WEBM008601

SHOP MANUAL

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 fol-
lowing marks. It is requested that necessary actions be
taken to these pages according to table below. Mark Indication Action required

Q Page to be newly Add

q Page to be replaced Replace

( ) Page to be delete Discard

Pages having no marks are those previously revised or

made additions.

Time Time Time Time Time

Mark Page Mark Page Mark Page Mark Page Mark Page
of rev. of rev. of rev. of rev. of rev.
q 00-1 (1) Q 10-27-3 (1) Q 20-1 (1) Q 20-55 (1) Q 30-42 (1)
q 00-2 (1) Q 10-27-4 (1) Q 20-2 (1) Q 20-56 (1) Q 30-43 (1)
q 00-3 (1) Q 10-27-5 (1) Q 20-3 (1) Q 20-57 (1) Q 30-44 (1)
q 00-4 (1) Q 10-27-6 (1) Q 20-4 (1) Q 20-58 (1) Q 30-45 (1)
00-5 Q 10-27-7 (1) Q 20-5 (1) Q 20-59 (1) Q 30-46 (1)
00-6 Q 10-27-8 (1) Q 20-6 (1) Q 20-60 (1) Q 30-47 (1)
00-7 Q 10-27-9 (1) Q 20-7 (1) Q 20-61 (1) Q 30-48 (1)
00-8 Q 10-27-10 (1) Q 20-8 (1) Q 20-62 (1) Q 30-49 (1)
00-9 Q 10-27-11 (1) Q 20-9 (1) Q 20-63 (1) Q 30-50 (1)
00-10 Q 10-27-12 (1) Q 20-10 (1) Q 20-64 (1) Q 30-51 (1)
00-11 Q 10-27-13 (1) Q 20-11 (1) Q 20-65 (1) Q 30-52 (1)
00-12 Q 10-27-14 (1) Q 20-12 (1) Q 20-66 (1) Q 30-53 (1)
00-13 Q 10-27-15 (1) Q 20-13 (1) Q 30-54 (1)
00-14 Q 10-27-16 (1) Q 20-14 (1) Q 30-1 (1) Q 30-55 (1)
00-15 Q 10-27-17 (1) Q 20-15 (1) Q 30-2 (1) Q 30-56 (1)
00-16 Q 10-27-18 (1) Q 20-16 (1) Q 30-3 (1) Q 30-57 (1)
00-17 Q 10-27-19 (1) Q 20-17 (1) Q 30-4 (1) Q 30-58 (1)
00-18 Q 10-27-20 (1) Q 20-18 (1) Q 30-5 (1) Q 30-59 (1)
00-19 Q 10-27-21 (1) Q 20-19 (1) Q 30-6 (1) Q 30-60 (1)
00-20 Q 10-27-22 (1) Q 20-20 (1) Q 30-7 (1) Q 30-61 (1)
00-21 Q 10-27-23 (1) Q 20-21 (1) Q 30-8 (1) Q 30-62 (1)
00-22 Q 10-27-24 (1) Q 20-22 (1) Q 30-9 (1) Q 30-63 (1)
00-23 Q 10-27-25 (1) Q 20-23 (1) Q 30-10 (1) Q 30-64 (1)
00-24 Q 10-27-26 (1) Q 20-24 (1) Q 30-11 (1) Q 30-65 (1)
Q 10-27-27 (1) Q 20-25 (1) Q 30-12 (1) Q 30-66 (1)
q 10-1 Q 10-27-28 (1) Q 20-26 (1) Q 30-13 (1) Q 30-67 (1)
q 10-2 Q 10-27-29 (1) Q 20-27 (1) Q 30-14 (1) Q 30-68 (1)
10-3 Q 10-27-30 (1) Q 20-28 (1) Q 30-15 (1) Q 30-69 (1)
10-4 10-28 Q 20-29 (1) Q 30-16 (1) Q 30-70 (1)
10-5 10-29 Q 20-30 (1) Q 30-17 (1) Q 30-71 (1)
10-6 10-30 Q 20-31 (1) Q 30-18 (1) Q 30-72 (1)
10-7 10-31 Q 20-32 (1) Q 30-19 (1) Q 30-73 (1)
10-8 10-32 Q 20-33 (1) Q 30-20 (1) Q 30-74 (1)
10-9 10-33 Q 20-34 (1) Q 30-21 (1) Q 30-75 (1)
10-10 10-34 Q 20-35 (1) Q 30-22 (1) Q 30-76 (1)
10-11 10-35 Q 20-36 (1) Q 30-23 (1) Q 30-77 (1)
10-12 10-36 Q 20-37 (1) Q 30-24 (1) Q 30-78 (1)
10-13 10-37 Q 20-38 (1) Q 30-25 (1) Q 30-79 (1)
10-14 10-38 Q 20-39 (1) Q 30-26 (1) Q 30-80 (1)
10-15 10-39 Q 20-40 (1) Q 30-27 (1) Q 30-81 (1)
10-16 10-40 Q 20-41 (1) Q 30-28 (1) Q 30-82 (1)
10-17 10-41 Q 20-42 (1) Q 30-29 (1) Q 30-83 (1)
10-18 10-42 Q 20-43 (1) Q 30-30 (1) Q 30-84 (1)
10-19 10-43 Q 20-44 (1) Q 30-31 (1) Q 30-85 (1)
10-20 10-44 Q 20-45 (1) Q 30-32 (1) Q 30-86 (1)
10-21 10-45 Q 20-46 (1) Q 30-33 (1) Q 30-87 (1)
10-22 10-46 Q 20-47 (1) Q 30-34 (1) Q 30-88 (1)
10-23 10-47 Q 20-48 (1) Q 30-35 (1) Q 30-89 (1)
10-24 10-48 Q 20-49 (1) Q 30-36 (1) Q 30-90 (1)
10-25 10-49 Q 20-50 (1) Q 30-37 (1) Q 30-91 (1)
10-26 10-50 Q 20-51 (1) Q 30-38 (1) Q 30-92 (1)
10-27 10-51 Q 20-52 (1) Q 30-39 (1) Q 30-93 (1)
Q 10-27-1 (1) 10-52 Q 20-53 (1) Q 30-40 (1) Q 30-94 (1)
Q 10-27-2 (1) Q 20-54 (1) Q 30-41 (1) Q 30-95 (1)

PC80MR-3 00-3
(1)
 REVISED PAGES

Time Time Time Time Time

Mark Page Mark Page Mark Page Mark Page Mark Page
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Q 30-96 (1)
Q 30-97 (1)
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Q 30-99 (1)
Q 30-100 (1)
Q 30-101 (1)
Q 30-102 (1)
Q 30-103 (1)
Q 30-104 (1)
Q 30-105 (1)
Q 30-106 (1)
Q 30-107 (1)
Q 30-108 (1)
Q 30-109 (1)
Q 30-110 (1)
Q 30-111 (1)
Q 30-112 (1)
Q 30-113 (1)
Q 30-114 (1)
Q 30-115 (1)
Q 30-116 (1)
Q 30-117 (1)
Q 30-118 (1)
Q 30-119 (1)
Q 30-120 (1)

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

00-4 PC80MR-3

(1)
 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 Ko-
matsu 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 PREPARATIONS FOR WORK
Mistakes in operation extremely dangerous. 7. Before adding or making any repairs, park the ma-
Read all the Operation and Maintenance Manual carefully chine on hard, level ground, and block the tracks to
BEFORE operating the machine. prevent the machine from moving.
1. Before carrying out any greasing or repairs, read all 8. Before starting work, lower outrigger, bucket or any
the precautions written on the decals which are suck other work equipment to the ground. If this is not pos-
on the machine. sible, use blocks to prevent the work equipment from
2. When carrying out any operation, always wear safety falling down. In addition, be sure to lock all the control
shoes and helmet. Do not wear loose work clothes, or levers and hang warning sign on them.
clothes with buttons missing. 9. When disassembling or assembling, support the ma-
• Always wear safety glasses when hitting parts chine with blocks, jacks or stands before starting
with a hammer. work.
• Always wear safety glasses when grinding parts 10. Remove all mud and oil from the steps or other places
with a grinder, etc. used to get on and off the machine. Always use the
3. If welding repairs are needed, always have a trained, handrails, ladders or steps when getting on or off the
experienced welder carry out the work. When carrying machine.
out welding work, always wear welding gloves, apron, Never jump on or off the machine.
glasses, cap and other clothes suited for welding If it is impossible to use the handrails, ladders or steps,
work. use a stand to provide safe footing.
4. When carrying out any operation with two or more
PRECAUTIONS DURING WORK
workers, always agree on the operating procedure be-
fore starting. Always inform your fellow workers be- 11. When removing the oil filler cap, drain plug or hydrau-
fore starting any step of the operation. Before starting lic pressure measuring plugs, loosen them slowly to
work, hang UNDER REPAIR signs on the controls in prevent the oil from spurting out.
the operator’s compartment. Before disconnecting or removing components of the
hydraulic circuit and engine cooling circuit, first re-
5. Keep all tools in good condition and learn the correct
move the pressure completely from the circuit.
way to use them.
6. Decide a place in the repair workshop to keep tools 12. The water and oil in the circuits are not hot when the
and removed parts. Always keep the tools and parts in engine in stopped, so be careful not to get burned.
their correct places. Always keep the work area clean Wait for the oil water to cool before carrying out any
and make sure that there is no dirt or oil on the floor. work on the cooling water circuits.
Smoke only in the areas provided for smoking. Never 13. Before starting work, remove the leads from the bat-
smoke while working. tery. Always remove the lead from the negative ( – )
terminal first.

PC80MR-3 00-5
 k SAFETY

14. When raising heavy components, use a hoist or 19. Be sure to assemble all parts again in their original
crane. Check that the wire rope, chains and hooks places. Replace any damage parts with new parts.
are free from damage. When installing hoses and wires, be sure that they
Always use lifting equipment which has ample ca- will not be damaged by contact with other parts
pacity. Install the lifting equipment at the correct when the machine is being operated.
places.
20. When installing high pressure hoses, make sure
Use a hoist or crane and operate slowly to prevent
that they are not twisted. Damaged tubes are dan-
the component from hitting any other part.
gerous, so be extremely careful when installing
Do not work with any part still raised by the hoist or
tubes for high pressure circuits. Also, check that
crane.
connecting parts are correctly tightened.
15. When removing covers which are under internal
21. When assembling or installing parts, always use
pressure or under pressure from a spring, always
specified tightening torques.
leave two bolts in position on opposite sides. Slowly
When installing the parts which vibrate violently or
release the pressure, then slowly loosen the bolts to
rotate at high speed, be particulary careful to check
remove.
that they are correctly installed.
16. When removing components, be careful not to
22. When aligning two holes, never insert your fingers or
break or damage the wiring.
hand.
Damage wiring may cause electrical fires.
23. When measuring hydraulic pressure, check that the
17. When removing piping, stop the fuel or oil from spill-
measuring tool is correctly assembled before taking
ing out. If any fuel or oil drips on to the floor, wipe it up
any measurement.
immediately.
Fuel or oil on the floor can cause you to slip, or can 24. Take sure when removing or installing tracks.
even start fires. When removing tha track, the track separately sud-
denly, so never let anyone stand at either end of the
18. As a general rule, do not use gasoline to wash parts.
track.
In particular, use only the minimum of gasoline when
washing electrical parts.

00-6 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 work-
shop.
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 no-
tice.
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 SYMBOLS
Shop manual are issued as a guide to carry out repairs. In order to make the shop manual greatly chelpful, im-
These various volumes are designed to avoid duplicat- portant points about safety and quality are marked with
ing the same information. the following symbols.

DISTRIBUTION AND UPDATING Symbol Item Remarks

Any additions, amendments or other changes will be
sent to Komatsu distributors. Special safety precautions
Get the most up-to-date information before you start any are necessary when

k
work. performing the work.

Safety
FILING METHOD Extra special safety precautions
are necessary when performing
1. See the page number on the bottom of the page. the work because it is under in-
File the pages in correct order. ternal pressure.
2. Following examples show you how to read the page
Special technical precautions or
number.
other precautions for preserving
Example: a Caution
standards are necessary when
10 - 3 performing the work.

Weight of parts or systems.

4
Item number (10. Structure and Caution necessary when select-
Weight
Function) ing hoisting wire, or when work-
ing posture is important, etc.
Consecutive page number for each

3 Tightening
item Parts that require special atten-
tion for the tightening torque dur-
3. Additional pages: additional pages are indicated by torque
ing assembly.
a hyphen (–) and number after the page number.
2
Fle as in the example. Parts to be coated with adhe-
Coat
Example: sives and lubricants etc.

5
10-4 Places where oil, water or fuel
Oil, water must be added, and their quan-
10-4-1 tity.
Added pages

6
10-4-2 Places where oil or water must
10-5 Drain 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

4
HOISTING INSTRUCTIONS

Hooks have maximum strength at the middle por-

k Heavy parts (25 kg or more) must be lifted with a

tion.

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 ma-

chine by hoisting, the following checks should be
made: 3) Do not sling a heavy load with one rope alone, but
sling with two or more ropes symmetrically wound
• Check for removal of all bolts fastening the part to
on to the load.
k Slinging with one rope may cause turning of the load
the relative parts.
• Check for any part causing interference with the
during hoisting, untwisting of the rope, or slipping of
part to be removed.
the rope from its original winding position on the
load, which can cause dangerous accidents.
2. Wire ropes
1) Use adequate ropes depending on the weight of 4) Do not sling a heavy load with ropes forming a wide
parts to be hoisted, referring to the table below: hanging angle from the hook.
When hoisting a load with two or more ropes, the
WIRE ROPES force subjected to each rope will increase with the
(Standard «S» or «Z» twist ropes hanging angles.
without galvanizing)
The table below shows the variation of allowable
Rope diameter (mm) Allowable load (tons) load (kg) when hoisting is made with two ropes,
each of which is allowed to sling up to 1000 kg ver-
10.0 1.0
tically, at various handing angles.
11.2 1.4 When two ropes sling a load vertically, up to 2000 kg
of total weight can be suspended.
12.5 1.6
This weight becomes 1000 kg when two ropes
14.0 2.2 make a 120° hanging angle.
On the other hand, two ropes are subjected to an ex-
16.0 2.8
cessive force as large as 4000 kg if they sling a 2000
18.0 3.6 kg load at a lifting angle of 150°.
20.0 4.4
22.4 5.6
30.0 10.0
40.0 18.0
50.0 28.0
60.0 40.0

The allowable load value is estimated to be one-

sixth 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 se-
rious accident can result.

PC80MR-3 00-9
 STANDARD TIGHTENING TORQUE

3
STANDARD TIGHTENING TORQUE

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

1. STANDARD TIGHTENING TORQUE OF BOLTS AND NUT

Width across flat

Thread Pitch of (mm)
diameter of bolts bolts
(mm) (mm) kgm Nm kgm Nm

6 1 10 8 0.96±0.1 9.5±1 1.3±0.15 13.5±1.5

8 1.25 13 6 2.3±0.2 23±2 3.2±0.3 32.2±3.5

10 1.5 17 8 4.6±0.5 45±4.9 6.5±0.6 63±6.5

12 1.75 19 10 7.8±0.8 77±8 11±1 108±11

14 2 22 12 12.5±1 122±13 17.5±2 172±18

16 2 24 14 19.5±2 191±21 27±3 268±29

18 2.5 27 14 27±3 262±28 37±4 366±36

20 2.5 30 17 38±4 372±40 53±6 524±57

22 2.5 32 17 52±6 511±57 73±8 719±80

24 3 36 19 66±7 644±70 92±10 905±98

27 3 41 19 96±10 945±100 135±15 1329±140

30 3.5 46 22 131±14 1287±140 184±20 1810±190

33 3.5 50 24 177±20 1740±200 250±27 2455±270

36 4 55 27 230±25 2250±250 320±35 3150±350

39 4 60 ---- 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

3
2. TIGHTENING TORQUE FOR NUTS OF FLARED

Use these torques for nut part of flared.

Thread diameter Width across flats TIGHTENING TORQUE

of nut part of nut part
(mm) (mm) kgm Nm

1/2” - 20 17 2.6±0.5 25.5±4.9

9/16” - 18 17 4±0.5 39.2±4.9

3/4” - 16 22 6.7±2 65.7±19.6

7/8” - 14 27 8±2 78.5±19.6

1.1/16 - 12 32 9.7±3 95.15±29.4

1.5/16 - 12 38 17±3 166.7±29.4

1.5/8 - 12 50 20±5 196.2±49

22 27 8±2 78.5±19.6

33 41 20±5 196.2±49

Sealing surface

Thread diameter Width across flats TIGHTENING TORQUE

of nut part of nut part
(mm) (mm) kgm Nm

9/16” - 18 17 2.3–2.5 23–25

11/16” - 16 22 3.4–3.9 33–38

13/16” - 16 24 5.2–5.8 51–57

1” - 14 30 8.2–9.2 80–90

1.3/16 - 12 36 12.2–13.3 120–130

1.7/16 - 12 41 15.3–17.3 150–170

1.11/16 - 12 50 18.4–20.4 180–200

2” - 12 57 20.4–24.4 200–240

PC80MR-3 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.

Used to apply resin, rubber, metallic and non-metallic parts when a fast, strong
ASL800020
seal is needed.

Loctite 222 Used for low resistance locking of screws, check nuts and adjustment nuts.

To prevent the loosening of bolts, nuts and plugs and the leakage of oil. Used for
Loctite 242 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.
Adhesives Used for high resistant locking and for sealing threaded parts, bolts and stud
Loctite 270
bolts.

Loctite 542 Used for sealing the union threads for hydraulic tubes.

Used for sealing rather exact plane surfaces when the option of possible future
Loctite 573
dismantling is required.

Used for high resistant locking of mechanical components that can be removed
Loctite 601
only after heating

Used to lock cylindrical couplings and for the permanent locking of threaded
Loctite 675
parts, and also to lock shafts to bearings, gears, pulleys, pins, bushings, etc.

Used by itself to seal grease fittings, tapered screw fittings and tapered screw
ASL800060
fittings in hydraulic circuits of less than 50 mm in diameter.

Used by itself on mounting flat surface

Gasket sealant Loctite 510
(Clearance between surfaces within 0.2 mm)

Used by itself on mounting flat surface

Loctite 518
(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 Applied to bearings, sliding parts and oil seals for lubrication, rust prevention
ASL800050
(Lithium grease) and facilitation of assembling work.

Vaseline ----- Used for protecting battery electrode terminals from corrosion

00-12 PC80MR-3
 ELECTRIC

ELECTRIC
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
Copper wire
Nominal Cable O.D. Current rating
number Number Ø of strands Cross section (mm) (A)
strands (mm) (mm)
0.5 16 0.20 0.35 1.55 3.5
1 14 0.30 0.99 2.80 11
1.5 21 0.30 1.48 3.35 14
2.5 35 0.30 2.47 3.80 20
4 56 0.30 3.95 4.60 28
6 84 0.30 5.93 5.20 37
10 84 0.40 10.55 7.10 53
50 399 0.40 50.11 14 160
CLASSIFICATION BY COLOUR AND CODE
Primary Auxiliary
Code A A–B A/B A–G – A–N A/N A–R A/R A–V A/V
Colour Light Blue Light Blue – White Light Blue–Yellow Light Blue–Black Light Blue–Red Light Blue–Green
Code B B–G – B–N B/N B–R B/R – B/V – –
Colour White White–Yellow White–Black White–Red White–Green –
Code C C–B C/B C–L – C–N – – – – –
Colour Orange Orange–White Orange–Blue Orange–Black – –
Code G G–N G/N G–R – G–V – – – – –
Colour Yellow Yellow–Black Yellow–Red Yellow–Green – –
Code H H–L – H–N H/N – – – – – –
Colour Grey Grey–Blue Grey–Black – – –
Code L L–B L/B L–G – – L/N – – – –
Colour Blue Blue–White Blue–Yellow Blue–Black – –
Code M M–B – M–N M/N M–V – – – – –
Colour Brown Brown–White Brown–Black Brown–Green – –
Code N – – – – – – – – – –
Colour Black – – – – –
Code R R–G – R–N R/N R–V – – – – –
Colour Red Red–Yellow Red–Black Red–Green – –
Code S S–G – S–N – – – – – – –
Colour Pink Pink–Yellow Pink–Black – – –
Code V V–B – V–N V/N – – – – – –
Colour Green Green–White Green–Black – – –
Code Z Z–B Z/B Z–N Z/N – – – – – –
Colour Violet Violet–White Violet–Black – – –

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

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

TABLE OF OIL AND COOLANT QUANTITIES

AMBIENT TEMPERATURE CAPACITY’(l)

TANK /
FLUID
RESERVOIR -30 -20 -10 0 10 20 30 40 50°C
1st filling. Change.
-22 -4 14 32 50 68 86 104 122°F

SAE 30

OIL SAE 10W

Engine oil pan API CD 9.8 9.4
SAE 10W-30

SAE 15W-40

Travel reduc-
OIL 2.7 2.7
tion gear
API GL5 SAE 85W-90
Final drive 1.3 1.3

SAE 10W

Hydraulic OIL
SAE 10W-30 110 65
system API CD

SAE 15W-40

Hydraulic sys-
tem with biode- 110 65
gradable oil

Fuel a
DIESEL OIL 110 —
tank
ASTM D975 N. 2

Engine PERMANENT
cooling COOLANT 18 18
system (aa)

Articulation
Lithium EP+MoS2 (NLGI 2)
greasing

Pinion/ball-bea- GREASE
ring ring grea- Lithium EP (NLGI 2)
sing

a 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 Engine oil change interval

from 0.5 to 1.0% 1/2 of regular interval
over 1.0% 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 mil-
limeters 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 B

1 mm = 0.03937 in.

0 1 2 3 4 5 6 7 8 9

0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748

20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142

30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536

40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929

C
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
A
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717

70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110

80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504

90 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 1 2 3 4 5 6 7 8 9

0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748

20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142

30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536

40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929

50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323

60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717

70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110

80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504

90 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 1 2 3 4 5 6 7 8 9

0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89

20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93

30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98

40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03

50 110.23 112.44 114.64 116.85 119.05 121.24 123.46 125.66 127.87 130.07

60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12

70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17

80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21

90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26

00-18 PC80MR-3
 CONVERSION TABLE

From liter to U.S. Gall.

1 ᐉ = 0.2642 U.S. Gall.

0 1 2 3 4 5 6 7 8 9

0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019

20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661

30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303

40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944

50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586

60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228

70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870

80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511

90 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.

