Page 1 SEN00373-06 HYDRAULIC EXCAVATOR PC800 PC800SE PC800LC PC850 PC850SE PC800- 50001 PC800SE- 50001 PC800LC- 50001 SERIAL NUMBERS and up PC850- 10001 PC850SE- 10001...
Page 3 SEN00375-06 HYDRAULIC EXCAVATOR PC800-8 PC850-8 PC800SE-8 PC850SE-8 PC800LC-8 Machine model Serial number PC800-8 50001 and up PC800SE-8 50001 and up PC800LC-8 50001 and up PC850-8 10001 and up PC850SE-8 10001 and up 00 Index and foreword Index Composition of shop manual ..........................2 Table of contents ..............................
Page 4 SEN00375-06 00 Index and foreword Composition of shop manual The contents of this shop manual are shown together with Form No. in a list. Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly. The marks shown to the right of Form No.
Page 5 SEN00375-06 00 Index and foreword Troubleshooting of engine (S-mode) SEN00795-02 50 Disassembly and assembly SEN00390-01 General information on disassembly and assembly SEN01052-01 Engine and cooling system (SAA6D140E-5) SEN01053-01 Engine (SAA6D140E-5) SEN01054-01 Power train SEN01055-01 Undercarriage and frame SEN01056-01 Hydraulic system SEN01057-01 Work equipment SEN01058-00...
Page 6: Table Of Contents
SEN00375-06 00 Index and foreword Table of contents 00 Index and foreword Index SEN00375-06 Composition of shop manual ....................Table of contents........................Foreword and general information SEN00376-02 Safety notice ..........................How to read the shop manual....................Explanation of terms for maintenance standard ..............Handling of electric equipment and hydraulic component ............
Page 7 SEN00375-06 00 Index and foreword Hydraulic system, Part 2 SEN00384-02 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 ....................... 14 Straight-travel valve .........................
Page 8 SEN00375-06 00 Index and foreword Testing and adjusting alternator belt tension ................21 Testing and adjusting air conditioner compressor belt............. 22 Testing and adjusting, Part 2 SEN00788-02 Testing and adjusting, Part 2 ....................... Inspection of swing circle bearing clearance ................Testing and adjusting track shoe tension.................
Page 9 SEN00375-06 00 Index and foreword Failure code [B@BCZK] Eng. Water Lvl Low ................12 Failure code [B@HANS] Hydr. Oil Overheat ................14 Failure code [CA111] ECM Critical Internal Failure ..............16 Failure code [CA115] Eng Ne and Bkup Speed Sens Error ............ 18 Failure code [CA122] Chg Air Press Sensor High Error............
Page 10 SEN00375-06 00 Index and foreword Failure code [CA1633] KOMNET Datalink Timeout Error............32 Failure code [CA1642] EGR Inter Press Sens Low Error ............34 Failure code [CA1653] EGR Inter Press Sens High Error ............36 Failure code [CA2185] Throt Sens Sup Volt High Error............38 Failure code [CA2186] Throt Sens Sup Volt Low Error ............
Page 11 SEN00375-06 00 Index and foreword Troubleshooting of electrical system (E-mode) SEN00793-02 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 ....................
Page 12 SEN00375-06 00 Index and foreword H-19 Travel speed or power is low ..................27 H-20 Machine does not travel (only one track) ................ 28 H-21 Travel speed does not change..................29 H-22 Upper structure does not swing ..................30 H-23 Swing speed or acceleration is low................. 32 H-24 Swing speed or acceleration is low during compound operation of swing and work equipment ......................
Page 13 SEN00375-06 00 Index and foreword Power train SEN01055-01 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 ............. 13 Removal and installation of swing circle assembly..............
Page 14 SEN00375-06 00 Index and foreword Electrical system SEN01060-01 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.............
Page 15 SEN00375-06 00 Index and foreword PC800, 850-8...
Page 16 SEN00375-06 00 Index and foreword PC800-8, PC800SE-8, PC800LC-8, PC850-8, PC850SE-8 Hydraulic excavator Form No. SEN00375-06...
Page 17 SEN00376-02 HYDRAULIC EXCAVATOR PC800-8 PC850-8 PC800SE-8 PC850SE-8 PC800LC-8 Machine model Serial number PC800-8 50001 and up PC800SE-8 50001 and up PC800LC-8 50001 and up PC850-8 10001 and up PC850SE-8 10001 and up 00 Index and foreword Foreword and general information Safety notice..............................2 How to read the shop manual..........................7 Explanation of terms for maintenance standard ....................9...
Page 18: Safety Notice
Proper service and repair are extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose.
Page 19 SEN00376-02 00 Index and foreword When disassembling or assembling, sup- When removing piping, stop the fuel or oil port the machine with blocks, jacks, or from spilling out. If any fuel or oil drips stands before starting work. onto the floor, wipe it up immediately. Fuel Remove all mud and oil from the steps or or oil on the floor can cause you to slip other places used to get on and off the...
Page 20 SEN00376-02 00 Index and foreword Precautions for sling work and making signs Only one appointed worker must make signs and co-workers must communicate with each other frequently. The appointed sign maker must make specified signs clearly at a place where he is seen well from the operator's seat and where he can see the working condition easily.
Page 21 SEN00376-02 00 Index and foreword If the load is unstable or the wire rope 13) If the hoist stops because of a power fail- or chains are twisted, lower the load ure, turn the power switch OFF. When and lift it up again. turning on a switch which was turned OFF Do not lift up the load slantingly.
Page 22 SEN00376-02 00 Index and foreword Precautions for disconnecting and con- necting hoses and tubes in air conditioner circuit Disconnection Collect the air conditioner refriger- ant (R134a) from the air condi- tioner circuit in advance. a Ask professional traders for collecting and filling operation of refrigerant (R134a).
Page 23: How To Read The Shop Manual
This section explains the method of reproducing, repairing, and replacing parts. 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. PC800, 850-8...
Page 24 SEN00376-02 00 Index and foreword Filing method File by the brochures in the correct order of the form number printed in the shop manual composition table. Revised edition mark When a manual is revised, the ones and tens digits of the form number of each brochure is increased by 1.
Page 25: Explanation Of Terms For Maintenance Standard
SEN00376-02 00 Index and foreword Explanation of terms for maintenance standard The maintenance standard values necessary for judgment of products and parts are described by the follow- ing terms. Standard size and tolerance To be accurate, the finishing size of parts is a little different from one to another.
Page 26 SEN00376-02 00 Index and foreword Standard clearance and standard value Clearance limit The clearance made when new parts are Parts can be used until the clearance assembled is called the “standard clear- between them is increased to a certain ance“, which is indicated by the range limit.
Page 27: Handling Of Electric Equipment And Hydraulic Component
SEN00376-02 00 Index and foreword Handling of electric equipment and hydraulic component To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur, correct “operation“, “maintenance and inspection“, “troubleshooting“, and “repairs” must be carried out.
Page 28 SEN00376-02 00 Index and foreword Disconnections in wiring If the wiring is held and the connectors are pulled apart, or components are lifted with a crane with the wiring still connected, or a heavy object hits the wiring, the crimping of the connector may separate, or the sol- dering may be damaged, or the wiring may be broken.
Page 29 SEN00376-02 00 Index and foreword Removing, installing, and drying connec- tors and wiring harnesses Disconnecting connectors Hold the connectors when discon- necting. 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 30 SEN00376-02 00 Index and foreword Connecting connectors Check the connector visually. Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). Check that there is no deformation, defective contact, corrosion, or dam- age to the connector pins. Check that there is no damage or breakage to the outside of the con- nector.
Page 31 SEN00376-02 00 Index and foreword Heavy duty wire connector (DT 8-pole, 12- Disconnection Connection (Example of pole) incomplete setting of (a)) Disconnection (Left of figure) While pressing both sides of locks (a) and (b), pull out female connector (2). Connection (Right of figure) Push in female connector (2) horizon- tally until the lock clicks.
Page 32 SEN00376-02 00 Index and foreword Drying wiring harness If there is any oil or dirt on the wiring har- ness, 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-pressure water or steam directly on the wiring harness.
Page 33 SEN00376-02 00 Index and foreword Handling controller The controller contains a microcomputer and electronic control circuits. These con- trol all of the electronic circuits on the machine, so be extremely careful when handling the controller. Do not place objects on top of the control- ler.
Page 34 SEN00376-02 00 Index and foreword Points to remember when handling hydraulic equipment With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary to be particularly careful.
Page 35 SEN00376-02 00 Index and foreword Change hydraulic oil when the 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 36: Handling Of Connectors Newly Used For Engines
SEN00376-02 00 Index and foreword Handling of connectors newly used for engines a Mainly, following engines are object for follow- Pull lock type (PACKARD-2) ing connectors. 107 – 170, 12V140 engine 107E-1 Various temperature sensors 114E-3 Example) 125E-5 Intake air temperature sensor in 140E-5 intake manifold: TIM 170E-5...
Page 37 SEN00376-02 00 Index and foreword Push lock type 107, 114 engines Example) Fuel pressure sensor in common rail (BOSCH-03) Disconnect connector (3) according to the fol- lowing procedure. While pressing lock (C), pull out connector (3) in the direction of the arrow. 114 engine 107, 114 engine Example)
Page 38 SEN00376-02 00 Index and foreword 125 – 170, 12V140 engine Turn-housing type (Round green connector) While pressing lock (E) of the connector, 140 engine pullout connector (5) in the direction of the Example) arrow. Intake air pressure sensor in intake mani- fold (CANNON-04): PIM etc.
Page 39: How To Read Electric Wire Code
SEN00376-02 00 Index and foreword How to read electric wire code a The information about the wires unique to each machine model is described in Troubleshooting section, Relational information of troubleshooting. In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by sym- bols.
Page 40 SEN00376-02 00 Index and foreword Dimensions (Table 2) Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) Number of strands/Diam- 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 41/0.32 65/0.32 eter of strand Conductor Sectional 0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09...
Page 41 SEN00376-02 00 Index and foreword 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 & Red Blue & White Brown &...
Page 42: Precautions When Carrying Out Operation
SEN00376-02 00 Index and foreword Precautions when carrying out operation [When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precautions given below when carrying out the operation.] Precautions when carrying out removal work If the coolant contains antifreeze, dispose of it correctly.
Page 43 SEN00376-02 00 Index and foreword Precautions when carrying out installation work Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque. Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
Page 44 SEN00376-02 00 Index and foreword Checking muffler and exhaust pipe for damage and looseness Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage. If any part is damaged, replace it. Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for looseness.
Page 45: Method Of Disassembling And Connecting Push-Pull Type Coupler
SEN00376-02 00 Index and foreword Method of disassembling and connecting push-pull type coupler Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to release the residual pressure from the hydraulic tank. Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected.
Page 46 SEN00376-02 00 Index and foreword Type 2 Disconnection Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexag- onal portion at the male end. (Fig. 6) While holding the condition of Step 1), turn lever (8) to the right (clockwise).
Page 47 SEN00376-02 00 Index and foreword Type 3 Disconnection Hold the tightening portion and push body (9) straight until sliding prevention ring (8) contacts contact surface (b) of the hexag- onal portion at the male end. (Fig. 10) While holding the condition of Step 1), push cover (10) straight until it contacts contact surface (b) of the hexagonal por- tion at the male end.
Page 48: Standard Tightening Torque Table
SEN00376-02 00 Index and foreword Standard tightening torque table Table of tightening torques for bolts and nuts a Unless there are special instructions, tighten metric nuts and bolts to the torque below. (When using torque wrench) a The following table corresponds to the bolts in Fig. A. Thread diameter of bolt Width across flats Tightening torque...
Page 49 SEN00376-02 00 Index and foreword Table of tightening torques for split flange bolts a Unless there are special instructions, tighten split flange bolts to the torque below. Thread diameter of bolt Width across flats Tightening torque 59 – 74 6.0 – 7.5 98 –...
Page 50 SEN00376-02 00 Index and foreword Table of tightening torques for hoses (taper seal type and face seal type) a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the torque below. a Apply the following torque when the threads are coated (wet) with engine oil. Tightening torque Nm {kgm} Taper seal Face seal...
Page 51 SEN00376-02 00 Index and foreword Table of tightening torques for 102, 107 and 114 engine series (Taper screws) a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114 engine series to the torque below. Thread size Tightening torque inch...
Page 52: Conversion Table
SEN00376-02 00 Index and foreword Conversion table Method of using the conversion table The conversion table in this section is provided to enable simple conversion of figures. For details of the method of using the conversion table, see the example given below. Example: Method of using the conversion table to convert from millimeters to inches Convert 55 mm into inches.
Page 53 SEN00376-02 00 Index and foreword Millimeters to inches 1 mm = 0.03937 in 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142 1.181...
Page 54 SEN00376-02 00 Index and foreword Liters to U.K. Gallons 1 l = 0.21997 U.K.Gal 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379...
Page 55 SEN00376-02 00 Index and foreword kg/cm to lb/in 1 kg/cm = 14.2233 lb/in 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5 426.7...
Page 56 SEN00376-02 00 Index and foreword Temperature Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi- grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column) of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahren- heit temperatures and read the corresponding Centigrade temperature in the column at the left.
Page 57 SEN00376-02 00 Index and foreword PC800, 850-8...
Page 58 SEN00376-02 00 Index and foreword PC800-8, PC800SE-8, PC800LC-8, PC850-8, PC850SE-8 Hydraulic excavator Form No. SEN00376-02...
Page 59: Specification
SEN00378-02 HYDRAULIC EXCAVATOR PC800-8 PC850-8 PC800SE-8 PC850SE-8 PC800LC-8 Machine model Serial number PC800-8 50001 and up PC800SE-8 50001 and up PC800LC-8 50001 and up PC850-8 10001 and up PC850SE-8 10001 and up Specification Specification and technical data Specification and technical data Specification drawings ............................
Page 60: Specification Drawings
SEN00378-02 01 Specification Specification and technical data Specification drawings Backhoe specification Item Unit PC800-8 PC800SE-8 PC800LC-8 PC850-8 PC850SE-8 Overall length 14,405 13,130 14,405 13,995 13,130 Overall height 4,660 4,615 4,690 4,850 4,615 Overall width 4,285 4,305 4,385 4,305 4,305 Track shoe width Height of cab 3,665 3,665...
Page 61 01 Specification SEN00378-02 Loading shovel specification Item Unit PC800-8 (Loading shovel specification) Overall length 10,075 Overall height 5,790 Overall width 4,285 Track shoe width Height of cab 3,560 Radius of upper structure 4,400 G Overall length of track 5,810 Tumbler center distance 4,500 Height of machine cab 4,000...
Page 62: Working Range Drawing
SEN00378-02 01 Specification Working range drawing Backhoe specification Item Unit PC800-8 PC800SE-8 PC800LC-8 PC850-8 PC850SE-8 Max. digging reach 13,740 12,265 13,740 13,660 12,265 Max. digging depth 8,600 7,130 8,600 8,445 7,130 Max. digging height 11,840 11,330 11,840 11,955 11,330 Max. vertical wall digging 5,575 4,080 5,575...
Page 63 01 Specification SEN00378-02 Loading shovel specification Item Unit PC800-8 (Loading shovel specification) Max. digging reach 10,370 Max. digging depth 9,595 Max. digging height 10,800 Max. vertical wall digging 3,605 depth Max. dumping height 5,730 Max. digging reach at 6,350 ground level PC800, 850-8...
Page 64: Specifications
SEN00378-02 01 Specification Specifications Backhoe specification PC800-8 Machine model PC800-8 Serial number 50001 and up Bucket capacity Weight of machine 75,000 Max. digging depth 8,600 Max. vertical wall depth 5,575 Max. digging reach 13,740 Max. reach at ground level 13,460 Max.
Page 65 01 Specification SEN00378-02 Machine model PC800-8 Serial number 50001 and up Model KOMATSU SAA6D140E-5 Type 4-cycle, water-cooled, in-line, vertical, direct injection, with turbocharger and aftercooler (air cooled) No. of cylinders – bore × stroke 6 – 140 × 165 l {cc}...
Page 66 SEN00378-02 01 Specification Machine model PC800-8 Serial number 50001 and up Boom Bucket Double-acting Double-acting Double-acting Type piston piston piston Inside diameter of cylinder Diameter of piston rod Stroke 1,950 2,250 1,610 Max. distance between pins 4,880 5,525 3,990 Min. distance between pins 2,930 3,275 2,380...
Page 67 01 Specification SEN00378-02 PC800SE-8 Machine model PC800SE-8 Serial number 50001 and up Bucket capacity Weight of machine 76,000 Max. digging depth 7,130 Max. vertical wall depth 4,080 Max. digging reach 12,265 Max. reach at ground level 11,945 Max. digging height 11,330 Max.
Page 68 01 Specification Machine model PC800SE-8 Serial number 50001 and up Model KOMATSU SAA6D140E-5 Type 4-cycle, water-cooled, in-line, vertical, direct injection, with turbocharger and aftercooler (air cooled) No. of cylinders – bore × stroke 6 – 140 × 165 l {cc}...
Page 69 01 Specification SEN00378-02 Machine model PC800SE-8 Serial number 50001 and up Boom Bucket Double-acting Double-acting Double-acting Type piston piston piston Inside diameter of cylinder Diameter of piston rod Stroke 1,950 1,610 1,420 Max. distance between pins 4,880 3,990 3,910 Min. distance between pins 2,930 2,380 2,490...
Page 70 SEN00378-02 01 Specification PC800LC-8 Machine model PC800LC-8 Serial number 50001 and up Bucket capacity Weight of machine 77,200 Max. digging depth 8,600 Max. vertical wall depth 5,575 Max. digging reach 13,740 Max. reach at ground level 13,460 Max. digging height 11,840 Max.
Page 71 01 Specification SEN00378-02 Machine model PC800LC-8 Serial number 50001 and up Model KOMATSU SAA6D140E-5 Type 4-cycle, water-cooled, in-line, vertical, direct injection, with turbocharger and aftercooler (air cooled) No. of cylinders – bore × stroke 6 – 140 × 165 l {cc}...
Page 72 SEN00378-02 01 Specification Machine model PC800LC-8 Serial number 50001 and up Boom Bucket Double-acting Double-acting Double-acting Type piston piston piston Inside diameter of cylinder Diameter of piston rod Stroke 1,950 2,250 1,610 Max. distance between pins 4,880 5,525 3,990 Min. distance between pins 2,930 3,275 2,380...
Page 73 01 Specification SEN00378-02 PC850-8 Machine model PC850-8 Serial number 10001 and up Bucket capacity Weight of machine 79,500 Max. digging depth 8,445 Max. vertical wall depth 5,230 Max. digging reach 13,660 Max. reach at ground level 13,400 Max. digging height 11,955 Max.
Page 74 01 Specification Machine model PC850-8 Serial number 10001 and up Model KOMATSU SAA6D140E-5 Type 4-cycle, water-cooled, in-line, vertical, direct injection, with turbocharger and aftercooler (air cooled) No. of cylinders – bore × stroke 6 – 140 × 165 l {cc}...
Page 75 01 Specification SEN00378-02 Machine model PC850-8 Serial number 10001 and up Boom Bucket Double-acting Double-acting Double-acting Type piston piston piston Inside diameter of cylinder Diameter of piston rod Stroke 1,950 2,250 1,610 Max. distance between pins 4,880 5,525 3,990 Min. distance between pins 2,930 3,275 2,380...
Page 76 SEN00378-02 01 Specification PC850SE-8 Machine model PC850SE-8 Serial number 10001 and up Bucket capacity Weight of machine 79,100 Max. digging depth 7,130 Max. vertical wall depth 4,080 Max. digging reach 12,265 Max. reach at ground level 11,945 Max. digging height 11,330 Max.
Page 77 01 Specification SEN00378-02 Machine model PC850SE-8 Serial number 10001 and up Model KOMATSU SAA6D140E-5 Type 4-cycle, water-cooled, in-line, vertical, direct injection, with turbocharger and aftercooler (air cooled) No. of cylinders – bore × stroke 6 – 140 × 165 l {cc}...
Page 78 SEN00378-02 01 Specification Machine model PC850SE-8 Serial number 10001 and up Boom Bucket Double-acting Double-acting Double-acting Type piston piston piston Inside diameter of cylinder Diameter of piston rod Stroke 1,950 1,610 1,420 Max. distance between pins 4,880 3,990 3,910 Min. distance between pins 2,930 2,380 2,490...
Page 79 01 Specification SEN00378-02 Loading shovel specification PC800-8 Machine model PC800-8 (Loading shovel specification) Serial number 50001 and up Bucket capacity Weight of machine 77,000 Max. digging depth 3,605 Max. vertical wall depth — Max. digging reach 10,370 Max. reach at ground level 9,595 Max.
Page 80 01 Specification Machine model PC800-8 Serial number 50001 and up Model KOMATSU SAA6D140E-5 Type 4-cycle, water-cooled, in-line, vertical, direct injection, with turbocharger and aftercooler (air cooled) No. of cylinders – bore × stroke 6 – 140 × 165 l {cc}...
Page 81 01 Specification SEN00378-02 Machine model PC800-8 Serial number 50001 and up Boom Bucket Bottom dump Type Double-acting piston Inside diameter of cylinder Diameter of piston rod Stroke 1,490 1,530 1,550 Max. distance between pins 4,340 4,130 4,275 1,235 Min. distance between pins 2,850 2,600 2,725...
Page 82: Weight Table
SEN00378-02 01 Specification Weight table k This weight table is a guide for use when transporting or handling components. PC800, 800SE-8 Unit: kg Machine model PC800-8 PC800SE-8 Serial number 50001 and up 50001 and up Engine assembly 2,950 2,950 • Engine 1,920 1,920 •...
Page 83 01 Specification SEN00378-02 Unit: kg Machine model PC800-8 PC800SE-8 Serial number 50001 and up 50001 and up Track shoe assembly • Narrow triple grouser shoe (610 mm) 7,550 7,550 • Standard triple grouser shoe (710 mm) 8,350 8,350 • Wide triple grouser shoe (810 mm) 8,880 8,880 •...
Page 84 SEN00378-02 01 Specification PC800LC-8 Unit: kg Machine model PC800LC-8 Serial number 50001 and up Engine assembly 2,950 • Engine 1,920 • Coupling (incl. lubricating piping) • Hydraulic pump (incl. fan pump, lubricating pump) Cooling assembly 1,020 (incl. fan, fan motor, shroud) Radiator assembly •...
Page 85 01 Specification SEN00378-02 Unit: kg Machine model PC800LC-8 Serial number 50001 and up Track shoe assembly • Narrow triple grouser shoe (610 mm) — • Standard triple grouser shoe (710 mm) — • Wide triple grouser shoe (810 mm) 10,020 •...
Page 86 SEN00378-02 01 Specification PC850, 850SE-8 Unit: kg Machine model PC850-8 PC850SE-8 Serial number 10001 and up 10001 and up Engine assembly 2,950 2,950 • Engine 1,920 1,920 • Coupling (incl. lubricating piping) • Hydraulic pump (incl. fan pump, lubricating pump) Cooling assembly 1,020 1,020...
Page 87 01 Specification SEN00378-02 Unit: kg Machine model PC850-8 PC850SE-8 Serial number 10001 and up 10001 and up Track shoe assembly • Narrow triple grouser shoe (610 mm) 7,550 7,550 • Standard triple grouser shoe (710 mm) 8,350 8,350 • Wide triple grouser shoe (810 mm) —...
Page 88: Table Of Fuel, Coolant And Lubricants
SEN00378-02 01 Specification Table of fuel, coolant and lubricants a For details of the notes (Note 1, Note 2, ---) in the table, see the Operation and Maintenance Manual. PC800, 850-8...
Page 89 01 Specification SEN00378-02 Unit: l PC800, PC800SE-8, PC800LC-8, PC850, PC850SE-8 Supply point Specified capacity Refill capacity Engine oil pan Coupling case Swing machinery case (each) 24.5 24.5 Final drive case (each) Hydraulic system Fuel tank — Cooling system — PC800, 850-8...
Page 90 SEN00378-02 01 Specification PC800-8, PC800SE-8, PC800LC-8, PC850-8, PC850SE-8 Hydraulic excavator Form No. SEN00378-02...
Page 91: Structure, Function And Maintenance Standard
SEN00380-01 HYDRAULIC EXCAVATOR PC800-8 PC850-8 PC800SE-8 PC850SE-8 PC800LC-8 Machine model Serial number PC800-8 50001 and up PC800SE-8 50001 and up PC800LC-8 50001 and up PC850-8 10001 and up PC850SE-8 10001 and up Structure, function and maintenance standard Engine and cooling system Engine and cooling system Coupling .................................
Page 92: Coupling
SEN00380-01 10 Structure, function and maintenance standard Engine and cooling system Coupling 1. Coupling case Specifications Lubricating oil: 6.0 l (TO30) 2. Shaft 3. Hub 4. Breather Unit: mm Check item Criteria Remedy Standard size Repair limit Backlash of gear pump Adjust or spline (for SAR375 + 375) 0.074 –...
Page 93: Coupling Lubrication System
SEN00380-01 10 Structure, function and maintenance standard Coupling lubrication system Hydraulic circuit diagram Hydraulic piping diagram 1. Coupling Outline 2. Coupling lubricating pump (FBR002-2.5) Coupling lubricating pump (2) sends lubricating oil 3. Oil strainer from the oil sump under coupling case (1) through oil strainer (3) into the coupling case to lubricate and cool the bearings and splines.
Page 94: Radiator, Oil Cooler
SEN00380-01 10 Structure, function and maintenance standard Radiator, oil cooler PC800, 850-8...
Page 95 SEN00380-01 10 Structure, function and maintenance standard 1. Radiator cap 2. Overflow hose 3. Fan 4. Air breather hose 5. Inlet hose 6. Outlet hose 7. Radiator 8. Aftercooler 9. Fuel cooler 10. Oil cooler 11. Condenser Outline • The reservoir tank is provided for radiator. •...
Page 96 SEN00380-01 10 Structure, function and maintenance standard PC800-8, PC800SE-8, PC800LC-8, PC850-8, PC850SE-8 Hydraulic excavator Form No. SEN00380-01...
Page 97 SEN00381-01 HYDRAULIC EXCAVATOR PC800-8 PC850-8 PC800SE-8 PC850SE-8 PC800LC-8 Machine model Serial number PC800-8 50001 and up PC800SE-8 50001 and up PC800LC-8 50001 and up PC850-8 10001 and up PC850SE-8 10001 and up Structure, function and maintenance standard Power train Power train Power train ..............................
Page 98: Power Train Power Train
SEN00381-01 10 Structure, function and maintenance standard Power train Power train PC800, 850-8...
Page 99 SEN00381-01 10 Structure, function and maintenance standard 1. Idler 11. Coupling 2. Center swivel joint 12. Hydraulic pump (HPV375 + 375) 3. Swing motor (KMF125AB-5) 13. Coupling lubricating pump (FBR00-2.5) 4. L.H. 5-spool control valve 14. Cooling fan pump (LPV90) 5.
Page 100: Swing Machinery
SEN00381-01 10 Structure, function and maintenance standard Swing machinery PC800, 850-8...
Page 101 SEN00381-01 10 Structure, function and maintenance standard 1. Swing pinion (No. of teeth: 13) 2. Cover 3. Case 4. Coupling 5. No. 2 planetary gear (No. of teeth: 38) 6. Ring gear (No. of teeth: 97) 7. No. 1 planetary gear (No.
Page 102: Swing Circle
SEN00381-01 10 Structure, function and maintenance standard Swing circle 1. Swing circle inner race (No. of teeth: 112) Specifications 2. Ball Reduction ratio: – 8.615 – 3. Swing circle outer race Amount of grease: 65 l (G2-LI) a. Inner race soft zone "S" position b.
Page 103 This Page Intentionally left Blank...
Page 104: Final Drive
SEN00381-01 10 Structure, function and maintenance standard Final drive 1. Level plug Specifications 2. Drain plug 13 + 68 19 + 69 Reduction ratio: – × × 3. Cover 4. No. 2 planetary carrier = –104.802 5. No. 2 sun gear (No. of teeth: 19) 6.
Page 105 SEN00381-01 10 Structure, function and maintenance standard Unit: mm Check item Criteria Remedy Standard clearance Clearance limit Backlash between No. 2 planetary carrier and case 0.08 – 0.27 — Backlash between drive gear 0.21 – 0.57 — and No. 1 planetary carrier Backlash between No.
Page 106: Sprocket
SEN00381-01 10 Structure, function and maintenance standard Sprocket Unit: mm Check item Criteria Remedy Standard size Repair limit Wear of tooth tip 403.6 391.6 Build-up welding Thickness of tooth root 28.4 22.4 or replace Width of tooth Wear of tooth shape Repair limit: 6 (measure with sprocket tooth shape) PC800, 850-8...
Page 107 SEN00381-01 10 Structure, function and maintenance standard Sprocket tooth shape of full scale a The above drawing is reduced to 50%. Enlarge it to 200% to return it to the full scale and make a copy on an OHP sheet. PC800, 850-8...
Page 108 SEN00381-01 10 Structure, function and maintenance standard PC800-8, PC800SE-8, PC800LC-8, PC850-8, PC850SE-8 Hydraulic excavator Form No. SEN00381-01...
Page 109: Undercarriage And Frame
SEN00382-01 HYDRAULIC EXCAVATOR PC800-8 PC850-8 PC800SE-8 PC850SE-8 PC800LC-8 Machine model Serial number PC800-8 50001 and up PC800SE-8 50001 and up PC800LC-8 50001 and up PC850-8 10001 and up PC850SE-8 10001 and up Structure, function and maintenance standard Undercarriage and frame Undercarriage and frame Track frame and recoil spring .........................
Page 110: Track Frame And Recoil Spring
SEN00382-01 10 Structure, function and maintenance standard Undercarriage and frame Track frame and recoil spring a The diagram shows the PC800-8. 1. Idler • The dimensions and number of track rollers may 2. Track frame differ according to the model, but the basic struc- 3.
Page 111 SEN00382-01 10 Structure, function and maintenance standard Standard shoe Unit: mm Model PC800-8 PC800SE-8 PC800LC-8 PC850-8 PC850SE-8 Item Shoe width (double shoe) Link pitch 260.6 260.6 260.6 260.6 260.6 No. of shoes (each side) Unit: mm Check item Criteria Remedy Standard Tolerance Repair limit...
Page 112: Idler
SEN00382-01 10 Structure, function and maintenance standard Idler PC800, 850-8...
Page 113 SEN00382-01 10 Structure, function and maintenance standard Unit: mm Check item Criteria Remedy Standard size Repair limit Outside diameter of protruding part — Outside diameter of tread sur- face Rebuild or Height of tread 22.5 28.5 replace Thickness of tread —...
Page 114: Carrier Roller
SEN00382-01 10 Structure, function and maintenance standard Carrier roller Unit: mm Check item Criteria Remedy Standard size Repair limit Outside diameter of flange — Outside diameter of tread Rebuild or replace Width of tread — Thickness of tread 57.6 47.6 Width of flange —...
Page 115 This Page Intentionally left Blank...
Page 116: Track Roller
SEN00382-01 10 Structure, function and maintenance standard Track roller PC800, 850-8...
Page 117 SEN00382-01 10 Structure, function and maintenance standard Unit: mm Check item Criteria Remedy Standard size Repair limit Outside diameter of outer flange — Outside diameter of inner — flange (double flange) Outside diameter of tread Thickness of tread 73.7 67.7 Overall width —...
Page 118: Track Shoe
SEN00382-01 10 Structure, function and maintenance standard Track shoe a P portion shows the link of bushing press-fitting end. PC800, 850-8...
Page 119 SEN00382-01 10 Structure, function and maintenance standard Unit: mm Check item Criteria Remedy Standard size Repair limit Link pitch 260.6 263.6 Reverse or replace Standard size When turned Bushing outside diameter 87.9 82.9 Standard size Repair limit Thickness of bushing metal Repair or 15.8 10.3...
Page 120 SEN00382-01 10 Structure, function and maintenance standard Unit: mm Check item Criteria Remedy Tightening torque Additional tightening a. Regular (Nm {kgm}) angle (deg.) link 784±78 {80±8} 120±10 Shoe bolt Retighten Tightening torque Additional tightening Lower limit torque b. Master (Nm {kgm}) angle (deg.) (Nm {kgm}) link...
Page 121: Double Shoe
SEN00382-01 10 Structure, function and maintenance standard Double shoe Unit: mm Check item Criteria Remedy Standard size Repair limit Height Height Thickness Rebuild or Length at bottom replace — Length at top Standard size Repair limit Thickness PC800, 850-8...
Page 122 SEN00382-01 10 Structure, function and maintenance standard PC800-8, PC800SE-8, PC800LC-8, PC850-8, PC850SE-8 Hydraulic excavator Form No. SEN00382-01...
Page 123: Hydraulic System, Part 1
SEN00383-03 HYDRAULIC EXCAVATOR PC800-8 PC850-8 PC800SE-8 PC850SE-8 PC800LC-8 Machine model Serial number PC800-8 50001 and up PC800SE-8 50001 and up PC800LC-8 50001 and up PC850-8 10001 and up PC850SE-8 10001 and up Structure, function and maintenance standard Hydraulic system, Part 1 Hydraulic system, Part 1 Hydraulic piping drawing ..........................
Page 124: Hydraulic Piping Drawing
SEN00383-03 10 Structure, function and maintenance standard Hydraulic system, Part 1 Hydraulic piping drawing 1. Bucket cylinder 2. Arm cylinder 3. Boom cylinder 4. Center swivel joint 5. Swing motor 6. Quick return valve (Arm) 7. Oil cooler 8. Cooling fan motor 9.
Page 125 SEN00383-03 10 Structure, function and maintenance standard PC800, 850-8...
Page 126: Hydraulic Tank, Hydraulic Filter
SEN00383-03 10 Structure, function and maintenance standard Hydraulic tank, hydraulic filter PC800, 850-8...
Page 127 SEN00383-03 10 Structure, function and maintenance standard Specifications 1. Hydraulic filter : 729 l Tank capacity 1A. Bypass valve Amount of oil inside tank : 482 l (at H level) 1B. Strainer 1C. Element Pressure valve 1D. Cooler check valve Relief cracking pressure : 16.7 ±...
Page 128: Hydraulic Pump
SEN00383-03 10 Structure, function and maintenance standard Hydraulic pump Type: HPV375+375 PC800, 850-8...
Page 129 SEN00383-03 10 Structure, function and maintenance standard Outline • The pump unit is composed of 2 variable-capac- ity swash plate-type piston pumps, VC valves, EPC valves and self pressure reducing valves. CE1 : Front EPC output pressure pick-up port CE2 : Rear EPC output pressure pick-up port CH1 : Front servo actuator pick-up port CH2 : Rear servo actuator pick-up port CP1 : Front pump discharge pressure pick-up port...
Page 130 SEN00383-03 10 Structure, function and maintenance standard PC800, 850-8...
