Complete service repair manual with Electrical Wiring Diagrams for Komatsu PC800-8, PC800LC-8, PC800SE-8, PC850-8, PC850SE-8 Hydraulic Excavators, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Komatsu PC800-8, PC800LC-8, PC800SE-8, PC850-8, PC850SE-8 Hydraulic Excavators workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 4,823 pages
File Format: PDF
Language: English
UEN00373-01 – Hydraulic Excavator GALEO PC800-8, PC800LC-8 Shop Manual.pdf
SEN00373-12 – Hydraulic Excavator PC800-8, PC800LC-8, PC800SE-8, PC850-8, PC850SE-8 Shop Manual.pdf
GEN00048-00 – Hydraulic Excavator GALEO PC800-8, PC850-8 Field Assembly Instruction.pdf
SEAM032605T – Hydraulic Excavator PC750-6, PC750LC-6, PC750SE-6, PC800-6, PC800SE-6 Operation & Maintenance Manual.pdf
UEAM005400 – Hydraulic Excavator PC800-8, PC800LC-8 Operation & Maintenance Manual.pdf
TEN00040-03 – Hydraulic Excavator PC750-7, PC750LC-7, PC750SE-7, PC800-7, PC800SE-7 Operation & Maintenance Manual.pdf
TEN00345-03 – Hydraulic Excavator PC800-8, PC800LC-8, PC800SE-8, PC850-8, PC850SE-8 Operation & Maintenance Manual.pdf
SEAM053403T – Hydraulic Excavator GALEO PC750-7, PC750LC-7, PC750SE-7, PC800-7, PC800SE-7 Operation & Maintenance Manual.pdf
TEN00135-08 – Hydraulic Excavator PC800-8, PC800LC-8, PC800SE-8, PC850-8, PC850SE-8 Operation & Maintenance Manual.pdf
SEAWD01803 – Hydraulic Excavator PC750-6, PC750LC-6, PC750SE-6, PC800-6, PC800SE-6 Field Assembly Instruction.pdf
SEAM032602T – Hydraulic Excavator PC750-6, PC750LC-6, PC750SE-6, PC800-6, PC800SE-6 Operation & Maintenance Manual.pdf
GEN00048-06 – Hydraulic Excavator PC800-8, PC800LC-8, PC800SE-8, PC850-8, PC850SE-8 Field Assembly Instruction.pdf
GEN00014-03 – Hydraulic Excavator PC750-7, PC750LC-7, PC750SE-7, PC800-7, PC800SE-7 Field Assembly Instruction.pdf
MAIN SECTIONS
GEN00014-03 – Hydraulic Excavator PC750-7, PC750LC-7, PC750SE-7, PC800-7, PC800SE-7 Field Assembly Instruction…..3
COVER…..3
Foreword…..4
CONTENTS …..6
SPECIFICATIONS…..8
Precautions for field assembly…..9
DISPOSAL OF REMOVED PARTS…..10
Assembling Procedures, Applicable Equipment and Schedule…..11
TRANSPORTATION…..13
List of Tools for Field Assembling…..19
TIGHTENING TORQUE…..20
COATING MATERIALS LIST…..24
A. ASSEMBLY OF CHASSIS…..26
A-1. Installation of Left and Right Track Frames …..27
A-2. Installation of Travel Pipe …..30
A-3. Installation of Top Guard …..33
A-4. Installation of Radiator Cover …..34
A-5. Installation of Rearview Mirror …..35
A-6. Installation of Handrail …..39
A-7. Installation of Step …..42
A-8. Installation of Left Side Step …..43
A-9. Installation of Muffler Tail Tube …..44
A-10. Sticking of Sheet (to Counterweight) …..45
A-11. Installation of Counterweight …..46
A-12. Installation of ORBCOMM Antenna (if equipped) …..47
A-13. Installation of Step Light …..48
A-14. Installation of Travel Pipe Cover …..50
A-15. Extension of Track Frame Gauge (Only When 3-split Packages are transported) …..51
A-16. Testing Track Shoe Tension …..54
A-17. Installation of Oil Amount and Water Amount …..57
A-18. Parts to be Touched up After Field Assembly …..59
B.ASSEMBLING OF WORK EQUIPMENT OF BACKHOE…..60
B-1. Pulling Out of Boom Foot Pin, and Boom Cylinder Foot Pin…..61
B-2. Installation of Boom Assembly…..62
B-3. Relieving Remaining Pressure from Hydraulic Circuit …..63
B-4. B-2. Installation of Boom Cylinder Foot…..64
B-5. Installation of Boom Cylinder Hose…..65
B-6. Installation of Boom Cylinder…..66
B-7. Installation of Arm Cylinder…..67
B-8. Installation of Arm Cylinder Hose…..68
B-9. Installation of Arm Assembly …..69
B-10. Installation of Hose between Boom and Bucket Cylinder…..71
B-11. Installation of Bucket Assembly…..72
B-12. Lubrication Piping to Work Equipment…..73
B-13. Connection of Wiring of Work Equipment…..74
B-14. Greasing after Assembling Work Equipment…..75
B-15. Air Bleeding from Hydraulic Cylinder…..76
C. ASSEMBLING OF WORK EQUIPMENT OF LOADING SHOVEL…..78
C-1. Releasing residual pressure in hydraulic circuit…..79
C-2. Pulling out boom foot pin and boom cylinder foot pin…..80
C-3. Installation of boom and arm assembly…..81
C-4. Installation of flushing piping between chassis and boom…..82
C-5. Installation of flushing piping for boom cylinder and arm cylinder…..83
C-6. Installation of…..84
C-7. Installation of flushing piping for bottom dump cylinder…..85
C-8. Installation of boom cylinder…..87
C-9. Installation of boom cylinder foot…..88
C-10. Installation of boom cylinder hoses…..89
C-11. Installation of boom cylinder rod pin…..90
C-12. Installation of arm cylinder hoses…..91
C-13. Installation of bucket cylinder…..92
C-14. Installation of bucket cylinder hose…..93
C-15. Installation of connecting hoses between chassis and boom top …..94
C-16. Installation of bottom dump cylinder hoses…..95
C-17. Installation of bucket assembly…..96
C-18. Installation of working lamps…..98
C-19. Installation of work equipment grease piping…..99
C-20. Greasing after assembling of work equipment…..100
C-21 Bleeding air from hydraulic cylinder…..101
M. PROCEDURE FOR INSPECTION AND MAINTENANCE AFTER COMPLETION OF ASSEMBLY…..102
M-1.Inspection of Oil Level in Hydraulic Tank and Refill…..103
M-2.Replacement of Return Filter (Standard Filter to Flushing Filter)…..105
M-3.Flushing of Hydraulic Circuit…..106
M-4.Replacement of Return Filter (Flushing Filter to Standard Filter)…..108
FIELD ASSEMBLY INSPECTION REPORT (Backhoe)…..110
FIELD ASSEMBLY INSPECTION REPORT (Loading Shovel)…..136
GEN00048-00 – Hydraulic Excavator GALEO PC800-8, PC850-8 Field Assembly Instruction…..162
COVER…..162
FOREWORD…..163
CONTENTS…..164
SPECIFICATIONS…..166
PRECAUTIONS FOR FIELD ASSEMBLY…..167
ASSEMBLING PROCEDURES, APPLICABLE EQUIPMENT AND SCHEDULE…..168
KIT LAYOUT DIAGRAM…..169
TRANSPORTATION…..170
LIST OF TOOLS FOR FIELD ASSEMBLING…..176
TIGHTENING TORQUE…..177
COATING MATERIALS…..181
A. ASSEMBLY OF BASE MACHINE…..183
A-1. INSTALLATION OF LEFT AND RIGHT TRACK FRAMES…..184
A-2. INSTALLATION OF TRAVEL PIPE…..188
A-3. INSTALLATION OF TOP GUARD…..191
A-4. INSTALLATION OF RADIATOR COVER…..192
A-5. INSTALLATION OF REARVIEW MIRROR…..193
A-6. INSTALLATION OF LEFT SIDE STEP…..197
A-7. INSTALLATION OF HANDRAIL…..198
A-8. INSTALLATION OF HANDRAIL (WITH TOP GUARD)…..199
A-9. INSTALLATION OF MUFFLER TAIL TUBE…..201
A-10. STICKING SHEET TO COUNTERWEIGHT…..202
A-11. INSTALLATION OF COUNTERWEIGHT…..203
A-12. INSTALLATION OF ORBCOMM ANTENNA (IF EQUIPPED)…..204
A-13. INSTALLATION OF STEP LIGHT…..205
A-14. AIR BLEEDING OF TRAVEL MOTOR…..207
A-15. INSTALLATION OF TRAVEL PIPING COVER…..208
A-16. TESTING TRACK SHOE TENSION…..210
A-17. CHECK FUEL, COOLANT AND OIL LEVELS …..213
A-18. PARTS TO BE TOUCHED UP AFTER FIELD ASSEMBLY…..216
B. ASSEMBLING OF WORK EQUIPMENT OF BACKHOE…..217
B-1. ASSEMBLY OF ARM CYLINDER…..218
B-2. CONNECTION OF ARM CYLINDER HOSES…..219
B-3. INSTALLATION OF BOOM CYLINDER FOOT …..221
B-4. RELIEVING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT…..222
B-5. INSTALLATION OF BOOM CYLINDER HOSES…..223
B-6. ASSEMBLY OF BOOM ASSEMBLY…..224
B-7. HOSE CONNECTION OF ARM AND BUCKET CIRCUITS…..225
B-8. INSTALLATION OF QUICK RETURN HOSE…..226
B-9. INSTALLATION OF BOOM CYLINDER …..227
B-10. INSTALLATION OF ARM ASSEMBLY…..228
B-11. INSTALLATION OF HOSE BETWEEN BOOM AND BUCKET CYLINDER…..230
B-12. INSTALLATION OF BUCKET ASSEMBLY…..231
B-13. LUBRICATION PIPING TO WORK EQUIPMENT…..232
B-14. AIR BLEEDING FROM CYLINDER…..233
B-15. WIRING OF WORK EQUIPMENT…..234
B-16. GREASING AFTER ASSEMBLING WORK EQUIPMENT…..235
M. PROCEDURE FOR INSPECTION AND MAINTENANCE AFTER COMPLETION OF ASSEMBLY…..236
M-1. INSPECTION OF OIL LEVEL IN HYDRAULIC TANK AND REFILL…..237
M-2. REPLACEMENT OF RETURN FILTER (STANDARD FILTER TO FLUSHING FILTER)…..239
M-3. FLUSHING OF HYDRAULIC CIRCUIT …..242
M-4. ERROR CODE…..244
C. ASSEMBLING OF WORK EQUIPMENT OF LOADING SHOVEL…..246
C-1. RELEASING RESIDUAL PRESSURE IN HYDRAULIC CIRCUIT…..247
C-2. PULLING OUT BOOM FOOT PIN AND BOOM CYLINDER FOOT PIN…..248
C-3. INSTALLATION OF BOOM AND ARM ASSEMBLY…..249
C-4. INSTALLATION OF FLUSHING PIPING BETWEEN CHASSIS AND BOOM…..250
C-5. INSTALLATION OF FLUSHING PIPING FOR BOOM CYLINDER AND ARM CYLINDER …..251
C-6. INSTALLATION OF FLUSHING PIPING FOR BUCKET CYLINDER…..252
C-7. INSTALLATION OF FLUSHING PIPING FOR BOTTOM DUMP CYLINDER…..253
C-8. INSTALLATION OF BOOM CYLINDER…..255
C-9. INSTALLATION OF BOOM CYLINDER FOOT…..256
C-10. INSTALLATION OF BOOM CYLINDER HOSES…..257
C-11. INSTALLATION OF BOOM CYLINDER ROD PIN…..258
C-12. INSTALLATION OF ARM CYLINDER HOSES…..259
C-13. INSTALLATION OF BUCKET CYLINDER…..260
C-14. INSTALLATION OF BUCKET CYLINDER HOSE…..261
C-15. INSTALLATION OF CONNECTING HOSES BETWEEN CHASSIS AND BOOM TOP…..262
C-16. INSTALLATION OF BOTTOM DUMP CYLINDER HOSES…..263
C-17. INSTALLATION OF BUCKET ASSEMBLY…..264
C-18. INSTALLATION OF WORKING LAMPS…..266
C-19. INSTALLATION OF WORK EQUIPMENT GREASE PIPING…..267
C-20. GREASING AFTER ASSEMBLING OF WORK EQUIPMENT…..268
C-21. BLEEDING AIR FROM WORK EQUIPMENT CIRCUIT…..269
C-22. CHECKING OIL LEVEL IN HYDRAULIC TANK AND ADDING OIL…..270
C-23. REPLACEMENT OF RETURN FILTER (STANDARD FILTER TO FLUSHING FILTER)…..271
C-24. FLUSHING OF HYDRAULIC CIRCUIT…..274
FIELD ASSEMBLY INSPECTION REPORT (BACKHOE)…..276
FIELD ASSEMBLY INSPECTION REPORT (LOADING SHOVEL)…..289
GEN00048-06 – Hydraulic Excavator PC800-8, PC800LC-8, PC800SE-8, PC850-8, PC850SE-8 Field Assembly Instruction…..302
COVER…..302
FOREWORD…..303
CONTENTS…..304
SPECIFICATIONS…..307
PRECAUTIONS FOR FIELD ASSEMBLY…..308
DISPOSAL OF REMOVED PARTS…..309
ASSEMBLING PROCEDURES, APPLICABLE EQUIPMENT AND SCHEDULE…..310
KIT LAYOUT DIAGRAM…..311
TRANSPORTATION…..312
LIST OF TOOLS FOR FIELD ASSEMBLING…..318
TIGHTENING TORQUE…..319
COATING MATERIALS…..323
A. ASSEMBLY OF CHASSIS…..325
A-1. Installation of Left and Right Track Frames…..326
A-2. Installation of Travel Pipe…..330
A-3. Installation of Top Guard…..333
A-4. Installation of Radiator Cover…..334
A-5. Installation of Rearview Mirror…..335
A-6…..339
A-7…..340
A-8…..341
A-9…..343
A-10…..344
A-11…..345
A-12. Installation of KOMTRAX Antenna (if equipped)…..346
A-13…..347
A-14…..349
A-15. Installation of Travel Piping Cover…..350
A-16. Testing Track Shoe Tension…..352
A-17…..355
A-18…..357
B. ASSEMBLING OF WORK EQUIPMENT OF BACKHOE…..359
B-1…..360
B-2…..361
B-3…..363
B-4…..364
B-5…..365
B-6…..366
B-7…..367
B-8…..368
B-9…..369
B-10…..370
B-11. Installation of Arm Assembly…..371
B-12…..373
B-13…..374
B-14…..375
B-15…..376
B-16…..377
B-17…..378
C. ASSEMBLING OF WORK EQUIPMENT OF LOADING SHOVEL…..379
C-1. Releasing residual pressure in hydraulic circuit…..380
C-2. Pulling out boom foot pin and boom cylinder foot pin…..381
C-3. Installation of boom and arm assembly…..382
C-4. Installation of flushing piping between chassis and boom…..383
C-5. Installation of flushing piping for boom cylinder and arm cylinder…..384
C-6. Installation of flushing piping for bucket cylinder…..385
C-7. Installation of flushing piping for bottom dump cylinder…..386
C-8. Installation of boom cylinder…..388
C-9. Installation of boom cylinder foot…..389
C-10. Installation of boom cylinder hoses…..390
C-11. Installation of boom cylinder rod pin…..391
C-12. Installation of arm cylinder hoses…..392
C-13. Installation of bucket cylinder…..393
C-14. Installation of bucket cylinder hose…..394
C-15. Installation of connecting hoses between chassis and boom top…..395
C-16. Installation of bottom dump cylinder hoses…..396
C-17. Installation of bucket assembly…..397
C-18. Installation of working lamps…..399
C-19. Installation of work equipment grease piping…..400
C-20. Greasing after assembling of work equipment…..401
C-21. Bleeding air from work equipment circuit…..402
D. ASSEMBLING OF COUNTERWEIGHT REMOVER…..403
D-1. Installation of Rubber Cushions…..404
D-2. Adjustment of Shims for Counterweight…..405
D-3. Greasing…..410
D-4. Installation of Counterweight Remover…..411
D-5. Installation of Covers…..412
D-6. Installation of Hoses…..413
D-7…..416
D-8. Installation of Counterweight…..417
D-9. Installation of Accessories…..419
D-10. Check of Operation…..420
M. PROCEDURE FOR INSPECTION AND MAINTENANCE AFTER COMPLETION OF ASSEMBLY…..421
M-1…..422
M-2…..424
M-3…..425
M-4…..427
M-5…..429
FIELD ASSEMBLY INSPECTION REPORT (Backhoe)…..431
FIELD ASSEMBLY INSPECTION REPORT (Loading Shovel…..457
SEAM032602T – Hydraulic Excavator PC750-6, PC750LC-6, PC750SE-6, PC800-6, PC800SE-6 Operation & Maintenance Manual…..482
COVER…..482
1. FOREWORD…..483
2. SAFETY INFORMATION…..486
3. INTRODUCTION…..487
4. LOCATION OF PLATES,TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…..488
5. CONTENTS…..490
SAFETY…..494
6. GENERAL PRECAUTIONS…..495
7. PRECAUTIONS DURING OPERATION…..502
7.1 BEFORE STARTING ENGINE…..502
7.2 AFTER STARTING ENGINE…..504
7.3 TRANSPORTATION…..511
7.4 BATTERY…..512
7.5 TOWING…..514
7.6 LIFTING OPERATIONS…..514
7.7 BUCKET WITH HOOK…..515
8. PRECAUTIONS FOR MAINTENANCE…..516
8.1 BEFORE CARRYING OUT MAINTENANCE…..516
8.2 DURING MAINTENANCE…..520
9. POSITION FOR ATTACHING SAFETY LABELS…..525
OPERATION…..529
10. GENERAL VIEW…..530
10.1 GENERAL VIEW OF MACHINE…..530
