Komatsu Excavadora Hydraulica PC800 PDF

GEN00048-05
Field Assembly Instruction
HYDRAULIC PC800 -8
EXCAVATOR PC800LC -8
PC800SE -8
PC850 -8
PC850SE -8
PC800- 50001
PC800LC- 50001
SERIAL NUMBERS PC800SE- 50001 and up
PC850- 10001
PC850SE- 10001
When the work equipment is installed, the engine must be operated.
Accordingly, before installing the work equipment, inspect and maintain the machine thoroughly.
Note that this manual does not describe the whole specification of the machine but describes only the basic
specification.
If you have any question when dividing and transporting the machine by yourself in future, ask one of our
distributors.
CONTENTS
Specifications...................................................................................................................... 1
Precautions for Field Assembly .......................................................................................... 2
Disposal of Removed Parts ................................................................................................ 3
Assembling Procedures, Applicable Equipment and Schedule .......................................... 4
Kit Layout Diagram ............................................................................................................. 5
Transportation..................................................................................................................... 6
List of Tools for Field Assembling....................................................................................... 12
Tightening Torque............................................................................................................... 13
Coating Materials................................................................................................................ 17
A. Assembly of Chassis ...................................................................................................... 19

A- 1. Installation of Left and Right Track Frames ........................................................... 20
A- 2. Installation of Travel Pipe ...................................................................................... 24
A- 3. Installation of Top Guard ....................................................................................... 27
A- 4. Installation of Radiator Cover ................................................................................ 28
A- 5. Installation of Rearview Mirror ............................................................................... 29
A- 6. Installation of Left Side Step .................................................................................. 33
A- 7. Installation of Handrail ........................................................................................... 34
A- 8. Installation of Handrail (With top guard) ................................................................ 35
A- 9. Installation of Muffler Tail Tube.............................................................................. 37
A-10. Sticking Sheet to Counterweight ........................................................................... 38
A-11. Installation of Counterweight ................................................................................. 39
A-12. Installation of KOMTRAX Antenna (if equipped) ................................................... 40
A-13. Installation of Step Light ........................................................................................ 41
A-14. Air Bleeding of Travel Motor .................................................................................. 43
A-15. Installation of Travel Piping Cover......................................................................... 44
A-16. Testing Track Shoe Tension.................................................................................. 46
A-17. Check Fuel, Coolant and Oil Levels ...................................................................... 49
A-18. Parts to be Touched up after Field Assembly........................................................ 51
B. Assembling of Work Equipment of Backhoe .................................................................. 53

B- 1. Assembly of Arm Cylinder ..................................................................................... 54
B- 2. Connection of Arm Cylinder Hoses........................................................................ 55
B- 3. Installation of Boom Cylinder Foot......................................................................... 57
B- 4. Relieving Remaining Pressure from Hydraulic Circuit ........................................... 58
B- 5. Installation of Boom Cylinder Hoses...................................................................... 59
B- 6. Installation of Boom Foot Dust Seal ...................................................................... 60
B- 7. Assembly of Boom Assembly ................................................................................ 61
B- 8. Hose Connection of Arm and Bucket Circuits........................................................ 62
B- 9. Installation of Quick Return Hose .......................................................................... 63
B-10. Installation of Boom Cylinder................................................................................. 64
B-11. Installation of Arm Assembly ................................................................................. 65
B-12. Installation of Hose between Boom and Bucket Cylinder...................................... 67
B-13. Installation of Bucket Assembly............................................................................. 68
B-14. Lubrication Piping to Work Equipment .................................................................. 69
B-15. Wiring of Work Equipment..................................................................................... 70
B-16. Greasing after Assembling Work Equipment......................................................... 71
B-17. Air Bleeding from Hydraulic Cylinder..................................................................... 72
C. Assembling of Work Equipment of Loading Shovel..................................................... 73
C- 1. Releasing residual pressure in hydraulic circuit .................................................. 74
C- 2. Pulling out boom foot pin and boom cylinder foot pin ......................................... 75
C- 3. Installation of boom and arm assembly............................................................... 76
C- 4. Installation of flushing piping between chassis and boom .................................. 77
C- 5. Installation of flushing piping for boom cylinder and arm cylinder....................... 78
C- 6. Installation of flushing piping for bucket cylinder................................................. 79
C- 7. Installation of flushing piping for bottom dump cylinder ...................................... 80
C- 8. Installation of boom cylinder................................................................................ 82
C- 9. Installation of boom cylinder foot......................................................................... 83
C-10. Installation of boom cylinder hoses ..................................................................... 84
C-11. Installation of boom cylinder rod pin ................................................................... 85
C-12. Installation of arm cylinder hoses........................................................................ 86
C-13. Installation of bucket cylinder.............................................................................. 87
C-14. Installation of bucket cylinder hose ..................................................................... 88
C-15. Installation of connecting hoses between chassis and boom top ....................... 89
C-16. Installation of bottom dump cylinder hoses......................................................... 90
C-17. Installation of bucket assembly ........................................................................... 91
C-18. Installation of working lamps............................................................................... 93
C-19. Installation of work equipment grease piping...................................................... 94
C-20. Greasing after assembling of work equipment.................................................... 95
C-21. Bleeding air from work equipment circuit ............................................................ 96
D. Assembling of Counterweight Remover ...................................................................... 97

D- 1. Installation of Rubber Cushions .......................................................................... 98
D- 2. Adjustment of Shims for Counterweight.............................................................. 99
D- 3. Greasing.............................................................................................................. 104
D- 4. Installation of Counterweight Remover ............................................................... 105
D- 5. Installation of Covers........................................................................................... 106
D- 6. Installation of Hoses............................................................................................ 107
D- 7. Bleeding Air from Counterweight Remover Circuit.............................................. 110
D- 8. Installation of Counterweight............................................................................... 111
D- 9. Installation of Accessories................................................................................... 113
D-10. Check of Operation ............................................................................................. 114
M. Procedure for Inspection and Maintenance after Completion of Assembly................. 115

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

SPECIFICATIONS
Machine model PC800-8 PC800LC-8 PC800SE-8 PC850-8 PC850SE-8

Weight of machine kg 75,000 77,200 76,000 79,500 79,100
3
Bucket capacity m 3.1 3.1 4.0 3.4 4.3
Engine model – SAA6D140E-5
Flywheel horsepower kW/rpm {HP/rpm} 363/1,800 {486/1,800}
Min. ground clearance mm 840
Travel speed (Low/High) km/h 2.8/4.2
Swing speed rpm 6.8
PC800-8
aThe figures in ( ) show the value when the track width is reduced.
PC850-8
aThe figures in ( ) show the value when the track width is reduced.
1
PRECAUTIONS FOR FIELD ASSEMBLY y
1. Selection of work place
1) When selecting a work place, consider the following.
• Is the work place sufficiently wide for loading and unloading the machine? (See the kit layout draw-
ing.)
• Is the ground sufficiently hard? (The machine and crane truck must not sink into the ground.)
• Is the ground flat? (The ground surface must not be uneven or sloping.)
• Is the road to inlet/outlet of the work place sufficient for turning the trailer and crane truck?
2) Take care extremely that dirt or water will not enter the hydraulic circuit while it is assembled.
3) Avoid working outdoors while strong wind is blowing or it is raining.
4) Take measures to protect the machine from sand, dirt and rainwater while the work is stopped.
2. How to do work
The work supervisor or the work leader should not do the work while reading this manual but should read
and understand this manual thoroughly and then start the work.
In particular, write the "Precautions" for each work process in a sheet to explain or stick that sheet to the
work place so that all the workers will observe the precautions.
3. Preparation and check of protective gear, slings and tools

The work supervisor or the work leader must perform the following checks about protective gear, slings and
tools.
1) Are all the workers wearing helmets and other protective gear which they are obliged to wear?
If special protective gear is necessary, check that it is prepared and can be used without problem.
2) Are all the slings and tools prepared? Check in advance that they are ready to be used without prob-
lem. In particular, check wooden blocks for internal decay and cracking.
4. k Check during actual work

The work supervisor or the work leader must check the following items constantly and make all the workers
observe them.
1) Are the parking brakes of the trailer and crane truck applied securely and are their wheels locked with
chocks during work? Are outriggers, if installed, used securely?
2) Are the temperature and pressure of the engine, hydraulic oil, coolant, etc. lowered sufficiently during
work?
3) Is horn or another signal is made to warn around when the engine is started? In addition, is it checked
that work equipment control lever and other control levers are in neutral and the fuel control dial (or fuel
control lever) is in the low idle position?
4) Is the balance of the slung item checked extremely during sling work with the crane?
5) Is entry prohibition for outsiders to the work place observed?
5. The work supervisor or the work leader is required to hold a meeting with all the workers at the beginning of
every morning and explain the work plan of the day to them and give them instructions to observe the safe
work.
2
DISPOSAL OF REMOVED PARTS
As described in "FOREWORD", when this machine is transported, it is divided into some units such as the body,
undercarriage, cab, work equipment, etc. according to the transportation measure, regulations, etc.
Accordingly, the hydraulic pipings and hydraulic hoses to connect the units, oil inlets and outlets of the hydraulic
devices, and parts which must not be damaged are plugged or covered to prevent oil leakage, entry of dirt and
dust, and damage during transportation.
In addition, fixing jigs are used to prevent a trouble caused by a fall or a shake during transportation and to facilitate
loading, unloading and crane work.
The above plugs, jigs, etc. are removed when the machine is assembled and become unnecessary after
completion of the machine. Since they are useful when the machine needs to be transported in future, however,
we recommend you to keep them as long as possible.
3
Days
Backhoe · Inspection of oil level and

4 Divisions
coolant level
· Air bleeding from work
equipment cylinder
·
Loading shovel- Flushing of hydraulic
Assembly unit Base machine circuit
type excavator
· Adjustment of track
t Counterweight tension
q Left track frame r Upper structure
y Platform group · Performance test
w Right track frame
· Inspection of oil u Assembling of work
ASSEMBLING PROCEDURES,
e Axle assembly
level and coolant level equipment
(Two)
Crane
APPLICABLE EQUIPMENT AND SCHEDULE
4
45t 45t 25t
Min. 0.7 MPa
Air compressor
Min. 1.5 m3/min
Worker
Leader + 3 mechanics
Start of assembling
Completion of body · Completion of general

· Meeting with all workers Completion of Installation of unit assembly to body assembling assembling
KIT LAYOUT DIAGRAM
• The dimensions given below are the minimum dimensions needed.
• The kit dimensions in the diagram are outline dimensions.
• When selecting a place, see precautions for “FIELD ASSEMBLING”.
Bucket
Arm link
Arm cylinder
Tools, facility Boom
Boom
45t crane cylinder
Foreword
Crawler frame
Crawler frame
Revolving
Left deck
frame
Counterweight 45t crane

Motor cover · handrails
5
TRANSPORTATION
Packing Style for Transportation
These machines can be divided into three or four kits for transportation. Please ask us or our service shop for
transportation.
t 4-kit Transportation
t Packing Style of Each Kit (Sizes in drawing are given in millimeters.)

