Komatsu F30791 Shop Manual Download

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Measurement check points

Symbol

Code

Name

Q.ty

Remarks

Valve clearance

Commercially

available

Feeler gauge

Compression pressure

ATR800090

Compression gauge

0-70 kg/cm

ATR800130

Adapter

Engine speed

ATR800070

Multi-scale tachometer

20 - 4000 rpm

ATR800060

Stroboscopic tachometer

6 - 30000 rpm

Hydraulic pressure

ATR800170

Compression gauge

Scale 60 bar

ATR800140

Compression gauge

Scale 400 bar

ATR800010

Compression gauge

Scale 600 bar

ATR800200

Servocontrol kit

(Differential pressure)

3F3055600

Elbow

P2 Pressure

Track shoe tension

823001135

Grease nipple

Included in the

machine tool kit

SPECIAL TOOLS

20-24

PC20R-8 PC27R-8

Summary of Contents for F30791

Page 1: ......

Page 2: ...40 28 PC15R 8...

Page 3: ...CONTENTS 00 1 PC20R 8 PC27R 8 10 STRUCTURE AND FUNCTION 10 1 20 TESTING AND ADJUSTING 20 1 30 REMOVAL AND INSTALLATION 30 1 40 MAINTENANCE STANDARD 40 1...

Page 4: ...00 2 PC20R 8 PC27R 8...

Page 5: ...8 10 29 10 30 10 31 10 32 10 33 10 34 10 35 10 36 10 37 10 38 10 39 10 40 10 41 10 42 10 43 10 44 10 45 10 46 10 47 10 48 10 49 10 50 10 51 10 52 10 53 10 54 10 55 10 56 10 57 10 58 10 59 10 60 10 61...

Page 6: ...42 30 43 30 44 30 45 30 46 30 47 30 48 30 49 30 50 30 51 30 52 30 53 30 54 30 55 30 56 30 57 30 58 30 59 30 60 30 61 30 62 30 63 30 64 30 65 30 66 30 67 30 68 30 69 30 70 30 71 30 72 30 73 30 74 30 7...

Page 7: ...t or any other work equipment to the ground If this is not possible use blocks to prevent the work equipment from falling down In addition be sure to lock all the control levers and hang warning sign...

Page 8: ...even start fires 18 As a general rule do not use gasoline to wash parts In particular use only the minimum of gaso line when washing electrical parts 19 Be sure to assemble all parts again in their or...

Page 9: ...each component It serves not only to give an understan ding of the structure but also serves as reference material for troubleshooting TESTING AND ADJUSTING This sections explains checks to be made be...

Page 10: ...pa ge SYMBOLS In order to make the shop manual greatly chelpful important points about safety and quality are marked with the following symbols Symbol Item Remarks Safety Special safety precautions a...

Page 11: ...during hoist ing and a serious accident can result Hooks have maximum strength at the middle portion 3 Do not sling a heavy load with one rope alone but sling with two or more ropes symmetrically wou...

Page 12: ...3w2 45w4 9 77w8 122w13 1 3w0 15 3 2w0 3 6 5w0 6 11w1 17 5w2 13 5w1 5 32 2w3 5 63w6 5 108w11 172w18 16 18 20 22 24 2 2 5 2 5 2 5 3 24 27 30 32 36 14 14 17 17 19 19 5w2 27w3 38w4 52w6 66w7 191w21 262w28...

Page 13: ...or high resistant of threaded parts that can be removed with normal tools Loctite 270 Used for high resistant locking and for sealing threaded parts bolts and stud bolts Loctite 542 Used for sealing t...

Page 14: ...20 125 Battery Ground CLASSIFICATION BY COLOUR AND CODE Primary Auxiliary Code A A R A R A V A N Colour Light blue Light blue Red Light blue Green Light blue Black Code B B G B N B R Colour White Whit...

Page 15: ...e hood 18 18 Fuel tank without fuel 14 14 Hydraulic tank without hydraulic oil 30 30 Control valve 31 31 Rear counterweight 70 150 Lateral counterweight L H R H 29 37 29 37 Swing motor 27 31 5 Swivel...

Page 16: ...ed for the engi ne the hydraulic circuit of equipment and for re ductions TABLE OF OIL AND COOLANT QUANTITIES 00 12 PC20R 8 PC27R 8 RESERVOIR KIND OF FLUID AMBIENT TEMPERATURE CAPACITY Specified Refil...

Page 17: ...GRUPPO 10...

Page 18: ...40 28 PC15R 8...

Page 19: ...stem 13 Hydraulic circuit diagram 17 Hydraulic pump 20 Control valve 44 CLSS 52 Swivel joint 69 Swing motor 70 Travel motor 74 Cylinder 77 Accumulator 81 PPC Valve 82 PPC Valve 86 Servocontrol feed un...

Page 20: ...circle 3 Track shoe idler 4 Control valve 5 Swivel joint 6 Travel motor 7 Engine 8 Hydraulic pump 9 Servocontrol travel speed increment solenoid valve POWER TRAIN PC20R 8 10 2 PC20R 8 PC27R 8 RKP0134...

Page 21: ...inery 3 Swing circle 4 Track shoe idler 5 Control valve 6 Swivel joint 7 Swivel joint 8 Engine 9 Hydraulic pump 10 Servocontrol travel speed increment solenoid valve PC27R 8 10 3 PC20R 8 PC27R 8 RKP01...

Page 22: ...1 Outer race 2 Upper seal 3 Ball bearing 4 Inner race 5 Lower seal SWING CIRCLE PC20R 8 10 4 PC20R 8 PC27R 8 RKP01350 5 Sezione B B Sezione A A 4 1 3 2 1 3 4 B B A A S Section A A Section B B...

Page 23: ...1 Outer race 2 Upper seal 3 Ball bearing 4 Inner race 5 Lower seal PC27R 8 10 5 PC20R 8 PC27R 8 RKP01360 A A B 5 Sezione B B Sezione A A B 4 1 3 2 4 1 3 S Section A A Section B B...

Page 24: ...3 Crown Z 72 4 Spacer 5 Sun gear Z 10 6 Planetary carrier 7 Planetary gear 8 Ring nut 9 Bearing 10 Bearing 11 Pinion SPECIFICATION Reduction ratio 1 8 2 SWING MACHINERY PC27R 8 10 6 PC20R 8 PC27R 8 R...

Page 25: ...uction gear 4 Cover 5 No 1 sun gear 6 Oil drainage plug 7 No 1 planetary gear 8 No 2 sun gear Z 16 9 Housing SPECIFICATIONS PC20R 8 Reduction ratio 1 41 92 PC27R 8 Reduction ratio 1 53 FINAL DRIVE 10...

Page 26: ...1 Idler 2 Track frame 3 Sliding plate 4 Travel motor 5 Sprocket 6 Track roller 7 Recoil spring 8 Track shoe TRACK FRAME PC20R 8 10 8 PC20R 8 PC27R 8 RKP01690 1 2 3 4 5 6 7 8...

Page 27: ...1 Idler 2 Track frame 3 Sliding plate 4 Travel motor 5 Sprocket 6 Track roller 7 Recoil spring 8 Track shoe PC27R 8 10 9 PC20R 8 PC27R 8 RKP01670 4 6 5 7 8 1 3 2...

Page 28: ...1 Idler 2 Support 3 Cylinder 4 Rod 5 Recoil spring 6 Nut 7 Nipple RECOIL SPRING 10 10 PC20R 8 PC27R 8 RKP01680 1 2 3 5 6 7 4 7 3 4 A A Sezione A A Section A A...

Page 29: ...OLLER CARRIER ROLLER PC27R 8 10 11 PC20R 8 PC27R 8 1 Bearing 2 Gasket 3 Shaft 4 Spacer 5 Cover 6 Seal ring 7 Roller 1 Roller 2 Shaft 3 Bushing 4 Shoulder 5 Seal ring RKP01400 4 6 5 7 1 3 2 RKP01410 4...

Page 30: ...1 Bushing 2 Pin 3 Master housing 4 Master pin 5 Cotter pin 6 Link 7 Shoe SPECIFICATIONS Width 300 mm Pitch 101 6 mm STEEL SHOE 10 12 PC20R 8 PC27R 8 RKP02010 4 6 5 7 1 3 2...

Page 31: ...8 7 6 5 4 3 1 Bucket cylinder 2 Arm cylinder 3 Boom swing cylinder 4 Control valve 5 R H PPC valve 6 Hydraulic tank 7 Hydraulic oil cooler 8 L H PPC valve 9 Hydraulic pump 10 Final drive 11 Servocont...

Page 32: ...10 14 PC20R 8 PC27R 8 PAGE INTENTIONALLY LEFT BLANK...

