Description

KOMATSU PC2000-11EO SHOP MANUAL

KOMATSU PC2000-11EO SHOP MANUAL INDEX

INDEX AND FOREWORD
ABBREVIATION LIST
FOREWORD, SAFETY, BASIC INFORMATION
HOW TO READ THE SHOP MANUAL
SAFETY NOTICE FOR OPERATION
PRECAUTIONS TO PREVENT FIR
ACTIONS IF FIRE OCCURS
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT
PRACTICAL USE OF KOMTRAX
DISCONNECT AND CONNECT PUSH PULL TYPE COUPLER
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUS
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTAT

DISCONNECT AND CONNECT MOLEX CONNECTOR
HOW TO READ ELECTRICAL WIRE COD
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD
STANDARD TIGHTENING TORQUE TABL
CONVERSION TABL
SPECIFICATIONS
CONTENTS
SPECIFICATIONS
SPECIFICATION DRAWING
WORKING RANGE DRAWINGS
SPECIFICATIONS
WEIGHT TABL
FUEL, COOLANT, LUBRICANTS (FOR EUROPEAN UNION)
STRUCTURE AND FUNCTION
CONTENTS
NOx CONTROL SYSTEM
FUNCTION OF NOx CONTROL SYSTEM
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
MULTIPLE INJECTION CONTROL SYSTEM
COMPONENT PARTS OF ENGINE SYSTEM
COOLING SYSTEM
LAYOUT DRAWING OF COOLING SYSTEM
FAN SPEED CONTROL SYSTEM OF HYDRAULIC FAN
INDEX INDEX AND FOREWORD
PC E
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
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
TRAVEL CONTROL SYSTEM DIAGRAM
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 FRAM
LAYOUT DRAWING OF UNDERCARRIAG
WORK EQUIPMENT
STRUCTURE OF WORK EQUIPMENT
FUNCTION OF WORK EQUIPMENT
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM
CAB AND ITS ATTACHMENTS
CAB KOMATSU PC2000-11EO SHOP MANUAL
WIPER SYSTEM
CAB MOUNT
STANDARD VALUE TABL
CONTENTS
STANDARD VALUE TABLE FOR ENGIN
STANDARD VALUE TABLE FOR ENGINE: PC
STANDARD VALUE TABLE FOR MACHIN
STANDARD VALUE TABLE FOR MACHINE: PC
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANC
TESTING AND ADJUSTING
CONTENTS
RELATED INFORMATION ON TESTING AND ADJUSTING
TOOLS FOR TESTING AND ADJUSTING
ENGINE AND COOLING SYSTEM
TEST ENGINE SPEED
TEST BOOST PRESSUR
TEST EXHAUST GAS TEMPERATUR
TEST EXHAUST GAS COLOR
TEST AND ADJUST VALVE CLEARANC
TEST COMPRESSION PRESSUR
TEST BLOWBY PRESSUR
TEST ENGINE OIL PRESSUR
TEST EGR VALVE AND VGT OIL PRESSUR
TEST FUEL PRESSUR
TEST FUEL RETURN RATE AND LEAKAG
BLEED AIR FROM FUEL SYSTEM
TEST FUEL CIRCUIT FOR LEAKAG
TEST SUPPLY PUMP
HANDLE CYLINDER CUT OUT MODE OPERATION
TEST ALTERNATOR
TEST AND ADJUST ALTERNATOR BELT TENSION
HANDLE NO INJECTION CRANKING OPERATION
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION
CLEAN FUEL DOSER
WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER
POWER TRAIN
TEST SWING CIRCLE BEARING CLEARANC
RELEASE REMAINING PRESSURE FROM HIC CIRCUIT
TEST AND CHARGE HIC CIRCUIT ACCUMULATOR NITROGEN GAS PRESSUR
BLEED AIR FROM HIC CIRCUIT
UNDERCARRIAGE AND FRAM
TEST SPROCKET WEAR
TEST AND ADJUST TRACK TENSION
HYDRAULIC SYSTEM
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS

TEST AND ADJUST OIL PRESSURE OF CONTROL CIRCUIT
TEST PUMP EPC SOLENOID VALVE OUTLET PRESSUR
TEST AND ADJUST JET SENSOR DIFFERENTIAL PRESSUR
TEST OUTLET PRESSURE OF SOLENOID VALV
METHOD FOR TESTING OUTLET PRESSURE OF EPC SOLENOID VALV
TEST PPC VALVE OUTLET PRESSUR
ADJUST WORK EQUIPMENT AND SWING PPC VALVES
TEST TRAVEL DEVIATION
TEST FAN SPEED
TEST OIL PRESSURE IN FAN PUMP CIRCUIT
TEST FAN PUMP EPC ELECTRIC CURRENT
TEST FAN PUMP EPC SOLENOID VALVE OUTLET PRESSUR
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT
TEST OIL LEAKAG
BLEED AIR FROM HYDRAULIC CIRCUIT
CAB AND ITS ATTACHMENTS
METHOD FOR ADJUSTING MIRRORS
AUTOMATIC LUBRICATION SYSTEM
TESTING AND ADJUSTING AUTOMATIC LUBRICATION SYSTEM
LIFTING SYSTEM
TEST AND ADJUST HYDRAULICALLY OPERATED STAIRWAY PROXIMITY SWITC
SERVICE CENTER SYSTEM
TEST AND ADJUST SERVICE ARM PROXIMITY SWITC
ELECTRICAL SYSTEM
SET AND OPERATE MACHINE MONITOR
METHOD FOR STARTING UP KOMTRAX TERMINAL
DEFAULT SETTING OF KOMTRAX Plus CONTROLLER
SETTING DEFAULT OF WIRELESS LAN MODEM
DOWNLOAD OF KOMTRAX Plus CONTROLLER DATA
ADJUST WHEN KOMTRAX Plus CONTROLLER IS REPLACED
ADJUST WHEN WIRELESS LAN MODEM IS REPLACED
ADJUST KomVision CAMERA ANGL
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER
HANDLE BATTERY ISOLATOR AND STARTING MOTOR ISOLATOR
TEST DIODES
Pm CLINIC
Pm CLINIC SERVIC
PERFORMING QUICK Pm
TROUBLESHOOTING
CONTENTS
RELATED INFORMATION ON TROUBLESHOOTING
GENERAL TROUBLESHOOTING POINTS
TROUBLESHOOTING POINTS FOR AFTERTREATMENT SYSTEM
SEQUENCE OF EVENTS IN TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING
TESTING IN ACCORDANCE WITH TESTING PROCEDUR
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM
PROCEDURE FOR TESTING AND TROUBLESHOOTING
SYMPTOM AND TROUBLESHOOTING NUMBERS
INFORMATION DESCRIBED IN TROUBLESHOOTING TABL
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR
SYSTEM
CONNECTORS LIST AND LAYOUT
CONNECTOR CONTACT IDENTIFICATION
T BRANCH BOX AND T BRANCH ADAPTER TABL
FUSE LOCATION TABL
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC)
PREPARATION OF SHORT SOCKET ADAPTER (FOR FAILURE CODES [CA ], [CB ],
[CA ] AND [CB ])
FAILURE CODES TABL
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)
ENGINE DOES NOT START (ENGINE DOES NOT CRANK)
MANUAL PREHEATING SYSTEM DOES NOT WORK
AUTOMATIC PREHEATING SYSTEM DOES NOT WORK
WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP
WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS
NOTHING
WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE
OIL LEVEL MONITOR LIGHTS UP IN YELLOW
WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR
COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW
ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING

HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING

AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING

CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING
FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING
ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING

ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING
HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING
KOMATSU PC2000-11EO SHOP MANUAL
FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM
DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL
ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM
OR MAXIMUM
DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT
TEMPERATUR
SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED
HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR
MAXIMUM
DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE

FUNCTION SWITCH DOES NOT OPERAT
AUTOMATIC WARM UP SYSTEM DOES NOT WORK (IN COLD WEATHER)
WHEN AUTO DECELERATOR SWITCH IS OPERATED, AUTO DECELERATOR MONITOR
DOES NOT LIGHT UP OR DOES NOT GO OFF
AUTO DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER
WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS
NOT DISPLAYED
WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS
NOT CHANGED
SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION

SERVICE MODE CANNOT BE SELECTED
ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOV
ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK
WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT
SWING
WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING
BRAKE DOES NOT OPERAT
HORN DOES NOT SOUND
HORN DOES NOT STOP SOUNDING
ALARM DOES NOT SOUND DURING TRAVEL
ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED
ALARM BUZZER CANNOT BE CANCELED
NONE OF ROOM LAMP, HEADLAMP, OR WORKING LAMP DOES NOT LIGHT UP
HEADLAMP OR WORKING LAMP DOES NOT LIGHT UP
ROOM LAMP DOES NOT LIGHT UP
WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF
WIPER DOES NOT OPERATE WHEN WIPER SWITCH IS OPERATED (UPPER WIPER SPECIFICATION)
WIPER DOES NOT OPERATE WHEN WIPER SWITCH IS OPERATED (LOWER WIPER SPECIFICATION)
FUEL FEED PUMP DOES NOT OPERATE OR STOP AUTOMATICALLY
WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERAT
ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION

ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION
BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION

BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION

SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION
TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION
BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION

BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION

KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY
MACHINE PUSH UP FUNCTION CANNOT BE CANCELED
MACHINE PUSH UP FUNCTION DOES NOT OPERAT
STEP LIGHT DOES NOT LIGHT UP
STEP LIGHT DOES NOT GO OUT
BOOM SHOCKLESS FUNCTION CANNOT BE CANCELED
BOOM SHOCKLESS FUNCTION DOES NOT WORK
AIR CONDITIONER CONTROL PANEL DOES NOT TURN ON
WIND DOES NOT COME OUT FROM THE AIR CONDITIONER
AIR CONDITIONER IS WEAK IN COLD(ELECTRIC CAPACITOR DOES NOT MOVE OR ONLY
HI ROTATION MOVES)
AIR CONDITIONER DOES NOT GET COLD(COMPRESSOR DOES NOT MOVE)
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)
ALL WORK EQUIPMENTS, SWING AND TRAVEL DO NOT WORK
ALL WORK EQUIPMENT, TRAVEL, SWING SPEED OR POWER IS LOW
ENGINE SPEED DROPS SIGNIFICANTLY OR ENGINE STALLS
UNUSUAL NOISE IS HEARD FROM AROUND WORK EQUIPMENT PUMP
BOOM SPEED OR POWER IS LOW IN NORMAL MOD
BOOM RAISE SPEED OR POWER IS LOW IN HEAVY LIFT MOD
BOOM LOWER SPEED OR POWER IS LOW IN MACHINE PUSH UP MOD
ARM SPEED OR POWER IS LOW
BUCKET SPEED OR POWER IS LOW
BOOM DOES NOT OPERAT
ARM DOES NOT OPERAT
BUCKET DOES NOT OPERAT
HYDRAULIC DRIFT OF BOOM IS LARG
HYDRAULIC DRIFT OF ARM IS LARG
HYDRAULIC DRIFT OF BUCKET IS LARG
TIME LAG OF BOOM IS LARG
TIME LAG OF ARM IS LARG
TIME LAG OF BUCKET IS LARG
BOOM SHOCKLESS FUNCTION DOES NOT WORK OR CANNOT BE RELEASED
MACHINE UNINTENTIONALLY TURNS TO ONE SIDE WHEN MACHINE TRAVELS (IT TURNS
IN THE SAME DIRECTION WHEN TRAVELING FORWARD AND REVERSE)
MACHINE UNINTENTIONALLY TURNS TO ONE SIDE WHEN MACHINE TRAVELS (IT TURNS
IN THE DIFFERENT DIRECTIONS WHEN TRAVELING FORWARD AND REVERSE)
ONLY WHEN OPERATING THE TRAVEL LEVER FULLY, TRAVEL DEVIATION IS LARGE AT
START OF TRAVELING
REGARDLESS OF THE STROKE OF THE TRAVEL LEVER, TRAVEL DEVIATION IS LARGE AT
START OF TRAVELING
TRAVEL DEVIATION IS LARGE AT COMBINED OPERATION
TRAVEL SPEED OR POWER IS LOW
ONLY THE ONE SIDE TRACK CAN OPERATE (MACHINE DOES NOT TRAVEL EITHER FORWARD
OR REVERSE)
ONLY THE ONE SIDE TRACK CAN OPERATE (MACHINE CAN TRAVEL ONLY FORWARD OR
REVERSE)
TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST
UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT
SWINGS ONLY IN ONE DIRECTION
SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND
LEFT)
SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY
ONE DIRECTION
IN COMBINED OPERATION OF WORK EQUIPMENT, SWING SPEED OR POWER IS LOW

WHILE COMBINED OPERATION WITH BOOM SWING SPEED IS LOW OR SWING ACCELERATION
PERFORMANCE IS POOR
UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH
RIGHT AND LEFT)