Komatsu Excavator PC800-8R,PC800LC-8R,PC800SE-8R,PC850-8R,PC850SE-8R Shop Manual PDF
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Komatsu Hydraulic Excavator PC800-8R,PC800LC-8R,PC800SE-8R,PC850-8R,PC850SE-8R Shop Manual SEN02316-15 – PDF DOWNLOAD
- SERIAL NUMBERS
PC800- 60001 and up
PC800LC- 60001 and up
PC800SE- 60001 and up
PC850- 60001 and up
PC850SE- 60001 and up
Description
Komatsu Hydraulic Excavator PC800-8R,PC800LC-8R,PC800SE-8R,PC850-8R,PC850SE-8R Shop Manual SEN02316-15 – PDF DOWNLOAD
FILE DETAILS:
Komatsu Hydraulic Excavator PC800-8R,PC800LC-8R,PC800SE-8R,PC850-8R,PC850SE-8R Shop Manual SEN02316-15 – PDF DOWNLOAD
Language : English
Pages : 1084
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Komatsu Hydraulic Excavator PC800-8R,PC800LC-8R,PC800SE-8R,PC850-8R,PC850SE-8R Shop Manual SEN02316-15 – PDF DOWNLOAD
- SERIAL NUMBERS
PC800- 60001 and up
PC800LC- 60001 and up
PC800SE- 60001 and up
PC850- 60001 and up
PC850SE- 60001 and up
COVER . 1
00 Index and foreword . 0
Index . 3
Composition of shop manual 4
Table of contents . 6
Foreword and general information 15
Safety notice . 16
How to read the shop manual . 21
Explanation of terms for maintenance standard . 23
Handling of electric equipment and hydraulic component 25
Handling of connectors newly used for engines . 34
How to read electric wire code 37
Precautions when carrying out operation . 40
Method of disassembling and connecting push-pull type coupler . 43
Standard tightening torque table 46
Conversion table 50
01 Specification 0
Specification and technical data 57
Specification drawings 58
Working range drawing . 60
Specifications 62
Weight table 80
Table of fuel, coolant and lubricants . 86
10 Structure, function and maintenance standard . 0
Engine and cooling system . 89
Coupling 90
Coupling lubrication system . 91
Radiator, oil cooler 92
Power train . 95
Power train . 96
Swing machinery . 98
Swing circle 100
Final drive . 102
Sprocket 104
Undercarriage and frame . 107
Track frame and recoil spring . 108
Idler . 110
Carrier roller 112
Track roller 114
Track shoe 116
Hydraulic system, Part 1 121
Hydraulic piping drawing 122
Hydraulic tank, hydraulic filter 124
Hydraulic pump 126
Cooling fan pump 146
Cooling fan motor . 154
Hydraulic system, Part 2 161
Motor grease pump . 164
Return oil filter . 165
Line oil filter . 166
Drain oil filter 167
L.H. 5-Spool control valve 168
R.H. 4-Spool control valve 174
Straight-travel valve . 180
Swing motor . 183
Center swivel joint . 188
Travel motor 189
PPC accumulator . 199
Work equipment, swing PPC valve . 200
Travel PPC valve 206
Solenoid valve 210
Quick return valve 216
Hydraulic cylinder 218
Work equipment 225
Work equipment 226
Dimensions of work equipment 232
Cab and its attachments . 237
Air conditioner piping 238
Electrical system . 241
Engine control 242
Electric control system . 251
Monitor system 285
Sensors . 303
KOMTRAX system 307
20 Standard value table . 0
Standard service value table 311
Standard service value table for engine . 312
Standard service value table for chassis 313
30 Testing and adjusting 0
Testing and adjusting, Part 1 . 325
Tools for testing, adjusting and troubleshooting 326
Measuring engine speed 329
Measuring intake air pressure (Boost pressure) 330
Measuring exhaust gas temperature . 331
Measuring exhaust gas color . 332
Adjusting valve clearance . 333
Measuring compression pressure 334
Measuring blow-by pressure 335
Measuring engine oil pressure . 336
Handling of fuel system equipment . 337
Remaining pressure relief from fuel system equipment 337
Measuring fuel pressure . 338
Testing fuel return rate and leakage 339
Bleeding air from fuel circuit 341
Testing and adjusting alternator belt tension . 343
Testing and adjusting air conditioner compressor belt . 344
Testing and adjusting, Part 2 . 347
Inspection of swing circle bearing clearance 348
Testing and adjusting track shoe tension 349
Testing and adjusting work equipment, swing, and travel circuit oil pressures . 350
Testing and adjusting control circuit oil pressure (self pressure reducing valve) . 356
Testing and adjusting main pump control pressure 357
Testing and adjusting, Part 3 . 365