Page 33: ...15 1 Bucket cylinder 2 Arm cylinder 3 Boom swing cylinder 4 Control valve 5 R H PPC valve 6 Hydraulic tank 7 Hydraulic oil cooler 8 L H PPC valve 9 Hydraulic pump 10 Final drive 11 Servocontrol feed...

Page 34: ...10 16 PC20R 8 PC27R 8 PAGE INTENTIONALLY LEFT BLANK...

Page 35: ...er Additional equipment Bucket Boom Arm Bucket Open Open Reverse Forwards Reverse Forwards Open Reverse Forwards Reverse Forwards Open Raise Lower R H PPC valve L H PPC valve ST1 solenoid valve Cylind...

Page 36: ...10 18 PC20R 8 PC27R 8 PAGE INTENTIONALLY LEFT BLANK...

Page 37: ...tional equipment Bucket Boom Arm Bucket Arm Bucket Open Open Reverse Forwards Reverse Forwards Open Reverse Forwards Reverse Forwards Open Raise Lower R H PPC valve L H PPC valve ST1 solenoid valve Cy...

Page 38: ...LS S1 P1 P2 a P1 Port To control valve P port b P2 Port To control valve P2 port c PLS Port From control valve LS port d S1 Port From hydraulic tank 1 Main pump 2 Gear pump SPECIFICATIONS Type PVK Dis...

Page 39: ...crew 4 Swash plate 5 Piston 6 Cylinder block 7 Valve plate 8 Spring 9 Adjustment screw 10 Joint 11 Control piston 12 Sliding shoe 13 Adjustment screw 10 21 PC20R 8 PC27R 8 RKP00070 10 1 4 6 5 7 8 9 3...

Page 40: ...n 2 depends on the angle of swash plate 4 so by changing the an gle of swash plate 4 it is possible to change the amount of the discharge flow 2 Constant horsepower control Rocker pin 6 is assembled t...

Page 41: ...ignal pressure from the LS valve is transmitted to control piston 8 and control piston 8 pushes swash plate 4 The angle of swash plate 4 changes to a point where this force is balanced with the total...

Page 42: ...Main pump a PS Port From hydraulic tank b P2 Port To control valve P2 port c P1 Port To control valve P port d PLS Port To control valve LS port HYDRAULIC PUMP PC27R 8 10 24 PC20R 8 PC27R 8 RKP01130 A...

Page 43: ...f the pump servo piston TCC valve and LS valve The explanation of the structure and function is di vided into separate sections 1 Main pump 2 TCC valve 3 LS valve 10 25 PC20R 8 PC27R 8 RKP01140 Pen PL...

Page 44: ...plate 5 Shoe 6 Piston 7 Cylinder block 8 Valve plate 9 Spring 10 Servo piston 1 Main pump 10 26 PC20R 8 PC27R 8 RKP01200 B B A A C C RKP01150 Sezione A A Sezione B B Sezione C C 4 1 3 2 6 5 7 8 9 10 S...

Page 45: ...4 has plane A and shoe 5 is always pressed against this surface as it slides in a circle Rocker cam 4 forms a static bearing sending high pressure oil at cylindrical surface B with to the case and car...

Page 46: ...harge of oil for the amount of this differ ence F E will be carried out In other words oil is discharge as the capacity of the chamber F decreases when the cylinder block 7 rotates In the mean time th...

Page 47: ...case 3 and the rocker cam slides in the semi circular reciprocating direc tion The upper and lower pressure receiving area of the servo piston are different from each other and to the pressure chambe...

Page 48: ...VALVE 5 Piston 6 Piston 7 Sleeve 8 Spring 9 Union a P1 Port Main pump pressure inlet port b GH Port Gear pump pressure inlet port c PLS Port From control valve LS port 2 TCC VALVE LS VALVE SERVO PIST...

Page 49: ...unction has been added to automatically lower the LS differential pressure and reduce the discharge amount when the engine is running at low idling The engine speed is detected by pressures GH and GL...

Page 50: ...bar 0 kg cm2 Spring chamber a is connected to the drain circuit through the control valve spool At the same time pump pressure PP is held at the unload pressure of approx 26 bar 27 kg cm 2 For this r...

Page 51: ...ects port d and port e As the result the pressurized oil acting on chamber X at the large diameter end of servo piston 4 flows from port d to port e and is connected to port f of the TCC valve At this...

Page 52: ...iston 4 is moved to the right in the direction of the minimum swash plate angle In other words the LS set differential pressure of the LS valve is taken as 16 bar 16 kg cm2 In the range from the neutr...

Page 53: ...valve is further increased and LS differ ential pressure DPLS goes below 7 bar 7 kg cm2 the pump swash plate angle is moved in the maxi mum direction Even if the area of opening of the control valve...

Page 54: ...ntral position As a result port c port d and port e open approxi mately the same amount so the pump pressure flows from port c to port d Part flows from port e to the tank case and is drained so the p...

Page 55: ...6 bar 16 kg cm2 so the pump discharge amount is in accor dance with the area of opening of the control valve For example after balancing at an area of opening 1 4 of the control valve if the system is...

Page 56: ...e horsepower control to prevent the hydraulic horsepower absorbed by the pump from exceeding the engine horsepower In other words if the load during operations be comes larger and pump discharge press...

Page 57: ...s chamber X at the large diameter end of servo piston 4 and stops the movement of servo piston 4 If pump discharge PP rises further piston 3 moves to the left and servo piston 4 moves to the right in...

Page 58: ...o in crease the pump discharge pressure the limit of the TCC valve disappears so the pressurized oil in chamber X at the large diameter end of servo pis ton 4 passes from port d of the LS valve to por...

Page 59: ...e fine pitch portion comes into close contact so only the rough pitch portion functions as a spring from this point In other words the spring load is changed by piston 4 extending or contracting sprin...

Page 60: ...by the position where the force of spring 1 pump pres sure PP acting on piston 3 are in balance In other words if pump discharge pressure PP in creases pump discharge amount Q is reduced and if pump...

Page 61: ...10 43 PC20R 8 PC27R 8 PAGE INTENTIONALLY LEFT BLANK...

Page 62: ...CONTROL VALVE 10 44 PC20R 8 PC27R 8 RKP01590 O M L K H E P P O M L K H E C B A A B C M M J J G G F D G G F D g f e d c b a r q p n m l k j i h t u v x y w z aa bb cc hh ff gg ee dd ii mm ll s...

Page 63: ...t cylinder Bottom side r B9 Port To attachment R H side s Pi2 Port To ST1 solenoid valve P Port t A9 Port To attachment L H side u A8 Port To bucket cylinder Head side v A7 Port To boom cylinder Head...

Page 64: ...m swing 5 Suction valve Raise boom 6 Suction valve Close bucket 7 Suction valve Work equipment R H side 8 Suction valve Lower boom 9 Suction valve Close arm 10 Suction valve R H Travel forward 11 Suct...

Page 65: ...pool bucket 3 Spool boom 4 Spool arm 5 Spool blade 6 Spool boom swing 7 Spool R H travel 8 Spool L H travel 9 Spool swing 10 Main relief valve 10 47 PC20R 8 PC27R 8 RKP01620 Sezione B B 4 6 5 7 8 9 10...

Page 66: ...tachment REDUCING PRESSURE COMPENSATION VALVE 10 Attachment 11 Bucket 12 Boom 13 Arm 14 Piston boom swing and blade 15 Boom swing and blade 16 R H Travel 17 L H Travel 18 Swing 19 LS bypass plug 20 Co...

Page 67: ...e compensation valve 9 Flow compensation valve TRAVEL VALVE 10 Suction valve FORWARD 11 Suction valve REVERSE 12 Reducing pressure compensation valve 13 Flow compensation valve 14 Spool 10 49 PC20R 8...

Page 68: ...e 9 Reducing pressure compensation valve 10 Flow compensation valve BOOM VALVE 11 Suction valve raise 12 Check valve 13 Suction valve lower 14 Reducing pressure compensation valve 15 Flow compensation...

Page 69: ...l HAMMER VALVE 6 Suction valve 7 Check valve 8 Reducing pressure compensation valve 9 Flow compensation valve 10 Spool 11 Plug 12 Cover 13 Pilot relief valve 10 51 PC20R 8 PC27R 8 RKP01630 Sezione O O...

Page 70: ...operability ensured by flow distribution determined according to the opening areas of spools during complex operation d Energy saving feature using variable pump control STRUCTURE The CLSS consists o...

Page 71: ...re DPLS Pump discharge pressure PP pressure PLS If the LS differential pressure DPLS becomes lower than the setting pressure of the LS valve the pump swash plate angle becomes larger and if it becomes...

Page 72: ...ctuators are complex operated the pressure differences DP at the upstream inlet and downstream outlet are made equal by these valves In this way the flow from the pump are distributed in proportion to...

