Hydraulic Excavator Field Assembly Manual

GEN00104-01
HYDRAULIC PC800 -8R1 PC800LC -8R1

EXCAVATOR PC800SE -8R1
PC850 -8R1 PC850SE -8R1
SERIAL NUMBERS 70001 and up
When the work equipment is installed, the engine must be operated.
Accordingly, before installing the work equipment, inspect and maintain the machine thoroughly.
Note that this manual does not describe the whole specification of the machine but describes only the basic
specification.
If you have any question when dividing and transporting the machine by yourself in future, ask one of our
distributors.
CONTENTS
Specifications...................................................................................................................... 1
Precautions for Field Assembly .......................................................................................... 2
Disposal of Removed Parts ................................................................................................ 3
Assembling Procedures, Applicable Equipment and Schedule .......................................... 4
Kit Layout Diagram ............................................................................................................. 5
Transportation..................................................................................................................... 6
List of Tools for Field Assembling....................................................................................... 11
Tightening Torque............................................................................................................... 13
Coating Materials List ......................................................................................................... 17
Selection of Wire Ropes Used for Assembly ...................................................................... 20
A. Assembly of Chassis ...................................................................................................... 21

A- 1. Installation of Left and Right Track Frames ........................................................... 22
A- 2. Installation of Travel Pipe ...................................................................................... 26
A- 3. Installation of Top Guard ....................................................................................... 29
A- 4. Installation of Radiator Cover ................................................................................ 30
A- 5. Installation of Rearview Mirror ............................................................................... 31
A- 6. Installation of Left Side Step .................................................................................. 35
A- 7. Installation of Handrail ........................................................................................... 36
A- 8. Installation of Handrail ........................................................................................... 37
A- 9. Installation of Muffler Tail Tube.............................................................................. 39
A-10. Sticking Sheet to Counterweight ........................................................................... 40
A-11. Installation of Counterweight ................................................................................. 41
A-12. Installation of KOMTRAX Antenna (if equipped) ................................................... 42
A-13. Installation of Step Light ........................................................................................ 43
A-14. Air Bleeding of Travel Motor .................................................................................. 45
A-15. Installation of Travel Piping Cover......................................................................... 46
A-16. Testing Track Shoe Tension.................................................................................. 50
A-17. Check Fuel, Coolant and Oil Levels ...................................................................... 53
A-18. Parts to be Touched up after Field Assembly........................................................ 55
B. Assembling of Work Equipment of Backhoe .................................................................. 57

B- 1. Assembly of Arm Cylinder ..................................................................................... 58
B- 2. Connection of Arm Cylinder Hoses........................................................................ 60
B- 3. Installation of Boom Cylinder Foot......................................................................... 63
B- 4. Relieving Remaining Pressure from Hydraulic Circuit ........................................... 64
B- 5. Installation of Boom Cylinder Hoses...................................................................... 65
B- 6. Installation of Boom Foot Dust Seal ...................................................................... 66
B- 7. Assembly of Boom Assembly ................................................................................ 67
B- 8. Hose Connection of Arm and Bucket Circuits........................................................ 68
B- 9. Installation of Quick Return Hose .......................................................................... 69
B-10. Installation of Boom Cylinder................................................................................. 70
B-11. Installation of Arm Assembly ................................................................................. 71
B-12. Installation of Hose between Boom and Bucket Cylinder...................................... 73
B-13. Installation of Bucket Assembly............................................................................. 74
B-14. Lubrication Piping to Work Equipment .................................................................. 75
B-15. Wiring of Work Equipment..................................................................................... 76
B-16. Greasing after Assembling Work Equipment......................................................... 77
B-17. Air Bleeding from Hydraulic Cylinder..................................................................... 78
C. Assembling of Work Equipment of Loading Shovel........................................................ 79
C- 1. Releasing residual pressure in hydraulic circuit ..................................................... 80
C- 2. Pulling out boom foot pin and boom cylinder foot pin ............................................ 81
C- 3. Installation of boom and arm assembly.................................................................. 82
C- 4. Installation of piping between chassis and boom................................................... 83
C- 5. Installation of flushing piping for boom cylinder and arm cylinder.......................... 84
C- 6. Installation of flushing piping for bucket cylinder.................................................... 85
C- 7. Installation of flushing piping for bottom dump cylinder ......................................... 86
C- 8. Installation of boom cylinder................................................................................... 88
C- 9. Installation of boom cylinder foot............................................................................ 89
C-10. Installation of boom cylinder hoses........................................................................ 90
C-11. Installation of boom cylinder rod pin ...................................................................... 91
C-12. Installation of arm cylinder hoses........................................................................... 92
C-13. Installation of bucket cylinder................................................................................. 93
C-14. Installation of bucket cylinder hose ........................................................................ 94
C-15. Installation of connecting hoses between chassis and boom top .......................... 95
C-16. Installation of bottom dump cylinder hoses............................................................ 96
C-17. Installation of bucket assembly .............................................................................. 97
C-18. Installation of working lamps.................................................................................. 99
C-19. Installation of work equipment grease piping......................................................... 100
C-20. Greasing after assembling of work equipment....................................................... 101
C-21. Bleeding air from work equipment circuit ............................................................... 102
M. Procedure for Inspection and Maintenance after Completion of Assembly.................... 103

M- 1. Inspection of Oil Level in Hydraulic Tank and Refill............................................... 104
M- 2. Replacement of Return Filter (Standard Filter to Flushing Filter) .......................... 106
M- 3. Flushing of Hydraulic Circuit .................................................................................. 107
M- 4. Replacement of Return Filter (Flushing Filter to Standard Filter) .......................... 109
M- 5. Failure Code .......................................................................................................... 111
Field Assembly Inspection Report (Backhoe)
Field Assembly Inspection Report (Loading Shovel)

SPECIFICATIONS
Machine model PC800-8 PC800LC-8 PC800SE-8C850-8C850SE-8

Weight of machine kg 74,500 77,500 75,500 79,000 78,600
Bucket capacity m3 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
a The figures in ( ) show the value when the track width is retracted.
a The figures in < > show the value when the long-track is used.
PC850-8
a The figures in ( ) show the value when the track width is retracted.
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
(5) Counterweight tension
(1) Left track frame (4) Upper structure
(6) Platform group · Performance test
(2) Right track frame
(3) Axle assembly
· Inspection of oil (7) Assembling of work
ASSEMBLING PROCEDURES,
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 ASSEMBLY.
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
These machines can be divided into four kits for transportation. Please ask us or our service shop for
transportation.
t 4-kit Transportation
Upper structure without head guard
Unit: mm
Equipped Not equipped
with cab with cab
Overall height H: 2,845
(mm)
Overall width 3,225 *3,195

(mm)
Weight (kg) 26,300

* Revolving frame
Upper structure with head guard
Unit: mm
Equipped Not equipped
with cab with cab
Overall height H: 2,845
(mm)
Overall width 3,225 *3,195

(mm)
Weight (kg) 26,360

* Revolving frame
Fix the upper structure on the truck by means of chain block.
6
Undercarriage
Unit: mm
Model PC800, PC850, PC800LC-8
PC800SE-8 PC850SE-8
Quantity 2
Weight 20,800 21,400 23,800

(kg) (10,400 × 2) (10,700 × 2) (11,900 × 2)
( ): PC800LC-8
Work equipment
(1) Boom
PC800-8
Model PC800LC-8 PC800SE-8
PC850-8C850SE-8
A (mm) 8,530 7,430 8,370 7,430
B (mm) 2,615 2,480 2,695 2,480
C (mm) 4,387 4,104 4,295 4,104
D (mm) 1,218 1,098 1,210 1,098

Overall
width (mm) 1,500 1,500 1,500 1,500
Weight
7,900 7,300 8,100 7,300
(kg)
(2) Arm
PC800-8
Model PC800LC-8 PC800SE-8
PC850-8C850SE-8
A (mm) 5,115 4,075 4,765 4,075
B (mm) 1,365 1,690 1,450 1,690
C (mm) 2,459 2,237 2,478 2,237
D (mm) 577 709 648 709

Overall
width (mm) 710 715 710 715
Weight
4,000 4,900 4,500 4,900
(kg)
7
(3) Bucket
PC800-8
Model PC800LC-8
PC800SE-8 PC850-8C850SE-8
A (mm) 2,430 2,280 2,470 2,280
B (mm) 1,855 1,950 1,880 1,950
C (mm) 1,052 889 1,118 889
D (mm) 646 714 599 714

Overall
width (mm) 1,875 2,100 2,070 2,250
Weight
2,900 3,400 3,800 3,800
(kg)
(4) Boom cylinder (for all models)
Unit: mm
Weight: 1,500 kg
(750 kg × 2 pcs)
(5) Arm cylinder
PC800SE-8
Model PC800-8 PC850-8
PC800LC-8 PC850SE-8
Quantity 1 2
A (mm) 3,580 2,595
B (mm) 1,885 1,391
Weight (kg) 830 960 (480 × 2)
8
(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
(kg) 9,800 11,850 (13,600)
(2) Top guard (PC850-8, PC850SE-8 only)
Unit: mm
Weight: 55 kg
(3) Catwalk (1) (for all models)
Unit: mm
Weight: 50 kg
9
(4) Catwalk (2) (for all models)
Unit: mm
Weight: 30 kg
(5) Radiator duct (for all models)
Unit: mm
Weight: 80 kg
(6) Travel motor cover (for all models)
Unit: mm
Weight: 130 kg × 2
10
LIST OF TOOLS FOR FIELD ASSEMBLING
No. Tool names Specifications Qty Remarks

1 Air compressor Min. 0.7 MPa, 15 m3/min 1
Equipment
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
Air impact wrench Tightening capacity (Nm) Socket mounting dimension (mm)
(Note 1) Qty (Note 2)
5 Up to 1,960 Nm {200 kgm} 1 T12.7 mm
6 Up to 5,880 Nm {600 kgm} 1 T19.0 mm
7 Up to 63,740 Nm {6,500 kgm} 1 T38.1 mm or spline type (Note 3)
Socket for air impact Socket mounting dimension (mm)
wrench Width across flats Qty (Note 2)
or
8 Socket for torque wrench 17, 19, 22 mm 1 each T12.7 mm
65 mm is for counterweight.
9 24 mm 1 T19.0 mm a Match the socket
10 36 mm 1 T25.4 mm mounting dimensions to
the impact wrench.
11 65 mm 1 T38.1 mm
12 Air hose 50 m 1 For impact wrench
13 16-time wrench 4413 Nm {450 kgm} 1 For counterweight
14 Socket for 16-time T38.1 × 65 mm 1 For counterweight
wrench
15 T38.1 × 55 mm 1 For track frame
16 T38.1 × 50 mm 1 For track frame
17 4-time wrench Output: 25.4, Input: 19.0 1
18 Socket for 4-time wrench T25.4 × 50 mm 1
Tool
19 T25.4 × 55 mm 1
20 Torque wrench 412 Nm {42 kgm} T25.4 mm 1 For 16-time wrench
21 834 Nm {85 kgm} T25.4 mm 1 For 4-time wrench
22 4118 Nm {420 kgm} T38.1 mm 1 For counterweight and track frame
23 Wrench 19 mm 1
24 Extension For impact L150 mm 1
25 Spanner Width across flats 10M 2
26 Width across flats 22M 2
29 Sledge hammer 10 P 1
30 Bar 1m 2
31 Hydraulic jack 490 kN {50 ton} (stroke 170) 2 Revolving frame pedestal
When tightening track frame connecting
32 196 kN {20 ton} 1 bolts.
When connecting travel and work
33 Waste oil pan Large, small 2 each equipment piping
34 Wooden block 300 × 400 mm 4 Revolving frame pedestal

35 Wire rope sling ø10 × 3,000 mm 2 For catwalk
36 ø20 × 5,000 mm 2 For boom, arm and bucket
Lifting tool
37 ø32 × 5,000 mm 4 For revolving frame

38 ø30 × 5,000 mm 2 For counterweight and track frame
39 Shackle SD30 3
40 SC18 4
11
No. Tool names Specifications Qty Remarks
41 Synthetic fiber sling 50 mm wide × 3,000 mm 2 For boom cylinder and arm cylinder
Lifting tool
42 Pin ø50 × 500 mm 2 Track frame

43 Lever block 14.7 29.4 kN {1.5 3 ton} 2
44 Eyebolt M16 1
45 M12 2
46 Detergent liquid Brake cleaner 10
Oil and grease
47 Hydraulic oil EO-10 300 l

