Komatsu Excavadora Pc800

GEN00048-05
Field Assembly Instruction
HYDRAULIC
EXCAVATOR
PC800
-8
PC800LC -8
PC800SE -8
PC850
-8
PC850SE -8
SERIAL NUMBERS
PC800- 50001
PC800LC- 50001
PC800SE- 50001
PC850- 10001
PC850SE- 10001
and up
When the work equipment is installed, the engine must be operated.

Accordingly, before installing the work equipment, inspect and maintain the machine thoroughly.
Note that this manual does not describe the whole specification of the machine but describes only the basic
specification.
If you have any question when dividing and transporting the machine by yourself in future, ask one of our
distributors.
CONTENTS
Specifications......................................................................................................................
1
Precautions for Field Assembly ..........................................................................................
2
Disposal of Removed Parts ................................................................................................
3
Assembling Procedures, Applicable Equipment and Schedule ..........................................
4
Kit Layout Diagram ............................................................................................................. 5
Transportation.....................................................................................................................
6
List of Tools for Field Assembling....................................................................................... 12
Tightening Torque............................................................................................................... 13
Coating Materials................................................................................................................ 17
A. Assembly of Chassis ......................................................................................................
A- 1. Installation of Left and Right Track Frames ...........................................................
A- 2. Installation of Travel Pipe ......................................................................................
A- 3. Installation of Top Guard .......................................................................................
A- 4. Installation of Radiator Cover ................................................................................
A- 5. Installation of Rearview Mirror ...............................................................................
A- 6. Installation of Left Side Step ..................................................................................
A- 7. Installation of Handrail ...........................................................................................
A- 8. Installation of Handrail (With top guard) ................................................................
A- 9. Installation of Muffler Tail Tube..............................................................................
A-10. Sticking Sheet to Counterweight ...........................................................................
A-11. Installation of Counterweight .................................................................................
A-12. Installation of KOMTRAX Antenna (if equipped) ...................................................
A-13. Installation of Step Light ........................................................................................
A-14. Air Bleeding of Travel Motor ..................................................................................
A-15. Installation of Travel Piping Cover.........................................................................
A-16. Testing Track Shoe Tension..................................................................................
A-17. Check Fuel, Coolant and Oil Levels ......................................................................
A-18. Parts to be Touched up after Field Assembly........................................................
19
20
24
27
28
29
33
34
35
37
38
39
40
41
43
44
46
49
51
B. Assembling of Work Equipment of Backhoe ..................................................................

B- 1. Assembly of Arm Cylinder .....................................................................................
B- 2. Connection of Arm Cylinder Hoses........................................................................
B- 3. Installation of Boom Cylinder Foot.........................................................................
B- 4. Relieving Remaining Pressure from Hydraulic Circuit ...........................................
B- 5. Installation of Boom Cylinder Hoses......................................................................
B- 6. Installation of Boom Foot Dust Seal ......................................................................
B- 7. Assembly of Boom Assembly ................................................................................
B- 8. Hose Connection of Arm and Bucket Circuits........................................................
B- 9. Installation of Quick Return Hose ..........................................................................
B-10. Installation of Boom Cylinder.................................................................................
B-11. Installation of Arm Assembly .................................................................................
B-12. Installation of Hose between Boom and Bucket Cylinder......................................
B-13. Installation of Bucket Assembly.............................................................................
B-14. Lubrication Piping to Work Equipment ..................................................................
B-15. Wiring of Work Equipment.....................................................................................
B-16. Greasing after Assembling Work Equipment.........................................................
B-17. Air Bleeding from Hydraulic Cylinder.....................................................................
53
54
55
57
58
59
60
61
62
63
64
65
67
68
69
70
71
72
C. Assembling of Work Equipment of Loading Shovel.....................................................

C- 1. Releasing residual pressure in hydraulic circuit ..................................................
C- 2. Pulling out boom foot pin and boom cylinder foot pin .........................................
C- 3. Installation of boom and arm assembly...............................................................
C- 4. Installation of flushing piping between chassis and boom ..................................
C- 5. Installation of flushing piping for boom cylinder and arm cylinder.......................
C- 6. Installation of flushing piping for bucket cylinder.................................................
C- 7. Installation of flushing piping for bottom dump cylinder ......................................
C- 8. Installation of boom cylinder................................................................................
C- 9. Installation of boom cylinder foot.........................................................................
C-10. Installation of boom cylinder hoses .....................................................................
C-11. Installation of boom cylinder rod pin ...................................................................
C-12. Installation of arm cylinder hoses........................................................................
C-13. Installation of bucket cylinder..............................................................................
C-14. Installation of bucket cylinder hose .....................................................................
C-15. Installation of connecting hoses between chassis and boom top .......................
C-16. Installation of bottom dump cylinder hoses.........................................................
C-17. Installation of bucket assembly ...........................................................................
C-18. Installation of working lamps...............................................................................
C-19. Installation of work equipment grease piping......................................................
C-20. Greasing after assembling of work equipment....................................................
C-21. Bleeding air from work equipment circuit ............................................................
73
74
75
76
77
78
79
80
82
83
84
85
86
87
88
89
90
91
93
94
95
96
D. Assembling of Counterweight Remover ......................................................................

D- 1. Installation of Rubber Cushions ..........................................................................
D- 2. Adjustment of Shims for Counterweight..............................................................
D- 3. Greasing..............................................................................................................
D- 4. Installation of Counterweight Remover ...............................................................
D- 5. Installation of Covers...........................................................................................
D- 6. Installation of Hoses............................................................................................
D- 7. Bleeding Air from Counterweight Remover Circuit..............................................
D- 8. Installation of Counterweight...............................................................................
D- 9. Installation of Accessories...................................................................................
D-10. Check of Operation .............................................................................................
97
98
99
104
105
106
107
110
111
113
114
M. Procedure for Inspection and Maintenance after Completion of Assembly.................

M- 1. Inspection of Oil Level in Hydraulic Tank and Refill............................................
M- 2. Replacement of Return Filter (Standard Filter to Flushing Filter) .......................
M- 3. Flushing of Hydraulic Circuit ...............................................................................
M- 4. Replacement of Return Filter (Flushing Filter to Standard Filter) .......................
M- 5. Error Code ..........................................................................................................
115
116
118
119
121
123
Field Assembly Inspection Report (Backhoe)

Field Assembly Inspection Report (Loading Shovel)
SPECIFICATIONS
Machine model
Weight of machine
Bucket capacity
Engine model
kg
3
PC800-8
PC800LC-8
PC800SE-8
PC850-8
PC850SE-8
75,000
77,200
76,000
79,500
79,100
3.1
3.1
4.0
3.4
4.3
SAA6D140E-5
Flywheel horsepower
kW/rpm {HP/rpm}
363/1,800 {486/1,800}
Min. ground clearance
mm
840
Travel speed (Low/High)
km/h
2.8/4.2
Swing speed
rpm
6.8
PC800-8
aThe figures in (
) show the value when the track width is reduced.
aThe figures in (
) show the value when the track width is reduced.
PC850-8
PRECAUTIONS FOR FIELD ASSEMBLY y

1. Selection of work place
1) When selecting a work place, consider the following.
Is the work place sufficiently wide for loading and unloading the machine? (See the kit layout drawing.)
Is the ground sufficiently hard? (The machine and crane truck must not sink into the ground.)
Is the ground flat? (The ground surface must not be uneven or sloping.)
Is the road to inlet/outlet of the work place sufficient for turning the trailer and crane truck?
2) Take care extremely that dirt or water will not enter the hydraulic circuit while it is assembled.
3) Avoid working outdoors while strong wind is blowing or it is raining.
4) Take measures to protect the machine from sand, dirt and rainwater while the work is stopped.
2. How to do work
The work supervisor or the work leader should not do the work while reading this manual but should read
and understand this manual thoroughly and then start the work.
In particular, write the "Precautions" for each work process in a sheet to explain or stick that sheet to the
work place so that all the workers will observe the precautions.
3. Preparation and check of protective gear, slings and tools
The work supervisor or the work leader must perform the following checks about protective gear, slings and
tools.
1) Are all the workers wearing helmets and other protective gear which they are obliged to wear?
If special protective gear is necessary, check that it is prepared and can be used without problem.
2) Are all the slings and tools prepared? Check in advance that they are ready to be used without problem. In particular, check wooden blocks for internal decay and cracking.
4. k Check during actual work
The work supervisor or the work leader must check the following items constantly and make all the workers
observe them.
1) Are the parking brakes of the trailer and crane truck applied securely and are their wheels locked with
chocks during work? Are outriggers, if installed, used securely?
2) Are the temperature and pressure of the engine, hydraulic oil, coolant, etc. lowered sufficiently during
work?
3) Is horn or another signal is made to warn around when the engine is started? In addition, is it checked
that work equipment control lever and other control levers are in neutral and the fuel control dial (or fuel
control lever) is in the low idle position?
4) Is the balance of the slung item checked extremely during sling work with the crane?
5) Is entry prohibition for outsiders to the work place observed?
5. The work supervisor or the work leader is required to hold a meeting with all the workers at the beginning of
every morning and explain the work plan of the day to them and give them instructions to observe the safe
work.
DISPOSAL OF REMOVED PARTS

As described in "FOREWORD", when this machine is transported, it is divided into some units such as the body,
undercarriage, cab, work equipment, etc. according to the transportation measure, regulations, etc.
Accordingly, the hydraulic pipings and hydraulic hoses to connect the units, oil inlets and outlets of the hydraulic
devices, and parts which must not be damaged are plugged or covered to prevent oil leakage, entry of dirt and
dust, and damage during transportation.
In addition, fixing jigs are used to prevent a trouble caused by a fall or a shake during transportation and to facilitate
loading, unloading and crane work.
The above plugs, jigs, etc. are removed when the machine is assembled and become unnecessary after
completion of the machine. Since they are useful when the machine needs to be transported in future, however,
we recommend you to keep them as long as possible.
Worker
Air compressor
Crane
Assembly unit
Days
45t
Meeting with all workers
Start of assembling
Leader + 3 mechanics
Min. 1.5 m3/min
Min. 0.7 MPa
45t
(Two)
q Left track frame

w Right track frame
e Axle assembly
Base machine
t Counterweight
y Platform group
Inspection of oil
level and coolant level
Completion of Installation of unit assembly to body
r Upper structure
Completion of body
assembling
25t
Completion of general
assembling
Backhoe Inspection of oil level and

coolant level
Air bleeding from work
equipment cylinder
Loading shovel- Flushing of hydraulic

circuit
type excavator
Adjustment of track
tension
Performance test
u Assembling of work
equipment
ASSEMBLING PROCEDURES,
APPLICABLE EQUIPMENT AND SCHEDULE
4 Divisions
KIT LAYOUT DIAGRAM

The dimensions given below are the minimum dimensions needed.
The kit dimensions in the diagram are outline dimensions.
When selecting a place, see precautions for FIELD ASSEMBLING.
Bucket
Tools, facility
Arm cylinder
Arm link
Boom
Boom
cylinder
45t crane
Motor cover handrails
Revolving
frame
Counterweight
Crawler frame
Crawler frame
Foreword
Left deck
45t crane
TRANSPORTATION
Packing Style for Transportation
These machines can be divided into three or four kits for transportation. Please ask us or our service shop for
transportation.
t 4-kit Transportation
t Packing Style of Each Kit (Sizes in drawing are given in millimeters.)