1 ᐉ = 0.21997 U.K. Gall.

0 1 2 3 4 5 6 7 8 9

0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179

20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379

30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579

40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778

50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978

60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178

70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378

80 17.598 17.818 18.037 12.257 18.477 18.697 18.917 19.137 19.357 19.577

90 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 1 2 3 4 5 6 7 8 9

0 0 0.737 1.474 2.211 2.948 3.685 4.422 5.159 5.896 6.633

10 7.370 8.107 8.844 9.581 10.318 11.055 11.792 12.529 13.266 14.003

20 14.740 15.477 16.214 16.951 17.688 18.425 19.162 19.899 20.636 21.373

30 22.110 22.847 23.584 24.321 25.058 25.795 26.532 27.269 28.006 28.743

40 29.480 30.217 30.954 31.691 32.428 33.165 33.902 34.639 35.376 36.113

50 36.850 37.587 38.324 39.061 39.798 40.535 41.272 42.009 42.746 43.483

60 44.220 44.957 45.694 46.431 47.168 47.905 48.642 49.379 50.116 50.853

70 51.590 52.327 53.064 53.801 54.538 55.275 56.012 56.749 57.486 58.223

80 58.960 59.697 60.434 61.171 61.908 82.645 63.382 64.119 64.856 65.593

90 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 1 2 3 4 5 6 7 8 9

0 0 0.102 0.204 0.306 0.408 0.510 0.612 0.714 0.816 0.918

10 1.020 1.222 1.224 1.326 1.428 1.530 1.632 1.734 1.836 1.938

20 2.040 2.142 2.244 2.346 2.448 2.550 2.652 2.754 2.856 2.958

30 3.060 3.162 3.264 3.366 3.468 3.570 3.672 3.774 3.876 3.978

40 4.080 4.182 4.284 4.386 4.488 4.590 4.692 4.794 4.896 4.998

50 5.100 5.202 5.304 5.406 5.508 5.610 5.712 5.814 5.916 6.018

60 6.120 6.222 6.324 6.426 6.528 6.630 6.732 6.834 6.936 7.038

70 7.140 7.242 7.344 7.446 7.548 7.650 7.752 7.854 7.956 8.058

80 8.160 8.262 8.364 8.466 8.568 8.670 8.772 8.874 8.976 9.078

90 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 1 2 3 4 5 6 7 8 9

0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4

20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8

30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1

40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4

50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8

60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1

70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4

80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7

90 651.0 658.2 665.4 672.2 679.9 687.1 694.4 701.6 708.8 716.1

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 1 2 3 4 5 6 7 8 9

0 0 14.5 29.0 43.5 58.0 72.5 87.0 101.5 116.0 130.5

10 145.0 159.5 174.0 188.5 203.0 217.5 232.0 246.5 261.0 275.6

20 290.0 304.6 319.1 333.6 348.1 362.6 377.1 391.6 406.1 420.6

30 435.1 449.6 464.1 478.6 493.1 507.6 522.1 536.6 551.1 565.6

40 580.1 594.6 609.1 623.6 638.1 652.6 667.1 681.6 696.1 710.6

50 725.1 739.6 754.1 768.6 783.2 797.7 812.2 826.7 841.2 855.7

60 870.2 884.7 899.2 913.7 928.2 942.7 957.2 971.7 986.2 1000.7

70 1015.2 1029.7 1044.2 1058.7 1073.2 1087.7 1102.2 1116.7 1131.2 1145.7

80 1160.2 1174.7 1189.2 1203.7 1218.2 1232.7 1247.2 1261.8 1276.3 1290.8

90 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 tem-
perature 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 tem-
peratures 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 val-
ues and read the corresponding Fahrenheit temperature on the right.
1 °C = 33.8°F

°C °F °C °F °C °F °C °F

–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 144.8 27.2 81 117.8

–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0

–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

–27.8 –18 –0.4 –8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
–27.2 –17 1.4 –7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
–26.7 –16 3.2 –7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
–26.1 –15 5.0 –6.7 20 68.0 12.8 55 131.0 32.2 90 194.0

–25.6 –14 6.8 –6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

–25.0 –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
–24.4 –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
–23.9 –11 12.2 –4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
–23.3 –10 14.0 –3.9 25 77.0 15.6 60 140.0 35.0 95 203.0

–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

–22.2 –8 17.6 –2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
–21.7 –7 19.4 –2.2 28 72.4 17.2 63 145.4 36.7 98 208.4
–21.1 –6 21.2 –1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
–20.6 –5 23.0 –1.1 30 86.0 18.3 65 149.0 37.8 100 212.0

–20.0 –4 24.8 –0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

–19.4 –3 26.6 0.0 32 89.6 19.4 67 152.6 43.3 110 230.0
–18.9 –2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
–18.3 –1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
–17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0

–17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

–16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
–16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
–15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 2930
–15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0

–14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0

00-24 PC80MR-3
 10 STRUCTURE AND FUNCTION

POWER TRAIN...............................................................2 SWIVEL JOINT ............................................................ 19

SWING CIRCLE..............................................................3 TRAVEL MOTOR ......................................................... 20
SWING MACHINERY .....................................................5 WORK EQUIPMENT CYLINDER................................. 22
TRACK FRAME AND IDLER CUSHION.........................8 SOLENOID VALVE GROUP ........................................ 26
IDLER............................................................................10 CONTROL VALVE .................................................... 27-1
TRACK ROLLER...........................................................11 CLSS ....................................................................... 27-12
CARRIER ROLLER.......................................................12 SWING MOTOR ........................................................... 28
SPROCKET ..................................................................13 ATTACHMENT ............................................................. 37
TRACK SHOE...............................................................14 TRAVEL PPC VALVE .................................................. 42
SHOES..........................................................................17 BLADE, BOOM SWING, 2-PIECE BOOM PPC
RUBBER SHOE ............................................................18 VALVES ....................................................................... 46
EQUIPMENT ................................................................ 50

PC80MR-3 10-1
(1)
STRUCTURE AND FUNCTION POWER TRAIN

POWER TRAIN

1 2 3 4 5

6
7

8
15
9
14
13
12
11
10

16

17

RKP15700

1. Idler 10. L.H. boom swing lock solenoid valve

2. Control valve 11. R.H. boom swing lock solenoid valve
3. Center swivel joint 12. Equipment solenoid valve
4. Swing motor 13. Swing holding brake solenoid valve
5. Travel motor 14. Travel speed solenoid valve
6. Control pump (for pilot control) 15. Servocontrol solenoid valve
7. Hydraulic pump (for swing and blade) 16. Swing machinery
8. Hydraulic pump (For travel and work equipment) 17. Swing circle
9. Engine

10-2 PC80MR-3
STRUCTURE AND FUNCTION SWING CIRCLE

SWING CIRCLE

b 2
a
S

3
245 – 309 Nm
A
4
2 1,6

245 – 309 Nm
5

A-A 7

RKP15710

Unit: mm
No. Control Criteria Remedy
Standard clearance Allowable clearance
1 Axial clearance of bearing Replace
0.20 – 0.80 2.0

2. Greasing for swing circle bearing a. Position of inner race soft zone
3. Greasing for swing circle pinion b. Position of outer race soft zone
4. Outer race
5. Inner race SPECIFICATIONS
6. Ball Grease G2-LI
7. Seal Quantity of grease 5.5 l
Reduction ratio 80/10=8.0

PC80MR-3 10-3
PAGE INTENTIONALLY
LEFT BLANK
STRUCTURE AND FUNCTION SWING MACHINERY

SWING MACHINERY

13

A
11 12
9
10
6

5 8
4 7

A 2
14
1
RKP16560

1. Pinion (Number of teeth: 10) 10. No. 1 planetary gear

2. Axle body 11. Swing motor
3. No. 2 planetary carrier 12. Oil filler pipe
4. Ring gear 13. Level gauge
5. No. 2 planetary gear 14. Drain plug
6. No. 2 sun gear
SPECIFICATIONS
7. No. 1 planetary carrier
Reduction ratio 27.8
8. Ring gear
Swing speed (rpm) –
9. No. 1 sun gear

PC80MR-3 10-5
STRUCTURE AND FUNCTION SWING MACHINERY

Loctite 242

.............. Nm
Loctite 262
1
2

4 3

6
950 – 150 Nm
Loctite 243
7

290 Nm
Loctite 262

8
RKP16570

10-6 PC80MR-3
STRUCTURE AND FUNCTION SWING MACHINERY

Unit: mm
Criteria
No. Control Remedy
Standard clearance Clearance limit
Backlash between swing motor
1
shaft and No. 1 sun gear
Backlash between No. 1 sun gear
2
and No. 1 planetary gear
Backlash between No. 1 planetary
3
gear and ring gear
Backlash between No. 1 planetary
4
carrier and No. 2 sun gear
Replace
Backlash between No. 1 sun gear
5 and No. 2 planetary gear
Backlash between No. 2 planetary
6
gear and ring gear
Backlash between No. 2 planetary
7
carrier and swing pinion
Backlash between pinion and swing
8
circle
Basic Plating with
Wear of sliding surface of pinion dimension Allowable Limit size
9 collar against oil seal
hard chromium
or replace

PC80MR-3 10-7
STRUCTURE AND FUNCTION TRACK FRAME AND IDLER CUSHION

TRACK FRAME AND IDLER CUSHION

A-A

245 – 309 Nm
Loctite 262
A

2
A 230 Nm
Loctite 262

4 5 6 7 8

12 11 10 9
11a 11b 3,11c 11d 11e

59 – 74 Nm

1
11f

RKP15720
156,8 – 196 Nm

10-8 PC80MR-3
STRUCTURE AND FUNCTION TRACK FRAME AND IDLER CUSHION

Unit: mm
No. Control Criteria
Remedy
Basic dimension Limit size
Track
Vertical width 74 78 Overlay
1 frame
of idler guide
Idler Overlay
73 69
support or replace
Track
158 162 Overlay
Lateral width frame
2 of idler guide Idler Overlay
156 152
support or replace
Basic dimension Limit size
Installed Installed Installed
Free length Free length
length load load

3 Recoil spring 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 SPECIFICATIONS
5. Track frame Quantity of grease:96 cc (steel shoe, road liner)
233 cc (rubber shoe)
6. Carrier roller
Grease: G2-LI
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 10-9
STRUCTURE AND FUNCTION IDLER

IDLER
5
3 6 4 10

1 2
8

RKP15730

Unit: mm
Criteria
No. Control Remedy
Basic dimension Limit size
1 Outside diameter of projected part Ø 460 –
2 Outside diameter of tread Ø 415 Ø 407
3 Depth of tread 22.5 26.5
4 Width of projected part 43 37
5 Overall width 100 92
6 Width of tread 28.5 32
Allowable Standar Standar
Basic
d d
dimensi
Clearance between idler shaft and Shaft Hole clearanc interfere
7 on
bushing e nce
-0.250 + 0.062 0.250–
Ø 44 1.5
-0.290 0 0.352
Repair
Interference between idler and +0.117 +0.025 0.062–
8 Ø 50 –
bushing +0.087 0 0.117
Allowable
Standard clearance
9 Side clearance of idler (Each side) clearance
0.190 – 0.395 1.5

Thickness of tread (at cen-ter of Basic dimension Limit size Overlay or

10
width of tread) 13.8 9.8 replace

– Quantity of oil 60 cc (Engine oil: SAE30CD) –

10-10 PC80MR-3
STRUCTURE AND FUNCTION TRACK ROLLER

TRACK ROLLER

4
5 3
8

7
2 1

RKP16550

Unit: mm
Criteria
No. Control Remedy
Basic dimension Limit size
1 Outer diameter of protrusion Ø 139 –
Overlay or
2 Outside diameter of tread Ø 110 Ø 103 replace
3 Width of projected part 43 36.6
4 Overall width 136.6 – –
Overlay or
5 Width of tread 46.8 51.1
replace
Allowable Standar Standar
Basic
d d
dimensi
Clearance between idler shaft and Shaft Hole clearanc interfere
6 on
bushing e nce
-0.250 + 0.165 0.230 –
Ø 40 1.5
-0.270 – 0.020 0.435 Replace
Interference between idler and +0.150 +0.025 0.075 –
7 Ø 44 –
bushing +0.110 -0.020 0.170
Minimum clearance Clearance limit
8 Side clearance of track roller
0.53 – 1.06 1.5

Thickness of tread (at center of width Basic dimension Limit size Overlay or
9 of tread) replace
33 29.5
– Quantity of oil 160 – 180 cc (Oil: G0140) –

PC80MR-3 10-11
STRUCTURE AND FUNCTION CARRIER ROLLER

CARRIER ROLLER

1 4 3

RKP15740

Unit: mm
Criteria
No. Control Remedy
Basic dimension Limit size
1 Outside diameter of tread Ø 82 Ø 72 Overlay or
2 Width of tread 100 – replace

Allowable Standar
Basic Allowabl
d
dimensi e
Interference between shaft and Shaft Hole interfere
3 on interfere
bearing nce
nce
Replace
+0.009 0 -0.004 –
Ø 30 –
- 0.004 -0.010 0.019
Interference between roller and 0 + 0.018 -0.031 –
4 Ø 62 –
bearing -0.013 - 0.012 0.012
Basic dimension Limit size Overlay or
5 Thickness of tread
10 5 replace

– Quantity of oil 47– 52 cc (Grease: ALVANIA EP-2) –

10-12 PC80MR-3
STRUCTURE AND FUNCTION SPROCKET

SPROCKET

4
A 3

2 1

A A-A

RKP15750

Unit: mm
No. Control Criteria Remedy
Basic
Allowable Limit size
dimension
1 Wear of root diameter
+ 1.0
Ø 433.004 Ø 421
- 2.0
2 Wear of tip diameter Ø 483.7 ± 2.0 Ø 472 Overlay or
3 Wear of dip width 28 – 23 replace

4 Wear of root width 38 + 0.5 33

- 2.5
+ 0.475
5 Thickness of root 84.002 78
- 1.150

PC80MR-3 10-13
STRUCTURE AND FUNCTION TRACK SHOE

TRACK SHOE
ROAD LINER - STEEL SHOE - CITY PAD

10 9 8 12 23 22 21 16 6 5 24 11 14 13

2 17 18 7 25 19 15

[*1]
3 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
Criteria
No. Control Remedy
Basic dimension Limit size
1 Link pitch 154.25 157.25 Reverse or
2 Outside diameter of bushing 41.2 37.2 replace

3 Height of link 74 70
Repair or
Thickness of link (Press fit-ting part of replace
4 20 16
bushing)
5 89
6 Shoe bolt pitch 73 Replace
7 57
8 Inside width 45
Repair or
9 Link Overall width 30
replace
10 Width of tread 26.3

11 Projection of pin 3 Adjust or

replace
12 Projection of regular bush-ing 3.15
13 Overall length of pin 131

14 Overall length of bushing 74.6

(Master bushing)
Basic dimension Limit size
15 Thickness of bushing
8.4 4.4
16 Thickness of spacer –
17 Bushing 19.6 -98.1 kN
18 Press fitting pressure Regular pin 49.0 -117.7 kN –
*19 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
Criteria
No. Control Remedy
Tightening torque Tightening torque
• City pad
117.7 ±
• Steel 90° ± 10°
19.6 Nm
shoe
a. Regular
link 60 ± 10
117.7 ± (Torque after
Screw • Road liner Retighten
19.6 Nm retightening)
20 Min. 343 Nm
Tightening Tightening
b. Master Lower limit torque
torque torque
link
– – –
Number of shoes (Each side) 39
Allowable Standard
Basic
interferenc
Clearance between regular pin and dimension Shaft Hole
21 e
bushing
+0.214 + 0.062 0.112 –
41
+0.174 0 0.214
Interference between regular pin and +0.150 - 0.198 0.198 –
22 24
link 0 - 0.250 0.400

Basic Allowable Standard

Clearance between regular pin and dimension Shaft Hole clearance
23
bushing
+ 0.150 +0.830 0.180 – Adjust or
24
0 +0.330 0.830 replace
Allowable Standard
Basic
interferenc
Interference between master pin and dimension Shaft Hole
*24 e
link
+ 0.020 -0.198 0.178 –
24
- 0.020 -0.250 0.270

Basic Allowable Standard

Clearance between master pin and dimension Shaft Hole clearance
*25
bushing
-0.150 +0.630 0.380 –
24
-0.250 +0.230 0.880
Basic dimension Limit size
26 Height of grouser Replace
Road liner 42 19

Items marked with * are for the dry track.

10-16 PC80MR-3
STRUCTURE AND FUNCTION SHOES

SHOES
STEEL SHOE - CITY PAD

4 5 6
A
1

A
A-A
3

RKP15770

Unit: mm
No. Control Criteria Remedy
Basic dimension Limit size
1 Height of grouser
20 12
2 Overall height of shoe 26 18
Overlay or
3 Thickness of plate 6
replace
4 14
5 Length of upper side of grouser 10
6 12

PC80MR-3 10-17
STRUCTURE AND FUNCTION RUBBER SHOE

RUBBER SHOE

A
A

3
2

1
A-A

RKP15780

Unit: mm
Criteria
No. Control Remedy
Basic dimension Limit size
1 Wear of lug height 30 5
2 Wear of roller guide 42 58
Standard Replace
Allowable Limit size
3 Wear of meshing part of sprocket dimension
22.5 ±0.5 27

10-18 PC80MR-3
STRUCTURE AND FUNCTION SWIVEL JOINT

SWIVEL JOINT

A2
G2 E2 A1 C1 E1 G1
DR1

C2 A A

B2
F2 DR2 B1 D1 F1
D2

2 3 4
11,8 – 14,7 Nm

5
A-A RKP16580

A1: From right travel control valve A2: To right travel motor
B1: From right travel control valve B2: To right travel motor
C1: From left travel control valve C2: To left travel motor
D1: From left travel control valve D2: To left travel motor
E1 From blade control valve E2: To blade cylinder (bottom side)
F1: From blade control valve F2: To blade cylinder (head side)
G1 From travel increment speed selector solenoid valve G2: To travel increment speed
DR1: To tank DR2: From travel motor drain port
1. Cover
2. Rotor
3. Sealing ring
4. Shaft
Unit: mm
No. Control Criteria Remedy
Basic Standard Allowable
dimension clearance clearance
5 Clearance between shaft and rotor Replace
70 – –

PC80MR-3 10-19
STRUCTURE AND FUNCTION TRAVEL MOTOR

TRAVEL MOTOR

PS

T1

P1

X
P2

T2

RKP16930
X

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: Fast: 29.1 (cm3/rev.)
Slow: 48.6 (cm3/rev.)
Max. engine speed: Fast: 2754 rpm
Slow: 1646 rpm
Min. pressure opening brake: 13 bar
Change displacement pressure: 32 bar
Reduction ratio 53.0

10-20 PC80MR-3
STRUCTURE AND FUNCTION TRAVEL MOTOR

290–310 Nm

7 8 9
128 ± 7 Nm 6 10 11 12 13
5

4
14
3
2
15
1
20–30 Nm

16

17

20–30 Nm

18
29,4 ± 2,0 Nm

25 19
20
24 21
23
22 RKP16920

1. Cover 14. No. 2 sun gear

2. Cover 15. No. 1 sun gear
3. Swash plate 16. Pad
4. Cylinder 17. Cover
5. Piston 18. Plug
6. Ring 19. No. 1 planetary
7. Steel disk 20. Piston spring
8. Brake disk 21. Piston
9. Bearing 22. Swash plate
10. Ring nut 23. Floating seal
11. No. 2 planetary gear 24. Shoe
12. Body 25. Spring
13. No. 1 planetary gear

PC80MR-3 10-21
STRUCTURE AND FUNCTION WORK EQUIPMENT CYLINDER

WORK EQUIPMENT CYLINDER

BOOM CYLINDER

2 4 1 5 3

RKP19460

ARM CYLINDER

2 4 1 5 3

RKP19470

BUCKET CYLINDER

2 4 1 5 3

RKP19480

10-22 PC80MR-3
STRUCTURE AND FUNCTION WORK EQUIPMENT CYLINDER

BOOM SWING CYLINDER

2 4 1 5 3

RKP19490

BLADE CYLINDER

2 4 1 5 3

RKP16910

PC80MR-3 10-23
STRUCTURE AND FUNCTION WORK EQUIPMENT CYLINDER

Unit: mm

No. Control Criteria Remedy

Basic Allowable
Standard Allowable
Cylinder dimensio clearance clearance
n Shaft Hole

-0.030 +0.250 0.085 –

Boom 65 0.654
-0.076 +0.055 0.326

-0.030 +0.151 0.036 –

Arm 60 0.567
Clearance between -0.067 +0.006 0.218 Replace
1 piston rod and bushing bushing
-0.030 +0.163 0.036 –
Bucket 55 0.567
-0.104 +0.006 0.267

-0.030 +0.163 0.036 –

Boom swing 60 0.567
-0.104 +0.006 0.267

-0.030 +0.250 0.085 –

Blade 65 0.654
-0.104 +0.055 0.354

-0.030 +0.174 0.130 –

Boom 60 1.0
-0.100 +0.100 0.274

-0.025 +0.142 0.105 –

Arm 50 1.0
-0.087 +0.080 0.229
Clearance between -0.030 +0.142 0.105 –
2 piston rod support shaft Bucket 50 1.0
-0.100 +0.080 0.229
and bushing
-0.025 +0.142 0.105 –
Boom swing 50 1.0
-0.064 +0.080 0.206

-0.030 +0.174 0.130 –

Blade 70 1.0
-0.104 +0.100 0.278
Replace pin
and bushing
-0.030 +0.174 0.130 –
Boom 60 1.0
-0.076 +0.100 0.240

-0.025 +0.142 0.105 –

Arm 50 1.0
-0.087 +0.080 0.229
Clearance between -0.030 +0.142 0.110 –
3 cylinder bottom support Bucket 50 -0.100 +0.080 0.242 1.0
shaft and bushing
-0.025 +0.142 0.105 –
Boom swing 50 1.0
-0.064 +0.080 0.206

-0.030 +0.174 0.130 –

Blade 70 1.0
-0.104 +0.100 0.278

10-24 PC80MR-3
STRUCTURE AND FUNCTION WORK EQUIPMENT CYLINDER

No. Control Criteria Remedy

Boom 961 ± 96.1 Nm

Procedure
1) Tighten at 1.11 -1.35 kNm
Arm
2) Loosen to 0 Nm
3) Tighten at 1.11 -1.35 kNm
Tightening torque of
4 cylinder head
Procedure
1) Tighten at 1.16 -1.42 kNm
Bucket
2) Loosen to 0 Nm
3) Tighten at 1.16 -1.42 kNm
Retighten
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).