Page 131 SEN00383-03 10 Structure, function and maintenance standard 1. Front shaft 9. Valve plate 2. Cradle 10. End cap 3. Front case 11. Rear case 4. Rocker cam 12. Rear shaft 5. Shoe 13. Bevel gear 6. Piston 14. lmpeller pump 7.
Page 132 SEN00383-03 10 Structure, function and maintenance standard Function • Piston (6) carries out relative movement in the axial direction inside each cylinder chamber of • The engine speed and torque are transmitted to cylinder block (7). the shaft of this pump. Then, this pump converts •...
Page 133 SEN00383-03 10 Structure, function and maintenance standard Operation of pump • Cylinder block (7) rotates together with shaft (1), and shoe (5) slides on flat surface (A). • When this happens, rocker cam (4) moves along cylindrical surface (B), so angle (a) between center line (X) of rocker cam (4) and the axial di- rection of cylinder block (7) changes.
Page 134 SEN00383-03 10 Structure, function and maintenance standard Control of delivery • If the swash plate angle (a) becomes larger, the • The relationship in the size of pressure (PH) at difference between volumes (E) and (F) be- the small diameter piston end and pressure (PS) comes larger and pump delivery (Q) increases.
Page 135 SEN00383-03 10 Structure, function and maintenance standard Pump controller System diagram PC800, 850-8...
Page 136 SEN00383-03 10 Structure, function and maintenance standard Pump control signal PC800, 850-8...
Page 137 SEN00383-03 10 Structure, function and maintenance standard Servo valve CE : EPC output pressure pick-up port VC valve CH : Servo actuator pressure pick-up port EPC valve CS : Pump control pressure pick-up port Spool PA : Main pump pressure port Sleeve PH : Servo actuator port Spring...
Page 138 SEN00383-03 10 Structure, function and maintenance standard 1. VC valve Outline Move of servo piston to the maximum side • VC valve controls servo piston (4) position (pump • As the EPC valve output pressure increases, delivery) responding to the EPC valve output sleeve (2) compresses spring (1) to move up- pressure (controller command current).
Page 139 SEN00383-03 10 Structure, function and maintenance standard Move of servo piston to the minimum side • As the EPC valve output pressure decreases, sleeve (2) elongates spring (1) to move down- ward. • Port (B) of sleeve (2) and spool (3) is opened and port (A) is closed.
Page 140 SEN00383-03 10 Structure, function and maintenance standard 2. Servo piston Outline Operation of servo piston • Port (PA) pressure or port (PR) pressure, which- (Movement of swash plate to intermediate point ever is higher, is applied to port (PH) by the shut- and mechanism of stopping servo piston) tle valve.
Page 141 SEN00383-03 10 Structure, function and maintenance standard When EPC valve is not operated • Sleeve (4) of VC valve (1) does not operate if the pilot pressure from EPC valve (2) is not present. • In this case, ports (PH) and (PS) are connected and the connection between ports (PS) and (TD) is cut off.
Page 142 SEN00383-03 10 Structure, function and maintenance standard 3. EPC valve C : To VC valve Body P : From pump Spool T : To pump case drain Spring Coil Plunger Connector PC800, 850-8...
Page 143 SEN00383-03 10 Structure, function and maintenance standard Function • The EPC valve consists of the proportional sole- noid portion and the hydraulic valve portion. • When it receives signal current (i) from the con- troller, it generates the EPC output pressure in proportion to the size of the signal, and outputs it to the VC valve.
Page 144 SEN00383-03 10 Structure, function and maintenance standard 2. When signal current is very small (coil is energized) • When a very small signal current flows to coil (5), coil (5) is energized, and a propulsion force is generated on the left side of plunger (6). •...
Page 145 SEN00383-03 10 Structure, function and maintenance standard Self pressure reducing valve Function • This valve reduces the discharge pressure of the fan pump and supplies it as the control pressure for the solenoid valve, EPC valve, etc. Operation 1. When engine is stopped •...
Page 146 SEN00383-03 10 Structure, function and maintenance standard 3. When load pressure (P3F) is high • Change in the fan revolution speed increases load pressure (P3) and, as the result, pump de- livery is increased. • Since pressure (P3F) increases, [(φd area × P3F pressure) >...
Page 147 SEN00383-03 10 Structure, function and maintenance standard PC800, 850-8...
Page 148: Cooling Fan Pump
SEN00383-03 10 Structure, function and maintenance standard Cooling fan pump LPV90 1. Piston pump P1 : Pump discharge port PD1 : Pump drain port 2. Servo valve PS : Pump suction port PD2 : Pump drain port 3. Gear pump (coupling lubrication) P : EPC valve basic pressure PAG: Gear pump discharge P1C : Pump pressure detection port...
Page 149 SEN00383-03 10 Structure, function and maintenance standard 1. Shaft 7. Cylinder block 2. Oil seal 8. Valve plate 3. Case 9. Spring 4. Rocker cam 10. Servo piston 5. Shoe 11. Ball 6. Piston 12. End cap PC800, 850-8...
Page 150 SEN00383-03 10 Structure, function and maintenance standard Function Structure • The rotation and torque of the engine are trans- • Cylinder block (7) is supported on shaft (1) mitted to the shaft of this pump and converted through spline a. Shaft (1) is supported by the into hydraulic energy in this pump.
Page 151 SEN00383-03 10 Structure, function and maintenance standard Operation 1. Operation of pump • Cylinder block (7) rotates together with shaft (1) and shoe (5) slides on plane A. At this time, rock- er cam (4) tilts around ball (11). As a result, angle (a) between center line X of rocker cam (4) and the axis of cylinder block (7) changes.
Page 152 SEN00383-03 10 Structure, function and maintenance standard 2. Control of discharge • If swash plate angle (a) is increased, the differ- ence between volumes E and F is increased, and so discharge Q is increased. Swash plate angle (a) is changed with servo piston (10). •...
Page 153 SEN00383-03 10 Structure, function and maintenance standard Servo valve P : EPC valve basic pressure : Drain PE : Control piston pressure PH : Pump discharge pressure 1. Plug 2. Lever 3. Retainer 4. Seat 5. Spool 6. Piston 7. Sleeve PC800, 850-8...
Page 154 SEN00383-03 10 Structure, function and maintenance standard Function • The servo valve controls the current input to the • The relationship between the input current to the EPC valve and the swash plate angle of the EPC valve and the output pressure of EPC valve pump so that they will be related as shown in the F is as follows.
Page 155 SEN00383-03 10 Structure, function and maintenance standard Operation • The output pressure of the EPC valve is applied to the piston chamber to push piston (6). Piston (6) pushes spool (5) until it is balanced with the spring. • Then, the land of the servo piston pressure pas- sage is connected to the pump discharge pas- sages by the cut of spool (5) and the discharge pressure is led to the servo piston.
Page 156: Cooling Fan Motor
SEN00383-03 10 Structure, function and maintenance standard Cooling fan motor Type: LMF110 Specifications : From fan pump Type: LMF110 TC : To tank Capacity: 110.7 cm /rev : From oil cooler to tank Rated speed: 1,050 rpm Rated flow rate: 120 l/min Cracking pressure of check valve: 76.5 kPa {0.78 kg/cm Cracking pressure of safety valve:...
Page 157 SEN00383-03 10 Structure, function and maintenance standard 1. Output shaft 9. Center spring 2. Case 10. Check valve spring 3. Thrust plate 11. Check valve 4. Shoe 12. Pilot valve 5. Piston 13. Reversible valve spool 6. Cylinder block 14. Safety valve 7.
Page 158 SEN00383-03 10 Structure, function and maintenance standard 1. Hydraulic motor unit Function • This hydraulic motor is called a swash plate type axial piston motor. It converts the energy of the pressurized oil sent from the hydraulic pump into rotary motion. Principle of operation •...
Page 159 SEN00383-03 10 Structure, function and maintenance standard 2. Suction valve Function • If the fan pump stops, the hydraulic oil does not flow into the motor. Since the motor continues revolution because of the force of inertia, howev- er, the pressure on the outlet side of the motor rises.
Page 160 SEN00383-03 10 Structure, function and maintenance standard 3. Operation of reversible valve 1) When ON-OFF solenoid for reversible valve is turned OFF • If ON-OFF solenoid (1) for reversible valve is turned "OFF", the hydraulic oil from the pump is blocked by ON-OFF reversible valve (2) and port C is connected to the tank circuit.
Page 161 SEN00383-03 10 Structure, function and maintenance standard 4. Safety valve Function • When the engine is started, the pressure in port P of the fan motor is heightened in some cases. • Safety valve (1) is installed to protect the fan sys- tem circuit.
Page 162 SEN00383-03 10 Structure, function and maintenance standard PC800-8, PC800SE-8, PC800LC-8, PC850-8, PC850SE-8 Hydraulic excavator Form No. SEN00383-03...
Page 163: Hydraulic System, Part 2
SEN00384-02 HYDRAULIC EXCAVATOR PC800-8 PC850-8 PC800SE-8 PC850SE-8 PC800LC-8 Machine model Serial number PC800-8 50001 and up PC800SE-8 50001 and up PC800LC-8 50001 and up PC850-8 10001 and up PC850SE-8 10001 and up Structure, function and maintenance standard Hydraulic system, Part 2 Hydraulic system, Part 2 Motor grease pump ............................
Page 164 SEN00384-02 10 Structure, function and maintenance standard Solenoid valve .............................. 50 Hydraulic cylinder ............................58 PC800, 850-8...
Page 165 10 Structure, function and maintenance standard SEN00384-02 PC800, 850-8...
Page 166: Motor Grease Pump
SEN00384-02 10 Structure, function and maintenance standard Hydraulic system, Part 2 Motor grease pump Function 1. Motor grease pump unit • The pump unit is divided into air chamber (4) and 2. Valve grease chamber (6). As the grease level in 3.
Page 167: Return Oil Filter
10 Structure, function and maintenance standard SEN00384-02 Return oil filter 1. Cover Outline 2. Spring There are two return oil filters installed to the rear face 3. Bypass valve of the hydraulic tank. They remove the dirt and dust in 4.
Page 168: Line Oil Filter
SEN00384-02 10 Structure, function and maintenance standard Line oil filter 1. Element 2. Body 3. Cover 1. Bracket 2. Cartridge 3. Safety valve PC800, 850-8...
Page 169: Drain Oil Filter
10 Structure, function and maintenance standard SEN00384-02 Drain oil filter 1. Cartridge 2. Safety valve 3. Bracket PC800, 850-8...
Page 170: 5-Spool Control Valve
SEN00384-02 10 Structure, function and maintenance standard L.H. 5-Spool control valve : From front pump : To tank (Main drain) A1 : To boom cylinder bottom A2 : To swing motor port MA (Swing RIGHT) A3 : To arm cylinder bottom A4 : To bucket cylinder bottom A5 : To travel motor (Left travel port P2) B1 : Plug...
Page 171 10 Structure, function and maintenance standard SEN00384-02 PC800, 850-8...
Page 172 SEN00384-02 10 Structure, function and maintenance standard 1. Main relief valve 7. Spool return spring 13. Throttle valve 2. Spool (boom Hi) 8. Valve body 14. Check valve spring 3. Spool (swing) 9. Jet sensor orifice 15. Check valve 4. Spool (arm Lo) 10.
Page 173 10 Structure, function and maintenance standard SEN00384-02 PC800, 850-8...
Page 174 SEN00384-02 10 Structure, function and maintenance standard Unit: mm Check item Criteria Remedy Standard size Repair limit Free length Installation Installation Installation Main relief valve, main valve Free length × OD length load load spring 394.2 N 315.2 N 34.7 × 10.1 32.5 —...
Page 175 10 Structure, function and maintenance standard SEN00384-02 PC800, 850-8...
Page 176: 4-Spool Control Valve
SEN00384-02 10 Structure, function and maintenance standard R.H. 4-Spool control valve : From rear pump : To tank A1 : To travel motor (Right travel port P1) A2 : To boom cylinder head A3 : To bucket cylinder bottom A4 : To arm cylinder head B1 : To travel motor (Right travel port P2) B2 : To boom cylinder bottom B3 : To bucket cylinder head...
Page 177 10 Structure, function and maintenance standard SEN00384-02 PC800, 850-8...
Page 178 SEN00384-02 10 Structure, function and maintenance standard 1. Main relief valve 6. Spool return spring 12. Check valve 2. Spool (R.H. travel) 7. Valve body 13. Check valve spring 3. Spool (boom Lo) 8. Jet sensor orifice 14. Straight-travel valve 4.
Page 179 10 Structure, function and maintenance standard SEN00384-02 PC800, 850-8...
Page 180 SEN00384-02 10 Structure, function and maintenance standard Unit: mm Check item Criteria Remedy Standard size Repair limit Free length Installation Installation Installation Main relief valve, main valve Free length × OD length load load spring 394.2 N 315.2 N 34.7 × 10.1 32.5 —...
Page 181 10 Structure, function and maintenance standard SEN00384-02 J/S differential pressure sensor • The J/S differential pressure sensor is installed to the each control valve on right and left sides. • This sensor senses differential pressure be- tween ports (NCA) and (NCB) and outputs it as a voltage.
Page 182: Straight-Travel Valve
SEN00384-02 10 Structure, function and maintenance standard Straight-travel valve P :From pump (Rear) PP:From straight travel changeover solenoid valve PT:Drain P1 :From pump (Front) P2 :To left travel (Left 5-spool control valve) P3 :To bucket and boom P4 :To arm PC800, 850-8...
Page 183 10 Structure, function and maintenance standard SEN00384-02 1. Orifice 2. Check valve 3. Spring 4. Spool return spring 5. Body 6. Spool 7. Cover PC800, 850-8...
Page 184 SEN00384-02 10 Structure, function and maintenance standard Function • When the travel is operated at the same time as the boom, arm, or bucket, the pressure oil flow- ing to the left and right travel circuits is divided and sent to the boom, arm, or bucket circuit. If the oil in one travel circuit is divided off, the amount of oil supplied to the travel motor will be less than in the travel circuit which is not divided,...
Page 185: Swing Motor
10 Structure, function and maintenance standard SEN00384-02 Swing motor KMF125AB-5 B : From swing brake solenoid valve Specifications : From back pressure compensation valve Model : KMF125AB-5 : To tank Theoretical displacement : 125.0 cm /rev MA : From control valve Safety valve set pressure: 27.9 MPa {285 kg/cm MB : From control valve Rated revolving speed...
Page 186 SEN00384-02 10 Structure, function and maintenance standard 1. Brake spring 7. Brake piston 13. Center spring 2. Drive shaft 8. Housing 14. Safety valve 3. Spacer 9. Piston 15. Check valve 4. Case 10. Cylinder block 16. Check valve spring 5.
Page 187 10 Structure, function and maintenance standard SEN00384-02 Unit: mm Check item Criteria Remedy Standard size Repair limit Free length Installed Installed Installed × Outside Free length Check valve spring length load load If damaged or diameter deformed, 3.5 N 2.8 N replace spring 62.5 ×...
Page 188 SEN00384-02 10 Structure, function and maintenance standard Relief valve portion 1. Outline The relief portion consists of check valves (2) and (3), shuttle valves (4) and (5), and relief valve (1). 2. Function When the swing is stopped, the outlet port circuit of the motor from the control valve is closed, but the motor continues to rotate under inertia, so the pressure at the output side of the motor...
Page 189 10 Structure, function and maintenance standard SEN00384-02 Operation of swing brake 1) When swing brake solenoid valve is de-ener- gized If the swing brake solenoid valve is de-ener- gized, the flow of pressurized oil from the control pump is shut off, and port B is connected to the tank circuit.
Page 190: Center Swivel Joint
SEN00384-02 10 Structure, function and maintenance standard Center swivel joint 1. Cover 2. Body 3. Slipper seal 4. Oil seal 5. Shaft Unit: mm Check item Criteria Remedy Standard size Standard clearance Clearance limit Clearance between rotor and Replace shaft 0.056 –...
Page 191: Travel Motor
10 Structure, function and maintenance standard SEN00384-02 Travel motor MSF-340VP-EH 1. Travel selector valve Specifications 2. Motor Model : MSF-340VP-EH 3. Travel brake valve Theoretical delivery : 1st 337.2 cc/rev : 2nd 12.6 cc/rev P1: From control valve Rated pressure : 31.4 MPa {320 kg/cm P2: From control valve Rated speed...
Page 192 SEN00384-02 10 Structure, function and maintenance standard 1. Travel motor, travel speed selector valve, relief valve 1. Travel speed selector valve 2. Relief valve 1a. Spool 2a. Shockless piston 1b. Spring 2b. Poppet PC800, 850-8...
Page 193 10 Structure, function and maintenance standard SEN00384-02 3. Rear cover 10. Piston assembly 17. Plate 4. Collar 11. Case 18. Brake piston 5. Valve plate 12. Shaft 19. Spring 6. Cylinder block assembly 13. Bearing collar 7. Piston assembly 14. Rocker cam 8.
Page 194 SEN00384-02 10 Structure, function and maintenance standard 1-1 Motor • There are 9 pistons (7) assembled in cylinder block (6). The end face of the cylinder block has a spherical surface and is in contact with valve plate (5), which has two half-moon shaped ports (divider valve for high/low speed selector).
Page 195 10 Structure, function and maintenance standard SEN00384-02 1-2 Speed selector valve Operation 1) At low speed (pilot pressure PI = 0) • When pilot pressure PI from the control pump is 0, spool (1a) of travel speed selector valve (1) is not switched.
Page 196 SEN00384-02 10 Structure, function and maintenance standard 2) At high speed (automatic 2nd) • When the pilot signal is ON, pilot pressure PI hydraulic force from propulsion force Fc of from the control pump acts on travel speed se- control piston (10). It rotates and holds the lector valve (1) and the capacity is automatically moment balance at the high speed surface changed by the drive pressure of the travel mo-...
Page 197 10 Structure, function and maintenance standard SEN00384-02 1-3 Parking brake The parking brake is a hydraulic release, wet type, multiple disc negative brake. The release pressure employs a self-pressure release method using the travel motor drive pressure through the oil passage in the counterbalance valve spool of the travel brake valve.
Page 198 SEN00384-02 10 Structure, function and maintenance standard 1-4 Relief valve 1. Shockless piston 2. Poppet 3. Poppet orifice 4. Relief housing orifice 5. Piston stroke Function In addition to the pressure control function, this relief valve has a shockless function (2-stage pressure increase function).
Page 199 10 Structure, function and maintenance standard SEN00384-02 1-5 Travel brake valve Function 1. Cap assembly • The brake valve consists of counterbalance 2. Return spring valve (3) and check valve (4). 3. Counterbalance valve • The counterbalance valve acts to prevent the 4.
Page 200 SEN00384-02 10 Structure, function and maintenance standard Operation when oil is supplied • When the travel lever is operated, the pressu- rized oil from the control valve is supplied to port P1. It pushes open check valve (5a) and flows from motor inlet port M1 to motor outlet port M2.
Page 201: Ppc Accumulator
10 Structure, function and maintenance standard SEN00384-02 PPC accumulator 1. Gas plug 2. Shell 3. Poppet 4. Holder 5. Bladder 6. Oil port Specifications Type of gas : Nitrogen gas Gas volume : 300 cc Max. actuating pressure: 3.1 MPa {32 kg/cm Min.
Page 202: Work Equipment, Swing Ppc Valve
SEN00384-02 10 Structure, function and maintenance standard Work equipment, swing PPC valve P. From control pump P2. Left: Arm OUT, Right: Boom LOWER T. To hydraulic tank P3. Left: Swing LEFT, Right: Bucket DUMP P1. Left: Arm IN, Right: Boom RAISE P4.
Page 203 10 Structure, function and maintenance standard SEN00384-02 1. Spool 6. Nut (for connecting lever) 2. Metering spring 7. Joint 3. Centering spring 8. Plate 4. Piston 9. Retainer 5. Disc 10. Body PC800, 850-8...
Page 204 SEN00384-02 10 Structure, function and maintenance standard Unit: mm Check item Criteria Remedy Standard size Repair limit Free length Installation Installation Installation Free length Centering spring (for P3, P4) × OD length load load Replace 17.6 N 13.7 N 42.48 × 15.5 spring if —...
Page 205 10 Structure, function and maintenance standard SEN00384-02 Operation 1) At neutral Ports A and B of the control valve and ports P1, P2, P3, and P4 of the PPC valve are connected to drain chamber D at the bottom. 2) Fine control (neutral o fine control) When piston (4) starts to be pushed by disc (5), retainer (9) is pushed.
Page 206 SEN00384-02 10 Structure, function and maintenance standard 3) Fine control (control lever returned) When disc (5) starts to be returned, spool (1) is pushed up by the force of centering spring (3) and the pressure at port P1. Because of this, port P1 is connected to drain chamber D, and the pressurized oil at port P1 is released.
Page 207 10 Structure, function and maintenance standard SEN00384-02 PC800, 850-8...
Page 208: Travel Ppc Valve
SEN00384-02 10 Structure, function and maintenance standard Travel PPC valve 1. Plate 5. Centering spring 2. Body 6. Metering spring 3. Piston 7. Valve 4. Collar 8. Bolt PC800, 850-8...
Page 209 10 Structure, function and maintenance standard SEN00384-02 P : From control pump T : To tank P1: Left travel forward P2: Left travel reverse P3: Right travel forward P4: Right travel reverse Unit: mm Check item Criteria Remedy Basic dimension Allowable limit Free length Installed...
Page 210 SEN00384-02 10 Structure, function and maintenance standard Operation 1. At neutral • Ports A and B of the control valve and ports P1 and P2 of the PPC valve are connected to drain chamber D through fine control hole f in spool (1).
Page 211 10 Structure, function and maintenance standard SEN00384-02 3. Fine control (control lever returned) • When disc (5) starts to be returned, spool (1) is pushed up by the force of centering spring (3) and the pressure at port P1. Because of this, fine control hole f is connected to drain chamber D, and the pressurized oil at port P1 is released.
Page 212: Solenoid Valve
SEN00384-02 10 Structure, function and maintenance standard Solenoid valve For swing brake, travel speed, machine push-up, heavy lift, straight travel 1. Unused : To tank 2. Travel speed solenoid valve A2 : To left and right travel motor 3. Swing brake solenoid valve A3 : To swing motor 4.
Page 213 10 Structure, function and maintenance standard SEN00384-02 1. Connector 2. Movable core 3. Coil 4. Cage 5. Spool 6. Block 7. Spring Operation When solenoid is de-energized • When the signal current does not flow from the PPC lock switch or swing lock switch, solenoid (3) is de-energized.
Page 214 SEN00384-02 10 Structure, function and maintenance standard For PPC lock (under cab) For PPC lock 1. PPC lock solenoid valve T : To tank A : To port P of work equipment PPC valve To port P of travel PPC valve P : From control pump PC800, 850-8...
Page 215 10 Structure, function and maintenance standard SEN00384-02 1. Connector 7. Spool 2. Solenoid 8. Body 3. Variable iron core 9. Plug 4. Body 10. Spring 5. Plug 11. Spool 6. Spring Operation When solenoid is de-energized • No signal current flows from the controller, so so- lenoid (2) is de-energized.
Page 216 SEN00384-02 10 Structure, function and maintenance standard For swing priority (On left side of machine body) 1. Swing priority solenoid valve T : To tank A : To 5-spool control valve P : From control pump PC800, 850-8...
Page 217 10 Structure, function and maintenance standard SEN00384-02 1. Connector 2. Movable iron core 3. Coil 4. Spool 5. Body 6. Spring 7. Plug Operation When solenoid is de-energized • The signal current does not flow from the control- ler, so coil (3) is de-energized. For this reason, spool (4) is returned to the neu- tral position by spring (6).
Page 218: Quick Return Valve
SEN00384-02 10 Structure, function and maintenance standard Quick return valve Function Operation • When arm OUT is operated, this valve reduces 1. Arm at OUT the pressure loss of the large amount of oil re- When arm OUT is operated, the pilot pressure turning from the cylinder bottom.
Page 219 10 Structure, function and maintenance standard SEN00384-02 2. Arm at HOLD The oil that has flowed through orifice a in valve (2) is closed by pilot piston (1). At the same time, the hold pressure at the bottom end of the arm acts in the bottom direction on ring-shaped area C (= Area of ød1 –...
Page 220: Hydraulic Cylinder
SEN00384-02 10 Structure, function and maintenance standard Hydraulic cylinder Backhoe specification PC800, 800LC, 850-8 STD Boom cylinder Arm cylinder Bucket cylinder PC800, 850-8...
Page 221 10 Structure, function and maintenance standard SEN00384-02 Unit: mm Check item Criteria Remedy Tolerance Name of Standard Standard Clearance cylinder size clearance limit Shaft Hole Clearance –0.043 +0.256 0.082 – Boom 0.062 between –0.106 +0.039 0.362 Replace piston rod and bushing –0.043 +0.256...
Page 222 SEN00384-02 10 Structure, function and maintenance standard PC800SE, 850SE-8 Boom cylinder Arm cylinder Bucket cylinder PC800, 850-8...
Page 223 10 Structure, function and maintenance standard SEN00384-02 Unit: mm Check item Criteria Remedy Tolerance Name of Standard Standard Clearance cylinder size clearance limit Shaft Hole Clearance –0.043 +0.256 0.082 – Boom 0.062 between –0.106 +0.039 0.362 Replace piston rod and bushing –0.036 +0.263...
Page 224 SEN00384-02 10 Structure, function and maintenance standard Loading shovel specification PC800-8 Boom cylinder Arm cylinder Bucket cylinder PC800, 850-8...
Page 225 10 Structure, function and maintenance standard SEN00384-02 Bottom dump cylinder Unit: mm Check item Criteria Remedy Tolerance Name of Standard Standard Clearance cylinder size clearance limit Shaft Hole –0.043 +0.256 0.082 – Boom 0.662 –0.106 +0.039 0.362 Clearance between Replace –0.043 +0.256 0.082 –...
Page 226 SEN00384-02 10 Structure, function and maintenance standard PC800-8, PC800SE-8, PC800LC-8, PC850-8, PC850SE-8 Hydraulic excavator Form No. SEN00384-02...
Page 227: Work Equipment
SEN00385-01 HYDRAULIC EXCAVATOR PC800-8 PC850-8 PC800SE-8 PC850SE-8 PC800LC-8 Machine model Serial number PC800-8 50001 and up PC800SE-8 50001 and up PC800LC-8 50001 and up PC850-8 10001 and up PC850SE-8 10001 and up Structure, function and maintenance standard Work equipment Work equipment Work equipment..............................
Page 228: Work Equipment
SEN00385-01 10 Structure, function and maintenance standard Work equipment Work equipment Backhoe specification PC800-8 PC800LC-8 PC800, 850-8...
Page 229 SEN00385-01 10 Structure, function and maintenance standard Unit: mm Check item Criteria Remedy Tolerance Standard Standard Clearance Clearance between bushing size clearance limit Shaft Hole and mounting pin of boom and revolving frame –0.043 +0.542 0.485 – –0.106 +0.442 0.648 Clearance between bushing –0.043 +0.542...
Page 230 SEN00385-01 10 Structure, function and maintenance standard PC800SE-8 PC850, 850SE-8 PC800, 850-8...
Page 231 SEN00385-01 10 Structure, function and maintenance standard Unit: mm Check item Criteria Remedy Tolerance Standard Standard Clearance Clearance between bushing size clearance limit Shaft Hole and mounting pin of boom and revolving frame –0.043 +0.542 0.485 – –0.106 +0.442 0.648 Clearance between bushing –0.043 +0.542...
Page 232 SEN00385-01 10 Structure, function and maintenance standard Loading shovel specification PC800-8 PC800, 850-8...
Page 233 SEN00385-01 10 Structure, function and maintenance standard Unit: mm Check item Criteria Remedy Tolerance Standard Standard Clearance Clearance between boom- size clearance limit Shaft Hole revolving frame mounting pin and bushing –0.043 +0.542 0.485 – –0.106 +0.442 0.648 Clearance between boom- –0.043 +0.542 0.485 –...
Page 234: Dimensions Of Work Equipment
SEN00385-01 10 Structure, function and maintenance standard Dimensions of work equipment 1. Arm PC800, 850-8...
Page 235 SEN00385-01 10 Structure, function and maintenance standard Unit: mm Model PC800SE-8 PC800-8 PC850-8 PC850SE-8 PC850SE-8 with 3.6 m with 3.6 m with 4.6 m with 5.6 m with 2.9 m with 3.6 m heavy-duty short arm ø115 ø115 ø115 ø110 ø110 ø110 ø140...
Page 236 SEN00385-01 10 Structure, function and maintenance standard 2. Bucket PC800, 850-8...
Page 237 SEN00385-01 10 Structure, function and maintenance standard Unit: mm Model PC800SE-8 PC800-8 PC850-8 PC850SE-8 PC850SE-8 with 4.0 m with 3.1 m with 3.4 m with 4.0 m with 4.3 m with 4.5 m with 2.8 m Light-load bucket bucket bucket bucket bucket bucket...
Page 238 SEN00385-01 10 Structure, function and maintenance standard PC800-8, PC800SE-8, PC800LC-8, PC850-8, PC850SE-8 Hydraulic excavator Form No. SEN00385-01...
Page 239: Cab And Its Attachments
SEN00396-01 HYDRAULIC EXCAVATOR PC800-8 PC850-8 PC800SE-8 PC850SE-8 PC800LC-8 Machine model Serial number PC800-8 50001 and up PC800SE-8 50001 and up PC800LC-8 50001 and up PC850-8 10001 and up PC850SE-8 10001 and up Structure, function and maintenance standard Cab and its attachments Cab and its attachments Air conditioner piping ............................
Page 240: Air Conditioner Piping
SEN00396-01 10 Structure, function and maintenance standard Cab and its attachments Air conditioner piping For the electric circuit diagram of the air conditioner, see “Others”. 1. Air conditioner unit A : Fresh air 2. Duct B : Recirculated air 3. Refrigerant piping C : Hot air/cold air 4.
Page 241 This Page Intentionally left Blank...
Page 242 SEN00396-01 10 Structure, function and maintenance standard PC800-8, PC800SE-8, PC800LC-8, PC850-8, PC850SE-8 Hydraulic excavator Form No. SEN00396-01...
Page 243: Electrical System
SEN00386-03 HYDRAULIC EXCAVATOR PC800-8 PC850-8 PC800SE-8 PC850SE-8 PC800LC-8 Machine model Serial number PC800-8 50001 and up PC800SE-8 50001 and up PC800LC-8 50001 and up PC850-8 10001 and up PC850SE-8 10001 and up Structure, function and maintenance standard Electrical system Electrical system Engine control..............................
Page 244: Engine Control
SEN00386-03 10 Structure, function and maintenance standard Electrical system Engine control Operation of system Starting engine Stopping engine • When the starting switch is turned to the • When detecting that the starting switch is set to “START” position, the starting signal flows to the the “STOP”...
Page 245 SEN00386-03 10 Structure, function and maintenance standard Component Fuel control dial 1. Knob 4. Ball 2. Dial 5. Potentiometer 3. Spring 6. Connector Function • A potentiometer is installed under the knob. As the knob is turned, the potentiometer shaft is turned.
Page 246 SEN00386-03 10 Structure, function and maintenance standard Engine controller • Meanings of signal classes in the terminal table CN-CE01 shown below are as follows. Input/ Pin No. Signal name A : Power Supply output B : Input EGR valve C : Ground/Shield/Return NC(*) —...
Page 247 SEN00386-03 10 Structure, function and maintenance standard CN-CE01 CN-CE02 Input/ Input/ Pin No. Signal name Pin No. Signal name output output NC(*) — NC(*) Bypass valve position sensor NC(*) Fuel temperature sensor NC(*) Bypass valve (+) NC(*) NC(*) — NC(*) 5 V electric power supply for sensor NC(*) NC(*)
Page 248 SEN00386-03 10 Structure, function and maintenance standard EGR valve inlet pressure sensor Fuel temperature sensor • This sensor is used to sense the EGR pressure. • The fuel temperature sensor senses the fuel temperature and sends it to the engine controller. The sensor unit is a thermistor the resistance of which changes according to the temperature.
Page 249 SEN00386-03 10 Structure, function and maintenance standard EGR valve position sensor, bypass valve position sensor • These sensors sense the opening and closing positions of the EGR valve and bypass valve. 1. EGR valve position sensor, bypass valve position sensor •...
Page 250 SEN00386-03 10 Structure, function and maintenance standard NE speed sensor (Crank angle sensor) Common rail pressure sensor, oil pressure sensor • If the signal hole made on the flywheel passes the sensor, the magnetic line of force changes. • If the magnetic line of force changes, the output of the Hall element sensor changes linearly and it is converted into pulse of 0 –...
Page 251 SEN00386-03 10 Structure, function and maintenance standard Bkup speed sensor (G sensor) Boost pressure sensor (Cylinder No. sensor) • This sensor is used to sense the boost pressure (charge pressure). • Similarly to the NE speed sensor, this sensor uti- lizes the pulses of 0 –...
Page 252 SEN00386-03 10 Structure, function and maintenance standard Boost temperature sensor Coolant temperature sensor • The boost temperature sensor senses the intake • The coolant temperature sensor senses the air temperature (charge temperature) and sends coolant temperature and sends it to the engine it to the engine controller.
Page 253: Electric Control System
SEN00386-03 10 Structure, function and maintenance standard Electric control system Control functions PC800, 850-8...
Page 254 SEN00386-03 10 Structure, function and maintenance standard Machine control system diagram PC800, 850-8...
Page 255 SEN00386-03 10 Structure, function and maintenance standard PC800, 850-8...
Page 256 SEN00386-03 10 Structure, function and maintenance standard 1. Auto deceleration system Function • If all the control levers are at neutral when wait- ing for work or waiting for a dump truck, the en- gine speed is automatically reduced to a midrange speed to reduce fuel consumption and noise.
Page 257 SEN00386-03 10 Structure, function and maintenance standard Operation When auto-deceleration switch is turned ON Control levers at neutral When control lever is operated • If all the control levers are set in neutral while the • If any control lever is operated while the engine engine is running at a speed higher than the de- speed is keeping to the deceleration activation celeration activation speed (approx.
Page 258 SEN00386-03 10 Structure, function and maintenance standard Electronic OLSS function Pump control system • Interconnected control of all pumps is carried out by one TVC valve. • P mode: Total horsepower control by sensing engine speed • E mode: Total horsepower control by sensing engine speed •...
Page 259 SEN00386-03 10 Structure, function and maintenance standard 1) Control method in each mode P, E mode • Matching point in P, E mode: Rated output point (Including fan pump absorption horsepower at fan max. speed) Model PC800-8 PC850-8 Mode 370 kW/1,800 rpm {496 HP/1,800 rpm} 316 kW/1,650 rpm {423 HP/1,650 rpm}...
Page 260 SEN00386-03 10 Structure, function and maintenance standard 2) Cut-off function • If the load during operation increases and the pump discharge pressure (P) rises to near the re- lief pressure, pump controller lowers pump dis- charge volume, to reduce the relief loss. 3) Cut-off cancel function •...
Page 261 SEN00386-03 10 Structure, function and maintenance standard 4) E mode adjustment function • The matching point in control of engine speed (N) and pump absorption torque (T) in E mode can be adjusted by operating the machine moni- tor. • The matching point can be set to 4 levels of E0 –...
