Komatsu PC800 -8E0 Install guide

HYDRAULIC
EXCAVATOR
SEN05276-06
PC800 -8E0
PC800LC -8E0
PC800SE-8E0
PC850 -8E0
PC850SE-8E0
SERIAL NUMBERS
PC800- 65001
PC800LC-65001
PC800SE-65001
PC850- 65001
PC850SE-65001
and up

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PC800,850-8E0 1
(01)
Notice of revision
Notice of revision
6th revision
The affected pages are indicated by the use of the
following marks. It is requested that necessary ac-
tions must be taken to these pages according to the
list below.
2017/07
List of revised pages
Mark Indication Action required
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2 (05) 00-35 01-22 10-35
q3 (06) 00-36 01-23 10-36
4 (01) 00-37 01-24 10-37
5 (01) 00-38 01-25 10-38
q6 (06) 00-39 01-26 10-39
q7 (06) 00-40 01-27 10-40
8 (01) 00-41 01-28 10-41
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00-11 00-52 10-11 (05) 10-52
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00-30 01-17 10-30 10-71
00-31 01-18 10-31 10-72
00-32 01-19 10-32 10-73
00-33 01-20 10-33 10-74
(06)
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Notice of revision
2PC800,850-8E0
(01)
10-75 10-127 10-179 30-19
10-76 (01) 10-128 10-180 30-20
10-77 10-129 10-181 30-21
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PC800,850-8E0 3
(06)
Notice of revision
30-71 30-123 40-45 40-97
30-72 (05) 30-124 40-46 40-98
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Notice of revision
4PC800,850-8E0
(01)
40-149 40-201 40-253 40-305
40-150 40-202 40-254 40-306
40-151 40-203 40-255 40-307
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PC800,850-8E0 5
(01)
Notice of revision
40-357 40-409 40-461 50-35
40-358 40-410 40-462 50-36
40-359 40-411 40-463 50-37
40-360 40-412 40-464 50-38
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Notice of revision
6PC800,850-8E0
(01)
50-87 50-137 50-189 60-3
50-88 50-138 50-190 60-4 (04)
50-89 (05) 50-139 50-191 60-5
50-90 (05) 50-140 50-192 60-6
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50-132 50-182 50-234 60-48
q50-133 (06) 50-183 50-235 60-49
50-134 50-184 50-236 60-50
50-135 50-185 50-237 60-51
50-136 50-186 50-238 60-52
50-136-1 (02) 50-187 60-1 60-53
50-136-2 (02) 50-188 60-2 60-54
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PC800,850-8E0 7
(01)
Notice of revision
80-1 80-53 90-31
80-2 80-54 90-33
80-3 80-55 90-35
80-4 80-56 90-37
80-5 80-57 90-39
80-6 80-58 90-41
80-7 80-59 90-43
80-8 80-60 90-45
80-9 80-61 90-47
80-10 80-62 1
80-11 80-63 2
80-12 80-64 3
80-13 80-65 4
80-14 80-66 5
80-15 80-67 6
80-16 80-68 qColophon (06)
80-17 80-69
80-18 80-70
80-19 80-71
80-20 80-72
80-21 80-73
80-22 80-74
80-23 80-75
80-24 80-76
80-25 80-77
80-26 80-78
80-27 80-79
80-28 80-80
80-29 80-81
80-30 80-82
80-31 80-83
80-32 80-84
80-33 90-1
80-34 90-2
80-35 90-3
80-36 90-4
80-37 90-5
80-38 90-6
80-39 90-7
80-40 90-9
80-41 90-11
80-42 90-12
80-43 90-13
80-44 90-14
80-45 90-15
80-46 90-17
80-47 90-19
80-48 90-21
80-49 90-23
80-50 90-25
80-51 90-27
80-52 90-29
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number Mark Page Revision
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Notice of revision
8PC800,850-8E0
(01)
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PC800, 850-8E0
SEN0527602-00 00-1
PC800, 850-8E0
Shop Manual
00-1
HYDRAULIC EXCAVATOR
PC800-8E0
PC800LC-8E0
PC800SE-8E0
PC850-8E0
PC850SE-8E0
Machine model Serial number
PC800-8E0 65001 and up
PC800LC-8E0 65001 and up
PC800SE-8E0 65001 and up
PC850-8E0 65001 and up
Machine model Serial number
PC850SE-8E0 65001 and up
00 Index and foreword 00-1
00-1

Table of contents
PC800, 850-8E0
Table of contents 00-2
Notice of revision........................................................................................................................ 1
00 Index and foreword
Table of contents .................................................................................................................... 00 - 2
Table of contents ................................................................................................................. 00 - 2
Foreword and general information.......................................................................................... 00- 12
Safety notice........................................................................................................................ 00- 12
How to read the shop manual.............................................................................................. 00- 17
Explanation of terms for maintenance standard .................................................................. 00- 19
Handling of hydraulic components....................................................................................... 00- 21
Method of disconnecting and connecting push-pull type coupler ........................................ 00- 23
Handling of electric equipment............................................................................................. 00- 26
How to read electric wire code............................................................................................. 00- 36
Precautions when performing work...................................................................................... 00- 39
Standard tightening torque table.......................................................................................... 00- 42
List of abbreviation............................................................................................................... 00- 46
Conversion table.................................................................................................................. 00- 50
01 Specification
Specifications.......................................................................................................................... 01- 4
Specifications drawing......................................................................................................... 01- 4
Specifications....................................................................................................................... 01- 8
Table of weight..................................................................................................................... 01- 18
Table of fuel, coolant and lubricants.................................................................................... 01- 26
10 Structure and function
Engine and cooling system..................................................................................................... 10- 3
Coupling............................................................................................................................... 10- 3
Coupling lubrication system................................................................................................. 10- 4
Cooling system .................................................................................................................... 10- 6
Power train system ................................................................................................................. 10- 8
Power train........................................................................................................................... 10- 8