Tightening torque of
5 cylinder piston
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).

PC80MR-3 10-25
STRUCTURE AND FUNCTION SOLENOID VALVE GROUP

SOLENOID VALVE GROUP

T A2

B2 B3

A4
B1

B4
A1

4 3 2 1 5

4 3 2 1

B1 B2 B3 A4 B4

SV4 SV3 SV2

SV1
5

T
RV1
CV1
35 bar

RKP19500
A1 A2

10-26 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. Equipment solenoid valve

2. Swing holding brake solenoid valve
3. Travel speed solenoid valve
4. Servocontrol solenoid valve
5. Main relief valve (32 kg/cm2)

PC80MR-3 10-27
STRUCTURE AND FUNCTION CONTROL VALVE

CONTROL VALVE
A1. To swing motor MA
A2. To blade cylinder head
A3. To L.H. travel motor A
A4. To R.H. travel motor A
A5. To boom cylinder bottom
A6. To arm cylinder head
A7. To bucket cylinder head
A8. To boom swing cylinder bottom
A9. To attachment cylinder
B1. To swing motor MB
B2. To blade cylinder bottom
B3. To L.H. travel motor B
B4. To R.H. travel motor B
B5. To boom cylinder head
B6. To arm cylinder bottom
B7. To bucket cylinder bottom
B8. To boom swing cylinder head
B9. To attachment cylinder
LS. To pump LS valve
P1. From main pump
P2. From gear pump for swing, blade
PA1. From right swing PPC valve
PB1. From left swing PPC valve
PA2. From blade RAISE PPC valve
PB2. From blade LOWER PPC VALVE
PA3. From L.H. travel FORWARD PPC valve
PB3. From L.H. travel REVERSE PPC valve
PA4. From R.H. travel FORWARD PPC valve
PB4. From R.H. travel REVERSE PPC valve
PA5. From boom RAISE PPC valve
PB5. From boom LOWER PPC valve
PA6. From arm OUT PPC valve
PB6. From arm IN PPC valve
PA7. From bucket DUMP PPC valve
PB7. From bucket CURL PPC valve
PA8. From boom swing PPC valve
PB8. From boom swing PPC valve
PA9. From attachment cylinder
PB9. From attachment cylinder
PS: From boom raise PPC valve
(only during boom raise + swing operation)
TB. To tank
TC. To oil cooler
TS. To tank
TSW. To swing motor

10-27-1 PC80MR-3

(1)
STRUCTURE AND FUNCTION CONTROL VALVE

9-SPOOL VALVE

C LS
B
A D
PB9
PA9
AA AA
PA8 PB8
M A9 B9 M
PB7
PA7 A8
L B8 L
PA6 PB6
K A7 B7 K
PA5 PB5
J
A6 B6 J
PB4 Z
PA4 H A5 B5 H

G A4 B4 G PB3
PA3
TS A3 B3
G G
PA2 PB2
PS A2 B2
F F N
PA1 A1 B1 PB1
E E

BB BB

D N
A TC
B TSW
C

P2

P1
RKP19640

PC80MR-3 10-27-2
(1)
STRUCTURE AND FUNCTION CONTROL VALVE

17

8 9

7 10

6 11

5 12

4 13

3 14

2 15

1 16

RKP19650

A- A
18

1. Stop plug (blade head) 10. Suction valve (boom swing bottom)
2. Suction valve (L.H. travel A) 11. Suction valve (bucket bottom)
3. Suction valve (R.H. travel A) 12. Suction valve (arm bottom)
4. Suction valve (boom bottom) 13. Suction valve (boom head)
5. Suction valve (arm head) 14. Suction valve (R.H. travel B)
6. Suction valve (bucket head) 15. Suction valve (L.H. travel B)
7. Suction valve (boom swing head) 16. Stop plug (Blade bottom)
8. Check valve (attachment) 17. Safety valve
9. Check valve (attachment) 18. Cooler bypass valve

10-27-3 PC80MR-3

(1)
STRUCTURE AND FUNCTION CONTROL VALVE

10

RKP19660
1
B- B

1. Main relief valve 6. Spool (boom)

2. Spool (swing) 7. Spool (arm)
3. Spool (blade) 8. Spool (bucket)
4. Spool (L.H. travel) 9. Spool (boom swing)
5. Spool (R.H. travel) 10. Spool (attachment)

PC80MR-3 10-27-4
(1)
STRUCTURE AND FUNCTION CONTROL VALVE

10

9 11

8 12

7 13

6 14

5 15

4 16

3 17

RKP19670

C- C

1. Spool (boom RAISE merge) 11. Pressure compensation valve R (attachment)

2. Gear pump relief valve for swing, blade 12. Pressure compensation valve R (boom swing)
3. Pressure compensation valve F (L.H. travel) 13. Pressure compensation valve R (bucket)
4. Pressure compensation valve F (R.H. travel) 14. Pressure compensation valve R
5. Pressure compensation valve F (Arm)
(Boom) 15. Pressure compensation valve R
6. Pressure compensation valve F (Boom)
(Arm) 16. Pressure compensation valve R (R.H. travel)
7. Pressure compensation valve F (bucket) 17. Pressure compensation valve R (L.H. travel)
8. Pressure compensation valve F (boom swing) a F: Flow control valve
9. Pressure compensation valve F (attachment) R: Reducing valve
10. Pump pressure detection plug

10-27-5 PC80MR-3

(1)
STRUCTURE AND FUNCTION CONTROL VALVE

RKP19680

D- D

1. Check valve (attachment) 5. Check valve (boom)

2. Check valve (boom swing) 6. Check valve (blade RAISE)
3. Check valve (bucket) 7. Load check valve
4. Check valve (arm)

PC80MR-3 10-27-6
(1)
STRUCTURE AND FUNCTION CONTROL VALVE

BB- BB

5 7

AA- AA N- N
RKP19690

1. Main relief valve 5. LS bypass plug

2. Back pressure valve 6. Pump pressure detection plug
3. Safety valve 7. Unload valve
4. Pressure release valve

10-27-7 PC80MR-3

(1)
STRUCTURE AND FUNCTION CONTROL VALVE

3
E- E

5
4

7
RKP19700
F- F

Swing valve Blade valve

1. Load check valve 4. Stop plug (head)
2. Spool 5. Stop plug (bottom)
3. Spool (boom RAISE merge) 6. Spool
7. Gear pump relief valve for swing, blade

PC80MR-3 10-27-8
(1)
STRUCTURE AND FUNCTION CONTROL VALVE

1 2

5 4
G- G

6 7

RKP19710
10 9
H- H

L.H., R.H. travel valve Boom valve

1. Suction valve (A) 6. Suction valve (bottom)
2. Suction valve (B) 7. Suction valve (head)
3. Spool 8. Spool
4. Pressure compensation valve R 9. Pressure compensation valve R
5. Pressure compensation valve F 10. Pressure compensation valve F

10-27-9 PC80MR-3

(1)
STRUCTURE AND FUNCTION CONTROL VALVE

1 2

5 4

G- G

6 7

10 9 RKP19720

K- K

Arm valve Bucket valve

1. Suction valve (head) 6. Suction valve (head)
2. Suction valve (bottom) 7. Suction valve (bottom)
3. Spool 8. Spool
4. Pressure compensation valve R 9. Pressure compensation valve R
5. Pressure compensation valve F 10. Pressure compensation valve F

PC80MR-3 10-27-10
(1)
STRUCTURE AND FUNCTION CONTROL VALVE

1 2

5 4 RKP19730

L- L

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 PC80MR-3

(1)
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
PP

Min. Max.

Servo piston

DPLS
LS valve Max.
Swash plate angle Q

Differential
pressure high Differential
pressure
low
PC valve Min.

0 LS differential
Pump pressure Pump pressure pressure DPLS Set differential
high low pressure of LS valve
RKP02931
RKP02921

10-27-13 PC80MR-3

(1)
STRUCTURE AND FUNCTION CLSS

2. 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
Load
W W

Actuator Actuator

P S1 S2 P

Pressure Pressure
compensation compensation
valve valve

Pump RKP19751

PC80MR-3 10-27-14
(1)
STRUCTURE AND FUNCTION CLSS

OPERATION FOR EACH FUNCTION AND VALVE

Hydraulic circuit diagram and name of valves

LS

294 bar
2 1. Unload valve
(LS pressure + 32 kg/cm2)
Ls ø0,5
4
A9
2. Safety valve
B9 Attachment
PA9 PB9 (300 kg/cm2)
4
3. Pressure compensation valve
3
4 4. Suction valve
A8

B8 Boom swing 5. Main relief valve

PA8
4 PB8 (270 kg/cm2)
3 6. Relief valve for swing, blade
4 (205 kg/cm2)
A7
7. Cooler bypass valve
B7
Bucket
PA7
4
PB7
(cracking pressure: 8.3 kg/cm2.
3 8. Boom RAISE boost merge valve
4 A6 9. Back pressure valve
B6 Arm (cracking pressure: 11.3 kg/cm2.
PA6 PB6
4
3
4 A5

PA5
B5
PB5
Boom
4
3
4 A4

B4
R.H. travel
PA4 PB4
4
3
4 A3
L.H. travel
B3
PA3 PB3
4
3
A2

B2 Blade
PA2 PB2

P2
TS
200 bar
6 A1

B1
Swing
PA1 PB1

Ps 8

5 1
265 bar 31 bar
TSW
7 TB
9 TC
P1
RKP19741

10-27-15 PC80MR-3

(1)
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)

PP PLS

T
1 2 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.

PP 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 PC80MR-3

(1)
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.

PP 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
1

a d

PP SA PA 3 PLS1 SLS
2

C 4 PLS
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 PC80MR-3

(1)
STRUCTURE AND FUNCTION CLSS

2. Travel valve

A
b
1

a d

PP 2 PA 3

e 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.

1 T

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 PC80MR-3

(1)
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).)

W W
A A
PA
PPA

a a

T
PLS1
PPA PA
2 1
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).

S1 PPB PP 2 1 PA 3 S2

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 PC80MR-3

(1)
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.

L.H. travel R.H. travel

Left A Left PA Right A Right PA

1 1

T T

PLS
3 2 2
a
a
PP
PP 3

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

2. Steering when traveling

L.H. travel R.H. travel

Left A Left PA Right A Right PA

1 1

T T

PLS
3 2 2
a
a
PP
PP 3

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 PC80MR-3

(1)
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.

A1 1 A2 PA

PLS
PLS1
a

4
PB c
2

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

2. Travel + other actuator operated

A1 1 A2 PA

PLS
PLS1
a

4
PB 2 c

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 PC80MR-3

(1)
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
3
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

2. 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.

B
A
4
2

T 3
a

PLS
PP

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 PC80MR-3

(1)
PAGE INTENTIONALLY
LEFT BLANK
STRUCTURE AND FUNCTION SWING MOTOR

SWING MOTOR

A C S

B B

MA
C
A

MB

RKP15890

B: From brake swing solenoid valve SPECIFICATIONS

S: From the tank Type: LMF30AEL
T: To tank Displacement 31 cc/rev
MA: From control valve Safety valve set pressure: 210 bar
MB: From control valve Suction valve cracking pressure: 0.3 bar

10-28 PC80MR-3
STRUCTURE AND FUNCTION SWING MOTOR

3 4 5

7
12 13 14 15 2

6 1
8

A-A

9
107,8 – 142,2 Nm

10
58,8 – 78,4 Nm
16
B-B
11
34,3 – 44,1 Nm

17
RKP15900

C-C

1. Output shaft 9. Safety valve

2. Body 10. Check valve
3. Shoe 11. Spring
4. Piston 12. Spring
5. Cylinder 13. Brake piston
6. Valve plate 14. Disk
7. Spring 15. Plate
8. Plate

Unit: mm
Criteria
Basic dimension Limit size
No. Control Free Remedy
length x Installed Installed Free Installed
Outside length load length load
diameter

A Check valve spring 15.5 x 9.0 11.5 0.9 N – 0.69 N

If damaged
33.0 x or deformed
B Suction valve spring 19.5 1.8 N – 1.41 N
13.8

PC80MR-3 10-29
STRUCTURE AND FUNCTION SWING MOTOR

BRAKE VALVE

OUTLINE OF CLSS 2. When swing stops

The brake valve consists of a check valve and a safety • When the swing control lever is returned to the
valve. NEUTRAL position, pressure oil from the control
valve is not sent to the Port MB. Since the return
FUNCTION
circuit for the oil from the motor outlet to the tank is
• When swing operation is stopped, outlet circuit of the closed by control valve, the pressure in port MA rises
motor is closed by the control valve. and revolution resis- tance is generated in the motor,
However, the motor will run for a while by inertial then the motor is braked.
force, so pressure at the outlet side of the motor will
• The pressure in port MA rises to the set pressure of
abnormally rise, which may cause damage to the
the safety valve. As a result, high braking torque is
motor.
generated in the motor, then the motor stops.
To avoid such danger, the safety valve releases the
abnormally high pressure oil from the outlet side of the • While the safety valve is operating, the oil discharged
motor. from the safety valve and the oil from port S are
supplied through check valve CB to port MB so that
OPERATION cavitation will not occur in port.
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 S
CA CB
starts to swing. Oil coming out of the outlet Port
returns to the tank from the Port MA though the control
valve.

CA S CB

MA MB 1

RKP15910

MA MB 1

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
1 2 a 3 4 5
pressure from rising sharply to reduce shocks when the
machine starts and stops swinging.

Modulating relief valve

P Ordinary relief valve
P
P2

P1
D2 D1 S D3 RKP16140

P0
t
T
RKP16150

OPERATION
P1
1. When circuit is > P0 P2
• 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 differ- ence between D1 S RKP16130
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 P2
(3).
• As a result, the relief pressure rises gradually from P1
to P2 while seat (1) is moving to sleeve (5).

S
RKP15920

PC80MR-3 10-31
STRUCTURE AND FUNCTION SWING MOTOR

OPERATION OF SWING BRAKE

1. When solenoid valve is de-energized 2. When solenoid valve is energized

OPERATION OPERATION
• When the solenoid valve of the swing brake is de- • When the solenoid valve of the swing brake is
energized, the hydraulic oil from the self- pressure energized, the valve is changed and hydraulic oil from
reducing valve is shut off and port B is connected to the self-pressure reducing valve flows through port B
the tank circuit. into brake chamber A.
• For this reason, brake piston (13) is pushed up by • The hydraulic oil in chamber A pushes brake spring
brake spring (12), and disc (14) and plate (15) are (12) and brake piston (13) moves down. As a result,
pushed together to apply the brake. disc (14) and plate (15) are separated and the brake is
released.

Self-pressure Self-pressure
reducing valve reducing valve

De-energized Energized

Main pump Main pump

Swing brake Swing brake
solenoid valve solenoid valve

15 15
14 14
B B
A A
13 13

12 12

RKP16170 RKP15930

10-32 PC80MR-3
STRUCTURE AND FUNCTION SWING MOTOR

REVERSE ROTATION PREVENTION LEVEL

1 2 3 4 MA T1

7 6 5 T2 MB
A-A Z
RKP15940

MA: Port 1. Body

MB: Port 2. Spool (MA Side)
T1: Port 3. Spring (MA Side)
T2: Port 4. Plug (MA Side)
5. Spool (MA Side)
6. Spring (MA Side)
7. Plug (MA Side)

PC80MR-3 10-33
STRUCTURE AND FUNCTION SWING MOTOR

EFFECT EXPLANATION DRAWING

With reverse rotation

prevention valve
Reverse Wihout reverse rotation
rotation pressure prevention valve

MA pressure
Containment
pressure Reverse
rotation pressure

MB 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 2. After motor stops Operation

• This valve reduces the swing back generated in the • The motor is reversed by the closing pressure
swing body by the inertia of the swing body, the generated at port MB. (1st reversal)
backlash and rigidity of the machinery sys- tem, and • When this happens, reversal pressure is generated at
the compression of the hydraulic oil when the swing is port MA. Pressure MA goes to chamber a,
stopped. compresses spring (3), spool (2) moves to the right,
• This is effective in preventing spillage of the load and MA o b is connected.
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 3
a

MA
MA

MB
MB b f
Notch K RKP16240 5 RKP15960

1. 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.

2 3
d b

MA

MB T

D1 D2 e f
6 5 RKP16230

PC80MR-3 10-35
PAGE INTENTIONALLY
LEFT BLANK
STRUCTURE AND FUNCTION ATTACHMENT

ATTACHMENT

A C

C A

E E
D D B
P T

P2 P4

P3 P1
RKP16450
Z

L.H. PPC VALVE R.H. PPC VALVE

P1: Arm (open) P1: Boom (lower)
P2: Arm (closes) P2: Boom (raise)
P3: Swing (R.H.) P3: Bucket (Dump)
P4: Swing (L.H.) P4: Bucket (Curl)
P: Feed P: Feed
T: Drain T: Drain

PC80MR-3 10-37
STRUCTURE AND FUNCTION ATTACHMENT

6
7 11,6 – 14,7 Nm
5

4
8

3 9
12
2
14

1 10
B-B

34 – 44 Nm 11

98 – 127 Nm

39 – 49 Nm

13
D-D 6 – 11 Nm

4 – 9 Nm

14

C-C

E-E RKP16460

1. Spool 7. Joint
2. Adjusting screw (inner) 8. Cover
3. Adjusting screw (outer) 9. Retainer
4. Piston 10. Body
5. Disk 11. Filter
6. Nut

10-38 PC80MR-3
STRUCTURE AND FUNCTION ATTACHMENT

Unit: mm
Criteria
Basic dimension Limit size
No. Control Free Remedy
length x Installed Installed Free Installed
Outside length load length load
diameter
Return spring (outer) (for ports 42.48 x
12 34.0 17.65 N – 14.1 N
P3 and P4) 15.5

13 Return spring (outer) (for ports 44.45 x 34.0 29.42 N – 23.5 N If damaged
P1 and P2) 15.5 or deformed
26.47 x
14 Adjusting screw (inner) 24.9 16.66 N – 13.3 N
8.20

PC80MR-3 10-39
STRUCTURE AND FUNCTION ATTACHMENT

PPC VALVES OPERATION a) as long as pressures at ports A and P1 are

perfectly balanced;
1. Control lever in neutral position
• Ports A and B of the control valve and Ports P1 and P2 b) until pressure in section A-P1 – i.e. the pressure
of the PPC valve are connected to drain chamber D acting on stem (1) – is enough to counteract the
through fine control hole f in spool (1). force of the spring (2).
• This ensures proportionality between control lever
position, A-P1 circuit pressure, and main control
valve stem displacement.

5
D 4
f T
9
P
2
D
1 f T
P3 (P1) P4 (P2) P

1 PP
A B
Control valve
RKP01090 P1 P2 10

2. During fine control (NEUTRAL o Actuator)

• When piston (4) starts to be pushed by disc (5), A B
Control valve
retainer (9) is pushed; spool (1) is also pushed by
metering spring (2), and moves down. RKP01102

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 PC80MR-3
STRUCTURE AND FUNCTION ATTACHMENT

3. During fine control (Actuator o NEUTRAL) 4. Control lever at full stroke

• When the disk (5) is released and moved to neutral (NEUTRAL o Full stroke)
position, the piston (4) is pushed upwards by the • When the disk (5) pushes down on the piston (4), and
spring (3) acting on the retainer (9), and spool (1) is the retainer (9) pushes down on the spool (1),
thrusted upwards both by the force of spring (2) and calibrated hole f is put in direct connection with
by the force that the pressure in section A-P1. chamber PP, which is in turn connected to a
applies against the stem. This movement moves the constantly pressurised servocontrols circuit.
calibrated hole f of spool (1) into the discharge • Oil is then allowed to flow directly into section A-P1,
chamber D, thereby allowing pressure in section A- thereby pushing the stem of the main control valve to
P1 to be released. the end of its travel. This causes the main control
• If pressure P1 drops too quickly, spool (1) is pushed valve to send the oil contained in chamber B towards
downwards by spring (2) and the calibrated hole f input P2, through calibrated hole f’ and into discharge
becomes cut off from the discharge chamber D; at chamber D.
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.
5
• When the spool of the control valve returns, oil flows
back into chamber D, through calibrated hole f’, and 4
into chamber B of the control valve spool opposite the
operating one. 9
Oil flows through duct P2 and into chamber Bo ensure
it is filled properly.
D
f T
P
f

5 1 PP

4 P1 P2

3
2 A Control valve
B
D
f T RKP01120

P
f
1 PP
P1 P2

A Control valve
B

RKP01110

PC80MR-3 10-41
STRUCTURE AND FUNCTION TRAVEL PPC VALVE

TRAVEL PPC VALVE

C C

A A

T P
B

P2 P1

P4 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 8

7,8 – 9,8 Nm

A-A B-B

27 – 34 Nm

2
1

10
3
4
7
9
4 – 9 Nm
D D
C-C
6 – 11 Nm
D-D
6
5
3,9 – 4,9 Nm
RKP16480

1. Piston 5. Spool
2. Cover 6. Adjusting screw (inner)
3. Gasket 7. Adjusting screw (outer)
4. Body 8. Screw
Unit: mm
Criteria
Basic dimension Limit size
No. Control Free Remedy
length x Installed Installed Free Installed
Outside length load length load
diameter
26.53 x
9 Return spring (outer) 24.9 16.7 N – 13.3 N
8.5 If damaged
52.06 x or deformed
10 Adjusting screw (inner) 31.9 135.2 N – 108 N
15.5

PC80MR-3 10-43
STRUCTURE AND FUNCTION TRAVEL PPC VALVE

1. Control lever in neutral position P1 increases in proportion to the travel of the lever (5).
• Ports A and B of the control valve and Ports P1 and P2 The equilibrium position is then kept until the position
of the PPC valve are connected to drain chamber D of piston (4) is changed, i.e.:
through fine control hole f in spool (1).
a) as long as pressures at ports A and P1 are
perfectly balanced;

b) 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
D valve stem displacement.

f
T
P
5
1
4
P1 P2 9 D
2
A Control valve B
f T
P

RKP16490 1
PP
P1 P2
2. During fine control 10
(NEUTRAL o fine control)
• When piston (4) starts to be pushed by lever (5), A Control valve B
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 RKP16500
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 PC80MR-3
STRUCTURE AND FUNCTION TRAVEL PPC VALVE

