PDF Manual Komatsu PC800-8 PC850-8 Series Excavator - 5 MB
This comprehensive manual covers the Komatsu PC800-8, PC800LC-8, PC850-8, and PC850LC-8 excavators.
It contains vital information for service, repair, and maintenance.
Technicians rely on this document for detailed specifications, troubleshooting charts, and step-by-step procedures.
Keep your large-scale excavator in top fighting form with this complete factory guide.
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--- Page 1 ---
SEN00373-12
HYDRAUlIC PC800 -8
EXCAVATOR PC800LC -8
PC800SE -8
PC850 -8
PC850SE -8
PC800- 50001
PC800LC- 50001
SERIAL NUMBERS PC800SE- 50001 and up
PC850- 10001
PC850SE- 10001
--- Page 3 ---
SEN00375-12 00 Index and foreword
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........................................................................................ 29
H-22 Upper structure does not swing ...................................................................................... 30
H-23 Swing speed or acceleration is low................................................................................. 32
H-24 Swing speed or acceleration is low during compound operation of swing and
work equipment .......................................................................................................... 34
H-25 Upper structure overruns excessively when it stops swinging ........................................ 36
H-26 Large shock is made when upper structure stops swinging ........................................... 37
H-27 Large abnormal sound is made when upper structure stops swinging ........................... 38
H-28 Hydraulic drift of swing is large ....................................................................................... 39
Troubleshooting of engine (S-mode) SEN00795-03
Troubleshooting of engine (S-mode) ........................................................................................... 3
Method of using troubleshooting chart..................................................................................... 3
S-1 Starting performance is poor ............................................................................................. 6
S-2 Engine does not start ........................................................................................................ 8
S-3 Engine does not pick up smoothly .................................................................................... 12
S-4 Engine stops during operations......................................................................................... 13
S-5 Engine does not rotate smoothly....................................................................................... 14
S-6 Engine lacks output (or lacks power) ................................................................................ 15
S-7 Exhaust gas color is black (incomplete combustion) ........................................................ 16
S-8 Oil consumption is excessive (or exhaust smoke is blue)................................................. 18
S-9 Oil becomes contaminated quickly.................................................................................... 19
S-10 Fuel consumption is excessive ....................................................................................... 20
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) .............................. 21
S-12 Oil pressure drops........................................................................................................... 22
S-13 Oil level rises (Entry of coolant/fuel)................................................................................ 24
S-14 Coolant temperature becomes too high (overheating).................................................... 26
S-15 Abnormal noise is made.................................................................................................. 27
S-16 Vibration is excessive...................................................................................................... 28
50 Disassembly and assembly
General information on disassembly and assembly SEN01052-03
General information on disassembly and assembly.................................................................... 2
How to read this manual .......................................................................................................... 2
Coating materials list ............................................................................................................... 4
Special tools list ....................................................................................................................... 7
Sketches of special tools ......................................................................................................... 14
Engine and cooling system (SAA6D140E-5) SEN01053-01
Engine and cooling system ......................................................................................................... 2
Removal and installation of engine, PTO and hydraulic pump assembly ................................ 2
Removal and installation of cooling assembly ......................................................................... 10
Removal and installation of aftercooler assembly ................................................................... 15
Removal and installation of fuel cooler and air conditioner condenser assembly ................... 17
Removal and installation of fan motor assembly ..................................................................... 19
Removal and installation of fuel tank assembly ....................................................................... 24
Engine (SAA6D140E-5) SEN01054-01
Engine (SAA6D140E-5) .............................................................................................................. 2
Removal and installation of fuel supply pump assembly ......................................................... 2
Removal and installation of cylinder head assembly ............................................................... 7
Removal and installation of fuel injector assembly .................................................................. 23
Removal and installation of engine front seal .......................................................................... 26
Removal and installation of engine rear seal........................................................................... 28
10 PC800, 850-8
--- Page 4 ---
00 Index and foreword SEN00376-03
How to read the shop manual 1
q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the βChassis volumeβ and βEngine volumeβ. For the engine unit, see the
engine volume of the engine model mounted on the machine.
