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

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Komatsu Hydraulic Excavator PC800-8E0,PC800LC-8E0,PC800SE-8E0,PC850-8E0,PC850SE-8E0 Shop Manual UEN05276-00 – PDF DOWNLOAD

  • SERIAL NUMBERS
    PC800-8E0 K55001            and up
    PC800LC-8E0 K55001       and up
    PC800SE-8E0 K55001       and up
    PC850-8E0 K55001           and up
    PC850SE-8E0 K55001       and up
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Description

Komatsu Hydraulic Excavator PC800-8E0,PC800LC-8E0,PC800SE-8E0,PC850-8E0,PC850SE-8E0 Shop Manual UEN05276-00 – PDF DOWNLOAD

FILE DETAILS:

Komatsu Hydraulic Excavator PC800-8E0,PC800LC-8E0,PC800SE-8E0,PC850-8E0,PC850SE-8E0 Shop Manual UEN05276-00 – PDF DOWNLOAD

Language : English
Pages : 1306
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu Hydraulic Excavator PC800-8E0,PC800LC-8E0,PC800SE-8E0,PC850-8E0,PC850SE-8E0 Shop Manual UEN05276-00 – PDF DOWNLOAD

  • SERIAL NUMBERS
    PC800-8E0 K55001           and up
    PC800LC-8E0 K55001      and up
    PC800SE-8E0 K55001      and up
    PC850-8E0 K55001          and up
    PC850SE-8E0 K55001     and up

