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Need factory answers for your Fiat Kobelco E80 Evolution crawler excavator? This 856-page Fiat Kobelco E80 Evolution repair manual PDF (OEM #604.13.253) covers the whole machine, from the Mechatro control system to the final drives. Inside: full hydraulic circuit schematics for the boom, arm, bucket, travel, and slewing circuits, electric circuit diagrams with harness connections, and troubleshooting tables for Mechatro, hydraulic, electric, and engine faults, including controller error codes. You also get complete teardown procedures for attachments, the upper swing body, the travel system, and the engine itself. Check boom and arm cylinder drift against the 3 mm per 5 minutes limit, and condemn a slewing motor once drain flow passes 15 L per 30 seconds. No more chasing hydraulic faults with a pressure gauge and a hunch. Bookmarked, text-searchable, and it opens on any device; take your tablet to the machine and get wrenching.
What's Inside This Fiat Kobelco E80 Evolution Repair Manual
| System | Pages | Key Topics |
|---|---|---|
| Workshop Manual English | 1-2 | Manual Identification, Print Number, Edition Date |
| Introduction | 3-8 | To the Reader, Reference Manuals, Workshop Manual Description, Safety Rules, Avoid Accidents |
| Outline | 9-14 | General Repair Precautions, International Unit Conversion System |
| Specifications | 15-29 | Name of Components, General Dimensions, Weight of Components, Lifting Diagram, Engine Specifications |
| Attachment Dimensions | 31-46 | Boom Dimension, Arm Dimension, Bucket Dimension, Dozer Dimension, Swing Bracket Dimension |
| Tools | 47-62 | Tightening Torques, Screw Size, Special Spanner, Sealant Application, Lifting Jigs |
| Standard Maintenance Time Table | 63-76 | Attachment Maintenance, Cab & Guard Maintenance, Upper Frame Maintenance, Travel System Maintenance, Engine Maintenance |
| Maintenance Standard and Test Procedure | 77-98 | Performance Inspection, Engine Speed Measurement, Hydraulic Pressure Measurement, Travel Performance, Slewing Performance |
| Mechatro Control System | 99-108 | Mechatro Control Summary, Boom Raise Conflux, Slewing Cut Valve, Arm In/Out Conflux, Service Diagnosis |
| Hydraulic System | 109-143 | Hydraulic Circuits, Neutral Circuit, Travel Circuit, Bucket Circuit, Boom Circuit, Slewing Circuit, Arm Circuit |
| Electric System | 165-202 | Electric Circuit Diagram, Electrical Equipment List, Harness Connection, Controller Assy, Battery |
| Components System | 203-286 | Hydraulic Pump & Regulator, Control Valve, Pilot Valve, Slewing Motor Unit, Travel Motor, Swivel Joint, Hydraulic Cylinder |
| Air-Conditioner System | 313-346 | Construction and Piping, Main Components, Cooling Circuit, Disassembly and Assembly, Charging Refrigerant, Troubleshooting |
| Disassembling and Assembling | 347-350 | Attachments, Upper Swing Body, Travel Frame |
| Attachment | 351-392 | Bucket Removal/Installation, Arm Removal/Installation, Boom Removal/Installation, Swing Removal/Installation, Dozer Removal/Installation |
| Upper Slewing Body | 393-430 | Cab Removal, Counterweight Removal, Hydraulic Tank Removal, Pump Removal, Engine Removal, Control Valve Removal |
| Travel System | 489-572 | Crawler Removal, Upper Roller Removal, Lower Roller Removal, Front Idler Removal, Sprocket Removal, Travel Reduction Unit Removal |
| Troubleshooting (Mechatro Control) | 579-586 | Trouble Diagnosis Table, Controller Error Code Display Function, Service Diagnosis, Check Points for Mechatro System |
| Troubleshooting (Hydraulic) | 587-604 | Trouble Diagnosis Table, Troubleshooting |
| Troubleshooting (Electric) | 605-624 | Mechatro Control, Hydraulic System, Electrical System, Engine |
| Troubleshooting (Engine) | 625-634 | Mechatro Control, Hydraulic System, Electrical System, Engine |
| Engine | 635-744 | General Information, Engine Maintenance, Engine Disassembly, Inspection and Repair, Reassembly, Lubricating System, Cooling System, Fuel System |
| Lubricating System | 745-756 | Main data, Oil pump, Oil filter, Oil cooler, Inspection and repair |
| Cooling System | 757-762 | Main data, Coolant flow, Water pump, Thermostat, Inspection and repair |
| Fuel System | 763-776 | Main data, Fuel flow, Injection nozzle, Fuel filter, Water separator, Calibration data |
| Engine Electricals | 777-804 | Starter, Alternator, Performance test, Rotor and bearing, Stator coil, Rectifier |
| Troubleshooting (Engine) | 805-830 | Hard starting, Unstable idling, Insufficient power, Excessive fuel consumption, Overheating, Abnormal engine noise |
