Komatsu PC800-8 PC800LC-8 PC800SE-8 PC850-8 PC850SE-8 Excavator Shop Manual SEN00373-18 PDF

Komatsu PC800-8 PC800LC-8 PC800SE-8 PC850-8 PC850SE-8 Hydraulic Excavator Shop Manual SEN00373-18 – PDF DOWNLOAD

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Komatsu PC800-8 PC800LC-8 PC800SE-8 PC850-8 PC850SE-8 Hydraulic Excavator Shop Manual SEN00373-18 – PDF DOWNLOAD

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Komatsu PC800-8 PC800LC-8 PC800SE-8 PC850-8 PC850SE-8 Hydraulic Excavator Shop Manual SEN00373-18 – PDF DOWNLOAD

SERIAL NUMBERS
PC800- 50001 and up
PC800LC- 50001 and up
PC800SE- 50001 and up
PC850- 10001 and up
PC850SE- 10001 and up

The Komatsu PC800-8, PC800LC-8, PC800SE-8, PC850-8, and PC850SE-8 hydraulic excavators are heavy-duty machines used in construction and earth-moving operations. A shop manual for these machines provides detailed information on maintenance, repair, and troubleshooting procedures for these machines.

A typical Komatsu PC800-8 series hydraulic excavator shop manual would cover topics such as:

• General Information: This section provides an overview of the machine and its specifications, as well as information on the location of major components, serial number ranges, and other important data.
• Engine: Detailed information on the engine, including specifications, disassembly and assembly procedures, maintenance procedures, and troubleshooting information.
• Fuel System: Information on the fuel system components, fuel injection pump, fuel injectors, fuel filters, and fuel tank, as well as maintenance and troubleshooting procedures.
• Lubrication System: Detailed information on the oil pump, oil filter, oil cooler, and other lubrication system components, as well as maintenance and troubleshooting procedures.
• Cooling System: Information on the water pump, radiator, fan, and other cooling system components, as well as maintenance and troubleshooting procedures.
• Electrical System: Detailed information on the electrical system, including the battery, alternator, starter motor, and other electrical components, as well as wiring diagrams and troubleshooting procedures.
• Hydraulic System: Information on the hydraulic pump, hydraulic control valves, hydraulic cylinder, and other hydraulic components, as well as maintenance and troubleshooting procedures.
• Undercarriage: Detailed information on the undercarriage components, including the tracks, rollers, idlers, and sprockets, as well as maintenance and troubleshooting procedures.
• Boom, Arm, Bucket, and Swing System: Information on the boom, arm, bucket, and swing system components, as well as maintenance and troubleshooting procedures.
• Cab and Control System: Detailed information on the cab and control system, including the operator’s seat, controls, instruments, and warning lights, as well as maintenance and troubleshooting procedures.

This is just a general overview of the information contained in a Komatsu PC800-8 series hydraulic excavator shop manual. The exact contents of the manual will vary depending on the specific model and year of the machine.

TABLE OF CONTENTS:

Komatsu PC800-8 PC800LC-8 PC800SE-8 PC850-8 PC850SE-8 Hydraulic Excavator Shop Manual SEN00373-18 – PDF DOWNLOAD

Cover……………………………………………………………………………………………………. 1
00 Index and foreword……………………………………………………………………………………… 0
Index………………………………………………………………………………………………… 3
Composition of shop manual………………………………………………………………………….. 4
Table of contents………………………………………………………………………………….. 6
Foreword and general information………………………………………………………………………… 17
Safety notice……………………………………………………………………………………… 18
How to read the shop manual…………………………………………………………………………. 23
Explanation of terms for maintenance standard…………………………………………………………. 25
Handling of electric equipment and hydraulic component…………………………………………………. 27
Handling of connectors newly used for engines…………………………………………………………. 36
How to read electric wire code………………………………………………………………………. 39
Precautions when carrying out operation………………………………………………………………. 42
Method of disassembling and connecting push-pull type coupler…………………………………………… 45
Standard tightening torque table…………………………………………………………………….. 48
Conversion table…………………………………………………………………………………… 52
01 Specification………………………………………………………………………………………….. 0
Specification and technical data………………………………………………………………………… 59
