Komatsu PC800 -8E0, Shop Manual

Page 1: ...HYDRAULIC EXCAVATOR SEN05276 06 PC800 8E0 PC800LC 8E0 PC800SE 8E0 PC850 8E0 PC850SE 8E0 SERIAL NUMBERS PC800 65001 PC800LC 65001 PC800SE 65001 PC850 65001 PC850SE 65001 and up...

Page 2: ...Find manuals at https best manuals com...

Page 3: ...0 8 01 00 41 01 28 10 41 00 1 00 42 10 1 10 42 00 2 01 00 43 10 2 10 43 00 3 00 44 10 3 10 44 00 4 00 45 10 4 10 45 00 5 00 46 10 5 10 46 00 6 00 47 10 6 10 47 00 7 00 48 10 7 10 48 00 8 00 49 10 8 10...

Page 4: ...99 10 151 20 7 30 43 10 100 10 152 20 8 30 44 10 101 10 153 20 9 30 45 10 102 10 154 20 10 30 46 10 103 10 155 20 11 30 47 10 104 10 156 20 12 30 48 10 105 10 157 20 13 30 49 10 106 10 158 20 14 30 5...

Page 5: ...69 40 121 30 96 40 18 40 70 40 122 30 97 40 19 40 71 40 123 30 98 40 20 40 72 40 124 30 99 40 21 40 73 40 125 30 100 40 22 40 74 40 126 30 101 40 23 40 75 40 127 30 102 40 24 40 76 40 128 30 103 40 2...

Page 6: ...0 225 40 277 40 329 40 174 40 226 40 278 40 330 40 175 40 227 40 279 40 331 40 176 40 228 40 280 40 332 40 177 40 229 40 281 40 333 40 178 40 230 40 282 40 334 40 179 40 231 40 283 40 335 40 180 40 23...

Page 7: ...58 40 381 40 433 50 7 50 59 40 382 40 434 50 8 50 60 40 383 40 435 50 9 50 61 40 384 40 436 50 10 50 62 40 385 40 437 50 11 50 63 40 386 40 438 50 12 50 64 40 387 40 439 50 13 50 65 40 388 40 440 50 1...

Page 8: ...50 213 60 27 50 112 50 162 50 214 60 28 50 113 50 163 50 215 60 29 50 114 50 164 50 216 60 30 50 115 50 165 50 217 60 31 50 116 50 166 50 218 60 32 50 117 50 167 50 219 60 33 50 118 50 168 50 220 60...

Page 9: ...1 80 20 80 72 80 21 80 73 80 22 80 74 80 23 80 75 80 24 80 76 80 25 80 77 80 26 80 78 80 27 80 79 80 28 80 80 80 29 80 81 80 30 80 82 80 31 80 83 80 32 80 84 80 33 90 1 80 34 90 2 80 35 90 3 80 36 90...

Page 10: ...Notice of revision 8 PC800 850 8E0 01 Find manuals at https best manuals com...

Page 11: ...EXCAVATOR PC800 8E0 PC800LC 8E0 PC800SE 8E0 PC850 8E0 PC850SE 8E0 Machine model Serial number PC800 8E0 65001 and up PC800LC 8E0 65001 and up PC800SE 8E0 65001 and up PC850 8E0 65001 and up Machine mo...

Page 12: ...le 00 50 01 Specification Specifications 01 4 Specifications drawing 01 4 Specifications 01 8 Table of weight 01 18 Table of fuel coolant and lubricants 01 26 10 Structure and function Engine and cool...

Page 13: ...engine oil pressure 30 16 Testing EGR valve and bypass valve drive pressure 30 17 Handling fuel system parts 30 18 Releasing remaining pressure from fuel system 30 19 Testing fuel pressure 30 20 Test...

Page 14: ...re sensor system 40 48 Connector list and layout 40 50 Connection table for connector pin numbers 40 61 T branch box and T branch adapter table 40 97 Fuse locations 40 100 Troubleshooting by failure c...

Page 15: ...r 40 175 Failure code CA451 Rail Press Sensor High Error 40 176 Failure code CA452 Rail Press Sensor Low Error 40 178 Failure code CA553 Rail Press High Error 40 180 Failure code CA554 Rail Press Sens...

Page 16: ...Priority Sol Short Circuit 40 278 Failure code DW43KA Travel Speed Sol Open Circuit 40 280 Failure code DW43KB Travel Speed Sol Short Circuit 40 282 Failure code DW45KA Swing Brake Sol Open Circuit 40...

Page 17: ...is not displayed properly with monitoring function 40 380 E 27 Boom LOWER indicator is not displayed properly with monitoring function 40 382 E 28 Arm IN indicator is not displayed properly with moni...

Page 18: ...ity is poor 40 454 S 2 Engine does not start 40 456 S 3 Engine does not pick up smoothly 40 460 S 4 Engine stops during operation 40 461 S 5 Engine runs rough or is unstable 40 462 S 6 Engine lacks po...

Page 19: ...stem 50 137 Removal and installation of hydraulic tank assembly 50 137 Removal and installation of main pump assembly 50 139 Removal and installation of main pump input shaft oil seal 50 146 Removal a...

Page 20: ...aulic system 60 24 Cooling fan motor 60 24 Control valve 60 26 Swing motor 60 32 Center swivel joint 60 34 PPC valve 60 35 Work equipment 60 38 Work equipment 60 38 Work equipment dimension 60 44 Hydr...

Page 21: ...ower motor system No air comes out or air flow is abnormal 80 63 Troubleshooting for temperature control 80 67 Troubleshooting for vent mode changeover 80 70 Troubleshooting for FRESH RECIRC air chang...

