Komatsu PC20R-8 PC25R-8 PC27R-8 Excavator Shop Manual SEBM010801 PDF

Description

Komatsu PC20R-8 PC25R-8 PC27R-8 Excavator Shop Manual SEBM010801 – PDF DOWNLOAD

FILE DETAILS:

Komatsu PC20R-8 PC25R-8 PC27R-8 Excavator Shop Manual SEBM010801 – PDF DOWNLOAD 

Language : English
Pages : 473
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Komatsu PC20R-8 PC25R-8 PC27R-8 Excavator Shop Manual SEBM010801 – PDF DOWNLOAD 

MACHINE MODEL       SERIAL NUMBER
PC20R-8                          10001 and up
PC25R-8                           10001 and up
PC27R-8                           10001 and up

COVER 1
CONTENTS 2
01 GENERAL 25
GENERAL ASSEMBLY DRAWING 26
SPECIFICATIONS 32
WEIGHT TABLE 38
LIST OF LUBRICANT AND WATER 40
10 STRUCTURE AND FUNCTION 42
POWER TRAIN 43
SWING CIRCLE 45
SWING MACHINERY 47
TRACK FRAME 48
RECOIL SPRING 51
HYDRAULIC PIPING 52
HYDRAULIC CIRCUIT DIAGRAM 54
HYDRAULIC TANK 57
HYDRAULIC PUMP 59
CONTROL VALVE 82
CLSS 90
CENTER SWIVEL JOINT 113
SWING MOTOR 114
TRAVEL MOTOR 122
VALVE CONTROL 127
PPC VALVE 128
WORK EQUIPMENT 132
ELECTRICAL CIRCUIT DIAGRAM 133
MACHINE MONITOR SYSTEM 134
20 TESTING AND ADJUSTING 139
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS 140
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS 142
STANDARD VALUE TABLE FOR ELECTRICAL PARTS 157
TOOLS FOR TESTING,ADJUSTING,AND TROUBLESHOOTING 159
MEASURING ENGINE SPEED 160
MEASURING EXHAUST COLOR 161
ADJUSTING VALVE CLEARANCE 162
MEASURING COMPRESSION PRESSURE 163
TESTING AND ADJUSTING FUEL INJECTION TIMING 164
MEASURING ENGINE OIL PRESSURE 166
TESTING AND ADJUSTING ALTERNATOR FAN BELT TENSION 167
MEASURING SPROCKET WEAR 168
TESTING AND ADJUSTING TRACK SHOE TENSION 169
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT,SWING,TRAVEL CIRCUIT 170
TESTING AND ADJUSTING LS DIFFERENTIAL PRESSURE 174
ADJUSTING PC VALVE 178
TESTING AND ADJUSTING CONTROL CIRCUIT PRESSURE 179
MEASURING OUTPUT PRESSURE OF PPC LOCK VALVE AND TRAVEL BOOST VALVE 181
TESTING PPC VALVE OUTPUT PRESSURE AND SWING HOLDING BRAKE INLET PORT PRESSURE 182
ADJUSTING WORK EQUIPMENT,SWING PPC VALVE 186
TESTING AND ADJUSTING TRAVEL DEVIATION 187
MEASURING OIL LEAKAGE INSIDE CYLINDER 188
RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT 189
RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK 189
PRESSURIZING HYDRAULIC TANK 189
BLEEDING AIR 190
TROUBLESHOOTING 192
POINTS TO REMEMBER WHEN TROUBLESHOOTING 193
SEQUENCE OF EVENTS IN TROUBLESHOOTING 194
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 195
CHECKS BEFORE TROUBLESHOOTING 203
TYPE OF CONNECTOR AND POSITION OF INSTALLATION 204
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 207
METHOD OF USING TROUBLESHOOTING CHARTS 217
