Komatsu PC800-8, PC800LC-8 Hydraulic Excavator Operation & Maintenance Manual (50001 and up)

This manual PDF download describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment for the PC800-8, PC800LC-8 Komatsu Hydraulic Excavator (S/N: 50001 and up). It will help the operator or anyone realize peak performance through effective, economical and safe machine operation and maintenance.

APPLICABLE MODELS :

Komatsu PC800-8 – S/N: 50001 and up
Komatsu PC800LC-8 – S/N: 50001 and up

TABLE OF CONTENTS :

– SAFETY
– OPERATION
– MAINTENANCE
– SPECIFICATIONS
– OPTIONS AND ATTACHMENTS
– INDEX
– COLOPHON

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : UEAM005400
Total Pages : 318

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FOREWORD
FOREWORD
SAFETY INFORMATION
Noise emission levels
Vibration levels
Guide to Reduce Vibration Levels on Machine
BREAKING-IN THE NEW MACHINE
INTRODUCTION
DIRECTIONS OF MACHINE
VISIBILITY FROM OPERATOR’S SEAT
PROXIMITY VISIBILITY
12M CIRCUMFERENCE VISIBILITY
PRODUCT INFORMATION
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE
EPA REGULATIONS, ENGINE NUMBER PLATE
SERVICE METER LOCATION
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR
MACHINE SERIAL PLATE
FOREWORD
SAFETY
OPERATION
MAINTENANCE
SPECIFICATIONS
ATTACHMENTS AND OPTIONS
INDEX
COLOPHON

SAFETY
SAFETY INFORMATION
SAFETY LABELS
LOCATION OF SAFETY LABELS
SAFETY LABELS
SAFETY INFORMATION
SAFETY MACHINE OPERATION
STARTING ENGINE
OPERATION
TRANSPORTATION
BATTERY
TOWING
LIFTING OBJECTS WITH BUCKET
SAFETY MAINTENANCE INFORMATION

OPERATION
MACHINE VIEW ILLUSTRATIONS
OVERALL MACHINE VIEW
CONTROLS AND GAUGES
DETAILED CONTROLS AND GAUGES
MONITORING SYSTEM
Basic Operation of Machine Monitor
Emergency Monitors
Caution Monitors
Basic Check Monitors
Meter Display Portion
Monitor Switches Portion
SWITCHES
CONTROL LEVERS AND PEDALS
SUN ROOF
Opening
Closing
WINDSHIELD
EMERGENCY EXIT FROM OPERATOR’S CAB
DOOR LOCK
CAP WITH LOCK
HOT AND COOL BOX
MAGAZINE BOX
ASHTRAY
AIR CONDITIONER CONTROLS
Air Conditioner Control Panel
Method of Operation
Use Air Conditioner with Care
Air Conditioner Maintenance
Other Functions
RADIO-CASSETTE (OPTION)
Use Radio with Care
AUXILIARY ELECTRIC POWER
24V power source
12V power source
FUSE
CIRCUIT BREAKER
CONTROLLER
TOOL BOX
GREASE PUMP
Method of Use
Precautions when Using
Supplying Grease
ACCUMULATOR HANDLING
RELEASING PRESSURE IN THE CONTROL CIRCUIT ON MACHINES EQUIPPED WITH AN ACCUMULATOR
MACHINE OPERATIONS AND CONTROLS
BEFORE STARTING ENGINE
Walk-around Checks
Checks Before Starting
Adjustment
Seat Belt
Operations Before Starting Engine
STARTING ENGINE
AFTER STARTING ENGINE
Engine Warm Up
Hydraulic Equipment Warm Up
Operation After Completion Of Warm-Up Operation
STOPPING THE ENGINE
MACHINE OPERATION
Preparations for Moving the Machine
Moving Machine Forward
Moving Machine Backward
Stopping Machine
STEERING THE MACHINE
Steering
SWINGING
WORK EQUIPMENT CONTROLS AND OPERATIONS
WORKING MODE
PROHIBITED OPERATIONS
GENERAL OPERATION INFORMATION
TRAVELING ON SLOPES
ESCAPE FROM MUD
Track on One Side Stuck
Tracks on Both Sides Stuck
RECOMMENDED APPLICATIONS
Backhoe Work
Ditching Work
Loading Work
BUCKET REPLACEMENT
Replacement
PARKING MACHINE
MACHINE INSPECTION AFTER DAILY WORK
LOCKING
TRANSPORTATION
TRANSPORTATION PROCEDURE
LIFTING MACHINE
SHIPPING MACHINE INFORMATION
TRANSPORTATION POSTURE
PROCEDURE FOR INCREASING OR REDUCING TRACK FRAME GAUGE
COLD WEATHER OPERATION
COLD WEATHER OPERATION INFORMATION
Fuel and Lubricants
Cooling System Coolant
Battery
Monitor
AFTER DAILY WORK COMPLETION
AFTER COLD WEATHER SEASON
LONG TERM STORAGE
BEFORE STORAGE
DURING STORAGE
AFTER STORAGE
STARTING MACHINE AFTER LONG-TERM STORAGE
TROUBLES AND ACTIONS
RUNNING OUT OF FUEL
PHENOMENA THAT ARE NOT FAILURES
TOWING THE MACHINE
SEVERE JOB CONDITION
DISCHARGED BATTERY
Battery Removal and Installation
Battery Charges
Starting Engine with Booster Cables
OTHER TROUBLE
Electrical System
Chassis
Engine
Electronic Control System
Point of Contact to Telephone when Error Occurs