Measuring PPC valve output pressure . 366
Measuring outlet pressures of solenoid valve, swing PPC shuttle valve, and swing priority selector valve 370
Adjusting work equipment, swing PPC valve . 374
Testing and adjusting travel deviation 375
Inspection of locations of hydraulic drift of work equipment 377
Measuring fan speed . 378
Measuring fan circuit oil pressure 378
Measuring fan pump EPC current 379
Measuring fan pump EPC solenoid valve output pressure . 379
Measuring oil leakage . 380
Release of residual pressure from hydraulic circuit . 384
Bleeding air from each part . 385
Inspection procedures for diode . 388
Testing and adjusting, Part 4 . 391
Special function of machine monitor . 392
Handling controller voltage circuit . 424
Testing and adjusting, Part 5 . 427
Procedure for turning on KOMTRAX terminal . 428
KOMTRAX terminal lamp indications . 431
Preparation work for troubleshooting electrical system 434
Pm-clinic service . 437
40 Troubleshooting 0
Failure code table and fuse locations . 447
Failure codes table . 448
Fuse locations 451
General information on troubleshooting 455
Points to remember when troubleshooting . 456
Sequence of events in troubleshooting . 457
Checks before troubleshooting . 458
Classification and troubleshooting steps 459
Information in troubleshooting table 464
Connection table for connector pin numbers 466
T- branch box and T- branch adapter table . 502
Troubleshooting by failure code (Display of code), Part 1 . 507
Failure code [AA10NX] Aircleaner Clogging . 510
Failure code [AB00KE] Charge Voltage Low 512
Failure code [B@BAZG] Eng Oil Press. Low 514
Failure code [B@BAZK] Eng. Oil Level Low 515
Failure code [B@BCNS] Eng. Water Overheat . 516
Failure code [B@BCZK] Eng. Water Lvl Low 518
Failure code [B@HANS] Hydr. Oil Overheat 520
Failure code [CA111] ECM Critical Internal Failure 522
Failure code [CA115] Eng Ne and Bkup Speed Sens Error . 524
Failure code [CA122] Chg Air Press Sensor High Error 525
Failure code [CA123] Chg Air Press Sensor Low Error . 527
Failure code [CA131] Throttle Sensor High Error . 528
Failure code [CA132] Throttle Sensor Low Error 530
Failure code [CA135] Eng Oil Press Sensor High Error 531
Failure code [CA141] Eng Oil Press Sensor Low Error . 533
Failure code [CA144] Coolant Temp Sens High Error . 534
Failure code [CA145] Coolant Temp Sens Low Error 536
Failure code [CA153] Chg Air Temp Sensor High Error . 537
Failure code [CA154] Chg Air Temp Sensor Low Error 539
Failure code [CA187] Sens Supply 2 Volt Low Error . 539
Failure code [CA221] Ambient Press Sens High Error 540
Failure code [CA222] Ambient Press Sens Low Error . 542
Failure code [CA227] Sens Supply 2 Volt High Error 543
Failure code [CA234] Eng Overspeed 545
Failure code [CA238] Ne Speed Sens Supply Volt Error 546
Failure code [CA263] Fuel Temp Sensor High Error 548
Failure code [CA265] Fuel Temp Sensor Low Error . 550
Failure code [CA271] IMV/PCV1 Short Error . 551
Failure code [CA272] IMV/PCV1 Open Error 552
Failure code [CA273] PCV2 Short Error . 553
Failure code [CA274] PCV2 Open Error 554
Failure code [CA322] Inj #1 Open/Short Error 555
Failure code [CA323] Inj #5 Open/Short Error 556
Failure code [CA324] Inj #3 Open/Short Error 558
Failure code [CA325] Inj #6 Open/Short Error 560
Failure code [CA331] Inj #2 Open/Short Error 562
Failure code [CA332] Inj #4 Open/Short Error 564
Failure code [CA342] Calibration Code Incompatibility . 565
Failure code [CA351] Injectors Drive Circuit Error 566
Failure code [CA352] Sens Supply 1 Volt Low Error . 568
Failure code [CA386] Sens Supply 1 Volt High Error 570
Troubleshooting by failure code (Display of code), Part 2 . 573
Failure code [CA441] Battery Voltage Low Error 575
Failure code [CA442] Battery Voltage High Error . 575
Failure code [CA449] Rail Press Very High Error . 576
Failure code [CA451] Rail Press Sensor High Error . 578
Failure code [CA452] Rail Press Sensor Low Error 580
Failure code [CA553] Rail Press High Error 580
Failure code [CA554] Rail Press Sensor In Range Error . 581
Failure code [CA559] Rail Press Low Error . 582
Failure code [CA689] Eng Ne Speed Sensor Error 586
Failure code [CA731] Eng Bkup Speed Sens Phase Error 588
