Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator GALEO PC2000-8, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Hydraulic Excavator GALEO PC2000-8 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 7,121 pages
File Format: PDF
Language: English
GEN00060-12 – Hydraulic Excavator PC2000-8 Field Assembly Manual.pdf
SEN01607-06 – Hydraulic Excavator GALEO PC2000-8 Shop Manual.pdf
SEN01607-19 – Hydraulic Excavator PC2000-8 Shop Manual.pdf
TEN00133-05 – Hydraulic Mining Shovel PC2000-8 Operation & Maintenance Manual.pdf
TEN00236-03 – Hydraulic Mining Shovel PC2000-8 Operation & Maintenance Manual.pdf
TEN00323-01 – Hydraulic Mining Shovel PC2000-8 Operation & Maintenance Manual.pdf
TEN00324-01 – Hydraulic Mining Shovel PC2000-8 Operation & Maintenance Manual.pdf
TEN00365-01 – Hydraulic Mining Shovel PC2000-8 Operation & Maintenance Manual.pdf
TEN00366-01 – Hydraulic Mining Shovel PC2000-8 Operation & Maintenance Manual.pdf
TEN00430-04 – Hydraulic Mining Shovel PC2000-8 Operation & Maintenance Manual.pdf
TEN00431-05 – Hydraulic Mining Shovel PC2000-8 Operation & Maintenance Manual.pdf
MAIN SECTIONS
GEN00060-12 – Hydraulic Excavator PC2000-8 Field Assembly Manual…2
COVER…2
FOREWORD…3
CONTENTS…4
SPECIFICATIONS…7
PRECAUTIONS FOR FIELD ASSEMBLY…8
DISPOSAL OF REMOVED PARTS…9
ASSEMBLY PROCEDURE, ASSEMBLY EQUIPMENT AND SCHEDULE…10
FLOWCHART OF MAIN ASSEMBLY PROCEDURE…11
KIT LAYOUT DIAGRAM…12
TRANSPORTATION POSTURES…13
LIST OF PARTS SENT INDIVIDUALLY…22
TOOLS AND EQUIPMENT TO BE USED FOR LOCAL ASSEMBLY…43
TIGHTENING TORQUE…45
COATING MATERIALS LIST…49
A. ASSEMBLY OF CHASSIS…51
<ASSEMBLY OF UNDERCARRIAGE>…0
A- 1. Assembly of track frame assembly and center frame assembly…52
A- 2. Installation of idler cushion cylinder piping…55
A- 3. Installation of travel motor piping…56
A- 4. Installation of travel motor cover…57
A- 5. Filling swing circle with grease…60
A- 6. Assembly of revolving frame assembly and undercarriage…61
A- 7. Installation of swing machinery (front) assembly (27t)…63
A- 7. Installation of swing motor (front) assembly (32t)…63
A- 8. Connection of swivel joint piping…64
A- 9. Connection of swing circle grease piping…66
<ASSEMBLY OF UPPER STRUCTURE>…0
A-10. Installation of hydraulic tank assembly…67
A-11. Installation of fuel tank assembly…72
A-12. Connection of fuel tank assembly piping and wiring…73
A-13. Installation of cab base assembly…75
A-14. Installation of emergency escape ladder…77
A-15. Installation of left floor assembly…78
A-16. Connection of cab base assembly piping…82
A-17. Connection of cab base assembly wiring…85
A-18. Connection of left floor assembly heater piping…91
<COUPLING OF POWER CONTAINER>…0
A-19. Connection of left floor assembly wiring…92
A-20. Installation of tail pipe…94
A-21. Installation of power container assembly…95
A-22. Connection of suction piping…97
A-23. Connection of oil cooler piping and pump drain piping…99
A-24. Connection of fan motor drain piping…100
A-25. Installation of suction unit undercover…101
A-26. Connection of delivery piping…102
A-27. Connection of pilot piping and fan motor piping…104
A-28. Connection of power container assembly fuel piping…105
A-29. Connection of power container assembly air conditioner piping…107
A-30. Connection of power container assembly heater piping…108
A-31. Connection of power container assembly wiring…109
<COUPLING OF OPERATOR'S CAB>…0
A-32. Installation of operator's cab assembly…113
A-33. Installation of rotary lamp (if equipped)…117
A-34. Installation of ORBCOMM antenna (if equipped)…119
A-35. Connection of operator's cab assembly wiring…120
A-36. Connection of operator's cab assembly hydraulic piping…123
A-37. Connection of operator's cab assembly window washer hose…125
A-38. Connection of operator's cab assembly air conditioner piping…126
A-39. Connection of operator's cab assembly heater piping…127
A-40. Installation of operator's cab rear floor assembly…128
A-41. Installation of handrail around operator's cab…129
<COUPLING OF EXTERIOR PARTS, COUNTERWEIGHT, ETC.>…0
A-42. Installation of track frame ladder…130
A-43. Installation of power container side catwalk assemblies (right and left)…131
A-44. Installation of right floor assembly, grease can cover assembly and center floor…132
A-45. Installation of fuel tank right catwalk assembly…134
A-46. Installation of fuel tank front catwalk assembly…135
A-47. Adjustment of exterior parts clearance…136
A-48. Connection of grease reel piping…137
A-49. Installation of access ladder assembly…138
A-50. Installation of counterweight assembly…139
A-51. Installation of deformation preventing stoppers for catwalk assemblies (left and right) on the side of power container…140
A-52. Installation of handrail on counterweight…141
A-53. Installation of handrail clamps…142
A-54. Connection of fuel cut wire…145
A-55. Connection of drain piping under power container…146
A-56. Connection of battery wiring…147
<STARTING OF ENGINE AND INSPECTION AND SERVICING PROCEDURES>…0
A-57. Setting of hydraulic tank strainer…148
A-58. Starting engine, checking oil and coolant levels, bleeding air from each part, and adjusting track…149
A-59. Permanent tightening of swing circle bolt…164
A-60. Parts to be touched up after field assembly (chassis side)…165
A-61. Connection of engine heater connection port…166
A-62. Installation of optional harness…169
A-63. Installation of rear lamps…170
A-64. Installation of rear camera…175
A-65. Connection of emergency stop switch (if equipped) (at the right below container)178…184
A-66. Connection of emergency stop switch (if equipped) (at the left side of ladder)…185
A-67. Installation of engine oil and PTO oil pipings…186
A-68. Installation of coolant piping…187
A-69. Installation of guard bracket (if equipped)…188
C. ASSEMBLY OF BACKHOE…189
<COUPLING OF BOOM>…0
C- 1. Installation of boom cylinder…190
C- 2. Installation of boom cylinder hoses (Serial No. 20095 and up)…192
C- 3. Assembly of boom sub assembly…193
C- 4. Installation of boom assembly…198
C- 5. Installation of boom cylinder head side…200
<COUPLING OF ARM>…0
C- 6. Installation of hoses between boom and chassis…202
C- 7. Installation of arm assembly…203
C- 8. Installation of arm cylinder…206
C- 9. Connection of hoses between boom and arm…207
C-10. Connection of auto grease piping…208
C-11. Connection of wiring between boom and chassis…209
<COUPLING OF BUCKET>…0
C-12. Installation of bucket assembly…210
C-13. Installation of bucket link…213
C-14. Bleeding air from cylinders…215
C-15. Parts to be touched up after field assembly (work equipment side)…218
C-16. Bleeding air from auto grease circuit…219
LS. ASSEMBLY OF LOADING SHOVEL WORK EQUIPMENT…223
LS- 1. Installation of arm cylinder bottom parts…224
LS- 2. Installation of boom cylinder to machine body…225
LS- 3. Installation of boom cylinder hoses…227
LS- 4. Installation of boom cylinder piping…228
LS- 5. Installation of boom assembly…229
LS- 6. Installation of boom cylinder head pins…230
LS- 7. Installation of hose between machine body and boom…231
LS- 8. Installation of bucket cylinder assembly…233
LS- 9. Installation of arm assembly…234
LS-10. Installation of arm cylinder assembly…235
LS-11. Installation of hoses between boom and arm…236
LS-12. Installation of bucket cylinder hoses…237
LS-13. Installation of grease feed hose of bucket cylinder…238
LS-14. Installation of bucket assembly…240
LS-15. Installation of arm cylinder junction hoses…241
LS-16. Installation of bottom dump hose and grease feed hose between arm and bucket…242
LS-17. Installation of arm dump cushion (proximity switch)…243
M. INSPECTION AND SERVICING PROCEDURES AFTER ASSEMBLY…245
M- 1. Inspection of oil levels and coolant levels and using standard of fuel and lubricant…246
M- 2. Flushing of hydraulic circuit…248
M- 3. Releasing residual pressure from hydraulic circuit…251
M- 4. Releasing residual pressure from HIC circuit and check of gas pressure in HIC accumulator…252
M- 5. Charging air conditioner with refrigerant…253
M- 6. Installed angles of mirrors…256
M- 7. Installed angles of lights…259
VHMS CONTOROLLER INITIAL SETTING PROCEDURE…263
PC2000-8 Main pump air bleeding check sheet…281
FIELD ASSEMBLY INSPECTION REPORT (BACKHOE)…283
FIELD ASSEMBLY INSPECTION REPORT (LOADING SHOVEL)…309
SEN01607-06 – Hydraulic Excavator GALEO PC2000-8 Shop Manual…334
COVER…334
00 INDEX AND FOREWORD…0
INDEX…336
COMPOSITION OF SHOP MANUAL…337
TABLE OF CONTENTS…339
FOREWORD AND GENERAL INFORMATION…352
SAFETY NOTICE…353
HOW TO READ THE SHOP MANUAL…358
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD…360
HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT…362
HANDLING OF CONNECTORS NEWLY USED FOR ENGINES…371
HOW TO READ ELECTRIC WIRE CODE…374
PRECAUTIONS WHEN CARRYING OUT OPERATION…377
METHOD OF DISASSEMBLING AND CONNECTING PUSH-PULL TYPE COUPLER…380
STANDARD TIGHTENING TORQUE TABLE…383
CONVERSION TABLE…387
01 SPECIFICATION…0
SPECIFICATION AND TECHNICAL DATA…394
SPECIFICATION DRAWINGS…395
SPECIFICATIONS…399
WEIGHT TABLE…403
TABLE OF FUEL, COOLANT AND LUBRICANTS…409
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD…0
ENGINE AND COOLING SYSTEM…412
RADIATOR AND OIL COOLER…413
PTO…415
PTO LUBRICATION SYSTEM…417
POWER TRAIN…419
POWER TRAIN…420
SWING MACHINERY…422
SWING CIRCLE…424
FINAL DRIVE…425
SPROCKET…427
UNDERCARRIAGE AND FRAME…430
TRACK FRAME…431
IDLER…433
CARRIER ROLLER…435
TRACK ROLLER…436
TRACK SHOE…437
HIC SYSTEM…442
HYDRAULIC SYSTEM, PART 1…445
HYDRAULIC PIPING DRAWING…448
HYDRAULIC TANK…452
OIL COOLER…454
LINE OIL FILTER…456
PILOT OIL FILTER…457
RETURN OIL FILTER…458
MOTOR DRAIN OIL FILTER…459
PUMP DRAIN FILTER…460
ACCUMULATOR…461
TRAVEL JUNCTION VALVE…463
SOLENOID VALVE…466
HYDRAULIC CYLINDER…474
GREASING SYSTEM…478
CENTER SWIVEL JOINT…488
HYDRAULIC SYSTEM, PART 2…491
CONTROL VALVE…492
ELECTRONIC OLSS SYSTEM…520
SWING MOTOR…524
COOLING FAN MOTOR (FOR RADIATOR AND OIL COOLER)…532
COOLING FAN PUMP…538
HYDRAULIC SYSTEM, PART 3…553
TRAVEL MOTOR…554
HYDRAULIC PUMP…566
PPC VALVE…584
VARIABLE BACK PRESSURE VALVE…596
SUCTION SELECTOR VALVE…600
PPC CUT-OFF VALVE…604
WORK EQUIPMENT…613
WORK EQUIPMENT…614
DIMENSIONS OF WORK EQUIPMENT…618
CAB AND ITS ATTACHMENTS…623
AIR CONDITIONER PIPING…624
CAB…625
ELECTRICAL SYSTEM…629
ENGINE CONTROL…630
ELECTRICAL CONTROL SYSTEM…641
MONITOR SYSTEM…683
SENSOR…711
ORBCOMM TERMINAL…723
20 STANDARD VALUE TABLE…0
STANDARD SERVICE VALUE TABLE…725
STANDARD SERVICE VALUE TABLE FOR TESTING, ADJUSTING, AND TROUBLESHOOTING…726
STANDARD SERVICE VALUE TABLE FOR CHASSIS…727
30 TESTING AND ADJUSTING…0
TESTING AND ADJUSTING, PART 1…739
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING…741
MEASURING ENGINE SPEED…744
TESTING AIR BOOST PRESSURE…745
TESTING EXHAUST TEMPERATURE…746
TESTING EXHAUST COLOR…747
ADJUSTING VALVE CLEARANCE…749
TESTING COMPRESSION PRESSURE…751
TESTING BLOW-BY PRESSURE…753
TESTING ENGINE OIL PRESSURE…754
HANDLING FUEL SYSTEM PARTS…755
RELEASING RESIDUAL PRESSURE IN FUEL SYSTEM…755
TESTING FUEL PRESSURE…756
TESTING LEAKAGE FROM PRESSURE LIMITER AND RETURN RATE FROM INJECTOR…757
BLEEDING AIR FROM FUEL CIRCUIT…760
BLEEDING AIR FROM FUEL CIRCUIT (LOW-GRADE FUEL SPECIFICATION)…764
TESTING FUEL SYSTEM FOR LEAKAGE…766
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION …768
TESTING AND ADJUSTING, PART 2…770
TESTING SWING CIRCLE BEARING CLEARANCE…772
REMAINING PRESSURE RELIEF FROM HIC CIRCUIT…773
GAS FILLING IN HIC CIRCUIT ACCUMULATOR…773
BLEEDING AIR FROM HIC CIRCUIT AND SUPPLYING OIL TO IT…775
TESTING AND ADJUSTING TRACK SHOE TENSION…777
TESTING AND ADJUSTING WORK EQUIPMENT, SWING AND TRAVEL CIRCUIT OIL PRESSURES…780
TESTING AND ADJUSTING CONTROL CIRCUIT OIL PRESSURE (OUTPUT PRESSURE OF SELF PRESSURE REDUCING VALVE)…784
TESTING AND ADJUSTING MAIN PUMP CONTROL SIGNAL…786
MEASURING FAN SPEED…789
MEASURING FAN PUMP EPC SOLENOID CURRENT…790
MEASURING FAN PUMP EPC SOLENOID VALVE OUTPUT PRESSURE…791
OIL PRESSURE MEASURING POINTS FOR PUMP DISCHARGE PRESSURE OR JET SENSOR DIFFERENTIAL PRESSURE…793
MEASURING PPC VALVE OUTPUT PRESSURE…794
MEASURING SOLENOID VALVE OUTLET PRESSURE…798
ADJUSTING WORK EQUIPMENT AND SWING PPC VALVE…800
TESTING AND ADJUSTING TRAVEL DEVIATION…801
TESTING WORK EQUIPMENT HYDRAULIC DRIFT CAUSE PORTION…803
TESTING OIL LEAKAGE…804
REMAINING PRESSURE RELIEF FROM HYDRAULIC CIRCUIT…807
AIR BLEEDING FROM EACH COMPONENT…808
AIR BLEEDING FROM PPC CIRCUIT…813
TESTING AND ADJUSTING AUTO GREASE SYSTEM…815
ADJUSTING MIRRORS…818
TESTING AND ADJUSTING, PART 3…821
SPECIAL FUNCTIONS OF MACHINE MONITOR…822
HANDLING CONTROLLER VOLTAGE CIRCUIT…877
TESTING AND ADJUSTING, PART 4…879
VHMS CONTROLLER INITIAL SETTING PROCEDURE…880
PRECAUTIONS FOR REPLACING VHMS CONTROLLER…897
PREPARATION WORK FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM…903
PM-CLINIC SERVICE…905
MEASUREMENT PROCEDURE…906
40 TROUBLESHOOTING…0
FAILURE CODE TABLE AND FUSE LOCATIONS…921
FAILURE CODE TABLE…922
BEFORE CARRYING OUT TROUBLESHOOTING OF ELECTRICAL SYSTEM…929
GENERAL INFORMATION ON TROUBLESHOOTING…935
POINTS TO REMEMBER WHEN TROUBLESHOOTING…936
SEQUENCE OF EVENTS IN TROUBLESHOOTING…937
CHECKS BEFORE TROUBLESHOOTING…938
CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING…939
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…943
T-ADAPTER BOX AND T-ADAPTER TABLE…976
TROUBLESHOOTING BY FAILURE CODE, PART 1…980
FAILURE CODE [0410KA] FUEL LV. SENSOR FAILURE…982
FAILURE CODE [0410KB] FUEL LV. SENSOR FAILURE…983
FAILURE CODE [6014NX] HYDRAULIC OIL FILTER CLOGGING (OR CHANGE OF VHMS-LED DISPLAY FROM n5 TO 51)…984
FAILURE CODE [8800ZG] AUTO GREASE ABNORMALLY…985
FAILURE CODE [7@HAZL] VR1/P1F RELIEF PRESS ABNORMALITY…986
FAILURE CODE [7@HBZL] VL1/P1R RELIEF PRESS ABNORMALITY…987
FAILURE CODE [7@HCZL] VR2/P2F RELIEF PRESS ABNORMALITY…988
FAILURE CODE [7@HDZL] VL2/P2R RELIEF PRESS ABNORMALITY…989
FAILURE CODE [AA10NX] AIRCLEANER CLOGGING…991
FAILURE CODE [AB00KE] CHARGE VOLTAGE LOW…993
FAILURE CODE [aB00KE] LOW UPPER ALR CHARGE VOLTAGE (OR CHANGE OF VHMS-LED DISPLAY FROM n9 TO 11)…995
FAILURE CODE [B@BAZG] ENG. OIL PRESS. LOW…997
FAILURE CODE [B@BAZK] ENG. OIL LEVEL LOW…999
FAILURE CODE [B@BCNS] ENG. WATER OVERHEAT…1001
