Komatsu Hydraulic Excavator PC800-8E0, PC800LC-8E0, PC800SE-8E0, PC850-8E0, PC850SE-8E0 Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC800-8E0, PC800LC-8E0, PC800SE-8E0, PC850-8E0, PC850SE-8E0, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Hydraulic Excavators PC800-8E0, PC800LC-8E0, PC800SE-8E0, PC850-8E0, PC850SE-8E0 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 3,253 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English / Spanish
GEN00102-02 - Hydraulic Excavator PC800-8E0, PC800LC-8E0, PC800SE-8E0, PC850-8E0, PC850SE-8E0 Field Assembly Instruction.pdf
TEN00379-04 - Hydraulic Excavator PC800-8E0, PC800LC-8E0, PC800SE-8E0, PC850-8E0, PC850SE-8E0 Operation & Maintenance Manual.pdf
SEN05276-03 - Hydraulic Excavator PC800-8E0, PC800LC-8E0, PC800SE-8E0, PC850-8E0, PC850SE-8E0 Shop Manual.pdf
GSN05276-03 - Excavadora Hidráulica PC800-8EO, PC800LC-8EO, PC800SE-8EO, PC850-8EO, PC850SE-8EO Manual de Taller.pdf
MAIN SECTIONS
GEN00102-02 - Hydraulic Excavator PC800-8E0, PC800LC-8E0, PC800SE-8E0, PC850-8E0, PC850SE-8E0 Field Assembly Instruction....2
COVER....2
FOREWORD....3
CONTENTS....4
SPECIFICATIONS....7
PRECAUTIONS FOR FIELD ASSEMBLY....8
DISPOSAL OF REMOVED PARTS....9
ASSEMBLING PROCEDURES, APPLICABLE EQUIPMENT AND SCHEDULE....10
5KIT LAYOUT DIAGRAM....11
TRANSPORTATION....12
LIST OF TOOLS FOR FIELD ASSEMBLING....17
TIGHTENING TORQUE....19
COATING MATERIALS LIST....23
SELECTION OF WIRE ROPES USED FOR ASSEMBLY....26
A. ASSEMBLY OF CHASSIS....27
A- 1. Installation of Left and Right Track Frames....28
A- 2. Installation of Travel Pipe....32
A- 3. Installation of Top Guard....35
A- 4. Installation of Radiator Cover....36
A- 5. Installation of Rearview Mirror....37
A- 6. Installation of Left Side Step....41
A- 7. Installation of Handrail....42
A- 8. Installation of Handrail....44
A- 9. Installation of Muffler Tail Tube....46
A-10. Sticking Sheet to Counterweight....47
A-11. Installation of Counterweight....48
A-12. Installation of KOMTRAX Antenna (if equipped)....51
A-13. Installation of Step Light....52
A-14. Air Bleeding of Travel Motor....54
A-15. Installation of Travel Piping Cover....55
A-16. Testing Track Shoe Tension....59
A-17. Check Fuel, Coolant and Oil Levels....62
A-18. Parts to be Touched up after Field Assembly....64
B. ASSEMBLING OF WORK EQUIPMENT OF BACKHOE....65
B- 1. Assembly of Arm Cylinder....66
B- 2. Connection of Arm Cylinder Hoses....68
B- 3. Installation of Boom Cylinder Foot....71
B- 4. Relieving Remaining Pressure from Hydraulic Circuit....72
B- 5. Installation of Boom Cylinder Hoses....73
B- 6. Installation of Boom Foot Dust Seal....74
B- 7. Assembly of Boom Assembly....75
B- 8. Hose Connection of Arm and Bucket Circuits....76
B- 9. Installation of Quick Return Hose....77
B-10. Installation of Boom Cylinder....78
B-11. Installation of Arm Assembly....79
B-12. Installation of Hose between Boom and Bucket Cylinder....81
B-13. Installation of Bucket Assembly....82
B-14. Lubrication Piping to Work Equipment....83
B-15. Wiring of Work Equipment....84
B-16. Greasing after Assembling Work Equipment....85
B-17. Air Bleeding from Hydraulic Cylinder....86
C. ASSEMBLING OF WORK EQUIPMENT OF LOADING SHOVEL....87
C- 1. Releasing residual pressure in hydraulic circuit....88
C- 2. Pulling out boom foot pin and boom cylinder foot pin....89
C- 3. Installation of boom and arm assembly....90
C- 4. Installation of piping between chassis and boom....91
C- 5. Installation of flushing piping for boom cylinder and arm cylinder....92
C- 6. Installation of flushing piping for bucket cylinder....93
C- 7. Installation of flushing piping for bottom dump cylinder....94
C- 8. Installation of boom cylinder....96
C- 9. Installation of boom cylinder foot....97
C-10. Installation of boom cylinder hoses....98
C-11. Installation of boom cylinder rod pin....99
C-12. Installation of arm cylinder hoses....100
C-13. Installation of bucket cylinder....101
C-14. Installation of bucket cylinder hose....102
C-15. Installation of connecting hoses between chassis and boom top....103
C-16. Installation of bottom dump cylinder hoses....104
C-17. Installation of bucket assembly....105
C-18. Installation of working lamps....107
C-19. Installation of work equipment grease piping....108
C-20. Greasing after assembling of work equipment....109
C-21. Bleeding air from work equipment circuit....110
D. ASSEMBLING OF COUNTERWEIGHT REMOVER....111
D- 1. Installation of Rubber Cushions....112
D- 2. Adjustment of Shims for Counterweight....113
D- 3. Greasing....118
D- 4. Installation of Counterweight Remover....119
D- 5. Installation of Covers....120
D- 6. Installation of Hoses....121
D- 7. Bleeding Air from Counterweight Remover Circuit....124
D- 8. Installation of Counterweight....125
D- 9. Installation of Accessories....127
D-10. Check of Operation....128
M. PROCEDURE FOR INSPECTION AND MAINTENANCE AFTER COMPLETION OF ASSEMBLY....129
M- 1. Inspection of Oil Level in Hydraulic Tank and Refill....130
M- 2. Replacement of Return Filter (Standard Filter to Flushing Filter)....132
M- 3. Flushing of Hydraulic Circuit....133
M- 4. Replacement of Return Filter (Flushing Filter to Standard Filter)....135
M- 5. Failure Code....137
Field Assembly Inspection Report (Backhoe)....141
Field Assembly Inspection Report (Loading Shovel)....167
GSN05276-03 - Excavadora Hidrulica PC800-8EO, PC800LC-8EO, PC800SE-8EO, PC850-8EO, PC850SE-8EO Manual de Taller....193
CUBIERTA....193
00 ndice y Prlogo....202
Tabla de contenido....203
Prefacio e informacin general....213
Avisos de seguridad....213
Cmo leer el manual de taller....218
Explicacin de trminos para normas de mantenimiento....220
Manipulacin de componentes hidrulicos....222
Mtodo para desconectar y conectar el tipo de acoplador de empuje-traccin....224
Manipulacin del equipo elctrico....227
Forma de leer el cdigo de alambres elctricos....237
Precauciones al realizar el trabajo....240
Tabla de torsin de apriete estndar....243
Lista de abreviacin....247
Tabla de conversin....251
Manual de Taller....257
01 Especificacin....257
Contenido....258
Especificaciones....260
Dibujo de especificaciones....260
Especificaciones....264
Tabla de peso....274
Tabla de combustible, lquido refrigerante y lubricantes....282
Manual de Taller....285
10 Estructura y funcionamiento....285
Contenido....286
Motor y sistema de enfriamiento....287
Acople....287
Sistema de lubricacin de acoplamiento....288
Sistema de enfriamiento....290
Sistema del tren de potencia....292
Tren de potencia....292
Crculo de giro....294
Maquinaria de giro....295
Mando final....297
Tren de rodaje y bastidor....298
Bastidor de oruga....298
Amortiguador de la rueda tensora....300
Sistema hidrulico....302
Diagrama de ubicacin....302
Tanque hidrulico y filtro....304
Bomba hidrulica....306
Sistema de control de la bomba....314
Servo-vlvula....316
Vlvula de auto-reduccin de presin....325
Bomba del ventilador de enfriamiento....328
Motor de ventilador de enfriamiento....337
Bomba de grasa elctrica....343
Vlvula de control....344
Vlvula de traslado en lnea recta....353
Motor de giro....356
Unin giratoria central....360
Motor de traslado....361
Vlvula PPC....371
Vlvula solenoide....379
Acumulador....387
Vlvula de retorno rpido....388
Filtro de Aceite de retorno....391
Filtro del aceite en la lnea....392
Filtro del aceite piloto....393
Drene el filtro de aceite....394
Sistema Elctrico....395
Control del motor....395
Control del sistema elctrico....405
Sistema monitor....444
Sensors....474
Sistema KOMTRAX....478
Manual de Taller....481
20 Tabla de valores estndar....481
Contenido....482
Tabla de valores estndar....483
Tabla de valores estndar para el motor....483
Tabla de valores estndar para la mquina....484
Manual de Taller....497
30 Pruebas y Ajustes....497
Contenido....498
Herramientas para comprobaciones, ajustes y localizacin de fallas....499
Herramientas para comprobaciones, ajustes y localizacin de fallas....499
Motor y sistema de enfriamiento....503
Comprobacin de la velocidad del motor....503
Forma de medir la presin del aire de admisin (presin de refuerzo)....504
Probando la temperatura del gas de escape....505
Comprobacin del color de los gases del escape....506
Ajustar la holgura de vlvulas....508
Prueba de presin de compresin....509
Prueba de la presin de gases de escape....511