Specification and technical data…………………………………………………………………….. 60
Specification drawings………………………………………………………………………….. 60
Working range drawing…………………………………………………………………………… 62
Specifications…………………………………………………………………………………. 64
Weight table…………………………………………………………………………………… 82
Table of fuel, coolant and lubricants…………………………………………………………….. 88
10 Structure, function and maintenance standard………………………………………………………………. 0
Engine and cooling system………………………………………………………………………………. 91
Engine and cooling system…………………………………………………………………………… 92
Coupling………………………………………………………………………………………. 92
Coupling lubrication system……………………………………………………………………… 93
Radiator, oil cooler……………………………………………………………………………. 94
Power train…………………………………………………………………………………………… 97
Power train……………………………………………………………………………………….. 98
Power train……………………………………………………………………………………. 98
Swing machinery………………………………………………………………………………… 100
Swing circle…………………………………………………………………………………… 102
Final drive……………………………………………………………………………………. 104
Sprocket………………………………………………………………………………………. 106
Undercarriage and frame………………………………………………………………………………… 109
Undercarriage and frame…………………………………………………………………………….. 110
Track frame and recoil spring……………………………………………………………………. 110
Idler…………………………………………………………………………………………. 112
Carrier roller…………………………………………………………………………………. 114
Track roller…………………………………………………………………………………… 116
Track shoe…………………………………………………………………………………….. 118
Hydraulic system, Part 1……………………………………………………………………………….. 123
Hydraulic system, Part 1……………………………………………………………………………. 124
Hydraulic piping drawing………………………………………………………………………… 124
Hydraulic tank, hydraulic filter…………………………………………………………………. 126
Hydraulic pump…………………………………………………………………………………. 128
Cooling fan pump……………………………………………………………………………….. 148
Cooling fan motor………………………………………………………………………………. 156
Hydraulic system, Part 2……………………………………………………………………………….. 163
Hydraulic system, Part 2……………………………………………………………………………. 166
Motor grease pump………………………………………………………………………………. 166
Return oil filter………………………………………………………………………………. 167
Line oil filter………………………………………………………………………………… 168
Drain oil filter……………………………………………………………………………….. 169
L.H. 5-Spool control valve………………………………………………………………………. 170
R.H. 4-Spool control valve………………………………………………………………………. 176
Straight-travel valve…………………………………………………………………………… 182
Swing motor……………………………………………………………………………………. 185
Center swivel joint…………………………………………………………………………….. 190
Travel motor…………………………………………………………………………………… 191
PPC accumulator………………………………………………………………………………… 201
Work equipment, swing PPC valve………………………………………………………………….. 202
Travel PPC valve……………………………………………………………………………….. 207
Anti-drop valve………………………………………………………………………………… 211
Solenoid valve…………………………………………………………………………………. 212
Quick return valve……………………………………………………………………………… 218
Hydraulic cylinder……………………………………………………………………………… 220
Work equipment………………………………………………………………………………………… 227
Work equipment…………………………………………………………………………………….. 228
Work equipment…………………………………………………………………………………. 228
Dimensions of work equipment…………………………………………………………………….. 234
Cab and its attachments………………………………………………………………………………… 239
Cab and its attachments…………………………………………………………………………….. 240
Air conditioner piping………………………………………………………………………….. 240
Electrical system……………………………………………………………………………………… 243
Engine control…………………………………………………………………………………….. 244
Electric control system…………………………………………………………………………….. 253
Monitor system…………………………………………………………………………………….. 287
Sensors…………………………………………………………………………………………… 305
KOMTRAX system…………………………………………………………………………………….. 309
20 Standard value table……………………………………………………………………………………. 0
Standard service value table……………………………………………………………………………. 313
Standard service value table………………………………………………………………………… 314
Standard service value table for engine…………………………………………………………… 314
Standard service value table for chassis………………………………………………………….. 315
30 Testing and adjusting…………………………………………………………………………………… 0
Testing and adjusting, Part 1…………………………………………………………………………… 327
Testing and adjusting, Part 1……………………………………………………………………….. 328
Tools for testing, adjusting and troubleshooting…………………………………………………… 328
Measuring engine speed………………………………………………………………………….. 331
Measuring intake air pressure (Boost pressure)…………………………………………………….. 332
Measuring exhaust gas temperature………………………………………………………………… 333
Measuring exhaust gas color……………………………………………………………………… 334
