Description

Komatsu PC800-8R, PC800SE-8R, PC800LC-8R, PC850-8R, PC850SE-8R Installation Manual

If you’re field-assembling a Komatsu PC800-8R, PC800SE-8R, PC800LC-8R, PC850-8R, PC850SE-8R Installation Manual should be within arm’s reach the whole time. I’ve seen too many guys skip the factory document and end up with a hydraulic leak or a counterweight that’s half a degree off. This isn’t a repair manual. It’s the step-by-step assembly sequence that Komatsu wrote for their own dealers. 177 pages of what to do, in what order, and exactly how tight to make every fastener.

What the 177-Page Installation Manual Includes

This manual covers two main work equipment configurations: backhoe and loading shovel. Each has its own assembly section (Section B and Section C). Starts with the base machine – left and right track frames, travel piping, top guard, radiator cover, even the rearview mirror. Page 20 shows you how to install the track frame correctly. Section A runs 18 sub-steps before you even touch the boom. The kit layout diagram on page 4 tells you where every part goes before you start. That alone will save you from hunting for hardware halfway through.

Tightening Torque: Why Factory Specs Are Non-Negotiable

Section titled “Tightening Torque” starts on page 12. If you’re using a generic chart from the internet, you’re taking a risk. Komatsu specifies torque values for every bolted joint in this machine – track shoe bolts, hydraulic line flanges, mounting brackets. One stripped thread on a travel motor mount means a week of downtime. The manual also lists coating materials (page 16) – thread locker, anti-seize, and gasket sealant by location. Use what they specify, not what’s sitting on your bench.

Backhoe and Loading Shovel Assembly: Two Separate Sections

Section B (Backhoe) runs from B-1 to B-16. You’ll assemble the arm cylinder, connect hoses, install the boom, then the bucket. Each step includes a list of tools required – see page 11 for the full list. Section C (Loading Shovel) is similar but with different piping for the bucket and bottom dump cylinder. The foreword warns that this work uses the machine’s own hydraulic pressure to lift components. That means you must relieve residual pressure before disconnecting anything – Section B-4 and C-1 cover that. If you don’t, you’re asking for a 3,000 psi oil injection injury.

Post-Assembly Inspection and Hydraulic Circuit Flushing

Section M (Procedure for Inspection and Maintenance After Completion of Assembly) is the part most people rush through. M-1 checks the hydraulic oil level. M-2 replaces the standard return filter with a flushing filter. Then M-3 flushes the hydraulic circuit. Skip this and you’ll be pulling contamination through brand-new cylinders. The manual even includes error code diagnostics (M-4) and operating method for the monitoring system (M-5). That’s not something you get from a third-party reprint.

Who Needs This Manual?

If you’re a field mechanic assembling one of these machines for a mining operation or a large earthmoving contractor, you need this. Same if you’re a shop owner taking delivery of a knocked-down machine and putting it together for a customer. The factory documentation is the only thing that tells you how to bleed the travel motor (A-14), test track shoe tension (A-16), and touch up paint after assembly (A-18). Don’t trust aftermarket summaries – they leave out the small details that cause comebacks.

Does this manual cover the engine overhaul?

No. This is strictly an installation manual – field assembly of the base machine and work equipment. Engine service requires a separate service manual.

Are torque values given in ft-lb or Nm?

The manual lists tightening torque in both Nm and kgf·m. You’ll need to convert if your wrench reads ft-lb. The values are on page 12-15.

What if I lose one of the tool list items on page 11?

The manual lists specialized Komatsu tools (part numbers included) and standard tools. You can substitute standard tools as long as you hit the torque spec. But for pin presses and cylinder lifting fixtures, use Komatsu tools to avoid damage.

Can I use this manual for the PC800LC-8R?

Yes. The PC800LC-8R is included in the title and throughout the text. Track frame installation differs slightly for the long-track version, and the manual notes those variations in Section A-1.

Don’t rely on memory or generic instructions when assembling a machine that weighs over 70,000 pounds. Get the real factory documentation. Access the Factory Manual from AutoRepairManuals and have the correct torque specs, assembly sequence, and safety precautions at your fingertips.

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