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Manuals and User Guides for Komatsu Galeo PC800SE-8. We have
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Komatsu Galeo PC800SE-8 manual available for free PDF download: Shop Manual
Komatsu Galeo PC800SE-8 Shop Manual (1117 pages)
Hydraulic Excavator
Brand:
Komatsu
| Category:
Excavators
| Size: 42.14 MB
Table of Contents
Table of Contents
6
Section 1
17
Safety Notice
18
How to Read the Shop Manual
23
Explanation of Terms for Maintenance Standard
25
Handling of Electric Equipment and Hydraulic Component
27
Handling of Connectors Newly Used for Engines
36
How to Read Electric Wire Code
39
Precautions When Carrying out Operation
42
Method of Disassembling and Connecting Push-Pull Type Coupler
45
Standard Tightening Torque Table
48
Conversion Table
52
Section 2
59
Specification
59
Specification and Technical Data
59
Specification Drawings
60
Specification and Technical Data
60
Working Range Drawing
62
Specifications
64
Weight Table
82
Table of Fuel, Coolant and Lubricants
88
Structure, Function and Maintenance Standard
91
Engine and Cooling System SEN00380-01
91
Engine and Cooling System
91
Coupling
92
Coupling Lubrication System
93
Radiator, Oil Cooler
94
Section 3
97
Power Train Power Train
98
Swing Machinery
100
Swing Circle
102
Final Drive
104
Sprocket
106
Section 4
109
Undercarriage and Frame
109
Track Frame and Recoil Spring
110
Undercarriage and Frame
110
Idler
112
Carrier Roller
114
Track Roller
116
Track Shoe
118
Double Shoe
121
Section 5
123
Hydraulic System, Part 1
123
Hydraulic Piping Drawing
124
Hydraulic System, Part 1
124
Hydraulic Tank, Hydraulic Filter
126
Hydraulic Pump
128
Cooling Fan Pump
148
Cooling Fan Motor
156
Section 6
163
Hydraulic System, Part 2
163
Motor Grease Pump
166
Hydraulic System, Part 2
166
Return Oil Filter
167
Line Oil Filter
168
Drain Oil Filter
169
5-Spool Control Valve
170
4-Spool Control Valve
176
Straight-Travel Valve
182
Swing Motor
185
Center Swivel Joint
190
Travel Motor
191
PPC Accumulator
201
Work Equipment, Swing PPC Valve
202
Travel PPC Valve
208
Solenoid Valve
212
Quick Return Valve
218
Hydraulic Cylinder
220
Work Equipment
227
Work Equipment
228
Dimensions of Work Equipment
234
Cab and Its Attachments
239
Air Conditioner Piping
240
Section 7
243
Electrical System
243
Engine Control
244
Electrical System Engine Control
244
Electric Control System
253
Monitor System
287
Sensors
305
Standard Value Table
311
Standard Service Value Table for Engine
312
Standard Service Value Table for Chassis
313
Section 8
325
Testing and Adjusting Testing and Adjusting, Part
325
Testing and Adjusting, Part 1
325
Tools for Testing, Adjusting and Troubleshooting
326
Testing and Adjusting, Part 1
326
Measuring Engine Speed
329
Measuring Intake Air Pressure (Boost Pressure)
330
Measuring Exhaust Gas Temperature
331
Measuring Exhaust Gas Color
332
Adjusting Valve Clearance
333
Measuring Compression Pressure
334
Measuring Blow-By Pressure
335
Measuring Engine Oil Pressure
336
Measuring EGR Valve and Bypass Valve Drive Pressure
337
Handling of Fuel System Equipment
338
Remaining Pressure Relief from Fuel System Equipment
338
Measuring Fuel Pressure
339
Testing Fuel Return Rate and Leakage
340
Bleeding Air from Fuel Circuit
342
Testing Fuel System for Leakage
