Komatsu Mining Excavator PC2000-11R service & repair manual

Description Komatsu Mining Excavator PC2000-11R service & repair manual

Komatsu Mining Hydraulic Excavator PC2000-11R pdf workshop service repair manual

Serial numbers:
30019 and up
30035 and up

Specifications, maintenance, technical documentation, troubleshooting, testing, electrical wiring diagrams, hydraulic schematics, adjusting, assembly, disassembly, removal, installation instructions and other information

MANUAL CONTENT:
Index and Foreword
Abbreviation List
Foreword, Safety, Basic Information
How to Read the Shop Manual
Safety Notice for Operation
Precautions to Prevent Fire
Procedures If Fire Occurs
Precautions When You Discard Waste Materials
Precautions When You Handle Hydraulic Equipment
Precautions When You Disconnect and Connect Pipings
Precautions When You Handle Electrical Equipment
Precautions When You Handle Fuel System Equipment
Precautions When You Handle Intake System Equipment
Practical Use of KOMTRAX
Disconnect and Connect Push-Pull Type Coupler
Precautions for Disconnection and Connection of Connectors
How to Disconnect and Connect Deutsch Connector
How to Disconnect and Connect Slide Lock Type Connector
How to Disconnect and Connect Connector with Lock to Pull
How to Disconnect and Connect Connector with Lock to Push
How to Disconnect and Connect Connector with Housing to Rotate
How to Disconnect and Connect Molex Connector
How to Read the Codes for Electric Cable
Explanation of Terms for Maintenance Standard
Standard Tightening Torque Table
Conversion Table

Specifications
Specification Drawing
Working Range Drawings
Weight Table
Fuel, Coolant, Lubricant

Structure and Function
Boot-up System
Layout Drawing of Boot-up System
System Operating Lamp System
Battery Isolator
Engine System
Layout Drawing of Engine System
Engine Control System
Auto-Deceleration System
Automatic Low Idle System
Engine Automatic Warm-up System
Overheat Prevention System
Turbocharger Protection System
Component Parts of Engine System
Cooling System
Layout Drawing of Cooling System
Fan Speed Control System of Hydraulic Fan
Engine Output Control System of Hydraulic Fan
Fan Reverse Rotation System of Hydraulic Fan
Component Parts of Cooling System
Control System
Layout Drawing of Control System
Machine Monitor System
KOMTRAX Plus System
Component Parts of Control System
Hydraulic System
Layout Drawing of Hydraulic System
Electronic OLSS
Engine and Pump Combined Control System
Component Parts of Hydraulic System
Work Equipment System
Layout Drawing of Work Equipment System
Layout Drawing of Work Equipment System (Loading Shovel Specification)
Work Equipment System Diagram
Machine Push-up System
Heavy Lift System
Boom Shockless Control Function
PPC Lock System
Work Equipment and Travel Automatic Lock System
Component Parts of Work Equipment System
Swing System
Layout Drawing of Swing System
Swing Control System Diagram
Swing Priority System Diagram
Component Parts of Swing System
Travel System
Layout Drawing of Travel System
System Diagram of Travel Control System
Travel Straight System Diagram
HIC System
Component Parts of Travel System
Accumulator for HIC System
Lifting System
Hydraulically Operated Stairway System
Component Parts of Lifting System
Service Center System
Layout Drawing of Service Center System
Service Center System Diagram
Component Parts of Service Center System
Grease Lubrication System
Grease Lubrication System Diagram
Component Parts of Grease Lubrication System
Undercarriage and Frame
Layout Drawing of Undercarriage
Work Equipment
Structure of Work Equipment
Structure of Work Equipment (Loading Shovel Specification)
Function of Work Equipment
Work Equipment Clearance Adjustment Shim
CAB Related Parts
CAB 
Wiper System
CAB Mount

Standard Value Table
Standard Value Table for Engine
Standard Value Table for Machine
Standard Value Table for Machine: PC2000-11R (Backhoe Specification)
Standard Value Table for Machine: PC2000-11R (Loading Shovel Specification)
Machine Posture and Procedures to Measure Performance (Backhoe Specification) 
Machine Posture and Procedures to Measure Performance (Loading Shovel Specification)