Swing circle.......................................................................................................................... 10- 10
Swing machinery.................................................................................................................. 10- 11
Final drive ............................................................................................................................ 10- 13
Undercarriage and frame........................................................................................................ 10- 14
Track frame.......................................................................................................................... 10- 14
Idler cushion......................................................................................................................... 10- 16
Hydraulic system..................................................................................................................... 10- 18
Hydraulic component layout................................................................................................. 10- 18
Hydraulic tank and filter .......................................................................................................10-20
Hydraulic pump.................................................................................................................... 10- 22
Pump control system ........................................................................................................... 10- 30
Servo valve.......................................................................................................................... 10- 32
Self-pressure reducing valve ............................................................................................... 10- 41
Cooling fan pump................................................................................................................. 10- 44
Cooling fan motor................................................................................................................. 10- 53
Electrical grease pump ........................................................................................................ 10- 59
Control valve........................................................................................................................ 10- 60
Straight-travel valve............................................................................................................. 10- 69
Swing motor......................................................................................................................... 10- 72
00-2 (01)

Table of contents
PC800, 850-8E0
PPC valve............................................................................................................................ 10- 87
Solenoid valve ..................................................................................................................... 10- 95
Accumulator......................................................................................................................... 10-103
Quick return valve................................................................................................................ 10-104
Return oil filter...................................................................................................................... 10-107
Line oil filter.......................................................................................................................... 10- 108
Pilot oil filter ......................................................................................................................... 10-109
Drain oil filter........................................................................................................................ 10-110
Electrical system..................................................................................................................... 10-111
Engine control...................................................................................................................... 10-111
Electric control system......................................................................................................... 10-121
Monitor system .................................................................................................................... 10-160
Sensors................................................................................................................................ 10- 190
KOMTRAX system............................................................................................................... 10-194
20 Standard value table
Standard value table............................................................................................................... 20- 3
Standard value table for engine........................................................................................... 20- 3
Standard value table for machine........................................................................................ 20- 4
30 Testing and adjusting
Tool for testing, adjusting and troubleshooting....................................................................... 30- 3
Tools for testing, adjusting, and troubleshooting ................................................................. 30- 3
Engine and cooling system..................................................................................................... 30- 7
Testing engine speed .......................................................................................................... 30- 7
Testing intake air pressure (boost pressure) ....................................................................... 30- 8
Testing exhaust gas temperature........................................................................................ 30- 9
Testing exhaust gas color.................................................................................................... 30-10
Adjusting valve clearance.................................................................................................... 30-12
Testing compression pressure............................................................................................. 30- 13
Testing blowby pressure...................................................................................................... 30-15
Testing engine oil pressure.................................................................................................. 30-16
Testing EGR valve and bypass valve drive pressure .......................................................... 30- 17
Handling fuel system parts .................................................................................................. 30- 18
Releasing remaining pressure from fuel system.................................................................. 30- 19
Testing fuel pressure ........................................................................................................... 30- 20
Testing fuel return rate and leakage.................................................................................... 30- 21