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 explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-section explains the structure and function of each component. It
serves not only to give an understanding of the structure, but also serves as reference material for
troubleshooting. The maintenance standard sub-section explains the criteria and remedies for dis-
assembly and service.
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 instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The βS modeβ 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.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
2. 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 7
--- Page 5 ---
SEN00376-03 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.
1. Be careful of the operating environment.
Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or
places where there is a lot of dust.
2. Disassembly and maintenance work in the
field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is
also difficult to check the performance after
repairs, so it is desirable to use unit exchange.
Disassembly and maintenance of hydraulic
equipment should be carried out in a specially
prepared dustproof workshop, and the perfor-
mance should be checked with special test
equipment.
3. Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is
blocked with a rag, there is danger of dirt
entering or of the surrounding area being
made dirty by leaking oil so never do this. Do
not simply drain oil out onto the ground, but
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
4. Do not let any dirt or dust get in during
refilling operations
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
18 PC800, 850-8
--- Page 6 ---
00 Index and foreword SEN00376-03
Method of disassembling and connecting push-pull type coupler 1
k 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.
k Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil receiving container.
Type 1
1. Disconnection
1) Hold adapter (1) and push hose joint (2)
into mating adapter (3). (Fig. 1)
a The adapter can be pushed in about
3.5 mm.
a Do not hold rubber cap portion (4).
2) After hose joint (2) is pushed into adapter
(3), press rubber cap portion (4) against
adapter (3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull
it out. (Fig. 3)
a Since some hydraulic oil flows out,
prepare an oil receiving container.
2. Connection
1) Hold hose adapter (1) or hose (5) and
insert it in mating adapter (3), aligning
them with each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose in the mating
adapter perfectly, pull it back to check its
connecting condition. (Fig. 5)
a When the hose is pulled back, the
rubber cap portion moves toward the
hose about 3.5 mm. This does not
indicate abnormality, however.
PC800, 850-8 29
--- Page 7 ---
SEN00376-03 00 Index and foreword
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahren-
heit temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centi-
grade values, and read the corresponding Fahrenheit temperature on the right.
1Β°C = 33.8Β°F
Β°C Β°F Β°C Β°F Β°C Β°F Β°C Β°F
β40.4 β40 β40.0 β11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
β37.2 β35 β31.0 β11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
β34.4 β30 β22.0 β10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
β31.7 β25 β13.0 β10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
β28.9 β20 β4.0 β9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
β28.3 β19 β2.2 β8.9 16 60.8 10.6 51 123.8 30.0 86 186.8
β27.8 β18 β0.4 β8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
β27.2 β17 1.4 β7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
β26.7 β16 3.2 β7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
β26.1 β15 5.0 β6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
β25.6 β14 6.8 β6.1 21 69.8 13.3 56 132.8 32.8 91 195.8
β25.0 β13 8.6 β5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
β24.4 β12 10.4 β5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
β23.9 β11 12.2 β4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
β23.3 β10 14.0 β3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
β22.8 β9 15.8 β3.3 26 78.8 16.1 61 141.8 35.6 96 204.8
β22.2 β8 17.6 β2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
β21.7 β7 19.4 β2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
β21.1 β6 21.2 β1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