10.2 GENERAL VIEW OF CONTROLS AND GAUGES…..531
11. EXPLANATION OF COMPONENTS…..532
11.1 MACHINE MONITOR…..532
11.2 SWITCHES…..543
11.3 CONTROL LEVERS,PEDALS…..548
11.4 CEILING WINDOW…..551
11.5 FRONT WINDOW…..552
11.6 DOOR LOCK…..554
11.7 CAP,COVER WITH LOCK…..555
11.8 HOT AND COOL BOX…..556
11.9 LUGGAGE BOX…..556
11.10 ASHTRAY…..556
11.11 HANDLING AIR CONDITIONER…..557
11.12 CAR RADIO…..560
11.13 POWER SUPPLY SOCKET…..564
11.14 FUSE…..565
11.15 FUSIBLE LINK…..566
11.16 CONTROLLERS…..566
11.17 TOOL HOLDER (CLOTH BAG)…..566
11.18 HANDLING GREASE PUMP…..566
11.19 HANDLING ACCUMULATOR…..569
12. OPERATION…..570
12.1 CHECK BEFORE STARTING ENGINE…..570
12.2 STARTING ENGINE…..580
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE…..582
12.4 MOVING MACHINE OFF…..587
12.5 STEERING MACHINE…..590
12.6 STOPPING MACHINE…..592
12.7 SWINGING…..593
12.8 OPERATION OF WORK EQUIPMENT…..594
12.9 HANDLING WORKING MODE…..595
12.10 PROHIBITIONS FOR OPERATION…..596
12.11 PRECAUTIONS FOR OPERATION…..598
12.12 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS…..599
12.13 HOW TO ESCAPE FROM MUD…..601
12.14 WORK POSSIBLE USING HYDRAULIC EXCAVATOR…..602
12.15 REPLACEMENT OF BUCKET…..603
12.16 PARKING MACHINE…..604
12.17 CHECK AFTER FINISHING WORK…..605
12.18 STOPPING ENGINE…..606
12.19 CHECK AFTER STOPPING ENGINE…..607
12.20 LOCKING…..607
13. TRANSPORTATION…..608
13.1 LOADING,UNLOADING WORK…..608
13.2 PRECAUTIONS FOR LOADING…..610
13.3 PRECAUTIONS FOR TRANSPORTATION…..610
13.4 TRANSPORTATION POSTURE…..611
13.5 PROCEDURE FOR INCREASING OR REDUCING TRACK FRAME GAUGE…..616
14. COLD WEATHER OPERATION…..618
14.1 PRECAUTIONS FOR LOW TEMPERATURE…..618
14.2 PRECAUTIONS AFTER COMPLETION OF WORK…..620
14.3 AFTER COLD WEATHER…..620
15. LONG-TERM STORAGE…..621
15.1 BEFORE STORAGE…..621
15.2 DURING STORAGE…..622
15.3 AFTER STORAGE…..622
15.4 STARTING MACHINE AFTER LONG-TERM STORAGE…..622
16. TROUBLESHOOTING…..623
16.1 WHEN MACHINE RUNS OUT OF FUEL…..623
16.2 PHENOMENA THAT ARE NOT FAILURES…..623
16.3 METHOD OF TOWING MACHINE…..623
16.4 PRECAUTIONS ON PARTICULAR JOBSITES…..623
16.5 IF BATTERY IS DISCHARGED…..624
16.6 OTHER TROUBLE…..628
MAINTENANCE…..633
17. GUIDES TO MAINTENANCE…..634
18. OUTLINES OF SERVICE…..636
18.1 OUTLINE OF OIL,FUEL,COOLANT…..636
18.2 OUTLINE OF ELECTRIC SYSTEM…..639
18.3 OUTLINE OF HYDRAULIC SYSTEM…..639
18.4 RELEASING PRESSURE…..640
18.5 BLEEDING AIR FROM CIRCUIT…..641
19. CONSUMABLE PARTS LIST…..644
20. USE OF FUEL,COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…..645
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…..649
21.1 INTRODUCTION OF NECESSARY TOOLS…..649
21.2 TORQUE LIST…..650
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…..651
23. MAINTENANCE SCHEDULE CHART…..653
23.1 MAINTENANCE SCHEDULE CHART…..653
24. SERVICE PROCEDURE…..657
24.1 INITIAL 100 HOURS SERVICE…..657
24.2 INITIAL 250 HOURS SERVICE…..657
24.3 WHEN REQUIRED…..658
24.4 CHECKS BEFORE STARTING…..672
24.5 EVERY 10 HOURS SERVICE…..673
24.6 EVERY 100 HOURS SERVICE…..675
24.7 EVERY 250 HOURS SERVICE…..676
24.8 EVERY 500 HOURS SERVICE…..684
24.9 EVERY 1000 HOURS SERVICE…..690
24.10 EVERY 2000 HOURS SERVICE…..695
24.11 EVERY 4000 HOURS SERVICE…..698
SPECIFICATIONS…..699
25. SPECIFICATIONS…..700
OPTIONS,ATTACHMENTS…..702
26. GENERAL PRECAUTIONS…..703
26.1 PRECAUTIONS RELATED TO SAFETY…..703
26.2 PRECAUTIONS WHEN INSTALLING ATTACHMENTS…..704
27. HANDLING BUCKET WITH HOOK…..705
27.1 CHECKING FOR DAMAGE TO BUCKET WITH HOOK…..705
27.2 PROHIBITED OPERATIONS…..705
27.3 PRECAUTIONS DURING OPERATIONS…..705
28. USING SEAT BELT…..706
28.1 SEAT BELT…..706
29. INTRODUCTION OF OPTIONAL PARTS,ATTACHMENTS…..708
29.1 COMBINATIONS OF WORK EQUIPMENT…..708
29.2 SELECTION OF TRACK SHOES…..710
LOADING SHOVEL…..712
30. GENERAL LOCATIONS…..713
31. INSTRUMENTS AND CONTROLS…..714
31.1 SWITCH…..714
31.2 CONTROL BOX…..716
32. OPERATIONS…..717
32.1 OPERATION OF WORK EQUIPMENT…..717
33. PRECAUTIONS FOR MACHINE OPERATION…..719
33.1 PRECAUTIONS DURING OPERATION…..719
34. PRECAUTIONS WHEN DISASSEMBLING MACHINE…..722
34.1 RELEASING PRESSURE…..722
35. MAINTENANCE…..723
35.1 CHECK BEFORE STARTING…..723
35.2 EVERY 10 HOURS SERVICE…..724
36. EXCAVATOR WORK…..727
37. TRANSPORTATION…..728
38. TROUBLESHOOTING…..729
39. CONSUMABLE PARTS LIST…..730
40. SPECIFICATIONS…..731
41. COMBINATIONS OF WORK EQUIPMENT…..732
41.1 COMBINATIONS OF WORK EQUIPMENT…..732
SEAM032605T – Hydraulic Excavator PC750-6, PC750LC-6, PC750SE-6, PC800-6, PC800SE-6 Operation & Maintenance Manual…..734
COVER…..734
FOREWORD…..735
FOREWORD…..736
SAFETY INFORMATION…..739
INTRODUCTION…..741
DIRECTIONS OF MACHINE…..741
BREAKING-IN THE NEW MACHINE…..741
PRODUCT INFORMATION…..742
MACHINE SERIAL NUMBER PLATE AND ITS LOCATION…..742
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION…..742
SERVICE METER LOCATION…..743
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…..743
CONTENTS…..744
SAFETY…..748
SAFETY INFORMATION…..749
SAFETY LABELS…..751
LOCATION OF SAFETY LABELS…..751
SAFETY LABELS…..752
SAFETY INFORMATION…..757
SAFETY RULES…..757
IF ABNORMALITIES ARE FOUND…..757
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS…..757
FIRE EXTINGUISHER AND FIRST AID KIT…..757
SAFETY EQUIPMENT…..757
KEEP MACHINE CLEAN…..758
KEEP OPERATOR'S COMPARTMENT CLEAN…..758
LEAVING OPERATOR'S SEAT WITH LOCK…..758
HANDRAILS AND STEPS…..759
MOUNTING AND DISMOUNTING…..759
NO PERSONS ON ATTACHMENTS…..759
BURN PREVENTION…..760
FIRE PREVENTION AND EXPLOSION PREVENTION…..760
ACTION IF FIRE OCCURS…..761
WINDSHIELD WASHER FLUID…..761
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION…..761
ATTACHMENT INSTALLATION…..762
ATTACHMENT COMBINATIONS…..762
CAB WINDOW GLASSES…..762
UNAUTHORIZED MODIFICATIONS…..762
SAFETY AT JOBSITE…..762
WORKING ON LOOSE GROUND…..763
DISTANCE TO HIGH VOLTAGE CABLES…..763
ENSURE GOOD VISIBILITY…..763
VENTILATION FOR ENCLOSED AREA…..764
SIGNALMAN'S SIGNAL AND SIGNS…..764
EMERGENCY EXIT FROM OPERATOR'S CAB…..764
ASBESTOS DUST HAZARD PREVENTION…..764
SAFETY MACHINE OPERATION…..765
STARTING ENGINE…..765
CHECKS BEFORE STARTING ENGINE…..765
SAFETY RULES FOR STARTING ENGINE…..765
STARTING ENGINE IN COLD WEATHER…..766
OPERATION…..767
CHECKS BEFORE OPERATION…..767
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS…..767
SAFETY RULES FOR TRAVELING…..768
TRAVELING ON SLOPES…..768
OPERATIONS ON SLOPES…..769
PROHIBITED OPERATIONS…..769
OPERATIONS ON SNOW…..771
PARKING MACHINE…..771
TRANSPORTATION…..772
LOADING AND UNLOADING…..772
SHIPPING THE MACHINE…..772
BATTERY…..773
BATTERY HAZARD PREVENTION…..773
STARTING ENGINE WITH BOOSTER CABLES…..774
TOWING…..775
SAFETY RULES FOR TOWING…..775
LIFTING OBJECTS WITH BUCKET…..776
SAFETY RULES FOR LIFTING OBJECTS…..776
SAFETY MAINTENANCE INFORMATION…..777
WARNING TAG…..777
KEEP WORK PLACE CLEAN AND TIDY…..777
APPOINT LEADER WHEN WORKING WITH OTHERS…..777
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE…..778
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING…..778
PROPER TOOLS…..779
ACCUMULATOR…..779
PERSONNEL…..779
ATTACHMENTS…..780
WORK UNDER THE MACHINE…..780
NOISE…..780
WHEN USING HAMMER…..780
WELDING WORKS…..780
REMOVING BATTERY TERMINALS…..781
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION…..781
DO NOT DISASSEMBLE RECOIL SPRINGS…..781
SAFETY RULES FOR HIGH-PRESSURE OIL…..781
PRECAUTION FOR HIGH FUEL PRESSURE…..782
SAFETY HANDLING HIGH-PRESSURE HOSES…..782
PRECAUTION FOR HIGH VOLTAGE…..782
WASTE MATERIALS…..783
AIR CONDITIONER MAINTENANCE…..783
COMPRESSED AIR…..783
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…..783
OPERATION…..784
MACHINE VIEW ILLUSTRATIONS…..785
OVERALL MACHINE VIEW…..785
CONTROLS AND GAUGES…..786
DETAILED CONTROLS AND GAUGES…..787
MONITORING SYSTEM…..787
SWITCHES…..802
CONTROL LEVERS AND PEDALS…..808
SUN ROOF…..811
WINDSHIELD…..812
EMERGENCY EXIT FROM OPERATOR'S CAB…..815
DOOR LOCK…..815
CAP WITH LOCK…..815
HOT AND COOL BOX…..817
LUGGAGE BOX…..817
ASHTRAY…..817
AIR CONDITIONER CONTROLS…..818
RADIO…..824
AUXILIARY ELECTRIC POWER…..829
FUSE…..829
CIRCUIT BREAKER…..830
CONTROLLERS…..831
TOOL BOX…..831
GREASE PUMP…..832
ACCUMULATOR…..835
MACHINE OPERATIONS AND CONTROLS…..836
BEFORE STARTING ENGINE…..836
STARTING ENGINE…..853
AFTER STARTING ENGINE…..857
STOPPING THE ENGINE…..863
MACHINE OPERATION…..864
STEERING THE MACHINE…..868
SWINGING…..870
WORK EQUIPMENT CONTROLS AND OPERATIONS…..871
WORKING MODE…..872
PROHIBITED OPERATIONS…..873
GENERAL OPERATION INFORMATION…..875
TRAVELING ON SLOPES…..876
ESCAPE FROM MUD…..878
RECOMMENDED APPLICATIONS…..879
BUCKET REPLACEMENT…..880
PARKING MACHINE…..882
CHECK AFTER SHUT OFF ENGINE…..884
MACHINE INSPECTION AFTER DAILY WORK…..884
LOCKING…..884
TRANSPORTATION…..885
PRECAUTIONS FOR TRANSPORTATION…..885
LIFTING MACHINE…..886
SHIPPING MACHINE INFORMATION…..887
TRANSPORTATION POSTURE…..888
PROCEDURE FOR INCREASING OR REDUCING TRACK FRAME GAUGE…..893
COLD WEATHER OPERATION…..895
COLD WEATHER OPERATION INFORMATION…..895
AFTER DAILY WORK COMPLETION…..897
AFTER COLD WEATHER SEASON…..897
LONG TERM STORAGE…..898
BEFORE STORAGE…..898
DURING STORAGE…..898
AFTER STORAGE…..898
STARTING MACHINE AFTER LONG-TERM STORAGE…..899
TROUBLES AND ACTIONS…..900
RUNNING OUT OF FUEL…..900
PHENOMENA THAT ARE NOT FAILURES…..902
TOWING THE MACHINE…..903
SEVERE JOB CONDITION…..903
DISCHARGED BATTERY…..904
OTHER TROUBLE…..908
MAINTENANCE…..913
MAINTENANCE INFORMATION…..914
LUBRICANTS, COOLANT AND FILTERS…..916
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…..916
ELECTRIC SYSTEM MAINTENANCE…..918
WEAR PARTS…..919
WEAR PARTS LIST…..919
LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS…..920
PROPER SELECTION…..920
TIGHTENING TORQUE SPECIFICATIONS…..924
TIGHTENING TORQUE LIST…..924
SAFETY CRITICAL PARTS…..925
SAFETY CRITICAL PARTS LIST…..926
MAINTENANCE SCHEDULE…..927
MAINTENANCE SCHEDULE CHART…..927
MAINTENANCE PROCEDURE…..929
INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS)…..929
INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)…..929
WHEN REQUIRED…..930
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT…..930
CLEAN INSIDE OF COOLING SYSTEM…..935
CHECK AND TIGHTEN TRACK SHOE BOLTS…..938
CHECK AND ADJUST TRACK TENSION…..939
CHECK ELECTRICAL INTAKE AIR HEATER…..940
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)…..941
ADJUST BUCKET CLEARANCE…..942
REPLACE OF FAN BELT AND ADJUSTMENT OF AUTO TENSIONER…..943
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…..944
CHECK AND ADJUST AIR CONDITIONER…..945
CLEAN LINE FILTER, REMOVE DIRT…..946
BLEEDING AIR FROM HYDRAULIC SYSTEM…..947
METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT…..950
CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (CONTROL CIRCUIT)…..951
CHECK BEFORE STARTING…..952
EVERY 10 HOURS MAINTENANCE…..953
LUBRICATING…..953
EVERY 100 HOURS MAINTENANCE…..956
LUBRICATING SWING CIRCLE…..956
DRAIN WATER AND SEDIMENT FROM FUEL TANK…..956
EVERY 250 HOURS MAINTENANCE…..957
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…..957
CHECK LEVEL OF BATTERY ELECTROLYTE…..958
CHECK, CLEAN FUEL TANK STRAINER…..961
CHECK AND TIGHTEN TRACK FRAME AND AXLE CONNECTING BOLTS…..961
CHECK ALTERNATOR DRIVE BELT TENSION, ADJUST…..962
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER)…..963
EVERY 500 HOURS MAINTENANCE…..964
REPLACE FUEL FILTER CARTRIDGE…..964
CHECK SWING PINION GREASE LEVEL, ADD GREASE…..966
CLEAN HYDRAULIC TANK STRAINER…..967
REPLACE HYDRAULIC OIL FILTER ELEMENT…..968
CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, AFTER COOLER FINS, FUEL COOLER FINS AND CONDENSER FINS (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER)…..969
CLEAN FRESH/RECIRC AIR FILTERS OF AIR CONDITIONER (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER)…..970
REPLACE PILOT FILTER ELEMENT…..971
CLEAN STRAINER OF P.T.O LUBRICATING OIL FILTER…..972
CHECK FAN BELT…..972
REPLACE DRAIN FILTER CARTRIDGE…..973
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE…..974
EVERY 1000 HOURS MAINTENANCE…..976
CHANGE OIL IN SWING MACHINERY CASE…..976
CHANGE OIL IN P.T.O CASE…..978
CHECK ALL TIGHTENING PARTS OF TURBOCHARGER…..978
CHECK PLAY TURBOCHARGER ROTOR…..978
REPLACE CORROSION RESISTOR CARTRIDGE…..979
LUBRICATING FAN PULLEY ASSEMBLY, TENSION PULLEY ASSEMBLY…..979
REPLACE HYDRAULIC TANK BREATHER FILTER ELEMENT…..980
CHECK WELDED STRUCTURE…..981
CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (FOR BREAKER)…..983
EVERY 2000 HOURS MAINTENANCE…..984
CHANGE OIL IN FINAL DRIVE CASE…..984
CHECK INJECTOR…..984
CLEAN ENGINE BREATHER…..985
CLEAN, CHECK TURBOCHARGER…..985
CHECK ALTERNATOR, STARTING MOTOR…..985
CHECK ENGINE VALVE CLEARANCE, ADJUST…..985
EVERY 4000 HOURS MAINTENANCE…..986
CHECK WATER PUMP…..986
CHECK VIBRATION DAMPER…..986
CHECK FAN PULLEY AND TENSION PULLEY…..986
CHECK FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER…..986
CHECK FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER…..988
EVERY 5000 HOURS MAINTENANCE…..989
CHANGE OIL IN HYDRAULIC TANK…..989
EVERY 8000 HOURS MAINTENANCE…..990
REPLACE HIGH-PRESSURE PIPING CLAMP…..990
REPLACE FUEL SPRAY PREVENTION CAP…..990
SPECIFICATIONS…..991
SPECIFICATIONS…..992
ATTACHMENTS, OPTIONS…..994
GENERAL PRECAUTIONS FOR SAFETY…..995
PRECAUTIONS WHEN SELECTING…..995
