Komatsu Galeo PC800-8 Shop Manual Download Page 4 | Manualshive

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SEN00375-06

00 Index and foreword

2

PC800, 850-8

Composition of shop manual

1

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. denote the following:

Q

: New issue (to be filed additionally)

q

: Revision (to be replaced for each Form No.)

Note 2: This shop manual can be supplied for each Form No.

Note 3: To file this shop manual in the special binder for management, handle it as follows:

• Place a divider on the top of each section in the file after matching the Tub No. with No. indicated

next to each Section Name shown in the table below:

• File overview and other materials in sections in the order shown below and utilize them accordingly.

Section Title

Form Number

Shop Manual, contents binder, binder label and tabs

SEN00373-06

00 Index and foreword

SEN00374-06

Index

SEN00375-06

q

Foreword and general information

SEN00376-02

01 Specification

SEN00377-02

Specification and technical data

SEN00378-02

10 Structure, function and maintenance standard

SEN00379-04

Engine and cooling system

SEN00380-01

Power train

SEN00381-01

Undercarriage and frame

SEN00382-01

Hydraulic system, Part 1

SEN00383-03

q

Hydraulic system, Part 2

SEN00384-02

Work equipment

SEN00385-01

Cab and its attachments

SEN00396-01

Electrical system

SEN00386-03

20 Standard value table

SEN00387-02

Standard service value table

SEN00784-02

30 Testing and adjusting

SEN00388-02

Testing and adjusting, Part 1

SEN00786-02

Testing and adjusting, Part 2

SEN00788-02

Testing and adjusting, Part 3

SEN00912-02

Testing and adjusting, Part 4

SEN00913-02

Testing and adjusting, Part 5

SEN00914-02

40 Troubleshooting

SEN00389-02

Failure code table and fuse locations

SEN02797-00

General information on troubleshooting

SEN00789-02

Troubleshooting by failure code (Display of code), Part 1

SEN00790-02

Troubleshooting by failure code (Display of code), Part 2

SEN00791-02

Troubleshooting by failure code (Display of code), Part 3

SEN00792-02

Troubleshooting of electrical system (E-mode)

SEN00793-02

Troubleshooting of hydraulic and mechanical system (H-mode)

SEN00794-02

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Summary of Contents for Galeo PC800-8

Page 1: ...SEN00373 06 HYDRAULIC EXCAVATOR PC800 8 PC800SE 8 PC800LC 8 PC850 8 PC850SE 8 SERIAL NUMBERS PC800 50001 and up PC800SE 50001 PC800LC 50001 PC850 10001 PC850SE 10001...

Page 2: ......

Page 3: ...C800 8 50001 and up PC800SE 8 50001 and up PC800LC 8 50001 and up PC850 8 10001 and up PC850SE 8 10001 and up HYDRAULIC EXCAVATOR PC800 8 PC800SE 8 PC800LC 8 PC850 8 PC850SE 8 00 Index and foreword 1...

Page 4: ...02 01 Specification SEN00377 02 Specification and technical data SEN00378 02 10 Structure function and maintenance standard SEN00379 04 Engine and cooling system SEN00380 01 Power train SEN00381 01 U...

Page 5: ...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 Ca...

Page 6: ...cation and technical data SEN00378 02 Specification and technical data 2 Specification drawings 2 Working range drawing 4 Specifications 6 Weight table 24 Table of fuel coolant and lubricants 30 10 St...

Page 7: ...2 Electric control system 11 Monitor system 45 Sensors 63 20 Standard value table Standard service value table SEN00784 02 Standard service value table for engine 2 Standard service value table for ch...

Page 8: ...hydraulic circuit 21 Bleeding air from each part 22 Inspection procedures for diode 25 Adjusting mirrors 26 Testing and adjusting Part 4 SEN00913 02 Testing and adjusting Part 4 2 Special function of...

Page 9: ...e code CA323 Inj 5 L 5 Open Short Error 58 Failure code CA324 Inj 3 L 3 Open Short Error 60 Failure code CA325 Inj 6 L 6 Open Short Error 62 Failure code CA331 Inj 2 L 2 Open Short Error 64 Failure co...

Page 10: ...2 02 Troubleshooting by failure code Display of code Part 3 4 Failure code DH25KA L Jet Sensor Disc 4 Failure code DH25KB L Jet Sensor S C 6 Failure code DH26KA R Jet Sensor Disc 8 Failure code DH26KB...

Page 11: ...et CURL is not correctly displayed in monitor function 48 E 23 Bucket DUMP is not correctly displayed in monitor function 49 E 24 SWING is not correctly displayed in monitor function 50 E 25 Left trav...

Page 12: ...y 19 S 10 Fuel consumption is excessive 20 S 11 Oil is in coolant or coolant spurts back or coolant level goes down 21 S 12 Oil pressure drops 22 S 13 Oil level rises Entry of coolant fuel 24 S 14 Coo...

Page 13: ...c tank assembly 2 Removal and installation of main pump assembly 5 Removal and installation of main pump input shaft oil seal 12 Removal and installation of cooling fan pump assembly 13 Removal and in...

Page 14: ...bly 6 Removal and installation of pump controller assembly 6 Removal and Installation of KOMTRAX terminal assembly 7 90 Diagrams and drawings Hydraulic diagrams and drawings SEN00392 02 Hydraulic circ...

Page 15: ...00 Index and foreword SEN00375 06 PC800 850 8 13...

Page 16: ...14 PC800 8 PC800SE 8 PC800LC 8 PC850 8 PC850SE 8 Hydraulic excavator Form No SEN00375 06 SEN00375 06 00 Index and foreword...

Page 17: ...foreword 1 Foreword and general information Safety notice 2 How to read the shop manual 7 Explanation of terms for maintenance standard 9 Handling of electric equipment and hydraulic component 11 Han...

Page 18: ...ith a grinder etc 4 When carrying out any operation with 2 or more workers always agree on the oper ating procedure before starting Always inform your fellow workers before starting any step of the op...

Page 19: ...er which is under internal pressure or under pressure from a spring always leave 2 bolts in diagonal positions Loosen those bolts gradually and alternately to release the pressure and then remove the...

Page 20: ...e hanging angle from the hook When hoisting a load with 2 or more ropes the force subjected to each rope will increase with the hanging angle The table below shows the variation of allow able load in...

Page 21: ...le the slung load is swinging 6 Do not raise or lower a load while the crane is moving longitudinally or laterally 7 Do not drag a sling 8 When lifting up a load stop it just after it leaves the groun...

Page 22: ...lling it you must be quali fied for handling the refrigerant and put on protective goggles 2 Connection 1 When installing the air conditioner cir cuit hoses and tubes take care that dirt dust water et...

Page 23: ...e standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting 40 Troubleshooting This section explains how to find out failed parts and how to repair them T...

Page 24: ...ted with International System of units SI For reference con ventionally used Gravitational System of units is indicated in parentheses Symbol Item Remarks k Safety Special safety precautions are neces...

Page 25: ...he range of differ ence from the standard size is called the tolerance q The tolerance with the symbols of or is indicated on the right side of the standard size a The tolerance may be indicated in th...

Page 26: ...hat the interference is in the standard range 4 Repair limit and allowable value q The size of a part changes because of wear and deformation while it is used The limit of changed size is called the r...

Page 27: ...more likely to be affected by the direct effects of rain water heat or vibration Furthermore during inspection and repair operations they are frequently removed and installed again so they are likely...

Page 28: ...er does enter it is difficult for it to be drained Therefore if water should get into the connector the pins will be short cir cuited by the water so if any water gets in immediately dry the connector...

Page 29: ...pull with one hand 2 When removing from clips q Both of the connector and clip have stoppers which are engaged with each other when the connector is installed q When removing a connector from a clip p...

Page 30: ...is will cause short circuits a If there is any damage or break age replace the connector 2 Fix the connector securely Align the position of the connector correctly and then insert it securely For conn...

Page 31: ...e 1 Push in female connector 2 horizon tally until the lock clicks Arrow 1 2 Since locks a and b may not be set completely push in female connector 2 while moving it up and down until the locks are se...

Page 32: ...the air may cause defective contact so remove all oil and water from the com pressed air before blowing with air 2 Dry the inside of the connector with a dryer If water gets inside the connector use...

Page 33: ...onnect all wiring harness con nectors connected to the controller Fit an arc welding ground close to the welding point 5 Points to remember when troubleshooting electric circuits 1 Always turn the pow...

Page 34: ...sassembly and maintenance of hydraulic equipment should be carried out in a specially prepared dustproof workshop and the perfor mance should be checked with special test equipment 3 Sealing openings...

Page 35: ...w oil and will shorten the life of the hydraulic oil 6 Flushing operations After disassembling and assembling the equip ment or changing the oil use flushing oil to remove the contaminants sludge and...

Page 36: ...gines Ambient pressure sensor PAMB 125 170 12V140 engines Disconnect connector 1 according to the fol lowing procedure 1 Slide lock L1 to the right 2 While pressing lock L2 pull out connec tor 1 towar...

Page 37: ...the direction of the arrow q 114 engine q 107 engine a If the lock is on the underside use flat head screwdriver 1 since you cannot insert your fingers 2 While pressing up lock C of the connec tor wit...

Page 38: ...Turn housing type Round green connector q 140 engine Example Intake air pressure sensor in intake mani fold CANNON 04 PIM etc 1 Disconnect connector 6 according to the following procedure 1 Turn housi...

Page 39: ...dicates color of wire by color code Color codes are shown in Table 3 Indicates size of wire by nominal No Size Nominal No is shown in Table 2 Indicates type of wire by symbol Type symbol and material...

Page 40: ...23 d approx 1 0 1 2 1 5 1 9 1 9 2 3 2 4 3 0 Cov er D AVS Standard 2 0 2 2 2 5 2 9 2 9 3 5 3 6 AV Standard 4 6 AEX Standard 2 0 2 2 2 7 3 0 3 1 3 8 4 6 Nominal No 8 15 20 30 40 50 60 85 100 Conductor N...

Page 41: ...ue White BrW Brown White LY Blue Yellow BrY Brown Yellow O Orange Ch Charcoal P Pink Dg Dark green R Red G Green RB Red Black GB Green Black RG Red Green GL Green Blue RL Red Blue Gr Gray RW Red White...

Page 42: ...use lifting equipment of ample strength q When using forcing screws to remove any components tighten the forcing screws uniformly in turn q Before removing any unit clean the surrounding area and fit...

Page 43: ...he cylinder 100 mm from the end of its stroke 3 Next operate the hydraulic cylinder 3 4 times to the end of its stroke 4 After doing this run the engine at normal speed a When using the machine for th...

Page 44: ...If any part is damaged replace it 2 Check the mounting bolts and nuts of the muffler exhaust pipe and their mounting parts for looseness If any bolt or nut is loosened retighten it 5 Checking muffler...

Page 45: ...er 3 Fig 1 a The adapter can be pushed in about 3 5 mm a Do not hold rubber cap portion 4 2 After hose joint 2 is pushed into adapter 3 press rubber cap portion 4 against adapter 3 until it clicks Fig...

Page 46: ...hexag onal portion at the male end Fig 6 2 While holding the condition of Step 1 turn lever 8 to the right clockwise Fig 7 3 While holding the condition of Steps 1 and 2 pull out whole body 7 to disc...

Page 47: ...Fig 10 2 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 Fig 11 3 While holding the condition of Steps 1 and...

Page 48: ...ter of bolt Width across flats Tightening torque mm mm Nm kgm 6 10 11 8 14 7 1 2 1 5 8 13 27 34 2 8 3 5 10 17 59 74 6 0 7 5 12 19 98 123 10 0 12 5 14 22 153 190 15 5 19 5 16 24 235 285 23 5 29 5 18 27...

Page 49: ...idth across flats Tightening torque Nm kgm mm mm Range Target 02 14 Varies depending on type of connec tor 35 63 3 5 6 5 44 4 5 03 04 20 84 132 8 5 13 5 103 10 5 05 06 24 128 186 13 0 19 0 157 16 0 10...

Page 50: ...107 and 114 engine series to the torque below Nominal No of hose Width across flats Tightening torque Nm kgm Taper seal Face seal Range Target Thread size mm Nominal No Number of threads type of thre...

Page 51: ...per 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 Nm kgm 1 16 3 1 0 31 0...

Page 52: ...so divide it by 10 move the decimal point one place to the left to convert it to 55 mm 2 Carry out the same procedure as above to convert 55 mm to 2 165 inches 3 The original value 550 mm was divided...

Page 53: ...79 37 81 57 83 78 85 98 40 88 18 90 39 92 59 94 80 97 00 99 21 101 41 103 62 105 82 108 03 50 110 23 112 44 114 64 116 85 119 05 121 25 123 46 125 66 127 87 130 07 60 132 28 134 48 136 69 138 89 141 1...

Page 54: ...73 6 180 8 188 1 195 3 202 5 209 8 30 217 0 224 2 231 5 238 7 245 9 253 2 260 4 267 6 274 9 282 1 40 289 3 296 6 303 8 311 0 318 3 325 5 332 7 340 0 347 2 354 4 50 361 7 368 9 376 1 383 4 390 6 397 8...

Page 55: ...1 451 1 465 1 479 1 493 1 508 1 522 1 536 1 550 110 1 565 1 579 1 593 1 607 1 621 1 636 1 650 1 664 1 678 1 693 120 1 707 1 721 1 735 1 749 1 764 1 778 1 792 1 806 1 821 1 835 130 1 849 1 863 1 877 1...

Page 56: ...12 2 54 129 2 31 7 89 192 2 26 1 15 5 0 6 7 20 68 0 12 8 55 131 0 32 2 90 194 0 25 6 14 6 8 6 1 21 69 8 13 3 56 132 8 32 8 91 195 8 25 0 13 8 6 5 6 22 71 6 13 9 57 134 6 33 3 92 197 6 24 4 12 10 4 5 0...

Page 57: ...00 Index and foreword SEN00376 02 PC800 850 8 41...

Page 58: ...42 SEN00376 02 00 Index and foreword PC800 8 PC800SE 8 PC800LC 8 PC850 8 PC850SE 8 Hydraulic excavator Form No SEN00376 02...

Page 59: ...up PC850 8 10001 and up PC850SE 8 10001 and up HYDRAULIC EXCAVATOR PC800 8 PC800SE 8 PC800LC 8 PC850 8 PC850SE 8 01 Specification Specification and technical data Specification and technical data Spec...

Page 60: ...4 660 4 615 4 690 4 850 4 615 C Overall width mm 4 285 4 305 4 385 4 305 4 305 D Track shoe width mm 610 610 810 610 610 E Height of cab mm 3 665 3 665 3 560 3 665 3 665 F Radius of upper structure m...

Page 61: ...cification A Overall length mm 10 075 B Overall height mm 5 790 C Overall width mm 4 285 D Track shoe width mm 610 E Height of cab mm 3 560 F Radius of upper structure mm 4 400 G Overall length of tra...

Page 62: ...ng reach mm 13 740 12 265 13 740 13 660 12 265 B Max digging depth mm 8 600 7 130 8 600 8 445 7 130 C Max digging height mm 11 840 11 330 11 840 11 955 11 330 D Max vertical wall digging depth mm 5 57...

Page 63: ...fication Item Unit PC800 8 Loading shovel specification A Max digging reach mm 10 370 B Max digging depth mm 9 595 C Max digging height mm 10 800 D Max vertical wall digging depth mm 3 605 E Max dumpi...

Page 64: ...Travel speed Gradeability Ground pressure standard triple grouser shoe width 710 mm kN kg rpm deg km h deg kPa kg cm2 333 4 34 000 6 8 16 Lo 2 8 Hi 4 2 35 105 1 1 07 Dimensions Overall length Overall...

Page 65: ...CF68 4 Undercarriage Carrier roller Track roller Track shoe 3 on each side 8 on each side Assembly type triple grouser 47 on each side Fan system Fan pump Type Variable swash plate type LPV90 Operati...

Page 66: ...Inside diameter of cylinder mm 200 200 185 Diameter of piston rod mm 140 140 130 Stroke mm 1 950 2 250 1 610 Max distance between pins mm 4 880 5 525 3 990 Min distance between pins mm 2 930 3 275 2...

Page 67: ...adeability Ground pressure standard triple grouser shoe width 710 mm kN kg rpm deg km h deg kPa kg cm2 430 5 43 900 6 8 16 Lo 2 8 Hi 4 2 35 106 5 1 09 Dimensions Overall length Overall width Overall w...

Page 68: ...F68 4 Undercarriage Carrier roller Track roller Track shoe 3 on each side 8 on each side Assembly type triple grouser 47 on each side Fan system Fan pump Type Variable swash plate type LPV90 Operating...

Page 69: ...Inside diameter of cylinder mm 200 185 225 Diameter of piston rod mm 140 120 160 Stroke mm 1 950 1 610 1 420 Max distance between pins mm 4 880 3 990 3 910 Min distance between pins mm 2 930 2 380 2...

Page 70: ...adeability Ground pressure standard triple grouser shoe width 810 mm kN kg rpm deg km h deg kPa kg cm2 333 4 34 000 6 8 16 Lo 2 8 Hi 4 2 35 108 1 1 10 Dimensions Overall length Overall width Overall w...

Page 71: ...F68 4 Undercarriage Carrier roller Track roller Track shoe 3 on each side 9 on each side Assembly type triple grouser 51 on each side Fan system Fan pump Type Variable swash plate type LPV90 Operating...

Page 72: ...Inside diameter of cylinder mm 200 200 185 Diameter of piston rod mm 140 140 130 Stroke mm 1 950 2 250 1 610 Max distance between pins mm 4 880 5 525 3 990 Min distance between pins mm 2 930 3 275 2...

Page 73: ...eability Ground pressure standard triple grouser shoe width 710 mm kN kg rpm deg km h deg kPa kg cm2 362 8 37 000 6 8 16 Lo 2 8 Hi 4 2 35 110 6 1 13 Dimensions Overall length Overall width Overall wid...

Page 74: ...68 4 Undercarriage Carrier roller Track roller Track shoe 3 on each side 8 on each side Assembly type triple grouser 47 on each side Fan system Fan pump Type Variable swash plate type LPV90 Operating...

Page 75: ...n Inside diameter of cylinder mm 200 200 185 Diameter of piston rod mm 140 140 130 Stroke mm 1 950 2 250 1 610 Max distance between pins mm 4 880 5 525 3 990 Min distance between pins mm 2 930 3 275 2...

Page 76: ...adeability Ground pressure standard triple grouser shoe width 710 mm kN kg rpm deg km h deg kPa kg cm2 430 5 43 900 6 8 16 Lo 2 8 Hi 4 2 35 110 5 1 13 Dimensions Overall length Overall width Overall w...

Page 77: ...CF68 4 Undercarriage Carrier roller Track roller Track shoe 3 on each side 8 on each side Assembly type triple grouser 47 on each side Fan system Fan pump Type Variable swash plate type LPV90 Operatin...

Page 78: ...Inside diameter of cylinder mm 200 185 225 Diameter of piston rod mm 140 120 160 Stroke mm 1 950 1 610 1 420 Max distance between pins mm 4 880 3 990 3 910 Min distance between pins mm 2 930 2 380 2...

Page 79: ...pe angle Travel speed Gradeability Ground pressure standard triple grouser shoe width 610 mm kN kg rpm deg km h deg kPa kg cm2 476 3 48 600 6 8 16 Lo 2 8 Hi 4 2 35 128 0 1 31 Dimensions Overall length...

Page 80: ...68 4 Undercarriage Carrier roller Track roller Track shoe 3 on each side 8 on each side Assembly type triple grouser 47 on each side Fan system Fan pump Type Variable swash plate type LPV90 Operating...

Page 81: ...der mm 200 225 185 140 Diameter of piston rod mm 140 160 130 90 Stroke mm 1 490 1 530 1 550 335 Max distance between pins mm 4 340 4 130 4 275 1 235 Min distance between pins mm 2 850 2 600 2 725 900...

Page 82: ...r 23 2 23 2 Hydraulic tank filter assembly excl hydraulic oil 656 656 Fuel tank excl fuel 640 640 Revolving frame 7 090 7 090 Operator s cab 280 280 Operator s seat 35 35 Counterweight 9 800 9 800 Swi...

Page 83: ...8 880 9 520 10 160 Boom assembly 7 865 7 310 Arm assembly 2 715 3 160 Bucket assembly 2 960 3 435 Boom cylinder assembly 762 2 762 2 Arm cylinder assembly 838 481 2 Bucket cylinder assembly 511 936 Bo...

Page 84: ...tank filter assembly excl hydraulic oil 656 Fuel tank excl fuel 640 Revolving frame 7 090 Operator s cab 280 Operator s seat 35 Counterweight 9 800 Swing machinery 490 2 L H 5 spool control valve 245...

Page 85: ...r shoe 1 110 mm 10 020 11 520 12 270 Boom assembly 7 865 Arm assembly 3 970 Bucket assembly 2 960 Boom cylinder assembly 774 2 Arm cylinder assembly 865 Bucket cylinder assembly 557 Boom foot pin 45 2...

Page 86: ...hydraulic oil 656 656 Fuel tank excl fuel 640 640 Revolving frame 7 090 7 090 Operator s cab 280 280 Operator s seat 35 35 Counterweight 11 850 11 850 Swing machinery 490 2 490 2 L H 5 spool control...

Page 87: ...om assembly 8 150 7 310 Arm assembly 3 155 3 160 Bucket assembly 3 850 3 850 Boom cylinder assembly 762 2 762 2 Arm cylinder assembly 481 2 481 2 Bucket cylinder assembly 550 936 Boom foot pin 45 2 2...

Page 88: ...30 PC800 850 8 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...

Page 89: ...Supply point PC800 PC800SE 8 PC800LC 8 PC850 PC850SE 8 Specified capacity Refill capacity Engine oil pan 58 53 Coupling case 7 7 Swing machinery case each 24 5 24 5 Final drive case each 20 20 Hydraul...

Page 90: ...32 PC800 8 PC800SE 8 PC800LC 8 PC850 8 PC850SE 8 Hydraulic excavator Form No SEN00378 02 SEN00378 02 01 Specification...

Page 91: ...50001 and up PC800LC 8 50001 and up PC850 8 10001 and up PC850SE 8 10001 and up HYDRAULIC EXCAVATOR PC800 8 PC800SE 8 PC800LC 8 PC850 8 PC850SE 8 10 Structure function and maintenance standard Engine...

Page 92: ...nd cooling system Coupling Unit mm 1 Coupling case Specifications Lubricating oil 6 0 l TO30 2 Shaft 3 Hub 4 Breather No Check item Criteria Remedy 5 Backlash of gear pump spline for SAR375 375 Standa...

Page 93: ...raulic circuit diagram Hydraulic piping diagram 1 Coupling Outline Coupling lubricating pump 2 sends lubricating oil from the oil sump under coupling case 1 through oil strainer 3 into the coupling ca...

Page 94: ...4 PC800 850 8 SEN00380 01 10 Structure function and maintenance standard Radiator oil cooler...

Page 95: ...n oil cooler is built in the lower tank of the radiator 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 Cond...

Page 96: ...6 PC800 8 PC800SE 8 PC800LC 8 PC850 8 PC850SE 8 Hydraulic excavator Form No SEN00380 01 SEN00380 01 10 Structure function and maintenance standard...

Page 97: ...001 and up PC800LC 8 50001 and up PC850 8 10001 and up PC850SE 8 10001 and up HYDRAULIC EXCAVATOR PC800 8 PC800SE 8 PC800LC 8 PC850 8 PC850SE 8 10 Structure function and maintenance standard Power tra...

Page 98: ...2 PC800 850 8 SEN00381 01 10 Structure function and maintenance standard Power train Power train...

Page 99: ...or KMF125AB 5 13 Coupling lubricating pump FBR00 2 5 4 L H 5 spool control valve 14 Cooling fan pump LPV90 5 R H 4 spool control valve 15 Self pressure reducing valve 6 Final drive sprocket 16 Swing b...

Page 100: ...4 PC800 850 8 SEN00381 01 10 Structure function and maintenance standard Swing machinery...

Page 101: ...17 0 52 1 00 22 Backlash between No 2 planet gear and ring gear 0 21 0 64 1 10 23 Backlash between coupling and swing pinion 0 08 0 25 24 Backlash between swing pin ion and swing circle 0 1 5 2 00 25...

Page 102: ...of grease 65 l G2 LI Unit mm 1 Swing circle inner race No of teeth 112 2 Ball 3 Swing circle outer race a Inner race soft zone S position b Outer race soft zone plug position 112 13 No Check item Crit...

Page 103: ...This Page Intentionally left Blank...

Page 104: ...gear No of teeth 19 6 Drive gear No of teeth 19 7 No 1 planetary carrier 8 No 2 planet gear No of teeth 24 9 Hub 10 Sprocket 11 Floating seal 12 Case 13 Coupling 14 No 1 sun gear No of teeth 13 15 Tra...

Page 105: ...and No 2 planet gear 0 23 0 68 25 Backlash between No 2 planetary carrier and No 2 ring gear 0 28 0 87 26 Backlash between coupling and drive gear 0 38 0 72 27 Backlash between No 1 ring gear and cas...

Page 106: ...ard Sprocket Unit mm No Check item Criteria Remedy 1 Wear of tooth tip Standard size Repair limit Build up welding or replace 403 6 391 6 2 Thickness of tooth root 28 4 22 4 3 Width of tooth 114 108 4...

Page 107: ...1 10 Structure function and maintenance standard SEN00381 01 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...

Page 108: ...12 PC800 8 PC800SE 8 PC800LC 8 PC850 8 PC850SE 8 Hydraulic excavator Form No SEN00381 01 SEN00381 01 10 Structure function and maintenance standard...

Page 109: ...8 50001 and up PC850 8 10001 and up PC850SE 8 10001 and up HYDRAULIC EXCAVATOR PC800 8 PC800SE 8 PC800LC 8 PC850 8 PC850SE 8 10 Structure function and maintenance standard Undercarriage and frame Unde...

Page 110: ...s the PC800 8 The dimensions and number of track rollers may differ according to the model but the basic struc ture is the same No of track rollers 1 Idler 2 Track frame 3 Carrier roller 4 Center fram...