Adjusting valve clearance……………………………………………………………………….. 335
Measuring compression pressure…………………………………………………………………… 336
Measuring blow-by pressure………………………………………………………………………. 337
Measuring engine oil pressure……………………………………………………………………. 338
Measuring EGR valve and bypass valve drive pressure………………………………………………… 339
Handling of fuel system equipment………………………………………………………………… 340
Remaining pressure relief from fuel system equipment……………………………………………….. 340
Measuring fuel pressure…………………………………………………………………………. 341
Testing fuel return rate and leakage……………………………………………………………… 342
Bleeding air from fuel circuit…………………………………………………………………… 344
Testing fuel system for leakage………………………………………………………………….. 346
Testing and adjusting alternator belt tension……………………………………………………… 347
Testing and adjusting air conditioner compressor belt………………………………………………. 348
Testing and adjusting, Part 2…………………………………………………………………………… 351
Testing and adjusting, Part 2……………………………………………………………………….. 352
Inspection of swing circle bearing clearance………………………………………………………. 352
Testing and adjusting track shoe tension………………………………………………………….. 353
Testing and adjusting work equipment, swing, and travel circuit oil pressures…………………………. 354
Testing and adjusting control circuit pressure (output pressure of self pressure reducing valve)………… 360
Testing and adjusting main pump control pressure…………………………………………………… 362
Testing and adjusting, Part 3…………………………………………………………………………… 369
Testing and adjusting, Part 3……………………………………………………………………….. 370
Measuring PPC valve output pressure………………………………………………………………. 370
Measuring outlet pressures of solenoid valve, swing PPC shuttle valve, and swing priority selector valve…. 374
Adjusting work equipment, swing PPC valve…………………………………………………………. 378
Testing and adjusting travel deviation……………………………………………………………. 379
Inspection of locations of hydraulic drift of work equipment………………………………………… 381
Measuring fan speed…………………………………………………………………………….. 382
Measuring fan circuit oil pressure……………………………………………………………….. 382
Measuring fan pump EPC current…………………………………………………………………… 383
Measuring fan pump EPC solenoid valve output pressure………………………………………………. 384
Measuring oil leakage…………………………………………………………………………… 385
Release of residual pressure from hydraulic circuit………………………………………………… 389
Bleeding air from each part……………………………………………………………………… 390
Inspection procedures for diode………………………………………………………………….. 393
Adjusting mirrors………………………………………………………………………………. 394
Testing and adjusting, Part 4…………………………………………………………………………… 397
Testing and adjusting, Part 4……………………………………………………………………….. 398
Special function of machine monitor………………………………………………………………. 398
Handling controller voltage circuit………………………………………………………………. 431
Testing and adjusting, Part 5…………………………………………………………………………… 433
Testing and adjusting, Part 5……………………………………………………………………….. 434
Procedure for turning on KOMTRAX terminal…………………………………………………………. 434
KOMTRAX terminal lamp indications………………………………………………………………… 437
Preparation work for troubleshooting electrical system……………………………………………… 440
Pm-clinic service………………………………………………………………………………. 443
40 Troubleshooting………………………………………………………………………………………… 0
Failure code table and fuse locations……………………………………………………………………. 453
Failure code table and fuse locations………………………………………………………………… 454
Failure codes table…………………………………………………………………………….. 454
Fuse locations…………………………………………………………………………………. 458
General information on troubleshooting…………………………………………………………………… 461
General information on troubleshooting……………………………………………………………….. 462
Points to remember when troubleshooting…………………………………………………………… 462
Sequence of events in troubleshooting…………………………………………………………….. 463
Checks before troubleshooting……………………………………………………………………. 464
Classification and troubleshooting steps………………………………………………………….. 465
Information in troubleshooting table……………………………………………………………… 466
Failure-looking phenomenon and troubleshooting No………………………………………………….. 468
Connection table for connector pin numbers………………………………………………………… 471
T- branch box and T- branch adapter table…………………………………………………………. 507
Troubleshooting by failure code (Display of code), Part 1………………………………………………….. 511
Troubleshooting by failure code (Display of code), Part 1………………………………………………. 514
Failure code [AA10NX] Aircleaner Clogging…………………………………………………………. 514
