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KOMATSU PC800-8R1 PC800LC-8R1 PC800SE-8R1 PC850-8R1 PC850SE-8R1 HYDRAULIC EXCAVATOR SHOP MANUAL – PDF
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Description
KOMATSU PC800-8R1 PC800LC-8R1 PC800SE-8R1 PC850-8R1 PC850SE-8R1 HYDRAULIC EXCAVATOR SHOP MANUAL SEN05279-08 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU PC800-8R1 PC800LC-8R1 PC800SE-8R1 PC850-8R1 PC850SE-8R1 HYDRAULIC EXCAVATOR SHOP MANUAL SEN05279-08 – PDF DOWNLOAD
Language : English
Pages : 1316
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU PC800-8R1 PC800LC-8R1 PC800SE-8R1 PC850-8R1 PC850SE-8R1 HYDRAULIC EXCAVATOR SHOP MANUAL SEN05279-08 – PDF DOWNLOAD
Cover..................................................................................................................... 1 00 Index and foreword................................................................................................. 3 Table of contents................................................................................................. 4 Foreword and general information ................................................................................. 14 Important safety notice....................................................................................... 14 How to read the shop manual................................................................................... 21 Explanation of terms for maintenance standard................................................................. 23 Handling equipment of fuel system devices..................................................................... 25 Handling of intake system parts............................................................................... 26 Handling of hydraulic components.............................................................................. 27 Method of disconnecting and connecting push-pull type coupler................................................. 29 Handling of electric equipment................................................................................ 32 How to read electric wire code................................................................................ 41 Practical use of KOMTRAX...................................................................................... 47 Precautions when performing work.............................................................................. 48 Standard tightening torque table.............................................................................. 51 List of abbreviation.......................................................................................... 55 Conversion table.............................................................................................. 60 01 Specification...................................................................................................... 65 Contents.......................................................................................................... 66 Specifications.................................................................................................... 68 Specifications drawing........................................................................................ 68 Specifications................................................................................................ 72 Table of weight............................................................................................... 84 Table of fuel, coolant and lubricants......................................................................... 94 10 Structure and function............................................................................................. 97 Contents.......................................................................................................... 98 Engine and cooling system......................................................................................... 99 Coupling...................................................................................................... 99 Coupling lubrication system................................................................................... 100 Cooling system................................................................................................ 102 Power train system................................................................................................ 104 Power train................................................................................................... 104 Swing circle.................................................................................................. 106 Swing machinery............................................................................................... 107 Final drive................................................................................................... 109 Undercarriage and frame........................................................................................... 110 Track frame................................................................................................... 110 Idler cushion................................................................................................. 112 Hydraulic system.................................................................................................. 114 Hydraulic component layout.................................................................................... 114 Hydraulic tank and filter..................................................................................... 116 Hydraulic pump................................................................................................ 118 Pump control system........................................................................................... 126 Servo valve................................................................................................... 128 Self-pressure reducing valve.................................................................................. 137 Cooling fan pump.............................................................................................. 140 Cooling fan motor............................................................................................. 149 Electrical grease pump........................................................................................ 155 Control valve................................................................................................. 156 Straight-travel valve......................................................................................... 165 Swing motor................................................................................................... 168 Center swivel joint........................................................................................... 172 Travel motor.................................................................................................. 173 PPC valve..................................................................................................... 183 Solenoid valve................................................................................................ 