48 Grease G2-LI 20 kg
49 Repair paint Natural yellow 5 Work equipment lubrication
50 Black gray 5
51 Waste cloth Bundle 20 kg For cleaning
a General assembling tools (box wrench, screw driver, pliers, etc.) are not described in this list. If necessary, prepare them
separately.
Note 1) Prepare an impact wrench according to the tightening capacity.
Note 2) The socket mounting dimensions are shown for reference. Match a wrench to the socket which is prepared separately.
Note 3) As for a spline type, prepare a socket with spline type too (one piece of 65 width across flats).
12
TIGHTENING TORQUE
Tightening torque
1. Tightening torque for bolts
1. Tightening torque for
Tightening torque forbolts
bolts is indicated in the text as shown below. Tighten each bolt to the specified
torque.
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
Part No.
No. ofof bolt
washer TTTTT-TTTTT
EEEEE-EEEEE
EEEEE -EEEEE
Part
BoltNo. of washer
specification EEEEE-EEEEE
Thread sizediameter
Thread (Diameter, pitch,
× Bolt length)
length
Bolt
Toolspecification
(Socket) Thread diameter
Applicable × Boltsize
socket length
Tool (Socket)
Tightening torque Applicable socketkgm}
Nm {QQQ size
Tightening torque Nm {QQQ kgm}
If tightening torque for a bolt is not specified in the text, tighten it according to Table 1.
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
Remarks
mm is
1. The expressed
thread as M20.
diameter is the nominal diameter. For example, 16 mm is expressed as M16 and 26
The pitch in Table
mm is expressed as 1 is the distance that the bolt advances every turn in the axial direction (Unit:
M20.
mm).
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.
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
3. The to dimension
applicable socket bsize
in Fig. 1, an applicable
is expressed socket
as 24 mm, 30 can
mm,be selected
etc. Since from Table
24 mm, 30 1,
mm,too.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
4. Tightening QQQ ± RR
of expressed
torque is as QQQ – www or QQQ ± RR. If the target tightening torque
is applied.
is set, expression of QQQ ± RR is applied.
Fig. 1
Fig. 1
a : Bolt thread diameter (Nominal diameter)

ba :: Width across
Bolt thread flats of bolt
diameter head diameter)
(Nominal
cb :: Bolt length
Width across flats of bolt head
dc :: Threaded
Bolt lengthpart of bolt
d : Threaded part of bolt
13
Table 1 Tightening torque for bolts not specified in text
Tightening torque
Nominal size of thread Width across flats Unit: Nm {kgm}
× pitch (= Socket size)
a (mm) b (mm) Target Tolerance
12 8.8 14.7
M6 × 1 10 {1.2} {0.9 1.5}
M8 × 1.25 13 25 14.7 34
{2.5} {1.5 3.5}
54 34 74
M10 × 1.5 17 {5.5} {3.5 7.5}
89 54 123
M12 × 1.75 19 {9} {5.5 12.5}
M14 × 2 22 137 84 196
{14} {8.5 20}
230 147 309
M16 × 2 24 {23.5} {15 31.5}
315 201 427
M18 × 2.5 27 {32} {20.5 43.5}
M20 × 2.5 30 460 319 608
{47} {32.5 62}
650 471 829
M22 × 2.5 32 {66.5} {48 84.5}
810 588 1,030
M24 × 3 36 {82.5} {60 105}
M27 × 3 41 1,180 883 1,470
{120} {90 150}
1,520 1,130 1,910
M30 × 3 46 {155} {115 195}
1,960 1,470 2,450
M33 × 3 50 {200} {150 250}
M36 × 3 55 2,450 1,860 3,040
{250} {190 310}
2,940 2,260 3,630
M39 × 3 60 {300} {230 370}
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}
3/8 16.7 26.5 13.7 21.6 9.8 16.7
{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}
1 86.2 173.5 72.5 146.0 54.9 111.7
{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}
1/4 19.6 44.1 16.7 37.2 12.7 28.4
{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}
3/4 170.5 316.5 141.1 247.0 105.8 186.2
{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. If tightening torque is specified specially in explanation, however, apply that
tightening torque.
Table 4
Outside diameter Width across flats Tightening torque (Nm {kgm})
of hose (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 LIST
(Rev. 2009.08)
a The recommended coating materials such as adhesives, liquid gaskets, and greases used for disassembly and
assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Cate- Komatsu
Part No. Capacity Container Main features and applications
gory code
q Use to prevent rubber gaskets, rubber cushions,

LT-1A 790-129-9030 150 g Tube
and cork plugs from coming out.
q Use for plastic (except polyethylene, polypropylene,

20 g Polyethylene tetrafluoroethylene and vinyl chloride), rubber, met-
LT-1B 790-129-9050
(2 pcs.) container al, and non-metal parts which require immediate
and strong adhesion.
Polyethylene q Features: Resistance to heat and chemicals.

LT-2 790-129-9040 50 g
container q Use to fix and seal bolts and plugs.
790-129-9060 Adhesive:
(Set of adhe- 1 kg
LT-3 Can q Use to bond and seal metal, glass and plastics.
sive and hard- Hardener:
ener) 500 g
Adhesive
Polyethylene
LT-4 790-129-9040 250 g q Use to seal plugs for blank holes
container
Holtz
790-129-9120 75 g Tube q Heat-resistant seal used to repair engines.
MH 705
q Instantaneous adhesive.
ThreeBond Polyethylene q Curing time: From 5 sec. to 3 min.
790-129-9140 50 g
1735 container q Use mainly to bond metals, rubbers, plastics, and
woods.
q Instantaneous adhesive.
Aron-alpha Polyethylene q Quick-curing type (max. strength is obtained after
790-129-9130 2g
201 container 30 minutes)
q Use mainly to bond rubbers, plastics, and metals.
q Features: Resistance to heat and chemicals.
Loctite Polyethylene
79A-129-9110 50 cc q Use for fitted portions subjected to high tempera-
648-50 container
ture.
q Use to seal various threaded portions, pipe joints,
Polyethylene and flanges.
LG-5 790-129-9080 1 kg
container q Use to seal taper plugs, elbows, and nipples for hy-
draulic piping.
q Features: Silicon-based heat and cold-resistant
sealant.
LG-6 790-129-9160 200 g Tube
q Use to seal flange surfaces and threaded portions.
Liquid gasket
q Use to seal oil pan, final drive case, etc.

q Features: Silicon-based quick-curing sealant.
LG-7 790-129-9170 1 kg Tube q Use to seal flywheel housing, intake manifold, oil
pan, thermostat housing, etc.
LG-8 q Features: Silicon-based, heat and cold-resistant, vi-
ThreeBond 419-15-18131 100 g Tube bration-resistant, impact-resistant sealant.
1207B q Use to seal transfer case, etc.
q Use for rough surfaces such as the circle gear top
LG-9
seal which is not clamped by bolts, gaps in the weld
ThreeBond 790-129-9310 200 g Tube
which must be caulked, etc.
1206D
q Can be coated with paint.
17
Cate- Komatsu
gory code
LG-10 q Use as lubricant/sealant when installing the radiator
ThreeBond 790-129-9320 200 g Tube hoses to the water tubes.
Liquid gasket
1206E q Can be coated with paint.

LG-11 q Feature: Can be used together with solid gaskets.
ThreeBond 790-129-9330 200 g Tube q Use for covers of the transmission case and steer-
1121 ing case etc.
ThreeBond
790-129-9090 100 g Tube q Liquid gasket used to repair engine.
1211
q Use to prevent galling and seizure of press-fitted
Molybdenum disulfide
portions, shrinkage-fitted portions, and threaded

LM-P 09940-00040 200 g Tube
portions.
lubricant
q Use to lubricate linkages, bearings, etc.

q Spray type
q Thin molybdenum disulphide films are made on
09995-00250 190 g Can metal surfaces to prevent the metals from galling.
q Use for the drive shaft splines, needle bearings,
various link pins, bolts, etc.
prevention compound
q Feature: Seizure and galling prevention compound

Seizure
LC-G with metallic super-fine-grain, etc.

NEVER- Can q Use for the mounting bolt in the high temperature
SEEZ area of the exhaust manifold and the turbocharger,
etc.
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI
SYG2-160LI
G0-LI (*) q Feature: Lithium grease with extreme pressure lu-
SYGA-160CNLI Various Various
*: For cold brication performance, general purpose type.
SYG0-400LI-A
district
(*)
SYG0-160CNLI
(*)
q Use for parts under heavy load.
Molybde- Caution:
num disul- SYG2-400M 400 g × 10 Bellows-type q Do not use this grease for rolling bearings like
fide grease SYG2-400M-A 400 g × 20 container swing circle bearings, etc. and spline.
LM-G SYGA-16CNM 16 kg Can q Use this grease for work equipment pins only
(G2-M) when installing them, but do not use it after-
ward.
Grease
SYG2-400T-A
Hyper White
SYG0-400T-A
G2-T, Bellows-type q Seizure resistance, heat resistance and water re-
(*) 400 g
G0-T (*) container sistance higher than molybdenum disulfide grease.
SYG2-16CNT
*: For cold 16 kg Can q Not conspicuous on machine since color is white.
SYG0-16CNT
district
(*)
Biogrease
G2-B SYG2-400B
G2-BT (*) SYG2-400BT
Bellows-type q Since this grease is biodegradable in short period,
*: For use at (*) 400 g
container it has less impact on microorganisms, animals, and
high temper- SYGA-16CNB
16 kg Can plants.
ature and SYGA-16CNBT
under high (*)
load
q Feature: Silicone grease with wide usable tempera-
G2-S ture range, high resistance to thermal-oxidative
ThreeBond 200 g Tube degradation and performance to prevent deteriora-
1855 tion of rubber and plastic parts.
q Use for oil seals of the transmission, etc.
18
Cate- Komatsu
gory code
q Feature: Urea (organic system) grease with heat re-
Grease
sistance and long life, can be packed into the con-
G2-U-S
427-12-11871 2 kg Can fined space and left intact until next overhaul.
ENS grease
q Use for rubber, bearing and oil seal in damper.
Caution: Do not mix with lithium grease.
SUNSTAR q Use as primer for painted cab sheet metal
PAINT Glass con- surface.
20 ml
PRIMER tainer (Effective period: four months after date of
580 SUPER manufacture)
417-926-3910
SUNSTAR
q Use as primer for glass.
GLASS Glass con-
20 ml (Effective period: four months after date of
For adhered window glass

PRIMER tainer
manufacture)
580 SUPER
SUNSTAR q Use as primer for painted cab sheet metal
PAINT Glass con- surface.
Primer
22M-54-27230 20 ml
435-95 manufacture)
q Use as primer for black ceramic-coated glass
SUNSTAR
surface and for hard polycarbonate-coated
GLASS
22M-54-27240 150 ml Can surface.
PRIMER
(Effective period: four months after date of
435-41
manufacture)
SUNSTAR q Use as primer for sash (anodized aluminum
SASH Glass con- surface).
22M-54-27250 20 ml
GP-402 manufacture)
SUNSTAR q Use "S" in high-temperature season and "W"
PENGUINE in low-temperature season as adhesive for
Polyethylene
SEAL580 417-926-3910 320 ml glass.
container
SUPER "S" (Effective period: four months after date of
Adhesive
or "W" manufacture)
Sika Japan, q Use as adhesive for glass.
Polyethylene
Sikaflex 20Y-54-39850 310 ml (Effective period: six months after date of
container
For adhered window glass
256HV manufacture)
SUNSTAR q Use as adhesive for glass.
Ecocart (Spe-
PENGUINE 22M-54-27210 320 ml (Effective period: six months after date of
cial container)
SUPER 560 manufacture)
SUNSTAR
q Use to seal glass-to-glass joints.
PENGUINE Polyethylene
417-926-3920 320 ml (Effective period: four months after date of
SEAL No. container
manufacture)
Caulking material
2505
SEKISUI q Use to seal front window.
Polyethylene
SILICONE 20Y-54-55130 333 ml (Effective period: six months after date of
container
SEALANT manufacture)
GE
q Use to seal glass-to-glass joint. Translucent
TOSHIBA
white seal.
SILICONES 22M-54-27220 333 ml Cartridge
(Effective period: 12 months after date of
TOSSEAL
manufacture)
381
19
SELECTION OF WIRE ROPES USED FOR ASSEMBLY
Select wire ropes to be used for assembly according to the following table.
Annex 2, Table 1 Using loads of 6 × 24 type rope slings.

Unit: kN {tf}
Number of wire ropes 1 pc. 2 pcs.
Selection of Wire Ropes Used for Assembly
Sling angle D D = 0° D Z 90° 90° < D Z 120°

Angle to vertical line E E = 0° E Z 45° 45° < E Z 60°
Mode coefficient M 1 1.4 1
Classification of wire rope
Outer diameter of 24G 24A 24G 24A 24G 24A
wire rope (2)d (mm)
8 Max. 4.8 {0.49} Max. 5.2 {0.53} Max. 6.7 {0.68} Max. 7.2 {0.74} Max. 4.8 {0.49} Max. 5.2 {0.53}
9 Max. 6.1 {0.63} Max. 6.6 {0.67} Max. 8.5 {0.88} Max. 9.2 {0.93} Max. 6.1 {0.63} Max. 6.6 {0.67}
20
10 Max. 7.6 {0.77} Max. 8.2 {0.83} Max. 10 {1.0} Max. 11 {1.1} Max. 7.6 {0.77} Max. 8.2 {0.83}
11.2 Max. 9.5 {0.97} Max. 10 {1.0} Max. 13 {1.3} Max. 14 {1.4} Max. 9.5 {0.97} Max. 10 {1.1}
(12) Max. 10 {1.1} Max. 11 {1.2} Max. 14 {1.5} Max. 15 {1.6} Max. 10 {1.1} Max. 11 {1.2}
12.5 Max. 11 {1.2} Max. 12 {1.3} Max. 15 {1.6} Max. 16 {1.8} Max. 11 {1.2} Max. 12 {1.3}
14 Max. 14 {1.5} Max. 16 {1.6} Max. 19 {2.1} Max. 22 {2.2} Max. 14 {1.5} Max. 16 {1.6}
(24) Max. 43 {4.4} Max. 60 {6.1} Max. 43 {4.4}
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
21
INSTALLATION OF LEFT AND RIGHT TRACK FRAMES
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 revolving frame assembly: 26,360 kg (with head guard)

26,300 kg (without head guard)
Sling the revolving frame with the transportation posture.
Front side sling position

Boom cylinder bottom pin,
2 points
Precautions Necessary tools Necessary equipment
Never enter under the lifted revolving frame Name Qty Name Qty
assembly. ø32 × 5,000 mm wire rope sling 4 45 ton crane 2
SD30 shackle 1
Others
22
Assembly procedure
A-1
Lower the revolving frame assembly 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 M36 × 3 bolts and tighten them

Track Frame R.H. with 250 to 310 kgm torque.
No. Loose-supply items Qty

Track Frame L.H. 1 209-09-11310 8
2 209-30-41630 8
3 209-09-51110 8
4 209-30-45121 4
5 01643-33690 8
6 209-30-11330 8
7 209-09-51110 32
8 209-30-41630 32
Put washer (5) under plate (4). Name Qty Name Qty
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 kgm) 1
etc.
Socket (25.4 Sq. × 55 mm) 1
Torque wrench (420 kgm) 1
Others
23
Assembly procedure
A-1
Secure two points of the center frame of the track by placing 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: 10,400 kg (PC800, PC800SE)

10,700 kg (PC850, PC850SE)
11,900 kg (PC800LC)
Decide the sling portions not to

interfere with the upper structure
rotation.

Name Qty Name Qty
Hydraulic jack (50 ton) 2 45 ton crane 1
Wooden block (300 × 400 mm) 2
Wire rope sling (ø30 mm, 5,000 mm long) 2
Pin (ø50 mm, 500 mm) 2
Others
24
Assembly procedure
A-1
Thickness of 100 mm
Wooden block
a When tightening bolts, raise the track with a hydraulic jack or wooden block as shown above so as to get sufficient space
for tightening.
Do not remove the shoes before assembling Name Qty Name Qty
(so as to maintain the tightening torques of 4 time wrench 1
the shoe bolts).
Socket (25.4 Sq. × 55 mm) 1
Others
25
INSTALLATION OF TRAVEL PIPE
Assembly procedure
Installation of Travel Pipe (1/3)
A-2
Fig. 1
L.H. R.H.
Undercarriage for standard spec.