READ THE INSTRUCTION MANUAL THOROUGHLY…..995
PRECAUTIONS WHEN REMOVING OR INSTALLING…..995
PRECAUTIONS WHEN USING…..995
ATTACHMENT GUIDE…..996
COMBINATIONS OF WORK EQUIPMENT…..996
LOADING SHOVEL…..999
EXPLANATION OF COMPONENTS…..1000
SWITCHES…..1000
OPERATIONS…..1002
OPERATION OF WORK EQUIPMENT…..1002
PRECAUTIONS DURING OPERATION…..1004
EXCAVATOR WORK…..1008
PRECAUTIONS WHEN DISASSEMBLING MACHINE…..1009
RELEASING PRESSURE…..1009
TRANSPORTATION…..1010
MACHINE CONFIGURATION FOR TRANSPORT…..1010
WEAR PARTS…..1011
WEAR PARTS LIST…..1011
MAINTENANCE…..1012
CHECK BEFORE STARTING…..1012
EVERY 10 HOURS MAINTENANCE…..1014
EVERY 5000 HOURS MAINTENANCE…..1016
SPECIFICATION…..1018
COMBINATION OF WORK EQUIPMENT …..1019
COMBINATION OF WORK EQUIPMENT …..1019
INDEX…..1021
SEAM053403T – Hydraulic Excavator GALEO PC750-7, PC750LC-7, PC750SE-7, PC800-7, PC800SE-7 Operation & Maintenance Manual…..1024
COVER…..1024
FOREWORD…..1025
FOREWORD…..1026
SAFETY INFORMATION…..1029
INTRODUCTION…..1031
DIRECTIONS OF MACHINE…..1031
BREAKING-IN THE NEW MACHINE…..1031
PRODUCT INFORMATION…..1032
MACHINE SERIAL NUMBER PLATE AND ITS LOCATION…..1032
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION …..1032
SERVICE METER LOCATION …..1033
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…..1033
CONTENTS…..1034
SAFETY…..1038
SAFETY INFORMATION…..1039
SAFETY LABELS…..1041
LOCATION OF SAFETY LABELS…..1042
SAFETY LABELS…..1043
SAFETY INFORMATION…..1049
SAFETY RULES…..1049
IF ABNORMALITIES ARE FOUND…..1049
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS…..1049
FIRE EXTINGUISHER AND FIRST AID KIT…..1049
SAFETY EQUIPMENT…..1049
KEEP MACHINE CLEAN…..1050
KEEP OPERATOR'S COMPARTMENT CLEAN…..1050
LEAVING OPERATOR'S SEAT WITH LOCK…..1050
HANDRAILS AND STEPS…..1051
MOUNTING AND DISMOUNTING…..1051
NO PERSONS ON ATTACHMENTS…..1051
BURN PREVENTION…..1052
FIRE PREVENTION AND EXPLOSION PREVENTION…..1052
ACTION IF FIRE OCCURS…..1053
WINDSHIELD WASHER FLUID…..1053
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION…..1053
ATTACHMENT INSTALLATION…..1054
ATTACHMENT COMBINATIONS…..1054
CAB WINDOW GLASSES…..1054
UNAUTHORIZED MODIFICATIONS…..1054
SAFETY AT JOBSITE…..1054
WORKING ON LOOSE GROUND…..1055
DISTANCE TO HIGH VOLTAGE CABLES…..1055
ENSURE GOOD VISIBILITY…..1055
VENTILATION FOR ENCLOSED AREA…..1056
SIGNALMAN'S SIGNAL AND SIGNS…..1056
EMERGENCY EXIT FROM OPERATOR'S CAB…..1056
ASBESTOS DUST HAZARD PREVENTION…..1056
SAFETY MACHINE OPERATION…..1057
STARTING ENGINE…..1057
CHECKS BEFORE STARTING ENGINE…..1057
SAFETY RULES FOR STARTING ENGINE…..1057
STARTING ENGINE IN COLD WEATHER…..1058
OPERATION…..1059
CHECKS BEFORE OPERATION…..1059
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS…..1059
SAFETY RULES FOR TRAVELING…..1060
TRAVELING ON SLOPES…..1060
OPERATIONS ON SLOPES…..1061
PROHIBITED OPERATIONS…..1061
OPERATIONS ON SNOW…..1063
PARKING MACHINE…..1064
TRANSPORTATION…..1065
LOADING AND UNLOADING …..1065
SHIPPING THE MACHINE…..1065
BATTERY…..1066
BATTERY HAZARD PREVENTION…..1066
STARTING ENGINE WITH BOOSTER CABLES…..1067
TOWING…..1068
SAFETY RULES FOR TOWING…..1068
LIFTING OBJECTS WITH BUCKET…..1069
SAFETY RULES FOR LIFTING OBJECTS…..1069
SAFETY MAINTENANCE INFORMATION…..1070
WARNING TAG…..1070
KEEP WORK PLACE CLEAN AND TIDY…..1070
APPOINT LEADER WHEN WORKING WITH OTHERS…..1070
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE…..1071
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING…..1072
PROPER TOOLS…..1072
ACCUMULATOR…..1073
PERSONNEL…..1073
ATTACHMENTS…..1073
WORK UNDER THE MACHINE…..1073
NOISE…..1073
WHEN USING HAMMER…..1074
WELDING WORKS…..1074
REMOVING BATTERY TERMINALS…..1074
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION…..1074
DO NOT DISASSEMBLE RECOIL SPRINGS…..1074
SAFETY RULES FOR HIGH-PRESSURE OIL…..1075
PRECAUTION FOR HIGH FUEL PRESSURE…..1075
SAFETY HANDLING HIGH-PRESSURE HOSES…..1075
PRECAUTION FOR HIGH VOLTAGE…..1075
WASTE MATERIALS…..1076
AIR CONDITIONER MAINTENANCE…..1076
COMPRESSED AIR…..1076
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…..1076
OPERATION…..1078
MACHINE VIEW ILLUSTRATIONS…..1079
OVERALL MACHINE VIEW …..1079
CONTROLS AND GAUGES …..1080
DETAILED CONTROLS AND GAUGES …..1082
MONITORING SYSTEM…..1082
SWITCHES…..1105
CONTROL LEVERS AND PEDALS…..1112
SUN ROOF…..1116
WINDSHIELD…..1117
EMERGENCY EXIT FROM OPERATOR'S CAB…..1122
DOOR LOCK…..1122
CAP WITH LOCK …..1123
HOT AND COOL BOX …..1124
MAGAZINE BOX …..1124
ASHTRAY…..1125
AIR CONDITIONER CONTROLS…..1126
RADIO …..1140
AUXILIARY ELECTRIC POWER…..1144
FUSE…..1145
CIRCUIT BREAKER …..1146
CONTROLLERS…..1147
TOOL BOX…..1147
GREASE PUMP…..1148
ACCUMULATOR…..1151
MACHINE OPERATIONS AND CONTROLS…..1152
BEFORE STARTING ENGINE…..1152
STARTING ENGINE…..1171
AFTER STARTING ENGINE…..1176
STOPPING THE ENGINE…..1184
MACHINE OPERATION…..1185
STEERING THE MACHINE…..1189
SWINGING…..1191
WORK EQUIPMENT CONTROLS AND OPERATIONS…..1192
WORKING MODE…..1194
PROHIBITED OPERATIONS…..1195
GENERAL OPERATION INFORMATION…..1197
TRAVELING ON SLOPES…..1199
ESCAPE FROM MUD…..1201
RECOMMENDED APPLICATIONS…..1202
BUCKET REPLACEMENT…..1203
PARKING MACHINE…..1205
CHECK AFTER SHUT OFF ENGINE…..1206
LOCKING…..1207
TRANSPORTATION…..1208
PRECAUTIONS FOR TRANSPORTATION …..1208
LIFTING MACHINE…..1208
SHIPPING MACHINE INFORMATION …..1210
TRANSPORTATION POSTURE…..1211
PROCEDURE FOR INCREASING OR REDUCING TRACK FRAME GAUGE…..1217
COLD WEATHER OPERATION…..1219
COLD WEATHER OPERATION INFORMATION…..1219
AFTER DAILY WORK COMPLETION…..1221
AFTER COLD WEATHER SEASON…..1221
LONG TERM STORAGE…..1222
BEFORE STORAGE…..1222
DURING STORAGE…..1222
AFTER STORAGE…..1222
STARTING MACHINE AFTER LONG-TERM STORAGE…..1223
TROUBLES AND ACTIONS…..1224
RUNNING OUT OF FUEL…..1224
PHENOMENA THAT ARE NOT FAILURES…..1226
TOWING THE MACHINE…..1227
SEVERE JOB CONDITION …..1227
DISCHARGED BATTERY…..1228
OTHER TROUBE…..1232
MAINTENANCE…..1238
MAINTENANCE INFORMATION…..1239
OUT OF SERVICE…..1241
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…..1241
ELECTRIC SYSTEM MAINTENANCE…..1243
WEAR PAARTS…..1244
WEAR PARTS LIST…..1245
LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS…..1246
PROPER SELECTION…..1246
TIGHTENING TORQUE SPECIFICATIONS…..1250
TIGHTENING TORQUE LIST…..1250
SAFETY CRITICAL PARTS …..1251
SAFETY CRITICAL PARTS LIST …..1252
MAINTENANCE SCHEDULE…..1253
MAINTENANCE SCHEDULE CHART…..1253
MAINTENANCE PROCEDURE…..1255
INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS)…..1255
INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)…..1255
WHEN REQUIRED…..1256
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT…..1256
CLEAN INSIDE OF COOLING SYSTEM…..1261
CHECK AND TIGHTEN TRACK SHOE BOLTS…..1265
CHECK AND ADJUST TRACK TENSION…..1266
CHECK ELECTRICAL INTAKE AIR HEATER…..1268
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)…..1268
ADJUST BUCKET CLEARANCE…..1269
REPLACE OF FAN BELT AND ADJUSTMENT OF AUTO TENSIONER…..1270
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…..1271
CHECK AND ADJUST AIR CONDITIONER (ONLY MACHINES EQUIPPED WITH AIR CONDITIONER)…..1272
CLEAN LINE FILTER, REMOVE DIRT…..1273
BLEEDING AIR FROM HYDRAULIC SYSTEM…..1274
METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT…..1277
CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (CONTROL CIRCUIT)…..1278
CHECK BEFORE STARTING…..1279
EVERY 10 HOURS MAINTENANCE…..1280
LUBRICATING…..1280
EVERY 100 HOURS MAINTENANCE…..1283
LUBRICATING SWING CIRCLE…..1283
EVERY 250 HOURS MAINTENANCE…..1284
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…..1284
CHECK LEVEL OF BATTERY ELECTROLYTE…..1285
CHECK, CLEAN FUEL TANK STRAINER …..1288
CHECK AND TIGHTEN TRACK FRAME AND AXLE CONNECTING BOLTS …..1288
CHECK ALTERNATOR DRIVE BELT TENSION, ADJUST …..1289
CHECK AIR CONDITIONR COMPRESSOR BELT TENSION, ADJUST (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER)…..1290
EVERY 500 HOURS MAINTENANCE…..1291
REPLACE FUEL FILTER CARTRIDGE …..1291
REPLACEMENT OF ADDITION FUEL FILTER CARTRIDGE (IF QUIPPED)…..1292
CHECK SWING PINION GREASE LEVEL, ADD GREASE …..1294
CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, AFTER COOLER FINS, FUEL COOLER FINS, AND CONDENSER FINS (ONLY MACHINES EQUIPPED WITH AIR CONDITIONER)…..1295
CLEAN FRESH/RECIRC AIR FILTERS OF AIR CONDITIONER (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER)…..1296
REPLACE PILOT FILTER ELEMENT …..1298
CLEAN STRAINER OF P.T.O LUBRICATING OIL FILTER…..1299
CHECK FAN BELT …..1299
REPLACE DRAIN FILTER CARTRIDGE …..1300
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL ILTER CARTRIDGE…..1301
EVERY 1000 HOURS MAINTENANCE…..1303
REPLACE BREATHER ELEMENT IN HYDRAULIC TANK …..1303
REPLACE HYDRAULIC OIL FILTER ELEMENT …..1304
CHANGE OIL IN SWING MACHINERY CASE…..1305
CHANGE OIL IN P.T.O CASE …..1307
CHECK ALL TIGHTENING PARTS OF TURBOCHARGER…..1307
CHECK PLAY OF TURBOCHARGER ROTOR…..1307
REPLACE CORROSION RESISTOR CARTRIDGE…..1308
LUBRICATING FAN PULLEY ASSEMBLY, TENSION PULLEY ASSEMBLY …..1308
CHECK WELDED STRUCTURE…..1309
CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (FOR BREAKER) …..1311
EVERY 2000 HOURS MAINTENANCE…..1312
CHANGE OIL IN FINAL DRIVE CASE…..1312
CHECK INJECTOR…..1312
CLEAN HYDRAULIC TANK STRAINER…..1313
CLEAN ENGINE BREATHER…..1314
CLEAN, CHECK TURBOCHARGER…..1314
CHECK ALTERNATOR, STARTING MOTOR …..1314
CHECK ENGINE VALVE CLEARANCE, ADJUST…..1314
EVERY 4000 HOURS MAINTENANCE…..1315
CHECK WATER PUMP …..1315
CHECK VIBRSTION DAMPER …..1315
CHECK FAN PULLEY AND TENSION PLLEY …..1315
CHECK FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER…..1315
REPLACE INJECTOR NOZZLE ASSEMBLY…..1316
CHECK FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER…..1317
EVERY 5000 HOURS MAINTENANCE…..1318
CHANGE OIL IN HYDRAULIC TANK…..1318
EVERY 8000 HOURS MAINTENANCE…..1319
REPLACE HIGH-PRESSURE PIPING CLAMP …..1319
REPLACE FUEL SPRAY PREVENTION CAP…..1319
SPECIFICATIONS…..1320
SPECIFICATIONS…..1321
ATTACHMENTS, OPTIONS…..1323
GENERAL PRECAUTIONS FOR SAFETY…..1324
PRECAUTIONS WHEN SELECTING …..1324
READ THE INSTRUCTION MANUAL THOROUGHLY …..1324
PRECAUTIONS WHEN REMOVING OR INSTALLING …..1324
PRECAUTIONS WHEN USING …..1324
ATTACHMENT GUIDE …..1325
COMBINATIONS OF WORK EQUIPMENT…..1325
LOADING SHOVEL…..1328
EXPLANATION O COMPONENTS …..1329
SWITCHES…..1329
FUSE…..1332
OPERATIONS…..1333
OPERATION OF WORK EQUIPMENT…..1333
PRECAUTIONS DURING OPERATION …..1335
EXCAVATOR WORK…..1339
PRECAUTIONS WHEN DISASSEMBLING MACHINE …..1340
RELEASING PRESSURE …..1340
TRANSPORTATION …..1341
MACHINE CONFIGURATION FOR TRANSPORT …..1341
WEAR PARTS …..1342
WEAR PARTS LIST …..1342
MAINTENANCE …..1343
CHECK BEFORE STARTING …..1343
EVERY 10 HOURS MAINTENANCE …..1345
EVERY 5000 HOURS MAINTENANCE…..1346
SPECIFICATION …..1348
COMBINATION OF WORK EQUIPMENT…..1349
COMBINATION OF WORK EQUIPMENT…..1349
INDEX…..1351
SEAWD01803 – Hydraulic Excavator PC750-6, PC750LC-6, PC750SE-6, PC800-6, PC800SE-6 Field Assembly Instruction…..1354
COVER…..1354
CONTENTS…..1356
SPECIFICATIONS…..1357
FIELD ASSEMBLING…..1358
ASSEMBLING PROCEDURES, APPLICABLE EQUIPMENT AND SCHEDULE…..1360
TRANSPORTATION…..1362
PACKING STYLE FOR TRANSPORTATION…..1362
LIST OF TOOLS FOR FIELD ASSEMBLING…..1368
STANDARD TIGHTENING TORQUE…..1369
A. ASSEMBLY OF BASE MACHINE…..1373
A-1 FITTING OF LEFT AND RIGHT TRACK FRAMES…..1374
A-2 ARRANGEMENT OF TRAVEL PIPE…..1378
A-3 INSTALLATION OF FOG…..1381
A-4 INSTALLATION OF RADIATOR COVER…..1382
A-5 INSTALLATION OF REAR VIEW MIRROR…..1383
A-6 INSTALLATION OF HANDRAIL…..1387
A-7 INSTALLATION OF STEP…..1390
A-8 INSTALLATION OF LEFT SIDE STEP…..1391
A-9 SETTING OF MUFFLER TAIL TUBE…..1392
A-10 STICKING SHEET (TO COUNTERWEIGHT)…..1393
A-11 INSTALLATION OF COUNTERWEIGHT…..1394
A-12 INSTALLATION OF RADIO ANTENNA…..1395
A-13 INSTALLATION OF CAB TOP LIGHT…..1397
A-14 SETTING OF TRAVEL PIPE COVER…..1400
A-15 ADJUSTMENT OF TRACK TENSION…..1401
A-15A EXTENSION OF TRACK FRAME GAUGE (ONLY WHEN 3-SPLIT PACKAGES ARE TRANSPORTED)…..1404
A-16 INSPECTION OF OIL AMOUNT AND WATER AMOUNT…..1407
B. ASSEMBLING OF WORK EQUIPMENT…..1409
B-1 BOOM FOOT PIN, AND BOOM CYLINDER FOOT PIN…..1410
B-2 BOOM ASSEMBLY…..1411
B-3 RELIEVING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT…..1412
B-4 INSTALLATION OF BOOM CYLINDER FOOT…..1413
B-5 ARRANGEMENT OF BOOM CYLINDER HOSE…..1414
B-6 INSTALLATION OF BOOM CYLINDER…..1415
B-7 INSTALLATION OF ARM CYLINDER…..1416
B-8 ARRANGEMENT OF ARM CYLINDER HOSE…..1417
B-9 INSTALLATION OF ARM ASSEMBLY…..1418
B-10 ARRANGEMENT OF HOSE BETWEEN BOOM AND BUCKET CYLINDER…..1420
B-11 INSTALLATION OF BUCKET ASSEMBLY…..1421
B-12 LUBRICATION PIPING TO WORK EQUIPMENT…..1422
B-13 AIR BLEEDING FROM CYLINDER…..1423
B-14 WIRING OF WORK EQUIPMENT…..1424
B-15 GREASING OF ASSEMBLED WORK EQUIPMENT…..1425
M. PROCEDURE FOR INSPECTION AND MAINTENANCE AFTER COMPLETION OF ASSEMBLY…..1427
M-1 INSPECTION OF OIL LEVEL IN HYDRAULIC TANK AND REFILL…..1428
M-2 REPLACEMENT OF RETURN FILTER (STANDARD FILTER TO FLUSHING FILTER)…..1430
M-3 FLUSHING OF HYDRAULIC CIRCUIT…..1434
C. ASSEMBLING OF WORK EQUIPMENT OF LOADING SHOVEL…..1437
CONTENTS…..1437
C-1 RELEASEING RESIDUAL PRESSURE IN HYDRAULIC CIRCUIT…..1438
C-2 PULLING OUT BOOM FOOT PIN AND BOOM CYLINDER FOOT PIN…..1439