3. During fine control (Actuator o NEUTRAL) 4. Control lever at full stroke

• When the control lever (5) is released and moved to (NEUTRAL o Full stroke)
neutral position, the piston (4) is pushed upwards by • When the lever (5) pushes down on the piston (4), and
the spring (3) acting on the retainer (9), and stem (1) is the retainer (9) pushes down on the stem (1),
thrust upwards both by the force of spring (2) and by calibrated hole f is put in direct connection with
the force that the pressure in section A-P1. chamber PP, which is in turn connected to a
applies against the stem. This movement moves the constantly pressurised servocontrols circuit.
calibrated hole f of stem (1) into the drain chamber D, • Oil is then allowed to flow directly into section A-P1,
thereby allowing pressure in section A-P1 to be thereby pushing the stem of the main control valve to
released. the end of its travel. This causes the main control
• If pressure P1 drops too quickly, spool (1) is pushed valve to send the oil contained in chamber B towards
downwards by spring (2) and the calibrated hole f input P2, through calibrated holef and into discharge
becomes cut off from the discharge chamber D; at chamber D.
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 5
into chamber B of the control valve spool opposite the
operating one. 4
Oil flows through duct P2 and into chamber B to D
ensure it is filled properly. 9

f T
P

1
5 PP
P1 P2
3 D
A Control valve B
2
f T RKP16520
P

1
PP
P1 P2

A Control valve B

RKP16510

PC80MR-3 10-45
STRUCTURE AND FUNCTION BLADE, BOOM SWING, 2-PIECE BOOM PPC VALVES

BLADE, BOOM SWING, 2-PIECE BOOM PPC VALVES

P1 P2

5 11,76 Ð 14,7 Nm

4
6

7 11
3
2
8 10 8,8 Ð 11,8 Nm
1
9
A-A RKP16540

BLADE PPC VALVE BOOM SWING PPC VALVE 2-PIECE BOOM PPC VALVE
P: Delivery P: Delivery P: Delivery
T: Drain T: Drain T: Drain
P1: Blade (raise) P1: Swing (R.H.) P1: 2-piece boom (open)
P2: Blade (lower) P2: Swing (L.H.) P2: 2-piece boom (closes)

1. Spool 6. Cover
2. Adjusting screw (inner) 7. Retainer
3. Adjusting screw (outer) 8. Body
4. Piston 9. Filter
5. Lever

10-46 PC80MR-3
STRUCTURE AND FUNCTION BLADE, BOOM SWING, 2-PIECE BOOM PPC VALVES

BLADE PPC VALVE

Unit: mm
Criteria
Basic dimension Limit size
No. Control Free Remedy
length x Installed Installed Free Installed
Outside length load length load
diameter

10 Return spring (outer) 42.4 x

32.5 147 N – 118 N
32.5 If damaged
22.7 x or deformed
11 Adjusting screw (inner) 22.0 16.7 N – 13.3 N
8.10

BOOM SWING, 2-PIECE BOOM PPC VALVE

Unit: mm
Criteria
Basic dimension Limit size
No. Control Free Remedy
length x Installed Installed Free Installed
Outside length load length load
diameter
33.9 x
10 Return spring (outer) 28.4 125 N – 100 N
15.3 If damaged
22.7 x or deformed
11 Adjusting screw (inner) 22.0 16.7 N – 13.3 N
8.10

PC80MR-3 10-47
STRUCTURE AND FUNCTION BLADE, BOOM SWING, 2-PIECE BOOM PPC VALVES

PPC VALVES OPERATION The spring (2) is compressed proportionally to the

movement of the lever (5) and therefore, pressure at
1. Control lever in neutral position P1 increases in proportion to the travel of the lever (5).
• Ports A and B of the control valve and Ports P1 and P2 The equilibrium position is then kept until the position
of the PPC valve are connected to drain chamber D of piston (4) is changed, i.e.:
through fine control hole f in spool (1).
a) as long as pressures at ports A and P1 are
perfectly balanced;
b) 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.

D
T
5
f P
4
1
P1 P2
7 D

T
2
A Control valve B 8

RKP13730
f P

2. During fine control (NEUTRAL o Actuator) 1 P1 P2

• 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. PP
As a result of this action, the calibrated hole f will be
A Control valve B
isolated from the discharge chamber D and at almost
at the same time it will be put in connection with the PP
RKP13750
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 PC80MR-3
STRUCTURE AND FUNCTION BLADE, BOOM SWING, 2-PIECE BOOM PPC VALVES

3. During fine control (Actuator o NEUTRAL) 4. Control lever at full stroke

• When the control lever (5) is released and moved to (NEUTRAL o Full stroke)
neutral position, the piston (4) is pushed upwards by
When the lever (5) pushes down on the piston (4), and
the spring (3) acting on the retainer (9), and stem (1) is
the retainer (9) pushes down on the stem (1),
thrust upwards both by the force of spring (2) and by
calibrated hole f is put in direct connection with
the force that the pressure in section A-P1.
chamber PP, which is in turn connected to a
applies against the stem. This movement moves the
constantly pressurised servocontrols circuit.
calibrated hole f of stem (1) into the drain chamber D,
thereby allowing pressure in section A-P1 to be Oil is then allowed to flow directly into section A-P1,
released. thereby pushing the stem of the main control valve to
• If pressure P1 drops too quickly, spool (1) is pushed the end of its travel. This causes the main control
downwards by spring (2) and the calibrated hole f valve to send the oil contained in chamber B towards
becomes cut off from the discharge chamber D; at input P2, through calibrated holef and into discharge
almost the same time, the calibrated hole f is put in chamber D.
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 5
into chamber B of the control valve spool opposite the
operating one. 4
Oil flows through duct P2 and into chamber B to
ensure it is filled properly.

7 D

T
5 2
8
P
4 f

1 P1 P2
PP f'
7 D

T
2 A Control valve B
P
f RKP13770

1 PP P1 P2 f'

A Control valve B

RKP13760

PC80MR-3 10-49
STRUCTURE AND FUNCTION EQUIPMENT

EQUIPMENT

E
D E
D
A
A

G
G
C C
F
B B
F

P R
H P
M L S
H J R
JK M
T S
K L T
N
N RKP16530

Unit: mm
Criteria
No. Control Allowable Standard Clearan Remedy
Basic ce
dimension Ø Shaft Hole clearance
Limit
Clearance betweenbushing and -0.036 +0.204 0.161 –
1 110 1.0
swingbracketrotating pin -0.090 +0.125 0.294
Clearance between bushings -0.030 +0.174 0.130 –
2 65 1.0
and boom mounting pin -0.100 +0.100 0.274
Clearance between bushings -0.030 +0.174 0.130 –
3 60 1.0
and arm mounting pin -0.100 +0.100 0.274
Clearance between arm -0.225 +0.062 0.105 –
4 bushings and bucket mounting 50 1.0
-0.285 +0.120 0.223
pin
Replace
Clearance between bushings -0.225 +0.062 0.105 –
5 50 1.0
and lever mounting pin -0.285 +0.120 0.223
Clearance between bushings -0.030 +0.173 0.130 –
6 60 1.0
and lever mounting pin -0.100 +0.100 0.273
Clearance between
-0.225 +0.040 0.131 –
7 linkbushings and bucket 50 1.0
-0.285 +0.094 0.245
mounting pin
Clearance between blade -0.025 +0.142 0.105–
8 50 1.0
fulcrum pin and bushing -0.087 +0.080 0.229

10-50 PC80MR-3
STRUCTURE AND FUNCTION EQUIPMENT

B-B C-C

D-D E-E

A-A 1 3

F-F G-G H-H J-J

4 5 6 7

K-K

L-L M-M N-N P-P

8

R-R S-S 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
METHODS FOR TESTING FOR LEAKAGES
TESTING AND ADJUSTING FUEL INJECTION
INSIDE THE SWIVEL JOINT............................................. 57
TIMING .............................................................................. 30
ELIMINATING PRESSURES FROM CIRCUITS ............... 58
CHECKING ENGINE OIL PRESSURE ............................. 34
MEASUREMENT OF CLEARANCE IN SWING
CHECKING AND REGULATING PRESSURE IN THE
CIRCLE BEARINGS .......................................................... 59
HYDRAULIC CIRCUITS.................................................... 35
TESTING AND ADJUSTING TRACK SHOE TENSION .... 60
CHECKING AND CALIBRATING PRESSURE IN THE
SECONDARY VALVES..................................................... 37 AIR BLEEDING FROM HYDRAULIC CIRCUITS .............. 61
CHECKING AND ADJUSTING THE LS TESTING THE AIR-CONDITIONING UNIT ....................... 64
(Load Sensing) VALVE...................................................... 40
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

Machine model PC80MR-3

Engine 4D88E-5KFD

Standard Permissible
Check item Test conditions Unit
value value
+ 100
High idling (no-load) 2250 – 50 —
Engine speed
Low idling (no-load) rpm 1100 ± 50 —
(without load):
Max. power rating 2000 —

Sudden acceleration Max. 3.5 6.0

Index
Exhaust gas colour
Bosch
At high idling speed Max. 1.0 2.0

Intake valve (20 °C) 0.35 ± 0.02 —

Valve clearance mm
Dump (20 °C) 0.50 ± 0.02 —

Compression
Oil temperature: 40-60°C
pressure kg/cm2 Min. 30 21
Engine speed: 320 -360 rpm
(SAE15W-40 oil)

Oil temperature: within range)

Blow-by pressure mmH2O 50 100
At max. power rating

Engine oil pressure Oil temperature: SAE 30 3.5 – 5.5 2.5

kg/cm2
High idling within range SAE 10W 3.0 – 5.0 2.1

Engine oil pressure Oil temperature: SAE 30 1.8 1.5

kg/cm2
Low idling within range SAE 10W 1.5 1.3

engine oil
Entire speed range ºC 90 – 110 120
temperature

Fuel injection timing

BTDC degrees 5 ± 0.75 5 ± 0.75
advance

Deflection when pressed with finger force

Fan-belt tension mm 6 – 10 6 – 10
of approx. 6 kg

Belt tension
Deflection when pressed with finger force
air conditioner mm 6 – 10 6 – 10
of approx. 6 kg
compressor

PC80MR-3 20-3
(1)
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA

FOR MACHINE

Machine model PC80MR-3

Classifi Standard Permissible
Check item Test conditions Unit
cation value value
• Oil temperature 45 – 55°C
Engine speed with • Coolant circuit needed: at working
Engine

pump at max. temperature. rpm 2080±100 1980 – 2180

pressure • With boom raise in mode system P
• With boom raise + swing in mode system P

Boom control Neutral oRaise,

85 76.5 – 93.5
lever Lower
Arm control Neutral o Open
85 76.5 – 93.5
lever Close
Neutral o Dump
Bucket control lever 85 76.5 – 93.5
Curl
Travel of levers and pedals

Revolving frame • Equipment on the Neutral o Swing R.H.

ground 85 76.5 – 93.5
swing lever Swing L.H.
• Engine: switched off
• At the end of the Neutral oRaise
Blade control lever mm 53 47.7 – 58.3
lever and at 90°. Lower
Reading at bottom of
stroke, adding half Neutral o Swing R.H.
Boom swing pedal 15 13.5 – 16.5
freeplay Swing L.H.
Neutral o Forward
Travel control lever 115 103.5 – 126.5
Reverse
2-piece boom Neutral o Open 20 18 – 22
control pedal Close 30 27 – 33
Optional attachment Neutral o R.H.
– –
pedal L.H.

Boom lever 1.75 1.4 – 2.1

Operaring force for control of levers and pedals

Arm lever 1.75 1.4 – 2.1

Bucket lever 1.5 1.04 – 2.0

Revolving frame
1.5 1.04 – 2.0
swing lever

Blade lever kg 2.6 2.08 – 3.12

Boom swing pedal 7.8 6.0 – 9.6

Travel levers 2.0 1.5 – 2.6

Neutral o Open 3.8 3.04 – 4.56

2nd boom pedal
Close 1.8 1.44 – 2.16
Optional attachment Neutral o R.H. 2.3 1.8 – 2.8
pedal L.H. 3.7 3.2 – 4.2

20-4 PC80MR-3

(1)
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA

Machine model PC80MR-3

Classific Standard Permissible

Check item Test conditions Unit
ation value value

General valve P1
(boom – arm - bucket)
265 256 – 275
- Boom swing and
travel

Main valve P2
211 201 – 215
(Blade - Swing)

Revolving frame
With blade raise 196 196 – 201
secondary valve

• Hydraulic system oil

Hydraulic pressure

Measured on the
Servocontrols feed temperature: 45-55 °C
servocontrols 31.4 31.4 – 33.3
valve • Engine speed: Max.
outlet tube
bar
Secondary valve for
optional attachment

Load limiter with 1- Measure on the

115 110– 120
piece boom cylinder

Load limiter with 2- Measure on the

110 105 – 115
piece boom cylinder

• Hydraulic system oil temperature: 45-55 °C

• Pressure difference with engine under load at
Pressure drop Max. 20 Max. 20
high idling and with engine at max. power
rating

Measuring position: See Fig. A

• Engine speed: Max.
Revolving frame • Hydraulic system oil temperature: 45-55 °C
• Swing the revolving frame 1 turn, and release the sec. 0.7 0.7–2
inertia
lever control.
• Measure the delay between actuator release
and stop.
Swing

Measuring position: See Fig. A

Time needed to start • Engine speed: Max. 90° : 2.2±0.3 90° : Max. 2.8
swing motion • Hydraulic system oil temperature: 45-55 °C sec.
180° : 3.7±0.3 180° : Max. 4.3
(after command) • Time required to swing 90° and 180°, after
command

PC80MR-3 20-5
(1)
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA

Machine model PC80MR-3

Classifi Standard Permissible
Check item Test conditions Unit
cation value value

Measuring position: See Fig. A

• Engine speed: Max.
• Hydraulic system oil temperature: 45-55 °C
• Mode system: P
Time taken to swing sec. 28 26.4 – 32
• Perform one turn to settle the machine and
measure the time needed to perform the next 5
turns.
• Check in both directions of rotation

Measuring position: See Fig. B

• Engine: switched off
• Hydraulic system oil temperature: 45-55 °C
• Revolving frame swung by 45° with vehicle on a mm
Swing

Mechanical drift of 0 0
15° slope. (degre
revolving frame (0) (0)
• Blade lowered. es)
• On the outer swing circle, mark the position
between turret and track frame.
• After 15 minutes measure the drift.

• Engine speed: Max.

Internal leakage from • Hydraulic system oil temperature: 45-55 °C l/
swing motor • Revolving frame locked min.
• Measure the leakage

Steel shoes

26.0 23.4 – 28.6

Normal

Measuring position: see Fig. D Rubber shoes

• Engine speed: Max.
• Mode system: P 24.0 21.5 – 26.5
Travel

• Hydraulic system oil temperature: 45-

Travel speed: sec.
55 °C
• Drive for at least 5 m, and then
Steel shoes
With increment

measure the time needed to cover 20

m 15.3 13.9 – 17.0

Rubber shoes

15.0 13.6 – 16.7

20-6 PC80MR-3

(1)
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA

Machine model PC80MR-3

Classifi Standard Permissible
Check item Test conditions Unit
cation value value

Measuring position: see Fig. D

• Mode system: position P
• Engine speed: Max.
Travel deviation • Hydraulic system oil temperature: 45-55 °C mm Max. 200
• After driving for 5 metres and then covering
another 20 metres.
• Measure deviation “X” (see Fig. E)
Travel

Measuring position: see Fig. F

• Engine: switched off
Hydraulic drift of travel • Hydraulic system oil temperature: 45-55 °C
mm 0 0
motors • Machine parked on sloping ground with blade
raised.
• Measure the drift after 5 minutes

• Engine speed: Max.

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

PC80MR-3 20-7
(1)
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA

Machine model PC80MR-3

Classifi Standard Permissible
Check item Test conditions Unit
cation value value
Total work equipment Standard
(Standard boom) Max. 350 Max. 600
boom
(Downward Measuring position: see Fig. G.
mo veme nt buc ket Max. 490 –
• In this position, measure extension or Long boom
teeth tips) retraction of each cylinder, and any
leakages occurring when a load is
applied to the tips of the bucket teeth.
Bomm cylinder • Horizontal and level ground. Max. 8 Max. 12
(Retraction) • Load in the bucket: 620 kg
• Levers: neutral
• Engine: switched off
• Hydraulic system oil temperature: 45-
Arm cylinder 55 °C
Work equipment (Hydraulic drifts)

• Safety valve disengaged Max. 41 Max. 62

(Extension)
• Take measurements as soon as the
engine stops.
• Measure the variations every 5
minutes and check the total variation
Arm cylinder after 15 mins.
mm Max. 25 Max. 38
(Retraction)

• Engine: switched off

• Hydraulic system oil temperature: 45-55 °C
Blade cylinder Max. 20 Max. 30
• Measure blade descent from max. height within a
timeframe of 15 minutes.

Measuring position: see Fig. H. Standard

Max. 16 –
• Engine: switched off boom
Boom swing
• Hydraulic system oil temperature: 45-
(Standard boom)
55 °C Long boom Max. 16 –
• In the same position as above, park the
machine on a 15° slope and bring the
turret round to 135°. Standard
Max. 16 –
Boom swing Measure the extension and retraction boom
(Boom + 2-piece of the cylinder after 15 mins.
boom) • Repeat the procedure on the other Long boom Max. 16 –
side.
Cylinder leankage

• Hydraulic system oil temperature: 45-55 °C cc/

All cylinders Max. 1.5 Max. 7.5
• Pressurize the cylinder min

20-8 PC80MR-3

(1)
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA

Machine model PC80MR-3

Classifi Standard Permissible
Check item Test conditions Unit
cation value value

Boom
2.6 2.35–2.95
Bucket teeth Measuring position: Raise
(2.5) (2.2–2.8)
on the ground See Fig.I.
• Engine speed: Max.
• Hydraulic system oil temperature: 45-
Cylinders 55 °C
2.8 2.5–3.1
completely • ( ): with long arm Lower
(2.55) (2.1–3.0)
extended

2nd boom
Cylinder
Measuring position: Closed 6.0 4.8–7.2
completely
See Fig. J.
retracted
• Working Mode: P
• Engine speed: Max.
• Hydraulic system oil temperature: 45-
Cylinders 55 °C Inout 6.0 4.8–7.2
completely
extended
Arm
Cylinder 3.3 3.0–3.6
Closed
completely Measuring position: (3.4) (3.1–3.7)
retracted See Fig. K.
• Engine speed: Max.
Work equipment (Speed)

• Oil temperature 45 – 55°C

Cylinders • ( ) boom with safety valve 2.9 2.6–3.2
Inout
completely (3.5) (2.8–3.4)
extended
sec.
Bucket
Cylinder
Closed 3.4 3.1–3.7
completely Measuring position:
retracted See Fig. L.
• Engine speed: Max.
• Hydraulic system oil temperature:
Cylinders 45-55 °C
Inout 2.6 2.3–2.9
completely
extended
Boom swing
Cylinder
Left 6.7 6.0–7.4
completely Measuring position:
retracted See Fig.M.
• Engine speed: Max.
• Hydraulic system oil temperature:
Cylinders 45-55 °C
Right 6.7 6.0–7.4
completely
extended

Blade Raise 1.3 1.0–1.6

Measuring position:
Blade on the ground
See Fig. N.
• Engine speed: Max.
• Hydraulic system oil temperature:
Blade at 45-55 °C
maximum height Lower 1.1 0.8–1.4

PC80MR-3 20-9
(1)
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA

Machine model PC80MR-3

Classifi Standard Permissible
Check item Test conditions Unit
cation value value

Measuring position:
See Fig. O.
• Engine speed: low idling
Boom • Hydraulic system oil temperature: 45-55 °C Max. 2 Max. 3.9
• Retract fully the cylinders of the arm and bucket.
Lower bucket to ground and measure time taken for
chassis to rise from ground.

Measuring position:
See Fig. P.
• Engine speed: low idling
Boom ( 2 - p i e c e • Hydraulic system oil temperature: 45-55 °C
Max. 2 Max. 3.9
boom) • 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.

Measuring position:
See Fig. Q.
• Engine speed: low idling
• Hydraulic system oil temperature: 45-55 °C
Work equipment (Time lags)

2nd boom
• 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.
• Engine speed: low idling
Arm • Hydraulic system oil temperature: 45-55 °C 0 Max. 1
• 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.
• Engine speed: low idling
Bucket • Hydraulic system oil temperature: 45-55 °C 0 Max. 1
• 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.
• Engine speed: low idling
Blade • Hydraulic system oil temperature: 45-55 °C 1 Max. 2
• 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.

20-10 PC80MR-3

(1)
TESTING AND ADJUSTMENTS PUMP FEATURES

PUMP FEATURES
PC80MR-3
Delivery of piston pumps

PC80MR-3 20-11
(1)
TESTING AND ADJUSTMENTS CHECK POSITIONS

CHECK POSITIONS

Fig. A Fig. B

45°

15°
RKP16600 RKP16610

Fig. C Fig. D

45°

RKP16620
RKP16630

20-12 PC80MR-3

(1)
TESTING AND ADJUSTMENTS CHECK POSITIONS

Fig. E Fig. F

20 m

30°

10 m 5m

RKP19950 RKP16650

Fig. G Fig. H

15°

135°
RKP16660 RKP16670

PC80MR-3 20-13
(1)
TESTING AND ADJUSTMENTS CHECK POSITIONS

Fig. J Fig. K

RKP16680 RKP16690

Fig. L Fig. M

RKP16700 RKP16710

20-14 PC80MR-3

(1)
TESTING AND ADJUSTMENTS CHECK POSITIONS

Fig. N Fig. O

RKP16720 RKP16770

Fig. P Fig. Q

RKP16740
RKP16730

PC80MR-3 20-15
(1)
TESTING AND ADJUSTMENTS CHECK POSITIONS

Fig. R Fig. S

RKP16750 RKP16760

Fig. T

RKP16780

20-16 PC80MR-3

(1)
TESTING AND ADJUSTMENTS SPECIAL TOOLS

SPECIAL TOOLS

Measurement check
Symbol Code Name Remarks
points

Digital display
1 709-203-9000 Multi-scale tachometer L: 60 -2000 rpm
Engine speed A R: 60 -19999 rpm

2 6210-81-4111 Diverter

Coolant liquid temperature B 799-101-1500 Digital temperature gauge -50 -1.200 °C

1 799-101-5002 Pressure gauge kit Scale 25-60-400-600 bar

790-261-1203 Digital pressure gauge Scale 600 bar

2 799-401-2320 Pressure gauge Scale 10 bar

799-101-5160 Union

3 799-101-5220 Union
Hydraulic pressure C
07002-11023 O-ring
799-401-2910 Union

4 02896-11008 O-ring

07043-00108 Union Hexagonal hole

5 799-401-2701 Differential pressure gauge

Compression pressure
1 795-502-1590 0–70 bar - (kit 795-502-1205)
Compression pressure D gauge

2 795-502-1370 Adapter

Blow-by pressure E 799-201-1504 Pressure gauge

Commercially
Valve clearance F Feeler gauge
available
0–70% with standard colour
1 790-201-9001 Probe
(%x1/10= Bosch scale)
Exhaust smoke G
Commercially
2 Readout device
available

Commercially
Force monitoring H Force gauge
available
Commercially
Drift monitoring I Gauge
available

Commercially
Attachment speed J Chronometer
available

YM158090-
1 Adapter
51841
YM23000-
K 2 Dial gauge port
013000
Injection advance check
Commercially
3 Dial gauge Travel 30 mm
available

Commercially
L Dial gauge Magnetic base
available

PC80MR-3 20-17
(1)
TESTING AND ADJUSTMENTS SPECIAL TOOLS

Measurement check
Symbol Code Name Remarks
points

790-601-9320 Connector 24 pins

1
790-601-9310 Plate For 40-pole connector

2 799-601-8000 Full adapter

799-601-7310 Adapters

Connector monitoring K 799-601-7050

799-601-7520
3
799-601-7360

799-601-7370

799-601-9200 Adapters Kit

Commercially
Fuel injection timing O 1 Dial gauge
available

20-18 PC80MR-3

(1)
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, 2 3
install and connect sensor (3) of speedometer A1 to the 1
injection pipe (2).

