MidWestTechService, Parts and Operator's Manuals, in stock and ready to ship!
Fast free USA shippingShips in 1 business daySave 10% on 2 manuals, 15% on 3+

Komatsu PC800-8, PC800LC-8, PC800SE-8, PC850-8, PC850SE-8 Hydraulic Excavator Service Manual

1,132 pages · Publication SEN00373-16

$119.65
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.
Models
PC800-8, PC800LC-8, PC800SE-8, PC850-8, PC850SE-8
Serial coverage
PC800-8 50001 and up, PC800LC-8 50001 and up, PC800SE-8 50001 and up, PC850-8 10001 and up, PC850SE-8 10001 and up
Manual type
Service Manual
Pages
1,132
Publication
SEN00373-16
Condition
Brand new
Komatsu PC800-8, PC800LC-8, PC800SE-8, PC850-8, PC850SE-8 Hydraulic Excavator Service Manual, publication SEN00373-16

What's inside

From the manual's own table of contents: 200 sections, 405 entries. See sample pages (PDF, 1368 KB)

Composition of shop manual
Safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling of electric equipment and hydraulic component
Handling of connectors newly used for engines
How to read electric wire code
Precautions when carrying out operation
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
Radiator, oil cooler
Power train
Swing machinery
Swing circle
Show all 200 sections
Final drive
Sprocket
Undercarriage and frame
Track frame and recoil spring
Idler
Carrier roller
Track roller
Track shoe
Double shoe
Hydraulic system, Part 1
Hydraulic piping drawing
Hydraulic tank, hydraulic filter
Hydraulic pump
Cooling fan pump
Cooling fan motor45 topics
  • Hydraulic system, Part 2
  • 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
  • Anti-drop valve
  • Solenoid valve
  • Quick return valve
  • Hydraulic cylinder
  • Work equipment
  • Dimensions of work equipment
  • Cab and its attachments
  • Air conditioner piping
  • Engine control
  • Electric control system
  • Monitor system
  • Sensors
  • KOMTRAX system
  • Standard service value table for engine
  • Standard service value table for chassis
  • Testing and adjusting, Part 1
  • 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
  • Measuring EGR valve and bypass valve drive 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 fuel system for leakage
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 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
Adjusting mirrors
Testing and adjusting, Part 4
Special function of machine monitor
Handling controller voltage circuit
Testing and adjusting, Part 5
Procedure for turning on KOMTRAX terminal
KOMTRAX terminal lamp indications
Preparation work for troubleshooting electrical system
Failure code table and fuse locations
Failure codes table
Fuse locations
General information on troubleshooting
Points to remember when troubleshooting
Sequence of events in troubleshooting
Checks before troubleshooting
Classification and troubleshooting steps
Information in troubleshooting table
Failure-looking phenomenon and troubleshooting No
Connection table for connector pin numbers
T- branch box and T- branch adapter table
Troubleshooting by failure code (Display of code), Part 1
Failure code [AA10NX] Aircleaner Clogging
Failure code [AB00KE] Charge Voltage Low
Failure code [B@BAZG] Eng. Oil Press. Low57 topics
  • 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 Error
  • 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 [CA342] Calibration Code Incompatibility
  • 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 2
  • 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 [CA1653] EGR Inter Press Sens High 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 [DA22KK] Pump Solenoid Power Low Error
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 [DW7BKB] Fan Reverse Sol. S/C
Failure code [DW7JKA] Bottom Dump Priority Sol. Disc
Failure code [DW7JKB] Bottom Dump Priority 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/C54 topics
  • 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 normally
  • 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)
  • Before troubleshooting
  • 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 low1 topic
  • work equipment
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 does not rotate smoothly
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
General information on disassembly and assembly
How to read this manual
Coating materials list
Special tools list
Sketches of special tools
Removal and installation of engine, PTO and hydraulic pump assembly
Removal and installation of cooling assembly
Removal and installation of aftercooler assembly