FAILURE CODE [B@BCZK] ENG. WATER LVL LOW…1003
FAILURE CODE [B@CBNS] PTO OIL OVERHEAT (OR CHANGE OF VHMS-LED DISPLAY FROM n5 TO 61)…1005
FAILURE CODE [B@HANS] HYDR. OIL OVERHEAT…1007
FAILURE CODE [B@HAZK] LOW HYDRAULIC OIL LEVEL (OR CHANGE OF VHMS-LED DISPLAY FROM n5 TO 52)…1009
FAILURE CODE [CA111] ECM CRITICAL INTERNAL FAILURE…1011
FAILURE CODE [CB111] ECM CRITICAL INTERNAL FAILURE…1013
FAILURE CODE [CA115] ENG. NE AND BKUP SPEED SENS ERROR…1015
FAILURE CODE [CB115] ENG. NE AND BKUP SPEED SENS ERROR…1016
FAILURE CODE [CA122] CHG AIR PRESS SENSOR HIGH ERROR…1017
FAILURE CODE [CA123] CHG AIR PRESS SENSOR LOW ERROR…1019
FAILURE CODE [CA131] THROTTLE SENSOR HIGH ERROR…1020
FAILURE CODE [CA132] THROTTLE SENSOR LOW ERROR…1022
FAILURE CODE [CA135] ENG OIL PRESS SENSOR HIGH ERROR…1023
FAILURE CODE [CA141] ENG OIL PRESS SENSOR LOW ERROR…1025
FAILURE CODE [CA144] COOLANT TEMP SENS HIGH ERROR…1026
FAILURE CODE [CA145] COOLANT TEMP SENS LOW ERROR…1028
FAILURE CODE [CA153] CHG AIR TEMP SENSOR HIGH ERROR…1030
FAILURE CODE [CA154] CHG AIR TEMP SENSOR LOW ERROR…1032
FAILURE CODE [CA187] SENS SUPPLY 2 VOLT LOW ERROR…1034
FAILURE CODE [CB187] SENS SUPPLY 2 VOLT LOW ERROR…1034
FAILURE CODE [CA212] ENG OIL TEMP SENSOR HIGH ERROR…1035
FAILURE CODE [CA213] ENG OIL TEMP SENSOR LOW ERROR…1037
TROUBLESHOOTING BY FAILURE CODE, PART 2…1039
FAILURE CODE [CA221] AMBIENT PRESS SENS HIGH ERROR…1041
FAILURE CODE [CA222] AMBIENT PRESS SENS LOW ERROR…1043
FAILURE CODE [CA227] SENS SUPPLY 2 VOLT HIGH ERROR…1044
FAILURE CODE [CB227] SENS SUPPLY 2 VOLT HIGH ERROR…1046
FAILURE CODE [CA234] ENG OVER SPEED…1048
FAILURE CODE [CA238] NE SPEED SENS SUPPLY VOLT ERROR…1049
FAILURE CODE [CB238] NE SPEED SENS SUPPLY VOLT ERROR…1051
FAILURE CODE [CA263] FUEL TEMP SENSOR HIGH ERROR…1053
FAILURE CODE [CB263] FUEL TEMP SENSOR HIGH ERROR…1055
FAILURE CODE [CA265] FUEL TEMP SENSOR LOW ERROR…1056
FAILURE CODE [CB265] FUEL TEMP SENSOR LOW ERROR…1056
FAILURE CODE [CA271] IMV/PCV1 SHORT ERROR…1057
FAILURE CODE [CB271] IMV/PCV1 SHORT ERROR…1059
FAILURE CODE [CA272] IMV/PCV1 OPEN ERROR…1061
FAILURE CODE [CB272] IMV/PCV1 OPEN ERROR…1063
FAILURE CODE [CA273] PCV2 SHORT ERROR…1065
FAILURE CODE [CB273] PCV2 SHORT ERROR…1067
FAILURE CODE [CA274] PCV2 OPEN ERROR…1069
FAILURE CODE [CB274] PCV2 OPEN ERROR…1071
FAILURE CODE [CA322] INJ #1(L#1) OPEN/SHORT ERROR…1072
FAILURE CODE [CA323] INJ #5(L#5) OPEN/SHORT ERROR…1074
FAILURE CODE [CA324] INJ #3(L#3) OPEN/SHORT ERROR…1076
FAILURE CODE [CA325] INJ #6(L#6) OPEN/SHORT ERROR…1078
FAILURE CODE [CA331] INJ #2(L#2) OPEN/SHORT ERROR…1080
FAILURE CODE [CA332] INJ #4(L#4) OPEN/SHORT ERROR…1082
FAILURE CODE [CA342] CALIBRATION CODE INCOMPATIBILITY…1084
FAILURE CODE [CB342] CALIBRATION CODE INCOMPATIBILITY…1084
FAILURE CODE [CA351] INJECTORS DRIVE CIRCUIT ERROR…1085
FAILURE CODE [CB351] INJECTORS DRIVE CIRCUIT ERROR…1087
FAILURE CODE [CA352] SENS SUPPLY 1 VOLT LOW ERROR…1089
FAILURE CODE [CB352] SENS SUPPLY 1 VOLT LOW ERROR…1089
FAILURE CODE [CA386] SENS SUPPLY 1 VOLT HIGH ERROR…1090
FAILURE CODE [CB386] SENS SUPPLY 1 VOLT HIGH ERROR…1092
FAILURE CODE [CA441] BATTERY VOLTAGE LOW ERROR…1094
FAILURE CODE [CB441] BATTERY VOLTAGE LOW ERROR…1094
FAILURE CODE [CA442] BATTERY VOLTAGE HIGH ERROR…1095
FAILURE CODE [CB442] BATTERY VOLTAGE HIGH ERROR…1095
FAILURE CODE [CA449] RAIL PRESS VERY HIGH ERROR…1096
FAILURE CODE [CB449] RAIL PRESS VERY HIGH ERROR…1096
TROUBLESHOOTING BY FAILURE CODE, PART 3…1098
FAILURE CODE [CA451] RAIL PRESS SENSOR HIGH ERROR…1100
FAILURE CODE [CB451] RAIL PRESS SENSOR HIGH ERROR…1102
FAILURE CODE [CA452] RAIL PRESS SENSOR LOW ERROR…1104
FAILURE CODE [CB452] RAIL PRESS SENSOR LOW ERROR…1104
FAILURE CODE [CA553] RAIL PRESS HIGH ERROR…1105
FAILURE CODE [CB553] RAIL PRESS HIGH ERROR…1106
FAILURE CODE [CA554] RAIL PRESS SENSOR IN RANGE ERROR…1107
FAILURE CODE [CB554] RAIL PRESS SENSOR IN RANGE ERROR…1107
FAILURE CODE [CA559] RAIL PRESS LOW ERROR…1108
FAILURE CODE [CB559] RAIL PRESS LOW ERROR…1112
FAILURE CODE [CA689] ENG NE SPEED SENSOR ERROR…1116
FAILURE CODE [CB689] ENG NE SPEED SENSOR ERROR…1118
FAILURE CODE [CA691] INTAKE AIR TEMP SENS HIGH ERROR…1120
FAILURE CODE [CA692] INTAKE AIR TEMP SENS LOW ERROR…1122
FAILURE CODE [CA731] ENG BKUP SPEED SENS PHASE ERROR…1123
FAILURE CODE [CB731] ENG BKUP SPEED SENS PHASE ERROR…1123
FAILURE CODE [CA757] ALL PERSISTENT DATA LOST ERROR…1124
FAILURE CODE [CB757] ALL PERSISTENT DATA LOST ERROR…1124
FAILURE CODE [CA778] ENG BKUP SPEED SENSOR ERROR…1125
FAILURE CODE [CB778] ENG BKUP SPEED SENSOR ERROR…1127
FAILURE CODE [CA781] CEN COMMUNICATION ERROR…1129
FAILURE CODE [CB781] CEN COMMUNICATION ERROR…1131
FAILURE CODE [CA1117] PERSISTENT DATA LOST ERROR…1132
FAILURE CODE [CB1117] PERSISTENT DATA LOST ERROR…1132
FAILURE CODE [CA1257] HARNESS KEY ERROR…1133
FAILURE CODE [CB1257] HARNESS KEY ERROR…1134
FAILURE CODE [CB1548] INJ #7(R#1) OPEN/SHORT ERROR…1135
FAILURE CODE [CB1549] INJ #8(R#2) OPEN/SHORT ERROR…1137
FAILURE CODE [CB1551] INJ #10(R#4) OPEN/SHORT ERROR…1139
FAILURE CODE [CB1552] INJ #11(R#5) OPEN/SHORT ERROR…1141
FAILURE CODE [CB1553] INJ #12(R#6) OPEN/SHORT ERROR…1143
FAILURE CODE [CB1622] INJ #9(R#3) OPEN/SHORT ERROR…1145
FAILURE CODE [CA1633] KOMNET DATA LINK TIME OUT ERROR…1147
FAILURE CODE [CA2185] THROT SENS SUP VOLT HIGH ERROR…1149
FAILURE CODE [CA2186] THROT SENS SUP VOLT LOW ERROR…1151
FAILURE CODE [CA2249] RAIL PRESS VERY LOW ERROR…1152
FAILURE CODE [CB2249] RAIL PRESS VERY LOW ERROR…1152
FAILURE CODE [CA2555] GRID HEATER RELAY VOLT LOW ERROR…1153
FAILURE CODE [CA2556] GRID HEATER RELAY VOLT HIGH ERROR…1154
TROUBLESHOOTING BY FAILURE CODE, PART 4…1157
FAILURE CODE [D110KB] BATTERY RELAY DRIVE S/C…1159
FAILURE CODE [D163KB] FLASH LIGHT RELAY S/C…1161
FAILURE CODE [D195KA] STEP LIGHT RELAY DISC…1163
FAILURE CODE [D195KY] STEP LIGHT RELAY S/C…1165
FAILURE CODE [D1E9KB] WIPER DRIVE RELAY 1 S/C…1167
FAILURE CODE [D1EAKB] WIPER DRIVE RELAY 2 S/C…1169
FAILURE CODE [D1EBKB] LOWER WIPER BRAKE RELAY SHORT CIRCUIT…1171
FAILURE CODE [D1ECKB] UPPER WIPER BRAKE RELAY SHORT CIRCUIT…1173
FAILURE CODE [DA22KK] PUMP 1 SOLENOID POWER LOW ERROR…1175
FAILURE CODE [dA22KK] PUMP 2 SOLENOID POWER LOW ERROR…1177
FAILURE CODE [DA25KP] PUMP 1 SENS SUPPLY VOL LOW ERROR…1179
FAILURE CODE [dA25KP] PUMP 2 SENS SUPPLY VOL LOW ERROR…1181
FAILURE CODE [DA26KP] 5V SENSOR 2 POWER ABNORMALITY…1183
FAILURE CODE [DA29KQ] PUMP 1 MODEL SELECT ABNORMALITY…1185
FAILURE CODE [dA29KQ] PUMP 2 MODEL SELECT ABNORMALITY…1187
FAILURE CODE [DA2RMC] CAN DISCON (PUMP 1 CON DETECTED)…1189
FAILURE CODE [dA2RMC] CAN DISCON (PUMP 2 CON DETECTED)…1191
FAILURE CODE [DA2TMC] PUMP COMM. ECM CHILD ABNORMALITY…1193
FAILURE CODE [DBB0KK] VHMS SOURCE VOLTAGE ERROR (OR CHANGE OF VHMS-LED DISPLAY FROM n9 TO 01)…1195
FAILURE CODE [DBB0KQ] VHMS CONNECTOR MISMATCH (OR CHANGE OF VHMS-LED DISPLAY FROM nF TO 11)…1197
FAILURE CODE [DBB5KP] VHMS 5V SOURCE SYS ERROR (OR CHANGE OF VHMS-LED DISPLAY FROM n9 TO 04)…1199
FAILURE CODE [DBB6KP] VHMS 24V SOURCE SYS ERROR (OR CHANGE OF VHMS-LED DISPLAY FROM n9 TO 02)…1201
FAILURE CODE [DBBQKR] KOM-NET/C ERROR (OR CHANGE OF VHMS-LED DISPLAY FROM n8 TO 02)…1203
FAILURE CODE [DGE5KX] AMBIENT AIR TEMP SENSOR FAILURE (OR CHANGE OF VHMS-LED DISPLAY FROM n4 TO 01)…1205
FAILURE CODE [DGH2KB] HYDR. OIL TEMP. SENSOR S/C…1207
FAILURE CODE [DGT3KZ] PTO TEMP SENSOR FAILURE (OR CHANGE OF VHMS-LED DISPLAY FROM n5 TO 01)…1209
TROUBLESHOOTING BY FAILURE CODE, PART 5…1212
FAILURE CODE [DGT5KA] EXHAUST TEMP. SENSOR LBF FAILURE (OR CHANGE OF VHMS-LED DISPLAY FROM n3 TO 12)…1214
FAILURE CODE [dGT5KA] EXHAUST TEMP. SENSOR LBR FAILURE (OR CHANGE OF VHMS-LED DISPLAY FROM n3 TO 22)…1216
FAILURE CODE [DGT5KB] EXHAUST TEMP. SENSOR LBF FAILURE (OR CHANGE OF VHMS-LED DISPLAY FROM n3 TO 11)…1218
FAILURE CODE [dGT5KB] EXHAUST TEMP. SENSOR LBR FAILURE (OR CHANGE OF VHMS-LED DISPLAY FROM n3 TO 21)…1220
FAILURE CODE [DGT6KA] EXHAUST TEMP. SENSOR RBF FAILURE (OR CHANGE OF VHMS-LED DISPLAY FROM n3 TO 24)…1222
FAILURE CODE [dGT6KA] EXHAUST TEMP. SENSOR RBR FAILURE (OR CHANGE OF VHMS-LED DISPLAY FROM n3 TO 26)…1224
FAILURE CODE [DGT6KB] EXHAUST TEMP. SENSOR RBF FAILURE (OR CHANGE OF VHMS-LED DISPLAY FROM n3 TO 23)…1226
FAILURE CODE [dGT6KB] EXHAUST TEMP. SENSOR RBR FAILURE (OR CHANGE OF VHMS-LED DISPLAY FROM N3 TO 26)…1228
FAILURE CODE [DH25KX] VR1/P1F J/S DIF PRESS SENSOR ABNORMALITY…1230
FAILURE CODE [DH26KX] VL1/P1R J/S DIF PRESS SENSOR ABNORMALITY…1232
FAILURE CODE [DH27KX] VR2/P2F J/S DIF PRESS SENSOR ABNORMALITY…1234
FAILURE CODE [DH28KX] VL2/P2R J/S DIF PRESS SENSOR ABNORMALITY…1236
FAILURE CODE [DHE5KB] BLOWBY PRES. SENSOR FAILURE (OR CHANGE OF VHMS-LED DISPLAY FROM n3 TO 32)…1238
FAILURE CODE [DHE5KY] BLOWBY PRES. SENSOR FAILURE (OR CHANGE OF VHMS-LED DISPLAY FROM n3 TO 31)…1240
FAILURE CODE [DHH2KA] HYDRAULIC OIL FILTER SENSOR FAILURE (OR CHANGE OF VHMS-LED DISPLAY FROM n5 TO 53)…1242
FAILURE CODE [DHPEKX] VR1/P1F PUMP P. SENSOR ABNORMALITY…1243
FAILURE CODE [DHPFKX] VL1/P1R PUMP P. SENSOR ABNORMALITY…1245
FAILURE CODE [DHPGKX] VR2/P2F PUMP P. SENSOR ABNORMALITY…1247
FAILURE CODE [DHPHKX] VL2/P2R PUMP P. SENSOR ABNORMALITY…1249
FAILURE CODE [DHPSKX] AUTO GREASE PRESS SENSOR ABNORMALITY…1251
FAILURE CODE [DHPTKX] FAN(RAD) PUMP P. SENSOR OPEN CIRCUIT…1253
FAILURE CODE [DHPUKX] FAN(O/C) PUMP P. SENSOR OPEN CIRCUIT…1255
FAILURE CODE [DHS3KX] ARM DIG PPC PRESS SENSOR ABNORMALITY…1257
FAILURE CODE [DHS4KX] BUCKET CURL PPC PRESS SENSOR ABNORMALITY…1259
FAILURE CODE [DHS8KX] BOOM RAISE PPC PRESS SENSOR ABNORMALITY…1261
FAILURE CODE [DHS9KX] BOOM LOWER PPC PRESS SENSOR ABNORMALITY…1263
FAILURE CODE [DHSAKX] SWING RIGHT PPC PRESS SENSOR ABNORMALITY…1265
FAILURE CODE [DHSBKX] SWING LEFT PPC PRESS SENSOR ABNORMALITY…1267
FAILURE CODE [DHSCKX] ARM DUMP PPC PRESS SENSOR ABNORMALITY…1269
FAILURE CODE [DHSDKX] BUCKET DUMP PPC PRESS SENSOR ABNORMALITY…1271
TROUBLESHOOTING BY FAILURE CODE, PART 6…1274
FAILURE CODE [DUM3KB] AUTO GREASE CAUTION LED SHORT CIRCUIT…1276
FAILURE CODE [DUM4KB] FAN REVERSE LED SHORT CIRCUIT…1277
FAILURE CODE [DV20KB] TRAVEL ALARM S/C…1278
FAILURE CODE [DW41KA] SWING PRIORITY SOL OPEN CIRCUIT…1280
FAILURE CODE [DW41KB] SWING PRIORITY SOL SHORT CIRCUIT…1282
FAILURE CODE [DW45KA] SWING BRAKE SOL. DISC…1284
FAILURE CODE [DW45KB] SWING BRAKE SOL. S/C…1287
FAILURE CODE [DW91KA] STRAIGHT-TRAVEL SOL. DISC…1289
FAILURE CODE [DW91KB] STRAIGHT-TRAVEL SOL. S/C…1291
FAILURE CODE [DW4XKA] BUCKET CURL HI CANCEL SOL. DISC…1293
FAILURE CODE [DW4XKB] BUCKET CURL HI CANCEL SOL. S/C…1294
FAILURE CODE [DW7BKA] FAN MOTOR (RAD) REVERSE SOL OPEN CIRCUIT…1295
FAILURE CODE [DW7BKB] FAN REVERSE SOL. S/C…1297
FAILURE CODE [DW7HKA] FAN MOTOR(O/C) REVERSE SOL OPEN CIRCUIT…1299
FAILURE CODE [DW7HKB] FAN MOTOR(O/C) REVERSE SOL SHORT CIRCUIT…1301
FAILURE CODE [DWA3KA] ARM THROTTLE VALVE/L SOL OPEN CIRCUIT…1303
FAILURE CODE [DWA3KB] ARM THROTTLE VALVE/L SOL SHORT CIRCUIT…1305
FAILURE CODE [DWA4KA] ARM THROTTLE VALVE/R SOL OPEN CIRCUIT…1307
FAILURE CODE [DWA4KB] ARM THROTTLE VALVE/R SOL SHORT CIRCUIT…1309
FAILURE CODE [DWA5KA] AUTO GREASE SOL OPEN CIRCUIT…1311
FAILURE CODE [DWA5KB] AUTO GREASE SOL SHORT CIRCUIT…1313
FAILURE CODE [DWA6KA] BOOM THROTTLE VALVE SOL OPEN CIRCUIT…1314
FAILURE CODE [DWA6KB] BOOM THROTTLE VALVE SOL SHORT CIRCUIT…1316
FAILURE CODE [DWK0KA] 2-STAGE RELIEF SOL. DISC…1318
FAILURE CODE [DWK0KB] 2-STAGE RELIEF SOL. S/C…1320
FAILURE CODE [DWK2KA] BACK PRESS COMP VALVE SOL OPEN CIRCUIT…1321
FAILURE CODE [DWK2KB] BACK PRESS COMP VALVE SOL SHORT CIRCUIT…1322
TROUBLESHOOTING BY FAILURE CODE, PART 7…1324
FAILURE CODE [DWN5KA] FAN (RAD) PUMP EPC SOL OPEN CIRCUIT…1326
FAILURE CODE [DWN5KB] FAN (RAD) PUMP EPC SOL SHORT CIRCUIT…1328
FAILURE CODE [DWNCKA] FAN (O/C) PUMP EPC SOL OPEN CIRCUIT…1329
FAILURE CODE [DWNCKB] FAN (O/C) PUMP EPC SOL SHORT CIRCUIT…1330
FAILURE CODE [DXAAKA] P1F EPC SOL DISC…1331
FAILURE CODE [DXAAKB] P1F EPC SOL S/C…1333
FAILURE CODE [DXABKA] P1R PUMP EPC SOL. DISC…1335
FAILURE CODE [DXABKB] P1R PUMP EPC SOL. S/C…1337
FAILURE CODE [DXACKA] P2F PUMP EPC SOL. DISC…1339
FAILURE CODE [DXACKB] P2F PUMP EPC SOL. S/C…1341
FAILURE CODE [DXADKA] P2R PUMP EPC SOL. DISC…1343
FAILURE CODE [DXADKB] P2R PUMP EPC SOL. S/C…1345
FAILURE CODE [DY2CKB] WASHER DRIVE S/C…1347
FAILURE CODE [DY20MA] LOW WIPER WORKING ABNORMALITY…1349
FAILURE CODE [DY2FMA] UPPER WIPER WORKING ABNORMALITY…1352
FAILURE CODE [F@BBZL] HIGH BLOWBY PRESSURE (OR CHANGE OF VHMS-LED DISPLAY FROM n3 TO 38)…1355
FAILURE CODE [F@BYNR] VERY HIGH LBF CYL EXHAUST TEMP (OR CHANGE OF VHMS-LED DISPLAY FROM n3 TO 62)…1357
FAILURE CODE [f@BYNR] VERY HIGH LBR CYL EXHAUST TEMP (OR CHANGE OF VHMS-LED DISPLAY FROM n3 TO 72)…1359
FAILURE CODE [F@BYNS] HIGH LBF CYL EXHAUST TEMP (OR CHANGE OF VHMS-LED DISPLAY FROM n3 TO 61)…1361
FAILURE CODE [f@BYNS] HIGH LBR CYL EXHAUST TEMP (OR CHANGE OF VHMS-LED DISPLAY FROM n3 TO 71)…1363
FAILURE CODE [F@BZNR] VERY HIGH RBF CYL EXHAUST TEMP (OR CHANGE OF VHMS-LED DISPLAY FROM n3 TO 82)…1365
FAILURE CODE [f@BZNR] VERY HIGH RBR CYL EXHAUST TEMP (OR CHANGE OF VHMS-LED DISPLAY FROM n3 TO 92)…1367
FAILURE CODE [F@BZNS] HIGH RBF CYL EXHAUST TEMP (OR CHANGE OF VHMS-LED DISPLAY FROM n3 TO 81)…1369
FAILURE CODE [f@BZNS] HIGH RBR CYL EXHAUST TEMP (OR CHANGE OF VHMS-LED DISPLAY FROM n3 TO 91)…1371
FAILURE CODE [LA10ZL] RAD SYSTEM FAN PUMP RELIEF PRESSURE HIGH ERROR …1373
FAILURE CODE [LA20ZL] O/C SYSTEM PUMP RELIEF PRESSURE HIGH ERROR…1374
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)…1377
CONTENTS OF TROUBLESHOOTING TABLE…1381
E-1 WHEN STARTING SWITCH IS TURNED ON, MACHINE MONITOR DISPLAYS NOTHING…1383
E-2 WHEN STARTING SWITCH TURNED ON (BEFORE STARTING ENGINE), BASIC CHECK ITEM LIGHTS UP…1385
E-3 ENGINE DOES NOT START (ENGINE DOES NOT TURN)…1387
E-4 AUTO-DECELERATOR DOES NOT OPERATE…1391
E-5 AUTOMATIC WARM-UP SYSTEM DOES NOT OPERATE…1392
E-6 PREHEATER DOES NOT WORK…1393
E-7 WHOLE WORK EQUIPMENT, SWING OPERATION AND MACHINE TRAVEL OPERATION ARE DISABLED…1395
E-8 MACHINE PUSH-UP FUNCTION DOES NOT WORK…1397
E-9 BOOM SHOCKLESS FUNCTION CANNOT BE RELEASED…1399
E-10 MACHINE MONITOR DOES NOT DISPLAY SOME ITEMS…1401
E-11 CONTENTS OF DISPLAY BY MACHINE MONITOR ARE DIFFERENT FROM APPLICABLE MACHINE…1402
