Komatsu PC500LC-10R Install guide

HYDRAULIC
EXCAVATOR
SEN06722-00
PC500LC-10R
SERIAL NUMBERS
100001
and up

00 INDEX AND FOREWORD
PC500LC-10R 00-1

INDEX
00 INDEX AND FOREWORD ........................................................................................................................ 00-1
ABBREVIATION LIST ............................................................................................................................. 00-6
FOREWORD, SAFETY, BASIC INFORMATION ................................................................................... 00-12
HOW TO READ THE SHOP MANUAL........................................................................................... 00-12
SAFETY NOTICE FOR OPERATION............................................................................................. 00-14
PRECAUTIONS TO PREVENT FIRE............................................................................................. 00-22
ACTIONS IF FIRE OCCURS ......................................................................................................... 00-24
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS ........................................................ 00-25
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT ...................................................... 00-26
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS................................ 00-29
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT..................................................... 00-35
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT .................................................. 00-37
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT .............................................. 00-38
PRACTICAL USE OF KOMTRAX .................................................................................................. 00-39
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER ................................................... 00-40
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS ..................... 00-44
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR ..................... 00-48
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR ....... 00-49
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL ... 00-51
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH .. 00-52
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE .
................................................................................................................................................... 00-54
HOW TO READ ELECTRICAL WIRE CODE ................................................................................. 00-55
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD.................................................... 00-59
STANDARD TIGHTENING TORQUE TABLE................................................................................. 00-62
CONVERSION TABLE................................................................................................................... 00-69
01 SPECIFICATIONS .................................................................................................................................... 01-1
CONTENTS ............................................................................................................................................ 01-2
ABBREVIATION LIST ............................................................................................................................. 01-3
SPECIFICATIONS .................................................................................................................................. 01-9
SPECIFICATION DRAWING............................................................................................................ 01-9
WORKING RANGE DRAWINGS ................................................................................................... 01-10
SPECIFICATIONS ..........................................................................................................................01-11
WEIGHT TABLE ............................................................................................................................ 01-14
TABLE OF FUEL, COOLANT, AND LUBRICANTS ........................................................................ 01-16
10 STRUCTURE AND FUNCTION ................................................................................................................ 10-1
CONTENTS ............................................................................................................................................ 10-2
ABBREVIATION LIST ............................................................................................................................. 10-5
BOOT-UP SYSTEM ...............................................................................................................................10-11
LAYOUT DRAWING OF BOOT-UP SYSTEM..................................................................................10-11
SYSTEM OPERATING LAMP SYSTEM ........................................................................................ 10-13
BATTERY DISCONNECT SWITCH ............................................................................................... 10-14
ENGINE SYSTEM ................................................................................................................................ 10-15
LAYOUT DRAWING OF ENGINE SYSTEM................................................................................... 10-15
ENGINE CONTROL SYSTEM ....................................................................................................... 10-17
AUTO-DECELERATION SYSTEM................................................................................................. 10-20
ENGINE AUTOMATIC WARM-UP SYSTEM .................................................................................. 10-22
OVERHEAT PREVENTION SYSTEM ............................................................................................ 10-24
TURBOCHARGER PROTECTION SYSTEM ................................................................................. 10-26
AUTOMATIC IDLE STOP SYSTEM ............................................................................................... 10-28
COMPONENT PARTS OF ENGINE SYSTEM ............................................................................... 10-31
COOLING SYSTEM.............................................................................................................................. 10-33
LAYOUT DRAWING OF COOLING SYSTEM ................................................................................ 10-33
FAN SPEED CONTROL SYSTEM OF FAN CLUTCH .................................................................... 10-35
ENGINE OUTPUT CONTROL SYSTEM OF FAN CLUTCH........................................................... 10-37
COMPONENT PARTS OF COOLING SYSTEM............................................................................. 10-39
INDEX 00 INDEX AND FOREWORD
00-2 PC500LC-10R

