Description

Komatsu PC750-6, PC800-6, PC750SE-6, PC750LC-6, PC800SE-6 1996 Installation Manual

If you’re assembling a Komatsu PC750-6, PC800-6, PC750SE-6, PC750LC-6, or PC800SE-6 from a shipped packet, you already know: one wrong bolt torque on a track frame can turn a two-day job into a two-week headache. I’ve spent 28 years wrenching on yellow iron, and the difference between a field-assembled machine that runs for 10,000 hours and one that leaks from day one is whether you follow the factory procedure. This 1996 Installation Manual (98 pages) from Komatsu America International Company is the only document that gives you the step-by-step order, tool list, and torque values for putting these excavators together right. No aftermarket condensation – this is the OEM print.

7 Systems Covered in This Installation Manual

You get the full table of contents from the original PDF. Starts with Points Regarding Local Assembly on page 3, then moves through Assembling Procedures, Applicable Equipment and Schedule (page 5). From there it dives into Packing Style for Transportation (page 7), which tells you exactly how the components come crated – crucial if you’re receiving a split shipment. Then List of Tools for Field Assembling on page 12 – don’t skip it. The manual expects you to have specific Komatsu tool numbers. After that, Field Assembling proper starts page 13, covering every major subsystem: track frames, travel pipes, FOPS (Falling Object Protective Structure), radiator cover, rearview mirrors, handrails, steps, muffler tail tube, counterweight installation, and hydraulic system assembly.

Fitting of Left and Right Track Frames: Why It Matters

Page 18 details the Fitting of Left and Right Track Frames. If you’ve ever tried to seat a frame without the proper gauge, you know the frustration of misaligned rollers. This section tells you the sequence – left frame first then right – and includes the extension procedure for 3-split package transport. The manual also gives you the Adjustment of Track Tension procedure later. I’ve seen guys crank tensioners by ear. That’s how you snap a chain on the first job site. The factory spec is there. Use it.

Hydraulic Circuit Assembly: Boom, Arm, Cylinder Hoses

The hydraulic section is the densest part. Starts with Relieving Remaining Pressure from Hydraulic Circuit (page not given, but it’s under Boom Assembly). Then Installation of Boom Cylinder Foot, Arrangement of Boom Cylinder Hose, Boom Cylinder, Arm Cylinder, and Arrangement of Arm Cylinder Hose. The manual even shows how to route the bucket cylinder hoses between boom and bucket. Then Lubrication Piping to Work Equipment and Air Bleeding from Cylinder. Every line routing matters – cross a hose and you’ll have a binding issue that chews through seals. After assembly, you run Inspection of Oil Level in Hydraulic Tank and Refill, then Replacement of Return Filter (Standard Filter to Flushing Filter). Finally, Flushing of Hydraulic Circuit clears any debris from assembly.

Does This Manual Cover the Electrical and Cab Systems?

Yes, but not the full electrical diagnostics – this is an installation manual, not a workshop manual. It covers Wiring of Work Equipment (the harness routing for boom sensors and lights), Installation of Cab Top Light, Installation of Radio Antenna, and Installation of FOPS. The FOPS section includes the structure mounting and roof panel alignment. For detailed wiring diagrams of the engine or controller, you’d want the 2000 Workshop Manual – see Komatsu PC750-6 PC800-6 2000 Workshop Manual – Factory Specs. But for initial assembly and cab fit-out, this manual gives you the physical mounting specs and hardware torques.

Source Validity: Why Aftermarket Manuals Fall Short

I’ve seen reprints sold as ‘OEM quality’ that omit the Related Laws and Regulations section (page 14 of this manual) – that page lists regional compliance items like lighting requirements and emissions tags. Without it, you might fail inspection. This PDF is a direct scan of the 1996 Komatsu publication, with the copyright notice, serial number range (PC750-6 – 10001 and up, PC800-6 – 30001 and up), and the statement that it is proprietary to Komatsu America International Company. No third-party rewriting. You get the exact language Komatsu engineers wrote. For that reason, I trust this over any aftermarket compilation. If you need a later revision, check Komatsu PC750-6 PC800-6 2004 Installation Manual – OEM Factory Specs or Komatsu PC750-6 PC800-6 2004 Workshop Manual – Factory Specs. But for a 1996 machine, this is the document the field technician used.

Who Needs This Manual?

If you’re a home garage enthusiast who bought a surplus PC750-6 in pieces, you need this. If you run a small equipment rental outfit and your mechanic is assembling a crate unit, you need this. If you’re a dealer technician who gets shipped a new machine for local assembly, you need this. The List of Tools for Field Assembling (page 12) will tell you exactly what wrenches, torque multipliers, and lifting gear you have to have on hand. Without that list, you’ll be running to the tool truck mid-job. I’ve been there – it costs billable hours. This manual prevents that.

FAQ

Does the manual include torque specifications for all bolts?

Yes, but indirectly. The manual gives torque values in the Field Assembling sections for track frame bolts, counterweight fasteners, and cylinder mounting pins. However, for engine internal or final drive torques you need the workshop manual. The installation manual focuses on assembly interfaces.

Is this the same as the operator’s manual?

No. The operator’s manual covers daily checks and controls. This is the field assembly instruction – it tells how to put the machine together after crate delivery.

Look, you can make a lot of money if you assemble these excavators fast and correctly. But the only way to do that is to have the factory procedure on your tablet next to the machine. Don’t guess on whether a hose goes above or below the boom cylinder – the manual shows the routing. Don’t risk cracking a counterweight mount because you used a different bolt pattern. Get the actual 1996 Komatsu publication with the serial number range that matches your machine. Access the Factory Manual from AutoRepairManuals and keep the job moving.

• Related Manual: Komatsu PC750-6 PC800-6 2004 Installation Manual – OEM Factory Specs
• Related Manual: Komatsu PC750-6 PC800-6 2000 Workshop Manual – Factory Specs
• Related Manual: Komatsu PC750-6 PC800-6 2004 Workshop Manual – Factory Specs
• External Reference: Manual Transmission
• External Reference: Manual Transmission