Komatsu PC80MR-5E0 Hydraulic Excavator Shop Manual WENBM00250 PDF

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Komatsu PC80MR-5E0 Hydraulic Excavator Shop Manual WENBM00250 – PDF DOWNLOAD

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Komatsu PC80MR-5E0 Hydraulic Excavator Shop Manual WENBM00250 – PDF DOWNLOAD 

Language : English
Pages : 1174
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu PC80MR-5E0 Hydraulic Excavator Shop Manual WENBM00250 – PDF DOWNLOAD 

SERIAL NUMBERS F70001 and up

00 INDEX AND FOREWORD 3
INDEX 4
ABBREVIATION LIST 13
FOREWORD, SAFETY, BASIC INFORMATION 19
HOW TO READ THE SHOP MANUAL 19
SAFETY NOTICE FOR OPERATION 21
PRECAUTIONS TO PREVENT FIRE 29
ACTIONS IF FIRE OCCURS 31
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 32
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 33
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 36
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 43
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 45
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 46
PRACTICAL USE OF KOMTRAX 47
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 48
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 48
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 49
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 50
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 52
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 56
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 57
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 59
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 60
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 62
HOW TO READ ELECTRICAL WIRE CODE 63
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 67
STANDARD TIGHTENING TORQUE TABLE 70
CONVERSION TABLE 77
01 SPECIFICATIONS 83
CONTENTS 84
ABBREVIATION LIST 85
SPECIFICATIONS 91
SPECIFICATION DRAWING 91
SPECIFICATION DRAWING (STANDARD BOOM) 91
SPECIFICATION DRAWING (2-PIECE BOOM) 93
WORKING RANGE DRAWINGS 94
WORKING RANGE (STANDARD BOOM) 94
WORKING RANGE (2-PIECE BOOM) 96
SPECIFICATIONS 98
SPECIFICATIONS 98
WEIGHT TABLE 103
WEIGHT TABLE 103
TABLE OF FUEL, COOLANT, AND LUBRICANTS 105
10 STRUCTURE AND FUNCTION 109
CONTENTS 110
ABBREVIATION LIST 112
NOx CONTROL SYSTEM 118
FUNCTION OF NOx CONTROL SYSTEM 118
BOOT-UP SYSTEM 122
LAYOUT DRAWING OF BOOT-UP SYSTEM 122
SYSTEM OPERATING LAMP SYSTEM 124
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 124
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 124
BATTERY DISCONNECT SWITCH 126
FUNCTION OF BATTERY DISCONNECT SWITCH 126
ENGINE SYSTEM 127
LAYOUT DRAWING OF ENGINE SYSTEM 127
ENGINE CONTROL SYSTEM 129
ENGINE CONTROL SYSTEM DIAGRAM 129
FUNCTION OF ENGINE CONTROL SYSTEM 130
AUTO-DECELERATION SYSTEM 133
AUTO-DECELERATION SYSTEM DIAGRAM 133
FUNCTION OF AUTO-DECELERATION SYSTEM 133
OPERATION OF AUTO-DECELERATION SYSTEM 134
OVERHEAT PREVENTION SYSTEM 135
OVERHEAT PREVENTION SYSTEM DIAGRAM 135
FUNCTION OF OVERHEAT PREVENTION SYSTEM 135
AUTOMATIC IDLE STOP SYSTEM 137
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 137
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 137
COMPONENT PARTS OF ENGINE SYSTEM 139
PTO 139
COOLING SYSTEM 141
LAYOUT DRAWING OF COOLING SYSTEM 141
SPECIFICATIONS OF COOLING SYSTEM 142
CONTROL SYSTEM 143
LAYOUT DRAWING OF CONTROL SYSTEM 143
MACHINE MONITOR SYSTEM 144
MACHINE MONITOR SYSTEM DIAGRAM 144
KOMTRAX SYSTEM 145
KOMTRAX SYSTEM DIAGRAM 145
FUNCTION OF KOMTRAX SYSTEM 145
COMPONENT PARTS OF CONTROL SYSTEM 146
MACHINE MONITOR 146
KOMTRAX TERMINAL 154
MACHINE CONTROLLER 156
RESISTOR FOR PC-EPC VALVE 160
FUEL CONTROL DIAL 161
HYDRAULIC SYSTEM 163
LAYOUT DRAWING OF HYDRAULIC SYSTEM 163
CLSS 165
STRUCTURE OF CLSS 165
FUNCTION OF CLSS 166
ENGINE AND PUMP COMBINED CONTROL SYSTEM 168
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM 168
