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Komatsu PC800-8E0, PC800LC-8E0, PC800SE-8E0, PC850-8E0, PC850SE-8E0 Hydraulic Excavator Service Manual

1,328 pages · Publication SEN05276-06

$139.67
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Models
PC800-8E0, PC800LC-8E0, PC800SE-8E0, PC850-8E0, PC850SE-8E0
Serial coverage
65001 and up
Manual type
Service Manual
Pages
1,328
Publication
SEN05276-06
Condition
Brand new
Komatsu PC800-8E0, PC800LC-8E0, PC800SE-8E0, PC850-8E0, PC850SE-8E0 Hydraulic Excavator Service Manual, publication SEN05276-06

What's inside

From the manual's own table of contents: 11 sections, 459 entries. See sample pages (PDF, 792 KB)

Notice of revision
Index and foreword12 topics
  • Foreword and general information
  • Safety notice
  • How to read the shop manual
  • Explanation of terms for maintenance standard
  • Handling of hydraulic components
  • Method of disconnecting and connecting push-pull type coupler
  • Handling of electric equipment
  • How to read electric wire code
  • Precautions when performing work
  • Standard tightening torque table
  • List of abbreviation
  • Conversion table
Specification4 topics
  • Specifications
  • Specifications drawing
  • Table of weight
  • Table of fuel, coolant and lubricants
Structure and function39 topics
  • Engine and cooling system
  • Coupling
  • Coupling lubrication system
  • Cooling system
  • Power train system
  • Power train
  • Swing circle
  • Swing machinery
  • Final drive
  • Undercarriage and frame
  • Track frame
  • Idler cushion
  • Hydraulic system
  • Hydraulic component layout
  • Hydraulic tank and filter
  • Hydraulic pump
  • Pump control system
  • Servo valve
  • Self-pressure reducing valve
  • Cooling fan pump
  • Cooling fan motor
  • Electrical grease pump
  • Control valve
  • Straight-travel valve
  • Swing motor
  • PPC valve
  • Solenoid valve
  • Accumulator
  • Quick return valve
  • Return oil filter
  • Line oil filter
  • Pilot oil filter
  • Drain oil filter
  • Electrical system
  • Engine control
  • Electric control system
  • Monitor system
  • Sensors
  • KOMTRAX system
Standard value table2 topics
  • Standard value table for engine
  • Standard value table for machine
Testing and adjusting42 topics
  • Tool for testing, adjusting and troubleshooting
  • Tools for testing, adjusting, and troubleshooting
  • Testing engine speed
  • Testing intake air pressure (boost pressure)
  • Testing exhaust gas temperature
  • Testing exhaust gas color
  • Adjusting valve clearance
  • Testing compression pressure
  • Testing blowby pressure
  • Testing engine oil pressure
  • Testing EGR valve and bypass valve drive pressure
  • Handling fuel system parts
  • Releasing remaining pressure from fuel system
  • Testing fuel pressure
  • Testing fuel return rate and leakage
  • Bleeding air from fuel circuit
  • Testing fuel circuit for leakage
  • Testing and adjusting alternator belt tension
  • Testing and adjusting air conditioner compressor belt tension
  • Testing swing circle bearing clearance
  • Checking and adjusting track tension
  • Testing and adjusting oil pressure in work equipment, swing, and travel circuits
  • Testing and adjusting control signal of main pump
  • Testing PPC valve output pressure
  • Adjusting play of work equipment and swing PPC vavles
  • Testing and adjusting travel deviation
  • Inspecting locations of hydraulic drift in work equipment
  • Measuring fan speed
  • Measuring fan circuit oil pressure
  • Measuring fan pump EPC current
  • Measuring fan pump EPC solenoid valve outlet pressure
  • Measuring oil leakage
  • Releasing remaining pressure from hydraulic circuit
  • Bleeding air from various parts
  • Inspection procedures for diode
  • Adjusting mirrors
  • Special functions of machine monitor
  • Handling voltage circuit of engine controller
  • Preparatory work for troubleshooting of electrical system
  • Pm Clinic
  • Pm clinic service
  • UNDERCARRIAGE INSPECTION REPORT
Troubleshooting228 topics
  • General information on troubleshooting
  • Points to remember when troubleshooting
  • Sequence of events in troubleshooting
  • Checks before troubleshooting
