Komatsu PC800LC-8 Shop Manual

Hydraulic excavator

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Shop manual (1117 pages)

Operation & maintenance manual (318 pages)

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HYDRAULIC

EXCAVATOR

PC800

PC800LC

PC800SE

PC850

PC850SE

SERIAL NUMBERS

-8

PC800-

50001

PC800LC- 50001

PC800SE- 50001

PC850-

10001

PC850SE- 10001

SEN00373-16

and up

Table of Contents

Summary of Contents for Komatsu PC800LC-8

Page 1 SEN00373-16 HYDRAULIC PC800 EXCAVATOR PC800LC PC800SE PC850 PC850SE PC800- 50001 PC800LC- 50001 PC800SE- 50001 SERIAL NUMBERS and up PC850- 10001 PC850SE- 10001...
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Page 3 SEN00375-16 HYDRAULIC EXCAVATOR PC800-8 PC850-8 PC800SE-8 PC850SE-8 PC800LC-8 Machine model Serial number PC800-8 50001 and up PC800SE-8 50001 and up PC800LC-8 50001 and up PC850-8 10001 and up PC850SE-8 10001 and up 00 Index and foreword Index Composition of shop manual ..........................2 Table of contents ..............................
Page 4 SEN00375-16 00 Index and foreword Composition of shop manual The contents of this shop manual are shown together with Form No. in a list. Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly. The marks shown to the right of Form No.
Page 5 SEN00375-16 00 Index and foreword Troubleshooting of engine (S-mode) SEN00795-03 50 Disassembly and assembly SEN00390-07 General information on disassembly and assembly SEN01052-03 Engine and cooling system (SAA6D140E-5) SEN01053-01 Engine (SAA6D140E-5) SEN01054-01 SEN01055-04 q Power train SEN01056-05 q Undercarriage and frame Hydraulic system SEN01057-03 Work equipment...
Page 6: Table Of Contents
SEN00375-16 00 Index and foreword Table of contents 00 Index and foreword Index SEN00375-16 Composition of shop manual ....................Table of contents........................Foreword and general information SEN00376-04 Safety notice ..........................How to read the shop manual....................Explanation of terms for maintenance standard ..............Handling of electric equipment and hydraulic component ............
Page 7 SEN00375-16 00 Index and foreword Hydraulic system, Part 2 SEN00384-04 Hydraulic system, Part 2 ......................Motor grease pump ......................... Return oil filter ......................... Line oil filter ..........................Drain oil filter..........................L.H. 5-Spool control valve......................R.H. 4-Spool control valve ....................... 14 Straight-travel valve .........................
Page 8 SEN00375-16 00 Index and foreword Testing fuel system for leakage ....................20 Testing and adjusting alternator belt tension ................21 Testing and adjusting air conditioner compressor belt............. 22 Testing and adjusting, Part 2 SEN00788-04 Testing and adjusting, Part 2 ....................... Inspection of swing circle bearing clearance ................
Page 9 SEN00375-16 00 Index and foreword Failure code [B@BAZK] Eng. Oil Level Low ................Failure code [B@BCNS] Eng. Water Overheat ............... 10 Failure code [B@BCZK] Eng. Water Lvl Low ................12 Failure code [B@HANS] Hydr. Oil Overheat ................14 Failure code [CA111] ECM Critical Internal Failure ..............16 Failure code [CA115] Eng Ne and Bkup Speed Sens Error ............
Page 10 SEN00375-16 00 Index and foreword Failure code [CA1631] BP Valve Pos Sens High Error............28 Failure code [CA1632] BP Valve Pos Sens Low Error ............30 Failure code [CA1633] KOMNET Datalink Timeout Error............32 Failure code [CA1642] EGR Inter Press Sens Low Error ............34 Failure code [CA1653] EGR Inter Press Sens High Error ............
Page 11 SEN00375-16 00 Index and foreword Failure code [DY2EKB] Wiper Drive (Rev) S/C ............... 70 Troubleshooting of electrical system (E-mode) SEN00793-02 Troubleshooting of electrical system (E-mode) ................Before carrying out troubleshooting of electrical system ............Information contained in troubleshooting table ................ E-1 Engine does not start (Engine does not rotate)..............
Page 12 SEN00375-16 00 Index and foreword H-17 Machine deviates largely at start ..................26 H-18 Machine deviates largely during compound operation............ 27 H-19 Travel speed or power is low ..................27 H-20 Machine does not travel (only one track) ................ 28 H-21 Travel speed does not change..................
Page 13 SEN00375-16 00 Index and foreword Power train SEN01055-04 Power train ..........................Removal and installation of PTO (coupling) assembly ............Disassembly and assembly of PTO (coupling) assembly............Removal and installation of swing motor and swing machinery assembly ......Disassembly and assembly of swing machinery assembly ............. 13 Removal and installation of swing circle assembly..............
Page 14 SEN00375-16 00 Index and foreword Electrical system SEN01060-01 Electrical system ......................... Removal and installation of air conditioner unit assembly ............Removal and installation of engine controller assembly............Removal and installation of monitor assembly ................ Removal and installation of pump controller assembly............Removal and Installation of KOMTRAX terminal assembly.............