Failure code [AB00KE] Charge Voltage Low………………………………………………………….. 516
Failure code [B@BAZG] Eng. Oil Press. Low…………………………………………………………. 518
Failure code [B@BAZK] Eng. Oil Level Low………………………………………………………….. 519
Failure code [B@BCNS] Eng. Water Overheat…………………………………………………………. 520
Failure code [B@BCZK] Eng. Water Lvl Low………………………………………………………….. 522
Failure code [B@HANS] Hydr. Oil Overheat………………………………………………………….. 524
Failure code [CA111] ECM Critical Internal Failure…………………………………………………. 526
Failure code [CA115] Eng Ne and Bkup Speed Sens Error………………………………………………. 528
Failure code [CA122] Chg Air Press Sensor High Error……………………………………………….. 530
Failure code [CA123] Chg Air Press Sensor Low Error………………………………………………… 532
Failure code [CA131] Throttle Sensor High Error……………………………………………………. 534
Failure code [CA132] Throttle Sensor Low Error…………………………………………………….. 536
Failure code [CA135] Eng Oil Press Sensor High Error……………………………………………….. 538
Failure code [CA141] Eng Oil Press Sensor Low Error………………………………………………… 540
Failure code [CA144] Coolant Temp Sens High Error………………………………………………….. 542
Failure code [CA145] Coolant Temp Sens Low Error…………………………………………………… 544
Failure code [CA153] Chg Air Temp Sensor High Error………………………………………………… 546
Failure code [CA154] Chg Air Temp Sensor Low Error…………………………………………………. 548
Failure code [CA187] Sens Supply 2 Volt Low Error………………………………………………….. 548
Failure code [CA221] Ambient Press Sens High Error…………………………………………………. 550
Failure code [CA222] Ambient Press Sens Low Error………………………………………………….. 552
Failure code [CA227] Sens Supply 2 Volt High Error…………………………………………………. 554
Failure code [CA234] Eng Overspeed……………………………………………………………….. 556
Failure code [CA238] Ne Speed Sens Supply Volt Error……………………………………………….. 558
Failure code [CA263] Fuel Temp Sensor High Error…………………………………………………… 560
Failure code [CA265] Fuel Temp Sensor Low Error……………………………………………………. 562
Failure code [CA271] IMV/PCV1 Short Error…………………………………………………………. 563
Failure code [CA272] IMV/PCV1 Open Error………………………………………………………….. 564
Failure code [CA273] PCV2 Short Error…………………………………………………………….. 565
Failure code [CA274] PCV2 Open Error……………………………………………………………… 566
Failure code [CA322] Inj #1 (L#1) Open/Short Error…………………………………………………. 567
Failure code [CA323] Inj #5 (L#5) Open/Short Error…………………………………………………. 568
Failure code [CA324] Inj #3 (L#3) Open/Short Error…………………………………………………. 570
Failure code [CA325] Inj #6 (L#6) Open/Short Error…………………………………………………. 572
Failure code [CA331] Inj #2 (L#2) Open/Short Error…………………………………………………. 574
Failure code [CA332] Inj #4 (L#4) Open/Short Error…………………………………………………. 576
Failure code [CA342] Calibration Code Incompatibility………………………………………………. 577
Failure code [CA351] Injectors Drive Circuit Error…………………………………………………. 578
Failure code [CA352] Sens Supply 1 Volt Low Error………………………………………………….. 580
Failure code [CA386] Sens Supply 1 Volt High Error…………………………………………………. 582
Troubleshooting by failure code (Display of code), Part 2………………………………………………….. 585
Troubleshooting by failure code (Display of code), Part 2………………………………………………. 587
Failure code [CA441] Battery Voltage Low Error…………………………………………………….. 587
Failure code [CA442] Battery Voltage High Error……………………………………………………. 587
Failure code [CA449] Rail Press Very High Error……………………………………………………. 588
Failure code [CA451] Rail Press Sensor High Error………………………………………………….. 590
Failure code [CA452] Rail Press Sensor Low Error…………………………………………………… 592
Failure code [CA553] Rail Press High Error………………………………………………………… 592
Failure code [CA554] Rail Press Sensor In Range Error………………………………………………. 593
Failure code [CA559] Rail Press Low Error…………………………………………………………. 594
Failure code [CA689] Eng Ne Speed Sensor Error…………………………………………………….. 598
Failure code [CA731] Eng Bkup Speed Sens Phase Error……………………………………………….. 600
Failure code [CA757] All Persistent Data Lost Error………………………………………………… 601
Failure code [CA778] Eng Bkup Speed Sensor Error…………………………………………………… 602
Failure code [CA1228] EGR Valve Servo Error 1……………………………………………………… 604
Failure code [CA1625] EGR Valve Servo Error 2……………………………………………………… 605
Failure code [CA1626] BP Valve Sol Current High Error………………………………………………. 606
Failure code [CA1627] BP Valve Sol Current Low Error……………………………………………….. 608
Failure code [CA1628] Bypass Valve Servo Error 1…………………………………………………… 609