• Upper structure (single piece of cab)
a Cab convex portion (air intake for air conditioner) 3,219
b Door hinge 3,204
Full width
(mm) c Lock used when the door is opened 3,262
d Stopper used when the door is opened 3,287
e Handrail 3,220
6
• Upper structure without head guard
Unit: mm
Equipped Not equipped
with cab with cab
Overall height H1: 2,840 H2: 2,840
(mm)
a 3,204
b 3,220
Overall width c 3,262 *3,195
(mm)
d 3,219
e 3,287
Weight (kg) 25,620 25,080
* Revolving frame
• Upper structure with head guard
Unit: mm
Equipped Not equipped
with cab with cab
Overall height H1: 2,910 H2: 2,840
(mm)
a 3,204
b 3,220
Overall width c 3,262 *3,195
(mm)
d 3,219
e 3,287
Weight (kg) 25,770 25,180
Fix the upper structure on the truck by means of chain block. * Revolving frame
• Undercarriage
Unit: mm
Model PC800, 800SE PC800LC-8

PC850, 850SE-8
Quantity 2
Weight (kg) 21,600 23,600

(10,800 × 2) (11,800 × 2)
( ): PC800LC-8
7
• Work equipment
(1) Boom
PC800-8
Model PC800LC-8
PC800SE-8 PC850-8 PC850SE-8
A (mm) 8,505 7,405 8,345 7,405
B (mm) 2,705 2,560 2,695 2,560
C (mm) 4,387 4,104 4,295 4,104
D (mm) 1,218 1,098 1,210 1,098
Overall
1,500 1,500 1,500 1,500
width (mm)
Weight
7,510 6,950 7,770 6,950
(kg)
(2) Arm
PC800-8
Model PC800SE-8 PC850-8 PC850SE-8
PC800LC-8
A (mm) 5,105 4,075 4,800 4,075
B (mm) 1,324 1,696 1,410 1,696
C (mm) 2,459 2,237 2,478 2,237
D (mm) 577 709 648 709
Overall
749 753 749 753
width (mm)
Weight
3,970 4,880 4,485 4,880
(kg)
(3) Bucket
Model PC800-8 PC800SE-8 PC850-8 PC850SE-8

PC800LC-8
A (mm) 2,365 2,200 2,390 2,200
B (mm) 1,850 1,950 1,880 1,950
C (mm) 1,052 889 1,118 889
D (mm) 646 714 599 714
Overall
1,845 2,105 1,870 2,255
width (mm)
Weight
(kg) 2,960 3,420 3,840 4,245
8
(4) Boom cylinder (for all models)
Weight: 1,550 kg
(775 kg × 2 pcs)
(5) Arm cylinder
PC800-8 PC800SE-8
Model PC800LC-8 PC850-8
PC850SE-8
Quantity 1 2
A (mm) 3,500 2,590
B (mm) 1,885 1,391

Weight 870 986 (493 × 2)
(kg)
• Others
(1) Counterweight
Unit: mm
PC800-8 PC850-8 PC800LC-8

Model PC800SE-8 PC850SE-8 (If equipped)
A (mm) 451 451 451
B (mm) 1,689 1,689 1,689
C (mm) 684 684 684

Weight 9,800 11,850 9,800, 11,850
(kg) (13,600)
9
(2) Top guard (PC850-8, PC850SE-8 only)
Unit: mm
Weight: 55 kg
(3) Catwalk (1) (for all models)
Unit: mm
Weight: 50 kg
(4) Catwalk (2) (for all models)
Unit: mm
Weight: 30 kg
10
(5) Radiator duct (for all models)
Unit: mm
Weight: 81 kg
(6) Travel motor cover (for all models)
Weight: 120 kg × 2
11
LIST OF TOOLS FOR FIELD ASSEMBLING
No. Tool names Specifications Q’ty. Remarks

1 Equipment Engine compressor Min. 0.7 MPa, 15m3/min 1
45 ton 2 1st day
2 Crane truck
25 ton 1 2nd day
3 Grease pump Air type 1 Work equipment lubrication
4 Stepladder 5 -stepped- 1500 mm 2
5 Impact wrench KW10P (for M10) 1
6 KW12PI (For M12) 1
7 KW20P (For M16) 1
8 KW45FS (Spline) 1 For counterweight
9 Socket for KW45FS Spline × 65 mm 1 For counterweight
10 Air hose 50 m 1 For impact wrench
11 16-time wrench 4413 Nm {450 kgm} 1 For counterweight
12 Socket for 16-time wrench T38.1 × 65 mm 1 For counterweight
13 T38.1 × 55 mm 1 For track frame
14 T38.1 × 50 mm 1 For track frame
15 4-time wrench 25.4, 19 1
16 Socket for 4-time wrench T25.4 × 50 mm 1
Tool
17 T25.4 × 55 mm 1
18 Torque wrench 412 Nm {42 kgm} – T25.4 mm 1 For 16-time wrench
19 834 Nm {85 kgm} – T25.4 mm 1 For 4-time wrench
20 4118 Nm {420 kgm} – T38.1 mm 1 For counterweight and track frame
21 Standard tool Socket, spanner, wrench 2 set
22 Sledge hammer 10 P 1
23 Bar 1m 2
24 Hydraulic jack 490 kN {50 ton} (stroke 170) 2 Revolving frame pedestal
25 196 kN {20 ton} 1 When tightening track frame
connecting bolts.
When connecting travel and
26 Waste oil pan Large, small 2 each work equipment piping
27 Wooden block 300 × 400 mm 4 Revolving frame pedestal
28 Wire rope sling ø10 × 3000 mm 2 For catwalk
29 ø20 × 5000 mm 2 For boom, arm and bucket
30 ø25 × 5000 mm 4 For revolving frame and track frame
31 ø30 × 5000 mm 2 For counterweight
32 Shackle SD30 3
Lifting tool
33 SC18 4
34 Synthetic fiber sling 50 mm wide × 3000 mm 2 For boom cylinder and arm cylinder
35 Pin ø50 × 500 mm 2 Track frame
36 Lever block 14.7 – 29.4 kN {1.5 – 3 ton} 2
37 Eyebolt M16 1
38 M12 2
39 Detergent liquid Brake cleaner 10
40 Hydraulic oil EO-10 300 l
41 Grease G2-LI 20 kg Work equipment lubrication
Oil and
grease
42 Repair paint Natural yellow 5

43 Black gray 5
44 Waste cloth Bundle 20 kg
12
TIGHTENING TORQUE
1. Tightening torque for bolts
Tightening torque for bolts is indicated in the text as shown below. Tighten each bolt to the specified
torque.
Part No. of bolt TTTTT-TTTTT

Part No. of washer ThreadEEEEE-EEEEE
size (Diameter, pitch, length)
Bolt specification Thread diameter × Bolt length
Tool (Socket) Applicable socket size
Tightening torque Nm {QQQ kgm}
If tightening torque for a bolt is not specified in the text, tighten it according to Table 1.
Remarks
1. The thread diameter is the nominal diameter. For example, 16 mm is expressed as M16 and 26
mm is expressed as M20.
The pitch in Table 1 is the distance that the bolt advances every turn in the axial direction (Unit:
mm).
2. The bolt length is dimension c in Fig. 1.
3. The applicable socket size is expressed as 24 mm, 30 mm, etc. Since 24 mm, 30 mm, etc. cor-
respond to dimension b in Fig. 1, an applicable socket can be selected from Table 1, too.
4. Tightening torque is expressed as QQQ – www or QQQ ± RR. If the target tightening torque
is set, expression of QQQ ± RR is applied.
Fig. 1
a : Bolt thread diameter (Nominal diameter)

b : Width across flats of bolt head
c : Bolt length
d : Threaded part of bolt
13
Table 1 Tightening torque for bolts not specified in text
Nominal size of thread Width across flats Tightening torque

× pitch (= Socket size)
a (mm) b (mm) Unit : Nm Unit : {kgm}
6×1 10 11.8 – 14.7 {1.2 – 1.5}
8 × 1.25 13 27 – 34 {2.8 – 3.5}
10 × 1.5 17 59 – 74 {6 – 7.5}
12 × 1.75 19 98 – 123 {10 – 12.5}
14 × 2 22 153 – 190 {15.5 – 19.5}
16 × 2 24 235 – 285 {23.5 – 29.5}
18 × 2.5 27 320 – 400 {33 – 41}
20 × 2.5 30 455 – 565 {46.5 – 58}
22 × 2.5 32 610 – 765 {62.5 – 78}
24 × 3 36 785 – 980 {80 – 100}
27 × 3 41 1150 – 1440 {118 – 147}
30 × 3 46 1520 – 1910 {155 – 195}
33 × 3 50 1960 – 2450 {200 – 250}
36 × 3 55 2450 – 3040 {250 – 310}
39 × 3 60 2890 – 3630 {295 – 370}
a For symbols “a” and “b” in the table, see Fig. 1.
14
2. Tightening torque for pipe threads
Proper tightening torque for pipe threads depends on combination of the materials of the male screw and
female screw. In this manual, however, select tightening torque from Table 2 and Table 3 on the basis of
the material of the male screw. If tightening torque is specified specially in explanation, however, apply that
tightening torque.
2.1 If the male screw is made of mild steel or cast iron, apply Table 2.
Table 2
Unit: Nm {kgm}
Material of female thread
Steel Cast iron Light alloy
Nominal size (in)
3.9 – 6.9 2.9 – 5.9 2.0 – 3.9
1/8
{0.4 – 0.7} {0.3 – 0.6} {0.2 – 0.4}
5.9 – 11.8 4.9 – 9.8 3.9 – 7.8
1/4
{0.6 – 1.2} {0.5 – 1.0} {0.4 – 0.8}
16.7 – 26.5 13.7 – 21.6 9.8 – 16.7
3/8
{1.7 – 2.7} {1.4 – 2.2} {1.0 – 1.7}
32.3 – 52.9 26.5 – 43.1 19.6 – 32.3
1/2
{3.3 – 5.4} {2.7 – 4.4} {2.0 – 3.3}
51.0 – 85.3 42.1 – 70.6 31.4 – 52.9
3/4
{5.2 – 8.7} {4.3 – 7.2} {3.2 – 5.4}
86.2 – 173.5 72.5 – 146.0 54.9 – 111.7
1
{8.8 – 17.7} {7.4 – 14.9} {5.6 – 11.4}
2.2 If the male screw is made of refined steel (heat-treated hard steel), apply Table 3.
Table 3
Unit: Nm {kgm}
Material of female thread
Steel Cast iron Light alloy
Nominal size (in)
16.7 – 29.4 9.8 – 19.6 6.9 – 14.7
1/8
{1.7 – 3.0} {1.0 – 2.0} {0.7 – 1.5}
19.6 – 44.1 16.7 – 37.2 12.7 – 28.4
1/4
{2.0 – 4.5} {1.7 – 3.8} {1.3 – 2.9}
44.1 – 93.1 37.2 – 77.4 27.4 – 58.8
3/8
{4.5 – 9.5} {3.8 – 7.9} {2.8 – 6.0}
98.0 – 188.2 83.3 – 157.8 60.8 – 115.6
1/2
{10.0 – 19.2} {8.5 – 16.1} {6.2 – 11.8}
170.5 – 316.5 141.1 – 247.0 105.8 – 186.2
3/4
{17.4 – 32.3} {14.4 – 25.2} {10.8 – 19.0}
367.5 – 612.5 309.7 – 514.5 235.2 – 392.0
1
{37.5 – 62.5} {31.6 – 52.5} {24.0 – 40.0}
15
3. Tightening torque for hydraulic hose connecting nut
For the connecting nuts installed to the hydraulic hose adapters in relatively low pressure systems, apply
tightening torque in Table 4.
Table 4
Outside diameter Width across Tightening torque (Nm {kgm})