C-3 INSTALLATION OF BOOM AND ARM ASSEMBLY…..1440
C-4 INSTALLATION OF FLUSHING PIPING BETWEEN CHASSIS AND BOOM…..1441
C-5 INSTALLATION OF FLUSHING PIPING FOR BOOM CYLINDER AND ARM CYLINDER…..1442
C-6 INSTALLATION OF FLUSHING PIPING FOR BUCKET CYLINDER…..1443
C-7 INSTALLATION OF FLUSHING PIPING FOR BOTTOM DUMP CYLINDER…..1444
C-8 INSTALLATION OF BOOM CYLINDER…..1446
C-9 ISTALLATION OF BOOM CYLINDER FOOT…..1447
C-10 INSTALLATION OF BOOM CYLINDER HOSES…..1448
C-11 INSTALLATION OF BOOM CYLINDER ROD PIN…..1449
C-12 INSTALLATION OF ARM CYLINDER HOSES…..1450
C-13 INSTALLATION OF BUCKET CYLINDER…..1451
C-14 INSTALLATION OF BUCKET CYLINDER HOSE…..1452
C-15 INSTALLATION OF CONNECTING HOSES BETWEEN CHASSIS AND BOOM TOP…..1453
C-16 INSTALLATION OF BOTTOM DUMP CYLINDER HOSES…..1454
C-17 INSTALLATION OF BUCKET ASSEMBLY…..1456
C-18 INSTALLATION OF WORKING LAMPS…..1459
C-19 INSTALLATION OF WORK EQUIPMENT FREASE PIPING …..1460
C-20 GREASING AFTER ASSEMBLING OF WORK EQUIPMENT…..1462
C-21 BLEEDING AIR FROM WORK EQUIPMENT CIRCUIT…..1463
C-22 FLUSHING OF WORK EQUIPMENT PIPING…..1464
C-23 CHECKING OIL LEVEL IN HYDRAULIC TANK AND ADDING OIL…..1466
FIELD ASSEMBLY INSPECTION REPORT…..1467
SEN00373-12 – Hydraulic Excavator PC800-8, PC800LC-8, PC800SE-8, PC850-8, PC850SE-8 Shop Manual…..1519
COVER…..1519
00 Index and foreword…..0
Index…..1521
Composition of shop manual…..1522
Table of contents…..1524
Foreword and general information…..1535
Safety notice…..1536
How to read the shop manual…..1541
Explanation of terms for maintenance standard…..1543
Handling of electric equipment and hydraulic component…..1545
Handling of connectors newly used for engines…..1554
How to read electric wire code…..1557
Precautions when carrying out operation…..1560
Method of disassembling and connecting push-pull type coupler…..1563
Standard tightening torque table…..1566
Conversion table…..1570
01 Specification…..0
Specification and technical data…..1577
Specification and technical data…..1578
Specification drawings…..1578
Working range drawing…..1580
Specifications…..1582
Weight table…..1600
Table of fuel, coolant and lubricants…..1606
10 Structure, function and maintenance standard…..0
Engine and cooling system…..1609
Engine and cooling system…..1610
Coupling…..1610
Coupling lubrication system…..1611
Radiator, oil cooler…..1612
Power train…..1615
Power train…..1616
Power train…..1616
Swing machinery…..1618
Swing circle…..1620
Final drive…..1622
Sprocket…..1624
Undercarriage and frame…..1627
Undercarriage and frame…..1628
Track frame and recoil spring…..1628
Idler…..1630
Carrier roller…..1632
Track roller…..1634
Track shoe…..1636
Double shoe…..1639
Hydraulic system, Part 1…..1641
Hydraulic system, Part 1…..1642
Hydraulic piping drawing…..1642
Hydraulic tank, hydraulic filter…..1644
Hydraulic pump…..1646
Cooling fan pump…..1666
Cooling fan motor…..1674
Hydraulic system, Part 2…..1681
Hydraulic system, Part 2…..1684
Motor grease pump…..1684
Return oil filter…..1685
Line oil filter…..1686
Drain oil filter…..1687
L.H. 5-Spool control valve…..1688
R.H. 4-Spool control valve…..1694
Straight-travel valve…..1700
Swing motor…..1703
Center swivel joint…..1708
Travel motor…..1709
PPC accumulator…..1719
Work equipment, swing PPC valve…..1720
Travel PPC valve…..1726
Solenoid valve…..1730
Quick return valve…..1736
Hydraulic cylinder…..1738
Work equipment…..1745
Work equipment…..1746
Work equipment…..1746
Dimensions of work equipment…..1752
Cab and its attachments…..1757
Cab and its attachments…..1758
Air conditioner piping…..1758
Electrical system…..1761
Engine control…..1762
Electric control system…..1771
Monitor system…..1805
Sensors…..1823
KOMTRAX system…..1827
20 Standard value table…..0
Standard service value table…..1831
Standard service value table…..1832
Standard service value table for engine…..1832
Standard service value table for chassis…..1833
30 Testing and adjusting…..0
Testing and adjusting, Part 1…..1845
Testing and adjusting, Part 1…..1846
Tools for testing, adjusting and troubleshooting…..1846
Measuring engine speed…..1849
Measuring intake air pressure (Boost pressure)…..1850
Measuring exhaust gas temperature…..1851
Measuring exhaust gas color…..1852
Adjusting valve clearance…..1853
Measuring compression pressure…..1854
Measuring blow-by pressure…..1855
Measuring engine oil pressure…..1856
Measuring EGR valve and bypass valve drive pressure…..1857
Handling of fuel system equipment…..1858
Remaining pressure relief from fuel system equipment…..1858
Measuring fuel pressure…..1859
Testing fuel return rate and leakage…..1860
Bleeding air from fuel circuit…..1862
Testing fuel system for leakage…..1864
Testing and adjusting alternator belt tension…..1865
Testing and adjusting air conditioner compressor belt…..1866
Testing and adjusting, Part 2…..1869
Testing and adjusting, Part 2…..1870
Inspection of swing circle bearing clearance…..1870
Testing and adjusting track shoe tension…..1871
Testing and adjusting work equipment, swing, and travel circuit oil pressures…..1872
Testing and adjusting control circuit pressure (output pressure of self pressure reducing valve)…..1878
Testing and adjusting main pump control pressure…..1880
Testing and adjusting, Part 3…..1887
Testing and adjusting, Part 3…..1888
Measuring PPC valve output pressure…..1888
Measuring outlet pressures of solenoid valve, swing PPC shuttle valve, and swing priority selector valve…..1892
Adjusting work equipment, swing PPC valve…..1896
Testing and adjusting travel deviation…..1897
Inspection of locations of hydraulic drift of work equipment…..1899
Measuring fan speed…..1900
Measuring fan circuit oil pressure…..1900
Measuring fan pump EPC current…..1901
Measuring fan pump EPC solenoid valve output pressure…..1902
Measuring oil leakage…..1903
Release of residual pressure from hydraulic circuit…..1907
Bleeding air from each part…..1908
Inspection procedures for diode…..1911
Adjusting mirrors…..1912
Testing and adjusting, Part 4…..1915
Testing and adjusting, Part 4…..1916
Special function of machine monitor…..1916
Handling controller voltage circuit…..1949
Testing and adjusting, Part 5…..1951
Testing and adjusting, Part 5…..1952
Procedure for turning on KOMTRAX terminal…..1952
KOMTRAX terminal lamp indications…..1955
Preparation work for troubleshooting electrical system…..1958
40 Troubleshooting…..0
Failure code table and fuse locations…..1971
Failure code table and fuse locations…..1972
Failure codes table…..1972
Fuse locations…..1976
General information on troubleshooting…..1979
General information on troubleshooting…..1980
Points to remember when troubleshooting…..1980
Sequence of events in troubleshooting…..1981
Checks before troubleshooting…..1982
Classification and troubleshooting steps…..1983
Information in troubleshooting table…..1984
Failure-looking phenomenon and troubleshooting No…..1986
Connection table for connector pin numbers…..1989
T- branch box and T- branch adapter table…..2025
Troubleshooting by failure code (Display of code), Part 1…..2029
Troubleshooting by failure code (Display of code), Part 1…..2032
Failure code [AA10NX] Aircleaner Clogging…..2032
Failure code [AB00KE] Charge Voltage Low…..2034
Failure code [B@BAZG] Eng. Oil Press. Low…..2036
Failure code [B@BAZK] Eng. Oil Level Low…..2037
Failure code [B@BCNS] Eng. Water Overheat…..2038
Failure code [B@BCZK] Eng. Water Lvl Low…..2040
Failure code [B@HANS] Hydr. Oil Overheat…..2042
Failure code [CA111] ECM Critical Internal Failure…..2044
Failure code [CA115] Eng Ne and Bkup Speed Sens Error…..2046
Failure code [CA122] Chg Air Press Sensor High Error…..2048
Failure code [CA123] Chg Air Press Sensor Low Error…..2050
Failure code [CA131] Throttle Sensor High Error…..2052
Failure code [CA132] Throttle Sensor Low Error…..2054
Failure code [CA135] Eng Oil Press Sensor High Error…..2056
Failure code [CA141] Eng Oil Press Sensor Low Error…..2058
Failure code [CA144] Coolant Temp Sens High Error…..2060
Failure code [CA145] Coolant Temp Sens Low Error…..2062
Failure code [CA153] Chg Air Temp Sensor High Error…..2064
Failure code [CA154] Chg Air Temp Sensor Low Error…..2066
Failure code [CA187] Sens Supply 2 Volt Low Error…..2066
Failure code [CA221] Ambient Press Sens High Error…..2068
Failure code [CA222] Ambient Press Sens Low Error…..2070
Failure code [CA227] Sens Supply 2 Volt High Error…..2072
Failure code [CA234] Eng Overspeed…..2074
Failure code [CA238] Ne Speed Sens Supply Volt Error…..2076
Failure code [CA263] Fuel Temp Sensor High Error…..2078
Failure code [CA265] Fuel Temp Sensor Low Error…..2080
Failure code [CA271] IMV/PCV1 Short Error…..2081
Failure code [CA272] IMV/PCV1 Open Error…..2082
Failure code [CA273] PCV2 Short Error…..2083
Failure code [CA274] PCV2 Open Error…..2084
Failure code [CA322] Inj #1 (L#1) Open/Short Error…..2085
Failure code [CA323] Inj #5 (L#5) Open/Short Error…..2086
Failure code [CA324] Inj #3 (L#3) Open/Short Error…..2088
Failure code [CA325] Inj #6 (L#6) Open/Short Error…..2090
Failure code [CA331] Inj #2 (L#2) Open/Short Error…..2092
Failure code [CA332] Inj #4 (L#4) Open/Short Error…..2094
Failure code [CA342] Calibration Code Incompatibility…..2095
Failure code [CA351] Injectors Drive Circuit Error…..2096
Failure code [CA352] Sens Supply 1 Volt Low Error…..2098
Failure code [CA386] Sens Supply 1 Volt High Error…..2100
Troubleshooting by failure code (Display of code), Part 2…..2103
Troubleshooting by failure code (Display of code), Part 2…..2105
Failure code [CA441] Battery Voltage Low Error…..2105
Failure code [CA442] Battery Voltage High Error…..2105
Failure code [CA449] Rail Press Very High Error…..2106
Failure code [CA451] Rail Press Sensor High Error…..2108
Failure code [CA452] Rail Press Sensor Low Error…..2110
Failure code [CA553] Rail Press High Error…..2110
Failure code [CA554] Rail Press Sensor In Range Error…..2111
Failure code [CA559] Rail Press Low Error…..2112
Failure code [CA689] Eng Ne Speed Sensor Error…..2116
Failure code [CA731] Eng Bkup Speed Sens Phase Error…..2118
Failure code [CA757] All Persistent Data Lost Error…..2119
Failure code [CA778] Eng Bkup Speed Sensor Error…..2120
Failure code [CA1228] EGR Valve Servo Error 1…..2122
Failure code [CA1625] EGR Valve Servo Error 2…..2123
Failure code [CA1626] BP Valve Sol Current High Error…..2124
Failure code [CA1627] BP Valve Sol Current Low Error…..2126
Failure code [CA1628] Bypass Valve Servo Error 1…..2127
Failure code [CA1629] Bypass Valve Servo Error 2…..2128
Failure code [CA1631] BP Valve Pos Sens High Error…..2130
Failure code [CA1632] BP Valve Pos Sens Low Error…..2132
Failure code [CA1633] KOMNET Datalink Timeout Error…..2134
Failure code [CA1642] EGR Inter Press Sens Low Error…..2136
Failure code [CA1653] EGR Inter Press Sens High Error…..2138
Failure code [CA2185] Throt Sens Sup Volt High Error…..2140
Failure code [CA2186] Throt Sens Sup Volt Low Error…..2142
Failure code [CA2249] Rail Press Very Low Error…..2143
Failure code [CA2271] EGR Valve Pos Sens High Error…..2144
Failure code [CA2272] EGR Valve Pos Sens Low Error…..2146
Failure code [CA2351] EGR Valve Sol Current High Error…..2148
Failure code [CA2352] EGR Valve Sol Current Low Error…..2150
Failure code [CA2555] Grid Htr Relay Volt Low Error…..2151
Failure code [CA2556] Grid Htr Relay Volt High Error…..2152
Failure code [D110KB] Battery Relay Drive S/C…..2154
Failure code [D163KB] Flash Light Relay S/C…..2156
Failure code [D195KB] Step Light Relay S/C…..2158
Failure code [DA22KK] Pump Solenoid Power Low Error…..2160
Failure code [DA25KP] Press. Sensor Power Abnormality…..2162
Failure code [DA2SKQ] Model Selection Abnormality…..2164
Failure code [DA80MA] Auto. Lub. Abnormal…..2166
Failure code [DA2RMC] Pump Comm. Abnormality…..2168
Failure code [DAFRMC] Monitor Comm. Abnormality…..2170
Failure code [DGE5KY] Ambi. Temp. Sensor S/C…..2172
Failure code [DGH2KB] Hydr. Oil Temp. Sensor S/C…..2174
Troubleshooting by failure code (Display of code), Part 3…..2177
Troubleshooting by failure code (Display of code), Part 3…..2180
Failure code [DH25KA] L Jet Sensor Disc…..2180
Failure code [DH25KB] L Jet Sensor S/C…..2182
Failure code [DH26KA] R Jet Sensor Disc…..2184
Failure code [DH26KB] R Jet Sensor S/C…..2186
Failure code [DHPEKA] F Pump P. Sensor Disc…..2188
Failure code [DHPEKB] F Pump P. Sensor S/C…..2190
Failure code [DHPFKA] R Pump P. Sensor Disc…..2192
Failure code [DHPFKB] R Pump P. Sensor S/C…..2194
Failure code [DV20KB] Travel Alarm S/C…..2196
Failure code [DW41KA] Swing Priority Sol. Disc…..2198
Failure code [DW41KB] Swing Priority Sol. S/C…..2200
Failure code [DW43KA] Travel Speed Sol. Disc…..2202
Failure code [DW43KB] Travel Speed Sol. S/C…..2204
Failure code [DW45KA] Swing Brake Sol. Disc…..2206
Failure code [DW45KB] Swing Brake Sol. S/C…..2208
Failure code [DW7BKA] Fan Reverse Sol. Disc…..2210
Failure code [DW7BKB] Fan Reverse Sol. S/C…..2212
Failure code [DW7JKA] Bottom Dump Priority Sol. Disc…..2214
Failure code [DW7JKB] Bottom Dump Priority Sol. S/C…..2216
Failure code [DWK0KA] 2-stage Relief Sol. Disc…..2218
Failure code [DWK0KB] 2-stage Relief Sol. S/C…..2220
Failure code [DX16KA] Fan Pump EPC Sol. Disc…..2222
