KOMATSU PC27R-8 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:F30671 & UP)
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KOMATSU PC27R-8 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:F30671 & UP)
MAIN MENU.................................................................................... 0 COVER........................................................................................ 1 CONTENTS..................................................................................... 2 FOREWARD..................................................................................... 5 FOREWARD................................................................................. 7 HOW TO READ THE SHOP MANUAL.............................................................. 8 HOISTING INSTRUCTIONS.................................................................... 9 STANDARD TIGHTENING TORQUE............................................................... 10 COATING MATERIALS........................................................................ 12 ELECTRIC WIRE CODE....................................................................... 13 WEIGHT TABLE............................................................................. 14 TABLE OF OIL AND COOLANT QUANTIES........................................................ 15 10 STRUCTURE AND FUNCTION.................................................................... 17 POWER TRAIN.............................................................................. 18 SWING CIRCLE............................................................................. 19 SWING MACHINERY.......................................................................... 20 FINAL DRIVE.............................................................................. 21 TRACK FRAME.............................................................................. 22 RECOIL SPRING............................................................................ 23 CARRIER ROLLER........................................................................... 24 TRACK ROLLER............................................................................. 24 STEEL SHOE............................................................................... 25 HYDRAULIC SYSTEM......................................................................... 26 HYDRAULIC CIRCUIT DIAGRAM................................................................ 27 HYDRAULIC PUMP........................................................................... 29 CONTROL VALVE............................................................................ 47 CLSS..................................................................................... 55 SWIVEL JOINT............................................................................. 72 SWING MOTOR.............................................................................. 73 TRAVEL MOTOR............................................................................. 75 CYLINDER................................................................................. 77 ACCUMULATOR.............................................................................. 80 PPC VALVE................................................................................ 85 SOLENOID VALVE........................................................................... 88 ELECTRICAL DIAGRAM (1/3)................................................................. 90 ELECTRICAL DIAGRAM (2/3)................................................................. 91 ELECTRICAL DIAGRAM (3/3)................................................................. 92 20 TESTING AND ADJUSTING..................................................................... 94 NORMAL OR STANDARD TECHNICAL DATA........................................................ 95 SPECIAL TOOLS............................................................................106 CHECKING THE ENGINE SPEED................................................................107 ADJUSTMENT OF VALVE CLEARANCE............................................................108 MEASUREMENT OF THE COMPRESSOR PRESSURE...................................................109 CONTROL AND ADJUSTMENT OF THE TENSION OF THE FAN BELT....................................110 CONTROL AND ADJUSTMENT OF THE INJECTION TIMING...........................................111 CONTROL AND ADJUSTMENT OF THE ACCELERATOR STROKE ........................................113 ADJUSTMENTOF THE STROKE OF THE BLADE COMMAND LEVER.......................................114 ADJUSTING THE FLEXIBLE CABLES............................................................115 CONTROL AND ADJUSTMENT OF THE STROKE OF THE TRAVEL LEVER.................................116 ADJUSTMENT OF THE STROKE OF THE BOOM SWING COMMAND PEDAL.................................117 ADJUSTMENT OF THE PPC VALVE CLEARANCES...................................................118 ADJUSTMENT OF THE RUBBER PAD AND SAFETY MICROSWITCH FOR SERVO-CONTROL ENGAGEMENT.........119 CONTROL AND ADJUSTMENTOF THE STROKE OF THE TRACK-SHOE TENSION............................120 CONTROL AND REGULATION OF THE PREEURES IN THE HYDRAULIC CIRCUTIS.........................121 CONTROL AND REGULATION OF THE LS DIFFERENTIAL PRESSURE AND ADJUSTMENT OF THE LS VALVE....124 REGULATION OF THE PC VALVE...............................................................126 CONTROL AND REGULATION O THE SERVO-CONTROL POWER SUPPLY..................................127 ELIMINATION OF RESIDUAL PRESSURES - PRESSURISATION OF THE TANK...........................128 BLEEDING AIR FROM THE HYDRAULIC CIRCUITS.................................................129 CONTROL OF HYDRAULIC DRIFTS - ANALYSIS OF THE CAUSES OF A DRIFT..........................131 CHECKING FOR ANY LEAKAGES INSIDE THE WORKING EQUIPMENT CYLINDERS.........................137 CHECKING FOR ANY LEAKAGES INSIDE THE SWING MOTOR.........................................138 METHODS FOR TESTING FOR LEAKAGES INSIDE THE SWIVEL JOINT.................................139 30 REMOVAL AND INSTALLATION..................................................................142 HOW TO READ THE MANUAL...................................................................144 PRECAUTIONS TO BE TAKEN WHILE WORKING....................................................145 SPECIAL TOOLS............................................................................146 STARTER MOTOR............................................................................148 REMOVAL..............................................................................148 INSTALLATION.........................................................................148 ALTERNATOR...............................................................................149 REMOVAL..............................................................................149 INSTALLATION.........................................................................149 INJECTION PUMP...........................................................................150 REMOVAL..............................................................................150 INSTALLATION.........................................................................151 NOZZLE HOLDER............................................................................152 REMOVAL..............................................................................152 INSTALLATION.........................................................................152 