KOMATSU PC2000-8 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL EENAM02993 – PDF DOWNLOAD
DESCRIPTION:
SERIAL NUMBER
PC2000-8 – 20223 and up
KOMATSU PC2000-8 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL EENAM02993 – PDF DOWNLOAD
BEFORE READING THIS MANUAL:
- This manual gives details of the operation and methods of inspection and maintenance for this machine that must
be obeyed in order to use the machine safely. Most accidents are caused by the failure to follow fundamental
safety rules for the operation and maintenance of machines. - Read, understand and follow all precautions and warnings in this manual and on the machine before performing
operation and maintenance. Failure to do so may result in serious injury or death.
Komatsu cannot predict every circumstance that might involve a potential hazard when the machine is used. - Therefore, the safety messages in this manual and on the machine may not include all possible safety precautions.
If you perform any operation, inspection, or maintenance under conditions that are not described in this
manual, understand that it is your responsibility to take the necessary precautions to ensure safety. In no event
should you or others engage in the prohibited uses or actions described in this manual. Improper operation and
maintenance of the machine can be hazardous and could result in serious injury or death.
TABLE OF CONTENTS:
KOMATSU PC2000-8 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL EENAM02993 – PDF DOWNLOAD
FOREWORD 3
BEFORE READING THIS MANUAL 4
SAFETY INFORMATION 5
Noise emission levels 6
Vibration levels 6
Guide to Reduce Vibration Levels on Machine 7
INTRODUCTION 8
USE OF MACHINE 8
DEMOLITION WORK 8
DIRECTIONS OF MACHINE 9
VISIBILITY FROM OPERATOR’S SEAT 10
PROXIMITY VISIBILITY 10
12M CIRCUMFERENCE VISIBILITY 11
PRODUCT INFORMATION 12
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO PLATE 12
EPA REGULATIONS, ENGINE NUMBER PLATE 13
Fluorinated Greenhouse Gases 14
SERVICE METER LOCATION 14
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR 15
MACHINE SERIAL NUMBER PLATE (according directive 2006/42/EC) 16
Declaration according Directive 2006/42/EC Annex I point 1 7 4 2 (c) 17
FOREWORD 18
SAFETY 18
OPERATION 19
MAINTENANCE 22
SPECIFICATIONS 24
ATTACHMENTS AND OPTIONS 24
LOADING SHOVEL 25
INDEX 26
COLOPHON 26
SAFETY 27
SAFETY 28
SAFETY LABELS 30
LOCATION OF SAFETY LABELS 31
SAFETY LABELS 32
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE 37
PRECAUTIONS BEFORE STARTING OPERATION 37
PREPARATIONS FOR SAFE OPERATION 37
FIRE PREVENTION 39
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE 40
DO NOT GET CAUGHT IN WORK EQUIPMENT 42
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 42
PROTECTION AGAINST FALLING, FLYING, INTRUDING OBJECTS 43
UNAUTHORIZED MODIFICATION 43
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 43
PRECAUTIONS RELATED TO CAB GLASS 44
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING 44
PRECAUTIONS FOR OPERATION 45
PRECAUTIONS FOR JOBSITE 45
STARTING ENGINE 47
OPERATION 50
TRANSPORTATION 56
TOWING 57
LIFTING OBJECTS WITH BUCKET 57
PRECAUTIONS FOR MAINTENANCE 59
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE 59