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM 169
COMPONENT PARTS OF HYDRAULIC SYSTEM 171
HYDRAULIC TANK 171
MAIN PUMP 173
CONTROL VALVE 183
WORK EQUIPMENT SYSTEM 222
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 222
STRUCTURE OF VALVE CONTROL 226
PPC LOCK SYSTEM 228
FUNCTION OF PPC LOCK SYSTEM 228
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 229
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 229
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 229
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 230
ATTACHMENT OIL FLOW ADJUSTER SYSTEM DIAGRAM 230
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 231
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 232
WORK EQUIPMENT AND SWING PPC VALVE 232
BLADE PPC VALVE 236
BOOM SWING AND 2-PIECE BOOM PPC VALVE 238
SOLENOID VALVE GROUP 239
PILOT CIRCUIT ACCUMULATOR 241
SWING SYSTEM 243
LAYOUT DRAWING OF SWING SYSTEM 243
COMPONENT PARTS OF SWING SYSTEM 244
SWING MOTOR 244
SWING MACHINERY 252
SWING CIRCLE 254
TRAVEL SYSTEM 256
LAYOUT DRAWING OF TRAVEL SYSTEM 256
TRAVEL CONTROL SYSTEM DIAGRAM 258
FUNCTION OF TRAVEL CONTROL SYSTEM 258
COMPONENT PARTS OF TRAVEL SYSTEM 260
TRAVEL MOTOR 260
TRAVEL PPC VALVE 268
CENTER SWIVEL JOINT 272
UNDERCARRIAGE AND FRAME 273
LAYOUT DRAWING OF UNDERCARRIAGE 273
SPECIFICATIONS OF UNDERCARRIAGE 273
IDLER CUSHION 274
STRUCTURE OF IDLER CUSHION 274
SPECIFICATIONS OF IDLER CUSHION 274
WORK EQUIPMENT 275
STRUCTURE OF WORK EQUIPMENT 275
FUNCTION OF WORK EQUIPMENT 277
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 278
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 278
CAB AND ITS ATTACHMENTS 279
ROPS CAB 279
STRUCTURE OF ROPS CAB 279
FUNCTION OF ROPS CAB 279
20 STANDARD VALUE TABLE 281
CONTENTS 282
ABBREVIATION LIST 283
STANDARD VALUE TABLE FOR ENGINE 289
STANDARD VALUE TABLE FOR ENGINE: PC80MR-5E0 289
STANDARD VALUE TABLE FOR MACHINE 291
STANDARD VALUE TABLE FOR MACHINE: PC80MR-5E0 291
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 303
30 TESTING AND ADJUSTING 307
CONTENTS 308
ABBREVIATION LIST 310
RELATED INFORMATION ON TESTING AND ADJUSTING 316
ENGINE AND COOLING SYSTEM 317
CONNECTING ENGINE SOFTWARE DIAGNOSTIC TOOL TO THE MACHINE 317
TEST ENGINE SPEED 318
METHOD FOR TESTING ENGINE SPEED 318
TEST EXHAUST GAS COLOR 320
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 320
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER 321
TEST AND ADJUST VALVE CLEARANCE 322
METHOD FOR TESTING VALVE CLEARANCE 322
METHOD FOR ADJUSTING VALVE CLEARANCE 323
TEST COMPRESSION PRESSURE 324
METHOD FOR TESTING COMPRESSION PRESSURE 324
TEST ENGINE OIL PRESSURE 326
METHOD FOR TESTING ENGINE OIL PRESSURE 326
BLEED AIR FROM FUEL SYSTEM 328
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 328
TEST FUEL CIRCUIT FOR LEAKAGE 329
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 329
HANDLE CYLINDER CUT-OUT MODE OPERATION 330
TEST AND ADJUST ALTERNATOR BELT TENSION 331
METHOD FOR TESTING ALTERNATOR BELT TENSION 331
METHOD FOR ADJUSTING ALTERNATOR BELT TENSION 331
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION 333
METHOD FOR CHECKING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION 333
POWER TRAIN 335
TEST SWING CIRCLE BEARING CLEARANCE 335
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE 335
UNDERCARRIAGE AND FRAME 336
TEST AND ADJUST TRACK TENSION 336
METHOD FOR TESTING TRACK TENSION 336
METHOD FOR ADJUSTING TRACK TENSION 336
HYDRAULIC SYSTEM 338
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 338
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK 338
METHOD FOR RELEASING REMAINING PRESSURE IN PPC ACCUMULATOR CIRCUIT 338
METHOD FOR RELEASING REMAINING PRESSURE IN HYDRAULIC CYLINDER CIRCUIT 338
METHOD FOR RELEASING REMAINING PRESSURE FROM SWING MOTOR CIRCUIT 343
METHOD FOR RELEASING REMAINING PRESSURE FROM TRAVEL MOTOR CIRCUIT 343
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, TRAVEL, AND BOOM SWING CIRCUITS 344