Page 111: ...o Check item Criteria Remedy 10 Top to bottom width of idler guide Standard size Tolerance Repair limit Rebuild or replace Track frame 185 185 190 Idler support 180 185 0 5 175 Replace 11 Left to righ...

Page 112: ...4 PC800 850 8 SEN00382 01 10 Structure function and maintenance standard Idler...

Page 113: ...5 4 Thickness of tread 5 Overall width 266 6 Width of tread 69 5 7 Clearance between shaft and bushing Standard size Tolerance Standard clearance Clearance limit Replace bush ing Shaft Hole 110 0 120...

Page 114: ...e diameter of tread 175 155 3 Width of tread 68 4 Thickness of tread 57 6 47 6 5 Width of flange 17 6 Interference between bearing and support Standard size Tolerance Standard interference Interferenc...

Page 115: ...This Page Intentionally left Blank...

Page 116: ...8 PC800 850 8 SEN00382 01 10 Structure function and maintenance standard Track roller...

Page 117: ...5 Overall width 328 6 Width of tread Single flange 72 Double flange 72 7 Width of flange Single flange 29 Double flange 29 8 Width of inner flange Double flange 126 9 Axial play 0 42 0 99 10 Clearanc...

Page 118: ...10 PC800 850 8 SEN00382 01 10 Structure function and maintenance standard Track shoe a P portion shows the link of bushing press fitting end...

Page 119: ...eplace 15 8 10 3 4 Link height 156 143 5 Thickness of link metal bushing press fitting portion 39 3 26 3 Replace 6 Shoe bolt pitch 234 95 7 184 2 8 76 2 9 Link Inside width 133 6 Repair or replace 10...

Page 120: ...Tolerance Standard interference Adjust or replace Shaft Hole 87 5 0 472 0 372 0 087 0 0 285 0 472 22 Interference between regular pin and link 55 2 0 596 0 496 0 074 0 0 422 0 596 23 Clearance betwee...

Page 121: ...standard SEN00382 01 Double shoe Unit mm No Check item Criteria Remedy 1 Height Standard size Repair limit Rebuild or replace 50 25 2 Height 50 3 Thickness 20 4 Length at bottom 39 5 6 Length at top...

Page 122: ...14 PC800 8 PC800SE 8 PC800LC 8 PC850 8 PC850SE 8 Hydraulic excavator Form No SEN00382 01 SEN00382 01 10 Structure function and maintenance standard...

Page 123: ...C850 8 10001 and up PC850SE 8 10001 and up HYDRAULIC EXCAVATOR PC800 8 PC800SE 8 PC800LC 8 PC850 8 PC850SE 8 10 Structure function and maintenance standard Hydraulic system Part 1 Hydraulic system Par...

Page 124: ...ooler 8 Cooling fan motor 9 Control valve 10 PPC shuttle valve 11 Hydraulic filter 12 Cooling fan pump 13 Hydraulic pump 14 L H travel motor 15 Hydraulic tank 16 PPC lock valve 17 L H PPC valve 18 R H...

Page 125: ...PC800 850 8 3 10 Structure function and maintenance standard SEN00383 03...

Page 126: ...4 PC800 850 8 SEN00383 03 10 Structure function and maintenance standard Hydraulic tank hydraulic filter...

Page 127: ...l at H level Pressure valve Relief cracking pressure 16 7 6 9 kPa 0 17 0 07 kg cm2 Suction cracking pressure 0 0 49 kPa 0 0 005 kg cm2 Bypass valve set pressure 0 15 0 03 MPa 1 5 0 3 kg cm2 1 Hydraul...

Page 128: ...6 PC800 850 8 SEN00383 03 10 Structure function and maintenance standard Hydraulic pump Type HPV375 375...

Page 129: ...Rear discharge port P3 Fan pump discharge port P4 Gear pump discharge port PF Self pressure reducing valve basic pressure port PR2 Pilot basic pressure output port preceding the inline filter attache...

Page 130: ...8 PC800 850 8 SEN00383 03 10 Structure function and maintenance standard...

Page 131: ...Rear case 12 Rear shaft 13 Bevel gear 14 lmpeller pump 15 lmpeller shaft 16 lmpeller pinion CS3 Fan pump control pressure pick up port PF1 Self pressure reducing valve basic pressure output port from...

Page 132: ...r cam 4 Rocker cam 4 brings high pressure oil at cylin der surface with cradle 2 which is secured to the case and forms a static pressure bearing when it slides Piston 6 carries out relative movement...

Page 133: ...In this way piston 6 slides on the inside of cyl inder block 7 so a difference between volumes E and F is created inside cylinder block 7 A single piston 6 sucks and discharges the oil by the amount F...

Page 134: ...cam 4 slides on the cylindrical surface of cradle 2 With servo piston 8 the area receiving the pressure is different on the left and the right The pump discharge pressure self pressure PH is constant...

Page 135: ...PC800 850 8 13 10 Structure function and maintenance standard SEN00383 03 Pump controller System diagram...

Page 136: ...14 PC800 850 8 SEN00383 03 10 Structure function and maintenance standard Pump control signal...

Page 137: ...put pressure pick up port CH Servo actuator pressure pick up port CS Pump control pressure pick up port PA Main pump pressure port PH Servo actuator port PR Servo basic pressure port PS Pump control p...

Page 138: ...d spool 3 plus by the switching of the connection port As the re sult servo piston 4 is moved Spool 3 is pressed against cam 8 by spring 7 and feeds back the position of servo piston 4 Move of servo p...

Page 139: ...ve 2 and spool 3 is opened and port A is closed Since the port on the large diameter side is con nected to the output pressure of the shuttle valve small diameter pressure PH servo piston 4 is moved t...

Page 140: ...the EPC valve 2 pilot pressure and the spring 5 force are balanced The pump controller controls magnitude of the command current sent to EPC valve 2 Operation of servo piston Movement of swash plate t...

Page 141: ...C 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 Since the pressure in...

Page 142: ...20 PC800 850 8 SEN00383 03 10 Structure function and maintenance standard 3 EPC valve C To VC valve P From pump T To pump case drain 1 Body 2 Spool 3 Spring 4 Rod 5 Coil 6 Plunger 7 Connector...

Page 143: ...ure in proportion to the size of the signal and outputs it to the VC valve Operation 1 When signal current is 0 coil is de energized When there is no signal current flowing from the controller to coil...

Page 144: ...t C and port T are connected Spool 2 moves up and down so that the propul sion force of plunger 6 may be balanced with pressure of port C the spring load of spring 3 The circuit pressure between the E...

Page 145: ...re reducing valve Valve 1 receives the force of spring 2 and pressure PR which is 0 MPa 0 kg cm2 when engine is stopped in the direction to close the circuit between ports P3F and P3 As the pressurize...

Page 146: ...4 opens The pressurized oil flows from port PR to inter nal orifice a of spool 6 and then flows to tank drain port T through the opening of poppet 4 The differential pressure is generated through in...

Page 147: ...PC800 850 8 25 10 Structure function and maintenance standard SEN00383 03...

Page 148: ...ump 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 coupling lubrication P...

Page 149: ...800 850 8 27 10 Structure function and maintenance standard SEN00383 03 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 ca...

Page 150: ...spline a Shaft 1 is supported by the front and rear bearings The end of piston 6 has a spherical hollow which is combined with shoe 5 Piston 6 and shoe 5 form a spherical bearing Rocker cam 4 has pla...

Page 151: ...made between vol umes E and F in cylinder block 7 As a result each piston 6 sucks and discharges oil by F E In other words if cylinder block 7 rotates and the volume of chamber E is decreased the oil...

Page 152: ...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 Servo piston 10 reciprocates straight according to the signal pres...

Page 153: ...Structure function and maintenance standard SEN00383 03 Servo valve P EPC valve basic pressure T Drain PE Control piston pressure PH Pump discharge pressure 1 Plug 2 Lever 3 Retainer 4 Seat 5 Spool 6...

Page 154: ...nction The servo valve controls the current input to the EPC valve and the swash plate angle of the pump so that they will be related as shown in the figure below The relationship between the input cu...

Page 155: ...iston is raised by the rocker cam The position feedback is applied and the lever moves to compress the spring If spool 5 is pushed back the pump discharge circuit and the servo piston circuit are shut...

Page 156: ...fan motor Type LMF110 Specifications Type LMF110 Capacity 110 7 cm3 rev Rated speed 1 050 rpm Rated flow rate 120 l min Cracking pressure of check valve 76 5 kPa 0 78 kg cm2 Cracking pressure of safe...

Page 157: ...Pilot valve 5 Piston 13 Reversible valve spool 6 Cylinder block 14 Safety valve 7 Valve plate 15 Reversible valve spring 8 End cover No Check item Criteria Remedy 10 Check valve spring Standard size...

Page 158: ...om dead center of the stroke of piston 4 The oil sent to supply side of cylinder block 5 presses pistons 4 4 or 5 pieces and generates force F1 F1 kg P kg cm2 x x 4D2 cm2 This force is applied to thru...

Page 159: ...rted If the hydraulic oil from the pump is supplied to port P and the pressure on MA side rises and starting torque is generated in the motor the mo tor starts revolution The oil on outlet MB side of...

Page 160: ...sible valve spool spring 4 to the right to open motor port MA and then the hydraulic oil flows in to revolve the motor forward clockwise 2 When ON OFF solenoid for reversible valve is turned ON If ON...

Page 161: ...P of the fan motor is heightened in some cases Safety valve 1 is installed to protect the fan sys tem circuit Operation If the pressure in port P rises above the cracking pressure of safety valve 1 v...

Page 162: ...40 PC800 8 PC800SE 8 PC800LC 8 PC850 8 PC850SE 8 Hydraulic excavator Form No SEN00383 03 SEN00383 03 10 Structure function and maintenance standard...

Page 163: ...00LC 8 PC850 8 PC850SE 8 10 Structure function and maintenance standard Hydraulic system Part 2 Hydraulic system Part 2 Motor grease pump 4 Return oil filter 5 Line oil filter 6 Drain oil filter 7 L H...

Page 164: ...2 PC800 850 8 SEN00384 02 10 Structure function and maintenance standard Solenoid valve 50 Hydraulic cylinder 58...

Page 165: ...PC800 850 8 3 10 Structure function and maintenance standard SEN00384 02...

Page 166: ...The pump unit is divided into air chamber 4 and grease chamber 6 As the grease level in grease chamber 6 lowers follower plate 5 is pulled down to push down the grease sticking to the rim of grease c...

Page 167: ...There are two return oil filters installed to the rear face of the hydraulic tank They remove the dirt and dust in the return oil Specifications Bypass valve set pressure 0 15 0 03 MPa 1 5 0 3 kg cm2...

Page 168: ...6 PC800 850 8 SEN00384 02 10 Structure function and maintenance standard Line oil filter 1 Element 2 Body 3 Cover 1 Bracket 2 Cartridge 3 Safety valve...

Page 169: ...PC800 850 8 7 10 Structure function and maintenance standard SEN00384 02 Drain oil filter 1 Cartridge 2 Safety valve 3 Bracket...

Page 170: ...From straight travel valve port P2 of right 4 spool valve PP From straight travel changeover solenoid valve TC Drain PA1 From PPC valve Boom LOWER PA2 From PPC valve Swing LEFT PA3 From PPC valve Arm...

Page 171: ...PC800 850 8 9 10 Structure function and maintenance standard SEN00384 02...

Page 172: ...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 Jet sensor mounting bracket 16 Suction safety valve 5 Spool bucket Hi 11 Je...

Page 173: ...PC800 850 8 11 10 Structure function and maintenance standard SEN00384 02...

Page 174: ...sensor relief valve pilot poppet spring 34 5 8 8 29 4 30 N 3 1 kg 24 3 N 2 5 kg 3 Jet sensor relief valve main valve spring 37 4 11 4 33 49 N 5 0 kg 39 2 N 4 0 kg 4 Spool return spring 69 9 57 63 431...

Page 175: ...PC800 850 8 13 10 Structure function and maintenance standard SEN00384 02...

Page 176: ...m P1 From front pump P2 To left 5 spool valve port P1 PP From straight travel changeover solenoid valve PR From 2 stage main relief valve changeover solenoid valve PS From 2 stage safety valve changeo...

Page 177: ...PC800 850 8 15 10 Structure function and maintenance standard SEN00384 02...

Page 178: ...ck 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 Spool bucket Lo 9 Jet sensor mounting bracket 15 Suction valve 5 Spool ar...

Page 179: ...PC800 850 8 17 10 Structure function and maintenance standard SEN00384 02...

Page 180: ...394 2 N 40 2 kg 315 2 N 32 2 kg 2 Jet sensor relief valve pilot poppet spring 34 5 8 8 29 4 30 N 3 1 kg 24 3 N 2 5 kg 3 Jet sensor relief valve main valve spring 37 4 11 4 33 49 N 5 0 kg 39 2 N 4 0 kg...

Page 181: ...ed 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 Output is characterized as in the following dia gra...

Page 182: ...cture 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 valv...

Page 183: ...PC800 850 8 21 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...

Page 184: ...qual so the left and right travel motors both rotate at the same speed and this prevents any travel de viation Operation When travel is operated independently straight travel solenoid valve de energiz...

Page 185: ...ng brake solenoid valve Specifications Model KMF125AB 5 Theoretical displacement 125 0 cm3 rev Safety valve set pressure 27 9 MPa 285 kg cm2 Rated revolving speed 1 936 rpm Brake release pressure 1 9...

Page 186: ...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 Disc 11 Valve plate 1...

Page 187: ...Criteria Remedy 1 Check valve spring Standard size Repair limit If damaged or deformed replace spring Free length Outside diameter Installed length Installed load Free length Installed load 62 5 20 0...

Page 188: ...ing torque is generat ed in the motor and the motor starts to ro tate The oil from the outlet port of the motor passes from port MB thought the control valve and returns to the tank Fig 1 2 When stopp...

Page 189: ...circuit As a result brake piston 6 is pushed down by brake spring 7 pushes disc 5 and plate 4 together and the brake is applied 2 When swing brake solenoid valve is excited When the swing brake solen...

Page 190: ...and maintenance standard Center swivel joint Unit mm 1 Cover 2 Body 3 Slipper seal 4 Oil seal 5 Shaft No Check item Criteria Remedy 6 Clearance between rotor and shaft Standard size Standard clearanc...

Page 191: ...el MSF 340VP EH Theoretical delivery 1st 337 2 cc rev 2nd 12 6 cc rev Rated pressure 31 4 MPa 320 kg cm2 Rated speed 1st 1 423 rpm at 500 l min 2nd 2 258 rpm at 500 l min Brake release pressure 1 8 MP...

Page 192: ...8 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 Sprin...

Page 193: ...e 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 Rocke...

Page 194: ...forming the non sliding surface of rocker cam 14 has two faces The high low speed vol ume selection for this motor is carried out by fix ing each face to provide large capacity low speed or small capa...

Page 195: ...When pilot pressure PI from the control pump is 0 spool 1a of travel speed selector valve 1 is not switched In this condition the oil from the chamber of control piston 10 passes through spool 1a and...

Page 196: ...on level ground if the travel motor drive pressure is low the condition becomes F1 F2 and spool 1a is pushed to the right When this happens the main oil pressure M1 M2 passes through spool 1a and goes...

Page 197: ...ol so the brake is applied by the force of the spring to mechanically lock the motor shaft and hold the machine in position When parking brake is ON When the travel lever is placed in neutral the coun...

Page 198: ...is reason it has a much larger pressure receiving area than the pressure receiving area when it is set S1 S2 so the relief actuating pressure becomes a low pressure of approx 15 7 MPa 160 kg cm2 This...

Page 199: ...ne is traveling with the engine running at low speed the motor will rotate under no load or may run away which is extremely dangerous To prevent this this valve controls the amount of oil on the retur...

Page 200: ...and the motor starts to rotate Operation of brake when traveling downhill If the machine tries to run away when traveling downhill the motor will turn under no load so the pressure at the motor inlet...

Page 201: ...control valve by the pressure of the nitrogen gas compressed inside the accumulator so it is possible to lower the work equipment under its own weight Operation After the engine stops when the PPC va...

Page 202: ...nction 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 R...

Page 203: ...PC800 850 8 41 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...

Page 204: ...for P3 P4 Standard size Repair limit Replace spring if damaged or deformed Free length OD Installation length Installation load Free length Installation load 42 48 15 5 34 17 6 N 1 8 kg 13 7 N 1 4 kg...

Page 205: ...pressure at port P1 rises spool 1 is pushed back Port P1 is shut off from pump pressure chamber PP At almost the same time it is connected to drain chamber D so the pres sure at port P1 escapes As a...

Page 206: ...pump pressure chamber PP so the pressure at port P1 supplies the pump pressure until the pres sure recovers to a pressure equivalent to the position of the lever When the control valve returns oil in...

Page 207: ...PC800 850 8 45 10 Structure function and maintenance standard SEN00384 02...

Page 208: ...46 PC800 850 8 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...

Page 209: ...Right travel forward P4 Right travel reverse No Check item Criteria Remedy 9 Metering spring Basic dimension Allowable limit If damaged or deformed replace spring Free length Outside diameter Install...

Page 210: ...port P1 rises spool 1 is pushed back Fine control hole f is shut off from pump pressure chamber PP At almost the same time it is connected to drain chamber D to re lease the pressure at port P1 As a r...

Page 211: ...e at port P1 supplies the pump pressure until the pressure re covers to a pressure equivalent to the position of the lever When the control valve returns oil in drain cham ber D flows in from fine con...

Page 212: ...used T To tank 2 Travel speed solenoid valve A2 To left and right travel motor 3 Swing brake solenoid valve A3 To swing motor 4 Machine push up solenoid valve A4 To main valve Safety valve 5 Heavy lif...

Page 213: ...he same time the pressurized oil from the ac tuator flows from port A to port T and is then drained to the tank When solenoid is energized When the signal current flows from the PPC lock switch or swi...

Page 214: ...00384 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...

Page 215: ...or flows from port A2 to port T and is drained to the tank When solenoid is energized When the signal current flows from the controller to solenoid 2 solenoid 2 is energized Accordingly spool 11 is pu...

Page 216: ...800 850 8 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...

Page 217: ...o the control valve When solenoid is energized When the signal current flows from the controller to coil 3 coil 3 is energized and movable iron core 2 is pushed to the right in the direction of the ar...

Page 218: ...e oil from chamber b inside the pop pet is drained through orifice c The oil at the bottom end of the arm flows from orifice a to chamber b to orifice c to drain so the oil pressure in chamber b drops...

Page 219: ...ed 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 d1 Area of d2 because of the difference in the outside d...

Page 220: ...58 PC800 850 8 SEN00384 02 10 Structure function and maintenance standard Hydraulic cylinder Backhoe specification PC800 800LC 850 8 STD Boom cylinder Arm cylinder Bucket cylinder...

Page 221: ...0 043 0 106 0 256 0 039 0 082 0 362 0 062 Bucket 130 0 036 0 090 0 263 0 048 0 084 0 353 0 062 2 Clearance between piston rod support shaft and bushing Boom 115 0 036 0 090 0 025 0 0 036 0 115 1 5 Re...

Page 222: ...60 PC800 850 8 SEN00384 02 10 Structure function and maintenance standard PC800SE 850SE 8 Boom cylinder Arm cylinder Bucket cylinder...

Page 223: ...0 036 0 090 0 263 0 048 0 084 0 353 0 062 Bucket 160 0 043 0 106 0 256 0 039 0 082 0 362 0 062 2 Clearance between piston rod support shaft and bushing Boom 115 0 036 0 090 0 025 0 0 036 0 115 1 5 Re...

Page 224: ...62 PC800 850 8 SEN00384 02 10 Structure function and maintenance standard Loading shovel specification PC800 8 Boom cylinder Arm cylinder Bucket cylinder...

Page 225: ...56 0 040 0 082 0 362 0 662 Bottom dump 90 0 036 0 090 0 257 0 048 0 084 0 347 0 647 2 Clearance between piston rod support shaft and bushing Boom 115 0 036 0 090 0 025 0 0 036 0 115 1 5 Replace pin bu...

Page 226: ...64 PC800 8 PC800SE 8 PC800LC 8 PC850 8 PC850SE 8 Hydraulic excavator Form No SEN00384 02 SEN00384 02 10 Structure function and maintenance standard...

Page 227: ...00SE 8 50001 and up PC800LC 8 50001 and up PC850 8 10001 and up PC850SE 8 10001 and up HYDRAULIC EXCAVATOR PC800 8 PC800SE 8 PC800LC 8 PC850 8 PC850SE 8 10 Structure function and maintenance standard...

Page 228: ...2 PC800 850 8 SEN00385 01 10 Structure function and maintenance standard Work equipment Work equipment Backhoe specification PC800 8 PC800LC 8...

Page 229: ...mounting pin of boom and arm 140 0 043 0 106 0 542 0 442 0 485 0 648 1 5 3 Clearance between bushing and mounting pin of arm and link 115 0 036 0 090 0 351 0 271 0 307 0 441 1 5 4 Clearance between bu...

Page 230: ...4 PC800 850 8 SEN00385 01 10 Structure function and maintenance standard PC800SE 8 PC850 850SE 8...

Page 231: ...0 043 0 106 0 542 0 442 0 485 0 648 1 5 3 Clearance between bushing and mounting pin of arm and link 115 0 036 0 090 0 351 0 271 0 307 0 441 1 5 4 Clearance between bushing and mounting pin of arm and...

Page 232: ...6 PC800 850 8 SEN00385 01 10 Structure function and maintenance standard Loading shovel specification PC800 8...

Page 233: ...043 0 106 0 542 0 442 0 485 0 648 1 5 2 Clearance between boom arm mounting pin and bush ing 140 0 043 0 106 0 542 0 442 0 485 0 648 1 5 3 Clearance between arm bucket mounting pin and bushing 140 0...

Page 234: ...8 PC800 850 8 SEN00385 01 10 Structure function and maintenance standard Dimensions of work equipment 1 Arm...

Page 235: ...39 663 750 663 6 397 467 530 329 401 329 7 1 332 1 389 1 328 925 916 925 8 3 578 4 569 5 575 3 585 2 917 3 585 9 3 675 3 688 3 673 4 011 3 580 4 011 10 585 570 585 585 500 585 11 950 950 950 1 035 840...

Page 236: ...10 PC800 850 8 SEN00385 01 10 Structure function and maintenance standard 2 Bucket...

Page 237: ...6 756 765 670 670 670 765 5 2 218 2 218 2 275 2 211 2 211 2 211 2 268 6 292 292 316 315 315 315 339 7 a 130 130 130 130 130 130 130 b 115 115 115 115 115 115 115 8 520 520 520 520 520 520 520 9 80 5 8...

Page 238: ...12 PC800 8 PC800SE 8 PC800LC 8 PC850 8 PC850SE 8 Hydraulic excavator Form No SEN00385 01 SEN00385 01 10 Structure function and maintenance standard...

Page 239: ...PC800SE 8 50001 and up PC800LC 8 50001 and up PC850 8 10001 and up PC850SE 8 10001 and up HYDRAULIC EXCAVATOR PC800 8 PC800SE 8 PC800LC 8 PC850 8 PC850SE 8 10 Structure function and maintenance standa...

Page 240: ...ir 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 Air cond...

Page 241: ...This Page Intentionally left Blank...

Page 242: ...4 PC800 8 PC800SE 8 PC800LC 8 PC850 8 PC850SE 8 Hydraulic excavator Form No SEN00396 01 SEN00396 01 10 Structure function and maintenance standard...

Page 243: ...d up PC800LC 8 50001 and up PC850 8 10001 and up PC850SE 8 10001 and up HYDRAULIC EXCAVATOR PC800 8 PC800SE 8 PC800LC 8 PC850 8 PC850SE 8 10 Structure function and maintenance standard Electrical syst...

Page 244: ...eed control The fuel control dial sends a signal voltage cor responding to the rotation angle to the engine controller The pump controller receives the fuel dial posi tion information from the engine...

Page 245: ...ctor Function A potentiometer is installed under the knob As the knob is turned the potentiometer shaft is turned As the potentiometer shaft is turned the resist ance of the variable resistor in poten...

Page 246: ...CAN E 7 NC 8 CAN E 9 Supply pump 2 D 10 Supply pump 2 C Never connect to NC or malfunctions or failures will occur 11 EGR valve D 12 NC 13 Engine oil pressure sensor B 14 NC 15 Coolant temperature sen...

Page 247: ...2 NC B 3 NC B 4 NC B 5 NC B 6 NC B 7 NC B 8 NC B 9 Fuel control dial B 10 NC E 11 NC B 12 NC B Never connect to NC or malfunctions or failures will occur CN CE01 Pin No Signal name Input output 13 NC...

Page 248: ...let pressure sensor Fuel temperature sensor 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 change...

Page 249: ...R 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 Th...

Page 250: ...e 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 5 V by the wave form shapin...

Page 251: ...disc gear installed to the central part of the camshaft of the high pressure pump has teeth cut parts around it at intervals of 120 In addition to the above teeth one more tooth is installed According...

Page 252: ...tage to the ther mistor and senses the temperature by the volt age divided by the resistance in the computer and the resistance of the thermistor Coolant temperature sensor The coolant temperature sen...

Page 253: ...PC800 850 8 11 10 Structure function and maintenance standard SEN00386 03 Electric control system Control functions...

Page 254: ...12 PC800 850 8 SEN00386 03 10 Structure function and maintenance standard Machine control system diagram...

Page 255: ...PC800 850 8 13 10 Structure function and maintenance standard SEN00386 03...

Page 256: ...ion 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 consumptio...

Page 257: ...d higher than the de celeration activation speed approx 1 425 rpm the engine speed lowers to the deceleration acti vation speed approx 1 425 rpm in 4 seconds and then keeps to that speed until any con...

Page 258: ...y one TVC valve P mode Total horsepower control by sensing engine speed E mode Total horsepower control by sensing engine speed Emergency pump drive circuit Constant delivery control The pump controll...

Page 259: ...f the pressure lowers the pump discharge Q is increased until the engine speed is set about the rated output point By repeating this control the engine can always be used at near the rated output poin...

Page 260: ...rge volume to reduce the relief loss 3 Cut off cancel function The cut off cancel function acts to stop the oper ation of the cut off function in order to ensure the pump flow when close to the relief...

Page 261: ...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 E3 As...

