Komatsu PC800-8R PC800SE-8R PC800LC-8R PC850-8R PC850SE-8R Hydraulic Excavator Shop Manual SEN02316-03

Description

Komatsu PC800-8R / PC850-8R Series Shop Manual — SEN02316-03

This Komatsu PC800-8R PC800SE-8R PC800LC-8R PC850-8R PC850SE-8R Hydraulic Excavator Shop Manual SEN02316-03 is the complete workshop reference for the -8R generation of Komatsu’s 80-tonne class excavators. Covering five machine variants powered by the SAA6D140E-5 engine, this shop manual delivers the full factory service workflow: structure and function, standard value tables, testing and adjusting, failure-code driven troubleshooting, disassembly and assembly, and full hydraulic and electrical drawings.

File Details

• Manual type: Shop Manual (workshop service and repair reference)
• Brand / models: Komatsu PC800-8R, PC800SE-8R, PC800LC-8R, PC850-8R, PC850SE-8R hydraulic excavators
• Engine covered: Komatsu SAA6D140E-5 (6-cylinder, 140 × 165 mm, 15.24 L)
• Serial number range: 60001 and up (all five models)
• Document number: SEN02316-03
• Language: English
• File format: PDF
• Page count: 1,060 pages
• Publication date: 2007

Chapters Covered

• 00 — Index and Foreword: composition of shop manual, safety notice, how to read the manual, handling of electric and hydraulic equipment, connector handling for engines, electric wire code reading, tightening torque tables, conversion tables
• 01 — Specification: specification drawings, working range drawings, full machine specifications, weight table, fuel/coolant/lubricant table
• 10 — Structure, Function and Maintenance Standard: engine and cooling system (coupling, lubrication system, radiator, oil cooler), power train (swing machinery, swing circle, final drive, sprocket), undercarriage and frame (track frame, recoil spring, idler, carrier roller, track roller, track shoe), hydraulic system Part 1 (hydraulic tank, main pump, fan pump, fan motor), hydraulic system Part 2 (control valves, straight-travel valve, swing motor, center swivel joint, travel motor, PPC accumulator, PPC valves, solenoid valves, quick return valve, hydraulic cylinders), work equipment, cab and attachments, electrical system (engine control, electric control system, monitor system, sensors)
• 20 — Standard Value Table: standard service value table for engine and standard service value table for chassis
• 30 — Testing and Adjusting (Parts 1–5): tools for testing and adjusting, engine speed, intake air pressure, exhaust gas temperature and color, valve clearance, compression pressure, blow-by pressure, engine oil pressure, fuel system handling and pressure, alternator and A/C belt tension, swing circle bearing clearance, track shoe tension, work equipment/swing/travel circuit oil pressures, control circuit and main pump control pressure, PPC valve output pressure, travel deviation, hydraulic drift, fan speed and circuit pressures, machine monitor special functions, KOMTRAX terminal procedure, Pm-clinic service
• 40 — Troubleshooting: general troubleshooting information, troubleshooting by failure code (Parts 1–3), troubleshooting of the electrical system (E-mode), troubleshooting of the hydraulic and mechanical system (H-mode), troubleshooting of the engine (S-mode)
• 50 — Disassembly and Assembly: general information, coating materials and special tools lists, engine and cooling system, engine (SAA6D140E-5), power train, undercarriage and frame, hydraulic system, work equipment, cab and attachments, electrical system
• 90 — Diagrams and Drawings: hydraulic circuit diagrams and electrical circuit diagrams (1/6 to 6/6)

Because this manual is divided into standalone Form Numbers (SEN02317-03 through SEN02337-00) that Komatsu supplies separately, the PDF serves as the complete bound workshop set. Every chapter that a technician needs to service a PC800-8R, PC800SE-8R, PC800LC-8R, PC850-8R or PC850SE-8R is present — from machine specifications and standard clearances right through to failure-code troubleshooting and step-by-step disassembly of the swing machinery, final drive, main pump, control valve assemblies, hydraulic cylinders and track components.

What This Manual Lets You Do

Anyone servicing a PC800-8R series machine knows that generic repair information is useless on a modern Komatsu excavator — the electronics are networked through the engine controller, pump controller and machine monitor, and the hydraulics run an Electronic OLSS pump control system that only behaves correctly when the specified pressures and EPC currents are met. This shop manual gives you the exact set points.

IMAGES PREVIEW

• Diagnose and clear the stored failure codes shown on the machine monitor, using the failure-code tables and the electrical/mechanical/engine troubleshooting flow.
• Test every major circuit — main relief pressures, control circuit oil pressure, main pump control pressure, PPC valve output pressure, jet sensor differential pressure, fan circuit oil pressure — against the standard value table for a new machine, plus the service limit values.
• Rebuild and adjust the swing machinery, final drive, idler, carrier roller, track roller and track shoe assemblies using the supplied assembly clearances, backlashes, wear limits and shimming/tightening torque figures.
• Remove, overhaul and reinstall the SAA6D140E-5 engine, main pump, cooling fan pump, control valves, center swivel joint, travel motors, swing motors, PPC valves and hydraulic cylinders safely, following the documented disassembly and assembly order.
• Read the hydraulic circuit diagram and the six electrical circuit diagrams end-to-end so that wiring, connectors and pressure lines can be traced on the machine.

Getting a pressure, clearance, backlash or tightening torque wrong on a machine of this size leads to accelerated wear, drift, deviation, overrunning swing, overheating or an engine that stalls under load. The Komatsu PC800-8R PC850-8R Shop Manual SEN02316-03 exists exactly to prevent that.

Instant PDF Delivery

The manual is delivered as a PDF download immediately after checkout — no shipping, no waiting, no binder to lose. Open it on a workshop PC, laptop, tablet or phone, zoom into the specification tables and diagrams, and print only the pages you need for the job in front of you. Keep it on the service truck and you have the full Komatsu workshop reference for every PC800-8R, PC800SE-8R, PC800LC-8R, PC850-8R and PC850SE-8R you work on.