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, TRAVEL, AND BOOM SWING CIRCUITS 344
TEST AND ADJUST SWING AND BLADE CIRCUIT OIL PRESSURE 354
METHOD FOR TESTING SWING AND BLADE CIRCUIT OIL PRESSURE 354
METHOD FOR ADJUSTING SWING AND BLADE CIRCUIT OIL PRESSURE 358
TEST AND ADJUST OIL PRESSURE OF CONTROL CIRCUIT 360
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 360
ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 363
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 363
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT 365
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY TESTING TOOL 365
METHOD FOR ADJUSTING LS VALVE 367
TEST OUTLET PRESSURE OF SOLENOID VALVE 368
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE BY MACHINE MONITOR 368
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE BY TESTING TOOL 369
OPERATING CONDITION OF SOLENOID VALVE 370
TEST PPC VALVE OUTLET PRESSURE 371
METHOD FOR TESTING OUTLET PRESSURE OF PPC VALVE BY MACHINE MONITOR 371
METHOD FOR TESTING OUTLET PRESSURE OF PPC VALVE BY TESTING TOOL 374
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 376
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 376
TEST AND ADJUST TRAVEL DEVIATION 377
METHOD FOR TESTING TRAVEL DEVIATION 377
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 378
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER 378
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 378
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE 379
TEST OIL LEAKAGE 380
METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER 380
METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER 380
METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER 381
METHOD FOR TESTING OIL LEAKAGE FROM BLADE CYLINDER 381
BLEED AIR FROM HYDRAULIC CIRCUIT 383
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 384
PRESSURIZE HYDRAULIC TANK 388
METHOD FOR PRESSURIZING HYDRAULIC TANK 388
ELECTRICAL SYSTEM 389
SET AND OPERATE MACHINE MONITOR 389
OPERATOR MODE 392
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 392
CHECKING FUNCTION OF SERVICE METER 392
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD 392
SERVICE MODE 395
METHOD FOR OPERATING SERVICE MODE 395
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 397
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 400
ABNORMALITY RECORD MENU 407
METHOD FOR CONFIRMING MAINTENANCE RECORD 410
METHOD FOR OPERATING MAINTENANCE MODE SETTING 411
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING 415
DEFAULT MENU 417
DIAGNOSTIC TESTS MENU 423
ADJUSTMENT MENU 431
METHOD FOR OPERATING BATTERY DISCONNECT SWITCH SETTING 439
KOMTRAX SETTINGS MENU 441
METHOD FOR DISPLAYING SERVICE MESSAGE 443
METHOD FOR STARTING UP KOMTRAX TERMINAL 445
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 450
TEST DIODES 451
METHOD FOR TESTING DIODE USING DIGITAL TESTER 451
METHOD FOR TESTING DIODE USING ANALOG TESTER 451
40 TROUBLESHOOTING 453
CONTENTS 454
ABBREVIATION LIST 458
RELATED INFORMATION ON TROUBLESHOOTING 464
GENERAL TROUBLESHOOTING POINTS 464
SEQUENCE OF EVENTS IN TROUBLESHOOTING 465
TROUBLESHOOTING POINTS FOR AFTERTREATMENT SYSTEM 467
CHECKS BEFORE TROUBLESHOOTING 475
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 477
WALK-AROUND CHECK 477
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 479
CHECK FUEL LEVEL AND TYPE 479
CHECK FUEL PREFILTER 480
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT 481
CHECK MAIN FILTER 482
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 483
CHECK COOLANT LEVEL (RESERVOIR TANK) 485
CHECK CLOGGING OF AIR CLEANER 485
CLEAN AIR CLEANER OUTER ELEMENT 486
REPLACE AIR CLEANER ELEMENT 488
CHECK HYDRAULIC OIL LEVEL 490
CHECK HYDRAULIC OIL STRAINER 492
CHECK HYDRAULIC FILTER 495
CHECK OIL LEVEL IN FINAL DRIVE CASE 496
BLEED AIR FROM FUEL SYSTEM 497