Testing and Adjusting
Precautions Before Work
Related Information on Testing and Adjusting
Tools for Testing and Adjusting
Engine and Cooling System
Examine Engine Speed
Examine Boost Pressure
Examine Exhaust Gas Temperature
Examine Exhaust Gas Color
Examine and Adjust Valve Clearance
Examine Compression Pressure
Examine Blowby Pressure
Examine Engine Oil Pressure
Examine Fuel Pressure
Examine Fuel Return Rate and Leakage
Bleed Air from Fuel System
Examine Fuel Circuit for Leakage
Examine Supply Pump
Handle Cylinder Cut-out Mode Operation
Examine Alternator
Examine and Adjust Alternator Belt Tension
Handle No-Injection Cranking Operation
Examine and Adjust Air Conditioner Compressor Belt Tension
Write Injector Compensation Value to Engine Controller
Power Train
Examine Swing Circle Bearing Clearance
Release Remained Pressure from HIC Circuit
Examine and Charge HIC Circuit Accumulator Nitrogen Gas Pressure
Bleed Air from HIC Circuit
Undercarriage and Frame
Examine Sprocket Wear
Examine and Adjust Track Tension
Hydraulic System
Release Remained Pressure in Hydraulic Circuit
Examine and Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits
Examine and Adjust Oil Pressure in Control Circuit
Examine Pump EPC Solenoid Valve Outlet Pressure
Examine and Adjust Jet Sensor Differential Pressure
Examine Outlet Pressure of Solenoid Valve
Examine Outlet Pressure of EPC Solenoid Valve
Examine PPC Valve Outlet Pressure
Adjust Play of Work Equipment and Swing PPC Valves
Examine Travel Deviation
Examine Fan Speed
Examine Oil Pressure in Fan Pump Circuit
Examine Fan Pump EPC Electric Current
Examine Fan Pump EPC Solenoid Valve Outlet Pressure
Examine Parts Which Cause Hydraulic Drift of Work Equipment
Examine Oil Leakage
Bleed Air from Hydraulic System
CAB Related Parts
How to Adjust Mirrors
Automatic Lubrication System
Examine and Adjust Automatic Lubrication System
Lifting System
Examine and Adjust Hydraulically Operated Stairway Proximity Switch
Service Center System
Examine and Adjust Service Arm Proximity Switch
Electrical System
Set and Operate Machine Monitor
How to Start Up KOMTRAX Terminal
How to Stop Use of KOMTRAX Terminal
Default Setting of KOMTRAX Plus Controller
Default Setting of Wireless LAN Modem
Download Data from KOMTRAX Plus Controller
Adjust After Replacement of KOMTRAX Plus Controller
Adjust After Replacement of Wireless LAN Modem 
Adjust KomVision Camera Angle
Set Region of Bluetooth® Compatible Radio
Handle Voltage Circuit of Engine Controller
Handle Battery Isolator and Starting Motor Isolator
Examine Diodes
Pm Clinic
Pm Clinic Service
Perform Quick Pm

Troubleshooting
Precautions Before Work
Related Information to Troubleshooting
General Troubleshooting Points
Sequence of Events in Troubleshooting
Checks Before Troubleshooting
Inspection Procedure Before Troubleshooting
Test in Accordance with Testing Procedure
Preparation for Troubleshooting of Electrical System
Procedure for Troubleshooting
Symptom and Troubleshooting Numbers
Information Shown in Troubleshooting Table
How to Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness
Connector List and Layout
Connector Contact Connection Table
T-Branch Box and T-Branch Adapter Table
Fuse Location Table
Failure Code Table
Troubleshooting by Failure Code (Display of Code)
Troubleshooting of Electrical System (E-Mode)
Troubleshooting for Hydraulic and Mechanical Systems (H Mode)
Troubleshooting of Engine (S-Mode)

