 -Remove snap ring (13) and scraper ring (14).

15 16

4 -Remove gasket pack (15). 5 -Remove bushing (16).

a Note down direction of installation of ring (14) and gasket pack (15).

12 13 RKP17160

PC80MR-3

30-99 (1)

REMOVAL AND INSTALLATION

CYLINDERS

Assembly

a Heat sealing rings in hot water at 50-60°C before installing.

a Lubricate mating surfaces with engine oil and pay attention not to damage the components.

14 16

RKP17170

1. HEAD 1 -Using tool U6, press bushing (16) into its seat.

2 -Mount gasket pack (15). 3 -Using tool U7, install scraper ring (14); also install snap ring (13).

4 -Install O-ring (12). 5 -Install O-ring (11).

13 RKP17160

2. PISTON

1 -Using tool U4, stretch sealing ring (10) and install.

a Turn handle 8 - 10 turns. 2 -Using tool U5 tighten seal (10) into the seat on the piston.

10 10

RKP17180

3 -Mount wear ring (9)

a Do not stretch the ring more than necessary.

RKP17150

30-100 (1)

PC80MR-3

REMOVAL AND INSTALLATION

CYLINDERS

3. PISTON ROD Only for arm cylinder 7

1 -Install the braking end (8) and nine balls (7), and install the dowel (6).

a Check to ensure that the braking end is allowed to turn.

RKP17140

2 -Install head (2) onto piston rod (5). 3 -Install piston (5) to rod (6).

2 RKP17130

4 -Position the complete rod (5) to equipment U1. 5 -Using a dynamometric wrench with torque amplifier and wrenchU3 wrench, tighten the nut (4).

2 Nut: Loctite 262

3 Nut: Arm cylinder: 33.3 ± 3.3 daNm Arm cylinder: 33.3 ± 3.3 daNm Bucket cylinder: 21.6 ± 2.2 daNm Blade cylinder: da 31.4 ± 3.1 daNm Boom swing cylinder: 26.0 ± 2.6 da Nm

U1 U3 RKP17120

PC80MR-3

30-101 (1)

REMOVAL AND INSTALLATION

CYLINDERS

4. CYLINDER 1 -Position cylinder to equipment U1. 2 -Install the entire piston (3). 3 -Using a dynamometric wrench with torque amplifier and wrench U2, tighten the head (2).

3 Boom head: 96.1 ± 9.61 daNm Arm cylinder: 111 ± 1.35 daNm Blade: 103 ± 10 daNm Arm cylinder: 78.5 ± 7.85 daNm Bucket: 1st stage, tighten to 116 – 142 daNm 2nd stage, loosen to 0 daNm 3rd stage, tighten to 116 – 142 daNm

a After bleeding the air, switch off the engine and check the oil level in the tank.

30-102 (1)

PC80MR-3

REMOVAL AND INSTALLATION

SWING SUPPORT

SWING SUPPORT Removal 3

1 -Remove the equipment. ( F or d et ai l s s ee "EQ U IPM E N T ( 1- pi ec e b oo m version)").

a Steps 2 and 3 are only for 1-piece boom versions. 2 -Disconnect hoses (1) and (2) and connector (3) from the boom lift cylinder.

a Plug all pipes to keep out impurity.

[*1]

RKPC8911

3 -Connect boom cylinder (4) to a hoist and slightly tension the cables. Remove pin (5) and cylinder (4). [*2]

a Inspect quantity and location of shims.

RKPC8791

4 -Position a block between frame and swing cylinder and remove pin (6). [*3]

a Inspect quantity and location of shims.

5 -Start and run the engine at low idling speed and retract the piston completely. 6 -Remove clamp (7).

RKPC9110

7 -Remove the hose clamp (8).

a Mark the positions of the hoses to prevent mixing connections during installation.

RKPC9070

PC80MR-3

30-103 (1)

REMOVAL AND INSTALLATION

SWING SUPPORT

8 -Connect a hoist to the support (9) and slightly tension the cable. Remove upper end lower pin screws. 9 -Pull out upper pin (10) and lower pin (11).

11 9 RKPC9080

10 -Slide the attachment hoses out of the swing bracket (9). 11 -Check and note down the amount and location of shims installed between frame and bracket.

12 -Lift out the swing bracket (9).

4 Bracket: approx. 270 kg

[*4]

RKPC9090

30-104 (1)

PC80MR-3

REMOVAL AND INSTALLATION

SWING SUPPORT

Installation •

To install, reverse the removal procedure.

[*1]

a Pay attention not to mix the hoses. [2*][3*]

k When aligning the positions between holes and pin, let the engine run at minimum idling. Do not insert fingers in the holes to check the alignment. •

Lubricate pins and bushings with grease.

•

Adjust clearance between cylinder rod and bracket using shims.

2 Pins and bushings: Molikote

14 RKP19970

a Standard clearance: Max. 1 mm [*5] •

Lubricate pins and bushings with grease.

2 Pins and bushings: Molikote

[*4] •

Adjust clearance between frame and swing bracket.

a Standard clearance: Max. 0.5 mm – measured on the lower side of the upper pin (14). a Available shims: 0.5 -1 -2 mm 1 -After assembly, lubricate the removed pins; inject grease until it squirts out from the sealing rings and supporting surfaces. 2 -Check the oil level in the tank. Start engine at low idling speed to allow the oil to flow. Bleed air from cylinders and pressurize the tank. (For details, see "20 TESTING AND ADJUSTMENTS"). 3 -Inspect the electrical system to confirm that it operates properly.