CONTROL SYSTEM............................................................................................................................. 10-40
LAYOUT DRAWING OF CONTROL SYSTEM ............................................................................... 10-40
MACHINE MONITOR SYSTEM ..................................................................................................... 10-43
KOMTRAX SYSTEM...................................................................................................................... 10-45
COMPONENT PARTS OF CONTROL SYSTEM............................................................................ 10-46
HYDRAULIC SYSTEM.......................................................................................................................... 10-73
LAYOUT DRAWING OF HYDRAULIC SYSTEM ............................................................................ 10-73
CLSS ............................................................................................................................................. 10-77
ENGINE AND PUMP COMBINED CONTROL SYSTEM................................................................ 10-96
PUMP AND VALVE CONTROL SYSTEM .....................................................................................10-102
COMPONENT PARTS OF HYDRAULIC SYSTEM .......................................................................10-105
WORK EQUIPMENT SYSTEM ............................................................................................................10-191
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM ..............................................................10-191
ONE-TOUCH POWER MAXIMIZING SYSTEM ............................................................................10-195
MACHINE PUSH-UP SYSTEM.....................................................................................................10-197
PPC LOCK SYSTEM ....................................................................................................................10-199
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM ..............................................10-200
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT.................................................................10-202
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM...........................................................10-204
SWING SYSTEM .................................................................................................................................10-222
LAYOUT DRAWING OF SWING SYSTEM ...................................................................................10-222
SWING CONTROL SYSTEM DIAGRAM ......................................................................................10-226
COMPONENT PARTS OF SWING SYSTEM................................................................................10-230
TRAVEL SYSTEM................................................................................................................................10-248
LAYOUT DRAWING OF TRAVEL SYSTEM ..................................................................................10-248
TRAVEL CONTROL SYSTEM DIAGRAM.....................................................................................10-252
COMPONENT PARTS OF TRAVEL SYSTEM ..............................................................................10-254
UNDERCARRIAGE AND FRAME........................................................................................................10-275
LAYOUT DRAWING OF UNDERCARRIAGE ................................................................................10-275
WORK EQUIPMENT............................................................................................................................10-276
STRUCTURE OF WORK EQUIPMENT ........................................................................................10-276
FUNCTION OF WORK EQUIPMENT ...........................................................................................10-277
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM............................................................10-278
BUCKET CLEARANCE ADJUSTMENT SHIM ..............................................................................10-279
CAB AND ITS ATTACHMENTS ...........................................................................................................10-280
ROPS CAB ...................................................................................................................................10-280
CAB MOUNT ................................................................................................................................10-281
CAB TIPPING STOPPER .............................................................................................................10-282
20 STANDARD VALUE TABLE ...................................................................................................................... 20-1
CONTENTS ............................................................................................................................................ 20-2
ABBREVIATION LIST ............................................................................................................................. 20-3
STANDARD VALUE TABLE FOR ENGINE ............................................................................................. 20-9
STANDARD VALUE TABLE FOR ENGINE: PC500LC-10R ............................................................. 20-9
STANDARD VALUE TABLE FOR MACHINE......................................................................................... 20-13
STANDARD VALUE TABLE FOR MACHINE: PC500LC-10R......................................................... 20-13
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE ......................... 20-27
30 TESTING AND ADJUSTING..................................................................................................................... 30-1
CONTENTS ............................................................................................................................................ 30-2
ABBREVIATION LIST ............................................................................................................................. 30-5
RELATED INFORMATION ON TESTING AND ADJUSTING .................................................................30-11
TOOLS FOR TESTING AND ADJUSTING......................................................................................30-11
SKETCH OF TOOLS FOR TESTING AND ADJUSTING ............................................................... 30-16
ENGINE AND COOLING SYSTEM....................................................................................................... 30-18
TEST ENGINE SPEED .................................................................................................................. 30-18
TEST BOOST PRESSURE............................................................................................................ 30-21
TEST EXHAUST GAS TEMPERATURE ........................................................................................ 30-24
TEST EXHAUST GAS COLOR...................................................................................................... 30-26
TEST AND ADJUST VALVE CLEARANCE .................................................................................... 30-28
00 INDEX AND FOREWORD INDEX
PC500LC-10R 00-3

TEST COMPRESSION PRESSURE.............................................................................................. 30-31
TEST BLOWBY PRESSURE ......................................................................................................... 30-34
TEST ENGINE OIL PRESSURE .................................................................................................... 30-37
TEST FUEL PRESSURE ............................................................................................................... 30-39
TEST FUEL RETURN RATE AND LEAKAGE................................................................................ 30-41
BLEED AIR FROM FUEL SYSTEM ............................................................................................... 30-44
TEST FUEL CIRCUIT FOR LEAKAGE .......................................................................................... 30-47
HANDLE CYLINDER CUT-OUT MODE OPERATION.................................................................... 30-49
HANDLE NO-INJECTION CRANKING OPERATION ..................................................................... 30-50
TEST FAN BELT ............................................................................................................................ 30-51
TEST ALTERNATOR BELT............................................................................................................ 30-52
TEST AUTOMATIC TENSIONER .................................................................................................. 30-54
TEST COOLING FAN SPEED ...................................................................................................... 30-56
POWER TRAIN..................................................................................................................................... 30-57
TEST SWING CIRCLE BEARING CLEARANCE ........................................................................... 30-57
UNDERCARRIAGE AND FRAME......................................................................................................... 30-58
TEST AND ADJUST TRACK TENSION......................................................................................... 30-58
HYDRAULIC SYSTEM.......................................................................................................................... 30-60
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM............................................. 30-60
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS ........
................................................................................................................................................... 30-63
TEST OIL PRESSURE OF CONTROL CIRCUIT ........................................................................... 30-74
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT .................................... 30-76
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT..................................... 30-80
TEST OUTLET PRESSURE OF SOLENOID VALVE ..................................................................... 30-86
TEST PPC VALVE OUTLET PRESSURE ...................................................................................... 30-90
ADJUST WORK EQUIPMENT AND SWING PPC VALVES ........................................................... 30-93
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT................................. 30-94
TEST OIL LEAKAGE ..................................................................................................................... 30-96
BLEED AIR FROM HYDRAULIC CIRCUIT .................................................................................... 30-99
CAB AND ITS ATTACHMENTS ...........................................................................................................30-104
TEST CAB TIPPING STOPPER ...................................................................................................30-104
METHOD FOR ADJUSTING MIRRORS .......................................................................................30-105
ELECTRICAL SYSTEM .......................................................................................................................30-112
SET AND OPERATE MACHINE MONITOR..................................................................................30-112
METHOD FOR STARTING UP KOMTRAX TERMINAL ................................................................30-173
ADJUST REARVIEW CAMERA ANGLE .......................................................................................30-178
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER .........................................................30-181
HANDLE BATTERY DISCONNECT SWITCH ...............................................................................30-182
TEST DIODES ..............................................................................................................................30-183
Pm CLINIC...........................................................................................................................................30-184
Pm CLINIC SERVICE ...................................................................................................................30-184
60 MAINTENANCE STANDARD.................................................................................................................... 60-1
CONTENTS ............................................................................................................................................ 60-2
ABBREVIATION LIST ............................................................................................................................. 60-3
ENGINE AND COOLING SYSTEM......................................................................................................... 60-9
MAINTENANCE STANDARD OF ENGINE MOUNT ........................................................................ 60-9
MAINTENANCE STANDARD OF COOLING SYSTEM .................................................................. 60-10
POWER TRAIN......................................................................................................................................60-11
MAINTENANCE STANDARD OF SWING CIRCLE .........................................................................60-11
MAINTENANCE STANDARD OF SWING MACHINERY................................................................ 60-13
MAINTENANCE STANDARD OF FINAL DRIVE ............................................................................ 60-15
MAINTENANCE STANDARD OF SPROCKET .............................................................................. 60-17
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING ......... 60-18
UNDERCARRIAGE AND FRAME......................................................................................................... 60-20
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION.................................... 60-20
MAINTENANCE STANDARD OF IDLER ....................................................................................... 60-22
MAINTENANCE STANDARD OF TRACK ROLLER....................................................................... 60-24
INDEX 00 INDEX AND FOREWORD
00-4 PC500LC-10R

