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Komatsu PC800-8, PC800LC-8, PC850-8, PC850LC-8 Excavator Manual SEN00373-12 – PDF DOWNLOAD
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Komatsu PC800-8, PC800LC-8, PC850-8, PC850LC-8 Excavator Manual
SERIAL NUMBERS:
PC800- 50001
PC800LC- 50001
PC800SE- 50001
PC850- 10001
PC850SE- 10001
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Description
Komatsu PC800-8, PC800LC-8, PC850-8, PC850LC-8 Excavator Manual
FILE DETAILS:
Komatsu PC800-8, PC800LC-8, PC850-8, PC850LC-8 Excavator Manual
Brands: Komatsu
Equipment Type: Hydraulic Excavator
Manuals Type: Shop Manual
Machine Model: PC800-8, PC800LC-8, PC800SE-8, PC850-8, PC850SE-8
Serial Number: 50001 and up, 10001 and up
Book Code: SEN00373-12
Language: English
Pages: 1129
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu PC800-8, PC800LC-8, PC850-8, PC850LC-8 Excavator Manual
How to read the shop manual:
1. Composition of shop manual:
This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
00. Index and foreword:
This section contains the index, foreword, safety and basic information. If any revision is made, the LIST OF REVISED PAGES will be added.
01. Specification:
This section explains the specifications of the machine.
10. Structure and function:
This section explains the structure and function of each component. It serves not only to give an understanding for the structure of each component, but also serves as reference material for troubleshooting.
20. Standard value table:
This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting:
This section explains measuring tools and measuring methods for testing and adjusting, as well as the adjusting method of each part. The standard values and judgment criteria for “Testing and adjusting” are explained in “Standard value table”.
40. Troubleshooting:
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly:
This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque, and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained.
60. Maintenance standard:
This section gives maintenance standard values of each component. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
80. Appendix:
This section explains the structure, function, testing, adjusting, and troubleshooting for the equipment not classifiable in other sections.
90. Diagrams and drawings (chassis volume) /Repair and replacement of parts (engine volume):
- Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams. - Engine volume
This section explains the method of remanufacturing and repairing engine and replacing parts.
TABLE OF CONTENTS:
Komatsu PC800-8, PC800LC-8, PC850-8, PC850LC-8 Excavator Manual
COVER .................................................................................................................. 1 00 Index and foreword................................................................................................... 0 Index............................................................................................................... 3 Composition of shop manual...................................................................................... 4 Table of contents............................................................................................... 6 Foreword and general information.................................................................................... 17 Safety notice................................................................................................... 18 How to read the shop manual..................................................................................... 23 Explanation of terms for maintenance standard................................................................... 25 Handling of electric equipment and hydraulic component.......................................................... 27 Handling of connectors newly used for engines................................................................... 36 How to read electric wire code.................................................................................. 39 Precautions when carrying out operation......................................................................... 42 Method of disassembling and connecting push-pull type coupler................................................... 45 Standard tightening torque table................................................................................ 48 Conversion table................................................................................................ 52 01 Specification........................................................................................................ 0 Specification and technical data.................................................................................... 59 Specification and technical data................................................................................ 60 Specification drawings...................................................................................... 60 Working range drawing....................................................................................... 62 Specifications.............................................................................................. 64 Weight table................................................................................................ 82 Table of fuel, coolant and lubricants....................................................................... 88 10 Structure, function and maintenance standard......................................................................... 0 Engine and cooling system........................................................................................... 91 Engine and cooling system....................................................................................... 92 Coupling.................................................................................................... 92 Coupling lubrication system................................................................................. 93 Radiator, oil cooler........................................................................................ 94 Power train......................................................................................................... 97 Power train..................................................................................................... 98 Power train................................................................................................. 98 Swing machinery............................................................................................. 100 Swing circle................................................................................................ 102 Final drive................................................................................................. 104 Sprocket.................................................................................................... 