Shop Manual . 1
00 Index and foreword . 3
Table of contents . 4
Foreword and general information 14
Safety notice . 14
How to read the shop manual . 19
Explanation of terms for maintenance standard . 21
Handling of hydraulic components 23
Method of disconnecting and connecting push-pull type coupler . 25
Handling of electric equipment 28
How to read electric wire code 38
Precautions when performing work 41
Standard tightening torque table 44
List of abbreviation 48
Conversion table 52
01 Specification 57
Contents 58
Specifications 60
Specifications drawing 60
Specifications 64
Table of weight . 74
Table of fuel, coolant and lubricants . 82
10 Structure and function . 85
Contents 86
Engine and cooling system . 87
Coupling 87
Coupling lubrication system . 88
Cooling system 90
Power train system 92
Power train . 92
Swing circle 94
Swing machinery . 95
Final drive . 97
Undercarriage and frame . 98
Track frame . 98
Idler cushion . 100
Hydraulic system 102
Hydraulic component layout 102
Hydraulic tank and filter . 104
Hydraulic pump 106
Pump control system . 114
Servo valve . 116
Self-pressure reducing valve 125
Cooling fan pump 128
Cooling fan motor . 137
Electrical grease pump 143
Control valve . 144
Straight-travel valve . 153
Swing motor . 156
Centre swivel joint . 160
Travel motor 161
PPC valve . 171
Solenoid valve 179
Accumulator . 187
Quick return valve 188
Return oil filter . 191
Line oil filter . 192
Pilot oil filter 193
Drain oil filter 194
Electrical system . 195
Engine control 195
Electric control system . 205
Monitor system 244
Sensors . 274
KOMTRAX system 278
20 Standard value table . 281
Contents 282
Standard value table 283
Standard value table for engine . 283
Standard value table for machine 284
30 Testing and adjusting 297
Contents 298
Tool for testing, adjusting and troubleshooting . 299
Tools for testing, adjusting, and troubleshooting . 299
Engine and cooling system . 303
Testing engine speed 303
Testing intake air pressure (boost pressure) 304
Testing exhaust gas temperature . 305
Testing exhaust gas colour 306
Adjusting valve clearance . 308
Testing compression pressure 309
Testing blowby pressure . 311
Testing engine oil pressure . 312
Testing EGR valve and bypass valve drive pressure . 313
Handling fuel system parts 314
Releasing remaining pressure from fuel system . 315
Testing fuel pressure . 316
Testing fuel return rate and leakage 317
Bleeding air from fuel circuit 320
Testing fuel circuit for leakage 322
Testing and adjusting alternator belt tension . 323
Testing and adjusting air conditioner compressor belt tension . 324
Undercarriage and frame . 325
Testing swing circle bearing clearance 325
Checking and adjusting track tension 326
Hydraulic system 327
Testing and adjusting oil pressure in work equipment, swing, and travel circuits 327
Testing and adjusting control circuit oil pressure (output pressure of self-pressure reducing valve) 333
Testing and adjusting control signal of main pump . 335
Testing PPC valve output pressure . 342
Measuring outlet pressure of solenoid valve, swing PPC shuttle valve, and swing priority selector valve . 346
Adjusting play of work equipment and swing PPC valves . 351
Testing and adjusting travel deviation 352
Inspecting locations of hydraulic drift in work equipment . 354
Measuring fan speed . 355
Measuring fan circuit oil pressure 356
Measuring fan pump EPC current 357
Measuring fan pump EPC solenoid valve outlet pressure . 358
Measuring oil leakage . 359
Releasing remaining pressure from hydraulic circuit . 363
Bleeding air from various parts . 364
Inspection procedures for diode . 367
Adjusting mirrors . 368
Electrical system . 369
Special functions of machine monitor 369
Handling voltage circuit of engine controller . 413
Preparatory work for troubleshooting of electrical system . 414
Pm Clinic . 418
Pm clinic service . 418
UNDERCARRIAGE INSPECTION REPORT . 425
40 Troubleshooting 427
Contents 428
General information on troubleshooting 433
Points to remember when troubleshooting . 433
Sequence of events in troubleshooting . 434
Checks before troubleshooting . 435
Classification and procedures for troubleshooting . 461
Failure codes table . 464
Symptom and troubleshooting numbers . 469
Information in troubleshooting table 472
Troubleshooting method for open circuit in wiring harness of pressure sensor system . 474
Connector list and layout . 476
Connection table for connector pin numbers 487
T- branch box and T- branch adapter table . 523
Fuse locations 526
Troubleshooting by failure code . 529
Failure code [989L00] Engine Controller Lock Caution 1 529
Failure code [989M00] Engine Controller Lock Caution 2 530
