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Komatsu PC800-8E0, PC800LC-8E0, PC800SE-8E0, PC850 -8E0 PC850SE- 8E0 Excavator Shop Manual – PDF DOWNLOAD
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Komatsu PC800-8E0, PC800LC-8E0, PC800SE-8E0, PC850 -8E0 PC850SE- 8E0 Excavator Shop Manual
SERIAL NUMBERS : 65001 and up
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Description
Komatsu PC800-8E0, PC800LC-8E0, PC800SE-8E0, PC850 -8E0 PC850SE- 8E0 Excavator Shop Manual
FILE DETAILS:
Komatsu PC800-8E0, PC800LC-8E0, PC800SE-8E0, PC850 -8E0 PC850SE- 8E0 Excavator Shop Manual
Brands: Komatsu
Equipment Type: Hydraulic Excavator
Manuals Type: Shop Manual
Machine Model: PC800-8E0, PC800LC-8E0, PC800SE-8E0, PC850-8E0, PC850SE-8E0
Serial Number: 65001 and up
Book Code: SEN05276-03
Language: English
Pages: 1327
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu PC800-8E0, PC800LC-8E0, PC800SE-8E0, PC850 -8E0 PC850SE- 8E0 Excavator Shop Manual
How to read the shop manual:
1. Composition of shop manual:
This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
00. Index and foreword:
This section contains the index, foreword, safety and basic information. If any revision is made, the LIST OF REVISED PAGES will be added.
01. Specification:
This section explains the specifications of the machine.
10. Structure and function:
This section explains the structure and function of each component. It serves not only to give an understanding for the structure of each component, but also serves as reference material for troubleshooting.
20. Standard value table:
This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting:
This section explains measuring tools and measuring methods for testing and adjusting, as well as the adjusting method of each part. The standard values and judgment criteria for “Testing and adjusting” are explained in “Standard value table”.
40. Troubleshooting:
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly:
This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque, and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained.
60. Maintenance standard:
This section gives maintenance standard values of each component. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
80. Appendix:
This section explains the structure, function, testing, adjusting, and troubleshooting for the equipment not classifiable in other sections.
90. Diagrams and drawings (chassis volume) /Repair and replacement of parts (engine volume):
- Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams. - Engine volume
This section explains the method of remanufacturing and repairing engine and replacing parts.
TABLE OF CONTENTS:
Komatsu PC800-8E0, PC800LC-8E0, PC800SE-8E0, PC850 -8E0 PC850SE- 8E0 Excavator Shop Manual
COVER ................................................................................................................ 1 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 "L.H. travel" is not displayed properly with monitoring function......................................... 828 E-34 "R.H. 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 assembly..........................................................1001 Removal and installation of swing circle assembly.............................................................1008 Disassembly and assembly of final drive assembly..............................................................1009 Undercarriage and frame...........................................................................................1021 Separation and connection of track shoe assembly..............................................................1021 Disassembly and assembly of one link in field.................................................................1023 Removal and installation of idler assembly....................................................................1027 Disassembly and assembly of idler assembly....................................................................1028 Disassembly and assembly of idler adjustment cylinder assembly................................................1031 Removal and installation of recoil spring assembly............................................................1032 Disassembly and assembly of recoil spring assembly............................................................1034 Removal and installation of carrier roller assembly...........................................................1036 Disassembly and assembly of carrier roller assembly...........................................................1037 Removal and installation of track roller assembly.............................................................1040 Disassembly and assembly of track roller assembly.............................................................1041 Removal and installation of revolving frame assembly..........................................................1044 Removal and installation of counterweight assembly............................................................1046 Removal and installation of counterweight remover assembly....................................................1047 Hydraulic system..................................................................................................1051 Removal and installation of hydraulic tank assembly...........................................................1051 Removal and installation of main pump assembly................................................................1053 Removal and installation of main pump input shaft oil seal....................................................1060 Removal and installation of cooling fan pump assembly.........................................................1061 Removal and installation of control valve assembly............................................................1064 Assembly of control valve assembly............................................................................1067 Removal and installation of swing motor assembly..............................................................1073 Removal and installation of center swivel joint assembly......................................................1074 Disassembly and assembly of center swivel joint assembly......................................................1076 Removal and installation of travel motor assembly.............................................................1078 Removal and installation of solenoid valve assembly...........................................................1079 Removal and installation of boom damping valve assembly.......................................................1081 Disassembly and assembly of work equipment PPC valve assembly.................................................1082 Disassembly and assembly of travel PPC valve assembly.........................................................1084 Disassembly and assembly of hydraulic cylinder assembly.......................................................1087 Disassembly and assembly of grease gun assembly...............................................................1094 Work equipment....................................................................................................1095 Removal and installation of bucket cylinder assembly..........................................................1095 Removal and installation of arm cylinder assembly.............................................................1099 Removal and installation of boom cylinder assembly............................................................1103 Removal and installation of bottom dump cylinder assembly.....................................................1107 Removal and installation of bucket assembly...................................................................1109 Removal and installation of arm assembly......................................................................1112 Removal and installation of boom assembly.....................................................................1116 Removal and installation of work equipment assembly...........................................................1120 Cab and its attachments...........................................................................................1124 Removal and installation of operator's cab assembly...........................................................1124 Removal and installation of operator's cab glass (adhered window glass).......................................1127 Removal and installation of front window assembly.............................................................1136 Electrical system.................................................................................................1143 Removal and