Komatsu PC800-8 PC800LC-8 Excavator Shop Manual UEN00373-03 PDF

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Komatsu PC800-8 PC800LC-8 Hydraulic Excavator Shop Manual UEN00373-03 – PDF DOWNLOAD

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Komatsu PC800-8 PC800LC-8 Hydraulic Excavator Shop Manual UEN00373-03 – PDF DOWNLOAD 

Language : English
Pages : 30
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu PC800-8 PC800LC-8 Hydraulic Excavator Shop Manual UEN00373-03 – PDF DOWNLOAD 

SERIAL NUMBERS
PC800- 50001 and up
PC800LC- 50001 and up
PC800- K50001 and up
PC800LC- K50001 and up

00 Index and foreword
Index UEN00375-01
Organization list of the shop manual 2
Table of contents 4
Foreword and general information UEN00376-00
Foreword and general information 2
Safety notice 2
How to read the shop manual 6
Explanation of terms for maintenance standard 8
Handling electric equipment and hydraulic component 10
How to read electric wire code 18
Method of disassembling and connecting push-pull type coupler 21
Standard tightening torque table 24
Conversion table 28
01 Specification
Specification and technical data UEN00378-00
Specification and technical data 2
Specification drawings 2
Working range drawing 3
Specifications 4
Weight table 10
Table of fuel, coolant and lubricants 13
10 Structure, function and maintenance standard
Engine and cooling system UEN00380-00
Engine and cooling system 2
Coupling 2
Coupling lubrication system 3
Power train UEN00381-00
Power train 2
Power train 2
Swing machinery 4
Swing circle 6
Final drive 8
Sprocket 10
Undercarriage and frame UEN00382-00
Undercarriage and frame 2
Track frame and recoil spring 2
Idler 4
Carrier roller 6
Track roller 8
Track shoe 10
Double shoe 13
Hydraulic system, Part 1 UEN00383-00
Hydraulic system, Part 1 2
Hydraulic tank, hydraulic filter 4
Hydraulic pump 6
Operation of pump control mechanism 12
EPC valve 14
Self pressure reducing valve 17
Cooling fan pump 21
Cooling fan motor 30
PC800, 800LC-8 5
00 Index and foreword UEN00375-03
Hydraulic system, Part 2 UEN00384-00
Hydraulic system, Part 2 3
Motor grease pump 3
Return oil filter 4
Line oil filter 5
Drain oil filter 6
L H 5-Spool control valve 8
R H 4-Spool control valve 14
Straight-travel valve 21
Swing motor 24
Center swivel joint 29
Travel motor 30
PPC accumulator 40
Work equipment, swing PPC valve 41
Travel PPC valve 46
Solenoid valve 50
Hydraulic cylinder 56
Work equipment UEN00385-00
Work equipment 2
Work equipment 2
Dimensions of work equipment 4
Cab and its attachments UEN00396-00
Cab and its attachments 2
Air conditioner piping 2
Electrical system UEN00386-00
Electrical system 2
Engine control 2
Electric control system 11
Monitor system 45
Sensors 63
20 Standard value table
Standard service value table UEN00784-00
Standard service value table for engine 2
Standard service value table for chassis 3
30 Testing and adjusting
Testing and adjusting, Part 1 UEN00786-00
Testing and adjusting, Part 1 2
Tools for testing, adjusting and troubleshooting 2
Measuring engine speed 4
Measuring intake air pressure (Boost pressure) 5
Measuring exhaust gas temperature 6
Measuring exhaust gas color 7
Adjusting valve clearance 8
Measuring compression pressure 9
Measuring blow-by pressure 10
Measuring engine oil pressure 11
Handling of fuel system equipment 12
Remaining pressure relief from fuel system equipment 12
Measuring fuel pressure 13
Testing fuel return rate and leakage 14
Bleeding air from fuel circuit 16
Testing and adjusting alternator belt tension 17
Testing and adjusting air conditioner compressor belt 18
6 PC800, 800LC-8
UEN00375-03 00 Index and foreword
Testing and adjusting, Part 2 UEN00788-00
Testing and adjusting, Part 2 2
Inspection of swing circle bearing clearance 2
Testing and adjusting track shoe tension 3
Testing and adjusting work equipment, swing, and travel circuit oil pressures 4
Testing and adjusting control circuit oil pressure (self pressure reducing valve) 9
Testing and adjusting main pump control pressure 10
Testing and adjusting, Part 3 UEN00912-00