of hose flatse.
(mm) (mm) Range Target
Approx. 6 19 35 – 63 {3.5 – 6.5} 44 {4.5}
22 54 – 93 {5.5 – 9.5} 74 {7.5}

Approx. 10
24 59 – 98 {6.0 – 10.0} 78 {8.0}
Approx. 13 27 84 – 132 {8.5 – 13.5} 103 {10.5}
Approx. 16 32 128 – 186 {13.0 – 19.0} 157 {16.0}
Approx. 20 36 177 – 245 {18.0 – 25.0} 216 {22.0}
Note : When connecting hoses, take care not to twist them.
4. Proper socket sizes for bolts of M39 and larger (Reference)

For the proper sizes of sockets or spanners (= width across flats) for tightening hexagon bolts of M39 and
larger, see Table 5.
Table 5
Unit: mm
Thread diameter Proper sizes of sockets or spanners
M42 65
M45 70
M48 75
M52 80
M56 85
M60 90
M64 95
16
COATING MATERIALS
a The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code Part No. Q'ty Container Main applications, features
• Used to prevent rubber gaskets, rub-

LT-1A 790-129-9030 150 g Tube ber cushions, and cock plug from
coming out.
• Used in places requiring an immedi-
ately effective, strong adhesive.
20 g Polyethylene Used for plastics (except polyethyl-
LT-1B 790-129-9050 (2 pcs.) container ene, polyprophylene, tetrafluoroeth-
lene and vinyl chloride), rubber,
metal and non-metal.
• Features: Resistance to heat and
Polyethylene chemicals
LT-2 09940-00030 50 g container • Used for anti-loosening and sealant
purpose for bolts and plugs.
Adhesive: • Used as adhesive or sealant for met-
790-129-9060 1 kg al, glass and plastic.
LT-3 (Set of adhesive Hardening Can
and hardening agent:
agent) 500 g
Adhesives
Polyethylene • Used as sealant for machined holes.
LT-4 790-129-9040 250 g container
Holtz • Used as heat-resisting sealant for re-

MH 705 790-126-9120 75 g Tube pairing engine.
• Quick hardening type adhesive

Three bond 790-129-9140 50 g Polyethylene • Cure time: within 5 sec. to 3 min.
1735 container • Used mainly for adhesion of metals,
rubbers, plastics and woods.
• Quick hardening type adhesive
• Quick cure type (max. strength after
Aron-alpha 790-129-9130 2g Polyethylene 30 minutes)
201 container • Used mainly for adhesion of rubbers,
plastics and metals.
• Resistance to heat, chemicals
Loctite 79A-129-9110 50 cc Polyethylene • Used at joint portions subject to high
648-50 container temperatures.
• Used as adhesive or sealant for gas-
LG-1 790-129-9010 200 g Tube kets and packing of power train case,
etc.
• Used as sealant for various threads,
LG-5 790-129-9080 1 kg Can pipe joints, flanges.
• Used as sealant for tapered plugs,
elbows, nipples of hydraulic piping.
• Features: Silicon based, resistance
to heat, cold
• Used as sealant for flange surface,
LG-6 790-129-9020 200 g Tube tread.
• Used as sealant for oil pan, final
Gasket drive case, etc.
sealant
• Features: Silicon based, quick hard-
ening type
LG-7 790-129-9070 1 kg Tube • Used as sealant for flywheel hous-
ing, intake manifold, oil pan, thermo-
stat housing, etc.
Three bond • Used as heat-resisting sealant for re-
1211 790-129-9090 100 g Tube pairing engine.
• Features: Silicone type, heat resist-

Three bond ant, vibration resistant, and impact
1207B 419-15-18131 100 g Tube resistant sealing material
• Used as sealing material for transfer
case
17
Category Komatsu code Part No. Q'ty Container Main applications, features
• Used as lubricant for sliding portion

LM-G 09940-00051 60 g Can (to prevent from squeaking).
Molybdenum • Used to prevent seizure or scuffling
disulphide of the thread when press fitting or
lubricant LM-P 09940-00040 200 g Tube shrink fitting.
• Used as lubricant for linkage, bear-
ings, etc.
SYG2-400LI • General purpose type
SYG2-350LI
G2-LI SYG2-400LI-A Various Various
SYG2-160LI
SYGA-160CNLI
SYG2-400CA • Used for normal temperature, light
SYG2-350CA load bearing at places in contact
G2-CA SYG2-400CA-A Various Various with water or steam.
SYG2-160CA
SYGA-160CNCA
Molybdenum • Used for heavy load portion

disulphide SYG2-400M 400 g × 10 Bellows type
Grease grease SYG2-400M-A 400 g × 20 Bellows type
LM-G (G2-M) SYGA-16CNM 16 kg Can
• Seizure resistance and heat resist-

Hyper White SYG2-400T-A ance higher than molybdenum di-
Grease G2-T SYG2-16CNT 400 g Bellows type sulfide grease
G0-T (*) SYG0-400T-A (*) 16 kg Can • Since this grease is white, it does
*: For use in cold SYG0-16CNT (*) not stand out against machine
district body.
Biogrease G2B • Since this grease is decomposed
SYG2-400B by bacteria in short period, it has
G2-BT (*) SYGA-16CNB 400 g Bellows type
*: For high less effects on microorganisms,
SYG2-400BT (*) 16 kg Can animals, and plants.
temperature SYGA-16CNBT (*)
and large load
SUNSTAR • Used as primer for cab side

Glass (Expiration date: 4 months)
PAINT PRIMER 20 ml container
580 SUPER
Primer
SUNSTAR • Used as primer for glass side
Glass (Expiration date: 4 months)
GLASS PRIMER 20 ml container
580 SUPER 417-926-3910
Adhesive for cab glass
• "S" is used for high-tempera-

SUNSTAR ture season (April - October)
PENGUINE Polyethylene and "W" for low-temperature
SEAL 580 320 ml container season (November - April) as
Adhesive SUPER "S" or adhesive for glass.
"W" (Expiration date: 4 months)
Sika Japan, Polyethylene • Used as adhesive for glass.
20Y-54-39850 310 ml (Expiration date: 6 months)
Sikaflex 256HV container
SUNSTAR • Used to seal joints of glass

Polyethylene parts.
PENGUINE 417-926-3920 320 ml container
SEAL No. 2505 (Expiration date: 4 months)
Caulking
material • Used to seal front window.
SEKISUI Polyethylene
SILICONE 20Y-54-55130 333 ml (Expiration date: 6 months)
container
SEALANT
18
A. ASSEMBLY OF CHASSIS
Remarks
1. In the "drawings" in this manual, parts and places are indicated by 1, 2, 3 ---,
but indicated by (1), (2), (3) --- in the tables and texts.
Example:
(1) Plate
(2) Collar
(3) Washer
(4) Bolt
(5) Bolt
(6) Washer
2. In some places of this manual, the words of front, rear, right hand and left hand
of machine are used. Those words indicate the directions seen from the opera-
tor's seat with the sprocket at the rear as shown below, unless otherwise speci-
fied.
Front
Front
Operator’s
Left hand seat Right hand
Left hand Right hand
Operator's seat
Sprocket
Sprocket
Rear
Rear
19
Assembly procedure
Installation of Left and Right Track Frames (1/4)
A-1
• Sling the revolving frame assembly with 2 cranes. Start the engine and return the center frame assembly slowly by 90°,
which has been turned by 90° for transportation, and then position the revolving frame assembly onto the track frame.
Weight of Upper Structure: 25,800 kg
Slowly rotate 90°
Fitting the wire at

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

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

Right track frame with 200 to 250 kgm torque.
No. Loose-supply items Q’ty

1 209-09-11310 8
2 209-30-61120 8
3 209-09-51110 8
Left track frame 4 209-30-71121 2
5 01643-33690 8
6 209-30-11330 8
7 209-09-51110 32
8 209-30-61120 32
Put washer (5) under plate (4). Name Q’ty Name Q’ty
4 time wrench 1 45 ton crane 2
When installing spacers (2) and (8), be
careful not to slant them to the spot facing, Torque wrench (100 kg) 1
etc.
Socket (25.4 Sq. × 55 mm) 1
Torque wrench (420 kgm) 1
Others
21
Assembly procedure
A-1
• Secure two points of the center frame of the track by placing a hydraulic jack and a 300 × 400 mm wooden block at
each point. Make sure that these points do not interfere with the upper structure rotation.
• Lift the Track Frame Assembly and install it on the Center Frame.
Weight of a single side of Track Frame

Assembly: 11,000 kg

Name Q’ty Name Q’ty
Hydraulic jack (50 ton) 2 45 ton crane 1
Wooden block (300 × 400 mm) 2
Wire rope sling (ø30 mm, 5000 mm long) 2
Pin (ø50 mm, 500 mm) 2
Others
22
Assembly procedure
A-1
Thickness of 100 mm
Wooden block
a When tightening bolts, raise the track with a hydraulic jack as shown above so as to get sufficient space for tightening.
Do not remove the shoes before assembling Name Q’ty Name Q’ty
(so as to maintain the tightening torques of 4 time wrench 1
the shoe bolts).
Torque wrench (100 kg) 1
Socket (25.4 Sq. × 55 mm) 1
Torque wrench (4,200 kg) 1
Others
23
Assembly procedure
Installation of Travel Pipe (1/3)
A-2
Fig. 1
L.H. R.H.
Fig. 2
No. Parts already installed to body Q’ty
1 209-64-12131 2
2 209-64-12141 2
3 209-62-42610 2
4 209-62-42520 1
5 209-62-42510 1

6 07000-13032 4
• Before removing the oil stopper of each Name Q’ty Name Q’ty
hose, turn the bolt slowly to release the Width across flats 32 spanner 2
internal pressure.
Width across flats 24 spanner 2
KW12P impact 1
L150 extension 1
M17 socket 1
Others
24
Assembly procedure
A-2
L.H. R.H.
Fig. 3

1 209-64-12131 2
2 209-64-12141 2
3 209-62-42610 2
4 209-62-42520 1
5 209-62-42510 1

6 07000-13032 4

Others
25
Assembly procedure
A-2
(1) Arrange the pilot hoses (4) (L.H.), (5) (R.H.) for selecting machine speed and the drain hoses (3) (Figs 1,2 and 3)
(2) Arrange the main hoses (1) and (2) on the travel motor side (Figs 1,2 and 3). Use new O-rings (6) out of the loose-supply
items and use split flange, bolt and washer out of the travel motor parts.
Machine front

1 209-64-12131 2
2 209-64-12141 2
3 209-62-42610 2
4 209-62-42520 1
5 209-62-42510 1

6 07000-13032 4

Others
26
Assembly procedure
Installation of Top Guard
A-3
.

