Komatsu Galeo PC800LC-8 Install guide

HYDRAULIC
EXCAVATOR
SEN00373-16
PC800 -8
PC800LC -8
PC800SE-8
PC850 -8
PC850SE-8
SERIAL NUMBERS
PC800- 50001
PC800LC-50001
PC800SE-50001
PC850- 10001
PC850SE-10001
and up

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SEN00375-16
PC800, 850-8 1
Machine model Serial number
PC800-8 50001 and up
PC800SE-8 50001 and up
PC800LC-8 50001 and up
PC850-8 10001 and up
PC850SE-8 10001 and up
HYDRAULIC EXCAVATOR
PC800-8
PC800SE-8
PC800LC-8
PC850-8
PC850SE-8
00 Index and foreword 1
Index
Composition of shop manual ............................................................................................................................... 2
Table of contents.................................................................................................................................................. 4
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SEN00375-16 00 Index and foreword
2PC800, 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 SEN00373-16
00 Index and foreword SEN00374-16
Index SEN00375-16 q
Foreword and general information SEN00376-04
01 Specification SEN00377-02
Specification and technical data SEN00378-02
10 Structure, function and maintenance standard SEN00379-09
Engine and cooling system SEN00380-01
Power train SEN00381-03
Undercarriage and frame SEN00382-02
Hydraulic system, Part 1 SEN00383-03
Hydraulic system, Part 2 SEN00384-04
Work equipment SEN00385-01
Cab and its attachments SEN00396-01
Electrical system SEN00386-05
20 Standard value table SEN00387-02
Standard service value table SEN00784-02
30 Testing and adjusting SEN00388-06
Testing and adjusting, Part 1 SEN00786-04
Testing and adjusting, Part 2 SEN00788-04
Testing and adjusting, Part 3 SEN00912-03
Testing and adjusting, Part 4 SEN00913-03
Testing and adjusting, Part 5 SEN00914-03
40 Troubleshooting SEN00389-05
Failure code table and fuse locations SEN02797-02
General information on troubleshooting SEN00789-04
Troubleshooting by failure code (Display of code), Part 1 SEN00790-04
Troubleshooting by failure code (Display of code), Part 2 SEN00791-03
Troubleshooting by failure code (Display of code), Part 3 SEN00792-03
Troubleshooting of electrical system (E-mode) SEN00793-02
Troubleshooting of hydraulic and mechanical system (H-mode) SEN00794-02
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00 Index and foreword SEN00375-16
PC800, 850-8 3
Troubleshooting of engine (S-mode) SEN00795-03
50 Disassembly and assembly SEN00390-07
General information on disassembly and assembly SEN01052-03
Engine and cooling system (SAA6D140E-5) SEN01053-01
Engine (SAA6D140E-5) SEN01054-01
Power train SEN01055-04 q
Undercarriage and frame SEN01056-05 q
Hydraulic system SEN01057-03
Work equipment SEN01058-01
Cab and its attachments SEN01059-01
Electrical system SEN01060-01
90 Diagrams and drawings SEN00391-04
Hydraulic diagrams and drawings SEN00392-02
Electrical diagrams and drawings SEN00393-03
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SEN00375-16 00 Index and foreword
4PC800, 850-8
Table of contents 1
00 Index and foreword
Index SEN00375-16
Composition of shop manual................................................................................................... 2
Table of contents...................................................................................................................... 4
Foreword and general information SEN00376-04
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
Handling of connectors newly used for engines...................................................................... 20
How to read electric wire code................................................................................................. 23
Precautions when carrying out operation ................................................................................ 26
Method of disassembling and connecting push-pull type coupler ........................................... 29
Standard tightening torque table.............................................................................................. 32
Conversion table...................................................................................................................... 36
01 Specification
Specification 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 Structure, function and maintenance standard
Engine and cooling system SEN00380-01
Engine and cooling system ......................................................................................................... 2
Coupling................................................................................................................................... 2
Coupling lubrication system.....................................................................................................3
Radiator, oil cooler................................................................................................................... 4
Power train SEN00381-03
Power train.................................................................................................................................. 2
Power train............................................................................................................................... 2
Swing machinery ..................................................................................................................... 4
Swing circle.............................................................................................................................. 6
Final drive................................................................................................................................ 8
Sprocket................................................................................................................................... 10
Undercarriage and frame SEN00382-02
Undercarriage and frame ............................................................................................................ 2
Track frame and recoil spring .................................................................................................. 2
Idler.......................................................................................................................................... 4
Carrier roller............................................................................................................................. 6
Track roller............................................................................................................................... 8
Track shoe............................................................................................................................... 10
Double shoe............................................................................................................................. 13
Hydraulic system, Part 1 SEN00383-03
Hydraulic system, Part 1 ............................................................................................................. 2
Hydraulic piping drawing.......................................................................................................... 2
Hydraulic tank, hydraulic filter.................................................................................................. 4
Hydraulic pump........................................................................................................................ 6
Cooling fan pump..................................................................................................................... 26