Failure code [CA1629] Bypass Valve Servo Error 2…………………………………………………… 610
Failure code [CA1631] BP Valve Pos Sens High Error…………………………………………………. 612
Failure code [CA1632] BP Valve Pos Sens Low Error………………………………………………….. 614
Failure code [CA1633] KOMNET Datalink Timeout Error………………………………………………… 616
Failure code [CA1642] EGR Inter Press Sens Low Error……………………………………………….. 618
Failure code [CA1653] EGR Inter Press Sens High Error………………………………………………. 620
Failure code [CA2185] Throt Sens Sup Volt High Error……………………………………………….. 622
Failure code [CA2186] Throt Sens Sup Volt Low Error………………………………………………… 624
Failure code [CA2249] Rail Press Very Low Error……………………………………………………. 625
Failure code [CA2271] EGR Valve Pos Sens High Error………………………………………………… 626
Failure code [CA2272] EGR Valve Pos Sens Low Error…………………………………………………. 628
Failure code [CA2351] EGR Valve Sol Current High Error……………………………………………… 630
Failure code [CA2352] EGR Valve Sol Current Low Error………………………………………………. 632
Failure code [CA2555] Grid Htr Relay Volt Low Error………………………………………………… 633
Failure code [CA2556] Grid Htr Relay Volt High Error……………………………………………….. 634
Failure code [D110KB] Battery Relay Drive S/C……………………………………………………… 636
Failure code [D163KB] Flash Light Relay S/C……………………………………………………….. 638
Failure code [D195KB] Step Light Relay S/C………………………………………………………… 640
Failure code [DA22KK] Pump Solenoid Power Low Error………………………………………………… 642
Failure code [DA25KP] Press. Sensor Power Abnormality………………………………………………. 644
Failure code [DA2SKQ] Model Selection Abnormality………………………………………………….. 646
Failure code [DA80MA] Auto. Lub. Abnormal…………………………………………………………. 648
Failure code [DA2RMC] Pump Comm. Abnormality………………………………………………………. 650
Failure code [DAFRMC] Monitor Comm. Abnormality……………………………………………………. 652
Failure code [DGE5KY] Ambi. Temp. Sensor S/C………………………………………………………. 654
Failure code [DGH2KB] Hydr. Oil Temp. Sensor S/C…………………………………………………… 656
Troubleshooting by failure code (Display of code), Part 3………………………………………………….. 659
Troubleshooting by failure code (Display of code), Part 3………………………………………………. 662
Failure code [DH25KA] L Jet Sensor Disc…………………………………………………………… 662
Failure code [DH25KB] L Jet Sensor S/C……………………………………………………………. 664
Failure code [DH26KA] R Jet Sensor Disc…………………………………………………………… 666
Failure code [DH26KB] R Jet Sensor S/C……………………………………………………………. 668
Failure code [DHPEKA] F Pump P. Sensor Disc……………………………………………………….. 670
Failure code [DHPEKB] F Pump P. Sensor S/C………………………………………………………… 672
Failure code [DHPFKA] R Pump P. Sensor Disc……………………………………………………….. 674
Failure code [DHPFKB] R Pump P. Sensor S/C………………………………………………………… 676
Failure code [DV20KB] Travel Alarm S/C……………………………………………………………. 678
Failure code [DW41KA] Swing Priority Sol. Disc…………………………………………………….. 680
Failure code [DW41KB] Swing Priority Sol. S/C……………………………………………………… 682
Failure code [DW43KA] Travel Speed Sol. Disc………………………………………………………. 684
Failure code [DW43KB] Travel Speed Sol. S/C……………………………………………………….. 686
Failure code [DW45KA] Swing Brake Sol. Disc……………………………………………………….. 688
Failure code [DW45KB] Swing Brake Sol. S/C………………………………………………………… 690
Failure code [DW7BKA] Fan Reverse Sol. Disc……………………………………………………….. 692
Failure code [DW7BKB] Fan Reverse Sol. S/C………………………………………………………… 694
Failure code [DW7JKA] Bottom Dump Priority Sol. Disc……………………………………………….. 696
Failure code [DW7JKB] Bottom Dump Priority Sol. S/C………………………………………………… 698
Failure code [DWK0KA] 2-stage Relief Sol. Disc…………………………………………………….. 700
Failure code [DWK0KB] 2-stage Relief Sol. S/C……………………………………………………… 702
Failure code [DX16KA] Fan Pump EPC Sol. Disc………………………………………………………. 704
Failure code [DX16KB] Fan Pump EPC Sol. S/C……………………………………………………….. 706
Failure code [DXAAKA] F Pump EPC Sol. Disc………………………………………………………… 708
Failure code [DXAAKB] F Pump EPC Sol. S/C…………………………………………………………. 710
Failure code [DXABKA] R Pump EPC Sol. Disc………………………………………………………… 712
Failure code [DXABKB] R Pump EPC Sol. S/C…………………………………………………………. 714
Failure code [DY20KA] Wiper Working Abnormality……………………………………………………. 716
Failure code [DY20MA] Wiper Parking Abnormality……………………………………………………. 718
Failure code [DY2CKB] Washer Drive S/C……………………………………………………………. 722
Failure code [DY2DKB] Wiper Drive (For) S/C……………………………………………………….. 724
Failure code [DY2EKB] Wiper Drive (Rev) S/C……………………………………………………….. 728