Page 73: ...e 0 4 bar 4 kg cm2 8 Pilot relief valve 29 bar 30 kg cm2 3 Functions and operation of each valve NAMES OF HYDRAULIC CIRCUITS AND VALVES 10 55 PC20R 8 PC27R 8 RKP04481 P1 P2 P1 P2 B A Bucket R H travel...

Page 74: ...1 pump pressure PP is acting on area S2 and LS pressure PLS is acting on area S3 When the control valve is at HOLD LS pressure PLS is not generated so only pump discharge PP has any effect and PP is...

Page 75: ...rried out on the control valve LS pressure PLS is generated and acts on area S3 at the right and of spool 1 When this happens the area of the opening of the control valve spool is small so there is a...

Page 76: ...acts on area S3 at the right end of spool 1 When this happens the area of the opening of the control valve spool is large so the difference be tween LS pressure PLS and pump discharge pres sure PP is...

Page 77: ...1 through bridge passage b to actuator circuit A At the same time reducing valve 3 also moves to the right so pump pressure PP has its pressure re duced by the pressure loss at notch C It is intro duc...

Page 78: ...same time the actuator circuit pressure passes through notch f in hammer spool 6 then goes through passage d and acts on the left end of piston 7 Piston 7 and reducing valve 3 then move to the right...

Page 79: ...flow of the spool or shuttle valve and increases the sta bility by lowering the effective LS differential pressure OPERATION The pressurized oil for LS circuit PLS passes from clearance filter a form...

Page 80: ...flow control valve 2 are pushed to the left Flow control valve 2 throttles the area of opening between pump circuit PP and spool upstream PPA and pressure loss is generated between PP and PPA Flow co...

Page 81: ...essure PP spool notch upstream pressure PPA 6 LS circuit pressure PLS actuator circuit pressure PA A and oil flow is divided in proportion to area of opening of spool When ratio is more than 1 00 PP P...

Page 82: ...ber PLS2 of the other ac tuator right side becomes the same as pump cir cuit pressure PP because of the balance of redu cing valve 1 PLS2 passes through LS introduction throttle b of reducing valve 1...

Page 83: ...er so the machine can be steered OPERATION When travelling in a straight lint When left and right travel spools 1 are operated the pump discharge flows from pump circuit PP and circuits PAL and PAR to...

Page 84: ...e with the high load pressure As a result flow control valve 3 on the left travel side is pushed on the left by LS circuit PLS Because of this the opening of the left notch a is made smaller so it bec...

Page 85: ...re to 29 5 bar 30 kg cm2 OPERATION The discharge pressure from the gear pump enter ing chamber A acts on the bottom of valve 1 The gear pump discharge pressure is set to 29 5 bar 30 kg cm2 10 67 PC20R...

Page 86: ...10 68 PC20R 8 PC27R 8 PAGE INTENTIONALLY LEFT BLANK...

Page 87: ...tor P2 Port g a Port To R H travel motor P1 Port h B Port From control valve A2 Port j E Port From control valve A5 Port k C Port From control valve A3 Port l F Port From control valve B5 Port m D Por...

Page 88: ...To hydraulic tank b B Port From control valve A1 Port c A Port From control valve B1 Port 1 Safety valve SPECIFICATION Displacement 195 rev SWING MOTOR PC20R 8 10 70 PC20R 8 PC27R 8 1 1 c a b T B A R...

Page 89: ...e housing 7 Pin 8 Balancing plate 9 Ball 10 Valve drive 11 Stator 12 Bearing 13 Bearing 14 Pinion 15 Valve 16 Cartridge 17 Spring 10 71 PC20R 8 PC27R 8 RKP01650 Sezione A A Sezione B B 4 6 9 10 11 12...

Page 90: ...plate 2 Cylinder 3 Piston 4 Disc 5 Shoe 6 Spring 7 Safety valve spring 8 Plug 9 Check valve spring 10 Check valve 11 Plug 12 Cylinder 13 Safety valve PC27R 8 10 72 PC20R 8 PC27R 8 RKP01500 2 a A A 1...

Page 91: ...ort To hydraulic tank b A Port From control valve A1 port c M Port To control valve C port d B Port From control valve B1 port 10 73 PC20R 8 PC27R 8 RKP01510 Sezione A A 11 10 13 12 7 8 9 c b d Sectio...

Page 92: ...TRAVEL MOTOR 10 74 PC20R 8 PC27R 8 A B B B B A RKP01380 Sezione A A 1 4 6 5 7 8 3 2 a 13 9 10 14 15 16 b c d e 11 12 Section A A...

Page 93: ...T1 Port Not used c P1 Port From swivel joint a Port d P2 Port From swivel joint c Port e T2 Port From swivel joint h Port L H motor a PS Port From swivel joint g Port b T1 Port From swivel joint h Por...

Page 94: ...10 76 PC20R 8 PC27R 8 PAGE INTENTIONALLY LEFT BLANK...

Page 95: ...side 3 Rod 4 Head 5 Gasket 6 Cylinder 7 Ring 8 Spacer 9 Piston gasket 10 Ring 11 Piston 12 Nut 1 Bushing Head side 2 Bushing Bottom side 3 Rod 4 Head 5 Gasket 6 Cylinder 7 Piston gasket 8 Ring 9 Pist...

Page 96: ...shing Bottom side 3 Rod 4 Head 5 Washer 6 Cylinder 7 Piston gasket 8 Ring 9 Piston 10 Nut 1 Bushing Head side 2 Bushing Bottom side 3 Rod 4 Head 5 Gasket 6 Cylinder 7 Piston gasket 8 Ring 9 Piston 10...

Page 97: ...1 46 36 46 41 PC27R 8 Cylinder Boom Arm Bucket Boom swing Blade with canopy with cabin Piston rod diameter 45 45 40 35 40 35 Cylinder inside diameter 75 75 70 60 80 70 Piston stroke 551 519 526 460 49...

Page 98: ...10 80 PC20R 8 PC27R 8 PAGE INTENTIONALLY LEFT BLANK...

Page 99: ...e in the circuit to which the accumulator is con nected OPERATION When the engine is running the chamber A of the rubber bag 1 containing nitrogen is compressed by oil under pressure coming from line...

Page 100: ...noid valve T port f P Port From ST1 solenoid valve A port R H PPC VALVE a P2 Port To control valve PA7 port b P4 Port To control valve PB8 port c P1 Port To control valve PB7 port d P3 Port To control...

Page 101: ...n spring external 4 Plunger 5 Disc 6 Nut 7 Joint 8 Cover 9 Pin 10 Body 10 83 PC20R 8 PC27R 8 RKP01080 Sezione A A 4 6 5 7 8 9 10 1 3 2 Sezione B B Sezione C C Sezione D D Sezione E E Section A A Secti...

Page 102: ...ost the same time it is connected to drain chamber D to release the pressure at port P1 When this happens spool 1 moves up or down so that the force of metering spring 2 is balanced with the pressure...

Page 103: ...e spool of the control valve returns oil in drain chamber D flows in from fine control hole f in the valve on the side that is not working The oil passes through port P2 and enters chamber B to fill t...

Page 104: ...To control valve PB9 port d P2 Port To control valve PA9 port 1 Spring 2 Adjusting spring internal 3 Return spring external 4 Plunger 5 Lever 6 Cover 7 Stopper 8 Body 9 Filter 100 mesh PPC VALVE HAMM...

Page 105: ...almost the same time it is connected to drain chamber D to release the pressure at port P1 When this happens spool 1 moves up or down so that the force of metering spring 2 is balanced with the press...

Page 106: ...spool of the control valve returns oil in drain chamber D flows in from fine control hole f in the valve on the side that is not working The oil passes through port P2 and enters chamber B to fill the...

Page 107: ...alve P port c B Port To swivel joint G port d P Port From control valve Pi2 port e T Port To hydraulic tank 1 Y2 Servocontrol 2 Y1 Travel increment SOLENOID VALVE ST1 SERVOCONTROL TRAVEL INCREMENT 10...

Page 108: ...10 90 PC20R 8 PC27R 8 PAGE INTENTIONALLY LEFT BLANK...

Page 109: ...RNING LIGHT NOT USED H2 PRESSURE OIL WARNING LIGHT H3 BATTERY WARNING LIGHT H4 PRE HEATER WARNING LIGHT H5 BRAKE PRESSURE WARNING LIGHT NOT USED H6 OIL LEVEL WARNING LIGHT NOT USED H7 POSITION LIGHT W...

Page 110: ...10 92 PC20R 8 PC27R 8 PAGE INTENTIONALLY LEFT BLANK...

