Field Assembly Instruction: PC7504 PC8004

SEAW000800
FieldAssembly
Instruction
PC7504
PC8004
HYDRAULIC EXCAVATOR
PC7504 - 10001
PC750SE-6 - 10001
SERIAL NUMBERS
PC75OI.C-6 - 10001 andw
PC800-6 30001 n
PC800SE-6 - 30001
This material is proprietary to Komatsu America International Company and is not to be reproduced, used, or
disdosed except in accordance with written authorization from Komatsu America IntemaQonal Company.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make
changes or add improvements at any time without incurring any obligation to install such changes on products sold
previously.
Due to thii continuous program of research and development, periodic revisions may be made to this publication.
it is recommended that customers contact their distributor for information on the latest revision.
August 1996 Copyright 1996 Komateu America IntemEltional Company

CONTENTS
Points Regarding Local Assembly ................................................................................................................ 3
Assembling Procedures, Applicable Equipment and Schedule ................................................................. 5
Packing Style for Transportation .................................................................................................................. 7
List of Tools for Field Assembling .............................................................................................................. 12
Field Assembling .......................................................................................................................................... 13
Related Laws and Regulations ................................................................................................................... .I4
Fitting of Left and Right Track Frames ....................................................................................................... 18
Arrangement of Travel Pipe ....................................................................................................................... .20
Installation of FOPS.. .................................................................................................................................... 23
Setting of Radiator Cover ............................................................................................................................ 26
Fitting of Rearview Mirror ........................................................................................................................... 27
Installation of Handrail ................................................................................................................................. 29
Prevention of Natural Closing of Ceiling Window .................................................................................... .30
Installation of Step ....................................................................................................................................... 31
Installation of Left Side Step ...................................................................................................................... .32
Setting of Muffler Tail Tube ........................................................................................................................ 33
Sticking of Sheet (to Counterweight) ...................................................................................................... 33-l
Installation of Counterweight ...................................................................................................................... 34
Installation of Radio Antenna ...................................................................................................................... 35
Installation of Cab Top Light ...................................................................................................................... .37
Fitting of Stopper (on Hydraulic Tank) ....................................................................................................... 41
Extension of Track Frame Gauge (Only when 3-split packages are transported). ................................. .42
Setting of Travel Pipe Cover ........................................................................................................................ 45
Adjustment of Track Tension ...................................................................................................................... 47
Inspection of Oil Amount and Water Amount ........................................................................................... 49
Boom Foot Pin and Boom Cylinder Foot Pin ............................................................................................. 50
Boom Assembly ........................................................................................................................................... 51
Relieving Remaining Pressure from Hydraulic Circuit.. ........................................................................... .52
Installation of Boom Cylinder Foot ............................................................................................................. 53
Arrangement of Boom Cylinder Hose ....................................................................................................... .54
Boom Cylinder .............................................................................................................................................. 55
Arm Cylinder ................................................................................................................................................. 56
Arrangement of Arm Cylinder Hose ........................................................................................................... 57
Installation of Arm Assembly ...................................................................................................................... 58
1
Arrangement of Bucket Cylinder Hose between Boom and Bucket Cylinder ........................................ .60
Bucket Cylinder Hose between Boom and Bucket Cylinder .................................................................... .61
Lubrication Piping to Work Equipment ..................................................................................................... .62
Air Bleeding from Cylinder .......................................................................................................................... 63
Wiring of Work Equipment .......................................................................................................................... 64
Inspection of Oil Level in Hydraulic Tank and Refill ................................................................................. .66
Replacement of Return Filter (Standard Filter to Flushing Filter) ........................................................... .67
Flushing of Hydraulic Circuit ...................................................................................................................... .69
APPENDIX
FIELD ASSEMBLY INSPECTION REPORT
POINTS REGARDING LOCAL ASSEMBLY
1. Selection of work place

1) The work place should be suitable for loading and unloading the machine. The following points
should be considered.
. Area
. Hardness of ground surface
. Levelness
. Entry/exit roads, turning space
2) Assembly work on the hydraulic circuit must not be carried out in any place where dust or rain
can get into the circuit during the operation.
3) If the work is carried out outside, avoid places where there is rain or strong wind.
2. Preparation and checks of lifting tools and jigs

1) Check each lifting tool and jig thoroughly.
Inparticular,checkstandsand blocksmadeofwoodtocheckthattheisideisnotrottedorcracked.
3. A Checks during actual operation

1) Apply the parking brake of the trailer ad crane securely, then put blocks under the wheel.
2) Lower the pressure and temperature of the engine, hydraulic oil, and cooling water before
starting work.
3) When starting the engine, always give an agreed signal, such as blowing the horn, to warn the
people around the machine. Check also that the work equipment levers and travel levers are in
neutral, and that the fuel control lever is at the low idlig position.
4) Be careful to maintain the balance of parts being lifted by the crane.
5) Do not allow unauthorized persons into the working area.
3
l Inspection of oil level and
l Air bleeding from work

equipment cylinder
* Flushing of hydraulic circuit
l Extension of track frame width
Assembly unit Base machine type excavator - Adjustment of track tension
l Performance test
@ Counterweight,
Platform group
@ Assembling of work equipment
Crane
0.49 - 0.69 MPa

Air compressor
Worker
Start of assembling Completion of inStallatiOn Of Unit Completionof body assembling l Completion of general assem-
assembly to body bling
l Meeting with all workers
Days
Loading shovel- * Adjustment of track tension

type excavator l Performance test
Assembly unit Base machine
0 Left track frame @ Upper structure @ Counterweight,

@ Counterweigh @ Platform group
@ Axle assembly
’ ~~~~$+: ,$/’ Ieve’ @) Assembling of work
equipment
Crane
B 196KN (200
343 KN 135t1 196~~ (2011
0.49 - 0.69 MPa

(5 - 7 kg/cd)
Air compressor
15 m’!min.
Worker Y//P//////////;////////////v////i//////////////./~~~/~/~////~,//~
Leader + 3 mechanics
Start of assembling
Completion of body Completion of installation of
* Meeting with all workers assembling unit assembly to body
Completion of Installation of unit assembly to body

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.
n 3-kit Transportation
(Upper structure + Undercarriage) (Work equipment) (Others)
n 4-kit Transportation
(Upper structure) (Undercarriage) (Work equipment) (Others)
n Packing Style of Each Kit (Sizes in drawing are given in millimeters.)

l Upper structure + Undercarriage
mm
PC750-6 PC800-6
Model Nos.
PC750SE-6 PC800SE-6
Overallwidth
(mm)
Weight
46,200 46,400
(kg)
, 6840
AAlOn930
7
Transportation
l Upper structure
unit : mm
Weight
23,700 23,800
kg)
AA307996
Fix the upper structure on the truck by means of chain block.
l Undercarriage
unit : mm
l Work equipment
(I) Boom
Model No.jPC750-6/PC750SE-61
PC800-61PC800SE-6
w;$t / 7,420 ( 6,850 j 7,770 1 6,850 j
8
Transportation
(2) Arm
Model No. PC750-6 PC750SE-6 PC800-6 PC800SE-6
A(mm) 5,105 4,075 4,800 4,075
Bfmm) 1,324 1,696 1,365 1,696
Overall
all width 749 753 749 753
(mm)
Weight
(kg) 3,950 4,880 4,410 4,880
(3) Bucket
(4) Boom cylinder (for all models)
3180 mm Weight : 1,620 kg

(810 kg x 2 PCS.)
10
AA308050
(5) Arm cylinder
Weight 915 1,080

kq (540 x 2)
9
Transportation
l Others
(1) Counterweight
unit : mm
“r
(2) FOPS (for PC800-6 and PC800SE-6 only)
Weight : 365 kg
IO
Transportation
(3) Catwalk @ (for all models)
unit : mm
Weight : 365 kg
(4) Catwalk @ (for all models)
unit : mm
Weight : 30 kg
AA300000
(5) Radiator duct (for all models)
unit : mm
Weight : 50 kg
11
Transportation
List of Tools for Field Assembling

Transportation
Field Assembling
1. Selection of Work Place

1) Select a work place taking the following into account so that the machine can be loaded and
unloaded.
l Area,
l Hardness,
l Flatness, .
l Access road and turning place
2) Avoid such a place where dusts or rain enter the hydraulic circuit when the circuit is assembled
3) Do not assemble the machine outdoors when it is stormy or it rains.
2. Preparation and Inspection of Sling, Jigs and Tools

I) -Inspect slings, jigsand tools carefully. Pay special attention to wooden supports and carefully
check if their insides have rotted or cracked.
3- f?Inspection of Actual Work

Apply the parking brake of the trailer or the crane truck certainly and drag their wheels.
2) Lower the temperature and/or the pressure of the engine, hydraulic oil and cooling water before
assembling.
3) When starting the engine, alarm works around by giving the specified signal such as horn, and
make sure that the levers of work equipment and travel levers have been set to the neutral
positions and that the fuel control lever has been set to the low idling position.
4) Balance the substance to be lifted before crane operation.
5) Prevent unauthorized persons from entering the work place.
13
Transportation
Related Laws and Regulations
When assembling these machines, observe stipulations of the following laws and regulations:
Ordinance on Vehicle Restriction
Restrictions to vehicles required to maintain road structure, to prevent risks in traffic or in relation with
road.
I. General Restrictions
l General restriction on width
l General restrictions on gross weight, axle load and unit load per travel wheel
l General restrictions on height, length and minimum turning radius
2. Restrictions on Bridge and Others

l Restrictions on bridge and others
l Restrictions on tunnel and others
3. Individual Restrictions
l Individual restriction on width
l Individual restrictions on gross weight, axle load and unit load per travel wheel
l Restriction on trafficking method on roads of remarkably reduced bearing power due to flood or
snowmelt
l Restrictions on automobile with caterpillar
l Restrictions on trafficking on road shoulder
4. Exceptions
l Exception of individual restrictions on width
l Exception to special vehicles- When trafficking special vehicles, you are requested to get approval
from the road administrator by submitting application.
In addition, you are requested to observe any rules based on the safety standard of the Road Vehicle Act
and on the Road Traffic Law.
14
Transportation
As for blinding jigs (such as flange, head, cap and O-ring) used for piping to work equipment and the
undercarriageatthetimeoftransportation, blindplugsforlubricationpiping,cylinderfixing jigsand blind
plugs removed from the loose-supply items, store them in order for next transportations.
Tightening torques of bolts shall be as perthe table below unless otherwise specified in the maintenance
standard table.
1. List of Torques
Tighten metric thread bolts and nuts without specific indication with torques shown in the table
below:
Decide proper tightening torques in view of width across flats (b) of bolt and nut.
When bolts and nuts have to be replaced, be sure to select those of the same size out of Komatsu
genuine parts.
Thread Width Tightening torque NmIkgmI 1
T
diameterra cross flz
It-
a(mm) b(mm) Target value Tolerance
6 10 13.2 Il.351 11.8-14.7 {1.2-1.51

8 13 31 {3.2} 27-34 {2.8-3.5)
10 17 66 16.7) 59-74 (6.0-7.5)
12 19 113 I11.5) 98-123 {lO.O-12.51
14 22 117 {18.01 157-196 {16.0-20.01
16 24 279 I28.51 245-309 (25.0-31.5)

