Komatsu Hydraulic Excavator PC800-8E0 PC800LC-8E0 PC800SE-8E0 PC850-8E0 PC850SE-8E0 Shop Manual SEN05276-11 PDF

Description

Komatsu Hydraulic Excavator PC800-8E0 PC800LC-8E0 PC800SE-8E0 PC850-8E0 PC850SE-8E0 Shop Manual SEN05276-11- PDF DOWNLOAD

FILE DETAILS:

Komatsu Hydraulic Excavator PC800-8E0 PC800LC-8E0 PC800SE-8E0 PC850-8E0 PC850SE-8E0 Shop Manual SEN05276-11- PDF DOWNLOAD

Language : English
Pages :1352
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu Hydraulic Excavator PC800-8E0 PC800LC-8E0 PC800SE-8E0 PC850-8E0 PC850SE-8E0 Shop Manual SEN05276-11- 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 SEN05276-11- PDF DOWNLOAD

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

Cover 1
00 Index and foreword 3
Table of contents 4
Table of contents 4
Foreword and general information 14
Safety notice 14
How to read the shop manual 19
Explanation of terms for maintenance standard 21
Handling of hydraulic components 23
Method of disconnecting and connecting push-pull type coupler 25
Handling of electric equipment 28
How to read electric wire code 38
Precautions when performing work 41
Standard tightening torque table 44
List of abbreviation 48
Conversion table 52
01 Specification 57
Specifications 60
Specifications drawing 60
Specifications 64
Table of weight 74
Table of fuel, coolant and lubricants 82
10 Structure and function 85
Engine and cooling system 87
Coupling 87
Coupling lubrication system 88
Cooling system 90
Power train system 92
Power train 92
Swing circle 94
Swing machinery 95
Final drive 97
Undercarriage and frame 98
Track frame 98
Idler cushion 100
Hydraulic system 102
Hydraulic component layout 102
Hydraulic tank and filter 104
Hydraulic pump 106
Pump control system 114
Servo valve 116
Self-pressure reducing valve 125
Cooling fan pump 128
Cooling fan motor 137
Electrical grease pump 143
Control valve 144
Straight-travel valve 153
Swing motor 156
Center swivel joint 160
Travel motor 161
PPC valve 171
Solenoid valve 179
Accumulator 187
Quick return valve 188
Return oil filter 191
Line oil filter 192
Pilot oil filter 193
Drain oil filter 194
Electrical system 195
Engine control 195
Electric control system 205
Monitor system 244
Sensors 274
KOMTRAX system 278
20 Standard value table 281
Standard value table 283
Standard value table for engine 283
Standard value table for machine 284
30 Testing and adjusting 297
Tool for testing, adjusting and troubleshooting 299
Tools for testing, adjusting, and troubleshooting 299
Engine and cooling system 303
Testing engine speed 303
Testing intake air pressure (boost pressure) 304
Testing exhaust gas temperature 305
Testing exhaust gas color 306
Adjusting valve clearance 308
Testing compression pressure 309
Testing blowby pressure 311
Testing engine oil pressure 312
Testing EGR valve and bypass valve drive pressure 313
Handling fuel system parts 314
Releasing remaining pressure from fuel system 315
Testing fuel pressure 316
Testing fuel return rate and leakage 317
Bleeding air from fuel circuit 320
Testing fuel circuit for leakage 322
Testing and adjusting alternator belt tension 323
Testing and adjusting air conditioner compressor belt tension 324
Undercarriage and frame 325
Testing swing circle bearing clearance 325
Checking and adjusting track tension 326
Hydraulic system 327
Testing and adjusting oil pressure in work equipment, swing, and travel circuits 327
Testing and adjusting control circuit oil pressure (output pressure of self-pressure reducing valve) 333
Testing and adjusting control signal of main pump 335
Testing PPC valve output pressure 342
Measuring outlet pressure of solenoid valve, swing PPC shuttle valve, and swing priority selector valve 346
Adjusting play of work equipment and swing PPC vavles 351
Testing and adjusting travel deviation 352
Inspecting locations of hydraulic drift in work equipment 354
Measuring fan speed 355