Failure code [989N00] Engine Controller Lock Caution 3 530
Failure code [AA10NX] Air Cleaner Clogging 531
Failure code [AB00KE] Charge Voltage Low 532
Failure code [B@BAZG] Eng Oil Press Low . 534
Failure code [B@BAZK] Eng Oil Level Low . 535
Failure code [B@BCNS] Eng Water Overheat 536
Failure code [B@BCZK] Eng Water Level Low . 538
Failure code [B@HANS] Hyd Oil Overheat 540
Failure code [CA111] ECM Critical Internal Failure 542
Failure code [CA115] Eng Ne and Bkup Speed Sens Error . 544
Failure code [CA122] Chg Air Press Sensor High Error 546
Failure code [CA123] Chg Air Press Sensor Low Error . 548
Failure code [CA131] Throttle Sensor High Error . 550
Failure code [CA132] Throttle Sensor Low Error 552
Failure code [CA135] Eng Oil Press Sensor High Error 554
Failure code [CA141] Eng Oil Press Sensor Low Error . 556
Failure code [CA144] Coolant Temp Sens High Error . 558
Failure code [CA145] Coolant Temp Sens Low Error 560
Failure code [CA153] Chg Air Temp Sensor High Error . 562
Failure code [CA154] Chg Air Temp Sensor Low Error 564
Failure code [CA187] Sens Supply 2 Volt Low Error . 566
Failure code [CA221] Ambient Press Sens High Error 568
Failure code [CA222] Ambient Press Sens Low Error . 570
Failure code [CA227] Sens Supply 2 Volt High Error 572
Failure code [CA234] Eng Overspeed 573
Failure code [CA238] Ne Speed Sens Supply Volt Error 574
Failure code [CA263] Fuel Temp Sensor High Error 576
Failure code [CA265] Fuel Temp Sensor Low Error . 578
Failure code [CA271] IMV/PCV1 Short Error . 580
Failure code [CA272] IMV/PCV1 Open Error 581
Failure code [CA273] PCV2 Short Error . 582
Failure code [CA274] PCV2 Open Error 583
Failure code [CA322] Inj #1(L#1) Open/Short Error . 584
Failure code [CA323] Inj #5 (L#5) Open/Short Error 586
Failure code [CA324] Inj #3(L#3) Open/Short Error . 588
Failure code [CA325] Inj #6 (L#6) Open/Short Error 590
Failure code [CA331] Inj #2(L#2) Open/Short Error . 592
Failure code [CA332] Inj #4 (L#4) Open/Short Error 594
Failure code [CA342] Calibration Code Incompatibility . 596
Failure code [CA351] Injectors Drive Circuit Error 597
Failure code [CA352] Sens Supply 1 Volt Low Error . 598
Failure code [CA386] Sens Supply 1 Volt High Error 600
Failure code [CA441] Battery Voltage Low Error 600
Failure code [CA442] Battery Voltage High Error . 601
Failure code [CA449] Rail Press Very High Error . 601
Failure code [CA451] Rail Press Sensor High Error . 602
Failure code [CA452] Rail Press Sensor Low Error 604
Failure code [CA553] Rail Press High Error 606
Failure code [CA554] Rail Press Sensor In Range Error . 607
Failure code [CA559] Supply Pump Press Low Error 1 608
Failure code [CA689] Eng Ne Speed Sensor Error 612
Failure code [CA731] Eng Bkup Speed Sens Phase Error 614
Failure code [CA757] All Continuous Data Lost Error . 615
Failure code [CA778] Eng Bkup Speed Sensor Error 616
Failure code [CA1228] EGR Valve Servo Error 1 . 618
Failure code [CA1625] EGR Valve Servo Error 2 . 619
Failure code [CA1626] BP Valve Sol Current High Error . 620
Failure code [CA1627] BP Valve Sol Current Low Error 622
Failure code [CA1628] Bypass Valve Servo Error 1 624
Failure code [CA1629] Bypass Valve Servo Error 2 625
Failure code [CA1631] BP Valve Pos Sens High Error 626
Failure code [CA1632] BP Valve Pos Sens Low Error . 628
Failure code [CA1633] KOMNET Datalink Timeout Error . 630
Failure code [CA2185] Throt Sens Sup Volt High Error 632
Failure code [CA2186] Throt Sens Sup Volt Low Error . 634
Failure code [CA2249] Rail Press Very Low Error . 635
Failure code [CA2271] EGR Valve Pos Sens High Error . 636
Failure code [CA2272] EGR Valve Pos Sens Low Error 638
Failure code [CA2351] EGR Valve Sol Current High Error 640
Failure code [CA2352] EGR Valve Sol Current Low Error . 642
Failure code [CA2555] Grid Htr Relay Open Circuit Error . 644
Failure code [CA2556] Grid Htr Relay Short Circuit Error 646
Failure code [D110KB] Battery Relay Drive Short Circuit . 648
Failure code [D163KB] Flash Light Relay Short Circuit . 650
Failure code [D195KA] Step Light Relay Open Circuit . 652
Failure code [D195KB] Step Light Relay Short Circuit 654
Failure code [D19JKZ] Personal Code Relay Abnormality . 656
Failure code [D862KA] GPS Antenna Open Circuit 658
Failure code [DA22KK] Pump Solenoid Power Low Error . 660
Failure code [DA25KP] 5V Sensor1 Power Abnormality 662
Failure code [DA29KQ] Model Selection Abnormality . 664
Failure code [DA2RMC] CAN Discon (Pump Con Detected) 666
Failure code [DA80MA] Auto. Lub. Abnormal . 670
Failure code [DAF8KB] Camera Power Supply Short Circuit . 672
Failure code [DAFGMC] GPS Module Error 674
Failure code [DAFRMC] CAN Discon (Monitor Detected) . 675
Failure code [DGE5KB] Ambi. Temp Sensor Short Circuit . 680
