Komatsu PC800LC - 8

SEN05276-03
HYDRAULIC
EXCAVATOR
PC800 -8E0
PC800LC -8E0
PC800SE -8E0
PC850 -8E0
PC850SE -8E0
SERIAL NUMBERS
65001
and up
Notice of revision
Notice of revision
3rd. revision
The affected pages are indicated by the use of the
following marks. It is requested that necessary actions must be taken to these pages according to the
list below.
2012/02
Mark
Indication
Action required
Page to be newly added
Page to be replaced
Replace
()
Page to be deleted
Discard
Add
List of revised pages

Mark
Page
1
2
3
4
5
6
7
8
00-1
00-2
00-3
00-4
00-5
00-6
00-7
00-8
00-9
00-10
00-11
00-12
00-13
00-14
00-15
00-16
00-17
00-18
00-19
00-20
00-21
00-22
00-23
00-24
00-25
00-26
00-27
00-28
00-29
00-30
00-31
00-32
00-33
q
q
q
q
q
q
q
PC800,850-8E0
(03)
(01)
Revision
number
(03)
(02)
(01)
(01)
(01)
(03)
(03)
(01)
(01)
(03)
(03)
(03)
(03)
(03)
Mark
Page
00-34
00-35
00-36
00-37
00-38
00-39
00-40
00-41
00-42
00-43
00-44
00-45
00-46
00-47
00-48
00-49
00-50
00-51
00-52
00-53
00-54
01-1
01-2
01-3
01-4
01-5
01-6
01-7
01-8
01-9
01-10
01-11
01-12
01-13
01-14
01-15
01-16
01-17
01-18
01-19
01-20
Revision
number
Mark
Page
01-21
01-22
01-23
01-24
01-25
01-26
01-27
01-28
10-1
10-2
10-3
10-4
10-5
10-6
10-7
10-8
10-9
10-10
10-11
10-12
10-13
10-14
10-15
10-16
10-17
10-18
10-19
10-20
10-21
10-22
10-23
10-24
10-25
10-26
10-27
10-28
10-29
10-30
10-31
10-32
10-33
Revision
number
Mark
Page
Revision
number
10-34
10-35
10-36
10-37
10-38
10-39
10-40
10-41
10-42
10-43
10-44
10-45
10-46
10-47
10-48
10-49
10-50
10-51
10-52
10-53
10-54
10-55
10-56
10-57
10-58
10-59
10-60
10-61
10-62
10-63
10-64
10-65
10-66
10-67
10-68
10-69
10-70
10-71
10-72
10-73
10-74
Notice of revision
Mark
Page
10-75
10-76
10-77
10-78
10-79
10-80
10-81
10-82
10-83
10-84
10-85
10-86
10-87
10-88
10-89
10-90
10-91
10-92
10-93
10-94
10-95
10-96
10-97
10-98
10-99
10-100
10-101
10-102
10-103
10-104
10-105
10-106
10-107
10-108
10-109
10-110
10-111
10-112
10-113
10-114
10-115
10-116
10-117
10-118
10-119
10-120
10-121
10-122
10-123
10-124
10-125
10-126
Revision
number
(01)
Mark
Page
10-127
10-128
10-129
10-130
10-131
10-132
10-133
10-134
10-135
10-136
10-137
10-138
10-139
10-140
10-141
10-142
10-143
10-144
10-145
10-146
10-147
10-148
10-149
10-150
10-151
10-152
10-153
10-154
10-155
10-156
10-157
10-158
10-159
10-160
10-161
10-162
10-163
10-164
10-165
10-166
10-167
10-168
10-169
10-170
10-171
10-172
10-173
10-174
10-175
10-176
10-177
10-178
Revision
number
Mark
Page
10-179
10-180
10-181
10-182
10-183
10-184
10-185
10-186
10-187
10-188
10-189
10-190
10-191
10-192
10-193
10-194
10-195
10-196
20-1
20-2
20-3
20-4
20-5
20-6
20-7
20-8
20-9
20-10
20-11
20-12
20-13
20-14
20-15
20-16
30-1
30-2
30-3
30-4
30-5
30-6
30-7
30-8
30-9
30-10
30-11
30-12
30-13
30-14
30-15
30-16
30-17
30-18
Revision
number
Mark
Page
Revision
number
30-19
30-20
30-21
30-22
30-23
30-24
30-25
30-26
30-27
30-28
30-29
30-30
30-31
30-32
30-33
30-34
30-35
30-36
30-37
30-38
30-39
30-40
30-41
30-42
30-43
30-44
30-45
30-46
30-47
30-48
30-49
30-50
30-51
30-52
30-53
30-54
30-55
30-56
30-57
30-58
30-59
30-60
30-61
30-62
30-63
30-64
30-65
30-66
30-67
30-68
30-69
30-70
PC800,850-8E0
(02)
(01)
Notice of revision
Mark
Page
30-71
30-72
30-73
30-74
30-75
30-76
30-77
30-78
30-79
30-80
30-81
30-82
30-83
30-84
30-85
30-86
30-87
30-88
30-89
30-90
30-91
30-92
30-93
30-94
30-95
30-96
30-97
30-98
30-99
30-100
30-101
30-102
30-103
30-104
30-105
30-106
30-107
30-108
30-109
30-110
30-111
30-112
30-113
30-114
30-115
30-116
30-117
30-118
30-119
30-120
30-121
30-122
PC800,850-8E0
(01)
Revision
number
Mark
Page
30-123
30-124
30-125
30-126
30-127
30-128
30-129
30-130
40-1
40-2
40-3
40-4
40-5
40-6
40-7
40-8
40-9
40-10
40-11
40-12
40-13
40-14
40-15
40-16
40-17
40-18
40-19
40-20
40-21
40-22
40-23
40-24
40-25
40-26
40-27
40-28
40-29
40-30
40-31
40-32
40-33
40-34
40-35
40-36
40-37
40-38
40-39
40-40
40-41
40-42
40-43
40-44
Revision
number
Mark
Page
40-45
40-46
40-47
40-48
40-49
40-50
40-51
40-52
40-53
40-54
40-55
40-56
40-57
40-58
40-59
40-60
40-61
40-62
40-63
40-64
40-65
40-66
40-67
40-68
40-69
40-70
40-71
40-72
40-73
40-74
40-75
40-76
40-77
40-78
40-79
40-80
40-81
40-82
40-83
40-84
40-85
40-86
40-87
40-88
40-89
40-90
40-91
40-92
40-93
40-94
40-95
40-96
Revision
number
Mark
Page
Revision
number
40-97
40-98
40-99
40-100
40-101
40-102
40-103
40-104
40-105
40-106
40-107
40-108
40-109
40-110
40-111
40-112
40-113
40-114
40-115
40-116
40-117
40-118
40-119
40-120
40-121
40-122
40-123
40-124
40-125
40-126
40-127
40-128
40-129
40-130
40-131
40-132
40-133
40-134
40-135
40-136
40-137
40-138
40-139
40-140
40-141
40-142
40-143
40-144
40-145
40-146
40-147
40-148
Notice of revision
Mark
Page
40-149
40-150
40-151
40-152
40-153
40-154
40-155
40-156
40-157
40-158
40-159
40-160
40-161
40-162
40-163
40-164
40-165
40-166
40-167
40-168
40-169
40-170
40-171
40-172
40-173
40-174
40-175
40-176
40-177
40-178
40-179
40-180
40-181
40-182
40-183
40-184
40-185
40-186
40-187
40-188
40-189
40-190
40-191
40-192
40-193
40-194
40-195
40-196
40-197
40-198
40-199
40-200
Revision
number
Mark
Page
40-201
40-202
40-203
40-204
40-205
40-206
40-207
40-208
40-209
40-210
40-211
40-212
40-213
40-214
40-215
40-216
40-217
40-218
40-219
40-220
40-221
40-222
40-223
40-224
40-225
40-226
40-227
40-228
40-229
40-230
40-231
40-232
40-233
40-234
40-235
40-236
40-237
40-238
40-239
40-240
40-241
40-242
40-243
40-244
40-245
40-246
40-247
40-248
40-249
40-250
40-251
40-252
Revision
number
Mark
Page
40-253
40-254
40-255
40-256
40-257
40-258
40-259
40-260
40-261
40-262
40-263
40-264
40-265
40-266
40-267
40-268
40-269
40-270
40-271
40-272
40-273
40-274
40-275
40-276
40-277
40-278
40-279
40-280
40-281
40-282
40-283
40-284
40-285
40-286
40-287
40-288
40-289
40-290
40-291
40-292
40-293
40-294
40-295
40-296
40-297
40-298
40-299
40-300
40-301
40-302
40-303
40-304
Revision
number
Mark
Page
Revision
number
40-305
40-306
40-307
40-308
40-309
40-310
40-311
40-312
40-313
40-314
40-315
40-316
40-317
40-318
40-319
40-320
40-321
40-322
40-323
40-324
40-325
40-326
40-327
40-328
40-329
40-330
40-331
40-332
40-333
40-334
40-335
40-336
40-337
40-338
40-339
40-340
40-341
40-342
40-343
40-344
40-345
40-346
40-347
40-348
40-349
40-350
40-351
40-352
40-353
40-354
40-355
40-356
PC800,850-8E0
(01)
Notice of revision
Mark
Page
40-357
40-358
40-359
40-360
40-361
40-362
40-363
40-364
40-365
40-366
40-367
40-368
40-369
40-370
40-371
40-372
40-373
40-374
40-375
40-376
40-377
40-378
40-379
40-380
40-381
40-382
40-383
40-384
40-385
40-386
40-387
40-388
40-389
40-390
40-391
40-392
40-393
40-394
40-395
40-396
40-397
40-398
40-399
40-400
40-401
40-402
40-403
40-404
40-405
40-406
40-407
40-408
PC800,850-8E0
(01)
Revision
number
Mark
Page
40-409
40-410
40-411
40-412
40-413
40-414
40-415
40-416
40-417
40-418
40-419
40-420
40-421
40-422
40-423
40-424
40-425
40-426
40-427
40-428
40-429
40-430
40-431
40-432
40-433
40-434
40-435
40-436
40-437
40-438
40-439
40-440
40-441
40-442
40-443
40-444
40-445
40-446
40-447
40-448
40-449
40-450
40-451
40-452
40-453
40-454
40-455
40-456
40-457
40-458
40-459
40-460
Revision
number
Mark
Page
40-461
40-462
40-463
40-464
40-465
40-466
40-467
40-468
40-469
40-470
40-471
40-472
40-473
40-474
40-475
40-476
40-477
40-478
50-1
50-2
50-3
50-4
50-5
50-6
50-7
50-8
50-9
50-10
50-11
50-12
50-13
50-14
50-15
50-16
50-17
50-18
50-19
50-20
50-21
50-22
50-23
50-24
50-25
50-26
50-27
50-28
50-29
50-30
50-31
50-32
50-33
50-34
Revision
number
Mark
Page
Revision
number
50-35
50-36
50-37
50-38
50-39
50-40
50-41
50-42
50-43
50-44
50-45
50-46
50-47
50-48
50-49
50-50
50-51
50-52
50-53
50-54
50-55
50-56
50-57
50-58
50-59
50-60
50-61
50-62
50-63
50-64
50-65
50-66
50-67
50-68
50-69
50-70
50-71
50-72
50-73
50-74
50-75
50-76
50-77
50-78
50-79
50-80
50-81
50-82
50-83
50-84
50-85
50-86
Notice of revision
Mark
Page
50-87
50-88
50-89
50-90
50-91
50-92
50-93
50-94
50-95
50-96
50-97
50-98
50-99
50-100
50-101
50-102
50-103
50-104
50-105
50-106
50-107
50-108
50-109
50-110
50-111
50-112
50-113
50-114
50-115
50-116
50-117
50-118
50-119
50-120
50-121
50-122
50-123
50-124
50-125
50-126
50-127
50-128
50-129
50-130
50-131
50-132
50-133
50-134
50-135
50-136
50-136-1
50-136-2
Revision
number
(02)
(02)
Mark
Page
50-137
50-138
50-139
50-140
50-141
50-142
50-143
50-144
50-145
50-146
50-147
50-148
50-149
50-150
50-151
50-152
50-153
50-154
50-155
50-156
50-157
50-158
50-159
50-160
50-161
50-162
50-163
50-164
50-165
50-166
50-167
50-168
50-169
50-170
50-171
50-172
50-173
50-174
50-175
50-176
50-177
50-178
50-179
50-180
50-181
50-182
50-183
50-184
50-185
50-186
50-187
50-188
Revision
number
Mark
Page
50-189
50-190
50-191
50-192
50-193
50-194
50-195
50-196
50-197
50-198
50-199
50-200
50-201
50-202
50-203
50-204
50-205
50-206
50-207
50-208
50-209
50-210
50-211
50-212
50-213
50-214
50-215
50-216
50-217
50-218
50-219
50-220
50-221
50-222
50-223
50-224
50-225
50-226
50-227
50-228
50-229
50-230
50-231
50-232
50-233
50-234
50-235
50-236
50-237
50-238
60-1
60-2
Revision
number
Mark
Page
Revision
number
60-3
60-4
60-5
60-6
60-7
60-8
60-9
60-10
60-11
60-12
60-13
60-14
60-15
60-16
60-17
60-18
60-19
60-20
60-21
60-22
60-23
60-24
60-25
60-26
60-27
60-28
60-29
60-30
60-31
60-32
60-33
60-34
60-35
60-36
60-37
60-38
60-39
60-40
60-41
60-42
60-43
60-44
60-45
60-46
60-47
60-48
60-49
60-50
60-51
60-52
60-53
60-54
PC800,850-8E0
(03)
(01)
Notice of revision
Mark
Page
80-1
80-2
80-3
80-4
80-5
80-6
80-7
80-8
80-9
80-10
80-11
80-12
80-13
80-14
80-15
80-16
80-17
80-18
80-19
80-20
80-21
80-22
80-23
80-24
80-25
80-26
80-27
80-28
80-29
80-30
80-31
80-32
80-33
80-34
80-35
80-36
80-37
80-38
80-39
80-40
80-41
80-42
80-43
80-44
80-45
80-46
80-47
80-48
80-49
80-50
80-51
80-52
PC800,850-8E0
(03)
(01)
Revision
number
Mark
Page
80-53
80-54
80-55
80-56
80-57
80-58
80-59
80-60
80-61
80-62
80-63
80-64
80-65
80-66
80-67
80-68
80-69
80-70
80-71
80-72
80-73
80-74
80-75
80-76
80-77
80-78
80-79
80-80
80-81
80-82
80-83
80-84
90-1
90-2
90-3
90-4
90-5
90-6
90-7
90-9
90-11
90-12
90-13
90-14
90-15
90-17
90-19
90-21
90-23
90-25
90-27
90-29
Revision
number
Mark
Page
90-31
90-33
90-35
90-37
90-39
90-41
90-43
90-45
90-47
1
2
3
4
5
6
Colophon
Revision
number
Mark
Page
Revision
number
(03)
Notice of revision
PC800,850-8E0
(01)
SEN0527602-00
0 -1
PC800, 850-8E0
HYDRAULIC EXCAVATOR
PC800-8E0
PC850SE-8E0
PC800LC-8E0
PC800SE-8E0
PC850-8E0
Shop Manual
Machine model
Serial number
Machine model
Serial number
PC800-8E0
PC800LC-8E0
PC800SE-8E0
PC850-8E0
65001 and up
65001 and up
65001 and up
65001 and up
PC850SE-8E0
65001 and up
00 Index and foreword
PC800, 850-8E0
0-1
0 -1
00-1
Table of contents
Table of contents
0 -2
Notice of revision........................................................................................................................
00 Index and foreword

Table of contents ....................................................................................................................
Table of contents .................................................................................................................
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 ..................................................................................................................
00 00 000000000000000000000000-
01 Specification
Specifications..........................................................................................................................
Specifications drawing .........................................................................................................
Specifications.......................................................................................................................
Table of weight.....................................................................................................................
Table of fuel, coolant and lubricants ....................................................................................
01- 4
01- 4
01- 8
01- 18
01- 26
10 Structure and function

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 .........................................................................................................................
10101010101010101010101010101010101010101010101010-
00-2
2
2
12
12
17
19
21
23
26
36
39
42
46
50
3
3
4
6
8
8
10
11
13
14
14
16
18
18
20
22
30
32
41
44
53
59
60
69
72
PC800, 850-8E0
(01)
Table of contents
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...............................................................................................................
10- 87
10- 95
10- 103
10- 104
10- 107
10- 108
10- 109
10- 110
10- 111
10- 111
10- 121
10- 160
10- 190
10- 194
20 Standard value table

Standard value table ............................................................................................................... 20Standard value table for engine........................................................................................... 20Standard value table for machine ........................................................................................ 20-
3
3
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
PC800, 850-8E0
00-3
Table of contents
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 ......................................................................
30- 58
30- 59
30- 60
30- 61
30- 62
30- 63
30- 67
30- 68
30- 71
30- 72
30- 73
30- 73
30- 117
30- 118
30- 122
30- 122
30- 129
40 Troubleshooting
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 ......................................................
40- 7
40- 7
40- 8
40- 9
40- 35
40- 38
40- 43
40- 46
40- 48
40- 50
40- 61
40- 97
40- 100
40- 103
40- 103
40- 104
40- 104
40- 105
40- 106
40- 108
40- 109
40- 110
40- 112
40- 114
40- 116
40- 118
40- 120
40- 122
40- 124
40- 126
40- 128
40- 130
40- 132
40- 134
40- 136
00-4
PC800, 850-8E0
Table of contents
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 [CA342] Calibration Code Incompatibility .......................................................
Failure code [CA351] Injectors Drive Circuit 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 [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 [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....................................................
PC800, 850-8E0
40- 138
40- 140
40- 142
40- 144
40- 146
40- 147
40- 148
40- 150
40- 152
40- 154
40- 155
40- 156
40- 157
40- 158
40- 160
40- 162
40- 164
40- 166
40- 168
40- 170
40- 171
40- 172
40- 174
40- 174
40- 175
40- 175
40- 176
40- 178
40- 180
40- 181
40- 182
40- 186
40- 188
40- 189
40- 190
40- 192
40- 193
40- 194
40- 196
40- 198
40- 199
40- 200
40- 202
40- 204
40- 206
40- 208
40- 209
40- 210
40- 212
40- 214
40- 216
40- 218
40- 220
40- 222
00-5
Table of contents
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) .............................................................
00-6
40- 224
40- 226
40- 228
40- 230
40- 232
40- 234
40- 236
40- 238
40- 240
40- 244
40- 246
40- 248
40- 249
40- 254
40- 256
40- 258
40- 260
40- 262
40- 264
40- 266
40- 268
40- 270
40- 272
40- 274
40- 276
40- 278
40- 280
40- 282
40- 284
40- 286
40- 288
40- 290
40- 292
40- 294
40- 296
40- 298
40- 300
40- 302
40- 304
40- 306
40- 308
40- 310
40- 312
40- 314
40- 316
40- 320
40- 322
40- 324
40- 326
40- 330
40- 334
40- 336
40- 339
40- 339
PC800, 850-8E0
Table of contents
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
PC800, 850-8E0
00-7
Table of contents
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 ...............................................................
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 ...........................................................
00-8
505050505050505050505050505050-
4
4
6
9
16
21
21
29
35
37
39
44
46
46
51
PC800, 850-8E0
Table of contents
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 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 ............................................
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 assembly .......................................................
Cab and its attachments .........................................................................................................
Removal and installation of operator's cab assembly..........................................................
Removal and installation of operator's cab glass (adhered window glass)..........................
PC800, 850-8E0
50- 67
50- 70
50- 72
50- 77
50- 77
50- 84
50- 86
50- 89
50- 96
50- 97
50- 109
50- 109
50- 111
50- 115
50- 116
50- 119
50- 120
50- 122
50- 124
50- 125
50- 128
50- 129
50- 132
50- 134
50- 135
50- 137
50- 137
50- 139
50- 146
50- 147
50- 150
50- 153
50- 159
50- 160
50- 162
50- 164
50- 165
50- 167
50- 168
50- 170
50- 173
50- 180
50- 181
50- 181
50- 185
50- 189
50- 193
50- 195
50- 198
50- 202
50- 206
50- 210
50- 210
50- 213
00-9
Table of contents
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 .................................................
50- 222
50- 229
50- 229
50- 232
50- 234
50- 236
50- 238
60 Maintenance standard
Coupling...............................................................................................................................
Power train..............................................................................................................................
Swing circle..........................................................................................................................
Swing machinery..................................................................................................................
Final drive ............................................................................................................................
Sprocket...............................................................................................................................
Track frame and idler cushion..............................................................................................
Idler ......................................................................................................................................
Carrier roller .........................................................................................................................
Track roller ...........................................................................................................................
Track shoe ...........................................................................................................................
Control valve ........................................................................................................................
Swing motor .........................................................................................................................
Center swivel joint................................................................................................................
PPC valve ............................................................................................................................
Work equipment......................................................................................................................
Work equipment...................................................................................................................
Work equipment dimension .................................................................................................
Hydraulic cylinder.................................................................................................................
6060606060606060606060606060606060606060606060-
3
3
4
4
5
8
10
12
12
14
16
18
20
24
24
26
32
34
35
38
38
44
48
80 Appendix
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 ............................................................................
8080808080808080808080808080808080808080-
3
3
4
6
7
10
15
16
17
18
20
22
24
26
28
31
32
35
37
40
00-10
PC800, 850-8E0
Table of contents
Testing inner sensor ............................................................................................................ 80- 42

Testing evaporator temperature sensor............................................................................... 80- 43
Testing sunlight sensor........................................................................................................ 80- 45
Testing (dual) pressure switch for refrigerant ...................................................................... 80- 46
Testing relays ...................................................................................................................... 80- 47
Troubleshooting chart 1 ....................................................................................................... 80- 48
Information in troubleshooting table..................................................................................... 80- 52
Troubleshooting for power supply and CAN communication system (Air conditioner does not operate)
............................................................................................................................................. 80- 54
Troubleshooting for compressor and refrigerant system (Air is not cooled) ........................ 80- 59
Troubleshooting for blower motor system (No air comes out or air flow is abnormal) ......... 80- 63
Troubleshooting for temperature control.............................................................................. 80- 67
Troubleshooting for vent (mode) changeover...................................................................... 80- 70
Troubleshooting for FRESH/RECIRC air changeover ......................................................... 80- 72
Troubleshooting for temperature sensor system ................................................................. 80- 74
Troubleshooting with gauge pressure.................................................................................. 80- 76
Connection of service tool ................................................................................................... 80- 78
Precautions for disconnecting and connecting air conditioner piping .................................. 80- 80
Handling of compressor oil .................................................................................................. 80- 82
90 Diagrams and drawings
Hydraulic circuit diagram ........................................................................................................
Symbols used in hydraulic circuit diagrams .........................................................................
Hydraulic circuit diagram .....................................................................................................
Electrical circuit diagram .........................................................................................................
Symbols used in electric circuit diagrams............................................................................
Electrical circuit diagram......................................................................................................
90- 3
90- 3
90- 7
90- 11
90- 11
90- 15
Index .......................................................................................................................................
PC800, 850-8E0
00-11
Foreword and general information

Safety notice
0 -12
Safety notice
0 -12
Important safety notice

Appropriate servicing and repair are extremely important to ensure safe operation of the machine.
The shop manuals describe the effective and safe servicing and repair methods recommended by Komatsu. Some of the servicing and repair methods require use of special tools designed by Komatsu
for special purposes.
The symbol mark "k" is indicated for such matters that require special precautions. The work indicated with the warning mark should be performed according to the instructions with special attention
to the precautions. Should a hazardous situation occur or be anticipated during such work, be sure
to keep safe first and take every necessary measure.
1. General precautions
k Inappropriate handling creates an extreme danger. Read and understand what
is described in the Operation and Maintenance Manual before operating the machine. Read and understand what is
described in this manual before starting
work.
1) Before performing any greasing or repairs,
read all the safety labels stuck to the
machine. For the locations of the safety
labels and detailed explanation of precautions, see the Operation and Maintenance
Manual.
2) Locate a place in the repair workshop to keep
tools and removed parts. Always keep the
tools and parts in their correct places. Always
keep the work area clean and make sure that
there is no dirt, water, or oil on the floor.
Smoke only in the areas provided for
smoking. Never smoke while working.
3) When performing any operation, always
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons
missing.
q Always wear the safety glasses when hitting parts with a hammer.
q Always wear the safety glasses when
grinding parts with a grinder, etc.
4) When performing any operation with two or
more workers, always agree on the operating
procedure before starting. Always inform
your fellow workers before starting any step
of the operation. Before starting work, hang
UNDER REPAIR warning tag in the operator's compartment.
5) Only qualified workers must perform the work
and operation which require license or qualification.
6) Keep all tools in good condition, learn the
correct way to use them, and use the proper
ones. Before starting work, thoroughly check
the tools, machine, forklift truck, service car,
etc.
00-12
7) If welding repairs are needed, always have a

trained and experienced welder perform the
work. When performing welding work, always
wear welding gloves, apron, shielding
goggles, cap and other clothes suited for
welding work.
8) Before starting work, warm up your body
thoroughly to start work under good condition.
9) Avoid continuing work for long hours and
take rests at proper intervals to keep your
body in good condition and at the provided
place.
Safety points
1 Good arrangement
2 Correct work clothes
3 Following work standard
4 Making and checking signals
5 Prohibition of operation and handling by unlicensed workers
6 Safety check before starting work
7 Wearing protective goggles (for cleaning or grinding work)
8 Wearing shielding goggles and protectors (for
welding work)
9 Good physical condition and preparation
10 Precautions against work which you are not used
to or you are used to too much
PC800, 850-8E0
(03)

Safety notice
2. Preparation work
1) Before adding oil or making any repairs, park
the machine on a hard and level ground, and
apply the parking brake and chock the
wheels or tracks to prevent the machine from
moving.
2) Before starting work, lower the work equipment (blade, ripper, bucket, etc.) to the
ground. If this is not possible, insert the lock
pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock
all the control levers and hang warning tag on
them.
3) When disassembling or assembling, support
the machine with blocks, jacks, or stands
before starting the work.
4) Remove all mud and oil from the steps or
other places used to get on and off the
machine. Always use the handrails, ladders
or steps when getting on or off the machine.
Never jump on or off the machine. If it is
impossible to use the handrails, ladders or
steps, use a stand to provide safe footing.
3. Precautions during work
1) Before disconnecting or removing components for the oil, water, or air circuits, first
release the pressure completely from the
circuit. When removing the oil filler cap, a
drain plug, or an oil pressure pickup plug,
loosen it slowly to prevent the oil from
spurting out.
2) The coolant and oil in the circuits are hot
when the engine is shut down, so be careful
not to get scalded. Wait for the oil and coolant
to cool before performing any work on the oil
or water circuits.
3) Before starting work, shut down the engine.
When working on or around a rotating part, in
particular, shut down the engine. When
checking the machine without shutting down
the engine (measuring oil pressure, revolving
speed, temperature, etc.), take extreme care
not to get caught in rotating parts or moving
parts.
4) For the machine equipped with a battery
disconnct switch, turn the battery disconnect switch to the OFF (O) position and
pull the switch key out, before starting the
work. For machines without a battery
disconnct switch, remove the cable from the
battery , before starting the work. Always
remove the cable from the negative (-)
terminal first.
PC800, 850-8E0
(03)
5) When raising a heavy component (heavier

than 25 kg), use a hoist or crane. Before
starting work, check that the slings (wire
ropes, chains, and hooks) are free from
damage. Always use slings which have
ample capacity and install them to proper
places. Operate the hoist or crane slowly to
prevent the component from hitting any other
part. Do not work with any part still raised by
the hoist or crane.
6) When removing a cover which is under
internal pressure or under pressure by a
spring, always leave two bolts in diagonal
positions. Loosen those bolts gradually and
alternately to release the pressure, and then
remove the cover.
7) When removing components, be careful not
to break or damage the electrical wiring.
Damaged wiring may cause electrical fires.
8) When removing piping, stop the fuel or oil
from spilling out. If any fuel or oil drips onto
the floor, wipe it off immediately. Fuel or oil
on the floor can cause you to slip and can
even cause fires.
9) As a general rule, do not use gasoline to
wash parts. Do not use it to clean electrical
parts, in particular.
10)Be sure to assemble all parts again in their
original places. Replace any damaged parts
and parts which must not be reused with new
parts. When installing hoses and wires, be
sure that they will not be damaged by contact
with other parts when the machine is operated.
11)When installing high pressure hoses and
tubes, make sure that they are not twisted.
Damaged hoses and tubes are dangerous,
so be extremely careful when installing
hoses and tubes for high pressure circuits. In
addition, check that connections of them are
correct.
00-13

Safety notice
12)When assembling or installing parts, always

tighten them to the specified torques. When
installing protective parts such as guards, or
parts which vibrate violently or rotate at high
speeds, be particularly careful to check that
they are installed correctly.
13)When aligning two holes, never insert your
fingers or hand. Be careful not to get your
fingers caught in a hole.
14)When measuring hydraulic pressure, check
that the measuring tools are correctly
installed.
15)Take care when removing or installing the
tracks of track-type machines. When
removing the track, the track separates
suddenly, so never let anyone stand at either
end of the track.
16)If the engine is operated for a long time in a
place which is not ventilated well, you may
suffer from gas poisoning. Accordingly, open
the windows and doors to ventilate well.
4. Precautions for slinging work and making
signals
1) Only one appointed worker must make
signals and co-workers must communicate
with each other frequently. The appointed
signaler must make specified signals clearly
at a place where he is well seen from the
operator's seat and where he can see the
working condition easily. The signaler must
always stand in front of the load and guide
the operator safely.
q Do not stand under the load.
q Do not step on the load.
2) Check the slings before starting sling work.
3) Keep putting on gloves during sling work.
(Put on leather gloves, if available.)
4) Measure the weight of the load by the eye
and check its center of gravity.
5) Use proper sling according to the weight of
the load and method of slinging. If too thick
wire ropes are used to sling a light load, the
load may slip and fall.
6) Do not sling a load with one wire rope alone.
If it is slung so, It may rotate and may slip out
of the rope. Install two or more wire ropes
symmetrically.
k Slinging with one rope may cause
turning of the load during hoisting, untwisting of the rope, or slipping of the
rope from its original winding position
on the load, which can result in a dangerous accident.
00-14
7) Limit the hanging angle to 60 degree, as a

rule.
Do not sling a heavy load (25 kg or more)
with ropes forming a wide hanging angle
from the hook.
When hoisting a load with two or more ropes,
the force subjected to each rope will increase
with the hanging angle. The table below
shows the variation of allowable load in kN
{kg} when hoisting is made with two ropes,
each of which is allowed to sling up to 9.8 kN
{1,000 kg} vertically, at various hanging
angles. When the two ropes sling a load vertically, up to 19.6 kN {2,000 kg} of total weight
can be suspended. This weight is reduced to
9.8 kN {1,000 kg} when the two ropes make
a hanging angle of 120 degree. If the two
ropes sling a 19.6 kN {2,000 kg} load at a
lifting angle of 150 degree, each of them is
subjected to a force as large as 39.2 kN
{4,000 kg}.
8) When installing wire ropes to an angular

load, apply pads to protect the wire ropes. If
the load is slippery, apply proper material to
prevent the wire rope from slipping.
9) Use the specified eyebolts and fix wire ropes,
chains, etc. to them with shackles, etc.
10)Apply wire ropes to the middle portion of the
hook.
q Slinging near the tip of the hook may
cause the rope to slip off the hook during
hoisting. The hook has the maximum
strength at the middle portion.
PC800, 850-8E0
(03)

Safety notice
11)Do not use twisted or kinked wire ropes.

12)When lifting up a load, observe the following.
q Wind in the crane slowly until wire ropes
are stretched. When settling the wire
ropes with the hand, do not grasp them
but press them from above. If you grasp
them, your fingers may be caught.
q After the wire ropes are stretched, stop
the crane and check the condition of the
slung load, wire ropes, and pads.
q If the load is unstable or the wire rope or
chains are twisted, lower the load and lift
it up again.
q Do not lift up the load at an angle.
13)When lowering a load, observe the following.
q When lifting down a load, stop it temporarily at 30 cm above the floor, and then
lower it slowly.
q Check that the load is stable, and then remove the sling.
q Remove kinks and dirt from the wire
ropes and chains used for the sling work,
and put them in the specified place.
5. Precautions for using mobile crane
a Read the Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely.
6. Precautions for using overhead traveling
crane
k A hoist crane or similar device must be
used for lifting a heavy load (25 kg or
more). The weight of a part that is 25 kg or
more is indicated with the symbol "4" in
"Disassembly and assembly".
1) Before starting work, inspect the wire ropes,
brake, clutch, controller, rails, over wind stop
device, ground fault circuit interrupter, crane
collision prevention device, and power application warning lamp, and check safety.
2) Observe the signals for sling work.
3) Operate the hoist at a safe place.
PC800, 850-8E0
(03)
4) Check the direction indicator plates (east,

west, south, and north) and the directions of
the control buttons without fail.
5) Do not sling a load at an angle. Do not move
the crane while the slung load is swinging.
6) Do not raise or lower a load while the crane
is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and lift
up a load to a safe height.
10)Place the control switch in a position where it
will not be an obstacle to work and passage.
11)After operating the hoist, do not swing the
control switch.
12)Remember the position of the main switch so
that you can turn off the power immediately in
an emergency.
13)If the hoist stops because of a power failure,
turn the power switch OFF. When turning on
a switch which was turned OFF by the
ground fault circuit interrupter, check that the
devices related to that switch are not in operating condition.
14)If you find an obstacle around the hoist, stop
the operation.
15)After finishing the work, stop the hoist at the
specified position and raise the hook to at
least 2 m above the floor. Do not leave the
sling installed to the hook.
7. Selecting wire ropes
1) Select adequate ropes depending on the
weight of parts to be hoisted, referring to the
table below
Wire ropes
(Standard "Z" twist ropes without galvanizing)
(JIS G3525, No. 6, Type 6X37-A)
Nominal diameter
Allowable load
of rope
mm
kN
ton
10
8.8
0.9
12
12.7
1.3
14
17.3
1.7
16
22.6
2.3
18
28.6
2.9
20
35.3
3.6
25
55.3
5.6
30
79.6
8.1
40
141.6
14.4
50
221.6
22.6
60
318.3
32.4
a The allowable load is one-sixth of the

breaking strength of the rope to be used
(Safety coefficient: 6).
00-15

Safety notice
8. Precautions
for
disconnecting
and
connecting hoses and tubes in an air conditioner circuit
1) Disconnection
k Although the refrigerant (refrigerant
gas: R134a) used on the machine's air
conditioner is less destructive to the
ozone layer for environmentally friendliness, it is not allowed to be released
into the atmosphere as is. Whenever
disconnecting the air conditioner gas
circuit, be sure to recover the refrigerant gas to reuse it.
a Ask a qualified person for collection and
charge of the refrigerant (R134a).
a Never release the refrigerant (R134a) to
the atmosphere.
k If the refrigerant gas gets in your eyes
or contacts your skin, you may lose
your sight or your skin may be frozen.
Whenever recovering or adding refrigerant gas, you must put on safety
glasses, safety gloves and long
sleeved clothes.
The refrigerant gas must be recovered
and added by a qualified person.
a For tightening torque, see the precautions for installation in each section of
"Disassembly and assembly".
2) Connection
1] When installing the air conditioner circuit
hoses and tubes, take care that dirt, dust,
water, etc. will not enter them.
2] When connecting the air conditioner
hoses and tubes, check that O-rings (1)
are fitted to their joints.
3] Check that O-ring (1) is free from flaw and
deterioration.
4] When connecting the refrigerant piping,
apply compressor oil for refrigerant
(R134a) (DENSO: ND-OIL8, VALEO
THERMAL SYSTEMS: ZXL100PG
(equivalent to PAG46)) to its O-rings.
a Example of O-ring (Fitted to every
joint of hoses and tubes)
00-16
PC800, 850-8E0
(03)

How to read the shop manual
0 -17
(Rev. 2010/03)
q
q
q
Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one of them is
required, consult KOMATSU distributors.
Materials and specifications are subject to change without notice.
Shop manuals are divided into the "Chassis volume" and "Engine volume". For the engine unit, see the engine volume of the engine model mounted on the machine.
1. Composition of shop manual

This shop manual contains the necessary technical information for services performed in a workshop. For
ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section contains the index, foreword, safety and basic information. If any revision is made, the LIST
OF REVISED PAGES will be added.
01. Specification
This section explains the specifications of the machine.
10. Structure and function
This section explains the structure and function of each component. It serves not only to give an understanding for the structure of each component, but also serves as reference material for troubleshooting.
20. Standard value table
This section explains the standard values for new machine and judgement criteria for testing, adjusting,
and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting
This section explains measuring tools and measuring methods for testing and adjusting, as well as the
adjusting method of each part. The standard values and judgment criteria for "Testing and adjusting" are
explained in "Standard value table".
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided
by failure modes. The "S mode" of the troubleshooting related to the engine may be also explained in the
Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque, and quantity and
weight of coating material, oil, grease, and coolant necessary for the work are also explained.
60. Maintenance standard
This section gives maintenance standard values of each component. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
80. Appendix
This section explains the structure, function, testing, adjusting, and troubleshooting for the equipment not
classifiable in other sections.
90. Diagrams and drawings (chassis volume) /Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of remanufacturing and repairing engine and replacing parts.
PC800, 850-8E0
00-17

2. Revision and distribution

Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most
up-to-date information before you start any work.
3. Filing method
File the revised or added pages in the correct order of the page numbers printed in the LIST OF REVISED
PAGES.
q
Revision number
When a manual is revised, revision number of each page is increased by 1.
(Example: (01), (02), (03)...)
Revisions
The revised pages are shown in the LIST OF REVISED PAGES.
4. Symbol
Important safety and quality portions are marked with the following symbols so that the shop manual will be
used practically.
Symbol
Item
Description
Safety
Caution
Special technical precautions or other precautions for preserving standards which

are necessary when performing work are described.
Weight
Weight of parts of component or parts are indicated. Caution necessary when

selecting hoisting wire, or when working posture is important, etc. are described.
Tightening torque
Coat
Oil, coolant
Drain
Special safety precautions which are necessary when performing work are
described.
Places that require special attention for tightening torque during assembly are
indicated.
Places to be coated with adhesives, etc. during assembly are indicated.
Places where oil, etc. must be added, and capacity are indicated.
Places where oil, etc. must be drained, and quantity to be drained are indicated.
5. Unit
In this shop manual, the units are indicated with International System of units (SI).
For reference, conventionally used Gravitational System of units is indicated in parentheses { }.
00-18
PC800, 850-8E0

Explanation of terms for maintenance standard
0 -19
(Rev. 2010/03)
The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the machine maintenance work. The following terms are used to explain the criteria.
1. Standard dimension and tolerance
q To be accurate, the finished dimension of
parts is slightly different from one to another.
q To specify the finished dimension of a part, a
certain dimension is set for the part and an allowable difference from that dimension is indicated.
q The above dimension set is called the "standard dimension" and the range of difference
from the standard dimension is called the
"tolerance".
q The tolerance with the symbols of + or is indicated on the right side of the standard dimension.
Example:
Standard dimension
120
When some parts are repaired, the value of

performance/function is set to the standard
value.
Tolerance
-0.022
-0.126
a The tolerance may be indicated in the text

and a table as [standard dimension (upper
limit of tolerance/lower limit of tolerance)].
Example) 120 (0.022/0.126)
q
Usually, the dimension of a hole and the dimension of the shaft to be inserted into that
hole are indicated by the same standard dimension and different tolerances of the hole
and shaft. The tightness of fit is decided by
the tolerance.
Indication of dimension of rotating shaft and
hole and their related drawing.
Example:
Standard dimension
60
Tolerance
Shaft
Hole
-0.030
+0.046
-0.076
0
2. Standard clearance and standard value

q The clearance made when new parts are assembled is called the "standard clearance",
which is indicated by the range from the minimum clearance to the maximum clearance.
q When some parts are repaired, the clearance
is generally adjusted to the standard clearance.
q The values indicating performance and function of new products or equivalent are called
the "standard value", which is indicated by a
range or a target value.
PC800, 850-8E0
3. Standard interference
q When the diameter of a hole of a part shown
in the given standard dimension and tolerance table is smaller than that of the shaft to
be inserted, the difference between those diameters is called the "interference".
q The range (between A and B) from the difference (A) between the minimum dimension of
the shaft and the maximum dimension of the
hole to the difference (B) between the maximum dimension of the shaft and the minimum dimension of the hole is the standard
interference.
q After repairing or replacing some parts, measure the dimension of their hole and shaft
and check that the interference is in the standard range.
00-19

4. Repair limit and allowable value or allowable

dimension
q The dimension of a part changes because of
wear and deformation while it is used. The
limit of changed dimension is called the "repair limit".
q If a part is worn to the repair limit, it must be
replaced or repaired.
q The performance and function of a product
lowers while it is used. A value with which the
product can be used without causing a problem is called the "allowable value" or "allowable dimension".
q If a product deviates from the allowable value, it must be checked or repaired. However,
since most of the allowable values are estimated from various tests or experiences in
most cases, it must be judged after considering the operating condition and customer's
requirement.
5. Allowable clearance
q Parts can be used until the clearance between them is increased to a certain limit.
The limit at which those parts cannot be used
is called the "allowable clearance".
q If the clearance between the parts exceeds
the allowable clearance, they must be replaced or repaired.
6. Allowable interference
q The allowable maximum interference between the hole of a part and the shaft of another part to be assembled is called the
"allowable interference".
q The allowable interference shows the repair
limit of the part of smaller tolerance.
q If the interference between the parts exceeds
the allowable interference, they must be replaced or repaired.
00-20
PC800, 850-8E0

Handling of hydraulic components
0 -21
(Rev. 2010/03)
With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt
(foreign material) in the hydraulic circuit. Therefore, special precaution is required when adding hydraulic oil,
or when disassembling or assembling hydraulic components.
1. Be careful of the operating environment
Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or at
places where there is a lot of dust.
2. Disassembly and maintenance work in the
field
If disassembly or maintenance work is
performed on hydraulic components in the field,
there is danger of dust entering the components.
It is also difficult to check the performance after
repairs, so it is desirable to use unit exchange.
Disassembly and maintenance of hydraulic
components should be performed in a specially
prepared dustproof workshop, and the performance should be checked with special test
equipment.
3. Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is blocked
with a rag, there is danger of dirt entering or of
the surrounding area being made dirty by
leaking oil so never do this. Do not simply drain
oil out onto the ground, but collect it and ask the
customer to dispose of it, or take it back with you
for disposal.
4. Preventing intrusion of foreign materials

during refilling operations.
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil cleaning
device is used, it is possible to filter out the dirt
that has been collected during storage, so this is
an even more effective method.
PC800, 850-8E0
00-21

5. Replacing hydraulic oil while its temperature is high

When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is still
warm. When changing the oil, as much as
possible of the old hydraulic oil must be drained
out. (Drain the oil from the hydraulic tank; also
drain the oil from the filter and from the drain plug
hole in the circuit.) If any old oil is left, the
contaminants and sludge in it will mix with the
new oil and will shorten the life of the hydraulic
oil.
6. Flushing operations
After disassembling and assembling the equipment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
performed twice. Primary flushing is performed
by use of flushing oil and secondary flushing is
performed by use of the specified hydraulic oil.
7. Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the machine,
perform oil cleaning to remove the sludge or
contaminants in the hydraulic oil circuit. The oil
cleaning equipment can remove the ultra fine
(about 3 m) particles that the filter built in the
hydraulic equipment cannot remove, so it is an
extremely effective device.
00-22
PC800, 850-8E0

Method of disconnecting and connecting push-pull type coupler

k
k
0 -23
(Rev. 2010/03)
Before performing the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the remaining pressure in the hydraulic tank.
Even if the remaining pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil container.
Type 1
0 -2 3
1. Disconnection
1) Hold adapter (1) and push hose joint (2) into
mating adapter (3). (Fig. 1)
a The adapter can be pushed in about 3.5
mm.
a Do not hold rubber cap portion (4).
2) With hose joint (2) pushed into adapter (3),
press rubber cap portion (4) against adapter
(3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull it
out. (Fig. 3)
a Since some hydraulic oil flows out, prepare an oil container.
2. Connection
1) Hold hose adapter (1) or hose (5) and insert
it in mating adapter (3), aligning them with
each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose fitting in the adapter
on the other side perfectly, pull it back to
check the connecting condition (Fig. 5)
a When the hose is pulled back, the rubber
cap portion moves toward the hose about
3.5 mm. This does not indicate abnormality, however.
PC800, 850-8E0
00-23

Type 2
0 -2 4
1. Disconnection
1) Hold the tightening portion and push body (7)
straight until sliding prevention ring (6)
contacts contact surface (a) of the hexagonal
portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1) and
2), pull out whole body (7) to disconnect it.
(Fig. 8)
2. Connection
q Hold the tightening portion and push body (7)
straight until sliding prevention ring (6) contacts contact surface (a) of the hexagonal
00-24
PC800, 850-8E0

Type 3
0 -2 5
1. Disconnection
1) Hold the tightening portion and push body (9)
straight until sliding prevention ring (8)
contacts contact surface (b) of the hexagonal
2) While holding the condition of Step 1), push
cover (10) straight until it contacts contact
surface (b) of the hexagonal portion at the
male end. (Fig. 11)
3) While holding the condition of Steps 1) and
2), pull out whole body (9) to disconnect it.
(Fig. 12)
2. Connection
q Hold the tightening portion and push body (9)
straight until sliding prevention ring (8) contacts contact surface (b) of the hexagonal
PC800, 850-8E0
00-25

Handling of electric equipment
0 -26
(Rev. 2010/03)
To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur, correct "operation", "maintenance and inspection", "troubleshooting", and "repairs" must be
performed. This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the quality of repairs. For this purpose, it gives sections on "Handling electric equipment".
Points to remember when handling electric equipment
1. Handling wiring harnesses and connectors
Wiring harnesses consist of wires connecting
one component to another component, connectors used for connecting and disconnecting one
wire from another wire, and protectors or tubes
used for protecting the wires.
Compared with other electrical components
fitted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects of
rain water, heat, or vibration. Furthermore,
during inspection and repair operations, they are
frequently removed and installed again, so they
are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely
careful when handling wiring harnesses.
0 -26
2. Main failures occurring in wiring harnesses

1) Defective contact of connectors (defective
contact between male and female connectors)
Problems with defective contact are likely to
occur because the male connector is not
properly fitted into the female connector, or
because one or both of the connectors is
deformed or the position is not correctly
aligned, or because there is corrosion or
oxidization of the contact surfaces. The
corroded or oxidized contact surfaces may
become shiny again (and contact may
become normal) by connecting and disconnecting the connector about ten times.
2) Defective crimping or soldering of connectors
The pins of the male and female connectors
are attached to wires by crimping or
soldering. If excessive force is applied to the
wire, the joint is separated and causes a
defective contact or the wire is broken.
00-26
PC800, 850-8E0

3) Disconnections in wiring
If the harness is pulled to disconnect the
connector, or components are lifted with a
crane with the harness still connected, or a
heavy object hits the harness, the crimping of
the connector may separate, or the soldering
may be damaged, or the harness may be
broken.
4) High-pressure water entering connector

The connector is designed to make it difficult
for water to enter (drip-proof structure), but if
high-pressure water is sprayed directly on
the connector, water may enter the
connector, depending on the direction of the
water jet.
Accordingly, take care not to spray water
over the connector.
The connector is designed to prevent water
from entering, but at the same time, if water
does enter, it is difficult for it to be drained.
Therefore, if water should get into the
connector, the pins will be short-circuited by
the water, so if any water gets in, immediately
dry the connector or take other appropriate
action before passing electricity through it.
5) Oil or dirt stuck to connector
If oil or grease are stuck to the connector and
an oil film is formed on the mating surface of
the male and female pins, the oil will not let
the electricity pass, so there will be defective
contact. If there is oil or grease stuck to the
connector, wipe it off with a dry cloth or blow
it to dry with compressed air and spray it with
electric contact cleaner.
a When wiping the joint portion of the connector, be careful not to apply excessive
force or deform the pins.
a If there is oil or water in the compressed
air, the contacts will become even dirtier,
so remove the oil and water from the compressed air completely before cleaning
with compressed air.
PC800, 850-8E0
00-27

3. Removing, installing, and drying connectors

and wiring harnesses
1) Disconnecting connectors
1] Hold the connectors when disconnecting.
When disconnecting the connectors, hold
the connectors. For connectors held by a
screw, loosen the screw fully, then hold
the male and female connectors in each
hand and pull apart. For connectors
which have a lock stopper, press down
the stopper with your thumb and pull the
connectors apart.
a Never pull with one hand.
2] When removing from clips
q Both of the connector and clip have
stoppers, which are engaged with
each other when the connector is installed.
When removing a connector from a

clip, pull the connector in a parallel direction to the clip for removing stoppers.
a If the connector is pried up and down
or to the left or right, the housing may
break.
3] Action to take after removing connectors

After removing a connector, cover it with
a vinyl bag to prevent the entry of dust,
dirt, oil, or water to the contact portion.
a If the machine is left disassembled for
a long time, it is particularly easy for
improper contact to occur, so always
cover the connector.
00-28
PC800, 850-8E0

2) Connecting connectors
1] Check the connector visually.
Check that no oil, dirt, or water is stuck to
connector pins (joint portion).
Check that connector pins are free from
deformation, defective contact, corrosion,
or damage.
Check that external surfaces of the
connectors are free from damage or
breakage.
a If there is any oil, water, or dirt stuck to
the connector, wipe it off with a dry
cloth. If any water has got inside the
connector, warm the inside of the connector and harness with a dryer, but
be careful not to make them too hot as
this will cause short circuits.
a If there is any damage or breakage,

replace the connector.
2] Fix the connector securely.

Position the connectors correctly, and
then fit them securely. For connectors
with the lock stopper, push in the
connector until the stopper clicks into
position.
3] Correcting protrusion of the boot and
misalignment of the wiring harness
For connectors fitted with the boot,
correct any extrusion of the boot. In addition, if the wiring harness is moved in
laying, or the clamp is out of position,
correct it to its right position.
a If the connector cannot be corrected
easily, remove the clamp and adjust
the position.
q If the connector clamp is removed, be
sure to return it to its original position.
Check also that there are no loose
clamps.
PC800, 850-8E0
00-29

3) Deutsch connector (DT 8-pin, 12-pin)

Disconnection (Left of figure)
While pressing locks (a) and (b), pull out the
female connector (2).
Connection (Right of figure)
1] Push in female connector (2) horizontally
until the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector (2)
while moving it up and down until the
locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled down
(not set completely) and lock (b) is set
completely.
(1): Male connector
(2): Female connector
(a), (b): Locks
00-30
Disconnection
Connection (Example of
incomplete setting of
(a))
PC800, 850-8E0

4) Drying wiring harness

If there is any oil or dirt on the wiring harness,
wipe it off with a dry cloth. Avoid washing it in
water or using steam. If the connector must
be washed in water, do not use high-pressure water or steam directly on the wiring
harness. If water gets directly on the
connector, do as follows.
1] Disconnect the connector and wipe off
the water with a dry cloth.
a If the connector is to be blown with dry
compressed air, there is the risk that
oil in the air may cause defective contact, remove oil and water in the air
before starting air blow.
2] Dry the inside of the connector with a
dryer.
If water gets inside the connector, use a
dryer to dry the connector.
a Hot air from the dryer can be used, but
regulate the time that the hot air is
used in order not to make the connector or related parts too hot, as this will
cause deformation or damage to the
connector.
3] Perform a continuity test on the

connector.
After drying, leave the wiring harness
disconnected and perform a continuity
test to check for any short circuits
between pins caused by water.
a After completely drying the connector,
blow it with electric contact cleaner
and reassemble.
PC800, 850-8E0
00-31

4. Handling of connectors used on engine

a Mainly, following engines are object for following connectors.
q 95E-5
q 107E-1
q 114E-3
q 125E-5
q 140E-5
q 170E-5
q 12V140E-3
1) Slide, lock type (FRAMATOME-3, FRAMATOME-2)
q 95/107/114/125/140/170/12V140 Series
q Various pressure sensors and NE
speed sensor
Examples)
Intake air pressure sensor in intake
manifold: PIM (125/170/12V140
series)
Oil
pressure
sensor:
POIL
(125/170/12V140 series)
Oil pressure switch (95/107/114
series)
Ne speed sensor on flywheel housing:
NE (95/107/114/125/140/170/12V140
series)
Ambient pressure sensor: PAMB
(125/170/12V140 series)
2) Pull lock type (PACKARD-2)

q 95/107/114/125/140/170/12V140 Series
q Various temperature sensors
Examples)
Intake air temperature sensor in
intake manifold: TIM
Fuel temperature sensor: TFUEL
Oil temperature sensor: TOIL
Coolant temperature sensor: TWTR,
etc.
Disconnection
Disconnect the connector by pulling lock (B)
(on the wiring harness side) of connector (2)
outward.
Disconnection
1] Slide lock L1 to the right.
2] While pressing lock L2, pull out connector
(1) toward you.
a Even if lock L2 is pressed, connector
(1) cannot be pulled out toward you, if
part (A) does not float. In this case,
float part (A) with a small screwdriver
while pressing lock L2, and then pull
out connector (1) toward you.
Connection
Insert the connector straight until it "clicks".
Connection
00-32
PC800, 850-8E0

3) Push lock type (1)

q 95/107/114 series
Example) Fuel pressure
common rail (BOSCH-03)
sensor
in
While pressing up lock (C) of the connector

with flat-head screwdriver [1], pull out
connector (3) in the direction of the arrow.
Disconnection
While pressing lock (C), pull out connector
(3) in the direction of the arrow.
q
114 series
Connection
q 107/114 series
Example) Intake air pressure/temperature sensor in intake manifold (SUMIq
107 series
TOMO-04)
Disconnection
While pressing lock (D), pull out connector
(4) in the direction of the arrow.
a If the lock is located on the underside, use

flat-head screwdriver [1] since you cannot
insert your fingers.
Connection
PC800, 850-8E0
00-33


q 95/125/140/170/12V140 series
Disconnection
While pressing lock (E) of the connector, pull
out connector (5) in the direction of the arrow.
Example) Fuel pressure sensor in common
rail: PFUEL etc. (AMP-3)
Example) Intake air pressure sensor in

intake manifold.
(CANNON-04): PIM, etc.
Disconnection
1] Turn housing (H1) in the direction of the
arrow.
a When connector is unlocked, housing
(H1) becomes heavy to turn.
2] Pull out housing (H1) in the direction of
the arrow.
a Housing (H1) is left on the wiring harness side.
Example) Injection pressure control valve of

fuel supply pump: PCV (SUMITOMO-2)
Connection
1] Insert the connector to the end, while
setting its groove.
2] Turn housing (H1) in the direction of the
arrow until it "clicks".
Examples) Speed sensor of fuel supply

pump: G (SUMITOMO-3)
a Pull the connector straight up.
Connection
6) Turn-housing
type
(Round
green
connector)
q 140 series
00-34
PC800, 850-8E0

5. Handling controller
1) The controller contains a microcomputer and
electronic control circuits. These control all of
the electronic circuits on the machine, so be
extremely careful when handling the
controller.
2) Do not place objects on top of the controller.
3) Cover the control connectors with tape or a
vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in a place that can be heated to a high
temperature even for a short time. (Place it
on a suitable dry stand.)
6) Precautions when performing arc welding
When performing arc welding on the
machine body, disconnect all of the wiring
harness connectors connected to the
controller. Fit an arc welding ground to the
place close to the welding point.
6. Points to remember when troubleshooting
electric circuits
1) Be sure to turn the power OFF before disconnecting or connecting connectors.
2) Before performing troubleshooting, check all
the related connectors for loose connection.
a Disconnect and connect the related connectors several times to check.
3) Be sure to connect any disconnected
connectors before going on to the next step.
a If the power is turned ON with the connectors still disconnected, unnecessary
warning will be displayed.
4) When performing troubleshooting of circuits
(measuring the voltage, resistance, continuity, or current), wag the related wiring
harnesses and connectors several times and
check that there is no change in the reading
of the tester.
a If there is any change, there may be defective contact in the circuit.
PC800, 850-8E0
00-35

How to read electric wire code
0 -36
(Rev. 2010/03)
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols.
The electric wire code is helpful in understanding the electric circuit diagram.
Exam- AEX
ple:
0.85
---
Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No.
of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
Indicates size of wire by nominal No.
Size (Nominal No.) is shown in Table 2.
Indicates type of wire by symbol.
Type, symbol, and material of wire are shown in Table 1.
(Since the use of AV and AVS wires depends on size (nominal No.), their symbols
are not indicated on the diagram.)
1. Type, symbol, and material

AV and AVS are different only in thickness and outside diameter of the cover. CAVS has a circular
compressed conductor. It differs from AV and AVS in the outside diameter and thickness of the cover. And
AEX is similar to AV in thickness and outside diameter of the cover but different from AV and AVS in material of the cover.
(Table 1)
Type
Low-voltage
wire for automobiles
Thin low-voltage wire for
automobile
(type 1)
Thin low-voltage wire for
automobile
(type 2)
Heat resistant
low-voltage wire
for automobiles
00-36
Symbol
Material
Conductor
Annealed copper for electric

appliance
Insulator
Soft polyvinyl chloride
Conductor

appliance
AV
AVS
Insulator
Conductor

appliance
Insulator
CAVS
Conductor
AEX
Insulator

appliance
Heat-resistant crosslinked
polyethylene
Temperature range
for use ( C)
Example of use
General wiring
(nominal No. 5 and above)
-30 +60
General wiring
(nominal No. 3 and below)
For mid- to small-size excavators

(nominal No. 1.25 and below)
-50 +110
General wiring in extremely cold

weather district, wiring at high
ambient temperature place
PC800, 850-8E0

2. Dimensions
(Table 2)
Nominal No.
Cover D
Conductor
Number of
strands/Diameter of strand
Sectional area
(mm2)
0.75f
(0.85)
1.25f
(1.25)
2f
3f
20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
0.51
0.56
0.76
0.88
1.27
1.29
1.96
2.09
3.08
3.30
5.23
1.0
1.2
1.5
1.9
1.9
2.3
2.4
3.0
AVS
Standard
2.0
2.2
2.5
2.9
2.9
3.5
3.6
AV
Standard
4.6
AEX
Standard
2.0
2.2
2.7
3.0
3.1
3.8
4.6
15
20
30
50/0.45
84/0.45
41/0.80
70/0.80
7.95
13.36
20.61
35.19
42.73
54.29
63.84
84.96
109.1
d (approx.)
3.7
4.8
6.0
8.0
8.6
9.8
10.4
12.0
13.6
AVS
Standard
AV
Standard
5.5
7.0
8.2
10.8
11.4
13.0
13.6
16.0
17.6
AEX
Standard
5.3
7.0
8.2
10.8
11.4
13.0
13.6
16.0
17.6
Conductor
Cover D
(0.5)
d (approx.)
Nominal No.
Number of
Sectional area
(mm2)
Nominal No.
Conductor
Cover D
0.5f
CAVS
40
50
60
85
100
85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
0.5f
0.5
0.75f
0.85
1.25f
1.25
7/Circular compressed
0.56
0.88
1.29
d (approx.)
0.9
1.1
1.4
Standard
1.6
1.8
2.1
Number of
Sectional area
(mm2)
"f" of nominal No. denotes "flexible".
PC800, 850-8E0
00-37

3. Color codes table

(Table 3)
Color Code
B
Br
BrB
BrR
BrW
BrY
Ch
Dg
G
GB
GL
Gr
GR
GW
GY
L
LB
Lg
LgB
LgR
Color of wire
Black
Brown
Brown & Black
Brown & Red
Brown & White
Brown & Yellow
Charcoal
Dark green
Green
Green & Black
Green & Blue
Gray
Green & Red
Green & White
Green & Yellow
Blue
Blue & Black
Light green
Light green & Black
Light green & Red
Color Code
LgW
LgY
LR
LW
LY
O
P
R
RB
RG
RL
RW
RY
Sb
Y
YB
YG
YL
YR
YW
Color of wire
Light green & White
Light green & Yellow
Blue & Red
Blue & White
Blue & Yellow
Orange
Pink
Red
Red & Black
Red & Green
Red & Blue
Red & White
Red & Yellow
Sky Blue
Yellow
Yellow & Black
Yellow & Green
Yellow & Blue
Yellow & Red
Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and the second
color is the color of the marking.
Example: "GW" means that the background is "Green" and marking is "White".
4. Types of circuits and color codes
(Table 4)
Type of wire
AEX
Charge
WG
Ground
Start
Light
RW
RB
RY
RG
RL
Instrument
YR
YB
YG
YL
YW
Gr
Signal
GW
GR
GY
GB
GL
Br
LW
LR
LY
LB
Br
BrW
BrR
BrY
BrB
Lg
LgR
LgY
LgB
LgW
Gr
Sb
Dg
Ch
Type of circuit
Others
00-38
AVS, AV, CAVS
PC800, 850-8E0

Precautions when performing work
0 -39
(Rev. 2010/03)
When removing, installing, disassembling or assembling a unit, be sure to follow the general precautions given below.
1. Precautions for removal work
q If the coolant contains antifreeze, dispose of it correctly as chemicals.
q After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering.
q When draining oil, prepare a container of adequate size to catch the oil.
q Check the match marks showing the installation position, and put match marks in the necessary places
before removal to prevent any mistake when assembling.
q To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. Do not pull the wires.
q Attach the tags to wires and hoses to show their installation position to prevent any mistake when installing.
q Check the number and thickness of the shims, and keep them in a safe place.
q When slinging component, be sure to use lifting equipment of ample strength.
q When using forcing screws to remove any component, tighten the forcing screws uniformly and alternately.
q Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from
entering after removal.
a Precautions when handling piping during disassembly
Put the following plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes
Nominal
number
02
03
04
05
06
10
12
Plug (nut end)
Sleeve nut (elbow end)
07376 - 70210
07376 - 70315
07376 - 70422
07376 - 70522
07376 - 70628
07376 - 71034
07376 - 71234
02789 - 20210
02789 - 20315
02789 - 20422
02789 - 20522
02789 - 20628
07221 - 21034
07221 - 21234
2) Split flange type hoses and tubes

Nominal
number
04
05
Flange (hose end)
Sleeve head (tube end)
Split flange
07379 - 00400
07379 - 00500
07378 - 10400
07378 - 10500
07371 - 30400
07371 - 30500
3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal
number
06
08
10
12
14
16
18
20
22
24
27
Part No.
07049 - 00608
07049 - 00811
07049 - 01012
07049 - 01215
07049 - 01418
07049 - 01620
07049 - 01822
07049 - 02025
07049 - 02228
07049 - 02430
07049 - 02734
PC800, 850-8E0
D
6
8
10
12
14
16
18
20
22
24
27
Dimensions
d
5
6.5
8.5
10
11.5
13.5
15
17
18.5
20
22.5
L
8
11
12
15
18
20
22
25
28
30
34
00-39

2. Precautions for installation work

q Tighten all of the bolts and nuts (sleeve nuts) to the specified torque (KES).
q Install the hoses without twisting or interference and fix them with intermediate clamps, if available.
q Replace all of the gaskets, O-rings, cotter pins, and lock plates with new parts.
q Bend the cotter pins and lock plates securely.
q When coating with adhesive, clean and degrease the part, and coat the threaded portion with two to
three drops of adhesive.
q When coating with liquid gasket, clean and degrease the surface, and apply it uniformly after making
sure that the surface is free from dirt or damage.
q Clean all of the parts, and correct any damage, dents, burrs, or rust found on them.
q Coat the rotating parts and sliding parts with engine oil.
q When press-fitting parts, coat the surface with molybdenum disulfide lubricant (LM-P).
q After installing the snap rings, check that the snap ring is settled in the ring groove completely.
q When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
them securely.
q When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align
the direction of the hook.
q When installing split flanges, fasten them uniformly and alternately to prevent excessive tightening on
one side.
a When operating the hydraulic cylinders for the first time after reassembling the cylinders, hydraulic
pumps and other hydraulic component removed for repair, be sure to bleed the air as follows:
1] Start and run the engine at low idle.
2] Operate the work equipment control lever to operate the hydraulic cylinder four to five times, stopping the piston at 100 mm off the end of its stroke.
3] Next, operate the hydraulic cylinder three to four times to the end of its stroke.
a When using the machine for the first time after repair or long storage, follow the same procedure.
3. Precautions for completing work
1) Refilling of coolant, oil and grease
q If the coolant is drained, close the drain valve, and add coolant to the specified level. Run the engine
to circulate the coolant through the system . Then add the coolant again if necessary.
q If the hydraulic component is removed and installed again, add engine oil to the specified level. Run
the engine to circulate the oil through the system. Then add the oil again if necessary.
q If the hydraulic piping or hydraulic equipment are removed, be sure to bleed air from the system
after reassembling the parts, by referring to "Testing and adjusting".
q Supply the specified amount of grease (molybdenum disulfide grease) to the work equipment parts.
2) Check of installed condition of cylinder head and manifolds
Check the cylinder head and intake and exhaust manifold mountings for looseness.
If any part is loosened, retighten it.
q For the tightening torques, see the "Disassembly and assembly".
3) Checking engine piping for damage and looseness
Intake and exhaust system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air suction and
exhaust gas leakage.
If any part is loosened or damaged, retighten or repair it.
Cooling system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for coolant leakage.
Fuel system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel leakage.
00-40
PC800, 850-8E0

4) Checking muffler, exhaust pipe and their mounts for damage and looseness
1] Visually check the muffler, exhaust pipe and their mounts for a crack and damage.
If any part is damaged, replace it.
2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounts for looseness.
If any part is loosened, retighten it.
5) Checking muffler function
Check the muffler for unusual sound and sound different from that of a new muffler.
If any unusual sound is heard, repair the muffler, referring to "Troubleshooting" and "Disassembly and
assembly".
PC800, 850-8E0
00-41

Standard tightening torque table
0 -42
(Rev. 2010/03)
1. Table of tightening torques for bolts and nuts
a Unless otherwise specified, tighten metric nuts and bolts to the torque shown in the following table.
1) The following table applies to the bolts in Fig. A.
Thread diam- Width across
eter of bolt
flats
mm
mm
6
10(10)
8
13(12)
10
17(14)
12
19(17)
14
22
16
24
18
27
20
30
22
32
24
36
27
41
30
46
33
50
36
55
39
60
Tightening torque
Nm
11.8 14.7
27 34
59 74
98 123
157 196
245 309
343 427
490 608
662 829
824 1,030
1,180 1,470
1,520 1,910
1,960 2,450
2,450 3,040
2,890 3,630
kgm
1.2 1.5
2.8 3.5
6.0 7.5
10.0 12.5
16 20
25 31.5
35 43.5
50 62
67.5 84.5
84 105
120 150
155 195
200 250
250 310
295 370
a Values with ( ) in the "Width across flats" column are for (*) marked bolt (flange bolt) shown in Fig. A.
2) The following table applies to the bolts in Fig. B.
eter of bolt
flats
mm
mm
6
10
8
12
10
14
12
17
Fig. A
Tightening torque
Nm
5.9 9.8
13.7 23.5
34.3 46.1
74.5 90.2
kgm
0.6 1.0
1.4 2.4
3.5 4.7
7.6 9.2
Fig. B
a Values with ( ) are applied to (*) marked bolt (flange bolt) as the width across flats.
00-42
PC800, 850-8E0

2. Table of tightening torque for split flanged bolts

a Unless otherwise specified, tighten split flanged bolts to the torque shown in the following table.
eter of bolt
flats
mm
mm
10
14
12
17
16
22
Tightening torque
Nm
59 74
98 123
235 285
kgm
6.0 7.5
10.0 12.5
23.5 29.5
3. Table of tightening torque for O-ring boss piping joints

a Unless otherwise specified, tighten O-ring boss piping joints to the torque shown in the following table.
Nominal No.
02
03, 04
05, 06
10, 12
14

eter
flats
mm
mm
14
Varies
20
depending on
24
type of con33
nector.
42
Tightening torque (Nm {kgm})

Range
35 63 {3.5 6.5}
84 132 {8.5 13.5}
128 186 {13.0 19.0}
363 480 {37.0 49.0}
746 1,010 {76.0 103}
Target
44 {4.5}
103 {10.5}
157 {16.0}
422 {43.0}
883 {90.0}
4. Table of tightening torque for O-ring boss plugs

a Unless otherwise specified, tighten O-ring boss plugs to the torque shown in the following table.
Nominal No.
08
10
12
14
16
18
20
24
30
33
36
42
52

eter
flats
mm
mm
8
14
10
17
12
19
14
22
16
24
18
27
20
30
24
32
30
32
33
36
36
42
52
PC800, 850-8E0

Range
5.88 8.82 {0.6 0.9}
9.8 12.74 {1.0 1.3}
14.7 19.6 {1.5 2.0}
19.6 24.5 {2.0 2.5}
24.5 34.3 {2.5 3.5}
34.3 44.1 {3.5 4.5}
44.1 53.9 {4.5 5.5}
58.8 78.4 {6.0 8.0}
93.1 122.5 { 9.5 12.5}
107.8 147.0 {11.0 15.0}
127.4 176.4 {13.0 18.0}
181.3 240.1 {18.5 24.5}
274.4 367.5 {28.0 37.5}
Target
7.35 {0.75}
11.27 {1.15}
17.64 {1.8}
22.54 {2.3}
29.4 {3.0}
39.2 {4.0}
49.0 {5.0}
68.6 {7.0}
107.8 {11.0}
127.4 {13.0}
151.9 {15.5}
210.7 {21.5}
323.4 {33.0}
00-43

5. Table of tightening torque for hoses (taper seal type and face seal type)
a Unless otherwise specified, tighten the hose fittings (taper seal type and face seal type) to the torque
shown in the following table.
a Apply the following torque when the threads are coated with engine oil (wetted).
Nominal
Width
number of across
hose
flats (mm)
02
03
04
05
06
(10)
(12)
(14)
19
22
24
27
32
36
41
46
55
Taper seal
Range
Target
Thread size
(mm)
34 54 {3.5 5.5}
34 63 {3.5 6.5}
54 93 {5.5 9.5}
59 98 {6.0 10.0}
84 132 {8.5 13.5}
128 186 {13.0 19.0}
177 245 {18.0 25.0}
177 245 {18.0 25.0}
197 294 {20.0 30.0}
246 343 {25.0 35.0}
44 {4.5}
44 {4.5}
74 {7.5}
78 {8.0}
103 {10.5}
157 {16.0}
216 {22.0}
216 {22.0}
245 {25.0}
294 {30.0}
14
18
22
24
30
33
36
42
Face seal
Nominal No.
Thread diameNumber of
ter (mm) (Refthreads, type of
erence)
thread
9/16-18UN
14.3
11/16 16UN
17.5
13/16 16UN
20.6
1 14UNS
25.4
1-3/16 12UN
30.2
6. Table of tightening torque for face seal joints

a Tighten the face seal joints (sleeve nut type) made of plated steel pipes for low pressure service to be
used for engines etc. to the torque shown in the following table.
a Apply the following torque to the face seal joint while their threaded parts are coated with engine oil
(wetted).
Outer diam- Width across
eter of pipe
flats
(mm)
(mm)
8
10
12
15 (16)
22 (20)
19
22
24 (27)
30 (32)
36
Range
Target
14 16 {1.4 1.6}
24 27 {2.4 2.7}
43 47 {4.4 4.8}
60 68 {6.1 6.8}
90 95 {9.2 9.7}
15 {1.5}
25.5 {2.6}
45 {4.6}
64 {6.5}
92.5 {9.4}
Face seal
Nominal No.
Thread diameter
Number of
(mm)
threads, type of
(Reference)
thread
9/16 18UN
14.3
11/16 16UN
17.5
13/16 16UN
20.6
1-14UNS
25.4
1 3/16 12UN
30.2
Reference: The face seal joints of the dimensions in ( ) are also used, depending on the specification.
00-44
PC800, 850-8E0

7. Table of tightening torque for 102, 107 and 114 engine series (bolts and nuts)
a Unless otherwise specified, tighten the metric bolts and nuts used for the 102, 107 and 114 engine series to the torque shown in the following table.
Tightening torque
Bolts and nuts
Thread size
mm
6
8
10
12
14
Nm
10 2
24 4
43 6
77 12
kgm
1.02 0.20
2.45 0.41
4.38 0.61
7.85 1.22
8. Table of tightening torque for 102, 107 and 114 engine series (eye joints)
a Unless otherwise specified, tighten the metric eye joints used for the 102, 107 and 114 engine series
to the torque shown in the following table.
Thread size
mm
6
8
10
12
14
Tightening torque
Nm
82
10 2
12 2
24 4
36 5
kgm
0.81 0.20
1.02 0.20
1.22 0.20
2.45 0.41
3.67 0.51
9. Table of tightening torque for 102, 107 and 114 engine series (taper screws)
a Unless otherwise specified, tighten NPT screws used for the 102, 107 and 114 engine series to the
torque shown in the following table.
Material
Thread size (inch)
1/16
1/8
1/4
3/8
1/2
3/4
PC800, 850-8E0
Tightening torque
In cast iron or steel
In aluminum
Nm
kgm
Nm
kgm
15 2
1.53 0.20
51
0.51 0.10
20 2
2.04 0.20
15 2
1.53 0.20
25 3
2.55 0.31
20 2
2.04 0.20
35 4
3.57 0.41
25 3
2.55 0.31
55 6
5.61 0.61
35 4
3.57 0.41
75 8
7.65 0.82
45 5
4.59 0.51
00-45

List of abbreviation
0 -46
(Rev. 2010/03)
This list of abbreviations includes the abbreviations used in the text of the shop manual for parts, components, and functions whose meaning is not immediately clear. The spelling is given in full with an outline
of the meaning.
q Abbreviations that are used in general society may not be included.
q Special abbreviations that appear infrequently are marked in the text with an *.
q This list of abbreviations consists of two parts. The first part is a list of abbreviations used in the text of the
manual, and the second part is a list of abbreviations used in circuit diagrams.
List of abbreviations used in the shop manual
q
Abbreviation
Full Spelling
Purpose of use (major applicable machine (*), or component/system)
Explanation
A.B.S.
Anti-skid Brake System
Travel and brake

(HD, HM)
With this function, when the tires skid (wheels stop

rotating), the brakes are released, and when the
wheels start to rotate, the brakes are applied again.
A.I.S.S.
Automatic Idling Setting

System
Engine
This function automatically sets the idle speed.
A.J.S.S.
Advanced Joystick Steer- Steering

ing System
(WA)
A.R.A.C.
Automatic Retarder
Accelerator Control
Travel and brake

(HD, HM)
A.R.S.C.
Automatic Retarder
Speed Control
Travel and brake

(HD, HM)
Automatic Spin Regulator
Travel and brake

(HD, HM)
Attachment
Work equipment
A.S.R.
ATT.
B.C.V.
Brake Cooling oil control Brake

Valve
(HD)
C.A.N.
Controller Area Network
Communication and electronic control
Closed-center Load
Sensing System
Hydraulic
C.R.I.
Common Rail Injection
Engine
E.C.M.
Electronic Control Module
Electronic control system
C.L.S.S.
E.C.M.V.
Electric Control Modula- Transmission

tion Valve
(D, HD, WA, etc.)
E.C.S.S.
Electronically Controlled Travel

Suspension System
(WA)
E.C.U.
Electronic Control Unit
E.G.R.
Exhaust Gas Recirculation
Engine
00-46
Instead of a steering wheel, a lever is used to perform the steering operations as well as to shift gear
and change direction (forward or reverse).
When the machine is traveling downhill, if the
accelerator pedal is released, this function automatically applies the retarder with a constant braking force.
When the machine is traveling downhill, if the
accelerator pedal is released, this function automatically applies the retarder to ensure that the
machine speed does not accelerate above the
speed set by the operator.
When the rear wheels spin on soft ground surfaces, this function automatically uses the optimum
braking force to drive both wheels.
A device that can be fixed onto a machine in order
to enable it to do different jobs.
When the retarder is not being used, this valve
bypasses part of the brake cooling oil to reduce the
load on the hydraulic pump.
Communications standard standardized as
ISO11898.
System that can simultaneously actuate multiple
actuators regardless of the load (provides better
ease of combined operation than O.L.S.S.).
Uses engine controller to perform electronic control
of supply pump, common rail, and injector. Functions to maintain optimum fuel injection amount
and fuel injection timing.
Electronic control device that uses the signals from
the sensors on the machine to indicate to the actuators the optimum actuation. (same as ECU)
Proportional electromagnetic valve that gradually
increases oil pressure to engage clutch and
reduces transmission shock.
System that ensures smooth high-speed travel by
using hydraulic spring effect of accumulator to
absorb vibration of machine during travel
Electronic control device that uses the signals from
the sensors on the machine to indicate to the actuators the optimum actuation. (same as ECM)
Functions to recirculate part of exhaust gas to combustion chamber in order to reduce combustion
temperature, controls emission of Nox.
PC800, 850-8E0

Abbreviation
Full Spelling
Equipment Management
E.M.M.S.
Machine monitor
Monitoring System
E.P.C.
Electromagnetic ProporHydraulic
tional Control
F-N-R
Forward-Neutral-Reverse Operation
G.P.S.
Global Positioning System
H.S.S.
Hydrostatic Steering Sys- Steering

tem
(D)
H.S.T.
Hydro Static Transmission
Transmission
(D, WA)
I.M.A.
Inlet Metering Actuator
Engine
I.M.V.
Inlet Metering Valve
Engine
L.C.D.
Liquid Crystal Display
Machine monitor
L.E.D.
Light Emitting Diode
Electronic parts
Load Sensing
Hydraulic
Multimedia Messaging
Service
Communication
N.C.
Normally Closed
Electric and hydraulic
N.O.
Normally Open
Electric and hydraulic
L.S.
M.M.S.
O.L.S.S.
P.C.
Explanation
System that allows data (filter, oil replacement
interval, malfunctions on machine, failure code,
and failure history) from each sensor on the
machine to be checked on monitor.
Control system that moves an actuator in proportion to the amperage of an electric current passing
through the solenoid.
Position of the gear shift lever or switch.
Open-center Load SensHydraulic

ing System
System that is used to determine the current location on the Earth of a ship, car, machine, etc. by
receiving the radio wave signals transmitted from
the navigation satellites.
Steering function that uses a combination of
hydraulic motor and bevel shaft to control difference in travel speed of right and left tracks to turn
machine without using steering clutch.
Hydraulic transmission system that uses a combination of hydraulic pump and hydraulic motor to
shift gear steplessly without using gears.
Valve installed at inlet port of pump to adjust fuel
intake amount in order to control fuel discharge
amount of supply pump. Same as IMV.
amount of supply pump. Described as IMV (IMA).
Image display device made up of a large number of
pixels filled with liquid crystal.
Semiconductor element that emits light when the
voltage is applied in forward direction, positive voltage to anode and negative voltage to cathode.
Function that senses differential pressure of pump
and controls discharge amount according to load.
Service that allows transmission and reception of
short messages consisting of characters or voice
or images between cell phones.
Device actuated to open electric or hydraulic circuits that are normally closed if not actuated.
Device actuated to close electric or hydraulic circuits that are normally open if not actuated.
Hydraulic system that can operate multiple actuators at the same time, regardless of the load.
Pressure Control
Controlling the oil pressure.
Communication
(KOMTRAX, VHMS)
Hydraulic
Palm Command Control Steering

P.C.C.S.
System
(D)
System in which a controller instantly analyses

data from each lever, pedal, and dial, and performs
optimum electronic control of the engine and transmission.
amount of supply pump.
Control system that moves an actuator in proportion to the oil pressure.
P.C.V.
Pump Control Valve
Engine
P.P.C.
Proportional Pressure
Control
Hydraulic
P.P.M.
Piston Pump and Motor
Hydraulic
(D, PC, etc.)
Piston pump and motor.
P.T.O.
Power Take Off
Power transmission
A device to take off power of the engine.
P.T.P.
Power Tilt and power

Pitch dozer
Work equipment
(D)
Function that performs hydraulic control of the tilt

and pitch of the bulldozer blade.
PC800, 850-8E0
00-47

Abbreviation
S.I.
Full Spelling
Le Systeme International
Unit
d Unites
SOL.
Solenoid
Electric
T.W.V.
Two Way Valve
Hydraulic and electric
Explanation
International System of Units (abbreviated SI from
the French Le Systeme Internationale dUnites) is
the modern form of the metric system, and is the
worlds most widely used system of measurement.
Therere seven base units: meter (m), kilogram
(kg), second (s), ampere (A), kelvin (K), candela
(cd), and mole (mol). The derived units include
Pascal (Pa), Newton (N), etc.
Solenoid is a loop of wire. However, as a matter of
fact in engineering, it refers to an actuator consists
of a solenoid and an iron core that is moved by the
magnetic force when the solenoid is energized.
The word solenoid also often refers to a solenoid
valve.
Solenoid valve that switches over direction of flow.
Communications system that transmits machine

data, such as the present position of the machine,
Monitoring and communica- daily or aggregate hours of operation, fuel conVehicle Health Monitoring
V.H.M.S.
tion
sumption, radiator coolant temperature, oil or filter
System
(D, HD, PC, WA : Large size) replacement interval, to make it possible to collect
and check this data from a distant place (Developed for use on large machines used in mines).
*: Code for machine family

D: bulldozer
HD: dump truck
HM: articulate dump truck
PC: hydraulic excavator
WA: wheel loader
00-48
PC800, 850-8E0

List of abbreviations used in the circuit diagrams

Abbreviation
Full Spelling
A/C
Air Conditioner
A/D
Analogue-to-Digital
A/M
Air Mix damper
ACC
Accessory
ADD
Additional
AUX
Auxiliary
BR
Battery Relay
CW
Clockwise
CCW
Counter Clockwise
ECU
Electronic Control Unit
ECM
Electronic Control Module
ENG
Engine
EXGND
External Ground
F.G.
Frame Ground
GND
Ground
IMA
Inlet Metering Actruator
NC
No Connection
S/T
Steering
STRG
SIG
Signal
SOL
Solenoid
STD
Standard
OPT
Option
OP
SW
Switch
T/C
Torque Converter
T/M
Transmission
PC800, 850-8E0
00-49

Conversion table
Conversion table
0 -50
(Rev. 2010/03)
0 -50
Method of using the conversion table
The conversion table in this section is provided to enable simple conversion of figures. For details of the method of using the conversion table, see the example given below.
Example: Method of using the conversion table to convert from millimeters to inches
1. Convert 55 mm into inches.
1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a horizontal
line from (A).
2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.
1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place to
the left) to convert it to 55 mm.
2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches
(A)
00-50
(B)
0
10
20
30
40
0
0
0.394
0.787
1.181
1.575
1
0.039
0.433
0.827
1.220
1.614
2
0.079
0.472
0.866
1.260
1.654
3
0.118
0.512
0.906
1.299
1.693
4
0.157
0.551
0.945
1.339
1.732
50
60
70
80
90
1.969
2.362
2.756
3.150
3.543
2.008
2.402
2.795
3.189
3.583
2.047
2.441
2.835
3.228
3.622
2.087
2.480
2.847
3.268
3.661
2.126
2.520
2.913
3.307
3.701
5
0.197
0.591
0.984
1.378
1.772
(C)
2.165
2.559
2.953
3.346
3.740
6
0.236
0.630
1.024
1.417
1.811
7
0.276
0.669
1.063
1.457
1.850
2.205
2.598
2.992
3.386
3.780
2.244
2.638
3.032
3.425
3.819
1 mm = 0.03937 in
8
9
0.315
0.354
0.709
0.748
1.102
1.142
1.496
1.536
1.890
1.929
2.283
2.677
3.071
3.465
3.858
2.323
2.717
3.110
3.504
3.898
PC800, 850-8E0

Conversion table
Millimeters to inches
0
10
20
30
40
0
0
0.394
0.787
1.181
1.575
1
0.039
0.433
0.827
1.220
1.614
2
0.079
0.472
0.866
1.260
1.654
3
0.118
0.512
0.906
1.299
1.693
4
0.157
0.551
0.945
1.339
1.732
5
0.197
0.591
0.984
1.378
1.772
6
0.236
0.630
1.024
1.417
1.811
7
0.276
0.669
1.063
1.457
1.850
1 mm = 0.03937 in
8
9
0.315
0.354
0.709
0.748
1.102
1.142
1.496
1.536
1.890
1.929
50
60
70
80
90
1.969
2.362
2.756
3.150
3.543
2.008
2.402
2.795
3.189
3.583
2.047
2.441
2.835
3.228
3.622
2.087
2.480
2.847
3.268
3.661
2.126
2.520
2.913
3.307
3.701
2.165
2.559
2.953
3.346
3.740
2.205
2.598
2.992
3.386
3.780
2.244
2.638
3.032
3.425
3.819
2.283
2.677
3.071
3.465
3.858
0
10
20
30
40
0
0
22.05
44.09
66.14
88.18
1
2.20
24.25
46.30
68.34
90.39
2
4.41
26.46
48.50
70.55
92.59
3
6.61
28.66
50.71
72.75
94.80
4
8.82
30.86
52.91
74.96
97.00
5
11.02
33.07
55.12
77.16
99.21
6
13.23
35.27
57.32
79.37
101.41
7
15.43
37.48
59.53
81.57
103.62
1 kg = 2.2046 lb
8
9
17.64
19.84
39.68
41.89
61.73
63.93
83.78
85.98
105.82
108.03
50
60
70
80
90
110.23
132.28
154.32
176.37
198.42
112.44
134.48
156.53
178.57
200.62
114.64
136.69
158.73
180.78
202.83
116.85
138.89
160.94
182.98
205.03
119.05
141.10
163.14
185.19
207.24
121.25
143.30
165.35
187.39
209.44
123.46
145.51
167.55
189.60
211.64
125.66
147.71
169.76
191.80
213.85
127.87
149.91
171.96
194.01
216.05
0
10
20
30
40
0
0
2.642
5.283
7.925
10.567
1
0.264
2.906
5.548
8.189
10.831
2
0.528
3.170
5.812
8.454
11.095
3
0.793
3.434
6.076
8.718
11.359
4
1.057
3.698
6.340
8.982
11.624
5
1.321
3.963
6.604
9.246
11.888
6
1.585
4.227
6.869
9.510
12.152
7
1.849
4.491
7.133
9.774
12.416
50
60
70
80
90
13.209
15.850
18.492
21.134
23.775
13.473
16.115
18.756
21.398
24.040
13.737
16.379
19.020
21.662
24.304
14.001
16.643
19.285
21.926
24.568
14.265
16.907
19.549
22.190
24.832
14.529
17.171
19.813
22.455
25.096
14.795
17.435
20.077
22.719
25.361
15.058
17.700
20.341
22.983
25.625
2.323
2.717
3.110
3.504
3.898
Kilogram to pound
Liters to U.S. Gallons
PC800, 850-8E0
130.07
152.12
174.17
196.21
218.26
1 l = 0.2642 U.S.Gal
8
9
2.113
2.378
4.755
5.019
7.397
7.661
10.039
10.303
12.680
12.944
15.322
17.964
20.605
23.247
25.889
15.586
18.228
20.870
23.511
26.153
00-51

Conversion table
Liters to U.K. Gallons
1 l = 0.21997 U.K.Gal
8
9
1.760
1.980
3.950
4.179
6.159
6.379
8.359
8.579
10.559
10.778
0
10
20
30
40
0
0
2.200
4.399
6.599
8.799
1
0.220
2.420
4.619
6.819
9.019
2
0.440
2.640
4.839
7.039
9.239
3
0.660
2.860
5.059
7.259
9.459
4
0.880
3.080
5.279
7.479
9.679
5
1.100
3.300
5.499
7.699
9.899
6
1.320
3.520
5.719
7.919
10.119
7
1.540
3.740
5.939
8.139
10.339
50
60
70
80
90
10.998
13.198
15.398
17.598
19.797
11.281
13.418
15.618
17.818
20.017
11.438
13.638
15.838
18.037
20.237
11.658
13.858
16.058
18.257
20.457
11.878
14.078
16.278
18.477
20.677
12.098
14.298
16.498
18.697
20.897
12.318
14.518
16.718
18.917
21.117
12.528
14.738
16.938
19.137
21.337
0
10
20
30
40
0
0
72.3
144.7
217.0
289.3
1
7.2
79.6
151.9
224.2
296.6
2
14.5
86.8
159.1
231.5
303.8
3
21.7
94.0
166.4
238.7
311.0
4
28.9
101.3
173.6
245.9
318.3
5
36.2
108.5
180.8
253.2
325.5
6
43.4
115.7
188.1
260.4
332.7
7
50.6
123.0
195.3
267.6
340.0
1 kgm = 7.233 ft.lb

8
9
57.9
65.1
130.2
137.4
202.5
209.8
274.9
282.1
347.2
354.4
50
60
70
80
90
361.7
434.0
506.3
578.6
651.0
368.9
441.2
513.5
585.9
658.2
376.1
448.5
520.8
593.1
665.4
383.4
455.7
528.0
600.3
672.7
390.6
462.9
535.2
607.6
679.9
397.8
470.2
542.5
614.8
687.1
405.1
477.4
549.7
622.0
694.4
412.3
484.6
556.9
629.3
701.6
419.5
491.8
564.2
636.5
708.8
426.8
499.1
571.4
643.7
716.1
100
110
120
130
140
723.3
795.6
868.0
940.3
1012.6
730.5
802.9
875.2
947.5
1019.9
737.8
810.1
882.4
954.8
1027.1
745.0
817.3
889.7
962.0
1034.3
752.2
824.6
896.9
969.2
1041.5
759.5
831.8
904.1
976.5
1048.8
766.7
839.0
911.4
983.7
1056.0
773.9
846.3
918.6
990.9
1063.2
781.2
853.5
925.8
998.2
1070.5
788.4
860.7
933.1
1005.4
1077.7
150
160
170
180
190
1084.9
1157.3
1129.6
1301.9
1374.3
1092.2
1164.5
1236.8
1309.2
1381.5
1099.4
1171.7
1244.1
1316.4
1388.7
1106.6
1179.0
1251.3
1323.6
1396.0
1113.9
1186.2
1258.5
1330.9
1403.2
1121.1
1193.4
1265.8
1338.1
1410.4
1128.3
1200.7
1273.0
1345.3
1417.7
1135.6
1207.9
1280.1
1352.6
1424.9
1142.8
1215.1
1287.5
1359.8
1432.1
1150.0
1222.4
1294.7
1367.0
1439.4
12.758
14.958
17.158
19.357
21.557
12.978
15.178
17.378
19.577
21.777
kgm to ft.lb
00-52
PC800, 850-8E0

Conversion table
kg/cm2 to lb/in2
0
10
20
30
40
0
0
142.2
284.5
426.7
568.9
1
14.2
156.5
298.7
440.9
583.2
2
28.4
170.7
312.9
455.1
597.4
3
42.7
184.9
327.1
469.4
611.6
4
56.9
199.1
341.4
483.6
625.8
5
71.1
213.4
355.6
497.8
640.1
6
85.3
227.6
369.8
512.0
654.3
1 kg/cm2 = 14.2233 lb/in2

7
8
9
99.6
113.8
128.0
241.8
256.0
270.2
384.0
398.3
412.5
526.3
540.5
554.7
668.5
682.7
696.9
50
60
70
80
90
711.2
853.4
995.6
1,138
1,280
725.4
867.6
1,010
1,152
1,294
739.6
881.8
1,024
1,166
1,309
753.8
896.1
1,038
1,181
1,323
768.1
910.3
1,053
1,195
1,337
782.3
924.5
1,067
1,209
1,351
796.5
938.7
1,081
1,223
1,365
810.7
953.0
1,095
1,237
1,380
825.0
967.2
1,109
1,252
1,394
839.2
981.4
1,124
1,266
1,408
100
110
120
130
140
1,422
1,565
1,707
1,849
1,991
1,437
1,579
1,721
1,863
2,005
1,451
1,593
1,735
1,877
2,020
1,465
1,607
1,749
1,892
2,034
1,479
1,621
1,764
1,906
2,048
1,493
1,636
1,778
1,920
2,062
1,508
1,650
1,792
1,934
2,077
1,522
1,664
1,806
1,949
2,091
1,536
1,678
1,821
1,963
2,105
1,550
1,693
1,835
1,977
2,119
150
160
170
180
190
2,134
2,276
2,418
2,560
2,702
2,148
2,290
2,432
2,574
2,717
2,162
2,304
2,446
2,589
2,731
2,176
2,318
2,460
2,603
2,745
2,190
2,333
2,475
2,617
2,759
2,205
2,347
2,489
2,631
2,773
2,219
2,361
2,503
2,646
2,788
2,233
2,375
2,518
2,660
2,802
2,247
2,389
2,532
2,674
2,816
2,262
2,404
2,546
2,688
2,830
200
210
220
230
240
2,845
2,987
3,129
3,271
3,414
2,859
3,001
3,143
3,286
3,428
2,873
3,015
3,158
3,300
3,442
2,887
3,030
3,172
3,314
3,456
2,901
3,044
3,186
3,328
3,470
2,916
3,058
3,200
3,343
3,485
2,930
3,072
3,214
3,357
3,499
2,944
3,086
3,229
3,371
3,513
2,958
3,101
3,243
3,385
3,527
2,973
3,115
3,257
3,399
3,542
PC800, 850-8E0
00-53

Conversion table
0 -5 4
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahrenheit
temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centigrade
values, and read the corresponding Fahrenheit temperature on the right.
C
-40.4
-37.2
-34.4
-31.7
-28.9
-40
-35
-30
-25
-20
F
-40.0
-31.0
-22.0
-13.0
-4.0
C
-11.7
-11.1
-10.6
-10.0
-9.4
11
12
13
14
15
F
51.8
53.6
55.4
57.2
59.0
C
7.8
8.3
8.9
9.4
10.0
-28.3
-27.8
-27.2
-26.7
-26.1
-19
-18
-17
-16
-15
-2.2
-0.4
1.4
3.2
5.0
-8.9
-8.3
-7.8
-7.2
-6.7
16
17
18
19
20
60.8
62.6
64.4
66.2
68.0
-25.6
-25.0
-24.4
-23.9
-23.3
-14
-13
-12
-11
-10
6.8
8.6
10.4
12.2
14.0
-6.1
-5.6
-5.0
-4.4
-3.9
21
22
23
24
25
-22.8
-22.2
-21.7
-21.1
-20.6
-9
-8
-7
-6
-5
15.8
17.6
19.4
21.2
23.0
-3.3
-2.8
-2.2
-1.7
-1.1
-20.0
-19.4
-18.9
-18.3
-17.8
-4
-3
-2
-1
0
24.8
26.6
28.4
30.2
32.0
-17.2
-16.7
-16.1
-15.6
-15.0
1
2
3
4
5
-14.4
-13.9
-13.3
-12.8
-12.2
6
7
8
9
10
00-54
1 C = 33.8F
F
81
177.8
82
179.6
83
181.4
84
183.2
85
185.0
46
47
48
49
50
F
114.8
116.6
118.4
120.2
122.0
C
27.2
27.8
28.3
28.9
29.4
10.6
11.1
11.7
12.2
12.8
51
52
53
54
55
123.8
125.6
127.4
129.2
131.0
30.0
30.6
31.1
31.7
32.2
86
87
88
89
90
186.8
188.6
190.4
192.2
194.0
69.8
71.6
73.4
75.2
77.0
13.3
13.9
14.4
15.0
15.6
56
57
58
59
60
132.8
134.6
136.4
138.2
140.0
32.8
33.3
33.9
34.4
35.0
91
92
93
94
95
195.8
197.6
199.4
201.2
203.0
26
27
28
29
30
78.8
80.6
82.4
84.2
86.0
16.1
16.7
17.2
17.8
18.3
61
62
63
64
65
141.8
143.6
145.4
147.2
149.0
35.6
36.1
36.7
37.2
37.8
96
97
98
99
100
204.8
206.6
208.4
210.2
212.0
-0.6
0
0.6
1.1
1.7
31
32
33
34
35
87.8
89.6
91.4
93.2
95.0
18.9
19.4
20.0
20.6
21.1
66
67
68
69
70
150.8
152.6
154.4
156.2
158.0
40.6
43.3
46.1
48.9
51.7
105
110
115
120
125
221.0
230.0
239.0
248.0
257.0
33.8
35.6
37.4
39.2
41.0
2.2
2.8
3.3
3.9
4.4
36
37
38
39
40
96.8
98.6
100.4
102.2
104.0
21.7
22.2
22.8
23.3
23.9
71
72
73
74
75
159.8
161.6
163.4
165.2
167.0
54.4
57.2
60.0
62.7
65.6
130
135
140
145
150
266.0
275.0
284.0
293.0
302.0
42.8
44.6
46.4
48.2
50.0
5.0
5.6
6.1
6.7
7.2
41
42
43
44
45
105.8
107.6
109.4
111.2
113.0
24.4
25.0
25.6
26.1
26.7
76
77
78
79
80
168.8
170.6
172.4
174.2
176.0
68.3
71.1
73.9
76.7
79.4
155
160
165
170
175
311.0
320.0
329.0
338.0
347.0
PC800, 850-8E0
SEN0527604-00
01-
PC800, 850-8E0
HYDRAULIC EXCAVATOR
PC800-8E0
PC850SE-8E0
PC800LC-8E0
PC800SE-8E0
PC850-8E0
Shop Manual
Machine model
Serial number
Machine model
Serial number
PC800-8E0
PC800LC-8E0
PC800SE-8E0
PC850-8E0
65001 and up
65001 and up
65001 and up
65001 and up
PC850SE-8E0
65001 and up
01 Specification
PC800, 850-8E0
0-1
01-
01-1
Contents
Contents
01-2
01 Specification
Specifications ..........................................................................................................................
Specifications drawing .........................................................................................................
Specifications.......................................................................................................................
Table of weight.....................................................................................................................
Table of fuel, coolant and lubricants ....................................................................................
01-2
01- 4
01- 4
01- 8
01- 18
01- 26
PC800, 850-8E0
Contents
PC800, 850-8E0
01-3
Specifications
Specifications drawing
Specifications
01-4
01-4
Dimensions
Backhoe specification
01-4
01-4
Item
Unit
PC800-8E0
PC800SE-8E0
PC850-8E0
PC850SE-8E0
A Overall length
mm
14,405
13,130
13,995
13,130
B Overall height
mm
4,690
4,615
4,850
4,615
C Overall width
mm
4,330
4,330
4,330
4,330
D Track shoe width
mm
710
710
710
710
E Height of machine cab
mm
3,570
3,570
3,640
3,640
F Tail swing radius
mm
4,400
4,400
4,400
4,400
G Track overall length
mm
5,810
5,810
5,810
5,810
Length of track on
H
ground
mm
4,500
4,500
4,500
4,500
Machine cab height
mm
3,670
3,670
3,670
3,670
Min. ground clearance
mm
840
840
840
840
01-4
PC800, 850-8E0
Specifications
Loading shovel specification
01-5
Item
Unit
PC800-8E0 Loading shovel specification
A Overall length
mm
10,075
B Overall height
mm
5,790
C Overall width
mm
4,330
D Track shoe width
mm
710
E Height of machine cab
mm
3,570
F Tail swing radius
mm
4,400
G Track overall length
mm
5,810
Length of track on
H
ground
mm
4,500
Machine cab height
mm
3,670
mm
840
PC800, 850-8E0
01-5
Specifications
01-6
Working ranges
Item
01-6
Unit
PC800-8E0
PC800SE-8E0
PC850-8E0
PC850SE-8E0
A Max. digging reach
mm
13,740
12,265
13,660
12,265
B Max. digging depth
mm
8,600
7,130
8,445
7,130
C Max. digging height
mm
11,840
11,330
11,955
11,330
Max. vertical wall digging depth
mm
5,575
4,080
5,230
4,080
E Max. dumping height
mm
8,145
7,525
8,235
7,525
Max. reach at ground

F
level
mm
13,460
11,945
13,400
11,945
01-6
PC800, 850-8E0
Specifications
Item
01-7
Unit
A Max. digging reach
mm
10,370
Max. reach at ground

B
level
mm
9,595
C Max. digging height
mm
10,800
D Max. digging depth
mm
3,605
mm
5,730
mm
5,250
Min. reach at ground

E
level
Min. swing radius of
F
work equipment
PC800, 850-8E0
01-7
Specifications
Specifications
01-8
PC800-8E0
01-8
Engine
Dimensions
Machine model
PC800-8E0
Serial number
65001 and up
Bucket capacity
m3
3.1 <former JIS: 2.8>
Machine weight
kg
75,300
Max. digging depth
mm
8,600
Max. vertical digging depth
mm
5,575
Max. digging reach
mm
13,740
Max. reach at ground level
mm
13,460
Max. digging height
mm
11,840
Max. dumping height
mm
8,145
kN {kg}
365 {37,200}/333 {34,000}
Swing speed
rpm
6.8
Swing operation max. slope angle
deg.
16
Travel speed
km/h
Lo: 2.8, Hi: 4.2
Gradeability
Ground pressure
(standard shoe width: 710 mm)
deg.
35
kPa {kg/cm2}
106 {1.08}
Overall length
mm
14,405
Overall width
mm
4,330
Overall track width (when increased)
mm
3,490 (4,210)
Overall height
mm
4,690
Overall height to top of machine
mm
4,000
Ground clearance of upper structure

bottom
mm
1,560
mm
840
Tail swing radius
mm
4,400
Min. swing radius of work equipment
mm
6,060
Top height at min. swing radius of work

equipment
mm
10,855
Length of track on ground
mm
4,500
Track gauge (when increased)
mm
2,780 (3,500)
Height of machine cab
mm
3,670
Working ranges
Performance
Specifications
Max. digging force (power max./normal)
Model
Komatsu SAA6D140E-5
Type
4-cycle, water-cooled in-line type, direct injection type with

turbocharger and air-cooled aftercooler
No. of cylinders - bore x stroke

Piston displacement
01-8
mm
6 140 x 165
l {cc}
15.24 {15,240}
PC800, 850-8E0
Performance
Engine
Specifications
Specifications
Machine model
PC800-8E0
Serial number
65001 and up
Rated horsepower
kW/rpm
{PS/rpm}
363/1,800 {493/1,800}
Max. torque
Nm/rpm
{kgm/rpm}
2,160/1,350 {221/1,350}
Max. speed with no load
rpm
1,980
Min. speed with no load
rpm
825
g/kWh
{g/PSh}
215 {158}
Min. fuel consumption ratio

Starting motor
24 V, 11 kW
Alternator
24 V, 60 A
Radiator type
CF68-4
Undercarriage
12 V, 170 Ah x 2
Carrier roller
3 on each side
Track roller
8 on each side
Track shoe
Assembly-type double grouser, 47 on each side
Fan system
Battery
Fan pump
Type
16.2 {165}
Type
Fan motor
Hydraulic
pump
Set pressure
Fixed swash plate type: LMF110

MPa {kg/cm2}
Delivery
24.5 {250}
Main pump: Variable displacement piston type:
HPV375+375
Fan pump: Variable displacement piston type: LPV90
Gear type: FBR00-2.5
Type and numbers

l/min
Main pump: 494 + 494, Fan pump: 120, Gear type: 6

Main pump: 31.4 {320}, Fan pump: 24.5 {250}
Type and numbers
Travel motor
MSF-340VP-EH11, Piston type (with brake valve, shaft

brake): 2 pcs
Swing motor
KMF125AB-5, Piston type (with safety valve, shaft brake): 2

pcs
Hydraulic cylinder
Control
valve
MPa
{kg/cm2}
Hydraulic
motor
Set pressure
Hydraulic system
Variable swash plate type: LPV90
Operation presMPa {kg/cm2}

sure
4-spool and 5-spool type: 1 piece
Operating method
Hydraulic
Type
Boom
Arm
Bucket
Double-acting
piston
Double-acting
piston
Double-acting
piston
Cylinder inner diameter
mm
200
200
185
Piston rod diameter
mm
140
140
130
Stroke
mm
1,950
2,250
1,610
Max. distance between pins
mm
4,880
5,525
3,990
Min. distance between pins
mm
2,930
3,275
2,380
Hydraulic tank
Hydraulic oil filter
Hydraulic oil cooler
PC800, 850-8E0
Box-shaped, with breather

Tank return side
Air cooled type (CF42-1)
01-9
Specifications
Specifications
PC800SE-8E0
PC800SE-8E0
Serial number
65001 and up
Bucket capacity
m3
Machine weight
kg
76,300
Max. digging depth
mm
7,130
Max. Vertical digging depth
mm
4,080
Max. digging reach
mm
12,265
mm
11,945
Max. digging height
mm
11,330
Max. dumping height
mm
7,525
kN {kg}
471 {48,000}/431 {43,900}
Swing speed
rpm
6.8
deg.
16
Travel speed
km/h
Lo: 2.8, Hi: 4.2
Gradeability
deg.
35
kPa {kg/cm2}
107 {1.09}
Overall length
mm
13,130
Overall width
mm
4,330
mm
3,490 (4,210)
Overall height
mm
4,615
mm
4,000

bottom
mm
1,560
mm
840
Tail swing radius
mm
4,400
mm
5,645

equipment
mm
9,750
mm
4,500
mm
2,780 (3,500)
mm
3,670
Working ranges
Performance
Machine model
Engine
Dimensions
Ground pressure
Model
Komatsu SAA6D140E-5
Type


Piston displacement
01-10
mm
6 140 x 165
l {cc}
15.24 {15,240}
PC800, 850-8E0
Performance
Engine
Specifications
Specifications
Machine model
PC800SE-8E0
Serial number
65001 and up
Rated horsepower
kW/rpm
{PS/rpm}
363/1,800 {493/1,800}
Max. torque
Nm/rpm
{kgm/rpm}
2,169/1,350 {221/1,350}
rpm
1,980
rpm
825
g/kWh
{g/PSh}
215 {158}

Starting motor
24 V, 11 kW
Alternator
24 V, 60 A
Radiator type
CF68-4
Undercarriage
12 V, 170 Ah x 2
Carrier roller
3 on each side
Track roller
8 on each side
Track shoe
Fan system
Battery
Fan pump
Type
16.2 {165}
Type
Fan motor
Hydraulic
pump
Set pressure
2}
Delivery
24.5 {250}
MPa {kg/cm

HPV375+375
Type and numbers
MPa {kg/cm2}
Type and number of units
Travel motor

brake): 2 pcs
Swing motor
KMF125AB-5, Piston type (with safety valve, shaft brake):

2 pcs
Hydraulic cylinder
Control
valve
l/min
Hydraulic
motor
Set pressure
Hydraulic system
Operation presMPa {kg/cm2}

sure
Operating method
Hydraulic
Type
Boom
Arm
Bucket
Double-acting
piston
Double-acting
piston
Double-acting
piston
mm
200
185
225
Piston rod diameter
mm
140
120
160
Stroke
mm
1,950
1,610
1,420
mm
4,880
3,990
3,910
mm
2,930
2,380
2,490
Hydraulic tank
PC800, 850-8E0

Tank return side
01-11
Specifications
Specifications
Machine model
PC850-8E0
Serial number
65001 and up
Bucket capacity
m3
Machine weight
kg
79,800
Max. digging depth
mm
8,445
mm
5,230
Max. digging reach
mm
13,660
mm
13,400
Max. digging height
mm
11,955
Max. dumping height
mm
8,235
kN {kg}
397 {40,500}/363 {37,000}
Swing speed
rpm
6.8
deg.
16
Travel speed
km/h
Lo: 2.8, Hi: 4.2
Gradeability
deg.
35
kPa {kg/cm2}
112 {1.14}
Overall length
mm
13,995
Overall width
mm
4,330
mm
3,490 (4,210)
Overall height
mm
4,850
mm
4,000

bottom
mm
1,560
mm
840
Tail swing radius
mm
4,400
mm
5,985

equipment
mm
10,430
mm
4,500
mm
2,780 (3,500)
mm
3,670
Working ranges
Performance
PC850-8E0
Engine
Dimensions
Ground pressure
Model
Komatsu SAA6D140E-5
Type


Piston displacement
01-12
mm
6 - 140 x 165
l {cc}
15.24 {15,240}
PC800, 850-8E0
Specifications
Specifications
Machine model
PC850-8E0
Serial number
65001 and up
kW/rpm
{PS/rpm}
Nm/rpm
{kgm/rpm}
Performance
Engine
Rated horsepower
Max. torque
363/1,800 {493/1,800}
2,169/1,350 {221/1,350}
rpm
1,980
rpm
825
g/kWh
{g/PSh}
215 {158}
Starting motor
24 V, 11 kW
Alternator
24 V, 60 A
Radiator type
CF68-4
Undercarriage
12 V, 170 Ah x 2
Carrier roller
3 on each side
Track roller
8 on each side
Track shoe
Fan system
Battery
Fan pump
Type
Operation
pressure
MPa {kg/cm2}
16.2 {165}
Type
Fan motor
Hydraulic
pump
Set pressure
2}
Delivery
24.5 {250}
MPa {kg/cm

HPV375+375
MPa {kg/cm2}
Type and numbers
Travel motor

brake): 2 pcs
Swing motor

2 pcs
Hydraulic cylinder
Control
valve
l/min
Hydraulic
motor
Set pressure
Hydraulic system
Operating method
Hydraulic
Type
Boom
Arm
Bucket
Double-acting
piston
Double-acting
piston
Double-acting
piston
mm
200
185
185
Piston rod diameter
mm
140
120
130
Stroke
mm
1,950
1,610
1,820
mm
4,880
3,990
4,410
mm
2,930
2,380
2,590
Hydraulic tank
PC800, 850-8E0

Tank return side
01-13
Specifications
Specifications
PC850SE-8E0
PC850SE-8E0
Serial number
65001 and up
Bucket capacity
m3
4.3 <former JIS: 3.8.0>
Machine weight
kg
79,400
Max. digging depth
mm
7,130
mm
4,080
Max. digging reach
mm
12,265
mm
11,945
Max. digging height
mm
11,330
Max. dumping height
mm
7,525
kN {kg}
471 {48000}/431 {43900}
Swing speed
rpm
6.8
deg.
16
Travel speed
km/h
Lo: 2.8, Hi: 4.2
Gradeability
deg.
35
kPa {kg/cm2}
111 {1.13}
Overall length
mm
13,130
Overall width
mm
4,330
mm
3,490 (4,210)
Overall height
mm
4,615
mm
4,000

bottom
mm
1,560
mm
840
Tail swing radius
mm
4,400
mm
5,645

equipment
mm
9,750
mm
4,500
mm
2,780 (3,500)
mm
3,670
Working ranges
Performance
Machine model
Engine
Dimensions
Ground pressure
Model
Komatsu SAA6D140E-5
Type


Piston displacement
01-14
mm
6 140 x 165
l {cc}
15.24 {15,240}
PC800, 850-8E0
Performance
Engine
Specifications
Specifications
Machine model
PC850SE-8E0
Serial number
65001 and up
Rated horsepower
kW/rpm
{PS/rpm}
363/1,800 {493/1,800}
Max. torque
Nm/rpm
{kgm/rpm}
2,169/1,350 {221/1,350}
rpm
1,980
rpm
825
g/kWh
{g/PSh}
215 {158}

Starting motor
24 V, 11 kW
Alternator
24 V, 60 A
Radiator type
CF68-4
Undercarriage
12 V, 170 Ah x 2
Carrier roller
3 on each side
Track roller
8 on each side
Track shoe
Fan system
Battery
Fan pump
Type
Operation
pressure

MPa {kg/cm2}
16.2 {165}
Type
Fan motor
2}
24.5 {250}
Hydraulic
pump
Set pressure MPa {kg/cm
Delivery
MPa {kg/cm2}
Type and numbers
Travel motor

brake): 2 pcs
Swing motor
KMF125AB-5, Piston type (with safety valve, shaft brake): 2

pcs
Hydraulic cylinder
Control
valve
l/min
Hydraulic
motor
Set pressure
Hydraulic system
Main pump: Variable displacement piston type: HPV375+375

Operating method
Hydraulic
Type
Boom
Arm
Bucket
Double-acting
piston
Double-acting
piston
Double-acting
piston
mm
200
185
225
Piston rod diameter
mm
140
120
160
Stroke
mm
1,950
1,610
1,420
mm
4,880
3,990
3,910
mm
2,930
3,380
2,490
Hydraulic tank
PC800, 850-8E0

Tank return side
01-15
Specifications
Specifications
01- 6
Machine model
Serial number
65001 and up
Bucket capacity
m3
4.5
Machine weight
kg
78,100
Max. digging depth
mm
3,605
mm
Max. digging reach
mm
10,370
mm
9,595
Max. digging height
mm
10,800
Max. dumping height
mm
7,260
kN {kg}
476 {48,600}
Swing speed
rpm
6.8
deg.
16
Travel speed
km/h
Lo: 2.8, Hi: 4.2
Gradeability
deg.
35
kPa {kg/cm2}
110 {1.12}
Overall length
mm
10,075
Overall width
mm
4,330
mm
3,490 (4,210)
Overall height
mm
5,790
mm
4,000

bottom
mm
1,560
mm
840
Tail swing radius
mm
4,400
mm
5,250
Top height at min. swing radius of

work equipment
mm
7,345
mm
4,500
mm
2,780 (3,500)
mm
3,670
Working ranges
Performance

PC800-8E0
Max. digging force
Engine
Dimensions
Ground pressure
Model
Komatsu SAA6D140E-5
Type


Piston displacement
01-16
mm
6 140 x 165
l {cc}
15.24 {15,240}
PC800, 850-8E0
Performance
Engine
Specifications
Specifications
Machine model
PC850SE-8E0 (Loading shovel specification)
Serial number
65001 and up
Rated horsepower
kW/rpm
{PS/rpm}
363/1,800 {493/1,800}
Max. torque
Nm/rpm
{kgm/rpm}
2,169/1,350 {221/1,350}
rpm
1,980
rpm
825
g/kWh
{g/PSh}
215 {158}

Starting motor
24 V, 11 kW
Alternator
24 V, 60 A
Radiator type
CF68-4
Undercarriage
12 V, 170 Ah x 2
Carrier roller
3 on each side
Track roller
8 on each side
Track shoe
Fan system
Battery
Fan pump
Type
Operation
pressure
MPa {kg/cm2}
16.2 {165}
Type
Fan motor
Hydraulic
pump
Set pressure
2}
Delivery
24.5 {250}
MPa{kg/cm
Main pump : Variable displacement piston type:

HPV375+375
MPa {kg/cm2}
Control
valve
l/min
Hydraulic
motor
Set pressure
Travel motor
MSF-340VP-EH11, Piston type(with brake valve, shaft

brake): 2 pcs
Swing motor

2 pcs
Type
Double-acting Double-acting Double-acting Double-acting

piston
piston
piston
piston
Operating method
Hydraulic
Boom
Hydraulic cylinder
Hydraulic system
Arm
Bucket
Bottom dump
mm
200
225
185
140
Piston rod diameter
mm
140
160
130
90
Stroke
mm
1,490
1,530
1,550
335
mm
4,340
4,130
4,275
1,235
mm
2,850
2,600
2,725
900
Hydraulic tank
PC800, 850-8E0

Tank return side
01-17
Specifications
Table of weight
Table of weight
01- 8
This weight table is prepared for your reference when handling or transporting the components.
PC800-8E0
Unit: kg
Machine model
PC800-8E0
Serial number
65001 and up
Engine assembly
2,950
Engine
1,920
Coupling (including lubricating piping)
q Hydraulic pump (including fan pump, lubricating pump)

Cooling assembly
(including fan, fan motor, and shroud)
Radiator assembly
q Radiator
Aftercooler
Oil cooler
268
528
1,035
258
25 x 3
45
23 x 2
Hydraulic tank and filter assembly (excluding hydraulic oil)
658
Fuel tank (excluding fuel)
640
Revolving frame
7,080
Cab
563
Operator seat
38
Counterweight
9,800
Swing machinery
493 x 2
L.H. 5-spool control valve
245
R. H. 4-spool control valve
240
Swing motor
56.5 x 2
Travel motor
130 x 2
Fan motor
25
Center swivel joint
69
Track frame assembly (excluding step, roller guard, track

shoe assembly, and lower piping)
20,405
Center frame
5,995
Track frame
2,628 x 2
Swing circle
1,401
Idler
465 x 2
Idler cushion
802 x 2
Carrier roller
52.3 x 6
Track roller
136 x 16
Final drive (including travel motor)
1,365 x 2
01-18
PC800, 850-8E0
Specifications
Table of weight
Unit: kg
Machine model
PC800-8E0
Serial number
65001 and up
Track shoe assembly

q
Narrow shoe (610 mm)
7,550
Standard shoe (710 mm)
8,350
Wide shoe (810 mm)
8,880
Wide shoe (910 mm)
9,520
Wide shoe (1,010 mm)
10,160
Boom assembly
7,890
Arm assembly
2,740
Bucket assembly
2,940
Boom cylinder assembly
758 x 2
Arm cylinder assembly
843
Bucket cylinder assembly
517
Boom foot pin
44.9 x 2
Boom cylinder foot pin
33.8 x 2
Boom cylinder top pin
32.5 x 2
Boom and arm connecting pin
110.4
Arm cylinder foot pin
53.6
Arm cylinder top pin
30
Link and arm connecting pin
56.1
Link and bucket connecting pin
62.2
Bucket cylinder top pin
49.3
Bucket cylinder foot pin
25.3
Arm and bucket connecting pin
91.4
Link assembly
715
PC800, 850-8E0
01-19
Specifications
Table of weight
PC800SE-8E0
Unit: kg
Machine model
PC800SE-8E0
Serial number
65001 and up
Engine assembly
2,950
Engine
1,920
268
Hydraulic pump (including fan pump, lubricating pump)
528
Cooling assembly
1,035
Radiator assembly
q Radiator
258
25 x 3
Aftercooler
Oil cooler
45
23 x 2
658
640
Revolving frame
7,080
Cab
563
Operator seat
38
Counterweight
9,800
Swing machinery
493 x 2
245
240
Swing motor
56.5 x 2
Travel motor
130 x 2
Fan motor
25
Center swivel joint
69

20,405
Center frame
5,995
Track frame
2,628 x 2
Swing circle
1,401
Idler
465 x 2
Idler cushion
802 x 2
Carrier roller
52.7 x 6
Track roller
52.3 x 16
1,365 x 2
01-20
PC800, 850-8E0
Specifications
Table of weight
Unit: kg
Machine model
PC800SE-8E0
Serial number
65001 and up
Track shoe assembly

q
7,550
8,350
Wide shoe (810 mm)
8,880
Wide shoe (910 mm)
9,520
10,160
Boom assembly
7,310
Arm assembly
3,160
Bucket assembly
3,440
758 x 2
481 x 2
936
Boom foot pin
44.9 x 2
33.8 x 2
32.5 x 2
110.4
24 x 2
24 x 2
56.1
62.2
84.5
43.8
91.4
Link assembly
793
PC800, 850-8E0
01-21
Specifications
Table of weight
PC850-8E0
Unit: kg
Machine model
PC850-8E0
Serial number
65001 and up
Engine assembly
2,950
Engine
1,920
268
Hydraulic pump (including fan pump, lubricating pump)
528
Cooling assembly
1,035
Radiator assembly
q Radiator
258
25 x 3
Aftercooler
Oil cooler
45
23 x 2
658
640
Revolving frame
7,080
Cab
548
Operator seat
38
Counterweight
11,850
Swing machinery
493 x 2
245
240
Swing motor
56.5 x 2
Travel motor
130 x 2
Fan motor
25
Center swivel joint
69

20,405
Center frame
5,995
Track frame
2,628 x 2
Swing circle
1,401
Idler
465 x 2
Idler cushion
802 x 2
Carrier roller
52.3 x 6
Track roller
136 x 16
1,365 x 2
01-22
PC800, 850-8E0
Specifications
Table of weight
Unit: kg
Machine model
PC850-8E0
Serial number
65001 and up
Track shoe assembly

q
7,550
8,350
Wide shoe (810 mm)
Wide shoe (910 mm)
Boom assembly
8,150
Arm assembly
3,155
Bucket assembly
3,800
758 x 2
481 x 2
550
Boom foot pin
44.9 x 2
33.8 x 2
32.5 x 2
110.4
24 x 2
24 x 2
56.1
62.2
49.3
25.3
91.4
Link assembly
769
PC800, 850-8E0
01-23
Specifications
Table of weight
PC850SE-8E0
Unit: kg
Machine model
PC850SE-8E0
Serial number
65001 and up
Engine assembly
2,950
Engine
1,920
Coupling (including. lubricating piping)
Hydraulic pump (including. fan pump, lubricating

pump)
Cooling assembly
(including. fan, fan motor, and shroud)
Radiator assembly
Radiator
Aftercooler
Oil cooler
268
528
1,035
258
25 x 3
45
23 x 2
658
640
Revolving frame
7,080
Cab
548
Operator seat
38
Counterweight
11,850
Swing machinery
493 x 2
245
240
Swing motor
56.5 x 2
Travel motor
130 x 2
Fan motor
25
Center swivel joint
69

20,405
Center frame
5,995
Track frame
2,628 x 2
Swing circle
1,401
Idler
465 x 2
Idler cushion
802 x 2
Carrier roller
52.3 x 6
Track roller
136 x 16
1,365 x 2
01-24
PC800, 850-8E0
Specifications
Table of weight
Unit: kg
Machine model
PC850SE-8E0
Serial number
65001 and up
Track shoe assembly

q
7,550
8,350
Wide shoe (810mm)
Wide shoe (910mm)
Wide shoe (1,010mm)
Boom assembly
7,310
Arm assembly
3,160
Bucket assembly
3,840
758 x 2
481 x 2
936
Boom foot pin
44.9 x 2
33.8 x 2
32.5 x 2
110.4
24 x 2
24 x 2
56.1
62.2
84.5
43.8
91.4
Link assembly
793
PC800, 850-8E0
01-25
Specifications
Table of fuel, coolant and lubricants
01-26
a For details of the notes (Notes 1, Note 2... ) in the table, see the Operation and Maintenance Manual.
01-26
PC800, 850-8E0
Specifications
Unit: l
PC800, 800SE-8E0, PC850, 850SE-8E0
Refilling points
Specified capacity
Refill capacity
Engine oil pan
58
53
Coupling case
24.5
24.5
Final drive case (right and left respectively)
20
20
Hydraulic system
800
470
Fuel tank
980
Cooling system
100
Swing machinery case
PC800, 850-8E0
01-27
Specifications
01-28
PC800, 850-8E0
SEN0527606-00
10-1
PC800, 850-8E0
HYDRAULIC EXCAVATOR
PC800-8E0
PC850SE-8E0
PC800LC-8E0
PC800SE-8E0
PC850-8E0
Shop Manual
Machine model
Serial number
Machine model
Serial number
PC800-8E0
PC800LC-8E0
PC800SE-8E0
PC850-8E0
65001 and up
65001 and up
65001 and up
65001 and up
PC850SE-8E0
65001 and up
PC800, 850-8E0
1-01
10-1
10-1
Contents
Contents
10-2

Coupling...............................................................................................................................
Coupling lubrication system .................................................................................................
Cooling system ....................................................................................................................
Power train system .................................................................................................................
Power train...........................................................................................................................
Swing circle..........................................................................................................................
Swing machinery..................................................................................................................
Final drive ............................................................................................................................
Track frame..........................................................................................................................
Idler cushion.........................................................................................................................
Hydraulic component layout.................................................................................................
Hydraulic tank and filter .......................................................................................................
Hydraulic pump ....................................................................................................................
Pump control system ...........................................................................................................
Servo valve ..........................................................................................................................
Self-pressure reducing valve ...............................................................................................
Cooling fan pump.................................................................................................................
Electrical grease pump ........................................................................................................
Control valve ........................................................................................................................
Straight-travel valve .............................................................................................................
Swing motor .........................................................................................................................
Travel motor.........................................................................................................................
PPC valve ............................................................................................................................
Solenoid valve......................................................................................................................
Accumulator .........................................................................................................................
Quick return valve ................................................................................................................
Return oil filter......................................................................................................................
Line oil filter..........................................................................................................................
Pilot oil filter..........................................................................................................................
Drain oil filter ........................................................................................................................
Engine control ......................................................................................................................
Electric control system .........................................................................................................
Monitor system.....................................................................................................................
Sensors................................................................................................................................
KOMTRAX system...............................................................................................................
10-2
10- 3
10- 3
10- 4
10- 6
10- 8
10- 8
10- 10
10- 11
10- 13
10- 14
10- 14
10- 16
10- 18
10- 18
10- 20
10- 22
10- 30
10- 32
10- 41
10- 44
10- 53
10- 59
10- 60
10- 69
10- 72
10- 76
10- 77
10- 87
10- 95
10- 103
10- 104
10- 107
10- 108
10- 109
10- 110
10- 111
10- 111
10- 121
10- 160
10- 190
10- 194
PC800, 850-8E0
Engine and cooling system

Coupling
10-3
Coupling
10-3
1. Coupling case
2. Shaft
3. Hub
4. Breather
PC800, 850-8E0
Specifications
Lubricating oil capacity: 6.0 l (T0-30)
10-3
10-3

Coupling lubrication system
10-4
Hydraulic circuit diagram
10-4
Hydraulic piping drawing
10-4
1. Coupling case
2. Coupling lubricating pump (FBR00-2.5)
3. Oil strainer
10-4
Outline
10-4
Coupling lubricating pump (2) sends lubricating oil
from the oil sump under coupling case (1) through
oil strainer (3) into the coupling case to lubricate and
cool bearings and splines.
PC800, 850-8E0

PC800, 850-8E0
10-5

Cooling system
Cooling system
10-6
Radiator and oil cooler
10-6
10-6
PC800, 850-8E0

Cooling system
1.
2.
3.
4.
5.
6.
Radiator cap
Overflow hose
Air bleeding hose
Inlet hose
Outlet hose
Fan
7. Radiator
8. Aftercooler
9. Fuel cooler
10. Oil cooler
11. Condenser
Outline
q A reservoir tank is installed at the rear of the radiator.
Core type
Pressure valve
(MPa {kg/cm2}
PC800, 850-8E0
Relief pressure
Vacuum pressure
Radiator
Oil cooler
CF68-4
CF42-1
0.09 {0.9}
0.005 {0.05}
10-7
10-7
Power train system

Power train
Power train system
10-8
Power train
10-8
10-8
PC800, 850-8E0
Power train system

Power train
1. Idler
2. Center swivel joint
3. Swing motor (KMF125AB-5)
4. L.H. 5-spool control valve
5. R.H. 4-spool control valve
6. Final drive, sprocket
7. Travel motor
8. Fan
9. Cooling fan motor (LMF110)
10. Engine (SAA6D140E-5)
PC800, 850-8E0
11. Coupling
12. Hydraulic pump (HPV375 + 375)
13. Coupling lubricating pump (FBR002-2.5)
14. Cooling fan pump (LPV90)
15. Self-pressure reducing valve
16. Swing holding brake solenoid valve
17. Travel speed solenoid valve
18. Swing machinery
19. Swing circle
10-9
Power train system

Swing circle
Swing circle
1. Swing circle inner race (number of teeth: 112)

2. Ball
3. Swing circle outer race
10-10
Specifications
Reduction ratio: -112 / 13 = -8.615
Amount of filled grease: 65 l (G2-LI)
10-10
a. Inner race soft zone "S" position

b. Outer race soft zone "plug" position
10-10
PC800, 850-8E0
Power train system

Swing machinery
Swing machinery
PC800, 850-8E0
10-1
10-11
Power train system

Swing machinery
1. Swing pinion (number of teeth: 13)

2. Cover
3. Case
4. Coupling
5. No. 2 planetary gear (number of teeth: 38)
6. Ring gear (No. of teeth: 97)
7. No. 1 planetary gear (number of teeth: 38)
8. Cover
9. Oil level gauge
10-12
10. Swing motor

11. No. 1 sun gear (number of teeth: 20)
12. No. 1 planetary carrier
13. No. 2 sun gear (number of teeth: 19)
14. No. 2 planetary carrier
15. Drain plug
10-12
Specifications
Reduction ratio: ((20 + 97) / 20) x ((19 + 97) /1 9) =
35.716
PC800, 850-8E0
Power train system

Final drive
Final drive
1. Level plug
2. Drain plug
3. Cover
4. No.2 planetary carrier
5. No.2 sun gear (number of teeth: 19)
6. Drive gear (number of teeth: 19)
7. No.1 planetary carrier
8. No.2 planetary gear (number of teeth: 24)
9. Hub
10. Sprocket
11. Floating seal
12. Case
PC800, 850-8E0
10-13
13. Coupling
14. No.1 sun gear (number of teeth: 13)
15. Travel motor
16. Idler gear (number of teeth: 27)
17. No.1 ring gear (number of teeth: 68)
18. No.1 planetary gear (Number of teeth: 24)
19. Driven gear (number of teeth: 69)
20. No.2 ring gear (number of teeth: 69)
10-13
Specifications
Reduction ratio:
-((13 + 68) / 13) x ((19 + 69) / 19) x (69 / 19) =
-104.802
10-13
Undercarriage and frame

Track frame
10-14
Track frame
10-14
a The figure shows the equipment on PC800-8.
1. Idler
2. Track frame
3. Carrier roller
4. Center frame
5. Final drive
6. Track roller
7. Track shoe
8. Idler cushion
9. Front guard
10-14
The dimensions and number of truck rollers differ according to the models, but the basic structure is the same.
Number of track rollers
Model
PC800, 800SE-8
PC850, 850SE-8
Q'ty (each side)

8
PC800, 850-8E0

Track frame
Standard shoe
Model
Item
Shoe width (double-grouser
shoe)
Link pitch
Q'ty (each side)
PC800, 850-8E0
10-15
PC800-8
PC800SE-8
PC850-8
PC850SE-8
710 mm
710 mm
710 mm
710 mm
260.6 mm
47
260.6 mm
47
260.6 mm
47
260.6 mm
47
10-15

Idler cushion
Idler cushion
10-16
1. Idler
2. Support
3. Valve
4. Fitting
5. Yoke
6. Recoil spring
7. Rod
8. Nut
9. Lock
10. Bolt
10-16
PC800, 850-8E0

Idler cushion
PC800, 850-8E0
10-17
Hydraulic system
Hydraulic component layout
Hydraulic system
10-18
10-18
1. Bucket cylinder
2. Arm cylinder
3. Boom cylinder
4. Center swivel joint
5. Swing motor
6. Quick return valve (arm)
7. Oil cooler
8. Fan motor
9. Control valve
10. PPC shuttle valve
11. Hydraulic oil filter
12. Fan pump
13. Hydraulic pump
14. L.H. travel motor
15. Hydraulic tank
16. PPC lock valve
17. L.H. PPC valve
18. R.H. PPC valve
19. Travel PPC valve
20. Accumulator
21. Solenoid valve assembly
21A. Straight-travel solenoid valve
21B. 2-stage relief solenoid valve
21C. Machine push-up solenoid valve
21D. Swing holding brake solenoid valve
21E. Travel speed solenoid valve
10-18
PC800, 850-8E0
Hydraulic system
PC800, 850-8E0
10-19
Hydraulic system
Hydraulic tank and filter
10-20
10-20
PC800, 850-8E0
Hydraulic system
1. Hydraulic oil filter

1A. Bypass valve
1B. Strainer
1C. Element
1D. Cooler check valve
2. Hydraulic tank
3. Suction strainer
4. Sight gauge
5. Oil filler port cap
Specifications
Tank capacity: 729 l
Amount of hydraulic oil in tank: 482 l (at level H)
10-21
Safety valve
Relief cracking pressure:
16.7 6.9 kPa {0.17 0.07 kg/cm2}
q Suction valve operating pressure:
0 0.49 kPa {0 0.005 kg/cm2}
q Bypass valve set pressure:
0.15 0.03 MPa {1.5 0.3 kg/cm2}
10-21
PC800, 850-8E0
10-21
Hydraulic system
Hydraulic pump
Hydraulic pump
10-2
Model: HPV375+375
10-22
PC800, 850-8E0
Hydraulic system
Hydraulic pump
This pump unit consists of two variable displacement swash plate type piston pumps, VC valve,
EPC valve, and self-pressure reducing valve.
CE1: Front EPC output pressure pickup port

CE2: Rear EPC output pressure pickup port
CH1: Front servo actuator pickup port
CH2: Rear servo actuator pickup port
CP1: Front pump delivery pressure pickup port
CP2: Rear pump delivery pressure pickup port
CP3: Fan pump delivery pressure pickup port
CPR: Pilot source pressure pickup port
CS1: Front control pressure pickup port
CS2: Rear control pressure pickup port
P1: Front discharge port.
P2: Rear discharge port
P3: Fan pump discharge port
P4: Gear pump discharge port
PF: Self-pressure reducing value source pressure
port
PR2: Pilot source pressure output port
(preceding the inline filter attached to the machine)
PR3: Pilot source pressure input port
(succeeding to the inline filter attached to the
machine)
PR5: Pilot source pressure pickup port
PR8: Pilot source pressure output port (to fan EPC)
PR10: Pilot source pressure output port
(to pilot valve)
S1: Main pump suction port
S3: Fan pump suction port
S4: Gear pump suction port
T1: Drain port
T2: Drain plug
T3: Drain plug
T4: Drain plug
T5: Drain plug
T6: Air bleeder
T7: Drain plug
T8: Drain plug
T9: Drain plug
T10: Drain plug
T16: Drain port
T17: Drain plug
T18: Air bleeder
PC800, 850-8E0
1. Front pump
2. Rear pump
3. VC valve
4. EPC valve
5. Self-pressure reducing valve
6. Filter
7. Cooling fan pump
8. PTO lubrication pump
10-23
Hydraulic system
Hydraulic pump
10-24
PC800, 850-8E0
Hydraulic system
Hydraulic pump
CS3: Fan pump control pressure pickup port

PF1: Self-pressure reducing valve source pressure output port (from pilot to self-pressure reducing valve)
PF2: Self-pressure reducing valve source pressure input port
PR9: Fan EPC source pressure input port
PR11: Pilot source pressure input port (for pilot valve back pressure)
1. Front shaft
2. Cradle
3. Front case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Servo piston
PC800, 850-8E0
9. Valve plate
10. End cap
11. Rear case
12. Rear shaft
13. Bevel gear
14. Impeller pump
15. Impeller shaft
16. Impeller pinion
10-25
Hydraulic system
Hydraulic pump
Function
10-26
q The engine rotation and torque transmitted to
the pump shaft is converted into the hydraulic
energy and the pressurized oil corresponding to
the load is discharged.
q It is possible to change the delivery by changing
the swash plate angle.
q
q
q
10-26
Structure
q Cylinder block (7) is supported on front shaft (1)
through spline (17).
q Shaft (1) is supported by each bearing (18) at the
front and rear.
q The tip of piston (6) is shaped as a concave
sphere and is crimped together with shoe (5).
q Piston (6) and shoe (5) form a spherical bearing.
q Rocker cam (4) has flat surface (A), and shoe (5)
is always pressed against this surface while sliding along an elliptic orbit.
q Rocker cam (4) transmits high pressure oil to cylindrical surface with cradle (2), which is secured
to the case, and forms a static pressure bearing
with oil when it pivots.
q Piston (6) performs the reciprocation axially inside each cylinder chamber of cylinder block (7).
10-26
Cylinder block (7) seals the pressurized oil to

valve plate (9) and performs relative rotation.
This surface is designed so that the oil pressure
balance is maintained at a suitable level.
The pressurized oil is sucked in and discharged
from each cylinder chamber in cylinder block (7)
through valve plate (9).
Impeller pump (14) and impeller pinion (16) are
integrated as a single unit by impeller shaft (15),
and are connected to shaft (1) through bevel
gear (13).
As they rotate together with the shaft, the sucked
pressurized oil is sent into the cylinder block (7)
by centrifugal force to help suction.
PC800, 850-8E0
Hydraulic system
Hydraulic pump
Operation of pump
10-27
q Cylinder block (7) rotates together with shaft (1)
and shoe (5) slides on plane (A).
q Rocker cam (4) moves along cylindrical surface
(B). As a result, angle (a) between center line (X)
of rocker cam (4) and the axis of cylinder block
(7) changes.
q Angle (a) is called the swash plate angle.
q
q
q
If angle (a) is made between center line (X) of

rocker cam (4) and the axis of cylinder block (7),
plane (A) works as a cam for shoe (5).
Piston (6) reciprocates inside cylinder block (7)
and a difference is made between volumes (E)
and (F) of cylinder chamber in cylinder block (7).
Oil in amount of (F) minus (E) goes in and out of
each cylinder.
Oil is discharged while cylinder block (7) rotates
and the volume of chamber (E) decreases.
Oil is sucked in when the volume of chamber (7)
increases.
When center line (X) of rocker cam (4) matches

the axis of cylinder block (7) (the swash plate angle is 0), the difference between volumes (E) and
(F) inside cylinder block (7) is 0.
Suction and discharge of pressurized oil is not
performed in this stage. Namely pumping action
is not performed. (Actually, however, a zero
swash plate angle never occurs.)
PC800, 850-8E0
10-27
Hydraulic system
Hydraulic pump
10-28
Control of delivery
q
q
q
q
q
When the swash plate angle (a) increases, the

difference between volumes (E) and (F) increases and also pump delivery (Q) increases.
Swash plate angle (a) is changed by servo piston (8).
Servo piston (8) moves in a linear reciprocating
movement according to the signal current from
the pump controller.
This linear movement is transmitted to rocker
cam (4) through rod (19).
Rocker cam (4) pivots on the cylindrical surface
of cradle (2).
The areas receiving the pressure on the right
and left sides of servo piston (8) are different
from each other, and delivery pressure (self
pressure) (PH) of the pump is constantly transmitted to the pressure chamber of the small diameter piston side.
The pressure chamber of the large diameter piston end is supplied with the VC valve output
pressure (PS).
10-28
The movement of servo piston (8) is controlled

by the relationship of pressure between small diameter piston side (PH) and large diameter piston side (PS) and by the ratio of the areas
receiving the pressure of the small diameter piston and large diameter piston.
PC800, 850-8E0
Hydraulic system
Hydraulic pump
PC800, 850-8E0
10-29
Hydraulic system
Pump control system
Pump control system
10-30
System diagram
10-30
10-30
PC800, 850-8E0
Hydraulic system
Pump control system
Pump control signals
PC800, 850-8E0
10-31
10-31
Hydraulic system
Servo valve
Servo valve
10-32
(This consists of VC valve, EPC valve, and shuttle valve)
10-32
PC800, 850-8E0
Hydraulic system
Servo valve
CE: EPC output pressure port

CH: Servo actuator pressure pickup port
CS: Pump control pressure pickup port
PA: Main pump pressure port
PH: Servo actuator port
PR: Servo source pressure port
PS: Pump control pressure output port
T: Drain port
1. VC valve
2. EPC valve
3. Spool
4. Sleeve
5. Spring
6. Shuttle valve
PC800, 850-8E0
10-33
Hydraulic system
Servo valve
10-34
VC valve
Outline
10-34
q The VC valve controls the position of servo piston (4) (i.e., the pump delivery) responding to the
EPC valve output pressure (i.e., the controller
command current).
10-34
Operation
Sleeve (2) moves to the position at which the
EPC valve output pressure and the force of
spring (1) are balanced, and it stops at that position.
q The large diameter end pressure ia changed by
the changes of the opening area on the notches
(A)and (B) between sleeve (2) and spool(3)" plus
by "the switching of the connection port". As the
result, servo piston (4) moves.
q
10-34
Spool (3) is pushed against cam (8) by spring

(7), and the position of servo piston (4).
Move of servo piston to the maximum position 10-34
q When the EPC valve output pressure increases,
sleeve (2) compresses spring (1) to move upward.
q Port (A) of sleeve (2) and spool (3) opens, and
port (B) closes.
q Large diameter port (PS) is connected to the
drain port.
q Servo piston (4) is pushed toward the MAX position by the pressure from small diameter port
(PH).
q Move of servo piston (4) toward the maximum
position is stopped at a position where it contacts
with the maximum position adjustment screw
(5).
q
PC800, 850-8E0
Hydraulic system
Servo valve
Move of servo piston to the minimum position 10-35

q When the EPC valve output pressure decreases, spring (1) extends and sleeve (2) moves
downwards.
q Port (B) of sleeve (2) and spool (3) opens, and
port (A) closes.
q Since the large diameter port is connected to the
output pressure from the shuttle valve (= small
diameter pressure (PH)), servo piston (4) is
moved toward the minimum position by the force
difference caused by the pressure receiving
area difference.
q Move of servo piston (4) toward the minimum position is stopped at a position where it contacts
with the minimum position adjustment screw (6).
PC800, 850-8E0
10-35
Hydraulic system
Servo valve
Servo piston
10-36
Outline
10-36
q Port (PA) pressure or port (PR) pressure, whichever is higher, is applied to port (PH) by the shuttle valve.
q The relation between pressure receiving area
(A) of chamber (a) and pressure receiving area
(B) of chamber (b) is expressed as (A) C [2 x (B)].
q The pressure from port (PH) is normally applied
to chamber (b).
PA: Main pump delivery pressure
PR: Pilot source pressure
PH: PA or PR pressures whichever is higher
10-36
10-36
Operation of the VC valve
q The command current flows from the pump controller to EPC solenoid (E1).
q This command current reduces the control
source pressure applied to EPC valve (2).
q EPC valve (2) transmits pilot pressure corresponding to the command current.
q The pilot pressure is transmitted to chamber
(se1) through port (SE1).
q Sleeve (4) of VC valve (1) is held at a position
whereat the pilot pressure from EPC valve (2)
and the force of spring (5) are balanced.
q The pump controller controls the magnitude of
the command current sent to EPC valve (2).
PC800, 850-8E0
Hydraulic system
Servo valve
Operation of the servo piston

10-37
(Movement of swash plate to intermediate position and mechanism of stopping servo piston)
q When sleeve (4) moves upwards, port (PH) and
port (PS) are disconnected, and port (PS) and
port (TD) are connected.
q Chamber (a) is connected to drain port (TD), and
therefore, servo piston (3) is moved to the right
by pressure (PH).
q When servo piston (3) moves to the right, cam
(6) connected to it also moves to the right.
q The spool of VC valve (1) moves upwards.
q When the spool of VC valve (1) moves upwards,
the connection between port (PS) and port (TD)
becomes like an orifice, and at the same time,
the connection between port (PS) and port (PH)
also becomes like an orifice.
q Servo piston (3) stops at the orifice-like position
(PS : PH C 1 : 2) whereat pressure (PS) from
chamber (a) is reduced to an intermediate pressure between pressure (PS) from chamber (b)
and drain pressure (TD).
q The position of the servo piston is decided by the
EPC command current (excluding the effect of
hysteresis).
10-37
When the EPC valve is not actuated
Sleeve (4) of VC valve (1) does not move when
the pilot pressure is supplied from EPC valve (2).
q In this case port (PH) and port (PS) are connected, and port (PS) and port (TD) are closed.
q Since the pressure in chamber (a) and (b) became same, servo piston (4) moves to the left.
q The pump delivery becomes minimum.
q
PC800, 850-8E0
10-37
Hydraulic system
Servo valve
EPC valve
C: To VC valve
P: From pump
T: To hydraulic tank
10-38
10-38
1. Body
2. Spool
3. Spring
4. Rod
5. Coil
6. Plunger
7. Connector
PC800, 850-8E0
Hydraulic system
Servo valve
Function
10-39
q The EPC valve consists of the proportional solenoid and the hydraulic valve.
q When signal current (i) from the controller is received, an EPC output pressure proportional to
the amperage of current is generated and output
to the VC valve.
PC800, 850-8E0
Operation
10-39
1. When signal current is 0 (coil is de-energized)10-39

q When there is no signal current flowing from the
controller to coil (5), the coil is de-energized.
q Spool (2) is pushed to the right by spring (3).
q Port (P) is closed, and the pressurized oil from
the self-pressure reducing valve does not flow to
the control valve.
q The pressurized oil from the VC valve flows
through port (C) and then port (T), and is drained
to the tank.
10-39
Hydraulic system
Servo valve
2. When signal current is minute (coil is ener10-40

gized)
q When minute signal current flows through coil
(5), coil (5) is energized and the thrust pushing
plunger (6) leftward is generated.
q Rod (4) pushes spool (2) to the left, and the pressurized oil flows from port (P) to port (C).
q The pressure at port (C) increases and the force
applied to surface (a) of spool (2) plus force of
spring (3) becomes larger than the thrust of
plunger (6).
q Spool (2) is pushed to the right, and port (P) and
port (C) are disconnected.
q Port (C) connects to port (T).
q Spool (2) moves to a position where the thrust of
plunger (6) becomes equal to the total of the
pressure at port (C) and the load of spring (3).
q The circuit pressure between the EPC valve and
the VC valve is controlled in proportion to the
size of the signal current.
10-40
3. When signal current is maximum (coil is ener10-40

gized)
q Coil (5) is energized when signal current is supplied to the coil).
q As the amperage of signal current is maximum,
the thrust of plunger (6) is also maximized.
q Spool (2) is pushed to the left by rod (4).
q The pressurized oil flows from port (P) to port (C)
at the maximum rate, and the circuit pressure
between the EPC valve and VC valve is maximized.
q Port (T) closes, and no pressurized oil flows to
the tank.
PC800, 850-8E0
Hydraulic system
Self-pressure reducing valve
10-41
Function
10-41
q Reduces the discharge pressure of the fan pump
and supplies it as the control pressure for the solenoid valve, EPC valve, etc.
2. When fan pump delivery pressure (P3F) is low10-41

a When load pressure (P3) is lower than output
pressure (PR) of the self-pressure reducing
valve
10-41
Operation
1. While engine is stopped
10-41
q Poppet (4) is pressed by spring (3) against the
seat, so port (PR) is disconnected from port (T).
q As valve (6) is pressed to the left by spring (5),
ports (P3F) and (PR) are connected.
q Valve (1) is pressed to the left by spring (2), so
port (P3F) is disconnected from port (P3).
q
q
PC800, 850-8E0
Force of spring (2) and the force exerted by the

(PR) pressure (0 MPa {0 kg/cm2}, when engine
is stopped), are applied to valve (1) in the direction to disconnect the circuit ports (P3F) and
(P3).
When pressurized oil flows in from port (P3F),
the valve balances when [Force (fd area x P3F
pressure) = force of spring (2) + force (fd area x
PR pressure)] holds.
The opening of valve (1) is adjusted so that pressure (P3F) is at a constant level over pressure
(PR).
When pressure (PR) rises above the set pressure, poppet (4) opens.
Pressurized oil flows from port (PR) to orifice (a)
in spool (6), then flows from poppet (4) opening
to tank drain port (T).
Differential pressure is generated across orifice
(a) in spool (6), and then spool (6) moves to
close the opening between ports (P3F) and
(PR).
Pressure (P3F) is reduced by the opening at this
time and adjusted to a constant pressure (the set
pressure), and supplied as pressure (PR).
10-41
Hydraulic system
10-43
3. When load pressure (P3F) is high
q The change in fan speed causes load pressure
(P3) to increase, and the pump delivery increases accordingly.
q Pressure (P3F) increases, and [(fd (area) x P3F
pressure > force of spring (2) + (fd (area) x PR
pressure)] holds. As a result, valve (1) moves to
the right stroke end.
q As a result, opening between ports (P3F) and
(P3) increases, and the passage resistance reduces, reducing the engine horsepower loss.
q When pressure (PR) rises above the set pressure, poppet (4) opens.
q Pressurized oil flows from port (PR) to orifice (a)
in spool (6), then flows from poppet (4) opening
to tank drain port (T).
q Differential pressure is generated across orifice
(a) in spool (6), and then spool (6) moves to
close the opening between ports (P3F) and
(PR).
q Pressure (P3F) is reduced by the opening at this
time and adjusted to a constant pressure (the set
pressure), and supplied as pressure (PR).
10-42
4. When unusual high pressure is generated 10-43

q If pressure (PR) of self-pressure reducing valve
becomes unusually high, valve (1) compresses
spring (2).
q Port (A) opens, and ports (PR) and (TS) are interconnected.
q The pressurized oil is allowed to flow to (TS)
from port (PR) to lower pressure (PR).
q Protects PPC valve, solenoid valve and other
devices from unusual pressure.
PC800, 850-8E0
Hydraulic system
PC800, 850-8E0
10-43
Hydraulic system
Cooling fan pump
Cooling fan pump
10-4
Model: LPV90
10-44
PC800, 850-8E0
Hydraulic system
Cooling fan pump
1. Piston pump
2. Servo valve assembly
3. Gear pump (for coupling lubrication)
P1: Pump delivery port
PS: Pump suction port
P: EPC valve source pressure
P1C: Pump pressure pickup port
Pen: Pump control pressure pickup port
PD1: Pump drain
PD2: Pump drain
PAG: Gear pump delivery (for coupling lubrication)
PSG: Gear pump suction (for coupling lubrication)
PC800, 850-8E0
10-45
Hydraulic system
Cooling fan pump
1. Shaft
2. Oil seal
3. Case
4. Rocker cam
5. Shoe
6. Piston
10-46
7. Cylinder block
8. Valve plate
9. Spring
10. Servo piston
11. Ball
12. End cap
PC800, 850-8E0
Hydraulic system
Cooling fan pump
Function
10-47
q The engine rotation and torque transmitted to
the pump shaft is converted into the hydraulic
energy and the pressurized oil corresponding to
the load is discharged.
q The discharge of this pump can be changed by
changing the swash plate angle in it.
PC800, 850-8E0
10-47
Structure
q Cylinder block (7) is supported on shaft (1)
through spline (a). Shaft (1) is supported on the
front and rear bearings.
q The tip of piston (6) is shaped as a concave
sphere and is crimped together with shoe (5).
The piston (6) and shoe (5) forms a spherical
bearing.
q Rocker cam (4) has flat surface (A), and shoe (5)
is always pressed against this surface while sliding in a circular pattern. Rocker cam (4) slides
while using ball (11) as the fulcrum.
q Piston (6) performs the reciprocation axially inside each cylinder chamber of cylinder block (7).
q Cylinder block (7) rotates relatively to valve plate
(8) while sealing the pressurized oil so that an
appropriate oil pressure balance is maintained
on this surface.
q The oil inside each cylinder chamber of cylinder
block (7) can be sucked in and delivered through
valve plate (8).
10-47
Hydraulic system
Cooling fan pump
Operation
1. Operation of pump
q Cylinder block (7) rotates together with shaft (1)
and shoe (5) slides on plane (A). Rocker cam (4)
tilts by using ball (11) as the fulcrum. As a result,
angle (a) between center line (X) of rocker cam
(4) and the axis of cylinder block (7) changes.
Angle (a) is called the swash plate angle.
q If angle (a) is made between center line (X) of
rocker cam (4) and the axis of cylinder block (7),
plane (A) works as a cam for shoe (5).
q Piston (6) reciprocates inside cylinder block (7)
and a difference is made between volumes (E)
and (F) of cylinder chamber in cylinder block (7).
Oil in amount of (F) minus (E) goes in and out of
each cylinder.
q Oil is discharged while cylinder block (7) rotates
and the volume of chamber (E) decreases. Oil is
sucked in when the volume of chamber (F) increases. (In the figure, chamber (F) shows a
chamber at the end of its intake stroke, and
chamber (E) shows a chamber at the end of its
discharge stroke.)
10-48
10-48
When center line (X) of rocker cam (4) matches

the axis of cylinder block (7) (swash plate angle
= 0), the difference between volumes (E) and (F)
inside cylinder block (7) is 0. There will be no
pumping effect. (Actually, however, a zero
swash plate angle never occurs.)
10-48
PC800, 850-8E0
Hydraulic system
Cooling fan pump
2. Control of delivery
10-49
q When the swash plate angle () increases, the
difference between volumes (E) and (F) increases, and pump delivery (Q) increases. Swash
plate angle () is changed by servo piston (10).
q Servo piston (10) moves in a linear reciprocating
movement according to the signal pressure from
the servo valve. This linear movement is transmitted to rocker cam (4). Rocker cam (4) is supported by ball (11) and uses this as the fulcrum
to pivot.
PC800, 850-8E0
10-49
Hydraulic system
Cooling fan pump
10-50
Servo valve
P: EPC valve source pressure