Measuring fan circuit oil pressure 356
Measuring fan pump EPC current 357
Measuring fan pump EPC solenoid valve outlet pressure 358
Measuring oil leakage 359
Releasing remaining pressure from hydraulic circuit 363
Bleeding air from various parts 364
Inspection procedures for diode 367
Adjusting mirrors 368
Electrical system 369
Special functions of machine monitor 369
Handling voltage circuit of engine controller 413
Preparatory work for troubleshooting of electrical system 414
Pm Clinic 418
Pm clinic service 418
UNDERCARRIAGE INSPECTION REPORT 425
40 Troubleshooting 427
General information on troubleshooting 433
Points to remember when troubleshooting 433
Sequence of events in troubleshooting 434
Checks before troubleshooting 435
Classification and procedures for troubleshooting 461
Failure codes table 464
Symptom and troubleshooting numbers 469
Information in troubleshooting table 472
Troubleshooting method for open circuit in wiring harness of pressure sensor system 474
Connector list and layout 476
Connection table for connector pin numbers 487
T- branch box and T- branch adapter table 523
Fuse locations 526
Troubleshooting by failure code 529
Failure code [989L00] Engine Controller Lock Caution 1 529
Failure code [989M00] Engine Controller Lock Caution 2 530
Failure code [989N00] Engine Controller Lock Caution 3 530
Failure code [AA10NX] Air Cleaner Clogging 531
Failure code [AB00KE] Charge Voltage Low 532
Failure code [B@BAZG] Eng Oil Press Low 534
Failure code [B@BAZK] Eng Oil Level Low 535
Failure code [B@BCNS] Eng Water Overheat 536
Failure code [B@BCZK] Eng Water Level Low 538
Failure code [B@HANS] Hyd Oil Overheat 540
Failure code [CA111] ECM Critical Internal Failure 542
Failure code [CA115] Eng Ne and Bkup Speed Sens Error 544
Failure code [CA122] Chg Air Press Sensor High Error 546
Failure code [CA123] Chg Air Press Sensor Low Error 548
Failure code [CA131] Throttle Sensor High Error 550
Failure code [CA132] Throttle Sensor Low Error 552
Failure code [CA135] Eng Oil Press Sensor High Error 554
Failure code [CA141] Eng Oil Press Sensor Low Error 556
Failure code [CA144] Coolant Temp Sens High Error 558
Failure code [CA145] Coolant Temp Sens Low Error 560
Failure code [CA153] Chg Air Temp Sensor High Error 562
Failure code [CA154] Chg Air Temp Sensor Low Error 564
Failure code [CA187] Sens Supply 2 Volt Low Error 566
Failure code [CA221] Ambient Press Sens High Error 568
Failure code [CA222] Ambient Press Sens Low Error 570
Failure code [CA227] Sens Supply 2 Volt High Error 572
Failure code [CA234] Eng Overspeed 573
Failure code [CA238] Ne Speed Sens Supply Volt Error 574
Failure code [CA263] Fuel Temp Sensor High Error 576
Failure code [CA265] Fuel Temp Sensor Low Error 578
Failure code [CA271] IMV/PCV1 Short Error 580
Failure code [CA272] IMV/PCV1 Open Error 581
Failure code [CA273] PCV2 Short Error 582
Failure code [CA274] PCV2 Open Error 583
Failure code [CA322] Inj #1(L#1) Open/Short Error 584
Failure code [CA323] Inj #5 (L#5) Open/Short Error 586
Failure code [CA324] Inj #3(L#3) Open/Short Error 588
Failure code [CA325] Inj #6 (L#6) Open/Short Error 590
Failure code [CA331] Inj #2(L#2) Open/Short Error 592
Failure code [CA332] Inj #4 (L#4) Open/Short Error 594
Failure code [CA342] Calibration Code Incompatibility 596
Failure code [CA351] Injectors Drive Circuit Error 597
Failure code [CA352] Sens Supply 1 Volt Low Error 598
Failure code [CA386] Sens Supply 1 Volt High Error 600
Failure code [CA441] Battery Voltage Low Error 600
Failure code [CA442] Battery Voltage High Error 601
Failure code [CA449] Rail Press Very High Error 601
Failure code [CA451] Rail Press Sensor High Error 602
Failure code [CA452] Rail Press Sensor Low Error 604
Failure code [CA553] Rail Press High Error 606
Failure code [CA554] Rail Press Sensor In Range Error 607
Failure code [CA559] Supply Pump Press Low Error 1 608