TROUBLESHOOTING OF ELECTRICAL SYSTEM(E MODE) 220
E-MODE RELATED ELECTRICAL CIRCUIT DIAGRAM 221
E-1 ENGINE DOES NOT START 222
a) WHEN STARTING MOTOR DOES NOT TURN(STARTING SYSTEM) 222
b) WHEN STARTING MOTOR TURNS(ENGINE STOP SOLENOID SYSTEM) 224
E-2 ENGINE DOES NOT STOP 226
TROUBLESHOOTING OF HYDRAULIC,MECHANICAL SYSTEM(H MODE) 227
TABLE OF FAILURE MODES AND CAUSES 228
H-1 SPEEDS OF ALL WORK EQUIPMENT,SWING,TRAVEL ARE SLOW OR LACK POWER 230
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED,OR ENGINE STALLS 231
H-3 NO WORK EQUIPMENT,TRAVEL,SWING MOVE 231
H-4 ABNORMAL NOISE GENERATED(FROM AROUND PUMP) 232
H-5 FINE CONTROL ABILITY IS POOR OR RESPONSE IS POOR 232
H-6 BOOM IS SLOW OR LACKS POWER 233
H-7 ARM IS SLOW OR LACKS POWER 233
H-8 BUCKET IS SLOW OR LACKS POWER 234
H-9 BOOM SWING IS SLOW OR LACKS POWER 234
H-10 BLADE IS SLOW OR LACKS POWER 235
H-11 BOOM,ARM,BUCKET DO NOT MOVE(BOOM SWING,BLADE,TRAVEL AND SWING ARE NORMAL) 235
H-12 EXCESSIVE HYDRAULIC DRIFT(BOOM,ARM,BUCKET,BOOM SWING,BLADE) 236
a) BOOM 236
b) ARM,BUCKET 236
c) BOOM SWING 236
d) BLADE 237
H-13 EXCESSIVE TIME LAG(ENGINE AT LOW IDLING) 237
H-14 IN COMPOUND OPERATIONS,WORK EQUIPMENT WITH LARGER LOAD IS SLOW 237
H-15 TRAVEL DEVIATION 238
a) DEVIATION IN NORMAL TRAVEL 238
b) DEVIATION WHEN STARTING 238
H-16 TRAVEL SPEED IS SLOW OR LACKS POWER 239
H-17 STEERING DOES NOT TURN EASILY 239
H-18 TRAVEL SPEED DOES NOT SWITCH 240
H-19 TRAVEL DOES NOT MOVE(ONE SIDE ONLY) 240
H-20 SWING SPEED IS SLOW OR LACKS POWER 241
a) SPEED IS SLOW OR LACKS POWER IN BOTH DIRECTIONS 241
b) SPEED IS SLOW OR LACKS POWER IN ONE DIRECTION ONLY(LEFT OR RIGHT) 241
H-21 DOES NOT SWING 242
a) DOES NOT SWING IN EITHER DIRECTION 242
b) DOES NOT SWING IN ONE DIRECTION(LEFT OR RIGHT) 242
H-22 SWING ACCELERATION IS POOR 243
a) ACCELERATION IS POOR IN BOTH DIRECTIONS 243
b) ACCELERATION IS POOR IN ONE DIRECTION ONLY(LEFT OR RIGHT) 243
H-23 EXCESSIVE OVERRUN WHEN STOPPING SWING 244
a) OVERRUN WHEN STOPPING IS EXCESSIVE IN BOTH DIRECTIONS 244
b) OVERRUN WHEN STOPPING IS EXCESSIVE IN ONE DIRECTION ONLY(LEFT OR RIGHT) 244
H-24 EXCESSIVE SHOCK WHEN STOPPING SWING(IN ONE DIRECTION ONLY) 245
H-25 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING 245
H-26 EXCESSIVE HYDRAULIC DRIFT OF SWING 245
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM(M MODE) 246
ELECTRICAL CIRCUIT DIAGRAM FOR M MODE RELATED PARTS 247
M-1 WHEN THE STARTING SWITCH IS TURNED ON,NO DISPLAY IS GIVEN 248
M-2 WHEN STARTING SWITCH IS TURNED ON,EVEN WHEN SELF CHECK IS COMPLETED(ALL LAMPS LIGHT UP FOR 3 SECONDS),LAMPS DO NOT GO OUT 248
M-3 WHEN STARTING SWITCH IS TURNED ON,SOME SELF CHECK LAMPS DO NOT LIGHT UP FOR 3 SECONDS 249
