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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Table of Contents
Section 1
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
Section 2
Specification
Specification and Technical Data
Specification Drawings
Specification and Technical Data
Working Range Drawing
Specifications
Weight Table
Table of Fuel, Coolant and Lubricants
Structure, Function and Maintenance Standard
Engine and Cooling System SEN00380-01
Engine and Cooling System
Coupling
Coupling Lubrication System
Radiator, Oil Cooler
Section 3
Power Train Power Train
Swing Machinery
Swing Circle
Final Drive
Sprocket
Section 4
Undercarriage and Frame
Track Frame and Recoil Spring
Undercarriage and Frame
Idler
Carrier Roller
Track Roller
Track Shoe
Double Shoe
Section 5
Hydraulic System, Part 1
Hydraulic Piping Drawing
Hydraulic System, Part 1
Hydraulic Tank, Hydraulic Filter
Hydraulic Pump
Cooling Fan Pump
Cooling Fan Motor
Section 6
Hydraulic System, Part 2
Motor Grease Pump
Hydraulic System, Part 2
Return Oil Filter
Line Oil Filter
Drain Oil Filter
5-Spool Control Valve
4-Spool Control Valve
Straight-Travel Valve
Swing Motor
Center Swivel Joint
Travel Motor
PPC Accumulator
Work Equipment, Swing PPC Valve
Travel PPC Valve
Solenoid Valve
Quick Return Valve
Hydraulic Cylinder
Work Equipment
Work Equipment
Dimensions of Work Equipment
Cab and Its Attachments
Air Conditioner Piping
Section 7
Electrical System
Engine Control
Electrical System Engine Control
Electric Control System
Monitor System
Sensors
Standard Value Table
Standard Service Value Table for Engine
Standard Service Value Table for Chassis
Section 8
Testing and Adjusting Testing and Adjusting, Part
Testing and Adjusting, Part 1
Tools for Testing, Adjusting and Troubleshooting
Testing and Adjusting, Part 1
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
Section 9
Testing and Adjusting, Part 2
Inspection of Swing Circle Bearing Clearance
Testing and Adjusting, Part 2
Testing and Adjusting Track Shoe Tension
Testing and Adjusting Work Equipment, Swing, and Travel Circuit Oil Pressures
Testing and Adjusting Control Circuit Pressure (Output Pressure of Self Pressure Reducing Valve)10
Testing and Adjusting Control Circuit Pressure (Output Pressure of Self Pressure Reducing Valve)
Testing and Adjusting Main Pump Control Pressure
Section 10
Testing and Adjusting, Part 3
Measuring PPC Valve Output Pressure
Testing and Adjusting, Part 3
Measuring Outlet Pressures of Solenoid Valve, Swing PPC Shuttle Valve, and Swing Priority Selector Valve
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
Section 11
30 Testing and Adjusting
Procedure for Turning on KOMTRAX Terminal
Testing and Adjusting, Part 5
KOMTRAX Terminal Lamp Indications
Preparation Work for Troubleshooting Electrical System
Pm-Clinic Service
Troubleshooting
Failure Code Table and Fuse Locations
Failure Codes Table
Fuse Locations
Section 12
General Information on Troubleshooting
Points to Remember When Troubleshooting
General Information on Troubleshooting
Troubleshooting
Sequence of Events in Troubleshooting
Checks before Troubleshooting
Classification and Troubleshooting Steps
Information in Troubleshooting Table
Failure-Looking Phenomenon and Troubleshooting no
Wiring Table for Connector Pin Numbers
T-Adapter Box and T-Adapter Table
Troubleshooting by Failure Code (Display of Code), Part 1
Table of Contents
Failure Code [AA10NX] Aircleaner Clogging
Failure Code [AB00KE] Charge Voltage Low
Failure Code [B@BAZG] Eng. Oil Press. Low
Failure Code [B@BAZK] Eng. Oil Level Low
Failure Code [B@BCNS] Eng. Water Overheat
Failure Code [B@BCZK] Eng. Water Lvl Low
Failure Code [B@HANS] Hydr. Oil Overheat
Failure Code [CA111] ECM Critical Internal Failure
Failure Code [CA115] Eng Ne and Bkup Speed Sens Error
Failure Code [CA122] Chg Air Press Sensor High 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] 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/C
