Komatsu PC2000-8 Hydraulic Excavator Shop Manual SEN01607-08 (Serial 20001 and Up)

Description

Komatsu PC2000-8 Hydraulic Excavator Shop Manual SEN01607-08 (Serial 20001 and Up)

This Komatsu PC2000-8 Hydraulic Excavator Shop Manual SEN01607-08 (Serial 20001 and Up) is the workshop volume used to service the large hydraulic excavator on serial numbers 20001 and up. It is written in English and assembled as form SEN01607-08, with supporting brochures such as SEN01609-08 (index), SEN01610-03 (foreword), and SEN01612-02 (specification and technical data). The copyright page shows © 2008 KOMATSU and Printed in Japan 04-08 (01). The book treats both backhoe specification and loading shovel specification on the same PC2000-8 chassis, so a shop can follow the correct piping, cylinder, and work-equipment path for the machine sitting in the bay.

File Details

• Manual type: Shop Manual (chassis volume)
• Brand / model: Komatsu PC2000-8 hydraulic excavator
• Serial range: 20001 and up
• Language: English
• Page count: 1463
• File format: PDF
• Document number: SEN01607-08
• Print date: 04-08 (01), © 2008 KOMATSU

Machine and Powerplant Coverage

The specification section identifies engine model SAA12V140E-3: a 4-cycle, water-cooled, V-type direct-injection diesel with turbocharger and air-cooled aftercooler. Cylinder layout is 12 − 140 × 165 mm, piston displacement 30.48 ℓ {30,480 cc}. Flywheel horsepower is given as 728 kW / 1,800 rpm {976 HP / 1,800 rpm}, maximum torque 4,510 Nm / 1,350 rpm {460 kgm / 1,350 rpm}, high idle 1,980 ± 50 rpm, and low idle 825 ± 25 rpm. Electrical starting and charging hardware is 24 V, 11 kW × 2 starting motors, 24 V, 50 A × 2 alternators, and 12 V, 170 Ah × 4 batteries.

Backhoe specification machine weight is 200,000 kg with a 12.0 m³ bucket. Loading shovel specification machine weight is 195,000 kg with an 11.0 m³ bucket. Travel speed is 2.7 km/h and swing speed is 4.8 rpm on both configurations. Gradeability is 33 deg. on the backhoe listing and 35 deg. on the loading shovel listing. Standard shoe width is 810 mm, track gauge 4,600 mm, length of track on ground 5,780 mm, and minimum ground clearance 825 mm. Ground pressure with the standard shoe is 190 kPa {1.94 kg/cm²} (backhoe) and 186 kPa {1.90 kg/cm²} (loading shovel).

Main pumps are two variable-displacement tandem piston units HPV375 + 375. Fan pump is HPV95 + 95 (shown with SAL / SBL gear-type PTO lubrication pump in the circuit). Published deliveries are main pump P1 629 + 629 ℓ/min, P2 518 + 518 ℓ/min, fan pump 160 + 160 ℓ/min, and PTO lubrication pump 35 ℓ/min. Set pressures are main pump 29.6 MPa {300 kg/cm²} and fan pump 24.5 MPa {250 kg/cm²}. Control valves are 5-spool + 5-spool type × 2. Travel motors are KMF340 piston motors with brake valve and shaft brake (two units). Swing motors are KMF230 piston motors with safety valve and shaft brake (two units). Fluid capacities in the lubricant table include engine oil pan 128 ℓ specified / 120 ℓ refill, PTO case 36 ℓ, swing machinery 30 ℓ each front and rear, final drive 85 ℓ each side, hydraulic system 2,400 ℓ specified / 1,300 ℓ refill, fuel tank 3,400 ℓ, cooling system 180 ℓ, and grease 200 ℓ.

How-to-read notes in the foreword state that shop manuals are divided into a chassis volume and an engine volume, and that the engine unit itself is covered in the engine volume for the mounted engine model. This SEN01607-08 file is the chassis shop manual: it still includes engine-related testing, injector and seal R&I, fuel-system work, S-mode engine troubleshooting charts, and controller procedures that a machine shop actually performs on the excavator, but it is not a substitute for a separate engine-only rebuild volume if one is required for deep internal engine overhaul.