Failure code [DGH2KB] Hyd Oil Sensor Short 682
Failure code [DH25KA] L Jet Sensor Open Circuit . 684
Failure code [DH25KB] L Jet Sensor Short Circuit 686
Failure code [DH26KA] R Jet Sensor Open Circuit . 688
Failure code [DH26KB] R Jet Sensor Short Circuit 690
Failure code [DHPEKA] F Pump P. Sensor Open Circuit . 692
Failure code [DHPEKB] F Pump P. Sensor Short Circuit 694
Failure code [DHPFKA] R Pump P. Sensor Open Circuit . 696
Failure code [DHPFKB] R Pump P. Sensor Short Circuit 698
Failure code [DV20KB] Travel alarm short circuit 700
Failure code [DW41KA] Swing Priority Sol Open Circuit . 702
Failure code [DW41KB] Swing Priority Sol Short Circuit 704
Failure code [DW43KA] Travel Speed Sol Open Circuit . 706
Failure code [DW43KB] Travel Speed Sol Short Circuit 708
Failure code [DW45KA] Swing Brake Sol Open Circuit 710
Failure code [DW45KB] Swing Brake Sol Short Circuit . 712
Failure code [DW7BKA] Fan Reverse Sol Open Circuit 714
Failure code [DW7BKB] Fan Reverse Sol Short Circuit . 716
Failure code [DW7JKA] Bottom Dump Priority Sol Open Circuit . 718
Failure code [DW7JKB] Bottom Dump Priority Sol Short Circuit 720
Failure code [DW91KA] Travel Junction Sol Open Circuit 722
Failure code [DW91KB] Travel Junction Sol Short Circuit . 724
Failure code [DWK0KA] 2-stage Relief Sol Open Circuit . 726
Failure code [DWK0KB] 2-stage Relief Sol Short Circuit 728
Failure code [DX16KA] Fan Pump EPC Sol Open Circuit . 730
Failure code [DX16KB] Fan Pump EPC Sol Short Circuit 732
Failure code [DXAAKA] F Pump EPC Sol Open Circuit . 734
Failure code [DXAAKB] F Pump EPC Sol Short Circuit 736
Failure code [DXABKA] R Pump EPC Sol Open Circuit . 738
Failure code [DXABKB] R Pump EPC Sol Short Circuit 740
Failure code [DY20KA] Wiper Working Abnormality . 742
Failure code [DY20MA] Wiper Parking Abnormality . 746
Failure code [DY2CKA] Washer Drive Open Circuit . 748
Failure code [DY2CKB] Washer Drive Short Circuit 750
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit . 752
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit . 756
Failure code [DY2FMA] Upper Wiper Working Abnormality . 760
Failure code [DY2GKM] Wiper Select Abnormality 762
Troubleshooting of electrical system (E-mode) . 765
E-1 Engine does not start (Engine does not crank) . 765
E-2 Preheater does not operate 770
E-3 When starting switch is turned to ON position, machine monitor displays nothing . 774
E-4 When starting switch is turned to ON position (before starting engine), basic check monitor lights up . 777
E-5 Precaution item lights up while engine is running . 778
E-6 Emergency stop item lights up while engine is running . 780
E-7 Engine coolant temperature gauge does not indicate properly . 781
E-8 Fuel gauge does not indicate properly . 782
E-9 Hydraulic oil temperature gauge does not indicate properly 784
E-10 Displays on machine monitor are different from those for actual machine 786
E-11 Some areas of machine monitor screen are not displayed . 786
E-12 Function switch does not operate . 786
E-13 Automatic warm-up system does not operate (in cold season) . 787
E-14 Auto-decelerator does not operate properly . 788
E-15 Working mode does not change . 789
E-16 Travel speed does not change . 790
E-17 Alarm buzzer cannot be cancelled . 791
E-18 When starting switch is turned OFF, service meter is not displayed . 791
E-19 Service mode cannot be selected 791
E-20 Any of work equipment, swing and travel do not operate or cannot be locked . 792
E-21 Machine push-up function does not operate or cannot be cancelled . 794
E-22 Boom shockless function does not operate properly 796
E-23 Swing brake does not operate properly 798
E-24 Windshield wiper and window washer do not operate 800
E-25 Travel alarm does not sound or does not stop sounding 804
E-26 Boom RAISE indicator is not displayed properly with monitoring function 806
E-27 Boom LOWER indicator is not displayed properly with monitoring function 808
E-28 Arm IN indicator is not displayed properly with monitoring function 810
E-29 Arm OUT indicator is not displayed properly with monitoring function . 812
E-30 Bucket CURL indicator is not displayed properly with monitoring function . 814
E-31 Bucket DUMP indicator is not displayed properly with monitoring function . 816
E-32 Swing indicator is not displayed properly with monitoring function . 818
E-33 “L.H. travel” is not displayed properly with monitoring function . 820
E-34 “R.H. travel” is not displayed properly with monitoring function . 822
E-35 “Attachment” is not displayed properly with monitoring function 824
E-36 Electric grease gun does not operate . 826
E-37 KOMTRAX system does not operate properly . 828