T: Drain
PE: Control piston pressure
PH: Pump delivery pressure
10-50
1. Plug
2. Lever
3. Retainer
4. Seat
5. Spool
6. Piston
7. Sleeve
PC800, 850-8E0
Hydraulic system
Cooling fan pump
Function
q The servo valve controls the servo piston so that
the swash plate angle (a) is related to the current
input to the EPC valve as shown in the figure below.
PC800, 850-8E0
10-51
The relationship between the EPC valve input
current (i) and EPC valve output pressure (F) is
as shown in the figure below.
10-51
Hydraulic system
Cooling fan pump
10-52
Operation
q The EPC valve output pressure enters the piston
chamber and presses the piston (6). Piston (6)
pushes spool (5) until it moves to a position
where it is balanced with the force of spring.
q Then, the notch in spool (5) aligns with land (PE)
in the servo piston pressure passage and the
pump delivery pressure passage. Pump delivery
pressure is transmitted to the servo piston.
q The servo piston is pushed up by the rocker
cam. Then a positioning feedback is applied,
and the lever moves in the direction compressing the spring.
q If spool (5) is pushed back, the pump discharge
pressure passage is disconnected from the servo piston circuit. The pressure in the servo piston
chamber lowers and the rocker cam returns toward the position for the maximum swash plate
angle.
q These processes are repeated until the swash
plate stabilizes at an angle where the EPC output pressure is balanced with the force of spring.
q Accordingly, as the EPC output pressure increases, the swash plate angle decreases. As
the EPC output pressure lowers, the swash plate
angle increases.
10-52
PC800, 850-8E0
Hydraulic system
Cooling fan motor
Cooling fan motor
10-53
Model: LMF110
P: From fan pump

TC: To tank
T: From oil cooler to tank
PC800, 850-8E0
Specifications
Model: LMF110
Capacity: 110.7 cc/rev
Rated speed: 1,050 rpm
Rated flow: 120 l/min
Check valve cracking pressure:
76.5 kPa {0.78 kg/cm2}
Safety valve cracking pressure:
24.5 kPa {250 kg/cm2}
10-53
10-53
Hydraulic system
Cooling fan motor
1. Output shaft
2. Case
3. Thrust plate
4. Shoe
5. Piston
6. Cylinder block
7. Valve plate
8. End cover
10-54
9. Center spring
10. Check valve spring
11. Check valve
12. Pilot valve
13. Reversible valve spool
14. Safety valve
15. Reversible valve spring
PC800, 850-8E0
Hydraulic system
Cooling fan motor
1. Hydraulic motor
Function
10-5
q This hydraulic motor is called a swash plate type
axial piston motor. It converts the energy of the
pressurized oil sent from the hydraulic pump into
rotary motion.
10-5
10-5
Principle of operation
Oil from the hydraulic pump is transmitted from
valve plate (7) to cylinder block (5). The system
is designed such that the oil is transmitted only
at one side of Y-Y joining top dead center (TDC)
and bottom dead center (BDC) of piston (4)
stroke.
q Pressurized oil having entered one side of cylinder block (5) pushes each of pistons (4) (four or
five pistons), producing force (F1)
(= Pkg/cm2xx/4D2cm2).
q This force acts on thrust plate (2), and as this
plate is attached to output shaft (1) at an angle
, the force is separated into component forces
(F2), (F3).
q The radial component (F3) produces torques (T
= F3 x ri) with respect to Y-Y joining TDC and
BDC.
q The resultant of these torques [T = (F3 x ri)]
acts on cylinder block (5) via the piston, causing
it to rotate.
q Since this cylinder block (5) is splined to the output shaft, the output shaft rotates to transmit the
torque.
q
PC800, 850-8E0
10-55
Hydraulic system
Cooling fan motor
2. Intake valve
Function
10-56
q When the fan pump stops rotating, the hydraulic
oil does not flow into the motor. Since the motor
continues rotation by the force of inertia, the
pressure at the outlet of the motor increases.
q In order to prevent cavitation, the intake valve
draws in pressurized oil from the output side
when supply thereof via intake port (P) stops,
thus ensuring that the amount provided to port
(MA) is sufficient.
10-56
Operation
1. Start-up
10-56
q If the pressurized oil from the pump is supplied
to port (P) and the pressure on (MA) side rises
and starting torque is generated in the motor, the
motor starts revolution.The pressurized oil on
the motor outlet (MB) side of the motor returns
through port (T) to the tank.
10-56
10-56
10-56
2. Stopping
q When the speed of the fan pump drops to 0 rpm
as a result of the engine being stopped, the supply of pressurized oil from the pump to port (P)
stops. The pressurized oil stops flowing into the
(MA) side of the motor, and as a result, the motor
gradually slows and comes to a stop.
q If the motor shaft is rotated by an inertial force
while the flow of pressurized oil into port (P) is
decreasing, pressurized oil from output-side port
(T) is supplied to the (MA) side by the intake
valve, thus preventing cavitation.
PC800, 850-8E0
Hydraulic system
Cooling fan motor
3. Operation of the reversible valve

1) De-energization of the reversible valve
10-57
ON/OFF solenoid
q When reversible valve ON/OFF solenoid (1) is
de-energized, the pressurized oil from the pump
is redirected by ON/OFF selector valve (2), connecting port (C) to the tank circuit.
q As a result, reversible valve spool (3) is pushed
to the right by reversible valve spring (4), the motor port (MA) opens, pressurized oil flows in, and
the motor begins to rotate in the normal direction
(clockwise).
PC800, 850-8E0
10-57
2) Energization of the reversible valve ON/OFF
10-57
solenoid
q When reversible valve ON/OFF solenoid (1) is
energized, ON/OFF selector valve (2) is
switched, pressurized oil from the pump enters
port (C), and it then flows into spool chamber
(D).
q The pressurized oil having entered chamber (D)
overcomes the force of reversible valve spring
(4) and pushes reversible valve spool (3) to the
left. As a result, motor port (MB) opens, pressurized oil flows in, and the motor begins reverse rotation (counterclockwise).
10-57
Hydraulic system
Cooling fan motor
10-58
3. Safety valve
Function
10-58
q The pressure in port (P) of the fan motor may
rise abnormally as in starting engine.
q Safety valve (1) is provided in order to protect
the fan system circuit.
10-58
Operation
When the pressure in port (P) rises above the
cracking pressure of safety valve (1), its valve (2)
opens and releases pressurized oil to port (T).
q By this operation, generation of abnormally high
pressure in port (P) is prevented.
q
10-58
PC800, 850-8E0
Hydraulic system
Electrical grease pump
1. Electrical grease pump body

2. Valve
3. Cover
4. Air chamber
5. Follow plate
6. Grease chamber
7. Grease tank
8. Wing bolt
PC800, 850-8E0
10-59
10-59
Outline
q The pump body is divided into air chamber (4)
and grease chamber (6). As the grease in
grease chamber (6) decreases, follow plate (5)
moves downwards to scrape down the grease
adhering to the wall of grease chamber (6).
10-59
Hydraulic system
Control valve
Control valve
10-60
L.H. 5-spool valve

10-60
P: From front pump
T: To tank (Main drain)
A1: To boom cylinder bottom
A2: To swing motor port (MA) (swing RIGHT)
A3: To arm cylinder bottom
A4: To bucket cylinder bottom
A5: To travel motor (L.H. travel port (P2))
B1: Plug
B2: To swing motor (Port (MB))
B3: To arm cylinder head
B4: Plug (Standard specification machine)
B5: To travel motor (L.H. travel port (P1))
P1: Valve (From straight-travel valve port (P2) of R.H. 4-spool valve)
PP: From straight-travel selector solenoid valve
TC: Drain
PA1: From PPC valve (boom LOWER)
PA2: From PPC valve (swing LEFT)
PA3: From PPC valve (arm OUT)
PA4: Standard: Bucket DUMP PPC valve or drain
Option: Optional PPC valve (via shuttle valve)
PA5: From PPC valve (L.H. travel FORWARD)
PB1: From PPC valve (boom RAISE)
PB2: From PPC valve (swing RIGHT)
PB3: From PPC valve (arm IN)
PB4: From PPC valve (bucket CURL)
PB5: From PPC valve (L.H. travel FORWARD)
PC1: From pilot valve (port (A2))
PC2: From pilot valve (port (A1))
NCA: J/S upstream pressure pickup port
NCB: J/S downstream pressure pickup port
10-60
PC800, 850-8E0
Hydraulic system
Control valve
PC800, 850-8E0
10-61
Hydraulic system
Control valve
10-62
PC800, 850-8E0
Hydraulic system
Control valve
1. Main relief valve

2. Spool (boom Hi)
3. Spool (swing)
4. Spool (arm Lo)
5. Spool (bucket Hi)
6. Spool (L.H. travel)
7. Spool return spring
8. Valve body
9. Jet sensor orifice
10. Jet sensor mounting bracket
11. Jet sensor relief valve
12. Jet sensor differential pressure sensor
13. Throttle valve
15. Check valve
16. Suction-safety valve
17. Suction valve
18. Check valve with orifice
PC800, 850-8E0
10-63
Hydraulic system
Control valve
10-64
R.H. 4-spool valve
P1: From rear pump
T: To tank
A1: To travel motor (R.H. travel port (P1))
A2: To boom cylinder head
A3: To bucket cylinder bottom
A4: To arm cylinder head
B1: To travel motor (R.H. travel port (P2))
B2: To boom cylinder bottom
B3: To bucket cylinder head
B4: To arm cylinder bottom
P1: From front pump
P2: To L.H. 5-spool valve port (P1)
PP: From straight travel selector solenoid valve
PR: From 2-stage main relief valve selector solenoid valve
PS: From 2-stage safety valve selector solenoid valve
PT: Drain
PA: From PPC valve (R.H. travel FORWARD)
PA2: From PPC valve (boom RAISE)
PA3: From PPC valve (bucket DUMP)
PA4: From PPC valve (arm IN)
PB1: From PPC valve (R.H. travel REVERSE)
PB2: From PPC valve (boom LOWER)
PB3: From PPC valve (bucket CURL)
PB4: From PPC valve (arm OUT)
NCA: J/S upstream pressure pickup port
NCB: J/S downstream pressure pickup port
10-64
PC800, 850-8E0
Hydraulic system
Control valve
PC800, 850-8E0
10-65
Hydraulic system
Control valve
10-66
PC800, 850-8E0
Hydraulic system
Control valve
1. Main relief valve

2. Spool (R.H. travel)
3. Spool (boom Lo)
4. Spool (bucket Lo)
5. Spool (arm Hi)
7. Valve body
8. Jet sensor orifice
9. Jet sensor mounting bracket
10. Jet sensor relief valve
11. Jet sensor differential pressure sensor
12. Check valve
14. Straight-travel valve
15. Suction valve
PC800, 850-8E0
10-67
Hydraulic system
Control valve
Joystick differential pressure sensor
10-68
The joystick differential pressure sensors are installed to the bottoms of R.H. and L.H. control
valves.
These sensors detect the pressure difference
between ports NCA and NCB, and output voltage signals. The output characteristics is as
shown in the following figure.
10-68
Based on outputs from these sensors and other

sensors, the pump controller sends commands
to the EPC valve to control the pump servo pistons.
PC800, 850-8E0
Hydraulic system
Straight-travel valve
10-69
P: From pump (rear)

PP: From straight-travel selector solenoid valve
PT: Drain
P1: From pump (front)
P2: To left travel (L.H. 5-spool control valve)
P3: To bucket and boom
P4: To arm
PC800, 850-8E0
10-69
Hydraulic system
1. Orifice
2. Check valve
3. Spring
5. Body
6. Spool
7. Cover
10-70
PC800, 850-8E0
Hydraulic system
Function
10-71
q When the travel is operated at the time as the
boom, arm, or bucket, the pressure oil flowing to
the left and right travel circuits is divided and
sent to the boom, arm, or bucket circuit.
q If the oil in one travel circuit is divided, the
amount of oil supplied to the travel motor will be
less than in the travel circuit which is not divided,
so the drop in the supply of oil to the travel motor
will cause the machine to deviate.
q To prevent this, the straight-travel valve is
switched to interconnect the left and right travel
circuits. This ensures that the amount of oil supplied to the left and right travel motors is equal,
so the left and right travel motors both rotate at
the same speed, and this prevents any travel deviation.
2. When a work equipment is operated while

10-71
travelling
(straight-travel solenoid valve energized)
q The straight-travel solenoid valve is energized
and pilot pressure oil flows to push spool (6) to
the right.
q Port (P2) and port (P1) is interconnected and the
oil delivery to the L.H. and R.H. travel motors are
equalized. The L.H. and R.H. travel motors operate at the same speed and the machine travels
straight.
10-71
Operation
1. When travelling only
10-71
(straight-travel solenoid valve de-energized)
q As the straight-travel solenoid valve is de-energized, pilot pressure oil flows, and spool (6) remains pressed to the left.
q Port (P2) (L.H. travel circuit) and port (P1) (R.H.
travel circuit) are disconnected and the circuits
are separated from each other.
PC800, 850-8E0
10-71
Hydraulic system
Swing motor
Swing motor
10-72
Model: KMF125AB-5
B: From swing holding brake solenoid valve

S: From back pressure compensation valve
T: To tank
MA: From control valve
MB: From control valve
10-72
10-72
Specifications
Model: KMF125AB-5
Theoretical delivery: 125.0 cm3/rev
Safety valve set pressure: 27.9 MPa {285 kg/cm2}
Rated speed: 1,936 rpm
Brake release pressure: 1.9 MPa {19 kg/cm2}
PC800, 850-8E0
Hydraulic system
Swing motor
1. Brake spring
2. Drive shaft
3. Spacer
4. Case
5. Disc
6. Plate
7. Brake piston
8. Housing
9. Piston
PC800, 850-8E0
10. Cylinder block

11. Valve plate
12. Center shaft
13. Center spring
14. Safety valve
15. Check valve
17. Shuttle valve
18. Shuttle valve spring
10-73
Hydraulic system
Swing motor
Relief valve portion

Outline
The relief valve portion consists of check valves (2)
and (3), shuttle valves (4) and (5), and relief valve
(1).
10-74
Function
When the swing is stopped, control valve (1) shuts
off the motor outlet circuit, but the motor rotation is
continued by inertial force. The pressure at the motor outlet becomes abnormally high, possibly damaging the motor. In order to prevent motor damage,
this abnormally high pressure is relieved to port (S)
from the motor outlet (high-pressure side) of the motor.
10-74
Operation
1. When starting swing
10-74
q When the swing control lever is moved to swing
RIGHT, pressurized oil from the pump is supplied to port (MA) through the control valve. The
pressure on port (MA) rises, the starting torque
is generated in the motor, and the motor starts to
rotate. The oil from the motor outlet passes from
port (MB) through the control valve and returns
to the tank. (Fig. 1)
10-74
10-74
10-74
10-74
2. When stopping swing
q When the swing control lever is returned to NEUTRAL, the supply of pressurized oil from the
pump to port (MA) is stopped. The oil from the
motor outlet cannot return to the tank since the
return circuit to the tank is shut off by the control
valve. Thus, pressure on port (MB) increases,
resistance force is generated in the motor, and
the braking effect starts.
q When the pressure at port (MB) becomes higher
than that at port (MA), (4) of shuttle valve (A) is
pressed. The pressure in chamber (C) becomes
the same as that of port (MB), and is increased
to the set pressure of relief valve (1). A high
braking torque works on the motor, thereby stopping the motor. (Fig. 2)
q When relief valve (1) is actuated, the relieved oil
and the pressurized oil from port (S) are supplied
to port (MA) through (3) of check valve (B). This
prevents cavitation in port (MA).
PC800, 850-8E0
Hydraulic system
Swing motor
Swing holding brake applied

1. When swing holding brake solenoid valve is
10-75
"deenergized"
q When the swing holding brake solenoid valve is
"de-energized", pressurized oil from the control
pump is shut off and port (B) is open to the tank
circuit. Brake piston (6) is push downwards by
brake spring (7). Disc (5) and plate (4) are
pressed against each other, and the brake is applied.
PC800, 850-8E0
10-75
2. When swing holding brake solenoid valve is
10-75
"energized"
q When the swing holding brake solenoid valve is
"energized", the valve switches and pressurized
oil from the control pump enters port (B), and
flows into brake chamber (a). After entering
chamber (a), the pressurized oil moves brake
piston (6) upwards against brake spring (7). Disc
(5) is separated from plate (4), releasing the
brake.
10-75
Hydraulic system
Center swivel joint
Center swivel joint
1. Cover
2. Body
3. Slipper seal
4. Oil seal
5. Shaft
10-76
A1. From control valve port A1

A2. To R.H. travel motot REVERSE port P1
B1. From control valve port B1
B2. To R.H. travel motor FORWARD port P2
C1. From control valve port A5
C2. To L.H. travel motot REVERSE port P2
10-76
D1. From control valve port B5

D2. To L.H. travel motor FORWARD port P1
P1. From travel speed EPC valve
P2. To L.H. and R.H. travel motors port P1
T1. To tank
T2. From L.H. and R.H. travel motors port DR
PC800, 850-8E0
(01)
Hydraulic system
Travel motor
Travel motor
10-7
Model: MSF-340VP-EH
1. Travel selector valve

2. Motor
3. Travel brake valve
P1. From control valve
P2. From control valve
PI. From travel speed solenoid valve
T. To hydraulic tank
PC800, 850-8E0
Specifications
Model: MSF-340VP-EH
Theoretical delivery:
First speed 337.2 cc/rev
Second speed 228.6 cc/rev
Rated pressure: 34.3 MPa {350 kg/cm2}
Rated speed:
First speed 1,423 rpm (at 500 l/min )
Second speed 2,010 rpm (at 500 l/min)
Brake release pressure: 1.8 MPa {18.4 kg/cm2}
10-7
10-77
Hydraulic system
Travel motor
10-78
1. Travel motor, speed selector valve, and relief valve
1. Travel speed selector valve

1a. Spool
1b. Spring
2. Relief valve
10-78
2a. Shockless piston

2b. Poppet
PC800, 850-8E0
Hydraulic system
Travel motor
3. Rear cover
4. Collar
5. Valve plate
6. Cylinder block assembly
7. Piston assembly
8. Holder
9. Retainer
10. Piston assembly
11. Case
PC800, 850-8E0
12. Shaft
13. Bearing collar
14. Rocker cam
15. Preload spring
16. Disc
17. Plate
18. Brake piston
19. Spring
10-79
Hydraulic system
Travel motor
1-1 Motor
10-80
Cylinder block (6) comprises nine pistons (7),

and one end thereof makes contact with a spherical valve plate (5) having a pair of half-moon
ports (divider valve for high/low pressure selection).
High/low speed volume selection in this motor is
realized using a pair of surfaces on the fixed
non-sliding face of rocker cam (14), which
makes contact with the motor case. Specifically,
each of these surfaces can be fixed in order to
achieve high-volume (low-speed) and low-volume (high-speed) conditions.
The tilting operation of rocker cam (14) is
perform by actuating control piston (10) with the
self-pressure through the travel speed selector
valve when the motor is being driven, and this
tilts the rocker cam (14).
There are two control pistons each for the
high/low pressure divider valve ports of valve
plat (5), and they apply thrust to the rocker cam.
10-80
PC800, 850-8E0
Hydraulic system
Travel motor
1-2 Speed selector valve

Operation
1) At low speed (pilot pressure PI = 0)
10-81
10-81
10-81
When no pilot pressure (PI) is being supplied by

the control pump (i.e., PI=0), spool (1a) of speed
selector valve (1) does not move.
At this time, the oil from the chamber of control
piston (10) passes through spool (1a) and is
drained into the motor case, and as no thrust by
tilting is applied to rocker cam (14), the low
speed surface is kept in a static condition.
PC800, 850-8E0
10-81
Hydraulic system
Travel motor
2) At high speed (automatic second speed)
When the pilot signal turns ON, pilot pressure

(PI) from the control pump acts on speed selector valve (1) and volume is automatically
changed by the drive pressure from the travel
motor.
Balance of force on travel speed selector valve

F1 [force pushing spool (1a) to the right (high-speed
side)]
= A (area of pressure-receiving surface of spool
(1a)) x PI
F2 [force pushing spool (1a) to the left (low-speed
side)]
= A (area of pressure-receiving surface of spool
(1a)) x PH (motor drive pressure) x force of
spring (1b)
10-82
10-82
1) When traveling on level ground and in other

cases where the travel motor drive pressure
is low, the relationship between these forces
is F1 > F2, and spool (1a) is pushed to the
right.
In this situation, main hydraulic pressures
(M1), (M2) are transmitted to the control
piston chamber via spool (1a), rocker cam
(14) overcomes moment (Mx) hydraulically
due to thrust (Fc) of control piston (10), and it
is tilted and fixed at the high-speed surface,
maintaining
equilibrium
of
moment.
(Mx<FcL)
2) When operating the steering, travelling uphill,
or in other cases where the travel motor drive
pressure is high, and it goes above the set
pressure, the relationship becomes F1 < F2,
and spool (1a) is pushed to the left.
In this situation, main hydraulic pressures
(M1), (M2) drain to the motor case via spool
(1a), and in the same way as when (PI) = 0,
a low-speed configuration is achieved.
PC800, 850-8E0
Hydraulic system
Travel motor
1-3 Parking brake

The parking brake is a hydraulic release, wet type,
multiple disc negative brake. The release pressure
employs a self-pressure release method using the
travel motor drive pressure through the oil passage
in the counterbalance valve spool of the travel brake
valve.
10-83
During travel, drive pressure is transmitted to parking-brake circuit port (P) where it acts on the piston
in the brake cylinder chamber, overcoming the force
of spring and releasing the brake.
When the machine is parked or stopped, the counterbalance valve spool returns to neutral, and the oil
in the cylinder chamber is released to the tank
through the counterbalance valve spool, so the
brake is applied by the force of the spring to mechanically lock the motor shaft and hold the machine
in position.
10-83
When parking brake is ON
When the travel lever is returned to NEUTRAL, the
counterbalance valve spool returns to the neutral
position, and parking brake circuit (P) is shut off.
Pressurized oil in the chamber (e) of brake piston
drains to the tank via the counterbalance valve
spool and brake piston (18) is pushed to the left by
force (Fs) of spring (19), thus applying the brake.
10-83
When parking brake is OFF
When the travel lever is operated, pressurized oil
from the pump actuates the counterbalance valve
spool to open the circuit to the parking brake, flows
into chamber (e) of brake piston (18), and overcomes the force of spring (19), pushing brake piston
(18) to the right.
As a result, a pressing force no longer acts on plate
(17) and disk (16), allowing them to move apart and
releasing the brake.
PC800, 850-8E0
10-83
Hydraulic system
Travel motor
10-84
1-4 Relief valve
1. Shockless piston
2. Poppet
3. Poppet orifice
4. Relief housing orifice

5. Piston stroke
10-84
Function
In addition to the pressure control function, this relief
valve has a shockless function (2-stage pressure increase function). This acts to reduce the shock generated at the beginning when the speed is reduced
(when the machine is stopped).
10-84
Operation
1) When relief valve starts to be actuated (1st
stage)
Poppet-seat surface (S1) constitutes the
pressure-receiving area for lifting of poppet
(2). As this provides a much larger area than
that of setting pressure-receiving surfaces
(S1), (S2), the relief operating pressure
becomes a low pressure of approximately
15.7 MPa {160 kg/cm2}. This condition is
maintained until the movement of shockless
piston (1) is completed (approx. 0.25
seconds).
2) When movement of shockless piston is
completed (2nd stage)
The pressure in the relief valve spring
chamber rises, the pressures upstream and
downstream of poppet (2) equalize, and the
rated set pressure is achieved.
a Set pressure and amount of adjustment
Per rotation: Approximately 7.8 MPa
{80 kg/cm2}
10-84
PC800, 850-8E0
Hydraulic system
Travel motor
1-5 Travel brake valve
10-85
1. Cap assembly
2. Return spring
3. Counterbalance valve
Specifications
Safety valve set pressure: 34 MPa {350 kg/cm2}
Counterbalance valve switching pressure:
1.0 0.1 MPa {10 1 kg/cm2}
Check valve switching pressure:
0.02 0.01 MPa {0.2 0.1 kg/cm2}
PC800, 850-8E0
4. Check valve
10-85
10-85
Function
q The brake valve consists of counterbalance
valve (3) and check valve (4).
q The counterbalance valve acts to prevent the
piston motor from a shock load when stopping
and overspeed while travelling down a slope.
q When traveling downhill, the weight of the machine makes it try to travel at a speed faster than
the rotation of the motor.
For this reason, if the machine is traveling with
the engine running at low speed, the motor will
rotate under no load and run out of control, which
results in extremely dangerous condition.
To prevent this, this valve controls the amount of
oil on the return side in order to keep the valve
pressure constant, and makes it possible to
perform the travel operations which are proportional to the oil delivery to the motor.
10-85
Hydraulic system
Travel motor
10-86
Operation when pressurized oil is supplied
q When the drive lever is operated, the pressurized oil is supplied from the control valve to port
(P1), it pushes open check valve (5a), and it then
flows from travel motor inlet port (M1) to travel
motor output port (M2).
However, as the travel motor outlet is closed by
check valve (5b) and spool (3), the pressure at
supply side rises.
10-86
Brake operation when travelling downhill
q If the machine attempts to run out of control
when it travels down a slope, the travel motor
runs idle, pressure at its inlet drops, and this produces a drop in the pressure in chamber (A) via
orifice (a).
When the pressure in chamber (A) becomes
lower than the spool switching pressure, spool
(3) is returned to the right by spring (2), throttling
the outlet port (M2).
As a result, the pressure at the outlet port side
rises, resistance to the rotation of the motor is
generated, and this prevents the machine from
running out of control.
In other words, the spool (3) moves to a position
whereat the pressure at outlet port (M2) is in a
state of equilibrium with the force corresponding
to the own weight of the machine and the pressure at the inlet port, throttling the outlet port,
and in this way, speed control is performed in
accordance with the pump delivery.
The pressurized oil at supply side flows from orifice (a) of spool (3) to chamber (A), and when
the pressure in chamber (A) rises above the
spool switching pressure, spool (3) is pushed to
the left. As a result thereof, port (M2) and port
(P2) are connected, the outlet port side of the
travel motor is opened, and the motor starts to
rotate.
10-86
PC800, 850-8E0
Hydraulic system
PPC valve
PPC valve
Work equipment and swing PPC valve
P: From control pump

T: To hydraulic tank
P1: L.H. PPC arm IN, R.H. PPC boom RAISE
PC800, 850-8E0
10-87
10-87
P2: L.H. PPC arm OUT, R.H. PPC boom LOWER

P3: L.H. PPC swing LEFT, R.H. PPC bucket DUMP
P4: L.H. PPC swing RIGHT, R.H. PPC bucket
CURL
10-87
Hydraulic system
PPC valve
1. Spool
2. Metering spring
3. Centering spring
4. Piston
5. Disc
10-88
6. Nut (for lever connection)

7. Joint
8. Plate
9. Retainer
10. Body
PC800, 850-8E0
Hydraulic system
PPC valve
Operation
10-89
10-89
Ports (A) and (B) of the control valve and ports
(P1), (P2), (P3), and (P4) of the PPC valve are
connected to drain chamber (D) through fine
control hole (f) in spool (1).
1.When in NEUTRAL position

q
As metering spring (2) is compressed in accordance with the control lever travel, the pressure
at port (P1) increases in proportion to the control
lever travel.
In this way, the control valve spool moves to a
position where the pressure of chamber (A)
(same as pressure at port (P1)) and the force of
the return spring of the control valve spool are
balanced.
10-89
2. When lever is in fine control
(NEUTRAL o Fine control)
q When piston (4) is pushed by disc (5), retainer
(9) is pushed and spool (1) is also pushed by
metering spring (2) and moves downward.
q This causes port (P1) to be disconnected from
drain chamber (D), and drain chamber (D) is
connected to pump pressure chamber (PP) at almost the same time. Pilot pressure oil of the control pump is transmitted from port (P1) to port
(A).
q When the pressure at port (P1) rises, spool (1) is
pushed back and port (P1) is disconnected from
pump pressure chamber (PP). At almost the
same time, it is connected to drain chamber (D)
to release the pressure at port (P1).
q As a result, spool (1) moves up and down until
the force of metering spring (2) is balanced with
the force exerted by the pressure at port (P1).
q The positional relationship between spool (1)
and body (10) does not change until retainer (9)
comes in contact with spool (1).
PC800, 850-8E0
10-89
Hydraulic system
PPC valve
10-90
(When returning control lever)
q When disc (5) starts to be returned, spool (1) is
pushed up by the force of centering spring (3)
and the force exerted by the pressure at port
(P1).
q Because of this, port (P1) is connected to drain
chamber (D), and the pressurized oil at port (P1)
is released.
q If the pressure at port (P1) is excessively reduced, spool (1) is pushed down by metering
spring (2). Port (P1) is disconnected from drain
chamber (D) and at almost the same time port
(P1) is connected to pump pressure chamber
(PP). So pump pressure is supplied until pressure at port (P1) is recovered to the level equivalent to the lever position.
q When the spool of the control valve returns, the
pressurized oil in drain chamber (D) flows in the
valve on the side that is not in operation. The oil
passes through port (P2) and is transmitted to
chamber (B) to replenish the chamber with pressurized oil.
10-90
10-90
4. At full stroke
q Disc (5) depresses piston (4), and retainer (9)
depresses spool (1). Port (P1) is disconnected
from drain chamber (D) and is connected to
pump pressure chamber (PP).
q The pilot pressure oil from the control pump is
transmitted from port (P1) to port (A) and pushes
the control valve spool.
q The oil returning from port (B) flows through port
(P2) to drain chamber (D).
PC800, 850-8E0
Hydraulic system
PPC valve
Travel PPC valve
1. Plate
2. Body
3. Piston
4. Collar
PC800, 850-8E0
10-91
5. Centering spring
6. Metering spring
7. Valve
8. Damper
10-91
Hydraulic system
PPC valve
P: From self-pressure reducing valve

P1: L.H. REVERSE
P2: L.H. FORWARD
10-92
P3: R.H. REVERSE

P4: R.H. FORWARD
T: To tank
PC800, 850-8E0
Hydraulic system
PPC valve
Pressure reducing valve function

Operation
10-93
1. When lever is in NEUTRAL
10-93
q Ports (A) and (B) of the control valve and ports
(P1) and (P2) of the PPC valve are connected to
drain chamber (D) through fine control hole (f) in
spool (1).
q
q
q
10-93
The positional relationship between spool (1)
and valve body (10) [where fine control hole (f) is
between drain chamber (D) and pump pressure
chamber (PP)] does not change until retainer (9)
comes in contact with spool (1).
Metering spring (2) is compressed in proportion
to the control lever travel.
In addition, the pressure at port (P1) increases in
proportion to the control lever travel.
The control valve spool moves to a position
where the pressure of chamber (A) (same as
pressure at port (P1)) and the force of the return
spring of the control valve spool are balanced.
10-93
(NEUTRAL o Fine control)
q When piston (4) is pushed by lever (5), retainer
(9) is pushed and spool (1) is also pushed by
metering spring (2) and moves downwards.
q When fine control hole (f) is disconnected from
drain chamber (D), it is connected to pump pressure chamber (PP) at almost the same time.
q The pilot pressure oil of control pump is transmitted from port (P1) through fine control hole (f) to
port (A).
q When the pressure at port (P1) rises, spool (1) is
pushed back and fine control hole (f) is disconnected from pump pressure chamber (PP). At almost the same time, it is connected to drain
chamber (D) to release the pressure at port (P1).
q As a result, spool (1) moves up and down until
the force of metering spring (2) is balanced with
the force exerted by the pressure at port (P1).
PC800, 850-8E0
10-93
Hydraulic system
PPC valve
10-94
(When returning control lever)
q When lever (5) starts to be returned, spool (1) is
pushed up by the force of centering spring (3)
and the force exerted by the pressure at port
(P1).
q Because of this, fine control hole (f) is connected
to drain chamber (D), and the pressurized oil at
port (P1) is released.
q If the pressure at port (P1) is excessively reduced, spool (1) is depressed by metering spring
(2).
q Fine control hole (f) is disconnected from drain
chamber (D), and at almost the same time, it is
connected to pump pressure chamber (PP).
q So the pump pressure is supplied until the pressure at port (P1) is recovered to the level equivalent to the lever position.
q When the spool of the control valve returns, the
pressurized oil in drain chamber (D) flows in
through fine control hole (f') in the valve on the
side that is not in operation. The oil passes
through port (P2) and is transmitted chamber (B)
to replenish the chamber with pressurized oil.
10-94
10-94
4. At full stroke
q Lever (5) depresses piston (4), and retainer (9)
depress spool (1).
q Fine control hole (f) is disconnected from drain
chamber (D), and it is connected to pump pressure chamber (PP).
q The pilot pressure oil from self-pressure reducing valve is transmitted from port (P1) to port (A)
through fine control hole (f) and pushes the control valve spool.
q The oil returning from chamber (B) flows from
port (P2) into drain chamber (D) through fine
control hole (f').
PC800, 850-8E0
Hydraulic system
Solenoid valve
Solenoid valve
10-95
For swing holding brake, travel speed, machine push-up, heavy lifting, and straight travel
10-95
1. Not used
2. Travel speed solenoid valve
3. Swing holding brake solenoid valve
4. Machine push-up solenoid valve
5. Heavy lift solenoid valve
6. Straight-travel solenoid valve
T: To tank
PC800, 850-8E0
A2: To L.H. and R.H. travel motors

A3: To swing motor
A4: To main valve (Safety valve)
A5: To main valve (Relief valve)
A6: To main valve (Straight-travel valve)
P1: From self-pressure reducing valve
ACC: Plug
10-95
Hydraulic system
Solenoid valve
1. Connector
2. Moving core
3. Coil
4. Cage
10-96
5. Spool
6. Block
7. Spring
PC800, 850-8E0
Hydraulic system
Solenoid valve
Operation
When solenoid is de-energized
10-97
q Solenoid (3) is de-energized when it receives no
signal current from the controller. As a result,
spool (5) is pushed to the left by spring (6). This
causes ports from (P) to (A) to close and prevents pressurised oil from the control pump flowing to the actuators. At the same time,
furthermore, oil from the actuators flows from
port (A) to port (T) and is drained to the tank.
PC800, 850-8E0
10-97
10-97
When solenoid is energized
q Solenoid (3) is energized when it receives signal
current from the controller. As a result, spool (5)
is pushed to the right. This causes pressurized
oil from the control pump to flow to the actuators
via port (P), inside of spool (5), and port (A). At
the same time, furthermore, port (T) closes and
the flow of oil to the tank is shut off.
10-97
Hydraulic system
Solenoid valve
For PPC locking (under the cab)
10-98
For PPC locking

1. PPC lock solenoid valve
10-98
T: To tank
A: To port (P) from work equipment PPC valve
To port (P) from travel PPC valve
10-98
PC800, 850-8E0
Hydraulic system
Solenoid valve
1. Connector
2. Solenoid
3. Moving core
4. Body
5. Plug
6. Spring
Operation
q Solenoid (2) is de-energized when it receives no
signal current from the controller.
As a result, spool (11) is pushed upward by
spring (10) and spool (7) is pushed to the left by
spring (6).
This causes port (P) to shut off and prevents
pressurized oil from the control pump flowing to
the actuators.
At this time, the oil from the actuator is drained
through ports (A) and (T) into the tank.
7. Spool
8. Body
9. Plug
10. Spring
11. Spool
10-9
10-9
10-9
Solenoid (2) is energized when it receives signal
current from the controller. As a result, spool (11)
is pushed downwards, causing the pressurized
oil from the control pump to flow from port (P) to
port (A) and pushing spool (7) to the right.
This causes pressurized oil from the control
pump to flow to the actuators via port (P) and
port (A).
At the same time, furthermore, port (T) closes
and the flow of oil to the tank is shut off.
PC800, 850-8E0
10-99
Hydraulic system
Solenoid valve
For swing priority (On left side of machine body)
10-10
1. Swing priority solenoid valve

T: To tank
A: To 5-spool control valve
10-100
PC800, 850-8E0
Hydraulic system
Solenoid valve
1. Connector
2. Moving core
3. Coil
4. Spool
5. Body
6. Spring
7. Plug
PC800, 850-8E0
10-101
Hydraulic system
Solenoid valve
Operation
10-102
q Coil (3) is de-energized when it receives no signal current from the controller. As a result, spool
(4) is in a neutral position by spring (6). This
causes ports (P) and (A) to become interconnected, and pressurized oil from the PPC valve
flows to the control valve.
10-102
10-102
10-102
q Coil (3) is energized when it receives signal current from the controller, and moving core (2) is
pushed to the right. As a result, spool (4) is
pushed to the right. This causes port (P) to close,
preventing pressurized oil from the PPC valve
from flowing to the control valve. At the same
time, furthermore, ports (A) and (T) become interconnected, and pressurized oil from the control valve drains to the tank.
PC800, 850-8E0
Hydraulic system
Accumulator
Accumulator
For PPC valve
10-103
10-103
10-103
Function
The accumulator is installed between the PPC
control pump and the PPC valve. Even if the engine is stopped during the work equipment to be
raised, pilot oil pressure can be supplied to the
main control valve by the pressure of the compressed nitrogen gas in the accumulator. The
work equipment can be lowered by its own
weight.
10-103
Operation
After the engine is stopped, when the PPC valve
is at neutral, chamber (A) inside the bladder is
compressed by the oil pressure in chamber (B).
q When the PPC valve is operated, oil pressure in
chamber (B) goes 2.9 MPa {30 kg/cm2} or less.
Pressure of the nitrogen gas in chamber (A)
causes the bladder to expand and oil from chamber (B) is sent as pilot pressure to actuate the
control valve.
q
1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
Specifications
Type of gas: Nitrogen gas
Gas capacity: 300 cc
Max. actuating pressure: 3.1 MPa {32 kg/cm2}
Min. actuating pressure: 1.2 MPa {12 kg/cm2}
PC800, 850-8E0
10-103
10-103
Hydraulic system
Quick return valve
Quick return valve
10-104
1. When arm OUT is operated
10-104
Function
10-104
q When arm OUT is operated, this valve reduces
the pressure loss of the large amount of oil returning from the cylinder bottom.
10-104
PC800, 850-8E0
Hydraulic system
Quick return valve
Operation
10-105
q When the control lever is moved to the arm OUT
position, pilot pressure from the PPC valve
pushes pilot spool (1) and the pressurized oil
from chamber (b) inside the valve is drained
through orifice (c). The oil in the arm bottom side
flows in the sequence of orifice (a) to chamber
(b) to orifice (c) to drain, and the pressure in
chamber (b) lowers. If the pressure of chamber
(b) drops lower than the pressure of port (A), port
(A) pressure acts on the ring shaped area (C)
formed by the difference between valve (2) outside diameter (d1) and seat diameter (d2) (=fd1
area fd2 area). Valve (2) moves to the left, and
the pressurized oil is transmitted from port (A) to
port (B). From port (B), the oil is drained directly
to the tank.
PC800, 850-8E0
10-105
Hydraulic system
Quick return valve
2. When arm lever is in NEUTRAL
10-106
Operation
10-106
q The pressurized oil that is transmitted through
orifice (a) in valve (2) is shut off by pilot piston
(1). At the same time, the holding pressure at the
arm bottom side acts on the ring shaped area (C)
formed by the difference between valve (2) outside diameter (d1) and seat diameter (d2) (=fd1
area fd2 area) in the right direction. This force
together with the force of spring (3) shuts off
valve (2) to be disconnected between port (A)
and port (B).
10-106
PC800, 850-8E0
Hydraulic system
Return oil filter
Return oil filter
1. Cover
2. Spring
3. Bypass valve
4. Bypass valve spring
5. Element
6. Housing
10-107
10-107
Outline
q Two return oil filters are installed to the side face
of the hydraulic tank. They remove the dirt and
foreign materials in the return oil.
q Bypass valve set pressure: 0.15 0.03 MPa
{1.5 0.3 kg/cm2}
A: From control valve

B: To oil cooler
PC800, 850-8E0
10-107
Hydraulic system
Line oil filter
Line oil filter
10-108
1. Element
2. Body
3. Cover
10-108
PC800, 850-8E0
Hydraulic system
Pilot oil filter
Pilot oil filter
10-109
1. Bracket
2. Cartridge
3. Safety valve
PC800, 850-8E0
10-109
Hydraulic system
Drain oil filter
Drain oil filter
10-1 0
1. Cartridge
2. Safety valve
3. Bracket
10-110
PC800, 850-8E0
Electrical system
Engine control
Electrical system
10-1 1
Engine control
10-1 1
Operation of system
Start engine
10-1 1
q When the starting switch is turned to the
START position, the starting signal flows to the
starting motor. Then, the starting motor turns to
start the engine.
At this time, the engine controller receives the
signal voltage from the fuel control dial and sets
the engine speed to the set speed.
10-1 1
10-1 1
Engine stopped
q When detecting that the starting switch is set to
the STOP position, the engine controller cuts
the fuel injection to stop the engine.
10-1 1
Engine speed control
The fuel control dial sends a signal voltage to the
engine controller corresponding to the fuel control dial position.
q The pump controller receives the fuel control dial
position information from the engine controller
through the network.
q The pump controller calculates the engine speed
in accordance with the working mode, the deceleration, and the like, and sends an instruction to
the engine controller.
q The engine controller determines the fuel injection quantity based on the instruction received
from the pump controller.
q
PC800, 850-8E0
10-111
Electrical system
Engine control
10-1 2
10-1 2
Component
Fuel control dial
1. Knob
2. Dial
3. Spring
Function
q A potentiometer is installed under the knob. As
the knob is turned, the potentiometer shaft is
turned.
q As the potentiometer shaft is turned, the resistance of the variable resistor in potentiometer (5)
changes and a throttle signal is sent to the engine controller.
q The hatched area in the graph shown at right is
the abnormality detection area. The engine
speed is set at low idle in this area.
10-112
4. Ball
5. Potentiometer
6. Connector
10-1 2
PC800, 850-8E0
Electrical system
Engine control
Engine controller
10-1 3
Meanings of signal category in the terminal table

are as follows.
A: Power supply
B: Input
C: Ground/Shield/Return
D: Output
E: Communication
CN-CE01
NC (*)
Signal
category
NC (*)
Ambient pressure sensor
Fuel supply pump #1 (+)
Fuel supply pump #1 ()
CAN (+)
NC (*)
CAN (+)
Fuel supply pump #2 (+)
10
Fuel supply pump #2 ()
Pin No.
Signal name
*: Never connect to NC, or malfunctions or failures will

occur.
PC800, 850-8E0
CN-CE01
Pin No.
Signal name
Signal
category
D
11
EGR valve
12
NC (*)
13
Engine oil pressure sensor
14
NC (*)
15
Coolant temperature sensor
16
5 V electric power supply for sensor
17
NC (*)
18
NC (*)
19
EGR valve position sensor
20
EGR valve inlet pressure sensor
21
NC (*)
22
EGR valve (+)
23
Boost temperature sensor
24
NC (*)
25
Common rail pressure sensor
26
Buckup sensor (+)
27
NE sensor (+)

occur.
10-113
Electrical system
Engine control
CN-CE01
CN-CE02
13
NC (*)
Signal
category
B
14
NC (*)
15
NC (*)
Bypass valve (+)
16
NC (*)
32
NC (*)
17
NC (*)
33
18
NC (*)
34
NC (*)
19
NC (*)
35
NC (*)
20
NC (*)
36
NC (*)
21
NC (*)
37
22
Fuel control dial (+ 5 V)
38
GND
23
Fuel control dial ()
39
NC (*)
24
NC (*)
40
NC (*)
25
NC (*)
41
NC (*)
26
NC (*)
42
NC (*)
27
NC (*)
43
NC (*)
28
NC (*)
44
Boost pressure sensor
29
NC (*)
45
Injector #1 (+)
30
NC (*)
46
Injector #5 (+)
31
NC (*)
47
Sensor GND
32
NC (*)
48
Ne sensor ()
33
NC (*)
49
NC (*)
34
NC (*)
50
NC (*)
35
NC (*)
51
Injector #2 ()
36
NC (*)
52
Injector #3 ()
37
NC (*)
53
Injector #1 ()
38
NC (*)
54
Injector #2 (+)
39
Key switch (ACC)
55
Injector #3 (+)
40
Electrical intake air heater relay drive
56
Injector #4 (+)
41
NC (*)
57
Injector #6 (+)
42
Electrical intake air heater relay return
58
Injector #4 ()
43
NC (*)
59
Injector #6 ()
44
NC (*)
60
Injector #5 ()
45
NC (*)
46
CAN (+)
47
CAN (-)
48
NC (*)
49
NC (*)
50
NC (*)
Pin No.
Signal name
28
NC (*)
29
Bypass valve position sensor
30
Fuel temperature sensor
31
Signal
category

occur.
CN-CE02
Pin No.
Signal name
NC (*)
Signal
category
B
NC (*)
NC (*)
NC (*)
NC (*)
NC (*)
NC (*)
GND
Signal
category
C
NC (*)
Electric power supply (+24V unswitched)
NC (*)
Pin No.
8
9
Signal name
NC (*)
Fuel control dial (+)
10
NC (*)
11
NC (*)
12
NC (*)

occur.
CN-CE03
Pin No.
Signal name

occur.

occur.
10-114
PC800, 850-8E0
Electrical system
Engine control
EGR valve inlet pressure sensor

10-1 5
q This sensor is used to detect the EGR pressure.
10-1 5
Fuel temperature sensor
q The fuel temperature sensor detects the fuel
temperature and sends it to the engine controller. The sensor unit is a thermistor the resistance
of which changes according to the temperature.
q The engine controller applies voltage to the
thermistor and detects the temperature by the
voltage divided by the resistance in the computer and the resistance of the thermistor.
The following graph shows the output characteristics of the EGR inlet pressure sensor.
PC800, 850-8E0
10-115
Electrical system
Engine control
EGR valve position sensor and bypass valve position sensor

q These sensors sense the opening and closing positions of the EGR valve and bypass valve.
10-1 6
1. EGR valve position sensor and bypass valve position sensor

The following graph shows the output characteristics of the position sensor.
10-116
PC800, 850-8E0
Electrical system
Engine control
NE speed sensor (Crank angle sensor)

10-1 7
q If the signal hole made on the flywheel passes
over the sensor, the magnetic line of force
changes.
q The output voltage of the hall element sensor
varies linearly in response to changes in magnetic field, however, the waveform shaping circuit built in the sensor converts the output
voltage into 0-5 V pulses.

This sensor is used to correct altitude.
Bkup speed sensor (G sensor)

10-1 7
(cylinder sensor)
10-1 7
q Similar to the NE speed sensor, this sensor outputs 0 - 5 V pulses in response to magnetic field
changes across the sensor.
q The disc gear installed to the central part of the
camshaft of the high-pressure pump has teeth
(cut parts) around it at intervals of 120 .
q In addition to the above teeth, one more tooth is
provided. Accordingly, seven pulses are generated every two rotations of the engine.
q The standard pulse of the No. 1 cylinder is recognized by the combination of the NE speed
sensor pulse and Bkup speed sensor pulse.
10-1 7
Common rail pressure sensor and oil pressure

sensor
10-1 7
PC800, 850-8E0
10-117
Electrical system
Engine control
10-1 8
q It is used to sense the boost pressure (charge
pressure).
10-118

10-1 8
q The boost temperature sensor detects the intake
air temperature (charge temperature) and sends
it to the engine controller.
q The sensor unit is a thermistor the resistance of
which changes according to the temperature.
The engine controller applies voltage to the
PC800, 850-8E0
Electrical system
Engine control
Coolant temperature sensor

10-1 9
q The coolant temperature sensor detects the
coolant temperature and sends it to the engine
controller.
q The sensor unit is a thermistor the resistance of
which changes according to the temperature.
The engine controller applies voltage to the
PC800, 850-8E0
10-119
Electrical system
Engine control
10-120
PC800, 850-8E0
Electrical system
Electric control system
10-121
General system drawing

Control function
10-121
10-121
1
Auto-deceleration function
OFF (release)
ON
Engine-pump combined control
P mode adjustment
E mode adjustment
NC control
Electronic OLSS function
PC characteristic control
Cut-off control
Cut-off release
Emergency pump drive
3 Heavy-duty lift function

One-touch power maximizing
4 2-stage boom pushing force

selector function
(Machine push-up)
5
OFF
ON
ON (high digging performance mode)
OFF (Machine push-up mode)
Swing control function
6 Engine automatic warming-up, Overheat prevention

function, Turbo protect function
7
Lo (Low speed) fixed

Travel speed selector function
8 Boom shockless control function

9
10
11
12
H i (High speed) io Lo (Low speed)

automatic gear shift
ON
Release
Straight-travel function
Swing priority function
Swing compensation function
Fan rotation control
Hydraulic fan control function
Engine output control
13
PC800, 850-8E0
Fan reverse rotation function
10-121
Electrical system
10-122
PC800, 850-8E0
Electrical system
PC800, 850-8E0
10-123
Electrical system
Auto-deceleration function, auto idle function
10-124
Function
10-124
q The purpose of the auto-deceleration function is
to automatically slow the engine to a medium
speed when all control levers are set to NEUTRAL while waiting to dump truck or work, thus
improving fuel efficiency and reducing noise.
q Operating when auto low idle has been turned
on*, the purpose of the auto idle function is to improve fuel efficiency and reduce noise by automatically slowing the engine to a medium speed
when all control levers are set to NEUTRAL
while waiting to dump truck or work, and furthermore, by automatically slowing the engine to a
low speed when this condition persists for 30
seconds.
q If any lever is operated, the engine speed returns
immediately to the set speed.
*: The machine monitor will display the message
"Auto low idle set".
10-124
PC800, 850-8E0
Electrical system
Operation
10-125
1) Operation when the auto-deceleration switch is turned on and the auto low idle setting is OFF: 10-125
Control lever in NEUTRAL
10-125
q After another four seconds have passed, the enq When all control levers are moved to NEUTRAL
gine speed will drop to No. 2 deceleration (apwhile the engine is running at a speed equal to
proximately 1,400 rpm), which is maintained
or greater than the automatic deceleration speed
until a lever is operated.
10-125
(approximately 1,400 rpm), the engine speed will
When any control lever is operated
q If any control lever is operated while the engine
immediately drop by approximately 100 rpm bespeed is being maintained at No. 1 or No. 2 delow the set speed to No. 1 deceleration.
celeration, the engine will immediately accelerate to the speed shown on the fuel control dial.
PC800, 850-8E0
10-125
Electrical system
10-126
2) Operation when the auto-deceleration switch is turned on and the auto low-idle setting is ON:
Control lever in NEUTRAL
10-126
q When a further thirty seconds have passed, the
q When all control levers are moved to NEUTRAL
engine will decelerate to the low idle speed (apwhile the engine is running at a speed equal to
proximately 825 rpm), which is maintained until
or greater than the automatic deceleration speed
a lever is operated.
10-126
(approximately 1,400 rpm), the engine speed will
When any control lever is operated
q If any control lever is operated while the engine
immediately drop by approximately 100 rpm bespeed is being maintained at No. 1 deceleration,
low the set speed to No. 1 deceleration.
q After another four seconds have passed, the enNo. 2 deceleration, or low idle speed, the engine
gine speed will drop to No. 2 deceleration (apwill immediately accelerate to the speed shown
proximately 1,400 rpm).
on the fuel control dial.
10-126
PC800, 850-8E0
Electrical system
Electronic OLSS function
10-127
Function
10-127
The electronic OLSS replaces the TVC, CO, and NC
valves of the earlier hydraulic OLSS with sensors
that convert pump delivery pressure and J/S differential pressure into electrical signals. This system
performs calculations for NC, PC characteristic, and
CO control within the controller, and via the controller, it adjusts the pump swash plate using the variable swash-plate control EPC.
PC800, 850-8E0
10-127
Electrical system
1) Engine-pump combined control function (mode-specific control methods)

P and E modes
Matching point for P and E modes: Rating

(Including fan pump absorption horsepower at fan max. speed)
Mode
10-128
Model
PC800-8
PC850-8
370 kW/1,800 rpm
{496 HP/1,800 rpm}
316 kW/1,650 rpm
{424 HP/1,650 rpm}
When the load on the pump increases and the

pressure rises, the engine speed goes down.
At this time, the pump delivery (Q) is reduced
and the engine speed (N) is set about the rated
output point. If the pressure lowers, the pump
delivery (Q) is increased until the engine speed
is set about the rated output point.
By repeating these controls, the engine can
always be used at near the rated output point.
Compared with the P mode, which provides the
maximum output, the E mode lowers the engine
output to provide matching at a point which gives
better fuel consumption efficiency than the P
mode.
As CO cancellation is performed in P0 mode, the
delivery (Q) at high pressure exceeds that of P1
and E modes.
10-128
PC800, 850-8E0
Electrical system
2) P-mode adjustment function

10-129
q Cut-off function can be selected in P mode by
operating the machine monitor. (P0, P1)
Model
Working mode
Selector switch
Cut-off function
P0
Released
P1
Actuated
10-129
3) E-mode adjustment function
The matching point in control of engine speed
(N) and engine torque (T) in E mode can be adjusted by operating the machine monitor.
q The matching point can be set to 4 levels of E0
E3. As the number is increased, fuel efficiency
is improved but production in unit time is decreased.
q
PC800, 850-8E0
10-129
Electrical system
10-130
4) NC control function
q If the stoke increases during operation, the carry-over flow rate (QC) drops (see Fig. 1), and the
jet sensor output pressure difference (Pt Pd)
decreases (see Fig. 2).
q The differential pressure (Pt Pd) is applied to
the differential pressure sensor and a voltage is
output. The relation between the input and output signals is shown in Fig. 3. If the output pressure difference (Pt Pd) is decreased, the
output voltage increases.
q The output voltage of the differential pressure
sensor is input to the controller.
q The pump capacity by the swash plate is set according to Fig. 4 and the controller supplies a
current to the pump EPC valve according to the
characteristics in Fig. 5.
q As the EPC output pressure (Pi) increases, the
pump delivery amount grows larger.
10-130
PC800, 850-8E0
Electrical system
5) PC characteristic control function

q The absorption torque of each pump is determined with the engine and pump combined function and the pump capacity is calculated based
on the characteristics in Fig. 6.
If the load on the machine increases and the pump
pressure rises, the pump capacity is decreased and
the pump absorption torque on the whole machine
is controlled constant.
10-131
When load increases while working, causing the
pump delivery amount (P) to rise to close to the
relief pressure level, the cut-off control function
makes it possible for the pump controller to decrease the pump delivery and thus reduces relief
loss.
10-131
6) Cut-off control function
10-131
7) Cut-off cancel function
The cut-off cancel function stops operation of the
cut-off function in order to keep the pump delivery amount at a level close to the relief pressure,
thus preventing any speed reductions.
Cut-off function and actuation of each switch

Switch
Function
Working mode selector

switch
P
E
P0
P1
Cut-off function
PC800, 850-8E0
release actud
ated
actuated
Travel lever
ON
OFF
Heavy-duty lift
ON
OFF
One-touch
power max.
Swing lock
ON
OFF
ON
OFF
actuated
release
d
actuated
release
release
actuated released actuated
d
d
10-131
Electrical system
10-132
8) Emergency pump drive function
q The emergency pump-drive function is used in
the case of breakdown (i.e., when user mode
E07 has been triggered).
When emergency pump drive switch (1) is
turned to the emergency position, a specific
delivery amount is supplied.
10-132
PC800, 850-8E0
Electrical system
Heavy-duty lift function and one-touch power maximizing function
10-13
1) Heavy-duty lift function

10-13
Outline
10-13
q The heavy-duty lift function increases the boom
raising by approximately 10%.
q It can be actuated only when the boom RAISE is
being actuated independently. If the arm IN or
bucket CURL are operated in combination, the
heavy-duty lift function is automatically released.
q When the heavy lift function is in operation the
Cut-off cancel function operates together.
PC800, 850-8E0
10-133
Electrical system
10-134
Operation
Heavy-duty lift
mode switch
OFF
Operation of lever
Arm IN or
Boom RAISE
bucket CURL
Operation
Neutral
ON
Operation
Operation
Heavy-duty lift solenoid valve
Main relief valve

set pressure
Boom raising
force
CO control
31.4 MPa
Operation
{320 kg/cm2}
34.3 MPa
Cancel
energized
{350 kg/cm2}
If the arm IN or bucket CURL is operated during
boom RAISE operations, this function is automatically released, and the condition becomes the same
as when the switch is turned to OFF.
De-energized
Normal
Increased by
approximately
10%
Normal
a Heavy-duty lift solenoid valve

For details of the structure and function, see Solenoid valve.
a Main relief valve
For details of the structure and function, see L.H. 5-spool control valve.
10-134
2) One-touch power maximizing function
Outline
q The one-touch power maximizing function allows power to be increased for a specific period
of time using the knob switch on the L.H. work
equipment control lever. As such, it can deliver
instantaneous power when needed during work
operations.
q Functions operate as shown below when the
knob switch on the L.H. work equipment control
lever is set to ON.
CO function
Main relief valve set
pressure
Operating time
10-134
10-134
One-touch power max. switch

ON
OFF
released
actuated
31.4 MPa
3.43 MPa
{320 kg/cm2}
{350 kg/cm2}
released after
8.5 sec even
when kept
pressed
PC800, 850-8E0
Electrical system
2-stage boom pushing force selector function 10-135
Outline
10-135
q This function selects the pushing force of the
boom. It is aimed to provide both increased digging efficiency by reducing the digging resistance of the boom, and increased ease of
operation by increasing the thrusting force for
excavation, digging square holes, carrying out
twist turns, or escaping from soft ground.
PC800, 850-8E0
10-135
Electrical system
10-136
Operation
q The 2-stage boom pushing force selector function is achieved by switching the set pressure for the
boom-cylinder-side safety valve corresponding to the R.H.4-spool control valve boom Lo between a low
pressure of 14.7 MPa {150 kg/cm2} and a high pressure of 33.3 MPa {340 kg/cm2}.
a Machine push-up solenoid

For details of the structure and function, see Solenoid valve.
a Boom safety valve
For details of the structure and function, see R.H. 4-spool valve.
10-136
PC800, 850-8E0
Electrical system
Swing control function
10-137
Function
10-137
q The system is provided with a swing lock and
swing holding brake function.
PC800, 850-8E0
10-137
Electrical system
10-138
1. Swing lock and swing holding brake functions

q The swing lock function (manual) is used to lock
the machine from swinging at any position.
The swing holding brake function (automatic) is
interconnected with the swing and it is interconnected with the swing and it is used to prevent
hydraulic drift after the machine stops swinging.
a Swing holding brake solenoid valve
For details of the structure and function, see
Solenoid valve assembly.
a Swing motor
For details of the structure and function, see
Swing motor.
Operation
Mode
Swing lock
switch
Swing lock
monitor
Swing holding
brake solenoid
valve
10-138
Operation
The swing holding brake is applied approximately
ten seconds after all swing and control levers are set
to the neutral position. If any of these levers is operated, the swing holding brake is released and swing
operations can be performed freely.
Swing holding
brake
OFF
OFF
See figure on right
Swing holding
lock
ON
ON
De-energized
10-138
The swing lock prevents swing operations being

performed; meanwhile, operation of the swing lever
does not cause the swing brake to be released.
PC800, 850-8E0
Electrical system
2. Operation of swing holding brake cancel

10-139
switch
q If any abnormality should occur in the controller,
and the swing holding brake is not actuated normally and the swing cannot be operated, the
swing holding brake cancel switch can be operated to release the swing lock and allow the
swing to be operated.
Swing holding
brake cancel switch
Swing lock
switch
Swing
brake
ON
(controller error)
ON
OFF
OFF
(controller normal)
ON
Swing lock Swing lock Swing lock

works
is released.
works
OFF
Swing holding brake
works.
a If the swing lock switch is set to the ON position,

it will not be possible to release the swing holding brake simply by setting the swing holding
brake cancel switch to ON.
a If the swing lock is released, only the hydraulic
brake is applied by the safety valve.
Note that if swinging is stopped on a slope, the
upper structure may swing by hydraulic drift.
PC800, 850-8E0
10-139
Electrical system
Engine automatic warm-up function, overheat prevention function, and turbo protection function
10-140
Function
10-140
q If the coolant temperature is low, this automatically raises the engine speed to warm up the engine after it is started. In addition, if the coolant
temperature rises too high during operations, it
reduces the load of the pump to prevent overheating.
q To protect the turbocharger bearing in cold
weather, the engine speed is kept below the
fixed speed when the engine is started. In addition, to improve the startability, a small amount of
fuel is injected two or more times before the main
injection.
10-140
PC800, 850-8E0
Electrical system
1. Engine automatic warming-up function

10-141
q After the engine is started, if the engine coolant temperature is low, the engine speed is automatically
raised to warm up the engine.
2. Engine overheat prevention function

10-141
This function protects the engine by lowering the pump load and engine speed to prevent overheating
when the engine coolant temperature has risen excessively.
q This system is actuated at 95 C and above.
q
PC800, 850-8E0
10-141
Electrical system
10-142
3. Turbocharger protection function
q Function to protect turbocharger bearing during
cold weather by keeping engine speed below
fixed speed when engine is started.
Operating condition
Coolant temperature
+10 C or above
+10 -10 C
-10 C or less
Turbocharger protect time

(sec)
0
Gradually changes between 0
and 5
5
Engine speed: 1000 rpm

q
Operation of the fuel control dial will have no effect on engine speed during the above period of
time.
Once the set time has passed, control is transferred to the engine automatic warming-up function in 1. above.
10-142
PC800, 850-8E0
Electrical system
Travel speed control function
10-143
The travel pressure (self-pressure) changes the

swash plate angle of travel motor and automatically
shifts the speed range.
q If, during high-speed travel with the travel speed
switch set to HI, the travel pressure rises to 22.6
MPa {230 kg/cm2} or higher when travelling up a
slope or the like, self-pressure will cause operation to switch to low speed travel. If travel continues in this condition and the ground again
becomes level, causing the travel pressure to
drop to 22.6 MPa {230 kg/cm2} or lower,
high-speed travel will be automatically restored.
PC800, 850-8E0
10-143
Electrical system
Travel speed
selector switch
Travel speed
solenoid valve
Travel motor
swash plate
angle
Travel speed
Lo
De-energized
Max.
Low speed
Energized
Max.
IO
Min.
Hi
Remarks
Suitable for traveling downhill or on rough
ground
Low speed (2.8

km/h)
IO
Suitable for use when travelling long distances
High speed (4.2
km/h)
Outline
q In order to ensure sufficient power for the drawbar pull during travel, the cut-off function is released and the main relief pressure rises from
31.4 MPa {320 kg/cm2} to 34.3 MPa
{350 kg/cm2}.
Operation
Cancel solenoid valve
During travel
Energized
When not traveling
De-energized
10-144
10-14
10-14
Main relief valve
set pressure
34.3 MPa
{350 kg/cm2}
31.4 MPa
{320 kg/cm2}
CO control
Released
Actuated
PC800, 850-8E0
Electrical system
Boom shockless control function

10-145
q This function reduces the shaking of the work equipment when the boom is stopped as well as operators
fatigue, and improves safety as well by preventing spillage of the load from the bucket.
10-145
Operation
Boom shockless
control switch
ON
(Contacts open)
OFF
(Contacts closed)
q
Cancel solenoid valve
Boom shockless control
Remarks
De-energized
ON
Suitable for normal operations
Energized
Released
Suitable for compacting or skeleton work
When a boom raise operation is now performed,

pilot pressure from the PPC valve is generated in
line (A).
The hydraulic pressure in (A) at this time acts on
the main valve spool via the check valve,
pushing it in the direction of the arrow. Although
the pilot pressure oil at the left side of the spool
returns to the tank via line (B) and the PPC
valve, the check valve is pushed open by the
pressure in (A) at this time, and therefore, oil
also flows in the opposite direction.
Accordingly, raising of the boom can be
performed without any delayed response.
If raising of the boom is stopped while in this condition, the main valve spool moves in a direction
opposite to that of the arrow, and oil is released
from line (A); however, oil must pass through the
orifice by the check valve.
This has the result of returning the spool gently
to the neutral position, thus creating a shockless
condition.
PC800, 850-8E0
10-145
Electrical system
Straight-travel function
10-146
Outline
q When the travel is operated in combination with
boom, arm, bucket or swing, the pressure oil
flowing to the left and right travel circuits is divided and sent to the boom, arm, bucket or swing
circuit.
If the oil in one travel circuit is divided off, the
amount of oil supplied to the travel motor will be
less than in the travel circuit which is not divided,
so the drop in the supply of oil to the travel motor
will cause the machine to deviate.
10-146
10-146
To prevent this, the straight-travel valve is
switched to interconnect the left and right travel
circuits. This ensures that the amount of oil supplied to the left and right travel motors is equal,
so the left and right travel motors both rotate at
the same speed, and this prevents any travel deviation.
PC800, 850-8E0
Electrical system
Operation
Left and right travel
levers
10-147
Work equipment
lever,
swing lever
Travel forward
solenoid valve
Straight-travel
valve
Neutral
De-energized
Not actuated
Operated
Energized
Actuated
Operation
PC800, 850-8E0
Remarks
Left and right travel motor circuits are
independent.
Left and right travel motor circuits are
merged.
10-147
Electrical system
10-148
Swing priority function
q There is a swing priority mode switch on the monitor panel. By turning this switch ON/OFF it is possible to
change the matching of the boom RAISE and swing. This divides the flow to provide a swing speed which
matches the swing angle, thereby enabling the operator to perform combined operations easily.
When swing priority mode is OFF: Loading a dump truck on the same ground
Swinging by 90 degree and loading a dump truck
When swing priority mode is ON: Swinging by 180 degree and loading a dump truck
Loading a dump truck from a bench
10-148
PC800, 850-8E0
Electrical system
PC800, 850-8E0
10-149
Electrical system
The boom raise operation and swing operation are matched to each other by changing the signal for the
swing circuit throttle valve and controlling the delivery of the front pump and rear pump.
1. Swing throttle valve
When swing priority mode is OFF (normal mode)

When priority mode is ON (swing priority)
Solenoid
Swing throttle valve
OFF (de-energized)
ON
ON (energized)
OFF
2. Front and rear pump flow control

Front and rear pump flow
When swing priority mode is OFF:
(normal mode)
QF < QR*
When swing priority mode is ON:

(swing priority)
QF = QR
Result
In combined operation of swing and boom
RAISE, more oil flows to boom RAISE side to
secure boom RAISE speed.
In combined operation of swing and boom
RAISE, more oil flows to swing side to increase
swing speed.
* QF: Front pump delivery, QR: Rear pump delivery
10-150
PC800, 850-8E0
Electrical system
PC800, 850-8E0
10-151
Electrical system
10-152
Swing compensation function
q During combined operations with the arm and swing or with the bucket and swing, the throttle valves in
the arm and bucket circuit ensure the flow rate of oil to the swing circuit in order to compensate ease of
combined operations.
10-152
Operation
When the swing PPC pressure increases to 1.5
MPa {15 kg/cm2} or higher (i.e., the control lever
is operated over approximately half of its stroke),
the swing compensation selector valve is actuated and the swing drive pressure locks the pilot
check valves for the arm and bucket throttle
valves of the 5-spool valve.
q In this condition, the circuits are in parallel, so
the oil from the 5-spool valve flowing to the arm
or bucket is throttled by the throttle valve, so the
swing drive pressure rises. In this way, the swing
drive is compensated.
q
10-152
PC800, 850-8E0
Electrical system
Hydraulic fan control function

10-153
1. Fan speed control
q The fan speed is controlled according to the engine speed, ambient temperature, hydraulic oil
temperature, and coolant temperature. While
these temperatures are low, the fan speed is
lowered to reduce the noise and fuel consumption.
PC800, 850-8E0
10-153
While the work equipment control lever is in
NEUTRAL, the fan speed is lowered, too. While
the hydraulic oil temperature and coolant temperature are high, however, fan speed is not lowered.
10-153
Electrical system
2. Engine output control

q The pump controller calculates the horsepower
consumed by the fan and controls engine output
curve (A) and (B) according to the fan speed to
decrease the fuel consumption.
10-154
Image of engine output (When fan speed changes)
10-154
PC800, 850-8E0
Electrical system
Fan reverse rotation function

q The cooling devices can be cleaned easily by rotating the fan in reverse.
q The fan rotation direction is reversed by operating the machine monitor.
q When the pump controller receives a fan reversal signal from the machine monitor, it actuates
the fan reverse ON/OFF solenoid valve of the
fan motor, and switches the fan reverse valve.
As a result, the fan rotation direction is reversed.
PC800, 850-8E0
10-15
The fan speed in reverse direction is controlled
by only the engine speed, regardless of the ambient temperature, hydraulic oil temperature,
and coolant temperature.
The auto-deceleration function is canceled during the fan reverse operation. Accordingly, the
engine speed does not lower even if the levers
are set in NEUTRAL.
Since the main pump delivery is minimized, the
normal operation cannot be performed.
10-155
Electrical system
Pump controller
10-156
10-156
PC800, 850-8E0
Electrical system
Input/output signal
CN1
Pin No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
Signal name
Unswitched power supply
Unswitched power supply GND
Window washer output
Unswitched power supply GND
NC
NC
NC
Sensor power supply (+5 V)
NC
NC
F, J/S differential pressure sensor
NC
Boom lower pressure SW
Arm Out pressure SW
Swing pressure switch
Arm IN pressure switch
Analog signal GND
Swing lock switch
Lower wiper activation switch
Model Selection 2
Step Light Switch
NC
Starter switch (ACC)
NC
NC
NC
NC
Hydraulic oil temperature sensor
NC
R, J/S differential pressure switch
NC
NC
Bucket DUMP pressure switch
NC
Travel L.H. pressure switch
Digital signal GND
Swing lock redundant switch
Model Select 5
Model Select 1
CN1
Input/out
put
Input
Input
Output
Input
Input
Input
Output
Output
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Output
Output
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Pin No.
41
42
43
44
Knob SW
NC
Starter switch (ACC)
Pulse input GND
45
CAN_H
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
Analog signal GND

Analog signal GND
Ambient temperature sensor
F pump pressure sensor
NC
NC
Service valve pressure switch
Boom RAISE pressure switch
Lower wiper contact (P)
Travel R.H. pressure switch
Upper wiper contact (W)
Window limit
Model Selection 4
Horn switch
Key SW (C)
NC
External drive signal
NC
64
CAN_L
65
66
67
68
69
70
71
72
73
74
75
76
77
Analog signal GND

Analog signal GND
NC
R pump pressure sensor
NC
Analog signal GND
NC
NC
Bucket CURL pressure switch
(Overload sensor (On/Off))
Upper wiper contact (P)
Lower wiper switch
Model Selection 3
(Overload warning activation
switch)
Key Switch (ACC)
NC
Digital signal GND
78
79
80
81
PC800, 850-8E0
Signal name
Input/out
put
Input
Input
Input
Input
Input/out
put
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input/out
put
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
10-157
Electrical system
CN2
Pin No.
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
10-158
Signal name
NC
NC
Flash light drive relay
NC
NC
Travel Hi/Lo selector solenoid
NC
NC
NC
NC
Step light drive relay
NC
NC
Bucket-Hi cancel solenoid
Fan pump EPC solenoid
Swing priority solenoid
NC
NC
NC
Swing holding brake solenoid
NC
NC
R-pump EPC solenoid
NC
Travel alarm
Battery relay drive
2-stage relief solenoid
Straight-travel solenoid
NC
NC
Fan reverse solenoid
Upper wiper (-) / Lower wiper (+)
Solenoid GND
Solenoid power supply
Solenoid GND
Upper wiper motor (+)
Solenoid GND
Input/out
put
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Input
Input
Input
Input
Output
Input
Input
PC800, 850-8E0
Electrical system
PC800, 850-8E0
10-159
Electrical system
Monitor system
Monitor system
The monitor system monitors the condition of the

machine with sensors installed on various parts
of the machine. It processes and immediately
displays the obtained information on the panel
notifying the operator of the condition of the machine.
The displayed information on the machine
monitor is roughly as follows.
1. Monitor section to sound alarms when the
machine has troubles
2. Gauge section that provides a constant status
display (i.e., coolant temperature, hydraulic oil
temperature, fuel level, etc.)
The machine monitor also has various mode selector switches and functions to operate the machine control system.
10-160
10-160
PC800, 850-8E0
Electrical system
Monitor system
Machine monitor
10-161
Outline
10-161
q The machine monitor has monitor display function, mode selection function and switch function
for electrical parts.
An internal central processing unit (CPU)
performs calculations and then displays and
outputs data.
The machine monitor features an LCD-type
screen. Flat, sheet-type switches are used.
PC800, 850-8E0
10-161
Electrical system
Monitor system
Input/Output signal
CN-CM01
Input/out
put
1
Battery power (+24V unswitched)
Input
2
Battery power (+24V unswitched)
Input
3
Battery power GND
4
Battery power GND
Input/out
5
Wake-up
put
6
Relay output
Output
7
Chassis signal GND
8
NC (*)
9
Fuel level
Input
10
NC (*)
11
Battery charge
Input
12
Chassis analog signal GND
13
Light (switch)
Input
14
Key switch (ACC)
Input
15
Key switch (C)
Input
16
Preheating
Input
17
NC (*)
18
NC (*)
* : Never connect to NC, or malfunctions or failures will

occur.
Pin No.
Signal name
10-162
CN-CM03
Pin No.
1
2
3
4
5
6
7
8
9
10
11
12
13
CN-CM02
Input/out
put
1
NC (*)
2
Engine oil level sensor
Input
3
Coolant level sensor
Input
4
Air cleaner clogging sensor
Input
5
Swing lock
Input
6
NC (*)
Input
7
Chassis signal GND
8
CAN terminating resistor
Input/out
9
CAN_H
put
Input/out
10
CAN_L
put
Input/out
11
NC (*)
put
Input/out
12
NC (*)
put
* : Never connect to NC, or malfunctions or failures will
occur.
Pin No.
Signal name
14
15
16
17
18
Input/out
put
Signal name
RS232C CD for communication terminal
RS232C RXD for communication
terminal
RS232C SG for communication terminal
Signal GND for communication terminal control
Communication terminal selector
signal
RS232C RTS for communication
terminal
RS232C TXD for communication
terminal
RS232C DTR for communication
terminal
RS232C DSR for communication
terminal
RS232C CTS for communication
terminal
RS232C RI for communication terminal
Power GND for communication terminal
Input CH1 for communication terminal status
Output for communication terminal
power control
Output CH1 for communication terminal control
Output CH2 for communication terminal control
Input CH2 for communication terminal status
Electric power supply for communication terminal
Input
Input
Input
Output
Output
Output
Input
Input
Input
Input
Output
Output
Output
Input
Output
CN-CM04
NC (*)
Input/out
put
NC (*)
NC (*)
NC (*)
NC (*)
NC (*)
NC (*)
NC (*)
NC (*)
10
NC (*)
11
NC (*)
Pin No.
Signal name
12
NC (*)

occur.
10-162
PC800, 850-8E0
Electrical system
Monitor system
CN-CM05
Pin No.
1
2
3
4
5
6
7
8
Signal name
Electric power supply for camera
Input 1 for camera NTSC signals
Electric power supply GND for
camera
Camera signal GND1
Camera signal GND2
Camera signal GND3
PC800, 850-8E0
Input/out
put
Output
Input
Input
Input
10-163
Electrical system
Monitor system
Monitor control and display portion
10-164
10-164
PC800, 850-8E0
Electrical system
Monitor system
1. Hydraulic oil temperature monitor

2. Hydraulic oil temperature gauge
3. Engine coolant temperature monitor
4. Engine coolant temperature gauge
5. KOMTRAX message monitor
6. Air conditioner monitor
7. Wiper monitor
8. Swing lock monitor
9. Engine pre-heating monitor/ one-touch power maximizing monitor
10. Clock / service meter
11. Auto-deceleration monitor
12. Working mode monitor
13. Travel speed monitor
14. ECO indicator
15. Fuel gauge
16. Fuel level monitor
17. Maintenance interval monitor
18. Engine oil pressure monitor
19. Charge level monitor
20. Radiator coolant level monitor
21. Engine oil level monitor
22. Air cleaner clogging monitor
Precautions on the machine monitor display 10-165
q One of the features of liquid crystal display panels is that there may be black spots (spots that
do not light up) or white spots (spots that stay
lighted up)on the screen. If there are fewer than
10 black or white spots, this is not a failure or a
defect.
q When the engine is started, the battery voltage
may suddenly drop depending on the temperature and the battery condition. If this happens,
the display on the machine monitor may momentarily go out, but this does not indicate any abnormality.
q Continuous operation of the machine monitor
may display blue bright spots on the screen having a black background; it is quite normal.
The screen normally displayed on the monitor
has a blue or white background. For this reason,
blue spots will not cause any problem (since the
liquid crystal lights up red, blue, and green spots
when displaying white).
PC800, 850-8E0
10-165
Electrical system
Monitor system
Monitor items and display
10-166
10-16
PC800, 850-8E0
Electrical system
Monitor system
The gauge pointer disappears when information on coolant temperature or hydraulic oil temperature cannot
be obtained due to disconnection of CAN.
Gauge
Coolant temperature
(C)
Hydraulic oil temperature

(C)
Fuel level
(l)
PC800, 850-8E0
Range
Temperature or volume
Indicator
Buzzer sounds.
A1
105
Red
A2
102
Red
A3
100
Off
A4
85
Off
A5
60
Off
A6
30
White
B1
105
Red
B2
102
Red
B3
100
Off
B4
85
Off
B5
40
Off
B6
20
White
C1
598
Off
C2
440
Off
C3
291
Off
C4
170
Off
C5
125
Off
C6
106
Red
10-167
Electrical system
Monitor system
10-168
At check before starting (all symbols light up) and when maintenance interval exceeded
If the check before starting or the maintenance interval exceeded items light up, the display of the hydraulic
oil temperature gauge and the hydraulic oil monitor go off, and the following symbols are displayed.
Symbols are displayed in order of occurrence from

the top left.
Only hydraulic oil temperature symbols are displayed when the temperature is high or low.
Condition of hydraulic oil
Color of symbol
Low temperature (below B6 Black on white background
or equivalent)
Normal (B6 B2)
No display
High temperature (Min. B2) White on red background
10-168
PC800, 850-8E0
Electrical system
Monitor system
PC800, 850-8E0
10-169
Electrical system
Monitor system
Switches
10-170
1. Buzzer cancel switch

2. Auto-deceleration switch / Auto low idle switch
3. Guidance icon
4. Function switch
5. Working mode selector switch
6. Travel speed selector switch
7. Window washer switch
8. Wiper switch
9. Air conditioner control switch
Auto-deceleration switch / Auto low idle switch10-170

Whenever the auto-deceleration or auto low idle
switch is pressed, the corresponding function toggles On and OFF.
Meanwhile, these functions turn on automatically
when the working mode is switched.
When ON, the auto-deceleration monitor is displayed.
10-170
Buzzer cancel switch
Pressing this switch when the alarm buzzer is making sound stops the alarm buzzer.
If a new abnormality is detected, the alarm buzzer
sounds.
Depending on the alarm buzzer type, it does not
stop even if you press the buzzer cancel switch.
10-170
PC800, 850-8E0
Electrical system
Monitor system
Guidance icon and function switch

The function switches vary depending on the screen
display. Each guidance icon shows the function of
the switch below it.
PC800, 850-8E0
10-171
Switches with no guidance icon are disabled.
The functions shown by the guidance icons are as
shown in the table below.
10-171
Electrical system
Monitor system
10-172
Working mode selector switch
q Switch (1) is used to configure the work equipment motion and power.
Switching the mode to suit the work being done
makes operations easier.
P mode: For heavy-duty operations
E mode: For fuel-conscious operation
Heavy-duty lift mode:
For increased boom raising power when boom
RAISE is operated independently
(Set with F1)
Swing priority mode:
(Set with F2)
q When the monitor is started up, the mode
used on the last such occasion is automatically set.
q The work equipment mode selection screen
is displayed each time switch (1) is pressed.
Display for each mode is provided in the pilot
monitor at the top right of the monitor display
section.
10-172
PC800, 850-8E0
Electrical system
Monitor system
Travel speed selector switch

10-173
q Each time the travel speed selector switch is
pressed, the travel speed changes.
Lo o Hi o Lo......
Check the travel speed monitor to see the
present travel speed setting. The relationship
between the set travel speed and the monitor
display is shown in the table below.
Display
Setting
Crawler symbol + Lo
Low speed (default)
Crawler symbol + Hi
High speed
10-173
Wiper switch
Each time the wiper switch is pressed, the wiper
setting changes
OFF o INT o ON o OFF o...
The wiper monitor can be used to confirm the
current setting. The relationship between wiper
settings and the monitor display is as follows.
Display
Setting
None
OFF
Wiper symbol
+ INT
Wiper symbol
+ ON
Wiper operation status

Stowing stopped or now stowing
INT
Intermittent operation
ON
Continuous operation
10-173
Window washer switch
While the switch is being pressed, window washer liquid is sprayed out. There is a time delay before the wiper starts.
10-173
Air conditioner switch
To operate the air conditioner, use the air conditioner control switches.
PC800, 850-8E0
10-173
Electrical system
Monitor system
9a: Switch to adjust the air flow

9b: Switch to control temperature inside the cab.
9c: AUTO
9d: A/C
9e: Switch to select the vents.
9f: FRESH/RECIRC air selector switch
9g: OFF
9a 9c : Switch to immediately enable information
input upon switching to the following
air-conditioner adjustment screen.
9d 9f : Switch to move to the following air-conditioner adjustment screen. Changes the
mode when pressed again.
9g : Switch to turn off air-conditioner functionality
without moving to the air-conditioner screen.
For a machine with no camera equipped, the

guidance icon for switching to the camera
screen does not appear; even if you press the
switch, the screen does not switch to the camera
image.
Up to three cameras are mountable.
F1: Displays the image of No. 1 camera full-screen.

F4: Displays the images of No. 1 and No. 2 cameras
at the same time.
F5: Returns to the standard screen.
q
Making operation of air conditioner button (1)

with the camera screen displayed may switch to
the air conditioner operation screen.
If you do no operation at least 5 sec. while the air

conditioner adjustment screen is displayed, the window returns to the standard screen.
a When communication with the air conditioner is
disconnected, or vent damper, air mixed
damper, or refrigerant has a problem, the following screen appears.
10-174
Camera image display function
For an optional-camera-equipped machine,
pressing the F3 on the standard screen switches
to the camera image.
10-174
PC800, 850-8E0
Electrical system
Monitor system
F6, or no operation for 5 sec.: Returns to the camera

screen.
q Even when the camera screen is displayed, the
working mode selector switch, travel speed selector switch, auto-deceleration switch, buzzer
cancel switch, wiper switch, and window washer
switch are enabled.
PC800, 850-8E0
10-175
Electrical system
Monitor system
q
q
Changing the working mode or travel speed returns to the standard screen.
If an abnormality corresponding to an alarm item
with the camera screen displayed, the alarm
monitor appears on the upper left of the screen.
If it appears, return to the standard screen with
F5 to check the alarm display.
If an abnormality corresponding to an error item
with the camera screen displayed, the error
monitor appears on the upper left of the screen.
If it appears, you must move the machine to safe
posture immediately and make inspections.
When the error monitor starts to blink, if no lever
is operated for more than 10 seconds, the
screen automatically returns to the standard
screen.
10-176
10-176
Service meter/ clock time selector function
q Pressing F4 on the standard screen when the
service meter is displayed in the top center of the
screen switches the display to the clock, and doing so when the clock is displayed switches the
display to the service meter.
PC800, 850-8E0
Electrical system
Monitor system
Maintenance function
10-17
q Pressing F5 on the standard screen switches to
the maintenance list screen.
If F6 is not pressed long enough, the switch

sound may be heard, but the maintenance time
reset screen will not be displayed.
F1:Displays the next page.

Displays the top page when the last page is displayed.
F2:Displays the previous page.
Displays the last page when the top page is displayed.
F3:Select (highlights) an item one line down.
F4:Select (highlights) an item one line up.
F5:Returns to the standard screen.
F6:If pressed and held, calls up the maintenance
time reset screen.
No operation at least thirty seconds: Screen returns
to standard screen.
q
On the maintenance list screen, if the time remaining until maintenance for any item is less
than 30 hours, the remaining time display is
highlighted in yellow. If the time remaining until
maintenance becomes 0 hour, the remaining
time display is highlighted in red.
On the maintenance time reset screen, reset the
remaining time for the selected item to return to
the default.
PC800, 850-8E0
10-177
Electrical system
Monitor system
The content of the caution display differs according to the remaining time. The relationship is as
shown in the table below.
Display
Condition
Remaining time for mainteNone
nance for all items is more than
30 hours.
Notice display
There is one or more items with
(black symbol displayed on less than 30-hour remaining
yellow background)
time for maintenance.
Warning display
There is one or more items with
(white symbol displayed on red less than 0-hour remaining time
background)
for maintenance.
q
F5: Cancels reset and returns to the maintenance

list screen.
F6: Displays the maintenance time reset reconfirmation screen.
No operation for 30 seconds: Returns to the maintenance list screen.
You can lock the maintenance time by a password to prevent it from carelessly being reset.
The default password is 000000.

a This password is another one for the engine start
lock.
a For information on changing the maintenance
password, see Maintenance password change
function in the Testing and adjusting section.
F5: Cancels the reset to return to the maintenance

list screen.
F6: Enter the reset.
No operation for 30 seconds: Returns to the maintenance list screen.
q
The table below shows the maintenance items

and replacement intervals.
The time remaining to maintenance is reduced
as the machine is operated.
NO.
01
02
03
41
04
05
06
07
08
09
10
30
31
44
Item
Engine oil
Engine oil filter
Fuel main filter
Fuel pre-filter
Hydraulic tank breather
Corrosion resistor
Coupling case oil
Final drive case oil
Machinery case oil
Hydraulic oil
Hydraulic oil pilot filter
Hydraulic oil drain filter
Fuel tank breather
10-178
Replacement interval
(Hours)
500
500
1000
500
1000
1000
1000
1000
2000
1000
5000
500
500
1000
PC800, 850-8E0
Electrical system
Monitor system
User mode
10-179
q Pressing F6 on the standard screen enters the
user mode, switching to the user menu screen.
q In user mode, you can specify items relating to
the machine monitor and machine shown below.
User Message
ECO Display
Power mode adjustment
Economy Mode Adjustment
Auto Low-idle setting
Hydraulic fan reverse setting
Screen clock adjustment
Clock Adjustment
Language selection
F3: Select (highlights) an item one line down.

F4: Select (highlights) an item one line up.
F5: Returns to the standard screen.
F6: Switches to the setting screen for the selected
item.
No operation at least thirty seconds: Screen returns
to standard display.
(If no switch is pressed for 30 seconds in user mode,
the previous screen is redisplayed.)
PC800, 850-8E0
10-179
Electrical system
Monitor system
10-180
Message display
q For a KOMTRAX-equipped machine, you can
view notification from the sales representative.
When there is a message, the message monitor
appears on the upper left of the standard screen.
q The lighting green monitor icon indicates that
there are unread messages.
q The lighting blue monitor appears when you
have not sent replies yet after opening messages which accept replies.
q
q
q
The messages will be deleted when their validity

expire or a new message is received.
If no message arrives, "No message" will be displayed in the subject section (c).
Separately from the message display for users
above, the service menu is provided with message display for technician.
Press F6 to enter user mode and select Message display and you can view (open) the messages.
F5: Returns to the user mode screen.

Messages for which a reply is possible contain
"Keypad input value: [ ]" in the lower (a) section.
In such a case, press the machine monitor
switch corresponding to the item number displayed in the message text (b) and press F6.
q The message "Return input value" will appear in
the lower (b) section. Press F6 to return the input
value.
q
10-180
PC800, 850-8E0
Electrical system
Monitor system
ECO Display selection
10-181
Select ECO Display on the user menu screen

and press F6, and the screen switches to the
ECO Display screen.
Press F3 or F4 on this screen to select "ECO
Display Target Select" or "ECO Display Data Reset" and press F6, and the screen changes.
PC800, 850-8E0
10-181
Electrical system
Monitor system
10-182
q To display the power mode adjustment screen,
select Power Mode Adjustment on the user
menu screen and press F6.
q By adjusting the high-load speed here, it is possible to improve the fuel consumption in P-mode.
q The following selections are available.
P0: Heavy Mode
P1: Common Mode
10-182
Economy mode adjustment
q Selecting the Economy Mode Adjustment from
the user menu and pressing F6 switches to the
Economy mode setting screen.
q By adjusting the high-load speed here, it is possible to improve the fuel consumption in P-mode.
q The fuel consumption level is specified to one of
four levels from E0 to E3. The larger the value,
the better the fuel consumption, but the smaller
the work rate.
F3: Selects (highlights) an item one line down.

F4: Selects (highlights) an item one line up.
F5: Cancels the changes to return to the user menu.
F6: Confirms the changes to return to the user
menu.

F6: Confirms the changes to return to the user
menu.
Auto low idle setting
10-182
Select Auto Low idle setting on the user menu

screen and press F6, and the screen changes to
the Auto low idle setting screen.
q In this menu, you can specify the auto-deceleration speed or low idle speed which is selected
when the auto-deceleration switch is pressed.
ON: Low idle speed
OFF: Auto-deceleration speed
q
10-182
PC800, 850-8E0
Electrical system
Monitor system
Hydraulic fan reverse setting

10-183
q Select Fan Reverse Mode on the user menu
screen and press F6, and the screen changes to
the screen to reverse the hydraulic fans.
q Perform instructions displayed on this screen in
order to operate the hydraulic fan in reverse.
q The user menu screen changes to screen A on
the right.
q While this screen is displayed, the fan is rotating
in the normal direction.
When you press F6, the selection process will
start and screen B will be displayed.
While the fan rotation direction is being changed,

the screen on the right is displayed.
After the changing operation is finished and the
hydraulic fans rotate in reverse, the screen
changes to screen C automatically.
When hydraulic fans are rotating in reverse, the

screen on the right is displayed.
To restore the normal direction of hydraulic fan
operation, press F5 and switch to screen D.
To perform the operation to return the rotation of

hydraulic fans to the normal direction, press F6,
and the screen changes to screen E.
If F5 is pressed or no switch is operated for 5
seconds, the screen returns to screen C.
PC800, 850-8E0
10-183
Electrical system
Monitor system
While the fan rotation direction is being changed,

the screen on the right is displayed.
After the changing operation is finished and the
hydraulic fans rotate in normal direction, the
screen changes to the standard screen automatically.
If the engine coolant temperature is 90 C or

above and the hydraulic oil temperature is below
15 C or 95 C or above, the screen on the right
is displayed. In this case, the hydraulic fans cannot be reversed.
Press F5 to switch to the user screen.
10-184
PC800, 850-8E0
Electrical system
Monitor system
Screen adjustment
10-185
q Selecting the Screen Adjustment from the user
menu and pressing F6 switches to the screen
adjustment screen.
q From this menu, you can adjust the brightness,
contrast, and luminance of the machine monitor
screen.
q When the light switch is in Night mode ON, the
night mode screen is adjustable.
q When the light switch is in Daytime mode ON or
OFF, the daytime mode screen is adjustable.
F2: Returns all adjusted values to the defaults.

F3: Decreases the value indicated by the indicator
one graduation left.
F4: Increases the value indicated by the indicator
one graduation right.
F5: Cancels changes you made before confirming
them with F6 to return to the menu screen.
F6: Confirms the changes and moves to the next
item.
q
F5: Cancels the changes prior to confirmation

with F6 and returns to the user menu screen.
F6: Moves to the setup items of the selected (highlighted) item.
q The adjustment methods for the camera screen
and standard screen are the same.
q The background when adjusting the camera
screen is the No. 1 camera image.

F5: Cancels the changes prior to confirmation with
F6 and return to the user menu screen.
F6: Moves to the setup items of the selected (highlighted) item.
For a camera-equipped machine, the brightness, contrast, and illuminance of the camera
screen are also adjustable.
For a camera-equipped machine, selecting
Screen Adjustment from the user menu switches to the screen for selecting a screen you want
to adjust.

PC800, 850-8E0
10-185
Electrical system
Monitor system
10-186
Clock adjustment
q Selecting the Clock Adjustment from the user
menu and pressing F6 switches to the clock adjustment screen.
q On this screen, you can change the setting of the
time displayed on the standard screen.
3) Summer time
Selecting ON for this sets the time forward
one hour. Setting OFF returns to the ordinary
time.
F3: Moves to the item one right.
F4: Moves to the item one left.
F5: Cancels the changes to return to the user
menu.
F6: Confirms the changes and moves to the
time setting.
a Summer time (daylight saving time) is a
system to lead a life according to the
one-hour advanced time in order to make
efficient use of daylight time.
1) Time setting
Adjust the clock time. If the time setting item
is not highlighted, press F6 to highlight it.
The time display part is highlighted.
F3: Advances the time one hour.
F4: Sets the time back one hour.
F5: Cancels the changes prior to confirmation with F6 and return to the user menu.
F6: Confirms the changes and moves to
minute setting.
The minute display part is highlighted.
F3: Advance the time one minute.
F4: Set the time back one minute.
F5: Cancels the changes prior to confirmation with F6 and return to the user menu.
F6: Confirms the changes and moves to the
12/24 display mode.
2) 12/24 display mode
Specify time display to 12-hour display
(AM/PM) or 24-hour display. If the item of
12/24 display mode is not highlighted, press
F6 to highlight it.
F3: Moves to the item one right.
F4: Moves to the item one left.
F5: Cancels the changes to return to the user
menu.
F6: Confirms the changes and moves to
summer time.
10-186
PC800, 850-8E0
Electrical system
Monitor system
Language selection
10-187
q Selecting the Language from the user menu
screen and pressing F6 switches to the language selection screen.
q From this menu, you can change the language to
be displayed on the monitor. Available languages are as follows.
English, Japanese, Chinese, French, Spanish,
Portuguese, Italian, German, Russian, Turkish,
Indonesian, and Thai.

F6: Enter the changes to return to the user menu.
PC800, 850-8E0
10-187
Idle stop guidance function
The idle stop guidance function provides instructions for limiting excessive consumption of fuel. The
corresponding display is presented when all of the
following conditions have been satisfied.
q Energy saving guidance display of the service
menu is specified to ON.
q No operation is made at least 5 min. and the engine is running at idle.
q No error or caution (excluding low hydraulic oil
temperature) is occurring.
This screen switches to the standard screen if one

of the following conditions occurs.
q When the lever is operated
q When F5 is pressed
q When an error or caution occurs
When you switch to the standard screen by pressing
F5, this screen does not appear even if the engine
continues to run at idle. If the engine continues to
run at least five min. after operating the lever, this
screen appears again.
10-187
Electrical system
Monitor system
10-18
Service meter check function
q If you continuously pressing auto-deceleration
switch (1) and buzzer cancel switch (2) at the
same time when setting the starting switch to the
OFF position, the service meter will appear on
the screen in 3 to 5 sec.
10-18
Display LCD check function
q Continuously pressing the buzzer cancel switch
(1) and F2 at the same time on the standard
screen causes the entire LCD to light in white.
Release F2 and buzzer cancel switch in order.
q One of the features of liquid crystal display panels is that there may be black spots (spots that
do not light up) or white spots (spots that stay
lighted up) on the screen. If there are fewer than
10 black or white spots, this is not a failure or a
defect.
When these switches are released, the LCD

goes out.
a Continuous operation of the machine monitor
may display blue bright spots on this screen; it is
quite normal.
10-188
Pressing any function switch returns to the previous screen.
PC800, 850-8E0
Electrical system
Monitor system
User code/ failure code display function

10-189
q If there is any problem in machine operation, the
user code and failure code are displayed on the
monitor to advise the operator of the steps to
take.
q These codes appear on the standard screen.
q On the standard screen, the user code (1) and
failure code (2) are displayed in the hydraulic oil
gauge section.
If multiple user codes or failure codes are issued,

they are displayed alternately every 2 sec. The
figure below shows the case two types of user
codes and failure codes are displayed.
If the telephone number has been set in the service menu, the screen shows the telephone
symbol and telephone number simultaneously
with the user code/ failure code. (For information
on how to input and set the telephone number,
see Special functions of monitor panel in the
Testing and adjusting section.)
PC800, 850-8E0
10-189
Electrical system
Sensors
Sensors
q
10-190
The signals from the sensors are input directly to

the engine controller and the pump controller.
The contact type sensors are always connected at one end to the chassis GND.
Sensor name
Coolant level
Engine oil level
Engine oil pressure
Coolant temperature
Fuel level
Air cleaner clogging
Hydraulic oil temperature
Main pump oil pressure
Coolant level sensor
1. Sub-tank
2. Float
10-190
Type of senWhen abnorWhen normal

sor
mal
Contact
ON (Closed) OFF (Open)
Contact
Resistance
Resistance
Resistance
Contact
Resistance
Analog
Input controller
Monitor
Monitor
Engine controller
Engine controller
Monitor
Monitor
Monitor
Pump controller
10-190
3. Sensor
4. Connector
PC800, 850-8E0
Electrical system
Sensors
Engine oil level sensor
1. Connector
2. Bracket
10-191
3. Float
4. Switch
10-191
Engine oil pressure sensor
1. Seal
Air cleaner clogging sensor
PC800, 850-8E0
2. Sensor
10-191
10-191
Electrical system
Sensors
Fuel level sensor
1. Float
2. Connector
10-192
3. Cover
4. Variable resistor
Hydraulic oil temperature sensor and coolant temperature sensor
1. Thermistor
2. Body
3. Conduit
10-192
10-192
4. Conduit
5. Wire
6. Connector
PC800, 850-8E0
Electrical system
Sensors
Main pump oil pressure sensor

(0 49.0 MPa {0 500 kg/cm2})
10-193
1. Sensor
Operation
q The oil pressure applied from the pressure intake part presses the diaphragm of the oil pressure sensor, the diaphragm is deformed.
q The deformation in the diaphragm causes the resistance of the gauge to change. This causes a
change in the output voltage, which is transmitted to the amplifier (voltage amplifier).
PC800, 850-8E0
2. Connector
10-193
The relationship between the pressure applied
to sensors (P) and output voltage (E) is shown in
the figure below.
10-193
Electrical system
KOMTRAX system
KOMTRAX system
10-194
The KOMTRAX system consists of the

KOMTRAX terminal, communication antenna,
machine monitor and GPS antenna.
q The system uses wireless communication to
transmit various kinds of machine information.
The KOMTRAX operator can obtain these information from the office to offer a range of services
to the customer.
q Information available from the KOMTRAX system include:
1. Operation map
2. Service meter reading
3. Location information
4. Failure record
and others.
a To provide the services, you need to make an arrangement for starting the KOMTRAX service
separately.
q
10-194
PC800, 850-8E0
Electrical system
KOMTRAX system
KOMTRAX terminal
Model: TH300
q The KOMTRAX system uses ground communication technology.
1. Communication antenna connection

2. Machine harness connection (AMP-14P)
3. Machine harness connection (AMP-10P)
Input/output signal
AMP-14P [CN-CK01]
Input/Output signal
A1
Power supply (12 V)
Input
A2
NC (*)
A3
NC (*)
A4
Power supply voltage switching
Output
A5
NC (*)
A6
NC (*)
A7
GND
A8
GND
A9
NC (*)
A10
NC (*)
A11
NC (*)
A12
NC (*)
A13
NC (*)
A14
NC (*)

occur.
Pin No.
Signal name
10-195
10-195
Outline
q The terminal is a wireless communication equipment which transmits various machine information obtained by the machine monitor through
network signals and input signals, as well as
GPS positioning data. The terminal can transmit
data via the communication antenna.
q The status of the terminal can be monitored on
the machine monitor when it is in the service
mode "KOMTRAX setting display".
q Use of KOMTRAX terminal must be limited for
the countries in which such communication is allowed.
a To use model TH300 out of Japan, you must
sign up with a different satellite communication
provider. Therefore, when operating the system
out of Japan, install a KOMTRAX terminal dedicated for overseas use. Also, when operating
the system out of Japan, you must give notice to
the concerned authorities in that country.
AMP-10P [CN-CK02]
Input/Output signal
B1
RS232C DCD
Output
B2
RS232C RXD
Output
B3
RS232C TXD
Input
B4
RS232C DTR
Input
B5
RS232C SGND
B6
RS232C DSR
Output
B7
NC (*)
Input
B8
NC (*)
Output
B9
NC (*)
Output
B10
NC (*)

occur.
Pin No.
PC800, 850-8E0
Signal name
10-195
Electrical system
KOMTRAX system
10-196
PC800, 850-8E0
SEN0527608-00
20-1
PC800, 850-8E0
HYDRAULIC EXCAVATOR
PC800-8E0
PC850SE-8E0
PC800LC-8E0
PC800SE-8E0
PC850-8E0
Shop Manual
Machine model
Serial number
Machine model
Serial number
PC800-8E0
PC800LC-8E0
PC800SE-8E0
PC850-8E0
65001 and up
65001 and up
65001 and up
65001 and up
PC850SE-8E0
65001 and up
PC800, 850-8E0
2-01
20-1
20-1
Contents
Contents
20-2

Standard value table ............................................................................................................... 20Standard value table for engine ........................................................................................... 20Standard value table for machine ........................................................................................ 20-
20-2
3
3
4
PC800, 850-8E0
Standard value table

Standard value table for engine
20-3
20-3
Item
Machine model
PC800, 800SE-8E0
PC850, 850SE-8E0
Engine
SAA6D140E-5
Measurement conditions
Unit
Standard value
Repair limit
1,980 50
1,980 50
825 25
825 25
1,800
1,800
kPa {mmHg}
Min. 184
{Min. 1,380}
157
{1,180}
Max. 650
Max. 700
Bosch
index
Max. 2.5
3.5
Max. 1.0
2.0
0.35
0.57
MPa
{kg/cm2}
Min. 4.1 {Min. 42}
2.8 {29}
(rpm)
(200 250)
(200 250)
kPa
{mmH2O}
Max. 2.94 {Max. 300}
3.92 {400}
Min. 0.34 {Min. 3.5}
0.21 {2.1}
Min. 0.10 {Min. 1.0}
0.08 {0.8}
At low idle
Min. 1.18 {Min. 12.0}
Min. 1.18
{Min. 12.0}
At high idle
Min. 1.43 {Min. 14.6}
Min. 1.43
{Min. 14.6}
90 110
120
High idle
Engine speed
Low idle
rpm
Rated speed
Boost pressure
At rated horsepower
Exhaust temperature
Whole speed range (Ambient temperature: (20 C)

At sudden acceleration
Exhaust gas color

At high idle
Valve clearance
(normal temperature)
Intake valve
mm
Exhaust valve
Oil temperature: 40 60 C
Compression pressure
(Engine speed)
Blowby pressure
Engine oil pressure
EGR valve and bypass

valve drive oil pressure
Coolant temperature: Within operating range

At rated horsepower
Coolant temperature: Within operating range
Oil temperature: Min. 80 C
SAE30EOS
At high idle
SAE5W40EOS
SAE10W30HD
SAE15W40HD
At low idle
SAE30HD
Engine oil temperature Whole speed range (inside oil pan)
MPa
{kg/cm2}
Alternator belt tension
Deflection when pressed with thumb

at 98 N {10 kg}
mm
13 16
13 16
Air conditioner compressor belt tension
Deflection when pressed with thumb

at 58.8 N {6 kg}
mm
Min. 10
PC800, 850-8E0
20-3

Standard value table for machine
20-4
PC800, 800SE-8E0
PC850, 850SE-8E0
Category
Machine model
Item
q
All pumps at
relief
q
q
q
Travel of control valve spool
Engine speed
When the
heavy-duty
lift mode is
selected and
all of the
pump circuits are
relieved
When the
auto-deceleration is
operated
Boom Lo
control valve
Boom Hi
control valve
Arm Lo control valve
Arm Hi control valve
Bucket Lo
control valve
Bucket Hi
control valve
Swing control valve
Travel control valve
Boom control lever
q
q
q
q
q
q
q
q
Travel of control lever
Swing control lever
Travel control lever
Play of control lever
20-4
Standard value
Repair limit
rpm
Min. 1,700
Min. 1,700
rpm
Min. 1,700
Min. 1,700
rpm
1,425 100
1,425 100
mm
16 0.5
16 0.5
N o RAISE,
LOWER
85 10
85 10
N o IN, OUT
85 10
85 10
85 10
85 10
85 10
85 10
115 12
115 12
Max. 10
Max. 15
Coolant temperature: Within operating

range
Hydraulic oil
temperature: 45 55 C
Engine at high idle
Working mode: P mode
When circuit is relieved at boom RAISE
stroke end
Coolant temperature: Within operating
range
Hydraulic oil temperature: 45 55 C
Engine at high idle
Working mode: P mode and heavy-duty lift mode
When circuit is relieved at boom RAISE
stroke end
Engine at high idle
Auto-decelerator switch in ON position
All control levers in NEUTRAL
position
Stroke on one side
Arm control
lever
Bucket control lever
Unit
Engine stopped
At center of control
lever grip
Read value to
stroke end (excepting lever play in
NEUTRAL
position)
N o CURL,
DUMP
N o RIGHT
SWING, LEFT
SWING
N o FORWARD,
REVERSE
(Right and left
travel control
levers)
Work equipment,
swing, and travel
control levers
mm
PC800, 850-8E0

PC800, 800SE-8E0
PC850, 850SE-8E0
Item
Standard value
Repair limit
15.7 4.9
{1.6 0.4}
15.7 4.9
{1.6 0.4}
15.7 4.9
{1.6 0.5}
15.7 4.9
{1.6 0.5}
12.7 3.9
{1.3 0.4}
12.7 3.9
{1.3 0.4}
12.7 3.9
{1.3 0.4}
12.7 3.9
{1.3 0.4}
Lever
24.5 5.9
{2.5 0.6}
Max. 39.2
{Max. 4.0}
Pedal
98 24.5
{10 2.5}
Max. 107.6
{Max. 11}
31.4 1.0
{320 10}
31.4 (+1.0/-2.0)
{320 (+10/-20)}
33.8 1.0
{345 10}
33.8 (+1.0/-2.0)
{345 (+10/-20)}
18.6 1.9
{190 20}
18.6 1.9
{190 20}
32.4 1.0
{330 10}
32.4 (+1.0/-2.0)
{330 (+10/-20)}
31.4 1.0
{320 10}
31.4 (+1.0/-2.0)
{320 (+10/-20)}
33.8 1.0
{345 10}
33.8 (+1.0/-2.0)
{345 (+10/-20)}
31.4 1.0
{320 10}
31.4 (+1.0/-2.0)
{320 (+10/-20)}
33.3 1.0
{34 10}
33.3 (+1.0/-2.0)
{340 (+10/-20)}
Swing relief
pressure
28.9 (+2.5/-0.5)
{295 (+25/-5)}
28.9 (+2.5/-0.5)
{295 (+25/-15)}
Travel relief
pressure
34.8 1.0
{355 10}
34.8 (+1.0/-2.0)
{355 (+10/-20)}
3.24 (+0.49/0)
{33 (+5/0)}
3.24 (+0.49/-0.20)
{33 (+5/-2)}
Arm control
lever
Bucket control lever
q
q

Engine at high idle
Control lever: At center of grip
Read value to stroke end
N {kg}
Swing control lever

Travel control lever,
pedal
Boom relief
pressure
q
q
Arm relief
pressure
Bucket relief
pressure
At normal condition
When
heavy-duty lift
mode is
selected
At normal condition
When machine
push-up operation is performed
Hydraulic oil temperature:

45 55 C
Engine at high idle
Working mode:
P mode
Hydraulic
pump
MPa
outlet pressure with
{kg/cm2}
all measurement When power max.
switch is ON
circuits relieved
Relieve either travCURL
el circuit.
LOWER
Oil pressure
Unit
Boom control lever
RAISE
Operating effort of control lever
Category
Machine model
DUMP
Control
q
q
PC800, 850-8E0

Engine at high idle
20-5

PC800, 800SE-8E0
PC850, 850SE-8E0
Category
Machine model
Item
Oil pressure
Pump EPC
solenoid
valve output pressure
q
q
Jet sensor
output differential pressure
PPC valve
output pressure
q
q
q
q
q
q
Lowering of
oil pressure
Output voltage of differential

pressure
sensor
q
q
Pump EPC
current
Swing
All control levers

Hydraulic oil temin NEUTRAL posiperature:
tion
MPa
45 55 C
When
running {kg/cm2}
Engine at high idle
track idle
Working mode:
P mode (lever at travel
end)
All control levers
tion
MPa
45 55 C
When running {kg/cm2}
Engine at high idle
track idle
Working mode:
end)
Engine at high idle
Control lever at travel end
MPa
Hydraulic oil temperature: 45 55 C {kg/cm2}
Difference between relief pressure at
engine high speed and that at engine at
low speed
All control levers
tion
45 55 C
When running
Engine at high idle
track idle
Working mode:
end)
All control levers
tion
45 55 C
When running
Engine at high idle
track idle
Working mode:
end)
Overrun of
swing
q
q
q
q
Standard value
Repair limit
Max. 0.78
{Max. 8}
Max. 0.78
{Max. 8}
Max. 1.23
{Max. 12.5}
Max. 1.23
{Max. 12.5}
Max. 1.28
{Max. 13.1}
Max. 1.28
{Max. 13.1}
0.15 or less
{Max. 1.5}
0.15 or less
{Max. 1.5}
2.9 (+0.8/-0.2)
{30 (+8/-2)}
2.9 (+0.8/-0.2)
{30 (+8/-2)}
Max.2.0
{Max. 20}
Max. 2.9
{Max. 30}
Min. 3
Min. 3
Max.1.2
Max.1.2
275 50
275 50
584 50
584 50
Max. 71
(Max. 1,225)
Max. 80
(Max. 1,380)
mA
deg.
(mm)
q
20-6
Unit

Bucket: No load
Engine at high idle
Swing circle misalignment amount
when stopping after one turn
PC800, 850-8E0

PC800, 800SE-8E0
PC850, 850SE-8E0
Category
Machine model
Item
Unit
Standard value
Repair limit
4.2 0.5
Max. 5.3
6.8 0.7
Max. 8.2
sec.
41 47
Max. 50
mm
l/min
Max. 5
Max. 10
90
Time
required to
start swinging
sec.
q
q
q
q
q
Swing
Time
required to
finish swinging
q
q
q
q
q
Swing drift
on a slope
q
q
q
q
q
q
Leakage
from swing
motor
q
q
q
PC800, 850-8E0
Hydraulic oil temperature: 45

55 C
Bucket: No load
180
Engine at high idle
Measure time required to pass
90 degree and 180 degree
points after starting swinging.

Bucket: No load
Engine at high idle
Time that is required to swing next five
turns after first one turn

Engine stopped
Set machine on 15 degree slope, and
set upper structure at 90 degree to the
side
Make matchmarks on inner and outer
races of swing circle.
Matchmark misalignment amount during 5 minutes
Engine at high idle
Swing lock switch: ON
Leakage amount for one minute during
swing relief
20-7

PC800, 800SE-8E0
PC850, 850SE-8E0
Category
Machine model
Item
Unit
Standard value
Repair limit
74 90
74 90
Hi
48 59
48 59
Lo
22 29
22 29
15 19
15 19
Max. 200
Max. 220
Lo
Travel speed
(idle running)
sec.
q
q
q
q
Travel speed
(actual running)
sec.
q
Travel
q
q
q
q
q
q
Travel deviation
q
q
q
q
20-8

55 C
Engine at high idle
Time required to make five turns
after making one turn for track
raised off the ground

55 C
Engine at high idle
Level ground
Time required for
traveling 20 m after 10 m trial run
Hi

Engine at high idle
Travel speed: Lo
Use a hard and level ground
Swerving amount (X) when traveling 20
m after initial trial run of 10 m
mm
PC800, 850-8E0

PC800, 800SE-8E0
PC850, 850SE-8E0
Category
Machine model
Item
Travel
Hydraulic
drift of travel
q
q
q
q
q
Leakage
from travel
motor
q
q
q
PC800, 850-8E0

Engine stopped
Park machine on slope of 12 with
sprocket faced to the uphill side.
Travel distance of hydraulic drift of travel for 5 minutes
Engine at high idle
Travel: Lock sprocket.
Oil leakage amount for one minute with
traveling in relief condition
Unit
Standard value
Repair limit
mm
l/min
Max. 20
Max. 40
20-9

PC800, 800SE-8E0
PC850, 850SE-8E0
Category
Machine model
Item
Unit
Standard value
Backhoe
specification
Working posture of bakchoe
Whole
work
equipment
(drop at
bucket
tooth tip)
Repair limit
PC800-8E0
PC800-8E0
Loading
Loading
Backhoe
shovel
shovel
specification
specificaspecification
tion
Max.
1,200
(Max.
900)
Max. 1,500
Max. 55
(Max. 35)
Max. 150
Max. 90
(Max. 50)
Max. 230
Max. 160
(Max. 70)
Max. 30
Max. 250
(Max. 105)
Max. 45
Max. 95
(Max. 15)
Max. 8
Max. 75
(Max. 25)
Max. 12
Max. 1,800
Max. 1,800
(Max. 1,000)
Work equipment
Hydraulic drift in work equipment
Working posture of loading shovel
Boom
cylinder
(retraction
amount
of cylinder)
Arm cylinder
(extension
amount
of cylinder)
q
q
q
Bucket
cylinder
(retraction
amount
of cylinder)
20-10
q
q
q
q
Measure extension and retraction of

each cylinder and drop of bucket tooth
tip in above posture.
Work equipment rated load (standard
bucket load)
PC800-8E0: 49 kN {5,000 kg}
: 62 kN {6,300 kg} (SE specification)
PC850-8E0: 53 kN {5400 kg}
: 68 kN {6,900 kg} (SE specification)
Without bucket link (4.5 m3 bucket)
79 kN {8,100 kg}
Measure on level and flat surface.
Set lever to NEUTRAL.
Engine stopped
Start measurement just after setting.
Measure drop distance every 5 minutes
and judge after 15 minutes
Values in ( ) are values when no load is
applied to work equipment.
mm
PC800, 850-8E0

PC800, 800SE-8E0
PC850, 850SE-8E0
Category
Machine model
Item
Unit
RAISE*
q
q

55 C
Engine at high speed
P mode
LOWER
q
q
q

55 C
P mode
PC800
5.3 0.5
PC800SE
5.6 0.6
PC850
5.3 0.5
PC850SE
5.6 0.6
5.7 0.6
PC800
Max. 6.7
PC800SE
Max. 7.2
PC850
Max. 6.7
PC850SE
Max. 7.2
Max. 7.0
5.5 0.5
PC800
Max. 5.1
PC800SE
Max. 5.2
PC850
Max. 5.0
PC850SE
Max. 5.2
Max. 6.5
4.3 0.4
PC800
Max. 6.1
PC800SE
Max. 6.8
PC850
Max. 6.8
PC850SE
Max. 6.8
Max. 5.4
2.5 0.3
PC800
Max. 4.4
PC800SE
Max. 4.9
PC850
Max. 4.9
PC850SE
Max. 4.9
Max. 3.4
PC800
4.3 0.4
PC800SE
4.4 0.4
PC850
4.2 0.4
PC850SE
4.4 0.4
PC800
4.7 0.5
PC800SE
5.4 0.5
PC850
5.4 0.5
PC850SE
5.4 0.5
PC800
3.4 0.3
PC800SE
3.8 0.4
PC850
3.8 0.4
PC850SE
3.8 0.4
Posture of work equipment:
Arm
Cylinder
fully
retracted
IO
Fully
extracted
PC800-8E0
PC800-8E0
Loading
Loading
Backhoe
shovel
shovel
specification
tion
IN*
sec.
Repair limit
Backhoe
specification
OUT*
Work equipment
Work equipment speed
Posture of work equipment:

Boom
Bucket
teeth in
contact
with
ground
IO
Boom
cylinder
fully
extended
Standard value
* Including cylinder cushion operating time
PC800, 850-8E0
20-11

PC800, 800SE-8E0
PC850, 850SE-8E0
Unit
Standard value
PC800
3.3 0.3
PC800SE
4.6 0.5
PC850
3.6 0.4
PC850SE
4.6 0.5
PC800-8E0
PC800-8E0
Loading
Loading
Backhoe
shovel
shovel
specification
tion
PC800
Max. 3.9
PC800SE
Max. 5.6
4.3 0.4
Max. 5.2
PC850
Max. 4.4
PC850SE
Max. 5.6
PC800
3.2 0.3
PC800SE
4.2 0.4
PC850
3.4 0.3
PC850SE
4.2 0.4
4.0 0.4
PC800
Max. 3.8
PC800SE
Max. 5.0
PC850
Max. 6.0
PC850SE
Max. 5.0
Max. 5.0
1.6 0.3
Max. 2.5
1.7 0.3
Max. 2.6
Working posture of backhoe
Bucket
Cylinder
Working posture of loaking shovel
fully
retracted
IO
Fully
extracted
q
q
DUMP
Work equipment
CURL*
Backhoe
specification

55 C
P mode
Bottom
cylinder Posture of work equipment:
Cylinder
fully
retracted
IO
Fully
extracted
(PC800-8
E0 Loading
q Hydraulic oil temperature: 45
shovel
55 C
specifica- q Engine at high speed
tion)
Repair limit
OPEN
Item
CLOSE
Category
Machine model
sec.
* Including cylinder cushion operating time
20-12
PC800, 850-8E0

PC800, 800SE-8E0
PC850, 850SE-8E0
Category
Machine model
Item
Unit
Standard value
Repair limit
PC800-8E0
PC800-8E0
Backhoe Loading Backhoe Loading
specificashovel
specificashovel
tion
specification
specification
tion
Boom
q
q
q

Engine at low speed
Time required to raise machine off the
ground after bucket touches the
ground
Arm
q
q
Time lag
Work equipment

Engine at low speed
Period of time while arm stops momentarily
Bucket
q
q
q
Bottom cylinder
(PC800-8E0
Loading
shovel
specification)
q
q
q
PC800, 850-8E0
Max. 6
Max. 6
Max. 5
Max. 5
Max. 4
Max. 4
Max. 3
Max. 3
sec.

Engine at low speed
Period of time while bucket stops momentarily

Engine at low speed
Time from stop of bottom to start after
bottom is moved from OPEN position
to CLOSE position
20-13

PC800, 800SE-8E0
PC850, 850SE-8E0
Category
Machine model
Work equipment
Internal oil leackage
Performance of hydraulic pump
Item
Hydraulic pump
delivery
q
q
Center
swivel joint
Fan circuit oil

pressure
Fan
Unit
Cylinder
Fan speed
Output pressure
of fan pump
EPC solenoid
valve
Fan pump EPC
current
20-14

Hydraulic oil pressure: 31.4 1.0 MPa cc/min
{320 10 kg/cm2}
See next page

Engine at high idle
Fan 100% speed mode
Engine at high idle
Fan 100% speed mode
q
q
q
q
q
q
q
q
q
q
q

Engine at high idle
Fan 100% speed mode
Engine at high idle
Fan 100% speed mode
Standard value
Repair limit
Max. 6
Max. 20
Max. 10
Max. 100
l/min
rpm
MPa
{kg/cm2}
mA
See next page
1,050 50
1,050 50
13.219.1
{135195}
13.219.1
{135195}
1.72 0.49
{17.5 0.5}
1.72 0.49
{17.5 0.5}
630 50
630 50
PC800, 850-8E0

PC800, 800SE-8E0
PC850, 850SE-8E0
Category
Machine model
Item
Unit
Standard value
Repair limit
Performance of hydraulic pump
Hydraulic pump delivery (per one pump)
q
q
Pump speed: at 1,800 rpm

Pump delivery pressure: 9.8 MPa {100 kg/cm2}
Pump EPC
Standard discurrent to be
Check point
charge
used for test
(l/min)
(mA)
Q (See the
Any
I
graph.)
PC800, 850-8E0
Criteria
(l/min)
<Lower limit>
Q (See the
graph.)
20-15

20-16
PC800, 850-8E0
SEN0527610-00
30-1
PC800, 850-8E0
HYDRAULIC EXCAVATOR
PC800-8E0
PC850SE-8E0
PC800LC-8E0
PC800SE-8E0
PC850-8E0
Shop Manual
Machine model
Serial number
Machine model
Serial number
PC800-8E0
PC800LC-8E0
PC800SE-8E0
PC850-8E0
65001 and up
65001 and up
65001 and up
65001 and up
PC850SE-8E0
65001 and up
PC800, 850-8E0
3-01
30-1
30-1
Contents
Contents
30-2

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
............................................................................................................................................. 30- 37
Testing and adjusting control signal of main pump.............................................................. 30- 39
Testing PPC valve output pressure ..................................................................................... 30- 46
............................................................................................................................................. 30- 50
Adjusting play of work equipment and swing PPC vavles ................................................... 30- 55
Testing and adjusting travel deviation.................................................................................. 30- 56
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
30-2
PC800, 850-8E0
Tool for testing, adjusting and troubleshooting

Tools for testing, adjusting, and troubleshooting
30-3
30-3
Testing and adjusting item
Symbol
Part number
Part name
Q'ty

Remarks
Intake air pressure (boost

pressure)
799-201-2202 Boost gauge kit
1 -101 200 kPa {-760 1,500 mmHg}
Exhaust gas temperature
799-101-1502 Digital thermometer
1 -99.9 1,299 C
1
Exhaust gas color
C
2
Valve clearance
D
1
Compression pressure
799-201-9001 Handy smoke checker 1

Commercially
Smoke meter
available
Commercially
Feeler gauge
available
Bosch index: 0 to 9 (with standard

color)
1
1
(Air intake: 0.35 mm, Exhaust air: 0.57

mm)
795-502-1590 Compression gauge
1 0 7 MPa {0 70 kg/cm2}
795-471-1310 Adapter
1 For 140E-3 and 5 engines
6217-71-6110 Gasket
1 For 140E-3 and 5 engines
799-201-1504 Blowby checker
799-101-5002 Hydraulic tester
2
Blowby pressure
1
Engine oil pressure
790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}

2
EGR valve and bypass

valve drive oil pressure
Pressure gauge: 2.5, 6.0, 40, 60 MPa

{25, 60, 400, 600 kg/cm2}
799-401-2320 Hydraulic gauge
1 Pressure gauge: 1.0 MPa {10 kg/cm2}

{25, 60, 400, 600 kg/cm2}


{25, 60, 400, 600 kg/cm2}

Fuel pressure
H
2
795-471-1450 Adapter
1 8 x 1.25 mm o R1/8
07005-00812 Gasket
6151-51-8490 Spacer
1 Internal diameter: 14 mm
6206-71-1770 Joint
1 Joint diameter: 10 mm
6217-71-8820
Commercially
available
Commercially
available
Commercially
available
Commercially
available
Commercially
available
Joint
1 Joint diameter: 14 mm
Hose
1 Size x Length: f 5 mm x 2 - 3 m
Hose
1 Size x Length: f 15 mm x 2 - 3 m
Measuring cylinder
1 Capacity: 2 l
Stopwatch
Dial gauge
1 With magnet
Fuel return rate and leakage
4
J
5
6
7
Swing circle bearing clearance

Work equipment, swing and
travel circuit oil pressures
PC800, 850-8E0
N
K

{25, 60, 400, 600 kg/cm2}

{25, 60, 400, 600 kg/cm2}
30-3
Symbol
Control circuit oil pressure
Part number
Part name
790-261-1204
1
Control oil pressure of main
M
pump
2
3
799-101-5002
790-261-1204
799-401-2701
799-101-5220
07002-11023
799-101-5002
Remarks

{25, 60, 400, 600 kg/cm2}
Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
Hydraulic tester
1
{25, 60, 400, 600 kg/cm2}
Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
Differential pressure
1
gauge
Nipple
2 Size: 10 x 1.25 mm
O-ring
2
Hydraulic tester
1
{25, 60, 400, 600 kg/cm2}
Q'ty


PPC valve output pressure
799-401-3200 Adapter
1 Size: 03
2
02896-11009 O-ring
3
799-401-2701
Differential pressure
gauge
1
1

{25, 60, 400, 600 kg/cm2}

Outlet pressure of solenoid
valve, swing PPC shuttle
valve, and swing priority
selector valve
799-401-3200 Adapter
1 Size: 03
2
Q
02896-11009 O-ring
799-401-3300 Adapter
1 Size:04
3
02896-11012 O-ring
799-101-5220 Nipple
2 Size: 10 x 1.25 mm
07002-11023 O-ring
799-205-1100 Multiple tachometer
1 L: 60 2,000 rpm H: 60 19,999 rpm
4
Fan speed
Fan circuit oil pressure

{25, 60, 400, 600 kg/cm2}

Oil leakage
Commercially
Measuring cylinder
available
1
outlet pressure

{25, 60, 400, 600 kg/cm2}
799-101-5220 Nipple
1 Size: 10 x 1.25 mm
07002-11023 O-ring
2
Wear of sprocket
796-627-1110 Wear gauge
Coolant temperature and oil

temperature
1 -99.9 1,299 C
Operating effort and

depressing effort
79A-264-0021 Push-pull scale
1 0 294 N {0 30 kg}
79A-264-0091 Push-pull scale
1 0 490 N {0 50 kg}
Measuring stroke and

hydraulic drift
30-4
Commercially
Ruler
available
Commercially
Stopwatch
available
1
1
PC800, 850-8E0
Symbol
Voltage and resistance
Removal and installation of

engine coolant temperature sensor
Diagnosis of sensor and

harness
PC800, 850-8E0
Part number
Part name
Commercially
Multimeter
available
Commercially
Socket
available
Q'ty

Remarks
799-601-7400 T-adapter assembly
21 mm deep socket (MITOLOY

4ML-21 or equivalent)
19 mm deep socket (MITOLOY
1
4ML-19 or equivalent)
1 SWP, X and M connectors
1 AMP070 connector
1 DT and HD30 connectors
795T-981-1010 Socket
1 DRC26-24, 40-pin
799-601-7360 Adapter
1 Relay (5-pin)
799-601-9420 T-adapter
1 Pressure sensor
1 Engine-related connectors
795-799-5530 Adapter
1 Engine coolant, oil, fuel temperature
799-799-5540 Adapter
1 Boost temperature sensor
799-601-4130 T-adapter
1 Ne Sensor
799-601-4150 T-adapter
1 Oil pressure sensor
799-601-4211 T-adapter
1 Controller (50 poles)
799-601-4220 T-adapter
799-601-4240 Socket
1 Ambient pressure sensor
799-601-4110 Socket
1 Boost pressure sensor
799-601-9460 T-adapter
799-601-9020 T-adapter
1 Injector
799-601-9420 T-adapter
1 Common rail pressure sensor
799-601-9430 Adapter
1 Supply pump PCV
799-601-4330 T-adapter
1 G sensor
30-5

Sketches of special tools
30-6
Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
Socket
30-6
PC800, 850-8E0

Testing engine speed

30-7
30-7
a Measure the engine speed under the following

conditions.
q Engine coolant temperature: within operating
range
q Hydraulic oil temperature: 45 - 55 C
1. Preparation work
Turn the starting switch to the ON position and
then switch the machine monitor display to
Monitoring.
a For operating method, see "Special functions
of machine monitor".
a Monitoring code: 01002 Engine Speed
01006 Engine Speed
a Engine speed is indicated in multiple of 1
r/min (1 rpm).
2. Measuring low idle speed

1) Start the engine and set the fuel control dial
to the low idle (MIN) position.
2) Set the work equipment control, swing
control, and travel levers to NEUTRAL position and measure the engine speed.
4. Measuring the speed when all of the pump

circuits are relieved
to the high idle (MAX) position.
2) Set the working mode switch to the Power
Mode (P).
3) Set the heavy-duty lift mode switch to the
OFF position.
4) Relieve the boom RAISE circuit and measure
the engine speed.
5. Measuring the speed when the heavy-duty
lift mode switch is set to ON position and all
of the pump circuits are relieved
Mode (P).
3) Set the heavy-duty lift mode switch to the
OFF position.
4) Relieve the boom RAISE circuit and measure
the engine speed.
6. Measuring the speed when auto-deceleration
is operated
2) Set the auto-deceleration switch to the ON
position.
3) Set the work equipment control, swing
control, and travel control levers to the
NEUTRAL position. When the auto-decelerator operates, measure the engine speed.
a The engine speed lowers to a certain level approximately 6 seconds after all the
levers are set to the NEUTRAL position.
This level is the auto-deceleration speed.
3. Measuring high idle speed

Mode (P).
3) Set the auto-deceleration switch to the OFF
position.
PC800, 850-8E0
30-7

Testing intake air pressure (boost pressure)

a Testing tools for intake air pressure (boost pressure)
Symbol
A
Part number
Part name
799-201-2202 Boost gauge kit
a Be careful not to touch any hot part of the engine

when removing or installing the testing tools.
a Measure the intake air pressure (boost pressure) under the following condition.
range
1. Open the engine compartment cover on the
counterweight side.
2. Remove intake air pressure (boost pressure)
pickup port plug (1).
3. Install nipple [1] of the boost gauge kit A and

connect gauge [2] to it.
30-8
30-8
4. Run the engine at middle or higher speed and

bleed oil from the hose.
a Insert the hose connector halfway into the
gauge in order to open the self-seal in the
hose connector. Repeating this action bleeds
the oil in the hose.
a If Pm kit (799-401-2301) is available, the air
bleed coupling (790-261-1130) inside the kit
can also be used.
a If oil is left in the hose, the gauge does not
work. Accordingly, be sure to purge the oil.
5. Set the working mode switch to the Power Mode
(P) and set the heavy-duty lift mode switch to the
ON position.
6. Measure the intake air pressure (boost pressure) when the engine speed is set to high idle
and the boom RAISE circuit is relieved.
7. After finishing test remove the testing tools and

return the removed parts.
PC800, 850-8E0

Testing exhaust gas temperature

a Testing tools for exhaust gas temperature
Symbol
B
Part number
Part name
Install or remove the testing tools after the

exhaust manifold temperature has lowered.
a Measure the exhaust gas temperature under the
following conditions.
range
counterweight side.
2. Remove exhaust gas temperature pickup port
plug (2).
a You may remove either of the two plugs.
3. Install sensor [1] of digital thermometer B and

connect it to meter [2].
a Clamp the harness of the digital thermometer
to prevent it from touching any hot part during
measurement.
PC800, 850-8E0
30-9
4. A procedure of measuring the maximum in troubleshooting
Measurement of the maximum exhaust gas
temperature must be done under actual working
conditions.
a Use the digital thermometer in the PEAK
mode.
5. Procedure for testing periodically for preventive
maintenance service (Pm clinic), etc.
Mode (P).
2) Set the heavy-duty lift mode switch to the ON
position.
3) Run the engine at high speed and then,
relieve the boom circuit by raising the boom,
and measure the exhaust gas temperature.
a Measure and record the exhaust gas temperature after making sure it is stabilized.

q Clean the threaded portion of the removed
plug, apply seizure prevention compound to
the plug and install it again.
2 Plug:
Seizure prevention compound (LC-G)
3 Plug:
2.9 5.9 Nm {0.3 0.6 kgm}
30-9

Testing exhaust gas color
30-10
a Testing tools for exhaust gas color

Symbol
Part name
799-201-9001 Handy smoke checker
Commercially
Smoke meter
available
C
k
Part number
2. Testing by using smoke meter C2

1) Insert probe [1] of smoke meter C2 to the
outlet of exhaust pipe (1) and fix it to the
exhaust pipe by using a clip.
Be careful not to touch the highly heated

parts, while removing and installing a testing
tool.
a If an air source and a electric power source are
not available in the field, use handy smoke
checker C1. When recording official data, etc.,
use smoke meter C2.
a Measure exhaust gas color under the following
conditions:
range
1. Testing by using handy smoke checker C1
1) Stock a sheet of filter paper to smoke
checker C1.
2) Insert the exhaust gas intake pipe in exhaust
pipe (1).
3) Start the engine.
4) Accelerate the engine sharply or run it at high
speed and operate the handle of the smoke
checker (C1) to absorb exhaust gas to the
filter paper.
2) Connect the probe hose, accelerator switch

outlet and air hose to smoke meter C2.
a Limit the supplied air pressure to 1.5 MPa
{15 kg/cm2} or below.
3) Connect the power cable to an AC receptacle.
a Check that the smoke meter power switch
is in the OFF position, before connecting
the power cable to the receptacle.
4) Loosen the cap nut of the suction pump and
place the filter paper.
a Fit the filtering paper securely so that air
does not leak.
5) Turn the power switch of smoke meter C2
ON.
5) Remove the filter paper and compare it with

the attached scale for judgement.
6) After finishing test remove the testing tools
and return the removed parts.
6) Start the engine.
7) Accelerate the engine sharply or run it at high
speed and press down the accelerator pedal
of the smoke meter C2 to absorb exhaust gas
to the filter paper.
30-10
PC800, 850-8E0

8) Put the polluted filter paper on non-polluted

filter paper (more than 10 sheets) in the filter
paper holder, and read the indicated value.
PC800, 850-8E0
30-11

Adjusting valve clearance
30-12
a Adjusting tools for valve clearance

Symbol
D
Part number
Part name
Commercially
Feeler gauge
available
1. Remove the engine hood assembly and muffler

(7).
4 Engine hood assembly:
340 kg
2. Remove all cylinder head covers (1).
3. Rotate the crankshaft in the normal direction in

order to bring the stamped 1.6TOP line (a) of
the damper to pointer (2) and set the No. 1
cylinder to the compression top dead center.
a Check the pointer from the alternator side.
a Crank the engine with the hexagonal part at
the water pump drive shaft on the alternator
side.
a When No. 1 cylinder is at the top dead center,
its rocker arm can be manually moved as
much as the valve clearance.If it cannot be
moved, that means that No. 1 cylinder is not
yet at the top dead center. In that case, rotate
it by one more turn.
30-12
4. Insert clearance gauge (D) in clearance (b)

between rocker arm (5) and crosshead (6), and
turn adjustment screw (3) to adjust the valve
clearance.
a With the feeler gauge inserted, turn the adjustment screw to a degree that you can
move the feeler gauge with some resistance.
a Valve clearance:
Intake valve: 0.35 mm, Exhaust valve: 0.57
mm
5. While fixing adjustment screw (3), tighten lock
nut (4).
3 Lock nut:
45.1 51.0 Nm {4.6 5.2 kgm}
a After tightening the lock nut, check the valve
clearance again.
6. Rotate the crankshaft 120 each time in the

normal direction and repeat Steps 2 to 4 in order
to adjust the valve clearance of each cylinder
according to the firing order.
q Firing order: 1 5 3 6 2 4
7. After finishing adjustment, return the removed
parts.
3 Cylinder head cover mounting bolt:
29.4 34.3 Nm {3.0 3.5 kgm}
PC800, 850-8E0

Testing compression pressure
30-13
a Testing tools for compression pressure

Symbol
1
E
Part number
Part name
a Pass a wire, etc. under the fuel path projected sideways and pull up the injector (Do not
pry the injector top up).
795-502-1590 Compression gauge

795-471-1310 Adapter
2
6217-71-6110 Gasket
k
Be careful not to get burnt by touching the

exhaust manifold or muffler, or get caught
with a rotating parts, while taking measurement of compression pressure.
a Measure the compression pressure under the
following condition.
q Engine oil temperature: 40 - 60 C
1. Remove the engine hood assembly and muffler.
4 Engine hood assembly:
Approx. 340 kg
2. Remove head cover (1) of the cylinder to
measure the compression pressure.
5. Install adapter E2 to the injector mounting hole

and connect compression gauge E1.
a Fit the gasket to the injector end without fail
a Fix the adapter with the injector holder.
3 Injector holder mounting bolt:
58.8 73.5 Nm {6.0 7.5 kgm}
a If a small amount of engine oil is applied to
the connecting portions of the adapter and
gauge, sealing properties will be improved.
6. Install rocker arm assembly (2) and adjust the
valve clearance.
3 Rocker arm assembly mounting bolt:
93 103 Nm {9.5 10.5 kgm}
a See "Adjusting valve clearance".
3. Bring the cylinder to be tested to the compression top dead center and remove rocker arm
assembly (2).
a See Disassembly and assembly, Removal
and installation of fuel injector assembly.
4. Disconnect fuel high-pressure tube (3) and
injector wiring harness and remove injector (4).
a Disconnect the terminal of the injector harness on the injector side and the bracket on
the rocker housing side and remove the injector harness (Loosen the two terminal nuts
alternately).
PC800, 850-8E0
30-13

7. Select the no injection cranking mode by operating the machine monitor.

k If the engine is not set in the no injection
cranking mode, it will start and will be
dangerous. Accordingly, be sure to set
the engine in this mode.
8. Crank the engine by using the starting motor and
measure the compression pressure.
a Read the pressure gauge pointer when it is
stabilized.
3) Tighten the nut on the injector side.

3 Nut:
2 0.2 Nm {0.2 0.02 kgm}
4) Secure the clamp and spacer with the bolt.
3 Rocker arm assembly mounting
bolt:
93 103 Nm {9.5 10.5 kgm}
a Adjust the valve clearance. For details, see
Adjusting valve clearance.
29.4 34.3 {3.0 3.5 kgm}

a Install the injector and fuel high-pressure
tube according to the following procedure.
1) Push in injector (11) with the hand to
assemble holder (12) lightly.
2) Tighten bolt (13) and washer (14) lightly.
2 Spherical surface of washer:
Engine oil
3) Tighten sleeve nut (15) of the fuel high-pressure tube lightly.
4) Tighten bolt (13) to the specified torque.
3 Mounting bolt:
58.8 73.5 Nm {6.0 7.5 kgm}
5) Tighten sleeve nut (15) to the specified
torque.
3 Sleeve nut:
39.2 49.0 Nm {4 5 kgm}
a Install the injector harness according to the

following procedure.
1) Install the injector harness to the rocker arm
housing and fix the connector side with the
plate.
2) Fix the intermediate clamp with the clip.
30-14
PC800, 850-8E0

Testing blowby pressure
30-15
a Testing tools for blowby pressure

Symbol
F
Part number
Part name
799-201-1504 Blowby checker
a Test the blowby pressure under the following

conditions.
range
1. Pull blowby hose out of hose guard (1) and
install nozzle [1] of blowby checker F.
a The hose is too short to take it out from under
cover (2).
2. Connect nozzle [1] and gauge [3] with the hose.
3. Start the engine and set the working mode

switch to the Power Mode (P).
4. While running the engine at full speed, relieve
the arm circuit by arm IN operation and test the
blowby pressure.

PC800, 850-8E0
30-15

Testing engine oil pressure
30-16
a Testing tools for engine oil pressure

Symbol
G
1
2
Part number
Part name
4. Start the engine and measure the oil pressure

with the engine at low idle and high idle.

790-261-1204 Digital hydraulic tester
a Measure the engine oil pressure under the following conditions.

range
1. Open the cover on the left of the engine compartment.
2. Remove oil pressure pickup port plug (1) from
the cylinder block.
3. Install nipple [1] of hydraulic tester G1 and

connect it to hydraulic gauge G2 (1.0 MPa
{10 kg/cm2}).
30-16
PC800, 850-8E0

Testing EGR valve and bypass valve drive pressure

a Measuring tools for EGR valve and bypass valve
drive pressure
Symbol
Part number
Part name

V
30-17
3. Install nipple [1] of hydraulic tester V and

connect hydraulic gauge [2] (2.5 MPa
{25 kg/cm2}).
4. Start the engine and measure the oil pressure at
low idle and high idle.
1. Open the inspection cover on the left side of the

engine.
2. Remove oil pressure pickup port plug (2) (R1/8)
on the left side of timing gear cover (1).
5. After finishing test, remove the testing tools and

a Remove old liquid gasket remained on
threaded portion of the removed plug using a
wire brush, and then apply adhesive or liquid
gasket to the plug and install it again.
2 Plug:
Adhesive (LT-2) or
Liquid gasket (LG-4)
3 Plug:
9.8 19.6 Nm {1.0 2.0 kgm}
PC800, 850-8E0
30-17

Handling fuel system parts
30-18
a Precautions in Inspection and Maintenance of

Fuel System
The common rail fuel injection system (CRI)
consists of more precise parts than the conventional fuel injection pump and nozzles. If foreign
matter enters this system, it can cause a trouble.
During inspection and maintenance of the fuel
system, pay more attention to foreign matters
than in case of usual fuel injection system and
wash the system carefully with clean fuel if dusts
enter the system.
a Precautions for replacing fuel filter cartridge
Be sure to use the Komatsu genuine fuel filter
cartridge.
The common rail fuel injection system (CRI)
consists of more precise parts than the conventional fuel injection pump and nozzle. It employs
a high-efficiency special filter to prevent foreign
matter from entering it.
If a filter other than the genuine one is used, the
fuel system may have a trouble. Accordingly,
never use such a filter.
30-18
PC800, 850-8E0

Releasing remaining pressure from fuel system
30-19
a Pressure is generated in the low-pressure circuit

and high-pressure circuit of the fuel system while
the engine is running.
Low pressure circuit Feed pump Fuel main
filter Fuel supply pump
High-pressure circuit: Fuel supply pump
Common rail Fuel injector
a The pressure in both low-pressure circuit and
high-pressure circuit lowers to a safety level automatically 30 seconds after the engine is
stopped.
a Before checking the fuel system and installing
and removing its parts, the remaining pressure
in the fuel system must be released completely.
Accordingly, observe the following.
k Before checking the fuel system, or installing
or removing its parts, wait at least 30 seconds after stopping the engine until the remaining pressure in the fuel system is
released. (Do not start the work just after
stopping the engine since there is the remaining pressure.)
PC800, 850-8E0
30-19

Testing fuel pressure
30-20
a Testing tools for fuel pressure

Symbol
Part number
Part name

1
H
2
3
4. Start the engine and measure fuel pressure at

the time of high idle.
a If the fuel pressure is in the following range, it
is normal.
Engine speed
Fuel pressure
At high idle
0.15 0.3 MPa

{1.5 3 kg/cm2}
795-471-1450 Adapter (8 x 1.25 o R1/8)

07005-00812 Gasket
a Measure fuel pressure in the low pressure circuit

among the feed pump the fuel filter the fuel
supply pump.
k Since very high pressure are generated in
the high pressure circuit among the fuel supply pump the common rail the fuel injector, they cannot be measured in the circuit.
1. Open the cover on the left of the engine compartment.
2. Remove the fuel pressure pickup port plug (1).

3. Install adapter H3 and nipple [1] of hydraulic

tester H1, and then connect them to hydraulic
gauge H2 (1.0 MPa {10 kg/cm2}).
30-20
PC800, 850-8E0

Testing fuel return rate and leakage
a If the engine has the intake manifold equipped

with the return block on it to return the fuel spilling from the injector to the fuel tank, test the fuel
return rate and fuel leakage according to the following procedure.
a Testing tools for fuel return rate and leakage
Symbol
1
2
3
4
J
5
6
7
Part number
6151-51-8490
6206-71-1770
6217-71-8820
Commercially
available
Commercially
available
Commercially
available
Commercially
available
Part name
Spacer
Joint
Joint
30-21
1. Preparation work
1) Remove tube (3) between common rail (1)
and supply pump (2).
2) Insert spacer J1 into supply pump (2) side
and tighten the removed joint bolt again.
a Connect the return pipe to the fuel tank
again, too.
a Be sure to fit the gaskets to both ends of
the spacer.
Hose (5 mm x 2 3 m)
Hose (15 mm x 2 3 m)
Measuring cylinder
Stopwatch
a Since some fuel flows out during test, prepare an

oil container of approximately 20 l.
PC800, 850-8E0
30-21

3) Insert joint J2 to common rail (1) side and

tighten the currently removed joint bolt again.
a Be sure to fit the gaskets to both ends of
the joint.
4) Connect test hose J4 to the end of joint J2.
a Bind the connecting part of the test hose
with a wire, etc. to prevent it from coming
off.
a The above is the preparation work for
testing the leakage from the pressure limiter.
2. Testing leakage from pressure limiter

1) Adjust the route of test hose J4 so that it does
not slacken and put its end in an oil container.
2) Set the machine monitor so that it can
measure the engine speed.
3) Start the engine and keep it running at the
rated load.
(Boom RAISE relief in the Power Mode (P))
4) After the engine speed is stabilized, test the
oil leakage in 1 minute using measuring
cylinder J6.
a You may test for 20 seconds and judge by
multiplying the result by 3.
a If the leakage from the pressure limiter is
in the following range, it is normal.
30-22
Engine speed (rpm)
Oil leakage (cc/min)
At rated output
Max. 10
5) After finishing testing, stop the engine.

3. Testing return rate from injector
a Keep the hose on the pressure limiter side
connected and keep its end in the oil container while testing the return rate from the injector.
1) Disconnect return hose (6) to fuel tank, install
joint J3, and connect test hose J5.
a Bind the connecting part of the test hose

with a wire, etc. to prevent it from coming
off.
PC800, 850-8E0

2) Route test hose J5 so that it does not

slacken, and put its end in an oil container.
6) After finishing testing, stop the engine.
3) Set the machine monitor so that it can

measure the engine speed.
4) Start the engine, set working mode to the
Power Mode (P), set the heavy-duty lift mode
switch to ON position, and relieve the boom
RAISE circuit.
5) After the engine speed is stabilized, test the
return rate in 1 minute using measuring
cylinder J6.
a You may test for 20 seconds and judge by
multiplying the result by 3.
a If the supply pump is not supplying fuel,
the engine speed may not rise. In this
case, record the engine speed, too, during the test.
a Injector return (spill) rate
Rated output speed
(rpm)
1,600
1,700
1,800
1,900
2,000
PC800, 850-8E0
4. Work after finishing testing

After finishing test, remove the testing tools and
3
Joint bolt for common rail pressure

limiter:
17.7 22.6 Nm {1.8 2.3 kgm}
Joint bolt for supply pump overflow:
14.8 19.6 Nm {1.5 2.0 kgm}
Limit of return rate

(spill) (cc/min)
960
1,020
1,080
1,140
1,200
30-23

Bleeding air from fuel circuit
30-24
a If fuel is used up or if a fuel circuit part is removed

and installed, bleed air from the fuel circuit according to the following procedure.
1. Remove fuel prefilter (1) and fill it with fuel.
a Fill the fuel prefilter with clean fuel and take
care that dirt does not enter it.
a Check that the cap is fitted to part (a) (central
hole) of the fuel prefilter, and then add fuel
through part (b) (holes around the central
hole).
a After filling the fuel prefilter with fuel, remove
the cap from part (a).
a If clean fuel is not available, do not remove
the prefilter but fill it by using the fuel by operating priming pump (4).
a Do not add fuel to fuel main filter (2) from outside.
2. Install fuel prefilter (1) to the filter head.

a Thinly apply engine oil to the packing surface
on the fuel prefilter.
a After the packing surface on the fuel prefilter
side touches the seal surface of the filter
head, tighten the fuel prefilter by 3/4 turns.
3. Remove air bleeding port plug (3) of the main

fuel filter and operate priming pump (4).
a For plug (3), see the illustration on the next
page.
30-24
PC800, 850-8E0

a Operate the priming pump until fuel flows out

of the plug hole. After fuel starts flowing out,
install plug (3).
3 Air bleeding port plug:
7.8 9.8 Nm {0.8 1.0 kgm}
6. Crank the engine by using the starting motor.

a The air in the high-pressure circuit is bled automatically by cranking the engine.
a If the engine does not start, there may be still
air in the low-pressure circuit. In this case, repeat the above procedure from step 3.
4. Loosen air bleeding port plug (5) of the main fuel

filter and operate priming pump (4).
of the plug hole. After fuel starts flowing out,
install plug (5).
3 Air bleeding port plug:
7.8 9.8 Nm {0.8 1.0 kgm}
5. Loosen air bleeder (6) of the fuel supply pump
and operate priming pump (4) 90 to 100 times.
of the bleeder. After fuel starts flowing out,
tighten the bleeder and operate the priming
pump several times until it becomes heavy.
3 Air bleeder:
4.9 6.9 Nm {0.5 0.7 kgm}
PC800, 850-8E0
30-25

Testing fuel circuit for leakage
30-26
Very high pressure is generated in the

high-pressure circuit of the fuel system. If
fuel leaks while the engine is running, it presents a serious danger that could result in a
fire.
After checking the fuel system or removing
its parts, check it for fuel leakage according
to the following procedure.
a Clean and degrease the engine and the parts
around it in advance so that you can check it
easily for fuel leakage.
9. Stop the engine and check the fuel piping and

devices for fuel leakage.
a Check mainly around the high-pressure circuit parts coated with the color checker for
fuel leakage.
a If any fuel leakage is detected, repair it and
check again from step 1.
a If no fuel leakage is detected, check is completed.
1. Spray color checker (developer) over the fuel

supply pump, common rail, fuel injector, and
joints of the high-pressure piping.
2. Run the engine at a speed below 1,000 rpm and
stop it after its speed is stabilized.
fuel leakage.
4. Run the engine at low idle for a while.
fuel leakage.
6. Run the engine at high idle for a while.
fuel leakage.
8. Start the engine and run it at high idle, then
perform the hydraulic pump relief operation, etc.
30-26
PC800, 850-8E0

Testing and adjusting alternator belt tension
30-27
Testing
30-27
counterweight side.
30-27
Adjust
a Adjust the belt according to the following procedure when the belt deflection is not normal.
2. Press the intermediate point of the belt between

fan pulley and compressor pulley with a thumb
and measure deflection (a) of the belt.
a Pressing effort: Deflection (a) when pressed
with approximately 98 N {approximately 10
kg}:
13 - 16 mm (a single belt)
1. Loosen nuts and bolts (1), (2), (3) and (4) in this
order.
PC800, 850-8E0
2. Turn nut (5) to move alternator (6), and adjust

the belt tension.
a If nut (5) is
q turned clockwise, the belt is loosened.
q turned counterclockwise, the belt is
tensed.
a Check the pulleys for breakage, V-groove for
wear, V-belt for wear and contact of the
V-belt and V-groove for any trouble.
a Replace the belt with a new one if it is too
much stretched and lose adjustment allowance, or cut or cracked.
3. Tighten nuts and bolts (4), (3), (2) and (1) in this
order.
a When the V-belt is replaced, measure its deflection again after one-hour operation and
then readjust it if necessary.
30-27

Testing and adjusting air conditioner compressor belt tension
Testing and adjusting air conditioner compressor belt tension

Testing
30-28
control valve side and remove the cover of the
air conditioner compressor belt.
30-28
3. Tighten nuts and bolts in the order of (3), (2), and

(1).
a When the V-belt is replaced, measure its deflection again after one-hour operation and
then readjust it if necessary.
2. Press the intermediate point between the air

conditioner compressor pulley and drive pulley
with a thumb and measure deflection (a).
a Pressing effort: Deflection (a) when pressed
with approximately 58.8 N {approximately 6
kg}:
10 15 mm
30-28
Adjust
a If the belt deflection is abnormal, adjust it according to the following procedure.
1. Loosen the bolts and nuts in the order of (1), (2),
and (3).
2. Turn nut (4) to move compressor (5) and adjust
the belt tension.
a If nut (4) is
q turned clockwise, the belt is loosened.
q turned counterclockwise, the belt is
tensed.
a Check the pulleys for breakage, V-groove for
wear, V-belt for wear and contact of the
V-belt and V-groove for any trouble.
a Replace the belt with a new one if it is too
much stretched and lose adjustment allowance, or cut or cracked.
30-28
PC800, 850-8E0

Testing swing circle bearing clearance
30-29
30-29
a Testing tools for swing circle bearing clearance

Symbol
Part number
Commercially
available
Part name
Dial gauge
(with magnet)
a When measuring swing circle bearing clearance

on machine, follow the procedures below:
a For the standard values, see Structure, function
and maintenance standard, Swing circle.
3. Set the reading of dial gauge N to the zero point.