PRECAUTIONS FOR INSPECTION AND MAINTENANCE 64
END OF SERVICE LIFE 70
OPERATION 71
MACHINE VIEW ILLUSTRATIONS 72
OVERALL MACHINE VIEW 72
CONTROLS AND GAUGES 73
DETAILED CONTROLS AND GAUGES 77
MONITORING SYSTEM 77
Basic Operation of Machine Monitor 78
Basic Check Monitors 81
Caution Monitors 84
Emergency Monitors 88
Meter Display Portion 91
Monitor Switches Portion 101
Handling Function Switches 109
SWITCHES (INSIDE OPERATOR’S CAB) 145
SWITCHES (INSIDE CAB BASE ROOM) 154
SWITCHES (OUTSIDE OF MACHINE) 157
LAMP (INSIDE OPERATOR’S CAB) 167
LAMP (OUTSIDE OF MACHINE) 170
CONTROL LEVERS AND PEDALS 172
DOOR LOCK 174
EMERGENCY EXIT FROM OPERATOR’S CAB 174
EMERGENCY ESCAPE HAMMER 175
HANDLING EMERGENCY LADDER 176
ESCAPE PROCEDURE 176
PRECAUTION WHEN STORING ROPE LADDER 178
FIRE EXTINGUISHER 179
CAP WITH LOCK 179
ASHTRAY 181
CUP HOLDER 181
MAGAZINE BOX 181
HOOK 182
UTILITY BOX 182
AIR CONDITIONER CONTROLS 183
Air Conditioner Control Panel 183
Method of Operation 189
Use Air Conditioner with Care 195
Inspection and maintenance of Air Conditioner Equipped Machine 195
Other Functions 195
RADIO 197
Control Panel 197
Controls of Radio 199
Use Radio with Care 202
AUXILIARY ELECTRIC POWER 203
24 V Power Source 203
12 V Power Source 203
Additional Power Source 203
FUSE 204
CIRCUIT BREAKER 206
FUSE (IF EQUIPPED) 209
CONTROLLER 210
TOOL, CAN STORAGE PLACE 211
HANDLING GREASE PUMP AND GREASE GUN 211
ACCUMULATOR 218
METHOD OF RELEASING PRESSURE IN ACCUMULATOR FOR HYDRAULIC CONTROL CIRCUIT 219
HANDLING HYDRAULIC LADDER 220
PROCEDURE FOR OPERATING HYDRAULIC LADDER 220
ACTION WHEN MACHINE DOES NOT MOVE BECAUSE OF FAILURE IN PROXIMITY SWITCH 222
HANDLING MACHINES EQUIPPED WITH KOMTRAX Plus 226
KOMTRAX Plus INSTALLED, COMMUNICATIONS TERMINAL NOT INSTALLED 226
KOMTRAX Plus AND COMMUNICATIONS TERMINAL INSTALLED 226
MACHINE OPERATIONS AND CONTROLS 228
BEFORE STARTING ENGINE 228
Walk-around Checks 228
Checks Before Starting 230
Adjustment 249
Seat Belt 254
Operations Before Starting Engine 255
STARTING ENGINE 259
AFTER STARTING ENGINE 262
Breaking-in the New Machine 262
Engine Warm Up 263
Hydraulic Equipment Warm Up 265
Operation After Completion Of Warm-Up Operation 270
STOPPING THE ENGINE 272
Normal Stopping 272
Stopping in Emergencies 273
Stopping When Fire Occurs 278
MACHINE OPERATION 280
Preparations for Moving the Machine 280
Moving Machine Forward 281
Moving Machine Backward 282
Stopping Machine 283
STEERING THE MACHINE 284
Steering 284
SWINGING 286
WORK EQUIPMENT CONTROLS AND OPERATIONS 287
WORKING MODE 289
PROHIBITED OPERATIONS 290
GENERAL OPERATION INFORMATION 294
TRAVELING ON SLOPES 295
ESCAPE FROM MUD 297
Track on One Side Stuck 297
Tracks on Both Sides Stuck 297
RECOMMENDED APPLICATIONS 298
Backhoe Work 298
Loading Work 298
BUCKET REPLACEMENT 299
Replacement 299
PARKING MACHINE 301
CHECK BEFORE SHUT OFF ENGINE 302
MACHINE INSPECTION AFTER DAILY WORK 302
LOCKING 303
TRANSPORTATION 304
TRANSPORTATION PROCEDURE 304
PRECAUTIONS FOR TRANSPORTATION 304
METHOD OF LIFTING UNITS FOR TRANSPORTATION 304
TRANSPORTATION POSTURE 304
COLD WEATHER OPERATION 305
COLD WEATHER OPERATION INFORMATION 305
Fuel and Lubricants 305
Cooling System Coolant 305