Troubleshooting of electrical system (E-mode)…………………………………………………………….. 731
Troubleshooting of electrical system (E-mode)…………………………………………………………. 733
Before carrying out troubleshooting of electrical system……………………………………………. 733
Information contained in troubleshooting table…………………………………………………….. 735
E-1 Engine does not start (Engine does not rotate)…………………………………………………. 736
E-2 Preheater does not operate…………………………………………………………………… 739
E-3 Auto engine warm-up device does not work………………………………………………………. 746
E-4 Auto-decelerator does not operate…………………………………………………………….. 747
E-5 All work equipment, swing and travel do not move……………………………………………….. 748
E-6 Machine push-up function does not operate normally……………………………………………… 750
E-7 Boom shockless function does not operate normally………………………………………………. 752
E-8 Any item is not displayed on machine monitor…………………………………………………… 754
E-9 Part of display on machine monitor is missing………………………………………………….. 755
E-10 Machine monitor displays contents irrelevant to the model………………………………………. 755
E-11 Fuel level monitor red lamp lights up while engine is running…………………………………… 756
E-12 Engine coolant thermometer does not display normally…………………………………………… 758
E-13 Hydraulic oil temperature gauge does not display correctly……………………………………… 760
E-14 Fuel gauge does not display correctly………………………………………………………… 761
E-15 Swing lock monitor does not display correctly…………………………………………………. 762
E-16 When monitor switch is operated, nothing is displayed………………………………………….. 764
E-17 Windshield wiper and window washer do not work………………………………………………… 766
E-18 “Boom RAISE” is not correctly displayed in monitor function…………………………………….. 774
E-19 “Boom LOWER” is not correctly displayed in monitor function…………………………………….. 775
E-20 “Arm IN” is not correctly displayed in monitor function………………………………………… 776
E-21 “Arm OUT” is not correctly displayed in monitor function……………………………………….. 777
E-22 “Bucket CURL” is not correctly displayed in monitor function……………………………………. 778
E-23 “Bucket DUMP” is not correctly displayed in monitor function……………………………………. 779
E-24 “SWING” is not correctly displayed in monitor function…………………………………………. 780
E-25 “Left travel” is not displayed normally in monitoring function………………………………….. 782
E-26 “Right travel” is not displayed normally in monitoring function…………………………………. 784
E-27 “Service” is not correctly displayed in monitor function……………………………………….. 786
E-28 KOMTRAX system does not operate normally……………………………………………………… 788
E-29 Air conditioner does not work……………………………………………………………….. 790
E-30 Step light does not light up or go off……………………………………………………….. 791
E-31 Electric grease gun does not operate…………………………………………………………. 794
E-32 Travel alarm does not sound or does not stop sounding………………………………………….. 796
Troubleshooting of hydraulic and mechanical system (H-mode)………………………………………………… 799
Troubleshooting of hydraulic and mechanical system (H-mode)…………………………………………….. 801
Before troubleshooting………………………………………………………………………….. 801
Information in troubleshooting table……………………………………………………………… 804
H-1 Speed or power of all work equipment, travel, and swing is low…………………………………… 806
H-2 Engine speed lowers remarkably or engine stalls………………………………………………… 808
H-3 All work equipment, travel, and swing systems do not work……………………………………….. 810
H-4 Abnormal sound is heard from around pump………………………………………………………. 811
H-5 Boom speed or power is low…………………………………………………………………… 812
H-6 Speed or power of arm is low…………………………………………………………………. 814
H-7 Speed or power of bucket is low………………………………………………………………. 815
H-8 Boom does not move………………………………………………………………………….. 816
H-9 Arm does not move…………………………………………………………………………… 816
H-10 Bucket does not move……………………………………………………………………….. 816
H-11 Hydraulic drift of work equipment is large……………………………………………………. 817
H-12 Time lag of work equipment is large………………………………………………………….. 819
H-13 Heavy lift function does not operate or stop………………………………………………….. 820
H-14 Machine push-up function does not operate or stop……………………………………………… 820
H-15 Boom shockless function cannot be turned ON or OFF…………………………………………….. 820
H-16 Machine deviates in one direction……………………………………………………………. 822
H-17 Machine deviates largely at start……………………………………………………………. 824
H-18 Machine deviates largely during compound operation…………………………………………….. 825
H-19 Travel speed or power is low………………………………………………………………… 825