Page 262 SEN00386-03 10 Structure, function and maintenance standard 3. Heavy lift function Outline • This function increases the boom lifting power by approx. 10%. • It can be actuated only when the boom RAISE is being actuated independently. If the arm IN or bucket CURL are operated at the same time, the heavy-lift function is automatically canceled.
Page 263 SEN00386-03 10 Structure, function and maintenance standard Operation Lever operation Heavy-lift Main relief Heavy-lift Boom lifting solenoid valve set CO control Arm IN or switch force Boom RAISE valve pressure bucket CURL 31.4 MPa Operated — De-energized Actuated Normal {320 kg/cm 34.3 MPa Neutral Energized...
Page 264 SEN00386-03 10 Structure, function and maintenance standard 4. 2-stage boom pushing force selector function Outline • This function switches the pushing force of the boom. It is aimed to provide both increased dig- ging efficiency by reducing the digging resist- ance of the boom, and increased ease of operation by increasing the thrusting force for ex- cavation, digging square holes, carrying out twist...
Page 265 SEN00386-03 10 Structure, function and maintenance standard Operation • This function acts to change the set pressure of the safety valve at the boom cylinder end of the R.H. 4-spool control valve boom Lo in 2 ways: to low pressure (14.7 MPa {150 kg/cm }) and high pressure (33.3 MPa {340 kg/cm Machine push-...
Page 266 SEN00386-03 10 Structure, function and maintenance standard 5. Swing control system Function • The system is provided with a swing lock and swing holding brake function. PC800, 850-8...
Page 267 SEN00386-03 10 Structure, function and maintenance standard a Swing brake solenoid valve Swing lock, swing holding brake function • The swing lock (manual) can be locked at any For details of the structure and function, see desired position, and the swing lock and swing Solenoid valve.
Page 268 SEN00386-03 10 Structure, function and maintenance standard 6. Engine automatic warming-up, overheat prevention function, turbo protect function Function • If the coolant temperature is low, this automati- cally raises the engine speed to warm up the en- gine after it is started. In addition, if the coolant temperature rises too high during operations, it reduces the load of the pump to prevent over- heating.
Page 269 SEN00386-03 10 Structure, function and maintenance standard 1) Engine automatic warming-up function • After the engine is started, if the engine coolant temperature is low, the engine speed is automatically raised to warm up the engine. 2) Engine overheat prevention function •...
Page 270 SEN00386-03 10 Structure, function and maintenance standard 3) Turbo protection function Function to protect turbocharger bearing during cold weather by keeping engine speed below fixed speed when engine is started. Actuation condition Engine coolant Turbo protect time temperature (sec) More than +10°C Gradually changes +10°C to –10°C between 0 and 5...
Page 271 SEN00386-03 10 Structure, function and maintenance standard 7. Travel speed selection function This is an automatic gear shift function in which the travel pressure (self pressure) switches the swash plate angle of the travel motor. • If the machine is traveling at high speed with the travel speed switch at Hi and the load increases, such as when traveling up a steep hill, if the trav- el pressure goes above 22.6 MPa {230 kg/cm...
Page 272 SEN00386-03 10 Structure, function and maintenance standard Outline • To maintain the drawbar pull when traveling, the cut-off is canceled and the main relief pressure is raised from 31.4 MPa {320 kg/cm } to 34.3 MPa {350 kg/cm Operation Pressure increase solenoid Main relief valve CO valve valve...
Page 273 SEN00386-03 10 Structure, function and maintenance standard 8. Boom shockless control function This function improves safety by preventing spillage of the load from the bucket and by reducing the shock when the boom is stopped, thereby reducing operator fatigue. Actuation Boom shockless Cancel solenoid Boom shockless...
Page 274 SEN00386-03 10 Structure, function and maintenance standard 9. Straight-travel function Outline • When the travel is operated at the same time as • To prevent this, the straight-travel valve is the boom, arm, or bucket, the pressure oil flow- switched to interconnect the left and right travel ing to the left and right travel circuits is divided circuits.
Page 275 SEN00386-03 10 Structure, function and maintenance standard Operation Work equipment Left and right Straight-travel Straight-travel control lever, Remarks travel levers solenoid valve valve swing lever Left and right travel motor circuits Neutral De-energized Not actuated independent Operation Left and right travel motor circuits Operated Energized Actuated...
Page 276 SEN00386-03 10 Structure, function and maintenance standard 10. Swing priority function • There is a swing priority mode switch on the monitor panel. By turning this switch ON/OFF it is possible to change the matching of the boom RAISE and swing. This divides the flow to pro- vide a swing speed which matches the swing an- gle, thereby enabling the operator to carry out compound operations easily.
Page 277 SEN00386-03 10 Structure, function and maintenance standard • The boom raise operation and swing operation are matched to each other by changing the sig- nal for the swing circuit throttle valve and control- ling the delivery of the front pump and rear pump. 1.
Page 278 SEN00386-03 10 Structure, function and maintenance standard PC800, 850-8...
Page 279 SEN00386-03 10 Structure, function and maintenance standard 11. Swing assurance function • During compound operations with the arm and swing or with the bucket and swing, the throttle valves in the arm and bucket circuit ensure the flow of oil to the swing circuit in order to assure ease of compound opera- tions.
Page 280 SEN00386-03 10 Structure, function and maintenance standard 12. Hydraulic fan control function 1) Fan speed control • The fan speed is controlled according to the en- • While the work equipment control lever is in neu- gine speed, ambient temperature, hydraulic oil tral, the fan speed is lowered, too.
Page 281 SEN00386-03 10 Structure, function and maintenance standard 2) Engine output control • The pump controller calculates the output con- sumed by the fan and controls engine output curves (A) and (B) according to the speed to re- duce loss fuel. •...
Page 282 SEN00386-03 10 Structure, function and maintenance standard 13. Fan reverse function • The cooling devices can be cleaned easily by ro- tating the fan in reverse. • The fan rotation direction is reversed by operat- ing the machine monitor. • Upon receiving the fan reverse signal from the machine monitor, the pump controller drives the fan reverse EPC valve of the fan motor to change...
Page 283 SEN00386-03 10 Structure, function and maintenance standard PC800, 850-8...
Page 284 SEN00386-03 10 Structure, function and maintenance standard Pump controller PC800, 850-8...
Page 285 SEN00386-03 10 Structure, function and maintenance standard Input and output signals CN1 [CN-C01] CN2 [CN-C02] Input/ Input/ Pin No. Signal name Pin No. Signal name Output Output CN1-1 NC (*) Input CN2-1 NC (*) Output CN1-2 R pump pressure sensor Input CN2-2 Swing prolix switch Input...
Page 286 SEN00386-03 10 Structure, function and maintenance standard CN3 [CN-C03] Input/ Pin No. Signal name Output CN3-1 VB (Controller PWR) Input CN3-2 VIS (Solenoid PWR) Input CN3-3 SOL_COM (solenoid GND) Input CN3-4 Battery relay hold Output CN3-5 NC (*) Output CN3-6 Fan pump EPC solenoid Output CN3-7...
Page 287: Monitor System
SEN00386-03 10 Structure, function and maintenance standard Monitor system • The monitor system monitors the condition of the machine with sensors installed on various parts of the machine. It processes and immediately displays the obtained information on the panel notifying the operator of the condition of the ma- chine.
Page 288 SEN00386-03 10 Structure, function and maintenance standard 1. Monitor panel Outline • The monitor panel has the functions to display various items and the functions to select modes and electric parts. The monitor panel has a CPU (Central Process- ing Unit) in it to process, display, and output the information.
Page 289 SEN00386-03 10 Structure, function and maintenance standard Input and output signals Input/ Input/ Signal name Signal name output output Key switch (Battery) Input Input Key switch (Battery) Input Input Washer motor output Output Input Key switch (Terminal C) Input Input Wiper contact W (Lower wiper contact P) Input Input...
Page 290 SEN00386-03 10 Structure, function and maintenance standard Monitor control, display portion Monitor portion 1. Wiper motor 11. Fuel level monitor 2. Preheating monitor 12. Hydraulic oil temperature monitor 3. Swing lock monitor 13. Auto-deceleration monitor 4. Engine coolant temperature monitor 14.
Page 291 SEN00386-03 10 Structure, function and maintenance standard Monitor items and display Symbol Display item Display method Swing holding brake Swing lock switch Swing lock monitor release switch Swing lock Flashes Continuous set time Preheating monitor status Up to 30 sec. Preheating From 30 sec.
Page 292 SEN00386-03 10 Structure, function and maintenance standard Gauge Range Temperature, volume Indicator Buzzer sound Green Engine coolant temperature (°C) Green Green White Green Hydraulic oil tempera- ture (°C) Green Green White Green Green Green Fuel level (l) Green Green PC800, 850-8...
Page 293 SEN00386-03 10 Structure, function and maintenance standard Checks before starting (caution lamps all light up), when maintenance interval is exceeded. If the checks before starting or maintenance interval is exceeded items light up, the display of the hydraulic oil temperature gauge and the hydraulic oil temperature monitor are stopped, and the following cautions are dis- played.
Page 294 SEN00386-03 10 Structure, function and maintenance standard Display category Symbol Display item Display range Display method Wiper Displays set condition Working mode Displays set mode Monitor Travel speed Displays set speed Auto-decelera- Displays actuation tion status Service meter Lights up when service Service meter When service meter is working indicator...
Page 295 SEN00386-03 10 Structure, function and maintenance standard Switches 1. Working mode selector switch 2. Select switch 3. Buzzer cancel switch 4. Display brightness, contrast adjustment switch 5. Return switch 6. Control switch 7. Input confirmation switch 8. Window washer switch 9.
Page 296 SEN00386-03 10 Structure, function and maintenance standard • Working mode selector switch Switch that is Working mode status The condition of the machine changes accord- Display pressed after setting ing to the switch that is pressed (Shown in the figure at right). It is possible to check the condi- P mode (default) tion on the working mode monitor display.
Page 297 SEN00386-03 10 Structure, function and maintenance standard Maintenance function When the maintenance time for replacement, inspection, or filling has approached for the 10 main- tenance items, press maintenance switch (1) and the caution display (yellow or red) appears on the monitor display for 30 seconds after the key is turned ON to remind the operator to carry out lubri- cation maintenance.
Page 298 SEN00386-03 10 Structure, function and maintenance standard Method of checking status Maintenance items a Operate as follows when on the operator screen. 1. Press maintenance switch (1) and switch to the maintenance list display screen. a The maintenance items are displayed as symbols on the screen.
Page 299 SEN00386-03 10 Structure, function and maintenance standard User mode function • In the user mode, you can rotate the fan in re- verse and change the set value in the E mode. • On the ordinary screen, if you press selector switch (1), the user mode menu is displayed.
Page 300 SEN00386-03 10 Structure, function and maintenance standard • If you press input confirm switch (4), the fan ro- tates in reverse. • If you press return switch (2), the previous screen is displayed again. a While the rotation direction of the fan is being changed, the engine speed is automatically set to low idle for 15 seconds.
Page 301 SEN00386-03 10 Structure, function and maintenance standard • If input confirm switch (4) is pressed, the screen at right is displayed and the fan rotation direction is returned to forward. • If the return switch is pressed, the previous screen is displayed again. a While the rotation direction of the fan is being changed, the engine speed is automatically set to low idle for 15 seconds.
Page 302 SEN00386-03 10 Structure, function and maintenance standard Brightness, contrast adjustment function This function is used to adjust the brightness and contrast of the display. Adjustment method a Operate as follows when on the operator screen. 1. Press display brightness/contrast adjustment switch (1) and switch to the adjustment screen.
Page 303 SEN00386-03 10 Structure, function and maintenance standard Service meter check function • When the starting switch is at the OFF position, keep return switch (1) and control switch (2) of the monitor pressed at the same time, and the service meter is shown on the display. •...
Page 304 SEN00386-03 10 Structure, function and maintenance standard • While the user code is being displayed, if the in- put confirmation switch is pressed, the service code and failure code can be displayed. • If there is more than one service code or failure code, the display switches every 2 seconds and displays all the service codes/failure codes that caused the user code to be displayed.
Page 305: Sensors
SEN00386-03 10 Structure, function and maintenance standard Sensors • The signals from the sensors are input directly to The contact type sensors are always connected the engine controller and the pump controller at one end to the chassis GND. monitor. Name of sensor Type of sensor When normal...
Page 306 SEN00386-03 10 Structure, function and maintenance standard Engine oil level sensor 1. Connector 2. Bracket 3. Float 4. Switch Engine oil pressure sensor 1. Seal 2. Sensor Air cleaner clogging sensor PC800, 850-8...
Page 307 SEN00386-03 10 Structure, function and maintenance standard Fuel level sensor 1. Float 2. Connector 3. Cover 4. Variable resistor Coolant temperature sensor Hydraulic oil temperature sensor 1. Thermistor 4. Tube 2. Body 5. Wire 3. Tube 6. Connector PC800, 850-8...
Page 308 SEN00386-03 10 Structure, function and maintenance standard Main pump oil pressure sensor (0 – 49.0 MPa {0 – 500 kg/cm 1. Sensor 2. Connector Operation • The oil pressure applied from the pressure intake part presses the diaphragm of the oil pressure sensor, the diaphragm is deformed.
Page 309 SEN00386-03 10 Structure, function and maintenance standard PC800, 850-8...
Page 310 SEN00386-03 10 Structure, function and maintenance standard PC800-8, PC800SE-8, PC800LC-8, PC850-8, PC850SE-8 Hydraulic excavator Form No. SEN00386-03...
Page 311: Standard Value Table
SEN00784-02 HYDRAULIC EXCAVATOR PC800-8 PC850-8 PC800SE-8 PC850SE-8 PC800LC-8 Machine model Serial number PC800-8 50001 and up PC800SE-8 50001 and up PC800LC-8 50001 and up PC850-8 10001 and up PC850SE-8 10001 and up Standard value table Standard service value table Standard service value table ..........................2 Standard service value table for engine......................
Page 312: Standard Service Value Table For Engine
SEN00784-02 20 Standard value table Standard service value table Standard service value table for engine PC800, SE, LC-8 Machine model PC850, SE-8 Engine SAA6D140E-5 Item Measurement condition Unit Standard value Permissible value High idle 1,980 ± 50 1,980 ± 50 Engine speed Low idle 825 ±...
Page 313: Standard Service Value Table For Chassis
SEN00784-02 20 Standard value table Standard service value table for chassis PC800, SE, LC-8 Applicable model PC850, SE-8 Cate- Standard value for Item Measurement conditions Unit Service limit value gory new machine • Engine coolant temperature: Within operating range • Hydraulic oil temperature: All pumps at relief Within operating range Min.
Page 314 SEN00784-02 20 Standard value table PC800, SE, LC-8 Applicable model PC850, SE-8 Cate- Standard value for Item Measurement conditions Unit Service limit value gory new machine 15.7 ± 4.9 15.7 ± 4.9 Boom control lever {1.6 ± 0.5} {1.6 ± 0.5} •...
Page 315 SEN00784-02 20 Standard value table PC800, SE, LC-8 Applicable model PC850, SE-8 Cate- Standard value for Item Measurement conditions Unit Service limit value gory new machine • Hydraulic oil All control Min. 1.14 Min. 1.14 temperature: levers at neutral {Min. 11.6} {Min.
Page 316 SEN00784-02 20 Standard value table PC800, SE, LC-8 Applicable model PC850, SE-8 Cate- Standard value for Item Measurement conditions Unit Service limit value gory new machine 90° 4.2 ± 0.5 Max. 5.3 • Hydraulic oil tempera- Time taken to start sec.
Page 317 SEN00784-02 20 Standard value table PC800, SE, LC-8 Applicable model PC850, SE-8 Cate- Standard value for Item Measurement conditions Unit Service limit value gory new machine 74 – 90 74 –90 (PC800LC-8: (PC800LC-8: 80 – 98) 80 – 98) • Hydraulic oil tempera- Travel speed ture: 45 –...
Page 318 SEN00784-02 20 Standard value table PC800, SE, LC-8 Applicable model PC850, SE-8 Cate- Standard value for new Item Measurement conditions Unit Service limit value gory machine • Hydraulic oil temperature: Hydraulic drift of 45 – 55°C travel • Engine stopped •...
Page 319 SEN00784-02 20 Standard value table PC800, SE, LC-8 Applicable model PC850, SE-8 Cate- Standard value for new Item Measurement conditions Unit Service limit value gory machine Posture of work equipment PC800-8 PC800-8 Backhoe Backhoe Loading Loading specification specification shovel shovel PC800(LC) PC800(LC) 5.3 ±...
Page 320 SEN00784-02 20 Standard value table PC800, SE, LC-8 Applicable model PC850, SE-8 Cate- Standard value for new Item Measurement conditions Unit Service limit value gory machine Bottom cylinder Posture of work equipment Retract cylinder — 1.6 ± 0.3 — Max. 2.5 to stroke end.
Page 321 SEN00784-02 20 Standard value table PC800, SE, LC-8 Applicable model PC850, SE-8 Cate- Standard value for new Item Measurement conditions Unit Service limit value gory machine • Hydraulic oil temperature: Cylinder Max. 5 Max. 20 45 - 55°C cc/min • Hydraulic pressure: Center swivel Max.
Page 322 SEN00784-02 20 Standard value table Cate- Discharge amount of one hydraulic pump gory • Pump speed: At 1800 rpm • Pump discharge pressure: 9.8 MPa {100 kg/cm Standard value Judgement Test pump Check point for discharge amount Q standard lower limit Q Test pump EPC current (mA) (l/min) (l/min)
Page 323 SEN00784-02 20 Standard value table PC800, 850-8...
Page 324 SEN00784-02 20 Standard value table PC800-8, PC800SE-8, PC800LC-8, PC850-8, PC850SE-8 Hydraulic excavator Form No. SEN00784-02...
Page 325: Testing And Adjusting Testing And Adjusting, Part
SEN00786-02 HYDRAULIC EXCAVATOR PC800-8 PC850-8 PC800SE-8 PC850SE-8 PC800LC-8 Machine model Serial number PC800-8 50001 and up PC800SE-8 50001 and up PC800LC-8 50001 and up PC850-8 10001 and up PC850SE-8 10001 and up Testing and adjusting Testing and adjusting, Part 1 Testing and adjusting, Part 1..........................
Page 326: Tools For Testing, Adjusting And Troubleshooting
SEN00786-02 30 Testing and adjusting Testing and adjusting, Part 1 Tools for testing, adjusting and troubleshooting Testing and adjusting item Part No. Part name Remarks Intake air pressure 799-201-2202 Boost gauge kit –101 to 200 kPa {–760 to 1,500 Hg} (boost pressure) Exhaust temperature 799-101-1502 Digital thermometer...
Page 327 SEN00786-02 30 Testing and adjusting Testing and adjusting item Part No. Part name Remarks Pressure gauge: 2.5, 6.0, 40, 60 MPa 799-101-5002 Hydraulic tester {25, 60, 400, 600 kg/cm 790-261-1204 Digital hydraulic tester Pressure gauge: 60 MPa {600 kg/cm Control oil pressure of Differential pressure main pump 2 799-401-2701...
Page 328 SEN00786-02 30 Testing and adjusting Testing and adjusting item Part No. Part name Remarks 799-601-7400 T-adapter assembly SWP, X, M connector 799-601-7500 T-adapter assembly AMP070 connector 799-601-9000 T-adapter assembly DT, HD30 connector 799-601-9300 T-adapter assembly DRC26 – 24, 40 pin 799-601-7360 Adapter Relay (5 pins) 799-601-9420 T-adapter...
Page 329: Measuring Engine Speed
SEN00786-02 30 Testing and adjusting Measuring engine speed 4. Measuring all-pump relief speed 1) Start the engine and set the fuel control dial in the high idle position (MAX). a Measure the engine speed under the following 2) Set the working mode switch in the P-mode condition.
Page 330: Measuring Intake Air Pressure (Boost Pressure)
SEN00786-02 30 Testing and adjusting Measuring intake air pressure 4. Run the engine at a medium or higher speed and drain the oil from the hose. (Boost pressure) a Insert the connecting parts of the gauge and hose about a half and open the self-seal on a Measuring instruments for intake air pressure the hose side repeatedly, and the oil will be (boost pressure)
Page 331: Measuring Exhaust Gas Temperature
SEN00786-02 30 Testing and adjusting Measuring exhaust gas 3. Install sensor [1] of digital thermometer B and connect them to meter [2]. temperature a Clamp the wiring harness of the digital tem- perature gauge so that it does not touch any a Measuring instrument of exhaust gas temperature high temperature part during the measure- ment.
Page 332: Measuring Exhaust Gas Color
SEN00786-02 30 Testing and adjusting Measuring exhaust gas color a Measuring instrument of exhaust gas color Symbol Part Number Part Name 799-201-9001 Handy smoke checker Purchased Smoke meter k Be careful not to touch hot areas when mount- ing and removing the measuring instrument. a When air source or electric power supply is not a v a i l ab l e i n f i e l d, u s e C 1 Ha n dy S m o k e Checker, but use C2 Smoke Meter, when...
Page 333: Adjusting Valve Clearance
SEN00786-02 30 Testing and adjusting Adjusting valve clearance 4. Insert clearance gauge D in clearance (b) between rocker arm (5) and crosshead (6), and turn adjustment screw (3) to adjust the valve a Adjusting tools for valve clearance clearance. Symbol Part No.
Page 334: Measuring Compression Pressure
SEN00786-02 30 Testing and adjusting Measuring compression 4. Disconnect fuel high-pressure tube (3) and injector wiring harness and remove injector (4). pressure a Disconnect the terminal of the injector wiring harness on the injector side and the bracket a Measuring instruments for compression pressure on the rocker housing side and remove the injector wiring harness (Loosen the 2 termi- Symbol...
Page 335: Measuring Blow-By Pressure
SEN00786-02 30 Testing and adjusting Measuring blow-by pressure 7. Set the engine in the no-injection cranking mode with the machine monitor. k If the engine is not set in the no-injection a Measuring instruments for blow-by pressure cranking mode, it will start and will be Symbol Part No.
Page 336: Measuring Engine Oil Pressure
SEN00786-02 30 Testing and adjusting Measuring engine oil pressure 4. Start the engine and measure the oil pressure with the engine at low idle and high idle. a Measuring instruments for engine oil pressure Symbol Part No. Part Name 799-101-5002 Hydraulic tester 790-261-1204 Digital hydraulic tester...
Page 337: Measuring Egr Valve And Bypass Valve Drive Pressure
SEN00786-02 30 Testing and adjusting Measuring EGR valve and 3. Install nipple [1] of hydraulic tester V and con- nect hydraulic gauge [2] (2.5 MPa {25 kg/cm bypass valve drive pressure 4. Run the engine at low idle and high idle and a Measuring instruments for EGR valve and measure the temperature at each speed.
Page 338: Handling Of Fuel System Equipment
Inspect the fuel system or mount or remove Be sure to use genuine fuel filter cartridge of cautions: Komatsu. The common rail type fuel injection system equipment more than 30 seconds later after the (CRI) is composed of more precise components...
Page 339: Measuring Fuel Pressure
SEN00786-02 30 Testing and adjusting Measuring fuel pressure 4. Start the engine and measure fuel pressure at the time of high idle. a If the fuel pressure is in the following range, a Measuring Instrument of Fuel Pressure it is normal. Symbol Part Number Part Name...
Page 340: Testing Fuel Return Rate And Leakage
SEN00786-02 30 Testing and adjusting Testing fuel return rate and leakage a If the engine has the intake manifold equipped 1. Preparation work with the return block on it to return the fuel spill- 1) Remove tube (3) between common rail (1) ing from the injector to the fuel tank, test the fuel and supply pump (2).
Page 341 SEN00786-02 30 Testing and adjusting 4) Connect test hose J4 to the end of joint J2. 3. Testing return rate from injector a Bind the connecting part of the test hose a Keep the hose on the pressure limiter side with a wire, etc.
Page 342: Bleeding Air From Fuel Circuit
SEN00786-02 30 Testing and adjusting Bleeding air from fuel circuit 5) After the engine speed is stabilized, test the return rate in 1 minute with measuring cylin- der J6. a If fuel is used up or if a fuel circuit part is a You may test for 20 seconds and judge removed and installed, bleed air from the fuel by multiplying the result by 3.
Page 343 SEN00786-02 30 Testing and adjusting 2. Install fuel prefilter (1) to the filter head. 4. Loosen air bleeding plug (5) of the main fuel fil- a Thinly apply engine oil to the packing surface ter and operate priming pump (4). a Operate the priming pump until fuel flows out on the fuel prefilter.
Page 344: Testing Fuel System For Leakage
SEN00786-02 30 Testing and adjusting Testing fuel system for leakage a If no fuel leakage is detected, check is com- pleted. k Very high pressure is generated in the high- pressure circuit of the fuel system. If fuel leaks while the engine is running, it is dangerous since it can catch fire.
Page 345: Testing And Adjusting Alternator Belt Tension
SEN00786-02 30 Testing and adjusting Testing and adjusting Adjustment procedure a Adjust the belt according to the following proce- alternator belt tension dure when the belt deflection is not normal. Testing procedure 1. Loosen nuts and bolts (1), (2), (3) and (4) in this 1.
Page 346: Testing And Adjusting Air Conditioner Compressor Belt
SEN00786-02 30 Testing and adjusting Testing and adjusting air 3. Tighten nuts and bolts in the order of (3), (2), and (1). conditioner compressor belt a When the V-belt was replaced, measure its deflection again after one-hour operation Testing and then readjust it if necessary. 1.
Page 347 SEN00786-02 30 Testing and adjusting PC800, 850-8...
Page 348 SEN00786-02 30 Testing and adjusting PC800-8, PC800SE-8, PC800LC-8, PC850-8, PC850SE-8 Hydraulic excavator Form No. SEN00786-02...
Page 349: Testing And Adjusting, Part 2
SEN00788-02 HYDRAULIC EXCAVATOR PC800-8 PC850-8 PC800SE-8 PC850SE-8 PC800LC-8 Machine model Serial number PC800-8 50001 and up PC800SE-8 50001 and up PC800LC-8 50001 and up PC850-8 10001 and up PC850SE-8 10001 and up Testing and adjusting Testing and adjusting, Part 2 Testing and adjusting, Part 2..........................
Page 350: Inspection Of Swing Circle Bearing Clearance
SEN00788-02 30 Testing and adjusting Testing and adjusting, Part 2 Inspection of swing circle 3. Set the dial gauge N to the zero point. bearing clearance 4. Arrange the arm almost at right angles to the ground and lower the boom until the front leg of a Inspection Device of Swing Circle Bearing the machine body rises.
Page 351: Testing And Adjusting Track Shoe Tension
SEN00788-02 30 Testing and adjusting Testing and adjusting track Adjusting a If the track shoe tension is not proper, adjust it in shoe tension the following manner. Testing 1. When the tension is too strong 1. Travel the machine forward by the length of Discharge grease by loosening valve (3).
Page 352: Testing And Adjusting Work Equipment, Swing, And Travel Circuit Oil Pressures
SEN00788-02 30 Testing and adjusting Testing and adjusting work 1. Preparation work k Lower the work equipment to the ground equipment, swing, and travel circuit oil pressures and stop the engine. Operate the control le- vers several times to release the residual a Testing and adjusting instruments for work pressure in the piping, and then loosen the equipment, swing, and travel circuit oil pres-...
Page 353 SEN00788-02 30 Testing and adjusting 2. Measuring work equipment circuit oil pressure 1) Measuring normal relief pressure a The case where the boom cylinder is set to the stroke end is explained below. Start the engine and set the working mode switch to the P-mode position.
Page 354 SEN00788-02 30 Testing and adjusting 4. Measuring travel circuit oil pressure Adjusting a Do not adjust any safety valve other than the 1) Start the engine and lock the travel mecha- nism. swing motor safety valve. k Put pin [2] between the sprocket and a When adjusting the main relief valves of the left 5-spool valve and right 4-spool valve, remove track frame to lock the travel mecha-...
Page 355 SEN00788-02 30 Testing and adjusting 3 Locknut: 5) Fix holder (9) and tighten locknut (10). 2. Adjusting main relief valve (low-pressure set- ting) of left 5-spool control valve a If the work equipment oil pressure in the front 93 – 123 Nm {9.5 – 12.5 kgm} a If the high-pressure setting side is ad- pump circuit (during normal relief operation) justed, the low-pressure setting side...
Page 356 SEN00788-02 30 Testing and adjusting 3. Adjusting main relief valve (high-pressure 5. Adjusting swing motor safety valve a If the relief pressure of the swing motor is ab- setting) of right 4-spool control valve a If the work equipment oil pressure in the rear normal, adjust safety valves (14) and (15) of pump circuit (during heavy lift operation) and the swing motor according to the following...
Page 357 SEN00788-02 30 Testing and adjusting a The front and rear swing motors are divided from one spool. Adjust the valves in the fol- lowing procedures. a If swing starting power is not powerful, or if swing speed is not fast: 1) Put match marks on the body and on adjust- ment screw (16) for safety valves (14) and (15) of each motor.
Page 358: Testing And Adjusting Control Circuit Pressure (Output Pressure Of Self Pressure Reducing Valve)10
SEN00788-02 30 Testing and adjusting Testing and adjusting control 3. While running the engine at high idle, set the work equipment, swing and travel levers in neu- circuit pressure (output pres- tral and measure the oil pressure. sure of self pressure reducing valve) a Testing and adjusting instruments for control cir- cuit pressure...
Page 359 SEN00788-02 30 Testing and adjusting 5) Referring to Measuring, Step 3, measure the output pressure of the self pressure reducing valve. PC800, 850-8...
Page 360: Testing And Adjusting Main Pump Control Pressure
SEN00788-02 30 Testing and adjusting Testing and adjusting main pump control pressure a Devices for inspecting and measuring main pump control oil pressure Symbol Part Number Part Name 799-101-5002 Hydraulic tester 790-261-1204 Digital hydraulic tester Differential pressure 799-401-2701 gauge 799-101-5220 Nipple (10 ×...
Page 361 SEN00788-02 30 Testing and adjusting 2. Measuring EPC valve current a The EPC current can be checked with the mon- itoring function of the machine monitor, too. (For the operating method, see “Special func- tions of machine monitor”.) • Monitoring code: 01300 F pump EPC solenoid current 01302 R pump EPC solenoid current 1) Start the engine and set the working mode...
Page 362 SEN00788-02 30 Testing and adjusting 7) While the track is running with no load, measure the VC valve basic pressure and output pressure under the following condi- tion. Using the boom and arm, push up the track shoe on the side to be measured. ii) While the engine is running at high idle, operate the travel lever to the stroke end and measure the basic pressure...
Page 363 SEN00788-02 30 Testing and adjusting Measuring jet sensor output differential pressure 2) Install measuring hose [2] of hydraulic tester When measuring output differential pressure M1 and connect it to differential pressure with machine monitor gauge M2 or oil pressure gauge [1]. a The jet sensor output differential pressure a When using differential pressure gauge: can be checked with the monitoring function...
Page 364 SEN00788-02 30 Testing and adjusting 5) Drive the travel motor idle and measure the 5. Measuring differential pressure sensor out- jet sensor output differential pressure under put voltage the following condition. • The differential pressure sensor output voltage Raise the track shoe to be measured by can be checked with the monitoring function of using the boom and arm.
Page 365 SEN00788-02 30 Testing and adjusting Adjusting 1. Adjusting jet sensors of left 5-spool control valve and right 4-spool control valve a If the jet sensor output differential pressure of the left 5-spool control valve or right 4- spool control valve is abnormal, adjust jet sensor relief valves (19) and (20) according to the following procedure.
Page 366 SEN00788-02 30 Testing and adjusting PC800-8, PC800SE-8, PC800LC-8, PC850-8, PC850SE-8 Hydraulic excavator Form No. SEN00788-02...
Page 367: Testing And Adjusting, Part 3
SEN00912-02 HYDRAULIC EXCAVATOR PC800-8 PC850-8 PC800SE-8 PC850SE-8 PC800LC-8 Machine model Serial number PC800-8 50001 and up PC800SE-8 50001 and up PC800LC-8 50001 and up PC850-8 10001 and up PC850SE-8 10001 and up Testing and adjusting Testing and adjusting, Part 3 Testing and adjusting, Part 3..........................
Page 368: Measuring Ppc Valve Output Pressure
SEN00912-02 30 Testing and adjusting Testing and adjusting, Part 3 Measuring PPC valve output 3. Install nipple [1] of hydraulic tester P1 and con- nect it to oil pressure gauge [2]. pressure a Use a pressure gauge of 6.0 MPa {60 kg/cm a The figure shows the measuring instruments a Devices for measuring PPC valve output pressure installed to the right travel (reverse) circuit of...
Page 369 SEN00912-02 30 Testing and adjusting 5. After the measurement, remove the measuring devices and return the valve to the original state. PC800, 850-8...
Page 370 SEN00912-02 30 Testing and adjusting Connection diagram of pilot piping (PPC-Solenoid circuit) PC800, 850-8...
Page 371 SEN00912-02 30 Testing and adjusting a The colors in ( ) in the figure are the colors of the tapes wound onto the hoses. PC800, 850-8...
Page 372: Measuring Outlet Pressures Of Solenoid Valve, Swing Ppc Shuttle Valve, And Swing Priority Selector Valve
SEN00912-02 30 Testing and adjusting Measuring outlet pressures of solenoid valve, swing PPC shuttle valve, and swing priority selector valve a Devices for measuring outlet pressures of sole- noid valve, swing PPC shuttle valve, and swing priority selector valve Symbol Part Number Part Name 799-101-5002...