Disassembly and Assembly
Precautions Before Work
Related Information on Disassembly and Assembly
How to Read This Manual
Coating Materials List
Special Tool List
Sketches of Special Tools
Engine and Cooling System
Remove and Install Supply Pump Assembly
Remove and Install Injector Assembly
Remove and Install Cylinder Head Assembly
Remove and Install Starter Assembly
Remove and Install Alternator Belt
Remove and Install Alternator Assembly
Remove and Install Radiator Assembly
Remove and Install Hydraulic Oil Cooler Assembly
Remove and Install Aftercooler Assembly
Remove and Install Cooling Fan Motor Assembly
Remove and Install Power Module Packaging Assembly
Remove and Install Engine, PTO, and Hydraulic Pump Assembly
Remove and Install Engine Front Oil Seal
Remove and Install Engine Rear Oil Seal
Remove and Install Fuel Cooler Assembly
Remove and Install Engine Hood Assembly
Remove and Install Fuel Tank Assembly
Remove and Install Muffler Assembly
Remove and Install Bellows Pipe Assembly
Remove and Install Turbocharger Assembly
Remove and Install Air Cleaner Assembly
Remove and Install Air Conditioner Compressor Assembly
Remove and Install Air Conditioner Condenser Assembly
Power Train
Disassemble and Assemble PTO Assembly
Remove and Install PTO Assembly
Remove and Install Travel Motor and Final Drive Assembly
Disassemble and Assemble Final Drive Assembly
Remove and Install Swing Motor and Swing Machinery Assembly
Disassemble and Assemble Swing Machinery Assembly
Remove and Install Swing Circle Assembly
Undercarriage and Frame
Remove and Install Idler Assembly
Remove and Install Track Roller Assembly
Remove and Install Carrier Roller Assembly
Separate and Connect Track Assembly
Disassemble and Assemble Idler Assembly
Disassemble and Assemble Idler Adjustment Cylinder Assembly
Disassemble and Assemble Track Roller Assembly
Disassemble and Assemble Carrier Roller Assembly
Remove and Install Revolving Frame Assembly
Remove and Install Counterweight Assembly
Hydraulic System
Remove and Install Center Swivel Joint Assembly
Disassemble and Assemble Center Swivel Joint Assembly
Remove and Install Hydraulic Tank Assembly
Remove and Install Hydraulic Pump Assembly
Remove and Install Control Valve Assembly
Remove and Install Swing Motor Assembly
Disassemble and Assemble Work Equipment PPC Valve Assembly
Disassemble and Assemble Travel PPC Valve Assembly
Disassemble and Assemble Grease Gun Assembly
Work Equipment
Remove and Install Bucket Cylinder Assembly (Backhoe Specification)
Remove and Install Bucket Cylinder Assembly (Loading Shovel Specification)
Remove and Install Arm Cylinder Assembly (Backhoe Specification)
Remove and Install Arm Cylinder Assembly (Loading Shovel Specification)
Remove and Install Boom Cylinder Assembly (Backhoe Specification)
Remove and Install Boom Cylinder Assembly (Loading Shovel Specification)
Remove and Install Bucket Assembly (Backhoe Specification)
Remove and Install Bucket Assembly (Loading Shovel Specification)
Remove and Install Arm Assembly (Backhoe Specification)
Remove and Install Arm Assembly (Loading Shovel Specification)
Remove and Install Boom Assembly (Backhoe Specification)
Remove and Install Boom Assembly (Loading Shovel Specification)
Disassemble and Assemble Work Equipment Cylinder Assembly (Backhoe Specification)
Remove and Install Bottom Dump Cylinder Assembly (Loading Shovel Specification)
CAB Related Parts
Remove and Install Operator Cab Assembly
Remove and Install CAB Base
Remove and Install Operator Cab Glass (Adhered Glass)
Remove and Install Operator Cab Glass (Assembling Type)
Remove and Install Air Conditioner Unit Assembly
Remove and Install Operator Seat
How to Remove and Install Seat Belt
Remove and Install Work Equipment Control Lever Assembly
Remove and Install Front Wiper Assembly
Electrical System
Remove and Install Engine Controller Assembly (Right Bank)
Remove and Install Engine Controller Assembly (Left Bank)
Remove and Install Pump Controller Assembly
Remove and Install KomVision Controller Assembly
Remove and Install Machine Monitor Assembly
Remove and Install Mass Air Flow and Temperature Sensor
Remove and Install Crankcase Pressure Sensor
Remove and Install KomVision Camera
Remove And Install KOMTRAX Plus Controller Assembly
Remove and Install Wireless LAN Unit Assembly

