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Komatsu PC800-8, PC800LC-8 Galeo Hydraulic Excavator Service Repair Manual – PDF Download
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- Komatsu PC800-8, PC800LC-8 Galeo Hydraulic Excavator Service Repair Manual
- SERIAL NUMBERS PC800- 50001 and up PC800LC- 50001
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Description
Komatsu PC800-8, PC800LC-8 Galeo Hydraulic Excavator Service Repair Manual
Description:
- Komatsu PC800-8, PC800LC-8 Galeo Hydraulic Excavator Service Repair Manual
- SERIAL NUMBERS PC800- 50001 and up PC800LC- 50001
- 1) Before carrying out any greasing or repairs, read all the safety plates stuck to the machine. For the locations of the safety plates and detailed explanation of precautions, see the Operation and Maintenance Manual.
- 2) Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
- 3) When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. q Always wear safety glasses when hitting parts with a hammer. q Always wear safety glasses when grinding parts with a grinder, etc.
- 4) When carrying out any operation with 2 or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs in the operator’s compartment.
- 5) Only qualified workers must carry out work and operation which require license or qualification.
- 6) Keep all tools in good condition, learn the correct way to use them, and use the proper ones of them. Before starting work, thoroughly check the tools, machine, forklift, service car, etc.
- 7) If welding repairs are needed, always have a trained and experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, shielding goggles, cap and other clothes suited for welding work.
- 8) Before starting work, warm up your body thoroughly to start work under good condition.
Table of Contents:
- Komatsu PC800-8, PC800LC-8 Galeo Hydraulic Excavator Service Repair Manual
- SERIAL NUMBERS PC800- 50001 and up PC800LC- 50001
PC800-8_PC800LC-8....................................................................................................... 1 00 Index and foreword................................................................................................... 3 Index............................................................................................................... 3 Organization list of the shop manual............................................................................ 4 Table of contents............................................................................................... 6 00 Index and foreword................................................................................................... 15 Foreword and general information.................................................................................... 15 Foreword and general information................................................................................ 16 Safety notice............................................................................................... 16 How to read the shop manual................................................................................. 20 Explanation of terms for maintenance standard............................................................... 22 Handling electric equipment and hydraulic component......................................................... 24 How to read electric wire code.............................................................................. 32 Method of disassembling and connecting push-pull type coupler............................................... 35 Standard tightening torque table............................................................................ 38 Conversion table............................................................................................ 42 01 Specification........................................................................................................ 49 Specification and technical data.................................................................................... 49 Specification and technical data................................................................................ 50 Specification drawings...................................................................................... 50 Working range drawing....................................................................................... 51 Specifications.............................................................................................. 52 Weight table................................................................................................ 58 Table of fuel, coolant and lubricants....................................................................... 61 10 Structure, function and maintenance standard......................................................................... 65 Engine and cooling system........................................................................................... 65 Engine and cooling system....................................................................................... 66 Coupling.................................................................................................... 66 Coupling lubrication system................................................................................. 67 Radiator, oil cooler........................................................................................ 68 10 Structure, function and maintenance standard......................................................................... 71 Power train......................................................................................................... 71 Power train..................................................................................................... 72 Power train................................................................................................. 72 Swing machinery............................................................................................. 74 Swing circle................................................................................................ 76 Final drive................................................................................................. 78 Sprocket.................................................................................................... 80 10 Structure, function and maintenance standard......................................................................... 83 Undercarriage and frame............................................................................................. 83 Undercarriage and frame......................................................................................... 84 Track frame and recoil spring............................................................................... 84 Idler....................................................................................................... 86 Carrier roller.............................................................................................. 88 Track roller................................................................................................ 90 Track shoe.................................................................................................. 92 10 Structure, function and maintenance standard......................................................................... 97 Hydraulic system, Part 1............................................................................................ 97 Hydraulic system, Part 1........................................................................................ 