  • Classification and procedures for troubleshooting
  • Failure codes table
  • Symptom and troubleshooting numbers
  • Information in troubleshooting table
  • Troubleshooting method for open circuit in wiring harness of pressure sensor system
  • Connector list and layout
  • Connection table for connector pin numbers
  • T- branch box and T- branch adapter table
  • Fuse locations
  • Troubleshooting by failure code
  • Failure code [989L00] Engine Controller Lock Caution 1
  • Failure code [989M00] Engine Controller Lock Caution 2
  • Failure code [989N00] Engine Controller Lock Caution 3
  • Failure code [AA10NX] Air Cleaner 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 Level Low
  • Failure code [B@HANS] Hyd 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
  • 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] Supply Pump Press Low Error 1
  • Failure code [CA689] Eng Ne Speed Sensor Error
  • Failure code [CA731] Eng Bkup Speed Sens Phase Error
  • Failure code [CA757] All Continuous 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 [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 Open Circuit Error
  • Failure code [CA2556] Grid Htr Relay Short Circuit Error
  • Failure code [D110KB] Battery Relay Drive Short Circuit
  • Failure code [D163KB] Flash Light Relay Short Circuit
  • Failure code [D195KA] Step Light Relay Open Circuit
  • Failure code [D195KB] Step Light Relay Short Circuit
  • Failure code [D19JKZ] Personal Code Relay Abnormality
  • Failure code [D862KA] GPS Antenna Open Circuit
  • Failure code [DA22KK] Pump Solenoid Power Low Error
  • Failure code [DA25KP] 5V Sensor1 Power Abnormality
  • Failure code [DA29KQ] Model Selection Abnormality
  • Failure code [DA2RMC] CAN Discon (Pump Con Detected)
  • Failure code [DA80MA] Auto. Lub. Abnormal
  • Failure code [DAF8KB] Camera Power Supply Short Circuit
  • Failure code [DAFGMC] GPS Module Error
  • Failure code [DAFRMC] CAN Discon (Monitor Detected)
  • Failure code [DGE5KB] Ambi. Temp Sensor Short Circuit
  • Failure code [DGH2KB] Hyd Oil Sensor Short
  • Failure code [DH25KA] L Jet Sensor Open Circuit
  • Failure code [DH25KB] L Jet Sensor Short Circuit
  • Failure code [DH26KA] R Jet Sensor Open Circuit
  • Failure code [DH26KB] R Jet Sensor Short Circuit
  • Failure code [DHPEKA] F Pump P. Sensor Open Circuit
  • Failure code [DHPEKB] F Pump P. Sensor Short Circuit
  • Failure code [DHPFKA] R Pump P. Sensor Open Circuit
  • Failure code [DHPFKB] R Pump P. Sensor Short Circuit
  • Failure code [DV20KB] Travel alarm short circuit
  • Failure code [DW41KA] Swing Priority Sol Open Circuit
  • Failure code [DW41KB] Swing Priority Sol Short Circuit
  • Failure code [DW43KA] Travel Speed Sol Open Circuit
  • Failure code [DW43KB] Travel Speed Sol Short Circuit
  • Failure code [DW45KA] Swing Brake Sol Open Circuit
  • Failure code [DW45KB] Swing Brake Sol Short Circuit
  • Failure code [DW7BKA] Fan Reverse Sol Open Circuit
  • Failure code [DW7BKB] Fan Reverse Sol Short Circuit
  • Failure code [DW7JKA] Bottom Dump Priority Sol Open Circuit
  • Failure code [DW7JKB] Bottom Dump Priority Sol Short Circuit
  • Failure code [DW91KA] Travel Junction Sol Open Circuit
  • Failure code [DW91KB] Travel Junction Sol Short Circuit
  • Failure code [DWK0KA] 2-stage Relief Sol Open Circuit
  • Failure code [DWK0KB] 2-stage Relief Sol Short Circuit
  • Failure code [DX16KA] Fan Pump EPC Sol Open Circuit
  • Failure code [DX16KB] Fan Pump EPC Sol Short Circuit
  • Failure code [DXAAKA] F Pump EPC Sol Open Circuit
  • Failure code [DXAAKB] F Pump EPC Sol Short Circuit
  • Failure code [DXABKA] R Pump EPC Sol Open Circuit
  • Failure code [DXABKB] R Pump EPC Sol Short Circuit
  • Failure code [DY20KA] Wiper Working Abnormality
  • Failure code [DY20MA] Wiper Parking Abnormality
  • Failure code [DY2CKA] Washer Drive Open Circuit
  • Failure code [DY2CKB] Washer Drive Short Circuit
  • Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit
  • Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit
  • Failure code [DY2FMA] Upper Wiper Working Abnormality
  • Failure code [DY2GKM] Wiper Select Abnormality
  • Troubleshooting of electrical system (E-mode)