106 Undercarriage and frame............................................................................................. 109 Undercarriage and frame......................................................................................... 110 Track frame and recoil spring............................................................................... 110 Idler....................................................................................................... 112 Carrier roller.............................................................................................. 114 Track roller................................................................................................ 116 Track shoe.................................................................................................. 118 Double shoe................................................................................................. 121 Hydraulic system, Part 1............................................................................................ 123 Hydraulic system, Part 1........................................................................................ 124 Hydraulic piping drawing.................................................................................... 124 Hydraulic tank, hydraulic filter............................................................................ 126 Hydraulic pump.............................................................................................. 128 Cooling fan pump............................................................................................ 148 Cooling fan motor........................................................................................... 156 Hydraulic system, Part 2............................................................................................ 163 Hydraulic system, Part 2........................................................................................ 166 Motor grease pump........................................................................................... 166 Return oil filter........................................................................................... 167 Line oil filter............................................................................................. 168 Drain oil filter............................................................................................ 169 L.H. 5-Spool control valve.................................................................................. 170 R.H. 4-Spool control valve.................................................................................. 176 Straight-travel valve....................................................................................... 182 Swing motor................................................................................................. 185 Center swivel joint......................................................................................... 190 Travel motor................................................................................................ 191 PPC accumulator............................................................................................. 201 Work equipment, swing PPC valve............................................................................. 202 Travel PPC valve............................................................................................ 208 Solenoid valve.............................................................................................. 212 Quick return valve.......................................................................................... 218 Hydraulic cylinder.......................................................................................... 220 Work equipment...................................................................................................... 227 Work equipment.................................................................................................. 228 Work equipment.............................................................................................. 228 Dimensions of work equipment................................................................................ 234 Cab and its attachments............................................................................................. 239 Cab and its attachments......................................................................................... 240 Air conditioner piping...................................................................................... 240 Electrical system................................................................................................... 243 Engine control.................................................................................................. 244 Electric control system......................................................................................... 253 Monitor system.................................................................................................. 287 Sensors......................................................................................................... 305 KOMTRAX system.................................................................................................. 309 20 Standard value table................................................................................................. 0 Standard service value table........................................................................................ 313 Standard service value table.................................................................................... 314 Standard service value table for engine..................................................................... 314 Standard service value table for chassis.................................................................... 315 30 Testing and adjusting................................................................................................ 0 Testing and adjusting, Part 1....................................................................................... 327 Testing and adjusting, Part 1................................................................................... 328 Tools for testing, adjusting and troubleshooting............................................................ 328 Measuring engine speed...................................................................................... 331 Measuring intake air pressure (Boost pressure).............................................................. 332 Measuring exhaust gas temperature........................................................................... 333 Measuring exhaust gas color................................................................................. 334 Adjusting valve clearance................................................................................... 