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING…1403
E-13 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY…1404
E-14 FUEL LEVEL GAUGE DOES NOT INDICATE NORMALLY…1405
E-15 SWING LOCK MONITOR DOES NOT INDICATE NORMALLY…1407
E-16 MACHINE MONITOR DISPLAY ANYTHING EVEN WHEN OPERATED ON MONITOR SWITCH SECTION…1409
E-17 WIPER DOES NOT WORK…1410
E-18 MONITORING FUNCTION DOES NOT DISPLAY "TRAVEL" NORMALLY…1416
E-19 TRAVEL ALARM DOES NOT SOUND…1418
E-20 ALL OF ROOM LAMP, HEADLAMP AND WORKING LAMP DO NOT LIGHT UP…1419
E-21 AIR CONDITIONER DOES NOT WORK…1423
E-22 STEP LIGHT DOES NOT LIGHT UP OR GOES OFF…1425
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)…1430
BEFORE TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS…1432
TABLE OF FAILURE MODES AND CAUSES…1436
INFORMATION IN TROUBLESHOOTING TABLE…1438
H-1 SPEED OR POWER OF WHOLE WORK EQUIPMENT, TRAVEL, AND SWING IS LOW…1439
H-2 ENGINE SPEED LOWERS REMARKABLY OR ENGINE STALLS…1441
H-3 WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT MOVE…1442
H-4 ABNORMAL NOISE COMES FROM AROUND HYDRAULIC PUMP…1444
H-5 SPEED OR POWER OF BOOM IS LOW…1445
H-6 SPEED OR POWER OF ARM IS LOW…1447
H-7 SPEED OR POWER OF BUCKET IS LOW…1448
H-8 BOOM DOES NOT MOVE…1449
H-9 ARM DOES NOT MOVE…1449
H-10 BUCKET DOES NOT MOVE…1449
H-11 HYDRAULIC DRIFT OF WORK EQUIPMENT IS LARGE…1450
H-12 TIME LAG OF WORK EQUIPMENT IS LARGE…1451
H-13 HEAVY LIFT FUNCTION DOES NOT WORK OR IS NOT RESET…1452
H-14 MACHINE PUSH-UP FUNCTION DOES NOT WORK OR IS NOT RESET…1452
H-15 BOOM SHOCKLESS FUNCTION DOES NOT WORK OR IS NOT RESET…1452
H-16 MACHINE GRADUALLY DEVIATES DURING TRAVELING…1453
H-17 MACHINE DEVIATES EXCESSIVELY WHEN STARTED TO TRAVEL…1456
H-18 MACHINE DEVIATES EXCESSIVELY DURING MULTIPLE OPERATIONS…1457
H-19 TRAVELING SPEED OR POWER IS LOW…1457
H-20 TRAVEL SYSTEM DOES NOT MOVE (ONLY ONE SIDE)…1458
H-21 UPPER STRUCTURE DOES NOT SWING…1459
H-22 SWING SPEED OR ACCELERATION IS LOW…1461
H-23 IN COMPOUND OPERATION OF WORK EQUIPMENT, SWING SPEED OR ACCELERATION IS LOW…1463
H-24 UPPER STRUCTURE OVERRUNS REMARKABLY WHEN IT STOPS SWINGING…1464
H-25 LARGE SHOCK IS MADE WHEN UPPER STRUCTURE STOPS SWINGING…1465
H-26 LARGE ABNORMAL SOUND COMES FROM WHEN UPPER STRUCTURE STOPS SWINGING…1466
H-27 HYDRAULIC DRIFT OF WORK EQUIPMENT IS LARGE IN SWING OPERATION…1467
H-28 FAN ROTATION IS ABNORMAL (LARGE NOISE OR VIBRATION OF FANS, OR FAN OVERHEATING)…1468
TROUBLESHOOTING OF MECHANICAL SYSTEM (S-MODE)…1470
METHOD OF USING TROUBLESHOOTING CHARTS…1472
S-1 STARTING PERFORMANCE IS POOR…1475
S-2 ENGINE DOES NOT START…1476
S-3 ENGINE DOES NOT PICK UP SMOOTHLY…1479
S-4 ENGINE STOPS DURING OPERATIONS…1480
S-5 ENGINE DOES NOT ROTATE SMOOTHLY…1481
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)…1482
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)…1484
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)…1485
S-9 OIL BECOMES CONTAMINATED QUICKLY…1486
S-10 FUEL CONSUMPTION IS EXCESSIVE…1487
S-11 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)…1488
S-12 OIL PRESSURE DROPS…1489
S-13 OIL LEVEL RISES (ENTRY OF COOLANT OR FUEL)…1490
S-14 COOLANT TEMPERATURE BECOMES TOO HIGH (OVERHEATING)…1491
S-15 ABNORMAL NOISE IS MADE…1492
S-16 VIBRATION IS EXCESSIVE…1493
50 DISASSEMBLY AND ASSEMBLY…0
GENERAL INFORMATION ON DISASSEMBLY AND ASSEMBLY…1495
HOW TO READ THIS MANUAL…1496
COATING MATERIALS LIST…1498
SPECIAL TOOL LIST…1501
SKETCHES OF SPECIAL TOOLS…1504
ENGINE AND COOLING SYSTEM (12V140E-3)…1510
REMOVAL AND INSTALLATION OF POWER CONTAINER ASSEMBLY…1511
REMOVAL AND INSTALLATION OF ENGINE, PTO AND HYDRAULIC PUMP ASSEMBLY…1516
REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY…1528
REMOVAL AND INSTALLATION OF AFTERCOOLER ASSEMBLY…1529
REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY…1531
REMOVAL AND INSTALLATION OF FUEL COOLER ASSEMBLY…1532
REMOVAL AND INSTALLATION OF COOLING ASSEMBLY…1533
REMOVAL AND INSTALLATION OF FAN MOTOR ASSEMBLY…1537
REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY…1538
ENGINE (12V140E-3) …1542
REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP ASSEMBLY…1543
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY…1546
REMOVAL AND INSTALLATION OF FUEL INJECTOR…1560
REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL…1571
REMOVAL AND INSTALLATION OF ENGINE REAR SEAL…1574
POWER TRAIN…1580
REMOVAL AND INSTALLATION OF PTO ASSEMBLY…1581
DISASSEMBLY AND ASSEMBLY OF PTO ASSEMBLY…1582
REMOVAL AND INSTALLATION OF SWING MOTOR AND SWING MACHINERY ASSEMBLY…1586
DISASSEMBLY AND ASSEMBLY OF SWING MACHINERY ASSEMBLY…1588
REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLY…1598
REMOVAL AND INSTALLATION OF FINAL DRIVE ASSEMBLY…1599
DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY…1601
UNDERCARRIAGE AND FRAME…1614
REMOVAL AND INSTALLATION OF TRACK SHOE ASSEMBLY…1615
REMOVAL AND INSTALLATION OF IDLER ASSEMBLY…1617
DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY…1618
DISASSEMBLY AND ASSEMBLY OF IDLER ADJUST CYLINDER ASSEMBLY…1620
REMOVAL AND INSTALLATION OF IDLER CUSHION CYLINDER ASSEMBLY…1621
DISASSEMBLY AND ASSEMBLY OF IDLER CUSHION CYLINDER ASSEMBLY…1622
REMOVAL AND INSTALLATION OF TRACK ROLLER ASSEMBLY…1623
DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY…1624
REMOVAL AND INSTALLATION OF CARRIER ROLLER ASSEMBLY…1626
DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY…1627
REMOVAL AND INSTALLATION OF REVOLVING FRAME ASSEMBLY…1631
REMOVAL AND INSTALLATION OF COUNTERWEIGHT ASSEMBLY…1634
HYDRAULIC SYSTEM…1636
REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY…1637
REMOVAL AND INSTALLATION OF HYDRAULIC PUMP ASSEMBLY…1640
REMOVAL AND INSTALLATION OF HYDRAULIC PUMP INPUT SHAFT OIL SEAL…1645
REMOVAL AND INSTALLATION OF CONTROL VALVE ASSEMBLY…1646
DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY…1653
REMOVAL AND INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY…1657
DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY…1658
REMOVAL AND INSTALLATION OF SWING MOTOR ASSEMBLY…1659
REMOVAL AND INSTALLATION OF TRAVEL MOTOR ASSEMBLY…1660
DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY…1661
DISASSEMBLY AND ASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY…1663
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY…1664
WORK EQUIPMENT…1672
REMOVAL AND INSTALLATION OF BUCKET CYLINDER ASSEMBLY…1673
REMOVAL AND INSTALLATION OF BUCKET ASSEMBLY…1675
REMOVAL AND INSTALLATION OF ARM CYLINDER…1677
REMOVAL AND INSTALLATION OF ARM ASSEMBLY…1679
REMOVAL AND INSTALLATION OF BOOM CYLINDER ASSEMBLY…1681
REMOVAL AND INSTALLATION OF BOOM ASSEMBLY…1683
CAB AND ITS ATTACHMENTS…1686
REMOVAL AND INSTALLATION OF OPERATOR CAB ASSEMBLY…1687
REMOVAL AND INSTALLATION OF OPERATOR CAB GLASS (ADHESION GLASS)…1690
REMOVAL AND INSTALLATION OF OPERATOR CAB (ASSEMBLY-TYPE)…1697
REMOVAL AND INSTALLATION OF CAB BASE ASSEMBLY…1698
ELECTRICAL SYSTEM …1701
REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY…1702
REMOVAL AND INSTALLATION OF MONITOR ASSEMBLY…1706
REMOVAL AND INSTALLATION OF ENGINE CONTROLLER ASSEMBLY…1707
REMOVAL AND INSTALLATION OF PUMP CONTROLLER ASSEMBLY…1708
REMOVAL AND INSTALLATION OF VHMS CONTROLLER ASSEMBLY…1709
REMOVAL AND INSTALLATION OF ORBCOMM TERMINAL ASSEMBLY FOR VHMS…1709
90 DIAGRAMS AND DRAWINGS…0
HYDRAULIC DIAGRAMS AND DRAWINGS…1711
HYDRAULIC CIRCUIT DIAGRAM…1712
ELECTRICAL DIAGRAMS AND DRAWINGS…1714
ELECTRICAL CIRCUIT DIAGRAM (1/2)…1716
ELECTRICAL CIRCUIT DIAGRAM (2/2)…1717
CONNECTOR ARRANGEMENT DIAGRAM…1718
SEN01607-19 – Hydraulic Excavator PC2000-8 Shop Manual…1721
COVER…1721
00 Index and foreword…0
Index…1723
Composition of shop manual…1724
Table of contents…1726
Foreword and general information…1739
Safety notice…1740
How to read the shop manual…1745
Explanation of terms for maintenance standard…1747
Handling of electric equipment and hydraulic component…1749
Handling of connectors newly used for engines…1758
How to read electric wire code…1761
Precautions when carrying out operation…1764
Method of disassembling and connecting push-pull type coupler…1767
Standard tightening torque table…1770
Conversion table…1774
01 Specification…0
Specification and technical data…1781
Specification drawings…1782
Specifications…1786
Weight table…1790
Table of fuel, coolant and lubricants…1796
10 Structure, function and maintenance standard…0
Engine and cooling system…1799
Radiator and oil cooler…1800
PTO…1802
PTO lubrication system…1804
Power train…1807
Power train…1808
Swing machinery…1810
Swing circle…1812
Final drive…1814
Sprocket…1816
Undercarriage and frame…1819
Track frame…1820
Idler…1822
Carrier roller…1824
Track roller…1825
Track shoe…1826
HIC system…1831
Hydraulic system, Part 1…1839
Hydraulic piping drawing…1842
Hydraulic tank…1846
Oil cooler…1848
Line oil filter…1850
Pilot oil filter…1851
Return oil filter…1852
Motor drain oil filter…1853
Pump drain filter…1854
Accumulator…1855
Travel junction valve…1857
Solenoid valve…1860
Hydraulic cylinder…1868
Greasing system…1872
Center swivel joint…1882
Hydraulic ladder system…1883
Service center system…1888
Hydraulic system, Part 2…1895
Hydraulic system, Part 2…1896
Control valve…1896
Electronic OLSS system…1924
Swing motor…1928
Cooling fan motor (For radiator and oil cooler)…1936
Cooling fan pump…1942
Hydraulic system, Part 3…1957
Travel motor…1958
Hydraulic pump…1970
PPC valve…1990
Variable back pressure valve…2002
Suction selector valve…2006
PPC cut-off valve…2010
Work equipment…2019
Work equipment…2020
Dimensions of work equipment…2024
Cab and its attachments…2029
Cab and its attachments…2030
Air conditioner piping…2030
Cab…2031
Electrical system…2035
Engine control…2036
Electrical control system…2047
Monitor system…2089
Sensor…2117
ORBCOMM terminal…2129
20 Standard value table…0
Standard service value table…2131
Standard service value table for engine…2132
Standard service value table for chassis (Backhoe specification)…2133
Standard service value table for chassis (Loading shovel specification)…2144
30 Testing and adjusting…0
Testing and adjusting, Part 1…2157
Tools for testing, adjusting, and troubleshooting…2159
Measuring engine speed…2162
Testing air boost pressure…2163
Testing exhaust temperature…2164
Testing exhaust color…2165
Adjusting valve clearance…2167
Testing compression pressure…2169
Testing blow-by pressure…2171
Testing engine oil pressure…2172
Handling fuel system parts…2173
Releasing residual pressure in fuel system…2173
Testing fuel pressure…2174
Reduced cylinder mode operation…2175
No-injection cranking…2175
Testing leakage from pressure limiter and return rate from injector…2176
Bleeding air from fuel circuit…2179
Bleeding air from fuel circuit (lowgrade fuel specification)…2183
Testing fuel system for leakage…2185
Testing and adjusting alternator belt tension…2186
Testing and adjusting air conditioner compressor belt tension…2187
Handling controller high-voltage circuit…2188
Testing and adjusting, Part 2…2191
Testing swing circle bearing clearance…2193
Remaining pressure relief from HIC circuit…2194
Gas filling in HIC circuit accumulator…2195
Bleeding air from HIC circuit and supplying oil to it…2198
Testing and adjusting track shoe tension…2202
Testing and adjusting work equipment, swing and travel circuit oil pressures…2206
Testing and adjusting control circuit oil pressure (output pressure of self pressure reducing valve)…2210
Testing and adjusting main pump control signal…2212
Measuring fan speed…2215
Measuring fan pump EPC solenoid current…2216
Measuring fan pump EPC solenoid valve output pressure…2217
Oil pressure measuring points for pump discharge pressure or jet sensor differential pressure…2219
Measuring PPC valve output pressure…2220
Measuring solenoid valve outlet pressure…2224
Adjusting work equipment and swing PPC valve…2226
Testing and adjusting travel deviation…2227
Testing work equipment hydraulic drift cause portion…2229
Testing oil leakage…2230
Remaining pressure relief from hydraulic circuit…2233
Air bleeding from each component…2234
Testing and adjusting auto grease system…2240
Adjusting mirrors…2243
Testing and adjusting clearance of hydraulic ladder proximity switch…2245
Testing and adjusting position of hydraulic ladder position sensor plate…2247
Testing and adjusting clearance to service arm proximity switch…2248
Testing and adjusting, Part 3…2251
Special functions of machine monitor…2252
Handling controller voltage circuit…2307
Testing and adjusting, Part 4…2309
VHMS controller initial setting procedure…2310
Precautions for replacing VHMS controller…2329
Preparation work for troubleshooting of electrical system…2335
Pm-clinic service…2337
Measurement procedure…2338
40 Troubleshooting…0
Failure code table and fuse locations…2357
Failure code table…2358
Before carrying out troubleshooting of electrical system…2365
General information on troubleshooting…2373
Points to remember when troubleshooting…2374
Sequence of events in troubleshooting…2375
Checks before troubleshooting…2376
Classification and procedures of troubleshooting…2377
Connection table for connector pin numbers…2381
T- branch box and T- branch adapter table…2417
Troubleshooting by failure code, Part 1…2421
Failure code [0410KA] Fuel LV. Sensor Failure…2424
Failure code [0410KB] Fuel LV. Sensor Failure…2426
Failure code [6014NX] Hydraulic Oil Filter Clogging (or change of VHMS-LED display from n5 to 51)…2428
Failure code [8800ZG] Auto grease abnormally…2429
Failure code [7@HAZL] VR1/P1F Relief Press Abnormality…2430
Failure code [7@HBZL] VL1/P1R Relief Press Abnormality…2431
Failure code [7@HCZL] VR2/P2F Relief Press Abnormality…2432
Failure code [7@HDZL] VL2/P2R Relief Press Abnormality…2434
Failure code [AA10NX] Aircleaner Clogging…2436
Failure code [AB00KE] Charge Voltage Low…2438
Failure code [aB00KE] Low Upper ALR Charge Voltage (or change of VHMS-LED display from n9 to 11)…2440
Failure code [B@BAZG] Eng. Oil Press. Low…2442
Failure code [B@BAZK] Eng. Oil Level Low…2444
Failure code [B@BCNS] Eng. Water Overheat…2446
Failure code [B@BCZK] Eng. Water Lvl Low…2448
Failure code [B@CBNS] PTO Oil Overheat (or change of VHMS-LED display from n5 to 61)…2450
Failure code [B@HANS] Hydr. Oil Overheat…2452
