Komatsu Hydraulic Excavator PC80MR Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC80MR, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Hydraulic Excavator PC80MR workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 302 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
WEBM008601 - Hydraulic Excavator PC80MR-3 Shop Manual.pdf
MAIN SECTIONS
CONTENTS...3
REVISED PAGES...5
k SAFETY...7
FOREWORD...9
HOW TO READ THE SHOP MANUAL...10
HOISTING INSTRUCTIONS...11
STANDARD TIGHTENING TORQUE...12
COATING MATERIALS...14
ELECTRIC...15
WEIGHT TABLE...16
TABLE OF OIL AND COOLANT QUANTITIES...17
CONVERSION TABLE...19
10 STRUCTURE AND FUNCTION...27
POWER TRAIN...28
SWING CIRCLE...29
SWING MACHINERY...31
TRACK FRAME AND IDLER CUSHION...34
IDLER...36
TRACK ROLLER...37
CARRIER ROLLER...38
SPROCKET...39
TRACK SHOE...40
SHOES...43
RUBBER SHOE...44
SWIVEL JOINT...45
TRAVEL MOTOR...46
WORK EQUIPMENT CYLINDER...48
SOLENOID VALVE GROUP...52
CONTROL VALVE...54
CLSS...65
SWING MOTOR...84
ATTACHMENT...93
TRAVEL PPC VALVE...98
BLADE, BOOM SWING, 2-PIECE BOOM PPC VALVES...102
EQUIPMENT...106
20 TESTING AND ADJUSTMENTS...109
NORMAL OR STANDARD TECHNICAL DATA...111
FOR THE ENGINE...111
FOR MACHINE...112
PUMP FEATURES...119
CHECK POSITIONS...120
SPECIAL TOOLS...125
MEASURING THE ENGINE SPEED...127
1. Measuring engine speed...127
2. Measuring engine speed to check compression pressure...128
CHECKING THE EXHAUST SMOKE COLOUR...129
1. Checking with tool G1...129
2. Checking with tool G2...129
REMOVAL OF VALVES COVER...131
ADJUSTING VALVE CLEARANCE...133
MEASURING COMPRESSION PRESSURE...136
TESTING AND ADJUSTING FUEL INJECTION TIMING...138
Test...138
Adjustment procedure...140
CHECKING ENGINE OIL PRESSURE...142
CHECKING AND REGULATING PRESSURE IN THE HYDRAULIC CIRCUITS...143
CHECKING AND CALIBRATING PRESSURE IN THE SECONDARY VALVES...145
1. Preparing the machine...145
2. Checking revolving frame rotational pressure...145
3. Adjusting general valve for revolving frame rotation and blade circuit...146
4. Checking boom, arm, bucket, boom swing and travel pressure...146
5. Adjusting secondary valve for boom, arm, bucket, boom swing and travel...147
6. Checking Unloading pressure...147
CHECKING AND ADJUSTING THE LS (Load Sensing) VALVE...148
1. Measuring DPLS differential pressure...148
2. With analog pressure gauge...149
3. Adjusting the valve...149
ADJUSTING PC VALVE...150
CHECKING SERVO-CONTROL CIRCUIT PRESSURE...151
1. Checking...151
2. Adjustment...151
CHECKING PPC VALVE DELIVERY PRESSURE...152
CHECKING SOLENOID VALVE OUTPUT PRESSURE...153
ADJUSTING BOOM SAFETY VALVE...154
SAFETY PRESSURE SWITCH CALIBRATION:...155
ADJUSTING PPC VALVE CLEARANCE...156
MEASURING TRAVEL DEVIATION...157
1. Measuring the deviation...157
CHECKING TRAVEL SPEED...158
ANALYSIS OF THE CAUSES OF HYDRAULIC DRIFTS...159
1. Boom test...159
2. Arm test...160
3. Testing the functionality of the boom safety valve...161
4. Bucket test...161
5. Boom swing test...162
8. Blade test...163
9. Swing motor test...164
10. Travel motors...164
METHODS FOR TESTING FOR LEAKAGES INSIDE THE SWIVEL JOINT...165
1. Functionality test...165
2. Identification of defective seal...165