Page 15 SEN00375-16 00 Index and foreword PC800, 850-8...
Page 17: Table Of Contents
SEN00376-04 HYDRAULIC EXCAVATOR PC800-8 PC850-8 PC800SE-8 PC850SE-8 PC800LC-8 Machine model Serial number PC800-8 50001 and up PC800SE-8 50001 and up PC800LC-8 50001 and up PC850-8 10001 and up PC850SE-8 10001 and up 00 Index and foreword Foreword and general information Safety notice.................................
Page 18: Safety Notice
Proper service and repair are extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose.
Page 19: Coupling Lubrication System
SEN00376-04 00 Index and foreword Preparations for work When removing a cover which is under Before adding oil or making any repairs, internal pressure or under pressure from a park the machine on a hard and level spring, always leave 2 bolts in diagonal ground, and apply the parking brake and positions.
Page 20: Table Of Contents
SEN00376-04 00 Index and foreword Precautions for sling work and making signs Only one appointed worker must make signs and co-workers must communicate with each other frequently. The appointed sign maker must make specified signs clearly at a place where he is well seen from the operator's seat and where he can see the working condition easily.
Page 21 SEN00376-04 00 Index and foreword If the load is unstable or the wire rope 13) If the hoist stops because of a power fail- or chains are twisted, lower the load ure, turn the power switch OFF. When and lift it up again. turning on a switch which was turned OFF Do not lift up the load slantingly.
Page 22: Specifications
SEN00376-04 00 Index and foreword a Example of O-ring (Fitted to every joint of Precautions for disconnecting and con- necting hoses and tubes in air conditioner hoses and tubes) circuit Disconnection For the environment, the air condi- tioner of this machine uses the refrigerant (air conditioner gas: R134a) which has fewer factors of the depletion of the ozone layer.
Page 23: How To Read The Shop Manual
This section explains the method of reproducing, repairing, and replacing parts. Revision and distribution Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most up-to-date information before you start any work. PC800, 850-8...
Page 24: Final Drive
SEN00376-04 00 Index and foreword Filing method File by the brochures in the correct order of the form number printed in the shop manual composition table. Revised edition mark When a manual is revised, the ones and tens digits of the form number of each brochure is increased by 1.
Page 25: Explanation Of Terms For Maintenance Standard
SEN00376-04 00 Index and foreword Explanation of terms for maintenance standard The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the machine maintenance work. The following terms are used to explain the criteria. Standard size and tolerance To be accurate, the finishing size of parts is a little different from one to another.
Page 26: Sprocket
SEN00376-04 00 Index and foreword Standard clearance and standard value Clearance limit The clearance made when new parts are Parts can be used until the clearance assembled is called the “standard clear- between them is increased to a certain ance“, which is indicated by the range limit.
Page 27: Handling Of Electric Equipment And Hydraulic Component
SEN00376-04 00 Index and foreword Handling of electric equipment and hydraulic component To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur, correct “operation“, “maintenance and inspection“, “troubleshooting“, and “repairs” must be carried out.
Page 28 SEN00376-04 00 Index and foreword Disconnections in wiring If the wiring is held and the connectors are pulled apart, or components are lifted with a crane with the wiring still connected, or a heavy object hits the wiring, the crimping of the connector may separate, or the sol- dering may be damaged, or the wiring may be broken.
Page 29: Double Shoe
SEN00376-04 00 Index and foreword Removing, installing, and drying connec- tors and wiring harnesses Disconnecting connectors Hold the connectors when discon- necting. When disconnecting the connectors, hold the connectors. For connectors held by a screw, loosen the screw fully, then hold the male and female connectors in each hand and pull apart.
Page 30 SEN00376-04 00 Index and foreword Connecting connectors Check the connector visually. Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). Check that there is no deformation, defective contact, corrosion, or dam- age to the connector pins. Check that there is no damage or breakage to the outside of the con- nector.
Page 31 SEN00376-04 00 Index and foreword Heavy duty wire connector (DT 8-pole, 12- Disconnection Connection (Example of pole) incomplete setting of (a)) Disconnection (Left of figure) While pressing both sides of locks (a) and (b), pull out female connector (2). Connection (Right of figure) Push in female connector (2) horizon- tally until the lock clicks.
Page 32 SEN00376-04 00 Index and foreword Drying wiring harness If there is any oil or dirt on the wiring har- ness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high-pressure water or steam directly on the wiring harness.