PC80MR-3

30-105 (1)

REMOVAL AND INSTALLATION

STEEL SHOES

STEEL SHOES Removal 1 -Stop the machine when the connecting pin (1) is between the track tensioner wheel (2) and the upper idler roller so that the track (3) can be unwound from the front as well as from the rear.

2 1

RKPC2840

2 -Allow the attachments to settle on the ground and slowly loosen the valve (4) to let grease out and to neutralise track tension. [*1]

k The grease contained in the track shoe stretching cylinder is under pressure and could cause serious injury to the operator. For this reason the valve should not be loosened by more than one turn.

a If the grease does not flow out easily, move the machine backwards and forwards slowly.

RKPC0861

3 -Using equipment “R”, remove connecting pin (1).

4 -Position a block “A” under the ribbing of track (3), idler roller side; slowly move the machine forward until the provisional pin can be removed. 5 -Slowly back up the machine to remove and stretch the track out on the ground (3).

a Hold the longer end lifted with a hoist and support the track while the machine is being moved 6 -Force the boom down to raise the lower chassis and lift the track shoe away.

30 ton

R Provisional pin RKP17190

Installation •

To install, reverse the removal procedure.

a Adjust the track shoe tension. (For details, see "20 TESTING AND ADJUSTMENTS").

A RKPC2850

30-106 (1)

PC80MR-3

REMOVAL AND INSTALLATION

RUBBER SHOES

RUBBER SHOES Removal 1 -Swing the revolving frame by 90° towards the track to be removed.

k Lower the equipment until the bucket sits on its back, and lift track off the ground (1).

RKPC9100

2- Loosen the valve (2) slowly to let grease out and to neutralise track tension.

k The grease contained in the track shoe stretching cylinder is under pressure and could cause serious injury to the operator. For this reason the valve should not be loosened by more than one turn.

a If grease is hard to come out, lift the bucket briefly and move vehicle forward and rearward slowly. RKPC0862

3 -Introduce three tubes “A” in the lower side of track (1); allow the drive wheel to turn in a reverse direction. When the tubes have reached the track shoe idler, slide the track off sideways (1).

A RKP17200

Installation •

To install, reverse the removal procedure.

a Adjust the track shoe tension. (For details, see "20 TESTING AND ADJUSTMENTS").

PC80MR-3

30-107 (1)

REMOVAL AND INSTALLATION

SPROCKET

SPROCKET Removal 1 -Remove the track shoe assembly. (For details, see "STEEL SHOES" or "RUBBER SHOES").

2 -Hold the frame (1) up and place a block “A” underneath; lower the frame and check to ensure that the drive wheel (2) remains lifted. 3 -Slowly loosen the tank cap to relieve any residual pressure. 4 -Take out 14 screws (3) and washers.

3 RKPC2870

5 -Remove the sprocket assembly (2).

4 Sprocket: approx. 19 kg

[*1]

Installation •

To install, reverse the removal procedure.

2 Bolt: Loctite 262

k Use the criss-cross torque sequence. 3 Bolt: Two-stage tightening: 1st torque: 80 Nm 2nd torque: 230±15 Nm 2 Bolt: Loctite 262

30-108 (1)

PC80MR-3

REMOVAL AND INSTALLATION

COMPLETE TRAVEL ASSEMBLY

COMPLETE TRAVEL ASSEMBLY Removal 1 -Remove the track shoe assembly. (For details, see "STEEL SHOES" or "RUBBER SHOES").

RKPC2871

4 -Remove travel motor guard (3).

RKPC2880

5 -Sling the travel assembly (4) and connect it to a hoisting device; apply a slight tension to the cable.

A 6 -Disconnect 3 hoses (6) and fitting (7) from motor (5).

a Plug all pipes to keep out impurity. 7 -Loosen and remove the screws (8) anchoring the assembly. [*1]

RKPC2890

6 5

8 - Remove the travel assembly (4).

7 RKPC0842

PC80MR-3

30-109 (1)

REMOVAL AND INSTALLATION

COMPLETE TRAVEL ASSEMBLY

Installation •

To install, reverse the removal procedure.

[*1]

2 Bolt: Loctite 262 (LT - 2) 2 Bolt: 245-310 Nm

1 -Bleed the air from the motor. (For details, see"20 TESTING AND ADJUSTMENTS"). 2 -Top up the oil in the tank; start the engine to circulate the oil throughout the system and check the level again.

30-110 (1)

PC80MR-3

REMOVAL AND INSTALLATION

TRACK SHOE IDLER

TRACK SHOE IDLER Assembly 1 -Using tool L1, introduce bushings (9) and (10) into the wheel (4).

a Force to apply: 2.6 – 5.3 ton.

10 RKP17210

2 -Install the O-ring and install shaft (5) to support (7): secure the shaft with pin (8).

6 5 8 6

7 RKP17220

3 -Using tool L2 , install floating seal (6) to wheel (4) and to the support (7) of shaft (5).

a Inspect the seal sliding surfaces to ensure that they are perfectly clean, then lubricate with oil.

RKP17230

a Make sure to thoroughly clean, degrease and dry the highlighted surfaces before installing the seals. a Use circular tool “A” when installing O-rings and check to ensure that the tool remains perfectly perpendicular to the seal and in contact with the outer surface without cutting it.

RKP17240

PC80MR-3

30-111 (1)

REMOVAL AND INSTALLATION

TRACK SHOE IDLER

a After installing the floating seal, check to ensure that parallelism with the outer surface is kept down to 1 mm and that it does not exceed the specified size.