Failure code [B@HAZK] Low Hydraulic Oil Level (or change of VHMSLED display from n5 to 52)…2454
Failure code [CA111] ECM Critical Internal Failure…2456
Failure code [CB111] ECM Critical Internal Failure…2458
Failure code [CA115] Eng. Ne and Bkup Speed Sens Error…2460
Failure code [CB115] Eng. Ne and Bkup Speed Sens Error…2461
Failure code [CA122] Chg Air Press Sensor High Error…2462
Failure code [CA123] Chg Air Press Sensor Low Error…2464
Failure code [CA131] Throttle Sensor High Error…2466
Failure code [CA132] Throttle Sensor Low Error…2468
Failure code [CA135] Eng Oil Press Sensor High Error…2470
Failure code [CA141] Eng Oil Press Sensor Low Error…2472
Failure code [CA144] Coolant Temp Sens High Error…2474
Failure code [CA145] Coolant Temp Sens Low Error…2476
Failure code [CA153] Chg Air Temp Sensor High Error…2478
Failure code [CA154] Chg Air Temp Sensor Low Error…2480
Failure code [CA187] Sens Supply 2 Volt Low Error…2482
Failure code [CB187] Sens Supply 2 Volt Low Error…2482
Failure code [CA212] Eng Oil Temp Sensor High Error…2484
Failure code [CA213] Eng Oil Temp Sensor Low Error…2486
Troubleshooting by failure code, Part 2…2489
Failure code [CA221] Ambient Press Sens High Error…2492
Failure code [CA222] Ambient Press Sens Low Error…2494
Failure code [CA227] Sens Supply 2 Volt High Error…2496
Failure code [CB227] Sens Supply 2 Volt High Error…2498
Failure code [CA234] Eng Over Speed…2500
Failure code [CA238] Ne Speed Sens Supply Volt Error…2502
Failure code [CB238] Ne Speed Sens Supply Volt Error…2504
Failure code [CA263] Fuel Temp Sensor High Error…2506
Failure code [CB263] Fuel Temp Sensor High Error…2508
Failure code [CA265] Fuel Temp Sensor Low Error…2509
Failure code [CB265] Fuel Temp Sensor Low Error…2509
Failure code [CA271] IMV/PCV1 Short Error…2510
Failure code [CB271] IMV/PCV1 Short Error…2512
Failure code [CA272] IMV/PCV1 Open Error…2514
Failure code [CB272] IMV/PCV1 Open Error…2516
Failure code [CA273] PCV2 Short Error…2518
Failure code [CB273] PCV2 Short Error…2520
Failure code [CA274] PCV2 Open Error…2522
Failure code [CB274] PCV2 Open Error…2524
Failure code [CA322] Inj #1(L/B#1) Open/Short Error…2526
Failure code [CA323] Inj #5(L/B#5) Open/Short Error…2528
Failure code [CA324] Inj #3(L/B#3) Open/Short Error…2530
Failure code [CA325] Inj #6(L/B#6) Open/Short Error…2532
Failure code [CA331] Inj #2(L/B#2) Open/Short Error…2534
Failure code [CA332] Inj #4(L/B#4) Open/Short Error…2536
Failure code [CA342] Calibration Code Incompatibility…2538
Failure code [CB342] Calibration Code Incompatibility…2538
Failure code [CA351] Injectors Drive Circuit Error…2540
Failure code [CB351] Injectors Drive Circuit Error…2542
Failure code [CA352] Sens Supply 1 Volt Low Error…2544
Failure code [CB352] Sens Supply 1 Volt Low Error…2544
Failure code [CA386] Sens Supply 1 Volt High Error…2546
Failure code [CB386] Sens Supply 1 Volt High Error…2548
Failure code [CA441] Battery Voltage Low Error…2550
Failure code [CB441] Battery Voltage Low Error…2550
Failure code [CA442] Battery Voltage High Error…2551
Failure code [CB442] Battery Voltage High Error…2551
Failure code [CA449] Rail Press Very High Error…2552
Failure code [CB449] Rail Press Very High Error…2552
Troubleshooting by failure code, Part 3…2555
Failure code [CA451] Rail Press Sensor High Error…2558
Failure code [CB451] Rail Press Sensor High Error…2560
Failure code [CA452] Rail Press Sensor Low Error…2562
Failure code [CB452] Rail Press Sensor Low Error…2562
Failure code [CA553] Rail Press High Error…2563
Failure code [CB553] Rail Press High Error…2564
Failure code [CA554] Rail Press Sensor In Range Error…2565
Failure code [CB554] Rail Press Sensor In Range Error…2565
Failure code [CA559] Rail Press Low Error…2566
Failure code [CB559] Rail Press Low Error…2570
Failure code [CA689] Eng Ne Speed Sensor Error…2574
Failure code [CB689] Eng Ne Speed Sensor Error…2576
Failure code [CA691] Intake Air Temp Sens High Error…2578
Failure code [CA692] Intake Air Temp Sens Low Error…2580
Failure code [CA731] Eng Bkup Speed Sens Phase Error…2581
Failure code [CB731] Eng Bkup Speed Sens Phase Error…2581
Failure code [CA757] All Persistent Data Lost Error…2582
Failure code [CB757] All Persistent Data Lost Error…2582
Failure code [CA778] Eng Bkup Speed Sensor Error…2584
Failure code [CB778] Eng Bkup Speed Sensor Error…2586
Failure code [CA781] CEN Communication Error…2588
Failure code [CB781] CEN Communication Error…2590
Failure code [CA1257] Harness Key Error…2592
Failure code [CB1257] Harness Key Error…2593
Failure code [CB1548] Inj #7(R/B#1) Open/Short Error…2594
Failure code [CB1549] Inj #8(R/B#2) Open/Short Error…2596
Failure code [CB1551] Inj #10(R/B#4) Open/Short Error…2598
Failure code [CB1552] Inj #11(R/B#5) Open/Short Error…2600
Failure code [CB1553] Inj #12(R/B#6) Open/Short Error…2602
Failure code [CB1622] Inj #9(R/B#3) Open/Short Error…2604
Failure code [CA1633] KOMNET Data link Time out Error…2606
Failure code [CA2185] Throt Sens Sup Volt High Error…2608
Failure code [CA2186] Throt Sens Sup Volt Low Error…2610
Failure code [CA2249] Rail Press Very Low Error…2611
Failure code [CB2249] Rail Press Very Low Error…2611
Failure code [CA2555] Grid Heater Relay Volt Low Error…2612
Failure code [CA2556] Grid Heater Relay Volt High Error…2614
Troubleshooting by failure code, Part 4…2617
Failure code [D110KB] Battery Relay Drive S/C…2620
Failure code [D163KB] Flash Light Relay S/C…2622
Failure code [D195KA] Step Light Relay Disc…2624
Failure code [D195KY] Step Light Relay S/C…2626
Failure code [D1E9KB] Wiper Drive Relay 1 S/C…2628
Failure code [D1EAKB] Wiper Drive Relay 2 S/C…2630
Failure code [D1EBKB] Lower Wiper Brake Relay Short Circuit…2632
Failure code [D1ECKB] Upper Wiper Brake Relay Short Circuit…2634
Failure code [DA22KK] Pump 1 Solenoid Power Low Error…2636
Failure code [dA22KK] Pump 2 Solenoid Power Low Error…2638
Failure code [DA25KP] Pump 1 Sens Supply Vol Low Error…2640
Failure code [dA25KP] Pump 2 Sens Supply Vol Low Error…2642
Failure code [DA26KP] 5V Sensor 2 Power Abnormality…2644
Failure code [DA29KQ] Pump 1 Model Select Abnormality…2646
Failure code [dA29KQ] Pump 2 Model Select Abnormality…2648
Failure code [DA2RMC] CAN Discon (Pump 1 Con Detected)…2650
Failure code [dA2RMC] CAN Discon (Pump 2 Con Detected)…2652
Failure code [DAFRMC] CAN Discon (Monitor Detected)…2654
Failure code [DA2TMC] Pump Comm. ECM Child Abnormality…2656
Failure code [DBB0KK] VHMS Source Voltage Error (or change of VHMS-LED display from n9 to 01)…2658
Failure code [DBB0KQ] VHMS Connector Mismatch (or change of VHMS-LED display from nF to 11)…2660
Failure code [DBB5KP] VHMS 5V source sys Error (or change of VHMSLED display from n9 to 04)…2662
Failure code [DBB6KP] VHMS 24V source sys Error (or change of VHMS-LED display from n9 to 02)…2664
Failure code [DBBQKR] KOM-NET/c error (or change of VHMS-LED display from n8 to 02)…2666
Failure code [DGE5KX] Ambient Air Temp Sensor Failure (or change of VHMS-LED display from n4 to 01)…2668
Failure code [DGH2KB] Hydr. Oil Temp. Sensor S/C…2670
Failure code [DGT3KZ] PTO Temp Sensor Failure (or change of VHMSLED display from n5 to 01)…2672
Troubleshooting by failure code, Part 5…2675
Failure code [DGT5KA] Exhaust Temp. Sensor LBF Failure (or change of VHMS-LED display from n3 to 12)…2678
Failure code [dGT5KA] Exhaust Temp. Sensor LBR Failure (or change of VHMS-LED display from n3 to 22)…2680
Failure code [DGT5KB] Exhaust Temp. Sensor LBF Failure (or change of VHMS-LED display from n3 to 11)…2682
Failure code [dGT5KB] Exhaust Temp. Sensor LBR Failure (or change of VHMS-LED display from n3 to 21)…2684
Failure code [DGT6KA] Exhaust Temp. Sensor RBF Failure (or change of VHMS-LED display from n3 to 24)…2686
Failure code [dGT6KA] Exhaust Temp. Sensor RBR Failure (or change of VHMS-LED display from n3 to 26)…2688
Failure code [DGT6KB] Exhaust Temp. Sensor RBF Failure (or change of VHMS-LED display from n3 to 23)…2690
Failure code [dGT6KB] Exhaust Temp. Sensor RBR Failure (or change of VHMS-LED display from n3 to 26)…2692
Failure code [DH25KX] VR1/P1F J/S Dif Press Sensor Abnormality…2694
Failure code [DH26KX] VL1/P1R J/S Dif Press Sensor Abnormality…2696
Failure code [DH27KX] VR2/P2F J/S Dif Press Sensor Abnormality…2698
Failure code [DH28KX] VL2/P2R J/S Dif Press Sensor Abnormality…2700
Failure code [DHE5KB] Blowby Pres. Sensor Failure (or change of VHMS-LED display from n3 to 32)…2702
Failure code [DHE5KY] Blowby Pres. Sensor Failure (or change of VHMS-LED display from n3 to 31)…2704
Failure code [DHH2KA] Hydraulic oil filter Sensor Failure (or change of VHMS-LED display from n5 to 53)…2706
Failure code [DHPEKX] VR1/P1F Pump P. Sensor Abnormality…2708
Failure code [DHPFKX] VL1/P1R Pump P. Sensor Abnormality…2710
Failure code [DHPGKX] VR2/P2F Pump P. Sensor Abnormality…2712
Failure code [DHPHKX] VL2/P2R Pump P. Sensor Abnormality…2714
Failure code [DHPSKX] Auto Grease Press Sensor Abnormality…2716
Failure code [DHPTKX] Fan(RAD) Pump P. Sensor Open Circuit…2718
Failure code [DHPUKX] Fan(O/C) Pump P. Sensor Open Circuit…2720
Failure code [DHS3KX] Arm Dig PPC Press Sensor Abnormality…2722
Failure code [DHS4KX] Bucket Curl PPC Press Sensor Abnormality…2724
Failure code [DHS8KX] Boom Raise PPC Press Sensor Abnormality…2726
Failure code [DHS9KX] Boom Lower PPC Press Sensor Abnormality…2728
Failure code [DHSAKX] Swing Right PPC Press Sensor Abnormality…2730
Failure code [DHSBKX] Swing Left PPC Press Sensor Abnormality…2732
Failure code [DHSCKX] Arm Dump PPC Press Sensor Abnormality…2734
Failure code [DHSDKX] Bucket Dump PPC Press Sensor Abnormality…2736
Troubleshooting by failure code, Part 6…2739
Failure code [DUM3KB] Auto Grease Caution LED Short Circuit…2741
Failure code [DUM4KB] FAN Reverse LED Short Circuit…2742
Failure code [DV20KB] Travel Alarm S/C…2743
Failure code [DW41KA] Swing Priority Sol Open Circuit…2745
Failure code [DW41KB] Swing Priority Sol Short Circuit…2747
Failure code [DW45KA] Swing Brake Sol. Disc…2749
Failure code [DW45KB] Swing Brake Sol. S/C…2752
Failure code [DW91KA] Straight-Travel Sol. Disc…2754
Failure code [DW91KB] Straight-Travel Sol. S/C…2756
Failure code [DW4XKA] Bucket Curl Hi Cancel Sol. Disc…2758
Failure code [DW4XKB] Bucket Curl Hi Cancel Sol. S/C…2759
Failure code [DW7BKA] Fan Motor (RAD) Reverse Sol Open Circuit…2760
Failure code [DW7BKB] Fan Motor (RAD) Reverse Sol. S/C…2762
Failure code [DW7HKA] Fan Motor(O/C) Reverse Sol Open Circuit…2764
Failure code [DW7HKB] Fan Motor(O/C) Reverse Sol Short Circuit…2766
Failure code [DWA3KA] Arm throttle Valve/L Sol Open Circuit…2768
Failure code [DWA3KB] Arm throttle Valve/L Sol Short Circuit…2770
Failure code [DWA4KA] Arm throttle Valve/R Sol Open Circuit…2772
Failure code [DWA4KB] Arm throttle Valve/R Sol Short Circuit…2774
Failure code [DWA5KA] Auto Grease Sol Open Circuit…2776
Failure code [DWA5KB] Auto Grease Sol Short Circuit…2778
Failure code [DWA6KA] Boom throttle Valve Sol Open Circuit…2779
Failure code [DWA6KB] Boom throttle Valve Sol Short Circuit…2781
Failure code [DWK0KA] 2-stage Relief Sol. Disc…2783
Failure code [DWK0KB] 2-stage Relief Sol. S/C…2785
Failure code [DWK2KA] Back Press Comp Valve Sol Open Circuit…2786
Failure code [DWK2KB] Back Press Comp Valve Sol Short Circuit…2787
Troubleshooting by failure code, Part 7…2789
Failure code [DWN5KA] Fan(RAD) Pump EPC Sol Open Circuit…2791
Failure code [DWN5KB] Fan(RAD) Pump EPC Sol Short Circuit…2792
Failure code [DWNCKA] Fan(O/C) Pump EPC Sol Open Circuit…2793
Failure code [DWNCKB] Fan(O/C) Pump EPC Sol Short Circuit…2794
Failure code [DXAAKA] P1F EPC Sol Disc…2796
Failure code [DXAAKB] P1F EPC Sol S/C…2798
Failure code [DXABKA] P1R Pump EPC Sol. Disc…2800
Failure code [DXABKB] P1R Pump EPC Sol. S/C…2802
Failure code [DXACKA] P2F Pump EPC Sol. Disc…2804
Failure code [DXACKB] P2F Pump EPC Sol. S/C…2806
Failure code [DXADKA] P2R Pump EPC Sol. Disc…2808
Failure code [DXADKB] P2R Pump EPC Sol. S/C…2810
Failure code [DY2CKB] Washer Drive S/C…2812
Failure code [DY20MA] Low Wiper Working Abnormality…2814
Failure code [DY2FMA] Upper Wiper Working Abnormality…2817
Failure code [F@BBZL] High Blowby Pressure (or change of VHMS-LED display from n3 to 38)…2820
Failure code [F@BYNR] Very High LBF CYL Exhaust Temp (or change of VHMS-LED display from n3 to 62)…2822
Failure code [f@BYNR] Very High LBR CYL Exhaust Temp (or change of VHMS-LED display from n3 to 72)…2824
Failure code [F@BYNS] High LBF CYL Exhaust Temp (or change of VHMS-LED display from n3 to 61)…2826
Failure code [f@BYNS] High LBR CYL Exhaust Temp (or change of VHMS-LED display from n3 to 71)…2828
Failure code [F@BZNR] Very High RBF CYL Exhaust Temp (or change of VHMS-LED display from n3 to 82)…2830
Failure code [f@BZNR] Very High RBR CYL Exhaust Temp (or change of VHMS-LED display from n3 to 92)…2832
Failure code [F@BZNS] High RBF CYL Exhaust Temp (or change of VHMS-LED display from n3 to 81)…2834
Failure code [f@BZNS] High RBR CYL Exhaust Temp (or change of VHMS-LED display from n3 to 91)…2836
Failure code [LA10ZL] RAD system fan pump relief pressure high error…2838
Failure code [LA20ZL] O/C system pump relief pressure high error…2840
Troubleshooting of electrical system (E-mode)…2843
Before carrying out troubleshooting of electrical system…2845
Contents of troubleshooting table…2852
E-1 When starting switch is turned ON, machine monitor displays nothing…2854
E-2 When starting switch turned ON (before starting engine), basic check item lights up…2856
E-3 Engine does not start (Engine does not turn)…2858
E-4 Auto-decelerator does not operate…2862
E-5 Automatic warm-up system does not operate…2863
E-6 Preheater does not work…2864
E-7 Whole work equipment, swing operation and machine travel operation are disabled…2866
E-8 Machine push-up function does not work…2868
E-9 Boom shockless function cannot be released…2870
E-10 Machine monitor does not display some items…2872
E-11 Contents of display by machine monitor are different from applicable machine…2873
E-12 Fuel level monitor lights up in red while engine is running…2874
E-13 Hydraulic oil temperature gauge does not indicate normally…2875
