Related Manuals for Komatsu PC800 -8E0
Summary of Contents for Komatsu PC800 -8E0
- Page 1 SEN05276-06 HYDRAULIC PC800 -8E0 EXCAVATOR PC800LC -8E0 PC800SE -8E0 PC850 -8E0 PC850SE -8E0 PC800- 65001 PC800LC- 65001 PC800SE- 65001 SERIAL NUMBERS and up PC850- 65001 PC850SE- 65001...
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- Page 3 Notice of revision Notice of revision 6th revision 2017/07 The affected pages are indicated by the use of the Mark Indication Action required following marks. It is requested that necessary ac- tions must be taken to these pages according to the Page to be newly added list below.
- Page 4 Notice of revision Revision Revision Revision Revision Mark Page Mark Page Mark Page Mark Page number number number number 10-75 10-127 10-179 30-19 10-76 (01) 10-128 10-180 30-20 10-77 10-129 10-181 30-21 10-78 10-130 10-182 30-22 10-79 10-131 10-183 30-23 10-80 10-132 10-184...
- Page 5 Notice of revision Revision Revision Revision Revision Mark Page Mark Page Mark Page Mark Page number number number number 30-71 30-123 40-45 40-97 30-72 (05) 30-124 40-46 40-98 30-73 30-125 40-47 40-99 30-74 30-126 40-48 40-100 30-75 30-127 40-49 40-101 30-76 30-128 40-50...
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- Page 8 Notice of revision Revision Revision Revision Revision Mark Page Mark Page Mark Page Mark Page number number number number 50-87 50-137 50-189 60-3 50-88 50-138 50-190 60-4 (04) 50-89 (05) 50-139 50-191 60-5 50-90 (05) 50-140 50-192 60-6 50-91 50-141 50-193 60-7 50-92...
- Page 9 Notice of revision Revision Revision Revision Revision Mark Page Mark Page Mark Page Mark Page number number number number 80-1 80-53 90-31 80-2 80-54 90-33 80-3 80-55 90-35 80-4 80-56 90-37 80-5 80-57 90-39 80-6 80-58 90-41 80-7 80-59 90-43 80-8 80-60 90-45...
- Page 10 Notice of revision PC800,850-8E0 (01) Find manuals at https://best-manuals.com...
- Page 11 SEN0527602-00 0 0 - 1 PC800, 850-8E0 HYDRAULIC EXCAVATOR Shop Manual 0 0 - 1 PC800-8E0 PC850SE-8E0 PC800LC-8E0 PC800SE-8E0 PC850-8E0 Machine model Serial number Machine model Serial number PC800-8E0 65001 and up PC850SE-8E0 65001 and up PC800LC-8E0 65001 and up PC800SE-8E0 65001 and up PC850-8E0...
- Page 12 Table of contents Table of contents 0 0 - 2 Notice of revision........................00 Index and foreword Table of contents ........................00 - 2 Table of contents ......................... 00 - 2 Foreword and general information ..................00- 12 Safety notice ........................00- 12 How to read the shop manual ....................
- Page 13 Table of contents PPC valve ..........................10- 87 Solenoid valve ........................10- 95 Accumulator......................... 10- 103 Quick return valve........................ 10- 104 Return oil filter........................10- 107 Line oil filter.......................... 10- 108 Pilot oil filter ......................... 10- 109 Drain oil filter........................10- 110 Electrical system ........................
- Page 14 Table of contents Inspecting locations of hydraulic drift in work equipment............. 30- 58 Measuring fan speed ......................30- 59 Measuring fan circuit oil pressure ..................30- 60 Measuring fan pump EPC current..................30- 61 Measuring fan pump EPC solenoid valve outlet pressure ........... 30- 62 Measuring oil leakage ......................
- Page 15 Table of contents Failure code [CA154] Chg Air Temp Sensor Low Error............40- 138 Failure code [CA187] Sens Supply 2 Volt Low Error ............40- 140 Failure code [CA221] Ambient Press Sens High Error ............40- 142 Failure code [CA222] Ambient Press Sens Low Error ............40- 144 Failure code [CA227] Sens Supply 2 Volt High Error ............
- Page 16 Table of contents Failure code [D163KB] Flash Light Relay Short Circuit ............40- 224 Failure code [D195KA] Step Light Relay Open Circuit ............40- 226 Failure code [D195KB] Step Light Relay Short Circuit............40- 228 Failure code [D19JKZ] Personal Code Relay Abnormality ..........40- 230 Failure code [D862KA] GPS Antenna Open Circuit.............
- Page 17 Table of contents E-2 Preheater does not operate ..................40- 344 E-3 When starting switch is turned to ON position, machine monitor displays nothing ..40- 348 E-4 When starting switch is turned to ON position (before starting engine), basic check monitor lights up..............................