BLEED AIR FROM HYDRAULIC SYSTEM 497
ELECTRICAL EQUIPMENT – CHECK METHOD 497
ELECTRICAL SYSTEM TROUBLESHOOTING – PREPARATION 504
PROCEDURE FOR TESTING AND TROUBLESHOOTING 508
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS 511
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 515
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 517
FUSE LOCATION TABLE 523
FAILURE CODES TABLE 525
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 536
FAILURE CODE [6AZ0ZG] 536
FAILURE CODE [989L00] 538
FAILURE CODE [989M00] 539
FAILURE CODE [989N00] 540
FAILURE CODE [AQ20R1] 541
FAILURE CODE [AS00R2] 542
FAILURE CODE [AS00R3] 543
FAILURE CODE [AS00R4] 544
FAILURE CODE [B@BCNS] 545
FAILURE CODE [D19JKZ] 546
FAILURE CODE [D811MC] 549
FAILURE CODE [D862KA] 550
FAILURE CODE [D8ALKA] 551
FAILURE CODE [D8ALKB] 553
FAILURE CODE [D8AQKR] 555
FAILURE CODE [DAF0KT] 557
FAILURE CODE [DAF0MB] 558
FAILURE CODE [DAF0MC] 559
FAILURE CODE [DAF3KK] 560
FAILURE CODE [DAF9KQ] 562
FAILURE CODE [DAFGMC] 563
FAILURE CODE [DAFLKA] 564
FAILURE CODE [DAFLKB] 566
FAILURE CODE [DAFQKR] 568
FAILURE CODE [DB2QKR] 569
FAILURE CODE [DBH0MC] 573
FAILURE CODE [DBH2KK] 574
FAILURE CODE [DBH5KP] 577
FAILURE CODE [DBHLKA] 579
FAILURE CODE [DBHLKB] 581
FAILURE CODE [DBHQKR] 583
FAILURE CODE [DDNRKA] 588
FAILURE CODE [DDNRKY] 590
FAILURE CODE [DDNS00] 592
FAILURE CODE [DDWLKA] 594
FAILURE CODE [DDWLKB] 596
FAILURE CODE [DFB1KZ] 598
FAILURE CODE [DFB2KZ] 600
FAILURE CODE [DFB3L8] 602
FAILURE CODE [DFB4L8] 604
FAILURE CODE [DFB5KZ] 606
FAILURE CODE [DFB6KZ] 608
FAILURE CODE [DHPAMA] 610
FAILURE CODE [DHX1MA] 612
FAILURE CODE [DKULKA] 614
FAILURE CODE [DKULKB] 616
FAILURE CODE [DKULKY] 618
FAILURE CODE [DV00KB] 620
FAILURE CODE [DV20KB] 621
FAILURE CODE [DV50KB] 623
FAILURE CODE [DV50KY] 625
FAILURE CODE [DW43KA] 627
FAILURE CODE [DW43KB] 629
FAILURE CODE [DW43KY] 631
FAILURE CODE [DW4CKY] 632
FAILURE CODE [DXA8KA] 634
FAILURE CODE [DXA8KB] 636
FAILURE CODE [DXE7KA] 638
FAILURE CODE [DXE7KB] 640
FAILURE CODE [DXE7KY] 642
FAILURE CODE [DXE8KA] 644
FAILURE CODE [DXE8KB] 646
FAILURE CODE [DXE8KY] 648
FAILURE CODE [DXE9KA] 650
FAILURE CODE [DXE9KB] 652
FAILURE CODE [DXE9KY] 654
FAILURE CODE [DXEAKA] 656
FAILURE CODE [DXEAKB] 658
FAILURE CODE [DXEAKY] 660
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 662
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 662
E-2 ENGINE DOES NOT START (FUEL FEED PUMP SYSTEM) 668
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK 670
E-4 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING 672
E-5 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 675
E-6 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 676
E-7 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 677
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 678
E-9 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 679
E-10 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 680
E-11 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL 682
E-12 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 683
E-13 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE 684
E-14 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED 685
E-15 FUNCTION SWITCH DOES NOT OPERATE 686
E-16 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER 687
E-17 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED 688
E-18 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE 689
E-19 ALARM BUZZER DOES NOT SOUND 691
E-20 ALARM BUZZER CANNOT BE CANCELED 692
E-21 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION 693
E-22 SERVICE MODE CANNOT BE SELECTED 694
E-23 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE 695
E-24 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK 697
E-25 ALARM DOES NOT SOUND DURING TRAVEL 699
E-26 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED 701
E-27 HORN DOES NOT SOUND 702
E-28 HORN DOES NOT STOP SOUNDING 704