Page 22: ...e while working 3 When performing any operation always wear safety shoes and helmet Do not wear loose work clothes or clothes with buttons missing q Always wear the safety glasses when hit ting parts...

Page 23: ...arts 4 For the machine equipped with a battery disconnct switch turn the battery discon nect switch to the OFF O position and pull the switch key out before starting the work For machines without a ba...

Page 24: ...according to the weight of the load and method of slinging If too thick wire ropes are used to sling a light load the load may slip and fall 6 Do not sling a load with one wire rope alone If it is slu...

Page 25: ...rate the hoist at a safe place 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...

Page 26: ...ts your skin you may lose your sight or your skin may be frozen Whenever recovering or adding refrig erant gas you must put on safety glasses safety gloves and long sleeved clothes The refrigerant gas...

Page 27: ...out failed parts and how to repair them The troubleshooting is divided by failure modes The S mode of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine...

Page 28: ...nits are indicated with International System of units SI For reference conventionally used Gravitational System of units is indicated in parentheses Symbol Item Description k Safety Special safety pre...

Page 29: ...y the tolerance q Indication of dimension of rotating shaft and hole and their related drawing 2 Standard clearance and standard value q The clearance made when new parts are as sembled is called the...

Page 30: ...ce most of the allowable values are esti mated from various tests or experiences in most cases it must be judged after consider ing the operating condition and customer s requirement 5 Allowable clear...

Page 31: ...hange Disassembly and maintenance of hydraulic components should be performed in a specially prepared dustproof workshop and the perfor mance should be checked with special test equipment 3 Sealing op...

Page 32: ...will mix with the new oil and will shorten the life of the hydraulic oil 6 Flushing operations After disassembling and assembling the equip ment or changing the oil use flushing oil to remove the cont...

Page 33: ...se joint 2 into mating adapter 3 Fig 1 a The adapter can be pushed in about 3 5 mm a Do not hold rubber cap portion 4 2 With hose joint 2 pushed into adapter 3 press rubber cap portion 4 against adapt...

Page 34: ...ntacts contact surface a of the hexagonal portion at the male end Fig 6 2 While holding the condition of Step 1 turn lever 8 to the right clockwise Fig 7 3 While holding the condition of Steps 1 and 2...

Page 35: ...xagonal portion at the male end Fig 10 2 While holding the condition of Step 1 push cover 10 straight until it contacts contact surface b of the hexagonal portion at the male end Fig 11 3 While holdin...

Page 36: ...o be affected by the direct effects of rain water heat or vibration Furthermore during inspection and repair operations they are frequently removed and installed again so they are likely to suffer def...

Page 37: ...e if water does enter it is difficult for it to be drained Therefore if water should get into the connector the pins will be short circuited by the water so if any water gets in immediately dry the co...

Page 38: ...s apart a Never pull with one hand 2 When removing from clips q Both of the connector and clip have stoppers which are engaged with each other when the connector is in stalled q When removing a connec...

Page 39: ...to make them too hot as this will cause short circuits a If there is any damage or breakage replace the connector 2 Fix the connector securely Position the connectors correctly and then fit them secu...

Page 40: ...ure 1 Push in female connector 2 horizontally until the lock clicks Arrow 1 2 Since locks a and b may not be set completely push in female connector 2 while moving it up and down until the locks are s...

Page 41: ...s the risk that oil in the air may cause defective con tact remove oil and water in the air before starting air blow 2 Dry the inside of the connector with a dryer If water gets inside the connector u...

Page 42: ...ure sensor PAMB 125 170 12V140 series Disconnection 1 Slide lock L1 to the right 2 While pressing lock L2 pull out connector 1 toward you a Even if lock L2 is pressed connector 1 cannot be pulled out...

Page 43: ...derside use flat head screwdriver 1 since you cannot insert your fingers While pressing up lock C of the connector with flat head screwdriver 1 pull out connector 3 in the direction of the arrow Conne...

Page 44: ...ly pump G SUMITOMO 3 a Pull the connector straight up Connection Insert the connector straight until it clicks 6 Turn housing type Round green connector q 140 series Example Intake air pressure sensor...

Page 45: ...ng on the machine body disconnect all of the wiring harness connectors connected to the controller Fit an arc welding ground to the place close to the welding point 6 Points to remember when troublesh...

Page 46: ...Size Nominal No is shown in Table 2 Indicates type of wire by symbol Type symbol and material of wire are shown in Table 1 Since the use of AV and AVS wires depends on size nominal No their symbols a...

Page 47: ...Standard 2 0 2 2 2 7 3 0 3 1 3 8 4 6 Nominal No 8 15 20 30 40 50 60 85 100 Conduc tor Number of strands Diame ter of strand 50 0 45 84 0 45 41 0 80 70 0 80 85 0 80 108 0 80 127 0 80 169 0 80 217 0 80...

Page 48: ...Red LW Blue White BrW Brown White LY Blue Yellow BrY Brown Yellow O Orange Ch Charcoal P Pink Dg Dark green R Red G Green RB Red Black GB Green Black RG Red Green GL Green Blue RL Red Blue Gr Gray RW...

Page 49: ...lifting equipment of ample strength q When using forcing screws to remove any component tighten the forcing screws uniformly and alter nately q Before removing any unit clean the surrounding area and...

Page 50: ...to operate the hydraulic cylinder four to five times stop ping the piston at 100 mm off the end of its stroke 3 Next operate the hydraulic cylinder three to four times to the end of its stroke a When...

Page 51: ...This as a preview PDF file from best manuals com Download full PDF manual at best manuals com...