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Komatsu PC800-8R1, PC850-8R1 Series Excavator Service Manual PDF Download
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- KOMATSU PC800-8R1 PC800LC-8R1 PC800SE-8R1 PC850-8R1 PC850SE-8R1 HYDRAULIC EXCAVATOR SHOP MANUAL SEN05279-04 – PDF DOWNLOAD
- SERIAL NUMBERS
PC800- 70001 and up
PC800LC- 70001 and up
PC800SE- 70001 and up
PC850- 70001 and up
PC850SE- 70001 and up
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Description
KOMATSU PC800-8R1 PC800LC-8R1 PC800SE-8R1 PC850-8R1 PC850SE-8R1 HYDRAULIC EXCAVATOR SHOP MANUAL SEN05279-04 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU PC800-8R1 PC800LC-8R1 PC800SE-8R1 PC850-8R1 PC850SE-8R1 HYDRAULIC EXCAVATOR SHOP MANUAL SEN05279-04 – PDF DOWNLOAD
Language : English
Pages : 1302
Downloadable : Yes
File Type : PDF
SERIAL NUMBERS
PC800- 70001 and up
PC800LC- 70001 and up
PC800SE- 70001 and up
PC850- 70001 and up
PC850SE- 70001 and up
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU PC800-8R1 PC800LC-8R1 PC800SE-8R1 PC850-8R1 PC850SE-8R1 HYDRAULIC EXCAVATOR SHOP MANUAL SEN05279-04 – PDF DOWNLOAD
COVER................................................................................................................. 1 00 Index and foreword................................................................................................. 11 Table of contents................................................................................................. 12 Foreword and general information ................................................................................. 22 Important safety notice....................................................................................... 22 How to read the shop manual................................................................................... 29 Explanation of terms for maintenance standard................................................................. 31 Handling equipment of fuel system devices..................................................................... 33 Handling of intake system parts............................................................................... 34 Handling of hydraulic components.............................................................................. 35 Method of disconnecting and connecting push-pull type coupler................................................. 37 Handling of electric equipment................................................................................ 40 How to read electric wire code................................................................................ 49 Practical use of KOMTRAX...................................................................................... 55 Precautions when performing work.............................................................................. 56 Standard tightening torque table.............................................................................. 59 List of abbreviation.......................................................................................... 63 Conversion table.............................................................................................. 68 01 Specification...................................................................................................... 73 Contents.......................................................................................................... 74 Specifications.................................................................................................... 76 Specifications drawing........................................................................................ 76 Specifications................................................................................................ 80 Table of weight............................................................................................... 92 Table of fuel, coolant and lubricants......................................................................... 102 10 Structure and function............................................................................................. 105 Contents.......................................................................................................... 106 Engine and cooling system......................................................................................... 107 Coupling...................................................................................................... 107 Coupling lubrication system................................................................................... 108 Cooling system................................................................................................ 110 Power train system................................................................................................ 112 Power train................................................................................................... 112 Swing circle.................................................................................................. 114 Swing machinery............................................................................................... 115 Final drive................................................................................................... 117 Undercarriage and frame........................................................................................... 118 Track frame................................................................................................... 118 Idler cushion................................................................................................. 120 Hydraulic system.................................................................................................. 122 Hydraulic component layout.................................................................................... 122 Hydraulic tank and filter..................................................................................... 124 Hydraulic pump................................................................................................ 126 Pump control system........................................................................................... 134 Servo valve................................................................................................... 136 Self-pressure reducing valve.................................................................................. 145 Cooling fan pump.............................................................................................. 148 Cooling fan motor............................................................................................. 157 Electrical grease pump........................................................................................ 163 Control valve................................................................................................. 164 Straight-travel valve......................................................................................... 173 Swing motor................................................................................................... 176 Center swivel joint........................................................................................... 180 Travel motor.................................................................................................. 181 PPC valve..................................................................................................... 