Removal and installation of fuel cooler and air conditioner condenser assembly
Removal and installation of fan motor assembly
Removal and installation of fuel tank assembly
Engine (SAA6D140E-5)
Removal and installation of fuel supply pump assembly
Removal and installation of cylinder head assembly
Removal and installation of fuel injector assembly
Removal and installation of engine front seal
Removal and installation of engine rear seal48 topics
  • Removal and installation of PTO (coupling) assembly
  • Disassembly and assembly of PTO (coupling) assembly
  • Removal and installation of swing motor and swing machinery assembly
  • Disassembly and assembly of swing machinery assembly
  • Removal and installation of swing circle assembly
  • Disassembly and assembly of final drive assembly
  • Removal and installation of track shoe assembly
  • Disassembly and assembly of one link in field
  • Removal and installation of idler assembly
  • Disassembly and assembly of idler assembly
  • Disassembly and assembly of idler adjustment cylinder assembly
  • Removal and installation of recoil spring assembly
  • Disassembly and assembly of recoil spring assembly
  • Removal and installation of carrier roller assembly
  • Disassembly and assembly of carrier roller assembly
  • Removal and installation of track roller assembly
  • Disassembly and assembly of track roller assembly
  • Removal and installation of revolving frame assembly
  • Removal and installation of counterweight assembly
  • Removal and installation of counterweight remover assembly
  • Hydraulic system
  • Removal and installation of hydraulic tank assembly
  • Removal and installation of main pump assembly
  • Removal and installation of main pump input shaft oil seal
  • Removal and installation of cooling fan pump assembly
  • Removal and installation of control valve assembly
  • Assembly of control valve assembly
  • Removal and installation of swing motor assembly
  • Removal and installation of center swivel joint assembly
  • Disassembly and assembly of center swivel joint assembly
  • Removal and installation of travel motor assembly
  • Removal and installation of solenoid valve assembly
  • Removal and installation of boom damping valve assembly
  • Disassembly and assembly of work equipment PPC valve assembly
  • Disassembly and assembly of travel PPC valve assembly
  • Disassembly and assembly of hydraulic cylinder assembly
  • Disassembly and assembly of grease gun assembly
  • Removal and installation of bucket cylinder assembly
  • Removal and installation of arm cylinder assembly
  • Removal and installation of boom cylinder assembly
  • Removal and installation of bottom dump cylinder assembly
  • Removal and installation of bucket assembly
  • Removal and installation of arm assembly
  • Removal and installation of boom assembly
  • Removal and installation of work equipment
  • Removal and installation of operator’s cab
  • Removal and installation of operator’s cab glass (stuck glass)
  • Removal and installation of front window assembly
Electrical system
Removal and installation of air conditioner unit assembly
Removal and installation of engine controller assembly
Removal and installation of monitor assembly
Removal and installation of pump controller assembly
Removal and Installation of KOMTRAX terminal assembly
Hydraulic circuit diagram
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)
Connector list and sterogram

Inside this manual

Real pages from this service manual (1,132 pages). Open the sample pages (PDF, 1367 KB)

Sample pages from the Komatsu PC800-8, PC800LC-8, PC800SE-8, PC850-8, PC850SE-8 Hydraulic Excavator Service Manual: Specifications, Troubleshooting, Diagram, Color page, Foldout diagram
  • Specifications, page 65: 01 Specification
  • Troubleshooting, page 677: Failure code [DHPFKB] R Pump P. Sensor S/C
  • Diagram, page 779: E-22 “Bucket CURL” is not correctly displayed in monitor function
  • Color page, page 451: 30 Testing and adjusting
  • Foldout diagram, page 1,130: Connector list and sterogram

Other manuals for this machine

Save 10% on 2 manuals, 15% on 3 or more. Other manuals 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 SEN00373-16$119.65
Other manuals for the PC800-8, PC800LC-8

Operator's manuals

Details
Details
Details

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, 1,132 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

Komatsu Galeo PC800-8, PC800LC-8Service Manual · UEN00373-01 · $79.91

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).