Bleeding air from fuel circuit ................................................................................................ 30- 24
Testing fuel circuit for leakage............................................................................................. 30-26
Testing and adjusting alternator belt tension....................................................................... 30- 27
Testing and adjusting air conditioner compressor belt tension............................................ 30- 28
Undercarriage and frame........................................................................................................ 30- 29
Testing swing circle bearing clearance................................................................................ 30- 29
Checking and adjusting track tension.................................................................................. 30- 30
Hydraulic system .................................................................................................................... 30- 31
Testing and adjusting oil pressure in work equipment, swing, and travel circuits................ 30- 31
Testing and adjusting control circuit oil pressure (output pressure of self-pressure reducing valve)
............................................................................................................................................. 30- 37
Testing and adjusting control signal of main pump.............................................................. 30- 39
Testing PPC valve output pressure ..................................................................................... 30- 46
Measuring outlet pressure of solenoid valve, swing PPC shuttle valve, and swing priority selector valve
............................................................................................................................................. 30- 50
Adjusting play of work equipment and swing PPC vavles ................................................... 30- 55
Testing and adjusting travel deviation ................................................................................. 30- 56
00-3

Table of contents
PC800, 850-8E0
Inspecting locations of hydraulic drift in work equipment..................................................... 30- 58
Measuring fan speed ........................................................................................................... 30- 59
Measuring fan circuit oil pressure........................................................................................ 30- 60
Measuring fan pump EPC current........................................................................................ 30- 61
Measuring fan pump EPC solenoid valve outlet pressure................................................... 30- 62
Measuring oil leakage.......................................................................................................... 30- 63
Releasing remaining pressure from hydraulic circuit ........................................................... 30- 67
Bleeding air from various parts............................................................................................ 30- 68
Inspection procedures for diode........................................................................................... 30- 71
Adjusting mirrors.................................................................................................................. 30- 72
Electrical system..................................................................................................................... 30- 73
Special functions of machine monitor.................................................................................. 30- 73
Handling voltage circuit of engine controller........................................................................ 30-117
Preparatory work for troubleshooting of electrical system ................................................... 30-118
Pm Clinic................................................................................................................................. 30-122
Pm clinic service.................................................................................................................. 30-122
UNDERCARRIAGE INSPECTION REPORT ...................................................................... 30-129
40 Troubleshooting
General information on troubleshooting.................................................................................. 40- 7
Points to remember when troubleshooting .......................................................................... 40- 7
Sequence of events in troubleshooting................................................................................ 40- 8
Checks before troubleshooting............................................................................................ 40- 9
Classification and procedures for troubleshooting............................................................... 40- 35
Failure codes table............................................................................................................... 40- 38
Symptom and troubleshooting numbers .............................................................................. 40- 43
Information in troubleshooting table..................................................................................... 40- 46
Troubleshooting method for open circuit in wiring harness of pressure sensor system ...... 40- 48
Connector list and layout ..................................................................................................... 40- 50
Connection table for connector pin numbers....................................................................... 40- 61
T- branch box and T- branch adapter table ......................................................................... 40- 97
Fuse locations...................................................................................................................... 40-100
Troubleshooting by failure code.............................................................................................. 40-103
Failure code [989L00] Engine Controller Lock Caution 1 .................................................... 40-103
Failure code [989M00] Engine Controller Lock Caution 2 ................................................... 40-104
Failure code [989N00] Engine Controller Lock Caution 3.................................................... 40-104
Failure code [AA10NX] Air Cleaner Clogging ...................................................................... 40-105
Failure code [AB00KE] Charge Voltage Low....................................................................... 40-106
Failure code [B@BAZG] Eng Oil Press Low........................................................................ 40-108
Failure code [B@BAZK] Eng Oil Level Low......................................................................... 40-109
Failure code [B@BCNS] Eng Water Overheat .................................................................... 40-110
Failure code [B@BCZK] Eng Water Level Low ................................................................... 40-112