191 Accumulator................................................................................................... 199 Quick return valve............................................................................................ 200 Line oil filter............................................................................................... 204 Pilot oil filter.............................................................................................. 205 Drain oil filter.............................................................................................. 206 Electrical system................................................................................................. 207 Engine control................................................................................................ 207 Electric control system....................................................................................... 215 Monitor system................................................................................................ 254 Sensors....................................................................................................... 284 KOMTRAX system................................................................................................ 288 20 Standard value table............................................................................................... 291 Contents.......................................................................................................... 292 Standard value table.............................................................................................. 293 Standard value table for engine............................................................................... 293 Standard value table for machine.............................................................................. 294 30 Testing and adjusting.............................................................................................. 307 Contents.......................................................................................................... 308 Tool for testing, adjusting and troubleshooting................................................................... 309 Tools for testing, adjusting, and troubleshooting............................................................. 309 Engine and cooling system......................................................................................... 313 Testing engine speed.......................................................................................... 313 Testing intake air pressure (Boost pressure).................................................................. 314 Testing exhaust gas temperature............................................................................... 315 Testing exhaust gas color..................................................................................... 316 Adjusting valve clearance..................................................................................... 318 Testing compression pressure.................................................................................. 319 Testing blowby pressure....................................................................................... 321 Handling fuel system parts.................................................................................... 323 Releasing remaining pressure from fuel system................................................................. 324 Testing fuel pressure......................................................................................... 325 Testing fuel return rate and leakage.......................................................................... 326 Bleeding air from fuel circuit................................................................................ 329 Testing fuel circuit for leakage.............................................................................. 331 Testing and adjusting alternator belt tension................................................................. 332 Testing and adjusting air conditioner compressor belt tension................................................. 333 Undercarriage and frame........................................................................................... 334 Testing swing circle bearing clearance........................................................................ 334 Testing and adjusting track tension........................................................................... 335 Hydraulic system.................................................................................................. 336 Testing and adjusting oil pressure in work equipment, swing, and travel circuits.............................. 336 Testing and adjusting control circuit oil pressure (output pressure of self-pressure reducing valve).......... 342 Testing and adjusting control signal of main pump............................................................. 344 Testing PPC valve output pressure............................................................................. 351 Testing outlet pressure of solenoid valve, swing PPC shuttle valve, and swing priority selector valve......... 356 Adjusting play of work equipment and swing PPC valves......................................................... 361 Testing and adjusting travel deviation........................................................................ 362 Inspecting locations of hydraulic drift in work equipment..................................................... 364 Testing fan speed............................................................................................. 365 Testing fan circuit oil pressure.............................................................................. 366 Testing fan pump EPC current.................................................................................. 367 Testing fan pump EPC solenoid valve outlet pressure........................................................... 368 Testing oil leakage........................................................................................... 369 Releasing remaining pressure from hydraulic circuit........................................................... 373 Bleeding air from various parts............................................................................... 374 Inspection procedures for diode............................................................................... 377 Adjusting mirrors............................................................................................. 378 Electrical system................................................................................................. 379 Special functions of machine monitor.......................................................................... 379 Handling voltage circuit of engine controller................................................................. 423 Preparatory work for troubleshooting of electrical system..................................................... 424 Pm Clinic......................................................................................................... 428 Pm clinic service............................................................................................. 