1 209-954-4211 1
2 195-Z11-2970 6
3 01011-81220 2
4 01643-31232 4
5 130-43-64260 6
6 01024-81280 2
7 01024-81295 2
8 01024-01220 2
9 20Y-954-4220 2
10 20Y-954-4240 2
11 20Y-954-4230 2
The top guard is installed when the machine Name Q’ty Name Q’ty
is delivered. Accordingly, the work on this
page is necessary only when the top guard is
supplied loose.
Others
27
Assembly procedure
Installation of Radiator Cover
A-4
• Set the radiator covers (1) and (2) on the body and fix them using the bolts and the washers (3) – (6).
Install to the hinge.

1 209-54-41500 1
T 2 01010-81245 3
w 3 01010-81275 2
4 01010-81290 4
A 5 01010-81235 9
6 01643-31232 17
Remove the plugs for rust prevention set in Name Q’ty Name Q’ty
the mounting tapped holes.
Of the 9 hinge mounting bolts, install the 3
bolts with the A mark when the duct is closed
and align with the position of the duct.
Others
28
Assembly procedure
Installation of Rearview Mirror (1/4)
A-5
• Install parts (1) – (5) to the handrail at the front of the machine right side.
220

1 421-54-25610 1
2 209-53-11450 1
3 20Y-54-61630 1
4 01252-71030 2
5 04025-00632 1

Others
29
Assembly procedure
A-5
• Pass pin (5) through the hole in ball busing (A), hold the mirror with the holder of mirror (1), then secure in position and
check that the mirror does not move.
Replace the screw (421-54-25660) of the mirror assembly

part with the hexagon head bolt (6) (01252-70545), and
tighten it.
Tightening torque: 1.5 – 2.0 Nm {0.15 – 0.2 kgm}

Others
30
Assembly procedure
A-5
With Top Guard
• Install parts (1) – (5) to the handrail at the front of the operator’s cab.

1 20Y-54-28911 1
2 209-53-13630 1
3 01024-D1235 2
4 20Y-54-35430 1
5 01252-71025 2

Others
31
Assembly procedure
A-5
Without Top Guard
• Install parts (1) – (5) to the handrail at the front of the operator’s cab.
Washer

1 20Y-54-28911 1
2 209-53-13691 1
3 20Y-54-35430 1
4 01252-71025 2
5 01024-D1245 1
6 208-01-11270 1

Others
32
Assembly procedure
Installation of Left Side Step
A-6
(1) Using bolts (5), temporarily tighten brackets (3) to chassis.
(2) Sling steps (1) and (2) with crane, using bolts (6) and washers (7), install them to bracket.
(2-1) Adjust the heights of steps (1) and (2) using brackets (3).
(3) Tighten bracket and mounting bolts. (* in Fig.)
(4) Using bolts (5), install grip (4) to chassis.

1 209-54-43950 1
2 209-54-43940 1
3 209-53-13761 5
4 209-53-13620 1
5 01024-81245 19
6 01010-81230 15
7 175-54-34170 15
Remove the rust prevention plug knocked Name Q’ty Name Q’ty
into the mounting tap hole. KW12P impact 1
L150 extension 1
M19 socket 1
Others
33
Assembly procedure
Installation of Handrail
A-7
(1) Install step (1) on the left side cover with bolts (2).
(2) Install handrails (3) and (4) with bolts (2).

1 209-54-63481 2
2 01014-81230 14
3 209-54-77581 1
4 209-54-77571 1

KW12P impact 1
L150 extension 1
M19 socket 1
Others
34
Assembly procedure
Installation of Handrail (With top guard) (1/2)
A-8
• Install handrail (1) with bolts (2) and spacers (3).

1 209-53-13640 1
2 01024-D1260 2
3 195-33-11220 2

KW12P impact 1
M19 socket 1
Others
35
Assembly procedure
Installation of Handrail (With top guard) (2/2)
A-8
• Install handrail (1) with bolts (2), (4) and pipes (3), (5).

1 209-53-13640 1
2 01024-D1260 1
3 20Y-954-4240 1
4 01024-D1275 1
5 20Y-954-4230 1

KW12P impact 1
M19 socket 1
Others
36
Assembly procedure
Installation of Muffler Tail Tube
A-9
(1) Fix the muffler tail tube (1) to the top of the hood by using the bolts (3) and the washer (4).
(2) Fix a rain cap (2) to the muffler tail tube.
Rain cap
(Decide the direction so that exhaust
is emitted backward)
Muffler tail tube
View from machine left side

1 209-01-77241 1
2 6164-12-5900 1
3 01010-81230 4
4 175-54-34170 4

KW12P impact 1
M19 socket 1
Others
37
Assembly procedure
Sticking Sheet to Counterweight
A-10
• Stick sheets to the surfaces of the counterweight in front of the machine as shown below.
Counterweight
a Note that steps (2) and (3) should be installed after the counterweight is mounted.

1 209-46-41230 1
2 209-54-42190 1
3 01024-81220 4
Remove all oil and rust from the surface Name Q’ty Name Q’ty
where the sheet is to be stuck.
Others
38
Assembly procedure
Installation of Counterweight
A-11
a When installing the counterweight, open the door at the rear

of the hood.
4 Counterweight : 9,740 kg

2 209-46-41550 6
3 209-46-11210 6
Install the counterweight so that there will be Name Q’ty Name Q’ty
the reference space of 15 mm between the Torque wrench (4,118.8 Nm {420 kgm}) 1 45 t crane 1
weight and the revolving frame or so that the
left level difference equals to the right one. 38sq. × 65 mm socket 1
KW45FS impact 1
The weight of each counterweight can be
distinguished by the shape of the eye plate. M65SP socket 1
ø30 x 5000 mm wire rope sling 2
For 4 ton shackle 2
(1) 9.8 ton (2) 11.85 ton (3) 13.6 ton

Others
39
Assembly procedure
Installation of KOMTRAX Antenna (if equipped)
A-12
Antenna
Bolt
After the installation of top guard,

move antenna and bracket together without
removing antenna (1) from plate (3).
Position of antenna during Plate

transportation

1 8A13-10-1310 1
2 01024-D1225 1
3 20Y-53-15140 1

Others
40
Assembly procedure
Installation of Step Light (1/2)
A-13

1 209-53-14430 1
2 01024-D1020 1

Others
41
Assembly procedure
Installation of Step Light (2/2)
A-13

1 209-53-14430 1
2 01024-D1020 1
3 209-53-14421 1
4 01024-D1220 1

Others
42
Assembly procedure
Air Bleeding of Travel Motor
A-14
1. Start and rotate engine at the low idle.
2. Loosen air bleeding plug (1) one turn (both right and left ones).
a Do not loosen air bleeding plug (1) more than one turn.
3. Repeat forward and backward travel operations four to five times.
4. Tighten air bleeding plug (1) when air bleeding plug (1) discharges oil without white bubble.

Width across flats 10 wrench 1 Oil pan plate 1
Others
43
Assembly procedure
Installation of Travel Piping Cover (1/2)
A-15
Weight of motor cover: 115 kg
a Swing upper structure to a position where the motor cover can be slung.
1. Install left travel piping cover.
a Cover installing order: (1), (4), (10), (12).

1 209-30-41310 1
2 01010-81645 10
3 01643-31645 10
4 209-30-41350 1
5 01010-81230 7
6 01010-81245 2
7 175-54-34170 11
8 01010-81640 1
9 21T-54-16150 1
10 209-30-41370 1
11 01010-81240 2
12 209-30-41330 1

M16 Eyebolt 1 25 ton crane 1
ø10 × 3000 mm wire rope sling 1
KW10P impact 1
KW20P impact 1
M19 socket 1
M24 socket 1
Others
44
Assembly procedure
Installation of Travel Piping Cover (2/2)
A-15
2. Install right travel piping cover.
a Cover installing order: (1), (4), (10), (12).

1 209-30-41320 1
2 01010-81645 10
3 01643-31645 10
4 209-30-41360 1
5 01010-81230 7
6 01010-81245 2
7 175-54-34170 11
8 01010-81640 1
9 21T-54-16150 1
10 209-30-41380 1
11 01010-81240 2
12 209-30-41330 1

M16 Eyebolt 1 25 ton crane 1
ø10 × 3000 mm wire rope sling 1
KW10P impact 1
KW20P impact 1
M19 socket 1
M24 socket 1
Others
45
Assembly procedure
Testing Track Shoe Tension (1/3)
A-16

Others
46
Assembly procedure
A-16

Others
47
Assembly procedure
A-16
k Warning
• Don’t stand at the front.
• Don’t look inside.