4. Arrange the arm almost at right angles to the
ground and lower the boom until the front end of
the track rises off the ground.
a At the time, the front side of the upper structure rises and the rear side lowers.
1. Fix dial gauge N to the track frame (center

frame) and apply the probe to the outer race end
face.
a Set the dial gauge to the front or to the rear of
the machine.
5. Read the value indicated on dial gauge N of this

time. This dial gauge reading represents the
clearance of bearing of swing circle.
k During the measurement, never place
hands and legs below the undercarriage.
2. Extend the work equipment to the maximum

reach and set the bucket tip at the height of the
revolving frame lower face.
a At this time, the front side of the upper structure lowers and the rear side rises.
PC800, 850-8E0
6. Restore the condition of step 2 and check that

dial gauge N indicates 0. If dial gauge pointer is
not returned to zero point, repeat the steps 2
through 5.
30-29

Checking and adjusting track tension

Testing
30-30
1. Run the engine at low idle and move the
machine forward by the length of track on the
ground, and then stop the machine slowly.
2. Place steel bar [1] on the track shoes located
between second carrier roller (1) and third carrier
roller (2).
a L beam is recommended for bar [1] because
of its deflection-free nature.
3. Measure maximum clearance (a) between steel
bar [1] and track shoe.
q Standard maximum clearance (a): 10 - 30
mm
30-30
30-30
30-30
Adjust
a If the track tension is improper, adjust it according to the following procedure.
1. If tension is too high:
Loosen valve (3) to discharge the grease.
k Do not loosen the valve more than one
turn. Otherwise, the valve jumps out because of the high-pressure grease inside.
2. If tension is too low:
Pump in grease through fitting (4).
a If the normal track tension is not restored
even after greasing, move the machine slowly back and forth.
PC800, 850-8E0
Hydraulic system
Testing and adjusting oil pressure in work equipment, swing, and travel circuits
Hydraulic system
30-31
Testing and adjusting oil pressure in work equipment, swing, and travel
30-31
circuits
a Testing and adjusting tools for oil pressure in
work equipment, swing, and travel circuits
Symbol
Part number
Part name

K
30-31
Testing
a Measure the hydraulic pressure in the work
equipment, swing, and travel circuits under the
a The oil pressure in the work equipment, swing,
and travel circuits can be checked also by using
monitoring function of the monitor panel, too (For
details, see Special functions of monitor panel).
q Monitoring code: 01100 F Pump Pressure
q Monitoring code: 01101 R Pump Pressure
q Pump oil pressure is indicated in multiples of 0.1
MPa (1 kg/cm2,1PSI).
PC800, 850-8E0
1. Preparation work
k Lower the work equipment to the ground
and stop the engine. Then, operate the
control levers several times to release the
remaining pressure in the piping and
loosen the hydraulic tank cap gradually to
release the pressure inside the hydraulic
tank.
1) Open the pump room cover.
2) Connect oil pressure gauges [1] of hydraulic
tester (K) to quick couplers (1) and (2)
installed to the outlet of each pump of the
circuit to be measured.
a (1) is on the front pump side and (2) is on
the rear pump side.
a The relief pressure in the boom LOWER
circuit can be measured only in the front
pump circuit.
a The relief pressure of the bucket DUMP
circuit can be measured only in the rear
pump circuit.
a The relief pressure of the swing circuit
can be measured only in the front pump
circuit.
a Use an oil pressure gauge of 58.8 MPa
{600 kg/cm2}.
30-31
Hydraulic system
2. Measuring oil pressure in work equipment

1) Measuring of normal relief pressure
a The case where the boom cylinder is set
to the stroke end is explained below.
1] Start the engine and set the working
mode switch to the Power Mode (P) position.
2] Run the engine at high idle and then,
relieve the oil circuit at the stroke end of
each cylinder respectively, and measure
the oil pressure.
a The main relief valves of the right and
left control valves relieve on the
low-pressure setting side.
a If the boom cylinder is relieved at the
LOWER stroke end, the suction safety
valve on the boom head side of the
right 4-spool valve relieves on the
low-pressure setting side. (because
the set pressure of the suction safety
valve is lower than that of the main relief valve).
2) Measuring relief pressure in the heavy-duty
lift mode operation
a The case where the boom cylinder is set
to the stroke end is explained below.
2] Set the heavy lift switch to ON position.
relieve the boom cylinder circuit only at
the RAISE stroke end, and measure the
hydraulic pressure.
a The heavy-duty lift mode function
works when only the boom RAISE operation is operated independently.
a The main relief valves of the right and
left control valves relieve on the
high-pressure setting side.
3) Measuring relief pressure during machine
push-up operation
2] Set the machine push-up switch to ON
position.
relieve the boom cylinder circuit only at
the LOWER stroke end, and measure the
oil pressure.
a The set pressure of the suction safety
valve on the boom head side of the
R.H. 4-spool valve rises higher than
the set pressure of the main relief
valve, so the main relief valve relieves
on the low-pressure setting side.
30-32
3. Measuring oil pressure in swing circuit

1) Start the engine and set the working mode
switch to the Power Mode (P) position.
2) Set the swing lock switch to ON position.
3) Run the engine at high idle and then, relieve
the swing motor circuit, and measure the oil
pressure.
a The safety valves of the front and rear
swing motors relieve. (The set pressure
of the safety valves is lower than that of
the main relief valve.)
PC800, 850-8E0
Hydraulic system
4. Testing oil pressure in travel circuit

1) Run the engine and lock the travel mechanism.
k Put pin [2] between the sprocket and
track frame to lock the travel mechanism securely.
30-3
Adjust
a Do not adjust any safety valve other than the
swing motor safety valve.
a When adjusting the main relief valves of the R.H.
4-spool valve and L.H. 5-spool valve, remove
the control valve top cover.
1. Adjusting main relief valve (high-pressure
setting) of L.H. 5-spool control valve
a If the work equipment oil pressure in the front
pump circuit (during the heavy-duty lift mode
operation) and the left travel oil pressure are
abnormal, adjust the high-pressure setting
side of main relief valve (5) of the L.H 5-spool
control valve according to the following procedure.
2) Run the engine at high idle and then, relieve

the travel motor circuit, and measure the oil
pressure.
a The main relief valves of the right and left
control valves relieve on the high-pressure setting side.
a The high pressure setting is the state in

which the 2-stage relief solenoid valve is energized and the pilot pressure is applied to
the selector port.
1) Disconnect hose (6).
2) Loosen lock nut (7) and set elbow (8) free.
3) While fixing holder (9), loosen lock nut (10).
4) Turn holder (9) to adjust the pressure.
a If the holder is
q turned clockwise, the pressure is increased.
q turned counterclockwise, the pressure
is decreased.
a Pressure of adjustment per turn of holder:
Approx. 20.5 MPa {Approx. 209 kg/cm2}
PC800, 850-8E0
30-33
Hydraulic system
5) While fixing holder (9), tighten lock nut (10).

3 Lock nut:
93 123 Nm {9.5 12.5 kgm}
a Adjusting the high-pressure setting side
changes the setting of the low-pressure
side. Thus, low-pressure setting side requires adjustment, too.
6) While fixing elbow (8) using a spanner,

tighten lock nut (7).
7) Connect hose (6).
8) After finishing adjustment, check the oil pressure again according to the above measurement procedure.
6) While fixing elbow (8), tighten lock nut (7).
7) Connect hose (6).
8) After finishing adjustment, check the
hydraulic pressure again according to the
above measurement procedure.
2. Adjusting main relief valve (low-pressure
setting) of L.H. 5-spool control valve
a If the work equipment oil pressure in the front
pump circuit (during normal relief operation)
is abnormal or the high-pressure setting side
was adjusted, adjust the low-pressure setting
side of main relief valve (5) of L.H. 5-spool
a Low pressure setting is the state that the
2-stage relief solenoid valve is not energized
and the pilot pressure is not applied to the selector port.
1) Disconnect hose (6).
2) Loosen lock nut (7) and set elbow (8) free.
3) While fixing union (11) using a spanner,
loosen lock nut (12).
4) Turn union (11) to adjust the pressure.
a If the union is
is decreased.
a Pressure changed by 1 turn of union:
Approx. 20.5 MPa {approx. 209 kg/cm2}
5) While fixing union (11) using a spanner,
tighten lock nut (12).
3 Lock nut:
3. Adjusting main relief valve (high-pressure

setting) of R.H. 4-spool control valve
a If the work equipment oil pressure in the rear
pump circuit (during the heavy-duty lift mode
operation) and the left travel oil pressure are
abnormal, adjust the high-pressure setting
side of main relief valve(13) of R.H. 4-spool
a Adjust the right 4-spool control valve similarly

to the left 5-spool control valve.
78 - 93 Nm {8.0 - 9.5 kgm}
30-34
PC800, 850-8E0
Hydraulic system
4. Adjusting main relief valve (low-pressure

setting) of R.H. 4-spool control valve
a If the work equipment oil pressure in the rear
pump circuit (during normal relief operation)
is abnormal or the high-pressure setting side
was adjusted, adjust the low-pressure setting
side of main relief valve (13) of R.H. 4-spool
a Adjust the right 4-spool control valve similarly
to the left 5-spool control valve.
a The match marks are for returning the

screw to the original position in the case
where no fault is found.
5. Adjustment of swing motor safety valve

a If the relief pressure of swing motor is abnormal, adjust safety valves (14) and (15) of
swing motor according to the following procedure.
q (14): Safety valve of front swing motor
(15): Safety valve of rear swing motor
a Since the valves are branched to front and

rear swing motors, adjust them in the following procedure.
a If swing starting force is not powerful, or if
swing speed is not fast:
1) Put match marks on the adjustment screw
(16) and body for safety valves (14) and (15)
of front and rear motors.
PC800, 850-8E0
30-35
Hydraulic system
2) Loosen lock nut (17) of safety valve on one

side and tighten adjustment screw (16).
a If the adjustment screw is
is decreased.
a Quantity of pressure adjustment per turn
of adjustment screw:
3.6 MPa {37 kg/cm2}
3 Lock nut:
147 - 186 Nm {15 - 19 kgm}
3) Start the engine, relieve the circuit by locking

the upper structure, and measure the relief
oil pressure.
4) Rise of the oil pressure shows lowering of the
valve set pressure. Adjust the pressure
according to the criteria.
5) If the oil pressure is not changed, return the
valves to the original positions in accordance
with the match marks.
6) Adjust the relief valves on the opposite side
in the same procedures 2) to 4) as described
above.
7) After finishing adjustment, check that the

pressure is normal according to the
measurement procedure described above.
30-36
PC800, 850-8E0
Hydraulic system
Testing and adjusting control circuit oil pressure (output pressure of

self-pressure reducing valve)
30-37
a Testing and adjusting tools for control circuit oil

pressure
Symbol
Part number
Part name

L
30-37
Testing
a Measure the control circuit oil pressure under
the following condition.
k Lower the work equipment to the ground and
stop the engine. Then, operate the control levers several times to release the remaining
pressure in the piping and loosen the hydraulic tank cap gradually to release the
pressure inside the hydraulic tank.
1. Open the pump room cover.
2. Connect oil pressure gauge [1] of hydraulic
tester (L) to oil pressure pickup port nipple (1) of
the main pump.
3. Start the engine and run it at full speed, and

measure the oil pressure when the work equipment/swing lever and travel lever are in
NEUTRAL position.
PC800, 850-8E0
30-37
Hydraulic system
30-38
Adjust
a If the output pressure of the self-pressure reducing valve (control circuit pressure) is abnormal,
adjust self-pressure reducing valve (2) according to the following procedure.
1. Open the pump room cover.

2. While fixing adjusting screw (3), loosen lock nut
(4).
3. Turn adjustment screw (3) and adjust oil pressure.
a Target value: 3.2 - 3.5 MPa {33 - 36 kg/cm2}
q Turned clockwise, the pressure is increased.
q Turned counterclockwise, the pressure is
decreased.
a Change of pressure in 45 turn of adjustment screw:
0.29 MPa {3.0 kg/cm2}
nut (4).
3 Lock nut (4):
49 69 Nm {5 7 kg/cm2}
5. Referring to Measuring, Step 3, measure the
output pressure of the self-pressure reducing
valve.
30-38
PC800, 850-8E0
Hydraulic system
Testing and adjusting control signal of main pump

a Testing and adjusting tools for control signal of
main pump
Symbol
Part number
Part name

1
30-39
3) Install nipple M3 to the plugs and connect it

to oil pressure gauge [1] of hydraulic tester
M1.
a Use an oil pressure gauge of 6 MPa
{60 kg/cm2}.

M
799-401-2701 Differential pressure gauge

799-101-5220 Nipple (10 x 1.25 mm)
3
07002-11023
O-ring
30-39
Testing
a Measure the piston pump control pressure under
stop the engine. Operate the control levers
several times to release the remaining pressure in the piping, and loosen the oil filler cap
of the hydraulic tank gradually to release the
1. Measuring EPC valve output pressure
a Since the source pressure of the EPC valve
is the control circuit pressure, check that the
control circuit pressure (self pressure reducing valve) is normal before measuring the
EPC valve output pressure.
a The EPC valve is controlled with the command current from the pump controller. (For
details, see Structure, function and maintenance standard.)
2) Remove pump output pressure pickup plug
(1) or (2).
a (1) is on the front pump side and (2) is on
the rear pump side.
PC800, 850-8E0

5) Set all control levers in NEUTRAL position
and measure the EPC valve output pressure
under the following condition.
1] Set all control levers in NEUTRAL position.
2] Run the engine at full speed and measure
the output pressure.
6) While the track is rotating under no load,
measure EPC valve output pressure under
1] Raise the track to be measured by using
the boom and arm
2] Run the engine at full speed and then, run
the track idle, and measure the output
pressure.
30-39
Hydraulic system
2. Measuring EPC valve current

a The EPC current can be checked by using
the monitoring function of the machine monitor, too.
(For the operating method, see"Special functions of machine monitor".)
q Monitoring code:
01300 F Pump PC-EPC Sol. Cur.
01302 R Pump PC-EPC Sol. Cur.
and measure the EPC current under the
measure the current.
measure EPC current under the following
condition.
the boom and arm.
2] Run the engine at high idle and then, run
the track idle and measure the current
value.
30-40
3. Measurement of VC valve source pressure

and output pressure
a Since the VC valve output pressure varies
with the output pressure of the EPC valve,
check that the EPC valve output pressure
(Pce1, Pce2) is normal in advance.
q See "Measuring EPC valve outlet pressure"
of Testing and adjusting control signal of
main pump.
a Since the source pressure of the VC valve is
the control circuit pressure and main pump
discharge pressure, check that the control
circuit pressure and main pump discharge
pressure are normal before measuring the
VC valve output pressure.
a Since the VC valve output pressure is judged
by comparing it with the VC valve source
pressure, measure the source pressure at
the same time as well.
2) Remove oil pressure pickup plugs (3) and (5)
or (4) and (6).
a Oil pressure pickup plugs
q For VC valve output pressure
(3): On front pump side
(4): On rear pump side
q For VC valve source pressure
(5): On front pump side
(6): On rear pump side
PC800, 850-8E0
Hydraulic system
3) Install nipple M3 to the plugs and connect it

to oil pressure gauge [1] of hydraulic tester
M1.
{600 kg/cm2}.

5) Set all control levers to NEUTRAL position,
measure the VC valve source pressure and
output pressure under the following condition.
measure the source pressure and output
pressure.
6) When the boom circuit is relieved in raising
operation (normal), measure the VC valve
source pressure and output pressure under
1] Set the heavy-duty lift mode switch to
OFF position.
relieve the boom circuit by raising the
boom, and measure the source pressure
and the output pressure simultaneously.
measure VC valve source pressure and
output pressure under the following condition.
1] Raise the track shoe to be measured by
using the boom and arm
operate the travel lever to the travel end
and measure the source pressure and
output pressure simultaneously.
q L.H travel: On front pump side
q R.H travel: On rear pump side
a See the next page for the judgment table.
PC800, 850-8E0
30-41
Hydraulic system
Judgment table
Operating mode
EPC valve output pressure
(Pce1(Pce2))
(VC valve control pressure)
MPa {kg/cm2}
Servo piston position
When circuit is relieved by

When running track idle
When all control levers are in
boom RAISE operation
(with lever at travel end posiNEUTRAL position
(heavy-duty lift mode switch;
tion)
OFF)
Max. 0.78
{Max. 8}
1.03 1.43
{10.5 14.5}
Min. 1.23
{Min. 1.25}
Contact with stopper on min. Intermediate between min.

Contact with stopper on
swash plate angle side
and max. swash plate angles max. swash plate angle side
VC valve output pressure

Drain pressure of approxiPressure of approximately 1/2 Pressure of approximately
(Pcs1 (Pcs2))
to 1 times of source pressure 1/2 times of source pressure mately 1/2 times of source
(Large-diameter pressure of
pressure
C 1/2Pch1 (Pch2) to Pcs1
C 1/2 x Pch1 (Pch2)
servo piston)
C 1/2 Pch1 (Pch2) to Pd
(Pcs2)
*1
Criterion
*1. Since the swash plate is at the intermediate point, the pressure is about "0.5 to 0.6 times" (approx. 1/2) of the relief
pressure (delivery pressure).
30-42
PC800, 850-8E0
Hydraulic system
4. Measuring jet sensor output differential pressure

a The jet sensor output differential pressure
can be checked also by using the monitoring
function of the machine monitor.
q Monitoring code:
13800 (L-jet sensor differential pressure)
13800 (R-jet sensor differential pressure)
a For the measurement conditions, see 3), 4),
and 5).
1) Remove clamping bolts (3) and (4) of
harness for differential pressure sensor,
remove oil pressure pickup port plugs (5) and
(6) located at bottom of L.H. 5-spool control
valve, and remove oil pressure pickup port
plugs (7) and (8) located at bottom of R.H.
4-spool control valve.
q (5): High pressure side (NCAI) of L.H.
5-spool control valve (F pump)
q (6): Low pressure side (NCBI) of L.H. 5spool control valve (F pump)
q (7): High pressure side (NCA) of L.H.
4-spool control valve (R pump)
q (8): Low pressure side (NCB) of R.H.
4-spool control valve (R pump)

and measure the jet sensor output differential
pressure under the following condition.
the output differential pressure.
a Jet sensor output differential pressure
=
High pressure (NCA) - Low pressure
(NCB)
5) While running the track idle, measure jet
sensor output differential pressure under the
the boom and arm.
the track idle, and measure the output
differential pressure.
a Jet sensor output differential pressure
=
High pressure (NCA) - Low pressure
(NCB)
2) Install test hose [2] of hydraulic tester M1 and

connect it to differential pressure gauge M2
or oil pressure gauge [1].
a When using differential pressure gauge:
Connect high pressure side (5) or (7) to
the differential pressure gauge of high
pressure side (back side) and connect
low pressure side (6) or (8) to the low
pressure side (bottom side).
The differential pressure gauge needs 12
V DC power, so connect a battery to it.
a When using the oil pressure gauge:
Connect 6.0 MPa {60 kg/cm2} to high
pressure side (5) or (7) of oil pressure
gauge and connect 2.5 {25 MPa} to low
pressure side (6) or (8).
PC800, 850-8E0
30-43
Hydraulic system
30-4
Adjust
1. Adjusting jet sensors of L.H. 5-spool control
valve and R.H. 4-spool control valve
a If the differential pressure of jet sensor output
of L.H. 5-spool control valve or R.H. 4-spool
control valve is abnormal, adjust jet sensor
relief valves (19) and (20) according to the
q (19): Jet sensor relief valve of L.H. 5-spool
control valve
q (20): Jet sensor relief valve of R.H. 4-spool
control valve.

5. Measuring output voltage of differential pressure sensor
a The jet sensor output differential pressure
can be checked also by using the monitoring
function of the machine monitor.
q Monitoring code:
13802 L Jet Sensor Vol.
13803 R Jet Sensor Vol.
and measure the voltage under the following
condition.
the voltage.
3) While running the track idle, measure voltage
under the following condition.
the boom and arm.
the track idle and measure the voltage.
1) While fixing adjustment screw (21), loosen

lock nut (22).
2) Turn adjustment screw (21) and adjust oil
pressure.
is decreased.
a Quantity of pressure adjustment per turn
of adjustment screw:
0.288 MPa {2.94 kg/cm2}
3) While fixing adjustment screw (21), tighten
lock nut (22).
3 Lock nut:
59 - 78 Nm {6 - 8 kgm}
21
22
BJ P14786
30-44
PC800, 850-8E0
Hydraulic system
4) After finishing adjustment, check the

hydraulic pressure again according to the
above measurement procedure.
PC800, 850-8E0
30-45
Hydraulic system
Testing PPC valve output pressure

a Testing tools for PPC valve output pressure
Symbol
Part number
Part name

1
P
799-401-3200 Adapter (size: 03)
30-46
3. Install nipple [1] of hydraulic tester P1 and
connect it to oil pressure gauge [2].
{60 kg/cm2}.
a The figure shows the condition that the testing tools are installed to the right travel (reverse) circuit of the left 5-spool control valve.
2
02896-11009
O-ring
a Measure the PPC valve output pressure under

q Hydraulic oil temperature: 45 55 C
stop the engine. Operate the control lever
internal pressure of the tank.
1. Remove the control valve top cover.
2. Disconnect hose (1) of the PPC circuit to be
measured. Install adapter P2 to it and connect
the hose again.
a For the hose to be disconnected, see the
connection diagram of PPC circuit.
30-46
4. Start the engine and run it at full speed, and

operate the control lever of the PPC circuit to be
measured, and measure the oil pressure.
a When measuring, set the lever to the travel
end.
a Condition of actuator to be measured
q When measuring the pressure in PPC circuit for the work equipment, move each
cylinder to the stroke end.
q When measuring the pressure for swing,
set the swing lock switch to ON position.
q When measuring the pressure for travel,
place pin [3] between sprocket and track
frame to lock the track.
PC800, 850-8E0
Hydraulic system

PC800, 850-8E0
30-47
Hydraulic system
Connection diagram of pilot piping (PPC and Solenoid circuit)
30-48
30-48
PC800, 850-8E0
Hydraulic system
a The colors in the parentheses in the figure are the colors of the tapes wound onto the hoses.
PC800, 850-8E0
30-49
Hydraulic system
Measuring outlet pressure of solenoid valve, swing PPC shuttle valve,

30-50
and swing priority selector valve
a Measuring tools for outlet pressures of solenoid
valve, swing PPC shuttle valve, and swing priority selector valve
Symbol
1
2
Q
3
4
Part number
799-101-5002
790-261-1204
799-401-3200
02896-11009
799-401-3300
02896-11012
799-101-5220
07002-11023
(1): PPC lock solenoid valve
(2): Travel speed selector solenoid valve

(3): Swing holding brake solenoid valve
(4): Machine push-up solenoid valve
(5): 2-stage relief solenoid valve
(6): Straight-travel solenoid valve
(7): Swing priority solenoid valve
Part name
Hydraulic tester
Digital hydraulic tester
Adapter (size: 03)
O-ring
Adapter (size: 04)
O-ring
Nipple (10 x 1.25 mm)
O-ring
a Measure the outlet pressures of solenoid valve,

swing PPC shuttle valve, and swing priority selector valve under the following condition.
stop the engine. Operate the control lever
internal pressure of the tank.
1. Measuring outlet pressure of solenoid valve
1) Disconnect the hose to be measured out of
outlet hoses (1) to (8) of the solenoid valves.
Install adapter Q2 and connect the hose
again.
a When measuring the PPC lock solenoid
valve, remove the operator's cab undercover (the 2nd piece on the front side).
a If the hose is connected to the solenoid
valve with a quick coupler, disconnect the
hose at the other end (see the connection
diagram in "Measuring PPC valve output
pressure").
30-50
q
q
q
PC800, 850-8E0
Hydraulic system
2) Install the nipple (R1/8) of hydraulic tester Q1

or nipple Q4(10 x 1.25 mm) and connect it to
oil pressure gauge [1].
a Use the nipple (R1/8) for the adapter of
size #03 and nipple Q4 for the adapter of
size #04.
{60 kg/cm2}.
a The figure shows the condition that the
measuring tools are installed to the outlet
hose of the PPC lock solenoid valve.
3) Start the engine and run it at full speed, and

set the conditions or operate the control
levers as shown in the table, and measure
the output pressure.
a When operating the work equipment,
swing, or travel control lever, operate it
finely to a degree that the PPC oil pressure switch is turned to ON position.
a If the solenoid valve outlet pressure is as
shown in the table, the solenoid valve is
normal.
4) After finishing measurement, remove the

measuring tools and return the removed
parts.
PC800, 850-8E0
30-51
Hydraulic system
Measurement conditions for solenoid valve

a The measurement conditions in the following table are for measuring the solenoid valve outlet pressure and they are
part of the operating condition of each solenoid valve.
Oil pressure
Operation
(MPa
No.
Solenoid valve
Machine operation
of solenoid
{kg/cm2})
q Work equipment lock lever:
Stop the source pressure
0
OFF
LOCK
circuit to the PPC valve.
{0}
Release the source pres1 PPC lock
q Work equipment lock lever:
Min. 2.74
sure circuit to the PPC
ON
FREE
{Min. 28}
valve.
Travel motor swash plate
0
q Travel speed switch: Lo
OFF
Selecting travel
angle at maximum
{0}
2
Travel motor swash plate
Min. 2.74
speed
q Travel speed switch: Hi
ON
angle at minimum
{Min. 28}
q Swing lock switch: ON
q Measure about 10 seconds after
Min. 2.74
work equipment and swing con- Swing brake is applied.
ON
{Min. 28}
trol lever is set in NEUTRAL po3 Swing holding brake
sition.
q Swing lock switch: Set the
switch to OFF position and opMin. 2.74
Swing brake is released.
ON
erate work equipment and
{Min. 28}
swing lever
Boom LOWER safety
valve: High- pressure set0
q Machine push-up switch: ON
OFF
ting
{0}
Machine push-up
4
Boom LOWER safety
valve: Low- pressure setMin. 2.74
q Machine push-up switch: OFF
ON
ting
{Min. 28}
q
Heavy-duty lift mode switch:

Main relief valve : Low
0
OFF
OFF
pressure setting
{0}
q Heavy-duty lift mode switch:
When independent boom
5 2-stage relief
Main relief valve : High
Min. 2.74
RAISE operation is made when
ON
pressure setting
{Min. 28}
the switch is set to ON position
q Travel lever operated
q All control levers in NEUTRAL F pump circuit and R pump
0
OFF
position
circuit are separated.
{0}
q When right/left travel levers and
6 Straight travel
F pump circuit and R pump
Min. 2.74
work equipment or swing lever
ON
circuit are merged.
{Min. 28}
are operated in combination
q Swing priority switch: When
Swing priority function is
Min. 2.35
boom RAISE operation is made
OFF
turned OFF.
{Min. 24}
Swing priority
when the switch is turned OFF
7
q Swing priority switch: When
(See note)
Swing priority function is
0
boom RAISE operation is made
ON
applied.
{0}
when the switch is turned ON
Note: The inlet pressure of the swing priority solenoid valve is the boom RAISE PPC circuit pressure. Accordingly, when
measuring the outlet pressure, move the boom control lever to the RAISE travel end (The boom cylinder can be at the
RAISE travel end).
30-52
PC800, 850-8E0
Hydraulic system
2. Measuring swing PPC shuttle valve

1) Disconnect outlet hose (9) of swing PPC
shuttle valve. Install adapter Q2 and connect
the hose again.
a When measuring the swing PPC shuttle
valve, remove the control valve top cover.

measuring instruments and return the
removed parts.
2) Install the nipple [2] (R1/8) of hydraulic tester

Q1 and connect it to the oil pressure gauge
[1].
{60 kg/cm2}.

operate the control levers as shown in the
table, and measure the output pressure.
a When the swing PPC shuttle valve outlet
pressure is as shown in the table, the
PPC shuttle valve is normal.
Oil pressure
(MPa {kg/cm2})
0
NEUTRAL
{0}
Min. 2.35
Left SWING
{Min. 24}
Min. 2.35
Right SWING
{Min. 24}
L.H. work
equipment
control lever
PC800, 850-8E0
3. Measuring outlet pressure of swing priority

selector valve
1) Disconnect outlet hoses (10) and (11) of
swing priority selector valve. Install adapter
Q2 and connect the hoses again.
a When measuring the swing priority selector valve, remove the control valve top
cover.
q (10): Port A1 (for swing)
q (11): Port A2 (for arm Lo and bucket Hi)
2) Install the nipple (R1/8) of hydraulic tester Q1

and connect it to oil pressure gauge [1].
{600 kg/cm2}.
k Since the outlet pressure of swing priority selector valve is the same as the
main pump pressure, take care not to
connect the oil pressure gauge for low
pressure.
30-53
Hydraulic system

operate the control levers as shown in the
table, and measure the output pressure.
a When swing priority selector valve outlet
pressure is as shown in the table, swing
priority selector valve is normal.
q Port A1 (10) (for swing)
Oil pressure
(MPa {kg/cm2})
Swing priority switch: OFF
0
R.H. work
NEUTRAL
{0}
equipment conSame as main
Boom RAISE
trol lever
pump pressure
Swing priority switch: ON
0
R.H. work
NEUTRAL
{0}
equipment con0
Boom RAISE
trol lever
{0}
Port A2 (11) (For arm Hi and bucket Lo)

NEUTRAL
R.H. work
equipment
control lever
Left SWING
Right SWING
Oil pressure
(MPa {kg/cm2})
0
{0}
Same as main
pump pressure
Same as main
pump pressure

measuring instruments and return the
removed parts.
30-54
PC800, 850-8E0
Hydraulic system
Adjusting play of work equipment and swing PPC vavles
30-5
a If there is excessive play at the tip of the work

equipment or swing lever, adjust at the PPC
valve end as follows.
q Standard play dimension (a): 0.5 - 3 mm at a position 200 mm away from lever rotation center
(both in longitudinal and horizontal directions)
1. Remove bellow (1).
2. Loosen lock nut (2) and rotate disc (3) to adjust
the amount of play.
a While keeping the lever in NEUTRAL position, turn disc (3) to a degree that does not
push in piston.
3. Secure disc (3) in position and tighten lock nut
(2).
3 Lock nut:
98.07 127.49 Nm {10 13 kgm}
4. Install bellow (1).
PC800, 850-8E0
30-55
Hydraulic system
Testing and adjusting travel deviation
30-56
Testing
30-56
a Measure when traveling on firm level ground.
a Hydraulic oil temperature: 45 - 55 C
1. Start the engine and bring the work equipment to
the travel posture.
a To set the machine to the travel posture, extend the bucket cylinder and arm cylinder fully and set the boom angle to 45.
2. Set the working mode switch to the Power Mode
(P) position and set the travel speed switch to
the Lo position.
3. Run up for 10 m with the engine at full speed and
continue travel under the same condition for 20
m and measure the deviation (a).
a Install an oil pressure gauge and measure
the pump delivery pressure at the same time,
(or monitor the pump delivery pressure by using the machine monitor).
30-56
PC800, 850-8E0
Hydraulic system
a Perform troubleshooting for "H-16 Machine deviates in one direction" to identify cause in advance.
30-57
Adjust
a Adjust the deviation with the motor idle running
mode.
a If the main pump is required to be adjusted, adjust the servo piston according to the following
procedure.
a The maximum delivery of the pump is "increased or decreased".
1. While fixing adjustment screw (1), loosen lock
nut (2).
2. Adjust the maximum delivery amount by turning
adjustment screw (1).
q turned clockwise, the delivery is decreased.
(The travel speed is decreased.)
q turned counterclockwise, the delivery is
increased.
(The travel speed is increased.)
a Quantity of adjustment per 45 turn of adjustment screw:
4.9 cm3/rev (equivalent pump delivery
amount)
a Standard pump delivery when shipped out
(for reference):
280 2 cm3/rev
nut (2).
3 Lock nut:
539 647 Nm {55 66 kgm}
PC800, 850-8E0
BJ P14844
30-57
Hydraulic system
Inspecting locations of hydraulic drift in work equipment

a When a hydraulic drift occurred in the work
equipment (cylinder), follow the procedures below to check if the problem is in the cylinder seal
or the control valve.
30-58
2. Testing arm cylinder

1) Stop the arm cylinder at a position approximately 100 mm in front of IN stroke end and
stop the engine.
1. Testing boom cylinder and bucket cylinder

1) Set the work equipment in the same posture
as when measuring hydraulic drift, and stop
the engine.
a Put a weight equivalent to the rated load
or fill the bucket with the earth and sand.
2) Operate the control lever to the arm IN position.

q If the lowering speed is increased at this
time, the cylinder seal is defective.
q If the lowering speed does not change at
this time, the control valve is defective.
2) When checking the boom cylinder, set the
boom control lever to the RAISE position,
when checking the bucket cylinder, set the
bucket control lever to the CURL position.
q If the lowering speed is increased at this
time, the cylinder seal is defective.
q If the lowering speed does not change at
this time, the control valve is defective.
a Operate the work equipment control lever
with the engine starting switch in the ON
position.
a If there is no more pressure in the accumulator, run the engine for approx. 10
seconds to charge the accumulator.
30-58
a Operate the control lever while the starting switch is in the ON position.
a If there is no more pressure in the accumulator, run the engine for approximately
10 seconds to charge the accumulator.
[Reference] Reason why the lowering speed is increased by the above operation when the cylinder
seal is the cause of the hydraulic drift:
1) If the work equipment is set to the above
posture (holding pressure is applied to the
bottom end), the oil at the bottom end leaks
to the head end. However, the volume at the
head end is smaller than the volume at the
bottom end by the volume of the rod, and the
internal pressure in the head end increases
by the oil flown in from the bottom end.
2) As the internal pressure on the head side
increases, both pressures come to balance
at a certain level of pressure (depending on
leakage), and the lowering speed becomes
slow.
3) If the head side circuit is opened to the drain
circuit at the time (the bottom side is closed
by the check valve) by the above lever operation, the oil will flow from the head side to
the drain circuit, which will put internal pressure out of balance and the lowering speed
becomes high.
PC800, 850-8E0
Hydraulic system
Measuring fan speed
Measuring fan speed
30-59
a Measuring tool for fan speed
5. Start the engine and set the fan 100% speed

mode, and measure the fan speed at high idle.
a If the fan is rotated in reverse, the measuring
tools may be sucked in. Be sure to rotate the
fan in normal direction when measuring.
Symbol
R
Part number
Part name
799-203-8001 Multiple tachometer
a Measure the fan speed under the following condition.

1. Open the inspection window cover of the engine
hood.
2. Paste a reflection tape (a) to fan (1).
3. Set probe [1] of multi tachometer R with stand
[2], match it to the reflection tape, and connect it
to meter [3].
a Be careful about the installing position to
avoid interference between probe and fan.
4. Close the cover of the engine hood.
a Do not start the engine without closing the
cover.
PC800, 850-8E0
6. After finishing measurement, remove the

measuring instruments and return the removed
parts.
30-59
Hydraulic system
Measuring fan circuit oil pressure
30-60
a Measuring tools for fan circuit oil pressure

Symbol
Part number
Part name

S
a Measure the fan circuit oil pressure under the following condition.
1. Connect gauge [1] of hydraulic tester S to oil
pressure pickup nipple (1) of the fan pump.
{400 kg/cm2}.
2. Start the engine and measure the fan circuit oil

pressure while running the engine at high idle.

parts.
30-60
PC800, 850-8E0
Hydraulic system
Measuring fan pump EPC current
30-61
a The fan pump EPC current can be checked by

using the monitoring function of the machine
monitor.
(For the operating method, see "Special functions of machine monitor".)
q Monitoring code:
31623 Fan Pump EPC Sol. Curr.
q The current is displayed in mA.
a Measure the fan pump EPC current under the
1. Start the engine and measure the EPC current
while running the engine at high idle.
PC800, 850-8E0
30-61
Hydraulic system
Measuring fan pump EPC solenoid valve outlet pressure

a Measuring tools for fan pump EPC solenoid
valve output pressure
Symbol
Part number
Part name
30-62
2. Install nipple U2 and connect it to oil pressure

gauge [1] of hydraulic tester U1.
{60 kg/cm2}.
1
U
799-101-5220 Nipple (M10 x 1.25 mm)
2
07002-11023
O-ring
a Measure the fan pump EPC solenoid valve output pressure under the following condition.
a Since the source pressure of the EPC solenoid
valve output pressure is the control circuit pressure, check that the control circuit pressure is
normal before measuring the EPC solenoid
valve output pressure.
1. Remove oil pressure pickup port plug (1) from
the top face of fan pump.
30-62
3. Start the engine and measure the solenoid

output pressure while running the engine at high
idle.
parts.
PC800, 850-8E0
Hydraulic system
Measuring oil leakage

a Measuring instruments for oil leakage
Symbol
Part number
Commercially
available
Part name
Measuring cylinder
a Measure the amount of oil leakage under the following condition.

1. Measurement of oil leakage from boom
cylinder
1) Run the engine and move the boom cylinder
to the RAISE stroke end.
k Release the remaining pressure from
the piping on the boom cylinder head
side. For details, see "Release of remaining pressure from hydraulic circuit".
(Operate the lever only in the boom
RAISE direction, however).
2) Disconnect hose (1) on the cylinder head
side and block the hose end by a flange.
k Take care not to disconnect the hose
on the cylinder bottom side.
a Use the following part to block on the
hose end.
07379-01260 (Flange #12)
3) Run the engine at full speed and relieve the

boom circuit by raising the boom.
k Take care not to "lower the boom".
4) Start measuring the oil leakage 30 seconds
after the boom cylinder is relieved and
measure for 1 minute.
5) After completing testing, return the condition
to its original condition.
PC800, 850-8E0
30-63
2. Measurement of oil leakage from arm
cylinder
1) Start the engine and move the arm in to the
stroke end.
k Release the residual pressure from the
piping on the arm cylinder head. See
"Release of residual pressure from hydraulic circuit".
(Operate the lever only in the arm IN direction, however).
k Since you will work on a high place,
prepare a stable foothold.
hose end.
07379-01470 (Flange #14)

arm circuit by moving the arm IN.
k Take care not to "move the arm OUT".
after the bucket cylinder is relieved and
30-63
Hydraulic system
3. Measurement of oil leakage from bucket

cylinder
1) Start the engine and curl the bucket to the
stroke end.
k Release the remaining pressure from
the piping on the bucket cylinder head
side. For details, see "Releasing remaining pressure from hydraulic circuit" (Operate the lever in the bucket
CURL direction only, however).
hose end.
07379-01470 (Flange #14)
4. Measuring swing motor

1) Disconnect drain hoses (4) and (5), and
block the hose side end with a plug.
hose end.
07376-70522 (Flange #05)
q (4): Drain hose of front swing motor

bucket circuit by curling the bucket.
k Take care not to perform "bucket
DUPM operation".
after the bucket cylinder is relieved and
30-64
(5): Drain hose of rear swing motor
2) Set the swing lock switch to ON position.

3) Run the engine at high idle and then relieve
the swing circuit and measure the oil
leakage.
a Start measuring the oil leakage 30 seconds after the swing motor circuit is relieved and measure for 1 minute.
4) After the fist measurement, swing the upper
structure 180 and measure the leakage
again according to steps 2) and 3).
PC800, 850-8E0
Hydraulic system
5. Measurement of oil leakage from travel

motor
1) Remove travel motor cover.
4 Travel motor cover:
130 kg
2) Run the engine and lock the travel mechanism.
k Insert pin [1] between the sprocket and
the track frame to securely lock the
track.

6. Measurement of oil leakage from center
swivel joint
1) Place block [1] between sprocket and frame
to lock rotation of the travel motor of the port
to be inspected, and then stop the engine.
3) Disconnect drain hose (6) of the travel motor

and block the hose end by a plug.
hose end.
07376-70522 (Flange #05)
Loosen the hydraulic tank cap gradually to release the pressure in the hydraulic tank.
2) Disconnect the hoses of the upper and lower
measurement ports of the inspection port
from the top of the swivel joint and block the
hose side.
hose end.
q A, B, C and D ports: 07379-01044
(Flange #10)
q Port P: 07376-70315 (Plug #03)
q T port: 07376-70522 (Plug#05)
3) Combination of inspection ports and
measurement ports
Inspection
port
4) Run the engine at full speed, relieve the

travel circuit, and measure the oil leakage.
k Wrong operation of the lever can
cause the personal injury. Make the
signals and checks securely.
a Start measuring the oil leakage 30 seconds after the swing motor circuit is relieved and measure for 1 minute.
a Measure the oil leakage several times,
moving the motor little by little (changing
the positions of the valve plate and cylinder and those of the cylinder and piston).
PC800, 850-8E0
Direction of
travel motor rota- Measuring port
tion
R.H. REVERSE
T and B
R.H. FORWARD
A and P
Speed selection
B and C
L.H. REVERSE
P and D
R.H. FORWARD
C and T
Drain
a For the inspection ports, travel directions

and measurement ports, see the figure in
the following page.
30-65
Hydraulic system
4) Start and run the engine at high idle, and

measure the oil leakage from the target ports
of measurement according to the following
procedure.
a When testing ports A, B, C and D, relieve
the travel motor slowly in the revolving direction (See the table shown in the preceding page).
30-66
a When testing port P, set the travel speed

selector switch to the Hi position.
a Start measuring the oil leakage 1 minute
after the swing motor circuit is relieved
and measure for 1 minute.
PC800, 850-8E0
Hydraulic system
Releasing remaining pressure from hydraulic circuit

1. Releasing remaining pressure from
hydraulic tank
k The hydraulic tank is airtight and pressurized, so release the remaining pressure
from it when removing a hose or a plug
connected to it.
1) Lower the work equipment to the ground in a
stable posture and stop the engine.
2) Loosen oil filler cap (1) of the hydraulic tank
gradually to release the air in the tank.
30-67
3. Releasing remaining pressure from swing

motor circuit
a Release the remaining pressure from the
swing motor circuit by performing the procedure for "2. Release of residual pressure
from hydraulic cylinder circuit" (Operate the
left control lever in only swing direction).
4. Releasing remaining pressure from travel
motor circuit
a The control valve spool of the travel motor
circuit is open, so the pressure in this circuit
can be released by performing the operation
for "2. Release remaining pressure from hydraulic tank".
2. Releasing remaining pressure from

hydraulic cylinder circuit
k When disconnecting a pipe between a hydraulic cylinder and the control valve, release the remaining pressure from the
piping according to the following procedure.
1) Release the residual pressure from the
hydraulic tank. For details, see "Releasing
residual pressure from hydraulic tank".
a Keep the oil filler cap of the hydraulic tank
removed.
2) Turn the starting switch to the ON position
and set the lock lever in the FREE position,
and then operate the work equipment control
levers on both sides forward, backward, to
the right, and to the left to release the
remaining pressure in the piping.
a The control valve is operated by the pressure in the accumulator. The pressure in
the accumulator is used up, however, after the work equipment control levers are
operated two to three times.
3) Start the engine and run it at low idle for 5
seconds to raise the pressure in the accumulator.
4) Repeat above steps 2) and 3) two to three
times, and all remaining pressure is released
from the piping completely.
PC800, 850-8E0
30-67
Hydraulic system
Bleeding air from various parts
30-68
Air bleeding item
Air bleeding procedure
Nature of work, remarks
Bleeding
air from
hydraulic
pump
Run
engine
Bleeding
air
from cylinder
Bleeding
air from
swing
motor
Bleeding
air from
travel
motor
Checking
oil level and
starting
work
Replacing or repairing swing motor

Removing swing motor piping
Replacing or repairing travel motor

Removing travel motor piping
Replacing or repairing swivel joint

Removing swivel joint piping
Replacing hydraulic oil

Cleaning strainer
Replacing return filter element
Replacing or repairing hydraulic

pump
Removing suction piping
Replacing or repairing control
valve
Removing control valve piping
Replacing and repairing cylinder
Removing cylinder piping
q
q
q
q
q
q
q
q
q
q
q
Note: Bleed air from the swing motor and travel motor only when the oil in the motor cases is drained.
1. Bleeding air from work equipment pump and fan
pump
1) Loosen work equipment pump bleeder (1)

and fan pump bleeder (2) by four turns and
remove oil filler cap of hydraulic tank.
a Leave the machine under the above condition for 10 minutes or more.
2) After oil flows out of bleeder (1), start and run
the engine at low idle.
a If the engine coolant temperature is low
and the automatic warm-up operation is
started, stop the engine temporarily and
reset the automatic warm-up operation
with the fuel control dial (Set the starting
switch in the ON position and hold the fuel
control dial in the MAX position for 3 seconds, and the automatic warm-up operation is reset).
a Set the lock lever in the LOCK position to
prevent the lever from operating.
3) After oil containing no bubbles flew out of
bleeders (1) and (2), tighten the bleeders.
3 Bleeder:
7.8 9.8 Nm {0.8 1.0 kgm}
30-68
2. Starting engine
When running the engine after performing step
1, let it low-idle for 10 minutes.
PC800, 850-8E0
Hydraulic system
3. Bleeding air from cylinder

a If a cylinder is replaced, bleed air from it before connection to the work equipment. In
particular, the boom cylinder does not move
to the lowering stroke end, if it is installed to
the work equipment.
1) Run the engine at low idle for approximately
5 minutes.
2) Running the engine at low idle, then extend
and retract the replaced cylinder four to five
times.
a Stop the piston rod approximately 100
mm before each stroke end. Do not cause
the relief.
3) While running the engine at full speed,
perform step 2).
4) While running the engine at low idle speed,
move the piston rod to the stroke end and
relieve the oil.
5) Bleed air from the arm cylinder and bucket
cylinder according to steps 2) to 4).
4. Bleeding air from swing motor
1) Motor unit
a Bleed air from the motor unit according to
the following procedure.
1] Start the engine and run it at low idle.
2] Swing to the right and left slowly to bleed
air.
2) Swing holding brake circuit
a Normally, air in the swing brake circuit is
bled by swing operation in step 1). If you
feel dragging of the brake during swing
operation, however, bleed air from the
swing brake circuit according to the following procedure.
1] Loosen fittings (3) and (4) of brake hoses
and start the engine.
2] Run the engine at low idle and set the
swing holding brake release switch to the
RELEASE and NORMAL positions
repeatedly. After oil containing no
bubbles oozes out, tighten the adapters.
PC800, 850-8E0
Front swing motor
Rear swing motor
3) Safety valve circuit

a Air in the safety valve circuit is bled by the
swing operation in step 1). If abnormal
sound is heard from around the safety
valve during swinging operation, however, bleed air from the safety valve circuit
according to the following procedure.
1] Loosen plugs (5) and (6) and start the
engine.
2] Run the engine at low idle. After oil
containing no bubbles oozes out, tighten
the plugs.
3 Plug:
9.8 12.74 Nm {1.0 1.3 kgm}
30-69
Hydraulic system
5. Bleeding air from travel motor

1) Remove travel motor cover.
4 Travel motor cover:
130 kg
2) Loosen bleeder (7) by one turn and start the
engine.
a Do not loosen the bleeder more than one
turn.
3) Run the engine at low idle and move the
travel control lever to FORWARD and
REVERSE four to five times. After oil
containing no bubbles flows out, tighten the
bleeder.
a Operate the lever finely without allowing
the machine to move off.
3 Bleeder:
9.8 12.74 Nm {1.0 1.3 kgm}
2) Check the oil level by using the sight gauge

in the rear of the hydraulic tank.
a The oil level is acceptable if it is situated
between H and L lines.
a If the oil level is below line L, it is insufficient. Add oil.
6. Checking oil level and starting work

1) Run the engine, retract the arm cylinder and
bucket cylinder to the stroke ends, lower the
work equipment to the ground, and stop the
engine.
30-70
PC800, 850-8E0
Hydraulic system
Inspection procedures for diode
30-71
a Test the diode array (8-pin) and the single diode

(2-pin) according to the following procedure.
a The continuity directions of the diode array are
as follows.
a The continuity direction of the single diode is indicated on the surface of the diode.
1. When using a digital multi meter

1) Set the multi meter to the diode range and
read the indicated value.
a When an ordinary circuit tester is used,
the voltage of the internal battery is indicated.
2) Put the red probe (+) of the test lead to the
anode (P) and the black probe () to the
cathode (N) of diode, and confirm the
displayed value.
3) Evaluate the condition of the diode by the
indicated value.
q The indicated value does not change:
The diode does not have continuity (Defective).
q The indicated value changes: The diode
has continuity (Normal).
Note: In the case of a silicon diode, a value in
the range from 460 to 600 is indicated.
PC800, 850-8E0
2. When using an analog multi meter

1) Set the multi meter in the resistance range.
2) Apply the leads of the multi meter as
explained below and check the movement of
the pointer.
1] Put the red probe (+) of the test lead to the
anode (P) and the black probe () to the
cathode (N) of diode.
2] Put the red probe (+) of the test lead to the
cathode (N) and the black probe () to the
anode (P) of diode.
3) Evaluate the condition of the diode by the
movement of the pointer.
q The pointer does not move in 1] but
moves in 2]: The diode is normal (The
moving range (resistance) depends on
the type and selected range of the multi
meter, however).
q The pointer moves in both 1] and 2]: The
diode is defective (internal short circuit).
q The pointer moves in neither of 1] and 2]:
The diode is defective (internal open circuit).
30-71
Hydraulic system
Adjusting mirrors
Adjusting mirrors
30-72
1. Mirror installing positions
3. Adjusting mirror (b)

Adjust mirror (b) so that shaded area (b') in the
left rear end of the machine becomes visible.
a Position and dimension for installation and
visibility
q Dimension of installed position X1: 220
mm
q Visible range Y (right): 2,000 mm
q Shaded area (b') must be visible.
a Loosen mirror mounting nut (2) and bolt (3),
and adjust the mirror so that (b') is most easily seen from the operator's seat.
2. Adjusting mirror (a)

Adjust mirror (a) so that shaded area (a') in the
left rear end of the machine becomes visible.
a Position and dimension for installation and
visibility
q Dimension of installed position X2: 145
mm
q Visible range Z (left): 3,700 mm
q Visible range H (height): 3,100 mm
q Shaded area (a') must be visible.
a Loosen mirror mounting nut (1), and adjust
the mirror so that (b') is most easily seen from
the operator's seat.
30-72
PC800, 850-8E0
Electrical system
Special functions of machine monitor
Electrical system
30-73
30-73
PC800, 850-8E0
30-73
Electrical system
Upper part of machine monitor (diaplay portion)

(a): Multi-display
a When the engine is started, the battery voltage
may lower suddenly, depending on the ambient
temperature and the condition of the battery.
In this case, the machine monitor goes off for a
moment. This phenomenon is not a failure,
however.
Upper part of machine monitor (switches portion)
[F1]: F1 function switch
a The function of each function switch is indicated
by a graphic in the multi-display (a) above the
function switch.
a If the graphic mark of a function switch is not displayed, that function switch is not working.
Lower part of machine monitor (switches portion)
[1]: Numeral 1 input switch/Auto-deceleration switch
[2]: Numeral 2 input switch/Working mode selector
switch
[3]: Numeral 3 input switch/Travel speed selector
switch
[4]: Numeral 4 input switch/Alarm buzzer stop switch
[5]: Numeral 5 input switch/Wiper switch
[6]: Numeral 6 input switch/Windshield washer
switch
[7]: Numeral 7 input switch/Air conditioner control
switch
switch
switch
switch
Switch having no numerals: Air conditioner control
switch
a Each switch has the function indicated by graphic mark and the function of inputting a numeral.
a The machine monitor automatically judges
which function of each switch is currently enabled according to the screen display of the
multi-display panel (a).
Reference
For the setup procedure after replacing the machine
monitor assembly, see Service News (AT07196).
30-74
PC800, 850-8E0
Electrical system
t Ordinary functions and special functions of machine monitor

30-75
The machine monitor has the ordinary functions and special functions and displays information of various
types on the multi-display.
Some items are displayed automatically according to the internal setting of the machine monitor and the others are displayed according to the operation of the switches.
1. Ordinary functions: Operator mode
The operator mode allows the operator to display various screens and use various functions by operating
the switches (some of them require special operations of the switches).
2. Special function: Service mode
The information items in this mode are not displayed ordinarily. Each technician can display them by operating the switches specially.
This mode is used for special setting, testing, adjusting, or troubleshooting.
Page
Page
Operator mode (outline)
Service mode
77P
KOMATSU logo screen
77P
Password input screen
78P
Display of check before starting
78P
Display of warning after check before starting
78P
Overdue replacement item screen
78P
87P
Monitoring
Abnormality
Record
88P
Mechanical system abnormality
record
Electrical system abnormality
record
Air-conditioning System/Heater
System
94P
95P
97P
98P
Working mode and travel speed check screen 79P
Change of maintenance mode
99P
Display of standard screen
79P
Telephone number registration
101P
Display of end screen
79P
Key-on Mode
102P
Selection of auto-deceleration
79P
Unit
103P
Setting of maintenance password
104P
Camera
105P
ECO Display
106P
Pump Absorption Torque
107P
Fan speed mode selection
108P
Fan 100% speed adjustment
108P
108P
Selection of working mode
80P
o Default
Selection of travel speed
80P
Stopping alarm buzzer
80P
Operation of windshield wiper
81P
Operation of window washer
81P
(Special operation)
Maintenance Record
B
B
B
Operation of air conditioner

Operation to display camera mode (if camera
is installed)
Switching between clock display and service
meter display
81P
ment
81P
82P
Cylinder Cut-Out
109P
Check of maintenance information
82P
No Injection
110P
Entering user mode

(including KOMTRAX messages for user)
83P
Fuel Consumption
112P
Display of energy-saving guidance
83P
Display of caution monitor
83P
Display function of user code and failure code 84P
O (Special operation)
Terminal Status
113P
GPS & Communication Status
114P
Modem S/N
115P
Service Message
Checking display condition of LCD (Liquid

Crystal Display)
86P
Function of checking service meter
86P
PC800, 850-8E0
KOMTRAX
Settings
116P
30-75
Electrical system
a Classification of operator mode

A: Display/Function from time when starting switch is set to ON position to time when screen changes to
standard screen and display after starting switch is set to OFF position
B:Display/Function when switch of machine monitor is operated
C:Display/Function when certain condition is satisfied
D:Screen or function that needs special operation of switches to be displayed or enabled
30-76
PC800, 850-8E0
Electrical system
t Operator mode (outline)

a Only outline of the operator mode is described in
this section.
For details of contents/operation of each function/display, see the Structure, function and
maintenance standard, or Operation and Maintenance Manual.
a The following are the displays or functions of the
operator mode explained in this section (including some items which need special operations).
30-7
30-7
KOMATSU logo screen
When starting switch is turned ON, KOMATSU logo
is displayed for 2 seconds.
a After the KOMATSU logo is displayed for two
seconds, the screen changes to "Password input" screen, or "Check before starting" screen.
Display pattern
A B C D E
1 1 1 1 1
2
3 2 3 2 2
3
KOMATSU logo screen

Display of warning after check
before starting
3
Working mode and travel speed
4 3 4 4 4
check screen
5 4 5 5 5
Operation to stop alarm buzzer
Operation of windshield wiper
Operation of windshield washer
Operation to display camera mode (if camera is
installed)
Switching between clock display and service meter display
Entering user mode
Display function of user code and failure code
O (Special operation)
Function of checking display of LCD (Liquid Crystal Display)
Function of changing maintenance password
a The following screen may be displayed instead

of the above Display of inputting password
screen.
a If this screen is displayed, call the person responsible to operation of KOMTRAX in your Komatsu distributor and ask for remedy.
a Display pattern of operator mode

The contents of display from the time when
starting switch is turned ON to time when screen
changes to standard screen depends on the
setting and condition of the machine.
A: When engine start lock is set effective
B: When engine start lock is set ineffective
C: When working mode at start is set to breaker
mode (B)
D: When there is abnormal item in
check-before-starting items
E: When there is maintenance item which is not
maintained after specified interval
PC800, 850-8E0
30-77
Electrical system
30-78
After the KOMATSU logo is displayed, the screen to
input the engine start lock password is displayed.
a This screen is displayed only when the engine
start lock function is set effective.
a If correct password is input, the screen changes
to "Check before starting" screen.
a The machine monitor has some password functions other than the engine start lock. Those
functions are independent from one another.
30-78
When the screen changes to the check-before-starting screen, the check before starting is carried out
for 2 seconds.
a If any abnormality is detected by the check before starting, the screen changes to "Display of
warning after check before starting" or "Display
of overdue maintenance".
a If no abnormality is detected by the check before
starting, the screen changes to "Working mode
and travel speed check" screen.
a The monitors (6 pieces) displayed on the screen
are the items under the check before starting.
30-78
Display of warning after check before starting 30-78

If any abnormality is detected by the check before
starting, the warning monitor is displayed on the
screen.
a The following figure shows that the engine oil
level monitor (a) is warning of low engine oil level.
30-78
When the check before starting is carried out, if a
maintenance item is near or after the end of the set
interval, the maintenance monitor is displayed for 30
seconds to urge the operator to maintenance.
a This screen is displayed only when the maintenance reminder function is enabled. The color of
the maintenance reminder monitor (yellow or
red) indicates that the maintenance is due in a
short time or overdue.
a The maintenance reminder function is enabled
or disabled by using the machine monitor in the
service mode.
a After this screen display is finished, the screen
changes to "Working mode and travel speed
check" screen.
PC800, 850-8E0
Electrical system
Working mode and travel speed check screen 30-79

If the check before starting is finished successfully,
the screen to check the working mode and travel
speed is displayed for 2 seconds.
a After the Working mode and travel speed
check screen is finished, the screen changes to
the "Standard screen.
30-79
If the machine monitor starts normally, the standard
screen is displayed.
a Service meter (a) or a clock is displayed at the
center upper section of the screen (use [F4] to
switch the display between the service meter
and clock).
a ECO gauge (b) is displayed at the right end of
the screen (specify display or non-display of the
ECO gauge in the service mode).
PC800, 850-8E0
30-79
When starting switch is turned OFF, the end screen
is displayed for 5 seconds.
a Another message may be displayed on the end
screen, depending on the message display function of KOMTRAX.
30-79
While the standard screen is displayed, if the auto-deceleration switch is pressed, large auto-deceleration monitor (a) is displayed for 2 seconds and
the setting of the auto-deceleration is changed.
a Each time the auto-deceleration switch is
pressed, the auto-deceleration is turned ON and
OFF alternately.
a If the auto-deceleration is set to ON, large monitor (a) and auto-deceleration monitor (b) are displayed simultaneously.
a If the auto-deceleration is set to OFF, auto-deceleration monitor (b) goes off.
30-79
Electrical system
30-80
Select a working mode according to the following
procedure.
1. While the standard screen is displayed, press
the working mode selector switch, and the
working mode selection screen is displayed.
2. Operate the function switches or working mode

selector switch to select the desired working
mode and enter the selection.
Function switch
q [F3]: Move to lower working mode
q [F4]: Move to upper working mode
q [F5]: Cancel selection and return to standard
screen
q [F6]: Confirm selection and return to standard screen
Working mode selector switch
q Press: Move to lower working mode
q Hold down:Confirm selection and return to
standard screen
a If you do not touch any of the function switches and working mode selector switch for 5
seconds, the selection is determined and the
screen changes to the standard screen.
a When large monitor (a) is displayed, the display of working mode monitor (b) is changed,
too.
30-80
While the standard screen is displayed, if the travel
speed shifting switch is pressed, large travel speed
monitor (a) is displayed for 2 seconds and the setting of the travel speed is changed.
a Each time the travel speed shifting switch is
pressed, the travel speed changes in the order of
[Lo], [Mi], [Hi] and [Lo].
a When large monitor (a) is displayed, the display
of travel speed monitor (b) is changed at the
same time.
30-80
Stopping alarm buzzer
While the alarm buzzer is sounding, if the alarm
buzzer stop switch is pressed, the alarm buzzer
stops.
a Even if the alarm buzzer cancel switch is
pressed, the screen display does not change.
3. When the standard screen is displayed again,

large working mode monitor (a) is displayed for
2 seconds, and then the setting of the working
mode is changed to the selected mode.
30-80
PC800, 850-8E0
Electrical system
Operation of wiper
30-81
While the standard screen is displayed, if the wiper
switch is pressed, large wiper monitor (a) is displayed for 2 seconds and the wiper starts or stops.
a Each time the wiper switch is pressed, the wiper
setting is changed in the order of INT, ON, OFF.
a When the wiper is set to INT or ON, large monitor (a) is displayed and the display of wiper monitor (b) is changed at the same time.
a If the wiper is set to OFF, large monitor (a) is not
displayed and the wiper monitor disappears.
Operation to display camera mode (if camera is

30-81
installed)
When a camera is installed, if [F3] is pressed, the
multi-display changes to the camera image (Set the
connection of the camera in the service mode).
a Up to three cameras can be connected. If the

camera mode is selected, however, only the image of camera 1 is always displayed.
30-81
Operation of window washer
While the standard screen is displayed, if the window washer switch is pressed, the washer fluid is
splashed only while the switch is held down.
a Even if the window washer switch is pressed, the
screen does not change.
30-81
While the standard screen is displayed, if the air
conditioner control switch is depressed the air conditioner adjustment screen is displayed.
a While the air conditioner adjustment screen is
displayed, if you do not touch any switch for 5
seconds, the screen changes to the standard
screen.
a If any caution occurs in the camera mode, the

corresponding caution monitor is displayed at
the left top of the screen (excluding the low hydraulic oil temperature caution).
a If no control lever is operated for 10 seconds

while a failure enough to diaplay user code is occurring in the camera mode, the screen returns
to the standard screen and displays information
about that failure.
PC800, 850-8E0
30-81
Electrical system
a When two or more cameras are connected, the

image of one of them or the images of two of
them can be displayed.
a As 2-camera image display [F4] is selected, the
image of camera 1 is displayed on the left side of
the screen and the image of camera 2 is displayed on the right side.
The image of camera 3 is displayed only singly.
a If 2-camera image display operation is made, the
images are displayed frame by frame at intervals
of approximately 1 second on the right and left
side of the screen.
Switching between clock display and service
30-82
meter display
While the standard screen is displayed, if [F4] is
pressed, the service meter and the clock are displayed alternately in section (a).
a When selecting the clock display, perform the
time adjustment, 12-hour or 24-hour display setting, and summer time setting by using the user
mode functions.
30-82
30-82
While the maintenance monitor or standard screen
is displayed, if [F5] is pressed, the Maintenance List
a To reset the remaining time after finishing maintenance, more operations are necessary.
PC800, 850-8E0
Electrical system
Entering user mode

30-83
To enter the user mode, press [F6] to display the
"User Menu" screen while the standard screen is
displayed.
30-83
When the machine is set in a certain operating condition, the energy-saving guidance screen is displayed automatically to urge the operator to the
energy-saving operation.
a The energy-saving guidance is displayed when
the following condition is satisfied while the display setting is set effective in the service mode.
a Condition for display:
"Engine is running" and "All levers have been in
neutral for 5 minutes"and "Caution (Note) or user
code is not indicated"
Note: Excluding hydraulic oil low temperature
caution.
a If any lever or pedal is operated, or [F5] is
pressed, the screen returns to the standard
screen.
a There are following items in the user menu.

Message display
ECO Display selection
Economy mode adjustment
Auto low idle setting
Fan reverse mode
Screen adjustment
Clock adjustment
Language setting
[KOMTRAX message]
q There are two types of KOMTRAX message;
one is for the user and the other is for the service.
q For user:
A message transmitted from the KOMTRAX
base station for the user. If it is received, the
message monitor is displayed on the standard
screen. To see the contents of the message,
operate "User Message" in the above user
menu.
q For service:
A message sent from the KOMTRAX base
station for the technician. Even if it is received,
no sign is displayed on the standard screen. To
read the message, select "KOMTRAX Message"
on the Service Menu screen.
PC800, 850-8E0
30-83
While the standard screen or the camera image
screen is displayed, if a problem enough to display
a caution monitor occurs, the caution monitor is displayed large for a moment and then displayed at
section (a) on the screen.
a On the camera mode screen, the caution monitor flashes at the left upper of the screen when a
caution item is detected.
30-83
Electrical system
Display function of user code and failure code 30-84

While the standard screen or the camera mode
screen is displsyed, if an abnormality which displays
a user code and a failure code occurs, all the information of the abnormality is displayed.
(a): User code (3 digits)
(b): Failure code (5 or 6 digits)
(c): Telephone symbol mark
(d): Telephone number
a This screen is displayed only when an abnormality (failure code) for which a user code is set occurs.
a The telephone mark and telephone number are
displayed only when the telephone number is
registered in the service mode.
a If multiple abnormalities occur simultaneously,
all the codes are displayed repeatedly in order.
a Since the information of the displayed failure
code is recorded in the abnormality record in the
service mode, check the details in the service
mode.
a When the caution monitor is also displayed, the

telephone mark is not displayed.
30-84
PC800, 850-8E0
Electrical system
a Remedies that the displayed user codes prompt the operator to take (The following table is an excerpt from
the Operation and Maintenance Manual)
User
code
E03
E07
E10
E11
E14
E15
E0E
Failure mode
Action
Swing brake system error
Have inspection carried out immediately.

An abnormality has occured in the electronic pump control system,
Pump control system error
and the emergency safeguard system is in action. Part of the
(Emergency safeguard system in action) machine's functions is lost. The ordinary work is still possible with
the machine, but ask your distributor for an inspection.
Defective engine controller power source
Engine controller drive system circuit
Have inspection carried out immediately.
error
(Engine stopps)
Engine controller system error
Operate machine to a safe posture and have inspection carried
(Output reduced to protect engine)
out immediately.
Operate machine to a safe posture and have inspection carried
Error in throttle system
out immediately.
If display of "CA2249" or "CA559" appears in the user code screen
and yet the machine has not run out of fuel, replace both fuel main
filter element and fuel pre-filter element immediately.
If the display of "CA2249" or "CA559" still does not disappear after
the replacement, ask your Komatsu distributor for an inspection
Engine sensor (coolant temperature, fuel immediately, even though normal operation of the machine is still
pressure, oil pressure) system failure
possible.
Abnormality in network
PC800, 850-8E0
On the other hand, if any other code than "CA2249" and "CA559"
appears in the user code screen, again ask your Komatsu distributor for an inspection immediately, even though normal operation of
the machine is still possible.
q If the engine can be operated, set the machine to a safe posture, then have inspection carried out immediately.
q If the engine is operated and stalls, turn the emergency pump
drive switch, set the machine to a safe posture, then have inspection carried out immediately.
q Even if the engine is stopped, have inspection carried out immediately.
30-85
Electrical system
Checking display condition of LCD (Liquid Crys30-86

tal Display)
While the standard screen is displayed, if the following numeral input switch and function switch are operated as follows, all the LCD (Liquid Crystal
Display) lights up in white.
q Operation of switches (simultaneous): "4" + "F2"
a When finishing the operation of the switches, release "F2" first.
a If there is a display error in the LCD, only that
part is indicated in black.
a The LCD panel sometimes has black points
(points which are not lighted) and bright points
(points which do not go off) for the reason of its
characteristics.
If the number of the bright points and black
points does not exceed 10, those points are not
a failure or a defect.
a To return to the former screen, press any one of
the function switches.
30-86
30-86
To check the service meter while the starting switch
is in OFF position, operate the numeral input switches as follows. At this time, only the service meter
section appears.
q Operation of switches (simultaneous): "4"+ "1"
a There is some time lag in start of the LCD, so
hold down the switches until the LCD displays
normally.
a In the case of a machine monitor that has been
used a long period of time, the machine monitor
may display blue bright spots (spots which do
not go off) on this screen; it is quite normal.
PC800, 850-8E0
Electrical system
t Service mode
30-87
To change the operator mode to the service mode,
perform the following operation.
This operation is always required when you use the
service mode.
1. Check of screen display and operation of
switches
While the standard screen is displayed, perform
the following operation with the numeral input
switches.
q Operation of switches (While pressing [4],
perform the operation in order):
[4]+[1]o[2]o[3]
a This operation of the switches is accepted
only while the standard screen is displayed.
a The items which can be selected in the service menu are as follows (including some
items which need special operations).
01 Monitoring
Mechanical system abnormality
record
02 Abnormality
Electrical system abnormality
Record
record
Air-conditioning System/Heater
System abnormality record
03 Maintenance Record
04 Maintenance Mode Change
05 Phone Number Entry
Key-on Mode
Unit
Setting of maintenance pass06 Default
word
Camera
ECO Display
Pump Absorption Torque
Fan rotation mode selection
07 Adjustment
08 Cylinder Cut-Out
09 No Injection
10 Fuel Consumption
Terminal Status
11 KOMTRAX
GPS & Communication Status
Settings
Modem S/N
12 Service message display
2. Selecting the service menu

When the "Service Menu" screen is displayed,
the service mode is selected. Select a service
menu you use by using the function switches or
numeral input switches.
q [F3]: Move to lower item
q [F4]: Move to upper item
q [F5]: Return to standard screen (operator
mode)
q [F6]: Confirm selection
a You may enter a 2-digit code with the numeral input switches to select the menu of that
code and confirm it with [F6].
PC800, 850-8E0
30-87
Electrical system
30-8
Monitoring
The machine monitor can monitor the condition of
the machine in real time by receiving signals from
various switches, sensors, and actuators installed to
many parts of the machine and the information from
the controllers which are controlling switches, etc.
1. Selecting menu
Select "Monitoring" on the "Service Menu"
screen.
2. Selecting monitoring item

After the "Monitoring selection menu screen" is
displayed, select items to be monitored by using
the function switches or numeral input switches.
q [F1]: Move to next page (screen)
q [F2]: Move to previous page (screen)
q [F5]: Delete input numeral/Return to service
menu screen
a Selection with function switches: Select an
item with [F3] or [F4] and determine it with
[F6].
a Selection with numeral input switches: Enter
a 5-digit code, and the item of that code is selected directly. Confirm that item with [F6].
a If the color of the selected box changes from
yellow to red, selection of the item of that box
is confirmed.
a Up to six monitoring items can be selected at
a time. You may not able to set up to six
items, however, depending on the display
form of the selected items.
30-88
3. Deciding monitoring items

After selecting monitoring items, execute monitoring with the function switch or numeral input
switch.
a Execution with function switch: Double click
or keep pressing [F6] (for approximately 2
seconds).
a Execution with numeral input switch: Input
[99999] and press [F6].
a When monitoring only two items, for example, select them and confirm with [F6]. If [F6]
is pressed once more at this time, monitoring
is executed.
a If monitoring items are selected up to the limit
number, monitoring is executed automatically.
PC800, 850-8E0
Electrical system
4. Performing monitoring
After the "Executing monitoring screen" is
displayed, perform the necessary operation of
the machine and check the monitoring information.
a Monitoring information is indicated by value,
ON/OFF, or special display.
a The unit of display can be selected in SI unit,
metric unit, or inch unit with the Default function in the service mode.
6. Changing machine setting mode

To change the setting of the working mode,
travel speed, or auto-deceleration during monitoring, operate the corresponding switch under
the current condition, and the mode setting
While this screen is displayed, if the corresponding switch is operated further, the corresponding mode is changed.
a After finishing changing the setting, press
[F6] to return to the monitoring information
screen.
a If the setting is changed during monitoring,
the new setting is held even after the screen
returns to the standard screen after monitoring is finished.
5. Holding monitoring information

The monitoring information can be held and
released with the function switches.
q [F3]: Release holding
q [F4]: Hold information (displayed data is
fixed)
q [F5]: Return to monitoring selection menu
screen
PC800, 850-8E0
30-89
Electrical system
Monitoring items list

Unit (Initial setting: SI)
Code No.
Monitoring item (Display on screen)

SI
meter
inch
Component in
charge
00200
Controller Model Select
PUMP
00201
Machine ID
ENG
01002
Engine Speed
r/min
rpm
rpm
ENG
01601
2nd Eng. Speed Command
r/min
rpm
rpm
PUMP
MPa
kg/cm2
psi
PUMP
MPa
psi
PUMP
01100
F Pump Pressure
01101
R Pump Pressure
04107
Coolant Temperature
ENG
14200
Fuel Temperature
ENG
04401
Hydr. Oil Temperature
PUMP
37502
Ambient Temperature
PUMP
01300
F Pump PC-EPC Sol. Curr.
mA
mA
mA
PUMP
01302
R Pump PC-EPC Sol. Curr.
mA
mA
mA
PUMP
31623
Fan Pump EPC Sol. Curr.
mA
mA
mA
PUMP
13800
L Jet Sensor Pressure
MPa
kg/cm2
psi
PUMP
MPa
kg/cm2
psi
PUMP
kg/cm
13801
R Jet Sensor Pressure
13802
L Jet Sensor Vol.
PUMP
13803
R Jet Sensor Vol.
PUMP
03200
Battery Voltage
PUMP
03203
Battery Power Supply
ENG
04300
Battery Charge Vol.
MON
37200
Engine Oil Pressure
kPa
kg/cm2
psi
ENG
36400
Rail Pressure
MPa
kg/cm2
psi
ENG
37400
Ambient Pressure
kPa
kg/cm2
psi
ENG
18400
Intake Temperature
ENG
18500
Charge Temperature
ENG
36500
Boost Pressure
kPa
kg/cm2
psi
ENG
18000
EGR Inlet Pressure-A
kPa
kg/cm2
psi
ENG
18100
EGR Valve Position
mm
mm
in
ENG
18200
BPS Valve Position
mm
mm
in
ENG
36700
Engine Torque Ratio
ENG
18700
Engine Output Torque
Nm
kgm
lbft
ENG
01112
F Pump Pres. Sensor Vol.
PUMP
01113
R Pump Pres. Sensor Vol.
PUMP
03000
Fuel Dial Pos Sens Volt
ENG
04200
Fuel Level Sensor Vol.
MON
04105
Eng. Water Temp. Vol. Lo
ENG
14201
Fuel Temp. Sensor Vol.
ENG
04402
Hydr. Temp. Sensor Vol.
PUMP
30-90
Remarks
PC800, 850-8E0
Electrical system
SI
meter
inch
Component in
charge

Code No.
37503
Ambi. Temp. Sensor Vol.
PUMP
37201
Eng Oil Press Sens Volt
ENG
37401
Ambient Press Sens Volt
ENG
18401
Intake Temp Sens Volt
ENG
18501
Charge Temp Sens Volt
ENG
36501
Charge press Sens volt
ENG
36401
Rail Pressure Sens Volt
ENG
18001
EGR In Press Sens Volt
ENG
18101
EGR Valve Pos Sens Volt
ENG
18201
BPS Valve Pos Sens Volt
ENG
17201
PCV Close Timing
CA
CA
CA
ENG
17500
Engine Power Mode
ENG
31701
Throttle Position
ENG
31706
Final Throttle Position
ENG
18600
Inject Fueling Command
mg/st
mg/st
mg/st
ENG
36200
Rail Press Command
MPa
kg/cm2
psi
ENG
36300
Injection Timing Command
CA
CA
CA
ENG
37300
Fuel Rate
l/h
l/h
gal/h
ENG
01602
2nd Eng. Speed Command
PUMP
13100
F Pump Absorb Torque
Nm
kgm
lbft
PUMP
13101
R Pump Absorb Torque
Nm
kgm
lbft
PUMP
13113
Main Pump Absorb Torque
Nm
kgm
lbft
PUMP
13114
Fan Pump Absorb Torque
Nm
kgm
lbft
PUMP
13112
Total Pump Absorb Torque
Nm
kgm
lbft
PUMP
01900
01901
02300
Swing
ON, OFF
PUMP
R.H travel
ON, OFF
PUMP
Boom Lower
ON, OFF
PUMP
Boom Raise
ON, OFF
PUMP
Arm Curl
ON, OFF
PUMP
Arm Dump
ON, OFF
PUMP
Bucket Curl
ON, OFF
PUMP
Bucket Dump
ON, OFF
PUMP
Service
ON, OFF
PUMP
L.H travel
ON, OFF
PUMP
Travel Junction
ON, OFF
PUMP
Remarks
Pressure Switch 1
Pressure Switch 2
Solenoid Valve 1
PC800, 850-8E0
Swing Brake
ON, OFF
PUMP
2-stage Relief
ON, OFF
PUMP
Travel Speed
ON, OFF
PUMP
Fan Reverse
ON, OFF
PUMP
Swing Priority
ON, OFF
PUMP
30-91
Electrical system
02301
Solenoid Valve 2
Bottom Priority
ON, OFF
Component in
charge
PUMP
Knob Sw.
ON, OFF
PUMP
02200
Switch Input 1
Swing Release SW.
ON, OFF
PUMP

Code No.

SI
02201
Switch Input 2
meter
inch
Swing Brake SW.
ON, OFF
PUMP
Model Select 1
ON, OFF
PUMP
Model Select 2
ON, OFF
PUMP
Model Select 3
ON, OFF
PUMP
Model Select 4
ON, OFF
PUMP
Model Select 5
ON, OFF
PUMP
Overload Alarm
ON, OFF
PUMP
02202
Switch Input 3
Key Switch (ACC)
ON, OFF
PUMP
02203
Switch input 4
Step Light Sw.
ON, OFF
PUMP
Window Limit SW.

Upper wiper P Limit
SW.
Upper wiper W Limit
SW.
Lower wiper P Limit
SW.
Lower wiper SW.
Lower wiper active
SW.
Lower wiper Select
ON, OFF
PUMP
ON, OFF
PUMP
ON, OFF
PUMP
ON, OFF
PUMP
ON, OFF
PUMP
ON, OFF
PUMP
02204
02209
Switch Input 5
Switch input 6
ON, OFF
PUMP
Over Load sensor
ON, OFF
PUMP
ON, OFF
PUMP
ON, OFF
PUMP
05500
Sensor input 1
03700
Controller Output 1
Auto Greasing
Batt. Relay Dr.
Battery Relay Drive
Step Relay
ON, OFF
PUMP
03701
Controller output 2
Flash L. Relay
ON, OFF
PUMP
Travel Alarm
ON, OFF
PUMP
Key Switch
ON, OFF
MON
Start
ON, OFF
MON
Preheat
ON, OFF
MON
04500
04501
04502
04503
30-92
Monitor Input 1
Monitor Input 2
Monitor Input 3
Monitor Function
Switches
Light
ON, OFF
MON
Rad Level
ON, OFF
MON
Air cleaner
ON, OFF
MON
Eng. Oil Level
ON, OFF
MON
Battery Charge
ON, OFF
MON
Swing Brake SW.
ON, OFF
MON
F1
ON, OFF
MON
F2
ON, OFF
MON
F3
ON, OFF
MON
F4
ON, OFF
MON
F5
ON, OFF
MON
F6
ON, OFF
MON
Remarks
PC800, 850-8E0
Electrical system
Code
No.
Unit (Initial setting: ISO)

ISO
meter
inch
Component in
charge
SW1
ON, OFF
MON
SW2
ON, OFF
MON
SW3
ON, OFF
MON
SW4
ON, OFF
MON
SW5
ON, OFF
MON
SW6
ON, OFF
MON
SW7
ON, OFF
MON
SW8
ON, OFF
MON
SW9
ON, OFF
MON
SW10
ON, OFF
MON
SW11
ON, OFF
MON
SW12
ON, OFF
MON
SW13
ON, OFF
MON
04506 Monitor 5th Row Switches SW14
ON, OFF
MON
SW15
ON, OFF
MON
20216 ECM Build Version
ENG
20217 ECM CAL Data Ver
ENG
04504
04505
Monitor 1st & 2nd Row

Switches
Monitor 3rd & 4th Row

Switches
18900 ECM Internal Temp
Remarks
ENG
20400 ECM Serial No
ENG
20227 Monitor Ass'y P/N
MON
20402 Monitor Serial No
MON
20228 Monitor Prog. P/N
MON
20229 Pump Con. Ass'y P/N
PUMP
20403 Pump Con. Serial No
PUMP
20230 Pump Con. Prog. P/N
PUMP
a Listing order of items in table

The items are listed in the order of display on the monitoring item selection menu screen.
a Unit
The display unit can be set to ISO, meter, or inch freely (Set it with unit selecting in "Default" setting of the
service menu).
"CA" in the display unit is an abbreviation for crankshaft angle.
"mg/st" in the display unit is an abbreviation for milligram/stroke.
a Component in charge
MON: The machine monitor is in charge of detection of monitoring information.
ENG: The engine controller is in charge of detection of monitoring information.
PUMP: The pump controller is in charge of detection of monitoring information.
PC800, 850-8E0
30-93
Electrical system
30-94
Abnormality Record (Mechanical Systems)
The machine monitor classifies and logs the failures
which occurred in the past or which are occurring at
present into the electrical system abnormality, mechanical system abnormality, Air-conditioning System abnormality, or heater system abnormality.
To check the mechanical system abnormality record, perform the following procedures.
1. Selecting menu
Select "Abnormality Record" on the "Service
Menu" screen.
2. Selecting sub menu

After the "Abnormality Record" screen is
displayed, select "Mechanical Systems" with the
function switches or numeral input switches.
q [F5]: Return to Service Menu screen
a You may enter a 2-digit code with the numeral input switches to select the item of that
a The following figure shows the display for the
machines with air conditioner.
As for machines with heater and heaterless
machines, the character string of "03
Air-conditioning System" is different or is not
displayed respectively.
3. Information displayed on "Abnormality Record"

screen
On the "Mechanical Systems" screen, the
following information is displayed.
(a): Occurrence order of abnormalities from
latest one/Total number of records
(b): Failure code
(c): Detail of failure
(d): Number of occurrences (limit of display: 0 65,535 times)
(e): Service meter reading at first occurrence
(f): Service meter reading at last occurrence
q [F1]: Move to next page (screen) (if displayed)
q [F2]: Move to previous page (screen) (if displayed)
q [F5]: Return to Abnormality Record screen
a If no abnormality is recorded, "No abnormality record" is displayed.
a If the number of occurrences is one (first occurrence), the service meter reading at the
first occurrence and that at the last occurrence are the same.
a If [E] is displayed on the left of a failure code,
the abnormality is still occurring or restoration of it has not been confirmed.
a For all the failure codes that the machine
monitor can record, see Troubleshooting,
"Failure codes table".
4. Clearing abnormality record

A contents of the mechanical system abnormality record cannot be clearing.
30-94
PC800, 850-8E0
Electrical system
Abnormality Record (Electrical Systems)

30-95
To check the electrical system abnormality record,
perform the following procedures.
1. Selecting menu
Menu" screen.

displayed, select "Electrical Systems" with the
a The following figure shows the display for the
machines with air conditioner.
As for machines with heater and heaterless
machines, the character string of "03
Air-conditioning System" is different or is not
displayed respectively.
PC800, 850-8E0

screen
On the "Electrical Systems" screen, the following
information is displayed.
(a): Occurrence order of abnormalities from
latest one/Total number of records
(b): Failure code
(c): Detail of failure
(d): Number of occurrences (limit of display: 0 65,535 times)
(e): Service meter reading at first occurrence
(f): Service meter reading at last occurrence
q [F1]: Move to next page (screen) (if displayed)
q [F2]: Move to previous page (screen) (if displayed)
q [F5]: Return to Abnormality record screen
a If no abnormality is recorded, "No abnormality record" is displayed.
a If the number of occurrences is one (first occurrence), the service meter reading at the
first occurrence and that at the last occurrence are the same.
a If [E] is displayed on the left of a failure code,
the abnormality is still occurring or restoration of it has not been confirmed.
a For all the failure codes that the machine
monitor can record, see Troubleshooting,
"Failure codes table".
30-95
Electrical system

1) While the "Electrical Systems" screen is
displayed, press the numeral input switches
as follows.
q Operation of switches (While pressing [4],
press the switches in order):
[4]+[1]o[2]o[3]
2) Check that the screen is set in the clear

mode, and then clear the items one by one or
together with the function switches.
a If the screen is set in the clear mode,
graphic mark [CLEAR] is indicated above
[F2].
q [F2]: Clear all items
q [F5]: Return to Abnormality Record
screen
q [F6]: Clear selected item
a To clear items one by one: Select the item
to be cleared with [F3] or [F4] and press
[F6].
a To clear all items together: Press [F2],
and all the items are cleared, regardless
of selection of the items.
a If [E] is displayed on the left of a failure
code, the clearing operation is accepted
but the information is not reset.
30-96
3) After the "Electrical Sys. Error Reset" screen

is displayed, operate the function switches.
q [F5]: Return to Electrical systems screen
(clear mode)
q [F6]: Execute clearing
a The following figure shows the screen
displayed when the items are cleared one
by one (which is a little different from the
screen displayed when all the items are
cleared together).
4) If the screen to notify completion of clearing

is displayed and then the "Electrical
Systems" (clear mode) screen is displayed,
the clearing of the abnormality record is
completed.
a After a while, the screen returns to the
"Electrical Systems" screen.
PC800, 850-8E0
Electrical system
Abnormality Record (Air conditioning Sys30-97

tem/Heater System)
To check the air-conditioning abnormality record or
heater abnormality record, perform the following
procedures.
a All the following figures show the screen for the
machine with air conditioner.
1. Selection of menu
Menu" screen.

displayed, select "Air-conditioning System" or
"Heater System" with the function switches or
PC800, 850-8E0

screen
On the "Air-conditioning System" or "Heater
System" screen, the following information is
displayed.
(a): System or Component name
(b): Number of abnormality occurrences
(c): Condition (Normal or abnormal)
q [F2]: Delete "Abnormality record"
q [F5]: Return to Abnormality record screen
a If [E] is displayed on the left of a status display, the failure is still occurring or controller
in charge can not recognize that the failure is
fixed.
a If "CAN disconnection" is displayed for CAN
Status, communication cannot be carried out
normally. Accordingly, the statuses of other
items are not displayed.

While the "Air-conditioning system" screen is
displayed, press [F2], and the number of occurrences of abnormality is cleared. If it is confirmed
at this time that the system is restored, the stauts
display changes to Normal.
a Machines with heater
In the machines with heater, the display of
"Air-conditioning" is replaced with "Heater" and
the items which are not related to the heater are
not displayed.
a Heaterless machines
In the heaterless machines, the Abnormality
Record menu and screen are not displayed.
30-97
Electrical system
30-98
Maintenance Record
The machine monitor records the maintenance information of the filters, oils, etc., which are displayed
and checked by the following operations.
When maintenance is performed, if the remaining
time is reset in the operator mode, the number of
maintenance times is recorded in this record.
1. Selecting menu
Select "Maintenance Record" on the "Service
Menu" screen.
a The following items can be selected in the

maintenance record.
01 Engine oil change
02 Engine oil filter change
03 Fuel main filter change
41 Change of fuel pre-filter
04 Hydraulic oil filter change
05 Hydraulic tank breather change
06 Corrosion resistor change
07 Coupling case service
08 Final drive case oil change int.
09 Machinery case oil change
10 Hydraulic oil change
3. Items displayed on Maintenance Record

screen
The following items are displayed.
(a): Maintenance items
(b): Number of replacements up to now
(c): Service meter reading (SMR) at previous
replacement
2. Selecting maintenance item

After the "Maintenance Record" screen is
displayed, select an item to be checked by using
code.
30-98
PC800, 850-8E0
Electrical system
Change of maintenance mode

30-9
The actuating condition of the maintenance reminder function in the operation mode can be set and
changed by using this menu.
q To enable or disable the function
q To change set replacement interval (by item)
q To initialize all set replacement intervals
1. Selecting menu
Select of "Maintenance Mode Change" on the
"Service Menu" screen.

After the "Maintenance Mode Change" screen is
displayed, select an item of which the setting is
to be changed by using the function switches or
PC800, 850-8E0
a The following items can be selected on the

change of maintenance mode screen.
00 Maintenance mode on/off
01 Engine oil change int.
02 Engine oil filter change int.
03 Fuel main filter change int.
41 Fuel pre-filter change int.
04 Hyd. oil filter change int.
05 Hyd. tank breather change int.
06 Corrosion resistor change int.
07 Coupling case service int.
08 Final drive case oil change int.
09 Machinery case oil change int.
10 Hydraulic oil change int.
30 Hydraulic oil pilot filter change
31 Hydraulic oil drain filter change
44 Hydraulic tank breather change
99 Initialize all items
3. Details of setting of maintenance mode

ON/OFF
After selecting "Maintenance Mode On/Off", if
the screen is displayed, select ON or OFF with
the function switches.
q ON: Maintenance reminder functions of all
maintenance items are enabled in operator
mode
q OFF: Maintenance reminder functions of all
maintenance items are disabled in operator
mode
q [F5]: Cancel selection and return to Maintenance Mode Change screen
q [F6]: Confirm selection and return to Maintenance Mode Change screen
a Even if ON/OFF of each item has been set, if
the above setting is changed, it overrides the
individual setting.
30-99
Electrical system
4. Setting of each maintenance item

After selecting each maintenance item, if the
screen is displayed, set the item with the function
switches.
q Initial value: Maintenance interval set in machine monitor (Recommended by manufacturer and not changeable).
q Set value: Maintenance interval which can be
set freely. Maintenance functions in operator
mode works according to this set time (which
is increased or decreased by 50 hours).
q ON: Maintenance reminder function of this
item is enabled in operator mode.
q OFF: Maintenance reminder function of this
item is disabled in operator mode.
q [F3]: Reduce set value (in upper column) or
select OFF (in lower column).
q [F4]: Increase set value (in upper column) or
select ON (in lower column).
q [F5]: Cancel setting before confirmation and
return to Maintenance Mode Change
screen.
q [F6]: Confirm setting of upper or lower column
a After the settings of the upper and lower columns are confirmed with [F6] and the screen
changes to the Maintenance Mode Change
screen with [F5], the settings are effective.
a If the set value of an item of which maintenance reminder function is set to "ON" is
changed after one operating hour or more
from the setup, the change is recognized as
a reset of the remaining time.
30-100
5. Function of initializing all items

After selecting "All Default Value", if the screen
is displayed, set it by using the function switches.
q If this function is executed, the set values of
all the maintenance items are initialized.
q [F5]: Return to Maintenance Mode Change
screen
q [F6]: Perform initialization
a A while after [F6] is pressed, the initialization
completion screen is displayed. Then, return
to the "Maintenance Mode Change" screen
to complete the initialization.
PC800, 850-8E0
Electrical system
Telephone number registration

30-101
The telephone number to be displayed together with
the user code and failure code in the operator mode
can be registered or changed according to the following procedure.
If a telephone No. is not input by using this function,
no telephone No. is displayed in the operator mode.
a If an input numeral is wrong, move the cursor

(orange background) to that digit and overwrite it with the correct numeral.
a If [F6] is pressed without inputting a digit,
there is not information of telephone No. Accordingly, no telephone No. is displayed in
the operator mode.
1. Selecting menu
Select "Phone Number Entry" on the "Service
Menu" screen.
2. Registering and changing phone number

After the "Phone Number Entry" screen is
displayed, register or change the phone number
q [F2]: Delete all input digits.
q [F3]: Move to left position (if not blank)
q [F4]: Move to right position (if not blank)
q [F5]: Reset input digit/Return to Service
Menu
q [F6]:Confirm input
a Up to 14 digits can be input from the left. Input nothing in the surplus positions.
PC800, 850-8E0
30-101
Electrical system
30-102
Default (Key-on Mode)
Use the menu of Default to check or change various settings of the machine monitor and machine.
Use the sub menu of "key-on Mode" to set the working mode selected and displayed on the machine
monitor when the starting switch is turned to ON position.
1. Selecting menu
Select "Default" on the "Service Menu" screen.
3. Selecting mode
After the "Key-on Mode" screen is displayed,
select the mode to be set by using the function
switches.
q Power mode: [P] is displayed when the starting switch is set to ON position
q Economy mode: [E] is displayed when the
starting switch is set to ON position
q Mode at Previous Key-off: Final mode in previous operation is displayed when the starting switch is turned to ON position.
q [F5]: Cancel selection and return to Default
screen
q [F6]: Confirm selection and return to Default
screen
a Factory default is, "Mode at Previous
Key-off".

After the "Default" screen is displayed, select
"Key-on Mode" by using the function switches or
a Select this item similarly to an item on the
30-102
PC800, 850-8E0
Electrical system
Default (Unit)
30-103
Use the sub menu of "Unit" to select the unit of the
data displayed for monitoring, etc.
1. Selecting menu
3. Selecting unit
After the "Unit" screen is displayed, select the
unit to be set by using the function switches.
screen
screen
a Factory default is the SI Unit.

"Unit" by using the function switches or numeral
input switches.
PC800, 850-8E0
30-103
Electrical system
30-104
Default (Setting of maintenance password)
The function of the setting of the maintenance password is used to set the display of the password
screen when the functions related to the maintenance are used in the operator mode.
1. Selecting menu

"Attachment/Maintenance Password" by using
3. Selecting Disable/Enable
After the "Maintenance Password" screen is
displayed, select the setting by using the function switches.
q Disable: Password screen is not displayed
q Enable: Password screen is displayed
screen
screen
4. Display of maintenance password screen

When the following operation is performed, the
password screen is displayed in the operator
mode.
q Maintenance mode: When the Maintenance
list screen is changed to the maintenance interval reset screen.
5. Change of maintenance password
The password can be changed with the special
switch operating in the operator mode.
a See Maintenance password changing function in the operator mode.
a Default password: [000000]
a If the password setting is changed from Enable to Disable, the password is reset to the
default.
When Enable is set again, be sure to set a
new password.
a The maintenance password is different from
the engine start lock password.
30-104
PC800, 850-8E0
Electrical system
Default (Camera)
30-105
Use the sub menu of "Camera" to configure camera
setting when the camera is installed or removed.
1. Selecting menu

"Camera" by using the function switches or
PC800, 850-8E0
3. Selecting camera setting

After the "Camera" screen for setting is
displayed, select the setting by using the function switches.
q OFF: Camera is not used
q Original Image: Image of connected camera
is displayed in original position (as in mirror,
used as back monitor)
q Reverse Image: Image of connected camera
is displayed in reverse position (as seen directly, used as front or side monitor)
q [F3]: Move to left item
q [F4]: Move to right item
q [F5]: Cancel settings before confirmation and
return to Default screen
q [F6]: Confirm selection of each column
a When "Camera" screen is displayed, camera
1 is always ready for setting.
When 2 or more cameras are connected, if
camera 1 is set, the screen changes to
setting of camera 2 automatically.
a After confirming the setting of each column
with [F6], return to the "Default" screen with
[F5], and the setting is effective.
a If a camera is connected but not configured
normally with this function, the graphic mark
of camera is not displayed above [F3] in the
operator mode. Accordingly, the image of the
camera cannot be screen.
a If 2 or more cameras are connected, be sure
to set the use of them from camera 1 in order.
a The simultaneous display function of two images becomes effective when camera 1 and
camera 2 are set for use.
a If the camera is installed, check that the right
and left portions of the displayed image are
correct.
30-105
Electrical system
30-106
Default (ECO Display)
Use the sub menu of "ECO Display" to set the ECO
mark and ECO guidance to be displayed.
a If ECO Mark is set to ON, ECO mark is displayed when the screen changes to the standard screen. Even if ECO Guidance is set to
ON, however, ECO Guidance screen is not
displayed if the condition for display is not
satisfied on the standard screen.
1. Selecting menu
a Display of ECO gauge (a)

"ECO Display" by using the function switches or
numeral input switches
a ECO Guidance screen
3. Selecting display setting

After the "ECO Display" screen is displayed,
select the setting by using the function switches.
q ON: Display ECO
q OFF: Do not display ECO
q [F3]: Move to left item
q [F4]: Move to right item
q [F5]: Cancel settings before confirmation and
return to Default screen
q [F6]: Confirm selection of each column
a After confirming the setting of the upper and
lower columns with [F6], return to the "Default" screen with [F5], and the setting is effective.
30-106
PC800, 850-8E0
Electrical system
Adjustment (Pump Absorption Torque)

30-107
The machine monitor allows for adjustment of various items related to the machine.
The pump absorption torque function is used to finely adjust the absorption torque on the front side of
the hydraulic pump.
1. Selecting menu
Select "Adjustment" on the "Service Menu"
screen.

After the Adjustment screen is displayed,
select Pump Absorption Torque by the function
switches or numeral input switches.
3. Selecting pump absorption torque setting

After the "Pump Absorption Torque" screen is
displayed, select the desired set value code to
be input in the right box by using the function
switches.
q Set value: For actual torque adjustment value, see table
q [F3]: Increase set value.
q [F4]: Decrease set value.
q [F6]: Confirm setting and return to Adjustment screen
a The 3-digit number in the left column do not
change since it is the code of this function.
a Relationship between set value and torque

adjustment value
Code
022
PC800, 850-8E0
Set
value
Torque adjustment value
000
+39.2 Nm {+4 KJV}
001
+29.4 Nm {+3 KJV}
002
+19.6 Nm {+2 KJV}
003
+9.8 Nm {+1 KJV}
004
0 Nm {0 KJV}
005
-9.8 Nm {-1 KJV}
006
-19.6 Nm {-2 KJV}
007
-29.4 Nm {-3 KJV}
008
-39.2 Nm {-4 KJV}
30-107
Electrical system
4. Fan speed mode selection function

To adjust the fan speed, it must be fixed. Select
one of the following modes as required.
Code
056
No.
Fan speed mode selection
055
056
057
Set value
000
001
002
003
004
005
006
007
008
009
010
011
012
013
014
Fan 100% speed

+105 rpm
+90 rpm
+75 rpm
+60 rpm
+45 rpm
+30 rpm
+15 rpm
0
-15 rpm
-30 rpm
-45 rpm
-60 rpm
-75 rpm
-90 rpm
-105 rpm
2) Fan 70% speed adjustment function

1] After 70% Speed is set, fan speed can be
adjusted within the following range.
Normal mode: For normal operation

100% speed mode: For adjusting fan
speed
70% speed mode: For inspection for regulation in the factory
a If starting switch is turned to OFF position, fan speed mode returns to 055: Normal mode.
a Keep the starting switch turned ON while
adjusting the fan speed.
1) Fan 100% speed adjustment function
1] After 100% speed is set, fan speed can
be adjusted within the following range. a
Adjust fan speed within standardizing (1050
50 rpm).
a Adjust fan speed within standard range
(1050 50 rpm).
a The set value is saved even after starting

switch is turned to OFF position.(only at
fan 70% speed mode)
Code
057
Set value
000
001
002
003
004
005
006
007
008
009
010
011
012
013
014
Fan 100% speed

+105 rpm
+90 rpm
+75 rpm
+60 rpm
+45 rpm
+30 rpm
+15 rpm
0
-15 rpm
-30 rpm
-45 rpm
-60 rpm
-75 rpm
-90 rpm
-105 rpm
a The set value is saved even after the

starting switch is turned to OFF position.
30-108
PC800, 850-8E0
Electrical system
Cylinder Cut-Out
30-109
The machine monitor allows for running the engine
in Cylinder Cut-Out mode.
Cylinder Cut-Out operation means to run the engine with 1 or more fuel injectors disabled electrically to reduce the number of effective cylinders. This
operation is used to locate a cylinder which does not
output power normally (combustion in it is abnormal).
1. Selecting menu
Select Cylinder Cut-out on the Service Menu
screen.
2. Selecting cylinder to be disabled

After the Cylinder Cut-Out screen is displayed,
select a cylinder to be cut out by using the function switches.
q [F1]: Move selection mark (R) to left
q [F2]: Move selection mark (R) to right
q [F3]: Reset holding
q [F4]: Hold
a This operation may be performed while the
engine is running.
a When [F6] is pressed, if background (a) of
the selected cylinder No. becomes white, the
cylinder is cut out.
a If the machine monitor cuts out a cylinder but
the engine controller cannot cut out that cylinder, the background (a) of the cylinder No.
becomes yellow.
a One or more cylinders can be cut-out.
a During the cylinder Cut-Out operation, the
auto-deceleration function can be enabled. If
the auto-deceleration is set to ON, auto-deceleration monitor (b) is displayed.
PC800, 850-8E0
3. Canceling cylinder cut-out

When changing a cylinder to be cut out or when
Cylinder Cut-Out operation is finished, select a
cut-out cylinder to be reset with the function
switches.
a This operation may be performed while the
engine is running.
a When [F6] is pressed, if background (a) of
the selected cylinder No. becomes blue, the
cylinder is reset.
a If the machine monitor resets a Cut-Out cylinder but the engine controller cannot reset
that Cut-Out cylinder, the background (a) of
the cylinder No. becomes red.
a The cut-out cylinder is not automatically reset
even after returning to the operator mode.
Accordingly, be sure to perform the resetting
operation after the Cylinder Cut-Out operation is finished.
4. Holding displayed data
Each time [F4] is pressed during the Cylinder
Cut-Out operation, the displayed data is newly
held (c) (the real-time data is kept displayed on
the left side).
If [F3] is pressed with the condition of hold, the
holding function is canceled.
a The holding function is available for a cylinder, regardless of whether it is cut out or not.
30-109
Electrical system
[Reference]
q If a normal cylinder is cut-out, the following
phenomena occur.
1)Lowering of engine speed
2) Increase of final injection rate command
(quantity)
q If the engine is running near the high idle,
however, the engine speed may not lower for
the reason of engine control.
q In this case, lower the engine speed with the
fuel control dial and judge by increase of the
injection rate command.
30-1 0
No Injection
If the engine is operated after long storage of the
machine, it may be worn or damaged because of insufficient lubrication with oil. To prevent this, the machine monitor allows for cranking the engine without
injecting fuel to lubricate the engine before starting
it.
Set the no-injection cranking while the engine is
stopped.
1. Selecting menu
Select No Injection on the Service Menu
screen.
2. Displaying confirmation screen

When the No injection screen is displayed, the
the message to ask if no injection cranking
should be performed appears. Answer with the
function switch.
q [F5]: Do not perform (return to Service Menu
screen)
q [F6]: Perform
a Before the following screen is displayed, the
message of Communication between controllers is being checked appears.
30-110
PC800, 850-8E0
Electrical system
3. Starting no injection cranking

If no injection cranking (fuel injection in no cylinders) becomes effective, No Injection. is
displayed on the screen. Under this condition,
crank the engine with the starting motor.
a Before the following screen is displayed, the
message of Setting is being prepared appears.
a Limit the cranking time to 20 seconds to protect the starting motor.
5. Prohibiting no injection cranking

If the operator tries to perform the no injection
cranking while the engine is running, the
message Engine is running is displayed and
the no injection cranking is not enabled.
a This function can be selected even while engine is running. If an injection cranking is attempted, however, the message of "Engine is
running" is displayed on the screen.
4. Finishing no injection cranking

After completing the no injection cranking operation, press [F6], and the message Finished is
displayed and the screen returns to the Service
Menu screen automatically.
PC800, 850-8E0
30-111
Electrical system
30-1 2
Fuel Consumption
Use this function to calculates the hourly fuel consumption from the actual fuel consumption in a measuring period and indicate it.
1. Selecting menu
Select Fuel Consumption on the Service
Menu screen.
2. Starting measurement
After the screen of Fuel Consumption is
displayed, start measurement by using the function switches.
q [F1]: START
q [F2]: CLEAR
a When the screen of Fuel Consumption is
displayed, if a data is indicated, it is the data
of the previous measurement. This data is
not an obstacle to new measurement and
can be deleted by pressing [F2].
a If [F1] is pressed, the data is displayed in the
Start Time column and measurement starts.
3. Display and function during measurement

Clock mark (a) flashes during test.
a While the fuel consumption is being tested,
the operator can work with the operator
mode and other functions. Test is not finished until [F1] is pressed again on this
screen (even if the starting switch is turned to
OFF positon, this function is kept effective,
although fuel consumption is tested only
while the engine is running).
4. Finishing measurement
Press [F1], and measurement is finished and the
data are displayed in the Stop Time column.
5. Displaying fuel consumption
If the test is finished, the hourly fuel consumption
calculated from the fuel consumption calculated
by the engine controller and the elapsed time are
displayed.
a The display unit of the fuel consumption

changes according to the unit set with the
Default (Unit) function.
SI and meter: l/h, inch: gal/h
30-112
PC800, 850-8E0
Electrical system
KOMTRAX Settings (Terminal Status)

30-1 3
The setting and operating status of KOMTRAX can
be checked by using the menu of "KOMTRAX Settings".
"KOMTRAX Settings" is used to check the setting
condition of the KOMTRAX terminal.
Select "KOMTRAX Settings" on the "Service
Menu" screen.
3. Contents displayed on Terminal Status screen

On the "Terminal Status" screen, the following
items are displayed.
q Terminal type: Model name of KOMTRAX
communication MODEM
q KOMTRAX communication: Executing condition of station opening inspection
q GMT time: Greenwich Mean Time
q [F5]: Return to KOMTRAX Settings screen

After the "KOMTRAX Settings" screen is
displayed, select "Terminal Status" by using the
a The following figure shows the display when
Model TH300 KOMTRAX is installed.
When TH300 is installed, "03 Modem S/N" is
displayed.
PC800, 850-8E0
30-113
Electrical system
KOMTRAX Settings (GPS & Communication Sta30-1 4

tus)
"GPS & Communication Status" is used to check the
positioning and communication status of the
KOMTRAX terminal.
Menu" screen.
3. Contents of display of GPS & Communication

Status
On the "GPS & Communication Status" screen,
the following items are displayed.
q Positioning: Positioning condition of GPS
q Communication: Communication environment of communication MODEM and connecting condition of communication MODEM
q Number of message not yet sent: Number of
mails which are saved in machine monitor
and not transmitted yet

displayed, select GPS & Communication
Status with the function switches or numeral
input switches.
a The following figure shows the display when
Model TH300 KOMTRAX is installed.
30-114
PC800, 850-8E0
Electrical system
KOMTRAX Setting (Modem S/N)

30-1 5
Modem S/N is used to check the serial No. and IP
address of the KOMTRAX communication modem.
3. Contents of display of Modem S/N

The serial No. of TH300 Modem is displayed.
Menu" screen.

displayed, select "Modem S/N" by using the
PC800, 850-8E0
30-115
Electrical system
30-1 6
Service Message
Special messages for the technician sent from the
KOMTRAX base station (a distributor, etc.) can be
checked with this function.
If a received message has return mail setting, a return mail can be sent by using the numeral input
switches.
Select "Service message" on the Service Menu
screen.
3. Display of message (with return mail function)

If a message provides the Numeric Input line
under the text, input a proper number by using
the numeral input switches and enter it by using
the function switch, and the information is
returned to the KOMTRAX base station.
q [F6]: To enter and return input value
a This message is different from that is sent for
the operator in the operator mode
a Since this message is special for the technician, the message monitor is not displayed
when it is received with the machine monitor
in the operator mode.
2. Display of message (read-only)

If there is a message, its contents are displayed.
If there is no message, "No message" is
displayed.
a This message is different from that is sent for
the operator in the operator mode
a Since this message is special for the technician, the message monitor is not displayed
when it is received with the machine monitor
in the operator mode.
30-116
PC800, 850-8E0
Electrical system
Handling voltage circuit of engine controller
30-1 7
1. Disconnecting or connecting operation of the

connector between the engine controller and the
engine shall be performed only when the starting
switch is in the OFF position.
2. Do not start the engine while a T-adapter is
inserted into or connected to the connector
between the engine controller and the engine for
troubleshooting purposes.
a You may turn the starting switch to the OFF
or ON position but must not turn it to the
START position.
PC800, 850-8E0
30-117
Electrical system
Preparatory work for troubleshooting of electrical system

a When carrying out troubleshooting of an electric
circuit related to the machine monitor, engine
controller, pump controller, or KOMTRAX terminal, expose the related connectors according to
a Disconnect and connect the connectors, which
have a special locking device, according to the
30-1 8
4) Insert or connect troubleshooting T-adapters

to connectors CM01, CM02, and CM03 on
machine monitor (4).
a Connectors CM02 and CM03 are of the
same type. When returning them, check
the mark plates on the mounting brackets
and take care not to make a wrong connection.
1. Machine monitor
1) Remove two mounting bolts and cover (1).
a One of the mounting bolts is installed in
the cover on the right of the sunlight sensor.
a While removing the mounting bolts, disconnect connector P31 of the sunlight
sensor.
2) Remove cover (2).
a The cover is fixed with the clip, so pull it
up to remove.
a While removing the cover, disconnect
connector M04 of the cigarette lighter.
3) Remove a mounting bolt and duct (3).
30-118
PC800, 850-8E0
Electrical system
2. Engine controller
1) Remove engine controller cover (1).
2) Insert or connect test T-adapters into or to

connectors ENG, CE02, and CE03 of engine
controller (2).
a Connectors are fixed with screw. Loosen
the screws before disconnecting them.
a When connecting the connectors, tighten
its screw to the specified torque.
3 Screw:
2.82 Nm {0.288 kgm}
3. Pump controller
1) Slide the operator's seat and seat stand to
the forward end.
2) Remove the five mounting bolts and cool &
hot box (5).
a While removing the cool & hot box, disconnect the drain hose.
3) Remove the two mounting bolts, one
fastener, and magazine box (6).
4) Remove the three mounting bolts and cover
(7).
5) Remove fuse box cover (8) and cover (9).
a Since the underside of cover (9) is
clamped, pull it up to remove.
6) Remove the seven mounting bolts and cover
(10).
PC800, 850-8E0
7) Connect test T-adapters to connectors CP01

and CP02 of pump controller (11).
a Connect the adapters to only the harness.
a The connectors of the pump controller
have a special locking mechanism. Disconnect them according to steps (a) to (c)
and connect them according to steps (d)
to (f) as shown below.
Disconnection: (a) Unlock - (b) Slide
lever
(c)
Disconnect
connector.
Connection: (d) Position connector - (e)
Slide lever - (f) Lock.
30-119
Electrical system
4. KOMTRAX communication module

1) Slide the operator's seat and seat stand to
the forward end.
2) Remove the five mounting bolts and cool &
hot box (5).
a While removing the cool & hot box, disconnect the drain hose.
3) Remove the two mounting bolts, one
fastener, and magazine box (6).
4) Remove the three mounting bolts and cover
(7).
5) Remove fuse box cover (8) and cover (9).
a Since the underside of cover (9) is
clamped, pull it up to remove.
6) Remove the seven mounting bolts and cover
(10).
7) Connect test T-adapters to connectors CK01

and CK02 of KOMTRAX terminal (12).
a Cable (13) is for the communication antenna.
5. Ambient
pressure
sensor
(AMBAIR
PRESURE)
Engine Ne speed sensor (CRANK SENSOR)
Engine Bkup speed sensor (CAM SENSOR)
a Disconnection and connection of connector
30-120
The connectors of the ambient pressure

sensor, engine Ne speed sensor, and engine
Bkup speed sensor have a special locking
mechanism. Disconnect them according to
steps (a) to (c) and connect them according
to steps (d) to (f) as shown below.
Disconnection: (a) Slide lever - (b) Unlock (c) Disconnect connector.
Connection: (d) Connect connector - (e) Lock
- (f) Slide lever.
6. Boost pressure temperature sensor (BOOST

PRES & IMT)
The connector of the boost pressure temperature sensor has a special locking mechanism. Disconnect it according to steps (a) (b), and connect it according to steps (c) - (d)
as shown below.
Disconnection: (a) Unlock - (b) Disconnect
connector.
Connection: (c) Connect connector - (d)
Lock.
a Removal and installation of sensor

A Torx wrench is necessary for removal
and installation of the boost pressure
temperature sensor. See "Tools for
testing, adjusting and troubleshooting".
PC800, 850-8E0
Electrical system
7. Common rail pressure sensor (FUEL RAIL

PRESS)
The connector of the common rail pressure
sensor has a special locking mechanism.
Disconnect it according to steps (a) to (b),
and connect it according to steps (c) to (d) as
shown below.
connector.
Lock.
a Precautions for disconnecting connector

The direction of the lock on the connector
varies depending on position at which the
tightening of the sensor has been
stopped and the lock may be in a direction
in which it is difficult to unlock (lock faces
the engine or downward).
In this case, pinch the lock in direction (a)
by bent-longnose pliers [1] (commercially
available), and the lock is unlocked.
The lock clicks when it is unlocked, so
disconnect the connector after a click is
heard.
Engage lock (e) on the wiring harness

side with triangular projection (f) on the
sensor side (Do not engage lock (e) with
square guide (g) on the opposite side of
triangular projection (f)).
8. Engine
coolant
temperature
sensor
(COOLANT TEMP)
The connector of the engine coolant temperature sensor has a special locking mechanism. Disconnect it according to steps (a) to
(b), and connect it according to steps (c) to
(d) as shown below.
connector.
Lock.
a Removal and installation of sensor

A deep socket is necessary for removal
and installation of the engine oil pressure
switch. See "Tools for testing, adjusting
and troubleshooting".
a Precautions for disconnecting/connecting

connector
Take care not to connect the connector
reversely.
PC800, 850-8E0
30-121
Pm Clinic
Pm clinic service
Pm Clinic
30-12
Pm clinic service
30-12
Model
T PC800-8E0 T PC800SE-8E0
T PC850-8E0 T PC850SE-8E0
User name
Main equipment
Boom
Arm
Bucket
Shoe
7.1 m SE
8.2 m Standard
8.2 m Quarry
2.9 m SE
3.6 m Standard
3.6 m Quarry
4.6 m Semi-long
5.6 m Long
2.8 m3 Narrow
3.1 m3 Standard
3.4 m3 Quarry
3.4 m3 Reinforced
4.0 m3 Civil engineering SE
4.3 m3 Quarry SE
4.5 m3 SE
610 mm Double grouser
Serial No.
Service meter reading
Date of inspection
/
/
Inspector
Specifications
T PC800-8E0
T PC800SE-8E0
STD specification
SE specification
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T PC850-8E0
T PC850SE-8E0
Quarry specification Quarry SE specifica
T
T
T
T
T
T
Type of work
T Construction, civil engineering T Roads
T Water supply
T Scrap
T Demolition
T(
)
Kind of operation
T Digging & Loading
T Basement digging
T Quarry
T Others
Type of soil
T Rock [ T Soft T Medium T Hard ]T Gravel T Sand T Clay soil T Sandy loam
Scheduled working hour
Replacement/day
Hour/replacement
Ambient temperature
Height above sea
T1T2T3
Time
Max.
C
Min.
C
m
T Quarry, mine
T Forestry
Was there any abnormality before inspection
a Highest reading on engine coolant temperature

gauge
30-122
a Highest range of power train oil temperature

gauge
PC800, 850-8E0
Pm Clinic
Pm clinic service
Installation positions of measuring instruments (related to engine)
PC800, 850-8E0
30-123
Pm Clinic
Pm clinic service
Installation positions of measuring instruments (related to relief pressure and OLSS oil pressure)
30-124
PC800, 850-8E0
Pm Clinic
Pm clinic service
Machine serial T PC800(SE)-8E0 #

number
T PC850(SE)-8E0 #
Pm Clinic check sheet

Work order
Item
Date of inspection
Year: Month: Day:
Test conditions
Unit
Low idle
1 Engine
1. Engine speed
Power Mode (P)
2. Blowby pressure
High idle (*1)

Engine at full speed + Boom RAISE relief
(Heavy-duty lift mode switch is in the OFF position.)
Engine at full speed + Boom RAISE relief
(Heavy-duty lift mode switch is in the ON position.)
Auto-deceleration switch is in ON position
Fuel control dial: Max.
Control lever: NEUTRAL
SAE30SE
SAE5W40EOS
SAE10W30DH
SAE15W40DH
SAE30DH
Full speed
3. Engine oil pressure
Low speed
4. Boost pressure
5. Exhaust gas temperature
Full speed
Turn the Heavy-duty lift mode switch ON.
Boom RAISE relief
Full speed
Exhaust temperaPower Mode (P)
ture
Turn the Heavy-duty lift mode
Ambient temperaswitch ON.
ture
Boom RAISE relief
Standard
800 850
Repair limit
800 850
1930 2030
1930 2030
Min. 1700
Min. 1700
Min. 1700
Min. 1700
1325 1525
1325 1525
Max. 2.94
{Max. 300}
Min. 0.34
{Max. 3.5}
3.92
{400}
0.21
{2.1}
Min. 0.10
{Min. 1.0}
0.08
{0.8}
Min. 184
{Min. 1380}
157
{1180}
Min. 450
700
Test results Good NG
rpm
kPa
<mmH20>
Torque converter stall
Inspector
h
MPa
<kg/cm2>
kPa
<mmHg>
*1: Turn swing lock switch to ON position and operate swing lever for swing finely (Do not relieve).
Item
Test conditions
PC800
1. Boom RAISE
2. Boom LOWER
3 Work equipment speed
3. Arm IN
4. Arm OUT.
5. Bucket CURL
Engine
Full speed
Power Mode (P)
Swing:
Five revolutions after first
one revolution
Travel:
Raise track shoe on one
side at a time and set travel
speed to Hi
Standard
4.8 5.8
Service limit
Max. 6.7
PC850
4.8 5.8
Max. 6.7
SE specification
PC800 Loading shovel
type
PC800
5.0 6.2
Max. 7.2
5.1 6.3
Max. 7.0
3.9 4.7
Max. 5.1
PC850
3.8 4.6
Max. 5.0
SE specification
type
PC800
4.0 4.8
Max. 5.2
4.5 5.5
Max. 6.5
4.2 5.2
Max. 6.1
PC850
4.9 5.9
Max. 6.8
SE specification
type
PC800
4.9 5.9
Max. 6.8
3.9 4.7
Max. 5.4
3.1to 3.7
Max. 4.4
PC850
3.4 4.2
Max. 4.9
3.4 4.2
Max. 4.9
SE specification
type
PC800
Rotate raised track five rev- PC850

olutions after first one revo- SE specification
lution
type
PC800
Unit
sec.
2.2 2.8
Max. 3.4
3.0 3.6
Max. 3.9
3.2 4.0
Max. 4.4
4.1 5.1
Max. 5.6
3.9 4.7
Max. 5.2
2.9 3.5
Max. 3.8
PC850
3.1 4.0
Max. 6.0
SE specification
type
3.8 4.6
Max. 5.0
3.6 4.4
Max. 5.0
1.3 1.9
Max. 2.5
1.4 2.0
Max. 2.6
9. Swing
41 47
Max. 50
10. Right turn steering
48 59
48 59
11.Left turn steering
48 59
48 59
6. Bucket DUMP
7. Bucket OPEN
8. Bucket CLOSE
PC800, 850-8E0
PC800 Loading
Test results Good NG
30-125
Pm Clinic
Pm clinic service
Measurement items
Test conditions
Boom RAISE relief
(heavy-duty lift mode; OFF)
Boom RAISE relief
(heavy-duty lift mode; ON)
Left travel relief
4 Relief pressure
1. F pump
relief pressure
Oil temperature: 45
55 C
Power Mode (P)
2. P pump
relief pressure
3. Control pressure
1. F-EPC valve
Output pressure
(Pce1)
5 OLSS oil pressure
2. R-EPC valve
Output pressure
(Pce2)
3. F-VC valve
Source pressure
(Pce1)
5. F-VC valve *
Output pressure
(Pce1)
4. R-VC valve
Source pressure
(Pce1)
6. R-VC valve *
Output pressure
(Pce1)
Hydraulic drift in
work equipment
Hydraulic tank
strainer
Unit
Left swing relief

Right swing relief
MPa
{kg/cm2}
Boom RAISE relief

Boom RAISE relief
Right travel relief

Left track idle-running
(lever at travel end)
Right track idle-running
(lever at travel end)
All control levers in NEUOil temperature: 45
TRAL
55 C
MPa
(control pressure)
Power Mode (P)
2
Boom RAISE relief
}
{kg/cm
Engine at high speed (heavy-duty lift mode; OFF)
Boom RAISE relief
(control pressure)
Boom RAISE relief
Boom RAISE relief
Standard
Repair limit
30.4 32.4
{310 330}
32.8 34.8
{335 355}
33.8 35.8
{345 365}
28.4 31.4
{290 320}
28.4 31.4
{290 320}
30.4 32.4
{310 330}
32.8 34.8
{335 355}
33.8 35.8
{345 365}
3.24 3.73
{33 38}
29.4 32.4
{300 330}
31.8 34.8
{325 355}
32.8 35.8
{335 365}
28.4 31.4
{290 320}
28.4 31.4
{290 320}
29.4 32.4
{300 330}
31.8 34.8
{325 355}
32.8 35.8
{335 365}
3.04 3.73
{31 38}
Max. 0.78
{Max. 8}
Min. 1.23
{Min. 12.5}
Max. 0.78
{Max. 8}
Min. 1.23
{Min. 12.5}
Max. 0.78
{Max. 8}
Min. 1.23
{Min. 12.5}
Max. 0.78
{Max. 8}
Min. 1.23
{Min. 12.5}
Test
Good NG
results
3.24 3.73 3.04 3.73

{33 38}
{31 38}
30.4 32.4
{310 330}
32.8 34.8
{335 355}
29.4 32.4
{300 330}
31.8 34.8
{325 355}
3.24 3.73
{33 38}
Max. 0.78
{Max. 8}
30.4 32.4
{310 330}
32.8 34.8
{335 355}
29.4 32.4
{300 330}
31.8 34.8
{325 355}
Oil temperature: 45 Lowering distance of tooth

55 C
tip
Max. 900 Max. 1,000
No load on bucket
PC800 Loading
mm/15min
shovel type
.
PC800 LoadMax. 1,500 Max. 1,800
Rated load applied to
ing
bucket
Visually check the strainer.

(Metallic powder or rubber chips)
There must not be excessive metallic powder or

foreign matter.
MEMO
* Since the pump is at the swash plate intermediate point, "5-5, 5-6 (VC valve output pressure)" is about "0.5
0.6 times" (approx. 1/2) of the "5-3, 5-4 (VC valve basic pressure)".
30-126
PC800, 850-8E0
Pm Clinic
Pm clinic service
Visual check of welded structures (for PC800, 850-8E0)
a If any crack is found, draw its shape below.

Arm
1.
Arm cylinder bracket

T Left
2.
4.
9.
T Right
6.
7.
T Right
Track frame
10.
T Right
T Right
Boom foot
T Left
PC800, 850-8E0
T Left
Boom lower plate

T Left
8.
T Right

T Left
T Right
T Right
Boom bracket
Boom cylinder bracket

T Left
Arm top boss

T Left
Boom top bracket

T Left
5.
T End plate
3.
Revolving frame
T Right
Arm foot
T Left
Boom
T Right
11.
Circle bracket
T Front
T Rear
T Left
T Right
Track frame mounting section

T Front
T Rear
T Left
T Right
30-127
Pm Clinic
Pm clinic service
Visual check of welded structures (for PC800SE, 850SE-8E0)
a If any crack is found, draw its shape below.

Arm
12.

T Left
13.
15.
20.
T Right
17.
18.
T Right
Track frame
21.
T Right
T Right
Boom foot
T Left
30-128
T Left
Boom lower plate

T Left
19.
T Right

T Left
T Right
T Right
Boom bracket
Boom cylinder bracket

T Left
Arm top boss

T Left
Boom top bracket

T Left
16.
T End plate
14.
Revolving frame
T Right
Arm foot
T Left
Boom
T Right
22.
Circle bracket
T Front
T Rear
T Left
T Right
Track frame mounting section

T Front
T Rear
T Left
T Right
PC800, 850-8E0
Pm Clinic
UNDERCARRIAGE INSPECTION REPORT
30-129
(Program form No. SELA195001)
PC800, 850-8E0
30-129
Pm Clinic
30-130
PC800, 850-8E0
SEN0527612-00
40-1
PC800, 850-8E0
HYDRAULIC EXCAVATOR
PC800-8E0
PC850SE-8E0
PC800LC-8E0
PC800SE-8E0
PC850-8E0
Shop Manual
Machine model
Serial number
Machine model
Serial number
PC800-8E0
PC800LC-8E0
PC800SE-8E0
PC850-8E0
65001 and up
65001 and up
65001 and up
65001 and up
PC850SE-8E0
65001 and up
40 Troubleshooting
PC800, 850-8E0
4-01
40-1
40-1
Contents
Contents
40-2
40 Troubleshooting
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 [CA221] Ambient Press Sens High Error ........................................................
Failure code [CA222] Ambient Press Sens Low 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............................................................
40-2
40- 7
40- 7
40- 8
40- 9
40- 35
40- 38
40- 43
40- 46
40- 48
40- 50
40- 61
40- 97
40- 100
40- 103
40- 103
40- 104
40- 104
40- 105
40- 106
40- 108
40- 109
40- 110
40- 112
40- 114
40- 116
40- 118
40- 120
40- 122
40- 124
40- 126
40- 128
40- 130
40- 132
40- 134
40- 136
40- 138
40- 140
40- 142
40- 144
40- 146
40- 147
40- 148
40- 150
40- 152
40- 154
40- 155
40- 156
40- 157
40- 158
40- 160
PC800, 850-8E0
Contents

Failure code [CA342] Calibration Code Incompatibility .......................................................
Failure code [CA351] Injectors Drive Circuit 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 [CA1626] BP Valve Sol Current High Error.....................................................
Failure code [CA1627] BP Valve Sol Current Low Error .....................................................
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 ....................................................................
PC800, 850-8E0
40- 162
40- 164
40- 166
40- 168
40- 170
40- 171
40- 172
40- 174
40- 174
40- 175
40- 175
40- 176
40- 178
40- 180
40- 181
40- 182
40- 186
40- 188
40- 189
40- 190
40- 192
40- 193
40- 194
40- 196
40- 198
40- 199
40- 200
40- 202
40- 204
40- 206
40- 208
40- 209
40- 210
40- 212
40- 214
40- 216
40- 218
40- 220
40- 222
40- 224
40- 226
40- 228
40- 230
40- 232
40- 234
40- 236
40- 238
40- 240
40- 244
40- 246
40- 248
40- 249
40- 254
40- 256
40-3
Contents
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
E-2 Preheater does not operate........................................................................................... 40- 344
E-3 When starting switch is turned to ON position, machine monitor displays nothing ....... 40- 348
............................................................................................................................................. 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
40-4
PC800, 850-8E0
Contents
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
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
............................................................................................................................................. 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
PC800, 850-8E0
40-5
Contents
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
............................................................................................................................................. 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
40-6
PC800, 850-8E0
General information on troubleshooting

Points to remember when troubleshooting
40-7
40-7
k
k
k
k
k
k
(Rev. 2010/03)
Stop the machine in a level place, and check that the lock pin, blocks, and parking brake are
securely fitted.
When carrying out the operation with two or more service technitians, keep strictly to the agreed
signals, and do not allow any unauthorized person to come near.
If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so
wait for the engine to cool down before starting troubleshooting.
Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
When disconnecting wiring, always disconnect the negative () terminal of the battery first.
When removing the plug or cap from a component which is under pressure from oil, water, or air,
always release the internal pressure first. When installing measuring equipment, be sure to
connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence of the failure. When carrying out troubleshooting, an important point is of course to understand the structure and function. However, a short cut to effective troubleshooting is to ask the operator
various questions to form some idea of possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not hurry
to disassemble the components.
If components are disassembled immediately
after any failure occurs:
q Parts that have no connection with the failure
or other unnecessary parts will be disassembled.
q It will become impossible to find the cause of
the failure.
It will also cause a waste of manhours, parts, or
oil or grease, and at the same time, will also lose
the confidence of the user or operator.
For this reason, when carrying out troubleshooting, it is necessary to carry out thorough
prior investigation and to carry out troubleshooting in accordance with the fixed procedure.
2. Points to ask the user or operator
1) Have any other problems occurred apart
from the problem that has been reported?
2) Was there anything strange about the
machine before the failure occurred?
3) Did the failure occur suddenly, or were there
problems with the machine condition before
the failure?
4) Under what conditions did the failure occur?
5) Had any repairs been carried out before the
failure? When were these repairs carried
out?
6) Has the same kind of failure occurred
before?
3) Make checks of other items.

4) Check other maintenance matters which can
be checked externally and are considered to
be necessary.
4. Confirming failure
Confirm the extent of the failure yourself, and
judge whether to handle it as a real failure or as
a problem with the method of operation, etc.
a When operating the machine to reenact the
troubleshooting symptoms, do not perform
any inspection or measurement that may
make the problem worse.
5. Troubleshooting
Use the results of the investigation and inspection in Items 2 to 4 to narrow down the causes of
failure, then use the troubleshooting flowchart to
locate the failure exactly.
a The basic procedure for troubleshooting is as
follows.
1] Start from the simple points.
2] Start from the most likely points.
3] Investigate other related parts or information.
6. Measures to remove root cause of failure
Even if the immediate failure is removed, the
same failure may occur again, unless the root
cause of the failure is repaired. To prevent this,
always investigate why the cause of the failure
occurred. Then, remove the root cause.
3. Check before troubleshooting

1) Is there any sign of irregularities of the
machine?
2) Make checks before starting day's work.
PC800, 850-8E0
40-7

Sequence of events in troubleshooting
40-8
(Rev.2007.12)
40-8
PC800, 850-8E0

Checks before troubleshooting
b: Hydraulic and mechanical equipment
a: Engine, lubricating oil and coolant
No.
Item
40-9
Criterion
Remedy
1 Check for unusual noise and smell
Repair
2 Check for dirt around engine
Remove
3 Check for water leakage around engine
Repair
4 Check for oil leakage around engine
Repair
5 Check for leakage from fuel line
Repair
6 Check of radiator for clogging
Remove
7 Check of level and type of fuel
Refill with oil
8 Check for foreign material in fuel
Clean and drain
9 Check of fuel pre-filter
Replace
10 Check of fuel main filter
Replace
11 Check of level (in oil pan) and type of engine oil
Between H and L
Refill with oil
12 Check of coolant level (in sub tank)
Between H and L
Refill with coolant
13 Check of air cleaner for clogging
Air cleaner clogging monitor is not

displayed on
machine monitor
Clean or replace
1 Check for unusual noise and smell
Repair
2 Check for oil leakage
Repair
Between H and L
Refill with oil
4 Check of hydraulic oil strainer
Clean or replace
5 Check of hydraulic oil filter
Replace
6 Check of swing machinery case oil level
Between H and L
Refill with oil
7 Check of coupling case oil level
Between H and L
Refill with oil
8 Check of coupling lubrication filter strainer
Clean or replace
9 Check of final drive case oil level
Refill with oil
10 Air bleeding
Air bleeding
3 Check of hydraulic oil level
PC800, 850-8E0
40-9

No.
Item
Criterion
Remedy
1 Check of battery terminal for looseness and corrosion
Retighten or replace
2 Check of alternator terminal for looseness and corrosion
3 Check of starting motor terminal for looseness and corrosion
20 30 V
Charge or replace
Between H and L
Add or replace
6 Check of wiring harness for discoloration, burn and cover peeling
Repair or replace
7 Check of wiring harness for coming off from clamp and sagging
Repair
8 Check of grounding
Repair
9 Check for loose connector and damaged lock
Repair or replace
10 Check of connector pin for corrosion, bending and deformation
Repair or replace
11 Check for water and foreign material in connector
Dry, clean or replace
12 Check of wiring harness for open or short circuit
Repair or replace
13 Check of fuse for blowout and corrosion
Replace
14 Check of circuit breaker
Push in reset button
After few minutes

operation: 27.5
29.5 V
Replace
Replace
17 Check and cleaning of rear view camera
Clean or repair
1 Check of undercarriage
Repair
2 Check of handrails and steps
Repair
3 Check of rear view mirrors
Clean or repair
1 Check of gauges and monitors
Clean or replace
2 Check of seat belt
Repair
4 Check of battery voltage (with engine stopped)
e: Interior parts d: Exterior parts
c: Electrical parts
5 Check of battery electrolyte level
40-10
15
Check of alternator voltage (when engine speed is medium or

higher)
16
Check of battery relay operation sound (when the starting switch

is turned to ON or OFF position)
PC800, 850-8E0

Testing procedure before troubleshooting

Walk-around check
40-1
40-1
Before starting the engine, look around and under the machine to check for any loose nuts or bolts, leakages
of oil, fuel or coolant, and check the condition of the work equipment and hydraulic system.
Check the connectors for looseness, the wiring harnesses for play, and the hot parts for accumulated dust.
k
Accumulated combustibles around hot engine parts such as the engine muffler and turbocharger,
etc. and fuel or oil leakages may cause a machine fire. Be sure to check thoroughly and repair any
failures.
a a1 and a2, ---, b1, b2, --- refer to the symbols in the table on the previous page.
a1. and b1. Check for unusual noise and smell
Check for unusual noise and smell.
Some causes of unusual noise and smell can
damage the machine if they are left as they are.
Therefore, stop the machine immediately when
you find any abnormality.
a2. Check for dirt around engine
Check for and remove any accumulated dirt
around the engine and any combustibles (dead
leaves, twigs, etc.) on hot engine parts such as
the engine muffler, turbocharger, etc.
a3. Check for water leakage around engine
a4. Check for oil leakage around engine
Check for any oil leaks from the engine and any
water leaks from the coolant system, and then
repair any failures.
a5. Check for leakage from fuel line
Check for any fuel leaks and damaged hoses
and tubes, and then repair any failures.
a6. Check of radiator for clogging
Check for and remove any accumulated dirt and
combustibles (dead leaves, twigs, etc.) around
the radiator.
For removal of dirt from the radiator, see the
Operation and Maintenance Manual, "Cleaning
and testing of radiator fins, oil cooler fins, aftercooler fins, fuel cooler fins and air conditioner
condenser fins (machine with the air conditioner)".
b2. Check of work equipment, cylinders, linkage
and hoses for breakage, wear and clearance
Check the work equipment, cylinders, linkage
and hoses for cracks and excessive wear, check
that the clearances in them are within the normal
range, and then repair any failures.
PC800, 850-8E0
b3. Check of hydraulic equipment, hydraulic

tank, hoses and joints for oil leakage
Check and repair any oil leaks.
c1. Check for dirt around battery
Check for and remove any accumulated dirt and
combustibles (dead leaves, twigs, etc.) around
the battery.
c16. Check and cleaning of rear view camera
Check the rear view camera for any defect, and
repair any failures.
d1. Check of undercarriage (track, sprocket,
idler and guard) for defect, wear, loose bolts and
oil leakage from roller
Repair any failures.
d2. Check of handrails and steps for defect and
loose bolts
Repair any failures and retighten any loose
bolts.
d3. Check and cleaning of rear view mirrors
Check for and repair any defective and broken
rear view mirrors.
Clean the mirror surfaces and adjust their angles
so that the operator can see the area behind
machine at the operator's seat.
e1. Check of gauges and monitors for defect
Check the gauges and monitors inside the operator's cab. If any of them is defective, replace it.
Clean up the surfaces.
e2. Check of seat belt and mounting hardware
Check the hooks, locks and hook fittings for
damage, and then repair any failures.
40-11

Test according to testing procedure

a. Engine, lubricating oil and coolant
40-12
40-12
a7. Check of level and type of fuel

k Fuel is flammable and dangerous. Do not
bring any open flame near fuel.
k When adding fuel, take care not to let it
overflow.
k Wipe off any spilt fuel. If fuel has spilt over
dirt and sand, remove the dirt and sand, too.
1. Turn the starting switch to ON position and
check the fuel level with fuel level gauge (1) on
the monitor panel.
After checking, return the switch to OFF position.
If breather hole (3) in the oil filler cap is

clogged, the pressure in the tank decreases
and fuel may not be supplied. To prevent this,
clean the breather hole.
2. If the fuel level is low, open fuel filler cap (F) of

the fuel tank and add fuel through the oil filler
port to the necessary level, referring to the position of float gauge (G).
a At full, float gauge (G) rises to the highest position (a = approx. 50 mm).
3. After adding fuel, push float gauge (G) straight
down with fuel filler cap (F) and tighten fuel filler
cap (F) securely while taking care the float
gauge (G) will not be caught in tab (2) of fuel filler
cap (F).
40-12
PC800, 850-8E0

a8. Check for foreign material in fuel

1. Open the side cover on the rear right side of the
machine.
2. Place a container under drain hose (1) to receive
the drained fuel.
3. Pull out drain hose (1) from clip at machine side,
and direct its end towards the container.
4. Turn drain valve (2) to "OPEN" position (parallel
to hose) to discharge the sediment and water in
the bottom together with fuel.
5. When only the clean fuel flows out, turn drain
valve (2) to the "CLOSE" position (right angle
against hose).
6. Close the side cover.
Check of water separator, and drainage of water

and sediments
1. Open the engine hood.
q The water separator is integrated with fuel
pre-filter (1).
2. Transparent cap (2) lets you identify the water

level and presence/absence of sediments. If
water or sediments are found, place a container
under drain hose (3) to receive the drained water
and sediments.
a9. Check of fuel pre-filter

k Immediately after the engine is stopped, its
parts and oil is still very hot and may cause
burn injury. Accordingly, wait until they have
cooled down before starting the work.
k High pressure is generated in the engine fuel
piping system while the engine is running.
Wait for at least 30 seconds after stopping
the engine until the internal pressure
decreases, and then replace the filter.
k Do not bring any open flame near the filter.
a Komatsu genuine fuel filter cartridges use a special filter with a high filtration efficiency. When replacing, be sure to use a Komatsu genuine
cartridge.
a The common rail fuel injection system of this machine consists of parts that are more precise
compared with the conventional injection pump
and nozzle. If a fuel filter cartridge other than Komatsu genuine one is used, foreign material may
enter, which can cause a trouble in the injection
system. Never use a substitute.
a When testing and servicing the fuel system, be
extremely careful that no foreign material enters.
If any dirt sticks, remove it completely by using
fuel.
q Prepare a container to receive the fuel.
q Prepare the filter wrench.
PC800, 850-8E0
3. Loosen drain valve (4) to discharge the water

and sediments in transparent cap (2).
4. If drain hose (3) starts to discharge fuel, close
drain valve (4) immediately.
a When the water in transparent cap (2) is frozen, drain the water after confirming the frozen water is melt completely. During the cold
weather, drain the water frequently.
a When it is difficult to check the condition of
the water in transparent cap (2) due to stain,
clean transparent cap (2) at the replacement
of fuel pre-filter cartridge (1). (see next item)
a When transparent cap (2) is removed for
cleaning, it must be tightened to the end after
applying grease to O-ring (5). (see next item)
40-13

Replacing fuel pre-filter cartridge

1. Turn valve (1) at the fuel tank bottom to
"CLOSE" position (right angle against hose).
10. After transparent cap (2) touches the seal

surface of pre-filter cartridge (1), tighten it by 1/4
to 1/2 turn.
a If transparent cap is over-tightened, O-ring is
damaged to cause fuel leakage. If it is not
tightened enough, fuel leaks through the
clearance at O-ring. Accordingly, tighten
transparent cap (2) as specified.
a Check that the drain plug (4) at the bottom of
transparent cap (2) is securely tightened.
3 Drain plug (4):
0.2 0.4 Nm {0.02 0.046 kgm}

3. Place a container under the fuel pre-filter
cartridge to receive the fuel.
4. Turn valves (2) and (3) under the pre-filter to the
right to close.
5. Loosen drain valve (4) and drain the water and

sediments from transparent cap (2) and drain all
the fuel from filter cartridge (1).
6. Remove transparent cap (2) from the pre-filter
cartridge, and check.
a If there is any damage, replace the cap.
7. Using the filter wrench, rotate filter cartridge (1)
to the left to remove.
8. Clean the transparent cap (2) and remove O-ring
(5).
9. Apply clean fuel or oil to O-ring (5) before installation.
a When replacing the filter cartridge, O-ring (5)
should be replaced with new one.
40-14
11. Clean the filter bracket and apply oil lightly to the
packing surface of the filter cartridge.
12. Add clean fuel to the filter cartridge.
a Be sure to add fuel through 8 small holes (A)
on the dirty side without removing center cap
(B).
a Add clean fuel and take care that dirt is not
mixed in it. Be sure to add fuel without removing cap (B) to prevent dirt from entering the
clean side of the central part.
13. Remove cap (B) at the center of the filter
cartridge and install the filter cartridge to the filter
bracket.
PC800, 850-8E0

14. Install the pre-filter cartridge.

a When installing it, tighten it by 3/4 turn after
O-ring touches the seal surface of filter
bracket.
a If the pre-filter cartridge is tightened excessively, fuel will leak because O-ring will be
damaged. If the filter cartridge is not tightened sufficiently, fuel will also leak through
the clearance at the packing. Therefore, observe the tightening angle.
15. Then, proceed to "a10. Check of fuel filter".
a10. Check of main filter
k High pressure is generated in the engine fuel
piping system while the engine is running.
Wait for at least 30 seconds after stopping
the engine until the internal pressure
decreases, and then replace the filter.
k Do not bring any open flame near the filter.
a Komatsu genuine fuel filter cartridges use a special filter with a high filtration efficiency. When replacing, be sure to use a Komatsu genuine
cartridge.

3. Place the fuel receiving container under main
fuel filter cartridge (2).
4. Using the filter wrench, rotate filter cartridge (2)
to remove.
5. Clean the filter holder. Apply a thin film of oil to

the packing of the new filter cartridge and install
the cartridge to the filter holder.
a Do not fill the new filter cartridge with fuel.
6. Remove center cap (A).
a The common rail fuel injection system of this machine consists of parts that are more precise
compared with the conventional injection pump
and nozzle. If a fuel filter cartridge other than Komatsu genuine one is used, foreign material may
enter, which can cause a trouble in the injection
system. Never use a substitute.
a When testing and servicing the fuel system, be
extremely careful that no foreign material enters.
If any dirt sticks, remove it completely by using
fuel.
q Prepare a container to receive the fuel.
q Prepare the filter wrench.
1. Turn valve (1) at the fuel tank bottom to
"CLOSE" position (right angle against hose).
PC800, 850-8E0
7. Install filter cartridge (2).

a When installing it, tighten it by 3/4 turn after
O-ring touches the seal surface of filter holder.
a If filter cartridge (2) is over-tightened, O-ring
is damaged to cause fuel leakage. If it is not
tightened enough, fuel leaks through the
clearance at O-ring. Accordingly, tighten filter
cartridge (2) as specified.
40-15

8. Turn valve (1) at the fuel tank bottom to "OPEN"

position.
9. Bleed air according to the following procedure.
1) Loosen air bleeding plug (A) at the top of fuel
main filter cartridge (2).
a Do not loosen the plug at head side of fuel
main filter, since it is at suction side. (If
loosen it, air bleeding can not be done.)
6) Tighten wing nut (4) securely and fix lever

(3).
Tightening torque: 11.8 Nm {1.5 kgm}
10. Turn valve (1) at the fuel tank bottom to the left,
and open fuel supply valve.
11. Start the engine and run at low idle for approximately 10 minutes.
12. Check the filter sealing surface for fuel leakage.If
fuel leakage is found, check the tightening condition of filter cartridge. If fuel leakage is still
existing, remove filter cartridge in accordance
with procedure 1 to 4. If O-ring is damaged or
pinched with foreign material, replace the
cartridge with a new one and perform procedure
5 and after.
2) Loosen wing nut (4) fixing priming pump lever

(3).
3) Push down lever (3) repeatedly.
Confirm that the fuel comes out following
bubble from air bleeding plug (A).
4) Tighten air bleeding plug (A).
Tightening torque: 4.9-6.9 Nm {0.50.7
kgm}
5) Perform priming for approximately 50 times

with supply pump priming pump (5).
40-16
PC800, 850-8E0

a11. Check of level (in oil pan) and type of

engine oil
a If the engine has been operated, wait for at least
15 minutes after stopping it, and check the oil
level.
a When checking, set the machine in a horizontal
position.
1. Stop the engine.
3. Remove oil level gauge (G) and wipe off oil on
the gauge with a cloth.
4. Insert oil level gauge (G) fully and pull it out.
6. If the oil level is above H, remove cover (1).

7. Drain excess oil from drain valve (P) at the
bottom of engine oil pan as follows, and then
check oil level again.
1) Connect hose (2) stored in tool box to drain
valve (P).
2) Drain the oil by lowering drain valve lever (3).
After draining the oil, close by raising the
lever.
a Never loosen plug (a). Without loosening
plug (a), oil comes out by lever operation.
a When hose (2) is not in use, store it in tool
box.
5. If the oil level is between stamped lines H and L

on oil level gauge (G), it is at the correct level.
If the oil level is below line L, add oil through oil
filler port (F).
8. If the oil is at the correct level, tighten the oil filler

cap securely and close the engine hood.
PC800, 850-8E0
40-17

a12. Check of coolant level (in sub tank)

k You do not need to open the radiator cap in
the ordinary check. Check the coolant on the
sub tank side after the engine has cooled
down.
k Immediately after the engine is stopped, the
coolant is hot and pressure is accumulated
in the radiator.
If the cap is opened under these conditions,
you may get burn injury. If you need to remove the radiator cap, wait until the temperature drops before you do. Then rotate the
cap slowly to release the pressure and remove it with care.
1. Open the side cover (1) at the rear left side of
machine and check whether the coolant level is
between lines FULL and LOW on sub tank (2)
(see following figure). If there is not enough
coolant, open cover (3) and add coolant through
the coolant filler port (4) of sub tank (2) until the
level reaches line FULL.
2. After adding the coolant, tighten the cap
securely.
3. If sub tank is empty, there may be water leakage.
After checking, repair any failures immediately. If
no failure is found, check the coolant level in the
radiator. If the level is low, add coolant to the
radiator first and then to the sub tank.
4. If sub tank (2) is dirty and it is difficult to check
the coolant level, clean it.
Refilling of coolant to radiator
1. Remove cover (5) and loosen radiator cap (6)

slowly. After confirming inner pressure is
released, push down the cap, and then loosen it
further to remove.
2. Check that the coolant level is above hatched

area shown in the right figure , and if it is insufficient, add coolant from coolant filler port.
3. After adding coolant, install radiator cap (3).
40-18
PC800, 850-8E0

a13. Check of air cleaner for clogging

k When using compressed air for cleaning, put
on personal protective items such as
protective eyeglasses, gloves, dust mask,
etc. to protect yourself from dirt that will fly
out.
k Removing the outer element from the air
cleaner body forcibly is dangerous .
When working in high places or on unstable
footing, you may fall off due to the reaction
when you pull out the outer element. Take
care.
Checking
Clean the air cleaner element if air cleaner clogging
monitor (1) on the monitor panel lights up.
a Do not clean the element until the air cleaner

clogging monitor lights up on the monitor panel.
If the element is cleaned frequently before the air
cleaner clogging monitor on the monitor panel
lights up, the true performance of the air cleaner
will not be realized and the filtration efficiency will
decrease.
a If the outer element is checked or cleaned while
the engine is running, the dirt sticking to it will fall
into the inner element side more frequently and
enter and damage the engine. Be sure to stop
the engine before cleaning.
PC800, 850-8E0
40-19

Cleaning of outer element

a Do not leave or store the element in direct sunlight before or after cleaning it.
a Replace the outer element after cleaning it six
times or after using it for 1 year. When replacing
the outer element, also replace the inner element.
a If the air cleaner clogging monitor (1) lights up
soon after cleaning when the outer element has
not been cleaned up to six times, replace both
the inner and outer elements.
1. Open the side cover at the rear left side of the
machine and disengage four hooks (2) to
remove cover (3).
5. If dirt has piled up on vacuator valve (4) installed
on cover (3), remove it.
2. Hold and pull out outer element (5) while

swinging it up, down and laterally and rotating
element to the left and right.
a Never remove inner element (6). If it is removed, dirt will enter and cause engine troubles.
a Do not use a screwdriver or another tool.
a After removing outer element (5), check that
the inner element has not come off or tilted. If
the inner element is tilted, push it in straight
by hand.
3. After removing outer element (5), cover the inner
element (6) with a clean cloth or tape to prevent
dirt from sticking to it.
4. Remove any dirt stuck to the inside of air cleaner
body (7) and cover (3) with a piece of clean cloth,
etc.
a When cleaning the element, do not tap it or
bump it against other objects.
40-20
6. Blow dry compressed air (Max. 0.69 MPa

{7 kg/cm2}) along the inside folds of the outer
element.
7. Next, blow air along the outside folds, and blow
again along the inside folds.
PC800, 850-8E0

a After cleaning, light up the inside of the element to check it. If the element has a small
hole or a thin component, replace it.
8. Remove the cloth or tape covering inner element

(6).
9. Check and remove any dirt, oil, etc. sticking to
the sealing surface of the cleaned or new
element.
a If the element or O-ring over one year age is
reused after cleaning, it may cause trouble,
so do not reuse it.
a Do not use the element if its folds, gasket or
seal is damaged.
10. Push the outer element straight into the air
cleaner body by hand while swinging it up, down
and laterally.
a Install the air cleaner element with its bottom
(end with no hole) (C) on cover (3) side.
If the air cleaner element is installed in
reverse, it may be broken and the engine
may be damaged seriously.
11. Install cover (3) according to the following procedure.