428 UNDERCARRIAGE INSPECTION REPORT............................................................................... 435 40 Troubleshooting.................................................................................................... 437 Contents.......................................................................................................... 438 General information on troubleshooting............................................................................ 443 Points to remember when troubleshooting....................................................................... 443 Sequence of events in troubleshooting......................................................................... 444 Checks before troubleshooting................................................................................. 445 Classification and procedures for troubleshooting............................................................. 471 Failure codes table........................................................................................... 474 Symptom and troubleshooting numbers........................................................................... 479 Information in troubleshooting table.......................................................................... 482 Troubleshooting method for open circuit in wiring harness of pressure sensor system........................... 484 Connector list and layout..................................................................................... 486 Connection table for connector pin numbers.................................................................... 497 T- branch box and T- branch adapter table..................................................................... 533 Fuse locations................................................................................................ 536 Troubleshooting by failure code................................................................................... 539 Failure code [989L00] Engine Controller Lock Caution 1........................................................ 539 Failure code [989M00] Engine Controller Lock Caution 2........................................................ 540 Failure code [989N00] Engine Controller Lock Caution 3........................................................ 540 Failure code [AA10NX] Air Cleaner Clogging.................................................................... 541 Failure code [AB00KE] Charge Voltage Low...................................................................... 542 Failure code [B@BAZG] Eng Oil Press Low....................................................................... 544 Failure code [B@BAZK] Eng Oil Level Low....................................................................... 545 Failure code [B@BCNS] Eng Water Overheat...................................................................... 546 Failure code [B@BCZK] Eng Water Level Low..................................................................... 548 Failure code [B@HANS] Hyd Oil Overheat........................................................................ 550 Failure code [CA111] ECM Critical Internal Failure............................................................ 552 Failure code [CA115] Eng Ne and Bkup Speed Sens Error......................................................... 554 Failure code [CA122] Chg Air Press Sensor High Error.......................................................... 556 Failure code [CA123] Chg Air Press Sensor Low Error........................................................... 558 Failure code [CA131] Throttle Sensor High Error............................................................... 560 Failure code [CA132] Throttle Sensor Low Error................................................................ 562 Failure code [CA135] Eng Oil Press Sensor High Error.......................................................... 564 Failure code [CA141] Eng Oil Press Sensor Low Error........................................................... 566 Failure code [CA144] Coolant Temp Sens High Error............................................................. 568 Failure code [CA145] Coolant Temp Sens Low Error.............................................................. 570 Failure code [CA153] Chg Air Temp Sensor High Error........................................................... 572 Failure code [CA154] Chg Air Temp Sensor Low Error............................................................ 574 Failure code [CA187] Sens Supply 2 Volt Low Error............................................................. 576 Failure code [CA221] Ambient Press Sens High Error............................................................ 578 Failure code [CA222] Ambient Press Sens Low Error............................................................. 580 Failure code [CA227] Sens Supply 2 Volt High Error............................................................ 582 Failure code [CA238] Ne Speed Sens Supply Volt Error.......................................................... 584 Failure code [CA263] Fuel Temp Sensor High Error.............................................................. 586 Failure code [CA265] Fuel Temp Sensor Low Error............................................................... 588 Failure code [CA271] IMV/PCV1 Short Error..................................................................... 590 Failure code [CA272] IMV/PCV1 Open Error...................................................................... 591 Failure code [CA273] PCV2 Short Error......................................................................... 592 Failure code [CA274] PCV2 Open Error.......................................................................... 593 Failure code [CA322] Inj #1(L#1) Open/Short Error............................................................. 594 Failure code [CA323] Inj #5 (L#5) Open/Short Error............................................................ 596 Failure code [CA325] Inj #6 (L#6) Open/Short Error............................................................ 600 Failure code [CA331] Inj #2(L#2) Open/Short Error............................................................. 602 Failure code [CA332] Inj #4 (L#4) Open/Short Error............................................................ 604 Failure code [CA342] Calibration Code Incompatibility......................................................... 606 Failure code [CA351] Injectors Drive Circuit Error............................................................ 607 Failure code [CA352] Sens Supply 1 Volt Low Error............................................................. 608 Failure code [CA386] Sens Supply 1 Volt High Error............................................................ 610 Failure code [CA441] Battery Voltage Low Error................................................................ 610 Failure code [CA442] Battery Voltage High Error............................................................... 611 Failure code [CA449] Rail Press Very High Error............................................................... 