Upper structure (single piece of cab)
Full width
(mm)
Cab convex portion (air intake for air conditioner)
3,219
Door hinge
3,204
Lock used when the door is opened
3,262
Stopper used when the door is opened
3,287
Handrail
3,220
Upper structure without head guard

Unit: mm
Overall height
(mm)
Overall width
(mm)
Equipped
with cab
Not equipped
with cab
H1: 2,840
H2: 2,840
3,204
3,220
3,262
3,219
e
Weight (kg)
* Revolving frame
*3,195
3,287
25,620
25,080
Equipped
with cab
Not equipped
with cab
H1: 2,910
H2: 2,840
Upper structure with head guard

Unit: mm
Overall height
(mm)
Overall width
(mm)
Fix the upper structure on the truck by means of chain block.
Weight (kg)
* Revolving frame
3,204
3,220
3,262
3,219
3,287
*3,195
25,770
25,180
Undercarriage
Unit: mm
Model
PC800, 800SE
PC850, 850SE-8
Quantity
Weight (kg)
): PC800LC-8
PC800LC-8
2
21,600
(10,800 2)
23,600
(11,800 2)
Work equipment
(1) Boom
Model
PC800-8
PC800LC-8
PC800SE-8
PC850-8
PC850SE-8
A (mm)
8,505
7,405
8,345
7,405
B (mm)
2,705
2,560
2,695
2,560
C (mm)
4,387
4,104
4,295
4,104
D (mm)
1,218
1,098
1,210
1,098
Overall
width (mm)
1,500
1,500
1,500
1,500
Weight
(kg)
7,510
6,950
7,770
6,950
Model
PC800-8
PC800LC-8
PC800SE-8
PC850-8
PC850SE-8
A (mm)
5,105
4,075
4,800
4,075
B (mm)
1,324
1,696
1,410
1,696
C (mm)
2,459
2,237
2,478
2,237
D (mm)
577
709
648
709
Overall
width (mm)
749
753
749
753
Weight
(kg)
3,970
4,880
4,485
4,880
Model
PC800-8
PC800LC-8
PC800SE-8
PC850-8
PC850SE-8
A (mm)
2,365
2,200
2,390
2,200
B (mm)
1,850
1,950
1,880
1,950
C (mm)
1,052
889
1,118
889
D (mm)
646
714
599
714
Overall
width (mm)
1,845
2,105
1,870
2,255
Weight
(kg)
2,960
3,420
3,840
4,245
(2) Arm
(3) Bucket
(4) Boom cylinder (for all models)
Weight: 1,550 kg
(775 kg 2 pcs)
(5) Arm cylinder
Model
PC800-8
PC800LC-8
PC800SE-8
PC850-8
PC850SE-8
Quantity
A (mm)
3,500
2,590
B (mm)
1,885
1,391
Weight
(kg)
870
986 (493 2)
Others
(1) Counterweight
Unit: mm
Model
PC800-8
PC800SE-8
PC850-8
PC850SE-8
PC800LC-8
(If equipped)
A (mm)
451
451
451
B (mm)
1,689
1,689
1,689
C (mm)
684
684
684
Weight
(kg)
9,800
11,850
9,800, 11,850
(13,600)
(2) Top guard (PC850-8, PC850SE-8 only)

Unit: mm
Weight: 55 kg
(3) Catwalk (1) (for all models)

Unit: mm
Weight: 50 kg
(4) Catwalk (2) (for all models)

Unit: mm
Weight: 30 kg
10
(5) Radiator duct (for all models)

Unit: mm
Weight: 81 kg
(6) Travel motor cover (for all models)
Weight: 120 kg 2
11
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Tool names
Engine compressor
Crane truck
Grease pump
Stepladder
Impact wrench
Socket for KW45FS

Air hose
16-time wrench
Socket for 16-time wrench
Tool
No.
1
Equipment
LIST OF TOOLS FOR FIELD ASSEMBLING
4-time wrench
Socket for 4-time wrench
Torque wrench
Standard tool
Sledge hammer
Bar
Hydraulic jack
25
Specifications
Min. 0.7 MPa, 15m3/min
45 ton
25 ton
Air type
5 -stepped- 1500 mm
KW10P (for M10)
KW12PI (For M12)
KW20P (For M16)
KW45FS (Spline)
Spline 65 mm
50 m
4413 Nm {450 kgm}
T38.1 65 mm
T38.1 55 mm
T38.1 50 mm
25.4, 19
T25.4 50 mm
T25.4 55 mm
412 Nm {42 kgm} T25.4 mm
834 Nm {85 kgm} T25.4 mm
4118 Nm {420 kgm} T38.1 mm
Socket, spanner, wrench
10 P
1m
490 kN {50 ton} (stroke 170)
196 kN {20 ton}
Waste oil pan
Large, small
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
Wooden block
Wire rope sling
300 400 mm
10 3000 mm
20 5000 mm
25 5000 mm
30 5000 mm
SD30
SC18
50 mm wide 3000 mm
50 500 mm
14.7 29.4 kN {1.5 3 ton}
M16
M12
Brake cleaner
EO-10
G2-LI
Natural yellow
Black gray
Bundle
Oil and
grease
Lifting tool
26
Shackle
Synthetic fiber sling
Pin
Lever block
Eyebolt
Detergent liquid
Hydraulic oil
Grease
Repair paint
Waste cloth
12
Qty.
1
2
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2 set
1
2
2
Remarks
1st day
2nd day
Work equipment lubrication
For counterweight
For counterweight
For impact wrench
For counterweight
For counterweight
For track frame
For track frame
For 16-time wrench

For 4-time wrench
For counterweight and track frame
Revolving frame pedestal

When
tightening track frame
1
connecting bolts.
When connecting travel and
2 each work equipment piping
4
Revolving frame pedestal
2
For catwalk
2
For boom, arm and bucket
4
For revolving frame and track frame
2
For counterweight
3
4
2
For boom cylinder and arm cylinder
2
Track frame
2
1
2
10
300 l
20 kg Work equipment lubrication
5
5
20 kg
TIGHTENING TORQUE
1. Tightening torque for bolts
Tightening torque for bolts is indicated in the text as shown below. Tighten each bolt to the specified
torque.
Part No. of bolt
TTTTT-TTTTT
Part No. of washer
ThreadEEEEE-EEEEE
size (Diameter, pitch, length)
Bolt specification
Thread diameter Bolt length
Tool (Socket)
Applicable socket size
Tightening torque
Nm {QQQ kgm}
If tightening torque for a bolt is not specified in the text, tighten it according to Table 1.
Remarks
1. The thread diameter is the nominal diameter. For example, 16 mm is expressed as M16 and 26
mm is expressed as M20.
The pitch in Table 1 is the distance that the bolt advances every turn in the axial direction (Unit:
mm).
2. The bolt length is dimension c in Fig. 1.
3. The applicable socket size is expressed as 24 mm, 30 mm, etc. Since 24 mm, 30 mm, etc. correspond to dimension b in Fig. 1, an applicable socket can be selected from Table 1, too.
4. Tightening torque is expressed as QQQ www or QQQ RR. If the target tightening torque
is set, expression of QQQ RR is applied.
Fig. 1
a
b
c
d
: Bolt thread diameter (Nominal diameter)

: Width across flats of bolt head
: Bolt length
: Threaded part of bolt
13
Table 1 Tightening torque for bolts not specified in text

Tightening torque
Nominal size of thread

pitch
a (mm)
Width across flats

(= Socket size)
b (mm)
Unit : Nm
Unit : {kgm}
61
10
11.8 14.7
{1.2 1.5}
8 1.25
13
27 34
{2.8 3.5}
10 1.5
17
59 74
{6 7.5}
12 1.75
19
98 123
{10 12.5}
14 2
22
153 190
{15.5 19.5}
16 2
24
235 285
{23.5 29.5}
18 2.5
27
320 400
{33 41}
20 2.5
30
455 565
{46.5 58}
22 2.5
32
610 765
{62.5 78}
24 3
36
785 980
{80 100}
27 3
41
1150 1440
{118 147}
30 3
46
1520 1910
{155 195}
33 3
50
1960 2450
{200 250}
36 3
55
2450 3040
{250 310}
39 3
60
2890 3630
{295 370}
a For symbols a and b in the table, see Fig. 1.
14
2. Tightening torque for pipe threads

Proper tightening torque for pipe threads depends on combination of the materials of the male screw and
female screw. In this manual, however, select tightening torque from Table 2 and Table 3 on the basis of
the material of the male screw. If tightening torque is specified specially in explanation, however, apply that
tightening torque.
2.1 If the male screw is made of mild steel or cast iron, apply Table 2.
Table 2
Unit: Nm {kgm}
Material of female thread
Steel
Cast iron
Light alloy
1/8
3.9 6.9
{0.4 0.7}
2.9 5.9
{0.3 0.6}
2.0 3.9
{0.2 0.4}
1/4
5.9 11.8
{0.6 1.2}
4.9 9.8
{0.5 1.0}
3.9 7.8
{0.4 0.8}
3/8
16.7 26.5
{1.7 2.7}
13.7 21.6
{1.4 2.2}
9.8 16.7
{1.0 1.7}
1/2
32.3 52.9
{3.3 5.4}
26.5 43.1
{2.7 4.4}
19.6 32.3
{2.0 3.3}
3/4
51.0 85.3
{5.2 8.7}
42.1 70.6
{4.3 7.2}
31.4 52.9
{3.2 5.4}
86.2 173.5
{8.8 17.7}
72.5 146.0
{7.4 14.9}
54.9 111.7
{5.6 11.4}
Nominal size (in)
2.2 If the male screw is made of refined steel (heat-treated hard steel), apply Table 3.
Table 3
Unit: Nm {kgm}
Material of female thread
Steel
Cast iron
Light alloy
1/8
16.7 29.4
{1.7 3.0}
9.8 19.6
{1.0 2.0}
6.9 14.7
{0.7 1.5}
1/4
19.6 44.1
{2.0 4.5}
16.7 37.2
{1.7 3.8}
12.7 28.4
{1.3 2.9}
3/8
44.1 93.1
{4.5 9.5}
37.2 77.4
{3.8 7.9}
27.4 58.8
{2.8 6.0}
1/2
98.0 188.2
{10.0 19.2}
83.3 157.8
{8.5 16.1}
60.8 115.6
{6.2 11.8}
3/4
170.5 316.5
{17.4 32.3}
141.1 247.0
{14.4 25.2}
105.8 186.2
{10.8 19.0}
367.5 612.5
{37.5 62.5}
309.7 514.5
{31.6 52.5}
235.2 392.0
{24.0 40.0}
Nominal size (in)
15
3. Tightening torque for hydraulic hose connecting nut

For the connecting nuts installed to the hydraulic hose adapters in relatively low pressure systems, apply
tightening torque in Table 4.
Table 4
Tightening torque (Nm {kgm})
Outside diameter
of hose
(mm)
Width across
flatse.
(mm)
Range
Target
Approx. 6
19
35 63 {3.5 6.5}
44 {4.5}
22
54 93 {5.5 9.5}
74 {7.5}
24
59 98 {6.0 10.0}
78 {8.0}
Approx. 13
27
84 132 {8.5 13.5}
103 {10.5}
Approx. 16
32
128 186 {13.0 19.0}
157 {16.0}
Approx. 20
36
177 245 {18.0 25.0}
216 {22.0}
Approx. 10
Note : When connecting hoses, take care not to twist them.
4. Proper socket sizes for bolts of M39 and larger (Reference)

For the proper sizes of sockets or spanners (= width across flats) for tightening hexagon bolts of M39 and
larger, see Table 5.
Table 5
Unit: mm
Thread diameter
Proper sizes of sockets or spanners
M42
65
M45
70
M48
75
M52
80
M56
85
M60
90
M64
95
16
COATING MATERIALS
a The recommended coating materials such as adhesives, gasket sealants 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 list.
Category
Komatsu code
Part No.
Q'ty
Container
Main applications, features
LT-1A
790-129-9030
150 g
Tube
Used to prevent rubber gaskets, rubber cushions, and cock plug from
coming out.
LT-1B
790-129-9050
20 g
(2 pcs.)
Polyethylene
container
Used in places requiring an immediately effective, strong adhesive.