98 Hydraulic piping drawing.................................................................................... 98 Hydraulic tank, hydraulic filter............................................................................100 Hydraulic pump..............................................................................................102 Operation of pump control mechanism.........................................................................108 EPC valve...................................................................................................110 Self pressure reducing valve................................................................................113 Cooling fan pump............................................................................................117 Cooling fan motor...........................................................................................126 10 Structure, function and maintenance standard.........................................................................133 Hydraulic system, Part 2............................................................................................133 Hydraulic system, Part 2........................................................................................135 Motor grease pump...........................................................................................135 Return oil filter...........................................................................................136 Line oil filter.............................................................................................137 Drain oil filter............................................................................................138 L.H. 5-Spool control valve..................................................................................140 R.H. 4-Spool control valve..................................................................................146 Straight-travel valve.......................................................................................153 Swing motor.................................................................................................156 Center swivel joint.........................................................................................161 Travel motor................................................................................................162 PPC accumulator.............................................................................................172 Work equipment, swing PPC valve.............................................................................173 Travel PPC valve............................................................................................178 Solenoid valve..............................................................................................182 Hydraulic cylinder..........................................................................................188 10 Structure, function and maintenance standard.........................................................................191 Work equipment......................................................................................................191 Work equipment..................................................................................................192 Work equipment..............................................................................................192 Dimensions of work equipment................................................................................194 10 Structure, function and maintenance standard.........................................................................199 Cab and its attachments.............................................................................................199 Cab and its attachments.........................................................................................200 Air conditioner piping......................................................................................200 10 Structure, function and maintenance standard.........................................................................203 Electrical system...................................................................................................203 Electrical system...............................................................................................204 Engine control..............................................................................................204 Electric control system.....................................................................................213 Monitor system..............................................................................................247 Sensors.....................................................................................................265 20 Standard value table.................................................................................................271 Standard service value table........................................................................................271 Standard service value table....................................................................................272 Standard service value table for engine.....................................................................272 Standard service value table for chassis....................................................................273 30 Testing and adjusting................................................................................................283 Testing and adjusting, Part 1.......................................................................................283 Testing and adjusting, Part 1...................................................................................284 Tools for testing, adjusting and troubleshooting............................................................284 Measuring engine speed......................................................................................286 Measuring intake air pressure (Boost pressure)..............................................................287 Measuring exhaust gas temperature...........................................................................288 Measuring exhaust gas color.................................................................................289 Adjusting valve clearance...................................................................................290 Measuring compression pressure..............................................................................291 Measuring blow-by pressure..................................................................................292 Measuring engine oil pressure...............................................................................293 Handling of fuel system equipment...........................................................................294 Remaining pressure relief from fuel system equipment........................................................294 Measuring fuel pressure.....................................................................................295 Testing fuel return rate and leakage........................................................................296 Bleeding air from fuel circuit..............................................................................298 Testing and adjusting alternator belt tension...............................................................299 Testing and adjusting air conditioner compressor belt.......................................................300 30 Testing and adjusting................................................................................................303 