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

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Komatsu PC800-8E0, PC800LC-8E0, PC800SE-8E0, PC850-8E0, PC850SE-8E0 Hydraulic Excavator Service Repair Workshop Manual (65001 and up) – SEN05276-03

This complete service repair workshop manual PDF download for the Komatsu PC800-8E0, PC800LC-8E0, PC800SE-8E0, PC850-8E0, PC850SE-8E0 Hydraulic Excavator (S/N: 65001 and up) has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.

APPLICABLE MODELS :

Machine Model :
Komatsu PC800-8E0
Komatsu PC800LC-8E0
Komatsu PC800SE-8E0
Komatsu PC850-8E0
Komatsu PC850SE-8E0

Serial Numbers :
65001 and up

TABLE OF CONTENTS :

– Index and foreword
– Specification
– Structure and function
– Standard value table
– Testing and adjusting
– Troubleshooting
– Disassembly and assembly
– Maintenance standard
– Appendix
– Diagrams and drawings

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : SEN05276-03
Total Pages : 1327

This service repair workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same Repair Service manual your local dealer will use when doing a repair.

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00 Index and foreword
Table of contents
Table of contents
Foreword and general information
Safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling of hydraulic components
Method of disconnecting and connecting push-pull type coupler
Handling of electric equipment
How to read electric wire code
Precautions when performing work
Standard tightening torque table
List of abbreviation
Conversion table

01 Specification
Specifications
Specifications drawing
Specifications
Table of weight
Table of fuel, coolant and lubricants

10 Structure and function
Engine and cooling system
Coupling
Coupling lubrication system
Cooling system
Power train system
Power train
Swing circle
Swing machinery
Final drive
Undercarriage and frame
Track frame
Idler cushion
Hydraulic system
Hydraulic component layout
Hydraulic tank and filter
Hydraulic pump
Pump control system
Servo valve
Self-pressure reducing valve
Cooling fan pump
Cooling fan motor
Electrical grease pump
Control valve
Straight-travel valve
Swing motor
Center swivel joint
Travel motor
PPC valve
Solenoid valve
Accumulator
Quick return valve
Return oil filter
Line oil filter
Pilot oil filter
Drain oil filter
Electrical system
Engine control
Electric control system
Monitor system
Sensors
KOMTRAX system

20 Standard value table
Standard value table
Standard value table for engine
Standard value table for machine

30 Testing and adjusting
Tool for testing, adjusting and troubleshooting
Tools for testing, adjusting, and troubleshooting
Engine and cooling system
Testing engine speed
Testing intake air pressure (boost pressure)
Testing exhaust gas temperature
Testing exhaust gas color
Adjusting valve clearance
Testing compression pressure
Testing blowby pressure
Testing engine oil pressure
Testing EGR valve and bypass valve drive pressure
Handling fuel system parts
Releasing remaining pressure from fuel system
Testing fuel pressure
Testing fuel return rate and leakage
Bleeding air from fuel circuit
Testing fuel circuit for leakage
Testing and adjusting alternator belt tension
Testing and adjusting air conditioner compressor belt tension
Undercarriage and frame
Testing swing circle bearing clearance
Checking and adjusting track tension
Hydraulic system
Testing and adjusting oil pressure in work equipment, swing, and travel circuits
Testing and adjusting control circuit oil pressure (output pressure of self-pressure reducing valve)
Testing and adjusting control signal of main pump
Testing PPC valve output pressure
Measuring outlet pressure of solenoid valve, swing PPC shuttle valve, and swing priority selector valve
Adjusting play of work equipment and swing PPC vavles
Testing and adjusting travel deviation
Inspecting locations of hydraulic drift in work equipment
Measuring fan speed
Measuring fan circuit oil pressure
Measuring fan pump EPC current
Measuring fan pump EPC solenoid valve outlet pressure
Measuring oil leakage
Releasing remaining pressure from hydraulic circuit
Bleeding air from various parts
Inspection procedures for diode
Adjusting mirrors
Electrical system
Special functions of machine monitor
Handling voltage circuit of engine controller
Preparatory work for troubleshooting of electrical system
Pm Clinic
Pm clinic service
UNDERCARRIAGE INSPECTION REPORT