5 9 mm

RKP17250

4 -Install the shaft (5) and support (7) into the wheel (4).

RKP17260

5 -Perform an oil fill between shaft (5) and wheel (4).

4 RKP17270

6 -Using tool L2, install floating seal (3) between wheel (4) and support (2).

a Inspect the seal contact surfaces and confirm that they are perfectly clean, grease-free and dent-free. a Lubricate seal and seats with oil.

L2 4

3 2

RKP17280

30-112 (1)

PC80MR-3

REMOVAL AND INSTALLATION

TRACK SHOE IDLER

2 3

RKP17290

7 -Install O-ring and support (2); lock into position with pin (1).

RKP17300

PC80MR-3

30-113 (1)

REMOVAL AND INSTALLATION

BUMPER SPRING

BUMPER SPRING Disassembly 1 -Remove the lubrication unit (1). 2 -Remove piston assembly (3) from spring assembly (2)

2 3 8

3 -Remove the screw (4) retaining the nut (5).

RKP17310

4 -Using tool M, disassemble the spring assembly (2).

k Before applying the compression force of spring (6), make sure that the assembly is properly positioned.

a Spring installation load: Rubber shoes: 7061 kg Steel shoes: 4837 kg a Apply pressure slowly, and when spring is compressed, remove nut (5). a Release pressure slowly until spring (6) is free.

RKP17320

5 -Remove spring guide (7) and cylinder (8); remove Oring (13) from cylinder. 6 -Break piston (9) down by removing the snap ring (11), “U” seal (12) and scraper ring (10).

2 3 8

a Note down seal orientation.

10 9

RKP17310

30-114 (1)

PC80MR-3

REMOVAL AND INSTALLATION

BUMPER SPRING

Assembly 1 -Assemble piston assembly disassembly procedure.

reversing

the

2 3

2 -Assemble O-ring (13) to cylinder (8).

3 -Install cylinder (8) to spring (6) and position the spring guide (7).

RKP17310

4 -Position the spring assembly (2) into tool “M”.

RKP17320

5 -Slowly apply pressure and compress the spring (6). Tighten nut (5) until a spring length (a) is obtained.

2 Nut: Molikote (LM - P)

a Spring length (a): Rubber shoes: 283 mm Steel shoes: 323 mm

a RKP17330

6 -Remove spring assembly (2) from tool M and tighten nut (5) with screw (4).

3 Screw: 60-73 Nm

2 3

7 -Fill cylinder (8) with grease.

2 Grease: G2 - LI

a Amount of grease: Rubber shoes: 232 cm3 Steel shoes: 96 cm3

10 9

RKP17310

PC80MR-3

30-115 (1)

REMOVAL AND INSTALLATION

BUMPER SPRING

8 -Loosen the lubricator (1) and introduce the piston (3) into the spring assembly (2) and let any residual air and excess grease escape from hole “B”. 9 -Tighten the lubricator (1).

3 Lubricator: 60-88 Nm

30-116 (1)

PC80MR-3

REMOVAL AND INSTALLATION

LOWER IDLER ROLLERS

LOWER IDLER ROLLERS Disassembly

1 -Pull out pin (2) from idler roller (1) and remove flange (3).

3 RKP17340

2 -Remove floating seals (4) from flange (3) and from roller (5).

4b 5

RKP17350

3 -Remove shaft and flange (6) from roller (5).

5 6

RKP17360

4 -Remove floating seals (7) from roller (5) and shaft flange (6).

7a 6 7b

RKP17370

PC80MR-3

30-117 (1)

REMOVAL AND INSTALLATION

LOWER IDLER ROLLERS

5 -Pull out pin (8) and remove flange (10) from shaft (9).

6 -Remove the shaft O-ring (9).

7 -Remove bushings (11) and (12) from roller (5).

a Replace the O-ring for shaft (9) at each disassembly. a With the roller disassembled, before attempting to re-assemble, thoroughly clean, degrease, and dry all components.

RKP17380

Assembly a Make sure to thoroughly clean, degrease and dry the highlighted surfaces before installing the seals.

a Use circular tool “A” when installing O-rings and check to ensure that the tool remains perfectly perpendicular to the seal and in contact with the outer surface without cutting it.

RKP17240

a After installing the floating seal, check to ensure that parallelism with the outer surface is kept down to 1 mm and that it does not exceed the specified size.

3 5 mm

a Replace the O-ring for shaft (9) at each disassembly. a With the roller disassembled, before attempting to reassemble, thoroughly clean, degrease, and dry all components.

RKP17251

1 -Using tool L3, install bushings (11) and (12) into roller (5). 2 -Install O-ring, flange (10) and retaining pin (8) to shaft (9).

L3 9

8 RKP17390

30-118 (1)

PC80MR-3

REMOVAL AND INSTALLATION

LOWER IDLER ROLLERS

3 -Using tool L4, install floating seals (7) to the shaft (9) and into the roller (5).

L4 9

7b 4a RKP17400

4 -Using tool L4, install floating seal (4) into the flange (3).

L4 4a

3 RKP17410

5 -Install shaft (9) complete with flange and seal into roller (5). Turn the roller upside down.

RKP17420

6 -Install flange (3) to shaft (9) and secure with pin (2). 7 -Fill up after removing the cap (13).