Cooling fan motor .................................................................................................................... 34
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00 Index and foreword SEN00375-16
PC800, 850-8 5
Hydraulic system, Part 2 SEN00384-04
Hydraulic system, Part 2............................................................................................................. 4
Motor grease pump ................................................................................................................. 4
Return oil filter ......................................................................................................................... 5
Line oil filter ............................................................................................................................. 6
Drain oil filter............................................................................................................................ 7
L.H. 5-Spool control valve........................................................................................................ 8
R.H. 4-Spool control valve....................................................................................................... 14
Straight-travel valve................................................................................................................. 20
Swing motor............................................................................................................................. 23
Center swivel joint ................................................................................................................... 28
Travel motor............................................................................................................................. 29
PPC accumulator..................................................................................................................... 39
Work equipment, swing PPC valve ......................................................................................... 40
Travel PPC valve..................................................................................................................... 45
Anti-drop valve......................................................................................................................... 49
Solenoid valve......................................................................................................................... 50
Quick return valve.................................................................................................................... 56
Hydraulic cylinder.................................................................................................................... 58
Work equipment SEN00385-01
Work equipment.......................................................................................................................... 2
Work equipment ...................................................................................................................... 2
Dimensions of work equipment ............................................................................................... 8
Cab and its attachments SEN00396-01
Cab and its attachments.............................................................................................................. 2
Air conditioner piping............................................................................................................... 2
Electrical system SEN00386-05
Engine control.......................................................................................................................... 2
Electric control system............................................................................................................. 11
Monitor system ........................................................................................................................ 45
Sensors ................................................................................................................................... 63
KOMTRAX system ..................................................................................................................67
20 Standard value table
Standard service value table SEN00784-02
Standard service value table for engine...................................................................................... 2
Standard service value table for chassis..................................................................................... 3
30 Testing and adjusting
Testing and adjusting, Part 1 SEN00786-04
Testing and adjusting, Part 1....................................................................................................... 2
Tools for testing, adjusting and troubleshooting ...................................................................... 2
Measuring engine speed......................................................................................................... 5
Measuring intake air 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 engine oil pressure ................................................................................................ 12
Measuring EGR valve and bypass valve drive pressure......................................................... 13
Handling of fuel system equipment ......................................................................................... 14
Remaining pressure relief from fuel system equipment .......................................................... 14
Measuring fuel pressure.......................................................................................................... 15
Testing fuel return rate and leakage ........................................................................................ 16
Bleeding air from fuel circuit.................................................................................................... 18
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SEN00375-16 00 Index and foreword
6PC800, 850-8
Testing fuel system for leakage ............................................................................................... 20
Testing and adjusting alternator belt tension ........................................................................... 21
Testing and adjusting air conditioner compressor belt............................................................. 22
Testing and adjusting, Part 2 SEN00788-04
Testing and adjusting, Part 2....................................................................................................... 2
Inspection of swing circle bearing clearance........................................................................... 2
Testing and adjusting track shoe tension................................................................................. 3
Testing and adjusting work equipment, swing, and travel circuit oil pressures........................ 4
Testing and adjusting control circuit pressure (output pressure of self pressure reducing valve) 10
Testing and adjusting main pump control pressure................................................................... 12
Testing and adjusting, Part 3 SEN00912-03
Testing and adjusting, Part 3....................................................................................................... 2
Measuring PPC valve output pressure.................................................................................... 2
Measuring 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 locations of hydraulic drift of work equipment .................................................... 13