191 Solenoid valve................................................................................................ 199 Accumulator................................................................................................... 207 Quick return valve............................................................................................ 208 Line oil filter............................................................................................... 212 Pilot oil filter.............................................................................................. 213 Drain oil filter.............................................................................................. 214 Electrical system................................................................................................. 215 Engine control................................................................................................ 215 Electric control system....................................................................................... 223 Monitor system................................................................................................ 262 Sensors....................................................................................................... 292 KOMTRAX system................................................................................................ 296 20 Standard value table............................................................................................... 299 Contents.......................................................................................................... 300 Standard value table.............................................................................................. 301 Standard value table for engine............................................................................... 301 Standard value table for machine.............................................................................. 302 30 Testing and adjusting.............................................................................................. 315 Contents.......................................................................................................... 316 Tool for testing, adjusting and troubleshooting................................................................... 317 Tools for testing, adjusting, and troubleshooting............................................................. 317 Engine and cooling system......................................................................................... 321 Testing engine speed.......................................................................................... 321 Testing intake air pressure (Boost pressure).................................................................. 322 Testing exhaust gas temperature............................................................................... 323 Testing exhaust gas color..................................................................................... 324 Adjusting valve clearance..................................................................................... 326 Testing compression pressure.................................................................................. 327 Testing blowby pressure....................................................................................... 329 Handling fuel system parts.................................................................................... 331 Releasing remaining pressure from fuel system................................................................. 332 Testing fuel pressure......................................................................................... 333 Testing fuel return rate and leakage.......................................................................... 334 Bleeding air from fuel circuit................................................................................ 337 Testing fuel circuit for leakage.............................................................................. 339 Testing and adjusting alternator belt tension................................................................. 340 Testing and adjusting air conditioner compressor belt tension................................................. 341 Undercarriage and frame........................................................................................... 342 Testing swing circle bearing clearance........................................................................ 342 Testing and adjusting track tension........................................................................... 343 Hydraulic system.................................................................................................. 344 Testing and adjusting oil pressure in work equipment, swing, and travel circuits.............................. 344 Testing and adjusting control circuit oil pressure (output pressure of self-pressure reducing valve).......... 350 Testing and adjusting control signal of main pump............................................................. 352 Testing PPC valve output pressure............................................................................. 359 Testing outlet pressure of solenoid valve, swing PPC shuttle valve, and swing priority selector valve......... 364 Adjusting play of work equipment and swing PPC valves......................................................... 369 Testing and adjusting travel deviation........................................................................ 370 Inspecting locations of hydraulic drift in work equipment..................................................... 372 Testing fan speed............................................................................................. 373 Testing fan circuit oil pressure.............................................................................. 374 Testing fan pump EPC current.................................................................................. 375 Testing fan pump EPC solenoid valve outlet pressure........................................................... 376 Testing oil leakage........................................................................................... 377 Releasing remaining pressure from hydraulic circuit........................................................... 381 Bleeding air from various parts............................................................................... 382 Inspection procedures for diode............................................................................... 385 Adjusting mirrors............................................................................................. 386 Electrical system................................................................................................. 387 Special functions of machine monitor.......................................................................... 387 Handling voltage circuit of engine controller................................................................. 431 Preparatory work for troubleshooting of electrical system..................................................... 432 Pm Clinic......................................................................................................... 436 Pm clinic service............................................................................................. 