Maintenance Standard
Engine and Cooling System
Maintenance Standard for Engine Mount
Maintenance Standard for PTO
Maintenance Standard for Cooling Fan Pump
Maintenance Standard for Cooling Fan Motor
Power Train
Maintenance Standard for Swing Circle
Maintenance Standard for Swing Machinery
Maintenance Standard for Final Drive
Maintenance Standard for Sprocket
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing
Undercarriage and Frame
Maintenance Standard for Track Frame and Idler Cushion
Maintenance Standard for Idler
Maintenance Standard for Track Roller
Maintenance Standard for Carrier Roller
Maintenance Standard for Track Shoes
Maintenance Standard for Double Shoes
Maintenance Standard for Triple Shoes
Hydraulic System
Maintenance Standard for Main Pump
Maintenance Standard for Swing Motor
Maintenance Standard for Travel Motor
Maintenance Standard for Control Valve
Maintenance Standard for Variable Back Pressure Valve
Maintenance Standard for PPC Cut-off Valve
Maintenance Standard for Suction Selector Valve
Maintenance Standard for PPC Cut-off Valve
Maintenance Standard for Suction Selector Valve
Maintenance Standard for Work Equipment and Swing PPC Valve
Maintenance Standard for Travel PPC Valve
Maintenance Standard for Center Swivel Joint
Work Equipment
Maintenance Standard for Work Equipment Linkage
Maintenance Standard for Boom Cylinder
Maintenance Standard for Arm Cylinder
Maintenance Standard for Bucket Cylinder
Maintenance Standard of Work Equipment Linkage (Loading Shovel Specification
Maintenance Standard of Boom Cylinder (Loading Shovel Specification)
Maintenance Standard of Arm Cylinder (Loading Shovel Specification)
Maintenance Standard of Bucket Cylinder (Loading Shovel Specification)

Appendix
Precautions Before Work
Air Conditioner System
Precautions for Refrigerant
Air Conditioner Component
Specifications of Air Conditioner
Structure and Function of Refrigeration Cycle
Outline of Refrigeration Cycle
Component Parts of Air Conditioner System
Air Conditioner Unit
Component Parts of Air Conditioner Unit
Air Conditioner Controller
Compressor
Condenser
Receiver Drier
Air Conditioner Related Sensors
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner
Circuit Diagram and Configuration of Connector Pins of Air Conditioner
System Diagram of Air Conditioner
Air Conditioner Control Panel
Input and Output Signals of Air Conditioner Controller
Locations of Air Conditioner Parts and Layout of Connectors
Examine Air Leakage (Duct)
How to Examine Air Leakage (Duct)
Examine Air Conditioner with Self-Diagnosis Function
Examine Vent (Mode) Changeover
How to Examine Vent (Mode) Changeover
Examine Fresh/Recirc Air Changeover
How to Examine Fresh/Recirc Air Changeover
Examine Sunlight Sensor
How to Examine Sunlight Sensor
Examine Refrigerant (Dual) Pressure Switch
How to Examine Refrigerant (Dual) Pressure Switch
Examine Relay
How to Examine Relay
Air Conditioner Troubleshooting Chart
Information Shown in Troubleshooting Table
A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate)
A-2 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled)
A-3 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal)
A-4 Troubleshooting for Fresh/Recirc Air Changeover
Troubleshooting by Gauge Pressure
Connect Service Tool
How to Connect Service Tool
Precautions for Disconnection and Connection of Air Conditioner Piping
Handle Compressor Oil
KomVision System
Structure and Operation of KomVision System
Precautions for KomVision System
Layout Drawing of KomVision System
Component Parts of KomVision System
Examine and Adjust KomVision System
Set and Operate KomVision Monitor
Camera Calibration
Troubleshooting for KomVision System
Related Information to Troubleshooting
Failure Code Table
Troubleshooting of Electrical System (E-Mode)

Circuit Diagrams
Hydraulic Circuit Diagram
Symbols Used in Hydraulic Circuit Diagram
Hydraulic Circuit Diagram (Loading Shovel Specification)
Electrical Circuit Diagram
Symbols Used in Electric Circuit Diagram

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