344
Testing and Adjusting Alternator Belt Tension
345
Testing and Adjusting Air Conditioner Compressor Belt
346
Section 9
349
Testing and Adjusting, Part 2
349
Inspection of Swing Circle Bearing Clearance
350
Testing and Adjusting, Part 2
350
Testing and Adjusting Track Shoe Tension
351
Testing and Adjusting Work Equipment, Swing, and Travel Circuit Oil Pressures
352
Testing and Adjusting Control Circuit Pressure (Output Pressure of Self Pressure Reducing Valve)10
358
Testing and Adjusting Control Circuit Pressure (Output Pressure of Self Pressure Reducing Valve)
358
Testing and Adjusting Main Pump Control Pressure
360
Section 10
367
Testing and Adjusting, Part 3
367
Measuring PPC Valve Output Pressure
368
Testing and Adjusting, Part 3
368
Measuring Outlet Pressures of Solenoid Valve, Swing PPC Shuttle Valve, and Swing Priority Selector Valve
372
Adjusting Work Equipment, Swing PPC Valve
376
Testing and Adjusting Travel Deviation
377
Inspection of Locations of Hydraulic Drift of Work Equipment
379
Measuring Fan Speed
380
Measuring Fan Circuit Oil Pressure
380
Measuring Fan Pump EPC Current
381
Measuring Fan Pump EPC Solenoid Valve Output Pressure
382
Measuring Oil Leakage
383
Release of Residual Pressure from Hydraulic Circuit
387
Bleeding Air from each Part
388
Inspection Procedures for Diode
391
Adjusting Mirrors
392
Testing and Adjusting, Part 4
395
Special Function of Machine Monitor
396
Handling Controller Voltage Circuit
429
Section 11
431
30 Testing and Adjusting
432
Procedure for Turning on KOMTRAX Terminal
432
Testing and Adjusting, Part 5
432
KOMTRAX Terminal Lamp Indications
435
Preparation Work for Troubleshooting Electrical System
438
Pm-Clinic Service
446
Troubleshooting
451
Failure Code Table and Fuse Locations
451
Failure Codes Table
452
Fuse Locations
456
Section 12
459
General Information on Troubleshooting
459
Points to Remember When Troubleshooting
459
General Information on Troubleshooting
460
Troubleshooting
460
Sequence of Events in Troubleshooting
461
Checks before Troubleshooting
462
Classification and Troubleshooting Steps
463
Information in Troubleshooting Table
464
Failure-Looking Phenomenon and Troubleshooting no
466
Wiring Table for Connector Pin Numbers
469
T-Adapter Box and T-Adapter Table
502
Troubleshooting by Failure Code (Display of Code), Part 1
507
Table of Contents
508
Failure Code [AA10NX] Aircleaner Clogging
510
Failure Code [AB00KE] Charge Voltage Low
512
Failure Code [B@BAZG] Eng. Oil Press. Low
514
Failure Code [B@BAZK] Eng. Oil Level Low
515
Failure Code [B@BCNS] Eng. Water Overheat
516
Failure Code [B@BCZK] Eng. Water Lvl Low
518
Failure Code [B@HANS] Hydr. Oil Overheat
520
Failure Code [CA111] ECM Critical Internal Failure
522
Failure Code [CA115] Eng Ne and Bkup Speed Sens Error
524
Failure Code [CA122] Chg Air Press Sensor High Error
526
Failure Code [CA123] Chg Air Press Sensor Low Error
528
Failure Code [CA131] Throttle Sensor High Error
530
Failure Code [CA132] Throttle Sensor Low Error
532
Failure Code [CA135] Eng Oil Press Sensor High Error
534
Failure Code [CA141] Eng Oil Press Sensor Low Error
536
Failure Code [CA144] Coolant Temp Sens High Error
538
Failure Code [CA145] Coolant Temp Sens Low Error
540
Failure Code [CA153] Chg Air Temp Sensor High Error
542