Page 111: ...COMPONENTS H10 WORKING BEAM HA2 HORN K2 STOP MOTOR RELAY K3 HORN RELAY M2 FUEL PUMP S5 OPTIONAL SWITCH TBG S6 LIGHT SWITCH S7 PUSH BUTTON S8 HAMMER SOLENOID VALVE PUSH BUTTON S9 N A PUSH BUTTON S10 P...

Page 112: ...10 94 PC20R 8 PC27R 8 PAGE INTENTIONALLY LEFT BLANK...

Page 113: ...2 3 L1 5 C1 5 N1 X27 3 R3 X27 1 B N1 X19 5 B N1 B N1 1 12 0 1 2 0 1 M RKP06590 COMPONENTS M3 VENTILATOR R3 FUEL LEVEL INDICATOR S11 ROTATING BEAM SWITCH S12 ARM REST MICRO S13 SERVOCONTROL MICRO S14...

Page 114: ...10 96 PC20R 8 PC27R 8...

Page 115: ...GRUPPO 20...

Page 116: ...40 28 PC15R 8...

Page 117: ...of the LS valve PC27R 8 47 Regulation of the PC valve PC27R 8 49 Control and regulation of the servo control power supply 50 Elimination of residual pressures pressurisation of the tank 51 Bleeding ai...

Page 118: ...rature 40 60 C Engine speed kg cm2 rpm 32w1 250 26w1 250 Blow by pressure SAE30 oil Water temperature in operating range At high idling speed mm H2O Engine oil pressure Water temperature in operating...

Page 119: ...AE 3FA Standard value Permissible value 2785 1050 2600 2760 2810 1025 1075 3 5 Max 0 5 5 0 Max 1 0 0 20 0 20 31w1 250 25w1 250 3 7 0 5 1 Min 1 0 Max 120 Max 120 14w1 14w1 10 15 FOR THE ENGINE 20 3 PC2...

Page 120: ...ol Swing control Work equipment control Blade control 20 6 6 20 6 6 Boom swing control Travel control Boom control lever At centre of lever knob Reading at end of travel Equipment on the ground Engine...

Page 121: ...Permissible value 2650 2600 2700 2625 2575 2675 a b a b 30 6 6 30 6 6 20 6 6 20 6 6 70 60 80 70 60 80 70 60 80 70 60 80 50 40 60 20 17 23 100 90 110 180 160 200 Max 5 Max 8 Max 10 Max 15 FOR THE MACHI...

Page 122: ...idling Hydraulic oil temperature 45 55 C All levers at HOLD Relieve pump outlet pressure kg cm2 Max 35 Max 35 Boom Engine speed high idling Hydraulic oil temperature 45 55 C Check one circuit at a tim...

Page 123: ...2 3 2 0 1 7 2 3 2 0 1 7 2 3 8 0 7 0 9 0 3 0 2 5 3 5 2 0 1 7 2 3 1 5 1 2 1 8 1 2 1 0 1 4 Max 35 Max 35 210 10 210 10 210 10 210 10 210 10 210 10 30 5 30 5 210 10 210 10 210 10 210 10 210 10 210 10 215...

Page 124: ...n for swings to start from positions at 90 and 180 90 sec 2 0 1 8 2 2 180 3 8 3 4 4 2 Time taken for to swing Work equipment at max reach No load in bucket Engine speed high idling Hydraulic oil tempe...

Page 125: ...PC27R 8 Standard value Permissible value 20 52 Max 24 Max 62 3 1 9 1 7 2 1 3 5 3 1 3 9 34 0 Max 38 0 194 7 75 Max 233 7 Max 90 FOR THE MACHINE 20 9 PC20R 8 PC27R 8...

Page 126: ...turn then measure time taken for next sec 25 0 21 29 13 0 11 15 Travel speed 2 Measuring posture Engine speed high idling Hydraulic oil temperature 45 55 C On flat ground Travel for at least 10 metres...

Page 127: ...PC27R 8 Standard value Permissible value 0 6 Max 1 0 30 0 24 36 15 0 12 18 33 0 29 37 16 0 14 18 Max 500 Max 550 FOR THE MACHINE 20 11 PC20R 8 PC27R 8...

Page 128: ...level ground Levers neutral Engine switched off Oil temperature 45 55 C Take measurements as soon as the engine stops Measure the variations every 5 minutes and check the total variation after 15 mins...

Page 129: ...dard value Permissible value Max 200 Max 240 Max 300 Max 340 Max 300 Max 350 Max 20 Max 30 Max 20 Max 33 Max 20 Max 30 Max 20 Max 33 Max 20 Max 20 Max 15 Max 20 Max 15 Max 22 FOR THE MACHINE 20 13 PC2...

Page 130: ...mum height and measure the height of the edge from the ground Measure the downward after 15 mins mm Max 20 Max 30 Boom Engine speed high idling Hydraulic oil temperature 45 55 C Check leakages on the...

Page 131: ...PC27R 8 Standard value Permissible value Max 20 Max 30 2 Max 5 2 Max 5 2 Max 5 FOR THE MACHINE 20 15 PC20R 8 PC27R 8...

Page 132: ...ylinder fully retracted Cylinder fully extended Measuring posture Engine speed high idling Hydraulic oil temperature 45 55 C 2 2 1 7 2 7 2 2 1 7 2 7 Boom swing Cylinder fully retracted Cylinder fully...

Page 133: ...PC27R 8 Standard value Permissible value 2 3 1 8 2 8 2 3 1 8 2 8 3 0 2 4 3 6 3 0 2 4 3 6 2 2 1 7 2 7 2 2 1 7 2 7 7 0 6 0 8 0 7 0 6 0 8 0 1 2 1 0 1 4 1 2 1 0 1 4 FOR THE MACHINE 20 17 PC20R 8 PC27R 8...

Page 134: ...asure the time elapsing from when the arm stops at dead centre until it starts to move again Max 2 Max 2 Bucket Measuring posture Engine speed low idling Hydraulic oil temperature 45 55 C Bring the bo...

Page 135: ...PC27R 8 Standard value Permissible value Max 2 Max 2 Max 2 Max 2 Max 2 Max 2 Max 1 Max 1 FOR THE MACHINE 20 19 PC20R 8 PC27R 8...

Page 136: ...ion Unit Standard value Permissible value Gear pump P2 Theoretical flow cm3 2 75 Motor speed rpm 2600 Test pressure kg cm2 30 5 Nominal capacity Hydraulic oil temperature 45 55 C min 6 6 Piston pump P...

Page 137: ...s test Make delivery measurements with the engine running at a speed close to the test speed and then make a proportional calculation Example MEASUREMENT Engine speed 2525 rpm Delivery 42 min PROPORTI...

Page 138: ...ion Unit Standard value Permissible value Gear pump P2 Theoretical flow cm3 3 44 Motor speed rpm 2600 Test pressure kg cm2 30 5 Nominal capacity Hydraulic oil temperature 45 55 C min 8 3 Piston pump P...

Page 139: ...the engine running at a speed close to the test speed and then make a proportional calculation Example MEASUREMENT Engine speed 2525 rpm Delivery 42 min PROPORTIONAL DELIVERY AT 2600 rpm 42x2600 2525...

Page 140: ...le tachometer 1 20 4000 rpm 2 ATR800060 Stroboscopic tachometer 1 6 30000 rpm Hydraulic pressure E 1 ATR800170 Compression gauge 1 Scale 60 bar 2 ATR800140 Compression gauge 1 Scale 400 bar 3 ATR80001...

Page 141: ...in mini mum position High idling without load accelerator lever in maximum position H Low idling PC20R 8 950w25 rpm PC27R 8 1050w25 rpm H High idling PC20R 8 2780w25 rpm PC27R 8 2785w25 rpm H If the...

Page 142: ...stem and that there is no lop sided wear 1 If the valve caps 5 are damaged replace them with new ones 2 Make sure that the valve caps fit perfectly and are lying flat on the valve stem 4 Insert the fe...

Page 143: ...H Check that the seal is mounted in the adapter and that it is undamaged 6 Turn the engine using the starting motor and read the compression value H Read the compression value when the pressure gauge...

Page 144: ...a new belt the flexion should be 7 9 mm 2 Adjusting the belt tension 1 Loosen the screws 4 that secure the alternator 2 and the screw 5 that secures the belt tighten ing stop 2 Rotate the alternator 2...

Page 145: ...1 cylinder is at the top dead centre B T D C Check that the cylinder is in a compression stroke i e that both valves are closed H Once the B T D C has been ascertained rotate the drive shaft in a clo...

Page 146: ...owards the outside To DELAY the injection rotate the pump 6 to wards the cylinder block H Check the extent of the movement on the scale 7 7 Lock the nuts 6 that fasten the pump to its block Pump faste...