436 UNDERCARRIAGE INSPECTION REPORT............................................................................... 443 40 Troubleshooting.................................................................................................... 445 Contents.......................................................................................................... 446 General information on troubleshooting............................................................................ 451 Points to remember when troubleshooting....................................................................... 451 Sequence of events in troubleshooting......................................................................... 452 Checks before troubleshooting................................................................................. 453 Classification and procedures for troubleshooting............................................................. 479 Failure codes table........................................................................................... 482 Symptom and troubleshooting numbers........................................................................... 487 Information in troubleshooting table.......................................................................... 490 Troubleshooting method for open circuit in wiring harness of pressure sensor system........................... 492 Connector list and layout..................................................................................... 494 Connection table for connector pin numbers.................................................................... 505 T- branch box and T- branch adapter table..................................................................... 541 Fuse locations................................................................................................ 544 Troubleshooting by failure code................................................................................... 547 Failure code [989L00] Engine Controller Lock Caution 1........................................................ 547 Failure code [989M00] Engine Controller Lock Caution 2........................................................ 548 Failure code [989N00] Engine Controller Lock Caution 3........................................................ 548 Failure code [AA10NX] Air Cleaner Clogging.................................................................... 549 Failure code [AB00KE] Charge Voltage Low...................................................................... 550 Failure code [B@BAZG] Eng Oil Press Low....................................................................... 552 Failure code [B@BAZK] Eng Oil Level Low....................................................................... 553 Failure code [B@BCNS] Eng Water Overheat...................................................................... 554 Failure code [B@BCZK] Eng Water Level Low..................................................................... 556 Failure code [B@HANS] Hyd Oil Overheat........................................................................ 558 Failure code [CA111] ECM Critical Internal Failure............................................................ 560 Failure code [CA115] Eng Ne and Bkup Speed Sens Error......................................................... 562 Failure code [CA122] Chg Air Press Sensor High Error.......................................................... 564 Failure code [CA123] Chg Air Press Sensor Low Error........................................................... 566 Failure code [CA131] Throttle Sensor High Error............................................................... 568 Failure code [CA132] Throttle Sensor Low Error................................................................ 570 Failure code [CA135] Eng Oil Press Sensor High Error.......................................................... 572 Failure code [CA141] Eng Oil Press Sensor Low Error........................................................... 574 Failure code [CA144] Coolant Temp Sens High Error............................................................. 576 Failure code [CA145] Coolant Temp Sens Low Error.............................................................. 578 Failure code [CA153] Chg Air Temp Sensor High Error........................................................... 580 Failure code [CA154] Chg Air Temp Sensor Low Error............................................................ 582 Failure code [CA187] Sens Supply 2 Volt Low Error............................................................. 584 Failure code [CA221] Ambient Press Sens High Error............................................................ 586 Failure code [CA222] Ambient Press Sens Low Error............................................................. 588 Failure code [CA227] Sens Supply 2 Volt High Error............................................................ 590 Failure code [CA238] Ne Speed Sens Supply Volt Error.......................................................... 592 Failure code [CA263] Fuel Temp Sensor High Error.............................................................. 594 Failure code [CA265] Fuel Temp Sensor Low Error............................................................... 596 Failure code [CA271] IMV/PCV1 Short Error..................................................................... 598 Failure code [CA272] IMV/PCV1 Open Error...................................................................... 599 Failure code [CA273] PCV2 Short Error......................................................................... 600 Failure code [CA274] PCV2 Open Error.......................................................................... 601 Failure code [CA322] Inj #1(L#1) Open/Short Error............................................................. 602 Failure code [CA323] Inj #5 (L#5) Open/Short Error............................................................ 604 Failure code [CA325] Inj #6 (L#6) Open/Short Error............................................................ 608 Failure code [CA331] Inj #2(L#2) Open/Short Error............................................................. 610 Failure code [CA332] Inj #4 (L#4) Open/Short Error............................................................ 612 Failure code [CA342] Calibration Code Incompatibility......................................................... 614 Failure code [CA351] Injectors Drive Circuit Error............................................................ 615 Failure code [CA352] Sens Supply 1 Volt Low Error............................................................. 616 Failure code [CA386] Sens Supply 1 Volt High Error............................................................ 618 Failure code [CA441] Battery Voltage Low Error................................................................ 618 Failure code [CA442] Battery Voltage High Error............................................................... 619 Failure code [CA449] Rail Press Very High Error............................................................... 619 Failure code [CA451] Rail Press Sensor High Error............................................................. 620 Failure code [CA452] Rail Press Sensor Low Error.............................................................. 