Battery 306
AFTER DAILY WORK COMPLETION 307
AFTER COLD WEATHER SEASON 307
LONG TERM STORAGE 308
BEFORE STORAGE 308
DURING STORAGE 308
AFTER STORAGE 309
STARTING MACHINE AFTER LONG-TERM STORAGE 309
TROUBLES AND ACTIONS 310
RUNNING OUT OF FUEL 310
PHENOMENA THAT ARE NOT FAILURES 310
TOWING THE MACHINE 311
SEVERE JOB CONDITION 311
DISCHARGED BATTERY 312
Battery Removal and Installation 312
Battery Charges 313
Starting Engine with Booster Cables 314
OTHER TROUBLE 316
Electrical System 316
Chassis 317
Engine 318
Electronic Control System 320
Point of Contact to Telephone when Error Occurs 321
MAINTENANCE 323
MAINTENANCE INFORMATION 324
OUTLINE OF SERVICE 327
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC 327
OIL 327
FUEL 328
COOLANT AND WATER FOR DILUTION 328
GREASE 329
PERFORMING KOWA (Komatsu Oil Wear Analysis) 329
STORING OIL AND FUEL 330
FILTERS 330
ELECTRIC SYSTEM MAINTENANCE 331
WEAR PARTS 332
WEAR PARTS LIST 332
RECOMMENDED FUEL, COOLANT, AND LUBRICANT 333
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL 335
TIGHTENING TORQUE SPECIFICATIONS 336
TIGHTENING TORQUE LIST 336
SAFETY CRITICAL PARTS 337
SAFETY CRITICAL PARTS LIST 338
MAINTENANCE SCHEDULE 339
MAINTENANCE SCHEDULE CHART 339
MAINTENANCE PROCEDURE 341
INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS) 341
INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS) 341
INITIAL 4000 HOURS MAINTENANCE (ONLY AFTER THE FIRST 4000 HOURS) 341
WHEN REQUIRED 342
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT 342
CLEAN INSIDE OF COOLING SYSTEM 349
CHECK AND TIGHTEN TRACK SHOE BOLTS 352
CHECK AND ADJUST TRACK TENSION 352
REPLACE BUCKET TEETH (XS) 357
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID 363
CHECK AND MAINTENANCE AIR CONDITIONER 364
CLEAN LINE FILTER, REMOVE DIRT 365
CHECK SEALS AROUND ENGINE COOLING 366
BLEEDING AIR FROM FUEL CIRCUIT 367
BLEEDING AIR FROM HYDRAULIC SYSTEM 371
METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT 382
INSPECTION OF ADDITIONAL WATER SEPARATOR AND CLEANING OF CASING INTERIOR 384
CHECK BEFORE STARTING 386
EVERY 250 HOURS MAINTENANCE 387
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL 387
CHECK LEVEL OF BATTERY ELECTROLYTE 388
CHECK AND TIGHTEN TRACK FRAME AND AXLE CONNECTING BOLTS 390
CHECK ALTERNATOR DRIVE BELT TENSION, ADJUST 390
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST 392
EVERY 500 HOURS MAINTENANCE 394
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE 394
CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, FUEL COOLER AND AFTERCOOLER FINS 396
CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS 399
CHECK, REPLACE HYDRAULIC PUMP DRAIN FILTER CARTRIDGE 401
REPLACE SWING, TRAVEL MOTOR DRAIN FILTER CARTRIDGE 401
REPLACE PILOT FILTER CARTRIDGE 402
CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL 402
REPLACE FUEL PREFILTER CARTRIDGE 403
EVERY 1000 HOURS MAINTENANCE 407
REPLACE FUEL MAIN FILTER CARTRIDGE 407
REPLACE FUEL TANK BREATHER ELEMENT 411
CHANGE OIL IN SWING MACHINERY CASE 412
CHANGE OIL IN PTO CASE 414
CLEAN PTO LUBRICATION OIL FILTER STRAINER 416
REPLACE HYDRAULIC OIL FILTER ELEMENT 417
REPLACE HYDRAULIC TANK BREATHER FILTER ELEMENT 418