  • E-1 Engine does not start (Engine does not crank)
  • E-2 Preheater does not operate
  • E-3 When starting switch is turned to ON position, machine monitor displays nothing
  • E-5 Precaution item lights up while engine is running
  • E-6 Emergency stop item lights up while engine is running
  • E-7 Engine coolant temperature gauge does not indicate properly
  • E-8 Fuel gauge does not indicate properly
  • E-9 Hydraulic oil temperature gauge does not indicate properly
  • E-10 Displays on machine monitor are different from those for actual machine
  • E-11 Some areas of machine monitor screen are not displayed
  • E-12 Function switch does not operate
  • E-13 Automatic warm-up system does not operate (in cold season)
  • E-14 Auto-decelerator does not operate properly
  • E-15 Working mode does not change
  • E-16 Travel speed does not change
  • E-17 Alarm buzzer cannot be canceled
  • E-18 When starting switch is turned OFF, service meter is not displayed
  • E-19 Service mode cannot be selected
  • E-20 Any of work equipment, swing and travel do not operate or cannot be locked
  • E-21 Machine push-up function does not operate or cannot be canceled
  • E-22 Boom shockless function does not operate properly
  • E-23 Swing brake does not operate properly
  • E-24 Windshield wiper and window washer do not operate
  • E-25 Travel alarm does not sound or does not stop sounding
  • E-26 Boom RAISE indicator is not displayed properly with monitoring function
  • E-27 Boom LOWER indicator is not displayed properly with monitoring function
  • E-28 Arm IN indicator is not displayed properly with monitoring function
  • E-29 Arm OUT indicator is not displayed properly with monitoring function
  • E-30 Bucket CURL indicator is not displayed properly with monitoring function
  • E-31 Bucket DUMP indicator is not displayed properly with monitoring function
  • E-32 Swing indicator is not displayed properly with monitoring function
  • E-33 "L.H. travel" is not displayed properly with monitoring function
  • E-34 "R.H. travel" is not displayed properly with monitoring function
  • E-35 "Attachment" is not displayed properly with monitoring function
  • E-36 Electric grease gun does not operate
  • E-37 KOMTRAX system does not operate properly
  • E-38 Horn does not sound or does not stop sounding
  • E-39 Step light does not light up or go off
  • Troubleshooting of hydraulic and mechanical system (H-mode)
  • Before starting troubleshooting for hydraulic and mechanical systems
  • Information in troubleshooting table (H-mode)
  • H-1 All of work equipment, swing and travel work slow or lack power
  • H-2 Engine speed lowers significantly or engine stalls
  • H-3 Any of work equipment, swing and travel does not work
  • H-4 Unusual noise is heard from around hydraulic pump
  • H-5 Boom operation lacks speed or power
  • H-6 Arm operation lacks speed or power
  • H-7 Bucket operation lacks speed or power
  • H-8 Boom does not move
  • H-9 Arm does not move
  • H-10 Bucket does not move
  • H-11 Hydraulic drift of work equipment is large
  • H-12 Time lag of work equipment is large
  • H-13 Heavy lift function does not work or is not released
  • H-14 Machine push-up function does not work or is not released
  • H-15 Boom shockless function does not work or is not canceled
  • H-16 Machine deviates in one direction against operator's intention when travelling
  • H-17 Machine deviates significantly at start
  • H-18 Machine deviates significantly during combined operation
  • H-19 Travel works slow or lack power
  • H-20 One of tracks does not run
  • H-21 Travel speed does not change
  • H-22 Upper structure does not swing
  • H-23 Swing speed is low or swing acceleration is poor
  • H-25 Upper structure overruns excessively when it stops swinging
  • H-26 Shock is large when upper structure stops swinging
  • H-27 Large unusual noise is heard when upper structure stops swinging
  • H-28 Swing drift on a slope is large
  • Troubleshooting of engine (S-mode)
  • Method of using troubleshooting chart
  • S-1 Startability is poor
  • S-2 Engine does not start
  • S-3 Engine does not pick up smoothly
