KOMATSU PC27R-8 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:F30671 & UP) – PDF DOWNLOAD

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KOMATSU PC27R-8 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:F30671 & UP)

KOMATSU PC27R-8 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:F30671 & UP) – PDF DOWNLOAD:

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TABLE OF CONTENTS:

KOMATSU PC27R-8 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:F30671 & UP)

MAIN MENU....................................................................................  0
COVER........................................................................................  1
CONTENTS.....................................................................................  2
FOREWARD.....................................................................................  5
	FOREWARD.................................................................................  7
	HOW TO READ THE SHOP MANUAL..............................................................  8
	HOISTING INSTRUCTIONS....................................................................  9
	STANDARD TIGHTENING TORQUE............................................................... 10
	COATING MATERIALS........................................................................ 12
	ELECTRIC WIRE CODE....................................................................... 13
	WEIGHT TABLE............................................................................. 14
	TABLE OF OIL AND COOLANT QUANTIES........................................................ 15
10 STRUCTURE AND FUNCTION.................................................................... 17
	POWER TRAIN.............................................................................. 18
	SWING CIRCLE............................................................................. 19
	SWING MACHINERY.......................................................................... 20
	FINAL DRIVE.............................................................................. 21
	TRACK FRAME.............................................................................. 22
	RECOIL SPRING............................................................................ 23
	CARRIER ROLLER........................................................................... 24
	TRACK ROLLER............................................................................. 24
	STEEL SHOE............................................................................... 25
	HYDRAULIC SYSTEM......................................................................... 26
	HYDRAULIC CIRCUIT DIAGRAM................................................................ 27
	HYDRAULIC PUMP........................................................................... 29
	CONTROL VALVE............................................................................ 47
	CLSS..................................................................................... 55
	SWIVEL JOINT............................................................................. 72
	SWING MOTOR.............................................................................. 73
	TRAVEL MOTOR............................................................................. 75
	CYLINDER................................................................................. 77
	ACCUMULATOR.............................................................................. 80
	PPC VALVE................................................................................ 85
	SOLENOID VALVE........................................................................... 88
	ELECTRICAL DIAGRAM (1/3)................................................................. 90
	ELECTRICAL DIAGRAM (2/3)................................................................. 91
	ELECTRICAL DIAGRAM (3/3)................................................................. 92
20 TESTING AND ADJUSTING..................................................................... 94
	NORMAL OR STANDARD TECHNICAL DATA........................................................ 95
	SPECIAL TOOLS............................................................................106
	CHECKING THE ENGINE SPEED................................................................107
	ADJUSTMENT OF VALVE CLEARANCE............................................................108
	MEASUREMENT OF THE COMPRESSOR PRESSURE...................................................109
	CONTROL AND ADJUSTMENT OF THE TENSION OF THE FAN BELT....................................110
	CONTROL AND ADJUSTMENT OF THE INJECTION TIMING...........................................111
	CONTROL AND ADJUSTMENT OF THE ACCELERATOR STROKE ........................................113
	ADJUSTMENTOF THE STROKE OF THE BLADE COMMAND LEVER.......................................114
	ADJUSTING THE FLEXIBLE CABLES............................................................115
	CONTROL AND ADJUSTMENT OF THE STROKE OF THE TRAVEL LEVER.................................116
	ADJUSTMENT OF THE STROKE OF THE BOOM SWING COMMAND PEDAL.................................117
	ADJUSTMENT OF THE PPC VALVE CLEARANCES...................................................118
	ADJUSTMENT OF THE RUBBER PAD AND SAFETY MICROSWITCH FOR SERVO-CONTROL ENGAGEMENT.........119
	CONTROL AND ADJUSTMENTOF THE STROKE OF THE TRACK-SHOE TENSION............................120
	CONTROL AND REGULATION OF THE PREEURES IN THE HYDRAULIC CIRCUTIS.........................121
	CONTROL AND REGULATION OF THE LS DIFFERENTIAL PRESSURE AND ADJUSTMENT OF THE LS VALVE....124
	REGULATION OF THE PC VALVE...............................................................126
	CONTROL AND REGULATION O THE SERVO-CONTROL POWER SUPPLY..................................127
	ELIMINATION OF RESIDUAL PRESSURES - PRESSURISATION OF THE TANK...........................128
	BLEEDING AIR FROM THE HYDRAULIC CIRCUITS.................................................129
	CONTROL OF HYDRAULIC DRIFTS - ANALYSIS OF THE CAUSES OF A DRIFT..........................131
	CHECKING FOR ANY LEAKAGES INSIDE THE WORKING EQUIPMENT CYLINDERS.........................137
	CHECKING FOR ANY LEAKAGES INSIDE THE SWING MOTOR.........................................138
	METHODS FOR TESTING FOR LEAKAGES INSIDE THE SWIVEL JOINT.................................139
30 REMOVAL AND INSTALLATION..................................................................142
	HOW TO READ THE MANUAL...................................................................144
	PRECAUTIONS TO BE TAKEN WHILE WORKING....................................................145
	SPECIAL TOOLS............................................................................146
	STARTER MOTOR............................................................................148
		REMOVAL..............................................................................148
		INSTALLATION.........................................................................148
	ALTERNATOR...............................................................................149
		REMOVAL..............................................................................149
		INSTALLATION.........................................................................149
	INJECTION PUMP...........................................................................150
		REMOVAL..............................................................................150
		INSTALLATION.........................................................................151
	NOZZLE HOLDER............................................................................152
		REMOVAL..............................................................................152