β20.6 β5 23.0 β1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
β20.0 β4 24.8 β0.6 31 87.8 18.9 66 150.8 40.6 105 221.0
β19.4 β3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
β18.9 β2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
β18.3 β1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
β17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
β17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0
β16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
β16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
β15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
β15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
β14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0
β13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
β13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
β12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
β12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
40 PC800, 850-8
--- Page 8 ---
01 Specification SEN00378-02
PC800SE-8
Machine model PC800SE-8
Serial number 50001 and up
Bucket capacity m3 4.0
Weight of machine kg 76,000
Max. digging depth mm 7,130
Working ranges
Max. vertical wall depth mm 4,080
Max. digging reach mm 12,265
Max. reach at ground level mm 11,945
Max. digging height mm 11,330
Performance
Max. dumping height mm 7,525
Max. digging force kN {kg} 430.5 {43,900}
Swing speed rpm 6.8
Swing max. slope angle deg. 16
Travel speed km/h Lo : 2.8, Hi : 4.2
Gradeability deg. 35
Ground pressure (standard triple kPa {kg/cm2} 106.5 {1.09}
grouser shoe width: 710 mm)
Overall length mm 13,130
Overall width mm 4,335
Overall width of track mm 3,490 (4,285)
(when increasing)
Overall height mm 4,615
Overall height to top of cab mm 4,000
Ground clearance of mm 1,560
Dimensions
counterweight
Min. ground clearance mm 840
Tail swing radius mm 4,400
Min. swing radius of work mm 5,645
equipment
Height of work equipment mm 9,750
at min. swing radius
Length of track on ground mm 4,500
Track gauge (when increasing) mm 2,780 (3,500)
Height of machine cab mm 3,670
PC800, 850-8 9
--- Page 9 ---
SEN00378-02 01 Specification
Machine model PC850SE-8
Serial number 10001 and up
Boom Arm Bucket
Double-acting Double-acting Double-acting
Type
Hydraulic cylinder
piston piston piston
Inside diameter of cylinder mm 200 185 225
Hydraulic system
Diameter of piston rod mm 140 120 160
Stroke mm 1,950 1,610 1,420
Max. distance between pins mm 4,880 3,990 3,910
Min. distance between pins mm 2,930 2,380 2,490
Hydraulic tank Box-shaped, with breather
Hydraulic filter Tank return side
Hydraulic cooler CF42-1 (Air cooled)
20 PC800, 850-8
--- Page 10 ---
01 Specification SEN00378-02
Unit: l
PC800, PC800SE-8, PC800LC-8, PC850, PC850SE-8
Supply point
Specified capacity Refill capacity
Engine oil pan 58 53
Coupling case 7 7
Swing machinery case (each) 24.5 24.5
Final drive case (each) 20 20
Hydraulic system 800 470
Fuel tank 980 β
Cooling system 104 β
PC800, 850-8 31
--- Page 11 ---
SEN00381-01 10 Structure, function and maintenance standard
Swing machinery
4 PC800, 850-8
--- Page 12 ---
10 Structure, function and maintenance standard SEN00382-01
Standard shoe
Unit: mm
Model
PC800-8 PC800SE-8 PC800LC-8 PC850-8 PC850SE-8
Item
Shoe width (double shoe) 710 710 810 710 710
Link pitch 260.6 260.6 260.6 260.6 260.6
No. of shoes (each side) 47 47 51 47 47
Unit: mm
No. Check item Criteria Remedy
Standard
Tolerance Repair limit
size Rebuild or
Top-to-bottom width of idler +3 replace
10 Track frame 185 185 β2 190
guide
Idler support 180 185 Β± 0.5 175 Replace
+3 Rebuild or
Track frame 345 345 β2 355
replace
11 Left-to-right width of idler guide
Idler support 340 β 332
Standard size Repair limit
Free length Installation Installation Installation Replace
Free length
12 Recoil spring Γ OD length load load
489.8 kN 392 kN
1,553 Γ 308 1,290 β
{49,986 kg} {40,000 kg}
PC800, 850-8 3
--- Page 13 ---
SEN00382-01 10 Structure, function and maintenance standard
PC800-8, PC800SE-8, PC800LC-8, PC850-8, PC850SE-8 Hydraulic excavator
Form No. SEN00382-01
14
--- Page 14 ---
10 Structure, function and maintenance standard SEN00383-03
Operation of pump
β’ Cylinder block (7) rotates together with shaft (1),
and shoe (5) slides on flat surface (A).
β’ When this happens, rocker cam (4) moves along
cylindrical surface (B), so angle (a) between
center line (X) of rocker cam (4) and the axial di-
rection of cylinder block (7) changes.
β’ Angle (a) is called the swash plate angle.