Failure Code [CA154] Chg Air Temp Sensor Low Error
544
Failure Code [CA187] Sens Supply 2 Volt Low Error
544
Failure Code [CA221] Ambient Press Sens High Error
546
Failure Code [CA222] Ambient Press Sens Low Error
548
Failure Code [CA227] Sens Supply 2 Volt High Error
550
Failure Code [CA234] Eng Overspeed
552
Failure Code [CA238] Ne Speed Sens Supply Volt Error
554
Failure Code [CA263] Fuel Temp Sensor High Error
556
Failure Code [CA265] Fuel Temp Sensor Low Error
558
Failure Code [CA271] IMV/PCV1 Short Error
559
Failure Code [CA272] IMV/PCV1 Open Error
560
Failure Code [CA273] PCV2 Short Error
561
Failure Code [CA274] PCV2 Open Error
562
Failure Code [CA322] Inj #1 (L#1) Open/Short Error
563
Failure Code [CA323] Inj #5 (L#5) Open/Short Error
564
Failure Code [CA324] Inj #3 (L#3) Open/Short Error
566
Failure Code [CA325] Inj #6 (L#6) Open/Short Error
568
Failure Code [CA331] Inj #2 (L#2) Open/Short Error
570
Failure Code [CA332] Inj #4 (L#4) Open/Short Error
572
Failure Code [CA342] Calibration Code Incompatibility
573
Failure Code [CA351] Injectors Drive Circuit Error
574
Failure Code [CA352] Sens Supply 1 Volt Low Error
576
Failure Code [CA386] Sens Supply 1 Volt High Error
578
Failure Code [CA441] Battery Voltage Low Error
583
Failure Code [CA442] Battery Voltage High Error
583
Failure Code [CA449] Rail Press very High Error
584
Failure Code [CA451] Rail Press Sensor High Error
586
Failure Code [CA452] Rail Press Sensor Low Error
588
Failure Code [CA553] Rail Press High Error
588
Failure Code [CA554] Rail Press Sensor in Range Error
589
Failure Code [CA559] Rail Press Low Error
590
Failure Code [CA689] Eng Ne Speed Sensor Error
594
Failure Code [CA731] Eng Bkup Speed Sens Phase Error
596
Failure Code [CA757] All Persistent Data Lost Error
597
Failure Code [CA778] Eng Bkup Speed Sensor Error
598
Failure Code [CA1228] EGR Valve Servo Error 1
600
Failure Code [CA1625] EGR Valve Servo Error 2
601
Failure Code [CA1626] BP Valve Sol Current High Error
602
Failure Code [CA1627] BP Valve Sol Current Low Error
604
Failure Code [CA1628] Bypass Valve Servo Error 1
605
Failure Code [CA1629] Bypass Valve Servo Error 2
606
Failure Code [CA1631] BP Valve Pos Sens High Error
608
Failure Code [CA1632] BP Valve Pos Sens Low Error
610
Failure Code [CA1633] KOMNET Datalink Timeout Error
612
Failure Code [CA1642] EGR Inter Press Sens Low Error
614
Failure Code [CA1653] EGR Inter Press Sens High Error
616
Failure Code [CA2185] Throt Sens Sup Volt High Error
618
Failure Code [CA2186] Throt Sens Sup Volt Low Error
620
Failure Code [CA2249] Rail Press very Low Error
621
Failure Code [CA2271] EGR Valve Pos Sens High Error
622
Failure Code [CA2272] EGR Valve Pos Sens Low Error
624
Failure Code [CA2351] EGR Valve Sol Current High Error
626
Failure Code [CA2352] EGR Valve Sol Current Low Error
628
Failure Code [CA2555] Grid Htr Relay Volt Low Error
629
Failure Code [CA2556] Grid Htr Relay Volt High Error
630
Failure Code [D110KB] Battery Relay Drive S/C
632
Failure Code [D163KB] Flash Light Relay S/C
634
Failure Code [D195KB] Step Light Relay S/C
636
Failure Code [DA22KK] Pump Solenoid Power Low Error
638
Failure Code [DA25KP] Press. Sensor Power Abnormality
640
Failure Code [DA2SKQ] Model Selection Abnormality
642
Failure Code [DA80MA] Auto. Lub. Abnormal
644
