PDF Shop Manual Komatsu PC500LC-8R Hydraulic Excavator - 7 MB
Unlock the full technical details of your Komatsu PC500LC-8R hydraulic excavator with this official shop manual.
It serves as the ultimate guide for professional service technicians, covering everything from testing and adjusting procedures to the complete disassembly and assembly of all major components.
This manual provides the detailed, factory-approved instructions necessary for complex repairs and major overhauls.
Following this guide ensures your powerful excavator is maintained to the highest standards, guaranteeing optimal performance and reliability on the job site.
This is the definitive resource for keeping your PC500LC-8R in peak condition.
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--- Page 1 ---
SEN06614-03
HYDRAULIC PC500LC -8R
EXCAVATOR
SERIAL NUMBERS 75979 and up
--- Page 3 ---
00 Index and foreword
Safety notice
Foreword and general information 1
Safety notice 1
Important 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.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
1. General precautions 7) If welding repairs are needed, always
k Mistakes in operation are extremely have a trained and experienced welder
dangerous. Read the Operation and carry out the work. When carrying out
Maintenance Manual carefully before w eld ing wo rk , alw ay s wear wel din g
operating the machine. gloves, apron, shielding goggles, cap and
1) Before carrying out any greasing or other clothes suited for welding work.
repairs, read all the safety plates stuck to 8) Before starting work, warm up your body
the machine. For the locations of the thoroughly to start work under good condi-
safety plates and detailed explanation of tion.
precautions, see the Operation and Main-
tenance Manual. Safety points
2) Decide a place in the repair workshop to
keep tools and removed parts. Always 1 Good arrangement
keep the tools and parts in their correct 2 Correct work clothes
places. Always keep the work area clean 3 Following work standard
and make sure that there is no dirt, water,
or oil on the floor. Smoke only in the areas 4 Making and checking signs
provided for smoking. Never smoke while Prohibition of operation and handling by
5
working. unlicensed workers
3) When carrying out any operation, always 6 Safety check before starting work
wear safety shoes and helmet. Do not
wear loose work clothes, or clothes with Wearing protective goggles
7
(for cleaning or grinding work)
buttons missing.
q Always wear safety glasses when hit- Wearing shielding goggles and protectors
8
ting parts with a hammer. (for welding work)
q Always wear safety glasses when 9 Good physical condition and preparation
grinding parts with a grinder, etc.
Precautions against work which you are
4) When carrying out any operation with 2 or 10
not used to or you are used to too much
more workers, always agree on the oper-
ating procedure before starting. Always
inform your fellow workers before starting 2. Preparations for work
any step of the operation. Before starting 1) Before adding oil or making any repairs,
work, hang UNDER REPAIR warning park the machine on hard and level
signs in the operator's compartment. ground, and apply the parking brake and
5) Only qualified workers must carry out work block the wheels or tracks to prevent the
and operation which require license or machine from moving.
qualification. 2) Before starting work, lower the work
6) Keep all tools in good condition, learn the equipment (blade, ripper, bucket, etc.) to
correct way to use them, and use the the ground. If this is not possible, insert
proper ones of them. Before starting work, the lock pin or use blocks to prevent the
thoroughly check the tools, machine, fork- work equipment from falling. In addition,
lift, service car, etc. be sure to lock all the control levers and
hang warning signs on them.
PC500LC-8R 00-9
--- Page 4 ---
00 Index and foreword
Handling of electric equipment and hydraulic component
3) 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.
4) High-pressure water entering connector
The connector is designed to make it diffi-
cult for water to enter (drip-proof struc-
ture), but if high-pressure water is sprayed
directly on the connector, water may enter
the connector, depending on the direction
of the water jet. Accordingly, take care not
to splash water over the connector. The
connector is designed to prevent water
from entering, but at the same time, if
water does enter, it is difficult for it to be
drained. Therefore, if water should get into
the connector, the pins will be short-
circuited by the water, so if any water gets
in, immediately dry the connector or take
other appropriate action before passing
electricity through it.
5) Oil or dirt stuck to connector
If oil or grease are stuck to the connector
and an oil film is formed on the mating sur-
face between the male and female pins,
the oil will not let the electricity pass, so
there will be defective contact. If there is
oil or grease stuck to the connector, wipe it
off with a dry cloth or blow it dry with com-
pressed air and spray it with a contact
restorer.
a When wiping the mating portion of the
connector, be careful not to use
excessive force or deform the pins.
a If there is oil or water in the com-
pressed air, the contacts will become
even dirtier, so remove the oil and
water from the compressed air com-
pletely before cleaning with com-
pressed air.
