Komatsu PC80MR-3 Hydraulic Excavator Shop Manual WEBM008601

Description

• Model List:
  • PC80MR-3 Hydraulic Excavator

• 1. CONTENTS
• 2. REVISED PAGES
• 3. k SAFETY
• 4. FOREWORD
• 5. HOW TO READ THE SHOP MANUAL
• 6. HOISTING INSTRUCTIONS
• 7. STANDARD TIGHTENING TORQUE
• 8. COATING MATERIALS
• 9. ELECTRIC
• 10. WEIGHT TABLE
• 11. TABLE OF OIL AND COOLANT QUANTITIES
• 12. CONVERSION TABLE
• 13. STRUCTURE AND FUNCTION
• 13.1. POWER TRAIN
• 13.2. SWING CIRCLE
• 13.3. SWING MACHINERY
• 13.4. TRACK FRAME AND IDLER CUSHION
• 13.5. WORK EQUIPMENT CYLINDER
• 13.6. SOLENOID VALVE GROUP
• 13.7. CONTROL VALVE
• 13.8. CLSS
• 13.9. SWING MOTOR
• 13.10. ATTACHMENT
• 13.11. TRAVEL PPC VALVE
• 13.12. BLADE, BOOM SWING, 2PIECE BOOM PPC VALVES
• 13.13. EQUIPMENT
• 14. TESTING AND ADJUSTMENTS
• 14.1. NORMAL OR STANDARD TECHNICAL DATA
• 14.1.1. FOR THE ENGINE
• 14.1.2. FOR MACHINE
• 14.2. PUMP FEATURES
• 14.3. CHECK POSITIONS
• 14.4. SPECIAL TOOLS
• 14.5. MEASURING THE ENGINE SPEED
• 14.5.1. Measuring engine speed
• 14.5.2. Measuring engine speed to check compression pressure
• 14.6. CHECKING THE EXHAUST SMOKE COLOUR
• 14.6.1. Checking with tool G1
• 14.6.2. Checking with tool G2
• 14.7. REMOVAL OF VALVES COVER
• 14.8. ADJUSTING VALVE CLEARANCE
• 14.9. MEASURING COMPRESSION PRESSURE
• 14.10. TESTING AND ADJUSTING FUEL INJECTION TIMING
• 14.10.1. Test
• 14.10.2. Adjustment procedure
• 14.11. CHECKING ENGINE OIL PRESSURE
• 14.12. CHECKING AND REGULATING PRESSURE IN THE HYDRAULIC CIRCUITS
• 14.13. CHECKING AND CALIBRATING PRESSURE IN THE SECONDARY VALVES
• 14.13.1. Preparing the machine
• 14.13.2. Checking revolving frame rotational pressure
• 14.13.3. Adjusting general valve for revolving frame rotation and blade circuit
• 14.13.4. Checking boom, arm, bucket, boom swing and travel pressure
• 14.13.5. Adjusting secondary valve for boom, arm, bucket, boom swing and travel
• 14.13.6. Checking Unloading pressure
• 14.14. CHECKING AND ADJUSTING THE LS (Load Sensing) VALVE
• 14.14.1. Measuring DPLS differential pressure
• 14.14.2. With analog pressure gauge
• 14.14.3. Adjusting the valve
• 14.15. ADJUSTING PC VALVE
• 14.16. CHECKING SERVOCONTROL CIRCUIT PRESSURE
• 14.16.1. Checking
• 14.16.2. Adjustment
• 14.17. CHECKING PPC VALVE DELIVERY PRESSURE
• 14.18. CHECKING SOLENOID VALVE OUTPUT PRESSURE
• 14.19. ADJUSTING BOOM SAFETY VALVE
• 14.20. SAFETY PRESSURE SWITCH CALIBRATION
• 14.21. ADJUSTING PPC VALVE CLEARANCE
• 14.22. MEASURING TRAVEL DEVIATION
• 14.22.1. Measuring the deviation
• 14.23. CHECKING TRAVEL SPEED