Page 147: ...ments secure the pump side of the sheathing in the intermediate position 2 Push the accelerator control lever 2 to the end of its stroke in the minimum position 3 Adjustment the sheathing 3 position o...

Page 148: ...with respect to the housing 5 by loosening the outside nut 6 of one of the sheathings and tightening the inside nut 7 of the other by the same amount 4 Secure the position with the nuts 8 and 9 5 Exe...

Page 149: ...for boom swing and travel 1 Remove the footboard 1 from the platform 2 Loosen the nut 2 in the sheath of the drive 3 to be adjusted 3 Adjust the locknuts of the sheath until the position of the lever...

Page 150: ...few turns 3 Loosen the nuts 4 and tighten the lock screws 5 by a few turns 4 Pull one of the levers 6 towards the operator s seat Keep this position and tighten the corresponding lock screw 3 until i...

Page 151: ...s 3 and screws 4 3 Push the pedal 5 to the end of its stroke in one direc tion Keep this position and tighten the screw 4 until it touches the support Tighten the screw 4 by a final half turn 4 Hold t...

Page 152: ...hydraulic circuits Return the ignition key to the O OFF position and remove it Push the lever of the safety device into the LOCKED position Slowly loosen the oil tank refuelling cap to eliminate resi...

Page 153: ...oughly 3 mm from the starting point of the cut off slot 4 Keep this position and bring the rubber pad into con tact with the console 6 5 Release the servo control engagement lever and se cure the rubb...

Page 154: ...the track shoe H Standard measurements Model RUBBER TRACK SHOE STEEL TRACK SHOE PC20R 8 A 10 15 mm A 10 30 mm PC27R 8 A 10 15 mm A 10 30 mm 2 Adjustment If the track shoe tensions do not fall within p...

Page 155: ...Curl A8 B8 Hammer Suction Delivery A9 B9 PC20R 8 PC27R 8 RKP06460 1 2 3 4 5 6 7 8 9 A B H Test conditions Engine at working temperature MIN and MAX engine speeds within permissi ble limits Hydraulic...

Page 156: ...sures of the working equipment machine travel and swing 1 Remove the plug 1 of pump P1 and mount a pressure adapter 2 Connect a pressure gauge E2 400 bar or E3 600 bar 3 Start the engine and bring it...

Page 157: ...e end of its stroke and with the pressure stabilised To check the pressure of the working equip ment push the piston to the end of its stroke To check the pressure of machine travel in sert a block A...

Page 158: ...25 bar 128 kg cm2 3 Lock the nut 2 Nut 59w10 Nm H After adjustment check the adjustment of the main relief valve with the same procedures as used for the measurements 2 Adjustment of the safety valve...

Page 159: ...Nm H After adjustment check the adjustment of the main relief valve with the same procedures as used for the measurements 2 Adjustment of the safety valve of the swing mo tor Do not calibrate the valv...

Page 160: ...oke Swing without load 2 Test method with pressure gauges E2 or E3 H The maximum differential pressure is 34 3 bar 35 kg cm2 For a precise check use the same pres sure gauge together with a decimal sc...

Page 161: ...he tube 2 2 Loosen the lock nut 3 and turn the adjusting screw 4 To INCREASE pressure turn in a CLOCKWISE direction To DECREASE pressure turn in a COUNTER CLOCKWISE direction H Each turn of the adjust...

Page 162: ...e PC valve 1 should be regulated as follows 1 Loosen the check nut 2 2 Turn the adjustment screw 3 If the working equipment speed is low turn the screw 3 in a CLOCKWISE direction to INCREASE the torqu...

Page 163: ...roke Swing without load 2 Test method with pressure gauges E2 or E3 H The maximum differential pressure is 34 3 bar 35 kg cm2 For a precise check use the same pres sure gauge together with a decimal s...

Page 164: ...the tube 2 2 Loosen the lock nut 3 and turn the adjusting screw 4 To INCREASE pressure turn in a CLOCKWISE direction To DECREASE pressure turn in a COUNTER CLOCKWISE direction H Each turn of the adjus...

Page 165: ...and the LS differen tial pressure are all normal the PC valve 1 should be regulated as follows 1 Loosen the check nut 2 2 Turn the adjustment screw 3 If the working equipment speed is low turn the scr...

Page 166: ...1 Checking the pressure of the servo controls 1 Remove the R H hood 1 2 Remove the cap 2 of pump P2 and a pressure adapter 3 Connect the pressure gauge E1 60 bar 4 Start the engine and bring it up to...

Page 167: ...nk is of the sealed and pres surised type When tubes are to be removed or disconnected for controls or repairs or when caps are re moved tank pressure must be eliminated using the following method 1 R...

Page 168: ...valve p p p p Repair Substitution cylinders Removal of cylinders tube p p p p Repair substitution swing motor Removal of tubes from swing motor p p p p Repair substitution travel motor joint Removal o...

Page 169: ...the swing locking pin is not en gaged 1 With the engine at low idling rotate the revolving frame three turns towards the left 2 Repeat the same manoeuvre rotating the revol ving frame to the right 4 B...

Page 170: ...ION OF THE RESIDUAL PRESSURES 1 Boom test 1 Position the machine with the arm vertical and with the back of the bucket resting on the ground 2 Stop the engine and release the residual hydrau lic press...

Page 171: ...and 2 from the arm cy linder and plug them to prevent the entry of impu rities 4 Plug the hole of the arm cylinder on the head side and attach a provisional tube on the base side to catch any oil lea...

Page 172: ...isconnect the bucket cylinder hoses 1 and 2 and plug them to prevent the entry of impurities 4 Plug the hole of the bucket cylinder on the base side and attach a provisional tube on the head side to c...

Page 173: ...and plug it H Plug the control valve union to prevent entry of impurities 4 Disconnect the boom swing cylinder hose 2 and plug it 5 Attach a provisional tube on the head side to catch any oil leakages...

Page 174: ...ch any oil leakages 6 Start the engine and force the boom down to raise the machine in order to remove the block on which the blade is resting 7 Lower the blade and stop the engine 8 Check the positio...

Page 175: ...rt the engine move the machine to a 15 slope and stop the engine 5 Mark the position between revolving frame and lower track frame on the swing circle and for 15 minutes check whether or not the revol...

Page 176: ...nnect the tube from the head side of the cylin der and bind it to the structure Take great care not to disconnect the tube on the base side of the cylinder 3 Start the engine bring it up to high idlin...

Page 177: ...nage oil 3 Start the motor and bring it up to maximum swing 4 Make sure that the turret is locked in place and push the swing command lever to the end of its stroke 5 Hold it in this position for 15 s...

Page 178: ...the line to be checked and measuring any leakages from the adja cent lines according to the following tables PC20R 8 PC27R 8 RKP04820 G Increment of travel speed F Blade cylinder base side Descent E...

Page 179: ...RES SURES FROM THE CIRCUITS 2 Disconnect from the blade cylinder 3 the tube 4 corresponding to the line to be checked and seal it Also plug the holes in the actuators to prevent entry of impurities 3...

Page 180: ...H 20 64 TESTING AND ADJUSTMENTS PC20R 8 PC27R 8...

Page 181: ...GRUPPO 30...

Page 182: ...40 28 PC15R 8...

Page 183: ...TANK Removal 22 Installation 22 HYDRAULIC OIL TANK Removal 23 Installation 24 OIL COOLER RADIATOR GROUP Removal 25 Installation 26 ENGINE PUMP GROUP Removal 27 Installation 29 PUMP Removal 30 Install...

Page 184: ...RS Removal 56 Installation 56 BOOM CYLINDER Removal 57 Installation 58 ARM CYLINDER Removal 59 Installation 59 BUCKET CYLINDER Removal 60 Installation 60 BOOM SWING CYLINDER Removal 61 Installation 62...

Page 185: ...tallation H Technique or important point to remember when re moving 2 Addition of water or oil Step in removal procedure H Point to remember when adding water or oil 2 To the precautions to be taken d...

Page 186: ...e oil and grease then apply just enough adhesive to cover the threading in a uniform manner When applying a liquid sealant clean the surface involved remove residual oil and grease check that there ar...

Page 187: ...rench for cylinder 65 1 Removal installation of head Wrench for cylinder 70 1 Wrench for cylinder 75 1 Wrench for cylinder 80 1 6 6 point socket wrench 30 1 Removal installation of piston 6 point sock...

Page 188: ...n Q ty Notes Disassembly assembly cylinders C 11 Bushing for piston 50 1 Assembling piston cylinder Bushing for piston 55 1 ATR201190 Bushing for piston 60 1 ATR201200 Bushing for piston 70 1 30 6 REM...

