Komatsu PC800-8 LOADING SHOVEL Manual

PC800 -8
PC800LC -8
SERIAL NUMBER
PC800-8 - 50001
and up
PC800LC-8 - 50001 and up
HYDRAULIC EXCAVATOR
Unsafe use of this machine may cause serious injury or
death. Operators and maintenance personnel must read
this manual before operating or maintaining this
machine. This manual should be kept inside the cab for
reference and periodically reviewed by all personel who
will come into contact with the machine.
Operation &
Maintenance Manual
UEAM005400
WARNING

FOREWORD
11

FOREWORD FOREWORD
1-2
FOREWORD 1
This manual provides rules and guidelines which will help you use this machine safely and effectively. The pre-
cautions in this manual must be followed at all times when performing operation and maintenance. Most accidents
are caused by the failure to follow fundamental safety rules for the operation and maintenance of machines. Acci-
dents can be prevented by knowing beforehand conditions that may cause a hazard when performing operation
and maintenance.
WARNING
Before beginning operation or maintenance, operators and maintenance personnel must always observe
the following points.
Read this manual thoroughly and understand its contents fully.
Read the safety messages and safety labels given in this manual carefully so that they should be under-
stood fully.
Keep this manual at the storage location for the Operation and Maintenance Manual given below so that
all personnel involved in working on the machine can consult it periodically.
In case this manual should be lost or damaged, immediately contact Komatsu or your Komatsu distributor
to obtain a new copy.
When you sell the machine, make sure that this manual should be provided to the new owner together
with the machine.
In this manual, measurements are expressed in international standard units (SI). For the reference pur-
pose, weight units used in the past are also displayed in ( ).
Storage location for the Operation and Maintenance Manual:
magazine box on the left side of the operator's seat.

FOREWORD SAFETY INFORMATION
1-3
SAFETY INFORMATION 1
To enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to the
machine to give explanations of situations involving potential hazards and of the methods of avoiding such situa-
tions.
Signal words
The following signal words are used to inform you that there is a potential hazardous situation that may lead to per-
sonal injury or damage.
In this manual and on machine labels, the following signal words are used to express the potential level of hazard.
.
Example of safety message using signal word
WARNING
When standing up from the operator's seat, always place the lock lever in the LOCK position.
If you accidentally touch the control levers when they are not locked, this may cause a serious injury or
death.
Other signal words
In addition to the above, the following signal words are used to indicate precautions that should be followed to pro-
tect the machine or to give information that is useful to know.
Indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, could result in death
or serious injury.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury. This word is used also to alert against unsafe practices that may
cause property damage.
NOTICE This word is used for precautions that must be taken to avoid actions which could shorten
the life of the machine.
REMARKS This word is used for information that is useful to know.
DANGER
WARNING
CAUTION

SAFETY INFORMATION FOREWORD
1-4
qSafety labels
Safety labels are affixed to the machine to inform the operator or maintenance worker on the spot when carrying
out operation or maintenance of the machine that may involve hazard.
This machine uses “Safety labels using words“ and “Safety labels using pictograms“ to indicate safety procedures.
Example of safety label using words
Safety labels using pictogram
Safety pictograms use a picture to express a level of hazard-
ous condition equivalent to the signal word. These safety pic-
tograms use pictures in order to let the operator or
maintenance worker understand the level and type of hazard-
ous condition at all times.
Safety pictograms show the type of hazardous condition at the
top or left side, and the method of avoiding the hazardous con-
dition at the bottom or right side. In addition, the type of haz-
ardous condition is displayed inside a triangle and the method
of avoiding the hazardous condition is shown inside a circle.
Komatsu cannot predict every circumstance that might involve a potential hazard in operation and maintenance.
Therefore, the safety messages in this manual and on the machine may not include all possible safety precau-
tions.
If any procedures or actions not specifically recommended or allowed in this manual are used, it is your responsi-
bility to take the necessary steps to ensure safety.
In no event should you engage in prohibited uses or actions described in this manual.
The explanations, values, and illustrations in this manual were prepared based on the latest information available
at that time. Continuing improvements in the design of this machine can lead to changes in detail which may not
be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information of
your machine or for questions regarding information in this manual.
The numbers in circles in the illustrations correspond to the numbers in ( ) in the text. (For example: 1-> (1))
Part No.
Part No.