Used for plastics (except polyethylene, polyprophylene, tetrafluoroethlene and vinyl chloride), rubber,
metal and non-metal.
LT-2
09940-00030
50 g
Polyethylene
container
Features: Resistance to heat and

chemicals
Used for anti-loosening and sealant
purpose for bolts and plugs.
LT-3
790-129-9060
(Set of adhesive
and hardening
agent)
Adhesive:
1 kg
Hardening
agent:
500 g
Can
LT-4
790-129-9040
250 g
Polyethylene
container
Holtz
MH 705
790-126-9120
75 g
Tube
Used as heat-resisting sealant for repairing engine.
50 g
Polyethylene
container
Quick hardening type adhesive

Cure time: within 5 sec. to 3 min.
Used mainly for adhesion of metals,
rubbers, plastics and woods.
Adhesives
Three bond
1735
790-129-9140
Used as adhesive or sealant for metal, glass and plastic.
Used as sealant for machined holes.
Aron-alpha
201
790-129-9130
2g
Polyethylene
container
Quick hardening type adhesive

Quick cure type (max. strength after
30 minutes)
Used mainly for adhesion of rubbers,
plastics and metals.
Loctite
648-50
79A-129-9110
50 cc
Polyethylene
container
Resistance to heat, chemicals

Used at joint portions subject to high
temperatures.
LG-1
790-129-9010
200 g
Tube
Used as adhesive or sealant for gaskets and packing of power train case,
etc.
LG-5
790-129-9080
1 kg
Can
Used as sealant for various threads,

pipe joints, flanges.
Used as sealant for tapered plugs,
elbows, nipples of hydraulic piping.
Tube
Features: Silicon based, resistance

to heat, cold
Used as sealant for flange surface,
tread.
Used as sealant for oil pan, final
drive case, etc.
LG-6
790-129-9020
200 g
Gasket
sealant
LG-7
790-129-9070
1 kg
Tube
Features: Silicon based, quick hardening type

Used as sealant for flywheel housing, intake manifold, oil pan, thermostat housing, etc.
Three bond
1211
790-129-9090
100 g
Tube
Used as heat-resisting sealant for repairing engine.
Tube
Features: Silicone type, heat resistant, vibration resistant, and impact

resistant sealing material
Used as sealing material for transfer
case
Three bond
1207B
419-15-18131
100 g
17
Molybdenum
disulphide
lubricant
Grease
Primer
Adhesive
Caulking
material
Komatsu code
Part No.
Q'ty
Container
Main applications, features
LM-G
09940-00051
60 g
Can
Used as lubricant for sliding portion

(to prevent from squeaking).
Tube
Used to prevent seizure or scuffling

of the thread when press fitting or
shrink fitting.
Used as lubricant for linkage, bearings, etc.
LM-P
09940-00040
G2-LI
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
SYG2-160LI
SYGA-160CNLI
G2-CA
SYG2-400CA
SYG2-350CA
SYG2-400CA-A
SYG2-160CA
SYGA-160CNCA
Molybdenum
disulphide
grease
LM-G (G2-M)
SYG2-400M
SYG2-400M-A
SYGA-16CNM
Hyper White
Grease G2-T
G0-T (*)
*: For use in cold
district
SYG2-400T-A
SYG2-16CNT
SYG0-400T-A (*)
SYG0-16CNT (*)
Biogrease G2B
G2-BT (*)
*: For high
temperature
and large load
SYG2-400B
SYGA-16CNB
SYG2-400BT (*)
SYGA-16CNBT (*)
200 g
General purpose type

Various
Various
Various
Various
400 g 10 Bellows type

400 g 20 Bellows type
16 kg
Can
400 g
16 kg
400 g
16 kg
Since this grease is decomposed

by bacteria in short period, it has
Bellows type
less effects on microorganisms,
Can
animals, and plants.
20 ml
Glass
container
SUNSTAR
GLASS PRIMER
580 SUPER
20 ml
Glass
container
SUNSTAR
PENGUINE
SEAL 580
SUPER "S" or
"W"
320 ml
Polyethylene
container
Sika Japan,
Sikaflex 256HV
20Y-54-39850
310 ml
Polyethylene
container
SUNSTAR
PENGUINE
SEAL No. 2505
417-926-3920
320 ml
Polyethylene
container
SEKISUI
SILICONE
SEALANT
20Y-54-55130
333 ml
Polyethylene
container
18
Used for heavy load portion
Seizure resistance and heat resistance higher than molybdenum diBellows type
sulfide grease
Can
Since this grease is white, it does
not stand out against machine
body.
SUNSTAR
PAINT PRIMER
580 SUPER
417-926-3910
Used for normal temperature, light

load bearing at places in contact
with water or steam.
Used as primer for cab side

(Expiration date: 4 months)
Used as primer for glass side
Adhesive for cab glass
Category
"S" is used for high-temperature season (April - October)

and "W" for low-temperature
season (November - April) as
adhesive for glass.
Used as adhesive for glass.
Used to seal joints of glass
parts.
Used to seal front window.
A. ASSEMBLY OF CHASSIS
Remarks
1. In the "drawings" in this manual, parts and places are indicated by 1, 2, 3 ---,
but indicated by (1), (2), (3) --- in the tables and texts.
Example:
(1)
(2)
(3)
(4)
(5)
(6)
2.
Plate
Collar
Washer
Bolt
Bolt
Washer
In some places of this manual, the words of front, rear, right hand and left hand
of machine are used. Those words indicate the directions seen from the operator's seat with the sprocket at the rear as shown below, unless otherwise specified.
Front
Front
Operators
Left
hand seat
Right hand
Left hand
Right hand
Operator's seat
Rear
Sprocket
Sprocket
Rear
19
Assembly procedure
A-1
Installation of Left and Right Track Frames (1/4)
Sling the revolving frame assembly with 2 cranes. Start the engine and return the center frame assembly slowly by 90,
which has been turned by 90 for transportation, and then position the revolving frame assembly onto the track frame.
Weight of Upper Structure: 25,800 kg

Slowly rotate 90
Fitting the wire at

counterweight portion
(Example):
Set the wire safely and
securely.
Wooden block
Use a shackle for
secure connection.
Precautions
Stopper
Necessary tools
Name
Never enter under the lifted Upper Structure.
Necessary equipment
Qty
4
4 ton shackle
Others
25 5000 mm wire rope sling
20
Name
45 ton crane
Qty
2
Assembly procedure
A-1
Lower the Upper Structure by two cranes and install it on the Track Frames as shown.
Mount the M36 3 bolts and tighten them

with 250 to 310 kgm torque.
Mount the M33 3 bolts and tighten them

with 200 to 250 kgm torque.
Right track frame
No.
1
2
3
4
5
6
7
8
Left track frame
Precautions
Necessary tools
Name
Put washer (5) under plate (4).
Qty
1
Torque wrench (100 kg)
Socket (25.4 Sq. 55 mm)
Torque wrench (420 kgm)
21
Qty
8
8
8
2
8
8
32
32
Necessary equipment
4 time wrench
Others
When installing spacers (2) and (8), be

careful not to slant them to the spot facing,
etc.
Loose-supply items
209-09-11310
209-30-61120
209-09-51110
209-30-71121
01643-33690
209-30-11330
209-09-51110
209-30-61120
Name
45 ton crane
Qty
2
Assembly procedure
A-1
Secure two points of the center frame of the track by placing a hydraulic jack and a 300 400 mm wooden block at
each point. Make sure that these points do not interfere with the upper structure rotation.
Lift the Track Frame Assembly and install it on the Center Frame.
Weight of a single side of Track Frame

Assembly: 11,000 kg
Precautions
Necessary tools
Name
Necessary equipment
Qty
Hydraulic jack (50 ton)
Wooden block (300 400 mm)
Wire rope sling (30 mm, 5000 mm long)
Pin (50 mm, 500 mm)
Others
22
Name
45 ton crane
Qty
1
Assembly procedure
A-1
Thickness of 100 mm
Wooden block
a When tightening bolts, raise the track with a hydraulic jack as shown above so as to get sufficient space for tightening.
Precautions
Name
Necessary equipment
Qty
4 time wrench
Socket (25.4 Sq. 55 mm)
Torque wrench (4,200 kg)
Others
Do not remove the shoes before assembling

(so as to maintain the tightening torques of
the shoe bolts).
Necessary tools
23
Name
Qty
Assembly procedure
Installation of Travel Pipe (1/3)
A-2
Fig. 1
L.H. R.H.
Fig. 2
Precautions
Name
Qty
2
Width across flats 24 spanner
KW12P impact
L150 extension
M17 socket
24
Parts already installed to body

209-64-12131
209-64-12141
209-62-42610
209-62-42520
209-62-42510
Qty
2
2
2
1
1
No.
6
Loose-supply items
07000-13032
Qty
4
Necessary equipment
Others
Before removing the oil stopper of each

hose, turn the bolt slowly to release the
internal pressure.
Necessary tools
No.
1
2
3
4
5
Name
Qty
Assembly procedure
A-2
L.H. R.H.
Fig. 3
Precautions
Necessary tools
Others
Name
25
No.
1
2
3
4
5

209-64-12131
209-64-12141
209-62-42610
209-62-42520
209-62-42510
Qty
2
2
2
1
1
No.
6
Loose-supply items
07000-13032
Qty
4
Necessary equipment
Qty
Name
Qty
Assembly procedure
A-2
(1) Arrange the pilot hoses (4) (L.H.), (5) (R.H.) for selecting machine speed and the drain hoses (3) (Figs 1,2 and 3)
(2) Arrange the main hoses (1) and (2) on the travel motor side (Figs 1,2 and 3). Use new O-rings (6) out of the loose-supply
items and use split flange, bolt and washer out of the travel motor parts.
Machine front
Precautions
Necessary tools
Others
Name
26
No.
1
2
3
4
5

209-64-12131
209-64-12141
209-62-42610
209-62-42520
209-62-42510
Qty
2
2
2
1
1
No.
6
Loose-supply items
07000-13032
Qty
4
Necessary equipment
Qty
Name
Qty
Assembly procedure
Installation of Top Guard
A-3
.
No.
1
2
3
4
5
6
7
8
9
10
11
Precautions
Necessary tools
Name
Others
The top guard is installed when the machine

is delivered. Accordingly, the work on this
page is necessary only when the top guard is
supplied loose.
27
Loose-supply items
209-954-4211
195-Z11-2970
01011-81220
01643-31232
130-43-64260
01024-81280
01024-81295
01024-01220
20Y-954-4220
20Y-954-4240
20Y-954-4230
Qty
1
6
2
4
6
2
2
2
2
2
2
Necessary equipment
Qty
Name
Qty
Assembly procedure
Installation of Radiator Cover
A-4
Set the radiator covers (1) and (2) on the body and fix them using the bolts and the washers (3) (6).
Install to the hinge.
No.
1
T 2
w 3
4
A 5
6
Precautions
Necessary tools
Name
Others
Remove the plugs for rust prevention set in

the mounting tapped holes.
Of the 9 hinge mounting bolts, install the 3
bolts with the A mark when the duct is closed
and align with the position of the duct.
28
Loose-supply items
209-54-41500
01010-81245
01010-81275
01010-81290
01010-81235
01643-31232
Qty
1
3
2
4
9
17
Necessary equipment
Qty
Name
Qty
Assembly procedure
A-5
220
Install parts (1) (5) to the handrail at the front of the machine right side.
No.
1
2
3
4
5
Precautions
Necessary tools
Name
Others
Installation of Rearview Mirror (1/4)
29
Loose-supply items
421-54-25610
209-53-11450
20Y-54-61630
01252-71030
04025-00632
Qty
1
1
1
2
1
Necessary equipment
Qty
Name
Qty
Assembly procedure
A-5
Pass pin (5) through the hole in ball busing (A), hold the mirror with the holder of mirror (1), then secure in position and
check that the mirror does not move.
Replace the screw (421-54-25660) of the mirror assembly

part with the hexagon head bolt (6) (01252-70545), and
tighten it.
Tightening torque: 1.5 2.0 Nm {0.15 0.2 kgm}
Precautions
Necessary tools
Name
Others
30
Necessary equipment
Qty
Name
Qty
Assembly procedure
A-5
With Top Guard

Install parts (1) (5) to the handrail at the front of the operators cab.
No.
1
2
3
4
5
Precautions
Necessary tools
Name
Others
31
Loose-supply items
20Y-54-28911
209-53-13630
01024-D1235
20Y-54-35430
01252-71025
Qty
1
1
2
1
2
Necessary equipment
Qty
Name
Qty
Assembly procedure
A-5
Without Top Guard

Install parts (1) (5) to the handrail at the front of the operators cab.
Washer
No.
1
2
3
4
5
6
Precautions
Necessary tools
Name
Others
32
Loose-supply items
20Y-54-28911
209-53-13691
20Y-54-35430
01252-71025
01024-D1245
208-01-11270
Qty
1
1
1
2
1
1
Necessary equipment
Qty
Name
Qty
Assembly procedure
Installation of Left Side Step
A-6
(1) Using bolts (5), temporarily tighten brackets (3) to chassis.

