Komatsu Hydraulic Excavator PC800-8E0 PC800LC-8E0 PC800SE-8E0 PC850-8E0 PC850SE-8E0 Shop Manual PDF

Description

Komatsu Hydraulic Excavator PC800-8E0 PC800LC-8E0 PC800SE-8E0 PC850-8E0 PC850SE-8E0 Shop Manual – PDF DOWNLOAD

FILE DETAILS:

Komatsu Hydraulic Excavator PC800-8E0 PC800LC-8E0 PC800SE-8E0 PC850-8E0 PC850SE-8E0 Shop Manual – PDF DOWNLOAD

Language : English
Pages :1327
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu Hydraulic Excavator PC800-8E0 PC800LC-8E0 PC800SE-8E0 PC850-8E0 PC850SE-8E0 Shop Manual – PDF DOWNLOAD

SERIAL NUMBERS
PC800- 65001
PC800LC- 65001
PC800SE- 65001
PC850- 65001
PC850SE- 65001
and up

1. General precautions

Inappropriate handling creates an extreme danger. Read and understand what is described in the Operation and Maintenance Manual before operating the machine. Read and understand what is described in this manual before starting work.

TABLE OF CONTENTS:

Komatsu Hydraulic Excavator PC800-8E0 PC800LC-8E0 PC800SE-8E0 PC850-8E0 PC850SE-8E0 Shop Manual – PDF DOWNLOAD

