Komatsu Galeo PC800-8, PC800LC-8 Hydraulic Excavator Service Manual
799 pages · Publication UEN00373-01
Fast free USA shippingShips in 1 business daySave 10% on 2 manuals, 15% on 3 or morePay by credit or debit card or with PayPal. No PayPal account needed.
Added to your cart. View cart
- Models
- Galeo PC800-8, PC800LC-8
- Serial coverage
- 50001 and up
- Manual type
- Service Manual
- Pages
- 799
- Publication
- UEN00373-01
- Condition
- Brand new
What's inside
From the manual's own table of contents: 177 sections, 323 entries. See sample pages (PDF, 915 KB)
Organization list of the shop manual
Foreword and general information
Safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling electric equipment and hydraulic component
How to read electric wire code
Method of disassembling and connecting push-pull type coupler
Standard tightening torque table
Conversion table
Specification and technical data
Specification drawings
Working range drawing
Specifications
Weight table
Table of fuel, coolant and lubricants
Engine and cooling system
Coupling
Coupling lubrication system
Power train
Swing machinery
Swing circle
Final drive
Sprocket
Show all 177 sections
Undercarriage and frame
Track frame and recoil spring
Idler
Carrier roller
Track roller
Track shoe
Double shoe
Hydraulic system, Part 1
Hydraulic tank, hydraulic filter
Hydraulic pump
Operation of pump control mechanism
EPC valve
Self pressure reducing valve
Cooling fan pump
Cooling fan motor
Hydraulic system, Part 215 topics
- Motor grease pump
- Return oil filter
- Line oil filter
- Drain oil filter
- 5-Spool control valve
- 4-Spool control valve
- Straight-travel valve
- Swing motor
- Center swivel joint
- Travel motor
- PPC accumulator
- Work equipment, swing PPC valve
- Travel PPC valve
- Solenoid valve
- Hydraulic cylinder
Work equipment1 topic
- Dimensions of work equipment
Cab and its attachments1 topic
- Air conditioner piping
Electrical system4 topics
- Engine control
- Electric control system
- Monitor system
- Sensors
Standard service value table for engine
Standard service value table for chassis
Testing and adjusting, Part 116 topics
- Tools for testing, adjusting and troubleshooting
- Measuring engine speed
- Measuring intake air pressure (Boost pressure)
- Measuring exhaust gas temperature
- Measuring exhaust gas color
- Adjusting valve clearance
- Measuring compression pressure
- Measuring blow-by pressure
- Measuring engine oil pressure
- Handling of fuel system equipment
- Remaining pressure relief from fuel system equipment
- Measuring fuel pressure
- Testing fuel return rate and leakage
- Bleeding air from fuel circuit
- Testing and adjusting alternator belt tension
- Testing and adjusting air conditioner compressor belt
Testing and adjusting, Part 2
Inspection of swing circle bearing clearance
Testing and adjusting track shoe tension
Testing and adjusting work equipment, swing, and travel circuit oil pressures
Testing and adjusting control circuit oil pressure (self pressure reducing valve)
Testing and adjusting main pump control pressure
Testing and adjusting, Part 3
Measuring PPC valve output pressure
Adjusting work equipment, swing PPC valve
Testing and adjusting travel deviation
Inspection of locations of hydraulic drift of work equipment
Measuring fan speed
Measuring fan circuit oil pressure
Measuring fan pump EPC current
Measuring fan pump EPC solenoid valve output pressure
Measuring oil leakage
Release of residual pressure from hydraulic circuit
Bleeding air from each part
Inspection procedures for diode
Testing and adjusting, Part 4
Special function of machine monitor
Handling engine controller high voltage circuit
Testing and adjusting, Part 5
Procedure for turning on KOMTRAX terminal
KOMTRAX terminal lamp indications