Page 189: ...ove the operator s cab forwards complete 3 Loosen bolts 1 and remove the cover 2 3 Disconnect cable 3 and connector 4 4 Loosen bolts 5 and remove starter motor 6 INSTALLATION OF THE STARTER MOTOR To i...

Page 190: ...onnect cable 3 and connectors 4 and 5 5 Loosen bolts 6 and 7 sufficiently to allow the alter nator to be rotate 6 Free the pulley 8 from the fan belt and remove alter nator 9 INSTALLATION OF THE ALTER...

Page 191: ...t high pressure pipes 7 from injection pump 3 6 Remove the inlet cover 8 to ignition gear system 7 Loosen and remove nut 9 and lock washer 10 of pump driving gear H Be careful not let nut 9 and lock w...

Page 192: ...accelerator stroke lever For details see 20 CONTROLS AND ADJUST MENTS Feed and return pipes 31 85w2 45 Nm H Align marks among gears before to install pump and nut Nuts Nm Pump lock nuts 25 5 Nm 1 Che...

Page 193: ...e fuel re turn tubes 4 3 Loosen nuts 5 and remove clips 6 4 Remove the complete injection nozzles INSTALLATION OF THE NOZZLE HOLDER To install reverse the removal procedure High pressure pipe union 31...

Page 194: ...in version Disconnect the cooling circuit tube 5 Disconnect the connectors 6 3 Remove from the radiator the fan cover 7 and dis connect the fan cooling conveyor 8 4 Loosen the screws 9 remove the cool...

Page 195: ...cuits Stop the engine and check the level H Only for cabin version Make sure that the heat ing cock is open R H lateral counterweight screws 180 Nm 1 To install the engine hood For details see REMOVAL...

Page 196: ...osen the screws 6 from support 7 and nuts 8 from muffler Remove muffler 4 5 Remove the fuel filter 9 without disconnecting the tubes Put it to rear side of machine 6 Remove nozzle holder 10 For detail...

Page 197: ...cock is open Screws Nm Nuts Nm Nut Nm Screw Nm H Adjust valve clearance For details see 20 CON TROLS AND ADJUSTMENTS Adjusting valve clear ance H Raise the cylinder head keeping it horizontal and pla...

Page 198: ...ised position take out the screws 2 that fasten the hinge 3 to the frame and remove the hood INSTALLATION OF THE ENGINE HOOD To install reverse the removal procedure H Check the alignment of the outsi...

Page 199: ...out the ignition key 1 Attach the canopy 1 to some hoisting tackle 2 Loosen and remove the screws 2 and 3 3 Remove the canopy Canopy 73 kg INSTALLATION OF CANOPY To install reverse the removal proced...

Page 200: ...1 Loosen the clamp 1 and disconnect the heating pipe 2 2 Remove the cover 3 3 Attach the cab 4 to some hoisting tackle 4 Loosen the cab lock crews No 10 5 Take out the cab 4 Cab 208 kg INSTALLATION O...

Page 201: ...COVER and remove the swivel pin 5 6 Disconnect the return tube 6 and delivery tube 7 to heating fan H Plug the tubes to prevent entry of impurities 7 Loosen screws 8 No 2 remove cover 9 and re move t...

Page 202: ...1 Make sure that the heating cock is fully open 2 Fill up the coolant circuit Coolant approx 4 3 Start the engine to circulate the coolant and check that there are no leaks 4 Stop the engine and top...

Page 203: ...Loosen the counterweight screws 4 to eliminate the tightening torque 4 Attach the counterweight 5 to some hoisting tackle remove the screws and pull out the counterweight 5 INSTALLATION OF THE COUNTE...

Page 204: ...changing them during re installation 3 Loosen the clip 4 the screws 5 and take out the fuel filling 6 4 Disconnect the connector 7 and loosen lock screws 8 No 4 of the fuel tank 9 5 Remove the fuel ta...

Page 205: ...pen the R H counterweight 1 the R H lateral cov er 2 the R H lower cover 3 For details see the single removal 2 Loosen the screws 4 and 5 3 Remove the pipe 6 from oil cooler and exhaust pipe 8 4 Remov...

Page 206: ...F THE HYDRAULIC TANK To install reverse the removal procedure 1 Fill the hydraulic oil tank to maximum level Hydraulic oil needed approx 29 Counterweight screws 180 Nm 2 Start the engine at low idling...

Page 207: ...raulic oil approx 29 H Drain the coolant Coolant approx 4 1 Open the R H counterweight 1 and remove the hood 2 2 Disconnect pipes 3 and 4 and drain the hydraulic oil from exchager and from drainage pi...

Page 208: ...s maximum level Coolant approx 4 Side counterweight screw 180 Nm 1 Start the engine to circulate the coolant throughout the system H Make sure that the heating cock is fully open in the cab version 2...

Page 209: ...ils see the single removal 2 Remove the expansion chamber 1 3 Disconnect the tubes 2 and remove the clip 3 H Plug the tubes to prevent entry of impurities 4 Disconnect from the pumps the Load Sensing...

Page 210: ...emove the screw starting from engine box to the fixed hood 19 11 Attach the fixed hood 19 to hoisting tackle and take out it H Check that the motor swings completely free while it is being raised and...

Page 211: ...TROLS AND ADJUSTMENTS Vibration damping nuts 56 Nm 1 Fill the tank with hydraulic oil up to the maximum le vel While filling the tank bleed air from the pump For details see 20 CONTROLS AND ADJUST MEN...

Page 212: ...n to the cable 6 Loosen the screws 7 PC20R 8 n 2 PC27R 8 n 4 and remove the pump 8 Pump PC20R 8 19 kg PC27R 8 22 kg INSTALLATION OF THE PUMP To install reverse the removal procedure Pump screws Loctit...

Page 213: ...oval procedure Flywheel cover screws 55 Nm Coupling screws 55 Nm 1 Fill the tank up to its maximum level Hydraulic oil required approx 22 Bleed the air from the pump For details see 20 CONTROLS AND AD...

Page 214: ...cover 2 H Take care not to damage the electrical socket wiring harness 4 Disconnect the electrical socket connectors 3 and take out the cover 2 2 Remove R H cover 1 Remove cover 4 No 4 screws 2 Loose...

Page 215: ...OF CABIN 3 Remove the screws 2 and move away the cock 3 from bracket 4 Loosen the screws 4 5 Loosen screws 5 6 Loosen screws 6 and remove the cover 7 INSTALLATION OF INNER CONTROL VALVE BOX COVER To...

Page 216: ...cover For details see the single removal 2 Disconnect all the servo control function delivery and exhaust pipes 4 from control valve 3 H Mark the tubes to avoid exchanging them during re assembly H Pl...

Page 217: ...VALVE To install reverse the removal procedure 1 Fill the tank with hydraulic oil up to the maximum le vel Hydraulic oil approx 29 2 Start the engine at low idling to circulate the oil throughout the...

Page 218: ...e PPC valve 8 5 Disconnect the six PPC valve tubes 9 and plug them to prevent entry of impurities H Check that the tubes are marked to avoid exchan ging them during re assembly INSTALLATION OF LEFT HA...

Page 219: ...nd remove the PPC valve 7 6 Disconnect the six PPC valve tubes 7 and plug them to prevent entry of impurities H Check that the tubes are marked to avoid exchan ging them during re assembly INSTALLATIO...

Page 220: ...nnect the connector 2 H Mark the connectors to avoid exchanging them during re assembly 3 Disconnect in sequence the travel increment control pipe 3 the union 4 the solenoid valve pipe 5 the union 6 H...

Page 221: ...nd the inner control valve box cover For details see the single removal 3 Disconnect the servo controls tubes 3 No 10 H Mark the tubes to avoid exchanging them during re assembly H Plug the tubes and...

Page 222: ...he cover 16 to ward engine hood 10 Disconnect the connectors 17 and ground cables 18 11 Only for cabin version H Drain the coolant Coolant Approx 4 12 Disconnect the return and delivery pipes 19 and 2...

Page 223: ...ulic oil approx 29 Only for cabin version H Fill the tank with coolant Coolant approx 4 H Make sure that the fan cock is fully open 1 Start the engine to circulate the oil and coolant and check that t...

Page 224: ...track frame 4 Disconnect the tubes 3 from the swivel joint 4 H Mark the tubes to avoid exchanging them during re assembly H Plug the tubes to prevent entry of impurities 5 Loosen the screws 5 and remo...

Page 225: ...in out the hydraulic oil Hydraulic oil approx 29 1 Remove the canopy or the cab For details see the removal of the each component 2 Remove the L H side lower panels 1 For details see REMOVAL OF THE SI...

Page 226: ...bes to avoid exchanging them during re assembly H Plug the tubes to prevent entry of impurities 10 Take out the screws 10 and remove the swing ma chinery 11 Swing machinery 27 kg PC27R 8 11 Disconnect...