40 Troubleshooting
General information on troubleshooting
Points to remember when troubleshooting
Sequence of events in troubleshooting
Checks before troubleshooting
Classification and procedures for troubleshooting
Failure codes table
Symptom and troubleshooting numbers
Information in troubleshooting table
Troubleshooting method for open circuit in wiring harness of pressure sensor system
Connector list and layout
Connection table for connector pin numbers
T- branch box and T- branch adapter table
Fuse locations
Troubleshooting by failure code
Failure code [989L00] Engine Controller Lock Caution 1
Failure code [989M00] Engine Controller Lock Caution 2
Failure code [989N00] Engine Controller Lock Caution 3
Failure code [AA10NX] Air Cleaner Clogging
Failure code [AB00KE] Charge Voltage Low
Failure code [[email protected]] Eng Oil Press Low
Failure code [[email protected]] Eng Oil Level Low
Failure code [[email protected]] Eng Water Overheat
Failure code [[email protected]] Eng Water Level Low
Failure code [[email protected]] Hyd Oil Overheat
Failure code [CA111] ECM Critical Internal Failure
Failure code [CA115] Eng Ne and Bkup Speed Sens Error
Failure code [CA122] Chg Air Press Sensor High Error
Failure code [CA123] Chg Air Press Sensor Low Error
Failure code [CA131] Throttle Sensor High Error
Failure code [CA132] Throttle Sensor Low Error
Failure code [CA135] Eng Oil Press Sensor High Error
Failure code [CA141] Eng Oil Press Sensor Low Error
Failure code [CA144] Coolant Temp Sens High Error
Failure code [CA145] Coolant Temp Sens Low Error
Failure code [CA153] Chg Air Temp Sensor High Error
Failure code [CA154] Chg Air Temp Sensor Low Error
Failure code [CA187] Sens Supply 2 Volt Low Error
Failure code [CA221] Ambient Press Sens High Error
Failure code [CA222] Ambient Press Sens Low Error
Failure code [CA227] Sens Supply 2 Volt High Error
Failure code [CA234] Eng Overspeed
Failure code [CA238] Ne Speed Sens Supply Volt Error
Failure code [CA263] Fuel Temp Sensor High Error
Failure code [CA265] Fuel Temp Sensor Low Error
Failure code [CA271] IMV/PCV1 Short Error
Failure code [CA272] IMV/PCV1 Open Error
Failure code [CA273] PCV2 Short Error
Failure code [CA274] PCV2 Open Error
Failure code [CA322] Inj #1(L#1) Open/Short Error
Failure code [CA323] Inj #5 (L#5) Open/Short Error
Failure code [CA324] Inj #3(L#3) Open/Short Error
Failure code [CA325] Inj #6 (L#6) Open/Short Error
Failure code [CA331] Inj #2(L#2) Open/Short Error
Failure code [CA332] Inj #4 (L#4) Open/Short Error
Failure code [CA342] Calibration Code Incompatibility
Failure code [CA351] Injectors Drive Circuit Error
Failure code [CA352] Sens Supply 1 Volt Low Error
Failure code [CA386] Sens Supply 1 Volt High Error
Failure code [CA441] Battery Voltage Low Error
Failure code [CA442] Battery Voltage High Error
Failure code [CA449] Rail Press Very High Error
Failure code [CA451] Rail Press Sensor High Error
Failure code [CA452] Rail Press Sensor Low Error
Failure code [CA553] Rail Press High Error
Failure code [CA554] Rail Press Sensor In Range Error
Failure code [CA559] Supply Pump Press Low Error 1
Failure code [CA689] Eng Ne Speed Sensor Error
Failure code [CA731] Eng Bkup Speed Sens Phase Error
Failure code [CA757] All Continuous Data Lost Error
Failure code [CA778] Eng Bkup Speed Sensor Error
Failure code [CA1228] EGR Valve Servo Error 1
Failure code [CA1625] EGR Valve Servo Error 2
Failure code [CA1626] BP Valve Sol Current High Error
Failure code [CA1627] BP Valve Sol Current Low Error
Failure code [CA1628] Bypass Valve Servo Error 1
Failure code [CA1629] Bypass Valve Servo Error 2
Failure code [CA1631] BP Valve Pos Sens High Error
Failure code [CA1632] BP Valve Pos Sens Low Error
Failure code [CA1633] KOMNET Datalink Timeout Error
Failure code [CA2185] Throt Sens Sup Volt High Error
Failure code [CA2186] Throt Sens Sup Volt Low Error
Failure code [CA2249] Rail Press Very Low Error
Failure code [CA2271] EGR Valve Pos Sens High Error
Failure code [CA2272] EGR Valve Pos Sens Low Error
Failure code [CA2351] EGR Valve Sol Current High Error
Failure code [CA2352] EGR Valve Sol Current Low Error
Failure code [CA2555] Grid Htr Relay Open Circuit Error
Failure code [CA2556] Grid Htr Relay Short Circuit Error
Failure code [D110KB] Battery Relay Drive Short Circuit
Failure code [D163KB] Flash Light Relay Short Circuit
Failure code [D195KA] Step Light Relay Open Circuit
Failure code [D195KB] Step Light Relay Short Circuit
Failure code [D19JKZ] Personal Code Relay Abnormality
Failure code [D862KA] GPS Antenna Open Circuit
Failure code [DA22KK] Pump Solenoid Power Low Error
Failure code [DA25KP] 5V Sensor1 Power Abnormality
Failure code [DA29KQ] Model Selection Abnormality
Failure code [DA2RMC] CAN Discon (Pump Con Detected)
Failure code [DA80MA] Auto. Lub. Abnormal.
Failure code [DAF8KB] Camera Power Supply Short Circuit
Failure code [DAFGMC] GPS Module Error
Failure code [DAFRMC] CAN Discon (Monitor Detected)
Failure code [DGE5KB] Ambi. Temp Sensor Short Circuit
Failure code [DGH2KB] Hyd Oil Sensor Short
Failure code [DH25KA] L Jet Sensor Open Circuit
Failure code [DH25KB] L Jet Sensor Short Circuit
Failure code [DH26KA] R Jet Sensor Open Circuit
Failure code [DH26KB] R Jet Sensor Short Circuit
Failure code [DHPEKA] F Pump P. Sensor Open Circuit
Failure code [DHPEKB] F Pump P. Sensor Short Circuit
Failure code [DHPFKA] R Pump P. Sensor Open Circuit
Failure code [DHPFKB] R Pump P. Sensor Short Circuit
Failure code [DV20KB] Travel alarm short circuit
Failure code [DW41KA] Swing Priority Sol Open Circuit
Failure code [DW41KB] Swing Priority Sol Short Circuit
Failure code [DW43KA] Travel Speed Sol Open Circuit
Failure code [DW43KB] Travel Speed Sol Short Circuit
Failure code [DW45KA] Swing Brake Sol Open Circuit
Failure code [DW45KB] Swing Brake Sol Short Circuit