E-29 NONE OF WORKING LAMP, TRAVEL LAMP, OR ADDITIONAL LAMP DOES NOT LIGHT UP 706
E-30 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE 710
E-31 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE 712
E-32 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 714
E-33 Swing or Arm IN IS NOT DISPLAYED NORMALLY IN MONITORING FUNCTION 715
E-34 Work equipment IS NOT DISPLAYED NORMALLY IN MONITORING FUNCTION 716
E-35 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY 718
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 719
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) 719
H-1 ALL WORK EQUIPMENT, TRAVEL, SWING OR BLADE DO NOT OPERATE 720
H-2 ALL WORK EQUIPMENTS OR TRAVEL DOES NOT OPERATE 721
H-3 TRAVEL OR BLADE DOES NOT OPERATE 722
H-4 SWING OR BLADE DOES NOT OPERATE 723
H-5 ALL WORK EQUIPMENT, TRAVEL, SWING AND BLADE SPEED OR POWER IS LOW 724
H-6 ALL WORK EQUIPMENT AND TRAVEL SPEED OR POWER IS LOW 725
H-7 TRAVEL AND BLADE SPEED OR POWER IS LOW 726
H-8 SWING AND BLADE SPEED OR POWER IS LOW 727
H-9 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR 728
H-10 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP 729
H-11 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 730
H-12 ALL WORK EQUIPMENTS SPEED OR POWER IS LOW 732
H-13 ALL WORK EQUIPMENTS AND BLADE SPEED OR POWER IS LOW 733
H-14 BLADE DOES NOT OPERATE 734
H-15 ALL WORK EQUIPMENTS DO NOT OPERATE 735
H-16 ALL WORK EQUIPMENTS OR BLADE DO NOT OPERATE 736
H-17 SPEED OR POWER OF BOOM IS LOW 737
H-18 ARM SPEED OR POWER IS LOW 739
H-19 BUCKET SPEED OR POWER IS LOW 740
H-20 BLADE SPEED OR POWER IS LOW 741
H-21 BOOM SWING SPEED OR POWER IS LOW 743
H-22 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION 744
H-23 HYDRAULIC DRIFT OF BOOM IS LARGE 745
H-24 HYDRAULIC DRIFT OF ARM IS LARGE 746
H-25 HYDRAULIC DRIFT OF BUCKET IS LARGE 747
H-26 HYDRAULIC DRIFT OF BLADE IS LARGE 748
H-27 TIME LAG OF WORK EQUIPMENT IS LARGE 750
H-28 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER 751
H-29 MACHINE DOES NOT TRAVEL STRAIGHT 752
H-30 MACHINE DOES NOT MOVE OFF STRAIGHT 754
H-31 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW 755
H-32 TRAVEL SPEED IS LOW 757
H-33 BOTH SIDES OF CRAWLERS DO NOT MOVE 759
H-34 ONE OF TRACKS DOES NOT RUN 760
H-35 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST 762
H-36 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT 763
H-37 SWINGS ONLY IN ONE DIRECTION 765
H-38 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT) 767
H-39 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION 769
H-40 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT) 770
H-41 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT) 771
H-42 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING 772
H-43 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING 773
H-44 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED) 774
H-45 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) 775
TROUBLESHOOTING OF ENGINE (S-MODE) 776
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) 776
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 777
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 778
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 779
S-4 ENGINE STARTABILITY IS POOR 780
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 782
S-6 ENGINE STOPS DURING OPERATION 784
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 785
S-8 ENGINE LACKS POWER 786
S-9 KDPF GETS CLOGGED IN A SHORT TIME 788
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 789
S-11 OIL BECOMES CONTAMINATED QUICKLY 790
S-12 FUEL CONSUMPTION IS EXCESSIVE 791
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 792
S-14 OIL PRESSURE DROPS 793
S-15 FUEL MIXES INTO ENGINE OIL 795
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 796
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) 797
S-18 UNUSUAL NOISE IS HEARD 798