2 13

3 Roller: 210–230 cm3 (Oil GO-140)

9 RKP17430

PC80MR-3

30-119 (1)

PAGE INTENTIONALLY LEFT BLANK

90 OTHER

HYDRAULIC CIRCUIT (STANDARD VERSION) ...... 3 ELECTRICAL DIAGRAM........................................... 5

PC80MR-3

90-1

OTHER

HYDRAULIC CIRCUIT (STANDARD VERSION)

PC80MR-3

90-3

OTHER

ELECTRICAL DIAGRAM

B-R1

V-B1

A-V1

B-N1

H-L1

R-V1

R-V1 6

10 11 12 13 14 15 16 17 2

X173.s 1

10 11 12 13 14 15 16 17 2

X174.s

C-B1 V-B1 R-V1 M-N1 H-L1 B1 A-V1 B-R1 B1

X214.s

11 12

X310.p

V201

JUMPER HAMMER

J1939

X204.s

X301

X203.s 1

SHELD.1

10 11 12

X198

85 30 87 87a

X188

85 30 87 87a

X202.s 1

CAN TERMINATOR

X201.s

V-N1.5

C-L1 C-L1

X202

C-L1 N1 A-V1 L/N1

S/N1 N1 R-G1 S1

X169

B0.5 R/N1

10 11 12 13 14

B0.5 B1 B0.5

A188

BRAKE ROTATION HAMMER MEMORY TIMER UNIT

CONNECTOR B0.5 B0.5 B0.5 B0.5 B0.5 B0.5

C1 H1

AUXILIARY COUPLER

YANMAR ENGINE TOOL

0.5 C0.5 N1

B0.5

C-B1 V-B1 5

A198

X201.s

CAN-CHECKER

CONNECTOR

A-R1 C-R1 B-L1 S0.5 G-R0.5 C1 G-V1 N1 L-G1

PUMP CONTROLLER

C-R1 B0.35 0.35 N1 A-G1 H-L0.5 A/G1 L-N1.5

X168

X202.p

11 12 10

X203.p

MIDAC

R4 G-V1.5 G-V0.5 C0.5 H-G0.5 V0.5 L0.5 G0.5 M0.5 H-R0.5 G-V0.5 A0.5 B-N0.5 Z0.5 B0.5

K1 K2 K3 L1 L2 L3 L4 M1 M3 M4

A301

V-B0.5 H-G0.5 B0.5 L0.5 H-N0.5 H-R0.5 Z0.5 S0.5 A0.5 G-N0.5 G-R0.5 R-N0.5

H-1 G-1.5 C-1.5 M-2.5 R-2.5 V-1.5

86 preheater ECU44

+15 main relay/E48ecu

csd coil/E41ecu

E42 ecu/RACK

E43 ecu/RACK

GND

gnd starter relay

E30ecu recan

CAN H

S1.5 V1.5 H1.5 A2.5

B0.35

B0.35 B0.5

B0.5 B0.5 B0.5 B0.5 B0.5 B0.5

B0.5

Can L

eng. speed sensor

Signal potentiometer

86 starter relay

eng. speed sensor

E28ecu

+ potentiometer power

E07ecu

E17 engine speed2 sw.

E06 speed selection sw.

E16 ecu - Water temp.

