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Komatsu PC800 -8E0, Руководство по ремонту

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Table of contents

PC800, 850-8E0

Table of contents

00-2

Notice of revision........................................................................................................................

1

00 Index and foreword

Table of contents .................................................................................................................... 00 -

2

Table of contents ................................................................................................................. 00 -

2

Foreword and general information .......................................................................................... 00- 12

Safety notice ........................................................................................................................ 00- 12
How to read the shop manual .............................................................................................. 00- 17
Explanation of terms for maintenance standard .................................................................. 00- 19
Handling of hydraulic components....................................................................................... 00- 21
Method of disconnecting and connecting push-pull type coupler ........................................ 00- 23
Handling of electric equipment............................................................................................. 00- 26
How to read electric wire code............................................................................................. 00- 36
Precautions when performing work...................................................................................... 00- 39
Standard tightening torque table.......................................................................................... 00- 42
List of abbreviation............................................................................................................... 00- 46
Conversion table .................................................................................................................. 00- 50

01 Specification

Specifications.......................................................................................................................... 01-

4

Specifications drawing ......................................................................................................... 01-

4

Specifications....................................................................................................................... 01-

8

Table of weight..................................................................................................................... 01- 18
Table of fuel, coolant and lubricants .................................................................................... 01- 26

10 Structure and function

Engine and cooling system ..................................................................................................... 10-

3

Coupling............................................................................................................................... 10-

3

Coupling lubrication system ................................................................................................. 10-

4

Cooling system .................................................................................................................... 10-

6

Power train system ................................................................................................................. 10-

8

Power train........................................................................................................................... 10-

8

Swing circle.......................................................................................................................... 10- 10
Swing machinery.................................................................................................................. 10- 11
Final drive ............................................................................................................................ 10- 13

Undercarriage and frame ........................................................................................................ 10- 14

Track frame.......................................................................................................................... 10- 14
Idler cushion......................................................................................................................... 10- 16

Hydraulic system..................................................................................................................... 10- 18

Hydraulic component layout................................................................................................. 10- 18
Hydraulic tank and filter ....................................................................................................... 10- 20
Hydraulic pump .................................................................................................................... 10- 22
Pump control system ........................................................................................................... 10- 30
Servo valve .......................................................................................................................... 10- 32
Self-pressure reducing valve ............................................................................................... 10- 41
Cooling fan pump................................................................................................................. 10- 44
Cooling fan motor................................................................................................................. 10- 53
Electrical grease pump ........................................................................................................ 10- 59
Control valve ........................................................................................................................ 10- 60
Straight-travel valve ............................................................................................................. 10- 69
Swing motor ......................................................................................................................... 10- 72

00-2

(01)

Содержание PC800 -8E0

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 25: ...rate the hoist at a safe place 4 Check the direction indicator plates east west south and north and the directions of the control buttons without fail 5 Do not sling a load at an angle Do not move the...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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