(2) Sling steps (1) and (2) with crane, using bolts (6) and washers (7), install them to bracket.
(2-1) Adjust the heights of steps (1) and (2) using brackets (3).
(3) Tighten bracket and mounting bolts. (* in Fig.)
(4) Using bolts (5), install grip (4) to chassis.
No.
1
2
3
4
5
6
7
Precautions
Name
Qty
1
L150 extension
M19 socket
33
Qty
1
1
5
1
19
15
15
Necessary equipment
KW12P impact
Others
Remove the rust prevention plug knocked

into the mounting tap hole.
Necessary tools
Loose-supply items
209-54-43950
209-54-43940
209-53-13761
209-53-13620
01024-81245
01010-81230
175-54-34170
Name
Qty
Assembly procedure
Installation of Handrail
A-7
(1) Install step (1) on the left side cover with bolts (2).
(2) Install handrails (3) and (4) with bolts (2).
No.
1
2
3
4
Precautions
Necessary tools
Name
Qty
1
L150 extension
M19 socket
Others
Qty
2
14
1
1
Necessary equipment
KW12P impact
34
Loose-supply items
209-54-63481
01014-81230
209-54-77581
209-54-77571
Name
Qty
Assembly procedure
A-8
Install handrail (1) with bolts (2) and spacers (3).
No.
1
2
3
Precautions
Necessary tools
Name
Qty
1
M19 socket
35
Loose-supply items
209-53-13640
01024-D1260
195-33-11220
Qty
1
2
2
Necessary equipment
KW12P impact
Others
Installation of Handrail (With top guard) (1/2)
Name
Qty
Assembly procedure
A-8
Install handrail (1) with bolts (2), (4) and pipes (3), (5).
No.
1
2
3
4
5
Precautions
Necessary tools
Name
Qty
1
M19 socket
36
Loose-supply items
209-53-13640
01024-D1260
20Y-954-4240
01024-D1275
20Y-954-4230
Qty
1
1
1
1
1
Necessary equipment
KW12P impact
Others
Installation of Handrail (With top guard) (2/2)
Name
Qty
Assembly procedure
Installation of Muffler Tail Tube
A-9
(1) Fix the muffler tail tube (1) to the top of the hood by using the bolts (3) and the washer (4).
(2) Fix a rain cap (2) to the muffler tail tube.
Rain cap
(Decide the direction so that exhaust
is emitted backward)
Muffler tail tube
View from machine left side
No.
1
2
3
4
Precautions
Necessary tools
Name
Qty
1
M19 socket
Others
Qty
1
1
4
4
Necessary equipment
KW12P impact
37
Loose-supply items
209-01-77241
6164-12-5900
01010-81230
175-54-34170
Name
Qty
Assembly procedure
Sticking Sheet to Counterweight
A-10
Stick sheets to the surfaces of the counterweight in front of the machine as shown below.
Counterweight
a Note that steps (2) and (3) should be installed after the counterweight is mounted.
No.
1
2
3
Precautions
Necessary tools
Name
Others
Remove all oil and rust from the surface

where the sheet is to be stuck.
38
Loose-supply items
209-46-41230
209-54-42190
01024-81220
Qty
1
1
4
Necessary equipment
Qty
Name
Qty
Assembly procedure
Installation of Counterweight
A-11
When installing the counterweight, open the door at the rear

of the hood.
Counterweight : 9,740 kg
No.
2
3
Precautions
Necessary tools
The weight of each counterweight can be

distinguished by the shape of the eye plate.
(1) 9.8 ton
(2) 11.85 ton
(3) 13.6 ton
Name
Qty
1
38sq. 65 mm socket
KW45FS impact
M65SP socket
30 x 5000 mm wire rope sling
For 4 ton shackle
39
Qty
6
6
Necessary equipment
Torque wrench (4,118.8 Nm {420 kgm})
Others
Install the counterweight so that there will be

the reference space of 15 mm between the
weight and the revolving frame or so that the
left level difference equals to the right one.
Loose-supply items
209-46-41550
209-46-11210
Name
45 t crane
Qty
1
Assembly procedure
A-12
Installation of KOMTRAX Antenna (if equipped)
Antenna
Bolt
After the installation of top guard,

move antenna and bracket together without
removing antenna (1) from plate (3).
Position of antenna during
transportation
No.
1
2
3
Precautions
Necessary tools
Others
Name
40
Plate
Loose-supply items
8A13-10-1310
01024-D1225
20Y-53-15140
Qty
1
1
1
Necessary equipment
Qty
Name
Qty
Assembly procedure
Installation of Step Light (1/2)
A-13
No.
1
2
Precautions
Necessary tools
Others
Name
41
Loose-supply items
209-53-14430
01024-D1020
Qty
1
1
Necessary equipment
Qty
Name
Qty
Assembly procedure
Installation of Step Light (2/2)
A-13
No.
1
2
3
4
Precautions
Necessary tools
Others
Name
42
Loose-supply items
209-53-14430
01024-D1020
209-53-14421
01024-D1220
Qty
1
1
1
1
Necessary equipment
Qty
Name
Qty
Assembly procedure
Air Bleeding of Travel Motor
A-14
1. Start and rotate engine at the low idle.
2. Loosen air bleeding plug (1) one turn (both right and left ones).
a Do not loosen air bleeding plug (1) more than one turn.
3. Repeat forward and backward travel operations four to five times.
4. Tighten air bleeding plug (1) when air bleeding plug (1) discharges oil without white bubble.
Precautions
Necessary tools
Name
Others
Width across flats 10 wrench
43
Necessary equipment
Qty
1
Name
Oil pan plate
Qty
1
Assembly procedure
A-15
Installation of Travel Piping Cover (1/2)
Weight of motor cover: 115 kg

a Swing upper structure to a position where the motor cover can be slung.
1. Install left travel piping cover.
a Cover installing order: (1), (4), (10), (12).
No.
1
2
3
4
5
6
7
8
9
10
11
12
Precautions
Necessary tools
Name
Qty
1
KW10P impact
KW20P impact
M19 socket
M24 socket
Others
Qty
1
10
10
1
7
2
11
1
1
1
2
1
Necessary equipment
M16 Eyebolt
44
Loose-supply items
209-30-41310
01010-81645
01643-31645
209-30-41350
01010-81230
01010-81245
175-54-34170
01010-81640
21T-54-16150
209-30-41370
01010-81240
209-30-41330
Name
25 ton crane
Qty
1
Assembly procedure
A-15
Installation of Travel Piping Cover (2/2)
2. Install right travel piping cover.

a Cover installing order: (1), (4), (10), (12).
No.
1
2
3
4
5
6
7
8
9
10
11
12
Precautions
Necessary tools
Name
Qty
1
KW10P impact
KW20P impact
M19 socket
M24 socket
Others
Qty
1
10
10
1
7
2
11
1
1
1
2
1
Necessary equipment
M16 Eyebolt
45
Loose-supply items
209-30-41320
01010-81645
01643-31645
209-30-41360
01010-81230
01010-81245
175-54-34170
01010-81640
21T-54-16150
209-30-41380
01010-81240
209-30-41330
Name
25 ton crane
Qty
1
Assembly procedure
Testing Track Shoe Tension (1/3)
A-16
Precautions
Necessary tools
Others
Name
46
Necessary equipment
Qty
Name
Qty
Assembly procedure
A-16
Precautions
Necessary tools
Others
Name
47
Necessary equipment
Qty
Name
Qty
Assembly procedure
A-16
Warning
Dont stand at the front.

Dont look inside.
Precautions
Necessary tools
Others
Name
48
Necessary equipment
Qty
Name
Qty
Assembly procedure
A-17
Check Fuel, Coolant and Oil Levels (1/2)
a For details of notes (Note.1,2,3,4) in the table, see the Operation and Maintenance Manual.
For details, refer to an Operation and Maintenance Manual about Recommended Komatsu fluids again.
49
Assembly procedure
Check Fuel, Coolant and Oil Levels (2/2)
A-17
For coolant ratio to water, investigate past minimum temperature and decide it according to the following Mixing Proportion
Table. In this case, regard temperatures about 10C lower than the actual temperatures as the minimum temperature in the
table.
Mixing Proportion Table of Water and Coolant

Min. atmospheric temperature
Amount of antifreeze
Amount of water
-10
-15
-20
-25
-30
-35
-40
14
-4
-13
-22
-31
-40
liters
31.2
37.4
42.6
47.8
52.0
56.2
60.3
US gal
8.24
9.88
11.25
12.63
13.74
12.13
15.93
liters
72.8
66.6
61.4
56.2
52.0
47.8
43.7
US gal
19.23
17.60
16.22
14.85
13.74
12.63
11.55
30
36
41
46
50
54
58
Proportion by volume
k Warning
The coolant is inflammable. So, keep it away from fire.
Use tap water as the cooling water.

We recommend you to control mixing ration with an antifreeze
concentration meter.
k Warning
When removing the drain plug, use care not to be

drenched by coolant mixing water.
Precautions
Necessary tools
Name
Others
Non-amine Supercoolant (Blue) is added when

shipped. Do not mix coolant of different type
with it.
50
Necessary equipment
Qty
Name
Qty
Assembly procedure
A-18
Parts to be Touched up after Field Assembly
Precautions
Necessary tools
Others
Name
51
Necessary equipment
Qty
Name
Qty
B. ASSEMBLING OF WORK EQUIPMENT

OF BACKHOE
Clean the mounting pin and pin hole and check them for a flaw.
53
Assembly procedure
Assembly of Arm Cylinder
B-1
(1) Remove the stopper fixed to the boom and the arm cylinder foot pin.
4 Arm cylinder foot pin: 24 kg 2
(2) For PC800 only, set the O-ring (07000-12130, 2 pcs.) to the arm cylinder foot.
(3) Lift the arm cylinder and fit it to the hole positions on the arm side.
4 Arm cylinder: 870 kg (PC800, PC800LC)

493 kg 2 (PC800SE, PC850, PC850SE)
Adjustment should be made using the shim (2) so that the clearance becomes less than 1 mm.
(4) Insert the arm cylinder foot pin.
2 Inside of pin hole: Lithium grease
(5) Install the stopper plate.