No. Parts already installed to body Qty
1 209-64-12132 2
2 209-64-12143 2
3 209-62-42611 2
4 209-62-42521 1
5 209-62-42510 1

6 07000-13032 4
Fig. 2
Undercarriage for LC spec.
1 209-64-45380 2
2 209-64-45390 2
3 209-62-43220 2
4 209-62-43240 1
5 209-62-43230 1

6 07000-13032 4
Before removing the oil stopper of each Name Qty Name Qty
hose, turn the bolt slowly to release the Width across flats 32 spanner 2 Waste oil pan, small 1
internal pressure.
Width across flats 24 spanner 2
L150 extension 1
M17 socket 1
Others
26
Assembly procedure
A-2
Fig. 3

1 209-64-12132 2
2 209-64-12143 2
3 209-62-42611 2
4 209-62-42521 1
5 209-62-42510 1

6 07000-13032 4

Name Qty Name Qty
Others
27
Assembly procedure
A-2
(1) Arrange the pilot hoses (4) (R.H.), (5) (L.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 fornt

1 209-64-12132 2
2 209-64-12143 2
3 209-62-42611 2
4 209-62-42521 1
5 209-62-42510 1

6 07000-13032 4

Name Qty Name Qty
Others
28
INSTALLATION OF TOP GUARD
Assembly procedure
Installation of Top Guard
A-3
Assemble top guard as shown in the diagram below.

a Make 3-point hitch at the a positions.
4 Top guard: 55 kg
.
Top guard mount

1 209-954-4311 1
2 195-Z11-2970 6
3 01024-81280 6
4 130-43-64260 6
5 01024-D1220 5
6 08037-02512 1
7 20Y-954-6250 1
8 01024-20612 2
9 20Y-954-6241 4
10 20Y-954-6490 4
The mounting parts at the front, central, and rear sections are 11 01024-D1016 1
different from one another. 12 01024-D1225 1
The top guard is installed when the machine Name Qty Name Qty
is delivered. Accordingly, the work on this
page is necessary only when the top guard is
supplied loose.
Others
29
INSTALLATION OF RADIATOR COVER
Assembly procedure
Installation of Radiator Cover
A-4
Set the radiator cover (1) on the body and fix them using the bolts and the washers (2) (5).
Install M12 eyebolts to

two places marked with a.
Install to the hinge.

1 209-54-41500 1
T 2 01024-81250 4
w 3 01024-81280 2
4 01011-81200 4
A 5 01024-81240 9
6 01643-31232 4
Remove the plugs for rust prevention set in Name Qty Name Qty
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
30
INSTALLATION OF REARVIEW MIRROR
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.
Mirror
Pin
Support
Clamp
Bolt

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

Name Qty Name Qty
Others
31
Assembly procedure
A-5
a Pass pin (5) through the hole in ball bushing (A), hold the mirror with the holder of mirror (1), then secure in position and
check that the mirror does not move.
Insert pin (5) in this hole
Holder
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}

Name Qty Name Qty
Others
32
Assembly procedure
A-5
With Top Guard

Install parts (1) (9) to the handrail at the front of the operators cab.
Bolt
Mirror
Pin
Bolt
Clamp
Support
Bolt
Clamp
Stay
a For details of mirror installation procedure, see (2/4).

1 421-54-25610 1
2 209-54-45611 1
3 01024-D1235 2
4 20Y-54-35430 1
5 01252-A1025 2
6 209-54-45660 1
7 20Y-54-27991 1
8 01252-A1025 2
9 04025-00632 1

Name Qty Name Qty
Others
33
Assembly procedure
A-5
Without Top Guard

Install parts (1) (10) to the handrail at the front of the operators cab.
Pin Bolt
Mirror Washer
Bolt
Clamp
Support
Bolt
Clamp
Stay
a For details of mirror installation procedure, see (2/4).

1 421-54-25610 1
2 209-54-45621 1
3 20Y-54-35430 1
4 01252-A1025 2
5 01024-D1270 1
6 20Y-03-11220 1
7 209-54-45660 1
8 20Y-54-27991 1
9 01252-A1025 2
10 04025-00632 1

Name Qty Name Qty
Others
34
INSTALLATION OF LEFT SIDE STEP
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 5 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 Qty Name Qty
into the mounting tap hole. L150 extension 1 25 ton crane 1
M19 socket 1
Others
35
INSTALLATION OF HANDRAIL
Assembly procedure
Installation of Handrail
A-7
(1) Install steps (1) on the left side cover with bolts (2).
(2) Install handrails (3) and (4) with bolts (2).

1 21M-54-32980 2
2 01014-81230 14
3 209-54-77581 1
4 209-54-77571 1

Name Qty Name Qty
L150 extension 1
M19 socket 1
Others
36
INSTALLATION OF HANDRAIL
Assembly procedure
Installation of Handrail (1/2)
A-8
With Top Guard

Install handrail (1) with bolts (2) and spacers (3).

1 209-54-45570 1
2 01024-D1260 2
3 195-33-11220 2

Name Qty Name Qty
M19 socket 1
Others
37
Assembly procedure
Installation of Handrail (2/2)
A-8
Without Top Guard

Install handrail (1) with bolts (2).

1 209-54-45580 1
2 01024-D1235 2

Name Qty Name Qty
M19 socket 1
Others
38
INSTALLATION OF MUFFLER TAIL TUBE
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 washers (4).
(2) Fix a rain cap (2) to the muffler tail tube.
Rain cap
(Decide the direction so that exhaust
is emitted rightward)
Muffler tail tube
View from machine left side

1 209-01-41310 1
2 6164-12-5900 1
3 01010-81230 4
4 175-54-34170 4

Name Qty Name Qty
M19 socket 1
Others
39
STICKING SHEET TO COUNTERWEIGHT
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
2 209-54-42191 1
3 01024-81220 4
Remove all oil and rust from the surface Name Qty Name Qty
where the sheet is to be stuck.
Others
40
INSTALLATION OF COUNTERWEIGHT
Assembly procedure
Installation of Counterweight
A-11
(1) Lift the counterweight assembly (1) and install it to the body.
(2) Use the bolts (2) (6 pcs.) and the spacers (3) (6 pcs.) for the installation.
a CHeck the seating condition when tightening the mounting bolts temporarily, then tighten them permanently.
a Bolt tightening torque: 3825 ± 392 Nm {390 ± 40 kgm}
a If no large torque wrench is available, tighten according to the turning angle below.
(1) Initial torque: Tighten to 1470 Nm {150 kgm}
(2) After that: Tighten 90° ± 5°
a When installing the counterweight, open the door at the rear of the hood.
4 Counterweight: 9,800 kg (PC800, PC800SE, PC800LC)

11,850 kg (PC850, PC850SE)
13,600 kg (PC800LC, if equipped)

2 209-46-41550 6
3 209-46-11210 6
Install the counterweight so that there will be Name Qty Name Qty
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
The weight of each counterweight can be M65SP socket 1

distinguished by the shape of the eye plate. ø30 x 5000 mm wire rope sling 2
SD30 2
(a) 9.8 ton

Others
(b) 11.85 ton (c) 13.6 ton
41
INSTALLATION OF KOMTRAX ANTENNA (IF EQUIPPED)
Assembly procedure
Installation of KOMTRAX Antenna (if equipped)
A-12
(1) Remove the cap from the antenna mounting part and install the antenna.
Antenna
Bolt
After the installation of top guard,

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

1 8A13-10-2100 1
2 01024-D1220 1
3 20Y-53-15140 1

Name Qty Name Qty
Others
42
INSTALLATION OF STEP LIGHT
Assembly procedure
Installation of Step Light (1/2)
A-13
When installing OPG TOP GUARD

1. Install step light (1) to the top guard.
2. When installing the light, remove the bolts marked with , remove and tighten the light, and then tighten the
bolts marked again.
Note) Tighten the bolts marked with to 7 8 Nm.
Connector connection position

1 20Y-06-41940 1
2 01024-D1020 1

Name Qty Name Qty
Others
43
Assembly procedure
Installation of Step Light (2/2)
A-13
When not installing OPG TOP GUARD

1. Install grommet (6) to bracket (3) and install bracket (3) to the cab. Tighten bolt (4) to secure the bracket and
rear view mirror together, and tighten bolt (5) to secure the bracket and cab handrail together.
2. Install step light (1) to bracket (3).
When installing the light, remove the bolts marked with ,

remove and tighten the light, and then tighten the bolts marked again.
Note) Tighten the bolts marked with to 7 8 Nm.

1 20Y-06-41940 1
2 01024-D1020 1
3 209-53-24420 1
4 01024-D1275 1
5 01435-40830 1
6 08037-02512 1

Name Qty Name Qty
Others
44
AIR BLEEDING OF TRAVEL MOTOR
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.

Name Qty Name Qty
Width across flats 10 wrench 1 Oil pan plate 1
Others
45
INSTALLATION OF TRAVEL PIPING COVER
Assembly procedure
Installation of Travel Piping Cover (1/4)
A-15
Undercarriage for standard specification
Weight of motor cover: 130 kg
a Swing upper structure to a position where the motor cover can be slung.
1. Install left travel piping cover.

1 209-30-41311 1
a Cover installing order: (1), (4), (10), (12). 2 01010-81645 10
3 01643-31645 10
4 209-30-41351 1
5 01010-81230 6
6 01010-81245 3
7 175-54-34170 11
8 01010-81640 1
9 21T-54-16150 1
10 209-30-41371 1
11 01010-81240 2
12 209-30-41330 1

Name Qty Name Qty
M16 Eyebolt 1 25 ton crane 1
ø10 × 3000 mm wire rope sling 1
M19 socket 1
M24 socket 1
Others
46
Assembly procedure
A-15
Undercarriage for standard specification
2. Install right travel piping cover.
a Cover installing order: (1), (4), (10), (12).

1 209-30-41321 1
2 01010-81645 10
3 01643-31645 10
4 209-30-41361 1
5 01010-81230 6
6 01010-81245 3
7 175-54-34170 11
8 01010-81640 1
9 21T-54-16150 1
10 209-30-41381 1
11 01010-81240 2
12 209-30-41340 1

Name Qty Name Qty
M19 socket 1
M24 socket 1
Others
47
Assembly procedure
A-15
Undercarriage for LC specification
Weight of motor cover: 130 kg
a Swing upper structure to a position where the motor cover can be slung.
1. Install left travel piping cover.

1 209-30-77630 1
a Cover installing order: (1), (4), (10), (12). 2 01010-81645 10
3 01643-31645 10
4 209-30-77670 1
5 01010-81230 11
6 01010-81245 2
7 175-54-34170 13
8 01010-81640 1
9 21T-54-16150 1
10 209-30-77690 1
11 21T-62-27270 1
12 209-30-77650 1

Name Qty Name Qty
M19 socket 1
M24 socket 1
Others
48
Assembly procedure
A-15
Undercarriage for LC specification
2. Install right travel piping cover.
a Cover installing order: (1), (4), (10), (12).

1 209-30-77640 1
2 01010-81645 10
3 01643-31645 10
4 209-30-77680 1
5 01010-81230 11
6 01010-81245 2
7 175-54-34170 13
8 01010-81640 1
9 21T-54-16150 1
10 209-30-77710 1
11 21T-62-27270 1
12 209-30-77660 1

Name Qty Name Qty
M19 socket 1
M24 socket 1
Others
49
TESTING TRACK SHOE TENSION
Assembly procedure
Testing Track Shoe Tension (1/3)
A-16

Name Qty Name Qty
Others
50
Assembly procedure
A-16
a If the track shoe tension is not correct, adjust as follows.

Name Qty Name Qty
Others
51
Assembly procedure
A-16
Decreasing Track Shoe Tension

k Warning
It is extremely dangerous to release the
grease by any method except the procedure
given below.
k Warning
Dont stand at the front.
Dont look inside.
(1) Loosen valve (1) gradually to release the grease.
(2) Turn valve (1) a maximum of one turn.
(3) If the grease does not come out smoothly, move the
machine forwards and backwards a short distance.
(4) Tighten valve (1).
(5) To check that the tension is correct, move the ma-

chine slowly forward.
(6) Check the track tension again, and if the tension is

not correct, adjust it again.

Name Qty Name Qty
Others
52
CHECK FUEL, COOLANT AND OIL LEVELS
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.
53
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 14.85 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 anti-

freeze 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 Qty Name Qty

shipped. Do not mix coolant of different type
with it.
Others
54
PARTS TO BE TOUCHED UP AFTER FIELD ASSEMBLY
Assembly procedure
Parts to be Touched up after Field Assembly
A-18

Name Qty Name Qty
Others
55
B. ASSEMBLING OF WORK EQUIPMENT
OF BACKHOE
• Clean the mounting pin and pin hole and check them for a flaw.
57
ASSEMBLY OF ARM CYLINDER
Assembly procedure
Assembly of Arm Cylinder (1/2)
B-1
(1) Remove the stopper fixed to the boom and the arm cylinder foot pin.
4 Arm cylinder foot pin: 24 kg × 2 (PC800)
54 kg (PC800SE, PC850, PC850SE)
(2) For PC800 only, set the O-rings (1) (07000-12130, 2 pcs.) to the arm cylinder foot. (See the next page.)
(3) Lift the arm cylinder and fit it to the hole positions on the arm side.
4 Arm cylinder: 843 kg (PC800, PC800LC)
481 kg × 2 (PC800SE, PC850, PC850SE)
Adjustment should be made using the shims (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}

1 07000-12130 2
2 207-70-11360 14

Name Qty Name Qty
50 mm wide, 3000 mm 25 ton crane 1

2
Synthetic fiber sling
M24 socket 1
Others
58
Assembly procedure
Assembly of Arm Cylinder (2/2)
B-1
PC800 only: Single cylinder

Name Qty Name Qty
Others
59
CONNECTION OF ARM CYLINDER HOSES
Assembly procedure
Connection of Arm Cylinder Hoses (1/3)
B-2
Remove the oil stopper plug from the arm cylinder pipe, replace the O-rings (PC850: 07000-13048, 4 pcs., 07000-13038,
4 pcs.) at the hose connection with new ones and connect the arm cylinder hoses (PC850: 07098-01414, 1 pc.,
07098-01417, 1 pc., 209-62-41910, 1 pc., 209-62-41920, 1 pc. and 07099-01214, 2 pcs.) 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
07098-01414 (STD spec.) 1
3
07098-01417 (SE spec.) 1
209-62-41920 (STD spec.) 1 L: 1350
4
07099-01417 (SE spec.) 1
07099-01214 (STD spec.) 2
5
07099-01217 (SE spec.) 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 Qty Name Qty
to prevent it from coming out during work. L150 extension 1
2. Remove and store the flange, O-rings and
heads so that you can reuse them later. M19 socket 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
60
Assembly procedure
B-2
Remove the oil stopper plug from the arm cylinder pipe, and replace O-rings (1) at the hose end with new ones
(PC850: Part No. 07000-13048, 4 pcs.). Then, connect the arm cylinder hoses (11) and (12) (PC850: 07098-01417 × 1,
209-62-41910 × 1).
a Use the oil stopper parts for split flange, bolts, and the like.
No. Loose-supply items Q’ty Remarks

1 07000-13048 4
07098-01417 (STD spec.) 1
11
209-62-45620 (SE spec.) 1
209-62-41910 (STD spec.) 1 L: 1650
12
209-62-45620 (SE spec.) 1
No. Housing fixing items Q’ty Remarks
6 07371-51470 8
7 01010-81455 16
8 01643-31445 16
the O-rings.
Others
61
Assembly procedure
B-2
For PC800
Remove the stopper plug from the arm cylinder pipe, and replace O-rings at the hose end with new ones. Then connect
the arm cylinder hoses.
a Use the oil stopper parts for split flange, bolts, and the like.