E-14 Fuel level gauge does not indicate normally…2876
E-15 Swing lock monitor does not indicate normally…2878
E-16 Machine monitor display anything even when operated on monitor switch section…2880
E-17 Wiper does not work…2881
E-18 Monitoring function does not display "Travel" normally…2888
E-19 Travel alarm does not sound…2890
E-20 All of room lamp, headlamp and working lamp do not light up…2891
E-21 Air conditioner does not work…2896
E-22 Step light does not light up or goes off…2898
Troubleshooting of hydraulic and mechanical system (H-mode)…2903
Before troubleshooting for hydraulic and mechanical systems…2905
Table of failure modes and causes…2910
Information in troubleshooting table…2912
H-1 Speed or power of whole work equipment, travel, and swing is low…2913
H-2 Engine speed lowers remarkably or engine stalls…2915
H-3 Work equipment, swing, and travel mechanism do not move…2916
H-4 Abnormal noise comes from around hydraulic pump…2918
H-5 Speed or power of boom is low…2919
H-6 Speed or power of arm is low…2921
H-7 Speed or power of bucket is low…2922
H-8 Boom does not move…2923
H-9 Arm does not move…2923
H-10 Bucket does not move…2923
H-11 Hydraulic drift of work equipment is large…2924
H-12 Time lag of work equipment is large…2925
H-13 Heavy lift function does not work or is not reset…2926
H-14 Machine push-up function does not work or is not reset…2926
H-15 Boom shockless function does not work or is not reset…2926
H-16 Machine gradually deviates during traveling…2928
H-17 Machine deviates excessively when started to travel…2931
H-18 Machine deviates excessively during multiple operations…2932
H-19 Traveling speed or power is low…2932
H-20 Travel system does not move (only one side)…2933
H-21 Upper structure does not swing…2934
H-22 Swing speed or acceleration is low…2936
H-23 In compound operation of work equipment, swing speed or acceleration is low…2938
H-24 Upper structure overruns remarkably when it stops swinging…2939
H-25 Large shock is made when upper structure stops swinging…2940
H-26 Large abnormal sound comes from when upper structure stops swinging…2941
H-27 Hydraulic drift of work equipment is large in swing operation…2942
H-28 Fan rotation is abnormal (large noise or vibration of fans, or fan overheating)…2943
H-29 Bottom dump speed or power is lower (Loading shovel specification)…2944
H-30 Bottom dump cylinder does not move (Loading shovel specification)…2945
Troubleshooting of mechanical system (S-mode)…2947
Method of using troubleshooting charts…2949
S-1 Starting performance is poor…2952
S-2 Engine does not start…2953
S-3 Engine does not pick up smoothly…2956
S-4 Engine stops during operations…2957
S-5 Engine does not rotate smoothly…2958
S-6 Engine lacks output (or lacks power)…2960
S-7 Exhaust smoke is black (incomplete combustion)…2962
S-8 Oil consumption is excessive (or exhaust smoke is blue)…2963
S-9 Oil becomes contaminated quickly…2964
S-10 Fuel consumption is excessive…2965
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)…2966
S-12 Oil pressure drops…2967
S-13 Oil level rises (Entry of coolant or fuel)…2968
S-14 Coolant temperature becomes too high (overheating)…2969
S-15 Abnormal noise is made…2970
S-16 Vibration is excessive…2971
50 Disassembly and assembly…0
General information on disassembly and assembly…2973
How to read this manual…2974
Coating materials list…2976
Special tool list…2979
Sketches of special tools…2983
Engine and cooling system…2987
Removal and installation of power container assembly…2988
Removal and installation of engine, PTO and hydraulic pump assembly…2993
Removal and installation of radiator assembly…3005
Removal and installation of aftercooler assembly…3006
Removal and installation of hydraulic oil cooler assembly…3008
Removal and installation of fuel cooler assembly…3009
Removal and installation of cooling assembly…3010
Removal and installation of fan motor assembly…3014
Removal and installation of fuel tank assembly…3015
Engine…3019
Removal and installation of fuel supply pump assembly…3020
Removal and installation of cylinder head assembly…3024
Removal and installation of fuel injector…3038
Removal and installation of engine front oil seal…3049
Removal and installation of engine rear oil seal…3052
Power train…3057
Removal and installation of PTO assembly…3058
Disassembly and assembly of PTO assembly…3059
Removal and installation of swing motor and swing machinery assembly…3063
Disassembly and assembly of swing machinery assembly…3065
Removal and installation of swing circle assembly…3075
Removal and installation of final drive assembly…3076
Disassembly and assembly of final drive assembly…3078
Undercarriage and frame…3091
Removal and installation of track shoe assembly…3092
Removal and installation of idler assembly…3094
Disassembly and assembly of idler assembly…3095
Disassembly and assembly of idler adjust cylinder assembly…3097
Removal and installation of idler cushion cylinder assembly…3098
Disassembly and assembly of idler cushion cylinder assembly…3099
Removal and installation of track roller assembly…3100
Disassembly and assembly of track roller assembly…3101
Removal and installation of carrier roller assembly…3103
Disassembly and assembly of carrier roller assembly…3104
Removal and installation of revolving frame assembly…3108
Removal and installation of counterweight assembly…3111
Removal and installation of hydraulic ladder…3112
Hydraulic system…3115
Removal and installation of hydraulic tank assembly…3116
Removal and installation of hydraulic pump assembly…3119
Removal and installation of hydraulic pump input shaft oil seal…3124
Removal and installation of control valve assembly…3125
Disassembly and assembly of control valve assembly…3132
Removal and installation of center swivel joint assembly…3136
Disassembly and assembly of center swivel joint assembly…3137
Removal and installation of swing motor assembly…3138
Removal and installation of travel motor assembly…3139
Disassembly and assembly of work equipment PPC valve assembly…3140
Disassembly and assembly of travel PPC valve assembly…3142
Disassembly and assembly of hydraulic cylinder assembly (Backhoe specification)…3145
Disassembly and assembly of hydraulic cylinder assembly (Loading shovel specification)…3152
Work equipment…3159
Removal and installation of bucket cylinder assembly (Backhoe specification)…3160
Removal and installation of bucket cylinder assembly (Loading shovel specification)…3162
Removal and installation of bucket assembly (Backhoe specification)…3164
Removal and installation of bucket assembly (Loading shovel specification)…3166
Removal and installation of arm cylinder (Backhoe specification)…3168
Removal and installation of arm cylinder (Loading shovel specification)…3170
Removal and installation of arm assembly (Backhoe specification)…3171
Removal and installation of arm assembly (Loading shovel specification)…3173
Removal and installation of boom cylinder assembly (Backhoe specification)…3174
Removal and installation of boom cylinder assembly (Loading shovel specification)…3176
Removal and installation of boom assembly (Backhoe specification)…3178
Removal and installation of boom assembly (Loading shovel specification)…3180
Removal and installation of bottom dump cylinder assembly (Loading shovel specification)…3182
Cab and its attachments…3185
Removal and installation of operator cab assembly…3186
Removal and installation of operator cab glass (adhesion glass)…3189
Removal and installation of operator cab (assembly-type)…3196
Removal and installation of cab base assembly…3197
Removal and installation of service center…3199
Electrical system…3203
Removal and installation of air conditioner unit assembly…3204
Removal and installation of monitor assembly…3208
Removal and installation of engine controller assembly…3209
Removal and installation of pump controller assembly…3210
Removal and installation of VHMS controller assembly…3211
Removal and installation of Orbcomm terminal assembly for VHMS…3211
90 Diagrams and drawings…0
Hydraulic diagrams and drawings…3213
Hydraulic circuit diagram (Backhoe specification) Serial No.: 20001 – 20197…3215
Hydraulic circuit diagram (Backhoe specification) Serial No.: 20198 and up…3216
Hydraulic circuit diagram (Loading shovel specification) Serial No.: 20001 – 20197…3217
Hydraulic circuit diagram (Loading shovel specification) Serial No.: 20198 and up…3218
Electrical diagrams and drawings…3221
Electrical circuit diagram (1/14)…3223
Electrical circuit diagram (2/14)…3224
Electrical circuit diagram (3/14)…3225
Electrical circuit diagram (4/14)…3226
Electrical circuit diagram (5/14)…3227
Electrical circuit diagram (6/14)…3228
Electrical circuit diagram (7/14)…3229
Electrical circuit diagram (8/14)…3230
Electrical circuit diagram (9/14)…3231
Electrical circuit diagram (10/14)…3232
Electrical circuit diagram (11/14)…3233
Electrical circuit diagram (12/14)…3234
Electrical circuit diagram (13/14)…3235
Electrical circuit diagram (14/14)…3236
Connector list and stereogram…3237
TEN00133-05 – Hydraulic Mining Shovel PC2000-8 Operation & Maintenance Manual…3240
COVER…3240
FOREWORD…3241
BEFORE READING THIS MANUAL…3242
SAFETY INFORMATION…3245
INTRODUCTION…3246
USE OF MACHINE…3246
DIRECTIONS OF MACHINE…3246
VISIBILITY FROM OPERATOR'S SEAT…3247
PRODUCT INFORMATION…3248
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…3248
EPA REGULATIONS, ENGINE NUMBER PLATE…3248
SERVICE METER LOCATION…3249
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…3249
CONTENTS…3250
SAFETY…3255
SAFETY…3256
SAFETY LABELS…3259
LOCATION OF SAFETY LABELS…3260
SAFETY LABELS…3261
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…3266
PRECAUTIONS BEFORE STARTING OPERATION…3266
PREPARATIONS FOR SAFE OPERATION…3266
FIRE PREVENTION…3268
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE…3269
DO NOT GET CAUGHT IN WORK EQUIPMENT…3271
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…3271
PROTECTION AGAINST FALLING, FLYING, INTRUDING OBJECTS…3272
UNAUTHORIZED MODIFICATION…3272
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…3273
PRECAUTIONS RELATED TO CAB GLASS…3273
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…3273
PRECAUTIONS FOR OPERATION…3274
PRECAUTIONS FOR JOBSITE…3274
STARTING ENGINE…3276
OPERATION…3278
TRANSPORTATION…3285
TOWING…3286
LIFTING OBJECTS WITH BUCKET…3286
PRECAUTIONS FOR MAINTENANCE…3287
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE…3287
PRECAUTIONS FOR INSPECTION AND MAINTENANCE…3291
OPERATION…3297
MACHINE VIEW ILLUSTRATIONS…3298
OVERALL MACHINE VIEW…3298
CONTROLS AND GAUGES…3299
DETAILED CONTROLS AND GAUGES…3303
MONITORING SYSTEM…3303
SWITCHES…3378
LAMP…3393
CONTROL LEVERS AND PEDALS…3396
DOOR LOCK…3399
EMERGENCY EXIT FROM OPERATOR'S CAB…3399
EMERGENCY ESCAPE HAMMER…3400
EMERGENCY ESCAPE EQUIPMENT…3401
FIRE EXTINGUISHER…3403
CAP WITH LOCK…3404
ASHTRAY…3405
CUP HOLDER…3405
MAGAZINE BOX…3406
HOOK…3406
UTILITY BOX…3407
AIR CONDITIONER CONTROLS…3408
RADIO…3426
AUXILIARY ELECTRIC POWER…3431
FUSE…3432
CIRCUIT BREAKER…3434
FUSE (IF EQUIPPED)…3437
CONTROLLER…3438
TOOL, CAN STORAGE PLACE…3439
HANDLING GREASE PUMP AND GREASE GUN…3439
ACCUMULATOR…3447
HANDLING OF SLIDING LADDER…3449
HANDLING MACHINES EQUIPPED WITH VHMS…3450
MACHINE OPERATIONS AND CONTROLS…3452
BEFORE STARTING ENGINE…3452
STARTING ENGINE…3482
AFTER STARTING ENGINE…3485
STOPPING THE ENGINE…3497
MACHINE OPERATION…3503
STEERING THE MACHINE…3507
SWINGING…3509
WORK EQUIPMENT CONTROLS AND OPERATIONS…3511
WORKING MODE…3513
PROHIBITED OPERATIONS…3514
GENERAL OPERATION INFORMATION…3518
TRAVELING ON SLOPES…3519
ESCAPE FROM MUD…3521
RECOMMENDED APPLICATIONS…3522
BUCKET REPLACEMENT…3523
PARKING MACHINE…3525
CHECK BEFORE SHUT OFF ENGINE…3526
MACHINE INSPECTION AFTER DAILY WORK…3526
LOCKING…3527
TRANSPORTATION…3528
TRANSPORTATION PROCEDURE…3528
PRECAUTIONS FOR TRANSPORTATION…3528
METHOD OF LIFTING UNITS FOR TRANSPORTATION…3528
TRANSPORTATION POSTURE…3528
COLD WEATHER OPERATION…3529
COLD WEATHER OPERATION INFORMATION…3529
AFTER DAILY WORK COMPLETION…3531
AFTER COLD WEATHER SEASON…3531
LONG TERM STORAGE…3532
BEFORE STORAGE…3532
DURING STORAGE…3532
AFTER STORAGE…3533
STARTING MACHINE AFTER LONG-TERM STORAGE…3533
TROUBLES AND ACTIONS…3534
RUNNING OUT OF FUEL…3534
PHENOMENA THAT ARE NOT FAILURES…3534
TOWING THE MACHINE…3535
SEVERE JOB CONDITION…3535
DISCHARGED BATTERY…3536
OTHER TROUBLE…3540
MAINTENANCE…3547
MAINTENANCE INFORMATION…3548
OUTLINE OF SERVICE…3550
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…3550
ELECTRIC SYSTEM MAINTENANCE…3554
WEAR PARTS…3555
WEAR PARTS LIST…3555
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…3556
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…3558
TIGHTENING TORQUE SPECIFICATIONS…3559
TIGHTENING TORQUE LIST…3559
SAFETY CRITICAL PARTS…3560
SAFETY CRITICAL PARTS LIST…3561
MAINTENANCE SCHEDULE…3562
MAINTENANCE SCHEDULE CHART…3562
MAINTENANCE PROCEDURE…3564
INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS)…3564
INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)…3564
INITIAL 4000 HOURS MAINTENANCE (ONLY AFTER THE FIRST 4000 HOURS)…3564
WHEN REQUIRED…3565
CHECK BEFORE STARTING…3609
EVERY 250 HOURS MAINTENANCE…3610
EVERY 500 HOURS MAINTENANCE…3619
EVERY 1000 HOURS MAINTENANCE…3631
EVERY 2000 HOURS MAINTENANCE…3650
EVERY 4000 HOURS MAINTENANCE…3652
EVERY 5000 HOURS MAINTENANCE…3656
EVERY 8000 HOURS MAINTENANCE…3660
SPECIFICATIONS…3661
SPECIFICATIONS…3662
ATTACHMENTS, OPTIONS…3665
GENERAL PRECAUTIONS FOR SAFETY…3666
PRECAUTIONS WHEN SELECTING…3666
READ THE INSTRUCTION MANUAL THOROUGHLY…3666
PRECAUTIONS WHEN REMOVING OR INSTALLING…3666
PRECAUTIONS WHEN USING…3666
ATTACHMENT GUIDE…3667
COMBINATIONS OF WORK EQUIPMENT…3667
FRONT GUARD…3667
EMERGENCY LADDER…3668
ESCAPE PROCEDURE…3669
PRECAUTION WHEN STORING ROPE LADDER…3671
CHECK EMERGENCY LADDER…3671
HANDLING FUEL QUICK CHARGE…3672
GENERAL LOCATIONS…3672
PROCEDURE FOR OPERATING FUEL CHARGE…3673
REPLACE FUEL TANK BREATHER ELEMENT…3675
ACTION WHEN MACHINE DOES NOT MOVE BECAUSE OF FAILURE IN PROXIMITY SWITCH…3676
HANDLING HYDRAULIC LADDER…3680
GENERAL LOCATIONS…3680
OTHER LAMPS AND SWITCHES…3681
PROCEDURE FOR OPERATING HYDRAULIC LADDER…3684
