Komatsu Excavator PC80MR-5E0 service & repair manual

Description Komatsu Excavator PC80MR-5E0 service & repair manual

Komatsu Hydraulic Excavator PC80MR-5E0 pdf workshop service repair manual

Serial numbers:
F70001 and up

Technical documentation, specifications, troubleshooting, maintenance, electrical diagrams, hydraulic schematics, adjusting, assembly, disassembly, removal, installation instructions and other information

SERVICE MANUAL CONTENT:
INDEX AND FOREWORD
ABBREVIATION LIST
FOREWORD, SAFETY, BASIC INFORMATION
HOW TO READ THE SHOP MANUAL
SAFETY NOTICE FOR OPERATION
PRECAUTIONS TO PREVENT FIRE
ACTIONS IF FIRE OCCURS
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT
PRACTICAL USE OF KOMTRAX
DISCONNECT AND CONNECT PUSHPULL TYPE COUPLER
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE
HOW TO READ ELECTRICAL WIRE CODE
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD
STANDARD TIGHTENING TORQUE TABLE
CONVERSION TABLE

SPECIFICATIONS
ABBREVIATION LIST
SPECIFICATIONS
SPECIFICATION DRAWING
WORKING RANGE DRAWINGS
SPECIFICATIONS
WEIGHT TABLE
TABLE OF FUEL, COOLANT, AND LUBRICANTS

STRUCTURE AND FUNCTION
ABBREVIATION LIST
NOx CONTROL SYSTEM
FUNCTION OF NOx CONTROL SYSTEM
BOOT-UP SYSTEM
LAYOUT DRAWING OF BOOT-UP SYSTEM
SYSTEM OPERATING LAMP SYSTEM
BATTERY DISCONNECT SWITCH
ENGINE SYSTEM
LAYOUT DRAWING OF ENGINE SYSTEM
ENGINE CONTROL SYSTEM
AUTODECELERATION SYSTEM
OVERHEAT PREVENTION SYSTEM
AUTOMATIC IDLE STOP SYSTEM
COMPONENT PARTS OF ENGINE SYSTEM
COOLING SYSTEM
LAYOUT DRAWING OF COOLING SYSTEM
CONTROL SYSTEM
LAYOUT DRAWING OF CONTROL SYSTEM
MACHINE MONITOR SYSTEM
KOMTRAX SYSTEM
COMPONENT PARTS OF CONTROL SYSTEM
HYDRAULIC SYSTEM
LAYOUT DRAWING OF HYDRAULIC SYSTEM
CLSS
ENGINE AND PUMP COMBINED CONTROL SYSTEM
COMPONENT PARTS OF HYDRAULIC SYSTEM
WORK EQUIPMENT SYSTEM
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM
STRUCTURE OF VALVE CONTROL
PPC LOCK SYSTEM
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM
SWING SYSTEM
LAYOUT DRAWING OF SWING SYSTEM
COMPONENT PARTS OF SWING SYSTEM
TRAVEL SYSTEM
LAYOUT DRAWING OF TRAVEL SYSTEM
TRAVEL CONTROL SYSTEM DIAGRAM
COMPONENT PARTS OF TRAVEL SYSTEM
UNDERCARRIAGE AND FRAME
LAYOUT DRAWING OF UNDERCARRIAGE
IDLER CUSHION
WORK EQUIPMENT
STRUCTURE OF WORK EQUIPMENT
FUNCTION OF WORK EQUIPMENT
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM
CAB AND ITS ATTACHMENTS
ROPS CAB

STANDARD VALUE TABLE
ABBREVIATION LIST 
STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR ENGINE: PC80MR-5E0
STANDARD VALUE TABLE FOR MACHINE
STANDARD VALUE TABLE FOR MACHINE: PC80MR-5E0
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE

TESTING AND ADJUSTING
ABBREVIATION LIST
RELATED INFORMATION ON TESTING AND ADJUSTING
ENGINE AND COOLING SYSTEM
CONNECTING ENGINE SOFTWARE DIAGNOSTIC TOOL TO THE MACHINE
TEST ENGINE SPEED
TEST EXHAUST GAS COLOR
TEST AND ADJUST VALVE CLEARANCE
TEST COMPRESSION PRESSURE
TEST ENGINE OIL PRESSURE
BLEED AIR FROM FUEL SYSTEM
TEST FUEL CIRCUIT FOR LEAKAGE
HANDLE CYLINDER CUTOUT MODE OPERATION
TEST AND ADJUST ALTERNATOR BELT TENSION
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION
POWER TRAIN
TEST SWING CIRCLE BEARING CLEARANCE
UNDERCARRIAGE AND FRAME
TEST AND ADJUST TRACK TENSION
HYDRAULIC SYSTEM
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, TRAVEL, AND BOOM SWING CIRCUITS
TEST AND ADJUST SWING AND BLADE CIRCUIT OIL PRESSURE
TEST AND ADJUST OIL PRESSURE OF CONTROL CIRCUIT
ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT
TEST OUTLET PRESSURE OF SOLENOID VALVE
TEST PPC VALVE OUTLET PRESSURE
ADJUST WORK EQUIPMENT AND SWING PPC VALVES
TEST AND ADJUST TRAVEL DEVIATION
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT
TEST OIL LEAKAGE
BLEED AIR FROM HYDRAULIC CIRCUIT
PRESSURIZE HYDRAULIC TANK
ELECTRICAL SYSTEM
SET AND OPERATE MACHINE MONITOR
METHOD FOR STARTING UP KOMTRAX TERMINAL
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER
TEST DIODES