MAINTENANCE STANDARD OF CARRIER ROLLER................................................................... 60-26
MAINTENANCE STANDARD OF TRACK SHOE........................................................................... 60-27
MAINTENANCE STANDARD OF TRIPLE SHOE........................................................................... 60-30
HYDRAULIC SYSTEM.......................................................................................................................... 60-31
MAINTENANCE STANDARD OF MAIN PUMP.............................................................................. 60-31
MAINTENANCE STANDARD OF SWING MOTOR........................................................................ 60-33
MAINTENANCE STANDARD OF TRAVEL MOTOR ...................................................................... 60-36
MAINTENANCE STANDARD OF CONTROL VALVE..................................................................... 60-39
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE ....................... 60-50
MAINTENANCE STANDARD OF TRAVEL PPC VALVE ................................................................ 60-53
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE)...... 60-56
MAINTENANCE STANDARD OF SOLENOID VALVE.................................................................... 60-60
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE ........................... 60-61
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT.......................................................... 60-62
WORK EQUIPMENT............................................................................................................................. 60-63
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE................................................. 60-63
MAINTENANCE STANDARD OF BOOM CYLINDER .................................................................... 60-72
MAINTENANCE STANDARD OF ARM CYLINDER ....................................................................... 60-73
MAINTENANCE STANDARD OF BUCKET CYLINDER................................................................. 60-74
90 CIRCUIT DIAGRAMS ............................................................................................................................... 90-1
CONTENTS ............................................................................................................................................ 90-2
ABBREVIATION LIST ............................................................................................................................. 90-3
HYDRAULIC CIRCUIT DIAGRAM .......................................................................................................... 90-9
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM .................................................................. 90-9
HYDRAULIC CIRCUIT DIAGRAM (WHEN BOOM IS RAISED) ..................................................... 90-13
HYDRAULIC CIRCUIT DIAGRAM (WHEN UPPER STRUCTURE IS SWING TO LEFT)............... 90-15
HYDRAULIC CIRCUIT DIAGRAM (WHEN BOOM IS RAISED AND UPPER STRUCTURE IS SWUNG
TO LEFT) ................................................................................................................................... 90-17
HYDRAULIC CIRCUIT DIAGRAM (1/2) ......................................................................................... 90-19
HYDRAULIC CIRCUIT DIAGRAM (2/2) ......................................................................................... 90-21
ELECTRICAL CIRCUIT DIAGRAM ....................................................................................................... 90-23
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM............................................................... 90-23
ELECTRICAL CIRCUIT DIAGRAM (1/7)........................................................................................ 90-27
ELECTRICAL CIRCUIT DIAGRAM (2/7)........................................................................................ 90-29
ELECTRICAL CIRCUIT DIAGRAM (3/7)........................................................................................ 90-31
ELECTRICAL CIRCUIT DIAGRAM (4/7)........................................................................................ 90-33
ELECTRICAL CIRCUIT DIAGRAM (5/7)........................................................................................ 90-35
ELECTRICAL CIRCUIT DIAGRAM (6/7)........................................................................................ 90-37
ELECTRICAL CIRCUIT DIAGRAM (7/7)........................................................................................ 90-39
CONNECTOR AND WIRING HARNESS CHART (1/15) ................................................................ 90-41
CONNECTOR AND WIRING HARNESS CHART (2/15) ................................................................ 90-43
CONNECTOR AND WIRING HARNESS CHART (3/15) ................................................................ 90-45
CONNECTOR AND WIRING HARNESS CHART (4/15) ................................................................ 90-47
CONNECTOR AND WIRING HARNESS CHART (5/15) ................................................................ 90-49
CONNECTOR AND WIRING HARNESS CHART (6/15) ................................................................ 90-51
CONNECTOR AND WIRING HARNESS CHART (7/15) ................................................................ 90-53
CONNECTOR AND WIRING HARNESS CHART (8/15) ................................................................ 90-55
CONNECTOR AND WIRING HARNESS CHART (9/15) ................................................................ 90-57
CONNECTOR AND WIRING HARNESS CHART (10/15) .............................................................. 90-59
CONNECTOR AND WIRING HARNESS CHART (11/15) .............................................................. 90-61
CONNECTOR AND WIRING HARNESS CHART (12/15) .............................................................. 90-63
CONNECTOR AND WIRING HARNESS CHART (13/15) .............................................................. 90-65
CONNECTOR AND WIRING HARNESS CHART (14/15) .............................................................. 90-67
CONNECTOR AND WIRING HARNESS CHART (15/15) .............................................................. 90-69
INDEX..................................................................................................................................................................1
00 INDEX AND FOREWORD INDEX
PC500LC-10R 00-5