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) a
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. 3 4 A1 RKPC0460

Bring the pump under load and rev up the engine to

Max. speed, then measure stabilized speed.
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 -Remove inspection cap (1) and apply a reflecting mark 1
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 PC80MR-3
(1)
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 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 RKPC0490

scale, take the intermediate value.

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 1
G2.

RKPC0500

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

4
a Before connecting the power cable, ensure that the
instrument switch is in the “OFF”position. G2

4 -Loosen the plug (5) of the suction pump and introduce a

paper filter. 3
a Ensure that the filter is properly seated, or the
exhaust smoke will be unable to pass through it.
1

2 5 RKPC0510

PC80MR-3 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 PC80MR-3
(1)
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.

RKPC7330

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

4
6

6
RKPC7340

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

(7). 6

6 7

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.

8
8

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.

10

RKPC7390

20-24 PC80MR-3
(1)
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 1 2 3 4

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 2 5
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

6 7

lock nut without previously securing the bridge into

position with a wrench to prevent it from rotating.

RKP19800

3 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 7
notice a clearance (1) between bridge and front valve 4
3
(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.
P
7
3

RKP19820

20-26 PC80MR-3
(1)
TESTING AND ADJUSTMENTS ADJUSTING VALVE CLEARANCE

7 -Tighten nut (6) while simultaneously holding the

adjusting screw (7) into position and ensure that 7
clearance (1) continues to be equal to zero while 6
tightening.
1
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 11
screw (11) by approximately 1 turn.
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). 12

F
4
RKP19840

10 -Tighten the adjusting screw (11) until it rubs against

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

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:
1
• Engine: at working temperature.
• Hydraulic oil: 55-60 °C.
• Battery: fully charged
• Valve clearance: adjusted RKPC7392

(See "ADJUSTING VALVE CLEARANCE").

1 -Remove the valve cover (1).
(For details, see "REMOVAL OF VALVES COVER"). 2
3
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). 5
a Pay attention not to kink the line.

RKPC7420

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

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

10
7
11

8
RKPC7430

20-28 PC80MR-3
(1)
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).

12

RKPC7301

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

gauge D1. D2

9 -Crank the engine using the starter and read the

pressure.

a Read the compression value when the

compression gauge has stabilised. D1
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

a Difference between cylinders: 2–3 bar

Compression pressure (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.
1
Test 2
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.

K2

K1

RKP19880

5 -Install a centesimal dial gauge K3 (30mm head travel)

and lock into position at about half way of its working
stroke.
K3

RKP19890

20-30 PC80MR-3
(1)
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 6
becomes visible in the inspection hole (8).
5

7
RKP19900

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

9
8

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").
9 A

RKP19920

9 -Slowly rotate the flywheel counterclockwise until the dial

gauge K3 completes its maximum stroke down.
K3
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 9
hole notch and advance) match, advance is correct.
A
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 9 A
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. RKP19920

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). 12
11

10

RKPC7460

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

delivery lines. 14

5 -Loosen the fuel delivery lines (14) on the pump. 13

13
RKPC7470

20-32 PC80MR-3
(1)
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.

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.

C2
C3

RKPC0590

20-34 PC80MR-3
(1)
TESTING AND ADJUSTMENTS CHECKING AND REGULATING PRESSURE IN THE HYDRAULIC

CHECKING AND REGULATING PRESSURE IN THE HYDRAULIC

CIRCUITS
INTRODUCTION • Each section is protected by safety valve with pre-
setting cartridge.
• The control valve is divided into two normally
1 - Main relief valve (Section 1)
independent sections, supplied by pumps P1 e P2
2 - Main relief valve (Section 2)
respectively.
3 - Safety valve
• Each section is protected against overpressures by
a main (or primary) relief valve with a regolable
cartridge.

SECTION 1
P3

SECTION 2
P2

DIESEL P1 P2 2
TANK

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 Control Ports

Swing (Left-Right) A1 - B1
2 10 10
Blade: (Lower - Raise) A2 - B2
9 9
L.H. travel motor
(Forward-Backward)
A3 - B3 8 8
7 7
R.H. travel motor
(Backward-Forward)
A4 - B4 6 6
5 5
Boom (Raise-Lower) A5 - B5
4 4
Arm (Open-Close) A6 - B6
3 3
1 Bucket (Curl-Dump) A7 - B7 2 2
Boom swing
A8 - B8
1 1
(Left-Right)

* 2nd boom
A9 - B9
PORTS A B RKP10592

(Open-Close)

Attachment
A10 - B10
(L.H. side - R.H. side)

* Opzional

20-36 PC80MR-3
(1)
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
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 4
3
digital pressure gauge C1 to one of the check points.

2
2

P2 P1

RKPC7510

2. Checking revolving frame rotational

pressure
1 -Lock the revolving frame into position by fully extending
C1
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 1
direction.
• To DECREASE pressure, turn in an
COUNTERCLOCKWISE direction. 2

k Adjusting amount for one turn of the screw: about RKPC7550

120 bar.

2 -Lock the position with nut.

3 Lock nut 39–49 Nm

1

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. C1
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 PC80MR-3
(1)
TESTING AND ADJUSTMENTS CHECKING AND CALIBRATING PRESSURE IN THE SECONDARY

5. Adjusting secondary valve for boom,

arm, bucket, boom swing and travel 1
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. 2
• To DECREASE pressure, turn in an
COUNTERCLOCKWISE direction. 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. C1
3 -Start and run the engine at Max. speed and check C3
pressure without load (unloading) with all control levers
in neutral position.

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 -Disconnect hose (1) and connect a “T” fitting. Fit a 1
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 C1

the conditions shown in table 1.

C3

C3
RKPC7590

Table 1

Accelerator Differential
Work
mode
lever Operation pressure C1
position. (bar)
Lever at
P Max. –
NEUTRAL
Bucket curl
C3
P Max. (lever operated to full 31
curl position)

RKPC0690

C1

C3

C4
RKPC0700

20-40 PC80MR-3
(1)
TESTING AND ADJUSTMENTS CHECKING AND ADJUSTING THE LS (Load Sensing) VALVE

2. With analog pressure gauge

1
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 C1
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 RKPC7600

gauge by holding it frontally.

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
C1
down.
C3
5 -Calculate differential pressure using the following
formula:
differential pressure LS = (pump delivery pressure) –
(LSpressure). C4

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.
3 4
RKPC7620
a Adjusting amount for one turn of the screw: about
12.75 bar.

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 2
differential pressure is normal, then the PC valve (1) 3
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).
1

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 2

value of torque increase will never be known,
a
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. 3
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 RKPC7790

20-42 PC80MR-3
(1)
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
1
RKPC7640

2 -Remove plug (3) and connect fitting C3; connect

pressure gauge C1 (60 bar).
C1
3 -Start and run the engine to Max. speed and check
pressure. 3
+ 1.9
a Normal pressure: 31.4 0 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 4
mm hex wrench).
• To INCREASE pressure, turn in a CLOCKWISE
direction.
• To DECREASE pressure, turn in an 5
COUNTERCLOCKWISE direction.
a Adjusting amount for one turn of the screw: about 6
3.5 bar.
4 -Tighten plug (4).
3 Plug: 20-29 Nm
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
1
• 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 C1

control lever for the circuit under examination; check
pressure.
C3
a If pressure is low, check PPC input pressure; if the
pressure is within normal values, then the PPC
valve is faulty. C4
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 q r
f - Left travel forward
g - Right travel reverse o p
h - Right travel forward m n
i - Raise boom
j - Lower boom k l
k - Arm open i j
l - Arm closing
m - Bucket dump g h
n - Bucket curl e f
o - Boom L.H. swing
p - Boom right swing c d
q - 2-piece boom closing a b
r - 2-piece-boom deployment
s - Equipment
*: Optional

RKP19940

20-44 PC80MR-3
(1)
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
1
RKPC7640

2 -Disconnect the outlet hose from the solenoid valve that

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

C4

RKPC0791

4 -Measure the output pressures from the solenoid valve

as per Table 2.

Table 2

Operating Pressure
Name EV Measuring condition Operating conditions
mode (bar)
Safety lever in operating
PCC locking PPC circuit under pressure ON 32±5
1 position
pressure
Lever in lock position Pressure not applied OFF Q
Travel speed Selector on Hi Speed increase engaged ON 32±5
2
selector Selector on Lo Speed increase disabled OFF Q
Perform one of the following
procedures: Brake is released ON 32±5
Swing motor
3 • Swing
brake
When moving the control back to
Brake is applied OFF Q
NEUTRAL (Check after 5 sec.)
Optional device
4 Service enable selector Services enabled ON 32±5
selection

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 8
• Secondary valves: set to normal values. 3

1 -Rest the work equipment on the ground, stop the engine V2

and release any residual pressures.
(For details see "ELIMINATING PRESSURES FROM 1 7
CIRCUITS").
2 -Disconnect the connector (1) for the overload alarm.
3 -Remove clamps (2). C2
4 -Loosen fittings (3), (4) and (5). 5
5 -Loosen the screws retaining the valve collars, and 6
remove pipe (6) from input C2.
4
a Plug the cylinder hole to prevent contamination.
6 -Disconnect hose (7) and connect it to input C2. 2

7 -Remove hose (8) from input V2.

9
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. 11
12 -Maintaining pressure, adjust the valve with the screw 10 10
(13), until a slight leakage of oil (just a few drops every
12
minute) is seen coming from the flange V2. 13
• To INCREASE pressure, turn in a CLOCKWISE 140 Nm
direction. 14
• To DECREASE pressure, turn in an
COUNTERCLOCKWISE direction.
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
C2
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). T
15 -Rest the equipment on the ground, stop the engine, and
release any residual pressures.
16 -Restore all connections and re-fasten the valve. P

RKP07442

20-46 PC80MR-3
(1)
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
3 -Remove connector (3) and middle bushing. 2
4
1

RKPC7710

4 -Remove plug (4), and install a pressure tap C3

connected to a pressure gauge C1.
C3
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) C1
6 -Hold the pressure and, using a thin screwdriver A, adjust A
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).

2
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).
5
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
4

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

RKP15170

20-48 PC80MR-3
(1)
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

Theorichal travel line 5m

Measuring the deviation

a m
10

m
10

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. 45°

• Engine at working temperature.

• Engine idling Min. and Max.: within the permissible
values
• Hydraulic system oil temperature: 45-55 °C
• Mod. System: P

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;

RKP15580
measure the time taken to cover an extra 20 metres.

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 26 23.4 28.6
Rubber 24 21.5 26.5

Travel speed FORWARD-BACKWARD

with increment (sec./20 m).

Track type Standard value Min. Max.

Steel 15.3 13.9 17
Rubber 15 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 5m

Measuring the deviation

a m
10

m
10

RKP12593

20-50 PC80MR-3
(1)
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. 6
3 -Disconnect the hose (1) that feeds the cylinder on the
head side. 3
a Plug the hose to keep out impurity.
1
4 -Disconnect tube (2).

a Plug the hose to keep out impurity. 5

5 -Disconnect the connector (3) for overload control.
2
6 -Remove clamps (4).

7 -Loosen the screws on the retaining straps and rotate the

safety valve (5) by 90°.
4
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 4
minutes. RKPC7691

• 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 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. 1 2
4 -Plug the arm cylinder feed hose (1) – head end – and fit 3
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 PC80MR-3
(1)
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
1 -Disconnect the hose (1) that supplies the valve (port
U2).

2 -Disconnect hose (2) – cylinder head side. 2

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.
3
a If an optional system is equipped for the 4
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. 1

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
15°
pressure.

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 1
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.
RKPC7750
• If the boom does not tend to swing, the drift is due to
the control valve.

RKPC7760

20-54 PC80MR-3
(1)
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. 4 2
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 3
is resting.
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.
1
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.
2
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
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.

3 A
a Take several measurements of the drive wheel in 2
different positions.

RKP15601

20-56 PC80MR-3
(1)
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
G F
causes of failure is the swivel joint.
2 -To confirm the defect it is sufficient to by-pass the joint by E
connecting (using an additional length of tubing) the D
input and output hoses of the joint of the branch to be
checked.
If the defect disappears, it is certainly due to the swivel
C
joint.
If the defect remains, it can be due to other causes, but B
not to the swivel joint.
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 RKP16870

examination and measuring any leakage from adjacent

branches, as set out in the following table:

TABLE A
Mark Branch to be tested (under pressure) Adjacent parts (Leakages) Mark
External leakage (visible) B
A R.H. travel motor - Backwards
R.H. travel motor - Forwards –
L.H. travel motor - Backwards C
B R.H. travel motor - Forwards
R.H. travel motor - Backwards A
L.H. travel motor - Forwards D
C L.H. travel motor - Backwards
R.H. travel motor - Forwards B
Blade cylinder head side - (rise) E
D L.H. travel motor - Forwards
L.H. travel motor - Backwards C
Blade cylinder bottom side (descent) F
E Blade cylinder head side - (rise)
L.H. travel motor - Forwards D
Speed increment G
F Blade cylinder bottom side (descent)
Blade cylinder head side - (rise) E
External leakage (visible) –
G Speed increment
Blade cylinder bottom side (descent) F
– –
H Drainage travel motor
– –

k The symbols correspond to the symbols stamped onto

the input and output ports of the swivel joint

PC80MR-3 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 PC80MR-3
(1)
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), 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.
150 ~ 200 mm
a If a value other than zero is displayed, repeat steps
RKP15630

from 3 through 5.

PC80MR-3 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. H
a
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 RKP15640
track shoe.
• Standard maximum clearance:
steel shoe specification: 5 – 15 mm
rubber shoe specification: 1-3 mm

2. Adjustment
2
• To heighten tension
1
1 -Supply grease through grease fitting (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 RKPC0860

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 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 PC80MR-3
(1)
TESTING AND ADJUSTMENTS AIR BLEEDING FROM HYDRAULIC CIRCUITS

AIR BLEEDING FROM HYDRAULIC CIRCUITS

Order for operations

Air bleeding item

1 – 2 3 4 5 6 7 8
Task
From pump
From From From From swing From travel From swing Task
Start engine to tank
pump LS circuit cylinders motor motors circuits start
circuit

• Oil change
Q Q Q Q Q Q Q Q
• Filter replacement

• Replace return filter

element
Q Q Q
• Pump replacement or
overhauling Q Q Q Q Q Q
• Suction tube removal

• Control valve replacement/

repair
Q Q Q Q
• Replace cylinder
Q Q Q
• Remove cylinder piping

• Replace swing motor

Q Q Q
• Remove swing motor piping

• Travel motor and swivel joint

replacement
Q Q Q
• Travel motor and swivel
joint removal

• Swing circuit part

replacement and removal
(PPC valve, lines, pressure
Q Q Q
switch, etc.)

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

1
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

1
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 RKPC7840

minutes.
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 PC80MR-3
(1)
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

1
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

2
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
20 25 30 35
temperature (°C)
Air outlet
6 -- 8 8 -- 10 8 -- 12 9 -- 14
temperature (°C)

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 PC80MR-3
(1)
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
L.P. (kg/cm²) H.P. (kg/cm²)
temperature (°C)
Min. Max. Min. Max.
20 1.2 2.5 6.0 9.0
25 1.0 2.5 7.5 10.5
30 1.1 2.4 9.5 13.0
35 1.3 2.4 12.0 15.5
40 1.5 1.8 18.0 18.8
45 1.8 1.9 21.5 22.0

The following conditions may be found:

Conditions Causes - Faults

• Electromagnetic pulley that slips or does not engage correctly
L.P. high - H.P. normal or low • Expansion valve blocked in open position
• Compressor damaged
• Expansion valve blocked in closed position or obstructed
• Filter saturated with moisture
L.P. low - A.P. high or normal
• 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
L.P. normal - H.P. normal • 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
L.P. high - H.P. high
• Air present in the unit
• Obstruction in the H.P. line between the compressor and the condenser-
filter 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)
L.P. normal or low - H.P. low • Obstruction in the H.P. line between the compressor and the condenser-
filter tube, before the measurement point of the H.P.
• Compressor damaged
• Compressor belt missing
L.P. roughly equal to H.P. • Electromagnetic pulley that slips or does not engage
• Compressor damaged

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

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 1
same quantity must be replaced when the air-
conditioning unit is refilled. RKPC7870

20-66 PC80MR-3
(1)
30 REMOVAL AND INSTALLATION

HOW TO READ THE MANUAL .....................................3 EQUIPMENT PPC VALVES ........................................ 56

PRECAUTIONS TO BE TAKEN WHILE WORKING .....4 • Assembly ................................................................ 56
SPECIAL TOOLS ...........................................................5 TRAVEL PPC VALVE.................................................. 57
• Removal.................................................................. 57
COUNTERWEIGHT ........................................................9
• Installation............................................................... 58
• Removal ....................................................................9
• Assembly ................................................................ 59
• Installation ...............................................................10
ADDITIONAL EQUIPMENT AND BOOM SWING PPC
INJECTION PUMP........................................................11
VALVE ......................................................................... 60
• Removal ..................................................................11
• Removal.................................................................. 60
• Installation ...............................................................13
• Installation............................................................... 60
ENGINE HEAD .............................................................14
BLADE PPC VALVE.................................................... 61
• Removal ..................................................................14
• Removal.................................................................. 61
• Installation ...............................................................18
• Installation............................................................... 61
PUMP GROUP..............................................................19
ACCELERATOR POTENTIOMETER .......................... 62
• Removal ..................................................................19
• Removal.................................................................. 62
• Installation ...............................................................21
• Installation............................................................... 62
GEAR-PUMP ................................................................22
CONTROLLER ............................................................ 63
• Installation ...............................................................22
• Removal.................................................................. 63
ENGINE - PUMPS ........................................................23 • Installation............................................................... 63
• Installation ...............................................................27
SAFETY MICROSWITCH ............................................ 64
COMPLETE RADIATOR AND AIR CONDITIONING • Removal.................................................................. 64
CONDENSER ...............................................................28 • Installation............................................................... 65
• Removal ..................................................................28
HYDRAULIC OIL TANK .............................................. 66
• Installation ...............................................................30
• Removal.................................................................. 66
SWING MOTOR AND REDUCTION GEAR .................31 • Installation............................................................... 67
• Removal ..................................................................31
FUEL TANK ................................................................. 68
• Installation ...............................................................32
• Installation............................................................... 70
SWING MOTOR............................................................33
CONTROL MODULES
• Removal ..................................................................33
(MACHINE - ENGINE - KOMTRAX) ............................ 71
• Installation ...............................................................33
• Removal.................................................................. 71
SWING REDUCTION GEAR ........................................34 • Installation............................................................... 71
• Disassembly ............................................................34
EVAPORATOR UNIT................................................... 72
• Assembly .................................................................40
• Removal.................................................................. 72
SWIVEL JOINT.............................................................47 • Installation............................................................... 76
• Removal ..................................................................47
CABIN .......................................................................... 77
• Installation ...............................................................48
• Removal.................................................................. 77
• Disassembly ............................................................49
• Installation............................................................... 81
• Assembly .................................................................49
SWING CIRCLE........................................................... 82
CONTROL VALVE .......................................................50
• Removal.................................................................. 82
• Removal ..................................................................50
• Installation............................................................... 82
• Installation ...............................................................52
REVOLVING FRAME .................................................. 83
LH PPC VALVE ............................................................53
• Removal.................................................................. 83
• Removal ..................................................................53
• Installation............................................................... 85
• Installation ...............................................................54
EQUIPMENT (1-piece boom version)........................ 86
R.H. PPC VALVE..........................................................55
• Removal.................................................................. 86
• Removal ..................................................................55
• Installation............................................................... 88
• Installation ...............................................................55

PC80MR-3 30-1
(1)
BOOM CYLINDER (For 1-piece boom)...................... 89 STEEL SHOES...........................................................106
• Removal.................................................................. 89 • Removal ................................................................106
• Installation............................................................... 90 • Installation .............................................................106
ARM CYLINDER .......................................................... 91 RUBBER SHOES .......................................................107
• Removal.................................................................. 91 • Removal ................................................................107
• Installation............................................................... 92 • Installation .............................................................107
BUCKET CYLINDER ................................................... 93 SPROCKET ................................................................108
• Removal.................................................................. 93 • Removal ................................................................108
• Installation............................................................... 94 • Installation .............................................................108
BOOM SWING CYLINDER.......................................... 95 COMPLETE TRAVEL ASSEMBLY............................109
• Removal.................................................................. 95 • Removal ................................................................109
• Installation............................................................... 96 • Installation .............................................................110
BLADE CYLINDER...................................................... 97 TRACK SHOE IDLER ................................................111
• Removal.................................................................. 97 • Assembly...............................................................111
• Installation............................................................... 97 BUMPER SPRING......................................................114
CYLINDERS................................................................. 98 • Disassembly ..........................................................114
• Disassembly............................................................ 98 • Assembly...............................................................115
• Assembly .............................................................. 100 LOWER IDLER ROLLERS.........................................117
SWING SUPPORT ..................................................... 103 • Disassembly ..........................................................117
• Removal................................................................ 103 • Assembly...............................................................118
• Installation............................................................. 105

30-2 PC80MR-3

(1)
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

q 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.