β’ With center line (X) of rocker cam (4) at swash
plate angle (a) in relation to the axial direction of
cylinder block (7), flat surface (A) acts as a cam
in relation to shoe (5).
β’ In this way, piston (6) slides on the inside of cyl-
inder block (7), so a difference between volumes
(E) and (F) is created inside cylinder block (7).
β’ A single piston (6) sucks and discharges the oil
by the amount (F) β (E).
β’ As cylinder block (7) rotates and the volume of
chamber (E) becomes smaller, the pressurized
oil is discharged.
β’ On the other hand, the volume of chamber (F) grows
larger and, in this process, the oil is suctioned.
β’ As center line (X) of rocker cam (4) matches the
axial direction of cylinder block (7) (swash plate
angle = 0), the difference between volumes (E)
and (F) inside cylinder block (7) becomes 0.
β’ Suction and discharge of pressurized oil is not
carried out in this state. Namely pumping action
is not performed. (Actually, however, the swash
plate angle is not set to 0)
PC800, 850-8 11
--- Page 15 ---
SEN00383-03 10 Structure, function and maintenance standard
2. When signal current is very small
(coil is energized)
β’ When a very small signal current flows to coil (5),
coil (5) is energized, and a propulsion force is
generated on the left side of plunger (6).
β’ Rod (4) pushes spool (2) to the left, and the pres-
surized oil flows from port (P) to port (C).
β’ Pressure on port (C) increases and the force to
act on surface (a) of spool (2) + the spring load
on spring (3) become larger than the propulsion
force of plunger (6).
β’ Spool (2) is pushed to the right, and port (P) is
shut off from port (C).
β’ Port (C) and port (T) are connected.
β’ Spool (2) moves up and down so that the propul-
sion force of plunger (6) may be balanced with
pressure of port (C) + the spring load of spring
(3).
β’ The circuit pressure between the EPC valve and
the VC valve is controlled in proportion to the
size of the signal current.
3. When signal current is maximum
(coil is energized)
β’ As the signal current flows to coil (5), coil (5) is
energized.
β’ When this happens, the signal current is at its
maximum, so the propulsion force of plunger (6)
is also at its maximum.
β’ Spool (2) is pushed to the left by rod (4).
β’ The maximum volume of pressurized oil is con-
ducted from port (P) to port (C), increasing the
circuit pressure across EPC valve and VC valve
to the maximum level.
β’ Since port (T) is closed, pressurized oil does not
flow to the tank.
22 PC800, 850-8
--- Page 16 ---
10 Structure, function and maintenance standard SEN00383-03
Operation
β’ The output pressure of the EPC valve is applied
to the piston chamber to push piston (6). Piston
(6) pushes spool (5) until it is balanced with the
spring.
β’ Then, the land of the servo piston pressure pas-
sage is connected to the pump discharge pas-
sages by the cut of spool (5) and the discharge
pressure is led to the servo piston.
β’ The servo piston is raised by the rocker cam. The
position feedback is applied and the lever moves
to compress the spring.
β’ If spool (5) is pushed back, the pump discharge
circuit and the servo piston circuit are shut off.
β’ The pressure in the servo piston chamber lowers
and the rocker cam returns toward the maximum
swash plate angle.
β’ These processes are repeated until the swash
plate is fixed to a position where the EPC output
pressure is balanced with the spring force.
β’ Accordingly as the EPC output pressure is
heightened, the swash plate angle is decreased.
As the EPC output pressure is lowered, the
swash plate angle is increased.
PC800, 850-8 33
--- Page 17 ---
SEN00384-03 10 Structure, function and maintenance standard
Hydraulic system, Part 2
Motor grease pump
1. Motor grease pump unit Function
2. Valve β’ The pump unit is divided into air chamber (4) and
3. Cover grease chamber (6). As the grease level in
4. Air chamber grease chamber (6) lowers, follower plate (5) is
5. Follower plate pulled down to push down the grease sticking to
6. Grease chamber the rim of grease chamber (6).
7. Grease tank
8. Wing nut
4 PC800, 850-8
--- Page 18 ---