E-38 Horn does not sound or does not stop sounding 829
E-39 Step light does not light up or go off . 832
Troubleshooting of hydraulic and mechanical system (H-mode) . 836
Before starting troubleshooting for hydraulic and mechanical systems 836
Information in troubleshooting table (H-mode) . 840
H-1 All of work equipment, swing and travel work slow or lack power . 842
H-2 Engine speed lowers significantly or engine stalls 844
H-3 Any of work equipment, swing and travel does not work . 846
H-4 Unusual noise is heard from around hydraulic pump . 848
H-5 Boom operation lacks speed or power . 849
H-6 Arm operation lacks speed or power 851
H-7 Bucket operation lacks speed or power . 852
H-8 Boom does not move 853
H-9 Arm does not move . 853
H-10 Bucket does not move . 853
H-11 Hydraulic drift of work equipment is large . 854
H-12 Time lag of work equipment is large 856
H-13 Heavy lift function does not work or is not released . 857
H-14 Machine push-up function does not work or is not released 857
H-15 Boom shockless function does not work or is not cancelled 857
H-16 Machine deviates in one direction against operator’s intention when travelling . 858
H-17 Machine deviates significantly at start 861
H-18 Machine deviates significantly during combined operation . 862
H-19 Travel works slow or lack power 863
H-20 One of tracks does not run . 864
H-21 Travel speed does not change . 865
H-22 Upper structure does not swing . 866
H-23 Swing speed is low or swing acceleration is poor . 867
H-24 In combined operation with work equipment, swing speed is low or swing acceleration is poor 868
H-25 Upper structure overruns excessively when it stops swinging 870
H-26 Shock is large when upper structure stops swinging . 871
H-27 Large unusual noise is heard when upper structure stops swinging . 872
H-28 Swing drift on a slope is large 873
H-29 Fan revolution is abnormal (Fan sound/vibration is abnormally large or engine overheats) . 874
Troubleshooting of engine (S-mode) 876
Method of using troubleshooting chart . 876
S-1 Startability is poor 880
S-2 Engine does not start . 882
S-3 Engine does not pick up smoothly 886
S-4 Engine stops during operation . 887
S-5 Engine runs rough or is unstable 888
S-6 Engine lacks power 890
S-7 Exhaust smoke is black (incomplete combustion) 892
S-8 Oil consumption is excessive (or exhaust smoke is blue) . 894
S-9 Oil becomes contaminated early 895
S-10 Fuel consumption is excessive 896
S-11 Oil is in coolant (or coolant spurts or coolant level goes down) . 897
S-12 Oil pressure drops . 898
S-13 Oil level rises (coolant or fuel in oil) . 900
S-14 Coolant temperature rises too high (overheating) . 902
S-15 Unusual noise is made 903
S-16 Vibration is excessive . 904
50 Disassembly and assembly . 905
Contents 906
General information on disassembly and assembly . 908
How to read Disassembly and Assembly 908
Coating materials list 910
Special tools list 913
Sketches of special tools . 920
Engine and cooling system . 925
Removal and installation of engine, PTO and hydraulic pump assembly . 925
Removal and installation of cooling assembly 933
Removal and installation of aftercooler assembly 939
Removal and installation of fuel cooler and air condenser assembly 941
Removal and installation of fan motor assembly 943
Removal and installation of fuel tank assembly 948
Engine 950
Removal and installation of fuel supply pump assembly . 950
Removal and installation of cylinder head assembly 955
Removal and installation of fuel injector assembly 971
Removal and installation of engine front seal . 974
Removal and installation of engine rear seal 976
Power train . 981
Removal and installation of PTO assembly 981
Disassembly and assembly of PTO assembly 988
Removal and installation of swing motor and swing machinery assembly 990
Disassembly and assembly of swing machinery assembly 993
Removal and installation of swing circle assembly .1000
Disassembly and assembly of final drive assembly 1001
Undercarriage and frame .1013
Separation and connection of track shoe assembly 1013
Disassembly and assembly of one link in field .1015
Removal and installation of idler assembly 1019
Disassembly and assembly of idler assembly 1020
Disassembly and assembly of idler adjustment cylinder assembly 1023
Removal and installation of recoil spring assembly 1024
Disassembly and assembly of recoil spring assembly 1026
Removal and installation of carrier roller assembly .1028
Disassembly and assembly of carrier roller assembly .1029
Removal and installation of track roller assembly .1032
Disassembly and assembly of track roller assembly .1033
Removal and installation of revolving frame assembly 1036