3. 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.

4. 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.
2. 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.
3. 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 PC80MR-3

(1)
REMOVAL AND INSTALLATION SPECIAL TOOLS

SPECIAL TOOLS

Nature of work Mark Code Name Q.ty Remarks

To remove and mount

1 Wrench 1
lock-nut

To remove inside ring

2 Plunger 3
Disassembly/Assembly of from pinion bearing
C
swing machinery To assemble inside
3 Plunger 1
bearing ring

To mount outside bearing

4 Plunger 1
ring

1 790-101-5001 Full piston 1 Bushing assembly

Assembly of track shoe idler
2 796-230-1110 Tool 1 Floating seal installation
L
Assembly of lower idler 3 790-101-5001 Full piston 1 Bushing assembly
rollers 4 796-230-1120 Tool 1 Floating seal installation

791-685-8005 Tool 1

790-201-2860 Spacer 1
Disassembly – assembly of
M 791-365-3160 Extension 1 Spring compression
recoil spring
790-101-1600 Cylinder (686 kN) 1

790-101-1102 Pump 1

791-616-1030 Tool 1

Removal of steel shoes R 790-105-1100 Cylinder (294 kN) 1 Connecting pin removal

790-101-1102 Pump 1

Swivel joint disassembly T 790-101-2501 Full puller 1 Rotor and ring removal

790-502-1003 Cylinder repair bench 1

1 All cylinders
790-101-1102 Pump 1

Boom, blade and boom

790-102-3802 1
2 Spanner with torque amplifier swing cylinders

Disassembly - Cylinder 790-330-1100 1 Arm and bucket cylinders

U
assembly 790-102-1330 Wrench (75 mm) 1 Blade cylinders

Boom, arm and boom

3 790-102-1470 Wrench (70 mm) 1
swing cylinders

790-302-1290 Wrench (60 mm) 1 Bucket

4 790-720-1000 Expander 1

PC80MR-3 30-5
(1)
REMOVAL AND INSTALLATION SPECIAL TOOLS

Nature of work Mark Code Name Q.ty Remarks

796-720-1660 Calibrator 1
Boom cylinder
07280-01279 Clamps 1

796-720-1650 Calibrator 1
Arm and boom
796-720-1660 Calibrator 1
swing cylinders
5 07281-01159 Clamps 1

796-720-1650 Calibrator 1
Arm cylinder
07281-01029 Clamps 1

796-720-1670 Calibrator 1
Blade cylinder
07281-01279 Clamps 1

790-201-1702 Driver kit 1

790-101-5021 . Handle 1
Disassembly - Cylinder All cylinders
U
assembly 01010-50816 . Screw: 1
6 790-201-1791 . Plunger 1 Blade and boom cylinder

Boom and arm swing

790-201-1781 . Plunger 1
cylinders

790-201-1771 . Plunger 1 Arm cylinder

790-201-1500 Driver kit 1

790-101-5021 . Handle 1
All cylinders
01010-50816 . Screw: 1
7 790-201-1620 . Plunger 1 Boom and blade cylinders

Arm and boom swing

790-201-1610 . Plunger 1
cylinders

790-201-1580 . Plunger 1 Arm cylinder

790-101-2102 Puller 1
Swing bracket removal V 2
790-101-1102 Pump 1

30-6 PC80MR-3

(1)
REMOVAL AND INSTALLATION SPECIAL TOOLS

60
C1 40
31
A
3.2

R2 20

Ø6.5 H7/m6
8
R2

3/4”
3.2
Ø76 ±0.01

Ø65
Ø90

Ø63

3.2
1x45°

N°4 SPINE A 90°

Nos 4 PINS AT 90°
1x45°

Particular «A»
Ø4

1x45°

RKP13300

C2 125 C3 59
10 15 14
3.2
3.2

3.2

Ø78.5 ± 0.1
Ø84.5 ± 0.1
Ø62

Ø76
Ø90

Ø74 ± 0.1

1 x45°
Ø35

8
1x45°
R2 R2

RKP13310
R2
RKP13330

C4
14
6

Ø40
3.2

Ø124 ±0.01
3.2

Ø130 ±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
1
2
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.

3 4

RKPC7890

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

RKPC7900

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

8
7

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). 12

10

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.

13 13

RKPC7930

8 -Loosen and remove the counterweight retaining screws

(14) and remove the counterweight (15). [*1]

4 Counterweight: approx. 965 kg

15
14 14

RKPC7891

Installation
• To install, reverse the removal procedure.

[*1]

3 Counterweight screws: Loctite 265

Counterweight screws: 3320 Nm

30-10 PC80MR-3
(1)
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. RKPC7940

(For details see "20 TESTING AND

ADJUSTMENTS").

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
1

RKPC7950

3 -Close the separator cock (4).

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

RKPC7960

PC80MR-3 30-11
(1)
REMOVAL AND INSTALLATION INJECTION PUMP

5 -Disconnect the fuel feed hose (7) and fuel return hoses
(8), (9) from the injection pump (6).
7
a Plug the hoses tight to avoid fuel leakage.

6
8

9
RKPC7970

6 -Disconnect the actuator and rev sensor connectors

(10), (11).

7 -Disconnect engine stop solenoid connector (12).

10 12

11

RKPC7980

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

the engine oil cooler.

13

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 14
manual (code no. 0BTNV-G00101).

RKPC8001

30-12 PC80MR-3
(1)
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.

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. RKPC7940

(For details see "20 TESTING AND

ADJUSTMENTS").

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
1

RKPC7950

3 -Close the separator cock (4).

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

RKPC7960

30-14 PC80MR-3
(1)
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.

7 6

RKPC7991

7 -Remove the straps (8) retaining the wiring harness (9).

8 -Remove the guard (10) the thermal starter.

9
8
10

RKPC8010

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

11

12

13
RKPC8021

10 -Take out screws (14) and remove cover (15).

16
11 -Loosen retaining nuts (16) and the screws (17). 14
18
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).

21

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").

24

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 PC80MR-3
(1)
REMOVAL AND INSTALLATION ENGINE HEAD

17 -Disconnect connector (27), disconnect hoses (28) and

remove the EGR assembly (29).

29
28
27

RKPC8060

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

30

RKPC9130

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

head.

a Plug the hose tight to avoid leakage.

31

RKPC7971

20 -Remove cover (32).

32

RKPC8080

PC80MR-3 30-17
(1)
REMOVAL AND INSTALLATION ENGINE HEAD

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

starter.

33

RKPC8070

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

muffler (36).

36 34

35

RKPC8090

23 -Disconnect wiring harness (37).

41
24 -Loosen screws (38), (39), disengage belt (40) and
remove bracket (41).
38

25 -Continue with the engine head removal procedure by

removing the valve cover and the rocker arm supports in 40 37
accordance with the instructions provided in the engine
workshop manual, code no. 0BTNV-G00101.

39
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 PC80MR-3
(1)
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

1 3
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

RKPC8121

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

9
a Plug all pipes to keep out impurity. 8

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).

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 PC80MR-3
(1)
REMOVAL AND INSTALLATION PUMP GROUP

Installation
• To install, reverse the removal procedure.

[*1]

2 Lubricate the shaft with G2 – LI grease

2 Loctite 243 16
1 -Fill the hydraulic oil tank to maximum level.

5 Hydraulic oil: approx 65 l

2 -Loosen the pump bleed screw (16) until bubble-free oil RKPC8150

comes out.

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. 1

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). 4
5
3 -Disconnect the outlet hoses (3) and (4). 3
4 -Loosen and remove screws (5) and remove the pump
group (6). 2 1

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 PC80MR-3
(1)
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

1 2 3
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).

4

6
RKPC8020

6 -Disconnect cab heating hoses (7), (8) and engine oil

cooler hose (9).

8
7

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). 13

a Plug lines and holes to prevent hose contamination

and fuel leakage.

11 12

12 10
RKPC8180

8 -Disconnect the ground plait (14).

14

RKPC8190

9 -Remove the radiator-oil cooler assembly (15).

(For details, see "COMPLETE RADIATOR AND AIR
CONDITIONING CONDENSER").

15

RKPC8000

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

a Plug all pipes to keep out impurity.

16

17
RKPC8120

30-24 PC80MR-3
(1)
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. 18

12 -Remove the tie straps and disconnect from engine all

connectors and wiring harnesses that are accessible 19
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

23
22

21

RKPC7512

13 -Remove upper guard (24).

24

RKPC8081

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

starter.

25

RKPC8071

PC80MR-3 30-25
(1)
REMOVAL AND INSTALLATION ENGINE - PUMPS

15 -Disconnect connector (27) and wiring harnesses (28),

(29) from alternator (26).

27

26 28

29

RKPC8101

16 -Disconnect wiring harnesses (31), (32) from starter (30).

17 -Remove tie strap (33) and ground wire to release the 31

wiring harnesses.

32
33

RKPC8200

18 -Using the brackets provided, connect the engine (34) to

some hoisting tackle and slightly tension the cables or
chains.

34

RKPC8210

19 -Loosen and remove the screws (35) securing the

engine.
[*1].
35
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. 36

RKPC8220

30-26 PC80MR-3
(1)
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. 1
2 -Remove the screws and remove the tank (2).

RKPC8003

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

RKPC8230

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

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

RKPC7921

30-28 PC80MR-3
(1)
REMOVAL AND INSTALLATION COMPLETE RADIATOR AND AIR CONDITIONING CONDENSER

6 -Disconnect hoses (9), (10) from radiator (8) connecting

to the engine.

8
10
RKPC8240

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

6 Hydraulic oil: approx 5 l

12

11

RKPC8250

9 -Remove the screws (14) and place the air conditioning

filter (15) to a side.

14

15

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).
19

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

21
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 PC80MR-3
(1)
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

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

2

RKPC8300

2 -Mark hose positions and disconnect hoses (4), (5), (6),

(7) and (8) from motor (3). 5
4
a Plug all pipes to keep out impurity.

6
3

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. 10
a Take care to not damage the cage of drain pipe (9).
[*1] 11
4 Complete group: 77 kg 12
RKPC7821

PC80MR-3 30-31
(1)
REMOVAL AND INSTALLATION SWING MOTOR AND REDUCTION GEAR

Installation
• To install, reverse the removal procedure.

[*1]

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 PC80MR-3
(1)
REMOVAL AND INSTALLATION SWING MOTOR

SWING MOTOR
Removal
2
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

1
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 5 1
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). 2
3
a Remove the oil drain pipe (5).
4

RKP17440

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

6
RKPC1640

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

7 8
RKPB6980

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

9

10

RKPB6990

30-34 PC80MR-3
(1)
REMOVAL AND INSTALLATION SWING REDUCTION GEAR

4 -Remove the planetary carrier (11). 11

RKPB7000

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

RKPB7010

6 -Remove the snap ring (2).

RKPB7020

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

13

13

RKPB7030

PC80MR-3 30-35
(1)
REMOVAL AND INSTALLATION SWING REDUCTION GEAR

8 -Remove the pinion (14).

14

RKPB7040

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

15

RKPB7050

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

RKPB7060

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

16
4

RKPB7070

30-36 PC80MR-3
(1)
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).

C1

RKPB7090

14 -Remove the spacer (19).

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).

20

RKPB7120

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

shaft (18). 4
18

RKPB7130

18 -Using a puller, remove the bearing outer ring (20) from

gearbox housing (4).

20

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). C2

18

22

21 23
RKPB2272

30-38 PC80MR-3
(1)
REMOVAL AND INSTALLATION SWING REDUCTION GEAR

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

ring (24).

24
4

RKPB7150

21 -Using a puller, remove the bearing outer ring (21) from

gearbox housing (4).

4 21

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.

23

18

RKPB2282

2 -Mount the metal sealing ring (22).

22

RKPB2292

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

22

RKPB2302

30-40 PC80MR-3
(1)
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).

C3

21

22

RKPB2322

6 -Using the tool C4 and a press, drive the outside bearing

ring (21) down over the gearbox housing (4).

C4

RKPB7220

7 -Using the same method as above, mount the outside

ring of the other bearing (29) in the gearbox housing.

20

RKPB7230

PC80MR-3 30-41
(1)
REMOVAL AND INSTALLATION SWING REDUCTION GEAR

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

24

RKPB7170

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

RKPB7130

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

(18).
20

18

RKPB7121

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

18

19

RKPB7101

30-42 PC80MR-3
(1)
REMOVAL AND INSTALLATION SWING REDUCTION GEAR

12 -Tighten the lock-nut (17).

a Use a new lock-nut.

2 Shaft nut: Loctite 242

17

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
C1
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 4
(19).

a If the torque is lower, decrease the thickness of shim RKPB7091

(19).
14 -Lock the position of the lock-nut (17) with 6 safety
caulkings, corresponding to the grooves in the pinion
shaft (18).

18

17

RKPB2402

15 -Lubricate the O-ring seating of the gearbox housing (4)

and mount the seal (16). 16
4
2 Seat: ASL800050

RKPB7070

PC80MR-3 30-43
(1)
REMOVAL AND INSTALLATION SWING REDUCTION GEAR

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

15

RKPB7210

17 -Mount the toothed ring (3).

a Check the position.
3

RKPB7240

18 -Install 2nd reduction pinion (14).

14

RKPB7040

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

the flange (2). 13

2 Seat: ASL800050 2

13

RKPB7030

30-44 PC80MR-3
(1)
REMOVAL AND INSTALLATION SWING REDUCTION GEAR

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

a Check the position.

2

RKPB7190

21 -Tighten the ten screws (12).

3 Bolt: 85 Nm
12

RKPB7200

22 -Mount the planetary carrier (11). 11

RKPB7000

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

28,9-29,5
gearbox checking the axial quota.

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

4 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. 1

6
RKPC1640

30-46 PC80MR-3
(1)
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

1
pressure.

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

RKPC8300

2 -Disconnect the travel motors drain hose (3).

3
3 -Mark and then disconnect seven hoses (4) coming from
the control valve and reserved for travel, blade and
speed increase. 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. 5

RKPC8330

5 -Remove the lower guard (7).

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.

RKPC8340

7 -Disconnect lower hoses (9) and remove fitting (10).

8 -Connect swivel joint to a hoist and slightly tension the

11
cable.
9 9
Loosen and remove four screws (11) (n°4) retaining joint
to bracket (12).

10
12

RKPC8360

9 -Remove swivel joint (13).

4 Swivel joint: approx. 18.5 kg

13

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 PC80MR-3
(1)
REMOVAL AND INSTALLATION SWIVEL JOINT

Disassembly
1
1 -Remove flange (1).

2 -Remove snap ring (2). 2

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

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

7

4
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. 6

2 Rings and shoes: G2 - LI
a Take care not to damage the sealing rings.
5
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. RKPC7940

(For details, see "FUEL TANK").

1-Disconnect the connectors (1) attached to the revolving

frame rotation and travel pressure-switches (2).
2 1
a Ensure that all connectors are marked as follows:

R.H. SIDE L.H. SIDE

Mark X381 4th element X383 4th element
X380 3rd element X382 3rd element
X199 1st 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”).
3
a Plug all pipes to keep out impurity.
3

RKPC8370

3 -Remove the U bolt (4) and reinforcement bracket (5)

supporting the delivery hose leading to the optional
attachments.
5

4
RKPC8380

30-50 PC80MR-3
(1)
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. 6

RKPC8390

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

7
8

RKPC8400

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

hose (11). 9

11

10 RKPC8410

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

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.

13

RKPC8430

9 -Loosen and remove screws (14) and remove vibration

dampeners and control valve (15).

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 PC80MR-3
(1)
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).

1 2

RKPC1750

3 -Slide the boot (3) up.

4 -Remove the collar (4) retaining the boot.

4
3
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).

6
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. 9
[1*][2*]
8

RKPC1790

Installation
• To install, reverse the removal procedure.
T
[*1]
P
a Location for hose connection: 1

P T 1 2 3 4 3
M S F F A A 4
white white yellow green yellow green
2
[*2] RKPC1800

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

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 PC80MR-3
(1)
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 2
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*] 5 4

RKPC1820

Installation
• To install, reverse the removal procedure.
P
[*1] T
a Location for hose connection:
1
P T 1 2 3 4
3
S M E E G G
white white green yellow yellow green 4
2
[*2]
3 Usable fittings (1-2-3-4): 34-35 Nm
RKPB9270

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.

PC80MR-3 30-55
(1)
REMOVAL AND INSTALLATION EQUIPMENT PPC VALVES

EQUIPMENT PPC VALVES

Assembly
a Cleanliness is of the essence when assembling PPC 5 – 7 mm
valves.
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).

9
a Spring inner diameter:
2
• Inner spring: 4.9 mm
• Outer spring: 5.55 mm 3
5 -When installing plug (7) into body (4), make sure that
plug does not bottom out on the 20 mm diameter hole. 8

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 1
7 -Tighten each part to the following torques: 1
• Swivel joint (3): 39-49 Nm 5
• Swivel joint (8): 11.8-14.7 Nm 6
• Nut (9): 98-127 Nm 5
• Plug (10): 6-11 Nm 6
4
10

7 RKP17070

30-56 PC80MR-3
(1)
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).

2
1
RKPC7640

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

a Mark the position of lines to avoid mixing them
during installation. 3 4
a Plug all pipes to keep out impurity.
4

4
RKPC8470

3 -Remove screws (5) and remove travel control levers (6)

and pedals (7). 7
[*1]

5
RKPC1840

4 -Remove the retaining screws and remove the PPC

valve unit (8) together with the mounting plate (9).

9
RKPC1850

PC80MR-3 30-57
(1)
REMOVAL AND INSTALLATION TRAVEL PPC VALVE

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

10

RKPC1860

6 -Remove seals (11) and springs (12); loosen screws (13)

and remove PPC valve (8). 11 12 13

11
12 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 PC80MR-3
(1)
REMOVAL AND INSTALLATION TRAVEL PPC VALVE

Assembly
14
a Cleanliness is of the essence when assembling PPC
valves.

1 -When installing pistons (1), lubricate seats and pistons 3

with grease (G2 - LI). 2
1 11 12
2 -Install smaller diameter springs (2) to shims (3).
c
a Spring inner diameter:
• Inner spring: 4.9 mm a
a b
• Outer spring: 5.55 mm

3 -Use the specific installation equipment to install

bushings (4) and pins (5).
10
k Do not use hammers but push in the bushings and
8 7 16
5 4
pins by applying consistent thrust (no blows 7
should be applied). c
13
4 -Apply grease to the shafts of levers (6), to the contact
9 5
surfaces on levers (7), to pistons (1), to the surfaces on 5 b
shoes (8) and to the pins of lever (9). 6 8

2 Grease G2 - LI
15 6
a Amount of grease:
• Bushings (4) and shoes (8): 4 -8 cm3 5 9
13
• Contact surfaces: 0.3 -0.8 cm3
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).

2
1
RKPC7640

3 -Disconnect lower hoses (3), side hoses (4) and side

fittings (5) from the PPC valve that is being removed.
5

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 PC80MR-3
(1)
REMOVAL AND INSTALLATION BLADE PPC VALVE

BLADE PPC VALVE

Removal
k Fully lower the attachments until they are resting on the
1
ground; stop the engine and turn the battery main
switch key to the O (OFF) position. 2
1 -Release residual pressures from all circuits. (For details
see "20 TESTING AND ADJUSTMENTS").

2 -Remove seat.
1
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).

3 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 2
control dashboard (2). 3

RKPC8510

3 -Remove control knob (3) and disconnect connector (4).

Take out screws (5) and remove potentiometer (6).
6

RKPC8520

Installation
• To install, reverse the removal procedure.

30-62 PC80MR-3
(1)
REMOVAL AND INSTALLATION CONTROLLER

CONTROLLER
Removal
k Stop the machine on firm level ground, with the
attachment to the ground.
3
k Cycle the battery main switch to the O (OFF) position.
1
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

5
the controller.

a Note down shim position and quantity (5).

3 -Disconnect the connectors and remove the controller 4
(3). 3

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 2
attachments to the ground, and the safety devices
engaged.

k Cycle the battery main switch to the O (OFF) position. 1

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).

4
5

RKPC1781

4 -Using a thin-bladed screwdriver, remove screw covers

(7) (LH side) from lower hood (6).

6 RKPC1970

30-64 PC80MR-3
(1)
REMOVAL AND INSTALLATION SAFETY MICROSWITCH

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

RKPC1980

6 -Lift hood (10), remove screws (11) and remove the

safety engagement lever (12).
[*1] 12

10
11

RKPC1990

7 -Lower hood (10) and disengage microswitch wiring

harness from tie straps.

8 -Disconnect the connector, remove screws (13) and

remove microswitch (14). 14

13
10
RKPC2000

Installation
• To install, reverse the removal procedure.

[*1]

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 1
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

2

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).

RKPC8580

5 -Disconnect the hoses (6), (7), (8) from the upper filter.

a Plug all pipes to keep out impurity.

7

8
6
RKPC8590

30-66 PC80MR-3
(1)
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). 10

a Plug all pipes to keep out impurity.

a Mark the hoses to prevent incorrect connections 11
during installation.
11

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

10

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 1
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 PC80MR-3
(1)
REMOVAL AND INSTALLATION FUEL TANK

6 -Remove washer tank (5) and set it aside.

7 -Remove the washer tank support (6).

6 5

RKPC8630

8 -Disconnect the connector (7) of the level gauge.

9 -Loosen the hose clamp and disconnect the fuel return 7

9
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. 4 8

10
RKPC8641

11 -Loosen the nuts (11) holding the retaining straps (12)

and remove the tank (8). [*1]
8
11

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 PC80MR-3
(1)
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).

RKPC2120

2 -Disconnect the connectors attached to the control

module to be removed:
5
- Machine control module (3). 3
- Engine control module (4).
- Komtrax control module (5). 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. 5

6
5

RKPC2150

30-72 PC80MR-3
(1)
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. 14 13

12

RKPC2180

9 -Remove screws (15) and (16) and remove duct (17)

from evaporator.

16
17

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).

21
20

RKPC8690

12 -Disconnect connectors (22), (23), (24).

22

24

23
RKPC2220

13 -Disconnect the connector (25) for the rear shutter (22).