E36 ecu/RACK

reverse droop sw/E05

Engine stop 1/E15 ecu

Dial control signal

Rmax2 switch/E14ecu

droop switch/E24ecu

85 main relay

Rmax1 switch/E13ecu

preheater/E23ecu

85 relay Rack/E33

Water temp la./E02

failure lamp/E12

engine speed monitor/E22

load monitor/E32ecu

EGR/E01ecu

EGR/E11ecu

A1 A2 A3 A4 B1 B2 B3 B4 C1 C2 C3 D1 D2 D3 E1 E3 E4 F1 F3 F4 G3 G4 H1 H2 H3 H4 X187

HEATER CONTROLLER

M0.5 B0.5 H-R0.5 G-V0.5 N0.5

EGR/E21ecu

EGR/E31ecu 7

3000

X203.p

A/C CONTROLLER

L0.5 G0.5 C0.5 V0.5 H0.5 S0.5 A0.5 M0.5 B-N0.5 Z0.5 H-G0.5 R-N0.5 C-N0.5

B2 B2 B0.5

N2 N2 B1

SHELD.2

N0.5 G0.5

B0.5 B0.5

R-G1

V-B1

B-R1

H-1

G-1.5 C-1.5 M-2.5

N1.5

N1.5 Z-G1.5 A1 B-G1.5

H-N1 H-R1 A-N1 B-R1 A1 A-R1 A-G1 C-B1

10 11 12 13 15 16

B0.5 B0.5 B0.5 B0.5 B0.5 B0.5 B0.5 B0.5 B0.5 B0.5 B0.5 B0.5 B0.5 B0.5 B0.5 B0.5 B0.5

H-G0.5 G-V0.5 A0.5 M0.5 M-B0.5 V0.5 N0.5

B-G0.5 R-N0.5

H-N0.5 B0.5

A-V0.5 H-B0.5

A168

R/N1

B-L1

S0.5

B-L0.5 G-R0.5 B0.35 V0.35

7826-24

MONITOR J1

YANMAR ENGINE ECU

A187

MONITOR J2

KOMTRAX UNIT

21700

R-V1

H-R1 A-N1 B-R1 A1 A-R1 A-G1 C-B1 Z-G1.5 A1 B-G1.5

86 87a

2 X5.s

GPS

10 11 12

ORBCOM

9 10 11 12 9

ANTENNA

8 8

H-N1

7 7

6 6

5 5

4 4

OPEN X3.s

3 3

X3.p

2 2

X5.s

X7.p

X155.p 1

Gnd4

V-B1 V-B1

X7.s

X155.s 1

22E-06

MONITOR PANEL

B-R1 B-R1

V-B0.5

ANTENNA

X350.s B A

X350.s

X310.s

X310.s 2 1

B0.5

R-V0.5

R-1.5

R10

M-N1

V-1.5

H0.5

2260

KOMTRAX UNIT

R-V1

7.5A

Z-G1.5

V-B1

GND4

21120

H-N0.5 H-R0.5 Z0.5 L0.5 S0.5

S0.5

V-1.5 86 87a

A/C ONLY 22E-06

R-V1 V-B1

V-B1

31130 ROOF HARNESS

V-B1 C-B1 C-B1 V-B1 V-B1 V-B1 V-B1

SAL3

B-G1.5

Z-G1.5

B-G1.5 N1.5

B0.5

R-2.5 M-2.5

SAL1

SAL2

20S-06

S0.5 Z0.5 A0.5 G-N0.5 G-R0.5

X165

R/N1

L/N1

R/N1

H0.5 S0.5

2 X410.s

N1 N1 N1

L/N1

R/N1

A2.5

C-N0.5

B0.5 Z-G1.5 B0.5

R-N0.5

S/N1

A/G1

2 X411.s

L-N1.5

B-G1.5

B0.5

SA16

X410.s

B0.35 V0.35 G-R0.5 B0.5

SA15 SA14 SA26

C2.5

SA22

SA23

V410

R-N0.5

SA20

G0.5

SA24

SA21

SA19

B0.5

SA25

X411.s

B0.5

A-R1

V411

R/N1

B-R1 A-N1 H-R1

A-V1 A-R1 N1

B0.5

B1 C-R1

C-R1

A-V1

X183

1 1

X184

1 1

X186

1 1

C-N0.5 6

L-N1.5

L-R1.5

G /N 1

A/B1

7 7

X167

X181

S167

S181

30 X302

X302

S171

S172

10 1

12 11

S183

S184

X183

S186

8 3

X186

X184

G/N1

X167

X181

S-N1.5

V-N1

X171

X172

H-L1

X303

B-V1

R-G1

7 X171

L/R1

M/N1 B0.5 85

X171

10 X303

X170

H-L1 N1 N1

N1 N1

7 7

V-N1.5

3 3

H-V1

10 X196

1 1

H-G1

N1 N1

S196

R-N1 R-N2.5

10 X197

X172

X302

87 0

85 10

S197

X302

H-N0.5

K302

X303

S-N1.5

K303

X170 X170

G/N1

B/R1

N1 N1 G/N1 G/N1 N1 N1 N1 N1

12 12

G/N1

5 5

G/N1

G/N1 G/N1 N1 N1 N1

4 4

N1 N1

L/R1

H0.5

C/N1

G/N1 G/N1 V-Z1 Z/N1 N1 N1

M/N1

B2 9

S0.5 G-R0.5

G/N1

H-B1

B0.5 B0.5

M/B1

12 7 12

G/N1

5 5

S-G1 Z/N1 Z/N1

R-G1.5

X196

B/R1

R-G1

V/N1

G/N1 L-R1.5

V-N1

R-N1

L-G1

L-R1.5

L-N1.5

X197

H-B1

L1 A1 A/N1 B-R1 B-R1 H/R1

B-R1 G/N1 G/N1

B-R1

A2.5

B0.5

H1.5

M/B1

M/B1 M/B1 C-B1 A-G1

M0.5

H-G1.5

B1.5

R180

X193

R-N0.5 N2.5

86 87a

X311

N2.5

N1 N1

L/R1

86 87a