1 07000-13048 6
2 07098-01416 1
3 209-62-43250 1
4 07098-01415 1
No. Boom fixing items Qty
5 07371-51470 4
6 01010-81455 8
7 01643-31445 8
the O-rings.
Others
62
INSTALLATION OF BOOM CYLINDER FOOT
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 (steel 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
Steel block

1 07000-12130 4
2 209-72-45240 4
3 209-72-45230 4
a Assemble the boom cylinder foot so that Name Qty Name Qty
the greasing port faces down.
50 mm wide, 3000 mm
2
a Use the adjustment shims (209-72-45230,
1.0 mm thick, and 209-72-45240, 1.5 mm
thick) to decide their combination. M24 socket 1
Others
63
RELIEVING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT
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 filler of the hy-
draulic tank, turn 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 dusts do not en-
ter the tank.
(6) Lower the lock lever and keep it locked.

Name Qty Name Qty
Others
64
INSTALLATION OF BOOM CYLINDER HOSES
Assembly procedure
Installation of Boom Cylinder Hoses
B-5
(1) Remove the oil stopper plug from the boom cylinder tube.
(2) Arrange the boom cylinder hoses (1) (07099-01216, 4 pcs.) to the normal circuit as shown below. Replace the O-rings (2)
(07000-13038, 8 pcs.) at the hose connection with the new ones out of the loose-supply items.
a Bleed air from the boom cylinder. For details, see Procedure B-16 "Air Bleeding from Hydraulic Cylinder".

1 07099-01216 4
2 07000-13038 8
1. When removing the oil stopper plug from Name Qty Name Qty
each hose, loosen the bolt slowly to L150 extension 1 Oil pan (small) 1
release the internal pressure and then
remove the oil stopper plug carefully. M19 socket 1
2. Keep the removed flanges, O-rings and
heads so that you can use them again.
3. When installing each hose, take care
extremely that the O-ring will not be
caught.
4. When installing each hose, take care
extremely that dirt will not enter the circuit.
Others
65
INSTALLATION OF BOOM FOOT DUST SEAL
Assembly procedure
Installation of Boom Foot Dust Seal
B-6
(1) Install the seals (209-72-11261) to the boom foot.
Take care of the

direction of its lip.
Take care of the

direction of its lip.

1 209-72-11261 4
1. Take care of the direction of its lip so that Name Qty Name Qty
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
66
ASSEMBLY OF BOOM ASSEMBLY
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 (3), and 209-70-71650, 1.5 mm thick (2)) to decide their combina-
tion.
a Adjust the clearance with shims at one place outside the revolving frame.
(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 Qty Name Qty
ted to the boom foot, use care not to break ø25 × 5000 mm wire rope sling 2 45 ton crane 1
them when inserting pins.
Large hammer (plastic) 1
M24 socket 1
Others
67
HOSE CONNECTION OF ARM AND BUCKET CIRCUITS
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 Qty

1 07000-13048 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 Qty Name Qty
hose, care should be taken and rotate bolt L150 Extension 1
slowly to let out pressure.
2. Store the removed flange, O-ring, and M22 Socket 1
head in order so that they can be used
again.
3. When connecting hose, great care should
be taken so that O-rings do not get
caught.
4. When connecting hose, great care should
be taken so that dusts do not fall in the
circuits.
Others
68
INSTALLATION OF QUICK RETURN HOSE
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 and washer (6).
a Air bleeding should be made for arm cylinder only.
No. Loose-supply items Qty Remarks

1 02896-11009 1
2 02896-11012 1
3 07094-30315 2
4 07095-00314 1
5 07095-00317 1
6 01024-81260 1
a When installing each hose, take care Name Qty Name Qty
extremely that dirt will not enter the circuit. M19 Socket 1
M17 Socket 1
L150 Extension 1
Others
69
INSTALLATION OF BOOM CYLINDER
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 top pin: 33 kg × 2
(2) Start the engine and idle it as a low speed.
(3) Lift the boom 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: 758 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 Qty Name Qty
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 M24 socket 1
full stroke point.
Large hammer 1
Others
70
INSTALLATION OF ARM ASSEMBLY
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: 4,000 kg (PC800, PC800LC)
4,900 kg (PC800SE, PC850SE)
4,500 kg (PC850)
(3) Fit the stopper plate to the pin.

3 Tightening torque of the plate fixing bolt: 245 309 Nm {25 31.5 kgm}
(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 Qty Name Qty
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
M24 socket 1
Others
71
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.
aAssembly 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 plate to the pin.

3 Tightening torque of the plate fixing bolt: 245 309 Nm {25 31.5 kgm}
a Operate the cylinder slowly. Name Qty Name Qty

Do not operate it quickly and do not bring it to ø20 x 5000 mm wire rope sling 1 25 ton crane 1
the stroke end.
SD30 shackle 1 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.
M24 socket 1
Others
72
INSTALLATION OF HOSE BETWEEN BOOM AND BUCKET CYLINDER
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-17 "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 Qty Name Qty
transportation for re-use in the future. L150 Extension 1 Five-stage step 1
2. Connect hoses carefully so that they do not
M19 Socket 1 Oil pan plate 1
get caught between other parts.
3. Connect hoses carefully so that they do not in-
terfere with other parts and are not twisted.
4. When connecting hoses, use care not to let
dusts enter the circuit.
Others
73
INSTALLATION OF BUCKET ASSEMBLY
Assembly procedure
Installation of Bucket Assembly
B-13
(1) Push in the arm to bucket connection pin and

adjust the clearance to the range from 0.5 to 1.0
mm by using the bushing (209-939-5410) and
shim (209-939-5431 ( t =1.0) 9 pcs. and 209-
939-5441 ( t= 0.5 mm) 2 pcs.) out of the loose-
supply items. Then, tighten the cover mounting
bolt (M24).
a Inside bushing: anti-friction compound
(LM-P).
3Tightening torque of the cover

fixing bolt:
824 1,030 Nm {84 105 kgm}
(2) Set two O-rings (21N-70-13150) for preventing (4) Push in the link to bucket connection pin and
earth and sand from penetrating into the bucket adjust the clearance to less than 1 mm by using
arm connection pin to the normal positions and fix the shim (209-72-11220, 1 pc. t = 1 mm) out of
a pin stopper. the loose-supply items. Then, install O-rings
a Since the seal (209-72-12211, 2 pcs.) to the (208-70-33181, 2 pcs.) for dust prevention to the
boss on the link side (link to bucket connec- proper position, and fix the pin stopper.
tion), use care not to break them when in- a Since the seal (209-72-12211, 2 pcs.) to the
serting the pin. boss on the link side (link to bucket connec-
tion), use care not to break them when in-
(3) Lift the link and align the bucket to link connection serting the pin.
pin to the hole while operating the bucket cylin-
der.

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 Qty Name Qty
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-
M36 socket 1
der at the first time, the cylinder may not oper-
ate for 10 seconds or more, but do not move Torque wrench (100 kgm) 1
the lever to the full stroke.
Others
74
LUBRICATION PIPING TO WORK EQUIPMENT
Assembly procedure
Lubrication Piping to Work Equipment
B-14

07020-00000 2

Name Qty Name Qty
Others
75
WIRING OF WORK EQUIPMENT
Assembly procedure
Wiring of Work Equipment
B-15
(1) Connect the connector (CN-A13) (A) of the working lamp cable to the body cable.
(2) Install the working lamps (both the right and left ones) as shown below:
To work equipment
(Wiring of frame side)
(Wiring of work
equipment side)
For the part marked , use the parts

temporarily installed on the frame.

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

Name Qty Name Qty
M19 socket 1
Others
76
GREASING AFTER ASSEMBLING WORK EQUIPMENT
Assembly procedure
Greasing after Assembling Work Equipment
B-16

Name Qty Name Qty
Others
77
AIR BLEEDING FROM HYDRAULIC CYLINDER
Assembly procedure
Air Bleeding from Hydraulic Cylinder
B-17

Name Qty Name Qty
Others
78
C. ASSEMBLING OF WORK EQUIPMENT
OF LOADING SHOVEL
• Clean the mounting pin hole and check them for a flaw.
79
RELEASING RESIDUAL PRESSURE IN HYDRAULIC CIRCUIT
Assembly procedure
Releasing residual pressure in hydraulic circuit
C-1
When removing the hydraulic piping, be sure to release the residual pressure according to the following procedure.
(1) Set the lock lever in the FREE position.
(2) Remove the oil filler cap of the hydraulic tank.
(3) Run the engine about 10 seconds, and then stop it.
a Limit the engine speed to 1,000 rpm.
a Keep the work equipment control levers in neutral.
a Raise the hydraulic lock to the FREE position.
(4) Move each work equipment control lever to the stroke end within 5 - 6 seconds after stopping the engine.
a Repeat steps (3) and (4) 3 times.
k When removing the oil filler cap of the hydraulic tank, turn it slowly to release the internal pressure, and then remove it.
(5) After releasing the residual pressure, install the oil filler cap of the hydraulic tank to prevent dirt from entering the tank.
(6) Lower the hydraulic lock to the LOCK position.

Name Qty Name Qty
Others
80
PULLING OUT BOOM FOOT PIN AND BOOM CYLINDER FOOT PIN
Assembly procedure
Pulling out boom foot pin and boom cylinder foot pin
C-2
(1) Remove the boom foot pin stopper fixed to the chassis and pull out the pin.
(2) Remove the boom cylinder foot pin stopper fixed to the chassis and pull out the pin.
a Use forcing screws (24 mm, P = 3.0, full thread bolt, stem length 80 mm and above) to pull out the pins.
Boom
Foot pin
Foot pin Revolving Frame
Boom cylinder

Name Qty Name Qty
Others
81
INSTALLATION OF BOOM AND ARM ASSEMBLY
Assembly procedure
Installation of boom and arm assembly
C-3
(1) Install the seals (209-72-11261, 4 pieces) to the boom foot.
(2) Sling the boom and arm assembly with a crane and match it to the pin holes of the chassis.
(3) Apply lithium grease to the pin holes and inside of the
bushing.
Boom
Shim
(4) Install the boom foot pin. (See the right figure.)
If the boom leans to the right or left at this time, balance it
with a jib crane.
a Install the seals (209-72-11261, 4 pieces) to the boom

foot as shown in the figure below.
Take care not to damage those seals when inserting the
pin.
Revolving Frame
Seal
Seal
Seal a Check the clearance at the boom foot on the outside of
the chassis and decide the thickness of the shim so that
Seal the clearance will be less than 1 mm.
Combine the 1.0-mm thick shims (209-70-71640, 2 pieces)

and 1.5-mm thick shims (209-70-71650, 4 pieces) to obtain
the necessary thickness.
(Adjust the shim at one outside position.)
(5) Push in the boom foot pin completely and install the lock plate.

1 209-72-11261 4
2 209-70-71650 4
3 209-70-71640 2

Name Qty Name Qty
Others
82
INSTALLATION OF PIPING BETWEEN CHASSIS AND BOOM
Assembly procedure
Installation of piping between chassis and boom
C-4
Both ends
are plugged
Bucket bottom
Arm bottom
Arm head
Bucket head
Boom seen from above
P (seen from side)

(1) Remove the plugs from the piping on the boom side and the hoses on the chassis side and install the hoses between the
chassis and boom.
For bottom dump Hose (07099-01219, 07099-01222, 2 pieces)

O-ring (07000-13038, 4 pieces)
Split flange (07371-51260, 8 pieces)
Bolt (01010-51245,16 pieces)
Washer (01643-31232, 16 pieces)
For bucket Hose (07098-01414, 4 pieces)

For arm O-ring (07000-13048, 8 pieces)
Split flange (07371-51470, 16 pieces)
Bolt (01010-81455, 32 pieces)
Washer (01643-31445, 32 pieces)
1. Keep the flanges, O-rings, and heads used Name Qty Name Qty
for transportation so that they can be
reused.
2. When connecting each hose, take extreme
care that the O-rings will not be caught.
care that dirt will not enter the circuit.
Others
83
INSTALLATION OF FLUSHING PIPING FOR BOOM CYLINDER AND ARM CYLINDER
Assembly procedure
Installation of flushing piping for
C-5 boom cylinder and arm cylinder
Connection of flushing piping for work equipment piping
Hose to be removed
Boom seen from below
(1) Install the hose (07098-01423) to part (a) to short the arm cylinder circuit as shown above.
(2) Remove the boom cylinder bottom circuit hoses. (2 pieces of both cylinders on the outside of the work equipment)
Install boom cylinder head hose end (b) to part (c) to short the boom cylinder circuit.
Reuse the removed split flanges, bolts, washers, and O-rings. Take care that dirt will not
enter the circuit.

1 07098-01423 1
2 07099-01216 4
reused.
Others
84
INSTALLATION OF FLUSHING PIPING FOR BUCKET CYLINDER
Assembly procedure
Installation of flushing piping for bucket cylinder
C-6
Hose to
be removed
Bucket bottom
Bucket head
Bucket head
Bucket bottom
Hose to
be removed
(1) Remove the bucket cylinder head hoses (2 pieces on the right and left sides) (Outside hose).
(2) Disconnect bucket cylinder bottom hose (209-62-74560) from (E) portion (cylinder bottom), and connect it to (F) portion to
bypass bucket cylinder circuit.