Page 262: ...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...

Page 263: ...lift switch Lever operation Heavy lift solenoid valve Main relief valve set pressure CO control Boom lifting force Boom RAISE Arm IN or bucket CURL OFF Operated De energized 31 4 MPa 320 kg cm2 Actuat...

Page 264: ...utline 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...

Page 265: ...ion see R H 4 spool control valve Mode Machine push up switch Machine push up solenoid valve Safety valve set pressure Effect Boom pushing force low mode Energized 14 7 MPa 150 kg cm2 By reducing the...

Page 266: ...24 PC800 850 8 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...

Page 267: ...swing holding brake release switch is turned ON the swing lock switch stays ON and the swing brake is not canceled a When the swing brake is canceled the swing has only a hydraulic brake operated by...

Page 268: ...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...

Page 269: ...Manual reset Operating condition Operation Remedy Resetting condition Coolant temperature Above 102 C Work mode Any mode Engine speed Keep as is Monitor alarm lamp Lights up Lower pump discharge Coola...

Page 270: ...xed speed when engine is started Actuation condition Engine speed 1000 rpm Even if the fuel control dial is operated during the above time the engine speed will not change After the set time passes th...

Page 271: ...el pressure goes above 22 6 MPa 230 kg cm2 the self pressure switches to low speed The machine continues to travel at low speed and when it comes to flat ground and the load is reduced if the travel p...

Page 272: ...raveling the cut off is canceled and the main relief pressure is raised from 31 4 MPa 320 kg cm2 to 34 3 MPa 350 kg cm2 Operation Pressure increase solenoid valve Main relief valve set pressure CO val...

Page 273: ...e and returns to the tank However when this happens check valve 4 is being pushed open by the pressure in line A so it also allows the oil to pass in the opposite direction For this reason the boom ca...

Page 274: ...l 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 so the drop in the supply of oil to the travel motor will cause the...

Page 275: ...nd right travel levers Work equipment control lever swing lever Straight travel solenoid valve Straight travel valve Remarks Operation Neutral De energized Not actuated Left and right travel motor cir...

Page 276: ...e 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 easil...

Page 277: ...trol QF Delivery of front pump QR Delivery of rear pump Solenoid Swing throttle valve Swing priority mode OFF normal mode OFF De energized ON Swing priority mode ON swing priority ON energized OFF Fro...

Page 278: ...36 PC800 850 8 SEN00386 03 10 Structure function and maintenance standard...

Page 279: ...d opera tions Operation If the swing PPC pressure goes above 1 5 MPa 15 kg cm2 the control lever is operated approximately half or more the swing assurance selector valve is actuated and the swing dri...

Page 280: ...e en gine speed ambient temperature hydraulic oil temperature and coolant temperature While these temperatures are low the fan speed is low ered to reduce the noise and fuel consumption While the work...

Page 281: ...nance standard SEN00386 03 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: ...e fan reverse EPC valve of the fan motor to change the fan reverse valve By this operation the fan rotation direction is reversed The fan speed in reverse direction is controlled by only the engine sp...

Page 283: ...PC800 850 8 41 10 Structure function and maintenance standard SEN00386 03...

Page 284: ...42 PC800 850 8 SEN00386 03 10 Structure function and maintenance standard Pump controller...

Page 285: ...N1 13 NC Input CN2 13 Model selection 5 Input CN1 14 NC Input CN2 14 RS232C T D Output CN1 15 NC Input CN2 15 NC Input CN1 16 NC Output CN2 16 Left travel pressure switch Input CN1 17 Key switch Termi...

Page 286: ...R pump EPC solenoid Output CN3 17 2 stage relief solenoid Output CN3 18 Flash light driver relay Output CN3 19 Bucket DUMP pressure switch Input CN3 20 Boom LOWER pressure switch Input CN3 21 GND Cont...

Page 287: ...splays the obtained information on the panel notifying the operator of the condition of the ma chine The panel is roughly divided as follows 1 Monitor section to output alarms when the machine has tro...

Page 288: ...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 info...

Page 289: ...Lower wiper motor Output 11 NC Input 10 NC Input output 12 Wiper contact P Upper wiper contact P Input 11 NC Input 12 NC Input CN2 13 NC Pin No Signal name Input output 14 CAN Shield Input 15 CAN Inpu...

Page 290: ...or 3 Swing lock monitor 13 Auto deceleration monitor 4 Engine coolant temperature monitor 14 Engine oil pressure caution 5 Hydraulic oil temperature gauge 15 Battery charge caution 6 Engine coolant te...

Page 291: ...ck Swing lock switch Swing holding brake release switch Swing lock monitor OFF OFF OFF ON OFF ON OFF ON Flashes ON ON ON Preheating Continuous set time Preheating monitor status Up to 30 sec ON From 3...

Page 292: ...icator Buzzer sound Engine coolant temperature C A1 105 Red A2 102 Red A3 100 Green A4 80 Green A5 60 Green A6 30 White Hydraulic oil tempera ture C B1 105 Red B2 102 Red B3 100 Green B4 80 Green B5 4...

Page 293: ...il temperature is high or low only the symbol is dis played Symbol Display item Check before starting item When engine is stopped When engine is running Engine oil pressure q When abnormal lights up a...

Page 294: ...item Display range Display method Monitor Wiper Displays set condition Working mode Displays set mode Travel speed Displays set speed Auto decelera tion ON OFF Displays actuation status Service meter...

Page 295: ...g 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 Wipe...

Page 296: ...T o ON o OFF o Use the wiper monitor display to check the present condition The relationship between the wiper setting and the monitor display is as shown in the table on the right Window washer switc...

Page 297: ...ing to the remaining time The relation ship is as shown in the table below No Item Replacement interval hours 01 Engine oil 500 02 Engine oil filter 500 03 Fuel main filter 1 000 41 Fuel pre filter 50...

Page 298: ...pleting the selection press input con firmation switch 3 The screen will change to the maintenance reset screen 2 Use the maintenance reset screen to check the content and if there is any problem pres...

Page 299: ...m switch 4 the next screen is displayed If you press return switch 2 the ordinary screen is displayed again If you select 01 the reverse confirm screen is displayed If you select 02 the E mode adjustm...

Page 300: ...eed is automatically set to low idle for 15 seconds a While the fan is rotating in reverse the swash plate angle of the main pump is minimized a If the engine is stopped while the fan is rotating in r...

Page 301: ...to low idle for 15 seconds 2 E mode adjustment With this menu you can change the balance of the fuel consumption and production per hour by changing the engine speed and target pump ab sorption torqu...

Page 302: ...2 Press control switch 2 or use the 10 key pad to input the number 00 02 to select either contrast or brightness After completing the selection press input con firmation switch 3 and return to the adj...

Page 303: ...input screen or on the normal screen if monitor return switch 1 and working mode A switch are kept pressed at the same time all the LCD display will light up and the whole screen will become white so...

Page 304: ...es failure codes that caused the user code to be displayed Even if service codes failure codes have occurred if they did not cause the user code to be displayed this function does not display them If...

Page 305: ...Type of sensor When normal When abnormal Input controller Coolant level Contact type ON closed OFF open Monitor Engine oil level Contact type ON closed OFF open Monitor Engine oil pressure Analog Eng...

Page 306: ...C800 850 8 SEN00386 03 10 Structure function and maintenance standard Engine oil level sensor Engine oil pressure sensor Air cleaner clogging sensor 1 Connector 2 Bracket 3 Float 4 Switch 1 Seal 2 Sen...

Page 307: ...e function and maintenance standard SEN00386 03 Fuel level sensor Coolant temperature sensor Hydraulic oil temperature sensor 1 Thermistor 4 Tube 2 Body 5 Wire 3 Tube 6 Connector 1 Float 2 Connector 3...

Page 308: ...resses the diaphragm of the oil pressure sensor the diaphragm is deformed The gauge layer facing the diaphragm measures the deformation of the diaphragm by the change of its resistance then converts t...

Page 309: ...PC800 850 8 67 10 Structure function and maintenance standard SEN00386 03...

Page 310: ...68 PC800 8 PC800SE 8 PC800LC 8 PC850 8 PC850SE 8 Hydraulic excavator Form No SEN00386 03 SEN00386 03 10 Structure function and maintenance standard...

Page 311: ...800LC 8 50001 and up PC850 8 10001 and up PC850SE 8 10001 and up HYDRAULIC EXCAVATOR PC800 8 PC800SE 8 PC800LC 8 PC850 8 PC850SE 8 20 Standard value table Standard service value table Standard service...

Page 312: ...pressure Oil temperature 40 60 C Engine speed 200 250 rpm MPa kg cm2 Min 4 1 Min 42 2 8 29 Blow by pressure Coolant temperature within operating range At rated output kPa mmH2O Max 2 94 Max 300 3 92 4...

Page 313: ...vy lift Boom up relief Min 1 700 Min 1 700 Auto deceleration actuated Engine at high idle Auto deceleration switch ON All control levers at neutral 1 425 100 1 400 100 Spool stroke Boom Lo control val...

Page 314: ...ng mode P Pump outlet pressure when mea sured circuit is relieved Relieve either travel circuit RAISE Normal MPa kg cm2 32 4 1 0 330 10 32 4 330 At heavy lift 33 8 1 0 345 10 33 8 345 LOWER Normal 18...

Page 315: ...draulic oil temperature 45 55 C Difference between relief pres sure at high idle and that at low idle Max 2 0 Max 20 Max 2 9 Max 30 Electronic control Output voltage of differ ential pressure sensor H...

Page 316: ...e taken to swing Hydraulic oil temperature 45 55 C Bucket No load Engine at high idle Working mode P Swing one turn then measure time taken to swing next 5 turns sec 41 47 Max 50 Hydraulic drift of sw...

Page 317: ...next 5 turns with no load Lo sec 74 90 PC800LC 8 80 98 74 90 PC800LC 8 80 98 Hi 48 59 PC800LC 8 52 64 48 59 PC800LC 8 52 64 Travel speed Actual travel Hydraulic oil tempera ture 45 55 C Engine at high...

Page 318: ...etrac tion distance of each cylinder and lowering distance of bucket tooth tip from above posture Rated load on work equipment Backhoe specification 49 kN 5 000 kg 64 kN 6 500 kg SE specification Load...

Page 319: ...850SE Max 5 2 Max 6 5 Arm Retract cylinder to stroke end Extract cylinder to stroke end Hydraulic oil temperature 45 55 C Run engine at full throttle Set in mode P IN PC800 4 9 0 5 PC800SE 5 6 0 5 PC8...

Page 320: ...hoe specification PC800 8 Loading shovel Backhoe specification PC800 8 Loading shovel Max 6 Max 6 Arm Hydraulic oil temperature 45 55 C Run engine at slow speed Time from stop of arm to start Max 5 Ma...

Page 321: ...e 45 55 C Engine High idle Fan 100 speed mode rpm 1 050 50 1 050 50 Fan circuit oil pressure Hydraulic oil temperature 45 55 C Engine High idle Fan 100 speed mode MPa kg cm2 13 2 19 1 135 195 13 2 19...

Page 322: ...f one hydraulic pump Performance of hydraulic pump Pump speed At 1800 rpm Pump discharge pressure 9 8 MPa 100 kg cm2 Check point Test pump Test pump EPC current mA Standard value for discharge amount...

Page 323: ...PC800 850 8 13 20 Standard value table SEN00784 02...

Page 324: ...14 PC800 8 PC800SE 8 PC800LC 8 PC850 8 PC850SE 8 Hydraulic excavator Form No SEN00784 02 SEN00784 02 20 Standard value table...

Page 325: ...ir pressure Boost pressure 6 Measuring exhaust gas temperature 7 Measuring exhaust gas color 8 Adjusting valve clearance 9 Measuring compression pressure 10 Measuring blow by pressure 11 Measuring eng...

Page 326: ...V 799 101 5002 Hydraulic tester 1 Pressure gauge 2 5 6 0 40 60 MPa 25 60 400 600 kg cm2 790 261 1204 Digital hydraulic tester 1 Pressure gauge 60 MPa 600 kg cm2 Fuel pressure H 1 799 101 5002 Hydrauli...

Page 327: ...3300 Adapter 1 Size 04 02896 11012 O ring 1 4 799 101 5220 Nipple 2 Size 10 1 25 mm 07002 11023 O ring 2 Fan speed R 799 205 1100 Multiple tachometer 1 L 60 2000 rpm H 60 19 999 rpm Fan circuit oil p...

Page 328: ...ins 799 601 9420 T adapter 1 Pressure sensor 799 601 4100 T adapter assembly 1 Engine related connectors 795 799 5530 Adapter 1 Engine coolant oil fuel temperature 795 799 5540 Adapter 1 Boost tempera...

Page 329: ...he high idle position MAX 2 Set the working mode switch to the P mode position 3 Turn the auto decelerator switch OFF 4 Measuring all pump relief speed 1 Start the engine and set the fuel control dial...

Page 330: ...nect gauge 2 4 Run the engine at a medium or higher speed and drain the oil from the hose a Insert the connecting parts of the gauge and hose about a half and open the self seal on the hose side repe...

Page 331: ...arness of the digital tem perature gauge so that it does not touch any high temperature part during the measure ment 4 Procedure for measuring maximum exhaust temperature for troubleshooting Operate t...

Page 332: ...l state 2 Measurement with Smoke Meter C2 1 Insert the probe 1 of the smoke meter C2 in the outlet of the exhaust pipe 1 and fix it to the exhaust pipe with clip 2 Connect the prove hose the receptacl...

Page 333: ...the compression top dead center so rotate the crankshaft one more turn 4 Insert clearance gauge D in clearance b between rocker arm 5 and crosshead 6 and turn adjustment screw 3 to adjust the valve c...

Page 334: ...injector wiring harness and remove injector 4 a Disconnect the terminal of the injector wiring harness on the injector side and the bracket on the rocker housing side and remove the injector wiring ha...

Page 335: ...g procedure 1 Install the injector wiring harness to the rocker arm housing and fix the connector side with the plate 2 Fix the intermediate clamp with the clip 3 Tighten the nut on the injector side...

Page 336: ...ve plug 1 R1 8 from the oil filter head 3 Install nipple 1 of hydraulic tester G1 and con nect them to hydraulic gauge G2 1 0 MPa 10 kg cm2 4 Start the engine and measure the oil pressure with the eng...

Page 337: ...hydraulic tester V and con nect hydraulic gauge 2 2 5 MPa 25 kg cm2 4 Run the engine at low idle and high idle and measure the temperature at each speed 5 After finishing measurement remove the meas u...

Page 338: ...t foreign matters from entering the system Therefore be sure to use genuine filters only Otherwise the fuel system will possibly get out of order Remaining pressure relief from fuel system equipment a...

Page 339: ...he engine com partment 2 Remove the fuel pressure measurement plug 1 3 Attach the nipple 1 of the adapter H3 and hydraulic tester H1 and connect the hydraulic gauge H2 1 0 MPa 10 kg cm2 4 Start the en...

Page 340: ...ion work 1 Remove tube 3 between common rail 1 and supply pump 2 2 Insert spacer J1 on supply pump 2 side and tighten the removed joint bolt again a Connect the return pipe to the fuel tank again too...

Page 341: ...a You may test for 20 seconds and judge by multiplying the result by 3 a If the leakage from the pressure limiter is in the following range it is normal 5 After finishing testing stop the engine 3 Te...

Page 342: ...eding air from fuel circuit a If fuel is used up or if a fuel circuit part is removed and installed bleed air from the fuel circuit according to the following procedure 1 Remove fuel prefilter 1 and f...

Page 343: ...of the main fuel fil ter and operate priming pump 4 a Operate the priming pump until fuel flows out of the plug hole After fuel starts flowing out install plug 5 3 Air bleeding plug 7 8 9 8 Nm 0 8 1 0...

Page 344: ...rts coated with the color checker for fuel leakage a If any fuel leakage is detected repair it and inspect again from step 1 4 Run the engine at low idle 5 Inspect the fuel piping and devices for fuel...

Page 345: ...on is not normal 1 Loosen nuts and bolts 1 2 3 and 4 in this order 2 Turn nut 5 to move alternator 6 and adjust the belt tension a Nut 5 It is moved to the side that belt is loos ened when turning it...

Page 346: ...according to the following procedure 1 Loosen the bolts and nuts in the order of 1 2 and 3 2 Rotate nut 4 to move compressor 5 and adjust the belt tension a If nut 4 is turned clockwise the belt is lo...

Page 347: ...PC800 850 8 23 30 Testing and adjusting SEN00786 02...

Page 348: ...24 PC800 8 PC800SE 8 PC800LC 8 PC850 8 PC850SE 8 Hydraulic excavator Form No SEN00786 02 SEN00786 02 30 Testing and adjusting...

Page 349: ...0 8 PC850SE 8 30 Testing and adjusting Testing and adjusting Part 2 Testing and adjusting Part 2 2 Inspection of swing circle bearing clearance 2 Testing and adjusting track shoe tension 3 Testing and...

Page 350: ...ip to the height of the revolv ing frame lower face a At the time the front of the upper structure lowers and its rear rises 3 Set the dial gauge N to the zero point 4 Arrange the arm almost at right...

Page 351: ...its deflection free nature 3 Measure max clearance a between bar 1 and the track shoe Max standard clearance a 10 30 mm Adjusting a If the track shoe tension is not proper adjust it in the following m...

Page 352: ...the work equipment to the ground and stop the engine Operate the control le vers several times to release the residual pressure in the piping and then loosen the oil filler cap of the hydraulic tank...

Page 353: ...ON iii Run the engine at high idle relieve the boom cylinder singly at the RAISE stroke end and measure the oil pressure a The heavy lift function operates only when the boom RAISE operation is per fo...

Page 354: ...lve top cover 1 Adjusting main relief valve high pressure setting of left 5 spool control valve a If the work equipment oil pressure in the front pump circuit during heavy lift operation and the left...

Page 355: ...d adjust the low pressure set ting side of main relief valve 5 of the left 5 spool control valve according to the following procedure a The low pressure setting is the state in which the 2 stage relie...

Page 356: ...ng main relief valve low pressure set ting of right 4 spool control valve a If the work equipment oil pressure in the rear pump circuit during normal relief operation is abnormal or the high pressure...

Page 357: ...ustment screw to the right and the pressure will rise Turn the adjustment screw to the left and the pressure will lower a Pressure adjusted by one turn of the ad justment screw Approx 3 6 MPa 37 kg cm...

Page 358: ...ssure pickup nipple 1 of the main pump 3 While running the engine at high idle set the work equipment swing and travel levers in neu tral and measure the oil pressure Adjusting a If the output pressur...

Page 359: ...PC800 850 8 11 30 Testing and adjusting SEN00788 02 5 Referring to Measuring Step 3 measure the output pressure of the self pressure reducing valve...

Page 360: ...ntroller For details see Structure function and mainte nance standard 1 Open the pump room cover 2 Remove oil pressure pickup plug 1 or 2 a Plug 1 is on the front pump side and plug 2 is on the rear p...

Page 361: ...rge pressure check that the control circuit pressure and main pump discharge pressure are normal before measuring the VC valve output pressure a Since the VC valve output pressure is judged by compari...

Page 362: ...nt the pressure is about 0 5 0 6 times approx 1 2 of the relief pressure discharge pressure Operation mode All levers in neutral Boom circuit relieved in raising operation With heavy lift OFF Track ru...

Page 363: ...ontrol valve F pump 7 High pressure side NCA of right 4 spool control valve R pump 6 Low pressure side NCB of right 4 spool control valve R pump 2 Install measuring hose 2 of hydraulic tester M1 and c...

Page 364: ...sure sensor output voltage can be checked with the monitoring function of the machine monitor For the operating method see Special func tions of machine monitor Monitoring code 13802 L jet sensor diff...

Page 365: ...lief valve of left 5 spool control valve 20 Jet sensor relief valve of right 4 spool control valve 1 Fix adjustment screw 21 and loosen lock nut 22 2 Turn adjustment screw 21 to adjust the pressure a...

Page 366: ...18 PC800 8 PC800SE 8 PC800LC 8 PC850 8 PC850SE 8 Hydraulic excavator Form No SEN00788 02 SEN00788 02 30 Testing and adjusting...

Page 367: ...outlet pressures of solenoid valve swing PPC shuttle valve and swing priority selector valve 6 Adjusting work equipment swing PPC valve 10 Testing and adjusting travel deviation 11 Inspection of locat...

Page 368: ...see the connection diagram on the next page 3 Install nipple 1 of hydraulic tester P1 and con nect it to oil pressure gauge 2 a Use a pressure gauge of 6 0 MPa 60 kg cm2 a The figure shows the measuri...

Page 369: ...PC800 850 8 3 30 Testing and adjusting SEN00912 02 5 After the measurement remove the measuring devices and return the valve to the original state...

Page 370: ...4 PC800 850 8 SEN00912 02 30 Testing and adjusting Connection diagram of pilot piping PPC Solenoid circuit...

Page 371: ...PC800 850 8 5 30 Testing and adjusting SEN00912 02 a The colors in in the figure are the colors of the tapes wound onto the hoses...

Page 372: ...ressure of solenoid valve 1 Disconnect the hoses to be measured out of outlet hoses 1 8 of the solenoid valves Install adapter Q2 and connect the hoses again a When measuring the PPC lock solenoid val...

Page 373: ...devices installed to the outlet hose of the PPC lock solenoid valve 3 Run the engine at high idle set the condition or operate the control levers as shown in the table and measure the output pressure...

Page 374: ...N Min 2 74 Min 28 3 Swing holding brake Turn swing lock switch ON Measure about 10 seconds after work equipment swing control lever is set in NEU TRAL position Swing holding brake is applied OFF 0 0 T...

Page 375: ...surement remove the measuring instruments and return the removed parts 3 Measuring outlet pressure of swing priority selector valve 1 Disconnect outlet hoses 10 and 11 of the swing priority selector v...

Page 376: ...rotating center of lever forward and re verse and left and right 1 Remove boot 1 2 Loosen locknut 2 then turn disc 3 to adjust the play of the lever a While keeping the lever in neutral and turn disc...

Page 377: ...avel posi tion extend the bucket and arm cylinders ful ly and set the boom angle to 45 2 Set the working mode switch to the P mode position and set the travel speed switch to the Lo position 3 Run up...

Page 378: ...x adjustment screw 1 and loosen locknut 2 2 Adjust the maximum delivery amount by turning adjustment screw 1 a If the adjustment screw is turned clockwise the delivery is de creased The travel speed i...

Page 379: ...the cyl inder packing is defective If there is no change the control valve is defective a Operate the control lever with the engine starting switch in the ON position a If pressure in the accumulator...

Page 380: ...asurement remove the meas uring instruments and return the removed parts Measuring fan circuit oil pressure a Tools for measuring fan circuit oil pressure a Measure the fan circuit oil pressure under...

Page 381: ...ing function of the machine monitor For the operating method see Special func tions of machine monitor Monitoring code 31623 Fan pump EPC solenoid current The current is displayed in mA a Measure the...

Page 382: ...stop the engine Then operate the control le vers several times to release the residual pres sure in the piping and loosen the hydraulic tank cap gradually to release the internal pressure of the hydr...

Page 383: ...easuring the oil leakage 30 seconds after the boom cylinder is relieved and measure for 1 minute 5 After finishing measurement return the parts 2 Measuring leakage from arm cylinder 1 Run the engine a...

Page 384: ...er in the CURL direction k Take care not to operate the bucket control lever in the DUMP direction 4 Start measuring the oil leakage 30 seconds after the bucket cylinder is relieved and measure for 1...

Page 385: ...the positions of the valve plate and cylin der and those of the cylinder and piston 5 After finishing measurement return the parts 6 Measuring leakage from center swivel joint 1 Put block 1 between th...

Page 386: ...nt 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 a When inspecting port...

Page 387: ...e hydraulic tank removed 2 Turn the starting switch to the ON position and set the lock lever in the FREE position and then operate the work equipment con trol levers on both sides forward backward to...

Page 388: ...p operation is reset a Set the lock lever in the LOCK position so that you will not operate a lever by mistake 3 After clear oil flows out of bleeders 1 and 2 tighten the bleeders 3 Bleeder 7 8 9 8 Nm...

Page 389: ...motor unit according to the following procedure i Run the engine at low idle ii Swing to the right and left slowly to bleed air 2 Parking brake circuit a Normally air in the parking brake circuit is b...

Page 390: ...imes After clear oil flows out tighten the bleeder a Limit the operation of the lever to a de gree that the machine starts travelling 3 Bleeder 9 8 12 74 Nm 1 0 1 3 kgm 6 Checking oil level and starti...

Page 391: ...icated value No continuity defective Change in the indicated value Continui ty established normal Note Note A silicon diode shows a value between 400 and 600 2 When using analog type circuit tester 1...

Page 392: ...ee a best 3 Adjusting mirror b Adjust mirror b so that you can see hatched part b at the right rear end of the machine a Dimension of installed position and visibility range Dimension X1 of installed...

Page 393: ...PC800 850 8 27 30 Testing and adjusting SEN00912 02...

Page 394: ...28 PC800 8 PC800SE 8 PC800LC 8 PC850 8 PC850SE 8 Hydraulic excavator Form No SEN00912 02 SEN00912 02 30 Testing and adjusting...

Page 395: ...p PC800LC 8 50001 and up PC850 8 10001 and up PC850SE 8 10001 and up HYDRAULIC EXCAVATOR PC800 8 PC800SE 8 PC800LC 8 PC850 8 PC850SE 8 30 Testing and adjusting Testing and adjusting Part 4 Testing and...

Page 396: ...gure 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 4...

Page 397: ...Function for showing KOMATSU logo 3 Function for check before starting 4 Function for showing machine maintenance 5 Function for showing caution items 6 Function for confirming working mode and travel...

Page 398: ...ne starting switch is turned ON KOMATSU logo is shown for 2 seconds 3 Function for check before starting Following the KOMATSU logo the display of machine inspection before starting day s work is show...

Page 399: ...celeration or windshield wiper setting is activated while this is in display an amplified corresponding symbol mark is shown for 2 seconds a In this display a symbol mark for preheat monitor is shown...

Page 400: ...e screen white If there is no showing in black the dis play is normal a This display returns to the immediately pre ceding one if making any other switching operation 12 Function for showing occurrenc...

