Komatsu PC800-8, PC850-8 Hydraulic Excavator Service Repair Shop Manual – SEN00373-12

This Complete Service Repair Workshop Manual PDF Download for the PC800-8, PC800LC-8, PC800SE-8, PC850-8, PC850SE-8 Komatsu Hydraulic Excavator 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 :

Komatsu PC800-8 – S/N: 50001 and up
Komatsu PC800LC-8 – S/N: 50001 and up
Komatsu PC800SE-8 – S/N: 50001 and up
Komatsu PC850-8 – S/N: 10001 and up
Komatsu PC850SE-8 – S/N: 10001 and up

TABLE OF CONTENTS :

00 INDEX AND FOREWORD
01 SPECIFICATION
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
20 STANDARD VALUE TABLE
30 TESTING AND ADJUSTING
40 TROUBLESHOOTING
50 DISASSEMBLY AND ASSEMBLY
90 DIAGRAMS AND DRAWINGS

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : SEN00373-12
Total Pages : 1130

This manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

This manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having PDF files instead of a hard-printed manual is that you can use the Search feature in Acrobat to find just what your looking for and just print out the exact pages you need or all manual.

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00 Index and foreword
Index
Composition of shop manual
Table of contents
Foreword and general information
Safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling of electric equipment and hydraulic component
Handling of connectors newly used for engines
How to read electric wire code
Precautions when carrying out operation
Method of disassembling and connecting push-pull type coupler
Standard tightening torque table
Conversion table

01 Specification
Specification and technical data
Specification and technical data
Specification drawings
Working range drawing
Specifications
Weight table
Table of fuel, coolant and lubricants

10 Structure, function and maintenance standard
Engine and cooling system
Engine and cooling system
Coupling
Coupling lubrication system
Radiator, oil cooler
Power train
Power train
Power train
Swing machinery
Swing circle
Final drive
Sprocket
Undercarriage and frame
Undercarriage and frame
Track frame and recoil spring
Idler
Carrier roller
Track roller
Track shoe
Double shoe
Hydraulic system, Part 1
Hydraulic system, Part 1
Hydraulic piping drawing
Hydraulic tank, hydraulic filter
Hydraulic pump
Cooling fan pump
Cooling fan motor
Hydraulic system, Part 2
Hydraulic system, Part 2
Motor grease pump
Return oil filter
Line oil filter
Drain oil filter
L.H. 5-Spool control valve
R.H. 4-Spool control valve
Straight-travel valve
Swing motor
Center swivel joint
Travel motor
PPC accumulator
Work equipment, swing PPC valve
Travel PPC valve
Solenoid valve
Quick return valve
Hydraulic cylinder
Work equipment
Work equipment
Work equipment
Dimensions of work equipment
Cab and its attachments
Cab and its attachments
Air conditioner piping
Electrical system
Engine control
Electric control system
Monitor system
Sensors
KOMTRAX system

20 Standard value table
Standard service value table
Standard service value table
Standard service value table for engine
Standard service value table for chassis

30 Testing and adjusting
Testing and adjusting, Part 1
Testing and adjusting, Part 1
Tools for testing, adjusting and troubleshooting
Measuring engine speed
Measuring intake air pressure (Boost pressure)
Measuring exhaust gas temperature
Measuring exhaust gas color
Adjusting valve clearance
Measuring compression pressure
Measuring blow-by pressure
Measuring engine oil pressure
Measuring EGR valve and bypass valve drive pressure
Handling of fuel system equipment
Remaining pressure relief from fuel system equipment
Measuring fuel pressure
Testing fuel return rate and leakage
Bleeding air from fuel circuit
Testing fuel system for leakage
Testing and adjusting alternator belt tension
Testing and adjusting air conditioner compressor belt
Testing and adjusting, Part 2
Testing and adjusting, Part 2
Inspection of swing circle bearing clearance
Testing and adjusting track shoe tension
Testing and adjusting work equipment, swing, and travel circuit oil pressures
Testing and adjusting control circuit pressure (output pressure of self pressure reducing valve)
Testing and adjusting main pump control pressure
Testing and adjusting, Part 3
Testing and adjusting, Part 3
Measuring PPC valve output pressure
Measuring outlet pressures of solenoid valve, swing PPC shuttle valve, and swing priority selector valve
Adjusting work equipment, swing PPC valve
Testing and adjusting travel deviation
Inspection of locations of hydraulic drift of work equipment
Measuring fan speed
Measuring fan circuit oil pressure
Measuring fan pump EPC current
Measuring fan pump EPC solenoid valve output pressure
Measuring oil leakage
Release of residual pressure from hydraulic circuit
Bleeding air from each part
Inspection procedures for diode
Adjusting mirrors
Testing and adjusting, Part 4
Testing and adjusting, Part 4
Special function of machine monitor
Handling controller voltage circuit
Testing and adjusting, Part 5
Testing and adjusting, Part 5
Procedure for turning on KOMTRAX terminal
KOMTRAX terminal lamp indications
Preparation work for troubleshooting electrical system