Testing and adjusting, Part 3 2
Measuring PPC valve output pressure 2
Measuring outlet pressures of solenoid valve, swing PPC shuttle valve, and swing priority selector valve 6
Adjusting work equipment, swing PPC valve 10
Testing and adjusting travel deviation 11
Inspection of locations of hydraulic drift of work equipment 13
Measuring fan speed 14
Measuring fan circuit oil pressure 14
Measuring fan pump EPC current 15
Measuring fan pump EPC solenoid valve output pressure 15
Measuring oil leakage 16
Release of residual pressure from hydraulic circuit 20
Bleeding air from each part 21
Inspection procedures for diode 24
Testing and adjusting, Part 4 UEN00913-00
Testing and adjusting, Part 4 2
Special function of machine monitor 2
Handling engine controller high voltage circuit 33
Testing and adjusting, Part 5 UEN00914-00
Testing and adjusting, Part 5 2
Procedure for turning on KOMTRAX terminal 2
KOMTRAX terminal lamp indications 5
Preparation work for troubleshooting electrical system 8
Pm-clinic service 11
40 Troubleshooting
General information on troubleshooting UEN00789-00
General information on troubleshooting 2
Points to remember when troubleshooting 2
Sequence of events in troubleshooting 3
Checks before troubleshooting 4
Classification and troubleshooting steps 5
Connection table for connector pin numbers 9
T-boxes and T-adapters table 32
Troubleshooting by failure code (Display of code), Part 1 UEN00790-00
Troubleshooting by failure code (Display of code), Part 1 3
Failure codes table 3
Information in troubleshooting table 8
Failure code [A000N1] Eng Hi Out of Std 10
Failure code [AA10NX] Aircleaner Clogging 12
Failure code [AB00KE] Charge Voltage Low 14
Failure code [B@BAZG] Eng Oil Press Low 16
Failure code [B@BAZK] Eng Oil Level Low 18
Failure code [B@BCNS] Eng Water Overheat 20
Failure code [B@BCZK] Eng Water Lvl Low 22
Failure code [B@HANS] Hydr Oil Overheat 24
Failure code [CA111] ECM Critical Internal Failure 26
Failure code [CA115] Eng Ne and Bkup Speed Sens Error 28
Failure code [CA122] Chg Air Press Sensor High Error 30
PC800, 800LC-8 7
00 Index and foreword UEN00375-03
Failure code [CA123] Chg Air Press Sensor Low Error 33
Failure code [CA131] Throttle Sensor High Error 34
Failure code [CA132] Throttle Sensor Low Error 36
Failure code [CA135] Eng Oil Press Sensor High Error 38
Failure code [CA141] Eng Oil Press Sensor Low Error 40
Failure code [CA144] Coolant Temp Sens High Error 42
Failure code [CA145] Coolant Temp Sens Low Error 44
Failure code [CA153] Chg Air Temp Sensor High Error 46
Failure code [CA154] Chg Air Temp Sensor Low Error 48
Failure code [CA187] Sens Supply 2 Volt Low Error 49
Failure code [CA221] Ambient Press Sens High Error 50
Failure code [CA222] Ambient Press Sens Low Error 52
Failure code [CA227] Sens Supply 2 Volt High Error 54
Failure code [CA234] Eng Overspeed 56
Failure code [CA238] Ne Speed Sens Supply Volt Error 58
Failure code [CA263] Fuel Temp Sensor High Error 60
Failure code [CA265] Fuel Temp Sensor Low Error 62
Failure code [CA271] IMV/PCV1 Short Error 63
Failure code [CA272] IMV/PCV1 Open Error 64
Failure code [CA273] PCV2 Short Error 65
Failure code [CA274] PCV2 Open Error 66
Failure code [CA322] Inj #1 (L#1) Open/Short Error 67
Failure code [CA323] Inj #5 (L#5) Open/Short Error 68
Failure code [CA324] Inj #3 (L#3) Open/Short Error 69
Failure code [CA325] Inj #6 (L#6) Open/Short Error 70
Failure code [CA331] Inj #2 (L#2) Open/Short Error 71
Failure code [CA332] Inj #4 (L#4) Open/Short Error 72
Failure code [CA351] Injectors Drive Circuit Error 74
Failure code [CA352] Sens Supply 1 Volt Low Error 76
Failure code [CA386] Sens Supply 1 Volt High Error 78
Troubleshooting by failure code (Display of code), Part 2 UEN00791-00
Troubleshooting by failure code (Display of code), Part 2 3
Failure code [CA441] Battery Voltage Low Error 3
Failure code [CA442] Battery Voltage High Error 3
Failure code [CA449] Rail Press Very High Error 4
Failure code [CA451] Rail Press Sensor High Error 6
Failure code [CA452] Rail Press Sensor Low Error 8
Failure code [CA553] Rail Press High Error 8