622 Failure code [CA553] Rail Press High Error.................................................................... 624 Failure code [CA554] Rail Press Sensor In Range Error......................................................... 625 Failure code [CA559] Supply Pump Press Low Error 1............................................................ 626 Failure code [CA689] Eng Ne Speed Sensor Error................................................................ 630 Failure code [CA731] Eng Bkup Speed Sens Phase Error.......................................................... 632 Failure code [CA757] All Continuous Data Lost Error........................................................... 633 Failure code [CA778] Eng Bkup Speed Sensor Error.............................................................. 634 Failure code [CA1633] KOMNET Datalink Timeout Error........................................................... 636 Failure code [CA2185] Throt Sens Sup Volt High Error.......................................................... 638 Failure code [CA2186] Throt Sens Sup Volt Low Error........................................................... 640 Failure code [CA2249] Rail Press Very Low Error............................................................... 641 Failure code [CA2555] Grid Htr Relay Open Circuit Error....................................................... 642 Failure code [CA2556] Grid Htr Relay Short Circuit Error...................................................... 644 Failure code [D110KB] Battery Relay Drive Short Circuit....................................................... 646 Failure code [D163KB] Flash Light Relay Short Circuit......................................................... 648 Failure code [D195KA] Step Light Relay Open Circuit........................................................... 650 Failure code [D195KB] Step Light Relay Short Circuit.......................................................... 652 Failure code [D19JKZ] Personal Code Relay Abnormality......................................................... 654 Failure code [D862KA] GPS Antenna Open Circuit................................................................ 656 Failure code [DA22KK] Pump Solenoid Power Low Error........................................................... 658 Failure code [DA25KP] 5V Sensor1 Power Abnormality............................................................ 660 Failure code [DA29KQ] Model Selection Abnormality............................................................. 662 Failure code [DA2RMC] CAN Discon (Pump Con Detected).......................................................... 664 Failure code [DA80MA] Auto. Lub. Abnormal..................................................................... 668 Failure code [DAF8KB] Camera Power Supply Short Circuit....................................................... 670 Failure code [DAFGMC] GPS Module Error........................................................................ 672 Failure code [DAFRMC] CAN Discon (Monitor Detected)........................................................... 673 Failure code [DGE5KB] Ambi. Temp Sensor Short Circuit......................................................... 678 Failure code [DGH2KB] Hyd Oil Sensor Short.................................................................... 680 Failure code [DH25KA] L Jet Sensor Open Circuit............................................................... 682 Failure code [DH25KB] L Jet Sensor Short Circuit.............................................................. 684 Failure code [DH26KA] R Jet Sensor Open Circuit............................................................... 686 Failure code [DH26KB] R Jet Sensor Short Circuit.............................................................. 688 Failure code [DHPEKA] F Pump P. Sensor Open Circuit........................................................... 690 Failure code [DHPEKB] F Pump P. Sensor Short Circuit.......................................................... 692 Failure code [DHPFKA] R Pump P. Sensor Open Circuit........................................................... 694 Failure code [DHPFKB] R Pump P. Sensor Short Circuit.......................................................... 696 Failure code [DV20KB] Travel alarm short circuit.............................................................. 698 Failure code [DW41KA] Swing Priority Sol Open Circuit......................................................... 700 Failure code [DW41KB] Swing Priority Sol Short Circuit........................................................ 702 Failure code [DW43KA] Travel Speed Sol Open Circuit........................................................... 704 Failure code [DW43KB] Travel Speed Sol Short Circuit.......................................................... 706 Failure code [DW45KA] Swing Brake Sol Open Circuit............................................................ 708 Failure code [DW45KB] Swing Brake Sol Short Circuit........................................................... 710 Failure code [DW7BKA] Fan Reverse Sol Open Circuit............................................................ 712 Failure code [DW7BKB] Fan Reverse Sol Short Circuit........................................................... 714 Failure code [DW7JKA] Bottom Dump Priority Sol Open Circuit................................................... 716 Failure code [DW7JKB] Bottom Dump Priority Sol Short Circuit.................................................. 718 Failure code [DW91KA] Travel Junction Sol Open Circuit........................................................ 720 Failure code [DW91KB] Travel Junction Sol Short Circuit....................................................... 722 Failure code [DWK0KA] 2-stage Relief Sol Open Circuit......................................................... 724 Failure code [DWK0KB] 2-stage Relief Sol Short Circuit........................................................ 726 Failure code [DX16KA] Fan Pump EPC Sol Open Circuit........................................................... 728 Failure code [DX16KB] Fan Pump EPC Sol Short Circuit.......................................................... 730 Failure code [DXAAKA] F Pump EPC Sol Open Circuit............................................................. 732 Failure code [DXAAKB] F Pump EPC Sol Short Circuit............................................................ 734 Failure code [DXABKA] R Pump EPC Sol Open Circuit............................................................. 736 Failure code [DXABKB] R Pump EPC Sol Short Circuit............................................................ 738 Failure code [DY20KA] Wiper Working Abnormality............................................................... 740 Failure code [DY20MA] Wiper Parking Abnormality............................................................... 744 Failure code [DY2CKA] Washer Drive Open Circuit............................................................... 746 Failure code [DY2CKB] Washer Drive Short Circuit.............................................................. 748 Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit......................................................... 750 Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit......................................................... 754 Failure code [DY2FMA] Upper Wiper Working Abnormality......................................................... 