FOREWORD SAFETY INFORMATION
1-5
Noise emission levels 1
Two labels indicating the machine noise level are affixed on the
machine.
qSound pressure level at the operator’s station, measured
according to ISO6396 (Dynamic test method, simulated
working cycle).
qSound power level emitted by the machine, measured
according to ISO 6395 (Dynamic test method, simulated
working cycle). This is the guaranteed value as specified
in European directive 2000/14/EC.
73
108

SAFETY INFORMATION FOREWORD
1-6
Vibration levels 1
When used for its intended purpose, levels of vibration for the
earth-moving machine transmitted from the operator’s seat are
lower than or equal to the tested vibrations for the relative
machinery class in compliance with ISO 7096.
The actual acceleration value for the hands and arms is less
than or equal to 2.5 m/s². The actual acceleration value for the
body is less than or equal to 0.5 m/s².
These values were determined using a representative machine
and measured during the typical operating condition indicated
below according to the measurement procedures that are
defined in the standards ISO 2631/1 and ISO 5349.
Operating condition:
Excavating (Digging-loading-rotating-unloading-rotating)
Guide to Reduce Vibration Levels on Machine 1
The following guides can help an operator of this machine to
reduce the whole body vibration levels:
1. Use the correct equipment and attachments.
2. Maintain the machine according to this manual
qTension of crawler (for crawler machines)
qBrake and steering systems
qControls, hydraulic system and linkages
3. Keep the terrain where the machine is working and travel-
ing in good condition
qRemove any large rocks or obstacles
qFill any ditches and holes
qSite manager should provide machine operators with
machine and schedule time to maintain terrain condi-
tions
4. Use a seat that meets ISO 7096 and keep the seat main-
tained and adjusted
qAdjust the seat and suspension for the weight and size
of the operator
qWear seat belt
qInspect and maintain the seat suspension and adjust-
ment mechanisms
5. Steer, brake, accelerate, and move the attachment levers
and pedals slowly so that the machine moves smoothly

FOREWORD SAFETY INFORMATION
1-7
6. Adjust the machine speed and travel path to minimize the
vibration level
qWhen pushing with bucket or blade, avoid sudden
loading; load gradually
qDrive around obstacles and rough terrain conditions
qSlow down when it is necessary to go over rough ter-
rain
qMake the curve radius of traveling path as large as
possible
qTravel at low speed when traveling around sharp
curves
7. Minimize vibrations for long work cycle or long distance
traveling
qReduce speed to prevent bounce
qTransport machines long distances between worksites
8. The following guidelines can be effective to minimize risks
of low back pain
qOperate the machine only when you are in good
health.
qProvide breaks to reduce long periods of sitting in the
same posture
qDo not jump down from the cab or machine
qDo not repeatedly handle and lift loads

SAFETY INFORMATION FOREWORD
1-8
BREAKING-IN THE NEW MACHINE 1
NOTICE
Your Komatsu machine has been thoroughly adjusted and tested before shipment from the factory. How-
ever, operating the machine under full load before breaking the machine in can adversely affect the perfor-
mance and shorten the machine life.
Be sure to break in the machine for the initial 100 hours (as indicated on the service meter).
Make sure that you fully understand the content of this manual, and pay careful attention to the following points
when breaking in the machine.
qRun the engine at idle for 15 seconds after starting it. During this time, do not operate the control levers or fuel
control dial.
qIdle the engine for 5 minutes after starting it up.
qAvoid operation with heavy loads or at high speeds.
qImmediately after starting the engine, avoid sudden starts, sudden acceleration, unnecessary sudden stops,
and sudden changes in direction.