Probando la presin de aceite del motor....512
Comprobacin de la presin de mando de la vlvula EGR y la vlvula de desvo....513
Manipulando partes del sistema de combustible....514
Purga de la presin restante del sistema de combustible....515
Comprobacin de las presiones de combustible....516
Comprobacin de la tasa de retorno y escapes del combustible....517
Purgar el aire del circuito de combustible....520
Probar el circuito de combustible para detectar fugas....522
Probando y ajustando la tensin de la correa del alternador....523
Prueba y ajuste de la tensin de la correa del compresor del acondicionador de aire....524
Tren de rodaje y bastidor....525
Comprobacin del espacio libre del rodamiento del crculo de giro....525
Comprobacin y ajuste de la tensin de la oruga....526
Sistema hidrulico....527
Comprobacin y ajuste de la presin de aceite en los circuitos del equipo de trabajo, giro y traslado....527
Comprobacin y ajuste de circuito de control de presin de aceite (presin de salida de la vlvula de auto-reductora de presin)....533
Comprobacin y ajuste de la seal de control de la bomba principal....535
Comprobar la presin de salida de la vlvula PPC....542
Medicin de la presin de salida de la vlvula de solenoide, vlvula de lanzadera oscilante PPC, y la vlvula de oscilacin prioridad selector....546
Ajuste el juego de la vlvula PPC de giro del equipo de trabajo....551
Comprobacin y ajuste del traslado....552
Inspeccionando los lugares con escape hidrulico interno en el equipo de trabajo....554
Medicin de la velocidad del ventilador....555
Medicin de la presin de aceite del circuito del ventilador....556
Corriente EPC bomba del ventilador....557
Mida la presin de salida del solenoide EPC de la bomba del ventilador....558
Medicin de la fuga de aceite....559
Liberar la presin restante del circuito hidrulico....563
Purgando el aire de varias partes....564
Procedimientos de inspeccin para los diodos....567
Ajuste del espejo....568
Sistema Elctrico....569
Funcin Especial del Monitor de la Mquina....569
Manejando el circuito de voltaje del controlador del motor....613
Trabajos de preparacin para la localizacin de fallas en el sistema elctrico....614
Pm Clinic....618
Pm Servicio Clnico....618
REPORTE DE INSPECCIN DEL TREN DE RODAJE....625
Manual de Taller....627
40 Localizacin de fallas....627
Contenido....628
Informacin general sobre localizacin de fallas....633
Aspectos a recordar durante la localizacin de fallas....633
Secuencia de eventos en la localizacin de fallas....634
Comprobaciones antes de localizar de fallas....635
Clasificacin y procedimientos de localizacin de fallas....661
Tabla de cdigos de falla....664
Nmeros de localizacin de fallas y sntomas....669
Informacin en la tabla de localizacin de fallas....672
Mtodo para la localizacin de fallas de un circuito abierto, en el cableado elctrico del sistema del sensor de presin....674
Lista de conector y diseo....676
Tabla de conexiones por nmero de espigas de los conectores....687
Caja del ramal "T" y tabla del adaptador ramal "T"....723
Localizacin del fusible....726
Localizacin de fallas por el cdigo de falla....729
Cdigo de falla [989L00] Cierre de Precaucin 1, controlador del motor....729
Cdigo de falla [989M00] Cierre del controlador del motor, Precaucin 2....730
Cdigo de falla [989N00] Cierre del controlador del motor, Precaucin 3....730
Cdigo de falla [AA10NX] Obstruccin del filtro de aire....731
Cdigo de falla [AB00KE] Bajo el Voltaje de Carga....732
Cdigo de falla [B@BAZG] Presin del aceite del motor baja....734
Cdigo de falla [B@BAZK] Nivel del aceite del motor baja....735
Cdigo de falla [B@BCNS] Agua del motor sobrecalentado....736
Cdigo de falla [B@BCZK] Bajo el nivel de agua del motor....738
Cdigo de falla [B@HANS] sobrecalentamiento del aceite hidrulico....740
Cdigo de falla [CA111] Falla Crtica Interna de la Vlvula Moduladora de Control Electrnico o ECMV....742
Cdigo de falla [CA115] error en el sensor de velocidad Ne del Motor y en el sensor de velocidad de reversa....744
Cdigo de falla [CA122] Error en sensor por alta presin de carga de aire....746
Cdigo de falla [CA123] Error en sensor por baja presin de aire de carga....748
Cdigo de falla [CA131] Error en Sensor por alta aceleracin....750
Cdigo de falla [CA132] Error en sensor por baja aceleracin....752
Cdigo de falla [CA135] Error en sensor de presin alta de aceite del motor....754
Cdigo de falla [CA141] Error. En sensor de baja presin de aceite del motor....756
Cdigo de falla [CA144] Error en sensor por alta temperatura del refrigerante....758
Cdigo de falla [CA145] Error en sensor por baja temperatura del refrigerante....760
Cdigo de falla [CA153] Error Alta temperatura del sensor del aire de carga....762
Cdigo de falla [CA154] Error en sensor por baja temperatura de aire de carga....764
Cdigo de falla [CA187] Error. Bajo suministro al sensor de 2 voltios....766
Cdigo de falla [CA221] Error. Sensor de alta presin ambiental....768
Cdigo de falla [CA222] Error. Sensor de presin ambiental, baja....770
Cdigo de falla [CA227] Error. Suministro 2 Alto voltaje al sensor....772
Cdigo de falla [CA234] Exceso de velocidad del motor....773
Cdigo de falla [CA238] Error. Suministro energtico al sensor de velocidad Ne....774
Cdigo de falla [CA263] Error en Sensor por Alta Temperatura del Combustible....776
Cdigo de falla [CA265] Error en Sensor por Baja Temperatura del Combustible....778
Cdigo de falla [CA271] IMV/PCV1 Error. Corto circuito....780
Cdigo de falla [CA272] IMV/PCV1 Error Abierto....781
Cdigo de falla [CA273] PCV2 Error. Corto circuito....782
Cdigo de falla [CA274] PCV2 Abierto. Error....783
Cdigo de falla [CA322] Inyector No. 1 (L No. 1) Abierto/Corto circuito Error....784
Cdigo de falla [CA323] Inyector No. 5 (L No. 5) Abierto/Corto circuito Error....786
Cdigo de falla [CA324] Inyector No. 3 (L No. 3) Abierto/Corto circuito Error....788
Cdigo de falla [CA325] Inyector No. 6 (L No. 6) Abierto/Corto circuito Error....790
Cdigo de falla [ CA331] Inyector No. 2 (L No. 2) Abierto/Corto circuito Error....792
Cdigo de falla [ CA332] Inyector No. 4 (L No. 4) Abierto/Corto circuito Error....794
Cdigo de falla [CA342] Incompatibilidad con el Cdigo de Calibracin....796
Cdigo de falla [CA351] Error en el circuito de mando de los inyectores....797
Cdigo de falla [CA352] Error. Bajo voltaje en el suministro energtico 1 del sensor....798
Cdigo de falla [CA386] Error. Alto el suministro 1 de voltaje al sensor....800
Cdigo de falla [CA441] Error. Bajo voltaje de batera....800
Cdigo de falla [CA442] Error. Alto voltaje de batera....801
Cdigo de falla [CA449] Error. Muy alta la presin en el mltiple de combustible....801
Cdigo de falla [CA451] Error. Alto. Sensor de presin en el mltiple de combustible....802
Cdigo de falla [CA452] Error. Bajo. Sensor de presin en el mltiple de combustible....804
Cdigo de falla [CA553] Error. Alto Presin del mltiple comn....806
Cdigo de falla [CA554] Sensor de Presin del Mltiple en Area de Error....807
Cdigo de falla [CA559] Baja Presin de la Bomba de Suministro Error 1....808
Cdigo de falla [CA689] Error en Sensor de velocidad Ne del Motor....812
Cdigo de falla [CA731] Error de fase en el sensor de velocidad de respaldo del Motor....814
Cdigo de falla [CA757] Error. Perdidos todos los datos de continuidad....815
Cdigo de falla [CA778] Error en el sensor de velocidad de reversa del motor....816
Cdigo de falla [CA1228] Error 1, Servo vlvula EGR....818
Cdigo de falla [CA1625] Error 2, Servo Vlvula EGR....819
Cdigo de falla [CA1626] Error. Corriente alta del solenoide de la vlvula BP....820
Cdigo de falla [CA1627] Error. Corriente baja del solenoide de la vlvula BP....822
Cdigo de falla [CA 1628] Error 1. Servo vlvula de desvo....824
Cdigo de falla [CA1629] Error 2. Servo vlvula de desvo....825
Cdigo de falla [CA 1631] Error. Alta seal de voltaje en el sensor de posicin de la vlvula BP....826
Cdigo de falla [CA 1632] Vlvula BP Pos Sens Bajo Error....828
Cdigo de falla [CA1633] Error de Tiempo Muerto del Enlace de Datos KOMNET....830
Cdigo de falla [CA2185] Error de Alto Voltaje Suministrado al Sensor de Aceleracin....832
Cdigo de falla [CA2186] Error por Bajo Voltaje Suministrado al Sensor de Aceleracin....834
Cdigo de falla [CA2249] Error. Muy baja la presin en el mltiple de combustible....835