Failure Code [DY2EKB] Wiper Drive (Rev) S/C
Troubleshooting of Electrical System (E-Mode)
Before Carrying out Troubleshooting of Electrical System
Information Contained in Troubleshooting Table
Engine Does Not Start (Engine Does Not Rotate)
Preheater Does Not Operate
Auto Engine Warm-Up Device Does Not Work
Auto-Decelerator Does Not Operate
All Work Equipment, Swing and Travel Do Not Move
Machine Push-Up Function Does Not Operate Normally
Boom Shockless Function Does Not Operate 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
Information in Troubleshooting Table
Speed or Power of All Work Equipment, Travel, and Swing Is Low
Engine Speed Lowers Remarkably or Engine Stalls
All Work Equipment, Travel, and Swing Systems Do Not Work
Abnormal Sound Is Heard from Around Pump
Boom Speed or Power Is Low
Speed or Power of Arm Is Low
Speed or Power of Bucket Is Low
Boom Does Not Move
Arm Does Not Move
Bucket Does Not Move
Hydraulic Drift of Work Equipment Is Large
Time Lag of Work Equipment Is Large
Heavy Lift Function Does Not Operate or Stop
Machine Push-Up Function Does Not Operate or Stop
Boom Shockless Function Cannot be Turned on or off
Machine Deviates in One Direction
Machine Deviates Largely at Start
Machine Deviates Largely During Compound Operation
Travel Speed or Power Is Low
Machine Does Not Travel (Only One Track)
Travel Speed Does Not Change
Upper Structure Does Not Swing
Swing Speed or Acceleration Is Low
Swing Speed or Acceleration Is Low During Compound Operation of Swing and
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
Disassembly and Assembly
General Information on Disassembly and Assembly
How to Read this Manual
Coating Materials List
Special Tools List
Sketches of Special Tools
Engine and Cooling System
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 Seal
Power Train
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
Undercarriage and Frame
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
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
Cab and Its Attachments
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
Diagrams and Drawings
Hydraulic Circuit Diagram
Connector Arrangement Diagram
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HYDRAULIC
EXCAVATOR
PC800
PC800SE
PC800LC
PC850
PC850SE
SERIAL NUMBERS
-8
-8
-8
-8
-8
PC800-
50001
PC800SE-
50001
PC800LC-
50001
PC850-
10001
PC850SE-
10001
SEN00373-06
and up
Table of
Contents
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Page
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Page
1
2
3
4
5
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Chapters
Table of Contents
6
Section 1
17
Section 2
59
Section 3
97
Section 4
109
Section 5
123
Section 6
163
Section 7
243
Section 8
325
Section 9
349
Section 10
367
Section 11
431
Section 12
459
Table of Contents
508
Table of Contents
Troubleshooting
Tools for testing, adjusting and troubleshooting
326
Preparation work for troubleshooting electrical system
438
Troubleshooting
451
General information on troubleshooting
459
Troubleshooting
460
Sequence of events in troubleshooting
461
Checks before troubleshooting
462
Classification and troubleshooting steps
463
Information in troubleshooting table
464
Failure-looking phenomenon and troubleshooting No
466
Troubleshooting by failure code (Display of code), Part 1
507
Troubleshooting by failure code (Display of code), Part 3
655
Troubleshooting of electrical system (E-mode)
727
Before carrying out troubleshooting of electrical system
729
Information contained in troubleshooting table
731
Troubleshooting of hydraulic and mechanical system (H-mode)
795
Before troubleshooting
797
Information in troubleshooting table
800
Troubleshooting of engine (S-mode)
837
Method of using troubleshooting chart
839
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This manual is also suitable for:
Galeo pc800se-8
Galeo pc800lc-8
Galeo pc850-8
Galeo pc850se-8
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