X311

N0.5

X311

G-M1

X311 X311

86 87a

L/R1

G-V1

86 87a

X311

A/V1

86 87a

X311

H-L1

X311

C-L1

B-V1

X193

Z-N0.5

86 87a

N2.5 N2.5

C-N0.5

K15 86 87a

B0.5

X189

H-V1

H-R1.5 L-R1

X193

K14 86 87a

B/R1

A1 X179

B-G1.5

86 87a

A-R1

M-B0.5

H-G0.5

H/R1

X311

X191.1

X102.s

ENGINE HARNESS

22E-06

FRAME HARNESS

X131.p

10 11 12

X207.p

X130.s

X131.s

X207.s

21181

SA06 X152

X179.s

H/N1 R-G1.5

N1 N1

S/N1

X200

X208.s

Y134

RACK ACTUATOR

Y116

Y132

X136

Y136

X137

X146

H137

X135

X209.s

X140.s

Y209

Y135

Y140

X139.s

Y139

Y133

X143

X380

X145

1 X210.s

B143

Y210

10 11

1,5A

X134

X143.p

SAL1

X132

X136

X137

X135

X146

X209.s

X140.s

X133

X139.s

M145

2 X210.s

22E-06 21360

R-G1 1

X381

X382

X383

S380

S381

S382

S383

A-G1.5

R-G1

V-Z1

H/R1

H/N1 1

X133

G-R1

S-G1

G-M1

L/N1

V-N1.5

A/V1 1

X132

X380

Y113

N0.5

X134

X179.s

X381

X382

X383

A-G1

R1311

A-G1

21W-06

X119

X208.s

TRAVEL ALARM

A-G1

M-B1

M/N1

Sa2

X145

1 X113

B0.5

B0.5 B0.5

EGR VALVE

V-N1 B0.5

B0.5 B1 B0.5 B0.5 B1 B0.5 2

B115

B119

1 X116

X111

B0.5

CDS COIL 2

X109

X110

B1.5

Y111

X108

X109

X119

M108

B109

B110

X115.1

X111

X110

M118

X108

A-G1

SA03

ENGINE B112 p SPEED SENSOR B114

X118

X112

Sa1

N1.5

M103

X114

H-L0.5

H-B0.5

R10

C1 -

ALTERNATOR

X114

X199

SA01

ADD. WORK LAMP

N1.5

D+

X107

R107

X142.3.p

R-G1.5

X103.1

11120

+30

X200

S200

ARM WORK LAMP

B1.5

B-G1

B2 X103.1

X199

S199

21290

N50

21150

X142.2

M105

R50

22E-06

21390 REFUELLING PUMP

N1.5

X105

S0.5

R10

R50

30A

SA01

12Vcc

22E-06

A-V0.5

R25

B0.5

80A

X106

F3G

F4G X122

60A

BATTERY SWITCH 42N-06

X120.2

A/G1

G-V1.5

TWIST1 R0.5

1 X142.3.p

B142b

E141 TWIST1 B0.5

R50

SB1

R10

B0.5

F2G

21130

X142.1

X138.1

X122

X121

80A

22E-06

K122

X121

X138.2

F1G

X400.s

S/N1 S/N1 R-G1 R-G1 R-G1

N1.5

ENGINE POWER BOX

Y138

B1.5

R8172

K121

X146.p

21W-06

GND5

N1.5

H-G1.5 X141.s

R16

TWIST1 B0.5 TWIST1 R0.5

SA07

SA02

GND3 GND3.1

SAL2 GND1 GND2

X181

E141

X182

E142

2 Gnd3

22E-06

N1 N1 N1 N1 N1

R-G1 S/N1 A-G1

22E-06

21191

N2.5

N1 M/N1 M-B0.5 A/V1 L/N1 Z1 S1 S-G1 R-G1.5 G-M1 V-Z1 B2

N2 N2

G-R0.5 N1 B-G1.5 H-G1.5 H/R1 V-N1.5

S0.5 B2 B0.5

H-B0.5 G-V1.5 C1 A/G1

A-V0.5 H-L0.5 B1.5 B0.5 B0.5 B0.5 B0.5 B0.5 B1 B0.5 B0.5 B0.5 V-N1 B1.5

L-G1 L-G1 N1

X130.p

X102.p

G-V1 M/N1 S0.5 M/N1

A-R1 C-R1 G-V1

G-V1

S/N1

R-G1 A-G1

X101.s

X102.p

R-G1

10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 X101.p

S/N1

R-G1

R-G1 S/N1 A-G1

CABIN HARNESS

21111

M/N1 M-B1 A/V1 L/N1 Z1 S1 S-G1 R-G1.5 G-M1 V-Z1 B2

G-R1

N1 B-G1 H-G1.5 H/R1 V-N1.5

B0.5 B1

N1.5

N0.5

N1 N1

SA05

S0.5 B2 B0.5

B1.5

A-V0.5 H-L0.5 B2 B0.5 B0.5 B0.5 B0.5 B0.5 B1 B1 B0.5 B1 V-N1

R/N1 B1 B0.35 V0.35 H-B0.5 G-V1.5 C1 A/G1 B-L0.5

R16

X101.p 1

X311

N0.5

X176.2

N0.5

X311

N0.5

X191.2

80A

Gnd5

B0.5

V0.5

B0.5

H191

X311

86 87a

X176.1

R176

L-N1.5

X150.2

R-N0.5

SA12

R/N1

G-R0.5 S0.5 B2 A-R1

X150.1

15730

K13

Z-N0.5 Z-N0.5

X311

86 87a

X189