Failure code [B@HANS] Hyd Oil Overheat.......................................................................... 40-114
Failure code [CA111] ECM Critical Internal Failure ............................................................. 40-116
Failure code [CA115] Eng Ne and Bkup Speed Sens Error ................................................ 40-118
Failure code [CA122] Chg Air Press Sensor High Error...................................................... 40-120
Failure code [CA123] Chg Air Press Sensor Low Error....................................................... 40-122
Failure code [CA131] Throttle Sensor High Error................................................................ 40-124
Failure code [CA132] Throttle Sensor Low Error................................................................. 40-126
Failure code [CA135] Eng Oil Press Sensor High Error ...................................................... 40-128
Failure code [CA141] Eng Oil Press Sensor Low Error ....................................................... 40-130
Failure code [CA144] Coolant Temp Sens High Error......................................................... 40-132
Failure code [CA145] Coolant Temp Sens Low Error.......................................................... 40-134
Failure code [CA153] Chg Air Temp Sensor High Error...................................................... 40-136
00-4

Table of contents
PC800, 850-8E0
Failure code [CA154] Chg Air Temp Sensor Low Error....................................................... 40-138
Failure code [CA187] Sens Supply 2 Volt Low Error........................................................... 40-140
Failure code [CA221] Ambient Press Sens High Error........................................................ 40-142
Failure code [CA222] Ambient Press Sens Low Error......................................................... 40-144
Failure code [CA227] Sens Supply 2 Volt High Error .......................................................... 40-146
Failure code [CA234] Eng Overspeed................................................................................. 40-147
Failure code [CA238] Ne Speed Sens Supply Volt Error..................................................... 40-148
Failure code [CA263] Fuel Temp Sensor High Error........................................................... 40- 150
Failure code [CA265] Fuel Temp Sensor Low Error............................................................ 40- 152
Failure code [CA271] IMV/PCV1 Short Error....................................................................... 40-154
Failure code [CA272] IMV/PCV1 Open Error ...................................................................... 40- 155
Failure code [CA273] PCV2 Short Error.............................................................................. 40-156
Failure code [CA274] PCV2 Open Error.............................................................................. 40-157
Failure code [CA322] Inj #1(L#1) Open/Short Error ............................................................ 40-158
Failure code [CA323] Inj #5 (L#5) Open/Short Error ........................................................... 40-160
Failure code [CA324] Inj #3(L#3) Open/Short Error ............................................................ 40-162
Failure code [CA325] Inj #6 (L#6) Open/Short Error ........................................................... 40-164
Failure code [CA331] Inj #2(L#2) Open/Short Error ............................................................ 40-166
Failure code [CA332] Inj #4 (L#4) Open/Short Error ........................................................... 40-168
Failure code [CA342] Calibration Code Incompatibility ....................................................... 40- 170
Failure code [CA351] Injectors Drive Circuit Error............................................................... 40-171
Failure code [CA352] Sens Supply 1 Volt Low Error........................................................... 40-172
Failure code [CA386] Sens Supply 1 Volt High Error .......................................................... 40-174
Failure code [CA441] Battery Voltage Low Error................................................................. 40- 174
Failure code [CA442] Battery Voltage High Error................................................................ 40-175
Failure code [CA449] Rail Press Very High Error................................................................ 40-175
Failure code [CA451] Rail Press Sensor High Error............................................................ 40-176
Failure code [CA452] Rail Press Sensor Low Error............................................................. 40-178
Failure code [CA553] Rail Press High Error ........................................................................ 40-180
Failure code [CA554] Rail Press Sensor In Range Error..................................................... 40-181
Failure code [CA559] Supply Pump Press Low Error 1....................................................... 40- 182
Failure code [CA689] Eng Ne Speed Sensor Error ............................................................. 40-186
Failure code [CA731] Eng Bkup Speed Sens Phase Error.................................................. 40-188
Failure code [CA757] All Continuous Data Lost Error ......................................................... 40-189
Failure code [CA778] Eng Bkup Speed Sensor Error.......................................................... 40-190
Failure code [CA1228] EGR Valve Servo Error 1................................................................ 40-192
Failure code [CA1625] EGR Valve Servo Error 2................................................................ 40-193
Failure code [CA1626] BP Valve Sol Current High Error..................................................... 40-194
Failure code [CA1627] BP Valve Sol Current Low Error ..................................................... 40- 196
Failure code [CA1628] Bypass Valve Servo Error 1............................................................ 40- 198
Failure code [CA1629] Bypass Valve Servo Error 2............................................................ 40- 199
Failure code [CA1631] BP Valve Pos Sens High Error ....................................................... 40- 200
Failure code [CA1632] BP Valve Pos Sens Low Error ........................................................ 40-202
Failure code [CA1633] KOMNET Datalink Timeout Error.................................................... 40-204
Failure code [CA2185] Throt Sens Sup Volt High Error ...................................................... 40-206
Failure code [CA2186] Throt Sens Sup Volt Low Error....................................................... 40-208
Failure code [CA2249] Rail Press Very Low Error............................................................... 40-209
Failure code [CA2271] EGR Valve Pos Sens High Error .................................................... 40- 210
Failure code [CA2272] EGR Valve Pos Sens Low Error ..................................................... 40- 212