Failure code [DX16KB] Fan Pump EPC Sol. S/C…..2224
Failure code [DXAAKA] F Pump EPC Sol. Disc…..2226
Failure code [DXAAKB] F Pump EPC Sol. S/C…..2228
Failure code [DXABKA] R Pump EPC Sol. Disc…..2230
Failure code [DXABKB] R Pump EPC Sol. S/C…..2232
Failure code [DY20KA] Wiper Working Abnormality…..2234
Failure code [DY20MA] Wiper Parking Abnormality…..2236
Failure code [DY2CKB] Washer Drive S/C…..2240
Failure code [DY2DKB] Wiper Drive (For) S/C…..2242
Failure code [DY2EKB] Wiper Drive (Rev) S/C…..2246
Troubleshooting of electrical system (E-mode)…..2249
Troubleshooting of electrical system (E-mode)…..2251
Before carrying out troubleshooting of electrical system…..2251
Information contained in troubleshooting table…..2253
E-1 Engine does not start (Engine does not rotate)…..2254
E-2 Preheater does not operate…..2257
E-3 Auto engine warm-up device does not work…..2264
E-4 Auto-decelerator does not operate…..2265
E-5 All work equipment, swing and travel do not move…..2266
E-6 Machine push-up function does not operate normally…..2268
E-7 Boom shockless function does not operate normally…..2270
E-8 Any item is not displayed on machine monitor…..2272
E-9 Part of display on machine monitor is missing…..2273
E-10 Machine monitor displays contents irrelevant to the model…..2273
E-11 Fuel level monitor red lamp lights up while engine is running…..2274
E-12 Engine coolant thermometer does not display normally…..2276
E-13 Hydraulic oil temperature gauge does not display correctly…..2278
E-14 Fuel gauge does not display correctly…..2279
E-15 Swing lock monitor does not display correctly…..2280
E-16 When monitor switch is operated, nothing is displayed…..2282
E-17 Windshield wiper and window washer do not work…..2284
E-18 Boom RAISE is not correctly displayed in monitor function…..2292
E-19 Boom LOWER is not correctly displayed in monitor function…..2293
E-20 Arm IN is not correctly displayed in monitor function…..2294
E-21 Arm OUT is not correctly displayed in monitor function…..2295
E-22 Bucket CURL is not correctly displayed in monitor function…..2296
E-23 Bucket DUMP is not correctly displayed in monitor function…..2297
E-24 SWING is not correctly displayed in monitor function…..2298
E-25 Left travel is not displayed normally in monitoring function…..2300
E-26 Right travel is not displayed normally in monitoring function…..2302
E-27 Service is not correctly displayed in monitor function…..2304
E-28 KOMTRAX system does not operate normally…..2306
E-29 Air conditioner does not work…..2308
E-30 Step light does not light up or go off…..2309
E-31 Electric grease gun does not operate…..2312
E-32 Travel alarm does not sound or does not stop sounding…..2314
Troubleshooting of hydraulic and mechanical system (H-mode)…..2317
Troubleshooting of hydraulic and mechanical system (H-mode)…..2319
Before troubleshooting…..2319
Information in troubleshooting table…..2322
H-1 Speed or power of all work equipment, travel, and swing is low…..2324
H-2 Engine speed lowers remarkably or engine stalls…..2326
H-3 All work equipment, travel, and swing systems do not work…..2328
H-4 Abnormal sound is heard from around pump…..2329
H-5 Boom speed or power is low…..2330
H-6 Speed or power of arm is low…..2332
H-7 Speed or power of bucket is low…..2333
H-8 Boom does not move…..2334
H-9 Arm does not move…..2334
H-10 Bucket does not move…..2334
H-11 Hydraulic drift of work equipment is large…..2335
H-12 Time lag of work equipment is large…..2337
H-13 Heavy lift function does not operate or stop…..2338
H-14 Machine push-up function does not operate or stop…..2338
H-15 Boom shockless function cannot be turned ON or OFF…..2338
H-16 Machine deviates in one direction…..2340
H-17 Machine deviates largely at start…..2342
H-18 Machine deviates largely during compound operation…..2343
H-19 Travel speed or power is low…..2343
H-20 Machine does not travel (only one track)…..2344
H-21 Travel speed does not change…..2345
H-22 Upper structure does not swing…..2346
H-23 Swing speed or acceleration is low…..2348
H-24 Swing speed or acceleration is low during compound operation of swing and work equipment…..2350
H-25 Upper structure overruns excessively when it stops swinging…..2352
H-26 Large shock is made when upper structure stops swinging…..2353
H-27 Large abnormal sound is made when upper structure stops swinging…..2354
H-28 Hydraulic drift of swing is large…..2355
H-29 Fan rotation is abnormal (Fan sound/vibration is abnormally large or fan overheats)…..2356
Troubleshooting of engine (S-mode)…..2359
Troubleshooting of engine (S-mode)…..2361
Method of using troubleshooting chart…..2361
S-1 Starting performance is poor…..2364
S-2 Engine does not start…..2366
S-3 Engine does not pick up smoothly…..2370
S-4 Engine stops during operations…..2371
S-5 Engine does not rotate smoothly…..2372
S-6 Engine lacks output (or lacks power)…..2373
S-7 Exhaust gas color is black (incomplete combustion)…..2374
S-8 Oil consumption is excessive (or exhaust smoke is blue)…..2376
S-9 Oil becomes contaminated quickly…..2377
S-10 Fuel consumption is excessive…..2378
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)…..2379
S-12 Oil pressure drops…..2380
S-13 Oil level rises (Entry of coolant/fuel)…..2382
S-14 Coolant temperature becomes too high (overheating)…..2384
S-15 Abnormal noise is made…..2385
S-16 Vibration is excessive…..2386
50 Disassembly and assembly…..0
General information on disassembly and assembly…..2389
General information on disassembly and assembly…..2390
How to read this manual…..2390
Coating materials list…..2392
Special tools list…..2395
Sketches of special tools…..2402
Engine and cooling system (SAA6D140E-5)…..2409
Engine and cooling system…..2410
Removal and installation of engine, PTO and hydraulic pump assembly…..2410
Removal and installation of cooling assembly…..2418
Removal and installation of aftercooler assembly…..2423
Removal and installation of fuel cooler and air conditioner condenser assembly…..2425
Removal and installation of fan motor assembly…..2427
Removal and installation of fuel tank assembly…..2432
Engine (SAA6D140E-5)…..2435
Engine (SAA6D140E-5)…..2436
Removal and installation of fuel supply pump assembly…..2436
Removal and installation of cylinder head assembly…..2441
Removal and installation of fuel injector assembly…..2457
Removal and installation of engine front seal…..2460
Removal and installation of engine rear seal…..2462
Power train…..2467
Power train…..2468
Removal and installation of PTO (coupling) assembly…..2468
Disassembly and assembly of PTO (coupling) assembly…..2475
Removal and installation of swing motor and swing machinery assembly…..2477
Disassembly and assembly of swing machinery assembly…..2479
Removal and installation of swing circle assembly…..2486
Disassembly and assembly of final drive assembly…..2487
Undercarriage and frame…..2499
Undercarriage and frame…..2500
Removal and installation of track shoe assembly…..2500
Disassembly and assembly of one link in field…..2502
Removal and installation of idler assembly…..2506
Disassembly and assembly of idler assembly…..2507
Disassembly and assembly of idler adjustment cylinder assembly…..2510
Removal and installation of recoil spring assembly…..2511
Disassembly and assembly of recoil spring assembly…..2513
Removal and installation of carrier roller assembly…..2515
Disassembly and assembly of carrier roller assembly…..2516
Removal and installation of track roller assembly…..2519
Disassembly and assembly of track roller assembly…..2520
Removal and installation of revolving frame assembly…..2523
Removal and installation of counterweight assembly…..2525
Removal and installation of counterweight remover assembly…..2526
Hydraulic system…..2531
Hydraulic system…..2532
Removal and installation of hydraulic tank assembly…..2532
Removal and installation of main pump assembly…..2535
Removal and installation of main pump input shaft oil seal…..2542
Removal and installation of cooling fan pump assembly…..2543
Removal and installation of control valve assembly…..2546
Assembly of control valve assembly…..2549
Removal and installation of swing motor assembly…..2555
Removal and installation of center swivel joint assembly…..2557
Disassembly and assembly of center swivel joint assembly…..2559
Removal and installation of travel motor assembly…..2561
Removal and installation of solenoid valve assembly…..2562
Removal and installation of boom damping valve assembly…..2564
Disassembly and assembly of work equipment PPC valve assembly…..2565
Disassembly and assembly of travel PPC valve assembly…..2567
Disassembly and assembly of hydraulic cylinder assembly…..2570
Disassembly and assembly of grease gun assembly…..2576
Work equipment…..2579
Work equipment…..2580
Removal and installation of bucket cylinder assembly…..2580
Removal and installation of arm cylinder assembly…..2584
Removal and installation of boom cylinder assembly…..2588
Removal and installation of bottom dump cylinder assembly…..2592
Removal and installation of bucket assembly…..2593
Removal and installation of arm assembly…..2595
Removal and installation of boom assembly…..2598
Removal and installation of work equipment…..2602
Cab and its attachments…..2607
Cab and its attachments…..2608
Removal and installation of operators cab…..2608
Removal and installation of operators cab glass (stuck glass)…..2611
Removal and installation of front window assembly…..2621
Electrical system…..2627
Electrical system…..2628
Removal and installation of air conditioner unit assembly…..2628
Removal and installation of engine controller assembly…..2630
Removal and installation of monitor assembly…..2632
Removal and installation of pump controller assembly…..2632
Removal and Installation of KOMTRAX terminal assembly…..2633
90 Diagrams and drawings…..0
Hydraulic diagrams and drawings…..2635
Hydraulic circuit diagram…..2636
Electrical diagrams and drawings…..2638
Electrical circuit diagram (1/5)…..2640
Electrical circuit diagram (2/5)…..2641
Electrical circuit diagram (3/5)…..2642
Electrical circuit diagram (4/5)…..2643
Electrical circuit diagram (5/5)…..2644
Connector list and sterogram…..2645
TEN00040-03 – Hydraulic Excavator PC750-7, PC750LC-7, PC750SE-7, PC800-7, PC800SE-7 Operation & Maintenance Manual…..2648
COVER…..2648
FOREWORD…..2649
FOREWORD…..2650
SAFETY INFORMATION…..2651
INTRODUCTION…..2653
DIRECTIONS OF MACHINE…..2653
BREAKING-IN THE NEW MACHINE…..2653
PRODUCT INFORMATION…..2654
MACHINE SERIAL NUMBER PLATE AND ITS LOCATION…..2654
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION…..2654
SERVICE METER LOCATION…..2655
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…..2655
CONTENTS…..2656
SAFETY…..2661
SAFETY…..2662
SAFETY LABELS…..2664
LOCATION OF SAFETY LABELS…..2665
SAFETY LABELS…..2666
GENERAL PRECAUTIONS…..2672
SAFETY MACHINE OPERATION…..2680
STARTING ENGINE…..2680
OPERATION…..2682
TRANSPORTATION…..2688
BATTERY…..2689
TOWING…..2691
LIFTING OBJECTS WITH BUCKET…..2692
SAFETY MAINTENANCE INFORMATION…..2693
OPERATION…..2701
MACHINE VIEW ILLUSTRATIONS…..2702
OVERALL MACHINE VIEW…..2702
CONTROLS AND GAUGES…..2703
DETAILED CONTROLS AND GAUGES…..2705
MONITORING SYSTEM…..2705
SWITCHES…..2728
CONTROL LEVERS AND PEDALS…..2735
SUN ROOF…..2738
WINDSHIELD…..2739
EMERGENCY EXIT FROM OPERATOR'S CAB…..2744
DOOR LOCK…..2744
CAP WITH LOCK…..2745
HOT AND COOL BOX…..2746
MAGAZINE BOX…..2746
ASHTRAY…..2747
AIR CONDITIONER CONTROLS…..2748
RADIO…..2762
AUXILIARY ELECTRIC POWER…..2767
FUSE…..2768
CIRCUIT BREAKER…..2769
CONTROLLER…..2770
TOOL BOX…..2770
GREASE PUMP…..2771
ACCUMULATOR…..2774
MACHINE OPERATIONS AND CONTROLS…..2775
BEFORE STARTING ENGINE…..2775
STARTING ENGINE…..2794
AFTER STARTING ENGINE…..2799
STOPPING THE ENGINE…..2807
MACHINE OPERATION…..2808
STEERING THE MACHINE…..2812
SWINGING…..2814
WORK EQUIPMENT CONTROLS AND OPERATIONS…..2815
WORKING MODE…..2817
PROHIBITED OPERATIONS…..2818
GENERAL OPERATION INFORMATION…..2821
TRAVELING ON SLOPES…..2823
ESCAPE FROM MUD…..2825
RECOMMENDED APPLICATIONS…..2826
BUCKET REPLACEMENT…..2827
PARKING MACHINE…..2829
CHECK AFTER SHUT OFF ENGINE…..2830
LOCKING…..2831
TRANSPORTATION…..2832
PRECAUTIONS FOR TRANSPORTATION…..2832
LIFTING MACHINE…..2833
SHIPPING MACHINE INFORMATION…..2835
TRANSPORTATION POSTURE…..2836
PROCEDURE FOR INCREASING OR REDUCING TRACK FRAME GAUGE…..2842
COLD WEATHER OPERATION…..2844
COLD WEATHER OPERATION INFORMATION…..2844
AFTER DAILY WORK COMPLETION…..2847
AFTER COLD WEATHER SEASON…..2847
LONG TERM STORAGE…..2848
BEFORE STORAGE…..2848
DURING STORAGE…..2848
AFTER STORAGE…..2848
STARTING MACHINE AFTER LONG-TERM STORAGE…..2849
TROUBLES AND ACTIONS…..2850
RUNNING OUT OF FUEL…..2850
PHENOMENA THAT ARE NOT FAILURES…..2851
TOWING THE MACHINE…..2852
SEVERE JOB CONDITION…..2852
DISCHARGED BATTERY…..2853
OTHER TROUBLE…..2857
MAINTENANCE…..2863
MAINTENANCE INFORMATION…..2864
OUTLINE OF SERVICE…..2866
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…..2866
ELECTRIC SYSTEM MAINTENANCE…..2868
WEAR PARTS…..2869
WEAR PARTS LIST…..2870
LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS…..2871
PROPER SELECTION…..2871
TIGHTENING TORQUE SPECIFICATIONS…..2875
TIGHTENING TORQUE LIST…..2875