GREASING LADDER…3687
ACTION WHEN PROXIMITY SWITCH HAS FAILED…3688
SPECIFICATIONS…3690
ORBCOM CONTROLLER (COMMUNICATIONS TERMINAL)…3691
LOADING SHOVEL…3693
MACHINE VIEW ILLUSTRATIONS…3694
OVERALL MACHINE VIEW…3694
EXPLANATION OF COMPONENTS…3695
SWITCHES…3695
OPERATIONS…3697
OPERATION OF WORK EQUIPMENT…3697
PRECAUTIONS DURING OPERATION…3699
EXCAVATOR WORK…3703
PRECAUTIONS WHEN DISASSEMBLING MACHINE…3704
RELEASING PRESSURE…3704
TRANSPORTATION…3705
MACHINE CONFIGURATION FOR TRANSPORT…3705
MAINTENANCE…3706
EVERY 10 HOURS MAINTENANCE…3706
SPECIFICATION…3711
WEAR PARTS…3713
WEAR PARTS LIST…3713
COMBINATION OF WORK EQUIPMENT…3714
COMBINATION OF WORK EQUIPMENT…3714
INDEX…3715
TEN00236-03 – Hydraulic Mining Shovel PC2000-8 Operation & Maintenance Manual…3719
COVER…3719
FOREWORD…3720
BEFORE READING THIS MANUAL…3721
SAFETY INFORMATION…3724
INTRODUCTION…3725
USE OF MACHINE…3725
DIRECTIONS OF MACHINE…3725
VISIBILITY FROM OPERATOR'S SEAT…3726
PRODUCT INFORMATION…3727
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…3727
EPA REGULATIONS, ENGINE NUMBER PLATE…3727
SERVICE METER LOCATION…3728
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…3728
CONTENTS…3729
SAFETY…3734
SAFETY…3735
SAFETY LABELS…3738
LOCATION OF SAFETY LABELS…3739
SAFETY LABELS…3740
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…3745
PRECAUTIONS BEFORE STARTING OPERATION…3745
PREPARATIONS FOR SAFE OPERATION…3745
FIRE PREVENTION…3747
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE…3748
DO NOT GET CAUGHT IN WORK EQUIPMENT…3750
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…3750
PROTECTION AGAINST FALLING, FLYING, INTRUDING OBJECTS…3751
UNAUTHORIZED MODIFICATION…3751
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…3752
PRECAUTIONS RELATED TO CAB GLASS…3752
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…3752
PRECAUTIONS FOR OPERATION…3753
PRECAUTIONS FOR JOBSITE…3753
STARTING ENGINE…3755
OPERATION…3757
TRANSPORTATION…3764
TOWING…3765
LIFTING OBJECTS WITH BUCKET…3765
PRECAUTIONS FOR MAINTENANCE…3766
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE…3766
PRECAUTIONS FOR INSPECTION AND MAINTENANCE…3770
OPERATION…3776
MACHINE VIEW ILLUSTRATIONS…3777
OVERALL MACHINE VIEW…3777
CONTROLS AND GAUGES…3778
DETAILED CONTROLS AND GAUGES…3782
MONITORING SYSTEM…3782
SWITCHES…3857
LAMP…3872
CONTROL LEVERS AND PEDALS…3875
DOOR LOCK…3878
EMERGENCY EXIT FROM OPERATOR'S CAB…3878
EMERGENCY ESCAPE HAMMER…3879
EMERGENCY ESCAPE EQUIPMENT…3880
FIRE EXTINGUISHER…3882
CAP WITH LOCK…3883
ASHTRAY…3884
CUP HOLDER…3884
MAGAZINE BOX…3885
HOOK…3885
UTILITY BOX…3886
AIR CONDITIONER CONTROLS…3887
RADIO…3905
AUXILIARY ELECTRIC POWER…3910
FUSE…3911
CIRCUIT BREAKER…3913
FUSE (IF EQUIPPED)…3916
CONTROLLER…3917
TOOL, CAN STORAGE PLACE…3918
HANDLING GREASE PUMP AND GREASE GUN…3918
ACCUMULATOR…3926
HANDLING OF SLIDING LADDER…3928
HANDLING MACHINES EQUIPPED WITH VHMS…3929
EXTERNAL POWER SOURCE TYPE ENGINE PREHEATING HEATER…3931
HANDLING PORTABLE COMBUSTION TYPE PREHEATING HEATER…3941
MACHINE OPERATIONS AND CONTROLS…3957
BEFORE STARTING ENGINE…3957
STARTING ENGINE…3987
AFTER STARTING ENGINE…3991
STOPPING THE ENGINE…4003
MACHINE OPERATION…4009
STEERING THE MACHINE…4013
SWINGING…4015
WORK EQUIPMENT CONTROLS AND OPERATIONS…4017
WORKING MODE…4019
PROHIBITED OPERATIONS…4020
GENERAL OPERATION INFORMATION…4024
TRAVELING ON SLOPES…4025
ESCAPE FROM MUD…4027
RECOMMENDED APPLICATIONS…4028
BUCKET REPLACEMENT…4029
PARKING MACHINE…4031
CHECK BEFORE SHUT OFF ENGINE…4032
MACHINE INSPECTION AFTER DAILY WORK…4032
LOCKING…4033
TRANSPORTATION…4034
TRANSPORTATION PROCEDURE…4034
PRECAUTIONS FOR TRANSPORTATION…4034
METHOD OF LIFTING UNITS FOR TRANSPORTATION…4034
TRANSPORTATION POSTURE…4034
COLD WEATHER OPERATION…4035
COLD WEATHER OPERATION INFORMATION…4035
AFTER DAILY WORK COMPLETION…4037
AFTER COLD WEATHER SEASON…4037
LONG TERM STORAGE…4038
BEFORE STORAGE…4038
DURING STORAGE…4038
AFTER STORAGE…4039
STARTING MACHINE AFTER LONG-TERM STORAGE…4039
TROUBLES AND ACTIONS…4040
RUNNING OUT OF FUEL…4040
PHENOMENA THAT ARE NOT FAILURES…4040
TOWING THE MACHINE…4041
SEVERE JOB CONDITION…4041
DISCHARGED BATTERY…4042
OTHER TROUBLE…4046
MAINTENANCE…4052
MAINTENANCE INFORMATION…4053
OUTLINE OF SERVICE…4055
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…4055
ELECTRIC SYSTEM MAINTENANCE…4059
WEAR PARTS…4060
WEAR PARTS LIST…4060
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…4061
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…4063
TIGHTENING TORQUE SPECIFICATIONS…4064
TIGHTENING TORQUE LIST…4064
SAFETY CRITICAL PARTS…4065
SAFETY CRITICAL PARTS LIST…4066
MAINTENANCE SCHEDULE…4067
MAINTENANCE SCHEDULE CHART…4067
MAINTENANCE PROCEDURE…4069
INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS)…4069
INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)…4069
INITIAL 4000 HOURS MAINTENANCE (ONLY AFTER THE FIRST 4000 HOURS)…4069
WHEN REQUIRED…4070
CHECK BEFORE STARTING…4114
EVERY 250 HOURS MAINTENANCE…4115
EVERY 500 HOURS MAINTENANCE…4124
EVERY 1000 HOURS MAINTENANCE…4136
EVERY 2000 HOURS MAINTENANCE…4155
EVERY 4000 HOURS MAINTENANCE…4157
EVERY 5000 HOURS MAINTENANCE…4161
EVERY 8000 HOURS MAINTENANCE…4165
SPECIFICATIONS…4166
SPECIFICATIONS…4167
ATTACHMENTS, OPTIONS…4170
GENERAL PRECAUTIONS FOR SAFETY…4171
PRECAUTIONS WHEN SELECTING…4171
READ THE INSTRUCTION MANUAL THOROUGHLY…4171
PRECAUTIONS WHEN REMOVING OR INSTALLING…4171
PRECAUTIONS WHEN USING…4171
ATTACHMENT GUIDE…4172
COMBINATIONS OF WORK EQUIPMENT…4172
FRONT GUARD…4172
EMERGENCY LADDER…4173
ESCAPE PROCEDURE…4174
PRECAUTION WHEN STORING ROPE LADDER…4176
CHECK EMERGENCY LADDER…4176
HANDLING HYDRAULIC LADDER…4177
GENERAL LOCATIONS…4177
OTHER LAMPS AND SWITCHES…4178
PROCEDURE FOR OPERATING HYDRAULIC LADDER…4181
GREASING LADDER…4184
ACTION WHEN PROXIMITY SWITCH HAS FAILED…4185
SPECIFICATIONS…4187
ORBCOM CONTROLLER (COMMUNICATIONS TERMINAL)…4188
LOADING SHOVEL…4190
MACHINE VIEW ILLUSTRATIONS…4191
OVERALL MACHINE VIEW…4191
EXPLANATION OF COMPONENTS…4192
SWITCHES…4192
OPERATIONS…4194
OPERATION OF WORK EQUIPMENT…4194
PRECAUTIONS DURING OPERATION…4196
EXCAVATOR WORK…4200
PRECAUTIONS WHEN DISASSEMBLING MACHINE…4201
RELEASING PRESSURE…4201
TRANSPORTATION…4202
MACHINE CONFIGURATION FOR TRANSPORT…4202
MAINTENANCE…4203
EVERY 10 HOURS MAINTENANCE…4203
SPECIFICATION…4208
WEAR PARTS…4210
WEAR PARTS LIST…4210
COMBINATION OF WORK EQUIPMENT…4211
COMBINATION OF WORK EQUIPMENT…4211
INDEX…4212
TEN00323-01 – Hydraulic Mining Shovel PC2000-8 Operation & Maintenance Manual…4216
COVER…4216
FOREWORD…4217
BEFORE READING THIS MANUAL…4218
SAFETY INFORMATION…4219
INTRODUCTION…4220
USE OF MACHINE…4220
DIRECTIONS OF MACHINE…4220
VISIBILITY FROM OPERATOR'S SEAT…4221
PRODUCT INFORMATION…4222
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…4222
EPA REGULATIONS, ENGINE NUMBER PLATE…4222
SERVICE METER LOCATION…4223
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…4223
CONTENTS…4224
SAFETY…4229
SAFETY…4230
SAFETY LABELS…4233
LOCATION OF SAFETY LABELS…4234
SAFETY LABELS…4235
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…4240
PRECAUTIONS BEFORE STARTING OPERATION…4240
PREPARATIONS FOR SAFE OPERATION…4240
FIRE PREVENTION…4242
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE…4243
DO NOT GET CAUGHT IN WORK EQUIPMENT…4245
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…4245
PROTECTION AGAINST FALLING, FLYING, INTRUDING OBJECTS…4246
UNAUTHORIZED MODIFICATION…4246
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…4247
PRECAUTIONS RELATED TO CAB GLASS…4247
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…4247
PRECAUTIONS FOR OPERATION…4248
PRECAUTIONS FOR JOBSITE…4248
STARTING ENGINE…4250
OPERATION…4252
TRANSPORTATION…4259
TOWING…4260
LIFTING OBJECTS WITH BUCKET…4260
PRECAUTIONS FOR MAINTENANCE…4261
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE…4261
PRECAUTIONS FOR INSPECTION AND MAINTENANCE…4265
OPERATION…4271
MACHINE VIEW ILLUSTRATIONS…4272
OVERALL MACHINE VIEW…4272
CONTROLS AND GAUGES…4273
DETAILED CONTROLS AND GAUGES…4277
MONITORING SYSTEM…4277
SWITCHES (INSIDE OPERATOR'S CAB)…4352
SWITCHES (INSIDE CAB BASE ROOM)…4362
SWITCHES (OUTSIDE OF MACHINE)…4365
LAMP (INSIDE OPERATOR'S CAB)…4376
LAMP (OUTSIDE OF MACHINE)…4380
CONTROL LEVERS AND PEDALS…4382
DOOR LOCK…4385
EMERGENCY EXIT FROM OPERATOR'S CAB…4385
EMERGENCY ESCAPE HAMMER…4386
HANDLING EMERGENCY LADDER…4387
FIRE EXTINGUISHER…4391
CAP WITH LOCK…4392
ASHTRAY…4393
CUP HOLDER…4393
MAGAZINE BOX…4394
HOOK…4394
UTILITY BOX…4395
AIR CONDITIONER CONTROLS…4396
RADIO…4414
AUXILIARY ELECTRIC POWER…4419
FUSE…4420
CIRCUIT BREAKER…4422
FUSE (IF EQUIPPED)…4425
CONTROLLER…4426
TOOL, CAN STORAGE PLACE…4427
HANDLING GREASE PUMP AND GREASE GUN…4427
ACCUMULATOR…4435
HANDLING HYDRAULIC LADDER…4437
HANDLING MACHINES EQUIPPED WITH VHMS…4444
MACHINE OPERATIONS AND CONTROLS…4446
BEFORE STARTING ENGINE…4446
STARTING ENGINE…4477
AFTER STARTING ENGINE…4480
STOPPING THE ENGINE…4492
MACHINE OPERATION…4501
STEERING THE MACHINE…4505
SWINGING…4507
WORK EQUIPMENT CONTROLS AND OPERATIONS…4509
WORKING MODE…4511
PROHIBITED OPERATIONS…4512
GENERAL OPERATION INFORMATION…4516
TRAVELING ON SLOPES…4517
ESCAPE FROM MUD…4519
RECOMMENDED APPLICATIONS…4520
BUCKET REPLACEMENT…4521
PARKING MACHINE…4523
CHECK BEFORE SHUT OFF ENGINE…4524
MACHINE INSPECTION AFTER DAILY WORK…4524
LOCKING…4525
TRANSPORTATION…4526
TRANSPORTATION PROCEDURE…4526
PRECAUTIONS FOR TRANSPORTATION…4526
METHOD OF LIFTING UNITS FOR TRANSPORTATION…4526
TRANSPORTATION POSTURE…4526
COLD WEATHER OPERATION…4527
COLD WEATHER OPERATION INFORMATION…4527
AFTER DAILY WORK COMPLETION…4529
AFTER COLD WEATHER SEASON…4529
LONG TERM STORAGE…4530
BEFORE STORAGE…4530
DURING STORAGE…4530
AFTER STORAGE…4531
STARTING MACHINE AFTER LONG-TERM STORAGE…4531
TROUBLES AND ACTIONS…4532
RUNNING OUT OF FUEL…4532
PHENOMENA THAT ARE NOT FAILURES…4532
TOWING THE MACHINE…4533
SEVERE JOB CONDITION…4533
DISCHARGED BATTERY…4534
OTHER TROUBLE…4539
MAINTENANCE…4545
MAINTENANCE INFORMATION…4546
OUTLINE OF SERVICE…4548
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…4548
ELECTRIC SYSTEM MAINTENANCE…4552
WEAR PARTS…4553
WEAR PARTS LIST…4553
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…4554
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…4556
TIGHTENING TORQUE SPECIFICATIONS…4557
TIGHTENING TORQUE LIST…4557
SAFETY CRITICAL PARTS…4558
SAFETY CRITICAL PARTS LIST…4559
MAINTENANCE SCHEDULE…4560
MAINTENANCE SCHEDULE CHART…4560
MAINTENANCE PROCEDURE…4562
INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS)…4562
INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)…4562
INITIAL 4000 HOURS MAINTENANCE (ONLY AFTER THE FIRST 4000 HOURS)…4562
WHEN REQUIRED…4563
CHECK BEFORE STARTING…4606
EVERY 250 HOURS MAINTENANCE…4607
EVERY 500 HOURS MAINTENANCE…4616
EVERY 1000 HOURS MAINTENANCE…4630
EVERY 2000 HOURS MAINTENANCE…4650
EVERY 4000 HOURS MAINTENANCE…4652
EVERY 5000 HOURS MAINTENANCE…4656
EVERY 8000 HOURS MAINTENANCE…4660
SPECIFICATIONS…4661
SPECIFICATIONS…4662
ATTACHMENTS, OPTIONS…4665
GENERAL PRECAUTIONS FOR SAFETY…4666
PRECAUTIONS WHEN SELECTING…4666
READ THE INSTRUCTION MANUAL THOROUGHLY…4666
PRECAUTIONS WHEN REMOVING OR INSTALLING…4666
PRECAUTIONS WHEN USING…4666
ATTACHMENT GUIDE…4667
COMBINATIONS OF WORK EQUIPMENT…4667
FRONT GUARD…4667
HANDLING FUEL QUICK CHARGE…4668
GENERAL LOCATIONS…4668
PROCEDURE FOR OPERATING FUEL CHARGE…4669
REPLACE FUEL TANK BREATHER ELEMENT…4671
ACTION WHEN MACHINE DOES NOT MOVE BECAUSE OF FAILURE IN PROXIMITY SWITCH…4672
HANDLING SERVICE CENTER…4676
GENERAL LOCATIONS…4676
PROCEDURE FOR OPERATING SERVICE ARM…4677
METHOD OF DRAINING, ADDING LUBRICANT AND COOLANT FROM SERVICE PANEL…4680
GREASING LADDER SERVICE ARM…4690
REPLACE FUEL TANK BREATHER ELEMENT…4691
ACTION WHEN MACHINE DOES NOT MOVE BECAUSE OF FAILURE IN PROXIMITY SWITCH…4692
HANDLING JUMP START RECEPTACLE…4696
GENERAL LOCATIONS…4696
CONNECTED PROCEDURE OF EXTERNAL POWER SOURCE…4696
ORBCOM CONTROLLER (COMMUNICATIONS TERMINAL)…4698
LOADING SHOVEL…4699
MACHINE VIEW ILLUSTRATIONS…4700
OVERALL MACHINE VIEW…4700
EXPLANATION OF COMPONENTS…4701
SWITCHES…4701
OPERATIONS…4703
OPERATION OF WORK EQUIPMENT…4703
PRECAUTIONS DURING OPERATION…4705
EXCAVATOR WORK…4709
PRECAUTIONS WHEN DISASSEMBLING MACHINE…4710
RELEASING PRESSURE…4710
TRANSPORTATION…4711
MACHINE CONFIGURATION FOR TRANSPORT…4711
MAINTENANCE…4712
EVERY 10 HOURS MAINTENANCE…4712
SPECIFICATION…4717
WEAR PARTS…4719
WEAR PARTS LIST…4719
COMBINATION OF WORK EQUIPMENT…4720
COMBINATION OF WORK EQUIPMENT…4720
INDEX…4721
TEN00324-01 – Hydraulic Mining Shovel PC2000-8 Operation & Maintenance Manual…4725
COVER…4725
FOREWORD…4726
BEFORE READING THIS MANUAL…4727
SAFETY INFORMATION…4728
INTRODUCTION…4729
USE OF MACHINE…4729
DIRECTIONS OF MACHINE…4729
VISIBILITY FROM OPERATOR'S SEAT…4730
PRODUCT INFORMATION…4731
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…4731
EPA REGULATIONS, ENGINE NUMBER PLATE…4731
SERVICE METER LOCATION…4732
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…4732
CONTENTS…4733
SAFETY…4738
SAFETY…4739
SAFETY LABELS…4742
LOCATION OF SAFETY LABELS…4743
SAFETY LABELS…4744
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…4749
PRECAUTIONS BEFORE STARTING OPERATION…4749
PREPARATIONS FOR SAFE OPERATION…4749
FIRE PREVENTION…4751
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE…4752
DO NOT GET CAUGHT IN WORK EQUIPMENT…4754
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…4754
PROTECTION AGAINST FALLING, FLYING, INTRUDING OBJECTS…4755
UNAUTHORIZED MODIFICATION…4755
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…4756
PRECAUTIONS RELATED TO CAB GLASS…4756
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…4756
PRECAUTIONS FOR OPERATION…4757
PRECAUTIONS FOR JOBSITE…4757
STARTING ENGINE…4759
OPERATION…4761
TRANSPORTATION…4768
TOWING…4769
LIFTING OBJECTS WITH BUCKET…4769
PRECAUTIONS FOR MAINTENANCE…4770
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE…4770
PRECAUTIONS FOR INSPECTION AND MAINTENANCE…4774
OPERATION…4780
MACHINE VIEW ILLUSTRATIONS…4781
OVERALL MACHINE VIEW…4781
CONTROLS AND GAUGES…4782
DETAILED CONTROLS AND GAUGES…4786
MONITORING SYSTEM…4786
SWITCHES (INSIDE OPERATOR'S CAB)…4861
SWITCHES (INSIDE CAB BASE ROOM)…4871