Failure code [CA554] Rail Press Sensor In Range Error 9
Failure code [CA559] Rail Press Low Error 10
Failure code [CA689] Eng Ne Speed Sensor Error 14
Failure code [CA731] Eng Bkup Speed Sens Phase Error 16
Failure code [CA757] All Persistent Data Lost Error 17
Failure code [CA778] Eng Bkup Speed Sensor Error 18
Failure code [CA1228] EGR Valve Servo Error 1 20
Failure code [CA1625] EGR Valve Servo Error 2 21
Failure code [CA1626] BP Valve Sol Current High Error 22
Failure code [CA1627] BP Valve Sol Current Low Error 24
Failure code [CA1628] Bypass Valve Servo Error 1 25
Failure code [CA1629] Bypass Valve Servo Error 2 26
Failure code [CA1631] BP Valve Pos Sens High Error 28
Failure code [CA1632] BP Valve Pos Sens Low Error 30
Failure code [CA1633] KOMNET Datalink Timeout Error 31
Failure code [CA1642] EGR Inter Press Sens Low Error 33
Failure code [CA2185] Throt Sens Sup Volt High Error 36
Failure code [CA2186] Throt Sens Sup Volt Low Error 38
Failure code [CA2249] Rail Press Very Low Error 39
Failure code [CA2271] EGR Valve Pos Sens High Error 40
8 PC800, 800LC-8
UEN00375-03 00 Index and foreword
Failure code [CA2272] EGR Valve Pos Sens Low Error 42
Failure code [CA2351] EGR Valve Sol Current High Error 44
Failure code [CA2352] EGR Valve Sol Current Low Error 46
Failure code [CA2555] Grid Htr Relay Volt Low Error 47
Failure code [CA2556] Grid Htr Relay Volt High Error 48
Failure code [D110KB] Battery Relay Drive S/C 50
Failure code [D163KB] Flash Light Relay S/C 52
Failure code [D195KB] Step Light Relay S/C 54
Failure code [DA25KP] Press Sensor Power Abnormality 56
Failure code [DA2SKQ] Model Selection Abnormality 58
Failure code [DA80MA] Auto Lub Abnormal 60
Failure code [DA2RMC] Pump Comm Abnormality 62
Failure code [DAFRMC] Monitor Comm Abnormality 64
Failure code [DGE5KY] Ambi Temp Sensor S/C 66
Failure code [DGH2KB] Hydr Oil Temp Sensor S/C 68
Troubleshooting by failure code (Display of code), Part 3 UEN00792-00
Troubleshooting by failure code (Display of code), Part 3 4
Failure code [DH25KA] L Jet Sensor Disc 4
Failure code [DH25KB] L Jet Sensor S/C 6
Failure code [DH26KA] R Jet Sensor Disc 8
Failure code [DH26KB] R Jet Sensor S/C 10
Failure code [DHPEKA] F Pump P Sensor Disc 12
Failure code [DHPEKB] F Pump P Sensor S/C 14
Failure code [DHPFKA] R Pump P Sensor Disc 16
Failure code [DHPFKB] R Pump P Sensor S/C 18
Failure code [DV20KB] Travel Alarm S/C 20
Failure code [DW41KA] Swing Priority Sol Disc 22
Failure code [DW41KB] Swing Priority Sol S/C 24
Failure code [DW43KA] Travel Speed Sol Disc 26
Failure code [DW43KB] Travel Speed Sol S/C 28
Failure code [DW45KA] Swing Brake Sol Disc 30
Failure code [DW45KB] Swing Brake Sol S/C 32
Failure code [DW7BKA] Fan Reverse Sol Disc 34
Failure code [DW78KB] Fan Reverse Sol S/C 36
Failure code [DWK0KA] 2-stage Relief Sol Disc 38
Failure code [DWK0KB] 2-stage Relief Sol S/C 40
Failure code [DX16KA] Fan Pump EPC Sol Disc 42
Failure code [DX16KB] Fan Pump EPC Sol S/C 44
Failure code [DXAAKA] F Pump EPC Sol Disc 46
Failure code [DXAAKB] F Pump EPC Sol S/C 48
Failure code [DXABKA] R Pump EPC Sol Disc 50
Failure code [DXABKB] R Pump EPC Sol S/C 52
Failure code [DY20KA] Wiper Working Abnormality 54
Failure code [DY20MA] Wiper Parking Abnormality 56
Failure code [DY2CKB] Washer Drive S/C 60
Failure code [DY2DKB] Wiper Drive (For) S/C 62
Failure code [DY2EKB] Wiper Drive (Rev) S/C 66
Troubleshooting of electrical system (E-mode) UEN00793-00
Troubleshooting of electrical system (E-mode) 3
Before carrying out troubleshooting of electrical system 3
Information contained in troubleshooting table 5
E-1 Engine does not start (Engine does not rotate) 6
E-2 Preheater does not operate 9
E-3 Auto engine warm-up device does not work 14
E-4 Auto-decelerator does not operate 15
E-5 All work equipment, swing and travel do not move 16
E-6 Machine push-up function does not operate normally 18
E-7 Boom shockless function does not operate normally 20
PC800, 800LC-8 9
00 Index and foreword UEN00375-03
E-8 Any item is not displayed on machine monitor 22