SERIAL NUMBERS
PC800- 65001
PC800LC- 65001
PC800SE- 65001
PC850- 65001
PC850SE- 65001
and up

COVER 1
Notice of revision 3
00 Index and foreword 11
Table of contents 12
Table of contents 12
Foreword and general information 22
Safety notice 22
How to read the shop manual 27
Explanation of terms for maintenance standard 29
Handling of hydraulic components 31
Method of disconnecting and connecting push-pull type coupler 33
Handling of electric equipment 36
How to read electric wire code 46
Precautions when performing work 49
Standard tightening torque table 52
List of abbreviation 56
Conversion table 60
01 Specification 65
Specifications 68
Specifications drawing 68
Specifications 72
Table of weight 82
Table of fuel, coolant and lubricants 90
10 Structure and function 93
Engine and cooling system 95
Coupling 95
Coupling lubrication system 96
Cooling system 98
Power train system 100
Power train 100
Swing circle 102
Swing machinery 103
Final drive 105
Undercarriage and frame 106
Track frame 106
Idler cushion 108
Hydraulic system 110
Hydraulic component layout 110
Hydraulic tank and filter 112
Hydraulic pump 114
Pump control system 122
Servo valve 124
Self-pressure reducing valve 133
Cooling fan pump 136
Cooling fan motor 145
Electrical grease pump 151
Control valve 152
Straight-travel valve 161
Swing motor 164
Center swivel joint 168
Travel motor 169
PPC valve 179
Solenoid valve 187
Accumulator 195
Quick return valve 196
Return oil filter 199
Line oil filter 200
Pilot oil filter 201
Drain oil filter 202
Electrical system 203
Engine control 203
Electric control system 213
Monitor system 252
Sensors 282
KOMTRAX system 286
20 Standard value table 289
Standard value table 291
Standard value table for engine 291
Standard value table for machine 292
30 Testing and adjusting 305
Tool for testing, adjusting and troubleshooting 307
Tools for testing, adjusting, and troubleshooting 307
Engine and cooling system 311
Testing engine speed 311
Testing intake air pressure (boost pressure) 312
Testing exhaust gas temperature 313
Testing exhaust gas color 314
Adjusting valve clearance 316
Testing compression pressure 317
Testing blowby pressure 319
Testing engine oil pressure 320
Testing EGR valve and bypass valve drive pressure 321
Handling fuel system parts 322
Releasing remaining pressure from fuel system 323
Testing fuel pressure 324
Testing fuel return rate and leakage 325
Bleeding air from fuel circuit 328
Testing fuel circuit for leakage 330
Testing and adjusting alternator belt tension 331
Testing and adjusting air conditioner compressor belt tension 332
Undercarriage and frame 333
Testing swing circle bearing clearance 333
Checking and adjusting track tension 334
Hydraulic system 335
Testing and adjusting oil pressure in work equipment, swing, and travel circuits 335
Testing and adjusting control circuit oil pressure (output pressure of self-pressure reducing valve) 341
Testing and adjusting control signal of main pump 343
Testing PPC valve output pressure 350
Measuring outlet pressure of solenoid valve, swing PPC shuttle valve, and swing priority selector valve 354
Adjusting play of work equipment and swing PPC vavles 359
Testing and adjusting travel deviation 360
Inspecting locations of hydraulic drift in work equipment 362
Measuring fan speed 363
Measuring fan circuit oil pressure 364
Measuring fan pump EPC current 365
Measuring fan pump EPC solenoid valve outlet pressure 366
Measuring oil leakage 367
Releasing remaining pressure from hydraulic circuit 371
Bleeding air from various parts 372
Inspection procedures for diode 375
Adjusting mirrors 376
Electrical system 377
Special functions of machine monitor 377
Handling voltage circuit of engine controller 421
Preparatory work for troubleshooting of electrical system 422
Pm Clinic 426
Pm clinic service 426
UNDERCARRIAGE INSPECTION REPORT 433
40 Troubleshooting 435
General information on troubleshooting 441
Points to remember when troubleshooting 441
Sequence of events in troubleshooting 442
Checks before troubleshooting 443
Classification and procedures for troubleshooting 469
Failure codes table 472
Symptom and troubleshooting numbers 477
Information in troubleshooting table 480
Troubleshooting method for open circuit in wiring harness of pressure sensor system 482
Connector list and layout 484
Connection table for connector pin numbers 495
T- branch box and T- branch adapter table 531
Fuse locations 534
Troubleshooting by failure code 537
Failure code [989L00] Engine Controller Lock Caution 1 537