Failure Code [DA2RMC] Pump Comm. Abnormality
646
Failure Code [DAFRMC] Monitor Comm. Abnormality
648
Failure Code [DGE5KY] Ambi. Temp. Sensor S/C
650
Failure Code [DGH2KB] Hydr. Oil Temp. Sensor S/C
652
Troubleshooting by Failure Code (Display of Code), Part 3
655
Failure Code [DH25KA] L Jet Sensor Disc
658
Failure Code [DH25KB] L Jet Sensor S/C
660
Failure Code [DH26KA] R Jet Sensor Disc
662
Failure Code [DH26KB] R Jet Sensor S/C
664
Failure Code [DHPEKA] F Pump P. Sensor Disc
666
Failure Code [DHPEKB] F Pump P. Sensor S/C
668
Failure Code [DHPFKA] R Pump P. Sensor Disc
670
Failure Code [DHPFKB] R Pump P. Sensor S/C
672
Failure Code [DV20KB] Travel Alarm S/C
674
Failure Code [DW41KA] Swing Priority Sol. Disc
676
Failure Code [DW41KB] Swing Priority Sol. S/C
678
Failure Code [DW43KA] Travel Speed Sol. Disc
680
Failure Code [DW43KB] Travel Speed Sol. S/C
682
Failure Code [DW45KA] Swing Brake Sol. Disc
684
Failure Code [DW45KB] Swing Brake Sol. S/C
686
Failure Code [DW7BKA] Fan Reverse Sol. Disc
688
Failure Code [DW7BKB] Fan Reverse Sol. S/C
690
Failure Code [DW7JKA] Bottom Dump Priority Sol. Disc
692
Failure Code [DW7JKB] Bottom Dump Priority Sol. S/C
694
Failure Code [DWK0KA] 2-Stage Relief Sol. Disc
696
Failure Code [DWK0KB] 2-Stage Relief Sol. S/C
698
Failure Code [DX16KA] Fan Pump EPC Sol. Disc
700
Failure Code [DX16KB] Fan Pump EPC Sol. S/C
702
Failure Code [DXAAKA] F Pump EPC Sol. Disc
704
Failure Code [DXAAKB] F Pump EPC Sol. S/C
706
Failure Code [DXABKA] R Pump EPC Sol. Disc
708
Failure Code [DXABKB] R Pump EPC Sol. S/C
710
Failure Code [DY20KA] Wiper Working Abnormality
712
Failure Code [DY20MA] Wiper Parking Abnormality
714
Failure Code [DY2CKB] Washer Drive S/C
718
Failure Code [DY2DKB] Wiper Drive (For) S/C
720
Failure Code [DY2EKB] Wiper Drive (Rev) S/C
724
Troubleshooting of Electrical System (E-Mode)
727
Before Carrying out Troubleshooting of Electrical System
729
Information Contained in Troubleshooting Table
731
Engine Does Not Start (Engine Does Not Rotate)
732
Preheater Does Not Operate
735
Auto Engine Warm-Up Device Does Not Work
742
Auto-Decelerator Does Not Operate
743
All Work Equipment, Swing and Travel Do Not Move
744
Machine Push-Up Function Does Not Operate Normally
746
Boom Shockless Function Does Not Operate Normally
748
Any Item Is Not Displayed on Machine Monitor
750
Part of Display on Machine Monitor Is Missing
751
Machine Monitor Displays Contents Irrelevant to the Model
751
Fuel Level Monitor Red Lamp Lights up While Engine Is Running
752
Engine Coolant Thermometer Does Not Display Normally
754
Hydraulic Oil Temperature Gauge Does Not Display Correctly
756
Fuel Gauge Does Not Display Correctly
757
Swing Lock Monitor Does Not Display Correctly
758
When Monitor Switch Is Operated, Nothing Is Displayed
760
Windshield Wiper and Window Washer Do Not Work
762
Boom RAISE" Is Not Correctly Displayed in Monitor Function
770
Boom LOWER" Is Not Correctly Displayed in Monitor Function
771
Arm IN" Is Not Correctly Displayed in Monitor Function
772
Arm OUT" Is Not Correctly Displayed in Monitor Function
773
Bucket CURL" Is Not Correctly Displayed in Monitor Function
774
Bucket DUMP" Is Not Correctly Displayed in Monitor Function
775
SWING" Is Not Correctly Displayed in Monitor Function
776