Cdigo de falla [CA2271] Error. Alta seal de voltaje del sensor de posicin de vlvula EGR....836
Cdigo de falla [CA2272] Error. Bajo voltaje en el sensor de posicin de la vlvula EGR....838
Cdigo de falla [CA2351] Error. Alta corriente en el solenoide de la vlvula EGR....840
Cdigo de falla [CA2352] Error. Baja corriente en el solenoide de la vlvula EGR....842
Cdigo de falla [CA2555] Error del Circuito Abierto Rel de la Parrilla del Calentador....844
Cdigo de falla [CA2556] Error del Circuito Corto Rel de la Parrilla del Calentador....846
Cdigo de falla [D110KB] Corto Circuito en el Mando del Rel de la Batera....848
Cdigo de falla [D163KB] Corto Circuito del Rel de la Luz Intermitente....850
Cdigo de falla [D195KA] Circuito Abierto del Rel de la Luz del Peldao....852
Cdigo de falla [D195KB] Circuito Corto del Rel de la Luz del Peldao....854
Cdigo de falla [D19JKZ] Anormalidad en el rel de cdigo personal....856
Cdigo de falla [D862KA] GPS circuito abierto de antena....858
Cdigo de falla [DA22KK] Error de Baja Energa en la Bomba 1 del Solenoide....860
Cdigo de falla [DA25KP] Anormalidad energtica de 5V en Sensor 1....862
Cdigo de falla [DA29KQ] Anormalidad en seleccin de modelo....864
Cdigo de falla [DA2RMC] CAN Discon (Detectado Con de Bomba)....866
Cdigo de Error [DA80MA] Anormal la Auto Lubricacin....870
Codigo de error [DAF8KB] Corto Circuito en la Camara de Suministro de Energa....872
Cdigo de falla [DAFGMC] Error. Mdulo GPS....874
Cdigo de falla [DAFRMC] Desconexin CAN (Monitor detectado)....875
Cdigo de falla [DGE5KB] Ambi. Cortocircuito en sensor de temperatura....880
Cdigo de falla [DGH2KB] Corto del sensor del aceite hidrulico....882
Cdigo de falla [DH25KA] Circuito Abierto del Sensor del Chorro Izquierdo....884
Cdigo de falla [DH25KB] Circuito Corto del Sensor del Chorro Izquierdo....886
Cdigo de falla [DH26KA] Circuito Abierto del Sensor del Chorro Derecho....888
Cdigo de falla [DH26KB] Circuito Corto del Sensor del Chorro Derecho....890
Cdigo de Falla [DHPEKA] Circuito Abierto del Sensor de Presin del Ventilador de la Bomba de Adelante....892
Cdigo de Falla [DHPEKB] Circuito Corto del Sensor de Presin del Ventilador de la Bomba de Adelante....894
Cdigo de Falla [DHPFKA] Circuito Abierto del Sensor de Presin del Ventilador de la Bomba Trasera....896
Cdigo de Falla [DHPFKB] Circuito Corta del Sensor de Presin del Ventilador de la Bomba Trasera....898
Cdigo de falla [DV20KB] Circuito corto en la alarma de traslado....900
Cdigo de falla [DW41KA] Circuito Abierto del Solenoide de Prioridad del Giro....902
Cdigo de falla [DW41KB] Corto Circuito en el Solenoide de la Prioridad del Giro....904
Cdigo de falla [DW43KA] Circuito Abierto del Solenoide de Velocidad de Traslado....906
Cdigo de falla [DW43KB] Corto Circuito en el Solenoide de la Velocidad de Traslado....908
Cdigo de falla [DW45KA] Circuito Abierto del Solenoide del Freno de Giro....910
Cdigo de falla [DW45KB] Corto Circuito en el Solenoide del Freno del Giro....912
Cdigo de Falla [DW7BKA] Circuito Abierto del Solenoide del Ventilador en Reversa....914
Cdigo de Falla [DW7BKB] Circuito Corto del Solenoide del Ventilador en Reversa....916
Cdigo de falla [DW7JKA] Circuito Abierto del Solenoide de Prioridad del Fondo de Descarga....918
Cdigo de falla [DW7JKB] Circuito Corto del Solenoide de Prioridad del Fondo de Descarga....920
Cdigo de falla [DW91KA] Circuito Abierto del Solenoide de la Unin de Traslado....922
Cdigo de falla [DW91KB] Corto Circuito en el Solenoide de Unin de Traslado....924
Cdigo de falla [DWK0KA] Circuito Abierto del Solenoide de Alivio de 2 Etapas....926
Cdigo de falla [DWK0KB] Corto circuito en el Solenoide de Alivio de 2 Etapas....928
Cdigo de falla [DX16KA] Circuito Abierto del Solenoide de la Bomba EPC del Ventilador....930
Cdigo de falla [DX16KB] Circuito Corto del Solenoide de la Bomba EPC del Ventilador....932
Cdigo de falla [DXAAKA] Circuito Abierto del Solenoide de la Bomba EPC del Ventilador....934
Cdigo de falla [DXAAKB] Circuito Corto del Solenoide de la Bomba EPC del Ventilador....936
Cdigo de falla [DXABKA] Circuito Abierto del Solenoide de la Bomba EPC Trasera....938
Cdigo de falla [DXABKB] Corto del Solenoide de la Bomba EPC Trasera....940
Cdigo de falla (DY20KA) Anormalidad en el Trabajo del Limpiaparabrisas....942
Cdigo de falla [DY20MA] Anormalidad en la Parada del Limpiaparabrisas....946
Cdigo de falla [DY2CKA] Circuito Abierto del Mando del Lavaparabrisas....948
Cdigo de falla [DY2CKB] Corto Circuito en el Mando del Lavaparabrisas....950
Cdigo de falla [DY2DKB] Corto circuito (Avance) en el Mando del limpiaparabrisas....952
Cdigo de falla [DY2EKB] Corto Circuito (Retroceso) en el Mando del Limpiaparabrisas....956
Cdigo de falla [DY2FMA] Anormalidad en el Funcionamiento del Limpiaparabrisas Superior....960
Cdigo de falla [DY2GKM] Anormalidad del Selector del Limpiaparabrisas....962
Localizacin de fallas del sistema elctrico (Modo E)....965
E-1 El motor no arranca (El motor no da vueltas)....965
E-2 El precalentador no trabaja....970
E-3 Cuando el interruptor de arranque est en posicin de ENDENDIDO (ON), el monitor de la mquina no muestra nada....974
E-4 Cuando el interruptor de arranque es colocado en la posicin "ON" (antes de arrancar el motor), se iluminan los tems de revisin bsica....977
E-5 La luz del tem de precaucin se enciende mientras el motor est funcionando....978
E-6 El tem de paro por emergencia se enciende mientras el motor est funcionando....980
E-7 El indicador de temperatura del refrigerante del motor no indica normalmente....981
E-8 El medidor del nivel de combustible no funciona normalmente....982
E-9 El indicador de temperatura del aceite hidrulico no indica normalmente....984
E-10 Las pantallas de monitor de la mquina son diferentes de los de la mquina real....986
E-11 Algunas reas del monitor de la mquina no se muestran....986
E-12 El interruptor de funcin no trabaja....986
E-13 El sistema de precalentamiento automtico no funciona (en temporada fra)....987
E-14 El auto desacelerador no funciona....988
E-15 El modo de trabajo no cambia....989
E-16 La velocidad de traslado no cambia....990
E-17 No se puede cancelar la alarma zumbadora....991
E-18 Cuando el interruptor de arranque es colocado en posicin "OFF", el hormetro de servicio no es exhibido....991
E-19 El modo de servicio no puede ser seleccionado....991
E-20 Cualquiera de los equipos de trabajo, giro, y el traslado no funciona o no se puede cerrar....992
E-21 Funcin de izamiento de la mquina no funciona o no se puede cancelar....994
E-22 La funcin de anti-impactos no opera apropiadamente....996
E-23 Freno de giro no funciona correctamente....998
E-24 El limpiaparabrisas y el lavaparabrisas no funcionan....1000
E-25 La alarma de traslado no suena o no para de sonar....1004
E-26 El indicador de SUBIR el Aguiln no se visualiza correctamente con la funcin de supervisin....1006
E-27 El indicador de BAJAR el Aguiln no se visualiza correctamente con la funcin de supervisin....1008
E-28 El indicador del Brazo ADENTRO no se visualiza correctamente con la funcin de supervisin....1010
E-29 El indicador del Brazo AFUERA no se visualiza correctamente con la funcin de supervisin....1012
E-30 REPLIEGUE del cucharn indicador no se visualiza correctamente con la funcin de supervisin....1014
E-31 DESCARGA del cucharn indicador no se visualiza correctamente con la funcin de supervisin....1016
E-32 Indicador de girono se visualiza correctamente con la funcin de supervisin....1018
E-33 "Traslado de la mano izquierda" no se visualiza correctamente con la funcin de supervisin....1020
E-34 "Traslado de la MANO DERECHA" no se visualiza correctamente con la funcin de supervisin....1022
E-35 Aditamento indicador no se visualiza correctamente con la funcin de supervisin....1024
E-36 La pistola elctrica de engrase no funciona....1026
E-37 El sistema KOMTRAX no funciona apropiadamente....1028
E-38 La bocina no suena o no se detiene....1029
E-39 La luz del peldao ni se enciende ni se apaga....1032
Localizacin de fallas de los sistemas hidrulico y mecnico (Modo H)....1036
Antes de la Localizacin de fallas en los sistemas hidrulico y mecnico....1036
Informacin en la tabla de localizacin de fallas (H-modo)....1040
H-1 Todo el equipo de trabajo, el giro y trabajo de traslado o falta de energa....1042