611 Failure code [CA451] Rail Press Sensor High Error............................................................. 612 Failure code [CA452] Rail Press Sensor Low Error.............................................................. 614 Failure code [CA553] Rail Press High Error.................................................................... 616 Failure code [CA554] Rail Press Sensor In Range Error......................................................... 617 Failure code [CA559] Supply Pump Press Low Error 1............................................................ 618 Failure code [CA689] Eng Ne Speed Sensor Error................................................................ 622 Failure code [CA731] Eng Bkup Speed Sens Phase Error.......................................................... 624 Failure code [CA757] All Continuous Data Lost Error........................................................... 625 Failure code [CA778] Eng Bkup Speed Sensor Error.............................................................. 626 Failure code [CA1633] KOMNET Datalink Timeout Error........................................................... 628 Failure code [CA2185] Throt Sens Sup Volt High Error.......................................................... 630 Failure code [CA2186] Throt Sens Sup Volt Low Error........................................................... 632 Failure code [CA2249] Rail Press Very Low Error............................................................... 633 Failure code [CA2555] Grid Htr Relay Open Circuit Error....................................................... 634 Failure code [CA2556] Grid Htr Relay Short Circuit Error...................................................... 636 Failure code [D110KB] Battery Relay Drive Short Circuit....................................................... 638 Failure code [D163KB] Flash Light Relay Short Circuit......................................................... 640 Failure code [D195KA] Step Light Relay Open Circuit........................................................... 642 Failure code [D195KB] Step Light Relay Short Circuit.......................................................... 644 Failure code [D19JKZ] Personal Code Relay Abnormality......................................................... 646 Failure code [D862KA] GPS Antenna Open Circuit................................................................ 648 Failure code [DA22KK] Pump Solenoid Power Low Error........................................................... 650 Failure code [DA25KP] 5V Sensor1 Power Abnormality............................................................ 652 Failure code [DA29KQ] Model Selection Abnormality............................................................. 654 Failure code [DA2RMC] CAN Discon (Pump Con Detected).......................................................... 656 Failure code [DA80MA] Auto. Lub. Abnormal..................................................................... 660 Failure code [DAF8KB] Camera Power Supply Short Circuit....................................................... 662 Failure code [DAFGMC] GPS Module Error........................................................................ 664 Failure code [DAFRMC] CAN Discon (Monitor Detected)........................................................... 665 Failure code [DGE5KB] Ambi. Temp Sensor Short Circuit......................................................... 670 Failure code [DGH2KB] Hyd Oil Sensor Short.................................................................... 672 Failure code [DH25KA] L Jet Sensor Open Circuit............................................................... 674 Failure code [DH25KB] L Jet Sensor Short Circuit.............................................................. 676 Failure code [DH26KA] R Jet Sensor Open Circuit............................................................... 678 Failure code [DH26KB] R Jet Sensor Short Circuit.............................................................. 680 Failure code [DHPEKA] F Pump P. Sensor Open Circuit........................................................... 682 Failure code [DHPEKB] F Pump P. Sensor Short Circuit.......................................................... 684 Failure code [DHPFKA] R Pump P. Sensor Open Circuit........................................................... 686 Failure code [DHPFKB] R Pump P. Sensor Short Circuit.......................................................... 688 Failure code [DV20KB] Travel alarm short circuit.............................................................. 690 Failure code [DW41KA] Swing Priority Sol Open Circuit......................................................... 692 Failure code [DW41KB] Swing Priority Sol Short Circuit........................................................ 694 Failure code [DW43KA] Travel Speed Sol Open Circuit........................................................... 696 Failure code [DW43KB] Travel Speed Sol Short Circuit.......................................................... 698 Failure code [DW45KA] Swing Brake Sol Open Circuit............................................................ 700 Failure code [DW45KB] Swing Brake Sol Short Circuit........................................................... 702 Failure code [DW7BKA] Fan Reverse Sol Open Circuit............................................................ 704 Failure code [DW7BKB] Fan Reverse Sol Short Circuit........................................................... 706 Failure code [DW7JKA] Bottom Dump Priority Sol Open Circuit................................................... 708 Failure code [DW7JKB] Bottom Dump Priority Sol Short Circuit.................................................. 710 Failure code [DW91KA] Travel Junction Sol Open Circuit........................................................ 712 Failure code [DW91KB] Travel Junction Sol Short Circuit....................................................... 714 Failure code [DWK0KA] 2-stage Relief Sol Open Circuit......................................................... 716 Failure code [DWK0KB] 2-stage Relief Sol Short Circuit........................................................ 718 Failure code [DX16KA] Fan Pump EPC Sol Open Circuit........................................................... 720 Failure code [DX16KB] Fan Pump EPC Sol Short Circuit.......................................................... 722 Failure code [DXAAKA] F Pump EPC Sol Open Circuit............................................................. 724 Failure code [DXAAKB] F Pump EPC Sol Short Circuit............................................................ 726 Failure code [DXABKA] R Pump EPC Sol Open Circuit............................................................. 728 Failure code [DXABKB] R Pump EPC Sol Short Circuit............................................................ 730 Failure code [DY20KA] Wiper Working Abnormality............................................................... 732 Failure code [DY20MA] Wiper Parking Abnormality............................................................... 736 Failure code [DY2CKA] Washer Drive Open Circuit............................................................... 