Tightening torque of the plate fixing bolt: 245 309 Nm {25 31.5 kgm}
PC800 only
No.
1
2
Precautions
Necessary tools
Name
Qty
2
KW20P impact wrench
M24 socket
Others
Qty
4
7
Necessary equipment
50 mm wide, 3000 mm
54
Loose-supply items
07000-12130
207-70-11360
Name
25 ton crane
Qty
1
Assembly procedure
B-2
Connection of Arm Cylinder Hoses (1/2)
(1) Remove the oil stopper plug from the arm cylinder pipe, replace the O-rings (07000-13048, 4 pcs. for PC850, 07000-13038,
4 pcs.) at the hose connection with new ones and connect the arm cylinder hoses (07098-01414, 1 pc. 07098-01417,
1 pc. and 209-62-41910, 1 pc. 209-62-41920, 1 pc. and 07099-01214, 2 pcs. for PC850) there.
a Use split flange and bolt out of the oil stopper parts.
No.
1
2
3
4
5
No.
6
7
8
9
10
Precautions
Name
Qty
1
L150 extension
M19 socket
M22 socket
55
Qty
4
4
1
1
2
Qty
8
16
16
8
16
Remarks
L: 1350
Remarks
Necessary equipment
KW12P impact
Others
1. Bind the arm cylinder rod with wires etc.

to prevent it from coming out during work.
2. Remove and store the flange, O-rings and
heads so that you can reuse them later.
3. When connecting the hoses, take
extremely care not to clinch or damage
the O-rings.
4. Also, take extremely care not to enter a
foreign material into the hydraulic circuit.
Necessary tools
Loose-supply items
07000-13048
07000-13038
07098-01414
209-62-41920
07099-01214
Housing fixing items
07371-51470
01010-81455
01643-31445
07371-51260
01024-81245
Name
Qty
Assembly procedure
B-2
Connection of Arm Cylinder Hoses (2/2)
(1) Remove the oil stopper plug from the arm cylinder pipe, and replace four O-rings (1) at the hose end with new ones (PC850:
Part No. 07000-13048). Then, connect the arm cylinder hoses (11) and (12) (PC850: 07098-01417 1, 209-62-41910 1).
a Use the oil stopper parts for split flange, bolts, and the like.
No.
1
11
12
No.
6
7
8
Precautions
Name
Qty
1
L150 extension
M22 socket
56
Qty
4
1
1
Qty
8
16
16
Remarks
L: 1650
Remarks
Necessary equipment
KW12P impact
Others
1. Bind the arm cylinder rod with wires etc.

to prevent it from coming out during work.
2. Remove and store the flange, O-rings and
heads so that you can reuse them later.
3. When connecting the hoses, take
extremely care not to clinch or damage
the O-rings.
4. Also, take extremely care not to enter a
foreign material into the hydraulic circuit.
Necessary tools
Loose-supply items
07000-13048
07098-01417
209-62-41910
Housing fixing items
07371-51470
01010-81455
01643-31445
Name
Qty
Assembly procedure
Installation of Boom Cylinder Foot
B-3
(1) Lift the boom cylinder with the crane and bring it to the body pin hole.
(2) Set the O-ring (07000-12130, 4 pcs, for the left and right cylinders) out of the loose-supply items on the boom cylinder foot
and push pins in it.
(3) Check the clearance (outside the machine) between the cylinder pin and the body, decide the size and quantity of shim so
that the clearance becomes below 1 mm and insert them there. Adjust the left and right cylinders with shims (outside the
machine).
(4) Sandwich the boom cylinder stand (wooden block) between the cylinder and the revolving frame.
(Height should be 40 to 50 mm, and width should be equal to or less than 90 mm)
(5) Push the boom foot pins in the holes completely and fit the lockplates there.
Tightening torque of the plate fixing bolt:

245 309 Nm {25 31 kgm}
Adjustment should be made so

that the clearance becomes
below 1 mm.
O-ring
Wooden block
No.
1
2
3
Precautions
a Use the adjustment shims (209-75-51230,

1.0 mm thick, and 209-72-51240, 1.5 mm
thick) to decide their combination.
Name
Qty
2
KW20P impact wrench
M24 socket
57
Qty
4
4
4
Necessary equipment
50 mm wide, 3000 mm
Others
a Assemble the boom cylinder foot so that

the greasing port faces down.
Necessary tools
Loose-supply items
07000-12130
209-72-51240
209-72-51230
Name
Qty
Assembly procedure
B-4
Relieving Remaining Pressure from Hydraulic Circuit
When removing hydraulic pipes, be sure to relieve remaining

pressure in accordance with the following procedures:
(1) Remove the cap from the hydraulic oil tank.
k When removing the cap from the oil it slowly to relieve
pressure in the tank and remove it carefully.

(2) Lower the lock lever and keep it locked.
(3) Start the engine, operate it for about 10 seconds and stop
the engine.
a Do not increase the engine speed to over 1,000 rpm.
a Keep the control lever of the work equipment neutral.
(4) Turn the starting switch to ON, set the lock lever to Free
and set the control lever of each work equipment to Full
Stroke within 5 to 6 seconds after stopping the engine.
a Repeat the procedures (2) to (4) three times.
(5) After relieving remaining pressure, set the cap to the oil
filler port of the hydraulic oil tank so that dust do not enter
the tank.
(6) Lower the lock lever and keep it locked.
Precautions
Necessary tools
Others
Name
58
Necessary equipment
Qty
Name
Qty
Assembly procedure
B-5
Installation of Boom Cylinder Hoses
(1) Remove the blind plug from the boom cylinder tube.
(2) Arrange the boom cylinder hose (1) (07099-01216, 4 pcs.) to the normal circuit as shown below. Replace the O-ring (2)
(07000-13038, 8 pcs.) at the hose connection with the new one out of the loose-supply items.
a Bleed air from the boom cylinder. For details, see Procedure B-17 "Air Bleeding from Hydraulic Cylinder".
No.
1
2
Precautions
Name
Qty
1
L150 extension
M19 socket
59
Qty
4
8
Necessary equipment
KW12P Impact
Others
1. When removing the oil plug from each

hose, loosen the bolt slowly to release the
internal pressure and then remove the oil
plug carefully.
2. Keep the removed flanges, O-rings and
heads so that you can use them again.
3. When installing each hose, take care
extremely that the O-ring will not be
caught.
4. When installing each hose, take care
extremely that dirt will not enter the circuit.
Necessary tools
Loose-supply items
07099-01216
07000-13038
Name
Oil pan (small)
Qty
1
Assembly procedure
Installation of Boom Foot Dust Seal
B-6
(1) Install the seal (209-72-11261) to the boom foot
Take care of the

direction of its lip.
Take care of the

direction of its lip.
No.
1
Precautions
Necessary tools
Name
Qty
Hammer
2. When installing the seal, be careful not to

slant it.
Template
Others
4. Do not hit seal with hammer directly but

use template, etc. to hit.
60
Qty
4
Necessary equipment
1. Take care of the direction of its lip so that

the grease can come out from inside.
3. Insert the seal until it touches the bushing.
Loose-supply items
209-72-11261
Name
Qty
Assembly procedure
Assembly of Boom Assembly
B-7
(1) Lift the boom assembly with the crane and bring it to the body pin hole.
4 Boom assembly: 7,900 kg (PC800, PC800LC)
8,100 kg (PC850)
7,300 kg (PC800SE, PC850SE)
(2) Fitting of Boom Foot Pin.

Insert a boom foot pin (which had been fitted on the revolving side) in a hole one side first and bring the body to the pin
hole on the other side. When the boom is inclined to the left or right at the time, balance it by using the jib crane.
a Check the clearance between the boom foot and the machine outside, decide the size and quantity of shim so that the
clearance becomes below 1 mm and insert the shim between them.
Use the adjustment shims (209-70-71640, 1.0 mm thick, and 209-70-71650, 1.5 mm thick) to decide their combination.
a Adjust the clearance with shims at one place outside.
(3) Insert the boom foot pins fully on both the left and right sides and fit lockplates there.
3 Tightening torque of the plate fixing bolt:
245 309 Nm {25 31 kgm}
No.
1
2
3
Precautions
Name
Qty
2
Large hammer (plastic)
KW20P impact
M24 socket
61
Qty
4
4
2
Necessary equipment
Others
a Since four seals (209-72-11261) have been fitted to the boom foot as shown below, use care
not to break them when inserting pins.
Necessary tools
Loose-supply items
209-72-11261
209-70-71650
209-70-71640
Name
25 ton crane
Qty
1
Assembly procedure
B-8
Hose Connection of Arm and Bucket Circuits
(1) Remove oil stopper plug from hose and oil stopper plug from boom tube.
(2) Connect on-boom arm cylinder, bucket cylinder hose (2) with regular circuits as shown below.
No.
1
No.
2
3
4
5
Precautions
Name
Qty
1
L150 Extension
M22 Socket
62
Qty
4
Qty
4
8
16
16
Necessary equipment
KW12P Impact
Others
1. When removing oil stopper plug from

hose, care should be taken and rotate bolt
slowly to let out pressure.
2. Store the removed flange, O-ring, and
head in order so that they can be used
again.
3. When connecting hose, great care should
be taken so that O-rings do not get
caught.
4. When connecting hose, great care should
be taken so that dusts do not fall in the
circuits.
Necessary tools
Main body mounted items

209-72-11261
Loose-supply items
07098-01414
07371-51470
01010-81455
01643-31445
Name
Qty
Assembly procedure
Installation of Quick Return Hose
B-9
(1) Connect quick return hoses (1) and (2).

(2) Install hose clamps (3), (4) and (5) with bolt (6) and washer (7).
a Air bleeding should be made for arm cylinder only.
No.
1
2
3
4
5
6
7
Precautions
Name
Qty
1
M19 Socket
M17 Socket
L150 Extension
63
Qty
1
1
2
1
1
1
1
Remarks
Necessary equipment
KW12P Impact
Others
a When installing each hose, take care

extremely that dirt will not enter the circuit.
Necessary tools
Loose-supply items
02896-11009
02896-11012
07094-30315
07095-00314
07095-00317
01010-81265
01643-31232
Name
Qty
Assembly procedure
Installation of Boom Cylinder
B-10
(1) Remove the stopper fixed to the boom and the boom cylinder top pin (1).
4 Boom cylinder to pin: 33kg
(2) Start the engine and idle it as a low speed.

(3) Lift the cylinder (2), extend the rod slowly and fit it to the pin hole.
a Before aligning the pin holes, bleed air from the cylinder.
4 Boom cylinder: 775 kg 2
(4) Insert the cylinder top pin in the pin hole.
2 Inside of pin hole: Lithium grease.
(5) Set the cylinder top pin to both the left and right cylinders in the same way.
(6) Fit the stopper to the boom.
3 Tightening torque of the plate fixing bolt: 245 309 Nm {25 31.5 kgm}
Precautions
Name
Necessary equipment
Qty
50 mm wide, 3000 mm
KW20P impact wrench
M24 socket
Large hammer
Others
a Extend the cylinder slowly, nor operate it

quickly, nor bring it to the stroke end.
Since air gathers inside the cylinder at the first
time, the cylinder may not move for 10 seconds or more, but do not bring the lever to the
full stroke point.
Necessary tools
64
Name
25 ton crane
Qty
1
Assembly procedure
B-11
Installation of Arm Assembly (1/2)
(1) Remove the stopper of the boom top pin fixed to the boom and pull out the top pin.
4 Boom top pin: 110 kg
(2) Lift the arm assembly, bring it to the boom hole.

Adjustment should be made using the shim (1) so that the clearance between the boom inside width and the arm outside
width becomes less than 1 mm.
a Before aligning the pin holes, bleed air from the cylinder.
4 Arm assembly: 3,970 kg (PC800, PC800LC)
4,880 kg (PC800SE, PC850SE)
4,485 kg (PC850)
(3) Fit the stopper to the pin.