H-2 La velocidad del motor disminuye significativamente o el motor se cala....1044
H-3 Cualquier del equipo de trabajo, del traslado y el giro no funcionan....1046
H-4 Se escucha ruido anormal alrededor de la bomba hidrulica....1048
H-5 La operacin del aguiln carece de velocidad o de potencia....1049
H-6 La operacin del brazo carece de velocidad o de potencia....1051
H-7 La operacin del cucharn carece de velocidad o de potencia....1052
H-8 El aguiln no se mueve....1053
H-9 El brazo no se mueve....1053
H-10 El cucharn no se mueve....1053
H-11 El deslizamiento hidrulico del equipo de trabajo es grande....1054
H-12 El lapso de tiempo en el equipo de trabajo es grande....1056
H-13 La funcin de levantamiento pesado no funciona o no esta restaurada....1057
H-14 La Funcin de elevacin de la mquina no funciona o no se libera....1057
H-15 La funcin anti-impactos del aguiln no funciona o no se cancela....1057
H-16 Mquina se desva en una direccin contra la intencin del operador cuando se traslada....1058
H-17 La mquina se desva en gran parte al arrancar....1061
H-18 La mquina se desva grandemente durante las operaciones combinadas....1062
H-19El traslado es lento, o le falta potencia....1063
H-20 Una de las pistas no se ejecuta....1064
H-21 La velocidad de traslado no cambia....1065
H-22 La estructura superior no gira....1066
H-23 La velocidad de giro es baja o de aceleracin es pobre....1067
H-24 En el funcionamiento combinado de los equipos de trabajo, la aceleracin de oscilacin es bajo o la velocidad de giro es pobre....1068
H-25 La estructura superior sigue movindose cuando se detiene el giro....1070
H-26 Se producen sacudidas grandes cuando la estructura superior termina su giro....1071
H-27 Ruido inusual grande se oye cuando la estructura superior deja de balanceo....1072
H-28 Desplazamiento del giro en una pendiente es grande....1073
H-29 La revolucin del ventilador es anormal (El sonido o vibracin es anormalmente grande, o el motor se recalienta)....1074
Localizacin de fallas en el motor (Modo-S)....1076
Mtodo para el uso de la tabla de localizacin de fallas....1076
S-1 El arranque es pobre....1080
S-2 El motor no arranca....1082
S-3 El motor no acelera suavemente....1086
S-4 El motor se para durante la operacin....1087
S-5 El motor funciona de forma irregular o est inestable....1088
S-6 El motor le falta potencia....1090
S-7 El gas de escape es negro (combustin incompleta)....1092
S-8 Excesivo consumo de aceite (o el humo de escape es color azul)....1094
S-9 El aceite se contamina rpidamente....1095
S-10 El consumo de combustible es excesivo....1096
S-11 Hay presencia de aceite en el enfriador (o el enfriador se escapa en borboteos o el nivel del enfriador desciende)....1097
S-12 Cae la presin del aceite....1098
S-13 Aumenta el nivel de aceite (refrigerante o combustible en el aceite)....1100
S-14 La temperatura del refrigerante se eleva demasiado (sobrecalentamiento)....1102
S-15 Un ruido anormal es producido....1103
S-16 La vibracin es excesiva....1104
Manual de Taller....1105
50 Desarme y Ensamblaje....1105
Contenido....1106
Informacin general sobre desensamble y ensamble....1108
Como leer Desarme y Ensamblaje....1108
Lista de materiales de recubrimiento....1110
Lista de herramientas especiales....1113
Dibujos de las herramientas especiales....1120
Motor y sistema de enfriamiento....1125
Desmontaje e instalacin del motor, PTO y conjunto de la bomba hidrulica....1125
Desmontaje e instalacin del conjunto del enfriador....1133
Remocin e instalacin del conjunto del posenfriador....1139
Desmontaje e instalacin del enfriador de combustible y el conjunto del condensador de aire....1141
Remocin e instalacin del conjunto del motor del ventilador....1143
Desmontaje e instalacin del conjunto del tanque de combustible....1148
Motor....1150
Desmontaje e instalacin del conjunto de la bomba de suministro de combustible....1150
Desmontaje e instalacin del conjunto del cabezal del cilindro....1155
Remocin e instalacin del conjunto del inyector de combustible....1171
Extraccin e instalacin del sello delantero del motor....1174
Extraccin e instalacin del sello trasero del motor....1176
Tren de potencia....1181
Remocin e instalacin de los conjuntos PTO....1181
Desensamblaje y ensamblaje del conjunto de la toma de fuerza (TDF)....1188
Remocin e instalacin del motor de giro y el conjunto de la maquinaria de giro....1190
Desarme y ensamblaje del conjunto de la maquinaria de giro....1193
Remocin e instalacin del conjunto del crculo de giro....1200
Desensamble y ensamble del conjunto del mando final....1201
Tren de rodaje y bastidor....1213
Separacin y conexin instalacin del conjunto de la zapata de la oruga....1213
Desensamble y ensamble de un eslabn en el campo....1215
Remocin e instalacin del conjunto de la rueda tensora....1219
Desensamble y ensamble de conjuntos de la rueda tensora....1220
Desensamble y ensamble de conjuntos de la rueda tensora del cilindro de ajuste....1223
Remocin e instalacin del conjunto del resorte tensor....1224
Desarme y ensamblaje del conjunto del resorte amortiguador....1226
Desmontaje e instalacin del conjunto del rodillo superior....1228
Desarme y ensamblaje del conjunto del rodillo superior....1229
Desmontaje e instalacin del conjunto de los rodillos....1232
Desarme y ensamblaje del conjunto del rodillo inferior....1233
Desmontaje y instalacin del conjunto de la estructura del piso....1236
Remocin e instalacin del conjunto del contrapeso....1238
Remocin e instalacin del conjunto de removedor del contrapeso....1239
Sistema hidrulico....1243
Desmontaje e instalacin del conjunto del tanque hidrulico....1243
Desmontaje e instalacin del conjunto de la bomba principal....1245
Desmontaje e instalacin del sello de aceite....1252
Desmontaje e instalacin del conjunto de la bomba del ventilador de enfriamiento....1253
Remocin e instalacin del conjunto de la vlvula de control....1256
Ensamblaje del conjunto de la vlvula reguladora....1259
Remocin e instalacin del conjunto del motor de giro....1265
Remocin e instalacin de conjunto de la unin giratoria central....1266
Desmontaje y montaje del conjunto de la junta central de montaje giratorio....1268
Remocin e instalacin del conjunto del motor de traslado....1270
Remocin e instalacin del conjunto de la vlvula de solenoide....1271
Remocin e instalacin del conjunto de la vlvula de amortiguacin del aguiln....1273
Desensamble y ensamble del conjunto de la vlvula PPC del equipo de trabajo....1274
Desensamble y ensamble del conjunto de la vlvula PPC de traslado....1276
Desarme y ensamble del conjunto del cilindro hidrulico....1279
Desmontaje y montaje del conjunto de pistola de grasa....1286
Equipo de trabajo....1287
Retiro e instalacin del conjunto del cilindro del cucharn....1287
Retiro e instalacin del conjunto del cilindro del brazo....1291
Retiro e instalacin del conjunto del cilindro del aguiln....1295
Retiro e instalacin del conjunto del cilindro del fondo de descarga....1299
Remocin e instalacin de los conjuntos del cucharn....1301
Remocin e instalacin del conjunto del brazo....1304
Remocin e instalacin del conjunto del aguiln....1308
Remocin e instalacin del conjunto del equipo de trabajo....1312
Cabina y sus aditamentos....1316
Remocin e instalacin del conjunto de la cabina del operador....1316
Remocin e instalacin del cristal de la cabina del operador (cristal adherido de las ventanas)....1319
Remocin e instalacin del conjunto de la ventana delantera....1328
Sistema Elctrico....1335
Extraccin e instalacin del conjunto de la unidad acondicionador de aire....1335
Remocin e instalacin del conjunto del controlador del motor....1338
Retiro e instalacin del conjunto del monitor....1340
Extraccin e instalacin del conjunto del controlador de la bomba....1342
Remocin e instalacin del conjunto del terminal KOMTRAX....1344
Manual de Taller....1345
60 Estndar de mantenimiento....1345
Contenido....1346
Motor y sistema de enfriamiento....1347
Acople....1347
Tren de potencia....1348
Crculo de giro....1348
Maquinaria de giro....1349
Mando final....1352
Rueda motriz....1354
Tren de rodaje y bastidor....1356
Bastidor de la oruga y gua de la rueda tensora....1356
Rueda tensora....1358
Rodillo superior....1360
Rodillo inferior....1362
Zapata de la oruga....1364
Sistema hidrulico....1368