Failure code [CA757] All Persistent Data Lost Error . 589
Failure code [CA778] Eng Bkup Speed Sensor Error 590
Failure code [CA1633] KOMNET Datalink Timeout Error . 592
Failure code [CA2185] Throt Sens Sup Volt High Error 594
Failure code [CA2186] Throt Sens Sup Volt Low Error . 596
Failure code [CA2249] Rail Press Very Low Error . 597
Failure code [CA2555] Grid Htr Relay Volt Low Error . 598
Failure code [CA2556] Grid Htr Relay Volt High Error 600
Failure code [D110KB] Battery Relay Drive S/C . 602
Failure code [D163KB] Flash Light Relay S/C . 604
Failure code [D195KB] Step Light Relay S/C 606
Failure code [DA22KK] Low pump controller solenoid power supply voltage . 608
Failure code [DA25KP] Press. Sensor Power Abnormality . 610
Failure code [DA2SKQ] Model Selection Abnormality . 612
Failure code [DA80MA] Auto. Lub. Abnormal . 614
Failure code [DA2RMC] Pump Comm. Abnormality 616
Failure code [DAFRMC] Monitor Comm. Abnormality . 618
Failure code [DGE5KY] Ambi. Temp. Sensor S/C 620
Failure code [DGH2KB] Hydr. Oil Temp. Sensor S/C 622
Troubleshooting by failure code (Display of code), Part 3 . 625
Failure code [DH25KA] L Jet Sensor Disc . 628
Failure code [DH25KB] L Jet Sensor S/C 630
Failure code [DH26KA] R Jet Sensor Disc . 632
Failure code [DH26KB] R Jet Sensor S/C 634
Failure code [DHPEKA] F Pump P. Sensor Disc . 636
Failure code [DHPEKB] F Pump P. Sensor S/C 638
Failure code [DHPFKA] R Pump P. Sensor Disc . 640
Failure code [DHPFKB] R Pump P. Sensor S/C 642
Failure code [DV20KB] Travel Alarm S/C 644
Failure code [DW41KA] Swing Priority Sol. Disc 646
Failure code [DW41KB] Swing Priority Sol. S/C . 648
Failure code [DW43KA] Travel Speed Sol. Disc 650
Failure code [DW43KB] Travel Speed Sol. S/C . 652
Failure code [DW45KA] Swing Brake Sol. Disc . 654
Failure code [DW45KB] Swing Brake Sol. S/C 656
Failure code [DW7BKA] Fan Reverse Sol. Disc . 658
Failure code [DW7BKB] Fan Reverse Sol. S/C 660
Failure code [DW7JKA] Disconnection in bottom dump priority solenoid system . 662
Failure code [DW7JKB] Short circuit in bottom dump priority solenoid system . 664
Failure code [DWK0KA] 2-stage Relief Sol. Disc 666
Failure code [DWK0KB] 2-stage Relief Sol. S/C . 668
Failure code [DX16KA] Fan Pump EPC Sol. Disc 670
Failure code [DX16KB] Fan Pump EPC Sol. S/C . 672
Failure code [DXAAKA] F Pump EPC Sol. Disc 674
Failure code [DXAAKB] F Pump EPC Sol. S/C . 676
Failure code [DXABKA] R Pump EPC Sol. Disc 678
Failure code [DXABKB] R Pump EPC Sol. S/C . 680
Failure code [DY20KA] Wiper Working Abnormality . 682
Failure code [DY20MA] Wiper Parking Abnormality . 684
Failure code [DY2CKB] Washer Drive S/C 688
Failure code [DY2DKB] Wiper Drive (For) S/C . 690
Failure code [DY2EKB] Wiper Drive (Rev) S/C . 694
Troubleshooting of electrical system (E-mode) . 697
Before carrying out troubleshooting of electrical system 699
Information contained in troubleshooting table 701
E-1 Engine does not start (Engine does not rotate) 702
E-2 Preheater does not operate 705
E-3 Auto engine warm-up device does not work 712
E-4 Auto-decelerator does not operate . 713
E-5 All work equipment, swing and travel do not move 714
E-6 Machine push-up function does not operate normally 716
E-7 Boom shockless function does not operate normally . 718
E-8 Any item is not displayed on machine monitor 720
E-9 Part of display on machine monitor is missing . 721
E-10 Machine monitor displays contents irrelevant to the model 721
E-11 Fuel level monitor red lamp lights up while engine is running 722
E-12 Engine coolant thermometer does not display normally . 724
E-13 Hydraulic oil temperature gauge does not display correctly . 726
E-14 Fuel gauge does not display correctly 727
E-15 Swing lock monitor does not display correctly 728
E-16 When monitor switch is operated, nothing is displayed 730
E-17 Windshield wiper and window washer do not work . 732
E-18 “Boom RAISE” is not correctly displayed in monitor function 740
E-19 “Boom LOWER” is not correctly displayed in monitor function 741
E-20 “Arm IN” is not correctly displayed in monitor function 742
E-21 “Arm OUT” is not correctly displayed in monitor function . 743