(Reuse the removed split flanges, bolts, and O-rings.)
1 209-62-74560 2
2 07084-21220 2

Name Qty Name Qty
Others
85
INSTALLATION OF FLUSHING PIPING FOR BOTTOM DUMP CYLINDER
Assembly procedure
Installation of
C-7 flushing piping for bottom dump cylinder (1/2)
Remove 1 of the 2 bottom dump cylinder hoses

(07084-21216). Disconnect the end of the other hose from
part (F) and connect it to part (G) to short the bottom dump
circuit.
(See the figure below.)
Arm seen from below
Short-circuit state
Reuse the removed split flanges,

bolts, washers, and O-rings.
reused.
Others
86
Assembly procedure
Installation of
C-7 flushing piping for bottom dump cylinder (2/2)
k Even if the bucket assembly is disassembled as shown below, short the bottom dump circuit at part (G) similarly to the
above.
Bucket cylinder

Name Qty Name Qty
Others
87
INSTALLATION OF BOOM CYLINDER
Assembly procedure
Installation of boom cylinder
C-8
(1) Remove the stopper fixed to the boom, and then remove the boom cylinder top pin.
4 Boom cylinder: 730 kg × 2
4 Boom cylinder top pin: 25 kg × 2
(2) Run the engine at low idle.
(3) Sling the cylinder and push the rod slowly to match the pin holes.
(4) Drive in the cylinder top pin.

2 Inside of bushing: Apply lithium grease.
a Move the cylinder slowly. Do not move it quickly or move it to the stroke end. It may not start for more than 10 seconds at
first because of air in it. Do not move the lever to the stroke end at this time.
(5) Install both side cylinders as same procedure.
(6) Install the stopper

1 209-72-51180 2
2 207-70-11230 2
3 01010-81640 4
4 01643-31645 4

Name Qty Name Qty
Others
88
INSTALLATION OF BOOM CYLINDER FOOT
Assembly procedure
Installation of boom cylinder foot
C-9
(1) Sling the boom cylinder with the crane and match it to the pin holes.
(2) Fit the O-rings (Parts sent individually) (07000-12130, 4 pieces for both cylinders) to the boom cylinder foot and push in the
pins.
(3) Check the clearance between the cylinder and chassis (outside of the chassis). Decide the thickness of the shim to be
inserted to reduce the clearance to below 1 mm. Adjust the shims for both cylinders. (Outside of chassis)
(4) Push in the boom cylinder foot pin completely and install the lock plate.
(5) Install the above parts to both sides similarly.

a Assemble the parts so that the grease hole of
the boom cylinder bottom will be on the lower
side.
Adjust to reduce clearance to

below 1 mm. Boom cylinder
O-ring
O-ring
a Combine the 1.0-mm thick shims (209-72-45230,

4 pieces) and 1.5-mm thick shims (209-72-45240,
4 pieces) to obtain the necessary thickness.

1 07000-12130 4
2 209-72-45240 4
3 209-72-45230 4

Name Qty Name Qty
Others
89
INSTALLATION OF BOOM CYLINDER HOSES
Assembly procedure
Installation of boom cylinder hoses
C-10
(1) Remove the tube plug on the boom cylinder.
(2) Install the boom cylinder hoses (07099-01216, 4 pieces) to the regular circuit as shown below.
Boom cylinder
Install
hoses to
this side.
Plug is installed

1 07099-01216 4

Name Qty Name Qty
Others
90
INSTALLATION OF BOOM CYLINDER ROD PIN
Assembly procedure
Installation of boom cylinder rod pin
C-11
(1) Remove the stopper fixed to the boom, and then remove the boom cylinder rod pin.
(4) Drive in the cylinder rod pin.
(5) Install both cylinders according to the same procedure.
(6) Install the stopper. (Tightening torque of M16 bolt: 25 31.5 kgm)
a Move the cylinder slowly. Do not move it quickly or move it to the stroke end. It may not start for more than
10 seconds at first because of air in it. Do not move the lever to the stroke end at this time.

Name Qty Name Qty
Others
91
INSTALLATION OF ARM CYLINDER HOSES
Assembly procedure
Installation of arm cylinder hoses
C-12
(1) Remove the tube oil stopper on the arm cylinder side and that on the boom side.
(2) Install the arm cylinder hoses (07084-21411) to the regular circuit (See the figure below).
Replace the hose O-rings (07000-13048, 4 pieces) with new ones.
Oil stoppers are installed Arm cylinder Oil stoppers are installed
Boom seen from below

1 07000-13048 4
2 07084-21411 2
reused.
Others
92
INSTALLATION OF BUCKET CYLINDER
Assembly procedure
Installation of bucket cylinder
C-13
(1) Remove the stopper fixed to the boom, and then remove the bucket cylinder rod pin.
4 Bucket cylinder: 630 kg × 2
(4) Install the cylinder rod pin.

a Move the cylinder slowly. Do not move it quickly or move it to the stroke end. It may not start for more than
10 seconds at first because of air in it. Do not move the lever to the stroke end at this time.
(5) Install the stopper.

Name Qty Name Qty
Others
93
INSTALLATION OF BUCKET CYLINDER HOSE
Assembly procedure
Installation of bucket cylinder hose
C-14
Installation of bucket cylinder piping

Return the hoses connected for flushing.
Cylinder bottom side angle : Cylinder head side angle :

75 degrees 90 degrees
Cylinder bottom side angle : Cylinder head side angle :
75 degrees 90 degrees
q
q

q
q

Plug is installed
Plug is installed


1 07000-13038 8
2 209-62-74560 2
3 07084-21220 2

Name Qty Name Qty
Others
94
INSTALLATION OF CONNECTING HOSES BETWEEN CHASSIS AND BOOM TOP
Assembly procedure
Installation of connecting hoses between
C-15 chassis and boom top
(1) Remove the tube plugs on the boom side.
(2) Install of hoses for boom, arm cylinder, and bucket cylinder (07098-01414, 4 pieces) and
hoses for bottom dump cylinder (07099-01219, 07099-01222, 2 pieces).
Oil stoppers are

installed on both sides.
Bucket bottom
Arm bottom
Arm head
Bucket head

1 07098-01414 4
2 07099-01219 1
3 07099-01222 1

Name Qty Name Qty
Others
95
INSTALLATION OF BOTTOM DUMP CYLINDER HOSES
Assembly procedure
Installation of bottom dump cylinder hoses
C-16
Installation of bottom dump cylinder piping

(1) When the bucket assembly is installed to the arm as shown at right
1) Return the bottom dump cylinder hoses (07084-21216, 2 pieces)

connected for flushing.
(2) When the bucket assembly is disassembled as shown at right, install

the bucket and bucket cylinders according to the procedure shown in
the following pages, and then install the bottom dump cylinder hoses
(07084-21216, 2 pieces).
(1) Similarly to (1), replace the O-rings (07000-13038, 4 pieces) with

new ones.
Bucket cylinder

Name Qty Name Qty
Others
96
INSTALLATION OF BUCKET ASSEMBLY
Assembly procedure
Installation of bucket assembly (1/2)
C-17
(1) Remove the bucket-arm connecting pins (fixed to the bucket) and bucket-link connecting pins (fixed to the bucket).
(2) Run the engine at low idle and move the boom cylinder and arm cylinder slowly to match the holes for the bucket-arm
connecting pins.
k Move the cylinder slowly. Do not move it quickly or move it to the stroke end.
It may not start for more than 10 seconds at first because of air in it. Do not move the lever to the stroke end
at this time.
Keep the arc-level selector switch in the arc digging position.
(3) Push in bucket-arm connecting pins (1) and install plates (2) with bolts (3) and washers (4).
(Tightening torque: 25 31.5 kgm)
(4) Install fittings (5) (07020-00000, 2 pieces).
Arm
Buc
ket

Name Qty Name Qty
Others
97
Assembly procedure
Installation of bucket assembly (2/2)
C-17
(5) Match the holes for the bucket cylinder-bucket connecting pins.
(6) Push in bucket cylinder-bucket connecting pins (6) and install plates (7) with bolts (9) and washers (8).
(Tightening torque: 25 31.5 kgm)
Bucket

Name Qty Name Qty
Others
98
INSTALLATION OF WORKING LAMPS
Assembly procedure
Installation of working lamps
C-18
Install lamps (1) (21T-06-32810) with brackets (4) (20Y-06-21551), bolts (2) (01010-81430), and washers (3) (01643-31445)
and connect the connector.
(Install the lamps to both sides of the boom.)

1 21T-06-32810 2
2 01010-81430 2
3 01643-31445 2
4 20Y-06-21551 2

Name Qty Name Qty
Others
99
INSTALLATION OF WORK EQUIPMENT GREASE PIPING
Assembly procedure
Installation of work equipment grease piping
C-19
(1) Install grease fittings (07020-00000, 2 pieces) to the boom cylinder foot.
(2) Install the grease piping of the boom cylinder top and bucket cylinder top to parts (a).
2 places on both sides

4 places in total
Bucket cylinder portion Boom cylinder portion
Detail (a)

1 07020-00000 2

Name Qty Name Qty
Others
100
GREASING AFTER ASSEMBLING OF WORK EQUIPMENT
Assembly procedure
Greasing after assembling of work equipment
C-20
Supply each pin of the work equipment with molybdenum disulfide grease to fit it well for the first 1 month of new machine
or until the first grease pail (16 kg) is used up.
[Komatsu genuine grease No. SYGA-16CNM (16 kg)]
<Precautions>
(1) Do not apply molybdenum disulfide grease to the swing circle bearing.
(Since the balls contact the races by points, they will be worn quickly.)
(2) Do not apply molybdenum disulfide grease to the pin holes when assembling the work equipment.
(After the grease in the pin fitting parts dries up, the parts are rusted easily and pins may be fixed.)

Name Qty Name Qty
Others
101
BLEEDING AIR FROM WORK EQUIPMENT CIRCUIT
Assembly procedure
Bleeding air from work equipment circuit
C-21
After assembling the work equipment piping, bleed the air from it.
(2) Move each cylinder to about 100 mm before each stroke end 4 5 times.
(3) Keeping the engine speed at low idle, move each cylinder from the point of 100 mm
before the stroke end to the stroke end very slowly (taking at least 10 seconds), and then keep the work equipment control
lever at the stroke end for 3 minutes.
[Bleed the air from the boom cylinder, arm cylinder, and bucket cylinder at the extraction stroke end, but bleed the air
from the bottom dump cylinder at the retraction stroke end (opening end of the bucket).]
a The cylinder may not start for more than 10 seconds at first because of the much air in the circuit. Do not move
the lever to the stroke end at this time.
(4) Keeping the engine speed at high idle, move each cylinder from the point of 100 mm before the stroke end to the stroke
end very slowly (taking at least 10 seconds), and then keep the work equipment control lever at the stroke end for 1 minute.
[Bleed the air from the boom cylinder, arm cylinder, and bucket cylinder at the extraction stroke end, but bleed the air
from the bottom dump cylinder at the retraction stroke end (opening end of the bucket).]
a The air in each cylinder is bled by performing steps (2) (4).
a If the engine speed is heightened or each cylinder is moved to the stroke end from the first, the piston packing may
be damaged by the air in the cylinder.

Name Qty Name Qty
Others
102
M. PROCEDURE FOR INSPECTION AND MAINTENANCE
AFTER COMPLETION OF ASSEMBLY
103
INSPECTION OF OIL LEVEL IN HYDRAULIC TANK AND REFILL
Inspection and maintenance

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

Name Qty Name Qty
Others
104
procedure
Inspection of Oil Level in Hydraulic Tank and Refill (2/2)
M-1

Name Qty Name Qty
Others
105
REPLACEMENT OF RETURN FILTER (STANDARD FILTER TO FLUSHING FILTER)

procedure Replacement of Return Filter
M-2 (Standard Filter to Flushing Filter)
The return filter element for hydraulic oil is replaced

with the special elements (1) and plates (2) for flush-
ing as follows:
a When replacing the element, take out the element

slowly so that refuses adhered to the element do
not fall inside. Also, take out refuses by hand from
the case.

1 209-60-77551 2
2 21T-60-13730 2

Name Qty Name Qty
Store the removed standard element (209-
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
106
FLUSHING OF HYDRAULIC CIRCUIT

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 Qty Name Qty
since the relief valve of the filter is closed.
Others
107
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.

Name Qty Name Qty
Others
108
REPLACEMENT OF RETURN FILTER (FLUSHING FILTER TO STANDARD FILTER)

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

Name Qty Name Qty
Others
109
M-4 (Flushing Filter to Standard Filter) (2/2)
a After completion of flushing, check the flushing Name Qty Name Qty
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
110
FAILURE CODE

procedure
Failure Code (1/4)
M-5
Abnormality Record (Mechanical Systems) 3. Information displayed on abnormality record

The machine monitor classifies and records the abnor- screen
malities which occurred in the past or which are occur- On the Mechanical Systems screen, the follow-
ring at present into the mechanical systems, electrical ing information is displayed.
systems, and air-conditioning system or heater sys- (a) : Occurrence order of abnormalities from latest
tem. one/Total number of records
To check the mechanical system abnormality record, (b) : Failure code
perform the following procedures. (c) : Contents of trouble
(d) : Number of occurrence time (Displayable
1. Selecting menu range: 0 65,535 times)
Select Abnormality Record on the Service (e) : Service meter reading at first occurrence
Menu screen. (f) : Service meter reach at last occurrence
q [F1]: Move to next page (screen)
(if displayed)
q [F2]: Move to previous page (screen)
(if displayed)
q [F5]: Return to abnormality record screen
a If no abnormality record is recorded, "No
abnormality record" is displayed.
a If the number of occurrence time is 1 (first
occurrence), the service meter reading at the
first occurrence and that at the last occur-
rence are the same.
a If [E] is displayed on the left of a failure code,
the abnormality is still occurring or resetting
of it has not been confirmed.
a For all the failure codes that the machine
2. Selecting sub menu
monitor can record, see the failure codes
After the Abnormality Record screen is dis-
table in Abnormality Record (Electrical Sys-
played, select Mechanical Systems with the
tems) of the Shop Manual.
function switches or numeral input switches.
q [F3]: Move to lower item
q [F4]: Move to upper item
q [F5]: Return to service menu screen
q [F6]: Confirm selection
a You may enter a 2-digit code with the
numeral input switches to select the record of
that code and confirm it with [F6].
a The following figure shows the display of the
air conditioner specification. The heater
specification and heaterless specification are
different from each other in the display of "03
Air-conditioning System", which may not be
displayed in the heaterless specification.
4. Resetting abnormality record