Testing and adjusting, Part 2.......................................................................................303 Testing and adjusting, Part 2...................................................................................304 Inspection of swing circle bearing clearance................................................................304 Testing and adjusting track shoe tension....................................................................305 Testing and adjusting work equipment, swing, and travel circuit oil pressures...............................306 Testing and adjusting control circuit oil pressure (self pressure reducing valve)...........................311 Testing and adjusting main pump control pressure............................................................312 30 Testing and adjusting................................................................................................319 Testing and adjusting, Part 3.......................................................................................319 Testing and adjusting, Part 3...................................................................................320 Measuring PPC valve output pressure.........................................................................320 Measuring outlet pressures of solenoid valve, swing PPC shuttle valve, and swing priority selector valve....324 Adjusting work equipment, swing PPC valve...................................................................328 Testing and adjusting travel deviation......................................................................329 Inspection of locations of hydraulic drift of work equipment................................................331 Measuring fan speed.........................................................................................332 Measuring fan circuit oil pressure..........................................................................332 Measuring fan pump EPC current..............................................................................333 Measuring fan pump EPC solenoid valve output pressure.......................................................333 Measuring oil leakage.......................................................................................334 Release of residual pressure from hydraulic circuit.........................................................338 Bleeding air from each part.................................................................................339 Inspection procedures for diode.............................................................................342 30 Testing and adjusting................................................................................................345 Testing and adjusting, Part 4.......................................................................................345 Testing and adjusting, Part 4...................................................................................346 Special function of machine monitor.........................................................................346 Handling engine controller high voltage circuit.............................................................377 30 Testing and adjusting................................................................................................379 Testing and adjusting, Part 5.......................................................................................379 Testing and adjusting, Part 5...................................................................................380 Procedure for turning on KOMTRAX terminal...................................................................380 KOMTRAX terminal lamp indications...........................................................................383 Preparation work for troubleshooting electrical system......................................................386 Pm-clinic service...........................................................................................389 UNDERCARRIAGE INSPECTION....................................................................................395 40 Troubleshooting......................................................................................................397 General information on troubleshooting..............................................................................397 General information on troubleshooting..........................................................................398 Points to remember when troubleshooting.....................................................................398 Sequence of events in troubleshooting.......................................................................399 Checks before troubleshooting...............................................................................400 Classification and troubleshooting steps....................................................................401 Connection table for connector pin numbers..................................................................405 T-boxes and T-adapters table................................................................................428 40 Troubleshooting......................................................................................................433 Troubleshooting by failure code (Display of code), Part 1...........................................................433 Troubleshooting by failure code (Display of code), Part 1.......................................................435 Failure codes table.........................................................................................435 Information in troubleshooting table........................................................................440 Failure code [A000N1] Eng. Hi Out of Std....................................................................442 Failure code [AA10NX] Aircleaner Clogging...................................................................444 Failure code [AB00KE] Charge Voltage Low....................................................................446 Failure code [B@BAZG] Eng. Oil Press. Low...................................................................448 Failure code [B@BAZK] Eng. Oil Level Low....................................................................450 Failure code [B@BCNS] Eng. Water Overheat...................................................................452 Failure code [B@BCZK] Eng. Water Lvl Low....................................................................454 Failure code [B@HANS] Hydr. Oil Overheat....................................................................456 Failure code [CA111] ECM Critical Internal Failure..........................................................458 Failure code [CA115] Eng Ne and Bkup Speed Sens Error.......................................................460 Failure code [CA122] Chg Air Press Sensor High Error........................................................462 Failure code [CA123] Chg Air Press Sensor Low Error.........................................................465 Failure code [CA131] Throttle Sensor High Error.............................................................466 Failure code [CA132] Throttle Sensor Low Error..............................................................468 Failure code [CA135] Eng Oil Press Sensor High Error........................................................470 Failure code [CA141] Eng Oil Press Sensor Low Error.........................................................472 Failure code [CA144] Coolant Temp Sens High Error...........................................................474 