Failure code [989M00] Engine Controller Lock Caution 2 538
Failure code [989N00] Engine Controller Lock Caution 3 538
Failure code [AA10NX] Air Cleaner Clogging 539
Failure code [AB00KE] Charge Voltage Low 540
Failure code [B@BAZG] Eng Oil Press Low 542
Failure code [B@BAZK] Eng Oil Level Low 543
Failure code [B@BCNS] Eng Water Overheat 544
Failure code [B@BCZK] Eng Water Level Low 546
Failure code [B@HANS] Hyd Oil Overheat 548
Failure code [CA111] ECM Critical Internal Failure 550
Failure code [CA115] Eng Ne and Bkup Speed Sens Error 552
Failure code [CA122] Chg Air Press Sensor High Error 554
Failure code [CA123] Chg Air Press Sensor Low Error 556
Failure code [CA131] Throttle Sensor High Error 558
Failure code [CA132] Throttle Sensor Low Error 560
Failure code [CA135] Eng Oil Press Sensor High Error 562
Failure code [CA141] Eng Oil Press Sensor Low Error 564
Failure code [CA144] Coolant Temp Sens High Error 566
Failure code [CA145] Coolant Temp Sens Low Error 568
Failure code [CA153] Chg Air Temp Sensor High Error 570
Failure code [CA154] Chg Air Temp Sensor Low Error 572
Failure code [CA187] Sens Supply 2 Volt Low Error 574
Failure code [CA221] Ambient Press Sens High Error 576
Failure code [CA222] Ambient Press Sens Low Error 578
Failure code [CA227] Sens Supply 2 Volt High Error 580
Failure code [CA234] Eng Overspeed 581
Failure code [CA238] Ne Speed Sens Supply Volt Error 582
Failure code [CA263] Fuel Temp Sensor High Error 584
Failure code [CA265] Fuel Temp Sensor Low Error 586
Failure code [CA271] IMV/PCV1 Short Error 588
Failure code [CA272] IMV/PCV1 Open Error 589
Failure code [CA273] PCV2 Short Error 590
Failure code [CA274] PCV2 Open Error 591
Failure code [CA322] Inj #1(L#1) Open/Short Error 592
Failure code [CA323] Inj #5 (L#5) Open/Short Error 594
Failure code [CA324] Inj #3(L#3) Open/Short Error 596
Failure code [CA325] Inj #6 (L#6) Open/Short Error 598
Failure code [CA331] Inj #2(L#2) Open/Short Error 600
Failure code [CA332] Inj #4 (L#4) Open/Short Error 602
Failure code [CA342] Calibration Code Incompatibility 604
Failure code [CA351] Injectors Drive Circuit Error 605
Failure code [CA352] Sens Supply 1 Volt Low Error 606
Failure code [CA386] Sens Supply 1 Volt High Error 608
Failure code [CA441] Battery Voltage Low Error 608
Failure code [CA442] Battery Voltage High Error 609
Failure code [CA449] Rail Press Very High Error 609
Failure code [CA451] Rail Press Sensor High Error 610
Failure code [CA452] Rail Press Sensor Low Error 612
Failure code [CA553] Rail Press High Error 614
Failure code [CA554] Rail Press Sensor In Range Error 615
Failure code [CA559] Supply Pump Press Low Error 1 616
Failure code [CA689] Eng Ne Speed Sensor Error 620
Failure code [CA731] Eng Bkup Speed Sens Phase Error 622
Failure code [CA757] All Continuous Data Lost Error 623
Failure code [CA778] Eng Bkup Speed Sensor Error 624
Failure code [CA1228] EGR Valve Servo Error 1 626
Failure code [CA1625] EGR Valve Servo Error 2 627
Failure code [CA1626] BP Valve Sol Current High Error 628
Failure code [CA1627] BP Valve Sol Current Low Error 630
Failure code [CA1628] Bypass Valve Servo Error 1 632
Failure code [CA1629] Bypass Valve Servo Error 2 633
Failure code [CA1631] BP Valve Pos Sens High Error 634
Failure code [CA1632] BP Valve Pos Sens Low Error 636
Failure code [CA1633] KOMNET Datalink Timeout Error 638
Failure code [CA2185] Throt Sens Sup Volt High Error 640
Failure code [CA2186] Throt Sens Sup Volt Low Error 642
Failure code [CA2249] Rail Press Very Low Error 643
Failure code [CA2271] EGR Valve Pos Sens High Error 644
Failure code [CA2272] EGR Valve Pos Sens Low Error 646
Failure code [CA2351] EGR Valve Sol Current High Error 648
Failure code [CA2352] EGR Valve Sol Current Low Error 650
Failure code [CA2555] Grid Htr Relay Open Circuit Error 652
Failure code [CA2556] Grid Htr Relay Short Circuit Error 654
Failure code [D110KB] Battery Relay Drive Short Circuit 656
Failure code [D163KB] Flash Light Relay Short Circuit 658
Failure code [D195KA] Step Light Relay Open Circuit 660
Failure code [D195KB] Step Light Relay Short Circuit 662
Failure code [D19JKZ] Personal Code Relay Abnormality 664
Failure code [D862KA] GPS Antenna Open Circuit 666
Failure code [DA22KK] Pump Solenoid Power Low Error 668
Failure code [DA25KP] 5V Sensor1 Power Abnormality 670
Failure code [DA29KQ] Model Selection Abnormality 672
Failure code [DA2RMC] CAN Discon (Pump Con Detected) 674
Failure code [DA80MA] Auto Lub Abnormal 678
Failure code [DAF8KB] Camera Power Supply Short Circuit 680