S-19 VIBRATION IS EXCESSIVE 799
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT 800
50 DISASSEMBLY AND ASSEMBLY 801
CONTENTS 802
ABBREVIATION LIST 805
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY 811
HOW TO READ THIS MANUAL 811
COATING MATERIALS LIST 813
SPECIAL TOOLS LIST 817
SPECIAL TOOLS LIST 822
ENGINE AND COOLING SYSTEM 828
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY 828
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 828
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 831
REMOVE AND INSTALL STARTER ASSEMBLY 834
METHOD FOR REMOVING STARTER ASSEMBLY 834
METHOD FOR INSTALLING STARTER ASSEMBLY 835
REMOVE AND INSTALL RADIATOR AND OIL COOLER ASSEMBLY 837
METHOD FOR REMOVING RADIATOR AND OIL COOLER ASSEMBLY 837
METHOD FOR INSTALLING RADIATOR AND OIL COOLER ASSEMBLY 840
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY 841
METHOD FOR REMOVING ENGINE AND MAIN PUMP ASSEMBLY 841
METHOD FOR INSTALLING ENGINE AND MAIN PUMP ASSEMBLY 845
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY 848
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY 848
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY 848
REMOVE AND INSTALL PARTITION COVER ASSEMBLY 850
METHOD FOR REMOVING PARTITION COVER ASSEMBLY 850
METHOD FOR INSTALLING PARTITION COVER ASSEMBLY 854
REMOVE AND INSTALL FUEL TANK ASSEMBLY 856
METHOD FOR REMOVING FUEL TANK ASSEMBLY 856
METHOD FOR INSTALLING FUEL TANK ASSEMBLY 858
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY 859
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY 859
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY 860
POWER TRAIN 861
REMOVE AND INSTALL TRAVEL MOTOR ASSEMBLY 861
METHOD FOR REMOVING TRAVEL MOTOR ASSEMBLY 861
METHOD FOR INSTALLING TRAVEL MOTOR ASSEMBLY 862
DISASSEMBLE AND ASSEMBLE TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 863
DISASSEMBLE TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 872
ASSEMBLE TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 892
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY 911
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY 911
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY 913
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY 914
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY 914
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY 919
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY 927
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY 927
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY 927
UNDERCARRIAGE AND FRAME 929
REMOVE AND INSTALL SPROCKET 929
METHOD FOR REMOVING SPROCKET 929
METHOD FOR INSTALLING SPROCKET 929
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY 930
METHOD FOR DISASSEMBLING IDLER ASSEMBLY 930
METHOD FOR ASSEMBLING IDLER ASSEMBLY 931
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY 934
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY 934
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY 935
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 937
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY 937
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY 939
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY 942
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY 942
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY 944
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY 945
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY 945
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY 947
HYDRAULIC SYSTEM 948
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY 948
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY 948
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY 950
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY 952
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 952
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 953