Page 401: ...pe system is in operation and machine performance is par tially lost Machine can operate normally Have it inspected immediately however E10 Error in engine controller power supply system Abnormality i...

Page 402: ...No are shown in turn Switching operation a The following display is repeated in order ac cording to the operation of the switch 1 Telephone symbol mark O 2 Telephone No O 3 Failure code No a The telep...

Page 403: ...7 Sens Supply 2 Volt Low Error ENG Electrical system E15 CA221 Ambient Press Sens High Error ENG Electrical system E15 CA222 Ambient Press Sens Low Error ENG Electrical system E15 CA227 Sens Supply 2...

Page 404: ...High Error ENG Electrical system E14 CA2186 Throt Sens Sup Volt Low Error ENG Electrical system E11 CA2249 Rail Press Very Low Error ENG Electrical system E11 CA2271 EGR Valve Pos Sens High Error ENG...

Page 405: ...Electrical system DW43KA Travel Speed Sol Disc PUMP Electrical system DW43KB Travel Speed Sol S C PUMP Electrical system E03 DW45KA Swing Brake Sol Disc PUMP Electrical system E03 DW45KB Swing Brake S...

Page 406: ...ears and the engine speed is lowered to low idle automatically After about 15 seconds the fan rotation is reversed After 4 seconds the engine speed returns to the level before the switch was pressed a...

Page 407: ...f the switch is pressed the pre vious screen appears 3 If the switch is pressed the screen to wait for change of the fan rotation direction appears and the engine speed is lowered to low idle automati...

Page 408: ...d Perform the procedure from 2 1 a Coolant temperature b Hydraulic oil temperature 3 Adjusting economy mode value 1 In the screen of 2 1 select 2 E mode and press the switch and the fol lowing screen...

Page 409: ...rvice Menu display The display is changed to the initial display of Service Menu program Select an appropriate item from among the menu 4 Termination of Service Menu function When terminating the init...

Page 410: ...e monitored information display through any of the following switch operations after the registration work has been completed Keep switch depressed For about 3 seconds Select Menu 99999 and depress sw...

Page 411: ...hile 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 turns to that of monitoring a...

Page 412: ...mA mA 31623 Fan Pump EPC Sol Curr mA mA mA 13800 L Jet Sensor Pressure MPa kg cm2 Psi 13801 R Jet Sensor Pressure MPa kg cm2 Psi 13802 L Jet Sensor Vol V V V 13803 R Jet Sensor Vol V V V 03200 Batter...

Page 413: ...hrottle Position 18600 Inject Fueling Command mg st mg st mg st 36200 Rail Press Command MPa kg cm2 PSi 36300 Injection Timing Command CA CA CA 37300 Fuel Rate L h L h L h 01602 2nd Eng Speed Command...

Page 414: ...ow viscosity fuel mode Not displayed 02202 Switch Input 3 Key Switch ACC Display of ON OFF 02203 Switch Input 4 Step Light Sw Display of ON OFF Horn Sw Display of ON OFF 05500 Sensor Input 1 Over Load...

Page 415: ...it is a little different from the actual fuel consumption ratio Note 2 The Fuel Consumption is the theoretical fuel consumption amount after the engine is started until the engine is stopped Since it...

Page 416: ...stem 1 The numerator expresses sequence of failure occurrence counting from the latest one The denominator expresses the total number of a specific failure recorded 2 E is displayed as long as the fai...

Page 417: ...tion explained below i Through the following switch operation call the resetting display in the display of Electrical Systems Switch operation E 1 o 2 o 3 a This is the same switch operation in changi...

Page 418: ...Name of oils and filters 2 Times of replacement to date 3 Service meter reading at the latest replacement 19 Function for maintenance mode change 04 Conditions set for controlling maintenance dis pla...

Page 419: ...et The maintenance mode pro gram functions based on this mainte nance time The maintenance time can be increased or decreased by 50 hours with E or R switch 3 On Maintenance display function with this...

Page 420: ...Entry automatically begins with a cursor at the left end i Enter a number into a cursor at the left end with a ten key ii Depress switch when all the num bers have been entered a Numbers can be entere...

Page 421: ...machine ramps up with the default mode P mode that was originally set at the time of delivery from the factory 4 Function for AA Language In Service Menu the language in use can be changed between Ja...

Page 422: ...01 55045 PC850 8 10001 10007 55001 55045 The machine can be adjusted with the machine monitor 1 Selection of menu Select 07 Adjustment on the service menu and press the switch 2 Selection of sub menu...

Page 423: ...hanged 4 Fan speed mode selection function To adjust the fan speed it must be fixed temporarily Select one of the following modes as necessary No Sub menu of adjustment 00 Return Finish adjustment 01...

Page 424: ...is turned OFF 6 Fan 70 speed adjustment function After 70 speed is set in 4 above the fan speed can be adjusted within the following range a The set value is kept even after the start ing switch is t...

Page 425: ...tch 2 Setting of cylinders to be disabled Press switches 1 6 on the machine monitor corresponding to the cylinder Nos to be disabled a After a switch is pressed if the cylinder No corresponding to it...

Page 426: ...ced cylinder mode Reference How to use holding function effec tively The engine speed displayed by the holding func tion is held on the screen until the holding func tion is cancelled regardless of se...

Page 427: ...ser vice menu initial screen and press switch 2 The initial screen for the no injection cranking will appear a Check Communication will be displayed in red 3 As the checkup is over following screen a...

Page 428: ...etters End are displayed in green 8 Press Return when ending the no injection cranking a If the no injection cranking function is inad vertently selected while the engine is run ning Engine Running wi...

Page 429: ...or 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 troubleshoo...

Page 430: ...36 PC800 8 PC800SE 8 PC800LC 8 PC850 8 PC850SE 8 Hydraulic excavator Form No SEN00913 02 SEN00913 02 30 Testing and adjusting...

Page 431: ...d up PC850SE 8 10001 and up HYDRAULIC EXCAVATOR PC800 8 PC800SE 8 PC800LC 8 PC850 8 PC850SE 8 30 Testing and adjusting Testing and adjusting Part 5 Testing and adjusting Part 5 2 Procedure for turning...

Page 432: ...owing procedure 1 Station opening inspection a Finish the operations of steps 4 to 7 within 30 seconds 1 Turn OFF the starting switch and then after making sure 5 seconds have elapsed pro ceed to the...

Page 433: ...PS antenna and cable for external troubles If any repair the trouble and repeat the procedure from step 1 a If Receiving error were displayed check the communication antenna and cable for external tro...

Page 434: ...on to the person responsible to operation of KOM TRAX 1 Information of the machine body for which the station opening inspection has been completed machine model model number and serial number 2 Part...

Page 435: ...dot for CPU 1 LED C1 R signal and ACC signal 7 7 segment Number of mails which are not trans mitted yet and condition of satellite link 2 LED C2 Initial output state 3 LED C3 S NET and C signal state...

Page 436: ...engine prior to inspection of LED display 1 Types of flashing and flashing duration Quick flashing Flashing of approximately 1 second cycle Slow flashing Flashing of approximately 4 seconds cycle No...

Page 437: ...t available in a location where radio waves are extremely weak or unreachable No Display unit Name and function Display 2 Contents of display 7 7 segment Number of mails which are not sent yet and sat...

Page 438: ...is installed disconnect connector P31 on the backside of the cover 2 Remove the 3 mounting screws and discon nect machine monitor 2 from the mount a Take care not to drop the mounting screws in the c...

Page 439: ...rs tighten the screws to the specified torque 3 Screw 2 82 Nm 0 288 kgm 4 KOMTRAX terminal a KOMTRAX terminal is installed in the cover situated in the rear side of the operator seat 1 Slide the opera...

Page 440: ...10 PC800 850 8 SEN00914 02 30 Testing and adjusting...

Page 441: ...PC800 850 8 11 Pm clinic service...

Page 442: ...MEASURING PROCEDURES 12 PC800 850 8 Positions to install measuring devices Related to engine and PTO...

Page 443: ...MEASURING PROCEDURES PC800 850 8 13 Positions to install measuring devices Related to relief pressure and OLSS oil pressure...

Page 444: ...ve Exhaust temperature C Max 650 700 Outside temperature 3 Work equipment speed 1 Raise boom High idle P mode Swing Measure time for 5 turns after 1 turn Travel Raise track of either side drive at Hi...

Page 445: ...PC800 850 8 15 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...

Page 446: ...Left T Right Track frame 3 Arm top boss 6 Arm cylinder bracket 10 Circle bracket T Left T Right T Left T Right T Front T Rear 7 Boom lower plate T Left T Right T Left T Right 11 Track frame mounting...

Page 447: ...T Right T End plate T Left T Right Track frame 3 Arm top boss 6 Arm cylinder bracket 10 Circle bracket T Left T Right T Left T Right T Front T Rear 7 Boom lower plate T Left T Right T Left T Right 11...

Page 448: ...Serial SMR Dealer Inspector Insp Date yyyy mm dd 100 Wear New Model Location Soil condition Working condition LH RH LH RH LH RH LH RH LH RH LH RH LH RH LH RH LH RH LH LH LH LH LH LH LH LH LH LH RH RH...

Page 449: ...PC800 850 8 19 30 Testing and adjusting SEN00914 02...

Page 450: ...20 PC800 8 PC800SE 8 PC800LC 8 PC850 8 PC850SE 8 Hydraulic excavator Form No SEN00914 02 SEN00914 02 30 Testing and adjusting...

Page 451: ...8 50001 and up PC800LC 8 50001 and up PC850 8 10001 and up PC850SE 8 10001 and up HYDRAULIC EXCAVATOR PC800 8 PC800SE 8 PC800LC 8 PC850 8 PC850SE 8 40 Troubleshooting Failure code table and fuse loca...

Page 452: ...ical system E15 CA144 Coolant Temp Sens High Error ENG Electrical system E15 CA145 Coolant Temp Sens Low Error ENG Electrical system E15 CA153 Chg Air Temp Sensor High Error ENG Electrical system E15...

Page 453: ...cal system E11 CA1626 BP Valve Sol Current High Error ENG Electrical system E11 CA1627 BP Valve Sol Current Low Error ENG Electrical system E15 CA1628 Bypass Valve Servo Error 1 ENG Electrical system...

Page 454: ...PUMP Electrical system DW41KA Swing Priority Sol Disc PUMP Electrical system DW41KB Swing Priority Sol S C PUMP Electrical system DW43KA Travel Speed Sol Disc PUMP Electrical system DW43KB Travel Spe...

Page 455: ...table is the same as that in Testing and adjusting Special functions of machine monitor DY2CKB Washer Drive S C PUMP Electrical system Troubleshooting by failure code Part 3 SEN00792 02 DY2DKB Wiper D...

Page 456: ...a When carrying out troubleshooting for a displayed code you should check the circuit breakers to see if the power is supplied normally Type of power supply Circuit breaker No Circuit breaker capacity...

Page 457: ...0 A EPC solenoid for emergency pump drive Swing holding brake solenoid for swing brake release 2 10 A Starting motor cut out relay Machine push up solenoid Boom shockless solenoid 3 10 A PPC lock sole...

Page 458: ...8 PC800 8 PC800SE 8 PC800LC 8 PC850 8 PC850SE 8 Hydraulic excavator Form No SEN02797 00 SEN02797 00 40 Troubleshooting...

Page 459: ...E 8 40 Troubleshooting General information on troubleshooting General information on troubleshooting Points to remember when troubleshooting 2 Sequence of events in troubleshooting 3 Checks before tro...

Page 460: ...same time will also lose the confidence of the user or operator For this reason when carrying out troubleshooting it is necessary to carry out thorough prior investiga tion and to carry out troublesho...

Page 461: ...PC800 850 8 3 40 Troubleshooting SEN00789 02 Sequence of events in troubleshooting...

Page 462: ...osion Retighten or replace 3 Check of starting motor terminals and wiring for loose ness and corrosion Retighten or replace Hydraulic Mechanical equipment 1 Check for abnormal noise and smell Repair 2...

Page 463: ...he monitor panel If a code is recorded carry out troubleshooting for the corresponding Display of code according to the recorded code a If an electrical system failure code is recorded delete all the...

Page 464: ...umbers which do not indicate priority Contents of description Standard value in normal state to judge possible causes Remarks on judgment Troubles in wiring harness Disconnection Connector is connecte...

Page 465: ...ooting 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 t...

Page 466: ...ine lacks output or lacks power S 6 12 Exhaust smoke is black incomplete combustion S 7 13 Oil consumption is excessive or exhaust smoke is blue S 8 14 Oil becomes contaminated quickly S 9 15 Fuel con...

Page 467: ...peed or acceleration is low during compound operation of swing and work equipment H 24 50 Upper structure overruns excessively when it stops swinging H 25 51 Large shock is made when upper structure s...

Page 468: ...E 22 69 Bucket DUMP is not correctly displayed in monitor function E 23 70 SWING is not correctly displayed in monitor function E 24 71 Left travel is not displayed normally in monitoring function E 2...

Page 469: ...oubleshooting SEN00789 02 Wiring table for connector pin numbers 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...

Page 470: ...12 PC800 850 8 SEN00789 02 40 Troubleshooting...

Page 471: ...PC800 850 8 13 40 Troubleshooting SEN00789 02...

Page 472: ...14 PC800 850 8 SEN00789 02 40 Troubleshooting...

Page 473: ...PC800 850 8 15 40 Troubleshooting SEN00789 02...

Page 474: ...16 PC800 850 8 SEN00789 02 40 Troubleshooting...

Page 475: ...PC800 850 8 17 40 Troubleshooting SEN00789 02...

Page 476: ...18 PC800 850 8 SEN00789 02 40 Troubleshooting...

Page 477: ...PC800 850 8 19 40 Troubleshooting SEN00789 02...

Page 478: ...20 PC800 850 8 SEN00789 02 40 Troubleshooting...

Page 479: ...PC800 850 8 21 40 Troubleshooting SEN00789 02...

Page 480: ...22 PC800 850 8 SEN00789 02 40 Troubleshooting...

Page 481: ...PC800 850 8 23 40 Troubleshooting SEN00789 02...

Page 482: ...24 PC800 850 8 SEN00789 02 40 Troubleshooting...

Page 483: ...PC800 850 8 25 40 Troubleshooting SEN00789 02...

Page 484: ...26 PC800 850 8 SEN00789 02 40 Troubleshooting...

Page 485: ...PC800 850 8 27 40 Troubleshooting SEN00789 02...

Page 486: ...28 PC800 850 8 SEN00789 02 40 Troubleshooting...

Page 487: ...PC800 850 8 29 40 Troubleshooting SEN00789 02...

Page 488: ...30 PC800 850 8 SEN00789 02 40 Troubleshooting...

Page 489: ...PC800 850 8 31 40 Troubleshooting SEN00789 02...

Page 490: ...32 PC800 850 8 SEN00789 02 40 Troubleshooting...

Page 491: ...PC800 850 8 33 40 Troubleshooting SEN00789 02...

Page 492: ...34 PC800 850 8 SEN00789 02 40 Troubleshooting...

Page 493: ...PC800 850 8 35 40 Troubleshooting SEN00789 02...

Page 494: ...36 PC800 850 8 SEN00789 02 40 Troubleshooting...

Page 495: ...PC800 850 8 37 40 Troubleshooting SEN00789 02...

Page 496: ...38 PC800 850 8 SEN00789 02 40 Troubleshooting...

Page 497: ...PC800 850 8 39 40 Troubleshooting SEN00789 02...

Page 498: ...40 PC800 850 8 SEN00789 02 40 Troubleshooting...

Page 499: ...PC800 850 8 41 40 Troubleshooting SEN00789 02...

Page 500: ...42 PC800 850 8 SEN00789 02 40 Troubleshooting...

Page 501: ...PC800 850 8 43 40 Troubleshooting SEN00789 02...

Page 502: ...4 MS 14P q 799 601 3470 Case q 799 601 2710 Adapter for MIC 5 MIC 5P q q q 799 601 2720 Adapter for MIC 13 MIC 13P q q q 799 601 2730 Adapter for MIC 17 MIC 17P q q q q q q 799 601 2740 Adapter for MI...

Page 503: ...99 601 9030 Adapter for DT 3 DT3 q q 799 601 9040 Adapter for DT 4 DT4 q q q q 799 601 9050 Adapter for DT 6 DT6 q q 799 601 9060 Adapter for DT Gray 8 DT8GR q q 799 601 9070 Adapter for DT Black 8 DT...

Page 504: ...CRI T3 Oil pressure switch 2 4160 q q 799 601 4180 Adapter for engine CRI T3 PEVA 3 4180 q q 799 601 4190 Socket for engine CRI T3 Commonrail pressure 3 1 2 3L q q 799 601 4230 Socket for engine CRI...

Page 505: ...PC800 850 8 47 40 Troubleshooting SEN00789 02...

Page 506: ...48 PC800 8 PC800SE 8 PC800LC 8 PC850 8 PC850SE 8 Hydraulic excavator Form No SEN00789 02 SEN00789 02 40 Troubleshooting...

Page 507: ...ure code AB00KE Charge Voltage Low 6 Failure code B BAZG Eng Oil Press Low 8 Failure code B BAZK Eng Oil Level Low 9 Failure code B BCNS Eng Water Overheat 10 Failure code B BCZK Eng Water Lvl Low 12...

Page 508: ...ode CA238 Ne Speed Sens Supply Volt Error 48 Failure code CA263 Fuel Temp Sensor High Error 50 Failure code CA265 Fuel Temp Sensor Low Error 52 Failure code CA271 IMV PCV1 Short Error 53 Failure code...

Page 509: ...PC800 850 8 3 40 Troubleshooting SEN00790 02...

Page 510: ...1 Clogging of air cleaner when system is normal aCheck the air cleaner for clogging and then clean or replace it if clogged 2 Defective air cleaner clog ging switch internal dis connection aTurn the...

Page 511: ...PC800 850 8 5 40 Troubleshooting SEN00790 02 Circuit diagram related to air cleaner clogging switch of machine monitor...

Page 512: ...Voltage Between R terminal chassis ground Above low idle 27 5 29 5 V If the voltage is abnormal check the belt tension too 2 Disconnection in wiring har ness Disconnection in wiring or defective cont...

Page 513: ...PC800 850 8 7 40 Troubleshooting SEN00790 02 Circuit diagram related to engine preheating starting and charging circuits...

Page 514: ...ars on machine Engine output lowers If machine is operated as it is engine may be damaged Related information Possible causes and standard value in normal state Cause Standard value in normal state Re...

Page 515: ...mal state Cause Standard value in normal state Remarks on troubleshooting 1 Lowering of engine oil level when system is normal aCheck the engine oil level and add new oil If this phenomenon frequently...

Page 516: ...n machine Engine output lowers If machine is operated as it is engine may be damaged Related information Possible causes and standard value in normal state Cause Standard value in normal state Remarks...

Page 517: ...PC800 850 8 11 40 Troubleshooting SEN00790 02...

Page 518: ...2 Defective radiator coolant level switch 1 Internal disconnection aPrepare with starting switch OFF then carry out troubleshooting with out turning starting switch ON P24A male Sub tank coolant level...

Page 519: ...PC800 850 8 13 40 Troubleshooting SEN00790 02 Circuit diagram related to radiator coolant level switch...

Page 520: ...dard value in normal state Remarks on troubleshooting 1 Hydr Oil Overheat when system is normal Check the hydraulic oil for overheating If it has been overheated find out the cause and check the hydra...

Page 521: ...PC800 850 8 15 40 Troubleshooting SEN00790 02 Circuit diagram related to hydraulic oil temperature sensor...

Page 522: ...eaker is turned OFF circuit probably has ground fault 2 Disconnection in wiring harness Disconnection in wiring or defective contact in con nector aPrepare with starting switch OFF then carry out trou...

Page 523: ...PC800 850 8 17 40 Troubleshooting SEN00790 02 Circuit diagram related to controller power supply...

Page 524: ...ut troubleshooting for failure code CA689 2 Defective Bkup speed sen sor system Carry out troubleshooting for failure code CA778 3 Defective installation of Ne speed sensor Ne speed sensor may be inst...

Page 525: ...PC800 850 8 19 40 Troubleshooting SEN00790 02...

Page 526: ...on in wiring or defective contact in connec tor aPrepare with starting switch OFF then carry out troubleshooting with out turning starting switch ON Wiring harness between ENG female 37 PIM female 1 R...

Page 527: ...PC800 850 8 21 40 Troubleshooting SEN00790 02 Circuit diagram related to charge pressure sensor...

Page 528: ...Action of controller Fixes charge pressure at 400 kPa 4 1 kg cm2 and continues operation Problem that appears on machine Engine does not accelerate easily Related information The signal voltage of the...

Page 529: ...PC800 850 8 23 40 Troubleshooting SEN00790 02...

Page 530: ...ng switch ON P20 male Resistance Between 1 3 4 0 6 0 kz Between 2 1 0 25 5 0 kz Between 2 3 0 25 5 0 kz 3 Disconnection in wiring har ness Disconnection in wiring or defective contact in connec tor aP...

Page 531: ...PC800 850 8 25 40 Troubleshooting SEN00790 02 Circuit diagram related to fuel control dial throttle sensor...

Page 532: ...ontroller Use a signal other than throttle sensor to set the throttle position for control Problem that appears on machine Engine speed can not be controlled Related information Signal voltage of the...

Page 533: ...PC800 850 8 27 40 Troubleshooting SEN00790 02...

Page 534: ...in wiring or defective contact in connec tor aPrepare with starting switch OFF then carry out troubleshooting with out turning starting switch ON Wiring harness between ENG female 37 POIL female 1 Res...

Page 535: ...oting 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 u...

Page 536: ...default 250 kPa 2 5 kg cm2 and continues operation Problem that appears on machine Starting performance of the engine lowers during low temperature Related information The signal voltage of engine oi...

Page 537: ...PC800 850 8 31 40 Troubleshooting SEN00790 02...

Page 538: ...era ture sensor Internal defect aPrepare with starting switch OFF then carry out troubleshooting with out turning starting switch ON TWTR male Coolant temperature Resistance Between A B 10 100 C 0 6 2...

Page 539: ...PC800 850 8 33 40 Troubleshooting SEN00790 02 Circuit diagram related to coolant temperature sensor...

Page 540: ...controller Fixes coolant temperature value 90 C and continues operation Problem that appears on machine Starting performance of the engine lowers during low temperature Related information The signal...

Page 541: ...PC800 850 8 35 40 Troubleshooting SEN00790 02...

Page 542: ...tem perature sensor Internal defect aPrepare with starting switch OFF then carry out troubleshooting with out turning starting switch ON TIM male Air intake temperature Resistance Between A B 10 100...

Page 543: ...PC800 850 8 37 40 Troubleshooting SEN00790 02 Circuit diagram related to charge temperature sensor...

Page 544: ...out troubleshooting for failure code CA153 Action code Failure code Trouble Sens Supply 2 Volt Low Error Engine controller system E15 CA187 Contents of trouble Low voltage error occurred in sensor pow...

Page 545: ...PC800 850 8 39 40 Troubleshooting SEN00790 02...

Page 546: ...onnection in wiring or defective contact in connec tor aPrepare with starting switch OFF then carry out troubleshooting with out turning starting switch ON Wiring harness between ENG female 37 PAMB fe...

Page 547: ...PC800 850 8 41 40 Troubleshooting SEN00790 02 Circuit diagram related to atmospheric pressure sensor...

Page 548: ...ts ambient pressure to default 52 44 kPa 0 53 kg cm2 and continues operation Problem that appears on machine Engine output lowers Related information The signal voltage of the atmospheric pressure sen...

Page 549: ...PC800 850 8 43 40 Troubleshooting SEN00790 02...

Page 550: ...andard value in normal state Remarks on troubleshooting 1 Defect in related system If another failure code is displayed carry out troubleshooting for it 2 Defective sensor Internal defect aPrepare wit...

Page 551: ...Cause Standard value in normal state Remarks on troubleshooting 5 Short circuit in wiring har ness with another wiring har ness aPrepare with starting switch OFF then carry out troubleshooting with o...

Page 552: ...rs on machine Engine speed fluctuates Related information Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defect in related system...

Page 553: ...PC800 850 8 47 40 Troubleshooting SEN00790 02...

Page 554: ...e Ne speed sensor NE connector 2 Disconnection in wiring harness Disconnection in wiring or defective contact in con nector aPrepare with starting switch OFF then carry out troubleshooting with out tu...

Page 555: ...PC800 850 8 49 40 Troubleshooting SEN00790 02 Circuit diagram related to Ne speed sensor power supply...

Page 556: ...tch OFF then carry out troubleshooting with out turning starting switch ON TFUEL male Fuel temperature Resistance Between A B 10 100 C 0 6 20 kz 2 Disconnection in wiring harness Disconnection in wiri...

Page 557: ...PC800 850 8 51 40 Troubleshooting SEN00790 02 Circuit diagram related to fuel temperature sensor...

Page 558: ...e sensor circuit Action of controller Fixes fuel temperature value at 90 C and continues operation Problem that appears on machine Related information The signal voltage of engine fuel temperature sen...

Page 559: ...2 chassis ground Min 1 Mz 2 Ground fault in wiring har ness Short circuit with GND cir cuit aPrepare with starting switch OFF then carry out troubleshooting with out turning starting switch ON Wiring...

Page 560: ...Disconnection in wiring harness Disconnection in wiring or defective contact in con nector aPrepare with starting switch OFF then carry out troubleshooting with out turning starting switch ON Wiring h...

Page 561: ...ssis ground Min 1 Mz 2 Ground fault in wiring har ness Short circuit with GND cir cuit aPrepare with starting switch OFF then carry out troubleshooting with out turning starting switch ON Wiring harne...

Page 562: ...sconnection in wiring harness Disconnection in wiring or defective contact in con nector aPrepare with starting switch OFF then carry out troubleshooting with out turning starting switch ON Wiring har...

Page 563: ...tion in wiring or defective contact in con nector aPrepare with starting switch OFF then carry out troubleshooting with out turning starting switch ON Wiring harness between ENG female 45 CN1 female 1...

Page 564: ...efective contact in con nector aPrepare with starting switch OFF then carry out troubleshooting with out turning starting switch ON Wiring harness between ENG female 46 CN5 female 1 Resis tance Max 1...