| Special Tools List and Repair Standards | 831-856 | Special tool list, Repair standards, Cylinder head, Piston and connecting rod, Crankshaft, Camshaft |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Att amout of dirft (Boom cylinder) | 3 mm / 5min | p. 81 |
| Att amout of dirft (Arm cylinder) | 3 mm / 5min | p. 81 |
| Power supply | 24V | p. 106 |
| Machine Complete Weight | 8,040 kg | p. 19 |
| Engine Rated Output | 40.5 kW (55 PS) / 2,100 rpm | p. 25 |
| Travel Speed (1st/2nd) | 3.1 / 5.5 km/h | p. 25 |
| Hydraulic Pump Max Pressure | 300 kgf/cm2 (4270 psi) | p. 205 |
| Engine Oil Capacity | 7.6 - 9.6 L | p. 642 |
| Coolant Capacity | 5.0 L | p. 90 |
| Fuel Tank Capacity | 100 L | p. 406 |
| Slewing Relief Valve Pressure | 250 kgf/cm2 (3560 psi) | p. 113 |
| Pilot Relief Valve Pressure | 35 kgf/cm2 (500 psi) | p. 113 |
Fiat Kobelco E80 Evolution Common Problems This Manual Covers
Fiat Kobelco E80 Evolution boom drifts down under load, arm movement jerky and slow after warm-up
Check main relief pressure at P1 and P2 against the 300 kgf/cm² (4270 psi) spec on page 127. Test boom drift with a loaded bucket; anything past 3 mm in 5 minutes (page 81 standard) points to internal cylinder leakage. Work the hydraulic trouble diagnosis table starting on page 587 to isolate pump or valve.
Manual Section: Troubleshooting (Hydraulic) p. 587Engine cranks but won't start, or idles rough and stalls when cold
Check the fuel filter and water separator first; drain and replace them per the fuel system chapter starting on page 763. Verify the battery delivers a full 24V to the starter circuit before condemning injectors. Then work through the hard starting diagnosis table beginning on page 805, testing injection nozzle spray pattern if fuel delivery checks clean.
Manual Section: Troubleshooting (Engine) p. 805Coolant temperature climbs into the red within thirty minutes of steady digging
Clean the radiator core with compressed air, blowing from the fan side outward. Verify coolant level; the system holds 5.0 L (page 90). Test thermostat opening in heated water following the cooling system chapter on page 757. If the gauge still climbs, run the overheating checks in the engine troubleshooting section starting on page 805.
Manual Section: Cooling System p. 757Machine pulls to one side when traveling straight, one track noticeably slower
Measure travel speed in both ranges; spec is 3.1 km/h low and 5.5 km/h high (page 25). Time each track separately over a marked distance to confirm which side lags. Check crawler tension and dig packed mud out of the rollers before pulling a motor. Follow the travel deviation diagnosis in the hydraulic troubleshooting section from page 587.
Manual Section: Troubleshooting (Hydraulic) p. 587Mechatro controller dead or throwing error codes after welding repairs on the frame
Disconnect both battery cables and unplug the controller connectors before striking an arc anywhere on the machine. Read stored error codes using the controller display function covered from page 579. Verify the 5V pressure sensor supply at the controller (page 106) and check harness continuity per the electric troubleshooting section on page 605 before replacing hardware.
Manual Section: Troubleshooting (Mechatro Control) p. 579Frequently Asked Questions
What are the tightening torque specifications for the main relief valve on the E80 Evolution?
The tightening torque for the main relief valve (P1, P2) is 300 kgf/cm² (4270 psi). p. 113
What is the standard valve clearance for the engine?
The standard valve clearance for both intake and exhaust valves is 0.40 mm (0.016 in) when the engine is cold. p. 87
What is the engine oil capacity for the E80 Evolution?
The engine oil capacity for the E80 Evolution is 7.6 to 9.6 liters (oil pan). p. 70
What is the correct tightening torque for the cylinder head bolts?
The cylinder head bolts should be tightened in three steps: 44-54 N·m (4.5-5.5 kgf·m) for the first step, followed by 60-75° for the second step, and 60-75° for the third step. p. 73
What is the standard compression pressure for the engine?
The standard compression pressure for the engine is 3.04 MPa (31 kgf/cm² or 441 psi) at 200 rpm. p. 90
What format is this Fiat Kobelco E80 Evolution manual in?
A 856-page Repair Manual in searchable PDF format, available the moment you complete checkout. View on computer, tablet, or phone, with no shipping wait.
Is this Fiat Kobelco E80 Evolution Repair Manual printable?
Absolutely. No DRM or copy protection. Print the whole manual or just the pages you need. Any home or office printer works.
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