SAFETY CRITICAL PARTS…..2876
SAFETY CRITICAL PARTS LIST…..2877
MAINTENANCE SCHEDULE…..2878
MAINTENANCE SCHEDULE CHART…..2878
MAINTENANCE PROCEDURE…..2880
INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS)…..2880
INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)…..2880
WHEN REQUIRED…..2881
CHECK BEFORE STARTING…..2904
EVERY 10 HOURS MAINTENANCE…..2905
EVERY 100 HOURS MAINTENANCE…..2908
EVERY 250 HOURS MAINTENANCE…..2909
EVERY 500 HOURS MAINTENANCE…..2916
EVERY 1000 HOURS MAINTENANCE…..2929
EVERY 2000 HOURS MAINTENANCE…..2940
EVERY 4000 HOURS MAINTENANCE…..2943
EVERY 5000 HOURS MAINTENANCE…..2946
EVERY 8000 HOURS MAINTENANCE…..2949
SPECIFICATIONS…..2951
SPECIFICATIONS…..2952
ATTACHMENTS, OPTIONS…..2955
GENERAL PRECAUTIONS FOR SAFETY…..2956
PRECAUTIONS WHEN SELECTING…..2956
READ THE INSTRUCTION MANUAL THOROUGHLY…..2956
PRECAUTIONS WHEN REMOVING OR INSTALLING…..2956
PRECAUTIONS WHEN USING…..2956
ATTACHMENT GUIDE…..2957
COMBINATIONS OF WORK EQUIPMENT…..2957
LOADING SHOVEL…..2961
EXPLANATION OF COMPONENTS…..2962
SWITCHES…..2962
FUSE…..2965
OPERATIONS…..2966
OPERATION OF WORK EQUIPMENT…..2966
PRECAUTIONS DURING OPERATION…..2968
EXCAVATOR WORK…..2972
PRECAUTIONS WHEN DISASSEMBLING MACHINE…..2973
RELEASING PRESSURE…..2973
TRANSPORTATION…..2974
MACHINE CONFIGURATION FOR TRANSPORT…..2974
WEAR PARTS…..2975
WEAR PARTS LIST…..2975
MAINTENANCE…..2976
CHECK BEFORE STARTING…..2976
EVERY 10 HOURS MAINTENANCE…..2978
EVERY 5000 HOURS MAINTENANCE…..2979
SPECIFICATION…..2981
COMBINATION OF WORK EQUIPMENT…..2982
COMBINATION OF WORK EQUIPMENT…..2982
INDEX…..2985
TEN00135-08 – Hydraulic Excavator PC800-8, PC800LC-8, PC800SE-8, PC850-8, PC850SE-8 Operation & Maintenance Manual…..2989
COVER…..2989
FOREWORD…..2990
BEFORE READING THIS MANUAL…..2991
SAFETY INFORMATION…..2992
INTRODUCTION…..2993
USE OF MACHINE…..2993
DIRECTIONS OF MACHINE…..2993
VISIBILITY FROM OPERATOR'S SEAT…..2994
PRODUCT INFORMATION…..2995
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…..2995
EPA REGULATIONS, ENGINE NUMBER PLATE…..2995
SERVICE METER LOCATION…..2996
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…..2996
CONTENTS…..2997
SAFETY…..3002
SAFETY…..3003
SAFETY LABELS…..3006
LOCATION OF SAFETY LABELS…..3007
SAFETY LABELS…..3008
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…..3014
PRECAUTIONS BEFORE STARTING OPERATION…..3014
PREPARATIONS FOR SAFE OPERATION…..3014
FIRE PREVENTION…..3016
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE…..3017
DO NOT GET CAUGHT IN WORK EQUIPMENT…..3019
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…..3019
PROTECTION AGAINST FALLING, FLYING, INTRUDING OBJECTS…..3019
UNAUTHORIZED MODIFICATION…..3020
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…..3020
PRECAUTIONS RELATED TO CAB GLASS…..3020
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…..3020
PRECAUTIONS FOR OPERATION…..3021
PRECAUTIONS FOR JOBSITE…..3021
STARTING ENGINE…..3023
OPERATION…..3025
TRANSPORTATION…..3032
TOWING…..3033
LIFTING OBJECTS WITH BUCKET…..3034
PRECAUTIONS FOR MAINTENANCE…..3035
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE…..3035
PRECAUTIONS FOR INSPECTION AND MAINTENANCE…..3039
OPERATION…..3046
MACHINE VIEW ILLUSTRATIONS…..3047
OVERALL MACHINE VIEW…..3047
CONTROLS AND GAUGES…..3048
DETAILED CONTROLS AND GAUGES…..3050
MONITORING SYSTEM…..3050
SWITCHES…..3079
CONTROL LEVERS AND PEDALS…..3086
SUN ROOF…..3089
WINDSHIELD…..3089
EMERGENCY EXIT FROM OPERATOR'S CAB…..3094
DOOR LOCK…..3094
CAP WITH LOCK…..3095
HOT AND COOL BOX…..3097
MAGAZINE BOX…..3097
ASHTRAY…..3097
FIRE EXTINGUISHER…..3098
AIR CONDITIONER CONTROLS…..3099
RADIO…..3113
AUXILIARY ELECTRIC POWER…..3117
FUSE…..3118
CIRCUIT BREAKER…..3119
CONTROLLER…..3120
TOOL BOX…..3120
GREASE PUMP…..3121
MACHINE OPERATIONS AND CONTROLS…..3124
BEFORE STARTING ENGINE…..3124
STARTING ENGINE…..3143
AFTER STARTING ENGINE…..3146
STOPPING THE ENGINE…..3155
MACHINE OPERATION…..3156
STEERING THE MACHINE…..3160
SWINGING…..3162
WORK EQUIPMENT CONTROLS AND OPERATIONS…..3163
WORKING MODE…..3164
PROHIBITED OPERATIONS…..3166
GENERAL OPERATION INFORMATION…..3171
TRAVELING ON SLOPES…..3173
ESCAPE FROM MUD…..3175
RECOMMENDED APPLICATIONS…..3176
BUCKET REPLACEMENT…..3177
PARKING MACHINE…..3179
MACHINE INSPECTION AFTER DAILY WORK…..3180
LOCKING…..3181
TRANSPORTATION…..3182
TRANSPORTATION PROCEDURE…..3182
LIFTING MACHINE…..3183
SHIPPING MACHINE INFORMATION…..3184
TRANSPORTATION POSTURE…..3185
PROCEDURE FOR INCREASING OR REDUCING TRACK FRAME GAUGE…..3191
COLD WEATHER OPERATION…..3193
COLD WEATHER OPERATION INFORMATION…..3193
AFTER DAILY WORK COMPLETION…..3196
AFTER COLD WEATHER SEASON…..3196
LONG TERM STORAGE…..3197
BEFORE STORAGE…..3197
DURING STORAGE…..3197
AFTER STORAGE…..3198
STARTING MACHINE AFTER LONG-TERM STORAGE…..3198
TROUBLES AND ACTIONS…..3199
RUNNING OUT OF FUEL…..3199
PHENOMENA THAT ARE NOT FAILURES…..3200
TOWING THE MACHINE…..3201
SEVERE JOB CONDITION…..3201
DISCHARGED BATTERY…..3202
OTHER TROUBLE…..3206
MAINTENANCE…..3212
MAINTENANCE INFORMATION…..3213
OUTLINE OF SERVICE…..3215
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…..3215
ELECTRIC SYSTEM MAINTENANCE…..3218
WEAR PARTS…..3219
WEAR PARTS LIST…..3219
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…..3220
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…..3222
TIGHTENING TORQUE SPECIFICATIONS…..3223
TIGHTENING TORQUE LIST…..3223
SAFETY CRITICAL PARTS…..3224
SAFETY CRITICAL PARTS LIST…..3225
MAINTENANCE SCHEDULE…..3226
MAINTENANCE SCHEDULE CHART…..3226
MAINTENANCE PROCEDURE…..3228
INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS)…..3228
INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)…..3228
WHEN REQUIRED…..3229
CHECK BEFORE STARTING…..3252
EVERY 10 HOURS MAINTENANCE…..3253
EVERY 100 HOURS MAINTENANCE…..3255
EVERY 250 HOURS MAINTENANCE…..3256
EVERY 500 HOURS MAINTENANCE…..3261
EVERY 1000 HOURS MAINTENANCE…..3270
EVERY 2000 HOURS MAINTENANCE…..3284
EVERY 4000 HOURS MAINTENANCE…..3290
EVERY 5000 HOURS MAINTENANCE…..3293
EVERY 8000 HOURS MAINTENANCE…..3295
SPECIFICATIONS…..3296
SPECIFICATIONS…..3297
ATTACHMENTS, OPTIONS…..3300
GENERAL PRECAUTIONS FOR SAFETY…..3301
PRECAUTIONS WHEN SELECTING…..3301
READ THE INSTRUCTION MANUAL THOROUGHLY…..3301
PRECAUTIONS WHEN REMOVING OR INSTALLING…..3301
PRECAUTIONS WHEN USING…..3301
ATTACHMENT GUIDE…..3302
COMBINATIONS OF WORK EQUIPMENT…..3303
TRACK SHOES SELECTION…..3305
HANDLING COUNTERWEIGHT REMOVER…..3306
HANDLING MACHINES EQUIPPED WITH KOMTRAX…..3318
BASIC PRECAUTIONS…..3318
LOADING SHOVEL…..3320
EXPLANATION OF COMPONENTS…..3321
SWITCHES…..3321
FUSE…..3324
OPERATIONS…..3325
OPERATION OF WORK EQUIPMENT…..3325
PRECAUTIONS DURING OPERATION…..3327
PRECAUTIONS FOR JOBSITE…..3330
EXCAVATOR WORK…..3332
TRANSPORTATION…..3333
MACHINE CONFIGURATION FOR TRANSPORT…..3333
WEAR PARTS…..3334
WEAR PARTS LIST…..3334
MAINTENANCE…..3335
CHECK BEFORE STARTING…..3335
EVERY 10 HOURS MAINTENANCE…..3337
EVERY 5000 HOURS MAINTENANCE…..3338
SPECIFICATION…..3340
COMBINATION OF WORK EQUIPMENT…..3341
COMBINATION OF WORK EQUIPMENT…..3341
INDEX…..3344
TEN00345-03 – Hydraulic Excavator PC800-8, PC800LC-8, PC800SE-8, PC850-8, PC850SE-8 Operation & Maintenance Manual…..3348
COVER…..3348
FOREWORD…..3349
BEFORE READING THIS MANUAL…..3350
SAFETY INFORMATION…..3351
INTRODUCTION…..3352
USE OF MACHINE…..3352
DIRECTIONS OF MACHINE…..3352
VISIBILITY FROM OPERATOR'S SEAT…..3353
PRODUCT INFORMATION…..3354
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…..3354
EPA REGULATIONS, ENGINE NUMBER PLATE…..3354
SERVICE METER LOCATION…..3355
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…..3355
CONTENTS…..3356
SAFETY…..3361
SAFETY…..3362
SAFETY LABELS…..3365
LOCATION OF SAFETY LABELS…..3366
SAFETY LABELS…..3367
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…..3373
PRECAUTIONS BEFORE STARTING OPERATION…..3373
PREPARATIONS FOR SAFE OPERATION…..3373
FIRE PREVENTION…..3375
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE…..3376
DO NOT GET CAUGHT IN WORK EQUIPMENT…..3378
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…..3378
PROTECTION AGAINST FALLING, FLYING, INTRUDING OBJECTS…..3379
UNAUTHORIZED MODIFICATION…..3380
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…..3380
PRECAUTIONS RELATED TO CAB GLASS…..3380
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…..3380
PRECAUTIONS FOR OPERATION…..3381
PRECAUTIONS FOR JOBSITE…..3381
STARTING ENGINE…..3383
OPERATION…..3385
TRANSPORTATION…..3392
TOWING…..3393
LIFTING OBJECTS WITH BUCKET…..3394
PRECAUTIONS FOR MAINTENANCE…..3395
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE…..3395
PRECAUTIONS FOR INSPECTION AND MAINTENANCE…..3399
OPERATION…..3405
MACHINE VIEW ILLUSTRATIONS…..3406
OVERALL MACHINE VIEW…..3406
CONTROLS AND GAUGES…..3407
DETAILED CONTROLS AND GAUGES…..3409
MONITORING SYSTEM…..3409
SWITCHES…..3438
CONTROL LEVERS AND PEDALS…..3445
SUN ROOF…..3448
WINDSHIELD…..3448
EMERGENCY EXIT FROM OPERATOR'S CAB…..3453
DOOR LOCK…..3453
CAP WITH LOCK…..3454
HOT AND COOL BOX…..3456
MAGAZINE BOX…..3456
ASHTRAY…..3456
FIRE EXTINGUISHER…..3457
AIR CONDITIONER CONTROLS…..3458
RADIO…..3472
AUXILIARY ELECTRIC POWER…..3476
FUSE…..3477
CIRCUIT BREAKER…..3478
CONTROLLER…..3479
TOOL BOX…..3479
GREASE PUMP…..3480
MACHINE OPERATIONS AND CONTROLS…..3483
BEFORE STARTING ENGINE…..3483
STARTING ENGINE…..3502
AFTER STARTING ENGINE…..3505
STOPPING THE ENGINE…..3514
MACHINE OPERATION…..3515
STEERING THE MACHINE…..3519
SWINGING…..3521
WORK EQUIPMENT CONTROLS AND OPERATIONS…..3522
WORKING MODE…..3523
PROHIBITED OPERATIONS…..3525
GENERAL OPERATION INFORMATION…..3530
TRAVELING ON SLOPES…..3532
ESCAPE FROM MUD…..3534
RECOMMENDED APPLICATIONS…..3535
BUCKET REPLACEMENT…..3536
PARKING MACHINE…..3538
MACHINE INSPECTION AFTER DAILY WORK…..3539
LOCKING…..3540
TRANSPORTATION…..3541
TRANSPORTATION PROCEDURE…..3541
LIFTING MACHINE…..3542
SHIPPING MACHINE INFORMATION…..3543
TRANSPORTATION POSTURE…..3544
PROCEDURE FOR INCREASING OR REDUCING TRACK FRAME GAUGE…..3550
COLD WEATHER OPERATION…..3552
COLD WEATHER OPERATION INFORMATION…..3552
AFTER DAILY WORK COMPLETION…..3555
AFTER COLD WEATHER SEASON…..3555
LONG TERM STORAGE…..3556
BEFORE STORAGE…..3556
DURING STORAGE…..3556
AFTER STORAGE…..3557
STARTING MACHINE AFTER LONG-TERM STORAGE…..3557
TROUBLES AND ACTIONS…..3558
RUNNING OUT OF FUEL…..3558
PHENOMENA THAT ARE NOT FAILURES…..3559
TOWING THE MACHINE…..3560
SEVERE JOB CONDITION…..3560
DISCHARGED BATTERY…..3561
OTHER TROUBLE…..3565
MAINTENANCE…..3571
MAINTENANCE INFORMATION…..3572
OUTLINE OF SERVICE…..3574
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…..3574
ELECTRIC SYSTEM MAINTENANCE…..3577
WEAR PARTS…..3578
WEAR PARTS LIST…..3578
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…..3579
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…..3581
TIGHTENING TORQUE SPECIFICATIONS…..3582
TIGHTENING TORQUE LIST…..3582
SAFETY CRITICAL PARTS…..3583
SAFETY CRITICAL PARTS LIST…..3584
MAINTENANCE SCHEDULE…..3585
MAINTENANCE SCHEDULE CHART…..3585
MAINTENANCE PROCEDURE…..3587
INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS)…..3587
INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)…..3587
WHEN REQUIRED…..3588
CHECK BEFORE STARTING…..3611
EVERY 10 HOURS MAINTENANCE…..3612
EVERY 100 HOURS MAINTENANCE…..3614
EVERY 250 HOURS MAINTENANCE…..3615
EVERY 500 HOURS MAINTENANCE…..3620
EVERY 1000 HOURS MAINTENANCE…..3629
EVERY 2000 HOURS MAINTENANCE…..3642
EVERY 4000 HOURS MAINTENANCE…..3648
EVERY 5000 HOURS MAINTENANCE…..3651
EVERY 8000 HOURS MAINTENANCE…..3655
SPECIFICATIONS…..3657
SPECIFICATIONS…..3658
ATTACHMENTS, OPTIONS…..3661
GENERAL PRECAUTIONS FOR SAFETY…..3662
PRECAUTIONS WHEN SELECTING…..3662
READ THE INSTRUCTION MANUAL THOROUGHLY…..3662
PRECAUTIONS WHEN REMOVING OR INSTALLING…..3662
PRECAUTIONS WHEN USING…..3662
ATTACHMENT GUIDE…..3663
COMBINATIONS OF WORK EQUIPMENT…..3664
TRACK SHOES SELECTION…..3666
HANDLING COUNTERWEIGHT REMOVER…..3667
HANDLING MACHINES EQUIPPED WITH KOMTRAX…..3679
BASIC PRECAUTIONS…..3679
LOADING SHOVEL…..3681
EXPLANATION OF COMPONENTS…..3682
SWITCHES…..3682
FUSE…..3685
OPERATIONS…..3686
OPERATION OF WORK EQUIPMENT…..3686
PRECAUTIONS DURING OPERATION…..3688
PRECAUTIONS FOR JOBSITE…..3691
EXCAVATOR WORK…..3693
TRANSPORTATION…..3694
MACHINE CONFIGURATION FOR TRANSPORT…..3694
WEAR PARTS…..3695
WEAR PARTS LIST…..3695
MAINTENANCE…..3696
CHECK BEFORE STARTING…..3696
EVERY 10 HOURS MAINTENANCE…..3698
EVERY 5000 HOURS MAINTENANCE…..3699
SPECIFICATION…..3701
COMBINATION OF WORK EQUIPMENT…..3702
COMBINATION OF WORK EQUIPMENT…..3702
INDEX…..3705
UEAM005400 – Hydraulic Excavator PC800-8, PC800LC-8 Operation & Maintenance Manual…..3709
FOREWORD…..3711
FOREWORD…..3712
SAFETY INFORMATION…..3713
Noise emission levels…..3715
Vibration levels…..3716
Guide to Reduce Vibration Levels on Machine…..3716
BREAKING-IN THE NEW MACHINE…..3718
INTRODUCTION…..3719
DIRECTIONS OF MACHINE…..3719
VISIBILITY FROM OPERATOR'S SEAT…..3720
PROXIMITY VISIBILITY…..3720
12M CIRCUMFERENCE VISIBILITY…..3720
PRODUCT INFORMATION…..3721
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…..3721
EPA REGULATIONS, ENGINE NUMBER PLATE…..3721
SERVICE METER LOCATION…..3722
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…..3722