H-20 Machine does not travel (only one track)……………………………………………………… 826
H-21 Travel speed does not change………………………………………………………………… 827
H-22 Upper structure does not swing………………………………………………………………. 828
H-23 Swing speed or acceleration is low…………………………………………………………… 830
H-24 Swing speed or acceleration is low during compound operation of swing and work equipment…………… 832
H-25 Upper structure overruns excessively when it stops swinging…………………………………….. 834
H-26 Large shock is made when upper structure stops swinging………………………………………… 835
H-27 Large abnormal sound is made when upper structure stops swinging………………………………… 836
H-28 Hydraulic drift of swing is large……………………………………………………………. 837
H-29 Fan rotation is abnormal (Fan sound/vibration is abnormally large or fan overheats)……………….. 838
Troubleshooting of engine (S-mode)………………………………………………………………………. 841
Troubleshooting of engine (S-mode)…………………………………………………………………… 843
Method of using troubleshooting chart…………………………………………………………….. 843
S-1 Starting performance is poor…………………………………………………………………. 846
S-2 Engine does not start……………………………………………………………………….. 848
S-3 Engine does not pick up smoothly……………………………………………………………… 852
S-4 Engine stops during operations……………………………………………………………….. 853
S-5 Engine does not rotate smoothly………………………………………………………………. 854
S-6 Engine lacks output (or lacks power)………………………………………………………….. 855
S-7 Exhaust gas color is black (incomplete combustion)……………………………………………… 856
S-8 Oil consumption is excessive (or exhaust smoke is blue)…………………………………………. 858
S-9 Oil becomes contaminated quickly……………………………………………………………… 859
S-10 Fuel consumption is excessive……………………………………………………………….. 860
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)……………………………. 861
S-12 Oil pressure drops…………………………………………………………………………. 862
S-13 Oil level rises (Entry of coolant/fuel)………………………………………………………. 864
S-14 Coolant temperature becomes too high (overheating)…………………………………………….. 866
S-15 Abnormal noise is made……………………………………………………………………… 867
S-16 Vibration is excessive……………………………………………………………………… 868
50 Disassembly and assembly………………………………………………………………………………… 0
General information on disassembly and assembly…………………………………………………………… 871
How to read this manual…………………………………………………………………………….. 872
Coating materials list……………………………………………………………………………… 874
Special tools list…………………………………………………………………………………. 877
Sketches of special tools…………………………………………………………………………… 884
Engine and cooling system (SAA6D140E-5)………………………………………………………………….. 891
Engine and cooling system…………………………………………………………………………… 892
Removal and installation of engine, PTO and hydraulic pump assembly………………………………….. 892
Removal and installation of cooling assembly………………………………………………………. 900
Removal and installation of aftercooler assembly…………………………………………………… 905
Removal and installation of fuel cooler and air conditioner condenser assembly………………………… 907
Removal and installation of fan motor assembly…………………………………………………….. 909
Removal and installation of fuel tank assembly…………………………………………………….. 914
Engine (SAA6D140E-5)…………………………………………………………………………………… 917
Engine (SAA6D140E-5)……………………………………………………………………………….. 918
Removal and installation of fuel supply pump assembly………………………………………………. 918
Removal and installation of cylinder head assembly…………………………………………………. 923
Removal and installation of fuel injector assembly…………………………………………………. 939
Removal and installation of engine front seal……………………………………………………… 942
Removal and installation of engine rear seal………………………………………………………. 944
Power train…………………………………………………………………………………………… 949
Power train……………………………………………………………………………………….. 950
Removal and installation of PTO (coupling) assembly………………………………………………… 950
Disassembly and assembly of PTO (coupling) assembly………………………………………………… 957
Removal and installation of swing motor and swing machinery assembly…………………………………. 959
Disassembly and assembly of swing machinery assembly……………………………………………….. 961
Removal and installation of swing circle assembly………………………………………………….. 968
Disassembly and assembly of final drive assembly…………………………………………………… 969
Undercarriage and frame………………………………………………………………………………… 981
Undercarriage and frame…………………………………………………………………………….. 982
Removal and installation of trackshoe assembly…………………………………………………….. 982
Disassembly and assembly of one link in field……………………………………………………… 984