Page 373 SEN00912-02 30 Testing and adjusting 2) Install the nipple (R1/8) of hydraulic tester Q1 or nipple Q4 (10 × 1.25 mm) and con- nect it to oil pressure gauge [1]. a Use nipple (R1/8) for adapter of size #03 and nipple Q4 for adapter of size #04. a Use a pressure gauge of 6.0 MPa {60 kg/cm a The following figure shows the measur-...
Page 374 SEN00912-02 30 Testing and adjusting Measurement conditions for solenoid valve a The measurement conditions in the following table are for measuring the solenoid valve outlet pressure and they are a part of the operating condition of each solenoid valve. Operation Oil pressure Solenoid valve Measurement condition...
Page 375 SEN00912-02 30 Testing and adjusting 2. Measuring outlet pressure of swing PPC shuttle valve 1) Disconnect outlet hose (9) of the swing PPC shuttle valve. Install adapter Q2 and con- nect the hose again. a When measuring the swing PPC shuttle valve, remove the control valve top cover.
Page 376: Adjusting Work Equipment, Swing Ppc Valve
SEN00912-02 30 Testing and adjusting Adjusting work equipment, 3) Run the engine at high idle, set the condition or operate the control levers as shown in the swing PPC valve table, and measure the output pressure. a If the swing priority selector valve outlet a If there is excessive play at the tip of the work pressure is as shown in the table, the equipment or swing lever, adjust at the PPC...
Page 377: Testing And Adjusting Travel Deviation
SEN00912-02 30 Testing and adjusting Testing and adjusting travel deviation Measuring a Measure on a hard and level ground. a Hydraulic oil temperature: 45 – 55°C 1. Start the engine and set the work equipment in the travel position. a To set the work equipment in the travel posi- tion, extend the bucket and arm cylinders ful- ly and set the boom angle to 45°.
Page 378 SEN00912-02 30 Testing and adjusting Adjusting a Carry out troubleshooting for “H-16 Machine deviates by itself during travel” to find out the causal part in advance. a Adjust the deviation with the motor idle running. a If the main pump is adjusted for measures, adjust the servo piston.
Page 379: Inspection Of Locations Of Hydraulic Drift Of Work Equipment
SEN00912-02 30 Testing and adjusting Inspection of locations of 2. Inspection of arm cylinder 1) Operate the arm cylinder to move the arm to hydraulic drift of work equipment the position 100 mm before the digging stroke end, and stop the engine. a If there is any hydraulic drift in the work equip- ment (cylinders), check in the following manner to determine if the cause is in the cylinder pack-...
Page 380: Measuring Fan Speed
SEN00912-02 30 Testing and adjusting Measuring fan speed Measuring fan circuit oil pressure a Tools for measuring fan speed a Tools for measuring fan circuit oil pressure Symbol Part Number Part Name Symbol Part Number Part Name 799-203-8001 Multitachometer 799-101-5002 Multitachometer 790-261-1203 Digital hydraulic tester...
Page 381: Measuring Fan Pump Epc Current
SEN00912-02 30 Testing and adjusting Measuring fan pump EPC current a The fuel pump EPC current can be checked with the monitoring function of the machine monitor. (For the operating method, see “Special func- tions of machine monitor”.) • Monitoring code: 31623 Fan pump EPC solenoid current •...
Page 382: Measuring Fan Pump Epc Solenoid Valve Output Pressure
SEN00912-02 30 Testing and adjusting Measuring fan pump EPC 2) Install nipple U2 and connect it to oil pres- sure gauge [1] of hydraulic tester U1. solenoid valve output pressure • Use the oil pressure gauge of 6.0 MPa {60 kg/cm a Measuring instruments for fan pump EPC sole- noid valve output pressure Symbol...
Page 383: Measuring Oil Leakage
SEN00912-02 30 Testing and adjusting Measuring oil leakage 2. Measuring leakage from arm cylinder 1) Run the engine and move in the arm to the stroke end. a Measuring device for oil leakage k Referring to “Release of residual pres- Symbol Part Number Part Name...
Page 384 SEN00912-02 30 Testing and adjusting 3. Measuring leakage from bucket cylinder 4. Measuring leakage from swing motor 1) Run the engine and curl the bucket to the 1) Disconnect drain hoses (4) and (5) and plug stroke end. them. k Referring to “Release of residual pres- a Use the following parts to block the hos- sure from hydraulic circuit”, release the 07376-70522 (Plug #05)
Page 385 SEN00912-02 30 Testing and adjusting 5. Measuring leakage from travel motor 6. Measuring leakage from center swivel joint 1) Remove the travel motor cover. 1) Put block [1] between the sprocket and frame to lock the travel motor of the port to Travel motor cover: 130 kg be inspected, and then stop the engine.
Page 386 SEN00912-02 30 Testing and adjusting 4) Run the engine at high idling and measure the oil leakage through the measurement ports according to the following procedure. a When inspecting ports A, B, C and D, re- lieve the travel motor slowly in the re- volving direction (See the table on the previous page).
Page 387: Release Of Residual Pressure From Hydraulic Circuit
SEN00912-02 30 Testing and adjusting Release of residual pressure 3. Release of residual pressure from swing mo- tor circuit from hydraulic circuit a Release the residual pressure from the swing motor circuit by performing the proce- 1. Release of residual pressure from hydraulic dure for 2.
Page 388: Bleeding Air From Each Part
SEN00912-02 30 Testing and adjusting Bleeding air from each part Air bleeding item Air bleeding procedure Bleeding Bleeding Bleeding Checking Bleeding air from Starting air from air from oil level air from hydraulic engine swing travel and start- cylinder Contents of work pump motor motor...
Page 389 SEN00912-02 30 Testing and adjusting 2. Starting engine • Front swing motor When running the engine after performing step 1, keep its speed at low idle for 10 minutes. 3. Bleeding air from cylinder a If a cylinder was replaced, bleed air from it before connecting the work equipment.
Page 390 SEN00912-02 30 Testing and adjusting 5. Bleeding air from travel motor 1) Remove the travel motor cover. Travel motor cover: 130 kg 2) Loosen bleeder (7) by 1 turn and start the engine. a Do not loosen the bleeder more than 1 turn.
Page 391: Inspection Procedures For Diode
SEN00912-02 30 Testing and adjusting Inspection procedures for diode 3) Determine if a specific diode is good or no good with the indicated value. • No change in the indicated value: No a Check an assembled-type diode (8 pins) and continuity (defective).
Page 392: Adjusting Mirrors
SEN00912-02 30 Testing and adjusting Adjusting mirrors 3. Adjusting mirror (b) Adjust mirror (b) so that you can see hatched part (b') at the right rear end of the machine. 1. Mirrors installed positions a Dimension of installed position and visibility range •...
Page 393 SEN00912-02 30 Testing and adjusting PC800, 850-8...
Page 394 SEN00912-02 30 Testing and adjusting PC800-8, PC800SE-8, PC800LC-8, PC850-8, PC850SE-8 Hydraulic excavator Form No. SEN00912-02...
Page 395: Testing And Adjusting, Part 4
SEN00913-02 HYDRAULIC EXCAVATOR PC800-8 PC850-8 PC800SE-8 PC850SE-8 PC800LC-8 Machine model Serial number PC800-8 50001 and up PC800SE-8 50001 and up PC800LC-8 50001 and up PC850-8 10001 and up PC850SE-8 10001 and up Testing and adjusting Testing and adjusting, Part 4 Testing and adjusting, Part 4..........................
Page 396: Special Function Of Machine Monitor
SEN00913-02 30 Testing and adjusting Testing and adjusting, Part 4 Special function of machine monitor [1] Figure input switch 1 [6] Figure input switch 6 ] Return switch [2] Figure input switch 2 [7] Figure input switch 7 [E] Upward move switch [3] Figure input switch 3 [8] Figure input switch 8 [R] Downward move switch...
Page 397 It is mainly used for inspection, adjustment, trou- bleshooting or special setting of machines. Operator's Menu Service Menu Password input and setting function Function for monitoring [01] Function for showing KOMATSU logo Electrical system Function for failure history [02] Function for check before starting Mechanical system...
Page 398 2. Function for showing KOMATSU logo When the engine starting switch is turned ON, KOMATSU logo is shown for 2 seconds. 5. Function for showing caution items If there is any item of machine inspection before...
Page 399 SEN00913-02 30 Testing and adjusting 6. Function for confirming working mode and 8. Function for adjusting display luminance and travel speed contrast After the display of machine inspection before Luminance as well as contrast of the display can day's work, amplified symbol marks for working be adjusted by operating the display adjusting mode and travel speed are shown for 2 seconds switch.
Page 400 SEN00913-02 30 Testing and adjusting 10. Function for showing service meter reading 12. Function for showing occurrence of caution Only the service meter reading can be shown by item the following switching operation, when the If any of the caution items occurs, the magnified engine starting switch is turned OFF.
Page 401 SEN00913-02 30 Testing and adjusting a Action codes and instructions given to operator Action Failure mode Instructions given to operator code Set the swing holding brake release switch to the upper (release) position to release the brake. When applying the swing brake, use the swing lock switch. Error in swing brake system The error may not be reset, depending on the cause of the failure.
Page 402 SEN00913-02 30 Testing and adjusting a The telephone symbol mark and telephone 14. Function for showing failure code No. If the following switching operation is made No. are shown only when they are registered while the action code No. is shown, a phone in the machine monitor.
Page 403 SEN00913-02 30 Testing and adjusting Failure codes table Action Device in Failure code Trouble (Displayed on screen) Category of record code charge — AA10NX Aircleaner Clogging Mechanical system — AB00KE Charge Voltage Low Mechanical system — B@BAZG Eng. Oil Press. Low Mechanical system —...
Page 404 SEN00913-02 30 Testing and adjusting Action Device in Failure code Trouble (Displayed on screen) Category of record code charge CA451 Rail Press Sensor High Error Electrical system CA452 Rail Press Sensor Low Error Electrical system CA553 Rail Press High Error Electrical system —...
Page 405 SEN00913-02 30 Testing and adjusting Action Device in Failure code Trouble (Displayed on screen) Category of record code charge DHPEKB F Pump P. Sensor S/C PUMP Electrical system DHPFKA R Pump P. Sensor Disc. PUMP Electrical system DHPFKB R Pump P. Sensor S/C PUMP Electrical system —...
Page 406 SEN00913-02 30 Testing and adjusting 15. Function of reversing fan rotation and adjust- 4] If the [ ] switch is pressed, the screen ing economy mode value to wait for change of the fan rotation 1) Reversing fan rotation direction appears and the engine speed 1] Press switch [5] of the monitor, and the is lowered to low idle automatically.
Page 407 SEN00913-02 30 Testing and adjusting 6] If any trouble occurs while the fan is 3] If the [ ] switch is pressed, the screen rotating in reverse, the following warning to wait for change of the fan rotation monitor is displayed. In this case, see the direction appears and the engine speed page of explanation of the monitoring is lowered to low idle automatically.
Page 408 SEN00913-02 30 Testing and adjusting 2) This state shows that reversing of the fan 3) Adjusting economy mode value rotation is prohibited to protect the compo- 1] In the screen of 2)-1], select “2” E mode nents under some conditions of coolant tem- and press the [ ] switch, and the fol- perature and hydraulic oil temperature.
Page 409 SEN00913-02 30 Testing and adjusting Operation and Display of Service Menu 3) Showing Service Menu display The display is changed to the initial display of Service Menu program. Select an appropriate Way of switching to Service Menu item from among the menu. a When using Service Menu, change the display to Service Menu display through the following special operation.
Page 410 SEN00913-02 30 Testing and adjusting a The display automatically moves to the dis- 16. Function for monitoring [01] The machine monitor monitors signals from an play of monitored information, when all of the assortment of switches, sensors and actuators registrable items have been duly registered. a Monitored information are transmitted via installed in various parts of the machine.
Page 411 SEN00913-02 30 Testing and adjusting 5) Machine setting mode switching function If it becomes necessary to change settings of working mode, travel speed and auto- decel while monitoring, depress the corre- sponding switch, then the mode confirma- tion display is shown. a When a specific setting is confirmed, de- press [ ] switch, then the display re-...
Page 412 SEN00913-02 30 Testing and adjusting Monitoring items list Unit (Default: ISO) Code Monitoring item Remarks meter inch 00000 Return (Not displayed) Ending menu 99999 To Display Screen (Not displayed) Display execution menu 00200 Controller Model Select Numeral 00201 Machine ID Numeral 01002 Engine Speed r/min...
Page 413 SEN00913-02 30 Testing and adjusting Unit (Default: ISO) Code Monitoring item Remarks meter inch 04105 Eng. Water Temp. Vol. Lo 14201 Fuel Temp. Sensor Vol. 04402 Hydr. Temp. Sensor Vol. 37503 Ambi. Temp. Sensor Vol. 37201 Eng Oil Press Sens Volt 37401 Ambient Press Sens Volt 18401 Intake Temp Sens Volt 18501 Charge Temp Sens Volt...
Page 414 SEN00913-02 30 Testing and adjusting Unit (Default: ISO) Code Monitoring item Remarks meter inch Travel Junction Display of ON/OFF Swing Brake Display of ON/OFF 2-Stage Relief Display of ON/OFF 02300 Solenoid Valve 1 Travel Speed Display of ON/OFF Fan Reverse Display of ON/OFF Swing Priority Display of ON/OFF...
Page 415 SEN00913-02 30 Testing and adjusting Unit (Default: ISO) Code Monitoring item Remarks meter inch Swing Brake Sw. Display of ON/OFF Bzzr Cancel Sw. Display of ON/OFF Window Limit Sw. Display of ON/OFF W Limit Sw. Display of ON/OFF 04502 Monitor Input 3 Upper P Limit Sw.
Page 416 SEN00913-02 30 Testing and adjusting 17. Function for Abnormality Record [02] 3) Information shown in display of Abnormality The machine monitor records failures that Record in the electrical system occurred on the machines in the past after clas- [1]: The numerator expresses sequence of sifying them into failures in the electric system failure occurrence, counting from the and those in the mechanical system.
Page 417 SEN00913-02 30 Testing and adjusting 5) Resetting Electrical Systems ii) Operate the switch, following the instruc- a Resetting Electrical Systems (deletion) tions shown in the resetting display. a When resetting specific information is possible only with the electrical sys- tem. The failure history in the mechani- only, call the display of that specific cal system cannot be reset.
Page 418 SEN00913-02 30 Testing and adjusting 18. Function for maintenance history [03] 19. Function for maintenance mode change [04] The machine monitor records information on the Conditions set for controlling maintenance dis- maintenance of filters and oils. The stored infor- play function can be changed in the following mation can be displayed through the following manner.
Page 419 SEN00913-02 30 Testing and adjusting 4) Set contents of individual items [1]: Default: The maintenance time set in Maintenance mode change item the monitor (recommended by the man- Return (Termination of maintenance ufacturer and cannot be changed). mode change) [2]: Set: Maintenance time that can be Maintenance Mode On/Off freely set.
Page 420 SEN00913-02 30 Testing and adjusting a When entering a wrong number, de- 20. Function for recording phone No. [05] In the display of action code, a telephone num- press [Swing priority] switch, then the ber and failure code are shown alternately. cursor goes back by one digit.
Page 421 SEN00913-02 30 Testing and adjusting 4) Function for AA/Language 2) Selection of submenu Select an item to change from the submenu, In Service Menu, the language in use can b e c h a n g e d b e t w e e n J a p a n e s e a n d and depress [ ] switch.
Page 422 SEN00913-02 30 Testing and adjusting 6) Function for selection of wiper specification The wiper specification can be set. • One wiper: Machine with standard cab or fixed-front window cab (Only upper wiper) • Two wipers: Machine with fixed-front window cab (if equipped) (Upper wiper and lower wiper) a If this setting is not matched to the spec- ification of the actually installed wiper,...
Page 423 SEN00913-02 30 Testing and adjusting 22. Function for adjustment [07] (Applicable for all machines: 55046 and up) The machine can be adjusted with the machine monitor. 1) Selection of menu Select “07 Adjustment” on the service menu and press the [ ] switch.
Page 424 SEN00913-02 30 Testing and adjusting a If the starting switch is turned OFF, the 6) Fan 70% speed adjustment function fan speed mode returns to “550: Normal After “70% speed” is set in 4) above, the fan mode”. speed can be adjusted within the following Keep the starting switch ON while ad- range.
Page 425 SEN00913-02 30 Testing and adjusting 23. Function of reduced cylinder mode operation [08] The reduced cylinder mode can be controlled with the machine monitor. Reduced cylinder mode operation means to run the engine with 1 or more fuel injectors disabled electrically to reduce the number of effective cyl- inders.
Page 426 SEN00913-02 30 Testing and adjusting 4) Function of holding engine speed [Reference]: How to use holding function effec- If the [E] switch is pressed while the tively reduced cylinder mode operation screen is The engine speed displayed by the holding func- used, the engine speed is held and dis- tion is held on the screen until the holding func- played on the lower line.
Page 427 SEN00913-02 30 Testing and adjusting 24. Function of no injection cranking [09] No injection cranking of the engine is available from 4) Select “No Injection” and press [ ] switch. the machine monitor. “Under Preparation” will be displayed on the No injection cranking denotes stopping injection of screen.
Page 428 SEN00913-02 30 Testing and adjusting 7) After the no injection cranking is over, press [ switch from the previous screen and the letters “End” will be displayed for 3 seconds. a The letters “End” are displayed in green. 8) Press “Return” when ending the no injection cranking.
Page 429: Handling Controller Voltage Circuit
SEN00913-02 30 Testing and adjusting Handling controller voltage circuit 1. When disconnecting or connecting a connector between the engine controller and engine, be sure to turn the starting switch OFF. 2. If a T-adapter is inserted in or connected to a connector between the engine controller and engine for troubleshooting, do not start the engine.
Page 430 SEN00913-02 30 Testing and adjusting PC800-8, PC800SE-8, PC800LC-8, PC850-8, PC850SE-8 Hydraulic excavator Form No. SEN00913-02...
Page 431 SEN00914-02 HYDRAULIC EXCAVATOR PC800-8 PC850-8 PC800SE-8 PC850SE-8 PC800LC-8 Machine model Serial number PC800-8 50001 and up PC800SE-8 50001 and up PC800LC-8 50001 and up PC850-8 10001 and up PC850SE-8 10001 and up Testing and adjusting Testing and adjusting, Part 5 Testing and adjusting, Part 5..........................
Page 432: Procedure For Turning On Komtrax Terminal
SEN00914-02 30 Testing and adjusting Testing and adjusting, Part 5 Procedure for turning on KOMTRAX terminal When the machine is delivered, KOMTRAX ter- minal is installed: a When the machine is delivered, KOMTRAX ter- minal is installed (machine with the standard equipment), implement the following procedure.
Page 433 30 Testing and adjusting SEN00914-02 a As [Normal] is indicated, proceed to the next step. a If [Abnormal] is indicated, repeat the pro- cedure from step 1). 9) Set the starting switch to START position and maintain it in that state for 5 seconds. Make sure the engine is not started.
Page 434 SEN00914-02 30 Testing and adjusting 2. Application for start of use a The application for start of use is allowed only after the terminal station opening in- spection has been successfully ended. 1) Concerning the machine body for which the station opening inspection has been com- pleted, report the following information to the person responsible to operation of KOM-...
Page 435: Komtrax Terminal Lamp Indications
30 Testing and adjusting SEN00914-02 KOMTRAX terminal lamp indications LED for CPU 7-segment and dot for CPU 1. LED-C1 (R signal and ACC signal) 7. 7-segment (Number of mails which are not trans- 2. LED-C2 (Initial output state) mitted yet and condition of satellite link) 3.
Page 436 SEN00914-02 30 Testing and adjusting KOMTRAX system displays various information in the system as well as contents of information processing on the LED display unit located at the top of KOMTRAX terminal. Thus, when a failure on the system is suspected, implement the following checkups.
Page 437 30 Testing and adjusting SEN00914-02 2. Display contents of 7-segment and dots for CPU a Turn ON the starting switch prior to inspection of LED display. Display unit Name and function Display (*2) Contents of display Figure indicates number of mails which are not sent yet Lighting of (When 10 or more mails are not sent yet, 9 is indicated).
Page 438: Preparation Work For Troubleshooting Electrical System
SEN00914-02 30 Testing and adjusting Preparation work for 2. Engine controller 1) Remove controller cover (1). troubleshooting electrical system a When troubleshooting an electric circuit related to the machine monitor, engine controller, or pump controller, expose the related connectors according to the following procedure. 1.
Page 439 30 Testing and adjusting SEN00914-02 3. Pump controller 4. KOMTRAX terminal a The pump controller is installed in the cover a KOMTRAX terminal is installed in the cover at the rear of the operator's seat. situated in the rear side of the operator seat. 1) Remove 3 caps (4) and 3 mounting bolts.
Page 440 SEN00914-02 30 Testing and adjusting PC800, 850-8...
Page 441 Pm-clinic service PC800, 850-8...
Page 442 MEASURING PROCEDURES Positions to install measuring devices (Related to engine and PTO) PC800, 850-8...
Page 443 MEASURING PROCEDURES Positions to install measuring devices (Related to relief pressure and OLSS oil pressure) PC800, 850-8...
Page 444 Standard value for Measurement item Condition Unit Service limit value Measurement result Good new machine Low idle 800 – 850 800 – 850 High idle (*1) 1930 – 2030 1930 – 2030 Run engine at high idle + Raise boom to Min.
Page 445 * Since the pump is at the swash plate intermediate point, "5-5, 5-6 (VC valve output pressure)" is about "0.5 – 0.6 times" (approx. 1/2) of the "5-3, 5-4 (VC valve basic pressure)". PC800, 850-8...
Page 446: Pm-Clinic Service
Pm-CLINIC SERVICE PC800 (LC, SE), 850 (SE)-8 Visual check of welded structures (For PC800, 800LC,850-8) a If any crack is found, draw its shape below. Boom Revolving frame 1. Arm cylinder bracket 4. Boom top bracket 9. Boom bracket T Left T Right T Left T Right...
Page 447 Visual check of welded structures (For PC800SE, 850SE-8) a If any crack is found, draw its shape below. Boom Revolving frame 1. Arm cylinder bracket 4. Boom top bracket 9. Boom bracket T Left T Right T Left T Right T Left T Right 2.
Page 448 SEN00914-02 30 Testing and adjusting UNDERCARRIAGE INSPECTION (Program form No.: ***************) Komatsu Undercarriage Inspection Customer name: Address: Equip# Model Serial# Work Order No Wet, AR, HD or Dry Location Shoe width (mm) Soil condition Dealer Shoe type Working condition Inspector Wear type Insp.Date(yyyy/mm/dd)
Page 449 30 Testing and adjusting SEN00914-02 PC800, 850-8...
Page 450 SEN00914-02 30 Testing and adjusting PC800-8, PC800SE-8, PC800LC-8, PC850-8, PC850SE-8 Hydraulic excavator Form No. SEN00914-02...
Page 451: Troubleshooting
SEN02797-00 HYDRAULIC EXCAVATOR PC800-8 PC850-8 PC800SE-8 PC850SE-8 PC800LC-8 Machine model Serial number PC800-8 50001 and up PC800SE-8 50001 and up PC800LC-8 50001 and up PC850-8 10001 and up PC850SE-8 10001 and up 40 Troubleshooting Failure code table and fuse locations Failure code table and fuse locations Failure codes table ............................
Page 452: Failure Codes Table
SEN02797-00 40 Troubleshooting Failure code table and fuse locations Failure codes table Action Failure Device in Category of Reference Trouble (Displayed on screen) code code charge record document No. — AA10NX Aircleaner Clogging Mechanical system — AB00KE Charge Voltage Low Mechanical system —...
Page 453 40 Troubleshooting SEN02797-00 Action Failure Device in Category of Reference Trouble (Displayed on screen) code code charge record document No. CA342 Calibration Code Incompatibility Electrical system Troubleshooting CA351 Injectors Drive Circuit Error Electrical system by failure code, Part 1 CA352 Sens Supply 1 Volt Low Error Electrical system SEN00790-02...
Page 454 SEN02797-00 40 Troubleshooting Action Failure Device in Category of Reference Trouble (Displayed on screen) code code charge record document No. Low pump controller solenoid power sup- DA22KK PUMP Electrical system ply voltage — DA25KP Press. Sensor Power Abnormality PUMP Electrical system —...
Page 455 40 Troubleshooting SEN02797-00 Action Failure Device in Category of Reference Trouble (Displayed on screen) code code charge record document No. — DY2CKB Washer Drive S/C PUMP Electrical system Troubleshooting by failure code, — DY2DKB Wiper Drive (For) S/C PUMP Electrical system Part 3 SEN00792-02 —...
Page 456: Fuse Locations
SEN02797-00 40 Troubleshooting Fuse locations Connection table of circuit breakers a This connection table shows the devices to which each power supply of the circuit breakers supplies power (A switch power supply is a device which supplies power while the starting switch is at the ON position and a constant power supply is a device which supplies power while the starting switch is at the OFF position).
Page 457 40 Troubleshooting SEN02797-00 Connection table of fuse boxes a This connection table shows the devices to which each power supply of the fuse boxes supplies power (A switch power supply is a device which supplies power while the starting switch is at the ON position and a constant power supply is a device which supplies power while the starting switch is at the OFF position).
Page 458 SEN02797-00 40 Troubleshooting PC800-8, PC800SE-8, PC800LC-8, PC850-8, PC850SE-8 Hydraulic excavator Form No. SEN02797-00...
Page 459: General Information On Troubleshooting
SEN00789-02 HYDRAULIC EXCAVATOR PC800-8 PC850-8 PC800SE-8 PC850SE-8 PC800LC-8 Machine model Serial number PC800-8 50001 and up PC800SE-8 50001 and up PC800LC-8 50001 and up PC850-8 10001 and up PC850SE-8 10001 and up 40 Troubleshooting General information on troubleshooting General information on troubleshooting Points to remember when troubleshooting .....................
Page 460: Troubleshooting
SEN00789-02 40 Troubleshooting General information on troubleshooting Points to remember when troubleshooting k Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fit- ted. k When carrying out the operation with 2 or more workers, keep strictly to the agreed signals, and do not allow any unauthorized person to come near.
Page 461: Sequence Of Events In Troubleshooting
40 Troubleshooting SEN00789-02 Sequence of events in troubleshooting PC800, 850-8...
Page 462: Checks Before Troubleshooting
SEN00789-02 40 Troubleshooting Checks before troubleshooting Item Criterion Remedy 1. Check of level and type of fuel — Add fuel 2. Check of fuel for foreign matter — Clean and drain 3. Check of hydraulic oil level — Add oil 4.
Page 463: Classification And Troubleshooting Steps
40 Troubleshooting SEN00789-02 Classification and troubleshooting steps Classification of troubleshooting Mode Contents Display of code Troubleshooting by failure code E-mode Troubleshooting of electrical system H-mode Troubleshooting of hydraulic and mechanical system S-mode Troubleshooting of engine Troubleshooting steps If a problem that appears to be a failure occurs on the machine, identify the relevant troubleshooting No. by per- forming the following steps and proceed to the main body of troubleshooting.
Page 464: Information In Troubleshooting Table
SEN00789-02 40 Troubleshooting Information in troubleshooting table a The following information is summarized in the troubleshooting table and the related electrical circuit dia- gram. Before carrying out troubleshooting, understand that information fully. Action code Failure code Display on Display on Trouble Title of failure phenomenon shown in failure history machine...
Page 465 40 Troubleshooting SEN00789-02 Related circuit diagram This drawing is a part of the electric circuit diagram related to troubleshooting. • Connector No.: Indicates (Model – Number of pins) and (Color). • (Arrow): Roughly shows the location on the machine. PC800, 850-8...
Page 466: Failure-Looking Phenomenon And Troubleshooting No
SEN00789-02 40 Troubleshooting Failure-looking phenomenon and troubleshooting No. Troubleshooting Failure-looking phenomenon Display of E mode H mode S mode code Action to be taken concerning action code and failure code Display action code in machine monitor Accord- Display failure code in electrical system after checking failure history ing to displayed Display failure code in mechanical system after checking failure his-...
Page 467 40 Troubleshooting SEN00789-02 Troubleshooting Failure-looking phenomenon Display of E mode H mode S mode code Boom does not move Arm does not move Bucket does not move H-10 Hydraulic drift of work equipment is large H-11 Time lag of work equipment is large H-12 Heavy lift function does not operate or stop H-13...
Page 468 SEN00789-02 40 Troubleshooting Troubleshooting Failure-looking phenomenon Display of E mode H mode S mode code Machine monitor-related failure (Service menu: Special function display) “Boom RAISE” is not correctly displayed in monitor function E-18 “Boom LOWER” is not correctly displayed in monitor function E-19 “Arm IN”...
Page 469: Wiring Table For Connector Pin Numbers
40 Troubleshooting SEN00789-02 Wiring table for connector pin numbers (Rev. 2006. 11) a The terms of male and female refer to the pins, while the terms of male housing and female housing refer to the mating portion of the housing. PC800, 850-8...
Page 470 SEN00789-02 40 Troubleshooting PC800, 850-8...
Page 471 40 Troubleshooting SEN00789-02 PC800, 850-8...
Page 472 SEN00789-02 40 Troubleshooting PC800, 850-8...
Page 473 40 Troubleshooting SEN00789-02 PC800, 850-8...
Page 474 SEN00789-02 40 Troubleshooting PC800, 850-8...
Page 475 40 Troubleshooting SEN00789-02 PC800, 850-8...
Page 476 SEN00789-02 40 Troubleshooting PC800, 850-8...
Page 477 40 Troubleshooting SEN00789-02 PC800, 850-8...
Page 478 SEN00789-02 40 Troubleshooting PC800, 850-8...
Page 479 40 Troubleshooting SEN00789-02 PC800, 850-8...
Page 480 SEN00789-02 40 Troubleshooting PC800, 850-8...
Page 481 40 Troubleshooting SEN00789-02 PC800, 850-8...
Page 482 SEN00789-02 40 Troubleshooting PC800, 850-8...
Page 483 40 Troubleshooting SEN00789-02 PC800, 850-8...
Page 484 SEN00789-02 40 Troubleshooting PC800, 850-8...
Page 485 40 Troubleshooting SEN00789-02 PC800, 850-8...
Page 486 SEN00789-02 40 Troubleshooting PC800, 850-8...
Page 487 40 Troubleshooting SEN00789-02 PC800, 850-8...
Page 488 SEN00789-02 40 Troubleshooting PC800, 850-8...
Page 489 40 Troubleshooting SEN00789-02 PC800, 850-8...
Page 490 SEN00789-02 40 Troubleshooting PC800, 850-8...
Page 491 40 Troubleshooting SEN00789-02 PC800, 850-8...
Page 492 SEN00789-02 40 Troubleshooting PC800, 850-8...
Page 493 40 Troubleshooting SEN00789-02 PC800, 850-8...
Page 494 SEN00789-02 40 Troubleshooting PC800, 850-8...
Page 495 40 Troubleshooting SEN00789-02 PC800, 850-8...
Page 496 SEN00789-02 40 Troubleshooting PC800, 850-8...
Page 497 40 Troubleshooting SEN00789-02 PC800, 850-8...
Page 498 SEN00789-02 40 Troubleshooting PC800, 850-8...
Page 499 40 Troubleshooting SEN00789-02 PC800, 850-8...
Page 500 SEN00789-02 40 Troubleshooting PC800, 850-8...
Page 501 40 Troubleshooting SEN00789-02 PC800, 850-8...
Page 502: T-Adapter Box And T-Adapter Table
SEN00789-02 40 Troubleshooting T-adapter box and T-adapter table (Rev. 2006. 11) a The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal col- umn indicates a part number of harness checker assembly. T-adapter kit Identification Part No.
Page 503 40 Troubleshooting SEN00789-02 T-adapter kit Identification Part No. Part name symbol q q q 799-601-7130 Adapter for M 799-601-7340 Adapter for M q q q 799-601-7140 Adapter for S q q q 799-601-7150 Adapter for S (White) S10P q q q 799-601-7160 Adapter for S (Blue) S12P q q q...
Page 504 SEN00789-02 40 Troubleshooting T-adapter kit Identification Part No. Part name symbol 799-601-9340 Case 799-601-9350 Adapter for DRC DRC-40 799-601-9360 Adapter for DRC DRC-24 799-601-9410* Socket for engine (CRI-T2) Adapter for engine (CRI-T2) 799-601-9420 Adapter for engine (CRI-T3) PFUEL Socket for engine (CRI-T2) 799-601-9430* Socket for engine (CRI-T3) PCV 799-601-9440* Socket for engine (CRI-T2)
Page 505 40 Troubleshooting SEN00789-02 PC800, 850-8...
Page 506 SEN00789-02 40 Troubleshooting PC800-8, PC800SE-8, PC800LC-8, PC850-8, PC850SE-8 Hydraulic excavator Form No. SEN00789-02...
Page 507: Troubleshooting By Failure Code (Display Of Code), Part 1
SEN00790-02 HYDRAULIC EXCAVATOR PC800-8 PC850-8 PC800SE-8 PC850SE-8 PC800LC-8 Machine model Serial number PC800-8 50001 and up PC800SE-8 50001 and up PC800LC-8 50001 and up PC850-8 10001 and up PC850SE-8 10001 and up 40 Troubleshooting Troubleshooting by failure code (Display of code), Part 1 Troubleshooting by failure code (Display of code), Part 1 Failure code [AA10NX] Aircleaner Clogging....................
Page 508 SEN00790-02 40 Troubleshooting Failure code [CA141] Eng Oil Press Sensor Low Error ................30 Failure code [CA144] Coolant Temp Sens High Error .................. 32 Failure code [CA145] Coolant Temp Sens Low Error ................... 34 Failure code [CA153] Chg Air Temp Sensor High Error ................36 Failure code [CA154] Chg Air Temp Sensor Low Error ................
Page 509 40 Troubleshooting SEN00790-02 PC800, 850-8...
Page 510: Failure Code [Aa10Nx] Aircleaner Clogging
SEN00790-02 40 Troubleshooting Troubleshooting by failure code (Display of code), Part 1 Failure code [AA10NX] Aircleaner Clogging Action code Failure code Aircleaner Clogging Trouble (Machine monitor system) — AA10NX Contents of • While engine was running, signal circuit of air cleaner clogging switch was opened (disconnected with trouble GND).
Page 511 40 Troubleshooting SEN00790-02 Circuit diagram related to air cleaner clogging switch of machine monitor PC800, 850-8...
Page 512: Failure Code [Ab00Ke] Charge Voltage Low