738 Failure code [DY2CKB] Washer Drive Short Circuit.............................................................. 740 Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit......................................................... 742 Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit......................................................... 746 Failure code [DY2FMA] Upper Wiper Working Abnormality......................................................... 750 Failure code [DY2GKM] Wiper Select Abnormality................................................................ 752 Troubleshooting of electrical system (E-mode)..................................................................... 755 E-1 Engine does not start (Engine does not crank)............................................................. 755 E-2 Preheater does not operate................................................................................ 760 E-3 When starting switch is turned to ON position, machine monitor displays nothing........................... 764 E-4 When starting switch is turned to ON position (before starting engine), basic check monitor lights up..... 767 E-5 Precaution item lights up while engine is running......................................................... 768 E-6 Emergency stop item lights up while engine is running..................................................... 770 E-7 Engine coolant temperature gauge does not indicate properly............................................... 771 E-8 Fuel gauge does not indicate properly..................................................................... 772 E-9 Hydraulic oil temperature gauge does not indicate properly................................................ 774 E-10 Displays on machine monitor are different from those for actual machine.................................. 776 E-11 Some areas of machine monitor screen are not displayed................................................... 776 E-12 Function switch does not operate......................................................................... 776 E-13 Automatic warm-up system does not operate (in cold season)............................................... 777 E-14 Auto-decelerator does not operate properly............................................................... 778 E-15 Working mode does not change............................................................................. 779 E-16 Travel speed does not change............................................................................. 780 E-17 Alarm buzzer cannot be canceled.......................................................................... 781 E-18 When starting switch is turned OFF, service meter is not displayed40..................................... 781 E-19 Service mode cannot be selected.......................................................................... 781 E-20 Any of work equipment, swing and travel do not operate or cannot be locked............................... 782 E-21 Machine push-up function does not operate or cannot be canceled40........................................ 784 E-22 Boom shockless function does not operate properly........................................................ 786 E-23 Swing brake does not operate properly.................................................................... 788 E-24 Windshield wiper and window washer do not operate........................................................ 790 E-25 Travel alarm does not sound or does not stop sounding.................................................... 794 E-26 Boom RAISE indicator is not displayed properly with monitoring function.................................. 796 E-27 Boom LOWER indicator is not displayed properly with monitoring function.................................. 798 E-28 Arm IN indicator is not displayed properly with monitoring function40.................................... 800 E-29 Arm OUT indicator is not displayed properly with monitoring function..................................... 802 E-30 Bucket CURL indicator is not displayed properly with monitoring function................................. 804 E-31 Bucket DUMP indicator is not displayed properly with monitoring function................................. 806 E-32 Swing indicator is not displayed properly with monitoring function....................................... 808 E-33 "L.H. travel" is not displayed properly with monitoring function......................................... 810 E-34 "R.H. travel" is not displayed properly with monitoring function......................................... 812 E-35 "Attachment" is not displayed properly with monitoring function.......................................... 814 E-36 Electric grease gun does not operate..................................................................... 816 E-37 KOMTRAX system does not operate properly................................................................. 818 E-38 Horn does not sound or does not stop sounding............................................................ 819 E-39 Step light does not light up or go off................................................................... 822 Troubleshooting of hydraulic and mechanical system (H-mode)....................................................... 826 Before starting troubleshooting for hydraulic and mechanical systems.......................................... 826 Information in troubleshooting table (H-mode)................................................................. 830 H-1 All of work equipment, swing and travel work slow or lack power........................................... 832 H-2 Engine speed lowers significantly or engine stalls........................................................ 834 H-3 Any of work equipment, swing and travel does not work..................................................... 836 H-4 Unusual noise is heard from around hydraulic pump......................................................... 838 H-5 Boom operation lacks speed or power....................................................................... 839 H-6 Arm operation lacks speed or power........................................................................ 841 H-7 Bucket operation lacks speed or power..................................................................... 842 H-8 Boom does not move........................................................................................ 843 H-9 Arm does not move......................................................................................... 843 H-10 Bucket does not move..................................................................................... 843 H-11 Hydraulic drift of work equipment is large............................................................... 844 H-12 Time lag of work equipment is large...................................................................... 846 H-13 Heavy lift function does not work or is not released..................................................... 847 H-14 Machine push-up function does not work or is not released................................................ 