Motor de ventilador de enfriamiento....1368
Vlvula de control....1370
Motor de giro....1376
Unin giratoria central....1378
Vlvula PPC....1379
Equipo de trabajo....1382
Equipo de trabajo....1382
Dimensin del equipo de trabajo....1388
Cilindro hidrulico....1392
Manual de Taller....1399
80 Apndice....1399
Tabla de contenido....1400
Acondicionador de aire....1401
Advertencias para refrigerante....1401
Componente del acondicionador de aire....1402
Configuracin y funcin del ciclo de refrigeracin....1404
Descripcin del ciclo de refrigeracin....1405
Unidad acondicionadora de aire....1408
Controlador del acondicionador de aire....1413
Compresor....1414
Condensador....1415
Recibidor-secador....1416
Procedimiento para realizar las pruebas y la localizacin de fallas....1418
Esquema elctrico y disposicin de las clavijas del conector....1420
Diagrama del sistema....1422
Detalle de la unidad acondicionador de aire....1424
Esquema de piezas y conectores....1426
Prueba de escapes de aire (conducto)....1429
Probando con la funcin de auto diagnstico....1430
Comprobacin del control de temperatura....1433
Comprobacin (modo) intercambio de ventilacin....1435
Comprobacin del amortiguador de cambio de aire FRESH/RECIRC (LIMPIO/DE RECIRCULACIN)....1438
Verificacin del sensor interior....1440
Verificacin del sensor de temperatura del evaporador....1441
Verificacin del sensor de la luz solar....1443
Comprobacin del (doble) interruptor de presin para el refrigerante....1444
Pruebas de rels....1445
Tablas de localizacin de fallas 1....1446
Tablas de localizacin de fallas 2....1448
Informacin en la tabla de localizacin de fallas....1450
Localizacin de fallas de problemas de alimentacin y sistema de comunicacin CAN (acondicionador de aire no funciona)....1452
Localizacin de fallas para el compresor y el sistema del refrigerante (Aire no esta fro)....1457
Localizacin de fallas para el sistema del soplador del motor (No sale aire o el fluyo de aire es anormal)....1461
Localizacin de fallas en el control de temperatura....1465
Comprobacin para el (modo) intercambio de ventilacin....1468
Localizacin de fallas para el intercambio de FRESH/RECIRC....1470
Localizacin de falla para el sistema de sensor de temperatura....1472
Localizacin de fallas con el medidor de la presin....1474
Conexin para herramienta de servicio....1476
Precauciones para desconectar la tuberia del acondicionador de aire....1478
Manipulacin del aceite del compresor....1480
Manual de Taller....1483
90 Diagramas y dibujos....1483
Contenido....1484
Diagrama del circuito hidrulico....1485
Smbolos usados en los diagramas del circuito hidrulico....1485
Diagrama del circuito elctrico....1491
Smbolos usados en los diagramas del circuito elctricos....1491
A....1512
B....1512
C....1512
D....1513
E....1513
F....1514
H....1514
I....1514
L....1514
M....1514
N....1515
P....1515
R....1515
S....1515
T....1515
U....1516
V....1516
ndice....1512
SEN05276-03 - Hydraulic Excavator PC800-8E0, PC800LC-8E0, PC800SE-8E0, PC850-8E0, PC850SE-8E0 Shop Manual....1520
COVER....1520
00 Index and foreword....1530
Table of contents....1531
Table of contents....1531
Foreword and general information....1541
Safety notice....1541
How to read the shop manual....1546
Explanation of terms for maintenance standard....1548
Handling of hydraulic components....1550
Method of disconnecting and connecting push-pull type coupler....1552
Handling of electric equipment....1555
How to read electric wire code....1565
Precautions when performing work....1568
Standard tightening torque table....1571
List of abbreviation....1575
Conversion table....1579
01 Specification....1584
Specifications....1587
Specifications drawing....1587
Specifications....1591
Table of weight....1601
Table of fuel, coolant and lubricants....1609
10 Structure and function....1612
Engine and cooling system....1614
Coupling....1614
Coupling lubrication system....1615
Cooling system....1617
Power train system....1619
Power train....1619
Swing circle....1621
Swing machinery....1622
Final drive....1624
Undercarriage and frame....1625
Track frame....1625
Idler cushion....1627
Hydraulic system....1629
Hydraulic component layout....1629
Hydraulic tank and filter....1631
Hydraulic pump....1633
Pump control system....1641
Servo valve....1643
Self-pressure reducing valve....1652
Cooling fan pump....1655
Cooling fan motor....1664
Electrical grease pump....1670
Control valve....1671
Straight-travel valve....1680
Swing motor....1683
Center swivel joint....1687
Travel motor....1688
PPC valve....1698
Solenoid valve....1706
Accumulator....1714
Quick return valve....1715
Return oil filter....1718
Line oil filter....1719
Pilot oil filter....1720
Drain oil filter....1721
Electrical system....1722
Engine control....1722
Electric control system....1732
Monitor system....1771
Sensors....1801
KOMTRAX system....1805
20 Standard value table....1808
Standard value table....1810
Standard value table for engine....1810
Standard value table for machine....1811
30 Testing and adjusting....1824
Tool for testing, adjusting and troubleshooting....1826
Tools for testing, adjusting, and troubleshooting....1826
Engine and cooling system....1830
Testing engine speed....1830
Testing intake air pressure (boost pressure)....1831
Testing exhaust gas temperature....1832
Testing exhaust gas color....1833
Adjusting valve clearance....1835
Testing compression pressure....1836
Testing blowby pressure....1838
Testing engine oil pressure....1839
Testing EGR valve and bypass valve drive pressure....1840
Handling fuel system parts....1841
Releasing remaining pressure from fuel system....1842
Testing fuel pressure....1843
Testing fuel return rate and leakage....1844
Bleeding air from fuel circuit....1847
Testing fuel circuit for leakage....1849
Testing and adjusting alternator belt tension....1850
Testing and adjusting air conditioner compressor belt tension....1851
Undercarriage and frame....1852
Testing swing circle bearing clearance....1852
Checking and adjusting track tension....1853
Hydraulic system....1854
Testing and adjusting oil pressure in work equipment, swing, and travel circuits....1854
Testing and adjusting control circuit oil pressure (output pressure of self-pressure reducing valve)....1860
Testing and adjusting control signal of main pump....1862
Testing PPC valve output pressure....1869
Measuring outlet pressure of solenoid valve, swing PPC shuttle valve, and swing priority selector valve....1873
Adjusting play of work equipment and swing PPC vavles....1878
Testing and adjusting travel deviation....1879
Inspecting locations of hydraulic drift in work equipment....1881
Measuring fan speed....1882
Measuring fan circuit oil pressure....1883
Measuring fan pump EPC current....1884
Measuring fan pump EPC solenoid valve outlet pressure....1885
Measuring oil leakage....1886
Releasing remaining pressure from hydraulic circuit....1890
Bleeding air from various parts....1891
Inspection procedures for diode....1894
Adjusting mirrors....1895
Electrical system....1896
Special functions of machine monitor....1896
Handling voltage circuit of engine controller....1940
Preparatory work for troubleshooting of electrical system....1941
Pm Clinic....1945
Pm clinic service....1945
UNDERCARRIAGE INSPECTION REPORT....1952
40 Troubleshooting....1954
General information on troubleshooting....1960
Points to remember when troubleshooting....1960
Sequence of events in troubleshooting....1961
Checks before troubleshooting....1962
Classification and procedures for troubleshooting....1988
Failure codes table....1991
Symptom and troubleshooting numbers....1996
Information in troubleshooting table....1999
Troubleshooting method for open circuit in wiring harness of pressure sensor system....2001
Connector list and layout....2003
Connection table for connector pin numbers....2014
T- branch box and T- branch adapter table....2050
Fuse locations....2053
Troubleshooting by failure code....2056
Failure code [989L00] Engine Controller Lock Caution 1....2056
Failure code [989M00] Engine Controller Lock Caution 2....2057
Failure code [989N00] Engine Controller Lock Caution 3....2057
Failure code [AA10NX] Air Cleaner Clogging....2058
Failure code [AB00KE] Charge Voltage Low....2059
Failure code [B@BAZG] Eng Oil Press Low....2061
Failure code [B@BAZK] Eng Oil Level Low....2062
