Komatsu GALEO PC2000-8 Hydraulic Excavator Workshop Repair Service Manual PDF - MKMTSPC2000.zip
Full service and repair guide featuring Electrical Wiring Diagrams for the Komatsu Hydraulic Excavator GALEO PC2000-8, containing every technical detail needed to service, troubleshoot, overhaul, and rebuild the machine just like an expert technician.
The Komatsu Hydraulic Excavator GALEO PC2000-8 workshop service repair manual covers:
* 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: 7,332 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
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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
...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
...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
...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
...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
...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
...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
...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
...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
...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