847 H-15 Boom shockless function does not work or is not canceled................................................. 847 H-16 Machine deviates in one direction against operator's intention when travelling........................... 848 H-17 Machine deviates significantly at start.................................................................. 851 H-18 Machine deviates significantly during combined operation................................................. 852 H-19 Travel works slow or lack power.......................................................................... 853 H-20 One of tracks does not run............................................................................... 854 H-21 Travel speed does not change............................................................................. 855 H-22 Upper structure does not swing........................................................................... 856 H-23 Swing speed is low or swing acceleration is poor......................................................... 857 H-24 In combined operation with work equipment, swing speed is low or swing acceleration is poor.............. 858 H-25 Upper structure overruns excessively when it stops swinging.............................................. 860 H-26 Shock is large when upper structure stops swinging....................................................... 861 H-27 Large unusual noise is heard when upper structure stops swinging40....................................... 862 H-28 Swing drift on a slope is large.......................................................................... 863 H-29 Fan revolution is abnormal (Fan sound/vibration is abnormally large or engine overheats)................. 864 Troubleshooting of engine (S-mode)................................................................................ 866 Method of using troubleshooting chart......................................................................... 866 S-1 Startability is poor...................................................................................... 870 S-2 Engine does not start..................................................................................... 871 S-3 Engine does not pick up smoothly.......................................................................... 874 S-4 Engine stops during operation............................................................................. 875 S-5 Engine runs rough or is unstable.......................................................................... 876 S-6 Engine lacks power........................................................................................ 878 S-7 Exhaust smoke is black (incomplete combustion)............................................................ 880 S-8 Oil consumption is excessive (or exhaust smoke is blue)................................................... 881 S-9 Oil becomes contaminated early............................................................................ 882 S-10 Fuel consumption is excessive............................................................................ 883 S-11 Oil is in coolant (or coolant spurts or coolant level goes down)......................................... 884 S-12 Oil pressure drops....................................................................................... 885 S-13 Oil level rises (coolant or fuel in oil)................................................................. 886 S-14 Coolant temperature rises too high (overheating)......................................................... 887 S-15 Unusual noise is made.................................................................................... 888 S-16 Vibration is excessive................................................................................... 889 50 Disassembly and assembly........................................................................................... 891 Contents.......................................................................................................... 892 General information on disassembly and assembly................................................................... 894 How to read Disassembly and Assembly.......................................................................... 894 Coating materials list........................................................................................ 896 Special tools list............................................................................................ 900 Sketches of special tools..................................................................................... 907 Engine and cooling system......................................................................................... 912 Removal and installation of engine, PTO and hydraulic pump assembly50-21...................................... 912 Removal and installation of cooling assembly.................................................................. 920 Removal and installation of aftercooler assembly.............................................................. 926 Removal and installation of fuel cooler and air condenser assembly............................................ 928 Removal and installation of fan motor assembly................................................................ 930 Removal and installation of fuel tank assembly................................................................ 935 Engine............................................................................................................ 937 Removal and installation of fuel supply pump assembly......................................................... 937 Removal and installation of cylinder head assembly............................................................ 942 Removal and installation of fuel injector assembly............................................................ 957 Removal and installation of engine front seal................................................................. 960 Removal and installation of engine rear seal.................................................................. 962 Power train....................................................................................................... 967 Removal and installation of PTO assembly...................................................................... 967 Disassembly and assembly of PTO assembly...................................................................... 974 Removal and installation of swing motor and swing machinery assembly.......................................... 976 Disassembly and assembly of swing machinery assembly.......................................................... 979 Removal and installation of swing circle assembly............................................................. 986 Disassembly and assembly of final drive assembly.............................................................. 987 Undercarriage and frame........................................................................................... 999 Separation and connection of track shoe assembly.............................................................. 