18 t 27 382 I39.0) 343-427 135.0-43.51
20 30 549 156.0) 490-608 {50.0-62.01
22 32 745 176.01 662-829 {67.5-84.51
24 36 927 I94.5) 824-1030 I84.0-1051
27 41 1320 {I351 1180-1470 I120-1501

30 46 1720 (175) 1520-1910 1155-1951
33 50 2210 1225) 1960-2450 I200-2501
36 55 2750 I2801 2450-3040 I250-3101
39 60 3290 {335) 2890-3630 I295-3701
Notice :
When tightening bolts to a panel board made of resin, use care not to break it with excessive torque.
15
Transportation
1-2. When torque wrench is used, tightening torques shall be as per Table 2.
These torques are used when tightening torques of narrow range are required.
Table 2 Unit : NmIkgmI
6 11.8-14.8 {1.2-1.5} 13.2 I1.35) 1150
8 27.5-34.3 {2.8-3.5) 31.4 (3.2) 2175
10 58.8-73.5 16-7.5) 65.7 I6.7) 3355
12 98.1-122.6 Il.O-12.5) 112.8 Ill.51 4865
I 156.9-196.1 {1.6-2001 1 176.5 {18) 6715
16 245.1-308.9 I25-31.51 279.4 {285) 9860
18 343.2-426.5 135-43.5) 382.4 (39) 11200
I 496.3-607.9 (50-62.0) j 549.1 (56)
22 661.9-828.5 (67.5-84.5) 745.2 (76) 18000
24 823.6-1029.5 (84-105) 926.6 (94.5) 20600
27 1176.6-1470.8 {120-150) 1323.7 (135) 26000
30 1519.8-1912.0 (155-195) 1715.9 I1751 30100
33 1 1961.0-2451.3 (200-250) / 2206.1 (225) I 35800
36 2451.3-3039.6 (250-310) 2745.5 (280) 40700
39 2892.5-3627.9 (295-370) 3284.7 (335) 45200
2. Tightening Torque of Pipe Thread

1. Scope This standard covers tightening torques of pipe threads, especially of thread nominal
sizes PT1/8” to PTI” and PS1/8” to PSI “. When otherwise specified, the following shall not apply.
2. Tightening Torque
2-l. When materials of parts with external thread are SS41, FC and SGP, their tightening
torque shall be as per Table 1.
Table 1
Unit : NmIkgm)
Steel Cast iron Light alloy
l/8 3.9-6.9 {0.4-0.7) 2.9-5.9 10.3~0.6) 2.0-3.9 (0.2-0.41
114 5.9-11.8 {0.6-1.2) 4.9-9.8 (0.5-1.0) 3.9-7.8 {0.4-0.8)
318 16.7-26.5 (1.7-2.7) 13.7-21.6 {1.4-2.2) 9.8-16.7 {l.O-1.7)
l/2 32.4-52.9 {3.3-5.4) 26.5-43.1 {2.7-4.4) 19.6-32.4 12.0-3.3)
314 51.0-85.3 {5.2-8.7) 42.2-70.6 14.3-7.2) 31.4-52.9 (3.2-5.4)
I 86.3-173.6 (8.8-17.7)
72.6-146.1 {7.4-14.9)
54.9-111.8 15.6-11.4)
16
Transportation
2-2. When materials of parts with external thread is S43C. their tightening torque shall be
as per table 1.
Table 2
Unit : NmIkgm)
Steel Cast iron Light alloy
118 11.8-24.5(1.2-2.5) 9.8-19.6(1.0-2.0) 6.9-14.7{0.7-1.5)
l/4 1 19.6-44.1{2.0-4.5)1 16.7-37.3{1.7-3.8)1 12.7-28.4(1.3-2.91
318 1 44.1-93.1(4.5-9.51) 37.3-77.5(3.8-7.911 27.5-58.812.8-6.01
II2 1 98.1-188.3{vm.19.2}183.3-157.918.5-16.11
1 60.8-115.70X2-11.8)
314 1170.-6 3167 I 17.-4 32.}I

3 1412-247.1(14.4-25.211
105.9-186.3110.8-19.0)
I 1367.7-612.8(36.5-62.5}1309.8-514.8
I31.6-52.511
235.3-392.2I24.0-40.0)
3. Tightening Torque of Rubber Hose with Taper Seal

Unit : Nm{kgm)
Nominal No. 02 03 04 05 06 IO 12 14
Appropriate 24.5+49 49f19.6 78.5k19.6 137.3f29.4 176.5*49 196.1+49 245.2+49 294.2+49

tightening I2.5f0.51 {5GI (8-I {14f3} {18f5} {20?5} {25*5} 130+51
torque
4. When assembling, use care not to twist rubber hoses.
17
Fitting of Left and Right Track Frames (l/Z)
Lift the upper structure with a crane and fit the

track frames as follows:
._M36x3, Tightening torque : 2451.3 to 3039.6 Nm (250 to 310 kgm}

/
..............................................................
,-?%
............................. & &
. P
rt,
..........
........................
....................................
..................................
................................
.......................................................... ..............................
.......................................................... 2451.3 to 3039.6 Nm I250 to 310 kgm} ............................
1
.......................................................... ...........................
.........................
........................
Precautions Loose-supply items

Place the washer @ on the plate @. No. Parts Names Parts Nos. Qty.
1 Bolt 209-09-51110 40
2 Spacer 209-30-61120 40
l Tightening Tools 3 Bolt 209-09-51110 8
4 Plate 209-30-71120 2
4-time wrench 78-2942 Nm 18-300 kgml 5 Washer 01643-33690 8
Torque wrench 980.5 Nm II00 kgm1 6 Spacer 209-30-I 1330 8
Socket, 25.4Sq. x 55 mm
1 I I I
18
Fitting of Left and Right Track Frames (2/2)
+r When tighten bolts, raise the track with a hy-

draulic jack as shown above so as to get suffi-
cient space for tightening.

Do not remove the shoes before No. Parts Names Parts Nos. Qtv.
assembling (so as to maintain the tightening
torques of the shoe bolts).
I I I I
I I I
I I I I
19
Arrangement of Travel Pipe (l/3)
.\
\ /‘.I \
,................... ... . . ....

\ I IiT-r-
Fig. 2
_-_ _-

No. Parts Names Parts Nos.
20
Arrangement of Travel Pipe (Z/3)
. . ____ __ ____ . .. __ .. . ... fgtgj
...............................................................................
Fig. 3 ... ..
...................::::::::::::::::::::::::::::::::::::::::::::::
................................................................
..........................................................................................................................................................
..................................................................................................

No. 1 Parts Names Parts Nos. 1 Qty.
I I I
21
Arrangement of Travel Pipe (3/3)
(I) Arrange the pilot hose @ for selecting

machine speed and the drain hose @ as
shown in Figs. 1 and 2.
(2) Arrange the main hose @ on the center
frame side as shown in Fig. 3. Use new O-
ring out ofthe loose-supply items and use
split flange, bolt and washer out of the
blinding parts.

No. Parts Names Parts Nos. Qty.
1 Hose 07099-01013 4
2 Hose 07103-20517 2
3 Hose 07103-20318 2
4 O-ring 07000-13032 8
22
Installation of FOPS (l/3)
(1) Assemble the FOPS as shown below.
&I kg FOPS : 365 kg
(Stopper) (Nut)

No. Parts Names Parts Nos. Qtv.
1 Frame 209-956-7112 1
2 Cover 209-956-7122 1
3 Bracket 209-956-7170 1
4 Bolt 01070-81630 4
5 Bolt 01010-81645 6
6 Washer 01643-31645 10
7 Stopper 09453-00002 1
8 Nut 01580-11210 1
23
Installation of FOPS (2/3)
(2) Open the grease can storage box behind

the cab, loosen and remove the frame @
mounting bolt.
(3) Lower the frame @ to the bottom.
(4) Loosen the frame @ mounting bolt.
...................................................................
......................................................
. ........................
....................
....................................
........................

No. ) Parts Names Parts Nos. 1 Qty.
I
24
Installation of FOPS (3/3)
(5) Liftthe FOPS assembly with thecrane and

fit it to the mounting holes on the revolv-
ing frame and fix it using the bolts @ @
and the washer 0.
(6) Re-assemble the frame @.
(7) Adjust the frame @ so that the space
between the FOPS rear pole and the cut-
out port of the cab rear cover comes to
5mm or more as shown below, and then
assemble it.
FOPS rear pole
djust so that the SP

comes to 5mm

No. Parts Names PartsNos. Qty.
9 Bolt 01010-81670 12
10 Bolt 01010-81650 5
11 Washer 01643-31645 17
25
Setting of Radiator Cover
(I) Set the radiator covers 0 and @ on the

body and fix them using the bolts @to @
and the washer 0.
+-
_--
_-
-__
,-:1-/Z
,‘,-_- ---
,;;,;/,/-- c::
i /, * ._ -- - -

Remove the plugs for rust prevention set No. Parts Names Parts Nos. c&y.
in the mounting tapped holes. 1 Duct 209-54-73581 1
2 Duct 209-54-7357 1 1
3 Bolt 01010-81250 2
4 Bolt 01010-81270 2
5 Bolt 01010-81280 2
6 Bolt 01010-81230 6
7 Washer 01643-31232 12
26
Fitting of Rearview Mirror (l/2)
(I) Fit the mirror 0 to the handrail in front of

the machine right side by using parts @ to
I-
L?
- ~_
_ -.-
- _-
_ _--.
_’ --
W_
-
-..
---._.- _-__L-__._
_-_L.---..-~-:f+J. --__
F
_- - _ ___ _ _ __ _ _ __-
- - --
- _ __ _
____--_.I~-
_ __. _ _.._
~__
I--====--
_-
- _ - _ ~_ __ - - _- _ - - - __ _ --L;. - - --_-I - ._ i_ ---
.----J---__‘--\
___,~-__-‘----
c::31
_-
____-/LL~_ - - .- _,- _ _-~~~~~‘~-~
it
----T - -
CJ
T-.‘;J
___ ‘i
I,
--.-.. . - - ,/’,:
..__”- - - --,i..-_m
‘I
//
,,[$, ;, /&’
I J’,(/
iT_
/,
I 1
II I’ _
? __A I,
nlr1 .> I.-
;:
I
27
Fitting of Rearview Mirror (Z/2)
(I) Fit the mirror 0 to the handrail in front of

the machine left side by using parts @to
0.
-------_-_-
---____-- _._,-+P
- - - __ - - _.-.-
-1---J;:
=~I=--
_---- -
_---
---
e-
=----
!&
_
<--
1...>-- \
._....
------
_-- -

1 Mirror 2OY-54-28911 1
2 support 209-54-73430 1
3 Clamp 207-54-17840 1
4 Bolt 01252-41025 2
28
Installation of Handrail
(I) Open the cover on the H tank and install

the handrails @ and @ to the tank using
the bolt @ and the washer 0.
(2) install the handrail @to the top of the cab.
Use the bolt and the washer fitted there.