Failure code [DAFGMC] GPS Module Error 682
Failure code [DAFRMC] CAN Discon (Monitor Detected) 683
Failure code [DGE5KB] Ambi Temp Sensor Short Circuit 688
Failure code [DGH2KB] Hyd Oil Sensor Short 690
Failure code [DH25KA] L Jet Sensor Open Circuit 692
Failure code [DH25KB] L Jet Sensor Short Circuit 694
Failure code [DH26KA] R Jet Sensor Open Circuit 696
Failure code [DH26KB] R Jet Sensor Short Circuit 698
Failure code [DHPEKA] F Pump P Sensor Open Circuit 700
Failure code [DHPEKB] F Pump P Sensor Short Circuit 702
Failure code [DHPFKA] R Pump P Sensor Open Circuit 704
Failure code [DHPFKB] R Pump P Sensor Short Circuit 706
Failure code [DV20KB] Travel alarm short circuit 708
Failure code [DW41KA] Swing Priority Sol Open Circuit 710
Failure code [DW41KB] Swing Priority Sol Short Circuit 712
Failure code [DW43KA] Travel Speed Sol Open Circuit 714
Failure code [DW43KB] Travel Speed Sol Short Circuit 716
Failure code [DW45KA] Swing Brake Sol Open Circuit 718
Failure code [DW45KB] Swing Brake Sol Short Circuit 720
Failure code [DW7BKA] Fan Reverse Sol Open Circuit 722
Failure code [DW7BKB] Fan Reverse Sol Short Circuit 724
Failure code [DW7JKA] Bottom Dump Priority Sol Open Circuit 726
Failure code [DW7JKB] Bottom Dump Priority Sol Short Circuit 728
Failure code [DW91KA] Travel Junction Sol Open Circuit 730
Failure code [DW91KB] Travel Junction Sol Short Circuit 732
Failure code [DWK0KA] 2-stage Relief Sol Open Circuit 734
Failure code [DWK0KB] 2-stage Relief Sol Short Circuit 736
Failure code [DX16KA] Fan Pump EPC Sol Open Circuit 738
Failure code [DX16KB] Fan Pump EPC Sol Short Circuit 740
Failure code [DXAAKA] F Pump EPC Sol Open Circuit 742
Failure code [DXAAKB] F Pump EPC Sol Short Circuit 744
Failure code [DXABKA] R Pump EPC Sol Open Circuit 746
Failure code [DXABKB] R Pump EPC Sol Short Circuit 748
Failure code [DY20KA] Wiper Working Abnormality 750
Failure code [DY20MA] Wiper Parking Abnormality 754
Failure code [DY2CKA] Washer Drive Open Circuit 756
Failure code [DY2CKB] Washer Drive Short Circuit 758
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit 760
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit 764
Failure code [DY2FMA] Upper Wiper Working Abnormality 768
Failure code [DY2GKM] Wiper Select Abnormality 770
Troubleshooting of electrical system (E-mode) 773
E-1 Engine does not start (Engine does not crank) 773
E-2 Preheater does not operate 778
E-3 When starting switch is turned to ON position, machine monitor displays nothing 782
E-4 When starting switch is turned to ON position (before starting engine), basic check monitor lights up 785
E-5 Precaution item lights up while engine is running 786
E-6 Emergency stop item lights up while engine is running 788
E-7 Engine coolant temperature gauge does not indicate properly 789
E-8 Fuel gauge does not indicate properly 790
E-9 Hydraulic oil temperature gauge does not indicate properly 792
E-10 Displays on machine monitor are different from those for actual machine 794
E-11 Some areas of machine monitor screen are not displayed 794
E-12 Function switch does not operate 794
E-13 Automatic warm-up system does not operate (in cold season) 795
E-14 Auto-decelerator does not operate properly 796
E-15 Working mode does not change 797
E-16 Travel speed does not change 798
E-17 Alarm buzzer cannot be canceled 799
E-18 When starting switch is turned OFF, service meter is not displayed40 799
E-19 Service mode cannot be selected 799
E-20 Any of work equipment, swing and travel do not operate or cannot be locked 800
E-21 Machine push-up function does not operate or cannot be canceled40 802
E-22 Boom shockless function does not operate properly 804
E-23 Swing brake does not operate properly 806
E-24 Windshield wiper and window washer do not operate 808
E-25 Travel alarm does not sound or does not stop sounding 812
E-26 Boom RAISE indicator is not displayed properly with monitoring function 814
E-27 Boom LOWER indicator is not displayed properly with monitoring function 816
E-28 Arm IN indicator is not displayed properly with monitoring function40 818
E-29 Arm OUT indicator is not displayed properly with monitoring function 820
E-30 Bucket CURL indicator is not displayed properly with monitoring function 822
E-31 Bucket DUMP indicator is not displayed properly with monitoring function 824
E-32 Swing indicator is not displayed properly with monitoring function40 826
E-33 “LH travel” is not displayed properly with monitoring function 828
E-34 “RH travel” is not displayed properly with monitoring function 830