Page 227: ...ulic oil up to the maximum le vel Hydraulic oil needed approx 22 2 Start the engine to circulate the oil and check that there are no leaks 3 Stop the engine check the oil hydraulic level and if necess...

Page 228: ...E REAR COUNTERWEIGHT 6 Remove the platform For details see REMOVAL OF THE PLATFORM 7 Disconnect the swing circle lubrication tube 2 and remove the coupling 3 8 Remove the swing machinery 4 For details...

Page 229: ...ill the fuel tank Fuel tank max 35 3 Start the engine to circulate the oil and check that tubes are leaktight H Only for cab version Make sure that the heating cock is fully open 4 Bleed air from the...

Page 230: ...swing circle 2 Swing circle PC20R 8 25 kg PC27R 8 33 kg INSTALLATION OF THE SWING CIRCLE To install reverse the removal procedure H Before attaching the swing circle check that the area marked with a...

Page 231: ...loosened by more than one turn H If the grease does not run out easily move the machine slowly backwards and forwards 3 Force the boom downwards to raise the machine 4 Insert three steel pipes into th...

Page 232: ...ack shoe raised move the machine in order to remove the track shoe 4 and lay it on the ground 5 Push down with the boom in order to raise the lower track frame and pull out the track shoe 4 Track shoe...

Page 233: ...ndicular to the ground and raise the lower track frame Insert safety blocks underneath the track frame 4 Take out the screws 1 and their washers 5 Remove the sprocket wheel 2 Sprocket wheel 7 kg INSTA...

Page 234: ...prevent entry of im purities 4 Take out the screws 3 5 Remove the final drive 3 Complete final drive 35 kg INSTALLATION OF THE FINAL DRIVE To install reverse the removal procedure Final drive screws L...

Page 235: ...SHOES 2 Pull the idler 2 and recoil spring 3 out of the lower track frame 1 INSTALLATION OF IDLER AND RECOIL SPRING To install reverse the removal procedure H Restore tension to the track shoe For det...

Page 236: ...pring 2 and the plate 6 Assembly To re assemble reverse the dismantling procedure H Tighten the nut 4 up to the indicated length of the spring See 40 STANDARD MAINTENANCE Mount the cotter pin 3 H Afte...

Page 237: ...e the screws 5 and their washers 5 3 Using a press take out the pin 6 and remove the supports 2 and the lateral seals 7 4 Remove the bushings 8 ASSEMBLY OF THE IDLER To re assemble reverse the dismant...

Page 238: ...n to raise the lower track frame 2 3 Only for steel track shoes Remove the guard 3 4 Loosen the screws 4 and remove the rollers 5 INSTALLATION OF THE TRACK ROLLERS To install reverse the removal proce...

Page 239: ...der 4 until it rests on a stand A 6 Start the engine to retract the piston 5 H Bind the piston rod with wire to secure the fully re tracted position 7 Stop the engine and release the residual hydrauli...

Page 240: ...tween the hole and the pin turn the engine over at low idling Do not insert fingers in the holes to check alignment H Adjust the shim thickness so that the clearance be tween cylinder 4 and boom 10 is...

Page 241: ...nnect the tubes 4 and plug them Also plug the holes in the cylinder to prevent the entry of impurities 7 Remove the pin 5 8 Remove the cylinder 1 Arm cylinder PC20R 8 20 kg PC27R 8 28 kg INSTALLATION...

Page 242: ...g them Also plug the holes in the cylinder to prevent the entry of impu rities 6 Put a sling round the cylinder 1 7 Remove the pin 5 8 Remove the cylinder 1 Bucket cylinder PC20R 8 11 kg PC27R 8 12 kg...

Page 243: ...ine and retract the piston rod 4 comple tely H Bind the piston rod with wire to secure the fully re tracted position 4 Stop the engine and move the command pedal boom swing cylinder several times to r...

Page 244: ...e tween cylinder 10 and swing bracket 2 is below 1 mm When aligning the positions between the hole and the pin turn the engine over at low idling Do not insert fingers in the holes to check alignment...

Page 245: ...he residual hydraulic pressures For details see 20 CONTROLS AND ADJUSTMENTS 6 Disconnect the tubes 5 and plug them Also plug the holes in the cylinder to prevent entry of impurities 7 Remove the pin 7...

Page 246: ...on the apparatus C1 Engage the cylinder in the tools C4 having the same bushing diameter 3 Attach the special wrench C5 adjusted to fit the cylin der to the head 3 and apply the dynamometric tool C2...

Page 247: ...k nut 5 of the piston 6 and using the dynamometric tool with a multiplier C2 remove the nut H Socket wrench measurement Unit mm Cylinder Boom Arm Bucket Boom swing Blade Model PC20R 8 41 46 36 46 41 P...

Page 248: ...d 3 H Check the orientation carefully 2 Mount the snap ring 8 3 Using the tool C3 mount the lip seal 9 H Check that the lips face into the cylinder 4 Mount the O ring 10 the anti extrusion ring 11 and...

Page 249: ...eter 3 Piston rod group assembly 1 Using a press and the tool C4 adapted to the dia meter insert the bushing 17 into the piston rod 4 2 Insert the support A beneath the piston rod 3 Mount the pilot bo...

Page 250: ...e socket wrench C6 and the dynamometric tool with a multiplier C2 Nut Loctite 262 Nut Unit mm Cylinder Boom Arm Bucket Boom swing Blade Model PC20R 8 618w62 785w78 412w41 539w54 618w62 PC27R 8 785w78...

Page 251: ...rom the cylinder and then lower the apparatus C1 even further until the head 3 and the piston rod approach the cylinder 9 Place the cylinder 2 in position for screwing in the head 3 10 Insert the head...

Page 252: ...til it rests on a stand A 6 Start the engine to retract the piston 4 H Bind the piston rod with wire to secure the fully re tracted position 7 Stop the engine and release the residual hydraulic pressu...

Page 253: ...he shim thickness so that the clearance be tween cylinder and boom is below 1 mm When aligning the positions between the hole and the pin turn the engine over at low idling Do not insert fingers in th...

Page 254: ...PC27R 8 50 kg INSTALLATION OF THE BUCKET To install reverse the removal procedure H Adjust the shim thickness so that the clearance be tween bucket 3 and link 4 is below 1 mm When aligning the positi...

Page 255: ...ntry of impurities 6 Put a sling round the cylinder 5 7 Remove the pin 6 and take out the cylinder 5 com pletely of levels Complete cylinder 35 kg 8 Position a block A beneath the arm cylinder com man...

Page 256: ...s between the hole and the pin turn the engine over at low idling Do not insert fingers in the holes to check alignment Internal bushings ASL800050 H Adjust the shim thickness so that the clearance be...

Page 257: ...ent tubes 5 H Plug the tubes to prevent entry of impurities 7 Remove the pin 6 and take out the arm complete 7 Arm complete PC20R 8 115 kg PC27R 8 160 kg INSTALLATION OF THE ARM ASSEMBLY To install re...

Page 258: ...th the cylinder 3 7 Remove the pin 4 and rest the cylinder on a stand 8 Start the engine and completely retract the piston rod 5 9 Stop the engine and release the residual hydraulic pressures For deta...

Page 259: ...holes to check alignment Internal bushings ASL800050 Internal bushings ASL800040 H Insert the shims on both sides of the arm When aligning the positions between the hole and the pin do not insert fing...

Page 260: ...t tension to the cable 7 Take out the bracket 5 remove the pin 6 and re move the boom swing support 4 H Make a note of the position of the spacer 7 and the quantity of shims 8 Boom swing support PC20R...

Page 261: ...r attachment 2 H Adjust the length of the cables to balance the group 4 Take out the pin 3 5 Remove the blade 4 Blade PC20R 8 100 kg PC27R 8 137 kg INSTALLATION OF THE BLADE To install reverse the rem...

Page 262: ...30 80 REMOVAL AND INSTALLATION PC20R 8 PC27R 8...

Page 263: ...GRUPPO 40...

Page 264: ...40 28 PC15R 8...

Page 265: ...drive 4 Sprocket 5 Track frame and recoil spring 6 Idler 7 Carrier roller 8 Track roller 9 Track shoe 10 Hydraulic pump 12 Control valve 14 Swivel joint 20 Swing motor 21 Travel motor 24 PPC Valve fo...

Page 266: ...em Criteria Remedy 1 Axial bearing clearance Standard clearance Clearance limit Replace 0 3 1 3 SWING CIRCLE M The figure represent PC20R 8 40 2 PC20R 8 PC27R 8 RKP01530 1 130 Nm with Loctite 262 130...