Preparation work for troubleshooting electrical system
Pm-clinic service
General information on troubleshooting
Points to remember when troubleshooting
Sequence of events in troubleshooting
Checks before troubleshooting
Classification and troubleshooting steps
Connection table for connector pin numbers
T-boxes and T-adapters table
Troubleshooting by failure code (Display of code), Part 1
Failure codes table
Information in troubleshooting table
Failure code [A000N1] Eng. Hi Out of Std
Failure code [AA10NX] Aircleaner Clogging
Failure code [AB00KE] Charge Voltage Low
Failure code [B@BAZG] Eng. Oil Press. Low
Failure code [B@BAZK] Eng. Oil Level Low
Failure code [B@BCNS] Eng. Water Overheat
Failure code [B@BCZK] Eng. Water Lvl Low
Failure code [B@HANS] Hydr. Oil Overheat
Failure code [CA111] ECM Critical Internal Failure
Failure code [CA115] Eng Ne and Bkup Speed Sens Error
Failure code [CA122] Chg Air Press Sensor High Error30 topics
- Failure code [CA123] Chg Air Press Sensor Low Error
- Failure code [CA131] Throttle Sensor High Error
- Failure code [CA132] Throttle Sensor Low Error
- Failure code [CA135] Eng Oil Press Sensor High Error
- Failure code [CA141] Eng Oil Press Sensor Low Error
- Failure code [CA144] Coolant Temp Sens High Error
- Failure code [CA145] Coolant Temp Sens Low Error
- Failure code [CA153] Chg Air Temp Sensor High Error
- Failure code [CA154] Chg Air Temp Sensor Low Error
- Failure code [CA187] Sens Supply 2 Volt Low Error
- Failure code [CA221] Ambient Press Sens High Error
- Failure code [CA222] Ambient Press Sens Low Error
- Failure code [CA227] Sens Supply 2 Volt High Error
- Failure code [CA234] Eng Overspeed
- Failure code [CA238] Ne Speed Sens Supply Volt Error
- Failure code [CA263] Fuel Temp Sensor High Error
- Failure code [CA265] Fuel Temp Sensor Low Error
- Failure code [CA271] IMV/PCV1 Short Error
- Failure code [CA272] IMV/PCV1 Open Error
- Failure code [CA273] PCV2 Short Error
- Failure code [CA274] PCV2 Open Error
- Failure code [CA322] Inj #1 (L#1) Open/Short Error
- Failure code [CA323] Inj #5 (L#5) Open/Short Error
- Failure code [CA324] Inj #3 (L#3) Open/Short Error
- Failure code [CA325] Inj #6 (L#6) Open/Short Error
- Failure code [CA331] Inj #2 (L#2) Open/Short Error
- Failure code [CA332] Inj #4 (L#4) Open/Short Error
- Failure code [CA351] Injectors Drive Circuit Error
- Failure code [CA352] Sens Supply 1 Volt Low Error
- Failure code [CA386] Sens Supply 1 Volt High Error
Troubleshooting by failure code (Display of code), Part 226 topics
- Failure code [CA441] Battery Voltage Low Error
- Failure code [CA442] Battery Voltage High Error
- Failure code [CA449] Rail Press Very High Error
- Failure code [CA451] Rail Press Sensor High Error
- Failure code [CA452] Rail Press Sensor Low Error
- Failure code [CA553] Rail Press High Error
- Failure code [CA554] Rail Press Sensor In Range Error
- Failure code [CA559] Rail Press Low Error
- Failure code [CA689] Eng Ne Speed Sensor Error
- Failure code [CA731] Eng Bkup Speed Sens Phase Error
- Failure code [CA757] All Persistent Data Lost Error
- Failure code [CA778] Eng Bkup Speed Sensor Error
- Failure code [CA1228] EGR Valve Servo Error 1
- Failure code [CA1625] EGR Valve Servo Error 2
- Failure code [CA1626] BP Valve Sol Current High Error
- Failure code [CA1627] BP Valve Sol Current Low Error
- Failure code [CA1628] Bypass Valve Servo Error 1
- Failure code [CA1629] Bypass Valve Servo Error 2
- Failure code [CA1631] BP Valve Pos Sens High Error
- Failure code [CA1632] BP Valve Pos Sens Low Error
- Failure code [CA1633] KOMNET Datalink Timeout Error
- Failure code [CA1642] EGR Inter Press Sens Low Error
- Failure code [CA2185] Throt Sens Sup Volt High Error
- Failure code [CA2186] Throt Sens Sup Volt Low Error
