Komatsu PC800 PC800LC PC800SE PC850 PC850SE-8R1 Shop Manual SEN05279-00

Description

Komatsu PC800 PC800LC PC800SE PC850 PC850SE-8R1 Shop Manual SEN05279-00

The Komatsu PC800 PC800LC PC800SE PC850 PC850SE-8R1 Shop Manual SEN05279-00 is a detailed workshop reference for the PC800-8R1, PC800LC-8R1, PC800SE-8R1, PC850-8R1 and PC850SE-8R1 hydraulic excavators from serial number 70001 and up. It brings together machine specifications, system construction and function, standard values, testing and adjustment procedures, troubleshooting, disassembly and assembly, maintenance standards, air-conditioner service information, and hydraulic and electrical circuit diagrams. The manual is organized for workshop service work, with procedures and reference data arranged by system so technicians can move from diagnosis to measurement, repair and final checks using the values and methods shown in the document.

File Details

• Manual type: Shop Manual
• Brand: Komatsu
• Models: PC800-8R1, PC800LC-8R1, PC800SE-8R1, PC850-8R1, PC850SE-8R1
• Serial coverage: 70001 and up for each listed model
• Document number: SEN05279-00
• Language: English
• Pages: 1,294
• File format: PDF

Workshop Information for the PC800 and PC850-8R1 Series

This manual goes well beyond basic maintenance. Its specification section identifies dimensional, performance, weight, fluid and lubricant information for the covered excavators, including the standard backhoe configurations and a PC800-8R1 loading shovel specification. The engine identified in the machine specifications is the Komatsu SAA6D140E-5, a six-cylinder engine, and the manual also provides machine-side engine testing, control, removal and installation information. For engine-part information, the manual itself directs the reader to the shop manual for the same engine model, an important distinction for anyone planning deep internal engine work.

The hydraulic coverage is extensive. System chapters explain component layout, the hydraulic tank and filters, the HPV375+375 main hydraulic pump, pump control system, servo valve, self-pressure reducing valve, LPV90 cooling fan pump, LMF110 cooling fan motor, control valves, straight-travel valve, swing and travel motors, PPC valves, solenoid valves, accumulator, quick return valve and filtration circuits. Detailed drawings show component construction and oil-flow relationships, while testing sections provide procedures for checking work-equipment, swing, travel and control circuit pressures, main-pump control signals, PPC valve output pressure, fan circuit pressure, oil leakage and hydraulic drift.

Electrical and electronic systems receive their own structured treatment. The manual explains electric equipment handling, connector and wiring precautions, wire codes, engine control, machine electric control, the monitor system, sensors and KOMTRAX. Troubleshooting material includes connector layouts, connector pin tables, fuse locations and failure-code diagnostics. It also separates symptom diagnosis into electrical E-mode, hydraulic and mechanical H-mode, and engine S-mode sections, allowing the technician to follow the type of failure being investigated rather than relying on a single generic troubleshooting chart.

Testing, Diagnosis and Adjustment

The Komatsu PC800 PC800LC PC800SE PC850 PC850SE-8R1 Shop Manual SEN05279-00 is especially useful when a repair requires measured confirmation rather than guesswork. The standard value tables provide reference values for the engine and machine, while the testing and adjusting chapter explains the tools and procedures used to obtain the measurements. Engine-related checks include engine speed, boost pressure, exhaust gas temperature and color, valve clearance, compression pressure, blowby pressure, engine oil pressure, fuel pressure, fuel return rate and leakage, fuel-circuit bleeding and leakage checks, plus belt tension procedures.

Machine testing reaches into the undercarriage, hydraulic and electrical systems. Procedures cover swing-circle bearing clearance, track tension, work-equipment and travel circuit pressures, pump control, PPC pressures, travel deviation, hydraulic drift, fan speed and fan circuit pressure. The electrical section includes machine-monitor functions, controller voltage-circuit handling and preparation for electrical troubleshooting. A PM Clinic section and undercarriage inspection report provide additional structured service references.

Disassembly, Installation and Component Repair

For major mechanical work, the disassembly and assembly chapter lays out safe removal, installation, disassembly and reassembly procedures together with special-tool information and coating materials. Coverage includes the engine, PTO and hydraulic pump assembly, cooling assembly, aftercooler, fuel cooler and condenser, fan motor and fuel tank. Engine-related procedures include the fuel supply pump, cylinder head, injectors, and front and rear seals.

Power-train and undercarriage procedures include PTO work, swing motor and swing machinery, swing circle, final drive, track shoe separation and connection, field link work, idler, idler adjustment cylinder, recoil spring, carrier and track rollers, revolving frame and counterweight. Hydraulic repair procedures cover the hydraulic tank, main pump, fan pump, control valve, swing motor, center swivel joint, travel motor, solenoid valve, boom damping valve, work-equipment and travel PPC valves, hydraulic cylinders and grease gun. Work-equipment procedures include bucket, arm and boom cylinders as well as bucket, arm, boom and complete work-equipment assemblies. The cab and electrical sections include cab and glass removal, air-conditioner unit, engine controller, monitor, pump controller and KOMTRAX terminal.

Safety and preparation are integrated throughout the manual. The foreword emphasizes correct servicing methods, safe support and lifting practices, pressure release before disconnecting circuits, care with hydraulic contamination, connector handling, specified tightening torque, replacement of seals and locking parts, and correct bleeding and refilling after hydraulic work. Special-tool lists and component weights support planning before heavy assemblies are removed or handled.