1) Set cover (3) to the element.
a Be sure to install cover (3) so that vacuator (4) is at the bottom (A).
2) Hitch the tips of hooks (2) to the projection of

the air cleaner body to lock.
a Hitch hooks (2) diagonally (top and bottom, or right and left) to lock.
a After installing cover (3), check for clearance between the air cleaner body and
cover (3). If there is any clearance, remove and install cover (3) correctly.
12. Peel off a seal after cleaning the element each

time.
PC800, 850-8E0
40-21

Replacement of element
1. Remove outer element (5). For details, see
"Cleaning of outer element".
2. Remove inner element (6) and install new inner
element (6) quickly to air cleaner body (7).
a Do not clean or reuse the inner element.
When replacing the outer element, also replace the inner element.
5. Install cover (3). For details, see "Cleaning of

outer element".
6. Replace the seal of cover (3) with a new one.
7. After replacing the element, press reset button
(9) of dust indicator to return yellow display plate
as before.
(end with no hole) (B) on cover (3) side.
a If the outer element and cover are installed
while the inner element is not installed securely, the outer element may be broken. Install the inner element securely.
3. Push the outer element straight into the air

cleaner body by hand while swinging it up, down
and laterally.
(end with no hole) (B) on cover (3) side.
4. Replace O-ring (8) of cover (3) with a new one.
40-22
PC800, 850-8E0

b. Hydraulic and mechanical equipment
40-23
b3. Check of hydraulic oil level

k If the oil filler cap is removed quickly, the oil
may spurt out. Accordingly, rotate the oil
filler cap slowly to release the internal
pressure and remove it with care.
1. Set the work equipment in the posture as shown
below and, after stopping the engine, check the
oil level and add new oil if necessary.
a If the work equipment posture is not as
shown below, start the engine, fully retract
the cylinder rod for arm and bucket at engine
low idle. Then lower the boom until bucket
teeth touch the ground, then stop the engine.
4. If oil is added to above line H,

1) Swing the upper structure to place drain plug
(P) at the pump bottom between right and left
tracks, then stop the engine and cool down
the hydraulic oil.
2) Remove the pump under cover.
2. Turn the starting switch to the ON position within
15 seconds after stopping the engine and
operate each control lever (work equipment and
travel) to the stroke end in each direction to
release the internal pressure.
3) When draining oil, remove lower drain plug

(P) first, and then loosen side drain plug (R)
to drain oil.
a After draining oil, tighten plugs (P) and
(R).
3. Open cover (1) on the left side of the machine

and check sight gauge (G). If the oil level is
between lines H and L, it is at the correct level.
a If the oil level is below line L, add oil through
oil filter port (F).
a Do not add oil to above line H. If too much is
added, it may damage the hydraulic circuit
and spurt out.
a Since the oil level fluctuates according to the
oil temperature, note the following when
checking it.
q Before operation (oil temperature: 10 to
30 C), the oil level should be at the
center between lines H and L.
q During normal operation (oil temperature:
50 to 80 C), the oil level should be near
line H.
PC800, 850-8E0
40-23

b4. Check of hydraulic oil strainer

may spurt out. Accordingly rotate the oil filler
cap slowly to release the internal pressure
and remove it with care.
1. Stop the engine and remove oil filler cap (F) of
the hydraulic tank to release the internal pressure.
2. Remove the bolts to remove cover (1).
When removing the bolts, keep pressing down
cover (1) since it may be flung toward you by
spring (2).
3. Pull out rod (3) from the top, and take out spring
(2) and strainer (4).
4. Remove dirt from strainer (4) and clean it using
cleaning oil. If strainer (4) is damaged, replace it
with a new one.
5. Insert and set strainer (4) in projected portion (5)
of the tank.
6. While pressing down spring (2) with the projection at the bottom of cover (1), install the bolts.
7. Tighten the mounting bolts.
40-24
PC800, 850-8E0

b5. Check of hydraulic oil filter

9. Tighten the mounting bolts.
1. On a level and firm ground, set the work equipment to the posture as shown below and stop the
engine.
10. Install oil filler cap (F).
11. Run the engine at low idle for 10 minutes to
bleed air.
12. Stop the engine.
2. Remove oil filler cap (F) of the hydraulic tank to

release the internal pressure.
3. Remove the bolts to remove cover (1).

When removing the bolts, keep pressing down
cover (1) since it may be flung toward you by
spring (2).
4. Remove spring (2), valve (3) and strainer (5),
and then remove element (4).
q Check the bottom of the filter case and remove dirt if there is. At this time, take extreme
care that dirt does not enter the hydraulic
tank.
5. Clean the removed parts using cleaning oil.
6. Install new element (4).
7. Place strainer (5), valve (3) and spring (2) onto
the element.
8. Set cover (1) and install it with the mounting bolts
while pressing it by hand.
PC800, 850-8E0
40-25

b6. Check of swing machinery case oil level

2. Insert oil level gauge (G) fully into the guide.
3. Pull out oil level gauge (G) and check the oil
level. If the oil level is between stamped lines (H)
and (L) on the oil level gauge, it is at the correct
level.
4. If the oil level is below line (L) on oil level gauge
(G), remove the cap of oil filter port (F) and add
oil. When adding oil, remove oil level gauge (G).
q Swing machinery on the front of machine
a (A): Front
6. Pull out drain hose (1) and loosen drain valve (P)
to drain excess oil.
a After draining excess oil, wind hose (1) to
store into hole (B).
7. After checking the oil level and adding oil, install
oil level gauge (G) and oil filler cap (F).
q Draining on the front of machine
Draining on the rear of machine
Swing machinery on the rear of machine

(A): Front
5. If the oil level is above line (H) on oil level gauge

(G), place the oil receiving container under drain
valve (P).
40-26
PC800, 850-8E0

b7. Check of coupling case oil level

k Before checking the oil level, stop the
machine in a level place and wait for at least
30 minutes after the engine is stopped.
1. Open the cover at the rear left side of the
machine.
3. Insert oil level gauge (G) fully and pull it out.
4. If the oil level is between lines H and L on oil level

gauge (G), it is at the correct level.
If oil level is below L, add oil through the hole (F)
of oil level gauge (G).
PC800, 850-8E0
b8. Check of coupling lubrication filter strainer

1. Stop the engine and remove oil filler cap (F) of
the hydraulic tank to release the internal pressure.
2. Place the oil receiving container under the filter

case.
3. Remove filter case (1).
4. Take out the strainer and remove dust etc. stuck
on it, then clean it with flushing oil. If the strainer
or O-ring is damaged, replace it with a new one.
q Check the bottom of filter case, and if there is
any dust etc., remove it.
5. Install filter case (1) with strainer inserted in it.
40-27

b9. Check of final drive case oil level

k Since the oil may spurt out due to internal
pressure, rotate the plug gradually from its
side to release the internal pressure and then
remove it carefully.
q Refill capacity (right and left, respectively): 10 l
q Prepare the handle.
1. Set the final drive with TOP mark at the top, and
the straight line connecting the mark and plug (p)
is vertical to the ground surface.
2. Place the fuel receiving container under plug (P).
3. Remove plug (P) and (F) using the handle to
drain oil.
a Check the O-ring fit on plug for damage, and
replace it if necessary.
4. Tighten plug (P).
5. Supply oil through the hole for plug (F).
6. If oil flows out from the hole for plug (F), install
plug (F).
3 Plugs (P) and (F):
68.6 9.8 Nm {7 1 kgm}
c. Electrical parts
40-28
c1. Check of battery terminal for looseness and

corrosion
1. Open battery cover (1).
2. Check battery terminals (A) for looseness and
corrosion.
c2. Check of alternator terminal for looseness

and corrosion
q Remove the engine under cover (1).
q Check alternator terminals B, R and E for breakage, looseness and corrosion.
c3. Check of starting motor terminal for
looseness and corrosion
q Check starting motor terminals B, C and R for
breakage, looseness and corrosion.
c4. Check of battery voltage (with engine
stopped)
Test the battery voltage by using the battery tester
while the engine is stopped.
b10. Air bleeding

For the procedure for bleeding air from the fuel
system, see Testing and adjusting, "Bleeding air
from fuel circuit".
q For the procedure for bleeding air from the hydraulic equipment, see Testing and adjusting,
"Bleeding air from each part".
q
40-28
c5. Check of battery electrolyte level

Check before operating the machine.
k Do not use the battery while its electrolyte
level is below LOWER LEVEL. If it is used
under that condition, its inside will
deteriorate, its service life will be shortened
and it may lead to an explosion.
k Since the battery produces combustible gas
that can explode, do not bring any open
flame near it.
k Battery electrolyte is dangerous. Take care
that it does not come in contact with your
eyes or skin. If it does, wash it away with
water and contact your doctor.
a Do not add battery electrolyte beyond the UPPER LEVEL mark. Excessive addition can
cause electrolyte leakage that damages the
painted surface and corrodes the parts.
a As purified water (example: commercially available battery fluid) added to the battery may
freeze, add it before starting work for the day so
that it does not freeze.
PC800, 850-8E0

When checking the electrolyte level through the

side face of the battery
1. Clean around the electrolyte level lines using a
cloth soaked in water, and check that the electrolyte level is between UPPER LEVEL (U.L.) and
LOWER LEVEL (L.L.)
a Do not clean the battery with a dry cloth since
static electricity may cause an explosion.
When electrolyte level cannot be checked

through the side face of the battery
1. Remove cap (2) on the top of the battery.
(Described previously)
2. Look into electrolyte level opening (3) to check
the electrolyte level. If the electrolyte level is
below sleeve (4), be sure to add purified water
(example: commercially available battery fluid)
up to the sleeve bottom (U.L. line).
q (A) Correct level: Since the electrolyte level
reaches to the sleeve bottom, the shape of
the electrode plates will appear distorted due
to the surface tension.
q (B) Low: Since the electrolyte level does not
reach the sleeve bottom, the shape of the
electrode plates will appear straight.
3. After adding the purified water, tighten cap (2).
2. If the electrolyte level is below the center

between the U.L. and L.L. lines, remove cap (2)
and add purified water (example: commercially
available battery fluid) to the U.L. line immediately.
3. After adding the purified water, tighten cap (2)
securely.
a If you have added purified water above the

U.L. line, take some of it out using a syringe
or similar tool. Neutralize the liquid that has
been taken out with sodium bicarbonate or
other suitable liquid, and wash it out with a
large amount of water.
a If you have added purified water above the

U.L. line, take some of it out using a syringe
or similar tool. Neutralize the liquid that has
been taken out with sodium bicarbonate or
other suitable liquid, and wash it out with a
large amount of water.
PC800, 850-8E0
c6. Check of wiring harness for discoloration,

burn and cover peeling
q Check the wiring harness and cables for discoloration and burn.
a Discoloration and burn indicate that short circuit
or ground fault is in the circuit.
q Check the wiring harnesses and cables for damage and peeling of the covers.
q If any failures are discovered, repair or replace
the wiring harness or cable.
40-29

c7. Check of wiring harness for coming off from

clamp and sagging
q Check the wiring harnesses for sagging and
loosening caused by coming off from a clamp.
a In particular, carefully check the wiring harness
around the hot and movable parts.
q If any part is off the clamp, resecure it to the
clamp.
Check the connection of ground terminal (T10).
c8. Check of grounding

a Check the ground terminal for looseness and
rust in particular.
q Open the battery cover.
q Check the connection of ground terminals (T04)
to (T08).
q SL: Step light
q CB: Circuit breaker box
40-30
PC800, 850-8E0

Open the engine hood.

a Check the connection of engine ground strap
from the bottom of engine.
q Remove cover (1).
q
c9. Check for loose connector and damaged

lock
q Pull the male and female connectors by hand to
check the connection.
q If the connection is defective, connect them securely.
Check the connection of ground strap (2) of engine controller (EC) and ground terminal (T09).
q
q
Check that the connector is not unlocked and

check its lock and housing for cracks.
Check lock screws (L) of engine controller (EC)
for looseness.
a Use a hexagonal wrench with 4 mm width
across flats.
Cab ground T02

a Since (T02) is situated at the bottom on the rear
left side of the cab and connected to (T01), it is
not particularly necessary to be checked.
q
q
Remove cab rear undercover.

Check the connection of ground terminal (T01).
(Left of air conditioner unit)
PC800, 850-8E0
c10. Check of connector pin for corrosion,

bending and deformation
q Disconnect the connector and check the pins for
corrosion, bending and withdrawing than other
pins. Check that the female pins have not expanded.
q If any pin is found to be defective, repair or replace it.
a If the pins are not shiny, apply contact restorer to
them and connect and disconnect several times
to shine them. (If the pins do not become shiny,
connect and disconnect the connector 10 times)
40-31

c11. Check for water and foreign material in

connector
q Disconnect the connector and check for water,
dirt, sand, etc. in it.
a If sand or foreign material is in the connector,

check the seal for damage.
q If the seal is defective, repair or replace it.
q Dry the moisture in the connector by using a drier.
c12. Check of wiring harness for open or short

circuit
q Check the connection (crimped parts) between
each connector pin and wiring harness.
q If any open circuit is in wiring harness or connector as (A) in the figure, repair or replace them.
Check that any pin does not contact any adjacent pin due to peeling of the wire cover, defective crimping of the pin, etc.
Remove foreign material in the connector by using a cloth or other material, and blow compressed air against the inside of the connector.
40-32
PC800, 850-8E0

c13. Check of fuse for blowout or corrosion

a When replacing a fuse, be sure to turn off the
power (turn the starting switch to OFF position).
q A fusible link is a large-capacity fuse.
q If a fuse is corroded and coated with white powder, or there is any play between the fuse and
fuse holder, replace the fuse.
q Replace each fuse with the one of the same capacity.
Remove the cover at the right rear of the operator's
cab, and fuse holder (F01) is seen.
c14. Check of circuit breaker

k Do not keep pressing the reset button of
circuit breaker. (It may cause fire.)
q The circuit breaker opens the electrical circuit to
protect the electrical parts and wiring when an
overcurrent flows through it. It can be used repeatedly.
If the circuit breaker works, reset button (1)
comes out.
q Check all the circuit breakers to see whether any
of reset buttons (1) have come out.
q To return the open electrical circuit to normal
condition, push in reset button (1) that has come
out.
a If reset button (1) comes out again soon after it
is pushed in and the starting switch is turned to
ON position, the overcurrent is still flowing.
Check the electrical circuit in this case.
q
Check of circuit breaker

1. Turn starting switch to OFF position.
2. Open the inspection cover in front of fuel tank at
the rear right side of the machine, then open the
circuit breaker box.
PC800, 850-8E0
40-33

3. Press each reset button (1) of circuit breakers

No.1 [1] to No.9 [9] in order.
a If the electrical circuit is open, the operating effort of the reset button is heavier compared with
the case when the circuit is operating normal.
c15. Check of alternator voltage (when engine

speed is medium or higher)
2. Connect the positive (+) lead of the multimatter
to alternator terminal (B) and connect the negative (-) lead to the chassis ground.
3. Start and warm up the engine and measure the
voltage while running the engine at a medium or
a higher speed.
q If the voltage is abnormal, repair or replace
the alternator.
c16. Check of battery relay operation sound
1. Open the battery cover.
2. Check whether the battery relay operation sound
is heard when starting switch is turned to
ON/OFF position.
q If the operation sound is not heard, check the
related circuits, referring to E-1 described in
the E mode troubleshooting.
q If the related circuits are normal, replace the
battery relay.
40-34
PC800, 850-8E0

Classification and procedures for troubleshooting
40-35
Classification for troubleshooting
40-35
Mode
Contents
Display of code Troubleshooting by failure code

E-mode
Troubleshooting of electrical system
H-mode
Troubleshooting of hydraulic and mechanical systems
S-mode
Troubleshooting of engine
Procedure for troubleshooting

40-35
If a problem occurs on the machine, proceed to the appropriate troubleshooting section according to the following procedure.
1. Procedure for troubleshooting when user code and failure code are displayed on machine
monitor:
If a user code and a failure code are displayed on the machine monitor, perform the troubleshooting for
the corresponding "Display of code".
a If multiple failure codes are displayed simultaneously, all the codes are displayed repeatedly in order.
Note down all the codes.
2. Procedure for troubleshooting when a user code and a failure code are not displayed on machine
monitou:
Check the mechanical system failure code and the electrical system failure code by using the abnormailty
record function of the machine monitor. (See [*1].)
1) If failure code (s) is (are) recorded, perform troubleshooting for the failure code described in Troubleshooting [Display of code].
a If electrical system failure code (s) is (are) recorded, delete all the codes and reproduce them in
order to see if the problem remains unsolved. (See [*2].)
a The failure code of the mechanical system cannot be deleted.
a If an air conditioner system failure is recorded in the abnormality record , perform "Inspection by
self-diagnosis function " in "Air conditioner ". (See [*3].)
2) If no failure code is found in the abnormality record, a problem that the machine monitor cannot find
out by itself may have occurred in the electrical system or hydraulic and mechanical system.
In this case, check the phenomenon which is assumed to show a trouble again and select the same
phenomenon from the list on the next page, and then perform troubleshooting corresponding to that
phenomenon in the "E-mode", "H-mode", or "S-mode".
3. Action to take after trouble is eliminated
Referring to the next page, clear all the failure codes in the electrical system abnormality record.
PC800, 850-8E0
40-35

[*1], [*2]
1. While pressing numerical key [4] of the panel
switch section with the standard screen
displayed, press [1], [2] and [3] in order.
2. On the Service Menu screen, press [F3] switch

(R) on the panel switch section once to select
"02 Abnormality Record".
3. Press [F6] switch ( ) on the panel switch to
confirm and go to "Abnormality Record" screen.
5. Press the [F3] switch (R) on the panel switch

section to see if the next failure code is displayed
and note down all the failure codes.
a A mechanical system failure code cannot be
cleared.
6. Press [F5] switch (Return) on the panel switch
section to return to the "Abnormality Record"
screen.
7. Select the "Electrical Systems " screen similarly
to steps 2 and 3.
8. Press the [F3] switch (R) on the panel switch
section to see if the next failure code is displayed
and note down all of the failure codes.
a "E" on the left of a failure code indicates that
the failure code is "active" (the failure remains or restoration to the normal condition
has not been verified). A failure code having
no "E" on its left is a "inactive" one. Since it
disappears at the following clear step, be
sure to note it down.
9. While pressing numerical key [4] on the panel
switch section, press [1], [2] and [3] in this order
to select the "Clear mode". (Same as step 1)
10. Press [F2] switch(CLEAR) on the panel switch
section.
11. Press [F6] switch ( ) on the panel switch to clear
all the failure codes temporarily.
section to return to the "Electrical Systems"
abnormality record screen. See if any failure
code is still displayed and note down displayed
ones.
screen.

confirm and go to "Mechanical system" screen.
40-36
PC800, 850-8E0

[*3]
a For the method of accessing the "Abnormality
Record" screen, see steps 1 to 3 in [*1] and [*2].
1. On the "Abnormality Record" screen, press [F3]
switch (R) on the panel switch section twice to
select "03 Air-conditioning System".
confirm and enter the "Air conditioner abnormality record" screen.
3. Note down the information in all the columns.

a "E" on the left of a failure code (same as in
the "Electrical Systems" abnormality record)
indicates that the failure code is "active" (the
failure remains or its restoration to the normal
condition has not been verified).
4. Press [F2] switch (CLEAR) on the panel switch
section to clear all the codes. Check whether any
failure code is still displayed and note down
displayed ones. (Same as step 10 of [*1] and
[*2])
screen.
PC800, 850-8E0
40-37

Failure codes table
Failure codes table

Failure code
Failure (Displayed on screen)
40-38
Component
Category of
User code
in charge
record
989L00
Engine Controller Lock Caution 1
MON
989M00
MON
989N00
MON
AA10NX
Air Cleaner Clogging
MON
AB00KE
Charge Voltage Low
MON
B@BAZG
Eng Oil Press Low
ENG
B@BAZK
Eng Oil Level Low
MON
B@BCNS
Eng Water Overheat
ENG
B@BCZK
Eng Water Level Low
MON
B@HANS
Hyd Oil Overheat
PUMP
CA111
EMC Critical Internal Failure
ENG
E10
CA115
Eng Ne and Bkup Speed Sens Error
ENG
E10
CA122
Chg Air Press Sensor High Error
ENG
E11
CA123
Chg Air Press Sensor Low Error
ENG
E11
CA131
Throttle Sensor High Error
ENG
E14
CA132
Throttle Sensor Low Error
ENG
E14
CA135
Eng Oil Press Sensor High Error
ENG
E15
CA141
Eng Oil Press Sensor Low Error
ENG
E15
CA144
Coolant Temp Sens High Error
ENG
E15
CA145
Coolant Temp Sens Low Error
ENG
E15
CA153
Chg Air Temp Sensor High Error
ENG
E15
CA154
Chg Air Temp Sensor Low Error
ENG
E15
CA187
Sens Supply 2 Volt Low Error
ENG
E15
CA221
Ambient Press Sens High Error
ENG
E11
CA222
Ambient Press Sens Low Error
ENG
E11
CA227
Sens Supply 2 Volt High Error
ENG
E15
CA234
Eng Overspeed
ENG
CA238
Ne Speed Sens Supply Volt Error
ENG
E15
CA263
Fuel Temp Sensor High Error
ENG
E15
CA265
Fuel Temp Sensor Low Error
ENG
E15
40-38
Electrical
system
Electrical
system
Electrical
system
Mechanical
system
Mechanical
system
Mechanical
system
Mechanical
system
Mechanical
system
Mechanical
system
Mechanical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Reference
document
page
40-103
40-104
40-104
40-105
40-106
40-108
40-109
40-110
40-112
40-114
40-116
40-118
40-120
40-122
40-124
40-126
40-128
40-130
40-132
40-134
40-136
40-138
40-140
40-142
40-144
40-146
40-147
40-148
40-150
40-152
PC800, 850-8E0

Failure codes table
CA271
IMV/PCV1 Short Error
ENG
E10
CA272
IMV/PCV1 Open Error
ENG
E10
CA273
PCV2 Short Error
ENG
E10
CA274
PCV2 Open Error
ENG
E10
CA322
Inj #1 (L#1) Open/Short Error
ENG
E11
CA323
ENG
E11
CA324
ENG
E11
CA325
ENG
E11
CA331
ENG
E11
CA332
ENG
E11
CA342
Calibration Code Incompatibility
ENG
E10
CA351
Injectors Drive Circuit Error
ENG
E10
CA352
Sens Supply 1 Volt Low Error
ENG
E15
CA386
Sens Supply 1 Volt High Error
ENG
E15
CA441
Battery Voltage Low Error
ENG
E10
CA442
Battery Voltage High Error
ENG
E10
CA449
Rail Press Very High Error
ENG
E11
CA451
Rail Press Sensor High Error
ENG
E11
CA452
Rail Press Sensor Low Error
ENG
E11
CA553
Rail Press High Error
ENG
E15
CA554
Rail Press Sensor In Range Error
ENG
E11
CA559
Rail Press Low Error
ENG
E15
CA689
Eng Ne Speed Sensor Error
ENG
E15
CA731
Eng Bkup Speed Sens Phase Error
ENG
E15
CA757
All Continuous Data Lost Error
ENG
E10
CA778
Eng Bkup Speed Sensor Error
ENG
E15
CA1228
EGR Valve Servo Error 1
ENG
E15
CA1625
EGR Valve Servo Error 2
ENG
E11
CA1626
BP Valve Sol Current High Error
ENG
E11
CA1627
BP Valve Sol Current Low Error
ENG
E11
CA1628
Bypass Valve Servo Error 1
ENG
E15
CA1629
Bypass Valve Servo Error 2
ENG
E11
PC800, 850-8E0
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
40-154
40-155
40-156
40-157
40-158
40-160
40-162
40-164
40-166
40-168
40-170
40-171
40-172
40-174
40-174
40-175
40-175
40-176
40-178
40-180
40-181
40-182
40-186
40-188
40-189
40-190
40-192
40-193
40-194
40-196
40-198
40-199
40-39

Failure codes table
CA1631
BP Valve Pos Sens High Error
ENG
E11
CA1632
BP Valve Pos Sens Low Error
ENG
E11
CA1633
KOMNET Datalink Timeout Error
ENG
E0E
CA2185
Throt Sens Sup Volt High Error
ENG
E14
CA2186
Throt Sens Sup Volt Low Error
ENG
E14
CA2249
Rail Press Very Low Error
ENG
E11
CA2271
EGR Valve Pos Sens High Error
ENG
E11
CA2272
EGR Valve Pos Sens Low Error
ENG
E11
CA2351
EGR Valve Sol Current High Error
ENG
E11
CA2352
EGR Valve Sol Current Low Error
ENG
E11
CA2555
Grid Htr Relay Open Circuit Error
ENG
E15
CA2556
Grid Htr Relay Short Circuit Error
ENG
E15
D110KB
Battery Relay Drive Short Circuit
PUMP
D163KB
Flash Light Relay Short Circuit
PUMP
D195KA
Step Light Relay Open Circuit
PUMP
E50
D195KB
Step Light Relay Short Circuit
PUMP
E50
D19JKZ
Personal Code Relay Abnormality
KOMTRAX
E01
D862KA
GPS Antenna Open Circuit
KOMTRAX
DA22KK
Pump Solenoid Power Low Error
PUMP
E0E
DA25KP
5 V Sensor1 Power Abnormality
PUMP
E07
DA29KQ
Model Selection Abnormality
PUMP
DA2RMC
CAN Discon (Pump Con Detected)
PUMP
E0E
DA80MA
Auto. Lub. Abnormal.
PUMP
DAF8KB
Camera Power Supply Short Circuit
MON
DAFGMC
GPS Module Error
KOMTRAX
DAFRMC
CAN Discon (Monitor Detected)
MON
E0E
DGE5KB
Ambi. Temp Sensor Short Circuit
PUMP
DGH2KB
Hyd Oil Sensor Short
PUMP
DH25KA
L Jet Sensor Open Circuit
PUMP
E07
DH25KB
L Jet Sensor Short Circuit
PUMP
E07
DH26KA
R Jet Sensor Open Circuit
PUMP
E07
DH26KB
R Jet Sensor Short Circuit
PUMP
E07
40-40
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Mechanical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
40-200
40-202
40-204
40-206
40-208
40-209
40-210
40-212
40-214
40-216
40-218
40-220
40-222
40-224
40-226
40-228
40-230
40-232
40-234
40-236
40-238
40-240
40-244
40-246
40-248
40-249
40-254
40-256
40-258
40-260
40-262
40-264
PC800, 850-8E0

Failure codes table
DHPEKA
F Pump P. Sensor Open Circuit
PUMP
E07
DHPEKB
F Pump P. Sensor Short Circuit
PUMP
E07
DHPFKA
R Pump P. Sensor Open Circuit
PUMP
E07
DHPFKB
R Pump P. Sensor Short Circuit
PUMP
E07
DV20KB
Travel alarm short circuit
PUMP
DW41KA
Swing Priority Sol Open Circuit
PUMP
DW41KB
Swing Priority Sol Short Circuit
PUMP
DW43KA
Travel Speed Sol Open Circuit
PUMP
DW43KB
Travel Speed Sol Short Circuit
PUMP
DW45KA
Swing Brake SolOpen Circuit
PUMP
E03
DW45KB
Swing Brake Sol Short Circuit
PUMP
E03
DW7BKA
Fan Reverse Sol Open Circuit
PUMP
DW7BKB
Fan Reverse Sol Short Circuit
PUMP
DW7JKA
Bottom Dump Priority Sol Open Circuit
PUMP
DW7JKB
Bottom Dump Priority Sol Short Circuit
PUMP
DW91KA
Travel Junction Sol Open Circuit
PUMP
DW91KB
Travel Junction Sol Short Circuit
PUMP
DWK0KA
2-stage Relief Sol Open Circuit
PUMP
DWK0KB
2-stage Relief Sol Short Circuit
PUMP
DX16KA
Fan Pump EPC Sol Open Circuit
PUMP
E11
DX16KB
Fan Pump EPC Sol Short Circuit
PUMP
E11
DXAAKA
F Pump EPC Sol Open Circuit
PUMP
E07
DXAAKB
F Pump EPC Sol Short Circuit
PUMP
E07
DXABKA
R Pump EPC Sol Open Circuit
PUMP
E07
DXABKB
R Pump EPC Sol Short Circuit
PUMP
E07
DY20KA
Wiper Working Abnormality
PUMP
DY20MA
Wiper Parking Abnormality
PUMP
DY2CKA
Washer Drive Open Circuit
PUMP
DY2CKB
Washer Drive Short Circuit
PUMP
DY2DKB
Wiper Drive (Fwd) Short Circuit
PUMP
DY2EKB
Wiper Drive (Rev) Short Circuit
PUMP
DY2FMA
Upper Wiper Working Abnormality
PUMP
PC800, 850-8E0
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
40-266
40-268
40-270
40-272
40-274
40-276
40-278
40-280
40-282
40-284
40-286
40-288
40-290
40-292
40-294
40-296
40-298
40-300
40-302
40-304
40-306
40-308
40-310
40-312
40-314
40-316
40-320
40-322
40-324
40-326
40-330
40-334
40-41

Failure codes table
DY2GKM
Wiper Select Abnormality
PUMP
Electrical
system
40-336
a In this table, failure codes are arranged in the order of characters from numeric to alphabelic character.
a A component in charge means a controller or the machine monitor that is in charge of the system check.
MON: Machine monitor
ENG: Engine controller
PUMP: Pump controller
KOMTRAX: KOMTRAX part of machine monitor
a The failure codes that do not have user codes in the user code columns are not displayed on the standard
screen even if a failure code is generated. They are just recorded in the abnormality record (electrical system and mechanical system) on the service menu.
a The category of record column shows in which system each failure is classified, the electrical equipment
system or mechanical equipment system, when it is recorded in the abnormality record.
For details, see "Troubleshooting by failure code (Display of code)".
40-42
PC800, 850-8E0

Symptom and troubleshooting numbers
40-43
Troubleshooting
NO.
Symptom of failure
Index
Reference document
page
User code, failure code

1 User code and failure code are displayed on machine monitor
The failure code is displayed on the mechanical system abnormality
2
record screen
The failure code is displayed on the electrical system abnormality
3
record screen
The failure code is displayed on the air conditioner or heater abnor4
mality record screen
NO.
Take actions by following the failure code.
"Inspection by self-diagnosis function" in

Chapter 80
Symptom of failure
Troubleshooting
Reference document
Index
page
Symptom related to engine

5 Startability is poor
6 Engine does not start
7 Engine does not pick up smoothly
8 Engine stops during operation
9 Engine runs rough or is unstable
S-1
40-454
E-1, S-2
40-339, 40-456
S-3
40-460
S-4, H-2
40-461, 40-418
S-5
40-462
10 Engine lacks power
S-6
40-464
11 Exhaust smoke is black (incomplete combustion)
S-7
40-466
12 Oil consumption is too much (or exhaust smoke is blue)
S-8
40-468
13 Oil becomes contaminated early
S-9
40-469
14 Fuel consumption is excessive
S-10
40-470
15 Oil is in coolant (or coolant spurts back or coolant level goes down)
S-11
40-471
16 Oil pressure drops
S-12
40-472
17 Oil level rises (coolant, fuel in oil)
S-13
40-474
18 Coolant temperature rises too high (overheating)
S-14
40-476
19 Unusual noise is heard
S-15
40-477
20 Vibration is excessive
S-16
40-478
21 Preheater does not operate
E-2
40-344
22 Automatic warm-up system does not operate (in cold season)
E-13
40-361
23 Auto-decelerator does not operate normally
E-14
40-362
Symptom related to work equipment, swing and travel

24 Any of work equipment, swing, and travel does not work
25 All of work equipment, swing and travel work slow or lack power
26 Engine speed lowers significantly or engine stalls
E-20, H-3
40-366, 40-420
H-1
40-416
H-2, S-6
40-418, 40-464
27 Working mode does not change
E-15
40-363
28 Unusual sound is heard from around hydraulic pump
H-4
40-422
H-5
40-423
Symptom related to work equipment

29 Speed or power of boom is low
30 Speed or power of arm is low
H-6
40-425
31 Speed or power of bucket is low
H-7
40-426
32 Boom does not move
H-8
40-427
33 Arm does not move
H-9
40-427
34 Bucket does not move
H-10
40-427
35 Hydraulic drift of work equipment is large
H-11
40-428
PC800, 850-8E0
40-43

Troubleshooting
NO.
Symptom of failure
Index
Reference document
page
36 Time lag of work equipment operation is large.
H-12
40-430
37 Heavy lift function does not operate or can not be released.
H-13
40-431
38 Machine push-up function does not operate or can not be released.
H-14, E-21
40-431, 40-368
39 Boom shockless function does not work or is not canceled
H-15, E-22
40-431, 40-370
40 Machine deviates in one direction
H-16
40-432
41 Machine deviates largely at start
H-17
40-435
42 Machine deviates largely during combined operation
H-18
40-436
43 Travel speed or power is low
H-19
40-437
Symptom related to travel
44 One of tracks does not run
H-20
40-438
H-21, E-16
40-439, 40-364
E-25
40-378
47 Upper structure does not swing
H-22
40-440
48 Swing acceleration is poor or swing speed is low

In combined operation of work equipment, swing acceleration is poor
49
or swing speed is low
50 Upper structure overruns excessively when it stops swinging
H-23
40-441
H-24
40-442
H-25
40-444
51 Shock is large when upper structure stops swinging.
H-26
40-445
52 Large unsual noise is heard when upper structure stops swinging
H-27
40-446
53 Swing drift on a slope is large
H-28
40-447
54 Swing brake does not operate properly
E-23
40-372
E-3
40-348
45 Travel speed does not change

46 Travel alarm does not sound or does not stop sounding
Symptom related to swing
Symptom is related to machine monitor

When starting switch is turned to ON position, machine monitor dis55
plays nothing
When starting switch is turned to ON position (before starting
56
engine),basic check monitor lights up
57 Precaution monitor lights up while engine is running.
E-4
40-351
E-5
40-352
58 Emergency stop monitor lights up while engine is running
E-6
40-354
59 Engine coolant temperature gauge does not indicate properly
E-7
40-355
60 Hydraulic oil temperature gauge does not indicate properly
E-9
40-358
61 Fuel level gauge does not indicate properly

Displays on machine monitor are different from those for actual
62
machine
63 Some areas of machine monitor are not displayed
E-8
40-356
E-10
40-360
E-11
40-360
64 Function switch does not operate
E-12
40-360
65 Alarm buzzer cannot be stopped
E-17
40-365
66 When starting switch is turned OFF, service meter is not displayed
E-18
40-365
67 Service mode can not be selected
E-19
40-365
68 Windshield wiper and window washer do not operate

E-24
40-374
Air conditioner does not operate normally (including air conditioner
"Testing and troubleshooting procedure" in
69
fault record)
Chapter 80
"Boom RAISE" indicator is not displayed properly with monitoring func70
E-26
40-380
tion
"Boom LOWER" indicator is not displayed properly with monitoring
71
E-27
40-382
function
72 "Arm IN" indicator is not displayed properly with monitoring function
E-28
40-384
73 "Arm OUT" indicator is not displayed properly with monitoring function
40-44
E-29
40-386
PC800, 850-8E0

Troubleshooting
NO.
Symptom of failure
Index
Reference document
page
E-30
40-388
"Bucket CURL" indicator is not displayed properly with monitoring

function
"Bucket DUMP" indicatior is not displayed properly with monitoting
75
function
76 "Swing" indicator is not displayed properly with monitoring function
E-31
40-390
E-32
40-392
77 "L.H. travel" is not displayed properly with monitoring function
E-33
40-394
78 "R.H. travel" is not displayed properly with monitoring function
E-34
40-396
79 "Attachment" is not displayed properly with monitoring function
E-35
40-398
H-29
40-448
E-36
40-400
82 KOMTRAX system does not work properly
E-37
40-402
83 Horn does not sound or does not stop
E-38
40-403
84 Step light does not light up or go off
E-39
40-406
74
Others
The fan rotation is unusual.
(Fan noises and vibrations are unusual large, or overheat)
81 Electric grease gun does not operate
80
PC800, 850-8E0
40-45

Information in troubleshooting table
40-46
(Rev. 2010/03)
a The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before performing troubleshooting, understand that information fully.
User code
Display on
machine monitor
Detail of failure
Action of
machine monitor or controller
Problem on
machine
Related information
Failure code
Display on machine
monitor
Failure
Failure name displayed on the Abnormality Record screen of the

machine monitor
Description of the failure detected by the machine monitor or controller

Action to be taken to protect the system and equipment when the machine monitor or controller
detects a trouble
Problem that appears on machine as result of action (above) taken by machine monitor or controller
Information related to detected failure or troubleshooting
Cause
Procedure, measuring location, criteria and remarks

<Details of description>
q Procedure
q Measuring location
Defective component
a "Between A and B" means the measurement of voltage, resistance or others between terminals A and B.
q Criteria to judge probable causes (normal value)
q Remarks for judgment
<How to use troubleshooting sheet>
q Perform troubleshooting procedures in numerical order.
Open or short circuit in wiring
q If the check result does not meet the criteria, the probable cause described
harness
on the left column is the actual cause of the failure.
q If the check result shows no abnormality, and unless otherwise specified, proceed to the next step (next cause item).
q Check that the failure is fixed after a failure was found and repaired.
Open circuit in wiring harness
<Failures in wiring harness>
(wire breakage or defective con- q Open circuit in wiring
tact of connector)
The connector connection is defective or the wire is broken.
q Ground fault
A harness not connected to ground circuit contacts the ground wiring or
machine.
q Hot short circuit
Ground fault in wiring harness
A harness not connected to the power circuit (24 V) contacts with the power
(contact with ground circuit)
circuit.
q Short circuit
An independent wire in the harness contacts with other wire.
(poor insulation at connector and others)
<Precautions for troubleshooting>
Hot short circuit
(1) Connector number indication method and handling of T-adapter
(contact with 24 V circuit)
For troubleshooting, insert or connect T-adapter as follows unless otherwise
specified.
q When "male" or "female" is not indicated with a connector number, disconnect the connector, and insert T-adapter between the male and female connectors.
q When "male" or "female" is indicated with a connector number, disconShort circuit in wiring harness
nect the connector, and connect T-adapter only to either male or femae
connector.
(2) Description sequence of pin number and handling of tester lead
For troubleshooting, connect the positive (+) and negative (-) leads as shown
below unless otherwise specified.
q Connect the positive (+) lead to pin or wire indicated first.
Defective controller
q Connect the negative (-) lead to a pin or wire indicated second.
40-46
PC800, 850-8E0

Related circuit diagram
40-47
This is the excerpted circuit diagram related to

troubleshooting
q The circuit diagram contains the connector Nos., pin
Nos., and connector colors related to the failure.
q The circuit diagram contains the destination or source of
the branch line in a wiring harness.
q Arrow (io): Roughly shows the location on the
machine.
q NO: Normally Open
q NC: Normally Closed
PC800, 850-8E0
40-47

Troubleshooting method for open circuit in wiring harness of pressure sensor system
Troubleshooting method for open circuit in wiring harness of pressure

sensor system
40-48
a Since pressure sensors consisting not only of resistors but also electronic circuit components such as amplifiers have variation in measured value and its own polarities. So troubleshooting must be performed
carefully.
Failure codes applicable to this diagnosis
q CA222: Ambient pressure sensor low error
Procedure
1. Measure and record resistance of pressure sensor unit.
1) Disconnect pressure sensor connector (1) and connect socket (2) to the sensor side connector.
2) Measure resistances R1 and R2 between pins.
a If polarities of multimeter probes to apply are reversed, measured values may change. Therefore,
when measuring resistances in steps 1 and 2, apply the multimeter probes to the pressure sensor
connector so that their polaritied match these of the sensor.
a If measured value is infinite, take measurements by applying the probes of opposite polarities and
record the finite value obtained as a measured value.
a Since measured values may be dispersed, take several measurements. Cause of this dispersion
appears to be a charge in a sensor. Repeat steps 1 and 2 several times. Consider this dipersion
when judging whether the wiring harness is open in step 3.
2. Measure and record resistance with the wiring harness between the pressure sensor and engine controller
connected.
1) Since 5 V power supply to the pressure sensor is supplied to other sensors, disconnect other sensor
connectors first. (*)
2) With the pressure sensor to measure connected, disconnect connector (3) on engine controller side,
and connect T-adapter (4) to the harness side connector.
3) Connect T-box (5) to T-adapter (4) and measure resistances R1' and R2' between respective pins.
3. Judging open circuit
a "Apparent difference" means a difference of 10 or more times.
If there is an "apparent difference" between resistances R1 and R2 measured in step 1 and resistances
R1' and R2' measured in step 2, "wiring harness is open".
40-48
PC800, 850-8E0

Troubleshooting method for open circuit in wiring harness of pressure sensor system
List of pressure sensor measuring locations and reference values

Sensor
Ambient pressure
sensor
Measuring location at
sensor pin
Measured internal resistance of

sensor
(Reference value)
Remarks
R2: Between (1) and (3)
Approx. 3.2 kz
Sensor is common to engine models 95, 125, 140, 170 and 12 V140
R1: Between (2) (+) and

(1) (-)
(2) (-)
Approx. 4.6 kz
Approx. 2.9 kz
If polarities are reversed, resistance value changes.
*: In addition to the above, when measuring R2', disconnect the following:(See circuit diagram related to failure code CA187)
q When measuring R2' of ambient pressure sensor (CA222):
Connectors of charge pressure sensor, resistance RES, engine oil pressure sensor, G sensor, EGR valve
lift sensor and bypass valve lift sensor
Measurement record (For measuring locations, see circuit diagram related to failure code CA222)
Sensor
Sensor unit (Measuring

location on sensor pin
side connector)
R2: Between (1) and (3)
Ambient pressure
sensor
PC800, 850-8E0

(1) (-)
(2) (-)
Measured value
Sensor + Wiring harness

(Measuring location on
harness side connector
of engine controller)
R2': Between (37) and
(38) (*)
R1': Between (3) (+)
and (38) (-)
R1': Between (38) (+)
and (3) (-)
Measured value
40-49

Connector list and layout
40-50
Location
Address
ConConnecnector
tor type
No.
Number of pins
ConConnecnector
tor type
No.
Number of pins
PC800, 850-8E0
Location
Address
A01
4 Intermediate connector
S-1
B27
Terminal 1 Circuit breaker (7)
Z-2
A02
S-1
B28
AB-1
A03
DT
M-2
B29
Terminal
A05
DT
S-1
BP
DT
A06
DT
N-1
CE02
A07
SWP
S-1
CE03
A09
SWP
N-1
CK01
070
A10
DT
O-1
A11
DT
E-9, T-1
CK02
070
A13
DT
E-9
CM01
A15
F-1
CM02
A16
DT
G-9
A22
DT
J-9
A23
A26
Intermediate connector
4 (loading shovel specification)
N-1
A40
DT
4 Camera
I-9
A41
DT
4 Camera 2 (if equipped)
A42
DT
4 Camera 3
A43
A44
A49
1 Circuit breaker (9)
AC-1
2 Bypass valve
AK-8
DRC
50 Engine controller
AM-2
DTP
AL-3
070
4 Engine controller
KOMTRAX communica14
tion terminal
KOMTRAX communica14
tion terminal
18 Machine monitor
070
12 Machine monitor
M-4
CM03
070
18 Machine monitor
M-3
CM04
12 Machine monitor
M-4
8 Machine monitor
N-6
CN1
070
MITSUMI
DT
CN2
CN3
DT
SWP
CM05
W-7
W-7
M-5
2 Injector #1
AM-8
DT
2 Injector #2
AM-8
DT
2 Injector #3
AM-8
CN4
DT
2 Injector #4
AK-4
CN5
DT
2 Injector #5
AK-3
R-8
CN6
DT
2 Injector #6
AP-7
N-1
CP01
AMP
81 Pump controller
T-9
CP02
AMP
40 Pump controller
U-8
AC01 YAZAKI 8 Air conditioner unit
W-3
D01
SWP
8 Diode
M-8
B01
HD30
AD-9
D02
SWP
8 Diode
M-8
B02
DT
AB-9
D03
SWP
8 Diode
M-9
B03
DT
AB-9
D04
SWP
8 Diode
V-8
8 Diode
B11
AC-5
D05
SWP
B12
AC-5
E22
DT
B13
AD-4
EGR
DT
B14
Z-3
ENG
DRC
B15
AD-3
F01
B16
AD-3
B17
AA-1
B18
AB-1
GT5
W-3
X-4
AM-1
2 EGR valve
AK-7
60 Engine controller
AL-2
20 Fuse
SUMI3 G sensor
TOMO
Terminal 1 Machine monitor
T-9
AK-4
B19
AD-2
H08
B21
AB-5
H09
B22
AA-5
H14
Q-8
090
Q-8
B23
AD-5
H15
B24
Z-3
H16
W-3
20 Junction connector
X-7
V-3
B25
AA-1
J01
B26
AD-4
J02
40-50
PC800, 850-8E0
ConConnecnector
tor type
No.
Location
Address
ConConnecnector
tor type
No.
Number of pins
Number of pins

Location
Address
J03
V-2
L02
DT
2 Right headlamp
J04
W-7
L03
2 Room lamp
AG-9
J05
V-8
L04A
SWP
2 Headlamp (right)
AE-7
J06
V-8
L04B
SWP
2 Headlamp (left)
AF-8
J07
L05
SWP
AH-9
J08
L06
SWP
AF-8
J09
L06A
SWP
2 Step light (if equipped)
AG-8
J1939
DT
AN-8
L07
DT
J11
Terminal block
C-1
L09
J12
Terminal block
J13
Terminal block
F-1
L15
DT
J14
Terminal block
F-1
M01
PA
J15
Terminal block
L-3
M02
KES0
2 Speaker (L.H.)
AJ-8
J16
Terminal block
L-2
M03
KES0
2 Speaker (R.H.)
AI-9
J17
Terminal block
K-2
M04
J18
Terminal block
I-1
M05
J19
Terminal block
L-4
J20
Terminal block
J-1
J21
Terminal block
K-8
J22
Terminal block
L-7
J23
Terminal block
J-1
J24
Terminal block
L-8
J25
Terminal block
I-9
J26
Terminal block
K-8
J27
Terminal block
K-9
J29
Terminal block
F-1
J30
Terminal block
F-1
3 CAN
J31
Terminal block
I-1
J32
Terminal block
H-1
J33
Terminal block
L-7
J34
Terminal block
L-7
JM01
AP-3
JM02
AP-3
JM03
AP-2
JM04
AM-2
JM05
AP-4
JM06
AP-4
JM07
AO-8
JM08
AO-8
K01
2 Pump (PC) resistor
N-6
K02
DT
L01A
DT
L01B
DT
3 CAN terminating resistor

Working lamp (L.H.)
2
(Boom)
Working lamp (R.H.)
2
(Boom)
PC800, 850-8E0
A-9
A-9
M06
2 Flash light (if equipped)

Backup lamp (if
2
equipped)
Revolving warning lamp
2
(if equipped)
9 Radio
YAZAKI 2 Cigarette lighter

M
6 Upper wiper
YAZAKI 2 Washer motor
A-3
E-1
AI-9
U-2
N-6
M-3,
AE-5
I-1
M07
090
2 Horn (high tone)
C-1
M08
090
C-2
M09
M10
M11
M12
M13
2 Horn (low tone)

Optional power supply
2
(1)
2
(2)
DC/DC converter (if
4
equipped)
2
(2)
2 12 V socket (if equipped)
M14
DT
2 Travel alarm
L-8
M15
6 Lower wiper
D-1
M16
2 Electrical grease gun

Electrical intake air
M23 Terminal 1
heater
Air conditioner compresM34
X
1 sor electromagnetic
clutch
Heated sheet (if
M35
DT
2
equipped)
Heated sheet (if
M36
DT
2
equipped)
N08
DT
12 Service connector
SUMIN10
4 Air conditioner unit
TOMO
FRAMNE
3 NE sensor
ATOME
OrbKOMTRAX communicaBNC
1
comm
tion terminal
Bucket CURL PPC presP01
X
2
sure switch
W-3
X-4
X-5
X-4
X-5
Y-6
AK-7
AK-5
T-2
T-1
T-9
S-9
AP-3
L-2
40-51
P02
P03
P04
P05
Location
Boom lower PPC pressure switch

Swing LEFT PPC pressure switch
Arm IN PPC pressure
switch #2
Bucket DUMP PPC
pressure switch
Boom UP PPC pressure switch
Swing RIGHT PPC pressure switch
Arm DUMP PPC pressure switch
Left travel (forward) PPC
pressure switch
Left travel (reverse) PPC
pressure switch
Right travel (forward)
PPC pressure switch
Right travel (reverse)
PPC pressure switch
Service connector
Bottom dump pressure
switch (loading shovel
specification)
Air conditioner high/low
pressure switch
Fuel control dial
Address
K-2
L-4
L-3
ConConnecnector
tor type
No.
Number of pins
ConConnecnector
tor type
No.
Number of pins

Location
CAN4 Boost pressure sensor

NON
FRAMPOIL
3 Engine Oil Pressure
ATOME
R01 Terminal 1 Battery relay terminal E
PIM
Address
AP-5
AL-2
Y-7
R02
Terminal 1 Battery relay terminal BR
Z-8
K-2
R03
Terminal 1 Battery relay terminal M
Z-8
K-2
R04
Z-8
P06
P07
P08
P09
P10
P11
P12
P13
P13
P17
S090
P20
P21
DT
C-9
R17
P22
DT
L-3
R18
Terminal 1 Battery relay terminal B

MIT5 Working lamp relay
SUBA
Starting motor cut-out
DENSO 5
relay (PPC lock)
Starting motor cut-out
DENSO 5
relay (Personal code)
MIT6 Horn relay
SUBA
MIT5 Step light relay
SUBA
MIT5 Flash L. Relay
SUBA
MIT6 Working lamp relay
SUBA
MIT5 Cab headlamp relay
SUBA
Terminal 1
heater relay
Terminal 1
heater relay
Terminal 1
heater relay
DENSO 5 Heater drive relay
R20
DENSO 5 Blower relay
R21
DENSO 4 Compressor relay
L-7
RES
DT
L-4
L-3
H-1
I-1
G-1
H-1
J-1
J-1
R05
R06
R07
R08
R09
R10
R11
R12
R15
Q-1
O-7
R16
S-9
M-9
M-9
T-9
U-9
U-9
T-9
AA-6
AA-6
Y-7
P23
DT
P24A
2 Fuel level sensor

Hydraulic oil tempera2
ture sensor
Air cleaner clogging sen2
sor
2 Coolant level sensor
P24B
2 Tank
L-8
S02
SWP
6 Light switch
P25
AMP
3 F pump pressure sensor
J-9
S04
SWP
6 Swing lock switch
P-7
P26
AMP
H-9
S05
SWP
DT
K-9
S06
SWP
P28
DT
J-9
S07
SWP
P29
DT
G-9
S08
SWP
P31
Y050
M-5
S10
Y090
P44
DT
S10
Y090
S11
Y090
6 Machine push-up switch

6
switch (if equipped)
6
switch (if equipped)
Lower wiper switch (if
6
equipped)
2 Right knob switch (horn)
Right knob switch (horn)
and bottom dump switch
6
(open): Loading shovel
specification
Left knob switch (power
2
max. switch)
P-7
P27
3 R pump pressure sensor

F J/S differential pres4
sure sensor
R J/S differential pres4
sure sensor
Ambient temperature
3
sensor
2 Sunlight sensor
Engine oil temperature
2
sensor
FRAM3 Ambient pressure sensor

ATOME
SUMIPCV1
2 Supply pump #1
TOMO
SUMIPCV2
2 Supply pump #2
TOMO
PFUE
Common rail pressure
AMP
3
sensor
L
PAMB
40-52
I-9
AL-2
AN-1
AK-5
U-8
V-8
2 Resistance: (620 z)
U-8
AN-8
O-7
P-7
O-6
T-1
AK-5
AK-3
PC800, 850-8E0
ConConnecnector
tor type
No.
S11
Y090
S13
S14
S15
SWP
S15
DT
V10
DT
P-7
V11
DT
V12
DT
2 R EPC solenoid
V13
DT
J-1
J-1
L-6
L-6
Terminal 1 Starting motor terminal S AP-9
Terminal 1 Alternator B terminal
AK-1
AP-7
Terminal 1 Alternator E terminal
AK-2
AP-4
Terminal 1 Alternator R terminal
AL-1
S46
SBP
DT
SEGR
DT
SSW Terminal 5

Coolant temperature
2
sensor
2 Floor frame ground
2
Terminal 1 Cab ground
A-3
N-9
N-9
N-8
V14
V17
V19
S-9
AI-9
V20
AL-8
AL-8
V21
V-3
AJ-3
1 Radio body ground
U-2
T03A Terminal 1 Radio body ground
U-2
T04
Terminal 1 Revolving frame ground
AB-7
T05
AB-6
T06
AA-6
T07
AA-6
T08
AA-6
T09
Terminal 1 Engine body
AM-2
T10
D-1
T11

PPC oil pressure lock
DT
2
solenoid
DT
2 Straight-travel valve
Travel speed selector
DT
2
solenoid
Swing holding brake
DT
2
solenoid
E-1
PC800, 850-8E0
V09
AJ-3
L-5
AP-7
V05
2 Fuel temperature sensor
S30
V04
DT
L-5
Terminal 1 Starting motor terminal R AO-9
16
V02
V08
Boom head 2-stage

safety solenoid
Main 2-stage relief solenoid
solenoid (Raise) (if
equipped)
solenoid (Lower) (if
equipped)
F EPC solenoid
090
V01
AP-7
S25
DT
Address
2 Starting motor
Terminal 6
T03
V06
Location
S22
T02
ConConnecnector
tor type
No.
O-6
Terminal 12
DT
PACKARD
PACKTIM
ARD
PACKTWTR
ARD
T01 Terminal
Left knob switch

(one-touch power maximizing switch) and bottom dump switch (close):
Step light switch
PPC oil pressure lock
switch: Loading shovel
specification
Heated sheet (if
equipped)
Electric grease gun
remote switch
Emergency pump drive
switch
Swing brake cancel
switch
Intermediate connector
Model selection connector
Rear limit switch
Bypass valve position
sensor (*)
EGR valve position sensor
Starting switch
Address
2 Fan EPC solenoid

L-7
Swing priority selector
DT
2
L-5
valve
Fan reverse solenoid
DT
2
H-9
valve
Bottom dump priority
DT
2 solenoid valve (loading
shovel specification)
Bottom dump open soleDT
2 noid (loading shovel
specification)
Bottom dump close soleDT
2 noid (loading shovel
specification)
Terminal 1 Starting motor terminal B AO-9
S21
ST
TFUE
L
Location
Number of pins
Number of pins

F-9
L-4
L-6
L-5
40-53

Layout of connector (1/7)
40-54
PC800, 850-8E0

(2/7)
PC800, 850-8E0
40-55

(3/7)
40-56
PC800, 850-8E0

(4/7)
PC800, 850-8E0
40-57

(5/7)
40-58
PC800, 850-8E0

(6/7)
PC800, 850-8E0
40-59

(5/7)
40-60
PC800, 850-8E0

Connection table for connector pin numbers
40-61
(Rev. 2009. 04)

a The terms of male and female refer to the pins, while the terms of male housing and female housing refer
to the mating portion of the housing.
PC800, 850-8E0
40-61

40-62
PC800, 850-8E0

PC800, 850-8E0
40-63

40-64
PC800, 850-8E0

PC800, 850-8E0
40-65

40-66
PC800, 850-8E0

PC800, 850-8E0
40-67

40-68
PC800, 850-8E0

PC800, 850-8E0
40-69

40-70
PC800, 850-8E0

PC800, 850-8E0
40-71

40-72
PC800, 850-8E0

PC800, 850-8E0
40-73

40-74
PC800, 850-8E0

PC800, 850-8E0
40-75

40-76
PC800, 850-8E0

PC800, 850-8E0
40-77

40-78
PC800, 850-8E0

PC800, 850-8E0
40-79

40-80
PC800, 850-8E0

PC800, 850-8E0
40-81

40-82
PC800, 850-8E0

PC800, 850-8E0
40-83

40-84
PC800, 850-8E0

PC800, 850-8E0
40-85

40-86
PC800, 850-8E0

PC800, 850-8E0
40-87

40-88
PC800, 850-8E0

PC800, 850-8E0
40-89

40-90
PC800, 850-8E0

PC800, 850-8E0
40-91

40-92
PC800, 850-8E0

PC800, 850-8E0
40-93

40-94
PC800, 850-8E0

PC800, 850-8E0
40-95

40-96
PC800, 850-8E0

T- branch box and T- branch adapter table
40-97
799-601-2600
799-601-3100
799-601-3200
799-601-3380
799-601-3410
799-601-3420
799-601-3430
799-601-3440
799-601-3450
799-601-3460
799-601-3510
799-601-3520
799-601-3530
799-601-2910
799-601-3470
799-601-2710
799-601-2720
799-601-2730
799-601-2740
799-601-2950
799-601-2750
799-601-2760
799-601-2770
799-601-2780
T-box (for ECONO)

T-box (for MS)
T-box (for MS)
Plate for MS (14-pin)
Adapter for BENDIX (MS)
Case
Adapter for MIC
Adapter for MIC
Adapter for MIC
Adapter for MIC
Adapter for MIC
Adapter for ECONO
Adapter for ECONO
Adapter for ECONO
Adapter for ECONO
24
24
17
17
5
10
5
17
19
14
MS-24P
MS-24P
MS-17P
MS-17P
MS-5P
MS-10P
MS-5P
MS-17P
MS-19P
MS-14P
5
13
17
21
9
2
3
4
8
MIC-5P
MIC-13P
MIC-17P
MIC-21P
MIC-9P
ECONO2P
ECONO3P
ECONO4P
ECONO8P
ECONO12
P
DLI-8P
DLI-12P
DLI-16P
ECONO12
P
12
799-601-2810 Adapter for DLI

8
12
16
799-601-2840 Extension cable (ECONO type)
12
Case
T-box (for DRC 60, ECONO)
Case
Adapter for X (T-adapter)
Adapter for X
Adapter for X
Adapter for X
Adapter for SWP
Adapter for SWP
Adapter for SWP
Adapter for SWP
Adapter for SWP
Adapter for M (T-adapter)
Adapter for M
Adapter for M
Adapter for M
Adapter for M
Adapter for M
PC800, 850-8E0
q
q
q
q
q
q
q q
q q
q
q
q
q
q
q
q
q
q
q
q q
q q
q q q
X2P
X3P
X4P
SW6P
SW8P
SW12P
SW14P
SW16P
M2P
M3P
M4P
M6P
M8P
Out of kit
799-601-4201
799-601-9300
799-601-9200
799-601-4101
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q q
q q
q q
q q
q q
60
1
2
3
4
6
8
12
14
16
1
2
3
4
6
8
799-601-9100
799-601-9000
799-601-8000
q q
799-601-7500
799-601-7400
799-601-7100
799-601-7000
799-601-2800
21
37
37
799-601-2790 Adapter for ECONO
799-601-2850
799-601-4350
799-601-4360
799-601-7010
799-601-7020
799-601-7030
799-601-7040
799-601-7050
799 -601-7060
799-601-7310
799-601-7070
799-601-7320
799-601-7080
799 -601-7090
799-601-7110
799-601-7120
799-601-7130
799-601-7340
Identificati-on
symbol
799-601-2700
Part name
T-adapter kit
799-601-2500
Part No.
Number of pins
(Rev. 2009. 03)

a The vertical column indicates a part number of T-branch box or T-branch adapter, while the horizontal column indicates a part number of harness checker assembly.
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
40-97

799-601-7140
799-601-7150
799-601-7160
799-601-7170
799-601-7330
799-601-7350
799-601-7180
799-601-7190
799-601-7210
799-601-7220
799-601-7230
799-601-7240
799-601-7270
799-601-7510
799-601-7520
799-601-7530
799-601-7540
799-601-7550
799-601-7360
799-601-7370
799-601-7380
799-601-9010
799-601- 9020
799-601-9030
799-601-9040
799-601-9050
799-601-9060
799-601-9070
799-601-9080
799-601-9090
799-601-9110
799-601-9120
799-601-9130
799-601-9140
799-601-9210
799-601-9220
799-601-9230
799-601-9240
799-601-9250
799-601-9260
799-601-9270
799-601-9280
799-601-9290
799-601-9310
799-601-9320
799-601-9330
799-601-9340
799-601-9350
799-601-9360
799-601-9410*
Adapter for M
Adapter for S (White)
Adapter for S (Blue)
Adapter for S (Blue)
Adapter for AMP040
Adapter for AMP040
Adapter for AMP040
Adapter for AMP040
Short connector for X
Case
Case
Adapter for 070
Adapter for 070
Adapter for 070
Adapter for 070
Adapter for 070
Adapter for relay
Adapter for relay
Adapter for JFC
Adapter for DTM
Adapter for DT
Adapter for DT
Adapter for DT
Adapter for DT
Adapter for DT (Gray)
Adapter for DT (Black)
Adapter for DT (Green)
Adapter for DT (Brown)
Adapter for DT (Gray)
Adapter for DT (Black)
Adapter for DT (Green)
Adapter for DT (Brown)
Adapter for HD30-18
Adapter for HD30-18
Adapter for HD30-18
Adapter for HD30-18
Adapter for HD30-24
Adapter for HD30-24
Adapter for HD30-24
Adapter for HD30-24
Adapter for HD30-24
Plate for HD30 (24-pin)
T-box (for ECONO)
Case
Case
Adapter for DRC
Adapter for DRC
Socket for engine (CRI-T2)
Adapter for engine (CRI-T2)
799-601-9420 Adapter for engine (CRI-T3) PFUEL
Oil pressure sensor
799-601-9430*
Socket for engine(CRI-T3) PCV
40-98
24
q
q
q q q
q q q
q q q
q q
q
q
q
Out of kit
799-601-4201
799-601-4101
799-601-9300
799-601-9200
799-601-9100
q
q
799-601-9000
799-601-8000
q
q
q
q
799-601-7500
q
q
q
q
799-601-7400
07-10
07-12
07-14
07-18
07-20
REL-5P
REL-6P
DTM2
DT2
DT3
DT4
DT6
DT8GR
DT8B
DT8G
DT8BR
DT12GR
DT12B
DT12G
DT12BR
D18-8
D18-14
D18-20
D18-21
D24-9
D24-16
D24-21
D24-23
D24-31
q
q
q
q
799-601-7100
10
12
14
18
20
5
6
2
2
2
3
4
6
8
8
8
8
12
12
12
12
8
14
20
21
9
16
21
23
31
799-601-7000
S8P
S10P
S12P
S16P
S16PW
S12PW
A8P
A12P
A16P
A20P
799-601-2800
8
10
12
16
16
12
8
12
16
20
2
799-601-2700
Identificati-on
symbol
799-601-2500
Part name
Number of pins
Part No.
T-adapter kit
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q q
q q
q
q
q
q
40
24
2
DRC-40
DRC-24
G
A3
q q
q q
PC800, 850-8E0

799-601-9440* Socket for engine (CRI-T2)

795-799-5520* Socket for engine (HPI-T2)
Socket for engine (HPI-T2)
795-799-5530* Socket for engine (CRI-T3)
Temperature sensor
Socket for engine (HPI-T2)
795-799-5540*
Socket for engine(CRI-T3) TIM
795-799-5460 Cable for engine (HPI-T2)
799-601-4110 Adapter for engine (140-T3) PIM
799-601-4130 Adapter for engine (CRI-T3) NE, CAM
799-601-4140
Ambient pressure
799-601-4150 Adapter for engine (CRI-T3) POIL
799-601-4160
Oil pressure switch
799-601-4180 Adapter for engine (CRI-T3) PEVA
799-601-4190*
799-601-4230*
Air intake pressure/temperature
799-601-4240* Socket for engine (CRI-T3) PAMB
799-601-4250* Socket for engine (CRI-T3) PIM
799-601-4330* Socket for engine (CRI-T3) G
799-601-4340*
Pump actuator
Socket for engine (CRI-T3)(95)
799-601-4380*
Air intake pressure/temperature
799 -601-4260 Adapter for controller (ENG)
799 -601-4211 Adapter for controller (ENG)
799-601-4220 Adapter for controller (ENG)
799-601-4390* Socket for controller (95 ENG)
799-601-4280* Box for controller (PUMP)
799-601-9720 Adapter for controller (HST)
799-601-9890 Multi-adapter for DT2 to 4 and DTM2
q q
FCIB
q q
4160
q q
4180
q q
1, 2, 3 L
q q
4 1, 2, 3, 4 C
q q
3
3
3
1, 2, 3 A
1, 2, 3 B
1, 2, 3, G
q q
q q
q q
2, PA
q q
1, 2, 3, 4T
4
DTP4
50
DRC50
60
DRC60
60
121
16 HST16A
16 HST16B
26 HST26A
2,
3,
Out of kit
FCIG
799-601-4201
799-601-4101
q q
q q
799-601-9300
ITT3N
FCIN
799-601-9200
3
3
3
4
3
799-601-9100
q q
799-601-9000
799-601-8000
799-601-7500
q q
799-601-7400
799-601-7100
799-601-7000
1, 2, 3
S
799-601-2800
3
2
799-601-2700
Identificati-on
symbol
799-601-2500
Part name
Number of pins
Part No.
T-adapter kit
q
q
q
q
q
q
q q
q
q
q
q
q
q
q
q
* Shows not T-adapter but socket.
PC800, 850-8E0
40-99

Fuse locations
Fuse locations
40-10
Connection table of circuit breaker

40-10
q This connection table shows the devices to which each power supply of the circuit breakers supplies power.
q When performing out troubleshooting related to the electrical system, check the circuit breakers first to see
if the power is supplied properly.
a If circuit breaker is turned ON, the button comes out. In such case, push in the button, turn the starting
switch to ON position and start engine to see whether the button comes out again. If the button comes out
again, cause of this failure is probably ground fault.
a The switching power supply is the power which is supplied (battery relay output) while starting switch is in
ON position. By contrast, the unswitched power supplies power (battery direct output) regardless of the
starting switch position, ON or OFF.
Type of power supply
Switching power supply

(battery relay M terminal)

(battery relay B terminal)
40-100
Circuit
breaker
capacity
40 A
20 A
Work equipment headlamp and right headlamp
20 A
Electric grease pump
20 A
Pump controller (solenoid power supply)
20 A
Cab top headlamp and backup lamp
20 A
Starting switch and pump controller (main power supply)
30 A
Engine controller
20 A
Machine monitor, Buzzer
20 A
Fuse box (Fuse No.16 - 20)
Circuit breaker
No.
Destination of power
Fuse box (Fuses No. 1 - 15)
PC800, 850-8E0

Fuse locations
Connection table of fuse

40-101
This connection table shows the devices to which fuses in the fuse box supply power.
a The switching power supply is the power (battery relay output) which is supplied while the stating
switch is in ON position and the unswitched power supply is the power (battery direct output) which is
supplied while the starting switch is in OFF and ON positions.
q When performing out troubleshooting related to the electric system, check the fuse box to see if the power
is supplied properly.
q
Type of power supply
Switching power supply

(circuit breaker No. 1)

(circuit breaker No. 9)
Fuse No.
Fuse capacity
10 A
10 A
10 A
20 A
10 A
10 A
Intake air heater relay
10 A
10 A
(Spare)
10 A
Radio, speaker and knob switch
10
20 A
(Spare)
11
20 A
Air conditioner unit and air conditioner compressor
12
20 A
(Spare)
13
20 A
(Spare)
14
10 A
15
20 A
16
10 A
Optianal power supply (1)

Optional power supply (2), 12 V power supply and heated
air suspension seat
Radio backup
17
10 A
Step light
18
10 A
(Spare)
19
20
(ACC circuit)
PC800, 850-8E0
Destination of power
EPC solenoid (for emergency pump drive)
Swing brake solenoid (for swing brake release)
Machine push-up solenoid
Boom shockless solenoid
PPC lock solenoid
Starting motor cut-out relay
Cigarette lighter
Wind washer motor
Horn
Flash light
Room lamp
10 A
(Spare)
5A
Engine controller
(ACC circuit)
40-101

Fuse locations
Location of fuse box and fuse number
40-102
40-102
PC800, 850-8E0
Troubleshooting by failure code

Failure code [989L00] Engine Controller Lock Caution 1
40-103
40-103
User code
Failure code
Failure
989L00
Detail of failure
Action of
machine monitor
Problem on
machine
Related information
Engine controller lock up is detected (Factor 1).
q
q
None in particular
If cause of failure disappears, machine becomes normal by itself.
Engine cannot be started.
If this failure code is generated after machine monitor is replaced, user password must be changed
to one before replacement.
Method of reproducing failure code: Turn starting switch to ON position.
Cause
1
Engine controller lock caution 1

(Machine monitor system)
Replacement of
machine monitor
PC800, 850-8E0

This problem may be caused by replacement of machine monitor.
40-103

Failure code [989M00] Engine Controller Lock Caution 2

User code
Failure code
Failure
989M00
Detail of failure
Action of
machine monitor
Problem on
machine
Related information
40-104

q
q
None in particular
Engine cannot be started.
If this failure code is generated after machine monitor is replaced, user password must be changed
to one before replacement.
Cause
Replacement of
machine monitor
If this failure code is displayed while machine monitor is not replaced, machine monitor
Defective machine monmay be defective. (Since this is an internal failure, troubleshooting cannot be peritor
formed.)
This problem may be caused by replacement of machine monitor.
Failure code [989N00] Engine Controller Lock Caution 3

User code
Failure code
Failure
989N00
Detail of failure
Action of
machine monitor
Problem on
machine
Related information
Tries automatic recovery.

Method of reproducing failure code: Failure code cannot be reproduced since machine recovers
when cause of failure disappears.
Cause
1 Defective engine controller
40-104

40-104

If this failure code is generated repeatedly, engine controller may be defective.
(Since this is an internal failure, troubleshooting cannot be performed.)
PC800, 850-8E0

Failure code [AA10NX] Air Cleaner Clogging

User code
Failure code
Failure
Detail of failure
Action of controller
Problem on
machine
Related information
AA10NX
Air cleaner clogging

Air cleaner clogging switch signal voltage is not below 1 V while engine is running, so machine monitor determines that air cleaner is clogged (switch contact is open).
Displays air cleaner clogging monitor red on machine monitor.
If machine is operated as it is, engine may be damaged.
Input (ON/OFF) from air cleaner clogging switch can be checked by using monitoring function.
(Code 04501: Monitor Input 2)
Method of reproducing failure code: Start engine.
Cause
1
40-105
Clogged air cleaner

(when system is normal)
Defective air cleaner clogging

switch (internal open circuit)

3 (wire breakage or defective contact of connector)
4 Defective machine monitor

Air cleaner may be clogged. Check it for clogging and then clean or replace it
if clogged.
2. Disconnect connector P23 and connect T-adapter to male side.
3. Start engine.
When air
cleaner is norResistance
Max. 1 z
Between P23 (male) (1) and
mal *1
When air
(2)
Resistance
Min. 1 Mz
cleaner is
clogged *2
2. Disconnect connectors CM02 and P23, and connect T-adapters to each
female side.
Between CM02 (female) (4) and P23 (female)
Resistance
Max. 1 z
(1)
2. Insert T-adapters into connectors CM01 and CM02.
3. Start engine
When air
cleaner is norVoltage
Max. 1 V
Between CM02 (4) and
mal
When air
CM01 (3)
cleaner is
Voltage
7 11 V
clogged
Air cleaner suction resistance

*1: Max. -3,430 Pa {-350 mmH2O}
*2: -7,470 490 Pa {-762 50 mmH2O}
Circuit diagram related to air cleaner clogging switch
PC800, 850-8E0
40-105
40-105

Failure code [AB00KE] Charge Voltage Low

User code
Failure code
Failure
AB00KE
Detail of failure
Action of
machine monitor
Problem on
machine
Related information
q
q
q
Charging voltage is low

While engine is running, voltage from alternator drops, and machine monitor detects that battery
charge voltage is low (below 7.8 V).
Displays charge level monitor red on machine monitor.
Even if cause of failure disappears, machine does not become normal until starting switch is turned
to OFF position.
If machine is operated as it is, battery may not be charged.
Signal voltage of alternator can be checked by using monitoring function.

(Code: 04300 Charge voltage)
Cause
1
40-106
Loose alternator terminal or

open circuit at terminal

2. Check terminal.

2. Insert T-adapter into connector E22.
Defective generation by alterna2
3. Start engine.
tor (when system is normal)
Between E22 (6) and
Engine speed: Medium
ground
or higher
2. Insert T-adapter into connector CM01.
Defective wiring harness or
3
3. Start engine
machine monitor
Between CM01 (11) and ground
Voltage
27.5 29.5 V
Voltage
20 30 V
a If no failure is found by checks on cause 2, this check is not required.

Open circuit in wiring harness 1. Turn starting switch to OFF position.
4 (wire breakage or defective con- 2. Disconnect connectors CM01 and E22, and connect T-adapters to each
female side.
tact of connector)
Between CM01 (female) (11) and E22 (female) (6)

40-106
Resistance
Max. 1 z

2. Disconnect connectors CM01 and E22, and connect T-adapters to either
female side.
Between CM01 (female) (11) or E22 (female) (6)
Resistance Min. 1 Mz
and ground
If no failure is found by above checks, machine monitor is defective. (Since this
is an internal failure, troubleshooting cannot be performed.)
PC800, 850-8E0

Electrical diagram related to charging cricuit
PC800, 850-8E0
40-107
40-107

Failure code [B@BAZG] Eng Oil Press Low

User code
Failure code
Failure
Detail of failure
Problem on
machine
Related information
B@BAZG
40-108
Engine oil pressure is low

(Engine controller system)
While engine is running, signal voltage from engine oil pressure sensor dropps, so engine controller determines that engine oil pressure is low.
Displays engine oil pressure monitor red on machine monitor.
If machine is operated as it is, engine may seize up.
Engine oil pressure sensor signal is input to engine controller and then transmitted to machine
monitor through CAN communication system.
Engine oil pressure can be checked by using monitoring function.
(Code: 37200 Engine Oil Pressure Sensor)
q
q
Cause
Lowering of engine oil pressure

If no failure is found by checks on cause 1, engine oil pressure sensor circuit

Defective engine oil pressure senmay be defective. Perform troubleshooting for failure codes [CA135] and
sor circuit
[CA141].
40-108
Engine oil pressure may be low. Check it and fix if it is low.
PC800, 850-8E0

Failure code [B@BAZK] Eng Oil Level Low

User code
Failure code
Failure
Detail of failure
Problem on
machine
Related information
B@BAZK
40-109
Engine oil level is low

While engine is running, signal voltage from engine oil level switch is not below 1 V, so machine
monitor determines that engine oil level is low (oil level switch is open).
Displays engine oil level monitor red on machine monitor.
Input (ON/OFF) from engine oil level switch can be checked by using monitoring function.
(Code: 04501 Monitor input 2)
Cause
Low engine oil level (when system
1
Check engine oil level. If it is low, remove cause.
is normal)
Defective engine oil level sensor 2. Disconnect connector P44.
2
(internal failure)
3. Turn starting switch to ON position.
Between P44 (male) (1) and ground
Resistance
Max. 1 z
2. Disconnect connectors CM02 and P44, and connect T-adapters to each
3 (wire breakage or defective confemale side.
Between CM02 (female) (2) and P44
tact of connector)
Resistance
Max. 1 z
(female) (1)
If no failure is found by above checks, machine monitor is defective.
q Reference
Between CM02 (female) (2) and ground
Voltage
Max. 1 V
Circuit diagram related to engine oil level
PC800, 850-8E0
40-109
40-109

Failure code [B@BCNS] Eng Water Overheat

User code
Failure code
Failure
Detail of failure
Problem on
machine
Related information
B@BCNS
40-1 0
Engine coolant overheats

While engine is running, voltage from engine coolant temperature sensor drops, so engine controller determines that engine coolant is overheated.
Displays engine coolant temperature monitor red on machine monitor.
Signal voltage of engine coolant temperature sensor is input to engine controller that transmits information to machine monitor through CAN communication system.
Engine coolant temperature can be checked by using monitoring function.
(Code: 04107 Engine coolant temperature)
q
q
Cause
Overheating of engine coolant

If no failure is found by checks on cause 1, engine coolant temperature sensor

Defective engine coolant temperamay be defective. Perform troubleshooting for failure codes [CA144] and
ture sensor system
[CA145].
40-110
Engine coolant may overheat. Check it and remove cause if it overheats.
PC800, 850-8E0

PC800, 850-8E0
40-111

Failure code [B@BCZK] Eng Water Level Low

User code
Failure code
Failure
B@BCZK
While starting switch is at ON position (engine is stopped) or engine is running, signal voltage of
radiator coolant level switch is not beow 1 V, so machine monitor determines that radiator coolant
level is low (sensor contact is open).
Displays radiator coolant level monitor red on machine monitor.
If machine is operated as it is, engine may overheat.
Input (ON/OFF) from coolant level switch of radiator sub tank can be checked by using monitoring
function.
Related information
q
Cause
1
Engine coolant level is low

Detail of failure
Problem on
machine
40-1 2
Lowered radiator coolant level


Engine coolant level may be low. Check it and add coolant if it is low.
2. Disconnect connector P24A and connect T-adapter to male side.
Defective coolant level switch 1

2 of radiator sub tank (internal open
Between P24A (male) (1) and
circuit)
(2)
Coolant level: Within

specified level
Resistance
Max. 1 z
Coolant level: Below

LOW level
Resistance
Min. 1 Mz

2. Disconnect connector P24B and connect T-adapter to male side.
Defective coolant level switch 2
3 of radiator sub tank (internal open
Between P24B (male) (1) and
circuit)
(2)

specified level
Resistance
Max. 1

LOW level
Resistance
Min.1 M

2. Disconnect connector CM02 and connect T-adapter to female side.
ResisBetween CM02 (female) (3) and ground
Max. 1
tance
a If no failure is found by above checks, this check is not required.
4 (wire breakage or defective con- 2. Disconnect connectors CM02, P24A and P24B, and connect T-adapters to
each female side.
tact)
ResisBetween CM02 (female) (3) and P24A (female) (1)
Max. 1
tance
ResisBetween P24A (female) (2) and P24B (female) (1)
Max. 1
tance
ResisBetween P24B (female) (2) and ground
Max. 1
tance
Voltage Max. 1 V
specified level
Between CM02 (3) and ground
Voltage
7 11 V
LOW level
40-112
PC800, 850-8E0

Circuit diagram related to radiator coolant level switch
PC800, 850-8E0
40-1 3
40-113

Failure code [B@HANS] Hyd Oil Overheat

User code
Failure code
Failure
Detail of failure
Problem on
machine
Related information
B@HANS
40-1 4
Hydraulic oil overheat

(Pump controller system)
While engine is running, overheating of hydraulic oil (above approx. 102 C) is detected in signal
of hydraulic oil temperature sensor.
q
q
Displays hydraulic oil temperature monitor in red on machine monitor.

If machine is operated as it is, hydraulic components may be damaged.
Signal of hydraulic oil temperature sensor is input to pump controller and then data is transmitted
to machine monitor through CAN communication system.
Hydraulic oil temperature can be checked by using monitoring function.
(Code: 04401 Hydraulic oil temperature)
See "E-9 Hydraulic oil temperature gauge does not display normally" in E-mode.
q
q
q
Cause
Overheating of hydraulic oil

Hydraulic oil may overheat. Check it and remove cause if it overheats
Defective hydraulic oil temperature gauge system
If no failure is found by check on cause 1, hydraulic oil temperature sensor

system may be defective. Perform troubleshooting for failure code [DGH2KB].
40-114
PC800, 850-8E0

PC800, 850-8E0
40-115

Failure code [CA111] ECM Critical Internal Failure

User code
Failure code
Failure
E10
Detail of failure
Problem on
machine
Related information
CA111
q
40-1 6
ECM critical internal failure

Engine controller has internal failure.
None in particular
Engine continues to run normally, but it may stop during running or may not be able to start if it is
stopped.
Power supply voltage of engine controller can be checked by using moniitoring funtion.
(Code: 03203 Battery voltage)
Method of reproducing failure code: Turn starting switch to ON position
q
q
Cause
1 Loose or corroded battery terminal Battery cable terminal may be loose or corroded. Check it directly.
2
Loosen terminal or partial open

circuit at terminal

Check terminals of alternator, battery relay, ground (T09) etc. for looseness.
See descriptions of wiring harness and connectors in "c: Electrical equipment"

Defective wiring harness connecin "Checks before troubleshooting" of "General information on troubleshoottor
ing", and check them directly.
1. Turn starting switch to OFF position, then perform troubleshooting.
2. Measure voltage at the time of cranking engine.
4 Improper battery voltage
Between battery terminals (+) and (-).
Voltage
20 30 V
3
5 Defective alternator

2. Insert T-adapter into connector E22.
3. Start engine (Engine speed: Middle or faster).
Between E22 (6) and ground
40-116
Voltage
26 30.5 V
If no failure is found by above checks, engine controller is defective. (Since

this is an internal failure, troubleshooting cannot be performed.)
q Reference
1. Turn starting switch to OFF position and disconnect battery ground cable.
2. Insert T-adapter into connector CE03.
3. Connect battery ground cable.
4. Measure voltage with starting switch at OFF position and when starting
engine.
Between CE03 (3) and (1)
Voltage
20 30 V
Voltage
20 30 V
PC800, 850-8E0

Circuit diagram related to engine controller power supply
PC800, 850-8E0
40-1 7
40-117

Failure code [CA115] Eng Ne and Bkup Speed Sens Error

User code
Failure code
Failure
E10
CA115
40-1 8
Engine Ne and Bkup speed sensor error

Detail of failure
Abnormality is detected in signal circuits of Ne and Bkup speed sensors at the same time.
Stops engine.
q
q
Engine does not start (if engine is stopped).

Engine stops (if engine is running).
Problem on
machine
Related information
Cause
Defective Ne speed sensor sys1

Perform troubleshooting for failure code [CA689].
tem
Defective Bkup speed sensor sys2
tem
40-118
PC800, 850-8E0

PC800, 850-8E0
40-119

Failure code [CA122] Chg Air Press Sensor High Error

User code
Failure code
Failure
E11
Detail of failure
Problem on
machine
Related information
CA122
40-120
Boost pressure sensor high error

High voltage appears in boost pressure sensor signal circuit.
Takes it that boost pressure is at fixed value (400 kPa {4.1 kg/cm2}), and allows engine to run.
Acceleration performance of engine drops.
Signal voltage from boost pressure sensor can be checked by using monitoring function. (Code:
36501 (V))
Boost pressure sensed by boost pressure sensor can be checked by using monitoring function.
(Code: 36500 (kPa))
If sensor connector is disconnected, code [CA123] for "Low Error" is displayed, even in normal
condition.
q
q
q
Cause

Defective wiring harness connec1
in "Checks before troubleshooting" of "General information on troubleshoottor
Defective sensor power supply
If failure code [CA187] or [CA227] is displayed at the same time, perform
2
system
troubleshooting for it first.
3 Defective boost pressure sensor
4 Short circuit in wiring harness

2. Disconnect connector PIM.
If failure code changes from [CA122] to [CA123], boost pressure sensor is
defective.
2. Disconnect connectors ENG and PIM, and connect T-adapter to female
side of ENG.
Between ENG (female) (37) and (44)
Resistance
Min. 1 Mz

2. Disconnect connector PIM, and connect T-adapter to female side or insert
T-adapter into connector ENG.
Hot short circuit in wiring harness
5
3.
Turn
starting switch to ON position (with connector PIM disconnected).
Between PIM (female) (3) and (2), or between ENG
Voltage
Max. 1 V
(44) and (47)
40-120

PC800, 850-8E0

Circuit diagram related to boost pressure sensor
PC800, 850-8E0
40-121
40-121

Failure code [CA123] Chg Air Press Sensor Low Error

User code
Failure code
Failure
E11
Detail of failure
Problem on
machine
Related information
CA123
40-12
Boost pressure sensor low error

Low voltage appears in boost pressure sensor signal circuit.
Takes it that boost pressure is at fixed value (400 kPa {4.1 kg/cm2}), and allows engine to run.
Acceleration performance of engine drops.
Signal voltage from boost pressure sensor can be checked by using monitoring function. (Code:
36501 (V))
Boost pressure sensed by boost pressure sensor can be checked by using monitoring function.
(Code: 36500 (kPa))
If sensor connector is disconnected, this failure code is displayed.
q
q
q
Cause

Defective wiring harness connecin "Checks before troubleshooting" of "General information on troubleshooting",
1
tor
and check them directly.
If failure code [CA187] or [CA227] is displayed, perform troubleshooting for it
first.
Defective power supply system of
charge pressure sensor (boost
2
2. Disconnect connectors PIM and connect T-adapter to female side.
pressure sensor)
Between PIM (female) (1) and (2)


6 Defective boost pressure sensor
40-122
Voltage
4.75 5.25 V
Between ENG (female) (37) and PIM (female) (1)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Min. 1 Mz

2. Disconnect connectors ENG and PIM.
3. Connect T-adapter to female side of ENG.
Power input

2. Disconnect connectors ENG and PIM and connect T-adapters to each
female side.

2. Disconnect connectors ENG and PIM, and connect T-adapters to either
female side.
Between ENG (female) (44) or PIM (female) (3)
and ground
a If no failure is found by checks on causes 1 to 5, and check result of checks
on cause 6 is abnormal, sensor is defective.
2. Insert T-adapter into connector ENG or PIM.
Between ENG (44) and (47), or
Sensor outVoltage
0.3 4.7 V
between PIM (3) and (2)
put
If no failure is found by above checks, engine controller is defective. (Since this
PC800, 850-8E0

Circuit diagram related to boost pressure sensor
PC800, 850-8E0
40-123
40-123

Failure code [CA131] Throttle Sensor High Error

User code
Failure code
Failure
E14
Detail of failure
Problem on
machine
Related information
CA131
40-124
Throttle sensor high error

High voltage appears in fuel control dial circuit.
q
q
Uses throttle value obtained before failure detection and allows engine to run if failure is detected
with starting switch at ON position.
Uses full throttle value to run engine if starting switch is set to ON position after detecting failure.
Engine speed cannot be controlled with fuel control dial.
Signal voltage of fuel control dial can be checked by using monitoring function.
(Code: 03000 Fuel control dial voltage)
Cause

of "Checks before troubleshooting" in "General information on troubleshoottor
Defective throttle sensor power
2
If failure code [CA2185] is also displayed, perform troubleshooting for it first.
supply system
3
Defective fuel control dial (throttle Between P20 (male) (1) and (3)
sensor)
Between P20 (male) (2) and (3)
Resistance
4.0 6.0 kz
Resistance
0.25 5.0 kz
Resistance
0.25 5.0 kz

2. Disconnect connector CE02, and connect T-adapter to female side.
Open or short circuit in wiring harBetween CE02 (famale) (22) and (23)
ness
Between CE02 (famale) (9) and (23)
Resistance
4.0 6.0 kz
Resistance
0.25 5.0 kz

2. Disconnect connectors CE02 and P20, and connect T-adapters to either
female side.
Between CE02 (female) (9) and (22), or
Resistance
Min. 1 Mz
between P20 (female) (1) and (2)

Hot short circuit in wiring harness 2. Disconnect connector P20, and connect T-adapter to female side.
6
Between P20 (female) (2) and ground
Voltage
Max. 1 V
40-124

q Reference
4. Operate fuel control dial and perform troubleshooting.
Between CE02 (22) and (23) Power supply
Voltage
4.75 5.25V
Voltage
0.5 4.5 V
Sensor output
PC800, 850-8E0

Circuit diagram related to throttle sensor
PC800, 850-8E0
40-125
40-125

Failure code [CA132] Throttle Sensor Low Error

User code
Failure code
Failure
E14
Detail of failure
Problem on
machine
Related information
CA132
40-126
Throttle sensor low error

Low voltage appears in fuel control dial circuit.
q
q
Uses throttle value obtained before failure detection and allows engine to run if failure is detected
with starting switch at ON position.
Uses full throttle value to run engine if starting switch is set to ON position after detecting failure.
Engine speed cannot be controlled with fuel control dial.
Signal voltage of fuel control dial can be checked by using monitoring function.
(Code: 03000 Fuel control dial votage)
Cause

Defective wiring harness connecof "Checks before troubleshooting" in "General information on troubleshoottor
Defective throttle sensor power
2
supply system
1
Defective fuel control dial (throttle Between P20 (male) (1) and (3)
sensor)
Resistance
4.0 - 6.0 kz
Resistance
0.25 - 5.0 kz
Resistance
0.25 - 5.0 kz

Open or short circuit in wiring harBetween CE02 (famale) (22) and (23)
ness
Between CE02 (famale) (9) and (23)

Ground fault of wiring harness

40-126
Resistance
4.0 - 6.0 kz
Resistance
0.25 - 5.0 kz

2. Disconnect connectors CE02 and P20, and connect T-adapters to each
female side.
Between CE02 (female) (22) and P20
Resistance
Max. 1 z
(female) (1)
Between CE02 (female) (9) and P20 (female)
Resistance
Max. 1 z
(2)
Between CE02 (female) (23) and P20
Resistance
Max. 1 z
(female) (3)
female side.
Between CE02 (female) (9) and (23), or
Resistance
Min. 1 Mz
between P20 (female) (2) and (3)
female side.
Between CE02 (female) (9) or P20 (female)
Resistance
Min. 1 Mz
(2) and ground
PC800, 850-8E0

Cause

q Reference
4. Operate fuel control dial and perform troubleshooting.
Between CE02 (22) and (23) Power supply
Voltage
4.75 5.25V
Voltage
0.4 4.5 V
PC800, 850-8E0
Sensor output
40-127
40-127

Failure code [CA135] Eng Oil Press Sensor High Error

User code
Failure code
Failure
E15
CA135
40-128
Engine oil pressure sensor high error

Detail of failure
High voltage appears in engine oil pressure sensor signal circuit.
Problem on
machine
Takes it that engine oil pressure is at default value (250 kPa {2.5 kg/cm2}), and allows engine to
run.
Signal voltage from engine oil pressure sensor can be checked by using monitoring function.
(Code: 37201 (V))
Engine oil pressure sensed by engine oil pressure sensor can be checked by using monitoring
function. (Code: 37200 (kPa))
Related information
q
q
Cause
1
Defective wiring harness connector
Defective power supply system of

engine oil pressure sensor
Defective engine oil pressure sensor

40-128

in "Checks before troubleshooting" of "General information on troubleshooting", and check them directly.
first.
2. Disconnect connector POIL.
If failure code changes from [CA135] to [CA141] , engine oil pressure sensor
is defective.
2. Disconnect connectors ENG and POIL, and connect T-adapters to either
female side.
Between ENG (female) (13) and (37), or
Resistance
Min. 1 Mz
between POIL (female) (1) and (3)
2. Disconnect connector POIL.
3. Connect T-adapter to female side of connector POIL or insert T-adapter
into connector ENG.
4. Turn starting switch to ON position (with connector POIL disconnected).
Voltage
Max. 1 V
between POIL (female) (3) and (2)
PC800, 850-8E0

Circuit diagram related to engine oil pressure sensor
PC800, 850-8E0
40-129
40-129

Failure code [CA141] Eng Oil Press Sensor Low Error

User code
Failure code
Failure
E15
Detail of failure
Problem on
machine
Related information
CA141
40-130
Engine oil pressure sensor low error

Low voltage appears in engine oil pressure sensor signal circuit.
Takes it that engine oil pressure is at default value (250 kPa {2.5 kg/cm2}), and allows engine to run.
Signal voltage from engine oil pressure sensor can be checked by using monitoring function. (Code:
37201 (V))
Engine oil pressure sensed by engine oil pressure sensor can be checked by using monitoring function. (Code: 37200 (kPa))
q
q
Cause
See descriptions of wiring harness and connectors in "c: Electrical equipment" in

"Checks before troubleshooting" of "General information on troubleshooting",
tor
If failure code [CA187] or [CA227] is displayed, carry out troubleshooting for it
first.
Defective power supply system of 1. Turn starting switch to OFF position.
2
2. Disconnect connector POIL and connect T-adapter to female side.
engine oil pressure sensor
Between POIL (female) (1) and (2)
Power input
Voltage
4.75 5.25V

2. Disconnect connectors ENG and POIL and connect T-adapters to each
female side.
a If power supply input in checks on cause 2 is normal, this check is not required.
Resistance
Max. 1 z
Between ENG (female) (37) and POIL (female)
(wire breakage or defective con(1)
a If power supply input in checks on cause 2 is nortact of connector)
mal, this check is not required.
Resistance
Max. 1 z
Between ENG (female) (47) and POIL (female)
(2)
Between ENG (female) (13) and POIL (female) (3)
Resistance
Max. 1 z
(Sensor output)
female side.
Between ENG (female) (13) or POIL (female) (3)
and ground
female side.
Short circuit in wiring harness
Between ENG (female) (13) and (47), or between
POIL (female) (2) and (3)
a If no failure is found by checks on causes 1 to 5 and check result of checks
on cause 6, sensor is defective.
Defective engine oil pressure sen- 1. Turn starting switch to OFF position.
2. Insert T-adapter into connector ENG or POIL.
sor (improper input voltage to
engine controller)
Between ENG (13) and (47), or
Sensor outVoltage
0.3 4.7 V
between POIL (3) and (2)
put
40-130

PC800, 850-8E0

Circuit diagram related to engine oil pressure sensor
PC800, 850-8E0
40-131
40-131

Failure code [CA144] Coolant Temp Sens High Error

User code
Failure code
Failure
E15
Detail of failure
Problem on
machine
CA144
Engine coolant temperature sensor high error

High voltage appears in engine coolant temperature sensor signal circuit.
Takes it that coolant temperature is at fixed value (90 C) and allows engine to run.
Engine does not start easily at low temperatures.

Overheat prevention function does not work.
Signal voltage from engine coolant temperature sensor can be checked by using monitoring function. (Code: 04105 (V))
Temperature sensed by engine coolant temperature sensor can be checked by using monitoring
function. (Code: 04107 (C))
This failure code is generated if temperature sensor connector is disconnected.
Because troubleshooting "socket" for this sensor features female connector alone, it is not connectable to female connector of sensor wiring harness, and thus not usable for checking open circuit (not designed as a T-adapter).
q
q
q
Related information
40-132
q
q
q
Cause

2. Disconnect connector TWTR and connect T-adapter to male side.
a If coolant temperature sensor has resistance of 700 z 37 kz with coolant
temperature above 0 C, regard coolant temperature sensor as normal.
2
Defective coolant temperature

sensor
Between TWTR (male) (A)

and (B)
a Coolant temperature
-Resistaure characteristics
0 C
Resistance
30 37 kz
25 C
Resistance
9.3 10.7 kz
50 C
Resistance
3.2 3.8 kz
80 C
Resistance
1.0 1.3 kz
95 C
Resistance
700 800 z

2. Disconnect connector ENG1 and connect T-adapter to female side.
Between ENG (female) (15) and (38) (CoolOpen or short circuit in wiring har- ant temperature: Min. 0 C)
3
ness
a The resistance is the same as that shown
Resistance
700 z 37 kz
in the resistance characteristics table of
the coolant temperature sensor of cause
2.
40-132
PC800, 850-8E0

Circuit diagram related to coolant temperature sensor
PC800, 850-8E0
40-13
40-133

Failure code [CA145] Coolant Temp Sens Low Error

User code
Failure code
Failure
E15
Detail of failure
Problem on
machine
CA145
Low voltage is appears in engine coolant temperature sensor signal circuit.
Takes it that coolant temperature is at fixed value (90 C) and allows engine to run.

Overheat prevention function does not work.
Signal voltage from engine coolant temperature sensor can be checked by using monitoring function. (Code: 04105 (V))
Temperature sensed by engine coolant temperature sensor can be checked by using monitoring
If temperature sensor connector is disconnected, this failure code is not generated but failure code
[CA144] for "High Error" is generated.
q
q
q
Cause
1
Engine coolant temperature sensor low error

Related information
40-134

tor
2. Disconnect connector TWTR and connect T-adapter to male side.
a If coolant temperature sensor has resistance of 700 z 37 kz with coolant
Defective coolant temperature

sensor
Between TWTR (male) (A) and (B)

a Coolant temperature-Resistaure
characteristics
0 C
Resistance
30 37 kz
25 C
Resistance 9.3 10.7 kz
50 C
Resistance
3.2 3.8 kz
80 C
Resistance
1.0 1.3 kz
95 C
Resistance
700 800 z
Whole coolant temper- Resistance

Min. 1 Mz
ature range
2. Disconnect connector ENG1 and connect T-adapter to female side.
Between ENG (female) (15) and (38) (Coolant
temperature: Min. 0 C)
a The resistance is the same as that shown in the Resistance 700 z 37 kz
resistance characteristics table of the coolant
temperature sensor of cause 2.
2. Disconnect connectors ENG and TWTR, and connect T-adapter to female
side of ENG.
Between (B) and ground

Between ENG (female) (15) and ground

40-134
Resistance
Min. 1 Mz

PC800, 850-8E0

Circuit diagram related to coolant temperature sensor
PC800, 850-8E0
40-135
40-135

Failure code [CA153] Chg Air Temp Sensor High Error

User code
Failure code
Failure
E15
CA153
40-136
Boost temperature sensor high error.

Detail of failure
High voltage appears in boost temperature sensor signal circuit.
Takes it that boost temperature is at fixed temperature (70 C) and allows engine to run.
Problem on
machine
Signal voltage from boost temperature sensor can be checked by using monitoring function. (Code:
18501 (V))
Temperature sensed by boost temperature sensor can be checked by using monitoring function.
(Code: 18500 (C))
Because troubleshooting "socket" for this sensor features female connector alone, it is not connectable to female connector of sensor wiring harness, and thus not usable for checking open circuit (not
designed as a T-adapter).
Related information
q
q
Cause
1

tor
2. Disconnect connector TIM and connect socket to male side.
a If temperature sensor has resistance of 280 z - 382 kz, regard boost
temperature sensor as normal.
Defective boost temperature sensor
Between TIM (male) (A) and (B)

a Boost temperature-Resistance
chariacteristic
-40 C
Resistance
291 382 kz
-20 C
Resistance
85 109 kz
0 C
Resistance
29 36 kz
30 C
Resistance
7.3 8.8 kz
60 C
Resistance
2.3 2.7 kz
90 C
Resistance
860 970 z
130 C
Resistance
280 320 z

2. Disconnect connector ENG and connect T-adapter to female side.
Open or short circuit in wiring har- Between ENG (female) (23) and (47)
3
ness
a The resistance is the same as that shown in
Resistance 280 z 382 kz
the resistance characteristics table of the
coolant temperature sensor of cause 2.
40-136
PC800, 850-8E0

Circuit diagram related to boost temperature sensor
PC800, 850-8E0
40-137
40-137

Failure code [CA154] Chg Air Temp Sensor Low Error

User code
Failure code
Failure
E15
CA154
40-138
Boost temperature sensor low error

Detail of failure
Low voltage appears in boost temperature sensor signal circuit.
Takes it that boost temperature is at fixed temperature (70 C) and allows engine to run.
Problem on
machine
Signal voltage from boost temperature sensor can be checked by using monitoring function. (Code:
18501 (V))
Temperature sensed by boost temperature sensor can be checked by using monitoring function.
(Code: 18500 (C))
Related information
q
q
q
Cause

1
tor
2. Disconnect connector TIM and connect socket to male side of.
a If temperature sensor has resistance of 280 z - 382 kz, regard boost
temperature sensor as normal.
Defective boost temperature sensor

-40 C
Resistance
291 382 kz
-20 C
Resistance
85 109 kz
0 C
Resistance
29 36 kz
30 C
Resistance
7.3 8.8 kz
60 C
Resistance
2.3 2.7 kz
90 C
Resistance
860 970 z
130 C
Resistance
280 320 z
Between TIM (male) (A) and (B)

a Boost temperature-Resistance
chariacteristic

a The resistance is the same as that shown in
Resistance 280 z 382 kz
the resistance characteristics table of the
coolant temperature sensor of cause 2.
2. Disconnect connectors ENG and TIM and connect T-adapter to female side
of ENG.
40-138
Resistance
Min. 1 Mz

PC800, 850-8E0

Circuit diagram related to boost temperature sensor
PC800, 850-8E0
40-139
40-139

Failure code [CA187] Sens Supply 2 Volt Low Error

User code
Failure code
Failure
E15
Detail of failure
CA187
Low voltage appears in sensor power supply 2 (5 V) circuit.
Ignores signals from Bkup speed sensor and controls engine by using Ne speed sensor signals.
Ignores signals from engine oil pressure sensor, takes it that engine oil pressure is default value (250
kPa {2.5 kg/cm2}), and allows engine to run.
Ignores signals from ambient pressure sensor, takes it that ambient pressure is at default value
(52.44 kPa {0.53 kg/cm2}), and allows engine to run.
Ignores signals from boost pressure sensor, takes it that boost pressure is at fixed value (400 kPa
{4.1 kg/cm2}), and allows engine to run.
Ignores signals from EGR valve lift sensor and bypass valve lift sensor, limits engine output and closes EGR valve and bypass valve.
q
q
q
Problem on
machine
Related information
Sensor power supply 2 voltage low error

q
q
40-140
Engine output lowers.
Cause

tor
2. Disconnect following connectors one by one and turn starting switch to ON
position each time.
3. After each troubleshooting, turn starting switch to OFF position.
If this failure code is not displayed when a connector is disconnected, that sensor or engine wiring harness is defective.
a Other failure codes are displayed, too. This is because the connector is disconnected. Ignore failure codes other than [CA187].
2 Defective sensor or wiring harness
Sensor or harness
Connector
Bkup speed sensor
G connector
Oil pressure sensor
POIL connector
PIM connector
PAMB connector
EGR valve lift sensor
SEGR connector
Bypass valve lift sensor
SBP connector
Engine wiring harness
ENG
3 Defect in related system
If another failure code is displayed, perform troubleshooting for it.

2. Disconnect connector ENG and connect T-adapter to male side.
3. Turn starting switch to ON position with connector ENG disconnected.
Between ENG (male) (37) and (47)
40-140
Voltage
4.75 5.25 V
PC800, 850-8E0

Circuit diagram related to sensor power supply 2 (5 V)
PC800, 850-8E0
40-141
40-141

Failure code [CA221] Ambient Press Sens High Error

User code
Failure code
Failure
E11
CA221
40-142
Ambient pressure sensor high error

Detail of failure
High voltage appears in ambient pressure sensor signal circuit .
Takes it that ambient pressure is at default value (52.44 kPa {0.53 kg/cm2}), and allows engine to
run.
Signal voltage from ambient pressure sensor can be checked by using monitoring function. (Code:
37401 (V))
Ambient pressure sensed by ambient pressure sensor can be checked by using monitoring function. (Code: 37400 (kPa))
Problem on
machine
Related information
q
q
Cause

Defective power supply line of
2
ambient pressure sensor
first.
1
Defective ambient pressure sensor

2. Disconnect connector PAMB.
If failure code changes from [CA221] to [CA222], sensor is defective.

2. Disconnect connector ENG and PAMB, and connect T-adapter to female
side of ENG.
1.
2.
Hot short circuit in wiring harness 3.
5
4.
40-142
Min. 1 Mz
Turn starting switch to OFF position.

Disconnect connector PAMB.
Insert T-adapter into connector ENG.
Turn starting switch to ON position (with connector PAMB disconnected).
Between ENG (3) and (38)

Resistance
Voltage
Max. 1 V

PC800, 850-8E0

Circuit diagram related to ambient pressure sensor
PC800, 850-8E0
40-143
40-143

Failure code [CA222] Ambient Press Sens Low Error

User code
Failure code
Failure
E11
CA222
40-14
Ambient pressure sensor low error

Detail of failure
Low voltage appears in ambient pressure sensor signal circuit .
Takes it that ambient pressure value is at default value (52.44 kPa {0.53 kg/cm2}), and allows
engine to run.
Signal voltage from ambient pressure sensor can be checked by using monitoring function. (Code:
37401 (V))
Ambient pressure sensed by ambient pressure sensor can be checked by using monitoring function. (Code: 37400 (kPa))
Since troubleshooting "socket" for this sensor features female connector alone, it is not usable for
checking open circuit in wiring harness and voltage at sensor connector (not designed as a
T-adapter).
If sensor connector is disconnected, this failure code is generated.
Problem on
machine
Related information
q
q
Cause

Defective power supply line of
2
ambient pressure sensor
first.
1

2. Disconnect connectors PAMB and ENG.

4
Defective ambient pressure sen6 sor (defective input voltage to

engine controller)
Min. 1 Mz

2. Disconnect connectors PAMB and ENG and connect T-adapter to female
side of ENG.
5 Open circuit in wiring harness
Resistance
Resistance
Min. 1 Mz
If no failure is found by above checks, wiring harness may have open circuit.
(*)
a If no failure is found by checks on causes 1 to 5 and check result of checks
on cause 6 is abnormal, sensor is defective.
2. Insert T-adapter into connector ENG.
Sensor outBetween ENG (3) and (38)
Voltage
0.3 4.7 V
put
*: Refer to "Troubleshooting method for open circuit in wiring harness of pressure sensor system" of "General
information on troubleshooting".
40-144
PC800, 850-8E0

Circuit diagram related to ambient pressure sensor
PC800, 850-8E0
40-145
40-145

Failure code [CA227] Sens Supply 2 Volt High Error

User code
Failure code
Failure
E15
Detail of failure
CA227
High voltage appears in sensor power supply 2 (5 V) circuit.
Ignores signals from Bkup speed sensor and controls engine by using Ne speed sensor signals.
Ignores signals from engine oil pressure sensor, takes it that engine oil pressure is at default value
(250 kPa {2.5 kg/cm2), and allows engine to run.
Ignores signals from ambient pressure sensor, takes it that ambient pressure is at default value
(52.44 kPa {0.53 kg/cm2}), and allows engine to run.
Ignores signals from boost pressure sensor, takes it that boost pressure is at fixed value (400 kPa
{4.1 kg/cm2}), and allows engine to run.
Ignores signals from EGR valve lift sensor and bypass valve lift sensor, limits engine output and
closes EGR valve and bypass valve.
q
q
q
Problem on
machine
Related information
Sensor power supply 2 voltage high error

q
q
40-146
Cause

40-146
PC800, 850-8E0

Failure code [CA234] Eng Overspeed

User code
Failure code
Failure
CA234
Engine overspeed
(Engine controller defective)
Detail of failure
Engine speed is above operating range.
Limits fuel injection rate until engine speed lowers to operating range.
Problem on
machine
Engine speed fluctuates.
Engine speed can be checked by using monitoring function. (Code: 01002 (rpm))
Method of reproducing failure code: Run engine at high idle.
Related information
Cause
1 Use of improper fuel
Fuel used may be improper. Check it directly.
3 Improper use
PC800, 850-8E0
40-147
Usage of machine may be improper. Instruct operator on proper use of

machine.
If no failure is found by checks on causes 1 and 2, engine controller may be
defective. (Since this is an internal failure, troubleshooting cannot be performed.)
40-147

Failure code [CA238] Ne Speed Sens Supply Volt Error

User code
Failure code
Ne speed sensor supply voltage error

Failure
E15
CA238
Detail of failure
Problem on
machine
Related information
q
q
40-148
Ne speed sensor power supply (5 V) circuit is defective.

Controls engine by using signals of Bkup speed sensor.
Limits engine output and allows engine to run.

Running engine stops (when Bkup speed sensor is also defective).
Stopped engine cannot be started (when Bkup speed sensor is also defective).
Cause

Defective wiring harness connec"Checks before troubleshooting" of "General information on troubleshooting",
tor
position each time.
If this failure code is not displayed when a sensor is disconnected, sensor or
engine wiring harness is defective.
2 Defective sensor or wiring harness a Other failure codes are displayed, too. This is because connector is disconnected. Ignore failure codes other than [CA238].
1
Sensor or harness
Connector
Ne speed sensor
NE
ENG

3. Turn starting switch to ON position with engine wiring harness disconnected.
Between ENG(male)(16) and (48)
Circuit diagram related to Ne speed sensor
40-148
Voltage
4.75 5.25 V
40-148
PC800, 850-8E0

PC800, 850-8E0
40-149

Failure code [CA263] Fuel Temp Sensor High Error

User code
Failure code
Failure
E15
Detail of failure
CA263
Fuel temperature sensor high error

High voltage appears in fuel temperature sensor signal circuit .
Uses signals from coolant temperature sensor to perform fuel injection rate correction based on fuel
temperature.
(Takes it that fuel temperature is at fixed value (90 C) and allows engine to run.)
Problem on
machine
q
q
Related information
40-150
q
q
q
Signal voltage from fuel temperature sensor can be checked by using monitoring function. (Code:
14201 (V))
Temperature sensed by fuel temperature sensor can be checked with monitoring function. (Code:
14200 (C))
Because troubleshooting "socket" for this sensor features female connector alone, it is not connectable to female connector of sensor wiring harness, and thus not usable for checking open circuit (not
designed as a T-adapter).
Cause

in "Checks before troubleshooting" of "General information on troubleshooting",
tor
2. Disconnect connector TFUEL and connect socket to male side.
a If coolant temperature sensor resistance is 700 z to 37 kz with coolant
2 Defective fuel temperature sensor
Between TFUEL (male)(A) and (B)
a Fuel temperature-Resistance
characteristics
0 C
Resistance
30 37 kz
25 C
Resistance
9.3 10.7 kz
50 C
Resistance
3.2 3.8 kz
80 C
Resistance
1.0 1.3 kz
95 C
Resistance
700 800 z

Open or short circuit in wiring har- Between ENG (female) (30) and (47) (Fuel tem3
perature: Min. 0 C)
ness
a The resistance is the same as that shown in Resistance 700 z 37 kz
the resistance characteristics table of the coolant temperature sensor of cause 2.
40-150
PC800, 850-8E0

Circuit diagram related to fuel temperature sensor
PC800, 850-8E0
40-151
40-151

Failure code [CA265] Fuel Temp Sensor Low Error

User code
Failure code
Failure
E15
Detail of failure
CA265
40-152
Fuel temperature sensor low error

Low voltage appears in fuel temperature sensor signal circuit.
Uses signals from coolant temperature sensor to perform fuel injection rate correction based on fuel
temperature.
(Takes it that fuel temperature is at fixed value (90 C) and allows engine to run.)
Signal voltage from fuel temperature sensor can be checked by using monitoring function. (Code:
14201 (V))
Temperature sensed by fuel temperature sensor can be checked with monitoring function. (Code:
14200 (C))
Problem on
machine
Related information
q
q
q
Cause
1

tor
2. Disconnect connector TFUEL and connect socket to male side.
a If coolant temperature sensor resistance is 700 z to 37 kz with coolant
2 Defective fuel temperature sensor Between TFUEL (male)(A) and (B)

a Fuel temperature-Resistance
characteristic

40-152
Resistance
30 37 kz
25 C
Resistance 9.3 10.7 kz
50 C
Resistance
3.2 3.8 kz
80 C
Resistance
1.0 1.3 kz
95 C
Resistance
700 800 z
All fuel temBetween (B) and ground

perature Resistance
Min. 1 Mz
range
Between ENG (female) (30) and (47) (Fuel temperature: Min. 0 C)
a The resistance is the same as that shown in the Resistance 700 z 37 kz
resistance characteristics table of the coolant
temperature sensor of cause 2.
2. Disconnect connector TFUEL, and connect T-adapter to female side of
ENG.
0 C
Resistance
Min. 1 Mz

PC800, 850-8E0

Circuit diagram related to fuel temperature sensor
PC800, 850-8E0
40-153
40-153

Failure code [CA271] IMV/PCV1 Short Error

User code
Failure code
Failure
E10
Detail of failure
CA271
40-154
IMV/PCV1 short circuit error

Short circuit is detected in supply pump PCV1 circuit.
Under normal conditions, pulse voltage of approx. 24 V is applied to PCV1 (1) while engine is running. However, it cannnot be measured by using multimeter since it is pulse voltage.
Problem on
machine
Related information
Cause
1

2. Disconnect connector PCV1.
Defective supply pump PCV1
(internal short circuit)
If failure code changes from [CA271] to [CA272], supply pump PCV1 is
defective.
Between ENG (female) (4) and (5) (PCV1 resisResistance 2.3 5.3 z
tance)
2. Disconnect connector ENG and PCV1, and connect T-adapter to female
side of ENG.
1.
2.
5
4.

Disconnect connector PCV1.
Turn starting switch to ON position (with connector PCV1 disconnected).

Circuit diagram related to PCV1
40-154
Voltage
Max. 3 V

40-154
PC800, 850-8E0

Failure code [CA272] IMV/PCV1 Open Error

User code
Failure code
Failure
E10
Detail of failure
CA272
40-15
IMV/PCV1 open circuit error

Open circuit is detected in supply pump PCV1 circuit.

Under normal conditions, pulse voltage of approx. 24 V is applied to PCV (1) while engine is runing.
However, it cannot be measured by using multimeter since it is pulse voltage.
Because troubleshooting "socket" for this sensor features female connector alone, it is not connectable to female connector of sensor wiring harness, and thus not usable for checking open circuit
(not designed as a T-adapter).
Problem on
machine
Related information
Cause
1

2. Disconnect connectors PCV1 and connect socket to male side.
(internal open circuit)
ResisBetween PCV1 (male) (1) and (2)
2.3 5.3 z
tance
Open or short circuit in wiring har- 2. Disconnect connector ENG and connect T-adapter to female side.
ness
ResisBetween ENG (female) (4) and (5) (PCV1 resistance)
2.3 5.3 z
tance
2. Disconnect connectors ENG and PCV1.
3. Connect T-adapter to female side of connector ENG.
ResisBetween ENG (4) and (5)
Min. 1 Mz
tance
Defective engine controller
PC800, 850-8E0
40-15
40-155

Failure code [CA273] PCV2 Short Error

User code
Failure code
Failure
E10
Detail of failure
CA273
40-156
PCV2 short circuit error

Short circuit is detected in supply pump PCV2 circuit.

Under normal conditions, pulse voltage of approx. 24 V is applied to PCV2 (1) while engine is running. However, it cannot be measured by using multimeter since it is pulse voltage.
Problem on
machine
Related information
Cause
1

2. Disconnect connector PCV2.
If failure code changes from [CA273] to [CA274], supply pump PCV2 is
defective.
tance)
2. Disconnect connectors ENG and PCV2, and connect Tadapter to female
side of ENG.
1.
2.
5
4.

Disconnect connector PCV2.
Turn starting switch to ON position (with connector PCV2 disconnected).

40-156
Voltage
Max. 3 V

40-156
PC800, 850-8E0

Failure code [CA274] PCV2 Open Error

User code
Failure code
Failure
E10
Detail of failure
CA274
40-157
PCV2 open circuit error

Open circuit is detected in supply pump PCV2 circuit.

Under normal conditions, pulse voltage of approx. 24 V is applied to PCV2 (1) while engine is running. However, it cannot be measured by using multimeter since it is pulse voltage.
Because troubleshooting "socket" for this sensor features female connector alone, it is not connectable to female connector of sensor wiring harness, and thus not usable for checking open circuit (not designed as a T-adapter).
Problem on
machine
Related information
Cause

2. Disconnect connector PCV2 and connect socket to male side.
2
Between PCV2 (male) (1) and (2)
Resistance 2.3 5.3 z
Open or short circuit in wiring har- 2. Disconnect connector ENG and connect T-adapter to female side.
3
ness
tance)
2. Disconnect connectors ENG and PCV2.
4
PC800, 850-8E0
Resistance
Min. 1 Mz

40-157
40-157

Failure code [CA322] Inj #1(L#1) Open/Short Error

User code
Failure code
Failure
E11
Detail of failure
CA322
40-158
Injector #1 open or short circuit error

Open circuit or short circuit is detected in injector #1 circuit.

Engine speed does not stabilize.
Problem on
machine
Related information
q
q
q

While engine is running normally, approximately 65 V of pulse voltage is applied to injector (positive side). But it is pulse voltage and cannot be measured by using multimeter.
Cause

2. Disconnect connector CN1 and connect T-adapter to male side.
2 Defective injector #1
Between CN1 (male) (1) and (2)
Between CN1 (male) (1) and ground
Resistance
Min. 1 Mz

Open circuit or ground fault in wirBetween ENG (female) (45) and (53)
ing harness


Defective other cylinder injectors

or injector wiring harness
40-158
Resistance
Min. 1 Mz

2. Disconnect connectors ENG and CN1, and connect T-adapters to each
female side.
Between ENG (female) (45) and CN1 (female) (1)
Resistance
Max. 1 z
Resistance
Max. 1 z

2. Disconnect connectors ENG and CN1, and connect T-adapters to either
female side.
Between ENG (female) (45) or CN1 (female) (1)
and ground
2. Disconnect connectors ENG and CN1, and connect T-adapter to female
side of ENG.
a Check by using multimeter in continuity mode.
Between ENG (female) (45) and each pin other
No continuity
than (45)
(No sound is heard)
than (53)
No continuity
(No sound is heard)
1. Troubleshoot injectors of other cylinders.

2. Confirm that injector wiring harnesses (H) of all cylinders are in good condition by referring to the following page.
PC800, 850-8E0

Circuit diagram related to injector #1
40-159
Improper installation of injector wiring harness

(H)
Q: Injector wiring harness (H) is in good condition

being laid close to injector (N)
PC800, 850-8E0
x: Injector wiring harness (H) is in bad condition

without being laid close to injector (N)
a: Injector wiring harness (H) may interfere with
rocker arm.
40-159

Failure code [CA323] Inj #5 (L#5) Open/Short Error

User code
Failure code
Failure
E11
Detail of failure
CA323
40-160


Problem on
machine
Related information
q
q
q

Cause

Resistance
Min. 1 Mz

ing harness



40-160
Resistance
Min. 1 Mz

female side.
Resistance
Max. 1 z
Resistance
Max. 1 z

female side.
and ground
side of ENG.
No continuity
than (46)
(No sound is heard)
than (60)
No continuity
(No sound is heard)

PC800, 850-8E0

40-161

(H)

PC800, 850-8E0

rocker arm.
40-161


User code
Failure code
Failure
E11
Detail of failure
CA324
40-162
Injectpr #3 open or short circuit error


Problem on
machine
Related information
q
q
q

Cause

1
Resistance
Min. 1 Mz

ing harness



40-162
Resistance
Min. 1 Mz

female side.
Resistance
Max. 1 z
Resistance
Max. 1 z

female side.
and ground
side of ENG.
No continuity
than (55)
(No sound is heard)
than (52)
No continuity
(No sound is heard)

PC800, 850-8E0

40-163

(H)

PC800, 850-8E0

rocker arm.
40-163


User code
Failure code
Failure
E11
Detail of failure
CA325
40-164


Problem on
machine
Related information
q
q
q

Cause

1
Resistance
Min. 1 Mz

ing harness



40-164
Resistance
Min. 1 Mz

female side.
Resistance
Max. 1 z
Resistance
Max. 1 z

female side.
and ground
side of ENG.
No continuity
than (57)
(No sound is heard)
than (59)
No continuity
(No sound is heard)

PC800, 850-8E0

40-165

(H)

PC800, 850-8E0

rocker arm.
40-165


User code
Failure code
Failure
E11
Detail of failure
CA331
40-16


Problem on
machine
Related information
q
q
q

While engine is running normally, approximately 65 V of pulse voltage is applied to injector (positive) side. But it is pulse voltage and cannot be measured by using multimeter.
Cause

Resistance
Min. 1 Mz

ing harness



40-166
Resistance
Min. 1 Mz

female side.
Resistance
Max. 1 z
Resistance
Max. 1 z

female side.
and ground
side of ENG.
No continuity
than (54)
(No sound is heard)
than (51)
No continuity
(No sound is heard)

PC800, 850-8E0

40-167

(H)

PC800, 850-8E0

rocker arm.
40-167


User code
Failure code
Failure
E11
Detail of failure
CA332
40-168


Problem on
machine
Related information
q
q
q

While engine is running normally, approximately 65 V of pulse voltage is applied to injector (positive) side. But it is pulse voltage and cannot be measured by using multimeter.
Cause

Resistance
Min. 1 Mz

ing harness



40-168
Resistance
Min. 1 Mz

female side.
Resistance
Max. 1 z
Resistance
Max. 1 z

female side.
and ground
side of ENG.
No continuity
than (56)
(No sound is heard)
than (58)
No continuity
(No sound is heard)

PC800, 850-8E0

40-169

(H)

PC800, 850-8E0

rocker arm.
40-169

Failure code [CA342] Calibration Code Incompatibility

User code
Failure code
Failure
E10
Detail of failure
CA342
40-170
Matching error in engine controller data

Matching error occurs in engine controller data.
Engine continues to run normally, but it may stop during running or may not be able to restart if it
is stopped.
Problem on
machine
Related information
Cause

Preform troubleshooting for failure code [CA111].
40-170
PC800, 850-8E0

Failure code [CA351] Injectors Drive Circuit Error
Failure code [CA351] Injectors Drive Circuit Error

User code
Failure code
Failure
E10
CA351
Injector drive circuit error

Detail of failure
Injector drive circuit is defective.
Limits engine output (limits common rail pressure) and allows engine to run.
Problem on
machine
Related information
Cause
PC800, 850-8E0
40-171

Check failure code (injector system failure code) that is displayed at the same
time. If another code is displayed, perform troubleshooting for it.
40-171


User code
Failure code
Failure
E15
CA352
40-172
Sensor power supply 1 voltage low error

Detail of failure
Low voltage appears in sensor power supply 1 (5 V) circuit.
Problem on
machine
Related information
Cause

tor
position each time.
If this failure code is not displayed when sensor is disconnected, sensor or
engine wiring harness is defective.
2 Defective sensor or wiring harness a Other failure code(s) is (are) displayed at the same time. This is because
sensor connector is disconnected. Therefore, ignore failure codes other than
[CA352].
Sensor or harness
Connector
PFUEL
ENG

3. Turn starting switch to ON position with connector ENG disconnected.
40-172
Voltage
4.75 5.25 V
PC800, 850-8E0

Circuit diagram related to sensor power supply 1 (5 V)
PC800, 850-8E0
40-173
40-173


User code
Failure code
Failure
E15
CA386
Sensor power supply 1 voltage high error

Detail of failure
High voltage appears in sensor power supply 1 (5 V) circuit.
Problem on
machine
Related information
Cause
40-174

Perform troubleshooting for failure code [CA352]
Failure code [CA441] Battery Voltage Low Error

User code
Failure code
Failure
E10
CA441
40-174
Battery voltage low error

Detail of failure
Low voltage appears in controller power supply circuit.
None in particular
is stopped.
Power supply voltage of engine controller can be checked by using monitoring function. (Code:
03203 (V))
Problem on
machine
Related information
q
q
Cause

40-174
PC800, 850-8E0

Failure code [CA442] Battery Voltage High Error
Failure code [CA442] Battery Voltage High Error

User code
Failure code
Failure
E10
CA442
40-175
Battery voltage high error

Detail of failure
High voltage (36 V or higher) appears in controller power supply circuit.
None in particular
is stopped.
Power supply voltage of engine controller can be checked by using monitoring function. (Code:
03203 (V))
Problem on
machine
Related information
q
q
Cause

Failure code [CA449] Rail Press Very High Error

User code
Failure code
Failure
E11
CA449
40-175
Common rail pressure sensor very high error

Abnormally high voltage (voltage exceeding set maximum level) appears in common rail pressure
sensor circuit.
Problem on
machine
Signal voltage from common rail pressure sensor can be checked by using monitoring function.
(Code: 36401 (V))
Common rail pressure sensed by common rail pressure sensor can be checked by using monitoring function. (Code: 36400 (MPa))
Detail of failure
Related information
q
q
Cause

PC800, 850-8E0
40-175

Failure code [CA451] Rail Press Sensor High Error

User code
Failure code
Failure
E11
CA451
40-176
Common rail pressure sensor high error

Detail of failure
High voltage appears in signal circuit of common rail pressure sensor.
Problem on
machine
(Code: 36401 (V))
Common rail pressure sensed by common rail pressure sensor can be checked by using monitoring
function. (Code: 36400 (MPa))
This failure code is generated if common rail pressure sensor connector is disconnected.
Related information
q
q
q
Cause
See the descriptions of wiring harness and connectors in "c: Electrical equipDefective wiring harness connecment" of "Checks before troubleshooting" in "General information on trouble1
tor
shooting", and check them directly.
a If failure code [CA352] or [CA386] is displayed, perform troubleshooting for
it first.
2
Defective common rail pressure

sensor power supply line


2. Disconnect connector PFUEL and connect T-adapter to female side.
Power supBetween PFUEL (female) (1) and (3)
Voltage
4.75 5.25 V
ply input
2. Disconnect connectors PFUEL and ENG and connect T-adapters to each
female side.
Resistance
Max. 1 z
Between ENG(female) (33) and PFUEL(female) (1)
Resistance
Max. 1 z
Between ENG (female) (47) and PFUEL (female)
(3)
Between ENG (female) (25) and PFUEL (female)
Resistance
Max. 1 z
(2) (sensor output)
2. Disconnect connectors PFUEL and ENG
1.
2.
5
a
Resistance
Min. 1 Mz

Disconnect connector PFUEL and insert T-adapter into connector ECM.
Turn starting switch to ON position (with connector PFUEL disconnected).
ENG (25) pin is connected to 5 V power supply through resistor in engine
controller.
Voltage
Approx. 5 V
a If no failure is found by checks on causes 1 to 5 and check result of cause 6

is abnormal, sensor is defective.
6 sensor (defective input voltage to 2. Insert T-adapter into connector ENG.
engine controller)
Sensor outBetween ENG (25) and (47)
Voltage
0.2 4.6 V
put
40-176
PC800, 850-8E0

Circuit diagram related to common rail pressure sensor
PC800, 850-8E0
40-17
40-177

Failure code [CA452] Rail Press Sensor Low Error

User code
Failure code
Failure
E11
CA452
40-178
Common rail pressure sensor low error

Detail of failure
Low voltage appears in signal circuit of common rail pressure sensor.
Problem on
machine
(Code: 36401 (V))
Common rail pressure sensed by common rail pressure sensor can be checked by using monitoring
function. (Code: 36400 (MPa))
If sensor connector is disconnected even in normal condition, failure code [CA451] for "High Error"
is generated instead of this code.
Related information
q
q
q
Cause

of "Checks before troubleshooting" in "General information on troubleshooting",
tor
a If failure code [CA352] or [CA386] is displayed, perform troubleshooting for
it first.
2

sensor power supply line

sensor

2. Disconnect connector PFUEL and connect T-adapter to female side.
Power supBetween PFUEL (female) (1) and (3)
Voltage
4.75 5.25 V
ply input
2. Disconnect connector PFUEL
If failure code [CA452] changes to [CA451] , sensor is defective.

4

2. Disconnect connectors ENG and PFUEL , and connect T-adapter to female
side of ENG

40-178
Resistance
Min. 1 Mz

2. Disconnect connectors ENG and PFUEL , and connect T-adapter to female
side of ENG
Resistance
Min. 1 Mz

PC800, 850-8E0

Circuit diagram related to common rail pressure sensor
PC800, 850-8E0
40-179
40-179

Failure code [CA553] Rail Press High Error

User code
Failure code
Failure
E15
CA553
40-180
Common rail pressure high error

Abnormal high voltage (higher than set voltage) appears more than 10 seconds in signal circuit of
common rail pressure sensor.
None in particular
Problem on
machine
(Code: 36401(V))
Common rail pressure sensed by common rail pressure sensor can be checked by using monitoring function. (Code: 36400(MPa))
Detail of failure
Related information
q
q
Cause
1 Defective related system
Check fuel used directly (for high viscosity).
Defective electrical system of

common rail pressure sensor
Electrical system of common rail pressure sensor may be defective. Perform

troubleshooting for failure codes [CA451] and [CA452].
Defective mechanical system of

common rail pressure sensor
Check mechanical system of common rail pressure sensor directly.
5 Defective overflow valve
Check overflow valve directly for broken spring, worn seat, and seized ball.
6 Clogging of overflow piping
Check overflow piping directly for clogging.
7 Defective pressure limiter
Mechanical system of pressure limiter may be defective. Check it directly.
40-180
PC800, 850-8E0

Failure code [CA554] Rail Press Sensor In Range Error

User code
Failure code
Failure
E11
CA554
40-181
Common rail pressure sensor signal voltage out of input range

Detail of failure
Signal voltage of common rail pressure sensor is out of input range.
Problem on
machine
(Code: 36401 (V))
Related information
q
q
Cause

Perform troubleshooting for failure code [CA451] and [CA452]
PC800, 850-8E0
40-181

Failure code [CA559] Supply Pump Press Low Error 1

User code
Failure code
Failure
E15
CA559
40-182
Common rail pressure low error

Detail of failure
Supply pump does not feed fuel (level 1).
Limits common rail pressure.
Problem on
machine
Related information
Cause
If another failure code is displayed, perform troubleshooting for it first.
Check fuel used directly (for high viscosity).
a For more information on troubleshooting, see "Note 1".

a For check of pressure in fuel low-pressure circuit, see Testing and adjusting, "Testing fuel pressure".
3 Defect in low pressure circuit parts
Pressure in fuel low-pressure circuit
0.15 0 .3 MPa
(At high idle or under load equivalent
{1.5 3.0 kg/cm2}
to rated output operation)
4 Clogged fuel filter,or strainer
a For more information on troubleshooting, see "Note 2".
Defective electrical system of sup- Electrical system of supply pump PCV may be defective. Perform troubleply pump PCV
shooting for failure code [CA271], [CA272], [CA273], or [CA274].

sensor
7 Defective pressure limiter
8 Defective injector
9 Defective supply pump
Common rail pressure sensor may be defective. Check wiring harness for
damage.
a For check of leakage from pressure limiter, see Testing and adjusting,
"Checking fuel return rate and leakage".
Leakage from pressure limiter
(Under load equivalent to rated output
Max. 10 cc/min
operation (torgue converter stall))
a For check of limit return rate (spill) from injector, see Testing and adjusting,
"Checking fuel return rate and leakage".
Engine speed for rated output operaInjector limit return rate
tion or equivalent
(spill)
(torgue converter stall)
1,600 rpm
960 cc/min
1,700 rpm
1,020 cc/min
1,800 rpm
1,080 cc/min
1,900 rpm
1,140 cc/min
2,000 rpm
1,200 cc/min
If no failure is found by checks on causes 1 to 8 , supply pump may be defective.
<How to use check sheet>

Perform the above troubleshooting and fill in the check results on the attached " Check sheet for no-fuel feed" .
40-182
PC800, 850-8E0

Note 1: To determine if low-pressure circuit parts is defective, check following items.

1) Fuel level
2) Clogging of fuel tank breather
3) Seizure and wear of feed pump and clogging of filter
4) Leakage or clogging of low-pressure fuel piping
5) Malfunction of bypass valve and installation of wrong part (See Fig. 1)
6) Clogged fuel filter
7) Fuel in oil pan (fuel leakage inside head cover)
Fig. 1: Locations of overflow valve (1) , bypass valve (2), and fuel inlet joint (3)
q
Overflow valve (1): Spring is visible through both holes.
q Bypass valve (2): Spring is visible through nut side hole.
q Fuel inlet joint (3): Gauze filter is visible through both holes
Note 2: Check, clean, and replace the filters and strainers according to the following procedure.
1) Gauze filter: Disassemble and check. If clogged, clean.
2) Upstream strainer of gauze filter: If the gauze filter is clogged, clean the upstream filter, too.
3) Fuel filter: If the problem is not solved by performing 1) and 2) above, replace the fuel filter.
PC800, 850-8E0
40-183

Check sheet for no-fuel feed

Model
Machine serial No.
Engine
Engine serial No.
#
SAA6D140E5
#
Work No.
Date of check
Worker's name
/
h
Go N
A. Visual check
1 Fuel leakage to outside
2 Clogging of fuel tank breather
B. Inspection with machine monitor (02 = Abnormality record; 01 = Monitoring; 09 = Cylinder cut-out operation Go N
3 Check of failure code
/
/
/
/
Check of monitoring information
Standard
Measure- Go N
Code
Display item
Checking condition
SI unit
Low speed
r/min
825 25
01002 Engine speed
Full speed
r/min
1,980 50
At torque converter stall
r/min
1,800
Low speed
%
0
31701 Throttle opening
Full speed
%
100
Inject fueling com18600 mand (weight)
mg/st

4
36200 Rail press command At torque converter stall
36400 Common rail pres- At torque converter stall
Low speed
Injection timing com36300
Full speed
mand
36500 Boost pressure
04107 Coolant temperature Low speed
14200 Fuel temperature
Low speed
Check result of cylinder cut-out operation (engine speed)
FuncCutout cylinder
Checking condition
No. 1 cylinder
Low speed
No. 2 cylinder
Low speed
5 Set by
No. 3 cylinder
Low speed
cylinNo. 4 cylinder
Low speed
der
No. 5 cylinder
Low speed
No. 6 cylinder
Low speed
C. Check of fuel circuit pressure
Fuel low-pressure circuit
6
pressure
Checking condition
Full speed or under load equivalent to rated output operation
MPa
MPa
CA
CA
CA
kPa
C
C
SI unit
r/min
r/min
r/min
r/min
r/min
r/min
Standard
Unit
MPa
{kg/cm2}
Standard
0.15 0.3
{1.5 3.0}
Measure-
Go
Measure-
Go N
Go N
D. Check of strainers and filters

7 Visual inspection of strainer
8 Visual check of gauze filter
9 Visual check of fuel filter
10 Visual check of bypass valve
E. Check of leakage and fuel
Leakage from pressure lim11
iter
12 Return rate from injector
40-184
Checking condition
Under load equivalent to rated
output operation(torgue conTorque converter stall at 1,600
rpm
Torque converter stall at 1,700
rpm
rpm
rpm
rpm
Unit
Standard
cc/min
Max. 10
cc/min
960
cc/min
1,020
cc/min
1,080
cc/min
1,140
cc/min
1,200
Measure-
Go N
Speed:
Return rate:
PC800, 850-8E0

PC800, 850-8E0
40-185

Failure code [CA689] Eng Ne Speed Sensor Error

User code
Failure code
Failure
E15
CA689
40-186
Engine Ne speed sensor error

Detail of failure
Signal from engine Ne speed sensor is abnormal.
Controls engine by using signals from engine Bkup speed sensor.
Running engine stops (when Bkup speed sensor is also defective).

Stopped engine cannot be started (when Bkup speed sensor is also defective).
Since inside of speed sensor is not composed of coil but Hall sensor and electronic circuit, speed
sensor cannot be determined to be normal by measuring its resistance by using multimeter.
Since speed sensor output is 5 V pulse voltage during normal operation, it cannot be measured by
using multimeter.
Speed sensor detects part of flywheel wehre hole is not made for calculation of engine speed.
Problem on
machine
q
q
q
Related information
q
q
Cause
See the descriptions of wiring harness and connectors in "c: Electrical equipDefective wiring harness connecment" of "Checks before troubleshooting" in "General information on trouble1
tor
shooting", and check them directly.
Defective Ne speed sensor power
2 supply line
Breakage or improper installation
Engine Ne speed sensor may be damaged or improperly installed (loose).
3 (looseness) of engine Ne speed
Check it directly.
sensor
2. Disconnect connector NE and connect T-adapter to female side.
Defective Ne speed sensor power
4
supply input
Power supBetween NE (female) (1) and (2)
Voltage
4.75 5.25 V
ply input
2. Disconnect connectors ENG and NE.
If no failure is found by checks on cause 4, this
check is not required.
Resistance
Max. 1 z
5 (wire breakage or defective con- Between ENG (female) (16) and NE (female) (1)
If no failure is found by checks on cause 4, this
tact of connector)
check is not required.
Resistance
Max. 1 z
Between ENG (female) (48) and NE (female) (2)
Between ENG (female) (27) and NE (female) (3)
Resistance
Max. 1 z
6 Ground fault in wiring harness
NE (female) (1) and (3)
NE (female) (2) and (3)
7
Between ENG (female) (27) or NE (female) (3) and
ground
Hot short circuit in wiring harness 2. Disconnect connector NE.
8
Between NE (female) (3) and ground
Voltage
Max. 1 V
If no failure is found by above checks, engine Ne speed sensor may be defec9 Defective engine Ne speed sensor
tive. (Since this is an internal failure, troubleshooting cannot be performed.)
40-186
PC800, 850-8E0

Circuit diagram related to engine Ne speed sensor
40-187
Ne speed sensor detects part (A) of flywheel (1), where hole (H) is not made to recognize one turn of flywheel, and the engine controller calculates the engine speed and phase.
PC800, 850-8E0
40-187

Failure code [CA731] Eng Bkup Speed Sens Phase Error

User code
Failure code
Failure
E15
Detail of failure
Problem on
machine
CA731
40-18
Engine Bkup speed sensor phase error

Engine controller detects unusual phase by the signal from engine Bkup speed sensor.
(Bkup speed sensor signal and Ne speed sensor signal are out of phase.)
Controls engine by using signals of engine Ne speed sensor.
Running engine stops (when Ne speed sensor is also defective).

Stopped engine cannot be started (when Ne speed sensor is also defective).
q Method of reproducing failure code: Start engine.

Related infora If Bkup speed sensor needs to be replaced, fuel supply pump must be replaced as a unit. (See
mation
"Disassembly and assembly", "Removal and installation of fuel supply pump".)
Cause
Defective engine Ne speed sensor Engine Ne speed sensor may be defective. Perform troubleshooting for failure
system
code [CA689].
Defective engine Bkup speed sen- Engine Bkup speed sensor may be defective. Perform troubleshooting for failsor system
ure code [CA778].
40-188
PC800, 850-8E0

Failure code [CA757] All Continuous Data Lost Error

User code
Failure code
Failure
E10
CA757
40-189
All continuous data lost error

Detail of failure
All data in engine controller are lost.
None in particular
is stopped.
Problem on
machine
Related information
Cause

PC800, 850-8E0
40-189

Failure code [CA778] Eng Bkup Speed Sensor Error

User code
Failure code
Failure
E15
CA778
40-190
Engine Bkup speed sensor error

Detail of failure
Abnormality occurred in engine Bkup speed sensor circuit.
Controls engine by using signals of Ne speed sensor.
Running engine stops (when Ne speed sensor is also defective).

Stopped engine cannot be started (when Ne speed sensor is also defective).
a If engine Bkup speed sensor needs to be replaced, fuel supply pump must be replaced as a
unit.
(See "Disassembly and assembly", "Removal and installation of fuel supply pump".)
Since inside of speed sensor is not composed of coil but electronic circuit, speed sensor cannot be
determined to be normal by measuring its resistance by using multimeter .
Since speed sensor output is 5 V pulse voltage during normal operation, it cannot be measured by
using multimeter.
Problem on
machine
q
q
Related information
q
q
Cause

If failure code [CA187] or [CA227] is also displayed, perform troubleshooting
2
system
for it first.
1
Damage or improper installation

Engine Bkup speed (G) sensor may be damaged or improperly installed
3 (loose) of engine Bkup speed (G)
(loose). Check it directly.
sensor
4 Defective resistor (RES)

2. Disconnect connector RES and connect T-adapter to male side.
Between RES (male) (1) and (2)
620 z
Resistance

Defective engine Bkup speed sen- 2. Disconnect connector G and connect T-adapter to female side.
5
sor power supply input
Between G (female) (1) and (2)
Power supply
Voltage
4.75 5.25 V

Open or short circuit in wiring har- 2. Disconnect connectors ENG and G, and connect T-adapter to female side
6
of ENG.
ness (resistor RES line)

Between ENG (female) (26) and G (female) (3)
40-190
Resistance
620 z

2. Disconnect connectors ENG, G and RES, and connect T-adapters to each
female side.
a If power supply voltage in checks on cause 5 is
normal, this check is not required.
Resistance
Max. 1 z
a If power supply voltage in checks on cause 5 is
Resistance
Max. 1 z
Resistance
Max. 1 z

2. Disconnect connectors ENG, G and RES, and connect T-adapter to female
side of ENG or G.
G (female) (1) and (3)
G (female) (2) and (3)
PC800, 850-8E0

Cause

2. Disconnect connectors ENG and G and connect T-adapters to either female
Ground fault in harness
9
side.
Between ENG (female) (26) or G (female) (3) and
Resistance
Min. 1 Mz
ground
Hot short circuit in wiring har- 2. Disconnect connectors G and RES, and connect T-adapter to female side.
10 ness (contact with 24 V cir3. Turn starting switch to ON position.
cuit)
Between G (female) (3) and ground
Voltage
Max. 1 V
11
Defective engine Bkup speed If no failure is found by above checks, engine Bkup speed sensor may be defective.
sensor
If no failure is found by above checks, engine controller is defective. (Since this is

an internal failure, troubleshooting cannot be performed.)
Circuit diagram related to engine Bkup speed sensor
PC800, 850-8E0
40-191
40-191

Failure code [CA1228] EGR Valve Servo Error 1

User code
Failure code
Failure
E15
Detail of failure
Problem on
machine
Related information
CA1228
40-192
EGR Valve servo error 1

EGR valve has servo error (level 1).

(Response from EGR lift sensor differs from EGR valve opening command value.)
q
q

Stops outputting current to EGR valve (closes EGR valve).
EGR valve position can be checked by using monitoring function. (Code: 18100 EGR valve position
(mm))
Cause

a For measurement of EGR valve drive pressure, see Testing and adjusting,
Measuring EGR valve and bypass valve drive pressure .
Improper EGR valve drive pres2

sure
Low speed
Engine speed
Full speed
EGR valve drive

pressure
Min. 1.18 MPa

{12 kg/cm2}
Min. 1.43 MPa
{14.6 kg/cm2}
If EGR valve drive pressure is not normal, perform checks on causes 3 and 4.
a For check of engine oil pressure, see Testing and adjusting, "Testing engine
oil pressure".
Min. 0.08 MPa
Low speed
{0.8 kg/cm2}
Engine oil presDefective engine oil system (main
Engine speed
3
sure
Min. 0.21 MPa
circuit)
Full speed
{2.1 kg/cm2}
If engine oil pressure is not normal, preform troubleshooting (S mode) for
mechanical system. (S-12 Oil pressure lowers.)
4 Defective oil pump for EGR valve
Oil pump or relief valve for EGR valve circuit may be defective. Check them
directly.
5 Defective oil pipe for EGR valve
Oil pipe for EGR valve circuit may be defective. Check it directly .
Defective oil return pipe for EGR

valve
Oil return pipe for EGR valve circuit may be defective. Check it directly.
7 Defective EGR valve
EGR valve may be defective. Check it directly.
8 Defective EGR valve lift sensor
If no failure is found by checks on causes 1 to 8, engine controller may be

40-192
PC800, 850-8E0


User code
Failure code
Failure
E11
Detail of failure
Problem on
machine
Related information
CA1625
40-193
EGR Valve servo error 2

EGR valve has servo error (level 2).

(Response from EGR lift sensor differs from EGR valve opening command value.)
q
q

Stops outputting current to EGR valve (closes EGR valve).
EGR valve position can be checked by using monitoring function. (Code: 18100 EGR valve position (mm))
Cause

PC800, 850-8E0
40-193

Failure code [CA1626] BP Valve Sol Current High Error

User code
Failure code
Failure
E11
CA1626
Short circuit in bypass valve solenoid drive circuit

Detail of failure
Short circuit is in bypass valve solenoid drive circuit.
q
q
Limits engine output and allows to engine to run.

Closes EGR valve and bypass valve.
Problem on
machine
Related information
Cause
40-194

2. Disconnect connector BP and connect T-adapter to male side.
Defective bypass valve solenoid
2
Between BP (male) (1) and (2)
Resistance
10 21 z
Between BP (male) (1) and ground
Resistance
Min. 1 Mz

Open or short circuit in wiring har- a If resistance is above 1 Mz, wiring harness has open circuit. If resistance
3
ness
is below 1 z, wiring harness has short circuit.
Resistance
10 21 z

2. Disconnect connectors ENG and BP, and connect T-adapters to either
female side.
BP (female) (1) and (2)

Hot short circuit in wiring harness 2. Disconnect connector BP and connect T-adapter to male side.
5
3. Turn starting switch to ON position (with connector BP disconnected).
Between BP (female) (1) and (2)
Voltage
Max. 1 V
40-194
If no failure is found by above checks, engine controller may be defective.

PC800, 850-8E0

Circuit diagram related to bypass valve
PC800, 850-8E0
40-195
40-195

Failure code [CA1627] BP Valve Sol Current Low Error

User code
Failure code
Failure
E11
CA1627
Open circuit in bypass valve solenoid drive circuit

Detail of failure
Open circuit is in bypass valve solenoid drive circuit.
q
q

Problem on
machine
Related information
Cause
1
40-196

Defective bypass valve solenoid 2. Disconnect connector BP and connect T-adapter to male side.
ResisBetween BP (male) (1) and (2)
10 21 z
tance
ness
ResisBetween ENG (female) (31) and (11)
10 21 z
tance
2. Disconnect connectors ENG and BP, and connect T-adapters to each
female side.
(wire breakage or defective conResistact of connector)
Between ENG (female) (31) and BP (female) (1)
Max. 1 z
tance
ResisBetween ENG (female) (11) and BP (female) (2)
Max. 1 z
tance
40-196
PC800, 850-8E0

Circuit diagram related to bypass valve
PC800, 850-8E0
40-197
40-197

Failure code [CA1628] Bypass Valve Servo Error 1

User code
Failure code
Failure
E15
Detail of failure
Problem on
machine
Related information
CA1628
40-198
Bypass valve servo error 1

Bypass valve has servo error (level 1).

(Response from bypass valve lift sensor differs from bypass valve opening command valve.)
q
q

Stops outputting current to EGR valve and bypass valve (closes EGR valve and bypass valve).
Bypass valve position can be checked by using monitoring function. (Code: 18200 Bypass valve
position (mm))
Cause

If another failure code is displayed, perform troubleshooting for it, too.
a For measurement of bypass valve drive pressure, see Testing and adjusting, "Measuring EGR valve and bypass valve drive pressure".
Min. 1.18 MPa

{12 kg/cm2}
Bypass valve
Engine speed
drive pressure
Min. 1.43 MPa
Full speed
{14.6 kg/cm2}
If bypass valve drive pressure is not normal, perfoem checks on causes 3 and
4.
a For check of engine oil pressure, see Testing and adjusting, "Testing engine
oil pressure".
Min. 0.08 MPa
Low speed
{0.8 kg/cm2}
Engine
oil
presDefective engine oil system (main
Engine speed
3
sure
Min. 0.21 MPa
circuit)
Full speed
{2.1 kg/cm2}
Improper bypass valve drive pres2
sure
Low speed
If engine oil pressure is not normal, preform troubleshooting (S mode) for

mechanical system. (S-12 Oil pressure lowers.)
4
Defective oil pump for bypass

valve
Oil pump or relief valve for bypass valve circuit may be defective. Check them
directly.
5 Defective oil pipe for bypass valve Oil pipe for bypass valve circuit may be defective. Check it directly .
6
Defective oil return pipe for

bypass valve
7 Defective bypass valve
Oil return pipe for bypass valve circuit may be defective. Check it directly .
Bypass valve may be defective. Check it directly .
8 Defective bypass valve lift sensor Perform troubleshooting for failure code [CA1631].
40-198
If no failure is found by checks on causes 1 to 8, engine controller may be

PC800, 850-8E0


User code
Failure code
Failure
E11
Detail of failure
Problem on
machine
Related information
CA1629
40-19
Bypass valve servo error 2

Bypass valve has servo error (level 2).