Failure code [CA689] Eng Ne Speed Sensor Error 612
Failure code [CA731] Eng Bkup Speed Sens Phase Error 614
Failure code [CA757] All Continuous Data Lost Error 615
Failure code [CA778] Eng Bkup Speed Sensor Error 616
Failure code [CA1228] EGR Valve Servo Error 1 618
Failure code [CA1625] EGR Valve Servo Error 2 619
Failure code [CA1626] BP Valve Sol Current High Error 620
Failure code [CA1627] BP Valve Sol Current Low Error 622
Failure code [CA1628] Bypass Valve Servo Error 1 624
Failure code [CA1629] Bypass Valve Servo Error 2 625
Failure code [CA1631] BP Valve Pos Sens High Error 626
Failure code [CA1632] BP Valve Pos Sens Low Error 628
Failure code [CA1633] KOMNET Datalink Timeout Error 630
Failure code [CA2185] Throt Sens Sup Volt High Error 632
Failure code [CA2186] Throt Sens Sup Volt Low Error 634
Failure code [CA2249] Rail Press Very Low Error 635
Failure code [CA2271] EGR Valve Pos Sens High Error 636
Failure code [CA2272] EGR Valve Pos Sens Low Error 638
Failure code [CA2351] EGR Valve Sol Current High Error 640
Failure code [CA2352] EGR Valve Sol Current Low Error 642
Failure code [CA2555] Grid Htr Relay Open Circuit Error 644
Failure code [CA2556] Grid Htr Relay Short Circuit Error 646
Failure code [D110KB] Battery Relay Drive Short Circuit 648
Failure code [D163KB] Flash Light Relay Short Circuit 650
Failure code [D195KA] Step Light Relay Open Circuit 652
Failure code [D195KB] Step Light Relay Short Circuit 654
Failure code [D19JKZ] Personal Code Relay Abnormality 656
Failure code [D862KA] GPS Antenna Open Circuit 658
Failure code [DA22KK] Pump Solenoid Power Low Error 660
Failure code [DA25KP] 5V Sensor1 Power Abnormality 662
Failure code [DA29KQ] Model Selection Abnormality 664
Failure code [DA2RMC] CAN Discon (Pump Con Detected) 666
Failure code [DA80MA] Auto Lub Abnormal 670
Failure code [DAF8KB] Camera Power Supply Short Circuit 672
Failure code [DAFGMC] GPS Module Error 674
Failure code [DAFRMC] CAN Discon (Monitor Detected) 675
Failure code [DGE5KB] Ambi Temp Sensor Short Circuit 680
Failure code [DGH2KB] Hyd Oil Sensor Short 682
Failure code [DH25KA] L Jet Sensor Open Circuit 684
Failure code [DH25KB] L Jet Sensor Short Circuit 686
Failure code [DH26KA] R Jet Sensor Open Circuit 688
Failure code [DH26KB] R Jet Sensor Short Circuit 690
Failure code [DHPEKA] F Pump P Sensor Open Circuit 692
Failure code [DHPEKB] F Pump P Sensor Short Circuit 694
Failure code [DHPFKA] R Pump P Sensor Open Circuit 696
Failure code [DHPFKB] R Pump P Sensor Short Circuit 698
Failure code [DV20KB] Travel alarm short circuit 700
Failure code [DW41KA] Swing Priority Sol Open Circuit 702
Failure code [DW41KB] Swing Priority Sol Short Circuit 704
Failure code [DW43KA] Travel Speed Sol Open Circuit 706
Failure code [DW43KB] Travel Speed Sol Short Circuit 708
Failure code [DW45KA] Swing Brake Sol Open Circuit 710
Failure code [DW45KB] Swing Brake Sol Short Circuit 712
Failure code [DW7BKA] Fan Reverse Sol Open Circuit 714
Failure code [DW7BKB] Fan Reverse Sol Short Circuit 716
Failure code [DW7JKA] Bottom Dump Priority Sol Open Circuit 718
Failure code [DW7JKB] Bottom Dump Priority Sol Short Circuit 720
Failure code [DW91KA] Travel Junction Sol Open Circuit 722
Failure code [DW91KB] Travel Junction Sol Short Circuit 724
Failure code [DWK0KA] 2-stage Relief Sol Open Circuit 726
Failure code [DWK0KB] 2-stage Relief Sol Short Circuit 728
Failure code [DX16KA] Fan Pump EPC Sol Open Circuit 730
Failure code [DX16KB] Fan Pump EPC Sol Short Circuit 732
Failure code [DXAAKA] F Pump EPC Sol Open Circuit 734
Failure code [DXAAKB] F Pump EPC Sol Short Circuit 736
Failure code [DXABKA] R Pump EPC Sol Open Circuit 738
Failure code [DXABKB] R Pump EPC Sol Short Circuit 740
Failure code [DY20KA] Wiper Working Abnormality 742
Failure code [DY20MA] Wiper Parking Abnormality 746
Failure code [DY2CKA] Washer Drive Open Circuit 748