25
26

RKPC2230

30-74 PC80MR-3
(1)
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. 27

15 -Remove feedthrough seal (31) and route hoses under 29
30
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. 32

17 -Remove the front screws (33) retaining the unit.

33

A RKPC2250

18 -Loosen the rear screws (34).

34
34

RKPC2221

19 -Lift the front part of the evaporator unit (27) and slide it
out towards the machine front.

27

RKPC2260

PC80MR-3 30-75
(1)
REMOVAL AND INSTALLATION EVAPORATOR UNIT

Installation
• To install, reverse the removal procedure.

1 -Refill the coolant liquid tank.

5 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 PC80MR-3
(1)
REMOVAL AND INSTALLATION CABIN

CABIN
Removal
k Lower the work equipment until it is resting on the
ground and switch off the engine. 1

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

2

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).

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 2-
6 10 7 11
piece-boom hoses (10), (11) from the distribution units
(6), (7).

k To avoid oil spillage, DO NOT disconnect hoses

(12) and (13).
9
a Check to ensure that all hoses have marks scribbled 8 8
on, so that delivery and discharge are not mixed up.
13

a Plug all pipes to keep out impurity. 12

[*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.

14

RKPC8730

H H B B

D D F F E E

C C A A G G

Green Yellow

RKP19960

9 -Disconnect connectors (15), (16), (17).

15
16

17

RKPC8740

30-78 PC80MR-3
(1)
REMOVAL AND INSTALLATION CABIN

10 -Disconnect the heating hoses (18) from the cab.

18

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). 20
[*2] 23

13 -Release from the straps all the hoses and wiring

harnesses secured to the lower frame.

21
22
RKPC2243

14 -Loosen and remove the inner cab retaining screw (24)

on the right rear side. 24
[*3]

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).

26

27

RKPC8631

17 -Remove plugs and thread some lifting eyes “A” into the
cab roof.
[*4]

A
A A

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 PC80MR-3
(1)
REMOVAL AND INSTALLATION CABIN

Installation
10 11
• To install, reverse the removal procedure.

[*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 RKPC8721

6 - L.H. PPC valve

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 Bracket bolt: ___ Nm

[*3]

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.

5 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)"). 1

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). 2

4 Swing circle: 105 kg RKPC9120

[*2]

Installation
• To install, reverse the removal procedure.

[*1]

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. 3

RKPC8780

30-82 PC80MR-3
(1)
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

3
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).

RKPC8321

4 -Remove pins (7) and bracket (8).

8
7

RKPC8331

5 -Remove lines (9), (10) and the complete air filter (11).
9
11

10
RKPC8022

6 -Sling boom cylinder (12), disconnect hoses, remove

fulcrum pin (13), (6) and cylinder.

12

13
RKPC8790

30-84 PC80MR-3
(1)
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.

14

RKPC8800

8 -Connect a hoisting device to boom-swing bracket and

counterweight (15).

15

RKPC8810

9 -Lift the complete revolving frame.

[*1]

RKPC9160

Installation
• To install, reverse the removal procedure.

[*1]

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 1

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). 5
[*1]

a Note down shim position and quantity.

RKPC8850

30-86 PC80MR-3
(1)
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 8

7

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.

2 Pins and bushings: Molikote

• Adjust clearance between cylinder rod and boom using
shims.

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 PC80MR-3
(1)
REMOVAL AND INSTALLATION BOOM CYLINDER (For 1-piece boom)

BOOM CYLINDER (For 1-piece boom)

Removal
3
k Extend the arm fully and open the bucket completely. 4
Lower the work equipment until it is resting on the
ground.

1 -Put a sling around the cylinder (1). 2

2 -Switch off the engine, release pressure in the cylinder by
moving the RH PPC valve lever several times.
1
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").
1

A
RKPC8940

7 -Disconnect hoses (5) and (6) and unplug connector (7).

a Plug all pipes to keep out impurity.

7
6

RKPC8950

8 -Take out screws (8) and remove pin (9).

[1*][2*][*3]

9- Remove cylinder (1).

1 9

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]

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.

[*3]

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 PC80MR-3
(1)
REMOVAL AND INSTALLATION ARM CYLINDER

ARM CYLINDER
Removal
k Fully dump the bucket (1).
3
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 A

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 6 4
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. 5

7 -Stop the engine and release any residual hydraulic B

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.

7

RKPC8980

9 -Connect the cylinder to a hoist, remove screws (8) and

remove pin (9).
[2*][3*][*4]

10 -Remove cylinder (4).

9
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]

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.

[*3]

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 PC80MR-3
(1)
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.
1
3 -Lower the blade. 2

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).
4
[1*][2*][*3]

6 -Start the engine and fully retract the piston.

k Stop the engine and release any residual 5

pressures.

RKPC9010

7 -Disconnect hoses (6) and (7).

8
a Plug all pipes to keep out impurity.
8 -Take out screws (8) and remove pin (9).
[1*][2*][*4]

9 -Remove cylinder.
9
7
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]

k When aligning the positions between hole and pin,

do not insert fingers into the hole to check the
alignment.

[*3]

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 PC80MR-3
(1)
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. 1

3 -Remove right guard (1) from revolving frame.

RKPC8820

4 -Disconnect hoses (2), (3) from the cylinder and plug

them.
3
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 5 6
the piston rod from its support (7).
[1*][2*]

7 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 9 10
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]

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.

[*3]

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 PC80MR-3
(1)
REMOVAL AND INSTALLATION BLADE CYLINDER

BLADE CYLINDER
Removal
k Swing the revolving frame 90° to the right and lower the 1
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*] 3
4
5 -Start the engine to retract the piston (4).
[*2] 8
6 -Stop the engine and release any residual hydraulic
pressure. 2
(For details see "20 TESTING AND ADJUSTMENTS").

7 -Disconnect hoses (5) and (6): plug holes and hoses to 6

prevent contamination from impurities.

8 -Remove the screws and remove pin (7). 7 5

RKPC9060

[2*][3*]

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]

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.
[*3]

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
1 -Position cylinder (1) to equipment U1.

2 -Using wrench U2 with torque amplifier, loosen the head U1

(2).

RKP17100

3 -Extract the entire piston (3).

U1

RKP17110

2. PISTON ROD
1 -Position piston rod (3) to equipment U1.
4 3
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 Bucket Boom swing Blade

U3
Wrench 70 70 60 70 75

RKP17120

3 -Remove the entire piston (6).

4 -Remove head (2).

5
6

2
RKP17130

30-98 PC80MR-3
(1)
REMOVAL AND INSTALLATION CYLINDERS

Only for arm cylinder:

5 - Remove dowel (6), nine balls (7) and remove braking
end (8).
7 6 8

RKP17140

3. PISTON
1 -Remove wear ring (9)

2 -Remove gaskets (10).

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. 11
15
2 -Remove O-ring (12).

3 -Remove snap ring (13) and scraper ring (14).

16
4 -Remove gasket pack (15).

5 -Remove bushing (16).

12
a Note down direction of installation of ring (14) and 14
gasket pack (15). 13
RKP17160

PC80MR-3 30-99
(1)
REMOVAL AND INSTALLATION CYLINDERS

Assembly
U6 U7
a Lubricate mating surfaces with engine oil and pay
attention not to damage the components.
14
a Heat sealing rings in hot water at 50-60°C before
installing. 16

RKP17170

1. HEAD
1 -Using tool U6, press bushing (16) into its seat. 11
15
2 -Mount gasket pack (15).

3 -Using tool U7, install scraper ring (14); also install snap 16
ring (13).

4 -Install O-ring (12).

5 -Install O-ring (11). 12
14
13
RKP17160

2. PISTON
1 -Using tool U4, stretch sealing ring (10) and install. U5
a Turn handle 8 - 10 turns. U4 10
2 -Using tool U5 tighten seal (10) into the seat on the
10
piston.

RKP17180

3 -Mount wear ring (9)

a Do not stretch the ring more than necessary.

10

RKP17150

30-100 PC80MR-3
(1)
REMOVAL AND INSTALLATION CYLINDERS

3. PISTON ROD
Only for arm cylinder
1 -Install the braking end (8) and nine balls (7), and install 7 6 8
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).

5
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). 4 3

2 Nut: Loctite 262

3 Nut:
U1
Arm cylinder: 33.3 ± 3.3 daNm
Arm cylinder: 33.3 ± 3.3 daNm
Bucket cylinder: 21.6 ± 2.2 daNm U3
Blade cylinder: da 31.4 ± 3.1 daNm
Boom swing cylinder: 26.0 ± 2.6 da Nm
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 PC80MR-3
(1)
REMOVAL AND INSTALLATION SWING SUPPORT

SWING SUPPORT
Removal
1 -Remove the equipment. 3
( F or d et ai l s s ee "EQ U IPM E N T ( 1- pi ec e b oo m 2
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] 1
RKPC8911

3 -Connect boom cylinder (4) to a hoist and slightly tension

the cables.
Remove pin (5) and cylinder (4).
[*2]
5
a Inspect quantity and location of shims. 4

RKPC8791

4 -Position a block between frame and swing cylinder and

remove pin (6).
[*3] 6
a Inspect quantity and location of shims.
7
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.
8

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.
10
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 9

installed between frame and bracket.

12 -Lift out the swing bracket (9).

[*4]

4 Bracket: approx. 270 kg

RKPC9090

30-104 PC80MR-3
(1)
REMOVAL AND INSTALLATION SWING SUPPORT

Installation
• To install, reverse the removal procedure.
14
[*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. 14
Do not insert fingers in the holes to check the alignment.

• Lubricate pins and bushings with grease. RKP19970

2 Pins and bushings: Molikote

• Adjust clearance between cylinder rod and bracket
using shims.

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
3
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

RKPC2840

2 -Allow the attachments to settle on the ground and slowly

loosen the valve (4) to let grease out and to neutralise 4
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 1
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).
30 ton
a Hold the longer end lifted with a hoist and support
the track while the machine is being moved
R
6 -Force the boom down to raise the lower chassis and lift
the track shoe away. Provisional pin
RKP17190

Installation
• To install, reverse the removal procedure.

a Adjust the track shoe tension. 3

(For details, see "20 TESTING AND ADJUSTMENTS").

A
RKPC2850

30-106 PC80MR-3
(1)
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. 2
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. 2
1
(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. 3
A
4 -Take out 14 screws (3) and washers. RKPC2870

5 -Remove the sprocket assembly (2).

[*1]

4 Sprocket: approx. 19 kg

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 PC80MR-3
(1)
REMOVAL AND INSTALLATION COMPLETE TRAVEL ASSEMBLY

COMPLETE TRAVEL ASSEMBLY

Removal
1 -Remove the track shoe assembly. 2
(For details, see "STEEL SHOES" or "RUBBER
1
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.
A
RKPC2871

4 -Remove travel motor guard (3).

3 RKPC2880

5 -Sling the travel assembly (4) and connect it to a hoisting

device; apply a slight tension to the cable.

4
A
RKPC2890

6 -Disconnect 3 hoses (6) and fitting (7) from motor (5).

6
a Plug all pipes to keep out impurity.
5
7 -Loosen and remove the screws (8) anchoring the
assembly.
[*1]

8 - Remove the travel assembly (4).

8

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 PC80MR-3
(1)
REMOVAL AND INSTALLATION TRACK SHOE IDLER

TRACK SHOE IDLER

Assembly
1 -Using tool L1, introduce bushings (9) and (10) into the
wheel (4).
4 L1
9 10
a Force to apply: 2.6 – 5.3 ton. 9

4 10

RKP17210

2 -Install the O-ring and install shaft (5) to support (7):

secure the shaft with pin (8). 4 6

6 7
RKP17220

3 -Using tool L2 , install floating seal (6) to wheel (4) and to

the support (7) of shaft (5). 5
a Inspect the seal sliding surfaces to ensure that they
L2 6
are perfectly clean, then lubricate with oil. L2
4
6
7

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 A
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 5 – 9 mm
mm and that it does not exceed the specified size.

RKP17250

4 -Install the shaft (5) and support (7) into the wheel (4).
7 5 4

RKP17260

5 -Perform an oil fill between shaft (5) and wheel (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

L2 L2
3
they are perfectly clean, grease-free and dent-free. 4 3
2
a Lubricate seal and seats with oil.

RKP17280

30-112 PC80MR-3
(1)
REMOVAL AND INSTALLATION TRACK SHOE IDLER

4 3
2

RKP17290

7 -Install O-ring and support (2); lock into position with pin
(1). 2 1 4

RKP17300

PC80MR-3 30-113
(1)
REMOVAL AND INSTALLATION BUMPER SPRING

BUMPER SPRING
Disassembly
1 -Remove the lubrication unit (1).
2
3
2 -Remove piston assembly (3) from spring assembly (2)

3 -Remove the screw (4) retaining the nut (5).

8
13 4
1
11
12
10 5
9 7
6
RKP17310

4 -Using tool M, disassemble the spring assembly (2).

k Before applying the compression force of spring 2 M

(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 O-

ring (13) from cylinder. 2
6 -Break piston (9) down by removing the snap ring (11), 3
“U” seal (12) and scraper ring (10).
8
a Note down seal orientation.
13 4
1
11
12
10 5
9 7
6
RKP17310

30-114 PC80MR-3
(1)
REMOVAL AND INSTALLATION BUMPER SPRING

Assembly
1 -Assemble piston assembly by reversing the
2
disassembly procedure. 3
2 -Assemble O-ring (13) to cylinder (8). 8
3 -Install cylinder (8) to spring (6) and position the spring 13 4
guide (7). 1
11
12
10 5
9 7
6
RKP17310

4 -Position the spring assembly (2) into tool “M”.

2 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)

B

a Spring length (a):

Rubber shoes: 283 mm
Steel shoes: 323 mm

RKP17330

6 -Remove spring assembly (2) from tool M and tighten nut

(5) with screw (4). 2
3 Screw: 60-73 Nm 3
7 -Fill cylinder (8) with grease. 8
2 Grease: G2 - LI 13 4
1
a Amount of grease: 11
12
Rubber shoes: 232 cm3 10 5
Steel shoes: 96 cm3 9 7
6
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 PC80MR-3
(1)
REMOVAL AND INSTALLATION LOWER IDLER ROLLERS

LOWER IDLER ROLLERS

Disassembly
1 2
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).
3 4a 4b 5

RKP17350

3 -Remove shaft and flange (6) from roller (5).

5

RKP17360

4 -Remove floating seals (7) from roller (5) and shaft flange
(6). 5 7a

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).
5 11
6 -Remove the shaft O-ring (9).

7 -Remove bushings (11) and (12) from roller (5). 9

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.
10 12
8
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

A
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 3 – 5 mm
and that it does not exceed the specified size.

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.

RKP17251

1 -Using tool L3, install bushings (11) and (12) into roller
(5). L3
5
2 -Install O-ring, flange (10) and retaining pin (8) to shaft 9
(9). 12

11 10
8
RKP17390

30-118 PC80MR-3
(1)
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
7a
L4

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). 6 5 6 5
Turn the roller upside down.

RKP17420

6 -Install flange (3) to shaft (9) and secure with pin (2).
3 2
7 -Fill up after removing the cap (13).
13
3 Roller: 210–230 cm3 (Oil GO-140)

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)

HYDRAULIC CIRCUIT (STANDARD VERSION)

PC80MR-3 90-3
OTHER ELECTRICAL DIAGRAM

ELECTRICAL DIAGRAM
N1 2

H-R1

B-R1
OFF B1 A/C GROUP 22E-979 MIX 42N-06 KOMTRAX

R-G1
A1
RADIO 207-06 BEACON 395-06 ANTENNA ORBCOM 8A13-10 ANTENNA GPS 8A13-10

N1
120 120
1
R1 2100 13730 HARNESS
R1711 LAMP 11470 2270 2260

M
1 2 3 +5V
B-R1 B-R1

X2
X156.1 X157.1 X159.1 X158 X158 1 1
ACC 1 B-R1

1
X163 X162 B-R1

Z-G1.5
DIN-RIC DISTR.

M
START
A156 A157
X304
B-R1 V-B1

2
42N-06 22E-06 E163 22E-06 E162 +5V
21W-09 S159 B-R1 M-N1

3
PO SITION
ECTIO
N B BR R1 R2 C ACC 21290 HEATER GROUP 22E-977
KEY CONN 12730 21290
R2790 V-B1 V-B1

4
X161.1
1
E304 2100 6 5 4 3 2 1 6 5 4 3 2 1
S0.5 C-B1 C-B1

5
ANTENNA
2 2

ANTENNA
X159.2
2 1 Z0.5 C-B1 C-B1

6
X163 X162
SPEAKERS REAR LIGHT X158 M
R/N1 X156.2 X157.2 X304
A0.5 SAL1
V-B1 R-G1

7
SAL2 SAL3
L2.5 21W-06 G-N0.5

H-N1

A-N1

B-R1
V-B1 B-N1

8
A1

N1

N1
R1450 G-R0.5
21W-06 2 2 V-B1
ORBCOM GPS

9
H-G0.5

H-N0.5
H-R0.5
E161

B-R1
R1450 V-B1 R-V1

10
S0.5

S0.5
Z0.5
L0.5
X161.2
21W-09 B-L1 LIGHT 1 1 B0.5
V-B1

11
X182.2 X182.3 X182.5 X182.1 EXTENSION R-2.5
R2850 V-B1

FAN

12

KOMTRAX UNIT
M-2.5

A-G1

C-B1
R1 ACC BR R2 C

R-N0.5
V-1.5

N1

N1
OFF ACC
V-B1

B-G1.5
N1.5
R1
ST

X1
A165 R-V1
S1

1
B
86 87a 87
M-N1

2
X182.4

Z-G1.5

7.5A

3
85 30

4
4 7 8 3 4 5 6

R-1.5
V-1.5

5
R10
X166 X165 4 3 2 1

20S-06

6
B-R1

7
V-B0.5 B-R1
31130 A/C ONLY

8
B-N1

R-G1

A-V1
B-R1
V-B1

V-B1
M-2.5
G-1.5
C-1.5

9
N1.5

N1.5

H-1
N1

N1

N1

N1

10
ROOF HARNESS 22E-06 GND4
V-B1

11
A156 Speaker (LH) 42N-06-12730
21120

B-G1.5
Z-G1.5
V-B1

12
X7.s
1 A157 Speaker (RH) 42N-06-12730

A-G1
H-N1
H-R1
A-N1

A-R1
B-R1

C-B1
X5.s

C-B1

13
V-B1
A165 Radio 207-06-R1711

X3.p
X5

A1

A1
X4
A168 A/C controller

14
Gnd4 OPEN 86 87a 87 22E-06-21830
X155.p 1 2 3 4 5 6 7 8 9 10 11 12
A168 Heater controller 22E-06-21860

15
A187 Controller ECU Yanmar

X3.s
85 30

X7.p

16
X155.s 1 2 3 4 5 6 7 8 9 10 11 12 2
X5.s A188 Hammer memory unit

17
B-G1.5
Z-G1.5
KOMTRAX UNIT 7826-24

H-L1
A198 Timer brake rotation 0117133

A-G1
H-N1
H-R1
A-N1

A-R1
B-R1

C-B1

18
A301 MIDAC UNIT (Pump controller)

A1

A1
3000

R-V1
MONITOR PANEL 22E-06 R-V1
B109 Air intake
B110 Travel alarm
21700
B112 Oil pressure
B114 Engine speed sensor
B115 CSD coil
A187 YANMAR ENGINE ECU B119 Water temp.ECU

R-V1

B0.5
engine speed monitor/E22
A168 B143 Fuel level sensor 22E-06-21210

B1

B1
E06 speed selection sw.
E17 engine speed2 sw.