758 Failure code [DY2GKM] Wiper Select Abnormality................................................................ 760 Troubleshooting of electrical system (E-mode)..................................................................... 763 E-1 Engine does not start (Engine does not crank)............................................................. 763 E-2 Preheater does not operate................................................................................ 768 E-3 When starting switch is turned to ON position, machine monitor displays nothing........................... 772 E-4 When starting switch is turned to ON position (before starting engine), basic check monitor lights up..... 775 E-5 Precaution item lights up while engine is running......................................................... 776 E-6 Emergency stop item lights up while engine is running..................................................... 778 E-7 Engine coolant temperature gauge does not indicate properly............................................... 779 E-8 Fuel gauge does not indicate properly..................................................................... 780 E-9 Hydraulic oil temperature gauge does not indicate properly................................................ 782 E-10 Displays on machine monitor are different from those for actual machine.................................. 784 E-11 Some areas of machine monitor screen are not displayed................................................... 784 E-12 Function switch does not operate......................................................................... 784 E-13 Automatic warm-up system does not operate (in cold season)............................................... 785 E-14 Auto-decelerator does not operate properly............................................................... 786 E-15 Working mode does not change............................................................................. 787 E-16 Travel speed does not change............................................................................. 788 E-17 Alarm buzzer cannot be canceled.......................................................................... 789 E-18 When starting switch is turned OFF, service meter is not displayed40..................................... 789 E-19 Service mode cannot be selected.......................................................................... 789 E-20 Any of work equipment, swing and travel do not operate or cannot be locked............................... 790 E-21 Machine push-up function does not operate or cannot be canceled40........................................ 792 E-22 Boom shockless function does not operate properly........................................................ 794 E-23 Swing brake does not operate properly.................................................................... 796 E-24 Windshield wiper and window washer do not operate........................................................ 798 E-25 Travel alarm does not sound or does not stop sounding.................................................... 802 E-26 Boom RAISE indicator is not displayed properly with monitoring function.................................. 804 E-27 Boom LOWER indicator is not displayed properly with monitoring function.................................. 806 E-28 Arm IN indicator is not displayed properly with monitoring function40.................................... 808 E-29 Arm OUT indicator is not displayed properly with monitoring function..................................... 810 E-30 Bucket CURL indicator is not displayed properly with monitoring function................................. 812 E-31 Bucket DUMP indicator is not displayed properly with monitoring function................................. 814 E-32 Swing indicator is not displayed properly with monitoring function....................................... 816 E-33 "L.H. travel" is not displayed properly with monitoring function......................................... 818 E-34 "R.H. travel" is not displayed properly with monitoring function......................................... 820 E-35 "Attachment" is not displayed properly with monitoring function.......................................... 822 E-36 Electric grease gun does not operate..................................................................... 824 E-37 KOMTRAX system does not operate properly................................................................. 826 E-38 Horn does not sound or does not stop sounding............................................................ 827 E-39 Step light does not light up or go off................................................................... 830 Troubleshooting of hydraulic and mechanical system (H-mode)....................................................... 834 Before starting troubleshooting for hydraulic and mechanical systems.......................................... 834 Information in troubleshooting table (H-mode)................................................................. 838 H-1 All of work equipment, swing and travel work slow or lack power........................................... 840 H-2 Engine speed lowers significantly or engine stalls........................................................ 842 H-3 Any of work equipment, swing and travel does not work..................................................... 844 H-4 Unusual noise is heard from around hydraulic pump......................................................... 846 H-5 Boom operation lacks speed or power....................................................................... 847 H-6 Arm operation lacks speed or power........................................................................ 849 H-7 Bucket operation lacks speed or power..................................................................... 850 H-8 Boom does not move........................................................................................ 851 H-9 Arm does not move......................................................................................... 851 H-10 Bucket does not move..................................................................................... 851 H-11 Hydraulic drift of work equipment is large............................................................... 852 H-12 Time lag of work equipment is large...................................................................... 854 H-13 Heavy lift function does not work or is not released..................................................... 855 H-14 Machine push-up function does not work or is not released................................................ 855 H-15 Boom shockless function does not work or is not canceled................................................. 855 H-16 Machine deviates in one direction against operator's intention when travelling........................... 856 H-17 Machine deviates significantly at start.................................................................. 859 H-18 Machine deviates significantly during combined operation................................................. 860 H-19 Travel works slow or lack power.......................................................................... 861 H-20 One of tracks does not run............................................................................... 862 H-21 Travel speed does not change............................................................................. 