999 Disassembly and assembly of one link in field.................................................................1001 Removal and installation of idler assembly....................................................................1005 Disassembly and assembly of idler assembly....................................................................1006 Disassembly and assembly of idler adjustment cylinder assembly................................................1009 Removal and installation of recoil spring assembly............................................................1010 Disassembly and assembly of recoil spring assembly............................................................1012 Removal and installation of carrier roller assembly...........................................................1014 Disassembly and assembly of carrier roller assembly...........................................................1015 Removal and installation of track roller assembly.............................................................1018 Disassembly and assembly of track roller assembly.............................................................1019 Removal and installation of revolving frame assembly..........................................................1022 Removal and installation of counterweight assembly............................................................1024 Removal and installation of counterweight remover assembly....................................................1025 Hydraulic system..................................................................................................1028 Removal and installation of hydraulic tank assembly...........................................................1028 Removal and installation of main pump assembly................................................................1030 Removal and installation of main pump input shaft oil seal....................................................1037 Removal and installation of cooling fan pump assembly.........................................................1038 Removal and installation of control valve assembly............................................................1041 Assembly of control valve assembly............................................................................1044 Removal and installation of swing motor assembly..............................................................1050 Removal and installation of center swivel joint assembly......................................................1051 Disassembly and assembly of center swivel joint assembly......................................................1053 Removal and installation of travel motor assembly.............................................................1055 Removal and installation of solenoid valve assembly...........................................................1056 Removal and installation of boom damping valve assembly.......................................................1058 Disassembly and assembly of work equipment PPC valve assembly.................................................1059 Disassembly and assembly of travel PPC valve assembly.........................................................1061 Disassembly and assembly of hydraulic cylinder assembly.......................................................1064 Disassembly and assembly of grease gun assembly...............................................................1071 Work equipment....................................................................................................1072 Removal and installation of bucket cylinder assembly..........................................................1072 Removal and installation of arm cylinder assembly.............................................................1076 Removal and installation of boom cylinder assembly............................................................1080 Removal and installation of bottom dump cylinder assembly.....................................................1084 Removal and installation of bucket assembly...................................................................1086 Removal and installation of arm assembly......................................................................1089 Removal and installation of boom assembly.....................................................................1093 Removal and installation of work equipment assembly...........................................................1097 Cab and its attachments...........................................................................................1101 Removal and installation of operator's cab assembly...........................................................1101 Removal and installation of operator's cab glass (adhered window glass).......................................1104 Removal and installation of front window assembly.............................................................1113 Removal and installation of work equipment control lever assembly 50..........................................1120 Electrical system.................................................................................................1134 Removal and installation of air conditioner unit assembly.....................................................1134 Removal and installation of engine controller assembly........................................................1137 Removal and installation of monitor assembly..................................................................1139 Removal and installation of pump controller assembly..........................................................1141 Removal and installation of KOMTRAX terminal assembly.........................................................1143 60 Maintenance standard...............................................................................................1145 Contents..........................................................................................................1146 Engine and cooling system.........................................................................................1147 Coupling......................................................................................................1147 Power train.......................................................................................................1148 Swing circle..................................................................................................1148 Swing machinery...............................................................................................1149 Final drive...................................................................................................1152 Sprocket......................................................................................................1154 Undercarriage and frame...........................................................................................1156 Track frame and idler cushion.................................................................................1156 Idler.........................................................................................................1158 Carrier roller................................................................................................1160 Track