Failure code [B@BCNS] Eng Water Overheat....2063
Failure code [B@BCZK] Eng Water Level Low....2065
Failure code [B@HANS] Hyd Oil Overheat....2067
Failure code [CA111] ECM Critical Internal Failure....2069
Failure code [CA115] Eng Ne and Bkup Speed Sens Error....2071
Failure code [CA122] Chg Air Press Sensor High Error....2073
Failure code [CA123] Chg Air Press Sensor Low Error....2075
Failure code [CA131] Throttle Sensor High Error....2077
Failure code [CA132] Throttle Sensor Low Error....2079
Failure code [CA135] Eng Oil Press Sensor High Error....2081
Failure code [CA141] Eng Oil Press Sensor Low Error....2083
Failure code [CA144] Coolant Temp Sens High Error....2085
Failure code [CA145] Coolant Temp Sens Low Error....2087
Failure code [CA153] Chg Air Temp Sensor High Error....2089
Failure code [CA154] Chg Air Temp Sensor Low Error....2091
Failure code [CA187] Sens Supply 2 Volt Low Error....2093
Failure code [CA221] Ambient Press Sens High Error....2095
Failure code [CA222] Ambient Press Sens Low Error....2097
Failure code [CA227] Sens Supply 2 Volt High Error....2099
Failure code [CA234] Eng Overspeed....2100
Failure code [CA238] Ne Speed Sens Supply Volt Error....2101
Failure code [CA263] Fuel Temp Sensor High Error....2103
Failure code [CA265] Fuel Temp Sensor Low Error....2105
Failure code [CA271] IMV/PCV1 Short Error....2107
Failure code [CA272] IMV/PCV1 Open Error....2108
Failure code [CA273] PCV2 Short Error....2109
Failure code [CA274] PCV2 Open Error....2110
Failure code [CA322] Inj #1(L#1) Open/Short Error....2111
Failure code [CA323] Inj #5 (L#5) Open/Short Error....2113
Failure code [CA324] Inj #3(L#3) Open/Short Error....2115
Failure code [CA325] Inj #6 (L#6) Open/Short Error....2117
Failure code [CA331] Inj #2(L#2) Open/Short Error....2119
Failure code [CA332] Inj #4 (L#4) Open/Short Error....2121
Failure code [CA342] Calibration Code Incompatibility....2123
Failure code [CA351] Injectors Drive Circuit Error....2124
Failure code [CA352] Sens Supply 1 Volt Low Error....2125
Failure code [CA386] Sens Supply 1 Volt High Error....2127
Failure code [CA441] Battery Voltage Low Error....2127
Failure code [CA442] Battery Voltage High Error....2128
Failure code [CA449] Rail Press Very High Error....2128
Failure code [CA451] Rail Press Sensor High Error....2129
Failure code [CA452] Rail Press Sensor Low Error....2131
Failure code [CA553] Rail Press High Error....2133
Failure code [CA554] Rail Press Sensor In Range Error....2134
Failure code [CA559] Supply Pump Press Low Error 1....2135
Failure code [CA689] Eng Ne Speed Sensor Error....2139
Failure code [CA731] Eng Bkup Speed Sens Phase Error....2141
Failure code [CA757] All Continuous Data Lost Error....2142
Failure code [CA778] Eng Bkup Speed Sensor Error....2143
Failure code [CA1228] EGR Valve Servo Error 1....2145
Failure code [CA1625] EGR Valve Servo Error 2....2146
Failure code [CA1626] BP Valve Sol Current High Error....2147
Failure code [CA1627] BP Valve Sol Current Low Error....2149
Failure code [CA1628] Bypass Valve Servo Error 1....2151
Failure code [CA1629] Bypass Valve Servo Error 2....2152
Failure code [CA1631] BP Valve Pos Sens High Error....2153
Failure code [CA1632] BP Valve Pos Sens Low Error....2155
Failure code [CA1633] KOMNET Datalink Timeout Error....2157
Failure code [CA2185] Throt Sens Sup Volt High Error....2159
Failure code [CA2186] Throt Sens Sup Volt Low Error....2161
Failure code [CA2249] Rail Press Very Low Error....2162
Failure code [CA2271] EGR Valve Pos Sens High Error....2163
Failure code [CA2272] EGR Valve Pos Sens Low Error....2165
Failure code [CA2351] EGR Valve Sol Current High Error....2167
Failure code [CA2352] EGR Valve Sol Current Low Error....2169
Failure code [CA2555] Grid Htr Relay Open Circuit Error....2171
Failure code [CA2556] Grid Htr Relay Short Circuit Error....2173
Failure code [D110KB] Battery Relay Drive Short Circuit....2175
Failure code [D163KB] Flash Light Relay Short Circuit....2177
Failure code [D195KA] Step Light Relay Open Circuit....2179
Failure code [D195KB] Step Light Relay Short Circuit....2181
Failure code [D19JKZ] Personal Code Relay Abnormality....2183
Failure code [D862KA] GPS Antenna Open Circuit....2185
Failure code [DA22KK] Pump Solenoid Power Low Error....2187
Failure code [DA25KP] 5V Sensor1 Power Abnormality....2189
Failure code [DA29KQ] Model Selection Abnormality....2191
Failure code [DA2RMC] CAN Discon (Pump Con Detected)....2193
Failure code [DA80MA] Auto. Lub. Abnormal....2197
Failure code [DAF8KB] Camera Power Supply Short Circuit....2199
Failure code [DAFGMC] GPS Module Error....2201
Failure code [DAFRMC] CAN Discon (Monitor Detected)....2202
Failure code [DGE5KB] Ambi. Temp Sensor Short Circuit....2207
Failure code [DGH2KB] Hyd Oil Sensor Short....2209
Failure code [DH25KA] L Jet Sensor Open Circuit....2211
Failure code [DH25KB] L Jet Sensor Short Circuit....2213
Failure code [DH26KA] R Jet Sensor Open Circuit....2215
Failure code [DH26KB] R Jet Sensor Short Circuit....2217
Failure code [DHPEKA] F Pump P. Sensor Open Circuit....2219
Failure code [DHPEKB] F Pump P. Sensor Short Circuit....2221
Failure code [DHPFKA] R Pump P. Sensor Open Circuit....2223
Failure code [DHPFKB] R Pump P. Sensor Short Circuit....2225
Failure code [DV20KB] Travel alarm short circuit....2227
Failure code [DW41KA] Swing Priority Sol Open Circuit....2229
Failure code [DW41KB] Swing Priority Sol Short Circuit....2231
Failure code [DW43KA] Travel Speed Sol Open Circuit....2233
Failure code [DW43KB] Travel Speed Sol Short Circuit....2235
Failure code [DW45KA] Swing Brake Sol Open Circuit....2237
Failure code [DW45KB] Swing Brake Sol Short Circuit....2239
Failure code [DW7BKA] Fan Reverse Sol Open Circuit....2241
Failure code [DW7BKB] Fan Reverse Sol Short Circuit....2243
Failure code [DW7JKA] Bottom Dump Priority Sol Open Circuit....2245
Failure code [DW7JKB] Bottom Dump Priority Sol Short Circuit....2247
Failure code [DW91KA] Travel Junction Sol Open Circuit....2249
Failure code [DW91KB] Travel Junction Sol Short Circuit....2251
Failure code [DWK0KA] 2-stage Relief Sol Open Circuit....2253
Failure code [DWK0KB] 2-stage Relief Sol Short Circuit....2255
Failure code [DX16KA] Fan Pump EPC Sol Open Circuit....2257
Failure code [DX16KB] Fan Pump EPC Sol Short Circuit....2259
Failure code [DXAAKA] F Pump EPC Sol Open Circuit....2261
Failure code [DXAAKB] F Pump EPC Sol Short Circuit....2263
Failure code [DXABKA] R Pump EPC Sol Open Circuit....2265
Failure code [DXABKB] R Pump EPC Sol Short Circuit....2267
Failure code [DY20KA] Wiper Working Abnormality....2269
Failure code [DY20MA] Wiper Parking Abnormality....2273
Failure code [DY2CKA] Washer Drive Open Circuit....2275
Failure code [DY2CKB] Washer Drive Short Circuit....2277
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit....2279
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit....2283
Failure code [DY2FMA] Upper Wiper Working Abnormality....2287
Failure code [DY2GKM] Wiper Select Abnormality....2289
Troubleshooting of electrical system (E-mode)....2292
E-1 Engine does not start (Engine does not crank)....2292
E-2 Preheater does not operate....2297
E-3 When starting switch is turned to ON position, machine monitor displays nothing....2301
E-4 When starting switch is turned to ON position (before starting engine), basic check monitor lights up....2304
E-5 Precaution item lights up while engine is running....2305
E-6 Emergency stop item lights up while engine is running....2307
E-7 Engine coolant temperature gauge does not indicate properly....2308
E-8 Fuel gauge does not indicate properly....2309
E-9 Hydraulic oil temperature gauge does not indicate properly....2311
E-10 Displays on machine monitor are different from those for actual machine....2313
E-11 Some areas of machine monitor screen are not displayed....2313
E-12 Function switch does not operate....2313
E-13 Automatic warm-up system does not operate (in cold season)....2314
E-14 Auto-decelerator does not operate properly....2315
E-15 Working mode does not change....2316
E-16 Travel speed does not change....2317
E-17 Alarm buzzer cannot be canceled....2318
E-18 When starting switch is turned OFF, service meter is not displayed40....2318
E-19 Service mode cannot be selected....2318
