Komatsu PC800-8 PC850-8 Series Hydraulic Excavator Operation and Maintenance Manual

Description

Komatsu PC800-8 PC850-8 Series Operation & Maintenance Manual

This is the complete Operation & Maintenance Manual for the Komatsu PC800-8, PC800LC-8, PC800SE-8, PC850-8 and PC850SE-8 hydraulic excavators, issued by Komatsu under Form No. PEN00126-06. It is the manual that would normally sit in the magazine box beside the operator’s seat, and it covers everything from the daily walk-around checks through to the 8000-hour maintenance interval and the specialised Loading Shovel variant of the PC800-8. Whether you are running the machine on site, servicing it in the workshop or rebuilding it after a failure, the Komatsu PC800-8 PC850-8 Series Operation & Maintenance Manual is the reference that keeps the procedures, torque values and safety warnings in one place.

File Details

• Manual type: Operation & Maintenance Manual (O&M)
• Brand: Komatsu
• Models covered: PC800-8, PC800LC-8, PC800SE-8, PC850-8, PC850SE-8
• Applicable serial numbers: PC800-50001 and up, PC850-10001
• Document number: PEN00126-06
• Publication date: March 2009 (03-09)
• Language: English
• File format: PDF
• Page count: 347 pages
• Section coverage: Safety, Operation, Maintenance, Specifications, Attachments and Options, Loading Shovel, Index

Chapters Covered

The Komatsu PC800-8 PC850-8 Series Operation & Maintenance Manual is structured into seven main sections plus an index, and this is what each one gives you:

• Safety
  • Safety information, signal words and safety alert symbols
  • Safety labels (part numbers and locations on the machine)
  • General precautions common to operation and maintenance
  • Precautions before starting operation, fire prevention, getting on/off the machine
  • Protection against falling, flying and intruding objects
  • Precautions for operation, jobsite hazards, starting engine, transportation and towing
  • Precautions for maintenance, high-temperature/high-pressure fluids, battery handling, accumulator and gas spring handling
• Operation
  • Machine view illustrations and component identification
  • Detailed controls and gauges
  • Monitoring system (emergency monitors, caution monitors, basic check monitors, gauges and meters)
  • Switches, lock lever, travel levers, work equipment control levers
  • Sun roof, windshield, door lock, cap with lock
  • Hot and cool box, magazine box, ashtray, fire extinguisher
  • Air conditioner controls, radio, auxiliary electric power, fuse and circuit breaker
  • Controller locations, tool box, grease pump
  • Walk-around checks, checks before starting, starting engine, warming up
  • Machine operation, moving, steering, swinging, work equipment controls
  • Recommended applications, backhoe work, ditching work, loading work
  • Parking machine, machine inspection after daily work, locking
  • Transportation, lifting machine, shipping machine information
  • Cold weather operation, long-term storage
  • Troubles and actions: running out of fuel, towing, discharged battery, booster cables, other trouble
• Maintenance
  • Maintenance information and outline of service
  • Wear parts and wear parts list
  • Recommended fuel, coolant and lubricant
  • Tightening torque specifications (metric bolts and hydraulic hoses)
  • Safety critical parts and safety critical parts list
  • Maintenance schedule chart (initial 100 / initial 500 / when required / every 10 / 100 / 250 / 500 / 1000 / 2000 / 4000 / 5000 / 8000 hours)
  • Maintenance procedures for each interval, including air cleaner element, cooling system, track shoe bolts, track tension, bucket teeth, bucket clearance, window washer fluid, air conditioner, line filter, gas spring, hydraulic air bleeding
• Specifications
  • Operating weight, bucket capacity, engine name, flywheel horsepower
  • Overall dimensions (length, height, width, track shoe width, cab height, tail swing radius, track length, tumbler centre distance)
  • Travel speed, swing speed
  • Working range (maximum digging radius, depth, height, vertical wall depth, dumping height, reach at ground level)
• Attachments and Options
  • General precautions for safety
  • Attachment guide and combinations of work equipment
  • Working range diagram
  • Track shoes selection
  • Handling machines equipped with KOMTRAX
• Loading Shovel
  • Switches, fuse
  • Operation of work equipment and precautions during operation
  • Precautions for jobsite, traveling on slopes, parking
  • Excavator work, shovel work, loading work
  • Transportation and machine configuration for transport
  • Wear parts list, maintenance, specification, combination of work equipment, working range diagram
• Index