FOREWORD INTRODUCTION
1-9
INTRODUCTION 1
This Komatsu machine is designed to be used mainly for the following work:
qDigging work
qLeveling work
qDitching work
qLoading work
qDemolition work
See the section “RECOMMENDED APPLICATIONS (3-121)“ for further details.
DIRECTIONS OF MACHINE 1
In this manual, the terms front, rear, left, and right refer to the travel direction as seen from the operator's seat
when the operator's seat is facing the front and the sprocket is at the rear of the machine.
(A) Front (E) Operator's seat
(B) Rear (F) Sprocket
(C) Left
(D) Right

INTRODUCTION FOREWORD
1-10
VISIBILITY FROM OPERATOR'S SEAT 1
The visibility standards (ISO 5006) for this machine require a view shown in the diagram below.
PROXIMITY VISIBILITY 1
The visibility of this machine in the area 1 m from the outside surface of the machine at a height of 1.5 m is shown
in the diagram below. The hatched area (A) shows the area where the view is blocked by part of the machine when
mirrors or other aids to visibility are installed as standard. Please be fully aware that there are places that cannot
be seen when operating the machine.
12M CIRCUMFERENCE VISIBILITY 1
The visibility at a radius of 12 m from the machine is as shown in the diagram below. The hatched areas (B) show
the areas where the view is blocked when mirrors or other aids to visibility are installed as standard. Please be
fully aware that there are places that cannot be seen when operating the machine.

FOREWORD PRODUCT INFORMATION
1-11
PRODUCT INFORMATION 1
When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following
items.
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE 1
On the bottom right of the operator's cab
The design of the nameplate differs according to the territory.
EPA REGULATIONS, ENGINE NUMBER PLATE 1
On the upper side of the engine cylinder head cover.
EPA: Environmental Protection Agency, U.S.A.

PRODUCT INFORMATION FOREWORD
1-12
SERVICE METER LOCATION 1
On top of the machine monitor
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR 1
Machine serial No.
Engine serial No.
Product Identification Number
Manufacturers name:
Address:
Distributor
Address
Phone
KOMATSU UK Ltd.
Durham Road
Birtley
Chester-Le street
County Durham DH32QX
United Kingdom

FOREWORD PRODUCT INFORMATION
1-13
MACHINE SERIAL PLATE
205-00-K1291
MODEL
SERIAL No.
MANUFACT. YEAR
MASS
ENGINE POWER
Product Identification Number
kg
kW
MANUFACTURER Manufactured by Komatsu UK Ltd.
for Komatsu Ltd.,Tokyo,Japan
MODEL
SERIAL
MANUFACTURING YEAR
WEIGHT
ENGINE POWER
MANUFACTURER
Komatsu UK Ltd, Birtley, Co Durham, United Kingdom
PRODUCT
IDENTIFICATION
NUMBER

PRODUCT INFORMATION FOREWORD
1-14

CONTENTS
1-15
CONTENTS
FOREWORD
FOREWORD......................................................................................................................................................... 1-2
SAFETY INFORMATION...................................................................................................................................... 1-3
Noise emission levels ................................................................................................................................. 1-5
Vibration levels............................................................................................................................................ 1-6
GUIDE TO REDUCE VIBRATION LEVELS ON MACHINE.............................................................. 1-6
BREAKING-IN THE NEW MACHINE ......................................................................................................... 1-8
INTRODUCTION................................................................................................................................................... 1-9
DIRECTIONS OF MACHINE...................................................................................................................... 1-9
VISIBILITY FROM OPERATOR'S SEAT.................................................................................................. 1-10
PROXIMITY VISIBILITY.................................................................................................................. 1-10
12M CIRCUMFERENCE VISIBILITY .............................................................................................. 1-10
PRODUCT INFORMATION................................................................................................................................1-11
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE ..................................... 1-11
EPA REGULATIONS, ENGINE NUMBER PLATE................................................................................... 1-11
SERVICE METER LOCATION................................................................................................................. 1-12
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR................................................................... 1-12
MACHINE SERIAL PLATE....................................................................................................................... 1-13
SAFETY
SAFETY INFORMATION...................................................................................................................................... 2-2
SAFETY LABELS................................................................................................................................................. 2-4
LOCATION OF SAFETY LABELS.............................................................................................................. 2-5
SAFETY LABELS ....................................................................................................................................... 2-6
SAFETY INFORMATION.................................................................................................................................... 2-13
SAFETY MACHINE OPERATION...................................................................................................................... 2-22
STARTING ENGINE................................................................................................................................. 2-22
OPERATION............................................................................................................................................. 2-23
TRANSPORTATION................................................................................................................................. 2-29
BATTERY ................................................................................................................................................. 2-30
TOWING................................................................................................................................................... 2-31
LIFTING OBJECTS WITH BUCKET......................................................................................................... 2-32
SAFETY MAINTENANCE INFORMATION........................................................................................................ 2-33