Page 565: ...PC800 850 8 59 40 Troubleshooting SEN00790 02 Circuit diagram related to injector 5...

Page 566: ...efective contact in connec tor aPrepare with starting switch OFF then carry out troubleshooting with out turning starting switch ON Wiring harness between ENG female 55 CN3 female 1 Resis tance Max 1...

Page 567: ...PC800 850 8 61 40 Troubleshooting SEN00790 02 Circuit diagram related to injector 3...

Page 568: ...efective contact in connec tor aPrepare with starting switch OFF then carry out troubleshooting with out turning starting switch ON Wiring harness between ENG female 57 CN6 female 1 Resis tance Max 1...

Page 569: ...PC800 850 8 63 40 Troubleshooting SEN00790 02 Circuit diagram related to injector 6...

Page 570: ...efective contact in connec tor aPrepare with starting switch OFF then carry out troubleshooting with out turning starting switch ON Wiring harness between ENG female 54 CN2 female 1 Resis tance Max 1...

Page 571: ...PC800 850 8 65 40 Troubleshooting SEN00790 02 Circuit diagram related to injector 2...

Page 572: ...tion in wiring or defective contact in connec tor aPrepare with starting switch OFF then carry out troubleshooting with out turning starting switch ON Wiring harness between ENG female 56 CN4 female 1...

Page 573: ...ouble Incompatibility of data occurred in engine controller Action of controller None in particular Problem that appears on machine Operations are continued but engine may stop during operations or ma...

Page 574: ...ker on machine side directly for defect If fuse is broken or circuit breaker is shut down circuit probably has ground fault 3 Disconnection in wiring har ness Disconnection in wiring or defective cont...

Page 575: ...PC800 850 8 69 40 Troubleshooting SEN00790 02 Circuit diagram related to controller power supply...

Page 576: ...w voltage error occurred in sensor power supply 1 5V circuit Action of controller Common rail pressure sensor limits output and continues operation limits common rail pressure Problem that appears on...

Page 577: ...PC800 850 8 71 40 Troubleshooting SEN00790 02...

Page 578: ...ector 3 Disconnection in wiring har ness Disconnection in wiring or defective contact in connec tor aPrepare with starting switch OFF then carry out troubleshooting with out turning starting switch ON...

Page 579: ...ng 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 an...

Page 580: ...74 PC800 8 PC800SE 8 PC800LC 8 PC850 8 PC850SE 8 Hydraulic excavator Form No SEN00790 02 SEN00790 02 40 Troubleshooting...

Page 581: ...CA442 Battery Voltage High Error 3 Failure code CA449 Rail Press Very High Error 4 Failure code CA451 Rail Press Sensor High Error 6 Failure code CA452 Rail Press Sensor Low Error 8 Failure code CA553...

Page 582: ...e CA2271 EGR Valve Pos Sens High Error 42 Failure code CA2272 EGR Valve Pos Sens Low Error 44 Failure code CA2351 EGR Valve Sol Current High Error 46 Failure code CA2352 EGR Valve Sol Current Low Erro...

Page 583: ...age can be checked with monitoring function Code No 03200 Power supply voltage Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting Carry...

Page 584: ...n rail pressure sensor circuit Action of controller Limits output and continues operation limits common rail pressure Problem that appears on machine Engine output lowers Related information Common ra...

Page 585: ...PC800 850 8 5 40 Troubleshooting SEN00791 02...

Page 586: ...r another cause of trouble and then judge 3 Disconnection in wiring har ness Disconnection in wiring or defective contact in con nector aPrepare with starting switch OFF then carry out troubleshooting...

Page 587: ...to the following machines PC800 8 55001 and up PC850 8 10007 55001 and up Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 6 Defective...

Page 588: ...rail pressure sensor circuit Action of controller None in particular Problem that appears on machine Engine output lowers Related information Common rail pressure can be checked with monitoring funct...

Page 589: ...ts of trouble In range error occurred in common rail pressure sensor circuit Action of controller Limits output and continues operation limits common rail pressure Problem that appears on machine Engi...

Page 590: ...and adjusting Checking fuel pressure Pressure in fuel low pressure circuit Min 0 15 MPa Min 1 5 kg cm2 4 Clogged fuel filter strainer aFor more information on troubleshooting see Note 2 5 Defective e...

Page 591: ...pan fuel leakage in head cover Fig 1 Locations of overflow valve 1 bypass valve 2 and fuel inlet joint 3 Overflow valve 1 Spring is seen through both holes Bypass valve 2 Spring is seen through hole...

Page 592: ...Engine coolant temperature Low idle C 9 Fuel temperature Low idle C 5 Checking cylinder cut out operation Engine speed Func tion Cut out cylinder Check conditions Unit Standard value Reference value M...

Page 593: ...PC800 850 8 13 40 Troubleshooting SEN00791 02...

Page 594: ...s Short circuit with GND cir cuit aPrepare with starting switch OFF then carry out troubleshooting with out turning starting switch ON Wiring harness between ENG female 16 NE female 1 and chassis grou...

Page 595: ...PC800 850 8 15 40 Troubleshooting SEN00791 02 Circuit diagram related to engine Ne speed sensor...

Page 596: ...on machine Engine stops during operations When engine Ne speed sensor is also defective Engine cannot be started while stopping When engine Ne speed sensor is also defective Related information Possi...

Page 597: ...of trouble All data in engine controller are lost Action of controller None in particular Problem that appears on machine Operations are continued but engine may stop during operations or may not star...

Page 598: ...s Short circuit with GND cir cuit aPrepare with starting switch OFF then carry out troubleshooting with out turning starting switch ON Wiring harness between ENG female 37 G female 1 and chassis groun...

Page 599: ...ng SEN00791 02 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...

Page 600: ...e pressure is abnormal carry out troubleshooting for 4 and 5 3 Defective engine oil pres sure system main circuit aFor check of engine oil pressure see Testing and adjusting Measur ing engine oil pres...

Page 601: ...Contents of trouble There is EGR valve servo error level 2 Action of controller Limits output and continues operation Close EGR and bypass valves Problem that appears on machine Engine output lowers R...

Page 602: ...ng switch OFF then carry out troubleshooting with out turning starting switch ON Wiring harness between ENG female 31 BP female 1 Resis tance Max 1 z Wiring harness between ENG female 11 BP female 2 R...

Page 603: ...PC800 850 8 23 40 Troubleshooting SEN00791 02 Circuit diagram related to bypass valve solenoid lift sensor 7...

Page 604: ...nts of trouble There is disconnection in drive circuit of bypass valve solenoid Action of controller Limits output and continues operation Closes EGR valve and bypass valve Problem that appears on mac...

Page 605: ...igh idle Min 1 43 MPa Min 14 6 kg cm2 If valve drive pressure is abnormal carry out troubleshooting for 4 and 5 3 Defective engine oil pres sure system main circuit aFor check of engine oil pressure s...

Page 606: ...ntents of trouble Abnormality level 2 occurred in bypass valve servo Action of controller Limits output and continues operation Closes EGR valve and bypass valve Problem that appears on machine Output...

Page 607: ...PC800 850 8 27 40 Troubleshooting SEN00791 02...

Page 608: ...defective contact in connector aPrepare with starting switch OFF then carry out troubleshooting with out turning starting switch ON Wiring harness between ENG female 37 SBP female 1 Resis tance Max 1...

Page 609: ...PC800 850 8 29 40 Troubleshooting SEN00791 02 Circuit diagram related to bypass valve solenoid lift sensor...

Page 610: ...rmally low Action of controller Limits output and continues operation Closes EGR valve and bypass valve Problem that appears on machine Output drops Related information Signal voltage of bypass valve...

Page 611: ...PC800 850 8 31 40 Troubleshooting SEN00791 02...

Page 612: ...ting switch OFF then carry out troubleshooting with out turning starting switch ON Wiring harness between CM03 female 16 CE02 female 47 CP02 female 22 CK01 female 7 other related circuit and chassis g...

Page 613: ...PC800 850 8 33 40 Troubleshooting SEN00791 02 Circuit diagram related to CAN communication of pump controller...

Page 614: ...cuit is abnormally low Action of controller Sets EGR inlet pressure to default value 102 kPa 1 0kg cm2 and continues operation Limits output and continues operation Problem that appears on machine Out...

Page 615: ...PC800 850 8 35 40 Troubleshooting SEN00791 02...

Page 616: ...heck wiring harness and controller too for another cause of trouble and then judge 3 Disconnection in wiring harness Disconnection in wiring or defective contact in connector aPrepare with starting sw...

Page 617: ...ot applied to the following machines PC800 8 55001 and up PC850 8 10007 55001 and up Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting...

Page 618: ...control dial P20 connector 2 Disconnection in wiring har ness Disconnection in wiring or defective contact in con nector aPrepare with starting switch OFF then carry out troubleshooting with out turn...

Page 619: ...PC800 850 8 39 40 Troubleshooting SEN00791 02 Circuit diagram related to fuel control dial throttle sensor...

Page 620: ...uit Action of controller Use a signal other than throttle sensor to set the throttle position for operations Problem that appears on machine Engine speed can not be controlled Related information Sign...

Page 621: ...system E11 CA2249 Contents of trouble There is rail press very low error level 2 Action of controller Limits common rail pressure Problem that appears on machine Engine output lowers Related informat...

Page 622: ...act in con nector aPrepare with starting switch OFF then carry out troubleshooting with out turning starting switch ON Wiring harness between ENG female 37 SEGR female 1 Resis tance Max 1 z Wiring har...

Page 623: ...N00791 02 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 5500...

Page 624: ...rcuit Action of controller Limits output and continues operation Close EGR and bypass valves Problem that appears on machine Engine output lowers Related information Signal voltage of EGR valve positi...

Page 625: ...PC800 850 8 45 40 Troubleshooting SEN00791 02...

Page 626: ...g switch OFF then carry out troubleshooting with out turning starting switch ON Wiring harness between ENG female 22 EGR female 1 Resis tance Max 1 z Wiring harness between ENG female 11 EGR female 2...

Page 627: ...N00791 02 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 5500...

Page 628: ...ts of trouble Low current error occurred in drive circuit of EGR valve solenoid Action of controller Limits output and continues operation Close EGR and bypass valves Problem that appears on machine E...

Page 629: ...2555 Contents of trouble Voltage low error was detected in grid heater relay circuit Action of controller None in particular Problem that appears on machine Engine does not start easily at low tempera...

Page 630: ...ON R18 male Resistance Between 1 2 200 400 z 2 Disconnection in wiring har ness Disconnection in wiring or defective contact in con nector aPrepare with starting switch OFF then carry out troubleshoo...

Page 631: ...PC800 850 8 51 40 Troubleshooting SEN00791 02 Circuit diagram related to engine preheater...

Page 632: ...Standard value in normal state Remarks on troubleshooting 1 Defective battery relay Internal short circuit aPrepare with starting switch OFF then carry out troubleshooting with out turning starting s...

Page 633: ...PC800 850 8 53 40 Troubleshooting SEN00791 02 Circuit diagram related to battery relay drive...

Page 634: ...2 This error code detects abnormality on the primary coil side of the flash light relay and cannot detect abnormality on the secondary contact side Possible causes and standard value in normal state C...

Page 635: ...PC800 850 8 55 40 Troubleshooting SEN00791 02 Electric circuit diagram related to horn and flash light relay...

Page 636: ...etects abnormality on the primary coil side of the step light relay and cannot detect abnormality on the secondary contact side Possible causes and standard value in normal state Cause Standard value...

Page 637: ...PC800 850 8 57 40 Troubleshooting SEN00791 02 Electric circuit diagram related to step light...

Page 638: ...Disconnection in wir ing or defective contact in connector aPrepare with starting switch OFF then carry out troubleshooting with out turning starting switch ON Wiring harness between CP03 female 2 12...

Page 639: ...PC800 850 8 59 40 Troubleshooting SEN00791 02 Circuit diagram related to power supply of pump controller...

Page 640: ...g switch OFF then turn starting switch ON and carry out troubleshooting Disconnect sensors at right in order If no error code is displayed that sensor is defec tive F pump pressure sensor P25 connecto...

Page 641: ...PC800 850 8 61 40 Troubleshooting SEN00791 02 Circuit diagram related to pressure sensor power supply of pump controller...

Page 642: ...circuit aPrepare with starting switch OFF then carry out troubleshooting with out turning starting switch ON S30 female Resistance Between 2 3 4 8 Min 1 Mz Between 1 8 Max 1 z 2 Disconnection in wirin...

Page 643: ...PC800 850 8 63 40 Troubleshooting SEN00791 02 Circuit diagram related to model selection connector of pump controller...

Page 644: ...64 PC800 850 8 SEN00791 02 40 Troubleshooting Failure code DA80MA Auto Lub Abnormal a This failure code is displayed only when automatic lubrication equipment is installed...

Page 645: ...PC800 850 8 65 40 Troubleshooting SEN00791 02...

Page 646: ...2 Ground fault in wiring har ness Short circuit with GND cir cuit aPrepare with starting switch OFF then carry out troubleshooting with out turning starting switch ON Wiring harness between CM03 femal...

Page 647: ...PC800 850 8 67 40 Troubleshooting SEN00791 02 Circuit diagram related to CAN communication of pump controller...

Page 648: ...1 z 2 Ground fault in wiring har ness Short circuit with GND cir cuit aPrepare with starting switch OFF then carry out troubleshooting with out turning starting switch ON Wiring harness between CM03...

Page 649: ...PC800 850 8 69 40 Troubleshooting SEN00791 02 Circuit diagram related to CAN communication of machine monitor...

Page 650: ...ing switch OFF then carry out troubleshooting with out turning starting switch ON P29 male Ambient temperature Resistance Between 1 2 20 C 4 6 kz 2 Disconnection in wiring harness Disconnection in wir...

Page 651: ...PC800 850 8 71 40 Troubleshooting SEN00791 02 Circuit diagram related to ambient temperature sensor...

Page 652: ...arks on troubleshooting 1 Hydraulic oil overheated While system is normal Check the hydraulic oil for overheating If it has been overheated find out the cause and check the hydraulic equipment for dam...

Page 653: ...PC800 850 8 73 40 Troubleshooting SEN00791 02 Circuit diagram related to hydraulic oil temperature sensor...

Page 654: ...74 PC800 8 PC800SE 8 PC800LC 8 PC850 8 PC850SE 8 Hydraulic excavator Form No SEN00791 02 SEN00791 02 40 Troubleshooting...

Page 655: ...L Jet Sensor Disc 4 Failure code DH25KB L Jet Sensor S C 6 Failure code DH26KA R Jet Sensor Disc 8 Failure code DH26KB R Jet Sensor S C 10 Failure code DHPEKA F Pump P Sensor Disc 12 Failure code DHP...

Page 656: ...ailure code DWK0KB 2 stage Relief Sol S C 44 Failure code DX16KA Fan Pump EPC Sol Disc 46 Failure code DX16KB Fan Pump EPC Sol S C 48 Failure code DXAAKA F Pump EPC Sol Disc 50 Failure code DXAAKB F P...

Page 657: ...PC800 850 8 3 40 Troubleshooting SEN00792 02...

Page 658: ...sor power supply system If failure code DA25KP is also displayed carry out troubleshooting for it first 2 Defective L jet sensor dif ferential pressure sensor aPrepare with starting switch OFF then tu...

Page 659: ...PC800 850 8 5 40 Troubleshooting SEN00792 02 Circuit diagram related to differential pressure sensor system...

Page 660: ...pressure Code 13802 Sensor voltage Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective 5V sensor power supply system If fail...

Page 661: ...PC800 850 8 7 40 Troubleshooting SEN00792 02 Circuit diagram related to differential pressure sensor system...

Page 662: ...ilure code DA25KP is also displayed carry out troubleshooting for it first 2 Defective R jet sensor dif ferential pressure sensor aPrepare with starting switch OFF then turn starting switch ON and car...

Page 663: ...PC800 850 8 9 40 Troubleshooting SEN00792 02 Circuit diagram related to differential pressure sensor system...

Page 664: ...pressure Code 13803 Sensor voltage Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective 5V sensor power supply system If fail...

Page 665: ...PC800 850 8 11 40 Troubleshooting SEN00792 02 Circuit diagram related to differential pressure sensor system...

Page 666: ...V sensor power supply system If failure code DA25KP is also displayed carry out troubleshooting for it first 2 Defective F pump pressure sensor Internal trouble aPrepare with starting switch OFF then...

Page 667: ...PC800 850 8 13 40 Troubleshooting SEN00792 02 Circuit diagram related to F pump pressure sensor...

Page 668: ...Internal defect aTurn the engine starting switch OFF for the preparations and turn to ON or keep the engine running during the troubleshooting P25 Voltage Between 3 1 Power supply 4 5 5 5 V Between 2...

Page 669: ...PC800 850 8 15 40 Troubleshooting SEN00792 02 Circuit diagram related to F pump pressure sensor...

Page 670: ...1 Defective 5V sensor power If failure code DA25KP is also displayed carry out troubleshooting for it first 2 Defective R pump pressure sensor Internal trouble aPrepare with starting switch OFF then...

Page 671: ...PC800 850 8 17 40 Troubleshooting SEN00792 02 Circuit diagram related to F pump pressure sensor...

Page 672: ...pump pressure sensor defective Internal defect aTurn the engine starting switch OFF for the preparations and turn to ON or keep the engine running during the troubleshooting P26 Voltage Between 3 1 P...

Page 673: ...PC800 850 8 19 40 Troubleshooting SEN00792 02 Circuit diagram related to R pump pressure sensor...

Page 674: ...ard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Travel alarm defective Internal defect aTurn the engine starting switch OFF for the preparations and keep th...

Page 675: ...PC800 850 8 21 40 Troubleshooting SEN00792 02 Circuit diagram related to travel alarm...

Page 676: ...hen checking the solenoid again after repairing it For how to turn power ON or OFF refer to the troubleshooting under failure code DW41KB Possible causes and standard value in normal state Cause Stand...

Page 677: ...PC800 850 8 23 40 Troubleshooting SEN00792 02 Electric circuit diagram related to swing priority solenoid...

Page 678: ...he monitoring function Code No 02300 Solenoid 1 Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Swing priority solenoid defective I...

Page 679: ...PC800 850 8 25 40 Troubleshooting SEN00792 02 Electric circuit diagram related to swing priority solenoid...

Page 680: ...r ON or OFF refer to the troubleshooting under failure code DW43KB Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Travel Speed Sol...

Page 681: ...PC800 850 8 27 40 Troubleshooting SEN00792 02 Circuit diagram related to travel speed solenoid of pump controller...

Page 682: ...eed is below 1 200 rpm Operation of the travel speed solenoid ON or OFF can be checked in the monitoring function Code No 02300 Solenoid 1 Possible causes and standard value in normal state Cause Stan...

Page 683: ...PC800 850 8 29 40 Troubleshooting SEN00792 02 Circuit diagram related to travel speed solenoid of pump controller...

Page 684: ...starting switch OFF then carry out troubleshooting with out turning starting switch ON V05A V05B male Resistance Between 2 1 20 60 z 2 Defective assembled type diode D01 Internal disconnection aPrepa...

Page 685: ...PC800 850 8 31 40 Troubleshooting SEN00792 02 Circuit diagram related to swing holding brake solenoid of pump controller...

Page 686: ...g holding brake does not work however after machine stops Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective swing holding b...

Page 687: ...PC800 850 8 33 40 Troubleshooting SEN00792 02 Circuit diagram related to swing holding brake solenoid of pump controller...

Page 688: ...ndard value in normal state Remarks on troubleshooting 1 Defective hydraulic fan reverse solenoid Internal disconnection aTurn the engine starting switch OFF for the preparations and hold it in the OF...

Page 689: ...PC800 850 8 35 40 Troubleshooting SEN00792 02 Circuit diagram related to hydraulic fan...

Page 690: ...Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective hydraulic fan reverse solenoid Internal disconnection aTurn the engine s...

Page 691: ...PC800 850 8 37 40 Troubleshooting SEN00792 02 Circuit diagram related to hydraulic fan...

Page 692: ...s on troubleshooting 1 Defective bottom dump pri ority solenoid Internal dis connection aPrepare with starting switch OFF then carry out troubleshooting with out turning starting switch ON V19 male Re...

Page 693: ...PC800 850 8 39 40 Troubleshooting SEN00792 02 Circuit diagram related to bottom dump priority solenoid...

Page 694: ...standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective bottom dump pri ority solenoid Internal short circuit aPrepare with starting switch OFF then...

Page 695: ...PC800 850 8 41 40 Troubleshooting SEN00792 02 Circuit diagram related to bottom dump priority solenoid...

Page 696: ...causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective 2 stage relief solenoid Internal disconnection aPrepare with starting switch OFF...

Page 697: ...PC800 850 8 43 40 Troubleshooting SEN00792 02 Circuit diagram related to 2 stage relief solenoid of pump controller...

Page 698: ...Code 02300 Solenoid 1 Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective 2 stage relief solenoid Internal short circuit or...

Page 699: ...PC800 850 8 45 40 Troubleshooting SEN00792 02 Circuit diagram related to 2 stage relief solenoid of pump controller...

Page 700: ...ic fan EPC solenoid Internal dis connection aTurn the engine starting switch OFF for the preparations and hold it in the OFF position during the troubleshooting V13 male Resistance Between 1 2 7 14 z...

Page 701: ...PC800 850 8 47 40 Troubleshooting SEN00792 02 Circuit diagram related to fan pump EPC solenoid...

Page 702: ...unction Code 31623 EPC solenoid current Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective hydraulic fan EPC solenoid Intern...

Page 703: ...PC800 850 8 49 40 Troubleshooting SEN00792 02 Circuit diagram related to fan pump EPC solenoid...

Page 704: ...ain pump EPC F solenoid Internal dis connection aPrepare with starting switch OFF then carry out troubleshooting with out turning starting switch ON V11 male Resistance Between 1 2 7 14 z 2 Defective...

Page 705: ...PC800 850 8 51 40 Troubleshooting SEN00792 02 Circuit diagram related to main pump EPC solenoid...

Page 706: ...s on troubleshooting 1 Defective main pump EPC F solenoid Internal short circuit or ground fault aPrepare with starting switch OFF then carry out troubleshooting with out turning starting switch ON V1...

Page 707: ...PC800 850 8 53 40 Troubleshooting SEN00792 02 Circuit diagram related to main pump EPC solenoid...

Page 708: ...pump EPC R solenoid Internal dis connection aPrepare with starting switch OFF then carry out troubleshooting with out turning starting switch ON V12 male Resistance Between 1 2 7 14 z 2 Defective eme...

Page 709: ...PC800 850 8 55 40 Troubleshooting SEN00792 02 Circuit diagram related to main pump EPC solenoid...

Page 710: ...on troubleshooting 1 Defective main pump EPC R solenoid Internal short circuit or ground fault aPrepare with starting switch OFF then carry out troubleshooting with out turning starting switch ON V12...

Page 711: ...PC800 850 8 57 40 Troubleshooting SEN00792 02 Circuit diagram related to main pump EPC solenoid...

Page 712: ...ing 1 Defective wiper motor Internal disconnection aPrepare with starting switch OFF then carry out troubleshooting with out turning starting switch ON M05 female Wiper blade Resistance Between 6 5 Up...

Page 713: ...PC800 850 8 59 40 Troubleshooting SEN00792 02 Circuit diagram related to wiper motor of machine monitor...

Page 714: ...orage area Max 1 z Working area Min 1 Mz 2 Defective lower windshield wiper motor Internal disconnection aPrepare with starting switch OFF then carry out troubleshooting with out turning starting swit...

Page 715: ...PC800 850 8 61 40 Troubleshooting SEN00792 02 Circuit diagram related to wiper motor of machine monitor Double wiper specification...

Page 716: ...arks on troubleshooting 1 Defective wiper motor Internal disconnection aPrepare with starting switch OFF then carry out troubleshooting with out turning starting switch ON M05 female Wiper blade Resis...

Page 717: ...PC800 850 8 63 40 Troubleshooting SEN00792 02 Circuit diagram related to wiper motor of machine monitor Single wiper specification...

Page 718: ...value in normal state Remarks on troubleshooting 1 Defective washer motor Internal short circuit aPrepare with starting switch OFF then carry out troubleshooting with out turning starting switch ON M...

Page 719: ...PC800 850 8 65 40 Troubleshooting SEN00792 02 Circuit diagram related to window washer motor of machine monitor...

Page 720: ...e troubleshooting M15 female Continuity and resistance value Between 3 1 Continued Between 3 chassis ground Min 1 Mz 3 Assembled type diode D04 defective Internal short circuiting aTurn the engine sta...

Page 721: ...PC800 850 8 67 40 Troubleshooting SEN00792 02 Circuit diagram related to wiper motor of machine monitor Double wiper specification...

Page 722: ...r Internal short circuit or ground fault aPrepare with starting switch OFF then carry out troubleshooting with out turning starting switch ON M05 female Continuity Resistance Between 3 1 There is cont...

Page 723: ...PC800 850 8 69 40 Troubleshooting SEN00792 02 Circuit diagram related to wiper motor of machine monitor Single wiper specification...

Page 724: ...efective wiper motor Internal short circuit or ground fault aPrepare with starting switch OFF then carry out troubleshooting with out turning starting switch ON M05 female Continuity Resistance Betwee...

Page 725: ...PC800 850 8 71 40 Troubleshooting SEN00792 02 Circuit diagram related to wiper motor of machine monitor Single wiper specification...

Page 726: ...72 PC800 8 PC800SE 8 PC800LC 8 PC850 8 PC850SE 8 Hydraulic excavator Form No SEN00792 02 SEN00792 02 40 Troubleshooting...

Page 727: ...5 E 1 Engine does not start Engine does not rotate 6 E 2 Preheater does not operate 9 E 3 Auto engine warm up device does not work 16 E 4 Auto decelerator does not operate 17 E 5 All work equipment sw...

Page 728: ...unction 46 E 21 Arm OUT is not correctly displayed in monitor function 47 E 22 Bucket CURL is not correctly displayed in monitor function 48 E 23 Bucket DUMP is not correctly displayed in monitor func...

Page 729: ...at the OFF position a When carrying out troubleshooting related to the electrical system you should check the circuit breakers first to see if the power is supplied normally Type of power supply Circu...