(Response from bypass valve lift sensor differs from bypass valve opening command valve.)
q
q

Stops outputting current to EGR valve and bypass valve (closes EGR valve and bypass valve).
Bypass valve position can be checked by using monitoring function. (Code: 18200 Bypass valve
position (mm))
Cause

PC800, 850-8E0
40-199

Failure code [CA1631] BP Valve Pos Sens High Error

User code
Failure code
Failure
E11
CA1631
40-20
Bypass valve lift sensor high error

Detail of failure
High voltage appears in bypass valve lift sensor signal circuit.
q
q

Signal voltage from bypass valve lift sensor can be checked by using monitoring function. (Code:
18200 (mm))
Bypass valve position (mm) sensed by bypass valve lift sensor can be checked by using monitoring
function. (Code: 18201 (V))
Problem on
machine
Related information
q
q
Cause

2
system
first.
Defective bypass valve lift sensor 2. Disconnect connector SBP.
3
3. Turn starting switch to ON position (with connector SBP disconnected).
(internal failure)
2. Disconnect connectors ENG and SBP, and connect T-adapters to either
female side.
Between ENG (female) (37) and (29), between SBP
(female) (1) and (3), or between SBP (female) (1)
and (4)
Hot short circuit in wiring harness 2. Disconnect connector SBP and connect T-adapter to female side.
5
3. Turn starting switch to ON position (with connector SBP disconnected).
Between SBP (female) (3) or (4) and (2)
Voltage
Max. 1 V

q Reference
40-200
Voltage
1.0 4.0 V
PC800, 850-8E0

Circuit diagram related to bypass valve lift sensor
PC800, 850-8E0
40-201
40-201

Failure code [CA1632] BP Valve Pos Sens Low Error

User code
Failure code
Failure
E11
CA1632
40-202
Bypass valve lift sensor low error

Detail of failure
Low voltage appears in bypass valve lift sensor signal circuit.
q
q

Signal voltage from bypass valve lift sensor can be checked by using monitoring function. (Code:
18201 (V))
Bypass valve position (mm) sensed by bypass valve lift sensor can be checked by using monitoring
function. (Code: 18200 (mm))
Problem on
machine
Related information
q
q
Cause

tor
first.
2

2. Disconnect connector SBP and connect T-adapter to female side.
Power supBetween SBP (female) (1) and (2)
Voltage
4.75 5.25 V
ply
2. Disconnect connectors SBP and ENG, and connect T-adapters to each
female side.
a If power supply voltage in check on cause 2 is
Resistance
Max. 1 z
Between ENG (female) (37) and SBP (female)
(1)
(wire breakage or defective cona If power supply voltage in check on cause 2 is
tact of connector)
Resistance
Max. 1 z
Between ENG (female) (38) and SBP (female)
(2)
Between ENG (female) (29) and SBP (female) (3)
and, between ENG (female) (29) and SBP (female) Resistance
Max. 1 z
(4) (sensor output)
female side.
Between ENG (female) (29) and ground, or
between SBP (female) (3) and ground
female side.
SBP (female) (2) and (3)
Defective bypass valve lift sensor 2. Insert T-adapter into connector ENG or SBP
Between ENG (29) and (38), or between SBP (3)
Voltage
1.0 4.0 V
and (2)
system
40-202
PC800, 850-8E0

Circuit diagram related to bypass valve lift sensor
PC800, 850-8E0
40-203
40-203

Failure code [CA1633] KOMNET Datalink Timeout Error

User code
Failure code
Failure
E0E
CA1633
Detail of failure
Problem on
machine
Related information
40-204
KOMNET datalink timeout error

Engine controller detects communication error in KOMNET communication circuit between engine
controller and pump controller or machine monitor.
Allows engine to run in default mode or keeps control conditions at the time of failure detection.
q
q
Machine may not operate normally because informations which are exchanged through KOMNET
communication are not transmitted properly.
(Failure symptom depends on failed section.)
Cause

Perform troubleshooting for failure code [DA2RMC].
40-204
PC800, 850-8E0

PC800, 850-8E0
40-205

Failure code [CA2185] Throt Sens Sup Volt High Error

User code
Failure code
Failure
E14
CA2185
40-206
Throttle sensor power supply voltage high error

Detail of failure
High voltage (5.25 V or higher) appears in throttle sensor power supply circuit.
Sets throttle position by using signal other than throttle sensor signal and allows engine to run.
Engine speed cannot be controlled by fuel control dial.
Problem on
machine
Related information
Cause

tor
2. Disconnect connector P20, and turn starting switch to ON position.
Defective throttle sensor (fuel con2
If this failure code is not displayed, throttle sensor is defective.
trol dial)
a Other failure codes are displayed, too. This is because connector is disconnected. Ignore failure codes other than [CA2185].
2. Disconnect connectors CE02, CE03 and P20, and connect T-adapters to
female connectors CE02 and CE03.
Between CE02 (female) (22) and each pin other
than (22)
Between CE02 (female) (22) and CE03 (female) (3) Resistance
Min. 1 Mz

Hot short circuit in wiring harness 2. Disconnect connector P20, and connect T-adapter to female side.
4
Voltage
4.75 5.25 V

2. Disconnect connector CE02, and connect T-adapter to male side.
3. Turn starting switch to ON position with connector CE02 disconnected.
Between CE02 (male) (22) and (23)
40-206
Voltage
4.75 5.25 V
PC800, 850-8E0

PC800, 850-8E0
40-207
40-207

Failure code [CA2186] Throt Sens Sup Volt Low Error

User code
Failure code
Failure
E14
CA2186
40-208
Throttle sensor power supply voltage low error

Detail of failure
Low voltage appears in throttle sensor power supply circuit.
Sets throttle position by using signal other than throttle sensor signal and allows engine to run.
Engine speed cannot be controlled by fuel control dial.
Problem on
machine
Related information
Cause
1

Defective wiring harness connecof "Checks before troubleshooting" in "General information on troubleshooting",
tor
2. Disconnect connector P20, and turn starting switch to ON position.
Defective throttle sensor (fuel conIf this failure code is not displayed, throttle sensor is defective.
trol dial)
a Other failure code is displayed too. This is because connector is disconnected. Ignore failure codes other than [CA2186].
female side.
Between CE02 (female) (22) or P20 (female) (1)
and ground
2. Disconnect connectors CE02 and P20, and connect T-adapter to female side
of connector CE02.
than (22)

2. Disconnect connector CE02, and connect T-adapter to male side.
3. Turn starting switch to ON position with connector CE02 disconnected.
40-208
Voltage
4.75 5.25 V
40-208
PC800, 850-8E0

Failure code [CA2249] Rail Press Very Low Error
Failure code [CA2249] Rail Press Very Low Error

User code
Failure code
Failure
E11
CA2249
40-209
Common rail pressure very low error

Detai of failure
Supply pump does not feed fuel (level 2).
Limits common rail pressure.
Problem on
machine
(Code: 36401 (V))
Common rail pressure sensed by common rail pressure sensor can be checked by using monitoring function. (Code: 36400(MPa))
Related information
q
q
Cause

Perform troubleshooting for failure code [CA559] .
PC800, 850-8E0
40-209

Failure code [CA2271] EGR Valve Pos Sens High Error

User code
Failure code
Failure
E11
CA2271
40-210
EGR valve lift sensor high error

Detail of failure
High voltage appears in EGR valve lift sensor signal circuit.
q
q

Closes EGR valve.
Signal voltage from EGR valve lift sensor can be checked by using monitoring function. (Code:
18100 (mm))
EGR valve position (mm) sensed by EGR valve lift sensor can be checked by using monitoring
function. (Code: 18101 (V))
Problem on
machine
Related information
q
q
Cause

2
system
first.
Defective EGR valve lift sensor

(internal failure)

2. Disconnect connector SEGR.
3. Turn starting switch to ON position (with connector SEGR disconnected).

2. Disconnect connectors ENG and SEGR, and connect T-adapter to either
female side.
Between ENG (female) (37) and (19), between
SEGR (female) (1) and (3), or between SEGR
(female) (1) and (4)
Hot short circuit in wiring harness 2. Disconnect connector SEGR and connect T-adapter to female side.
5
3. Turn starting switch to ON position (with connector SEGR disconnected).
Between SEGR (female) (3) or (4) and (2)
Voltage
Max. 1 V

q Reference
40-210
Voltage
1.0 4.0 V
PC800, 850-8E0

Circuit diagram related to EGR valve lift sensor
PC800, 850-8E0
40-21
40-211

Failure code [CA2272] EGR Valve Pos Sens Low Error

User code
Failure code
Failure
E11
CA2272
40-212
EGR valve lift sensor low error

Detail of failure
Low voltage appears in EGR valve lift sensor signal circuit.
q
q

Closes EGR valve.
Signal voltage from EGR valve lift sensor can be checked by using monitoring function. (Code:
18101 (V))
EGR valve position (mm) sensed by EGR valve lift sensor can be checked by using monitoring function. (Code: 18100 (mm))
Problem on
machine
Related information
q
q
Cause

tor
first.
2

system


6 Defective EGR valve lift sensor
40-212

2. Disconnect connector SEGR and connect T-adapter to female side.
Power supBetween SEGR (female) (1) and (2)
Voltage
4.75 5.25 V
ply
2. Disconnect connectors SEGR and ENG, and connect T-adapters to each
female side.
Resistance
Max. 1 z
Between ENG (female) (37) and SEGR (female)
(1)
Resistance
Max. 1 z
Between ENG (female) (47) and SEGR (female)
(2)
Between ENG (female) (19) and SEGR (female) (3)
and, between ENG (female) (19) and SEGR
Resistance
Max. 1 z
(female) (4), (sensor output)
2. Disconnect connectors ENG and SEGR, and connect T-adapters to either
female side.
Between ENG (female) (19) and ground, or
between SEGR (female) (3) and ground
2. Disconnect connectors ENG and SEGR, and connect T-adapters to either
female side.
SEGR (female) (2) and (3)
2. Insert T-adapter into connector ENG or SEGR.
Between ENG (19) and (47), or between SEGR (3)
Voltage
1.0 4.0 V
and (2)
PC800, 850-8E0

Circuit diagram related to EGR valve lift sensor
PC800, 850-8E0
40-213
40-213

Failure code [CA2351] EGR Valve Sol Current High Error

User code
Failure code
Failure
E11
CA2351
Short circuit in EGR valve solenoid drive circuit

Detail of failure
Short circuit is in EGR valve solenoid drive circuit.
q
q

Problem on
machine
Related information
Cause
40-214

2. Disconnect connector EGR and connect T-adapter to male side.
Defective EGR valve solenoid
2
Between EGR (male) (1) and (2)
Resistance 10 21 z
Between EGR (male) (1) and ground
Resistance
Min. 1 Mz

3
ness
Resistance
10 21 z

2. Disconnect connectors ENG and EGR, and connect T-adapters to either
female side.
Between EGR (female) (1) and (2)

Hot short circuit in wiring harness 2. Disconnect connector EGR and connect T-adapter to male side.
5
3. Turn starting switch to ON position (with connector EGR disconnected).
Between EGR (female) (1) and (2)
Voltage
Max. 1 V
40-214

PC800, 850-8E0

Circuit diagram related to EGR valve solenoid
PC800, 850-8E0
40-215
40-215

Failure code [CA2352] EGR Valve Sol Current Low Error

User code
Failure code
Failure
E11
CA2352
Open circuit in EGR valve solenoid drive circuit

Detail of failure
Open circuit is in EGR valve solenoid drive circuit .
q
q

Problem on
machine
Related information
Cause
1
40-216

Defective wiring harness connecof "Checks before troubleshooting" in "General information on troubleshooting",
tor
Defective EGR valve solenoid
2. Disconnect connector EGR and connect T-adapter to male side.
ResisBetween EGR (male) (1) and (2)
10 21 z
tance
Open or short circuit in wiring har- a If resistance is above 1 Mz, wiring harness has open circuit. If resistance is
ness
below 1 z, wiring harness has short circuit.
ResisBetween ENG (female) (22) and (11)
10 21 z
tance
2. Disconnect connectors ENG and EGR, and connect T-adapters to each
female side.
(wire breakage or defective conResistact of connector)
Between ENG (female) (22) and EGR (female) (1)
Max. 1 z
tance
ResisBetween ENG (female) (11) and EGR (female) (2)
Max. 1 z
tance
40-216
PC800, 850-8E0

Circuit diagram related to EGR valve solenoid
PC800, 850-8E0
40-217
40-217

Failure code [CA2555] Grid Htr Relay Open Circuit Error

User code
Failure code
Failure
E15
CA2555
Intake air heater relay open circuit

Detail of failure
Open circuit is detected in drive circuit (primary circuit) of preheat relay.
None in particular
Problem on
machine
40-218
Intake air heater does not work in auto preheating (degraded starting performance at low temperature and emission of white smokes)
q Temperature sensed by engine coolant temperature sensor can be checked by using monitoring
q Method of reproducing failure code: Turn starting switch to ON position (Coolant temperature: Max.
-5 C)
Related inforq Troubleshooting for this failure code covers circuit starting from engine controller to primary (coil)
mation
side of preheat relay R18.
q For troubleshooting related to heater relay and secondary side of preheat relay R18, see E-2 in
E-mode.
a Relay R18 is called preheat relay in this manual to distinguish it from heater relay HT.
Cause
1 Defective harness connector

See the descriptions of harness and connectors in "c: Electrical equipment" of
"Checks before troubleshooting" in "General information on troubleshooting",
2. Disconnect relay R18, and connect T-adapter to male side.
Between R18 (male) (1) and (2)
2 Defective preheat relay R18
Resistance 200 400 z

2. Replace relay R18 with another one.
If this failure code disappears, original preheat relay R18 is defective.
3 Open or short circuit in harness
4 Open circuit in harness
40-218

Between CE02 (female) (40) and ground
a Relay R18 coil resistance
a If no abnormality is found in checks on cause 3, this check is not required.
2. Disconnect connector CE02 and relay R18, and connect T-adapter to
female side.
Between CE02 (female) (40) and R18 (female) (1) Resistance
Max. 1 z
Between R18 (female) (2) and ground
Max. 1 z
Resistance
If no abnormality is found by above checks, engine controller is defective.

PC800, 850-8E0

Circuit diagram related to intake air heater
PC800, 850-8E0
40-219
40-219

Failure code [CA2556] Grid Htr Relay Short Circuit Error

User code
Failure code
Failure
E15
CA2556
Intake air heater relay short circuit

Detail of failure
Short circuit is detected in drive circuit (primary circuit) of preheat relay.
None in particular
Problem on
machine
40-2 0
Intake air heater does not work in auto preheating (degraded starting performance at low temperature and emission of white smokes)
q Temperature sensed by engine coolant temperature sensor can be checked by using monitoring
q Method of reproducing failure code: Turn starting switch to ON position (Coolant temperature: Max.
-5 C)
Related inforq Troubleshooting for this failure code covers circuit starting from engine controller to primary (coil)
mation
side of preheat relay R18.
q For troubleshooting related to heater relay and secondary side of preheat relay R18, see E-2 in
E-mode.
a Relay R18 is called preheat relay in this manual to distinguish it from heater relay HT.
Cause
1 Defective harness connector

See the descriptions of harness and connectors in "c: Electrical equipment" of
"Checks before troubleshooting" in "General information on troubleshooting",
2 Defective preheat relay R18

2. Replace relay R18 with another one.
If this failure code disappears, original preheat relay R18 is defective.
3 Ground fault in harness
4 Short circuit in harness
40-220

2. Disconnect connector CE02 and relay R18, and connect T-adapters to
either female side.
Between CE02 (female) (40) or R18 (female) (1)
and ground
2. Disconnect connector CE02 and relay R18, and connect T-adapter to
female side of CE02.
No continuity
than (40)
(No sound is heard)
If no abnormality is found by above checks, engine controller is defective.
PC800, 850-8E0

Circuit diagram related to intake air heater
PC800, 850-8E0
40-2 1
40-221

Failure code [D110KB] Battery Relay Drive Short Circuit

User code
Failure code
Failure
Detail of failure
Problem on
machine
Related information
D110KB
Battery relay output system short circuit

Abnormal current flowed when outputting 24 V to battery relay primary circuit (coil side).
q
q
Stops 24 V output to battery relay primary circuit (coil side).

to OFF position.
There may be a trouble in writing data into the ROM (non-volatile memory) of each controller.
As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be measured at pump controller connector.
Output state (ON/OFF) to battery relay can be checked by using monitoring function.
(Code: 03700 Controller output 1)
Method of reproducing failure code: For 0.5 seconds after turning starting switch from ON to OFF
q
q
Cause
1
40-2 2
Defective battery relay

(Internal short circuit)

Between terminal RE and terminal BR
Continuity

2. Disconnect negative battery cable (in order not to make short circuit).
3. Disconnect terminals R01 and R02, and connectors D01, H15 and CP02.
2

(Contact with ground circuit)
3 Defective pump controller
Between terminal R02 (BR) and ground
Min. 1 Mz
Between ground and terminal R02 (harness side) or

D01 (female) (1) or D01 (female) (2)
Between CP02 (female) (108) and ground, or
between D01 (female) (5) and ground
If cause is not found by above checks, pump controller is defective.
q Reference
2. Insert T-adapter into connector D01.
4. For 0.5 seconds after starting switch is turned ON once and then turned
OFF
Between D01 (5) and ground
40-222
Resistance
Voltage
20 30 V
PC800, 850-8E0

Circuit diagram related to battery relay
PC800, 850-8E0
40-2 3
40-223

Failure code [D163KB] Flash Light Relay Short Circuit

User code
Failure code
Failure
Detail of failure
Problem on
machine
D163KB
q
q
q
Abnormal current flowed in the flash light relay circuit (the primary circuit of the relay), when driving
the circuit.
The controller turns OFF the output to the circuit of the flash light relay.
Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
The flash light does not flash.
Flash light is the light which flashes five times when the horn sounds. (It is located at the lower left
of operator's cab.)
Output (ON/OFF) to flash light relay circuit (primary side of relay) can be checked by using monitoring function. (Code: 03701 Controller output 2)
This error code is displayed when the failure is detected on the primary (coil) side of the step light
relay, and the failure on the secondary (contact) side is not detected.
q
q
Cause
1
Flash light relay system short circuit

Related information
Defective flash light relay



2. Disconnect connector R10 and connect T-adapter to male side.

2. Disconnect connectors CP02 and R10, and connect T-adapters to either
female side.
between R10 (female) (1) and ground
2. Insert T-adapter into connector R10.
4. Writes program
20 30 V io 1 V or less
Voltage
(at constant cycle, for 5
Between R10 (1) and (2)
seconds)
Voltage
40-224
40-2 4
Max. 1 V
PC800, 850-8E0

Circuit diagram related to flash light relay
PC800, 850-8E0
40-2 5
40-225

Failure code [D195KA] Step Light Relay Open Circuit

User code
Failure code
Failure
D195KA
40-2 6
Step light relay system open circuit

Detail of failure
When step light relay circuit (primary circuit of relay) is grounded, no current flows.
q
q
Stops output to the step light relay circuit.

Step light does not light up.
Output (ON/OFF) to step light relay circuit (primary side of relay) can be checked by using monitoring
function. (Code: 03701 Controller output 2)
Method of reproducing failure code: Turn starting switch to ON position and turn on step light switch.
Problem on
machine
Related information
q
q
q
Cause
1 Defective circuit breaker No. 9
If circuit breaker works, circuit probably has ground fault, etc.
2 Defective fuse No. 17 of FB1
If fuse is broken, circuit probably has ground fault.
Defective step light relay



1.
2.
3.
a

Remove fuse No. 17 in fuse box FB1.
Disconnect connector CP02 and connect T-adapter to female side.
If resistance is above 1 Mz, harness has open circuit. If resistance is below
1 z, harness has short circuit.
Between CP02 (female) (92) and FB1-17
Open circuit in harness

a
1.
2.
3.
If cause 4 is not the cause for the failure, this check is not required.
Remove fuse No. 17 in fuse box FB1.
Disconnect connectors CP02 and R09, and connect T-adapters to each
female side.
Between FB1-17 and R09 (female) (1)
Resistance
Max. 1 z
Between CP02 (female) (92) and R09 (female) (2)
Resistance
Max. 1 z
If no abnormality is found by the above checks, pump controller may be defective. (Since this is an internal failure, troubleshooting cannot be performed.)
q Reference
4. Turn step light switch ON and OFF, and troubleshoot.
OFF
Voltage
20 30 V
ON
Voltage
Max. 1 V
(Kept for 60
sec.)
40-226
PC800, 850-8E0

Circuit diagram related to step light relay
PC800, 850-8E0
40-2 7
40-227

Failure code [D195KB] Step Light Relay Short Circuit

User code
Failure code
Failure
Detail of failure
Problem on
machine
D195KB
q
q
q
Step light relay system short circuit

When driving the step light relay circuit (the primary circuit of the relay), abnormal current flowed in
the circuit .
Stops output to the step light relay circuit.
Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Step light does not light up.
Output (ON/OFF) to step light relay circuit (primary side of relay) can be checked by using monitoring
function. (Code: 03701 Controller output 2)
Method of reproducing failure code: Turn starting switch to ON position and step light switch to ON
position.
Related information
40-2 8
q
q
Cause
If circuit breaker works, circuit probably has ground fault, etc.
2 Defective fuse No. 17 of FB1
If fuse is broken, circuit probably has ground fault.




2. Disconnect connectors CP02 and R09, and connect T-adapters to either
female side.
between R09 (female) (2) and ground
q Reference
4. Turn step light switch ON and OFF, and troubleshoot.
OFF
Voltage
20 30 V
ON
Voltage
Max. 1 V
(Kept for 60
sec.)
40-228
PC800, 850-8E0

Circuit diagram related to step light relay
PC800, 850-8E0
40-2 9
40-229

Failure code [D19JKZ] Personal Code Relay Abnormality

User code
Failure code
Failure
E01
Detail of failure
D19JKZ
q
q
Action of
machine monitor
q
q
q
40-230
Personal code relay abnormality

(KOMTRAX system in machine monitor)
Open circuit or short circuit was detected in primary coil side of personal code relay circuit.
None in particular (in the case of open circuit)
Stops output to personal code relay (when short circuit is detected).
If cause of failure disappears, machine becomes normal by itself (when open circuit is detected).
Even if cause of failure disappears, machine does not become normal starting switch is turned to
OFF position (when short circuit is detected).
Problem on
machine
q
Related information
q
q
This failure code is displayed only when engine lock function is enabled.
Method of reproducing failure code: Turn starting switch to ON position (open circuit). Trouble cannot be reproduced on machine (short circuit).
Troubleshooting for this failure code covers circuit starting from No. 3 of fuse F01, through primary
(coil) circuit of personal code relay R07, to machine monitor.
Cause
Defective No. 3 of fuse F01
1
(3rd fuse from the right top)

When fuse is blown, ground fault may have probably occurred in circuit.

Defective personal code
relay R07
2. Replace relay R07 with heater relay R18.
If this failure code disappears, original personal code relay R07 is defective.
2. Remove fuse No. 3 of F01 (3rd fuse from the right top).
3. Disconnect connectors CM01 and S14, and connect T-adapter to female side of
Open circuit or short circuit
CM01.
or ground fault in harness
Between F01-3 and CM01 (female) (6)
Between F01-3 and ground, or between CM01 (female)
(6) and ground
3. Disconnect connector CM01 and relay R07, and connect T-adapters to each
female side.
Between F01-3 and R07 (female) (1)
Resistance
Max. 1 z
Between R07 (female) (2) and CM01 (female) (6)
Resistance
Max. 1 z
2. Remove fuse No. 3 of F01 (3rd from right top).
3. Disconnect connector CM01 and relay R07, and connect T-adapters to either
female side.
Between F01-3 and ground, or between R07 (female)
(1) and ground
Between R07 (female) (2) and ground, or between
CM01 (female) (6) and ground
3. Disconnect connectors CM01 and relay R07, and connect T-adapter to female
Short circuit in harness
side of connector CM01.
a Check by using multimeter tester in continuity mode.
Between CM01 (female) (6) and each pin other than
No continuity
pin (6)
(No sound is heard)
Machine monitor
If no abnormality is found by the above checks, the machine monitor (KOMTRAX
(KOMTRAX portion is defec- portion) is defective. (Since this is an internal failure, troubleshooting cannot be pertive.)
formed.)
40-230
PC800, 850-8E0

Circuit diagram related to personal code relay
PC800, 850-8E0
40-231
40-231

Failure code [D862KA] GPS Antenna Open Circuit

User code
Failure code
Failure
D862KA
Detail of failure
Action of
machine monitor
Problem on
machine
Related information
Open circuit is detected in GPS antenna circuit.
q
q
None in particular
GPS positioning cannot work.
Defective GPS antenna or

antenna cable
Structural illustration
40-232
GPS antenna open circuit

Cause
40-232

Probable causes are defective GPS antenna, open circuit or short circuit in antenna
cable, and defective connection of antenna cable connector (GPS).
40-232
PC800, 850-8E0

PC800, 850-8E0
40-233

Failure code [DA22KK] Pump Solenoid Power Low Error

User code
Failure code
Failure
E0E
Detail of failure
Problem on
machine
DA22KK
Pump solenoid power supply voltage reduction (input)

Solenoid power supply voltage of controller is below 20 V.
Stops detection of failure codes (open circuit/short circuit) for all the solenoid systems while this
failure code is displayed.
Restricts the upper limit of engine throttle to 1,400 rpm.
to OFF position.
No solenoid valve is energized properly, so machine does not work properly.
(Work equipment, swing, and travel systems do not work.)
Hydraulic fan cannot be rotated in reverse direction.
If failure code [D110KB] is displayed, perform troubleshooting for it first.
As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be
measured at pump controller connector.
q
q
q
q
q
Related information
40-234
q
q
Cause
If circuit breaker No. 4 works, circuit may have ground fault (see cause 5).
2 Improper battery voltage

2. After measuring voltage, measure it again when starting engine.
Between battery (+) and ground
3 Defective harness
4 Open circuit in harness

40-234
Voltage
20 30 V
2. Disconnect connector CP02 and connect T-adapter to female side.
3. Connect the battery ground cable and turn the starting switch to ON position.
Between each of CP02 (female) (116), (118) and
Voltage
20 30 V
(121) and ground
a If circuit breaker No. 4 is turned ON, reset it.
Between R03 and CP02 (female) (116) or (118) or
Resistance Max. 1 z
(121)
a If no abnormality is found by the above checks, this check is not required.
1. Disconnect connector B01, and connect T-adapter to female side.
Between B01 (female) (K) and CP02 (female) (116)
Resistance Max. 1 z
or (118) or (121)
Between B01 (female) (J) and ground, or between
Resistance Max. 1 z
terminal R03 (M) and ground
2. Remove terminal R03.
3. Disconnect connectors B01 and CP02, and connect T-adapters to each
female side.
Between ground and CP02 (female) (116) or (118)
or (121) or B01 (female) (K)
Between B01 (female) (J) and ground, or between
terminal R03 (M) and ground
If no abnormality is found by the above checks, the pump controller is defective. (Since this is an internal failure, troubleshooting cannot be performed.)
PC800, 850-8E0

Circuit diagram related to solenoid power supply
PC800, 850-8E0
40-235
40-235

Failure code [DA25KP] 5V Sensor1 Power Abnormality

User code
Failure code
Failure
Detail of failure
DA25KP
Voltage of 5V sensor power supply output 1 circuit is below 2.5 V or above 6.0 V.
Stops output of 5V sensor power supply output 1.

to OFF position.
Signals of pressure sensor and jet sensor differential pressure sensor are not input normally.
Error code of abnormality in pressure sensor and jet sensor differential pressure sensor is displayed, too.
Travel and work equipment speeds are insufficient.
Automatic gear shifting function does not work (pump pressure sensor system).
Auto-decelerator remains activated without accepting reset, or fine control performance of work
equipment is low.
q
q
q
q
Related information
Cause
5V sensor power supply output 1 abnormality

Problem on
machine
Defective pressure sensor

Hot short circuit in harness


2. Disconnect following sensors one by one, and turn starting switch to ON
position for each test.
a If this failure code disappears, disconnected sensor is defective.
a Since connector is disconnected, other failure codes appear. Ignore all
displayed failure codes other than this.
a
1.
2.
3.
4.
Sensor
Connector
F pump pressure sensor
P25
R pump pressure sensor
P26
F J/S differential pressure sensor
P27
R J/S differential pressure sensor
P28
Measure voltage before controller stops output.

Disconnect connectors P25 to P28.
Connect T-adapter to female side of connector P27.
Turn starting switch to ON position (with connectors P25 to P28 disconnected).

3
Voltage
4.5 5.5 V

2. Disconnect connectors CP01 and P25 to P28.
3. Connect T-adapter to female side of connector CP01.
Between CP01 (female) (9) and ground
40-236
40-236
Resistance
Min. 1 Mz
If no abnormality is found by above checks, the pump controller is defective.

PC800, 850-8E0

Circuit diagram related to 5 V sensor power supply 1 circuit
PC800, 850-8E0
40-237
40-237

Failure code [DA29KQ] Model Selection Abnormality

User code
Failure code
Failure
Detail of failure
Problem on
machine
Related information
DA29KQ
40-238
Model selection abnormality

Model code signal for model which is not registered in controller is input.
q
q
Controls machine taking it that machine is default model (PC800).

to OFF position.
No problem in particular with PC800, PC850 model.
Model code input to pump controller can be checked by using monitoring function.
(Code: 00200 Controller model code)
Activation status (ON/OFF) of model selection signal can be checked by using monitoring function.
(Code: 02201 Switch Input 2)
q
q
Cause

2. Disconnect connector S30 and connect T-adapter to female side.
Defective model selection connec- Between S30 (female) (2) and (8)
tor
Between S30 (female) (1) and (2)
1
(internal open circuit or short cirBetween S30 (female) (2) and (3)
cuit)
Resistance
Max. 1 z
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz


Resistance
Max. 1 z

2. Disconnect connectors CP01 and S30, and insert T-adapter into connector
S30.
Between S30 (1) and (2)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

4
Ground fault of harness

40-238
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
PC800, 850-8E0

Circuit diagram related to model selection
PC800, 850-8E0
40-239
40-239

Failure code [DA2RMC] CAN Discon (Pump Con Detected)

User code
Failure code
Failure
E0E
Detail of failure
DA2RMC
CAN communication disable (pump controller detected)

Pump controller has failed CAN communication with machine monitor or engine controller.
Continues to control machine by using information of CAN communication just before detection of
error.
Fix engine output to P mode, and limit pump absorption torque to fixed value.
Output lowers (Pump absorption torque decreases)
If work load increases, engine may stall.
Information may not be transmitted normally through CAN communication lines and machine may
not operate normally.
(Trouble phenomenon depends on failed section.)
Start of CAN communication is recognized by each controller when ACC signal of starting switch
is received.
Failure code is sent to machine monitor by CAN communication. Accordingly, if failure code
[DA2RMC] is displayed on the machine monitor, CAN communication between pump controller
and machine monitor is normal. That is, there can not be short circuit, ground fault or hot short circuit in CAN communication line.
Since air conditioner is also controlled via CAN communication, check whether you can operate air
conditioner (such as power on/off switching and air flow rate control) on "Air conditioner" screen.)
(air conditioner can be controlled even if failure code [DA2RMC] is displayed.)
If failure code [DAFRMC] is also displayed, engine controller may be defective.
If failure code [DY20KA], [DY20MA] or [DW43KA] is displayed, pump controller may be defective.
Since each controller and machine monitor are connected to battery directly, they receive unswitched power even while starting switch is at OFF position.
Since signal of active CAN communication line is pulse voltage, it cannot be measured by using
multimeter.
q
q
q
Problem on
machine
40-240
q
q
q
q
q
Related information
q
q
q
q
q
Cause

If circuit breaker works, controller probably has short circuit in it.
2 Defective fuse No. 20 of fuse F01 If fuse is blown, ground fault may have probably occurred in circuit.

a
1.
2.
a
If circuit breaker works, this check is not required.

Turn starting switch to OFF position and disconnect battery ground cable.
Disconnect connector CE03, and connect T-adapter to male side.
If measured resistance is below 10 z, engine controller is defective
(internal short circuit).
Improper power supply to engine

controller
a
1.
2.
3.
4.
a
Resistance
Min. 10 z
Check ground terminal T09 for looseness and rust.

Disconnect connector CE03, and connect T-adapter to female side.
Connect battery ground cable.
Turn starting switch to ON position.
If circuit breaker works, reset it.
Between CE03 (female) (3) and (1)
Voltage
20 30 V
a If result is abnormal, perform troubleshooting for cause 7.

Defective CAN terminating
resistor
5
(internal open circuit or short circuit)
40-240

2. Disconnect connectors K02 and CM02, and connect T-adapter to each
male side.
Between K02 (male) (A) and (B)
Resistance 120 12 z
Between CM02 (male) (8) and (10)
Resistance 120 12 z
PC800, 850-8E0

Cause

q

CAN communication line

a There is 120 z CAN terminating resistor inside machine monitor, too. Since
120 z resistors are connected in parallel, if combined resistance measured
at connector of controller other than machine monitor is 60 z, there is no
open circuit in harness.
2. Disconnect connector CE02 or CP01 or N10 or K02 or CM02, and connect
T-adapter to female side of connector disconnected.
a If short circuit occurs (if resistance between terminals is 1 z or less),
disconnect all of connectors CE02, CP01, N10, K02 and CM02. Then,
check whether failure is short circuit between harnesses or within the
controller.
Approx.
Resistance
60 z
Approx.
Between CP01 (female) (45) and (64)
Resistance
60 z
Approx.
Between N10 (female) (1) and (2)
Resistance
60 z
Approx.
Between K02 (female) (A) and (B)
Resistance
120 z
Approx.
Between CM02 (female) (9) and (10)
Resistance
120 z
a If check result of cause 6 is normal, this check is not required.
2. Disconnect connectors CE02, CP01, N10, K02 and CM02, and connect
T-adapter to each female side.
Between CP01 (female) (45) and CM02 (female)
(9), or between CP01 (female) (45) and CM02
Resistance Max. 1 z
(female) (8)
Resistance Max. 1 z
(10)
Between CP01 (female) (45) and CE02 (female)
Resistance Max. 1 z
(46)
Resistance Max. 1 z
(47)
Between CP01 (female) (45) and N10 (female) (1)
Resistance
Max. 1 z
Resistance
Max. 1 z
Between CE02 (female) (46) and K02 (female) (A)
Resistance
Max. 1 z
Between CE02 (female) (47) and K02 (female) (B)
Resistance
Max. 1 z
1.
2.
3.
4.
PC800, 850-8E0
ACC signal from starting switch

Insert T-adapters into connectors CE02, C01 and CM01.
Connect the battery ground cable and turn the starting switch to ON position.
Between CE02 (39) and ground
Voltage
20 30 V
Voltage
20 30 V
Between CM01 (14) and (3)
Voltage
20 30 V
40-241

Cause


a If above check result is normal, this check is not required.
2. Disconnect connectors CE02, CP01, CM01, and D02, and connect
T-adapters to each female side.
Between starting switch (ACC) and CP01 (female)
Resistance Max. 1 z
(79)
Between starting switch (ACC) and CM01 (female)
Resistance Max. 1 z
(14)
Between starting switch (ACC) and CE02 (female)
Resistance Max. 1 z
(39)
Between starting switch (ACC) and D02 (female)
Resistance Max. 1 z
(8)
Between D02 (female) (4) and CP01 (female) (24)
Resistance
Max. 1 z
Resistance
Max. 1 z

a Reset circuit breaker.
Between CE03 (female) (3) and battery relay termiResistance Max. 1 z
nal R04
Defective diode D02

8 (internal open circuit or short circuit)
Resistance
Max. 1 z

2. Disconnect connector D02 and connect T-adapter to diode.
a Measure by using multimeter in diode range.
Between D02 (male) (4) (+) and (8) (-)
No continuity
Continuity
If no abnormality is found by above checks and if failure code [DAFRMC] is

also displayed on the machine monitor, the engine controller is defective.

40-242
PC800, 850-8E0

Circuit diagram related to CAN communication 40-243
* RB and LW indicate colors of wires.
PC800, 850-8E0
40-243

Failure code [DA80MA] Auto. Lub. Abnormal.
40-24
a This failure code is displayed only when auto-greasing system is installed.
40-244
PC800, 850-8E0

PC800, 850-8E0
40-245

Failure code [DAF8KB] Camera Power Supply Short Circuit

User code
Failure code
Failure
DAF8KB
Detail of failure
Action of
machine monitor
q
q
q
Camera power supply short circuit

Output power supply voltage (Rating: 8 V) from machine monitor to camera is below 6.0 V or above
10 V.
Stops output power supply voltage (Rating: 8 V) to camera.
to OFF position.
Problem on
machine
Camera image is not displayed on monitor screen.
Related information
Cause
Defective camera
1
40-246
Defective machine
monitor

2. Disconnect camera connector(s), and turn starting switch to ON position.
Disconnect camera connectors and perform failure reproduction operation. If failure code
disappears at this time, camera is defective.
2. Disconnect connector CM05.
3. Connect T-adapter to male side of connector CM05.
Between CM05 (male) (1) and ground

3
(contact with ground
circuit)
Voltage
6 10 V
Resistance
Min. 1 Mz

2. Disconnect connector CM05 and camera connector(s).
3. Connect T-adapter to female side of connector CM05.
Between CM05 (female) (1) and ground

Hot short circuit in har- 2. Disconnect camera connector(s).
ness
4
(contact with 24 V cir- 4. Turn starting switch to ON position.
(Disconnect camera connector(s) and check that camera is not defective in advance.)
cuit)
40-246
Voltage
Max. 10 V
PC800, 850-8E0

Circuit diagram related to camera power supply
PC800, 850-8E0
40-247
40-247

Failure code [DAFGMC] GPS Module Error

User code
Failure code
Failure
DAFGMC
Detail of failure
Action of
machine monitor
Problem on
machine
Related information
40-248
GPS module error

Position data is not sent from GPS module (in machine monitor) to KOMTRAX communication modem in 50 seconds after KOMTRAX started.
None in particular
Method of reproducing failure code: Turn starting switch to ON position (At least 50 seconds after
starting switch is turned to ON position).
Cause
GPS module of machine monitor may be defective. (Since this is an internal failure,
troubleshooting cannot be performed.)
40-248
PC800, 850-8E0

Failure code [DAFRMC] CAN Discon (Monitor Detected)

User code
Failure code
Failure
E0E
DAFRMC
40-249
CAN communication disabled (monitor detected)

Detail of failure
The machine monitor has failed CAN communication with the pump controller or engine controller.
Action of
machine monitor
Continues to control machine by using information of CAN communication just before detection of
error.
Output lowers (Pump absorption torque decreases).
If work load increases, engine may stall.
Information may not be transmitted normally through CAN communication lines and machine may
not operate normally.
(Trouble phenomenon depends on failed section.)
Start of CAN communication is recognized by each controller when ACC signal of starting switch
is received.
Since air conditioner is also controlled via CAN communication, check whether air conditioner can
be operated (turned ON/OFF and air flow can be adjusted) on air conditioner screen. (Air conditioner can be operated even while failure code is displayed on monitor screen.)
If air conditioner can be operated, there is no possibility of ground fault or short circuit or hot short
circuit in harness (CAN communication line)
If failure code [DA2RMC] is also displayed, engine controller may be defective.
If failure code [DY20KA], [DY20MA] or [DW43KA] is displayed, pump controller may be defective.
Since each controller and machine monitor are connected to battery directly, they receive unswitched power even while starting switch is at OFF position.
Since signal of active CAN communication line is pulse voltage, it cannot be measured by using
multimeter.
q
q
Problem on
machine
q
q
q
q
q
Related information
q
q
q
q
q
Cause

If circuit breaker works, controller probably has short circuit in it.
2 Defective fuse No. 20 of fuse F01 If fuse is blown, ground fault may have probably occurred in circuit.

a
1.
2.
a
If circuit breaker works, this check is not required.

Disconnect connector CE03, and connect T-adapter to male side.
If measured resistance is below 10 z, engine controller is defective
(internal short circuit).
Improper power supply to engine

controller
a
1.
2.
3.
4.
a
Resistance
Min. 10 z
Check ground terminal T09 for looseness and rust.

Disconnect connector CE03, and connect T-adapter to female side.
Voltage
20 30 V
a If result is abnormal, perform troubleshooting for cause 7.

Defective CAN terminating
resistor
5
PC800, 850-8E0

2. Disconnect connectors K02 and CM02, and connect T-adapter to each
male side.
Between K02 (male) (A) and (B)
Resistance 120 12 z
Between CM02 (male) (8) and (10)
Resistance 120 12 z
40-249

Cause

q

CAN communication line

a There is 120 z CAN terminating resistor inside machine monitor, too. Since
120 z resistors are connected in parallel, if combined resistance measured
at connector of controller other than machine monitor is 60 z, there is no
open circuit in harness.
2. Disconnect connector CE02 or CP01 or N10 or K02 or CM02, and connect
T-adapter to female side of connector disconnected.
a If short circuit occurs (if resistance between terminals is 1 z or less),
disconnect all of connectors CE02, CP01, N10, K02 and CM02. Then,
check whether failure is short circuit between harnesses or within the
controller.
Approx.
Resistance
60 z
Approx.
Resistance
60 z
Approx.
Between N10 (female) (1) and (2)
Resistance
60 z
Approx.
Between K02 (female) (A) and (B)
Resistance
120 z
Approx.
Resistance
120 z
2. Disconnect connectors CE02, CP01, N10, K02 and CM02, and connect
T-adapter to each female side.
(9), or between CP01 (female) (45) and CM02
Resistance Max. 1 z
(female) (8)
Resistance Max. 1 z
(10)
Resistance Max. 1 z
(46)
Resistance Max. 1 z
(47)
Resistance
Max. 1 z
Resistance
Max. 1 z
Between CE02 (female) (46) and K02 (female) (A)
Resistance
Max. 1 z
Between CE02 (female) (47) and K02 (female) (B)
Resistance
Max. 1 z
1.
2.
3.
4.
40-250
ACC signal from starting switch

Insert T-adapters into connectors CE02, C01 and CM01.
Connect the battery ground cable and turn the starting switch to ON position.
Between CE02 (39) and ground
Voltage
20 30 V
Voltage
20 30 V
Voltage
20 30 V
PC800, 850-8E0

Cause


a If above check result is normal, this check is not required.
2. Disconnect connectors CE02, CP01, CM01, and D02, and connect
T-adapters to each female side.
Between starting switch (ACC) and CP01 (female)
Resistance Max. 1 z
(79)
Between starting switch (ACC) and CM01 (female)
Resistance Max. 1 z
(14)
Between starting switch (ACC) and CE02 (female)
Resistance Max. 1 z
(39)
Between starting switch (ACC) and D02 (female)
Resistance Max. 1 z
(8)
Resistance
Max. 1 z
Resistance
Max. 1 z

a Reset circuit breaker.
Between CE03 (female) (3) and battery relay termiResistance Max. 1 z
nal R04
Defective diode D02

8 (internal open circuit or short circuit)
Short circuit or hot short circuit

9 (contact with 24 V circuit) in harness
PC800, 850-8E0
Max. 1 z

No continuity
Continuity
a If failure code [DA2RMC] is displayed on machine monitor, or you can

operate air conditioner on air conditioner screen, this check is not required.
a If check result of cause 5 is normal (no open circuit), measure at only one
place each.
2. Insert T-adapter into either of connectors CE02 or CM02.
3. Connect battery ground cable.
a Since voltages of CAN_H and CAN_L lines are supposed to be in the range
of 2.51 V including during communication, they should be considered normal as long as their voltages are between 1 and 4 V.
Between ground and CM02 (8) or (9) or CE02 (46)
Resistance
Voltage
14V
Between CM02 (10) and ground, or between CE02

Voltage
14V
(47) and ground
If no abnormality was found in the above checks and if failure code [DA2RMC]
is also displayed, engine controller is defective. (Since this is an internal failure, troubleshooting cannot be performed.)
40-251

Cause
If no abnormality is found by above checks, and if failure code [DA2RMC] is

not displayed or if air conditioner cannot be operated, locate defective controller as follows.
A. Procedure for judging by operating air conditioner
q Step 1
2. Disconnect engine controller (connector CE02) and pump controller
(connector CP01)
4. Operate air conditioner.
a If air conditioner can be operated, go to step 2.
Defective air conditioner
NO
unit
Can air conditioner be operated?
Removed controller is
YES
defective
q Step 2
Defective engine controller, pump 1. Turn starting switch to OFF position and disconnect battery ground cable.
11
controller or air conditioner unit
2. Disconnect either engine controller (connector CE02) or pump controller
(connector CP01).
3. Connect battery ground cable, turn starting switch to ON position and
perform troubleshooting.
4. Return to Step 1, to troubleshoot the other controller.
Removed controller is
Can air conditioner be operated?
YES
defective
B Judgment method for failure code [DA2RMC]
(When air conditioner is not installed)
2. Disconnect engine controller (connector CE03).
Defective pump controlNO
ler
Is failure code [DA2RMC] displayed?
Defective engine controlYES
ler
40-252
If no abnormality is found by above checks, machine monitor is defective.

PC800, 850-8E0

Circuit diagram related to CAN communication
40-253
* RB and LW indicate colors of wires.
PC800, 850-8E0
40-253

Failure code [DGE5KB] Ambi. Temp Sensor Short Circuit

User code
Failure code
Failure
DGE5KB
40-254
Ambient temperature sensor short circuit

Detail of failure
Signal voltage of ambient temperature sensor circuit is below 0.3 V and ground fault is detected.
Problem on
machine
Fan speed may increase (depending on operating condition)
Signal voltage of ambient temperature sensor can be checked by using monitoring function.
(Code: 37503 Ambient temperature sensor voltage)
Temperature sensed by ambient temperature sensor can be checked by using monitoring function
(Code: 37502).
Related information
q
q
Cause

Defective ambient temperature

sensor
1
Between P29 (male) (A) and

(B)
a Temperature-resistance
characteristics of ambient temperature sensor
-30 C
Resistance
Approx. 50 kz
0 C
Resistance
Approx. 12 kz
25 C
Resistance
Approx. 4 kz
45 C
Resistance
Approx. 2 kz
Resistance
Min. 1 Mz

1.
2.
3.
a

Disconnect connector P29, and connect T-adapter to female side.
Open circuit or short circuit or
If voltage is 0 V, harness has open circuit or ground fault or short circuit, and
2 ground fault or hot short circuit in
if voltage is 24 V, harness has hot short circuit.
harness
a Voltage of approximately 5 V is applied to temperature sensor signal lines
through resistor in pump controller.
Between P29 (female) (A) and (B)
Voltage
Approx. 5 V

a Use temperature-resistance characteristics table for troubleshooting on
cause 1.
Short circuit or ground fault in hara If resistance is above 1 Mz, harness has open circuit. If resistance is below
3
ness

40-254
Resistance
2 50 kz
Resistance
Min. 1 Mz
a If cause 2 is not the cause of failure, this check is not required.

2. Disconnect connectors CP01 and P29, and connect T-adapters to either
female side.
Resistance
Min. 1 Mz
between P29 (female) (A) and ground
If no abnormality is found by above checks, pump controller is defective.
PC800, 850-8E0

Circuit diagram related to ambient temperature sensor
PC800, 850-8E0
40-25
40-255

Failure code [DGH2KB] Hyd Oil Sensor Short

User code
Failure code
Failure
DGH2KB
q
Detail of failure
Problem on
machine
q
q
q
q
q
Related information
q
q
40-256
Hydraulic oil temperature sensor ground fault

Signal voltage of hydraulic oil temperature sensor circuit is below 1 V and ground fault is detected
while engine is running.
(Signal voltage of hydraulic oil temperature sensor is equivalent to 102 C or above.)
None in particular
If machine is operated as it is, hydraulic components may be damaged.
While hydraulic oil temperature rises normally, hydraulic oil temperature gauge does not move from
top of white range (bottom of green range).
If the hydraulic oil temperature monitor on the machine monitor lights up in red while the engine is
running, this failure code is recorded.
Signal voltage of hydraulic oil temperature sensor can be checked by using monitoring function.
(Code: 04402 Hydraulic oil temperature sensor voltage)
Cause

Defective hydraulic oil temperature sensor

1
Between P22 (male) (1) and

(2)
a Temperature-resistance
characteristics of oil temperature sensor
10 C
Resistance
Approx. 90 kz
30 C
Resistance
Approx. 35 kz
80 C
Resistance
Approx. 6.5 kz
100 C
Resistance
Approx. 3.5 kz
Resistance
Min. 1 Mz
Open circuit or short circuit or

2 ground fault or hot short circuit in
harness
1.
2.
3.
a

Disconnect connector P22 and connect T-adapter to female side.
If voltage is 0 V, harness has open circuit or ground fault or short circuit, and
if voltage is 24 V, harness has hot short circuit.
a Voltage of approximately 5 V is applied to temperature sensor signal lines
through resistor in machine monitor.
Between P22 (female) (1) and (2)
Voltage
Approx. 5 V

a Use temperature-resistance characteristics table for troubleshooting on
cause 1.
Short circuit or ground fault in hara If resistance is above 1 Mz, harness has open circuit. If resistance is below
3
ness

40-256
Resistance
3.5 90 kz
Resistance
Min. 1 Mz

female side.
Resistance
Min. 1 Mz
between P22 (female) (1) and ground
PC800, 850-8E0

Circuit diagram related to hydraulic oil temperature sensor
PC800, 850-8E0
40-257
40-257

Failure code [DH25KA] L Jet Sensor Open Circuit

User code
Failure code
Failure
E07
Detail of failure
DH25KA
Signal voltage of L-jet differential pressure sensor circuit dropped below 0.3 V.
When the abnormality was detected during operation, controller sets both F pump and R pump to
the minimum flow rate.
After the abnormality was detected, returning travel or work equipment lever once to the neutral position sets the fixed-capacity control (50% capacity) on both F pump and R pump.
OFF position.
Fine control performance deteriorates.
q
q
q
Related information
L-jet differential pressure sensor open circuit

Problem on
machine
40-258
q
q
Information of L-jet differential pressure sensor can be checked by using monitoring function.
(Code 13800: L jet sensor differential pressure, Code 13802: L jet sensor voltage)
Cause

If failure code [DA25KP] is displayed, perform troubleshooting for it first.
Defective 5 V sensor power supply system

2. Disconnect connector P27, and connect T-adapter to female side.


Defective L-jet differential pressure sensor
40-258
Power input
Voltage
4.5 5.5 V

female side.
Resistance Max. 1 z
Between CP01 (female) (9) and P27 (female) (1)
Resistance Max. 1 z
Between CP01 (female) (12) and P27 (female) (3), or
between CP01 (female) (12) and P27 (female) (4)
Resistance Max. 1 z
(sensor output)
female side.
Between CP01 (12) and ground, or between P27
(female) (3) and ground
2. Disconnect connectors CP01 and P27, and connect T-adapter to either
female side.
Between CP01 (female) (12) and (18), or between
P27 (female) (2) and (3)
a If no abnormality was found in checking causes 1 to 4 and it was found in 5,
sensor is defective.
2. Insert T-adapter into connector P27.
Between P27 (3) and (2)
Sensor output
Voltage
0.5 1.5 V
Sensor output
Voltage
0.5 1.5 V
If no abnormality is found by the above checks, the pump controller is defective.

PC800, 850-8E0

Circuit diagram related to differential pressure sensor
PC800, 850-8E0
40-259
40-259

Failure code [DH25KB] L Jet Sensor Short Circuit

User code
Failure code
Failure
E07
Detail of failure
DH25KB
Signal voltage of L-jet differential pressure sensor circuit increased to 4.5 V or above.
After the abnormality was detected, returning travel or work equipment lever once to the neutral
position sets the fixed-capacity control (50% capacity) on both F pump and R pump.
to OFF position.
q
q
q
Related information
q
q
Information of L-jet differential pressure sensor can be checked by using monitoring function.
(Code 13800: L jet sensor differential pressure, Code 13802: L jet sensor voltage)
Cause
1
L-jet differential pressure sensor short circuit

Problem on
machine
40-260
Defective L-jet differential pres2

sure sensor

2. Disconnect connector P27.
failure code changed from [DH25KB] to [DH25KA] ,sensor is defective.

(contact with 24 V or 5 V circuit)

female side.
1.
2.
3.
4.

Disconnect connector P27.
Turn starting switch to ON position (with connector P27 disconnected).

40-260
Voltage
Max. 1 V
PC800, 850-8E0

PC800, 850-8E0
40-261
40-261

Failure code [DH26KA] R Jet Sensor Open Circuit

User code
Failure code
Failure
E07
Detail of failure
DH26KA
Signal voltage of R-jet differential pressure sensor circuit dropped below 0.3 V.
After the abnormality was detected, returning travel or work equipment lever once to the neutral position sets the fixed-capacity control (50% capacity) on both F pump and R pump.
OFF position.
q
q
q
Related information
R-jet differential pressure sensor open circuit

Problem on
machine
40-262
q
q
Information of R jet differential pressure sensor can be checked by using monitoring function.
(Code 13801: R-jet sensor differential pressure, Code 13803: R jet sensor voltage)
Cause


2. Disconnect connector P28 and connect T-adapter to female side.


Defective R-jet differential pressure sensor
40-262
Power input
Voltage
4.5 5.5 V

2. Disconnect connectors CP01 and P28, and connect T-adapters to each
female side.
Resistance Max. 1 z
Resistance Max. 1 z
Between CP01 (female) (70) and P28 (female)
(2)
Between CP01 (female) (31) and P28 (female) (3),
or between CP01 (female) (31) and P28 (female) (4) Resistance Max. 1 z
(sensor output)
female side.
female side.
2. Insert T-adapter into connector P28
Sensor output
Voltage
0.5 1.5 V
Sensor output
Voltage
0.5 1.5 V
PC800, 850-8E0

PC800, 850-8E0
40-263
40-263

Failure code [DH26KB] R Jet Sensor Short Circuit

User code
Failure code
Failure
E07
Detail of failure
DH26KB
Signal voltage of R-jet differential pressure sensor circuit increased to 4.5 V or above.
After the abnormality was detected, returning travel or work equipment lever once to the neutral
position sets the fixed-capacity control (50% capacity) on both F pump and R pump.
to OFF position.
q
q
q
Related information
q
q
Information of R-jet differential pressure sensor can be checked by using monitoring function.
(Code 13801: R-jet sensor differential pressure, Code 13803: R jet sensor voltage)
Cause
1
R-jet differential pressure sensor short circuit

Problem on
machine
40-264
Defective R-jet differential pres2

sure sensor

failure code changed from [DH26KB] to [DH26KA] ,sensor is defective.


female side.
1.
2.
3.
4.


40-264
Voltage
Max. 1 V
PC800, 850-8E0

PC800, 850-8E0
40-265
40-265

Failure code [DHPEKA] F Pump P. Sensor Open Circuit

User code
Failure code
Failure
E07
Detail of failure
DHPEKA
Front pump pressure sensor open circuit

Signal voltage of front pump pressure sensor circuit dropped below 0.3 V.
Fixes travel speed to Lo.

Continues controls, assuming pressure to be constant {350 kg/cm2}.
to OFF position.
Front pump pressure cannot be monitored.
Problem on
machine
q
q
Related information
40-26
q
q
Input voltage from front pump pressure sensor can be checked by using monitoring function.
(Code: 01112 Front pump pressure sensor voltage)
Method of reproducing failure code: Turn starting switch to ON position or start engine.
Cause




Defective front pump pressure

sensor
40-266
Power input
Voltage
4.5 5.5 V

female side.
Resistance Max. 1 z
Resistance Max. 1 z
(1)
Resistance Max. 1 z
(sensor output)
female side.
female side.
Sensor outBetween P25 (2) and (1)
Voltage
0.5 4.5 V
put
PC800, 850-8E0

Circuit diagram related to front pump pressure sensor
PC800, 850-8E0
40-267
40-267

Failure code [DHPEKB] F Pump P. Sensor Short Circuit

User code
Failure code
Failure
E07
Detail of failure
DHPEKB
Signal voltage from front pump pressure sensor increased to 4.5 V or above.

to OFF position.
Front pump pressure cannot be monitored.
Problem on
machine
q
q
q
q
Input voltage from front pump pressure sensor can be checked by using monitoring function.
(Code: 01112 Front pump pressure sensor voltage)
Cause
1
Front pump pressure sensor short circuit

Related information
40-268
Defective front pump pressure

2
sensor

failure code changed from [DHPEKB] to [DHPEKA], sensor is defective.


female side.
1.
2.
3.
4.


40-268
Voltage
Max. 1 V
PC800, 850-8E0

Circuit diagram related to front pump pressure sensor
PC800, 850-8E0
40-269
40-269

Failure code [DHPFKA] R Pump P. Sensor Open Circuit

User code
Failure code
Failure
E07
Detail of failure
DHPFKA
Rear pump pressure sensor open circuit

Signal voltage of rear pump pressure sensor circuit dropped below 0.3 V.

to OFF position.
Rear pump pressure cannot be monitored.
Input voltage from rear pump pressure sensor can be checked by using monitoring function.
(Code: 01113 Rear pump pressure sensor voltage)
Problem on
machine
q
q
Related information
40-270
q
q
Cause




Defective rear pump pressure

sensor
40-270
Power input
Voltage
4.5 5.5 V

female side.
Resistance Max. 1 z
Resistance Max. 1 z
(1)
Resistance Max. 1 z
(Sensor output)
female side.
female side.
2. Connect T-adapter to connector P26.
Sensor outBetween P26 (2) and (1)
Voltage
0.5 4.5 V
put
PC800, 850-8E0

Circuit diagram related to rear pump pressure sensor
PC800, 850-8E0
40-271
40-271

Failure code [DHPFKB] R Pump P. Sensor Short Circuit

User code
Failure code
Failure
E07
Detail of failure
DHPFKB
Signal voltage from rear pump pressure sensor increased to 4.5 V or above.

OFF position.
Rear pump pressure cannot be monitored.
Problem on
machine
q
q
q
q
Input voltage from rear pump pressure sensor can be checked by using monitoring function.
(Code: 01113 Rear pump pressure sensor voltage)
Cause
1
Rear pump pressure sensor short circuit

Related information
40-272
Defective rear pump pressure

2
sensor

failure code changed from [DHPFKB] to [DHPFKA], sensor is defective.


female side.
1.
2.
3.
4.


40-272
Voltage
Max. 1 V
PC800, 850-8E0

Circuit diagram related to rear pump pressure sensor
PC800, 850-8E0
40-273
40-273

Failure code [DV20KB] Travel alarm short circuit

User code
Failure code
Failure
Detail of failure
Problem on
machine
Related information
DV20KB
40-274
Travel alarm short circuit

Abnormal current flowed when driving alarm buzzer circuit.
q
q
Stops output to travel alarm circuit.

to OFF position.
Travel alarm does not sound.
Output state (ON/OFF) to travel alarm buzzer can be checked by using monitoring function.
Method of reproducing failure code: Turn starting switch to ON position and operate travel lever
q
q
Cause

2. Disconnect connector M14 and connect T-adapter to male side.
Between M14 (male) (1) and (2)
Defective travel alarm buzzer

(internal failure)

1.
2.
3.
4.

Disconnect connector M14, and connect T-adapter to female side.
Operate travel lever and perform troubleshooting.
Travel lever: When in
Voltage
Max. 1 V
Between M14 (female)
NEUTRAL
(1) and (2)
Travel lever: Operated
Voltage
20 30 V
If the above voltage is normal but travel alarm does not sound, travel alarm is
defective.
2. Disconnect connectors CP02 and M14, and connect T-adapters to either
female side.
Between M14 (female) (1) and ground, or between
CP02 (female) (107) and ground
Circuit diagram related to travel alarm buzzer
40-274
Continuity
40-274
PC800, 850-8E0

PC800, 850-8E0
40-275

Failure code [DW41KA] Swing Priority Sol Open Circuit

User code
Failure code
Failure
DW41KA
40-276
Swing priority soplenoid system open circuit

Detail of failure
Current does not flow when power is output to swing priority solenoid circuit.
None in particular (Since no current flows, solenoid does not operate).

Problem on
machine
Related information
q
q
When combined operation of boom RAISE and SWING is perfomed in swing priority mode, swing
speed is slow (Flow in swing circuit is kept throttled low).
Controller's command (ON/OFF) to swing priority valve solenoid can be checked by using monitoring function. (If controller sends solenoid ON command, monitoring display is ON even if solenoid
is not switched ON due to open circuit.)
(Code: 02300 Solenoid 1)
Method of reproducing failure code: Start engine, turn swing priority mode switch to ON position
and perform swing operation.
Cause
Defective swing priority solenoid
1

3 (Wire breakage or defective contact of connector)

2. Disconnect connector V14, and connect T-adapter to male side.
Between V14 (male) (1) and (2)
40-276
20 60 z

a If resistance is above 1 Mz, harness has open circuit. If resistance is below
Between CP02 (female) (97) and (115) or (117) or
Resistance 20 60 z
(120)
a If cause 2 is not the cause for the failure, this check is not required.
2. Disconnect connectors CP02 and V14, and connect T-adapters to each
female side.
Between V14 (female) (1) and CP02 (female) (115)
Resistance Max. 1 z
or (117) or (120)
Between CP02 (female) (97) and V14 (female) (2)
Resistance
Resistance
Max. 1 z
PC800, 850-8E0

Circuit diagram related to swing priority solenoid
PC800, 850-8E0
40-27
40-277

Failure code [DW41KB] Swing Priority Sol Short Circuit

User code
Failure code
Failure
Detail of failure
Problem on
machine
DW41KB
Abnormal current flowed when driving swing priority circuit.
Power supply to swing priority solenoid circuit is switched OFF.

to OFF position.
When combined operation of boom RAISE and SWING is performed in swing priority mode, swing
speed is slow (Flow in swing circuit is kept throttled low).
Controller's command (ON/OFF) to swing priority valve solenoid can be checked by using monitoring function. (If controller sends solenoid ON command, monitoring display is ON even if solenoid
is not switched ON due to open circuit.)
Method of reproducing failure code: Start engine, turn swing priority mode switch to ON position
and perform swing operation.
q
q
q
q
Cause
Defective swing priority solenoid


40-278
Swing priority solenoid system short circuit

Related information
40-278

Resistance
20 60 z
Between V14 (female) (1) and ground
Resistance
Min. 1 Mz

2. Disconnect connectors CP02 and V14, and connect T-adapters to either
female side.
between V14 (female) (2) and ground
female side.
(120), or between V14 (female) (1) and (2)
PC800, 850-8E0

Circuit diagram related to swing priority solenoid
PC800, 850-8E0
40-279
40-279

Failure code [DW43KA] Travel Speed Sol Open Circuit

User code
Failure code
Failure
DW43KA
40-280
Travel speed selector solenoid system open circuit

Detail of failure
Current does not flow when driving travel speed selector solenoid circuit.
q
q
None in particular. (Since no current flows, solenoid does not operate.)

Travel speed does not shift to Hi. (The swash plate angle of travel motor is not minimized.)
Travel speed selector solenoid is not energized when engine speed is below 1,200 rpm.
Controller's command (ON/OFF) to travel speed selector solenoid can be checked by using monitoring function. (If controller sends solenoid ON command, monitoring display is ON even if solenoid is not energized due to open circuit.)
Method of reproducing failure code: Run engine at full throttle.
Problem on
machine
Related information
q
q
Cause
Defoctive travel speed selector
1
solenoid (internal open circuit)


40-280
20 60 z

Resistance 20 60 z
(120)
female side.
Resistance Max. 1 z
or (117) or (120)
Resistance
Resistance
Max. 1 z
PC800, 850-8E0

Circuit diagram related to travel speed selector solenoid
PC800, 850-8E0
40-281
40-281

Failure code [DW43KB] Travel Speed Sol Short Circuit

User code
Failure code
Failure
Detail of failure
Problem on
machine
DW43KB
Travel speed solenoid system short circuit

Abnormal current flowed when driving travel speed selector solenoid circuit.
q
q
Power supply to the travel speed selector solenoid circuit is stopped.

to OFF position.
Travel speed does not shift to Hi. (The swash plate angle of travel motor is not minimized.)
Travel speed selector solenoid is not energized when engine speed is below 1,200 rpm.
Controller's command (ON/OFF) to travel speed selector solenoid can be checked by using monitoring function. (If controller sends solenoid ON command, monitoring display is ON even if solenoid is not energized due to open circuit.)
Method of reproducing failure code: Run engine at full throttle.
Related information
q
q
Cause
Defective travel speed solenoid
1 (internal short circuit or ground
fault)


Resistance
20 60 z

female side.
female side.
(120), or between V04 (female) (1) and (2)
Circuit diagram related to travel speed selector solenoid
40-282
40-282
40-282
PC800, 850-8E0

PC800, 850-8E0
40-283

Failure code [DW45KA] Swing Brake Sol Open Circuit

User code
Failure code
Failure
E03
DW45KA
40-284
Swing brake solenoid system open circuit

Detail of failure
Current does not flow when driving swing brake solenoid circuit.
q
q

Swing operation cannot be performed (Swing brake is not released).
Controller's command (ON/OFF) to swing brake solenoid can be checked by using monitoring function. (If controller sends solenoid ON command, monitoring display is ON even if solenoid is not
energized due to open circuit.)
If solenoid and harness are normal, operator can swing upper structure by setting swing brake cancel switch in release position (Swing brake does not work, however, when performing stop operation of upper structure).
Keep the swing lock switch in the OFF position and the swing brake cancel switch in the RELEASE
position during troubleshooting.
Method of reproducing failure code: Start engine and perform swing operation.
Problem on
machine
Related information
q
q
q
Cause
Defective swing brake solenoid
1
Defective diode array D01

(internal open circuit in harness)
Defective swing lock switch


Resistance
20 60 z

2. Disconnect connector D01 and connect T-adapter to male side.
Between D01 (male) (7) (+) and (3)
Continuity
Between D01 (male) (3) (+) and (7)
No continuity

3. Turn swing lock switch ON and OFF, and troubleshoot.
Between S04 (male) (3)
and (4)
Switch: OFF
Resistance
Max. 1 z
Switch: LOCK (ON)
Resistance
Min. 1 Mz

2. Disconnect connector D01 and connect T-adapter to female side.

40-284
Between D01 (female) (3) and ground

Resistance 20 60 z
a Coil resistance of solenoid V05
2. Disconnect connectors CP02, D01, S04 and V05 and connect T-adapters
to each female side.
Between CP02 (female) (101) and D01 (female) (7) Resistance
Max. 1 z
a If no abnormality is found in checks on cause 4,

go to cause 5.
Resistance
Between D01 (female) (3) and S04 (female) (3)
Max. 1 z
Between S04 (female) (4) and V05 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
PC800, 850-8E0

Circuit diagram related to swing brake solenoid
PC800, 850-8E0
40-285
40-285

Failure code [DW45KB] Swing Brake Sol Short Circuit

User code
Failure code
Failure
E03
Detail of failure
Problem on
machine
DW45KB
Swing brake solenoid system short circuit

Abnormal current flowed when driving swing brake solenoid circuit.
q
q
Power supply to swing brake solenoid circuit is stopped.

to OFF position.
Swing operation cannot be performed (Swing brake is not released).
Controller's command (ON/OFF) to swing brake solenoid can be checked by using monitoring function. (If controller sends solenoid ON command, monitoring display is ON even if solenoid is not
energized due to short circuit.)
If solenoid and harness are normal, operator can swing upper structure by setting swing brake cancel switch in release position (Swing brake does not work, however, when performing stop operation of upper strueture).
Keep the swing lock switch in the OFF position and the swing brake cancel switch in the RELEASE
position during troubleshooting.
Method of reproducing failure code: Start engine and perform swing operation.
Related information
q
q
q
Cause
Defective swing brake solenoid
fault)
40-286


Resistance
20 60 z
Resistance
Min. 1 Mz

2. Disconnect connectors CP02, V05 and D01, and connect T-adapter to
female side of D01.
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
q
Reference
Insert T-adapter into connector D01.
Start engine
Operate work equipment control lever and perform troubleshooting.
Max. 1 V
When all control levers in
(5 sec after
Voltage
Between D01 (7) and
NEUTRAL position
setting in
ground
neutral)
1.
2.
3.
4.
Operated for swing
40-286
Voltage
20 30 V
PC800, 850-8E0

PC800, 850-8E0
40-287
40-287

Failure code [DW7BKA] Fan Reverse Sol Open Circuit

User code
Failure code
Failure
DW7BKA
40-28
Hydraulic fan reverse solenoid system open circuit

Detail of failure
Current does not flow when driving hydraulic drive solenoid circuit.
q
q

The fan does not rotate in reverse direction.
Controller's command (ON/OFF) to fan reverse solenoid can be checked by using monitoring function. (If controller sends solenoid ON command, monitoring display is ON even if solenoid is not
energized due to open circuit.)
Method of reproducing failure code: Turn starting switch to ON position and fan reverse switch to
ON position.
Problem on
machine
Related information
q
q
Cause
Defective hydraulic fan reverse
1
solenoid (internal open circit)

40-288

Resistance
20 60

Resistance 20 60
(120)
female side.
Between CP02 (female) (113) and V17 (female) (1) Resistance
Max. 1 z

Resistance Max. 1 z
or (117) or (120)
PC800, 850-8E0

Circuit diagram related to hydraulic fan
PC800, 850-8E0
40-289
40-289

Failure code [DW7BKB] Fan Reverse Sol Short Circuit

User code
Failure code
Failure
Detail of failure
Problem on
machine
Related information
DW7BKB
Abnormal current flowed when driving hydraulic fan reverse solenoid circuit.
q
q
Stops the output to hydraulic fan reverse solenoid circuit.

to OFF position.
The fan does not rotate in reverse direction.
Controller's command (ON/OFF) to fan reverse solenoid can be checked by using monitoring function. (If controller sends solenoid ON command, monitoring display is ON even if solenoid is not
energized due to short circuit.)
Method of reproducing failure code: Turn starting switch to ON position and fan reverse switch to
ON position.
Cause
Sudden stop prevention solenoid valve short circuit

(Power train controller system)
Defective hydraulic fan reverse

solenoid (internal open circuit)


Resistance
20 60 z
Resistance
Min. 1 Mz

2. Disconnect connectors V17 and CP02, and connect T-adapters to female
sides of V17.
Resistance
Min. 1 Mz

2. Disconnect connectors CP02 and V17, and connect T-adapters to female
sides of V17.
Between V17 (female) (1) and (2)
Resistance
Min. 1 Mz
40-290
40-290
40-290
PC800, 850-8E0

PC800, 850-8E0
40-291

Failure code [DW7JKA] Bottom Dump Priority Sol Open Circuit

User code
Failure code
Failure
DW7JKA
40-292
Bottom dump priority solenoid system open circuit

Detail of failure
Current does not flow when driving bottom damp priority solenoid circuit.
q
q
None in particular. (Current does not flow due to open circuit and solenoid does not work.)
Since bottom dump priority function does not work, bottom dump speed is low.
Controller's command (ON/OFF) to bottom damp priority solenoid can be checked by using monitoring function. (If controller sends solenoid ON command, monitoring display is ON even if solenoid is not energized due to open circuit.)
(Code: 02301 Solenoid valve 2)
Method of reproducing failure code: Turn starting switch to ON position and bottom damp
open/close switch to ON position or perform arm OUT operation.
Problem on
machine
Related information
q
q
Cause
Defective bottom damp priority
1 solenoid


2. Disconnect connector V19 and connect T-adapter to male side.
40-292
20 60 z

Resistance 20 60 z
(120)
female side.
Resistance Max. 1 z
or (117) or (120)
Resistance
Resistance
Max. 1 z
PC800, 850-8E0

Circuit diagram related to bottom damp priority solenoid
PC800, 850-8E0
40-293
40-293

Failure code [DW7JKB] Bottom Dump Priority Sol Short Circuit

User code
Failure code
Failure
Detail of failure
Problem on
machine
DW7JKB
Abnormal current flowed when driving bottom damp priority solenoid circuit.
Stops outputting signal. (Since no current flows, solenoid does not operate.)
to OFF position.
Since bottom dump priority function does not work, bottom dump speed is low when bucket CURL
is operated in combination.
Controller's command (ON/OFF) to bottom damp priority solenoid can be checked by using monitoring function. (If controller sends solenoid ON command, monitoring display is ON even if solenoid is not switched ON due to open circuit.)
(Code: 02301 Solenoid valve 2)
Method of reproducing failure code: Turn starting switch to ON position and bottom damp
open/close switch to ON position or perform arm OUT operation.
q
q
q
q
Cause
Defective bottom damp priority
1 solenoid
Bottom dump priority solenoid system short circuit

Related information
40-294


Resistance
20 60 z
Resistance
Min. 1 Mz

female side.
female side.
Resistance
Min. 1 Mz
q Reference
2. Insert T-adapter into connector V19.
Between V19 (2) and (1) Control lever: NEUTRAL
Voltage
Max. 1 V
Descriptions for 1 to 3 are the same as above.

4. Turn bottom damp open/close switch to ON position or perform arm OUT
operation.
Turn bottom damp
open/close switch to ON
Between V19 (2) and (1)
Voltage
20 30 V
position or perform arm
OUT operation.
40-294
PC800, 850-8E0

Circuit diagram related to bottom damp priority solenoid
PC800, 850-8E0
40-295
40-295

Failure code [DW91KA] Travel Junction Sol Open Circuit

User code
Failure code
Failure
DW91KA
Straight-travel solenoid system open circuit

Detail of failure
When driving straight-travel solenoid circuit, no current flows.
None in particular. (Since no current flows, solenoid does not operate.)

Problem on
machine
Related information
q
q
40-296
Travel deviation occurs when right and left turn steering operation and work equipment operation
are performed at the same time.
Controller's command (ON/OFF) to travel-straight solenoid can be checked by using monitoring
function. (If controller sends solenoid ON command, monitoring display is ON even if solenoid is
not energized due to open circuit.)
Method of reproducing failure code: Start engine, and then perform right and left turn steering operation and work equipment operation at the same time.
Cause
Defective straight-travel solenoid
1


Resistance

Resistance 20 60 z
(120)
female side.
Resistance Max. 1 z
or (117) or (120)
40-296
20 60 z
Max. 1 z
PC800, 850-8E0

Circuit diagram related to straight-travel solenoid
PC800, 850-8E0
40-297
40-297

Failure code [DW91KB] Travel Junction Sol Short Circuit

User code
Failure code
Failure
Detail of failure
Problem on
machine
DW91KB
When driving straight-travel solenoid circuit, abnormal current flows.
Stops power supply to the straight-travel solenoid circuit.

to OFF position.
Travel deviation occurs when right and left turn steering operation and work equipment operation
are performed at the same time.
Controller's command (ON/OFF) to travel-straight solenoid can be checked by using monitoring
not energized due to short circuit.)
Method of reproducing failure code: Start engine, and then perform right and left turn steering operation and work equipment operation at the same time.
q
q
q
q
Cause
Defective travel speed solenoid
fault)
Straight-travel solenoid system short circuit

Related information


Resistance
20 60 z

2. Disconnect connectors CP02 and V02, and connect T-adapter to either
female side.
2. Disconnect connectors CP02 and V02, and connect T-adapter to either
female side.
(120),or between V02 (female) (1) and (2)
Circuit diagram related to straight-travel solenoid
40-298
40-298
40-298
PC800, 850-8E0

PC800, 850-8E0
40-299

Failure code [DWK0KA] 2-stage Relief Sol Open Circuit

User code
Failure code
Failure
DWK0KA
2-stage relief solenoid system open circuit

Detail of failure
Current does not flow when driving 2-stage relief solenoid circuit.

Problem on
machine
q
q
Related information
q
q
q
Travel power is low (The main relief valve is not set in the HIGH PRESSURE position)
One-touch power maximizing function does not work.
Controller's command (ON/OFF) to 2-stage relief solenoid can be checked by using monitoring
not energized due to open circuit.)
Controller detects open circuit if output to solenoid is OFF.
Cause
Defective 2-stage relief solenoid
1

40-300
40-30

Resistance
20 60 z

Between CP02 (female) (109) and (115) or
Resistance
20 60 z
(117) or (120)
female side.
Between V08 (female) (1) and CP02 (female)
Resistance
Max. 1 z
(115) or (117) or (120)
Between CP02 (female) (109) and V08
Resistance
Max. 1 z
(female) (2)
PC800, 850-8E0

Circuit diagram related to 2-stage relief solenoid
PC800, 850-8E0
40-301
40-301

Failure code [DWK0KB] 2-stage Relief Sol Short Circuit

User code
Failure code
Failure
Detail of failure
Problem on
machine
DWK0KB
Abnormal current flowed when driving 2-stage relief solenoid circuit.
Stops the power supply to 2-stage relief solenoid circuit.

to OFF position.
Travel power is low (The main relief valve is not set in the HIGH PRESSURE position)
One-touch power maximizing function does not work.
Controller's command (ON/OFF) to 2-stage relief solenoid can be checked by using monitoring
not energized due to short circuit.)
Controller detects open circuit if output to solenoid is OFF.
q
q
q
q
q
q
Cause
Defective 2-stage relief solenoid
fault)
2-stage relief solenoid system short circuit

Related information


Resistance
20 60 z
Resistance
Min. 1 Mz

sides of V08.
sides of V08.
40-302
40-302
Resistance
Min. 1 Mz
PC800, 850-8E0

Circuit diagram related to 2-stage relief solenoid
PC800, 850-8E0
40-303
40-303

Failure code [DX16KA] Fan Pump EPC Sol Open Circuit

User code
Failure code
Failure
E11
Detail of failure
Problem on
machine
DX16KA
No current flows into hydraulic fan EPC solenoid circuit.
If open circuit occurs, power supply is stopped. And fan pump swash plate is set to the maximum
angle, potentially inducing over speed of fan. Pump controller, therefore, turns on the protection
mode for reducing the engine speed.
The fan motor speed cannot be controlled.
When the fan EPC solenoid is open-circuited or short-circuited, fan reverse rotation cannnot be
made.
State of output (current) to hydraulic fan EPC solenoid can be checked by using monitoring function.
(Code 31623: Hydraulic fan EPC solenoid current)
q
q
q
q
Cause
1
Hydraulic fan EPC solenoid system open circuit

Related information
40-304

Defective hydraulic fan EPC sole- 2. Disconnect connector V13, and connect T-adapter to male side.
noid (internal open circuit)
Resistance 3 14 z

40-304

Resistance 3 14 z
(120)
female side.
Max. 1 z

Resistance Max. 1 z
or (117) or (120)
PC800, 850-8E0

PC800, 850-8E0
40-305
40-305

Failure code [DX16KB] Fan Pump EPC Sol Short Circuit

User code
Failure code
Failure
E11
Detail of failure
Problem on
machine
DX16KB
Hydraulic fan EPC solenoid system short circuit

Abnormal current flows in hydraulic fan EPC solenoid circuit.
If short circuit occurs, power is stopped. And fan pump swash plate is set to the maximum angle,
potentially inducing over speed of fan. Pump controller, therefore, turns on the protection mode for
reducing engine speed.
The fan motor speed cannot be controlled.
When the fan EPC solenoid is open-eircuited or short-circuited, fan reverse rotation cannnot be
made.
State of output (current) to hydraulic fan EPC solenoid can be checked by using monitoring function.
(Code 31623: Hydraulic fan EPC solenoid current)
q
q
q
Related information
40-306
q
q
Cause

Defective hydraulic fan EPC sole- 2. Disconnect connector V13, and connect T-adapter to male side.
1 noid (internal short circuit or
Resistance
3 14 z
ground fault)
Resistance
Min. 1 Mz

40-306

female side.
Resistance
Min. 1 Mz
female side.
Between CP02 (female) (105) and (115) or
(117) or (120), or between V13 (female) (1)
Resistance
Min. 1 Mz
and (2)
PC800, 850-8E0

PC800, 850-8E0
40-307
40-307

Failure code [DXAAKA] F Pump EPC Sol Open Circuit

User code
Failure code
Failure
E07
Detail of failure
DXAAKA
q
q
40-308
Frout pump EPC solenoid system open circuit

Pump controller detected open circuit that current did not flow to circuit when it tried to energized
front pump EPC solenoid.
When the abnormality was detected during travel, controller sets both F pump and R pump to the
minimum flow rate.
Energizes "straight travel solenoid", once lever is set to neutral.
to OFF position.
Problem on
machine
Travel and work equipment speeds lower.
Current to energize front pump EPC solenoid can be checked by using monitoring function.
(Code: 01300 F pump EPC solenoid current)
Related information
q
q
Cause
1
Defective front pump EPC solenoid (internal orpen circuit)

3 14 z
Resistance

2. Disconnect connector S25, and connect T-adapter to male side.
Defective emergency pump drive
2 switch
Between S25 (male) (3) Switch: Normal (bottom) Resistance

and (2)
Switch: Emergency (top) Resistance
and (5)
40-308
Min. 1 Mz
Max. 1 z
Min. 1 Mz
1.
2.
a
a

Check that emergency pump drive switch is at normal position (lower side).
If resistance is above 1 Mz, harness has open circuit. If resistance is below
Resistance 3 14 z
(120)
a If cause 3 is not the cause for the trouble, this check is not required.
female side.

Max. 1 z
Resistance
Max. 1 z
Between each of CP02 (female) (115), (117) and

Resistance Max. 1 z
(120) and V11 (female) (2)
a If an abnormality is still present, continue troubleshooting after disconnecting connector S25.
Between CP02 (female) (96) and S25 (female) (3)
Resistance
Max. 1 z
Resistance
Max. 1 z
Between S25 (female) (6) and CP02 (female) (115)

Resistance
or (117) or (120)
Max. 1 z
Max. 1 z
Resistance
PC800, 850-8E0

Circuit diagram related to main pump EPC solenoid
PC800, 850-8E0
40-309
40-309

Failure code [DXAAKB] F Pump EPC Sol Short Circuit

User code
Failure code
Failure
E07
Detail of failure
DXAAKB
q
q
40-310
Frout pump EPC solenoid system short circuit

Pump controller detected short circuit that abnormal current flowed to circuit when it tried to energized front pump EPC solenoid.
minimum flow rate.
Energizes "straight-travel solenoid", once lever is set to neutral.
to OFF position.
Problem on
machine
Current to energize front pump EPC solenoid can be checked by using monitoring function.
(Code: 01300 F pump EPC solenoid current)
Related information
q
q
Cause
Defective front pump EPC sole1 noid (internal short circuit or
ground fault)

Resistance
3 14 z
Resistance
Min. 1 Mz

2. Emergency pump drive switch Normal (bottom)
Defective emergency pump drive 3. Disconnect connector S25, and connect T-adapter to male side.
2 switch (internal short circuit or
Between S25 (male) (2) and (4), or between S25
ground fault)
(male) (3) and (4)
Between S25 (male) (2) and (3) and ground

40-310
Resistance
Min. 1 Mz

2. Disconnect connectors CP02, S25 and V11, and connect T-adapters to
each female side.
between S25 (female) (3) and ground
Between S25 (female) (5) and groud, or between
V11 (female) (2) and ground
either female side.
Resistance
Min. 1 Mz
Between S25 (female) (3) and (6), or between CP02

Resistance
(female) (96) and (115) or (117) or (120)
Min. 1 Mz
PC800, 850-8E0

PC800, 850-8E0
40-31
40-311

Failure code [DXABKA] R Pump EPC Sol Open Circuit

User code
Failure code
E07
Detail of failure
q
q
Failure
40-312
Rear pump EPC solenoid system open circuit

DXABKA
Pump controller detected open circuit that current did not flow to circuit when it tried to energized
rear pump EPC solenoid.
minimum flow rate.
to OFF position.
Problem on
machine
Drive current to rear pump EPC solenoid can be checked by using monitoring function.
(Code: 01302 R pump EPC solenoid current)
Related information
q
q
Cause

Defective rear pump EPC solenoid 2. Disconnect connector V12, and connect T-adapter to male side.
1
Resistance 3 14 z
Defective emergency pump drive
2 switch


and (8)
Between S25 (male) (12) Switch: Normal (bottom) Resistance Max. 1 z

and (11)
Switch: Emergency (top) Resistance Min. 1 Mz
a Check that emergency pump drive switch is at normal position (lower side).
Resistance 3 14 z
(120)
a If cause 3 is not the cause for the trouble, this check is not required.
female side.
Between CP02 (female) (104) and V12 (female) (1) Resistance Max. 1 z
Resistance Max. 1 z
or (117) or (120)
a If an abnormality is still present, continue troubleshooting after disconnecting connector S25.
Between CP02 (female) (104) and S25 (female) (9) Resistance Max. 1 z
Between S25 (female) (12) and CP02 (female)
(115) or (117) or (120)
40-312
Max. 1 z
Min. 1 Mz
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
PC800, 850-8E0

PC800, 850-8E0
40-313
40-313

Failure code [DXABKB] R Pump EPC Sol Short Circuit

User code
Failure code
Failure
E07
Detail of failure
DXABKB
q
q
40-314
Rear pump EPC solenoid system short circuit

Pump controller detected short circuit that abnormal current flowed to circuit when it tried to energized rear pump EPC solenoid.
minimum flow rate.
to OFF position.
Problem on
machine
Drive current to rear pump EPC solenoid can be checked by using monitoring function.
(Code: 01302 R pump EPC solenoid current)
Related information
q
q
Cause

Defective rear pump EPC solenoid

Resistance
3 14 z
Resistance
Min. 1 Mz

2. Emergency pump drive switch Normal (bottom)
Defective emergency pump drive 3. Disconnect connector S25, and connect T-adapter to male side.
2 switch (internal short circuit or
Between S25 (male) (8) and (10), or between S25
ground fault)
(male) (9) and (10)
Between S25 (male) (8) and (9) and ground

40-314
Resistance
Min. 1 Mz

each female side.
between S25 (female) (9) and ground
Between S25 (female) (8) and ground, or between
V12 (female) (1) and ground
2. Disconnect connectors CP02, S25 and V12, and connect T-adapter to
either female side.
Resistance
Min. 1 Mz
Between S25 (female) (9) and (12), or between

CP02 (female) (104) and (115) or (117) or (120)
Resistance
Min. 1 Mz
PC800, 850-8E0

PC800, 850-8E0
40-315
40-315

Failure code [DY20KA] Wiper Working Abnormality
40-316
Single wiper specification
40-316
User code
Failure code
Failure
DY20KA
Wiper working abnormality

Detail of failure
When windshield wiper works, W signal of working ends is not input.
q
q
Stops working output to wiper motor.

Wiper motor does not work.
Problem on
machine
Signal input (ON/OFF) of W contact signal that indicates wiper working area end can be checked
by using monitoring function.
(Code: 02204 Switch input 5)
Related infor- q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be meamation
sured at pump controller connector.
a Single wiper does not have lower wiper of double wiper (Upper wiper is called windshield wiper).
q Method of reproducing failure code: Turn starting switch to ON position and and set wiper switch
to INT or ON position.
Cause
Defective wiper motor


40-316

2. Disconnect connector M05 and connect T-adapter to female side.
Wiper position: working
Resistance Max. 1 z
Between M05 (female) area end
Wiper position: other than
(6) and (5)
working area end
Between M05 (female) Wiper position: whole
Resistance Max. 20 z
(1) and (3)
range
2. Disconnect connectors CP01 and CP02, and connect T-adapters to each
female side.
Wiper position: both
Resistance Max. 1 z
Between CP01 (female) working area ends
Wiper position: other than
(56) and ground
working area end
Between CP02 (female) Wiper position: whole
(114) and (119)
range
2. Disconnect connectors CP01, CP02, and M05.
3. Connect T-adapters to female sides of connector CP01 and CP02 and male
side of M05.
Between CP01 (female) (56) and M05 (male) (6)
Resistance
Max. 1 z
Between M05 (male) (5) and ground (T07)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z

PC800, 850-8E0

Circuit diagram related to wiper motor (single wiper specification)
PC800, 850-8E0
40-317
40-317

40-318
Double wiper specification

User code
Failure code
Failure
DY20KA
Wiper working abnormality

Detail of failure
While lower wiper is working, P signal that indicates rest area is not input.
q
q
Stops output to lower wiper motor.

Lower wiper motor does not work.
Signal input (ON/OFF) of P contact signal of lower wiper rest area can be checked by using monitoring function.
Method of reproducing failure code: Turn starting switch to ON position, and set lower wiper switch
to ON position, and set wiper switch to INT or ON position.
Problem on
machine
Related information
q
q
Cause
Defective lower wiper motor

2 Defective diode (D05)

Lower wiper position: rest
Resistance Max. 1 z
area
Lower wiper position:
(4) and (5)
other than rest area
Lower wiper position:
(1) and (3)
whole area
2. Disconnect connector D05.
4. Turn lower wiper switch to ON position and turn wiper switch to ON position.
If this code does not appear, diode (D05) is defective.
a
1.
2.
3.

40-318
If cause 2 is not the cause of failure, this check is not required.

Disconnect connectors CP01, CP02, D05, and M15.
Connect T-adapters to female side of connector CP01, CP02, and D05, and
male side of M15.
Resistance
Max. 1 z
Between D05 (female) (7) and ground (T07), or

between D05 (female) (8) and ground (T07)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Between M15 (male) (3) and D05 (female) (4)
Resistance
Max. 1 z
Resistance
Max. 1 z

PC800, 850-8E0

Circuit diagram related to wiper motor (double wiper specification)
PC800, 850-8E0
40-319
40-319

Failure code [DY20MA] Wiper Parking Abnormality
40-320
Single wiper specification alone
40-320
User code
Failure code
Failure
DY20MA
Wiper resting abnormality

Detail of failure
When windshield wiper rests, P signal for rest area is not input.
q
q
Stops output for resting to wiper motor.

Wiper motor does not rest.
Condition of P contact signal of wiper resting area can be checked by using monitoring function.
Method of reproducing failure code: Turn starting switch to ON position and set wiper switch to
INT/ON to OFF position.
Problem on
machine
Related information
q
q
Cause



40-320

(4) and (5)
Wiper position: rest area Resistance
Max. 1 z

area
Wiper position: whole
(1) and (3)
range
2. Disconnect diode arrays CP01 and CP02 and connect T-adapters to each
female side.
Between CP01 (female)
(75) and ground
Wiper position: rest area Resistance
Max. 1 z

area
Between CP02 (female) Wiper position: whole
(114) and (119)
range
side of M05.
Resistance
Max. 1 z
Between M05 (male) (5) and ground (T07)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z

PC800, 850-8E0

PC800, 850-8E0
40-321
40-321

Failure code [DY2CKA] Washer Drive Open Circuit

User code
Failure code
Failure
Detail of failure
Problem on
machine
Related information
DY2CKA
q
Window washer drive system open circuit

When power to window washer drive was stopped, open circuit was detected because output pin
(2-pin) voltage of controller did not increase.
None in particular (Washer motor does not work because no current flows to it).
Window washer does not operate.
Cause
1 Defective fuse No.4
Defective washer motor

2 (internal open circuit or ground
fault)
40-32


If the fuse is broken, the circuit probably has a ground fault, etc. (See Cause
6.)
5 20 z
Continuity
No continuity
1.
2.
Open circuit or ground fault in har- 3.
4
ness
a

Disconnect connectors CP01 and connect T-adopters to each female side.
Ignore failure code displayed on machine monitor.

Resistance
Between M06 (male) (1) and ground, or between

M06 (male) (2) and ground
2. Disconnect connector D04, and connect T-adopter to male side.
a
1.
2.
3.
Voltage
20 30 V
If no abnormality is found by check on cause 4, this check is not required.

Disconnect fuse No. 4 of fuse box F01.
Disconnect connectors M06 and C01 and connect T-adapters to each
female side.
Between F01-4 and M06 (female) (2)
Resistance
Max. 1 z
Between CP01 (female) (3) and M06 (female) (1)
Resistance
Max. 1 z
a
1.
2.
3.
6

If no abnormality is found by check on cause 4, this check is not required.

Disconnect fuse No. 4 of fuse box F01.
Disconnect connectors M06, CP01 and D04, and connect T-adapters to
either female side.
Between ground and F01-4 or M06 (female) (2) or
D04 (female) (2)
Between ground and CP01 (female) (3) or M06
(female) (1) or D04 (female) (6)
40-322
Resistance
Min. 1 Mz
If no failure is found by above checks, pump controller is defective. (Since this

PC800, 850-8E0

Circuit diagram related to window washer motor
PC800, 850-8E0
40-323
40-323

Failure code [DY2CKB] Washer Drive Short Circuit

User code
Failure code
Failure
Detail of failure
Problem on
machine
Related information
DY2CKB
q
q
q
Window washer does not operate.
Method of reproducing failure code: Turn starting switch to ON position and turn washer switch to
ON position.
Defective washer motor

2 (internal open circuit or ground
fault)
Window washer drive system short circuit

When power to window washer drive was supplied (grounding), short circuit was detected because
of abnormal current flown to the circuit.
Stops output to washer motor.
to OFF position.
Cause



If the fuse is broken, the circuit probably has a ground fault, etc. (See failure
code [DY2CKA].)
Resistance
5 20 z
Between M06 (male) (1) and ground, or between

a Check the continuity in diode range.
Continuity
No continuity

2. Disconnect connectors CP01 and M06, and connect T-adapter to female
side of CP01.
a Ignore failure code displayed on machine monitor.
40-324
40-324
Voltage
Max. 1 V

PC800, 850-8E0

Circuit diagram related to window washer motor
PC800, 850-8E0
40-325
40-325

Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit

User code
Failure code
Failure
Detail of failure
Problem on
machine
DY2DKB
q
q
q
40-326
Wiper motor drive normal rotation system short circult

When power to normal rotation side of wiper motor drive is supplied, short circuit was detected because of abnormal current flown to the circuit.
Stops output to wiper motor drive normal rotation side.
to OFF position.
Windshield wiper does not operate.
Related inforq Method of reproducing failure code: Turn starting switch to ON position and set wiper switch to INT
mation
or ON position.
a As for the double wiper specifications, this code is applicable to upper wiper alone.
40-326
Cause
fault)

Between M05 (female) (3) and (1)
Continuity
Between M05 (female) (3) and ground

1.
2.
3.
4.
Reference
Insert T-adapter into connector M05.
Turn wiper switch ON and OFF, and troubleshoot.
Between M05 (3) and

(5)
40-326
Min. 1 Mz

2. Disconnect connectors CP02 and M05 and connect T-adapter to either
harness side.
M05 (male) (1) and (3)
harness side.
between M05 (male) (3) and ground
If no abnormality is found by above checks, pump controller is defective. (Since
q
Resistance
Wiper switch:
OFF
Voltage
Max. 3 V
Wiper switch: ON
Voltage
Pulse below 3 V io
above 20 V
PC800, 850-8E0

PC800, 850-8E0
40-327
40-327

40-328

Cause
Defective upper wiper motor
fault)

Continuity
1.
2.
3.
4.
Resistance
Min. 1 Mz

Disconnect connector D05.
Wiper switch ON


harness side.
M05 (male) (1) and (3)
harness side.
q
1.
2.
3.
4.
Reference
Between M05 (3) and

(5)
40-328
Wiper switch:
OFF
Voltage
Max. 3 V
Wiper switch: ON
Voltage
Pulse below 3 V io
above 20 V
PC800, 850-8E0

PC800, 850-8E0
40-329
40-329

Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit

User code
Failure code
Failure
Detail of failure
Problem on
machine
DY2EKB
q
q
q
40-3 0
Wiper motor drive reverse rotation system short circuit

When driving reverse side of wiper motor drive circuit, short circuit was detected because of abnormal current flown to the circuit.
Stops output to wiper motor drive reverse side.
to OFF position.
Windshield wiper does not operate.
Related inforq Method of reproducing failure code: Turn starting switch to ON position and and set wiper switch to
mation
INT or ON position.
a As for the double wiper specifications, this code is applicable to lower wiper alone.

Cause
fault)

40-3 0
Resistance
Min. 1 Mz

harness side.
M05 (male) (1) and (3)
harness side.
q Reference
2. Insert T-adapter into connector M05.
4. Turn wiper switch ON and OFF, and troubleshoot.
Between M05 (1) and
(5)
40-330
Continuity
Wiper switch:
OFF
Voltage
Max. 3 V
Wiper switch: ON
Voltage
Pulse below 3 V io
above 20 V
PC800, 850-8E0

PC800, 850-8E0
40-3 1
40-331

40-3 2

Cause
Defective lower wiper motor
fault)

2. Disconnect connector M15, and connect T-adapter to female side.
Continuity
1.
2.
3.
4.
Resistance
Min. 1 Mz

Disconnect connector D05.
Turn lower wiper switch to ON position and turn wiper switch to ON positon.


2. Disconnect connectors CP01, CP02 and M15 and connect T-adapter to
either harness side.
Between CP01 (female) (20) and CP02 (female)
(114), or between M15 (male) (1) and (3)
harness side.
q
1.
2.
3.
4.
Reference
Between M15 (3) and

(5)
40-332
Wiper switch:
OFF
Voltage
Max. 3 V
Wiper switch: ON
Voltage
Pulse below 3 V io
above 20 V
PC800, 850-8E0

PC800, 850-8E0
40-3 3
40-333

Failure code [DY2FMA] Upper Wiper Working Abnormality
40-3 4
Double wiper specification alone
40-3 4
User code
Failure code
Failure
DY2FMA
Abnormality detected while upper wiper is working

Detail of failure
While upper wiper is working, P signal that indicates both ends of rest area is not input.
q
q
Stops output to upper wiper motor.

Upper wiper motor does not work.
Signal input (ON/OFF) of P contact signal of upper wiper rest area end can be checked by using
monitoring function.
Method of reproducing failure code: Turn starting switch to ON position and set wiper switch to INT
or ON position.
Problem on
machine
Related information
q
q
Cause
Defective upper wiper motor


Upper wiper position:
ResisMax. 1 z
tance
Between M05 (female) (6) rest area
Resisand (5)
Min. 1 Mz
tance
Between M05 (female) (1) Upper wiper position:
ResisMax. 20 z
and (3)
whole range
tance
4. Turn wiper switch to ON position.

40-334

2. Disconnect connectors CP01, CP02 and D05, and connect T-adapters to
each female side.
ResisMax. 1 z
rest
area
tance
Resis(75) and ground
Min. 1 Mz
tance
ResisMax. 20 z
(119) and ground
whole range
tance
side of M05.
ResisBetween CP01 (female) (75) and M05 (male) (4)
Max. 1 z
tance
ResisBetween M05 (male) (5) and ground (T07)
Max. 1 z
tance
ResisBetween M05 (male) (1) and ground (T07)
Max. 1 z
tance
ResisBetween CP02 (female) (119) and M05 (male) (3)
Max. 1 z
tance
PC800, 850-8E0

PC800, 850-8E0
40-3 5
40-335

Failure code [DY2GKM] Wiper Select Abnormality

User code
Failure code
Failure
DY2GKM
40-3 6
Wiper selection harness abnormality

State of lower wiper effective signal input (pin 20 of connector CP01) changed continuously for
more than five seconds just after starting switch was turned to ON position.
Keeps state of lower wiper effective signal input just after starting switch is turned to ON position.
Problem on
machine
Windshield wiper does not operate normally
Pin 20 of connector CP01 is connected to GND for double wiper specification, and it is not connected to GND for single wiper specification.
Input of lower wiper effective signal (if normal, ON: single wiper specification/OFF: double wiper
specification) can be checked by using monitoring function.
(Code: 02209 Switch input 6, lower wiper effective SW)
Input (ON/OFF) of current lower wiper effective signal can be checked by using monitoring function.
(Code: 02209 Switch input 6, lower wiper selection state)
Detail of failure
Related information
Cause
1 (wire breakage or defective contact)

a
1.
2.
a

Loose or rusted ground T07

40-336
Resistance
Max. 1 z
a Single wiper specification

Resistance
Min. 1 Mz

q Reference
2. Insert T-adapter into connector A49
a Single wiper specification: Between A49 (5) and
Voltage
Min. 6 V
(1)
a Double wiper specification: Between A49 (5) and
Voltage
Max. 1 V
(1)
PC800, 850-8E0

PC800, 850-8E0
40-3 7
40-337

40-338
40-3 8
PC800, 850-8E0
Troubleshooting of electrical system (E-mode)

E-1 Engine does not start (Engine does not crank)
40-3 9
40-3 9
Failure
Related information
Engine does not start (Engine does not crank).
Engine starting circuit has following two start lock mechanisms.

1) Start lock by using password of machine monitor
2) Start lock by using lock lever
In the case of "Battery relay does not make operating sound" when the starting switch is turned to
ON position, perform trouble shooting for E-1 also.
Cause
If circuit breakers No. 1 and No. 6 are still operating, ground fault has most
Defective circuit breaker No. 1 and
probably occurred in the circuit. In this case, perform troubleshooting for
No. 6
Cause 15 first.
Defective fuse No. 3 in fuse box

F01
Loose terminal connection or open 1. Turn starting switch to OFF position.

circuit at terminal
Check terminals of starting motor, alternator, battery relay, grounds T08, etc.
If the fuse is broken, the circuit probably has grounding fault. (See Cause 15.)

Defective contact (ground)
4
between battery relay and frame
Between battery relay terminal R01 and ground

a Check grounding at machine frame.
a Looseness or rusted terminal T05
Resistance
Max. 1 z
a Be ready with starting switch OFF, then perform troubleshooting without

turning starting switch ON.
5 Insufficient battery capacity
Battery voltage (two pieces)
Min. 24 V
Electrolyte specific gravity (one piece)
Min. 1.26
Engine controller power supply and ACC signal are diagnosed with procedures
6 Defective engine controller system for failure codes [DA2RMC] and [DAFRMC]. If these codes are displayed, perform troubleshooting for them first.
Defective starting switch

(open circuit in internal wiring)
Defective lock lever switch

PC800, 850-8E0

2. Disconnect connector H15 and connect T-adapter to male side.
3. After troubleshooting, turn starting switch to ON/START position and
perform troubleshooting again.
Turn starting switch to
Between H15 (male) (1)
OFF position.
and (2)
Resistance Max. 1 z
ON position.
OFF position.
and (5)
Resistance Max. 1 z
ON position.
OFF position.
and (4)
Resistance Max. 1 z
START position
Between S14 (female)
(1) and (3)
Lock lever FREE position Resistance
Min. 1 Mz
Lock lever LOCK position Resistance
Max. 1 z
40-339

Cause

2. Disconnect connectors R06 and R07 and connect T-adapter to male side.
Defective starting motor cutout

relay R06 or R07
9
(open or short circuit in internal
wiring)
Resistance 200 - 600 z
Resistance
Max. 1 z
Resistance
Min. 1 Mz
Resistance
Max. 1 z
Resistance
Min. 1 Mz

2. Turn starting switch to START position and perform troubleshooting.
10
11
Defective starting motor

(internal defect)
Defective alternator
(short circuit in internal wiring)
Defective diode D01

12 (open or short circuit in internal
wiring)
40-340
Between starting motor terminal B and Power supVoltage

20 - 30 V
ground
ply
Input from
Between starting motor terminal R and
alternator
Voltage
Max. 1 V
ground
generation
Starting
Between starting motor terminal S and
command
Voltage
20 - 30 V
ground
input
If power supply, input from alternator generation and starting command input
are normal but starting motor does not run, starting motor is defective.
a Be ready with starting switch OFF, then turn starting switch to ON position
and perform troubleshooting.
Output from
Between alternator R terminal and
alternator
Voltage
Max. 1 V
ground
generation
No continuity
Continuity
No continuity
Continuity
PC800, 850-8E0

Cause

q Battery relay
Between terminal B02 and H15 (female) (2)
Resistance
Max. 1 z
q Battery relay
a Check to where 24 V is supplied to isolate open section.
Between terminals R04 and R01
Voltage
20 - 30 V
Voltage
20 - 30 V
Voltage
20 - 30 V
Between terminal R01 and ground
Voltage
Max. 1 V

1.
2.
3.
4.
5.
a
Between H15 (4) and ground
Voltage
20 - 30 V
Between S14 (1) and ground
Voltage
20 - 30 V
Between S14 (3) and ground
Voltage
20 - 30 V
Between R07 (4) and ground
Voltage
20 - 30 V
Between ST (1) and ground
Voltage
20 - 30 V
Between ST (2) and ground
Voltage
Max. 1 V
Between alternator B terminal and ground
Voltage
20 - 30 V
Between starting motor terminal B and ground
Voltage
20 - 30 V
a
1.
2.
3.

14

(Does not work)
PC800, 850-8E0
Alternator and starting motor

Disconnect battery ground cable.
Insert T-adapters into connectors H15, S14, R07 and ST.
Turn starting switch to START position and troubleshoot.
Check to where 24 V power is supplied to isolate open section.

Disconnect H15, S14, R06 and R07.
Connect T-adapter to female sides of H15, R06 and R07, and to male side
of S14.
Between H15 (female) (4) and R06 (female) (5)
Resistance
Max. 1 z
Between R06 (female) (3) and R07 (female) (4)
Resistance
Max. 1 z
Between R07 (female) (1) and S14 (male) (1)
Resistance
Max. 1 z
Resistance
Max. 1 z
Between R07 (female) (3) and starting motor termiResistance

nal S
Max. 1 z
Between alternator B and starting motor B
Resistance
Max. 1 z
Between starting motor B and battery relay R03
Resistance
Max. 1 z
Between alternator R and starting motor R
Resistance
Max. 1 z
Between alternator R and D01 (female) (6)
Resistance
Max. 1 z
Between S14 (male) (3) and R06 (male) (1)
Resistance
Max. 1 z
Between R06 (female) (2) and ground (T07)
Resistance
Max. 1 z
If only terminal R03 voltage is abnormal during battery relay check for cause
13, battery relay is defective.
40-341

Cause

a
1.
2.
3.

Disconnect connectors H15, S14, R06, and R07.
Connect T-adapters to each female side of connectors H15, R06, R07 and
ST, and each male side of ST and S14.
Between H15 (female) (4) and ground, or between
R06 (female) (5) and ground

15
16

40-342

Resistance
Min. 1 Mz

Resistance
ST (female) (1) and ground
Min. 1 Mz
Between starting motor B and ground, or between

battery relay R03 and ground
Resistance
Min. 1 Mz
Between ST (male) (1) and ground, or between

starting motor S and ground
Resistance
Min. 1 Mz

Resistance
S14 (male) (1) and ground
Min. 1 Mz
Between S14 (male) (3) and ground, or between

Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

2. Insert T-adapter into connector D01, or CM01, or ST
Between ground and ST (2) or D01 (6) or CM01
(11)
Voltage
Max. 1 V
PC800, 850-8E0

Circuit diagram related to engine start circuit
PC800, 850-8E0
40-343
40-343

E-2 Preheater does not operate

Failure
40-34
1) Manual preheater does not operate.
a This troubleshooting describes the procedures to be followed when manual preheating does
not function to heat the electrical intake air heater mounting section.
q There are Automatic preheater and Manual preheater installed. When either function is operated, preheating monitor lights up. (When only preheating monitor does not light up, troubleshoot "3) While preheater is operating, preheating monitor does not light up")
Related information
q If "machine monitor does not light up" or "battery relay does not make operating sound" when
turning starting switch ON, main electric power supply system is supposed to be defective.
So, troubleshoot E-3 and E-1.
q Before performing troubleshooting, check that no related failure code is displayed.
(If failure codes [D110KB] is displayed, troubleshoot it first.)
Cause
2

If circuit breaker No. 1 is turned ON, circuit probably has ground fault. In this
case, perform troubleshooting for cause 7 first.
Loose terminal or disconnection at 1. Turn starting switch to OFF position.

terminal
Check terminals of heater relay, battery relay, electrical intake air heater, etc.
Defective diode D02

3 (open circuit or short circuit in
internal wiring)
Defective electrical intake air

4 heater
5 Defective starting switch
No continuity
Continuity
No continuity
Continuity

2. Disconnect terminal M23.
Between terminal M23 and ground
1.
2.
3.
4.
Continuity

Disconnect battery ground cable.
Disconnect connector H15 and connect T-adapter to male side.
Turn starting switch to OFF/HEAT position and troubleshoot.
OFF
Resistance
Min. 1 Mz
HEAT
Resistance
Max. 1 z
Between H15 (male) (1) and (3)
a If circuit breaker works, reset it.

2. Disconnect connectors CM01 and H15, and connect T-adapter to female
side of H15.
Between H15 (female) (3) and ground
Open or short circuit in wiring har- 2. Turn starting switch to ON position.
6
ness
Between heater rely HT terminal R15 and ground
Continuity
Voltage
20 - 30 V

2. Disconnect heater relay terminal R16.
a Disconnect so that current does not flow in heater when starting switch
is turned to HEAT position.
3. Turn starting switch to HEAT position (connect R1).
Between heater rely HT terminal R17 and ground
7
Defective heater relay HT

(Does not work) (Terminal R16)
40-344
Voltage
20 - 30 V
If no failure is found by check on cause 6 and heater relay operation sound is

not heard, heater relay is defective.
PC800, 850-8E0

Cause

a
a
1.
2.

Failure
If cause 6 is not cause for trouble, this check is not required.

Disconnect connectors H15 and CM01, terminals R15, R17 and M23, and
starting motor terminal B.
Between heater relay HT terminal R15 and ground
Resistance
Min. 1 Mz
Between heater relay HT terminal R17 (wiring harness side) and ground
Resistance
Min. 1 Mz
Between heater relay terminal M23 (wiring harness

Resistance
side) and ground
Min. 1 Mz
2) Automatic preheater does not operate.

q
q
Related information
q
q
q
Automatic preheater operates when engine coolant temperature is below -5 C.

(Monitoring code Engine coolant temperature: 04107)
If automatic preheater does not operate, check if manual preheater operates.
Heater relay R18 is called preheater relay to distinguish it from heater relay HT.
Engine controller troubleshoots primary (coil) side of preheater relay (connector R18) by failure
codes [CA2555] and [CA2556].
Engine controller troubleshoots engine coolant temperature sensor by failure codes [CA144] and
[CA145].
Cause
Defective circuit breaker No. If circuit breaker No. 1 works, circuit probably has ground fault. In this case, perform
1
troubleshooting for cause 6 first.
Defective fuse No. 6 in fuse

box 01
If fuse No. 6 in fuse box 01 is broken, circuit probably has ground fault. In this case,
perform troubleshooting for cause 6 first.

2. Replace preheater relay (connector R18) with starting motor cut relay
Defective preheater relay
(connector: R06 or R07).
R18
3
(open or short circuit in inter- 3. Turn starting switch to ON position.
nal wiring)
If automatic preheater operates when engine coolant temperature is below -5 C,
original preheater relay is defective.
2. Disconnect connectors CM01 and R18, and connect T-adapter to female side of
R18.
Open circuit or ground fault in a If resistance is above 1 Mz, wiring harness has open circuit. If resistance is
4
wiring harness
below 1 z, wiring harness has short circuit.
a Heater relay HT coil resistance
Resistance Approx. 20 z

5
(wire breakage or defective
contact)
Ground fault in wiring har6 ness


2. Disconnect connectors R18 and CM01, and connect T-adapter to female side of
R18.
Between R18 (female) (3) and battery relay terminal
R03
Max. 1 z
Between R18 (female) (5) and heater relay HT terminal

Resistance
Max. 1 z
R17
If circuit breaker works or fuse is not blown, this check is not required.
2. Disconnect connectors CM01, R18, and starting motor terminal B, and connect
T-adapter to female side of R18.
PC800, 850-8E0
Resistance
Resistance
Min. 1 Mz
40-345

Failure
3) While preheater is operating, preheating monitor does not light up.
Related information
q
q
There are "Automatic preheater" and "Manual preheater" installed. When either function is operated, preheating lamp lights up.
Check that manual preheater operates first.
Cause
1
(open circuit or defective
contact)

2. Disconnect connectors H15, CM01, and R18, and connect T-adapters to each
female side.
Between H15 (female) (3) and CM01 (female) (16)
Resistance
Max. 1 z
Resistance
Max. 1 z
If cause is not found by above checks, machine monitor is defective.

q Reference
3. Disconnect heater relay HT terminal R16.
a Disconnect so that current does not flow in heater when starting switch is turned
to HEAT position.
4. Turn the starting switch to HEAT position.
40-346
Resistance
20 - 30 V
PC800, 850-8E0

Circuit diagram related to preheating of engine
PC800, 850-8E0
40-347
40-347

E-3 When starting switch is turned to ON position, machine monitor displays nothing
E-3 When starting switch is turned to ON position, machine monitor

displays nothing
Failure
Related information
When starting switch is turned to ON position, machine monitor displays nothing
When starting switch is turned to ON position, machine monitor displays KOMATSU logo, screen
to input password (if set), screen to check breaker mode (if set), screen of check before starting,
screen to check working mode and travel speed, and standard screen in order.
When engine is started, battery voltage may lower suddenly, depending on ambient temperature
and condition of the battery.
In this case, machine monitor goes off for a moment. This phenomenon is not a failure, however.
Cause
40-348
Defective circuit breaker (No. 2 or If circuit breaker works, the circuit probably has ground fault. In this case, perNo. 6)
form troubleshooting for cause 9 first.
Loose terminal or disconnection at 1. Turn starting switch to OFF position.

terminal
Check terminals of battery, battery relay, ground (T08), etc.
a Be ready with starting switch in OFF position, then perform troubleshooting
without turning starting switch ON.
3 Insufficient battery capacity
4 Wrong connection of connector
5 Defective diodes (D01)
Battery voltage (two pieces)
Min. 24 V
Electrolyte specific gravity (one piece)
Min. 1.26
a If machine monitor is not replaced, this check is not required.

Machine monitor connector may be connected wrongly. Check it directly.
a Connector CM02 and CM03 can be installed even if they are exchanged.
Since both male and female parts of CM03 are green, check their colors.
If machine monitor lights up, diode (D01) is defective.
2. Disconnect connector H15 and connect T-adapter to male side.
3. Turn starting switch to OFF and ON positions and troubleshoot.
Defective starting switch (internal

failure)

and (5)
1.
2.
3.
7 Defective wiring harness
40-348

OFF position.
Resistance
Min. 1 Mz

Resistance Max. 1 z
ON position.
Turn starting switch to OFF position and disconnect ground cable.
Disconnect connector CM01 and connect T-adapter to female side.
Connect the battery ground cable, and turn the starting switch to ON position (connect ACC).
Keep machine monitor disconnected.
Voltage
20 - 30 V
Voltage
20 - 30 V
Voltage
20 - 30 V
PC800, 850-8E0

Cause

If check result on cause 7 is normal, this check is not required.
1. Turn starting switch to OFF position and disconnect ground cable.
2. Disconnect connectors B01, H15, and CM01, and connect T-adapters to
each female side.


PC800, 850-8E0
Between battery (-) and ground
Resistance
Max. 1 z
Between battery (+) and battery relay terminal R04
Resistance
Max. 1 z
Between battery relay terminal R04 and each of

B01 (female) (R) and (V)
Resistance
Max. 1 z
Between B01 (female) (W) and each of CM01

(female) (1) and (2)
Resistance
Max. 1 z
Between CM01 (female) (3), (4) and ground (T08)
Resistance
Max. 1 z
Between B01 (female) (S) and H15 (female) (1)
Resistance
Max. 1 z
Between H15 (female) (5) and CM01 (female) (14)
Resistance
Max. 1 z
If check result on cause 7 is normal, this check is not required.

1. Turn starting switch to OFF position and disconnect ground cable.
2. Disconnect No. 20 of fuse F01 and connectors H15 and CM01.
3. Connect T-adapter to female side of connectors H15 and CM01.
Between battery (+) and ground, or between battery
relay terminal R04 and ground
Between CM01 (female) (1), (2) and ground
Resistance
Min. 1 Mz
Between H15 (female) (1) and ground
Resistance
Min. 1 Mz
Between H15 (female) (5) and ground, or between

Resistance
Min. 1 Mz
If no failure is found by above checks, machine monitor is defective. (Since

40-349

Circuit diagram related to machine monitor power supply
40-350
40-350
PC800, 850-8E0

E-4 When starting switch is turned to ON position (before starting

engine), basic check monitor lights up.
40-351
1) When starting switch is turned to ON position (with engine stopped), engine oil level monitor
lights up in red.
Failure
Related information
Cause
1
Defective engine oil level switch

Perform troubleshooting for failure code [B@BAZK].
system (machine monitor system)

Failure
If cause 1 is not detected, machine monitor may be defective.

2) Radiator coolant level monitor lights up in red.
Related information
Cause
Low radiator coolant level

(When system works properly)
Coolant level may be low. Check coolant level and add coolant if necessary.
Radiator sub tank coolant level

switch system
Perform troubleshooting for failure code [B@BCZK].
PC800, 850-8E0
40-351

E-5 Precaution item lights up while engine is running

Failure
1) Charge level monitor lights up in red while engine is running
Related information
Condition of generation signal of alternator can be checked with monitoring function.

(Code: 04300 Charge voltage)
Cause
1 Defective alternator system
Failure
Signal voltage of fuel sensor can be checked with monitoring function.

(Code: 04200 Fuel sensor voltage)
Cause
Low fuel level

2 Defective fuel level gauge system
Failure
If cause 1 is not cause for trouble, fuel level gauge system may be defective.
Perform troubleshooting for "E-8 Fuel level gauge does not display properly".
Condition of air cleaner clogging switch signal can be checked with monitoring function.
Cause
Clogging of air cleaner
Defective air cleaner clogging
2
switch system
40-352
Fuel level may be low. Check it and add fuel if necessary.
3) Air cleaner clogging monitor lights up in red
Related information
Perform troubleshooting for failure code [AB00KE].
2) Fuel level monitor lights up in red
Related information
40-352

Air cleaner may be clogged. Check it, then clean or replace if necessary.
Perform troubleshooting for failure code [AA10NX].
PC800, 850-8E0

Failure
4) Engine coolant temperature monitor lights up in white.

q
Related information
Signal of engine coolant temperature sensor is input to engine controller and then data is
transmitted to machine monitor through CAN communication system.
Cause
If monitor lights up in white, engine coolant temperature may be low (below

approximately 30 C). Warm up engine.
q Lighting up in white: Engine coolant temperature is low.
q Lighting up in blue: Engine coolant temperature is proper.
If cause 1 is not cause for the trouble, engine coolant temperature gauge sysDefective engine coolant temperatem may be defective. Perform troubleshooting for "E-7 Engine coolant tem2
ture gauge system
perature gauge does not display properly".
Insufficient warm-up of machine

1
Failure
5) Hydraulic oil temperature monitor lights up in white.

q
Related information
Signal of hydraulic oil temperature sensor is input to pump controller and then data is transmitted to machine monitor through CAN communication system.
Hydraulic oil temperature can be checked with monitoring function
Cause
If monitor lights up in white, hydraulic oil temperature may be low (below

approximately 20 C). Warm up engine.
q Lighting up in white: Hydraulic oil temperature is low.
q Lighting up in blue: Hydraulic oil temperature is proper.
If cause 1 is not cause for trouble, hydraulic oil temperature gauge system
Defective hydraulic oil temperature
2
may be defective. Perform troubleshooting for "E-9 hydraulic oil temperature
gauge system
gauge does not display properly".
Insufficient warm-up of machine

1
PC800, 850-8E0
40-353

E-6 Emergency stop item lights up while engine is running

Failure
1) Engine coolant temperature monitor lights up in red.

q
Related information
Signal voltage of engine coolant temperature sensor is input to engine controller and then
data is transmitted to machine monitor through CAN communication system.
Cause
1
40-354
Overheating of engine coolant

(when system works properly)
Engine coolant may overheat. Check it and remove cause if it overheats.
If cause 1 is not cause for trouble, engine coolant temperature sensor system
Defective engine coolant temperamay be defective. Perform troubleshooting for failure codes [CA144] and
ture sensor system
[CA145].
If causes 1 2 are not cause for trouble, machine monitor may be defective
Failure
2) Engine oil pressure monitor lights up in red

q
Related information
q
q
Signal of engine oil pressure sensor is input to engine controller and then the data is transmitted to machine monitor through CAN communication system.
Engine oil pressure can be checked with monitoring function.
(Code: 37200 Engine Oil Pressure Sensor)
Cause
Low of engine oil pressure

Defective engine oil pressure sys- If cause 1 is not cause for trouble, engine oil pressure switch system may be
tem
defective. Perform troubleshooting for failure codes [CA135] and [CA141].
Failure
Check engine oil pressure as low engine oil pressure is detected.

Perform troubleshooting "S-12 (Oil pressure decreases)".
If causes 1 - 2 are not cause for trouble, machine monitor may be defective
3) Hydraulic oil temperature monitor lights up in red
Related information
q
q

Cause
Hydraulic oil may be overheating. Check it and remove cause if it is overheating.

If cause 1 is not cause for trouble, hydraulic oil temperature sensor system or
2
machine monitor may be defective. Perform troubleshooting for "E-9 Hydraulic
gauge system or machine monitor
oil temperature gauge does not indicate properly".
1
Overheating of hydraulic oil

40-354
PC800, 850-8E0

E-7 Engine coolant temperature gauge does not indicate properly
E-7 Engine coolant temperature gauge does not indicate properly
40-35
1) While engine coolant temperature is rising properly, temperature gauge does not rise from
white range (C).
Failure
2) While engine coolant temperature is stabilized properly, temperature gauge rises to red range
(H).
q Signal voltage of engine coolant temperature sensor is input to engine controller and then
Related information
q Engine coolant temperature can be checked by using monitoring function.
Cause
1
Defective engine coolant tempera- Engine coolant temperature sensor system may be defective. Perform troubleture sensor system
shooting for failure codes [CA144] and [CA145].
If cause 1 is not cause for trouble, machine monitor may be defective.

3) Indication of the coolant temperature gauge is different from actual engine coolant temperature.
Failure
4) Indication of engine coolant temperature gauge is different from display of engine coolant
temperature monitor.
q Signal voltage of engine coolant temperature sensor is input to engine controller and then
Related information
q Engine coolant temperature can be checked by using monitoring function.
Cause

a Turn starting switch to ON position or start engine and perform troubleshooting.
Coolant temperature
Coolant temperature
Color of monitor light (a)
level
105 C
102 C
100 C
85 C
60 C
30 C
Red
Blue
White
Engine coolant temperature gauge and coolant

40-35
temperature monitor
PC800, 850-8E0
40-355

E-8 Fuel gauge does not indicate properly
40-356
1) While fuel is added, fuel level gauge indicator does not rise from red range (E).
2) While fuel level is low, fuel level gauge indicator does not lower from green range top (F).
Failure
Related information

Cause

Defective fuel level sensor 2. Disconnect connector P21 and connect T-adapter to male side.
1 (open or short circuit in interFuel level: FULL
Between P21 (male) (1)
nal wiring)
and ground
Fuel level: EMPTY
Open or short circuit in wiring harness

3
contact of connector)

2. Disconnect connector CM01 and connect T-adapter to female side.
Between CM01 (female)
(9) and ground
Fuel level: FULL

Fuel level: EMPTY
Resistance
85 - 110 z
a If check result on cause 2 is normal, this check is not required.

2. Disconnect connectors CM01 and P21, and connect T-adapters to each female
side.
Between CM01 (female) (9) and P21 (female) (1)
Resistance
Max. 1 z

Ground fault in wiring har2. Disconnect connectors CM01 and P21, and connect T-adapters to either female
4 ness
side.
(contact with ground circuit) Between CM01 (female) (9) and ground, or between
P21 (female) (1) and ground
Hot short circuit in wiring
3. Insert T-adapter between male and female sides of connector CM01 or connect
5 harness
T-adapter to female side of connector P21.
Between CM01 (9) and ground, or between P21
Voltage
Approx. 3.3 V
If no failure is found by above checks, machine monitor is defective. (Since this is an
internal failure, troubleshooting cannot be performed.)
Circuit diagram related to fuel level sensor
40-356
40-356
PC800, 850-8E0

3) Indication of fuel level gauge is different from actual fuel level.

4) Indication of fuel level gauge is different from display of fuel level monitor.
Failure
Related information

Cause

Fuel level
598 l
440 l
291 l
170 l
125 l
106 l
Fuel level gauge and fuel level monitor
PC800, 850-8E0
Reading of fuel level gauge Color of monitor light (a)
Off
Red
40-357
40-357

E-9 Hydraulic oil temperature gauge does not indicate properly
40-358
1) While hydraulic oil temperature is rising properdy, temperature gauge does not rise from white
range (C).
2) While hydraulic oil temperature is stabilized properly, temperature gauge rises to red range
(H).
Failure
Related information
Signal of hydraulic oil temperature sensor is input to pump controller and then data is transmitted to machine monitor through CAN communication system.
Cause

See the next page.

sensor
2
a Temperature characteristics of oil
temperature sensor
wiring)
10 C
Resistance Approx. 90 kz
30 C
Resistance Approx. 35 kz
80 C
Resistance Approx. 6.5 kz
100 C
Resistance Approx. 3.5 kz

Resistance
Min. 1 Mz

3
Open circuit or ground fault in wir- Between CP01 (female) (29) and (46)
a Resistance accords with value on temperature Resistance
ing harness
characteristics table in cause 2.



40-358
Resistance
3.5 - 90 kz
Min. 1 Mz
a If no failure is found in checks on cause 3, this check is not required.

female side.
Between CP01 (female) (29) and P22 (female) (2) Resistance
Max. 1 z
Between CP01 (female) (46) and P22 (female) (1) Resistance
Max. 1 z

2. Disconnect connectors CP01 and P22, and connect T-adapter to either
female side.
Between CP01 (female) (29) and gound, or
Resistance
Min. 1 Mz
3. Insert T-adapter between male and female sides of connector CP01 or
connect T-adapter to female side of connector P22.
Between CP01 (29) or P22 (female) (2) and
Voltage
Approx. 5 V
ground
If no failure is found by above checks, pump controller is defective. (Since this
PC800, 850-8E0

Circuit diagram related to hydraulic oil temperature sensor
40-359
3) Indication of hydraulic oil temperature gauge is different from actual hydraulic oil temperature.
4) Indication of hydraulic oil temperature gauge is different from display of hydraulic oil
temperature monitor.
q Signal of hydraulic oil temperature sensor is input to pump controller and then data is transmitted to machine monitor through CAN communication system.
Related information
q Hydraulic oil temperature can be checked with monitoring function
Failure
Cause

Hydraulic oil temperaHydraulic oil temperature
Color of monitor light (a)
ture level
105 C
102 C
100 C
85 C
40 C
20 C
Red
Blue
White
Hydraulic oil temperature gauge and hydraulic

40-359
oil temperature monitor
PC800, 850-8E0
40-359

E-10 Displays on machine monitor are different from those for actual machine
E-10 Displays on machine monitor are different from those for actual
machine
q
Failure
40-360
Displays on machine monitor are different from those for applicable model.
Related information
Cause

a Turn starting switch to ON position and perform troubleshooting (with monitoring function).
1 Defective model code signal
Monitoring code
Correct display
00200 Controller model code
PC800
If display on monitor is incorrect, perform troubleshooting for failure code

[DA29KQ].
If no failure is found in check on cause 1, machine monitor is defective. (Since

E-11 Some areas of machine monitor screen are not displayed

Failure
Related information
Machine monitor does not display some items
LCD panel may have black pixels (that do not light up) or bright pixels (that stay on). If number
of the bright pixels and black pixels do not exceed ten, it does not indicate a failure or a defect.
Cause
40-360

a Turn starting switch to ON position and perform troubleshooting.
Defective machine monitor

(LCD panel)
When following switches are operated, if whole LCD panel is lighted up (whole
surface becomes white), LCD panel has no failure.
q Operation of switches: [4] and [F2] (Press simultaneously)

(body)
If no failure is found in check on cause 1, machine monitor may be defective.

E-12 Function switch does not operate

Failure
Related information
Function switch does not work.
Condition of signal of function switch can be checked with the monitoring function.
(Code: 04503 Monitor function switch)
Cause
40-360
40-360

Machine monitor may be defective. (Since this is an internal failure, troubleshooting cannot be performed.)
PC800, 850-8E0

E-13 Automatic warm-up system does not operate (in cold season)
E-13 Automatic warm-up system does not operate (in cold season)
Failure
Related information
40-361
Automatic warm-up system does not operate (in cold weather).
Automatic warm-up function increases engine speed to 1,200 rpm when engine coolant temperature is below 30 C.
With starting switch at ON position or after engine is started, if fuel control dial is kept at 70%
of full open range or more for 3 seconds, automatic warm-up operation is canceled.
If engine coolant temperature is below 10 C, turbocharger protection function operates to
keep engine speed below 1,000 rpm for up to 5 seconds after engine is started.
q
q
Cause

Engine coolant temperaCoolant temperature
Monitoring code
ture
gauge level
04107
Defective engine coolant temperaEngine coolant temperature signal system
ture
105 C
6 (a: Red)
102 C
5 (a: Red)
100 C
4 (a: Blue)
85 C
3 (a: Blue)
60 C
2 (a: Blue)
30 C
1 (a: White)
If engine coolant temperature does not match with coolant temperature gauge
level, perform troubleshooting for "E-7 Engine coolant temperature gauge
does not indiate correctly".
If no failure is found in cause 1, engine controller is defective. (Since this is an
Engine coolant temperature gauge and engine

40-361
coolant temperature monitor
PC800, 850-8E0
40-361

E-14 Auto-decelerator does not operate properly
E-14 Auto-decelerator does not operate properly
40-362
1) When auto-decelerator switch is operated, auto-decelerator monitor does not light up or does
not go off.
q Condition of signal of auto-decelerator switch can be checked with monitoring function.
Related information
(Code: 04504 Monitor 1st, 2nd line switches)
Failure
Cause

Failure
2) Auto-decelerator is not operated or canceled with lever.

q
Related information
q
Since set speed of auto-decelerator is 1,400 rpm, it is not operated or canceled if fuel control
dial is set below this speed.
Auto-deceleration does not function in arm crane mode (L) for machines with arm crane.
Cause

a Start engine and perform troubleshooting (with monitoring function).
Monitoring code
Item
Correct display
Swing
Right travel
01900
Pressure switch 1
Boom LOWER
Boom RAISE
When lever is operated:

ON
When lever is in neutral:
OFF
Arm IN
1 Defective PPC oil pressure signal
Arm OUT
Bucket CURL
01901
Pressure Switch 2
Bucket DUMP
Service

ON
OFF
Left travel

40-362
If display of monitor is incorrect, perform troubleshooting for "E-26 to 35 Monitoring function does not display *** properly".
If no failure is found in checks on cause 1 and 2, pump controller may be
defective (Since this is an internal failure, troubleshooting cannot be performed.)
If no failure is found in checks on cause 1 to 3, engine controller may be defective. (Since this is an internal failure, troubleshooting cannot be performed.)
PC800, 850-8E0

E-15 Working mode does not change

Failure
40-363
1) When working mode switch is operated, working mode selection screen is not displayed.
Related information
Condition of signal of working mode switch can be checked with monitoring function.
Cause
Failure

2) When working mode is changed, setting of engine and hydraulic pump is not changed.
Related information
Cause
Pump controller may be defective. (Since this is an internal failure, troubleshooting cannot be performed.)
PC800, 850-8E0
40-363

E-16 Travel speed does not change

Failure
1) When travel speed switch is operated, travel speed monitor does not change.
Related information
Condition of signal of travel speed switch can be checked with monitoring function.
Cause
Failure
2) When travel speed selection is changed, actual travel speed does not change.
q
Related information
If cause 1 occurs, actual travel speed does not lower when travel speed selection is changed
to Lo.
As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be
Cause


2. Disconnect connector V04 and connect T-adapter to female side.

Voltage
Max. 1 V

If no failure is found in checks on cause 1 and 2, pump controller may be
defective (Since this is an internal failure, troubleshooting cannot be performed.)
Circuit diagram related to travel speed solenoid
40-364
40-364
40-364
PC800, 850-8E0

E-17 Alarm buzzer cannot be canceled

Failure
Related information
40-365
Alarm buzzer cannot be canceled
Condition of signal of alarm buzzer cancel switch can be checked with monitoring function.
Cause
E-18 When starting switch is turned OFF, service meter is not displayed40-365
Failure
When starting switch is turned OFF, service meter is not displayed.
While starting switch is at OFF position, if following switches are operated, service meter is
displayed at top center of screen.
Operation of switches: [4] and [1] (Press simultaneously)
Related information
Cause
Defective backup power supply

1
system
When starting switch is turned to ON position, if machine monitor displays

nothing, backup power supply system may be defective. In this case, perform
troubleshooting for "E-3 When starting switch is turned to ON position,
machine monitor displays nothing".

E-19 Service mode cannot be selected

Failure
Related information
Machine monitor cannot be set in service mode
Following switch operation sets machine monitor in service mode.

Switch operation: [4] and [1] o [2] o [3] (While pressing [4], press [1], [2], and [3] in order)
Cause
PC800, 850-8E0
40-365

40-365

E-20 Any of work equipment, swing and travel do not operate or cannot be locked
E-20 Any of work equipment, swing and travel do not operate or cannot
be locked
40-36
Failure
1) All of work equipments, swing, and travel mechanism do not move.
Related information
Cause
1 Defective fuse No. 3
Defective PPC lock switch


If fuse is blown, circuit may have ground fault. (See cause 7.)
3. Operate lock lever and perform troubleshooting.
Free
Resistance
Max. 1 z
LOCK
Resistance
Min. 1 Mz
Between S14 (male) (1) and (2)
Defective PPC lock solenoid

wiring, or ground fault)

(internal ground fault)

Resistance
20 - 60 z
Between V01 (male) (1) and ground
Resistance
Min. 1 Mz

a Check the continuity by using multimeter in diode range.
Continuity
No continuity

2. Remove fuse No. 3.
Open or short circuit in wiring har5
3. Set PPC lock switch to FREE position.
ness
Between fuse F01-3 and ground
a Resistance of PPC lock solenoid
a If cause 5 is not cause for trouble, this check is not required.
3. Disconnect connectors S14 and V01 and connect T-adapters to each
female side.
Resistance Max. 1 z

Between V01 (female) (2) and S14 (male) (2)
Resistance
Max. 1 z
Between fuse F01-3 and S14 (male) (1)
Resistance
Max. 1 z
a
1.
2.
3.
If cause 4 is not cause for trouble, this check is not required.

Remove fuse No. 3.
Disconnect connectors S14, D01, and V01 and then connect T-adapter to
male side of S14 or female side of V01.
Between V01 (female) (2) and ground, or between
S14 (male) (2) and ground
Between S14 (male) (1) and ground
40-366
Resistance
Min. 1 Mz
PC800, 850-8E0

E-20 Any of work equipment, swing and travel do not operate or cannot be locked
Failure
2) All of work equipment, swing, and travel mechanism do not lock.
Related information
Cause
Defective lock lever switch
1 (short circuit in internal wiring)

Lock lever: LOCK
Resistance
Min. 1 Mz
Lock lever: FREE
Resistance
Max. 1 z

Hot short circuit in wiring har- 2. Disconnect connector V01 and connect T-adapter to female side.
2 ness
4. Turn lock lever to LOCK position.
Voltage
Max. 1 V

and (2)
Circuit diagram related to PPC lock solenoid
PC800, 850-8E0
40-367
40-367

E-21 Machine push-up function does not operate or cannot be canceled
E-21 Machine push-up function does not operate or cannot be canceled40-368

1) Machine push-up function cannot be canceled.
q 2-stage safety solenoid is not energized.
Related informa- q If normal, 2-stage safety solenoid is energized when machine push-up switch is set to low pressure.
tion
Failure
Cause
Defective machine push-up

2 switch (open circuit in internal wiring)

2. Disconnect S05 and connect T-adapter to female side.
3. Turn switch to OFF and ON position and perform troubleshooting.
High pressure (Switch
Between S05 (female) (5)
OFF)
and (6)
Low pressure (Switch ON) Resistance
Max. 1 z

Defective 2-stage safety
solenoid
3
(open or short circuit in inter- Between V06 (male) (2) and (1)
Resistance
nal wiring, or ground fault)
Resistance

Min. 1 Mz

2. Remove diode array D03 and connect T-adapter.
Continuity
Between D03 (male) (1) (-) and (5) (+)
No continuity

3. Turn machine push-up switch to lower pressure (ON) position and perform troubleshooting.
a Resistance of 2-stage safety solenoid coil
Between F01-2 and ground

6
20 - 60 z
Resistance
20 - 60 z

2. Disconnect connectors S05, V06, and D03, and connect T-adapters to female
side of V06 and to male side of S05.
Between F01-2 and S05 (male) (5)
Resistance
Max. 1 z
Between S05 (male) (6) and V06 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
a
1.
2.
3.
If the fuse is not blown, this check is not required.

Remove fuse No. 2.
Disconnect connectors S05, V06, and D03, and connect T-adapter to male side
Ground fault in wiring harof S05 or female side of V06 or D03.
7 ness
Between
F01-2 and ground, or between S05 (female)
(5) and ground
Between ground and S05 (male) (6) or V06 (female) (2)
or D03 (female) (1)
40-368
Resistance
Min. 1 Mz
PC800, 850-8E0

E-21 Machine push-up function does not operate or cannot be canceled
2) Machine push-up function does not operate

q 2-stage safety solenoid is kept energized.
Failure
Related information
Cause
If normal, 2-stage safety solenoid is de-energized when machine push-up switch is set to high
pressure.

2. Disconnect S05 and connect T-adapter to male side.
3. Turn machine push-up switch to OFF and ON positions and perform trouDefective machine push-up switch
bleshooting.
1
(short circuit in internal wiring)
High pressure (Switch
OFF)
Low pressure (Switch
and (6)
Resistance Max. 1 z
ON)
2. Disconnect connectors D03 and V06, and connect T-adapters to either
female side.
Hot short in wiring harness ( con- 3. Turn starting switch to ON position.
2
tact with 24 V circuit)
a Machine push-up switch OFF (High pressure)
Between V06 (female) (2) and ground, or between
Voltage
Max. 1 V
D03 (female) (1) and ground
Circuit diagram related to machine push-up switch
PC800, 850-8E0
40-369
40-369

E-22 Boom shockless function does not operate properly
40-370
1) Boom shockless function cannot be canceled.

q Boom shockless solenoid is not energized.
Related informa- q If normal, boom shockless solenoid is energized when boom shockless switch is turned to OFF
position.
tion
Failure
Cause


Defective boom shockless 2. Disconnect connector S06 and connect T-adapter to each female side.
2 control switch (open circuit in
Switch: OFF
Resistance
Max. 1 z
Between S06 (female) (3)
internal wiring)
and (4)
Switch: ON
2. Disconnect connectors V09 and V10 and connect T-adapter to each male side.
Defective boom shockless
solenoid
3
(open or short circuit in inter- Between V09 (male) (1) and ground
nal wiring)

20 - 60 z
Resistance
Min. 1 Mz
Resistance
20 - 60 z
Resistance
Min. 1 Mz

2. Remove diode array D04 and connect T-adapter.
Continuity
Between D04 (male) (1) (-) and (5) (+)
No continuity

a Resistance of parallel coils of boom shockless solenoids V09 and V10
Between F01-2 and ground
1.
2.
3.
4.

6
Resistance
Resistance
10 30 z

Remove fuse No. 2.
Disconnect connectors V09, V10, and S06.
Connect T-adapters to female side of connectors V09 and V10 and male side of
S06.
Between F01-2 and S06 (male) (4)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
1.
2.
3.
4.

Remove fuse No. 2.
Disconnect connectors V09, V10, S06, and D04.
Connect T-adapters to male side of connector S06 and female side of V09 or
Ground fault in wiring harV10.
7 ness
(contact with ground circuit) Between F01-2 and ground, or between S06 (female)
(4) and ground
Between ground and S06 (male) (3) or V09 (female) (2)
or V10 (female) (2) or D04 (female) (1)
40-370
Resistance
Min. 1 Mz
PC800, 850-8E0

2) Boom shockless function does not operate

q Boom shockless solenoid is kept energized.
q If normal, boom shockless solenoid is de-energized when boom shockless switch is turned to
Related information
ON position.
Failure
Cause

a Be ready with starting switch OFF, then perform troubleshooting without
turning starting switch to ON position.
Defective boom shockless control

1 switch (short-circuit in internal wiring)
S06 (female)

switch
Resistance
OFF
Max. 1 z
ON
Min. 1 Mz
Between (2) and (3)
Hot short in wiring harness (contact with 24 V circuit)

2. Disconnect connectors V09, V10, and D04, and connect T-adapters to
either female side.
a Turn boom shockless control switch to ON position.
Between ground and V09 (female) (2) or V10
Voltage
Max. 1 V
(female) (2) or D04 (female) (1)
Circuit diagram related to boom shockless solenoid
PC800, 850-8E0
40-371
40-371

E-23 Swing brake does not operate properly

Failure
40-372
1) When swing brake cancel switch is set to CANCEL position, machine cannot swing.
Related information
Condition of swing lock switch signal can be checked with monitoring function.
(Pump controller system code: 02200 Switch input 1)
Cause
1 Defective No. 1 in fuse box F01

If fuse is blown out, circuit probably has ground fault. In this case, perform
Defective swing brake cancel

Swing brake cancel
2 switch (short circuit in internal wirResistance Min. 1 Mz
Between S25 (male) (13) switch: Normal
ing)
and (14)
Swing brake cancel
Resistance Max. 1 z
switch: FREE
a Swing lock switch OFF position.
Swing brake cancel
Voltage
20 - 30 V
Between V05 (female) switch: FREE
(2) and (1)
Swing brake cancel
Voltage
Max. 1 V
switch: Normal
2. Disconnect connectors V05 and S25, and connect T-adapters to each
female side.
4 (wire breakage or defective cona Swing lock switch OFF position.
tact of connector)
Between V05 (female) (2) and S25 (female) (14)
Resistance Max. 1 z

Failure
Resistance
Max. 1 z

2. Disconnect connectors S25 and V05, and connect T-adapter to female side
of V05.
Resistance
Min. 1 Mz
2) When swing brake cancel switch is set to Normal position, swing brake does not operate.
Related information
Cause

Defective swing brake cancel

Swing brake cancel
1 switch (short circuit in internal wirResistance Min. 1 Mz
switch: Normal
Between
S25
(male)
(13)
ing)
and (14)
Swing brake cancel
Resistance Max. 1 z
switch: FREE
Hot short circuit in wiring harness 3. Turn starting switch to ON position.
2
4. Turn swing lock switch to ON position.
a Measure voltage again under swing lock switch OFF position.
Voltage
Max. 1 V
40-372
PC800, 850-8E0

PC800, 850-8E0
40-373
40-373

E-24 Windshield wiper and window washer do not operate

Failure
40-374
1) When wiper switch is operated, wiper monitor does not light up or go off.
Related information
Condition of wiper switch signal can be checked with monitoring function.

Cause
Machine monitor may be defective. (Since this is an internal failure, troubleshooting

cannot be performed.)
Failure
2) When wiper switch is operated, windshield wiper does not operate.

q
Related information
Condition of window rear limit switch signal can be checked with monitoring function.
As for wiper motor, perform troubleshooting for failure codes [DY20KA], [DY20MA], [DY2DKB],
[DY2EKB], and [DY2FMA].
Cause

2. Disconnect connector S46.
Defective rear limit switch for

1 window (short circuit in interBetween S46 (male) (1)
nal wiring)
and (2)

2 (open circuit in internal wiring)

3
Front window: when closed Resistance
Min. 1 Mz
Front window: when pulled

up
Max. 1 z

Failure
Continuity
a Wiper motor system

See troubleshooting for [DY20KA], [DY20MA], [DY2DKB], [DY2EKB], and
[DY2FMA].
a Wiper limit switch system
3. Front window: when pulled up
Ground fault in wiring har4 ness

Resistance
Resistance
Max. 1 z

3. Front window: when closed
Resistance
Min. 1 Mz
If no failure is found by above checks, pump controller is defective. (Since this is an

3) When window washer switch is operated, window washer does not operate.
Related information
q
q
Condition of window washer switch signal can be checked with monitoring function.
As for window washer, perform troubleshooting for failure codes [DY2CKA] and [DY2CKB].
Cause
Machine monitor may be defective. (Since this is an internal failure, troubleshooting

cannot be performed.)
40-374
PC800, 850-8E0

Circuit diagram related to wiper motor (Double wiper specification)
PC800, 850-8E0
40-375
40-375

Circuit diagram related to wiper motor (Single wiper specification)
40-376
40-376
PC800, 850-8E0

PC800, 850-8E0
40-377

E-25 Travel alarm does not sound or does not stop sounding
Failure
40-378
1) Alarm does not sound during travel.
Related information
Output to travel alarm can be checked with monitoring function.

Cause

a Be ready with starting switch OFF, then start engine and perform troubleshooting.
Monitoring code
1 Defective travel signal
Defective travel alarm

2
(internal defect)


Failure
Item
Correct display

01901
ON
Left travel
Pressure Switch 2
OFF
01900
ON
Right travel
Pressure Switch 2
OFF
If display of monitor is properly, perform troubleshooting for "E-26 to 35 Monitoring function does not display *** properly".
Continuity

2. Disconnect connectors M14 and CP02, and connect T-adapters to each
female side.
Between CP02 (female) (107) and M14 (female) (1) Resistance
Max. 1 z
Max. 1 z
Resistance

2. Disconnect connectors CP02 and M14, and connect T-adapters to either
female side.
between M14 (female) (1) and ground
2) Alarm does not stop sounding while machine is stopped.
Related information
Cause
1

40-378
Voltage
Max. 1 V
PC800, 850-8E0

Circuit diagram related to travel alarm
PC800, 850-8E0
40-379
40-379

E-26 Boom RAISE indicator is not displayed properly with monitoring function
E-26 Boom RAISE indicator is not displayed properly with monitoring

function
40-380
Failure
"Boom RAISE" is not displayed properly by monitoring function.

q
Related information
q
q
Monitoring code: 01900 Pressure switch 1

Use "short connector" 799-601-7230 for 2-pin X connector in test for Cause 6.
As pump controller connector uses "socket-type box" T-adapter, operating voltage cannot be
Cause

3. Start engine
Defective boom RAISE PPC
4. Operate R.H. work equipment control lever and perform troubleshooting.
oil pressure switch (open or
1
R.H. work equipment conshort circuit in internal wirResistance Min. 1 Mz
Between P06 (male) (1) trol lever: NEUTRAL
ing)
and (2)
R.H. work equipment conResistance
Max. 1 z
trol lever: Boom RAISE
2. Insert T-adapter in connector P06.
3. Start engine
Defective harness or pump
2
R.H. work equipment concontroller
Voltage
Approx. 7 V
trol lever: NEUTRAL
R.H. work equipment conVoltage
Max. 1 V
trol lever: Boom RAISE
Open circuit in wiring har2. Disconnect connectors CP01 and P06, and connect T-adapters to each female
ness
side.
3
Between
CP01 (female) (53) and P06 (female) (2)
Resistance
Max. 1 z
Between P06 (female) (1) and ground (T04)
Resistance
Max. 1 z

Ground fault in wiring har2. Disconnect connectors CP01 and P06, and connect T-adapters to either female
4 ness
side.
Between CP01 (female) (53) and ground, or between
5 harness
Voltage
Approx. 7 V
40-380

3. Connect "short connector" to male side of T-adapter.
If voltage between P06 (2) and (1) is below 1 V but "OFF" is displayed for "Boom
RAISE" , pump controller is defective.
PC800, 850-8E0

E-26 Boom RAISE indicator is not displayed properly with monitoring function
Boom RAISE PPC oil pressure switch
PC800, 850-8E0
40-381
40-381

E-27 Boom LOWER indicator is not displayed properly with monitoring function
E-27 Boom LOWER indicator is not displayed properly with monitoring

function
40-382
Failure
"Boom LOWER" is not displayed properly by monitoring function.

q
Related information
q
q

Cause
Defective boom LOWER PPC

1 pressure switch (open or short circuit in internal wiring)
Defective harness or pump controller




1.
2.
3.
4.

Disconnect connector P02 and connect T-adapter to male side.
Start engine
Operate R.H. work equipment control lever and perform troubleshooting.
R.H. work equipment

control lever: NEUTRAL
R.H. work equipment
and (2)
control lever: Boom
Resistance Max. 1 z
LOWER
3. Start engine
R.H. work equipment
Voltage
Approx. 7 V
Between P02 (2) and (1) R.H. work equipment
control lever: Boom
Voltage
Max. 1 V
LOWER
female side.
Resistance
Max. 1 z
Resistance
Max. 1 z

female side.
a
1.
2.
3.
If no failure is found in checks on cause 2, this check is not required.

40-382
Voltage
Approx. 7 V

If voltage between P02 (2) and (1) is below 1 V but "Boom LOWER" is displayed "OFF", pump controller is defective.
a After finishing test, restore connector.
PC800, 850-8E0

E-27 Boom LOWER indicator is not displayed properly with monitoring function
Boom LOWER PPC oil pressure switch
PC800, 850-8E0
40-383
40-383

E-28 Arm IN indicator is not displayed properly with monitoring function
E-28 Arm IN indicator is not displayed properly with monitoring function40-384

Failure
"Arm IN" is not displayed properly with monitoring function

q
Related information
q
q

Cause

3. Start engine
Defective arm IN PPC oil pressure
4. Operate L.H. work equipment control lever and perform troubleshooting.
1 switch (open or short circuit in
L.H. work equipment
internal wiring)
Between P04 (male) (1) control lever: NEUTRAL
L.H. work equipment
and (2)
Resistance Max. 1 z
control lever: Arm IN
2. Insert T-adapter into connector P04
3. Start engine
4. Operate L.H. work equipment control lever and perform troubleshooting.
Defective harness or pump con2
L.H. work equipment
troller
Voltage
Approx. 7 V
L.H. work equipment
Voltage
Max. 1 V
control lever: Arm IN
female side.
Between CP01 (female) (17) and P04 (female) (2) Resistance Max. 1 z


Max. 1 z

female side.
a
1.
2.
3.

Resistance
1.
2.
3.
4.
Voltage
Approx. 7 V

Connect "short connector" to male side of T-adapter.
If voltage between P04 (2) and (1) is below 1 V but "OFF" is displayed for "Arm
IN", pump controller is defective.
40-384
PC800, 850-8E0

E-28 Arm IN indicator is not displayed properly with monitoring function
Circuit diagram related to arm IN PPC oil pressure switch
PC800, 850-8E0
40-385
40-385

E-29 Arm OUT indicator is not displayed properly with monitoring function
E-29 Arm OUT indicator is not displayed properly with monitoring

function
Failure
40-386
"Arm OUT" is not displayed properly with monitoring function.

q
Related information
q
q

Cause

3. Start engine
Defective Arm OUT PPC oil pres- 4. Operate L.H. work equipment control lever and perform troubleshooting.
1 sure switch (open or short circuit in
L.H. work equipment
internal wiring)
Between P08 (male) (1) control lever: NEUTRAL
and (2)
L.H. work equipment
Resistance Max. 1 z
control lever: Arm OUT
1.
2.
3.
4.

Insert T-adapter into connector P08.
Start engine
Operate L.H. work equipment control lever and perform troubleshooting.



L.H. work equipment

Approx. 7 V
L.H. work equipment

Voltage
Max. 1 V
control lever: Arm OUT
female side.
Resistance
Max. 1 z
Resistance
Max. 1 z

female side.
a
1.
2.
3.

Voltage
1.
2.
3.
4.
Voltage
Approx. 7 V

If voltage between P08 (2) and (1) is below 1 V but "OFF" is displayed for "Arm
OUT", pump controller is defective.
40-386
PC800, 850-8E0

E-29 Arm OUT indicator is not displayed properly with monitoring function
Circuit diagram related to arm OUT PPC oil pressure switch
PC800, 850-8E0
40-387
40-387

E-30 Bucket CURL indicator is not displayed properly with monitoring function
E-30 Bucket CURL indicator is not displayed properly with monitoring

function
40-38
Failure
"Bucket CURL" is not displayed properly with monitoring function.

q
Related information
q
q

Cause
Defective bucket CURL PPC oil





1.
2.
3.
4.

Start engine
R.H. work equipment

R.H. work equipment
and (2)
control lever: Bucket
Resistance Max. 1 z
CURL
3. Start engine
R.H. work equipment
Voltage
Approx. 7 V
Voltage
Max. 1 V
CURL
2. Disconnect connectors CP01 and P01 and connect T-adapters to each
female side.
Resistance
Max. 1 z
Resistance
Max. 1 z

female side.
a
1.
2.
3.

1.
2.
3.
4.
Voltage
Approx. 7 V

If voltage between P01 (2) and (1) is below 1 V but "OFF" is displayed for
"Bucket CURL" , pump controller is defective.
40-388
PC800, 850-8E0

E-30 Bucket CURL indicator is not displayed properly with monitoring function
Circuit diagram related to bucket CURL PPC oil pressure switch
PC800, 850-8E0
40-389
40-389

E-31 Bucket DUMP indicator is not displayed properly with monitoring function
E-31 Bucket DUMP indicator is not displayed properly with monitoring

function
40-390
Failure
"Bucket DUMP" is not displayed properly with monitoring function.

q
Related information
q
q

As pump controller connector uses a "socket-type box" T-adapter, operating voltage cannot
be measured at pump controller connector.
Cause
Defective bucket DUMP PPC oil





1.
2.
3.
4.

Start engine
R.H. work equipment

R.H. work equipment
and (2)
control lever: Bucke
Resistance Max. 1 z
DUMP
3. Start engine
R.H. work equipment
Voltage
Approx. 7 V
Voltage
Max. 1 V
DUMP
female side.
Resistance
Max. 1 z
Resistance
Max. 1 z

female side.
a
1.
2.
3.