Removal and installation of counterweight assembly 1038
Removal and installation of counterweight remover assembly 1039
Hydraulic system 1041
Removal and installation of hydraulic tank assembly .1041
Removal and installation of main pump assembly 1043
Removal and installation of main pump input shaft oil seal 1050
Removal and installation of cooling fan pump assembly .1051
Removal and installation of control valve assembly 1054
Assembly of control valve assembly 1057
Removal and installation of swing motor assembly 1063
Removal and installation of centre swivel joint assembly 1064
Disassembly and assembly of centre swivel joint assembly 1066
Removal and installation of travel motor assembly .1068
Removal and installation of solenoid valve assembly .1069
Removal and installation of boom damping valve assembly .1071
Disassembly and assembly of work equipment PPC valve assembly .1072
Disassembly and assembly of travel PPC valve assembly .1074
Disassembly and assembly of hydraulic cylinder assembly .1077
Disassembly and assembly of grease gun assembly .1084
Work equipment 1085
Removal and installation of bucket cylinder assembly 1085
Removal and installation of arm cylinder assembly .1089
Removal and installation of boom cylinder assembly 1093
Removal and installation of bottom dump cylinder assembly .1097
Removal and installation of bucket assembly .1099
Removal and installation of arm assembly 1102
Removal and installation of boom assembly .1106
Removal and installation of work equipment assembly .1110
Cab and its attachments .1114
Removal and installation of operator’s cab assembly .1114
Removal and installation of operator’s cab glass (adhered window glass) .1117
Removal and installation of front window assembly .1126
Electrical system .1133
Removal and installation of air conditioner unit assembly .1133
Removal and installation of engine controller assembly 1136
Removal and installation of monitor assembly 1138
Removal and installation of pump controller assembly 1140
Removal and installation of KOMTRAX terminal assembly .1142
60 Maintenance standard .1143
Contents 1144
Engine and cooling system .1145
Coupling 1145
Power train .1146
Swing circle 1146
Swing machinery .1147
Final drive .1150
Sprocket 1152
Undercarriage and frame .1154
Track frame and idler cushion .1154
Idler .1156
Carrier roller 1158
Track roller 1160
Track shoe 1162
Hydraulic system 1166
Cooling fan motor .1166
Control valve .1168
Swing motor .1174
Centre swivel joint .1176
PPC valve .1177
Work equipment 1180
Work equipment 1180
Work equipment dimension 1186
Hydraulic cylinder 1190
80 Appendix .1197
Table of contents .1198
Air conditioner .1199
Precautions for refrigerant .1199
Air conditioner component .1200
Configuration and function of refrigeration cycle .1202
Outline of refrigeration cycle 1203
Air conditioner unit 1206
Air conditioner controller 1211
Compressor 1212
Condenser .1213
Receiver drier 1214
Procedure for testing and troubleshooting .1216
Circuit diagram and arrangement of connector pins .1218
System diagram 1220
Detail of air conditioner unit 1222
Parts and connectors layout .1224
Testing air leakage (duct) 1227
Testing with self-diagnosis function 1228
Testing temperature control .1231
Testing vent (mode) changeover 1233
Testing FRESH/RECIRC air changeover .1236
Testing inner sensor 1238
Testing evaporator temperature sensor .1239
Testing sunlight sensor .1241
Testing (dual) pressure switch for refrigerant 1242
Testing relays 1243
Troubleshooting chart 1 .1244
Troubleshooting chart 2 .1246
Information in troubleshooting table 1248
Troubleshooting for power supply and CAN communication system (Air conditioner does not operate) 1250
Troubleshooting for compressor and refrigerant system (Air is not cooled) .1255
Troubleshooting for blower motor system (No air comes out or air flow is abnormal) 1259
Troubleshooting for temperature control .1263
Troubleshooting for vent (mode) changeover 1266
Troubleshooting for FRESH/RECIRC air changeover .1268
Troubleshooting for temperature sensor system .1270
Troubleshooting with gauge pressure .1272
Connection of service tool 1274
Precautions for disconnecting and connecting air conditioner piping .1276
Handling of compressor oil 1278
90 Diagrams and drawings 1281
Contents 1282
Hydraulic circuit diagram .1283
Symbols used in hydraulic circuit diagrams 1283
Hydraulic circuit diagram (1/2) .1287
Hydraulic circuit diagram (2/2) .1289
Electrical circuit diagram 1291
Symbols used in electric circuit diagrams .1291
Electrical circuit diagram (1/5) 1295
Electrical circuit diagram (2/5) 1297
Electrical circuit diagram (3/5) 1299
Electrical circuit diagram (4/5) 1301
Electrical circuit diagram (5/5) 1303