Failure code [DY2CKB] Washer Drive Short Circuit 750
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit 752
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit 756
Failure code [DY2FMA] Upper Wiper Working Abnormality 760
Failure code [DY2GKM] Wiper Select Abnormality 762
Troubleshooting of electrical system (E-mode) 765
E-1 Engine does not start (Engine does not crank) 765
E-2 Preheater does not operate 770
E-3 When starting switch is turned to ON position, machine monitor displays nothing 774
E-4 When starting switch is turned to ON position (before starting engine), basic check monitor lights up 777
E-5 Precaution item lights up while engine is running 778
E-6 Emergency stop item lights up while engine is running 780
E-7 Engine coolant temperature gauge does not indicate properly 781
E-8 Fuel gauge does not indicate properly 782
E-9 Hydraulic oil temperature gauge does not indicate properly 784
E-10 Displays on machine monitor are different from those for actual machine 786
E-11 Some areas of machine monitor screen are not displayed 786
E-12 Function switch does not operate 786
E-13 Automatic warm-up system does not operate (in cold season) 787
E-14 Auto-decelerator does not operate properly 788
E-15 Working mode does not change 789
E-16 Travel speed does not change 790
E-17 Alarm buzzer cannot be canceled 791
E-18 When starting switch is turned OFF, service meter is not displayed40 791
E-19 Service mode cannot be selected 791
E-20 Any of work equipment, swing and travel do not operate or cannot be locked 792
E-21 Machine push-up function does not operate or cannot be canceled40 794
E-22 Boom shockless function does not operate properly 796
E-23 Swing brake does not operate properly 798
E-24 Windshield wiper and window washer do not operate 800
E-25 Travel alarm does not sound or does not stop sounding 804
E-26 Boom RAISE indicator is not displayed properly with monitoring function 806
E-27 Boom LOWER indicator is not displayed properly with monitoring function 808
E-28 Arm IN indicator is not displayed properly with monitoring function40 810
E-29 Arm OUT indicator is not displayed properly with monitoring function 812
E-30 Bucket CURL indicator is not displayed properly with monitoring function 814
E-31 Bucket DUMP indicator is not displayed properly with monitoring function 816
E-32 Swing indicator is not displayed properly with monitoring function40 818
E-33 “LH travel” is not displayed properly with monitoring function 820
E-34 “RH travel” is not displayed properly with monitoring function 822
E-35 “Attachment” is not displayed properly with monitoring function 824
E-36 Electric grease gun does not operate 826
E-37 KOMTRAX system does not operate properly 828
E-38 Horn does not sound or does not stop sounding 829
E-39 Step light does not light up or go off 832
Troubleshooting of hydraulic and mechanical system (H-mode) 836
Before starting troubleshooting for hydraulic and mechanical systems 836
Information in troubleshooting table (H-mode) 840
H-1 All of work equipment, swing and travel work slow or lack power 842
H-2 Engine speed lowers significantly or engine stalls 844
H-3 Any of work equipment, swing and travel does not work 846
H-4 Unusual noise is heard from around hydraulic pump 848
H-5 Boom operation lacks speed or power 849
H-6 Arm operation lacks speed or power 851
H-7 Bucket operation lacks speed or power 852
H-8 Boom does not move 853
H-9 Arm does not move 853
H-10 Bucket does not move 853
H-11 Hydraulic drift of work equipment is large 854
H-12 Time lag of work equipment is large 856
H-13 Heavy lift function does not work or is not released 857
H-14 Machine push-up function does not work or is not released 857
H-15 Boom shockless function does not work or is not canceled 857
H-16 Machine deviates in one direction against operator’s intention when travelling 858
H-17 Machine deviates significantly at start 861