Failure code [CA145] Coolant Temp Sens Low Error............................................................476 Failure code [CA153] Chg Air Temp Sensor High Error.........................................................478 Failure code [CA154] Chg Air Temp Sensor Low Error..........................................................480 Failure code [CA187] Sens Supply 2 Volt Low Error...........................................................481 Failure code [CA221] Ambient Press Sens High Error..........................................................482 Failure code [CA222] Ambient Press Sens Low Error...........................................................484 Failure code [CA227] Sens Supply 2 Volt High Error..........................................................486 Failure code [CA234] Eng Overspeed..........................................................................488 Failure code [CA238] Ne Speed Sens Supply Volt Error........................................................490 Failure code [CA263] Fuel Temp Sensor High Error............................................................492 Failure code [CA265] Fuel Temp Sensor Low Error.............................................................494 Failure code [CA271] IMV/PCV1 Short Error...................................................................495 Failure code [CA272] IMV/PCV1 Open Error....................................................................496 Failure code [CA273] PCV2 Short Error.......................................................................497 Failure code [CA274] PCV2 Open Error........................................................................498 Failure code [CA322] Inj #1 (L#1) Open/Short Error..........................................................499 Failure code [CA323] Inj #5 (L#5) Open/Short Error..........................................................500 Failure code [CA324] Inj #3 (L#3) Open/Short Error..........................................................501 Failure code [CA325] Inj #6 (L#6) Open/Short Error..........................................................502 Failure code [CA331] Inj #2 (L#2) Open/Short Error..........................................................503 Failure code [CA332] Inj #4 (L#4) Open/Short Error..........................................................504 Failure code [CA342] Calibration Code Incompatibility.......................................................505 Failure code [CA351] Injectors Drive Circuit Error..........................................................506 Failure code [CA352] Sens Supply 1 Volt Low Error...........................................................508 Failure code [CA386] Sens Supply 1 Volt High Error..........................................................510 40 Troubleshooting......................................................................................................513 Troubleshooting by failure code (Display of code), Part 2...........................................................513 Troubleshooting by failure code (Display of code), Part 2.......................................................515 Failure code [CA441] Battery Voltage Low Error..............................................................515 Failure code [CA442] Battery Voltage High Error.............................................................515 Failure code [CA449] Rail Press Very High Error.............................................................516 Failure code [CA451] Rail Press Sensor High Error...........................................................518 Failure code [CA452] Rail Press Sensor Low Error............................................................520 Failure code [CA553] Rail Press High Error..................................................................520 Failure code [CA554] Rail Press Sensor In Range Error.......................................................521 Failure code [CA559] Rail Press Low Error...................................................................522 Failure code [CA689] Eng Ne Speed Sensor Error..............................................................526 Failure code [CA731] Eng Bkup Speed Sens Phase Error........................................................528 Failure code [CA757] All Persistent Data Lost Error.........................................................529 Failure code [CA778] Eng Bkup Speed Sensor Error............................................................530 Failure code [CA1228] EGR Valve Servo Error 1...............................................................532 Failure code [CA1625] EGR Valve Servo Error 2...............................................................533 Failure code [CA1626] BP Valve Sol Current High Error.......................................................534 Failure code [CA1627] BP Valve Sol Current Low Error........................................................536 Failure code [CA1628] Bypass Valve Servo Error 1............................................................537 Failure code [CA1629] Bypass Valve Servo Error 2............................................................538 Failure code [CA1631] BP Valve Pos Sens High Error..........................................................540 Failure code [CA1632] BP Valve Pos Sens Low Error...........................................................542 Failure code [CA1633] KOMNET Datalink Timeout Error.........................................................543 Failure code [CA1642] EGR Inter Press Sens Low Error........................................................545 Failure code [CA1653] EGR Inter Press Sens High Error.......................................................546 Failure code [CA2185] Throt Sens Sup Volt High Error........................................................548 Failure code [CA2186] Throt Sens Sup Volt Low Error.........................................................550 Failure code [CA2249] Rail Press Very Low Error.............................................................551 Failure code [CA2271] EGR Valve Pos Sens High Error.........................................................552 Failure code [CA2272] EGR Valve Pos Sens Low Error..........................................................554 Failure code [CA2351] EGR Valve Sol Current High Error......................................................556 Failure code [CA2352] EGR Valve Sol Current Low Error.......................................................558 Failure code [CA2555] Grid Htr Relay Volt Low Error.........................................................559 Failure code [CA2556] Grid Htr Relay Volt High Error........................................................560 Failure code [D110KB] Battery Relay Drive S/C...............................................................562 Failure code [D163KB] Flash Light Relay S/C.................................................................564 Failure code [D195KB] Step Light Relay S/C..................................................................566 Failure code [DA25KP] Press. Sensor Power Abnormality.......................................................568 Failure code [DA2SKQ] Model Selection Abnormality...........................................................570 Failure code [DA80MA] Auto. Lub. Abnormal...................................................................572 Failure code [DA2RMC] Pump Comm. Abnormality................................................................574 Failure code [DAFRMC] Monitor Comm. Abnormality.............................................................576 