MACHINE SERIAL PLATE…..3723
FOREWORD…..3725
SAFETY…..3725
OPERATION…..3726
MAINTENANCE…..3728
SPECIFICATIONS…..3730
ATTACHMENTS AND OPTIONS…..3731
INDEX…..3731
COLOPHON…..3731
SAFETY…..3733
SAFETY INFORMATION…..3734
SAFETY LABELS…..3736
LOCATION OF SAFETY LABELS…..3737
SAFETY LABELS…..3738
SAFETY INFORMATION…..3745
SAFETY MACHINE OPERATION…..3754
STARTING ENGINE…..3754
OPERATION…..3755
TRANSPORTATION…..3761
BATTERY…..3762
TOWING…..3763
LIFTING OBJECTS WITH BUCKET…..3764
SAFETY MAINTENANCE INFORMATION…..3765
OPERATION…..3773
MACHINE VIEW ILLUSTRATIONS…..3774
OVERALL MACHINE VIEW…..3774
CONTROLS AND GAUGES…..3775
DETAILED CONTROLS AND GAUGES…..3777
MONITORING SYSTEM…..3777
Basic Operation of Machine Monitor…..3778
Emergency Monitors…..3781
Caution Monitors…..3783
Basic Check Monitors…..3785
Meter Display Portion…..3787
Monitor Switches Portion…..3791
SWITCHES…..3806
CONTROL LEVERS AND PEDALS…..3813
SUN ROOF…..3815
Opening…..3816
Closing…..3816
WINDSHIELD…..3816
EMERGENCY EXIT FROM OPERATOR'S CAB…..3821
DOOR LOCK…..3821
CAP WITH LOCK…..3821
HOT AND COOL BOX…..3823
MAGAZINE BOX…..3823
ASHTRAY…..3823
AIR CONDITIONER CONTROLS…..3824
Air Conditioner Control Panel…..3824
Method of Operation…..3828
Use Air Conditioner with Care…..3834
Air Conditioner Maintenance…..3835
Other Functions…..3835
RADIO-CASSETTE (OPTION)…..3837
Use Radio with Care…..3837
AUXILIARY ELECTRIC POWER…..3838
24V power source…..3838
12V power source…..3839
FUSE…..3840
CIRCUIT BREAKER…..3841
CONTROLLER…..3842
TOOL BOX…..3842
GREASE PUMP…..3843
Method of Use…..3843
Precautions when Using…..3844
Supplying Grease…..3845
ACCUMULATOR HANDLING…..3847
RELEASING PRESSURE IN THE CONTROL CIRCUIT ON MACHINES EQUIPPED WITH AN ACCUMULATOR…..3847
MACHINE OPERATIONS AND CONTROLS…..3848
BEFORE STARTING ENGINE…..3848
Walk-around Checks…..3848
Checks Before Starting…..3849
Adjustment…..3857
Seat Belt…..3860
Operations Before Starting Engine…..3861
STARTING ENGINE…..3864
AFTER STARTING ENGINE…..3867
Engine Warm Up…..3867
Hydraulic Equipment Warm Up…..3869
Operation After Completion Of Warm-Up Operation…..3874
STOPPING THE ENGINE…..3876
MACHINE OPERATION…..3877
Preparations for Moving the Machine…..3877
Moving Machine Forward…..3878
Moving Machine Backward…..3879
Stopping Machine…..3880
STEERING THE MACHINE…..3881
Steering…..3881
SWINGING…..3883
WORK EQUIPMENT CONTROLS AND OPERATIONS…..3884
WORKING MODE…..3886
PROHIBITED OPERATIONS…..3887
GENERAL OPERATION INFORMATION…..3889
TRAVELING ON SLOPES…..3890
ESCAPE FROM MUD…..3892
Track on One Side Stuck…..3892
Tracks on Both Sides Stuck…..3892
RECOMMENDED APPLICATIONS…..3893
Backhoe Work…..3893
Ditching Work…..3893
Loading Work…..3893
BUCKET REPLACEMENT…..3894
Replacement…..3894
PARKING MACHINE…..3896
MACHINE INSPECTION AFTER DAILY WORK…..3898
LOCKING…..3898
TRANSPORTATION…..3899
TRANSPORTATION PROCEDURE…..3899
LIFTING MACHINE…..3899
SHIPPING MACHINE INFORMATION…..3901
TRANSPORTATION POSTURE…..3902
PROCEDURE FOR INCREASING OR REDUCING TRACK FRAME GAUGE…..3907
COLD WEATHER OPERATION…..3909
COLD WEATHER OPERATION INFORMATION…..3909
Fuel and Lubricants…..3909
Cooling System Coolant…..3909
Battery…..3910
Monitor…..3910
AFTER DAILY WORK COMPLETION…..3912
AFTER COLD WEATHER SEASON…..3912
LONG TERM STORAGE…..3913
BEFORE STORAGE…..3913
DURING STORAGE…..3914
AFTER STORAGE…..3914
STARTING MACHINE AFTER LONG-TERM STORAGE…..3914
TROUBLES AND ACTIONS…..3915
RUNNING OUT OF FUEL…..3915
PHENOMENA THAT ARE NOT FAILURES…..3916
TOWING THE MACHINE…..3916
SEVERE JOB CONDITION…..3917
DISCHARGED BATTERY…..3918
Battery Removal and Installation…..3918
Battery Charges…..3919
Starting Engine with Booster Cables…..3920
OTHER TROUBLE…..3922
Electrical System…..3922
Chassis…..3923
Engine…..3924
Electronic Control System…..3926
Point of Contact to Telephone when Error Occurs…..3927
MAINTENANCE…..3929
MAINTENANCE INFORMATION…..3930
OUTLINE OF SERVICE…..3932
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…..3932
OIL…..3932
FUEL…..3933
COOLANT AND WATER FOR DILUTION…..3933
GREASE…..3934
CARRYING OUT KOWA (Komatsu Oil Wear Analysis)…..3934
STORING OIL AND FUEL…..3935
FILTERS…..3935
ELECTRIC SYSTEM MAINTENANCE…..3936
EXPLANATION OF LUBRICATION CHART DECAL…..3937
WEAR PARTS…..3939
WEAR PARTS LIST…..3939
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…..3940
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…..3942
TIGHTENING TORQUE SPECIFICATIONS…..3943
TIGHTENING TORQUE LIST…..3943
SAFETY CRITICAL PARTS…..3944
SAFETY CRITICAL PARTS LIST…..3944
MAINTENANCE SCHEDULE…..3945
MAINTENANCE SCHEDULE CHART…..3945
MAINTENANCE PROCEDURE…..3947
INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS)…..3947
INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)…..3947
WHEN REQUIRED…..3947
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT…..3947
CLEAN INSIDE OF COOLING SYSTEM…..3952
CHECK AND TIGHTEN TRACK SHOE BOLTS…..3955
CHECK AND ADJUST TRACK TENSION…..3956
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)…..3958
REPLACE BUCKET TEETH (KMAX)…..3959
ADJUST BUCKET CLEARANCE…..3960
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…..3962
CHECK AND MAINTENANCE AIR CONDITIONER…..3963
CLEAN LINE FILTER, REMOVE DIRT…..3964
CHECK GAS SPRING…..3964
BLEEDING AIR FROM HYDRAULIC SYSTEM…..3965
CHECK BEFORE STARTING…..3968
EVERY 10 HOURS MAINTENANCE…..3969
LUBRICATING…..3969
EVERY 100 HOURS MAINTENANCE…..3971
LUBRICATING SWING CIRCLE…..3971
EVERY 250 HOURS MAINTENANCE…..3972
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…..3972
CHECK LEVEL OF BATTERY ELECTROLYTE…..3972
CHECK AND TIGHTEN TRACK FRAME AND AXLE CONNECTING BOLTS…..3974
CHECK ALTERNATOR DRIVE BELT TENSION, ADJUST…..3975
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST…..3976
EVERY 500 HOURS MAINTENANCE…..3977
REPLACE FUEL PRE-FILTER CARTRIDGE…..3977
CHECK SWING PINION GREASE LEVEL, ADD GREASE…..3979
CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, AFTERCOOLER FINS, FUEL COOLER FINS, AND AIR CONDITIONER CONDENSER FINS (only machines equipped with air conditioner)…..3980
CLEAN FRESH/RECIRC AIR FILTERS OF AIR CONDITIONER (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER)…..3981
REPLACE PILOT FILTER…..3982
CLEAN STRAINER OF COUPLING LUBRICATING OIL FILTER…..3983
REPLACE DRAIN FILTER CARTRIDGE…..3983
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE…..3984
EVERY 1000 HOURS MAINTENANCE…..3986
REPLACE FUEL MAIN FILTER CARTRIDGE…..3986
REPLACE BREATHER ELEMENT IN HYDRAULIC TANK…..3989
REPLACE HYDRAULIC TANK ADDITIONAL BREATHER ELEMENT…..3990
REPLACE HYDRAULIC OIL FILTER ELEMENT…..3990
CHANGE OIL IN SWING MACHINERY CASE…..3991
CHANGE OIL IN COUPLING CASE…..3993
REPLACE CORROSION RESISTOR CARTRIDGE…..3994
CHECK WELDED STRUCTURE…..3994
CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (for breaker)…..3996
EVERY 2000 HOURS MAINTENANCE…..3997
CHANGE OIL IN FINAL DRIVE CASE…..3997
CLEAN HYDRAULIC TANK STRAINER…..3998
CHECKING CHARGE PRESSURE OF NITROGEN GAS IN ACCUMULATOR (FOR CONTROL CIRCUIT)…..3999
CHECK ALTERNATOR…..4002
CHECK ENGINE VALVE CLEARANCE, ADJUST…..4002
CHECK ALL TIGHTENING POINTS OF ENGINE EXHAUST PIPE CLAMPS…..4002
EVERY 4000 HOURS MAINTENANCE…..4003
CHECK WATER PUMP…..4003
REPLACE ACCUMULATOR (FOR CONTROL CIRCUIT)…..4003
CHECK FOR LOOSENESS OF HIGH-PRESSURE PIPING CLAMP, HARDENING OF RUBBER…..4004
CHECK FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER…..4004
CHECK OPERATING CONDITION OF COMPRESSOR…..4005
CHECK STARTING MOTOR…..4005
EVERY 5000 HOURS MAINTENANCE…..4006
CHANGE OIL IN HYDRAULIC TANK…..4006
EVERY 8000 HOURS MAINTENANCE…..4008
REPLACE HIGH-PRESSURE PIPING CLAMP…..4008
REPLACE FUEL SPRAY PREVENTION CAP…..4008
SPECIFICATIONS…..4009
SPECIFICATIONS…..4010
ATTACHMENTS AND OPTIONS…..4013
GENERAL PRECAUTIONS FOR SAFETY…..4014
PRECAUTIONS WHEN SELECTING…..4014
READ THE INSTRUCTION MANUAL THOROUGHLY…..4014
PRECAUTIONS WHEN REMOVING OR INSTALLING…..4014
PRECAUTIONS WHEN USING…..4015
ATTACHMENT GUIDE…..4016
COMBINATIONS OF WORK EQUIPMENT…..4017
Working Range Diagram…..4018
TRACK SHOES SELECTION…..4019
HANDLING MACHINES EQUIPPED WITH KOMTRAX…..4020
BASIC PRECAUTIONS…..4020
INDEX…..4021
<A>…..4023
<B>…..4023
<C>…..4023
<D>…..4023
<E>…..4023
<F>…..4023
<G>…..4023
<H>…..4023
<I>…..4023
<L>…..4023
<M>…..4023
<O>…..4023
<P>…..4023
<R>…..4024
<S>…..4024
<T>…..4024
<V>…..4024
<W>…..4024
<Y>…..4024
COLOPHON…..4025
UEN00373-01 – Hydraulic Excavator GALEO PC800-8, PC800LC-8 Shop Manual…..4027
PC800-8_PC800LC-8…..4027
00 Index and foreword…..4029
Index…..4029
Organization list of the shop manual…..4030
Table of contents…..4032
00 Index and foreword…..4041
Foreword and general information…..4041
Foreword and general information…..4042
Safety notice…..4042
How to read the shop manual…..4046
Explanation of terms for maintenance standard…..4048
Handling electric equipment and hydraulic component…..4050
How to read electric wire code…..4058
Method of disassembling and connecting push-pull type coupler…..4061
Standard tightening torque table…..4064
Conversion table…..4068
01 Specification…..4075
Specification and technical data…..4075
Specification and technical data…..4076
Specification drawings…..4076
Working range drawing…..4077
Specifications…..4078
Weight table…..4084
Table of fuel, coolant and lubricants…..4087
10 Structure, function and maintenance standard…..4091
Engine and cooling system…..4091
Engine and cooling system…..4092
Coupling…..4092
Coupling lubrication system…..4093
Radiator, oil cooler…..4094
10 Structure, function and maintenance standard…..4097
Power train…..4097
Power train…..4098
Power train…..4098
Swing machinery…..4100
Swing circle…..4102
Final drive…..4104
Sprocket…..4106
10 Structure, function and maintenance standard…..4109
Undercarriage and frame…..4109
Undercarriage and frame…..4110
Track frame and recoil spring…..4110
Idler…..4112
Carrier roller…..4114
Track roller…..4116
Track shoe…..4118
10 Structure, function and maintenance standard…..4123
Hydraulic system, Part 1…..4123
Hydraulic system, Part 1…..4124
Hydraulic piping drawing…..4124
Hydraulic tank, hydraulic filter…..4126
Hydraulic pump…..4128
Operation of pump control mechanism…..4134
EPC valve…..4136
Self pressure reducing valve…..4139
Cooling fan pump…..4143
Cooling fan motor…..4152
10 Structure, function and maintenance standard…..4159
Hydraulic system, Part 2…..4159
Hydraulic system, Part 2…..4161
Motor grease pump…..4161
Return oil filter…..4162
Line oil filter…..4163
Drain oil filter…..4164
L.H. 5-Spool control valve…..4166
R.H. 4-Spool control valve…..4172
Straight-travel valve…..4179
Swing motor…..4182
Center swivel joint…..4187
Travel motor…..4188
PPC accumulator…..4198
Work equipment, swing PPC valve…..4199
Travel PPC valve…..4204
Solenoid valve…..4208
Hydraulic cylinder…..4214
10 Structure, function and maintenance standard…..4217
Work equipment…..4217
Work equipment…..4218
Work equipment…..4218
Dimensions of work equipment…..4220
10 Structure, function and maintenance standard…..4225
Cab and its attachments…..4225
Cab and its attachments…..4226
Air conditioner piping…..4226
10 Structure, function and maintenance standard…..4229
Electrical system…..4229
Electrical system…..4230
Engine control…..4230
Electric control system…..4239
Monitor system…..4273
Sensors…..4291
20 Standard value table…..4297
Standard service value table…..4297
Standard service value table…..4298
Standard service value table for engine…..4298
Standard service value table for chassis…..4299
30 Testing and adjusting…..4309
Testing and adjusting, Part 1…..4309
Testing and adjusting, Part 1…..4310
Tools for testing, adjusting and troubleshooting…..4310
Measuring engine speed…..4312
Measuring intake air pressure (Boost pressure)…..4313
Measuring exhaust gas temperature…..4314
Measuring exhaust gas color…..4315
Adjusting valve clearance…..4316
Measuring compression pressure…..4317
Measuring blow-by pressure…..4318
Measuring engine oil pressure…..4319
Handling of fuel system equipment…..4320
Remaining pressure relief from fuel system equipment…..4320
Measuring fuel pressure…..4321
Testing fuel return rate and leakage…..4322
Bleeding air from fuel circuit…..4324
Testing and adjusting alternator belt tension…..4325
Testing and adjusting air conditioner compressor belt…..4326
30 Testing and adjusting…..4329
Testing and adjusting, Part 2…..4329
Testing and adjusting, Part 2…..4330
Inspection of swing circle bearing clearance…..4330
Testing and adjusting track shoe tension…..4331
Testing and adjusting work equipment, swing, and travel circuit oil pressures…..4332
Testing and adjusting control circuit oil pressure (self pressure reducing valve)…..4337
Testing and adjusting main pump control pressure…..4338
30 Testing and adjusting…..4345
Testing and adjusting, Part 3…..4345
Testing and adjusting, Part 3…..4346
Measuring PPC valve output pressure…..4346
Measuring outlet pressures of solenoid valve, swing PPC shuttle valve, and swing priority selector valve…..4350
Adjusting work equipment, swing PPC valve…..4354
Testing and adjusting travel deviation…..4355
Inspection of locations of hydraulic drift of work equipment…..4357
Measuring fan speed…..4358
Measuring fan circuit oil pressure…..4358