335 Measuring compression pressure.............................................................................. 336 Measuring blow-by pressure.................................................................................. 337 Measuring engine oil pressure............................................................................... 338 Measuring EGR valve and bypass valve drive pressure......................................................... 339 Handling of fuel system equipment........................................................................... 340 Remaining pressure relief from fuel system equipment........................................................ 340 Measuring fuel pressure..................................................................................... 341 Testing fuel return rate and leakage........................................................................ 342 Bleeding air from fuel circuit.............................................................................. 344 Testing fuel system for leakage............................................................................. 346 Testing and adjusting alternator belt tension............................................................... 347 Testing and adjusting air conditioner compressor belt....................................................... 348 Testing and adjusting, Part 2....................................................................................... 351 Testing and adjusting, Part 2................................................................................... 352 Inspection of swing circle bearing clearance................................................................ 352 Testing and adjusting track shoe tension.................................................................... 353 Testing and adjusting work equipment, swing, and travel circuit oil pressures............................... 354 Testing and adjusting control circuit pressure (output pressure of self pressure reducing valve)............ 360 Testing and adjusting main pump control pressure............................................................ 362 Testing and adjusting, Part 3....................................................................................... 369 Testing and adjusting, Part 3................................................................................... 370 Measuring PPC valve output pressure......................................................................... 370 Measuring outlet pressures of solenoid valve, swing PPC shuttle valve, and swing priority selector valve.... 374 Adjusting work equipment, swing PPC valve................................................................... 378 Testing and adjusting travel deviation...................................................................... 379 Inspection of locations of hydraulic drift of work equipment................................................ 381 Measuring fan speed......................................................................................... 382 Measuring fan circuit oil pressure.......................................................................... 382 Measuring fan pump EPC current.............................................................................. 383 Measuring fan pump EPC solenoid valve output pressure....................................................... 384 Measuring oil leakage....................................................................................... 385 Release of residual pressure from hydraulic circuit......................................................... 389 Bleeding air from each part................................................................................. 390 Inspection procedures for diode............................................................................. 393 Adjusting mirrors........................................................................................... 394 Testing and adjusting, Part 4....................................................................................... 397 Testing and adjusting, Part 4................................................................................... 398 Special function of machine monitor......................................................................... 398 Handling controller voltage circuit......................................................................... 431 Testing and adjusting, Part 5....................................................................................... 433 Testing and adjusting, Part 5................................................................................... 434 Procedure for turning on KOMTRAX terminal................................................................... 434 KOMTRAX terminal lamp indications........................................................................... 437 Preparation work for troubleshooting electrical system...................................................... 440 40 Troubleshooting...................................................................................................... 0 Failure code table and fuse locations............................................................................... 453 Failure code table and fuse locations........................................................................... 454 Failure codes table......................................................................................... 454 Fuse locations.............................................................................................. 458 General information on troubleshooting.............................................................................. 461 General information on troubleshooting.......................................................................... 462 Points to remember when troubleshooting..................................................................... 462 Sequence of events in troubleshooting....................................................................... 463 Checks before troubleshooting............................................................................... 464 Classification and troubleshooting steps.................................................................... 465 Information in troubleshooting table........................................................................ 466 Failure-looking phenomenon and troubleshooting No........................................................... 468 Connection table for connector pin numbers.................................................................. 471 T- branch box and T- branch adapter table................................................................... 507 Troubleshooting by failure code (Display of code), Part 1........................................................... 511 Troubleshooting by failure code (Display of code), Part 1....................................................... 