The contents of the mechanical system abnormal-
ity record cannot be reset.
111
procedure
Failure Code (2/4)
M-5
Abnormality Record (Electrical Systems) 3. Information displayed on abnormality record

The machine monitor classifies and records the abnor- screen
malities which occurred in the past or which are occur- On the Electrical Systems screen, the following
ring at present into the mechanical systems, electrical information is displayed.
systems, and air-conditioning system or heater system. (a) : Occurrence order of abnormalities from latest
To check the electrical system abnormality record, one/Total number of records
perform the following procedures. (b) : Failure code
(c) : Contents of trouble
1. Selecting menu (d) : Number of occurrence time
Select Abnormality Record on the Service (Displayable range: 0 65,535 times)
Menu Screen. (e) : Service meter reading at first occurrence
(f) : Service meter reach at last occurrence
q [F1]: Move to next page (screen)
(if displayed)
q [F2]: Move to previous page (screen)
(if displayed)
q [F5]: Return to abnormality record screen
a If no abnormality record is recorded, "No
abnormality record" is displayed.
a If the number of occurrence time is 1 (first
occurrence), the service meter reading at the
first occurrence and that at the last occur-
rence are the same.
a If [E] is displayed on the left of a failure code,
the abnormality is still occurring or resetting
After the Abnormality Record screen is dis-
played, select Electrical Systems with the func-
a For all the failure codes that the machine
tion switches or numeral input switches.
monitor can record, see the failure codes
table.
q [F6]: Confirm selection
a You may enter a 2-digit code with the
numeral input switches to select the record of
that code and confirm it with [F6].
a The following figure shows the display of the
air conditioner specification. The heater
specification and heaterless specification are
different from each other in the display of "03
Air-conditioning System", which may not be
displayed in the heaterless specification.
112
procedure
Failure Code (3/4)
M-5
4. Resetting abnormality record 3) After the Electrical Sys. Error Reset screen
1) While the Electrical Systems screen is dis- is displayed, operate the function switches.
played, perform the following operation with q [F5]: Return to Electrical systems
the numeral input switches. screen (Reset mode)
q Operation of switches (While pressing q [F6]: Execute reset
[4], perform the operation in order): a The following figure shows the screen
[4] + [1] o [2] o [3] displayed when the items are reset one
by one. (If the [F2] switch is depressed to
delete all the information, Reset All? is
displayed.).
2) Check that the screen is set in the reset

mode, and then reset the items one by one or
together with the function switches.
a If the screen is set in the reset mode, 4) After the selected information or all the infor-
[CLEAR] graphic mark is indicated at mation is deleted, Reset! or All Reset! is
[F2]. displayed for a while, and then No error is
q [F2]: Reset all items displayed.
q [F5]: Return to abnormality record
screen
q [F6]: Reset selected item
a To reset items one by one: Select the
item to be reset with [F3] or [F4] and
press [F6].
a To reset all items together: Press [F2],
and all the items are reset, regardless of
selection of the items.
a If [E] is displayed on the left of a failure
code, the resetting operation is accepted
but the information is not reset.
113
procedure
Failure Code (4/4)
M-5
Abnormality Record (Air-conditioning System/ 3. Information displayed on abnormality record

Heater System) screen
The machine monitor classifies and records the abnor- On the Air-conditioning System or Heater Sys-
malities which occurred in the past or which are occur- tem screen, the following information is dis-
ring at present into the mechanical systems, electrical played.
systems, and air-conditioning abnormalities or heater (a): System/Component name
abnormalities. (b): Number of occurrence time
To check the air-conditioning abnormality record or (c): Condition (Normal or abnormal)
heater abnormality record, perform the following pro- q [F2]: Reset abnormality record
cedures. q [F5]: Return to abnormality record screen
a All the following figures show the air conditioner a If [E] is displayed on the left of a condition,
specification. the abnormality is still occurring or resetting
1. Selecting menu a If CAN disconnection is displayed in Commu-
Select Abnormality Record on the Service nication condition, communication cannot be
Menu screen. carried out normally. Accordingly, the condi-
tions of other items are turned OFF.

After the Abnormality Record screen is dis- 4. Resetting abnormality record
played, select Air-conditioning System or While the abnormality record screen is dis-
Heater System with the function switches or played, press [F2], and the number of occurrence
numeral input switches. time of abnormality is reset. If it is confirmed at
q [F3]: Move to lower item this time that the abnormality has been reset, the
q [F4]: Move to upper item display changes to Normal.
q [F6]: Confirm selection a Heater specification
a You may enter a 2-digit code with the In the heater specification, the display of Air-con-
numeral input switches to select the record of ditioning is replaced with Heater and the items
that code and confirm it with [F6]. which are not related to the heater are not dis-
played.
a Heaterless specification
In the heaterless specification, the abnormality
record menu and screen are not displayed.
114
Backhoe 1/13
Report No.
FIELD ASSEMBLY INSPECTION REPORT
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. SAA6D140E-5
Service Meter Reading Date of Inspection

Attachment
1 2
Location of Machine at Inspection Manufacturer
Model
Distributor’s Name
Serial No.
Signature : Delivery
Customer’s Name Address : Report
No. attached
Date :
Inspector’s Comments :
Inspector’s Name : KOMATSU USE ONLY :

C. Sheet Receiving Date :
Title :
By :
Signature : Remark :
Check sheet filling instructions :
1. Use following indexes for entry of judgment
□ ……Normal □ ……Correction made on abnormal point

□ ……Abnormal □ ……Not applied
2. Enter actually measured values in parentheses, [ ].
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.
2/13
Category
Revision
Local After
Check item assembly hours of Judgment standard
time operation
Actual
Oil and water levels
measuremet
Cooling water Soft water [ ]
A : -50 to -40 °C D: -20 to -10 °C

Anti-freeze Density of
[ ] B : -40 to -30 °C E: -10 to 0 °C
(A, B, C, D, E) anti-freeze
C : -30 to -20 °C (Not necessary in summer)
EO10W30-DH L to H+5 mm (10 minutes after stopping

Engine oil [ ]
See operation EO15W40-DH engine)
Checks before assembly
and
maintenance
manual for
Coupling details. TO10 L+5 mm to H (10 minutes after stopping
[ ]
case oil TO30 engine)
Swing machinery TO30 [ ] L+5 mm to H+10 mm(10 minutes after stopping

gear case oil engine)
Right TO30 [ ]
Final drive gear Bottom edge of level plug : 0 to -10 mm
case oil
Left TO30 [ ]
Hydraulic oil TO10 [ ] Between the H and L marks
Battery electrolyte – [ ] Within 13 mm from bottom surface of filler

port
Engine No. [ ]
When accepted After check
Service meter [ ] [ ]
Loose, untightened lock bolts for connecting pins There must be none.
Loose, untightened split flange bolts for work equipment piping There must be none.
Forgotten, missing, catching O-rings for work equipment piping There must be none.
Checks during assembly
Loose, twisted connections for grease piping There must be none.
Shim adjustment for work equipment pins Max. 1mm (for locations, see assembly
procedure manual)
Improperly inserted wiring, unconnected wiring There must be none.
Loose, untightened ladder mounting bolts There must be none.

3/13
Category
Revision
Local After
time operation
Loose, untightened counterweight bolts There must be none.
Stepped clearance between counterweight and frame Max. 15mm
Loose, untightened operator’s cab mounting bolts There must be none.
Loose, untightened operator’s seat mounting bolts There must be none.
Loose, untightened mounting bolts and joints for travel There must be none.
Forgotten, missing, catching O-rings for travel 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.
Are there any other parts not yet installed (rear view mirror, etc.)? There must be none.
Follow instructions in assembly procedure

Bleed air from hydraulic pump
manual.
Bleed air from travel motor
manual.

Flush hydraulic circuit
manual.
Bleed air from work equipment cylinder circuit Follow instructions in assembly procedure
manual.
Grease all parts of work equipment All locations must be greased.
Add to between L and H marks at inspection

Add hydraulic oil
posture.
Add fuel, washer fluid Fill tank.
Dirty oil on paintwork, damage to paintwork at any part Clean, repair damaged paintwork
4/13
Category
Revision 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 should be as on left.
display lamps should go out after approx. 3 sec.
For another 2 seconds, 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 idle – high idle.
There should be no scratches or misting of
Operation of service meter the lens or variation in operation.
MONITOR
AA: Screen for standard
BB: Screen with all lamps lighted up
CC: Maintenance time warning screen
(1) Wiper switch
(2) Buzzer cancel switch
(3) Auto-deceleration switch
(4) Engine coolant temperature monitor
Check monitor
(5) Engine coolant temperature gauge

(6) Hydraulic oil temperature gauge
(7) Service meter, Clock
(8) Hydraulic oil temperature monitor
(9) Working mode monitor
(10) Travel speed monitor
(11) Fuel gauge
(12) ECO gauge
(13) Fuel level monitor
(14) Working mode selector switch
(15) Travel speed selector switch
(16) Window washer switch
(17) Air conditioner control switches
(18) Engine oil pressure monitor
(19) Charge level monitor
(20) Radiator coolant level monitor
(21) Message monitor
(22) Air conditioner monitor
(23) Wiper monitor
(24) Swing lock monitor
(25) Engine pre-heating monitor or One-touch power max.
monitor
(26) Auto-deceleration monitor
(27) Engine oil level monitor
(28) Air cleaner clogging monitor
(29) Function switches (F1 to F6)
(30) Maintenance interval monitor
5/13
Category

time operation
(1) Car Radio

(2) Lock lever
(3) LH work equipment control lever
(4) One-touch power max. switch
(5) Travel pedals
(6) Travel levers
(7) Horn switch
(8) Machine monitor
(9) Cigarette lighter
(10) RH work equipment control lever
(11) Starting switch
(12) Fuel control dial
(13) Lamp switch
(14) Swing lock switch
(15) Machine push-up switch
(16) Boom shockless control switch
(17) Lower wiper switch (if equipped)
(18) Revolving warning lamp switch (if equipped)
(19) Heated operator seat switch (if equipped)
(20) Room lamp switch
(21) Emergency pump drive switch
(22) Swing brake cancel switch
(23) Step lamp switch
Check of switches, control levers
Operation of horn switch Press the switch to sound the horn.

At the same time, the flashing light (if
equipped) at the bottom front of the cab
will flash for approx. 5 seconds.
Operation of lock lever Push down the lever to apply the lock.
Engine can be started but all work
equipment control levers do not move.
Push up the lever to release the lock.
Engine cannot be started but all work
equipment levers move.
Operation of fuel control dial MAX: Full speed
MIN: Low idle
Operation of preheating pilot Rotate the key at the preheating position so
that the monitor display shows "preheating
ON". The preheating pilot will flash after
approx. 30 seconds to indicate the
completion of preheating.
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

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

the 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

be 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)

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

INT lights up: Wiper moves intermittently
OFF: Wiper stops

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 (canceled):
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 ON: While the boom stop operation, shock of
the boom is controlled.
Operation of step lamp switch • 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.
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

position, the room lamp will light up when the
switch is pressed.
Operation of emergency pump drive switch When normal: Switch is pushed down.
When the monitor display shows E02 (TVC valve system error), When switch is pushed up, alarm buzzer
sounds.
move the switch "up" to make it possible to perform work
7/13
Category
Revision
Local After
time operation
Operation of swing brake cancel switch When normal: Switch is pushed down.
When the monitor display shows E03 (Swing brake system error), When switch is pushed up, alarm buzzer
move the switch "up" to cancel the brake, and it becomes possible to sounds, and swing lock symbol flashes
actuate the swing. However, the swing brake remains released.
This is used to stop alarm buzzer if it
Operation of alarm buzzer stop switch sounds to warn of an abnormality of
warning item during engine operation.
ON: Lower wiper moves.
Operation of lower wiper switch (if equipped)
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 left work equipment control lever This lever is used to operate the arm and
(with auto-deceleration device) upper structure.
Arm operation Swing operation
(a) Arm OUT (c) Swing to right
(b) Arm IN (d) Swing to leftt
N (Neutral):
When the lever is in this position, the
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-deceleration device) bucket.
Boom operation Bucket operation
(a) RAISE (c) DUMP
(b) LOWER (d) CURL
N (Neutral):
boom and the bucket will be retained in the
position in which they stop.
Confirmation of failure history Delete the failure history after confirming
(Both electrical and mechanical) that no abnormality sign is displayed.
Confirm that no failure history is provided
after completion of the test.
8/13
Category

time operation
Swing operation running in: Engine high idle speed.
(Work equipment posture: Max. reach)
Right Left
6.8 ± 0.4 rpm
Constant swing speed [ rpm] [ rpm]
Swing performance
Brake angle Max. 70° (feeling)
Swing variation, hunting There must be none.
Abnormal noise, irregular swing There must be none.
Travel operation running in: Engine high idle speed.
(Work equipment posture: Travel posture)
Abnormal noise, heat from carrier roller, track roller, idler There must be no abnormal noise or
abnormal heat.
Operation of travel brake Must brake securely without pulling to one
side.
Abnormal noise, irregular travel There must be none.
Travel deviation (feeling) There must be no abnormal deviation from

fine control range to full stroke
range(feeling).
Forward Reverse
Travel deviation High [ Max. 200 mm / 20 m
] [ ]
(measured) speed
mm / 20 m mm / 20 m
(Only when it is Forward Reverse

considered that Low Max. 200 mm / 20 m
[ ] [ ]
speed
there is abnormality.) mm / 20 m mm / 20 m
Travel performance
Track rotating
High Forward Reverse
speed speed [ ] [ ]
- Right sec sec 53.6 ± 5.4 sec / 5 turns
(PC800LC: 58 ± 6 sec / 5 turns)
Difference between left and right: 1.2 sec
speed [ ] [ ]
- Left sec sec
Low Forward Reverse

speed [ ] [ ]
- Right sec sec 82 ± 8.0 sec / 5 turns
(PC800LC: 89 ± 9 sec / 5 turns)
Low Forward Reverse
speed [ ] [ ]
- Left sec sec
Righ Left
Track tension [ ] [ ]
mm mm
9/13
Category

time operation
Work equipment operation running in: Engine high idle speed,

(Note: Boom cylinder to ground level)
Pressurized: each port relief 2 minutes, shock 20 times (except BOOM LOWER)
Work equipment posture
In P mode
Work equip- RAISE: 5.3 ± 0.5 sec. (PC800(LC), 850)

ment speed 5.6 ± 0.6 sec. (PC800SE, 850SE)
(Incl.cushion RAISE sec LOWER sec
Boom [ LOWER:4.3 ± 0.4 sec. (PC800(LC))
actuating time) ] [ ]
4.2 ± 0.4 sec. (PC850)
4.4 ± 0.4 sec. (PC800SE, 850SE)
IN: 4.7 ± 0.5 sec. (PC800(LC))
IN sec OUT sec 5.4 ± 0.5 sec. (PC850, 800SE, 850SE)
Arm 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)
CURL sec DUMP sec 4.6 ± 0.5 sec. (PC800SE, 850SE)
Bucket [ ] [ ] DUMP: 3.2 ± 0.3 sec. (PC800(LC))
3.4 ± 0.3 sec. (PC850)
4.2 ± 0.4 sec. (PC800SE, 850SE)
Work equip- LOWER sec

ment time lag Boom [ ] Max. 6 sec.
Work equipment performance
(Engine low Only when there is considered to be abnormality.

idle)
IN sec
Arm [ ] Max. 5 sec.
Only when there is considered to be abnormality.
DUMP sec
Bucket [ ] Max. 4 sec.
There must be no abnormality during

Abnormal noise from hydraulic pump, coupling case operation under no load and during relief.
There must be no abnormal generation of
Generation of heat by coupling case heat.
There must be no hunting at any speed

Engine partial performance under no load, there must be no stalling of
engine even at low idle and relief.
Fine control performance Must operate smoothly.