Failure code [DW7BKA] Fan Reverse Sol Open Circuit
Failure code [DW7BKB] Fan Reverse Sol Short Circuit
Failure code [DW7JKA] Bottom Dump Priority Sol Open Circuit
Failure code [DW7JKB] Bottom Dump Priority Sol Short Circuit
Failure code [DW91KA] Travel Junction Sol Open Circuit
Failure code [DW91KB] Travel Junction Sol Short Circuit
Failure code [DWK0KA] 2-stage Relief Sol Open Circuit
Failure code [DWK0KB] 2-stage Relief Sol Short Circuit
Failure code [DX16KA] Fan Pump EPC Sol Open Circuit
Failure code [DX16KB] Fan Pump EPC Sol Short Circuit
Failure code [DXAAKA] F Pump EPC Sol Open Circuit
Failure code [DXAAKB] F Pump EPC Sol Short Circuit
Failure code [DXABKA] R Pump EPC Sol Open Circuit
Failure code [DXABKB] R Pump EPC Sol Short Circuit
Failure code [DY20KA] Wiper Working Abnormality
Failure code [DY20MA] Wiper Parking Abnormality
Failure code [DY2CKA] Washer Drive Open Circuit
Failure code [DY2CKB] Washer Drive Short Circuit
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit
Failure code [DY2FMA] Upper Wiper Working Abnormality
Failure code [DY2GKM] Wiper Select Abnormality
Troubleshooting of electrical system (E-mode)
E-1 Engine does not start (Engine does not crank)
E-2 Preheater does not operate
E-3 When starting switch is turned to ON position, machine monitor displays nothing
E-4 When starting switch is turned to ON position (before starting engine), basic check monitor lights up.
E-5 Precaution item lights up while engine is running
E-6 Emergency stop item lights up while engine is running
E-7 Engine coolant temperature gauge does not indicate properly
E-8 Fuel gauge does not indicate properly
E-9 Hydraulic oil temperature gauge does not indicate properly
E-10 Displays on machine monitor are different from those for actual machine
E-11 Some areas of machine monitor screen are not displayed
E-12 Function switch does not operate
E-13 Automatic warm-up system does not operate (in cold season)
E-14 Auto-decelerator does not operate properly
E-15 Working mode does not change
E-16 Travel speed does not change
E-17 Alarm buzzer cannot be canceled
E-18 When starting switch is turned OFF, service meter is not displayed40
E-19 Service mode cannot be selected
E-20 Any of work equipment, swing and travel do not operate or cannot be locked
E-21 Machine push-up function does not operate or cannot be canceled40
E-22 Boom shockless function does not operate properly
E-23 Swing brake does not operate properly
E-24 Windshield wiper and window washer do not operate
E-25 Travel alarm does not sound or does not stop sounding
E-26 Boom RAISE indicator is not displayed properly with monitoring function
E-27 Boom LOWER indicator is not displayed properly with monitoring function
E-28 Arm IN indicator is not displayed properly with monitoring function40
E-29 Arm OUT indicator is not displayed properly with monitoring function
E-30 Bucket CURL indicator is not displayed properly with monitoring function
E-31 Bucket DUMP indicator is not displayed properly with monitoring function
E-32 Swing indicator is not displayed properly with monitoring function40
E-33 “L.H. travel” is not displayed properly with monitoring function
E-34 “R.H. travel” is not displayed properly with monitoring function
E-35 “Attachment” is not displayed properly with monitoring function
E-36 Electric grease gun does not operate
E-37 KOMTRAX system does not operate properly
E-38 Horn does not sound or does not stop sounding
E-39 Step light does not light up or go off
Troubleshooting of hydraulic and mechanical system (H-mode)
Before starting troubleshooting for hydraulic and mechanical systems
Information in troubleshooting table (H-mode)
H-1 All of work equipment, swing and travel work slow or lack power
H-2 Engine speed lowers significantly or engine stalls
H-3 Any of work equipment, swing and travel does not work
H-4 Unusual noise is heard from around hydraulic pump
H-5 Boom operation lacks speed or power
H-6 Arm operation lacks speed or power
H-7 Bucket operation lacks speed or power
H-8 Boom does not move
H-9 Arm does not move
H-10 Bucket does not move
H-11 Hydraulic drift of work equipment is large
H-12 Time lag of work equipment is large
H-13 Heavy lift function does not work or is not released
H-14 Machine push-up function does not work or is not released
H-15 Boom shockless function does not work or is not canceled
H-16 Machine deviates in one direction against operator’s intention when travelling
H-17 Machine deviates significantly at start
H-18 Machine deviates significantly during combined operation
H-19 Travel works slow or lack power
H-20 One of tracks does not run
H-21 Travel speed does not change
H-22 Upper structure does not swing
H-23 Swing speed is low or swing acceleration is poor
H-24 In combined operation with work equipment, swing speed is low or swing acceleration is poor
H-25 Upper structure overruns excessively when it stops swinging
H-26 Shock is large when upper structure stops swinging
H-27 Large unusual noise is heard when upper structure stops swinging40
H-28 Swing drift on a slope is large
H-29 Fan revolution is abnormal (Fan sound/vibration is abnormally large or engine overheats)
Troubleshooting of engine (S-mode)
Method of using troubleshooting chart
S-1 Startability is poor
S-2 Engine does not start
S-3 Engine does not pick up smoothly
S-4 Engine stops during operation
S-5 Engine runs rough or is unstable
S-6 Engine lacks power
S-7 Exhaust smoke is black (incomplete combustion)
S-8 Oil consumption is excessive (or exhaust smoke is blue)
S-9 Oil becomes contaminated early
S-10 Fuel consumption is excessive
S-11 Oil is in coolant (or coolant spurts or coolant level goes down)
S-12 Oil pressure drops
S-13 Oil level rises (coolant or fuel in oil)
S-14 Coolant temperature rises too high (overheating)
S-15 Unusual noise is made
S-16 Vibration is excessive