SEN00790-02 40 Troubleshooting Failure code [AB00KE] Charge Voltage Low Action code Failure code Charge Voltage Low Trouble (Machine monitor system) — AB00KE Contents of • Signal voltage from alternator is below 20 V while the engine is running. trouble Action of •...
Page 513 40 Troubleshooting SEN00790-02 Circuit diagram related to engine preheating, starting and charging circuits PC800, 850-8...
Page 514: Failure Code [B@Bazg] Eng. Oil Press. Low
SEN00790-02 40 Troubleshooting Failure code [B@BAZG] Eng. Oil Press. Low Action code Failure code Engine oil pressure low Trouble (Engine controller system) — B@BAZG Contents of • Engine oil pressure drops while engine is running. trouble Action of • Limits output and continues operation. controller Problem that •...
Page 515: Failure Code [B@Bazk] Eng. Oil Level Low
40 Troubleshooting SEN00790-02 Failure code [B@BAZK] Eng. Oil Level Low Action code Failure code Eng. Oil Level Low Trouble (Machine monitor system) — B@BAZK Contents of • The signal circuit of the engine oil level switch is opened (disconnected from grounding) while the trouble engine is stopped.
Page 516: Failure Code [B@Bcns] Eng. Water Overheat
SEN00790-02 40 Troubleshooting Failure code [B@BCNS] Eng. Water Overheat Action code Failure code Engine coolant overheat Trouble (Engine controller system) — B@BCNS Contents of Engine coolant overheats while engine is running. trouble Action of • Limits output and continues operation. controller Problem that •...
Page 517 40 Troubleshooting SEN00790-02 PC800, 850-8...
Page 518: Failure Code [B@Bczk] Eng. Water Lvl Low
SEN00790-02 40 Troubleshooting Failure code [B@BCZK] Eng. Water Lvl Low Action code Failure code Eng. Water Lvl Low Trouble (Machine monitor system) — B@BCZK Contents of • While engine was running, signal circuit of radiator coolant level switch was opened (disconnected trouble with GND).
Page 519 40 Troubleshooting SEN00790-02 Circuit diagram related to radiator coolant level switch PC800, 850-8...
Page 520: Failure Code [B@Hans] Hydr. Oil Overheat
SEN00790-02 40 Troubleshooting Failure code [B@HANS] Hydr. Oil Overheat Action code Failure code Hydr. Oil Overheat Trouble (Machine monitor system) — B@HANS Contents of • While engine was running, signal of hydraulic oil temperature sensor input 102°C or higher. trouble Action of •...
Page 521 40 Troubleshooting SEN00790-02 Circuit diagram related to hydraulic oil temperature sensor PC800, 850-8...
Page 522: Failure Code [Ca111] Ecm Critical Internal Failure
SEN00790-02 40 Troubleshooting Failure code [CA111] ECM Critical Internal Failure Action code Failure code ECM Critical Internal Failure Trouble (Engine controller system) CA111 Contents of • Incompatibility of data occurred in engine controller. trouble Action of • None in particular. controller Problem that appears on...
Page 523 40 Troubleshooting SEN00790-02 Circuit diagram related to controller power supply PC800, 850-8...
Page 524: Failure Code [Ca115] Eng Ne And Bkup Speed Sens Error
SEN00790-02 40 Troubleshooting Failure code [CA115] Eng Ne and Bkup Speed Sens Error Action code Failure code Eng Ne and Bkup Speed Sens Error Trouble (Engine controller system) CA115 Contents of • Failure occurred simultaneously in engine Ne speed sensor and engine Bkup speed sensor. trouble Action of •...
Page 525 40 Troubleshooting SEN00790-02 PC800, 850-8...
Page 526: Failure Code [Ca122] Chg Air Press Sensor High Error
SEN00790-02 40 Troubleshooting Failure code [CA122] Chg Air Press Sensor High Error Action code Failure code Chg Air Press Sensor High Error Trouble (Engine controller system) CA122 Contents of • High pressure error occurred in charge air pressure sensor circuit. trouble Action of •...
Page 527 40 Troubleshooting SEN00790-02 Circuit diagram related to charge pressure sensor PC800, 850-8...
Page 528: Failure Code [Ca123] Chg Air Press Sensor Low Error
SEN00790-02 40 Troubleshooting Failure code [CA123] Chg Air Press Sensor Low Error Action code Failure code Chg Air Press Sensor Low Error Trouble (Engine controller system) CA123 Contents of • Low pressure error occurred in charge air pressure sensor circuit. trouble Action of •...
Page 529 40 Troubleshooting SEN00790-02 PC800, 850-8...
Page 530: Failure Code [Ca131] Throttle Sensor High Error
SEN00790-02 40 Troubleshooting Failure code [CA131] Throttle Sensor High Error Action code Failure code Throttle Sensor High Error Trouble (Engine controller system) CA131 Contents of • High error occurred in throttle sensor circuit. trouble Action of • Use a signal other than throttle sensor to set the throttle position and continues operation. controller Problem that appears on...
Page 531 40 Troubleshooting SEN00790-02 Circuit diagram related to fuel control dial throttle sensor PC800, 850-8...
Page 532: Failure Code [Ca132] Throttle Sensor Low Error
SEN00790-02 40 Troubleshooting Failure code [CA132] Throttle Sensor Low Error Action code Failure code Throttle Sensor Low Error Trouble (Engine controller system) CA132 Contents of • Low error occurred in throttle sensor circuit. trouble Action of • Use a signal other than throttle sensor to set the throttle position for control. controller Problem that appears on...
Page 533 40 Troubleshooting SEN00790-02 PC800, 850-8...
Page 534: Failure Code [Ca135] Eng Oil Press Sensor High Error
SEN00790-02 40 Troubleshooting Failure code [CA135] Eng Oil Press Sensor High Error Action code Failure code Eng Oil Press Sensor High Error Trouble (Engine controller system) CA135 Contents of • High pressure error occurred in engine oil pressure sensor circuit. trouble Action of •...
Page 535 40 Troubleshooting SEN00790-02 Circuit diagram related to oil pressure sensor Applicable machines PC800-8: 50001 – 50062 PC850-8: 10001 – 10006 Connector “PEVA” is not applied to the following machines: • PC800-8: 55001 and up • PC850-8: 10007, 55001 and up PC800, 850-8...
Page 536: Failure Code [Ca141] Eng Oil Press Sensor Low Error
SEN00790-02 40 Troubleshooting Failure code [CA141] Eng Oil Press Sensor Low Error Action code Failure code Trouble Eng Oil Press Sensor Low Error (Engine controller system) CA141 Contents of • Low pressure error occurred in engine oil pressure sensor circuit. trouble Action of •...
Page 537 40 Troubleshooting SEN00790-02 PC800, 850-8...
Page 538: Failure Code [Ca144] Coolant Temp Sens High Error
SEN00790-02 40 Troubleshooting Failure code [CA144] Coolant Temp Sens High Error Action code Failure code Coolant Temp Sens High Error Trouble (Engine controller system) CA144 Contents of • High temperature error occurred in coolant temperature sensor circuit. trouble Action of •...
Page 539 40 Troubleshooting SEN00790-02 Circuit diagram related to coolant temperature sensor PC800, 850-8...
Page 540: Failure Code [Ca145] Coolant Temp Sens Low Error
SEN00790-02 40 Troubleshooting Failure code [CA145] Coolant Temp Sens Low Error Action code Failure code Coolant Temp Sens Low Error Trouble (Engine controller system) CA145 Contents of • Low temperature error occurred in coolant temperature sensor circuit. trouble Action of •...
Page 541 40 Troubleshooting SEN00790-02 PC800, 850-8...
Page 542: Failure Code [Ca153] Chg Air Temp Sensor High Error
SEN00790-02 40 Troubleshooting Failure code [CA153] Chg Air Temp Sensor High Error Action code Failure code Chg Air Temp Sensor High Error Trouble (Engine controller system) CA153 Contents of • High temperature error occurred in charge air temperature sensor circuit. trouble Action of •...
Page 543 40 Troubleshooting SEN00790-02 Circuit diagram related to charge temperature sensor PC800, 850-8...
Page 544: Failure Code [Ca154] Chg Air Temp Sensor Low Error
SEN00790-02 40 Troubleshooting Failure code [CA154] Chg Air Temp Sensor Low Error Action code Failure code Chg Air Temp Sensor Low Error Trouble (Engine controller system) CA154 Contents of • Low temperature error occurred in charge air temperature sensor circuit. trouble Action of •...
Page 545 40 Troubleshooting SEN00790-02 PC800, 850-8...
Page 546: Failure Code [Ca221] Ambient Press Sens High Error
SEN00790-02 40 Troubleshooting Failure code [CA221] Ambient Press Sens High Error Action code Failure code Ambient Press Sens High Error Trouble (Engine controller system) CA221 Contents of • High pressure error occurred in ambient pressure sensor circuit. trouble Action of •...
Page 547 40 Troubleshooting SEN00790-02 Circuit diagram related to atmospheric pressure sensor PC800, 850-8...
Page 548: Failure Code [Ca222] Ambient Press Sens Low Error
SEN00790-02 40 Troubleshooting Failure code [CA222] Ambient Press Sens Low Error Action code Failure code Ambient Press Sens Low Error Trouble (Engine controller system) CA222 Contents of • Low pressure error occurred in engine ambient pressure sensor circuit. trouble Action of •...
Page 549 40 Troubleshooting SEN00790-02 PC800, 850-8...
Page 550: Failure Code [Ca227] Sens Supply 2 Volt High Error
SEN00790-02 40 Troubleshooting Failure code [CA227] Sens Supply 2 Volt High Error Action code Failure code Sens Supply 2 Volt High Error Trouble (Engine controller system) CA227 Contents of • High voltage error occurred in sensor power supply 2 (5V) circuit. trouble •...
Page 551 40 Troubleshooting SEN00790-02 Cause Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting with- Short circuit in wiring har- out turning starting switch ON. ness Wiring harness between ENG (female) (37) – Possible causes (with another wiring har- Resis- each sensor (female) and between ENG...
Page 552: Failure Code [Ca234] Eng Overspeed
SEN00790-02 40 Troubleshooting Failure code [CA234] Eng Overspeed Action code Failure code Eng Overspeed Trouble (Engine controller system) — CA234 Contents of • Engine speed exceeded operating range. trouble Action of • Limits fuel injection rate until it lowers in operating range. controller Problem that appears on...
Page 553 40 Troubleshooting SEN00790-02 PC800, 850-8...
Page 554: Failure Code [Ca238] Ne Speed Sens Supply Volt Error
SEN00790-02 40 Troubleshooting Failure code [CA238] Ne Speed Sens Supply Volt Error Action code Failure code Ne Speed Sens Supply Volt Error Trouble (Engine controller system) CA238 Contents of • High voltage error in engine Ne speed sensor power supply (5V) circuit. trouble Action of •...
Page 555 40 Troubleshooting SEN00790-02 Circuit diagram related to Ne speed sensor power supply PC800, 850-8...
Page 556: Failure Code [Ca263] Fuel Temp Sensor High Error
SEN00790-02 40 Troubleshooting Failure code [CA263] Fuel Temp Sensor High Error Action code Failure code Fuel Temp Sensor High Error Trouble (Engine controller system) CA263 Contents of • High temperature error occurred in fuel temperature sensor circuit. trouble Action of •...
Page 557 40 Troubleshooting SEN00790-02 Circuit diagram related to fuel temperature sensor PC800, 850-8...
Page 558: Failure Code [Ca265] Fuel Temp Sensor Low Error
SEN00790-02 40 Troubleshooting Failure code [CA265] Fuel Temp Sensor Low Error Action code Failure code Fuel Temp Sensor Low Error Trouble (Engine controller system) CA265 Contents of • Low temperature error occurred in fuel temperature sensor circuit. trouble Action of •...
Page 559: Failure Code [Ca271] Imv/Pcv1 Short Error
40 Troubleshooting SEN00790-02 Failure code [CA271] IMV/PCV1 Short Error Action code Failure code IMV/PCV1 Short Error Trouble (Engine controller system) CA271 Contents of • Short circuit was detected in PCV1 circuit of supply pump. trouble Action of • None in particular. controller Problem that appears on...
Page 560: Failure Code [Ca272] Imv/Pcv1 Open Error
SEN00790-02 40 Troubleshooting Failure code [CA272] IMV/PCV1 Open Error Action code Failure code IMV/PCV1 Open Error Trouble (Engine controller system) CA272 Contents of • Open error was detected in PCV1 circuit of supply pump. trouble Action of • None in particular. controller Problem that appears on...
Page 561: Failure Code [Ca273] Pcv2 Short Error
40 Troubleshooting SEN00790-02 Failure code [CA273] PCV2 Short Error Action code Failure code PCV2 Short Error Trouble (Engine controller system) CA273 Contents of • Short circuit was detected in PCV2 circuit of supply pump. trouble Action of • None in particular. controller Problem that appears on...
Page 562: Failure Code [Ca274] Pcv2 Open Error
SEN00790-02 40 Troubleshooting Failure code [CA274] PCV2 Open Error Action code Failure code PCV2 Open Error Trouble (Engine controller system) CA274 Contents of • Open error was detected in PCV2 circuit of supply pump. trouble Action of • None in particular. controller Problem that appears on...
Page 563: Failure Code [Ca322] Inj #1 (L#1) Open/Short Error
40 Troubleshooting SEN00790-02 Failure code [CA322] Inj #1 (L#1) Open/Short Error Action code Failure code Inj #1 (L#1) Open/Short Error Trouble (Engine controller system) CA322 Contents of • Opening or short circuit was detected in injector #1 circuit. trouble Action of •...
Page 564: Failure Code [Ca323] Inj #5 (L#5) Open/Short Error
SEN00790-02 40 Troubleshooting Failure code [CA323] Inj #5 (L#5) Open/Short Error Action code Failure code Inj #5 (L#5) Open/Short Error Trouble (Engine controller system) CA323 Contents of • Opening or short circuit was detected in injector #5 circuit. trouble Action of •...
Page 565 40 Troubleshooting SEN00790-02 Circuit diagram related to injector #5 PC800, 850-8...
Page 566: Failure Code [Ca324] Inj #3 (L#3) Open/Short Error
SEN00790-02 40 Troubleshooting Failure code [CA324] Inj #3 (L#3) Open/Short Error Action code Failure code Inj #3 (L#3) Open/Short Error Trouble (Engine controller system) CA324 Contents of • Opening or short circuit was detected in injector #3 circuit. trouble Action of •...
Page 567 40 Troubleshooting SEN00790-02 Circuit diagram related to injector #3 PC800, 850-8...
Page 568: Failure Code [Ca325] Inj #6 (L#6) Open/Short Error
SEN00790-02 40 Troubleshooting Failure code [CA325] Inj #6 (L#6) Open/Short Error Action code Failure code Inj #6 (L#6) Open/Short Error Trouble (Engine controller system) CA325 Contents of • Opening or short circuit was detected in injector #6 circuit. trouble Action of •...
Page 569 40 Troubleshooting SEN00790-02 Circuit diagram related to injector #6 PC800, 850-8...
Page 570: Failure Code [Ca331] Inj #2 (L#2) Open/Short Error
SEN00790-02 40 Troubleshooting Failure code [CA331] Inj #2 (L#2) Open/Short Error Action code Failure code Inj #2 (L#2) Open/Short Error Trouble (Engine controller system) CA331 Contents of • Opening or short circuit was detected in injector #2 circuit. trouble Action of •...
Page 571 40 Troubleshooting SEN00790-02 Circuit diagram related to injector #2 PC800, 850-8...
Page 572: Failure Code [Ca332] Inj #4 (L#4) Open/Short Error
SEN00790-02 40 Troubleshooting Failure code [CA332] Inj #4 (L#4) Open/Short Error Action code Failure code Inj #4 (L#4) Open/Short Error Trouble (Engine controller system) CA332 Contents of • Opening or short circuit was detected in injector #4 circuit. trouble Action of •...
Page 573: Failure Code [Ca342] Calibration Code Incompatibility
40 Troubleshooting SEN00790-02 Failure code [CA342] Calibration Code Incompatibility Action code Failure code Calibration Code Incompatibility Trouble (Engine controller system) CA342 Contents of • Incompatibility of data occurred in engine controller. trouble Action of • None in particular. controller Problem that appears on •...
Page 574: Failure Code [Ca351] Injectors Drive Circuit Error
SEN00790-02 40 Troubleshooting Failure code [CA351] Injectors Drive Circuit Error Action code Failure code Injectors Drive Circuit Error Trouble (Engine controller system) CA351 Contents of • There is error in injector drive circuit. trouble Action of • Limits output and continues operation (limits common rail pressure). controller Problem that appears on...
Page 575 40 Troubleshooting SEN00790-02 Circuit diagram related to controller power supply PC800, 850-8...
Page 576: Failure Code [Ca352] Sens Supply 1 Volt Low Error
SEN00790-02 40 Troubleshooting Failure code [CA352] Sens Supply 1 Volt Low Error Action code Failure code Sens Supply 1 Volt Low Error Trouble (Engine controller system) CA352 Contents of • Low voltage error occurred in sensor power supply 1 (5V) circuit. trouble Action of •...
Page 577 40 Troubleshooting SEN00790-02 PC800, 850-8...
Page 578: Failure Code [Ca386] Sens Supply 1 Volt High Error
SEN00790-02 40 Troubleshooting Failure code [CA386] Sens Supply 1 Volt High Error Action code Failure code Sens Supply 1 Volt High Error Trouble (Engine controller system) CA386 Contents of • High voltage error occurred in sensor power supply 1 (5V) circuit. trouble Action of •...
Page 579 40 Troubleshooting SEN00790-02 Circuit diagram related to sensor power supply 1 (5 V) Applicable machines PC800-8: 50001 – 50062 PC850-8: 10001 – 10006 Connector “PEVA” is not applied to the following machines: • PC800-8: 55001 and up • PC850-8: 10007, 55001 and up PC800, 850-8...
Page 580 SEN00790-02 40 Troubleshooting PC800-8, PC800SE-8, PC800LC-8, PC850-8, PC850SE-8 Hydraulic excavator Form No. SEN00790-02...
Page 581 SEN00791-02 HYDRAULIC EXCAVATOR PC800-8 PC850-8 PC800SE-8 PC850SE-8 PC800LC-8 Machine model Serial number PC800-8 50001 and up PC800SE-8 50001 and up PC800LC-8 50001 and up PC850-8 10001 and up PC850SE-8 10001 and up 40 Troubleshooting 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 ....................
Page 582 SEN00791-02 40 Troubleshooting Failure code [CA1626] BP Valve Sol Current High Error ................22 Failure code [CA1627] BP Valve Sol Current Low Error................24 Failure code [CA1628] Bypass Valve Servo Error 1 ..................25 Failure code [CA1629] Bypass Valve Servo Error 2 ..................26 Failure code [CA1631] BP Valve Pos Sens High Error.................
Page 583: Failure Code [Ca441] Battery Voltage Low Error
SEN00791-02 40 Troubleshooting Troubleshooting by failure code (Display of code), Part 2 Failure code [CA441] Battery Voltage Low Error Action code Failure code Battery Voltage Low Error Trouble (Engine controller system) CA441 Contents of • Low voltage error occurred in power supply circuit. trouble Action of •...
Page 584: Failure Code [Ca449] Rail Press Very High Error
SEN00791-02 40 Troubleshooting Failure code [CA449] Rail Press Very High Error Action code Failure code Rail Press Very High Error Trouble (Engine controller system) CA449 Contents of • There is high pressure error (level 2) in common rail pressure sensor circuit. trouble Action of •...
Page 585 SEN00791-02 40 Troubleshooting PC800, 850-8...
Page 586: Failure Code [Ca451] Rail Press Sensor High Error
SEN00791-02 40 Troubleshooting Failure code [CA451] Rail Press Sensor High Error Action code Failure code Rail Press Sensor High Error Trouble (Engine controller system) CA451 Contents of • High pressure error occurred in common rail pressure sensor circuit. trouble Action of •...
Page 587 SEN00791-02 40 Troubleshooting Cause Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then turn starting switch ON or start Possible causes engine and carry out troubleshooting. and standard value in normal Voltage 6 Defective engine controller state Between (33) –...
Page 588: Failure Code [Ca452] Rail Press Sensor Low Error
SEN00791-02 40 Troubleshooting Failure code [CA452] Rail Press Sensor Low Error Action code Failure code Rail Press Sensor Low Error Trouble (Engine controller system) CA452 Contents of • Low pressure error occurred in common rail pressure sensor circuit. trouble Action of •...
Page 589: Failure Code [Ca554] Rail Press Sensor In Range Error
SEN00791-02 40 Troubleshooting Failure code [CA554] Rail Press Sensor In Range Error Action code Failure code Rail Press Sensor In Range Error Trouble (Engine controller system) — CA554 Contents of • In range error occurred in common rail pressure sensor circuit. trouble Action of •...
Page 590: Failure Code [Ca559] Rail Press Low Error
SEN00791-02 40 Troubleshooting Failure code [CA559] Rail Press Low Error Action code Failure code Rail Press Low Error Trouble (Engine controller system) CA559 Contents of • There is rail press very low error (level 1). trouble Action of • Limits common rail pressure. controller Problem that appears on...
Page 591 SEN00791-02 40 Troubleshooting Note 1: When low-pressure circuit is defective, check the following: • Fuel level • Clogged fuel tank breather • Water separator/Prefilter filled with water • Clogged fuel filter • Clogged screen in water separator • Stuck or worn feed pump, clogged filter •...
Page 592 SEN00791-02 40 Troubleshooting Check sheet for no-pressure feed Machine model Working No. Model serial No. Checked on Engine Service meter Engine serial No. Worker name A. Visual check Good 1 Fuel leakage to outside 2 Clogged fuel tank breather B. Check with machine monitor (Abnormality record, monitoring, cylinder cut-out operation) Good 3 Checking error/failure code Checking monitoring information...
Page 593 SEN00791-02 40 Troubleshooting PC800, 850-8...
Page 594: Failure Code [Ca689] Eng Ne Speed Sensor Error
SEN00791-02 40 Troubleshooting Failure code [CA689] Eng Ne Speed Sensor Error Action code Failure code Eng Ne Speed Sensor Error Trouble (Engine controller system) CA689 Contents of • There is error in engine Ne speed sensor circuit. trouble Action of •...
Page 595 SEN00791-02 40 Troubleshooting Circuit diagram related to engine Ne speed sensor PC800, 850-8...
Page 596: Failure Code [Ca731] Eng Bkup Speed Sens Phase Error
SEN00791-02 40 Troubleshooting Failure code [CA731] Eng Bkup Speed Sens Phase Error Action code Failure code Eng Bkup Speed Sens Phase Error Trouble (Engine controller system) CA731 Contents of • There is phase error in engine Bkup speed sensor circuit. trouble Action of •...
Page 597: Failure Code [Ca757] All Persistent Data Lost Error
SEN00791-02 40 Troubleshooting Failure code [CA757] All Persistent Data Lost Error Action code Failure code All Persistent Data Lost Error Trouble (Engine controller system) CA757 Contents of • All data in engine controller are lost. trouble Action of • None in particular. controller Problem that appears on...
Page 598: Failure Code [Ca778] Eng Bkup Speed Sensor Error
SEN00791-02 40 Troubleshooting Failure code [CA778] Eng Bkup Speed Sensor Error Action code Failure code Engine Bkup speed sensor error Trouble (Engine controller system) CA778 Contents of • There is error in engine Bkup speed sensor circuit. trouble Action of •...
Page 599 SEN00791-02 40 Troubleshooting Circuit diagram related to engine Bkup speed sensor Applicable machines PC800-8: 50001 – 50062 PC850-8: 10001 – 10006 Connector “PEVA” is not applied to the following machines: • PC800-8: 55001 and up • PC850-8: 10007, 55001 and up PC800, 850-8...
Page 600: Failure Code [Ca1228] Egr Valve Servo Error 1
SEN00791-02 40 Troubleshooting Failure code [CA1228] EGR Valve Servo Error 1 Action code Failure code EGR Valve Servo Error 1 Trouble (Engine controller system) CA1228 Contents of • There is EGR valve servo error (level 1). trouble Action of • Performs open control. controller Problem that appears on...
Page 601: Failure Code [Ca1625] Egr Valve Servo Error 2
SEN00791-02 40 Troubleshooting Failure code [CA1625] EGR Valve Servo Error 2 Action code Failure code EGR Valve Servo Error 2 Trouble (Engine controller system) CA1625 Contents of • There is EGR valve servo error (level 2). trouble Action of • Limits output and continues operation. controller •...
Page 602: Failure Code [Ca1626] Bp Valve Sol Current High Error
SEN00791-02 40 Troubleshooting Failure code [CA1626] BP Valve Sol Current High Error Action code Failure code BP Valve Sol Current High Error Trouble (Engine controller system) CA1626 Contents of • There is short circuit in drive circuit of bypass valve solenoid. trouble Action of •...
Page 603 SEN00791-02 40 Troubleshooting Circuit diagram related to bypass valve solenoid & lift sensor PC800, 850-8...
Page 604: Failure Code [Ca1627] Bp Valve Sol Current Low Error
SEN00791-02 40 Troubleshooting Failure code [CA1627] BP Valve Sol Current Low Error Action code Failure code BP Valve Sol Current Low Error Trouble (Engine controller system) CA1627 Contents of • There is disconnection in drive circuit of bypass valve solenoid. trouble Action of •...
Page 605: Failure Code [Ca1628] Bypass Valve Servo Error 1
SEN00791-02 40 Troubleshooting Failure code [CA1628] Bypass Valve Servo Error 1 Action code Failure code Bypass Valve Servo Error 1 Trouble (Engine controller system) CA1628 Contents of • Abnormality (level 1) occurred in bypass valve servo. trouble Action of • Performs open control. controller Problem that appears on...
Page 606: Failure Code [Ca1629] Bypass Valve Servo Error 2
SEN00791-02 40 Troubleshooting Failure code [CA1629] Bypass Valve Servo Error 2 Action code Failure code Bypass Valve Servo Error 2 Trouble (Engine controller system) CA1629 Contents of • Abnormality (level 2) occurred in bypass valve servo. trouble Action of • Limits output and continues operation. controller •...
Page 607 SEN00791-02 40 Troubleshooting PC800, 850-8...
Page 608: Failure Code [Ca1631] Bp Valve Pos Sens High Error
SEN00791-02 40 Troubleshooting Failure code [CA1631] BP Valve Pos Sens High Error Action code Failure code BP Valve Pos Sens High Error Trouble (Engine controller system) CA1631 Contents of • Signal voltage in bypass valve lift sensor circuit is abnormally high. trouble Action of •...
Page 609 SEN00791-02 40 Troubleshooting Circuit diagram related to bypass valve solenoid & lift sensor PC800, 850-8...
Page 610: Failure Code [Ca1632] Bp Valve Pos Sens Low Error
SEN00791-02 40 Troubleshooting Failure code [CA1632] BP Valve Pos Sens Low Error Action code Failure code BP Valve Pos Sens Low Error Trouble (Engine controller system) CA1632 Contents of • Signal voltage in bypass valve lift sensor circuit is abnormally low. trouble Action of •...
Page 611 SEN00791-02 40 Troubleshooting PC800, 850-8...
Page 612: Failure Code [Ca1633] Komnet Datalink Timeout Error
SEN00791-02 40 Troubleshooting Failure code [CA1633] KOMNET Datalink Timeout Error Action code Failure code KOMNET Datalink Timeout Error Trouble (Engine controller system) CA1633 Contents of • There is error in KOMNET communication circuit with machine monitor, pump controller or KOMTRAX trouble controller.
Page 613 SEN00791-02 40 Troubleshooting Circuit diagram related to CAN communication of pump controller PC800, 850-8...
Page 614: Failure Code [Ca1642] Egr Inter Press Sens Low Error
SEN00791-02 40 Troubleshooting Failure code [CA1642] EGR Inter Press Sens Low Error Applicable machines PC800-8: 50001 – 50062 PC850-8: 10001 – 10006 Action code Failure code EGR Inter Press Sens Low Error Trouble (Engine controller system) CA1642 Contents of • Signal voltage in EGR inlet pressure sensor circuit is abnormally low. trouble Action of •...
Page 615 SEN00791-02 40 Troubleshooting PC800, 850-8...
Page 616: Failure Code [Ca1653] Egr Inter Press Sens High Error
SEN00791-02 40 Troubleshooting Failure code [CA1653] EGR Inter Press Sens High Error Applicable machines PC800-8: 50001 – 50062 PC850-8: 10001 – 10006 Action code Failure code EGR Inter Press Sens High Error Trouble (Engine controller system) CA1653 Contents of • Signal voltage in EGR inlet pressure sensor circuit is abnormally high. trouble Action of •...
Page 617 SEN00791-02 40 Troubleshooting Cause Standard value in normal state/Remarks on troubleshooting Possible causes a Prepare with starting switch OFF, then turn starting switch ON or start and standard engine and carry out troubleshooting. value in normal 6 Defective engine controller Voltage state Between (37) –...
Page 618: Failure Code [Ca2185] Throt Sens Sup Volt High Error
SEN00791-02 40 Troubleshooting Failure code [CA2185] Throt Sens Sup Volt High Error Action code Failure code Throt Sens Sup Volt High Error Trouble (Engine controller system) CA2185 Contents of • High voltage error occurred in throttle sensor power supply (5V) circuit. trouble Action of •...
Page 619 SEN00791-02 40 Troubleshooting Circuit diagram related to fuel control dial throttle sensor PC800, 850-8...
Page 620: Failure Code [Ca2186] Throt Sens Sup Volt Low Error
SEN00791-02 40 Troubleshooting Failure code [CA2186] Throt Sens Sup Volt Low Error Action code Failure code Throt Sens Sup Volt Low Error Trouble (Engine controller system) CA2186 Contents of • Low voltage error occurred in throttle sensor power supply (5V) circuit. trouble Action of •...
Page 621: Failure Code [Ca2249] Rail Press Very Low Error
SEN00791-02 40 Troubleshooting Failure code [CA2249] Rail Press Very Low Error Action code Failure code Rail Press Very Low Error Trouble (Engine controller system) CA2249 Contents of • There is rail press very low error (level 2). trouble Action of •...
Page 622: Failure Code [Ca2271] Egr Valve Pos Sens High Error
SEN00791-02 40 Troubleshooting Failure code [CA2271] EGR Valve Pos Sens High Error Action code Failure code EGR Valve Pos Sens High Error Trouble (Engine controller system) CA2271 Contents of • High error occurred in EGR valve lift sensor circuit. trouble Action of •...
Page 623 SEN00791-02 40 Troubleshooting Circuit diagram related to EGR valve solenoid and lift sensor Applicable machines PC800-8: 50001 – 50062 PC850-8: 10001 – 10006 Connector “PEVA” is not applied to the following machines: • PC800-8: 55001 and up • PC850-8: 10007, 55001 and up PC800, 850-8...
Page 624: Failure Code [Ca2272] Egr Valve Pos Sens Low Error
SEN00791-02 40 Troubleshooting Failure code [CA2272] EGR Valve Pos Sens Low Error Action code Failure code EGR Valve Pos Sens Low Error Trouble (Engine controller system) CA2272 Contents of • Low error occurred in EGR valve lift sensor circuit. trouble Action of •...
Page 625 SEN00791-02 40 Troubleshooting PC800, 850-8...
Page 626: Failure Code [Ca2351] Egr Valve Sol Current High Error
SEN00791-02 40 Troubleshooting Failure code [CA2351] EGR Valve Sol Current High Error Action code Failure code EGR Valve Sol Current High Error Trouble (Engine controller system) CA2351 Contents of • High current error occurred in drive circuit of EGR valve solenoid. trouble Action of •...
Page 627 SEN00791-02 40 Troubleshooting Circuit diagram related to EGR valve solenoid and lift sensor Applicable machines PC800-8: 50001 – 50062 PC850-8: 10001 – 10006 Connector “PEVA” is not applied to the following machines: • PC800-8: 55001 and up • PC850-8: 10007, 55001 and up PC800, 850-8...
Page 628: Failure Code [Ca2352] Egr Valve Sol Current Low Error
SEN00791-02 40 Troubleshooting Failure code [CA2352] EGR Valve Sol Current Low Error Action code Failure code EGR Valve Sol Current Low Error Trouble (Engine controller system) CA2352 Contents of • Low current error occurred in drive circuit of EGR valve solenoid. trouble Action of •...
Page 629: Failure Code [Ca2555] Grid Htr Relay Volt Low Error
SEN00791-02 40 Troubleshooting Failure code [CA2555] Grid Htr Relay Volt Low Error Action code Failure code Grid Htr Relay Volt Low Error Trouble (Engine controller system) CA2555 Contents of • Voltage low error was detected in grid heater relay circuit. trouble Action of •...
Page 630: Failure Code [Ca2556] Grid Htr Relay Volt High Error
SEN00791-02 40 Troubleshooting Failure code [CA2556] Grid Htr Relay Volt High Error Action code Failure code Grid Htr Relay Volt High Error Trouble (Engine controller system) CA2556 Contents of • Open error was detected in intake air heater relay circuit trouble Action of •...
Page 631 SEN00791-02 40 Troubleshooting Circuit diagram related to engine preheater PC800, 850-8...
Page 632: Failure Code [D110Kb] Battery Relay Drive S/C
SEN00791-02 40 Troubleshooting Failure code [D110KB] Battery Relay Drive S/C Action code Failure code Battery Relay Drive S/C Trouble (Pump controller system) D110KB Contents of • Abnormal current flowed at output to battery relay drive circuit. trouble Action of • Turns output to battery relay drive circuit OFF. controller •...
Page 633 SEN00791-02 40 Troubleshooting Circuit diagram related to battery relay drive PC800, 850-8...
Page 634: Failure Code [D163Kb] Flash Light Relay S/C
SEN00791-02 40 Troubleshooting Failure code [D163KB] Flash Light Relay S/C Action code Failure code Flash Light Relay S/C Trouble (Pump controller system) — D163KB Contents of • Abnormal current flowed in the flash light relay circuit (the primary circuit of the relay), when power is trouble supplied to the circuit.
Page 635 SEN00791-02 40 Troubleshooting Electric circuit diagram related to horn and flash light relay PC800, 850-8...
Page 636: Failure Code [D195Kb] Step Light Relay S/C
SEN00791-02 40 Troubleshooting Failure code [D195KB] Step Light Relay S/C Action code Failure code Step Light Relay S/C Trouble (Pump controller system) — D195KB Contents of • Abnormal current flowed in the step light relay circuit (the primary circuit of the relay), when power is trouble supplied to the circuit.
Page 637 SEN00791-02 40 Troubleshooting Electric circuit diagram related to step light PC800, 850-8...
Page 638: Failure Code [Da22Kk] Pump Solenoid Power Low Error
SEN00791-02 40 Troubleshooting Failure code [DA22KK] Pump Solenoid Power Low Error Action code Failure code Pump Solenoid Power Low Error Trouble (Pump controller system) DA22KK Contents of • Pump controller solenoid power supply voltage is below 20 V. trouble Action of •...
Page 639 SEN00791-02 40 Troubleshooting Circuit diagram related to power supply of pump controller PC800, 850-8...
Page 640: Failure Code [Da25Kp] Press. Sensor Power Abnormality
SEN00791-02 40 Troubleshooting Failure code [DA25KP] Press. Sensor Power Abnormality Action code Failure code Press. Sensor Power Abnormality Trouble (Pump controller system) — DA25KP Contents of • Abnormal current flowed in pressure sensor power supply (5V) circuit. trouble • Turns output to power supply (5V) circuit OFF. Action of •...
Page 641 SEN00791-02 40 Troubleshooting Circuit diagram related to pressure sensor power supply of pump controller PC800, 850-8...
Page 642: Failure Code [Da2Skq] Model Selection Abnormality
SEN00791-02 40 Troubleshooting Failure code [DA2SKQ] Model Selection Abnormality Action code Failure code Model Selection Abnormality Trouble (Pump controller system) — DA2SKQ Contents of • Model code signal for model which is not registered in controller is input. trouble Action of •...
Page 643 SEN00791-02 40 Troubleshooting Circuit diagram related to model selection connector of pump controller PC800, 850-8...
Page 644: Failure Code [Da80Ma] Auto. Lub. Abnormal
SEN00791-02 40 Troubleshooting Failure code [DA80MA] Auto. Lub. Abnormal. a This failure code is displayed only when automatic lubrication equipment is installed. PC800, 850-8...
Page 645 SEN00791-02 40 Troubleshooting PC800, 850-8...
Page 646: Failure Code [Da2Rmc] Pump Comm. Abnormality
SEN00791-02 40 Troubleshooting Failure code [DA2RMC] Pump Comm. Abnormality Action code Failure code Pump Comm. Abnormality Trouble (Pump controller system) DA2RMC Contents of • Pump controller detected communication error in CAN communication circuit between machine moni- trouble tor, engine controller and KOMTRAX controller. Action of •...