There must be no escape of boom, arm, or
Operation when raising chassis bucket.
(Including machine push-up function) ON: Machine is lifted up.
OFF: Machine is not lifted up.
Abnormal noise, grating noise from work equipment There must be none.
Cushion must be fully effective.

Shock at end of cylinder stroke
(Shock at end of stroke for BOOM RAISE and ARM IN)
Immediately after engine is stopped, boom

Function of accumulator cylinder must move from fully extended
position to ground level. (Arm at Max. reach)
10/13
Category
Revision
Local After
time operation
Check all parts
• There must be no catching during oper-

Operating force of control lever when each actuator is
During operation
ation.
actuated.
• Must return naturally to neutral.
Feeling and noise of vibration in operator’s cab There must be none.
Vibration noise from frame, guard, ladder There must be none.
Movement of doors and windows Must move smoothly.

Around operator’s cab
Door, window locks Must lock securely.
Adjustment of operator’s seat Must be possible to make all adjustments.
There must be none.

Oil leakage
(Idler, roller, sprocket, final drive gear case, motor, brake
valve)
Undercarriage
Interference at any part There must be none.
Looseness of track shoe bolt There must be none.
There must be no overlapping, separation,

Contact of link tread
or missing or broken parts.
Oil leakage There must be none.
Center swivel, pump, solenoid valve, relief valve, control

valve, PPC valve, swing motor, brake valve, shuttle valve,
swing machinery, hydraulic tank, piping
There must be none.

Leakage of fuel
(Fuel tank, engine, piping)
Around chassis
Leakage of water from engine cooling water system There must be none.
Leakage of oil from engine lubrication system There must be none.
Leakage of gas from engine gas system There must be none.
Movement of covers Must move smoothly.
Cover locks Must lock securely.

11/13
Category
Revision
Local After
time operation
Operation of grease pump Must move smoothly.
Looseness, insufficient insertion of electric wiring terminals There must be none.
There must be a clearance of at least 10

Around chassis
Position for passing electrical wiring through

mm from any moving part or edge.
Leakage of air from air system There must be none.
There must be none.

Oil leakage
(Cylinder, piping, block)
Grease leakage from grease piping There must be none.

Around work equipment
Interference of work equipment There must be none.
Looseness of work equipment piping clamps, play in piping There must be none.
Twisting of hydraulic hoses and operation of work equipment

There must be none.
when turning over
12/13
Note: If the operation or function is defective, measure as necessary. All judgment standard values for speeds are the values in P mode.
Category
Revision
Local After
time operation
1. Engine speed Confirmed on monitoring mode [01002]
Low idle speed [ rpm] 825 ± 25 rpm

High idle speed (When
lever is operated a little) [ rpm] 1980 ± 50 rpm (In P mode)
High idle (When lever is not operated) 1880 rpm (In P mode)
Speed at boom raise relief
(Heavy lift: OFF) [ rpm] Min. 1700 rpm
at P mode
(Heavy lift: ON) [ rpm] Min. 1700 rpm
[55] for service mode

2. Radiator fan speed Confirmed (on fan rotation 100 %
fixed mode)
Speed at engine rated speed[ rpm] 1050 ± 50 rpm (Engine full, Oil temp. 50°C)
3. Oil pressure Confirmed on the monitoring mode

measurement [01100] for F pump and [01101] for R
pump
Main measurement items
Control valve main MPa

+1.0
31.4 –1.5 MPa
set pressure F pump At engine high idle,
{kg/cm²} {320 +10
–15 kg/cm²}
boom raise, P mode
Control valve main MPa 31.4 +1.0 and Heavy lift OFF,
–1.5 MPa
set pressure R pump +10 relief
{kg/cm²} {320 –15 kg/cm²}
Control valve main MPa 31.4 +1.0

–1.5 MPa
set pressure F pump
{kg/cm²} +10
{320 –15 kg/cm²} At engine high idle,
(increase) boom raise, P mode
Control valve main MPa and Heavy lift OFF,
31.4 +1.0
–1.5 MPa
set pressure R pump relief
{kg/cm²} +10
{320 –15 kg/cm²}
(increase)
Swing relief set MPa 28.9 +2.5
–0.5 MPa
At engine high idle,
pressure +25 swing and P mode,
{kg/cm²} {295 +–5 kg/cm²}
relief
Self pressure MPa +0.49 +5
3.24+0 MPa {33.0 +0 kg/cm²}
reducing valve
{kg/cm²} (At engine high idle, neutral)
output pressure
4. Current value Confirmed on the monitoring mode

pump
At neutral At boom raise

Pump EPC current value At neutral
F pump mA mA 250 ± 20 mA
Engine
Pump EPC current value high idle
At boom raise
R pump mA mA 540 ±120 mA
Note: Measure the following J/S differential pressure sensor

voltage only if the NC valve output pressure does not
pass the test.
Confirmed on the monitoring mode
[13802] for F pump and [13803] for R pump
J/S differential pressure

At neutral
sensor voltage V V Min. 3 V
F pump Engine
J/S differential pressure high idle
At boom raise
sensor voltage V V Min. 1.2 V
R pump
13/13
Category
Revision
Local After
time operation
5. Hydraulic drift of work equipment

(bucket unloaded, hydraulic oil temperature 50 ± 5°C)
Bucket tooth tip [ mm] Max. 1200(900) mm/15 minutes
Rated load:
PC800: 5,000 kg
Note: Measure the hydraulic drift of the following cylinders PC850: 5,400 kg
only if the hydraulic drift at the bucket tooth tip does PC800SE: 6,300 kg
not pass the test.
PC850SE: 6,900 kg
Oil temperature: 45 to 55 °C
Boom cylinder [ mm] Max. 55(35) mm/15 minutes
Arm cylinder [ mm] Max. 160(70) mm/15 minutes
Bucket cylinder [ mm] Max. 95(15) mm/15 minutes
( ): Work equipment: no load
6. Operation force, travel

Boom lever RAISE N LOWER N
Operating 15.7 ± 4.9 N
force {kg} {kg} {1.6 ± 0.5 kg}
RAISE LOWER PLAY Stroke: 85 ± 10 mm

Stroke
[ mm] [ mm] [ mm] Play: Max. 10 mm
Swing lever RIGHT N LEFT N

force {kg} {kg} {1.3 ± 0.4 kg}
RIGHT LEFT PLAY Stroke: 85 ± 10 mm

Stroke
Bucket DUMP N
lever Operating CURL N 12.8 ± 3.9 N
force {kg} {kg} {1.3 ± 0.4 kg}
CURL DUMP PLAY Stroke: 85 ± 10 mm

Stroke
At engine high
Arm lever IN N OUT N idle, relief
force {kg} {kg} {1.6 ± 0.5 kg}
IN OUT PLAY Stroke: 85 ± 10 mm

Stroke
Right travel FOR- N RE- N

lever Operating WARD VERSE
24.5 ± 5.9 N
force {kg} {kg} {2.5 ± 0.6 kg}
FORWARD REVERSE PLAY Stroke: 115 ± 12 mm

Stroke
Left travel FOR- N RE- N

24.5 ± 5.9 N
force {kg} {kg} {2.5 ± 0.6 kg}
FORWARD REVERSE PLAY Stroke:115 ± 12 mm

Stroke
Loading shovel 1/13
Report No.
FIELD ASSEMBLY INSPECTION REPORT
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.
Loading shovel spec. SAA6D140E-5
Service Meter Reading Date of Inspection

Attachment
1 2
Location of Machine at Inspection Manufacturer
Model
Distributor’s Name
Serial No.
Signature : Delivery
Customer’s Name Address : Report
No. attached
Date :
Inspector’s Comments :
Inspector’s Name : KOMATSU USE ONLY :

C. Sheet Receiving Date :
Title :
By :
Signature : Remark :
Check sheet filling instructions :
1. Use following indexes for entry of judgment
□ ……Normal □ ……Correction made on abnormal point

□ ……Abnormal □ ……Not applied
2. Enter actually measured values in parentheses, [ ].
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.
2/13
Category
Revision
Local After
time operation
Actual
Oil and water levels
measuremet
Cooling water Soft water [ ]
A : -50 to -40 °C D: -20 to -10 °C

Anti-freeze Density of
[ ] B : -40 to -30 °C E: -10 to 0 °C
(A, B, C, D, E) anti-freeze
C : -30 to -20 °C (Not necessary in summer)
EO10W30-DH L to H+5 mm (10 minutes after stopping

Engine oil [ ]
See operation EO15W40-DH engine)
Checks before assembly
and
maintenance
manual for
Coupling details. TO10 L+5 mm to H (10 minutes after stopping
[ ]
case oil TO30 engine)
Swing machinery TO30 [ ] L+5 mm to H+10 mm(10 minutes after stopping

gear case oil engine)
Right TO30 [ ]
Final drive gear Bottom edge of level plug : 0 to -10 mm
case oil
Left TO30 [ ]
Hydraulic oil TO10 [ ] Between the H and L marks
Battery electrolyte – [ ] Within 13 mm from bottom surface of filler

port
Engine No. [ ]
When accepted After check
Service meter [ ] [ ]
Loose, untightened lock bolts for connecting pins There must be none.
Loose, untightened split flange bolts for work equipment piping There must be none.
Forgotten, missing, catching O-rings for work equipment piping There must be none.
Loose, twisted connections for grease piping There must be none.
Shim adjustment for work equipment pins Max. 1mm (for locations, see assembly
procedure manual)
Improperly inserted wiring, unconnected wiring There must be none.
Loose, untightened ladder mounting bolts There must be none.

3/13
Category
Revision
Local After
time operation
Loose, untightened counterweight bolts There must be none.
Stepped clearance between counterweight and frame Max. 15mm
Loose, untightened operator’s cab mounting bolts There must be none.
Loose, untightened operator’s seat mounting bolts There must be none.
Loose, untightened mounting bolts and joints for travel There must be none.
Forgotten, missing, catching O-rings for travel 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.
Are there any other parts not yet installed (rear view mirror, etc.)? There must be none.

Bleed air from hydraulic pump
manual.
Bleed air from travel motor
manual.

Flush hydraulic circuit
manual.
Bleed air from work equipment cylinder circuit Follow instructions in assembly procedure
manual.
Grease all parts of work equipment All locations must be greased.
Add to between L and H marks at inspection

Add hydraulic oil
posture.
Add fuel, washer fluid Fill tank.
Dirty oil on paintwork, damage to paintwork at any part Clean, repair damaged paintwork
4/13
Category

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 should be as on left.
display lamps should go out after approx. 3 sec.
For another 2 seconds, 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 idle – high idle.
There should be no scratches or misting of
Operation of service meter the lens or variation in operation.
MONITOR
AA: Screen for standard
BB: Screen with all lamps lighted up
CC: Maintenance time warning screen
(1) Wiper switch
(2) Buzzer cancel switch
(3) Auto-deceleration switch
(4) Engine coolant temperature monitor
Check monitor
(5) Engine coolant temperature gauge

(6) Hydraulic oil temperature gauge
(7) Service meter, Clock
(8) Hydraulic oil temperature monitor
(9) Working mode monitor
(10) Travel speed monitor
(11) Fuel gauge
(12) ECO gauge
(13) Fuel level monitor
(14) Working mode selector switch
(15) Travel speed selector switch
(16) Window washer switch
(17) Air conditioner control switches
(18) Engine oil pressure monitor
(19) Charge level monitor
(20) Radiator coolant level monitor
(21) Message monitor
(22) Air conditioner monitor
(23) Wiper monitor
(24) Swing lock monitor
(25) Engine pre-heating monitor or One-touch power max.
monitor
(26) Auto-deceleration monitor
(27) Engine oil level monitor
(28) Air cleaner clogging monitor
(29) Function switches (F1 to F6)
(30) Maintenance interval monitor
5/13
Category

time operation
(1) Car Radio

(2) Lock lever
(3) LH work equipment control lever
(4) Bottom dump switch
(5) Travel pedals
(6) Travel levers
(7) Horn switch
(8) Machine monitor
(9) Cigarette lighter
(10) RH work equipment control lever
(11) Starting switch
(12) Fuel control dial
(13) Lamp switch
(14) Swing lock switch
(15) Machine push-up switch
(16) Boom shockless control switch
(17) Lower wiper switch (if equipped)
(18) Revolving warning lamp switch (if equipped)
(19) Heated operator seat switch (if equipped)
(20) Room lamp switch
(21) Emergency pump drive switch
(22) Swing brake cancel switch
(23) Step lamp switch
Operation of horn switch Press the switch to sound the horn.

At the same time, the flashing light (if
equipped) at the bottom front of the cab
will flash for approx. 5 seconds.
Operation of lock lever Push down the lever to apply the lock.
Engine can be started but all work
equipment control levers do not move.
Push up the lever to release the lock.
Engine cannot be started but all work
equipment levers move.
Operation of fuel control dial MAX: Full speed
MIN: Low idle
Operation of preheating pilot Rotate the key at the preheating position so
that the monitor display shows "preheating
ON". The preheating pilot will flash after
approx. 30 seconds to indicate the
completion of preheating.
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

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.