Page 267: ...0 0 30 2 Clearance between planetary gear and ring gear 0 15 0 35 3 Clearance between pinion and swing circle teething 0 30 0 70 4 Size of pinion in the zone of contact with the sealing ring Standard...

Page 268: ...it Replace 0 15 0 35 2 Backlash between No 1 planetary gear and housing 0 10 0 35 3 Backlash between No 2 sun gear and No 2 planetary gear 0 10 0 30 4 Backlash between No 1 sun gear and No 1 planetary...

Page 269: ...ndard size Tolerance Repair limit Build up by solder or replace 344 3 1 2 332 2 Wear at tips of sprocket teeth 386 2 w1 5 374 3 Face width at tips of sprocket teeth 20 18 4 Face width at base of sproc...

Page 270: ...orizontal width of idler guide Track frame 161 165 Build up by welding Idler support 159 155 Build up by welding or replace 3 Recoil spring Standard size Repair limit Replace Free length Preloaded len...

Page 271: ...00 292 3 Width of track shoe guide 28 20 4 Total width 64 59 5 Width of tread 18 22 6 Clearance between bushing and idler Standard size Tolerance Standard clearance Clearance limit Replace Shaft Hole...

Page 272: ...medy 1 Outer diameter of tread Standard size Repair limit Replace 70 60 2 Width of tread 100 3 Axial play of roller Standard tolerance Clearance limit Replace 0 0 5 1 CARRIER ROLLER PC27R 8 40 8 PC20R...

Page 273: ...ft and bushing Standard size Tolerance Standard clearance Clearance limit Replace bushing Shaft Hole 25 0 0 013 0 183 0 144 0 2 0 3 6 Interference between roller and bushing Standard size Tolerance St...

Page 274: ...height 61 5 5 Interference between regular pin and link Standard size Tolerance Standard interference Interference limit Replace Shaft Hole 32 0 22 0 12 0 0 05 0 07 0 22 6 Interference between pin and...

Page 275: ...ia Remedy 1 Wear of lug height Standard size Repair limit Replace 25 5 2 Wear of roller guard portion 71 65 3 Wear of meshing portion of sprocket 23 27 RUBBER SHOE 40 11 PC20R 8 PC27R 8 RKP01730 3 A A...

Page 276: ...HYDRAULIC PUMP PC20R 8 40 12 PC20R 8 PC27R 8 RKP00061 Vista Z Z 63 7w4 9 Nm 6 5w0 5 kgm 30 4w2 9 Nm 3 1w0 3 kgm 57 9w6 9 Nm 5 9w0 7 kgm View Z...

Page 277: ...8 40 13 PC20R 8 PC27R 8 RKP01300 24 5w4 9 Nm 2 5w0 5 kgm 34 3w4 9 Nm 3 5w0 5 kgm 30 9w3 4 Nm 3 15w0 35 kgm 69 7w1 0 Nm 7w1 kgm 22 1w2 5 Nm 2 25w0 25 kgm 22 1w2 5 Nm 2 25w0 25 kgm 13 3w1 5 Nm 1 35w0 1...

Page 278: ...CONTROL VALVE 40 14 PC20R 8 PC27R 8 RKP01591 O M L K J E P P O M L K J E C B A A B C 31 9w2 5 Nm 3 25w0 25 kgm 11 3w1 5 Nm 1 15w0 15 kgm 11 3w1 5 Nm 1 15w0 15 kgm 11 3w1 5 Nm 1 15w0 15 kgm...

Page 279: ...40 15 PC20R 8 PC27R 8 RKP01661 Sezione A A 44 1w4 9 Nm 4 5w0 5 kgm 44 1w4 9 Nm 4 5w0 5 kgm Section A A...

Page 280: ...ngth x D Installed length Installed load Free length Installed load 29x17 5 28 5 22 6 N 2 3 kg 18 1 N 1 84 kg 2 Spool return spring boom blade 46 2x20 25 4 98 N 10 kg 78 4 N 8 kg 3 Spool return spring...

Page 281: ...kg 3 Unload valve spring 28 94x11 8 13 22 5 N 2 3 kg 18 N 1 84 kg 4 Pressure compensation valve spring 38 2x9 2 20 30 4 N 3 1 kg 24 3 N 2 5 kg 5 Cooler check valve spring 29 1x18 7 18 82 4 N 8 4 kg 6...

Page 282: ...ce the spring Free length x D Installed length Installed load Free length Installed load 21 9x5 15 8 1 96 N 0 2 kg 1 57 N 0 16 kg 40 18 PC20R 8 PC27R 8 RKP02030 Sezione J J Sezione K K Sezione E E 1 1...

Page 283: ...led load Free length Installed load 21 9x5 15 8 1 96 N 0 2 kg 1 57 N 0 16 kg 2 Pilot relief valve spring 32 4x10 4 27 83 3 N 8 5 kg 66 6 N 6 8 kg 40 19 PC20R 8 PC27R 8 RKP02040 Sezione O O Sezione P P...

Page 284: ...Unit mm No Check item Criteria Remedy 1 Clearance between rotor and shaft Standard size Standard clearance Clearance limit Replace 45 0 055 0 085 0 090 SWIVEL JOINT 40 20 PC20R 8 PC27R 8 RKP00500 1...

Page 285: ...ing Standard size Repair limit When damage or deformation is found replace the spring Free length x D Installed length Installed load Free length Installed load SWING MOTOR PC20R 8 40 21 PC20R 8 PC27R...

Page 286: ...ngth Installed length Installed load Free length Installed load 30 1 15 7 2 3 N 25 5 1 6 N 2 Clearance between piston and cylinder Standard clearance Clearance limit Replace 0 03 0 15 0 4 3 Clearance...

Page 287: ...40 23 PC20R 8 PC27R 8 PAGE INTENTIONALLY LEFT BLANK...

Page 288: ...TRAVEL MOTOR 40 24 PC20R 8 PC27R 8 A B B B B A RKP01381 Sezione A A 4 1 2 3 63 7w5 Nm 34 3w5 Nm 240w5 Nm 31 9w2 5 Nm 2 5w0 5 Nm 2 5w0 5 Nm 10w1 Nm Section A A...

Page 289: ...increment piston spring Standard size Repair limit When damage or deformation is found replace the spring Free length Installed length Installed load Free length Installed load 15 7 7 7 8 N 13 9 6 3...

Page 290: ...kg 2 Centering spring P1 and P2 port 42 5x15 5 34 17 7 N 1 8 kg 14 1 N 1 44 kg 3 Metering spring 26 5x9 2 24 9 16 7 N 1 7 kg 13 7 N 1 4 kg PPC VALVE FOR BOOM ARM BUCKET SWING 40 26 PC20R 8 PC27R 8 Sez...

Page 291: ...Replace Free length x D Installed length Installed load Free length Installed load 54 4x21 2 40 5 308 7 N 31 5 kg 53 1 277 5 N 28 3 kg 2 Metering spring 25 9x11 0 25 0 24 5 N 2 5 kg 25 8 21 6 N 2 2 kg...

Page 292: ...0 0 130 0 117 0 080 0 170 0 247 1 0 Boom swing 40 0 010 0 050 0 134 0 072 0 082 0 184 1 0 Blade 35 0 090 0 130 0 142 0 080 0 170 0 272 1 0 3 Clearance between cylinder bottom bushing and pin Boom 35 0...

Page 293: ...0 090 0 130 0 142 0 080 0 170 0 272 1 0 Boom swing 40 0 010 0 050 0 134 0 072 0 082 0 184 1 0 Blade 35 0 090 0 130 0 142 0 080 0 170 0 272 1 0 3 Clearance between cylinder bottom bushing and pin Boom...

Page 294: ...20R 8 PC27R 8 RKP01750 I J G L N M K F E Q D B A P O C H Sezione A A Sezione B B Sezione C C Sezione D D Sezione E E Sezione F F Sezione G G 1 2 3 Section A A Section B B Section C C Section D D Secti...

Page 295: ...130 0 117 0 080 0 170 0 247 1 0 5 Clearance between bushing and mounting pin of bucket and arm 30 0 090 0 130 0 117 0 080 0 170 0 247 1 0 6 Clearance between bushing and mounting pin of link and link...

Page 296: ...C27R 8 Sezione A A Sezione B B Sezione C C Sezione D D Sezione E E Sezione F F Sezione G G RKP01740 I J G L N M K F E Q D B A P O C H 1 3 2 Section A A Section B B Section C C Section D D Section E E...

Page 297: ...130 0 142 0 080 0 170 0 272 1 0 5 Clearance between bushing and mounting pin of bucket and arm 35 0 090 0 130 0 142 0 080 0 170 0 272 1 0 6 Clearance between bushing and mounting pin of link and link...

Page 298: ...40 34 PC20R 8 PC27R 8...

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Komatsu F30791, Shop Manual

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