- Page 18 Table of contents H-13 Heavy lift function does not work or is not released............ 40- 431 H-14 Machine push-up function does not work or is not released ........40- 431 H-15 Boom shockless function does not work or is not canceled........40- 431 H-16 Machine deviates in one direction against operator's intention when travelling..
- Page 19 Table of contents Removal and installation of fuel injector assembly .............. 50- 67 Removal and installation of engine front seal ..............50- 70 Removal and installation of engine rear seal............... 50- 72 Power train..........................50- 77 Removal and installation of PTO assembly ................. 50- 77 Disassembly and assembly of PTO assembly..............
- Page 20 Table of contents Removal and installation of front window assembly ............50- 222 Electrical system ........................50- 229 Removal and installation of air conditioner unit assembly ........... 50- 229 Removal and installation of engine controller assembly ............50- 232 Removal and installation of monitor assembly..............50- 234 Removal and installation of pump controller assembly............
- Page 21 Table of contents Testing inner sensor ......................80- 42 Testing evaporator temperature sensor................80- 43 Testing sunlight sensor......................80- 45 Testing (dual) pressure switch for refrigerant ..............80- 46 Testing relays ........................80- 47 Troubleshooting chart 1 ....................... 80- 48 Troubleshooting chart 2 .......................
- Page 22 Appropriate servicing and repair are extremely important to ensure safe operation of the machine. The shop manuals describe the effective and safe servicing and repair methods recommended by Ko- matsu. Some of the servicing and repair methods require use of special tools designed by Komatsu for special purposes.
- Page 23 Foreword and general information Safety notice 2. Preparation work 1) Before adding oil or making any repairs, park the machine on a hard and level ground, and apply the parking brake and chock the wheels or tracks to prevent the machine from moving.
- Page 24 Foreword and general information Safety notice 12)When assembling or installing parts, always 7) Limit the hanging angle to 60 degree, as a tighten them to the specified torques. When rule. installing protective parts such as guards, or Do not sling a heavy load (25 kg or more) parts which vibrate violently or rotate at high with ropes forming a wide hanging angle speeds, be particularly careful to check that...
- Page 25 Foreword and general information Safety notice 4) Check the direction indicator plates (east, west, south, and north) and the directions of the control buttons without fail. 5) Do not sling a load at an angle. Do not move the crane while the slung load is swinging. 6) Do not raise or lower a load while the crane is moving longitudinally or laterally.
- Page 26 Foreword and general information Safety notice a For tightening torque, see the precau- 8. Precautions disconnecting connecting hoses and tubes in an air condi- tions for installation in each section of tioner circuit "Disassembly and assembly". 1) Disconnection Although the refrigerant (refrigerant gas: R134a) used on the machine's air conditioner is less destructive to the ozone layer for environmentally friend-...
- Page 27 (Rev. 2010/03) Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one of them is required, consult KOMATSU distributors. Materials and specifications are subject to change without notice. Shop manuals are divided into the "Chassis volume" and "Engine volume". For the engine unit, see the engine vol- ume of the engine model mounted on the machine.
- Page 28 Foreword and general information How to read the shop manual 2. Revision and distribution Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most up-to-date information before you start any work. 3. Filing method File the revised or added pages in the correct order of the page numbers printed in the LIST OF REVISED PAGES.
- Page 29 Foreword and general information Explanation of terms for maintenance standard Explanation of terms for maintenance standard 0 0 - 1 9 (Rev. 2010/03) The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the ma- chine maintenance work.
- Page 30 Foreword and general information Explanation of terms for maintenance standard 4. Repair limit and allowable value or allowable dimension The dimension of a part changes because of wear and deformation while it is used. The limit of changed dimension is called the "re- pair limit".
- Page 31 Foreword and general information Handling of hydraulic components Handling of hydraulic components 0 0 - 2 1 (Rev. 2010/03) With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in the hydraulic circuit. Therefore, special precaution is required when adding hydraulic oil, or when disassembling or assembling hydraulic components.
- Page 32 Foreword and general information Handling of hydraulic components 5. Replacing hydraulic oil while its temperature is high When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil, so it is best to change the oil when it is still warm.
- Page 33 Foreword and general information Method of disconnecting and connecting push-pull type coupler Method of disconnecting and connecting push-pull type coupler 0 0 - 2 3 (Rev. 2010/03) Before performing the following work, loosen the oil filler cap of the hydraulic tank gradually to release the remaining pressure in the hydraulic tank.
- Page 34 Foreword and general information Method of disconnecting and connecting push-pull type coupler Type 2 0 0 - 2 4 1. Disconnection 1) Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexagonal portion at the male end.