H-18 Machine deviates significantly during combined operation 862
H-19 Travel works slow or lack power 863
H-20 One of tracks does not run 864
H-21 Travel speed does not change 865
H-22 Upper structure does not swing 866
H-23 Swing speed is low or swing acceleration is poor 867
H-24 In combined operation with work equipment, swing speed is low or swing acceleration is poor 868
H-25 Upper structure overruns excessively when it stops swinging 870
H-26 Shock is large when upper structure stops swinging 871
H-27 Large unusual noise is heard when upper structure stops swinging40 872
H-28 Swing drift on a slope is large 873
H-29 Fan revolution is abnormal (Fan sound/vibration is abnormally large or engine overheats) 874
Troubleshooting of engine (S-mode) 876
Method of using troubleshooting chart 876
S-1 Startability is poor 880
S-2 Engine does not start 882
S-3 Engine does not pick up smoothly 886
S-4 Engine stops during operation 887
S-5 Engine runs rough or is unstable 888
S-6 Engine lacks power 890
S-7 Exhaust smoke is black (incomplete combustion) 892
S-8 Oil consumption is excessive (or exhaust smoke is blue) 894
S-9 Oil becomes contaminated early 895
S-10 Fuel consumption is excessive 896
S-11 Oil is in coolant (or coolant spurts or coolant level goes down) 897
S-12 Oil pressure drops 898
S-13 Oil level rises (coolant or fuel in oil) 900
S-14 Coolant temperature rises too high (overheating) 902
S-15 Unusual noise is made 903
S-16 Vibration is excessive 904
50 Disassembly and assembly 905
General information on disassembly and assembly 908
How to read Disassembly and Assembly 908
Coating materials list 910
Special tools list 913
Sketches of special tools 920
Engine and cooling system 925
Removal and installation of engine, PTO and hydraulic pump assembly50 925
Removal and installation of cooling assembly 933
Removal and installation of aftercooler assembly 939
Removal and installation of fuel cooler and air condenser assembly 941
Removal and installation of fan motor assembly 943
Removal and installation of fuel tank assembly 948
Engine 950
Removal and installation of fuel supply pump assembly 950
Removal and installation of cylinder head assembly 955
Removal and installation of fuel injector assembly 971
Removal and installation of engine front seal 974
Removal and installation of engine rear seal 976
Power train 981
Removal and installation of PTO assembly 981
Disassembly and assembly of PTO assembly 988
Removal and installation of swing motor and swing machinery assembly50 990
Disassembly and assembly of swing machinery assembly 993
Removal and installation of swing circle assembly1000
Disassembly and assembly of final drive assembly1001
Undercarriage and frame1013
Separation and connection of track shoe assembly1013
Disassembly and assembly of one link in field1015
Removal and installation of idler assembly1019
Disassembly and assembly of idler assembly1020
Disassembly and assembly of idler adjustment cylinder assembly1023
Removal and installation of recoil spring assembly1024
Disassembly and assembly of recoil spring assembly1026
Removal and installation of carrier roller assembly1028
Disassembly and assembly of carrier roller assembly1029
Removal and installation of track roller assembly1032
Disassembly and assembly of track roller assembly1033
Removal and installation of revolving frame assembly1036
Removal and installation of counterweight assembly1038
Removal and installation of counterweight remover assembly1039
Hydraulic system1043
Removal and installation of hydraulic tank assembly1043
Removal and installation of main pump assembly1045
Removal and installation of main pump input shaft oil seal1052
Removal and installation of cooling fan pump assembly1053
Removal and installation of control valve assembly1056
Assembly of control valve assembly1059
Removal and installation of swing motor assembly1065