514 Failure code [AA10NX] Aircleaner Clogging................................................................... 514 Failure code [AB00KE] Charge Voltage Low.................................................................... 516 Failure code [B@BAZG] Eng. Oil Press. Low................................................................... 518 Failure code [B@BAZK] Eng. Oil Level Low.................................................................... 519 Failure code [B@BCNS] Eng. Water Overheat................................................................... 520 Failure code [B@BCZK] Eng. Water Lvl Low.................................................................... 522 Failure code [B@HANS] Hydr. Oil Overheat.................................................................... 524 Failure code [CA111] ECM Critical Internal Failure.......................................................... 526 Failure code [CA115] Eng Ne and Bkup Speed Sens Error....................................................... 528 Failure code [CA122] Chg Air Press Sensor High Error........................................................ 530 Failure code [CA123] Chg Air Press Sensor Low Error......................................................... 532 Failure code [CA131] Throttle Sensor High Error............................................................. 534 Failure code [CA132] Throttle Sensor Low Error.............................................................. 536 Failure code [CA135] Eng Oil Press Sensor High Error........................................................ 538 Failure code [CA141] Eng Oil Press Sensor Low Error......................................................... 540 Failure code [CA144] Coolant Temp Sens High Error........................................................... 542 Failure code [CA145] Coolant Temp Sens Low Error............................................................ 544 Failure code [CA153] Chg Air Temp Sensor High Error......................................................... 546 Failure code [CA154] Chg Air Temp Sensor Low Error.......................................................... 548 Failure code [CA187] Sens Supply 2 Volt Low Error........................................................... 548 Failure code [CA221] Ambient Press Sens High Error.......................................................... 550 Failure code [CA222] Ambient Press Sens Low Error........................................................... 552 Failure code [CA227] Sens Supply 2 Volt High Error.......................................................... 554 Failure code [CA234] Eng Overspeed.......................................................................... 556 Failure code [CA238] Ne Speed Sens Supply Volt Error........................................................ 558 Failure code [CA263] Fuel Temp Sensor High Error............................................................ 560 Failure code [CA265] Fuel Temp Sensor Low Error............................................................. 562 Failure code [CA271] IMV/PCV1 Short Error................................................................... 563 Failure code [CA272] IMV/PCV1 Open Error.................................................................... 564 Failure code [CA273] PCV2 Short Error....................................................................... 565 Failure code [CA274] PCV2 Open Error........................................................................ 566 Failure code [CA322] Inj #1 (L#1) Open/Short Error.......................................................... 567 Failure code [CA323] Inj #5 (L#5) Open/Short Error.......................................................... 568 Failure code [CA324] Inj #3 (L#3) Open/Short Error.......................................................... 570 Failure code [CA325] Inj #6 (L#6) Open/Short Error.......................................................... 572 Failure code [CA331] Inj #2 (L#2) Open/Short Error.......................................................... 574 Failure code [CA332] Inj #4 (L#4) Open/Short Error.......................................................... 576 Failure code [CA342] Calibration Code Incompatibility....................................................... 577 Failure code [CA351] Injectors Drive Circuit Error.......................................................... 578 Failure code [CA352] Sens Supply 1 Volt Low Error........................................................... 580 Failure code [CA386] Sens Supply 1 Volt High Error.......................................................... 582 Troubleshooting by failure code (Display of code), Part 2........................................................... 585 Troubleshooting by failure code (Display of code), Part 2....................................................... 587 Failure code [CA441] Battery Voltage Low Error.............................................................. 587 Failure code [CA442] Battery Voltage High Error............................................................. 587 Failure code [CA449] Rail Press Very High Error............................................................. 588 Failure code [CA451] Rail Press Sensor High Error........................................................... 590 Failure code [CA452] Rail Press Sensor Low Error............................................................ 592 Failure code [CA553] Rail Press High Error.................................................................. 592 Failure code [CA554] Rail Press Sensor In Range Error....................................................... 593 Failure code [CA559] Rail Press Low Error................................................................... 594 Failure code [CA689] Eng Ne Speed Sensor Error.............................................................. 598 Failure code [CA731] Eng Bkup Speed Sens Phase Error........................................................ 600 Failure code [CA757] All Persistent Data Lost Error......................................................... 601 Failure code [CA778] Eng Bkup Speed Sensor Error............................................................ 602 Failure code [CA1228] EGR Valve Servo Error 1............................................................... 604 Failure code [CA1625] EGR Valve Servo Error 2............................................................... 605 Failure code [CA1626] BP Valve Sol Current High Error....................................................... 606 Failure code [CA1627] BP Valve Sol Current Low Error........................................................ 608 Failure code [CA1628] Bypass Valve Servo Error 1............................................................ 609 Failure code [CA1629] Bypass Valve Servo Error 2............................................................ 