PC500LC-8R 00-19
--- Page 5 ---
00 Index and foreword
Handling of connectors newly used for engines
q 125 β 170, 12V140 engine 4. Turn-housing type (Round green connector)
4) While pressing lock (E) of the connector, q 140 engine
pullout connector (5) in the direction of the Example)
arrow. Intake air pressure sensor in intake mani-
fold (CANNON-04): PIM etc.
Example)
Fuel pressure in common rail: PFUEL etc. 1) Disconnect connector (6) according to the
(AMP-3) following procedure.
1] Turn housing (H1) in the direction of
the arrow.
a When connector is unlocked,
housing (H1) becomes heavy to
turn.
2] Pull out housing (H1) in the direction
of the arrow.
a Housing (H1) is left on the wiring har-
ness side.
Example)
Injection pressure control valve of fuel
supply pump: PCV (SUMITOMO-2)
2) Connect the connector according to the
following procedure.
1] Insert the connector to the end, while
setting its groove.
2] Turn housing (H1) in the direction of
the arrow until it βclicksβ.
Example)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.
PC500LC-8R 00-29
--- Page 6 ---
00 Index and foreword
Standard tightening torque table
Standard tightening torque table 1
1. Table of tightening torques for bolts and nuts
a Unless there are special instructions, tighten metric nuts and bolts to the torque below. (When using
torque wrench)
a The following table corresponds to the bolts in Fig. A.
Thread diameter of bolt Width across flats Tightening torque
mm mm Nm kgm
6 10 11.8 β 14.7 1.2 β 1.5
8 13 27 β 34 2.8 β 3.5
10 17 59 β 74 6.0 β 7.5
12 19 98 β 123 10.0 β 12.5
14 22 153 β 190 15.5 β 19.5
16 24 235 β 285 23.5 β 29.5
18 27 320 β 400 33.0 β 41.0
20 30 455 β 565 46.5 β 58.0
22 32 610 β 765 62.5 β 78.0
24 36 785 β 980 80.0 β 100.0
27 41 1,150 β 1,440 118 β 147
30 46 1,520 β 1,910 155 β 195
33 50 1,960 β 2,450 200 β 250
36 55 2,450 β 3,040 250 β 310
39 60 2,890 β 3,630 295 β 370
a The following table corresponds to the bolts in Fig. B.
Thread diameter of bolt Width across flats Tightening torque
mm mm Nm kgm
6 10 5.9 β 9.8 0.6 β 1.0
8 13 13.7 β 23.5 1.4 β 2.4
10 14 34.3 β 46.1 3.5 β 4.7
12 27 74.5 β 90.2 7.6 β 9.2
a Fig. A a Fig. B
PC500LC-8R 00-39
--- Page 7 ---
01 Specification 01
PC500LC-8R 01-1
--- Page 8 ---
01 Specification
Table of fuel, coolant and lubricants
Unit: l
PC500LC-8R
Reservoir
Specified Refill
Engine oil pan 46 37
Swing machinery case 20 20
Final drive case (each side) 11 11
Damper case 1.07 β
Hydraulic system 472 248
Fuel tank 650 β
Cooling system 36 β
a For the HO46-HM, use the oil recommended by Komatsu.
PC500LC-8R 01-11
--- Page 9 ---
10 Structure, function and maintenance standard
1
Specifications
Reduction ratio:
19 + 68 Γ 16 + 68 = 24.039
19 16
Unit: mm
No. Check item Criteria Remedy
Backlash between swing motor Standard clearance Clearance limit
14 shaft and No. 1 sun gear 0.18 β 0.28 β
Backlash between No. 1 sun gear
15 and No. 1 planetary gear
0.15 β 0.51 1.00
Backlash between No. 1 planetary
16 gear and ring gear 0.17 β 0.60 1.10
Backlash between No. 1 planetary
17 carrier and No. 2 sun gear 0.40 β 0.75 1.20
Backlash between No. 2 sun gear Replace
18 and No. 2 planetary gear 0.16 β 0.55 1.00
Backlash between No. 2 planetary
19 gear and ring gear 0.17 β 0.60 1.10
Backlash between coupling and
20 swing pinion 0.08 β 0.25 β
Backlash between swing pinion and
21 swing circle 0.00 β 1.21 2.00
Clearance between plate and cou-
22 pling 0.57 β 1.09 β
Standard size Repair limit Apply hard
Wear of swing pinion surface con- chrome plating,
23 tacting with oil seal recondition, or
150 β0
β0.100
β
replace
PC500LC-8R 10-9
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10 Structure, function and maintenance standard
Track shoe
Unit: mm
No. Check Item Criteria Remedy
Inside
9 width
106
Overall
10 Link width
55.2 Repair or replace
Tread
11 width
48.4
12 Protrusion of pin 4.4
13 Protrusion of regular bushing 5.25
14 Overall length of pin 258 Adjust or replace
15 Overall length of bushing 167.9
16 Thickness of spacer β
17 Bushing 127 to 333 kN {13 to 34 ton}
Regu-
18 larpin
198 to 510 kN {20 to 52 ton}
Press fitting force β
19
Materpin 147 to 412 kN {15 to 42 ton}
(*)
a. Tightening torque (Nm {kgm}) Retightening angle (deg.)