1.
2.
3.
4.
Voltage
Approx. 7 V

"Bucket DUMP", pump controller is defective.
40-390
PC800, 850-8E0

E-31 Bucket DUMP indicator is not displayed properly with monitoring function
Circuit diagram related to bucket DUMP PPC oil pressure switch
PC800, 850-8E0
40-391
40-391

E-32 Swing indicator is not displayed properly with monitoring function
E-32 Swing indicator is not displayed properly with monitoring function40-392

Failure
"Swing" is not displayed properly with monitoring function.

q
Related information
q
q

Cause

3. Start engine
Defective swing LEFT PPC oil
1 pressure switch (open or short cir- 4. Operate control lever and troubleshoot.
Control levers: NEUcuit in internal wiring)
Between P03 (male) (1) TRAL
and (2)
Control lever: Left swing Resistance Max. 1 z
3. Start engine
Defective swing right PPC oil pres4. Operate control lever and troubleshoot.
2 sure switch (wire breakage or
Control levers: NEUshort circuit in internal wiring)
Control lever: Right
and (2)
Resistance Max. 1 z
swing
3. Start engine
4. Operate control lever and troubleshoot.
Defective harness or pump conControl levers: NEU3
Voltage
Approx. 7 V
troller
Between P03 (2) and (1) TRAL



40-392
Voltage
Max. 1 V
or between P07 (2) and Control lever: Left swing
(1)
Control lever: Right
Voltage
Max. 1 V
swing
2. Disconnect connectors CP01, P03, and P07, and connect T-adapters to
each female side.
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z

2. Disconnect connectors CP01, P03 and P07, and connect T-adapters to
either female side.
Between ground and CP01 (female) (16) or P03
(female) (2) or P07 (female) (2)
2. Disconnect connectors P03 and P07 and connect T-adapters to either
female side.
Between P03 (female) (2) and ground, or between
Voltage
Approx. 7 V
PC800, 850-8E0

E-32 Swing indicator is not displayed properly with monitoring function
Cause

2. Disconnect connectors P03 and P07 and connect T-adapters to either
female side.
5. Return to Step 1 and troubleshoot the other connector.
"Swing", pump controller is defective.
"Swing", pump controller is defective.
Circuit diagram related to swing PPC oil pressure switch
PC800, 850-8E0
40-393
40-393

E-33 "L.H. travel" is not displayed properly with monitoring function

Failure
40-394
"L.H. travel" is not displayed properly with monitoring function.

q
Related information
q
q

Cause

a Extend tester probe and measure inside cab.
Defective L.H. travel forward PPC 3. Start engine
1 oil pressure switch (open or short 4. Operate L.H. travel lever and perform troubleshooting.
circuit in internal wiring)
L.H. travel lever: NEUResistance Min. 1 Mz
and (2)
L.H. travel lever: Forward Resistance Max. 1 z
Defective L.H. travel reverse PPC
3. Start engine
oil pressure switch
2
4. Operate L.H. travel lever and perform troubleshooting.
L.H. travel lever: NEUwiring)
and (2)
L.H. travel lever: Reverse Resistance Max. 1 z



40-394

2. Insert T-adapter into connector P09 or P10.
3. Start engine
4. Operate L.H. travel lever and perform troubleshooting.
L.H. travel lever: NEUVoltage
Between P09 (2) and (1) TRAL
or between P10 (2) and L.H. travel lever: Forward Voltage
(1)
L.H. travel lever: Reverse Voltage
Approx. 7 V
Max. 1 V
Max. 1 V

each female side.
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z

either female side.
2. Disconnect connectors P09 and P10, and connect T-adapters to either
female side.
Between P09 (female) (2) and ground, or between
Voltage
Approx. 7 V
PC800, 850-8E0

Cause

2. Disconnect connectors P09 and P10, and connect T-adapters to either
female side.
If voltage between P10 (2) and (1) is below 1 V but "OFF" is displayed for "L.H.
travel", pump controller is defective.
If voltage between P09 (2) and (1) is below 1 V but "OFF" is displayed for "L.H.
Circuit diagram related to L.H. travel PPC oil pressure switch
PC800, 850-8E0
40-395
40-395

E-34 "R.H. travel" is not displayed properly with monitoring function

Failure
"R.H. travel" is not displayed properly with monitoring function.

q
Related information
q
q

Cause

Defective R.H. travel forward
3. Start engine
PPC oil pressure switch
1
(open or short circuit in inter- 4. Operate R.H. travel lever and perform troubleshooting.
R.H. travel lever: NEUnal wiring)
Resistance
and (2)
R.H. travel lever: Forward Resistance
Defective R.H. travel reverse
3. Start engine
PPC oil pressure switch
2
(open or short circuit in inter- 4. Operate R.H. travel lever and perform troubleshooting.
R.H. travel lever: NEUnal wiring)
Resistance
TRAL
and (2)
R.H. travel lever: Reverse Resistance
40-396
Defective harness or pump

controller

2. Insert T-adapter into connector P11 or P12.
3. Start engine
4. Operate R.H. travel lever and perform troubleshooting.
R.H. travel lever: NEUVoltage
TRAL
Between P11 (2) and (1) or
Voltage
between P12 (2) and (1) R.H. travel lever: Forward
R.H. travel lever: Reverse

4
Min. 1 Mz
Max. 1 z
Min. 1 Mz
Max. 1 z
Approx. 7 V
Max. 1 V
Voltage
Max. 1 V

2. Disconnect connectors CP01, P11, and P12, and connect T-adapters to each
female side.
Between CP01 (female) (55) and P11 or P12 (female)
Resistance
Max. 1 z
(2)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z

Ground fault in wiring har2. Disconnect connectors CP01, P11, and P12, and connect T-adapters to either
5 ness
female side.
2. Disconnect connectors P11 and P12, and connect T-adapters to either female
side.
6 harness
3.
Turn
starting switch to ON position.
Between P11 (female) (2) and ground, or between P12
Voltage
Approx. 7 V
40-396
PC800, 850-8E0

Cause

2. Disconnect connectors P11 and P12, and connect T-adapters to either female
side.
If voltage between P11 (2) and (1) is below 1 V but "OFF" is displayed for "R.H.
If voltage between P12 (2) and (1) is below 1 V but "OFF" is displayed for "R.H.
Circuit diagram related to R.H. travel PPC oil pressure switch
PC800, 850-8E0
40-397
40-397

E-35 "Attachment" is not displayed properly with monitoring function
E-35 "Attachment" is not displayed properly with monitoring function 40-398

Failure
"Attachment" is not displayed properly with monitoring function.

q
Related information
q
q

Cause

3. Start engine
Defective attachment PPC oil
4. Operate attachment control pedal, and perform troubleshooting.
1 pressure switch ( open or short cirAttachment control
cuit in internal wiring)
pedal: NEUTRAL
and (2)
Attachment control
Resistance Max. 1 z
pedal: Operated
3. Start engine
Defective harness or pump con4. Operate blade control lever and perform troubleshooting.
2
troller
Attachment control
Voltage
Approx. 7 V
pedal: NEUTRAL
Attachment control
Voltage
Max. 1 V
pedal: Operated



female side.
Resistance
Max. 1 z
Resistance
Max. 1 z

female side.

a
1.
2.
3.
Min. 1 Mz


1.
2.
3.
4.
Resistance
Voltage
Approx. 7 V

"Attachment", pump controller is defective.
40-398
PC800, 850-8E0

E-35 "Attachment" is not displayed properly with monitoring function
Circuit diagram related to attachment PPC oil pressure switch
PC800, 850-8E0
40-39
40-399

E-36 Electric grease gun does not operate

q
Failure
40-40
Electric grease gun does not operate
Related information
Cause
Defective grease pump (open or

short circuit in internal wiring)

If circuit breaker works, circuit may have ground fault etc. (See cause 5.)
2. Disconnect connector M16, and connect T-adapter to female side.
Continuity

Defective grease gun remote
3 switch (open circuit in internal wirSwitch: OFF
Between S15 (female)
ing)
(1) and (2)
Switch: ON
Resistance Max. 1 z
2. Disconnect connector B01, and connect T-adapters to male and female
sides.
3. Turn remote switch to ON position.
Between B01 (male) (C) and (F)

6 Defective grease pump
40-400
Between B01 (female) (F) and ground
Resistance
Max. 1 z
Continuity
a If no failure is found by above checks, this check is not required.

2. Disconnect connectors S15 and M16, and connect T-adapter to each male
side.
Between B23 and S15 (male) (1)
Resistance
Max. 1 z
Between S15 (male) (2) and M16 (male) (1)
Resistance
Max. 1 z
Between M16 (male) (2) and ground
Resistance
Max. 1 z

2. Disconnect connectors S15 and M16, and connect T-adapter to either
female side.
Between S15 (male) (1) and ground
Between S15 (male) (2) and ground, or between

If cause is not found by the above checks, grease pump may be defective.
PC800, 850-8E0

Circuit diagram related to electric grease gun 40-401
PC800, 850-8E0
40-401

E-37 KOMTRAX system does not operate properly

Failure
Related information
40-402
KOMTRAX system does not operate properly.
Perform following troubleshooting if administrator of KOMTRAX system requests to check

whether failure is occurring in system on machine.
Even when KOMTRAX system is defective, no problem appears on machine.
Check all of results of troubleshooting on service menu display of machine monitor.
q
q
Cause
1 Defective communication 1

2. Display Terminal status screen.
Check item:
To be completed
Station set-up check
2. Display GPS & Communication Status screen.
N ###.##.## (Latitude)
2 Defective positioning by GPS
Check item:
Positioning
E ###.##.## (Longitude)
In positioning
Defective communication environment
4 Defective communication 2
If latitude and longitude are not displayed within 5 minutes with machine
stayed outdoor where opens clearly for sky, contact KOMTRAX service hot
line.
Check item:
Satellite in View or No Satellite in
Communication
View
If Communication Status does never display Satellite in View within 15 minutes with machine stayed outdoor where opens clearly for sky, check if connector of TH300 or antenna on top of cab are properly connected.
Check item:
0 to 60 (normally 0)
Number of message not yet sent
a Select Terminal Status from 12 Display of

KOMTRAX setting in service menu of machine
monitor.
40-402
a Select GPS & Communication Status from 12

Display of KOMTRAX setting in service menu of
machine monitor.
PC800, 850-8E0

E-38 Horn does not sound or does not stop sounding

Failure
40-403
1) Horn does not sound.
Related information
Cause
1 Defective fuse F01-5
Defective horn relay

wiring)

If fuse F01(5) is broken, circuit probably has ground fault. In this case, perform
1.
2.
3.
4.

Replace horn relay (connector: R08) with another relay.
Press right knob switch.
If horn sounds, original horn relay is defective.

2. Disconnect connector S10 and connect T-adapter to male side.
Switch: OFF
and (2)
Switch: ON
Resistance Max. 1 z
a B/H specification
Switch: OFF
and (3)
Switch: ON
Resistance Max. 1 z
a L/S specification
2. Disconnect connectors M07 and M08, and connect T-adapters to their male
Defective high-tone horn (M07) or
sides.
4 low-tone horn (M08) (open or short
Between
M07 (male) (1) and (2)
Continuity
circuit in internal wiring)
Defective horn switch
wiring)
1.
2.
3.
4.
Continuity

Disconnect connector R08 and connect T-adapter to female side.
Press right knob switch.
Between R08 (female) (5) and (6)
Voltage
20 - 30 V
Between R08 (female) (3) and (1)
Voltage
20 - 30 V

2. Disconnect connector R08 and connect T-adapter to female side.

Continuity
Continuity
a
1.
2.
3.
If no failure is found in above checks, this check is not required.

Remove fuse F01(5).
Disconnect connectors R08 and S10, and connect T-adapters to each
female side.
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Between R08 (female) (3) and F01(5)
Resistance
Max. 1 z
Between F01-5 and S10 (female) (1)

Between S10 (female) (2) and R08 (female) (5)
aB/H specification
Between S10 (female) (3) and R08 (female) (5)
aL/S specification
PC800, 850-8E0
40-403

Cause

a
1.
2.
3.

Defective horn
(internal failure)
Failure
If fuse is not blown, this check is not required.

Remove fuse F01(5).
Disconnect connectors R08, M07, and M08, and connect T-adapter to
female side of R08.
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
If cause cannot be found by above checks, horn may be defective.
2) Horn does not stop sounding.
Related information
Cause
Defective horn relay (R08)
wiring)

40-404

2. Remove horn relay (connector R08).
If horn stops sounding, original horn relay is defective.
2. Disconnect connectors M07 and M08, and connect T-adapters to their
female sides.
Voltage
Max. 1 V
Voltage
Max. 1 V
PC800, 850-8E0

Circuit diagram related to horn (B/H specification)
40-405
Circuit diagram related to horn (L/S specification)
40-405
PC800, 850-8E0
40-405

E-39 Step light does not light up or go off

Failure
1) Step light does not light up.

q
Related information
Troubleshooting for primary side of step light relay is performed with failure codes [D195KA] and
[D195KB].
As pump controller connector uses "socket-type box" T-adapter, operating voltage cannot be measured at pump controller connector.
Cause
1 Circuit breaker No. 9
2
Defective fuse No. 17 in fuse box

F01
3 Defective step light
40-406
Defective step light switch


If circuit breaker No. 9 works, the circuit probably has ground fault. In this
case, perform troubleshooting for cause 9 first.
If fuse is blown out, circuit probably has ground fault. In this case, perform
Check whether the bulb is burned out.
3. Turn step light switch to ON and OFF positions, and perform troubleshooting at both positions.
a Switch OFF: Release, Switch ON: Press
Between S13 (male) (1) Switch: OFF
and (2)
Switch: ON

wiring)
1.
2.
3.
4.
Resistance
Min. 1 Mz
Resistance
Max. 1 z

Disconnect connector R09 and replace step light relay with another one.
Turn step light switch to ON position
If step light lights up, original step light relay is defective.
6 Defective diode array D03
1.
2.
3.
4.

Remove diode array D03.
Turn step light switch to ON position
If step light lights up, diode array D03 is defective.

2. Disconnect connector R09, and connect T-adapter to female side.
a If there is no continuity, wiring harness has open circuit. If voltage is 0 V, it
has open circuit or ground fault.
Continuity

Voltage
20 - 30 V
Open circuit or ground fault in wir7
Voltage
20 - 30 V
ing harness
4. Turn step light switch to ON position
a If voltage is 0 V, wiring harness has open circuit or ground fault.
40-406
Voltage
20 - 30 V
PC800, 850-8E0

Cause

a
1.
2.
3.

Between F01-17 and R09 (female) (3)
Resistance
Max. 1 z
Between F01-17 and S13 (female) (2)
Resistance
Max. 1 z
Between CP01 (female) (22) and S13 (female) (1)
Resistance
Max. 1 z
Between R09 (female) (5) and L06A (female) (1)
Resistance
Max. 1 z
Between L06A (female) (2) and ground
Resistance
Max. 1 z
a
1.
2.
3.
9

If cause 7 is not the cause for failure, this check is not required.
Remove fuses No. 17.
Disconnect connectors CP01, R09, L06A and S13, and connect T-adapters
to each female side.
If fuse is not blown, this check is not required.

Remove fuses No. 17.
Disconnect connectors CP01, R09, D03, L06A and S13, and connect
T-adapters to female side of S13 and R09 or S13 and L06A.
Between S13 (female) (1) and ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Between L06A (female) (1) and ground, or R09

If no failure is found by above checks, pump controller is defective.
q Reference
2. Insert T-adapter into connectors S13 and R09.
3. Turn starting switch to ON position and perform troubleshooting.
Between S13 (1) and
Switch: Release
Voltage
Max. 1 V
ground
Switch: Press
Voltage
20 - 30 V
(Step light switch input)
Between R09 (2) and
ground
(Step light relay output)
PC800, 850-8E0
Switch: Release
Voltage
20 - 30 V
Switch: Press
Voltage
Max. 1 V
(For 1 minute)
40-407

Failure
2) Switch is not pressed but step light keeps to light up.

q
Related information
Troubleshooting for primary side of step light relay is performed with failure codes [D195KA]
and [D195KB].
Cause
Defective step light switch


Between S13 (male) (1) Switch: OFF
and (2)
Switch: ON

wiring)
Resistance
Min. 1 Mz
Resistance
Max. 1 z

2. Disconnect connector R09.
a With step light relay disconnected.
If step light goes off, removed step light relay is defective.


4

2. Disconnect connectors S13 and L06A, and connect T-adapters to each
female side.
Voltage
20 - 30 V
Between L06A (female) (1) and ground
Voltage
20 - 30 V

2. Disconnect connectors CP02 and R09, and connect T-adapters to female
side of R09.
Between R09 (2) and

ground
(Step light relay output)
40-408
Resistance
Min. 1 Mz
If no failure is found by above checks, pump controller is defective.

q Reference
2. Insert T-adapter into connectors S13 and R09.
3. Turn starting switch to ON position and perform troubleshooting.
Between S13 (1) and
Switch: Release
Voltage
Max. 1 V
ground
Switch: Press
Voltage
20 - 30 V
(Step light switch input)
Switch: Release
Voltage
20 - 30 V
Switch: Press
Voltage
Max. 1 V
(For 1 minute)
PC800, 850-8E0

Circuit diagram related to step light
PC800, 850-8E0
40-409
40-409
Troubleshooting of hydraulic and mechanical system (H-mode)

Before starting troubleshooting for hydraulic and mechanical systems
40-410
Before starting troubleshooting for hydraulic and mechanical systems 40-410
40-410
PC800, 850-8E0

1. Combination and operation of hydraulic

40-41
pumps
q For the work equipment, travel, and swing circuit, 1 tandem pump (HPV375+375) is used.
q The oil from the front pump flows in the L.H.
5-spool control valve and the oil from the rear
pump flows in the R.H. 4-spool control valve.
q The deliveries of the front pump and rear pump
are controlled by using the EPC solenoid valves
installed to the pumps respectively.
q The pump controller uses the signals from the
differential pressure sensor installed to the L.H.
5-spool control valve to calculate the command
value and outputs the command signal to the
front pump EPC solenoid to perform the NC control of the front pump.
differential pressure sensor installed to the R.H.
4-spool control valve to calculate the command
value and outputs the command signal to the
rear pump EPC solenoid to perform the NC control of the rear pump.
both pump pressure sensors (front and rear) to
calculate the command value and outputs the
command signal to the front and rear pump EPC
solenoids to perform the equal horsepower control and cut-off control.
PC800, 850-8E0
2. Judgment for cause of failure that "work

equipment speed is low and machine
40-41
deviates to right"
q Possible failure of this problem:
1) Defective main relief valve of L.H. 5-spool
control valve
2) Defective jet sensor of L.H. 5-spool control
valve
3) Defective differential pressure sensor of L.H.
5-spool control valve
4) Defective EPC solenoid valve of front pump
5) Defective servo valve of front pump
6) Defective front pump
q For the judgement, measure the following pressure: relief pressure for main relief valve, differential pressure for jet sensor, and output voltage
for differential pressure sensor.
q The pump EPC solenoid valve can be checked
by measuring its output pressure.
q To judge if the problem is in the servo valve or
the pump, remove the servo valve and perform
the unit tests, or measure the stroke of the servo
piston.
a For details, perform the judgement procedure in
accordance with "4. Judgement chart for failure
that work equipment speed is low and machine
deviates".
40-411

3. Judgment for cause of failure that "work

40-412
deviates to left"
q Possible failure of this problem:
1) Defective main relief valve of L.H. 4-spool
control valve
2) Defective jet sensor of L.H. 4-spool control
valve
3) Defective differential pressure sensor of R.H.
4) Defective rear pump EPC solenoid valve
5) Defective servo valve of rear pump
6) Defective rear pump
q For the judgement, measure the following pressure: relief pressure for main relief valve, differential pressure for jet sensor, and output voltage
for differential pressure sensor.
q The pump EPC solenoid valve can be checked
by measuring its output pressure.
q To judge if the problem is in the servo valve or
the pump, remove the servo valve and perform
the unit tests, or measure the stroke of the servo
piston.
a For details, perform the judgement procedure in
accordance with "4.Judgement chart for failure
that work equipment speed is low and machine
deviates".
40-412
4. Judgment chart for failure that work

40-412
deviates (next page)
a Sequentially check the failure on the list, and locate the possible cause indicated by the largest
number of q symbols.
1) To check the servo valve, remove the servo
valve and perform the unit test, or measure
the stroke of the servo piston.
a The unit test of the servo piston must be
performed by the qualified workshop.
2) If there is a big drop in speed and it seems
that there is an abnormality in the pump,
check the line filter also.
3) If there is only a small drop in speed and the
problem is not corrected by adjusting each
equipment, check the line filter also.
4) To check the movement of the servo piston,
remove the caps from both sides of it and
move the servo piston by hand.
PC800, 850-8E0

Remedy
No.
3
4
5
6
7
8
9
10
11
12
13
14
L.H. travel motor
R.H. travel motor
Defective differential pressure sensor
Defective jet sensor
Defective main relief valve
Defective differential pressure sensor
Defective jet sensor
A A
A A
x x x x x x x x
Troubleshooting
Machine deviates to "left" and work equipment speed and
q q q
q q q
swing speed are low.
Machine deviates to "left" and swing speed is particularly low
q q q
q q
when swing lever is operated in single operation.
Machine deviates to "left" and single swing speed is normal
q
when swing lever is operated in single operation.
Travel relief pressure of front pump is low.
q
Jet sensor differential pressure of L.H. 5-spool control valve is
q
abnormal.
Differential pressure sensor outup voltage of L.H. 5-spool
q
control valve is abnormal.
Output pressure of front pump EPC solenoid valve is unusual. q
Machine deviates to "right" and work equipment speed is low
q q q
q q q
Machine deviates to "right" and bucket DUMP speed is particq q q
q q
ularly low
Machine deviates to "right" and bucket DUMP speed is norq
mal
Travel relief pressure of rear pump circuit is low.
q
Jet sensor differential pressure of R.H. 4-spool control valve
q
is abnormal
Difference pressure sensor output voltage of R.H. 4-spool
q
control valve is abnormal.
Output pressure of rear pump EPC solenoid valve is unusual.
q
Travel deviation to "left"
R.H.
4-spool
control
valve
Travel deviation to "right"
x x
Defective main relief valve
Defective pump
x x x
Defective servo valve
Defective EPC solenoid valve
Defective pump
Defective servo valve
Rear
pump
Defective EPC solenoid valve
Front
pump
Cause
L.H.
5-spool
control
valve
A: Adjust, x: Repair or replace
PC800, 850-8E0
40-413

Information in troubleshooting table (H-mode)
40-414
a The following information is summarized in the troubleshooting table and the related circuit
diagram. Before performing troubleshooting, understand that information fully.
Failure
Description of failure code
Related inforInformation related to the detected failure or troubleshooting

mation
Cause
Criteria and troubleshooting procedure
Probable
causes and criteria
Probable causes for

trouble
3 Each number is serial
number, not priority
sequence.
4
<Contents of description>
Standard value in normal condition to judge probable
causes
q Remarks on judgment
q
40-414
PC800, 850-8E0

PC800, 850-8E0
40-415

H-1 All of work equipment, swing and travel work slow or lack power
Failure
Speed or power of all work equipment, swing and travel is low.
Measure the speed of the work equipment, travel, and swing and check that all of them are slow
(or their power is low).
Check that unusual sound is not heard around the pump.(If the unusual sound is heard, perform
the related troubleshooting.)
Check that machine does not deviate. (If the machine deviates, perform the related troubleshooting.)
Perform all troubleshooting with working mode in POWER (P) mode.
If a failure code relating to the pump control is displayed, perform the troubleshooting for the code
first.
Related information
q
q
q
Cause
40-416

a Troubleshoot with engine at full speed.
1 Defective engine
Heavy-duty lift switch and right

Engine speed
work equipment control lever
When heavy-duty lift switch is
OFF and boom RAISE circuit is
Min. 1,700 rpm
relieved
ON and boom RAISE circuuit is
Min. 1,700 rpm
relieved
a Prepare with engine stopped, then troubleshoot with engine at
full speed.
Control lever
Malfunction of self-pressure
2
reducing valve
Probable
causes and criteria
3
Leakage in control system

devices
Control relief pressure
3.24 (+0.49/-0.20) MPa

All levers in NEUTRAL
{33 (+5/-2) kg/cm2}
If the control circuit pressure is low, adjust the self-pressure reducing valve.
(See Testing and adjusting.)
a Stop the engine, block the oil flow at (1) to (9) in Fig. 1, one at a
time, then troubleshoot with engine at full speed.
Control lever
Control circuit pressure
3.24 (+0.49/-0.20) MPa

{33 (+5/-2) kg/cm2}
full speed.
Heavy-duty lift switch and right
Main relief pressure
32.4 (+1.0/-2.0) MPa
OFF and boom RAISE circuuit is
Defective adjustment or mal{330
(+10/-20) kg/cm2}
4
relieved
function of main relief valve
33.8 (+1.0/-2.0) MPa
ON and boom RAISE circuuit is
{345
(+10/-20) kg/cm2}
relieved
If normal oil pressure is not obtained after adjustment, main relief
valve may malfunction (at low or high pressure set side). Check
main relief valve directly.
40-416
PC800, 850-8E0

Cause
Defective pump EPC current output
Probable
causes and criteria
Malfunction of pump EPC

solenoid valve
Malfunction of pump VC
valve
Fig. 1: Control system devices
PC800, 850-8E0

full speed.
(Make sure that results of troubleshooting for failure cause 2
and 4 are normal before this troubleshooting.)
Control lever
Pump EPC current
265 50 mA
Run track idle off ground

575.5 50 mA
(at lever stroke end)
full speed.
(Make sure that result of troubleshooting for failure cause 5 is
normal before this troubleshooting.)
EPC solenoid valve output presControl lever
sure
Max. 0.78 MPa
{Max. 8 kg/cm2}
Min. 1.23 MPa
{Min. 10.5 kg/cm2}
See Table 1 of H-2.
40-417
40-417

H-2 Engine speed lowers significantly or engine stalls

Failure
Related information
40-418
Engine speed lowers significantly or the engine stalls.

first.
Cause
Defective pump EPC current output
Malfunction of pump EPC

solenoid valve
Malfunction of pump VC
valve
Probable
causes and criteria
4 Defective engine

full speed.
Pump EPC current
Control lever
When all control levers in NEU265 50 mA
TRAL position
575.5 50 mA
full speed.
EPC solenoid valve output presControl lever
sure
Max. 0.78 MPa
{Max. 8 kg/cm2}
Min. 1.23 MPa
{Min. 12.5 kg/cm2}
See table 1
If causes 1 through 3 are normal, the engine may be defective, so
check it (in S-mode).
Table 1
(Judgment table)
Operation mode
Boom RAISE to hydraulic

relief
(heavy-duty lift; OFF)
EPC valve output pressure

(Pce1 (Pce2))
(VC valve control pressure)
MPa {kg/cm2}
Max. 0.78
{Max. 8}
1.03 1.43
{10.5 14.5}
Servo piston position
Contact with stopper on min.

swash plate angle side

Min. 1.23
{Min. 1.25}
Intermediate between min.

Contact with stopper on
and max. swash plate angles max. swash plate angle side
Judgement value for VC

Approx. 1/2 of source pres- Approx. 1/2 of source presvalve output pressure Approx. 1/2 to 1 of source pressure is nearly equal to 1/2 x
sure to drain pressure is
(Pcs1 (Pcs2))
sure is nearly equal to 1/2 Pch1
Pch1 (Pch2)
nearly equal to 1/2 Pch1
(Servo piston large-diam(Pch2) to Pcs1 (Pcs2)
*1
(Pch2) to Pd
eter pressure)
*1. Since the swash plate is at the intermediate point, the pressure is about "0.5 - 0.6 times" (approx. 1/2) of
the relief pressure (delivery pressure).
40-418
PC800, 850-8E0

PC800, 850-8E0
40-419

H-3 Any of work equipment, swing and travel does not work
Failure
Related information
40-420
Any of work equipment, swing, and travel does not work.

first.
Cause
Internal defect of coupling

(Main pump drive system)
Malfunction of self-pressure
reducing valve
Leakage in control system

devices
Probable
causes and criteria

a Prepare with engine stopped, then perform troubleshooting with
engine stopped.
When rotating crankshaft with main pump pressure measuring
coupler disconnected, if oil flows out from coupler hole, coupling is
normal.
full speed.
Control circuit pressure
Control lever
3.24 (+0.49/-0.20) MPa
{33 (+5/-2) kg/cm2}
If the control circuit pressure is low, adjust the self-pressure reducing valve.
(See Testing and adjusting.)
Stop engine and block oil flow at (1) to (7) in Fig.1, one at a time
(See figure in next page), then troubleshoot with engine at full
speed.
Control relief pressure
Control lever
3.24 (+0.49/-0.20) MPa

{33 (+5/-2) kg/cm2}
full speed.
Solenoid valve outlet pressure
Lock lever
Malfunction of PPC lock

solenoid valve
FREE
LOCK
40-420
2.9 (+0.8/-0.2) MPa

{30 (+8/-2) kg/cm2}
0 MPa
{0 kg/cm2}
PC800, 850-8E0

Fig. 1: Control system devices
PC800, 850-8E0
40-421
40-421

H-4 Unusual noise is heard from around hydraulic pump

Failure
40-42
Unusual sound is heard around the hydraulic pump.
Related information
Cause
Probable
causes and criteria
1 Lowering hydraulic oil level
Hydraulic oil level may be low. Check it directly.
2 Loosened piping clamp
Since piping clamp between hydraulic tank and hydraulic pump

may be loosened, check it directly.
Clogging of hydraulic tank

strainer
Internal defect of hydraulic
4
pump
5 Observe change of condition
40-422
Hydraulic tank strainer may be clogged. Check it directly.

Hydraulic pump may have a internal defect. Check pump directly.
If cause cannot be found by troubleshooting, operate the machine
as it is for a while and observe the condition for change.
PC800, 850-8E0

H-5 Boom operation lacks speed or power

Failure
q
q
q
Related information
q
q
q
(1) Boom operation lacks speed or power in normal

mode.
The normal mode means the condition that the heavy-duty lift switch, swing priority mode switch,
and machine pushup switch are OFF.
Check that other work equipment, travel, and swing are normal. (If any of them is abnormal, perform troubleshooting related to it.)
Perform troubleshooting after checking that the electric circuit related to the boom control is normal.
Speed or power of boom is low.
Cause
Probable
causes and criteria
40-423

full speed.
Right work equipment control
Malfunction of R.H. PPC
1
lever
valve (boom circuit)
2.9 (+0.8/-0.2) MPa
Boom RAISE or LOWER at lever
{30 (+8/-2) kg/cm2}
stroke end
full speed.
Swing priority switch and right
Malfunction of swing priority
2
0 MPa
Swing priority switch OFF and
solenoid valve
{0 kg/cm2}
Lever in NEUTRAL
2.9 (+0.8/-0.2) MPa
Swing priority switch ON and
{30 (+8/-2) kg/cm2}
Boom RAISE operation
Malfunction of boom control The spool of boom control valve (Lo, Hi) may malfunction. Check it
valve (spool)
directly.
Since suction-safety valve of boom control valve (Lo) may malfunction, check it directly. (When checking by replacing suction-safety
Malfunction of boom control valve with the one for another work equipment circuit, stop oil in
4
valve (suction-safety valves) machine push-up solenoid. After checking however, be sure to
restore suction safety valve since its set pressure and structure are
different from the others.
Defective boom control valve
5
Boom control valve (Lo, Hi) may malfunction, check it directly.
(control valve itself)
full speed.
Defective sealing for of boom Right work equipment control
Leakage from cylinder
6
cylinder
lever
Max. 20 cc/min
Boom RAISE to hydraulic relief
PC800, 850-8E0
40-423

Failure
(2) The boom raise speed or power is low in the

heavy-duty lift mode.
The heavy lift mode means the condition that the heavy-duty lift switch is ON.
Check that other work equipment, travel, and swing system are normal. (If any of them is abnormal,
perform troubleshooting related to it.)
Perform troubleshooting after checking that the electric circuit related to the heavy-duty lift solenoid
valve is normal.
q
q
Related information
q
q
q
Cause
Probable
causes and criteria
Failure
q
q
q
Related information

full speed.
lever
Malfunction of 2-stage relief
1
0 MPa
solenoid valve
NEUTRAL
{0 kg/cm2}
Min. 2.74 MPa
Boom RAISE in single operation
{Min. 28 kg/cm2}
full speed.
Main relief pressure
lever
Defective adjustment or mal33.8 (+1.0/-2.0) MPa
2
function of main relief valve Boom RAISE in single operation
{345 (+10/-20) kg/cm2}
valve (high pressure side) may malfunction. Check main relief
valve directly.
q
q
q
(3) Boom LOWER speed or power is low in the

machine push-up mode.
The machine push-up mode means the condition that the machine push-up switch is ON.
Check the electric circuit of machine push-up solenoid valve first.
Cause

full speed.
Machine push-up switch
Probable
causes and criteria
Malfunction of machine
push-up solenoid valve
OFF
ON
40-424
Min. 2.74 MPa

{Min. 28 kg/cm2}
0 MPa
{0 kg/cm2}
Malfunction of boom control Suction-safety valve (high pressure side on head side) of the boom
valve (suction-safety valves) control valve (Lo) may malfunction. Check it directly.
PC800, 850-8E0

H-6 Arm operation lacks speed or power

Failure
Related information
Speed or power of arm is low.
Perform troubleshooting after checking that the electric circuit related to arm control is normal.
q
q
q
Probable
causes and criteria
40-425
Cause
Malfunction of L.H. PPC

valve (arm circuit)

full speed.
Left work equipment control
lever
2.9 (+0.8/-0.2) MPa
Arm IN or OUT
{30 (+8/-2) kg/cm2}
at lever stroke end
Malfunction of arm control

valve (spool)
Spool of arm control valve (Lo or Hi) may malfunction. Check it

directly.
Suction-safety valve of arm control valves (Lo or Hi) may have malfunction. Check it directly. (The suction-safety valve may be
3
checked by replacing it with one for another work equipment cirvalve (suction-safety valve)
cuit. After checking, however, be sure to restore it since its set
pressure is different from the others.)
4
Defective arm control valve

Defective sealing for arm

cylinder
PC800, 850-8E0
Arm control valve (Lo or Hi) may have malfunction. Check it

directly.
full speed.
lever
Max. 20 cc/min
Arm IN to hydraulic relief
40-425

H-7 Bucket operation lacks speed or power

Failure
Related information
40-426
Speed or power of bucket is low.
Perform troubleshooting after checking that the electric circuit related to the bucket control is normal.
q
q
q
Cause

valve (bucket circuit)

full speed.
lever
2.9 (+0.8/-0.2) MPa
Bucket CURL, DUMP
{30 (+8/-2) kg/cm2}
at lever stroke end
Malfunction of bucket control Spool of bucket control valve (Lo/Hi) may malfunction. Check it
valve (spool)
directly.
Since Suction-safety valve of the bucket control valve (Lo or Hi)
may have a malfunction, check it directly. (Suction-safety valve
Malfunction of bucket control
3
may be checked by replacing it with one for another work equipvalve (suction-safety valve)
ment circuit. After checking, however, be sure to restore suction-safety valve since its set pressure is different from the others.)
Defective bucket control
4
Bucket control valve (Lo/Hi) may malfunction. Check it directly.
valve (control valve itself)
full speed.
Defective sealing for bucket
5
cylinder
lever
Max. 20 cc/min
Bucket CURL to hydraulic relief
2
Probable
causes and criteria
40-426
PC800, 850-8E0

H-8 Boom does not move

Failure
Related information
Probable
causes and criteria
40-427
Boom does not move.
Cause

valve (boom circuit)

full speed.
lever
2.9 (+0.8/-0.2) MPa
Boom RAISE or LOWER at lever
{30 (+8/-2) kg/cm2}
stroke end
Malfunction of boom control The spool of the boom control valve (Lo/Hi) may have malfunction.
valve (spool)
Check it directly.
H-9 Arm does not move

Failure
Related information
Probable
causes and criteria
40-427
Arm does not move.
Cause

valve (arm circuit)

full speed.
lever
2.9 (+0.8/-0.2) MPa
Arm IN or OUT at lever stroke
{30 (+8/-2) kg/cm2}
end

valve (spool)
Spool of arm control valve (Lo or Hi) may have malfunction. Check
it directly.
H-10 Bucket does not move

Failure
Related information
Probable
causes and criteria
40-427
Bucket does not move.
Check that operations of the other work equipment, travel, and swing are normal. (If they are abnormal, perform the related troubleshooting.)
Cause

valve (bucket circuit)

full speed.
lever
2.9 (+0.8/-0.2) MPa
Bucket CURL or DUMP at lever
{30 (+8/-2) kg/cm2}
stroke end
Malfunction of bucket control The spool of bucket control valve (Lo/Hi) may malfunction. Check it
valve (spool)
directly.
PC800, 850-8E0
40-427

H-11 Hydraulic drift of work equipment is large

Failure
40-428
Hydraulic drift of work equipment is large. (1) Hydraulic drift of boom is large.
Related information
Cause
Sealing for spool in boom control valve(Lo) may be defective.

Check it directly.
Since suction-safety valve (bottom side) of boom control valve (Lo)
may malfunction, check it directly. (The suction-safety valve may
Malfunction of boom control
2
be checked by replacing it with one for another work equipment cirvalve (suction-safety valves)
cuit. After checking, however, be sure to restore suction-safety
valve since its set pressure is different from the others.)
full speed.
Defective sealing for boom
Right
work equipment control
3
cylinder
lever
Probable
causes and criteria
Defective sealing for boom

control valve (spool)
Boom RAISE to hydraulic relief
Failure
Max. 20 cc/min
Hydraulic drift of work equipment is large. (2) Hydraulic drift of arm is large.
Related information
Cause
Spool of arm control valve (Lo) may have defective seal. Check it
directly.
Since suction-safety valve (head side) of arm control valve (Lo)
may malfunction, check it directly. (The suction-safety valve may
2
be checked by replacing it with one for another work equipment cirvalve (suction-safety valve)
full speed.
3
cylinder
lever
Probable
causes and criteria

control valve (spool)
Arm IN to hydraulic relief
40-428
Max. 20 cc/min
PC800, 850-8E0

Failure
Hydraulic drift of work equipment is large. (3) Hydraulic drift of bucket is large.
Related information
Cause
Defective sealing for bucket Sealing for the spool of bucket control valve (Lo/Hi) may malfunccontrol valve (spool)
tion. Check it directly.
Since suction-safety valve (bottom side) of the bucket control valve
(Lo, Hi) may have a malfunction, check it directly. (Suction-safety
Malfunction of bucket control valve may be checked by replacing it with one for another work
2
valve (suction-safety valve) equipment circuit. After checking, however, be sure to restore the
suction-safety valve since its set pressure is different from the others.)
full speed.
Defective sealing for bucket
3
cylinder
lever
Probable
causes and criteria
Bucket CURL to hydraulic relief
PC800, 850-8E0
Max. 20 cc/min
40-429

H-12 Time lag of work equipment is large

Failure
40-430
Time lag of work equipment operation is

(1) Time lag of boom is large.
large.
Related information
Cause
Probable
causes and criteria
Failure
Since suction-safety valve (head side) of boom control valve (Lo)

may malfunction, check it directly. (Suction-safety valve may be
Malfunction of boom control
1
checked by replacing it with one for another work equipment cirvalve (suction-safety valves)
Time lag of work equipment is large.
(2) Time lag of arm operation is large.
Related information
Cause
Probable
causes and criteria
Failure
Since suction-safety valve (bottom side) of arm control valve (Lo,

Hi) may malfunction, check it directly. (Suction-safety valve may be
1
checked by replacing it with one for another work equipment cirvalve (suction-safety valve)
Time lag of work equipment is large.
(3) Time lag of bucket is large.
Related information
Cause
Probable
causes and criteria
40-430
Since suction-safety valve (bottom side) of the bucket control valve

(Lo, Hi) may malfunction, check it directly. (Suction-safety valve
Malfunction of bucket control
1
may be checked by replacing it with one for another work equipvalve (suction-safety valve)
ment circuit. After checking, however, be sure to restore suction-safety valve since its set pressure is different from the others.)
PC800, 850-8E0

H-13 Heavy lift function does not work or is not released

Failure
40-431
The heavy lift function does not work or is not released.
Related information
Probable
causes and criteria
Cause
1
Perform troubleshooting by (2) in "H-5 Boom operation lacks speed or power.
H-14 Machine push-up function does not work or is not released

Failure
40-431
The machine push-up function does not work or is not canceled.
Related information
Probable
causes and criteria
Cause
1
Perform troubleshooting by (3) in "H-5 Boom operation lacks speed or power.
H-15 Boom shockless function does not work or is not canceled

Failure
40-431
Boom shockless function does not work or is not canceled.
Related information
Cause
Probable
causes and criteria
Malfunction of boom shockless solenoid valve
a Be ready with starting switch OFF, then turn starting switch to

ON position and perform troubleshooting.
Remove solenoid valve from valve assembly, connect it to connector, and then operate boom shockless switch. If spool moves, solenoid valve is normal.
Malfunction of boom shockless valve
Since boom shockless valve may malfunction, check it directly.
PC800, 850-8E0
40-431

H-16 Machine deviates in one direction against operator's intention when travelling
H-16 Machine deviates in one direction against operator's intention

when travelling
Failure
Related information
q
q
40-432
(1) Machine deviates in the same direction, regardless

of its forward or reverse traveling.
Check that the travel speed is normal. (If it is abnormal, perform the related troubleshooting.)
Machine deviates in one direction.
Cause
Defective adjustment of main See TESTING AND ADJUSTING, "Testing and adjusting travel
1
pump
deviation".
full speed.
Malfunction of travel PPC
Travel lever
2
valve
2.9 (+0.8/-0.2) MPa
FORWARD, REVERSE at levers
stroke end
{30 (+8/-2) kg/cm2}
3
4
Probable
causes and criteria
5
Malfunction of travel control

valve (spool)
Spool of travel control valve may malfunction. Check it directly.
Defective travel control valve

Travel control valve may be defective. Check it directly.
full speed.
Defective sealing for center
swivel joint
Travel lever
Leakage from swivel joint
When relieved on one side
Max. 100 cc/min
If defective sealing is detected, machine deviates as shown in Fig.

2.
40-432
Internal leakage of travel

motor

full speed.
Travel lever
Leakage from travel motor
Max. 40 l/min
7 Defective travel motor
The travel motor may be defective, check it directly.
8 Internal defect of final drive
Final drive may have internal defect. Check it directly.

(It may be checked by unusual sound, unusual heat, metal chips in
drain oil, etc.)
PC800, 850-8E0

Fig. 2: Defective sealing for center swivel joint and travel deviation directions
PC800, 850-8E0
40-43
40-433

Failure
Related information
q
q
(2) Machine deviates to different sides with forward and

reverse traveling
Check that the travel speed is normal. (If it is abnormal, perform the related troubleshooting.)
Machine deviates in one direction.
Cause
2
Probable
causes and criteria
3

valve

valve (spool)
Defective seal for center

swivel joint
Low set pressure of travel

motor safety valve

full speed.
Travel lever
FORWARD, REVERSE
at levers stroke end

full speed.
Travel lever
Max. 100 cc/min
If defective sealing is detected, machine deviates as shown in Fig.

2.
full speed.
Travel relief pressure
Travel lever
2: Defective sealing for center swivel joint and travel deviation directions
40-434
2.9 (+0.8/-0.2) MPa

{30 (+8/-2) kg/cm2}
34.8 (+1.0/-2.0) MPa

{355 (+10/-20) kg/cm2}
40-434
PC800, 850-8E0

H-17 Machine deviates significantly at start

Failure
Related information
Machine deviates largely at start.
Check that the machine does not deviate during constant-speed travel. (If the machine deviates,
perform the related troubleshooting..)
Malfunction of main pump

servo valve

valve (spool)
Related information
Defective sealing for center

swivel joint

full speed.
Travel lever
Max. 100 cc/min
Internal defect of travel motor The travel motor may have an internal defect, check the motor
(travel motor itself)
directly.
(2) Machine deviates excessively regardless of the

stroke of travel lever.
Machine deviates largely at start.
Check that the machine does not deviate during constant-speed travel. (If the machine deviates,
perform the related troubleshooting..)
Cause
Malfunction of differential
1 pressure sensor on jet sensor
Probable
causes and criteria

The main pump servo valve may have a malfunction. Check it
directly. (Measure lever stroke to judge whether unit test of servo
valve is required.)
Failure
(1) Machine deviates only when started with travel

levers at stroke end.
Cause
Probable
causes and criteria
40-435
Malfunction of main pump

servo valve
Defective adjustment or mal3

function of jet sensor
PC800, 850-8E0

full speed.
Output voltage of differential
Travel lever
pressure sensor
Min. 3 V
NEUTRAL
Max. 1.2 V
(lever stroke end)
The main pump servo valve may have a malfunction. Check it
directly. (Measure lever stroke to judge whether unit test of servo
valve is required. )
full speed.
Jet sensor differential pressure
Travel lever
Min. 1.28 MPa
{Min. 13.1 kg/cm2}
Max. 0.15 MPa
Either lever at stroke end
{Max. 1.5 kg/cm2}
(run track idle off ground)
If normal oil pressure is not obtained after adjustment, relief valve
may malfunction or orifice may be defective. Check valve and orifice directly.
NEUTRAL
40-435

H-18 Machine deviates significantly during combined operation
H-18 Machine deviates significantly during combined operation

Failure
Related information
Machine deviates largely during combined operation.
Check that the machine does not deviate when the machine is operated only to travel. (If the machine deviates under that condition, perform the related troubleshooting.)
Cause
40-436

full speed.
Control lever
Probable
causes and criteria

Combined operation of travel
and work equipment or swing of
upper structure
40-436
Malfunction of straight travel

solenoid valve
0 MPa
{0 kg/cm2}
Min. 2.74 MPa
{Min. 28 kg/cm2}
Malfunction of striaght travel

Straight travel valve may malfunction. Check it directly.
valve
PC800, 850-8E0

H-19 Travel works slow or lack power

Failure
Related information
Travel speed or power is low
Make sure that the work equipment and swing speed is normal.
q
q
Cause
Probable
causes and criteria
40-437

valve
Malfunction of 2-stage relief

solenoid valve
Defective adjustment or malfunction of main relief valve

full speed.
Travel lever
2.9 (+0.8/-0.2) MPa
FORWARD or REVERSE
{30 (+8/-2) kg/cm2}
at levers stroke end
full speed.
Travel lever
0 MPa
{0 kg/cm2}
Min. 2.74 MPa
FORWARD or REVERSE
{Min. 28 kg/cm2}
full speed.
Travel lever
NEUTRAL
34.8 (+1.0/-2.0) MPa

{355 (+10/-20) kg/cm2}

valve (high pressure side) may malfunction. Check it directly.
PC800, 850-8E0
40-437

H-20 One of tracks does not run

Failure
40-438
Track does not move (only track on one

side)
(1) Machine does not travel in either direction.
Related information
Cause
Probable
causes and criteria
Malfunction of travel motor

(parking brake)
Internal defect of travel motor

Travel motor may have an internal defect, check the motor directly.
(travel motor itself)
3 Internal defect of final drive
Failure
Related information

Parking brake of travel motor may malfunction. Check it directly.
Final drive may have internal failure. Check it directly.

(It may be checked by unusual sound, unusual heat, metal chips in
drain oil, etc.)
Track does not move (only track on one

side)

Cause
(2) Machine does not travel in only forward or reverse

direction.

full speed.
2
Probable
causes and criteria

valve (spool)
Travel lever
FORWARD, REVERSE
at lever stroke end
2.9 (+0.8/-0.2) MPa

{30 (+8/-2) kg/cm2}
Suction valve of travel control valve may malfunction. Check valve

Defective travel control valve
directly. (Suction valve can be checked by replacing it with normal
(suction valve)
one.)
full speed.
Malfunctioning of travel
Travel lever
4
motor (safety valve)
34.8 (+1.0/-2.0) MPa
When relieved on one side (in
non-traveling direction)
{355 (+10/-20) kg/cm2}
3
40-438

valve

(counterbalance valve)
Counterbalance valve of travel motor may malfunction. Check it

directly.
PC800, 850-8E0

H-21 Travel speed does not change

Failure
Related information
40-439
Travel speed does not change.
Check that the Lo and Hi travel speeds are normal. (If they are unusual, perform the related troubleshooting.)
The travel speed selection system has the automatic speed changing function. If the oil pressure
rises 22.6 MPa or above {230 kg/cm2 or above} during travel, the travel speed is changed to Lo
even while the machine is traveling at Hi (Hi is still displayed on the monitor panel).
Cause

full speed.
Travel speed selector switch
Probable
causes and criteria
PC800, 850-8E0
Malfunction of travel speed

solenoid valve

(servo mechanism)
Lo
0 MPa
{0 kg/cm2}
Hi
Min. 2.74 MPa

{Min. 28 kg/cm2}
The servo mechanism of travel motor may malfunction. Check it

directly.
40-439

H-22 Upper structure does not swing

Failure
Related information
40-4 0
Upper structure does not swing.
Check that the work equipment and travel are normal.(If they are abnormal, perform the related
troubleshooting.)
Perform all troubleshooting with working mode in POWER (P) mode and with the swing lock switch
OFF.
Cause
(1) Upper structure swings neither to right nor left.

full speed.
lever
Malfunction of swing holding
1
0 MPa
When in NEUTRAL (after 10 sec
brake solenoid valve
{0 kg/cm2}
or more)
Min. 2.74 MPa
Operated for swing
{Min. 28 kg/cm2}
(in either right or left direction)
Swing holding brake of swing motor may malfunction. check it
directly.
full speed.
Swing relief pressure
Defective adjustment or mallever
3 function of swing motor
28.9 (+2.5/-0.5) MPa
Swing to hydraulic relief
(safety valve)
{295
(+25/-5) kg/cm2}
2
Probable
causes and criteria
Malfunction of swing motor

(swing brake)
If normal oil pressure is not obtained after adjustment, safety valve

may malfunction. Check it directly.
Failure
Related information
Internal defect of swing

motor (swing motor itself)
The swing motor may have internal defect, check it directly.

machinery
Swing machinery may internal failure. Check it directly.

(It may be checked by unusual sound, unusual heating, metal
chips in drain oil, etc.)
Upper structure does not swing.
troubleshooting.)
Perform all troubleshooting with working mode in POWER (P) mode. P and with the swing lock
switch OFF.
Cause
Probable
causes and criteria
40-440

valve (swing circuit)
(2) Upper structure does not swing in only one direction.

full speed.
Left work equipment control lever
Swing RIGHT/LEFT
At lever stroke end
2.9 (+0.8/-0.2) MPa

{30 (+8/-2) kg/cm2}
Malfunction of swing control

Spool of swing control valve may malfunction. Check it directly.
valve (spool)
Suction valve of swing control valve may malfunction. Check it
3
directly. (This failure can be checked by interchanging right and left
valve (suction valve)
swing motor suction valves and how condition changes.)
Suction valve of swing motor may have malfunction. Check it
4
(suction valve)
swing motor suction valves and how condition changes.)
Check valve of swing motor may have malfunction. Check it
5
(check valve)
swing motor check valves and how condition changes.)
PC800, 850-8E0

H-23 Swing speed is low or swing acceleration is poor

Failure
q
q
Related information
Probable
causes and criteria
40-4 1
Swing acceleration is poor or swing

(1) Swing acceleration is poor or swing speed is slow in
speed is low.
both right and left directions.
troubleshooting.)
OFF.
Cause
Internal leakage of swing

motor

full speed.
Leakage from swing motor
lever
Max. 10 l/min

(swing brake)
Swing brake of swing motor may malfunction. check it directly.

full speed.
28.9 (+2.5/-0.5) MPa
(safety valve)
{295 (+25/-5) kg/cm2}
may have a malfunction. Check it directly.
Failure

The swing motor may have internal defect, check it directly.

machinery
Swing machinery may have internal defect, check it directly. (The

defect can be judged by unusual noise, unusual heat, metallic powder in the drained oil, etc.)
q
q
Related information
Probable
causes and criteria
Swing acceleration is poor or swing

(2) Swing speed is slow or swing acceleration is poor in
speed is low.
only one direction.
troubleshooting.)
OFF.
Cause


full speed.
lever
2.9 (+0.8/-0.2) MPa
Swing RIGHT/LEFT
{30 (+8/-2) kg/cm2}
lever stroke end

valve (spool)

swing motor suction valves and watching how condition changes.)

(suction valve)
Suction valve of swing motor may malfunction. Check it directly.

(This failure can be checked by interchanging right and left swing
motor suction valves and watching how condition changes.)

(check valve)
Check valve of swing motor may malfunction. Check it directly.

motor check valves and watching how condition changes.)
PC800, 850-8E0
40-441

H-24 In combined operation with work equipment, swing speed is low or

swing acceleration is poor
40-4 2
q
Failure
Related information
In combined operation with work equip- (1) Swing acceleration or swing speed of upper strucment, swing acceleration is poor or swing ture is low during combined operations of swing priority
speed is low
mode OFF.
Perform all troubleshooting with working mode in POWER (P) mode and with the swing priority
switch OFF.
Cause
Probable
causes and criteria

solenoid valve

full speed.
Min. 2.35 MPa

{Min. 24 kg/cm2}
0 MPa
{0 kg/cm2}
full speed.
Swing PPC shuttle valve outlet
Malfunction of swing PPC
2
lever
pressure
shuttle valve
2.9 (+0.8/-0.2) MPa
Right or left swing at lever stroke
end
{30 (+8/-2) kg/cm2}
full speed.
Swing priority selector valve outRight work equipment control
let pressure
lever
(Port A2)
3
selector valve
0 MPa
NEUTRAL
{0 kg/cm2}

end
40-442
Same as main pump pressure

valve (throttle valve)
Throttle valve of arm control valve (Lo) may malfunction. Check it

directly.
Malfunction of bucket control Throttle valve of the bucket control valve (Hi) may malfunction.
Check it directly.
PC800, 850-8E0

Failure
q
Related information
In combined operation with work equip- (2) Swing acceleration or swing speed of upper strucment, swing acceleration is poor or swing ture is low during combined operations of swing and
speed is low
work equipment with swing priority mode.
Before perform the following troubleshooting, check that the swing operation is normal when swing
priority switch is OFF.
Perform all troubleshooting with working mode in POWER (P) mode and with the swing priority
switch ON.
Cause
Probable
causes and criteria

full speed.

solenoid valve
Malfunction of swing control Throttle valve of swing control valve may malfunction. Check it
directly.
Min. 2.35 MPa

{Min. 24 kg/cm2}
0 MPa
{0 kg/cm2}
full speed.
Swing priority selector valve outRight work equipment control
let pressure
lever
(Port A1)
2
selector valve
0 MPa
NEUTRAL
{0 kg/cm2}
0 MPa
Boom RAISE at lever stroke end
{0 kg/cm2}
PC800, 850-8E0

40-443

H-25 Upper structure overruns excessively when it stops swinging
H-25 Upper structure overruns excessively when it stops swinging

Failure
Upper structure overruns excessively

when it stops swinging.
40-4 4
(1) Upper structure overruns excessively when it stops

swinging in both right and left directions.
Related information
Cause

full speed.
Defective adjustment or mal1 function of swing motor

(safety valve)
Probable
causes and criteria

lever

28.9 (+2.5/-0.5) MPa

{295 (+25/-5) kg/cm2}

may a malfunction. Check it directly.
Internal leakage of swing

motor

full speed.
Leakage from swing motor
lever
Failure
Upper structure overruns excessively

when it stops swinging.
Max. 10 l/min
(2) Upper structure overruns excessively when it stops

swinging in only one direction.
Related information
Cause

full speed.
Probable
causes and criteria


end
2.9 (+0.8/-0.2) MPa

{30 (+8/-2) kg/cm2}

valve (spool)


(suction valve)

5 (check valve)
40-444

lever

motor check valves and watching how condition changes.)
PC800, 850-8E0

H-26 Shock is large when upper structure stops swinging

Failure
Related information
40-4 5
Shock is large when upper structure

stops swinging.
OFF.
Cause
(1) Shock is large when upper structure stops swinging

in both directions.

full speed.
lever
0 MPa
1
NEUTRAL (after 10 sec or more)
{0 kg/cm2}
Min. 2.74 MPa
Swing operation
{Min. 28 kg/cm2}
2
Probable
causes and criteria

(swing brake)

full speed.
28.9 (+2.5/-0.5) MPa
(safety valve)
{295 (+25/-5) kg/cm2}
If normal oil pressure is not obtained after adjustment, the safety
valve may malfunction. Check it directly.
Failure
Related information

Swing motor may have internal defect, check it directly.

machinery
Swing machinery may have internal defect, check it directly. (The

defect can be judged by unusual noise, unusual heat, metallic powder in the drained oil, etc.)
Shock is large when upper structure

stops swinging.
Perform all troubleshooting with working mode in POWER mode and with the swing lock switch
OFF.
Cause
(2) Shock is large when upper structure stops swinging

in only one direction.

full speed.
Probable
causes and criteria

1

lever
NEUTRAL
end

0 MPa
{0 kg/cm2}
2.9 (+0.8/-0.2) MPa
{30 (+8/-2) kg/cm2}

valve (spool)

(suction valve)
PC800, 850-8E0
Suction valve of swing motor may have malfunction. Check it

swing motor suction valves and watching condition changes.)
40-445

H-27 Large unusual noise is heard when upper structure stops swinging
H-27 Large unusual noise is heard when upper structure stops swinging40-4 6
Failure
Large unsual noise is heard when upper (1) Large unusual noise is heard when upper structure
structure stops swinging
stops swinging in both directions.
Related information
Cause
1
Probable
causes and criteria
Malfunction of back pressure compensation valve
Defective adjustment or mal2 function of swing motor

(safety valve)

Back pressure compensation valve may malfunction. Check it
directly.
full speed.
lever
28.9 (+2.5/0.5) MPa

{295 (+25/-5) kg/cm2}

may malfunction. Check it directly.
2
Failure

machinery
Swing machinery may malfunction. Check it directly. (The defect

can be judged by unusual noise, unusual heat, metallic powder in
the drained oil, etc.)
Large unsual noise is heard when upper (2) Large unusual noise is heard when upper structure
structure stops swinging.
stops swinging in only one direction.
Related information
Cause
Probable
causes and criteria
40-446


(suction valve)

PC800, 850-8E0

H-28 Swing drift on a slope is large
40-4 7
Failure
Swing drift on a slope is large
Related information

Cause
Probable
causes and criteria

full speed.
lever
1
0 MPa
NEUTRAL (after 10 sec or more)
{0 kg/cm2}
Min. 2.74 MPa
Swing operation
{Min. 28 kg/cm2}
2
Failure
(1) While swing holding brake is applied.

(swing brake)
Swing drift on a slope is large.
(2) While swing holding brake is released.
Related information
Cause
Probable
causes and criteria

valve (spool)
Malfunction of swing control Suction valve of swing control valve may malfunction. Check it
directly.

(safety valve)
Safety valve of swing motor may malfunction. Check it directly.

(suction valve)

(check valve)
PC800, 850-8E0
40-447

H-29 Fan revolution is abnormal (Fan sound/vibration is abnormally

large or engine overheats)
Failure
The fan speed is abnormal (excessive noise from or vibration of fan, or overheating).
Related information
Measure the fan speed to check if it is in a normal range or not.

Perform all troubleshooting with working mode in POWER (P) mode and fan 100% speed mode.
Cause
40-4 8

a Perform troubleshooting with engine at full speed.
Defective fan pump EPC cur1

rent output
Probable
causes and criteria
Fan pump EPC current
630 50 mA
a Perform troubleshooting with engine at full speed.

2
40-448
Control lever
Defective fan pump EPC

solenoid valve
Defect in fan pump or fan

motor
Control lever
Outlet pressure of fan pump

EPC solenoid valve
1.72 0.05 MPa

{17.5 0.5 kg/cm2}
If causes 1 and 2 are normal, fan pump and fan motor may be
defective, so check them directly.
PC800, 850-8E0

PC800, 850-8E0
40-449
Troubleshooting of engine (S-mode)

Method of using troubleshooting chart
40-450
40-450
The troubleshooting chart consists of the "Questions", "Check items", "Causes", and "Troubleshooting" blocks.
The Questions and Check items are used to narrow
down high probability causes by simple inspection
or from symptoms without using troubleshooting
tools.
Next, use troubleshooting tools or perform direct inspection to check the selected Causes in the order
of probability to determine the real cause.
Questions:
Questions placed in the sections A and B in the
table on the next page are those to be answered
by the customer or operator.
Questions in section A are for basic information
about the failure. Depth and accuracy of their answers to the questions in section B may depend
on their concerns on the machine condition.
Check items:
Check items placed in the section C in the table
on the right are to be simply checked by the technician to select highly probable causes.
[Causes]:
Various causes are listed is this block.
The technician will be able to narrows down the
probable causes by taking the actions listed in
the blocks A, B, and C.
[Troubleshooting]:
This section includes various items of
troubleshooting that are performed in order to
verify the results of the diagnosis made by
asking the questions and inspecting the
machine. The troubleshooting is performed in
order from the most probable one by applying
troubleshooting tools or direct inspection.
40-450
PC800, 850-8E0

This troubleshooting chart marks the content of the questions and check items with E, Q or w according to
their closer relationship with the causes.
E: Reference information for estimation of the cause
Q: Information and inspection result that indicate the cause of the failure
w: A cause particularly probable among those marked with Q above.
a Count the priority level of each marking as w > Q when determining the cause.
Don't count E when determining the cause. The item with this marking may be counted, however, if no
difference is present than this and the cause cannot be determined.
PC800, 850-8E0
40-451

40-452
<Example of troubleshooting> Exhaust smoke is black (Incomplete combustion)
Let us assume that a trouble of Exhaust smoke is black occurred and we checked the [Questions] and
[Check items] and found the following 3 items to be the causal symptoms; [Color of exhaust smoke gradually
became black], [Power was lost gradually], and [Dust indicator indicates a red zone].
40-452
PC800, 850-8E0

There is a causal relationship between 3 items in the [Questions] and [Check items] sections and 6 items in
the [Causes] sections.
The method of pinpointing the [cause] from the causal relationship and approaching the [troubleshooting] is
explained according to Step 1 Step 3 shown below.
PC800, 850-8E0
40-453

S-1 Startability is poor
40-454
General causes why startability is poor
For *1 and *2, see the next page
40-454
Remedy
Clogged fuel filter or element

Clogged feed pump strainer filter
Stuck or seized supply pump plunger
Defective injector
Defective intake air heater system
Defective alternator (regulator section)
Defective alternator (generator section)
Defective or deteriorated battery
E E
Q Q
E
w
Q Q Q Q
w
w w Q Q
w
w
w w
w
w
w
w
Q
Q Q
w
w w
w
w
Q Q
w
Q
Q Q
w
q
q
q q
q
q
q
q
q
q
q
q
q
Replace
Check air cleaner.

When EGR cooler outlet gas piping is removed, coolant containing antifreeze
flows out (*1).
When compression pressure is measured, it is found to be low.
When air is bled from fuel system, air comes out.
Check fuel filter or strainer.
Check fuel feed pump/strainer.
Perform troubleshoot according to "Rail Press Very Low Error" (*2).
Even if a cylinder is cut out, engine speed does not change.
Even if starting switch is turned to HEAT, intake air heater mount does not
become warm.
Does voltage (26 - 30 V) appear between alternator Yes
terminals B and E with engine at low idle?
No
Specific gravity of electrolyte and voltage of battery are low.
E E
Q Q w w
Clean
Clean
Replace
Replace
Replace
Replace
Replace
Check recent repair history.

Machine operation hours Operated for long period.
Became worse gradually.
Starting performance
Engine starts easily when warm.
Fuel other than specified one is used.
The filter was not replaced as specified by the Operation and Maintenance
Manual.
Engine oil must be added more frequently.
When engine is preheated or when temperature is low, preheating monitor does
not indicate proper functioning of preheating system
(if installed).
During operation, charge level monitor indicates abnormal charge (if monitor is
installed).
Dust indicator indicates a red zone. (if indicator is installed)
Air breather hole in fuel tank cap is clogged.
Fuel leaks from fuel piping.
When priming pump is operated, no resistance is felt or it is heavy.
Starting motor cranks engine slowly.
Even if air bleeding plug in fuel filter head is
While engine is cranked removed, fuel does not flow out
Even if spill hose from injector is disconnected, little
with starting motor,
fuel spills.
When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low.
Engine does not pick up smoothly and combustion is irregular.
Engine hunts.
Blowby gas is excessive.
Correct
Troubleshooting
Check items
Questions
Defective electrical system

Insufficient supply of fuel
Insufficient intake of air
Improper selection of fuel
Coolant leaks into exhaust pipe.
a Common rail fuel injection system (CRI) controls the fuel injection timing electrically. Therefore, there are cases where the engine does not start before the
crankshaft makes two revolutions maximum after starting operation. This is not
an abnormal state, however.
Clean
Replace
Correct
Replace
Clean
q
q
q
q
q
Clogged air cleaner element

Cracked EGR cooler (coolant in exhaust pipe)
Defective contact of valve with valve seat
Worn piston ring or cylinder
Clogged air breather hole in fuel tank cap
Leakage or clogging of fuel piping or air in the
fuel piping
Cause
PC800, 850-8E0

*1: EGR cooler outlet gas piping

Loosen four mounting bolts (1) of the EGR cooler outlet gas piping and check that the coolant flows out.
Condensed water from cooled exhaust gas may come out in small quantity but it is no problem if colorless
and transparent.
*2: See failure codes [CA559] and [CA2249].
PC800, 850-8E0
40-455

S-2 Engine does not start
40-456
a) Engine does not crank
Cracked EGR cooler (Coolant in exhaust pipe)

Broken flywheel ring gear
Defective connection of battery cable terminal
Defective starting switch
Defective starting motor (safety relay section)
Defective starting motor (motor section)
Defective starting circuit wiring
Defective hydraulic pump or PTO
Cause
General causes why engine does not crank
q
q
Troubleshooting
Check items
Questions
Internal parts of engine seized

o See "S-4 Engine stops during operation".
Coolant entered in cylinder, producing water hammer
Defective electrical system
Defect in hydraulic pump

Machine operation
Operated for long period
EEE
hours
Condition of horn when Horn does not sound.
Q
Q
w
w
starting switch is
Horn volume is low.
turned ON
Battery electrolyte level is low.
w
Battery cable terminal is loose.
w
When starting switch is turned ON, no operating sound is heard from battery relay.
Q
w
When starting switch is turned to START, starter pinion does not plunge.
Q
Q
w
Rotation speed is low.
Q
w
When starting switch is
Unusual noise is heard around ring gear.
w
w
turned to START,
Pinion returns halfway.
w
starter pinion plunges,
Unusual noise is heard around relay and engine does not
Q
Q w
w
but:
rotate.
When compression pressure is measured, it is found to be low
q
Check flywheel ring gear.
q
q
Voltage (20 30 V) between battery relay terminal M and
terminal E is not found.
Turn starting switch to When terminal B and terminal C of starting switch are conOFF position, connect nected, engine cranks.
When terminals B and C at safety relay outlet are concable, and perform
nected, engine starts
troubleshooting with
starting switch in ON.
Even if terminals B and C at safety relay outlet are connected, engine does not start
For *1, see the next page.
40-456
Remedy
Replace
Replace
Replace
Correct
Replace
Replace
Replace
Replace
Perform E-mode troubleshooting
Perform H-mode troubleshooting.
PC800, 850-8E0


and transparent.
PC800, 850-8E0
40-457

b) Engine cranks but no exhaust smoke comes out

General causes why engine cranks but no exhaust smoke comes out
Troubleshooting
Check items
Questions
Fuel is not being supplied.

Supply of fuel is extremely small.
Improper selection of fuel (particularly in winter)

Machine operaOperated for long period
EEE
tion hours
Exhaust smoke suddenly stopped coming out (at restarting after short
w Q w w w
time stoppage).
The filter was not replaced as specified by the Operation and Maintew w
E
nance Manual.
Fuel tank is found to be empty.
w
Air breather hole in fuel tank cap is clogged
w
Rust and water are found when fuel tank is drained
Q
Q Q Q
Q Q
There is no fuel in the removal fuel filter.
Q
w
Fuel is leaking from fuel piping.
w
w Q Q
Even if air bleeding plug in fuel filter head is removed,
While engine is
Q
Q
w Q
fuel does not flow out
cranked with
Even if spill hose from injector is disconnected, little
Q
w w w w
starting motor,
fuel spills.
Check fuel filter.
Check feed pump gauze filter.
Check feed pump.
Perform troubleshooting according to "PCV1 Error (*2) or PCV2 Error"
(*3)
Check pressure relief valve.
Engine can be started in cylinder cutout mode.
Remedy
q q
EE
Q
q
q
q q
Replace
Add
Correct
Correct
Replace
Clean
Replace
Replace
Replace
Replace
Correct
Replace
Replace
Replace
Use of improper fuel

Insufficient fuel in tank
Clogged fuel tank air breather
Leakage or clogging of fuel piping or air in the fuel piping
Clogged fuel filter or element
Clogging of feed pump gauze filter
Seized or prematurely worn feed pump
Broken supply pump shaft or key
Defective supply pump PCV
Improper connection of supply pump PCV
Malfunction of overflow valve (Does not close)
Malfunction of flow damper
Defective fuel injector
Cause

40-458
PC800, 850-8E0

General causes why exhaust smoke comes out but engine does not start
q
q
Troubleshooting
Check items
Questions
Lack of cranking force due to defective electrical system


Machine operation
E
EE
E
hours
Suddenly become unstartable.
w
w
Q
Q
Q Q
w
w w
Manual.
Engine oil must be added more frequently
w
When engine is preheated or when temperature is low, preheating monitor
w
does not indicate normally (if monitor is installed)
Dust indicator indicates a red zone (if indicator is installed)
w
Q
Q
w w
There is no fuel in the removal fuel filter.
Q Q
w
w Q Q
Starting motor cranks engine slowly
w
While engine is running, unusual noise is heard around cylinder head
w
Even if air bleeding plug in fuel filter head is removed,
While engine is
Q
w w
fuel does not flow out
cranked with startEven if spill hose from injector is disconnected, little fuel
w
ing motor,
spills.
When exhaust manifold is touched immediately after starting engine, temw
perature of some cylinders is low.
Check air cleaner.
q
Check valve system.
q
q
Check the feed pump strainer.
When injector is tested alone, condition of spray is poor
Coolant temperature gauge indication is not correct (if the gauge is installed)
Even if starting switch is turned to HEAT, intake air heater mount does not
become warm.
Remedy
q
q
Clean
Replace
Replace
Replace
Clean
Correct
Clean
Clean
Replace
Clean
Replace
Replace
Replace
Cause
Worn valve system (valve, rocker lever, etc.)
Worn piston ring or cylinder
Leakage or clogging of fuel piping or air in the fuel
Clogged fuel filter, strainer
Clogged strainer in feed pump
Clogged injection nozzle, or defective spray
Defective coolant temperature sensor, wiring harness
Defective intake air heater system
c) Exhaust smoke comes out but engine does not start (Fuel is being
injected)
PC800, 850-8E0
40-459

S-3 Engine does not pick up smoothly
40-460
General causes why engine will not pick up smoothly
Troubleshooting
Check items
Questions

tion hours
Engine pickup suddenly became worse.
Manual.
Rust and water are observed when fuel tank is drained
When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low.
Color of exhaust Blue under light load
Black
smoke:
While engine is running, unusual noise is heard around cylinder head
While engine is running, interference sound is heard around turbocharger.
High idle speed is normal, but speed suddenly drops when load is applied.
Engine hunts.
Check air cleaner.
Perform troubleshooting according to "Abnormality in EGR valve servo
(*1)"
Check valve clearance.
When turbocharger is rotated by hand, it is found to be heavy.
Remedy
EEE
EE
Q Q
Q
w
w w w
w w
w w
w
w Q Q
Q
w
w w
w
Q
Q
w w
Q w
q
q
q
q
q
q
Correct
Replace
Insufficient intake air flow

Improper fuel injection
Controller is controlling in derate mode.
(limiting injection rate (power) because of an error in electrical system)
EGR valve is stuck in open state
(Shortage of air intake due to excessive EGR gas)

Stuck EGR valve
Improper valve clearance
Seizure or interference at turbocharger
Worn piston ring or cylinder line
Malfunction of flow damper (large amounts of leakage
from injector)
Clogged injection nozzle, or defective spray
Clean
Replace
Replace
Adjust
Replace
Replace
Clean
Correct
Clean
Clean
Replace
Cause

40-460
PC800, 850-8E0

S-4 Engine stops during operation
40-461
Cause
Troubleshooting
Check items
Questions
Internal parts of engine seized

Engine overheating
Defective hydraulic pump

tion hours
Unusual noise was heard and engine stopped
w w w w
suddenly.
Condition when
Engine overheated and stopped.
w Q
engine stopped
Engine stopped slowly.
Engine hunted and stopped.
The filter was not replaced as specified by the Operation and Maintenance Manual.
Fuel level monitor indicates low level (if monitor is installed)
Metal particles are found in oil drained from oil pan.
w w
It does not rotate at all.
w w
When engine is It rotates only in opposite direction
w
w
rotated by hand: Crankshaft moves by amount of gear backlash.
Supply pump shaft does not turn.
q
Check valve system.

Check piston and connecting rod.
Check crankshaft bearing.
Check gear train.
Check feed pump.
Engine rotates when auxiliary equipment (pump, etc.) is removed.

Check engine controller power supply wiring.
Check starting switch wiring.
Remedy
EE
Q w Q w
w
w Q
Q Q
Q Q Q
Q Q Q
w
Q Q
Q Q
w w
w
w
w
w Q Q
w w
Q Q
w
q q
Replace
Replace
Replace
Replace
Add
Clean
Correct
Clean
Clean
Replace
Replace
Replace
Replace
Correct
Correct
Damage of valve system (valve, rocker lever, etc.)

Broken or seized piston connecting rod
Broken or seized crankshaft bearing
Broken or seized gear train
Clogged or leaking fuel piping
Broken or seized feed pump
Broken supply pump shaft or key
Broken auxiliary equipment (pump, etc.)
Defective engine controller power supply wiring
Defective starting switch wiring
Defective hydraulic pump
General causes why engine stops during operation

PC800, 850-8E0
40-461

S-5 Engine runs rough or is unstable
40-462
General causes why engine runs rough or is unstable
Troubleshooting
Check items
Questions

Machine operation
hours
Occurs at a certain speed range.
Occurs at low idle.
Hunting:
Occurs even when speed is raised.
Occurs on slope.
The filter was not replaced as specified by the Operation and Maintenance Manual.
EE
Q Q Q
w
Q Q
Remedy
Q
Q Q Q Q Q Q
Q
Q
w
Q
Q
Q
Q
Q
w w
w
w
w
Q Q
w Q Q

(*1)"
Perform troubleshooting according to "Bypass Valve Servo Error (*2)"
Perform troubleshooting according to "Abnormality in engine Ne speed
sensor (*3)"
Perform troubleshooting according to "Abnormality in engine Bkup speed
sensor (*4)"
EE
q
q
q q
q
q
Correct
Air in fuel system

Defective engine speed sensor (error at degree that does not generate
failure code)
Defective EGR valve
Defective bypass valve
Low idle speed is set too low

Malfunction of EGR valve
Malfunction of bypass valve
Malfunction of Ne speed sensor, wiring harness
Clogged injector nozzle, or defective spray (dirt in injector)
Defective Ne speed sensor, or wiring harness
Defective Ne speed sensor, or wiring harness
Correct
Replace
Replace
Add
Clean
Replace
Replace
Replace
Replace
Correct
Correct
Cause

*3: See failure code [CA689].
*4: See failure code [CA778].
40-462
PC800, 850-8E0

PC800, 850-8E0
40-463

S-6 Engine lacks power
40-464
General causes why engine lacks power
40-464
Defective fuel temperature sensor, wiring harness

w
q
q
q
q
q
q q
q
q
Replace
Replace
Correct
Replace
Replace
Replace
Clean
Replace
Correct
Clean
Replace
q
Adjust
Remedy
q
q q q
Replace
For *1,*2 and *3, see the next page.
Q
Q
Replace
Check air cleaner.

Check air intake piping.
When boost pressure is measured, it is found to be low.
Check boost pressure sensor mount
Perform troubleshooting according to "Charge Air Press Sensor Error
(*3)"
Perform troubleshooting according to "Abnormality in fuel temperature
sensor (*2)"
Defective installation of charge air pressure sensor

(air leakage)
Defective boost pressure sensor or wiring harness
Defective injector drive (signal or solenoid)
Clogged injector nozzle, or defective spray (dirt in injector)
Clogged or leaking fuel piping
Worn piston ring or cylinder liner
Air leakage from air intake piping and aftercooler

Machine operation
E
E
E
E E
hours
Suddenly
Q
Q
Power was lost
Gradually
Q
Q
Q
Q Q
Q
Q Q
The filter was not replaced as specified by the Operation and Maintew
nance Manual.
Q Q Q
w
w
w
Power becomes insufficient after short stop of operation.
Black
w w w
w
Color of exhaust
smoke:
Blue under light load
When exhaust manifold is touched immediately after starting engine,
w
temperature of some cylinders is low.
While engine is running, interference sound is heard around turbow
charger.
When engine is cranked, unusual noise is heard around cylinder head.
w
High idle speed is too high.
Q
High idle speed is normal, but speed suddenly drops when load is
w w Q
applied.
Engine does not pick up smoothly and combustion is irregular.
w
Q Q
w
The engine hunts. (unstable engine rotation)
Q Q Q Q
w
Clean
Troubleshooting
Check items
Questions

Engine overheating
o See "S-14 Coolant temperature becomes too high (overheating)"
Correct
q
q
q
q
q
Cause
PC800, 850-8E0

*1: See failure codes [CA559] and [CA2249]

PC800, 850-8E0
40-465

S-7 Exhaust smoke is black (incomplete combustion)
40-46
Cause
q
q
q
q
q
Troubleshooting
Check items
Questions

Supply of fuel is excessive
Engine overheating
o See "S-14 Coolant temperature becomes too high (overheating)"
EGR valve is stuck in open state
(Shortage of air intake due to excessive EGR gas)

Machine operation hours Operated for long period
Suddenly became black.
Color of exhaust smoke: Gradually became black.
Is blue under light load
Suddenly
Power was lost
Gradually
Muffler is crushed.
Air leaks at tubing between turbocharger and cylinder head, and loose
clamp
Engine is operated in low-temperature mode at normal temperature.
When the engine is running, interfering noise is heard around the turbocharger.
While engine is running, unusual noise is heard around cylinder head.
Torque converter stall speed or pump relief speed is high (Fuel is
injected excessively).
Exhaust noise is unusual.
The engine does not pick up smoothly and combustion is irregular.
When spill hose from injector is disconnected, fuel spills excessively.
E
w
Q
w
EE
w Q
E
Q
40-466
Remedy
w
Q
Q Q
Q Q
w
w
Q Q Q
Q w
w
w
Q Q
Q
Q Q
w
Q Q Q
Check air cleaner.

q
q
q
(*1)"
q
q
If muffler is removed, exhaust sound improves.
Check fuel spill tube (cylinder head side).
Perform troubleshooting according to "Coolant Temp Sensor Error (*3)".
For *1,*2 and *3, see the next page.
E
Q Q Q
Q
Q
Q w
w
q
q
q
q
Clean
Replace
Replace
Replace
Adjust
Correct
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Replace
Adjust

Stuck EGR valve
Air leak at tubing between turbocharger and cylinder head
Crushed or clogged muffler
Clogged or seized injector
Prematurely worn injector
Clogged fuel spill tube (cylinder head side)
Improper fuel injection pressure
Defective coolant temperature sensor or wiring harness
Improper injection timing
General causes why exhaust smoke is black
PC800, 850-8E0


PC800, 850-8E0
40-467

S-8 Oil consumption is excessive (or exhaust smoke is blue)
S-8 Oil consumption is excessive (or exhaust smoke is blue)

General causes why oil consumption is excessive
Troubleshooting
Check items
Questions
Excessive oil carry-over

Long-time operation of engine at low idle or high idle (Do not idle engine for more than 20 minutes continuously)
External leakage of oil
Wear of parts in lubrication system

Machine operation
hours
The oil consumption suddenly increases.
Oil becomes contaminated quickly
Outside of engine is dirty with oil.
Loose hose clamps are found in air intake system
Inside of turbocharger intake outlet pipe is dirty with oil
Inside of turbocharger exhaust outlet pipe is dirty with oil
Oil in coolant
Oil level in damper chamber is increasing.
Exhaust smoke is blue under light load.
Amount of blowby
Excessive
None
gas
Dust sucked in at air intake system

Worn/damaged valve (stem, guide, seal)
Worn seal at turbine end
Turbocharger
Worn seal at compressor end
Oil leakage from valve stem of EGR valve
Clogged breather or breather hose
Broken piston rings
Worn or damaged rear oil seal
Broken oil cooler
Oil leakage from oil cooler
Oil leakage from oil filter
Oil leakage from oil piping
Oil leakage from oil drain plug
Leakage from oil pan, cylinder head, etc.
Cause
EEEE
Q
w
Q w
E
w
Q
Q
w
Q Q w
w w w w w
Q Q Q
Q
w
w w
w w
When intake manifold is removed, dust is found inside.

q
When intake manifold is removed, inside is abnormally dirty.
q
Excessive play of turbocharger shaft
q q
When EGR valve is removed, exhaust port is found to be dirty with oil.
q
Check breather or breather hose.
q
q q
Check rear oil seal.
q
Pressure tightness test result of oil cooler shows oil leakage.
q q
External leakage of oil from engine
q q q q
Remedy
40-468
Correct
Correct
Replace
Replace
Replace
Clean
Replace
Replace
Correct
Replace
Replace
Correct
Correct
Correct
Correct
40-468
PC800, 850-8E0

S-9 Oil becomes contaminated early
40-469
General causes why oil becomes contaminated early
Troubleshooting
Check items
Questions

Machine operation
hours
Even if engine oil temperature rises, oil filter clogging monitor indicates clogging
(when monitor is installed)
Metal particles are found in the removed oil filter.
Inside of exhaust pipe is dirty with oil.
Engine oil temperature rises quickly.
Color of exhaust
Blue under light load
Black
smoke:
Excessive
Amount of blowby gas
None
Remedy
w Q
Q Q
w
w
w
w
Q
Q w
w
q
Excessive play of turbocharger shaft

When EGR valve is removed, exhaust port is found to be dirty with oil.
Check breather or breather tube.
Check oil cooler.
Check oil filter.
Spring of oil filter safety valve is stiff, or it is broken
Check turbocharger lubrication oil drain tube.
PC800, 850-8E0
EEEE
q q
See S-7.
Entry of exhaust gas into oil due to internal wear

Clogging of lubrication passage
Use of improper oil
Operation under excessive load
Defective sealing at turbocharger turbine end

Worn valve, valve guide
Worn valve or valve guide
Clogged breather or breather hose
Clogged oil cooler
Clogged oil filter
Defective oil filter safety valve
Clogged turbocharger lubrication oil drain tube
Exhaust smoke is bad
Replace
Replace
Replace
Replace
Clean
Clean
Replace
Replace
Clean
Cause
40-469

S-10 Fuel consumption is excessive
40-470
General causes why fuel consumption is excessive
Troubleshooting
Check items
Questions
Fuel leakage at cylinder head

Fuel leakage from fuel filter, piping, etc.
Defective feed pump oil seal
Defective supply pump plunger
Improper common rail fuel pressure
Defective atomization by injector
Defective operation of injector
Defective coolant temperature sensor, wiring harness
Defective fuel injection timing
Leakage of fuel
Improper fuel injection (fuel pressure or injection timing)
Excessive injection of fuel
External leakage of fuel from engine

EE
E
tion hours
is more than that on other machines of same model.
Q
Q Q Q
Fuel consumpGradually increased.
Q
Q
tion:
Suddenly increased.
Q Q
External leakage of fuel from engine
w
Combustion is irregular.
w w
Engine oil level rises and oil smells of diesel fuel
w
w
Q
When exhaust manifold is touched immediately after starting engine, temperature of
w
some cylinders is low.
Low idle speed is high.
Pump relief speed is high.
Q
Q Q
Q
Color of exhaust Black
smoke:
White
Q
Remove head cover and check for fuel leak.
Check oil seal of feed pump.
Amount of fuel is too much when spill tube from injector is disconnected and spill of
fuel is measured.
Perform troubleshooting according to "Coolant Temp Sensor Error (*2)".
Check the condition by using monitoring function of machine monitor.
Remedy
q q
q
q
Correct
Correct
Replace
Replace
Correct
Replace
Replace
Correct
Correct
Cause

40-470
PC800, 850-8E0

S-11 Oil is in coolant (or coolant spurts or coolant level goes down)
S-11 Oil is in coolant (or coolant spurts or coolant level goes down)
Unusual air bubbles are found in radiator, or coolant spurts.
Pressure tightness test result of cylinder head shows oil leakage.
E
Q
Q Q
Q
Q Q
Q
w
w
q q
Check cylinder block and liner.
Check oil cooler.
Replace
Replace
Replace
Remedy
Replace
PC800, 850-8E0
Broken oil cooler core or O-ring
Insufficient amount of thrust by cylinder liner
Replace
Questions
Check items
Troubleshooting

Machine operation
hours
Suddenly
Oil level rose:
Gradually
Hard water is being used as coolant.
Oil level has risen and oil is milky.
Internal cracks in cylinder block
Internal leakage in lubrication system

Internal leakage in cooling system
Broken cylinder head or cylinder head gasket
Damaged cylinder liner O-ring or holes caused by pitting
Cause
General causes why oil is present in coolant

q
40-471
40-471

S-12 Oil pressure drops
40-472
Cause
Troubleshooting
Check items
Questions
Leakage, clogging, or wear on lubrication system

Defective oil pressure control
Improper selection of oil (improper viscosity)
Deterioration of oil due to overheating

tion hours
Oil pressure monitor indicates low oil pressure (if monitor is installed)
Non-specified oil is being used.
The filter was not replaced as specified by Operation and Maintenance
Manual.
Indicates pressure drop at low idle.
Oil pressure
Indicates pressure drop at low and high idle
monitor (if
Indicates pressure drop on slope.
installed)
Sometimes indicates pressure drop.
Oil level monitor indicates low oil pressure (when monitor is installed)
Oil level in oil pan is low.
External lubrication piping is leaking or crushed.
Oil is milky or smells of diesel fuel
Metal particles are found in oil drained from oil pan.
Q
Q
Q Q
w
w
w
w w w Q
Metal particles are found in oil filter

q
Inspect oil pan strainer and pipe.
Oil pump rotation is heavy or there is play in oil pump
Valve spring of oil pump relief valve is fatigued, damaged
Check oil filter.
Relief valve of EGR oil pump is fatigued or damaged.
Check EGR hydraulic piping.
Perform troubleshooting according to "Abnormality in oil pressure sensor
(*1)"
If oil level sensor is replaced, oil pressure monitor indicates correct oil pressure.
Remedy
Metal particles are found when oil filter is drained
E
Q w
Q
q q
See S-13
Q Q
w
w
q
q
q
Replace
Add
Clean
Replace
Replace
Adjust
Replace
Correct
Replace
Replace
Replace
Replace
Worn main bearing

Lack of oil in oil pan
Coolant or fuel in oil
Clogged strainer in oil pan
Clogged, broken pipe in oil pan
Defective oil pump
Defective oil pump relief valve
Clogged oil filter
Leaking, crushed, clogged oil piping
Defective EGR oil pump
Leakage from EGR hydraulic piping
Defective oil pressure sensor, wiring harness
Defective oil level sensor, wiring harness
General causes why oil pressure drops
40-472
PC800, 850-8E0

PC800, 850-8E0
40-473

S-13 Oil level rises (coolant or fuel in oil)
40-474
General causes why oil level rises

q
Coolant in oil (milky)

Fuel in oil (oil smell of diluted diesel fuel)
a If oil mixes with the coolant, perform troubleshooting for "S-11 Oil is in coolant".

EE
E
tion hours
Fuel must be added more frequently.
w
w
Coolant must be added more in quantity.
Q Q
Oil in coolant
Q
Q Q
w
Oil smells of diesel fuel
w
w
Oil is milky.
Q Q
While engine is running, drops of water come from muffler.
Q Q
If radiator cap is removed and engine is run at low idle, an unusual number of bubbles
w
Q
appears, or coolant spurts.
Exhaust smoke is white.
Q
Water pump drain hole (breather hole) is clogged.
w
When water pump drain hole (breather hole) is cleaned up, water comes out.
w
Oil level in damper chamber decreases.
w
When EGR cooler outlet gas piping is removed, coolant containing antifreeze flows out
q
(*1)
q
Remove head cover and check for fuel leak.
q
Check cylinder block and liner.
q q
Check rear oil seal.
q
q
Remove and check water pump.
q
Remove and check supply pump.
q
For *1, see the next page.
40-474
Remedy
Replace
Replace
Correct
Replace
Replace
Replace
Replace
Replace
Replace
Troubleshooting
Check items
Questions
Cracked EGR cooler (Entry of coolant)

Fuel leakage inside head cover
Internal cracks in cylinder block
Worn or damaged rear oil seal
Broken oil cooler core or O-ring
Clogged water pump drain hole (breather hole) or defective oil seal
Defects in supply pump
Cause
PC800, 850-8E0


and transparent.
PC800, 850-8E0
40-475

S-14 Coolant temperature rises too high (overheating)

General causes why coolant temperature rises too high
Check coolant leakage from EGR cooler.

Check cylinder liner.
Check oil cooler.
Temperature difference between upper and lower tanks of radiator is
large.
When operation of thermostat is tested, it does not open at specified
opening temperature.
Temperature difference between upper and lower tanks of radiator is
slight.
Check radiator core.
When operation of radiator cap is tested, its opening pressure is low.
Check the fan rotation.
When coolant temperature is measured, it is found to be normal.
Remedy
40-476
q
q
q
q
q

EEE
EE
tion hours
Suddenly occurred.
Q
Q w
Q
Overheating
Tends to occur always.
Q w w
Q
Coolant temper- Indicates quick temperature rise.
Q
w
ature gauge
Does not go down from red range.
w
(if installed)
Radiator coolant level monitor indicates drop of coolant level (if monitor is
Q
w
installed)
Engine oil level has risen and oil is milky.
w Q
The fan speed is low.
w
Milky oil is floating on coolant.
w
Unusual air bubbles are found in radiator, or coolant spurts.
w
When light bulb is held behind radiator core, no light passes through.
w
Radiator shroud, inside of under guard are clogged with dirt or mud
w
w
Coolant is leaking because of cracks in hose or loose clamps.
w
Coolant flows out from radiator overflow hose.
w
Troubleshooting
Check items
Questions
Check or Replace
Lack of cooling air (deformation, damage of fan), or performance deterioration of fan pump or monitor
Drop in heat dissipation efficiency
Problem in coolant circulation system
Increase of oil temperature
Coolant leakage to external of EGR cooler

Clogged or broken oil cooler
Lack of coolant
Broken water pump
Malfunction of thermostat
Clogged or crushed radiator fins
Clogged radiator core
Defective radiator cap (pressure valve)
Deformation and damage of fan
Defective coolant temperature gauge
Performance deterioration of fan pump or fan motor
Cause
Replace
Replace
Replace
Replace
Add
Replace
Replace
Correct
Correct
Replace
Replace
40-476
PC800, 850-8E0

S-15 Unusual noise is made
40-47
General causes why unusual noise is heard
Questions
Check items
Troubleshooting

tion hours
Gradually occurred.
Abnormal noise
Suddenly occurred.
Engine oil must be added more frequently.
Air leakage between turbocharger and cylinder head.
While engine is running, interference sound is heard around turbocharger.
When engine is running, unusual noise is generated around EGR gas
piping
While engine is running, unusual noise is heard around cylinder head.
While engine is running, beat noise is heard around muffler.
Color of exhaust Blue under light load
Black
smoke:
Engine does not pick up smoothly and combustion is irregular
Unusual noise is loud when engine is accelerated
Check EGR gas piping
Check valve system.
If muffler is removed, unusual noise disappears.
Check gear train.
Check fan.
Unusual noise is heard only when engine is cranked.
Remedy
PC800, 850-8E0
E
Q
Q Q Q
w
w
Q
Q
w
w
w
w
w Q
Q w
Q
Q
w
q
q q
w
Q Q
q q
q
q
Correct
Abnormality due to defective parts

Abnormal combustion
q Air sucked in from air intake system
a Judge if the noise is an internal noise or an external noise before starting
troubleshooting.
a The engine is operated in the low-temperature mode while it is not
warmed up sufficiently. Accordingly, the engine sound becomes a little
larger. This does not indicate abnormality, however.
a When the engine is accelerated, it is operated in the acceleration mode
and its sound becomes a little larger for up to about three seconds. This
does not indicate abnormality, however.
q
Replace
Replace
Replace
Correct
Replace
Replace
Replace
Replace
Replace
Correct
Replace
Correct
Air leakage at between turbocharger and cylinder head

Cracked EGR gas piping or gas leakage
Damage of valve system (valve or rocker lever)
Defective inside of muffler (partition board out of position)
Improper gear train backlash
Coming off or seizure of gear train bushing
Deformation and damage of fan
Clogged or seized injector
Dirt caught in injector
Defective fuel injection timing (defective coolant
temperature sensor)
Cause
40-477

S-16 Vibration is excessive
40-478
General causes why vibration is excessive
Defective parts (premature wear or breakage)

Misalignment between engine and chassis
Abnormal combustion
Troubleshooting
Check items
Questions
a If unusual noise is heard and vibration is excessive, perform troubleshooting also for "S-15
Unusual noise is heard".

tion hours
Suddenly increased.
Vibration
Gradually increased.
Non-specified oil is being used.
Metal particles are found in the oil drained from oil pan
Oil pressure is low at low idle.
Vibration occurs at mid-range speed.
Vibration follows engine speed.
Stuck valve system (valve, rocker arm, etc.)

Worn main bearing and connecting rod bearing
Improper gear train backlash
Worn camshaft bushing
Improper injection timing
Loose engine mount bolts or broken cushions
Breakage of PTO, output shaft and parts in damper
Q
Q
w
w
Q
Q
Q
w
w
Q
Check valve system.

Check main bearing and connecting rod bearing.
Check gear train
Check camshaft bushing.
Check engine mounting bolts and cushions.
Check the output shaft or the inside of damper.
Remedy
Q Q
Q Q
Exhaust smoke is black.
40-478
Replace
Replace
Replace
Replace
Adjust
Replace
Replace
Cause
PC800, 850-8E0
SEN0527627-00
50-1
PC800, 850-8E0
HYDRAULIC EXCAVATOR
PC800-8E0
PC850SE-8E0
PC800LC-8E0
PC800SE-8E0
PC850-8E0
Shop Manual
Machine model
Serial number
Machine model
Serial number
PC800-8E0
PC800LC-8E0
PC800SE-8E0
PC850-8E0
65001 and up
65001 and up
65001 and up
65001 and up
PC850SE-8E0
65001 and up
5-01
50 Disassembly and assembly 50-1
PC800, 850-8E0
50-1
Contents
Contents
50-2
50 Disassembly and assembly

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 .......................................................................
Power train..............................................................................................................................
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................................................
50-2
50- 4
50- 4
50- 6
50- 9
50- 16
50- 21
50- 21
50- 29
50- 35
50- 37
50- 39
50- 44
50- 46
50- 46
50- 51
50- 67
50- 70
50- 72
50- 77
50- 77
50- 84
50- 86
50- 89
50- 96
50- 97
50- 109
50- 109
50- 111
50- 115
50- 116
50- 119
50- 120
50- 122
50- 124
50- 125
50- 128
50- 129
50- 132
50- 134
50- 135
50- 137
50- 137
50- 139
50- 146
50- 147
50- 150
50- 153
50- 159
50- 160
50- 162
PC800, 850-8E0
Contents
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 .................................................
PC800, 850-8E0
50- 164
50- 165
50- 167
50- 168
50- 170
50- 173
50- 180
50- 181
50- 181
50- 185
50- 189
50- 193
50- 195
50- 198
50- 202
50- 206
50- 210
50- 210
50- 213
50- 222
50- 229
50- 229
50- 232
50- 234
50- 236
50- 238
50-3
General information on disassembly and assembly

How to read Disassembly and Assembly
50-4
50-4
(Rev. 2009. 01)
50-4
1. Removal and installation of assemblies

Special tools
50-4
q Special tools which are necessary for removal or
installation of parts are described as A1 X1
etc. and their part numbers, part names and
quantities are described in the special tool list.
q The following information is described in the
special tool list as well.
1) Necessity
t: Special tools that cannot be substituted
and should always be used.
q: Special tools that will be useful if available
and are substitutable with tools available
on the market.
2) New/redesign
N : Tools newly developed for this model.
They have a new part number respectively.
R : Tools made available by redesigning
the existing tools which were developed for other models. Each of them
has a new part number assigned by
setting forward the part number of the
existing tool.
Blank :Tools already available for other
models. They can be used without any
modification.
3) Circle mark Q in sketch column:
q The sketch of the special tool is presented in the section of Sketches of special
tools.
q Part numbers of special tools starting with
part number 79*T-***-****indicate that
they are not available from Komatsu Ltd.
(i.e. tools to be made locally).
50-4
Removal
q In Removal section, the work procedures, precautions and know-how to do the work, and the
amount of oil and coolant to be drained are described.
q Common tools that are necessary for removal
are described as [1], [2] etc. and their part
numbers, part names and quantities are not described.
q Various symbols used in Removal section are
explained and listed below.
k : Precautions related to work safety are
described.
a : Know-how or precautions for work are described.
[*1] : This mark shows that instructions or
precautions for parts installation work are
given in Installation section.
6 : This mark shows the amount of oil or
coolant to be drained
4 : This mark shows the weight of a part
or a component.
50-4
Installation
Unless otherwise instructed, installation of parts
is to be done in the reverse order to removal.
q Instructions and precautions for parts installation
are shown with the mark ([*1], [*2]...) which corresponds to the mark in Removal section.
q Common tools that are necessary for installation
q Marks shown in the "Installation" section stand
for the following.
described.
2 : Type of coating material
3 : Tightening torque
5 : Amount of oil or coolant to be replenished
q
50-4
Various special tools are illustrated for the local
manufacture.
50-4
PC800, 850-8E0

2. Disassembly and assembly of assemblies

Special tools
50-5
q Special tools which are necessary for disassembly and assembly of parts are described as
A1X1 etc. and their part numbers, part names
and quantities are described in the special tool
list.
q The following information is described in the
special tool list as well.
1) Necessity
t: Special tools that cannot be substituted
and should always be used.
q: Special tools that will be useful if available
and are substitutable with tools available
on the market.
2) New/redesign
N : Tools newly developed for this model.
They have a new part number respectively.
R : Tools made available by redesigning
the existing tools which were developed for other models. Each of them
has a new part number assigned by
setting forward the part number of the
existing tool.
Blank :Tools already available for other
models. They can be used without any
modification.
3) Circle mark Q in sketch column:
q The sketch of the special tool is presented in the section of Sketches of special
tools.
q Part No. of special tools starting with
79*T-***-****: means that they are not
available from Komatsu Ltd. (i.e. tools to
be made locally).
50-5
Assembly
50-5
q In Assembly section, the work procedures, precautions and know-how to do the work, and the
amount of oil and coolant to be replenished are
described.
q Common tools that are necessary for assembly
q The meanings of the symbols used in "Assembly" section are as follows.
described.
2 : Type of coating material
3 : Tightening torque
5 : Amount of oil or coolant to be replenished
50-5
Various special tools are illustrated for the local
manufacture.
50-5
Disassembly
In Disassembly section, the work procedures,
precautions and know-how to do the work, and
the amount of oil and coolant to be drained are
described.
q Common tools that are necessary for disassembly are described as [1], [2] etc. and their part
q The meanings of the symbols used in "Disassembly" section are as follows.
described.
6 : Amount of oil or coolant drained.
q
PC800, 850-8E0
50-5

Coating materials list
50-6
(Rev. 2009. 02)

a The recommended coating materials such as adhesives, liquid gaskets, and greases used for disassembly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Adhesive
CateKomatsu code
gory
Part No.
Capacity
Container
LT-1A
790-129-9030
150 g
Tube
LT-1B
20 g
Polyethylene
790-129-9050
(2 pcs.
container
contained )
Polyethylene
container
q
q
Can
Use to bond and seal metal, glass and plastics.
250 g
Polyethylene
container
Use to seal plugs for blank holes.
75 g
Tube
Heat-resistant seal used to repair engines
50 g
Polyethylene
container
Instanetaneous adhesive
Curing time: From 5 sec. to 3 min.
Use mainly to bond metals, rubbers, plastics,
and woods.
Instanetaneous adhesive
Quick-curing type (max. strength is obtained after 30 minutes)
Use mainly to bond rubbers, plastics, and metals.
Features: Resistance to heat and chemicals
Use for fitted portions used at high temperatures.
Use to seal various threaded portions, pipejoints, and flanges.
Use to seal taper plugs, elbows, and nipples for
hydraulic piping.
Features: Silicon-based heat and cold-resistant
sealant.
Use to seal threaded portions on flange surface
Use to seal oil pan, final drive case, etc.
Features: Silicon-based quick-curing sealant
Use to seal flywheel housing, intake manifold, oil
pan, thermostat housing, etc.
Features: Silicon-based, heat and cold-resistant, vibration-resistant, impact-resistant sealant
Use to seal transfer case, etc.
Use for rough surfaces such as the circle gear
top seal which is not clamped by bolts, gaps in
the weld which must be caulked, etc.
Can be coated with paint.
09940-00030
LT-3
790-129-9060 Adhesive:
(Set of adhe1 kg
sive and hard- Hardener:
ener)
500 g
LT-4
790-129-9040
Holtz
MH 705
790-129-9120
790-129-9140
Use to prevent rubber gaskets, rubber cushions,

and cork plugs from coming out.
Use for plastic (except polyethylene, polypropylene, tetrafluoroethylene and vinyl chloride), rubber, metal, and non-metal parts which require
immediate and strong adhesion.
Features: Resistance to heat and chemicals
Use to fix and seal bolts and plugs.
LT-2
ThreeBond
1735
Main features and applications
50 g
q
q
q
Aron-alpha
201
790-129-9130
Loctite 648-50 79A-129-9110
2g
Polyethylene
container
50 cc
Polyethylene
container
1 kg
Polyethylene
container
q
q
q
q
q
LG-5
790-129-9080
q
q
Liquid gasket
LG-6
200 g
Tube
q
q
q
LG-7
790-129-9170
1 kg
Tube
LG-8
ThreeBond
1207B
419-15-18131
100 g
Tube
LG-9
ThreeBond
1206D
50-6
790-129-9160
q
q
q
q
790-129-9310
200 g
Tube
q
PC800, 850-8E0

Seizure
prevention compound
Molybdenum disulphide
lubricant
Liquid gasket
CateKomatsu code
Part No.
gory
LG-10
ThreeBond
790-129-9320
1206E
Container
200 g
Tube
q
q
790-129-9330
200 g
Tube
ThreeBond
1211
790-129-9090
100 g
Tube
LM-P

q
LG-11
ThreeBond
1121
09940-00040
200 g
Liquid gasket used to repair engine
Use to prevent galling and seizure of press-fitted

portions, shrinkage-fitted portions, and threaded
portions.
Use to lubricate linkages, bearings, etc.
Spray type
Thin molybdenum disulphide films are made on
metal surfaces to prevent the metals from galling.
Use for the drive shaft splines, needle bearings,
various link pins, bolts, etc.
Tube
q
q
09995-00250
190 g
Can
q
LC-G
NEVER-SEEZ
Molybdenum
SYG2-400M
disulphide
SYG2-400M-A
grease
SYGA-16CNM
LM-G (G2-M)
Can
Various
Various
400 g x 10
400 g x 20
16 kg
400 g
16 kg
Bellows-type
container
Can
Biogrease
G2-B
G2-BT (*)
*: For use at
high temperature and under
high load
SYG2-400B
SYGA-16CNB
SYG2-400BT
(*)
SYGA-16CNBT
(*)
400 g
16 kg
Bellows-type
container
Can
200 g
Feature: Lithium grease with extreme pressure

lubrication performance, general purpose type.
Use for parts under heavy load.

Caution:
q Do not use this grease for rolling bearings
like swing circle bearings, etc. and spline.
q Use this grease for work equipment pins
only when installing them, but do not use it
afterward.
Seizure resistance, heat resistance and water

resistance higher than molybdenum disulphide
grease.
Not conspicuous on machine since color is
white.
Since this grease is biodegradable in short period, it has less impact on microorganisms, animals, and plants.
Feature: Silicone grease with wide usable temperature range, high resistance to thermal-oxidative degradation and performance to prevent
deterioration of rubber and plastic parts.
Use for oil seals of the transmission, etc.
Tube
q
PC800, 850-8E0
Feature: Seizure and galling prevention compound with metallic super-fine-grain, etc.
Use for the mounting bolt in the high temperature area of the exhaust manifold and the turbocharger, etc.
Can
SYG2-400T-A
SYG2-16CNT
SYG0-400T-A
(*)
SYG0-16CNT
(*)
G2-S
ThreeBond
1855
Bellows-type
container
Hyper White
G2-T
G0-T (*)
*: For cold district
Use as lubricant/sealant when installing the radiator hoses to the water tubes.
Can be coated with paint.
Feature: Can be used together with solid gaskets.
Use for covers of the transmission case and
steering case etc.
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI
SYG2-160LI
G0-LI (*)
SYGA-160CNLI
*: For cold disSYG0-400LI-A
trict
(*)
SYG0-16CNLI
(*)
Grease
Capacity
50-7

CateKomatsu code
gory
Part No.
Capacity
Container
G2-U-S
ENS grease
Adhesive
Caulking material
2 kg
Can
q
SUNSTAR
SASH
PRIMER
GP-402
SUNSTAR
PENGUINE
SEAL580
SUPER S" or
W"
Sika Japan,
Sikaflex
256HV
SUNSTAR
PENGUINE
SUPER 560
SUNSTAR
PENGUINE
SEAL No.
2505
SEKISUI SILICONE SEALANT
20 ml
Glass container
20 ml
Glass container
20 ml
Glass container
Feature: Urea (organic system) grease with heat

resistance and long life, can be packed into the
confined space and left intact until next overhaul.
Use for rubber, bearing and oil seal in damper.
Caution: Do not mix with lithium grease.
q
Use as primer for painted cab sheet metal

surface.
(Effective period: four months after date of
manufacture)
Use as primer for glass.

manufacture)
Use as primer for painted cab sheet metal

surface.
manufacture)
Use as primer for black ceramic-coated
glass surface and for hard polycarbonate-coated surface.
manufacture)
Use as primer for sash (anodized aluminum surface).
manufacture)
Use S" in high-temperature season and
W" in low-temperature season as adhesive for glass.
manufacture)
Use as adhesive for glass.
(Effective period: six months after date of
manufacture)
Use as adhesive for glass.
manufacture)
417-926-3910
22M-54-27230
22M-54-27240
150 ml
Can
20 ml
Glass container
For adhered window glass
SUNSTAR
PAINT
PRIMER580
SUPER
SUNSTAR
GLASS
PRIMER 580
SUPER
SUNSTAR
PAINT
PRIMER
435-95
SUNSTAR
GLASS
PRIMER
435-41
50-8
427-12-11871
22M-54-27250
417-926-3910
320 ml
Polyethylene
container
20Y-54-39850
310 ml
Polyethylene
container
22M-54-27210
320 ml
Ecocart (Special container)
417-926-3920
320 ml
Polyethylene
container
20Y-54-55130
333 ml
Polyethylene
container
GE TOSHIBA
SILICONES
22M-54-27220
TOSSEAL381
For adhered window glass
Primer
Grease
Use to seal glass-to-glass joints.

manufacture)
Use to seal front window.

manufacture)
Use to seal glass-to-glass joint. Translucent white seal.
(Effective period: 12 months after date of
manufacture)
333 ml
Cartridge
PC800, 850-8E0

Special tools list
Special tools list
50-9
Removal and
installation of
fuel supply
pump assembly
Removal and
installation of
cylinder head
assembly,
engine rear seal
Standard puller
q Bolt
t 1
t 2
01643-31032
Washer
t 2
790-331-1110
Wrench (angle)
q 1
795-931-1100
795T-421-1230
01050-31645
01050-31625
795T-421-1220
01050-31625
01050-31645
795-521-1110
01050-31640
Seal puller
Push tool
Bolt
Bolt
Push tool
Bolt
Bolt
Push tool
Bolt
Pin gauge pin (7.50 mm
diameter x 6.30 mm notch
height) for bore of module
of 3.75 mm
Micrometer for bore(75
100 mm)
diameter) for shaft of module of 5.0 mm
diameter x 8.40 mm notch
height) for bore of module
of 5.0 mm
Micrometer for bore (100
125 mm)
t
t
t
t
t
t
t
t
t
4
Removal and
installation of
engine front
seal, rear seal
Installation of
PTO (coupling)
assembly
PC800, 850-8E0
Commercially
available
Commercially
available
Commercially
available
Commercially
available
Commercially
available
Sketch
Part name
795-630-5500
01010-81090
Part number
Q'ty
Symbol
New/redesign
Work
Necessity
a Part Nos. of special tools starting with 79*T-***-**** mean that they are not available from Komatsu Ltd.
(i.e. tools to be made locally).
a Necessity:
t............Special tools that cannot be substituted and should always be used
q............Special tools that will be useful if available and are substitutable with tools available on the
market
a New/redesign:
N .............Tools newly developed for this model. They have a new part number respectively.
R .............Tools made available by redesigning the existing tools which were developed for other models.
Each of them has a new part number assigned by setting forward the part number of the existing tool.
Blank .............Tools already available for other models. They can be used without any modification.
a Tools marked with Q in the sketch column are presented in the sketches of the special tools. (See "Sketches of special tools")
Contents of work and remarks
Pulling-out of drive gear
Tightening of cylinder head

bolts, flywheel bolts
1
Pulling-out of oil seal
1 N Q Press-fitting of engine rear
4
seal
(Standard type)
4
1 N Q Press-fitting of engine rear
4
seal
(Sleeve type)
4
1
Press-fitting of engine front
seal
3
t 2 N
t 1 N
t 2 N
Measuring spline wear
t 2 N
t 1 N
50-9
1
F
2
3
1
2
Disassembly
and assembly of
final drive
assembly
4
J
5
Disassembly
and assembly of
travel motor
assembly
50-10
790-101-5401
790-101-5541
790-101-5421
01010-51240
790-201-2780
790-201-2880
796T-626-1120
796-627-1050
796-627-1030
790-101-2300
790-101-2310
790-101-2350
790-101-2360
02215-11622
791-181-1010
796T-627-1340
790-101-2102
790-101-1102
Push tool kit

q Plate
q Grip
q Bolt
Spacer
Spacer
Push tool
Installer
Push tool
Push-puller
q Block
q Leg
q Plate
q Nut
Adapter
Push tool
Puller (294 kN {30 ton})
Pump
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
1
1
1
2
1
1
1
1
1
1
1
2
2
2
2
1
1
1
790-627-1200
Wrench assembly
t 1
796-627-1070
01017-52450
01580-12419
790-201-2830
790-101-5151
790-101-5401
790-101-5441
790-101-5421
01010-51240
790-101-5001
790-101-5151
790-101-5061
790-101-5021
Spacer
Bolt
Nut
Spacer
Plate
Push tool kit (C)
q Plate
q Grip
q Bolt
Push tool kit (A)
q Plate
q Plate
q Grip
t
t
t
t
t
t
t
t
t
t
t
t
t
796-660-1560
Guide bolt
t 2
Part number
Part name
1
1
1
1
1
1
1
1
1
1
1
1
1
Sketch
Q'ty
Disassembly
and assembly of
swing machinery assembly
Symbol
New/redesign
Work
Necessity

Special tools list
Press fit of oil seal

Press fit of main bearing
Press fit of main bearing
Q Press fit of sub bearing
Installation of floating seal
Press fit of bearing outer race
Press fit of bearing inner race
Q
Long stroke
round nut
Removal of No. 1 carrier pin
holder
Removal of No. 1 carrier pin
Press fit of bearing outer race
Press fit of needle bearing

No. 2 carrier
No. 3 carrier

travel motor assembly
PC800, 850-8E0
Disassembly
and assembly of
ldler assembly
Disassembly
and assembly of
carrier roller
assembly
790-201-2680
Plate
t 1
796-675-1510
Installer
t 1
11
791-601-1000
Oil pump
q 1
790-1101-5201
Push tool kit (B)
t 1
796T-630-1130
Push tool
t 1
5
6
796T-630-1140
796-670-1010
790-401-1700
790-401-1761
790-401-1540
790-401-1770
791-580-1520
790-201-2670
791-601-1000
or
791-646-8002
790-701-3000
791-680-9501
Adapter
Installer
Lifting tool
Adapter
Shackle
T-bolt
Installer
Plate
Oil pump
t
t
t
t
t
t
t
t
8
9
10
Separation and
connection of
track shoe
assembly
2
M
Disassembly
and assembly of
recoil spring
assembly
PC800, 850-8E0
790-101-4300
790-101-4200
790-101-1102
790-331-1100
791-685-8502
791-635-3160
796-630-1110
01010-51640
796-630-1120
790-101-1600
790-010-1102
796-630-1110
1
1
1
1
2
2
1
1
t 1
Oil lubricator
Seal checker
Remover, installer
Cylinder
(1,471 kN {150 ton})
Pump
Wrench
Compressor
Extension
Plate
Bolt
Spacer
Cylinder (686 kN {70 ton})
Pump
Plate
t 1
t 1
t 1
t
t
t
t
t
t
t
t
t
t
t
1
1
1
1
1
1
2
1
1
1
1
Sketch
Part name
Disassembly
and assembly of
track roller
assembly
Part number
Q'ty
Symbol
New/redesign
Work
Necessity

Special tools list
Press fit of idler bushing

Installation of idler floating
seal
Pouring of oil
Press fit of carrier roller bearing
Press fit of carrier roller bearQ
ing inner race
Q Press fit of roller
track roller assembly
Press fit of track roller bushing
Filling with oil, checking sealing

master pin
Tightening shoe bolt angle
Disassembly and assembly of

recoil spring
50-11
Disassembly
and assembly of
N
one link assembly in field
50-12
791-680-9580
791-680-9590
01010-52760
01010-51440
790-101-1102
Adapter
Guide
Bolt
Bolt
Pump
t
t
t
t
t
1
1
2
2
1
790-101-4300
Cylinder
t 1
791-685-9510
791-685-9520
791-685-9530
791-685-9550
791-685-9560
791-680-9570
01010-51030
04530-12030
790-101-1102
Frame
Frame
Rod
Nut
Bolt
Adapter
Bolt
Eyebolt
Pump
t
t
t
t
t
t
t
t
t
790-101-4300
Cylinder
t 1
791-685-9540
791-685-9550
791-685-9510
791-685-9520
791-685-9530
791-685-9550
791-685-9560
791-126-0150
791-680-5520
791-126-0140
791-680-9570
01010-51030
04530-12030
791-685-9620
790-101-1102
Rod
Nut
Frame
Frame
Rod
Nut
Bolt
Adapter
Guide
Pusher
Adapter
Bolt
Eyebolt
Extension
Pump
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
790-101-4300
Cylinder
t 1
790-101-1102
Pump
t 1
790-101-4200
Puller
t 1
Part number
Part name
Sketch
Q'ty
Symbol
New/redesign
Work
Necessity

Special tools list
1,471 kN
{150 ton}
1
1
1
1
4
1
1
1
1
1,471 kN
{150 ton}
1
3
1
1
1
1
4
1
1
1
1
1
1
1
1
1,471 kN
{150 ton}
294 kN
{30 ton}
PC800, 850-8E0
7
8
Disassembly
and assembly of
N
10
11
12
13
PC800, 850-8E0
791-680-5542
791-632-1110
791-680-5580
791-685-9510
791-685-9520
791-685-9530
791-685-9540
791-685-9550
791-685-9560
791-126-0150
01010-51030
791-685-9620
791-680-5542
791-680-5560
790-101-1102
Adapter
Adapter
Guide
Frame
Frame
Rod
Rod
Nut
Bolt
Adapter
Bolt
Extension
Adapter
Guide
Pump
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
1
1
1
1
1
1
1
3
4
1
1
1
1
1
1
790-101-4300
Cylinder
t 1
791-685-9510
791-685-9520
791-685-9530
791-685-9540
791-685-9550
791-685-9560
791-126-0150
01010-51030
791-685-9620
791-680-5560
791-632-1110
791-680-9630
790-101-1102
Frame
Frame
Rod
Rod
Nut
Bolt
Adapter
Bolt
Extension
Guide
Adapter
Adapter
Pump
t
t
t
t
t
t
t
t
t
t
t
t
t
790-101-4300
Cylinder
t 1
791-680-1520
791-685-9510
791-685-9520
791-685-9530
791-685-9540
791-685-9550
791-685-9560
791-126-0150
791-680-5560
791-680-9570
01010-51030
791-680-1520
790-101-1102
Guide
Frame
Frame
Rod
Rod
Nut
Bolt
Adapter
Guide
Adapter
Bolt
Guide
Pump
t
t
t
t
t
t
t
t
t
t
t
t
t
790-101-4300
Cylinder
t 1
790-101-1102
Pump
t 1
790-101-4200
Puller
t 1
Part number
Part name
1
1
1
1
3
4
1
1
1
1
1
1
1
Sketch
Q'ty
Symbol
New/redesign
Work
Necessity

Special tools list
Press fit of regular pin

Press fit of bushing
1,471 kN
{150 ton}
Installation of master pin and

regular pin and press fit of
bushing
1,471 kN
{150 ton}
1
1
1
1
1
3
4
1
1
1
1
1
1
1,471 kN
{150 ton}
294 kN
{30 ton}
50-13
Disassembly
and assembly of
N
Disassembly
and assembly of
main pump
assembly, etc.
Disassembly
and assembly of
center swivel
joint assembly
Remover and installer
t 1
790-101-1102
Pump
t 1
790-101-4200
Puller
t 1
790-101-4300
Cylinder
t 1
796-770-1301
q 1
Commercially
available
Oil stopper
Pin gauge Pin (6.75 mm
diameter) for outer diameter
of module 3.75 mm
Push tool
Spacer
14
3
4
790-502-1003
Cylinder repair stand
790-720-1000
796-720-1670
07281-01279
790-201-1702
Expander
Ring
Clamp
Push tool kit
t
t
t
t
790-201-1881
Push tool
790-201-1871
Push tool
790-445-4210
Push tool
790-101-5021
01010-50816
790-201-1500
Grip
Bolt
Push tool kit
t
t
t
790-201-1690
Plate
790-201-1680
Plate
790-201-1970
Push tool
792-715-1400
Plate
790-101-5021
01010-50816
790-102-4300
q
q
Grip
Bolt
Wrench
t
t
t
790-102-4310
Pin
50-14
Push-puller
q Block
q Screw
q Nut
q Washer
q Leg
q Plate
q Nut
q Adapter
Push tool
Push tool
Push tool
t
t
t
t
t
t
t
t
t
t
t
t
t
t
2
3
4
t 2 N
796T-72K-1010
708-2K-12350
790-101-2501
790-101-2510
790-101-2520
791-112-1180
790-101-2540
790-101-2630
790-101-2570
790-101-2560
790-101-2660
796T-416-1010
796T-416-1030
796T-416-1020
Disassembly
and assembly of
hydraulic cylinder assembly
Sketch
Part name
791-680-9501
Disassembly
and assembly of
hydraulic cylinder assembly
Part number
Q'ty
Symbol
New/redesign
Work
Necessity

Special tools list
KIT
294 kN
{30 ton}
1,471 kN
{150 ton}
Measuring spline wear
1 N Q Installation of main pump

input shaft oil seal
1
1
1
1
1
Disassembly of center swivel
1
joint
2
2
2
2
1
Q
1
Q
travel PPC valve
1
Q
1
hydraulic cylinder
Installation of piston ring
1
1
1
Boom cylinder
1
Arm cylinder
Arm cylinder
1
Press fit of roll
(SE)
Bucket cylin- bushing
1
der
1
All cylinders
1
1
Boom cylinder
1
Arm cylinder
Arm cylinder
1
(SE)
Bucket cylin- Press fit of
1
dust seal
der
Bucket cylin1
der (SE)
1
All cylinders
1
1
piston
2
PC800, 850-8E0
Remover
t 1
790-101-4200
790-101-1102
791-650-1610
790-445-4130
791-112-1180
01643-32780
790-101-2102
790-101-1102
790-445-4120
791-520-4140

Pump
Bracket
Screw
Nut
Washer
Pump
Sleeve
Screw
t
t
t
t
t
t
t
t
t
t
796-775-1110
Adapter
t 1
791-112-1180
01643-32780
790-101-2102
790-101-1102
793-498-1210
Nut
Washer
Sleeve
Lifter (Suction cup)
t
t
t
t
t
20Y-54-13180
Adapter
t 2
Impact wrench
q 1
Socket wrench (width

across flats: 65 mm)
q 1
2
V
Installation of
operator's cab
glass
Removal and
installation of
counterweight
assenbly
PC800, 850-8E0
Commercially
available
Commercially
available
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
Sketch
Part name
790-445-4100
1
Removal and
installation of
work equipment
assembly
Part number
Q'ty
Symbol
New/redesign
Work
Necessity

Special tools list
Removal of boom foot pin and

boom cylinder bottom pin
Short stroke
Removal of arm cylinder rod

head and bottom pin
Long stroke
Removal of boom top pin and
boom cylinder head pin
Boom top pin
only
Installation of operator's cab

glass
Removal and installation
of counter weight
mounting bolts
50-15

50-16
50-16
A4: Push tool
A5: Push tool
50-16
50-16
PC800, 850-8E0

50-17
F3: Push tool
J3: Push tool
PC800, 850-8E0
50-17
50-17

50-18
L4: Push tool
L5: Adapter
50-18
50-18
PC800, 850-8E0

50-19
S3: Push tool
T2: Push tool
PC800, 850-8E0
50-19
50-19

50-20
T3: Push tool
T4: Push tool
50-20
50-20
PC800, 850-8E0

Removal and installation of engine, PTO and hydraulic pump assembly
50-21
Removal and installation of engine, PTO and hydraulic pump assembly50-21
Symbol Part number
50-21
Part name
1 796-770-1301 Oil stopper
q 1
Removal
50-21
k Lower the work equipment completely to the
ground and stop the engine. Then, loosen the
hydraulic tank cap gradually to release the
k Disconnect the cable from the negative(-) terminal of the battery.
a Before disconnecting the hoses and tubes, put
match marks on them.
a Install oil stopper plugs to the disconnected hoses and tubes.
1. Remove the counterweight. For details, see
"Removal and installation of counterweight
assembly".
2. Remove under cover (1).
PC800, 850-8E0
3. Remove undercover (2).
Necessity
Q'ty
New/redesign
Sketch
Special tools
4. Remove the hydraulic tank strainer and stop the

oil using oil stopper tool S1.
q When not using tool S1, remove the drain
plug and drain the oil.
6 Hydraulic tank:
470 l
5. Drain the coolant.
6 Coolant:
100 l
6. Remove three covers (3).
a Remove the covers on the rear side as well.
7. Open engine hood (4).
a Open the rear side as well.
50-21

8. Disconnect filter (5).

9. Disconnect clamp (6).
10. Disconnect filter (7).
a Disconnect the hose clamp.
14. Remove partition cover (10).

a Disconnect the hose clamp from the bottom.
15. Disconnect connectors P24B (11) and P24A

(12).
11. Sling and remove engine hood (8).
12. Remove cover A.
13. Remove cover (9).
16. Disconnect reservoir tank hose (13).

a Disconnect the hose clamp as well.
17. Remove reservoir tank (14) and bracket
together.
18. Remove covers (15) and (16).
50-22
PC800, 850-8E0

19. Remove stays (17) and (18).
27. Disconnect connectors (33) and (34).

20. Sling and remove cover assembly (19).
21. Remove stay (20).
a Before disconnecting each hose, mark it with

a tag etc. to indicate its connecting position.
22. Disconnect hoses (21) to (25).
23. Remove clamp (26).
25. Disconnect connector (31).
PC800, 850-8E0
28. Disconnect tubes (35) and (36) from the pump.

a Since the hose on the tube is fixed with MIKALOR clamp, do not disconnect the hose. If
it is disconnected, put a mark on the tube to
show the position of the hose end.
50-23

29. Disconnect air hoses (37) and (38).
34. Remove radiator hose (44).
[*1]
a Put a mark on the tube to show the position
of the hose end.
30. Disconnect tube (39).
31. Disconnect air hose (40).
[*2]
of the hose end.
32. Disconnect reservoir tank hoses (41) and (42).
33. Disconnect radiator hose (43).
[*3]
[*4]
35. Disconnect harness (45) from the starting motor

terminal.
36. Disconnect ground strap (46).
37. Disconnect hose (47).
38. Remove the engine undercover.

39. Disconnect connectors P44 (48) and E22 (49).
40. Disconnect ground strap (50).
a Bottom view
50-24
PC800, 850-8E0

41. Remove controller cover (51).

a Note that there are spacers.
43. Disconnect fuel hose (53).

[*6]
[*5]
44. Disconnect connectors CE03 (54) and CE02

(55).
47. Disconnect connector M34 (58).

48. Remove air conditioner cover (59).
49. Loosen mounting bolts and remove air conditioner compressor (60).
[*8]
[*7]
51. Remove mounting bolt (62).
45. Disconnect terminal M23 (56) located between

the fan guard and engine.
a Disconnect the harness clamp as well.
52. Install two eyebolts (EB) (M30) to the PTO.
PC800, 850-8E0
50-25

53. Sling and remove the engine, PTO and hydraulic

pump assembly (63).
[*9]
4 Engine, PTO and hydraulic pump assembly:
Approx. 3,000 kg
a The air cleaner (64) is not removed in this photo
as T-sling [1] is used. If T-sling is not used, normally the air cleaner (64) interferes with the
sling; therefore, perform the following work and
then sling and remove the engine, PTO and
pump assembly (63).
1) Disconnect air tube (65).
[*10]
2) Disconnect dust indicator hose (66).
3) Remove air cleaner bands (67) and air

cleaner (64).
[*11]
50-26
PC800, 850-8E0

Installation
50-27
q Perform installation in the reverse order to
removal.
[*1] [*2]
MIKALOR clamp
a Use a new MIKALOR clamp.
1) Set the hose to the original position.
(Fitting length of air hose: 80 mm)
2) Set the bridge (BR) under the clamping bolt
so that it overlaps with band (BD) at least 5
mm (b).
3) Tightening of the clamp.
a Do not use an impact wrench.
2 Clamp bolt (BC):
Lubricating oil (THREEBOND, PANDO
18B)
q
If hoses are to be reused
Install the clamp at the clamp mark put on the

hose.
3 Clamp bolt (BC):
Min. 6 Nm {0.6 kgm}
q When using a new hose
Tighten until BDG dimension becomes 7 to 10
mm.
[*4]
Fitting length of hose: 78 mm
3 Radiator hose clamp:
10.8 11.8 Nm {1.1 1.2 kgm}
[*5]
Fuel hose (53):

128 186 Nm {13.0 19.0 kgm}
[*6]
Joint bolt for fuel hose (57):

14.8 19.6 Nm {1.5 2.0 kgm}
[*7]

14.8 19.6 Nm {1.5 2.0 kgm}
[*8]
Adjust the air conditioner compressor belt tension. For details, see Testing and adjusting,
Testing and adjusting air conditioner compressor belt.
[*9]
Engine mounting bolt:

823.8 1029.7 Nm {84 105 kgcm}
[*10]
Air hose clamp:

8.8 0.5 Nm {0.9 0.05 kgm}
[*11]
Air cleaner band:

9.8 11.8 Nm {1 1.2 kgm}
[*3]
10.8 11.8 Nm {1.1 1.2 kgm}
PC800, 850-8E0
50-27

Reference
q Procedure for replacing hoses (MSH) and (FSH)
between the suction tubes (MIKALOR clamp)
1) Apply adhesive evenly over the tube.
2 Apply evenly on entire periphery of
tube:
Adhesive (THREEBOND No.4314)
Fitting length of hose:
95 mm: MSH (main pump suction hose)
80 mm: FSH (fan pump suction hose)
3) Set the bridge (BR) under the clamp bolt and

lap it over band (BD) at least 5 mm (b).
2 Clamp bolt (BC):
18B)
q If hoses are to be reused
hose.
3 Clamp bolt (BC):
Min. 6 Nm {0.6 kgm}
When using a new hose

Tighten until dimension BDG becomes as
follows.
12 15 mm: MSH (main pump suction
hose)
7 10 mm: FSH (fan pump suction hose)
Refilling of oil
Add oil through the oil filler to the specified
level. Run the engine tso circulate the oil
through the system. Then, check the oil level
again.
5 Hydraulic tank:
470 l
Refilling of coolant
q Add coolant to the specified level. Run
engine to circulate the coolant through
the system. Then, check the coolant level
again.
5 Coolant:
100 l
Bleed air from the fuel system. For details,

see Testing and adjusting, Bleeding air from
fuel system .
50-28
Before starting the engine, check that the

wiring harnesses are at least 10 mm apart
from the high-pressure pipe.
PC800, 850-8E0

Removal and installation of cooling assembly

Removal
50-29
stop the engine.
k Loosen the cap of the hydraulic tank gradually to release the internal pressure of the hydraulic tank.
k You may be scalded if you disconnect the
heater hose without draining the coolant
when coolant temperature is high. Disconnect the heater hose after lowering the coolant temperature sufficiently.
k Collect the refrigerant (air conditioner gas:
R134a) from the air conditioner circuit.
a Ask a qualified person for collecting, adding and
filling operation of refrigerant (R134a).
a Never release the refrigerant (R134a) to the atmosphere.
k If refrigerant gas (R134a) gets in your eyes,
you may lose your sight. Accordingly, put on
protective eyeglasses while you are collecting the refrigerant (R134a) or filling the air
conditioner circuit with the refrigerant
(R134a). Collecting and filling work must be
conducted by a qualified person.
a Before disconnecting each hose, put a tag etc. to
indicate its position.
a Install oil stopper plugs to the disconnected
tubes and hoses.
50-29

oil using tool S1.
a When not using tool S1, remove the drain
6 Hydraulic tank:
470 l
6 Coolant:
100 l

assembly".
PC800, 850-8E0
50-29

7. Remove filter (5).

a Remove hose clamp as well.
14. Disconnect lower ends of radiator hoses (13) to

(15).
[*1]

[*2]
of the hose end.
17. Disconnect air hose (19).
[*3]
of the hose end.
19. Disconnect radiator hoses (21) and (22).
[*4]
11. Open radiator grille (9) and sling it.

12. Sling and remove radiator grille (9).
20. Remove covers (23) (three pieces) and (24).

50-30
PC800, 850-8E0

21. Disconnect connector (25) from B.

22. Disconnect three hoses (26) and two hoses (27).
a Prepare an oil container.
23. Sling and remove frame (28).

a AC: Air conditioner condenser
FC: Fuel cooler
24. Disconnect two air conditioner hoses (29).

[*5]
PC800, 850-8E0
50-31

27. Disconnect two fuel hoses (32).
31. Sling and remove cooling assembly (36).

4 Cooling assembly:
1020 kg

30. Sling cooling assembly (36) and remove four

mounting bolts (35) on right and left sides each.
50-32
PC800, 850-8E0

Installation
50-3
removal.
a Apply sufficient amount of compressor oil [DENSO: ND-OIL8, ZEXEL: ZXL100PG (equivalent to
PAG46) ] for R134a to each O-ring.
[*1]
10.8 11.8 Nm {1.1 1.2 kgm}
[*2], [*3]
MIKALOR clamp
2) Set the bridge (BR) under the clamping bolt
so that it overlaps with band (BD) at least 5
mm (b).
3) Tighten the clamp.
2 Clamp bolt (BC):
18B)
hose.
3 Clamp bolt:
Min. 6 Nm {0.6 kgm}
mm.
[*4]
10.8 11.8 Nm {1.1 1.2 kgm}
[*5]
a Install the hose without twisting it.
a Care must be taken when connecting the air
condtioner hoses to prevent dusts, dirt and water
from entering in the air conditioner circuit.
a When connecting the air conditioner hoses,
check that O-rings (70) are fitted to their joints.
PC800, 850-8E0
Tightening torque for air conditioner refrigerant piping fastener:
Thread size
16 x 1.5
22 x 1.5
24 x 1.5
Tightening torque
11.8 14.7 Nm {1.2 1.5 kgm}
19.6 24.5 Nm {2.0 2.5 kgm}
29.4 34.3 Nm {3.0 3.5 kgm}
Filling air conditioner circuit with refrigerant

(R134a)
Charge the air conditioner circuit with refrigerant
(R134a).
a Amount of refrigerant: 1330 50 g
Refilling of compressor oil

a If any air conditioner hose is replaced, add
the compressor oil for R134a (DENSO:
ND-OIL8, ZEXEL: ZXL100PG (equivalent to
PAG46)) to the air conditioner compressor by
the following quantity. (Take care not to add
the compressor oil too much. If do so, the
cooling performance lowers.)
5 Air conditioner compressor: Compressor oil [DENSO: ND-OIL8, ZEXEL:
ZXL100PG] (equivalent to PAG46) for
R134a
: 45 ml
(After replacement of hose between
compressor and condenser)
: 30 ml
condenser and receiver drier)
: 21 ml
(After replacement of hose between receiver drier and air conditioner unit)
: 80 ml
compressor and air conditioner unit)
50-33

a Since the compressor oil for R134a absorbs

moisture very easily, put the cap on the oil
container to shut off air immediately after
supplying the oil.
a The compressor oil for R134a can dissolve
acrylic resin and polystyrene. Care must be
taken for the use of the oil.
q
Refilling of oil
Add oil through the oil filler to the specified level.
Run the engine to circulate the oil through the
system. Then, check the oil level again.
5 Hydraulic tank:
470 l
Add coolant to the specified level. Run the
engine to circulate the coolant through the
system. Then, check the coolant level again.
5 Coolant:
100 l
Bleed air from the fuel system. For details, see

Testing and adjusting, Bleeding air from fuel
circuit .
50-34
PC800, 850-8E0

Removal and installation of aftercooler assembly

Removal
50-35
stop the engine.
1. Open radiator grille (1) and sling and remove it.
2. Remove three upper radiator covers (2).
50-35
4. Sling and remove frame (4).

5. Sling aftercooler assembly (5).
6. Remove the mounting bolts. While disconnecting aftercooler assembly (5) from the rubber
hoses, sling and remove it.
4 Aftercooler assembly:
45 kg
3. Loosen clamps (3) on the rubber hoses.

[*1]
of the hose end. (See the figure below).
PC800, 850-8E0
50-35

50-36
Installation
q perform installation in the reverse order to
removal.
[*1]
MIKALOR clamp
(Fitting length of hose: 80 mm)
2) Set the bridge (BR) under the clamp bolt so
that lap it over band (BD) at least 5 mm (b).
2 Clamp bolt (BC):
18B)
hose.
3 Clamp bolt (BC):
Min. 6 Nm {0.6 kgm}
Tighten until BDG dimension becomes 7 to10
mm.
50-36
PC800, 850-8E0

Removal and installation of fuel cooler and air condenser assembly

Removal
50-37
stop the engine.
k Collect the refrigerant (air conditioner gas:
50-37
2. Open radiator grille (2).
3. Remove fuel cooler guard (3).

4. Disconnect fuel cooler hoses (4) and (5).
5. Remove fuel cooler (6).

tubes and hoses.
1. Close the fuel tank valve (1) in advance.

7. Disconnect air conditioner condenser hoses (8)
and (9).
[*1]
8. Remove air conditioner condenser (10).
PC800, 850-8E0
50-37

50-38
Installation
removal.
[*1]
a Install the hose without twisting it.
a Care must be taken when connecting the air
condtioner hoses to prevent dusts, dirt and water
from entering in the air conditioner circuit.
a When connecting the air conditioner hoses,
check that O-rings (70) are fitted to their joints.
a Apply sufficient amount of compressor oil [DENSO: ND-OIL8, ZEXEL: ZXL100PG] (equivalent
to PAG46) for R134a to each O-ring.
Refilling of compressor oil

a If the air conditioner condenser is replaced,
add compressor oil [DENSO: ND-OIL8, ZEXEL: ZXL100PG] (equivalent to PAG46) for
R134a to the air conditioner compressor by
40 ml. (Cooling ability will decrease if
much oil is added.)
too
Air conditioner compressor:

Compressor oil [DENSO: ND-OIL8,
ZEXEL: ZXL100PG] (equivalent to
PAG46) for R134a 40 ml
a If any air conditioner hose is replaced, add

the compressor oil [DENSO: ND-OIL8, ZEXEL: ZXL100PG] (equivalent to PAG46) for
R134a to the air conditioner compressor by
the following quantity. (Take care not to add
the compressor oil too much. If do so, the
cooling performance lowers.)
5 Air conditioner compressor:
Compressor oil [DENSO: ND-OIL8, ZEXEL:
ZXL100PG (equivalent to PAG46) for R134a
Tightening torque for air conditioner refrigerant piping fastener:
Thread size
16 x 1.5
22 x 1.5
24 x 1.5
q
Tightening torque
11.8 14.7 Nm {1.2 1.5 kgm}
19.6 24.5 Nm {2.0 2.5 kgm}
29.4 34.3 Nm {3.0 3.5 kgm}
Filling air conditioner circuit with refrigerant

(R134a)
Refill the air conditioner circuit with refrigerant

(R134a).
50-38
: 45 ml
compressor and condenser)
: 30 ml
condenser and receiver drier)
: 21 ml
(After replacement of hose between receiver drier and air conditioner unit)
: 80 ml
compressor and air conditioner unit)
a Since the compressor oil for R134a absorbs
moisture very easily, put the cap on the oil
container to shut off air immediately after
supplying the oil.
a The compressor oil for R134a can dissolve
acrylic resin and polystyrene. Care must be
taken for the use of the oil.
PC800, 850-8E0

Removal and installation of fan motor assembly

Removal
50-39
stop the engine.
50-39


assembly".

a Remove the hose clamp.

a When not using tool S1, remove the drain
6 Hydraulic tank:
470 l
6 Coolant:
100 l
PC800, 850-8E0
50-39

12. Disconnect radiator hose (9).

[*1]

[*2]
of the hose end.
[*3]
of the hose end.
18. Disconnect radiator hoses (17) and (18).
[*4]
19. Remove upper tank (20) according to the

1) Remove mounting bolts (19).
k Do not lift upper tank (20) directly upward. Nut (N) welded on the upper tank
and part (W) welded on the frame in
area P will interfere if doing so.

3) Remove right and left side mounting bolts
(22) of radiator assembly (23).
4) Push radiator assembly (23) in the direction
of arrow to avoid the interference in section
P.
50-40
PC800, 850-8E0

5) Sling and remove upper tank (20).

20. Remove fan guard (24).
22. Sling and remove shroud (26).

28. Disconnect three hoses (32).
a Before disconnecting each hose, mark it with
a tag etc. to indicate its connecting position.
a Plug the openings.
q Fitting size: #062 pieces
#041 piece
29. Disconnect the connector (33) under cover (31).
30. Disconnect harness clamp (34).
23. Remove right and left brackets (27).

24. Remove right and left brackets (28).
25. Disconnect hose clamp (29).
PC800, 850-8E0
50-41

a Do not remove the fan assembly by hitting it

with a hammer, but remove it with a puller.
34. Remove bolts (38-1) to remove the fan.
[*7]
31. Remove the mounting bolts and sling and

remove fan and fan motor assembly (35).
a Take care not to damage the radiator core
with the tip of the motor. (part Q)
a Pay attention to the EGR valve, piping, and
connectors of the engine. (part R)
4 Fan and fan motor assembly:
100 kg

37. Disconnect clamps (41) to (43).

38. Disconnect three tubes (44).
39. Remove fan motor assembly (45).
4 Fan motor assembly:
25 kg
32. Remove lock plate (36).

[*5]
33. Remove bolt (37) and fan assembly (38).
[*6]
50-42
PC800, 850-8E0

Installation
50-43
removal.
[*4]
10.8 11.8 Nm {1.1 1.2 kgm}
[*1]
Upper tank hose clamp:

10.8 11.8 Nm {1.1 1.2 kgm}
[*2] [*3]
a MIKALOR clamp
3) Tighten the clamp.
2 Clamp bolt (BC):
18B)
hose.
3 Clamp bolt (BC):
Min. 6 Nm {0.6 kgm}
Tighten until BDG dimension becomes 7 10
mm.
PC800, 850-8E0
[*5]
When aligning the bolt hole of the lock plate, do not
turn the lock plate in the loosening direction. (If the
bolt hole is not aligned, turn the lock plate clockwise.)
[*6]
a Degrease the shaft and hole.
q Put a bar etc. in the pipe to lock the fan assembly
and then tighten the nut.
3 Fan assembly mounting nut:
833 882 Nm {85 90 kgm}
[*7]
Fan assembly mounting nut:

98 122.5 Nm {10 12.5 kgm}
Refilling of oil
5 Hydraulic tank:
470 l
5 Coolant:
100 l
50-43

Removal and installation of fuel tank assembly

Removal
50-4
stop the engine.
50-4
6. Remove fuel level gauge wiring cover (5) and

disconnect wiring connector (6).
1. Open the drain valve to drain the fuel.

6 Fuel tank:
980 l (at full)
2. Remove handrail (1).
4. Remove control valve cover bracket (3).

5. Disconnect fuel return hose (4).
a Disconnect the hose clamp as well.
8. Disconnect fuel return hose (8), fuel supply hose

(9) and drain hose (10) from the bottom of fuel
tank assembly (11).
50-44
PC800, 850-8E0


remove fuel tank assembly (11).
[*1]
4 Fuel tank assembly:
640 kg
50-45
Installation
Perform installation in the reverse order to
removal.
[*1]
Fuel tank mounting bolt:

549 58 Nm {56 6 kgm}
PC800, 850-8E0
50-45
Engine
Removal and installation of fuel supply pump assembly
Engine
50-46
50-46
Symbol
Part number
50-46
Part name
795-630-5500 Standard puller

A 1 01010-81090 Bolt
01643-31032 Washer
7. Remove oil level gauge (6).
Necessity
Q'ty
New/redesign
Sketch
Special tools
t 1
t 2
t 2
Removal
50-46
stop the engine.
assembly".
2. Remove the engine hood. For details, see
"Removal and installation of cylinder head
assembly".
3. Remove cover (1) from air conditioner
compressor (2).
4. Disconnect connector M34 (3).
5. Loosen lock nut (4) and disconnect air conditioner compressor (2).
[*1]
a Do not disconnect the air conditioner hoses
from the air conditioner compressor.
6. Remove the air conditioner compressor belt.
50-46
8. Remove muffler drain tube (7).

9. Disconnect fuel tubes (8).
[*2]
PC800, 850-8E0
Engine
10. Remove fuel tubes (9).

[*3]
11. Remove fuel hose (10).
[*4]
12. Remove lubrication tube (11).
[*5]
17. Remove four covers (20).

a Two each on fuel supply pump side and common rail side
18. Remove high-pressure pipe assembly (21).
19. Remove lubrication tube (22).
[*6]
20. Remove lubrication tube (23) and fuel tube (24)

assembly.
[*7]
21. Disconnect fuel tube (25).
[*8]
13. Disconnect connectors PCV1 (12), PCV2 (13)

and G (14).
a Remove the harness clamps.
14. Loosen bracket (15).

15. Remove clamps (16) and (17).
16. Remove brackets (18) and (19).
PC800, 850-8E0
50-47
Engine
22. Remove bracket (26).

24. By barring the engine by using bolt (BB), align

stamp (A) of the damper with pointer (P).
(Perform from the counterweight side.)
a At this time, the stamp of 2, 5 TOP is almost at
the top.
29. Disconnect bracket (29).

30. Remove fuel supply pump (30).
25. Check that bolt hole (H) is aligned with the tap
ped hole of the fuel supply pump drive gear.
a If these holes are not aligned, bar the engine
one more turn. (These holes are aligned
when the key is at the upper side.)
26. Remove nut (28).
[*9]
a The washer is built in nut (28). Take care not
to drop nut (28).
27. Install tool A1.
28. Tighten bolt (B) to pull out the gear.
a Keep tool A1 installed until the gear is reinstalled.
50-48
PC800, 850-8E0
Engine
Installation
50-49
1. While aligning keyway (G) on the gear with key

(K) on the fuel supply pump, install fuel supply
pump (30).
2. Loosely install supply pump (30),bracket (29)

and high-pressure pipe (21) by finger-tightening
the fixtures.
3. Tighten the fixtures for high-pressure pipe (21)
to their specified torques.
3 Sleeve nut:
39.2 44.1 Nm {4.0 4.5 kgm}
(Common rail side)
39.2 44.1 Nm {4.0 4.5 kgm}
(Supply pump side)
4. Tighten the fixtures for supply pump (30) to the
specified torque.
5. Tighten the fixtures for bracket (29) to the specified torque.
6. Install cover (20).
a Face the slit on the fuel supply pump side to
the cylinder block and that on the common
rail side down.
7. Install bracket (15).
8. Finger-tighten the fixtures for high-pressure pipe
clamps (16), (17) and (19) together with the
fixtures for the bracket, and upper and lower
clamps and then tighten them to their specified
torques one by one.
3 Clamp bolt:
9.8 1 Nm {1 0.1 kgm}
PC800, 850-8E0
Perform the following installation in the reverse order to removal.
[*1]
Adjust the air conditioner compressor belt tension.
For details, see Testing and adjusting, Testing and
adjusting air conditioner compressor belt .
[*2]
Fuel tube (8):

43 47 Nm {4.4 4.8 kgm}
(Upper sleeve nut)
14.8 19.6 Nm {1.5 2.0 kgm}
(Lower sleeve nut)
50-49
Engine
[*3]
[*9]
Joint bolt for fuel tube (9):

14.8 19.6 Nm {1.5 2.0 kgm}
(Supply pump side)
24.5 34.3 Nm {2.5 3.5 kgm}
(filter side)

14.8 19.6 Nm {1.5 2.0 kgm}
[*4]
[*5]
Mounting nut of fuel supply pump drive

gear:
176 196 Nm {18 20 kgm}
Check that the fuel injector wiring harness is

at least 10 mm apart from the high-pressure
pipe.
system .
Lubricating tube (11):

34.3 44.1 Nm {3.5 4.5 kgm}
[*6]
Lubricating tube (22):

43 47 Nm {4.4 4.8 kgm}
[*7]
Joint bolt for fuel tube (24):

14.8 19.6 Nm {1.5 2.0 kgm}
(Supply pump side)
17.7 22.6 Nm {1.8 3.0 kgm}
(Common rail side)
Joint bolt for lubricating tube (23):
7.9 12.7 Nm {0.8 1.3 kgm}
(Supply pump side)
9.8 12.7 Nm {1.0 1.3 kgm}
(Block side)
Clamp for lubricating tube (23) and fuel
tube (24) assembly:
9.8 1 Nm {1.0 0.1 kgm}
[*8]
50-50
Fuel tube (25):

14.8 19.6 Nm {1.5 2.0 kgm}
PC800, 850-8E0
Engine
Removal and installation of cylinder head assembly
Symbol
Part number
50-51
Part name
A 2 790-331-1110 Wrench (angle)
Necessity
Q'ty
New/redesign
Sketch
Special tools
50-51

q 1
Removal
50-51
stop the engine.
assembly".

6 Coolant:
100 l
10. Remove cover A.


PC800, 850-8E0
50-51
Engine
12. Remove reservoir tank hose (10) from the

bottom of cover (11).

20. Remove air tube (18).
[*3]
13. Sling and remove cover (11).


[*1]

16. Remove air cleaner (14).
[*2]

50-52
PC800, 850-8E0
Engine
23. Sling and remove muffler (22).

24. Disconnect air tube (23).
[*4]
25. Disconnect heater terminal (24) from the bottom

of air connector (25).
26. Disconnect air connector (25).
PC800, 850-8E0

30. Remove fuel filter and bracket assembly (29).
[*5]
31. Disconnect harnesses (30) and (31).

32. Disconnect connector SBP (32), BP (33), SEGR
(34) and EGR (35).
34. Disconnect connector PEVA (37).
a After serial number 530897, connector PEVA
is canceled.
50-53
Engine

36. Remove corrosion resistor and bracket
assembly (39).
[*7]
45. Disconnect connector FUEL (48).

46. Remove brackets (49) to (51).
49. Disconnect connector (54) according to the
[*13]
1) Turn housing (H1) in the direction of the
arrow.
2) Pull out housing (H1) in the direction of the
arrow.
37. Remove muffler drain tube (40).

[*8]
[*9]
40. Remove pump and bracket assembly (43).
41. Disconnect fuel return tube (44).
[*10]
[*11]
43. Disconnect turbocharger cooling tube (46).
[*12]
44. Disconnect turbocharger lubrication tube (47).
a Up to step 51, disconnect parts sequentially.
50-54
PC800, 850-8E0
Engine
50. Disconnect fuel return tube (55).

[*14]
51. Disconnect turbocharger lubrication tube (47).
[*15]
a Remove turbocharger lubrication tube (47)
after removing the intake manifold.

55. Disconnect turbocharger cooling tube (62) and
lubricating oil drain tube (63).
[*16]
56. Remove exhaust tube (64).
[*17]
52. Sling and remove diffuser (56).

a When removing, take care not to hit spout
(M).
[*18]
Exhaust side
53. Remove covers (57) to (60).
PC800, 850-8E0
50-55
Engine
66. Disconnect harness (78).

a White portion (W) is a piece of sealing tape
applied to cover the hole.
62. Remove fan guard (72).
63. Remove brackets (73) and (74).

67. Disconnect lubrication tubes (79) and (80).

[*19]
[*21]
a Check the positions of the connectors and
disconnect the clip as well.
69. Remove bypass valve (82).
[*21]
a Remove bolts (B).
70. Disconnect lubrication tubes (83) and (84).
[*21]
71. Remove EGR valve (85).
[*21]
a Remove bolts (B1).
65. Sling and remove the turbocharger, exhaust

manifold and connector assembly (77).
[*20]
4 Turbocharger, exhaust manifold and
connector assembly:
70 kg
50-56
PC800, 850-8E0
Engine

a After serial number 530897, tube (86) is canceled.
73. Remove tube (88) from the bottom of air housing
assembly (87).
[*22]
74. Remove air housing assembly (87).
75. Remove high-pressure pipe clamps (89).

a There are the same clamps also on the right
side.
76. Disconnect breather (90).

77. Remove coolant tube (91).
[*23]
78. Disconnect air vent hose (92).
79. Remove air vent tube (93).
[*24]
80. Sling and remove air intake manifold assembly

(94).
4 Air intake manifold assembly:
40 kg
PC800, 850-8E0
50-57
Engine


89. Remove spill tube (104).
90. Remove cylinder head cover (105).
84. Remove twelve covers (98).

86. Remove six high-pressure pipes (101).
a Regarding connector (102), insert flat-head
screwdriver [3] in stepped portion (a). While
pressing stopper (b), move the screwdriver in
direction (X) to disconnect connector (c).
(d): Connector on fuel injector wiring side
91. Using bolt (BB) to turn, align stamp (1,6 TOP) of

the damper with pointer (P).
50-58
PC800, 850-8E0
Engine
92. Loosen lock nut (106), then loosen adjustment

screw (107) by two to three turns.
93. Remove rocker arm and shaft assembly (108).
94. Remove push rods (109).
95. Remove capture nut (111) from fuel injector

(110) and disconnect the harness.
99. Loosen locknut (114) and adjustment screw

(115).
100.Remove crosshead assembly (116).
101.Remove mounting bolts (117) and auxiliary
bolt.
102.Remove cylinder head assembly (118).