Page 33 SEN00376-04 00 Index and foreword Handling controller The controller contains a microcomputer and electronic control circuits. These con- trol all of the electronic circuits on the machine, so be extremely careful when handling the controller. Do not place objects on top of the control- ler.
Page 34 SEN00376-04 00 Index and foreword Points to remember when handling hydraulic equipment With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary to be particularly careful.
Page 35 SEN00376-04 00 Index and foreword Change hydraulic oil when the temperature is high When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil, so it is best to change the oil when it is still warm.
Page 36: Handling Of Connectors Newly Used For Engines
SEN00376-04 00 Index and foreword Handling of connectors newly used for engines a Mainly, following engines are object for follow- Pull lock type (PACKARD-2) ing connectors. 95 – 170, 12V140 engines 95E-5 Various temperature sensors 107E-1 Example) 114E-3 Intake air temperature sensor in 125E-5 intake manifold: TIM 140E-5...
Page 37 SEN00376-04 00 Index and foreword Push lock type 95, 107, 114 engines Example) Fuel pressure sensor in common rail (BOSCH-03) Disconnect connector (3) according to the fol- lowing procedure. While pressing lock (C), pull out connector (3) in the direction of the arrow. 114 engine 107, 114 engines Example)
Page 38 SEN00376-04 00 Index and foreword 95, 125 – 170, 12V140 engines Turn-housing type (Round green connector) While pressing lock (E) of the connector, 140 engine pull out connector (5) in the direction of Example) the arrow. Intake air pressure sensor in intake mani- fold (CANNON-04): PIM etc.
Page 39: How To Read Electric Wire Code
SEN00376-04 00 Index and foreword How to read electric wire code a The information about the wires unique to each machine model is described in Troubleshooting section, Relational information of troubleshooting. In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by sym- bols.
Page 40: Weight Table
SEN00376-04 00 Index and foreword Dimensions (Table 2) Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) Number of strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32 eter of strand Conductor Sectional 0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09...
Page 41 SEN00376-04 00 Index and foreword Color codes table (Table 3) Color Code Color of wire Color Code Color of wire Black Light green & White Brown Light green & Yellow Brown & Black Blue & Red Brown & Red Blue & White Brown &...
Page 42: Precautions When Carrying Out Operation
SEN00376-04 00 Index and foreword Precautions when carrying out operation [When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precautions given below when carrying out the operation.] Precautions when carrying out removal work If the coolant contains antifreeze, dispose of it correctly.
Page 43 SEN00376-04 00 Index and foreword Precautions when carrying out installation work Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque. Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
Page 44 SEN00376-04 00 Index and foreword Checking muffler and exhaust pipe for damage and looseness Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage. If any part is damaged, replace it. Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for looseness.
Page 45: Method Of Disassembling And Connecting Push-Pull Type Coupler
SEN00376-04 00 Index and foreword Method of disassembling and connecting push-pull type coupler Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to release the residual pressure from the hydraulic tank. Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected.
Page 46: Table Of Fuel, Coolant And Lubricants
SEN00376-04 00 Index and foreword Type 2 Disconnection Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexag- onal portion at the male end. (Fig. 6) While holding the condition of Step 1), turn lever (8) to the right (clockwise).
Page 47 SEN00376-04 00 Index and foreword Type 3 Disconnection Hold the tightening portion and push body (9) straight until sliding prevention ring (8) contacts contact surface (b) of the hexag- onal portion at the male end. (Fig. 10) While holding the condition of Step 1), push cover (10) straight until it contacts contact surface (b) of the hexagonal por- tion at the male end.
Page 48: Standard Tightening Torque Table
SEN00376-04 00 Index and foreword Standard tightening torque table Table of tightening torques for bolts and nuts a Unless there are special instructions, tighten metric nuts and bolts to the torque below. a The following table applies to the bolts in Fig. A. Thread diameter of bolt Width across flats Tightening torque...
Page 49 SEN00376-04 00 Index and foreword Table of tightening torques for split flange bolts a Unless there are special instructions, tighten split flange bolts to the torque below. Thread diameter of bolt Width across flats Tightening torque 59 – 74 6.0 – 7.5 98 –...
Page 50: Cooling Fan Motor
SEN00376-04 00 Index and foreword Table of tightening torques for hoses (taper seal type and face seal type) a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the torque below. a Apply the following torque when the threads are coated (wet) with engine oil. Tightening torque Nm {kgm} Taper seal Face seal...
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Pc800-8 Pc800se-8 Pc850-8 Pc850se-8

Komatsu PC800LC-8 Shop Manual

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