Page 730: ...10 A EPC solenoid for emergency pump drive Swing holding brake solenoid for swing brake release 2 10 A Starting motor cut out relay Machine push up solenoid Boom shockless solenoid 3 10 A PPC lock so...

Page 731: ...is ground circuit is in contact with chassis ground circuit Hot short Wiring harness which is not connected to power source 24 V cir 2 3 Precautions for troubleshooting 1 Method of indicating connecto...

Page 732: ...lock switch Internal short circuiting aTurn the engine starting switch OFF for the preparations and hold it in the OFF position during the troubleshooting S14 female Lock lever Resistance Between 1 3...

Page 733: ...arting switch OFF for the preparations and hold it in the OFF position during the troubleshooting Wiring harness between B26 J07 H06 female 1 and chassis ground Resis tance Min 1 Mz Wiring harness bet...

Page 734: ...8 PC800 850 8 SEN00793 02 40 Troubleshooting Circuit diagram related to engine preheat start and battery charging...

Page 735: ...and carry out troubleshooting in each case H06 male Starting switch Resistance Between 1 5 ON Max 1 z OFF Min 1 Mz 3 Defective auto preheater relay aPrepare with starting switch OFF then carry out tr...

Page 736: ...rness between battery relay terminal M air heater relay terminal R15 Resistance Max 1 z Wiring harness between air heater relay termi nal engine ground Resistance Max 1 z 7 Ground fault in wiring har...

Page 737: ...PC800 850 8 11 40 Troubleshooting SEN00793 02 Circuit diagram related to engine preheat start and battery charging...

Page 738: ...sible causes and standard value in normal state Cause Standard value in normalcy and references for troubleshooting 1 Defective starting switch system If the preheater does not operate the heater unit...

Page 739: ...PC800 850 8 13 40 Troubleshooting SEN00793 02...

Page 740: ...n aTurn the engine starting switch OFF for the preparations with the wir ing harness connected and hold it in the OFF or HEAT position dur ing troubleshooting Heater relay Starting switch Continuity a...

Page 741: ...PC800 850 8 15 40 Troubleshooting SEN00793 02 Circuit diagram related to engine preheat start and battery charging...

Page 742: ...tion operates to keep the engine speed below 1 000 rpm for up to 5 seconds after the engine is started Possible causes and standard value in normal state Cause Standard value in normalcy and reference...

Page 743: ...ay 01900 Pressure switch 1 Arm OUT Lever operated ON Lever in neutral OFF 5 Defective bucket CURL signal Monitoring code Item Normal display 01901 Pressure switch 2 Bucket CURL Lever operated ON Lever...

Page 744: ...n 2 chassis ground Min 1 Mz 4 Assembled type diode D01 fault Internal short circuiting aTurn the engine starting switch OFF for the preparations and hold it in the OFF position during the troubleshoot...

Page 745: ...PC800 850 8 19 40 Troubleshooting SEN00793 02 Circuit diagram related to PPC lock solenoid...

Page 746: ...ndard value in normalcy and references for troubleshooting 1 Defective machine push up switch Internal short circuiting aTurn the engine starting switch OFF for the preparations and hold it in the OFF...

Page 747: ...roubleshooting V06 male Resistance Between 2 1 20 60 z Between 1 chassis ground Min 1 Mz 4 Defective assembled type diode D03 Internal short circuiting aTurn the engine starting switch OFF for the pre...

Page 748: ...ndard value in normalcy and references for troubleshooting 1 Defective boom shockless control switch Internal short circuiting aTurn the engine starting switch OFF for the preparations and hold it in...

Page 749: ...en 1 chassis ground Min 1 Mz 4 Defective assembled type diode D04 Internal short circuiting aTurn the engine starting switch OFF for the preparations and hold it in the OFF position during the trouble...

Page 750: ...he preparations and hold it in the OFF position during the troubleshooting Wiring harness between CM01 female 1 2 FB1 10 outlet Resis tance Max 1 z Wiring harness between FB1 inlet B21 Resis tance Max...

Page 751: ...onitor is normal Switching operation P push switches simultaneously 2 Defective machine monitor If cause 1 is not detected the machine monitor may be defective Since trouble is in the machine monitor...

Page 752: ...el sensor fault Internal disconnection aTurn the engine starting switch OFF for the preparations and hold it in the OFF position during the troubleshooting P21 male Fuel level Resistance Between 1 cha...

Page 753: ...PC800 850 8 27 40 Troubleshooting SEN00793 02...

Page 754: ...e troubleshooting TWTR male Resistance Between A B 3 5 k 90 kz Between 1 2 chassis ground Min 1 Mz 2 Disconnection of wiring harness Disconnection or defec tive contact with connector aTurn the engine...

Page 755: ...PC800 850 8 29 40 Troubleshooting SEN00793 02 Circuit diagram related to engine coolant temperature sensor...

Page 756: ...een 1 2 10 100 C 90 3 5 kz Between 1 chassis ground Min 1 Mz 2 Disconnection of wiring harness Disconnection or defec tive contact with connector aTurn the engine starting switch OFF for the preparati...

Page 757: ...5 110 z 2 Disconnection of wiring harness Disconnection or defec tive contact with connector aTurn the engine starting switch OFF for the preparations and hold it in the OFF position during the troubl...

Page 758: ...ith connector aTurn the engine starting switch OFF for the preparations and hold it in the OFF position during the troubleshooting Wiring harness from CM02 female 17 J07 S04 male 1 Resis tance Max 1 z...

Page 759: ...PC800 850 8 33 40 Troubleshooting SEN00793 02 Circuit diagram related to swing holding brake...

Page 760: ...item selec tion screen is not displayed Relative information Possible causes and standard value in normal state Cause Standard value in normalcy and references for troubleshooting 1 Defective machine...

Page 761: ...not displayed Relative information When the wiper does not operate either conduct the troubleshooting for Windshield wiper and win dow washer do not work Possible causes and standard value in normal s...

Page 762: ...aTurn the engine starting switch OFF for the preparations and hold it in the OFF position during the troubleshooting M05 female Continuity and resistance Between 3 1 Continued 2 Disconnection of wirin...

Page 763: ...PC800 850 8 37 40 Troubleshooting SEN00793 02 Circuit diagram related to wiper motor double wiper specification...

Page 764: ...Continuity and resistance Between 3 1 Continued 3 Disconnection of wiring harness Disconnection or defec tive contact with connector aTurn the engine starting switch OFF for the preparations and hold...

Page 765: ...PC800 850 8 39 40 Troubleshooting SEN00793 02 Circuit diagram related to wiper motor double wiper specification...

Page 766: ...tor aTurn the engine starting switch OFF for the preparations and hold it in the OFF position during the troubleshooting Wiring harness between CM01 male 9 M05 female 3 Resis tance Max 1 z Wiring harn...

Page 767: ...PC800 850 8 41 40 Troubleshooting SEN00793 02 Circuit diagram related to windshield wiper motor single wiper specification...

Page 768: ...ess Disconnection or defec tive contact with connector aTurn the engine starting switch OFF for the preparations and hold it in the OFF position during the troubleshooting Wiring harness from FB1 4 ou...

Page 769: ...PC800 850 8 43 40 Troubleshooting SEN00793 02 Circuit diagram related to window washer motor...

Page 770: ...tact with connector aTurn the engine starting switch OFF for the preparations and hold it in the OFF position during the troubleshooting Wiring harness between CP03 female 10 P06 female 2 Resis tance...

Page 771: ...ct with connector aTurn the engine starting switch OFF for the preparations and hold it in the OFF position during the troubleshooting Wiring harness between CP03 female 20 P02 female 2 Resis tance Ma...

Page 772: ...t with connector aTurn the engine starting switch OFF for the preparations and hold it in the OFF position during the troubleshooting Wiring harness between CP03 female 30 P04 female 2 Resis tance Max...

Page 773: ...ontact with connector aTurn the engine starting switch OFF for the preparations and hold it in the OFF position during the troubleshooting Wiring harness between CP03 female 40 P08 female 2 Resis tanc...

Page 774: ...fec tive contact with connector aTurn the engine starting switch OFF for the preparations and hold it in the OFF position during the troubleshooting Wiring harness between CP03 female 9 P01 female 2 R...

Page 775: ...ec tive contact with connector aTurn the engine starting switch OFF for the preparations and hold it in the OFF position during the troubleshooting Wiring harness between CP03 female 19 P05 female 2 R...

Page 776: ...ector aTurn the engine starting switch OFF for the preparations and hold it in the OFF position during the troubleshooting Wiring harness between CP03 female 29 J15 P03 female 2 or wiring harness betw...

Page 777: ...PC800 850 8 51 40 Troubleshooting SEN00793 02 Circuit diagram related to right and left swing PPC hydraulic switches...

Page 778: ...fec tive contact with connector aTurn the engine starting switch OFF for the preparations and hold it in the OFF position during the troubleshooting Wiring harness between CP02 female 16 J31 P09 femal...

Page 779: ...PC800 850 8 53 40 Troubleshooting SEN00793 02 Circuit diagram related to left travel forward PPC oil pressure switch and left travel reverse PPC oil pressure switch...

Page 780: ...ection or defec tive contact with connector aTurn the engine starting switch OFF for the preparations and hold it in the OFF position during the troubleshooting Wiring harness between CP03 female 39 J...

Page 781: ...PC800 850 8 55 40 Troubleshooting SEN00793 02 Circuit diagram related to right travel forward PPC oil pressure switch and right travel reverse PPC oil pressure switch...

Page 782: ...tor aTurn the engine starting switch OFF for the preparations and hold it in the OFF position during the troubleshooting Wiring harness between CP02 female 35 P13 female 2 Resis tance Max 1 z Wiring h...

Page 783: ...PC800 850 8 57 40 Troubleshooting SEN00793 02 Circuit diagram related to service PPC hydraulic switch...

Page 784: ...with starting switch OFF then start engine and carry out trou bleshooting CK01 Signal Voltage Between 36 37 38 Starting switch ACC 20 30 V Between 28 37 38 Alternator R 20 30 V 3 Defective starting sw...

Page 785: ...PC800 850 8 59 40 Troubleshooting SEN00793 02 LED display unit CK01 connector...

Page 786: ...reparations and hold it in the OFF position during the troubleshooting Wiring harness between FB1 11 M26 male 5 Resis tance Max 1 z Wiring harness between M26 male 8 chassis ground Resis tance Max 1 z...

Page 787: ...troubleshooting Wiring harness between FB1 17 outlet S13 female 2 or between FB1 17 outlet R09 female 1 3 Resis tance Max 1 z Wiring harness between S13 female 1 J06 CP01 female 24 or between S13 fem...

Page 788: ...s repaired the relay is defective R09 3 Short circuiting of wiring harness Contact with 24 V circuit aTurn the engine starting switch OFF for the preparations and hold it in the ON position during the...

Page 789: ...PC800 850 8 63 40 Troubleshooting SEN00793 02 Circuit diagram related to step light...

Page 790: ...g harness Disconnection or defec tive contact with connector aTurn the engine starting switch OFF for the preparations and hold it in the OFF position during the troubleshooting Wiring harness between...

Page 791: ...PC800 850 8 65 40 Troubleshooting SEN00793 02 Circuit diagram related to electric grease gun...

Page 792: ...e engine starting switch OFF for the preparations and keep the engine running during the troubleshooting M14 female Travel lever Voltage Between 1 2 Neutral Below 1 V Operated 20 30 V If the above vol...

Page 793: ...PC800 850 8 67 40 Troubleshooting SEN00793 02 Circuit diagram related to travel alarm...

Page 794: ...68 PC800 8 PC800SE 8 PC800LC 8 PC850 8 PC850SE 8 Hydraulic excavator Form No SEN00793 02 SEN00793 02 40 Troubleshooting...

Page 795: ...troubleshooting 3 Information in troubleshooting table 6 H 1 Speed or power of all work equipment travel and swing is low 8 H 2 Engine speed lowers remarkably or engine stalls 10 H 3 All work equipme...

Page 796: ...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...

Page 797: ...PC800 850 8 3 40 Troubleshooting SEN00794 02 Troubleshooting of hydraulic and mechanical system H mode Before troubleshooting...

Page 798: ...easuring its output pressure The servo valve and pump unit can be judged by removing and testing the servo valve or measur ing the stroke of the servo piston a Actually perform the judgment procedure...

Page 799: ...PC800 850 8 5 40 Troubleshooting SEN00794 02...

Page 800: ...g out troubleshooting Failure phenomenon Phenomena on machine Relative information Information concerning to failure or troubleshooting Possible causes and standard value in normal state Cause Standar...

Page 801: ...PC800 850 8 7 40 Troubleshooting SEN00794 02...

Page 802: ...switch ON Boom RAISE relief Above 1 700 rpm 2 Malfunction of self pressure reducing valve aKeep the engine stopped for the preparations and run it at high idle during troubleshooting Control levers C...

Page 803: ...ecking that causes 2 4 are not detected Control levers Pump EPC current All levers in neutral 265 50 mA Idle travel Lever full stroke 575 5 50 mA 6 Malfunction of pump EPC solenoid valve aKeep the eng...

Page 804: ...t high idle speed and carry out troubleshooting Make sure that failure cause 1 is normal before troubleshooting Control lever EPC solenoid valve output pressure All levers in neutral Max 0 78 MPa Max...

Page 805: ...PC800 850 8 11 40 Troubleshooting SEN00794 02...

Page 806: ...shaft If oil flows out of the pump outlet PTO is normal 2 Malfunction of self pressure reducing valve aKeep the engine stopped for the preparations and run it at high idle during troubleshooting Contr...

Page 807: ...vel Since the hydraulic oil level may be low check it directly 2 Loosened piping clamp Since a piping clamp between the hydraulic tank and hydraulic pump may be loosened check it directly 3 Clogged hy...

Page 808: ...g cm2 2 Malfunction of swing priority solenoid valve aKeep the engine stopped for the preparations and run it at high idle during troubleshooting Swing priority switch and right work equipment control...

Page 809: ...ipment control lever Main relief pressure Single boom RAISE operation 33 8 MPa 345 kg cm2 If the main relief valve is still abnormal after adjustment its operation on the high pressure set side may be...

Page 810: ...oubleshooting with the engine at high idle L H work equipment control lever PPC valve output pressure Arm IN OUT Full stroke 2 9 MPa 30 kg cm2 2 Malfunction of arm control valve spool Since the spool...

Page 811: ...uipment control lever bucket PPC valve output pressure Bucket CURL DUMP Full stroke 2 9 MPa 30 kg cm2 2 Malfunction of bucket con trol valve spool Since the spool of the bucket control valve Lo Hi may...

Page 812: ...n working mode P Possible causes and standard value in normal state Cause Standard value in normalcy and references for troubleshooting 1 Malfunction of left PPC valve arm circuit aPrepare with the en...

Page 813: ...rry out troubleshooting with the engine at high idle R H work equipment control lever Leakage from cylinder Relieved in boom RAISE position Max 20 cc min Failure phenomenon Hydraulic drift of work equ...

Page 814: ...ction of bucket con trol valve safety suction valve Since the safety suction valve bottom side of the bucket control valve Lo Hi may have a malfunction check it directly The safety suction valve may b...

Page 815: ...e Cause Standard value in normalcy and references for troubleshooting 1 Malfunction of arm control valve safety suction valve Since the safety suction valve bottom side of the arm control valve Lo Hi...

Page 816: ...lue in normal state Cause Standard value in normalcy and references for troubleshooting 1 Check by 3 in H 5 Boom speed or power is low Failure phenomenon Boom shockless function cannot be turned ON or...

Page 817: ...PC800 850 8 23 40 Troubleshooting SEN00794 02...

Page 818: ...0 kg cm2 3 Malfunction of travel control valve spool Since the spool of the travel control valve may have a malfunction check it directly 4 Defective travel control valve body Since the body of the tr...

Page 819: ...e stopped then carry out troubleshooting with the engine at high idle Travel lever PPC valve output pressure FORWARD REVERSE Full stroke 2 9 MPa 30 kg cm2 2 Malfunction of travel control valve spool S...

Page 820: ...ine deviates when started regardless of travel lever stroke Relative information Check that the machine does not deviate during constant speed travel If the machine deviates even during constant speed...

Page 821: ...l speed or power is low Relative information Check that speed of work equipment and travel is normal Check that the machine does not deviate If the machine deviates carry out the related troubleshooti...

Page 822: ...in working mode P Possible causes and standard value in normal state Cause Standard value in normalcy and references for troubleshooting 1 Malfunction of travel PPC valve aPrepare with the engine sto...

Page 823: ...ven while the machine is traveling at Hi Hi is still displayed on the monitor panel Carry out all the troubleshooting in working mode P Possible causes and standard value in normal state Cause Standar...

Page 824: ...utlet pressure Neutral After 10 seconds or more 0 MPa 0 kg cm2 Operated to swing in either direction Min 2 74 MPa Min 28 kg cm2 2 Malfunction of swing motor parking brake The parking brake of the swin...

Page 825: ...T stroke end 2 9 MPa 30 kg cm2 2 Malfunction of swing control valve spool The spool of the swing control valve may malfunction Check it directly 3 Malfunction of swing control valve suction valve The...

Page 826: ...nt control lever Leakage from swing motor Swing relief in either direction Max 10 l min 2 Malfunction of swing motor parking brake The parking brake of the swing motor may malfunction Check it directl...

Page 827: ...T LEFT stroke end 2 9 MPa 30 kg cm2 2 Malfunction of swing control valve spool The spool of the swing control valve may malfunction Check it directly 3 Malfunction of swing control valve suction valve...

Page 828: ...control lever Solenoid valve outlet pressure Swing priority switch OFF Boom RAISE operation Min 2 35 MPa Min 24 kg cm2 Swing priority switch ON Boom RAISE operation 0 Pa 0 kg cm2 2 Malfunction of swi...

Page 829: ...rmalcy and references for troubleshooting 1 Malfunction of swing priority solenoid valve aKeep the engine stopped for the preparations and run it at high idle during troubleshooting Swing priority swi...

Page 830: ...stops swinging in only 1 direction Relative information Possible causes and standard value in normal state Cause Standard value in normalcy and references for troubleshooting 1 Malfunction of left PPC...

Page 831: ...nt the safety valve may malfunction Check the safety valve directly 4 Swing motor motor unit defective internally The motor unit of the swing motor may have a defect in it Check it directly 5 Swing ma...

Page 832: ...Check the safety valve directly 3 Swing machinery defective internally Swing machinery may have a defect in it Check it directly The swing machinery can be checked by abnormal sound abnormal heating...

Page 833: ...swing motor parking brake The parking brake of the swing motor may malfunction Check it directly Failure phenomenon Hydraulic drift of swing is large 2 While the swing holding brake is released Relati...

Page 834: ...dard value in normal state Cause Standard value in normalcy and references for troubleshooting 1 Defective fan pump EPC current output aCarry out troubleshooting with engine running at high idle Contr...

Page 835: ...PC800 850 8 41 40 Troubleshooting SEN00794 02...

Page 836: ...42 PC800 8 PC800SE 8 PC800LC 8 PC850 8 PC850SE 8 Hydraulic excavator Form No SEN00794 02 SEN00794 02 40 Troubleshooting...

Page 837: ...es not start 8 S 3 Engine does not pick up smoothly 12 S 4 Engine stops during operations 13 S 5 Engine does not rotate smoothly 14 S 6 Engine lacks output or lacks power 15 S 7 Exhaust gas color is b...

Page 838: ...2 PC800 850 8 SEN00795 02 40 Troubleshooting S 16 Vibration is excessive 28...

Page 839: ...r depending on their level Check items Simple check items used by the serviceman to nar row the causes They correspond to C in the chart on the right Causes Items to be narrowed from the questions and...

Page 840: ...ck 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 Exha...

Page 841: ...l 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 trouble...

Page 842: ...tor is installed w During operation charge level monitor indicates abnormal charge if monitor is installed w w Dust indicator is red if indicator is installed w Air breather hole of fuel tank cap is c...

Page 843: ...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 tra...

Page 844: ...urned ON there is no operating sound from battery relay Q w Check items When starting switch is turned to START starting pinion does not move out Q Q w When starting switch is turned to START start in...

Page 845: ...ooler 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 c...

Page 846: ...Manual w w E Q When fuel tank is inspected it is found to be empty w Air breather hole of fuel tank cap is clogged Q w Rust and water are found when fuel tank is drained Q Q Q Q Q Q Check items When f...

Page 847: ...cator is installed w Air breather hole of fuel tank cap is clogged Q Rust and water are found when fuel tank is drained Q w w When fuel filter is removed there is not fuel in it Q Fuel is leaking from...

Page 848: ...ded more frequently w Dust indicator is red if indicator is installed w Air breather hole of fuel tank cap is clogged w Rust and water are found when fuel tank is drained w w Fuel is leaking from fuel...

Page 849: ...g used Q Q Q Q Replacement of filters has not been carried out according to Operation and Mainte nance Manual w w Fuel level monitor indicates low level if monitor is installed w When fuel tank is ins...

Page 850: ...certain speed range Q Q Q Q Q Occurs at low idle w Q Q Q Q Q Q Q Occurs even when speed is raised Q Q Q Q Q Occurs on slopes w Q Q Replacement of filters has not been carried out according to Operati...

Page 851: ...ed more frequently Q Q Q Dust indicator is red if indicator is installed w Air breather hole of fuel tank cap is clogged w Fuel is leaking from fuel piping w Output becomes insufficient after short st...

Page 852: ...Power was lost Suddenly w Q Q Q Gradually Q Q Q Q Dust indicator is red if indicator is installed w Muffler is crushed w Air leaks between turbocharger and cylinder head clamp is loosened w Check item...

Page 853: ...ure 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...

Page 854: ...n suddenly increased w Q Oil must be added more frequently Q w Q Oil becomes contaminated quickly Q Q w Outside of engine is dirty with oil w w w w w There are loose piping clamps in intake system w C...

Page 855: ...used Q Engine oil must be added more frequently Q w Even when engine oil temperature rises oil filter clogging monitor indi cates clogging if monitor is installed w Q Metal particles are found when oi...

Page 856: ...ally increased Q Q Suddenly increased Q Q There is external leakage of fuel from engine w Combustion is irregular w Engine oil level rises and oil smells of diesel fuel w w Check items When exhaust ma...

Page 857: ...oil cooler core O ring Questions Confirm recent repair history Degree of use of machine Operated for long period E E Oil level Suddenly increased Q Q Check items Gradually increased Q Q Hard water is...

Page 858: ...d Maintenance Manual w Oil pressure monitor if installed Indicates pressure drop at low idle w Q Q Indicates pressure drop at low high idle Q w w w Q Q Q Indicates pressure drop on slopes w Sometimes...

Page 859: ...PC800 850 8 23 40 Troubleshooting SEN00795 02...

Page 860: ...Q Q w Oil smells of diesel fuel w w Oil is milky Q Q w When engine is started drops of water come from muffler Q Q Check items When radiator cap is removed and engine is run at low idle an abnormal nu...

Page 861: ...ooler 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 c...

Page 862: ...indicates drop of coolant level if monitor is installed Q w Engine oil level has risen oil is milky w Q Fan speed is low w Check items Milky oil is floating on coolant w There are excessive air bubbl...

Page 863: ...al noise Gradually occurred Q Q Sudden occurred Q Q Q Q Non specified fuel is being used Q Oil must be added more frequently w Metal particles are found when oil filter is drained w w Air leaks betwee...

Page 864: ...f machine Operated for long period E E E Condition of vibration Suddenly increased Q Q Gradually increased Q Q Q Q Non specified fuel is being used Q Q Metal particles are found when oil filter is dra...

Page 865: ...PC800 850 8 29 40 Troubleshooting SEN00795 02...

Page 866: ...30 PC800 8 PC800SE 8 PC800LC 8 PC850 8 PC850SE 8 Hydraulic excavator Form No SEN00795 02 SEN00795 02 40 Troubleshooting...

Page 867: ...00 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 informa...

Page 868: ...val section contains procedures and precautions for implementing the work know how and the amount of oil or coolant to be drained q General tools that are necessary for removal are described as 1 2 et...

Page 869: ...lied from Komatsu in Japan i e locally made parts Disassembly q In Disassembly section the work procedures precautions and know how for carrying out those procedures and quantity of the oil and coolan...

Page 870: ...29 9140 50 g Polyethylene container Quick setting adhesive Setting time Within 5 sec to 3 min Used mainly to stick metals rubbers plastics and woods Aron alpha 201 790 129 9130 2 g Polyethylene contai...

Page 871: ...SYG2 400T A SYG2 16CNT SYG0 400T A SYG0 16CNT 400 g 16 kg Bellows type container Can Seizure resistance and heat resistance higher than molybdenum disulfide grease Not conspicuous on machine since co...

Page 872: ...lass Using limit 6 months after date of manu facture SUNSTAR PENGUINE SUPER 560 22M 54 27210 320 ml Ecocart Special container Used as adhesive for glass Using limit 6 months after date of manu facture...

Page 873: ...032 Washer t 2 Removal and instal lation of cylinder head assembly engine rear seal 2 790 331 1110 Wrench Angle q 1 Tightening of cylinder head bolt flywheel bolt Removal and instal lation of engine f...

Page 874: ...2215 11622 Nut t 2 791 181 1010 Adapter t 2 796T 627 1340 Push tool t 1 Q 790 101 2102 Puller 294 kN 30 ton t 1 Long stroke 790 101 1102 Pump t 1 4 790 627 1200 Wrench assembly t 1 Removal installatio...

Page 875: ...1540 Shackle t 2 790 401 1770 T bolt t 2 8 791 580 1520 Installer t 1 Installation of floating seal 9 790 201 2670 Plate t 1 Press fitting of track roller bushing 10 791 601 1000 or 791 646 8002 Oil p...

Page 876: ...40 Rod t 1 791 685 9550 Nut t 3 5 791 685 9510 Frame t 1 Removal press fitting of master pin and regular pin 791 685 9520 Frame t 1 791 685 9530 Rod t 1 791 685 9550 Nut t 1 791 685 9560 Bolt t 4 791...

Page 877: ...5 9530 Rod t 1 791 685 9540 Rod t 1 791 685 9550 Nut t 3 791 685 9560 Bolt t 4 791 126 0150 Adapter t 1 01010 51030 Bolt t 1 791 685 9620 Extension t 1 791 680 5560 Guide t 1 791 632 1110 Adapter t 1...