roller..................................................................................................1162 Track shoe....................................................................................................1164 Hydraulic system..................................................................................................1168 Cooling fan motor.............................................................................................1168 Control valve.................................................................................................1170 Swing motor...................................................................................................1176 Center swivel joint...........................................................................................1178 PPC valve.....................................................................................................1179 Work equipment....................................................................................................1182 Work equipment................................................................................................1182 Work equipment dimension......................................................................................1188 Hydraulic cylinder............................................................................................1192 80 Appendix...........................................................................................................1199 Table of contents.................................................................................................1200 Air conditioner...................................................................................................1201 Precautions for refrigerant...................................................................................1201 Air conditioner component.....................................................................................1202 Configuration and function of refrigeration cycle.............................................................1204 Outline of refrigeration cycle................................................................................1205 Air conditioner controller....................................................................................1213 Compressor....................................................................................................1214 Condenser.....................................................................................................1215 Receiver drier................................................................................................1216 Procedure for testing and troubleshooting.....................................................................1218 Circuit diagram and arrangement of connector pins.............................................................1220 System diagram................................................................................................1222 Detail of air conditioner unit................................................................................1224 Parts and connectors layout...................................................................................1226 Testing air leakage (duct)....................................................................................1229 Testing with self-diagnosis function..........................................................................1230 Testing temperature control...................................................................................1233 Testing vent (mode) changeover................................................................................1235 Testing FRESH/RECIRC air changeover...........................................................................1238 Testing inner sensor..........................................................................................1240 Testing evaporator temperature sensor.........................................................................1241 Testing sunlight sensor.......................................................................................1243 Testing (dual) pressure switch for refrigerant................................................................1244 Testing relays................................................................................................1245 Troubleshooting chart 1.......................................................................................1246 Troubleshooting chart 2.......................................................................................1248 Information in troubleshooting table..........................................................................1250 Troubleshooting for power supply and CAN communication system (Air conditioner does not operate)..............1252 Troubleshooting for compressor and refrigerant system (Air is not cooled).....................................1257 Troubleshooting for blower motor system (No air comes out or air flow is abnormal)............................1261 Troubleshooting for temperature control.......................................................................1265 Troubleshooting for vent (mode) changeover....................................................................1268 Troubleshooting for FRESH/RECIRC air changeover...............................................................1270 Troubleshooting for temperature sensor system.................................................................1272 Troubleshooting with gauge pressure...........................................................................1274 Connection of service tool....................................................................................1276 Precautions for disconnecting and connecting air conditioner piping...........................................1278 Handling of compressor oil....................................................................................1280 90 Diagrams and drawings..............................................................................................1283 Contents..........................................................................................................1284 Hydraulic circuit diagram.........................................................................................1285 Symbols used in hydraulic circuit diagrams....................................................................1285 Hydraulic circuit diagram.....................................................................................1289 Electrical circuit diagram........................................................................................1293 Symbols used in electric circuit diagrams.....................................................................1293 Electrical circuit diagram....................................................................................1297 Index.................................................................................................................1309
DESCRIPTION:
KOMATSU PC800-8R1 PC800LC-8R1 PC800SE-8R1 PC850-8R1 PC850SE-8R1 HYDRAULIC EXCAVATOR SHOP MANUAL SEN05279-08 – 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