Specifications, Service Limits and Maintenance Standards

The specification pages provide model-by-model working ranges, dimensions, machine weights, bucket capacities, digging performance, travel and swing data, ground pressure and engine information. Separate tables cover component weights and fuel, coolant and lubricant information. Refilling information includes the engine oil pan, coupling case, swing machinery, final drives, hydraulic system, fuel tank and cooling system, helping the technician identify the correct service reference before work begins.

The maintenance-standard chapter then supplies wear and service criteria for key assemblies. It covers the coupling, swing circle, swing machinery, final drive, sprocket, track frame and idler cushion, idler, carrier roller, track roller, track shoe, cooling fan motor, control valve, swing motor, center swivel joint, PPC valve, work equipment and hydraulic cylinders. The manual explains how standard dimensions, tolerances, clearances, repair limits and allowable values are used to judge whether components remain serviceable or require repair or replacement.

Chapters Covered

• 00 Index and foreword
  • Safety and general information; how to read the shop manual
  • Maintenance-standard terminology; fuel, intake and hydraulic component handling
  • Push-pull couplers; electric equipment and electric wire codes
  • KOMTRAX use; work precautions; tightening torque, abbreviations and conversion tables
• 01 Specification
  • Specification drawings, dimensions and working ranges
  • Model specifications and performance data
  • Component weight tables
  • Fuel, coolant, lubricant and refill information
• 10 Structure and function
  • Engine and cooling system, coupling and coupling lubrication
  • Power train, swing circle, swing machinery and final drive
  • Undercarriage, track frame and idler cushion
  • Hydraulic component layout, tank, pumps, pump control and servo systems
  • Control valves, swing and travel motors, PPC and solenoid valves, accumulator and filters
  • Engine control, electric control, monitor, sensors and KOMTRAX
• 20 Standard value table
  • Engine standard values
  • Machine standard values for testing, adjustment and troubleshooting
• 30 Testing and adjusting
  • Tools for testing, adjusting and troubleshooting
  • Engine speed, boost, exhaust, compression, blowby, oil and fuel checks
  • Swing-circle clearance and track tension
  • Hydraulic pressures, pump control, PPC output, travel deviation and hydraulic drift
  • Fan tests, leakage checks, pressure release and air bleeding
  • Electrical preparation, monitor functions and PM Clinic inspection
• 40 Troubleshooting
  • Troubleshooting principles, failure-code tables and symptom indexes
  • Connector layouts, pin tables, branch adapters and fuse locations
  • Failure-code diagnosis for engine, machine control and electrical circuits
  • E-mode electrical troubleshooting
  • H-mode hydraulic and mechanical troubleshooting
  • S-mode engine troubleshooting
• 50 Disassembly and assembly
  • General procedures, coating materials and special tools
  • Engine, cooling system, PTO and fuel-system component procedures
  • Swing machinery, swing circle and final drive procedures
  • Track, idler, recoil spring, rollers, frame and counterweight procedures
  • Hydraulic pump, valve, motor, swivel joint, PPC valve and cylinder procedures
  • Work equipment, cab, air conditioner, controllers, monitor and KOMTRAX terminal
• 60 Maintenance standard
  • Power-train and undercarriage service standards
  • Hydraulic component service standards
  • Work-equipment dimensions and hydraulic cylinder standards
• 80 Appendix
  • Air-conditioner components and refrigeration cycle
  • Testing, self-diagnosis, sensor, pressure-switch and relay checks
  • Air-conditioner troubleshooting charts, gauge-pressure testing and service-tool connection
• 90 Diagrams and drawings
  • Hydraulic circuit symbols and hydraulic circuit diagrams
  • Electrical circuit symbols and electrical circuit diagrams

Taken together, these chapters make the Komatsu PC800 and PC850-8R1 shop manual a complete machine-service reference for tracing how a system works, comparing measured values with the stated standards, identifying a fault, planning component removal, carrying out repair or reassembly, and checking the machine after the work is completed. The combination of component illustrations, circuit diagrams, testing sequences, failure-code information, service limits and disassembly procedures is particularly useful for workshop jobs that cross hydraulic, mechanical and electrical systems.

Hydraulic and Electrical Diagrams for Complex Fault Finding

The diagram section provides both hydraulic and electrical circuit references, while earlier structure-and-function chapters show component layouts and internal construction. This allows a technician to connect a symptom with the actual control path: pump and valve operation can be compared with pressure-testing procedures, and electrical symptoms can be followed through connectors, sensors, controller circuits and failure-code tables. The manual also includes air-conditioner circuit and connector information in the appendix, so climate-control diagnosis is handled within the same service volume.

Put the Manual to Work Immediately

Use the Komatsu PC800 PC800LC PC800SE PC850 PC850SE-8R1 Shop Manual SEN05279-00 when servicing, testing, diagnosing, dismantling or reassembling the covered excavators from serial number 70001 and up. Following the documented procedures, standard values, service limits, tightening information and circuit diagrams helps keep repair decisions tied to the machine-specific data in the manual rather than assumptions. After payment, the manual is delivered as an instant PDF with no shipping required. Open it on a computer, tablet or phone, keep it available on any device that can read PDF files, and print the pages you need for the job.