Left Travel" Is Not Displayed Normally in Monitoring Function
778
Right Travel" Is Not Displayed Normally in Monitoring Function
780
Service" Is Not Correctly Displayed in Monitor Function
782
KOMTRAX System Does Not Operate Normally
784
Air Conditioner Does Not Work
786
Step Light Does Not Light up or Go off
787
Electric Grease Gun Does Not Operate
790
Travel Alarm Does Not Sound or Does Not Stop Sounding
792
Troubleshooting of Hydraulic and Mechanical System (H-Mode)
795
Before Troubleshooting
797
Information in Troubleshooting Table
800
Speed or Power of All Work Equipment, Travel, and Swing Is Low
802
Engine Speed Lowers Remarkably or Engine Stalls
804
All Work Equipment, Travel, and Swing Systems Do Not Work
806
Abnormal Sound Is Heard from Around Pump
807
Boom Speed or Power Is Low
808
Speed or Power of Arm Is Low
810
Speed or Power of Bucket Is Low
811
Boom Does Not Move
812
Arm Does Not Move
812
Bucket Does Not Move
812
Hydraulic Drift of Work Equipment Is Large
813
Time Lag of Work Equipment Is Large
815
Heavy Lift Function Does Not Operate or Stop
816
Machine Push-Up Function Does Not Operate or Stop
816
Boom Shockless Function Cannot be Turned on or off
816
Machine Deviates in One Direction
818
Machine Deviates Largely at Start
820
Machine Deviates Largely During Compound Operation
821
Travel Speed or Power Is Low
821
Machine Does Not Travel (Only One Track)
822
Travel Speed Does Not Change
823
Upper Structure Does Not Swing
824
Swing Speed or Acceleration Is Low
826
Swing Speed or Acceleration Is Low During Compound Operation of Swing and
829
Upper Structure Overruns Excessively When It Stops Swinging
830
Large Shock Is Made When Upper Structure Stops Swinging
831
Large Abnormal Sound Is Made When Upper Structure Stops Swinging
832
Hydraulic Drift of Swing Is Large
833
Troubleshooting of Engine (S-Mode)
837
Method of Using Troubleshooting Chart
839
Starting Performance Is Poor
842
Engine Does Not Start
844
Engine Does Not Pick up Smoothly
848
Engine Stops During Operations
849
Engine Does Not Rotate Smoothly
850
Engine Lacks Output (or Lacks Power)
851
Exhaust Gas Color Is Black (Incomplete Combustion)
852
Oil Consumption Is Excessive (or Exhaust Smoke Is Blue)
854
Oil Becomes Contaminated Quickly
855
Fuel Consumption Is Excessive
856
Oil Is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down)
857
Oil Pressure Drops
858
Oil Level Rises (Entry of Coolant/Fuel)
860
Coolant Temperature Becomes too High (Overheating)
862
Abnormal Noise Is Made
863
Vibration Is Excessive
864
Disassembly and Assembly
867
General Information on Disassembly and Assembly
867
How to Read this Manual
868
Coating Materials List
870
Special Tools List
873
Sketches of Special Tools
880
Engine and Cooling System
886
Removal and Installation of Engine, PTO and Hydraulic Pump Assembly
886
Removal and Installation of Cooling Assembly
894
Removal and Installation of Aftercooler Assembly
899
Removal and Installation of Fuel Cooler and Air Conditioner Condenser Assembly
901
Removal and Installation of Fan Motor Assembly
903
Removal and Installation of Fuel Tank Assembly
908
Engine (SAA6D140E-5)
911
Removal and Installation of Fuel Supply Pump Assembly
912
Removal and Installation of Cylinder Head Assembly
917
Removal and Installation of Fuel Injector Assembly
933