  • S-4 Engine stops during operation
  • S-5 Engine runs rough or is unstable
  • S-6 Engine lacks power
  • S-7 Exhaust smoke is black (incomplete combustion)
  • S-8 Oil consumption is excessive (or exhaust smoke is blue)
  • S-9 Oil becomes contaminated early
  • S-10 Fuel consumption is excessive
  • S-11 Oil is in coolant (or coolant spurts or coolant level goes down)
  • S-12 Oil pressure drops
  • S-13 Oil level rises (coolant or fuel in oil)
  • S-14 Coolant temperature rises too high (overheating)
  • S-15 Unusual noise is made
  • S-16 Vibration is excessive
Disassembly and assembly71 topics
  • General information on disassembly and assembly
  • How to read Disassembly and Assembly
  • 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 condenser assembly
  • Removal and installation of fan motor assembly
  • Removal and installation of fuel tank assembly
  • Engine
  • 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 seal
  • Removal and installation of PTO assembly
  • Disassembly and assembly of PTO 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
  • Separation and connection 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
  • 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
  • Work equipment
  • 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 assembly
  • Cab and its attachments
  • Removal and installation of operator's cab assembly
  • Removal and installation of operator's cab glass (adhered window glass)
  • Removal and installation of front window assembly
  • 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
Maintenance standard9 topics
  • Sprocket
  • Track frame and idler cushion
  • Idler
  • Carrier roller
  • Track roller
  • Track shoe
  • Center swivel joint
  • Work equipment dimension
  • Hydraulic cylinder
Appendix37 topics
  • Air conditioner
  • Precautions for refrigerant
  • Air conditioner component
  • Configuration and function of refrigeration cycle
  • Outline of refrigeration cycle
  • Air conditioner unit
  • Air conditioner controller
  • Compressor
  • Condenser
  • Receiver drier
  • Procedure for testing and troubleshooting
  • Circuit diagram and arrangement of connector pins
  • System diagram
  • Detail of air conditioner unit
  • Parts and connectors layout
  • Testing air leakage (duct)
  • Testing with self-diagnosis function
  • Testing temperature control
  • Testing vent (mode) changeover
  • Testing FRESH/RECIRC air changeover
  • Testing inner sensor
  • Testing evaporator temperature sensor
  • Testing sunlight sensor
  • Testing (dual) pressure switch for refrigerant
  • Testing relays
  • Troubleshooting chart 1
  • Troubleshooting chart 2
  • Troubleshooting for compressor and refrigerant system (Air is not cooled)
  • Troubleshooting for blower motor system (No air comes out or air flow is abnormal)
  • Troubleshooting for temperature control
  • Troubleshooting for vent (mode) changeover
  • Troubleshooting for FRESH/RECIRC air changeover
  • Troubleshooting for temperature sensor system
  • Troubleshooting with gauge pressure
  • Connection of service tool
  • Precautions for disconnecting and connecting air conditioner piping
  • Handling of compressor oil
Diagrams and drawings4 topics
  • Hydraulic circuit diagram
  • Symbols used in hydraulic circuit diagrams
  • Electrical circuit diagram
  • Symbols used in electric circuit diagrams

Inside this manual

Real pages from this service manual (1,328 pages). Open the sample pages (PDF, 792 KB)

Sample pages from the Komatsu PC800-8E0, PC800LC-8E0, PC800SE-8E0, PC850-8E0, PC850SE-8E0 Hydraulic Excavator Service Manual: Specifications, Troubleshooting, Diagram, Foldout diagram
  • Specifications, page 196: Hydraulic system
  • Troubleshooting, page 616: Troubleshooting by failure code
  • Diagram, page 1,276: Air conditioner
  • Foldout diagram, page 1,310: PC800, PC850-8E0

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This manual: Service Manual SEN05276-06$139.67
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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, 1,328 pages

Quantity one is the manual described above.

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