610 Failure code [CA1631] BP Valve Pos Sens High Error.......................................................... 612 Failure code [CA1632] BP Valve Pos Sens Low Error........................................................... 614 Failure code [CA1633] KOMNET Datalink Timeout Error......................................................... 616 Failure code [CA1642] EGR Inter Press Sens Low Error........................................................ 618 Failure code [CA1653] EGR Inter Press Sens High Error....................................................... 620 Failure code [CA2185] Throt Sens Sup Volt High Error........................................................ 622 Failure code [CA2186] Throt Sens Sup Volt Low Error......................................................... 624 Failure code [CA2249] Rail Press Very Low Error............................................................. 625 Failure code [CA2271] EGR Valve Pos Sens High Error......................................................... 626 Failure code [CA2272] EGR Valve Pos Sens Low Error.......................................................... 628 Failure code [CA2351] EGR Valve Sol Current High Error...................................................... 630 Failure code [CA2352] EGR Valve Sol Current Low Error....................................................... 632 Failure code [CA2555] Grid Htr Relay Volt Low Error......................................................... 633 Failure code [CA2556] Grid Htr Relay Volt High Error........................................................ 634 Failure code [D110KB] Battery Relay Drive S/C............................................................... 636 Failure code [D163KB] Flash Light Relay S/C................................................................. 638 Failure code [D195KB] Step Light Relay S/C.................................................................. 640 Failure code [DA22KK] Pump Solenoid Power Low Error......................................................... 642 Failure code [DA25KP] Press. Sensor Power Abnormality....................................................... 644 Failure code [DA2SKQ] Model Selection Abnormality........................................................... 646 Failure code [DA80MA] Auto. Lub. Abnormal................................................................... 648 Failure code [DA2RMC] Pump Comm. Abnormality................................................................ 650 Failure code [DAFRMC] Monitor Comm. Abnormality............................................................. 652 Failure code [DGE5KY] Ambi. Temp. Sensor S/C................................................................ 654 Failure code [DGH2KB] Hydr. Oil Temp. Sensor S/C............................................................ 656 Troubleshooting by failure code (Display of code), Part 3........................................................... 659 Troubleshooting by failure code (Display of code), Part 3....................................................... 662 Failure code [DH25KA] L Jet Sensor Disc..................................................................... 662 Failure code [DH25KB] L Jet Sensor S/C...................................................................... 664 Failure code [DH26KA] R Jet Sensor Disc..................................................................... 666 Failure code [DH26KB] R Jet Sensor S/C...................................................................... 668 Failure code [DHPEKA] F Pump P. Sensor Disc................................................................. 670 Failure code [DHPEKB] F Pump P. Sensor S/C.................................................................. 672 Failure code [DHPFKA] R Pump P. Sensor Disc................................................................. 674 Failure code [DHPFKB] R Pump P. Sensor S/C.................................................................. 676 Failure code [DV20KB] Travel Alarm S/C...................................................................... 678 Failure code [DW41KA] Swing Priority Sol. Disc.............................................................. 680 Failure code [DW41KB] Swing Priority Sol. S/C............................................................... 682 Failure code [DW43KA] Travel Speed Sol. Disc................................................................ 684 Failure code [DW43KB] Travel Speed Sol. S/C................................................................. 686 Failure code [DW45KA] Swing Brake Sol. Disc................................................................. 688 Failure code [DW45KB] Swing Brake Sol. S/C.................................................................. 690 Failure code [DW7BKA] Fan Reverse Sol. Disc................................................................. 692 Failure code [DW7BKB] Fan Reverse Sol. S/C.................................................................. 694 Failure code [DW7JKA] Bottom Dump Priority Sol. Disc........................................................ 696 Failure code [DW7JKB] Bottom Dump Priority Sol. S/C......................................................... 698 Failure code [DWK0KA] 2-stage Relief Sol. Disc.............................................................. 700 Failure code [DWK0KB] 2-stage Relief Sol. S/C............................................................... 702 Failure code [DX16KA] Fan Pump EPC Sol. Disc................................................................ 704 Failure code [DX16KB] Fan Pump EPC Sol. S/C................................................................. 706 Failure code [DXAAKA] F Pump EPC Sol. Disc.................................................................. 708 Failure code [DXAAKB] F Pump EPC Sol. S/C................................................................... 710 Failure code [DXABKA] R Pump EPC Sol. Disc.................................................................. 712 Failure code [DXABKB] R Pump EPC Sol. S/C................................................................... 714 Failure code [DY20KA] Wiper Working Abnormality............................................................. 716 Failure code [DY20MA] Wiper Parking Abnormality............................................................. 718 Failure code [DY2CKB] Washer Drive S/C...................................................................... 722 Failure code [DY2DKB] Wiper Drive (For) S/C................................................................. 724 Failure code [DY2EKB] Wiper Drive (Rev) S/C................................................................. 728 Troubleshooting of electrical system (E-mode)....................................................................... 731 Troubleshooting of electrical system (E-mode)................................................................... 