Removal and Installation of Engine Front Seal
936
Removal and Installation of Engine Rear Seal
938
Power Train
943
Removal and Installation of PTO (Coupling) Assembly
944
Disassembly and Assembly of PTO (Coupling) Assembly
951
Removal and Installation of Swing Motor and Swing Machinery Assembly
953
Disassembly and Assembly of Swing Machinery Assembly
955
Removal and Installation of Swing Circle Assembly
962
Disassembly and Assembly of Final Drive Assembly
963
Undercarriage and Frame
975
Removal and Installation of Track Shoe Assembly
976
Disassembly and Assembly of One Link in Field
978
Removal and Installation of Idler Assembly
982
Disassembly and Assembly of Idler Assembly
983
Disassembly and Assembly of Idler Adjustment Cylinder Assembly
986
Removal and Installation of Recoil Spring Assembly
987
Disassembly and Assembly of Recoil Spring Assembly
989
Removal and Installation of Carrier Roller Assembly
991
Disassembly and Assembly of Carrier Roller Assembly
992
Removal and Installation of Track Roller Assembly
995
Disassembly and Assembly of Track Roller Assembly
996
Removal and Installation of Revolving Frame Assembly
999
Removal and Installation of Counterweight Assembly
1001
Removal and Installation of Counterweight Remover Assembly
1002
Hydraulic System
1005
Removal and Installation of Hydraulic Tank Assembly
1006
Removal and Installation of Main Pump Assembly
1009
Removal and Installation of Main Pump Input Shaft Oil Seal
1016
Removal and Installation of Cooling Fan Pump Assembly
1017
Removal and Installation of Control Valve Assembly
1020
Assembly of Control Valve Assembly
1023
Removal and Installation of Swing Motor Assembly
1029
Removal and Installation of Center Swivel Joint Assembly
1031
Disassembly and Assembly of Center Swivel Joint Assembly
1033
Removal and Installation of Travel Motor Assembly
1035
Removal and Installation of Solenoid Valve Assembly
1036
Removal and Installation of Boom Damping Valve Assembly
1038
Disassembly and Assembly of Work Equipment PPC Valve Assembly
1039
Disassembly and Assembly of Travel PPC Valve Assembly
1041
Disassembly and Assembly of Hydraulic Cylinder Assembly
1042
Disassembly and Assembly of Grease Gun Assembly
1048
Work Equipment
1051
Removal and Installation of Bucket Cylinder Assembly
1052
Removal and Installation of Arm Cylinder Assembly
1056
Removal and Installation of Boom Cylinder Assembly
1060
Removal and Installation of Bottom Dump Cylinder Assembly
1064
Removal and Installation of Bucket Assembly
1065
Removal and Installation of Arm Assembly
1067
Removal and Installation of Boom Assembly
1070
Removal and Installation of Work Equipment
1074
Cab and Its Attachments
1079
Removal and Installation of Operator's Cab
1080
Removal and Installation of Operator's Cab Glass (Stuck Glass)
1083
Removal and Installation of Front Window Assembly
1093
Electrical System
1099
Removal and Installation of Air Conditioner Unit Assembly
1100
Removal and Installation of Engine Controller Assembly
1102
Removal and Installation of Monitor Assembly
1104
Removal and Installation of Pump Controller Assembly
1104
Removal and Installation of KOMTRAX Terminal Assembly
1105
Diagrams and Drawings
1107
Hydraulic Circuit Diagram
1108
Connector Arrangement Diagram
1110
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