		INSTALLATION.........................................................................152
	WATER COOLANT PUMP.......................................................................153
		REMOVAL..............................................................................153
		INSTALLATION.........................................................................154
	CYLINDER HEAD............................................................................155
		REMOVAL..............................................................................155
		INSTALLATION.........................................................................156
	OIL COOLER...............................................................................157
		REMOVAL..............................................................................157
		INSTALLATION.........................................................................157
	RADIATOR.................................................................................158
		REMOVAL..............................................................................158
		INSTALLATION.........................................................................158
	ENGINE HOOD..............................................................................159
		REMOVAL..............................................................................  2
		INSTALLATION.........................................................................  2
	CANOPY...................................................................................160
		REMOVAL..............................................................................160
		INSTALLATION.........................................................................160
	CAB......................................................................................161
		REMOVAL..............................................................................161
		INSTALLATION.........................................................................161
	HEATING FAN..............................................................................162
		REMOVAL..............................................................................162
		INSTALLATION.........................................................................163
	COUNTERWEIGHT............................................................................164
		REMOVAL..............................................................................164
		INSTALLATION.........................................................................164
	DIESEL FUEL TANK.........................................................................165
		REMOVAL..............................................................................165
		INSTALLATION.........................................................................165
	HYDRAULIC OIL TANK.......................................................................166
		REMOVAL..............................................................................166
		INSTALLATION.........................................................................167
	OIL-COOLER-RADIATOR GROUP................................................................168
		REMOVAL..............................................................................168
		INSTALLATION.........................................................................169
	ENGINE-PUMP GROUP........................................................................170
		REMOVAL..............................................................................170
		INSTALLATION.........................................................................172
	PUMP.....................................................................................173
		REMOVAL..............................................................................173
		INSTALLATION.........................................................................173
	ENGINE-PUMP COUPLING.....................................................................174
		REMOVAL..............................................................................174
		INSTALLATION.........................................................................174
	SIDE LOWER PANELS........................................................................175
		REMOVAL..............................................................................175
		INSTALLATION.........................................................................175
	INNER CONTROL VALVE BOX COVER............................................................176
		REMOVAL..............................................................................176
		INSTALLATION.........................................................................176
	CONTROL VALVE............................................................................177
		REMOVAL..............................................................................177
		INSTALLATION.........................................................................178
	LEFT-HAND PPC VALVE (ARM-BUCKET).........................................................179
		REMOVAL..............................................................................179
		INSTALLATION.........................................................................179
	RIGHT-HAND PPC VALVE (BOOM-BUCKET).......................................................180
		REMOVAL..............................................................................180
		INSTALLATION.........................................................................180
	SERVOCONTROL SOLENOID GROUP..............................................................181
		REMOVAL..............................................................................181
		INSTALLATION.........................................................................181
	PLATFORM.................................................................................182
		REMOVAL..............................................................................182
		INSTALLATION.........................................................................184
	SWIVEL JOINT.............................................................................185
		REMOVAL..............................................................................185
		INSTALLATION.........................................................................185
	SWING MACHINERY..........................................................................186
		REMOVAL..............................................................................185
		INSTALLATION.........................................................................187
	REVOLVING FRAME..........................................................................188
		REMOVAL..............................................................................188
		INSTALLATION.........................................................................189
	SWING CIRCLE.............................................................................190
		REMOVAL..............................................................................190
		INSTALLATION.........................................................................190
	RUBBER TRACK SHOES.......................................................................191
		REMOVAL..............................................................................191
		INSTALLATION.........................................................................191
	STEEL TRACK-SHOES........................................................................192
		REMOVAL..............................................................................192
		INSTALLATION.........................................................................192