Put together, the Komatsu PC800-8 PC850-8 Series Operation & Maintenance Manual gives an operator or technician a single source that runs from the safety decals on the machine through the correct warm-up routine, the daily and periodic service schedule, the torque charts for the fasteners and hydraulic fittings, and the full working range and dimension data for both the excavator and the Loading Shovel configuration. Instead of working from guesswork or from notes passed between operators, you get the manufacturer’s own sequence of steps, the values that go with them, and the warning notes that tell you when a job needs to be handled by a Komatsu distributor rather than in the field.

What You Can Do With This Manual

The Komatsu PC800-8 PC850-8 Series Operation & Maintenance Manual supports the full life of the machine, not just the routine services.

• Commission a new or unfamiliar machine — walk-around checks, breaking-in the new machine for the first 100 hours, seat and mirror adjustment, and the correct control-pattern check before first use.
• Start, warm up and operate correctly in any climate — from the automatic engine warm-up cycle and hydraulic equipment warm-up, through to cold-weather fuel and lubricant selection and the post-work procedures that stop the undercarriage freezing overnight.
• Carry out the full periodic maintenance schedule — every 10, 100, 250, 500, 1000, 2000, 4000, 5000 and 8000-hour tasks, plus the initial 100-hour and 500-hour services for a new machine.
• Diagnose faults from the machine monitor — the meaning of every red emergency monitor, caution monitor and basic check monitor, the E-code error table (E03, E07, E10, E11, E14, E15, E0E) and the remedial action for each.
• Handle field emergencies — running out of fuel and bleeding the fuel system, towing limits and correct wire rope use, starting with booster cables, discharged battery handling, escaping from mud, and releasing hydraulic pressure before opening a circuit.
• Adjust and replace wear items — track tension, bucket teeth (KMAX type), bucket clearance shims, track shoe bolts, filter cartridges and elements, air cleaner element and battery electrolyte level.
• Transport and store the machine — loading and unloading, lifting with a crane using the correct pin and hole diameters, shipping postures, long-term storage preparation and monthly rust-prevention procedure.
• Reference the Loading Shovel variant — the dedicated PC800-8 Loading Shovel section covers bottom-dump switches, bottom-dump work equipment operation and the shovel’s own wear parts and working ranges.

Why the Correct Procedures and Specifications Matter

A machine the size of the PC800-8 or PC850-8 does not forgive guesswork. The hydraulic system alone holds 800 litres of oil, the cooling system 104 litres, and the fuel tank 980 litres — servicing any of those systems with the wrong fluid, the wrong interval or the wrong tightening torque can turn a routine job into a pump or cylinder failure. The Komatsu PC800-8 PC850-8 Series Operation & Maintenance Manual is written to keep you inside the manufacturer’s limits: torque values for every metric bolt size and hydraulic hose fitting, the permissible track tension deflection, the correct engine oil and hydraulic oil refill capacities, and the specified warm-up times before the machine is put under load. Following those values protects not only the excavator but the operator and anyone working around it, because the same manual also carries the safety distances for high-voltage cables, the correct lifting geometry, and the warnings about hot coolant, high-pressure oil and the accumulator. Having the manual on hand is what lets a technician work confidently rather than cautiously, and what lets a buyer verify that a used machine is being serviced to the standard Komatsu intended.

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Instant PDF Delivery

The Komatsu PC800-8 PC850-8 Series Operation & Maintenance Manual is delivered as an instant-download PDF. There is no shipping, no waiting for a physical book and no risk of a copy going missing in transit. The file works on a workshop PC, a laptop, a tablet or a phone, so the section you need can be on screen next to the machine while you work. Every page is printable, which means you can take a single maintenance table, torque chart or safety label page out to the machine rather than carrying the whole document. For anyone maintaining, repairing or operating a PC800-8, PC800LC-8, PC800SE-8, PC850-8 or PC850SE-8, this Komatsu PC800-8 PC850-8 Series Operation & Maintenance Manual is the reference you want within reach.