Measuring fan speed ............................................................................................................... 14
Measuring fan circuit oil pressure............................................................................................ 14
Measuring fan pump EPC current ........................................................................................... 15
Measuring fan pump EPC solenoid valve output pressure...................................................... 16
Measuring oil leakage.............................................................................................................. 17
Release of residual pressure from hydraulic circuit................................................................. 21
Bleeding air from each part...................................................................................................... 22
Inspection procedures for diode .............................................................................................. 25
Adjusting mirrors...................................................................................................................... 26
Testing and adjusting, Part 4 SEN00913-03
Testing and adjusting, Part 4....................................................................................................... 2
Special function of machine monitor........................................................................................ 2
Handling controller voltage circuit............................................................................................ 35
Testing and adjusting, Part 5 SEN00914-03
Testing and adjusting, Part 5....................................................................................................... 2
Procedure for turning on KOMTRAX terminal ......................................................................... 2
KOMTRAX terminal lamp indications ...................................................................................... 5
Preparation work for troubleshooting electrical system ........................................................... 8
40 Troubleshooting
Failure code table and fuse locations SEN02797-02
Failure code table and fuse locations.......................................................................................... 2
Failure codes table .................................................................................................................. 2
Fuse locations.......................................................................................................................... 6
General information on troubleshooting SEN00789-04
General information on troubleshooting...................................................................................... 2
Points to remember when troubleshooting .............................................................................. 2
Sequence of events in troubleshooting.................................................................................... 3
Checks before troubleshooting................................................................................................ 4
Classification and troubleshooting steps ................................................................................. 5
Information in troubleshooting table......................................................................................... 6
Failure-looking phenomenon and troubleshooting No............................................................. 8
Connection table for connector pin numbers........................................................................... 11
T- branch box and T- branch adapter table.............................................................................. 47
Troubleshooting by failure code (Display of code), Part 1 SEN00790-04
Troubleshooting by failure code (Display of code), Part 1........................................................... 4
Failure code [AA10NX] Aircleaner Clogging............................................................................ 4
Failure code [AB00KE] Charge Voltage Low........................................................................... 6
Failure code [B@BAZG] Eng. Oil Press. Low.......................................................................... 8
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00 Index and foreword SEN00375-16
PC800, 850-8 7
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
Failure code [B@HANS] Hydr. Oil Overheat........................................................................... 14
Failure code [CA111] ECM Critical Internal Failure ................................................................. 16
Failure code [CA115] Eng Ne and Bkup Speed Sens Error .................................................... 18
Failure code [CA122] Chg Air Press Sensor High Error.......................................................... 20
Failure code [CA123] Chg Air Press Sensor Low Error........................................................... 22
Failure code [CA131] Throttle Sensor High Error.................................................................... 24
Failure code [CA132] Throttle Sensor Low Error..................................................................... 26
Failure code [CA135] Eng Oil Press Sensor High Error.......................................................... 28
Failure code [CA141] Eng Oil Press Sensor Low Error........................................................... 30
Failure code [CA144] Coolant Temp Sens High Error............................................................. 32
Failure code [CA145] Coolant Temp Sens Low Error.............................................................. 34
Failure code [CA153] Chg Air Temp Sensor High Error.......................................................... 36
Failure code [CA154] Chg Air Temp Sensor Low Error........................................................... 38
Failure code [CA187] Sens Supply 2 Volt Low Error............................................................... 38
Failure code [CA221] Ambient Press Sens High Error............................................................ 40
Failure code [CA222] Ambient Press Sens Low Error............................................................. 42
Failure code [CA227] Sens Supply 2 Volt High Error .............................................................. 44
Failure code [CA234] Eng Overspeed..................................................................................... 46
Failure code [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 [CA272] IMV/PCV1 Open Error.......................................................................... 54
Failure code [CA273] PCV2 Short Error.................................................................................. 55
Failure code [CA274] PCV2 Open Error.................................................................................. 56
Failure code [CA322] Inj #1 (L#1) Open/Short Error............................................................... 57
Failure 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 code [CA332] Inj #4 (L#4) Open/Short Error............................................................... 66
Failure code [CA342] Calibration Code Incompatibility ........................................................... 67
Failure code [CA351] Injectors Drive Circuit Error................................................................... 68
Failure code [CA352] Sens Supply 1 Volt Low Error............................................................... 70