ABBREVIATION LIST
• This list of abbreviations includes the abbreviations used in the text of the shop manual for parts, compo-
nents, and functions whose meaning is not immediately clear. The spelling is given in full with an outline of
the meaning.
• Abbreviations that are used in general society may not be included.
• Special abbreviations which appear infrequently are noted in the text.
• This list of abbreviations consists of two parts. The first part is a list of the abbreviations used in the text of
the manual, and the second part is a list of the abbreviations used in the circuit diagrams.
List of abbreviations used in the text
Abbrevia-
tion Actual word spelled out
Purpose of use (major ap-
plicable machine (*1), or
component/system)
Explanation
ABS Antilock Brake System
Travel and brake This is a function that releases the brake when
the tires skid (tires are not rotated). This function
applies the brake again when the tires rotate.
(HD, HM)
AISS Automatic Idling Setting
System Engine This is a function that automatically sets the idle speed.
AJSS Advanced Joystick
Steering System
Steering This is a function that performs the steering oper-
ations with a lever instead of using a steering
wheel. This function performs gear shifting and
changing forward and reverse direction.
(WA)
ARAC Automatic Retarder Ac-
celerator Control
Travel and brake This is a function that automatically operates the
retarder with a constant braking force when let-
ting go of the accelerator pedal on the downhill.
(HD, HM)
ARSC Automatic Retarder
Speed Control
Travel and brake This is a function that automatically operates the
retarder to ensure that the machine speed does
not accelerate above the speed set by the opera-
tor when letting go of the accelerator pedal on
the downhill.
(HD, HM)
ASR Automatic Spin Regula-
tor
Travel and brake This is a function that drives both wheels auto-
matically using the optimum braking force when
the tire on one side spins on the soft ground sur-
faces.
(HD, HM)
ATT Attachment Work equipment A function or component that can be added to the
standard specification.
BCV Brake cooling oil control
valve
BRAKE This is a valve that bypasses a part of the brake
cooling oil to reduce the load applied to the hy-
draulic pump when the retarder is not being
used.
(HD)
CAN Controller Area Network Communication and elec-
tronic control
This is one of communication standards that are
used in the network on the machine.
CDR Crankcase Depression
Regulator Engine
This is a regulator valve that is installed to KCCV
ventilator. It is written as CDR valve and is not
used independently.
CLSS Closed-center Load
Sensing System Hydraulic system
This is a system that can actuate multiple actua-
tors simultaneously regardless of the load (pro-
vides better combined operation than OLSS).
ABBREVIATION LIST 00 INDEX AND FOREWORD
00-6 PC500LC-10R

Abbrevia-
tion Actual word spelled out
Purpose of use (major ap-
plicable machine (*1), or
component/system)
Explanation
CRI Common Rail Injection Engine
This is a function that maintains optimum fuel in-
jection amount and fuel injection timing. This is
performed the engine controller which electroni-
cally controls supply pump, common rail, and in-
jector.
ECM Electronic Control Mod-
ule Electronic control system
This is an electronic control device that send the
command to actuators using the signals from the
sensors on the machine so that the optimum ac-
tuation is performed. (Same as ECU)
ECMV Electronic Control Mod-
ulation Valve
Transmission This is a proportional electromagnetic valve that
decreases the transmission shock by gradually
increasing oil pressure for engaging clutch.
(D, HD, WA, etc)
ECSS Electronically Controlled
Suspension System
Travel This is a device that ensures smooth high-speed
travel by absorbing vibration of machine during
travel with hydraulic spring effect of accumulator.
(WA)
ECU Electronic Control Unit Electronic control system
This is an electronic control device that send the
command to actuators using the signals from the
sensors on the machine so that the optimum ac-
tuation is performed. (Same as ECM)
EGR Exhaust Gas Recircula-
tion Engine
This is a function that recirculates a part of ex-
haust gas to combustion chamber, so that it re-
duces combustion temperature, and reduces
emission of NOx.
EMMS Equipment Manage-
ment Monitoring System Machine monitor
This is a function with which operator can check
information from each sensor on the machine (fil-
ter, oil replacement interval, malfunctions on ma-
chine, failure code, and failure history).
EPC Electromagnetic Propor-
tional Control Hydraulic system
Electromagnetic proportional control This is a
mechanism with which actuators operate in pro-
portion to the current.
FOPS Falling Object Protective
Structure Cab and canopy
This structure protects the operator's head from
falling objects. (Falling object protective struc-
ture)
This performance is standardized as ISO 3449.
F-N-R Forward-Neutral-Re-
verse Operation Forward - Neutral - Reverse
GPS Global Positioning Sys-
tem
Communication This system uses satellites to determine the cur-
rent location on the earth.
(KOMTRAX, KOMTRAX
Plus)
GNSS Global Navigation Satel-
lite System
Communication This is a general term for system uses satellites
such as GPS, GALILEO, etc.
(KOMTRAX, KOMTRAX
Plus)
HSS Hydrostatic Steering
System
Steering This is a function that enables the machine to
turn without steering clutch by controlling a differ-
ence in travel speed of right and left tracks with a
combination of hydraulic motor and bevel shaft.
(D Series)
HST Hydro Static Transmis-
sion
Transmission Hydraulic transmission system that uses a com-
bination of hydraulic pump and hydraulic motor
without using gears for stepless gear shifting.
(D, WA)
00 INDEX AND FOREWORD ABBREVIATION LIST
PC500LC-10R 00-7