1 Handrail 209-54-74311 1
2 Handrail 209-54-74321 1
3 Bolt 01010-81250 8
4 Washer 01643-31232 8
5 Handrail 209-54-73171
29
Prevention of Natural Closing of Ceiling Window
(When FOPS is fitted)

(This arrangement is not necessary when FOPS is
not fitted.)
To prevent the ceiling window from closing natu-
rally due to vibration, fix these parts @to @to the
top of the cab.

1 No. 1 Parts Names Parts Nos. / my.
1 Bracket 209-54-73190 1.
2 Stopper 2OY-54-11611 1
3 Nut 01580-01008 1
4 1 Bolt 01010-81250 1
5 1 Washer 01643-31232 I 1
6 1 Collar 202-54-I 1640 1 1
7 Collar 209-54-7s 188l-l I 1
8 O-ring 07002-12434
9 Plate 209-54-73890 -++
30
Installation of Step
(I) Install the steps @ and @ to the left out-

side of the track frame by using the bolt @
and the washer 0.
(2) Install the step @to the left side cover by
using the bolt @ and the washer 0.

Remove the plugs for rust prevent set in the No. Parts Names Parts Nos. Qty.
mounting tapped holes. 1 Step 209-30-71131 1
2 Step 209-30-7 1140 1
3 Bolt 01010-81640 8
4 Washer 01643-31645 8
5 Step 209-54-63481 1
6 Bolt 01010-81230 4
7 Washer 01643-31232 4
31
Installation of Left Side Step
(I) Lift the steps @ and @with the crane and

install them to the body by using the bolt
@ and the washer 0.
.. .
,...
Step._._._
mating
_._..
_.._ surfaces
___._ (21;places)
..............._- _.____ _
............._.... .
,_. . _. _. __ .

Remove the plugs for rust prevention set in No. Parts Names Parts Nos. Qty.
the mounting tapped holes. 1 Step 209-54-73832 1
2 Step 209-54-73822 2
3 Bolt 01010-81230 19
4 Washer 01643-31232 19
32
Setting of Muffler Tail Tube
(1) Fixthemufflertaletube@tothetopofthe
hood by using the bolt @ and the washer
0.
(2) Fix a rain cap to the muffler tail tube.
Decide the direction so that exhaust is emitted backward
................................................... .......
. ... . ..... ...
.............................
_- .......................................................................
........................................................
.................... .................................................................................................
................ ........................................................................................................
............ ....................................................................................
.........
....... ......................................................................................................................
..... .............................................................................
.... ....................................................
_.........................................
........................................
......................................
......................................
.....
.......... .................................................
__ _..... ____._ __
.__ _. .___ __ ____
____
__ _... __..... ...... . ..... . .. .. .. ... . . . . . ..... ..
View from machine left side
_ -4.” .. _^_ _ _.^ . . . _.._.__._.. .._
._,___._.__,_.._......._
._.___._....______........................: ._ __. _.. .. .. . ......._.... . .... ...

1 Muffler tail tube 6212-12-5560 1
2 Rain cap 6164-12-5900 1
3 Bolt 01010-81230 8
4 Washer 01643-31232 8
33
Sticking of Sheet (to Counterweight)
Sticksheetstothesurfacesofthecounterweightin
front of the machine as shown below.
unit : mm
.................. ........_...
......_....
.. ........ ..... .. .. ... ...
~____,,...,,_.,_____...,..,,..,.................,.........................................,...........................................................................
Counterweight
.... . ..... . ..... .
___._
.._._ __ ._____... .. .. . .. ..... .... ..
........... ..
f0-t
.......
........
- .........
I
._.... _ _________..___._.................
+...
C...

Remove oil and rust from the surfaces on No. Parts Names Parts Nos. Qty.
which sheets are adhered. 1 Sheet 209-54-74910 1
2 Sheet 209-54-74920 1
33-l
Installation of Counterweight
(I) Lift the counterweight assembly with

the crane and install it to the body.
(2) Use the bolt @ (6 PCS.) and the spacer @
(6 PCS.) for the installation.

Install the counterweight so that there will No. Parts Names Parts Nos. Qty.
be the reference space of 15 mm between 1 Bolt 209-46-51190 6
the weight and the revolving frame or so
2 Spacer 209-46-I 1210 6
that the left level difference equals to the
right one.
ir Tightening tools
16-time wrench (Input side 245.1 Nm
I25 kgm1 x 1
Socket (38 Sq. x 65)
Torque wrench 980.5 Nm 1100 kgm} x 1
34
Installation of Radio Antenna (l/2)
When FOPS is fitted
(I) Set the antenna @ in the hole on the left

side behind the FOPS.
(2) Stick the clip @ at three places inside

the FOPS head guard and at three
places on the pole at the right side
behind FOPS and lay the antenna cable
to the connector on the right side of the
cab. (At the time, direct the connector
downward so that water does not enter
it, and wind vinyl tape around the
connector.)
1625 mm
Remove paint from the 025 mm area of the inside
surface of the cover. (Radio antenna)
Direct the connector

downward so that
water does not enter it.
ind vinyl tape

ound the connector.

1 Antenna 362-56-42260 1
2 Clip 08051-00801 6
35
Installation of Radio Antenna (2/2)
When FOPS is not fitted
(1) Fittheantenna@tothestay@andtighten
it together with the handrail on the cab
top.
(2) Stick the clip @ at two places on the cap

top and at four places on the right side
behind the cab and lay the antenna cable
to the connector on the right side of the
cab. (At the time, direct the connector
downward so that water does not enter it,
and wind vinyl table around the connec-
tor.)
l-l
lighten it together
with.the hpndrait -
Remove paint from
the hatched section (pr25
of the antenna bracket.
-..
(To ground the antenna.)
Direct the connector

downward so that
water does not enter it.
Wind vinyl tape

around the
connector.

1 Antenna 362-56-42260 1
2 Bracket 6162-63-1920 1
3 Clip 08051-00801 6
36
Installation of Cab Top Light (l/4)
When FOPS is fitted
(I) Fit the light @ on the front of the FOPS.
(2) Fit the light @ to the bracket 0, and fix the

bracket on the left section of the cab top
surface using the bolt @ and the washer
@.
(3) Fix the bracket @ on the right section of

the cap top surface using the bolt @ and
the washer 0.
(4) Connect the harness @ to the step light

(CN-M75), the head lamp (CN-M74, CN-
M76) and to the relay point (CN-M73).
(5) Tighten the earth cable of the harness @I

and the ones ofthe step light and the head
lamp together using the bolt @ and the
washer 0.
(6) Fix the harness @ with the clip @ (at 2

places marked with :), with the band @ (at
3 places marked with n) and with the clip
@ (at 2 places marked with * inside the
FOPS).
(7) Connect the harness @ at the relay point

(CN-M73) and the main harness (CN-M72,
on the left outside the main beam), and fix
it with the clip @ (at 4 places marked with
* on the right side of the cab).

No. Parts Names Parts Nos. C&y.
1 Harness 209-06-71221 1
2 Harness 209-06-71231 1
3 Lamp 2OY-06-21480 3
4 Bracket 209-06-71251 1
5 Bracket 209-06-71241 1
6 Bolt 01010-81220 1
7 Washer 01643-31232 1
37
Installation of Cab Top Light (Z/4)
When FOPS is fitted
Tighten the harness earth cable

n
and the light earth cable together
7 CN-M73
Main harness
(right side only).

8 Bolt 01010-80820 2
9 Washer 01643-30823 2
10 Bolt 01010-80612 3
11 Washer 209-72-12230 3
12 Clip 2O't-54-13440 6
1 13 1 Band I 08034-20536 I 3
14 Clip 08051-00801 2
38
Installation of Cab Top Light (3/4)
(1) Fit the light @ to the brackets @ and @,

and fix them to the cab top by using the
bolt @ and the washer @.
(2) Fix the bracket @ on the right section of

the cab top surface by using the bolt @
and the washer 0.
(3) Connect the harness @ to the step light

(CN-M75), the head lamp (CN-M74, CN-
M76) and to the relay point (CN-M73).
(4) Tighten the earth cable of the harness @

and the earth cables of the step light and
the head lamp (right) together by using
the bolt @ and the washer 0.
(5) Fix the harness @with the clip @ (at two

places marked with *) and with the band
@ (at two places marked with I&).
(6) Connect the harness @to the relay point

(CN-M73) and the main harness (CN-M72,
left outside the main beam), and fix it with
the clip @ (at four places marked with * on
the right side of the cab).

No. Parts Names Parts Nos. I C2tv.
1 Harness 209-06-7122 1 I I.
2 Harness 209-06-7 1231 I 1
3 Lamp 2OY-06-21480 3
4 1 Bracket 209-06-7 1251 1
5 1 Bracket 209-06-7 1241 1
6 1 Bolt 01010-81220 1
1 7 1 Washer 01643-31232 1
39
Installation of Cab Top Light (4/4)
Tighten the harness earth cable

and the light earth cable together.
Main harness . .
Head lamp (right)
only).

8 Bolt 01010-80860 4
9 Washer 01643-30823 4
10 Bolt 01010-80612 3
11 Washer 209-72-12230 3
12 Clip 2OY-54-13440 6
13 Band 08034-20414 6
14 Bracket 203-06-61810 1
40
Fitting of Stopper (on Hydraulic Tank)
. ....... ... .......1........__..__...____...............................................................................................
. . .... . . .. .. . .. .. . _.. . . 9 .. . . .. .. ... . . . ...... ...... ....

................ cs
. . .........................................i...... 1
. . . . .. .. .. ... .... . ..... . . ....
i_“l,
c
,/‘/ ,,,,,>,;
._. . . . .... . . . ...... .

‘1,.7
‘j ii ’ .....
i,!.’ ,
.. . . .... ... . ... ...... \ \_i _,-:... ..____.___.____..................................................................................................

1 Stopper 2OY-54-11611 1
2 Nut 01580-31008 1
41
Extension of Track Frame Gauge (Only when 3-split packages
are transported) (l/3)
Extending and Contracting Procedures

of Track Frame Gauge
l Reduction of Gauge Width
[II Remove the center frame mounting bolt @ (20

bolts on one side).
121 Turn the upper structure square to the track

frame @ to be contracted, and raise the track
frame with a jack by using a work equipment.
131 Place a block (a 20 to 30cm square crossite)

outside the track frame @ and lower the ma-
chine little by little with the boom cylinder.
And the track frame will slide, hit against the
stopper and stop.
[41 Lower the machine slowly on the ground and

tighten the bolt @ (8 bolts on one side out of
the bolt 0) with the tightening torque
2745.9f294.2 Nm {280*30 kgm}.
151 For the track frame on the opposite side, re-

peat the above procedures.