E-22 “Bucket CURL” is not correctly displayed in monitor function . 744
E-23 “Bucket DUMP” is not correctly displayed in monitor function . 745
E-24 “SWING” is not correctly displayed in monitor function . 746
E-25 “Left travel” is not displayed normally in monitoring function . 748
E-26 “Right travel” is not displayed normally in monitoring function 750
E-27 “Service” is not correctly displayed in monitor function . 752
E-28 KOMTRAX system does not operate normally . 754
E-29 Air conditioner does not work 756
E-30 Step light does not light up or go off . 757
E-31 Electric grease gun does not operate . 760
E-32 Travel alarm does not sound or does not stop sounding 762
E-33 Electric priming pump does not operate or does not stop automatically 764
Troubleshooting of hydraulic and mechanical system (H-mode) . 767
Information in troubleshooting table 769
H-1 Speed or power of all work equipment, travel, and swing is low 770
H-2 Engine speed lowers remarkably or engine stalls . 772
H-3 All work equipment, travel, and swing systems do not work . 773
H-4 Abnormal sound is heard from around pump 774
H-5 Boom speed or power is low 775
H-6 Speed or power of arm is low 777
H-7 Speed or power of bucket is low . 778
H-8 Boom does not move 779
H-9 Arm does not move . 779
H-10 Bucket does not move . 779
H-11 Hydraulic drift of work equipment is large . 780
H-12 Time lag of work equipment is large 782
H-13 Heavy lift function does not operate or stop . 783
H-14 Machine push-up function does not operate or stop 783
H-15 Boom shockless function cannot be turned ON or OFF . 783
H-16 Machine deviates in one direction 784
H-17 Machine deviates largely at start 786
H-18 Machine deviates largely during compound operation . 787
H-19 Travel speed or power is low . 787
H-20 Machine does not travel (only one track) . 788
H-21 Travel speed does not change . 789
H-22 Upper structure does not swing . 790
H-23 Swing speed or acceleration is low . 792
H-24 Swing speed or acceleration is low during compound operation of swing and work equipment . 793
H-25 Upper structure overruns excessively when it stops swinging 795
H-26 Large shock is made when upper structure stops swinging 796
H-27 Large abnormal sound is made when upper structure stops swinging . 797
H-28 Hydraulic drift of swing is large 798
H-29 Fan rotation is abnormal (Fan sound/vibration is abnormally large or fan overheats) 799
Troubleshooting of engine (S-mode) 801
Method of using troubleshooting chart . 803
S-1 Starting performance is poor 806
S-2 Engine does not start . 807
S-3 Engine does not pick up smoothly 810
S-4 Engine stops during operations 811
S-5 Engine does not rotate smoothly . 812
S-6 Engine lacks output (or lacks power) 813
S-7 Exhaust gas color is black (incomplete combustion) 814
S-8 Oil consumption is excessive (or exhaust smoke is blue) . 815
S-9 Oil becomes contaminated quickly 816
S-10 Fuel consumption is excessive 817
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) 818
S-12 Oil pressure drops . 819
S-13 Oil level rises (Entry of coolant/fuel) 820
S-14 Coolant temperature becomes too high (overheating) . 821
S-15 Abnormal noise is made . 822
S-16 Vibration is excessive . 823
S-17 Air cannot be bled from fuel circuit . 824
50 Disassembly and assembly . 0
General information on disassembly and assembly . 827
How to read this maHow to read this manual 828
Coating materials list 830
Special tools list 833
Sketches of special tools . 840
Engine and cooling system (SAA6D140E-5) . 847
Removal and installation of engine, PTO and hydraulic pump assembly . 848
Removal and installation of cooling assembly 855
Removal and installation of aftercooler assembly 860
Removal and installation of fuel cooler and air conditioner condenser assembly 862
Removal and installation of fan motor assembly 864
Removal and installation of fuel tank assembly 869
Engine (SAA6D140E-5) 873
Removal and installation of fuel supply pump assembly . 874
Removal and installation of cylinder head assembly 878
Removal and installation of fuel injector assembly 892
Removal and installation of engine front seal . 895
Removal and installation of engine rear seal 897
Power train . 903