Z-N0.5

H-R1.5

R-G1

L-N1.5

X311

H-G0.5 A-R1

X193

K12 86 87a

V/N1

C-R1

X189

Z-N0.5

N0.5

R-N2.5 C-R1

H-G0.5

POWER CABIN HARNESS

R10

L-N1.5 R-N2.5 C-R1 S-N1.5

SA11

F150

R-G1

A-R1

X179

B0.5

X151.p R10

H-L1.5

L-N1.5 L-N1.5 G/N1 L-R1 L-R1.5 H-L1.5

C-R1

H-R1.5 H-G0.5 H-G0.5 R-G1 R-G1

C2.5

S-N1.5

A-R1.5

R-N2.5

CONNECT TO X151.s

M179

SA28

X151.p

21310

22E-06

X189

K11 86 87a

F16b

F15b

X189

K10

M 31b

V/N1

F14b

X189

53a

86 87a

X190

X151.s

A/N1 53

10A

H-G1

F13b

7,5A

H-L1.5

F12b

7,5A

F11b

25A

F10b

7,5A

B0.5

X180.s

L-R1

F9b

7,5A

B0.5

F8b

7,5A

Z-N0.5

7,5A

X179

F16a

X179

F15a

F9 F10 F11 F12 F13 F14 F15 F16

7,5A

F7b

F14a

B0.5 X

F6b

F13a

N1.5

L2.5 L2.5 L2.5 L2.5 L2.5 L2.5 L2.5 L2.5 L2.5 L2.5 L2.5 L2.5 L4 L2.5 L2.5 L2.5 L2.5 L2.5 L2.5 L2.5

F5b

7,5A

F12a

X180.s

F4b

10A

F11a

B0.5 X1

F3b

10A

F10a

X180.s

F2b

F9a

B-R1.5

F1b

F8a

S0.5 G-R0.5

10A

F7a

H/R1 M-B0.5

25A

F6a

N0.5 B0.5

F190 F1 F2

F5a

B-R1.5

F4a

A-V1

F3a

B0.5

F2a

L2.5

R4 R1.5 R1.5 R1.5 R1.5 R1.5 R1.5 F1a

B0.5

B0.5 B0.5

B0.5

R4 SA08

R/N1

B0.5 H-N1

8A13-10

X166

H-G0.5

E161

X161.2

X182.4

R-N0.5

FAN

A-N1

B-R1

R1450

21W-06

R1450 LIGHT EXTENSION

X182.1

ANTENNA GPS

2270

OFF ACC

2100

B-R1 B-R1 V-B1 M-N1 V-B1 C-B1 C-B1 R-G1 B-N1

A165

X182.5

X182.3

ACC

X162

+5V

22E-977

8A13-10

ANTENNA ORBCOM B-R1 B-R1 B-R1 B-R1

X163

X158

21W-06

B-L1 X182.2

R2850

REAR LIGHT

HEATER GROUP

X161.1

KOMTRAX HARNESS

13730

DISTR.

H-N1

2 X304

+5V

SPEAKERS

X157.2

E162

42N-06

MIX

120

DIN-RIC

21W-09

X159.2

21290

E304

X156.2

E163

22E-06

S159

12730

R/N1 L2.5

R-G1

42N-06

ACC

120

2100

N1 C-B1

A-G1 N1

22E-06

22E-979

11470

A157

X162

A/C GROUP

395-06

BEACON LAMP

X163

X158

N SITION ECTIO CONN

PO KEY

R2790

X158

1 X304

21W-09

X159.1

X157.1

A156

START

2 1

X156.1

ACC

N1 B1

R1711

B-R1

OFF

207-06

RADIO

H-R1

ELECTRICAL DIAGRAM

A156 A157 A165 A168 A168 A187 A188 A198 A301 B109 B110 B112 B114 B115 B119 B143 B208 B142b E141 E158 E161 E162 E163 E304 F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 F14 F15 F16 F1G F4G F2G F3G F150 F190 G1 H137 H191 K1 K2 K3 K4 K5 K6 K9 K10 K11 K12 K13 K14 K15 K121 K122 K193 K302 K303 K7 E142 M103 M105 M108 M118 M145 M179 PA PB R107 R176 R180 S1 S159 S167 S170 S171 S172 S181 S183 S184 S186 S196 S197 S199 S200 V201 V410 V411 Y113 X202 Y111 Y116 Y132 Y133 Y134 Y135 Y136 Y138 Y139 Y140 Y209 Y210 X155.p X106 X151.s X152 X130.s X131.s X132 X133 X134 X135 X136 X137 X138.1 X138.2 X139.s X140.s X141 X142.1 X142.2 X142.3.p X143 X145 X146 X199 X200 X207.s X208.s X209.s X210.s X101.p X102.p X130.p X131.p X151.p X155.s X165 X166 X167 X168 X169 X170 X171 X172 X173.s X174.s X176.1 X176.2 X179 X180.s X181 X182.1 X182.2 X182.3 X182.4 X182.5 X183 X184 X186 X187 X188 X189 X190 X191.1 X191.2 X193 X196 X197 X198 X201.s X202.p X202.s X203.p X203.s X204.s X207.p X214.s X301 X302 X303 X310.p X310.s X311 X350.s X400.p X400.s X410.s X411.s XA XB X101.s X102.s X103.1 X107 X112 X120.2 X121 X121.87 X122 X122.87