Regular 588 Β± 59
link Triple grouser shoe 120 Β± 10
{60 Β± 6}
20 Shoe bolt Retighten
b. Tightening torque Retightening angle Lower limit torque
Master (Nm {kgm}) (degree) (Nm {kgm})
link β β β
Standard Tolerance Standard
Interference between bushing and dimension Shaft Hole interference
21 link +0.494 +0.074
73.5 0.380 to 0.494
+0.454 0
Interference between regular pin +0.184 +0.330
22 and link 48.8
+0.034 +0.268
0.302 to 0.514
Standard Tolerance Standard
Clearance between regular pin and dimension Shaft Hole clearance
23 bushing +0.184 +0.864
48.8 0.180 to 0.830 Adjust or replace
+0.034 +0.364
Standard Tolerance Standard
24 Interference between master pin dimension Shaft Hole interference
(*) and link +0.03 β0.218
48.75 0.218 to 0.310
0 β0.280
Standard Tolerance Standard
25 Clearance between master pin and dimension Shaft Hole clearance
(*) bushing β0.2 +0.914
48.75 0.614 to 1.318
β0.4 +0.414
*: Dry type track link
PC500LC-8R 10-19
--- Page 11 ---
10 Structure, function and maintenance standard
Hydraulic tank and filter
Hydraulic tank oil filler cap Hydraulic tank breather
Structure Structure
1: Bottom plate 1: Nut
2: Gasket 2: Cover
3: Filter element
Function 4: Case
Prevention of pressure rise in hydraulic tank 5: Valve assembly
While the hydraulic circuit is in operation, the pres- 6: Body
sure in the hydraulic tank increases as the oil level
and the temperature in the hydraulic tank rise cor- Function
responding to the operation of the hydraulic cylin- Prevention of negative pressure in hydraulic tank
ders. When the pressure in the tank exceeds the Since the hydraulic tank is pressurized and sealed,
set pressure, bottom plate (1) is pushed up to if the oil level in it decreases, negative pressure is
release the pressure in the tank and prevent pres- generated in it. At this time, valve assembly (5) is
sure rise. opened by the differential pressure from the ambi-
(Set pressure of exhaust valve: 16.7 Β± 6.86 kPa ent pressure, and ambient pressure is transmitted
{0.17 Β± 0.07 kg/cm2} ) into the tank to prevent generation of negative pres-
sure in the tank
(Set pressure of intake valve: Max. 0.002 MPa
{0.02 kg/cm2})
PC500LC-8R 10-29
--- Page 12 ---
10 Structure, function and maintenance standard
Hydraulic pump
3) Action for the direction of minimizing the pump delivery
q When LS differential pressure (dPLS) becomes
larger (for example, when the area of opening of
the control valve becomes smaller and pump
pressure (PP) rises) because of the rightward
move (it reduces pump delivery) of servo piston
(12), pump pressure (PP) pushes spool (6) to the
right.
q When spool (6) moves, main pump pressure
(PP) flows from port (C) to port (D) and from
port (K), it enters the large diameter end of the
piston.
q Main pump pressure (PP) also enters port (J)
of the small diameter end of the piston, but
because of the difference in area between the
large diameter end and the small diameter end
on servo piston (12), it is pushed to the right.
As the result, the servo piston (12) moves into
the direction of reducing the swash plate
angle.
q As LS selector pressure (PSIG) is input to port
(G), setting force of spring (4) is reduced.
PC500LC-8R 10-39
--- Page 13 ---
10 Structure, function and maintenance standard
Hydraulic pump
(2) When the main pump is under heavy load
q If the emergency pump drive switch is turned q The curve resulting when the emergency pump
on In the same way as in above, the command drive switch is ON is situated further to the left (B)
current (X) sent to PC-EPC valve solenoid (1) than when the pump controller is normal (A).
becomes constant.
q For this reason, the force of piston (2) pushing
spool (3) is constant.
q If main pump pressures (PP1) and (PP2)
increase, spool (3) moves further to the right
than when the main pump load is light, and is
balanced at the position in the diagram above.
q In this case, the pressure from port (B) flows to
port (C), so servo piston (9) moves to the right
(smaller pump delivery) and stops at a position
to the further to the right then when the load on
the pump is light.
q When the emergency pump drive switch is
turned on, too, the pump pressure (PP) and
pump delivery (Q) have a relationship as
shown with the curve in the diagram corre-
sponding to the current sent to the PC-EPC
valve solenoid through the resistor.