After the extension of the gauge width, No. Parts Names Parts Nos. 1 Qty.
make sure that the track frame does not Bolt 209-09-51110 I 20
interfere with the pipe to the travel motor c)nn 9l-l Cllln
Spacer I LVJ-La”-” I IL” I 20
and is not twisted.
l Tightening tools:
4-time wrench 78-2942 Nm {8-30 kgm}
Torque wrench 980.5 Nm II00 kgm)
Socket, 25.4 Sq. x 55 mm
42
Extension of Track Frame Gauge (Only when S-split packages
are transported) (2/3)
l Extension of Gauge Width
III Remove the center frame mounting bolt @ (8

bolts on one side) around the track frame to be
extended.
121 Turn the upper structure square to the oppo-

site side of the track frame @ to be extended.
Supplementary Explanation :
Make the track frame relief height “H” less than

50mm. If it is raised too much, the stopper bolt will
be twisted and bent.
131 Pull the body forward by using the arm, and

the track frame will slide.
141 Stretch it until it hits the stopper. Then, lower

the machine slowly on the ground and tighten
the bolt @ (20 bolts on one side) with the
tightening torque 2745.9k294.2 Nm I280?30
&r-n).
151 For the track frame on the opposite side, re-

peat the above procedures.
l Extend or contract the track frame gauge

on a flat and strong ground.
l It is very dangerous to operate each cylin-

der quickly during the extension or con-
traction of the track frame gauge width.
So, never operate it quickly.
Precautions Loose-supply item

1 No. I Parts Names Parts Nos. I Qtv.
43
Extension of Track Frame Gauge (Only when S-split packages
are transported) (3/3)
% To tighten bolts, raise the track by using a

hydraulic jack to get sufficient space for tight-
ening.

Setting of Travel Pipe Cover (l/Z)
Set the travel pipe covers as shown below:
Precautions
.__.
5 Bolt 01010-81230 14
6 Bolt 01010-81240 4
7 Washer 175-54-34170 18
45
Setting of Travel Pipe Cover (2/2)

For fixing, use the bolts and washers 8 Cover 209-30-7 1391 1
temporarily fitted in the center frame.
46
Adjustment of Track Tension (l/Z)
Inspection and Adjustment of Track Supplementary Explanation :

Tension
The grease amount to the track of standard tension
is 5OOcc on one side.
A Warning
An operator and a worker shall always work n Adjustment

together, and the operator shall manipulate When the track tension is not of the standard,
the machine in accordance with signals of adjust it as follows:
the worker. Since the machine is raised for
inspection of track tension, fall of machine 7 A Warning
due to erroneous handling is quite danger-
ous. Never move the machine during the The internal high pressure grease may burst
inspection. out. Do not loosen the valve more than one
turn when it is required. Also, do not loosen
Since pins and bushings used on the undercar- any parts other than the valve at the time.
riage are worn out variously depending on work- Keep your head away from the valve.
ing conditions and soil conditions, inspect track If the tracks cannot be loosened in accord-
tension from time to time to keep the standard ancewiththefoIlowingprocedures,askusor
tension. Inspect and adjust track tension under one of our service shops for repair.
the same conditions as the operating conditions
(including load of mud if the track is loaded with
mud in general during operation).
n Inspection
111 Raise the machine by means of the boom and

arm. At the time, move the levers slowly.
121 Carefully select a safe place protected from

unexpected fall of the machine. Then, meas-
ure the clearance between the bottom end of
the track frame and the top surface ofthe track
shoe.
131 When the clearance between the track frame

between the 4th and 5th track rollers and the
rolling contact surface of the track link roller
ranges from 340 to 390 mm, the standard 340-390 mm
I
tension is available.

47
Adjustment of Track Tension (Z/Z)
l To increase track tension

Prepare a grease gun.
[II Press grease in through the valve @) by using

the grease gun.
El To check if the tension is appropriate, move

the machine back and forth.
131 Check the track tension again. If the tension

is not appropriate, adjust it once again.
Grease may be pressed in until @ comes to

148mm. If the track is still loose, pins and
bushings might have been worn out. They Grease cylinder *LI,p(I,*
should be reversed or replaced. Ask us or one
of our service shops for repair.
. To reduce track tension
/ AWarning
------I
It is very dangerous to discharge grease by
any method other than the following proce-
dures. When the track cannot be loosened,
ask us or one of our service shops for repair.
[II Loosen the valve @ little by little to discharge

grease.
PI Loosen the valve @ up to one turn and not

more.
[31 When grease is not discharged smoothly,

move the machine back and forth a little.
141 Tighten the valve 0.
151 To check if the track tension is appropriate,

move the machine back and forth.
[61 Check the track tension again. If the tension

is not appropriate, adjust it once again.

I I I
48
Inspection of Oil Amount and Water Amount
Fuel and Oil following Mixing Proportion Table. In this case,

regard temperatures about 10°C lower than the
Change oils depending on ambient temperature actual temperatures as the minimum temperature
as shown in the following table. in the table.
Specified Oil Amount means the total oil amount Mixing Proportion Table of Water and Coolant
including oil in pipes to various equipment, and
Refill Capacity means the amount of oil to be
replaced at the time of inspection and mainte-
nance.
When starting the engine at a temperature below

O”C, be sure to use SAEIOW, SAEIOW-30 or
SAE15W-40 even if the ambient temperature rises A Warning
to around 10°C in the day time. The coolant is inflammable. So, keep it
away from fire.
Cooling Water
Use tap water as the cooling water. If cooling
Since Komatsu genuine super coolant (AF-ACL) water should be obtained from river, well or small
has been added in the cooling water, it is not water supply system, consult with us or one of our
necessary to change the cooling water until the service shops.
ambient temperature falls to -10°C. When it goes
We recommend you to control mixing ration with
down below-IO%, adjust the concentration of the
an antifreeze concentration meter.
cooling water referring to “IrregularMaintenance”.
For coolant ratio tc water, investigate past mini-

When removing the drain plug, use care not
mum temperature and decide it according to the
to be drenched A
I---- by coolant
Warning mixed
7 water.
Engine oil pan
P.T.O. case
Fuel tank
Cooling water system
When oil and water amounts are insuffi- No. Parts Names Parts Nos. Qty.
cient, supply them.
49
Boom Foot Pin and Boom Cylinder Foot Pin
(I) Boom Foot Pin fixed to the body

Remove the stopper and pull out the pin.
(2) Boom Cylinder Foot fixed to the body

Remove the stopper and pull out the pin.
* To pull out pins, use a forcing screw

(!=I6 mm, P=2 mm).

I I I
50
Boom Assembly
(I) Lift the boom assembly with the crane L 1 PC750 1 PC750SE 1 PC800
and bring it to the body pin hole.
&I
kg 1 PC800SE
7,500 kg / 6,900 kg 7,800 kg
(2) Fitting of Boom Foot Pin (See the figure.) .-
. . .._
Insert a boom foot pin (which had been ;:--
L.--L\ -.“‘-.
245.1 to’3b8.9 Nm”
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.
I& Sincefourseals(209-72-11261) have been

11:L:_::<(-.- .- )_ ,_‘_ :’
fitted to the boom foot as shown below,
use care notto breakthem when inserting
pins.
-
Q Check the clearance between the boom

foot and the machine outside, decide the
sizeandquantityofshimsothattheclear-
ante becomes below 1 mm and insert the
shim between them.
Use the adjustment shims (209-72-I 1180,
1.0 mm thick, 2 PCS. and 209-72-I 1190,1.5
mm thick, 4 PCS.) to decide their combina-
(3) Insertthe boom foot pins fully on both the tion. (Adjust the clearance with shims at
leftand rightsidesandfit lockplatesthere. one place outside.)
& Inside bushing: anti-friction com-

pound (LM-PI.

Shim (t : 1.0 mm) 209-72-I 1180 2
Shim (t : 1.5 mm) 209-72-I 1190 4
Seal 209-72-I 1261 4
II
51
Relieving Remaining Pressure from Hydraulic Circuit
When removing hydraulic pipes, be sure to relieve

remaining pressure in accordance with thefollow-
ing procedures:
[II Set the lock lever to “Free.”
PI Remove the cap from the hydraulic oil tank.
[31 Start the engine, operate it for about 10 sec-

onds and stop the engine.
I% Do not increase the engine speed to over

1,OOOrpm.
97 Keep the control lever of the work equipment
neutral.
* Lower the hydraulic safety lock and keep it
free.
141 Set the control lever of each work equipment

to Full Stroke within 5 to 6 second after stop-
ping the engine.
I% Repeat the the procedures [II to [41 three

times.
A When removing the cap from the oil filler port

of the hydraulic oil tank, turn it slowly to
relieve pressure in the tank and remove it
carefully.
[51 After relieving remaining pressure, setthecap

to the oil filler port of the hydraulic oil tank so
that dust do not enter the tank.
% Raise the hydraulic safety lock and keep it

locked.ame and the top surface of the track
shoe.

1 No. 1 Parts Names Parts Nos. 1 Qtv.
, <
52
Installation of Boom Cylinder Foot
(I) Lift the boom cylinder with the crane and

bring it to the body pin hole.
(2) Set the O-ring (07000-12130,4 PCS. forthe

left and right cylinders) out of the loose-
supply items on the boom cylinder foot
and push pins in it.
& Inside bushing: anti-friction com-
pound (LM-P).
(3) Checktheclearance(outsidethemachine)
between the cylinder pin and the body.
decide the size and quantity of shim so
that the clearance become below Imm
and insert them there. Adjust the left and
right cylinders with shims (outside the
machine).
(4) Push the boom foot pins in the holes

completely and fit the lockplates there.
(5) Fit them on the right and left sides in the

same way. ................................
...........................................
% Assemble the boom cylinder foot so that
the greasing port faces down. ........................................................................................
$r Use the adjustment shims (209-72-51230,

l.Omm thick, 4 PCS. and 209-72-51240,
1.5mmthick,4pcs.)todecidetheircombi-
nation.

Shim (t : 1.0 mm) 209-72-51230 4
Shim (t : 1.5 mm) 209-72-51240 4
O-ring 07000-12130 4
I I I
53
Arrangement of Boom Cylinder Hose
(I) Remove the blind plug from the boom

cylinder tube.
(2) Arrange the boom cylinder hose (07099-

01217, 4 PCS.) to the normal circuit as
shown below. Replace the O-ring (07000-
13038) at the hose connection with the
new one out of the loose-supply items.
................................................................
.............................................................
............................................................
............................................................
.............................................................
............................................................
............................................................
............................................................
............................................................
Boom cylinder

O-ring 07000-13038 8
54
Boom Cylinder
(I) Remove the stopper fixed to the boom

and the boom cylinder top pin. 790 kg
Boom cylinder top pin : 33kg

&I kg
(2) Start the engine and idle it at a low speed.
(3) Lift the cylinder, extend the rod slowly

and fit it to the pin hole.
(4) Insert the cylinder top pin in the pin hole.

6 Insidefushing: anti-frictioncom-
pound (LM-P)
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. Since air
gather inside the cylinder at the first time,
the cylinder may not move for over 10
minutes, but do not move the lever to the
full stroke.
(5) Setthecylindertoppintoboththeleftand
right cylinders in the same way.
(6) Fit the stopper to the boom.

No. Parts Names Parts Nos. oty.
55
Arm Cylinder
(I) Remove the stopper fixed to the boom PC750 PC800

and the arm cylinder foot pin. PC750SE, PC800SE
r+Ikg
913 kg 541 kg
Arm cylinder
foot pin : 24kg, 2 PCS. (for
PC800, PC750SE,
PC800SE)
54kg (for PC750)
(2) For PC750 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 boom side.
(4) Insert the arm cylinder foot pin.
& Inside-bushing : anti-friction

compound (LM-P).
(5) Fit the stopper to the boom.

