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Komatsu PC20R-8, PC25R-8, PC27R-8 Hydraulic Excavator Shop Manual SN 10001 and up – PDF DOWNLOAD
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Komatsu PC20R-8, PC25R-8, PC27R-8 Hydraulic Excavator Shop Manual
Book Code: SEBM010801
MACHINE MODEL SERIAL NUMBER
PC20R-8 10001 and up
PC25R-8 10001 and up
PC27R-8 10001 and up
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Description
Komatsu PC20R-8, PC25R-8, PC27R-8 Hydraulic Excavator Shop Manual
FILE DETAILS:
Komatsu PC20R-8, PC25R-8, PC27R-8 Hydraulic Excavator Shop Manual
Brands: Komatsu
Equipment Type: Hydraulic Excavator
Manuals Type: Shop Manual
Machine Model: PC20R-8, PC25R-8, PC27R-8
Serial Number: 10001 and up
Book Code: SEBM010801
Language: English
Pages: 473
File Format: Portable Document Format (PDF)
KOMATSU PC20R-8, PC25R-8, PC27R-8 HYDRAULIC EXCAVATOR SHOP MANUAL SN 10001 AND UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu PC20R-8, PC25R-8, PC27R-8 Hydraulic Excavator Shop Manual
FOREWORD:
GENERAL:
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the servicemen 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. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
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 section 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 thissection.
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.
TABLE OF CONTENTS:
Komatsu PC20R-8, PC25R-8, PC27R-8 Hydraulic Excavator Shop Manual
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
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