40 Troubleshooting
Failure code table and fuse locations
Failure code table and fuse locations
Failure codes table
Fuse locations
General information on troubleshooting
General information on troubleshooting
Points to remember when troubleshooting
Sequence of events in troubleshooting
Checks before troubleshooting
Classification and troubleshooting steps
Information in troubleshooting table
Failure-looking phenomenon and troubleshooting No.
Connection table for connector pin numbers
T- branch box and T- branch adapter table
Troubleshooting by failure code (Display of code), Part 1
Troubleshooting by failure code (Display of code), Part 1
Failure code [AA10NX] Aircleaner 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 Lvl Low
Failure code [[email protected]] Hydr. 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
Troubleshooting by failure code (Display of code), Part 2
Troubleshooting by failure code (Display of code), Part 2
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] Rail Press Low Error
Failure code [CA689] Eng Ne Speed Sensor Error
Failure code [CA731] Eng Bkup Speed Sens Phase Error
Failure code [CA757] All Persistent 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 [CA1642] EGR Inter Press Sens Low Error
Failure code [CA1653] EGR Inter Press Sens High 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 Volt Low Error
Failure code [CA2556] Grid Htr Relay Volt High Error
Failure code [D110KB] Battery Relay Drive S/C
Failure code [D163KB] Flash Light Relay S/C
Failure code [D195KB] Step Light Relay S/C
Failure code [DA22KK] Pump Solenoid Power Low Error
Failure code [DA25KP] Press. Sensor Power Abnormality
Failure code [DA2SKQ] Model Selection Abnormality
Failure code [DA80MA] Auto. Lub. Abnormal.
Failure code [DA2RMC] Pump Comm. Abnormality
Failure code [DAFRMC] Monitor Comm. Abnormality
Failure code [DGE5KY] Ambi. Temp. Sensor S/C
Failure code [DGH2KB] Hydr. Oil Temp. Sensor S/C
Troubleshooting by failure code (Display of code), Part 3
Troubleshooting by failure code (Display of code), Part 3
Failure code [DH25KA] L Jet Sensor Disc
Failure code [DH25KB] L Jet Sensor S/C
Failure code [DH26KA] R Jet Sensor Disc.
Failure code [DH26KB] R Jet Sensor S/C
Failure code [DHPEKA] F Pump P. Sensor Disc.
Failure code [DHPEKB] F Pump P. Sensor S/C
Failure code [DHPFKA] R Pump P. Sensor Disc.
Failure code [DHPFKB] R Pump P. Sensor S/C
Failure code [DV20KB] Travel Alarm S/C
Failure code [DW41KA] Swing Priority Sol. Disc.
Failure code [DW41KB] Swing Priority Sol. S/C
Failure code [DW43KA] Travel Speed Sol. Disc.
Failure code [DW43KB] Travel Speed Sol. S/C
Failure code [DW45KA] Swing Brake Sol. Disc.
Failure code [DW45KB] Swing Brake Sol. S/C
Failure code [DW7BKA] Fan Reverse Sol. Disc.
Failure code [DW7BKB] Fan Reverse Sol. S/C
Failure code [DW7JKA] Bottom Dump Priority Sol. Disc.
Failure code [DW7JKB] Bottom Dump Priority Sol. S/C
Failure code [DWK0KA] 2-stage Relief Sol. Disc.
Failure code [DWK0KB] 2-stage Relief Sol. S/C
Failure code [DX16KA] Fan Pump EPC Sol. Disc.
Failure code [DX16KB] Fan Pump EPC Sol. S/C
Failure code [DXAAKA] F Pump EPC Sol. Disc.
Failure code [DXAAKB] F Pump EPC Sol. S/C
Failure code [DXABKA] R Pump EPC Sol. Disc.
Failure code [DXABKB] R Pump EPC Sol. S/C
Failure code [DY20KA] Wiper Working Abnormality
Failure code [DY20MA] Wiper Parking Abnormality
Failure code [DY2CKB] Washer Drive S/C
Failure code [DY2DKB] Wiper Drive (For) S/C
Failure code [DY2EKB] Wiper Drive (Rev) S/C
Troubleshooting of electrical system (E-mode)
Troubleshooting of electrical system (E-mode)
Before carrying out troubleshooting of electrical system
Information contained in troubleshooting table
E-1 Engine does not start (Engine does not rotate)
E-2 Preheater does not operate
E-3 Auto engine warm-up device does not work
E-4 Auto-decelerator does not operate
E-5 All work equipment, swing and travel do not move
E-6 Machine push-up function does not operate normally
E-7 Boom shockless function does not operate normally
E-8 Any item is not displayed on machine monitor
E-9 Part of display on machine monitor is missing
E-10 Machine monitor displays contents irrelevant to the model
E-11 Fuel level monitor red lamp lights up while engine is running
E-12 Engine coolant thermometer does not display normally
E-13 Hydraulic oil temperature gauge does not display correctly
E-14 Fuel gauge does not display correctly
E-15 Swing lock monitor does not display correctly
E-16 When monitor switch is operated, nothing is displayed
E-17 Windshield wiper and window washer do not work
E-18 “Boom RAISE” is not correctly displayed in monitor function
E-19 “Boom LOWER” is not correctly displayed in monitor function
E-20 “Arm IN” is not correctly displayed in monitor function
E-21 “Arm OUT” is not correctly displayed in monitor function
E-22 “Bucket CURL” is not correctly displayed in monitor function
E-23 “Bucket DUMP” is not correctly displayed in monitor function
E-24 “SWING” is not correctly displayed in monitor function
E-25 “Left travel” is not displayed normally in monitoring function
E-26 “Right travel” is not displayed normally in monitoring function
E-27 “Service” is not correctly displayed in monitor function
E-28 KOMTRAX system does not operate normally
E-29 Air conditioner does not work
E-30 Step light does not light up or go off
E-31 Electric grease gun does not operate
E-32 Travel alarm does not sound or does not stop sounding
Troubleshooting of hydraulic and mechanical system (H-mode)
Troubleshooting of hydraulic and mechanical system (H-mode)
Before troubleshooting
Information in troubleshooting table
H-1 Speed or power of all work equipment, travel, and swing is low
H-2 Engine speed lowers remarkably or engine stalls
H-3 All work equipment, travel, and swing systems do not work
H-4 Abnormal sound is heard from around pump
H-5 Boom speed or power is low
H-6 Speed or power of arm is low
H-7 Speed or power of bucket is low
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 operate or stop
H-14 Machine push-up function does not operate or stop
H-15 Boom shockless function cannot be turned ON or OFF
H-16 Machine deviates in one direction
H-17 Machine deviates largely at start
H-18 Machine deviates largely during compound operation
H-19 Travel speed or power is low
H-20 Machine does not travel (only one track)
H-21 Travel speed does not change
H-22 Upper structure does not swing
H-23 Swing speed or acceleration is low
H-24 Swing speed or acceleration is low during compound operation of swing and work equipment
H-25 Upper structure overruns excessively when it stops swinging
H-26 Large shock is made when upper structure stops swinging
H-27 Large abnormal sound is made when upper structure stops swinging
H-28 Hydraulic drift of swing is large
H-29 Fan rotation is abnormal (Fan sound/vibration is abnormally large or fan overheats)
Troubleshooting of engine (S-mode)
Troubleshooting of engine (S-mode)
Method of using troubleshooting chart
S-1 Starting performance is poor
S-2 Engine does not start
S-3 Engine does not pick up smoothly
S-4 Engine stops during operations
S-5 Engine does not rotate smoothly
S-6 Engine lacks output (or lacks power)
S-7 Exhaust gas color is black (incomplete combustion)
S-8 Oil consumption is excessive (or exhaust smoke is blue)
S-9 Oil becomes contaminated quickly
S-10 Fuel consumption is excessive
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)
S-12 Oil pressure drops
S-13 Oil level rises (Entry of coolant/fuel)
S-14 Coolant temperature becomes too high (overheating)
S-15 Abnormal noise is made
S-16 Vibration is excessive