a) NO GAUGE LAMPS LIGHT UP(FUEL,COOLANT TEMPERATURE) 249
b) CAUTION LAMPS(ENGINE OIL PRESSURE,BATTERY CHARGE),PILOT LAMP(PREHEATING) DO NOT LIGHT UP 249
M-4 DURING SELF CHECK(ALL LAMPS LIGHT UP FOR 3 SECONDS),EVEN IF STARTING SWITCH IS TURNED TO START,SELF CHECK IS NOT COMPLETED IN 3 SECONDS 249
M-5 WHEN STARTING SWITCH IS ON(ENGINE STOPPED),ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP 250
M-6 WHEN STARTING SWITCH IS ON(ENGINE STOPPED),CHARGE CAUTION LAMP DOES NOT LIGHT UP 251
M-7 WHEN STARTING SWITCH IS TURNED TO HEAT,PREHEATING PILOT LAMP DOES NOT LIGHT UP 252
M-8 WHEN ENGINE IS RUNNING,ENGINE OIL PRESSURE CAUTION LAMP LIGHTS UP 252
M-9 WHEN ENGINE IS RUNNING,CHARGE CAUTION LAMP LIGHTS UP 253
M-10 ABNORMALITY IN COOLANT TEMPERATURE GAUGE 255
a) LEVEL DOES NOT RISE FROM SEGMENT C 255
b) LEVEL DOES NOT GO DOWN FROM SEGMENT H,OR ALL SEGMENTS GO OUT 255
c) COOLANT TEMPERATURE DOES NOT MATCH GAUGE DISPLAY 256
M-11 ABNORMALITY IN FUEL GAUGE 257
a) LEVEL DOES NOT RISE FROM SEGMENT E OR ALL SEGMENTS GO OUT 257
b) LEVEL DOES NOT GO DOWN FROM SEGMENT F 257
c) FUEL LEVEL DOES NOT MATCH GAUGE DISPLAY 258
M-12 DEFECTIVE OPERATION OF ALARM BUZZER 259
a) BUZZER DOES NOT SOUND 259
b) BUZZER CONTINUES TO SOUND AND DOES NOT STOP 259
M-13 WHEN ENGINE IS RUNNING,SERVICE METER DOES NOT ADVANCE 260
a) WHEN CHARGE CAUTION LAMP DOES NOT LIGHT UP 260
b) WHEN CHARGE CAUTION LAMP LIGHTS UP 260
c) PILOT LAMP DOES NOT FLASH(SERVICE METER IS ACTUATED) 260
M-14 NIGHT LIGHTING DOES NOT LIGHT UP 261
a) GAUGE LIGHTING DOES NOT LIGHT UP 261
b) SERVICE METER LIGHTING DOES NOT LIGHT UP 261
30 DISASSEMBLY AND ASSEMBLY 262
METHOD OF USING MANUAL 264
PRECAUTIONS WHEN CARRYING OUT OPERATION 265
SPECIAL TOOL LIST 267
SKETCHES OF SPECIAL TOOLS 271
STARTING MOTOR 276
REMOVAL AND INSTALLATION 276
ALTERNATOR 277
REMOVAL AND INSTALLATION 277
FUEL INJECTION PUMP 278
REMOVAL 278
INSTALLATION 279
NOZZLE HOLDER 280
REMOVAL AND INSTALLATION 280
WATER PUMP 281
REMOVAL 281
INSTALLATION 282
THERMOSTAT 283
REMOVAL AND INSTALLATION 283
ENGINE FRONT SEAL 284
REMOVAL AND INSTALLATION 284
ENGINE REAR SEAL 285
REMOVAL 285
INSTALLATION 286
CYLINDER HEAD 287
REMOVAL 287
INSTALLATION 288
RADIATOR 289
REMOVAL AND INSTALLATION 289
ENGINE,HYDRAULIC PUMP 290
REMOVAL 290
INSTALLATION 293
FUEL TANK 294
REMOVAL AND INSTALLATION 294
DAMPER 295
REMOVAL AND INSTALLATION 295
CENTER SWIVEL JOINT 296
REMOVAL AND INSTALLATION 296
DISASSEMBLY AND ASSEMBLY 297
TRAVEL MOTOR 298
REMOVAL AND INSTALLATION 298
DISASSEMBLY AND ASSEMBLY(PHV-190(FOR PC20R-8)) 299
DISASSEMBLY AND ASSEMBLY(PHV-200(FOR PC25R-8),PHV-250(FOR PC27R-8)) 310
SPROCKET 325
REMOVAL AND INSTALLATION 325
SWING MOTOR,SWING MACHINERY 326