Failure code [CA386] Sens Supply 1 Volt High Error .............................................................. 72
Troubleshooting by failure code (Display of code), Part 2 SEN00791-03
Troubleshooting by failure code (Display of code), Part 2........................................................... 3
Failure code [CA441] Battery Voltage Low Error..................................................................... 3
Failure code [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] Rail Press High Error............................................................................ 8
Failure code [CA554] Rail Press Sensor In Range Error ........................................................ 9
Failure code [CA559] Rail Press Low Error............................................................................. 10
Failure code [CA689] Eng Ne Speed Sensor Error................................................................. 14
Failure code [CA731] Eng Bkup Speed Sens Phase Error...................................................... 16
Failure code [CA757] All Persistent Data Lost Error ............................................................... 17
Failure code [CA778] Eng Bkup Speed Sensor Error.............................................................. 18
Failure code [CA1228] EGR Valve Servo Error 1.................................................................... 20
Failure code [CA1625] EGR Valve Servo Error 2.................................................................... 21
Failure code [CA1626] BP Valve Sol Current High Error......................................................... 22
Failure code [CA1627] BP Valve Sol Current Low Error.......................................................... 24
Failure code [CA1628] Bypass Valve Servo Error 1................................................................ 25
Failure code [CA1629] Bypass Valve Servo Error 2................................................................ 26
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SEN00375-16 00 Index and foreword
8PC800, 850-8
Failure code [CA1631] BP Valve Pos Sens High Error............................................................ 28
Failure code [CA1632] BP Valve Pos Sens Low Error ............................................................ 30
Failure code [CA1633] KOMNET Datalink Timeout Error........................................................ 32
Failure code [CA1642] EGR Inter Press Sens Low Error........................................................ 34
Failure code [CA1653] EGR Inter Press Sens High Error....................................................... 36
Failure code [CA2185] Throt Sens Sup Volt High Error........................................................... 38
Failure code [CA2186] Throt Sens Sup Volt Low Error ........................................................... 40
Failure code [CA2249] Rail Press Very Low Error................................................................... 41
Failure code [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 Error....................................................... 48
Failure code [CA2555] Grid Htr Relay Volt Low Error.............................................................. 49
Failure code [CA2556] Grid Htr Relay Volt High Error............................................................. 50
Failure code [D110KB] Battery Relay Drive S/C...................................................................... 52
Failure code [D163KB] Flash Light Relay S/C......................................................................... 54
Failure code [D195KB] Step Light Relay S/C .......................................................................... 56
Failure code [DA22KK] Pump Solenoid Power Low Error....................................................... 58
Failure code [DA25KP] Press. Sensor Power Abnormality ..................................................... 60
Failure code [DA2SKQ] Model Selection Abnormality............................................................. 62
Failure code [DA80MA] Auto. Lub. Abnormal.......................................................................... 64
Failure code [DA2RMC] Pump Comm. Abnormality................................................................ 66
Failure code [DAFRMC] Monitor Comm. Abnormality............................................................. 68
Failure code [DGE5KY] Ambi. Temp. Sensor S/C................................................................... 70
Failure code [DGH2KB] Hydr. Oil Temp. Sensor S/C.............................................................. 72
Troubleshooting by failure code (Display of code), Part 3 SEN00792-03
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] R Jet Sensor S/C............................................................................... 10
Failure code [DHPEKA] F Pump P. Sensor Disc..................................................................... 12
Failure code [DHPEKB] F Pump P. Sensor S/C...................................................................... 14
Failure code [DHPFKA] R Pump P. Sensor Disc..................................................................... 16
Failure code [DHPFKB] R Pump P. Sensor S/C...................................................................... 18
Failure code [DV20KB] Travel Alarm S/C................................................................................ 20
Failure code [DW41KA] Swing Priority Sol. Disc..................................................................... 22
Failure code [DW41KB] Swing Priority Sol. S/C...................................................................... 24
Failure code [DW43KA] Travel Speed Sol. Disc...................................................................... 26
Failure code [DW43KB] Travel Speed Sol. S/C....................................................................... 28
Failure code [DW45KA] Swing Brake Sol. Disc....................................................................... 30
Failure code [DW45KB] Swing Brake Sol. S/C........................................................................ 32
Failure code [DW7BKA] Fan Reverse Sol. Disc...................................................................... 34
Failure code [DW7BKB] Fan Reverse Sol. S/C....................................................................... 36
Failure code [DW7JKA] Bottom Dump Priority Sol. Disc......................................................... 38
Failure code [DW7JKB] Bottom Dump Priority Sol. S/C.......................................................... 40
Failure code [DWK0KA] 2-stage Relief Sol. Disc. ................................................................... 42
Failure 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 Pump EPC Sol. S/C....................................................................... 52
Failure code [DXABKA] R Pump EPC Sol. Disc...................................................................... 54
Failure code [DXABKB] R Pump EPC Sol. S/C....................................................................... 56
Failure code [DY20KA] Wiper Working Abnormality................................................................ 58
Failure code [DY20MA] Wiper Parking Abnormality................................................................ 60
Failure code [DY2CKB] Washer Drive S/C.............................................................................. 64
Failure code [DY2DKB] Wiper Drive (For) S/C........................................................................ 66
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