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

the 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

be 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)

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

INT lights up: Wiper moves intermittently
OFF: Wiper stops

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 (canceled):
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 ON: While the boom stop operation, shock of
the boom is controlled.
Operation of step lamp switch • 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.
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

position, the room lamp will light up when the
switch is pressed.
Operation of emergency pump drive switch When normal: Switch is pushed down.
When the monitor display shows E02 (TVC valve system error), When switch is pushed up, alarm buzzer
sounds.
move the switch "up" to make it possible to perform work
7/13
Category
Revision
Local After
time operation
Operation of swing brake cancel switch When normal: Switch is pushed down.
When the monitor display shows E03 (Swing brake system error), When switch is pushed up, alarm buzzer
move the switch "up" to cancel the brake, and it becomes possible to sounds, and swing lock symbol flashes
actuate the swing. However, the swing brake remains released.
This is used to stop alarm buzzer if it
Operation of alarm buzzer stop switch sounds to warn of an abnormality of
warning item during engine operation.
ON: Lower wiper moves.
Operation of lower wiper switch (if equipped)
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 left work equipment control lever This lever is used to operate the arm and
(with auto-deceleration device) upper structure.
Arm operation Swing operation
(a) Arm OUT (c) Swing to right
(b) Arm IN (d) Swing to leftt
N (Neutral):
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-deceleration device) bucket.
Boom operation Bucket operation
(a) RAISE (c) DUMP
(b) LOWER (d) CURL
N (Neutral):
boom and the bucket will be retained in the
position in which they stop.
Confirmation of failure history Delete the failure history after confirming
(Both electrical and mechanical) that no abnormality sign is displayed.
Confirm that no failure history is provided
after completion of the test.
Right: Bottom opened
The operation of bottom dump switch
Left: Bottom closed
8/13
Category

time operation
Swing operation running in: Engine high idle speed.

P mode
(Work equipment posture: Max. reach)
Right Left
6.8 ± 0.4 rpm
Constant swing speed [ rpm] [ rpm]
Swing performance
Brake angle Max. 70° (feeling)
Swing variation, hunting There must be none.
Abnormal noise, irregular swing There must be none.
Travel operation running in: Engine high idle speed.
(Work equipment posture: Travel posture)
Abnormal noise, heat from carrier roller, track roller, idler There must be no abnormal noise or
abnormal heat.
Operation of travel brake Must brake securely without pulling to one
side.
Abnormal noise, irregular travel There must be none.
Travel deviation (feeling) There must be no abnormal deviation from

fine control range to full stroke
range(feeling).
Forward Reverse
Travel deviation High [ Max. 200 mm / 20 m
] [ ]
(measured) speed
mm / 20 m mm / 20 m
(Only when it is Forward Reverse

considered that Low Max. 200 mm / 20 m
[ ] [ ]
speed
there is abnormality.) mm / 20 m mm / 20 m
Travel performance
Track rotating
speed speed [ ] [ ]
- Right sec sec
53.6 ± 5.4 sec / 5 turns
speed [ ] [ ]
- Left sec sec
Low Forward Reverse

speed [ ] [ ]
- Right sec sec
82 ± 8 sec / 5 turns
Low Forward Reverse
speed [ ] [ ]
- Left sec sec
Righ Left
Track tension [ ] [ ]
mm mm
9/13
Category

time operation
Work equipment operation running in: Engine midrange speed, all cylinders full stroke 3 times
(Note: Boom cylinder to ground level)
Pressurized: each port relief 2 minutes, shock 20 times (except BOOM LOWER)
Work equipment posture
Work equip- RAISE sec LOWER sec

ment speed RAISE: 6.1 ± 0.6 sec.
Boom [ ] [ ] LOWER: 4.8 ± 0.5 sec.
OUT sec IN sec IN: 4.1 ± 0.4 sec.

Arm (arc) [ ] [ ] OUT: 2.5 ± 0.3 sec.
CURL sec DUMP sec CURL: 4.6 ± 0.5 sec.

Bucket [ ] [ ] DUMP: 4.0 ± 0.4 sec.
Bottom OPEN sec CLOSE sec OPEN: 1.6 ± 0.3 sec.

dump [ ] [ ] CLOSE: 1.8 ± 0.3 sec.
Work equip- LOWER sec

ment time lag Boom [ ] Max. 3 sec.
(Engine low Only when there is considered to be abnormality.
idle)
IN sec
Arm [ ] Max. 3 sec.
Work equipment performance
DUMP sec
Bucket [ ] Max. 3 sec.
CLOSE sec
Bottom
[ ] Max. 3 sec.
dump Only when there is considered to be abnormality.
There must be no abnormality during

Abnormal noise from hydraulic pump, coupling case operation under no load and during relief.
There must be no abnormal generation of
Generation of heat by coupling case heat.
There must be no hunting at any speed

Engine partial performance under no load, there must be no stalling of
engine even at low idle and relief.
Fine control performance Must operate smoothly.

There must be no escape of boom, arm, or
Operation when raising chassis bucket.
(Including machine push-up function) ON: Machine is lifted up.
OFF: Machine is not lifted up.
Abnormal noise, grating noise from work equipment There must be none.
Cushion must be fully effective.

Shock at end of cylinder stroke
(Shock at end of stroke for BOOM RAISE and ARM IN)
Immediately after engine is stopped, boom

Function of accumulator cylinder must move from fully extended
position to ground level. (Arm at Max. reach)
10/13
Category
Revision
Local After
time operation
Check all parts
• There must be no catching during oper-

Operating force of control lever when each actuator is
During operation
ation.
actuated.
• Must return naturally to neutral.
Feeling and noise of vibration in operator’s cab There must be none.
Vibration noise from frame, guard, ladder There must be none.
Movement of doors and windows Must move smoothly.

Around operator’s cab
Door, window locks Must lock securely.
Adjustment of operator’s seat Must be possible to make all adjustments.
There must be none.

Oil leakage
(Idler, roller, sprocket, final drive gear case, motor, brake
valve)
Undercarriage
Looseness of track shoe bolt There must be none.
There must be no overlapping, separation,

Contact of link tread
or missing or broken parts.
Oil leakage There must be none.
Center swivel, pump, solenoid valve, relief valve, control

valve, PPC valve, swing motor, brake valve, shuttle valve,
swing machinery, hydraulic tank, piping
There must be none.

Leakage of fuel
(Fuel tank, engine, piping)
Around chassis
Leakage of water from engine cooling water system There must be none.
Leakage of oil from engine lubrication system There must be none.
Leakage of gas from engine gas system There must be none.
Movement of covers Must move smoothly.
Cover locks Must lock securely.

11/13
Category
Revision
Local After
time operation
Operation of grease pump Must move smoothly.
Looseness, insufficient insertion of electric wiring terminals There must be none.
There must be a clearance of at least 10

Around chassis
Position for passing electrical wiring through

mm from any moving part or edge.
Leakage of air from air system There must be none.
There must be none.

Oil leakage
(Cylinder, piping, block)
Grease leakage from grease piping There must be none.

Around work equipment
One side in contact, clearance at other

(CURL side)
side within 5 mm.
Contact between bucket and arm stopper
(DUMP side) One side in contact, clearance at other
side within 5 mm.
Contact between front bucket and rear bucket stopper One side in contact, clearance at other
side within 10 mm.
12/13
Note: If the operation or function is defective, measure as necessary. All judgment standard values for speeds are the values in P mode.
Category
Revision
Local After
time operation
1. Engine speed Confirmed on monitoring mode [01002]
Low idle speed [ rpm] 825 ± 25 rpm

1980 ± 50 rpm *
High idle speed [ rpm] Min. 1880 rpm **

(Heavy lift: OFF) [ rpm] Min. 1700 rpm
at P mode
(Heavy lift: ON) [ rpm] Min. 1700 rpm
[55] for service mode

2. Radiator fan speed Confirmed (on fan rotation 100 %
fixed mode)
Speed at engine rated speed[ rpm] 1050 ± 50 rpm (Engine full, Oil temp. 50°C)
3. Oil pressure Confirmed on the monitoring mode

pump
Control valve main MPa

+1.0
31.4 –1.5 MPa
set pressure F pump At engine high idle,
{kg/cm²} {320 +10
–15 kg/cm²}
boom raise, P mode
Control valve main MPa 31.4 +1.0 and Heavy lift OFF,
–1.5 MPa
set pressure R pump +10 relief
{kg/cm²} {320 –15 kg/cm²}
Control valve main MPa 31.4 +1.0

–1.5 MPa
set pressure F pump
{kg/cm²} +10
{320 –15 kg/cm²} At engine high idle,
(increase) boom raise, P mode
Control valve main MPa and Heavy lift OFF,
31.4 +1.0
–1.5 MPa
set pressure R pump relief
{kg/cm²} +10
{320 –15 kg/cm²}
(increase)
Swing relief set MPa 28.9 +2.5
–0.5 MPa
At engine high idle,
pressure +25 swing and P mode,
{kg/cm²} {295 +–5 kg/cm²}
relief
Self pressure MPa +0.49 +5
3.24+0 MPa {33.0 +0 kg/cm²}
reducing valve
{kg/cm²} (At engine high idle, neutral)
output pressure
4. Current value Confirmed on the monitoring mode

pump

Pump EPC current value At neutral
F pump mA mA 250 ± 20 mA
Engine
Pump EPC current value high idle
At boom raise
R pump mA mA 540 ±120 mA
Note: Measure the following J/S differential pressure sensor

voltage only if the NC valve output pressure does not
pass the test.
Confirmed on the monitoring mode
[13802] for F pump and [13803] for R pump
J/S differential pressure

At neutral
sensor voltage V V Min. 3 V
F pump Engine
J/S differential pressure high idle
At boom raise
sensor voltage V V Min. 1.2 V
R pump
* (When lever is operated a little and working mode is P)

** (When auto-decelerator is turned off and lever is at OFF)
13/13
Category
Revision
Local After
time operation
5. Hydraulic drift of work equipment

(bucket unloaded, hydraulic oil temperature 50 ± 5°C)
Bucket tooth tip [ mm] Max. 350 mm / 15 minutes
Note: Measure the hydraulic drift of the following cylinders

only if the hydraulic drift at the bucket tooth tip does
not pass the test.
Boom cylinder [ mm] Max. 7 mm / minutes
Arm cylinder [ mm] Max. 7 mm / minutes
Bucket cylinder [ mm] Max. 7 mm / minutes
6. Operation force, travel

Boom lever RAISE N LOWER N
force {kg} {kg} {1.6 ± 0.3 kg}
RAISE LOWER PLAY Stroke: 85 ± 10 mm

Stroke
Swing lever RIGHT N LEFT N

force {kg} {kg} {1.3 ± 0.4 kg}
RIGHT LEFT PLAY Stroke: 85 ± 10 mm

Stroke
Bucket DUMP N
lever Operating CURL N 12.8 ± 3.9 N

force {kg} {kg} {1.3 ± 0.4 kg}
CURL DUMP PLAY Stroke: 85 ± 10 mm

Stroke
At engine high
Arm lever IN N OUT N idle, relief
force {kg} {kg} {1.6 ± 0.5 kg}
IN OUT PLAY Stroke: 85 ± 10 mm

Stroke
Right travel FOR- N RE- N

24.5 ± 5.9 N
force {kg} {kg} {2.5 ± 0.6 kg}
FORWARD REVERSE PLAY Stroke: 115 ± 12 mm

Stroke
Left travel FOR- N RE- N

24.5 ± 5.9 N
force {kg} {kg} {2.5 ± 0.6 kg}
FORWARD REVERSE PLAY Stroke:115 ± 12 mm

Stroke

Hydraulic Excavator Field Assembly Manual

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GEN00104-01

HYDRAULIC PC800 -8R1 PC800LC -8R1

A. Assembly of Chassis ...................................................................................................... 21

B. Assembling of Work Equipment of Backhoe .................................................................. 57

M. Procedure for Inspection and Maintenance after Completion of Assembly.................... 103

Field Assembly Inspection Report (Backhoe)

Field Assembly Inspection Report (Loading Shovel)

Machine model PC800-8 PC800LC-8 PC800SE-8C850-8C850SE-8

1. Selection of work place

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

4. k Check during actual work

Backhoe · Inspection of oil level and

level and coolant level equipment

Min. 0.7 MPa

Min. 1.5 m3/min

Completion of body · Completion of general

Counterweight 45t crane

 Upper structure without head guard

Overall width 3,225 *3,195

Weight (kg) 26,300

 Upper structure with head guard

Overall width 3,225 *3,195

Weight (kg) 26,360

Weight 20,800 21,400 23,800

A (mm) 8,530 7,430 8,370 7,430

B (mm) 2,615 2,480 2,695 2,480

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

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

A (mm) 5,115 4,075 4,765 4,075

B (mm) 1,365 1,690 1,450 1,690

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

D (mm) 577 709 648 709

A (mm) 2,430 2,280 2,470 2,280

B (mm) 1,855 1,950 1,880 1,950

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

D (mm) 646 714 599 714

(4) Boom cylinder (for all models)

(5) Arm cylinder

A (mm) 3,580 2,595

B (mm) 1,885 1,391

Weight (kg) 830 960 (480 × 2)

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

C (mm) 684 684 684

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

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

(5) Radiator duct (for all models)

(6) Travel motor cover (for all models)

No. Tool names Specifications Qty Remarks

34 Wooden block 300 × 400 mm 4 Revolving frame pedestal

37 ø32 × 5,000 mm 4 For revolving frame

42 Pin ø50 × 500 mm 2 Track frame

47 Hydraulic oil EO-10 300 l

a : Bolt thread diameter (Nominal diameter)

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

Approx. 6 19 35  63 {3.5  6.5} 44 {4.5}

22 54  93 {5.5  9.5} 74 {7.5}

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)

q Use to prevent rubber gaskets, rubber cushions,

Machine model PC800-8 PC800LC-8 PC800SE-8C850-8C850SE-8

Upper structure without head guard

Upper structure with head guard

No. Tool names Specifications Qty Remarks

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

Approx. 6 19 35 63 {3.5 6.5} 44 {4.5}

22 54 93 {5.5 9.5} 74 {7.5}

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}

Sling the revolving frame with the transportation posture.

No. Loose-supply items Qty

No. Loose-supply items Qty

No. Loose-supply items Qty

No. Parts already installed to body Qty

No. Loose-supply items Qty

No. Parts already installed to body Qty

No. Loose-supply items Qty

Assemble top guard as shown in the diagram below.

No. Loose-supply items Qty

No. Loose-supply items Qty

No. Loose-supply items Qty

No. Loose-supply items Qty

No. Loose-supply items Qty

No. Loose-supply items Qty

No. Loose-supply items Qty

No. Loose-supply items Qty

No. Loose-supply items Qty