E-35 “Attachment” is not displayed properly with monitoring function 832
E-36 Electric grease gun does not operate 834
E-37 KOMTRAX system does not operate properly 836
E-38 Horn does not sound or does not stop sounding 837
E-39 Step light does not light up or go off 840
Troubleshooting of hydraulic and mechanical system (H-mode) 844
Before starting troubleshooting for hydraulic and mechanical systems 844
Information in troubleshooting table (H-mode) 848
H-1 All of work equipment, swing and travel work slow or lack power 850
H-2 Engine speed lowers significantly or engine stalls 852
H-3 Any of work equipment, swing and travel does not work 854
H-4 Unusual noise is heard from around hydraulic pump 856
H-5 Boom operation lacks speed or power 857
H-6 Arm operation lacks speed or power 859
H-7 Bucket operation lacks speed or power 860
H-8 Boom does not move 861
H-9 Arm does not move 861
H-10 Bucket does not move 861
H-11 Hydraulic drift of work equipment is large 862
H-12 Time lag of work equipment is large 864
H-13 Heavy lift function does not work or is not released 865
H-14 Machine push-up function does not work or is not released 865
H-15 Boom shockless function does not work or is not canceled 865
H-16 Machine deviates in one direction against operator’s intention when travelling 866
H-17 Machine deviates significantly at start 869
H-18 Machine deviates significantly during combined operation 870
H-19 Travel works slow or lack power 871
H-20 One of tracks does not run 872
H-21 Travel speed does not change 873
H-22 Upper structure does not swing 874
H-23 Swing speed is low or swing acceleration is poor 875
H-24 In combined operation with work equipment, swing speed is low or swing acceleration is poor 876
H-25 Upper structure overruns excessively when it stops swinging 878
H-26 Shock is large when upper structure stops swinging 879
H-27 Large unusual noise is heard when upper structure stops swinging40 880
H-28 Swing drift on a slope is large 881
H-29 Fan revolution is abnormal (Fan sound/vibration is abnormally large or engine overheats) 882
Troubleshooting of engine (S-mode) 884
Method of using troubleshooting chart 884
S-1 Startability is poor 888
S-2 Engine does not start 890
S-3 Engine does not pick up smoothly 894
S-4 Engine stops during operation 895
S-5 Engine runs rough or is unstable 896
S-6 Engine lacks power 898
S-7 Exhaust smoke is black (incomplete combustion) 900
S-8 Oil consumption is excessive (or exhaust smoke is blue) 902
S-9 Oil becomes contaminated early 903
S-10 Fuel consumption is excessive 904
S-11 Oil is in coolant (or coolant spurts or coolant level goes down) 905
S-12 Oil pressure drops 906
S-13 Oil level rises (coolant or fuel in oil) 908
S-14 Coolant temperature rises too high (overheating) 910
S-15 Unusual noise is made 911
S-16 Vibration is excessive 912
50 Disassembly and assembly 913
General information on disassembly and assembly 916
How to read Disassembly and Assembly 916
Coating materials list 918
Special tools list 921
Sketches of special tools 928
Engine and cooling system 933
Removal and installation of engine, PTO and hydraulic pump assembly50 933
Removal and installation of cooling assembly 941
Removal and installation of aftercooler assembly 947
Removal and installation of fuel cooler and air condenser assembly 949
Removal and installation of fan motor assembly 951
Removal and installation of fuel tank assembly 956
Engine 958
Removal and installation of fuel supply pump assembly 958
Removal and installation of cylinder head assembly 963
Removal and installation of fuel injector assembly 979
Removal and installation of engine front seal 982
Removal and installation of engine rear seal 984
Power train 989
Removal and installation of PTO assembly 989
Disassembly and assembly of PTO assembly 996
Removal and installation of swing motor and swing machinery assembly50 998
Disassembly and assembly of swing machinery assembly1001
Removal and installation of swing circle assembly1008
Disassembly and assembly of final drive assembly1009
Undercarriage and frame1021
Separation and connection of track shoe assembly1021
Disassembly and assembly of one link in field1023
Removal and installation of idler assembly1027
Disassembly and assembly of idler assembly1028
Disassembly and assembly of idler adjustment cylinder assembly1031
Removal and installation of recoil spring assembly1032
Disassembly and assembly of recoil spring assembly1034
Removal and installation of carrier roller assembly1036