WATER COOLANT PUMP.......................................................................153 REMOVAL..............................................................................153 INSTALLATION.........................................................................154 CYLINDER HEAD............................................................................155 REMOVAL..............................................................................155 INSTALLATION.........................................................................156 OIL COOLER...............................................................................157 REMOVAL..............................................................................157 INSTALLATION.........................................................................157 RADIATOR.................................................................................158 REMOVAL..............................................................................158 INSTALLATION.........................................................................158 ENGINE HOOD..............................................................................159 REMOVAL.............................................................................. 2 INSTALLATION......................................................................... 2 CANOPY...................................................................................160 REMOVAL..............................................................................160 INSTALLATION.........................................................................160 CAB......................................................................................161 REMOVAL..............................................................................161 INSTALLATION.........................................................................161 HEATING FAN..............................................................................162 REMOVAL..............................................................................162 INSTALLATION.........................................................................163 COUNTERWEIGHT............................................................................164 REMOVAL..............................................................................164 INSTALLATION.........................................................................164 DIESEL FUEL TANK.........................................................................165 REMOVAL..............................................................................165 INSTALLATION.........................................................................165 HYDRAULIC OIL TANK.......................................................................166 REMOVAL..............................................................................166 INSTALLATION.........................................................................167 OIL-COOLER-RADIATOR GROUP................................................................168 REMOVAL..............................................................................168 INSTALLATION.........................................................................169 ENGINE-PUMP GROUP........................................................................170 REMOVAL..............................................................................170 INSTALLATION.........................................................................172 PUMP.....................................................................................173 REMOVAL..............................................................................173 INSTALLATION.........................................................................173 ENGINE-PUMP COUPLING.....................................................................174 REMOVAL..............................................................................174 INSTALLATION.........................................................................174 SIDE LOWER PANELS........................................................................175 REMOVAL..............................................................................175 INSTALLATION.........................................................................175 INNER CONTROL VALVE BOX COVER............................................................176 REMOVAL..............................................................................176 INSTALLATION.........................................................................176 CONTROL VALVE............................................................................177 REMOVAL..............................................................................177 INSTALLATION.........................................................................178 LEFT-HAND PPC VALVE (ARM-BUCKET).........................................................179 REMOVAL..............................................................................179 INSTALLATION.........................................................................179 RIGHT-HAND PPC VALVE (BOOM-BUCKET).......................................................180 REMOVAL..............................................................................180 INSTALLATION.........................................................................180 SERVOCONTROL SOLENOID GROUP..............................................................181 REMOVAL..............................................................................181 INSTALLATION.........................................................................181 PLATFORM.................................................................................182 REMOVAL..............................................................................182 INSTALLATION.........................................................................184 SWIVEL JOINT.............................................................................185 REMOVAL..............................................................................185 INSTALLATION.........................................................................185 SWING MACHINERY..........................................................................186 REMOVAL..............................................................................185 INSTALLATION.........................................................................187 REVOLVING FRAME..........................................................................188 REMOVAL..............................................................................188 INSTALLATION.........................................................................189 SWING CIRCLE.............................................................................190 REMOVAL..............................................................................190 INSTALLATION.........................................................................190 RUBBER TRACK SHOES.......................................................................191 REMOVAL..............................................................................191 INSTALLATION.........................................................................191 STEEL TRACK-SHOES........................................................................192 REMOVAL..............................................................................192 INSTALLATION.........................................................................192 