863 H-22 Upper structure does not swing........................................................................... 864 H-23 Swing speed is low or swing acceleration is poor......................................................... 865 H-24 In combined operation with work equipment, swing speed is low or swing acceleration is poor.............. 866 H-25 Upper structure overruns excessively when it stops swinging.............................................. 868 H-26 Shock is large when upper structure stops swinging....................................................... 869 H-27 Large unusual noise is heard when upper structure stops swinging40....................................... 870 H-28 Swing drift on a slope is large.......................................................................... 871 H-29 Fan revolution is abnormal (Fan sound/vibration is abnormally large or engine overheats)................. 872 Troubleshooting of engine (S-mode)................................................................................ 874 Method of using troubleshooting chart......................................................................... 874 S-1 Startability is poor...................................................................................... 878 S-2 Engine does not start..................................................................................... 879 S-3 Engine does not pick up smoothly.......................................................................... 882 S-4 Engine stops during operation............................................................................. 883 S-5 Engine runs rough or is unstable.......................................................................... 884 S-6 Engine lacks power........................................................................................ 886 S-7 Exhaust smoke is black (incomplete combustion)............................................................ 888 S-8 Oil consumption is excessive (or exhaust smoke is blue)................................................... 889 S-9 Oil becomes contaminated early............................................................................ 890 S-10 Fuel consumption is excessive............................................................................ 891 S-11 Oil is in coolant (or coolant spurts or coolant level goes down)......................................... 892 S-12 Oil pressure drops....................................................................................... 893 S-13 Oil level rises (coolant or fuel in oil)................................................................. 894 S-14 Coolant temperature rises too high (overheating)......................................................... 895 S-15 Unusual noise is made.................................................................................... 896 S-16 Vibration is excessive................................................................................... 897 50 Disassembly and assembly........................................................................................... 899 Contents.......................................................................................................... 900 General information on disassembly and assembly................................................................... 902 How to read Disassembly and Assembly.......................................................................... 902 Coating materials list........................................................................................ 904 Special tools list............................................................................................ 908 Sketches of special tools..................................................................................... 915 Engine and cooling system......................................................................................... 920 Removal and installation of engine, PTO and hydraulic pump assembly50-21...................................... 920 Removal and installation of cooling assembly.................................................................. 928 Removal and installation of aftercooler assembly.............................................................. 934 Removal and installation of fuel cooler and air condenser assembly............................................ 936 Removal and installation of fan motor assembly................................................................ 938 Removal and installation of fuel tank assembly................................................................ 943 Engine............................................................................................................ 945 Removal and installation of fuel supply pump assembly......................................................... 945 Removal and installation of cylinder head assembly............................................................ 950 Removal and installation of fuel injector assembly............................................................ 965 Removal and installation of engine front seal................................................................. 968 Removal and installation of engine rear seal.................................................................. 970 Power train....................................................................................................... 975 Removal and installation of PTO assembly...................................................................... 975 Disassembly and assembly of PTO assembly...................................................................... 982 Removal and installation of swing motor and swing machinery assembly.......................................... 984 Disassembly and assembly of swing machinery assembly.......................................................... 987 Removal and installation of swing circle assembly............................................................. 994 Disassembly and assembly of final drive assembly.............................................................. 995 Undercarriage and frame...........................................................................................1007 Separation and connection of track shoe assembly..............................................................1007 Disassembly and assembly of one link in field.................................................................1009 Removal and installation of idler assembly....................................................................1013 Disassembly and assembly of idler assembly....................................................................1014 Disassembly and assembly of idler adjustment cylinder assembly................................................1017 Removal and installation of recoil spring assembly............................................................1018 Disassembly and assembly of recoil spring assembly............................................................1020 Removal and installation of carrier roller assembly...........................................................1022 Disassembly and assembly of carrier roller assembly...........................................................1023 Removal and installation of track roller assembly.............................................................1026 Disassembly and