Measuring fan pump EPC current…..4359
Measuring fan pump EPC solenoid valve output pressure…..4359
Measuring oil leakage…..4360
Release of residual pressure from hydraulic circuit…..4364
Bleeding air from each part…..4365
Inspection procedures for diode…..4368
30 Testing and adjusting…..4371
Testing and adjusting, Part 4…..4371
Testing and adjusting, Part 4…..4372
Special function of machine monitor…..4372
Handling engine controller high voltage circuit…..4403
30 Testing and adjusting…..4405
Testing and adjusting, Part 5…..4405
Testing and adjusting, Part 5…..4406
Procedure for turning on KOMTRAX terminal…..4406
KOMTRAX terminal lamp indications…..4409
Preparation work for troubleshooting electrical system…..4412
Pm-clinic service…..4415
UNDERCARRIAGE INSPECTION…..4421
40 Troubleshooting…..4423
General information on troubleshooting…..4423
General information on troubleshooting…..4424
Points to remember when troubleshooting…..4424
Sequence of events in troubleshooting…..4425
Checks before troubleshooting…..4426
Classification and troubleshooting steps…..4427
Connection table for connector pin numbers…..4431
T-boxes and T-adapters table…..4454
40 Troubleshooting…..4459
Troubleshooting by failure code (Display of code), Part 1…..4459
Troubleshooting by failure code (Display of code), Part 1…..4461
Failure codes table…..4461
Information in troubleshooting table…..4466
Failure code [A000N1] Eng. Hi Out of Std…..4468
Failure code [AA10NX] Aircleaner Clogging…..4470
Failure code [AB00KE] Charge Voltage Low…..4472
Failure code [B@BAZG] Eng. Oil Press. Low…..4474
Failure code [B@BAZK] Eng. Oil Level Low…..4476
Failure code [B@BCNS] Eng. Water Overheat…..4478
Failure code [B@BCZK] Eng. Water Lvl Low…..4480
Failure code [B@HANS] Hydr. Oil Overheat…..4482
Failure code [CA111] ECM Critical Internal Failure…..4484
Failure code [CA115] Eng Ne and Bkup Speed Sens Error…..4486
Failure code [CA122] Chg Air Press Sensor High Error…..4488
Failure code [CA123] Chg Air Press Sensor Low Error…..4491
Failure code [CA131] Throttle Sensor High Error…..4492
Failure code [CA132] Throttle Sensor Low Error…..4494
Failure code [CA135] Eng Oil Press Sensor High Error…..4496
Failure code [CA141] Eng Oil Press Sensor Low Error…..4498
Failure code [CA144] Coolant Temp Sens High Error…..4500
Failure code [CA145] Coolant Temp Sens Low Error…..4502
Failure code [CA153] Chg Air Temp Sensor High Error…..4504
Failure code [CA154] Chg Air Temp Sensor Low Error…..4506
Failure code [CA187] Sens Supply 2 Volt Low Error…..4507
Failure code [CA221] Ambient Press Sens High Error…..4508
Failure code [CA222] Ambient Press Sens Low Error…..4510
Failure code [CA227] Sens Supply 2 Volt High Error…..4512
Failure code [CA234] Eng Overspeed…..4514
Failure code [CA238] Ne Speed Sens Supply Volt Error…..4516
Failure code [CA263] Fuel Temp Sensor High Error…..4518
Failure code [CA265] Fuel Temp Sensor Low Error…..4520
Failure code [CA271] IMV/PCV1 Short Error…..4521
Failure code [CA272] IMV/PCV1 Open Error…..4522
Failure code [CA273] PCV2 Short Error…..4523
Failure code [CA274] PCV2 Open Error…..4524
Failure code [CA322] Inj #1 (L#1) Open/Short Error…..4525
Failure code [CA323] Inj #5 (L#5) Open/Short Error…..4526
Failure code [CA324] Inj #3 (L#3) Open/Short Error…..4527
Failure code [CA325] Inj #6 (L#6) Open/Short Error…..4528
Failure code [CA331] Inj #2 (L#2) Open/Short Error…..4529
Failure code [CA332] Inj #4 (L#4) Open/Short Error…..4530
Failure code [CA342] Calibration Code Incompatibility…..4531
Failure code [CA351] Injectors Drive Circuit Error…..4532
Failure code [CA352] Sens Supply 1 Volt Low Error…..4534
Failure code [CA386] Sens Supply 1 Volt High Error…..4536
40 Troubleshooting…..4539
Troubleshooting by failure code (Display of code), Part 2…..4539
Troubleshooting by failure code (Display of code), Part 2…..4541
Failure code [CA441] Battery Voltage Low Error…..4541
Failure code [CA442] Battery Voltage High Error…..4541
Failure code [CA449] Rail Press Very High Error…..4542
Failure code [CA451] Rail Press Sensor High Error…..4544
Failure code [CA452] Rail Press Sensor Low Error…..4546
Failure code [CA553] Rail Press High Error…..4546
Failure code [CA554] Rail Press Sensor In Range Error…..4547
Failure code [CA559] Rail Press Low Error…..4548
Failure code [CA689] Eng Ne Speed Sensor Error…..4552
Failure code [CA731] Eng Bkup Speed Sens Phase Error…..4554
Failure code [CA757] All Persistent Data Lost Error…..4555
Failure code [CA778] Eng Bkup Speed Sensor Error…..4556
Failure code [CA1228] EGR Valve Servo Error 1…..4558
Failure code [CA1625] EGR Valve Servo Error 2…..4559
Failure code [CA1626] BP Valve Sol Current High Error…..4560
Failure code [CA1627] BP Valve Sol Current Low Error…..4562
Failure code [CA1628] Bypass Valve Servo Error 1…..4563
Failure code [CA1629] Bypass Valve Servo Error 2…..4564
Failure code [CA1631] BP Valve Pos Sens High Error…..4566
Failure code [CA1632] BP Valve Pos Sens Low Error…..4568
Failure code [CA1633] KOMNET Datalink Timeout Error…..4569
Failure code [CA1642] EGR Inter Press Sens Low Error…..4571
Failure code [CA1653] EGR Inter Press Sens High Error…..4572
Failure code [CA2185] Throt Sens Sup Volt High Error…..4574
Failure code [CA2186] Throt Sens Sup Volt Low Error…..4576
Failure code [CA2249] Rail Press Very Low Error…..4577
Failure code [CA2271] EGR Valve Pos Sens High Error…..4578
Failure code [CA2272] EGR Valve Pos Sens Low Error…..4580
Failure code [CA2351] EGR Valve Sol Current High Error…..4582
Failure code [CA2352] EGR Valve Sol Current Low Error…..4584
Failure code [CA2555] Grid Htr Relay Volt Low Error…..4585
Failure code [CA2556] Grid Htr Relay Volt High Error…..4586
Failure code [D110KB] Battery Relay Drive S/C…..4588
Failure code [D163KB] Flash Light Relay S/C…..4590
Failure code [D195KB] Step Light Relay S/C…..4592
Failure code [DA25KP] Press. Sensor Power Abnormality…..4594
Failure code [DA2SKQ] Model Selection Abnormality…..4596
Failure code [DA80MA] Auto. Lub. Abnormal…..4598
Failure code [DA2RMC] Pump Comm. Abnormality…..4600
Failure code [DAFRMC] Monitor Comm. Abnormality…..4602
Failure code [DGE5KY] Ambi. Temp. Sensor S/C…..4604
Failure code [DGH2KB] Hydr. Oil Temp. Sensor S/C…..4606
40 Troubleshooting…..4609
Troubleshooting by failure code (Display of code), Part 3…..4609
Troubleshooting by failure code (Display of code), Part 3…..4612
Failure code [DH25KA] L Jet Sensor Disc…..4612
Failure code [DH25KB] L Jet Sensor S/C…..4614
Failure code [DH26KA] R Jet Sensor Disc…..4616
Failure code [DH26KB] R Jet Sensor S/C…..4618
Failure code [DHPEKA] F Pump P. Sensor Disc…..4620
Failure code [DHPEKB] F Pump P. Sensor S/C…..4622
Failure code [DHPFKA] R Pump P. Sensor Disc…..4624
Failure code [DHPFKB] R Pump P. Sensor S/C…..4626
Failure code [DV20KB] Travel Alarm S/C…..4628
Failure code [DW41KA] Swing Priority Sol. Disc…..4630
Failure code [DW41KB] Swing Priority Sol. S/C…..4632
Failure code [DW43KA] Travel Speed Sol. Disc…..4634
Failure code [DW43KB] Travel Speed Sol. S/C…..4636
Failure code [DW45KA] Swing Brake Sol. Disc…..4638
Failure code [DW45KB] Swing Brake Sol. S/C…..4640
Failure code [DW7BKA] Fan Reverse Sol. Disc…..4642
Failure code [DW78KB] Fan Reverse Sol. S/C…..4644
Failure code [DWK0KA] 2-stage Relief Sol. Disc…..4646
Failure code [DWK0KB] 2-stage Relief Sol. S/C…..4648
Failure code [DX16KA] Fan Pump EPC Sol. Disc…..4650
Failure code [DX16KB] Fan Pump EPC Sol. S/C…..4652
Failure code [DXAAKA] F Pump EPC Sol. Disc…..4654
Failure code [DXAAKB] F Pump EPC Sol. S/C…..4656
Failure code [DXABKA] R Pump EPC Sol. Disc…..4658
Failure code [DXABKB] R Pump EPC Sol. S/C…..4660
Failure code [DY20KA] Wiper Working Abnormality…..4662
Failure code [DY20MA] Wiper Parking Abnormality…..4664
Failure code [DY2CKB] Washer Drive S/C…..4668
Failure code [DY2DKB] Wiper Drive (For) S/C…..4670
Failure code [DY2EKB] Wiper Drive (Rev) S/C…..4674
40 Troubleshooting…..4677
Troubleshooting of electrical system (E-mode)…..4677
Troubleshooting of electrical system (E-mode)…..4679
Before carrying out troubleshooting of electrical system…..4679
Information contained in troubleshooting table…..4681
E-1 Engine does not start (Engine does not rotate)…..4682
E-2 Preheater does not operate…..4685
E-3 Auto engine warm-up device does not work…..4690
E-4 Auto-decelerator does not operate…..4691
E-5 All work equipment, swing and travel do not move…..4692
E-6 Machine push-up function does not operate normally…..4694
E-7 Boom shockless function does not operate normally…..4696
E-8 Any item is not displayed on machine monitor…..4698
E-9 Part of display on machine monitor is missing…..4699
E-10 Machine monitor displays contents irrelevant to the model…..4699
E-11 Fuel level monitor red lamp lights up while engine is running…..4700
E-12 Engine coolant thermometer does not display normally…..4702
E-13 Hydraulic oil temperature gauge does not display correctly…..4704
E-14 Fuel gauge does not display correctly…..4705
E-15 Swing lock monitor does not display correctly…..4706
E-16 When monitor switch is operated, nothing is displayed…..4708
E-17 Windshield wiper and window washer do not work…..4710
E-18 "Boom RAISE" is not correctly displayed in monitor function…..4718
E-19 "Boom LOWER" is not correctly displayed in monitor function…..4719
E-20 "Arm IN" is not correctly displayed in monitor function…..4720
E-21 "Arm OUT" is not correctly displayed in monitor function…..4721
E-22 "Bucket CURL" is not correctly displayed in monitor function…..4722
E-23 "Bucket DUMP" is not correctly displayed in monitor function…..4723
E-24 "SWING" is not correctly displayed in monitor function…..4724
E-25 "Left travel" is not displayed normally in monitoring function…..4726
E-26 "Right travel" is not displayed normally in monitoring function…..4728
E-27 "Service" is not correctly displayed in monitor function…..4730
E-28 KOMTRAX system does not operate normally…..4732
E-29 Air conditioner does not work…..4734
E-30 Step light does not light up or go off…..4735
E-31 Electric grease gun does not operate…..4738
E-32 Travel alarm does not sound or does not stop sounding…..4740
40 Troubleshooting…..4743
Troubleshooting of hydraulic and mechanical system (H-mode)…..4743
Troubleshooting of hydraulic and mechanical system (H-mode)…..4745
Information in troubleshooting table…..4745
H-1 Speed or power of all work equipment, travel, and swing is low…..4746
H-2 Engine speed lowers remarkably or engine stalls…..4748
H-3 All work equipment, travel, and swing systems do not work…..4749
H-4 Abnormal sound is heard from around pump…..4750
H-5 Boom speed or power is low…..4751
H-6 Speed or power of arm is low…..4753
H-7 Speed or power of bucket is low…..4754
H-8 Boom does not move…..4755
H-9 Arm does not move…..4755
H-10 Bucket does not move…..4755
H-11 Hydraulic drift of work equipment is large…..4756
H-12 Time lag of work equipment is large…..4758
H-13 Heavy lift function does not operate or stop…..4759
H-14 Machine push-up function does not operate or stop…..4759
H-15 Boom shockless function cannot be turned ON or OFF…..4759
H-16 Machine deviates in one direction…..4760
H-17 Machine deviates largely at start…..4762
H-18 Machine deviates largely during compound operation…..4763
H-19 Travel speed or power is low…..4763
H-20 Machine does not travel (only one track)…..4764
H-21 Travel speed does not change…..4765
H-22 Upper structure does not swing…..4766
H-23 Swing speed or acceleration is low…..4768
H-24 Swing speed or acceleration is low during compound operation of swing andwork equipment…..4769
H-25 Upper structure overruns excessively when it stops swinging…..4771
H-26 Large shock is made when upper structure stops swinging…..4772
H-27 Large abnormal sound is made when upper structure stops swinging…..4773
H-28 Hydraulic drift of swing is large…..4774
40 Troubleshooting…..4777
Troubleshooting of engine (S-mode)…..4777
Troubleshooting of engine (S-mode)…..4779
Method of using troubleshooting chart…..4779
S-1 Starting performance is poor…..4782
S-2 Engine does not start…..4784
S-3 Engine does not pick up smoothly…..4788
S-4 Engine stops during operations…..4789
S-6 Engine lacks output (or lacks power)…..4791
S-7 Exhaust gas color is black (incomplete combustion)…..4792
S-8 Oil consumption is excessive (or exhaust smoke is blue)…..4794
S-9 Oil becomes contaminated quickly…..4795
S-10 Fuel consumption is excessive…..4796
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)…..4797
S-12 Oil pressure drops…..4798
S-13 Oil level rises (Entry of coolant/fuel)…..4799
S-14 Coolant temperature becomes too high (overheating)…..4801
S-15 Abnormal noise is made…..4802
S-16 Vibration is excessive…..4803
90 Diagrams and drawings…..4805
Hydraulic diagrams and drawings…..4805
Hydraulic diagrams and drawings…..4807
90 Diagrams and drawings…..4811
Electrical diagrams and drawings…..4811
Electrical circuit diagram (1/5)…..4813
Electrical circuit diagram (2/5)…..4815
Electrical circuit diagram (3/5)…..4817
Electrical circuit diagram (4/5)…..4819
Electrical circuit diagram (5/5)…..4821
Komatsu PC800, PC800LC, PC800SE, PC850, PC850SE Hydraulic Excavators Repair Service Manuals