SWITCHES (OUTSIDE OF MACHINE)…4874
LAMP (INSIDE OPERATOR'S CAB)…4885
LAMP (OUTSIDE OF MACHINE)…4889
CONTROL LEVERS AND PEDALS…4891
DOOR LOCK…4894
EMERGENCY EXIT FROM OPERATOR'S CAB…4894
EMERGENCY ESCAPE HAMMER…4895
HANDLING EMERGENCY LADDER…4896
FIRE EXTINGUISHER…4900
CAP WITH LOCK…4901
ASHTRAY…4902
CUP HOLDER…4902
MAGAZINE BOX…4903
HOOK…4903
UTILITY BOX…4904
AIR CONDITIONER CONTROLS…4905
RADIO…4923
AUXILIARY ELECTRIC POWER…4928
FUSE…4929
CIRCUIT BREAKER…4931
FUSE (IF EQUIPPED)…4934
CONTROLLER…4935
TOOL, CAN STORAGE PLACE…4936
HANDLING GREASE PUMP AND GREASE GUN…4936
ACCUMULATOR…4944
HANDLING HYDRAULIC LADDER…4946
HANDLING MACHINES EQUIPPED WITH VHMS…4953
EXTERNAL POWER SOURCE TYPE ENGINE PREHEATING HEATER…4955
HANDLING PORTABLE COMBUSTION TYPE PREHEATING HEATER…4965
MACHINE OPERATIONS AND CONTROLS…4981
BEFORE STARTING ENGINE…4981
STARTING ENGINE…5012
AFTER STARTING ENGINE…5016
STOPPING THE ENGINE…5028
MACHINE OPERATION…5037
STEERING THE MACHINE…5041
SWINGING…5043
WORK EQUIPMENT CONTROLS AND OPERATIONS…5044
WORKING MODE…5046
PROHIBITED OPERATIONS…5047
GENERAL OPERATION INFORMATION…5051
TRAVELING ON SLOPES…5052
ESCAPE FROM MUD…5054
RECOMMENDED APPLICATIONS…5055
BUCKET REPLACEMENT…5056
PARKING MACHINE…5058
CHECK BEFORE SHUT OFF ENGINE…5059
MACHINE INSPECTION AFTER DAILY WORK…5059
LOCKING…5060
TRANSPORTATION…5061
TRANSPORTATION PROCEDURE…5061
PRECAUTIONS FOR TRANSPORTATION…5061
METHOD OF LIFTING UNITS FOR TRANSPORTATION…5061
TRANSPORTATION POSTURE…5061
COLD WEATHER OPERATION…5062
COLD WEATHER OPERATION INFORMATION…5062
AFTER DAILY WORK COMPLETION…5064
AFTER COLD WEATHER SEASON…5064
LONG TERM STORAGE…5065
BEFORE STORAGE…5065
DURING STORAGE…5065
AFTER STORAGE…5066
STARTING MACHINE AFTER LONG-TERM STORAGE…5066
TROUBLES AND ACTIONS…5067
RUNNING OUT OF FUEL…5067
PHENOMENA THAT ARE NOT FAILURES…5067
TOWING THE MACHINE…5068
SEVERE JOB CONDITION…5068
DISCHARGED BATTERY…5069
OTHER TROUBLE…5074
MAINTENANCE…5080
MAINTENANCE INFORMATION…5081
OUTLINE OF SERVICE…5083
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…5083
ELECTRIC SYSTEM MAINTENANCE…5087
WEAR PARTS…5088
WEAR PARTS LIST…5088
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…5089
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…5091
TIGHTENING TORQUE SPECIFICATIONS…5092
TIGHTENING TORQUE LIST…5092
SAFETY CRITICAL PARTS…5093
SAFETY CRITICAL PARTS LIST…5094
MAINTENANCE SCHEDULE…5095
MAINTENANCE SCHEDULE CHART…5095
MAINTENANCE PROCEDURE…5097
INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS)…5097
INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)…5097
INITIAL 4000 HOURS MAINTENANCE (ONLY AFTER THE FIRST 4000 HOURS)…5097
WHEN REQUIRED…5098
CHECK BEFORE STARTING…5141
EVERY 250 HOURS MAINTENANCE…5142
EVERY 500 HOURS MAINTENANCE…5151
EVERY 1000 HOURS MAINTENANCE…5165
EVERY 2000 HOURS MAINTENANCE…5185
EVERY 4000 HOURS MAINTENANCE…5187
EVERY 5000 HOURS MAINTENANCE…5191
EVERY 8000 HOURS MAINTENANCE…5195
SPECIFICATIONS…5196
SPECIFICATIONS…5197
ATTACHMENTS, OPTIONS…5200
GENERAL PRECAUTIONS FOR SAFETY…5201
PRECAUTIONS WHEN SELECTING…5201
READ THE INSTRUCTION MANUAL THOROUGHLY…5201
PRECAUTIONS WHEN REMOVING OR INSTALLING…5201
PRECAUTIONS WHEN USING…5201
ATTACHMENT GUIDE…5202
COMBINATIONS OF WORK EQUIPMENT…5202
FRONT GUARD…5202
HANDLING SERVICE CENTER…5203
GENERAL LOCATIONS…5203
PROCEDURE FOR OPERATING SERVICE ARM…5204
METHOD OF DRAINING, ADDING LUBRICANT AND COOLANT FROM SERVICE PANEL…5207
GREASING LADDER SERVICE ARM…5217
REPLACE FUEL TANK BREATHER ELEMENT…5218
ACTION WHEN MACHINE DOES NOT MOVE BECAUSE OF FAILURE IN PROXIMITY SWITCH…5219
HANDLING JUMP START RECEPTACLE…5223
GENERAL LOCATIONS…5223
CONNECTED PROCEDURE OF EXTERNAL POWER SOURCE…5223
ORBCOM CONTROLLER (COMMUNICATIONS TERMINAL)…5225
LOADING SHOVEL…5226
MACHINE VIEW ILLUSTRATIONS…5227
OVERALL MACHINE VIEW…5227
EXPLANATION OF COMPONENTS…5228
SWITCHES…5228
OPERATIONS…5230
OPERATION OF WORK EQUIPMENT…5230
PRECAUTIONS DURING OPERATION…5232
EXCAVATOR WORK…5236
PRECAUTIONS WHEN DISASSEMBLING MACHINE…5237
RELEASING PRESSURE…5237
TRANSPORTATION…5238
MACHINE CONFIGURATION FOR TRANSPORT…5238
MAINTENANCE…5239
EVERY 10 HOURS MAINTENANCE…5239
SPECIFICATION…5244
WEAR PARTS…5246
WEAR PARTS LIST…5246
COMBINATION OF WORK EQUIPMENT…5247
COMBINATION OF WORK EQUIPMENT…5247
INDEX…5248
TEN00365-01 – Hydraulic Mining Shovel PC2000-8 Operation & Maintenance Manual…5252
COVER…5252
FOREWORD…5253
BEFORE READING THIS MANUAL…5254
SAFETY INFORMATION…5255
INTRODUCTION…5256
USE OF MACHINE…5256
DIRECTIONS OF MACHINE…5256
VISIBILITY FROM OPERATOR'S SEAT…5257
PRODUCT INFORMATION…5258
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…5258
EPA REGULATIONS, ENGINE NUMBER PLATE…5258
SERVICE METER LOCATION…5259
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…5259
CONTENTS…5260
SAFETY…5265
SAFETY…5266
SAFETY LABELS…5269
LOCATION OF SAFETY LABELS…5270
SAFETY LABELS…5271
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…5276
PRECAUTIONS BEFORE STARTING OPERATION…5276
PREPARATIONS FOR SAFE OPERATION…5276
FIRE PREVENTION…5278
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE…5279
DO NOT GET CAUGHT IN WORK EQUIPMENT…5281
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…5281
PROTECTION AGAINST FALLING, FLYING, INTRUDING OBJECTS…5282
UNAUTHORIZED MODIFICATION…5282
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…5283
PRECAUTIONS RELATED TO CAB GLASS…5283
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…5283
PRECAUTIONS FOR OPERATION…5284
PRECAUTIONS FOR JOBSITE…5284
STARTING ENGINE…5286
OPERATION…5288
TRANSPORTATION…5295
TOWING…5296
LIFTING OBJECTS WITH BUCKET…5296
PRECAUTIONS FOR MAINTENANCE…5297
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE…5297
PRECAUTIONS FOR INSPECTION AND MAINTENANCE…5301
OPERATION…5307
MACHINE VIEW ILLUSTRATIONS…5308
OVERALL MACHINE VIEW…5308
CONTROLS AND GAUGES…5309
DETAILED CONTROLS AND GAUGES…5313
MONITORING SYSTEM…5313
SWITCHES (INSIDE OPERATOR'S CAB)…5388
SWITCHES (INSIDE CAB BASE ROOM)…5398
SWITCHES (OUTSIDE OF MACHINE)…5401
LAMP (INSIDE OPERATOR'S CAB)…5412
LAMP (OUTSIDE OF MACHINE)…5416
CONTROL LEVERS AND PEDALS…5418
DOOR LOCK…5421
EMERGENCY EXIT FROM OPERATOR'S CAB…5421
EMERGENCY ESCAPE HAMMER…5422
HANDLING EMERGENCY LADDER…5423
FIRE EXTINGUISHER…5427
CAP WITH LOCK…5428
ASHTRAY…5429
CUP HOLDER…5429
MAGAZINE BOX…5430
HOOK…5430
UTILITY BOX…5431
AIR CONDITIONER CONTROLS…5432
RADIO…5450
AUXILIARY ELECTRIC POWER…5455
FUSE…5456
CIRCUIT BREAKER…5458
FUSE (IF EQUIPPED)…5461
CONTROLLER…5462
TOOL, CAN STORAGE PLACE…5463
HANDLING GREASE PUMP AND GREASE GUN…5463
ACCUMULATOR…5471
HANDLING HYDRAULIC LADDER…5473
HANDLING MACHINES EQUIPPED WITH VHMS…5480
MACHINE OPERATIONS AND CONTROLS…5482
BEFORE STARTING ENGINE…5482
STARTING ENGINE…5513
AFTER STARTING ENGINE…5516
STOPPING THE ENGINE…5528
MACHINE OPERATION…5537
STEERING THE MACHINE…5541
SWINGING…5543
WORK EQUIPMENT CONTROLS AND OPERATIONS…5544
WORKING MODE…5546
PROHIBITED OPERATIONS…5547
GENERAL OPERATION INFORMATION…5551
TRAVELING ON SLOPES…5552
ESCAPE FROM MUD…5554
RECOMMENDED APPLICATIONS…5555
BUCKET REPLACEMENT…5556
PARKING MACHINE…5558
CHECK BEFORE SHUT OFF ENGINE…5559
MACHINE INSPECTION AFTER DAILY WORK…5559
LOCKING…5560
TRANSPORTATION…5561
TRANSPORTATION PROCEDURE…5561
PRECAUTIONS FOR TRANSPORTATION…5561
METHOD OF LIFTING UNITS FOR TRANSPORTATION…5561
TRANSPORTATION POSTURE…5561
COLD WEATHER OPERATION…5562
COLD WEATHER OPERATION INFORMATION…5562
AFTER DAILY WORK COMPLETION…5564
AFTER COLD WEATHER SEASON…5564
LONG TERM STORAGE…5565
BEFORE STORAGE…5565
DURING STORAGE…5565
AFTER STORAGE…5566
STARTING MACHINE AFTER LONG-TERM STORAGE…5566
TROUBLES AND ACTIONS…5567
RUNNING OUT OF FUEL…5567
PHENOMENA THAT ARE NOT FAILURES…5567
TOWING THE MACHINE…5568
SEVERE JOB CONDITION…5568
DISCHARGED BATTERY…5569
OTHER TROUBLE…5574
MAINTENANCE…5581
MAINTENANCE INFORMATION…5582
OUTLINE OF SERVICE…5584
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…5584
ELECTRIC SYSTEM MAINTENANCE…5588
WEAR PARTS…5589
WEAR PARTS LIST…5589
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…5590
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…5592
TIGHTENING TORQUE SPECIFICATIONS…5593
TIGHTENING TORQUE LIST…5593
SAFETY CRITICAL PARTS…5594
SAFETY CRITICAL PARTS LIST…5595
MAINTENANCE SCHEDULE…5596
MAINTENANCE SCHEDULE CHART…5596
MAINTENANCE PROCEDURE…5598
INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS)…5598
INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)…5598
INITIAL 4000 HOURS MAINTENANCE (ONLY AFTER THE FIRST 4000 HOURS)…5598
WHEN REQUIRED…5599
CHECK BEFORE STARTING…5641
EVERY 250 HOURS MAINTENANCE…5642
EVERY 500 HOURS MAINTENANCE…5651
EVERY 1000 HOURS MAINTENANCE…5665
EVERY 2000 HOURS MAINTENANCE…5684
EVERY 4000 HOURS MAINTENANCE…5686
EVERY 5000 HOURS MAINTENANCE…5690
EVERY 8000 HOURS MAINTENANCE…5694
SPECIFICATIONS…5695
SPECIFICATIONS…5696
ATTACHMENTS, OPTIONS…5699
GENERAL PRECAUTIONS FOR SAFETY…5700
PRECAUTIONS WHEN SELECTING…5700
READ THE INSTRUCTION MANUAL THOROUGHLY…5700
PRECAUTIONS WHEN REMOVING OR INSTALLING…5700
PRECAUTIONS WHEN USING…5700
ATTACHMENT GUIDE…5701
COMBINATIONS OF WORK EQUIPMENT…5701
FRONT GUARD…5701
HANDLING FUEL QUICK CHARGE…5702
GENERAL LOCATIONS…5702
PROCEDURE FOR OPERATING FUEL CHARGE…5703
REPLACE FUEL TANK BREATHER ELEMENT…5705
ACTION WHEN MACHINE DOES NOT MOVE BECAUSE OF FAILURE IN PROXIMITY SWITCH…5706
HANDLING SERVICE CENTER…5710
GENERAL LOCATIONS…5710
PROCEDURE FOR OPERATING SERVICE ARM…5711
METHOD OF DRAINING, ADDING LUBRICANT AND COOLANT FROM SERVICE PANEL…5714
GREASING LADDER SERVICE ARM…5724
REPLACE FUEL TANK BREATHER ELEMENT…5725
ACTION WHEN MACHINE DOES NOT MOVE BECAUSE OF FAILURE IN PROXIMITY SWITCH…5726
HANDLING JUMP START RECEPTACLE…5730
GENERAL LOCATIONS…5730
CONNECTED PROCEDURE OF EXTERNAL POWER SOURCE…5730
ORBCOM CONTROLLER (COMMUNICATIONS TERMINAL)…5732
LOADING SHOVEL…5733
MACHINE VIEW ILLUSTRATIONS…5734
OVERALL MACHINE VIEW…5734
EXPLANATION OF COMPONENTS…5735
SWITCHES…5735
OPERATIONS…5737
OPERATION OF WORK EQUIPMENT…5737
PRECAUTIONS DURING OPERATION…5739
EXCAVATOR WORK…5743
PRECAUTIONS WHEN DISASSEMBLING MACHINE…5744
RELEASING PRESSURE…5744
TRANSPORTATION…5745
MACHINE CONFIGURATION FOR TRANSPORT…5745
MAINTENANCE…5746
EVERY 10 HOURS MAINTENANCE…5746
SPECIFICATION…5751
WEAR PARTS…5753
WEAR PARTS LIST…5753
COMBINATION OF WORK EQUIPMENT…5754
COMBINATION OF WORK EQUIPMENT…5754
INDEX…5755
TEN00366-01 – Hydraulic Mining Shovel PC2000-8 Operation & Maintenance Manual…5759
COVER…5759
FOREWORD…5760
BEFORE READING THIS MANUAL…5761
SAFETY INFORMATION…5762
INTRODUCTION…5763
USE OF MACHINE…5763
DIRECTIONS OF MACHINE…5763
VISIBILITY FROM OPERATOR'S SEAT…5764
PRODUCT INFORMATION…5765
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…5765
EPA REGULATIONS, ENGINE NUMBER PLATE…5765
SERVICE METER LOCATION…5766
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…5766
CONTENTS…5767
SAFETY…5772
SAFETY…5773
SAFETY LABELS…5776
LOCATION OF SAFETY LABELS…5777
SAFETY LABELS…5778
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…5783
PRECAUTIONS BEFORE STARTING OPERATION…5783
PREPARATIONS FOR SAFE OPERATION…5783
FIRE PREVENTION…5785
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE…5786
DO NOT GET CAUGHT IN WORK EQUIPMENT…5788
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…5788
PROTECTION AGAINST FALLING, FLYING, INTRUDING OBJECTS…5789
UNAUTHORIZED MODIFICATION…5789
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…5790
PRECAUTIONS RELATED TO CAB GLASS…5790
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…5790
PRECAUTIONS FOR OPERATION…5791
PRECAUTIONS FOR JOBSITE…5791
STARTING ENGINE…5793
OPERATION…5795
TRANSPORTATION…5802
TOWING…5803
LIFTING OBJECTS WITH BUCKET…5803
PRECAUTIONS FOR MAINTENANCE…5804
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE…5804
PRECAUTIONS FOR INSPECTION AND MAINTENANCE…5808
OPERATION…5814
MACHINE VIEW ILLUSTRATIONS…5815
OVERALL MACHINE VIEW…5815
CONTROLS AND GAUGES…5816
DETAILED CONTROLS AND GAUGES…5820
MONITORING SYSTEM…5820
SWITCHES (INSIDE OPERATOR'S CAB)…5895
SWITCHES (INSIDE CAB BASE ROOM)…5905
SWITCHES (OUTSIDE OF MACHINE)…5908
LAMP (INSIDE OPERATOR'S CAB)…5919
LAMP (OUTSIDE OF MACHINE)…5923
CONTROL LEVERS AND PEDALS…5925
DOOR LOCK…5928
EMERGENCY EXIT FROM OPERATOR'S CAB…5928
EMERGENCY ESCAPE HAMMER…5929
HANDLING EMERGENCY LADDER…5930
FIRE EXTINGUISHER…5934
CAP WITH LOCK…5935
ASHTRAY…5936
CUP HOLDER…5936
MAGAZINE BOX…5937
HOOK…5937
UTILITY BOX…5938
AIR CONDITIONER CONTROLS…5939
RADIO…5957
AUXILIARY ELECTRIC POWER…5962
FUSE…5963
CIRCUIT BREAKER…5965
FUSE (IF EQUIPPED)…5968
CONTROLLER…5969
TOOL, CAN STORAGE PLACE…5970
HANDLING GREASE PUMP AND GREASE GUN…5970
ACCUMULATOR…5978
HANDLING HYDRAULIC LADDER…5980
HANDLING MACHINES EQUIPPED WITH VHMS…5987
EXTERNAL POWER SOURCE TYPE ENGINE PREHEATING HEATER…5989
HANDLING PORTABLE COMBUSTION TYPE PREHEATING HEATER…5999
MACHINE OPERATIONS AND CONTROLS…6015
BEFORE STARTING ENGINE…6015
STARTING ENGINE…6046
AFTER STARTING ENGINE…6050
STOPPING THE ENGINE…6062
MACHINE OPERATION…6071
STEERING THE MACHINE…6075
SWINGING…6077
WORK EQUIPMENT CONTROLS AND OPERATIONS…6078
WORKING MODE…6080
PROHIBITED OPERATIONS…6081
GENERAL OPERATION INFORMATION…6085
TRAVELING ON SLOPES…6086
ESCAPE FROM MUD…6088
RECOMMENDED APPLICATIONS…6089
BUCKET REPLACEMENT…6090
PARKING MACHINE…6092
CHECK BEFORE SHUT OFF ENGINE…6093
MACHINE INSPECTION AFTER DAILY WORK…6093
LOCKING…6094
TRANSPORTATION…6095
TRANSPORTATION PROCEDURE…6095
PRECAUTIONS FOR TRANSPORTATION…6095
METHOD OF LIFTING UNITS FOR TRANSPORTATION…6095
TRANSPORTATION POSTURE…6095
COLD WEATHER OPERATION…6096
COLD WEATHER OPERATION INFORMATION…6096
AFTER DAILY WORK COMPLETION…6098
AFTER COLD WEATHER SEASON…6098
LONG TERM STORAGE…6099
BEFORE STORAGE…6099
DURING STORAGE…6099
AFTER STORAGE…6100
STARTING MACHINE AFTER LONG-TERM STORAGE…6100
TROUBLES AND ACTIONS…6101
RUNNING OUT OF FUEL…6101
PHENOMENA THAT ARE NOT FAILURES…6101
TOWING THE MACHINE…6102
SEVERE JOB CONDITION…6102
DISCHARGED BATTERY…6103
OTHER TROUBLE…6108
MAINTENANCE…6114
MAINTENANCE INFORMATION…6115
OUTLINE OF SERVICE…6117
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…6117
ELECTRIC SYSTEM MAINTENANCE…6121
WEAR PARTS…6122
WEAR PARTS LIST…6122