- Failure code [CA2249] Rail Press Very Low Error
- Failure code [CA2271] EGR Valve Pos Sens High Error
Failure code [CA2272] EGR Valve Pos Sens Low Error
Failure code [CA2351] EGR Valve Sol Current High Error
Failure code [CA2352] EGR Valve Sol Current Low Error
Failure code [CA2555] Grid Htr Relay Volt Low Error
Failure code [CA2556] Grid Htr Relay Volt High Error
Failure code [D110KB] Battery Relay Drive S/C
Failure code [D163KB] Flash Light Relay S/C
Failure code [D195KB] Step Light Relay S/C
Failure code [DA25KP] Press. Sensor Power Abnormality
Failure code [DA2SKQ] Model Selection Abnormality
Failure code [DA80MA] Auto. Lub. Abnormal
Failure code [DA2RMC] Pump Comm. Abnormality
Failure code [DAFRMC] Monitor Comm. Abnormality
Failure code [DGE5KY] Ambi. Temp. Sensor S/C
Failure code [DGH2KB] Hydr. Oil Temp. Sensor S/C
Troubleshooting by failure code (Display of code), Part 3
Failure code [DH25KA] L Jet Sensor Disc
Failure code [DH25KB] L Jet Sensor S/C
Failure code [DH26KA] R Jet Sensor Disc
Failure code [DH26KB] R Jet Sensor S/C
Failure code [DHPEKA] F Pump P. Sensor Disc
Failure code [DHPEKB] F Pump P. Sensor S/C
Failure code [DHPFKA] R Pump P. Sensor Disc
Failure code [DHPFKB] R Pump P. Sensor S/C
Failure code [DV20KB] Travel Alarm S/C
Failure code [DW41KA] Swing Priority Sol. Disc
Failure code [DW41KB] Swing Priority Sol. S/C
Failure code [DW43KA] Travel Speed Sol. Disc
Failure code [DW43KB] Travel Speed Sol. S/C
Failure code [DW45KA] Swing Brake Sol. Disc
Failure code [DW45KB] Swing Brake Sol. S/C
Failure code [DW7BKA] Fan Reverse Sol. Disc
Failure code [DW78KB] Fan Reverse Sol. S/C
Failure code [DWK0KA] 2-stage Relief Sol. Disc
Failure code [DWK0KB] 2-stage Relief Sol. S/C
Failure code [DX16KA] Fan Pump EPC Sol. Disc
Failure code [DX16KB] Fan Pump EPC Sol. S/C
Failure code [DXAAKA] F Pump EPC Sol. Disc
Failure code [DXAAKB] F Pump EPC Sol. S/C
Failure code [DXABKA] R Pump EPC Sol. Disc
Failure code [DXABKB] R Pump EPC Sol. S/C
Failure code [DY20KA] Wiper Working Abnormality
Failure code [DY20MA] Wiper Parking Abnormality
Failure code [DY2CKB] Washer Drive S/C
Failure code [DY2DKB] Wiper Drive (For) S/C
Failure code [DY2EKB] Wiper Drive (Rev) S/C
Troubleshooting of electrical system (E-mode)
Before carrying out troubleshooting of electrical system
Information contained in troubleshooting table
Engine does not start (Engine does not rotate)
Preheater does not operate
Auto engine warm-up device does not work
Auto-decelerator does not operate
All work equipment, swing and travel do not move
Machine push-up function does not operate normally
Boom shockless function does not operate normally25 topics
- Any item is not displayed on machine monitor
- Part of display on machine monitor is missing
- Machine monitor displays contents irrelevant to the model
- Fuel level monitor red lamp lights up while engine is running
- Engine coolant thermometer does not display normally
- Hydraulic oil temperature gauge does not display correctly
- Fuel gauge does not display correctly
- Swing lock monitor does not display correctly
- When monitor switch is operated, nothing is displayed
- Windshield wiper and window washer do not work
- Boom RAISE" is not correctly displayed in monitor function
- Boom LOWER" is not correctly displayed in monitor function
- Arm IN" is not correctly displayed in monitor function
- Arm OUT" is not correctly displayed in monitor function
- Bucket CURL" is not correctly displayed in monitor function
- Bucket DUMP" is not correctly displayed in monitor function
- SWING" is not correctly displayed in monitor function
- Left travel" is not displayed normally in monitoring function
- Right travel" is not displayed normally in monitoring function