MAINTENANCE
MAINTENANCE INFORMATION
OUTLINE OF SERVICE
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC
OIL
FUEL
COOLANT AND WATER FOR DILUTION
GREASE
CARRYING OUT KOWA (Komatsu Oil Wear Analysis)
STORING OIL AND FUEL
FILTERS
ELECTRIC SYSTEM MAINTENANCE
EXPLANATION OF LUBRICATION CHART DECAL
WEAR PARTS
WEAR PARTS LIST
RECOMMENDED FUEL, COOLANT, AND LUBRICANT
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL
TIGHTENING TORQUE SPECIFICATIONS
TIGHTENING TORQUE LIST
SAFETY CRITICAL PARTS
SAFETY CRITICAL PARTS LIST
MAINTENANCE SCHEDULE
MAINTENANCE SCHEDULE CHART
MAINTENANCE PROCEDURE
INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS)
INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)
WHEN REQUIRED
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT
CLEAN INSIDE OF COOLING SYSTEM
CHECK AND TIGHTEN TRACK SHOE BOLTS
CHECK AND ADJUST TRACK TENSION
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)
REPLACE BUCKET TEETH (KMAX)
ADJUST BUCKET CLEARANCE
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID
CHECK AND MAINTENANCE AIR CONDITIONER
CLEAN LINE FILTER, REMOVE DIRT
CHECK GAS SPRING
BLEEDING AIR FROM HYDRAULIC SYSTEM
CHECK BEFORE STARTING
EVERY 10 HOURS MAINTENANCE
LUBRICATING
EVERY 100 HOURS MAINTENANCE
LUBRICATING SWING CIRCLE
EVERY 250 HOURS MAINTENANCE
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL
CHECK LEVEL OF BATTERY ELECTROLYTE
CHECK AND TIGHTEN TRACK FRAME AND AXLE CONNECTING BOLTS
CHECK ALTERNATOR DRIVE BELT TENSION, ADJUST
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST
EVERY 500 HOURS MAINTENANCE
REPLACE FUEL PRE-FILTER CARTRIDGE
CHECK SWING PINION GREASE LEVEL, ADD GREASE
CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, AFTERCOOLER FINS, FUEL COOLER FINS, AND AIR CONDITIONER CONDENSER FINS (only machines equipped with air conditioner)
CLEAN FRESH/RECIRC AIR FILTERS OF AIR CONDITIONER (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER)
REPLACE PILOT FILTER
CLEAN STRAINER OF COUPLING LUBRICATING OIL FILTER
REPLACE DRAIN FILTER CARTRIDGE
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE
EVERY 1000 HOURS MAINTENANCE
REPLACE FUEL MAIN FILTER CARTRIDGE
REPLACE BREATHER ELEMENT IN HYDRAULIC TANK
REPLACE HYDRAULIC TANK ADDITIONAL BREATHER ELEMENT
REPLACE HYDRAULIC OIL FILTER ELEMENT
CHANGE OIL IN SWING MACHINERY CASE
CHANGE OIL IN COUPLING CASE
REPLACE CORROSION RESISTOR CARTRIDGE
CHECK WELDED STRUCTURE
CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (for breaker)
EVERY 2000 HOURS MAINTENANCE
CHANGE OIL IN FINAL DRIVE CASE
CLEAN HYDRAULIC TANK STRAINER
CHECKING CHARGE PRESSURE OF NITROGEN GAS IN ACCUMULATOR (FOR CONTROL CIRCUIT)
CHECK ALTERNATOR
CHECK ENGINE VALVE CLEARANCE, ADJUST
CHECK ALL TIGHTENING POINTS OF ENGINE EXHAUST PIPE CLAMPS
EVERY 4000 HOURS MAINTENANCE
CHECK WATER PUMP
REPLACE ACCUMULATOR (FOR CONTROL CIRCUIT)
CHECK FOR LOOSENESS OF HIGH-PRESSURE PIPING CLAMP, HARDENING OF RUBBER
CHECK FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER
CHECK OPERATING CONDITION OF COMPRESSOR
CHECK STARTING MOTOR
EVERY 5000 HOURS MAINTENANCE
CHANGE OIL IN HYDRAULIC TANK
EVERY 8000 HOURS MAINTENANCE
REPLACE HIGH-PRESSURE PIPING CLAMP
REPLACE FUEL SPRAY PREVENTION CAP

SPECIFICATIONS
SPECIFICATIONS

ATTACHMENTS AND OPTIONS
GENERAL PRECAUTIONS FOR SAFETY
PRECAUTIONS WHEN SELECTING
READ THE INSTRUCTION MANUAL THOROUGHLY
PRECAUTIONS WHEN REMOVING OR INSTALLING
PRECAUTIONS WHEN USING
ATTACHMENT GUIDE
COMBINATIONS OF WORK EQUIPMENT
Working Range Diagram
TRACK SHOES SELECTION
HANDLING MACHINES EQUIPPED WITH KOMTRAX
BASIC PRECAUTIONS

INDEX
<A
<B
<C
<D
<E
<F
<G
<H
<I
<L
<M
<O
<P
<R
<S
<T
<V
<W
<Y

COLOPHON

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