REMOVAL 326
INSTALLATION 327
DISASSEMBLY 328
ASSEMBLY 331
SWING MOTOR(LMF16AB(FOR PC25R-8 AND PC27R-8) 334
DISASSEMBLY 334
ASSEMBLY 339
REVOLVING FRAME 347
REMOVAL 347
INSTALLATION 348
SWING CIRCLE 349
REMOVAL AND INSTALLATION 349
IDLER 350
REMOVAL AND INSTALLATION 350
DISASSEMBLY 351
ASSEMBLY 352
RECOIL SPRING 354
REMOVAL AND INSTALLATION 354
DISASSEMBLY AND ASSEMBLY 355
TRACK ROLLER 356
REMOVAL AND INSTALLATION 356
DISASSEMBLY 357
ASSEMBLY 358
CARRIER ROLLER 359
REMOVAL AND INSTALLATION 359
DISASSEMBLY AND ASSEMBLY 360
RUBBER SHOE 361
REMOVAL AND INSTALLATION 361
STEEL SHOE 362
REMOVAL AND INSTALLATION 362
HYDRAULIC TANK 363
REMOVAL AND INSTALLATION 363
HYDRAULIC COOLER 364
REMOVAL AND INSTALLATION 364
HYDRAULIC PUMP 365
REMOVAL AND INSTALLATION 365
MAIN PUMP(LPV-30(FOR PC25R-8 AND PC27R-8) 366
DISASSEMBLY 366
ASSEMBLY 374
CONTROL VALVE 385
REMOVAL 385
INSTALLATION 386
DISASSEMBLY 387
ASSEMBLY 392
PPC VALVE 399
REMOVAL AND INSTALLATION 399
DISASSEMBLY 400
ASSEMBLY 401
BOOM CYLINDER 402
REMOVAL 402
INSTALLATION 403
ARM CYLINDER 404
REMOVAL 404
INSTALLATION 405
BUCKET CYLINDER 406
REMOVAL 406
INSTALLATION 407
BOOM SWING CYLINDER 408
REMOVAL 408
INSTALLATION 409
BLADE CYLINDER 410
REMOVAL AND INSTALLATION 410
HYDRAULIC CYLNDER 411
DISASSEMBLY 411
ASSEMBLY 414
WORK EQUIPMENT 417
REMOVAL 417
INSTALLATION 418
BUCKET 419
REMOVAL AND INSTALLATION 419
ARM 420
REMOVAL 420
INSTALLATION 421
BUCKET,ARM 422
REMOVAL 422
INSTALLATION 423
BOOM 424
REMOVAL 424
INSTALLATION 425
BOOM SWING BRACKET 426
REMOVAL 426
INSTALLATION 427
BLADE 428
REMOVAL AND INSTALLATION 428
OPERATOR’S CAB 429
REMOVAL AND INSTALLATION 429
CANOPY 429
REMOVAL AND INSTALLATION 429
FLOOR FRAME 430
REMOVAL 430
INSTALLATION 431
40 MAINTENANCE STANDARD 432
SWING CIRCLE 433
SWING MACHINERY 435
TRACK FRAME,RECOIL SPRING 437
IDLER 438
CARRIER ROLLER 439
TRACK ROLLER 440
TRACK SHOE 441
HYDRAULIC PUMP 443
HYDRAULIC PUMP(LPV30) 444
CONTROL VALVE 445
CENTER SWIVEL JOINT 451
SWING MOTOR 452
TRAVEL MOTOR 454
PPC VALVE 455
HYDRAULIC CYLINDER 456
WORK EQUIPMENT 459
90 OTHERS 465
HYDRAULIC PIPING PC20R-8 466
HYDRAULIC PIPING PC25R,27R-8 467
HYDRAULIC CIRCUIT DIAGRAM PC20R-8 468
HYDRAULIC CIRCUIT DIAGRAM PC25R-8 469
HYDRAULIC CIRCUIT DIAGRAM PC27R-8 470
CLSS 10A OPERATION OF THE SYSTEM AS A WHOLE PC20R-8 471
CLSS 10B OPERATION OF THE SYSTEM AS A WHOLE PC25R,PC27R-8 472
ELECTRICAL CIRCUIT DIAGRAM PC20R,25R,27R-8 473

DESCRIPTION:

Komatsu PC20R-8 PC25R-8 PC27R-8 Excavator Shop Manual SEBM010801 – PDF DOWNLOAD 

GENERAL PRECAUTIONS :

Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine.

PREPARATIONS FOR WORK:

PRECAUTIONS DURING WORK :

IMAGES PREVIEW OF THE MANUAL:

S.V 22/12/24