Failure code [CA2351] EGR Valve Sol Current High Error.................................................. 40-214
Failure code [CA2352] EGR Valve Sol Current Low Error .................................................. 40- 216
Failure code [CA2555] Grid Htr Relay Open Circuit Error................................................... 40-218
Failure code [CA2556] Grid Htr Relay Short Circuit Error ................................................... 40- 220
Failure code [D110KB] Battery Relay Drive Short Circuit.................................................... 40-222
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Table of contents
PC800, 850-8E0
Failure code [D163KB] Flash Light Relay Short Circuit ....................................................... 40-224
Failure code [D195KA] Step Light Relay Open Circuit ........................................................ 40-226
Failure code [D195KB] Step Light Relay Short Circuit......................................................... 40-228
Failure code [D19JKZ] Personal Code Relay Abnormality.................................................. 40-230
Failure code [D862KA] GPS Antenna Open Circuit............................................................. 40-232
Failure code [DA22KK] Pump Solenoid Power Low Error................................................... 40-234
Failure code [DA25KP] 5V Sensor1 Power Abnormality ..................................................... 40-236
Failure code [DA29KQ] Model Selection Abnormality ......................................................... 40-238
Failure code [DA2RMC] CAN Discon (Pump Con Detected)............................................... 40-240
Failure code [DA80MA] Auto. Lub. Abnormal...................................................................... 40-244
Failure code [DAF8KB] Camera Power Supply Short Circuit .............................................. 40-246
Failure code [DAFGMC] GPS Module Error........................................................................ 40-248
Failure code [DAFRMC] CAN Discon (Monitor Detected) ................................................... 40-249
Failure code [DGE5KB] Ambi. Temp Sensor Short Circuit.................................................. 40-254
Failure code [DGH2KB] Hyd Oil Sensor Short..................................................................... 40-256
Failure code [DH25KA] L Jet Sensor Open Circuit.............................................................. 40-258
Failure code [DH25KB] L Jet Sensor Short Circuit.............................................................. 40-260
Failure code [DH26KA] R Jet Sensor Open Circuit ............................................................. 40-262
Failure code [DH26KB] R Jet Sensor Short Circuit.............................................................. 40-264
Failure code [DHPEKA] F Pump P. Sensor Open Circuit.................................................... 40-266
Failure code [DHPEKB] F Pump P. Sensor Short Circuit.................................................... 40-268
Failure code [DHPFKA] R Pump P. Sensor Open Circuit.................................................... 40-270
Failure code [DHPFKB] R Pump P. Sensor Short Circuit.................................................... 40-272
Failure code [DV20KB] Travel alarm short circuit................................................................ 40-274
Failure code [DW41KA] Swing Priority Sol Open Circuit..................................................... 40-276
Failure code [DW41KB] Swing Priority Sol Short Circuit ..................................................... 40-278
Failure code [DW43KA] Travel Speed Sol Open Circuit...................................................... 40-280
Failure code [DW43KB] Travel Speed Sol Short Circuit...................................................... 40-282
Failure code [DW45KA] Swing Brake Sol Open Circuit....................................................... 40-284
Failure code [DW45KB] Swing Brake Sol Short Circuit....................................................... 40-286
Failure code [DW7BKA] Fan Reverse Sol Open Circuit...................................................... 40-288
Failure code [DW7BKB] Fan Reverse Sol Short Circuit ...................................................... 40-290
Failure code [DW7JKA] Bottom Dump Priority Sol Open Circuit ......................................... 40-292
Failure code [DW7JKB] Bottom Dump Priority Sol Short Circuit ......................................... 40-294
Failure code [DW91KA] Travel Junction Sol Open Circuit................................................... 40-296
Failure code [DW91KB] Travel Junction Sol Short Circuit................................................... 40-298
Failure code [DWK0KA] 2-stage Relief Sol Open Circuit..................................................... 40-300
Failure code [DWK0KB] 2-stage Relief Sol Short Circuit..................................................... 40-302
Failure code [DX16KA] Fan Pump EPC Sol Open Circuit................................................... 40-304
Failure code [DX16KB] Fan Pump EPC Sol Short Circuit ................................................... 40-306
Failure code [DXAAKA] F Pump EPC Sol Open Circuit ...................................................... 40-308
Failure code [DXAAKB] F Pump EPC Sol Short Circuit....................................................... 40-310
Failure code [DXABKA] R Pump EPC Sol Open Circuit...................................................... 40-312
Failure code [DXABKB] R Pump EPC Sol Short Circuit...................................................... 40-314
Failure code [DY20KA] Wiper Working Abnormality............................................................ 40-316
Failure code [DY20MA] Wiper Parking Abnormality ............................................................ 40-320
Failure code [DY2CKA] Washer Drive Open Circuit............................................................ 40-322
Failure code [DY2CKB] Washer Drive Short Circuit............................................................ 40-324
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit..................................................... 40-326
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit...................................................... 40-330
Failure code [DY2FMA] Upper Wiper Working Abnormality................................................ 40-334
Failure code [DY2GKM] Wiper Select Abnormality.............................................................. 40-336
Troubleshooting of electrical system (E-mode)....................................................................... 40-339
E-1 Engine does not start (Engine does not crank)............................................................. 40-339
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PC800, 850-8E0
E-2 Preheater does not operate .......................................................................................... 40-344
E-3 When starting switch is turned to ON position, machine monitor displays nothing....... 40- 348
E-4 When starting switch is turned to ON position (before starting engine), basic check monitor lights up.