Chapters Covered

• 00 Index and foreword — composition of shop manual, table of contents, safety notice, how to read the shop manual, maintenance-standard terms, electric and hydraulic component handling, engine connectors, electric wire code, operation precautions, push-pull coupler method, standard tightening torque table, conversion table
• 01 Specification — specification drawings, specifications, weight table, table of fuel, coolant and lubricants
• 10 Structure, function and maintenance standard — engine and cooling system (radiator and oil cooler, PTO, PTO lubrication); power train (swing machinery, swing circle, final drive, sprocket); undercarriage and frame (track frame, idler, carrier roller, track roller, track shoe, HIC system)
• Hydraulic system, Part 1 — piping drawings, hydraulic tank, oil cooler, line / pilot / return / motor-drain / pump-drain filters, accumulator, travel junction valve, solenoid valve, hydraulic cylinder, greasing system, center swivel joint, hydraulic ladder
• Hydraulic system, Part 2 — control valve, electronic OLSS system, swing motor, cooling fan motor, cooling fan pump
• Hydraulic system, Part 3 — travel motor, hydraulic pump, PPC valve, variable back pressure valve, suction selector valve, PPC cut-off valve
• Work equipment — dimensions for backhoe and loading shovel arrangements
• Cab and its attachments — air conditioner piping, cab
• Electrical system — engine control, electrical control system, monitor system, sensors, ORBCOMM terminal
• 20 Standard value table — testing/adjusting/troubleshooting values plus chassis tables for backhoe specification and loading shovel specification
• 30 Testing and adjusting, Parts 1–4 — engine measurements (speed, boost, exhaust temperature and color, valve clearance, compression, blow-by, oil and fuel pressure, air bleed, belt tension); HIC and track tension; circuit pressures, fan speed and EPC current, PPC and solenoid outlet pressures, travel deviation, hydraulic drift and leakage, residual-pressure relief, air bleeding, auto-grease and hydraulic ladder adjustments; machine-monitor special functions; VHMS initial setting and Pm-clinic measurement
• 40 Troubleshooting — failure code table and fuse locations; general troubleshooting information; troubleshooting by failure code Parts 1–7; electrical system E-mode; hydraulic and mechanical H-mode; mechanical / engine S-mode
• 50 Disassembly and assembly — general information, special tools, coating materials; power container, engine/PTO/pump, radiator, aftercooler, oil cooler, fuel cooler, cooling assembly, fan motor, fuel tank; fuel supply pump, cylinder head, fuel injector, front and rear engine oil seals; PTO, swing machinery, swing circle, final drive; undercarriage components, revolving frame, counterweight, hydraulic ladder; hydraulic tank, pumps, control valve, center swivel joint, swing and travel motors, PPC valves, hydraulic cylinders; boom, arm, bucket and bottom-dump work equipment; cab glass and cab base; air conditioner, monitor, engine / pump / VHMS controllers, Orbcomm terminal
• 90 Diagrams and drawings — hydraulic circuit diagram; electrical circuit diagrams 1/12 through 12/12; connector arrangement diagram

Taken as a whole, the Komatsu PC2000-8 Hydraulic Excavator Shop Manual SEN01607-08 (Serial 20001 and Up) gives a technician the structure of every major chassis system, the numbers used to decide whether a reading is still in spec, the step-by-step tests that produce those readings, the failure-code trees that isolate a sensor, solenoid, pump, or controller, and the lift-and-fit procedures used to change the assemblies once the diagnosis is finished.

Testing, Adjusting, and Standard Values

Section 20 publishes separate chassis standard-value tables for backhoe specification and loading shovel specification. Engine-side figures used during testing include intake/exhaust valve clearance 0.57 ± 0.02 mm and engine oil pressure minima tied to 40–60°C oil temperature. Chassis figures used again and again in the field include engine speed 1,780 ± 100 rpm with all pumps at relief in P mode and boom-up relief, hydraulic oil temperature 45–55°C for pressure work, and rated work-equipment load 21,600 kg when measuring hydraulic drift. Fan speed in 100% mode at high idle is listed as 840 ± 50 rpm on the standard specification and 1,100 ± 50 rpm on the +55°C specification.