E-9 Part of display on machine monitor is missing 23
E-10 Machine monitor displays contents irrelevant to the model 23
E-11 Fuel level monitor red lamp lights up while engine is running 24
E-12 Engine coolant thermometer does not display normally 26
E-13 Hydraulic oil temperature gauge does not display correctly 28
E-14 Fuel gauge does not display correctly 29
E-15 Swing lock monitor does not display correctly 30
E-16 When monitor switch is operated, nothing is displayed 32
E-17 Windshield wiper and window washer do not work 34
E-18 “Boom RAISE” is not correctly displayed in monitor function 42
E-19 “Boom LOWER” is not correctly displayed in monitor function 43
E-20 “Arm IN” is not correctly displayed in monitor function 44
E-21 “Arm OUT” is not correctly displayed in monitor function 45
E-22 “Bucket CURL” is not correctly displayed in monitor function 46
E-23 “Bucket DUMP” is not correctly displayed in monitor function 47
E-24 “SWING” is not correctly displayed in monitor function 48
E-25 “Left travel” is not displayed normally in monitoring function 50
E-26 “Right travel” is not displayed normally in monitoring function 52
E-27 “Service” is not correctly displayed in monitor function 54
E-28 KOMTRAX system does not operate normally 56
E-29 Air conditioner does not work 58
E-30 Step light does not light up or go off 59
E-31 Electric grease gun does not operate 62
E-32 Travel alarm does not sound or does not stop sounding 64
Troubleshooting of hydraulic and mechanical system (H-mode) UEN00794-00
Troubleshooting of hydraulic and mechanical system (H-mode) 3
Information in troubleshooting table 3
H-1 Speed or power of all work equipment, travel, and swing is low 4
H-2 Engine speed lowers remarkably or engine stalls 6
H-3 All work equipment, travel, and swing systems do not work 7
H-4 Abnormal sound is heard from around pump 8
H-5 Boom speed or power is low 9
H-6 Speed or power of arm is low 11
H-7 Speed or power of bucket is low 12
H-8 Boom does not move 13
H-9 Arm does not move 13
H-10 Bucket does not move 13
H-11 Hydraulic drift of work equipment is large 14
H-12 Time lag of work equipment is large 16
H-13 Heavy lift function does not operate or stop 17
H-14 Machine push-up function does not operate or stop 17
H-15 Boom shockless function cannot be turned ON or OFF 17
H-16 Machine deviates in one direction 18
H-17 Machine deviates largely at start 20
H-18 Machine deviates largely during compound operation 21
H-19 Travel speed or power is low 21
H-20 Machine does not travel (only one track) 22
H-21 Travel speed does not change 23
H-22 Upper structure does not swing 24
H-23 Swing speed or acceleration is low 26
H-24 Swing speed or acceleration is low during compound operation of swing andwork equipment 27
H-25 Upper structure overruns excessively when it stops swinging 29
H-26 Large shock is made when upper structure stops swinging 30
H-27 Large abnormal sound is made when upper structure stops swinging 31
H-28 Hydraulic drift of swing is large 32
Troubleshooting of engine (S-mode) UEN00795-00
Troubleshooting of engine (S-mode) 3
10 PC800, 800LC-8
UEN00375-03 00 Index and foreword
Method of using troubleshooting chart 3
S-1 Starting performance is poor 6
S-2 Engine does not start 8
S-3 Engine does not pick up smoothly 12
S-4 Engine stops during operations 13
S-6 Engine lacks output (or lacks power) 15
S-7 Exhaust gas color is black (incomplete combustion) 16
S-8 Oil consumption is excessive (or exhaust smoke is blue) 18
S-9 Oil becomes contaminated quickly 19
S-10 Fuel consumption is excessive 20
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) 21
S-12 Oil pressure drops 22
S-13 Oil level rises (Entry of coolant/fuel) 23
S-14 Coolant temperature becomes too high (overheating) 25
S-15 Abnormal noise is made 26
S-16 Vibration is excessive 27
50 Disassembly and assembly
General information on disassembly and assembly UEN01052-00
How to read this manual2
Coating materials list 4
Special tools list 7
Sketches of special tools 14
Engine and cooling system, Part 1 UEN01053-00
Removal and installation of engine, PTO and hydraulic pump assembly 2