O-ring 07000-12130 2
56
Arrangement of Arm Cylinder Hose
(1) Remove the blind plug from the arm cyl-

inder pipe, replace the O-ring (07000-
13048, 4 PCS. for PC750, 07000-13038, 4
PCS. and 07000-13048, 4 PCS. for PC800,
PC750SE and PC800SE) at the hose con-
nection with new ones and connect the
arm cylinder hose (07098-01416,2 PCS. for
PC750, 07099-01217, 2 PCS. and 07099-
01417, 2 PCS. for PC800, PC750SE and
PC800SE) there.
Use split flange and bolt out of the blind-
.....______......___..........................................
..._
___
_....
.......... .. ....
._. ..... ....... .
Loose-supply items . . ..
Hose, 07099-01214,2 PCS. __ . ..

___ .. . .
Hose, 07099-01417,2 PCS.
O-ring, 07000-13038, 4 PCS.
O-ring, 07000-13048, 4 PCS. ___........._.___.__................................
The above parts are for PC800.

1. Use care not to let the arm cylinder No. Parts Names Parts Nos. c&y.
rod jump out during the work. Hose 07099-01217 2
2. Store the removed flanges, O-rings and Hose 07099-01417 2
heads for re-use in the future. O-ring 07000-13038 4
3. When connecting hoses, use care that
O-ring 07000-13048 4
O-rings do not get caught between parts.
The above parts are for PC750SE and PCIOOSE.
4. When connecting hoses, use care not to
let dusts enter the circuit. Hose 07098-01416 2
O-ring 07000-I 3048 4
The above parts are for PC750.
57
Installation of Arm Assembly (l/Z)
(I) Remove the stopper of the boom top pin PC750 PC750SE PC800
fixed to the boom and pull out the top pin. PC800SE
2,700 kg 3,200 kg 3,200 kg
Boom top pin : 105 kg
(2) Lift the boom assembly, bring it to the

boom hole, insert the l.Omm thick shim (5) Startthe engine, idle it and extend the arm
(209-72-11180) between them and push cylinder rod slowly to adjust the pin hole
the pin in the hole. position. At the time, lift the arm cylinder
with the crane for positioning during op-
+r Since the seal (209-72-11261, 2 PCS.) is eration of the arm cylinder.
fitted to the inside of the arm side bush-
ing, use care notto break itwhen inserting
the pin.
& Inside bushing : anti-friction
compound (LM-P).
(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.
Arm cylinder
top pin :
r&l
kg
24kg, 2 PCS. (for
PC800, PC750SE and
PC800SE)
30kg (for PC750)
......................................................... n/b
, - .. ..
.. _._.___ ... . .. .. . . ... . ... .. .. ....M. .. . . .. :
Shim :t 1.0 mm r
_.__
____.___
. . .. .... . ... . .. ....... . .... ..... ... .... .. . .. ._.. ... . ........ .. . ..
‘i-lib
Shim 209-72-I 1180 1
Seal 209-72-I 1261 2
I I
I I
58
Installation of Arm Assembly (Z/Z)
(6) Push the arm cylinder top pin in the pin

hole.
Apply the anti-friction compound (LM-P)
to the inside of the bushing.
(7) Fit the stopper to the pin.
Note 1 : 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 leverto the full stroke.
2 : When installing the arm, ex-

treme caution should be exer-
cised so that the bucket cylinder
rod does not jump out.

59
Arrangement of Bucket Cylinder Hose between Boom and
Bucket Cylinder
(1) Remove the blind plug from the bucket

cylinder tube, set new O-rings (07000-
13038,4 PCS. for PC750 and PC800,07000-
13038, 4 PCS. and 07000-13048,2 PCS. for
PC750SE and PC800SE) there and con-
nect two bucket cylinder hoses (07098-
21219 for PC750 and PC800,07098-21221
for PC750SE and PC800SE) there.
Use split flange and bolt out of the blind-

ing parts.
............................................ .....................................
_ \ I
.................................. Blind plug on cylinder side
..............................
... . . . . _.._ .
Detailed view of P

1. Store the flanges, O-rings and heads No. Parts Names Parts Nos. Qty.
used for transportation for re-use in Hose 07098-21219 2
the future. (PC750, PC800)
2. Connect hoses carefully so that they Hose 07098-21221 2
do not get caught between other parts.
(PC750SE, PC8OrXSE) 1
3. Connect hoses carefully so that they do -
not interfere with other parts and are O-ring 07000-I 3038 1 4
not twisted.
O-ring 07000-I 3048 2
(PC750SE. PC800SE)
60
Bucket Cylinder Hose between Boom and Bucket Cylinder
(2) Push in the arm to bucket connection pin

andadjusttheclearancetotherangefrom
0.5 to l.Omm by using the shim (209-939-
5431 (t=l .O) 9 PCS. and 209-939-5441 (t=0.5
mm) 2 PCS.) out ofthe loose-supply items.
Then, tighten the cover mounting bolt
(M24).
& Inside bushing : anti-friction

compound (LM-P).
(3) Set two O-rings (21N-70-13150) for pre-
Aftertighteningthe bolt,
check the torque. If it is ....
............................................................
............................................................... ..............................................
..........
...........................................................
thickness : 8 mm
.................. .......
_.,~..,...,_.,.__...........................................................................................................................
venting earth and sand from penetrating and adjust the clearance to less than 1 mm
into the bucket arm connection pin to the by using the shim (209-72-I 1220,l pc. t=l
normal positions and fix a pin stopper. mm) out ofthe loose-supply items. Then,
fix the pin stopper.
(4) Since the seal (209-72-12211,2 PCS.) to the
boss on the link side (link to bucket con- Note : Be sure to operate the cylinder slowly.
nection), use care not to break them when Do not operate it quickly and do not
inserting the pin. bring it to the stroke end. Since air
gathers inside the cylinder at the first
(5) Lift the link and align the bucket to link time, the cylinder may not operate for
connection pin to the hole while operat- 10 seconds or more, but do not move
ing the bucket cylinder. the lever to the full stroke.
(6) Push in the link to bucket connection pin

1. Clearances at connections shall conform Nc. Parts Names Parts Nos. Qty.
to the Maintenance Standard. Bushing 209-939-5410 1
Shim (t=l.O mm) 209-939-5431 9
Shim (t=0.5 mm) 209-939-5441 2
O-ring 21N-70-13150 2
Shim 209-72-I 1220 1
O-ring 208-70-33181 2
61
Lubrication Piping to Work Equipment
(I) Remove the blind plugs from the cylinder the cylinder side, and connect the lubrica-
side and from the hose nipple side, re- tion hose for the arm cylinder foot @ (2
move the nipple from the hose and set it places in case of PC800, PC759SE and
to the cylinder side, and connect the lubri- PC800SE).
cation hose (2 places) @ for the boom
cylinder. (3) Remove the blind plugs from the cylinder
side and from the hose elbow side, re-
(2) Remove the blind plugs from the cylinder movetheelbowfromthe hoseandsetitto
side and from the hose elbow side, re- the cylinder side, and connect the lubrica-
movetheelbowfromthehoseandsetitto tion hose for the bucket cylinder foot 0.
..-
...._._....................................................................... .. . .
(4) Remove the blind plugs from the cylinder

side and from the hose elbow side, re-
movetheelbowfromthehoseandsetitto
the cylinder side, and connect the lubrica-
tion hose for the arm cylinder top@.
(5) Remove the blind plugs from the right

and left cylinder sides and set the grease
nipple (07020-00000,2 PCS.) for the boom
cylinder foot @ to the both cylinders.

No. / Parts Names Parts Nos. 1 c&y.
1 Fitting 07020-00000 1 2
62
Air Bleeding from Cylinder
After assembling the work equipment, start the

engine, idle it at a low speed and bleed air from the
cylinders as follows:
[II Extend and contract each cylinder 4 or 5 times

without bringing it to the stroke end (up to
about IOOmm before the stroke end).
t Since a lot air remains inside the circuit at the

first time of operation, the work equipment
does not operate for 10 seconds or more, but
do not move the lever to the full stroke.
El Keep the engine idling at the low speed and

move each cylinder slowly (for 10 seconds or
more) in thefineoperation modefrom IOOmm
before the stroke end to the stroke end to
extend it fully. And retain the workequipment
lever at the full stroke point for 3 minutes.
[31 Idle the engine at a high speed and move each

cylinder slowly (for 10 seconds or more) in the
fine operation mode from IOOmm before the
stroke end to the stroke end to extend it fully.
Andretaintheworkequipmentleveratthefull
stroke point for 1 minute.
* The procedures [II to [31 can bleed air from

each cylinder.
A If the engine is rotated at a high speed or each

cylinder is moved to the stroke end from the
beginning, air in each cylinder may break
piston packing.

No. Parts Names Parts Nos. oty.
63
Wiring of Work Equipment
(I) Connect the connector (CN-Ml01 @ of

the working lamp cable to the body cable.
(2) Install the working lamp (both the right
and left ones) as shown below:
.. . ... .. . _- ... . .... . . ... ... ... ........ .. .. .. ....... . .. . .... .. .

\
ek
I
LF-.__-&G, ‘-F-i
. . . . . . . . .._______
_. \‘. ,A . . . . . . . . . . . .. .._..._...........................~..~.......... ________.__....
‘. .

Working lamp assembly 2OY-06-21480 2
Bracket 2OY-06-21550 2
Bolt 01010-81230 4
Washer 01643-31232 4
64
InsDection of Oil Level in Hvdraulic Tank and Refill (l/Z)
Inspection of Oil Level in Hydraulic

Oil Tank and Refill
A Warning
Back of machine
When removing the cap from the oil
filler port, turn it slowly to relieve the
internal pressure so that the oil will not
burst out.
If oil is supplied beyond the H level, stop c?-@
the engine and drain excess oil through 1810146A
the drain plug @ after the hydraulic oil
cools down. To drain oil, loosen the
lower drain plug @and then loosen the
drain plug@on the side. After draining
oil, tighten the drain plugs @and@.
[II If the machine is not in the state illustrated

here, start the engine, rotate it at a low speed,
reduce the arm and the bucket cylinder, lower
the boom so that the bucket teeth touch the
ground, and then stop the engine.
121 Set the start switch to the ON position within

15 seconds after stopping the engine and set
each control lever (work equipment and travel)
to the full stroke in each direction to relieve
internal pressure.
[31 Check the sight gauge @on the left side of the
machine. When the oil level is between the H
and L lines, the level is appropriate.
Notice:
Do not supply oil beyond the H line, but the hy-
draulic circuit may be damaged or oil may burst
out.
141 When the oil level is belowthe L line, open the

cover @ on the top of the hydraulic tank and
supply oil through the oil filler port@.

No. Parts Names Parts Nos. 1 Qty.
I
I I I
I I I
65
Inspection of Oil Level in Hydraulic Tank and Refill (Z/Z)
For applicable oil, see “Use of Fuel and Lubricating

Oil Depending on Ambient Temperature.”
Supplementary Explanation :
Since the oil level changes as the oil temperature

changes, checkthe oil level noting the following as
guides:
l The oil level shall be around the L level

before operation (when the oil temperature
ranges from 10 to 30°C).
l The oil level shall be around the H level

during normal operation (when the oil tem-
perature ranges from 50 to 80°C).