• 14.24. ANALYSIS OF THE CAUSES OF HYDRAULIC DRIFTS
• 14.24.1. Boom test
• 14.24.2. Arm test
• 14.24.3. Testing the functionality of the boom safety valve.
• 14.24.4. Bucket test
• 14.24.5. Boom swing test
• 14.24.6. Blade test
• 14.24.7. Swing motor test
• 14.24.8. Travel motors
• 14.25. METHODS FOR TESTING FOR LEAKAGES INSIDE THE SWIVEL JOINT
• 14.25.1. Functionality test
• 14.25.2. Identification of defective seal
• 14.26. ELIMINATING PRESSURES FROM CIRCUITS
• 14.27. MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS
• 14.28. TESTING AND ADJUSTING TRACK SHOE TENSION
• 14.28.1. Checking
• 14.28.2. Adjustment
• 14.29. AIR BLEEDING FROM HYDRAULIC CIRCUITS
• 14.29.1. Order for operations
• 14.29.2. Bleeding air from pump
• 14.29.3. Bleeding air from tank
• 14.29.4. Bleeding air from LS circuits
• 14.29.5. Bleeding air from hydraulic cylinders
• 14.29.6. Bleeding air from swing motors
• 14.29.7. Air bleeding from travel motors
• 14.29.8. Bleeding air from the revolving frame servocontrol circuit
• 14.30. TESTING THE AIRCONDITIONING UNIT
• 14.30.1. Testing the working temperature
• 14.30.2. Checking the unit
• 14.31. EMPTYING THE AIRCONDITIONING UNIT
• 15. REMOVAL AND INSTALLATION
• 15.1. HOW TO READ THE MANUAL
• 15.2. PRECAUTIONS TO BE TAKEN WHILE WORKING
• 15.3. COMPLETE RADIATOR AND AIR CONDITIONING CONDENSER
• 15.3.1. Removal
• 15.3.2. Installation
• 15.4. SWING MOTOR AND REDUCTION GEAR
• 15.5. SWING REDUCTION GEAR
• 15.6. EQUIPMENT PPC VALVES
• 15.7. TRAVEL PPC VALVE
• 15.7.1. Removal
• 15.7.2. Installation
• 15.8. ADDITIONAL EQUIPMENT AND BOOM SWING PPC VALVE
• 15.8.1. Removal
• 15.8.2. Installation
• 15.9. BLADE PPC VALVE
• 15.9.1. Removal
• 15.9.2. Installation
• 15.10. ACCELERATOR POTENTIOMETER
• 15.11. SAFETY MICROSWITCH
• 15.11.1. Removal
• 15.11.2. Installation
• 15.12. HYDRAULIC OIL TANK
• 15.12.1. Removal
• 15.12.2. Installation
• 15.13. FUEL TANK
• 15.13.1. Installation
• 15.14. CONTROL MODULES (MACHINE ENGINE KOMTRAX)
• 15.14.1. Removal
• 15.14.2. Installation
• 15.15. EVAPORATOR UNIT
• 15.16. REVOLVING FRAME
• 15.16.1. Removal
• 15.16.2. Installation
• 15.17. EQUIPMENT (1piece boom version)
• 15.17.1. Removal
• 15.17.2. Installation
• 15.18. BOOM CYLINDER (For 1piece boom)
• 15.19. BUCKET CYLINDER
• 15.19.1. Removal
• 15.19.2. Installation
• 15.20. BOOM SWING CYLINDER
• 15.21. COMPLETE TRAVEL ASSEMBLY
• 15.21.1. Removal
• 15.21.2. Installation
• 15.22. TRACK SHOE IDLER
• 15.23. BUMPER SPRING
• 15.24. LOWER IDLER ROLLERS
• 16. OTHER
• 16.1. HYDRAULIC CIRCUIT (STANDARD VERSION)
• 16.2. ELECTRICAL DIAGRAM