Komatsu Excavator PC800-8R PC800LC-8R PC800SE-8R PC850-8R PC850SE-8R service manual

Description Komatsu Excavator PC800-8R PC800LC-8R PC800SE-8R PC850-8R PC850SE-8R service manual

Komatsu Hydraulic Excavator PC800-8R, PC800LC-8R, PC800SE-8R, PC850-8R, PC850SE-8R pdf workshop service manual

Serial numbers:
PC800-8R 60001 and up
PC800LC-8R 60001 and up
PC800SE-8R 60001 and up
PC850-8R 60001 and up
PC850SE-8R 60001 and up

Specifications, testing, adjusting, troubleshooting, technical documentation, electrical wiring diagrams, hydraulic schematics, assembly, disassembly, removal, installation instructions and other information

MANUAL CONTENT:
Index and foreword
Composition of shop manual
Foreword and general information
Safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling of electric equipment and hydraulic component
Handling of connectors newly used for engines
How to read electric wire code
Precautions when carrying out operation
Method of disassembling and connecting push-pull type coupler
Standard tightening torque table
Conversion table

Specification
Specification and technical data
Specification drawings
Working range drawing
Weight table
Table of fuel, coolant and lubricants

Structure, function and maintenance standard
Engine and cooling system
Coupling
Coupling lubrication system
Radiator, oil cooler
Power train
Swing machinery
Swing circle
Final drive
Sprocket
Undercarriage and frame
Track frame and recoil spring
Idler
Carrier roller
Track roller
Track shoe
Hydraulic system
Hydraulic piping drawing
Hydraulic tank, hydraulic filter
Hydraulic pump
Cooling fan pump
Cooling fan motor
Motor grease pump
Return oil filter
Line oil filter
Drain oil filter
L.H. 5-Spool control valve
R.H. 4-Spool control valve
Straight-travel valve
Swing motor
Center swivel joint
Travel motor
PPC accumulator
Work equipment, swing PPC valve
Travel PPC valve
Solenoid valve
Quick return valve
Hydraulic cylinder
Work equipment
Dimensions of work equipment
Cab and its attachments
Air conditioner piping
Electrical system
Engine control
Electric control system
Monitor system
Sensors
KOMTRAX system

Standard value table
Standard service value table
Standard service value table for engine
Standard service value table for chassis

Testing and adjusting
Tools for testing, adjusting and troubleshooting
Measuring engine speed
Measuring intake air pressure (Boost pressure)
Measuring exhaust gas temperature
Measuring exhaust gas color
Adjusting valve clearance
Measuring compression pressure
Measuring blow-by pressure
Measuring engine oil pressure
Handling of fuel system equipment
Remaining pressure relief from fuel system equipment
Measuring fuel pressure
Testing fuel return rate and leakage
Bleeding air from fuel circuit
Testing and adjusting alternator belt tension
Testing and adjusting air conditioner compressor belt
Inspection of swing circle bearing clearance
Testing and adjusting track shoe tension
Testing and adjusting work equipment, swing, and travel circuit oil pressures
Testing and adjusting control circuit oil pressure (self pressure reducing valve)
Testing and adjusting main pump control pressure
Measuring PPC valve output pressure
Measuring outlet pressures of solenoid valve, swing PPC shuttle valve and swing priority selector valve
Adjusting work equipment, swing PPC valve
Testing and adjusting travel deviation
Inspection of locations of hydraulic drift of work equipment
Measuring fan speed
Measuring fan circuit oil pressure
Measuring fan pump EPC current
Measuring fan pump EPC solenoid valve output pressure
Measuring oil leakage
Release of residual pressure from hydraulic circuit
Bleeding air from each part
Inspection procedures for diode
Special function of machine monitor
Handling controller voltage circuit
Procedure for turning on KOMTRAX terminal
KOMTRAX terminal lamp indications
Preparation work for troubleshooting electrical system
Pm-clinic service

Troubleshooting
Failure code table and fuse locations
Failure codes table
Fuse locations
General information on troubleshooting
Points to remember when troubleshooting
Sequence of events in troubleshooting
Checks before troubleshooting
Classification and troubleshooting steps
Information in troubleshooting table
Connection table for connector pin numbers
T- branch box and T- branch adapter table
Troubleshooting by failure code (Display of code)
Troubleshooting of electrical system (E-mode)
Troubleshooting of hydraulic and mechanical system (H-mode)
Troubleshooting of engine (S-mode)

Disassembly and assembly
General information on disassembly and assembly
How to read this maHow to read this manual
Coating materials list
Special tools list
Sketches of special tools
Engine and cooling system (SAA6D140E-5)
Removal and installation of engine, PTO and hydraulic pump assembly
Removal and installation of cooling assembly
Removal and installation of aftercooler assembly
Removal and installation of fuel cooler and air conditioner condenser assembly
Removal and installation of fan motor assembly
Removal and installation of fuel tank assembly
Engine (SAA6D140E-5)
Removal and installation of fuel supply pump assembly
Removal and installation of cylinder head assembly
Removal and installation of fuel injector assembly
Removal and installation of engine front seal
Removal and installation of engine rear seal
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
Removal and installation of swing circle assembly
Disassembly and assembly of final drive assembly
Undercarriage and frame
Removal and installation of track shoe assembly
Disassembly and assembly of one link in field
Removal and installation of idler assembly
Disassembly and assembly of idler assembly
Disassembly and assembly of idler adjustment cylinder assembly
Removal and installation of recoil spring assembly
Disassembly and assembly of recoil spring assembly
Removal and installation of carrier roller assembly
Disassembly and assembly of carrier roller assembly
Removal and installation of track roller assembly
Disassembly and assembly of track roller assembly
Removal and installation of revolving frame assembly
Removal and installation of counterweight assembly
Hydraulic system
Removal and installation of hydraulic tank assembly
Removal and installation of main pump assembly
Removal and installation of main pump input shaft oil seal
Removal and installation of cooling fan pump assembly
Removal and installation of control valve assembly
Assembly of control valve assembly
Removal and installation of swing motor assembly
Removal and installation of center swivel joint assembly
Disassembly and assembly of center swivel joint assembly
Removal and installation of travel motor assembly
Removal and installation of solenoid valve assembly
Removal and installation of boom damping valve assembly
Disassembly and assembly of work equipment PPC valve assembly
Disassembly and assembly of travel PPC valve assembly
Disassembly and assembly of hydraulic cylinder assembly
Disassembly and assembly of grease gun assembly
Work equipment
Removal and installation of bucket cylinder assembly
Removal and installation of arm cylinder assembly
Removal and installation of boom cylinder assembly
Removal and installation of bottom dump cylinder assembly
Removal and installation of bucket assembly
Removal and installation of arm assembly
Removal and installation of boom assembly
Removal and installation of work equipment assembly
Cab and its attachments
Removal and installation of operator’s cab
Removal and installation of operator’s cab glass (stuck glass)
Removal and installation of front window assembly
Removal and installation of work equipment control lever assembly
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

Diagrams and drawings
Hydraulic diagrams and drawings
Hydraulic circuit diagram
Electrical diagrams and drawings
Electrical circuit diagram
Connector arrangement diagram

Engine SAA6D140E-5 workshop service manual