Removal and installation of idler assembly………………………………………………………… 988
Disassembly and assembly of idler assembly………………………………………………………… 989
Disassembly and assembly of idler adjustment cylinder assembly………………………………………. 992
Removal and installation of recoil spring assembly…………………………………………………. 993
Disassembly and assembly of recoil spring assembly…………………………………………………. 995
Removal and installation of carrier roller assembly………………………………………………… 997
Disassembly and assembly of carrier roller assembly………………………………………………… 998
Removal and installation of track roller assembly…………………………………………………..1001
Disassembly and assembly of track roller assembly…………………………………………………..1002
Removal and installation of revolving frame assembly………………………………………………..1005
Removal and installation of counterweight assembly………………………………………………….1007
Removal and installation of counterweight remover assembly…………………………………………..1008
Hydraulic system……………………………………………………………………………………….1013
Removal and installation ofhydraulic tank assembly……………………………………………………..1014
Removal and installation of mainpump assembly………………………………………………………….1017
Removal and installation of mainpump input shaft oil seal……………………………………………….1024
Removal and installation ofcooling fan pump assembly……………………………………………………1025
Removal and installation ofcontrol valve assembly………………………………………………………1028
Assembly of control valveassembly…………………………………………………………………….1031
Removal and installation of swingmotor assembly………………………………………………………..1037
Removal and installation of centerswivel joint assembly…………………………………………………1039
Disassembly and assembly ofcenter swivel joint assembly…………………………………………………1041
Removal and installation of travelmotor assembly……………………………………………………….1043
Removal and installation of solenoidvalve assembly……………………………………………………..1044
Removal and installation of boomdamping valve assembly………………………………………………….1046
Disassembly and assembly ofwork equipment PPC valveassembly……………………………………………..1047
Disassembly and assembly oftravel PPC valve assembly……………………………………………………1049
Disassembly and assembly ofhydraulic cylinder assembly………………………………………………….1052
Disassembly and assembly ofgrease gun assembly…………………………………………………………1058
Work equipment…………………………………………………………………………………………1061
Work equipment……………………………………………………………………………………..1062
Removal and installation of bucket cylinder assembly………………………………………………..1062
Removal and installation of arm cylinder assembly…………………………………………………..1066
Removal and installation of boom cylinder assembly………………………………………………….1070
Removal and installation of bottom dump cylinder assembly……………………………………………1074
Removal and installation of bucket assembly………………………………………………………..1075
Removal and installation of arm assembly…………………………………………………………..1077
Removal and installation of boom assembly………………………………………………………….1080
Removal and installation of work equipment…………………………………………………………1084
Cab and its attachments…………………………………………………………………………………1089
Cab and its attachments……………………………………………………………………………..1090
Removal and installation of operator’s cab…………………………………………………………1090
Removal and installation of operator’s cab glass (stuck glass)……………………………………….1093
Removal and installation of front window assembly…………………………………………………..1103
Electrical system………………………………………………………………………………………1109
Electrical system…………………………………………………………………………………..1110
Removal and installation of air conditioner unit assembly……………………………………………1110
Removal and installation of engine controller assembly………………………………………………1112
Removal and installation of monitor assembly……………………………………………………….1114
Removal and installation of pump controller assembly………………………………………………..1114
Removal and Installation of KOMTRAX terminal assembly……………………………………………….1115
90 Diagrams and drawings…………………………………………………………………………………… 0
Hydraulic diagrams and drawings………………………………………………………………………….1117
Hydraulic circuit diagram……………………………………………………………………………1119
Electrical diagrams and drawings…………………………………………………………………………1123
Electrical circuit diagram (1/5)……………………………………………………………………..1125
Electrical circuit diagram (2/5)……………………………………………………………………..1127
Electrical circuit diagram (3/5)……………………………………………………………………..1129
Electrical circuit diagram (4/5)……………………………………………………………………..1131
Electrical circuit diagram (5/5)……………………………………………………………………..1133
Connector list and sterogram…………………………………………………………………………1135