E-20 Any of work equipment, swing and travel do not operate or cannot be locked....2319
E-21 Machine push-up function does not operate or cannot be canceled40....2321
E-22 Boom shockless function does not operate properly....2323
E-23 Swing brake does not operate properly....2325
E-24 Windshield wiper and window washer do not operate....2327
E-25 Travel alarm does not sound or does not stop sounding....2331
E-26 Boom RAISE indicator is not displayed properly with monitoring function....2333
E-27 Boom LOWER indicator is not displayed properly with monitoring function....2335
E-28 Arm IN indicator is not displayed properly with monitoring function40....2337
E-29 Arm OUT indicator is not displayed properly with monitoring function....2339
E-30 Bucket CURL indicator is not displayed properly with monitoring function....2341
E-31 Bucket DUMP indicator is not displayed properly with monitoring function....2343
E-32 Swing indicator is not displayed properly with monitoring function40....2345
E-33 "L.H. travel" is not displayed properly with monitoring function....2347
E-34 "R.H. travel" is not displayed properly with monitoring function....2349
E-35 "Attachment" is not displayed properly with monitoring function....2351
E-36 Electric grease gun does not operate....2353
E-37 KOMTRAX system does not operate properly....2355
E-38 Horn does not sound or does not stop sounding....2356
E-39 Step light does not light up or go off....2359
Troubleshooting of hydraulic and mechanical system (H-mode)....2363
Before starting troubleshooting for hydraulic and mechanical systems....2363
Information in troubleshooting table (H-mode)....2367
H-1 All of work equipment, swing and travel work slow or lack power....2369
H-2 Engine speed lowers significantly or engine stalls....2371
H-3 Any of work equipment, swing and travel does not work....2373
H-4 Unusual noise is heard from around hydraulic pump....2375
H-5 Boom operation lacks speed or power....2376
H-6 Arm operation lacks speed or power....2378
H-7 Bucket operation lacks speed or power....2379
H-8 Boom does not move....2380
H-9 Arm does not move....2380
H-10 Bucket does not move....2380
H-11 Hydraulic drift of work equipment is large....2381
H-12 Time lag of work equipment is large....2383
H-13 Heavy lift function does not work or is not released....2384
H-14 Machine push-up function does not work or is not released....2384
H-15 Boom shockless function does not work or is not canceled....2384
H-16 Machine deviates in one direction against operator's intention when travelling....2385
H-17 Machine deviates significantly at start....2388
H-18 Machine deviates significantly during combined operation....2389
H-19 Travel works slow or lack power....2390
H-20 One of tracks does not run....2391
H-21 Travel speed does not change....2392
H-22 Upper structure does not swing....2393
H-23 Swing speed is low or swing acceleration is poor....2394
H-24 In combined operation with work equipment, swing speed is low or swing acceleration is poor....2395
H-25 Upper structure overruns excessively when it stops swinging....2397
H-26 Shock is large when upper structure stops swinging....2398
H-27 Large unusual noise is heard when upper structure stops swinging40....2399
H-28 Swing drift on a slope is large....2400
H-29 Fan revolution is abnormal (Fan sound/vibration is abnormally large or engine overheats)....2401
Troubleshooting of engine (S-mode)....2403
Method of using troubleshooting chart....2403
S-1 Startability is poor....2407
S-2 Engine does not start....2409
S-3 Engine does not pick up smoothly....2413
S-4 Engine stops during operation....2414
S-5 Engine runs rough or is unstable....2415
S-6 Engine lacks power....2417
S-7 Exhaust smoke is black (incomplete combustion)....2419
S-8 Oil consumption is excessive (or exhaust smoke is blue)....2421
S-9 Oil becomes contaminated early....2422
S-10 Fuel consumption is excessive....2423
S-11 Oil is in coolant (or coolant spurts or coolant level goes down)....2424
S-12 Oil pressure drops....2425
S-13 Oil level rises (coolant or fuel in oil)....2427
S-14 Coolant temperature rises too high (overheating)....2429
S-15 Unusual noise is made....2430
S-16 Vibration is excessive....2431
50 Disassembly and assembly....2432
General information on disassembly and assembly....2435
How to read Disassembly and Assembly....2435
Coating materials list....2437
Special tools list....2440
Sketches of special tools....2447
Engine and cooling system....2452
Removal and installation of engine, PTO and hydraulic pump assembly50....2452
Removal and installation of cooling assembly....2460
Removal and installation of aftercooler assembly....2466
Removal and installation of fuel cooler and air condenser assembly....2468
Removal and installation of fan motor assembly....2470
Removal and installation of fuel tank assembly....2475
Engine....2477
Removal and installation of fuel supply pump assembly....2477
Removal and installation of cylinder head assembly....2482
Removal and installation of fuel injector assembly....2498
Removal and installation of engine front seal....2501
Removal and installation of engine rear seal....2503
Power train....2508
Removal and installation of PTO assembly....2508
Disassembly and assembly of PTO assembly....2515
Removal and installation of swing motor and swing machinery assembly50....2517
Disassembly and assembly of swing machinery assembly....2520
Removal and installation of swing circle assembly....2527
Disassembly and assembly of final drive assembly....2528
Undercarriage and frame....2540
Separation and connection of track shoe assembly....2540
Disassembly and assembly of one link in field....2542
Removal and installation of idler assembly....2546
Disassembly and assembly of idler assembly....2547
Disassembly and assembly of idler adjustment cylinder assembly....2550
Removal and installation of recoil spring assembly....2551
Disassembly and assembly of recoil spring assembly....2553
Removal and installation of carrier roller assembly....2555
Disassembly and assembly of carrier roller assembly....2556
Removal and installation of track roller assembly....2559
Disassembly and assembly of track roller assembly....2560
Removal and installation of revolving frame assembly....2563
Removal and installation of counterweight assembly....2565
Removal and installation of counterweight remover assembly....2566
Hydraulic system....2570
Removal and installation of hydraulic tank assembly....2570
Removal and installation of main pump assembly....2572
Removal and installation of main pump input shaft oil seal....2579
Removal and installation of cooling fan pump assembly....2580
Removal and installation of control valve assembly....2583
Assembly of control valve assembly....2586
Removal and installation of swing motor assembly....2592
Removal and installation of center swivel joint assembly....2593
Disassembly and assembly of center swivel joint assembly....2595
Removal and installation of travel motor assembly....2597
Removal and installation of solenoid valve assembly....2598
Removal and installation of boom damping valve assembly....2600
Disassembly and assembly of work equipment PPC valve assembly....2601
Disassembly and assembly of travel PPC valve assembly....2603
Disassembly and assembly of hydraulic cylinder assembly....2606
Disassembly and assembly of grease gun assembly....2613
Work equipment....2614
Removal and installation of bucket cylinder assembly....2614
Removal and installation of arm cylinder assembly....2618
Removal and installation of boom cylinder assembly....2622
Removal and installation of bottom dump cylinder assembly....2626
Removal and installation of bucket assembly....2628
Removal and installation of arm assembly....2631
Removal and installation of boom assembly....2635
Removal and installation of work equipment assembly....2639
Cab and its attachments....2643
Removal and installation of operator's cab assembly....2643
Removal and installation of operator's cab glass (adhered window glass)....2646
Removal and installation of front window assembly....2655
Electrical system....2662
Removal and installation of air conditioner unit assembly....2662
Removal and installation of engine controller assembly....2665
Removal and installation of monitor assembly....2667