4 Cylinder head assembly:
97. Remove holder mounting bolt (113).
98. Insert small L-bar [2] under connector (CN) of
fuel injector (110) and pry off fuel injector (110)
slowly.
a Never pull out fuel injector (110) by holding
the solenoid valve at the top of fuel injector
using pliers, etc.
PC800, 850-8E0
25 kg
103.Remove cylinder head gasket (119).
50-59
Engine
50-60
Installation
a Before installing the cylinder head, check the following items.
1) Measure stem length (e) of every mounting
bolt.
2) Make sure that stem length (e) of every bolt
is as follows.
q Short bolt: less than 170.8 mm
q Long bolt: less than 205.8 mm
3) If the mounting bolt is longer than the above
using limit or it has been tightened five times
(there are five punch marks on it), do not
reuse it but replace it with a new one.
a Tighten cylinder head mounting bolts (1) to

(6) and auxiliary bolt (7) in the following order.
a A special socket is required to tighten the
head bolts.
2 Mounting bolt:
3
Molybdenum disulfide lubricant (LM-P)
Mounting bolt ((1) (6) in following figure):

a Tighten the bolts in the order of (1) to (6).
1st time: 137 157 Nm {14 16 kgm}
2nd time: 284 294 Nm {29 30 kgm}
3rd time:
1) When using tool A2
Retighten the bolts in the order of (1) (6) by
the retightening angle of 90(+30/0).
4) Check that the cylinder head mounting face

and inside of the cylinders are free from
foreign matter.
5) When installing the gasket, check that the
grommets are fitted correctly.
1. Set cylinder head gasket (119).
2. Install cylinder head assembly (118).
50-60
PC800, 850-8E0
Engine
2) When not using tool A2

Put marks (a, b) on the bolts and cylinder
heads using a felt pen, then tighten the
bolts in the order of (1) to (6) by the retightening angle of 90(+30/0).
a After tightening bolts (1) to (6), tighten
auxiliary bolt (7).
3 Auxiliary bolt (7):
66.6 7.4 Nm {6.8 0.8 kgm}
4. Fuel injector
a Check that the inside of the injector sleeve is
free from dirt and damage.
1) Install gasket (120) and O-ring (121) to fuel
injector (110).
2 O-ring:
Engine oil (E030)
2) Install holder (122) to fuel injector (110), then
insert the injector connector while facing it to
the high-pressure pipe insertion hole.
3) Install spherical washer (123) to bolt (113)
and tighten holder (122) lightly.
2 Spherical washer:
Engine oil (EO30)
a The holder mounting bolt must be tightened to the specified torque after installing the harness and connector and
tightening the high pressure pipe fixture
lightly.
3. Crosshead
Install crosshead (116).
a Adjust the crossheads according to the following procedure.
1) Loosen locknut (114) and adjustment screw
(115).
2) While pressing the top of crosshead lightly,
tighten the adjustment screw (115).
3) After tightening adjustment screw (115) until
it touches the valve stem, tighten it further by
20.
4) While keeping this condition, tighten locknut
(114).
3 Locknut:
58.7 5.9 Nm {6.0 0.6 kgm}
PC800, 850-8E0
50-61
Engine
4) Install harness terminal (111) to fuel injector

(110) at its right and left ends with the nuts.
3 Terminal nut:
1.8 2.2 Nm {0.18 0.22 kgm}
5) Install spring clamp (124) and harness holder
clamp (112).
a Remove slack of the wiring harness and
press it against the injector.
5. Push rod
Install push rod (109).
a Check that the push rod end is securely
placed in the cam follower socket.
6. Install connector (102).

a Connector (102) must be installed before installing the high-pressure pipe.
50-62
7. High-pressure pipe
k Before installing the high-pressure pipe,
check it for the following defects. If it has
any defect, replace it with a new one since
fuel may leak.
q Make sure with visual check that the taper
seal portion of the connection (a portion:
2 mm area from the tip-end) is free from
longitudinal slits b or pits c.
q Make sure that there are no steps or wear
which your fingernail can feel on the portion d (end of taper seal: portion at the
area of 2 mm from the tip). (Namely, this
portion must be free from fatigue.)
1) Put sleeve (126) of high-pressure pipes (101)

in the fuel high-pressure pipe insertion part
and install it lightly.
a Check that the O-rings are attached to
both of the injector and sleeve nut.
2) Tighten sleeve nut (127) by two turns with
your fingers on the threads of the injector,
and then tighten sleeve nut (127) using a
wrench (do not tighten to the specified torque
yet).
a If sleeve nut (127) does not catch the
threads of the injector, press its end with
another small wrench, etc. and rotate its
hexagonal part with the wrench.
a After tightening the sleeve nut, check that
the O-ring is not squeezed out of the end
of sleeve nut (127).
3) Tighten bolt (113) of holder (122) to the specified torque.
3 Injector holder mounting bolt:
58.8 73.5 Nm {6.0 7.5 kgm}
PC800, 850-8E0
Engine
4) Tighten sleeve nut (127) of high pressure

pipe (101).
a Tighten the sleeve nuts also on common
rail side.
a Control the tightening torque by using
open-end torque wrench [1].
3 Sleeve nut:
39.2 44.1 Nm {4 4.5 kgm}
9. Install cylinder head cover (105).

29.4 34.3 Nm {3.0 3.5 kgm}
10. Install covers (98) to the sleeve nuts of
high-pressure pipes (101).
a Face the slits to the following directions.
Cylinder head side: Lower side
Common rail side: Cylinder block side
11. Install fuel spill tube (104).
3 Fuel spill tube joint bolt:
9.8 12.7 Nm {1.0 1.3 kgm}
12. Install harness (103).
13. Finger-tighten the clamp mounting bolts for the
upper and lower clamps (126) and (99) for the
high-pressure pipes and the stay mounting bolts.
a Tighten the clamp mounting bolts to the
specified torque after installing the air intake
manifold.
8. Install rocker arm and shaft assembly (108).

a Check that the spherical portion of adjustment screw (107) is fitted properly in the
socket of the push rod (109), and then tighten
the mounting bolt.
3 Mounting bolt:
93 103 Nm {9.5 10.5 kgm}
a Adjust the valve clearance. For details, see
Testing and adjusting, "Adjusting valve clearance".
3 Lock nut (106):
53.0 64.7 Nm {5.4 6.6 kgm}
a After tightening the locknut, check the valve
clearance again.
PC800, 850-8E0
50-63
Engine
14. Place the lubrication tube (129) for turbocharger

(TC) inside beforehand.
a The lubrication tube cannot be placed inside
after the air intake manifold is installed.
15. Install the air intake manifold.

a Before installing the air intake manifold, insert three bolts (B).
a Tighten the mounting bolts of air intake manifold assembly in the order of [1] to [24]
shown below.
3 Air intake manifold assembly mounting bolt:
59 74 Nm {6.0 7.5 kgm}
50-64
16. High-pressure pipe clamp

1) Tighten the fixtures for high-pressure pipe
clamps (126) and stays (127) on the air
intake manifold (described above) to their
specified torques.
a Bend the rubber beforehand.
3 Clamping bolt:
9.8 1 Nm {1 0.1 kgm}
2) Fasten stays (128) of clamps (99) under the
air intake manifold (described above) lightly.
3) Finger-tighten the bolts for high-pressure
pipe clamp (100) and bracket (96).
4) Lightly install high-pressure pipe clamp (95)
and bracket (97).
5) First, tighten the bolts for high-pressure pipe
clamps (100) and (95) to the specified
torque.
3 Clamping bolt:
9.8 1Nm {1 0.1 kgm}
6) Tighten fixtures for bracket (96) and (97) to
the specified torque.
7) Tighten fixtures for high-pressure pipe clamp
(99) to the specified torque.
3 Clamping bolt:
9.8 1 Nm {1 0.1 kgm}
8) Tighten fixtures for stay (128) to the specified
torque.
PC800, 850-8E0
Engine
Perform the following installation in the reverse

order to removal.
[*1]
Air hose clamp:

8.8 0.5 Nm {0.9 0.05 kgm}
[*4]
Inside:
3
Air hose clamp:

10.5 0.5 Nm {1.07 0.05 kgm}
Outside: See MIKALOR clamp [*3].
[*5]
[*2]
Air cleaner band:

9.8 11.8 Nm {1 1.2 kgm}
Fuel tube joint bolt:

24.5 34.3 Nm {2.5 3.5 kgm} (filter side)
[*7]
[*3]
MIKALOR clamp
3) Tighten the clamp bolts.
2 Clamp bolt (BC):
18B)
hose.
3 Clamp bolt (BC):
Min. 6 Nm {0.6 kgm}
mm.
Corrosion resistor, bracket assembly (39)

tube joint bolt:
24.5 34.3 Nm {2.5 3.5 kgm}
[*8]
Fuel tube (41):

43 47 Nm {4.4 4.8 kgm} (upper side)
14.8 19.6 Nm {1.5 2.0 kgm} (lower side)
[*9]
Fuel hose (42):

43 47 Nm {4.4 4.8 kgm}
[*10]
Joint bolt for fuel return tube (44):

9.8 12.7 Nm {1.0 1.3 kgm}
[*11]
Fuel tube (45):

14.8 19.6 Nm {1.5 2.0 kgm} (supply
pump side)
[*12]
PC800, 850-8E0
Joint bolt for turbocharger cooling tube

(46):
24.5 34.3 Nm {2.5 3.5 kgm}
50-65
Engine
a Lightly tighten the three bolts of (1) to (3)

shown below in this order and then the remaining bolts (4) to (24) in this order. After
that, tighten all bolts (1) to (24) to the
specified torque in this order.
2 Mounting bolt:
Seizure prevention compound
(LC-G)
3 Mounting bolt:
59 74 Nm {6.0 7.5 kgm}
[*13]
1) Insert the connector to the end, while aligning
its groove to the other.
2) Turn housing (H1) in the direction of the
arrow until it "clicks".
[*14]
Joint bolt for fuel return tube (55):

9.8 12.7 Nm {1.0 1.3 kgm}
[*15], [*16]
3 Joint bolts for turbocharger lubrication
tube (47) and cooling tube (62):
24.5 34.3 Nm {2.5 3.5 kgm}
Mounting bolt for EGR cooler tube (64):

44.1 53.9 Nm {4.5 5.5 kgm}
[*18]

34.3 44.1 Nm {3.5 4.5 kgm}
[*23]
Mounting bolt for bypass tube (75):
44.1 53.9 Nm {4.5 5.5 kgm}
[*20]
Exhaust manifold, turbocharger and connector
assembly
1) Apply heat-resistant sealant to the fitting
parts of the exhaust manifold (between ports
No. 2 and No. 3 and between ports No. 4 and
No. 5).
2 Fitting parts:
Heat-resistant sealant (HOLTS
MH705)
2) Fit the gasket to the exhaust manifold (1).
Sling and install exhaust manifold (1).
3) Tighten the mounting bolts in the following
order.
50-66
Joint bolts for lubricating tubes (80) and

(84):
24.5 34.3 Nm {2.5 3.5 kgm}
Mounting bolts for EGR valve (85) and bypass valve (82):
59 74 Nm {6.0 7.5 kgm}
[*22]
Air tube clamp:
8.8 0.5 Nm {0.9 0.05 kgm}
[*19]
[*17]
[*21]
Joint bolt for cooling tube (91):

9.8 12.7 Nm {1.0 1.3 kgm}
[*24]
q
Joint bolt for air vent tube (93):

9.8 12.7 Nm {1.0 1.3 kgm}


system.
Before starting the engine, check that the
wiring harnesses are at least 10 mm apart
from the high-pressure pipe.
PC800, 850-8E0
Engine
Removal and installation of fuel injector assembly

assembly".
(The counterweight must be removed for
barring.)
2. Remove the air intake manifold assembly (1).
For details, see "Removal and installation of
cylinder head assembly".
50-67
7. Disconnect connector (6) of the injector wiring.

a Insert flat-head screwdriver [3] in stepped
portion (a). While pressing stopper (b), move
the screwdriver in direction (X) to disconnect
connector (c).
(d): Fuel injector wiring side
8. Remove cylinder head cover (7).

9. Using bolt (BB) to turn the engine, align stamp

(1,6 TOP) on the damper with pointer (P).
5. Remove fuel spray prevention cap (4).

a Remove the caps on the common rail side as
well.
6. Remove the clamps and high-pressure pipes
(5).
PC800, 850-8E0
50-67
Engine
10. Remove the mounting bolts and rocker arm

assembly (8).
a Loosen locknut (9) and loosen adjustment
screw (10) by two to three turns so that excessive force is not applied to the push rod
when installing the rocker arm assembly.
12. Remove holder mounting bolt (19) of fuel injector

(11) and remove fuel injector assembly (11).
a Insert small L-shaped bar [2] under the connection of the fuel injector and pry off the injector slowly.
a Do not nip the solenoid valve on the fuel injector with pliers etc. to remove.
11. Disconnect the injector wiring harness according

to the following procedure.
1) Remove two nuts (12) of the solenoid valve
of fuel injector (11).
2) Remove spring clamp (13).
3) Disconnect clamp (14).
a Remove the injector wiring harness according to the following procedure.
1] Remove one mounting bolt (hexagon
socket head bolt) (17) of holder (16) of
connector (with O-ring) (15).
2] Remove holder (16) and push in
connector (15) to remove it.
[*1]
50-68
PC800, 850-8E0
Engine
Installation
50-69
1. Install the removed parts up to the air intake
manifold. For details, see the removal steps 4
and after in "Removal and installation of cylinder
head assembly".
a When installing the injector harness, press the

harness against the injector.
If the harness is not fit securely to the injector, it
may interfere with the exhaust rocker arm,
causing a short-circuit.
Good: Harness is fit securely to the injector.
Perform the following installation in the reverse

order to removal.
a Install the parts. For details, see the precautions

described in Removal and installation of cylinder head assembly.
[*1]
Installation procedure for fuel injector harness assembly
a It is difficult to install the connector having the

O-ring, from inside.
1) Remove O-ring (23) from harness connector
(22). Take out the harness connector from
the connector insertion opening.
2) Fit O-ring (23) and apply engine oil (SAE30)
to its outside surface.
3) Install connector holder (24) and push it in.
4) Fix connector holder (24) with mounting bolt
(17).
PC800, 850-8E0
Not good: Harness is not fit securely to the injector.
50-69
Engine
Removal and installation of engine front seal
Sym
Part number
bol
50-70
Part name
3 795-931-1100 Seal puller

795-521-1110 Push tool
6
01050-31640 Bolt
Necessity
Q'ty
New/redesign
Sketch
Special tools
t 1
t 1
t 3
50-70
How to remove the front seal using tool A3

1) Drill several holes of about 3 mm in diameter
on front seal (2).
2) Set tool A3 to the drilled hole.
(Tip of tool: Drill type)
3) Remove the front seal with impacts of slide
hammer (SH).
a Remove all the chips.
q Tool A3
Removal
50-70
1. Remove the fan and fan shroud assembly. For
details, see Removal and installation of fan
motor assembly .
2. Remove pulley and damper assembly (1).
a Since there is a stamp on damper (1), put a
match mark (M) on it and the front cover.
3. Remove front seal (2).
50-70
Installation
50-70
1. Install front seal (2).
a Before installing the seal, check that the end
corner and lip sliding contact surface and the
housing are free from flaw, burr, and rust.
a When installing the seal, do not apply oil or
grease to the shaft and seal lip. Wipe off the
oil on the shaft.
a Never remove the inner plastic tube (6) of the
supply part seal just before installation.
PC800, 850-8E0
Engine
1) Put large inside diameter side (b) of the

plastic inner tube to the end of crankshaft (5).
a Take care not to put the wrong end.
2) Put both of your hands to the metal ring of

seal (2) and push the seal evenly to pass
over the large inside diameter side of the
plastic inner tube (6).
3) After pushing in the seal, remove plastic
inner tube (6).
a When removing the plastic inner tube,
take care not to damage the seal lip.
PC800, 850-8E0
4) Tighten the bolts of tool A6 evenly to press-fit

seal (2) until the end of tool A6 reaches the
end face of crankshaft (5).
a Press-fitting depth of seal from crankshaft
end face a: 9.1 10.1(mm)
a Take care not to damage the lip on the
PTO side when setting the tools for press
fitting.
a After press-fitting the seal, remove the
red sealant layer from its periphery.
2. Align the matchmarks (M), install pulley and

damper assembly (1), and tighten the mounting
bolts.
3 Mounting bolt:
245 308.7 Nm {25.0 31.5 kgm}
50-71
Engine
Removal and installation of engine rear seal
Symbol
Part number
2 790-331-1110
3 795-931-1100
795T-421-1230
4 01050-31645
A
01050-31625
795T-421-1220
5 01050-31625
01050-31645
50-72
Part name
Wrench (angle)
Seal puller
Push tool
Bolt
Bolt
Push tool
Bolt
Bolt
Necessity
Q'ty
New/redesign
Sketch
Special tools
q
t
t
t
t
t
t
t
1
1
1 N Q
4
4
1 N Q
4
4
Removal
50-72
1. Remove the PTO assembly and hub assembly.
PTO assembly".
2. Remove one mounting bolt of flywheel (1) and
install a guide bolt.
3. Using eyebolt [1] (12 mm, P=1.75), sling
flywheel (1) and remove the eight mounting
bolts.
4. Move flywheel (1) toward this side little by little
and sling and remove it.
k Take care not to damage your fingers by
the flywheel that can fall off suddenly because of the shallow spigot joint.
4 Flywheel:
65 kg
50-72
50-72
5. Remove rear seal (2) according to the following

procedure.
a Measure the distance between the rear seal
and the end of the flywheel housing (FWH).
1) Before pulling out rear seal (2), drive it in a
little to separate it from the flywheel housing
(FWH).
2) If the seal is sleeved, cut and remove sleeve

(5) using a chisel and a hammer.
a When cutting, take sufficient care not to
damage crankshaft (4).
3) Hitch the end of tool A3 to the metal ring of
rear seal (2) and pull out the seal by applying
impacts using slide hammer (SH).
a Do not use a drill, etc. as metal chips may
enter the engine.
a Remove all the chips.
PC800, 850-8E0
Engine
Tool A3
Standard spare part of

seal
Sleeved seal
a Left: standard seal, Right: sleeved seal

a Clean, degrease, and dry the contacting surface
against the flywheel housing.
a Clean, degrease, and dry the seal lip sliding surface (peripheral surface of the crankshaft).
a Check that the end corner of the crankshaft and
lip sliding surface and housing are free from flaw,
burr, sharp fin, rust, etc.
Installation
50-73
a When using a teflon seal (Laydown lip seal),
check the wear of the crankshaft and select
"standard seal" or "sleeved seal" to be installed
depending on the wear.
If the wear condition of the shaft is glossy and no
scratches (no scratch is felt when touched by a
finger, wear depth is 10 mm or less), install standard seal A. In other cases, install sleeved seal
B.
a (3): Shows the inner plastic tube/installation
guide.
a (5): Shows the sleeve.
a Do not remove installation guide (3) from rear
seal (2) before installing it.
a Handle rear seal (2) and sleeve (5) as an assembly and never separate them from each
other.
PC800, 850-8E0
50-73
Engine
1. Procedure for installing standard seal

a When installing rear seal (2), do not apply oil
or grease to the shaft and seal lip.
1) Put the large inside diameter side (b) of
plastic inner tube (3) of rear seal (2) to the
end of crankshaft (4).
a Take care not to install the wrong end.
2) Put both of your hands to the metal ring of

rear seal (2) and push it in firmly.
3) After pushing in the rear seal, remove plastic
inner tube (3).
a When removing the plastic inner tube,
take care not to damage the seal lip.
50-74
4) Tighten the three bolts evenly to press-fit rear

seal (2) until the end of tool A4 (for press
fitting the seal) reaches the end of crankshaft
(4).
a On tool A4 (for press fitting the seal), first
tighten the 45 mm bolt until it bottoms and
then tighten the 25 mm bolt.
a When press-fitting the seal, take care not
to damage the lip on the PTO side by the
tool set, etc.
2. Procedure for installing sleeved seal

a When installing the rear seal, do not apply oil
or grease to the shaft, sleeve inside surface
C and seal lip surface.
1) Set sleeve and rear seal assembly(6) to tool
A5 (for press-fitting the sleeved seal).
2 Inside surface (C) of sleeve:
PC800, 850-8E0
Engine
2) Put the sleeve of the rear seal to the end face

of crankshaft (4). Press-fit sleeve and rear
seal assembly (6) by tightening the three
bolts evenly until the end face of tool A5
reaches the end of crankshaft (4).
a On tool A5 (for press-fitting the seal with a
sleeve), first tighten the 45 mm bolt until it
hits the bottom and then tighten the 25
mm bolt.
3) Remove tool A5 (for press-fitting the seal with

a sleeve) and install tool A4 (for press-fitting
the seal).
4) Press-fit sleeve and rear seal assembly (6)
by tightening the three bolts evenly until the
end of tool A4 (for press-fitting the seal)
reaches the end of crankshaft (4).
a On tool A4 (for press-fitting the seal), first
tighten the 45 mm bolt until it hits the bottom and then tighten the 25 mm bolt.
a Rear seal driving depth:
13.2 0.2 (mm) from the end of crankshaft
PC800, 850-8E0
3. Flywheel
Using eyebolt [1] (12 mm, P=1.75), sling
flywheel (1), install it to the crankshaft, and
tighten the bolts.
a Install the flywheel while aligning the dowel
pin of the crankshaft with the dowel hole of
flywheel.
a The bolt which has five punch marks must be
replaced without being reused.
2 Threaded part and seat surface of bolt:
Engine oil SAE No. 30
4 Flywheel:
65 kg
50-75
Engine
a After installing the flywheel, measure the facial runout and radial runout using tool [1].
a Radial runout: Max. 0.13 mm
a Facial runout: Max. 0.02 mm
a Tighten the mounting bolts according to the

3 Flywheel mounting bolt
1st time: 118 4.9 Nm {12 0.5 kgm}
2nd time:
1) When using tool A2(refer to the tool table)
Retighten the bolts in the order of [1] to [8]
by the retightening angle of 90(+30/0).
2) When not using tool A2
Put marks on each bolt and the flywheel
with paint, then retighten each bolt by
90(+30/0) in the order of [1] to [8].
Perform the installation to follow in the reverse order to removal.
a After tightening, put a punch mark (9) on

each bolt head to indicate the number of
times the bolt has been tightened.
50-76
PC800, 850-8E0
Power train
Removal and installation of PTO assembly
Power train
50-7
50-7
SymPart number
bol
Commercially
available
Commercially
available
Commercially
B 4
available
Commercially
available
Commercially
available
S 1 796-770-1301
6
50-7
Part name
Pin gauge pin (7.50

mm diameter,6.30
mm notch height) for
the bore of module of
3.75 mm
Micrometer for the
bore(75 100 mm)
Pin gauge pin (9.00
mm diameter) for the
shaft of module of 5.0
mm
Pin gauge pin (10.00
mm diameter x 8.40
mm notch height) for
the bore of module of
5.0 mm
Micrometer for the
bore (100 125 mm)
Oil stopper
Necessity
Q'ty
New/redesign
Sketch
Special tools
t 2 N
t 1 N
t 2 N
t 2 N
t 1 N
q 1
Figure on the left: pin gauge, figure on the right: micrometer for the bore
PC800, 850-8E0
50-7
Removal
stop the engine.
match marks on them. After disconnecting them,
install oil stopper plugs to them.
6 Hydraulic tank:
470 l
2. Drain the oil in the PTO case.
6 PTO case:
approx. 6 l
3. Remove main pump and cooling fan pump
assembly (1). For details, see "Removal and
installation of main pump assembly".
4 Main pump and cooling fan pump assembly:
560 kg
50-77
Power train
4. Remove hose (2) from bracket (3).

5. Disconnect hoses (4) and (5).
6. Disconnect hoses (6) and (7) from the bottom of
bracket (3).
7. Sling and remove bracket (3). (Lower to the
ground.)
11. Disconnect two dust indicator hoses (13).

a Remove the clamp inside bracket (16).
14. Disconnect stay (17).

15. Sling and remove frame assembly (18).

10. Disconnect hoses (11) and (12).
50-78
16. Disconnect right and left brackets (19).

17. Remove two clamps (20).
PC800, 850-8E0
Power train
18. Remove belt cover (21) from the air conditioner

compressor.
19. Loosen lock nut (22).
20. Remove the mounting bolts and disconnect air
conditioner compressor (23).
[*1]
a Do not disconnect the air conditioner hoses
from the air conditioner compressor.
21. Remove the air conditioner compressor belt
(24).
22. Remove right and left mounting bolts (25).
[*2]
26. Slightly raise engine and PTO assembly (28).

4 Engine and PTO assembly:
Approx. 3000 kg
a Since clearance A is narrow, take care that
valve cover (BC) of the engine dose not hit
fan guard (FG).
27. Support engine and PTO assembly (28).

k Loosen sling [6] and check that engine
and PTO assembly (28) is supported.
28. Strain sling [6].
29. Remove mounting bolt (29).
[*4]
24. Remove right and left mounting bolts (27).
[*3]
a Take care not to fall the nut plate.
25. Install M30 eyebolts (B) to the right and left, and
sling engine and PTO assembly (28) using sling
[6].
a RF: Rear frame
PC800, 850-8E0
50-79
Power train
30. Sling and remove PTO assembly (30).

4
[*5]
PTO Ass'y:
270 kg
31. Remove hub assembly (31).

[*6]
50-80
Installation
a Measure the wear of coupling spline to see if the
wear of the spline is within standard value. (If
not, replace the coupling.)
a Measure the wear of hub spline to see if the wear
of the spline is within the standard value. (If not,
replace the hub.)
a Measure the wear of the main pump spline to
see if the wear is within the standard value. (If
not, replace the main pump.) Refer to "Installation of Main pump".
Preparation
1) Two pin gauges: (module 3.75 mm) pin (7.50
mm diameter and 6.30 mm cutout height) for
internal diameter
Pin (6.75 mm diameter) for the outside diameter
2) Two pin gauges: (module 5.0 mm) pin (10.00
mm diameter and 8.40 mm cutout height) for
internal diameter
3) Petrolatum (for pasting pin gauge)
4) Micrometer for the bore: 75 to 100 mm, 100
to 125 mm
5) Micrometer: 75 to 100 mm, 125 to 150 mm
1. Apply petrolatum to pin gauges B2 and stick the
gauge to the inner splines of coupling.
a Face the cutout of pin gauge B2 outside.
a When sticking the pin gauge in Y direction
50-80
PC800, 850-8E0
Power train
2. Using the micrometer for the bore (75 to 100

mm) B3, measure the over pin dimension of the
shaft internal splines of the coupling (between
B2). Measure at portions A and B in X and Y
directions (at four positions in total).
a OK: 76.26 mm or smaller
4. Using micrometer (125 to 150 mm) [1], measure

the over pin dimension of the shaft external
splines of coupling (between B4). Measure at
portions A and B in X and Y directions (at four
positions in total).
a OK: 147.88 mm or larger
a Measuring in direction X at portion B
3. Similarly, apply petrolatum to pin gauges B4 and

stick them to the outer splines of coupling.
a When pasting the pin gauge in X direction
PC800, 850-8E0
5. Apply petrolatum to pin gauges B5 and stick

them to the inner spline of the hub.
50-81
Power train

mm) B6, measure the over pin dimension of the
hub splines (between B5). Measure at portions A
and B in X and Y directions (at four positions in
total).
Perform the rest of installation in the reverse

order to removal.
[*1]
q
Adjust the air conditioner compressor belt

tension. For details, see Testing and adjusting,Testing and adjusting air conditioner
compressor belt tension.
[*2] [*3]
3 Engine mounting bolt and PTO bracket
mounting bolt:
823.8 1029.7 Nm {84 105 kgm}
[*4]
a Degrease the bolt and tap hole.
2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
98 123 Nm {10.0 12.5 kgm}
[*5]
a Do not apply the grease to the splines.
2 Spline:
Transmission oil TO30 (TO10 in winter)
[*6]
Hub assembly (31)
a Degrease the bolt and tap holes.
2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
98 123 Nm {10.0 12.5 kgm}
a When installing hub assembly (31), measure
the following dimension a at eight points (A to
H) around the entire periphery to check the
seating condition of the spigot joint. Make
sure that measured value is within the specified value shown below at any point. (Record
the measured values.)
a Measuring in direction Y at portion B
a = 11.2 0.7 mm
50-82
PC800, 850-8E0
Power train
a FW: Flywheel
Table for judging hub assembly fitting dimension

a
11.2 0.7 mm (standard value)
A
B
C
D
E
F
G
H
Refilling of oil (PTO case)
Add oil through the oil filler port to the specified

level.
a Summer (0 40 C):
TO30
a Winter (-30 10 C):
TO10
5 PTO case:
approx. 6 l
PC800, 850-8E0
50-83
Power train
Disassembly and assembly of PTO assembly

Disassembly
50-84
1. Remove PTO assembly (1). For details, see
"Removal and installation of PTO assembly".
50-84
5. Remove bearing (6) from shaft (5) using push

tools [1] and [2].
2. Remove snap rings (2) and (3).

3. Raise PTO assembly (1).
4. Lightly hit the periphery A of shaft assembly (4)
from the backside and remove shaft assembly
(4).
50-84
PC800, 850-8E0
Power train
Assembly
50-85
a Clean each part and check it for dirt or damage.
Apply engine oil to its sliding surface before installation.
1. Install bearing (6) to shaft (5) using push tools [1]
and [3].
2 Bearing:
Grease (G2-LI)
2. Install shaft assembly (4) to PTO assembly (1).

3. Install snap rings (2) and (3).
PC800, 850-8E0
50-85
Power train
Removal and installation of swing motor and swing machinery assembly
Removal and installation of swing motor and swing machinery assembly50-86

Removal
50-86
stop the engine.
k Release the remaining pressure in the hydraulic circuit. Refer to the Releasing remaining pressure from hydraulic circuit
section in the Testing and adjusting chapter
of this manual.
a Before disconnecting the hoses, put match
marks on them. After disconnecting them, install
oil stopper plugs to them and swing motor assembly.
a Rear side
1. Disconnect hoses (1) and (2) from the control
valve and hoses (3) and (4) to the swing motor at
the front section of the machine body.
2. Disconnect swing brake hose (5) and drain hose
(6).

remove swing motor and swing machinery
assembly (7).
[*1]
4 Swing motor and swing machinery assembly:
570 kg
50-86
PC800, 850-8E0
Power train
a Front side
1. Disconnect hoses (8) and (9) from the swing
motor in the central section of the machine body.
2. Disconnect swing brake hose (10) and drain
hose (11).
3. Disconnect hose (12) in swivel joint section.
4. Disconnect horn assembly (13).

5. Remove spacer (14).
6. Remove bolts (15) and remove swing motor and

swing machinery assembly (16).
[*1]
4 Swing motor and swing machinery assembly:
570 kg
PC800, 850-8E0
50-87
Power train
50-8
Installation
q Perform installation in the reverse order to removal.
[*1]
Swing motor and swing machinery assembly

Mounting bolt:
926.7 102.9 Nm {94.5 10.5 kg}
Refilling of oil (Hydraulic tank)

a Add oil through oil filler port to the specified level.
Circulate the oil through the system. Then check
the oil level again.
a Add oil by the quantity of the oil which spilled

during the removal work.
50-88
PC800, 850-8E0
Power train
Disassembly and assembly of swing machinery assembly
Symbol
50-89
Part number
790-101-5401
790-101-5541
1
790-101-5421
F
01010-51240
790-201-2780
2
790-201-2880
3 796T-626-1120
Part name
Push tool kit

Plate
q Grip
q Bolt
Spacer
Spacer
Push tool
q
Necessity
Q'ty
New/redesign
Sketch
Special tools
t
t
t
t
t
t
t
1
1
1
2
1
1
1
50-89
3. No. 1 carrier assembly

1) Remove thrust washer (2).
2) Remove No. 1 sun gear (3).
Disassembly
50-89
1. Draining oil
Loosen the drain plug to drain the oil from the
swing machinery case.
6 Swing machinery case:
approx. 24.3 l
2. Cover
Remove the mounting bolts and sling and
remove cover (1).
3) Remove No. 1 carrier assembly (4).
4. Disassemble No. 1 carrier assembly as follows.

1) Push in pin (5) and drive out shaft (6) from
carrier (7).
a After removing the shaft, remove pin (5).
2) Remove thrust washer (8), gear (9), bearing
(10) and thrust washer (11).
PC800, 850-8E0
50-89
Power train
5. Ring gear
Sling and remove ring gear (12).

Sling and remove No. 2 carrier assembly (17).
6. No. 1 sun gear

2) Remove button (36) and spacer (14).
8. Disassemble No. 2 carrier assembly according to

1) Push in pin (18) and drive out shaft (19) from

carrier (17).
a After removing the shaft, remove pin (18).
2) Remove thrust washer (20), gear (21),
bearing (22) and thrust washer (23).

a Remove the washer after removing No. 2
carrier assembly (17).
50-90
PC800, 850-8E0
Power train
9. Pinion shaft assembly

1) Remove bolt (24), then remove holder (25).
2) Remove gear (26).
3) Turn over the case and pinion assembly and

remove mounting bolt (28) of cover assembly
(27).
10. Disassemble pinion shaft assembly as follows.

1) Using push tool [1], remove cover assembly
(27) and bearing (31) from shaft (32).
2) Remove oil seal (33) from cover (27).
11. Bearing
Remove bearing (34) from case (35) using the
push tool.
4) Turn over case and pinion assembly (29) and
set it on the press stand.
5) Press out pinion shaft assembly (30) using
push tool F3 and press.
a Set a wooden block under the press and
pull out the pinion shaft assembly with
care not to damage it.
PC800, 850-8E0
50-91
Power train
50-92
Assembly
a Clean each part and check them for dirt or damage. Apply engine oil to their sliding surfaces before installing.
1. Bearing
Press bearing (31) into case (35) using tool F2.
2. Cover assembly
1) Press oil seal (33) into cover (27) using push
tool F1.
2 Outer periphery of oil seal:
a Take care not to stick the liquid gasket
(LG-6) to the oil seal lip at the time of
press-fitting.
50-92
2) Install cover assembly (27) to case (35) and

tighten mounting bolts (28).
2 Cover mounting face:
2 Oil seal lip:
Grease (G2-LI)
a Take care not to stick liquid gasket (LG-6)
to attach on the seal lip.
3. Case assembly
1) Set case assembly (35) to shaft (32), then
press-fit the bearing inner race using push
tool [2].
a When setting the case assembly to the
shaft, take care not to damage the oil
seal.
PC800, 850-8E0
Power train
2) Bearing
Use tool F3 to press-fit bearing (34).
a Press both inner race and outer race of
the bearing simultaneously when
press-fitting. Do not press only the inner
race when press-fitting.
a After press-fitting the bearing, check that
the case turns smoothly.
3) Gear and holder

Fit gear (26) and holder (25), then tighten bolt
(24).
2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
385 42 Nm {39.25 4.25 kgm}
PC800, 850-8E0
4. Assemble the No. 2 carrier assembly according to

a There is a trace of punching on the end surface of carrier side hole h, which is caused
when the pin is inserted and locked by using
a punch. Remove the protrusion in the pin
hole before inserting the pin.
1) Install bearing (22) to gear (21). Fit upper and
lower thrust washers (23) and (20) and set
the gear assembly to carrier (17).
2) Align the pin hole positions of the shaft and

carrier, then install shaft(19) by lightly
tapping it with a plastic hammer.
a When installing the shaft, rotate the planetary gear, and be careful not to damage
the thrust washer.
3) Insert pin (18).
a After inserting the pin, punch the carrier at
the portion of the pin.
a After assembling the carrier assembly, check
that gear (21) rotates smoothly.
50-93
Power train

Sling and install No. 2 carrier assembly (17).
a Position the assembly so that the four gears
fit properly in the housing.
6. No. 2 sun gear

1) Install thrust washer (16).
a Set it before installing No. 2 carrier assembly (17).
7. Ring gear
Sling and install ring gear (12).
a Apply the liquid gasket to the periphery of the
oil level check hole only.
2 Mating faces of ring gear and case:
8. Assemble No. 1 carrier assembly according to the

a There is a trace of punching on the end surface of carrier side hole h, which is caused
when the pin is inserted and locked by using
a punch. Remove the protrusion in the pin
hole before inserting the pin.
1) Assemble bearing (10) to gear (9), fit the top
and bottom thrust washers (8) and (11), then
set gear assembly to carrier (7).
2) Install No. 2 sun gear (15) to No. 2 carrier.

3) Install spacer (14) and button (36).
50-94
PC800, 850-8E0
Power train
2) Align the pin hole positions of the shaft and

carrier, then install shaft(6) by lightly tapping
it with a plastic hammer.
a When installing the shaft, rotate the planetary gear, and be careful not to damage
the thrust washer.
3) Insert pin (5).
a After inserting the pin, punch the carrier at
the portion of the pin.
a After assembling the carrier assembly,
check that gear (9) rotates smoothly.
10. No. 1 sun gear

1) Install No.1 sun gear (3) to carrier assembly.
11. Cover
Install cover (1).
2 Cover mounting face:
3 Mounting bolt:
1st time: 98 Nm {10 kgm}
2nd time: 105 5
Install No. 1 carrier assembly (4).
12. Refilling of oil

Tighten the drain plug and supply oil through the
oil filler port.
6 Swing machinery case:
approx. 24.3 l
PC800, 850-8E0
50-95
Power train
Removal and installation of swing circle assembly
Removal and installation of swing circle assembly

Removal
50-96
1. Remove the revolving frame assembly. For
details, see "Removal and installation of
revolving frame assembly".
2. Remove lubrication tubes (1).
3. Remove mounting bolts (2).
[*1]
50-96
5. Remove seal (4).
50-96
Installation
[*1]
4. Pass a round bar through revolving frame
mounting bolt holes, then put the wire on the bar
and sling and remove swing circle assembly (3).
[*2]
4 Swing circle assembly:
1,263 kg
50-96
2
3
Mounting bolt:
Adhesive (LT-2)
Mounting bolt:
1,715 195 Nm {175 20 kgm}
[*2]
Mounting face of swing circle:

a Amount of grease (G2-LI) in oil bath: Approx.65 l
a Coat the inner teeth with grease (G1-LI). Approx.10 l
a Turn the soft zone mark on the inner ring to the
left side of the machine when installing.
PC800, 850-8E0
Power train
Disassembly and assembly of final drive assembly
50-97
Special tools
50-97
Symbol
Part number
1 796-627-1050
2 796-627-1030
790-101-2300
790-101-2310
790-101-2350
790-101-2360
02215-11622
3
791-181-1010
796T-627-1340
790-101-2102
790-101-1102
4 790-627-1200
796-627-1070
J
5 01017-52450
01580-12419
790-201-2830
6
790-101-5151
790-101-5401
7 790-101-5441
790-101-5421
01010-51240
790-101-5001
8 790-101-5151
790-101-5061
790-101-5021
PC800, 850-8E0
Part name
Installer
Push tool
Push-puller
q Block
q Leg
q Plate
q Nut
Adapter
Push tool
Puller
(294 kN {30 ton})
Pump
Wrench assembly
Spacer
Bolt
Nut
Spacer
Plate
Push tool
KIT(C)
q Plate
q Grip
q Bolt
Push tool
KIT(A)
q Plate
q Plate
q Grip
Necessity
Q'ty
New/redesign
Sketch

final drive assembly
t
t
t
t
t
t
t
t
t
1
1
1
1
2
2
2
2
1
Disassembly
50-97
1. Draining oil
Remove the drain plug and drain the oil in the
final drive case.
6 Final drive case:
approx. 20 l
2. Set the final drive assembly on a block (approx.
350 mm in height) with its travel motor downward.
a Note that No. 1 sun gear falls off (see step
15.) if the travel motor is removed.
3. Cover
Remove cover (1) using forcing screws and
eyebolts [1].
t 1
t
t
t
t
t
t
t
1
1
1
1
1
1
1
t 1
t 1
t 1
t 1
t 1
t 1
t 1
t 1

2) Remove No. 3 carrier assembly (2) using
eyebolts [2].
50-97
Power train
3) Disassemble No. 3 carrier assembly

1] Remove mounting bolts (3).
2] Remove holder (4) using tool J5.
5. No. 3 sun gear

1) Remove thrust washer (11) from No. 3 sun
gear (10).
3] Turn over carrier assembly (2) and set it
to the press, then pull out shaft (5) and
remove gear assembly (6) using tool J6.
6. No. 3 ring gear

Remove No. 3 ring gear (12) using eyebolts [3].
4] Remove bearing (7) and spacer (8) from
gear (6).
a If the parts are to be used again, put
matchmarks to prevent any change in
the combination with the outer race.
5] Remove outer race (9) from gear (6).
50-98
PC800, 850-8E0
Power train
7. Hub assembly
1) Remove lock plate (13).
2) Remove nut (14) using tool J4.
3) Remove hub assembly (15) with bearing (16)

from shaft (41) using eyebolts [4].
4) Remove bearing (16) from hub (49).
8. Spacer
Remove spacer (19) from shaft (41).

eyebolts [5].
1] Drive pin (21) into shaft (22).
2] Remove shaft (22) by pushing it from pin
side.
a Remove the pin from the shaft.
5) Remove floating seal (17) from hub (49).

a If the seal is to be used again, be careful
not to damage the contact surface, and
keep it in a safe place.
6) Remove outer races (18).
PC800, 850-8E0
50-99
Power train
3] Remove gear (23) from carrier (27), then

remove thrust washer (24) and bearing
(25).
4] Remove thrust assembly (26) from carrier
(27).
10. No. 2 sun gear

Remove No. 2 sun gear (28).
11. No. 2 ring gear
Remove No. 2 ring gear (30).
12. Spacer
Remove spacer (31).
50-100

eyebolts [6].
1] Drive pin (33) into shaft (34).
2] Pull out shaft (34) to pin side.
a Remove the pin from the shaft.
3] Remove gear (35) from carrier (36), then

remove thrust washer (37) and bearing
(38).
PC800, 850-8E0
Power train
14. No. 1 ring gear

Remove No. 1 ring gear (39).
15. No. 1 sun gear
Remove No. 1 sun gear (40).
16. Thrust washer
Remove thrust washer (48) from the travel
motor.
17. Floating seal
Remove floating seal (17) from shaft (41).
a If the seal is to be used again, be careful not
to damage the contact surface, and keep it in
a safe place.
50-101
Assembly
a 1) Clean each part and check for dirt and damage. Correct dents and burrs as necessary.
2) Apply engine oil to the bearings and surfaces
of all of the parts before installing.
1. Travel motor assembly
1) Fit O-ring to the travel motor, and install
travel motor assembly (42) to shaft (41) using
eyebolts [7].
a Note that the mounting direction of the
motor is opposite for the right and left final
drive assemblies being installed.
2) Reverse the travel motor and shaft assembly
and set it on a block (approx.350 mm in
height).
3) Press-fit thrust washer (48) for the drive
motor. After installing, check that thrust
washer (48) seats on motor (42) firmly using
the feeler gauge.
Press-fitting force: 225 to 2,646 N {23 to 270
kg}
18. Travel motor assembly

Reverse shaft (41) and remove travel motor
assembly (42) using eyebolts [7].
PC800, 850-8E0
50-101
Power train
2. No. 1 sun gear

Install No. 1 sun gear (40).
3. No. 1 ring gear
Install No. 1 ring gear (39).
a Install the ring gear with the periphery chamfered turning to the motor.
4. Spacer
Remove spacer (31).

1) Assemble the No. 1 carrier assembly
according to the following procedures.
a There is a punching mark made when the
pin was inserted at the end face of carrier
side hole h and the inside wall of the hole
is swelled at that mark. Flatten the
swelled part in advance.
1] Install bearing (38) into gear (35), fit thrust
washers (37) on both sides, then set the
gear to carrier (36).
50-102
2] Align the pin holes of the shaft and carrier,

then install shaft(34) by lightly tapping it
with a plastic hammer.
a When installing the shaft, rotate the
planetary gear so that the thrust washers are not damaged.
3] Install pin (33).
a Check the pin groove and protruding
part of the pin for fatigue. If the pin is
defective, replace it with a new part.
a If the pins are reused, avoid the position previously used for punching.
a After inserting the pin, punch the carrier at the portion (indicated by arrow)
of the pin.
a After building the carrier assembly,
2) Install No. 1 carrier assembly (32) using

eyebolts [6].
PC800, 850-8E0
Power train
6. No. 2 sun gear

1) Press-fit thrust (29) into No. 2 sun gear (28).
2) Install No. 2 sun gear (28).
7. No. 2 ring gear
Install No. 2 ring gear (30).

1) Build up No. 2 carrier assembly according to
1] Press-fit thrust (44) into plate (43).
2] Press-fit thrust assembly (26) into carrier
(27).
4] Align the pin holes of the shaft and carrier,

then install shaft (22) by lightly tapping it
with a plastic hammer.
a When installing the shaft, rotate the
gear, and be careful not to damage
the thrust washer.
5] Install pin (21).

a Check the pin groove and protruding
part of the pin for fatigue. If the pin is
defective, replace it with a new part.
a If the pins are reused, avoid the position previously used for punching.
a After inserting the pin, punch the carrier at the portion (indicated by arrow)
of the pin. (Refer to 5-1)-3].)
a After building the carrier assembly,
eyebolts [5].
a There is a punching mark made when

the pin was inserted at the end face of
carrier side hole h and the inside wall
of the hole is swelled at that mark.
Flatten the swelled part in advance.
3] Install bearing (25) into gear (23), fit thrust
washers (24) on both sides, then set the
gear to carrier (27).
PC800, 850-8E0
50-103
Power train
9. Spacer
Install spacer (19) to shaft (41) while matching
their protruding portions.
a Set the spacer with the smaller protrusion
faced the motor.
10. Hub assembly
1) Floating seal on shaft side
Install floating seal (17) to shaft (41) using
tool J1.
a Install the floating seal after degreasing
and drying the O-ring and O-ring contacting surface completely.
a After installing the floating seal, check the
inclination of the seal. It must be 1 mm or
less.
a After installing the floating seal, apply engine oil to the sliding surface lightly.
2) Inside bearing
Install bearing (16) to shaft
shrink-fitting or using tool J3.
(41)
by
a When using tool J3, see the figure below.
3) Outer race at hub end

Install outer race (18) to hub (49) by expansion-fitting or using tool J2.
a When using tool J2, see the figure below.
50-104
PC800, 850-8E0
Power train
4) Floating seal at hub end

Install floating seal (17) to hub (49) using tool
J1.
a For precautions and details of the tool,
see Step 10-1).
a When reverse the hub, the floating seal
will be at the bottom, so fix it temporarily
with some of bolts [8].
5) Installation of hub assembly
Install hub assembly (15) to shaft (41) using
eyebolts [4].
7) Install the nut according to the following

procedure.
1] Set tool J3 in position.
2] Press the bearing inner race with the
specified force.
a Pressing force:
34.3 38.2 kN {3.5 3.9 ton}
3] Rotate the hub assembly two to three

times to settle the bearing.
4] Under the above condition, measure

dimension (a).
6) Outer bearing
Install bearing (16).
PC800, 850-8E0
50-105
Power train
5] Measure thickness (b) of nut (14).

6] Calculate (c) = (a) - (b).
7] Tighten nut (14) using tool J4 to obtain
dimension (c) +0.0/-0.1mm.
8) Install lock plate (13).

Install the lock plate as shown in the following
figure.
2 Mounting bolt thread:
Adhesive (LT-2)
3 Mounting bolt:
66.2 7.3 Nm {6.75 0.75 kgm}

1) Assemble No. 3 carrier assembly according
to the following procedures.
1] Press-fit outer race (9) into gear (46)
using tool J7.
2] Install bearing (7) and spacer (8) into gear

(46) and set them to carrier (47).
a Align the carrier, bearing and spacer
holes accurately.
11. No. 3 ring gear

1) Install the O-ring to the shaft.
2) Install No. 3 ring gear (12) using eyebolts [3].
a Align the bolt holes.
a Install the ring gear with the machined periphery up (outward).
50-106
PC800, 850-8E0
Power train
3] Install shaft (5) by expansion-fitting or

using a press.
a Do not rotate the gear until the tip of
shaft (5) enters in the carrier. Be careful that the spacer is in position.
a Check that the gear rotates smoothly
after press-fitting the pin.
a When press-fitting the shaft, be careful not to tilt the shaft.
4] Install holder (4) to shaft (5).
5] Tighten bolts (3).

2 Bolt:
Adhesive (LT-2)
Bolt:
927 103 Nm {94.5 10.5 kgm}
6] Install thrust washer (50).
3
PC800, 850-8E0

eyebolts [2].
a Fit the holder section of the carrier assembly to the four lower portions of shaft
(41) and spacer (19).
a Align the bolt holes also.
a After installing No. 3 carrier assembly (2),

measure dimension (i) from the top of
planetary gear (46) to that of No. 3 ring
gear (12) to check the assembly condition.
a If dimension (i) is 2.6 mm or larger, it is
not assembled correctly. Check the assembling condition.
50-107
Power train
13. No. 3 sun gear

1) Install thrust washer (11) to No. 3 sun gear
(10).
2) Install No. 3 sun gear (10).
a Be careful not to get your finders caught.
14. Cover
Using eyebolts [1], install cover (1).
2 Mounting surface:
2 Bolt:
Adhesive (LT-2)
3 Bolt:
980.1 49.5 Nm {100 5 kgm}
50-108
PC800, 850-8E0

Separation and connection of track shoe assembly
50-109
50-109
791-680-9501
790-101-4300
790-101-4200
790-101-1102
790-331-1100
Remover,
installer
Cylinder
(1,471 kN {150
t})
Puller
(294 kN {30 t})
Pump
Wrench
3. Using tool M, pull out master pin.
Sketch
Part name
New/redesign
Part number
Q'ty
Symbol
50-109
Necessity
Special tools
t 1
t 1
t 1
t 1
t 1
Separation
50-109
1. Positioning master pin
a Move the track so that the master pin comes
midway between the idler and the carrier roller. The track is developed to the rear, so be
sure that there is enough space to lay it out.
4. Place a block or hydraulic jack [1] (10 ton) under

the shoe at front idler end, then remove guide pin
[2].
[*2]
2. Loosen track shoe tension.

[*1]
Never loosen lubricator (1) more than one
turn.
a If the track tension is not relieved even when
the lubricator is loosened, move the machine
back and forth.
5. Raise tip of the track shoe with a crane. Move

the machine slowly backward to spread track
shoe assembly (3).
PC800, 850-8E0
50-109

50-1 0
Installation
[*1]
a Adjust the track shoe tension. For details, see
Testing and adjusting, "Adjusting track shoe tension."
3 Lubricator:
73.5 14.7 Nm {7.5 1.5 kgm}
[*2]
a Install spacer (4) and washer (5) to the link, connect to bottom link, then install guide pin.
50-110
PC800, 850-8E0

Disassembly and assembly of one link in field
790-101-4300
791-685-9510
791-685-9520
791-685-9530
791-685-9550
791-685-9560
3 791-680-9570
01010-51030
04530-12030
790-101-1102
790-101-4300
791-685-9540
791-685-9550
791-685-9510
791-685-9520
791-685-9530
791-685-9550
791-685-9560
791-126-0150
791-680-5520
5 791-126-0140
791-680-9570
01010-51030
04530-12030
791-685-9620
790-101-1102
4
790-101-4300
790-101-1102
6
790-101-4200
791-680-5542
791-632-1110
8 791-680-5580
7
Adapter
Guide
Bolt
Bolt
Pump
Cylinder
(1,471 kN {150
ton})
Frame
Frame
Rod
Nut
Bolt
Adapter
Bolt
Eyebolt
Pump
Cylinder
(1,471 kN {150
ton})
Rod
Nut
Frame
Frame
Rod
Nut
Bolt
Adapter
Guide
Pusher
Adapter
Bolt
Eyebolt
Extension
Pump
Cylinder
(1,471 kN {150
ton})
Pump
Puller
(294 kN {30 ton})
Adapter
Adapter
Guide
791-685-9510
791-685-9520
791-685-9530
791-685-9540
791-685-9550
791-685-9560
791-126-0150
9 01010-51030
791-685-9620
791-680-5542
791-680-5560
790-101-1102
t 1
t
t
t
t
t
t
t
t
t
1
1
1
1
4
1
1
1
1
790-101-4300
t 1
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
1
3
1
1
1
1
4
1
1
1
1
1
1
1
1
t 1
t 1
t 1
t 1
t 1
t 1
791-685-9510
791-685-9520
791-685-9530
791-685-9540
791-685-9550
791-685-9560
791-126-0150
10 01010-51030
791-685-9620
791-680-5560
791-632-1110
791-680-9630
790-101-1102
790-101-4300
11 791-680-1520
791-685-9510
791-685-9520
791-685-9530
791-685-9540
791-685-9550
791-685-9560
791-126-0150
12 791-680-5560
791-680-9570
01010-51030
791-680-1520
790-101-1102
790-101-4300
PC800, 850-8E0
Frame
Frame
Rod
Rod
Nut
Bolt
Adapter
Bolt
Extension
Adapter
Guide
Pump
Cylinder
(1,471 kN {150
ton})
Frame
Frame
Rod
Rod
Nut
Bolt
Adapter
Bolt
Extension
Guide
Adapter
Adapter
Pump
Cylinder
(1,471 kN {150
ton})
Guide
Frame
Frame
Rod
Rod
Nut
Bolt
Adapter
Guide
Adapter
Bolt
Guide
Pump
Cylinder
(1,471 kN {150
ton})
t
t
t
t
t
t
t
t
t
t
t
t
1
1
1
1
3
4
1
1
1
1
1
1
Sketch
1
1
2
2
1
Part name
New/redesign
t
t
t
t
t
Symbol Part number
Q'ty
791-680-9580
791-680-9590
1
01010-52760
01010-51440
790-101-1102
Part name
Necessity
Symbol Part number
Sketch
50-1 1
New/redesign
Special tools
Q'ty
50-1 1
Necessity
t 1
t
t
t
t
t
t
t
t
t
t
t
t
t
1
1
1
1
3
4
1
1
1
1
1
1
1
t 1
t
t
t
t
t
t
t
t
t
t
t
t
t
1
1
1
1
1
3
4
1
1
1
1
1
1
t 1
50-111
790-101-1102 Pump
13
Puller
790-101-4200
(294 kN {30 ton})
Remover and
791-680-9501
installer (kit)
790-101-1102 Pump
Puller
14 790-101-4200
(294 kN {30 ton})
Cylinder
790-101-4300 (1,471 kN {150
ton})
t 1
t 1
t 1
Sketch
New/redesign
Part name
Q'ty
Symbol Part number
Necessity

50-1 2
Disassembly
1. Remove the two track shoes installed to the link
to be replaced and to the link next to the first link.
2. Using two bolts (2), install tool N1 (adapter,
guide and bolts) to link (1).
a It is also possible to use track bolts in place
of two bolts (2).
t 1
t 1
t 1
3. Assemble tool N2 (pump, cylinder 1,471 kN {150

ton}) and tool N3 (frame, rod, adapter, bolt and
eyebolt), then raise the assembled tools and set
the assembly on the track.
50-112
PC800, 850-8E0

4. Insert the rod of tool N4 into the guide pipes of

tools N3 and N4 from the cylinder side, and fix
the rod with two nuts.
a Pass the rod through the window of link (1) to
install.
5. Set tool N5 (adapter, guide, pusher) in position,

then apply hydraulic pressure and remove pin
(3).
a When the cylinder rod reaches the end of its
stroke, put extension (N5) in between the
adapter and guide, and repeat the operation.
7. Set tool N6 (294 kN {30 ton} puller) and spacer[1]

to the center of tread area of the link to be disassembled, then apply hydraulic pressure to the
puller and open the link 5 to 6 mm.
50-1 3
Assembly
1. Build the link sub-assembly.
1) Set tool N7 to the end face of the link, and
then press-fit bushing (1).
2) Set tool N7 to the end face of the link (pin
end), and press-fit pin (2).
6. In the same manner, pull out another pin (3).
PC800, 850-8E0
50-113

2. Set link sub-assembly (3) to the link to be

connected.
3. Set link (4) on opposite side, and support it with

tool N8 (guide).
4. Set tools N9 and N10 in the same way as for the

operation to remove the pin, then use tool N9
(adapter, extension, guide, adapter and bolt) for
press-fitting the pin, and tool N10 (extension,
guide, adapter and bolt) for press-fitting bushing,
and press-fit the pin and bushing alternately.
50-114
5. Use tool N13 (294 kN {30 ton} puller) in the same

way as when disassembling, and push open link
(5) at bushing end.
6. Set link (6) at pin end to link (5) at bushing end,

connect them with tool N11 (guide), then remove
tool N13 (puller).
7. Set tool N9 at pin (7) end, then use tool N12

(adapter, bolt, and guide) to press-fit pin (7).
2 Pin press-fitting hole in link:
PC800, 850-8E0

Removal and installation of idler assembly
Removal and installation of idler

50-1 5
assembly
Removal
50-1 5
1. Separate the track shoe assembly. For details,
see Removal and installation of track shoe
assembly.
2. Remove idler assembly (1).
a Pull out the idler assembly, then sling off the
idler and adjustment cylinder.
4 Idler assembly:
460 kg
Installation
50-1 5
Perform installation in the reverse order to removal.
PC800, 850-8E0
50-115

Disassembly and assembly of idler assembly
1
2
11
5. Remove shaft (8) from the idler.
Sketch
Part name
New/redesign
Part number
Q'ty
Symbol
50-1 6
Necessity
Special tools
50-1 6
790-201-2680 Plate
t 1
796-675-1510 Installer
t 1
791-601-1000 Oil pump ass'y q 1
Disassembly
50-1 6
1. Remove the plug and drain the oil.
6 Idler:
Approx. 550 630 cc
2. Set idler assembly (1) on blocks [1], remove bolt
and nut (2), then remove support (3).
6. Remove floating seal (4) from idler (7).
3. Remove floating seal (4).
7. Remove bushings (9) and (10) from the idler.

4. Turn over the idler assembly, remove bolt and
nut (5), then remove support (6).
50-116
PC800, 850-8E0

8. Remove floating seals (4) from supports (3) and

(6).
Assembly
50-1 7
a Clean all the parts, and check them for dirt or
damage. Then, assemble them.
1. Install floating seals (4) into supports (3) and (6)
using tool L2.
2. Press-fit bushings (10) and (9) to the idler using

tool L1.
3. Install floating seal (4) to the idler using tool L2.
PC800, 850-8E0
50-117

4. Turn over the idler and install floating seal (4) to

the idler using tool L2.
6. Install support (6) to the shaft.

a Align the groove in the support with the
groove in the shaft when installing the shaft.
7. Install bolt and nut (5), and secure support (6).
5. Install shaft (8) to the idler.

a Install the shaft with its oil filler plug faced to
as follows:
q Right-side shaft: Outward
q Left-side shaft: Inward
8. Turn over the idler, and install support (3) to the

shaft.
a Align the groove in the support with the
groove in the shaft when assembling.
9. Install bolt and nut (2), and secure support (3).
10. Add oil to specified level using tool L11 (refer to

special tools table), then tighten the plug.
5 Idler:
550 630 cc(GO140)
3 Plug:
210.7 29.4 Nm {21.5 3 kgm}
50-118
PC800, 850-8E0

Disassembly and assembly of idler adjustment cylinder assembly
Disassembly and assembly of idler adjustment cylinder assembly

Disassembly
50-1 9
1. Remove plunger (2) from yoke (1).
2. Remove snap ring (3) from plunger (2) and then
remove packing (4), backup ring (5), and wear
ring (6).
3. Remove dust seal (7) from yoke (1).
PC800, 850-8E0
50-1 9
50-1 9
Assembly
1. Install wear ring (6) to plunger (2).
2. Install backup ring (5) and packing (4) to plunger
(2), and install snap ring (3).
3. Fill the inside with grease (G2-LI), then install
plunger (2) into yoke (1).
4. Install dust seal (7)
50-119

Removal and installation of recoil spring assembly
50-120
Removal
50-120
a The coil portion of the recoil spring assembly is
hooked on the rib inside the track frame, so prepare a special tool for disassembly.
1. Separate the track shoe assembly. For details,
see "Separation and connection of track shoe
assembly".
2. Remove the idler assembly. For details, see
"Removal and installation of the front idler
assembly".
3. Recoil spring assembly
1) Remove No. 2 and No. 3 track roller assemblies. For details, see "Removal and installation of track roller assembly".
2) After removing the track roller assembly,
install tool [1].
a When making tool [1], see Fig. 1.
a Lower the track frame on the track.
3) Using eyebolts (thread dia. = 16 mm, pitch =
2.0 mm), pull out recoil spring assembly (1)
and sling it off.
4 Recoil spring assembly:
250 kg
50-120
50-120
Installation
a Check that the spring is securely fitted inside
the track frame by seeing it through the hole
located on the inside (at the 5th track roller
from the front).
PC800, 850-8E0

Fig. 1 (for tool [1])
PC800, 850-8E0
50-121

Disassembly and assembly of recoil spring assembly

50-12
2. Apply hydraulic pressure slowly to compress the

spring, then remove the lock plate, and remove
nut (2).
Disassembly
50-12
1. Set recoil spring assembly (1) to tool M3.
k The tool must be installed firmly as the
load at installed length of the spring is
large and dangerous.
a Load at installed length of spring:
490 kN {50 ton}
3. Release hydraulic pressure gradually to relieve

the tension of the spring, then remove recoil
spring assembly (1) from tool M3.
Symbol
Part number
791-685-8502
791-635-3160
796-630-1110
01010-51640
796-630-1120
M 3
Part name
Compressor
Extension
Plate
Bolt
Spacer
Cylinder
790-101-1600 (686 kN {70
ton})
790-010-1102 Pump
796-630-1110 Plate
50-122
Necessity
Q'ty
New/redesign
Sketch
Special tools
50-12
t
t
t
t
t
1
1
1
2
1
t 1
t 1
t 1
4. Remove rear pilot (4) and rod (5) from spring (3).
PC800, 850-8E0

Assembly
50-123
1. Install tool M3 to the tip of rod (5).
a Tool M3 prevents damage to the threads
when inserting the rear pilot.
2. Install rod (5) to spring (3).

Install rear pilot (4), and set them to tool M3.
k The tool must be installed firmly as the
load at installed length of the spring is
large and dangerous.
3. Apply hydraulic pressure slowly to compress the
spring so that the installed length of the spring
becomes standard dimension.
a Installed length of spring a: 1,290 mm
4. Install nut (2) and secure it with the lock plate.

5. Release hydraulic pressure gradually to relieve
the tension of the spring, then remove recoil
spring assembly (1) from tool M3.
PC800, 850-8E0
50-123

Removal and installation of carrier roller assembly
Removal and installation of carrier roller assembly

Removal
50-124
1. Loosen the track shoe tension a bit. For details,
see Testing adjusting, Testing and adjusting
track shoe tension.
50-124
50-124
Installation
3 Carrier roller mounting bolt:
549 58 Nm {56 6 kgm}
2. Use the hydraulic jack [1] to push up the track.

3. Remove four mounting bolts (1).
4. Sling and remove carrier roller assembly (2).

a Pull the carrier roller assembly out to a marginal point where it does not fall.
4 Carrier roller assembly:
52 kg
50-124
PC800, 850-8E0

Disassembly and assembly of carrier roller assembly
3
L
4
5
6
Push tool kit

(B)
796T-630-1130 Push tool
796T-630-1140 Adapter
796-670-1010 Installer
791-1101-5201
Sketch
Part name
Q'ty
Part number
New/redesign
Symbol
50-125
Necessity
Special tools
50-125
5. Remove the assembly of roller (4) and floating

seal (5) on support (2).
6. Remove floating seal (5) from support (2).
7. Remove bearing (6) from support (2).
t 1
t 1
t 1
t 1
Q
Q
Disassembly
50-125
6 Carrier roller assembly:
Approximately 300 350 cc
2. Set carrier roller assembly (1) on the press table.
a Since support (2), shaft (3) and roller (4) drop
if shaft (3) is removed from roller (1), set a
pedestal below the roller.
3. Push the end face of shaft (3) with the press and
remove the assembly of support (2), shaft (3)
and roller (4).
a Remove floating seal (5) from support (2).
4. Push the end face of shaft (3) and remove shaft
(3), bearing (6) and spacer (8) from roller (4).
8. Remove floating seal (5) from roller (4).

9. Remove bearing (6) from shaft (3) by using tool
L4 and push tool [1].
10. Remove bearing outer race (7) from support (2).
PC800, 850-8E0
50-125

50-126
Assembly
1. Press-fit bearing outer race (7) in the both sides
of support (2) by using tool L3.
2. Press fit bearing (6) in shaft (3) by using tool L4.
7. Install floating seal (5) to another roller (4).

8. Install floating seal (5) to support (2).
a Make sure that the seal is inclined less than
1 mm.
a Clean the O-ring and the O-ring contacting
surface to degrease them completely and dry
them.
3. Install spacer (8) to shaft (3).

4. Install shaft (3) to support (2).
5. Use toolL4 to press-fit bearing (6).
9. Press-fit the shaft (3) in roller (4).
a Check that floating seal (5) is installed to support (2) and roller (4).
a Press-fit roller (4) to the shaft end face (face
under the shaft in the figure) and press-fit the
roller finally by using tool L5. (the shaft protrudes by 3 mm)
a Secure more than 18 ton of press-fitting force
between the shaft and each roller.
10. Install floating seal (5) to support (2) by using
tool L6.
6. Install floating seal (5) to roller (4) by using tool

L6.
a Make sure that the seal is inclined less than
1 mm.
a Clean the O-ring and the O-ring contacting
surface to degrease them completely and dry
them.
50-126
PC800, 850-8E0

11. Use tool L5 and [2] to press-fit roller (4).

a Secure a force of 18 tons on move to press-fit
the shaft and roller.
12. Build the carrier roller assembly and fill it with oil.
5 Lubricating oil:
300 to 350 cc(GO140)
13. After filling it with oil, plug the assembly.
3 Plug:
206 49 Nm {21 5 kgm}
PC800, 850-8E0
50-127

Removal and installation of track roller assembly
Removal and installation of track roller assembly
SymPart number
bol
790-401-1700
790-401-1761
L 7
790-401-1540
790-401-1770
50-128
Part name
Lifting tool
Adapter
Shackle
T-bolt
Necessity
Q'ty
New/redesign
Sketch
Special tools
t
t
t
t
50-128
4. Using tool L7, remove track roller assembly (2).

[*1]
4 Track roller assembly (Single flange):
140 kg
1
1
2
2
Removal
50-128
1. Loosen track shoe tension. For details, see
"Separation and connection of track shoe
assembly".
2. Remove track roller guard (1).
4 Track roller guard:
170 kg
Installation
50-128
[*1]
Roller mounting bolt:

137.2 98 Nm {140 10 kgm}
3. Using work equipment, raise the track frame

which is on the side where the track roller
assemblies are removed.
k After raising up the chassis, set a block
on the track shoe.
50-128
PC800, 850-8E0

Disassembly and assembly of track roller assembly
Symbol
Part number
50-129
Part name
8 791-580-1520 Installer
9 790-201-2670 Plate
791-601-1000
L
Oil pump assembly
or
Oil lubricator
10
791-646-8002
790-701-3000 Seal checker
Necessity
Q'ty
New/redesign
Sketch
Special tools
t 1
t 1
50-129
4. Pull out shaft (5) from roller (4).

a It is filled with 420 to 480 cc of oil, so drain the
oil at this point or lay a cloth to prevent the
area from becoming dirty.
5. Remove floating seal (6) from roller (4) and collar
(8) on the opposite side.
t 1
t 1
Disassembly
50-129
a Drain the oil while rotating the shaft.
6 Track roller:
Approximately 420 480 cc
2. Remove pin (1), then remove collar (2).
6. Remove pin (7), then remove collar (8) from
shaft (5).
7. Remove bushings (9) and (10) from roller (4).
3. Remove floating seals (3) from collar (2) and

roller (4).
PC800, 850-8E0
50-129

50-130
Assembly
1. Using tool L10, press-fit bushings (9) and (10) to
roller (4).
2. Install collar (8) to shaft (5), and install pin (7).
4. Using tool L9, install floating seals (6) and (3) to

roller (4).
a For details of the precautions when installing
floating seals (6b) and (6d), and (3b) and
(3d), see the precautions marked a at step
3.
3. Using toolL9, install floating seal (6) to shaft (5).

5. Install shaft (5) to roller (4).
a When assembling the floating seal, clean the

contact surface of O-ring (6c) and floating
seal (6a), remove all the grease and oil, and
dry them. Make sure that no dirt or dust sticks
to the contact surface of the floating seal.
a After inserting the floating seal, check that
the inclination of the seal is less than 1 mm
and that the protrusion of the seal is within a
range of 5 to 7 mm.
50-130
6. Reverse the assembly of roller (4) and shaft (5).

7. Using tool L9, install floating seal (3) to collar (2).
a For details of the precautions when installing
floating seals (3a) and (3c), see the precautions marked a at step 3.
PC800, 850-8E0

8. Install collar (2) to shaft (5), and install pin (1).
10. Using tool L10, fill track roller assembly with oil,
then tighten plug (11).
5 Track roller oil:
420 480 cc(GO140)
3 Plug:
16.7 37.2 Nm {1.7 3.8 kgm}
9. Using tool L10, apply standard pressure to roller

oil filler port, and check for leakage of air through
the seal.
a Standard pressure: 0.1 MPa {1 kg/cm2}
a Check method
The standard pressure must be maintained
for 10 seconds and the indicator of the gauge
dose not go down.
PC800, 850-8E0
50-131

Removal and installation of revolving frame assembly

Removal
50-132
1. Remove the work equipment assembly. For
details, see Removal and installation of work
equipment.
2. Remove the counterweight assembly. For
details, see Removal and installation of counterweight assembly.
3. Disconnect four grease tubes (1).
4. Leaving three or four bolts each at the front and
rear, remove the rest of the revolving frame
mounting bolts (2).
[*1]
a While running the engine and swinging the
upper structure, remove the mounting bolts.
a If the engine is not started, remove the swing
motor and swing the upper structure with a
crane.
50-132
9. Pull out pin (11) and move link (12) toward the
frame.
5. Drain the oil from the hydraulic tank.

6 Hydraulic tank:
470 l
6. Remove work equipment hose (3).
7. Remove swing motor hose (4).
8. Disconnect swivel joint upper pipings (5) to (10).
50-132
PC800, 850-8E0

10. Revolving frame assembly

[*1][*2]
1) Install the sling to the counterweight
mounting frame and boom mounting portion
and sling the revolving frame assembly.
2) Remove remaining bolts (2) and revolving
frame assembly (13).
a Use the sling which is not damaged and
apply pads to corners.
a Since the revolving frame leans toward
the operator's cab, adjust it with the lever
blocks, etc.
4 Revolving frame assembly:
Approx. 19,500 kg
Installation
50-13
[*1]
2
3
Adhesive (LT-2)
Mounting bolt:
1,814 98 Nm {185 10 kgm}
[*2]
PC800, 850-8E0
Mounting bolt:
Swing circle top surface:

Refilling of oil
5 Hydraulic tank:
470 l
50-133

Removal and installation of counterweight assembly
Symbol
Part number
50-134
Part name
Necessity
Q'ty
New/redesign
Sketch
Special tools
Commercially
Impact wrench
q 1
available
Socket wrench
Commercially
(Width across flats: q 1
available
65 mm)
a Use the impact wrench and socket wrench with

the torque capacities enough for tightening the
counterweight mounting bolts.
3 Counterweight mounting bolt:
3,822 392 Nm {390 40 kgm}
50-134
Removal
1. Install the hanging hook chain to counterweight
assembly (2) and sling the counterweight
assembly.
a No eyebolts are necessary.
2. Remove six mounting bolts (1).
a Width across flats: 65 mm
3. Sling and remove counterweight assembly (2).
[*1]
4 Counterweight assembly:
11,850 kg(PC850)
9,800 kg(PC800)
50-134
50-134
Installation
50-134
removal.
[*1]
a Adjust the level difference between the exterior
parts and counterweight assembly with shims
(top and bottom clearances).
a Adjust the clearance between the counterweight
and revolving frame to the standard of 15 mm
and adjust the right and left level differences to
be even.
3 Counterweight mounting bolt:
3,822 392 Nm {390 40 kgm}
a The thickness of the paint film on the counterweight mounting seat (revolving frame and
counterweight) and mounting bolt seat underside of the revolving frame) must be 0.03 mm (30
mm) or less.
PC800, 850-8E0

Removal and installation of counterweight remover assembly

Removal
50-135
stop the engine.
tubes and hoses.
50-135
3. Disconnect hoses (3), (5) and (6).

1. Remove the mounting bolts and lower counterweight (2).

[*1]
a Width across flats:
65 mm
k
Loosen the cap of the hydraulic tank gradually to release the internal pressure of
the hydraulic tank.
2. Remove pin (1) and disconnect counterweight

(2).

PC800, 850-8E0
50-135

6. Disconnect clamps (13) to (17).
50-136
Installation
removal.
[*1]
Counterweight mounting bolt:

3,430 4,212 Nm {350 430 kgm}

7. Sling counterweight remover assembly (11).
8. Remove mounting bolts (12) and sling off counterweight remover assembly (11).
4 Counterweight remover assembly:
1270 kg
50-136
PC800, 850-8E0

Attaching procedure for counterweight noise insulation sheet

a Attach the counterweight noise insulation
sheets according to the following procedure.
1. Attach the noise insulation sheet (1) to the front
surface of the counterweight.
a The surface of the counterweight for noise
insulation sheets to be attached should be
degreased and free from rust completely.
2. Attach the noise insulation sheets with the surface (a) which has no SG sheet (black surface)
facing downward.
PC800, 850-8E0
(02)
50-136-1

50-136-2
PC800, 850-8E0
(02)
Hydraulic system
Removal and installation of hydraulic tank assembly
Hydraulic system
50-137
50-137
Removal
50-137
k Swing the frame to set the hydraulic tank between the right and left tracks.
stop the engine.
a Before disconnecting the hoses, put match
marks on them.
6 Hydraulic tank:
6. Disconnect drain filter assembly bracket (6) from

the hydraulic tank.
7. Disconnect pilot filter bracket (7) from the
hydraulic tank.
470 l
2. Remove control valve cover (1).
10. Disconnect hose (12) from the oil cooler.

11. Disconnect hose (13) between the return filter
and the oil cooler.

4. Disconnect piping clamps (3) and (4).
5. Disconnect brackets (5).
PC800, 850-8E0
50-137
Hydraulic system
13. Remove hydraulic tank undercover (20).
16. Sling and remove tank assembly (24).

4
[*1]
Hydraulic tank assembly:
640 kg
a In the photo, case (23) is removed without
being removed from the hydraulic tank.
a In the photo, the hoses are disconnected
without removing drain filter assembly bracket (6) and PTO pilot filter bracket (7) from the
hydraulic tank.
14. Disconnect suction tube (21) at the bottom of the

hydraulic tank.
50-138
Installation
[*1]
15. Remove four mounting bolts (22) and disconnect

case (23) from the hydraulic tank.
50-138
Mounting bolt:
Adhesive (LT-2)
Hydraulic oil tank mounting bolt:
549 58 Nm {56 6 kgm}

Circulate the oil through the system and then
check the oil level again.
5 Hydraulic tank:
470 l (Refill capacity)
Bleeding air
Bleed air. For details, see Testing and adjusting,
Bleeding air from each part.
PC800, 850-8E0
Hydraulic system
Removal and installation of main pump assembly
2
B
Commercially available
Sketch
1. Remove the counterweight assembly. For

details, see Removal and installation of counterweight assembly.
2. Remove pump undercovers (1) and (2).
Pin gauge Pin (7.50

mm diameter 6.30
mm notch height) for t 2 N
bore of module of
3.75 mm
CommerMicrometer for bore

cially avail(75 100 mm)
able
1 796-770-1301 Oil stopper
Pin gauge Pin (6.75
CommerS
mm diameter) for
2 cially availouter diameter of
able
module of 3.75 mm
3
New/redesign
Part name
Q'ty
Sym
Part number
bol
50-139
Necessity
Special tools
50-139
t 1 N
q 1
t 2 N
Figure on the left: Pin gauge; Figure on the right: Micrometer for the bore

oil with oil stopper tool S1.
6 Hydraulic tank:
470 l
50-139
Removal
stop the engine.
a Put match marks on hoses and tubes.
PC800, 850-8E0
50-139
Hydraulic system

12. Remove reservoir tank hose (10) from the

bottom of cover (11).

10. Remove cover A.
[*1]
16. Remove air cleaner (14).
[*2]

50-140
PC800, 850-8E0
Hydraulic system
19. Disconnect connectors P24B (17) and P24A

(18) from the reservoir tank.
20. Disconnect reservoir tank hoses (19).

21. Remove reservoir tank (20) and bracket
together.
PC800, 850-8E0

24. Remove cooling fan pump assembly (24). For
details, see "Removal and installation of cooling
fan pump assembly".
25. Disconnect outlet hose (25).
26. Disconnect branch hose (26) and outlet hose
(27).
28. Disconnect suction tube (29) from the pump.
a The photo shows the pump piping of the machine with the counterweight remover. For
the photo of the pump piping of the standard
specification of the machine, see Removal
of engine, PTO and hydraulic pump assembly.
29. Disconnect clamp (30) from the left side on the

photo.
30. Disconnect EPC solenoid connectors V11 (31)
and V12 (32).
50-141
Hydraulic system
32. Disconnect branch hose (34) and main pump

drain hose (35).
36. Sling and remove main pump assembly (39).

[*4]
4 Main pump assembly:
550 kg
33. Disconnect breather hose (36) and EPC source

pressure hose (37).
34. Disconnect clamp (38) from the bottom of main

pump assembly (39).
35. Sling main pump assembly (39) and remove six
bolts (40).
[*3]
50-142
PC800, 850-8E0
Hydraulic system
Installation
50-143
a Measure the wear of the main pump spline to
see if the wear is within the standard value. (If
not, replace the main pump.)
a Measure the wear of coupling spline in the PTO
and check if the wear is within the standard value. (If not, remove the PTO and replace the coupling.)
2. Using the micrometer (75 to 100 mm) [1],

measure the over pin dimension of main pump
shaft (between S2).
Measure at portions A and B in X and Y directions (at four positions in total).
a OK: 95.72 mm or larger
50-143
Preparation
1) Two each of pin gauge: Pin (7.50 mm diameter x notch height of 6.30 mm) for the bore
of module of 3.75 mm
2) Petrolatum (for pasting pin gauge)
3) Inside diameter micrometer for the bore 75 to
100 mm
4) Micrometer: 75 to 100 mm
1. Apply petrolatum to pin gauge S2 and paste it to
the shaft (SH) of the main pump.
a Pin gauge S2: Pin (6.75 mm in diameter) for
external gear (shaft) of module 3.75 mm.
a Measuring in direction Y at portion B
PC800, 850-8E0
50-143
Hydraulic system
3. Apply petrolatum to pin gauge B2 and paste it to

the spline on the PTO side (coupling).
a Face the notch of pin gauge B2 to the outside.
a When pasting the pin gauge in Y direction
Perform the rest of installation in the reverse order to removal.
[*1]
Air hose clamp:

8.8 0.5 Nm {0.9 0.05 kgm}
[*2]
Air cleaner band:

9.8 11.8 Nm {1 1.2 kgm}
[*3]

mm) B3, measure the over pin dimension inside
the shaft (between B2) on the PTO side
(coupling) from X and Y directions at portions A
and B (at four locations in total).
a Measuring in direction X and Y at portion A.
50-144
Main pump mounting bolt:

785 980 Nm {80 100 kgm}
[*4]
a Do not apply grease to the spline part.
2 Spline:
Apply transmission oil TO30 (TO10 in winter).
Summer (0 to 40 C): TO30
Winter (-30 to 10 C): TO10)
PC800, 850-8E0
Hydraulic system
Reference
q Procedure for replacing hoses (MSH) and (FSH)
tube:
Filling length of hose:
95 mm: MSH (Main pump suction hose)
80 mm: FSH (Fan pump suction hose)

4) Tightening of the clamp
2 Clamp bolt (BC):
Lubricating oil (THREEBOND, PANDO 18B)
When reusing the hose
hose.
3 Clamp bolt (BC):
Min. 6 Nm {0.6 kgm}
PC800, 850-8E0

Tighten until dimension BDG comes as follows.
12 15 mm: MSH (Main pump suction hose)
7 10 mm: FSH (Fan pump suction hose)

Supply hydraulic oil through the oil filler port to
the specified level. Run the engine to circulate
the oil through the piping. Then, check the oil
level again.
5 Hydraulic tank:
470 l
Bleed air from each part. For details, see Testing

and adjusting, Bleeding air from each part.
50-145
Hydraulic system
Removal and installation of main pump input shaft oil seal
Removal and installation of main

50-146
pump input shaft oil seal
3 796T-72K-1010 Push tool

4 708-2K-12350 Spacer
Sketch
Part name
New/redesign
Part number
Q'ty
Symbol
50-146
Necessity
Special tools
t 1 N Q
t 1
Removal
50-146
1. Remove the main pump assembly. For details,
see "Removal and installation of main pump
assembly".
a After removal, place the pump assembly horizontally.
a Clean around the pump oil seal and the tip of
the shaft.
[*1]
[*2]
4. Remove oil seal (3) from cover (1).
[*3]
5. Pry off oil seal (4) using a flat-head screwdriver.
[*4]
a Take care not to damage the shaft when removing the oil seal.
50-146
50-146
Installation
[*1]
a When installing cover (1), put the special cap to
the shaft to protect the oil seal.
3 Cover mounting bolt:
27 34 Nm {2.8 3.5 kgm}
[*2]
Cover mounting bolt:

27 34 Nm {2.8 3.5 kgm}
[*3]
Install the oil seal similarly to [*4].
[*4]
Periphery of main lip (ML) and dust lip

(DL) of oil seal (Hatch part A):
Lithium grease (G2-LI)
2 When press-fitting the oil seal, apply
grease (G2-LI) lightly to its periphery.
Press-fit oil seal (4) using tool S3.
a Insert spacer [5] between tool S3 and oil seal (4).
PC800, 850-8E0
Hydraulic system
Removal and installation of cooling fan pump assembly
796-770-1301 Oil stopper
Sketch
Part name
Q'ty
Part number
New/redesign
Symbol
50-147
Necessity
Special tools
50-147
q 1
Removal
50-147
stop the engine.
a Put match marks on the hoses and the tubes.
a Install the oil stopper plugs to the disconnected
hoses and tubes.
1. Remove pump undercovers (1) and (2).
5. Sling and remove cover and frame assembly (5).

a You can remove cover and frame assembly
(5) without removing cover (A).

oil with oil stopper tool S1.
6 Hydraulic tank:
470 l
PC800, 850-8E0
50-147
Hydraulic system
6. Disconnect two hoses (6).

7. Disconnect fan pump drain hose (7), fan pump
outlet hose (8), coupling lubrication hose (9),
and hose (10).
8. Disconnect suction tube (11) from the pump.
11. Sling and remove cooling fan pump assembly

(14).
[*1]
4 Cooling fan pump assembly:
40 kg

10. Disconnect EPC solenoid connector V13 (13).
50-148
PC800, 850-8E0
Hydraulic system
Installation
50-149
[*1]
Fan pump mounting bolt:

245 309 Nm {25 31.5 kgm}
Reference
Procedure for replacing hoses (MSH) and (FSH)
tube:
Filling length of hose:
95 mm: MSH (Main pump suction hose)
80 mm: FSH (Fan pump suction hose)
When reusing the hose

hose.
3 Clamp bolt (BC):
Min. 6 Nm {0.6 kgm}
Tighten until dimension BDG comes as follows.
12 15 mm: MSH (Main pump suction hose)
7 10 mm: FSH (Fan pump suction hose)

Supply hydraulic oil through the oil filler port to
the oil through the piping. Then, check the oil
level again.
5 Hydraulic tank:
470 l
Bleed air from each part. For details, see Testing


4) Tightening of the clamp
2 Clamp bolt (BC):
Lubricating oil (THREEBOND, PANDO 18B)
PC800, 850-8E0
50-149
Hydraulic system
Removal and installation of control valve assembly

Removal
50-150
stop the engine.
k Release the remaining pressure from the hydraulic circuit. For details, see Testing and
adjusting, Releasing remaining pressure
from hydraulic circuit.
match marks on them.
6 Hydraulic tank:
2. Remove control valve covers (1).
50-150
4. Disconnect PPC hoses (3) of the pilot selector

valve and hose (4) between the control valves
and remove valve assembly (5).
5. Disconnect sensor (6) from the filter.
470 l
6. Remove tubes (7) between main pumps and
tube (8) between the 4-spool control valve and
5-spool control valve.
50-150
PC800, 850-8E0
Hydraulic system

50-151
1. Disconnect 14 PPC hoses (9).
2. Disconnect travel (10), boom (11), bucket (12),
and arm (13) tubes.
3. Disconnect tube (14) between the 5-spool
control valves.
50-151
1. Disconnect the lower back pressure compensation valve hose and sensor (6).
2. Disconnect hose clamps (45).
3. Disconnect left swing motor hose (17).
4. Disconnect right swing motor hose (18).
5. Remove tube clamp (19) and tube (20).
6. Remove piping brackets (21) and (22).
7. Remove boom (23), swing (24), arm (25), bucket
(26), and travel (27) tubes.
8. Disconnect tube (28) between the 4-spool
control valves.
9. Disconnect 16 PPC hoses (29).
4. Disconnect tube (43) and hose (44) from the

bottom.
5. Sling 4-spool control valve assembly (16),

loosen three mounting bolts (15), and remove
4-spool control valve assembly (16).
4 4-spool control valve assembly:
250 kg
PC800, 850-8E0
50-151
Hydraulic system
10. Disconnect tubes (46) and (47) from the bottom.

50-152
Installation
a Install tube (51), adjust the position of the valve,

and tighten valve assembly mounting bolts (52).
3 Control valve assembly mounting bolt:
279 29 Nm {28.5 3 kgm}
12. Sling 5-spool control valve assembly (30),

loosen three mounting bolts (31), and remove
5-spool control valve assembly (30).
4 5-spool control valve assembly:
250 kg
a Check the oil pressure and speed of the work
equipment, travel, and swing circuits. For details, see Testing and adjusting.
q
50-152

5 Hydraulic tank:
470 l (Refill capacity)
PC800, 850-8E0
Hydraulic system
Assembly of control valve assembly
50-153
a In this section, only the precautions for assembling the control valve assembly are described.
PC800, 850-8E0
50-153
50-153
Hydraulic system
Precaution
1. Arm Hi (AMH), bucket Lo (BKL), and boom Lo
(BML) spools must be installed in the correct
directions. Take care not to install them in opposite directions.
50-154
50-154
PC800, 850-8E0
Hydraulic system
2. Apply two drops (approx. 0.04 g) of LOCTITE

(No. 638) to the threads of plug (PL).
2 Threads of plug (PL):
Two drops (approx. 0.04 g) of LOCTITE
(No. 638)
3 Plug (PL):
117 161.8 Nm {12 16.5 kgm}
3. Apply liquid gasket (SEALEND No. 242 or equivalent) to the threaded portion (*) of plug (PS).
2 Threads (*) of plug (PS):
Liquid gasket (SEALEND No. 242 or
equivalent)
3 Plug (PS):
196.1 19.6 Nm {20 2 kgm}
PC800, 850-8E0
4. Tighten the mounting bolts (1) to (14) in the

following order.
3 Bolts (1), (3), (5) to (14):
78.5 98.1 Nm {8 10 kgm}
50-155
Hydraulic system
50-156
50-156
PC800, 850-8E0
Hydraulic system
Precaution
1. Arm Lo (AML) and bucket Hi (BKH) spools must
be installed in the correct directions. Take care
not to install them in opposite directions.
PC800, 850-8E0
50-157
50-157
Hydraulic system
2. Apply two drops (approx. 0.04 g) of LOCTITE

(No. 638) to the threads of plug (PL).
2 Threads of plug (PL):
Two drops (approx. 0.04 g) of LOCTITE
(No. 638)
3 Plug (PL):
117 161.8 Nm {12 16.5 kgm}
3. Apply liquid gasket (SEALEND No. 242 or equivalent) to the threaded portion of plug (PS).
2 Threads of plug (PS):
Liquid gasket (SEALEND No. 242 or
equivalent)
3 Plug (PS):
196.1 19.6 Nm {20 2 kgm}
50-158
PC800, 850-8E0
Hydraulic system
Removal and installation of swing motor assembly

Removal
50-159
stop the engine.
k 1) Release the pressure remaining in the circuit. For details, see Testing and adjusting,
"Releasing hydraulic pressure from PPC
valve equipped vehicles".
2) Loosen the hydraulic tank cap gradually to
release the pressure in the hydraulic tank.
50-159
Center of chassis
1. Disconnect hoses (1) and (2) from the control
valve and disconnect hoses (3) and (4) from the
swing motor positioned in the front section of the
machine body.
2. Remove swing holding brake hose (5) and drain
hose (6).
3. Remove U-bolt (7) of the oil gauge tube, remove
bolt (8) and remove bracket (9).
50-159
Front side of machine
1. Disconnect the hoses (10) and (11) from the
swing motor positioned in the central section of
the machine body.
2. Disconnect the swing holding brake hose (12)
and the drain hose (13).
3. Remove bolt (15) and remove bracket (16).
PC800, 850-8E0
50-159
4. Disconnect the swivel joint section hose (14).
5. Loosen four bolts (17) and remove swing motor

assembly (18) and (19).
4 Swing motor assembly:
57 kgx2
50-159
Installation
3 Swing motor assembly mounting bolt:
926.7 102.9 Nm {94.5 10.5 kgm}
Refilling of oil (hydraulic tank)

a Add oil through the oil filler port to the specified
level. Circulate the oil through the system. Then
a Add the quantity of the oil which leaks when the
motor assembly is removed.
50-159
Hydraulic system
Removal and installation of center swivel joint assembly
50-160
Removal
50-160
stop the engine.
k Release the remaining pressure from the hydraulic circuit. For details, see Testing and
adjusting, Releasing remaining pressure
from hydraulic circuit.
a Put match marks on hoses.
a Plug ends of disconnected hoses and the openings in the center swivel joint assembly.
a Prepare an oil contains.
1. Disconnected the lower section hoses (1), (2),
(3) and (4) of the swivel joint.
5. Pull out pin (13) and move link (14) toward the
frame.
6. Sling the swivel joint assembly.
a Use the hole for the split flange bolt.
7. Removing the lower side mounting bolt, sling off
the swivel joint assembly (15).
[*1]
4 Center swivel joint assembly:
70 kg
2. Remove work equipment hose (5).

3. Remove swing motor hoses (6).
4. Disconnect hoses (7) to (12) from the top of the
swivel joint.
50-160
PC800, 850-8E0
Hydraulic system
Installation
50-161
[*1]
a Regarding the port located in the lower section of
the swivel joint, install the swivel joint so that the
"A port" faces the front-RH side.
Refilling of oil (hydraulic tank)

a Add oil through the oil filler port to the specified
level. Circulate the oil through the system. Then
a Add the quantity of the oil which leaks when the
swivel joint assembly is removed.
PC800, 850-8E0
50-161
Hydraulic system
Disassembly and assembly of center swivel joint assembly
790-101-2501 Push-puller
790-101-2510 q Block
790-101-2520 q Screw
791-112-1180 q Nut
790-101-2540 q Washer
790-101-2630 q Leg
790-101-2570 q Plate
790-101-2560 q Nut
790-101-2660 q Adapter
t
t
t
t
t
t
t
t
t
1
1
1
1
1
2
2
2
2
Sketch
Part name
Q'ty
Part number
New/redesign
Symbol
50-162
Necessity
Special tools
50-162
Disassembly
50-162
2. Remove snap ring (2).
3. Using tool T1, pull swivel rotor (4) and ring (3)
out of swivel shaft (5).
4. Remove O-rings (6) and slipper seals (7) from
swivel rotor (4).
50-162
PC800, 850-8E0
Hydraulic system
Assembly
50-163
1. Install slipper seal (7) and O-ring (6) to swivel
rotor (4).
2. Set swivel shaft (5) on block [2], then using push
tool [1], tap swivel rotor (4) with a plastic hammer
to install.
2 Contact surface of rotor, shaft:
Grease (G2-LI)
a When installing the rotor, be extremely careful not to damage the slipper seal and O-ring.
PC800, 850-8E0
3. Install ring (3) and secure it with snap ring (2).

4. Install cover (1) with the O-ring.
3 Mounting bolt:
66.15 7.35 Nm {6.75 0.75 kgm}
50-163
Hydraulic system
Removal and installation of travel motor assembly
Removal and installation of travel motor assembly
Part name
796-660-1560 Guide bolt
New/redesign
Sketch
Part number
Q'ty
Symbol
50-164
Necessity
Special tools
t 2
Removal
50-164
k Swing the work equipment 90, then lower it
completely to the ground.
k Loosen the oil filler cap gradually to release
the pressure inside the hydraulic tank.
50-164
3. Remove two mounting bolts from the travel

motor and set tool K in position.
4. Remove remaining mounting bolts, then pull out
travel motor assembly (6) and sling.
[*2]
5. Sling off travel motor assembly (6).
[*3]
4 Travel motor assembly:
140 kg

4 Cover:
130 kg
Installation
50-164
[*1]
a After connecting the hoses, add engine oil
through plug (7) until it reaches the top of the
port.
2. Disconnect hoses (2), (3), (4), and (5).
a Put the plug to the disconnected hose.
a (7): Oil filler port plug
[*1]
[*2]
Mounting bolt:
384.7 41.65 Nm {39.25 4.25 kgm}
[*3]
a There is no air bleed plug, so add oil through
plug (7) on the brake valve side, when installing.
a Run the engine to circulate the oil through the
system. Then add hydraulic oil to the hydraulic
tank to the specified level.
50-164
PC800, 850-8E0
Hydraulic system
Removal and installation of solenoid valve assembly

Removal
50-165
stop the engine.
a Put the match mark before disconnecting the
PPC circuit hose.
a Put the plug to the disconneced tube and hose.
50-165
2. Straight travel valve, boom head 2-stage

safety valve, travel speed selector valve,
main 2-stage relief valve, and swing brake
valve
1) Access through hole (1) on the bottom of the
revolving frame.
1. Boom damping valve

1) Remove tool box (1) located in front of the
hydraulic oil tank.
2) Disconnect wiring connectors (2) (V9 and

V10).
3) Remove nuts (3) and remove coils (4).
a V9, V10: Boom damping solenoid valve
PC800, 850-8E0
2) Remove clips (2).

3) Disconnect hoses (3).
4) Disconnect wiring connectors (4).
(From the top: A1, A2 (V04), A3 (V05), A4
(V06), A5 (V08) and A6 (V02))
5) Remove bolt (5) and coils (6).
a V08: Main 2-stage relief valve
V02: Straight travel valve
V06: Boom head 2-stage safety valve
V04: Travel speed selector valve
V05: Swing brake valve
50-165
Hydraulic system
3. Swing priority selector valve

1) Access through hole (1) on the bottom of the
revolving frame.
50-16
Installation
a Take care that dirt does not stick to the coil insertion parts.
2) Disconnect wiring connector (2) (V14).

3) Remove coil (3).
a V14: Swing priority selector valve
50-166
PC800, 850-8E0
Hydraulic system
Removal and installation of boom damping valve assembly
Removal and installation of boom damping valve assembly

Removal
50-167
stop the engine.
a Release the remaining pressure from the PPC
circuit.
a Put the plug to the disconnected hose.
50-167
50-167
Installation
q
Bleeding air
Perform air bleeding of the PPC piping circuit.
For details, see Testing and adjusting,
Bleeding air from each part.
1. Remove tool box (1) located in front of the

hydraulic oil tank.
2. Disconnect solenoid wiring connectors (2) (V9

and V10).
3. Disconnect four hoses of hose (3) and hose (4)
between the solenoid valve and the damping
valve.
a Disconnect the hose between the damping
valve and the PPC valve, RH and disconnect
the hose between the damping valve and the
relay joint.
4. Remove the mounting bolt to remove damping
valve assembly (5).
PC800, 850-8E0
50-167
Hydraulic system
Disassembly and assembly of work equipment PPC valve assembly

a Only precautions for assembling the work equipment PPC valve assembly are described below.
50-168
Assembly
50-168
q Work equipment PPC valve assembly
a Install spring (8) with its small (inside) diameter
end on the shim (10) side.
a Springs (9) having different numbers of turns are
used for the following hydraulic ports. Install
them with care.
a Installed height (34 mm), Spring constant: 0.98
Nm {0.1 kg/mm}
(Common to P1, P2, P3, and P4)
Port
Installed load
P1, P2
3.92 N {0.4 kg}
P3, P4
11.76 N {1.2 kg}
a The location of each port is stamped on the underside of the valve body.
2 Piston (7):
Grease (G2-LI)
a When installing piston (7), apply grease to the
outside of the piston and inside of the body hole.
3 Mounting bolt (3) of plates (5) and (6):
11.8 14.7 Nm {1.2 1.5 kgm}
2 Sliding parts of joint (4):
7 10 cc of grease (G2-LI)
a Degrease the male threads of joint (4) and female threads of body (12) thoroughly, and then
dry them.
2
Female thread of body :

Adhesive (ThreeBond No. 648)
a Apply one drop (about 0.02 g) of LOCTITE each
to two places of the female threads of the body
as shown in the figure.
3 Joint (4):
39 49 Nm {4 5 kgm}
a Observe the tightening torque for the joint.
50-168
PC800, 850-8E0
Hydraulic system
2
Contact faces of piston and disc (2):

0.3 0.8 cc of grease (G2-LI)
3 Nut (1):
69 87 Nm {7 9 kgm}
a After installing the disc, see Testing and adjusting, Adjusting play of work equipment and
swing PPC valve.
a Pay attention to the direction of piston (11).
3 Mounting bolt (14) of cover (13):
19.6 27.5 Nm {2.0 2.8 kgm}
PC800, 850-8E0
50-169
Hydraulic system
Disassembly and assembly of travel PPC valve assembly
2 796T-416-1010 Push tool

T 3 796T-416-1030 Push tool
4 796T-416-1020 Push tool
t 1
t 1
t 1
Sketch
Part name
New/redesign
Part number
Q'ty
Symbol
Necessity
Special tools
50-170
50-170
a Note the thickness and installed position of
each washer (12).
a Remove pin (24) from valve body (1).
6. Remove seal (9) and collar (8).
Q
Q
Q
Disassembly
50-170
1. Remove screws (22) and remove damper
assemblies (21).
7. Remove pistons (7) to remove retainer (6),

springs (5) and (4), and shims (3).
a Note the installed position, quantity and
thickness of each pack of shims (3) and keep
them.
8. Remove valves (2) from valve body (1).
2. Remove mounting bolt (19) and remove case

(18), shafts (16) and levers (13) together.
3. Remove pins (17).
4. Remove levers (13), bushings (14) and (14a),
and shafts (16) from the case.
5. Remove mounting bolts (11) to remove plate
(10).
50-170
PC800, 850-8E0
Hydraulic system
Assembly
Only precautions for assembly are described.
50-171
a When assembling, clean and inspect the parts

closely and take care fully so that dirt, rust, flaw,
etc. will not cause a problem.
a When installing piston (7), apply grease (G2-LI)
to its periphery and the inside of the valve body
hole.
a Install spring (4) with its small diameter end toward shim (3).
q Diameter of spring (inside diameter)
Small diameter end: f4.9 Large diameter end:
f5.55
a Install shaft (16) according to the following procedure.
1) Install bushing (14) to the case using tool T2.
a Insert the bushing from the 10 chamfered side.
a Install the bushing so that distance A is as
follows.
q Distance A: 20.4 0.3 mm
a Do not hit it with a hammer directly.
2) Install bushing (14a) to the case using tool

T3.
a Insert the bushing from the 10 chamfered side.
a Install the bushing so that distance B is as
follows (bushing end face flushes with
case end face).
q Distance B: 0 mm
PC800, 850-8E0
3) Install lever (13).

4) Install shaft (16).
5) Using tool T4, install pin (17).
a Install the pin so that distance C is as follows.
q Distance C: 0 0.5 mm
a Apply grease (G2-LI) to the sliding surfaces of

shaft (16), contact surfaces of lever (13) and piston (7), and contact surfaces of damper (21) and
pin (20).
2 Quantity of grease (G2-LI)
Sliding parts of shaft: 4 8 cc/periphery
Contact surfaces of lever and piston: 0.3
0.8 cc/part
Contact surfaces of damper and pin: 0.3
0.8 cc/part
a First install washer (12) of t = 1.6. If the right and
left difference when the lever is at full stroke position is 0.7 or larger, change the thickness of
washer to make the difference to 0.7 or smaller.
(If the thickness of washer is reduced by 0.3 mm,
the full stroke angle increases by 0.39.)
q Available washer: t = 1.0, 1.3, 1.6, 1.9, 2.2
50-171
Hydraulic system
1. Tighten each part to the following torque.

q Plug (26): 6 11 Nm {0.6 1.1 kgm}
q Plug (25): 4 9 Nm {0.4 0.9 kgm}
q Screw (22): 7.8 9.8 Nm {0.8 1.0 kgm}
q Bolt (19): 25 30 Nm {2.5 3.2 kgm}
q Bolt (11): 27 34 Nm {2.8 3.5 kgm}
50-172
PC800, 850-8E0
Hydraulic system
Disassembly and assembly of hydraulic cylinder assembly
1 790-502-1003 Cylinder repair stand

2 790-720-1000 Expander
796-720-1670 Ring
3
07281-01279 Clamp
790-201-1702 Push tool kit
790-201-1881 q Push tool
790-201-1871 q Push tool
4
790-445-4210 Push tool
790-101-5021 q Grip
U
01010-50816 q Bolt
790-201-1500 Push tool kit
790-201-1690 q Plate
790-201-1680 q Plate
5 790-201-1970 Push tool
792-715-1400 Plate
790-101-5021 q Grip
01010-50816 q Bolt
790-102-4300 Wrench
6
790-102-4310 Pin
Q'ty
Part name
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
New/redesign
Sketch
SymPart number
bol
50-173
Necessity
Special tools
Disassembly
50-173
1. Piston rod assembly
1) Remove piping from the cylinder assembly.
2) Remove mounting bolts, and disconnect
head assembly (1).
3) Pull out piston rod assembly (2).
a Place a container under the cylinder to
collect the oil.
PC800, 850-8E0
50-173
4) Disassemble the piston rod assembly as

follows.
1] Set piston rod assembly (2) to tool U1.
2] Remove piston assembly lock screw (3).

q Applicable to: Boom and arm cylinders on the machines of standard and
SE specifications. Bucket cylinder on
the machines of standard specification.
Screw size: M12 x pitch 1.75
50-173
Hydraulic system
a If screw (3) is punched strongly and

cannot be removed, screw it in fully,
then apply the tap the thread hole and
pull it out.
3] Using tool U6, remove piston assembly

(4).
q When not using tool U6, loosen the
piston assembly using the pin holes
for tool U6 (f10: two places).
q Applicable to: Boom and arm cylinder
on the machine of standard and SE
specifications. Bucket cylinder on the
machines of standard specification.
4] Remove six screws (21), then remove

spacer (22), and remove piston assembly
(4), and O-ring and back-up ring (23).
q Applicable to bucket cylinder on the
machines of SE specification
5] Remove plunger (5).

6] Remove collar (6), O-ring and backup
ring.
7] Remove head assembly (7).
8] Remove cap (8), and pull out eleven balls

(9), then remove cushion plunger (10).
q Applicable to arm cylinder
50-174
PC800, 850-8E0
Hydraulic system
2. Disassembly of piston assembly

1) Remove ring (11).
2) Remove wear rings (12).
a Number of wear rings: Bucket and boom
cylinder: 2 pcs.; Standard arm cylinder: 2
pcs.; Civil engineering specification arm
cylinder: 4 pcs.
3) Remove piston ring (13).
4) Remove O-ring and backup ring (14).
50-175
Assembly
a Be careful not to damage the packings, dust
seals, O-rings, etc.
a Do not install the backup ring forcibly. Warm the
ring using hot water of approximately 50 to 60 C
before installation.
1. Building of cylinder head assembly
1) Press-fit bushing (20) using tool U4. Install
bushing stopper snap ring (21).
2) Install buffer ring (19).
3) Install rod packing (18).
4) Using tool U5, install dust seal (17), and
secure it with snap ring (16).
5) Install O-ring and backup ring (15).
3. Disassembly of cylinder head assembly

1) Remove O-ring and backup ring (15).
2) Remove snap ring (16), then remove dust
seal (17).
3) Remove rod packing (18).
4) Remove buffer ring (19). Remove bushing
stopper snap ring (21).
5) Remove bushing (20).
PC800, 850-8E0
50-175
Hydraulic system
2. Building of piston assembly

1) Using tool U2, expand piston ring (13).
a Set the piston ring on tool U2, and turn the
handle eight to ten times to expand the
ring.
2) Set tool U3 in position, and compress piston
ring (13).
3) Install O-ring and backup ring (14).

q Applicable to: Boom and arm cylinder for
standard bucket
4) Install wear ring (12).
5) Install ring (11).
a Be careful not to open the end gap of the
ring excessively.
2 Ring groove:
Grease (G2-LI)
3. Piston rod assembly

1) Set piston rod assembly (2) on tool U1.
2) Assemble head assembly (7).

3) Fit the O-ring and backup ring to collar (6),
and then install them.
4) Set cushion plunger (10) to piston rod, then
install eleven balls (9), and secure them with
cap (8).
a After installing, check that the cushion
plunger end has a little play.
5) Install plunger (5).
a Build up the assembly with stepped portion of plunger faced the piston.
50-176
PC800, 850-8E0
Hydraulic system
b. Tighten screw (3).

2 Threads of screw:
Adhesive
(LOCTITE 262 or equivalent)
3 Screw (3):
58.9 73.6 Nm {6 7.5 kgm}
c. Punch the thread at four places.
Applicable to bucket cylinder on machine

of SE specification
6) Build piston assembly (4) according to the

1] When reusing rod and piston assembly
(4)
a Wash it thoroughly and remove all the
metal particles and dirt.
a. Screw piston assembly (4), then
tighten piston assembly using tool U6 to
align the screw holes.
a Remove any burrs on the threaded
portion with a file.
a After tightening the piston, check that
there is play in plunger (5).
PC800, 850-8E0
2] When using a new part for either or both

of rod (2) and piston assembly (4)
a For the rod with bottom cushion, put a
mark to indicate the position of the
cushion plug on the end surface of the
rod.
a. Screw piston assembly (4) it until it
contacts end face of rod (2), then tighten
it using tool U6 (described above).
3 Piston assembly (4):
294 29.4 Nm {30 3.0 kgm}
a After tightening the piston, check that
there is play in plunger (5).
50-177
Hydraulic system
b. Make a threaded hole to install screw

(3).
a Apply the drill to the V-groove between piston assembly (4) and threaded part of rod (2), and make a hole
horizontally.
a The cylinder with bottom cushion (arm
cylinder) must not be machined in the
cushion plug position.
q Screw machining dimension (mm)
Cylinder name
Bucket, standard arm
Boom, civil engineering specification arm
Tap drill
diameter
Tap drill
hole
depth
Tap to be
used
Screw hole
depth
10.3
36
12x1.75
29
10.3
43
12x1.75
36
c. After machining, wash the parts thoroughly to remove all the metal particles
and dust.
d. Tighten screw (3).
2 Threads of screw:
Adhesive
3 Screw (3):
58.9 73.6 Nm {6 7.5 kgm}
e. Punch the thread at four places.
50-178
7) Install O-ring and back-up ring (23), piston

assembly (4) and spacer (22), then tighten
them with screw (21).
a After tightening, wait for approximately 30
minutes.
a Apply hardening accelerator and liquid
adhesive to the threaded portions of the
screw.
2 Threads of screw:
Liquid accelerator
(LOCTITE Primer T or equivalent)
2 Threads of screw:
Adhesive
3 Screw (21):
245 309 Nm {25 31.5 kgm}
q Applicable to bucket cylinder of SE specification machine
8) Install piston rod assembly (2).

2 Seal portion:
Grease (G2-LI)
a Set the piston rod assembly with the ring
and gap in a horizontal line and insert the
assembly into the cylinder tube aligning it
with the cylinder tube.
a After inserting, check that the ring is not
broken and does not come out, then push
it in fully.
PC800, 850-8E0
Hydraulic system
9) Install and tighten head assembly (1) with

mounting bolts.
3 Mounting bolt:
Cylinder name
Standard bucket, standard
arm
Civil engineering specification arm, boom
SE Bucket
Tightening torque
892 137 Nm
{91.0 14 kgm}
1.27 0.20 kNm
{130 20 kgm}
1.67 0.25 kNm
{170 25 kgm}
10)Install piping.
PC800, 850-8E0
50-179
Hydraulic system
Disassembly and assembly of grease gun assembly

Disassembly
1. Remove joint (1) from the hose.
2. Remove gun assembly (2) from joint (1).
3. Remove nozzle (3) from gun assembly (2).
4. Remove cap (4) from nozzle (3).
50-180
50-180
50-180
50-180
Assembly
1. Install joint (1) to the hose.
a Wind the seal tape two to three times around
the threaded portion as the tape bites into the
thread starting from a position one winding
away from the end of the threaded portion.
3 Screw portion of joint:
5.9 11.8 Nm {0.6 1.2 kgm}
2. Install gun assembly (2) to joint (1).
a Wind the seal tape two to three times around
the threaded portion as the tape bites into the
3 Screw portion of joint:
3.9 6.9 Nm {0.4 0.7 kgm}
3. Install nozzle (3) to gun assembly (2).
a Wind seal tape two to three times around the
threaded portion as the tape bites into the
Screw in nozzle (3) manually. When manual
screwing becomes disabled, use the tool and
further screw in nozzle (3).
4. Install cap (4) to nozzle (3).
PC800, 850-8E0
Work equipment
Removal and installation of bucket cylinder assembly
Work equipment
50-181
50-181
Backhoe equipment
50-181
Removal
50-181
k Retract the arm and bucket cylinder piston
rods, lower the work equipment to the
ground and set the lock lever to the lock position.
6. Remove bucket cylinder assembly (5).

4 Bucket cylinder assembly:
520 kg(PC800)
940 kg (PC800SE, PC850SE)
560 kg(PC850)
1. Set block (1) between bucket cylinder and arm,

and block (2) between link and arm.
2. Remove three pin lock bolts (1) and cover (2),
then pull out the pin using forcing screws.
[*1]
a Shims are installed, so note their quantity
and thickness.
3. Start the engine, and retract piston rod, then tie

piston rod by using a wire to prevent it from
coming out.
k Stop the engine, and release the pressure
remaining in the circuit. For details, see
Testing and adjusting, Releasing remaining pressure in hydraulic circuit.
4. Disconnect two hoses (3).
a Plug the disconnected hoses to prevent dirt
or dust from entering.
5. Sling bucket cylinder assembly (5), then remove
plate (6) and pull out pin (7).
[*2]
and thickness.
PC800, 850-8E0
50-181
Work equipment
50-182
Installation
[*1]
Inside surface of bushing when installing

pin:
Antifriction compound (LM-P)
2 Greasing after installing pin:
Grease (LM-G)
k When aligning the pin holes, never insert
your fingers in them.
a Adjust clearance (a) between link (7) and cover
(2) to 1 mm or less using shim (4).
q Shim thickness: 0.8 mm (STD)
1.0 mm(SE)
Bleeding air
a Perform air bleeding. For details, see Testing and adjusting, Bleeding air from each
part.

a Supply oil through the oil filler port to the
specified level. Run the engine to circulate
the oil through the system. Then check the oil
level again.
[*2]

pin:
Grease (LM-G)
a Adjust clearance (b) between bottom end of cylinder (5) and bracket (8) to 1 mm or less using
shim (9).
q Shim thickness: 0.8 mm (STD)
1.0 mm(SE)
50-182
PC800, 850-8E0
Work equipment
Loading shovel equipment
50-183
3. Disconnect grease tube (2).

4. Disconnect hoses (3).
Removal
50-183
k Extend the arm cylinder fully to level the bottom of the bucket, lower the work equipment
to the ground and stop the engine.
Operate the control levers several times to
release the remaining pressure in the hydraulic piping.
k Loosen the cap of the hydraulic tank gradually to release the remaining pressure inside
the hydraulic tank.
a Plug the disconnected hoses to prevent dirt or
dust from entering.
1. Sling the bucket cylinder assembly, and remove
plate, then using forcing screws (thread dia. = 16
mm, pitch = 2 mm), pull out pin (1).
[*1]
4 Pin:
40 kg
2. Start the engine and retract the piston rod fully.

k Tie the piston rod with a wire to prevent it
from coming out.
Testing and adjusting, "Releasing remaining pressure in PPC valve hydraulic
circuit".
PC800, 850-8E0
5. Sling the piston rod end and bottom end to

remove the plate, then pull out pin (4) using
forcing screws (thread diameter: 16 mm; pitch: 2
mm).
[*2]
a Pull out the pin to a position where the cylinder bottom can be disconnected.
4 Pin:
35 kg
6. Sling bucket cylinder assembly (5) and remove it

with care.
630 kg
50-183
Work equipment
50-184
Installation
removal.
[*1]
When aligning the mounting holes for the
pin, never insert your fingers in the pin hole.
[*2]
a Adjust with shims so that the clearance at the
cylinder bottom end is less than 1 mm.
a Bleed the air from the work equipment circuit.

For details, see Testing and adjusting, Bleeding
air from hydraulic cylinder.
q
Refilling of oil
a Add oil through oil filler port to the specified
level. Circulate the oil through the system.
Then check the oil level again.
50-184
PC800, 850-8E0
Work equipment
Removal and installation of arm cylinder assembly

50-185
Special tools
50-185
Sym
Part number
bol
791-650-1610
790-445-4130
791-112-1180
V 2 01643-32780
Part name
Bracket
Screw
Nut
Washer
Puller
790-101-2102
(294 kN {30 ton})
790-101-1102 Pump
t
t
t
t
1
1
1
1
t 1
t 1
Removal
50-185
k Extend the arm cylinder piston rod to approximately 200 mm before the excavating stroke
end, lower the work equipment to the ground,
and set the lock lever in the lock position.
1. Set block (1) between the arm cylinder and
boom.
2. Disconnect grease hose (1).
3. Remove plate (2) and pull out head pin (3).
[*1]
PC800, 850-8E0
a If the pin cannot be pulled out, use tool V2

and pull out the pin at the head end.
Necessity
Q'ty
New/redesign
Sketch
Backhoe equipment
50-185
4. Start the engine, and retract the piston rod, then

tie the piston rod with a wire to prevent it from
coming out.
5. Disconnect hose (4) and lubrication hose (5).
a Plug the disconnected hoses to prevent dirt
or dust from entering.
6. Sling arm cylinder assembly (6), then remove
plate (7) and pull out bottom pin (8).
[*2]
a If the pin cannot be pulled out, use tool V2 to
pull out the bottom pin.
and thickness.
50-185
Work equipment
7. Remove arm cylinder assembly (6).

4
[*2]
Arm cylinder assembly:
845 kg(PC800STD)
485 kg x 2
(PC800SE, PC850, 850SE)
Installation
50-186
removal.
[*1]

pin:
Grease (LM-P)
[*2]

pin:
Grease (LM-G)
a Adjust clearance (a) between bottom end of cylinder (6) and bracket (9) to 1 mm or less using
shim (10).
q Shim thickness: 0.8 mm
50-186
Bleeding air
a Perform air bleeding. For details, see Testing and adjusting, Bleeding air from each
part.

a Supply oil through oil filler port to the specified level. Run the engine to circulate the oil
through the system. Then check the oil level
again.
PC800, 850-8E0
Work equipment
50-187
Removal
50-187
k Retract boom cylinder fully, and extend arm
cylinder, then level the bottom of the bucket,
lower the work equipment to the ground and
stop the engine.
the hydraulic tank.
dust from entering.

4. Sling the piston rod end and bottom end to
remove the plate, then pull out pin (4) using
forcing screws (thread diameter: 16 mm; pitch: 2
mm).
[*2]
a Pull out the pin to a position where the cylinder bottom can be disconnected.
4 Pin:
40 kg
1. Sling arm cylinder assembly, remove plate, then

remove pin (2) using forcing screws (thread
diameter: 16 mm; pitch: 2 mm).
[*1]
a Pull out the pin to a position where the piston
rod can be disconnected.
4 Pin:
40 kg
5. Remove arm cylinder assembly (5).
4 Arm cylinder assembly:
855 kg

from coming out.
circuit".
PC800, 850-8E0
50-187
Work equipment
50-18
Installation
removal.
[*1]
When aligning the mounting holes of the pin,
never insert your fingers in the pin hole.
[*2]

air from hydraulic cylinder (work equipment circuit).
q
Refilling of oil
50-188
PC800, 850-8E0
Work equipment
Removal and installation of boom cylinder assembly

50-189
Special tools
50-189
Sym
Part number
bol
Part name
790-445-4100 Remover
Puller
1 790-101-4200
(294 kN {30 ton})
790-101-1102 Pump
790-445-4120 Sleeve
791-520-4140 Screw
V
796-775-1110 Adapter
791-112-1180 Nut
3
01643-32780 Washer
Puller
790-101-2102
(294 kN {30 ton})
790-101-1102 Sleeve
t 1
t 1
t
t
t
t
t
t
1
1
1
1
1
1
t 1
t 1
Removal
50-189
dust from entering.
1. Disconnect grease tube (1).
2. Remove plate (2).
4. Using tool V3, pull out pin (3) on the head side,
then disconnect the piston rod from the boom.
[*1]
Necessity
Q'ty
New/redesign
Sketch
Backhoe equipment
50-189

tie the piston rod with a wire to prevent it from
coming out.
6. Lower the boom cylinder assembly on a stand,
then disconnect hoses (4).
7. Disconnect greasing hose (5).
8. Sling boom cylinder assembly and remove plate
(6).
3. Sling boom cylinder assembly.
PC800, 850-8E0
50-189
Work equipment
9. Using tool V1, pull out pin (7) on the bottom side.
[*2]
10. Remove boom cylinder assembly.
4 Boom cylinder assembly:
760 kgx2
Installation
50-190
removal.
Bleeding air
a Perform air bleeding. For details, see Testing

again.
[*1]

pin:
Grease (LM-G)
[*2]

pin:
Grease (LM-G)
a Set the clearance a between the bottom end face
of boom cylinder (8) and bracket (9) to 1 mm or
less by using shims (10).
q Shim thickness: 1.0, 1.5 mm
50-190
PC800, 850-8E0
Work equipment
50-191
5. Lower the boom cylinder assembly onto a stand,

then disconnect hoses (4).
Removal
50-191
k Extend the arm and bucket cylinder rods fully, lower the work equipment to the ground
and stop the engine. Operate the control levers several times to release the remaining
pressure in the hydraulic piping.
the hydraulic tank.
dust from entering.
1. Disconnect greasing tube (1).
3. Sling the boom cylinder assembly, then using
forcing screws (thread dia. = 16 mm, pitch = 2
mm), pull out pin (3), and disconnect piston rod
from boom.
[*1]

k Tie the piston rod with wire to prevent it
from coming out.
circuit".
PC800, 850-8E0
6. Sling the boom cylinder assembly, and remove

the plate, then using forcing screws (thread dia.
= 16 mm, pitch = 2 mm), pull out foot pin (5).
[*2]
7. Remove boom cylinder assembly (6).

4 Boom cylinder assembly:
730 kg
50-191
Work equipment
50-192
Installation
removal.
[*1]
[*2]

q
Refilling of oil
a Add oil through the oil filler port to the specified level. Circulate the oil through the system. Then check the oil level again.
50-192
PC800, 850-8E0
Work equipment
Removal and installation of bottom dump cylinder assembly

50-193
50-193
Removal
50-193
k Level the bottom of the bucket, and retract
the rod to a position where the rod connecting pin of the bottom dump cylinder can be
removed. Then place a block under the bucket, lower the work equipment to the ground
and stop the engine.
dust from entering.
2. Sling the bottom dump cylinder assembly, and
remove lock plate, then using forcing screws
(thread dia. = 16 mm, pitch = 2 mm), pull out pin
(2).
[*1]
5. Remove three mounting bolts, then using forcing

screws (thread dia. = 16 mm, pitch = 2 mm), pull
out pin (4).
[*2]
4 Pin:
35 kg
6. Remove bottom dump cylinder assembly (5).
4 Bottom dump cylinder assembly:
120 kg

circuit".
PC800, 850-8E0
50-193
Work equipment
50-194
Installation
removal.
[*1]
[*2]

q
Refilling of oil
50-194
PC800, 850-8E0
Work equipment
Removal and installation of bucket assembly

Backhoe equipment
50-195
Removal
50-195
k Face the back of the bucket down, lower the
work equipment to the ground, then set the
lock lever to the LOCK position.
1. Remove three pin lock bolts (1), then remove
stopper (2).
2. Using the forcing screws, remove the connecting

pin of the link and bucket.
[*1]
tie the link to the arm with a wire to prevent the
piston rod from coming out.
PC800, 850-8E0
50-195
4. Remove three pin lock bolts (3), then remove

stopper (4).
5. Remove cover (5) and shim (6).
a Check the quantity and locations of the
shims.
6. Using forcing screws, remove arm connecting
pin (7).
[*2]
7. Start the engine and raise the work equipment,

disconnect the arm from the bucket, then
remove the bucket assembly.
4 Bucket assembly:
2,940 kg(PC800STD)
3,800 kg(PC850STD)
3,440 kg(PC800SE)
3,840 kg(PC850SE)
50-195
Work equipment
50-196
Installation
removal.
[*1]

pin:
Grease (LM-G)
a Adjusting of bucket clearance

1) Measure clearance a between arm (8) and
bushing (9).
a It is easier to measure if the bucket is
moved to one side so that all the plays
gather in one place.
2) Select shims so that clearance a is 0.5 to 1.0
mm.
q Shim thickness b: 0.5, 1.0 mm
3) Install selected shims and install cover (5).
[*2]

pin:
Grease (LM-G)
a Install the O-ring to the end face of the bucket
boss securely.
50-196
PC800, 850-8E0
Work equipment
50-197
Removal
50-197
k Level the bottom of the bucket horizontally,
lower the work equipment completely to the
ground and stop the engine.
the hydraulic tank.
dust from entering.
1. Sling bucket cylinder assembly, and remove
plate, then using forcing screws (thread dia. = 16
mm, pitch = 2 mm), pull out pin (1).
[*1]
a Remove the pin on the opposite side in the
same way.
from coming out.
4 Pin:
40 kg
Testing and adjusting, "Releasing remaining pressure in hydraulic circuit".
3. Disconnect bottom dump cylinder hoses (2).
4. Sling the bucket assembly, and remove three

mounting bolts, then using forcing screws
(4).
[*2]
a Remove the pin on the opposite side in the
same way.
4 Pin:
55 kg
5. Remove bucket assembly (5).

4 Bucket assembly:
6,995 kg
Installation
50-197
removal.
[*1] [*2]
air from hydraulic cylinder (work equipment circuit). After completion of the air bleeding operation, add hydraulic oil to the hydraulic tank to the
specified level.
PC800, 850-8E0
50-197
Work equipment
Removal and installation of arm assembly

50-198
Special tools
50-198
Sym
Part number
bol
791-650-1610
790-445-4130
791-112-1180
2 01643-32780
790-101-2102
V
790-101-1102
790-445-4120
791-520-4140
796-775-1110
791-112-1180
3
01643-32780
790-101-2102
790-101-1102
Part name
Bracket
Screw
Nut
Washer
Puller
(294 kN {30 ton})
Pump
Sleeve
Screw
Adapter
Nut
Washer
Puller
(294 kN {30 ton})
Sleeve
t
t
t
t
1
1
1
1
t 1
t 1
t 1
t 1
t 1
t 1
t 1
t 1
a If the pin cannot be pulled out, use tool V2

and pull out the pin on the head end.
t 1
Removal
50-198
1. Remove bucket assembly. For detail, see
"Removal and installation of bucket assembly".
2. Secure the linkage to the arm with wire.
k Extend the arm cylinder piston rod to a
point approximately 200 mm before the
end of the arm IN stroke, then lower the
arm on to block [1] and stand [2]. Set the
lock lever to the LOCK position. Stop the
engine.
3. Set a block between the arm cylinder and boom.
4. Disconnect grease hose (1).
50-198
5. Remove plate (2), and pull out head pin (3) of the
arm cylinder.
[*1]
Necessity
Q'ty
New/redesign
Sketch
Backhoe equipment
50-198

tie the piston rod to the arm with a wire to prevent
it from coming out.
7. Disconnect two bucket cylinder hoses (4).
PC800, 850-8E0
Work equipment
8. Remove plate (5), then using tool V3, pull out

boom top pin (6).
[*2]
and thickness.
50-19
Installation
removal.
[*1]

pin:
Antifriction compound (LM-G)
Grease (LM-G)
[*2]
9. Start the engine, then raise boom and remove

arm assembly (7).
4 Arm assembly:
4,000 kg(PC800STD)
4,500 kg(PC850STD)
4,900 kg (PC800SE, PC850SE)
PC800, 850-8E0

pin:
Grease (LM-P)
a Set the clearance a between the bottom end
face of arm (7) and boom (8) to 1 mm or less by
using shims.
q Shim thickness: 1.0 mm
Bleeding air

again.
50-199
Work equipment
50-20
Removal
50-20
1. Remove the bucket assembly.
bucket assembly".
2. Lower the tip of the arm assembly to the ground.
3. Sling arm cylinder assembly (1) and disconnect
the rod side from the arm.
For details, see Removal of arm cylinder
assembly.
a Secure the arm cylinder assembly to the
boom using lever block [1].
k
Stop the engine, and release the pressure

circuit".
50-200
4. Disconnect left and right bottom dump cylinder

hoses (2).
5. Disconnect two bucket cylinder hoses (3) and (4)
on each side.
6. Sling the arm assembly, and remove three

mounting bolts, then using forcing screws
(5).
[*1]
a Pull out the pin to a position where the arm
can be disconnected from the boom.
Remove the pin on the opposite side in the
same way.
4 Pin:
55 kg
7. Remove the arm assembly (6).
4 Arm assembly:
3,410 kg
PC800, 850-8E0
Work equipment
Installation
50-201
removal.
[*1]
air from hydraulic cylinder. After completion of
the air bleeding operation, add hydraulic oil to
the hydraulic tank to the specified level.
PC800, 850-8E0
50-201
Work equipment
Removal and installation of boom assembly
Special tools
50-202
Sym
Part number
bol
790-445-410
0
790-101-420
V 1
0
790-101-110
2
Part name
Q'ty
New/redesign
Sketch
50-202
Necessity
Backhoe equipment
50-202
Remover
t 1
Puller
(294 kN {30 ton})
t 1
Pump
t 1
Removal
50-202
1. Remove bucket and arm assembly. For details,
see " Removal and installation of bucket and arm
assembly".
k Lower the boom assembly completely to
the ground, then set the work equipment
lock lever to LOCK position.
2. Remove the boom cylinder assembly from the
boom. For details, see "Removal of boom
cylinder assembly."
3. Disconnect connector A13 (1) for the head lamp
wiring.
8. Sling boom assembly (10).
9. Using tool V1, remove two boom foot pins (7),

then remove boom assembly (10).
[*1]
and thickness.
4 Boom assembly:
8,650 kg(PC800STD)
9,090 kg(PC850STD)
8,250 kg (PC800SE, PC850SE)
4. Disconnect bucket cylinder hoses (2) and arm

cylinder hoses (3).
50-202
PC800, 850-8E0
Work equipment
Installation
50-203
removal.
[*1]

pin:
Grease (LM-G)
a Set the clearance a between the foot end face of
boom (3) and bracket (4) to 1 mm or less by using shims (5).
Bleeding air

a Supply oil through the oil filler port to the
specified level. Run the engine to circulate
the oil through the system. Then check the oil
level again.
PC800, 850-8E0
50-203
Work equipment
50-204
Removal
50-204
1. Remove the arm assembly.
For details, see "Removal and installation of arm
assembly".
2. Sling bucket cylinder assembly (1), remove
plate, then pull out pin (2), and remove bucket
cylinder assembly.
[*1]
4 Pin:
35 kg
630 kg
a Remove the bucket cylinder on the opposite
side in the same way.
4. Remove the boom cylinder from the boom.

boom cylinder assembly".
a Remove the boom cylinder on the opposite
side from the boom in the same way.
5. Disconnect bottom dump cylinder hoses (3),
bucket cylinder hoses (4) and arm cylinder
hoses (5).
a When the hoses are disconnected, oil may
spurt out, so loosen the hose flanges slowly
before disconnecting.
6. Disconnect the head lamp wiring.
3. Sling the boom, set stand [1] at tip of the boom

to support boom.
50-204
PC800, 850-8E0
Work equipment
7. Using forcing screws (thread dia. = 16 mm, pitch

= 2 mm), pull out left and right boom foot pins (6),
then remove boom assembly (7).
[*2]
a Check and record the quantity and thickness
of the shims, and keep them in a safe place.
4 Boom assembly:
5,320 kg
PC800, 850-8E0
Installation
50-205
removal.
[*1] [*2]
50-205
W o rk e q u ip m e n t
Removal and installation of work equipment assembly

50-206
Special tools
50-206
Sym
Part number
bol
Part name
790-445-4100 Remover
Puller
V 1 790-101-4200
(294 kN {30 ton})
790-101-1102 Pump
Necessity
Q'ty
New/redesign
Sketch
Backhoe equipment
50-206
t 1
t 1
t 1
Removal
50-206
a Release the remaining pressure from the hydraulic circuit. For details, see Testing and adjusting, Releasing remaining pressure from
hydraulic circuit.
7. Sling the work equipment assembly.
1. Disconnect boom cylinder assembly from boom.

For details, see "Removal of boom cylinder
assembly."
2. Disconnect connector A13 (1) for the head lamp
wiring.
8. Using tool V1, remove two boom foot pins (7).

[*1]
and thickness.
3. Disconnect bucket cylinder hoses (2) and arm

cylinder hoses (3).
50-206
PC800, 850-8E0
Work equipment
9. Start the engine, reverse the machine slowly and

lower the boom foot section to touch the ground
by using a crane.
k When reversing the machine, check that
the boom foot is completely separated
from the machine body before reversing
the machine.
4 Work equipment assembly:
15,590 kg(PC800STD)
17,390 kg(PC850STD)
16,590 kg(PC800SE)
16,990 kg(PC850SE)
PC800, 850-8E0
50-207
Installation
removal.
[*1]

pin:
Grease (LM-G)
a Set the clearance a between the foot end face of
boom (3) and bracket (4) to 1 mm or less by using shims (5).
Bleeding air

again.
50-207
Work equipment
50-208
Removal
50-208
k Retract the boom cylinder piston rod fully,
and extend the arm cylinder piston rod, then
level the bottom of the bucket horizontal,
lower the work equipment to the ground and
stop the engine.
the hydraulic tank.
a Stop the engine, and release the pressure remaining in the circuit. For details, see Testing
and adjusting, "Releasing remaining pressure in
PPC valve hydraulic circuit".
3. Disconnect head lamp wiring.

4. Level the bottom of the bucket horizontal, lower
the work equipment completely to the ground,
then sling boom assembly (4).
1. Remove the boom cylinder from the boom.

boom cylinder assembly".
2. Disconnect bottom dump cylinder hoses (1),
bucket cylinder hoses (2) and arm cylinder
hoses (3).
a When the hoses are disconnected, oil may
spurt out, so loosen the hose flanges slowly
before disconnecting.
k In order to prevent spurting out of oil
when the engine is started, plug the pipes
on the chassis.
50-208
PC800, 850-8E0
Work equipment
5. Using forcing screws (thread dia. = 16 mm, pitch

= 2 mm), pull out left and right boom foot pins (5),
then disconnect the work equipment assembly
from the machine.
[*1]
a Check and record the quantity and thickness
of the shims, and keep them in a safe place.
50-209
Installation
removal.
[*1]
a Adjust the lifting height of the boom assembly so
that the boom foot is at the height of the mount
for the foot on the chassis.
6. Start the engine, reverse the machine slowly,

and operate the crane to lower the boom foot to
the ground.
k Before reversing the machine, check that
the boom foot is completely separated
from the machine body.
4 Work equipment assembly:
18,700 kg
PC800, 850-8E0
50-209
Cab and its attachments

Removal and installation of operator's cab assembly
50-210
50-210
Removal
50-210
9. Remove rear covers (10) to (13).
1.
2.
3.
4.
Remove front window (1).

Remove step plate (2).
Remove floor mat (3).
Remove monitor assembly (4). For details, see
"Removal and installation of monitor assembly".
6. Remove cover duct assembly
10. Remove duct (14).

a Remove connectors A43, H14 and H15 fixed
on the back from the clip.
7. Insert key (8), turn it to the right, and open the

fresh air filter cover.
8. Remove fresh air filter (9).

14. Remove lock pin (18) and remove duct (19).
50-210
PC800, 850-8E0


16. Disconnect connector L03 (21).
17. Remove plates (22) and (23) from the operator's
cab.

18. Disconnect antenna line (24) from KOMTRAX

terminal (K) by turning.
19. Disconnect connectors CK01 (25) and CK02
(26).
20. Disconnect connector M10 (27) from the operator's cab. (if equipped)
21. Disconnect cab wiring intermediate connectors
H09 (28), H08 (29), and H16 (30).
a Cut cable tie (T).
22. Disconnect radio antenna (31).
a (23) is a removed plate.
28. Disconnect window washer hose (39).
29. Disconnect harness clamp (40).
30. Haul in antenna line (36).
23. Remove ducts (32) and (33).

a Cut a cable tie.
24. Disconnect wiper motor connector M05 (34).
25. Remove harness (35) and antenna line (26) from
the cab wall.
a Cut cable ties at two places.
PC800, 850-8E0
50-211

31. Disconnect harness clamp (41) from the right

back side of cab.
32. Remove bolt (42) under the cab and remove lock
plate (43).
[*1]
33. Remove bolt (44).
[*2]
35. Sling and remove operator's cab assembly (47).

4 Operator's cab assembly:
470 kg
50-212
Installation
[*1]
Mounting bolt (42) of lock plate (43):

98 123 Nm {10 12.5 kgm}
[*2]
Bolt (44):
245 309 Nm {25 31.5 kgm}
34. Remove six mounting bolts (45) and four

mounting nuts (46).
a Check the bolt length beforehand.
50-212
PC800, 850-8E0

Removal and installation of operator's cab glass (adhered window glass)
Removal and installation of operator's cab glass (adhered window glass)50-213
a Among the panes of window glass on the four

sides of the operator's cab, five panes (1) to (4)
and (18) are adhered.
a In this section, the procedure for replacing the
adhered glasses is explained.
a When replacing front window glass (4), remove
front window assembly (5). (It is impossible to replace only the front window glass while the front
window assembly is installed to the operators
cab.) (It is impossible to replace only the front
window glass while the front window assembly is
installed to the operator's cab.)
a For the procedure for replacing the front window
assembly, see Removal and installation of front
window assembly.
PC800, 850-8E0
(1): Right side window glass

(2): Left side rear window glass
(3): Door lower window glass
(4): Front window glass
(5): Front window assembly
(Front window glass and Front frame)
(6): Dam rubber
(17): Center trim seal
(18): Rear glass
50-213

50-214
Symbol
Part number
Part name
1 793-498-1210 Lifter (Suction cup)

2 20Y-54-13180 Stopper rubber
Necessity
Q'ty
New/redesign
Sketch
Special tools
t 2
t 2
Removal
50-214
a Remove the window glass to be replaced according to the following procedure.
1. Using seal cutter [1], cut the adhesive between
broken window glass (7) and operator's cab (8).
a If the window glass is broken finely, it may be

removed with knife [4] and a flat-head screwdriver.
a Widening the cut with a flat-head screwdriver, cut the adhesive and dam rubber with
knife [4].
50-214
Installation
1. Using a knife and scraper [5], remove the
remaining adhesive and dam rubber from the
sheet metal (adhesion surfaces) of the operators cab.
a Remove the adhesive and dam rubber to a
degree that they will not affect adhesion of
the new adhesive. Take care not to scratch
the painted surfaces.
(If the painted surfaces are damaged, adhesion will be lowered.)
(The figure shows the operators cab of a wheel
loader.)
2. Remove oil, dust, dirt, etc. from the adhesion

surfaces on cab (8) and window glass (9) with
white gasoline.
a If the adhesion surfaces are not cleaned well,
the glass may not be stuck perfectly.
a Clean all the black part on the back of the
window glass.
a After cleaning the adhesion surfaces, leave
them for at lease 5 minutes to dry.
(The figure shows the operators cab of a wheel
loader.)
2. Remove the window glass.
50-214
PC800, 850-8E0

3. Apply primer (10).

a The using limit of primer is four months after
the date of manufacture. Do not use the primer after this limit.
a Use the primer within two hours after opening
the container.
a Even if the primer is packed again just after it
is unpacked, use it within 24 hours after it is
unpacked for the first time.
(Discard the primer in twenty-four hours after
it is unpacked.)
1) Stir the primers for painted surface and glass
sufficiently before using them.
a If the primer is stored in a refrigerator,
leave it at the room temperature for at
least half a day before stirring it.
(If the primer is unpacked just after taken
out of the refrigerator, water will be
condensed. Accordingly, leave the primer
at the room temperature for a sufficient
time.)
2) When reusing primer brush (11), wash it in
white gasoline.
a After washing the brush, check it again for
dirt and contaminant.
a Prepare respective brushes for the painted surface primer and glass primer.
a Places to apply: Apply over the entire circumferential area of dimension (a).
q Primer applying dimension (a): 25 mm
a In addition to the above places, additionally apply primer to right side window
glass (1) and lower door window glass
(3).
q Range to apply primer additionally for
right side window glass (1): (b)
q Range to apply primer additionally for
lower door window glass (3): (c)
a After applying the primer, leave it in air for
at least five minutes (maximum eight
hours) to dry.
3) Evenly apply paint surface primer to the
surfaces to stick dam rubber and its outside
surfaces to apply adhesive on operator cab
(8).
2 Primer for painted surface:
SUNSTAR PAINT PRIMER 580 SUPER
a Do not apply the primer more than two
times.
(If it is applied more than two times, its
performance will be lowered.)
PC800, 850-8E0
50-215

a Never apply the wrong primer.

If the glass primer, etc. is applied by
mistake, wipe it off with white gasoline.
4) Evenly apply the glass primer on the adhesion surfaces of window glass (9).
2 Primer for glass:
SUNSTAR GLASS PRIMER 580 SUPER
a Do not apply the primer more than two
times.
(If it is applied more than two times, its
performance will be lowered.)
a Places to apply: Apply the primer to entire

circumferential area sticking surface (d)
of window glass (9) for dam rubber (6) installation position and operators cab (8).
a Do not apply the primer to the boarder are
of about 5 mm wide between the black
portion and transparent portion of the
glass.
a After applying the primer, leave it in air for
at least five minutes (maximum eight
hours) to dry.
a Never apply the wrong primer.
If you apply the primer for painted
surface, etc. by mistake, wipe it off with
white gasoline.
50-216
4. Install dam rubber (double-faced tape)(6) along

the inside edge of the glass sticking section.
a Do not remove the release tape of dam rubber on the glass sticking side before sticking
the glass.
a When installing the dam rubber, do not touch
the cleaned surface.
a Care should be taken not to float the dam
rubber of each sticking corner.
a When adhering dam rubber (6) goes around,

mind not to overlap dam rubber at the both
ends. Or, provide a clearance of approximately 5 mm at the mating portion (e).
1) Install dam rubber (6) for right side window
glass (1) to the position as shown in the
figure.
PC800, 850-8E0

a Install additional dam rubber (6a) for right

side window glass (1).
q Positions to stick additional dam rubber
for right side window glass:
(f): 50 mm
(g): 90 mm
(h): 250 mm
a Stick dam rubber (6b) additionally to door

lower window glass (3).
q Positions to stick additional dam rubber to the door lower window class:
(j): 110 mm
(k): 90 mm
(m): 200 mm
2) Stick dam rubber (6) for left side rear window

figure.
4) Stick dam rubber (6) for front window glass

(4) to the position as shown in the figure.
3) Stick dam rubber (6) for door lower window

figure.
PC800, 850-8E0
a Stick dam rubber (6c) of the lower side of

the front window glass along the outside
edge of the lower line, differently from
other dam rubbers (6). (If it is stuck along
the inside, it will be seen through the
transparent portion of the glass.)
50-217

5. Position the new window glass.

1) Check the clearances between the window
glass and the operators cab on the right, left,
upper, and lower sides, and then position the
window glass with the clearance evenly.
2) Stick tapes [6] between window glass (9) and
operators cab (8) and draw a positioning line
(n) on the tape.
a Stick tapes [6] to three points, that is,
right, left and lower portions of the right
side window glass, left side rear window
glass, and door lower window glass for
accurate positioning.
3) Cut the tape between window glass (9) and
operators cab (8) with a knife, etc. and then
remove the window glass.
a Do not remove the tapes left on the window glass and the operator's cab before
installing the window glass.
a When positioning front window glass (4),

set right and left installing position to the
frame width.
And set its vertical position to make the
height difference (p) between the frame
top and the front window glass (4) 3 mm.
50-218
6. Apply adhesive.
a Use either of two types of adhesives according to the season.
2 Adhesive (summer):
SUNSTAR penguine seal 580 super
"S"
2 Adhesive (winter):
SUNSTAR penguine seal 580 super
"W"
a The effective period of the adhesive is four
months after the date of manufacture. Do not
use the adhesive after this limit.
a Keep the adhesive in a dark place where the
temperature is below 25 C.
a Never heat the adhesive higher than 30 C.
a When reusing the adhesive, remove all the
hardened part from the nozzle tip.
1) Remove aluminum seal (13) of the outlet of
adhesive cartridge (12) and install the
nozzle.
2) Cut the tip of the adhesive nozzle (14) so that

dimensions (q) and (r) are as follows.
q Dimension (q): 10 mm
q Dimension (r): 15 mm
PC800, 850-8E0

3) Set adhesive cartridge (12) to caulking gun

[7].
a An electric caulking gun is more efficient.
a Apply adhesive (15) additionally to additional dam rubber (6a) of right side window glass and additional dam rubber (6b)
of door lower window glass.
4) Remove the release tape of the dam rubber

on the glass adhesive side.
5) Apply adhesive (15) to the outside of dam
rubber (6) of the operators cab.
a Apply adhesive (15) to dam rubber (6) of

operators cab (8) in the (s) and (t) dimensions shown in the figure.
q Dimension (s): 10 mm
q Dimension (t): 15 mm
a Apply adhesive (15) with the height higher than that of dam rubber (6).
a Apply the adhesive evenly with same
height level.
PC800, 850-8E0
50-219

7. Install the window glass.

1) Install window glass (9) with the alignment of
the lines of the positioning tapes drawn in
step 5.
a Since the window glass cannot be removed and adhered again, adhere it with
utmost care.
a Adhere the glass within 5 minutes after
applying the adhesive.
2) After adhering window glass (9), press all
around the glass until it adheres to the dam
rubber.
a Press the corners of the window glass
firmly.
a After installing front window glass (4) fill

the clearances between the glass and
center trim seal (16) by using caulking
material in range (s) with dimensions of (t)
and (u).
After applying the primer to glass (4) of
section A-A, apply the adhesive as
caulking material.
q Caulking dimension (t): 2 mm
q Caulking dimension (u): 5 mm
a When caulking, apply masking to the
glass side and form the adhesive with a
rubber spatula as shown in the figure.
a Wipe off the squeezed adhesive.
2 Primer for glass:
SUNSTAR GLASS PRIMER 580 SUPER
2 Adhesive:
SUNSTAR PENGUINE SEAL 580
SUPER "S" or "W"
a You can perform this work efficiently by

pulling window glass (9) from the inside of
the operator's cab by using suction cup
Y1.
50-220
PC800, 850-8E0

8. Fix the window glass.

1) After installing right window glass (1) to the
operator's cab, insert stopper rubbers Y2 to
two places (v) at the bottom of the glass to fix
the glass.
9. After installing the window glass, remove any

excess of the primer and adhesive from the
operator's cab and window glass.
a By using white gasoline, wipe off the adhesive before it dries off.
a When cleaning the glass, do not give an impact on it.
10. Cure the adhered window glass.
1) Keep the stopper rubbers, styrene foam
blocks, and rubber bands installed for ten
hours as a curing period.
(ambient temperature 20 C / humidity 60%)
2) After removing the stopper rubbers, styrene
foam blocks, and rubber bands, wait at least
fourteen hours, at least twenty-four hours in
total, before operating the machine actually.
2) Using styrene foam blocks [9] and rubber

bands [10], fix the window glass and dam
rubber to adhere them completely.
PC800, 850-8E0
50-221

Removal and installation of front window assembly
50-2 2
Lower the work equipment to the ground and

stop the engine.
a To replace the front window glass, the front window assembly must be removed from the operator's cab. The procedure for removing and
installing the front window assembly (front frame
and front window glass) is explained below.
50-2 2
Removal
1. Pull up the front window assembly over the
ceiling and fix it with the rear locks (on the right
and left sides).
2. Remove left corner block (1) and right corner
block (2).
[*1]
a Mounting bolt (4) and washer (3) for the left
corner block are used to hang the pull-up assist cable in the following step 6.
6. Remove left lower pin (7).
3. Release the rear locks of the cab.

4. Lower the front window assembly carefully a
little. Put out rollers (5) and (6) under the both
sides of the front window through the portion
from which the corner blocks were removed in
the above step 2. (the portion where the rail is
open) and hold them.
[*2]
a By removing left lower pin (7), plate (8) at the
end of pull-up assist cable (9) comes off.
a Hang plate (8) on the mounting bolt for the
left corner block (use washer) and set in
place.
k Pull-up assist cable (9) has a return load
of 58.8 N {6 kg} on the rear side of the operator's cab. Accordingly, care must be
taken when removing left lower pin (7) to
disconnect pull-up assist cable (9).
5. Remove rollers (5) and (6) at the bottom of both

sides of the front window.
50-222
PC800, 850-8E0

9. Remove front window assembly (10) by twisting

it to the right and left to release right and left
upper rollers (11) and (12) from the rail.
7. Pull out the bottom of front window assembly

(10) though the rail opening portion and lower it
gradually.
8. Lower front window assembly (10) completely.

a Take care not to touch the front window assembly to the monitor.
PC800, 850-8E0
50-223

50-2 4
Installation
[*1]
Adjust opening and closing of the front window
assembly according to the following procedure.
1. Open and close the front window to check that it
does not interfere with the rails and that the
rollers are not caught.
2. If there is any problem in opening and closing of
the front window, loosen the mounting bolt of
roller adjustment bracket (13) and adjust the
condition of the front window, and then tighten
the mounting bolt again.
a Make sure that bracket (13) is not slanted
when mounted.
3 Mounting bolt:
34.3 Nm {3.5 kgm}
a Install right corner block (2) so that clearance

(a) between the rail and right corner block (2)
becomes 0 to 2.0 mm.
a Install right corner block (2) so that there is no
level difference on rail surface (R) for the roller.
5. Install left corner block (1).

a Fully tighten the block after adjusting the
"Close" position in the following step 6.
a Install left corner block (1) so that clearance
(b) between the rail and left corner block (1)
becomes 0 to 2.0 mm.
a Install left corner block (1) so that there is no
level difference on rail surface (R) for the roller. (See the figure above.)
3. Pull up the front window assembly and fix it with

the rear locks (on the right and left).
a Check that the locks in the rear of the operator's cab securely fasten.
4. Install right corner block (2).
a Fully tighten the block after adjusting the
"Close" position in the following step 6.
50-224
PC800, 850-8E0

6. Adjust the "Close" position of the front window

assembly lock according to the following procedure.
1) Install right and left corner blocks (2) and (1)
in roughly right positions so that front window
glass (14) is closely attached to cab-side trim
seal (15).
7. After the adjustment, splash water heavily over

the front window glass and check that the water
does not leak into the cab.
2) Check the working condition of right and left

locks (17) and (16) when opening and
closing the front window assembly.
q If right and left locks (17) and (16) do not
work normally;
1] Loosen lock fixing bolt (18), move lock
(16) forward, and then tighten the bolt
again;
a The same applies to the right side.
2] After moving the lock, check the fitness of
the front window glass (14) and cab-side
trim seal (15) which is checked in step 1).
3] Repeat the work in 1] and 2] until the
fitness of the front window glass and the
working condition of locks (16) and (17)
are both acceptable, and then tighten the
mounting bolts of the right and left corner
blocks.
PC800, 850-8E0
50-225

8. Adjust the "Open" position of the front window

assembly lock.
1) After adjusting the "Close" position of the
front window assembly lock in steps 6 and 7,
pull up the front window assembly to the
ceiling.
2) Set the front window assembly locks at the
both sides of rear of the operator's cab to the
Open" position, and then check the following
items.
q Check the working condition of right and
left locks (16) and (17) (as explained
above).
q Front window assembly must be in contact with the right and left rubber stoppers
(18) and furthermore, must be pushing
them backward by 1.5 to 3.0 mm.
q The front window assembly must be
pushing the limit switch (19) backward by
4 to 7 mm.
a The position of limit switch (19) cannot be
adjusted. Therefore, the "Open" position
of the front window assembly is set within
the range where this switch works.
a The limit switch (19) prevents wiper operation if the wiper switch is accidentally
turned on when the front window assembly is in "Open" position. If the wiper is operated when the front glass is missing,
the wiper will fall inside the cab and may
fail.
To check whether limit switch (19) is
working, turn the key switch on and see
that, even if the wiper switch is turned on,
the wiper does not operate when the front
window assembly is in "Open" position.
3) Close front window assembly (10).

4) Loosen locknut (20) of right and left sides of
rubber stoppers (18), and then pull back both
rubber stoppers (18) so that they won't
contact with the front window assembly when
it is in "Open" position.
5) Loosen both sides of locknuts (22), and

adjust the position of striker bolts (21).
a Striker bolt (21): M10
Diameter of hole in plate (23): f14.5 mm
1] The front window assembly (10) (in

"Open" position) must be pushing the limit
switch (19) backward by 4 to 7 mm.
2] Working condition of lock (17).
50-226
After checking the above items, if it becomes necessary to do the adjustment;
PC800, 850-8E0

6) Adjustment of right and left rubber stoppers

(18).
1] Bring front window assembly (10) (the
lock should be in "Open" position) into
contact with right and left rubber stoppers
(18).
2] Close front window assembly (10).