Abbrevia-
tion Actual word spelled out
Purpose of use (major ap-
plicable machine (*1), or
component/system)
Explanation
ICT Information and Com-
munication Technology
Communication and elec-
tronic control
A general term for the engineering and its social-
ly applied technology of information processing
and communication.
IMA Inlet Metering Actuator Engine
This is a valve that adjusts the fuel intake amount
at the pump inlet in order to control the supply
pump fuel discharged volume. (Same as IMV)
IMU Inertial Measurement
Unit Engine
This is a device to detect the angle (or angular
velocity) and acceleration of the 3 axes that con-
trol motions.
IMV Inlet Metering Valve Engine
This is a valve that adjusts the fuel intake amount
at the pump inlet in order to control the supply
pump combustion discharged volume. (Same as
IMA)
KCCV Komatsu Closed Crank-
case Ventilation Engine
This is a mechanism that burns the blowby gas
again by separating oil from blowby gas and re-
turning it to the intake side. It primarily consists of
filters.
KCSF Komatsu Catalyzed
Soot Filter Engine This is a filter that captures soot in exhaust gas.
It is built in to KDPF.
KDOC Komatsu Diesel Oxida-
tion Catalyst Engine
This is a catalyst that is used for purifying ex-
haust gas.
It is built in to KDPF or assembled with the muf-
fler.
KDPF Komatsu Diesel Particu-
late Filter Engine
This is a component that is used to purify the ex-
haust gas. KDOC (catalyst) and KCSF (filter to
capture soot) are built-in it.
It is installed instead of the conventional muffler.
KTCS Komatsu Traction Con-
trol System
Travel and brake This is a function that performs braking with the
optimum force and recovers the driving force of
the wheels by actuating the inter-axle differential
lock when the wheels runs idle while the machine
travels on the soft ground.
(HM)
LCD Liquid Crystal Display Machine monitor
This is an image display equipment such as a
monitor in which the liquid crystal elements are
assembled.
LED Light Emitting Diode Electronic parts This is a semiconductor element that emits light
when the voltage is applied in forward direction.
LIN Local Interconnect Net-
work
Communication and elec-
tronic control
This is one of communication standards that are
used in the network on the machine.
LS Load Sensing Hydraulic system
This is a function that detects differential pres-
sure of pump, and controls discharged volume
corresponding to load.
LVDS Low Voltage Differential
Signaling
Communication and elec-
tronic control
This is one of communication standards that are
used in the network on the machine.
MAF Mass Air Flow Engine
This indicates engine intake air flow. This is not
used independently but is used as combined with
sensor. Mass air flow sensor can be called as
MAF sensor.
ABBREVIATION LIST 00 INDEX AND FOREWORD
00-8 PC500LC-10R