+15 main relay/E48ecu

Engine stop 1/E15 ecu

+ potentiometer power
E16 ecu - Water temp.
Rmax1 switch/E13ecu

Rmax2 switch/E14ecu

reverse droop sw/E05

B208 Presetting travel alarm

droop switch/E24ecu
load monitor/E32ecu

Signal potentiometer

86 preheater ECU44
Water temp la./E02

eng. speed sensor

eng. speed sensor

85 relay Rack/E33
preheater/E23ecu
X202.p

Dial control signal

PA
X203.p
PB B142b Full fuel (refuelling pump)

gnd starter relay

failure lamp/E12
A/C CONTROLLER

csd coil/E41ecu
11 12 10 1 2

E36 ecu/RACK

E43 ecu/RACK

E42 ecu/RACK
5 8 1 2

86 starter relay
A301 A198 A188 X202

E30ecu recan
85 main relay
E141 Arm working lamp 22E-06-21290

EGR/E31ecu
EGR/E21ecu
EGR/E11ecu
EGR/E01ecu
X203.p 1 X310.p

H-G0.5

G-N0.5
G-R0.5
H-N0.5
H-R0.5

R-N0.5
V-B0.5
X201.s

M-2.5
R-2.5
G-1.5
CAN-CHECKER E158 Room lamp

C-1.5

V-1.5
HEATER CONTROLLER MIDAC V201

A0.5

M-N1
B0.5

S0.5
AUXILIARY COUPLER

Z0.5

R-V1

A-V1
L0.5

C-B1

B-R1
MONITOR J1 BRAKE ROTATION HAMMER JUMPER

V-B1
E07ecu

E28ecu
MONITOR J2

H-L1
H-1
CAN H
YANMAR
CAN

Can L
E161 Beacon 395-06-11470

GND
GND

B1

B1
ENGINE TOOL
TIMER UNIT MEMORY HAMMER J1939
PUMP CONTROLLER CONNECTOR CONNECTOR TERMINATOR E162 Head lamp (lh) 22E-06-21290
1 2 3 4 5 6 7 8 9 10 11 12 13 15 16 1 2 3 4 5 6 7 8 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 J3 J1 K1 K2 K3 L1 L2 L3 L4 M1 M3 M4 1 2 3 5 6 7 8 9 10 11 12 13 14 1 2 4 5 6
1 2 3 4 5 6 3 6 7 10 11 12 13 14 15 16 17 2 X204.s
2
E163 Head lamp (rh) 22E-06-21290
XA XB X173.s 1 2 3 4 5 6
X174.s
3 6 7 10 11 12 13 14 15 16 17 2 A1 B6 B7 A8 B2 C1 C2 B8 1 2 5 6 7 8 9 11 12 1 2 3 4 X203.s 1 2 3 4 5 6 7 8 9 10 11 12 85 30 87 87a 85 30 87 87a X202.s 1 2 X201.s X350.s A
X350.s B X310.s 1
X310.s 2 E304 Work lamp 22E-06-21290
X187 X168 X169 X301 X198 X188
X214.s

R/N1
G0.5
F1 Heater Fan fuse - Compressor 08041-02500 163023

N0.5

B1

B0.5

B0.5
B0.5
B0.5
B0.5
B0.5
B0.5
B0.5

B0.5
B0.5
B2
N2
N2

B1
B2
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
B0.5
B0.5
B0.5
B0.5
B0.5
B0.5
B0.5
B0.35

B0.35
B0.5

SHELD.2

B1
F2 Main relay fuse 21D-06-11820 163007

M-B0.5
H-G0.5
G-V0.5
G-R0.5

V0.35

H-N0.5
SHELD.1

B-G0.5
B0.35

A-V0.5

R-N0.5
B0.5

B0.5
H-B0.5

B0.5
S0.5
B-L0.5

R-V0.5
B-G1.5
V-N1.5
F3 +30 Radio, komtrax, room lamp, monitor 21D-06-11790 163010

H-G0.5

G-V0.5

G-V0.5

H-G0.5

G-V0.5
R-N0.5
C-N0.5

H-R0.5

G-R0.5
H-R0.5
B-N0.5

G-V1.5

B-N0.5

H-L0.5
M0.5

L-N1.5
A0.5

V0.5
N0.5

R-G1
S/N1

A-V1
L/N1
C-L1

C-L1
C-L1

H0.5

B0.5
A/G1
A-G1

G-V1
C-R1

A-R1
C-R1
B0.35
M0.5

M0.5

M0.5

L-G1
G0.5

G0.5
C0.5
V0.5
H0.5

A0.5

N0.5

A2.5

B-L1
C0.5

V0.5

A0.5
S0.5

B0.5

B0.5
B0.5
Z0.5

Z0.5
F4 Beacon lamp fuse 163031

S0.5
V1.5
H1.5
S1.5
L0.5

L0.5
21D-06-12060

0.35

C0.5

N1

N1
S1
0.5
R4

H1

N1
N1

C1

N1

C1
F5 Fuel pump ECU fuse 21D-06-11820 163007

B-L1

R/N1
F6 Cigar lighter fuse 21D-06-11820 163007
F7 Monitor - Buzzer fuse 21D-06-11810 163005
R/N1
F8 PPC valve fuse 21D-06-11810 163005
B0.5 F9 +15 Midac (Cpu line)+Komtrax fuse 21D-06-11810 163005
H-N1 F10 Joystick right, switch overload fuse Midac (Load) 21D-06-11810 163005
H-R1

L/N1
B-R1
A-N1

F11 Switch lamp fuse 21D-06-11810 163005

N1

F12 Switch quick_coupler, joystick left fuse 21D-06-11810 163005

A-V1
A-R1

R/N1
1 1
B0.5 X411.s X410.s
F13 Working lamp relay,working lamp sw fuse 08041-02500 163023
V411 V410
F14 A/C controller fuse 21D-06-11810 163005
F15 Hammer memory, radio fuse 21D-06-11810 163005
A-R1

R/N1
B0.5 F16 Wiper motor fuse 21D-06-11820 163007
2 2
X411.s X410.s F1G Alternator fuse 163101
F4G Pre-heather relay Fuse 163067

SA24

R-N0.5
SA21

B0.5
SA19
SA25 F2G Starter relay fuse 163064
G0.5 SA23
SA22
F3G Refuelling pump fuse 163072

SA20
F150 Power box
B0.35
F190 Fuse box 113627
SA15 V0.35
SA14
G1 Battery 22E-06-11120
G-R0.5 H137 Horn 42N-06-11240
SA26
B0.5 H191 Buzzer alarm
K1 Quick coupler relay 395-06-12870 157061
K2 Pliers relay 395-06-12870 157061
B0.5

K3 2° Hydraulic relay 395-06-12870 157061

H0.5
S0.5
L-N1.5 K4 Mordant bucket relay 395-06-12870 157061
C1 K5 Hammer relay 395-06-12870 157061
A/G1 K6 Engine Start cut relay 395-06-12870 157061

B-G1.5
C1

R-N0.5 K9 Working light relay (Arm) 157104

R/N1

R/N1
S/N1

L/N1
C2.5 C1 K10 Working light relay (Cabin) 157104
B0.5

N1
N1
N1
S1
SA16

C-N0.5
Z-G1.5 K11 Working light relay (Cabin) 157104

A2.5
R4 K12 First speed fan relay 157104
B0.5
K13 Second speed fan relay 157104
K14 Third speed fan relay 157104
B1 K15 Fourth speed fan relay 157104
C-R1 C-R1 K121 Engine starter relay (Power Box) 226-06-11350 157102
K122 Pre-heater Relay (Power Box) 226-06-11350 157102
K193 Relay box "A/C" 113628
K302 Actuator Relay 157159
A-V1 K303 Main Relay 157159
H-B1 K7 Pre-Heater lamp relay 157061
L-R1.5
M/B1

E142 Additional working lamp (Arm) 22E-06-21290

M103 Alternator

B0.5
B0.5
B-R1 V/N1

B0.5
M/N1

B1
G/N1 M105 Engine starter motor

B2
L-R1.5 M108 Fuel pump
B/R1

C-N0.5
L-R1.5

L-N1.5
M118 Air conditionary compressor
G/N1

G-R0.5
G/N1
G/N1
A/N1

H/R1

C/N1
B-R1
B-R1

B-R1

H-B1

H-B1

A/B1
M145 Washer tank

L/R1

1
M/N1
B/R1

/N
S0.5

R-G1

G/N1
A1
L1

Z1
R-N1 M179 Wiper motor

L-G1

G/N1
V-N1
6 6 PA Monitor J2 22E-06-21700

H0.5

L/R1
9 2 1 4 3 5 12 7 9 2 1 4 3 5 12 7 C B 9 1 3 7 9 7 9 1 3 5 12 7 9 1 3 5 12 7 9 1 3 7 X167 X181
X197 X196 X170 X170
K302
X172 X171 X171 X183 X184 X186 PB Monitor J1 22E-06-21700
9 2 1 4 3 5 12 7 9 2 1 4 3 5 12 7
K303 X303 X303 X302 X302
9 1 3 7 9 7 9 1 3 5 12 7 9 1 3 5 12 7 9 1 3 7
S167 S181 R107 Heater group
86 87 86 87
0 1 2 0 1 2 0
1
1
0
2 0
1
0
1
0
1 R176 Cigar lighter
85 30 85 30
R180 Potentiometer 22E-06-21811
10 6 8 10 6 8 S1 Starter switch 20S-06-31130 109066
S196 10 2 8 S171 10 1 2 3 4 5 6 12 11 8 10 2 6 8 10 2 6 8 10 2 8
A X303 X303 X302 X302 S159 Limit switch (Window) 21W-54-R2540
S197 10 6 8 10 6 8 X170 S172 10 2 8 10 1 2 3 4 5 6 12 11 8 S183 10 2 6 8 S184 10 2 6 8 S186 10 2 8
X196 X171 S167 Left joystick 702-16-09460

R-N2.5
X197 X183
X172 X184 X186 3 4 5 3 4 5

R-G1
S170 PPC Lock switch 22U-06-R2360

R-N1
N1
H-L1

X181

S-N1.5
X167 S171 Quick coupler switch 22E-06-21460 17.1900.1400.64
N1

N1
N1

N1
N1

N1
N1

R-G1.5
L1

G/N1
G/N1

G/N1

G/N1
G/N1
L-N1.5

G/N1

G/N1
G/N1
S-G1
S172 Overload switch 22E-06-21440 0A023596

Z/N1
Z/N1

Z/N1
V-Z1

N1
N1

N1
N1
N1

N1
N1

N1
N1
N1
N1

N1

N1
N1

N1

N1
N1
S181 Right joystick 702-16-09440
G/N1

H-N0.5

V-N1.5
S-N1.5 S183 Mordant Bucket/hammer switch 22E-06-21450 0A023597

H-G1

H-V1

B-V1

H-L1
S184 2° hydraulic/pliers switch 22E-06-21430 0A023595
S186 Beacon lamp switch 22L-09-R9230 0A009636
S196 Working lamp switch 2A1-06-11210 0A022984
S197 Wiper switch 22E-06-21420 0A020715
S199 Rotation press.sw right 21W-06-R1520
S200 Rotation press.sw left 21W-06-R1520

V-N1
V201 Diode 124219
V410 Diode 124219
R4 B0.5 B0.5 B0.5 V411 Diode 124219
Y113 Rack actuator
SA08

B1.5

H1.5
B0.5

B0.5
B0.5
X202 Jumper hammer memory
A/N1
R1.5
R1.5
R1.5
R1.5
R1.5
R1.5

B0.5

A2.5
L2.5

L2.5
L2.5
L2.5
L2.5
L2.5
L2.5
L2.5
L2.5
L2.5
L2.5
L2.5
L2.5

L2.5
L2.5
L2.5
L2.5
L2.5
L2.5
L2.5

H-G1.5

B-G1.5
N1.5
R4

L4

L4

M/B1
M/B1

A-G1

M/B1
C-B1
M0.5
Y111 Tvc valve
R180
A1

3
Y116 EGR valve
2 4 3 X180.s
F1a F2a F3a F4a F5a F6a F7a F8a F9a F10a F11a F12a F13a F14a F15a Y132 2nd speed
X179

F16a
X179
X179

X193 X193 X193

F190 53a
X189 X189 X189 X193
K13 K14 K15 Y133 Rotation brake
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 F14 F15 F16 53 M 31b K9 K10 K11 K12 86 87a 87 86 87a 87 86 87a 87 Y134 PPC valve
25A 10A 3A 5A 10A 10A 7,5A 7,5A 7,5A 7,5A 7,5A 7,5A 25A 7,5A 7,5A 10A 86 87a 87 86 87a 87 86 87a 87 86 87a 87
Y135 Hammer
31 85 30 85 30 85 30 Y136 Mordant bucket
M-B0.5

G-R0.5

85 30 85 30 85 30 85 30
M179 1 Y138 Overload pressure switch
H/R1

N0.5
B0.5

S0.5

F1b F2b F3b F4b F5b F6b F7b F8b F9b F10b F11b F12b F13b F14b F15b F16b X179 2 1
Y139 Quick coupler
B0.5 X1

X193 X193 X193

B0.5 X

B/R1
B0.5
X190

C-N0.5
B-R1.5

X189 X189 X189 X193

Y140 Pliers

N2.5
X180.s

N2.5
B0.5
X180.s
H-G0.5
H-G0.5
CONNECT TO X151.s

R-N2.5

R-N0.5
A-R1.5

H-R1.5
S-N1.5

B-R1.5
L-N1.5
L-N1.5

L-R1.5
H-L1.5

Y209 2° hydraulic

N1

N1
G/N1
R-G1
R-G1

A-V1
C-R1

L-R1

Z-N0.5
C2.5

B0.5

N1
Z-N0.5 Z-N0.5 N2.5

C-L1
Y210 3° hydraulic
R4

Z-N0.5 Z-N0.5 X155.p Connector to roof wiring harness 125831

H-L1.5
N1
Z-N0.5
SA28 R-G1 X106 50 starter pin

H-L1.5
X311 X311 X311 X311 X151.s Connector to harness 0A021542 124046
L-N1.5 X311
X311
K3 K4 K6 K5 X152 Main switch pin 101089
K1 K2
X151.s X151.p R10 R-N2.5 R-N2.5 86 87a 87 86 87a 87 86 87a 87 86 87a 87 X130.s Connector to cabin harness 125414
1 1 A-R1 86 87a 87 86 87a 87
C-R1 C-R1 C-R1 X131.s Connector to cabin harness 124095
85 30 85 30 85 30 85 30
S-N1.5 85 30 85 30
X132 Connector (2nd speed) 124451
H-G0.5
B0.5

X133 Connector (Brake rotation) 124451

H-G0.5 X311 X311 X311 X311 X134 Connector (PPC valve) 124451
H-R1.5

X311 X311
L-N1.5
R-G1

X135 Connector (Hammer) 124451

G-M1

G-V1
H-G1

V/N1

A/V1
V/N1

H-V1
H-R1.5

B-V1
L/R1
L/R1
L-R1

H-L1
N0.5

N2.5

N0.5
A-R1
X151.p

X136 Connector (Mordant bucket) 124451

N1
N1

B1
Z1
L-R1
X137 Connector (Horn) 300004
M-B0.5 X138.1 Pin Overload (Pressure switch) 101077
A-R1
22E-06

X138.2 Pin Overload (Pressure switch) 101081

21310

H/R1 X139.s Connector (Quick coupler) 124451

X140.s Connector (Pliers) 124451
X141 Connector (Arm working lamp) 124451
X142.1 Connector Full fuel (refuelling pump) 125135
H-G0.5

SA11
POWER CABIN HARNESS

G-R0.5 X142.2 Pin Gnd fuel sensor 120022

SA12
X142.3.p Connector Full fuel (refuelling pump) 125400
S0.5
X143 Connector (Fuel sensor level) 124452
B2

R-N0.5
X145 Connector (Washer tank) 125018

R/N1
A-R1 X146 Connector (Overload pressure switch) 124484
X199 Connector (Rotation press.sw right) 125117
X311 X311 X200 Connector (Rotation press.sw left) 125117
L-N1.5 K7
X191.1 X207.s Connector to cabin harness 125406
86 87a 87
X176.1 X208.s Connector (Presetting travel alarm) 124451
X209.s Connector (2° hydraulic) 124451
H191 R176 85 30
R10

X210.s Connector (3° hydraulic) 124451

B0.5

B0.5

X101.p Connector (To engine harness) XE0803213

X311 X311
X102.p Connector (To engine harness) 125408
V0.5
N1

X150.1 X191.2 N0.5 N0.5

X130.p Connector (To Carriage/frame harness) 125412
F150
80A B1 X176.2
X131.p Connector (To Carriage/frame harness) 124094
SA05
N0.5 X151.p Connector (To harness 0A021544) XE0803220

N2.5
X155.s Connector (To left cabin harness) 125825

N1
N1
N1.5

N1.5

N0.5

CABIN HARNESS 22E-06

N2
N2

X165 Radio connector 125548

N1
X150.2 X166 Radio connector 125549
21111
X167 Connector (Left joystick) 124666
R16

X168 Connector (A/C controller) 124534

B1.5

M-B0.5
G-R0.5
A-V0.5
H-B0.5
G-V1.5

H-G1.5

R-G1.5
B-G1.5
H-L0.5

V-N1.5
B-L0.5
V0.35
B0.35

B0.5
B0.5
B0.5
B0.5

G-M1
B0.5

M/N1
B0.5

B0.5
A/G1

R-G1

A-G1
A/V1
R/N1

H/R1

S-G1

X169 Connector (A/C controller) 124669

S/N1
V-N1

L/N1

V-Z1

N1
N1
N1
N1
N1
S0.5
B1
B2

B1
B1

B1

B2
B2
C1

N1

S1
Z1

Gnd5 GND5 X170 Connector (Micro switch harness) 125406

A B C
X102.p 1 2 3 4 X130.p 1 2 3 4 5 6 X131.p 1 2 3 4 5 6 7 8 9 10 11 12 X207.p X171 Connector (Switch quick-coupler) 16.650.003
X101.p 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 X101.p X102.p X172 Connector (Switch overload) 16.650.003
X173.s Connector (A/C) 125015

M/N1

M/N1
G-V1

G-V1
A-R1
C-R1

L-G1
L-G1
X101.s 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 X102.s 1 2 3 4

S0.5
1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10 11 12 A B C
X130.s X131.s X207.s
X174.s Connector (A/C) 125649

N1
A-V0.5
H-B0.5
G-V1.5

H-G1.5

R-G1.5
H-L0.5

B0.5 X176.1 Connector (Cigar lighter) 104007

R-G1

A-G1
V-N1.5

S/N1
ENGINE HARNESS 22E-06 FRAME HARNESS 22E-06
G-M1
A/G1

M/N1
M-B1
G-R1

A/V1
B-G1

H/R1

S-G1
V-N1

L/N1

V-Z1
B0.5
B0.5
B0.5
B0.5
B0.5

B0.5
B0.5
B0.5

S0.5

B0.5
B1.5

B1.5

B1 X400.s 1 2 3 4 5 6 7 8 9 10 11 12 X176.2 Connector (Cigar lighter) 104007

B2

B2
C1

B1

N1

S1
Z1

21191 21181 3 5 6 8 10 11 X179 Connector (Wiper motor) 125410

S/N1
X180.s Connector (Potentiometer) 125477
SA06 S/N1

G-V1
X181 Connector (Right joystick) 124666

L1
S1
X152 R-G1
SA07
X182.1 Pin Starter switch (C) 120011
R-G1 X182.2 Pin Starter switch (R1) 120011
R-G1 X182.3 Pin Starter switch (ACC) 101124
X182.4 Pin Starter switch (B) 101124
TWIST1 R0.5
TWIST1 B0.5
R16

X182.5 Pin Starter switch (BR)

H-G1.5

X183 Connector (Switch mordant buchet / hammer) 16.650.003

N1.5

SA02 X184 Connector (Switch pliers / 2°hydraulic) 16.650.003

X186 Connector (Switch beacon) 16.650.003

H/N1
X187 Connector (Controller ECU) XE0803782

B2
X141.s

X188 Connector (Hammer memory) 125026

R-G1.5

1 2 1 1
X189 Connector (Relay box "a") 113628
X142.1 X142.3.p X190 Connector Fuse box +30/+15ACC 113627

R-G1

R-G1
S/N1

S/N1
21W-06
X146.p

B142b 22E-06 X191.1 Connector Buzzer alarm 104007

R8172 X138.1 M X191.2 Connector Buzzer alarm 104007
Y138 21390 X193 Connector (Relay box "A/C") 113628
p 1 1 X196 Connector (Switch working lamp) 16.650.003
N1.5
B1.5

X199 X200
REFUELLING PUMP X197 Connector (Switch wiper front) 16.650.003
ENGINE X138.2 S199 S200 X198 Connector (Brake timer rotation) 125026

R-G1
A-G1
X201.s Connector (Diode) 125226
B0.5

POWER BOX 2
p p
R10
R4

B2
B1

X142.3.p
X179.s

X142.2
X202.p Connector (Jamper hammer) 125008
B-G1

1 2
X202.s Connector (Jamper hammer) 125007
K121 K122 2 2
X121 X122 1 2 X203.p Auxiliary connector 124094
N1
N1

X199 X200
86 87 86 87 E141 X208.s X208.s
X203.s Auxiliary connector 124095

S/N1

S/N1
X204.s Connector (Can Checker) 124067
X120.2 TRAVEL 22E-06
85 30 85 30
22E-06 X207.p Connector (To Carriage/frame harness) 125404
TWIST1 R0.5
TWIST1 B0.5

F1G F2G F4G F3G ALARM 21360 X214.s Komtrax Connector 124456
21290
80A
X121
60A
X122
80A 30A
X301 Connector (MIDAC) 124234
B0.5

22E-06 R-G1.5 A-G1.5 X302 Connector (Actuator relay) 125514

ARM WORK LAMP X303 Connector (Main Relay) 125514
21130
SA03

X310.p Connector (CAN TERMINATOR) 125400

Sa1
SA01 X310.s Connector (CAN TERMINATOR) 125402
R25

SA01

R-G1

R-G1

R-G1

R-G1
A-V0.5
H-B0.5

G-V1.5

H-L0.5

V-N1.5

V-N1.5

R50 ADD. WORK LAMP X311 Connector (Box relay "b") 113629
A/G1

G-M1
M/N1
V-N1

M-B1

G-R1
A/V1

S-G1

H/N1

H/R1
B0.5

B0.5
B0.5

B0.5

B0.5

B0.5
B0.5

B0.5
S0.5

B0.5

B0.5

L/N1

V-Z1
B1.5
R10

R10

X350.s Connector (J1939) 125406

R4

C1

C1

B1

B1

N1
S1
Z1

1 1 1 1
X380 X381 X382 X383 X400.p Connector (Antitheft) 125420
1
21W-06 X400.s Connector (Antitheft) 125422
R50

+ - 1 2 - 1 2 1 2 3 4 5 6 1 2 3 4 5 6
X106
X103.1 X103.1
X107
X114 X114 X112
X118
X108 1 1 X115.1 X119 1 1 1 1 1 2 1 1 1 1 1
A
X143
B
X143
C
X143
X145
1
S380 S381 S382 S383 X410.s Connector (Diode) 125226
R107 X110 1 X111 X116 X113
R1311 X134 X132 X136 X137 X146 X146 X135 X209.s X140.s X133 X139.s X210.s
p p p p
G1 X105 X109 B119 B143 X411.s Connector (Diode) 125226
SB1
30
M
50 +30 W D+ -
ENGINE B112 M M B109 Y111 CDS EGR RACK Y134 Y132 Y136 H137 Y135 Y209 Y140 Y133 Y139 M Y210
B110 XA Connector (Monitor J2) 125150
12Vcc
ALTERNATOR SPEED p
COIL VALVE ACTUATOR 2 2 2 2 XB Connector (Monitor J1) 125819
BATTERY SWITCH 42N-06 SENSOR t X179.s
X380 X381 X382 X383
X101.s Connector (To cabin harness) XE0803216
A-G1

A-G1

A-G1

A-G1
2 1,5A

M105 B114 M118 M108 B115 Y116 Y113 1 2

M145 X102.s Connector (To cabin harness) 125410
15730 M103 +
2
X110
X109 2
X111 1 X134
2 2
X132
2
X136
2
X137
2
X135
2 2 2
X133
2 2
X103.1 Connector (Alternator) 125683
R50 X108 X119
X143.p X209.s X140.s X139.s
2
X210.s

X146 X145
Sa2
X107 Pin (Heater group) 101083
N1.5
B1.5

X112 Pin (Oil pressure) 120010

N50

N1.5

N1.5

N2
N1

N1

N1

N1

N1

N1

N1

N1

N1

N1

SAL1 GND3 X120.2 Pin (Refuelling pump fuse) 120011

N0.5

N0.5

X121 Connector (Starter Relay) 125117

N1

N1
N1

SAL2 GND3.1
GND1 X121.87 Pin (87 Starter relay) 120029
22E-06 22E-06 GND2 X181
1 2 X182
1 2
X122 Connector (Pre-heater relay) 125117
21150 11120 X122.87 Pin (87 Pre-heater relay) 101124
E141 E142 Gnd3 Gnd3.1
Gnd1

Gnd2

22E-06-21000E
PC80MR-3 90-5
© 2009 KOMATSU UTILITY EUROPE S.p.A.
All Rights Reserved
Printed in Europe 01-09