(4) Remove the stopper of the arm cylinder top pin fixed to the arm side and pull out the top pin.
4 Arm cylinder top pin: 24 kg 2 (PC850, PC800SE, and PC850SE)
30 kg (PC800, 800LC)
No.
1
Precautions
Name
Qty
1
Necessary equipment
Qty
Name
Qty
25 ton crane
SD30 shackle
Five-stage step
KW20P impact
M24 socket
Others
a Since the seal (209-72-11261, 2 pcs.) is fitted

to the inside of the arm side bushing, use care
not to break it when inserting the pin.
Necessary tools
Loose-supply items
209-70-71641
65
Assembly procedure
Installation of Arm Assembly (2/2)
B-11
(5) Start the engine, idle it and extend the arm cylinder rod slowly to adjust the pin hole position. At the time, lift the arm cylinder
with the crane for positioning during operation of the arm cylinder.
a Assembly should be made so that the lubrication hole faces upward.
(6) Push the arm cylinder top pin in the pin hole.
(7) Fit the stopper to the pin.

Precautions
Name
Necessary equipment
Qty
Name
Qty
25 ton crane
SD30 shackle
Five-stage step
KW20P impact
M24 socket
Others
a Operate the cylinder slowly.

Do not operate it quickly and do not bring it to
the stroke end.
Since air gathers inside the cylinder at the first
time, it may not move for over 10 seconds, but
do not move the lever to the full stroke.
Necessary tools
66
Assembly procedure
B-12
Installation of Hose between Boom and Bucket Cylinder
(1) Remove oil stopper plug from bucket cylinder tube.

(2) Connect two bucket cylinder hoses (2) there after they are fitted with O-rings (1).
a Use split flange and bolt out of the oil stopper parts.
a Bleed air from the bucket cylinder. For details, see Procedure B-16 "Air Bleeding from Hydraulic Cylinder".
No.
Loose-supply items
Qty
The parts below are

for PC800, 850-8
1
2
07000-13038
07098-21219
4
2
The parts below are

for PC800SE, 850SE-8
1
2
Precautions
Name
4
2
Necessary equipment
Qty
Name
Qty
KW12P Impact
Five-stage step
L150 Extension
Oil pan plate
M19 Socket
Others
1. Store the flanges, O-rings and heads used for

transportation for re-use in the future.
2. Connect hoses carefully so that they do not
get caught between other parts.
3. Connect hoses carefully so that they do not interfere with other parts and are not twisted.
4. When connecting hoses, use care not to let
dusts enter the circuit.
Necessary tools
07000-13038
07098-21221
67
Assembly procedure
Installation of Bucket Assembly
B-13
3 Tightening torque of the cover

fixing bolt:
824 1,030 Nm {84 105 kgm}
No.
Precautions
Name
Qty
1
KW20P impact
M36 socket
68
Qty
2
2
2
2
9
1
Necessary equipment
Others
a Be sure to operate the cylinder slowly. Do not

operate it quickly and do not bring it to the
stroke end. Since air gathers inside the cylinder at the first time, the cylinder may not operate for 10 seconds or more, but do not move
the lever to the full stroke.
Necessary tools
Loose-supply items
208-70-33181
209-72-11220
21N-70-13150
209-939-5441
209-939-5431
209-939-5410
Name
25 ton crane
Qty
1
Assembly procedure
B-14
Lubrication Piping to Work Equipment
No.
Precautions
Necessary tools
Others
Name
69
Loose-supply items
07020-00000
Qty
2
Necessary equipment
Qty
Name
Qty
Assembly procedure
Wiring of Work Equipment
B-15
No.
1
2
3
4
Precautions
Necessary tools
Name
Qty
1
M19 socket
Others
Qty
2
2
4
2
Necessary equipment
KW12P impact
70
Loose-supply items
21T-06-32810
20Y-06-21551
01024-81230
08193-20012
Name
Qty
Assembly procedure
B-16
Greasing after Assembling Work Equipment
Precautions
Necessary tools
Others
Name
71
Necessary equipment
Qty
Name
Qty
Assembly procedure
B-17
Air Bleeding from Hydraulic Cylinder
Precautions
Necessary tools
Others
Name
72
Necessary equipment
Qty
Name
Qty
C. ASSEMBLING OF WORK EQUIPMENT

OF LOADING SHOVEL
Clean the mounting pin hole and check them for a flaw.
73
74
Use forcing screws (24 mm, P = 3.0, full thread bolt, stem length 80 mm and above)
to pull out the pins.
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
D. ASSEMBLING OF COUNTERWEIGHT REMOVER
97
Assembly procedure
Installation of Rubber Cushions
D-1
Install rubber cushion (1), spacer (2), bolt (3) and washer (4).
No.
1
2
3
4
Precautions
Necessary tools
Name
Qty
1
M19 socket
Others
Qty
2
6
6
6
Necessary equipment
KW12P impact wrench
98
Loose-supply items
209-46-74150
205-03-71330
01010-81260
427-06-13240
Name
Qty
Assembly procedure
D-2
Adjustment of Shims for Counterweight (1/5)
Before installing the counterweight normally, adjust the shims to prevent the counterweight bolt holes from moving to the
right or left by method I or II.
Method I. When actually placing and setting the counterweight on the revolving frame and adjusting the shims
1) Sling counterweight assembly (1) and install it to the machine.
2) Check that bolts (2) (6 pieces) can be installed.
(Tighten the bolts with the fingers. You do not need to tighten them securely at this time.)
Weight of counterweight assembly: 12,400 kg
No.
2
3
Precautions
Necessary tools
Name
Qty
2
SD30 shackle
Others
Qty
6
6
Necessary equipment
300 5,000 mm wire rope sling
99
Loose-supply items
209-46-41550
209-46-11210
Name
45 t crane
Qty
1
Assembly procedure
D-2
3) Decide the thickness of shims (2), (3) and (4) at the 4 places so that the clearance between the revolving frame
and plate (1) will be 2 0.5 mm.
4) Remove the counterweight mounting bolts and lift the counterweight assembly down from the revolving frame.
5) Install plate (1) and shims (2), (3) and (4) decided by step 3) above to the counterweight with bolts and washers
(5) (or (6)).
If the thickness of shims (2), (3) and (4) decided by step 3) is less than 5 mm, use bolts (5). If the former is 5 mm
or larger, use bolts (6).
Clearance: 2 0.5 mm
Shim installing place P

No.
1
2
3
4
5
6
Precautions
Necessary tools
Name
Qty
1
M19 socket
Others
Qty
4
12
4
8
8
8
Necessary equipment
KW12P impact wrench
100
Loose-supply items
209-46-42431
209-46-42440
209-46-42450
209-46-42460
01024-81235
01024-81240
Name
Qty
Assembly procedure
D-2

(For only 1st time)
Method II. When adjusting the shims without placing the counterweight on the revolving frame.
a If a crane is not available, adjust the shims for the counterweight according to the following procedure.
1) Measure distances A (LH) and A (RH) between the center of the counterweight mounting hole of the revolving
frame and outside end of the revolving frame top plate.
Precautions
Necessary tools
Others
Name
101
Necessary equipment
Qty
Name
Qty
Assembly procedure
D-2
2) Measure distances B (LH) and B (RH) between the center of the counterweight hole and end of plate (1).
Precautions
Necessary tools
Others
Name
102
Necessary equipment
Qty
Name
Qty
Assembly procedure
D-2
3) Decide the thickness of shims (2), (3) and (4) at the 4 places so that B (LH) A (LH) and B (RH) A (RH) will be
2 0.5 mm respectively.
4) Install plate (1) and shims (2), (3) and (4) decided by step 3) above to the counterweight with bolts and washers
(5) (or (6)).
If the thickness of shims (2), (3) and (4) decided by step 3) is less than 5 mm, use bolts (5). If the former is 5 mm
or larger, use bolts (6).
Clearance: 2 0.5 mm
No.
1
2
3
4
5
6
Shim installing place P
Precautions
Necessary tools
Name
Qty
1
M19 socket
Others
Qty
4
12
4
8
8
8
Necessary equipment
KW12P impact wrench
103
Loose-supply items
209-46-42431
209-46-42440
209-46-42450
209-46-42460
01024-81235
01024-81240
Name
Qty
Assembly procedure
Greasing
D-3
Before assembling the counterweight remover assembly, grease each pin.
Precautions
Necessary tools
Name
Qty
1
Others
Grease pump
Necessary equipment
104
Name
Qty
Assembly procedure
D-4
Installation of Counterweight Remover
1) Sling counterweight remover assembly (1) and install it to the machine.

2) Fix the counterweight remover assembly with mounting bolts (2) (6 pieces) and washers (3) (6 pieces).
Weight of counterweight remover assembly: 1,300 kg
3 Tightening torque for bolt

2,450 3,040 Nm
{250 310 kgm}
No.
2
3
Precautions
Necessary tools
Name
Qty
3
4:1 torque multiplier
85 kg torque wrench
T 25 socket, 55 mm
width across flats
KW45F impact wrench
Others
Qty
6
6
Necessary equipment
50 3,000 mm synthetic fiber sling
105
Loose-supply items
01011-83625
01643-33690
Name
25 t crane
Qty
1
Assembly procedure
Installation of Covers
D-5
Install bracket (1), covers (2) and (3), and bolts and washers (4), (5) and (6).
No.
1
2
3
4
5
6
Precautions
Necessary tools
Name
Qty
1
M19 socket
Others
Qty
1
1
1
2
4
8
Necessary equipment
KW12P impact wrench
106
Loose-supply items
209-46-42380
209-46-42421
209-46-42521
01024-81225
01024-81225
01024-81225
Name
Qty
Assembly procedure
Installation of Hoses (1/3)
D-6
1) Remove the oil plugs of the cylinder and those of the hoses and connect the hoses.
When connecting the hoses, take care of their colors.
2) Install clamps (1), cushions (2), and bolts and washers (3).
Clamp 209-62-42870 (hose)

at position of white tape.
White (Yellow)
Blue
Green
Yellow
White
Brown
Red
No.
1
2
3
Precautions
Name
Qty
1
Spanner, 19 mm width across flats
KW12P impact wrench
M19 socket
107
Qty
4
2
2
Necessary equipment
Oil receiving pan (small)
Others
1. When removing each oil plug, loosen it

slowly to release the internal pressure
and then remove it carefully.
2. When installing each hose, take extreme
care that the O-ring will not be caught.
3. When installing each hose, take extreme
care that dirt will not enter the circuit.
Necessary tools
Loose-supply items
07094-10417
07095-00420
01024-81265
Name
Qty
Assembly procedure
D-6
3) Install clamps (1), cushions (2), and bolts and washers (3).
Red
Brown
Clamp 209-62-42870 (hose)

No.
1
2
3
Precautions
Necessary tools
Name
Qty
1
M19 socket
Others
Qty
4
2
2
Necessary equipment
KW12P impact wrench
108
Loose-supply items
07094-10417
07095-00420
01024-81265
Name
Qty
Assembly procedure
D-6
4) Install clamps (1), (4) and (7), cushions (2), (5) and (8), and bolts and washers (3), (6) and (9).
Blue
Green
Clamp 209-62-42870 (hose)

No.
1
2
3
4
5
6
7
8
9
Clamp 209-62-42870 (hose)