733 Before carrying out troubleshooting of electrical system.................................................... 733 Information contained in troubleshooting table.............................................................. 735 E-1 Engine does not start (Engine does not rotate).......................................................... 736 E-2 Preheater does not operate.............................................................................. 739 E-3 Auto engine warm-up device does not work................................................................ 746 E-4 Auto-decelerator does not operate....................................................................... 747 E-5 All work equipment, swing and travel do not move........................................................ 748 E-6 Machine push-up function does not operate normally...................................................... 750 E-7 Boom shockless function does not operate normally....................................................... 752 E-8 Any item is not displayed on machine monitor............................................................ 754 E-9 Part of display on machine monitor is missing........................................................... 755 E-10 Machine monitor displays contents irrelevant to the model.............................................. 755 E-11 Fuel level monitor red lamp lights up while engine is running.......................................... 756 E-12 Engine coolant thermometer does not display normally................................................... 758 E-13 Hydraulic oil temperature gauge does not display correctly............................................. 760 E-14 Fuel gauge does not display correctly.................................................................. 761 E-15 Swing lock monitor does not display correctly.......................................................... 762 E-16 When monitor switch is operated, nothing is displayed.................................................. 764 E-17 Windshield wiper and window washer do not work......................................................... 766 E-18 “Boom RAISE” is not correctly displayed in monitor function............................................ 774 E-19 “Boom LOWER” is not correctly displayed in monitor function............................................ 775 E-20 “Arm IN” is not correctly displayed in monitor function................................................ 776 E-21 “Arm OUT” is not correctly displayed in monitor function............................................... 777 E-22 “Bucket CURL” is not correctly displayed in monitor function........................................... 778 E-23 “Bucket DUMP” is not correctly displayed in monitor function........................................... 779 E-24 “SWING” is not correctly displayed in monitor function................................................. 780 E-25 “Left travel” is not displayed normally in monitoring function......................................... 782 E-26 “Right travel” is not displayed normally in monitoring function........................................ 784 E-27 “Service” is not correctly displayed in monitor function............................................... 786 E-28 KOMTRAX system does not operate normally............................................................... 788 E-29 Air conditioner does not work.......................................................................... 790 E-30 Step light does not light up or go off................................................................. 791 E-31 Electric grease gun does not operate................................................................... 794 E-32 Travel alarm does not sound or does not stop sounding.................................................. 796 Troubleshooting of hydraulic and mechanical system (H-mode)......................................................... 799 Troubleshooting of hydraulic and mechanical system (H-mode)..................................................... 801 Before troubleshooting...................................................................................... 801 Information in troubleshooting table........................................................................ 804 H-1 Speed or power of all work equipment, travel, and swing is low.......................................... 806 H-2 Engine speed lowers remarkably or engine stalls......................................................... 808 H-3 All work equipment, travel, and swing systems do not work............................................... 810 H-4 Abnormal sound is heard from around pump................................................................ 811 H-5 Boom speed or power is low.............................................................................. 812 H-6 Speed or power of arm is low............................................................................ 814 H-7 Speed or power of bucket is low......................................................................... 815 H-8 Boom does not move...................................................................................... 816 H-9 Arm does not move....................................................................................... 816 H-10 Bucket does not move................................................................................... 816 H-11 Hydraulic drift of work equipment is large............................................................. 817 H-12 Time lag of work equipment is large.................................................................... 819 H-13 Heavy lift function does not operate or stop........................................................... 820 H-14 Machine push-up function does not operate or stop...................................................... 820 H-15 Boom shockless function cannot be turned ON or OFF..................................................... 820 H-16 Machine deviates in one direction...................................................................... 822 H-17 Machine deviates largely at start...................................................................... 824 H-18 Machine deviates largely during compound operation..................................................... 825 H-19 Travel speed or power is low........................................................................... 825 H-20 Machine does not travel (only one track)............................................................... 826 H-21 Travel speed does not change........................................................................... 827 H-22 Upper structure does not swing......................................................................... 828 H-23 Swing speed or acceleration is low..................................................................... 830 H-24 Swing speed or acceleration is low during compound operation of swing and work equipment............... 