Page 647 SEN00791-02 40 Troubleshooting Circuit diagram related to CAN communication of pump controller PC800, 850-8...
Page 648: Failure Code [Dafrmc] Monitor Comm. Abnormality
SEN00791-02 40 Troubleshooting Failure code [DAFRMC] Monitor Comm. Abnormality Action code Failure code Monitor Comm. Abnormality Trouble (Machine monitor system) DAFRMC Contents of • Machine monitor detected communication error in CAN communication circuit between pump control- trouble ler, KOMTRAX controller and engine controller. Action of •...
Page 649 SEN00791-02 40 Troubleshooting Circuit diagram related to CAN communication of machine monitor PC800, 850-8...
Page 650: Failure Code [Dge5Ky] Ambi. Temp. Sensor S/C
SEN00791-02 40 Troubleshooting Failure code [DGE5KY] Ambi. Temp. Sensor S/C Action code Failure code Ambi. Temp. Sensor S/C Trouble (Pump controller system) — DGE5KY Contents of • Abnormal current flowed in ambient temperature sensor circuit. trouble Action of • None in particular. controller •...
Page 651 SEN00791-02 40 Troubleshooting Circuit diagram related to ambient temperature sensor PC800, 850-8...
Page 652: Failure Code [Dgh2Kb] Hydr. Oil Temp. Sensor S/C
SEN00791-02 40 Troubleshooting Failure code [DGH2KB] Hydr. Oil Temp. Sensor S/C Action code Failure code Hydr. Oil Temp. Sensor S/C Trouble (Mechanical system) — DGH2KB Contents of • The signal of the hydraulic oil temperature sensor rises above 102°C while the engine is running. trouble Action of •...
Page 653 SEN00791-02 40 Troubleshooting Circuit diagram related to hydraulic oil temperature sensor PC800, 850-8...
Page 654 SEN00791-02 40 Troubleshooting PC800-8, PC800SE-8, PC800LC-8, PC850-8, PC850SE-8 Hydraulic excavator Form No. SEN00791-02...
Page 655: Troubleshooting By Failure Code (Display Of Code), Part 3
SEN00792-02 HYDRAULIC EXCAVATOR PC800-8 PC850-8 PC800SE-8 PC850SE-8 PC800LC-8 Machine model Serial number PC800-8 50001 and up PC800SE-8 50001 and up PC800LC-8 50001 and up PC850-8 10001 and up PC850SE-8 10001 and up 40 Troubleshooting 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......................
Page 656 SEN00792-02 40 Troubleshooting Failure code [DW45KB] Swing Brake Sol. S/C..................... 32 Failure code [DW7BKA] Fan Reverse Sol. Disc................... 34 Failure code [DW7BKB] Fan Reverse Sol. S/C .................... 36 Failure code [DW7JKA] Bottom Dump Priority Sol. Disc................38 Failure code [DW7JKB] Bottom Dump Priority Sol. S/C ................40 Failure code [DWK0KA] 2-stage Relief Sol.
Page 657 SEN00792-02 40 Troubleshooting PC800, 850-8...
Page 658: Failure Code [Dh25Ka] L Jet Sensor Disc
SEN00792-02 40 Troubleshooting Troubleshooting by failure code (Display of code), Part 3 Failure code [DH25KA] L Jet Sensor Disc Action code Failure code L Jet Sensor Disc Trouble (Pump controller system) — DH25KA Contents of • Signal voltage of L jet sensor differential pressure sensor circuit is below 0.3 V. trouble •...
Page 659 SEN00792-02 40 Troubleshooting Circuit diagram related to differential pressure sensor system PC800, 850-8...
Page 660: Failure Code [Dh25Kb] L Jet Sensor S/C
SEN00792-02 40 Troubleshooting Failure code [DH25KB] L Jet Sensor S/C Action code Failure code L Jet Sensor S/C Trouble (Pump controller system) — DH25KB Contents of • Signal voltage of L jet sensor differential pressure sensor circuit is above 4.5 V. trouble •...
Page 661 SEN00792-02 40 Troubleshooting Circuit diagram related to differential pressure sensor system PC800, 850-8...
Page 662: Failure Code [Dh26Ka] R Jet Sensor Disc
SEN00792-02 40 Troubleshooting Failure code [DH26KA] R Jet Sensor Disc. Action code Failure code R Jet Sensor Disc Trouble (Pump controller system) — DH26KA Contents of • Signal voltage of L jet sensor differential pressure sensor circuit is below 0.3 V. trouble •...
Page 663 SEN00792-02 40 Troubleshooting Circuit diagram related to differential pressure sensor system PC800, 850-8...
Page 664: Failure Code [Dh26Kb] R Jet Sensor S/C
SEN00792-02 40 Troubleshooting Failure code [DH26KB] R Jet Sensor S/C Action code Failure code R Jet Sensor S/C Trouble (Pump controller system) — DH26KB Contents of • Signal voltage of R jet sensor differential pressure sensor circuit is above 4.5 V. trouble •...
Page 665 SEN00792-02 40 Troubleshooting Circuit diagram related to differential pressure sensor system PC800, 850-8...
Page 666: Failure Code [Dhpeka] F Pump P. Sensor Disc
SEN00792-02 40 Troubleshooting Failure code [DHPEKA] F Pump P. Sensor Disc. Action code Failure code F pump P. Sensor Disc. Trouble (Pump controller system) DHPEKA Contents of • Signal voltage of F pump pressure sensor circuit is below 0.5 V. trouble •...
Page 667 SEN00792-02 40 Troubleshooting Circuit diagram related to F pump pressure sensor PC800, 850-8...
Page 668: Failure Code [Dhpekb] F Pump P. Sensor S/C
SEN00792-02 40 Troubleshooting Failure code [DHPEKB] F Pump P. Sensor S/C Action code Failure code F Pump P. Sensor S/C Trouble (Pump controller system) DHPEKB Contents of • Signal voltage from the front pump pressure sensor is below 0.3 V or above 4.42 V. trouble •...
Page 669 SEN00792-02 40 Troubleshooting Circuit diagram related to F pump pressure sensor PC800, 850-8...
Page 670: Failure Code [Dhpfka] R Pump P. Sensor Disc
SEN00792-02 40 Troubleshooting Failure code [DHPFKA] R Pump P. Sensor Disc. Action code Failure code R Pump P. Sensor Disc. Trouble (Pump controller system) DHPFKA Contents of • Signal voltage of R pump pressure sensor circuit is below 0.5 V or above 4.5 V. trouble •...
Page 671 SEN00792-02 40 Troubleshooting Circuit diagram related to F pump pressure sensor PC800, 850-8...
Page 672: Failure Code [Dhpfkb] R Pump P. Sensor S/C
SEN00792-02 40 Troubleshooting Failure code [DHPFKB] R Pump P. Sensor S/C Action code Failure code R Pump P. Sensor S/C Trouble (Pump controller system) — DHPFKB Contents of • Signal voltage from the front pump pressure sensor is below 0.3 V or above 4.42 V. trouble •...
Page 673 SEN00792-02 40 Troubleshooting Circuit diagram related to R pump pressure sensor PC800, 850-8...
Page 674: Failure Code [Dv20Kb] Travel Alarm S/C
SEN00792-02 40 Troubleshooting Failure code [DV20KB] Travel Alarm S/C Action code Failure code Travel Alarm S/C Trouble (Pump controller system) — DV20KB Contents of • Abnormal current flowed in the travel alarm circuit, when power is supplied to the circuit. trouble •...
Page 675 SEN00792-02 40 Troubleshooting Circuit diagram related to travel alarm PC800, 850-8...
Page 676: Failure Code [Dw41Ka] Swing Priority Sol. Disc
SEN00792-02 40 Troubleshooting Failure code [DW41KA] Swing Priority Sol. Disc. Action code Failure code Swing Priority Sol. Disc. Trouble (Pump controller system) — DW41KA Contents of • No current flows to the swing priority solenoid circuit, when power is supplied to the circuit. trouble Action of •...
Page 677 SEN00792-02 40 Troubleshooting Electric circuit diagram related to swing priority solenoid PC800, 850-8...
Page 678: Failure Code [Dw41Kb] Swing Priority Sol. S/C
SEN00792-02 40 Troubleshooting Failure code [DW41KB] Swing Priority Sol. S/C Action code Failure code Swing Priority Sol. S/C Trouble (Pump controller system) — DW41KB Contents of • Abnormal current flew to the swing priority solenoid, when power was supplied to the circuit. trouble •...
Page 679 SEN00792-02 40 Troubleshooting Electric circuit diagram related to swing priority solenoid PC800, 850-8...
Page 680: Failure Code [Dw43Ka] Travel Speed Sol. Disc
SEN00792-02 40 Troubleshooting Failure code [DW43KA] Travel Speed Sol. Disc. Action code Failure code Travel Speed Sol. Disc. Trouble (Pump controller system) — DW43KA Contents of • No current flows travel speed solenoid circuit as power is turned on. trouble Action of •...
Page 681 SEN00792-02 40 Troubleshooting Circuit diagram related to travel speed solenoid of pump controller PC800, 850-8...
Page 682: Failure Code [Dw43Kb] Travel Speed Sol. S/C
SEN00792-02 40 Troubleshooting Failure code [DW43KB] Travel Speed Sol. S/C Action code Failure code Travel Speed Sol. S/C Trouble (Pump controller system) — DW43KB Contents of • Abnormal current flowed at output to travel speed solenoid circuit. trouble Action of •...
Page 683 SEN00792-02 40 Troubleshooting Circuit diagram related to travel speed solenoid of pump controller PC800, 850-8...
Page 684: Failure Code [Dw45Ka] Swing Brake Sol. Disc
SEN00792-02 40 Troubleshooting Failure code [DW45KA] Swing Brake Sol. Disc. Action code Failure code Swing Brake Sol. Disc. Trouble (Pump controller system) DW45KA Contents of • No current flows at output to swing brake solenoid circuit. trouble Action of • None in particular. (Since no current flows, solenoid does not operate.) controller •...
Page 685 SEN00792-02 40 Troubleshooting Circuit diagram related to swing holding brake solenoid of pump controller PC800, 850-8...
Page 686: Failure Code [Dw45Kb] Swing Brake Sol. S/C
SEN00792-02 40 Troubleshooting Failure code [DW45KB] Swing Brake Sol. S/C Action code Failure code Swing Brake Sol. S/C Trouble (Pump controller system) DW45KB Contents of • Abnormal current flowed at output to swing brake solenoid circuit. trouble Action of • Turns output to swing brake solenoid circuit OFF. controller •...
Page 687 SEN00792-02 40 Troubleshooting Circuit diagram related to swing holding brake solenoid of pump controller PC800, 850-8...
Page 688: Failure Code [Dw7Bka] Fan Reverse Sol. Disc
SEN00792-02 40 Troubleshooting Failure code [DW7BKA] Fan Reverse Sol. Disc. Action code Failure code Fan Reverse Sol. Disc. Trouble (Pump controller system) — DW7BKA Contents of • When signal is output to hydraulic fan reverse solenoid circuit, no current flows. trouble Action of •...
Page 689 SEN00792-02 40 Troubleshooting Circuit diagram related to hydraulic fan PC800, 850-8...
Page 690: Failure Code [Dw7Bkb] Fan Reverse Sol. S/C
SEN00792-02 40 Troubleshooting Failure code [DW7BKB] Fan Reverse Sol. S/C Action code Failure code Fan Reverse Sol. S/C Trouble (Pump controller system) — DW7BKB Contents of • When signal was output to hydraulic fan reverse solenoid circuit, abnormal current flowed. trouble Action of •...
Page 691 SEN00792-02 40 Troubleshooting Circuit diagram related to hydraulic fan PC800, 850-8...
Page 692: Failure Code [Dw7Jka] Bottom Dump Priority Sol. Disc
SEN00792-02 40 Troubleshooting Failure code [DW7JKA] Bottom Dump Priority Sol. Disc. Action code Failure code Bottom Dump Priority Sol. Disc. Trouble (Pump controller system) — DW7JKA Contents of • When signal is output to bottom dump priority solenoid circuit, no current flows. trouble Action of •...
Page 693 SEN00792-02 40 Troubleshooting Circuit diagram related to bottom dump priority solenoid PC800, 850-8...
Page 694: Failure Code [Dw7Jkb] Bottom Dump Priority Sol. S/C
SEN00792-02 40 Troubleshooting Failure code [DW7JKB] Bottom Dump Priority Sol. S/C Action code Failure code Bottom Dump Priority Sol. S/C Trouble (Pump controller system) — DW7JKB Contents of • When signal is output to bottom dump priority solenoid circuit, abnormal current flows. trouble Action of •...
Page 695 SEN00792-02 40 Troubleshooting Circuit diagram related to bottom dump priority solenoid PC800, 850-8...
Page 696: Failure Code [Dwk0Ka] 2-Stage Relief Sol. Disc
SEN00792-02 40 Troubleshooting Failure code [DWK0KA] 2-stage Relief Sol. Disc. Action code Failure code 2-stage Relief Sol. Disc. Trouble (Pump controller system) — DWK0KA Contents of • No current flows at output to 2-stage relief solenoid circuit. trouble Action of •...
Page 697 SEN00792-02 40 Troubleshooting Circuit diagram related to 2-stage relief solenoid of pump controller PC800, 850-8...
Page 698: Failure Code [Dwk0Kb] 2-Stage Relief Sol. S/C
SEN00792-02 40 Troubleshooting Failure code [DWK0KB] 2-stage Relief Sol. S/C Action code Failure code 2-stage Relief Sol. S/C Trouble (Pump controller system) — DWK0KB Contents of • Abnormal current flowed at output to 2-stage relief solenoid circuit. trouble Action of •...
Page 699 SEN00792-02 40 Troubleshooting Circuit diagram related to 2-stage relief solenoid of pump controller PC800, 850-8...
Page 700: Failure Code [Dx16Ka] Fan Pump Epc Sol. Disc
SEN00792-02 40 Troubleshooting Failure code [DX16KA] Fan Pump EPC Sol. Disc. Action code Failure code Fan Pump EPC Sol. Disc. Trouble (Pump controller system) DX16KA Contents of • No current flows into hydraulic fan EPC solenoid circuit. trouble • If circuit is disconnected, power supply is turned OFF and fan pump is set to maximum swash plate Action of angle and fan may rotate at excessive speed.
Page 701 SEN00792-02 40 Troubleshooting Circuit diagram related to fan pump EPC solenoid PC800, 850-8...
Page 702: Failure Code [Dx16Kb] Fan Pump Epc Sol. S/C
SEN00792-02 40 Troubleshooting Failure code [DX16KB] Fan Pump EPC Sol. S/C Action code Failure code Fan Pump EPC Sol. S/C Trouble (Pump controller system) DX16KB Contents of • Abnormal current flowed in hydraulic fan EPC solenoid circuit. trouble • If circuit has short circuit, power supply is turned OFF and fan pump is set to maximum swash plate Action of angle and fan may rotate at excessive speed.
Page 703 SEN00792-02 40 Troubleshooting Circuit diagram related to fan pump EPC solenoid PC800, 850-8...
Page 704: Failure Code [Dxaaka] F Pump Epc Sol. Disc
SEN00792-02 40 Troubleshooting Failure code [DXAAKA] F Pump EPC Sol. Disc. Action code Failure code F Pump EPC Sol. Disc. Trouble (Pump controller system) DXAAKA Contents of • When main pump EPC (F) solenoid was energized, disconnection was detected in solenoid. trouble •...
Page 705 SEN00792-02 40 Troubleshooting Circuit diagram related to main pump EPC solenoid PC800, 850-8...
Page 706: Failure Code [Dxaakb] F Pump Epc Sol. S/C
SEN00792-02 40 Troubleshooting Failure code [DXAAKB] F Pump EPC Sol. S/C Action code Failure code F Pump EPC Sol. S/C Trouble (Pump controller system) DXAAKB Contents of • When main pump EPC (F) solenoid was energized, short circuit was detected in solenoid. trouble •...
Page 707 SEN00792-02 40 Troubleshooting Circuit diagram related to main pump EPC solenoid PC800, 850-8...
Page 708: Failure Code [Dxabka] R Pump Epc Sol. Disc
SEN00792-02 40 Troubleshooting Failure code [DXABKA] R Pump EPC Sol. Disc. Action code Failure code R Pump EPC Sol. Disc. Trouble (Pump controller system) DXABKA Contents of • When main pump EPC (R) solenoid was energized, disconnection was detected in solenoid. trouble •...
Page 709 SEN00792-02 40 Troubleshooting Circuit diagram related to main pump EPC solenoid PC800, 850-8...
Page 710: Failure Code [Dxabkb] R Pump Epc Sol. S/C
SEN00792-02 40 Troubleshooting Failure code [DXABKB] R Pump EPC Sol. S/C Action code Failure code R Pump EPC Sol. S/C Trouble (Pump controller system) DXABKB Contents of • When main pump EPC (R) solenoid was energized, short circuit was detected in solenoid. trouble •...
Page 711 SEN00792-02 40 Troubleshooting Circuit diagram related to main pump EPC solenoid PC800, 850-8...
Page 712: Failure Code [Dy20Ka] Wiper Working Abnormality
SEN00792-02 40 Troubleshooting Failure code [DY20KA] Wiper Working Abnormality Action code Failure code Wiper Working Abnormality Trouble (Machine monitor system) — DY20KA Contents of • When windshield wiper works, W signal of working ends is not input. trouble Action of •...
Page 713 SEN00792-02 40 Troubleshooting Circuit diagram related to wiper motor of machine monitor PC800, 850-8...
Page 714: Failure Code [Dy20Ma] Wiper Parking Abnormality
SEN00792-02 40 Troubleshooting Failure code [DY20MA] Wiper Parking Abnormality Double-wiper specification Action code Failure code Wiper Parking Abnormality Trouble (Machine monitor system) — DY20MA Contents of • When parking windshield wiper, P signal for storage area is not input. trouble Action of •...
Page 715 SEN00792-02 40 Troubleshooting Circuit diagram related to wiper motor of machine monitor (Double-wiper specification) PC800, 850-8...
Page 716 SEN00792-02 40 Troubleshooting Single-wiper specification Action code Failure code Wiper Parking Abnormality Trouble (Machine monitor system) — DY20MA Contents of • When parking windshield wiper, P signal for storage area is not input. trouble Action of • Turns parking output to wiper motor OFF. controller Problem that appears on...
Page 717 SEN00792-02 40 Troubleshooting Circuit diagram related to wiper motor of machine monitor (Single-wiper specification) PC800, 850-8...
Page 718: Failure Code [Dy2Ckb] Washer Drive S/C
SEN00792-02 40 Troubleshooting Failure code [DY2CKB] Washer Drive S/C Action code Failure code Washer Drive S/C Trouble (Machine monitor system) — DY2CKB Contents of • When washer drive circuit was connected to GND (when output was turned ON), abnormal current trouble flowed.
Page 719 SEN00792-02 40 Troubleshooting Circuit diagram related to window washer motor of machine monitor PC800, 850-8...
Page 720: Failure Code [Dy2Dkb] Wiper Drive (For) S/C
SEN00792-02 40 Troubleshooting Failure code [DY2DKB] Wiper Drive (For) S/C Double-wiper specification Action code Failure code Wiper Drive (For) S/C Trouble (Machine monitor system) — DY2DKB Contents of • Abnormal current flowed at output to wiper motor (for) circuit. trouble Action of •...
Page 721 SEN00792-02 40 Troubleshooting Circuit diagram related to wiper motor of machine monitor (Double-wiper specification) PC800, 850-8...
Page 722 SEN00792-02 40 Troubleshooting Single-wiper specification Action code Failure code Wiper Drive (For) S/C Trouble (Machine monitor system) — DY2DKB Contents of • Abnormal current flowed at output to wiper motor (for) circuit. trouble Action of • Turns output to wiper motor (for) circuit OFF. controller Problem that appears on...
Page 723 SEN00792-02 40 Troubleshooting Circuit diagram related to wiper motor of machine monitor (Single-wiper specification) PC800, 850-8...
Page 724: Failure Code [Dy2Ekb] Wiper Drive (Rev) S/C
SEN00792-02 40 Troubleshooting Failure code [DY2EKB] Wiper Drive (Rev) S/C Single-wiper specification Action code Failure code Wiper Drive (Rev) S/C Trouble (Machine monitor system) — DY2EKB Contents of • Abnormal current flowed at output to wiper motor (rev.) circuit. trouble Action of •...
Page 725 SEN00792-02 40 Troubleshooting Circuit diagram related to wiper motor of machine monitor (Single-wiper specification) PC800, 850-8...
Page 726 SEN00792-02 40 Troubleshooting PC800-8, PC800SE-8, PC800LC-8, PC850-8, PC850SE-8 Hydraulic excavator Form No. SEN00792-02...
Page 727: Troubleshooting Of Electrical System (E-Mode)
SEN00793-02 HYDRAULIC EXCAVATOR PC800-8 PC850-8 PC800SE-8 PC850SE-8 PC800LC-8 Machine model Serial number PC800-8 50001 and up PC800SE-8 50001 and up PC800LC-8 50001 and up PC850-8 10001 and up PC850SE-8 10001 and up 40 Troubleshooting Troubleshooting of electrical system (E-mode) Troubleshooting of electrical system (E-mode)....................3 Before carrying out troubleshooting of electrical system ................
Page 728 SEN00793-02 40 Troubleshooting E-13 Hydraulic oil temperature gauge does not display correctly..............30 E-14 Fuel gauge does not display correctly....................31 E-15 Swing lock monitor does not display correctly ..................32 E-16 When monitor switch is operated, nothing is displayed ............... 34 E-17 Windshield wiper and window washer do not work................
Page 729: Before Carrying Out Troubleshooting Of Electrical System
40 Troubleshooting SEN00793-02 Troubleshooting of electrical system (E-mode) Before carrying out troubleshooting of electrical system Connection table of circuit breakers a This connection table shows the devices to which each power supply of the circuit breakers supplies power (A switch power supply is a device which supplies power while the starting switch is at the ON position and a constant power supply is a device which supplies power while the starting switch is at the OFF position).
Page 730 SEN00793-02 40 Troubleshooting Connection table of fuse boxes a This connection table shows the devices to which each power supply of the fuse boxes supplies power (A switch power supply is a device which supplies power while the starting switch is at the ON position and a constant power supply is a device which supplies power while the starting switch is at the OFF position).
Page 731: Information Contained In Troubleshooting Table
40 Troubleshooting SEN00793-02 Information contained in troubleshooting table a Troubleshooting Table and Related Circuit Diagram collectively carry the following information. Carry out troubleshooting work after fully grasping their contents. Failure Phenomenon occurring on machine phenomenon Relative Information on the failure occurred as well as the troubleshooting information Cause Standard value in normal state/Remarks on troubleshooting...
Page 732: Engine Does Not Start (Engine Does Not Rotate)
SEN00793-02 40 Troubleshooting E-1 Engine does not start (Engine does not rotate) Failure • The engine does not start. (Engine does not rotate) phenomenon Relative • The engine starting circuit is equipped with the start lock mechanism of lock lever type. information Cause Standard value in normalcy and references for troubleshooting...
Page 733 40 Troubleshooting SEN00793-02 Cause Standard value in normalcy and references for troubleshooting aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between battery relay terminal Resis- Max. 1 z B and B16 tance Wiring harness between B26 –...
Page 734 SEN00793-02 40 Troubleshooting Circuit diagram related to engine preheat, start and battery charging PC800, 850-8...
Page 735: Preheater Does Not Operate
40 Troubleshooting SEN00793-02 E-2 Preheater does not operate Failure • Preheater does not operate (1) When starting switch is turned ON, auto-preheater does not work. phenomenon • When starting switch is turned ON, HEAT lamp on panel lights up for about 30 seconds and then starts Relative blinking to notify completion of preheating.
Page 736 SEN00793-02 40 Troubleshooting Cause Standard value in normalcy and references for troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting with- out turning starting switch ON. Wiring harness between H06 (female) (5) – J03 Resistance Max. 1 z FB1 (20) – CE02 (female) (39) Wiring harness between CE02 (female) (40) Resistance Max.
Page 737 40 Troubleshooting SEN00793-02 Circuit diagram related to engine preheat, start and battery charging PC800, 850-8...
Page 738 SEN00793-02 40 Troubleshooting Failure (2) When the starting switch is turned to the HEAT posi- • The preheater does not operate. phenomenon tion, the preheating monitor does not light up. • The preheating monitor starts lighting when the starting switch is turned to the HEAT position. After about Relative 30 seconds, it start flashing to notify that preheating is finished (It stops flashing in about 10 seconds).
Page 739 40 Troubleshooting SEN00793-02 PC800, 850-8...
Page 740 SEN00793-02 40 Troubleshooting Failure (3) When the starting switch is turned to the HEAT • The preheater does not operate. phenomenon position, the heater unit is not warmed. Relative • Check that the starting motor rotates normally. information (If the starting motor does not rotate, carry out troubleshooting in “Engine does not start”.) Cause Standard value in normalcy and references for troubleshooting aTurn the engine starting switch OFF for the preparations, and hold it in...
Page 741 40 Troubleshooting SEN00793-02 Circuit diagram related to engine preheat, start and battery charging PC800, 850-8...
Page 742: Auto Engine Warm-Up Device Does Not Work
SEN00793-02 40 Troubleshooting E-3 Auto engine warm-up device does not work Failure • The auto engine warm-up device does not work. phenomenon • The auto engine warm-up device is activated, when the engine coolant temperature is below 30°C, and raise the engine rotation up to 1,200 rpm. Relative •...
Page 743: Auto-Decelerator Does Not Operate
40 Troubleshooting SEN00793-02 E-4 Auto-decelerator does not operate Failure • The auto-decelerator does not operate. phenomenon • Since the auto-decelerator is set to 1,400 rpm, it does not operate if the fuel control dial is not set above this level. Relative •...
Page 744: All Work Equipment, Swing And Travel Do Not Move
SEN00793-02 40 Troubleshooting E-5 All work equipment, swing and travel do not move Failure • All the work equipment, swing and travel do not move. phenomenon Relative information Cause Standard value in normalcy and references for troubleshooting If the fuse is blown, there is a big possibility that grounding fault 1 Fuse No.
Page 745 40 Troubleshooting SEN00793-02 Circuit diagram related to PPC lock solenoid PC800, 850-8...
Page 746: Machine Push-Up Function Does Not Operate Normally
SEN00793-02 40 Troubleshooting E-6 Machine push-up function does not operate normally Failure • The machine push-up function does not oper- (1) The machine push-up function does not operate. phenomenon ate normally. Relative • When the machine push-up function is set in the high pressure position, the solenoid is turned OFF. information Cause Standard value in normalcy and references for troubleshooting...
Page 747 40 Troubleshooting SEN00793-02 Failure • The machine push-up function does not oper- (2) The machine push-up function is not turned OFF. phenomenon ate normally. Relative • When the machine push-up function is set in the low pressure position, the solenoid is turned ON. information Cause Standard value in normalcy and references for troubleshooting...
Page 748: Boom Shockless Function Does Not Operate Normally
SEN00793-02 40 Troubleshooting E-7 Boom shockless function does not operate normally Failure • The boom shockless function does not oper- (1) The boom shockless function does not operate. phenomenon ate normally. Relative • When the boom shockless function is turned ON, the solenoid is turned OFF. information Cause Standard value in normalcy and references for troubleshooting...
Page 749 40 Troubleshooting SEN00793-02 Failure • The boom shockless function does not oper- (2) The boom shockless function is not turned OFF. phenomenon ate normally. Relative • When the boom shockless function is turned OFF, the solenoid is turned ON. information Cause Standard value in normalcy and references for troubleshooting If the fuse is broken, the circuit probably has grounding fault (See cause...
Page 750: Any Item Is Not Displayed On Machine Monitor
SEN00793-02 40 Troubleshooting E-8 Any item is not displayed on machine monitor Failure • Any item is not displayed on machine moni- When the starting switch is turned ON, any item is not phenomenon tor. displayed on machine monitor. Relative information Cause Standard value in normalcy and references for troubleshooting...
Page 751: Part Of Display On Machine Monitor Is Missing
40 Troubleshooting SEN00793-02 E-9 Part of display on machine monitor is missing Failure Part of display on machine monitor is missing during • Part of display on machine monitor is missing phenomenon starting switch in ON. Relative information Cause Standard value in normalcy and references for troubleshooting aTurn the starting switch ON during the troubleshooting.
Page 752: Fuel Level Monitor Red Lamp Lights Up While Engine Is Running
SEN00793-02 40 Troubleshooting E-11 Fuel level monitor red lamp lights up while engine is running Failure • Fuel level monitor red lamp lights up while the engine is running. phenomenon Relative • If the fuel gauge shows in a red range on the machine monitor, the fuel level monitor lamp lights up information red.
Page 753 40 Troubleshooting SEN00793-02 PC800, 850-8...
Page 754: Engine Coolant Thermometer Does Not Display Normally
SEN00793-02 40 Troubleshooting E-12 Engine coolant thermometer does not display normally (1) While the engine coolant temperature rises nor- mally, the thermometer does not rise above the Failure • Engine coolant thermometer does not display white range (C). phenomenon normally (2) While the engine coolant temperature is stabilized normally, the thermometer rises up to the red range (H).
Page 755 40 Troubleshooting SEN00793-02 Circuit diagram related to engine coolant temperature sensor PC800, 850-8...
Page 756: Hydraulic Oil Temperature Gauge Does Not Display Correctly
SEN00793-02 40 Troubleshooting E-13 Hydraulic oil temperature gauge does not display correctly (1) Hydraulic oil temperature rises normally, but the dis- Failure • Hydraulic oil temperature gauge does not dis- play does not exceed the white range (C). phenomenon play correctly (2) Hydraulic oil temperature remains stable, but the display rises up the red range (H).
Page 757: Fuel Gauge Does Not Display Correctly
40 Troubleshooting SEN00793-02 E-14 Fuel gauge does not display correctly (1) Though fuel was refilled, the display does not Failure exceed the red range (E). • Fuel gauge does not display correctly phenomenon (2) Though the remaining fuel level is low, the display does not drop below the green range (F).
Page 758: Swing Lock Monitor Does Not Display Correctly
SEN00793-02 40 Troubleshooting E-15 Swing lock monitor does not display correctly (1) Though the swing lock switch was turned ON, the Failure swing lock monitor does not light up. • Swing lock monitor does not display correctly phenomenon (2) Though the swing lock switch was turned OFF, the swing lock monitor lights up.
Page 759 40 Troubleshooting SEN00793-02 Circuit diagram related to swing holding brake PC800, 850-8...
Page 760: When Monitor Switch Is Operated, Nothing Is Displayed
SEN00793-02 40 Troubleshooting E-16 When monitor switch is operated, nothing is displayed Failure • When monitor switch is operated, nothing is (1) When mode selector switch is operated, working phenomenon displayed. mode monitor is not displayed. Relative information Possible causes Cause Standard value in normalcy and references for troubleshooting and standard...
Page 761 40 Troubleshooting SEN00793-02 Failure • When monitor switch is operated, nothing is (6) When wiper switch is operated, wiper monitor is not phenomenon displayed. displayed. Relative • When the wiper does not operate either, conduct the troubleshooting for “Windshield wiper and win- information dow washer do not work”.
Page 762: Windshield Wiper And Window Washer Do Not Work
SEN00793-02 40 Troubleshooting E-17 Windshield wiper and window washer do not work Double-wiper specification Failure • Windshield wiper and window washer do not (1) The upper windshield wiper does not operate phenomenon work Relative information Cause Standard value in normalcy and references for troubleshooting aTurn the engine starting switch OFF for the preparations, and hold it in Defective upper wiper the OFF position during the troubleshooting.
Page 763 40 Troubleshooting SEN00793-02 Circuit diagram related to wiper motor (double-wiper specification) PC800, 850-8...
Page 764 SEN00793-02 40 Troubleshooting Double-wiper specification Failure • Windshield wiper and window washer do not (2) Lower windshield wiper does not operate. phenomenon work Relative information Cause Standard value in normalcy and references for troubleshooting aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
Page 765 40 Troubleshooting SEN00793-02 Circuit diagram related to wiper motor (double-wiper specification) PC800, 850-8...
Page 766 SEN00793-02 40 Troubleshooting Single-wiper specification Failure • Windshield wiper and window washer do not (3) The windshield wiper does not work. phenomenon work. Relative information Cause Standard value in normalcy and references for troubleshooting aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
Page 767 40 Troubleshooting SEN00793-02 Circuit diagram related to windshield wiper motor (single-wiper specification) PC800, 850-8...
Page 768 SEN00793-02 40 Troubleshooting Failure • Windshield wiper and window washer do not (4) Windshield washer does not operate. phenomenon work. Relative information Cause Standard value in normalcy and references for troubleshooting If fuse is broken, the circuit probably has grounding fault, etc. (See 1 Defective fuse No.
Page 769 40 Troubleshooting SEN00793-02 Circuit diagram related to window washer motor PC800, 850-8...
Page 770: Boom Raise" Is Not Correctly Displayed In Monitor Function
SEN00793-02 40 Troubleshooting E-18 “Boom RAISE” is not correctly displayed in monitor function Failure • “Boom RAISE” is not correctly displayed in mon- “Boom RAISE” is not correctly displayed in the moni- phenomenon itor function tor function on the machine monitor. Relative •...
Page 771: Boom Lower" Is Not Correctly Displayed In Monitor Function
40 Troubleshooting SEN00793-02 E-19 “Boom LOWER” is not correctly displayed in monitor function Failure • “Boom LOWER” is not correctly displayed in “Boom LOWER” is not correctly displayed in the phenomenon monitor function monitor function on the machine monitor. Relative •...
Page 772: Arm In" Is Not Correctly Displayed In Monitor Function
SEN00793-02 40 Troubleshooting E-20 “Arm IN” is not correctly displayed in monitor function Failure • “Arm IN” is not correctly displayed in monitor “Arm IN” is not correctly displayed in the monitor phenomenon function function (special function) on the machine monitor. Relative •...
Page 773: Arm Out" Is Not Correctly Displayed In Monitor Function
40 Troubleshooting SEN00793-02 E-21 “Arm OUT” is not correctly displayed in monitor function Failure • “Arm OUT” is not correctly displayed in monitor “Arm OUT” is not correctly displayed in the monitor phenomenon function function (special function) on the machine monitor. Relative •...
Page 774: Bucket Curl" Is Not Correctly Displayed In Monitor Function
SEN00793-02 40 Troubleshooting E-22 “Bucket CURL” is not correctly displayed in monitor function Failure • “Bucket CURL” is not correctly displayed in “Bucket CURL” is not correctly displayed in the monitor phenomenon monitor function function (special function) on the machine monitor. Relative •...
Page 775: Bucket Dump" Is Not Correctly Displayed In Monitor Function
40 Troubleshooting SEN00793-02 E-23 “Bucket DUMP” is not correctly displayed in monitor function Failure “Bucket DUMP” is not correctly displayed in moni- “Bucket DUMP” is not correctly displayed in the moni- phenomenon tor function tor function (special function) on the machine monitor. Relative •...
Page 776: Swing" Is Not Correctly Displayed In Monitor Function
SEN00793-02 40 Troubleshooting E-24 “SWING” is not correctly displayed in monitor function Failure • “SWING” is not correctly displayed in monitor “SWING” is not correctly displayed in the monitor phenomenon function function (special function) on the machine monitor. Relative • Monitoring code: 01901 (Pressure switch 2) information Cause Standard value in normalcy and references for troubleshooting...
Page 777 40 Troubleshooting SEN00793-02 Circuit diagram related to right and left swing PPC hydraulic switches PC800, 850-8...
Page 778: Left Travel" Is Not Displayed Normally In Monitoring Function