Removal and installation of pump controller assembly....2669
Removal and installation of KOMTRAX terminal assembly....2671
60 Maintenance standard....2672
Engine and cooling system....2674
Coupling....2674
Power train....2675
Swing circle....2675
Swing machinery....2676
Final drive....2679
Sprocket....2681
Undercarriage and frame....2683
Track frame and idler cushion....2683
Idler....2685
Carrier roller....2687
Track roller....2689
Track shoe....2691
Hydraulic system....2695
Cooling fan motor....2695
Control valve....2697
Swing motor....2703
Center swivel joint....2705
PPC valve....2706
Work equipment....2709
Work equipment....2709
Work equipment dimension....2715
Hydraulic cylinder....2719
80 Appendix....2726
Air conditioner....2728
Precautions for refrigerant....2728
Air conditioner component....2729
Configuration and function of refrigeration cycle....2731
Outline of refrigeration cycle....2732
Air conditioner unit....2735
Air conditioner controller....2740
Compressor....2741
Condenser....2742
Receiver drier....2743
Procedure for testing and troubleshooting....2745
Circuit diagram and arrangement of connector pins....2747
System diagram....2749
Detail of air conditioner unit....2751
Parts and connectors layout....2753
Testing air leakage (duct)....2756
Testing with self-diagnosis function....2757
Testing temperature control....2760
Testing vent (mode) changeover....2762
Testing FRESH/RECIRC air changeover....2765
Testing inner sensor....2767
Testing evaporator temperature sensor....2768
Testing sunlight sensor....2770
Testing (dual) pressure switch for refrigerant....2771
Testing relays....2772
Troubleshooting chart 1....2773
Troubleshooting chart 2....2775
Information in troubleshooting table....2777
Troubleshooting for power supply and CAN communication system (Air conditioner does not operate)....2779
Troubleshooting for compressor and refrigerant system (Air is not cooled)....2784
Troubleshooting for blower motor system (No air comes out or air flow is abnormal)....2788
Troubleshooting for temperature control....2792
Troubleshooting for vent (mode) changeover....2795
Troubleshooting for FRESH/RECIRC air changeover....2797
Troubleshooting for temperature sensor system....2799
Troubleshooting with gauge pressure....2801
Connection of service tool....2803
Precautions for disconnecting and connecting air conditioner piping....2805
Handling of compressor oil....2807
90 Diagrams and drawings....2810
Hydraulic circuit diagram....2812
Symbols used in hydraulic circuit diagrams....2812
Hydraulic circuit diagram....2816
Electrical circuit diagram....2818
Symbols used in electric circuit diagrams....2818
Electrical circuit diagram....2822
Index....2839
TEN00379-04 - Hydraulic Excavator PC800-8E0, PC800LC-8E0, PC800SE-8E0, PC850-8E0, PC850SE-8E0 Operation & Maintenance Manual....2847
COVER....2847
FOREWORD....2848
BEFORE READING THIS MANUAL....2849
SAFETY INFORMATION....2850
INTRODUCTION....2851
USE OF MACHINE....2851
DIRECTIONS OF MACHINE....2851
VISIBILITY FROM OPERATOR'S SEAT....2852
PRODUCT INFORMATION....2854
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE....2854
EPA REGULATIONS, ENGINE NUMBER PLATE....2854
SERVICE METER LOCATION....2855
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR....2855
CONTENTS....2856
SAFETY....2860
SAFETY....2861
SAFETY LABELS....2864
LOCATION OF SAFETY LABELS....2865
SAFETY LABELS....2866
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE....2873
PRECAUTIONS BEFORE STARTING OPERATION....2873
PREPARATIONS FOR SAFE OPERATION....2873
FIRE PREVENTION....2875
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE....2876
DO NOT GET CAUGHT IN WORK EQUIPMENT....2878
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES....2878
PROTECTION AGAINST FALLING, FLYING, INTRUDING OBJECTS....2879
UNAUTHORIZED MODIFICATION....2879
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS....2880
PRECAUTIONS RELATED TO CAB GLASS....2880
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING....2880
PRECAUTIONS FOR OPERATION....2881
PRECAUTIONS FOR JOBSITE....2881
STARTING ENGINE....2883
OPERATION....2885
TOWING....2893
LIFTING OBJECTS WITH BUCKET....2894
PRECAUTIONS FOR MAINTENANCE....2895
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE....2895
PRECAUTIONS FOR INSPECTION AND MAINTENANCE....2899
OPERATION....2906
MACHINE VIEW ILLUSTRATIONS....2907
OVERALL MACHINE VIEW....2907
CONTROLS AND GAUGES....2908
DETAILED CONTROLS AND GAUGES....2910
MONITORING SYSTEM....2910
SWITCHES....2978
CONTROL LEVERS AND PEDALS....2985
SUN ROOF....2988
WINDSHIELD....2989
EMERGENCY ESCAPE HAMMER....2995
DOOR LOCK....2995
CAP WITH LOCK....2996
HOT AND COOL BOX....2998
MAGAZINE BOX....2998
ASHTRAY....2998
AIR CONDITIONER CONTROLS....2999
RADIO....3012
AUXILIARY ELECTRIC POWER....3017
FUSE....3018
CIRCUIT BREAKER....3019
CONTROLLER....3020
TOOL BOX....3020
GREASE PUMP....3021
FIRE EXTINGUISHER....3024
MACHINE OPERATIONS AND CONTROLS....3025
BEFORE STARTING ENGINE....3025
STARTING ENGINE....3046
AFTER STARTING ENGINE....3049
STOPPING THE ENGINE....3059
MACHINE OPERATION....3060
STEERING THE MACHINE....3064
SWINGING....3066
WORK EQUIPMENT CONTROLS AND OPERATIONS....3067
WORKING MODE....3069
PROHIBITED OPERATIONS....3072
GENERAL OPERATION INFORMATION....3077
TRAVELING ON SLOPES....3079
ESCAPE FROM MUD....3081
RECOMMENDED APPLICATIONS....3082
BUCKET REPLACEMENT....3083
PARKING MACHINE....3085
MACHINE INSPECTION AFTER DAILY WORK....3086
LOCKING....3087
TRANSPORTATION....3088
TRANSPORTATION PROCEDURE....3088
LIFTING MACHINE....3088
SHIPPING MACHINE INFORMATION....3090
TRANSPORTATION POSTURE....3091
PROCEDURE FOR INCREASING OR REDUCING TRACK FRAME GAUGE....3097
COLD WEATHER OPERATION....3099
COLD WEATHER OPERATION INFORMATION....3099
AFTER DAILY WORK COMPLETION....3101
AFTER COLD WEATHER SEASON....3101
LONG TERM STORAGE....3102
BEFORE STORAGE....3102
DURING STORAGE....3102
AFTER STORAGE....3102
STARTING MACHINE AFTER LONG-TERM STORAGE....3103
TROUBLES AND ACTIONS....3104
RUNNING OUT OF FUEL....3104
PHENOMENA THAT ARE NOT FAILURES....3105
TOWING THE MACHINE....3106
SEVERE JOB CONDITION....3106
DISCHARGED BATTERY....3107
OTHER TROUBLE....3111
MAINTENANCE....3118
MAINTENANCE INFORMATION....3119
OUTLINE OF SERVICE....3121
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC....3121
ELECTRIC SYSTEM MAINTENANCE....3124
WEAR PARTS....3125
WEAR PARTS LIST....3125
RECOMMENDED FUEL, COOLANT, AND LUBRICANT....3126
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL....3128
TIGHTENING TORQUE SPECIFICATIONS....3129
TIGHTENING TORQUE LIST....3129
SAFETY CRITICAL PARTS....3130
SAFETY CRITICAL PARTS LIST....3131
MAINTENANCE SCHEDULE....3132
MAINTENANCE SCHEDULE CHART....3132
MAINTENANCE PROCEDURE....3134
INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS)....3134
INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)....3134
WHEN REQUIRED....3135
CHECK BEFORE STARTING....3157
EVERY 10 HOURS MAINTENANCE....3158
EVERY 100 HOURS MAINTENANCE....3160
EVERY 250 HOURS MAINTENANCE....3161
EVERY 500 HOURS MAINTENANCE....3167
EVERY 1000 HOURS MAINTENANCE....3176
EVERY 2000 HOURS MAINTENANCE....3189
EVERY 4000 HOURS MAINTENANCE....3195
EVERY 5000 HOURS MAINTENANCE....3198
EVERY 8000 HOURS MAINTENANCE....3202
SPECIFICATIONS....3204
SPECIFICATIONS....3205
ATTACHMENTS AND OPTIONS....3208
GENERAL PRECAUTIONS FOR SAFETY....3209
PRECAUTIONS WHEN SELECTING....3209
READ THE INSTRUCTION MANUAL THOROUGHLY....3209
PRECAUTIONS WHEN REMOVING OR INSTALLING....3209
PRECAUTIONS WHEN USING....3209
ATTACHMENT GUIDE....3210
COMBINATIONS OF WORK EQUIPMENT....3211
TRACK SHOES SELECTION....3213
HANDLING COUNTERWEIGHT REMOVER....3214
HANDLING MACHINES EQUIPPED WITH KOMTRAX....3226
BASIC PRECAUTIONS....3226
LOADING SHOVEL....3228
EXPLANATION OF COMPONENTS....3229
SWITCHES....3229
FUSE....3232
OPERATIONS....3233
OPERATION OF WORK EQUIPMENT....3233
PRECAUTIONS DURING OPERATION....3235
PRECAUTIONS FOR OPERATION....3238
LOADING SHOVEL WORK....3240
TRANSPORTATION....3241
MACHINE CONFIGURATION FOR TRANSPORT....3241
WEAR PARTS....3242
WEAR PARTS LIST....3242
MAINTENANCE....3243
CHECK BEFORE STARTING....3243
EVERY 10 HOURS MAINTENANCE....3245
EVERY 5000 HOURS MAINTENANCE....3246
SPECIFICATION....3248
COMBINATION OF WORK EQUIPMENT....3249
COMBINATION OF WORK EQUIPMENT....3249
INDEX....3252