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

°C -10 -15 -20 -25 -30 -35 -40
Min. atmospheric temperature
°F 14 5 -4 -13 -22 -31 -40
liters 31.2 37.4 42.6 47.8 52.0 56.2 60.3
Amount of antifreeze
US gal 8.24 9.88 11.25 12.63 13.74 12.13 15.93
liters 72.8 66.6 61.4 56.2 52.0 47.8 43.7
Amount of water
US gal 19.23 17.60 16.22 14.85 13.74 12.63 11.55
Proportion by volume % 30 36 41 46 50 54 58
k Warning
The coolant is inflammable. So, keep it away from fire.
Use tap water as the cooling water.
We recommend you to control mixing ration with an antifreeze

concentration meter.
k Warning
When removing the drain plug, use care not to be

drenched by coolant mixing water.
• Non-amine Supercoolant (Blue) is added when Name Q’ty Name Q’ty

shipped. Do not mix coolant of different type
with it.
Others
50
Assembly procedure
Parts to be Touched up after Field Assembly
A-18

Others
51
B. ASSEMBLING OF WORK EQUIPMENT
OF BACKHOE
• Clean the mounting pin and pin hole and check them for a flaw.
53
Assembly procedure
Assembly of Arm Cylinder
B-1
(1) Remove the stopper fixed to the boom and the arm cylinder foot pin.
4 Arm cylinder foot pin: 24 kg × 2
(2) For PC800 only, set the O-ring (07000-12130, 2 pcs.) to the arm cylinder foot.
(3) Lift the arm cylinder and fit it to the hole positions on the arm side.
4 Arm cylinder: 870 kg (PC800, PC800LC)

493 kg × 2 (PC800SE, PC850, PC850SE)
Adjustment should be made using the shim (2) so that the clearance becomes less than 1 mm.
(4) Insert the arm cylinder foot pin.

2 Inside of pin hole: Lithium grease
(5) Install the stopper plate.

Tightening torque of the plate fixing bolt: 245 – 309 Nm {25 – 31.5 kgm}
PC800 only

1 07000-12130 4
2 207-70-11360 7

50 mm wide, 3000 mm 25 ton crane 1

2
Synthetic fiber sling
KW20P impact wrench 1

M24 socket 1
Others
54
Assembly procedure
Connection of Arm Cylinder Hoses (1/2)
B-2
(1) Remove the oil stopper plug from the arm cylinder pipe, replace the O-rings (07000-13048, 4 pcs. for PC850, 07000-13038,
4 pcs.) at the hose connection with new ones and connect the arm cylinder hoses (07098-01414, 1 pc. 07098-01417,
1 pc. and 209-62-41910, 1 pc. 209-62-41920, 1 pc. and 07099-01214, 2 pcs. for PC850) there.
a Use split flange and bolt out of the oil stopper parts.
No. Loose-supply items Q’ty Remarks

1 07000-13048 4
2 07000-13038 4
3 07098-01414 1
4 209-62-41920 1 L: 1350
5 07099-01214 2
No. Housing fixing items Q’ty Remarks
6 07371-51470 8
7 01010-81455 16
8 01643-31445 16
9 07371-51260 8
10 01024-81245 16
1. Bind the arm cylinder rod with wires etc. Name Q’ty Name Q’ty
to prevent it from coming out during work. KW12P impact 1
2. Remove and store the flange, O-rings and
heads so that you can reuse them later. L150 extension 1
3. When connecting the hoses, take
M19 socket 1
extremely care not to clinch or damage
the O-rings. M22 socket 1
4. Also, take extremely care not to enter a
foreign material into the hydraulic circuit.
Others
55
Assembly procedure
Connection of Arm Cylinder Hoses (2/2)
B-2
(1) Remove the oil stopper plug from the arm cylinder pipe, and replace four O-rings (1) at the hose end with new ones (PC850:
Part No. 07000-13048). Then, connect the arm cylinder hoses (11) and (12) (PC850: 07098-01417 × 1, 209-62-41910 × 1).
a Use the oil stopper parts for split flange, bolts, and the like.

1 07000-13048 4
11 07098-01417 1
12 209-62-41910 1 L: 1650
No. Housing fixing items Q’ty Remarks
6 07371-51470 8
7 01010-81455 16
8 01643-31445 16
1. Bind the arm cylinder rod with wires etc. Name Q’ty Name Q’ty
to prevent it from coming out during work. KW12P impact 1
2. Remove and store the flange, O-rings and
heads so that you can reuse them later. L150 extension 1
3. When connecting the hoses, take
M22 socket 1
extremely care not to clinch or damage
the O-rings.
4. Also, take extremely care not to enter a
foreign material into the hydraulic circuit.
Others
56
Assembly procedure
Installation of Boom Cylinder Foot
B-3
(1) Lift the boom cylinder with the crane and bring it to the body pin hole.
(2) Set the O-ring (07000-12130, 4 pcs, for the left and right cylinders) out of the loose-supply items on the boom cylinder foot
and push pins in it.
(3) Check the clearance (outside the machine) between the cylinder pin and the body, decide the size and quantity of shim so
that the clearance becomes below 1 mm and insert them there. Adjust the left and right cylinders with shims (outside the
machine).
(4) Sandwich the boom cylinder stand (wooden block) between the cylinder and the revolving frame.
(Height should be 40 to 50 mm, and width should be equal to or less than 90 mm)
(5) Push the boom foot pins in the holes completely and fit the lockplates there.
Tightening torque of the plate fixing bolt:

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

that the clearance becomes
below 1 mm.
O-ring
Wooden block

1 07000-12130 4
2 209-72-51240 4
3 209-72-51230 4
a Assemble the boom cylinder foot so that Name Q’ty Name Q’ty
the greasing port faces down.
50 mm wide, 3000 mm
2
a Use the adjustment shims (209-75-51230,
1.0 mm thick, and 209-72-51240, 1.5 mm
thick) to decide their combination. KW20P impact wrench 1
M24 socket 1
Others
57
Assembly procedure
Relieving Remaining Pressure from Hydraulic Circuit
B-4
When removing hydraulic pipes, be sure to relieve remaining

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

pressure in the tank and remove it carefully.
(2) Lower the lock lever and keep it locked.
(3) Start the engine, operate it for about 10 seconds and stop
the engine.
a Do not increase the engine speed to over 1,000 rpm.
a Keep the control lever of the work equipment neutral.
(4) Turn the starting switch to ON, set the lock lever to “Free”
and set the control lever of each work equipment to Full
Stroke within 5 to 6 seconds after stopping the engine.
a Repeat the procedures (2) to (4) three times.
(5) After relieving remaining pressure, set the cap to the oil
filler port of the hydraulic oil tank so that dust do not enter
the tank.
(6) Lower the lock lever and keep it locked.

Others
58
Assembly procedure
Installation of Boom Cylinder Hoses
B-5
(1) Remove the blind plug from the boom cylinder tube.
(2) Arrange the boom cylinder hose (1) (07099-01216, 4 pcs.) to the normal circuit as shown below. Replace the O-ring (2)
(07000-13038, 8 pcs.) at the hose connection with the new one out of the loose-supply items.
a Bleed air from the boom cylinder. For details, see Procedure B-17 "Air Bleeding from Hydraulic Cylinder".

1 07099-01216 4
2 07000-13038 8
1. When removing the oil plug from each Name Q’ty Name Q’ty
hose, loosen the bolt slowly to release the KW12P Impact 1 Oil pan (small) 1
internal pressure and then remove the oil
plug carefully. L150 extension 1
2. Keep the removed flanges, O-rings and
heads so that you can use them again. M19 socket 1
3. When installing each hose, take care
extremely that the O-ring will not be
caught.
4. When installing each hose, take care
extremely that dirt will not enter the circuit.
Others
59
Assembly procedure
Installation of Boom Foot Dust Seal
B-6
(1) Install the seal (209-72-11261) to the boom foot
Take care of the

direction of its lip.
Take care of the No. Loose-supply items Q’ty

direction of its lip. 1 209-72-11261 4
1. Take care of the direction of its lip so that Name Q’ty Name Q’ty
the grease can come out from inside. Hammer 1
2. When installing the seal, be careful not to
slant it. Template 1
3. Insert the seal until it touches the bushing.

4. Do not hit seal with hammer directly but
use template, etc. to hit.
Others
60
Assembly procedure
Assembly of Boom Assembly
B-7
(1) Lift the boom assembly with the crane and bring it to the body pin hole.
4 Boom assembly: 7,900 kg (PC800, PC800LC)

8,100 kg (PC850)
7,300 kg (PC800SE, PC850SE)
(2) Fitting of Boom Foot Pin.

Insert a boom foot pin (which had been fitted on the revolving side) in a hole one side first and bring the body to the pin
hole on the other side. When the boom is inclined to the left or right at the time, balance it by using the jib crane.
a Check the clearance between the boom foot and the machine outside, decide the size and quantity of shim so that the
clearance becomes below 1 mm and insert the shim between them.
Use the adjustment shims (209-70-71640, 1.0 mm thick, and 209-70-71650, 1.5 mm thick) to decide their combination.
a Adjust the clearance with shims at one place outside.
(3) Insert the boom foot pins fully on both the left and right sides and fit lockplates there.
3 Tightening torque of the plate fixing bolt:

245 – 309 Nm {25 – 31 kgm}

1 209-72-11261 4
2 209-70-71650 4
3 209-70-71640 2
a Since four seals (209-72-11261) have been fit- Name Q’ty Name Q’ty
ted to the boom foot as shown below, use care ø20 × 5000 mm wire rope sling 2 25 ton crane 1
not to break them when inserting pins.
Large hammer (plastic) 1
KW20P impact 1
M24 socket 1
Others
61
Assembly procedure
Hose Connection of Arm and Bucket Circuits
B-8
(1) Remove oil stopper plug from hose and oil stopper plug from boom tube.
(2) Connect on-boom arm cylinder, bucket cylinder hose (2) with regular circuits as shown below.
No. Main body mounted items Q’ty

1 209-72-11261 4
2 07098-01414 4
3 07371-51470 8
4 01010-81455 16
5 01643-31445 16
1. When removing oil stopper plug from Name Q’ty Name Q’ty
hose, care should be taken and rotate bolt KW12P Impact 1
slowly to let out pressure.
2. Store the removed flange, O-ring, and L150 Extension 1
head in order so that they can be used
again. M22 Socket 1
3. When connecting hose, great care should
be taken so that O-rings do not get
caught.
4. When connecting hose, great care should
be taken so that dusts do not fall in the
circuits.
Others
62
Assembly procedure
Installation of Quick Return Hose
B-9
(1) Connect quick return hoses (1) and (2).
(2) Install hose clamps (3), (4) and (5) with bolt (6) and washer (7).
a Air bleeding should be made for arm cylinder only.