Removal and installation of cooling assembly 10
Removal and installation of aftercooler 15
Removal and installation of fuel cooler and air conditioner condenser assembly 17
Removal and installation of fan motor assembly 19
Removal and installation of fuel tank assembly 24
Engine and cooling system, Part 2 UEN01054-00
Removal and installation of fuel supply pump assembly 2
Removal and installation of cylinder head assembly 7
Removal and installation of fuel injector assembly 23
Removal and installation of engine front seal 26
Removal and installation of engine rear seal 28
Power train UEN01055-00
Removal and installation of PTO (coupling) assembly 2
Disassembly and assembly of PTO (coupling) assembly 6
Removal and installation of swing motor and swing machinery assembly 8
Disassembly and assembly of swing machinery assembly 10
Removal and installation of swing circle assembly 17
Disassembly and assembly of final drive assembly 18
Undercarriage and frame UEN01056-00
Removal and installation of track shoe assembly 2
Disassembly and assembly of one link in field 4
Removal and installation of idler assembly 8
Disassembly and assembly of idler assembly 9
Disassembly and assembly of idler adjustment cylinder assembly 12
Removal and installation of recoil spring assembly 13
Disassembly and assembly of recoil spring assembly 15
Removal and installation of carrier roller assembly 17
Disassembly and assembly of carrier roller assembly 18
Removal and installation of track roller assembly 20
Disassembly and assembly of track roller assembly 21
Removal and installation of revolving frame assembly 24
Removal and installation of counterweight assembly 26
PC800, 800LC-8 11
00 Index and foreword UEN00375-03
Hydraulic system UEN01057-00
Removal and installation of hydraulic tank assembly 2
Removal and installation of main pump assembly 5
Removal and installation of main pump input shaft oil seal 10
Removal and installation of cooling fan pump assembly 11
Removal and installation of control valve assembly 14
Assembly of control valve assembly 17
Removal and installation of swing motor assembly 21
Removal and installation of center swivel joint 23
Disassembly and assembly of center swivel joint assembly 25
Removal and installation of travel motor assembly 27
Removal and installation of solenoid valve assembly 28
Removal and installation of boom damping valve assembly 30
Disassembly and assembly of work equipment PPC valve assembly 31
Disassembly and assembly of travel PPC valve assembly 33
Disassembly and assembly of hydraulic cylinder assembly 34
Work equipment UEN01058-00
Removal and installation of bucket cylinder assembly 2
Removal and installation of arm cylinder assembly 6
Removal and installation of boom cylinder assembly 10
Removal and installation of bottom dump cylinder assembly 14
Removal and installation of bucket assembly 15
Removal and installation of arm assembly 17
Removal and installation of boom assembly 20
Removal and installation of work equipment 24
Cab and its attachments UEN01059-00
Removal and installation of operator’s cab 2
Removal and installation of operator’s cab glass (stuck glass) 5
Removal and installation of front window assembly 15
Electrical system UEN01060-00
Removal and installation of air conditioner unit assembly 2
Removal and installation of engine controller assembly 4
Removal and installation of monitor assembly 6
Removal and installation of pump controller 6
Removal and Installation of KOMTRAX terminal assembly 7
90 Diagrams and drawings
Hydraulic diagrams and drawings UEN00392-00
Hydraulic diagrams and drawings 3
Hydraulic circuit diagram 3
Electrical diagrams and drawings UEN00393-01
Electrical circuit diagram (1/5) 3
Electrical circuit diagram (2/5) 5
Electrical circuit diagram (3/5) 7
Electrical circuit diagram (4/5) 9
Electrical circuit diagram (5/5) 11
Connector arrangement diagram 13
12
PC800-8, PC800LC-8 Hydraulic excavator
Form No UEN00375-03
©2008 KOMATSU
All Rights Reserved
Printed in Belgium 06-08 (01)
UEN00375-03 00

S.V 16/12/24