............................................................................................................................................. 40-351
E-5 Precaution item lights up while engine is running ......................................................... 40-352
E-6 Emergency stop item lights up while engine is running ................................................ 40- 354
E-7 Engine coolant temperature gauge does not indicate properly..................................... 40-355
E-8 Fuel gauge does not indicate properly.......................................................................... 40- 356
E-9 Hydraulic oil temperature gauge does not indicate properly......................................... 40-358
E-10 Displays on machine monitor are different from those for actual machine ................. 40-360
E-11 Some areas of machine monitor screen are not displayed......................................... 40-360
E-12 Function switch does not operate ............................................................................... 40-360
E-13 Automatic warm-up system does not operate (in cold season) .................................. 40-361
E-14 Auto-decelerator does not operate properly................................................................ 40- 362
E-15 Working mode does not change ................................................................................. 40- 363
E-16 Travel speed does not change.................................................................................... 40-364
E-17 Alarm buzzer cannot be canceled............................................................................... 40-365
E-18 When starting switch is turned OFF, service meter is not displayed........................... 40-365
E-19 Service mode cannot be selected............................................................................... 40-365
E-20 Any of work equipment, swing and travel do not operate or cannot be locked........... 40-366
E-21 Machine push-up function does not operate or cannot be canceled........................... 40-368
E-22 Boom shockless function does not operate properly .................................................. 40-370
E-23 Swing brake does not operate properly ...................................................................... 40-372
E-24 Windshield wiper and window washer do not operate ................................................ 40-374
E-25 Travel alarm does not sound or does not stop sounding ............................................ 40-378
E-26 Boom RAISE indicator is not displayed properly with monitoring function.................. 40- 380
E-27 Boom LOWER indicator is not displayed properly with monitoring function ............... 40-382
E-28 Arm IN indicator is not displayed properly with monitoring function............................ 40-384
E-29 Arm OUT indicator is not displayed properly with monitoring function........................ 40-386
E-30 Bucket CURL indicator is not displayed properly with monitoring function ................. 40-388
E-31 Bucket DUMP indicator is not displayed properly with monitoring function ................ 40- 390
E-32 Swing indicator is not displayed properly with monitoring function ............................. 40- 392
E-33 "L.H. travel" is not displayed properly with monitoring function................................... 40- 394
E-34 "R.H. travel" is not displayed properly with monitoring function.................................. 40-396
E-35 "Attachment" is not displayed properly with monitoring function................................. 40- 398
E-36 Electric grease gun does not operate ......................................................................... 40-400
E-37 KOMTRAX system does not operate properly............................................................ 40-402
E-38 Horn does not sound or does not stop sounding ........................................................ 40-403
E-39 Step light does not light up or go off............................................................................ 40-406
Troubleshooting of hydraulic and mechanical system (H-mode)............................................ 40-410
Before starting troubleshooting for hydraulic and mechanical systems............................... 40-410
Information in troubleshooting table (H-mode) .................................................................... 40-414
H-1 All of work equipment, swing and travel work slow or lack power ................................ 40-416
H-2 Engine speed lowers significantly or engine stalls........................................................ 40- 418
H-3 Any of work equipment, swing and travel does not work.............................................. 40-420
H-4 Unusual noise is heard from around hydraulic pump.................................................... 40-422
H-5 Boom operation lacks speed or power.......................................................................... 40-423
H-6 Arm operation lacks speed or power ............................................................................ 40-425
H-7 Bucket operation lacks speed or power........................................................................ 40- 426
H-8 Boom does not move.................................................................................................... 40- 427
H-9 Arm does not move....................................................................................................... 40-427
H-10 Bucket does not move ................................................................................................ 40- 427
H-11 Hydraulic drift of work equipment is large................................................................... 40-428
H-12 Time lag of work equipment is large ........................................................................... 40-430
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PC800, 850-8E0
H-13 Heavy lift function does not work or is not released.................................................... 40-431
H-14 Machine push-up function does not work or is not released....................................... 40-431
H-15 Boom shockless function does not work or is not canceled........................................ 40-431
H-16 Machine deviates in one direction against operator's intention when travelling.......... 40-432
H-17 Machine deviates significantly at start......................................................................... 40-435
H-18 Machine deviates significantly during combined operation......................................... 40-436
H-19 Travel works slow or lack power................................................................................. 40-437
H-20 One of tracks does not run.......................................................................................... 40-438
H-21 Travel speed does not change.................................................................................... 40-439
H-22 Upper structure does not swing .................................................................................. 40-440
H-23 Swing speed is low or swing acceleration is poor....................................................... 40-441
H-24 In combined operation with work equipment, swing speed is low or swing acceleration is poor
............................................................................................................................................. 40-442
H-25 Upper structure overruns excessively when it stops swinging.................................... 40-444
H-26 Shock is large when upper structure stops swinging.................................................. 40-445
H-27 Large unusual noise is heard when upper structure stops swinging........................... 40-446
H-28 Swing drift on a slope is large..................................................................................... 40-447
H-29 Fan revolution is abnormal (Fan sound/vibration is abnormally large or engine overheats)
............................................................................................................................................. 40-448
Troubleshooting of engine (S-mode) ...................................................................................... 40-450
Method of using troubleshooting chart................................................................................. 40-450
S-1 Startability is poor.......................................................................................................... 40-454