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…6123
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…6125
TIGHTENING TORQUE SPECIFICATIONS…6126
TIGHTENING TORQUE LIST…6126
SAFETY CRITICAL PARTS…6127
SAFETY CRITICAL PARTS LIST…6128
MAINTENANCE SCHEDULE…6129
MAINTENANCE SCHEDULE CHART…6129
MAINTENANCE PROCEDURE…6131
INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS)…6131
INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)…6131
INITIAL 4000 HOURS MAINTENANCE (ONLY AFTER THE FIRST 4000 HOURS)…6131
WHEN REQUIRED…6132
CHECK BEFORE STARTING…6174
EVERY 250 HOURS MAINTENANCE…6175
EVERY 500 HOURS MAINTENANCE…6184
EVERY 1000 HOURS MAINTENANCE…6198
EVERY 2000 HOURS MAINTENANCE…6217
EVERY 4000 HOURS MAINTENANCE…6219
EVERY 5000 HOURS MAINTENANCE…6223
EVERY 8000 HOURS MAINTENANCE…6227
SPECIFICATIONS…6228
SPECIFICATIONS…6229
ATTACHMENTS, OPTIONS…6232
GENERAL PRECAUTIONS FOR SAFETY…6233
PRECAUTIONS WHEN SELECTING…6233
READ THE INSTRUCTION MANUAL THOROUGHLY…6233
PRECAUTIONS WHEN REMOVING OR INSTALLING…6233
PRECAUTIONS WHEN USING…6233
ATTACHMENT GUIDE…6234
COMBINATIONS OF WORK EQUIPMENT…6234
FRONT GUARD…6234
HANDLING SERVICE CENTER…6235
GENERAL LOCATIONS…6235
PROCEDURE FOR OPERATING SERVICE ARM…6236
METHOD OF DRAINING, ADDING LUBRICANT AND COOLANT FROM SERVICE PANEL…6239
GREASING LADDER SERVICE ARM…6249
REPLACE FUEL TANK BREATHER ELEMENT…6250
ACTION WHEN MACHINE DOES NOT MOVE BECAUSE OF FAILURE IN PROXIMITY SWITCH…6251
HANDLING JUMP START RECEPTACLE…6255
GENERAL LOCATIONS…6255
CONNECTED PROCEDURE OF EXTERNAL POWER SOURCE…6255
ORBCOM CONTROLLER (COMMUNICATIONS TERMINAL)…6257
LOADING SHOVEL…6258
MACHINE VIEW ILLUSTRATIONS…6259
OVERALL MACHINE VIEW…6259
EXPLANATION OF COMPONENTS…6260
SWITCHES…6260
OPERATIONS…6262
OPERATION OF WORK EQUIPMENT…6262
PRECAUTIONS DURING OPERATION…6264
EXCAVATOR WORK…6268
PRECAUTIONS WHEN DISASSEMBLING MACHINE…6269
RELEASING PRESSURE…6269
TRANSPORTATION…6270
MACHINE CONFIGURATION FOR TRANSPORT…6270
MAINTENANCE…6271
EVERY 10 HOURS MAINTENANCE…6271
SPECIFICATION…6276
WEAR PARTS…6278
WEAR PARTS LIST…6278
COMBINATION OF WORK EQUIPMENT…6279
COMBINATION OF WORK EQUIPMENT…6279
INDEX…6280
TEN00430-04 – Hydraulic Mining Shovel PC2000-8 Operation & Maintenance Manual…6284
COVER…6284
FOREWORD…6285
BEFORE READING THIS MANUAL…6286
SAFETY INFORMATION…6287
INTRODUCTION…6288
USE OF MACHINE…6288
DIRECTIONS OF MACHINE…6288
VISIBILITY FROM OPERATOR'S SEAT…6289
PRODUCT INFORMATION…6290
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…6290
EPA REGULATIONS, ENGINE NUMBER PLATE…6290
SERVICE METER LOCATION…6291
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…6291
CONTENTS…6292
SAFETY…6297
SAFETY LABELS…6301
LOCATION OF SAFETY LABELS…6302
SAFETY LABELS…6303
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…6308
PRECAUTIONS BEFORE STARTING OPERATION…6308
PREPARATIONS FOR SAFE OPERATION…6308
FIRE PREVENTION…6310
DO NOT GET CAUGHT IN WORK EQUIPMENT…6313
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…6313
PROTECTION AGAINST FALLING, FLYING, INTRUDING OBJECTS…6314
UNAUTHORIZED MODIFICATION…6314
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…6315
PRECAUTIONS RELATED TO CAB GLASS…6315
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…6315
PRECAUTIONS FOR OPERATION…6316
PRECAUTIONS FOR JOBSITE…6316
STARTING ENGINE…6318
OPERATION…6320
TRANSPORTATION…6327
TOWING…6328
LIFTING OBJECTS WITH BUCKET…6328
PRECAUTIONS FOR MAINTENANCE…6329
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE…6329
PRECAUTIONS FOR INSPECTION AND MAINTENANCE…6333
OPERATION…6339
MACHINE VIEW ILLUSTRATIONS…6340
OVERALL MACHINE VIEW…6340
CONTROLS AND GAUGES…6341
DETAILED CONTROLS AND GAUGES…6345
MONITORING SYSTEM…6345
SWITCHES (INSIDE OPERATOR'S CAB)…6420
SWITCHES (INSIDE CAB BASE ROOM)…6430
SWITCHES (OUTSIDE OF MACHINE)…6433
LAMP (INSIDE OPERATOR'S CAB)…6444
LAMP (OUTSIDE OF MACHINE)…6448
CONTROL LEVERS AND PEDALS…6450
DOOR LOCK…6453
EMERGENCY EXIT FROM OPERATOR'S CAB…6453
EMERGENCY ESCAPE HAMMER…6454
HANDLING EMERGENCY LADDER…6455
FIRE EXTINGUISHER…6459
CAP WITH LOCK…6460
ASHTRAY…6461
CUP HOLDER…6461
MAGAZINE BOX…6462
HOOK…6462
UTILITY BOX…6463
AIR CONDITIONER CONTROLS…6464
RADIO…6482
AUXILIARY ELECTRIC POWER…6487
FUSE…6488
CIRCUIT BREAKER…6490
FUSE (IF EQUIPPED)…6493
CONTROLLER…6494
TOOL, CAN STORAGE PLACE…6495
HANDLING GREASE PUMP AND GREASE GUN…6495
ACCUMULATOR…6503
HANDLING HYDRAULIC LADDER…6506
HANDLING MACHINES EQUIPPED WITH KOMTRAX Plus…6513
MACHINE OPERATIONS AND CONTROLS…6515
BEFORE STARTING ENGINE…6515
STARTING ENGINE…6546
AFTER STARTING ENGINE…6549
STOPPING THE ENGINE…6561
MACHINE OPERATION…6570
STEERING THE MACHINE…6574
SWINGING…6576
WORK EQUIPMENT CONTROLS AND OPERATIONS…6577
WORKING MODE…6579
PROHIBITED OPERATIONS…6580
GENERAL OPERATION INFORMATION…6584
TRAVELING ON SLOPES…6585
ESCAPE FROM MUD…6587
RECOMMENDED APPLICATIONS…6588
BUCKET REPLACEMENT…6589
PARKING MACHINE…6591
CHECK BEFORE SHUT OFF ENGINE…6592
MACHINE INSPECTION AFTER DAILY WORK…6592
LOCKING…6593
TRANSPORTATION…6594
TRANSPORTATION PROCEDURE…6594
PRECAUTIONS FOR TRANSPORTATION…6594
METHOD OF LIFTING UNITS FOR TRANSPORTATION…6594
TRANSPORTATION POSTURE…6594
COLD WEATHER OPERATION…6595
COLD WEATHER OPERATION INFORMATION…6595
AFTER DAILY WORK COMPLETION…6597
AFTER COLD WEATHER SEASON…6597
LONG TERM STORAGE…6598
BEFORE STORAGE…6598
DURING STORAGE…6598
AFTER STORAGE…6599
STARTING MACHINE AFTER LONG-TERM STORAGE…6599
TROUBLES AND ACTIONS…6600
RUNNING OUT OF FUEL…6600
PHENOMENA THAT ARE NOT FAILURES…6600
TOWING THE MACHINE…6601
SEVERE JOB CONDITION…6601
DISCHARGED BATTERY…6602
OTHER TROUBLE…6607
MAINTENANCE…6613
MAINTENANCE INFORMATION…6614
OUTLINE OF SERVICE…6616
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…6616
ELECTRIC SYSTEM MAINTENANCE…6620
WEAR PARTS…6621
WEAR PARTS LIST…6621
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…6622
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…6625
TIGHTENING TORQUE SPECIFICATIONS…6626
TIGHTENING TORQUE LIST…6626
SAFETY CRITICAL PARTS…6627
SAFETY CRITICAL PARTS LIST…6628
MAINTENANCE SCHEDULE…6629
MAINTENANCE SCHEDULE CHART…6629
MAINTENANCE PROCEDURE…6631
INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS)…6631
INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)…6631
INITIAL 4000 HOURS MAINTENANCE (ONLY AFTER THE FIRST 4000 HOURS)…6631
WHEN REQUIRED…6632
CHECK BEFORE STARTING…6675
EVERY 250 HOURS MAINTENANCE…6676
EVERY 500 HOURS MAINTENANCE…6685
EVERY 1000 HOURS MAINTENANCE…6699
EVERY 2000 HOURS MAINTENANCE…6722
EVERY 4000 HOURS MAINTENANCE…6724
EVERY 5000 HOURS MAINTENANCE…6728
EVERY 8000 HOURS MAINTENANCE…6732
SPECIFICATIONS…6733
SPECIFICATIONS…6734
ATTACHMENTS AND OPTIONS…6737
GENERAL PRECAUTIONS FOR SAFETY…6738
PRECAUTIONS WHEN SELECTING…6738
READ THE INSTRUCTION MANUAL THOROUGHLY…6738
PRECAUTIONS WHEN REMOVING OR INSTALLING…6738
PRECAUTIONS WHEN USING…6738
ATTACHMENT GUIDE…6739
COMBINATIONS OF WORK EQUIPMENT…6739
FRONT GUARD…6739
HANDLING FUEL QUICK CHARGE…6740
GENERAL LOCATIONS…6740
PROCEDURE FOR OPERATING FUEL CHARGE…6741
REPLACE FUEL TANK BREATHER ELEMENT…6743
ACTION WHEN MACHINE DOES NOT MOVE BECAUSE OF FAILURE IN PROXIMITY SWITCH…6744
HANDLING SERVICE CENTER…6748
GENERAL LOCATIONS…6748
PROCEDURE FOR OPERATING SERVICE ARM…6749
METHOD OF DRAINING, ADDING LUBRICANT AND COOLANT FROM SERVICE PANEL…6752
GREASING LADDER SERVICE ARM…6762
REPLACE FUEL TANK BREATHER ELEMENT…6763
ACTION WHEN MACHINE DOES NOT MOVE BECAUSE OF FAILURE IN PROXIMITY SWITCH…6764
HANDLING JUMP START RECEPTACLE…6768
GENERAL LOCATIONS…6768
CONNECTED PROCEDURE OF EXTERNAL POWER SOURCE…6768
ORBCOM CONTROLLER (COMMUNICATIONS TERMINAL)…6770
LOADING SHOVEL…6771
MACHINE VIEW ILLUSTRATIONS…6772
OVERALL MACHINE VIEW…6772
EXPLANATION OF COMPONENTS…6773
SWITCHES…6773
OPERATIONS…6775
OPERATION OF WORK EQUIPMENT…6775
PRECAUTIONS DURING OPERATION…6777
LOADING SHOVEL WORK…6781
PRECAUTIONS WHEN DISASSEMBLING MACHINE…6782
RELEASING PRESSURE…6782
TRANSPORTATION…6783
MACHINE CONFIGURATION FOR TRANSPORT…6783
MAINTENANCE…6784
EVERY 10 HOURS MAINTENANCE…6784
SPECIFICATION…6789
WEAR PARTS…6791
WEAR PARTS LIST…6791
COMBINATION OF WORK EQUIPMENT…6792
COMBINATION OF WORK EQUIPMENT…6792
INDEX…6793
TEN00431-05 – Hydraulic Mining Shovel PC2000-8 Operation & Maintenance Manual…6797
COVER…6797
FOREWORD…6798
BEFORE READING THIS MANUAL…6799
SAFETY INFORMATION…6800
INTRODUCTION…6801
USE OF MACHINE…6801
DIRECTIONS OF MACHINE…6801
VISIBILITY FROM OPERATOR'S SEAT…6802
PRODUCT INFORMATION…6803
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…6803
EPA REGULATIONS, ENGINE NUMBER PLATE…6804
SERVICE METER LOCATION…6805
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…6805
CONTENTS…6806
SAFETY…6810
SAFETY…6811
SAFETY LABELS…6814
LOCATION OF SAFETY LABELS…6815
SAFETY LABELS…6816
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…6821
PRECAUTIONS BEFORE STARTING OPERATION…6821
PREPARATIONS FOR SAFE OPERATION…6821
FIRE PREVENTION…6823
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE…6824
DO NOT GET CAUGHT IN WORK EQUIPMENT…6826
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…6826
PROTECTION AGAINST FALLING, FLYING, INTRUDING OBJECTS…6827
UNAUTHORIZED MODIFICATION…6827
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…6828
PRECAUTIONS RELATED TO CAB GLASS…6828
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…6828
PRECAUTIONS FOR OPERATION…6829
PRECAUTIONS FOR JOBSITE…6829
STARTING ENGINE…6831
OPERATION…6833
TRANSPORTATION…6840
TOWING…6841
LIFTING OBJECTS WITH BUCKET…6841
PRECAUTIONS FOR MAINTENANCE…6842
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE…6842
PRECAUTIONS FOR INSPECTION AND MAINTENANCE…6846
OPERATION…6852
MACHINE VIEW ILLUSTRATIONS…6853
OVERALL MACHINE VIEW…6853
CONTROLS AND GAUGES…6854
DETAILED CONTROLS AND GAUGES…6858
MONITORING SYSTEM…6858
SWITCHES (INSIDE OPERATOR'S CAB)…6933
SWITCHES (INSIDE CAB BASE ROOM)…6943
SWITCHES (OUTSIDE OF MACHINE)…6946
LAMP (INSIDE OPERATOR'S CAB)…6957
LAMP (OUTSIDE OF MACHINE)…6961
CONTROL LEVERS AND PEDALS…6963
DOOR LOCK…6966
EMERGENCY EXIT FROM OPERATOR'S CAB…6966
EMERGENCY ESCAPE HAMMER…6967
HANDLING EMERGENCY LADDER…6968
FIRE EXTINGUISHER…6972
CAP WITH LOCK…6973
ASHTRAY…6974
CUP HOLDER…6974
MAGAZINE BOX…6975
HOOK…6975
UTILITY BOX…6976
AIR CONDITIONER CONTROLS…6977
RADIO…6995
AUXILIARY ELECTRIC POWER…7000
FUSE…7001
CIRCUIT BREAKER…7003
FUSE (IF EQUIPPED)…7006
CONTROLLER…7007
TOOL, CAN STORAGE PLACE…7008
HANDLING GREASE PUMP AND GREASE GUN…7008
ACCUMULATOR…7016
HANDLING HYDRAULIC LADDER…7019
HANDLING MACHINES EQUIPPED WITH KOMTRAX Plus…7026
EXTERNAL POWER SOURCE TYPE ENGINE PREHEATING HEATER…7028
HANDLING PORTABLE COMBUSTION TYPE PREHEATING HEATER…7038
MACHINE OPERATIONS AND CONTROLS…7054
BEFORE STARTING ENGINE…7054
STARTING ENGINE…7088
AFTER STARTING ENGINE…7092
STOPPING THE ENGINE…7104
MACHINE OPERATION…7113
STEERING THE MACHINE…7117
SWINGING…7119
WORK EQUIPMENT CONTROLS AND OPERATIONS…7120
WORKING MODE…7122
PROHIBITED OPERATIONS…7123
GENERAL OPERATION INFORMATION…7127
TRAVELING ON SLOPES…7128
ESCAPE FROM MUD…7130
RECOMMENDED APPLICATIONS…7131
BUCKET REPLACEMENT…7132
PARKING MACHINE…7134
CHECK BEFORE SHUT OFF ENGINE…7135
MACHINE INSPECTION AFTER DAILY WORK…7135
LOCKING…7136
TRANSPORTATION…7137
TRANSPORTATION PROCEDURE…7137
PRECAUTIONS FOR TRANSPORTATION…7137
METHOD OF LIFTING UNITS FOR TRANSPORTATION…7137
TRANSPORTATION POSTURE…7137
COLD WEATHER OPERATION…7138
COLD WEATHER OPERATION INFORMATION…7138
AFTER DAILY WORK COMPLETION…7140
AFTER COLD WEATHER SEASON…7140
LONG TERM STORAGE…7141
BEFORE STORAGE…7141
DURING STORAGE…7141
AFTER STORAGE…7142
STARTING MACHINE AFTER LONG-TERM STORAGE…7142
TROUBLES AND ACTIONS…7143
RUNNING OUT OF FUEL…7143
PHENOMENA THAT ARE NOT FAILURES…7143
TOWING THE MACHINE…7144
SEVERE JOB CONDITION…7144
DISCHARGED BATTERY…7145
OTHER TROUBLE…7150
MAINTENANCE…7156
MAINTENANCE INFORMATION…7157
OUTLINE OF SERVICE…7159
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…7159
ELECTRIC SYSTEM MAINTENANCE…7163
WEAR PARTS…7164
WEAR PARTS LIST…7164
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…7165
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…7168
TIGHTENING TORQUE SPECIFICATIONS…7169
TIGHTENING TORQUE LIST…7169
SAFETY CRITICAL PARTS…7170
SAFETY CRITICAL PARTS LIST…7171
MAINTENANCE SCHEDULE…7172
MAINTENANCE SCHEDULE CHART…7172
MAINTENANCE PROCEDURE…7174
INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS)…7174
INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)…7174
INITIAL 4000 HOURS MAINTENANCE (ONLY AFTER THE FIRST 4000 HOURS)…7174
WHEN REQUIRED…7175
CHECK BEFORE STARTING…7221
EVERY 250 HOURS MAINTENANCE…7222
EVERY 500 HOURS MAINTENANCE…7231
EVERY 1000 HOURS MAINTENANCE…7245
EVERY 2000 HOURS MAINTENANCE…7268
EVERY 4000 HOURS MAINTENANCE…7270
EVERY 8000 HOURS MAINTENANCE…7278
SPECIFICATIONS…7280
SPECIFICATIONS…7281
ATTACHMENTS AND OPTIONS…7284
GENERAL PRECAUTIONS FOR SAFETY…7285
PRECAUTIONS WHEN SELECTING…7285
READ THE INSTRUCTION MANUAL THOROUGHLY…7285
PRECAUTIONS WHEN REMOVING OR INSTALLING…7285
PRECAUTIONS WHEN USING…7285
ATTACHMENT GUIDE…7286
COMBINATIONS OF WORK EQUIPMENT…7286
FRONT GUARD…7286
HANDLING SERVICE CENTER…7287
GENERAL LOCATIONS…7287
PROCEDURE FOR OPERATING SERVICE ARM…7288
METHOD OF DRAINING, ADDING LUBRICANT AND COOLANT FROM SERVICE PANEL…7291
GREASING LADDER SERVICE ARM…7302
REPLACE FUEL TANK BREATHER ELEMENT…7303
ACTION WHEN MACHINE DOES NOT MOVE BECAUSE OF FAILURE IN PROXIMITY SWITCH…7304
HANDLING JUMP START RECEPTACLE…7308
GENERAL LOCATIONS…7308
CONNECTED PROCEDURE OF EXTERNAL POWER SOURCE…7308
ORBCOM CONTROLLER (COMMUNICATIONS TERMINAL)…7310
LOADING SHOVEL…7312
MACHINE VIEW ILLUSTRATIONS…7313
OVERALL MACHINE VIEW…7313
EXPLANATION OF COMPONENTS…7314
SWITCHES…7314
OPERATIONS…7316
OPERATION OF WORK EQUIPMENT…7316
PRECAUTIONS DURING OPERATION…7318
LOADING SHOVEL WORK…7322
PRECAUTIONS WHEN DISASSEMBLING MACHINE…7323
RELEASING PRESSURE…7323
TRANSPORTATION…7324
MACHINE CONFIGURATION FOR TRANSPORT…7324
MAINTENANCE…7325
EVERY 10 HOURS MAINTENANCE…7325
SPECIFICATION…7330
WEAR PARTS…7332
WEAR PARTS LIST…7332
COMBINATION OF WORK EQUIPMENT…7333
COMBINATION OF WORK EQUIPMENT…7333
INDEX…7334
Komatsu Hydraulic Excavator GALEO PC2000 Repair Service Manuals