assembly of track roller assembly.............................................................1027 Removal and installation of revolving frame assembly..........................................................1030 Removal and installation of counterweight assembly............................................................1032 Removal and installation of counterweight remover assembly....................................................1033 Hydraulic system..................................................................................................1036 Removal and installation of hydraulic tank assembly...........................................................1036 Removal and installation of main pump assembly................................................................1038 Removal and installation of main pump input shaft oil seal....................................................1045 Removal and installation of cooling fan pump assembly.........................................................1046 Removal and installation of control valve assembly............................................................1049 Assembly of control valve assembly............................................................................1052 Removal and installation of swing motor assembly..............................................................1058 Removal and installation of center swivel joint assembly......................................................1059 Disassembly and assembly of center swivel joint assembly......................................................1061 Removal and installation of travel motor assembly.............................................................1063 Removal and installation of solenoid valve assembly...........................................................1064 Removal and installation of boom damping valve assembly.......................................................1066 Disassembly and assembly of work equipment PPC valve assembly.................................................1067 Disassembly and assembly of travel PPC valve assembly.........................................................1069 Disassembly and assembly of hydraulic cylinder assembly.......................................................1072 Disassembly and assembly of grease gun assembly...............................................................1079 Work equipment....................................................................................................1080 Removal and installation of bucket cylinder assembly..........................................................1080 Removal and installation of arm cylinder assembly.............................................................1084 Removal and installation of boom cylinder assembly............................................................1088 Removal and installation of bottom dump cylinder assembly.....................................................1092 Removal and installation of bucket assembly...................................................................1094 Removal and installation of arm assembly......................................................................1097 Removal and installation of boom assembly.....................................................................1101 Removal and installation of work equipment assembly...........................................................1105 Cab and its attachments...........................................................................................1109 Removal and installation of operator's cab assembly...........................................................1109 Removal and installation of operator's cab glass (adhered window glass).......................................1112 Removal and installation of front window assembly.............................................................1121 Electrical system.................................................................................................1128 Removal and installation of air conditioner unit assembly.....................................................1128 Removal and installation of engine controller assembly........................................................1131 Removal and installation of monitor assembly..................................................................1133 Removal and installation of pump controller assembly..........................................................1135 Removal and installation of KOMTRAX terminal assembly.........................................................1137 60 Maintenance standard...............................................................................................1139 Contents..........................................................................................................1140 Engine and cooling system.........................................................................................1141 Coupling......................................................................................................1141 Power train.......................................................................................................1142 Swing circle..................................................................................................1142 Swing machinery...............................................................................................1143 Final drive...................................................................................................1146 Sprocket......................................................................................................1148 Undercarriage and frame...........................................................................................1150 Track frame and idler cushion.................................................................................1150 Idler.........................................................................................................1152 Carrier roller................................................................................................1154 Track roller..................................................................................................1156 Track shoe....................................................................................................1158 Hydraulic system..................................................................................................1162 Cooling fan motor.............................................................................................1162 Control valve.................................................................................................1164 Swing motor...................................................................................................1170 Center swivel joint...........................................................................................1172 PPC valve.....................................................................................................1173 Work equipment....................................................................................................1176 Work equipment................................................................................................1176 Work equipment dimension......................................................................................1182 Hydraulic