INSPECTION OF ENGINE SUCTION HOSE CLAMP FOR LOOSENING 418
CHECK FOR LOOSE CLAMPS OF AFTERCOOLER HOSE 420
CHECK GAS PRESSURE IN ACCUMULATOR FOR OPERATION CONTROL CIRCUIT 421
CHECK WELDED STRUCTURE 421
CHECK EMERGENCY LADDER 424
GREASING HYDRAULIC LADDER 425
REPLACE SWING MOTOR COOLING FILTER ELEMENT 426
EVERY 2000 HOURS MAINTENANCE 430
CHANGE OIL IN FINAL DRIVE CASE 430
CHECK GREASE LEVEL IN SWING PINION, ADD GREASE 431
CHECK ALTERNATOR, STARTING MOTOR 431
CHECK ENGINE VALVE CLEARANCE, ADJUST 431
EVERY 4000 HOURS MAINTENANCE 432
GREASE ENGINE MOUNT 432
CHECK WATER PUMP 432
CHECK FOR LOOSENESS OF HIGH-PRESSURE PIPING CLAMP, HARDENING OF RUBBER 433
CHECK FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER 434
REPLACE ACCUMULATOR IN OIL COOLER CIRCUIT 435
EVERY 5000 HOURS MAINTENANCE 436
CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER 436
EVERY 8000 HOURS MAINTENANCE 440
REPLACE INJECTOR NOZZLE ASSEMBLY 440
REPLACE HIGH-PRESSURE PIPING CLAMP 440
REPLACE FUEL SPRAY PREVENTION CAP 440
SPECIFICATIONS 441
SPECIFICATIONS 442
ATTACHMENTS AND OPTIONS 445
GENERAL PRECAUTIONS FOR SAFETY 446
PRECAUTIONS WHEN SELECTING 446
READ THE INSTRUCTION MANUAL THOROUGHLY 446
PRECAUTIONS WHEN REMOVING OR INSTALLING 446
PRECAUTIONS WHEN USING 447
ATTACHMENT GUIDE 448
COMBINATIONS OF WORK EQUIPMENT 448
FRONT GUARD 449
HANDLING FUEL QUICK CHARGE 450
GENERAL LOCATIONS 450
PROCEDURE FOR OPERATING FUEL CHARGE 451
REPLACE FUEL TANK BREATHER ELEMENT 454
ACTION WHEN MACHINE DOES NOT MOVE BECAUSE OF FAILURE IN PROXIMITY SWITCH 455
HANDLING SERVICE CENTER 459
GENERAL LOCATIONS 459
PROCEDURE FOR OPERATING SERVICE ARM 460
METHOD OF DRAINING, ADDING LUBRICANT AND COOLANT FROM SERVICE PANEL 463
GREASING LADDER SERVICE ARM 474
REPLACE FUEL TANK BREATHER ELEMENT 475
ACTION WHEN MACHINE DOES NOT MOVE BECAUSE OF FAILURE IN PROXIMITY SWITCH 476
HANDLING JUMP START RECEPTACLE 480
GENERAL LOCATIONS 480
CONNECTED PROCEDURE OF EXTERNAL POWER SOURCE 480
ORBCOM CONTROLLER (COMMUNICATIONS TERMINAL) 482
STARTING IN COLD AREAS 483
EXTERNAL POWER SOURCE TYPE ENGINE PREHEATING HEATER 484
Procedure For Setting Up External Power Source 485
Procedure For Handling 491
HANDLING PORTABLE COMBUSTION TYPE PREHEATING HEATER 494
Name Of Parts 496
Explanation Of Components 499
Method Of Operation 504
Specifications 509
LOADING SHOVEL 511
MACHINE VIEW ILLUSTRATIONS 512
OVERALL MACHINE VIEW 512
EXPLANATION OF COMPONENTS 513
SWITCHES 513
OPERATIONS 515
OPERATION OF WORK EQUIPMENT 515
PRECAUTIONS DURING OPERATION 517
LOADING SHOVEL WORK 521
PRECAUTIONS WHEN DISASSEMBLING MACHINE 522
RELEASING PRESSURE 522
Releasing Pressure from Work Equipment Circuit, Swing Circuit, Travel Circuit 522
Releasing Pressure in Accumulator Circuit 522
TRANSPORTATION 523
MACHINE CONFIGURATION FOR TRANSPORT 523
MAINTENANCE 524
EVERY 10 HOURS MAINTENANCE 524
SPECIFICATION 529
WEAR PARTS 531
WEAR PARTS LIST 531
COMBINATION OF WORK EQUIPMENT 532
COMBINATION OF WORK EQUIPMENT 532
INDEX 533
<A> 535
<B> 535
<C> 535
<D> 535
<E> 535
<F> 535
<G> 535
<H> 535
<I> 536
<L> 536
<M> 536
<O> 536
<P> 536
<R> 536
<S> 536
<T> 537
<U> 537
<V> 537
<W> 537
<Y> 537
COLOPHON 539
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