- Service" is not correctly displayed in monitor function
- KOMTRAX system does not operate normally
- Air conditioner does not work
- Step light does not light up or go off
- Electric grease gun does not operate
- Travel alarm does not sound or does not stop sounding
Troubleshooting of hydraulic and mechanical system (H-mode)28 topics
- Information in troubleshooting table
- Speed or power of all work equipment, travel, and swing is low
- Engine speed lowers remarkably or engine stalls
- All work equipment, travel, and swing systems do not work
- Abnormal sound is heard from around pump
- Boom speed or power is low
- Speed or power of arm is low
- Speed or power of bucket is low
- Boom does not move
- Arm does not move
- Bucket does not move
- Hydraulic drift of work equipment is large
- Time lag of work equipment is large
- Heavy lift function does not operate or stop
- Machine push-up function does not operate or stop
- Boom shockless function cannot be turned ON or OFF
- Machine deviates in one direction
- Machine deviates largely at start
- Machine deviates largely during compound operation
- Travel speed or power is low
- Machine does not travel (only one track)
- Travel speed does not change
- Upper structure does not swing
- Swing speed or acceleration is low
- Upper structure overruns excessively when it stops swinging
- Large shock is made when upper structure stops swinging
- Large abnormal sound is made when upper structure stops swinging
- Hydraulic drift of swing is large
Troubleshooting of engine (S-mode)
Method of using troubleshooting chart
Starting performance is poor
Engine does not start
Engine does not pick up smoothly
Engine stops during operations
Engine lacks output (or lacks power)
Exhaust gas color is black (incomplete combustion)
Oil consumption is excessive (or exhaust smoke is blue)
Oil becomes contaminated quickly
Fuel consumption is excessive
Oil is in coolant (or coolant spurts back or coolant level goes down)
Oil pressure drops
Oil level rises (Entry of coolant/fuel)
Coolant temperature becomes too high (overheating)
Abnormal noise is made
Vibration is excessive
Hydraulic diagrams and drawings
Hydraulic circuit diagram
Electrical diagrams and drawings
Electrical circuit diagram (1/5)
Electrical circuit diagram (2/5)
Electrical circuit diagram (3/5)
Electrical circuit diagram (4/5)
Electrical circuit diagram (5/5)
Inside this manual
Real pages from this service manual (799 pages). Open the sample pages (PDF, 914 KB)
- Specifications, page 286: 30 Testing and adjusting
- Diagram, page 694: E-19 "Boom LOWER" is not correctly displayed in monitor function
- Troubleshooting, page 754: Troubleshooting of engine (S-mode)
- Color page, page 396: UNDERCARRIAGE INSPECTION
- Foldout diagram, page 788: Electrical circuit diagram (1/5)
Other manuals for this machine
Save 10% on 2 manuals, 15% on 3 or more. Other manuals for the PC800LC-8 are listed below. Editions cover different serial number ranges: check the serial coverage and tick only the ones that match your machine.
This manual: Service Manual UEN00373-01$79.91
Added to your cart. View cart
This is a service manual
Here's how it compares to the other manual types.
This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 799 pages
Quantity one is the manual described above.
Fast free USA shipping
Ships in 1 business day.
60-day returns
Free if the mistake is ours. A manual ordered in error must come back unopened in its shrink-wrap; you pay return shipping and a 20% restocking fee applies. Return policy
Binder not included
Manuals over about 300 pages may need a standard 3-ring binder, which you can buy locally to keep the pages organized for shop use.
Other editions and similar models
Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).