Precautions
Necessary tools
Name
Qty
1
M19 socket
M17 socket
Others
Qty
2
2
1
2
2
1
1
1
1
Necessary equipment
KW12P impact wrench
109
Loose-supply items
07094-30417
07095-00420
01024-81265
07094-30417
07095-00420
01024-81265
04434-52711
07095-00420
01024-81020
Name
Qty
Assembly procedure
D-7
Bleeding Air from Counterweight Remover Circuit
a After assembling the piping, bleed air from the counterweight remover circuit.
(1) Run the engine at low idle.
(2) Extend and retract each cylinder 4 5 times, stopping it at about 100 mm before each stroke end.
(3) While running the engine at low idle, extend each cylinder from 100 mm before each stroke end to the stroke end very
slowly (taking at least 10 seconds) and then keep the remover control lever at the stroke end for 4 minutes.
a At the first operation, the remover link does not move for more than 10 seconds since much air is in the circuit. Do
not move the lever to the stroke end, however.
a The air in the cylinder is bled by operations (1) to (3).
a If each cylinder is moved to the stroke end from the first operation, the air in the cylinder may damage the piston
packing, etc.
Precautions
Necessary tools
Others
Name
110
Necessary equipment
Qty
Name
Qty
Assembly procedure
D-8
Installation of Counterweight (1/2)
1) Set the pin holes of the link to those of the counterweight by operating the counterweight remover and then install
counterweight pins (1) and lock plates (2) with bolts (3), washers (4) and nuts (5).
No.
1
2
3
4
5
Precautions
Necessary tools
Name
Qty
1
M19 socket
Others
Qty
2
2
2
4
4
Necessary equipment
KW12P impact wrench
111
Loose-supply items
21M-46-24360
21M-46-24570
01011-81250
01643-31232
01580-11210
Name
Qty
Assembly procedure
Installation of Counterweight (2/2)
D-8
2) Place the counterweight on the revolving frame by operating the counterweight remover.
3) Install bolts (1) (6 pieces) and spacers (2) (6 pieces).
a If a large torque wrench is not available, tighten the bolts by the following angle tightening method.
(1) Tighten the bolts to 1,471 Nm {150 kgm} first.
(2) Tighten the bolts by 90 5.
Outside diameter: 90 mm, 1.0 kg
L = 480 mm, 5.8 kg

Width across flats: 65 mm
3 Tightening torque
3,825 392 Nm
{390 40 kgm}
No.
1
2
Precautions
Name
Qty
1
Socket, 65 mm width across flats
420 kgm torque wrench
T 38 socket,
65 mm width across flats
112
Qty
6
6
Necessary equipment
KW45FS impact wrench
Others
Install the counterweight so that the level

difference on the right side and left side will
be even.
Necessary tools
Loose-supply items
209-46-41550
209-46-11210
Name
Qty
Assembly procedure
Installation of Accessories
D-9
After tightening counterweight mounting bolts, install cover (1), step (2), grips (3), bolts (4), washers (5), and bolts and
washers (6) and (7).
No.
1
2
3
4
5
6
7
Note)Install the 3 parts of (1), (2) and (3) at last since they can interfere
with the counterweight remover when the latter is operated.
Precautions
Necessary tools
Name
Qty
1
M19 socket
Others
Qty
1
1
2
2
2
4
4
Necessary equipment
KW12P impact wrench
113
Loose-supply items
209-46-42411
209-54-42191
209-54-43610
01010-81225
175-54-34170
01024-81220
01024-81240
Name
Qty
Assembly procedure
Check of Operation
D-10
After assembling the counterweight remover, check the following 3 items.

(1) The cylinders move as operated with the levers.
(2) No oil is leaking.
(3) No parts interfere with each other.
Precautions
Necessary tools
Others
Name
114
Necessary equipment
Qty
Name
Qty
M. PROCEDURE FOR INSPECTION AND MAINTENANCE

AFTER COMPLETION OF ASSEMBLY
115
Inspection and maintenance

procedure
M-1
Inspection of Oil Level in Hydraulic Tank and Refill (1/2)
Precautions
Necessary tools
Others
Name
116
Necessary equipment
Qty
Name
Qty

procedure
M-1
Inspection of Oil Level in Hydraulic Tank and Refill (2/2)
Precautions
Necessary tools
Others
Name
117
Necessary equipment
Qty
Name
Qty

procedure
M-2
Replacement of Return Filter

(Standard Filter to Flushing Filter)
No.
1
2
Precautions
Necessary tools
Name
Others
Store the removed standard element (20960-77532) 2 pcs., strainer (206-60-31140)

2 pcs. and valve (20Y-60-31131) 2 pcs.
in order because they are used again after
flushing.
118
Loose-supply items
209-60-77551
21T-60-13730
Qty
2
2
Necessary equipment
Qty
Name
Qty

procedure
M-3
Flushing of Hydraulic Circuit (1/2)
Rotate the engine at the low idle (in the E

mode) with the lever in the neutral position for
15 minutes, and follow the procedures below.
Precautions
Necessary tools
Name
Full operation may damage the filter element

since the relief valve of the filter is closed.
Others
Do not relieve any circuits !
119
Necessary equipment
Qty
Name
Qty

procedure
M-3
Confirmation
After flushing, replace the standard element with
flushing element referring to step M-4.
While doing above, check the collected dusts in
the flushing element if they are not unusual.
If uncertain, contact your distributor.
Precautions
Necessary tools
Name
Others
(4)
Flushing of Hydraulic Circuit (2/2)
120
Necessary equipment
Qty
Name
Qty

procedure
M-4

(Flushing Filter to Standard Filter) (1/2)
Precautions
Necessary tools
Others
Name
121
Necessary equipment
Qty
Name
Qty

procedure
M-4

(Flushing Filter to Standard Filter) (2/2)
Precautions
Necessary tools
Name
a After completion of flushing, check the flushing

element referring to the caution in M-3, and
discard it.
Others
a Store the strainer, valve and replaced plate

because they can be used again..
122
Necessary equipment
Qty
Name
Qty

procedure
M-5
Error Code (1/2)
Turn the starting switch ON, operate on the multi-monitor panel in the following procedure, and make sure that no error codes
have been generated.
123

procedure
M-5
Error Code (2/2)
124
After completion of assembling a machine, make inspections according to these check sheets for assuring machine performance.
After checking, send these check sheets to the Osaka plant.
2/13
Coupling
case oil
EO10W30-DH
See operation
EO15W40-DH
and maintenance
manual for details. TO10
TO30
TO30
TO30
TO30
TO10
3/13
4/13
Check of switches, control levers
Revision
Category
5/13
Check item
1. Car radio
2. Lower wiper switch (fixed front window cab specs, if equipped)
3. Revolving warning lamp switch (if equipped)
4. Large capacity air conditioner blower switch (if equipped)
5. Air conditioner control switch
6. Lock lever
7. LH work equipment control lever
8. Travel pedal
9. Travel lever
Local
After
assembly hours of
time
operation
Judgement standard
10. Cigarette lighter

11. Machine monitor
12. Horn switch
13. RH work equipment control lever
14. Starting switch
15. Fuel control dial
16. Lamp switch
17. Swing lock switch
18. Machine push-up switch
19. Boom shockless control switch
20. Swing holding brake release switch
21. Emergency pump drive switch
22. Step light switch
23. Room lamp switch
Operation of horn switch
Press the switch on the right footrest to

sound the horn. At the same time, the flashing light (if equipped) at the bottom front of
the cab will flash for approx. 5 seconds.
Operation of lock lever
Push down the lever to apply the lock.

Engine can be started but all work
equipment control levers do not move
Push up the lever to release the lock.
Engine cannot be started but all work
equipment levers move.
Operation of fuel control dial
MAX: Full speed

Min: Low idle
Operation of preheating pilot
Rotate the key at the preheating position

so that the monitor display shows "preheating ON". The preheating pilot will
flash after approx. 30 seconds to indicate
the completion of preheating.
Revision
Category
6/13
Check item
Operation of working mode selector switch
Local
After
assembly hours of
time
operation
Judgement standard
P lights up: Heavy-duty operations
E lights up: Fuel-efficient operations
Monitor display changes in synchronous with the
switch operation.
Engine switches to or from the full operation
Operation of auto-deceleration switch
ON lights up: Auto-deceleration is actuated.

OFF: Auto-deceleration is cancelled.
Each time the switch is pressed, the monitor display changes so that ON or OFF state can be
selected.
Operation of travel speed switch
Lo lights up: Low speed travel

High lights up: High speed travel
switch operation. When the engine is started, the
travel speed is automatically set to Lo.
Operation of heavy lift switch
ON lights up: Boom lifting force is increased.

OFF: Normal
selected.
Operation of swing priority mode switch
ON lights up:
Able to swing 180 while loading
OFF:
Normal work (able to swing 90 while loading)
selected.
Operation of wiper switch
ON: lights up: Wiper moves continuously

INT: lights up: Wiper moves intermittently
OFF: Wiper stops
Each time the switch is pressed, the monitor
display changes so that any state can be
selected.
Operation of window washer switch
Window washer fluid is sprayed out to the front

glass (in combination with wiper) when the switch
is pressed continuously.
Operation of cigarette lighter
This is used to light cigarettes. To use, push the

lighter in. After a few seconds it will spring back,
and glow.
Operation of lamp switch
This switch is used to turn on the front lamps,

working lamps, additional lamp at the top front of
the cab, and monitor lighting.
Operation of swing lock switch
ON position (actuated):
The swing lock is always applied, and the
upper structure will not swing even if the swing
is operated. In this condition, the swing lock
monitor lights up.
OFF position (cancelled):
Swing operation is possible. In this condition,
the swing lock monitor goes off.
Operation of machine push-up switch
Low pressure setting:

The boom thrust force is weak.
High pressure setting:
The boom thrust force becomes more powerful.
Operation of boom shockless control switch (if equipped)
ON: While the boom stop operation, shock of

the work equipment is controlled.
Operation of step light switch (if equipped)
When the switch is pressed, the step light will

light up for approx. 60 seconds.
Even if the starting switch key is at the OFF
position, the step light will light up for approx.
60 seconds when the switch is pressed.
Revision
Category
7/13
Check item
Operation of room lamp switch
Local
After
assembly hours of
time
operation
Judgement standard
ON position: Room lamp lights up
OFF position: Room lamp lights off
Even if the starting switch key is at the OFF position, the room lamp will light up when the switch is
pressed.
Operation of emergency pump drive switch
When normal: Switch is pushed down:
When the monitor display shows E02 (TVC valve system error),
move the switch "up" to make it possible to carry out work
When switch is pushed up, alarm buzzer sounds.
Operation of swing holding brake release switch
When normal: Switch is pushed down
When the monitor display shows E03 (Swing brake system error),
move the switch "up" to cancel the brake, and it becomes possible to
actuate the swing. However, the swing brake remains released.
When switch is pushed up, alarm buzzer sounds,

and swing lock symbol flashes
Operation of alarm buzzer stop switch
This is used to stop alarm buzzer if it sounds to

warn of an abnormality of warning item during
engine operation.
Operation of lower wiper switch (if equipped)
ON: Lower wiper moves.

OFF: Lower wiper stops.
Operation of travel levers
FORWARD: The lever is pushed forward.

(The pedal is angled forward)
REVERSE: The lever is pulled back.
(The pedal is angled back)
N (Neutral): The machine stops
Operation of LH work equipment control lever

(with auto-deceleration device)
This lever is used to operate the arm and upper

structure.
Arm operation
Swing operation
(a) Arm OUT
(c) Swing to right
(b) Arm IN
(d) Swing to left
N (Neutral): When the lever in this position, the

upper structure and the arm will be
retained in the position in which they
stop.
Operation of RH work equipment control lever
This lever is used to operate the boom and bucket.

Boom operation
Bucket operation
(a) RAISE
(c) DUMP
(b) LOWER
(d) CURL

stop.
Confirmation of failure history (Both electrical and mechanical)
Delete the failure history after confirming that no

abnormality sign is displayed. Confirm that no failure history is provided after completion of the test.
8/13
6.8 +0.6
- 0.2 rpm
53.6 5.4 sec / 5 turns

(PC800LC: 58 6 sec / 5 turns)
Difference between left and right:
82 8.0 sec / 5 turns

(PC800LC: 89 9 sec / 5 turns)
Difference between left and right: 1.2 sec
9/13
RAISE:
5.3 0.5 sec. (PC800(LC), 850)

5.6 0.6 sec. (PC800SE, 850SE)
LOWER: 4.3 0.4 sec. (PC800(LC))
4.2 0.4 sec. (PC850)
4.4 0.4 sec. (PC800SE, 850SE)
IN: 4.7 0.5 sec. (PC800)
5.4 0.5 sec. (PC850, 800SE, 850SE)
6.0 0.6 sec. (PC800LC)
OUT: 3.4 0.3 sec. (PC800(LC))
3.8 0.4 sec. (PC850, 800SE, 850SE)
CURL: 3.3 0.3 sec. (PC800(LC))
3.6 0.4 sec. (PC850)
4.6 0.4 sec. (PC800SE, 850SE)
DUMP: 3.1 0.3 sec. (PC800(LC))
3.4 0.3 sec. (PC850)
4.2 0.4 sec. (PC800SE, 850SE)
Max. 5.5 sec.
Max. 5.2 sec.
Max. 3.5 sec.
coupling case
coupling case
(Including machine push-up function)
ON: Machine is lifted up.