No. Parts Names Parts Nos. ) Qty.
66
Replacement of Return Filter (Standard Filter to Flushing Filter)
(l/Z)
The return filter element for hydraulic oil is re-

placed with the special elements @ and @ for
flushing as follows:
....................B
.=
0
.....................
L 0
+I When replacing the element, take out the
element slowly so that refuses adhered to the
.....................
element do not fall inside. Also, take out
a
.....................
.....................
refuses by hand from the case.
......................
0
Q
(_: ~~~~~ (Nippon Poal HC8300 FUN-16H or equivalent)
u
__..... .. . .
I
2-p.
t+
... ... /
.. ... ... .. ... .
3
0
I
..__....................
,.......................
.. . . . . . . . .
$G
. . . . . . . . .. . . .
,9
. ..... .. .... b
. ... .
@/
Store the removed standard element No. Parts Names Parts Nos. oty.
(07063-01210) 2 PCS.,strainer (206-60-41220) 1 Element 209-60-31130 2
2 PCS.and valve (12R-60-11300) 2 PCS.in 2 Plate 21T-60-13730 2
order because they are used again after
flushing.
67
Replacement of Return Filter (Standard Filter to Flushing Filter)
(Z/2)
State of Inserted Element

._. -- _’
‘u---_=;
-
...... .. .... . .-’ .
___+---_=-: .
,.
),
.c
.. . . _=--I
_.‘I
:‘a
-’ \r”+ .Q I’;
‘..... I
.-
..-.. _A-
fL_Q[.
p: g .-.7
G i.
i
...
.. t.
I=-E
--.LIz!II.
, 1
z
,. .--
.-
. , .
-I
. . . . . . . . . . . . . _.._.
Fig. 1 Correct State Fig. 2 Incorrect State
Caution:
Do not insert the element so that it stands on the
step at the bottom of the case as shown in Fig. 2.
When the filter case is filled with oil, it is difficult to
check if the element is inserted correctly, so turn
the element by hand after inserting it in the case.
When it turns smoothly, it is considered to be
inserted correctly.

68
Flushing of Hydraulic Circuit (l/Z)
After completion of assembling, flush the hydrau-

lic circuit as follows:
% Rotate the engine at the full speed (in the

H mode), and follow the procedures be-
low:
(I) Flushing of Work Equipment Pipes

Extend and contract each cylinder for sev-
eral minutes with reaching them to the
stroke end.
(a) Extension and contraction of bucket cyl- Bucket operation

inder for 5 minutes
(b) Extension and contraction of arm cylin-

der for 5 minutes Arm operation
(c) Extension and contraction of boom cyl-

inder for 5 minutes Boom operation

69
Flushing of Hydraulic Circuit (Z/Z)
Swing operation
(2) Flushing of Swing Circuit
Right swing and left swing for 3 minutes

each
.. . __
(3) Flushing of Travel Circuit r
Press the ground with the work equip-

ment as illustrated here to raise one side
of the machine, and operate the travel
lever as follows:
l Forward travel and backward travel to the

right
AA3061 IO
For 3 minutes each
l Forward travel and backward travel to the

left
For 3 minutes each

70
Komatsu America international Company
440 North Fairwav Drive I 1
Vernon Hills, IL 66061-8112 U.S.A.
Attn: Technical Publications PROPOSAL FOR MANUAL REVlslON
Fax No. (847) 970-4186
FOR INTERNAL USE ONLY -- No. PMR
2 NAME OF COMPANY: LOCATION:
: PHONE NO:
:
S DEPARTMENT: DATE:
E
R NAME:
MANUAL NAME:
MANUAL NO:
MACHINE MODEL:
S/N IF APPLICABLE:
PAGE NO:
PROBLEM:
Attach photo or sketch.

If more space is needed, use another sheet.
1 FOR INTERNAL USE ONLY

CORRECTIVE ACTION:
PFMRl 081696
Backhoe l/l 3
KOM&U Report No.
After completion of assembling a machine, make inspections according to these check sheets for assuring machine performance and quality.
Model -Type Machine Serial No. User Unit No. Engine Model Engine Serial No.
I SAA6D140-2
1 I
I
Attachment
I
I
1 2
Location of Machine at Inspection

Manufacture
Model
Distributor’s Name
Serial No.
Customer’s Name Address Signature: Delivery

Report
No. attached
Date:
E
Inspector’s Comments:
Check sheets fillino instructions:
1. Use following indexes for entry of judgement
q. . Normal q Correction made on abnormal point

q Abnormal q .._...___.Not applied
2. Enter actually measured values in parenthese, [ I.
Notes:
(1) Criteria are based on the standards when the machine is shipped out of the factory.
(2) This FIELD ASSEMBLY INSPECTION REPORT is for “A” specification.
SUBMITTANCE OF THIS REPORT (AND CHECK SHEETS) TO KOMATSU IS ONE OF THE CONDITIONS OF WARRANTY VALIDATION,
COPY FOR KOMATSU SHALL BE FORWARDED TO THE KOMATSU REGIONAL OFFICE TOGETHER WITH THE COPY OF DELIVERY
SERVICE REPORT,
@ Komatsu copy
Backhoe 1113
KOMAaU Report No.
After completion of assembling a machine, make inspections according to these check sheets for assuring machine performance and quality.
Model - Type Machine Serial No. User Unit No. Engine Model Engine Serial No.
Backhoe spec. SAABDI 40-2
Service Meter Reading Date of Inspection

Attachment
1 2
Location of Machine at Inspection

Manufacture
Model
Distributor’s Name
Serial No.
Customer’s Name Address Signature:
Date:
Inspector’s Comments:
Check sheets filling instructions:
1. Use following indexes for entry of judgement
q Normal q Correction made on abnormal point

(XI Abnormal, q ..____._.
Not applied
2. Enter actually measured values in parenthese. [ I.
Notes:
(1) Criteria are based on the standards when the machine is shipped out of the factory.
(2) This FIELD ASSEMBLY INSPECTION REPORT is for “A” specification.
SUBMR-TANCE OF THIS REPORT (AND CHECK SHEETS) TO KOMATSU IS ONE OF THE CONDITIONS OF WARRANTY VALIDATION,
COPY FOR KOMATSU SHALL BE FORWARDED TO THE KOMATSU REGIONAL OFFICE TOGETHER WITH THE COPY OF DELIVERY
SERVICE REPORT
0 Distributor copy
2l13
Local After
Check item assembly hours of Judgement standard
time operation
Oil and water levels Actual measurement

-
RESERVE TANK
Cooling water Soft water [ 1
BetweenFull and Low Ieva
Yes/No I
- Anti-freeze
A: -50 - -40°C D: -20 - -10°C
(A, B, C, D, E) Density of I B: -40 - -30°C E: -10 - 0°C
anti-freeze
C: -30 - -20% (Not necessary in summer)
EOl ow L_H +5mm (10 minutes after stopping
Engine oil
E030
1 1 engine)
EOl OW (10 minutes after stopping
PTO oil
E030
1 1 Lc5-H
engine)
Swing machinery L+5_H+10 (10 minutes after stopping

E030 [ 1
gear case oil enoine)
Right E030 1 1
_ Final drive gear Bottom edge of level plug: 0 to -10 mm
case oil
Left E030 [ 1
Hydraulic oil EOlOW 1 1 Between the H and L marks.
Within 13 mm from bottom surface of filler

Battery electrolyte [ 1
port
Must match Serial No.
There must be none.
There must be none.
There must be none.
There must be none.
Max, , mm (for locations, see assembly

Shim adjustment for work equipment pins orocedure manual)
Improperly inserted wiring, unconnected wiring There must be none.
There must be none.
@ Komatsu copy
2ll3
RESERVE TANK
B: -40 - -30% E: -10 - 0°C
Bottom edge of level plug: 0 to -10 mm
Must match Serial No.
@ Distributor copy
3113
Check item
Loose, untightened counterweight bolts There must be none.
Stepped clearance between counterweight and frame Max. 15 mm
Loose, untightened operator’s cab mounting bolts There must be none.
Loose, untightened operator’s seat mounting bolts There must be none.
1Loose, untightened mounting bolts and joints for travel, HIC piping 1 ITheremustbenone.
Follow instructions in assembly procedure

manual.

I IFlush hydraulic circuit
I IBleed air from work equipment cylinder circuit

I I
I I I
I
4Follow instructions in assembly procedure

manual.
Grease all parts of work equipment All locations must be greased.
Add to between Land H marks at inspection

I I Add hydraulic oil
I I I wsture
Add fuel, washer fluid Fill tank.
Dirty oil on paintwork, damage to paintwork at any part Clean, repair damaged paintwork
@ Komatsu copy
3113
Check item
Loose, untightened counterweight bolts There must be none.
Stepped clearance between counterweight and frame Max. 15 mm
Loose, untightened operator’s cab mounting bolts There must be none.
Loose, untightened operator’s seat mounting bolts There must be none.
1Loose, untightened mounting bolts and joints for travel, HIC piping 1 1 ITheremustbenone.
Forgotten, missing, catching O-rings for travel, HIC piping There must be none.
Loose, untightened track frame mounting bolts There must be none.
Loose, untightened bolts for travel motor cover There must be none.
I Bleed air from work equipment cylinder circuit

1Follow instructions in assembly procedure 1
manual.
Grease all parts of work equipment All locations must be greased.
I I Add hydraulic oil

Add to between Land H marks at inspection
Add fuel, washer fluid Fill tank.
Dirty oil on paintwork, damage to paintwork at any part Clean, repair damaged paintwork
0 Distributor copy
s
.-
I
LOcal After
.” Check item assembly hours of Judgement standard
5
a / time operation
Monitor display
1. Check of monitor function
When the starting switch is turned ON, the gauges, CHECK items,
and all display items on the monitor should light up. At the same
the alarm buzzer should sound.
2. Check of gauges and CHECK items
When starting switch is turned to ON (all lamps on), all display
lamps should go out after approx. 3 sec. For another 2 seconds, Display should be as on left.
only the gauges are displayed, and the CHECK and monitor items
disappear.
3. Check of monitor items
After starting the engine, the caution lamps should not light up and
the alarm buzzer should not sound when the engine speed is low
idling - high idling.
There should be no scratches or misting of
Operation of service meter
the lens or variation in operation.
MONITOR
Engine water
temperature monitor e
Fuel level monitor

3
Air cleaner
- Enoine oi I
Radiator rater
level monitor
Enaine oil -Charoe level
Pressure man i
m\\bT\__ monitor
Engine
r,
Pre-heating monitor
\
\
Swine lock monitor
Working mode Hrdraulic oil

selector switch
Heavy lift switch’ 1 (I(( w

n
Auto-deceleration
snitch
Travel sueed switch Swine Driority
@ Komatsu copy
4/l 3
LOcal After
time operation
Monitor display
1. Check of monitor function
When the starting switch is turned ON, the gauges, CHECK items,
and all display items on the monitor should light up. At the same
the alarm buzzer should sound.
2. Check of gauges and CHECK items
When starting switch is turned to ON (all lamps on), all display
lamps should go out after approx. 3 sec. For another 2 seconds, Display should be as on left.
only the gauges are displayed, and the CHECK and monitor items
disappear.
3. Check of monitor items
After starting the engine, the caution lamps should not light up and
the alarm buzzer should not sound when the engine speed is low
idling - high idling.
There should be no scratches or misting of
Operation of service meter
the lens or variation in operation.
MONITOR
Service meter
Engine rater Engine water

temperature moni temoerature aauae
Fuel level moni Fuel *aulJe
Air cleaner
c10091n~ moni
/------E”oi”e level Oii
monitor
Radiator w - HYdraul ic oi I
level monit level monitor
Engine oil Charge level