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 954
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY 954
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY 956
REMOVE AND INSTALL MAIN PUMP ASSEMBLY 957
METHOD FOR REMOVING MAIN PUMP ASSEMBLY 957
METHOD FOR INSTALLING MAIN PUMP ASSEMBLY 959
REMOVE AND INSTALL HYDRAULIC GEAR PUMP ASSEMBLY 960
METHOD FOR REMOVING HYDRAULIC GEAR PUMP ASSEMBLY 960
METHOD FOR INSTALLING HYDRAULIC GEAR PUMP ASSEMBLY 961
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 963
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 963
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 964
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 966
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY 966
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY 967
WORK EQUIPMENT 969
REMOVE AND INSTALL BUCKET CYLINDER ASSEMBLY 969
METHOD FOR REMOVING BUCKET CYLINDER ASSEMBLY 969
METHOD FOR INSTALLING BUCKET CYLINDER ASSEMBLY 970
REMOVE AND INSTALL BLADE CYLINDER ASSEMBLY 972
METHOD FOR REMOVING BLADE CYLINDER ASSEMBLY 972
METHOD FOR INSTALLING BLADE CYLINDER ASSEMBLY 972
REMOVE AND INSTALL ARM CYLINDER ASSEMBLY 974
METHOD FOR REMOVING ARM CYLINDER ASSEMBLY 974
METHOD FOR INSTALLING ARM CYLINDER ASSEMBLY 975
REMOVE AND INSTALL BOOM CYLINDER ASSEMBLY 977
METHOD FOR REMOVING BOOM CYLINDER ASSEMBLY 977
METHOD FOR INSTALLING BOOM CYLINDER ASSEMBLY 978
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 980
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY 980
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY 982
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY 984
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 985
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 987
REMOVE AND INSTALL SWING BRACKET ASSEMBLY 991
METHOD FOR REMOVING SWING BRACKET ASSEMBLY 991
METHOD FOR INSTALLING SWING BRACKET ASSEMBLY 992
CAB AND ITS ATTACHMENTS 994
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 994
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY 994
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY 999
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) 1001
METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS) 1002
METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS) 1003
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY 1011
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY 1011
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY 1012
REMOVE AND INSTALL OPERATOR’S SEAT 1014
METHOD FOR REMOVING OPERATOR’S SEAT 1014
METHOD FOR INSTALLING OPERATOR’S SEAT 1014
REMOVE AND INSTALL SEAT BELT 1016
METHOD FOR REMOVING SEAT BELT 1016
METHOD FOR INSTALLING SEAT BELT 1016
ELECTRICAL SYSTEM 1017
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY 1017
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 1017
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 1018
REMOVE AND INSTALL MACHINE CONTROLLER ASSEMBLY 1019
METHOD FOR REMOVING MACHINE CONTROLLER ASSEMBLY 1019
METHOD FOR INSTALLING MACHINE CONTROLLER ASSEMBLY 1020
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 1022
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 1022
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 1023
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 1025
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY 1025
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY 1025
60 MAINTENANCE STANDARD 1027
CONTENTS 1028
ABBREVIATION LIST 1029
ENGINE AND COOLING SYSTEM 1035
MAINTENANCE STANDARD FOR PTO 1035
MAINTENANCE STANDARD OF COOLING SYSTEM 1036
POWER TRAIN 1037
MAINTENANCE STANDARD OF SWING CIRCLE 1037
MAINTENANCE STANDARD OF SWING MACHINERY 1038
MAINTENANCE STANDARD OF SPROCKET 1039
UNDERCARRIAGE AND FRAME 1040
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION 1040
MAINTENANCE STANDARD OF IDLER 1041
MAINTENANCE STANDARD OF TRACK ROLLER 1043