50 Disassembly and assembly
General information on disassembly and assembly
How to read Disassembly and Assembly
Coating materials list
Special tools list
Sketches of special tools
Engine and cooling system
Removal and installation of engine, PTO and hydraulic pump assembly50
Removal and installation of cooling assembly
Removal and installation of aftercooler assembly
Removal and installation of fuel cooler and air condenser assembly
Removal and installation of fan motor assembly
Removal and installation of fuel tank assembly
Engine
Removal and installation of fuel supply pump assembly
Removal and installation of cylinder head assembly
Removal and installation of fuel injector assembly
Removal and installation of engine front seal
Removal and installation of engine rear seal
Power train
Removal and installation of PTO assembly
Disassembly and assembly of PTO assembly
Removal and installation of swing motor and swing machinery assembly50
Disassembly and assembly of swing machinery assembly
Removal and installation of swing circle assembly
Disassembly and assembly of final drive assembly
Undercarriage and frame
Separation and connection of track shoe assembly
Disassembly and assembly of one link in field
Removal and installation of idler assembly
Disassembly and assembly of idler assembly
Disassembly and assembly of idler adjustment cylinder assembly
Removal and installation of recoil spring assembly
Disassembly and assembly of recoil spring assembly
Removal and installation of carrier roller assembly
Disassembly and assembly of carrier roller assembly
Removal and installation of track roller assembly
Disassembly and assembly of track roller assembly
Removal and installation of revolving frame assembly
Removal and installation of counterweight assembly
Removal and installation of counterweight remover assembly
Hydraulic system
Removal and installation of hydraulic tank assembly
Removal and installation of main pump assembly
Removal and installation of main pump input shaft oil seal
Removal and installation of cooling fan pump assembly
Removal and installation of control valve assembly
Assembly of control valve assembly
Removal and installation of swing motor assembly
Removal and installation of center swivel joint assembly
Disassembly and assembly of center swivel joint assembly
Removal and installation of travel motor assembly
Removal and installation of solenoid valve assembly
Removal and installation of boom damping valve assembly
Disassembly and assembly of work equipment PPC valve assembly
Disassembly and assembly of travel PPC valve assembly
Disassembly and assembly of hydraulic cylinder assembly
Disassembly and assembly of grease gun assembly
Work equipment
Removal and installation of bucket cylinder assembly
Removal and installation of arm cylinder assembly
Removal and installation of boom cylinder assembly
Removal and installation of bottom dump cylinder assembly
Removal and installation of bucket assembly
Removal and installation of arm assembly
Removal and installation of boom assembly
Removal and installation of work equipment assembly
Cab and its attachments
Removal and installation of operator’s cab assembly
Removal and installation of operator’s cab glass (adhered window glass)
Removal and installation of front window assembly
Electrical system
Removal and installation of air conditioner unit assembly
Removal and installation of engine controller assembly
Removal and installation of monitor assembly
Removal and installation of pump controller assembly
Removal and installation of KOMTRAX terminal assembly