Pressure moni monitor
Engine
Pre-heating monitor
Swing lock monitor
Working mode Hydraulic oil

selector swi temperature monitor
Heavy lift swi Working mode
Travel sseed switch’
0 Distributor copy
5/l 3
Check item Judgement standard
Travel lever
Machine monitor
Horn switch
Left work equipment
Right work equipment
control lever
control lever
tartina swich
Fuel control dial
Safety lock lever
isarette lighter
ins lock switch

iper switch
ddi t ional lamp)

zzer stop switch
ar heater fan swi tch
Step Iioht switch

\ \Boom shockless control
switch AA307248
lperation of mode selector switch DH lights up: Powerful operation for short
time during heavy-duty
operations
H lights up: Heavy-duty operations
G lights up: Nomal operations
When starting the engine, H (heavy-duty

operation) mode is automatically selected.
Operation of auto-deceleration switch ON lights up: Auto-deceleration is
actuated.
OFF: Auto-deceleration is canceled
Each time the switch is pressed, the auto-

deceleration is actuated or canceled.
Operation of travel speed switch This is used to select the two travel speeds.
Lo lights up: Low speed travel
Hi lights up: High speed travel
When the engine is started, the travel speec

is automatically set to Lo.
Operation of heavy lift switch When the switch is turned ON during
independent operations of the boom, the
boom lifting power is increased.
Operation of swing priority mode switch When ON lights up: Effective for 180’ swing
and loading
When ON goes out: For normal operations
(90’ swing and loading)
Operation of starting switch OFF position: Engine is stopped
ON position: Electric current flows in thf
charging and lamp circuits
1START position: Engine is started.
2peration of fuel control dial
3peration of cigarette lighter This is used to light cigarettes. To use, pust

I I I the lighter
in. After a few seconds it will
1spring back.
@ Komatsu copy
S/l 3
-
.-E
.” Check item Judgement standard
3
a
-
Travel lever
Machine monitor
Horn switch
Left work equipment
Right work equipment
control lever
control lever
LStartino swich
Fuel control dial
Safety lock leve
Cigarette lighter
LCar radio
@wins lock switch
>Wiper switch
i\LamP switch
i (additional lamp)
zzer stop switch
ar heater fan swit ch
opt ion)
control switch h ‘Machine push UP
Steo light switch \\--!\ switch
\ \Boom shockless con trol
switch AA307248
Operation of mode selector switch DH lights up: Powerful operation for short
time during heavy-duty
operations
H lights up: Heavy-duty operations
G lights up: Normal operations
When starting the engine, H (heavy-duty

operation) mode is automatically selected.
Operation of auto-deceleration switch ON lights up: Auto-deceleration is
actuated.
OFF: Auto-deceleration is cancelec
Each time the switch is pressed, the auto-

deceleration is actuated or canceled.
Operation of travel speed switch This is used to select the two travel speeds.
Lo lights up: Low speed travel
Hi lights up: High speed travel
When the engine is started, the travel speec

is automatically set to Lo.
3peration of heavy lift switch When the switch is turned ON during
independent operations of the boom, the
boom lifting power is increased.
3peration of swing priority mode switch When ON lights up: Effective for 180’ swing
and loadina
When ON goes out: For norrnaioperations
(90’ swing and loading)
2peration of starting switch OFF position: Engine is stopped
ON position: Electric current flows in thf
charging and lamp circuits
START position: Engine is started.
3peration of fuel control dial MAX: Full speed
MIN: Low idlina
3peration of cigarette lighter This is used to light cigarettes. To use, pust
I I I thelighter in. After a few seconds it will
1spring back.
@ Distributor copy
6/l 3
Local After
time operation
Operation of swing lock switch ON position (actuated):

The swing lock is always applied, and thl
+ upper structure will not swing even if the
swing is operated. In this condition, the
swing lock lamp lights up.
OFF position (canceled):
The swing lock is applied only when all
work equipment control levers are at
neutral; when any work equipment
control lever is operated, it is canceled.
The swing lock is actuated approx. 4
seconds after all work equipment control
lever is placed in neutral.
3peration of wiper switch @ OFF: Wiper stops
@ ON: Wiper moves continuously
@ Window washer fluid is sprayed out.
When switch is released it returns to
position 0.
@ ON: Wiper moves intermittenly
position @.
1Operation of lamp switch This switch is used to turn on the front lamps
working lamps, additional lamp at the top
front of the cab, rear lamps, and monitor
lighting.
Ooeration of alarm buzzer stop switch This is used to stop alarm buzzer if it sounds
to warn of an abnormality during operation.
Operation of car heater fan switch (option) ON: Fan is started.
OFF: Fan is StODDed.
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 shockless boom control switch When the switch is at the ON position and
the boom is stopped, the shaking is not felt.
Operation of horn switch Press the switch on the right work equipmen
control lever to sound the horn.
At the same time, the flashing light (option)
at the too front of the cab will flash for
approx. 5 seconds.
Operation of room lamp switch ON position: Room lamp lights up.
Operation of pump prolix switch When normal:

Switch is pushed down.
When abnormal:
When the monitor display shows E02
(NC valve system error), move the
switch up to make it possible to carry ou
work.
Operation of swing prolix switch When normal:
When abnormal:
(Swing brake system error), the brake is
canceled, and it becomes possible to
actuate the swing and carry out normal
operations. However, the swing brake
remains released.
Operation of step light switch l When the switch is pressed, the step
light will light up for approx. 60 seconds.
I I I
l Even if the starting switch key is at the
OFF position, the step light will light up
for approx. 60 seconds when the switch
@ Komatsu copy
6113
2
8
s
:?j
Local After
‘u Check item assembly hours of Judgement standard
L
3 K time operation
Operation of swing lock switch ON position (actuated):

The swing lock is always applied, and tt
upper structure will not swing even if the
swing is operated. In this condition, the
swing lock lamp lights up.
OFF position (canceled):
The swing lock is applied only when all
work equipment control levers are at
neutral; when any work equipment
control lever is operated, it is canceled.
The swing lock is actuated approx. 4
seconds after all work equipment contra
lever is placed in neutral.
Operation of wiper switch @ OFF: Wiper stops
@ ON: Wiper moves continuously
position 0.
@ ON: Wiper moves intemtittenly
position @I).
Operation of lamp switch This switch is used to turn on the front lamp
working lamps, additional lamp at the top
front of the cab, rear lamps, and monitor
lighting.
Operation of alarm buzzer stop switch This is used to stop alarm buzzer if it sound
to warn of an abnormality during operation.
S
J Operation of car heater fan switch (option) ON: Fan is started.
u OFF: Fan is stopped.
E Low pressure setting:
Operation of machine push-up switch
: The boom thrust force is weak.
$ High pressure setting:
The boom thrust force becomes more
.s
powerful.
f
B Operation of shockless boom control switch When the switch is at the ON position and
“0 the boom is stopped, the shaking is not felt.
c”
0 Operation of horn switch Press the switch on the right work equipmet
control lever to sound the horn.
At the same time, the flashing light (option)
at the top front of the cab will flash for
approx. 5 seconds.
Operation of room lamp switch ON position: Room lamp lights up.
Operation of pump prolix switch When normal:

When abnormal:
(TVC valve system error), move the
switch up to make it possible to carry oi
work.
Operation of swing prolix switch When normal:
When abnormal:
(Swing brake system error), the brake is
canceled, and it becomes possible to
actuate the swing and carry out normal
operations. However, the swing brake
remains released.
Operation of step light switch l When the switch is pressed, the step
light will light up for approx. 60 seconds.
l 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.
0 Distributor copy
7113
2
$
‘0
:g
LOcal After
‘u 5 Check item assembly hours of Judgement standard
0” d time operation
Operation of safety lock lever Pull the lever up to apply the lock.
This lock lever is a hydraulic lock, so even if
it is in the lock position, the work equipment
control lever and travel lever will move, but
the work equipment, travel motor, and swing
motor will not work.
Operation of travel levers FORWARD:
The lever is pushed forward.
(The pedal is angled forward)
REVERSE:
The lever is pulled back.
e (The pedal is angled back)
z
‘D N (Neutral):
g The machine stops.
Operation of left work equipment control lever This lever is used to operate the arm and
g
ui (with autodeceleration device) upper structure.
m
An operation Swing operation
z @ ArmOUT @ Swing to right
5 @ ArmIN @ Swing to left
a N (Neutral):
P When the lever in this position, the
6 upper structure and the arm will be
retained in the position in which they
stop.
Operation of right work equipment control lever This lever is used to operate the boom and
(with auto-deceleratiom device) bucket.
Boom operation Bucket operation
@ RAISE @ DUMP
@ LOWER @ CURL
N (Neutral):
When the lever in this position, the boon
and the bucket will be retained in the
position in which they stop.
@ Komatsu copy
2
$
s
;g
LOcal After
2 5 Check item assembly hours of Judgement standard
d d time operation
Operation of safety lock lever Pull the lever up to apply the lock.
This lock lever is a hydraulic lock, so even if
it is in the lock position, the work equipment
control lever and travel lever will move, but
the work equipment, travel motor, and swing
motor will not work.
Operation of travel levers FORWARD:
The lever is pushed forward.
(The pedal is angled forward)
REVERSE:
The lever is pulled back.
2 (The pedal is angled back)
z
P N (Neutral):
g The machine stops.
Operation of left work equipment control lever This lever is used to operate the arm and
$
ui (with auto-deceleration device) upper structure.
m
Arm operation Swing operation
2 @ AmtOUT @ Swing to right
5 @ ArmIN @ Swing to left
B N (Neutral):
P When the lever in this position, the
f upper structure and the arm will be
retained in the position in which they
stop.
Operation of right work equipment control lever This lever is used to operate the boom and
(with auto-deceleratiom device) bucket.
Boom operation Bucket operation
@ RAISE @ DUMP
@ LOWER @ CURL
N (Neutral):
When the lever in this position, the boon
and the bucket will be retained in the
position in which they stop.
0 Distributor copy
8ll3
Swing operation running in: Engine high idling speed,
(Work equipment posture: Travel posture)
Travel deviation (feeling) There must be no abnormal deviation from

fine control range to full stroke range
Travel deviation
Max. 200 mnV20m
Max. 200 mmI20m
@ Komatsu copy
8l13
Swing operation running in: Engine high idling speed,
(Work equipment posture: Travel posture)
Travel deviation (feeling) There must be no abnormal deviation from

fine control range to full stroke range
Travel deviation
Max. 200 mml20m
Max. 200 mmf20m
0 Distributor copy
9/l 3
I jL 2ement standard values for speeds are the values in DH mode.