CONTENTS
1-16
OPERATION
MACHINE VIEW ILLUSTRATIONS .....................................................................................................................3-2
OVERALL MACHINE VIEW........................................................................................................................3-2
CONTROLS AND GAUGES.......................................................................................................................3-3
DETAILED CONTROLS AND GAUGES..............................................................................................................3-5
MONITORING SYSTEM.............................................................................................................................3-5
BASIC OPERATION OF MACHINE MONITOR ................................................................................3-6
EMERGENCY MONITORS ...............................................................................................................3-9
CAUTION MONITORS ....................................................................................................................3-11
BASIC CHECK MONITORS............................................................................................................3-13
METER DISPLAY PORTION...........................................................................................................3-15
MONITOR SWITCHES PORTION ..................................................................................................3-19
SWITCHES...............................................................................................................................................3-34
CONTROL LEVERS AND PEDALS .........................................................................................................3-41
SUN ROOF...............................................................................................................................................3-43
OPENING ........................................................................................................................................3-44
CLOSING.........................................................................................................................................3-44
WINDSHIELD ...........................................................................................................................................3-44
EMERGENCY EXIT FROM OPERATOR'S CAB......................................................................................3-49
DOOR LOCK ............................................................................................................................................3-49
CAP WITH LOCK......................................................................................................................................3-49
HOT AND COOL BOX..............................................................................................................................3-51
MAGAZINE BOX.......................................................................................................................................3-51
ASHTRAY.................................................................................................................................................3-51
AIR CONDITIONER CONTROLS.............................................................................................................3-52
AIR CONDITIONER CONTROL PANEL .........................................................................................3-52
METHOD OF OPERATION.............................................................................................................3-56
USE AIR CONDITIONER WITH CARE...........................................................................................3-62
AIR CONDITIONER MAINTENANCE .............................................................................................3-63
OTHER FUNCTIONS ......................................................................................................................3-63
RADIO-CASSETTE (OPTION)-65
USE RADIO WITH CARE................................................................................................................3-65
AUXILIARY ELECTRIC POWER..............................................................................................................3-66
24V POWER SOURCE ...................................................................................................................3-66
12V POWER SOURCE ...................................................................................................................3-67
FUSE ........................................................................................................................................................3-68
CIRCUIT BREAKER .................................................................................................................................3-69
CONTROLLER .........................................................................................................................................3-70
TOOL BOX................................................................................................................................................3-70
GREASE PUMP........................................................................................................................................3-71
METHOD OF USE...........................................................................................................................3-71
PRECAUTIONS WHEN USING ......................................................................................................3-72
SUPPLYING GREASE ....................................................................................................................3-73
ACCUMULATOR HANDLING...................................................................................................................q-75
RELEASING PRESSURE IN THE CONTROL CIRCUIT ON MACHINES EQUIPPED WITH AN
ACCUMULATOR............................................................................................................................ Q-75