DESCRIPTION:

Komatsu Hydraulic Excavator PC800-8E0,PC800LC-8E0,PC800SE-8E0,PC850-8E0,PC850SE-8E0 Shop Manual UEN05276-00 – PDF DOWNLOAD

  • SERIAL NUMBERS
    PC800-8E0 K55001           and up
    PC800LC-8E0 K55001      and up
    PC800SE-8E0 K55001      and up
    PC850-8E0 K55001          and up
    PC850SE-8E0 K55001     and up
GENERAL PRECAUTIONS:
1) Before performing any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the Operation and Maintenance Manual.
2) Locate 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 performing any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. q Always wear the safety glasses when hitting parts with a hammer. q Always wear the safety glasses when grinding parts with a grinder, etc.
4) When performing any operation with two 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 warning tag in the operator’s compartment.
5) Only qualified workers must perform the 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. Before starting work, thoroughly check the tools, machine, forklift truck, service car, etc.
7) If welding repairs are needed, always have a trained and experienced welder perform the work. When performing 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.
9) Avoid continuing work for long hours and take rests at proper intervals to keep your body in good condition and at the provided place
2. Preparation work:
1) Before adding oil or making any repairs, park the machine on a hard and level ground, and apply the parking brake and chock the wheels or tracks to prevent the machine from moving.
2) Before starting work, lower the work equipment (blade, ripper, bucket, etc.) to the ground. If this is not possible, insert the lock pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning tag on them.
3) When disassembling or assembling, support the machine with blocks, jacks, or stands before starting the work.
4) Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing
3. Precautions during work:
1) Before disconnecting or removing components for the oil, water, or air circuits, first release the pressure completely from the circuit. When removing the oil filler cap, a drain plug, or an oil pressure pickup plug, loosen it slowly to prevent the oil from spurting out.
2) The coolant and oil in the circuits are hot when the engine is shut down, so be careful not to get scalded. Wait for the oil and coolant to cool before performing any work on the oil or water circuits.
3) Before starting work, shut down the engine. When working on or around a rotating part, in particular, shut down the engine. When checking the machine without shutting down the engine (measuring oil pressure, revolving speed, temperature, etc.), take extreme care not to get caught in rotating parts or moving parts.
4) Before starting work, remove the cables from the battery. Always remove the cable from the negative (–) terminal first.
5) When raising a heavy component (heavier than 25 kg), use a hoist or crane. Before starting work, check that the slings (wire ropes, chains, and hooks) are free from damage. Always use slings which have ample capacity and install them to proper places. Operate the hoist or crane slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane.

G.B 27/12/24

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