3] Turn right and left rubber stoppers (18) to
the left for one and a half rotation.
a One turn of rubber stopper (18) to the
left is equivalent to squashing the rubber by approximately 1.5 mm.
a When the front window assembly is in
"Open" position, the front window assembly must be pushing right and left
rubber stoppers (18) by 1.5 to 3.0 mm.
PC800, 850-8E0
4] Tighten locknuts (20) of right and left

rubber stoppers (18).
9. Adjust stopper (24) of the front window

assembly.
1) Adjust and lock both sides of stopper (24) so
that when pulling up the front window
assembly (10), surface d of stopper (D) of
front window assembly (10) is in contact with
surface c of stopper (24).
50-227

10. Check the operating effort of the lock of the front

window assembly.
1) After finishing the adjustment of steps 6 to 9,
check that latching efforts of both right and
left locks (16) and (17) are even.
a Check the latching efforts on both "Close"
side (in the front of the operator's cab)
and "Open" side (in the rear of the operator's cab).
[*2]
3
2
Left lower pin:

27 34 Nm {2.75 3.47 kgm}
Mounting bolt:
Adhesive (LT-2)
50-228
PC800, 850-8E0
Electrical system
Removal and installation of air conditioner unit assembly
Electrical system
50-2 9
50-2 9
Removal
50-2 9
q
7. Pull down opening and closing lever (8) of the

fresh air filter cover.
8. Remove fresh air filter (9).
Cautions about refrigerant
Collect the refrigerant (air conditioner gas:

a Ask a qualified person for collecting, adding
and filling operations of the refrigerant
(R134a).
a Never release the refrigerant (R134a) to the
atmosphere.
k If you drain the coolant or disconnect the
heater hose when the coolant temperature in
the radiator is high, you may be scalded. In
this case, wait until the coolant temperature
lowers and then disconnect the heater hose.
9. Remove rear covers (10) to (13).
1. Turn the upper structure by 90 degrees.

6 Coolant:
approx. 100 l
3. Remove front window (1).
4. Remove step plate (2).
5. Remove floor mat (3).
PC800, 850-8E0
50-229
Electrical system

a Disconnect connectors A43, H14 and H15
fixed on the back from the clip.

a Cut a cable tie.
17. Remove upper and lower parts of duct (24).
18. Remove upper and lower parts of duct (25).
19. Remove plate (26) from cab wall.
14. Remove lock pin (18) and remove duct (19).

a Cut a cable tie.
50-230
20. Disconnect connectors N10 (27) and AC01 (28).

21. Disconnect connectors ECU10 and ECU11 (29)
from the air conditioner controller (ACCONT).
22. Loosen cable tie (30) and draw in wiring harness
(31).
PC800, 850-8E0
Electrical system
50-231
Installation
[*1]
a When installing the air conditioner hose, take
care so that dust, dirt or water does not enter the
hose.
a Make sure before the installation that there is an
O-ring in the connecting part of the air conditioner hose.
a Check that there is no defect or deterioration on
the O-ring.
a When connecting the refrigerant piping, coat the
O-ring with compressor oil (Dense: ND-OIL8) for
24. Remove mounting bolt (33) and air conditioner

tubes (34).
[*1]
25. Disconnect heater hoses (35).
a Check the connecting points.
new refrigerant (R134a).
Mounting bolt:
8 12 Nm {0.8 1.2 kgm}
Charging air conditioner with refrigerant

Refill the air conditioner circuit with refrigerant
(R134a).
Supply coolant through the coolant filler port to
the coolant through the system. Then, check the
coolant level again.
5 Coolant:
approx. 100 l
26. Remove the seven mounting bolts and remove

air conditioner unit assembly (36).
PC800, 850-8E0
50-231
Electrical system
Removal and installation of engine controller assembly

Removal
50-232
1. Remove filter assembly (1).
50-232
3. Disconnect connectors CE02 (3) and CE03 (4).

a Use a 4 mm hexagonal wrench.
5. Disconnect connectors (8).
a Use a 4 mm hexagonal wrench.
6. Remove engine controller assembly (9).
[*1]
2. Remove controller cover (2).
50-232
PC800, 850-8E0
Electrical system
Installation
50-23
[*1]
When connecting connectors (3), (4) and (8), check
that there is no dust, dirt, etc. in them.
a Reference
q
Method of replacing the O-ring seal of power supply connector (4).
O-ring seal: 1010-074-0406 (Deutsch Japan

Ltd.)
1) Remove the cover (6) by holding down the
tabs with tweezers [1].
2) Use tweezers [1] to remove O-ring (7).
PC800, 850-8E0
50-233
Electrical system
Removal and installation of monitor assembly
50-234
Removal
50-234
1. Remove cap (1).
2. Remove cover (2), and disconnect connector
P31 (3) for the air conditioner sunlight sensor
(S).
3. Remove duct (4).
4. Remove cover (5) as shown in the following.
[*1]
1) Insert a flat-head screwdriver into the slit (SL)
and lift it up.
2) Release lock (L) and remove cover (5).
3) At the back of cover (5), disconnect
connector (M04) for the cigarette lighter
wiring.
50-234
5. Remove four mounting bolts and lift up monitor

assembly (6).
[*2]
6. Disconnect connectors CM01 (7), CM02 (8) and
CM03 (9).
a CM02 and CM03 can be installed to either
place, so take care not to install them to
wrong places. CM03 is a green connector.
7. Disconnect connector CM05 (11).
PC800, 850-8E0
Electrical system
Installation
50-235
a If installation is done in the reverse order to removal, cover (5) may not be installed. Perform
installation as follows.
[*1], [*2]
1. Install monitor assembly (6) by tightening four
mounting bolts lightly, and install cover (5).
2. With cover (5) installed, tighten the mounting
bolts for the monitor assembly.
q
Perform the rest of installation in the reverse

order to removal.
PC800, 850-8E0
50-235
Electrical system
Removal and installation of pump controller assembly
50-236
Removal
50-236
50-236
Installation
2. Disconnect relay R08 (4) from the clip.

3. Disconnect bracket (5) and move it toward the
right.
4. Disconnect wiring connectors CP01 (6) and
CP02 (7) according to the following procedure.
q While pressing lock (L1), turn lock (L2) in inward.
a Bar (B) comes out and the lock is released.
5. Remove four mounting bolts and pump
controller assembly (8).
a Reference
1. Procedure for removing connector cover (1)
1) Cut and remove cable tie (2).
2) Move lever (3) up.
3) Lightly press part A of connector cover (1)

from both sides to release tabs (B).
4) Remove connector cover (1) around claw
(C).
50-236
PC800, 850-8E0
Electrical system
a Connector without connector cover (1).
2. Procedure for installing connector cover

1) Push in right and left sliders (4) as far as they
go.
a Right and left sliders (4) pushed in as far

as they go (Left figure)
2) Move lever (3) of connector cover (1) from
the upper position to the left position (lock
position) in the figure.
a (B), (C): Tabs
a If the sliders and lever are not set as
shown in the following figure, the connector is not disconnected or locked securely
with the lever. Accordingly, check their
positions again
PC800, 850-8E0
3) Set tab (C) to the connector and place

connector cover (1).
a Take care that wiring harness (5) is not
caught.
4) Set tab (B) and install connector cover (1).
5) Bind connector cover (1) and wiring harness

with a new cable tie. (See 1.1)
50-237
Electrical system
Removal and installation of KOMTRAX terminal assembly
50-238
Removal
50-238
2. Twist antenna wire (5) and disconnect it.

3. Disconnect connectors CK01 (6) and CK02 (7).
4. Remove four mounting bolts and remove
KOMTRAX terminal assembly (8).
50-238
Installation
50-238
PC800, 850-8E0
SEN0527629-00
60-1
PC800, 850-8E0
HYDRAULIC EXCAVATOR
PC800-8E0
PC850SE-8E0
PC800LC-8E0
PC800SE-8E0
PC850-8E0
Shop Manual
Machine model
Serial number
Machine model
Serial number
PC800-8E0
PC800LC-8E0
PC800SE-8E0
PC850-8E0
65001 and up
65001 and up
65001 and up
65001 and up
PC850SE-8E0
65001 and up
PC800, 850-8E0
6-01
60-1
60-1
Contents
Contents
60-2
Coupling...............................................................................................................................
Power train..............................................................................................................................
Swing circle..........................................................................................................................
Swing machinery..................................................................................................................
Final drive ............................................................................................................................
Sprocket...............................................................................................................................
Track frame and idler cushion..............................................................................................
Idler ......................................................................................................................................
Carrier roller .........................................................................................................................
Track roller ...........................................................................................................................
Track shoe ...........................................................................................................................
Control valve ........................................................................................................................
Swing motor .........................................................................................................................
PPC valve ............................................................................................................................
Work equipment......................................................................................................................
Work equipment...................................................................................................................
Work equipment dimension .................................................................................................
Hydraulic cylinder.................................................................................................................
60-2
6060606060606060606060606060606060606060606060-
3
3
4
4
5
8
10
12
12
14
16
18
20
24
24
26
32
34
35
38
38
44
48
PC800, 850-8E0

Coupling
60-3
Coupling
60-3
Unit: mm
No.
Item
Backlash of main pump spline (for

HPV375 + 375)
Backlash of hub
PC800, 850-8E0
Criteria
Remedy
Standard dimension
Repair limit
0.074 0.226
0.087 0.258
Adjust or replace the

parts
60-3
Power train
Swing circle
Power train
60-4
Swing circle
60-4
a.Inner race soft zone "S" position

b.Outer race soft zone "plug" position
Unit: mm
No.
1
60-4
Item
Axial clearance of bearing
(when mounted on machine)
Criteria
Remedy
Standard clearance
Allowable clearance
0.5 1.6
3.2
Replace
PC800, 850-8E0
Power train
Swing machinery
Swing machinery
PC800, 850-8E0
60-5
60-5
Power train
Swing machinery
60-6
PC800, 850-8E0
Power train
Swing machinery
Unit: mm
No.
1
Item
Backlash between swing motor
shaft and No. 1 sun gear
Backlash between No. 1 sun gear

and No. 1 planetary gear
Backlash between No. 1 planetary
3
gear and ring gear
4
carrier and coupling
5
carrier and No. 2 sun gear
Backlash between No.2 sun gear
6
and No.2 planetary gear
7
gear and ring gear
Backlash between coupling and
8
swing pinion
Backlash between swing pinion and
9
swing circle
Clearance between plate and cou10
pling
11
Wear of swing pinion in contact

surface with oil seal
PC800, 850-8E0
Criteria
Remedy
Standard clearance
Allowable clearance
0.19 0.29
0.19 0.51
0.90
0.24 0.70
0.90
0.06 0.24
0.38 0.78
1.10
0.17 0.52
1.00
0.21 0.64
1.10
0.08 0.25
0 1.5
2.00
0.06 0.86
Standard dimension
Repair limit
150(0/-0.100)
Replace
Repair by hard
chrome-plating or
replace
60-7
Power train
Final drive
Final drive
60-8
60-8
PC800, 850-8E0
Power train
Final drive
Unit: mm
No.
1
Item
carrier and case
Backlash between drive gear and

No. 1 planetary carrier
3
and No. 1 planetary carrier
Backlash between No.2 sun gear
4
and No.2 planetary gear
5
gear and No. 2 ring gear
Backlash between coupling and
6
drive gear
Backlash between No. 1 ring gear
7
and case
8
and travel motor coupling
9
and idler gear
Backlash between No. 1 ring gear
10
and idler gear
Backlash between driven gear and
11
No. 1 planetary gear
Criteria
Standard clearance
Allowable clearance
0.08 0.27
0.21 0.57
0.24 0.91
0.23 0.68
0.28 0.87
0.38 0.72
0.08 0.26
0.07 0.18
0.15 0.53
0.19 0.62
0.19 0.62
12 Amount of wear on sprocket tooth

13 Width of sprocket tooth
PC800, 850-8E0
Remedy
Replace
Repair limit: 6
Standard dimension
Repair limit
114
108
Build-up welding for

rebuilding or replace
60-9
Power train
Sprocket
Sprocket
60-10
Unit: mm
No.
Item
Criteria
Remedy
Standard dimension
Repair limit
403.6
391.6
2 Thickness of tooth root
28.4
22.4
3 Width of tooth
114
108
1 Wear of tooth tip
4 Wear of tooth shape
60-10

rebuilding or replace
Repair limit: 6 (use a full-scale drawing of sprocket tooth shape to

judge)
PC800, 850-8E0
Power train
Sprocket
Full-scale drawing of sprocket tooth shape
60-1
a The above drawing is reduced to 50%. Enlarge it to 200% to return it to the full scale and make a copy on
an OHP sheet.
PC800, 850-8E0
60-11

Track frame and idler cushion
60-12
60-12
PC800, 850-8E0
Unit: mm
No.
Item
1 Recoil spring
2 Height of idler guide
Criteria
Remedy
Standard dimension
Repair limit
Free length x
Installed
Load at
Load at
Free length
Outside diameter
length
installed length
installed length
490.2 kN
392 kN
1,553 x 308
1,290
{49,986 kg}
{40,000 kg}
Standard
Tolerance
Repair limit
dimension
Build-up welding for rebuilding
Track frame
185
185 (+3/-2)
190
Idler support
180
180 0.5
175
Replace
Track frame
345
345 (+3/-2)
355
Build-up welding for rebuilding
Idler support
340
332
Replace
3 Width of idler guide
60-12
Replace
PC800, 850-8E0

PC800, 850-8E0
60-13

Idler
Idler
60-14
60-14
PC800, 850-8E0

Idler
Unit: mm
No.
Item
Criteria
Remedy
Standard dimension
Repair limit
875
2 Outside diameter of tread
830
818
3 Depth of tread
22.5
28.5
5 Overall width
266
6 Width of tread
69.5
75.5
1 Outside diameter of protrusion
4 Thickness of tread
Clearance between shaft and bushing
Interference between idler and

bushing
9 Axial play
PC800, 850-8E0
Tolerance
Shaft
Hole
-0.120
+0.361
110
-0.207
+0.281
Tolerance
Standard
dimension
Shaft
Hole
+0.087
-0.036
120
+0.037
-0.136
Standard clearance (Each side)
Standard
dimension
0.32 0.54

rebuilding or
replace
Standard
clearance
Allowable
clearance
0.401
0.568
Standard
Allowable
interference interference
Replace bushing
0.073
0.223
Allowable clearance
Replace
60-15

Carrier roller
Carrier roller
60-16
Unit: mm
No.
Item
Criteria
Remedy
Standard dimension
Repair limit
194
175
155
3 Width of tread
68
57.6
47.6
17
1 Outside diameter of flange
5 Width of flange
Interference between bearing and

support
Interference between bearing and

shaft
8 End play in axial direction
60-16
Tolerance
Shaft
Hole
0
0
110
-0.015
-0.035
+0.039
0
60
+0.020
-0.015
Standard clearance
Standard
dimension
0 0.301
Replace
Standard
Allowable
-0.015
0.035
0.020
0.054
Allowable clearance
PC800, 850-8E0

Carrier roller
PC800, 850-8E0
60-17

Track roller
Track roller
60-18
60-18
PC800, 850-8E0

Track roller
Unit: mm
No.
Item
Criteria
Remedy
Standard dimension
Repair limit
298
295
255
243
73.7
67.7
5 Ovevall width
328
Single
flange
72
Double
flange
72
Single
flange
29
Double
flange
29
33
0.42 0.99
1 Outside diameter of outer flange

2
Outside diameter of inner flange

(double flange)
6 Width of tread
7 Width of outer flange

8
Width of inner flange

(double flange)
9 Axial play
Clearance between shaft and bush10
ing
11
Interference between roller and

bushing
PC800, 850-8E0
Standard
dimension
100
Standard
dimension
107.6
Tolerance
Shaft
Hole
-0.140
+0.375
-0.207
+0.235
Tolerance
Shaft
+0.087
+0.037
Hole
+0.020
-0.015

rebuilding or
replace
Standard
clearance
Allowable
clearance
0.375
0.582
Standard
Allowable
0.017
0.102
Replace bushing
60-19

Track shoe
Track shoe
60-20
a Portion P shows the link on the side where the bushing is press-fitted.
60-20
PC800, 850-8E0

Track shoe
Unit: mm
No.
Item
Criteria
Standard dimension
Repair limit
260.6
263.6
Standard dimension
Repair limit
87.9
82.9
15.8
10.3
Standard dimension
Repair limit
156
143
39.3
26.3
1 Link pitch
2 Outside diameter of bushing

3 Thickness of bushing
4 Link height
5
Remedy
Thickness of link (bushing press fit

part)
234.95
7 Shoe bolt pitch
184.2
76.2
Turn 180 deg. or

replace
Adjust or replace
Repair or replace
Replace
Inside width
133.6
10 Link
Overall width
73
11
Tread width
65
12 Protrusion of pin
4.5
13 Regular bushing projection
10.8
14 Overall length of pin
320.4
15 Overall length of bushing
225.8
16 Thickness of spacer
12.45
17
18
Press fitting force
*19
Bushing
137 431 kN {14 44 ton}
Regular pin
294 647 kN {30 66 ton}
Master pin
255 608 kN {26 62 ton}
Repair or replace
Adjust or replace
Items marked with * are for the dry track.
PC800, 850-8E0
60-21

Track shoe
Unit: mm
No.
Item
Criteria
a. Regular
link
20 Shoe bolt
b. Master
link
Interference between bushing and

21
link
22
Interference between regular pin

and link
23
Clearance between regular pin and

bushing
*24
Interference between master pin
and link
*25
Clearance between master pin and
bushing
Remedy
Tightening torque
(Nm {kgm})
Retightening angle
(deg.)
784 78 {80 8}
120 10
Tightening torque
(Nm {kgm})
Retightening angle (deg.)
Lower limit torque

(Nm {kgm})
Tolerance
Shaft
Hole
+0.472
+0.087
+0.372
0
+0.496
+0.074
+0.396
0
Tolerance
Shaft
Hole
+0.296
+1.036
+0.196
+0.536
Tolerance
Shaft
Hole
+0.342
+0.074
+0.312
0
Tolerance
Standard interference
Standard dimension
87.5
55.3
Standard dimension
55.5
Standard dimension
55.3
Standard dimension
55.5
Shaft
-0.200
-0.300
Hole
+1.036
+0.536
Retighten
0.285 0.472
0.322 0.496
Standard clearance
0.24 0.84
Adjust or replace
Standard interference
0.238 0.342
Standard clearance
0.736 1.336
Items marked with * are for the dry track.
60-22
PC800, 850-8E0

Track shoe
Double grouser shoe
60-23
Unit: mm
No.
Item
1 Height
Criteria
Standard dimension
Repair limit
50
25
2 Height
50
3 Thickness
20
39
Length at base
30
Length at tip
30
8 Thickness
70
PC800, 850-8E0
Remedy

rebuilding or
replace
45
60-23
Hydraulic system
Cooling fan motor
Hydraulic system
60-24
Cooling fan motor
60-24
Model: LMF110
60-24
60-24
PC800, 850-8E0
Hydraulic system
Cooling fan motor
Unit: mm
No.
Item
1 Check valve spring
PC800, 850-8E0
Criteria
Standard dimension
Free length x
Load at
Installed
Outside diameinstalled
length
ter
length
13.72 N
16.4 x 8.9
11.5
{1.4 kg}
Remedy
Repair limit
Load at
Free
installed
length
length
10.29 N
{1.05 kg}
If damaged or
deformed, replace
spring
60-25
Hydraulic system
Control valve
Control valve
60-26
L.H. 5-spool valve
60-26
60-26
PC800, 850-8E0
Hydraulic system
Control valve
PC800, 850-8E0
60-27
Hydraulic system
Control valve
Unit: mm
No.
2
3
Item
Main relief valve

Main valve spring
Jet sensor relief valve

Pilot poppet spring
Main valve spring
4 Spool return spring

5
6
Spool return spring

(travel)
Spool return spring
(other than travel)
7 Throttle valve spring

9
Check valve spring

(throttle valve)
60-28
Criteria
Standard dimension
Free length x
Load at
Installed
length
ter
length
400.1 N
34.8 x 10.4
32.5
{40.8 kg}
20 N
34.5 x 8.8
31.1
{2.04 kg}
49 N
37.4 x 11.4
33
{5.0 kg}
431 N
69.9 x 57
63
{44 kg}
0N
75 x 37
74.5
{0 kg}
0N
74.5 x 38.1
74.5
{0 kg}
1N
31.8 x 7.6
26.5
{0.1 kg}
18.8 N
78.2 x 26.6
52
{1.92 kg}
18.8 N
65.3 x 14
46
{1.92 kg}
Remedy
Repair limit
Load at
Free
installed
length
length
320.5 N
{32.7 kg}
16.2 N
{7.65 kg}
39.2 N
{4.0 g}
345 N
{35.2 kg}
0N
{0 kg}
0N
{0 kg}
0.78 N
{0.08 kg}
15.1 N
{1.54 kg}
15.1 N
{1.54 kg}
If damaged or
deformed, replace
spring
PC800, 850-8E0
Hydraulic system
Control valve
R.H. 4-spool valve
PC800, 850-8E0
60-29
60-29
Hydraulic system
Control valve
60-30
PC800, 850-8E0
Hydraulic system
Control valve
Unit: mm
No.
2
3
Item
Main relief valve

Main valve spring

Pilot poppet spring
Main valve spring
4 Spool return spring

5
6
Spool return spring

(travel)
Spool return spring
(other than travel)

PC800, 850-8E0
Criteria
Standard dimension
Free length x
Load at
Installed
length
ter
length
400.1 N
34.8 x 10.4
32.5
{40.8 kg}
20 N
34.5 x 8.8
31.1
{2.0 kg}
49 N
37.4 x 11.4
33
{5.0 kg}
431 N
69.9 x 57
63
{44 kg}
0N
75 x 37
74.5
{0 kg}
0N
74.5 x 38.1
74.5
{0 kg}
18.8 N
78.2 x 26.6
52
{1.92 kg}
18.8 N
41.3 x 35.5
25.5
{1.92 kg}
Remedy
Repair limit
Load at
Free
installed
length
length
320.5 N
{32.7 kg}
16.2 N
{1.65 kg}
39.2 N
{4.0 g}
345 N
{35.2 kg}
0N
{0 kg}
0N
{0 kg}
15.1 N
{1.54 kg}
15.1 N
{1.54 kg}
If damaged or
deformed, replace
spring
60-31
Hydraulic system
Swing motor
Swing motor
60-32
Model: KMF125AB-5
60-32
PC800, 850-8E0
Hydraulic system
Swing motor
Unit: mm
No.
Item
2 Shuttle valve spring
PC800, 850-8E0
Criteria
Standard dimension
Free length x
Load at
Installed
length
ter
length
3.5 N
62.5 x 20.0
35.0
{0.36 kg}
13.7 N
16.4 x 8.9
11.5
{1.40 kg}
Remedy
Repair limit
Load at
installed
length
2.8 N
{0.29 kg}
10.8 N
{1.1 kg}
Free
length
If damaged or
deformed, replace
spring
60-33
Hydraulic system
Center swivel joint
Center swivel joint
60-34
Unit: mm
No.
Item
1 Clearance between rotor and shaft
60-34
Criteria
Remedy
Standard dimension
Standard clearance
Allowable clearance
110
0.056 0.105
0.111
Replace
PC800, 850-8E0
Hydraulic system
PPC valve
PPC valve
60-35
Work equipment and swing PPC valve
60-35
PC800, 850-8E0
60-35
Hydraulic system
PPC valve
Unit: mm
No.
Item
Centering spring
(for ports P3 and P4)
2 Metering spring
3
Centering spring
(for ports P1 and P2)
60-36
Criteria
Standard dimension
Free length x
Load at
Installed
length
ter
length
17.6 N
42.48 x 15.5
34
{1.8 kg}
16.6 N
26.7x8.14
24.9
{1.69 kg}
9.8 N
38.71 x 15.5
34
{1 kg}
Remedy
Repair limit
Load at
Free
installed
length
length
13.7 N
{1.4 kg}
13.2 N
{1.35 kg}
7.8 N
{0.8 kg}
If damaged or
deformed, replace
spring
PC800, 850-8E0
Hydraulic system
PPC valve
Travel PPC valve
60-37
Unit: mm
No.
Item
1 Centering spring
2 Metering spring
PC800, 850-8E0
Criteria
Standard dimension
Free length x
Installation
Outside diameInstalled load
length
ter
108 N
47.6x15.5
32.5
{11.0 kg}
16.7 N
26.7x8.14
24.9
{1.7 kg}
Remedy
Repair limit
Free
length
Installed load
86.3 N
{8.8 kg}
13.7 N
{1.4 kg}
If damaged or
deformed, replace
spring
60-37
Work equipment
Work equipment
Work equipment
60-38
Work equipment
60-38
PC800-8E0
60-38
60-38
PC800, 850-8E0
Work equipment
Work equipment
Unit: mm
No.
Item
Clearance between pin and bushing connecting boom and revolving

frame
2
3
4
5
6
Clearance between pin and bushing connecting boom and arm

Clearance between pin and bushing connecting arm and link
Clearance between pin and bushing connecting arm and bucket
Clearance between pin and bushing connecting links
Clearance between pin and bushing connecting link and bucket
7 Bucket clearance
PC800, 850-8E0
Criteria
Standard
dimension
140
140
115
130
110
115
Tolerance
Shaft
-0.043
-0.106
-0.043
-0.106
-0.036
-0.090
-0.043
-0.106
-0.036
-0.090
-0.036
-0.090
Hole
+0.542
+0.442
+0.419
+0.308
+0.351
+0.271
+0.393
+0.293
+0.457
+0.370
+0.351
+0.271
0.5 1.0
Remedy
Standard
clearance
0.485
0.648
0.351
0.525
0.307
0.441
0.336
0.499
0.406
0.547
0.307
0.441
Allowable
clearance
1.5
1.5
1.5
Replace
1.5
1.5
1.5
Adjust shim
60-39
Work equipment
Work equipment
PC800SE-8E0
PC850, 850SE-8E0
60-40
PC800, 850-8E0
Work equipment
Work equipment
Unit: mm
No.
Item
Clearance between pin and bushing connecting boom and revolving

frame
2
3
4
Criteria
Clearance between pin and bushing connecting boom and arm

Clearance between pin and bushing connecting arm and link
Clearance between pin and bushing connecting arm and bucket
Clearance between pin PC850
5 and bushing connecting
140
140
115
130
110
PC800SE
PC850SE
140
Clearance between pin and bushing connecting link and bucket
115
links
Standard
dimension
7 Bucket clearance
PC800, 850-8E0
Tolerance
Shaft
-0.043
-0.106
-0.043
-0.106
-0.036
-0.090
-0.043
-0.106
-0.036
-0.090
-0.043
-0.106
-0.036
-0.090
Hole
+0.542
+0.442
+0.419
+0.308
+0.351
+0.271
+0.482
+0.392
+0.393
+0.293
+0.397
+0.312
+0.351
+0.271
0.5 1.0
Remedy
Standard
clearance
0.485
0.648
0.351
0.525
0.307
0.441
0.435
0.588
0.336
0.499
0.355
0.503
0.307
0.441
Allowable
clearance
1.5
1.5
1.5
Replace
1.5
1.5
1.5
1.5
Adjust shim
60-41
Work equipment
Work equipment

PC800-8E0
60-42
60-42
PC800, 850-8E0
Work equipment
Work equipment
Unit: mm
No.
Item
Clearance between pin and bushing

connecting boom and revolving
frame
2
3
4
5

connecting boom and arm
connecting arm and bucket
connecting bucket cylinder and
bucket
connecting front bucket and rear
bucket
PC800, 850-8E0
Criteria
Standard
dimension
140
140
140
Tolerance
Shaft
Hole
-0.043
+0.542
-0.106
+0.442
-0.043
+0.542
-0.106
+0.442
-0.043
+0.523
-0.106
+0.460
Remedy
Standard
clearance
Allowable
clearance
0.485
0.648
0.485
0.648
0.503
0.629
1.5
1.5
1.5
115
-0.036
-0.090
+0.457
+0.370
0.406
0.547
1.5
95
-0.036
-0.090
+0.457
+0.370
0.406
0.547
1.5
Replace
60-43
Work equipment
Work equipment dimension
60-4
1. Arm
60-4
60-44
PC800, 850-8E0
Work equipment
Unit: mm
Model
PC800-8E0
PC850-8E0
PC800SE-8E
0
PC850SE-8E
PC850SE-8E
0
0
3.6 m
arm
4.6 m
arm
5.6 m
arm
f115
f115
f115
f110
f110
f110
100
100
100
129
129
129
531
531
531
531
531
531
f140
f140
f140
f140
f140
f140
580
620
639
663
750
663
397
467
530
329
401
329
1,332
1,389
1,328
925
916
925
3,578
4,569
5,575
3,585
2,917
3,585
3,675
3,668
3,673
4,011
3,580
4,011
10
585
570
585
585
500
585
11
950
950
950
1,035
840
1,035
12
740
740
740
865
640
865
13
756
756
756
765
670
765
14
2,285
2,237
2,237
2,295
2,280
2,295
15
f115
f115
f115
f115
f115
f115
16(link)
519
519
519
519
519
519
17
f130
f130
f130
f130
f130
f130
519
519
519
519
519
519
535
535
535
535
535
535
Min.
2,380
2,380
2,380
2,590
2,490
2,590
Max.
3,990
3,990
3,990
4,410
3,910
4,410
No.
Arm boss (without bushing)

18
When press fitting bushing (with bushing)
3.6 m
2.9 m short arm
heavy-duty arm
3.6 m
arm
19
PC800, 850-8E0
60-45
Work equipment
2. Bucket
60-46
60-46
PC800, 850-8E0
Work equipment
Unit: mm
Mode
l
PC800-8E0
PC850-8E0
PC800SE-8E0, PC850SE-8E0
PC850SE-8E
0
2.8 m3
bucket
3.1 m3
bucket
3.4 m3
bucket
4.0 m3
bucket
4.3 m3
bucket
4.5 m3
bucket
4.0 m3
light-load
bucket
749
749
747
667
667
667
747
104
104
164
61
61
61
164
98 deg.
98 deg.
102 deg.
95 deg.
95 deg.
95 deg.
102 deg.
756
756
765
670
670
670
765
2,266
2,218
2,295
2,258
2,211
2,211
2,270
292
292
316
315
315
315
339
f130
f130
f130
f130
f130
f130
f130
f115
f115
f115
f115
f115
f115
f115
520
520
520
520
520
520
520
80.5
80.5
80.5
80.5
80.5
80.5
80.5
10
88.5
88.5
88.5
88.5
88.5
88.5
88.5
11
f208
f208
f238
f208
f208
f208
f238
12
f255
f255
f255
f255
f255
f255
f255
13
f275
f275
f275
f275
f275
f275
f275
14
208
217
238
151
135
135
235
15
200
175
201
185
181
181
212
16
157.5
157.5
157.5
157.5
157.5
157.5
157.5
17
125
125
140
125
125
125
140
18
559.5
559.5
559.5
559.5
559.5
559.5
559.5
19
79
79
79
79
79
79
79
No.
PC800, 850-8E0
60-47
Work equipment
Hydraulic cylinder
Hydraulic cylinder
60-48
PC800, 850-8E0 STD
Boom cylinder
60-48
60-48
60-48
Arm cylinder
60-48
Bucket cylinder
60-48
60-48
PC800, 850-8E0
Work equipment
Hydraulic cylinder
Unit: mm
Item
No.
Clearance between piston rod and bushing
Clearance between piston rod support shaft

and bushing
Clearance between cylinder bottom support

shaft and bushing
PC800, 850-8E0
Criteria
Cylinder
name
Standard
dimension
Boom
140
Arm
140
Bucket
130
Boom
115
Arm
125
Bucket
110
Boom
130
Arm
130
Bucket
110
Tolerance
Shaft
Hole
-0.043
+0.256
-0.106
+0.039
-0.043
+0.256
-0.106
+0.039
-0.043
+0.256
-0.105
+0.040
-0.036
+0.025
-0.090
+0
-0.043
+0.025
-0.106
+0
-0.036
+0.457
-0.090
+0.370
-0.043
+0.025
-0.106
0
-0.043
+0.025
-0.106
0
-0.036
+0.457
-0.090
+0.370
Remedy
Standard
clearance
0.082
0.362
0.082
0.362
0.083
0.361
0.036
0.115
0.036
0.115
0.406
0.547
0.043
0.131
0.043
0.131
0.406
0.547
Allowable
clearance
0.062
Replace bushing
0.062
0.062
1.5
1.5
1.5
1.5
Replace pin and

bushing
1.5
1.5
60-49
Work equipment
Hydraulic cylinder
PC800SE, 850SE-8E0
Boom cylinder
60-50
60-50
60-50
Arm cylinder
60-50
Bucket cylinder
60-50
60-50
PC800, 850-8E0
Work equipment
Hydraulic cylinder
Unit: mm
No.
Item
Clearance between piston rod support shaft

and bushing
Clearance between cylinder bottom support

shaft and bushing
PC800, 850-8E0
Criteria
Cylinder
name
Standard
dimension
Boom
140
Arm
120
Bucket
160
Boom
115
Arm
110
Bucket
140
Boom
130
Arm
110
Bucket
140
Tolerance
Shaft
Hole
-0.043
+0.256
-0.106
+0.039
-0.036
+0.263
-0.090
+0.048
-0.043
+0.256
-0.106
+0.039
-0.036
+0.025
-0.090
0
-0.036
+0.457
-0.090
+0.370
-0.043
+0.025
-0.106
0
-0.043
+0.025
-0.106
0
-0.036
+0.457
-0.090
+0.370
-0.043
+0.025
-0.106
0
Remedy
Standard
clearance
0.082
0.362
0.084
0.353
0.082
0.362
0.036
0.115
0.406
0.547
0.043
0.131
0.043
0.131
0.406
0.547
0.043
0.131
Allowable
clearance
0.062
Replace bushing
0.062
0.062
1.5
1.5
1.5
1.5
Replace pin and

bushing
1.5
1.5
60-51
Work equipment
Hydraulic cylinder

PC800-8E0
Boom cylinder
60-52
60-52
60-52
Arm cylinder
60-52
Bucket cylinder
60-52
60-52
PC800, 850-8E0
Work equipment
Hydraulic cylinder
Bottom dump cylinder
60-53
Unit: mm
No.
Item
Clearance between pis-
Criteria
Cylinder
name
Standard
dimension
Boom
140
Arm
160
Bucket
130
Bottom
dump
90
Boom
115
Arm
140
Bucket
115
Bottom
dump
90
Boom
130
Arm
140
Bucket
115
Bottom
dump
90
2 ton rod support shaft

and bushing
Clearance between cyl-
3 inder bottom support

shaft and bushing
PC800, 850-8E0
Tolerance
Shaft
Hole
-0.043
+0.256
-0.106
+0.039
-0.043
+0.256
-0.106
+0.039
-0.043
+0.256
-0.106
+0.040
-0.036
+0.257
-0.090
+0.048
-0.036
+0.025
-0.090
0
-0.043
+0.025
-0.106
0
-0.036
0
-0.090
+0.020
-0.036
+0.457
-0.090
+0.370
-0.043
+0.025
-0.106
0
-0.043
+0.025
-0.106
0
-0.036
0
-0.090
+0.020
-0.036
+0.457
-0.090
+0.370
Remedy
Standard
clearance
0.082
0.362
0.082
0.362
0.082
0.362
0.084
0.347
0.036
0.115
0.043
0.131
0.016
0.090
0.406
0.547
0.043
0.131
0.043
0.131
0.016
0.090
0.406
0.547
Allowable
clearance
0.662
0.662
Replace bushing
0.662
0.647
1.5
1.5
1.5
1.5
1.5
Replace pin and

bushing
1.5
1.5
1.5
60-53
Work equipment
Hydraulic cylinder
60-54
PC800, 850-8E0
SEN0527631-00
80-1
PC800, 850-8E0
HYDRAULIC EXCAVATOR
PC800-8E0
PC850SE-8E0
PC800LC-8E0
PC800SE-8E0
PC850-8E0
Shop Manual
Machine model
Serial number
Machine model
Serial number
PC800-8E0
PC800LC-8E0
PC800SE-8E0
PC850-8E0
65001 and up
65001 and up
65001 and up
65001 and up
PC850SE-8E0
65001 and up
80 Appendix
PC800, 850-8E0
8-01
80-1
80-1
Table of contents
Table of contents
80-2
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
Testing inner sensor ............................................................................................................ 80- 42
Testing evaporator temperature sensor............................................................................... 80- 43
Testing sunlight sensor ........................................................................................................ 80- 45
Testing (dual) pressure switch for refrigerant ...................................................................... 80- 46
Testing relays....................................................................................................................... 80- 47
Information in troubleshooting table..................................................................................... 80- 52
............................................................................................................................................. 80- 54
Troubleshooting for compressor and refrigerant system (Air is not cooled) ........................ 80- 59
Troubleshooting for blower motor system (No air comes out or air flow is abnormal) ......... 80- 63
Troubleshooting for temperature control.............................................................................. 80- 67
Troubleshooting for vent (mode) changeover ...................................................................... 80- 70
Troubleshooting for FRESH/RECIRC air changeover ......................................................... 80- 72
Troubleshooting for temperature sensor system ................................................................. 80- 74
Troubleshooting with gauge pressure.................................................................................. 80- 76
Connection of service tool.................................................................................................... 80- 78
Precautions for disconnecting and connecting air conditioner piping .................................. 80- 80
Handling of compressor oil .................................................................................................. 80- 82
80-2
PC800, 850-8E0
Air conditioner
Precautions for refrigerant
Air conditioner
80-3
80-3
Collect the refrigerant (Air conditioner gas:

R134a) from air conditioner circuit before
disconnecting air conditioner hose to replace air conditioner unit, air conditioner
compressor or receiver drier and so on.

filling operations of the refrigerant (R134a).
a Never release the refrigerant (R134a) to the atmok
sphere.
If refrigerant gas (R134a) gets in your eyes,

you may lose your sight. And if it touches
your skin, you may suffer from frostbite. Accordingly, put on protective eyeglasses,
gloves and working cloth with long sleeves
while collecting the refrigerant or filling the
air conditioner circuit with the refrigerant.
PC800, 850-8E0
80-3
Air conditioner
Air conditioner component
80-4
80-4
PC800, 850-8E0
Air conditioner
1. Compressor
2. Condenser
3. Receiver drier
4. Hot water piping
5. Hot water return piping
6. Refrigerant piping
7. Dual pressure switch
8. Sight glass
9. Air conditioner controller
10. Air conditioner unit
11. Recirculation air filter
12. Fresh air filter
13. Machine monitor
14. Sunlight sensor
PC800, 850-8E0
A: Front warm/cool air outlet

B: Rear warm/cool air outlet
C: Foot warm/cool air outlet
D: Defroster warm
E: Recirculation air inlet
F: Fresh air inlet
80-5
Specifications
Refrigerant
Refrigerant refilling level (g)
R134a
1330 50
80-5
Air conditioner
Configuration and function of refrigeration cycle

Cycle
(Component)
Compression
(Compressor)
Condensation
(Condenser)
Location
Engine compartment
Front of radiator
Function
State of refrigerant
80-6
Circulates refrigerant
gas and increases its
temperature and pressure so that it can be
liquefied easily in condenser.
(Compression of
refrigerant)
Gas o Gas
Adiabatic compression
Condenses refrigerant
to discharge heat
absorbed in evaporator.
(condensation of refrigerant)
Gas o Liquid
Cnstant pressure
change
80-6
Expansion
(Expansion valve)
In operator cab
(Built in air conditioner
unit)
Evaporation
(Evaporator)
In operator cab
(Built in air conditioner
unit)
Lowers temperature and

pressure of refrigerant liquid and gas for easy evaporation with throttle.
Controls flow rate, too.
(Throttle of refrigerant)
Evaporates refrigerant to
absorb heat from air
around evaporator, and
cool the air.
(Evaporation of refrigerant)
Liquid o Liquid and gas
Liquid and gas o Gas
Adiabatic expansion
Cnstant pressure change
PC800, 850-8E0
Air conditioner
Outline of refrigeration cycle
80-7
The refrigeration cycle is comprised of 4 cycles. The refrigerant is circulated while repeatedly vaporizing and
liquefying.
1. Compression (Compressor)
The compressor sucks in the refrigerant that has
been vaporized in the evaporator and
compresses it into a state where it can be easily
liquefied at the ambient temperature.
The gaseous refrigerant sucked into the
compressor cylinder is compressed to a temperature and pressure at which it can be easily
liquefied when cooled to the ambient temperature.
2. Condensation (Condenser)
The condenser cools and liquefies the high pressure and high-temperature gaseous refrigerant
sent from the compressor.
The heat released to the outside from the
condenser is called condensation heat.
The amount of condensation heat is the sum
total of the heat absorbed by the evaporator from
the air in the cab and the quantity of the work
applied (the value converted into a heat quantity)
by compression of the compressor.
The refrigerant liquefied in the condenser is sent
to the receiver drier, where moisture is removed.
In the compression cycle, the gaseous refrigerant and liquid refrigerant coexist.
The temperature (condensation temperature)
and the pressure (condensation pressure) at
which the gaseous refrigerant is liquefied are
proportional to each other.
Reference: The pressure varies depending on
the condensation temperature of the refrigerant.
3. Expansion (Expansion valve)
The expansion valve reduces the liquid refrigerant pressure to a level where liquid refrigerant
can be easily evaporated by the throttle action
(*1).
The action of reducing the liquid refrigerant pressure to a level where it can be easily evaporated
before it is sent to the evaporator is called
expansion.
The expansion valve, which reduces the refrigerant pressure, also adjusts the refrigerant flow
rate simultaneously.
The quantity of the liquid refrigerant that can be
evaporated in the evaporator depends on the
amount of heat (refrigeration load) to be
removed under the specific evaporation temperature (evaporation pressure).
PC800, 850-8E0
The expansion valve controls the refrigerant

feed rate so that the optimum quantity of liquid
refrigerant is supplied to the evaporator.
(*1) Throttle action
If there is a narrow section in the passage
through which liquid is flowing at a constant rate,
a resistance to the flow will be generated.
The liquid expands when it passes through the
narrow section and rushes into the passage
where the sectional area is larger, and consequently, its pressure and temperature are
reduced.
No heat is transferred from or to the outside
during the throttle action.
4. Evaporation (Evaporator)
The evaporator evaporates the liquid refrigerant
(superheated vapor).
The refrigerant evaporates, while absorbing an
amount of heat necessary for evaporation (evaporation heat) from the air around the cooling fins
(air in the cab).
After the heat has been removed, the cooled air
is sent into the cab by the blower fan, reducing
the temperature inside the cab.
The mist refrigerant that has been sent from the
expansion valve coexists with the evaporated
refrigerant in the evaporator
The temperature (evaporation temperature) and
the pressure (evaporation pressure) at which the
liquid refrigerant is evaporated are proportional
to each other.
The compressor sucks in the evaporated refrigerant in order to keep the pressure level in the
evaporator as low as possible so that the liquid
refrigerant can be evaporated at a much lower
temperature.
Relationship between refrigerant and defective
80-7
air conditioning
q The refrigerant circulates in the refrigeration circuit while repeating the refrigeration cycle to expel the heat from inside the cab.
q If there is an insufficient quantity of refrigerant,
all of it will be evaporated while it is passing
through the evaporator. This causes evaporator
efficiency to deteriorate, which will result in defective air conditioning.
80-7
Air conditioner
If there is excessive refrigerant, not all of it will be

evaporated and part of it will be sucked into the
compressor in liquid form, which will cause the
compressor to compress the liquid and may
damage the components.
If water gets into the refrigeration circuit, it will
freeze at a small hole in the expansion valve,
lower the refrigerant flow, and may result in defective air conditioning.
80-8
PC800, 850-8E0
Air conditioner
PC800, 850-8E0
80-9
Air conditioner
Air conditioner unit
80-10
a This air conditioner unit is auto temperature control type.
80-10
PC800, 850-8E0
Air conditioner
A: Refrigerant inlet (from condenser)

B: Refrigerant outlet (to compressor)
C: Hot water inlet
D: Hot water outlet
1. Evaporator
2. Heater core
3. Expansion valve
4. Blower fan, blower motor
5. Air mix servomotor
Air mix door
6-1. Cool door
6-2. Hot door
6-3. Sub-hot door
7. Vent (mode) changeover servomotor (MODES)
Vent (mode) changeover door
8-1. Differential door
8-2. Foot door
8-3. Front door
8-4. Rear door
9. FRESH/RECIRC air changeover servomotor
(R/FS)
10. FRESH/RECIRC air changeover door
11. Power transistor
12. Evaporator temperature sensor
13. Insidel air temperature sensor
14. Holder
80-1
Air flow adjustment
q Whenever an air flow control switch is operated
on the machine monitor, air flow setting data is
sent to the air conditioner controller. The air conditioner controller controls blower motor (4) using power transistor (11) in order to adjust the air
flow.
80-1
Vent (mode) changeover
Whenever a vent switch is operated on the machine monitor, mode data is sent to the air conditioner controller. The air conditioner controller
controls mode changeover servomotor (7) to adjust the opening angle of mode changeover
doors (8-1) to (8-4) and thus perform vent
changeover.
80-1
FRESH/RECIRC air changeover
Whenever a FRESH/RECIRC air changeover
switch is operated on the machine monitor,
FRESH/RECIRC air changeover setting data is
sent to the air conditioner controller. The air conditioner controller controls FRESH/RECIRC air
changeover servomotor (9) to open and close
FRESH/RECIRC air changeover door (10).
80-1
Automatic air conditioner
Inside air temperature sensor (13) detects the inside temperature based on changes in resistance. The air conditioner controller detects the
inside temperature by converting the changes in
the resistance of inside air temperature sensor
(13) into voltage changes.
The air conditioner controller checks the voltage
of inside air temperature sensor (13) and
controls the inside air temperature so that it
matches the setting made on the machine
monitor.
Data from sunlight sensor is also taken into
consideration when adjusting the inside temperature.
80-1
Outline
q The air conditioner unit consists of the evaporator (1) and heater core (2), and is used to cool
down or warm up the air in the cab.
80-1
Temperature control
Operating the temperature control switch on the
machine monitor sends the temperature setting
data to the air conditioner controller located in
the rear side of the operator seat. The air conditioner controller controls air mix servomotor (5)
and change the angle of air mix doors (6-1), (6-2)
and (6-3) in order to adjust the temperature.
80-1
Over-cooling (Freezing) prevention
The resistance of the evaporator temperature
sensor (12) changes in response to temperature.
q The air conditioner controller detects the temperature of the evaporator (1) by converting the
changes in the resistance of the evaporator temperature sensor (12) into voltage changes.
q The air conditioner controller performs control to
prevent freezing of the evaporator (1) by operating the compressor clutch relay (*) to stop the
compressor.
*: See "Parts and connectors layout" for details regarding the compressor clutch relay.
q
PC800, 850-8E0
a 5 A fuse for the air conditioner unit is attached to

the wiring harness.
a The door is the same as the damper.
80-11
Air conditioner
80-12
Functions of major components
Evaporator
80-12
q Evaporator (1) is cooled by the low-pressure,
low-temperature refrigerant gas being sent from
expansion valve (3). Air from blower motor (4) is
cooled and dehumidified when passing through
the evaporator fins.
80-12
Heater core
Heater core (2) is warmed by the hot water (engine coolant) being sent from the engine. Air
from blower motor (4) is warmed when passing
through the heater core fins.
When the potential difference fails to reach a

predefined voltage for control of the servomotor,
the air conditioner controller notifies the machine
monitor of an abnormality. "A/C Controller Error"
is displayed in red on the air conditioner operation screen of machine monitor.
a FRESH/RECIRC air changeover servo motor
does not feature a variable resistance, and
therefore, does not have a self-diagnosis
function.
a When attempting to operate a servomotor during
inspecting, do not supply power directly between
servomotor terminals (6) and (7).
80-12
Evaporator temperature sensor
Evaporator temperature sensor (12) is installed
to evaporator (1) with holder (14). Its resistance
changes in response to the temperature change
of the evaporator. The air conditioner controller
monitors the evaporator temperature to prevent
its freezing.
Servomotors
80-12
a Servomotors are used to adjust the temperature

(air mix) and to perform vent (mode) changeover.
q
Whenever a switch on the machine monitor is

operated, the air conditioner controller delivers
power to the servomotor by raising the voltage
between terminals (6) and (7) to 24 V. (The rotation direction changes based on the supply polarity.)
The servomotor contains a variable resistance,

and its resistance value changes as the motor
turns.
The air conditioner controller delivers voltage at
5 V to the variable resistance and detects motor
rotation angle based on the potential difference.
When the door (damper) reaches the position
specified by each switch, the air conditioner controller stops the supply of current to the servomotor, then the corresponding door stops.
80-12
PC800, 850-8E0
Air conditioner
Expansion valve
A: When evaporator outlet temperature is high

B: When evaporator outlet temperature is low
C: From receiver drier (high-pressure refrigerant)
D: To compressor (low-pressure refrigerant)
1. Expansion valve
1a. Needle valve
1a-1. Diaphragm
1a-2. Thermoprobe
1b. Spring
2. Refrigerant gas
3. Evaporator
80-13
Outline
q The expansion valve converts high-pressure
and high-temperature liquid refrigerant from the
receiver drier to low-pressure, low-temperature
misty refrigerant through the throttle action.
q It controls the flow rate of refrigerant by changing
the level of throttling depending on the temperature in the cab.
q The temperature of the air blown out of the air
vent is adjusted depending on the volume of refrigerant circulating in the evaporator (3).
PC800, 850-8E0
80-13
80-13
Structure
q Box-type expansion valve (1) consists of needle
valve (1a), spring (1b), etc.
q Refrigerant gas (2) is sealed in the diaphragm
chamber (hatched area) outside diaphragm
(1a-1) of needle valve (1a).
q The opening level of needle valve (1a) is determined based on the balance between the reaction force exerted by spring (1b) in a rightward
direction, and force (Fg) of refrigerant gas (2)
pushing needle valve (1a) through diaphragm
(1a-1) in a leftward direction.
q The refrigerant flow rate flowing from the receiver drier to evaporator (3) is determined based on
the opening level of needle valve (1a).
80-13
Air conditioner
80-14
Operation
q Thermoprobe (1a-2) senses the refrigerant temperature after it passes through the evaporator
(3).
q After the refrigerant passes through evaporator
(3), its temperature is transferred to the refrigerant gas (2) in the diaphragm chamber (hatched
area) through the thermoprobe (1a-2).
q The pressure of the refrigerant gas (2) sealed in
the diaphragm chamber (hatched area) changes
in response to the temperature change of the
thermoprobe (1a-2), which therefore changes
the force (Fg) pushing the needle valve (1a).
q The opening level of the needle valve (1a) is determined based on the balance between the reaction force exerted by the spring (1b) in a
rightward direction, and the force (Fg) of the refrigerant gas (2) pushing the needle valve (1a)
through the diaphragm (1a-1) in a leftward direction.
When evaporator (3) outlet temperature is high: 80-14
[When not cooled yet: Condition (A) in the fig80-14
ure]
q The pressure of the refrigerant gas (2) in the diaphragm chamber is high and the volume is increased.
q The force (Fg) of the refrigerant gas (2) pushing
the needle valve (1a) is increased, and the needle valve (1a) moves leftward.
q As a result, the opening level of the needle valve
(1a) is increased and the refrigerant flow rate to
the evaporator (3) is increased to improve cooling capacity.
Dual pressure switch

80-14
a The dual pressure switch is mounted on the air
conditioner hose under the floor.
q The dual pressure switch turns "OFF" when the
refrigerant circuit pressure becomes abnormally
low or abnormally high.
q When the dual pressure switch turns "OFF", the
air conditioner controller turns the compressor
clutch relay "OFF". As a result, the compressor's
magnet clutch is released and air conditioner
components are protected.
a LA or lower: Abnormally low pressure

a HA or higher: Abnormally high pressure
LA: 0.20 MPa {2 kg/cm2}
LB: 0.02 MPa {0.2 kg/cm2}
HA: 3.14 MPa {32 kg/cm2}
HB: 0.59 MPa {6 kg/cm2}
When evaporator (3) outlet temperature is low: 80-14

[When cooled already: Condition (B) in the fig80-14
ure]
q The pressure of the refrigerant gas (2) in the diaphragm chamber is low and the volume is decreased.
q The force (Fg) of the refrigerant gas (2) pushing
the needle valve (1a) is reduced, and the needle
valve (1a) is moved rightward by the spring force
(1b).
q The opening level of the needle valve (1a) is reduced and the refrigerant flow rate to the evaporator (3) is reduced to lower the cooling capacity.
80-14
PC800, 850-8E0
Air conditioner
Air conditioner controller
80-15
a See "System Diagrams" for details regarding input/output signals.
PC800, 850-8E0
80-15
Air conditioner
Compressor
Compressor
A: Refrigerant inlet (from air conditioner unit)

B: Refrigerant outlet (to condenser)
1. Pulley
2. Magnetic clutch
3. Relief valve
80-16
80-16
Function
q The compressor circulates the refrigerant and
compresses the gaseous refrigerant from the
evaporator into a misty refrigerant at high pressure and high temperature so that it will be easily
regenerated (liquefied) at the normal temperature.
q Calling into account of the evaporator temperature and refrigerant pressure, the air conditioner
controller activates magnetic clutch (2) built in
the compressor.
q When the magnetic clutch is engaged, the power
of the engine rotates the compressor shaft along
with pulley (1) to drive the compressor.
80-16
Specifications
Number of cylinder Bore x
Stroke
(mm)
Piston capacity
(cc/rev)
80-16
10 - 32 x 20.8
157.3
Allowable maximum speed

(rpm)
6,000
Compressor oil
Denso: ND-OIL8 (For

R134a)
Compressor oil refill capacity

(cc)
180
PC800, 850-8E0
Air conditioner
Condenser
Condenser
A: Refrigerant inlet (from compressor)

B: Refrigerant outlet (to receiver drier)
80-17
Function
q The condenser cools and liquefies the high pressure and high temperature misty refrigerant sent
from the compressor.
80-17
80-17
Specifications
Fin pitch (mm)
Height x width x thickness
(mm)
Max. working pressure (MPa
{kg/cm2}
4.0
357 x 540 x 16
3.6 {36}
a If the fin is crushed or is clogged with dust, heat

exchange efficiency is reduced and complete liquefaction of refrigerant becomes impossible.
If the heat exchange efficiency is reduced, pressure in the refrigerant circulation circuit will be
increased, applying extra load to the engine or
reducing the cooling effect. Take extreme care
not to crush or damage the fins when hangling it
or performing daily inspection.
PC800, 850-8E0
80-17
Air conditioner
Receiver drier
Receiver drier
80-18
80-18
Function
q The receiver drier temporarily stores the high
pressure and high temperature liquid refrigerant
from the condenser so that it can be supplied to
the evaporator according to the need of cooling.
q It sends the stored refrigerant from its bottom to
the evaporator, allowing the refrigerant to be liquefied completely ever when it contains bubbles
due to the lowerd heat dissipation of the condenser.
q The built-in filter and desiccating agent eliminate
foreign substances in the circulation circuit and
water content in the refrigerant.
80-18
Specification
Effective volume (cc)
Weight of desiccating agent
(g)
370
290
A: Refrigerant inlet (from condenser)

B: Refrigerant outlet (to air conditioner unit)
80-18
PC800, 850-8E0
Air conditioner
Receiver drier
PC800, 850-8E0
80-19
Air conditioner
Procedure for testing and troubleshooting
80-20
The air conditioner is provided with self-diagnosis functionality in order to provide for inspection of its main
components. Specifically, the operation of sensors and servomotors can be examined.
If a troubled section is detected, every part of that section must be inspected.
1. After basic check, find the troubled section according to the detected trouble of the air conditioner.
2. Narrow down the sections with the self-diagnosis function (See Check with self-diagnosis).
If, however, the entire air conditioner unit fails to operate, inspect for problems with the supply of power to
the air conditioner controller and with CAN communication between the machine monitor and the air conditioner controller.
If any part of the air conditioner unit can operate, it will indicate that the air conditioner controller is
receiving power normally and that CAN communication between the machine monitor and the air conditioner controller is normal.
3. After finding out the troubled section, inspect the component parts in that section and repair the troubled
part.
Basic testing and troubleshooting sequence
80-20
PC800, 850-8E0
Air conditioner
*1: By error display or abnormal display on Abnormality Record screen on machine monitor.
*2: Simple checking of refrigerant volume by sight glass.
Start up the engine, set the air conditioner switch to ON, and then wait for five minutes before proceeding
with the inspection.
A) If the continuous stream of bubbles can be seen, the system contains insufficient refrigerant.
B) If the bubbles can be seen intermittently, the refrigerant volume is sufficient.
C) If no bubbles can be seen (i.e., the liquid is perfectly clear), the system contains too much refrigerant
or no refrigerant at all.
The above should be treated as general guidelines as certain exceptions do exist.
See "Troubleshooting with gauge pressure" and use gauge pressure to determine whether or not the
condition is normal.
S: Sight glass condition
R: Receiver drier internal condition
LR: Liquid refrigerant
*3: If any leakage of refrigerant is occurring, the compressor oil circulating within the air conditioner circuit will
definitely be leaking from the same point.
In such a case, retighten in accordance with the table of retightening torques from "Precautions for disconnecting and connecting air conditioner piping."
*4: Start the engine and perform the check with the air conditioner switch set to ON.
PC800, 850-8E0
80-21
Air conditioner
Circuit diagram and arrangement of connector pins
80-22
80-2
PC800, 850-8E0
Air conditioner
a BLOW OUT (MODE) SERVOMOTOR means BLOW OUT (MODE) CHANGEOVER SERVOMOTOR.
PC800, 850-8E0
80-23
Air conditioner
System diagram
System diagram
80-24
a This air conditioner unit is auto temperature control type.
80-24
PC800, 850-8E0
Air conditioner
System diagram
Input/output signals of the air conditioner con80-25

troller (CNT)
Controller side connector: AMP 040 - 36PM
Harness side connectors: [1], [2]
[1] AMP040 - 16PF
Pin
Input/o
Symbol
Signal name
No.
utput
1
A/M servo potentiometer volt2

A/MP
Input
age
Servo potentiometer 5 V
3
POT 5 V
Output
power supply
PRESS (Dual) pressure switch
4
Input
SW
(Refrigerant pressure)
5
6
+24 V
Power supply
Input
7 BLOW F/B Blower feedback signal
Input
Power transistor control sig8
PTR B
Output
nal
Blow out (mode) servo poten9
MODE P
Input
tiometer voltage
10
11
THI
Inside air temperature sensor Input
Evaporator temperature sen12
THEVA
Input
sor
13
14
15
SS
Sunlight sensor
Input
16
GND
GND
Input
[2]AMP040 - 20PF
Pin
Symbol
No.
17
CAN (+)
CAN communication +
18
CAN (-)
CAN communication -
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
q
q
q
Signal name
Fresh/Recirculated air servo

terminal A
Fresh/Recirculated air servo
F/RB
terminal B
A/MA
A/M servo terminal A
A/MB
A/M servo terminal B
Blow out (mode) servo termiMODE A
nal A
Blow out (mode) servo termiMODE B
nal B
GND S Sensor GND
CCRL Compressor clutch relay

BLOW RL Blower main relay
F/RA
Input/o
utput
Input/
output
Input/
output
Output
Output
Output
Output
Output
Output
Input
Output
Output
Operation of air conditioner controller

1. Performing CAN communication with the
machine monitor, the air conditioner controller
controls the air conditioner unit by inputting
switches associated with air conditioning.
2. The air conditioner controller controls three
servomotors located inside the air conditioner
unit in order to adjust the temperature (airmix),
perform vent (mode) changeover, and perform
FRESH/RECIRC air changeover.
3. The air conditioner controller controls the
ON/OFF condition of the blower main relay (i.e.,
a switch for blowing air) and of the compressor
clutch relay (i.e., a switch for activating the
compressor).
4. The air conditioner controller controls the air flow
volume using the power transistor.
a The power transistor has an overcurrent prevention fuse in it.
5. The air conditioner controller detects the evaporator temperature using the evaporator temperature sensor.
6. In order to prevent freezing of the evaporator,
the air conditioner controller controls the
compressor by turning the compressor clutch
relay ON and OFF.
a When the dual pressure switch detects a
pressure abnormality (i.e., turns OFF), the air
conditioner controller turns the compressor
clutch relay OFF, and therefore, the compressor stops operating.
7. When performing automatic air conditioning, the
air conditioner controller controls the inside air
temperature to the set temperature based on
data from the sunlight sensor and the inner
sensor (inside air temperature sensor).
8. The air conditioner controller has the self-diagnosis function. If any abnormality is detected, the
control amplifier notifies it to the machine
monitor by the CAN communication. Then, the
letters of "A/C Controller Error" are displayed in
red on the air conditioner operation screen of the
machine monitor.
A/M: Air mix

F/B: Feedback
F/R: Fresh/Recirculated air
PC800, 850-8E0
80-25
Air conditioner
Detail of air conditioner unit
80-26
1. Foot door
2. Defroster door
3. Front face door
4. Rear face door
5. FRESH/RECIRC air changeover door
6. Insidel air temperature sensor
[8]: Inner sensor (inside air temperature sensor)

connector
[9]: Evaporator temperature sensor connector
[1], [2]: Control amplifier connector

[3]: Blower (fan) motor connector
[4]: Power transistor (PTR) connector
[5]: Vent (mode) servomotor connector
[6]: Temperature control (air mix) servomotor connector
[7]: FRESH/RECIRC air changeover servomotor
connector
EXPV: Expansion valve

Fu5A: Fuse (5 A)
PTR: Power transistor
A/MS: Air mix servomotor
MODES: Vent (mode) servomotor
R/FS: FRESH/RECIRC air changeover servomotor
80-26
A: Recirculation air port

B: Fresh air port
PC800, 850-8E0
Air conditioner
Evaporator
Temperature sensor installation position
PC800, 850-8E0
80-27
Air conditioner
Parts and connectors layout

a There are two fuses. One is in the fuse box at
the right rear of the operator seat and the other
is wound onto the wiring harness between the air
conditioner unit and control amplifier.
a The air conditioner unit is located at the bottom
in the rear side of the operator's seat.
1. Open the cover of the fuse box located at the
bottom in the rear right side of the operator's
seat.
(See fuse mounting positions in "Troubleshooting.")
q No. 11 (20 A) from fuse box:
For power supply of blower (fan), air conditioner compressor and air conditioner unit (all
components related to the air conditioner)
q Part No. of fuse
20 A: 08041-02000
80-28
q
q
q
q
q
q
q
q
Fu5A: Fuse 5 A
For power supply of air conditioner unit
(including primary side of relays for blower
(fan) and air conditioner compressor)
Part No. of fuse
Fu5A: ND93950-05003
CNT: Air conditioner controller
[1], [2]: Air conditioner controller connectors
BRL: Blower main relay
R20: Blower main relay connector
CCRL: Compressor clutch relay
R21: Compressor clutch relay connector
N10: Air conditioner unit connector for 24 V
power supply and CAN communication with
the machine monitor (communication lines
shared with engine controller and pump controller)
AC01: Connector to air conditioner unit for
GND, compressor, pressure switch, relay
and sunlight sensor
a State with cover (3) removed

q A/C U: Air conditioner unit
q CNT: Air conditioner controller
80-28
PC800, 850-8E0
Air conditioner
a Fu5A is installed inside the holder.

Part No. of fuse
Fu5A: ND93950-05003
q
q
q
q
q
q
q
q
A/CU: Air conditioner unit

CNT: Air conditioner controller
[1], [2]: Air conditioner controller connectors
MODES: Vent (mode) servomotor
[5]: Vent (mode) servomotor connector
A/MS: Temperature control (air mix) servomotor
[6]: Temperature control (air mix) servomotor
connector
a Bottom of the air conditioner unit

[7]: FRESH/RECIRC air changeover servomotor (R/FS) connector
[8]: Inner sensor (inside air temperature
sensor) connector
H: Air conditioner unit wiring harness
4. Turn 90 degrees to remove cover (5).
q
q
P17: Pressure switch connector
[3]: Blower (fan) motor connector

PC800, 850-8E0
80-29
Air conditioner

q ACC: Air conditioner compressor
q M34: Air conditioner compressor connector
6. Testing sunlight sensor connector P31 and

machine monitor connector CM02 (CAN
communication connector)
a If machine monitor connector CM02 is disconnected, neither of the engine controller
and pump controller can carry out the CAN
communication and failure code [DAFRMC]
is displayed. If the screen changes to the air
conditioner operation screen at this time,
A/C Controller error is displayed in red. If
the above error is not displayed, no check is
necessary.
Note: "A/C Controller Error" is also displayed
on the air conditioner operation screen when
the vent changeover is not possible, when a
temperature control abnormality occurs, or
when the refrigerant's pressure switch is set
to OFF.
1) Remove cap (1).
2) Remove cover (2), and disconnect wiring
connector P31 (3) for the air conditioner
sunlight sensor (S).
3) Remove duct (4).
4) Remove cover (5) as shown in the following.
[*1]
80-30
1] Insert a flat-head screwdriver into the slit

(SL) and lift up.
2] Release lock (L) and remove cover (5).
3] At the rear of cover (5), disconnect the
connector (M04) for the cigarette lighter.
5) Remove four mounting bolts and lift up

monitor assembly (6).
[*2]
6) Check connector CM02.
a CM02 and CM03 can be installed in reverse, so take care not to install them in
reverse. CM03 is a green connector.
a The connector CN-5 is connected on
models with rear view camera specification.
Caution about installation

[*1], [*2]
1. Fix machine monitor assembly (6) temporarily
using four mounting bolts, and install cover (5).
2. With cover (5) installed, tighten the mounting
bolts of monitor assembly.
q Carry out the rest of installation in the reverse
order to removal.
PC800, 850-8E0
Air conditioner
Testing air leakage (duct)

1.
2.
3.
4.
Remove front window (1).

Remove step plate (2).
Remove floor mat (3).
Referring to item 6 of parts and connectors
layout, remove cover (4) from machine monitor.
6. Remove rear covers (7) - (10).
80-31
8. Rear duct
Check ducts (12) and (13) for disconnection.
9. Face duct and defroster duct

Check ducts (14) (20) for disconnection.
10. Fresh air duct
Check pin (P) and duct (21) for disconnection.
A: Packing
7. Foot duct
a Duct to under operator seat
1) Check duct (11) for disconnection.
2) Check the seal between duct (11) and cover
(11-1).
3) Remove duct (11) and cover (11-1).
4) Check that packing (A) is attached.
(See figure bottom)
PC800, 850-8E0
80-31
Air conditioner
Testing with self-diagnosis function

Outline
80-32
On the air conditioner operation screen of the machine monitor, the system performs self-diagnosis
for the communication with the air conditioner unit,
temperature control, vent (mode) changeover and
refrigerant pressure with the pressure switch, and if
a problem is detected, the failure is displayed in red
as "A/C Controller Error"
80-32
How to enter air conditioner "Abnormality Record" screen in service mode of machine
80-32
monitor.
q
Overview of machine monitor operating procedure

Normal screen
O While pressing [4], press [1], [2], and [3] in this
order.
Service menu (Mode)
O Press [F3] once. Press [F6].
02 Abnormality Record
O Press [F3] twice. Press [F6].
03Air-conditioning System "Abnormality Record"
screen
Detailed description of machine monitor operating procedure

1. On the normal operation screen, while pressing
number key [4], press [1], [2], and [3] in this
order.
a Even if the cause of a detected problem is restored to normal, the self-diagnosis failure condition will not automatically be reset. To reset the
failure condition, the starter switch must be set to
OFF.
a On the air-conditioning system abnormality record screen that appears in service mode of the
machine monitor, the system performs self-diagnosis for various sensors in addition to the above
items, and if a problem is detected, screen displays it in red as "Abnormal."
a FRESH/RECIRC air changeover servomotor is
not checked with self-diagnosis function.
2. On the service menu screen, press [F3] (R)

once, and then select "02 Abnormality Record."
3. Press [F6] ( ) to confirm.
80-32
PC800, 850-8E0
Air conditioner
4. On the Abnormality Record screen, press [F3]

(R) twice, and then select "03 Air conditioning
System."
5. Press [F6] ( ) to confirm.
Air Conditioning System Abnormality Record screen: Information displayed in "03 Air
Conditioning System"
(a): System or Component name
(b): Number of abnormality occurrence time
(c): Condition (Normal or abnormal)
(d): If the CAN communication condition is
displayed as being abnormal, it will indicate that
the air conditioner unit is disconnected and CAN
communication is not possible. Accordingly, the
display for the other (d) items will be cleared.
(e): If [E] is displayed to the left of the condition,
it indicates that the abnormality is ongoing or that
restoration to normal has not yet been detected.
[F2]: Clear "Abnormality Record"
[F5]: Return to Abnormality Record screen
Caution
Inner Sensor means "inside temp. sensor" on
"system diagram " or "circuit diagram".
"Ventilating Sensor is abnormal" means that
evaporator temperature sensor is short circuit or
disconnected.
Sunlight Sensor is abnormal" meas that Sunlight
Sensor is short circuit only.
"Ventilation is abnormal" means servomotor for
vent changeover (mode) damper does not rotate
judging from the servomotor potentiometer
voltage.
a Damper is the same as door.
"Air Mix is abnormal" means servomotor for Air
Mix (temperature adjustment) damper does not
rotate judging from the servomotor potentiometer voltage. "Refrigerant" means refrigerant
pressure from dual pressure switch. Namely,
"refrigerant is abnormal" means that dual pressure switch of refrigerant is OFF.
1. CAN status: Abnormal
Normal communication is not possible between
the machine monitor and air conditioner
controller.
a Display of failure code [DAFRMC] CAN communication failure (with engine controller) indicates that the entire communication line
has failed. In this case, see failure code [DAFRMC] in Chapter 40. If failure code [DAFRMC] is not displayed, communication
failure is limited to between the controller and
the machine monitor alone.
In such a case, confirm whether connectors
AC01, CN-N10, [1], and [2] have been
disconnected. See item 2 from "Parts and
connectors layout." Alternatively, see "Troubleshooting for power supply and CAN
communication system."
2. Setting : Abnormal
The air conditioner controller software and the
monitor software are not compatible. Confirm
the part number of each.
Clearing "Abnormality Record" on machine

monitor
While the "Abnormality Record" screen is
displayed, press [F2], and the number of occurrence time of abnormality is reset. If it is
confirmed at this time that the abnormality has
been reset, the trouble was resolved.
PC800, 850-8E0
3. Inner sensor: Abnormal

a Inner Sensor is the same as inside temp.
sensor on "System diagram" or "circuit diagram".
An open circuit or short circuit has been detected
between the air conditioner controller and the
inner sensor.
a Air conditioner controller remedy:
As it is not possible to use data from inner
sensor, control the air conditioner using only
the temperature setting in automatic air
conditioning mode.
80-33
Air conditioner
a Trouble: Automatic air conditioner functions

do not work, but manual operations do.
a If an abnormality is detected in inner sensor,
see "Testing inner sensor."
4. Ventilating sensor: Abnormal
a Ventilating sensor means the evaporator
temperature sensor.
An open circuit or short circuit has been
detected between the air conditioner
controller and the evaporator temperature
sensor.
Output to the compressor is stopped.
a Trouble: The air conditioner does not
work.
a If an abnormality is detected in the ventilating sensor, see "Troubleshooting for
temperature sensor system."
5. Sunlight sensor: Abnormal
A short circuit has been detected between the air
conditioner controller and the sunlight sensor.
Control is carried out without referencing
sunlight sensor.
a Trouble: The automatic air conditioner does
not work when the machine is exposed to the
direct sunlight in the automatic air conditioner
mode.
a If an abnormality is detected in the sunlight
sensor, see "Testing sunlight sensor."
6. Ventilation: Abnormal
It has been determined based on the servomotor's potentiometer voltage that the servomotor for the vent (mode) changeover damper is
not operating.
a Trouble: Vent is not changed over.
Output to the vent (mode) selection servomotor is stopped.
a Even if the link is disconnected and the
damper does not rotate, the self-diagnosis
system judges the damper normal since the
servomotor potentiometer voltage changes
normally.
a In the case of "Ventilation: Abnormal", see
"Testing vent (mode) changeover."
80-34
7. Air Mix: Abnormal

It has been determined based on the servomotor's potentiometer voltage that the servomotor for the air mix (temperature adjustment)
damper is not operating.
a Trouble: The temperature control system
does not work.
Output to the air mix servomotor is stopped.
a Even if the link is disconnected and the
damper does not rotate, the self-diagnosis
system judges the damper normal since the
servomotor potentiometer voltage changes
normally.
a If an abnormality is detected in the Air Mix
(A/M) damper, repeat the temperature setting 18.0 C (Max. cooling) io 32.0 C
(Max. heating) several times. If the A/M
damper abnormality count does not increase,
A/M damper is normal. (This abnormality potentially happens at low temperature) When
the A/M damper abnormality count increases, see "Troubleshooting for temperature
control."
8. Refrigerant: Abnormal
(Dual) pressure switch signal for refrigerant is
abnormal. Namely pressure switch for refrigerant is OFF.
a Trouble: The air conditioner does not work.
Output to the compressor is stopped.
k When replacing a pressure switch, refrigerant must be collected in advance. See
"Caution about refrigerant"
a If an abnormality is detected in the refrigerant, see "Testing (dual) pressure switch for
refrigerant."
PC800, 850-8E0
Air conditioner
Testing temperature control

Outline
80-35
q The air mix portion in air conditioner unit controls
temperature by changing the angle of four doors
(dampers) and thereby changing the mixing ratio
of hot air from heater and cold air from evaporator. The air mix servomotor changes the angle of
the doors (dampers) through plate (P1), lever 1
(L1) to lever 6 (L6) and rod (RODAM). Rod (RODAM), lever 5 (L5) and lever 6 (L6) alone are
seen from outside. (See Item 5 for the figure)
a If lever 5 (L5) and lever 6 (L6) move smoothly
between COOLMAX and HOTMAX, you can
judge that plate (P1) and lever 1 (L1) to lever 4
(L4) are also operating normally.
a Control amplifier (CNTAMP) automatically controls the temperature based on data from inner
sensor (inside air temperature sensor). Therefore, movement between COOLMAX and HOTMAX is not available at the certain room
temperature.
a To reset the self-diagnosis system (to clear the
"A/C Controller Error" displayed on the air conditioner screen of the machine monitor), the starting switch must be turned OFF (While "A/C
Controller Error" is displayed with self-diagnosis
system, no signals are output to the servomotor).
1. Remove covers (1) - (3).
PC800, 850-8E0
80-35
a State with cover (3) removed
q A/C U: Air conditioner unit
q CNT: Air conditioner controller
a Remove connectors H14 and H15 from clip
on the back.
3. Check contact of connector [6] of air mix servomotor (A/MS). (Check whether the connector is
coming off.)
4. Check rod (RODAM) for disconnection.
5. Start the engine and turn the air conditioner
power ON.
6. From the machine monitor's air conditioner operation screen, set the temperature to 18 C and
32 C and visually check whether lever 5 (L5)
and lever 6 (L6) move smoothly between
COOLMAX and HOTMAX shown in the figure.
a See the next page for COOLMAX and HOTMAX.
80-35
Air conditioner
a Plate (P1) and lever 1 (L1) to lever 4 (L4) are not

seen from outside.
When lever 5 (L5) and lever 6 (L6) do not move

smoothly between the points shown in the figure:
1) Disconnect connectors (5) and [6] of the
servomotor.
2) Apply a match mark to the servomotors (5)
and (6) to identify later on which side they
were attached. (It might be required later to
install servomotors (5) and (6) after swapping
their mutual positions.)
3) Remove servo motors (5) and (6).
q MODES: Vent (mode) servomotor
q A/MS: Temperature control (air mix) servomotor
5) Turn plate (P1) with your hand between

COOLMAX and HOTMAX to identify on
which of lever 1 (L1) to lever 6 (L6) hang-up
occurs, and correct the hang-up portion.
a If the levers do not move smoothly, clean
them and apply grease to the links.
2 Link:
Molykote MH62 grease
(Toray, Dow Corning Corporation)
6) If movement of lever 1 (L1) to lever 6 (L6) is
normal when you have manually rotated
plate (P1) between COOLMAX and
HOTMAX, confirm whether the servomotors
are the cause of the trouble by installing
servomotors (5) and (6) swapping their
mutual positions and run them.
a For an electrical trouble, see "Troubleshooting for temperature control".
80-36
PC800, 850-8E0
Air conditioner
Testing vent (mode) changeover
80-37
Outline
80-37
The vent (mode) is selected by changing the angles
of the four doors (dampers) provided inside. The
servomotor changes the angles of the doors (dampers) through plate (P2), rod for differential (RODD),
rod for front face (RODF) and lever 7 (L7) to lever 12
(L12). Rod for differential (RODD), rod for front face
(RODF), and levers 7 (L7) and 8 (L8) alone are seen
from outside. (See Item 5 for the figure.) Visually
check the opening and closing operation of the front
face and rear face doors (dampers) and the position
of these levers.
The servo motor changes the angle of the rear face
door (damper) through lever (13) and rod (RODR).
Lever (L11) of the front face, lever (13) of the rear
face and rod (RODR) are not seen from outside. Accordingly, remove the duct and check the rotation of
the door (damper) directly.
a To reset the self-diagnosis system (to clear the
"A/C Controller Error" displayed on the air conditioner screen of the machine monitor), the starting switch must be turned OFF (While "A/C
Controller Error" is displayed with self-diagnosis
system, no signals are output to the servomotor).
1. Remove covers (1) - (4) by referring to "Testing
temperature control 1 and 2".
2. Check contact of connector [5] of the mode
servomotor (MODES). (Check whether the
connector is coming off.)
3. Check the defroster rod (RODD) and foot rod
(RODF) for disconnection.
power ON.
5. Press the vent changeover switch on the air
conditioner operation screen of the machine
monitor and visually check that lever 7 (L7) and
lever 8 (L8) move smoothly between the foot
mode and differential mode.
6. Stop the engine.
7. Remove the rear face duct (RFD).
8. Referring to "Testing air leakage (duct)", remove
the ducts sequentially starting with the monitor
side up to the front face duct (FFD).
PC800, 850-8E0
80-37
Air conditioner

power ON.
10. Press the vent changeover switch on the air
conditioner operation screen of the machine
monitor, and visually check the opening and
closing movement of front face door (1) and rear
face door (damper) (2).
1.
2.
3.
4.
80-38
When lever 7 (L7) and lever 8 (L8) do not move

smoothly between the points shown in the figure,
or when the front face door and rear face door do
not open:
Disconnect wiring connectors (5) and [6] of the
servomotor.
Apply a match mark to the servomotors (5) and
(6) to identify later on which side they were
attached. (It might be required later to install
servomotors (5) and (6) after swapping their
mutual positions.)
Remove servo motors (5) and (6).
Remove cover (7).
PC800, 850-8E0
Air conditioner
5. Turn plate (P2) with your hand to identify on

which lever 7 (L7) to lever 12 (L12) hang-up
occurs, and correct the hang-up portion.
a If the levers do not move smoothly, clean
them and apply grease to the links.
2 Link: Molykote MH62 grease (Toray,
Dow Corning Corporation)
6. If movement of lever 7 (L7) to lever 12 (L12) is
normal when you manually rotated plate (P2),
confirm whether the servomotor is the cause of
the trouble by installing servomotors (5) and (6)
swapping their mutual positions and run them.
a The figures in the foot mode and defroster
mode are shown before.
a For an electrical failure, see "Troubleshooting for
vent (mode) changeover."
a When increasing the set temperature from 18 C

to 32 C, position of the front face (F.Face) door
changes from "OPEN" to "HALF".
PC800, 850-8E0
80-39
Air conditioner
Testing FRESH/RECIRC air changeover

Outline
80-40
FRESH/RECIRC air is selected by changing the
door (damper) angle in the air conditioner unit with
the servo motor. Check the opening and closing operations of the door (damper) visually.
a The system does not have self-diagnosis function for FRESH/RECIRC air changeover servo
motor.
1. Remove recirculation air filter from behind the
operator seat.
power ON.
3. Press the FRESH/RECIRC selector switch on
the air conditioner operation screen of the
machine monitor, and visually check the opening
and closing operation of the FRESH/RECIRC air
changeover door (damper) (F/RD).
4. If opening and closing of the FRESH/RECIRC
air changeover door (damper) (F/RD) is not
available, check the connection of connector [7]
of the servomotor (F/RS) in the following way.
(Check whether the connector is coming off.)
A: Recirculation air
B: Fresh air
80-40
1) Remove covers (1) - (3) by referring to
"Testing temperature control 1".
2) Remove duct (4).
a Remove connectors H14 and H15 fixed
on the back from the clip.
4) Trace the routing of the air conditioner wiring

harness (H) with your hand and check by
touch whether connector [7] of the
FRESH/RECIRC air changeover servomotor
(F/RS) is connected. (Check whether the
q [8]: Inside air temperature sensor connector
q [4]: Power transistor (PTR) connector
Reference
How to remove fresh air duct.
1. Remove plate (6). (See the previous figure)
80-40
PC800, 850-8E0
Air conditioner
2. Open fresh air filter cover (7).

3. Remove fresh air filter cover (8).
4. Remove pin (9) and remove fresh air duct (10).

a F/RD: FRESH/RECIRC air changeover door
(damper)
1.
2.
3.
4.
FRESH/RECIRC air changeover servomotor

(F/RS) replacement procedure
a Remove the fresh air duct before starting the
replacement.
Disconnect connector [7]. (As mentioned earlier)
Disconnect connector [8] of inner sensor (inside
air temperature sensor) (12).
Remove box assembly (11).
Remove the FRESH/RECIRC air changeover
servomotor (F/RS) from box assembly (11).
a For an electrical trouble, see "Troubleshooting

for FRESH/RECIRC air changeover".
PC800, 850-8E0
80-41
Air conditioner
Testing inner sensor

a Inner sensor means inside (air) temperature
sensor.
q To reset the self-diagnosis system (detection of
abnormality), the starting switch must be turned
OFF.
temperature control 1 and 2".
2. Check the contact of connector [8] of inner
sensor (12). (Check whether the connector is
coming off.)
3. Remove the fresh air duct by referring to "How to
remove
fresh
air
duct"
in
"Testing
FRESH/RECIRC air changeover".
4. Remove box assembly (11) by referring to
"FRESH/RECIRC air changeover servomotor
(F/RS) replacement procedure" in "Testing
FRESH/RECIRC air changeover".
5. Standard resistance between terminals on
sensor side of connector [8]:
1.6 kz (at 0 C)
5 kz (at 25 C)
80-42
6. Disconnect connector [1] and [2] from the air
conditioner controller (CNT) by referring to 5 of
item 1 in "Testing evaporator temperature
sensor".
7. Ensure that the female terminals (on the wiring
harness side) of connector [8] are not being
shorted by each other. (If the terminals are
shorted, the wiring harness is defective.)
8. Confirm the resistance between the female
terminal of connector [8] (wiring harness side)
(2) (PB) and the terminal of connector [1] (wiring
harness side) (11) (PB): Max. 1 z. (If not, the
wiring harness is defective.)
terminal of connector [8] (wiring harness side)
(1) (BrR) and the terminal of connector [2] (wiring
harness side) (27) (BrR): Max. 1 z. (If not, the
10. Connect all the connectors.
11. Turn the starting switch to ON position and if
"Inner sensor Abnormal" is still displayed with
self-diagnosis (on "03 Air conditioning System"
screen of "Abormality Record" in the machine
monitor), replace the air conditioner controller.
a Bottom of the air conditioner unit

[7]: FRESH/RECIRC air changeover servomotor connector
[8]: Inner sensor (inside air temperature
sensor) connector
H: Air conditioner unit wiring harness
80-42
PC800, 850-8E0
Air conditioner
Testing evaporator temperature sensor

q
1.
2.
3.
4.
5.
When "Ventilating Sensor abnormal" is displayed by the self-diagnosis (on "03 Air-conditioning System" screen of "Abormality Record" in
the machine monitor), test the evaporator temperature sensor.
To reset the self-diagnosis system (detection of
OFF.
Referring to testing temperature control 1,
remove covers (1) - (3).
Check the contact of connector (9). (Check
whether the connector is coming off.)
Remove connector (9).
Measure the resistance between the opponent
(female) of connector(9) and the terminal at
evaporator temperature sensor side. Standard
resistance:
4.8 kz (0 C)
2.3 kz (15 C)
a If error is detected with self-diagnosis and
evaporator temperature control sensor is
normal, air conditioner controller (CNT) or
wiring harness is defective.
Remove connectors [1], [2] from air conditioner
controller (CNT). (Connector [9] must be
connected.)
80-43
a If the evaporator temperature sensor is defective, replace it according to the following procedure.
q Replacement of evaporator temperature sensor
1. Referring to Shop Manual Chapter 50, "Removal
and installation of air conditioner unit assembly",
remove air conditioner unit assembly (A/CU).
2. Remove wiring harness. (For each connector,
see "Parts and connectors layout".)
3. Remove servo motors (2) and (3).
5. Remove the link section. For details, see Shop
Manual, Chapter 80, Structure and function, "Air
conditioner unit".
6. Disconnect cases (5) and (6).
7. Remove the evaporator.
Standard resistance between terminal (11) (PB)

of connector [1] and terminal (27) (BrR) of
connector (2):
4.8 kz (0 C)
2.3 kz (15 C)
a If item 5 above is normal, the controller (CNT)
is defective. If item 5 above is abnormal and
item 4 is normal, wiring harness is defective.
PC800, 850-8E0
80-43
Air conditioner
8. Remove the holder from part (P) and remove the

evaporator temperature sensor.
80-4
Connection
1. Install the evaporator temperature sensor to the
position shown in the previous figure with the
holder.
2. Carry out the following installation in the reverse
order to removal.
80-44
PC800, 850-8E0
Air conditioner
Testing sunlight sensor

q
1.
2.
3.
When "Sunlight Sensor Abnormal" is displayed

by the self-diagnosis (on "03 Air conditioning
System" screen of "Abormality Record" in the
machine monitor), test sunlight sensor connector P31.
To reset the self-diagnosis system (detection of
OFF.
If sunlight sensor (S) is mesured with resistance
range of tester, sunlight sensor may be destroyed, so do not measure with resistance
range of tester.
Remove cap (1).
Remove cover (2) and check the connector P31
(3) for sunlight sensor (S), which is located on
back side of the cover. (Check whether the
Disconnect connector P31, and using a tester
set to the voltage range, measure the voltage
between the male side terminals on sunlight
sensor (S).
q Approximate voltage of sunlight sensor unit
0.55 V: Direct sunlight
0.45 V: Cloudy
0.4 V: Indoors
PC800, 850-8E0
80-45
4. Referring to item 2 of "Parts and connectors
layout", disconnect connector [1] from the air
conditioner controller.
5. Ensure that the female terminals of the
connector P31 (wiring harness side) are not
being shorted. (If the terminals are shorted, the
terminal of the connector P31 (wiring harness
side) (2) (YW) and the terminal of connector [1]
(wiring harness side) (15) (YW): Max. 1 z.
(If not, the wiring harness is defective.)
a If the result of item 6 or item 7 is abnormal,
check the contact of connector CN-AC01.
(See "Parts and connectors layout".)
terminal of connector P31 (wiring harness side)
(1) (RB) and the terminal of connector [1] (wiring
harness side) (3) (RB): Max. 1 z. (If not, the
9. Turn the starting switch to ON position, and if
"Sunlight Sensor Abnormal" is still displayed
with self-diagnosis (on "03 Air conditioning
System" screen of "Abnormal Record" in the
machine monitor), replace the air conditioner
controller.
80-45
Air conditioner
Testing (dual) pressure switch for refrigerant

When "Refrigerant Abnormal" is displayed by
the self-diagnosis (on "03 Air-conditioning System" screen of "Abnormality Record" in the machine monitor), test the dual pressure switch
connector P17.
q To reset the self-diagnosis system (detection of
OFF.
q The dual pressure switch is ON when the refrigerant pressure is normal and OFF when it is abnormal.
a As the refrigerant pressure will drop when the
ambient temperature is below 0 C, there is a
possibility that the dual pressure switch is
OFF. In such a case, the dual pressure
switch is actually normal (I.e., not defective).
q
2. Disconnect dual pressure switch connector P17.
3. Ensure that the resistance between the

switch-side terminals from connector P17 is
shorted (ON). (If not shorted (OFF), the dual
pressure switch will detect a refrigerant pressure
abnormality.)
a When the pressure switch is OFF, connect a
pressure gauge to the high pressure side of
the air conditioner compressor and check the
refrigerant pressure. See "Connection of service tool" and "Troubleshooting with gauge
pressure."
80-46
80-46
a If refrigerant pressure is normal, the pressure

switch is defective.
(Dual) pressure switch
LA: 0.20 MPa {2 kg/cm2}

LB: 0.02 MPa {0.2 kg/cm2}
HA: 3.14 MPa {32 kg/cm2}
HB: 0.59 MPa {6 kg/cm2}
k When replacing the pressure switch, refrigerant must be collected in advance.
q If resistance between the switch-side terminals
from connector P17 is shorted (ON): (See "Troubleshooting for the compressor and refrigerant
system" for the circuit diagram.)
1. Referring to item 1 and 5 of testing evaporator
temperature sensor, disconnect connector [1]
from air conditioner controller (CNT).
side) (2) (B) and the machine ground: Max. 1 z.
(If not, the wiring harness is defective.)
side) (1) (GB) and the terminal of connector [1]
(wiring harness side) (4) (GB): Max. 1 z. (If not,
the wiring harness is defective.)
a If the result of item 3 is abnormal, check contact of connector CN-AC01. (See "Parts and
connectors layout".)
5. Turn the starting switch ON and if "Refrigerant
abnormal" is still displayed with self-diagnosis
(on "03 Air-conditioning System" screen of
"Abnormality Record" in the machine monitor),
replace the control amplifier.
PC800, 850-8E0
Air conditioner
Testing relays
Testing relays
a If the air conditioner compressor is normal (air is
cooled) and air comes out, the relays are normal.
Accordingly, the test can be omitted.
a Listen closely to the relay to check whether or
not it is defective.
There are two relays.
q Blower main relay R20:
Turning the fan motor ON/OFF
q Compressor clutch relay R21:
Used to turn the air conditioner compressor
(clutch) ON/OFF
temperature control 1".
2. Check the connections of connectors R20 and
R21. (Check whether the connectors are coming
off.)
3. Turn the starting switch ON (do not start the
engine) and turn the main power of the air conditioner ON. If the blower main relay (BRL) is
normal, it is turned ON. Check its click.
4. If the air conditioner switch is turned ON at this
time, the compressor relay is turned ON if it is
normal. Check its click.
a The air conditioner controller (CNT) will not
turn on the compressor relay (CCRL) in the
following cases.
1) When the evaporator temperature is below
3 C (depending on the input voltage from
the evaporator temperature sensor).
2) When the pressure switch detects abnormality (it is turned OFF).
a If the sound produced by the compressor relay
(CCRL) cannot be heard due to the sound of the
fan, turn the starting switch off temporarily and
disconnect the connector R20 before starting the
operation.
PC800, 850-8E0
80-47
Checking relay unit
a Since no T-adapter is available, it is impossible
to check the relay while the voltage is applied to
the coil actually.
Blower main relay (BRL), connector (R20)

1) The coil resistance between terminals (1)
and (2) is 140 340 z.
2) While the voltage (20 - 30 VDC) is not applied
between terminals (1) (+) and (2), terminals
(3) and (4) are disconnected and terminals
(3) and (5) are connected.
3) While the voltage (20 - 30 VDC) is applied
(3) and (4) are connected and terminals (3)
and (5) are disconnected.
Compressor clutch relay (CCRL), connector (R21)

1) The coil resistance between terminals (1)
and (3) is 140 340 z.
2) While the voltage (20 - 30 VDC) is not applied
(2) and (4) are disconnected.
3) While the voltage (20 - 30 VDC) is applied
between terminal (1) (+) and (3), terminals
(3) and (4) are connected.
80-47
Air conditioner
Troubleshooting chart 1
80-48
The numbers in the boxes are the item numbers in the troubleshooting table.
1. Cooling trouble
80-48
80-48
PC800, 850-8E0
Air conditioner
2. Heating trouble
PC800, 850-8E0
80-49
80-49
Air conditioner
80-50
1. During cooling, the blower fan motor does not operate or the rotation speed does not match the air flow
setting.
a See "Troubleshooting of blower motor system (Air does not come out or air flow is abnormal)".
Probable cause
Defective blower main relay
Check method
See "Testing relays"
Check connector of blower fan motor for disconnection.
Wire breakage or defective conSee "Detail of air conditioner unit" and "Parts and connectors
nection
layout".
See "Troubleshooting of blower motor system" and "Parts and
Defective blower fan motor
connector layout".
Operate the fan switches in order and check the fan speed.
Defective power transistor (PTR)
See "Troubleshooting the blower motor system."
Remedy
Replace
Repair broken parts
and connect correctly
Replace
Replace
2. During cooling, the blower fan motor is normal but the flow of air is very light.
Probable cause
Large duct resistance
Air leakage through duct joints
Obstruction at evaporator inlet
Check method
Check the filter for clogging and the duct for crushing.
Check duct joints.
See "Testing air leakage (duct)".
Check evaporator for stain and obstruction
Remedy
Repair
Repair
Remove obstruction and clean
Evaporator is frozen.
Sensor fixing clip inspection, sensor contaminated
Inspect the air conditioner hose around the pressure switch for Repair or replace
frost.
(when freezing has advanced even further)
*: The evaporator temperature sensor and expansion valve are located inside the air conditioner unit.
Defective evaporator temperature sensor, defective contact of

evaporator temperature sensor,
defective expansion valve*
3. Pressure abnormality (high-pressure/low-pressure) during cooling.

Probable cause
Check method
Insufficient refrigerant
Check the refrigerant volume through sight glass.
Specifically, perform checking with the gauge manifold connected.
Overcharge with refrigerant
Judgment by pressure at
inlet/outlet of compressor
80-50
Normal pressure range

Low-pressure: Approx. 0.13 - 0.2 MPa {1.3 - 2.0 kg/cm2}
High pressure: Approx. 1.5 - 1.7 MPa {15 17 kg/cm2}
Temperature in operator's cab: 30 - 35 C, Engine speed:
Approx. 1,500 rpm
Remedy
Repair leaking part,
then charge with
proper quantity of
refrigerant again
Collect refrigerant,
then fill up with
proper quantity of
refrigerant again
See Troubleshooting with gauge pressure
PC800, 850-8E0
Air conditioner
4. During cooling, the compressor cannot operate easily or at all.

a See "Troubleshooting of compressor system (Air is not cooled)".
Troubled part
Probable cause
Compressor
Slack of belt
belt
Trouble in compressor
Compressor Insufficient compressor oil
Seizing on compressor
Drop of battery voltage
Open or short circuit in coil
Magnet clutch
Wire breakage or defective connection of ground wire
Relay
Refrigerant
pressure
Pressure
switch
Check method
Remedy
Deflection of belt is large.
Adjust tension
Slip of belt
Repair or replace
See "Handling compressor oil".
Charge battery
Replace
Heating of compressor
Slip of clutch
Inspect with multimeter (10 - 20 z)
Check ground wire and connections
See "Troubleshooting for compressor and
refrigerant system".
Defective compressor clutch relay See "Testing relays"
Low/high pressure (Operation of
See "Troubleshooting with gauge pressure".
pressure switch)
See "Troubleshooting for compressor and
Defective pressure switch
refrigerant system".
Repair
Replace
See "Troubleshooting
with gauge pressure".
Replace
5. During heating, blower fan motor is normal but air flow alone is insufficient.
Probable cause
Large duct resistance
Check method
Check the filter for clogging and the duct for crushing.
Check the duct joints by referring to "Testing air leakage
Air leakage through duct joints
(duct)."
Clogging of heater core fins
Check heater core fins for clogging
Remedy
Repair
Repair
Clean
6. Engine coolant temperature or volume abnormalities during heating or cooling

Probable cause
Low engine coolant temperature
Low engine coolant level
Insufficient circulation of engine
coolant
The connection of IN and OUT
heater hoses is in reverse.
Check method
Remedy
Warm up engine, and then check engine coolant temperature
Find out cause
Check coolant level in radiator

Check engine coolant piping for clogging
(Hose, pipe, and core)
Add coolant
Check the destination of heater hoses
Correct
Bleed air and correct
7. Fan speed abnormalities during cooling

Probable cause
Fan speed is low
Check method
See "Testing and adjusting of Air conditioner compressor belt
tension" in the "Testing and adjusting" of Chapter 30 of the
shop manual.
Remedy
Correct
8. Other abnormalities
Probable cause
Temperature cannot be controlled
Vent (mode) changeover is not
possible.
FRESH/RECIRC air cannot be
changed over
Excessive compressor oil
Water leakage into the cab
PC800, 850-8E0
Check method
See "Testing temperature control" and "Troubleshooting for
temperature control"
"Testing vent (mode) changeover"
See "Troubleshooting vent (mode) changeover."
See "Testing FRESH/RECIRC air changeover" and "Troubleshooting for FRESH/RECIRC air changeover"
See "Handling compressor oil".
Clogging of drain hole
Remarks
Common to cooling and

heating
Cooling only
80-51
Air conditioner
80-52

80-52
a The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before performing troubleshooting, understand that information fully.
Failure
Related information
Cause
1
Probable causes of
failure
(Perform troubleshooting according
to these.)
2
3 - defective
Problem on machine
Information related to detected failure or troubleshooting
<Information described>
q Procedure
q Measuring location
a "Between A B" means Measure voltage or resistance and so on between A and B".
q Standard value in normal condition to judge probable causes
q Remarks required for judgement
<Notes on troubleshooting>
(1) Pin number description sequence and tester lead handling
For troubleshooting, connect the plus (+) and minus () tester leads as shown below unless
otherwise specified.
q Connect the plus (+) lead to a pin or harness indicated in the front.
q Connect the minus () lead to a pin or harness indicated in the rear.
(2) Example of troubleshooting by inspection of multiple items
a Normal in 1 but abnormal in 2
At this time - defective shown at left is applied
a If a wiring harness is burnt, replace it.

<Defective wiring harness>
q Open circuit
Connection of connector is defective or wiring harness is broken.
q Ground fault
A harness not to be connected to the ground (earth) circuit comes into contact with the ground (earth)
circuit or chassis accidentally.
q Hot short circuit
A harness not to be connected to the power (24 V) circuit comes into contact with the power (24 V) circuit
accidentally.
q Short circuit
An independent wire in the harness abnormally comes into contact with one of another wire. (Defective
insulation in connector or others)
Related circuit diagram
80-52
This is the excerpted circuit diagram related to failure

q Indicates connector No., and pin No.
q See "Circuit diagram and arrangement of connector pins" and "Parts and connectors layout" for connector location
q The circuit diagram shows the size and colors of wires.
W: White, B: Black, R: Red, G: Green, Y: Yellow, L: Blue, V: Purple, P: Pink, O: Orange, Br: Brown, Gr: Gray, Sb:
Sky blue, Lg: Light green, Dg: Dark green, Ch: Dark brown
a When there are two colors
Example: WY: Yellow line on white background
a The number before the wire color indicates the wire size.
q N.C.: Normally closed (Normally ON)
q [1], [2], are numbers of unlabeled connectors.
q Arrow (): Roughly indicates their mounting place on the machine.
80-52
PC800, 850-8E0
Air conditioner
PC800, 850-8E0
80-53
Air conditioner
Troubleshooting for power supply and CAN communication system (Air

conditioner does not operate)
80-54
Air conditioner does not operate due to failure in power supply system or CAN communication system.
Problem on q "A/C Controller Error" is displayed in red on air conditioner screen of machine monitor.
q No air blows out (Blower motor does not rotate).
machine
q If a failure code or [DAFRMC] error is displayed on the machine monitor, see first of all Chapter 40
and troubleshoot it.
a The machine monitor, engine controller, pump controller, and air conditioner controller are connected via CAN communication.
q In the following cases, "A/C Controller Error" will be displayed in red on the machine monitor's air
conditioner operation screen. Of these, 1), 2), and 3) will be covered below.
1) The air conditioner controller is receiving no power.
2) The air conditioner controller is malfunctioning.
3) No communication is possible between the air conditioner controller and the machine monitor.
4) Vent (mode) door (damper) servomotor does not rotate.
5) Temperature control (Air Mix) door (damper) servomotor does not rotate.
6) Refrigerant pressure is abnormal.
Related infor- q Referring to "Testing with self-diagnosis function", display the air conditioning system abnormality
record screen on the machine monitor and check condition of CAN communication. Abnormality in
mation
CAN communication denotes that CAN communication is disabled between the air conditioner controller behind the air conditioner unit and the machine monitor.
CAN Status is indicated as abnormal in any case of 1), 2) and 3) above.
q Referring to "Parts and connectors layout", ensure that No. 11 fuse (20A) of fuse box F01 and Fu5A
fuse of the air conditioner wiring harness are not blown.
q Ground cable of air conditioner is connected in machine wiring harness together with electrical
equipment of machine.
q For each connector, see "Parts and connectors layout".
q In cases where fuses are blown when the A/C switch is pressed, see "Troubleshooting for compressor and refrigerant system."
q T-adapter for connector [1]: 799-601-7210, T-adapter for connector [2]: 799-601-7220
a T-adapter is not prepared for other connectors.
Failure
Cause

2. Disconnect the cable from the negative () terminal of the battery.
3. Disconnect connector [1] from the air conditioner controller, and connect
1 Defective wiring harness (ground)
the T-adapter to the harness side.
Between (16) (black) on the harness side of connector
Resistance Max. 1 z
[1] and the chassis ground
2. Referring to "Parts and connectors layout", confirm that No. 11 fuse (20A)
2 Blown fuse
of fuse box F01 and the Fu5A fuse of the air conditioner wiring harness are
not blown.
80-54
PC800, 850-8E0
Air conditioner
Cause

a
1.
2.
3.

If fuse described in related information is blown, replace it.

Disconnect the cable from the negative () terminal of the battery.
Disconnect connector [1] from the air conditioner controller, and connect
the T-adapter on the wiring harness side.
Between wiring harness side (6) (red) and
Voltage 20 30 V
A
(16) (B) of connector [1]
a If fuse is blown again in test A above, perform following procedure.
(Replace blown fuse )
3. Disconnect connector [1] of the air conditioner controller, and connect the
T-adapter on the wiring harness side.
a If the fuse is blown again in the above test A and both B and C below are
normal, it is likely that the cause of the problem lies within the blower motor
circuit. In such a case, see "Troubleshooting the blower motor system."
B
(16) (black) of connector [1]
Between (6) (red) on the harness side of
C
connector [1] and the chassis ground
a If fuse is blown again in test A for cause 3 and result of B or C is abnormal,
identify wiring harness having ground fault.
3. Disconnect connectors AC01, N10, and [1].
4. Connect the T-adapter to the harness side of connector [1], and connect the
T-adapter to the harness side.
a Abnormality in D or E below: Short circuit in the air conditioner wiring harness
a Abnormality in F or G below: Short circuit in the chassis wiring harness
D
(16) (black) of connector [1]
Between (6) (red) on the harness side of
connector [1] and the chassis ground
PC800, 850-8E0
Between connector N10 (female) (4) and

F
AC01 (female) (4) (black)
Between connector AC01 (female) (5)
G
(red) and (4) (black)
a If none of the fuses described in the related information is blown and an abnormality is recorded for cause 3 A, check the circuit relating to circuit diagrams.
80-55
Air conditioner
Cause
a When short circuit or ground fault occurs in CAN communication line, a

[DAFRMC] error is displayed.
a Terminating resistor: Terminating resistors of approximately 120 z are provided inside the machine monitor and engine. Since they are connected in
parallel, the combined resistance is approximately 60 z.
3. Disconnect connectors [1] and [2] from the air conditioner controller, and
connect the T-adapter to the harness side.
Between (17) and (18) on the wiring harApprox.
Resistance
H
Open circuit in CAN communica- ness side of connector [2]
60 z
a If result H above is abnormal, perform following procedure.
tion line
a If an abnormality is recorded for H above and J below, the cab harness is
6 (Communication is not possible
defective.
between the machine monitor and
a If an abnormality is recorded for H above but J below is normal, the air conthe air conditioner controller.)
ditioner harness is defective.
a Terminating resistor: Terminating resistors of approximately 120 z are provided inside the machine monitor and engine. Since they are connected in
parallel, the combined resistance is approximately 60 z.
3. Disconnect connectors [1] and [2] from the air conditioner controller, and
connect the T-adapter to the harness side.
Between (male) (1) and (2) of connector
Approx.
Resistance
J
N10
60 z
If results of cause 1 and cause 2, 3 A, and 6 H are normal, replace the air con7 Defective air conditioner controller
ditioner controller.
If no abnormality is found in the checkup of potential causes 1 - 7, the machine
monitor is defective.
80-56
PC800, 850-8E0
Air conditioner
Circuit diagram related to power supply and CAN communication
PC800, 850-8E0
80-57
80-57
Air conditioner
80-58
PC800, 850-8E0
Air conditioner
Troubleshooting for compressor and refrigerant system (Air is not cooled)
Troubleshooting for compressor and refrigerant system (Air is not

cooled)
Failure
80-59
Air is not cooled due to compressor or refrigerant system failure.

q
When engine is started and A/C switch is pressed on air conditioner screen of machine monitor, air
is not cooled as displayed on screen.
q Air conditioner compressor does not operate.
Problem on
q A/C Controller Error may be displayed in red on air conditioner screen of machine monitor.
machine
There are 6 cases, items 1) to 6), of the information relevant to "Troubleshooting for power supply
and CAN communication system". As for 1) through 3), see "Troubleshooting for the power supply
and CAN communication system."
The following description deals with item 6), refrigerant pressure abnormality.
q Referring to "Testing with self-diagnosis function", display air conditioner abnormality record screen
on machine monitor and check to see if refrigerant pressure is abnormal. If refrigerant pressure is
abnormal, compressor is not turned ON and air is not cooled consequently.
Related infor- a Abnormal refrigerant pressure indicates that "Signal (connector [1] (4)) from pressure switch is not
mation
grounded".
q In certain cases, the air conditioner will not turn on at 3 C or lower (normal).
q For each connector and fuse, see "Parts and connectors layout".
a A T-adapter is prepared only for connectors [1], [2], and M34.
Cause
1 Defective pressure switch

a When "A/C Controller Error" is displayed in red on air conditioner operation
screen of machine monitor, perform following procedure.
3. Disconnect pressure switch connector P17.
a In certain cases, the pressure switch may be operating normally and set to
OFF, therefore, if a failure is recorded for the following (i.e., switch OFF),
attach a pressure gauge to the air conditioner compressor and check the
refrigerant pressure. (See "Troubleshooting with gauge pressure.")
Between (1) and (2) of connector P17 (male)
Resistance
Max. 1 z
Before replacing pressure switch, collect refrigerant.

2. Disconnect connector M34 from the air conditioner compressor and
connect the T-adapter to the male side.
Defective air conditioner compres- a Ensure connection of air conditioner compressor ground cable (E).
2
sor
(See "Parts and connectors layout".)
Between connector M34 (male) (1) and chassis
Approx.
ground (i.e., air conditioner compressor coil resisResistance
15 z
tance)
2. Disconnect connectors [1] and R21, and troubleshoot in that condition.
a Ensure that test result for cause 1 (pressure switch ON) and cause 2 (air
conditioner compressor normal) are both normal.
Between connector [1] (4) and the chassis ground
Resistance Max. 1 z
(Pressure switch is turned ON)
Between connector R21 (female) (2) and the chasApprox.
sis ground
Resistance
15 z
(Air conditioner compressor coil resistance)
PC800, 850-8E0
80-59
Air conditioner
Cause

q
Referring to "Testing relays", check sound made when compressor clutch

relay is turned ON.
a If the sound produced when the compressor clutch relay turns ON cannot
be heard due to the sound of the blower, turn the starter switch off temporarily and disconnect the connector R20.
Click is heard.
A
a If A above and B below are abnormal and C is normal (relay is normal), go
to causes 7 and 8.
Defective compressor clutch relay 2. Disconnect connector R21.
4
3. Use a wire to short-circuit (2) (white) and (4) (blue on red) of connector R21
(does not turn ON)
(wiring harness side) . (This forces the compressor to operate without using
the relay.)
Air is cooled.
B
2. Disconnect connector R21 and troubleshoot in that condition.
Approx. 140
Between (1) and (3) of connector R21
Resistance
C
(male) (i.e., coil resistance)
340 z
a If the fuse is not blown, skip troubleshooting.
2. Disconnect connectors R21 and M34, and connect the T-adapter to the
5
female side of M34.
Between M34 (female) (1) and chassis ground
Resistance
Min. 1 Mz

2. Disconnect connectors R21, [1] and [2], and then connect the T-adapter to
[1] and [2] on the wiring harness side.
a Ensure that test result for cause 2 is normal.
Between wiring harness side (6) of connector [1]
and wiring harness side (35) of connector [2]
a See circuit diagram and inspect.
2. Disconnect connectors [1] and [2] and insert the T-adapter to the harness
side.
3.
Turn
starting switch to ON position.
8 Defective air conditioner controller
4. Display the air conditioner operation screen on the machine monitor and
press the A/C switch.
Between connector [2] (35) and connector [1] (16)
9
(defective switch)
80-60
Voltage
Max. 1 V

2. Display the air conditioner operation screen on the machine monitor.
Press A/C switch.
"A/C ON" is displayed
PC800, 850-8E0
Air conditioner
Circuit diagram related to compressor and refrigerant system
PC800, 850-8E0
80-61
80-61
Air conditioner
80-62
PC800, 850-8E0
Air conditioner
Troubleshooting for blower motor system (No air comes out or air flow is abnormal)
Troubleshooting for blower motor system (No air comes out or air flow
is abnormal)
80-63
Failure
No air comes out or air flow is abnormal due to blower motor system failure.
q
LCD of machine monitor on air conditioner operation screen lights up normally but air does not
come out.
q Air flow does not match fan switch setting on air conditioner operation screen.
q This failure is not checked with self-diagnosis function.
q In cases where the blown-air volume begins to behave in an unpredictable manner after a certain
while during cooling, freezing of the evaporator is a likely cause.
This may be due to the followings.
1) Defective compressor clutch relay (i.e., stuck in ON position) (see item 4 A from "Troubleshooting for compressor and refrigerant system")
2) Evaporator temperature sensor mounting holder has come off. (Remove and disassemble air
conditioner unit.)
3) Incorrect adjustment of the expansion valve. (Remove air conditioner unit and replace expansion valve.)
Related inforq If air comes out, fuse and relay are normal and wiring harness is seldom abnormal.
mation
q For each connector, relay, and power transistor, see "Parts and connectors layout".
a Since the power transistor is located at the bottom of the air conditioner unit, its troubleshooting or
troubleshooting by disconnecting connector (4) is not available as long as it is installed on the machine.
q In cases where air is discharged but with unpredictable volumes even during heating, the power
transistor has failed, and therefore, the air conditioner unit must be replaced.
a The power transistor and blower motor cannot be replaced unless the air conditioner unit is once
removed.
a T-adapter is not prepared for other connectors.
Problem on
machine
Cause
1 Defective blower (fan) motor

2. Disconnect connector [3], and troubleshoot in that condition.
Between wiring harness terminals at blower motor
Continuity
side of connecter [3]
q Referring to "Testing relays", check sound made
Click is
A
when blower main relay is turned ON.
heard.
a When A above is abnormal and B below is abnormal and C is normal (if relay is normal), go to cause 3.
Defective blower main relay

(does not turn ON)

2. Disconnect connector R20.
3. Using a wire, cause short-circuit between (wiring side) (3) (red/yellow) and
(red/blue) of connector R20 (This forces ON without using the relay.)
Operate fan on air conditioner operation screen.
Air comes
out.
a If air does not come out even when blower motor is turned ON forcibly without using relay, cause is part other than relay.
2. Disconnect connector R20 and troubleshoot in that condition.
Between (1) and (2) of R20 (relay
side) (coil resistance)
PC800, 850-8E0
Resistance
Approx. 140
340 z
80-63
Air conditioner
Cause

2. Disconnect connectors [1], [2], and [3], and then connect T-adapter to [1]
on the wiring harness side.
Between (8) and (16) on the harness side of conApprox.
Resistance
nector [1] (power transistor's internal resistance)
11 kz
Between connector [1] (wiring harness side) (7) and
Open circuit in wiring harness or
Approx.
connector [3] (female) (2) (power transistor's inter- Resistance
22 kz
3 defective power transistor (replace
nal resistance)
the air conditioner unit)
Approx.
Resistance
ground (power transistor's internal resistance)
11 kz
2. Disconnect connectors R20 and [3].
Between R20 (female) (3) and [3] (female) (1)
Between (8) and (16) of connector [1]
Resistance
Max. 1 z

2. Disconnect connectors R20, [1] and [2], and then connect T-adapter to [1]
on wiring harness side.
Between (16) and (7) on the wiring harness side of
connector [1]
Between wiring harness side (16) of connector [1]
and wiring harness side (36) of connector [2]
Between (2) and (1) on wiring harness side of conResistance Min. 1 Mz
nector R20.
Between (6) and (7) on the wiring harness side of
connector [1]
q Blower motor input voltage
2. Disconnect connector [3].
4. Press the fan switch on the air conditioner operation screen. (Air flow may
be set to any position.)
a If abnormal, go to cause 7.
Between (1) (red/yellow) on the wiring harness side
Approx. 24
Voltage
V
Check of input and output voltages of connector [3] and the chassis ground
q Power transistor voltage
2. Insert T-adapter to connector [1]
Min. 24 V
Between (7) and (16) of connector [1]
Voltage
D
*1
If no abnormality is found in the checkup of potential causes 5-D and 7 (motor
Defective blower (fan) motor
does not run though the voltage is normal), the blower (fan) motor is defective.
2. Disconnect connectors [1] and [2] and insert the T-adapter.
Defective air conditioner controller
Between (36) of connector [2] and (16) of connector
Voltage
Max. 1 V
[1]

(defective switch)
Voltage
Max. 2 V

Press the fan switches from MIN to MAX
LCD display of air flow

changes from MIN to
MAX.
*1: When Blower main relay is turned ON
80-64
PC800, 850-8E0
Air conditioner
Circuit diagram related to blower motor system
PC800, 850-8E0
80-65
80-65
Air conditioner
80-66
PC800, 850-8E0
Air conditioner
Troubleshooting for temperature control

Failure
80-67
Temperature cannot be controlled
"A/C Controller Error" may be displayed in red on air conditioner operation screen of the machine
monitor. (See "Troubleshooting for power supply and CAN communication system.")
q While air conditioner operation screen of machine monitor is displayed, temperature does not
change even if temperature control switch is operated.
a Temperature control means Air Mix of cooled air and hot air.
q Referring to "Testing with self-diagnosis function", display "03 Air conditioning system" screen of
"Abnormality Record" of the machine monitor and check whether an "Air Mix" or "Inner sensor" abnormality has occurred.
In the case of "Inner sensor Abnormal", see "Testing inner sensor".
q In the case of "Air Mix damper Abnormal", repeat the temperature setting 18.0 C (Max. cooling)
io32.0 C (Max. heating) several times. If the Air Mix damper Abnormal count does not increase,
Air Mix damper is normal. (This abnormality potentially happens only at low temperature.)
q When rod etc. is disconnected (See Testing temperature control (Air Mix)), if current is supplied
to air mix servomotor by operating switches and potentiometer in servomotor reaches normal voltage, self-diagnosis function judges system normal.
Related inforq Referring to Testing temperature control (Air Mix), check that there is not contact of connector [6]
mation
or mechanical trouble (coming off or interference of link, etc.)
q Air Mix servomotor and air vent (mode) servomotor are same part number. Operating angle of temperature control (Air Mix) is less, however. Accordingly, do not test servomotor to see if it rotates
by connecting connector [5] to connector [6]. It is allowed, however, to exchange air mix servomotor and vent (mode) servomotor to see if they are normal.
q Air Mix servomotor can be checked for failure by connecting new servomotor to connector [6] and
see if it operates normally.
a Since T-adapters are not prepared for other connectors, check the signals while the air conditioner
controller is in operation.
Problem on
machine
Cause

Between (6) and (7) (servomotor side) of connector

Resistance
Defective air mix servomotor (unit [6] (There must not be open circuit or short circuit.)
1
test)
Resistance
[6] (There must not be open circuit or short circuit.)
Resistance
PC800, 850-8E0
400
3000 z
4 - 8 kz
4 - 8 kz
80-67
Air conditioner
Cause

Voltage
5V
1.
2.
3.
4.

Disconnect connectors [1] and [2] and insert the T-adapter.
Operate the temperature control switch on air conditioner control screen
and prepare by setting to COOL MAX.
Defective air mix servomotor or
5. Operate the temperature control switch on air conditioner control screen
2 defective air conditioner wiring harand set to HOT MAX.
ness
a Voltage will be output between connector [2] (24) and [2] (23) for approximately 3 seconds (only while door moves).
a The voltage will be vary between connectors [1](2) and [2](27) for approximately 3 seconds (only while door moves). (When the door stops, the voltage will stabilize.)
Between (21) (+) and (22) () of connector [2]
Approx. 24
a If temperature is changed from HOT MAX to Voltage
V
COOL MAX, voltage polarities are reversed.
Between connector [1] (2) (+) and connector [2] (22)
Variable
Voltage
(-)
max. 5 V
a When test result for cause 1 is normal and that for cause 2 is abnormal, perDefective air conditioner wiring
form following procedure.
3
harness
Check with circuit diagram.

(defective switch)
80-68
a When test result for cause 1 is normal and that for cause 2 is abnormal and
that for cause 3 is normal, air conditioner controller is defective.
Press temperature control switch.
LCD display changes

from 18 to 32 C.
PC800, 850-8E0
Air conditioner
Circuit diagram related to temperature control
80-69
a Servomotors are common.
PC800, 850-8E0
80-69
Air conditioner
Troubleshooting for vent (mode) changeover

Failure
80-70
Vent (mode) cannot be changed over.
"A/C Controller Error" is sometimes displayed in red on the air conditioner operation screen of machine monitor. (See "Troubleshooting for power supply and CAN communication system")
q When vent selector switch of machine monitor is operated, vent does not change over.
q Referring to "Testing with self-diagnosis function", display Air Conditioning System Abnormality Record screen on machine monitor and check to see if vent damper is abnormal.
q When rod etc. is disconnected (See Testing vent (mode) changeover), if current is supplied to
vent (mode) servomotor by operating switches and potentiometer in servomotor reaches normal
voltage, self-diagnosis function judges system normal.
q Referring to "Testing vent (mode) changeover", check that there is not contact of connector [5] or
mechanical trouble (coming off or interference of link, etc.).
q Air Mix servomotor and vent (mode) servomotor are same part number. Operating angle of temperRelated inforature control (Air Mix) is less, however. Accordingly, do not test servomotor to see if it rotates by
mation
connecting connector [5] to connector [6]. It is allowed, however, to exchange air mix servomotor
and vent (mode) servomotor to see if they are normal.
q Vent servomotor can be checked for failure by connecting new servomotor to connector [5] and see
if it operates normally.
Problem on
machine
Cause


Resistance
Defective vent (mode) servomotor [5] (There must not be open circuit or short circuit.)
1
(unit test)
Resistance
Resistance
400
3000 z
4 - 8 kz
4 - 8 kz

Voltage
5V
1.
2.
3.
4.

Operate the vent switch on air conditioner control screen and prepare by
setting to FACE mode.
Defective vent (mode) servomotor 5. Operate the vent switch on air conditioner control screen and set to
2 or defective air conditioner wiring
DEFROST mode.
harness
a Voltage will be output between connector [2] (24) and [2] (23) for approximately 3 seconds (only while door moves).
a The voltage will be vary between connectors [1] (9) and [2] (27) for approximately 3 seconds (only while door moves). (When the door stops, the voltage will stabilize.)
Between (24) (+) and (23) () of connector [2]
Approx. 24
a If vent is changed from DEFROST to FACE, volt- Voltage
V
age polarities are reversed.
Variable
Voltage
(-)
max. 5 V
a When test result for cause 1 is normal and that for cause 2 is abnormal, perDefective air conditioner wiring
form following procedure.
3
harness
80-70
a When test result for cause 1 is normal and that for cause 2 is abnormal and
that for cause 3 is normal, air conditioner controller is defective.
PC800, 850-8E0
Air conditioner
Cause

(defective switch)

Operate air vent switch and change LCD display to
FACE, FACE and REAR, FOOT and FACE and
LCD display changes to
REAR, FOOT, FOOT and DEFRSOT, and
each mode
DEFROST.
Circuit diagram related to vent (mode) changeover
80-71
a Servomotors are common.
PC800, 850-8E0
80-71
Air conditioner
Troubleshooting for FRESH/RECIRC air changeover

Failure
80-72
FRESH/RECIRC air cannot be changed over

q
When FRESH/RECIRC air selector switch of machine monitor is operated, recirculated or fresh air
does not change over.
(FRESH/RECIRC air changeover door (damper) does not rotate)
q FRESH/RECIRC air changeover is not checked with self-diagnosis function.
q Referring toTesting FRESH/RECIRC air changeover, operate FRESH/RECIRC air selector
switch and check that there is not mechanical trouble (coming off or interference of link, etc.) in
FRESH/RECIRC air changeover door.
Related inforq Operating angle of FRESH/RECIRC air changeover servo motor is 90.
mation
Problem on
machine
Cause
a Since connector [7] is located at the bottom of air controller unit, check it on
the air conditioner controller side.
2. Disconnect connectors [1] and [2] and insert the T-adapter on the wiring
harness side.
Defective FRESH/RECIRC air
3.
Perform
troubleshooting without turning starting switch ON.
changeover servo motor (unit test)
1
Between
connector
[1] (wiring harness side) (6) and
or defective air conditioner wiring
400
connector
[2]
(wiring
harness side) (19)
Resistance
harness
3000 z
(There must not be open circuit or short circuit.)
connector [2] (wiring harness side) (20)
Resistance
(There must not be open circuit or short circuit.)
2
Defective air conditioner wiring

harness
400
3000 z
a When test result for cause 1 is abnormal, perform following procedure.

1.
2.
3.
4.
4
5

Operate FRESH/RECIRC air selector switch on air conditioner operation
screen, and prepare by setting RECIRC.
5. Operate FRESH/RECIRC air selector switch on air conditioner operation
screen, and set to FRESH.
a Voltage will be output between connectors [1] (6) and [2] (20) for approximately 3 seconds (only while door moves to the fresh-air position).
Defective control amplifier or
Approx. 24
defective FRESH/RECIRC air
Voltage
(-)
V
changeover servo motor
See1. 3. above.
screen, and prepare by setting FRESH.
screen to RECIRC.
a Voltage will be output between connectors [1] (6) and [2] (20) for approximately 3 seconds (only while door moves to the fresh-air position).
Approx. 24
Voltage
(-)
V
a When test result for cause 1 is abnormal and that for cause 2 is normal.
Defective FRESH/RECIRC air
(If all test results for causes 1, 2 and 3 are normal, cause may be mechanchangeover servo motor
ical trouble such as hitch.)
a When test result for cause 1 is normal and that for cause 2 is normal and
Defective air conditioner controller
that for cause 3 is abnormal, air conditioner controller is defective.
(defective switch)
Display of Recirc/Fresh
Press FRESH/RECIRC air selector switch.
changes.
80-72
PC800, 850-8E0
Air conditioner
Circuit diagram related to FRESH/RECIRC air changeover
PC800, 850-8E0
80-73
80-73
Air conditioner
Troubleshooting for temperature sensor system
80-74
Air is not cooled or automatic air conditioner mode does not operate due to the failure of temperature sensor system.
q Air conditioner does not operate even when its activation switch is pressed, or automatic air
Problem on machine
conditioner mode does not operate even when the AUTO switch is pressed.
q There are two types of temperature sensors: evaporator temperature sensor and inside air
temperature sensor.
q Referring to "Test with self-diagnosis function", perform troubleshooting if either of the following two abnormalities is found. Abnormality of ventilating sensor (evaporator temperature
Related information
sensor) or abnormality of inner sensor (inside air temperature sensor).
q Troubleshooting for inside air temperature sensor connector is not possible, when it is mounted on the machine.
q For each connector and other parts, see "Parts and connectors layout".
Failure
Cause

2. Disconnect connectors [1] and [2] from air conditioner controller, and
Defective evaporator temperature
connect T-adapter to each connector on the wiring harness side.
1 sensor or open circuit in wiring har- Between connector [1] (12) and conApprox.
0 C
Resistance
ness
nector [2] (27)
4.8 kz
Approx.
(Resistance of evaporator temperature
15 C
Resistance
2.3 kz
sensor)
2. Disconnect connectors [1] and [2] from air conditioner controller, and
Defective inside air temperature
connect T-adapter to each connector on the wiring harness side.
2 sensor or open circuit in wiring har- Between connector [1] (11) and conApprox.
0 C
Resistance
ness
nector [2] (27)
1.6 kz
Approx.
(Resistance of inside air temperature
25 C
Resistance
5 kz
sensor)
4 Defective air conditioner controller If cause is not found by above checks, air conditioner controller is defective.
Circuit diagram related to temperature sensor system
80-74
80-74
PC800, 850-8E0
Air conditioner
PC800, 850-8E0
80-75
Air conditioner
Troubleshooting with gauge pressure

Perform troubleshooting according to the high and
low gauge pressures of the cooling cycle. For details, see "Connection of service tool".
a The gauge pressure varies largely with the
weather condition and operating condition of the
machine. Check the gauge pressure under the
pressure measurement conditions.
q High-pressure line pressure is too high: Above
approx. 2.5 MPa {25 kg/cm2}
q High-pressure line pressure is too low: Below
approx. 1 MPa {10 kg/cm2}
q Low-pressure line pressure is too high: Above
approx. 0.3 MPa {3 kg/cm2}
q Low-pressure line pressure is too low: Below approx. 0.05 MPa {0.5 kg/cm2}
a Dual pressure switch turns "OFF" to protect the
air conditioner circuit if the pressure of the
high-pressure or low-perssure line is abnormal.
80-76
<Measurement condition for pressure>

Item
Condition value
Ambient temperature
25 50 C
Engine speed
1,500 rpm
Air conditioner switch
ON
Fan switch
HI
Set temperature
Full cool
Dual pressure switch

a The swiths is normally "ON", and becomes
"OFF" when it detects abnormal pressure for
compressor operation.
LA: 0.20 MPa {2 kg/cm2}

LB: 0.02 MPa {0.2 kg/cm2}
HA: 3.14 MPa {32 kg/cm2}
HB: 0.59 MPa {6 kg/cm2}
80-76
PC800, 850-8E0
Air conditioner
Indicated gauge
pressure
Pressure is normal
Cause
Check method
Air conditioner cycle is operating normally.

If there is any trouble (cooling trouble), there is another cause.
High-pressure: Approx. 1.5 - 1.7 MPa {15 - 17 kg/cm2}
Low-pressure: Approx. 0.13 - 0.2 MPa {1.3 - 2.0
Remedy
kg/cm2}
Collect refrigerant, then

Bubble can be seen through sight glass. *1, fill up with proper quanInsufficient refrigerant
*3
tity of refrigerant again
*2
There is a temperature difference between
Replace
Clogging of receiver drier
inlet and outlet pipes of receiver drier.
*2
Tank is frosty
Clean or replace
Both high-pressure Clogging of expansion valve
Expansion valve is frosted
*2
and low-pressure
Gas leakage at thermoprobe of expanReplace
Low-pressure gauge reads vacuum
are too low>
sion valve
*2
Repair or replace
Evaporator
is
frozen
Low-pressure gauge
Replace receiver drier
Defective evaporator temperature sensor Flow rate of refrigerant is reduced due to
reads vacuum
or defective contact of sensor (coming off freezing.
fill up with proper quanof mounting clip)
(At Cool Max. and HI speed of fan, later it
becomes not to cold.)
*2
Piping between receiver drier and compressor is clogged or crushed.
Clean or replace
Clogged or crushed piping
If clogged completely, low-pressure gauge
*2
reads vacuum
fill up with proper quanFilling too much with refrigerant
Connect gauge manifold
*2
Clean, repair fins, or
Dirty condenser, clogging or crushing of
repair or replace con<Both high-presDefective cooling of condenser
fins, or defective rotation of cooling fan
denser
sure and low-pres*2
sure are too high>
Improper adjustment of expansion valve
Replace
Bubble can be seen through sight glass. *3
(Valve is opened too wide)
*2
Evacuate and then fill up
with proper quantity of
Air in cycle parts
Bubble can be seen through sight glass. *3
refrigerant again
*2
<High-pressure is
Clean inside of cycle or
Clogged or crushed piping between com- There is a remarkable temperature differtoo high and lowreplace
pressor and condenser
ence across clogged part
pressure is too low>
*2
<High-pressure is
Both high-pressure and low-pressure are
too low and
Defective compressor (Compression
balanced while compressor is in operation. Replace
low-pressure is too trouble of compressor)
Compressor has seized and is extremely
*2
high>
hot.
*1: If refrigerant leaks, compressor oil in the air conditioner circuit always leaks, too. So perform the check
mainly on pipe joints and dirty parts with oil.
*2:
k When replacing a cooling cycle part, see Caution about refrigerant and collect refrigerant. After
replacing it, fill up the air conditioner system with refrigerant again.
*3: Sight glass is on the receiver drier .
PC800, 850-8E0
80-77
Air conditioner
Connection of service tool

Symbol
X
Part number
Part name
799 - 703 - 1200
Service tool kit
a Use the service tool kit for R134a.

Service tool kit X
(1): Gauge manifold
(2): High-pressure charging hose (red)
(3): Low pressure charging hose (blue)
(4): Quick joint for HI side (large diameter)
(5): Quick joint for LO side (small diameter)
80-78
Connect the gauge manifold, hoses and other service tools according to the following procedure.
1. Close high-pressure valve (6) and low-pressure
valve (7) of gauge manifold (1).
2. Connect the red charging hose (2) to the HI side
of the gauge manifold and the blue charging
hose (3) to the LO side.
3. Connect quick joints (4) and (5) to each hose.
4. Connect quick joints (4) and (5) to service valves
(8) and (9) of high- and low-pressure piping
respectively.
(a): As the thread is coarse, care should be taken

with regard to loosening.
80-78
PC800, 850-8E0
Air conditioner
A: From Cab
B: To Condenser
PC800, 850-8E0
80-79
Air conditioner
Precautions for disconnecting and connecting air conditioner piping

Precautions for disconnecting
80-80
k Collect the refrigerant (Air conditioner gas:
R134a) from air conditioner circuit before
disconnecting air conditioner hose to replace air conditioner unit, air conditioner
compressor or receiver drier and so on.
you may lose your sight. And if it touches
your skin, you may suffer from frostbite. Accordingly, put on protective eyeglasses,
gloves and working cloth with long sleeves
while collecting the refrigerant or filling the
air conditioner circuit with the refrigerant.
q
80-80
80-80
Precautions for connecting
q When connecting piping, apply compressor oil
(ND-OIL8) for R134a to its O-rings. (See item 4
of "Handling compressor oil")
Do not apply oil to the threads of a bolt, nut or
union, however.
q Once an O-ring is used, it is deformed and deteriorated. Accordingly, do not reuse it. When removing it, use a soft tool (such as a toothpick) so
that the piping will not be damaged.
q Push in each pipe to the stopper and tighten the
bolt or nut fully with your fingers.
q Be sure to use two wrenches to tighten each nut.
Use one wrench to fix and tighten the nut with
the other wrench to the specified torque (Use a
torque wrench for tightening).
When loosening the air conditioner hose nuts after collecting the refrigerant, be sure to use 2
wrenches. Use one wrench to fix and use the
other one to loosen the nuts.
80-80
PC800, 850-8E0
Air conditioner
Table of tightening torque for refrigerant pipe joint.

Thread size
M6 x 1.0
M16 x 1.5
Tightening torque Nm {kgm}

3.9 to 6.9 {0.4 to 0.7} (Receiver drier and condenser)
8 12 {0.8 1.2} (A/C unit and compressor)
12 15(1.2 1.5)
1. Engine
2. Compressor
3. Condenser
4. Receiver drier
5. Air conditioner unit
PC800, 850-8E0
80-81
Air conditioner
Handling of compressor oil

1. Compressor oil management (DENSO:
ND-OIL8 for R134a)
80-82
Although compressor oil differs from engine oil in

that it does not need regular checking or filling, the
following types of problem can occur if the amount
in the system is too high or too low.
Condition
Content
Insufficiency of Lubrication trouble and seizure of comoil
pressor
Cooling trouble
Excess of oil
(Excessive oil stick to parts and lower
heat exchange performance)
Accordingly, compressor oil must be filled to the

specified level, similarly to refrigerant.
Refrigerant is potentially hazardous to health

and to the environment. Before disconnecting air conditioner hoses, therefore, refrigerant should be collected in accordance with
"Precautions for connecting air conditioner
piping."
a If oil for CFC-12 (R-12) is used, lubrication trouble will occur and the compressor may be broken
or seized.
Be sure to use an oil suitable for R134a (
DENSO: ND-OIL8).
a Oil for use with R134a is extremely hygroscopic,
and therefore, the cap must be immediately
closed after use to limit contact with air.
Store the oil can in a dry and ventilated place.
a Precautions for using oil
Do not allow oil for use with R134a to come into
contact with acrylic plastic or polystyrene
surfaces (except a baked finish) as it may
dissolve these plastics.
Check compressor oil in the following cases, and
then add new oil if necessary.
q When much refrigerant is discharged because of
leakage.
q When the compressor is troubled and replaced.
(See 3 below)
q When a cycle parts such as condenser, receiver
drier, evaporator unit, etc. is replaced.
q
Quantity of oil to be added when cycle part is replaced

Air conditioner part
Air conditioner unit, evaporator
Condenser
Receiver drier
Hose (Compressor Cab)
Hose (Compressor Condenser)
Hose
(Condenser Receiver dryer)
Hose (Cab Receiver drier)
80-82
80-82
2. Filling compressor oil

80-82
Quantity to be
added (cc)
Approx. 40
Approx. 40
Approx. 20
Approx. 50
Approx. 45
Approx. 30
Approx. 20
PC800, 850-8E0
Air conditioner
3. Replacement of compressor
q
80-83
In case of compressor seizure or breakage.

Metal chips will circulate through the air conditioner circuit and contaminate the compressor oil
extremely.
In this case, flush the air conditioner circuit and
replace the compressor and receiver drier.
The compressor oil is removed from the air
conditioner circuit by flushing. Accordingly,
install a new compressor with the oil of the specified quantity (180 cc) filled in it.
4. Applying compressor oil to O-rings
80-83
Whenever connecting piping or hoses, the compressor oil (ND-OIL8) must be applied to O-rings in
order to prevent the leakage of refrigerant.
Other cases
a New compressor contains compressor oil of 180
cc in it.
1) Prepare an oil container and drain oil from
the old compressor.
2) Measure the quantity of the drained oil with a
measuring cylinder, and note the quantity or
mark the level.
3) Drain below-mentioned quantity of oil from

the new compressor.
Quantity to be drained= 180 cc - "Noted
quantity"
Example: If 30 cc was drained from the
removed compressor, the quantity to be
drained from the new compressor would be
150 cc (i.e., 180 - 30 cc).
PC800, 850-8E0
80-83
Air conditioner
80-84
PC800, 850-8E0
SEN0527633-00
90-1
PC800, 850-8E0
HYDRAULIC EXCAVATOR
PC800-8E0
PC850SE-8E0
PC800LC-8E0
PC800SE-8E0
PC850-8E0
Shop Manual
Machine model
Serial number
Machine model
Serial number
PC800-8E0
PC800LC-8E0
PC800SE-8E0
PC850-8E0
65001 and up
65001 and up
65001 and up
65001 and up
PC850SE-8E0
65001 and up
PC800, 850-8E0
9-01
90-1
90-1
Contents
Contents
90-2

Hydraulic circuit diagram.........................................................................................................
Symbols used in hydraulic circuit diagrams .........................................................................
Hydraulic circuit diagram......................................................................................................
Electrical circuit diagram .........................................................................................................
Symbols used in electric circuit diagrams ............................................................................
Electrical circuit diagram ......................................................................................................
90-2
90- 3
90- 3
90- 7
90- 11
90- 11
90- 15
PC800, 850-8E0

Symbols used in hydraulic circuit diagrams
90-3
90-3
(Rev. 2010/03)
PC800, 850-8E0
90-3

90-4
PC800, 850-8E0

PC800, 850-8E0
90-5

90-6
PC800, 850-8E0
Hydraulic circuit diagram (1/2)

PC800, 850-8E0

PC800,850-8E0
a This figure covers the equipment and devices that are unavailable as optional items in some areas.
PC800, PC850-8E0
90-7

PC800, 850-8E0

PC800,850-8E0
PC800, PC850-8E0
90-8
90-9
Electrical circuit diagram

Symbols used in electric circuit diagrams
90-1
90-1
(Rev. 2010/03)
PC800, 850-8E0
90-11

90-12
PC800, 850-8E0

PC800, 850-8E0
90-13

90-14
PC800, 850-8E0
Electrical circuit diagram (1/6)

PC800, 850-8E0

PC800, 850-8E0
PC800, PC850-8E0
90-15

PC800, 850-8E0

PC800, 850-8E0
PC800, PC850-8E0
90-16
90-17

PC800, 850-8E0

PC800, 850-8E0
PC800, PC850-8E0
90-17
90-19

PC800, 850-8E0

PC800, 850-8E0
PC800, PC850-8E0
90-18
90-21

PC800, 850-8E0

PC800, 850-8E0
PC800, PC850-8E0
90-19
90-23

PC800, 850-8E0

PC800, 850-8E0
PC800, PC850-8E0
90-20
90-25
Electrical circuit diagram (1/6) L/S SPEC

PC800, 850-8E0

PC800, 850-8E0
This figure covers the equipment and devices that are unavailable as optional items in some areas.
PC800, PC850-8E0
90-27

PC800, 850-8E0

PC800, 850-8E0
PC800, PC850-8E0
90-28
90-29

PC800, 850-8E0

PC800, 850-8E0
PC800, PC850-8E0
90-29
90-31

PC800, 850-8E0

PC800, 850-8E0
PC800, PC850-8E0
90-30
90-33

PC800, 850-8E0

PC800, 850-8E0
PC800, PC850-8E0
90-31
90-35

PC800, 850-8E0

PC800, 850-8E0
PC800, PC850-8E0
90-32
90-37
Electrical circuit diagram (1/5) KAL SPEC

PC800, 850-8E0

PC800, 850-8E0
PC800, PC850-8E0
90-39

PC800, 850-8E0

PC800, 850-8E0
PC800, PC850-8E0
90-40
90-41

PC800, 850-8E0

PC800, 850-8E0
PC800, PC850-8E0
90-41
90-43

PC800, 850-8E0

PC800, 850-8E0
PC800, PC850-8E0
90-42
90-45

PC800, 850-8E0

PC800, 850-8E0
PC800, PC850-8E0
90-43
90-47
Index
Index
A
Accumulator
10-103
Adjusting mirrors
30-72
30-55
30-12
80-4
80-15
80-10
50-153
B
Before starting troubleshooting for hydraulic and
mechanical systems
40-410
30-24
30-68
C
Carrier roller
60-16
Center swivel joint
10-76, 60-34
30-30
40-9
Circuit diagram and arrangement of connector pins 80-22
Classification and procedures for troubleshooting 40-35
50-6
Compressor
80-16
Condenser
80-17
80-6
80-78
40-61
40-50
Control valve
10-60, 60-26
Conversion table
00-48
Cooling fan motor
10-53, 60-24
Cooling fan pump
10-44
Cooling system
10-6
Coupling
10-3, 60-3
10-4
D
80-26
50-125
Disassembly and assembly of center swivel joint
50-162
assembly
Disassembly and assembly of final drive assembly 50-97
50-180
Disassembly and assembly of hydraulic cylinder
50-173
assembly
Disassembly and assembly of idler adjustment cylinder
50-119
assembly
50-116
50-111
50-84
50-122
50-89
PC800, 850-8E0

50-129
50-170
Disassembly and assembly of work equipment PPC valve
50-168
assembly
Drain oil filter
10-110
E
40-339
40-344
E-3 When starting switch is turned to ON position,
40-348
machine monitor displays nothing
E-4 When starting switch is turned to ON position (before
starting engine), basic check monitor lights up.
40-351
40-352
40-354
E-7 Engine coolant temperature gauge does not indicate
40-355
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
40-360
displayed
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
40-363
40-364
40-365
E-18 When starting switch is turned OFF, service meter is
40-365
not displayed
E-19 Service mode cannot be selected
40-365
E-20 Any of work equipment, swing and travel do not
40-366
operate or cannot be locked
E-21 Machine push-up function does not operate or
cannot be canceled
40-368
40-370
40-372
40-374
E-25 Travel alarm does not sound or does not stop
40-378
sounding
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
40-384
monitoring function
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
Index
E-31 Bucket DUMP indicator is not displayed properly

with monitoring function
40-390
E-32 Swing indicator is not displayed properly with
40-392
monitoring function
E-33 "L.H. travel" is not displayed properly with monitoring
40-394
function
E-34 "R.H. travel" is not displayed properly with
monitoring function
40-396
E-35 "Attachment" is not displayed properly with
40-398
monitoring function
40-400
40-402
40-403
40-406
10-121
90-15
10-59
Engine control
10-111
00-17
F
40-103
40-104
Failure code [989N00] Engine Controller Lock Caution 3
40-104
40-105
40-106
40-108
40-109
40-110
40-112
40-114
40-116
40-118
40-120
Failure code [CA1228] EGR Valve Servo Error 1 40-192
40-122
Failure code [CA131] Throttle Sensor High Error 40-124
Failure code [CA132] Throttle Sensor Low Error 40-126
40-128
40-130
40-132
40-134
40-136
40-138
Failure code [CA1625] EGR Valve Servo Error 2 40-193
40-194

40-196
40-198
40-199
40-200
40-202
40-204
40-140
40-206
40-208
40-142
40-144
Failure code [CA2249] Rail Press Very Low Error 40-209
40-146
40-210
40-212
40-147
40-214
40-216
40-148
40-218
40-220
40-150
40-152
40-154
40-155
40-156
40-157
40-158
40-160
40-162
40-164
40-166
40-168
40-170
Failure code [CA351] Injectors Drive Circuit Error 40-171
PC800, 850-8E0
Index

40-172
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
40-176
40-178
40-180
40-181
40-182
40-186
40-188
40-189
40-190
40-222
40-224
40-226
40-228
40-230
40-232
40-234
40-236
40-238
Failure code [DA2RMC] CAN Discon (Pump Con
40-240
Detected)
40-244
Failure code [DAF8KB] Camera Power Supply Short
40-246
Circuit
40-248
40-249
40-254
40-256
Failure code [DH25KA] L Jet Sensor Open Circuit 40-258
Failure code [DH25KB] L Jet Sensor Short Circuit 40-260
40-262
Failure code [DH26KB] R Jet Sensor Short Circuit40-264
40-266
40-268
PC800, 850-8E0

40-270
40-272
Failure code [DV20KB] Travel alarm short circuit 40-274
40-276
40-278
40-280
40-282
40-284
40-286
40-288
40-290
Failure code [DW7JKA] Bottom Dump Priority Sol Open
40-292
Circuit
Failure code [DW7JKB] Bottom Dump Priority Sol Short
Circuit
40-294
40-296
40-298
40-300
40-302
40-304
40-306
40-308
40-310
40-312
40-314
40-316
40-320
40-322
40-324
40-326
40-330
Failure code [DY2FMA] Upper Wiper Working
40-334
Abnormality
Failure code [DY2GKM] Wiper Select Abnormality40-336
Failure codes table
40-38
Final drive
10-13, 60-8
Fuse locations
40-100
Index
H
H-1 All of work equipment, swing and travel work slow or
lack power
40-416
40-418
H-3 Any of work equipment, swing and travel does not
40-420
work
40-422
40-423
40-425
40-426
40-427
H-9 Arm does not move
40-427
H-10 Bucket does not move
40-427
40-428
40-430
40-431
H-14 Machine push-up function does not work or is not
40-431
released
H-15 Boom shockless function does not work or is not
40-431
canceled
H-16 Machine deviates in one direction against operator's
intention when travelling
40-432
40-435
H-18 Machine deviates significantly during combined
operation
40-436
40-437
40-438
40-439
40-440
40-441
H-24 In combined operation with work equipment, swing
40-442
speed is low or swing acceleration is poor
H-25 Upper structure overruns excessively when it stops
40-444
swinging
40-445
H-27 Large unusual noise is heard when upper structure
stops swinging
40-446
40-447
H-29 Fan revolution is abnormal (Fan sound/vibration is
40-448
abnormally large or engine overheats)
30-18
80-82
00-24
00-19
30-117
50-4
00-34
00-15
90-7
10-18
Hydraulic cylinder
60-48
Hydraulic pump
10-22
10-20
I
Idler
Idler cushion
60-14
10-16
40-46,80-52

40-414
30-58
30-71
K
KOMTRAX system
10-194
L
Line oil filter
10-108
00-44
M
30-60
30-61
30-62
Measuring fan speed
30-59
30-63
Measuring outlet pressure of solenoid valve, swing PPC
30-50
shuttle valve, and swing priority selector valve
Method of disconnecting and connecting push-pull type
coupler
00-21
40-450
Monitor system
10-160
O
80-7
P
80-28
Pilot oil filter
10-109
Pm clinic service
30-122
40-7
Precautions for disconnecting and connecting air
80-80
conditioner piping
Power train
10-8
PPC valve
10-87, 60-35
80-3
00-37
30-118
80-20
Pump control system
10-30
Q
Quick return valve
10-104
R
Receiver drier
80-18
30-19
30-67
Removal and installation of aftercooler assembly 50-35
50-229
50-198
50-185
50-202
PC800, 850-8E0
Index

50-189
Removal and installation of boom damping valve
50-167
assembly
Removal and installation of bottom dump cylinder
50-193
assembly
50-195
50-181
Removal and installation of carrier roller assembly50-124
50-160
50-150
50-29
50-147
50-134
Removal and installation of counterweight remover
50-135
assembly
50-51
50-232
50-70
50-72
Removal and installation of engine, PTO and hydraulic
50-21
pump assembly
50-39
50-222
Removal and installation of fuel cooler and air condenser
50-37
assembly
Removal and installation of fuel injector assembly 50-67
50-46
50-44
50-137
Removal and installation of idler assembly
50-115
50-238
Removal and installation of main pump assembly 50-139
Removal and installation of main pump input shaft oil seal
50-146
50-234
50-210
Removal and installation of operator's cab glass (adhered
50-213
window glass)
50-77
50-236
50-120
50-132
50-165
Removal and installation of swing circle assembly 50-96
Removal and installation of swing motor and swing
50-86
machinery assembly
PC800, 850-8E0

50-159
Removal and installation of track roller assembly 50-128
Removal and installation of travel motor assembly50-164
50-206
Return oil filter
10-107
S
40-454
40-456
40-460
40-461
40-462
40-464
40-466
S-8 Oil consumption is excessive (or exhaust smoke is
40-468
blue)
40-469
40-470
S-11 Oil is in coolant (or coolant spurts or coolant level
goes down)
40-471
40-472
40-474
40-476
40-477
40-478
Safety notice
00-10
10-41
Sensors
10-190
50-109
40-8
Servo valve
10-32
50-16
Solenoid valve
10-95
30-73
Special tools list
50-9
Specifications
01-8
01-4
Sprocket
60-10
00-40
20-3
20-4
10-69
Swing circle
10-10, 60-4
Swing machinery
10-11, 60-5
Swing motor
10-72, 60-32
90-11
90-3
40-43
System diagram
80-24
T
40-97
01-26
Table of weight
01-18
80-46
80-31
Testing and adjusting air conditioner compressor belt
30-28
tension
Index

30-27
Testing and adjusting control circuit oil pressure (output
30-37
pressure of self-pressure reducing valve)
Testing and adjusting control signal of main pump 30-39
Testing and adjusting oil pressure in work equipment,
30-31
swing, and travel circuits
30-56
30-15
30-13
30-17
30-16
30-7
80-43
30-10
30-9
80-40
30-26
30-20
30-21
80-42
30-8
30-46
Testing relays
80-47
80-45
30-29
80-35
80-37
80-32
30-3
Track frame
10-14
60-12
Track roller
60-18
Track shoe
60-20
Travel motor
10-77
80-48
80-50
Troubleshooting for blower motor system (No air comes
80-63
out or air flow is abnormal)
Troubleshooting for compressor and refrigerant system
(Air is not cooled)
80-59
80-72
Troubleshooting for power supply and CAN
communication system (Air conditioner does not operate)
80-54
80-67
80-74
80-70
Troubleshooting method for open circuit in wiring harness
40-48
of pressure sensor system
80-76
U
30-129
W
Work equipment
60-38
60-44
PC800, 850-8E0
PC800-8E0, PC800LC-8E0, PC800SE-8E0, PC850-8E0, PC850SE-8E0 HYDRAULIC EXCAVATOR

Form No. SEN05276-03
2012 KOMATSU
All Rights Reserved
Printed in Japan 02-12

Komatsu PC800LC - 8

Загружено:

Сведения о документе

Оригинальное название

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

Komatsu PC800LC - 8

Загружено:

Авторское право:

Доступные форматы

SEN05276-03

Page to be newly added

List of revised pages

00 Index and foreword

00 Index and foreword

10 Structure and function

PPC valve ............................................................................................................................

20 Standard value table

30 Testing and adjusting

Inspecting locations of hydraulic drift in work equipment.....................................................

Failure code [CA154] Chg Air Temp Sensor Low Error.......................................................

Failure code [D163KB] Flash Light Relay Short Circuit .......................................................

E-2 Preheater does not operate .......................................................................................... 40- 344

Removal and installation of fuel injector assembly ..............................................................

Removal and installation of front window assembly ............................................................

Testing inner sensor ............................................................................................................ 80- 42

Foreword and general information

Foreword and general information

Important safety notice

7) If welding repairs are needed, always have a

Foreword and general information

5) When raising a heavy component (heavier

Foreword and general information

12)When assembling or installing parts, always

7) Limit the hanging angle to 60 degree, as a

8) When installing wire ropes to an angular

Foreword and general information

11)Do not use twisted or kinked wire ropes.

4) Check the direction indicator plates (east,

a The allowable load is one-sixth of the

Foreword and general information

Foreword and general information

How to read the shop manual

1. Composition of shop manual

Foreword and general information

2. Revision and distribution

Special technical precautions or other precautions for preserving standards which

Weight of parts of component or parts are indicated. Caution necessary when

Foreword and general information

Explanation of terms for maintenance standard

When some parts are repaired, the value of

a The tolerance may be indicated in the text

2. Standard clearance and standard value

Foreword and general information

4. Repair limit and allowable value or allowable

Foreword and general information

Handling of hydraulic components

4. Preventing intrusion of foreign materials

Foreword and general information

5. Replacing hydraulic oil while its temperature is high

Foreword and general information

Method of disconnecting and connecting push-pull type coupler

Foreword and general information

Foreword and general information

Foreword and general information

Handling of electric equipment

2. Main failures occurring in wiring harnesses

Foreword and general information

4) High-pressure water entering connector

Foreword and general information

3. Removing, installing, and drying connectors

When removing a connector from a

3] Action to take after removing connectors