Failure code [DGE5KY] Ambi. Temp. Sensor S/C................................................................578 Failure code [DGH2KB] Hydr. Oil Temp. Sensor S/C............................................................580 40 Troubleshooting......................................................................................................583 Troubleshooting by failure code (Display of code), Part 3...........................................................583 Troubleshooting by failure code (Display of code), Part 3.......................................................586 Failure code [DH25KA] L Jet Sensor Disc.....................................................................586 Failure code [DH25KB] L Jet Sensor S/C......................................................................588 Failure code [DH26KA] R Jet Sensor Disc.....................................................................590 Failure code [DH26KB] R Jet Sensor S/C......................................................................592 Failure code [DHPEKA] F Pump P. Sensor Disc.................................................................594 Failure code [DHPEKB] F Pump P. Sensor S/C..................................................................596 Failure code [DHPFKA] R Pump P. Sensor Disc.................................................................598 Failure code [DHPFKB] R Pump P. Sensor S/C..................................................................600 Failure code [DV20KB] Travel Alarm S/C......................................................................602 Failure code [DW41KA] Swing Priority Sol. Disc..............................................................604 Failure code [DW41KB] Swing Priority Sol. S/C...............................................................606 Failure code [DW43KA] Travel Speed Sol. Disc................................................................608 Failure code [DW43KB] Travel Speed Sol. S/C.................................................................610 Failure code [DW45KA] Swing Brake Sol. Disc.................................................................612 Failure code [DW45KB] Swing Brake Sol. S/C..................................................................614 Failure code [DW7BKA] Fan Reverse Sol. Disc.................................................................616 Failure code [DW78KB] Fan Reverse Sol. S/C..................................................................618 Failure code [DWK0KA] 2-stage Relief Sol. Disc..............................................................620 Failure code [DWK0KB] 2-stage Relief Sol. S/C...............................................................622 Failure code [DX16KA] Fan Pump EPC Sol. Disc................................................................624 Failure code [DX16KB] Fan Pump EPC Sol. S/C.................................................................626 Failure code [DXAAKA] F Pump EPC Sol. Disc..................................................................628 Failure code [DXAAKB] F Pump EPC Sol. S/C...................................................................630 Failure code [DXABKA] R Pump EPC Sol. Disc..................................................................632 Failure code [DXABKB] R Pump EPC Sol. S/C...................................................................634 Failure code [DY20KA] Wiper Working Abnormality.............................................................636 Failure code [DY20MA] Wiper Parking Abnormality.............................................................638 Failure code [DY2CKB] Washer Drive S/C......................................................................642 Failure code [DY2DKB] Wiper Drive (For) S/C.................................................................644 Failure code [DY2EKB] Wiper Drive (Rev) S/C.................................................................648 40 Troubleshooting......................................................................................................651 Troubleshooting of electrical system (E-mode).......................................................................651 Troubleshooting of electrical system (E-mode)...................................................................653 Before carrying out troubleshooting of electrical system....................................................653 Information contained in troubleshooting table..............................................................655 E-1 Engine does not start (Engine does not rotate)..........................................................656 E-2 Preheater does not operate..............................................................................659 E-3 Auto engine warm-up device does not work................................................................664 E-4 Auto-decelerator does not operate.......................................................................665 E-5 All work equipment, swing and travel do not move........................................................666 E-6 Machine push-up function does not operate normally......................................................668 E-7 Boom shockless function does not operate normally.......................................................670 E-8 Any item is not displayed on machine monitor............................................................672 E-9 Part of display on machine monitor is missing...........................................................673 E-10 Machine monitor displays contents irrelevant to the model..............................................673 E-11 Fuel level monitor red lamp lights up while engine is running..........................................674 E-12 Engine coolant thermometer does not display normally...................................................676 E-13 Hydraulic oil temperature gauge does not display correctly.............................................678 E-14 Fuel gauge does not display correctly..................................................................679 E-15 Swing lock monitor does not display correctly..........................................................680 E-16 When monitor switch is operated, nothing is displayed..................................................682 E-17 Windshield wiper and window washer do not work.........................................................684 E-18 "Boom RAISE" is not correctly displayed in monitor function............................................692 E-19 "Boom LOWER" is not correctly displayed in monitor function............................................693 E-20 "Arm IN" is not correctly displayed in monitor function................................................694 E-21 "Arm OUT" is not correctly displayed in monitor function...............................................695 E-22 "Bucket CURL" is not correctly displayed in monitor function...........................................696 E-23 "Bucket DUMP" is not correctly displayed in monitor function...........................................697 E-24 "SWING" is not correctly displayed in monitor function.................................................698 E-25 "Left travel" is not displayed normally in monitoring function.........................................700 E-26 "Right travel" is not displayed normally in monitoring function........................................702 E-27 "Service" is not correctly displayed in monitor function...............................................704 E-28 KOMTRAX system does not operate