1 02896-11009 1
2 02896-11012 1
3 07094-30315 2
4 07095-00314 1
5 07095-00317 1
6 01010-81265 1
7 01643-31232 1
a When installing each hose, take care Name Q’ty Name Q’ty
extremely that dirt will not enter the circuit. KW12P Impact 1
M19 Socket 1
M17 Socket 1
L150 Extension 1
Others
63
Assembly procedure
Installation of Boom Cylinder
B-10
(1) Remove the stopper fixed to the boom and the boom cylinder top pin (1).
4 Boom cylinder to pin: 33kg
(2) Start the engine and idle it as a low speed.
(3) Lift the cylinder (2), extend the rod slowly and fit it to the pin hole.
a Before aligning the pin holes, bleed air from the cylinder.
4 Boom cylinder: 775 kg × 2
(4) Insert the cylinder top pin in the pin hole.
2 Inside of pin hole: Lithium grease.
(5) Set the cylinder top pin to both the left and right cylinders in the same way.
(6) Fit the stopper to the boom.
3 Tightening torque of the plate fixing bolt: 245 – 309 Nm {25 – 31.5 kgm}
a Extend the cylinder slowly, nor operate it Name Q’ty Name Q’ty
quickly, nor bring it to the stroke end. 50 mm wide, 3000 mm 25 ton crane 1
Since air gathers inside the cylinder at the first 2
time, the cylinder may not move for 10 sec-
onds or more, but do not bring the lever to the KW20P impact wrench 1
full stroke point.
M24 socket 1
Large hammer 1
Others
64
Assembly procedure
Installation of Arm Assembly (1/2)
B-11
(1) Remove the stopper of the boom top pin fixed to the boom and pull out the top pin.
4 Boom top pin: 110 kg
(2) Lift the arm assembly, bring it to the boom hole.

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

4,880 kg (PC800SE, PC850SE)
4,485 kg (PC850)
(3) Fit the stopper to the pin.
(4) Remove the stopper of the arm cylinder top pin fixed to the arm side and pull out the top pin.
4 Arm cylinder top pin: 24 kg × 2 (PC850, PC800SE, and PC850SE)

30 kg (PC800, 800LC)
1 209-70-71641 1
a Since the seal (209-72-11261, 2 pcs.) is fitted Name Q’ty Name Q’ty
to the inside of the arm side bushing, use care ø20 x 5000 mm wire rope sling 2 25 ton crane 1
not to break it when inserting the pin.
SD30 shackle 2 Five-stage step 2
2 Inside of pin hole: Lithium grease Large hammer (plastic) 1
KW20P impact 1
M24 socket 1
Others
65
Assembly procedure
Installation of Arm Assembly (2/2)
B-11
(5) Start the engine, idle it and extend the arm cylinder rod slowly to adjust the pin hole position. At the time, lift the arm cylinder
with the crane for positioning during operation of the arm cylinder.
a Assembly should be made so that the lubrication hole faces upward.
(6) Push the arm cylinder top pin in the pin hole.
(7) Fit the stopper to the pin.
a Operate the cylinder slowly. Name Q’ty Name Q’ty

Do not operate it quickly and do not bring it to ø20 x 5000 mm wire rope sling 2 25 ton crane 1
the stroke end.
SD30 shackle 2 Five-stage step 2
Since air gathers inside the cylinder at the first
time, it may not move for over 10 seconds, but Large hammer (plastic) 1
do not move the lever to the full stroke.
KW20P impact 1
M24 socket 1
Others
66
Assembly procedure
Installation of Hose between Boom and Bucket Cylinder
B-12
(1) Remove oil stopper plug from bucket cylinder tube.
(2) Connect two bucket cylinder hoses (2) there after they are fitted with O-rings (1).
a Use split flange and bolt out of the oil stopper parts.
a Bleed air from the bucket cylinder. For details, see Procedure B-16 "Air Bleeding from Hydraulic Cylinder".

The parts below are
for PC800, 850-8
1 07000-13038 4
2 07098-21219 2
The parts below are
for PC800SE, 850SE-8
1 07000-13038 4
2 07098-21221 2
1. Store the flanges, O-rings and heads used for Name Q’ty Name Q’ty
transportation for re-use in the future. KW12P Impact 1 Five-stage step 1
2. Connect hoses carefully so that they do not
L150 Extension 1 Oil pan plate 1
get caught between other parts.
3. Connect hoses carefully so that they do not in- M19 Socket 1
terfere with other parts and are not twisted.
4. When connecting hoses, use care not to let
dusts enter the circuit.
Others
67
Assembly procedure
Installation of Bucket Assembly
B-13
3 Tightening torque of the cover

fixing bolt:
824 – 1,030 Nm {84 – 105 kgm}

208-70-33181 2
209-72-11220 2
21N-70-13150 2
209-939-5441 2
209-939-5431 9
209-939-5410 1
a Be sure to operate the cylinder slowly. Do not Name Q’ty Name Q’ty
operate it quickly and do not bring it to the ø20 x 5000 mm wire rope sling 1 25 ton crane 1
stroke end. Since air gathers inside the cylin-
KW20P impact 1
der at the first time, the cylinder may not oper-
ate for 10 seconds or more, but do not move M36 socket 1
the lever to the full stroke.
Torque wrench (100 kg) 1
Others
68
Assembly procedure
Lubrication Piping to Work Equipment
B-14

07020-00000 2

Others
69
Assembly procedure
Wiring of Work Equipment
B-15

1 21T-06-32810 2
2 20Y-06-21551 2
3 01024-81230 4
4 08193-20012 2

KW12P impact 1
M19 socket 1
Others
70
Assembly procedure
Greasing after Assembling Work Equipment
B-16

Others
71
Assembly procedure
Air Bleeding from Hydraulic Cylinder
B-17

Others
72
C. ASSEMBLING OF WORK EQUIPMENT
OF LOADING SHOVEL
• Clean the mounting pin hole and check them for a flaw.
73
74
Use forcing screws (24 mm, P = 3.0, full thread bolt, stem length 80 mm and above)
to pull out the pins.
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
D. ASSEMBLING OF COUNTERWEIGHT REMOVER
97
Assembly procedure
Installation of Rubber Cushions
D-1
• Install rubber cushion (1), spacer (2), bolt (3) and washer (4).

1 209-46-74150 2
2 205-03-71330 6
3 01010-81260 6
4 427-06-13240 6

M19 socket 1
Others
98
Assembly procedure
Adjustment of Shims for Counterweight (1/5)
D-2
• Before installing the counterweight normally, adjust the shims to prevent the counterweight bolt holes from moving to the
right or left by method I or II.
Method I. When actually placing and setting the counterweight on the revolving frame and adjusting the shims
1) Sling counterweight assembly (1) and install it to the machine.
2) Check that bolts (2) (6 pieces) can be installed.
(Tighten the bolts with the fingers. You do not need to tighten them securely at this time.)
Weight of counterweight assembly: 12,400 kg

2 209-46-41550 6
3 209-46-11210 6

ø300 × 5,000 mm wire rope sling 2 45 t crane 1
SD30 shackle 2
Others
99
Assembly procedure
D-2
3) Decide the thickness of shims (2), (3) and (4) at the 4 places so that the clearance between the revolving frame
and plate (1) will be 2 ± 0.5 mm.
4) Remove the counterweight mounting bolts and lift the counterweight assembly down from the revolving frame.
5) Install plate (1) and shims (2), (3) and (4) decided by step 3) above to the counterweight with bolts and washers
(5) (or (6)).
If the thickness of shims (2), (3) and (4) decided by step 3) is less than 5 mm, use bolts (5). If the former is 5 mm
or larger, use bolts (6).
Clearance: 2 ± 0.5 mm
Shim installing place P

1 209-46-42431 4
2 209-46-42440 12
3 209-46-42450 4
4 209-46-42460 8
5 01024-81235 8
6 01024-81240 8

M19 socket 1
Others
100
Assembly procedure
D-2 (For only 1st time)
Method II. When adjusting the shims without placing the counterweight on the revolving frame.
a If a crane is not available, adjust the shims for the counterweight according to the following procedure.
1) Measure distances A (LH) and A (RH) between the center of the counterweight mounting hole of the revolving
frame and outside end of the revolving frame top plate.

Others
101
Assembly procedure
D-2
2) Measure distances B (LH) and B (RH) between the center of the counterweight hole and end of plate (1).

Others
102
Assembly procedure
D-2
3) Decide the thickness of shims (2), (3) and (4) at the 4 places so that B (LH) – A (LH) and B (RH) – A (RH) will be
2 ± 0.5 mm respectively.
4) Install plate (1) and shims (2), (3) and (4) decided by step 3) above to the counterweight with bolts and washers
(5) (or (6)).
If the thickness of shims (2), (3) and (4) decided by step 3) is less than 5 mm, use bolts (5). If the former is 5 mm
or larger, use bolts (6).
Clearance: 2 ± 0.5 mm

Shim installing place P
1 209-46-42431 4
2 209-46-42440 12
3 209-46-42450 4
4 209-46-42460 8
5 01024-81235 8
6 01024-81240 8

M19 socket 1
Others
103
Assembly procedure
Greasing
D-3
• Before assembling the counterweight remover assembly, grease each pin.

Grease pump 1
Others
104
Assembly procedure
Installation of Counterweight Remover
D-4
1) Sling counterweight remover assembly (1) and install it to the machine.
2) Fix the counterweight remover assembly with mounting bolts (2) (6 pieces) and washers (3) (6 pieces).
Weight of counterweight remover assembly: 1,300 kg
3 Tightening torque for bolt

2,450 – 3,040 Nm
{250 – 310 kgm}

2 01011-83625 6
3 01643-33690 6

50 × 3,000 mm synthetic fiber sling 3 25 t crane 1
4:1 torque multiplier 1
85 kg torque wrench 1
T 25 × socket, 55 mm 1
width across flats
KW45F impact wrench 1
Others
105
Assembly procedure
Installation of Covers
D-5
• Install bracket (1), covers (2) and (3), and bolts and washers (4), (5) and (6).