832 H-25 Upper structure overruns excessively when it stops swinging............................................ 834 H-26 Large shock is made when upper structure stops swinging................................................ 835 H-27 Large abnormal sound is made when upper structure stops swinging....................................... 836 H-28 Hydraulic drift of swing is large...................................................................... 837 H-29 Fan rotation is abnormal (Fan sound/vibration is abnormally large or fan overheats).................... 838 Troubleshooting of engine (S-mode).................................................................................. 841 Troubleshooting of engine (S-mode).............................................................................. 843 Method of using troubleshooting chart....................................................................... 843 S-1 Starting performance is poor............................................................................ 846 S-2 Engine does not start................................................................................... 848 S-3 Engine does not pick up smoothly........................................................................ 852 S-4 Engine stops during operations.......................................................................... 853 S-5 Engine does not rotate smoothly......................................................................... 854 S-6 Engine lacks output (or lacks power).................................................................... 855 S-7 Exhaust gas color is black (incomplete combustion)...................................................... 856 S-8 Oil consumption is excessive (or exhaust smoke is blue)................................................. 858 S-9 Oil becomes contaminated quickly........................................................................ 859 S-10 Fuel consumption is excessive.......................................................................... 860 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down).................................. 861 S-12 Oil pressure drops..................................................................................... 862 S-13 Oil level rises (Entry of coolant/fuel)................................................................ 864 S-14 Coolant temperature becomes too high (overheating)..................................................... 866 S-15 Abnormal noise is made................................................................................. 867 S-16 Vibration is excessive................................................................................. 868 50 Disassembly and assembly............................................................................................. 0 General information on disassembly and assembly..................................................................... 871 General information on disassembly and assembly................................................................. 872 How to read this manual..................................................................................... 872 Coating materials list...................................................................................... 874 Special tools list.......................................................................................... 877 Sketches of special tools................................................................................... 884 Engine and cooling system (SAA6D140E-5)............................................................................. 891 Engine and cooling system....................................................................................... 892 Removal and installation of engine, PTO and hydraulic pump assembly......................................... 892 Removal and installation of cooling assembly................................................................ 900 Removal and installation of aftercooler assembly............................................................ 905 Removal and installation of fuel cooler and air conditioner condenser assembly.............................. 907 Removal and installation of fan motor assembly.............................................................. 909 Removal and installation of fuel tank assembly.............................................................. 914 Engine (SAA6D140E-5)................................................................................................ 917 Engine (SAA6D140E-5)............................................................................................ 918 Removal and installation of fuel supply pump assembly....................................................... 918 Removal and installation of cylinder head assembly.......................................................... 923 Removal and installation of fuel injector assembly.......................................................... 939 Removal and installation of engine front seal............................................................... 942 Removal and installation of engine rear seal................................................................ 944 Power train......................................................................................................... 949 Power train..................................................................................................... 950 Removal and installation of PTO (coupling) assembly......................................................... 950 Disassembly and assembly of PTO (coupling) assembly......................................................... 957 Removal and installation of swing motor and swing machinery assembly........................................ 959 Disassembly and assembly of swing machinery assembly........................................................ 961 Removal and installation of swing circle assembly........................................................... 968 Disassembly and assembly of final drive assembly............................................................ 969 Undercarriage and frame............................................................................................. 981 Undercarriage and frame......................................................................................... 982 Removal and installation of track shoe assembly............................................................. 982 Disassembly and assembly of one link in field............................................................... 984 Removal and installation of idler assembly.................................................................. 988 Disassembly and assembly of idler assembly.................................................................. 