S-2 Engine does not start .................................................................................................... 40-456
S-3 Engine does not pick up smoothly................................................................................. 40-460
S-4 Engine stops during operation....................................................................................... 40-461
S-5 Engine runs rough or is unstable................................................................................... 40-462
S-6 Engine lacks power....................................................................................................... 40-464
S-7 Exhaust smoke is black (incomplete combustion)......................................................... 40-466
S-8 Oil consumption is excessive (or exhaust smoke is blue)............................................. 40-468
S-9 Oil becomes contaminated early................................................................................... 40-469
S-10 Fuel consumption is excessive.................................................................................... 40-470
S-11 Oil is in coolant (or coolant spurts or coolant level goes down) .................................. 40-471
S-12 Oil pressure drops....................................................................................................... 40-472
S-13 Oil level rises (coolant or fuel in oil)............................................................................. 40-474
S-14 Coolant temperature rises too high (overheating)....................................................... 40-476
S-15 Unusual noise is made................................................................................................ 40-477
S-16 Vibration is excessive.................................................................................................. 40-478
50 Disassembly and assembly
General information on disassembly and assembly ............................................................... 50- 4
How to read Disassembly and Assembly............................................................................. 50- 4
Coating materials list............................................................................................................ 50- 6
Special tools list ................................................................................................................... 50- 9
Sketches of special tools ..................................................................................................... 50- 16
Engine and cooling system..................................................................................................... 50- 21
Removal and installation of engine, PTO and hydraulic pump assembly............................ 50- 21
Removal and installation of cooling assembly ..................................................................... 50- 29
Removal and installation of aftercooler assembly................................................................ 50- 35
Removal and installation of fuel cooler and air condenser assembly .................................. 50- 37
Removal and installation of fan motor assembly ................................................................. 50- 39
Removal and installation of fuel tank assembly................................................................... 50- 44
Engine..................................................................................................................................... 50- 46
Removal and installation of fuel supply pump assembly ..................................................... 50- 46
Removal and installation of cylinder head assembly........................................................... 50- 51
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PC800, 850-8E0
Removal and installation of fuel injector assembly.............................................................. 50- 67
Removal and installation of engine front seal...................................................................... 50- 70
Removal and installation of engine rear seal....................................................................... 50- 72
Power train.............................................................................................................................. 50- 77
Removal and installation of PTO assembly......................................................................... 50- 77
Disassembly and assembly of PTO assembly..................................................................... 50- 84
Removal and installation of swing motor and swing machinery assembly .......................... 50- 86
Disassembly and assembly of swing machinery assembly................................................. 50- 89
Removal and installation of swing circle assembly.............................................................. 50- 96
Disassembly and assembly of final drive assembly............................................................. 50- 97
Undercarriage and frame........................................................................................................ 50-109
Separation and connection of track shoe assembly ............................................................ 50- 109
Disassembly and assembly of one link in field .................................................................... 50- 111
Removal and installation of idler assembly.......................................................................... 50- 115
Disassembly and assembly of idler assembly ..................................................................... 50- 116
Disassembly and assembly of idler adjustment cylinder assembly ..................................... 50-119
Removal and installation of recoil spring assembly............................................................. 50- 120
Disassembly and assembly of recoil spring assembly......................................................... 50-122
Removal and installation of carrier roller assembly............................................................. 50- 124
Disassembly and assembly of carrier roller assembly......................................................... 50- 125
Removal and installation of track roller assembly................................................................ 50- 128
Disassembly and assembly of track roller assembly ........................................................... 50-129
Removal and installation of revolving frame assembly........................................................ 50-132
Removal and installation of counterweight assembly.......................................................... 50-134
Removal and installation of counterweight remover assembly............................................ 50-135
Hydraulic system .................................................................................................................... 50-137
Removal and installation of hydraulic tank assembly .......................................................... 50- 137
Removal and installation of main pump assembly............................................................... 50-139
Removal and installation of main pump input shaft oil seal................................................. 50-146
Removal and installation of cooling fan pump assembly..................................................... 50- 147
Removal and installation of control valve assembly............................................................ 50-150
Assembly of control valve assembly.................................................................................... 50-153
Removal and installation of swing motor assembly............................................................. 50-159
Removal and installation of center swivel joint assembly.................................................... 50-160
Disassembly and assembly of center swivel joint assembly................................................ 50- 162
Removal and installation of travel motor assembly ............................................................. 50- 164
Removal and installation of solenoid valve assembly.......................................................... 50- 165
Removal and installation of boom damping valve assembly............................................... 50-167
Disassembly and assembly of work equipment PPC valve assembly................................. 50-168