1 209-46-42380 1
2 209-46-42421 1
3 209-46-42521 1
4 01024-81225 2
5 01024-81225 4
6 01024-81225 8

M19 socket 1
Others
106
Assembly procedure
Installation of Hoses (1/3)
D-6
1) Remove the oil plugs of the cylinder and those of the hoses and connect the hoses.
When connecting the hoses, take care of their colors.
2) Install clamps (1), cushions (2), and bolts and washers (3).
Clamp 209-62-42870 (hose)

at position of white tape.
White (Yellow)
Blue
Green
Yellow
White
Brown
Red
1 07094-10417 4
2 07095-00420 2
3 01024-81265 2
1. When removing each oil plug, loosen it Name Q’ty Name Q’ty
slowly to release the internal pressure Oil receiving pan (small) 1
and then remove it carefully.
2. When installing each hose, take extreme Spanner, 19 mm width across flats 2
care that the O-ring will not be caught.
Spanner, 22 mm width across flats 2
3. When installing each hose, take extreme
care that dirt will not enter the circuit. KW12P impact wrench 1
M19 socket 1
Others
107
Assembly procedure
D-6
3) Install clamps (1), cushions (2), and bolts and washers (3).
Red
Brown
Clamp 209-62-42870 (hose)


1 07094-10417 4
2 07095-00420 2
3 01024-81265 2

M19 socket 1
Others
108
Assembly procedure
D-6
4) Install clamps (1), (4) and (7), cushions (2), (5) and (8), and bolts and washers (3), (6) and (9).
Blue
Green
Clamp 209-62-42870 (hose)


1 07094-30417 2
Clamp 209-62-42870 (hose) 2 07095-00420 2
at position of white tape. 3 01024-81265 1
4 07094-30417 2
5 07095-00420 2
6 01024-81265 1
7 04434-52711 1
8 07095-00420 1
9 01024-81020 1

M19 socket 1
M17 socket 1
Others
109
Assembly procedure
Bleeding Air from Counterweight Remover Circuit
D-7
a After assembling the piping, bleed air from the counterweight remover circuit.
(1) Run the engine at low idle.
(2) Extend and retract each cylinder 4 – 5 times, stopping it at about 100 mm before each stroke end.
(3) While running the engine at low idle, extend each cylinder from 100 mm before each stroke end to the stroke end very
slowly (taking at least 10 seconds) and then keep the remover control lever at the stroke end for 4 minutes.
a At the first operation, the remover link does not move for more than 10 seconds since much air is in the circuit. Do
not move the lever to the stroke end, however.
a The air in the cylinder is bled by operations (1) to (3).
a If each cylinder is moved to the stroke end from the first operation, the air in the cylinder may damage the piston
packing, etc.

Others
110
Assembly procedure
Installation of Counterweight (1/2)
D-8
1) Set the pin holes of the link to those of the counterweight by operating the counterweight remover and then install
counterweight pins (1) and lock plates (2) with bolts (3), washers (4) and nuts (5).

1 21M-46-24360 2
2 21M-46-24570 2
3 01011-81250 2
4 01643-31232 4
5 01580-11210 4

Spanner, 19 mm width across flats 2
M19 socket 1
Others
111
Assembly procedure
Installation of Counterweight (2/2)
D-8
2) Place the counterweight on the revolving frame by operating the counterweight remover.
3) Install bolts (1) (6 pieces) and spacers (2) (6 pieces).

a If a large torque wrench is not available, tighten the bolts by the following angle tightening method.
(1) Tighten the bolts to 1,471 Nm {150 kgm} first.
(2) Tighten the bolts by 90 ± 5°.
Outside diameter: ø90 mm, 1.0 kg
L = 480 mm, 5.8 kg

Width across flats: 65 mm
3 Tightening torque
3,825 ± 392 Nm
{390 ± 40 kgm}

1 209-46-41550 6
2 209-46-11210 6
Install the counterweight so that the level Name Q’ty Name Q’ty
difference on the right side and left side will KW45FS impact wrench 1
be even.
Socket, 65 mm width across flats 1
420 kgm torque wrench 1
T 38 × socket, 1
65 mm width across flats
Others
112
Assembly procedure
Installation of Accessories
D-9
• After tightening counterweight mounting bolts, install cover (1), step (2), grips (3), bolts (4), washers (5), and bolts and
washers (6) and (7).

1 209-46-42411 1
Note)Install the 3 parts of (1), (2) and (3) at last since they can interfere 2 209-54-42191 1
with the counterweight remover when the latter is operated. 3 209-54-43610 2
4 01010-81225 2
5 175-54-34170 2
6 01024-81220 4
7 01024-81240 4

M19 socket 1
Others
113
Assembly procedure
Check of Operation
D-10
• After assembling the counterweight remover, check the following 3 items.
(1) The cylinders move as operated with the levers.
(2) No oil is leaking.
(3) No parts interfere with each other.

Others
114
M. PROCEDURE FOR INSPECTION AND MAINTENANCE
AFTER COMPLETION OF ASSEMBLY
115
Inspection and maintenance
procedure
Inspection of Oil Level in Hydraulic Tank and Refill (1/2)
M-1

Others
116
procedure
Inspection of Oil Level in Hydraulic Tank and Refill (2/2)
M-1

Others
117
procedure Replacement of Return Filter
M-2 (Standard Filter to Flushing Filter)

1 209-60-77551 2
2 21T-60-13730 2
Store the removed standard element (209- Name Q’ty Name Q’ty
60-77532) 2 pcs., strainer (206-60-31140)
2 pcs. and valve (20Y-60-31131) 2 pcs.
in order because they are used again after
flushing.
Others
118
procedure
Flushing of Hydraulic Circuit (1/2)
M-3
a Rotate the engine at the low idle (in the E

mode) with the lever in the neutral position for
15 minutes, and follow the procedures below.
Full operation may damage the filter element Name Q’ty Name Q’ty
since the relief valve of the filter is closed.
Do not relieve any circuits !

Others
119
procedure
Flushing of Hydraulic Circuit (2/2)
M-3
(4) Confirmation
After flushing, replace the standard element with
flushing element referring to step M-4.
While doing above, check the collected dusts in
the flushing element if they are not unusual.
If uncertain, contact your distributor.

Others
120
M-4 (Flushing Filter to Standard Filter) (1/2)

Others
121
M-4 (Flushing Filter to Standard Filter) (2/2)
a After completion of flushing, check the flushing Name Q’ty Name Q’ty
element referring to the caution in M-3, and
discard it.
a Store the strainer, valve and replaced plate

because they can be used again..
Others
122
procedure
Error Code (1/2)
M-5
Turn the starting switch ON, operate on the multi-monitor panel in the following procedure, and make sure that no error codes
have been generated.
123
procedure
Error Code (2/2)
M-5
124
After completion of assembling a machine, make inspections according to these check sheets for assuring machine performance.
After checking, send these check sheets to the Osaka plant.
2/13
EO10W30-DH
See operation EO15W40-DH
and maintenance
Coupling manual for details. TO10
case oil TO30
TO30
TO30
TO30
TO10
3/13
4/13
5/13
Category
Revision
Local After
Check item assembly hours of Judgement standard
time operation
10. Cigarette lighter

11. Machine monitor
Check of switches, control levers
12. Horn switch

13. RH work equipment control lever
14. Starting switch
1. Car radio 15. Fuel control dial
2. Lower wiper switch (fixed front window cab specs, if equipped) 16. Lamp switch
3. Revolving warning lamp switch (if equipped) 17. Swing lock switch
4. Large capacity air conditioner blower switch (if equipped) 18. Machine push-up switch
5. Air conditioner control switch 19. Boom shockless control switch
6. Lock lever 20. Swing holding brake release switch
7. LH work equipment control lever 21. Emergency pump drive switch
8. Travel pedal 22. Step light switch
9. Travel lever 23. Room lamp switch
Operation of horn switch Press the switch on the right footrest to

sound the horn. At the same time, the flash-
ing light (if equipped) at the bottom front of
the cab will flash for approx. 5 seconds.
Operation of lock lever Push down the lever to apply the lock.
Engine can be started but all work
equipment control levers do not move
Push up the lever to release the lock.
Engine cannot be started but all work
equipment levers move.
Operation of fuel control dial MAX: Full speed

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

so that the monitor display shows "pre-
heating ON". The preheating pilot will
flash after approx. 30 seconds to indicate
the completion of preheating.
6/13
Category
Revision
Local After
time operation
Operation of working mode selector switch P lights up: Heavy-duty operations

E lights up: Fuel-efficient operations
Monitor display changes in synchronous with the

switch operation.
Engine switches to or from the full operation
Operation of auto-deceleration switch ON lights up: Auto-deceleration is actuated.

OFF: Auto-deceleration is cancelled.
Each time the switch is pressed, the monitor dis-

play changes so that ON or OFF state can be
selected.
Operation of travel speed switch Lo lights up: Low speed travel

High lights up: High speed travel

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

selected.
Operation of swing priority mode switch ON lights up:

Able to swing 180° while loading
OFF:
Normal work (able to swing 90° while loading)

selected.
Operation of wiper switch ON: lights up: Wiper moves continuously

INT: lights up: Wiper moves intermittently
OFF: Wiper stops
Each time the switch is pressed, the monitor

display changes so that any state can be
selected.
Operation of window washer switch Window washer fluid is sprayed out to the front
glass (in combination with wiper) when the switch
is pressed continuously.
Operation of cigarette lighter This is used to light cigarettes. To use, push the
lighter in. After a few seconds it will spring back,
and glow.
Operation of lamp switch This switch is used to turn on the front lamps,
working lamps, additional lamp at the top front of
the cab, and monitor lighting.
Operation of swing lock switch ON position (actuated):

The swing lock is always applied, and the
upper structure will not swing even if the swing
is operated. In this condition, the swing lock
monitor lights up.
OFF position (cancelled):
Swing operation is possible. In this condition,
the swing lock monitor goes off.
Operation of machine push-up switch Low pressure setting:

The boom thrust force is weak.
High pressure setting:
The boom thrust force becomes more powerful.
Operation of boom shockless control switch (if equipped) ON: While the boom stop operation, shock of
the work equipment is controlled.
Operation of step light switch (if equipped) • When the switch is pressed, the step light will
light up for approx. 60 seconds.
• Even if the starting switch key is at the OFF
position, the step light will light up for approx.
60 seconds when the switch is pressed.
7/13
Category
Revision
Local After
time operation
Operation of room lamp switch ON position: Room lamp lights up

OFF position: Room lamp lights off
Even if the starting switch key is at the OFF posi-

tion, the room lamp will light up when the switch is
pressed.
Operation of emergency pump drive switch When normal: Switch is pushed down:
When the monitor display shows E02 (TVC valve system error), When switch is pushed up, alarm buzzer sounds.
move the switch "up" to make it possible to carry out work
Operation of swing holding brake release switch When normal: Switch is pushed down
When the monitor display shows E03 (Swing brake system error), When switch is pushed up, alarm buzzer sounds,
move the switch "up" to cancel the brake, and it becomes possible to and swing lock symbol flashes
actuate the swing. However, the swing brake remains released.
Operation of alarm buzzer stop switch This is used to stop alarm buzzer if it sounds to
warn of an abnormality of warning item during
engine operation.
Operation of lower wiper switch (if equipped) ON: Lower wiper moves.
OFF: Lower wiper stops.
Operation of travel levers FORWARD: The lever is pushed forward.