MAINTENANCE STANDARD OF CARRIER ROLLER 1044
MAINTENANCE STANDARD OF TRACK SHOE 1045
MAINTENANCE STANDARD OF TRIPLE SHOE 1048
MAINTENANCE STANDARD OF ROAD LINER 1049
MAINTENANCE STANDARD FOR RUBBER SHOE 1050
HYDRAULIC SYSTEM 1051
MAINTENANCE STANDARD OF HYDRAULIC TANK 1051
MAINTENANCE STANDARD OF MAIN PUMP 1052
MAINTENANCE STANDARD OF SWING MOTOR 1054
MAINTENANCE STANDARD OF TRAVEL MOTOR 1055
MAINTENANCE STANDARD OF CONTROL VALVE 1056
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE 1067
MAINTENANCE STANDARD OF BLADE PPC VALVE 1070
MAINTENANCE STANDARD OF BOOM SWING AND 2-PIECE BOOM PPC VALVE 1072
MAINTENANCE STANDARD OF TRAVEL PPC VALVE 1074
WORK EQUIPMENT 1077
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 1077
DIMENSIONS OF BUCKET 1086
MAINTENANCE STANDARD OF BOOM CYLINDER 1088
MAINTENANCE STANDARD OF ARM CYLINDER 1089
MAINTENANCE STANDARD OF BUCKET CYLINDER 1090
MAINTENANCE STANDARD OF BLADE CYLINDER 1091
MAINTENANCE STANDARD OF 2-PIECE BOOM CYLINDER 1092
MAINTENANCE STANDARD OF BOOM SWING CYLINDER 1093
80 APPENDIX 1095
CONTENTS 1096
ABBREVIATION LIST 1097
AIR CONDITIONER SYSTEM 1103
PRECAUTIONS FOR REFRIGERANT 1103
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE 1104
OUTLINE OF REFRIGERATION CYCLE 1105
COMPONENT PARTS OF AIR CONDITIONER SYSTEM 1107
AIR CONDITIONER UNIT 1107
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT 1107
COMPRESSOR 1109
STRUCTURE OF COMPRESSOR 1109
SPECIFICATIONS OF COMPRESSOR 1109
FUNCTION OF COMPRESSOR 1109
CONDENSER 1111
STRUCTURE OF CONDENSER 1111
SPECIFICATIONS OF CONDENSER 1111
FUNCTION OF CONDENSER 1111
RECEIVER DRIER 1113
STRUCTURE OF RECEIVER DRIER 1113
SPECIFICATIONS OF RECEIVER DRIER 1113
FUNCTION OF RECEIVER DRIER 1113
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 1114
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 1116
A-2 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 1119
A-3 TROUBLESHOOTING FOR TEMPERATURE CONTROL FUNCTION 1123
A-4 TROUBLESHOOTING FOR AIR CONDITINOER COMPRESSOR AND COOLING SYSTEM (ELECTRICAL SYSTEM) 1126
A-5 TROUBLESHOOTING FOR AIR CONDITINOER COMPRESSOR AND COOLING SYSTEM (MECHANICAL SYSTEMS) 1130
A-6 TROUBLESHOOTING FOR HOT WATER CIRCUIT SYSTEM 1131
A-7 UNUSUAL NOISE IS HEARD FROM AIR CONDITINOER RELATED PARTS 1132
A-8 WATER LEAKS FROM AIR CONDITINOER RELATED PARTS 1133
A-9 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER 1134
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS 1135
HANDLE COMPRESSOR OIL 1137
90 CIRCUIT DIAGRAMS 1139
CONTENTS 1140
ABBREVIATION LIST 1141
HYDRAULIC CIRCUIT DIAGRAM 1147
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 1147
HYDRAULIC CIRCUIT DIAGRAM (1/2) 1151
HYDRAULIC CIRCUIT DIAGRAM (2/2) 1153
ELECTRICAL CIRCUIT DIAGRAM 1155
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 1155
ELECTRICAL CIRCUIT DIAGRAM (1/2) 1159
ELECTRICAL CIRCUIT DIAGRAM (2/2) 1161
INDEX 1163

DESCRIPTION:

Komatsu PC80MR-5E0 Hydraulic Excavator Shop Manual WENBM00250 – PDF DOWNLOAD 

SERIAL NUMBERS F70001 and up

FOREWORD, SAFETY, BASIC INFORMATION:
HOW TO READ THE SHOP MANUAL:
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.

Composition of the shop manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. “STRUCTURE
AND FUNCTION” is helpful in not only understanding the structure of each component but performing
troubleshooting.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 TESTING AND ADJUSTING
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “STANDARD VALUE TABLE”.
40 TROUBLESHOOTING
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation,
disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.
80 THE OTHER INFORMATION
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other
components or equipment which cannot be separately classified in the appendix.
90 Circuit diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.

S.V 30/12/24