Removal and installation of center swivel joint assembly1066
Disassembly and assembly of center swivel joint assembly1068
Removal and installation of travel motor assembly1070
Removal and installation of solenoid valve assembly1071
Removal and installation of boom damping valve assembly1073
Disassembly and assembly of work equipment PPC valve assembly1074
Disassembly and assembly of travel PPC valve assembly1076
Disassembly and assembly of hydraulic cylinder assembly1079
Disassembly and assembly of grease gun assembly1086
Work equipment1087
Removal and installation of bucket cylinder assembly1087
Removal and installation of arm cylinder assembly1091
Removal and installation of boom cylinder assembly1095
Removal and installation of bottom dump cylinder assembly1099
Removal and installation of bucket assembly1101
Removal and installation of arm assembly1104
Removal and installation of boom assembly1108
Removal and installation of work equipment assembly1112
Cab and its attachments1116
Removal and installation of operator’s cab assembly1116
Removal and installation of operator’s cab glass (adhered window glass)1119
Removal and installation of front window assembly1128
Removal and installation of work equipment control lever assembly1135
Electrical system1149
Removal and installation of air conditioner unit assembly1149
Removal and installation of engine controller assembly1152
Removal and installation of monitor assembly1154
Removal and installation of pump controller assembly1156
Removal and installation of KOMTRAX terminal assembly1158
60 Maintenance standard1159
Engine and cooling system1161
Coupling1161
Power train1162
Swing circle1162
Swing machinery1163
Final drive1166
Sprocket1168
Undercarriage and frame1170
Track frame and idler cushion1170
Idler1172
Carrier roller1174
Track roller1176
Track shoe1178
Hydraulic system1182
Cooling fan motor1182
Control valve1184
Swing motor1190
Center swivel joint1192
PPC valve1193
Work equipment1196
Work equipment1196
Work equipment dimension1202
Hydraulic cylinder1206
80 Appendix1213
Air conditioner1215
Precautions for refrigerant1215
Air conditioner component1216
Configuration and function of refrigeration cycle1218
Outline of refrigeration cycle1219
Air conditioner unit1222
Air conditioner controller1227
Compressor1228
Condenser1229
Receiver drier1230
Procedure for testing and troubleshooting1232
Circuit diagram and arrangement of connector pins1234
System diagram1236
Detail of air conditioner unit1238
Parts and connectors layout1240
Testing air leakage (duct)1243
Testing with self-diagnosis function1244
Testing temperature control1247
Testing vent (mode) changeover1249
Testing FRESH/RECIRC air changeover1252
Testing inner sensor1254
Testing evaporator temperature sensor1255
Testing sunlight sensor1257
Testing (dual) pressure switch for refrigerant1258
Testing relays1259
Troubleshooting chart 11260
Troubleshooting chart 21262
Information in troubleshooting table1264
Troubleshooting for power supply and CAN communication system (Air conditioner does not operate)1266
Troubleshooting for compressor and refrigerant system (Air is not cooled)1271
Troubleshooting for blower motor system (No air comes out or air flow is abnormal)1275
Troubleshooting for temperature control1279
Troubleshooting for vent (mode) changeover1282
Troubleshooting for FRESH/RECIRC air changeover1284
Troubleshooting for temperature sensor system1286
Troubleshooting with gauge pressure1288
Connection of service tool1290
Precautions for disconnecting and connecting air conditioner piping1292
Handling of compressor oil1294
90 Diagrams and drawings1297
Hydraulic circuit diagram1299
Symbols used in hydraulic circuit diagrams1299
Hydraulic circuit diagram1303
Electrical circuit diagram1307
Symbols used in electric circuit diagrams1307
Electrical circuit diagram1311
Index1345

IMAGES PREVIEW OF THE MANUAL:

S.M 26/12/24