Page 878: ...0 Leg t 2 790 101 2570 Plate t 2 790 101 2560 Nut t 2 790 101 2660 Adapter t 2 Disassembly assembly of hydraulic cylinder assembly U 1 790 502 1003 Cylinder repair stand t 1 Disassembly assembly of hy...

Page 879: ...Nut t 1 01643 32780 Washer t 1 790 101 2102 Puller 294 kN 30 ton t 1 Long stroke 790 101 1102 Pump t 1 3 790 445 4120 Sleeve t 1 Removal of boom top pin and boom cylinder head pin 791 520 4140 Screw t...

Page 880: ...2 01 50 Disassembly and assembly 14 PC800 850 8 Sketches of special tools 1 Note Komatsu cannot accept any responsibility for special tools manufactured according to these sketches A4 Push tool A5 Pus...

Page 881: ...50 Disassembly and assembly SEN01052 01 PC800 850 8 15 F3 Push tool J3 Push tool...

Page 882: ...SEN01052 01 50 Disassembly and assembly 16 PC800 850 8 L4 Push tool L5 Adapter...

Page 883: ...50 Disassembly and assembly SEN01052 01 PC800 850 8 17...

Page 884: ...18 SEN01052 01 PC800 8 PC800SE 8 PC800LC 8 PC850 8 PC850SE 8 Hydraulic excavator Form No SEN01052 01...

Page 885: ...0 Disassembly and assembly1 Engine and cooling system SAA6D140E 5 Engine and cooling system 2 Removal and installation of engine PTO and hydraulic pump assembly 2 Removal and installation of cooling a...

Page 886: ...nd tubes make match marks on them After disconnect ing them install oil stopper plugs to them 1 Remove the counterweight assembly For details see Removal and installation of coun terweight assembly 2...

Page 887: ...e hose clamp 11 Lift off engine hood 8 12 Remove cover A 13 Remove cover 9 14 Remove partition cover 10 a Disconnect the hose clamp from the bot tom 15 Disconnect connectors P24B 11 and P24A 12 16 Dis...

Page 888: ...he connecting position 22 Disconnect hoses 21 25 23 Disconnect clamp 26 24 Disconnect hoses 27 30 25 Disconnect connector 31 26 Disconnect clamp 32 27 Disconnect connectors 33 and 34 28 Disconnect tub...

Page 889: ...si tion of the hose end 32 Disconnect reservoir tank hoses 41 and 42 33 Disconnect radiator hose 43 3 34 Remove radiator hose 44 4 35 Disconnect starting motor terminal 45 36 Disconnect ground wire 46...

Page 890: ...between the fan and engine a Disconnect wiring harness clamp too 46 Disconnect fuel hose 57 6 47 Disconnect connector M34 58 48 Remove air conditioner cover 59 49 Loosen the mounting bolts and discon...

Page 891: ...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 assemb...

Page 892: ...e hose 3 Tighten to torque of at least 6 Nm 0 6 kgm q When using a new hose Tighten until dimension BDG is 7 10 mm 3 Hose insertion depth 70 mm 3 Radiator hose clamp 10 8 11 8 Nm 1 1 1 2 kgm 4 Hose in...

Page 893: ...ose Install the clamp to the clamp mark made on the hose 3 Clamp bolt BC Min 6 Nm 0 6 kgm q When using a new hose Tighten until dimension BDG is as fol lows 12 15 mm MSH Main pump suction hose 7 10 mm...

Page 894: ...g operation of refrigerant R134a a Never release the refrigerant R134a to the atmosphere k If refrigerant gas R134a gets in your eyes you may lose your sight Accordingly put on protective goggles whil...

Page 895: ...orarily 12 Lift off radiator grille 9 13 Remove cover 10 14 Disconnect radiator lower hoses 13 15 1 15 Disconnect air hoses 16 and 17 2 a Make a mark at the hose end of each tube to indicate the conne...

Page 896: ...21 Disconnect connector 25 from B 22 Disconnect 3 hoses 26 and 2 hoses 27 a Prepare an oil receiver 23 Lift off frame 28 a AC Air conditioner condenser FC Fuel cooler 24 Disconnect 2 air conditioner...

Page 897: ...n depth 65 mm 3 Radiator hose clamp 10 8 11 8 Nm 1 1 1 2 kgm 2 3 MIKALOR clamp a Use a new MIKALOR clamp 1 Set the hose to the original position Insertion depth of air hose 80 mm 2 Set the bridge BR u...

Page 898: ...sor Compressor oil for R134a DENSO ND OIL8 ZEXEL ZXL100PG equivalent to PAG46 45 ml After replacement of hose between compressor and condenser 30 ml After replacement of hose between condenser and rec...

Page 899: ...le 1 and lift it off 2 Remove 3 radiator upper covers 2 3 Loosen clamps 3 of the rubber hose 1 a Make a mark at the tube of each hose end to indicate the connecting position See the following figure 4...

Page 900: ...n Insertion depth of air hose 80 mm 2 Set the bridge BR under the clamp bolt and lap it over band BD at least b reaches 5 mm 3 Tightening of the clamp a Do not use an impact wrench 2 Clamp bolt BC Lub...

Page 901: ...air conditioner circuit in advance a Ask professional traders for collecting and fill ing operation of refrigerant R134a a Never release the refrigerant R134a to the atmosphere k If refrigerant gas R...

Page 902: ...nce lowers Take care 5 Air conditioner compressor Compressor oil for R134a DENSO ND OIL8 ZEXEL ZXL100PG equivalent to PAG46 40 ml a If any air conditioner hose was replaced add compressor oil for R134...

Page 903: ...he counterweight assembly For details see Removal and installation of coun terweight assembly 2 Remove undercover 1 3 Remove undercover 2 4 Remove the hydraulic tank strainer and stop the oil with oil...

Page 904: ...ube 15 17 Disconnect reservoir tank hose 16 18 Disconnect radiator hoses 17 and 18 4 19 Remove upper tank 20 according to the fol lowing procedure 1 Remove mounting bolts 19 k Nut N welded to part P o...

Page 905: ...ight and left brackets 28 25 Disconnect hose clamp 29 26 Remove 3 covers 30 27 Remove cover 31 28 Disconnect 3 hoses 32 a Prepare an oil receiver a Before disconnecting each hose mark it with a tag et...

Page 906: ...valve piping and connectors of the engine Part R 4 Fan and fan motor assembly 100 kg 32 Remove lock plate 36 5 33 Remove bolt 37 and fan assembly 38 6 a Do not remove the fan assembly by hitting it wi...

Page 907: ...sion BDG is 7 10 mm 4 Hose insertion depth 70 mm 3 Radiator hose clamp 10 8 11 8 Nm 1 1 1 2 kgm 5 Do not match the bolt holes of the lock plate by turning in the loosening direction If bolt hole does...

Page 908: ...the drain valve to drain the fuel 6 Fuel tank 980 l When full 2 Remove handrail 1 3 Remove cover 2 4 Remove control valve cover bracket 3 5 Disconnect fuel return hose 4 a Disconnect the hose clamp t...

Page 909: ...053 01 PC800 850 8 25 10 Remove the mounting bolts and lift off fuel tank assembly 11 1 4 Fuel tank assembly 640 kg Installation q Carry out installation in the reverse order to removal 1 3 Fuel tank...

Page 910: ...26 SEN01053 01 PC800 8 PC800SE 8 PC800LC 8 PC850 8 PC850SE 8 Hydraulic excavator Form No SEN01053 01...

Page 911: ...50001 and up PC850 8 10001 and up PC850SE 8 10001 and up 50 Disassembly and assembly1 Engine SAA6D140E 5 Engine SAA6D140E 5 2 Removal and installation of fuel supply pump assembly 2 Removal and insta...

Page 912: ...e the engine hood For details see Removal and installation of cylinder head assembly 3 Remove cover 1 from air conditioner com pressor 2 4 Disconnect connector M34 3 5 Loosen locknut 4 and disconnect...

Page 913: ...G 14 a Disconnect the wiring harness clamp 15 Loosen bracket 15 16 Disconnect clamps 16 and 17 17 Remove brackets 18 and 19 18 Remove 4 covers 20 a Remove 2 from the fuel supply pump side and 2 from t...

Page 914: ...that bolt hole H is set to the tap hole of the fuel supply pump drive gear a If the bolt hole is not set accurately bar the engine one more turn The bolt hole is set when the key is on the upper side...

Page 915: ...on the common rail side down 7 Install bracket 15 8 Tighten the brackets and upper and lower clamps of high pressure pipe clamps 16 17 and 19 temporarily with the fingers and then tighten them permane...

Page 916: ...9 12 7 Nm 0 8 1 3 kgm Supply pump side 3 Joint bolt of lubrication tube 23 9 8 12 7 Nm 1 0 1 3 kgm Block side 3 Clamp of lubrication tube 23 and fuel tube 24 assembly 9 8 1 Nm 1 0 0 1 kgm 9 3 Fuel tub...

Page 917: ...terweight assembly For details see Removal and installation of coun terweight assembly 2 Remove undercover 1 3 Drain the coolant 6 Coolant 100 l 4 Remove front and rear covers 2 and 3 5 Open engine ho...

Page 918: ...rvoir tank hose 10 from cover 11 bottom 13 Lift off cover 11 14 Disconnect hose 12 1 15 Disconnect hose 13 16 Remove air cleaner 14 2 17 Disconnect clamp 15 18 Remove bracket 16 19 Remove bracket 17 2...

Page 919: ...connector 25 26 Remove air connector 25 27 Remove bracket 26 28 Remove cover 27 29 Remove bracket 28 30 Remove fuel filter and bracket assembly 29 5 31 Disconnect wiring harnesses 30 and 31 32 Disconn...

Page 920: ...l return tube 44 10 42 Remove fuel tube 45 11 43 Remove turbocharger cooling tube 46 12 44 Disconnect turbocharger lubrication tube 47 a Disconnect the lubrication tube in order through the procedure...

Page 921: ...n tube 47 after removing the exhaust manifold 52 Lift off diffuser 56 a When removing take care not to hit spout M Exhaust side 53 Remove covers 57 60 54 Remove cover 61 55 Remove turbocharger cooling...

Page 922: ...77 21 4 Turbocharger exhaust manifold and con nector assembly 70 kg 68 Disconnect wiring harness 78 a White portion w is sealing tape applied to cover the hole 69 Disconnect lubrication tubes 79 and 8...

Page 923: ...ttom of air hous ing assembly 87 23 76 Remove air housing assembly 87 77 Disconnect high pressure pipe clamps 89 a There are the same clamps on the right side too 78 Disconnect breathers 90 79 Remove...

Page 924: ...ollowing procedure Insert flat head screwdriver 3 in shoulder a While pressing stopper b move the screw driver in direction X and connector c is disconnected d Fuel injector wiring side 90 Disconnect...

Page 925: ...tor assembly 110 a Insert small L bar 2 under connector CN of fuel injector 110 and pry off fuel injector 110 slowly a Never hold and pull out the solenoid valve on the top of fuel injector 110 with p...

Page 926: ...Check that the cylinder head mounting face and inside of the cylinder are free from foreign matter 5 When fitting the gasket check that the grommets are fitted correctly 1 Set cylinder head gasket 11...

Page 927: ...or a Check that the inside of the injector sleeve is free from dirt 1 Install gasket 120 and O ring 121 to fuel injector 110 2 O ring Engine oil EO30 2 Install holder 122 in fuel injector 110 then ins...

Page 928: ...ure pipe inser tion part and tighten it temporarily a Check that the O rings are fitted to both of the injector and sleeve nut 2 Rotate sleeve nut 127 by 2 turns with the fingers on the threads of the...

Page 929: ...slit as follows Cylinder head side Direct the slit down Common rail side Direct the slit toward the cylinder block 11 Install fuel spill tube 104 3 Fuel spill tube joint bolt 9 8 12 7 Nm 1 0 1 3 kgm...

Page 930: ...ghten brackets 96 and 97 perma nently 7 Tighten high pressure pipe clamp 99 permanently 3 Clamping bolt 9 8 1 Nm 1 0 1 kgm 8 Tighten stays 128 permanently q Carry out the following installation in the...

Page 931: ...8 12 7 Nm 1 0 1 3 kgm 11 3 Fuel tube 45 14 8 19 6 Nm 1 5 2 0 kgm Supply pump side 12 3 Joint bolt of turbocharger cooling tube 46 24 5 34 3 Nm 2 5 3 5 kgm 13 1 Set the connector groove in position an...

Page 932: ...eric order 2 Mounting bolt Anti seizure compound LC G 3 Mounting bolt 59 74 Nm 6 7 5 kgm 22 3 Joint bolt of lubrication tubes 80 and 84 24 5 34 3 Nm 2 5 3 5 kgm 3 Mounting bolt of EGR valve 85 and byp...

Page 933: ...r intake manifold assembly 1 For details see Removal and installation of cylinder head assembly 3 Remove clamp 2 4 Remove brackets 3 5 Remove covers 4 a Remove the common rail side too 6 Remove the cl...

Page 934: ...ure 1 Remove 2 nuts 12 of the upper solenoid valve of fuel injector 11 2 Pull out spring clamp 13 3 Disconnect clamp 14 a Remove the injector wiring harness according to the following procedure 1 Remo...

Page 935: ...installing the parts observe the precau tions described in Removal and installation of cylinder head assembly 1 Procedure for installing fuel injector wiring harness assembly a It is difficult to ins...

Page 936: ...t tool A3 to the drilled holed Tip Drill type 3 Remove the front seal with impacts of slide hammer SH a Remove all the chips q Tool A3 Installation 1 Install front seal 2 a Before installing the seal...

Page 937: ...the seal remove plastic inside cylinder 6 a When removing the inside cylinder take care not to damage the seal lip 4 Tighten the bolts of tool A6 evenly to press fit seal 2 until the end of tool A6 re...

Page 938: ...dure a Measure the distance from the end of the housing 1 Before pulling out rear seal 2 drive in it a little to separate it from the flywheel hous ing FWH 2 If the seal is sleeved cut and remove slee...

Page 939: ...q Standard spare seal q Sleeved seal a Clean degrease and dry the seal surface on the flywheel housing side a Clean degrease and dry the seal lip sur face periphery of the crankshaft a Before installi...

Page 940: ...surface C Gasket sealant LG 7 2 Set sleeve 5 of the rear seal to the end of crankshaft 4 and tighten the 3 bolts evenly to press fit sleeve and rear seal assembly 6 until the end of tool A5 reaches t...

Page 941: ...ting bolts 1st time 118 4 9 Nm 12 0 5 kgm 2nd time 1 When using tool A2 See the tools list Retighten each bolt by 90 in the order of 1 8 2 When not using tool A2 Make marks on each bolt and fly wheel...

Page 942: ...32 SEN01054 01 PC800 8 PC800SE 8 PC800LC 8 PC850 8 PC850SE 8 Hydraulic excavator Form No SEN01054 01...

Page 943: ...up PC850SE 8 10001 and up 50 Disassembly and assembly1 Power train Power train 2 Removal and installation of PTO coupling assembly 2 Disassembly and assembly of PTO coupling assembly 9 Removal and ins...

Page 944: ...sing tool S1 remove the drain plug and drain the oil 6 Hydraulic tank Approx 470 l 2 Drain the oil from the PTO case 6 PTO case Approx 6 l 3 Remove main pump and cooling fan pump assembly 1 For detail...

Page 945: ...3 7 Lift off bracket 3 Lower it 8 Disconnect clamps 8 and 9 9 Remove bracket 10 10 Disconnect hoses 11 and 12 11 Disconnect 2 dust indicator hoses 13 12 Disconnect clamps 14 and 15 a Disconnect the c...

Page 946: ...mp 26 24 Remove right and left mounting bolts 27 3 a The nut plate falls at this time Take care 25 Install M30 eyebolts B to the right and left and sling engine and PTO assembly 28 tempo rarily with s...

Page 947: ...not replace the main pump Refer to Installation of main pump Preparation 1 Each 2 units of pin gauge Pin 7 50 mm diameter notch height of 6 30 mm for the bore of module of 3 75 mm Pin 6 75 mm diameter...

Page 948: ...spline of coupling a Face the notch of pin gauge B4 to the spline side a When pasting the pin gauge in X direction 4 Using the micrometer for the bore 125 150 mm 1 measure the spline over pin dimensio...

Page 949: ...nd adjusting air conditioner compres sor belt 2 3 3 Engine mounting bolt and PTO bracket mounting bolt 823 8 1029 7 Nm 84 105 kgm 4 a Degrease the bolt and tap hole 2 Mounting bolt Adhesive LT 2 3 Mou...

Page 950: ...a FW Flywheel q Table for judging hub assembly fitting dimen sion a q Refilling with oil PTO case Add oil through the oil filler to the specified level a Summer 0 40 C TO30 a Winter 30 10 C TO10 5 PTO...

Page 951: ...embly 1 Disassembly 1 Remove PTO assembly 1 For details see Removal and installation of PTO assembly 2 Remove snap rings 2 and 3 3 Raise PTO assembly 1 4 Lightly hit periphery A of shaft assembly 4 on...

Page 952: ...lean all the parts and check them for dirt or damage Coat their sliding surfaces with engine oil before installing 1 Using push tools 1 and 3 install bearing 6 to shaft 5 2 Bearing Grease G2 LI 2 Inst...

Page 953: ...s on them After disconnecting them install oil stopper plugs to them and swing motor assembly a Prepare an oil receiver a Rear side 1 Disconnect hoses 1 and 2 coming from the control valve and hoses 3...

Page 954: ...lation q Carry out installation in the reverse order to removal 1 3 Swing motor and swing machinery assembly mounting bolt 926 7 102 9 Nm 94 5 10 5 kgm q Refilling with oil Hydraulic tank a Add oil th...

Page 955: ...her 2 2 Remove No 1 sun gear 3 3 Remove No 1 carrier assembly 4 4 Disassemble No 1 carrier assembly as follows 1 Push in pin 5 and knock out shaft 6 from carrier 7 a After removing the shaft remove pi...

Page 956: ...r assembly 17 before removing the washer 7 No 2 carrier assembly Lift No 2 carrier assembly 17 and remove it 8 Disassemble No 2 carrier assembly as follows 1 Push in pin 18 and knock out shaft 19 from...

Page 957: ...push tool F3 remove pinion shaft assembly 30 with press a Set a wooden block under the press and be careful not to damage the pin ion shaft assembly when removing it 10 Disassemble pinion shaft assem...

Page 958: ...sealant LG 6 a Be careful not to let the gasket seal ant LG 6 get on the oil seal lip when press fitting 2 Fit cover assembly 27 to case 35 and tighten mounting bolts 28 2 Cover mounting surface Gaske...

Page 959: ...of the caulking when the pin is inserted at the end face of hole h at the side of the carrier so remove the caulked metal from the inside diameter of the hole before starting to assemble 1 Assemble be...

Page 960: ...and button 36 4 Install thrust washer 13 7 Ring gear Lift ring gear 12 and install it a Apply gasket sealant to the periphery of the oil level check hole only 2 Mating face of ring gear and case Gaske...

Page 961: ...portion of the carrier a After assembling the carrier assembly check that gear 9 rotates smoothly 9 No 1 carrier assembly Install No 1 carrier assembly 4 10 No 1 sun gear 1 Assemble No 1 sun gear 3 t...

Page 962: ...wire then lift off swing circle assembly 3 2 4 Swing circle assembly 1 263 kg 5 Remove seal 4 Installation q Carry out installation in the reverse order to removal 1 2 Mounting bolt Thread tightener L...

Page 963: ...carrier assembly 2 Symbol Part number Part name Necessity Q ty N R Sketch J 1 796 627 1050 Installer t 1 2 796 627 1030 Push tool t 1 3 790 101 2300 Push puller t 1 790 101 2310 Block t 1 790 101 235...

Page 964: ...t 5 and remove gear assem bly 6 iv Remove bearings 7 and spacer 8 from gear 6 a If the parts are to be used again make match marks to prevent any change in the combination with the outer race v Remove...

Page 965: ...e outer races 18 8 Spacer Remove spacer 19 from shaft 41 9 No 2 carrier assembly 1 Using eyebolts 5 remove No 2 carrier assembly 20 2 Disassemble No 2 carrier assembly as follows i Knock pin 21 into s...

Page 966: ...ft iii Pull out gear 35 from carrier 36 then remove thrust washer 37 and bearing 38 14 No 1 ring gear Remove No 1 ring gear 39 15 No 1 sun gear Remove No 1 sun gear 40 16 Thrust washer Remove thrust w...

Page 967: ...side cir cumference facing the motor 4 Spacer Install spacer 31 5 No 1 carrier assembly 1 Assemble No 1 carrier assembly as follows a There are the remains of the caulking when the pin is inserted at...

Page 968: ...ore starting to assemble iii Assemble bearing 25 to gear 23 put thrust washer 24 in contact with both ends then set to carrier 27 iv Align position of pin holes of carrier and shaft then tap with a pl...

Page 969: ...grease from the O ring and O ring contact surface and dry the parts before installing the floating seal a After installing the floating seal check that the angle of the floating seal is within 1 mm a...

Page 970: ...allation of hub assembly Using eyebolts 4 install hub assembly 15 to shaft 41 6 Outside bearing Install bearing 16 7 Install nut as follows i Set tool J3 in position ii Push bearing inner race portion...

Page 971: ...ircumference facing up out side 12 No 3 carrier assembly 1 Assemble No 3 carrier assembly as follows i Using tool J7 press fit outer race 9 to gear 46 ii Assemble bearing 7 and spacer 8 to gear 46 and...

Page 972: ...No 3 carrier assembly 2 a Align the low portion 4 places of spacer 19 and shaft 41 with the carrier assembly holder a Align the bolt holes also 13 No 3 sun gear 1 Install thrust washer 11 to No 3 sun...

Page 973: ...50 Disassembly and assembly SEN01055 01 PC800 850 8 31...

Page 974: ...32 SEN01055 01 PC800 8 PC800SE 8 PC800LC 8 PC850 8 PC850SE 8 Hydraulic excavator Form No SEN01055 01...

Page 975: ...tallation of idler assembly 8 Disassembly and assembly of idler assembly 9 Disassembly and assembly of idler adjustment cylinder assembly 12 Removal and installation of recoil spring assembly 13 Disas...

Page 976: ...ator 1 more than one turn a If the track tension is not relieved even when the lubricator is loosened move the machine backwards and forwards 3 Using tool M pull out master pin 4 Fit block or hydrauli...

Page 977: ...llation 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 3 Lubricator 73 5 14 7 Nm 7 5 1 5 kgm 2 a Assem...

Page 978: ...Puller 2 t 1 7 791 680 5542 Adapter t 1 791 632 1110 Adapter t 1 8 791 680 5580 Guide t 1 N 9 791 685 9510 Frame t 1 791 685 9520 Frame t 1 791 685 9530 Rod t 1 791 685 9540 Rod t 1 791 685 9550 Nut...

Page 979: ...rack bolts for bolt 2 3 Assemble tool N2 pump cylinder 1471 kN 150 ton and tool N3 frame rod adapter bolt 1 eyebolt then raise chassis and set on track 4 Insert rod of tool N4 from cylinder end and in...

Page 980: ...tion 6 Similarly pull out another pin 3 7 Set tool N6 294 kN 30 ton puller and spacer 1 to center of roller tread of link to be disas sembled then apply hydraulic pressure to puller and open link 5 6...

Page 981: ...guide adapter bolt for press fitting bushing and press fit in turn 5 Use tool N13 294 kN 30 ton puller in same way as when disassembling and push open link 5 at bushing end 6 Set link 6 at pin end to...

Page 982: ...Removal 1 Remove track shoe assembly For details see Removal and installation of track shoe assembly 2 Remove idler assembly 1 a Pull out the idler assembly then lift off the idler and adjustment cyli...

Page 983: ...blocks 1 remove bolt and nut 2 then remove support 3 3 Remove floating seal 4 4 Turn over idler assembly remove bolt and nut 5 then remove support 6 5 Remove shaft 8 from idler 6 Remove floating seal...

Page 984: ...e floating seals 4 from supports 3 and 6 Assembly a Clean all parts and check for dirt or damage 1 Using tool L2 assemble floating seals 4 to supports 3 and 6 2 Using tool L1 press fit bushings 10 and...

Page 985: ...ng inside 6 Assemble support 6 to shaft a Align the groove in the support with the groove in the shaft when assembling 7 Install bolt and nut 5 and secure support 6 8 Turn over idler and assemble supp...

Page 986: ...2 from yoke 1 2 Remove snap ring 3 from plunger 2 and then remove packing 4 backup ring 5 and wear ring 6 3 Remove dust seal 7 from yoke 1 Assembly 1 Install wear ring 6 to plunger 2 2 Assemble backup...

Page 987: ...mbly 3 Recoil spring assembly 1 Remove No 2 and No 3 track roller assemblies For details see Removal and installation of track roller assembly 2 After removing track roller assembly install tool 1 a W...

Page 988: ...SEN01056 01 50 Disassembly and assembly 14 PC800 850 8 Fig 1 for tool 1...

Page 989: ...0 ton 2 Apply hydraulic pressure slowly to compress spring then remove lock plate and remove nut 2 3 Release hydraulic pressure gradually to relieve tension of spring then remove recoil spring assembl...

Page 990: ...tool M3 k The recoil spring is under large installed load so be sure to set the parts properly Failure to do this is dangerous 3 Apply hydraulic pressure slowly to compress spring so that installed le...

Page 991: ...rack shoe tension in Testing and adjusting 2 Use the hydraulic jack 1 to push up the track shoe 3 Remove 4 pieces of mounting bolt 1 4 Lift carrier roller assembly 2 and remove it a Take out the carri...

Page 992: ...bly of support 2 shaft 3 and roller 4 a Remove floating seal 5 from support 2 4 Push the end face of shaft 3 and remove shaft 3 bearing 6 and spacer 8 from roller 4 5 Remove the assembly of roller 4 a...

Page 993: ...ompletely and dry them 7 Mount floating seal 5 on another roller 4 8 Assemble floating seal 5 in support 2 by using tool L6 9 Press fit the shaft 3 in roller 4 a Check that floating seal 5 was assem b...