(The pedal is angled forward)
REVERSE: The lever is pulled back.
(The pedal is angled back)
N (Neutral): The machine stops
Operation of LH work equipment control lever This lever is used to operate the arm and upper
(with auto-deceleration device) structure.
Arm operation Swing operation
(a) Arm OUT (c) Swing to right
(b) Arm IN (d) Swing to left
N (Neutral): When the lever in this position, the

upper structure and the arm will be
retained in the position in which they
stop.
Operation of RH work equipment control lever This lever is used to operate the boom and bucket.
(with auto-deceleration device) Boom operation Bucket operation
(a) RAISE (c) DUMP
(b) LOWER (d) CURL

stop.
Confirmation of failure history (Both electrical and mechanical) Delete the failure history after confirming that no
abnormality sign is displayed. Confirm that no fail-
ure history is provided after completion of the test.
8/13
6.8 +0.6
- 0.2 rpm
53.6 ± 5.4 sec / 5 turns

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

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

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

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

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

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

[01100] for F pump and [01101] for R pump
F pump At engine high idle,

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

set pressure (increase) 320 boom raise, P mode
Control valve main 31.4 and Heavy lift ON,
R pump relief
set pressure (increase) 320
27.9 At engine high idle,
285 swing and P mode, relief
Self pressure reducing 3.33 +0.49
0
+5
34.0 0
valve output pressure (At engine high idle, neutral)
4. Current value measurement Confirmed on the monitoring mode

Run one side idle

(Idling side)
Pump EPC current value At neutral

mA mA
F pump 250 ± 20 mA
Engine
Run one side idle high idle
Pump EPC current value (Idling side)
mA mA
R pump 540 ± 120 mA
Note: Measure the following J/S differential pressure only if the

pump EPC current does not pass the test.
Run one side idle

(Idling side)
J/S differential pressure sensor voltage At neutral

F pump V V
Min.2.5 V
Engine
Run one side idle high idle
J/S differential pressure sensor voltage (Idling side)
R pump V V
Min. 1.3 V
13/13
Loading Shovel 1/13
After completion of assembling a machine, make inspections according to these check sheets for assuring machine performance.
After checking, send these check sheets to the Osaka plant.
2/13
EO10W30-DH
See operation EO15W40-DH
and maintenance
Coupling manual for details. TO10
case oil TO30
TO30
TO30
TO30
TO10
3/13
4/13
5/13
Category
Revision
Local After
time operation
10. Cigarette lighter

11. Machine monitor

12. Horn switch
1. Car radio 13. RH work equipment control lever
2. Lower wiper switch (fixed front window cab specs, if equipped) 14. Starting switch
3. Revolving warning lamp switch (if equipped) 15. Fuel control dial
4. Large capacity air conditioner blower switch (if equipped) 16. Lamp switch
5. Air conditioner control switch 17. Swing lock switch
6. Lock lever 18. Machine push-up switch
7. LH work equipment control lever 19. Boom shockless control switch
8. Travel pedal 20. Swing holding brake release switch
9. Travel lever 21. Emergency pump drive switch
22. Step light switch
23. Room lamp switch
24. Bottom dump switch
Operation of horn switch Press the switch on the right footrest to

sound the horn. At the same time, the flash-
ing light (if equipped) at the bottom front of
the cab will flash for approx. 5 seconds.
Operation of lock lever Push down the lever to apply the lock.
Engine can be started but all work
equipment control levers do not move
Push up the lever to release the lock.
Engine cannot be started but all work
equipment levers move.
Operation of fuel control dial MAX: Full speed

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

so that the monitor display shows "pre-
heating ON". The preheating pilot will
flash after approx. 30 seconds to indicate
the completion of preheating.
6/13
Category
Revision
Local After
time operation
Operation of working mode selector switch P lights up: Heavy-duty operations

E lights up: Fuel-efficient operations

switch operation.
Engine switches to or from the full operation
Operation of auto-deceleration switch ON lights up: Auto-deceleration is actuated.

OFF: Auto-deceleration is cancelled.

selected.
Operation of travel speed switch Lo lights up: Low speed travel

High lights up: High speed travel

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

selected.
Operation of swing priority mode switch ON lights up:

Able to swing 180° while loading
OFF:
Normal work (able to swing 90° while loading)

selected.
Operation of wiper switch ON: lights up: Wiper moves continuously

INT: lights up: Wiper moves intermittently
OFF: Wiper stops
Each time the switch is pressed, the monitor

display changes so that any state can be
selected.
Operation of window washer switch Window washer fluid is sprayed out to the front
glass (in combination with wiper) when the switch
is pressed continuously.
Operation of cigarette lighter This is used to light cigarettes. To use, push the
lighter in. After a few seconds it will spring back,
and glow.
Operation of lamp switch This switch is used to turn on the front lamps,
working lamps, additional lamp at the top front of
the cab, and monitor lighting.
Operation of swing lock switch ON position (actuated):

The swing lock is always applied, and the
upper structure will not swing even if the swing
is operated. In this condition, the swing lock
monitor lights up.
OFF position (cancelled):
Swing operation is possible. In this condition,
the swing lock monitor goes off.
Operation of machine push-up switch Low pressure setting:

The boom thrust force is weak.
High pressure setting:
The boom thrust force becomes more powerful.
Operation of boom shockless control switch (if equipped) ON: While the boom stop operation, shock of
the work equipment is controlled.
Operation of step light switch (if equipped) • When the switch is pressed, the step light will
light up for approx. 60 seconds.
• Even if the starting switch key is at the OFF
position, the step light will light up for approx.
60 seconds when the switch is pressed.
7/13
Category
Revision
Local After
time operation
Operation of room lamp switch ON position: Room lamp lights up

OFF position: Room lamp lights off
Even if the starting switch key is at the OFF posi-

tion, the room lamp will light up when the switch is
pressed.
Operation of emergency pump drive switch When normal: Switch is pushed down:
When the monitor display shows E02 (TVC valve system error), When switch is pushed up, alarm buzzer sounds.
move the switch "up" to make it possible to carry out work
Operation of swing holding brake release switch When normal: Switch is pushed down
When the monitor display shows E03 (Swing brake system error), When switch is pushed up, alarm buzzer sounds,
move the switch "up" to cancel the brake, and it becomes possible to and swing lock symbol flashes
actuate the swing. However, the swing brake remains released.
Operation of alarm buzzer stop switch This is used to stop alarm buzzer if it sounds to
warn of an abnormality of warning item during
engine operation.
Operation of lower wiper switch (if equipped) ON: Lower wiper moves.
OFF: Lower wiper stops.
Operation of travel levers FORWARD: The lever is pushed forward.

(The pedal is angled forward)
REVERSE: The lever is pulled back.
(The pedal is angled back)
N (Neutral): The machine stops
Operation of LH work equipment control lever This lever is used to operate the arm and upper
(with auto-deceleration device) structure.

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

stop.
Operation of RH work equipment control lever This lever is used to operate the boom and bucket.
(with auto-deceleration device) Boom operation Bucket operation
(a) RAISE (c) DUMP
(b) LOWER (d) CURL

stop.
Confirmation of failure history (Both electrical and mechanical) Delete the failure history after confirming that no
abnormality sign is displayed. Confirm that no fail-
ure history is provided after completion of the test.
The operation of bottom dump switch Right: Bottom opened

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

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

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

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


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

set pressure (increase) 320 boom raise, P mode
Control valve main 31.4 and Heavy lift ON,
R pump relief
set pressure (increase) 320
27.9 At engine high idle,
285 swing and P mode, relief
Self pressure reducing 3.33+0.49

0 34.0 0
+5
valve output pressure (At engine high idle, neutral)

4. Current value measurement Confirmed on the monitoring mode
Run one side idle

(Idling side)
Pump EPC current value At neutral
mA mA
F pump 275 ± 80 mA
Engine high idle
Pump EPC current value Run one side idle
mA mA (Idling side)
R pump 584 ± 80 mA
Note: Measure the following J/S differential pressure only if the
pump EPC current does not pass the test.
Run one side idle

(Idling side)
J/S differential pressure sensor voltage At neutral

V V Min.2.5 V
F pump
Engine high idle
Run one side idle
J/S differential pressure sensor voltage (Idling side)
V V
R pump Min. 1.3 V
13/13
Measure the travel of the lever at the

center of the lever tip

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What are the main components and procedures described in the assembly instructions?

What are the main components and procedures described in the assembly instructions?

What safety precautions should be followed when assembling the excavator?

What safety precautions should be followed when assembling the excavator?

GEN00048-05

Field Assembly Instruction

A. Assembly of Chassis ...................................................................................................... 19

B. Assembling of Work Equipment of Backhoe .................................................................. 53

D. Assembling of Counterweight Remover ...................................................................... 97

M. Procedure for Inspection and Maintenance after Completion of Assembly................. 115

Field Assembly Inspection Report (Backhoe)

Field Assembly Inspection Report (Loading Shovel)

Machine model PC800-8 PC800LC-8 PC800SE-8 PC850-8 PC850SE-8

3. Preparation and check of protective gear, slings and tools

4. k Check during actual work

Backhoe · Inspection of oil level and

Min. 0.7 MPa

Min. 1.5 m3/min

Completion of body · Completion of general

Counterweight 45t crane

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

• Upper structure with head guard

Model PC800, 800SE PC800LC-8

Weight (kg) 21,600 23,600

A (mm) 8,505 7,405 8,345 7,405

B (mm) 2,705 2,560 2,695 2,560

C (mm) 4,387 4,104 4,295 4,104

D (mm) 1,218 1,098 1,210 1,098

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

B (mm) 1,324 1,696 1,410 1,696

C (mm) 2,459 2,237 2,478 2,237

D (mm) 577 709 648 709

Model PC800-8 PC800SE-8 PC850-8 PC850SE-8

A (mm) 2,365 2,200 2,390 2,200

B (mm) 1,850 1,950 1,880 1,950

C (mm) 1,052 889 1,118 889

D (mm) 646 714 599 714

(5) Arm cylinder

A (mm) 3,500 2,590

B (mm) 1,885 1,391

PC800-8 PC850-8 PC800LC-8

A (mm) 451 451 451

B (mm) 1,689 1,689 1,689

C (mm) 684 684 684

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

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

(6) Travel motor cover (for all models)

No. Tool names Specifications Q’ty. Remarks

42 Repair paint Natural yellow 5

Part No. of bolt TTTTT-TTTTT

2. The bolt length is dimension c in Fig. 1.

a : Bolt thread diameter (Nominal diameter)

Nominal size of thread Width across flats Tightening torque

6×1 10 11.8 – 14.7 {1.2 – 1.5}

8 × 1.25 13 27 – 34 {2.8 – 3.5}

12 × 1.75 19 98 – 123 {10 – 12.5}

14 × 2 22 153 – 190 {15.5 – 19.5}

16 × 2 24 235 – 285 {23.5 – 29.5}

18 × 2.5 27 320 – 400 {33 – 41}