Testing and adjusting walks through measuring engine speed from monitor codes 01002 and 01006, testing air boost and exhaust temperature, reading exhaust color, setting valve clearance with the barring tool on the flywheel housing, measuring compression after warm-up, checking blow-by at rated output, testing engine oil pressure, releasing residual fuel pressure (wait at least 30 seconds after stop), measuring low-pressure fuel circuit values at high idle (0.15–0.3 MPa), and bleeding both standard and low-grade fuel circuits. Chassis work covers HIC remaining-pressure relief and accumulator gas fill, track shoe tension, work-equipment / swing / travel circuit pressures, self-pressure reducing valve output, main-pump control signal, fan pump EPC current and output pressure, PPC valve output, solenoid outlet pressure, travel deviation, cylinder leakage, air bleed of pumps, swing motors, travel motors, PPC circuits and control-valve spool bleeders, auto-grease checks, and hydraulic-ladder proximity-switch clearance.

Failure Codes and Three Troubleshooting Modes

Failure-code coverage is unusually wide for a mining excavator. Engine-controller codes run through left-bank CA and right-bank CB families: ECM internal failure, Ne and backup speed sensor errors, charge-air pressure and temperature, throttle, oil pressure and temperature, coolant, sensor supplies, overspeed, fuel temperature, IMV/PCV open and short, injector open/short on L1–L6 and R1–R6, injector drive circuit, battery voltage, rail-pressure high/low/in-range/very-high/very-low, CEN communication, KOMNET timeout, grid-heater relay, and harness-key errors. Machine and pump-controller codes cover battery and lamp relays, wiper drives, pump solenoid power, 5 V sensor supplies, CAN disconnect between pump controllers, VHMS source and connector mismatch, KOM-NET, ambient / hydraulic / PTO / exhaust temperature sensors, jet-sensor and pump-pressure sensors, PPC pressure sensors for boom, arm, bucket and swing, auto-grease, travel alarm, swing priority and swing brake solenoids, straight-travel, fan reverse, arm and boom throttle valves, 2-stage relief, back-pressure compensation, and fan / main-pump EPC solenoids.

E-mode electrical troubleshooting starts from “monitor displays nothing,” no-start (engine does not turn), auto-decelerator and automatic warm-up, preheater, disabled work equipment / swing / travel, push-up and boom shockless functions, gauge and monitor faults, wiper, travel alarm, lamps, air conditioner, and step light. H-mode hydraulic and mechanical charts cover low speed or power of the whole machine, engine stall under load, no movement, pump noise, boom / arm / bucket power or no movement, hydraulic drift and time lag, heavy-lift and push-up functions, travel deviation and one-side travel failure, swing speed, overrun and shock, fan noise or overheating, and loading-shovel bottom-dump faults. S-mode engine charts cover hard starting, no start, poor pickup, stop during work, rough running, lack of power, black or blue smoke, oil consumption and contamination, fuel consumption, oil in coolant, low oil pressure, rising oil level, overheating, abnormal noise, and vibration.

Disassembly Weights and Shop Practice

Section 50 records the weights a crane operator actually needs. Power container assembly is 16,238 kg. Combined engine, PTO and hydraulic pump assembly is approximately 6,100 kg, with engine-mount bolts specified 824–1,030 Nm {84–105 kgm}, target 927 Nm {94.5 kgm}. Engine hood assembly is 210 kg. Hydraulic tank refill after service is approximately 1,300 ℓ. Coolant refill after cooling-system work is 180 ℓ. Ladder assembly is 170 kg. Special-tool lists and coating-material lists sit at the front of the disassembly section so the shop can stage stands, forcing screws, seal drivers, and sealants before the first hose comes off.

What This Manual Enables

The Komatsu PC2000-8 Hydraulic Excavator Shop Manual SEN01607-08 (Serial 20001 and Up) supports pressure setting and confirmation on the work-equipment, swing, travel, fan, and pilot circuits; diagnosis of VHMS, pump-controller, and dual-bank engine-controller faults; injector, supply-pump, and oil-seal replacement on the installed SAA12V140E-3; removal of the power container and the engine-PTO-pump stack; rebuild or exchange of control valves, PPC valves, swing and travel motors, center swivel joint, final drives, rollers, idlers, and hydraulic cylinders for both backhoe and loading shovel front ends; cab, monitor, and controller exchange; and tracing of the full hydraulic circuit plus the twelve-sheet electrical diagram set. Using the printed clearances, relief values, current ranges, and torque figures keeps a 200-tonne class excavator from being adjusted by guesswork. After payment the file is delivered as an instant PDF download with no shipping wait. Open it on a shop PC, tablet, or phone and print the pages needed for the job.