SPROCKET WHEEL...........................................................................193 REMOVAL..............................................................................193 INSTALLATION.........................................................................193 FINAL DRIVE..............................................................................194 REMOVAL..............................................................................194 INSTALLATION.........................................................................194 IDLER AND RECOIL SPRING ASSEMBLY.........................................................195 REMOVAL..............................................................................195 INSTALLATION.........................................................................195 SPRING RECOIL AND THRUST CYLINDER GROUPS.................................................196 DISASSEMBLY..........................................................................196 ASSEMBLY.............................................................................196 IDLER....................................................................................197 DISASSEMBLY..........................................................................197 ASSEMBLY.............................................................................197 TRACK ROLLERS............................................................................198 REMOVAL..............................................................................198 INSTALLATION.........................................................................198 BOOM CYLINDER............................................................................199 REMOVAL..............................................................................199 INSTALLATION.........................................................................200 ARM CYLINDER.............................................................................201 REMOVAL..............................................................................201 INSTALLATION.........................................................................201 BUCKET CYLINDER..........................................................................202 REMOVAL..............................................................................202 INSTALLATION.........................................................................202 BOOM SWING CYLINDER......................................................................203 REMOVAL..............................................................................203 INSTALLATION.........................................................................204 BLADE CYLINDER...........................................................................205 REMOVAL..............................................................................205 INSTALLATION.........................................................................205 WORKING EQUIPMENT CYLINDERS..............................................................206 DISASSEMBLY..........................................................................206 ASSEMBLY.............................................................................208 UPPER WORKING EQUIPMENT..................................................................212 REMOVAL..............................................................................212 INSTALLATION.........................................................................213 ARM......................................................................................214 REMOVAL..............................................................................214 INSTALLATION.........................................................................215 ARM ASSEMBLY.............................................................................216 REMOVAL..............................................................................216 INSTALLATION.........................................................................216 BOOM.....................................................................................217 REMOVAL..............................................................................217 INSTALLATION.........................................................................218 BOOM SWING SUPPORT.......................................................................219 REMOVAL..............................................................................219 INSTALLATION.........................................................................219 BLADE....................................................................................220 REMOVAL..............................................................................220 INSTALLATION.........................................................................220 40 MAINTENANCE STANDARD......................................................................222 SWING CIRCLE.............................................................................223 SWING MACHINERY..........................................................................224 FINAL DRIVE..............................................................................225 SPROCKET.................................................................................226 TRACK FRAME AND RECOIL SPRING............................................................227 IDLER....................................................................................228 CARRIER ROLLER...........................................................................229 TRACK ROLLER.............................................................................230 TRACK SHOE...............................................................................231 HYDRAULIC PUMP...........................................................................233 CONTROL VALVE............................................................................234 SWIVEL JOINT.............................................................................240 SWING MOTOR..............................................................................241 TRAVEL MOTOR.............................................................................242 PPC VALVE (FOR BOOM, ARM, BUCKET, SWING).................................................244 PPC VALVE (FOR HAMMER)...................................................................245 CYLINDER.................................................................................246 WORK EQUIPMENT...........................................................................248
DESCRIPTION:
KOMATSU PC27R-8 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:F30671 & UP)
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the operator an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
- This shop manual mainly contains the necessary technical information for operations performed in a service workshop. The manual is divided into chapters on each main group of components; these chapters are further divided into the following sections.
- STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. - TESTING AND ADJUSTING
This sections explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating «Problems» to «Causes» are also included in this section. - DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations. - MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
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