60 Maintenance standard
Engine and cooling system
Coupling
Power train
Swing circle
Swing machinery
Final drive
Sprocket
Undercarriage and frame
Track frame and idler cushion
Idler
Carrier roller
Track roller
Track shoe
Hydraulic system
Cooling fan motor
Control valve
Swing motor
Center swivel joint
PPC valve
Work equipment
Work equipment
Work equipment dimension
Hydraulic cylinder

80 Appendix
Air conditioner
Precautions for refrigerant
Air conditioner component
Configuration and function of refrigeration cycle
Outline of refrigeration cycle
Air conditioner unit
Air conditioner controller
Compressor
Condenser
Receiver drier
Procedure for testing and troubleshooting
Circuit diagram and arrangement of connector pins
System diagram
Detail of air conditioner unit
Parts and connectors layout
Testing air leakage (duct)
Testing with self-diagnosis function
Testing temperature control
Testing vent (mode) changeover
Testing FRESH/RECIRC air changeover
Testing inner sensor
Testing evaporator temperature sensor
Testing sunlight sensor
Testing (dual) pressure switch for refrigerant
Testing relays
Troubleshooting chart 1
Troubleshooting chart 2
Information in troubleshooting table
Troubleshooting for power supply and CAN communication system (Air conditioner does not operate)
Troubleshooting for compressor and refrigerant system (Air is not cooled)
Troubleshooting for blower motor system (No air comes out or air flow is abnormal)
Troubleshooting for temperature control
Troubleshooting for vent (mode) changeover
Troubleshooting for FRESH/RECIRC air changeover
Troubleshooting for temperature sensor system
Troubleshooting with gauge pressure
Connection of service tool
Precautions for disconnecting and connecting air conditioner piping
Handling of compressor oil

90 Diagrams and drawings
Hydraulic circuit diagram
Symbols used in hydraulic circuit diagrams
Hydraulic circuit diagram
Electrical circuit diagram
Symbols used in electric circuit diagrams
Electrical circuit diagram

Index

 

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