installation of air conditioner unit assembly.....................................................1143 Removal and installation of engine controller assembly........................................................1146 Removal and installation of monitor assembly..................................................................1148 Removal and installation of pump controller assembly..........................................................1150 Removal and installation of KOMTRAX terminal assembly.........................................................1152 60 Maintenance standard...............................................................................................1153 Engine and cooling system.........................................................................................1155 Coupling......................................................................................................1155 Power train.......................................................................................................1156 Swing circle..................................................................................................1156 Swing machinery...............................................................................................1157 Final drive...................................................................................................1160 Sprocket......................................................................................................1162 Undercarriage and frame...........................................................................................1164 Track frame and idler cushion.................................................................................1164 Idler.........................................................................................................1166 Carrier roller................................................................................................1168 Track roller..................................................................................................1170 Track shoe....................................................................................................1172 Hydraulic system..................................................................................................1176 Cooling fan motor.............................................................................................1176 Control valve.................................................................................................1178 Swing motor...................................................................................................1184 Center swivel joint...........................................................................................1186 PPC valve.....................................................................................................1187 Work equipment....................................................................................................1190 Work equipment................................................................................................1190 Work equipment dimension......................................................................................1196 Hydraulic cylinder............................................................................................1200 80 Appendix...........................................................................................................1207 Air conditioner...................................................................................................1209 Precautions for refrigerant...................................................................................1209 Air conditioner component.....................................................................................1210 Configuration and function of refrigeration cycle.............................................................1212 Outline of refrigeration cycle................................................................................1213 Air conditioner unit..........................................................................................1216 Air conditioner controller....................................................................................1221 Compressor....................................................................................................1222 Condenser.....................................................................................................1223 Receiver drier................................................................................................1224 Procedure for testing and troubleshooting.....................................................................1226 Circuit diagram and arrangement of connector pins.............................................................1228 System diagram................................................................................................1230 Detail of air conditioner unit................................................................................1232 Parts and connectors layout...................................................................................1234 Testing air leakage (duct)....................................................................................1237 Testing with self-diagnosis function..........................................................................1238 Testing temperature control...................................................................................1241 Testing vent (mode) changeover................................................................................1243 Testing FRESH/RECIRC air changeover...........................................................................1246 Testing inner sensor..........................................................................................1248 Testing evaporator temperature sensor.........................................................................1249 Testing sunlight sensor.......................................................................................1251 Testing (dual) pressure switch for refrigerant................................................................1252 Testing relays................................................................................................1253 Troubleshooting chart 1.......................................................................................1254 Troubleshooting chart 2.......................................................................................1256 Information in troubleshooting table..........................................................................1258 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 control.......................................................................1273 Troubleshooting for vent (mode) changeover....................................................................1276 Troubleshooting for FRESH/RECIRC air changeover...............................................................1278 Troubleshooting for temperature sensor system.................................................................1280 Troubleshooting with gauge pressure...........................................................................1282 Connection of service tool....................................................................................1284 Precautions for disconnecting and connecting air conditioner piping...........................................1286 Handling of compressor oil....................................................................................1288 90 Diagrams and drawings..............................................................................................1291 Hydraulic circuit diagram.........................................................................................1293 Symbols used in hydraulic circuit diagrams....................................................................1293 Hydraulic circuit diagram.....................................................................................1297 Electrical circuit diagram........................................................................................1299 Symbols used in electric circuit diagrams.....................................................................1299 Electrical circuit diagram....................................................................................1303 Index.................................................................................................................1320
KOMATSU PC800-8E0, PC800LC-8E0, PC800SE-8E0, PC850 -8E0 PC850SE- 8E0 EXCAVATOR SHOP MANUAL – PDF DOWNLOAD:
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