cylinder............................................................................................1186 80 Appendix...........................................................................................................1193 Table of contents.................................................................................................1194 Air conditioner...................................................................................................1195 Precautions for refrigerant...................................................................................1195 Air conditioner component.....................................................................................1196 Configuration and function of refrigeration cycle.............................................................1198 Outline of refrigeration cycle................................................................................1199 Air conditioner controller....................................................................................1207 Compressor....................................................................................................1208 Condenser.....................................................................................................1209 Receiver drier................................................................................................1210 Procedure for testing and troubleshooting.....................................................................1212 Circuit diagram and arrangement of connector pins.............................................................1214 System diagram................................................................................................1216 Detail of air conditioner unit................................................................................1218 Parts and connectors layout...................................................................................1220 Testing air leakage (duct)....................................................................................1223 Testing with self-diagnosis function..........................................................................1224 Testing temperature control...................................................................................1227 Testing vent (mode) changeover................................................................................1229 Testing FRESH/RECIRC air changeover...........................................................................1232 Testing inner sensor..........................................................................................1234 Testing evaporator temperature sensor.........................................................................1235 Testing sunlight sensor.......................................................................................1237 Testing (dual) pressure switch for refrigerant................................................................1238 Testing relays................................................................................................1239 Troubleshooting chart 1.......................................................................................1240 Troubleshooting chart 2.......................................................................................1242 Information in troubleshooting table..........................................................................1244 Troubleshooting for power supply and CAN communication system (Air conditioner does not operate)..............1246 Troubleshooting for compressor and refrigerant system (Air is not cooled).....................................1251 Troubleshooting for blower motor system (No air comes out or air flow is abnormal)............................1255 Troubleshooting for temperature control.......................................................................1259 Troubleshooting for vent (mode) changeover....................................................................1262 Troubleshooting for FRESH/RECIRC air changeover...............................................................1264 Troubleshooting for temperature sensor system.................................................................1266 Troubleshooting with gauge pressure...........................................................................1268 Connection of service tool....................................................................................1270 Precautions for disconnecting and connecting air conditioner piping...........................................1272 Handling of compressor oil....................................................................................1274 90 Diagrams and drawings..............................................................................................1277 Contents..........................................................................................................1278 Hydraulic circuit diagram.........................................................................................1279 Symbols used in hydraulic circuit diagrams....................................................................1279 Hydraulic circuit diagram.....................................................................................1283 Electrical circuit diagram........................................................................................1285 Symbols used in electric circuit diagrams.....................................................................1285 Electrical circuit diagram....................................................................................1289 Index.................................................................................................................1295
DESCRIPTION:
KOMATSU PC800-8R1 PC800LC-8R1 PC800SE-8R1 PC850-8R1 PC850SE-8R1 HYDRAULIC EXCAVATOR SHOP MANUAL SEN05279-04 – PDF DOWNLOAD
General precautions
- 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.
- Locate a place in the repair workshop to keep the 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.
- When performing any work, always wear the safety shoes and helmet. Do not wear loose work cloths, or clothes with buttons missing.
1. Always wear the protective eyeglasses when hitting parts with a hammer.
2. Always wear the protective eyeglasses when grinding parts with a grinder, etc. - When performing any work with two or more workers, always agree on the working procedure before starting. While working, always keep conversations of the work between your fellow workers and your self on any step of the work. During the work, hang the warning tag of “UNDER WORKING” in the operator's compartment.
- Only qualified workers must perform the work and operation which require license or qualification.
- Keep the tools in good condition. And learn the correct way to use the tools, and use the proper ones among them. Before starting the work, thoroughly check the tools, forklift truck, service car, etc.
- If welding repairs is required, always have a trained and experienced welder with good knowledge of welding perform the work. When performing welding work, always wear welding gloves, apron, shielding goggles, cap, etc.
Before starting work, warm up your body thoroughly to start work under good condition. - Avoid continuing work for long hours and take rests with proper intervals to keep your body in good condition. Take a rest in a specified safe place.
S.S 28/12/24