Disassembly and assembly of carrier roller assembly1037
Removal and installation of track roller assembly1040
Disassembly and assembly of track roller assembly1041
Removal and installation of revolving frame assembly1044
Removal and installation of counterweight assembly1046
Removal and installation of counterweight remover assembly1047
Hydraulic system1051
Removal and installation of hydraulic tank assembly1051
Removal and installation of main pump assembly1053
Removal and installation of main pump input shaft oil seal1060
Removal and installation of cooling fan pump assembly1061
Removal and installation of control valve assembly1064
Assembly of control valve assembly1067
Removal and installation of swing motor assembly1073
Removal and installation of center swivel joint assembly1074
Disassembly and assembly of center swivel joint assembly1076
Removal and installation of travel motor assembly1078
Removal and installation of solenoid valve assembly1079
Removal and installation of boom damping valve assembly1081
Disassembly and assembly of work equipment PPC valve assembly1082
Disassembly and assembly of travel PPC valve assembly1084
Disassembly and assembly of hydraulic cylinder assembly1087
Disassembly and assembly of grease gun assembly1094
Work equipment1095
Removal and installation of bucket cylinder assembly1095
Removal and installation of arm cylinder assembly1099
Removal and installation of boom cylinder assembly1103
Removal and installation of bottom dump cylinder assembly1107
Removal and installation of bucket assembly1109
Removal and installation of arm assembly1112
Removal and installation of boom assembly1116
Removal and installation of work equipment assembly1120
Cab and its attachments1124
Removal and installation of operator’s cab assembly1124
Removal and installation of operator’s cab glass (adhered window glass)1127
Removal and installation of front window assembly1136
Electrical system1143
Removal and installation of air conditioner unit assembly1143
Removal and installation of engine controller assembly1146
Removal and installation of monitor assembly1148
Removal and installation of pump controller assembly1150
Removal and installation of KOMTRAX terminal assembly1152
60 Maintenance standard1153
Engine and cooling system1155
Coupling1155
Power train1156
Swing circle1156
Swing machinery1157
Final drive1160
Sprocket1162
Undercarriage and frame1164
Track frame and idler cushion1164
Idler1166
Carrier roller1168
Track roller1170
Track shoe1172
Hydraulic system1176
Cooling fan motor1176
Control valve1178
Swing motor1184
Center swivel joint1186
PPC valve1187
Work equipment1190
Work equipment1190
Work equipment dimension1196
Hydraulic cylinder1200
80 Appendix1207
Air conditioner1209
Precautions for refrigerant1209
Air conditioner component1210
Configuration and function of refrigeration cycle1212
Outline of refrigeration cycle1213
Air conditioner unit1216
Air conditioner controller1221
Compressor1222
Condenser1223
Receiver drier1224
Procedure for testing and troubleshooting1226
Circuit diagram and arrangement of connector pins1228
System diagram1230
Detail of air conditioner unit1232
Parts and connectors layout1234
Testing air leakage (duct)1237
Testing with self-diagnosis function1238
Testing temperature control1241
Testing vent (mode) changeover1243
Testing FRESH/RECIRC air changeover1246
Testing inner sensor1248
Testing evaporator temperature sensor1249
Testing sunlight sensor1251
Testing (dual) pressure switch for refrigerant1252
Testing relays1253
Troubleshooting chart 11254
Troubleshooting chart 21256
Information in troubleshooting table1258
Troubleshooting for power supply and CAN communication system (Air conditioner does not operate)1260
Troubleshooting for compressor and refrigerant system (Air is not cooled)1265
Troubleshooting for blower motor system (No air comes out or air flow is abnormal)1269
Troubleshooting for temperature control1273
Troubleshooting for vent (mode) changeover1276
Troubleshooting for FRESH/RECIRC air changeover1278
Troubleshooting for temperature sensor system1280
Troubleshooting with gauge pressure1282
Connection of service tool1284
Precautions for disconnecting and connecting air conditioner piping1286
Handling of compressor oil1288
90 Diagrams and drawings1291
Hydraulic circuit diagram1293
Symbols used in hydraulic circuit diagrams1293
Hydraulic circuit diagram1297
Electrical circuit diagram1299
Symbols used in electric circuit diagrams1299
Electrical circuit diagram1303
Index1320

IMAGES PREVIEW OF THE MANUAL:

S.M 27/12/24