Komatsu Excavator PC800-8R1 PC800LC-8R1 PC800SE-8R1 PC850-8R1 PC850SE-8R1 service manual

Description Komatsu Excavator PC800-8R1 PC800LC-8R1 PC800SE-8R1 PC850-8R1 PC850SE-8R1 service manual

Komatsu Hydraulic Excavator PC800-8R1, PC800LC-8R1, PC800SE-8R1, PC850-8R1, PC850SE-8R1 pdf workshop service manual

Serial numbers:
PC800-8R1 70001 and up
PC800LC-8R1 70001 and up
PC800SE-8R1 70001 and up
PC850-8R1 70001 and up
PC850SE-8R1 70001 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
Foreword and general information
Important safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling equipment of fuel system devices
Handling of intake system parts
Handling of hydraulic components
Method of disconnecting and connecting push-pull type coupler
Handling of electric equipment
How to read electric wire code
Practical use of KOMTRAX
Precautions when performing work
Standard tightening torque table
List of abbreviation
Conversion table

Specification
Specifications drawing
Table of weight
Table of fuel, coolant and lubricants

Structure and function
Engine and cooling system
Coupling
Coupling lubrication system
Cooling system
Power train system
Power train
Swing circle
Swing machinery
Final drive
Undercarriage and frame
Track frame
Idler cushion
Hydraulic system
Hydraulic component layout
Hydraulic tank and filter
Hydraulic pump
Pump control system
Servo valve
Self-pressure reducing valve
Cooling fan pump
Cooling fan motor
Electrical grease pump
Control valve
Straight-travel valve
Swing motor
Center swivel joint
Travel motor
PPC valve
Solenoid valve
Accumulator
Quick return valve
Return oil filter
Line oil filter
Pilot oil filter
Drain oil filter
Electrical system
Engine control
Electric control system
Monitor system
Sensors
KOMTRAX system

Standard value table
Standard value table for engine
Standard value table for machine

Testing and adjusting
Tool for testing, adjusting and troubleshooting
Tools for testing, adjusting, and troubleshooting
Engine and cooling system
Testing engine speed
Testing intake air pressure (Boost pressure)
Testing exhaust gas temperature
Testing exhaust gas color
Adjusting valve clearance
Testing compression pressure
Testing blowby pressure
Testing engine oil pressure
Handling fuel system parts
Releasing remaining pressure from fuel system
Testing fuel pressure
Testing fuel return rate and leakage
Bleeding air from fuel circuit
Testing fuel circuit for leakage
Testing and adjusting alternator belt tension
Testing and adjusting air conditioner compressor belt tension
Undercarriage and frame
Testing swing circle bearing clearance
Testing and adjusting track tension
Hydraulic system
Testing and adjusting oil pressure in work equipment, swing, and travel circuits
Testing and adjusting control circuit oil pressure (output pressure of self-pressure reducing valve)
Testing and adjusting control signal of main pump
Testing PPC valve output pressure
Testing outlet pressure of solenoid valve, swing PPC shuttle valve, and swing priority selector valve
Adjusting play of work equipment and swing PPC valves
Testing and adjusting travel deviation
Inspecting locations of hydraulic drift in work equipment
Testing fan speed
Testing fan circuit oil pressure
Testing fan pump EPC current
Testing fan pump EPC solenoid valve outlet pressure
Testing oil leakage
Releasing remaining pressure from hydraulic circuit
Bleeding air from various parts
Inspection procedures for diode
Adjusting mirrors
Electrical system
Special functions of machine monitor
Handling voltage circuit of engine controller
Preparatory work for troubleshooting of electrical system
Pm Clinic
Pm clinic service
UNDERCARRIAGE INSPECTION REPORT

Troubleshooting
General information on troubleshooting
Points to remember when troubleshooting
Sequence of events in troubleshooting
Checks before troubleshooting
Classification and procedures for troubleshooting
Failure codes table
Symptom and troubleshooting numbers
Information in troubleshooting table
Troubleshooting method for open circuit in wiring harness of pressure sensor system
Connector list and layout
Connection table for connector pin numbers
T- branch box and T- branch adapter table
Fuse locations
Troubleshooting by failure 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 Disassembly and Assembly
Coating materials list
Special tools list
Sketches of special tools
Engine and cooling system
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 condenser assembly
Removal and installation of fan motor assembly
Removal and installation of fuel tank assembly
Engine
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 assembly
Disassembly and assembly of PTO 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
Separation and connection 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
Removal and installation of counterweight remover 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 assembly
Removal and installation of operator's cab glass (adhered window 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

Maintenance standard
Engine and cooling system
Coupling
Power train
Swing circle
Swing machinery
Final drive
Sprocket
Undercarriage and frame
Track frame and idler cushion
Idler
Carrier roller
Track roller
Track shoe
Hydraulic system
Cooling fan motor
Control valve
Swing motor
Center swivel joint
PPC valve
Work equipment
Work equipment dimension
Hydraulic cylinder

Appendix
Air conditioner
Precautions for refrigerant
Air conditioner component
Configuration and function of refrigeration cycle
Outline of refrigeration cycle
Air conditioner unit
Air conditioner controller
Compressor
Condenser
Receiver drier
Procedure for testing and troubleshooting
Circuit diagram and arrangement of connector pins
System diagram
Detail of air conditioner unit
Parts and connectors layout
Testing air leakage (duct)
Testing with self-diagnosis function
Testing temperature control
Testing vent (mode) changeover
Testing FRESH/RECIRC air changeover
Testing inner sensor
Testing evaporator temperature sensor
Testing sunlight sensor
Testing (dual) pressure switch for refrigerant
Testing relays
Troubleshooting chart
Information in troubleshooting table
Troubleshooting for power supply and CAN communication system (Air conditioner does not operate)
Troubleshooting for compressor and refrigerant system (Air is not cooled)
Troubleshooting for blower motor system (No air comes out or air flow is abnormal)
Troubleshooting for temperature control
Troubleshooting for vent (mode) changeover
Troubleshooting for FRESH/RECIRC air changeover
Troubleshooting for temperature sensor system
Troubleshooting with gauge pressure
Connection of service tool
Precautions for disconnecting and connecting air conditioner piping
Handling of compressor oil

Diagrams and drawings
Hydraulic circuit diagram
Symbols used in hydraulic circuit diagrams
Electrical circuit diagram
Symbols used in electric circuit diagrams

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