Speaker (LH) Speaker (RH) Radio A/C controller Heater controller Controller ECU Yanmar Hammer memory unit Timer brake rotation MIDAC UNIT (Pump controller) Air intake Travel alarm Oil pressure Engine speed sensor CSD coil Water temp.ECU Fuel level sensor Presetting travel alarm Full fuel (refuelling pump) Arm working lamp Room lamp Beacon Head lamp (lh) Head lamp (rh) Work lamp Heater Fan fuse - Compressor Main relay fuse +30 Radio, komtrax, room lamp, monitor Beacon lamp fuse Fuel pump ECU fuse Cigar lighter fuse Monitor - Buzzer fuse PPC valve fuse +15 Midac (Cpu line)+Komtrax fuse Joystick right, switch overload fuse Midac (Load) Switch lamp fuse Switch quick_coupler, joystick left fuse Working lamp relay,working lamp sw fuse A/C controller fuse Hammer memory, radio fuse Wiper motor fuse Alternator fuse Pre-heather relay Fuse Starter relay fuse Refuelling pump fuse Power box Fuse box Battery Horn Buzzer alarm Quick coupler relay Pliers relay 2° Hydraulic relay Mordant bucket relay Hammer relay Engine Start cut relay Working light relay (Arm) Working light relay (Cabin) Working light relay (Cabin) First speed fan relay Second speed fan relay Third speed fan relay Fourth speed fan relay Engine starter relay (Power Box) Pre-heater Relay (Power Box) Relay box "A/C" Actuator Relay Main Relay Pre-Heater lamp relay Additional working lamp (Arm) Alternator Engine starter motor Fuel pump Air conditionary compressor Washer tank Wiper motor Monitor J2 Monitor J1 Heater group Cigar lighter Potentiometer Starter switch Limit switch (Window) Left joystick PPC Lock switch Quick coupler switch Overload switch Right joystick Mordant Bucket/hammer switch 2° hydraulic/pliers switch Beacon lamp switch Working lamp switch Wiper switch Rotation press.sw right Rotation press.sw left Diode Diode Diode Rack actuator Jumper hammer memory Tvc valve EGR valve 2nd speed Rotation brake PPC valve Hammer Mordant bucket Overload pressure switch Quick coupler Pliers 2° hydraulic 3° hydraulic Connector to roof wiring harness 50 starter pin Connector to harness 0A021542 Main switch pin Connector to cabin harness Connector to cabin harness Connector (2nd speed) Connector (Brake rotation) Connector (PPC valve) Connector (Hammer) Connector (Mordant bucket) Connector (Horn) Pin Overload (Pressure switch) Pin Overload (Pressure switch) Connector (Quick coupler) Connector (Pliers) Connector (Arm working lamp) Connector Full fuel (refuelling pump) Pin Gnd fuel sensor Connector Full fuel (refuelling pump) Connector (Fuel sensor level) Connector (Washer tank) Connector (Overload pressure switch) Connector (Rotation press.sw right) Connector (Rotation press.sw left) Connector to cabin harness Connector (Presetting travel alarm) Connector (2° hydraulic) Connector (3° hydraulic) Connector (To engine harness) Connector (To engine harness) Connector (To Carriage/frame harness) Connector (To Carriage/frame harness) Connector (To harness 0A021544) Connector (To left cabin harness) Radio connector Radio connector Connector (Left joystick) Connector (A/C controller) Connector (A/C controller) Connector (Micro switch harness) Connector (Switch quick-coupler) Connector (Switch overload) Connector (A/C) Connector (A/C) Connector (Cigar lighter) Connector (Cigar lighter) Connector (Wiper motor) Connector (Potentiometer) Connector (Right joystick) Pin Starter switch (C) Pin Starter switch (R1) Pin Starter switch (ACC) Pin Starter switch (B) Pin Starter switch (BR) Connector (Switch mordant buchet / hammer) Connector (Switch pliers / 2°hydraulic) Connector (Switch beacon) Connector (Controller ECU) Connector (Hammer memory) Connector (Relay box "a") Connector Fuse box +30/+15ACC Connector Buzzer alarm Connector Buzzer alarm Connector (Relay box "A/C") Connector (Switch working lamp) Connector (Switch wiper front) Connector (Brake timer rotation) Connector (Diode) Connector (Jamper hammer) Connector (Jamper hammer) Auxiliary connector Auxiliary connector Connector (Can Checker) Connector (To Carriage/frame harness) Komtrax Connector Connector (MIDAC) Connector (Actuator relay) Connector (Main Relay) Connector (CAN TERMINATOR) Connector (CAN TERMINATOR) Connector (Box relay "b") Connector (J1939) Connector (Antitheft) Connector (Antitheft) Connector (Diode) Connector (Diode) Connector (Monitor J2) Connector (Monitor J1) Connector (To cabin harness) Connector (To cabin harness) Connector (Alternator) Pin (Heater group) Pin (Oil pressure) Pin (Refuelling pump fuse) Connector (Starter Relay) Pin (87 Starter relay) Connector (Pre-heater relay) Pin (87 Pre-heater relay)

42N-06-12730 42N-06-12730 207-06-R1711 22E-06-21830 22E-06-21860

0117133

22E-06-21210

22E-06-21290 395-06-11470 22E-06-21290 22E-06-21290 22E-06-21290 08041-02500 21D-06-11820 21D-06-11790 21D-06-12060 21D-06-11820 21D-06-11820 21D-06-11810 21D-06-11810 21D-06-11810 21D-06-11810 21D-06-11810 21D-06-11810 08041-02500 21D-06-11810 21D-06-11810 21D-06-11820

22E-06-11120 42N-06-11240 395-06-12870 395-06-12870 395-06-12870 395-06-12870 395-06-12870 395-06-12870

226-06-11350 226-06-11350

22E-06-21290

163023 163007 163010 163031 163007 163007 163005 163005 163005 163005 163005 163005 163023 163005 163005 163007 163101 163067 163064 163072 113627

157061 157061 157061 157061 157061 157061 157104 157104 157104 157104 157104 157104 157104 157102 157102 113628 157159 157159 157061

22E-06-21700 22E-06-21700

22E-06-21811 20S-06-31130 21W-54-R2540 702-16-09460 22U-06-R2360 22E-06-21460 22E-06-21440 702-16-09440 22E-06-21450 22E-06-21430 22L-09-R9230 2A1-06-11210 22E-06-21420 21W-06-R1520 21W-06-R1520

109066

17.1900.1400.64 0A023596 0A023597 0A023595 0A009636 0A022984 0A020715

124219 124219 124219

125831 124046 101089 125414 124095 124451 124451 124451 124451 124451 300004 101077 101081 124451 124451 124451 125135 120022 125400 124452 125018 124484 125117 125117 125406 124451 124451 124451 XE0803213 125408 125412 124094 XE0803220 125825 125548 125549 124666 124534 124669 125406 16.650.003 16.650.003 125015 125649 104007 104007 125410 125477 124666 120011 120011 101124 101124 16.650.003 16.650.003 16.650.003 XE0803782 125026 113628 113627 104007 104007 113628 16.650.003 16.650.003 125026 125226 125008 125007 124094 124095 124067 125404 124456 124234 125514 125514 125400 125402 113629 125406 125420 125422 125226 125226 125150 125819 XE0803216 125410 125683 101083 120010 120011 125117 120029 125117 101124

Gnd3.1

Gnd1 Gnd2

PC80MR-3

22E-06-21000E

90-5