Page 994: ...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 5 Lubricating oil 300 350cc GO140 13 After f...

Page 995: ...equipment push up track frame on side which is to be removed k After jacking up the chassis set a block on the track shoe 4 Using tool L7 remove track roller assembly 2 1 4 Track roller assembly S fla...

Page 996: ...ed with 420 480 cc of oil so drain the oil at this point or lay a cloth to prevent the area from becoming dirty 5 Remove floating seal 6 on opposite side from roller 4 and collar 8 6 Remove pin 7 then...

Page 997: ...g the floating seal check that the angle of the seal is less than 1 mm and that the protrusion of the seal is within a range of 5 7 mm 4 Using tool L9 install floating seals 6 and 3 to roller 4 a For...

Page 998: ...age of air from seal a Standard pressure 0 1 MPa 1 kg cm2 a Method of checking The standard pressure shall be main tained for 10 seconds and the indicator of the gauge shall not go down 10 Using tool...

Page 999: ...mbly 3 Disconnect 4 grease tubes 1 4 Remove all revolving frame mounting bolts 2 except 3 4 pieces at the front and rear 1 a While running the engine and swinging the upper structure remove the mounti...

Page 1000: ...e leans toward the operator s cab adjust it with lever blocks etc 4 Revolving frame assembly Approx 19 500 kg a The weight of the revolving frame of PC800LC 8 for USA is approximately 20 000 kg Instal...

Page 1001: ...kg PC850 9 800 kg PC800 Installation q Carry out installation in the reverse order to removal 1 a Adjust the level difference from the exterior parts with shims top and bottom clearances a Adjust the...

Page 1002: ...ore disconnecting each hose mark it with a tag etc to indicate its position 1 Remove the mounting bolts and lower counter weight 2 1 a Width across flats of mounting bolt 65 mm k Loosen the cap of the...

Page 1003: ...assembly 11 4 Counterweight remover assembly 1 270 kg Installation q Carry out installation in the reverse order to removal 1 3 Counterweight mounting bolt 3 430 4 212 Nm 350 430 kgm q Refilling with...

Page 1004: ...30 SEN01056 01 PC800 8 PC800SE 8 PC800LC 8 PC850 8 PC850SE 8 Hydraulic excavator Form No SEN01056 01...

Page 1005: ...n of cooling fan pump assembly 13 Removal and installation of control valve assembly 16 Assembly of control valve assembly 19 Removal and installation of swing motor assembly 25 Removal and installati...

Page 1006: ...nk a Before disconnecting the hoses make match marks on them a Install oil stopper plugs to the disconnected tubes and hoses 1 Drain the hydraulic oil 6 Hydraulic oil 470 l 2 Remove control valve cove...

Page 1007: ...ank 15 Remove 4 mounting bolts 22 and disconnect case 23 from the hydraulic tank 16 Lift off hydraulic tank assembly 24 1 4 Hydraulic tank assembly 640 kg a In the photo case 23 is removed without bei...

Page 1008: ...l 1 2 Mounting bolt Adhesive LT 2 3 Hydraulic tank mounting bolt 549 58 Nm 56 6 kgm q Refilling with oil Hydraulic tank Circulate the oil through the system and then check the oil level again 5 Hydrau...

Page 1009: ...ounterweight assembly For details see Removal and installation of coun terweight assembly 2 Remove pump undercovers 1 and 2 3 Remove the hydraulic tank strainer and stop the oil with oil stopper tool...

Page 1010: ...nnect filter 7 a Disconnect the hose clamp 9 Lift off engine hood 8 10 Remove cover A 11 Remove cover 9 12 Remove reservoir tank hose 10 from the bot tom of cover 11 13 Lift off cover 11 14 Disconnect...

Page 1011: ...nect branch hose 26 and outlet hose 27 27 Disconnect clamp 28 28 Disconnect suction tube 29 from the pump a Since the hose side is fixed with MIKALOR clamps do not disconnect the hose When disconnecti...

Page 1012: ...nd main pump drain hose 35 33 Disconnect breather hose 36 and EPC basic pressure hose 37 34 Disconnect clamp 38 from the bottom of main pump assembly 39 35 Sling main pump assembly 39 temporarily and...

Page 1013: ...mm Pin 6 75 mm diameter for the outside diameter 2 Vaseline for pasting pin gauge 3 Micrometer for the bore 75 100 mm 4 Micrometer 75 100 mm 1 Apply Vaseline to pin gauge S2 and paste it on to the sha...

Page 1014: ...between B2 of the PTO side coupling from X and Y directions of portions A and B at 4 locations in total a OK Between B2 is less than 76 26 mm a Measuring in direction X and Y of portion A q Carry out...

Page 1015: ...BD at least b reaches 5 mm 4 Tightening of the clamp a Do not use an impact wrench 2 Clamp bolt BC Lubricating oil THREEBOND PANDO 18B q When reusing the hose Install the clamp to the clamp mark made...

Page 1016: ...l seal 4 4 Installation q Carry out installation in the reverse order to removal 1 a When installing cover 1 put the special cap to the shaft to protect the oil seal 3 Cover mounting bolt 27 34 Nm 2 8...

Page 1017: ...a Before disconnecting the hoses and tubes make match marks on them After disconnect ing them install oil stopper plugs to them 1 Remove pump undercovers 1 and 2 2 Remove the hydraulic tank strainer...

Page 1018: ...isconnect EPC solenoid connector V13 13 11 Lift off cooling fan pump assembly 14 1 4 Cooling fan pump assembly 40 kg Installation q Carry out installation in the reverse order to removal 1 3 Fan mount...

Page 1019: ...clamp to the clamp mark made on the hose 3 Clamp bolt BC Min 6 Nm 0 6 kgm q When using a new hose Tighten until dimension BDG is as follows 12 15 mm MSH Main pump suc tion hose 7 10 mm FSH Fan pump su...

Page 1020: ...eleasing residual pres sure from hydraulic circuit a Before disconnecting the hoses and tubes make match marks on them a Install oil stopper plugs to the disconnected hoses and tubes 1 Drain the oil f...

Page 1021: ...mounting bolts 15 and remove 4 spool control valve assembly 16 4 4 spool control valve assembly 250 kg 5 spool control valve 12 Disconnect the lower back pressure compen sation valve hose and sensor...

Page 1022: ...arry out installation in the reverse order to removal a Install tube 51 adjust the position of the valve and tighten valve assembly mounting bolts 52 3 Control valve assembly mounting bolt 279 29 Nm 2...

Page 1023: ...sassembly and assembly SEN01057 01 PC800 850 8 19 Assembly of control valve assembly 1 a In this section only the precautions for assem bling the control valve assembly are described 4 spool control v...

Page 1024: ...EN01057 01 50 Disassembly and assembly 20 PC800 850 8 Precaution 1 Arm Hi AH bucket Lo BKL and boom Lo BML spools must be installed in the correct directions Take care not to install opposite directio...

Page 1025: ...ops approx 0 04 g of LOCTITE No 638 3 Plug PL 137 8 19 6 Nm 14 2 kgm 3 Apply liquid seal equivalent to SEALEND No 242 to the threaded portion of plug PS 2 Threaded portion of plug PS Liquid seal equiv...

Page 1026: ...SEN01057 01 50 Disassembly and assembly 22 PC800 850 8 5 spool control valve...

Page 1027: ...50 Disassembly and assembly SEN01057 01 PC800 850 8 23 Precaution 1 Arm Lo AML and bucket Hi BKH spools must be installed in the correct directions Take care...

Page 1028: ...o 638 to the threads of plug PL 2 Threads of plug PL 2 drops approx 0 04 g of LOCTITE No 638 3 Plug PL 137 8 19 6 Nm 14 2 kgm 3 Apply liquid seal SEALEND No 242 or equiv alent to the threads of plug P...

Page 1029: ...il tank Center side of the machine body 1 Separate hoses 1 and 2 from the control valve and separate hoses 3 and 4 from the swing motor positioned in the front section of the machine body 2 Separate s...

Page 1030: ...moval procedure 3 Swing motor assembly mounting bolt 926 7 102 9 Nm 94 5 10 5 kgm q Filling the oil Hydraulic tank a Fill the oil to the stipulated level from the oil filler port and circulate the oil...

Page 1031: ...ydraulic circuit a Before disconnecting the hoses make match marks on them After disconnecting them install oil stopper plugs to them and center swivel joint assembly a Prepare an oil receiver 1 Separ...

Page 1032: ...in the lower sec tion of the swivel joint install the swivel joint so that the A port may be directed to the front RH side q Filling the oil Hydraulic tank a Fill the oil to the stipulated level from...

Page 1033: ...ll out swivel rotor 4 and ring 3 from swivel shaft 5 4 Remove O rings 6 and slipper seals 7 from swivel rotor 4 Symbol Part number Part name Necessity Q ty N R Sketch T 790 101 2501 Push puller t 1 79...

Page 1034: ...en using push tool 1 tap swivel rotor 4 with a plastic hammer to install 2 Contact surface of rotor shaft Grease G2 LI a When installing the rotor be extremely careful not to damage the slipper seal a...

Page 1035: ...n 4 Remove remaining mounting bolts then pull out travel motor assembly 6 and sling 2 5 Lift off travel motor assembly 6 3 4 Travel motor assembly 140 kg Installation q Carry out installation in the r...

Page 1036: ...tool box 1 positioned in front of the hydraulic oil tank 2 Disconnect wiring connectors 2 V9 and V10 3 Remove nuts 3 and remove coils 4 a V9 and V10 Boom damping solenoid valve 2 Straight travel valv...

Page 1037: ...1 Access through hole 1 on the bottom of the revolving frame 2 Disconnect wiring connector 2 V14 3 Remove coil 3 a V14 Swing priority selector valve Installation q Carry out installation in the rever...

Page 1038: ...1 Remove tool box 1 positioned in front of the hydraulic oil tank 2 Disconnect solenoid wiring connectors 2 V9 and V10 3 Disconnect 4 pcs of hoses 3 and 4 between the solenoid valve and the damping v...

Page 1039: ...on to P1 P2 P3 and P4 a The location of each port is stamped at the lower part of the valve body 2 Piston 7 Grease G2 LI a When installing piston 7 apply grease to the outside of the piston and inside...

Page 1040: ...aces of piston and disc 2 Grease of 0 3 0 8 cc G2 LI 3 Nut 1 69 78 Nm 7 8 kgm a After installing the disc see Testing and adjust ing Adjusting work equipment swing PPC valve a Take care of the directi...

Page 1041: ...ts of shaft 6 contacting parts of lever 7 and pis ton 1 and contacting parts of the lever of damper 9 and pin 8 2 Quantity of grease G2 LI to be applied Rocking parts of shaft 6 4 8 cc periphery Conta...

Page 1042: ...s Bucket cylinder for standard specification Screw size M12 pitch 1 75 a If screw 3 has been caulked strongly and cannot be removed screw it in fully then fit a tap to the thread and pull it out Symbo...

Page 1043: ...ble to Boom and arm cylinder for stan dard and SE specifications Bucket cylinder for standard specification iv Remove 6 screws 21 then remove spacer 22 and remove piston assembly 4 and O ring back up...

Page 1044: ...ve O ring and backup ring 15 2 Remove snap ring 16 then remove dust seal 17 3 Remove rod packing 18 4 Remove buffer ring 19 5 Remove bushing 20 Assembly a Be careful not to damage the packings dust se...

Page 1045: ...ear rings 12 5 Assemble rings 11 a Be careful not to open the end gap of the ring too wide 2 Ring groove Grease G2 LI 3 Piston rod assembly 1 Set piston rod assembly 2 to tool U1 2 Assemble head assem...

Page 1046: ...2 or piston assembly 4 a For the rod with bottom cushion mark the cushion plug position on the end face of the rod q Applicable to arm cylinder a Screw in until piston assembly 4 contacts end face of...

Page 1047: ...Loctite No 262 or equivalent 3 Screw 21 245 309 Nm 25 31 5 kgm q Applicable to bucket cylinder of SE specification 8 Assemble piston rod assembly 2 2 Seal portion Grease G2 LI a Set the end gap of th...

Page 1048: ...ortion 3 Joint screwing portion 5 9 11 8 Nm 0 6 1 2 kgm 2 Install gun assembly 2 to joint 1 a Wind seal tape two to three times around the threaded portion as to bite into it start ing from a position...

Page 1049: ...50 Disassembly and assembly SEN01057 01 PC800 850 8 45...

Page 1050: ...46 SEN01057 01 PC800 8 PC800SE 8 PC800LC 8 PC850 8 PC850SE 8 Hydraulic excavator Form No SEN01057 01...

Page 1051: ...mbly and assembly1 Work equipment Work equipment 2 Removal and installation of bucket cylinder assembly 2 Removal and installation of arm cylinder assembly 6 Removal and installation of boom cylinder...

Page 1052: ...details see Testing and adjusting Releasing remain ing pressure from hydraulic circuit 4 Disconnect 2 hoses 3 a Fit plugs in the hoses to prevent dust or dirt from entering 5 Sling bucket cylinder as...

Page 1053: ...n the hole a Adjust with shims 9 so that the clearance b between bracket 8 and the end face of bottom of cylinder 5 is less than 1 mm q Shim thickness 0 8 mm STD LC 1 0 mm SE q Bleeding air a Bleed th...

Page 1054: ...m entering 1 Sling bucket cylinder assembly and remove plate then using forcing screws Thread dia 16 mm Pitch 2 0 mm remove pin 1 1 4 Pin 40 kg 2 Start engine and retract piston rod fully k Tie the ro...

Page 1055: ...g the mounting position of the pin do not insert your fingers in the pin hole a Adjust with shims so that the clearance at the cylinder bottom end is less than 1 mm a Bleed the air from the work equip...

Page 1056: ...release the remain ing pressure in the circuit For details see Testing and adjusting Releasing pressure in hydraulic circuit 5 Disconnect hose 4 and grease hose 5 a Fit plugs in the hoses to prevent...

Page 1057: ...g pin Anti friction compound LM P 2 Grease after assembling pin Grease LM G k When aligning the position of the pin hole never insert your fingers in the hole a Adjust with shims 10 so that clearance...

Page 1058: ...ntering 1 Sling arm cylinder assembly and remove plate then using forcing screws Thread dia 16 mm Pitch 2 0 mm pull out pin 2 1 a Pull out the pin to a position where the pis ton rod can be disconnect...

Page 1059: ...g the mounting position of the pin do not insert your fingers in the pin hole a Adjust with shims so that the clearance at the cylinder bottom end is less than 1 mm a Bleed the air from the work equip...

Page 1060: ...tart engine and retract piston rod then tie pis ton rod with wire to prevent it from coming out k Stop the engine and release the remain ing pressure in the circuit For details see Testing and adjusti...

Page 1061: ...hole 2 2 Inside surface of bushing when assembling pin Anti friction compound LM P 2 Grease after assembling pin Grease LM G k When aligning the position of the pin hole never insert your fingers in...

Page 1062: ...rom entering 1 Disconnect grease hose 1 2 Remove plate 2 3 Sling boom cylinder assembly then using forc ing screws Thread dia 16 mm Pitch 2 0 mm pull out pin 3 and disconnect piston rod from boom 1 4...

Page 1063: ...ng the mounting position of the pin do not insert your fingers in the pin hole a Adjust with shims so that the clearance at the cylinder bottom end is less than 1 mm a Bleed the air from the work equi...

Page 1064: ...After stopping the engine release the pressure inside the piping For details see Testing and adjusting Releasing pressure in PPC circuit 4 Remove hoses 3 5 Remove 3 mounting bolts then using forcing...

Page 1065: ...2 7 Start engine and raise work equipment discon nect arm from bucket then remove bucket assembly 4 Bucket assembly 2 960 kg PC800 PC800LC 3 920 kg PC850 3 435 kg PC800SE 3 870 kg PC850SE Installation...

Page 1066: ...k Bind the piston rod with wires etc to prevent it from coming out 4 Pin 37 kg k After stopping the engine release the resid ual pressure in the piping For details see Testing and adjusting Releasing...

Page 1067: ...a If the pin does not come out use tool V2 and remove the pin from the head end 6 Start engine and retract piston rod then tie pis ton rod with wire to prevent it from coming out k Stop the engine and...

Page 1068: ...ing pin Grease LM G k When aligning the position of the pin hole never insert your fingers in the hole 2 2 Inside surface of bushing when assembling pin Anti friction compound LM P 2 Grease after asse...

Page 1069: ...rcuit 4 Disconnect right and left bottom dump cylinder hoses 2 5 Disconnect right and left bucket cylinder hoses 3 and 4 2 pieces on each side 6 Sling arm assembly and remove 3 mounting bolts then usi...

Page 1070: ...m cylinder assembly 3 Disconnect headlamp wiring connector A13 1 4 Disconnect bucket cylinder hose 2 and arm cylinder hose 3 5 Disconnect hose 4 6 Disconnect clamp 5 7 Disconnect hose 6 8 Sling boom a...

Page 1071: ...on of the pin hole never insert your fingers in the hole a Adjust with shims so that clearance a between bracket 4 and the end face of the foot of boom 3 is less than 1 mm q Shim thickness 1 0 1 5 mm...

Page 1072: ...f boom to sup port boom 4 Remove boom cylinder from boom For details see Removal and installation of boom cylinder assembly a Remove the boom cylinder on the other side from the boom in the same way 5...

Page 1073: ...2 k When aligning the mounting position of the pin do not insert your fingers in the pin hole a Bleed the air from the work equipment circuit For details see Testing and adjusting Bleed ing air from...

Page 1074: ...lic circuit 1 Referring to the section Removal and installa tion of the boom cylinder assembly separate the boom cylinder assembly from the boom 2 Disconnect headlamp wiring connector A13 1 3 Disconne...

Page 1075: ...ure 1 2 To the inner surface of the bushing when assembling the pin Anti friction material LM P 2 Greasing after assembling the pin Grease LM G k When matching the position of the pin hole never inser...

Page 1076: ...assembly 2 Disconnect bottom dump cylinder hose 1 bucket cylinder hoses 2 and arm cylinder hoses 3 a When the hoses are disconnected oil may spurt out so loosen the hose flanges slowly before disconne...

Page 1077: ...sert your fingers in the pin hole a Adjusting the lifting height of the boom assem bly so that the boom foot is at the height of the mount on the chassis a Bleed the air from the work equipment circui...

Page 1078: ...28 SEN01058 00 PC800 8 PC800SE 8 PC800LC 8 PC850 8 PC850SE 8 Hydraulic excavator Form No SEN01058 00...

Page 1079: ...0001 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 Cab and its attachments Cab and its attachments 2 Removal and install...

Page 1080: ...ate 7 3 Remove plate 8 duct 9 and the element a Remove the duct lock clip 4 Disconnect connector S13 10 5 Disconnect cab wiring connectors N02 11 M10 12 H08 13 and H09 14 a Remove the clip and separat...

Page 1081: ...29 are 2 in number a Cut the tie wrap on the monitor wiring har ness a Sling the monitor assembly and cab together a When removing the monitor assembly remove cover 30 in advance 15 Disconnect radio a...

Page 1082: ...nitor panel assembly 30 Part No 208 53 13910 Installation q Carry out installation in the reverse order to removal Reference Connection of window washer hoses 1 Hose length from clamp end of part A Co...

Page 1083: ...g front window glass 4 remove front window assembly 5 It is impossible to replace only the front window glass while the front window assembly is installed to the oper ator s cab For the procedure for...

Page 1084: ...shows the operator s cab of a wheel loader a If the window glass is broken finely it may be removed with knife 4 and a screwdriver a Widening the cut with a screwdriver cut the adhesive and both side...

Page 1085: ...he primers for paint and glass suffi ciently before using them a If the primer has been stored in a refrigerator leave it at the room tem perature for at least half a day before stirring it If the pri...

Page 1086: ...primer to the sticking surfaces of window glass 9 2 Glass primer SUNSTAR GLASS PRIMER 580 SUPER or equivalent a Do not apply the primer more than 2 times If it is applied more than 2 times its perfor...

Page 1087: ...he window frame a When sticking both sided adhesive tape 6 around a frame do not lap its finishing end over the starting end but make clear ance e of about 5 mm between them 1 Stick both sided adhesiv...

Page 1088: ...stuck along the inside it will be seen through the transparent part of the glass 5 Position the new window glass 1 Check the clearance between the window glass and the operator s cab on the right left...

Page 1089: ...nths after the date of manufacture Do not use the adhesive after this limit a Keep the adhesive in a dark place where the temperature is below 25 C a Never heat the adhesive higher than 30 C a When re...

Page 1090: ...of the right side window glass and additional both sided adhesive tape 6b of door lower window glass 7 Install the window glass 1 Install window glass 9 matching it to the lines of the positioning ta...

Page 1091: ...imension u 5 mm a When caulking mask the glass side and form the adhesive with a rubber spatula as shown in the figure a Wipe off projected adhesive 2 Glass primer SUNSTARGLASS PRIMER 580 SUPER 2 Adhe...

Page 1092: ...ve before it is dried up a When cleaning the glass do not give an impact to it 10 Protect the stuck window glass 1 Keep the stopper rubbers styrene foam blocks and rubber bands installed for 10 hours...

Page 1093: ...eft striker bolt 2 will be used to hang the pull up assist cable in step 6 3 Release the rear locks of the cab 4 Lower the front window assembly carefully a little Put out rollers 8 and 9 under the ri...

Page 1094: ...then remove front win dow assembly 13 Installation q Carry out installation in the reverse order to removal 1 q Adjust opening and closing of the front window assembly according to the following proce...

Page 1095: ...e following procedure 1 Tighten left striker bolt 2 and right striker bolt 3 at roughly right positions so that cab side trim seal 18 will be fitted to front window glass 19 2 Open and close the front...

Page 1096: ...that the wiper will not move even if the wiper switch is turned ON by mistake while the front window assembly is open If the wiper operates while there is not the front glass it will fall into the ca...

Page 1097: ...eft rubber stoppers 22 by 1 5 3 0 mm 4 Tighten locknuts 26 of right and left rubber stoppers 22 8 Adjust front window assembly stopper 28 1 Adjust and fix right and left stoppers 28 so that stoppers D...

Page 1098: ...20 SEN01059 01 PC800 8 PC800SE 8 PC800LC 8 PC850 8 PC850SE 8 Hydraulic excavator Form No SEN01059 01...

Page 1099: ...and up PC850 8 10001 and up PC850SE 8 10001 and up 50 Disassembly and assembly1 Electrical system Electrical system 2 Removal and installation of air conditioner unit assembly 2 Removal and installati...

Page 1100: ...Never release the refrigerant R134a to the atmosphere k If refrigerant gas R134a gets in your eyes you may lose your sight Accordingly put on protective goggles while you are collect ing the refriger...

Page 1101: ...the O ring is fitted to the joint a Check that each O ring is free from flaw and deterioration a Coat the O ring with compressor oil for R134a DENSO ND OIL 8 ZEXEL ZXL 100 PG PAG 46 or equivalent and...

Page 1102: ...l k Disconnect the cable from the negative terminal of the battery 1 Disconnect filter assembly 1 2 Disconnect controller cover 2 3 Disconnect connectors CE02 3 and CE03 4 a Use a 4 mm hexagonal wrenc...

Page 1103: ...e order to removal 1 When connecting connectors 3 4 and 8 check that there is no dust dirt etc in them a Reference q Method of replacing O ring seal of power connector 4 O ring seal 1010 074 0406 NIHO...

Page 1104: ...assembly 3 a Disconnect monitor panel wiring connec tors P01 P02 and P70 before removing the monitor assembly Installation q Carry out installation in the reverse order to removal Removal and install...

Page 1105: ...sembly 1 Removal k Disconnect the negative terminal of bat tery 1 Remove covers 1 2 and 3 2 Disconnect GPS connector 4 and antenna wire 5 3 Disconnect connector G01 6 4 Remove 4 mounting bolts and rem...

Page 1106: ...8 SEN01060 01 PC800 8 PC800SE 8 PC800LC 8 PC850 8 PC850SE 8 Hydraulic excavator Form No SEN01060 01...

Page 1107: ...0 8 50001 and up PC800SE 8 50001 and up PC800LC 8 50001 and up PC850 8 10001 and up PC850SE 8 10001 and up HYDRAULIC EXCAVATOR PC800 8 PC800SE 8 PC800LC 8 PC850 8 PC850SE 8 90 Diagrams and drawings Hy...

Page 1108: ...3 Hydraulic circuit diagram PC800 850 8 PC800 850 8 SEN00392 02 Hydraulic circuit diagram...

Page 1109: ...6 PC800 8 PC800SE 8 PC800LC 8 PC850 8 PC850SE 8 Hydraulic excavator Form No SEN00392 02 SEN00392 02 90 Diagrams and drawings...

Page 1110: ...850SE 8 10001 and up HYDRAULIC EXCAVATOR PC800 8 PC800SE 8 PC800LC 8 PC850 8 PC850SE 8 90 Diagrams and drawings Electrical diagrams and drawings Electrical circuit diagram 1 5 3 Electrical circuit dia...

Page 1111: ...3 Electrical circuit diagram 1 5 PC800 850 8 PC800 850 8 SEN00393 02 Electrical circuit diagram 1 5...

Page 1112: ...5 Electrical circuit diagram 2 5 PC800 850 8 PC800 850 8 SEN00393 02 Electrical circuit diagram 2 5...

Page 1113: ...7 Electrical circuit diagram 3 5 PC800 850 8 PC800 850 8 SEN00393 02 Electrical circuit diagram 3 5...

Page 1114: ...9 Electrical circuit diagram 4 5 PC800 850 8 PC800 850 8 SEN00393 02 Electrical circuit diagram 4 5...

Page 1115: ...11 Electrical circuit diagram 5 5 PC800 850 8 PC800 850 8 SEN00393 02 Electrical circuit diagram 5 5...

Page 1116: ...Air conditioner control panel X 2 M30 AMP 16 Air conditioner control panel X 2 M33 SUMITOMO 4 Air conditioner unit AA 6 M34 X 1 Air conditioner compressor electromagnetic clutch AO 5 M40 SWP 2 Headla...

Page 1117: ...16 PC800 8 PC800SE 8 PC800LC 8 PC850 8 PC850SE 8 Hydraulic excavator Form No SEN00393 02 SEN00393 02 90 Diagrams and drawings...

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