Abbrevia-
tion Actual word spelled out
Purpose of use (major ap-
plicable machine (*1), or
component/system)
Explanation
MMS Multimedia Messaging
Service Communication
This is a service that allows transmission and re-
ception of short messages consisting of charac-
ters or voice or images between cell phones.
NC Normally Closed Electrical system, hydraulic
system
This is a characteristic of electrical or hydraulic
circuits. Circuit is normally closed if it is not actu-
ated, and it opens when it is actuated.
NO Normally Open Electrical system, hydraulic
system
This is a characteristic of electrical or hydraulic
circuits. Circuit is normally open if it is not actuat-
ed, and it closes when it is actuated.
OLSS Open-center Load
Sensing System Hydraulic system
This is a hydraulic system that can operate multi-
ple actuators at the same time regardless of the
load.
PC Pressure Compensation Hydraulic system This is a function that corrects the oil pressure.
PCCS Palm command control
system
Steering This is a function that electrically controls the en-
gine and transmission in an optimal way with the
controller instantly analyzing data from levers,
pedals, and dials.
(D Series)
PCV Pre-stroke Control Valve Engine
This is a valve that adjusts the fuel intake amount
at the pump inlet in order to control fuel dis-
charged volume of supply pump.
PPC Proportional Pressure
Control Hydraulic system This is a system that operates actuators in pro- portion to the oil pressure.
PPM Piston Pump and Motor Hydraulic system Piston type hydraulic pump and motor.
(D, PC, etc)
PTO Power Take Off Power train system Power take-off mechanism
PTP Power Tilt and power
Pitch dozer
Work equipment This is a function that performs hydraulic control
of the tilt and pitch of the dozer blade of the bull-
dozer.
(D Series)
ROPS Roll-Over Protective
Structure Cab and canopy
ROPS is a protective structure that intended to
protect the operator wearing seat belt from suffer-
ing injury which may be caused if the cab is
crushed when the machine rolls over. (Roll-over
protective structure)
This performance is standardized as ISO 3471 or
ISO 12117-2.
SCR Selective Catalytic Re-
duction Urea SCR system
This is an exhaust gas purifier using urea water
that converts nitrogen oxides (NOx) into harm-
less nitrogen and water by oxidation-reduction re-
action. It may also be mentioned as exhaust gas
purification catalyst or part of the name of related
devices.
SI
Le Systeme Internation-
al d' Unites (Internation-
al unit system)
Unit
Abbreviation for "International System of Units" It
is the universal unit system and "a single unit for
a single quantity" is the basic principle applied.
SOL Solenoid Electrical system
This is an actuator that consists of a solenoid and
an iron core that is operated by the magnetic
force when the solenoid is energized.
00 INDEX AND FOREWORD ABBREVIATION LIST
PC500LC-10R 00-9

Abbrevia-
tion Actual word spelled out
Purpose of use (major ap-
plicable machine (*1), or
component/system)
Explanation
TOPS Tip-Over Protective
Structure Cab and canopy
This is a protective structure that intended to pro-
tect the operator wearing seat belt from suffering
injury which may be caused if the cab is crushed
when the machine tips over. (Roll-over protective
structure of hydraulic excavator)
This performance is standardized as ISO 12117.
TWV 2-Way Valve Hydraulic system This is a solenoid valve that switches over direc-
tion of flow.
VGT Variable Geometry Tur-
bocharger Engine This is a turbocharger on which the cross-section area of the exhaust passage is variable.
VHPC Variable Horse Power
Control Engine control
This is a function that finely controls the maxi-
mum output of the machine so that high work effi-
ciency and low fuel consumption rate are both
achieved.
*1: Code for applicable machine model
D: Bulldozer
HD: Dump truck
HM: Articulate dump truck
PC: Hydraulic excavator
WA: Wheel loader
List of abbreviations used in the circuit diagrams
Abbreviation Actual word spelled out
A/C Air Conditioner
A/D Analogue-to-Digital
A/M Air Mix Damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
CCW Counter Clockwise
ECU Electronic Control Unit
ECM Electronic Control Module
ENG Engine
EXGND External Ground
F.G. Frame Ground
GND Ground
IMA Inlet Metering Actuator
NC No Connection
ABBREVIATION LIST 00 INDEX AND FOREWORD
00-10 PC500LC-10R

Abbreviation Actual word spelled out
S/T Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
T/C Torque Converter
T/M Transmission
00 INDEX AND FOREWORD ABBREVIATION LIST
PC500LC-10R 00-11

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. "STRUC-
TURE 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 ad-
justing 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, instal-
lation, 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.
Symbols
Important safety and quality portions are marked with the following symbols so that shop manual is used effec-
tively.
HOW TO READ THE SHOP MANUAL 00 INDEX AND FOREWORD
00-12 PC500LC-10R

Symbol Item Remark
Danger This signal indicates an extremely hazardous situation which will result in
death or serious injury if it is not avoided.
Warning This signal indicates a potentially hazardous situation which will result in
death or serious injury if it is not avoided.
Caution This signal indicates a potentially hazardous situation which will result in
injury or property damage around the machine if it is not avoided.
Weight
This signal indicates the weight of parts and components, and items which
requires great attention to a selection of wires and working posture for
slinging work.
Tightening torque This signal indicates the tightening torque for portions which requires spe-
cial care in assembling work.
Coat This signal indicates a place to be coated with adhesive, grease, etc. in
assembling work.
Oil and coolant This signal indicates a place to supply oil, coolant, etc. and the quantity.
Draining This signal indicates a place to drain oil, coolant, etc. and the quantity.
Signal word
Signal word for notice and remark describes the following.
Symbol Item Remark
NOTICE Notice If the precaution of this signal word is not observed, the machine damage
or shortening of service life may occur.
REMARK Remark This signal word contains useful information to know.
Unit
International System of Units (SI) is used in this manual. For reference, units that have been used in the past
are given in { }.
00 INDEX AND FOREWORD HOW TO READ THE SHOP MANUAL
PC500LC-10R 00-13