normally...............................................................706 E-29 Air conditioner does not work..........................................................................708 E-30 Step light does not light up or go off.................................................................709 E-31 Electric grease gun does not operate...................................................................712 E-32 Travel alarm does not sound or does not stop sounding..................................................714 40 Troubleshooting......................................................................................................717 Troubleshooting of hydraulic and mechanical system (H-mode).........................................................717 Troubleshooting of hydraulic and mechanical system (H-mode).....................................................719 Information in troubleshooting table........................................................................719 H-1 Speed or power of all work equipment, travel, and swing is low..........................................720 H-2 Engine speed lowers remarkably or engine stalls.........................................................722 H-3 All work equipment, travel, and swing systems do not work...............................................723 H-4 Abnormal sound is heard from around pump................................................................724 H-5 Boom speed or power is low..............................................................................725 H-6 Speed or power of arm is low............................................................................727 H-7 Speed or power of bucket is low.........................................................................728 H-8 Boom does not move......................................................................................729 H-9 Arm does not move.......................................................................................729 H-10 Bucket does not move...................................................................................729 H-11 Hydraulic drift of work equipment is large.............................................................730 H-12 Time lag of work equipment is large....................................................................732 H-13 Heavy lift function does not operate or stop...........................................................733 H-14 Machine push-up function does not operate or stop......................................................733 H-15 Boom shockless function cannot be turned ON or OFF.....................................................733 H-16 Machine deviates in one direction......................................................................734 H-17 Machine deviates largely at start......................................................................736 H-18 Machine deviates largely during compound operation.....................................................737 H-19 Travel speed or power is low...........................................................................737 H-20 Machine does not travel (only one track)...............................................................738 H-21 Travel speed does not change...........................................................................739 H-22 Upper structure does not swing.........................................................................740 H-23 Swing speed or acceleration is low.....................................................................742 H-24 Swing speed or acceleration is low during compound operation of swing andwork equipment................743 H-25 Upper structure overruns excessively when it stops swinging............................................745 H-26 Large shock is made when upper structure stops swinging................................................746 H-27 Large abnormal sound is made when upper structure stops swinging.......................................747 H-28 Hydraulic drift of swing is large......................................................................748 40 Troubleshooting......................................................................................................751 Troubleshooting of engine (S-mode)..................................................................................751 Troubleshooting of engine (S-mode)..............................................................................753 Method of using troubleshooting chart.......................................................................753 S-1 Starting performance is poor............................................................................756 S-2 Engine does not start...................................................................................758 S-3 Engine does not pick up smoothly........................................................................762 S-4 Engine stops during operations..........................................................................763 S-6 Engine lacks output (or lacks power)....................................................................765 S-7 Exhaust gas color is black (incomplete combustion)......................................................766 S-8 Oil consumption is excessive (or exhaust smoke is blue).................................................768 S-9 Oil becomes contaminated quickly........................................................................769 S-10 Fuel consumption is excessive..........................................................................770 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)..................................771 S-12 Oil pressure drops.....................................................................................772 S-13 Oil level rises (Entry of coolant/fuel)................................................................773 S-14 Coolant temperature becomes too high (overheating).....................................................775 S-15 Abnormal noise is made.................................................................................776 S-16 Vibration is excessive.................................................................................777 90 Diagrams and drawings................................................................................................779 Hydraulic diagrams and drawings.....................................................................................779 Hydraulic diagrams and drawings.................................................................................781 90 Diagrams and drawings................................................................................................785 Electrical diagrams and drawings....................................................................................785 Electrical circuit diagram (1/5)................................................................................787 Electrical circuit diagram (2/5)................................................................................789 Electrical circuit diagram (3/5)................................................................................791 Electrical circuit diagram (4/5)................................................................................793 Electrical circuit diagram (5/5)................................................................................795
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KOMATSU PC800-8, PC800LC-8 GALEO HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL – PDF DOWNLOAD:
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