Komatsu PC2000-8 Hydraulic Excavator Official Field Assembly Instruction Manual
Komatsu PC2000-8 Hydraulic Excavator Official Field Assembly Instruction Manual
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This is the COMPLETE Official Field Assembly Instruction Manual for the Hydraulic Excavator.
This manual describes how to assemble the units into the complete
machine in the field.
It's contains information and data to this model. has specs, diagrams, and actual real photo illustrations, and schemes.
This PDF file is Bookmarked and SEARCHABLE to make what you need easy to find.
This Field Assembly Instruction manual provides you with everything you need to know in order to assembly your tractor safely and effectively. Step-by-step assembly procedure, parts installation, adjustment and maintenance procedure after completion of assembly.
Diagrams are provided with the listings to aid the service technician in identifying clearly the parts that need to be ordered.
Models And Serials :
SERIAL NUMBERS 20001 and up
CONTENTS :
SPECIFICATIONS.........................................................................................1
PRECAUTIONS FOR FIELD ASSEMBLY......................................................2
DISPOSAL OF REMOVED PARTS................................................................3
ASSEMBLY PROCEDURE, ASSEMBLY EQUIPMENT AND SCHEDULE... 4
FLOWCHART OF MAIN ASSEMBLY PROCEDURE...................................5
KIT LAYOUT DIAGRAM..............................................................................6
TRANSPORTATION POSTURES................................................................7
LIST OF PARTS SENT INDIVIDUALLY.....................................................16
TOOLS AND EQUIPMENT TO BE USED FOR LOCAL ASSEMBLY........ 37
TIGHTENING TORQUE ...........................................................................39
COATING MATERIALS LIST ................................................................... 43
A. ASSEMBLY OF CHASSIS ...................................................................45
<Assembly of undercarriage>
A- 1. Assembly of track frame assembly and center frame assembly....... 46
A- 2. Installation of idler cushion cylinder piping ....................................... 49
A- 3. Installation of travel motor piping ..................................................... 50
A- 4. Installation of travel motor cover........................................................ 51
A- 5. Filling swing circle with grease .......................................................... 54
A- 6. Assembly of revolving frame assembly and undercarriage .............. 55
A- 7. Installation of swing machinery (front) assembly (27t)
Installation of swing motor (front) assembly (32t) ...................................... 57
A- 8. Connection of swivel joint piping........................................................ 58
A- 9. Connection of swing circle grease piping .......................................... 60
<Assembly of upper structure>
A-10. Installation of hydraulic tank assembly ............................................. 61
A-11. Installation of fuel tank assembly........................................................66
A-12. Connection of fuel tank assembly piping and wiring...........................67
A-13. Installation of cab base assembly...................................................... 69
A-14. Installation of emergency escape ladder ........................................... 71
A-15. Installation of left floor assembly ........................................................ 72
A-16. Connection of cab base assembly piping ...........................................76
A-17. Connection of cab base assembly wiring ...........................................79
A-18. Connection of left floor assembly heater piping...................................85
<Coupling of power container>
A-19. Connection of left floor assembly wiring ........................................... 86
A-20. Installation of tail pipe ........................................................................88
A-21. Installation of power container assembly........................................... 89
A-22. Connection of suction piping ............................................................ 91
A-23. Connection of oil cooler piping and pump drain piping.......................93
A-24. Connection of fan motor drain piping................................................. 94
A-25. Installation of suction unit undercover .............................................. 95
A-26. Connection of delivery piping ........................................................... 96
A-27. Connection of pilot piping and fan motor piping ................................98
A-28. Connection of power container assembly fuel piping ........................99
A-29. Connection of power container assembly air conditioner piping ......101
A-30. Connection of power container assembly heater piping....................102
A-31. Connection of power container assembly wiring ..............................103
<Coupling of operator's cab>
A-32. Installation of operator's cab assembly .......................................... 107
A-33. Installation of rotary lamp (if equipped) .......................................... 111
A-34. Installation of ORBCOMM antenna (if equipped).............................113
A-35. Connection of operator's cab assembly wiring.................................114
A-36. Connection of operator's cab assembly hydraulic piping ............... 117
A-37. Connection of operator's cab assembly window washer hose.........119
A-38. Connection of operator's cab assembly air conditioner piping........ 120
A-39. Connection of operator's cab assembly heater piping .................... 121
A-40. Installation of operator's cab rear floor assembly............................ 122
A-41. Installation of handrail around operator's cab ................................ 123
<Coupling of exterior parts, counterweight, etc.>
A-42. Installation of track frame ladder ..................................................124
A-43. Installation of power container side catwalk assemblies (right and left).125
A-44. Installation of right floor assembly,
grease can cover assembly and center floor......................................... 126
A-45. Installation of fuel tank right catwalk assembly .............................128
A-46. Installation of fuel tank front catwalk assembly ............................ 129
A-47. Adjustment of exterior parts clearance......................................... 130
A-48. Connection of grease reel piping ..................................................131
A-49. Installation of access ladder assembly......................................... 132
A-50. Installation of counterweight assembly .........................................133