989 Disassembly and assembly of idler adjustment cylinder assembly.............................................. 992 Removal and installation of recoil spring assembly.......................................................... 993 Disassembly and assembly of recoil spring assembly.......................................................... 995 Removal and installation of carrier roller assembly......................................................... 997 Disassembly and assembly of carrier roller assembly......................................................... 998 Removal and installation of track roller assembly...........................................................1001 Disassembly and assembly of track roller assembly...........................................................1002 Removal and installation of revolving frame assembly........................................................1005 Removal and installation of counterweight assembly..........................................................1007 Removal and installation of counterweight remover assembly..................................................1008 Hydraulic system....................................................................................................1013 Hydraulic system................................................................................................1014 Removal and installation of hydraulic tank assembly.........................................................1014 Removal and installation of main pump assembly..............................................................1017 Removal and installation of main pump input shaft oil seal..................................................1024 Removal and installation of cooling fan pump assembly.......................................................1025 Removal and installation of control valve assembly..........................................................1028 Assembly of control valve assembly..........................................................................1031 Removal and installation of swing motor assembly............................................................1037 Removal and installation of center swivel joint assembly....................................................1039 Disassembly and assembly of center swivel joint assembly....................................................1041 Removal and installation of travel motor assembly...........................................................1043 Removal and installation of solenoid valve assembly.........................................................1044 Removal and installation of boom damping valve assembly.....................................................1046 Disassembly and assembly of work equipment PPC valve assembly...............................................1047 Disassembly and assembly of travel PPC valve assembly.......................................................1049 Disassembly and assembly of hydraulic cylinder assembly.....................................................1052 Disassembly and assembly of grease gun assembly.............................................................1058 Work equipment......................................................................................................1061 Work equipment..................................................................................................1062 Removal and installation of bucket cylinder assembly........................................................1062 Removal and installation of arm cylinder assembly...........................................................1066 Removal and installation of boom cylinder assembly..........................................................1070 Removal and installation of bottom dump cylinder assembly...................................................1074 Removal and installation of bucket assembly.................................................................1075 Removal and installation of arm assembly....................................................................1077 Removal and installation of boom assembly...................................................................1080 Removal and installation of work equipment..................................................................1084 Cab and its attachments.............................................................................................1089 Cab and its attachments.........................................................................................1090 Removal and installation of operator’s cab..................................................................1090 Removal and installation of operator’s cab glass (stuck glass)..............................................1093 Removal and installation of front window assembly...........................................................1103 Electrical system...................................................................................................1109 Electrical system...............................................................................................1110 Removal and installation of air conditioner unit assembly...................................................1110 Removal and installation of engine controller assembly......................................................1112 Removal and installation of monitor assembly................................................................1114 Removal and installation of pump controller assembly........................................................1114 Removal and Installation of KOMTRAX terminal assembly.......................................................1115 90 Diagrams and drawings................................................................................................ 0 Hydraulic diagrams and drawings.....................................................................................1117 Hydraulic circuit diagram.......................................................................................1118 Electrical diagrams and drawings....................................................................................1120 Electrical circuit diagram (1/5)................................................................................1122 Electrical circuit diagram (2/5)................................................................................1123 Electrical circuit diagram (3/5)................................................................................1124 Electrical circuit diagram (4/5)................................................................................1125 Electrical circuit diagram (5/5)................................................................................1126 Connector list and sterogram....................................................................................1127
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