PC500LC-8R 10-49
--- Page 14 ---
10 Structure, function and maintenance standard
Control valve
1. Safety-suction valve (Arm out)
2. Suction valve (Right travel reverse)
3. Suction valve (Boom raise)
4. Suction valve (Left travel reverse)
5. Suction valve (Boom Hi raise)
6. Safety-suction valve (Service 1)
7. Safety-suction valve (Service 2)
8. 2-stage safety-suction valve (Service 1)
9. Safety-suction valve (Arm Hi in)
10. Safety-suction valve (Bucket curl)
11. Suction valve (Left travel forward)
12. 2-stage safety-suction valve (Boom lower)
13. Suction valve (Right travel forward)
14. Safety-suction valve (Arm in)
15. LS shuttle valve (Arm)
16. LS shuttle valve (Right travel)
17. LS select valve
18. LS shuttle valve (Boom)
19. LS shuttle valve (Left travel)
20. LS shuttle valve (Bucket)
21. LS shuttle valve (Service 1)
22. LS shuttle valve (Service 2)
23. LS check valve
24. Pressure relief plug
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length Γ
Installed
Outside Installed load Free length Installed load
25 Suction valve spring length If damaged or
diameter
deformed, replace
5.5 N 4.4 N
46.8 Γ 7.5 40.6 β spring.
{0.56 kg} {0.45 kg}
1.5 N 1.2 N
26 Check valve spring 11.5 Γ 4.6 8.5 β
{0.15 kg} {0.12 kg}
PC500LC-8R 10-59
--- Page 15 ---
10 Structure, function and maintenance standard
CLSS
3. System diagram
a The illustration shows actuator (7) in the merge
mode with stroke end at the time of relief.
1. Front pump 9. LS circuit
2. Rear pump 10. Tank circuit
3. Main relief valve 11. Valve
4. Unload valve 12. Spring
5. Merge-divider valve 13. LS bypass valve
6. Control valve 14. LS valve
7. Actuator 15. PC valve
8. Pump circuit
PC500LC-8R 10-69
--- Page 16 ---
10 Structure, function and maintenance standard
Functions and operation by valve
Pressure compensation valve inner shuttle valve
1.If holding pressure at port (A) is larger than LS pressure in the springing chamber (B)
1. Hydraulic pump
2. Valve
3. Pressure compensation valve inner shuttle valve
4. Piston
Function
q Shuttle valve (3) is pushed to the right by port (A)
pressure and cuts off interconnection between
ports (A) and (C).
q Holding pressure at port (A) is led to the spring
chamber (B) to push piston (4) to the left so that
piston (4) and valve (2) will not be separated.
PC500LC-8R 10-79
--- Page 17 ---
10 Structure, function and maintenance standard
Merge-divider valve
2. During neutral and when load pressure (P2) is 3. When load pressure (P2) is high
low q Load pressure (A2) increases with the operation
a When load pressure (A2) is lower than self pres- of digging, etc, and the pump discharge increas-
sure reducing valve output pressure (PR) es accordingly.
q Pressure (P2) increases to [(fd area Γ P2 pres-
q Valve (7) is pressed to the closing direction of sure) = force of spring (8) + (fd area Γ PR pres-
circuit between ports (P2) and (A2) by spring (8) sure)], and valve (7) moves to the right to the
and under pressure (PR) (which is 0 MPa {0 kg/ stroke end.
cm2}). q As a result, opening between ports (P2) and (A2)
q When pressurized oil flows in from port (P2), a increases, and the pass resistance reduces, re-
balance is reached due to [(fd area Γ P2 pres- ducing the engine horsepower loss.
sure) = force of spring (8) + (fd area Γ PR pres- q When pressure (PR) rises above the set pres-
sure)]. sure, poppet (11) opens.
q Adjusts valve (7) opening to keep pressure (P2) q Pressurized oil flows from port (PR) to orifice (a)
at a constant level over pressure (PR). in spool (14), then flows to seal drain port (TS)
q When pressure (PR) rises above the set pres- from poppet (11) opening.
sure, poppet (11) opens. q Differential pressure is generated before and af-
q Pressurized oil flows from port (PR) to orifice (a) ter orifice (a) in spool (14) and then spool (14)
in spool (14), then flows to seal drain port (TS) moves to close the pass between ports (P2) and
from poppet (11) opening. (PR).
q Differential pressure is generated before and af- q Pressure (P2) is reduced by the opening at this
ter orifice (a) in spool (14) and then spool (14) time and adjusted to a constant pressure (the set
moves to close the pass between ports (P2) and pressure) and supplied as pressure (PR).
(PR).
q Pressure (P2) is reduced by the opening at this
time and adjusted to a constant pressure (the set
pressure) and supplied as pressure (PR).
PC500LC-8R 10-89
--- Page 18 ---
10 Structure, function and maintenance standard