TROUBLESHOOTING
ABBREVIATION LIST
RELATED INFORMATION ON TROUBLESHOOTING
GENERAL TROUBLESHOOTING POINTS
SEQUENCE OF EVENTS IN TROUBLESHOOTING
TROUBLESHOOTING POINTS FOR AFTERTREATMENT SYSTEM
CHECKS BEFORE TROUBLESHOOTING
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING
TESTING IN ACCORDANCE WITH TESTING PROCEDURE
ELECTRICAL SYSTEM TROUBLESHOOTING  PREPARATION
PROCEDURE FOR TESTING AND TROUBLESHOOTING
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE
FUSE LOCATION TABLE
FAILURE CODES TABLE
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H-MODE)
TROUBLESHOOTING OF ENGINE (S-MODE)

DISASSEMBLY AND ASSEMBLY
ABBREVIATION LIST
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY
HOW TO READ THIS MANUAL
COATING MATERIALS LIST
SPECIAL TOOLS LIST
SPECIAL TOOLS LIST
ENGINE AND COOLING SYSTEM
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY
REMOVE AND INSTALL STARTER ASSEMBLY
REMOVE AND INSTALL RADIATOR AND OIL COOLER ASSEMBLY
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY
REMOVE AND INSTALL PARTITION COVER ASSEMBLY
REMOVE AND INSTALL FUEL TANK ASSEMBLY
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY
POWER TRAIN
REMOVE AND INSTALL TRAVEL MOTOR ASSEMBLY
DISASSEMBLE AND ASSEMBLE TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY
UNDERCARRIAGE AND FRAME
REMOVE AND INSTALL SPROCKET
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY
HYDRAULIC SYSTEM
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY
REMOVE AND INSTALL MAIN PUMP ASSEMBLY
REMOVE AND INSTALL HYDRAULIC GEAR PUMP ASSEMBLY
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY
WORK EQUIPMENT
REMOVE AND INSTALL BUCKET CYLINDER ASSEMBLY
REMOVE AND INSTALL BLADE CYLINDER ASSEMBLY
REMOVE AND INSTALL ARM CYLINDER ASSEMBLY
REMOVE AND INSTALL BOOM CYLINDER ASSEMBLY
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY
REMOVE AND INSTALL SWING BRACKET ASSEMBLY
CAB AND ITS ATTACHMENTS
REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLY
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS)
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY
REMOVE AND INSTALL OPERATOR'S SEAT
REMOVE AND INSTALL SEAT BELT
ELECTRICAL SYSTEM
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY
REMOVE AND INSTALL MACHINE CONTROLLER ASSEMBLY
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY

MAINTENANCE STANDARD
ABBREVIATION LIST
ENGINE AND COOLING SYSTEM
MAINTENANCE STANDARD FOR PTO
MAINTENANCE STANDARD OF COOLING SYSTEM
POWER TRAIN
MAINTENANCE STANDARD OF SWING CIRCLE
MAINTENANCE STANDARD OF SWING MACHINERY
MAINTENANCE STANDARD OF SPROCKET
UNDERCARRIAGE AND FRAME
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION
MAINTENANCE STANDARD OF IDLER
MAINTENANCE STANDARD OF TRACK ROLLER
MAINTENANCE STANDARD OF CARRIER ROLLER
MAINTENANCE STANDARD OF TRACK SHOE
MAINTENANCE STANDARD OF TRIPLE SHOE
MAINTENANCE STANDARD OF ROAD LINER
MAINTENANCE STANDARD FOR RUBBER SHOE
HYDRAULIC SYSTEM
MAINTENANCE STANDARD OF HYDRAULIC TANK
MAINTENANCE STANDARD OF MAIN PUMP
MAINTENANCE STANDARD OF SWING MOTOR
MAINTENANCE STANDARD OF TRAVEL MOTOR
MAINTENANCE STANDARD OF CONTROL VALVE
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE
MAINTENANCE STANDARD OF BLADE PPC VALVE
MAINTENANCE STANDARD OF BOOM SWING AND 2-PIECE BOOM PPC VALVE
MAINTENANCE STANDARD OF TRAVEL PPC VALVE
WORK EQUIPMENT
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE
MAINTENANCE STANDARD OF BOOM CYLINDER
MAINTENANCE STANDARD OF ARM CYLINDER
MAINTENANCE STANDARD OF BUCKET CYLINDER
MAINTENANCE STANDARD OF BLADE CYLINDER
MAINTENANCE STANDARD OF 2-PIECE BOOM CYLINDER
MAINTENANCE STANDARD OF BOOM SWING CYLINDER

APPENDIX
ABBREVIATION LIST
AIR CONDITIONER SYSTEM
PRECAUTIONS FOR REFRIGERANT
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE
OUTLINE OF REFRIGERATION CYCLE
COMPONENT PARTS OF AIR CONDITIONER SYSTEM
AIR CONDITIONER UNIT
COMPRESSOR
CONDENSER
RECEIVER DRIER
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)
A-2 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)
A-3 TROUBLESHOOTING FOR TEMPERATURE CONTROL FUNCTION
A-4 TROUBLESHOOTING FOR AIR CONDITINOER COMPRESSOR AND COOLING SYSTEM (ELECTRICAL SYSTEM)
A-5 TROUBLESHOOTING FOR AIR CONDITINOER COMPRESSOR AND COOLING SYSTEM (MECHANICAL SYSTEMS)
A-6 TROUBLESHOOTING FOR HOT WATER CIRCUIT SYSTEM
A-7 UNUSUAL NOISE IS HEARD FROM AIR CONDITINOER RELATED PARTS
A-8 WATER LEAKS FROM AIR CONDITINOER RELATED PARTS
A-9 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS
HANDLE COMPRESSOR OIL

CIRCUIT DIAGRAMS
ABBREVIATION LIST
HYDRAULIC CIRCUIT DIAGRAM
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM