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KOMATSU PC800-8R PC800LC-8R PC800SE-8R PC850-8R PC850SE-8R HYDRAULIC EXCAVATOR SHOP MANUAL SEN02316-19 – PDF
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KOMATSU PC800-8R PC800LC-8R PC800SE-8R PC850-8R PC850SE-8R HYDRAULIC EXCAVATOR SHOP MANUAL SEN02316-19 – PDF DOWNLOAD
SERIAL NUMBERS
PC800- 60001 and up
PC800LC- 60001 and up
PC800SE- 60001 and up
PC850- 60001 and up
PC850SE- 60001 and up
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Description
KOMATSU PC800-8R PC800LC-8R PC800SE-8R PC850-8R PC850SE-8R HYDRAULIC EXCAVATOR SHOP MANUAL SEN02316-19 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU PC800-8R PC800LC-8R PC800SE-8R PC850-8R PC850SE-8R HYDRAULIC EXCAVATOR SHOP MANUAL SEN02316-19 – PDF DOWNLOAD
Language : English
Pages : 1106
Downloadable : Yes
File Type : PDF
SERIAL NUMBERS
PC800- 60001 and up
PC800LC- 60001 and up
PC800SE- 60001 and up
PC850- 60001 and up
PC850SE- 60001 and up
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU PC800-8R PC800LC-8R PC800SE-8R PC850-8R PC850SE-8R HYDRAULIC EXCAVATOR SHOP MANUAL SEN02316-19 – PDF DOWNLOAD
Cover................................................................................................................... 1 00 Index and foreword............................................................................................... 3 Index........................................................................................................... 3 Composition of shop manual.................................................................................. 4 Table of contents........................................................................................... 6 Foreword and general information................................................................................ 15 Safety notice............................................................................................... 16 How to read the shop manual................................................................................. 21 Explanation of terms for maintenance standard............................................................... 23 Handling of electric equipment and hydraulic component...................................................... 25 Handling of connectors newly used for engines............................................................... 34 How to read electric wire code.............................................................................. 37 Precautions when carrying out operation..................................................................... 40 Method of disassembling and connecting push-pull type coupler............................................... 43 Standard tightening torque table............................................................................ 46 Conversion table............................................................................................ 50 01 Specification.................................................................................................... 57 Specification and technical data................................................................................ 57 Specification drawings...................................................................................... 58 Working range drawing....................................................................................... 60 Specifications.............................................................................................. 62 Weight table................................................................................................ 80 Table of fuel, coolant and lubricants....................................................................... 86 10 Structure, function and maintenance standard..................................................................... 89 Engine and cooling system....................................................................................... 89 Coupling.................................................................................................... 90 Coupling lubrication system................................................................................. 91 Radiator, oil cooler........................................................................................ 92 Power train..................................................................................................... 95 Power train................................................................................................. 96 Swing machinery............................................................................................. 98 Swing circle................................................................................................ 100 Final drive................................................................................................. 102 Sprocket.................................................................................................... 104 Undercarriage and frame......................................................................................... 107 Track frame and recoil spring............................................................................... 108 Idler....................................................................................................... 110 Carrier roller.............................................................................................. 112 Track roller................................................................................................ 114 Track shoe.................................................................................................. 116 Hydraulic system, Part 1........................................................................................ 121 Hydraulic piping drawing.................................................................................... 122 Hydraulic tank, hydraulic filter............................................................................ 124 Hydraulic pump.............................................................................................. 126 Cooling fan pump............................................................................................ 146 Cooling fan motor........................................................................................... 154 Hydraulic system, Part 2........................................................................................ 161 Motor grease pump........................................................................................... 164 Return oil filter........................................................................................... 165 Line oil filter............................................................................................. 166 Drain oil filter............................................................................................ 167 L.H. 5-Spool control valve.................................................................................. 168 R.H. 4-Spool control valve.................................................................................. 174 Straight-travel valve....................................................................................... 180 Swing motor................................................................................................. 183 Center swivel joint......................................................................................... 188 Travel motor................................................................................................ 189 PPC accumulator............................................................................................. 199 Work equipment, swing PPC valve............................................................................. 200 Travel PPC valve............................................................................................ 206 Solenoid valve.............................................................................................. 210 Quick return valve.......................................................................................... 216 Hydraulic cylinder.......................................................................................... 218 Work equipment.................................................................................................. 225 Work equipment.............................................................................................. 226 Dimensions of work equipment................................................................................ 232 Cab and its attachments......................................................................................... 237 Air conditioner piping...................................................................................... 238 Electrical system............................................................................................... 241 Engine control.............................................................................................. 242 Electric control system..................................................................................... 251 Monitor system.............................................................................................. 285 Sensors..................................................................................................... 303 KOMTRAX system.............................................................................................. 307 20 Standard value table............................................................................................. 311 Standard service value table.................................................................................... 311 Standard service value table for engine..................................................................... 312 Standard service value table for chassis.................................................................... 313 30 Testing and adjusting............................................................................................ 325 Testing and adjusting, Part 1................................................................................... 325 Tools for testing, adjusting and troubleshooting............................................................ 326 Measuring engine speed...................................................................................... 329 Measuring intake air pressure (Boost pressure).............................................................. 330 Measuring exhaust gas temperature........................................................................... 331 Measuring exhaust gas color................................................................................. 332 Adjusting valve clearance................................................................................... 333 Measuring compression pressure.............................................................................. 334 Measuring blow-by pressure.................................................................................. 335 Measuring engine oil pressure............................................................................... 336 Handling of fuel system equipment........................................................................... 337 Remaining pressure relief from fuel system equipment........................................................ 337 Measuring fuel pressure..................................................................................... 338 Testing fuel return rate and leakage........................................................................ 339 Bleeding air from fuel circuit.............................................................................. 341 Testing and adjusting alternator belt tension............................................................... 343 Testing and adjusting air conditioner compressor belt....................................................... 344 Testing and adjusting, Part 2................................................................................... 347 Inspection of swing circle bearing clearance................................................................ 348 Testing and adjusting track shoe tension.................................................................... 349 Testing and adjusting work equipment, swing, and travel circuit oil pressures............................... 350 Testing and adjusting control circuit oil pressure (self pressure reducing valve)........................... 356 Testing and adjusting main pump control pressure............................................................ 357 Testing and adjusting, Part 3................................................................................... 365 Measuring PPC valve output pressure......................................................................... 366 Measuring outlet pressures of solenoid valve, swing PPC shuttle valve, and swing priority selector valve.... 370 Adjusting work equipment, swing PPC valve................................................................... 374 Testing and adjusting travel deviation...................................................................... 375 Inspection of locations of hydraulic drift of work equipment................................................ 377 Measuring fan speed......................................................................................... 378 Measuring fan circuit oil pressure.......................................................................... 378 Measuring fan pump EPC current.............................................................................. 379 Measuring fan pump EPC solenoid valve output pressure....................................................... 379 Measuring oil leakage....................................................................................... 380 Release of residual pressure from hydraulic circuit......................................................... 384 Bleeding air from each part................................................................................. 385 Inspection procedures for diode............................................................................. 388 Testing and adjusting, Part 4................................................................................... 391 Special function of machine monitor......................................................................... 392 Handling controller voltage circuit......................................................................... 424 Testing and adjusting, Part 5................................................................................... 427 Procedure for turning on KOMTRAX terminal................................................................... 428 KOMTRAX terminal lamp indications........................................................................... 431 Preparation work for troubleshooting electrical system...................................................... 434 Pm-clinic service........................................................................................... 437 40 Troubleshooting.................................................................................................. 447 Failure code table and fuse locations........................................................................... 447 Failure codes table......................................................................................... 448 Fuse locations.............................................................................................. 451 General information on troubleshooting.......................................................................... 455 Points to remember when troubleshooting..................................................................... 456 Sequence of events in troubleshooting....................................................................... 457 Checks before troubleshooting............................................................................... 458 Classification and troubleshooting steps.................................................................... 459 Information in troubleshooting table........................................................................ 464 Connection table for connector pin numbers.................................................................. 466 T- branch box and T- branch adapter table................................................................... 502 Troubleshooting by failure code (Display of code), Part 1....................................................... 507 Failure code [AA10NX] Aircleaner Clogging................................................................... 510 Failure code [AB00KE] Charge Voltage Low.................................................................... 512 Failure code [B@BAZG] Eng Oil Press. Low.................................................................... 514 Failure code [B@BAZK] Eng. Oil Level Low.................................................................... 515 Failure code [B@BCNS] Eng. Water Overheat................................................................... 516 Failure code [B@BCZK] Eng. Water Lvl Low.................................................................... 518 Failure code [B@HANS] Hydr. Oil Overheat.................................................................... 520 Failure code [CA111] ECM Critical Internal Failure.......................................................... 522 Failure code [CA115] Eng Ne and Bkup Speed Sens Error....................................................... 524 Failure code [CA122] Chg Air Press Sensor High Error........................................................ 525 Failure code [CA123] Chg Air Press Sensor Low Error......................................................... 527 Failure code [CA131] Throttle Sensor High Error............................................................. 528 Failure code [CA132] Throttle Sensor Low Error.............................................................. 530 Failure code [CA135] Eng Oil Press Sensor High Error........................................................ 531 Failure code [CA141] Eng Oil Press Sensor Low Error......................................................... 533 Failure code [CA144] Coolant Temp Sens High Error........................................................... 534 Failure code [CA145] Coolant Temp Sens Low Error............................................................ 536 Failure code [CA153] Chg Air Temp Sensor High Error......................................................... 537 Failure code [CA154] Chg Air Temp Sensor Low Error.......................................................... 539 Failure code [CA187] Sens Supply 2 Volt Low Error........................................................... 539 Failure code [CA221] Ambient Press Sens High Error.......................................................... 540 Failure code [CA222] Ambient Press Sens Low Error........................................................... 542 Failure code [CA227] Sens Supply 2 Volt High Error.......................................................... 543 Failure code [CA234] Eng Overspeed.......................................................................... 545 Failure code [CA238] Ne Speed Sens Supply Volt Error........................................................ 546 Failure code [CA263] Fuel Temp Sensor High Error............................................................ 548 Failure code [CA265] Fuel Temp Sensor Low Error............................................................. 550 Failure code [CA271] IMV/PCV1 Short Error................................................................... 551 Failure code [CA272] IMV/PCV1 Open Error.................................................................... 552 Failure code [CA273] PCV2 Short Error....................................................................... 553 Failure code [CA274] PCV2 Open Error........................................................................ 554 Failure code [CA322] Inj #1 Open/Short Error................................................................ 555 Failure code [CA323] Inj #5 Open/Short Error................................................................ 556 Failure code [CA324] Inj #3 Open/Short Error................................................................ 558 Failure code [CA325] Inj #6 Open/Short Error................................................................ 560 Failure code [CA331] Inj #2 Open/Short Error................................................................ 562 Failure code [CA332] Inj #4 Open/Short Error................................................................ 564 Failure code [CA342] Calibration Code Incompatibility....................................................... 565 Failure code [CA351] Injectors Drive Circuit Error.......................................................... 566 Failure code [CA352] Sens Supply 1 Volt Low Error........................................................... 568 Failure code [CA386] Sens Supply 1 Volt High Error.......................................................... 570 Troubleshooting by failure code (Display of code), Part 2....................................................... 573 Failure code [CA441] Battery Voltage Low Error.............................................................. 575 Failure code [CA442] Battery Voltage High Error............................................................. 575 Failure code [CA449] Rail Press Very High Error............................................................. 576 Failure code [CA451] Rail Press Sensor High Error........................................................... 578 Failure code [CA452] Rail Press Sensor Low Error............................................................ 580 Failure code [CA553] Rail Press High Error.................................................................. 580 Failure code [CA554] Rail Press Sensor In Range Error....................................................... 581 Failure code [CA559] Rail Press Low Error................................................................... 582 Failure code [CA689] Eng Ne Speed Sensor Error.............................................................. 586 Failure code [CA731] Eng Bkup Speed Sens Phase Error........................................................ 588 Failure code [CA757] All Persistent Data Lost Error......................................................... 589 Failure code [CA778] Eng Bkup Speed Sensor Error............................................................ 590 Failure code [CA1633] KOMNET Datalink Timeout Error......................................................... 592 Failure code [CA2185] Throt Sens Sup Volt High Error........................................................ 594 Failure code [CA2186] Throt Sens Sup Volt Low Error......................................................... 596 Failure code [CA2249] Rail Press Very Low Error............................................................. 597 Failure code [CA2555] Grid Htr Relay Volt Low Error......................................................... 598 Failure code [CA2556] Grid Htr Relay Volt High Error........................................................ 600 Failure code [D110KB] Battery Relay Drive S/C............................................................... 602 Failure code [D163KB] Flash Light Relay S/C................................................................. 604 Failure code [D195KB] Step Light Relay S/C.................................................................. 606 Failure code [DA22KK] Low pump controller solenoid power supply voltage..................................... 608 Failure code [DA25KP] Press. Sensor Power Abnormality....................................................... 610 Failure code [DA2SKQ] Model Selection Abnormality........................................................... 612 Failure code [DA80MA] Auto. Lub. Abnormal................................................................... 614 Failure code [DA2RMC] Pump Comm. Abnormality................................................................ 616 Failure code [DAFRMC] Monitor Comm. Abnormality............................................................. 618 Failure code [DGE5KY] Ambi. Temp. Sensor S/C................................................................ 620 Failure code [DGH2KB] Hydr. Oil Temp. Sensor S/C............................................................ 622 Troubleshooting by failure code (Display of code), Part 3....................................................... 625 Failure code [DH25KA] L Jet Sensor Disc..................................................................... 628 Failure code [DH25KB] L Jet Sensor S/C...................................................................... 630 Failure code [DH26KA] R Jet Sensor Disc..................................................................... 632 Failure code [DH26KB] R Jet Sensor S/C...................................................................... 634 Failure code [DHPEKA] F Pump P. Sensor Disc................................................................. 636 Failure code [DHPEKB] F Pump P. Sensor S/C.................................................................. 638 Failure code [DHPFKA] R Pump P. Sensor Disc................................................................. 640 Failure code [DHPFKB] R Pump P. Sensor S/C.................................................................. 642 Failure code [DV20KB] Travel Alarm S/C...................................................................... 644 Failure code [DW41KA] Swing Priority Sol. Disc.............................................................. 646 Failure code [DW41KB] Swing Priority Sol. S/C............................................................... 648 Failure code [DW43KA] Travel Speed Sol. Disc................................................................ 650 Failure code [DW43KB] Travel Speed Sol. S/C................................................................. 652 Failure code [DW45KA] Swing Brake Sol. Disc................................................................. 654 Failure code [DW45KB] Swing Brake Sol. S/C.................................................................. 656 Failure code [DW7BKA] Fan Reverse Sol. Disc................................................................. 658 Failure code [DW7BKB] Fan Reverse Sol. S/C.................................................................. 660 Failure code [DW7JKA] Disconnection in bottom dump priority solenoid system................................. 662 Failure code [DW7JKB] Short circuit in bottom dump priority solenoid system................................. 664 Failure code [DWK0KA] 2-stage Relief Sol. Disc.............................................................. 666 Failure code [DWK0KB] 2-stage Relief Sol. S/C............................................................... 668 Failure code [DX16KA] Fan Pump EPC Sol. Disc................................................................ 670 Failure code [DX16KB] Fan Pump EPC Sol. S/C................................................................. 672 Failure code [DXAAKA] F Pump EPC Sol. Disc.................................................................. 674 Failure code [DXAAKB] F Pump EPC Sol. S/C................................................................... 676 Failure code [DXABKA] R Pump EPC Sol. Disc.................................................................. 678 Failure code [DXABKB] R Pump EPC Sol. S/C................................................................... 680 Failure code [DY20KA] Wiper Working Abnormality............................................................. 682 Failure code [DY20MA] Wiper Parking Abnormality............................................................. 684 Failure code [DY2CKB] Washer Drive S/C...................................................................... 688 Failure code [DY2DKB] Wiper Drive (For) S/C................................................................. 690 Failure code [DY2EKB] Wiper Drive (Rev) S/C................................................................. 694 Troubleshooting of electrical system (E-mode)................................................................... 697 Before carrying out troubleshooting of electrical system.................................................... 699 Information contained in troubleshooting table.............................................................. 701 E-1 Engine does not start (Engine does not rotate).......................................................... 702 E-2 Preheater does not operate.............................................................................. 705 E-3 Auto engine warm-up device does not work................................................................ 712 E-4 Auto-decelerator does not operate....................................................................... 713 E-5 All work equipment, swing and travel do not move........................................................ 714 E-6 Machine push-up function does not operate normally...................................................... 716 E-7 Boom shockless function does not operate normally....................................................... 718 E-8 Any item is not displayed on machine monitor............................................................ 720 E-9 Part of display on machine monitor is missing........................................................... 721 E-10 Machine monitor displays contents irrelevant to the model.............................................. 721 E-11 Fuel level monitor red lamp lights up while engine is running.......................................... 722 E-12 Engine coolant thermometer does not display normally................................................... 724 E-13 Hydraulic oil temperature gauge does not display correctly............................................. 726 E-14 Fuel gauge does not display correctly.................................................................. 727 E-15 Swing lock monitor does not display correctly.......................................................... 728 E-16 When monitor switch is operated, nothing is displayed.................................................. 730 E-17 Windshield wiper and window washer do not work......................................................... 732 E-18 "Boom RAISE" is not correctly displayed in monitor function............................................ 740 E-19 "Boom LOWER" is not correctly displayed in monitor function............................................ 741 E-20 "Arm IN" is not correctly displayed in monitor function................................................ 742 E-21 "Arm OUT" is not correctly displayed in monitor function............................................... 743 E-22 "Bucket CURL" is not correctly displayed in monitor function........................................... 744 E-23 "Bucket DUMP" is not correctly displayed in monitor function........................................... 745 E-24 "SWING" is not correctly displayed in monitor function................................................. 746 E-25 "Left travel" is not displayed normally in monitoring function......................................... 748 E-26 "Right travel" is not displayed normally in monitoring function........................................ 750 E-27 "Service" is not correctly displayed in monitor function............................................... 752 E-28 KOMTRAX system does not operate normally............................................................... 754 E-29 Air conditioner does not work.......................................................................... 756 E-30 Step light does not light up or go off................................................................. 757 E-31 Electric grease gun does not operate................................................................... 760 E-32 Travel alarm does not sound or does not stop sounding.................................................. 762 E-33 Electric priming pump does not operate or does not stop automatically.................................. 764 Troubleshooting of hydraulic and mechanical system (H-mode)..................................................... 767 Information in troubleshooting table........................................................................ 769 H-1 Speed or power of all work equipment, travel, and swing is low.......................................... 770 H-2 Engine speed lowers remarkably or engine stalls......................................................... 772 H-3 All work equipment, travel, and swing systems do not work............................................... 773 H-4 Abnormal sound is heard from around pump................................................................ 774 H-5 Boom speed or power is low.............................................................................. 775 H-6 Speed or power of arm is low............................................................................ 777 H-7 Speed or power of bucket is low......................................................................... 778 H-8 Boom does not move...................................................................................... 779 H-9 Arm does not move....................................................................................... 779 H-10 Bucket does not move................................................................................... 779 H-11 Hydraulic drift of work equipment is large............................................................. 780 H-12 Time lag of work equipment is large.................................................................... 782 H-13 Heavy lift function does not operate or stop........................................................... 783 H-14 Machine push-up function does not operate or stop...................................................... 783 H-15 Boom shockless function cannot be turned ON or OFF..................................................... 783 H-16 Machine deviates in one direction...................................................................... 784 H-17 Machine deviates largely at start...................................................................... 786 H-18 Machine deviates largely during compound operation..................................................... 787 H-19 Travel speed or power is low........................................................................... 787 H-20 Machine does not travel (only one track)............................................................... 788 H-21 Travel speed does not change........................................................................... 789 H-22 Upper structure does not swing......................................................................... 790 H-23 Swing speed or acceleration is low..................................................................... 792 H-24 Swing speed or acceleration is low during compound operation of swing and work equipment............... 793 H-25 Upper structure overruns excessively when it stops swinging............................................ 795 H-26 Large shock is made when upper structure stops swinging................................................ 796 H-27 Large abnormal sound is made when upper structure stops swinging....................................... 797 H-28 Hydraulic drift of swing is large...................................................................... 798 H-29 Fan rotation is abnormal (Fan sound/vibration is abnormally large or fan overheats).................... 799 Troubleshooting of engine (S-mode).............................................................................. 801 Method of using troubleshooting chart....................................................................... 803 S-1 Starting performance is poor............................................................................ 806 S-2 Engine does not start................................................................................... 807 S-3 Engine does not pick up smoothly........................................................................ 810 S-4 Engine stops during operations.......................................................................... 811 S-5 Engine does not rotate smoothly......................................................................... 812 S-6 Engine lacks output (or lacks power).................................................................... 813 S-7 Exhaust gas color is black (incomplete combustion)...................................................... 814 S-8 Oil consumption is excessive (or exhaust smoke is blue)................................................. 815 S-9 Oil becomes contaminated quickly........................................................................ 816 S-10 Fuel consumption is excessive.......................................................................... 817 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down).................................. 818 S-12 Oil pressure drops..................................................................................... 819 S-13 Oil level rises (Entry of coolant/fuel)................................................................ 820 S-14 Coolant temperature becomes too high (overheating)..................................................... 821 S-15 Abnormal noise is made................................................................................. 822 S-16 Vibration is excessive................................................................................. 823 S-17 Air cannot be bled from fuel circuit................................................................... 824 50 Disassembly and assembly......................................................................................... 827 General information on disassembly and assembly................................................................. 827 How to read this maHow to read this manual.................................................................. 828 Coating materials list...................................................................................... 830 Special tools list.......................................................................................... 833 Sketches of special tools................................................................................... 840 Engine and cooling system (SAA6D140E-5)......................................................................... 847 Removal and installation of engine, PTO and hydraulic pump assembly......................................... 848 Removal and installation of cooling assembly................................................................ 855 Removal and installation of aftercooler assembly............................................................ 860 Removal and installation of fuel cooler and air conditioner condenser assembly.............................. 862 Removal and installation of fan motor assembly.............................................................. 864 Removal and installation of fuel tank assembly.............................................................. 869 Engine (SAA6D140E-5)............................................................................................ 873 Removal and installation of fuel supply pump assembly....................................................... 874 Removal and installation of cylinder head assembly.......................................................... 878 Removal and installation of fuel injector assembly.......................................................... 892 Removal and installation of engine front seal............................................................... 895 Removal and installation of engine rear seal................................................................ 897 Power train..................................................................................................... 903 Removal and installation of PTO (coupling) assembly......................................................... 904 Disassembly and assembly of PTO (coupling) assembly......................................................... 911 Removal and installation of swing motor and swing machinery assembly........................................ 913 Disassembly and assembly of swing machinery assembly........................................................ 915 Removal and installation of swing circle assembly........................................................... 922 Disassembly and assembly of final drive assembly............................................................ 923 Undercarriage and frame......................................................................................... 935 Removal and installation of track shoe assembly............................................................. 936 Disassembly and assembly of one link in field............................................................... 938 Removal and installation of idler assembly.................................................................. 942 Disassembly and assembly of idler assembly.................................................................. 943 Disassembly and assembly of idler adjustment cylinder assembly.............................................. 946 Removal and installation of recoil spring assembly.......................................................... 947 Disassembly and assembly of recoil spring assembly.......................................................... 949 Removal and installation of carrier roller assembly......................................................... 951 Disassembly and assembly of carrier roller assembly......................................................... 952 Removal and installation of track roller assembly........................................................... 955 Disassembly and assembly of track roller assembly........................................................... 956 Removal and installation of revolving frame assembly........................................................ 959 Removal and installation of counterweight assembly.......................................................... 961 Hydraulic system................................................................................................ 965 Removal and installation of hydraulic tank assembly......................................................... 966 Removal and installation of main pump assembly.............................................................. 969 Removal and installation of main pump input shaft oil seal.................................................. 976 Removal and installation of cooling fan pump assembly....................................................... 977 Removal and installation of control valve assembly.......................................................... 980 Assembly of control valve assembly.......................................................................... 983 Removal and installation of swing motor assembly............................................................ 989 Removal and installation of center swivel joint assembly.................................................... 991 Disassembly and assembly of center swivel joint assembly.................................................... 993 Removal and installation of travel motor assembly........................................................... 995 Removal and installation of solenoid valve assembly......................................................... 996 Removal and installation of boom damping valve assembly..................................................... 998 Disassembly and assembly of work equipment PPC valve assembly............................................... 999 Disassembly and assembly of travel PPC valve assembly.......................................................1001 Disassembly and assembly of hydraulic cylinder assembly.....................................................1004 Disassembly and assembly of grease gun assembly.............................................................1010 Work equipment..................................................................................................1013 Removal and installation of bucket cylinder assembly........................................................1014 Removal and installation of arm cylinder assembly...........................................................1018 Removal and installation of boom cylinder assembly..........................................................1022 Removal and installation of bottom dump cylinder assembly...................................................1026 Removal and installation of bucket assembly.................................................................1027 Removal and installation of arm assembly....................................................................1029 Removal and installation of boom assembly...................................................................1032 Removal and installation of work equipment assembly.........................................................1036 Cab and its attachments.........................................................................................1041 Removal and installation of operator’s cab..................................................................1042 Removal and installation of operator’s cab glass (stuck glass)..............................................1045 Removal and installation of front window assembly...........................................................1055 Removal and installation of work equipment control lever assembly...........................................1060 Electrical system...............................................................................................1075 Removal and installation of air conditioner unit assembly...................................................1076 Removal and installation of engine controller assembly......................................................1078 Removal and installation of monitor assembly................................................................1080 Removal and installation of pump controller assembly........................................................1080 Removal and Installation of KOMTRAX terminal assembly.......................................................1081 90 Diagrams and drawings............................................................................................1083 Hydraulic diagrams and drawings.................................................................................1083 Hydraulic circuit diagram...................................................................................1085 Electrical diagrams and drawings................................................................................1089 Electrical circuit diagram (1/6)............................................................................1091 Electrical circuit diagram (2/6)............................................................................1093 Electrical circuit diagram (3/6)............................................................................1095 Electrical circuit diagram (4/6)............................................................................1097 Electrical circuit diagram (5/6)............................................................................1099 Electrical circuit diagram (6/6)............................................................................1101 Connector arrangement diagram...............................................................................1103
DESCRIPTION:
KOMATSU PC800-8R PC800LC-8R PC800SE-8R PC850-8R PC850SE-8R HYDRAULIC EXCAVATOR SHOP MANUAL SEN02316-19 – PDF DOWNLOAD
General precautions
1) Before carrying out any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the Operation and Maintenance Manual.
2) Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
3) When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.
A. Always wear safety glasses when hitting parts with a hammer.
B. Always wear safety glasses when grinding parts with a grinder, etc.
4) When carrying out any operation with 2 or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR warning signs in the operator’s compartment.
5) Only qualified workers must carry out work and operation which require license or qualification.
6) Keep all tools in good condition, learn the correct way to use them, and use the proper ones of them. Before starting work, thoroughly check the tools, machine, forklift, service car, etc.
7) If welding repairs are needed, always have a trained and experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, shielding goggles, cap and other clothes suited for welding work.
8) Before starting work, warm up your body thoroughly to start work under good condition.
9) Avoid continuing work for long hours and take rests at proper intervals to keep your body in good condition. Take rests in specified safe places.
S.S 28/12/24