SEN00793-02 40 Troubleshooting E-25 “Left travel” is not displayed normally in monitoring function Failure • “Left travel” is not displayed normally in monitor- “Left travel” is not displayed normally in the monitoring phenomenon ing function. function (special function) of the machine monitor. Relative •...
Page 779 40 Troubleshooting SEN00793-02 Circuit diagram related to left travel forward PPC oil pressure switch and left travel reverse PPC oil pressure switch PC800, 850-8...
Page 780: Right Travel" Is Not Displayed Normally In Monitoring Function
SEN00793-02 40 Troubleshooting E-26 “Right travel” is not displayed normally in monitoring function Failure • “Right travel” is not displayed normally in moni- “Right travel” is not displayed normally in the monitor- phenomenon toring function ing function (special function) of the machine monitor. Relative •...
Page 781 40 Troubleshooting SEN00793-02 Circuit diagram related to right travel forward PPC oil pressure switch and right travel reverse PPC oil pressure switch PC800, 850-8...
Page 782: Service" Is Not Correctly Displayed In Monitor Function
SEN00793-02 40 Troubleshooting E-27 “Service” is not correctly displayed in monitor function When attachment is installed Failure • “Service” is not correctly displayed in monitor “Service” is not correctly displayed in the monitor func- phenomenon function tion (special function) on the machine monitor. Relative •...
Page 783 40 Troubleshooting SEN00793-02 Circuit diagram related to service PPC hydraulic switch PC800, 850-8...
Page 784: Komtrax System Does Not Operate Normally
SEN00793-02 40 Troubleshooting E-28 KOMTRAX system does not operate normally Failure • KOMTRAX system does not operate normally. phenomenon • If KOMTRAX system administrator makes request for checking system on machine side for trouble, Related carry out following troubleshooting. information •...
Page 785 40 Troubleshooting SEN00793-02 LED display unit CK01 connector PC800, 850-8...
Page 786: Air Conditioner Does Not Work
SEN00793-02 40 Troubleshooting E-29 Air conditioner does not work Failure • Air conditioner does not work. phenomenon Relative information Cause Standard value in normalcy and references for troubleshooting When fuse is blown, there is a big possibility that grounding fault 1 Fuse No.
Page 787: Step Light Does Not Light Up Or Go Off
40 Troubleshooting SEN00793-02 E-30 Step light does not light up or go off Failure (1) When the switch is pressed, the light does not keep • Step light does not light up or go off. phenomenon lighting up for 1 minute. Relative •...
Page 788 SEN00793-02 40 Troubleshooting Failure • Step light does not light up or go off. (2) While the switch is not pressed, the light lights up. phenomenon Relative information Cause Standard value in normalcy and references for troubleshooting aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
Page 789 40 Troubleshooting SEN00793-02 Circuit diagram related to step light PC800, 850-8...
Page 790: Electric Grease Gun Does Not Operate
SEN00793-02 40 Troubleshooting E-31 Electric grease gun does not operate Failure • Electric grease gun does not operate. phenomenon Relative information Cause Standard value in normalcy and references for troubleshooting If the circuit breaker is turned OFF, the circuit probably has grounding Defective circuit breaker fault No.
Page 791 40 Troubleshooting SEN00793-02 Circuit diagram related to electric grease gun PC800, 850-8...
Page 792: Travel Alarm Does Not Sound Or Does Not Stop Sounding
SEN00793-02 40 Troubleshooting E-32 Travel alarm does not sound or does not stop sounding (1) The alarm does not sound while the machine is trav- Failure • Travel alarm does not sound or does not stop eling. phenomenon sounding. (2) The alarm sounds while the machine is stopped. Relative information Cause...
Page 793 40 Troubleshooting SEN00793-02 Circuit diagram related to travel alarm PC800, 850-8...
Page 794 SEN00793-02 40 Troubleshooting PC800-8, PC800SE-8, PC800LC-8, PC850-8, PC850SE-8 Hydraulic excavator Form No. SEN00793-02...
Page 795: Troubleshooting Of Hydraulic And Mechanical System (H-Mode)
SEN00794-02 HYDRAULIC EXCAVATOR PC800-8 PC850-8 PC800SE-8 PC850SE-8 PC800LC-8 Machine model Serial number PC800-8 50001 and up PC800SE-8 50001 and up PC800LC-8 50001 and up PC850-8 10001 and up PC850SE-8 10001 and up 40 Troubleshooting Troubleshooting of hydraulic and mechanical system (H-mode) Troubleshooting of hydraulic and mechanical system (H-mode) .................
Page 796 SEN00794-02 40 Troubleshooting H-13 Heavy lift function does not operate or stop..................22 H-14 Machine push-up function does not operate or stop................22 H-15 Boom shockless function cannot be turned ON or OFF ..............22 H-16 Machine deviates in one direction......................24 H-17 Machine deviates largely at start ......................
Page 797: Before Troubleshooting
SEN00794-02 40 Troubleshooting Troubleshooting of hydraulic and mechanical system (H-mode) Before troubleshooting PC800, 850-8...
Page 798 SEN00794-02 40 Troubleshooting 1. Combination and operation of hydraulic 3. Judgment of cause of trouble that “work pumps equipment speed is low and machine devi- • For the work equipment and travel and swing cir- ates to right” cuit, 1 tandem pump (HPV375+375) is used. •...
Page 799 SEN00794-02 40 Troubleshooting PC800, 850-8...
Page 800: Information In Troubleshooting Table
SEN00794-02 40 Troubleshooting Information in troubleshooting table a Tables and related circuit diagrams concerning troubleshooting contains the following information. Please understand the contents sufficiently before carrying out troubleshooting. Failure Phenomena on machine phenomenon Relative Information concerning to failure or troubleshooting. information Cause Standard value in normalcy and references for troubleshooting...
Page 801 SEN00794-02 40 Troubleshooting PC800, 850-8...
Page 802: Speed Or Power Of All Work Equipment, Travel, And Swing Is Low
SEN00794-02 40 Troubleshooting H-1 Speed or power of all work equipment, travel, and swing is low Failure • Speed or power of all work equipment, travel, and swing is low phenomenon • Measure the speed of the work equipment, travel, and swing speed and check that all of them are slow (or their power is low).
Page 803 SEN00794-02 40 Troubleshooting Cause Standard value in normalcy and references for troubleshooting aKeep the engine stopped for the preparations, and run it at high idle during troubleshooting (Start troubleshooting after checking that causes 2, 4 are not detected). Defective pump EPC cur- Control levers Pump EPC current rent output...
Page 804: Engine Speed Lowers Remarkably Or Engine Stalls
SEN00794-02 40 Troubleshooting H-2 Engine speed lowers remarkably or engine stalls Failure • Engine speed lowers remarkably or engine stalls phenomenon Related • Set the working mode in P-mode when troubleshooting is carried out. information • If a failure code relating to the pump control is displayed, carry out the troubleshooting for it first. Cause Standard value in normalcy and references for troubleshooting aPrepare with engine stopped, then run engine at high idle speed and...
Page 805 SEN00794-02 40 Troubleshooting PC800, 850-8...
Page 806: All Work Equipment, Travel, And Swing Systems Do Not Work
SEN00794-02 40 Troubleshooting H-3 All work equipment, travel, and swing systems do not work Failure • All work equipment, travel, and swing systems do not work phenomenon Relative • Carry out all the troubleshooting in working mode P. information • If failure code related to pump control is also displayed, carry out troubleshooting for it first. Cause Standard value in normalcy and references for troubleshooting aKeep the engine stopped for the preparations and troubleshooting.
Page 807: Abnormal Sound Is Heard From Around Pump
SEN00794-02 40 Troubleshooting Fig. 1: Control system devices H-4 Abnormal sound is heard from around pump Failure • Abnormal sound is heard from around pump phenomenon Relative information Cause Standard value in normalcy and references for troubleshooting 1 Low hydraulic oil level Since the hydraulic oil level may be low, check it directly.
Page 808: Boom Speed Or Power Is Low
SEN00794-02 40 Troubleshooting H-5 Boom speed or power is low Failure (1) The boom speed or power is low in the normal • Boom speed or power is low phenomenon mode. • The normal mode is the state that the heavy lift switch, swing priority switch, and machine push-up switch are turned OFF.
Page 809 SEN00794-02 40 Troubleshooting Failure (2) The boom raise speed or power is low in the heavy • Boom speed or power is low phenomenon lift mode. • The heavy lift mode is the state that the heavy lift switch is turned ON. •...
Page 810: Speed Or Power Of Arm Is Low
SEN00794-02 40 Troubleshooting H-6 Speed or power of arm is low Failure • Speed or power of arm is low phenomenon • Check that the speeds of the other work equipment, travel, and swing are normal. (If they are abnormal, carry out the related troubleshooting.) Relative •...
Page 811: Speed Or Power Of Bucket Is Low
SEN00794-02 40 Troubleshooting H-7 Speed or power of bucket is low Failure • Speed or power of bucket is low phenomenon • Check that the speeds of the other work equipment, travel, and swing are normal. (If they are abnormal, carry out the related troubleshooting.) Relative •...
Page 812: Boom Does Not Move
SEN00794-02 40 Troubleshooting H-8 Boom does not move Failure • Boom does not move phenomenon • Check that operations of the other work equipment, travel, and swing are normal. Relative (If they are abnormal, carry out the related troubleshooting.) information •...
Page 813: Hydraulic Drift Of Work Equipment Is Large
SEN00794-02 40 Troubleshooting H-11 Hydraulic drift of work equipment is large Failure • Hydraulic drift of work equipment is large (1) Hydraulic drift of boom is large phenomenon Relative information Cause Standard value in normalcy and references for troubleshooting Defective seal of boom Since the spool of the boom control valve (Lo) may have a malfunction, control valve (spool) check it directly.
Page 814 SEN00794-02 40 Troubleshooting Failure • Hydraulic drift of work equipment is large (3) Hydraulic drift of bucket is large phenomenon Relative information Cause Standard value in normalcy and references for troubleshooting Defective seal of bucket Since the spool of the bucket control valve (Lo, Hi) may have a malfunc- control valve (spool) tion, check it directly.
Page 815: Time Lag Of Work Equipment Is Large
SEN00794-02 40 Troubleshooting H-12 Time lag of work equipment is large Failure • Time lag of work equipment is large (1) Time lag of boom is large phenomenon Relative information Cause Standard value in normalcy and references for troubleshooting Since the safety & suction valve (head side) of the boom control valve Possible causes (Lo) may have a malfunction, check it directly.
Page 816: Heavy Lift Function Does Not Operate Or Stop
SEN00794-02 40 Troubleshooting H-13 Heavy lift function does not operate or stop Failure • Heavy lift function does not operate or stop phenomenon Relative information Possible causes Cause Standard value in normalcy and references for troubleshooting and standard value in normal Check by (2) in “H-5 Boom speed or power is low”.
Page 817 SEN00794-02 40 Troubleshooting PC800, 850-8...
Page 818: Machine Deviates In One Direction
SEN00794-02 40 Troubleshooting H-16 Machine deviates in one direction Failure (1) Machine deviates in the same direction, regardless • Machine deviates in one direction phenomenon of its travel direction Relative • Check that the travel speed is normal. (If it is abnormal, carry out the related troubleshooting.) information •...
Page 819 SEN00794-02 40 Troubleshooting Failure (2) Machine deviates in different directions, depending • Machine deviates in one direction phenomenon on its travel direction Relative • Check that the travel speed is normal. (If it is abnormal, carry out the related troubleshooting.) information •...
Page 820: Machine Deviates Largely At Start
SEN00794-02 40 Troubleshooting H-17 Machine deviates largely at start Failure (1) Machine deviates only when started with travel lever • Machine deviates largely at start phenomenon at full stroke • Check that the machine does not deviate during constant-speed travel. Relative (If the machine deviates even during constant-speed travel, carry out the related troubleshooting.) information...
Page 821: Machine Deviates Largely During Compound Operation
SEN00794-02 40 Troubleshooting H-18 Machine deviates largely during compound operation Failure • Machine deviates largely during compound operation phenomenon • Check that the machine does not deviate when the work equipment is not operated. Relative (If the machine deviates under that condition, carry out the related troubleshooting.) information •...
Page 822: Machine Does Not Travel (Only One Track)
SEN00794-02 40 Troubleshooting H-20 Machine does not travel (only one track) Failure • Machine does not travel (only one track) (1) Machine does not travel in either direction. phenomenon Relative information Cause Standard value in normalcy and references for troubleshooting Malfunction of travel motor Since the parking brake of the travel motor may have a malfunction, (parking brake)
Page 823: Travel Speed Does Not Change
SEN00794-02 40 Troubleshooting H-21 Travel speed does not change Failure • Travel speed does not change phenomenon • Check that the Lo and Hi travel speeds are normal. (If they are abnormal, carry out the related troubleshooting.) Relative • The travel speed selection system has the automatic speed changing function. If the oil pressure rises information above 22.6 MPa {230 kg/cm } during travel, the travel speed is changed to Lo even while the machine...
Page 824: Upper Structure Does Not Swing
SEN00794-02 40 Troubleshooting H-22 Upper structure does not swing Failure • Upper structure does not swing (1) The upper structure swings in neither direction. phenomenon • Check that the other work equipment and travel are normal. (If either of them is abnormal, carry out Relative troubleshooting related to it.) information...
Page 825 SEN00794-02 40 Troubleshooting Failure • Upper structure does not swing (2) The upper structure does not swing in only 1 direction. phenomenon • Check that the other work equipment and travel are normal. (If either of them is abnormal, carry out Relative troubleshooting related to it.) information...
Page 826: Swing Speed Or Acceleration Is Low
SEN00794-02 40 Troubleshooting H-23 Swing speed or acceleration is low Failure (1) The swing speed or acceleration is low in both direc- • Swing speed or acceleration is low phenomenon tions. • Check that the other work equipment and travel are normal. (If either of them is abnormal, carry out Relative troubleshooting related to it.) information...
Page 827 SEN00794-02 40 Troubleshooting Failure (2) The swing speed or acceleration is low in only 1 • Swing speed or acceleration is low phenomenon direction. • Check that the other work equipment and travel are normal. (If either of them is abnormal, carry out Relative troubleshooting related to it.) information...
Page 828 SEN00794-02 40 Troubleshooting H-24 Swing speed or acceleration is low during compound operation of swing and work equipment • Swing speed or acceleration is low during (1) The swing speed or acceleration is low during com- Failure compound operation of swing and work pound operation of swing and work equipment with phenomenon equipment...
Page 829: Swing Speed Or Acceleration Is Low During Compound Operation Of Swing And
SEN00794-02 40 Troubleshooting • Swing speed or acceleration is low during (2) The swing speed or acceleration is low during com- Failure compound operation of swing and work pound operation of swing and work equipment with phenomenon equipment the swing priority mode ON. •...
Page 830: Upper Structure Overruns Excessively When It Stops Swinging
SEN00794-02 40 Troubleshooting H-25 Upper structure overruns excessively when it stops swinging Failure • Upper structure overruns excessively when it (1) The upper structure overruns excessively when it phenomenon stops swinging stops swinging in both directions. Relative information Cause Standard value in normalcy and references for troubleshooting aKeep the engine stopped for the preparations, and run it at high idle during troubleshooting.
Page 831: Large Shock Is Made When Upper Structure Stops Swinging
SEN00794-02 40 Troubleshooting H-26 Large shock is made when upper structure stops swinging Failure • Large shock is made when upper structure (1) Large shock is made when the upper structure stops phenomenon stops swinging swinging in both directions. Relative •...
Page 832: Large Abnormal Sound Is Made When Upper Structure Stops Swinging
SEN00794-02 40 Troubleshooting H-27 Large abnormal sound is made when upper structure stops swinging Failure • Large abnormal sound is made when upper (1) Large abnormal sound is made when the upper phenomenon structure stops swinging structure stops swinging in both directions. Relative information Cause...
Page 833: Hydraulic Drift Of Swing Is Large
SEN00794-02 40 Troubleshooting H-28 Hydraulic drift of swing is large Failure • Hydraulic drift of swing is large (1) While the swing holding brake is applied. phenomenon Relative • Carry out all the troubleshooting in working mode P. information Cause Standard value in normalcy and references for troubleshooting aKeep the engine stopped for the preparations, and run it at high idle during troubleshooting.
Page 834 SEN00794-02 40 Troubleshooting H-29 Fan rotation is abnormal (Fan sound/vibration is abnormally large or fan overheats) Failure • Fan rotation is abnormal (Fan sound/vibration is abnormally large or fan overheats) phenomenon Relative • Measure fan speed to see if it is out of service limit values. information •...
Page 835 SEN00794-02 40 Troubleshooting PC800, 850-8...
Page 836 SEN00794-02 40 Troubleshooting PC800-8, PC800SE-8, PC800LC-8, PC850-8, PC850SE-8 Hydraulic excavator Form No. SEN00794-02...
Page 837: Troubleshooting Of Engine (S-Mode)
SEN00795-02 HYDRAULIC EXCAVATOR PC800-8 PC850-8 PC800SE-8 PC850SE-8 PC800LC-8 Machine model Serial number PC800-8 50001 and up PC800SE-8 50001 and up PC800LC-8 50001 and up PC850-8 10001 and up PC850SE-8 10001 and up 40 Troubleshooting Troubleshooting of engine (S-mode) Troubleshooting of engine (S-mode)........................3 Method of using troubleshooting chart ......................
Page 838 SEN00795-02 40 Troubleshooting S-16 Vibration is excessive........................... 28 PC800, 850-8...
Page 839: Method Of Using Troubleshooting Chart
SEN00795-02 40 Troubleshooting Troubleshooting of engine (S-mode) Method of using troubleshooting chart The troubleshooting chart consists of the “questions”, “check items”, “causes”, and “troubleshooting” blocks. The questions and check items are used to pinpoint high probability causes by simple inspection or from phe- nomena without using troubleshooting tools.
Page 840 SEN00795-02 40 Troubleshooting <Example of troubleshooting> Exhaust gas color is black (incomplete combustion) Let us assume that a trouble of “Exhaust gas color is black” occurred and we checked the [Questions] and [Check items] and found the following 3 items to be the causal symptoms; [Exhaust gas color slowly became black], [Power slowly became weaker], and [Dust indicator is lighting red].
Page 841 SEN00795-02 40 Troubleshooting There is a causal relationship between 3 items in the [Questions] and [Check items] sections and 6 items in the [Causes] sections. The method of pinpointing the [cause] from the causal relationship and approaching the [troubleshooting] is explained according to Step 1 —...
Page 842: Starting Performance Is Poor
SEN00795-02 40 Troubleshooting S-1 Starting performance is poor General causes why starting performance is poor Causes • Defective electrical system • Insufficient supply of fuel • Insufficient intake of air • Improper selection of fuel • Coolant in exhaust pipe aThe common rail fuel injection system (CRI) recognizes the fuel injection tim- ing electrically.
Page 843 SEN00795-02 40 Troubleshooting *1: EGR cooler outlet gas piping Loosen 4 mounting bolts (1) of the EGR cooler outlet gas piping and check that the coolant flows out. A lit- tle condensate produced from cooled exhaust gas may flow out. If it is colorless and transparent, however, it is not a problem.
Page 844: Engine Does Not Start
SEN00795-02 40 Troubleshooting S-2 Engine does not start a) Engine does not turn Causes General causes why engine does not turn • Internal parts of engine seized → See “S-4 Engine stops during operations.” • Water hammer caused by coolant which entered cylinder •...
Page 845 SEN00795-02 40 Troubleshooting *1: EGR cooler outlet gas piping Loosen 4 mounting bolts (1) of the EGR cooler outlet gas piping and check that the coolant flows out. A lit- tle condensate produced from cooled exhaust gas may flow out. If it is colorless and transparent, however, it is not a problem.
Page 846 SEN00795-02 40 Troubleshooting b) Engine turns but no exhaust smoke comes out Causes General causes why engine turns but no exhaust smoke comes out • Fuel is not being supplied • Supply of fuel is extremely small • Improper selection of fuel (particularly in winter) Confirm recent repair history Degree of use of E E E...
Page 847 SEN00795-02 40 Troubleshooting c) Exhaust smoke comes out but engine does not start (fuel is being injected) Causes General causes why exhaust smoke comes out but engine does not start • Lack of rotating force due to defective electrical system •...
Page 848: Engine Does Not Pick Up Smoothly
SEN00795-02 40 Troubleshooting S-3 Engine does not pick up smoothly General causes why engine does not pick up smoothly Causes • Insufficient intake of air • Insufficient supply of fuel • Defective condition of fuel spray • Improper selection of fuel •...
Page 849: Engine Stops During Operations
SEN00795-02 40 Troubleshooting S-4 Engine stops during operations General causes why engine stops during operations Causes • Seized parts inside engine • Insufficient supply of fuel • There is overheating • Defective hydraulic pump Confirm recent repair history Degree of use of machine Operated for long period w w w w Q w Q w Abnormal noise was heard and engine stopped suddenly...
Page 850: Engine Does Not Rotate Smoothly
SEN00795-02 40 Troubleshooting S-5 Engine does not rotate smoothly General causes why engine does not rotate smoothly Causes • Air in fuel system • Defective speed sensor (Error at degree that it is not indicated) • Defective EGR valve • Defective bypass valve Confirm recent repair history Degree of use of machine Operated for long period Q Q Q...
Page 851: Engine Lacks Output (Or Lacks Power)
SEN00795-02 40 Troubleshooting S-6 Engine lacks output (or lacks power) General causes why engine lacks output Causes • Insufficient intake of air • Insufficient supply of fuel • Defective spray condition of fuel • Improper selection of fuel • There is overheating →...
Page 852: Exhaust Gas Color Is Black (Incomplete Combustion)
SEN00795-02 40 Troubleshooting S-7 Exhaust gas color is black (incomplete combustion) General causes why exhaust gas color is black Causes • Insufficient intake of air • Excessive injection of fuel • Defective condition of fuel injection • Improper selection of fuel •...
Page 853 SEN00795-02 40 Troubleshooting *1: Failure codes [CA1228] and [CA1625] *2: EGR gas pressure piping Remove 2 EGR gas pressure pipes (2) and check their inside for clogging. Applicable machines PC800-8: 50001 – 50062 PC850-8: 10001 – 10006 *3: Failure codes [CA559] and [CA2249] *4: Failure codes [CA144] and [145/CA145] PC800, 850-8...
Page 854: Oil Consumption Is Excessive (Or Exhaust Smoke Is Blue)
SEN00795-02 40 Troubleshooting S-8 Oil consumption is excessive (or exhaust smoke is blue) General causes why oil consumption is excessive Causes • Abnormal consumption of oil • Long-time operation of engine at low idle or high idle (Do not run engine at idle for more than 20 minutes continuously) •...
Page 855: Oil Becomes Contaminated Quickly
SEN00795-02 40 Troubleshooting S-9 Oil becomes contaminated quickly General causes why oil becomes contaminated quickly Causes • Entry of exhaust gas into oil due to internal wear • Clogging of lubrication passage • Use of improper fuel • Use of improper oil •...
Page 856: Fuel Consumption Is Excessive
SEN00795-02 40 Troubleshooting S-10 Fuel consumption is excessive General causes why fuel consumption is excessive Causes • Leakage of fuel • Defective condition of fuel injection (fuel pressure, injection timing) • Excessive injection of fuel Confirm recent repair history Degree of use of Operated for long period machine More than for other machines of same model...
Page 857: Oil Is In Coolant (Or Coolant Spurts Back Or Coolant Level Goes Down)
SEN00795-02 40 Troubleshooting S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) General causes why oil is in coolant Causes • Internal leakage in lubrication system • Internal leakage in cooling system Confirm recent repair history Degree of use of machine Operated for long period Suddenly increased Oil level...
Page 858: Oil Pressure Drops
SEN00795-02 40 Troubleshooting S-12 Oil pressure drops General causes why oil pressure drops Causes • Leakage, clogging, wear in lubrication system • Defective oil pressure control • Improper selection of fuel (improper viscosity) • Deterioration of oil due to overheating Confirm recent repair history Degree of use of Operated for long period...
Page 859 SEN00795-02 40 Troubleshooting PC800, 850-8...
Page 860: Oil Level Rises (Entry Of Coolant/Fuel)
SEN00795-02 40 Troubleshooting S-13 Oil level rises (Entry of coolant/fuel) General causes why oil level rises Causes • Coolant in oil (milky) • Fuel in oil (smells diluted diesel fuel) aIf oil is in coolant, carry out troubleshooting for “S-11 Oil is in coolant” Confirm recent repair history Degree of use of Operated for long period...
Page 861 SEN00795-02 40 Troubleshooting *1: EGR cooler outlet gas piping Loosen 4 mounting bolts (1) of the EGR cooler outlet gas piping and check that the coolant flows out. A lit- tle condensate produced from cooled exhaust gas may flow out. If it is colorless and transparent, however, it is not a problem.
Page 862: Coolant Temperature Becomes Too High (Overheating)
SEN00795-02 40 Troubleshooting S-14 Coolant temperature becomes too high (overheating) General causes why coolant temperature becomes too high Causes • Lack of cooling air (deformation, damage of fan) • Drop in heat dissipation efficiency • Problem in coolant circulation system •...
Page 863: Abnormal Noise Is Made
SEN00795-02 40 Troubleshooting S-15 Abnormal noise is made General causes why abnormal noise is made Causes • Abnormality due to defective parts • Abnormal combustion • Air sucked in from intake system aJudge if the noise is an internal noise or an external noise before starting troubleshooting.
Page 864: Vibration Is Excessive
SEN00795-02 40 Troubleshooting S-16 Vibration is excessive General causes why vibration is excessive Causes • Defective parts (abnormal wear, breakage) • Misalignment between engine and chassis • Abnormal combustion aIf abnormal noise is made and vibration is excessive, carry out troubleshoot- ing for “S-15 Abnormal noise is made”, too.
Page 865 SEN00795-02 40 Troubleshooting PC800, 850-8...
Page 866 SEN00795-02 40 Troubleshooting PC800-8, PC800SE-8, PC800LC-8, PC850-8, PC850SE-8 Hydraulic excavator Form No. SEN00795-02...
Page 867: Disassembly And Assembly
SEN01052-01 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC800-8 PC800SE-8 PC800LC-8 PC850-8 PC850SE-8 Machine model Serial number PC800-8 50001 and up PC800SE-8 50001 and up PC800LC-8 50001 and up PC850-8 10001 and up PC850SE-8 10001 and up 50 Disassembly and assembly1 General information on disassembly and assembly General information on disassembly and assembly ..................
Page 868: How To Read This Manual
79 T- tion are described as [1], [2]•••etc. and their and that they can not be supplied part names, part numbers and quantities are from Komatsu in Japan (i.e. locally not described. made parts). Marks shown in the Installation Section stand for the following.
Page 869 * *** **** when doing the procedure. and that they can not be supplied : Type of coating material from Komatsu in Japan (i.e. locally : Tightening torque made parts). : Quantity of oil or coolant to be added Sketches of special tools Various special tools are illustrated for the con- venience of local manufacture.
Page 870: Coating Materials List
The recommended coating materials such as adhesives, gasket sealants, and greases used for disas- sembly and assembly are listed below. a For coating materials not listed below, use the equivalent of products shown in this manual. Cate- Komatsu Part number Q'ty Container...
Page 871 50 Disassembly and assembly SEN01052-01 Cate- Komatsu code Part number Q'ty Container Main features and applications gory • Used to lubricate sliding portions. LM-G 09940-00051 60 g (to prevent squeaking) • Used to prevent scuffing and seizure of press-fit- ted portions, shrink-fitted portions, and threaded...
Page 872 SEN01052-01 50 Disassembly and assembly Cate- Komatsu code Part number Q'ty Container Main features and applications gory SUNSTAR • “S” is used for high-temperature season PENGUINE and “W” for low-temperature season as Polyethylene SEAL 580 417-926-3910 320 ml adhesive for glass.
Page 873: Special Tools List
50 Disassembly and assembly SEN01052-01 Special tools list QQQQ a Tools with part number 79 cannot be supplied (they are items to be locally manufac- tured). a Necessity: Cannot be substituted, must always be installed (used) Extremely useful if available or can be substituted with commercially available part a New/Remodel: N Tools with new part numbers, newly developed for this model...
Page 874 SEN01052-01 50 Disassembly and assembly Component Symbol Part No. Part Name Nature of work, remarks 790-101-5401 Push tool kit 790-101-5541 • Plate Press fitting of oil seal 790-101-5421 • Grip Disassembly, assembly of swing 01010-81240 • Bolt machinery assembly 790-201-2780 Spacer Press fitting of main bearing 790-201-2880...
Page 875 50 Disassembly and assembly SEN01052-01 Component Symbol Part No. Part Name Nature of work, remarks 790-201-2680 Plate Press fitting of idler bushing Disassembly, assembly of idler 796-675-1510 Installer Installation of idler floating seal assembly Oil pump assembly q 1 791-601-1000 Pouring of oil Press fitting of carrier roller bear- 790-1101-5201...
Page 876 SEN01052-01 50 Disassembly and assembly Component Symbol Part No. Part Name Nature of work, remarks 791-680-9580 Adapter 791-680-9590 Guide 01010-52760 Bolt 01010-51440 Bolt 790-101-1102 Pump 790-101-4300 Cylinder 1,471 kN {150 ton} 791-685-9510 Frame 791-685-9520 Frame 791-685-9530 791-685-9550 791-685-9560 Bolt 791-680-9570 Adapter 01010-51030 Bolt...
Page 877 50 Disassembly and assembly SEN01052-01 Component Symbol Part No. Part Name Nature of work, remarks 791-685-9510 Frame 791-685-9520 Frame 791-685-9530 791-685-9540 791-685-9550 791-685-9560 Bolt 791-126-0150 Adapter 01010-51030 Bolt 791-685-9620 Extension 791-680-5542 Adapter 791-680-5560 Guide 790-101-1102 Pump 790-101-4300 Cylinder 1,471 kN {150 ton} 791-685-9510 Frame 791-685-9520...
Page 878 SEN01052-01 50 Disassembly and assembly Component Symbol Part No. Part Name Nature of work, remarks Removal, press fitting of master 790-101-1102 Pump pin and regular pin 790-101-4200 Puller 294 kN {30 ton} Disassembly, 791-680-9501 Remover, installer assembly of 1 link at field 790-101-1102 Pump...
Page 879 50 Disassembly and assembly SEN01052-01 Component Symbol Part No. Part Name Nature of work, remarks Removal of boom foot pin, boom 790-445-4100 Remover cylinder bottom pin Puller 790-101-4200 Short stroke (294 kN {30 ton}) 790-101-1102 Pump 791-650-1610 Bracket 790-445-4130 Screw Removal of arm cylinder rod head and bottom pin 791-112-1180...
Page 880: Sketches Of Special Tools
SEN01052-01 50 Disassembly and assembly Sketches of special tools Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. A4 Push tool A5 Push tool PC800, 850-8...
Page 881 50 Disassembly and assembly SEN01052-01 F3 Push tool J3 Push tool PC800, 850-8...
Page 882 SEN01052-01 50 Disassembly and assembly L4 Push tool L5 Adapter PC800, 850-8...
Page 883 50 Disassembly and assembly SEN01052-01 PC800, 850-8...
Page 884 SEN01052-01 PC800-8, PC800SE-8, PC800LC-8, PC850-8, PC850SE-8 Hydraulic excavator Form No. SEN01052-01...
Page 885 SEN01053-01 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC800-8 PC800SE-8 PC800LC-8 PC850-8 PC850SE-8 Machine model Serial number PC800-8 50001 and up PC800SE-8 50001 and up PC800LC-8 50001 and up PC850-8 10001 and up PC850SE-8 10001 and up 50 Disassembly and assembly1 Engine and cooling system (SAA6D140E-5) Engine and cooling system ..........................
Page 886: Engine And Cooling System
SEN01053-01 50 Disassembly and assembly Engine and cooling system Removal and installation of Remove undercover (2). engine, PTO and hydraulic pump assembly Special tools Part number Part name S 1 796-770-1301 Oil stopper Removal Lower the work equipment to the ground and stop the engine.
Page 887 50 Disassembly and assembly SEN01053-01 Disconnect filter (5). 14. Remove partition cover (10). a Disconnect the hose clamp from the bot- Disconnect clamp (6). tom. 10. Disconnect filter (7). a Disconnect the hose clamp. 15. Disconnect connectors P24B (11) and P24A (12).
Page 888 SEN01053-01 50 Disassembly and assembly 19. Remove stays (17) and (18). 27. Disconnect connectors (33) and (34). 20. Lift off cover assembly (19). 21. Remove stay (20). 28. Disconnect tubes (35) and (36) from the pump. a Since the hose side is fixed with MIKALOR clamps, do not disconnect the a Before removing the stay, install a tag to it hose.
Page 889 50 Disassembly and assembly SEN01053-01 29. Disconnect air hoses (37) and (38). [*1] 35. Disconnect starting motor terminal (45). a Make a mark on the tube to show the posi- tion of the hose end. 36. Disconnect ground wire (46). 30.
Page 890 SEN01053-01 50 Disassembly and assembly 44. Disconnect connectors CE03 (54) and CE02 47. Disconnect connector M34 (58). (55). 48. Remove air conditioner cover (59). 49. Loosen the mounting bolts and disconnect air conditioner compressor (60). [*8] 50. Disconnect fuel hose (61). [*7] 51.
Page 891 50 Disassembly and assembly SEN01053-01 53. Lift off engine and pump assembly (63). [*9] Engine assembly: Approx. 3,000 kg a Since T-sling [1] is used in this photo, air cleaner (64) is not removed. Since the air cleaner (64) interferes normally, however, per- form the following work before lifting off engine and pump assembly (63).
Page 892 SEN01053-01 50 Disassembly and assembly Installation [*7] Joint bolt of fuel hose (61): Carry out installation in the reverse order to 14.8 – 19.6 Nm {1.5 – 2.0 kgm} removal. [*8] [*1], [*2] Adjust the air conditioner compressor belt ten- MIKALOR clamp sion.