- Page 35 Foreword and general information Method of disconnecting and connecting push-pull type coupler Type 3 0 0 - 2 5 1. Disconnection 1) Hold the tightening portion and push body (9) straight until sliding prevention ring (8) contacts contact surface (b) of the hexagonal portion at the male end.
- Page 36 Foreword and general information Handling of electric equipment Handling of electric equipment 0 0 - 2 6 (Rev. 2010/03) To maintain the performance of the machine over a long period, and to prevent failures or other troubles be- fore they occur, correct "operation", "maintenance and inspection", "troubleshooting", and "repairs" must be performed.
- Page 37 Foreword and general information Handling of electric equipment 3) Disconnections in wiring If the harness is pulled to disconnect the connector, or components are lifted with a crane with the harness still connected, or a heavy object hits the harness, the crimping of the connector may separate, or the soldering may be damaged, or the harness may be broken.
- Page 38 Foreword and general information Handling of electric equipment 3. Removing, installing, and drying connectors and wiring harnesses 1) Disconnecting connectors 1] Hold the connectors when disconnecting. When disconnecting the connectors, hold the connectors. For connectors held by a screw, loosen the screw fully, then hold the male and female connectors in each hand and pull apart.
- Page 39 Foreword and general information Handling of electric equipment 2) Connecting connectors a If there is any damage or breakage, 1] Check the connector visually. Check that no oil, dirt, or water is stuck to replace the connector. connector pins (joint portion). Check that connector pins are free from deformation, defective contact, corrosion, or damage.
- Page 40 Foreword and general information Handling of electric equipment 3) Deutsch connector (DT 8-pin, 12-pin) Disconnection (Left of figure) Disconnection Connection (Example of While pressing locks (a) and (b), pull out the incomplete setting of female connector (2). (a)) Connection (Right of figure) 1] Push in female connector (2) horizontally until the lock clicks.
- Page 41 Foreword and general information Handling of electric equipment 4) Drying wiring harness If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high-pres- sure water or steam directly on the wiring harness.
- Page 42 Foreword and general information Handling of electric equipment 4. Handling of connectors used on engine a Mainly, following engines are object for following connectors. 95E-5 107E-1 114E-3 125E-5 140E-5 170E-5 12V140E-3 1) Slide, lock type (FRAMATOME-3, FRAM- 2) Pull lock type (PACKARD-2) ATOME-2) 95/107/114/125/140/170/12V140 Series 95/107/114/125/140/170/12V140 Series...
- Page 43 Foreword and general information Handling of electric equipment 3) Push lock type (1) While pressing up lock (C) of the connector 95/107/114 series with flat-head screwdriver [1], pull out Example) Fuel pressure sensor connector (3) in the direction of the arrow. common rail (BOSCH-03) Disconnection While pressing lock (C), pull out connector...
- Page 44 Foreword and general information Handling of electric equipment 5) Push lock type (3) Example) Intake air pressure sensor in 95/125/140/170/12V140 series intake manifold. (CANNON-04): PIM, etc. Disconnection While pressing lock (E) of the connector, pull out connector (5) in the direction of the arrow. Disconnection Example) Fuel pressure sensor in common 1] Turn housing (H1) in the direction of the...
- Page 45 Foreword and general information Handling of electric equipment 5. Handling controller 1) The controller contains a microcomputer and electronic control circuits. These control all of the electronic circuits on the machine, so be extremely careful when handling controller. 2) Do not place objects on top of the controller. 3) Cover the control connectors with tape or a vinyl bag.
- Page 46 Foreword and general information How to read electric wire code How to read electric wire code 0 0 - 3 6 (Rev. 2010/03) In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols. The electric wire code is helpful in understanding the electric circuit diagram.
- Page 47 Foreword and general information How to read electric wire code Dimensions (Table 2) Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) Number of 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 65/0.32 41/0.32 strands/Diame- ter of strand Conduc- Sectional area 0.51 0.56 0.76...
- Page 48 Foreword and general information How to read electric wire code Color codes table (Table 3) Color Code Color of wire Color Code Color of wire Black Light green & White Brown Light green & Yellow Brown & Black Blue & Red Brown &...
- Page 49 Foreword and general information Precautions when performing work Precautions when performing work 0 0 - 3 9 (Rev. 2010/03) When removing, installing, disassembling or assembling a unit, be sure to follow the general precautions giv- en below. 1. Precautions for removal work If the coolant contains antifreeze, dispose of it correctly as chemicals.
- Page 50 Foreword and general information Precautions when performing work 2. Precautions for installation work Tighten all of the bolts and nuts (sleeve nuts) to the specified torque (KES). Install the hoses without twisting or interference and fix them with intermediate clamps, if available. Replace all of the gaskets, O-rings, cotter pins, and lock plates with new parts.
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