Disassembly and assembly of travel PPC valve assembly ................................................. 50-170
Disassembly and assembly of hydraulic cylinder assembly ................................................ 50-173
Disassembly and assembly of grease gun assembly.......................................................... 50-180
Work equipment...................................................................................................................... 50-181
Removal and installation of bucket cylinder assembly ........................................................ 50-181
Removal and installation of arm cylinder assembly............................................................. 50-185
Removal and installation of boom cylinder assembly.......................................................... 50- 189
Removal and installation of bottom dump cylinder assembly.............................................. 50-193
Removal and installation of bucket assembly...................................................................... 50-195
Removal and installation of arm assembly.......................................................................... 50- 198
Removal and installation of boom assembly ....................................................................... 50-202
Removal and installation of work equipment assembly....................................................... 50- 206
Cab and its attachments......................................................................................................... 50-210
Removal and installation of operator's cab assembly.......................................................... 50-210
Removal and installation of operator's cab glass (adhered window glass).......................... 50-213
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Table of contents
PC800, 850-8E0
Removal and installation of front window assembly ............................................................ 50-222
Electrical system..................................................................................................................... 50-229
Removal and installation of air conditioner unit assembly................................................... 50-229
Removal and installation of engine controller assembly...................................................... 50-232
Removal and installation of monitor assembly..................................................................... 50-234
Removal and installation of pump controller assembly........................................................ 50-236
Removal and installation of KOMTRAX terminal assembly................................................. 50-238
60 Maintenance standard
Engine and cooling system..................................................................................................... 60- 3
Coupling............................................................................................................................... 60- 3
Power train.............................................................................................................................. 60- 4
Swing circle.......................................................................................................................... 60- 4
Swing machinery.................................................................................................................. 60- 5
Final drive ............................................................................................................................ 60- 8
Sprocket............................................................................................................................... 60- 10
Undercarriage and frame........................................................................................................ 60- 12
Track frame and idler cushion.............................................................................................. 60- 12
Idler...................................................................................................................................... 60- 14
Carrier roller......................................................................................................................... 60- 16
Track roller........................................................................................................................... 60- 18
Track shoe ........................................................................................................................... 60- 20
Hydraulic system..................................................................................................................... 60- 24
Cooling fan motor................................................................................................................. 60- 24
Control valve........................................................................................................................ 60- 26
Swing motor......................................................................................................................... 60- 32
Center swivel joint................................................................................................................ 60- 34
PPC valve............................................................................................................................ 60- 35
Work equipment...................................................................................................................... 60- 38
Work equipment................................................................................................................... 60- 38
Work equipment dimension ................................................................................................. 60- 44
Hydraulic cylinder................................................................................................................. 60- 48
80 Appendix
Air conditioner......................................................................................................................... 80- 3
Precautions for refrigerant ................................................................................................... 80- 3
Air conditioner component................................................................................................... 80- 4
Configuration and function of refrigeration cycle.................................................................. 80- 6
Outline of refrigeration cycle................................................................................................ 80- 7
Air conditioner unit............................................................................................................... 80- 10
Air conditioner controller...................................................................................................... 80- 15
Compressor ......................................................................................................................... 80- 16
Condenser ........................................................................................................................... 80- 17
Receiver drier....................................................................................................................... 80- 18
Procedure for testing and troubleshooting........................................................................... 80- 20
Circuit diagram and arrangement of connector pins............................................................ 80- 22
System diagram................................................................................................................... 80- 24
Detail of air conditioner unit ................................................................................................. 80- 26
Parts and connectors layout ................................................................................................ 80- 28
Testing air leakage (duct) .................................................................................................... 80- 31
Testing with self-diagnosis function..................................................................................... 80- 32
Testing temperature control................................................................................................. 80- 35
Testing vent (mode) changeover......................................................................................... 80- 37
Testing FRESH/RECIRC air changeover ............................................................................ 80- 40
00-10