	SPROCKET WHEEL...........................................................................193
		REMOVAL..............................................................................193
		INSTALLATION.........................................................................193
	FINAL DRIVE..............................................................................194
		REMOVAL..............................................................................194
		INSTALLATION.........................................................................194
	IDLER AND RECOIL SPRING ASSEMBLY.........................................................195
		REMOVAL..............................................................................195
		INSTALLATION.........................................................................195
	SPRING RECOIL AND THRUST CYLINDER GROUPS.................................................196
		DISASSEMBLY..........................................................................196
		ASSEMBLY.............................................................................196
	IDLER....................................................................................197
		DISASSEMBLY..........................................................................197
		ASSEMBLY.............................................................................197
	TRACK ROLLERS............................................................................198
		REMOVAL..............................................................................198
		INSTALLATION.........................................................................198
	BOOM CYLINDER............................................................................199
		REMOVAL..............................................................................199
		INSTALLATION.........................................................................200
	ARM CYLINDER.............................................................................201
		REMOVAL..............................................................................201
		INSTALLATION.........................................................................201
	BUCKET CYLINDER..........................................................................202
		REMOVAL..............................................................................202
		INSTALLATION.........................................................................202
	BOOM SWING CYLINDER......................................................................203
		REMOVAL..............................................................................203
		INSTALLATION.........................................................................204
	BLADE CYLINDER...........................................................................205
		REMOVAL..............................................................................205
		INSTALLATION.........................................................................205
	WORKING EQUIPMENT CYLINDERS..............................................................206
		DISASSEMBLY..........................................................................206
		ASSEMBLY.............................................................................208
	UPPER WORKING EQUIPMENT..................................................................212
		REMOVAL..............................................................................212
		INSTALLATION.........................................................................213
	ARM......................................................................................214
		REMOVAL..............................................................................214
		INSTALLATION.........................................................................215
	ARM ASSEMBLY.............................................................................216
		REMOVAL..............................................................................216
		INSTALLATION.........................................................................216
	BOOM.....................................................................................217
		REMOVAL..............................................................................217
		INSTALLATION.........................................................................218
	BOOM SWING SUPPORT.......................................................................219
		REMOVAL..............................................................................219
		INSTALLATION.........................................................................219
	BLADE....................................................................................220
		REMOVAL..............................................................................220
		INSTALLATION.........................................................................220
40 MAINTENANCE STANDARD......................................................................222
	SWING CIRCLE.............................................................................223
	SWING MACHINERY..........................................................................224
	FINAL DRIVE..............................................................................225
	SPROCKET.................................................................................226
	TRACK FRAME AND RECOIL SPRING............................................................227
	IDLER....................................................................................228
	CARRIER ROLLER...........................................................................229
	TRACK ROLLER.............................................................................230
	TRACK SHOE...............................................................................231
	HYDRAULIC PUMP...........................................................................233
	CONTROL VALVE............................................................................234
	SWIVEL JOINT.............................................................................240
	SWING MOTOR..............................................................................241
	TRAVEL MOTOR.............................................................................242
	PPC VALVE (FOR BOOM, ARM, BUCKET, SWING).................................................244
	PPC VALVE (FOR HAMMER)...................................................................245
	CYLINDER.................................................................................246
	WORK EQUIPMENT...........................................................................248

DESCRIPTION:

KOMATSU PC27R-8 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:F30671 & UP)

• This shop manual has been prepared as an aid to improve the quality of repairs by giving the operator an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
• This shop manual mainly contains the necessary technical information for operations performed in a service workshop. The manual is divided into chapters on each main group of components; these chapters are further divided into the following sections.
• STRUCTURE AND FUNCTION
  This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
• TESTING AND ADJUSTING
  This sections explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating «Problems» to «Causes» are also included in this section.
• DISASSEMBLY AND ASSEMBLY
  This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
• MAINTENANCE STANDARD
  This section gives the judgement standards when inspecting disassembled parts.

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