Page 893 50 Disassembly and assembly SEN01053-01 Reference When using a new hose Tighten until dimension (BDG) is as fol- Procedure for replacing hoses (MSH) and lows. (FSH) between the suction tubes (MIKALOR 12 – 15 mm: MSH (Main pump suction clamp) hose) a Use new MIKALOR clamps.
Page 894: Removal And Installation Of Cooling Assembly
SEN01053-01 50 Disassembly and assembly Removal and installation of Remove the hydraulic tank strainer and stop the oil with tool S1. cooling assembly a When not using tool S1, remove the drain plug and drain the oil. Removal Lower the work equipment to the ground Hydraulic tank: Approx.
Page 895 50 Disassembly and assembly SEN01053-01 Disconnect filter (5). 14. Disconnect radiator lower hoses (13) – (15). [*1] Disconnect clamp (6). Disconnect filter (7). a Disconnect the hose clamp. 15. Disconnect air hoses (16) and (17). [*2] a Make a mark at the hose end of each tube to indicate the connecting position.
Page 896 SEN01053-01 50 Disassembly and assembly 20. Remove 3 covers (23) and cover (24). 24. Disconnect 2 air conditioner hoses (29). [*5] 21. Disconnect connector (25) from (B). 25. Disconnect clamps (30). 22. Disconnect 3 hoses (26) and 2 hoses (27). a Prepare an oil receiver.
Page 897 50 Disassembly and assembly SEN01053-01 28. Disconnect connector (33). Installation Carry out installation in the reverse order to 29. Disconnect clamp (34). removal. [*1] Hose insertion depth: 65 mm Radiator hose clamp: 10.8 – 11.8 Nm {1.1 – 1.2 kgm} [*2], [*3] MIKALOR clamp a Use a new MIKALOR clamp.
Page 898 SEN01053-01 50 Disassembly and assembly [*4] Refilling with compressor oil a If any air conditioner hose was replaced, Hose insertion depth: 70 mm Radiator hose clamp: add compressor oil for R134a (DENSO: 10.8 – 11.8 Nm {1.1 – 1.2 kgm} ND-OIL8, ZEXEL: ZXL100PG (equivalent to PAG46)) to the air conditioner compres- [*5]...
Page 899: Removal And Installation Of Aftercooler Assembly
50 Disassembly and assembly SEN01053-01 Removal and installation of Lift off frame (4). aftercooler assembly Sling aftercooler assembly (5) temporarily. Removal Remove the mounting bolts. While disconnect- Lower the work equipment to the ground ing aftercooler assembly (5) from the rubber and stop the engine.
Page 900 SEN01053-01 50 Disassembly and assembly Installation Carry out installation in the reverse order to removal. [*1] MIKALOR clamp a Use a new MIKALOR clamp. Set the hose to the original position. (Insertion depth of air hose: 80 mm) Set the bridge (BR) under the clamp bolt and lap it over band (BD) at least (b) reaches 5 mm.
Page 901: Removal And Installation Of Fuel Cooler And Air Conditioner Condenser Assembly
50 Disassembly and assembly SEN01053-01 Removal and installation of fuel Open radiator grille (2). cooler and air conditioner condenser assembly Lower the work equipment to the ground and stop the engine. Loosen the cap of the hydraulic tank gradu- ally to release the internal pressure of the hydraulic tank.
Page 902 SEN01053-01 50 Disassembly and assembly Installation Refilling with compressor oil a If the air conditioner condenser was Carry out installation in the reverse order to replaced, add compressor oil for R134a removal. (DENSO: ND-OIL8, ZEXEL: ZXL100PG (equivalent to PAG46)) to the air condi- [*1] tioner compressor by 40 ml.
Page 903: Removal And Installation Of Fan Motor Assembly
50 Disassembly and assembly SEN01053-01 Removal and installation of fan Remove 3 covers (3). a Remove the rear side, too. motor assembly Open engine hood (4). Removal a Open the rear side, too. Lower the work equipment to the ground and stop the engine.
Page 904 SEN01053-01 50 Disassembly and assembly 12. Disconnect radiator hoses (9). [*1] 19. Remove upper tank (20) according to the fol- lowing procedure. Remove mounting bolts (19). Nut (N) welded to part (P) of upper tank (20) interferes with part (W) welded to the frame.
Page 905 50 Disassembly and assembly SEN01053-01 20. Remove fan guard (24). 26. Remove 3 covers (30). 21. Remove cover (25). 27. Remove cover (31). 22. Lift off shroud (26). 28. Disconnect 3 hoses (32). a Prepare an oil receiver. a Before disconnecting each hose, mark it with a tag etc.
Page 906 SEN01053-01 50 Disassembly and assembly 31. Remove the mounting bolts and lift off fan and 35. Disconnect connector (39). fan motor assembly (35). a Take care not to damage the radiator core 36. Remove cover (40). with the tip of the motor. (Part Q) a Take care of the EGR valve, piping, and connectors of the engine.
Page 907 50 Disassembly and assembly SEN01053-01 Installation [*4] Hose insertion depth: 70 mm Carry out installation in the reverse order to Radiator hose clamp: removal. 10.8 – 11.8 Nm {1.1 – 1.2 kgm} [*1] [*5] Upper tank hose clamp: Do not match the bolt holes of the lock plate by 10.8 –...
Page 908: Removal And Installation Of Fuel Tank Assembly
SEN01053-01 50 Disassembly and assembly Removal and installation of fuel Remove fuel level gauge wiring cover (5) and disconnect wiring connector (6). tank assembly Removal Lower the work equipment to the ground and stop the engine. Disconnect the cable from the negative (–) terminal of the battery.
Page 909 50 Disassembly and assembly SEN01053-01 10. Remove the mounting bolts and lift off fuel tank assembly (11). [*1] Fuel tank assembly: 640 kg Installation Carry out installation in the reverse order to removal. [*1] Fuel tank mounting bolt: 549 ± 58 Nm {56 ± 6 kgm} PC800, 850-8...
Page 910 SEN01053-01 PC800-8, PC800SE-8, PC800LC-8, PC850-8, PC850SE-8 Hydraulic excavator Form No. SEN01053-01...
Page 911: Engine (Saa6D140E-5)
SEN01054-01 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC800-8 PC800SE-8 PC800LC-8 PC850-8 PC850SE-8 Machine model Serial number PC800-8 50001 and up PC800SE-8 50001 and up PC800LC-8 50001 and up PC850-8 10001 and up PC850SE-8 10001 and up 50 Disassembly and assembly1 Engine (SAA6D140E-5) Engine (SAA6D140E-5) ..........................
Page 912: Removal And Installation Of Fuel Supply Pump Assembly
SEN01054-01 50 Disassembly and assembly Engine (SAA6D140E-5) Removal and installation of fuel Remove corrosion resistor and bracket assem- bly (5). [*2] supply pump assembly Remove oil level gauge (6). Special tools Part number Part name 795-630-5500 Standard puller 01010-81090 Bolt 01643-31032 Washer Removal...
Page 913 50 Disassembly and assembly SEN01054-01 11. Remove fuel tube (9). [*4] 18. Remove 4 covers (20). a Remove 2 from the fuel supply pump side 12. Remove fuel hose (10). [*5] and 2 from the common rail side. 13. Remove lubrication tube (11). [*6] 19.
Page 914 SEN01054-01 50 Disassembly and assembly 23. Remove bracket (26). 24. Remove cover (27). 25. By barring the engine with bolt (BB), set stamp (A) of the damper to pointer (P) (from the coun- terweight side). a At this time, the stamp of 2.5 TOP is almost at the top.
Page 915 50 Disassembly and assembly SEN01054-01 Installation While setting key (K) of fuel supply pump (30) to key way (G) of the gear, install fuel supply pump (30). Tighten all of supply pump (30), bracket (29), and high-pressure pipes (21) temporarily with the fingers.
Page 916 SEN01054-01 50 Disassembly and assembly [*6] Lubrication tube (11): 34.3 – 44.1 Nm {3.5 – 4.5 kgm} [*7] Lubrication tube (22): 43 – 47 Nm {4.4 – 4.8 kgm} [*8] Joint bolt of fuel tube (24): 14.8 – 19.6 Nm {1.5 – 2.0 kgm} (Supply pump side) 17.7 –...
Page 917: Removal And Installation Of Cylinder Head Assembly
50 Disassembly and assembly SEN01054-01 Removal and installation of Disconnect filter (5). cylinder head assembly Disconnect clamp (6). Special tools Disconnect filter (7). a Disconnect the hose clamp. Part number Part name A 2 790-331-1110 Wrench (Angle) Removal Lower the work equipment to the ground and stop the engine.
Page 918 SEN01054-01 50 Disassembly and assembly 12. Disconnect reservoir tank hose (10) from cover 19. Remove bracket (17). (11) bottom. 20. Remove air tube (18). [*3] 13. Lift off cover (11). 21. Remove covers (19) and (20). 14. Disconnect hose (12). [*1] 15.
Page 919 50 Disassembly and assembly SEN01054-01 23. Lift off muffler (22). 29. Remove bracket (28). 24. Remove air tube (23). [*4] 30. Remove fuel filter and bracket assembly (29). [*5]. 25. Disconnect heater terminal (24) from the bot- tom of air connector (25). 31.
Page 920 SEN01054-01 50 Disassembly and assembly 35. Remove bracket (38). 45. Disconnect connector FUEL (48). 36. Remove corrosion resistor and bracket assem- 46. Disconnect brackets (49) – (51). bly (39). [*7] 47. Disconnect clamp (52). 48. Disconnect connector (53). 49. Disconnect connector (54) by the following method.
Page 921 50 Disassembly and assembly SEN01054-01 50. Remove fuel return tube (55). [*14] 54. Remove cover (61). 51. Disconnect turbocharger lubrication tube (47). 55. Remove turbocharger cooling tube (62) and [*15] lubricating oil drain tube (63). [*16] a Disconnect turbocharger lubrication tube (47) after removing the exhaust manifold.
Page 922 SEN01054-01 50 Disassembly and assembly 62. Remove cover (71). 68. Disconnect wiring harness (78). a White portion (w) is sealing tape applied to 63. Remove fan guard (72). cover the hole. 64. Remove brackets (73) and (74). [*19] 69. Disconnect lubrication tubes (79) and (80). [*22] 65.
Page 923 50 Disassembly and assembly SEN01054-01 77. Disconnect high-pressure pipe clamps (89). a There are the same clamps on the right side, too. 74. Remove tube (86). a Tube (86) is abolished after serial number 530897. 78. Disconnect breathers (90). 75. Remove tube (88) from the bottom of air hous- ing assembly (87).
Page 924 SEN01054-01 50 Disassembly and assembly 83. Remove clamp (95). 90. Disconnect wiring harness (103). 84. Remove cover (96). 91. Remove spill tube (104). 85. Remove bracket (97). 92. Remove cylinder head cover (105). 86. Remove 12 covers (98). 87. Remove clamps (99) and (100). 88.
Page 925 50 Disassembly and assembly SEN01054-01 96. Remove push rod (109). 100.Loosen locknut (114) and adjustment screw (115). 101.Remove crosshead assembly (116). 102.Remove mounting bolts (117) and auxiliary bolt. 97. Remove capture nut (111) from fuel injector (110) and disconnect the wiring harness. 98.
Page 926 SEN01054-01 50 Disassembly and assembly a Tighten cylinder head mounting bolts (1) – Installation (6) and auxiliary bolt (7) in the following a Before installing the cylinder head, check the order. following items. a A special socket is required to tighten the Measure stem length (e) of every bolt.
Page 927 50 Disassembly and assembly SEN01054-01 When not using tool A2 Fuel injector a Check that the inside of the injector sleeve Make marks (a) and (b) on the bolts and cylinder head, then retighten is free from dirt. +30° each bolt by 90° in the order of (1) Install gasket (120) and O-ring (121) –...
Page 928 SEN01054-01 50 Disassembly and assembly a If sleeve nut (127) does not catch the Install connector (102). a Install the connector before installing the threads of the injector, press its end high-pressure pipe. with another small spanner etc. and rotate its hexagonal part with the spanner.
Page 929 50 Disassembly and assembly SEN01054-01 Install rocker arm and shaft assembly (108). a Before tightening the mounting bolt, check that the ball of adjustment screw (107) is fitted to the socket of the push rod (109) securely. Mounting bolt: 93 – 103 Nm {9.5 – 10.5 kgm} a Adjust the engine valve clearance.
Page 930 SEN01054-01 50 Disassembly and assembly 16. High-pressure pipe clamp Carry out the following installation in the Tighten high-pressure pipe clamp (126) reverse order to removal. above the air intake manifold (described above) and stay (127) permanently. [*1] a Bend the rubber in advance. Air hose clamp: Clamping bolt: 8.8 ±...
Page 931 50 Disassembly and assembly SEN01054-01 [*13] Set the connector groove in position and insert to the end. Rotate housing (H1) in the direction of the arrow until it clicks. [*4] Inside: Air hose clamp: 10.5 ± 0.5 Nm {1.07 ± 0.05 kgm} Outside: See MIKALOR clamp [*3].
Page 932 SEN01054-01 50 Disassembly and assembly [*21] Refilling with coolant Exhaust manifold, turbocharger and connector Add coolant through the coolant filler to the specified level. Run the engine to cir- assembly culate the coolant through the system. Apply heat-resistant sealant to the fitting Then, check the coolant level again.
Page 933: Removal And Installation Of Fuel Injector Assembly
50 Disassembly and assembly SEN01054-01 Removal and installation of fuel Remove the clamp and high-pressure pipes (5). injector assembly Disconnect connector (6) of the injector wiring. Remove the counterweight assembly. For details, a Insert flat-head screwdriver [3] in shoulder see “Removal and installation of counterweight (a).
Page 934 SEN01054-01 50 Disassembly and assembly By barring the engine with bolt (BB), set stamp 11. Disconnect the injector wiring harness accord- 1.6TOP of the damper to pointer (P). ing to the following procedure. Remove 2 nuts (12) of the upper solenoid valve of fuel injector (11).
Page 935 50 Disassembly and assembly SEN01054-01 Installation Referring to removal steps 4 and after in “Removal and installation of cylinder head assembly”, install the removed parts up to the air intake manifold. Carry out the following installation in the reverse order to removal. a When installing the parts, observe the precau- tions described in “Removal and installation of cylinder head assembly”.
Page 936: Removal And Installation Of Engine Front Seal
SEN01054-01 50 Disassembly and assembly Removal and installation of Removal with tool A3 Drill several holes about 3 mm in diameter into engine front seal front seal (2). Set tool A3 to the drilled holed. (Tip: Drill type) Special tools Remove the front seal with impacts of slide hammer (SH).
Page 937 50 Disassembly and assembly SEN01054-01 Set large inside diameter side (b) of plas- Tighten the bolts of tool A6 evenly to press tic inside cylinder (6) to the end of crank- fit seal (2) until the end of tool A6 reaches shaft (5).
Page 938: Removal And Installation Of Engine Rear Seal
SEN01054-01 50 Disassembly and assembly Removal and installation of Before pulling out rear seal (2), drive in it a little to separate it from the flywheel hous- engine rear seal ing (FWH). Special tools Part number Part name 2 790-331-1110 Wrench (Angle) 3 795-931-1100 Seal puller...
Page 939 50 Disassembly and assembly SEN01054-01 Installation Procedure for installing standard seal a When installing rear seal (2), do not apply a Check the Teflon seal (Laydown lip seal) by oil or grease to the shaft and seal lip. checking the wear of the shaft and replace it Set large inside diameter side (b) of plas- with the “standard seal”...
Page 940 SEN01054-01 50 Disassembly and assembly Tighten the 3 bolts evenly to press fit rear Set sleeve (5) of the rear seal to the end of seal (2) until the end of tool A4 (for press crankshaft (4) and tighten the 3 bolts fitting the seal) reaches the end of crank- evenly to press fit sleeve and rear seal shaft (4).
Page 941 50 Disassembly and assembly SEN01054-01 a After tightening, make 1 punch mark (9) on Flywheel Using eyebolt [1] (12 mm, P = 1.75), sling fly- each bolt head to indicate the number of tight- wheel (1), install it to the crankshaft, and ening time.
Page 942 SEN01054-01 PC800-8, PC800SE-8, PC800LC-8, PC850-8, PC850SE-8 Hydraulic excavator Form No. SEN01054-01...
Page 943: Power Train
SEN01055-01 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC800-8 PC800SE-8 PC800LC-8 PC850-8 PC850SE-8 Machine model Serial number PC800-8 50001 and up PC800SE-8 50001 and up PC800LC-8 50001 and up PC850-8 10001 and up PC850SE-8 10001 and up 50 Disassembly and assembly1 Power train Power train..............................
Page 944: Removal And Installation Of Pto (Coupling) Assembly
SEN01055-01 50 Disassembly and assembly Power train Removal and installation of PTO Removal (coupling) assembly Lower the work equipment to the ground and stop the engine. Special tools Loosen the cap of the hydraulic tank gradu- ally to release the internal pressure of the hydraulic tank.
Page 945 50 Disassembly and assembly SEN01055-01 Disconnect hose (2) from bracket (3). 11. Disconnect 2 dust indicator hoses (13). Disconnect hoses (4) and (5). 12. Disconnect clamps (14) and (15). a Disconnect the clamp on the inside of Disconnect hoses (6) and (7) from the bottom bracket (16).
Page 946 SEN01055-01 50 Disassembly and assembly 18. Remove belt cover (21) from the air condi- 26. Float engine and PTO assembly (28) a little. tioner compressor. Engine, PTO assembly: Approx. 3,000 kg 19. Loosen locknut (22). a Since clearance (A) is narrow, take care 20.
Page 947 50 Disassembly and assembly SEN01055-01 30. Lift off PTO assembly (30). Installation a Measure the wear of coupling spline and check PTO assembly: 270 kg [*5] if the spline is within standard value. (If not, replace the coupling.) a Measure the wear of hub spline and check if the spline is within the standard value.
Page 948 SEN01055-01 50 Disassembly and assembly Using the micrometer for the bore (75 – Using the micrometer for the bore (125 – 100 mm) B3, measure the spline over pin 150 mm) [1], measure the spline over pin dimension (between B2) inside the shaft of the dimension (between B4) outside the shaft of coupling from X and Y directions of portions A the coupling from X and Y directions of por-...
Page 949 50 Disassembly and assembly SEN01055-01 Using the micrometer for the bore (100 – Carry out the following installation in the 125 mm) B6, measure the spline over pin reverse order to removal. dimension (between B5) of the hub from X and Y directions of portions A and B (at 4 locations [*1] in total).
Page 950 SEN01055-01 50 Disassembly and assembly a FW: Flywheel Table for judging hub assembly fitting dimen- sion (a) 11.2 ± 0.7 mm (Criterion) Refilling with oil (PTO case) Add oil through the oil filler to the specified level. a Summer (0 – 40°C): TO30 a Winter (–30 –...
Page 951: Disassembly And Assembly Of Pto (Coupling) Assembly
50 Disassembly and assembly SEN01055-01 Disassembly and assembly of Using push tools [1] and [2], remove bearing (6) from shaft (5). PTO (coupling) assembly Disassembly Remove PTO assembly (1). For details, see “Removal and installation of PTO assembly”. Remove snap rings (2) and (3). Raise PTO assembly (1).
Page 952 SEN01055-01 50 Disassembly and assembly Assembly a Clean all the parts and check them for dirt or damage. Coat their sliding surfaces with engine oil before installing. Using push tools [1] and [3], install bearing (6) to shaft (5). Bearing: Grease (G2-LI) Install shaft assembly (4) to PTO assembly (1).
Page 953: Removal And Installation Of Swing Motor And Swing Machinery Assembly
50 Disassembly and assembly SEN01055-01 Removal and installation of swing Remove the mounting bolts and lift off swing motor and swing machinery assembly (7). [*1] motor and swing machinery assembly Swing motor and swing machinery assembly: 570 kg Removal Lower the work equipment to the ground and stop the engine.
Page 954 SEN01055-01 50 Disassembly and assembly Loosen bolts (15) and remove swing motor Installation and swing machinery assembly (16). [*1] Carry out installation in the reverse order to removal. Swing motor and swing machinery assembly: 570 kg [*1] Swing motor and swing machinery assembly mounting bolt: 926.7 ±...
Page 955: Disassembly And Assembly Of Swing Machinery Assembly
50 Disassembly and assembly SEN01055-01 Disassembly and assembly of No. 1 carrier assembly Remove thrust washer (2). swing machinery assembly Remove No. 1 sun gear (3). Special tools Part number Part name 790-101-5401 Push tool kit 790-101-5541 • Plate 790-101-5421 •...
Page 956 SEN01055-01 50 Disassembly and assembly Ring gear No. 2 carrier assembly Lift ring gear (12) and remove it. Lift No. 2 carrier assembly (17) and remove it. No. 1 sun gear Disassemble No. 2 carrier assembly as follows. Remove thrust washer (13). Push in pin (18), and knock out shaft (19) Remove button (36) and spacer (14).
Page 957 50 Disassembly and assembly SEN01055-01 Turn over case and pinion assembly, then 11. Bearing remove mounting bolts (28) of cover Using push tool, remove bearing (34) from assembly (27). case (35). CEP00215 CEP00220 Turn over case and pinion assembly (29), and set on press stand.
Page 958 SEN01055-01 50 Disassembly and assembly Assembly Fit cover assembly (27) to case (35), and tighten mounting bolts (28). a Clean all parts, and check for dirt or damage. Cover mounting surface: Coat the sliding surfaces of all parts with Gasket sealant (LG-6) engine oil before installing.
Page 959 50 Disassembly and assembly SEN01055-01 Bearing Assemble No. 2 carrier assembly as follows. a There are the remains of the caulking Using tool F3, press fit bearing (34). a Push the bearing inner race and outer when the pin is inserted at the end face of race at the same time when press fit- hole (h) at the side of the carrier, so ting.
Page 960 SEN01055-01 50 Disassembly and assembly No. 2 carrier assembly Ring gear Lift No. 2 carrier assembly (17) and install it. Lift ring gear (12) and install it. a Adjust the positions of the 4 gear shaft a Apply gasket sealant to the periphery of ends before installing it.
Page 961 50 Disassembly and assembly SEN01055-01 Align position of pin holes of shaft and car- 10. No. 1 sun gear rier, then tap with a plastic hammer to Assemble No.1 sun gear (3) to carrier install shaft (6). assembly. a When installing the shaft, rotate the Install thrust washer (2).
Page 962: Removal And Installation Of Swing Circle Assembly
SEN01055-01 50 Disassembly and assembly Removal and installation of swing Installation circle assembly Carry out installation in the reverse order to removal. Removal [*1] Remove revolving frame assembly. Mounting bolt: Thread tightener (LT-2) For details, see “Removal and installation of Mounting bolt: revolving frame assembly”.
Page 963: Disassembly And Assembly Of Final Drive Assembly
50 Disassembly and assembly SEN01055-01 Disassembly and assembly of Disassembly final drive assembly Draining oil Remove drain plug and drain oil from final Special tools drive case. Final drive case: Approx. 20 l Part number Part name Put travel motor at bottom and set on block of height approx.
Page 964 SEN01055-01 50 Disassembly and assembly Disassemble No. 3 carrier assembly as No. 3 sun gear follows. Remove thrust washer (11) from No. 3 sun Remove mounting bolts (3). gear (10). Using tool J5, remove holder (4). Remove No. 3 sun gear (10). iii) Turn over carrier assembly (2) and No.
Page 965 50 Disassembly and assembly SEN01055-01 Using eyebolts [4], remove hub assembly (15) together with bearing (16) from shaft (41). Remove bearing (16) from hub (49). iii) Pull out gear (23) from carrier (27), and remove thrust washer (24) and bearing (25). iv) Remove thrust assembly (26) from Remove floating seal (17) from hub (49).
Page 966 SEN01055-01 50 Disassembly and assembly 13. No. 1 carrier assembly 14. No. 1 ring gear Using eyebolts [6], remove No. 1 carrier Remove No. 1 ring gear (39). assembly (32). Disassemble No. 1 carrier assembly as 15. No. 1 sun gear follows.
Page 967 50 Disassembly and assembly SEN01055-01 Assembly No. 1 carrier assembly Assemble No. 1 carrier assembly as follows. a 1) Clean all parts, check for dirt or damage, a There are the remains of the caulking and correct all dents and burrs. when the pin is inserted at the end Coat the bearings and surfaces of all parts face of hole (h) at the side of the car-...
Page 968 SEN01055-01 50 Disassembly and assembly a There are the remains of the caulking Using eyebolts [6], install No. 1 carrier assembly (32). when the pin is inserted at the end face of hole (h) at the side of the car- rier, so remove the caulked metal from the inside diameter of the hole before starting to assemble.
Page 969 50 Disassembly and assembly SEN01055-01 Spacer Inside bearing Align protruding portion with protruding portion Shrink fit bearing (16) to shaft (41), or use of shaft (41), and install spacer (19). tool J3 to install. a Set the spacer with the shallow protruding part facing the motor.
Page 970 SEN01055-01 50 Disassembly and assembly Floating seal at hub end Install nut as follows. Using tool J1, install floating seal (17) to Set tool J3 in position. hub (49). Push bearing inner race portion with a For precautions and details of the specified force.
Page 971 50 Disassembly and assembly SEN01055-01 Install lock plate (13) as shown in the dia- 12. No. 3 carrier assembly gram below. Assemble No. 3 carrier assembly as follows. Thread of mounting bolt: Using tool J7, press fit outer race (9) Thread tightener (LT-2) to gear (46).
Page 972 SEN01055-01 50 Disassembly and assembly iv) Assemble holder (4) to shaft (5). 13. No. 3 sun gear Install thrust washer (11) to No. 3 sun gear (10). Install No. 3 sun gear (10). a Be careful not to get your fingers caught. Tighten bolt (3).
Page 973 50 Disassembly and assembly SEN01055-01 PC800, 850-8...
Page 974 SEN01055-01 PC800-8, PC800SE-8, PC800LC-8, PC850-8, PC850SE-8 Hydraulic excavator Form No. SEN01055-01...
Page 975: Undercarriage And Frame
SEN01056-01 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC800-8 PC800SE-8 PC800LC-8 PC850-8 PC850SE-8 Machine model Serial number PC800-8 50001 and up PC800SE-8 50001 and up PC800LC-8 50001 and up PC850-8 10001 and up PC850SE-8 10001 and up 50 Disassembly and assembly1 Undercarriage and frame Undercarriage and frame ..........................
Page 976: Removal And Installation Of Track Shoe Assembly
SEN01056-01 50 Disassembly and assembly Undercarriage and frame Removal and installation of track Using tool M, pull out master pin. shoe assembly Special tools Part number Part name Remover, installer t 1 791-680-9501 Cylinder (1,471 790-101-4300 kN {150 ton}) Puller 790-101-4200 (294 kN {30 ton}) 790-101-1102...
Page 977 50 Disassembly and assembly SEN01056-01 Installation Carry out installation in the reverse order to removal. [*1] a Adjust the track shoe tension. For details, see Testing and adjusting, “Testing and adjusting track shoe tension”. Lubricator: 73.5 ± 14.7 Nm {7.5 ± 1.5 kgm} [*2] a Assemble spacer (4) and washer (5) to the link, connect to bottom link, then install guide...
Page 978: Disassembly And Assembly Of One Link In Field
SEN01056-01 50 Disassembly and assembly Disassembly and assembly of one link in field Part number Part name Special tools 791-685-9510 Frame 791-685-9520 Frame Part number Part name 791-685-9530 791-685-9540 791-680-9580 Adapter 791-685-9550 791-680-9590 Guide 791-685-9560 Bolt 01010-52760 Bolt 791-126-0150 Adapter 01010-51440 Bolt 01010-51030...
Page 979 50 Disassembly and assembly SEN01056-01 Disassembly Remove 2 track shoes of the link to be Part number Part name changed. Remover, Using 2 bolts (2), install tool N1 (adapter, 791-680-9501 installer (kit) guide, bolt) to link (1). 790-101-1102 Pump a It is also possible to use 2 track bolts for N 14 bolt (2).
Page 980 SEN01056-01 50 Disassembly and assembly Set tool N5 (adapter, guide, pusher) in posi- Assembly tion, then apply hydraulic pressure and remove Assemble link sub-assembly. pin (3). Set tool N7 to end face of link, then press a When the cylinder reaches the end of its fit bushing (1).
Page 981 50 Disassembly and assembly SEN01056-01 Set tools N9 and N10 in same way as for oper- Set tool N9 at pin (7) end, then use tool N12 ation to remove pin, then use tool N9 (adapter, (adapter, bolt, and guide) to press fit pin (7). extension, guide, adapter, bolt) for press fitting Pin press-fitting hole in link: pin, and tool N10 (extension, guide, adapter,...
Page 982: Removal And Installation Of Idler Assembly
SEN01056-01 50 Disassembly and assembly Removal and installation of idler assembly Removal Remove track shoe assembly. For details, see “Removal and installation of track shoe assembly”. Remove idler assembly (1). a Pull out the idler assembly, then lift off the idler and adjustment cylinder.
Page 983: Disassembly And Assembly Of Idler Assembly
50 Disassembly and assembly SEN01056-01 Disassembly and assembly of Remove shaft (8) from idler. idler assembly Special tools Part number Part name 790-201-2680 Plate 796-675-1510 Installer Oil pump assem- 791-601-1000 Remove floating seal (4) from idler (7). Disassembly Remove plug and drain oil. Idler : Approx.
Page 984 SEN01056-01 50 Disassembly and assembly Remove floating seals (4) from supports (3) Assembly and (6). a Clean all parts, and check for dirt or damage. Using tool L2, assemble floating seals (4) to supports (3) and (6). Using tool L1, press fit bushings (10) and (9) to idler.
Page 985 50 Disassembly and assembly SEN01056-01 Turn over idler and using tool L2, assemble Turn over idler, and assemble support (3) to floating seal (4). shaft. a Align the groove in the support with the groove in the shaft when assembling. Install bolt and nut (2), and secure support (3).
Page 986: Disassembly And Assembly Of Idler Adjustment Cylinder Assembly
SEN01056-01 50 Disassembly and assembly Disassembly and assembly of Assembly idler adjustment cylinder Install wear ring (6) to plunger (2). assembly Assemble backup ring (5) and packing (4) to plunger (2), and install snap ring (3). Disassembly Remove plunger (2) from yoke (1). Fill inside with grease (G2-LI), then assemble plunger (2) into yoke (1).
Page 987: Removal And Installation Of Recoil Spring Assembly
50 Disassembly and assembly SEN01056-01 Removal and installation of recoil Installation spring assembly Carry out installation in the reverse order to removal. a To check that the spring is securely fitted Removal inside the track frame, check through the a The coil portion of the recoil spring assembly is side hole on the inside (at the 5th track hooked on the rib inside the track frame, so roller from the front).
Page 988 SEN01056-01 50 Disassembly and assembly Fig. 1 (for tool [1]) PC800, 850-8...
Page 989: Disassembly And Assembly Of Recoil Spring Assembly
50 Disassembly and assembly SEN01056-01 Disassembly and assembly of Apply hydraulic pressure slowly to compress spring, then remove lock plate, and remove nut recoil spring assembly (2). Special tools Part number Part name 791-685-8502 Compressor 791-635-3160 Extension 796-630-1110 Plate 01010-51640 Bolt 796-630-1120 Spacer...
Page 990 SEN01056-01 50 Disassembly and assembly Assembly Install tool M3 to tip of rod (5). a Tool M3 is to prevent damage to the thread when inserting the rear pilot. Install rod (5) to spring (3). Assemble rear pilot (4), and set to tool M3. The recoil spring is under large installed load, so be sure to set the parts properly.
Page 991: Removal And Installation Of Carrier Roller Assembly
50 Disassembly and assembly SEN01056-01 Removal and installation of Installation carrier roller assembly To install this assembly, reverse the remov- ing procedures. Removal Carrier roller mounting bolt: 549 ± 58 Nm {56 ± 6 kgm} Loosen the track shoe a bit referring to the paragraph of “Testing and adjusting track shoe tension”...
Page 992: Disassembly And Assembly Of Carrier Roller Assembly
SEN01056-01 50 Disassembly and assembly Disassembly and assembly of Remove the assembly of roller (4) and floating seal (5) on support (2). carrier roller assembly Remove floating seal (5) from support (2). Special tools Remove bearing (6) from support (2). Part number Part name 3 790-1101-5201 Push tool kit (B)
Page 993 50 Disassembly and assembly SEN01056-01 Assembly Press fit the shaft (3) in roller (4). a Check that floating seal (5) was assem- Press fit bearing outer race (7) in the both bled in support (2) and on roller (4). sides of support (2) by using tool L3. a Press fit roller (4) to the shaft end face (face under the shaft in the figure) and Press fit bearing (6) in shaft (3) by using tool...
Page 994 SEN01056-01 50 Disassembly and assembly 11. Use tool L5 and [2] to press roller (4). a Retain a force of 18 tons and over to press the shaft and roller. 12. Assemble carrier roller assembly and fill it with oil. Lubricating oil: 300 –...
Page 995: Removal And Installation Of Track Roller Assembly
50 Disassembly and assembly SEN01056-01 Removal and installation of track Using tool L7, remove track roller assembly (2). [*1] roller assembly Track roller assembly (S flange): 140 kg Special tools Part number Part name 791-401-1700 Lifting tool 791-401-1761 Adapter 791-401-1540 Shackle 791-401-1770 T-bolt...
Page 996: Disassembly And Assembly Of Track Roller Assembly
SEN01056-01 50 Disassembly and assembly Disassembly and assembly of Pull out shaft (5) from roller (4). a It is filled with 420 – 480 cc. of oil, so drain track roller assembly the oil at this point or lay a cloth to prevent the area from becoming dirty.
Page 997 50 Disassembly and assembly SEN01056-01 Assembly Using tool L9, install floating seals (6) and (3) to roller (4). Using tool L10, press fit bushings (9) and (10) a For details of the precautions when install- to roller (4). ing floating seals (6b) and (6d), and (3b) and (3d), see the precautions marked a Assemble collar (8) to shaft (5), and install pin for Step 3.
Page 998 SEN01056-01 50 Disassembly and assembly Using tool L10, apply standard pressure to roller oil filler port, and check for leakage of air from seal. a Standard pressure: 0.1 MPa {1 kg/cm a Method of checking The standard pressure shall be main- tained for 10 seconds and the indicator of the gauge shall not go down.
Page 999: Removal And Installation Of Revolving Frame Assembly
50 Disassembly and assembly SEN01056-01 Removal and installation of Disconnect swivel joint upper pipings (5) – (10). revolving frame assembly Removal Remove the work equipment assembly. For details, see “Removal and installation of work equipment”. Remove the counterweight assembly. For details, see “Removal and installation of counterweight assembly”.
Page 1000 SEN01056-01 50 Disassembly and assembly 10. Revolving frame assembly [*1], [*2] Installation Install wires to the counterweight mount- Carry out installation in the reverse order to ing frame and boom mounting portion and removal. sling the revolving frame assembly tempo- rarily.
Page 1001: Removal And Installation Of Counterweight Assembly
50 Disassembly and assembly SEN01056-01 Removal and installation of Installation counterweight assembly Carry out installation in the reverse order to removal. Removal [*1] Set the hanging hook chain of counterweight a Adjust the level difference from the exterior assembly (2) and sling the counterweight parts with shims (top and bottom clearances).

This manual is also suitable for:

Galeo pc800se-8 Galeo pc800lc-8 Galeo pc850-8 Galeo pc850se-8

Komatsu Galeo PC800-8 Shop Manual

Table of Contents

Section 1

Section 2

Section 3

Section 4

Section 5

Section 6

Section 7

Section 8

Section 9

Section 10

Section 11

Section 12

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Summary of Contents for Komatsu Galeo PC800-8