A-51. Installation of deformation preventing stoppers for catwalk assemblies
(left and right) on the side of power container ....................................... 134
A-52. Installation of handrail on counterweight....................................... 135
A-53. Installation of handrail clamps....................................................... 136
A-54. Connection of fuel cut wire............................................................ 139
A-55. Connection of drain piping under power container........................ 140
A-56. Connection of battery wiring.......................................................... 141
<Starting of engine and inspection and servicing procedures>
A-57. Setting of hydraulic tank strainer................................................... 142
A-58. Starting engine, checking oil and coolant levels, bleeding air from each part,and adjusting track ......................................................................... 143
A-59. Permanent tightening of swing circle bolt......................................158
A-60. Parts to be touched up after field assembly (chassis side) ...........159
A-61. Connection of engine heater connection port ............................... 160
A-62. Installation of optional harness...................................................... 163
A-63. Installation of rear lamps .............................................................. 164
A-64. Installation of rear camera............................................................. 169
A-65. Connection of emergency stop switch (if equipped) (at the right below container).................................................................................................178
A-66. Connection of emergency stop switch (if equipped) (at the left side of ladder)...................................................................................................... 179
A-67. Installation of engine oil and PTO oil pipings ..................................180
A-68. Installation of coolant piping.............................................................181
A-69. Installation of guard bracket (if equipped) .......................................182
C. ASSEMBLY OF BACKHOE...................................................................183
<Coupling of boom>
C- 1. Installation of boom cylinder...............................................................184
C- 2. Installation of boom cylinder hoses (Serial No. 20095 and up)..........186
C- 3. Assembly of boom sub assembly...................................................... 187
C- 4. Installation of boom assembly........................................................... 192
C- 5. Installation of boom cylinder head side ............................................. 194
<Coupling of arm>
C- 6. Installation of hoses between boom and chassis ...............................196
C- 7. Installation of arm assembly .............................................................. 197
C- 8. Installation of arm cylinder.................................................................. 200
C- 9. Connection of hoses between boom and arm.....................................201
C-10. Connection of auto grease piping.......................................................202
C-11. Connection of wiring between boom and chassis ..............................203
<Coupling of bucket>
C-12. Installation of bucket assembly ......................................................... 204
C-13. Installation of bucket link ................................................................... 207
C-14. Bleeding air from cylinders ............................................................... 209
C-15. Parts to be touched up after field assembly (work equipment side)...212
C-16. Bleeding air from auto grease circuit..................................................213
LS. ASSEMBLY OF LOADING SHOVEL WORK EQUIPMENT.................. 217
LS- 1. Installation of arm cylinder bottom parts ...........................................218
LS- 2. Installation of boom cylinder to machine body.................................. 219
LS- 3. Installation of boom cylinder hoses.................................................. 221
LS- 4. Installation of boom cylinder piping.................................................. 222
LS- 5. Installation of boom assembly ......................................................... 223
LS- 6. Installation of boom cylinder head pins............................................ 224
LS- 7. Installation of hose between machine body and boom.................... 225
LS- 8. Installation of bucket cylinder assembly ......................................... 227
LS- 9. Installation of arm assembly ........................................................... 228
LS-10. Installation of arm cylinder assembly.............................................. 229
LS-11. Installation of hoses between boom and arm.................................. 230
LS-12. Installation of bucket cylinder hoses................................................ 231
LS-13. Installation of grease feed hose of bucket cylinder.......................... 232
LS-14. Installation of bucket assembly....................................................... 234
LS-15. Installation of arm cylinder junction hoses...................................... 235
LS-16. Installation of bottom dump hose and grease feed hose between arm and bucket ..... ............................................................................................236
LS-17. Installation of arm dump cushion (proximity switch) .......................237
M. INSPECTION AND SERVICING PROCEDURES AFTER ASSEMBLY... 239
M- 1. Inspection of oil levels and coolant levels andusing standard of fuel and lubricant ..................................................................................................... 240
M- 2. Flushing of hydraulic circuit................................................................242
M- 3. Releasing residual pressure from hydraulic circuit............................245
M- 4. Releasing residual pressure from HIC circuit and check of gas pressure in HIC accumulator......................................................................................... 246
M- 5. Charging air conditioner with refrigerant ............................................247
M- 6. Installed angles of mirrors ................................................................ 250
M- 7. Installed angles of lights..................................................................... 253
VHMS CONTOROLLER INITIAL SETTING PROCEDURE ........................257
PC2000-8 Main pump air bleeding check sheet ........................................ 275
FIELD ASSEMBLY INSPECTION REPORT (BACKHOE)
FIELD ASSEMBLY INSPECTION REPORT (LOADING SHOVEL)
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