SAFETY NOTICE FOR OPERATION
• Appropriate servicing and repair are extremely important to ensure safe operation of the machine. The shop
manuals describe the effective and safe servicing and repair methods recommended by Komatsu. Some of
the servicing and repair methods require the use of special tools designed by Komatsu for special purpos-
es.
• The symbol mark is indicated for such matters that require special precautions. The work indicated with
this warning mark should be performed according to the instructions with special attention. Should a
hazardous situation occurs or be anticipated during such work, be sure to keep safe first and take every
necessary measures.
Safety matters
• Well organized work place
• Correct work clothes
• Observance of work standard
• Enforcement of hand signals
• Prohibition against unlicensed persons operating and handling the machine
• Safety check before starting work
• Wear of dust glasses (for cleaning or grinding work)
• Wear of welding goggles and protectors (for welding work)
• Being in good physical condition, and good preparation
• Always be alert and careful.
General precautions
k
If the machine is handled incorrectly, it is dangerous. Read and understand what is described in the
operation and maintenance manual before operation. Read and understand what is described in this
manual before operation.
• Read and understand the meaning of all the safety labels stuck to the machine before performing any
greasing or repairs. For the locations of the safety labels and detailed explanation of precautions, see Oper-
ation and Maintenance Manual.
• Tools and removed parts in the workshop should be well organized. Always keep the tools and parts in their
correct places. Always keep the work area clean and make sure that there is no dust, dirt, oil, or water on
the floor. Smoke only in the designated areas. Never smoke while working.
• Keep all tools in good condition, learn the correct way to use them, and use the proper ones. Check the
tools, machine, forklift truck, service car, etc. thoroughly before starting the work.
• Always wear safety shoes and helmet when performing
any operation. Do not wear loose clothes, or clothes with
buttons missing.
SAFETY NOTICE FOR OPERATION 00 INDEX AND FOREWORD
00-14 PC500LC-10R

• Always wear the protective eyeglasses when hitting parts
with a hammer.
• Always wear the protective eyeglasses when grinding
parts with a grinder, etc.
• When performing any operation with multiple workers, al-
ways agree on the operating procedure before starting. Be
clear in verbal communication, and observe hand signals.
Hang "UNDER REPAIR" warning tag in the operator's
compartment Before starting work.
• Work and operation which require license or qualification
should be performed by qualified workers.
• Welding repairs should be performed by trained and experienced welders. When performing welding work,
always wear welding gloves, apron, welding goggles, cap and other clothes suited for welding work.
• Warm up before starting the work with exercise which increases alertness and the range of motion in order
to prevent injury.
• Avoid prolonged work, and take a rest at times to keep up a good condition. Take a rest at designated safe
area.
Precautions for preparatory work
• Place the machine on a firm and level ground, and apply the parking brake and chock the wheels or tracks
to prevent the machine from moving before adding oil or making any repairs.
• Lower the work equipment (blade, ripper, bucket, etc.) to the ground before starting work. If this is not pos-
sible, insert the lock pin or use blocks to prevent the work equipment from falling. In addition, be sure to
lock all the control levers and hang "UNDER REPAIR" warning tag on them.
• When performing the disassembling or assembling work, support the machine securely with blocks, jacks,
or stands before starting the work.
• Remove all mud and oil from the steps or other places for
going up and down on the machine. Always use the hand-
rails, ladders or steps when for going up and down on the
machine. Never jump on or off the machine. When the
scaffold is not provided, use steps or stepladder to secure
your footing. Do not use handrails, ladders, or steps if they
are damaged or deformed. Repair it or replace it immedi-
ately.
Precautions during work
• For the machine with the battery disconnect switch, check before starting the work that the system operat-
ing lamp is not lit. Then, turn the battery disconnect switch to OFF (○) position.
REMARK
Remove the key after it is turned to OFF (○) position if the battery disconnect switch is a switch key type.
For the machine without the battery disconnect switch, turn the starting switch to OFF position, wait for two
minutes or more before starting the work. Disconnect the battery cable by starting from the negative (-) ter-
minal first.
• For the machine with the quick release battery terminal (-), check before starting the work that the system
operating lamp is not lit. Then, disconnect the quick release battery terminal (-).
REMARK
For the machine without the system operating lamp, turn the starting switch to OFF position, wait for two
minutes or more before starting the work. Disconnect the quick release battery terminal (-).
,&
,&
00 INDEX AND FOREWORD SAFETY NOTICE FOR OPERATION
PC500LC-10R 00-15

• Release the remaining pressure from the circuit before starting the work of disconnecting and removing of
oil, fuel, water, or air from the circuit. When removing the cap of oil filter, drain plug, or oil pressure plug, it
should be done slowly otherwise the oil spills.
• When removing or installing the checking plug or the piping in the fuel circuit, wait 30 seconds or longer
after the engine is shut down and start the work after the remaining pressure is released from the fuel cir-
cuit.
• The coolant and oil in the circuits are hot when the engine
is shut down. Be careful not to get scalded. Wait for the oil
and coolant to cool before performing any work on the oil
or coolant circuits.
• Before starting work, shut down the engine. When working
on or around a rotating part, in particular, shut down the
engine. When checking the machine without shutting down
the engine (measuring oil pressure, revolving speed, tem-
perature, etc.), take extreme care not to get caught in ro-
tating parts or moving parts.
• When raising a heavy component (heavier than 25 kg),
use a hoist or crane. Before starting work, check that the
slings (wire ropes, webbing slings, chains, and hooks) are
free from damage. Always use slings which have ample
capacity and install them to proper places. Operate the
hoist or crane slowly to prevent the component from hitting
any other part. Do not work with any part still raised by the
hoist or crane.
• When removing a part which is under internal pressure or
under reaction force of a spring, always leave 2 bolts in di-
agonal positions. Loosen those 2 bolts gradually and alter-
nately to release the pressure, and then remove the part.
• When removing components, do not break or damage the
electrical wiring. Damaged wiring may cause a fire.
• When removing piping, do not spill the fuel or oil. If any
fuel or oil drips onto the floor, wipe it off immediately. Fuel
or oil on the floor can cause you to slip and can even cause fires.
• Do not use gasoline to wash parts as a general rule. Do not use gasoline to clean electrical parts, in partic-
ular.
,&
SAFETY NOTICE FOR OPERATION 00 INDEX AND FOREWORD
00-16 PC500LC-10R