ELIMINATING PRESSURES FROM CIRCUITS...166
MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS...167
TESTING AND ADJUSTING TRACK SHOE TENSION...168
1. Checking...168
2. Adjustment...168
AIR BLEEDING FROM HYDRAULIC CIRCUITS...169
Order for operations...169
1. Bleeding air from pump...169
2. Bleeding air from tank...170
3. Bleeding air from LS circuits...170
4. Bleeding air from hydraulic cylinders...170
5. Bleeding air from swing motors...171
6. Air bleeding from travel motors...171
7. Bleeding air from the revolving frame servocontrol circuit...171
TESTING THE AIR-CONDITIONING UNIT...172
1. Testing the working temperature...172
2. Checking the unit...173
EMPTYING THE AIR-CONDITIONING UNIT...174
30 REMOVAL AND INSTALLATION...175
HOW TO READ THE MANUAL...177
PRECAUTIONS TO BE TAKEN WHILE WORKING...178
SPECIAL TOOLS...179
COUNTERWEIGHT...183
Removal...183
Installation...184
INJECTION PUMP...185
Removal...185
Installation...187
ENGINE HEAD...188
Removal...188
Installation...192
PUMP GROUP...193
Removal...193
Installation...195
GEAR-PUMP...196
Installation...196
ENGINE - PUMPS...197
Installation...201
COMPLETE RADIATOR AND AIR CONDITIONING CONDENSER...202
Removal...202
Installation...204
SWING MOTOR AND REDUCTION GEAR...205
Removal...205
Installation...206
SWING MOTOR...207
Removal...207
Installation...207
SWING REDUCTION GEAR...208
SWIVEL JOINT...221
Removal...221
Installation...222
CONTROL VALVE...224
Removal...224
Installation...226
LH PPC VALVE...227
Removal...227
Installation...228
R.H. PPC VALVE...229
Removal...229
Installation...229
EQUIPMENT PPC VALVES...230
TRAVEL PPC VALVE...231
Removal...231
Installation...232
ADDITIONAL EQUIPMENT AND BOOM SWING PPC VALVE...234
Removal...234
Installation...234
BLADE PPC VALVE...235
Removal...235
Installation...235
ACCELERATOR POTENTIOMETER...236
Removal...236
Installation...236
CONTROLLER...237
Removal...237
Installation...237
SAFETY MICROSWITCH...238
Removal...238
Installation...239
HYDRAULIC OIL TANK...240
Removal...240
Installation...241
FUEL TANK...242
Installation...244
CONTROL MODULES (MACHINE - ENGINE - KOMTRAX)...245
Removal...245
Installation...245
EVAPORATOR UNIT...246
Removal...246
Installation...250
CABIN...251
Removal...251
Installation...255
SWING CIRCLE...256
Removal...256
Installation...256
REVOLVING FRAME...257
Removal...257
Installation...259
EQUIPMENT (1-piece boom version)...260
Removal...260
Installation...262
BOOM CYLINDER (For 1-piece boom)...263
Removal...263
Installation...264
ARM CYLINDER...265
Removal...265
Installation...266
BUCKET CYLINDER...267
Removal...267
Installation...268
BOOM SWING CYLINDER...269
Removal...269
Installation...270
BLADE CYLINDER...271
Removal...271
Installation...271
CYLINDERS...272
SWING SUPPORT...277
Removal...277
Installation...279
STEEL SHOES...280
Removal...280
Installation...280
RUBBER SHOES...281
Removal...281
Installation...281
SPROCKET...282
Removal...282
Installation...282
COMPLETE TRAVEL ASSEMBLY...283
Removal...283
Installation...284
TRACK SHOE IDLER...285
BUMPER SPRING...288
LOWER IDLER ROLLERS...291
90 OTHER...295
HYDRAULIC CIRCUIT (STANDARD VERSION)...297
ELECTRICAL DIAGRAM...299