OFF: Machine is not lifted up.
Immediately after engine is stopped, boom

cylinder must move from fully extended
position to ground level. (Arm at max. reach)
10/13
11/13
12/13
P
1980
[55] for service mode

Confirmed (on fan rotation 100 % fixed mode)
1050 50 rpm (Engine full, Oil temp. 50C)
Confirmed on the monitoring mode

[01100] for F pump and [01101] for R pump
At engine high idle,
boom raise, P mode
and Heavy lift OFF,
relief
F pump
R pump
Control valve main
F pump
set pressure (increase)
31.4
320
Control valve main

R pump
31.4
320
27.9
285

boom raise, P mode
and Heavy lift ON,
relief
swing and P mode, relief
+5
3.33 +0.49
34.0 0
0
(At engine high idle, neutral)
Self pressure reducing

valve output pressure
4. Current value measurement Confirmed on the monitoring mode

Run one side idle
(Idling side)
Pump EPC current value
F pump
R pump
mA
mA
mA
At neutral
250 20 mA
mA
Run one side idle

(Idling side)
540 120 mA
Engine
high idle
Note: Measure the following J/S differential pressure only if the

pump EPC current does not pass the test.
Run one side idle
(Idling side)
J/S differential pressure sensor voltage
F pump
R pump
At neutral
Min.2.5 V
Run one side idle

(Idling side)
Min. 1.3 V
Engine
high idle
13/13
Loading Shovel 1/13
After completion of assembling a machine, make inspections according to these check sheets for assuring machine performance.
After checking, send these check sheets to the Osaka plant.
2/13
Coupling
case oil
EO10W30-DH
See operation
EO15W40-DH
and maintenance
manual for details. TO10
TO30
TO30
TO30
TO30
TO10
3/13
4/13
Revision
Category
5/13
Check item
1. Car radio
2. Lower wiper switch (fixed front window cab specs, if equipped)
3. Revolving warning lamp switch (if equipped)
4. Large capacity air conditioner blower switch (if equipped)
5. Air conditioner control switch
6. Lock lever
7. LH work equipment control lever
8. Travel pedal
9. Travel lever
Local
After
assembly hours of
time
operation
Judgement standard
10. Cigarette lighter

11. Machine monitor
12. Horn switch
13. RH work equipment control lever
14. Starting switch
15. Fuel control dial
16. Lamp switch
17. Swing lock switch
18. Machine push-up switch
19. Boom shockless control switch
20. Swing holding brake release switch
21. Emergency pump drive switch
22. Step light switch
23. Room lamp switch
24. Bottom dump switch
Operation of horn switch
Press the switch on the right footrest to

sound the horn. At the same time, the flashing light (if equipped) at the bottom front of
the cab will flash for approx. 5 seconds.
Operation of lock lever
Push down the lever to apply the lock.

Engine can be started but all work
equipment control levers do not move
Push up the lever to release the lock.
Engine cannot be started but all work
equipment levers move.
Operation of fuel control dial
MAX: Full speed

Min: Low idle
Operation of preheating pilot
Rotate the key at the preheating position

so that the monitor display shows "preheating ON". The preheating pilot will
flash after approx. 30 seconds to indicate
the completion of preheating.
Revision
Category
6/13
Check item
Operation of working mode selector switch
Local
After
assembly hours of
time
operation
Judgement standard
P lights up: Heavy-duty operations
E lights up: Fuel-efficient operations
switch operation.
Engine switches to or from the full operation
Operation of auto-deceleration switch
ON lights up: Auto-deceleration is actuated.

OFF: Auto-deceleration is cancelled.
selected.
Operation of travel speed switch
Lo lights up: Low speed travel

High lights up: High speed travel
switch operation. When the engine is started, the
travel speed is automatically set to Lo.
Operation of heavy lift switch
ON lights up: Boom lifting force is increased.

OFF: Normal
selected.
Operation of swing priority mode switch
ON lights up:
Able to swing 180 while loading
OFF:
Normal work (able to swing 90 while loading)
selected.
Operation of wiper switch
ON: lights up: Wiper moves continuously

INT: lights up: Wiper moves intermittently
OFF: Wiper stops
Each time the switch is pressed, the monitor
display changes so that any state can be
selected.
Operation of window washer switch
Window washer fluid is sprayed out to the front

glass (in combination with wiper) when the switch
is pressed continuously.
Operation of cigarette lighter
This is used to light cigarettes. To use, push the

lighter in. After a few seconds it will spring back,
and glow.
Operation of lamp switch
This switch is used to turn on the front lamps,

working lamps, additional lamp at the top front of
the cab, and monitor lighting.
Operation of swing lock switch
ON position (actuated):
The swing lock is always applied, and the
upper structure will not swing even if the swing
is operated. In this condition, the swing lock
monitor lights up.
OFF position (cancelled):
Swing operation is possible. In this condition,
the swing lock monitor goes off.
Operation of machine push-up switch
Low pressure setting:

The boom thrust force is weak.
High pressure setting:
The boom thrust force becomes more powerful.
Operation of boom shockless control switch (if equipped)
ON: While the boom stop operation, shock of

the work equipment is controlled.
Operation of step light switch (if equipped)
When the switch is pressed, the step light will

light up for approx. 60 seconds.
Even if the starting switch key is at the OFF
position, the step light will light up for approx.
60 seconds when the switch is pressed.
Revision
Category
7/13
Check item
Operation of room lamp switch
Local
After
assembly hours of
time
operation
Judgement standard
ON position: Room lamp lights up
OFF position: Room lamp lights off
Even if the starting switch key is at the OFF position, the room lamp will light up when the switch is
pressed.
Operation of emergency pump drive switch
When normal: Switch is pushed down:
When the monitor display shows E02 (TVC valve system error),
move the switch "up" to make it possible to carry out work
When switch is pushed up, alarm buzzer sounds.
Operation of swing holding brake release switch
When normal: Switch is pushed down
When the monitor display shows E03 (Swing brake system error),
move the switch "up" to cancel the brake, and it becomes possible to
actuate the swing. However, the swing brake remains released.
When switch is pushed up, alarm buzzer sounds,

and swing lock symbol flashes
Operation of alarm buzzer stop switch
This is used to stop alarm buzzer if it sounds to

warn of an abnormality of warning item during
engine operation.
Operation of lower wiper switch (if equipped)
ON: Lower wiper moves.

OFF: Lower wiper stops.
Operation of travel levers
FORWARD: The lever is pushed forward.

(The pedal is angled forward)
REVERSE: The lever is pulled back.
(The pedal is angled back)
N (Neutral): The machine stops
Operation of LH work equipment control lever

This lever is used to operate the arm and upper

structure.
Arm operation
Swing operation
(a) Arm OUT
(c) Swing to right
(b) Arm IN
(d) Swing to left

stop.
Operation of RH work equipment control lever
This lever is used to operate the boom and bucket.

Boom operation
Bucket operation
(a) RAISE
(c) DUMP
(b) LOWER
(d) CURL

stop.
Confirmation of failure history (Both electrical and mechanical)
Delete the failure history after confirming that no

abnormality sign is displayed. Confirm that no failure history is provided after completion of the test.
The operation of bottom dump switch
Right: Bottom opened

Left: Bottom closed
8/13
6.8 +0.6
- 0.2 rpm
9/13
5.7
5.0
4.3
2.5
4.3
4.0
1.6
1.7
Max. 3 sec.
Max. 3 sec.
Max. 3 sec.
coupling case
coupling case
(Including machine push-up function)
ON: Machine is lifted up.

OFF: Machine is not lifted up.
Immediately after engine is stopped, boom

cylinder must move from fully extended
position to ground level. (Arm at max. reach)
10/13
11/13
12/13
[55] for service mode

Confirmed (on fan rotation 100 % fixed mode)
1050 50 rpm (Engine full, Oil temp. 50C)

boom raise, P mode
and Heavy lift OFF,
relief
F pump
R pump
Control valve main
F pump
31.4
320
Control valve main

R pump
31.4
320

boom raise, P mode
and Heavy lift ON,
relief
27.9
285

swing and P mode, relief
+5
3.33+0.49
34.0 0
0
(At engine high idle, neutral)
Self pressure reducing

valve output pressure
4. Current value measurement Confirmed on the monitoring mode
Run one side idle
(Idling side)
F pump
mA
mA
At neutral
275 80 mA

R pump
mA
mA
Run one side idle

(Idling side)
584 80 mA
Engine high idle
Note: Measure the following J/S differential pressure only if the

pump EPC current does not pass the test.
Run one side idle
(Idling side)
F pump
R pump
At neutral
Min.2.5 V
Run one side idle

(Idling side)
Min. 1.3 V
Engine high idle
13/13
Measure the travel of the lever at the

center of the lever tip

Komatsu Excavadora Pc800

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GEN00048-05

Field Assembly Instruction

When the work equipment is installed, the engine must be operated.

B. Assembling of Work Equipment of Backhoe ..................................................................

C. Assembling of Work Equipment of Loading Shovel.....................................................

D. Assembling of Counterweight Remover ......................................................................

M. Procedure for Inspection and Maintenance after Completion of Assembly.................

Field Assembly Inspection Report (Backhoe)

Min. ground clearance

Travel speed (Low/High)

) show the value when the track width is reduced.

) show the value when the track width is reduced.

PRECAUTIONS FOR FIELD ASSEMBLY y

DISPOSAL OF REMOVED PARTS

Meeting with all workers

Min. 1.5 m3/min

Min. 0.7 MPa

q Left track frame

Completion of Installation of unit assembly to body

Backhoe Inspection of oil level and

Loading shovel- Flushing of hydraulic

KIT LAYOUT DIAGRAM

Motor cover handrails

t Packing Style of Each Kit (Sizes in drawing are given in millimeters.)

Cab convex portion (air intake for air conditioner)

Lock used when the door is opened

Stopper used when the door is opened

Upper structure without head guard

Upper structure with head guard

Fix the upper structure on the truck by means of chain block.

(4) Boom cylinder (for all models)

(5) Arm cylinder

(2) Top guard (PC850-8, PC850SE-8 only)

(3) Catwalk (1) (for all models)

(4) Catwalk (2) (for all models)

(5) Radiator duct (for all models)

(6) Travel motor cover (for all models)

Socket for KW45FS

LIST OF TOOLS FOR FIELD ASSEMBLING

Waste oil pan

For 16-time wrench

Revolving frame pedestal

Part No. of washer

Thread diameter Bolt length

Applicable socket size

: Bolt thread diameter (Nominal diameter)

Table 1 Tightening torque for bolts not specified in text

Nominal size of thread

Width across flats

a For symbols a and b in the table, see Fig. 1.

2. Tightening torque for pipe threads

Nominal size (in)

Nominal size (in)

3. Tightening torque for hydraulic hose connecting nut

84 132 {8.5 13.5}

128 186 {13.0 19.0}

177 245 {18.0 25.0}

Note : When connecting hoses, take care not to twist them.

4. Proper socket sizes for bolts of M39 and larger (Reference)

Proper sizes of sockets or spanners

Main applications, features

Used in places requiring an immediately effective, strong adhesive.

Features: Resistance to heat and

Used as heat-resisting sealant for repairing engine.