• Be sure to assemble all parts again in their original places. Replace any damaged parts and parts which
must not be reused with new parts. When installing hoses and wiring harnesses, be sure that they will not
be damaged by contact with other parts when the machine is operated.
• When installing high pressure hoses and tubes, make sure that they are not twisted. Damaged hoses and
tubes are dangerous, so be extremely careful when installing hoses and tubes for high pressure circuits. In
addition, check that high pressure hoses and tubes are correctly installed.
• When assembling or installing parts, always tighten them to the specified torques. When installing protec-
tive parts such as guards, or parts which vibrate violently or rotate at high speed, check again that they are
installed correctly.
• Never insert your fingers or hand when aligning 2 holes. Be careful not to get your fingers caught in a hole.
• Check that the measuring tools are correctly installed when measuring hydraulic pressure.
• Take care when removing or installing the tracks of track-type machines. Since the track shoe may sepa-
rate suddenly when you remove it, never let anyone stand at either end of the track shoe.
• If the engine is operated for a long time in a closed place
with poor ventilation, it may cause gas poisoning. Open
the windows and doors to ventilate the place well.
Precautions for slinging work and making signals
• Only one appointed worker must make signals and co-workers must communicate with each other fre-
quently. The appointed signaler must make specified signals clearly at a place where he is well seen from
the operator's seat and where he can see the working condition easily. The signaler must always stand in
front of the load and guide the operator safely.
k
Never stand under the load.
k
Do not move a load over a person.
k
Never step on the load.
k
Do not prevent the load from swinging or falling down by holding it simply with the hands.
k
The sling workers and assistant workers other than the guide must move to a place where they
are not caught between the load and materials or equipment on the ground or hit by the load
even if the crane starts abruptly.
• Check the slings before starting sling work.
• Keep putting on gloves during sling work. (Put on leather gloves, if available.)
• Measure the weight of the load by the eye and check its center of gravity.
• Use proper sling corresponding to the weight of the load and method of slinging. If too thick wire ropes are
used to sling a light load, the load may slip and fall.
• Do not sling a load with 1 wire rope alone. If it is slung so, it may rotate and may slip out of the rope. Install
2 or more wire ropes symmetrically.
k
Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or
slipping of the rope from its original slinging position on the load, which can result in a danger-
ous accident.
• Hanging angle must be 60 ° or smaller as a rule.
• When slinging a heavy load (25 kg or heavier), the hanging angle of the rope must be narrower than that of
the hook.
,&
00 INDEX AND FOREWORD SAFETY NOTICE FOR OPERATION
PC500LC-10R 00-17

REMARK
When slinging a load with 2 or more ropes, the force sub-
jected to each rope increases with the hanging angle. The
figure below shows the variation of allowable load in kN
{kg} when slinging is made with 2 ropes, each of which is
allowed to sling up to 9.8 kN {1000 kg} vertically, at vari-
ous hanging angles. When the 2 ropes sling a load verti-
cally, they can sling up to 2000 kg of total weight. This
weight is reduced to 1000 kg when the 2 ropes make a
hanging angle of 120 °. If the 2 ropes sling a 2000 kg load
at a hanging angle of 150 °, each rope is subjected to a
force as large as 39.2 kN {4000 kg} .
• When installing wire ropes to an angular load, apply pads to protect the wire ropes. If the load is slippery,
apply proper material to prevent the wire rope from slipping.
• Use the specified eye bolts and fix wire ropes, chains, etc. to them with shackles, etc.
• Apply wire ropes to the middle part of the hook.
k
Do not use hooks if it does not have a latch sys-
tem.
k
Slinging near the tip of the hook may cause the
rope to slip off the hook during hoisting.
REMARK
The strength of the hook is maximum at its central part.
• Never use a wire rope which has breaks in strands (A), re-
duced diameter (B), or kinks (C). There is a danger that
the rope may break during the towing operation.
Precautions for slinging up
• Wind in the crane slowly until wire ropes are stretched.
When settling the wire ropes with the hand, do not grasp
them but press them from above. If you grasp them, your
fingers may be caught.
• After the wire ropes are stretched, stop the crane and
check the condition of the slung load, wire ropes, and
pads.
• If the load is unstable or the wire rope or chains are twisted, lower the load and lift it up again.
• Do not lift up the load at an angle.
Precautions for slinging down
• When slinging down a load, stop it temporarily at 30 cm above the floor, and then lower it slowly.
• Check that the load is stable, and then remove the sling.
• Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the specified
place.
Precautions for using mobile crane
REMARK
Read Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely.
Precautions for using overhead traveling crane
k
When raising a heavy component (heavier than 25 kg), use a hoist or crane.
SAFETY NOTICE FOR OPERATION 00 INDEX AND FOREWORD
00-18 PC500LC-10R