CONTENTS
1-17
MACHINE OPERATIONS AND CONTROLS..................................................................................................... 3-76
BEFORE STARTING ENGINE................................................................................................................. 3-76
WALK-AROUND CHECKS..............................................................................................................3-76
CHECKS BEFORE STARTING....................................................................................................... 3-77
ADJUSTMENT................................................................................................................................. 3-85
SEAT BELT ..................................................................................................................................... 3-88
OPERATIONS BEFORE STARTING ENGINE ............................................................................... 3-89
STARTING ENGINE................................................................................................................................. 3-92
AFTER STARTING ENGINE.................................................................................................................... 3-95
ENGINE WARM UP......................................................................................................................... 3-95
HYDRAULIC EQUIPMENT WARM UP........................................................................................... 3-97
OPERATION AFTER COMPLETION OF WARM-UP OPERATION............................................. 3-102
STOPPING THE ENGINE ...................................................................................................................... 3-104
MACHINE OPERATION......................................................................................................................... 3-105
PREPARATIONS FOR MOVING THE MACHINE......................................................................... 3-105
MOVING MACHINE FORWARD................................................................................................... 3-106
MOVING MACHINE BACKWARD................................................................................................. 3-107
STOPPING MACHINE................................................................................................................... 3-108
STEERING THE MACHINE.................................................................................................................... 3-109
STEERING .................................................................................................................................... 3-109
SWINGING ............................................................................................................................................. 3-111
WORK EQUIPMENT CONTROLS AND OPERATIONS........................................................................ 3-112
WORKING MODE................................................................................................................................... 3-114
PROHIBITED OPERATIONS ................................................................................................................. 3-115
GENERAL OPERATION INFORMATION .............................................................................................. 3-117
TRAVELING ON SLOPES...................................................................................................................... 3-118
ESCAPE FROM MUD............................................................................................................................. 3-120
TRACK ON ONE SIDE STUCK..................................................................................................... 3-120
TRACKS ON BOTH SIDES STUCK.............................................................................................. 3-120
RECOMMENDED APPLICATIONS........................................................................................................ 3-121
BACKHOE WORK......................................................................................................................... 3-121
DITCHING WORK......................................................................................................................... 3-121
LOADING WORK .......................................................................................................................... 3-121
BUCKET REPLACEMENT ..................................................................................................................... 3-122
REPLACEMENT............................................................................................................................ 3-122
PARKING MACHINE.............................................................................................................................. 3-124
MACHINE INSPECTION AFTER DAILY WORK.................................................................................... 3-126
LOCKING................................................................................................................................................ 3-126
TRANSPORTATION......................................................................................................................................... 3-127
TRANSPORTATION PROCEDURE.......................................................................................................3-127
LIFTING MACHINE................................................................................................................................. 3-127
SHIPPING MACHINE INFORMATION...................................................................................................3-129
TRANSPORTATION POSTURE ............................................................................................................ 3-130
PROCEDURE FOR INCREASING OR REDUCING TRACK FRAME GAUGE...................................... 3-135

CONTENTS
1-18
COLD WEATHER OPERATION ......................................................................................................................3-137
COLD WEATHER OPERATION INFORMATION...................................................................................3-137
FUEL AND LUBRICANTS .............................................................................................................3-137
COOLING SYSTEM COOLANT....................................................................................................3-137
BATTERY ......................................................................................................................................3-138
MONITOR......................................................................................................................................3-138
AFTER DAILY WORK COMPLETION....................................................................................................3-140
AFTER COLD WEATHER SEASON ......................................................................................................3-140
LONG TERM STORAGE..................................................................................................................................3-141
BEFORE STORAGE...............................................................................................................................3-141
DURING STORAGE ...............................................................................................................................3-142
AFTER STORAGE..................................................................................................................................3-142
STARTING MACHINE AFTER LONG-TERM STORAGE ......................................................................3-142
TROUBLES AND ACTIONS ............................................................................................................................3-143
RUNNING OUT OF FUEL ......................................................................................................................3-143
PHENOMENA THAT ARE NOT FAILURES...........................................................................................3-144
TOWING THE MACHINE .......................................................................................................................3-144
SEVERE JOB CONDITION ....................................................................................................................3-145
DISCHARGED BATTERY ......................................................................................................................3-146
BATTERY REMOVAL AND INSTALLATION ................................................................................3-146
BATTERY CHARGES ...................................................................................................................3-147
STARTING ENGINE WITH BOOSTER CABLES..........................................................................3-148
OTHER TROUBLE .................................................................................................................................3-150
ELECTRICAL SYSTEM.................................................................................................................3-150
CHASSIS.......................................................................................................................................3-151
ENGINE.........................................................................................................................................3-152
ELECTRONIC CONTROL SYSTEM ............................................................................................. 3-154
POINT OF CONTACT TO TELEPHONE WHEN ERROR OCCURS............................................3-155
MAINTENANCE
MAINTENANCE INFORMATION .........................................................................................................................4-2
OUTLINE OF SERVICE........................................................................................................................................4-4
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC......................................................4-4
OIL.....................................................................................................................................................4-4
FUEL..................................................................................................................................................4-5
COOLANT AND WATER FOR DILUTION.........................................................................................4-5
GREASE............................................................................................................................................4-6
CARRYING OUT KOWA (KOMATSU OIL WEAR ANALYSIS).........................................................4-6
STORING OIL AND FUEL.................................................................................................................4-7
FILTERS............................................................................................................................................4-7
ELECTRIC SYSTEM MAINTENANCE .......................................................................................................4-8
EXPLANATION OF LUBRICATION CHART DECAL .................................................................................q-9