-
I I I
.-E Local After
.Y Check item assembly hours of Judgement standard
2
a time operation
-
Work equipment operation running in: Engine high idling speed,
(Note: Boom cylinder to ground level)
Pressurized; each port relief 2 minutes, shock 20 times (except BOOM LOWER).
Work equipmentposture Bucket
-
DUMP: 3.3 * 0.4 sec. (STD)
-
ment time lag Boom [
Arm
-
Fine control performance Must operate smoothly.
-
-
Dperation when raising chassis
I I I I I There must be no escape of boom, arm, or
hIckat
4bnormal noise noise from work e There must be none.

-
Shock at end of stroke for BOOM RAISE and ARM OUT)
-
-
Immediately after engine is stopped, boom
- cylinder must move from fully extended
position to ground level. (Arm at max. reach)
@ Komatsu copy
9113
I jl gement standard values for speeds are the values in DH mode.

I I I
s
.- Local After
.Y
a
zi time operation
Work equipment operation running in: Engine high idling speed,

(Note: Boom cylinder to ground level)
Pressurized: each port relief 2 minutes, shock 20 times (except BOOM LOWER).
Work equipmentposture
BKWOlll BKPOOll
RAISE: 4.9 t 0.6 sec.
UMP: 3.3 * 0.4 sec. (STD)
Work equip- LOWER

ment time lag Boom [
Arm
-
There must be no hunting in BOOM RAISE
Engine partial perfonance at above 1000 rpm; there must be no stalling
- of engine.
Fine control performance Must operate smoothly.

-
must be no escape of boom, arm, or
Dperation when raising chassis
-
4bnormal noise noise from work e There must be none.
-
Shock at end of stroke for BOOM RAISE and ARM OUT)
-
-
Immediately after engine is stopped, boom
- cylinder must move from fully extended
position to ground level. (An at max. reach)
@ Distributor copy
lOll3
Local After
time operation
l There must be no catching during

5 Operating force of control lever when each actuator is actuated. operation.
‘G
z l Must return naturally to neutral.
;
en Feeling and noise of vibration in operator’s cab There must be none.
.= I I I I I I
3
1.
Vrbratron noise from frame, guard, ladder ITheremustbenone.
%I I
_v,t
Movement of doors and windows 1Must move smoothly.
21 IDoor, window
I I I I I I
I I I I I Must locksecurely.
c I I I I ! I
m
1Adjustment of operator’s seat I I I I I Must be possible to make all adjustments.
(Idle: roller, sprocket, final drive gear case, motor, brake valve)
Interference at any part I I I I ITheremustbenone.
I ILooseness of track shoe bolt I I I I ITheremustbenone.
There must be no ovedapping, separation, r
Center swivel, pump, solenoid valve, relief valve, control valve,

PPC valve, swing motor, brake valve, shuttle valve, swing
machinery, hydraulic tank, piping)
Leakage of oil from engine lubrication system There must be none.
There must be none.
1Movement of covers 1Must move smoothly.
Must lock securely.
@ Komatsu copy
10113
Local After
time operation
l There must be no catching during

5 Operating force of control lever when each actuator is actuated. operation.
‘G
9 l Must return naturally to neutral.
E
Feeling and noise of vibration in operator’s cab There must be none.
P
‘P
0’ There must be none.
Vibration noise from frame, guard, ladder
%I I Movement of doors and windows 1Must move smoothly.
There must be none.

(idler, roller, sprocket, final drive gear case, motor, brake valve)
I IOi’
leakage ITheremustbenone.
Center swivel, pump, solenoid valve, relief valve, control valve,

PPC valve, swing motor, brake valve, shuttle valve, swing
machinery, hydraulic tank, piping)
[Fuel tank, engine, piping]
.G
%
2
Leakage of water from engine cooling water system There must be none.
;
2 I I I I I I
$1 ILeakage of oil from engine lubrication system 1 1 1 1 ITheremustbenone.
There must be none.
1Movement of covers 1Must move smoothly.
Must lock securely.
@ Distributor copy
11/13
* c Local After
8 f
S Check item assembly hours of Judgement standard
2
d a time operation
Operation of grease pump Must work smoothly.
There must be none.
1llnterference at any part ITheremust benone.
There must be none.

[Cylinder, piping, block]
i Interference of work equipment There must be none.

E
.a
Looseness of work equipment piping clamps, play in piping There must be none.
2
@ Komatsu copy
llll3
Operation of grease pump Must work smoothly.
There must be a clearance of at least 10 mr;

Position for passing electrical wiring throuth
Leakage of air from air system ITheremustbenone.
Looseness of work equipment piping clamps, play in piping 1 I 1 ITheremustbenone.

f
2
-0
5
2
I I I I I I I
@ Distributor copy
12l13
vote: If the operation or function is defective, measure as necessary. All judgement standard values for speeds are the values in DH mode.
I I
I 825*25rpm
I
1980 f 50 rpm
Speed at bucket DUMP relief
I I Speed at swing relief rpm 1
1050 rpm at 1800 rpm
I I3. Oil pressure measurement (measure at pump outlet port)
a \ A+PnninD hinh
Pilot relief valve set pressure
Min. \ A,^“,.:..^ I
I I
NC valve output pressure (at top
surface of NC valve) No.1 pump
II
Ma.
I at neutral
y;,,
surface of NC valve) No.2 pump III 0.39 MPa
I I valve output pressure does not pass the test.
At neutral At relief
J/S differential pressure (differential
MPa
pressure at input and output ports
I (k$$/ [ (k~cm2)l
J/S differential pressure (differential
II pressure at input and output ports

of iet sensor) No.2 qumo
MPa
(kg/cm’}
@ Komatsu copy
12/13
Note: If the operation or function is defective, measure as necessaw. All iudaement standard values for s
embly ) hours of Judgement standard I
I 825 f 25 mm I
I1980t50rpm
I
Speed at bucket DUMP relief at DH mode
I I Speed at swing relief 1 rpm 1
1050 rpm at 1800 rpm
13. Oil pressure measurement (measure at pump outlet port)
Control valve main 4-spool MPa 31.38 + 0.98 MPa At engine high
set pressure valve I (ks/cm’l i(320 * 10 kg/cm’) idling, an
Control valve main 5-spool MPa 31.38 f 0.98 MPa OUT and DH mode,
set pressure valve 1 (k@cm*) 1
Travel relief Right MPa
set pressure travel 1 (ks/cms) 1 wn + 1” k”hrn2l 1 Relieved onone
Travel relief Left MPa

set pressure travel I (ks/cma) I
Pilot relief valve set pressure I ,. 9. 1
MPa
Max. \ Min.
I I
surface of NC valve) No.1 pump I MPa
(k@cma)11
I I i I I Ma. at neutral Min.
I I I NC valve output pressure (at top

surface of NC valve) No.2 pump
0.39 MPa
(4 k&m21
1.42 MPa
114.5k&m*1
I I I valve output pressure does not pass the test.
highicing, idling,
J/S differential pressure (differential at neutral Max. control
I pressure at input and output ports

of iet sensor) No 2 oumo
MPa
(kg/cm2)
I/ I
-t
1.77* 0.2MPa _ _ ._ t IO”., I
@ Distributor copy
13113
Check item
Note: Measure the hydraulic drift of the following cylinders only if t

hydraulic drift at the bucket tooth tip does not pass the test.
Max. 5 cc/minutes
Stroke: 115 f 15
@ Komatsu copy
13113
Check item
Note: Measure the hydraulic drift of the following cylinders only if t

hydraulic drift at the bucket tooth tip does not pass the test.
Max. 5 cc/minutes
@ Distributor copy

Field Assembly Instruction: PC7504 PC8004

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Field Assembly Instruction: PC7504 PC8004

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SEAW000800

August 1996 Copyright 1996 Komateu America IntemEltional Company

Points Regarding Local Assembly ................................................................................................................ 3

Assembling Procedures, Applicable Equipment and Schedule ................................................................. 5

Packing Style for Transportation .................................................................................................................. 7

List of Tools for Field Assembling .............................................................................................................. 12

Field Assembling .......................................................................................................................................... 13

Related Laws and Regulations ................................................................................................................... .I4

Fitting of Left and Right Track Frames ....................................................................................................... 18

Arrangement of Travel Pipe ....................................................................................................................... .20

Installation of FOPS.. .................................................................................................................................... 23

Setting of Radiator Cover ............................................................................................................................ 26

Fitting of Rearview Mirror ........................................................................................................................... 27

Installation of Handrail ................................................................................................................................. 29

Prevention of Natural Closing of Ceiling Window .................................................................................... .30

Installation of Step ....................................................................................................................................... 31

Installation of Left Side Step ...................................................................................................................... .32

Setting of Muffler Tail Tube ........................................................................................................................ 33

Sticking of Sheet (to Counterweight) ...................................................................................................... 33-l

Installation of Counterweight ...................................................................................................................... 34

Installation of Radio Antenna ...................................................................................................................... 35

Installation of Cab Top Light ...................................................................................................................... .37

Fitting of Stopper (on Hydraulic Tank) ....................................................................................................... 41

Setting of Travel Pipe Cover ........................................................................................................................ 45

Adjustment of Track Tension ...................................................................................................................... 47

Inspection of Oil Amount and Water Amount ........................................................................................... 49

Boom Foot Pin and Boom Cylinder Foot Pin ............................................................................................. 50

Boom Assembly ........................................................................................................................................... 51

Relieving Remaining Pressure from Hydraulic Circuit.. ........................................................................... .52

Installation of Boom Cylinder Foot ............................................................................................................. 53

Arrangement of Boom Cylinder Hose ....................................................................................................... .54

Boom Cylinder .............................................................................................................................................. 55

Arm Cylinder ................................................................................................................................................. 56

Arrangement of Arm Cylinder Hose ........................................................................................................... 57

Installation of Arm Assembly ...................................................................................................................... 58

Lubrication Piping to Work Equipment ..................................................................................................... .62

Air Bleeding from Cylinder .......................................................................................................................... 63

Wiring of Work Equipment .......................................................................................................................... 64

Inspection of Oil Level in Hydraulic Tank and Refill ................................................................................. .66

Replacement of Return Filter (Standard Filter to Flushing Filter) ........................................................... .67

Flushing of Hydraulic Circuit ...................................................................................................................... .69

1. Selection of work place

2. Preparation and checks of lifting tools and jigs

3. A Checks during actual operation

l Air bleeding from work

@ Assembling of work equipment

0.49 - 0.69 MPa

Loading shovel- * Adjustment of track tension

0 Left track frame @ Upper structure @ Counterweight,

0.49 - 0.69 MPa

Completion of Installation of unit assembly to body

Packing Style for Transportation

(Upper structure + Undercarriage) (Work equipment) (Others)

(Upper structure) (Undercarriage) (Work equipment) (Others)

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

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

w;$t / 7,420 ( 6,850 j 7,770 1 6,850 j

Model No. PC750-6 PC750SE-6 PC800-6 PC800SE-6

A(mm) 5,105 4,075 4,800 4,075

Bfmm) 1,324 1,696 1,365 1,696

(4) Boom cylinder (for all models)

3180 mm Weight : 1,620 kg

(5) Arm cylinder

. . . .. .. . ... fgtgj