50 Disassembly and assembly
General information on disassembly and assembly
General information on disassembly and assembly
How to read this manual
Coating materials list
Special tools list
Sketches of special tools
Engine and cooling system (SAA6D140E-5)
Engine and cooling system
Removal and installation of engine, PTO and hydraulic pump assembly
Removal and installation of cooling assembly
Removal and installation of aftercooler assembly
Removal and installation of fuel cooler and air conditioner condenser assembly
Removal and installation of fan motor assembly
Removal and installation of fuel tank assembly
Engine (SAA6D140E-5)
Engine (SAA6D140E-5)
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
Power train
Removal and installation of PTO (coupling) assembly
Disassembly and assembly of PTO (coupling) assembly
Removal and installation of swing motor and swing machinery assembly
Disassembly and assembly of swing machinery assembly
Removal and installation of swing circle assembly
Disassembly and assembly of final drive assembly
Undercarriage and frame
Undercarriage and frame
Removal and installation 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
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
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
Cab and its attachments
Cab and its attachments
Removal and installation of operator’s cab
Removal and installation of operator’s cab glass (stuck glass)
Removal and installation of front window assembly
Electrical system
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

90 Diagrams and drawings
Hydraulic diagrams and drawings
Hydraulic circuit diagram
Electrical diagrams and drawings
Electrical circuit diagram (1/5)
Electrical circuit diagram (2/5)
Electrical circuit diagram (3/5)
Electrical circuit diagram (4/5)
Electrical circuit diagram (5/5)
Connector list and sterogram

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