Removal and installation of PTO (coupling) assembly . 904
Disassembly and assembly of PTO (coupling) assembly . 911
Removal and installation of swing motor and swing machinery assembly 913
Disassembly and assembly of swing machinery assembly 915
Removal and installation of swing circle assembly . 922
Disassembly and assembly of final drive assembly 923
Undercarriage and frame . 935
Removal and installation of track shoe assembly . 936
Disassembly and assembly of one link in field . 938
Removal and installation of idler assembly 942
Disassembly and assembly of idler assembly 943
Disassembly and assembly of idler adjustment cylinder assembly 946
Removal and installation of recoil spring assembly 947
Disassembly and assembly of recoil spring assembly 949
Removal and installation of carrier roller assembly . 951
Disassembly and assembly of carrier roller assembly . 952
Removal and installation of track roller assembly . 955
Disassembly and assembly of track roller assembly . 956
Removal and installation of revolving frame assembly 959
Removal and installation of counterweight assembly 961
Hydraulic system 965
Removal and installation of hydraulic tank assembly . 966
Removal and installation of main pump assembly 969
Removal and installation of main pump input shaft oil seal 976
Removal and installation of cooling fan pump assembly . 977
Removal and installation of control valve assembly 980
Assembly of control valve assembly 983
Removal and installation of swing motor assembly 989
Removal and installation of center swivel joint assembly 991
Disassembly and assembly of center swivel joint assembly 993
Removal and installation of travel motor assembly . 995
Removal and installation of solenoid valve assembly . 996
Removal and installation of boom damping valve assembly . 998
Disassembly and assembly of work equipment PPC valve assembly . 999
Disassembly and assembly of travel PPC valve assembly .1001
Disassembly and assembly of hydraulic cylinder assembly .1004
Disassembly and assembly of grease gun assembly .1010
Work equipment 1013
Removal and installation of bucket cylinder assembly 1014
Removal and installation of arm cylinder assembly .1018
Removal and installation of boom cylinder assembly 1022
Removal and installation of bottom dump cylinder assembly .1026
Removal and installation of bucket assembly .1027
Removal and installation of arm assembly 1029
Removal and installation of boom assembly .1032
Removal and installation of work equipment assembly .1036
Cab and its attachments .1041
Removal and installation of operator’s cab 1042
Removal and installation of operator’s cab glass (stuck glass) 1045
Removal and installation of front window assembly .1055
Electrical system .1061
Removal and installation of air conditioner unit assembly .1062
Removal and installation of engine controller assembly 1064
Removal and installation of monitor assembly 1066
Removal and installation of pump controller assembly 1066
Removal and Installation of KOMTRAX terminal assembly .1067
90 Diagrams and drawings 0
Hydraulic diagrams and drawings .1069
Hydraulic circuit diagram .1071
Electrical diagrams and drawings 1074
Electrical circuit diagram (1/6) 1076
Electrical circuit diagram (2/6) 1077
Electrical circuit diagram (3/6) 1078
Electrical circuit diagram (4/6) 1079
Electrical circuit diagram (5/6) 1080
Electrical circuit diagram (6/6) 1081
Connector arrangement diagram .1082
DESCRIPTION:
Komatsu Hydraulic Excavator PC800-8R,PC800LC-8R,PC800SE-8R,PC850-8R,PC850SE-8R Shop Manual SEN02316-15 – PDF DOWNLOAD
- SERIAL NUMBERS
PC800- 60001 and up
PC800LC- 60001 and up
PC800SE- 60001 and up
PC850- 60001 and up
PC850SE- 60001 and up
This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-section explains the structure and function of each component. It
serves not only to give an understanding of the structure, but also serves as reference material for
troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly
and service.
20. Standard value table
This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
2. Revision and distribution
Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most
up-to-date information before you start any work.
G.B 26/12/24
