Komatsu Hydraulic Excavator PC20R, PC25R, PC27R Repair Service Manuals
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Model:
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC20R, PC25R, PC27R, PC27R Deluxe, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Hydraulic Excavator PC20R-8, PC25R-8, PC27R-8, PC27R-8 Deluxe workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
WEBM000200 - Hydraulic Excavator PC20R-8, PC27R-8 Shop Manual.pdf
WEBM000201 - Hydraulic Excavator PC20R-8, PC27R-8 Shop Manual.pdf
WEBM002900 - Hydraulic Excavator PC27R-8 Shop Manual.pdf
WEBM003800 - Hydraulic Excavator PC27R-8 Deluxe Shop Manual.pdf
SEBM010801 - Hydraulic Excavator PC20R-8, PC25R-8, PC27R-8 Shop Manual.pdf
SEAM015203T - Hydraulic Excavator PC20R-8, PC25R-8, PC27R-8 Operation & Maintenance Manual.pdf
WEAM000101 - Hydraulic Excavator PC20R-8, PC27R-8 Operation & Maintenance Manual.pdf
WEAM003100 - Hydraulic Excavator PC27R-8 Operation & Maintenance Manual.pdf
WEAM003102 - Hydraulic Excavator PC27R-8 Deluxe Operation & Maintenance Manual.pdf
Total Pages: 2,419 pages
File Format: PDF
Language: English
SEAM015203T - Hydraulic Excavator PC20R-8, PC25R-8, PC27R-8 Operation & Maintenance Manual...2
COVER...2
1.FOREWORD...3
2.SAFETY INFORMATION...6
3.INTRODUCTION...7
4.LOCATION OF PLATES,TABLE TO ENTER SERIAL NO.AND DISTRIBUTOR...8
5.CONTENTS...9
SAFETY...13
6.GENERAL PRECAUTIONS...14
7.PRECAUTIONS DURING OPERATION...19
7.1 BEFORE STARTING ENGINE...19
7.2 OPERATING MACHINE...21
7.3 TRANSPORTATION...28
7.4 BATTERY...29
7.5 TOWING...31
7.6 LIFTING OPERATIONS...31
7.7 WINDOW WASHER FLUID...31
8.PRECAUTIONS FOR MAINTENANCE...32
8.1 BEFORE CARRYING OUT MAINTENANCE...32
8.2 DURING MAINTENANCE...36
9.POSITION FOR ATTACHING SAFETY LABELS...41
OPERATION...45
10.GENERAL VIEW...46
10.1 GENERAL VIEW OF MACHINE...46
10.2 GENERAL VIEW OF CONTROLS AND GAUGES...47
11.EXPLANATION OF COMPONENTS...48
11.1 MACHINE MONITOR...48
11.2 SWITCHES...53
11.3 CONTROL LEVERS AND PEDALS...56
11.4 ENGINE HOOD ...60
11.5 FRONT WINDOW(MACHINE EQUIPPED WITH CAB)...61
11.6 SLIDING DOOR(MACHINE EQUIPPED WITH CAB)...63
11.7 HAMMER FOR EMERGENCY ESCAPE(MACHINE EQUIPPED WITH CAB)...64
11.8 FUSES...64
11.9 FUSIBLE LINK...65
11.10 CAP,COVER WITH LOCK...65
11.11 MANUAL STORING SPACE...66
11.12 TOOL BOX...66
11.13 DUST INDICATOR...66
12.OPERATION...67
12.1 CHECK BEFORE STARTING ENGINE...67
12.2 STARTING ENGINE...75
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE...77
12.4 MOVING MACHINE OFF...79
12.5 STEERING MACHINE...82
12.6 STOPPING MACHINE...84
12.7 SWINGING...85
12.8 OPERATION OF WORK EQUIPMENT...86
12.9 PRECAUTIONS FOR OPERATION...87
12.10 PRECAUTIONS FOR OPERATION...89
12.11 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS...90
12.12 HOW TO ESCAPE FROM MUD...92
12.13 WORK POSSIBLE USING HYDRAULIC EXCAVATOR...93
12.14 REPLACEMENT OF BUCKET...95
12.15 PARKING MACHINE...96
12.16 CHECK AFTER FINISHING WORK...97
12.17 STOPPING ENGINE...97
12.18 CHECK AFTER STOPPING ENGINE...98
12.19 LOCKING...98
12.20 HANDLING RUBBER SHOES (RUBBER SHOES ONLY)...99
13.TRANSPORTATION...104
13.1 LOADING,UNLOADING WORK...104
13.2 METHOD OF LIFTING MACHINE...106
13.3 PRECAUTIONS FOR LOADING AND SECURING MACHINE...108
13.4 PRECAUTIONS FOR TRANSPORTATION...109
14.COLD WEATHER OPERATION...110
14.1 PRECAUTIONS FOR LOW TEMPERATURE...110
14.2 PRECAUTIONS AFTER COMPLETION OF WORK...112
14.3 PREPARING THE CAB HEATER(MACHINE EQUIPPED WITH CAB)...112
14.4 AFTER COLD WEATHER...112
15.LONG-TERM STORAGE...113
15.1 BEFORE STORAGE...113
15.2 DURING STORAGE...114
15.3 AFTER STORAGE...114
16.TROUBLESHOOTING...115
16.1 PHENOMENA THAT ARE NOT FAILURES...115
16.2 METHOD OF TOWING MACHINE...115
16.3 PRECAUTIONS ON PARTICULAR JOBSITES...115
16.4 IF BATTERY IS DISCHARGED...116
16.5 OTHER TROUBLE...121
MAINTENANCE ...125
17.GUIDES TO MAINTENANCE...126
18.OUTLINES OF SERVICE...128
18.1 OUTLINE OF OIL,FUEL,COOLANT...128
18.2 OUTLINE OF ELECTRIC SYSTEM...131
18.3 OUTLINE OF HYDRAULIC SYSTEM...132
19.WEAR PARTS LIST...133
20.USE OF FUEL,COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...134
21.STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...138
21.1 INTRODUCTION OF NECESSARY TOOLS...138
21.2 TORQUE LIST...139
22.PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...140
23.MAINTENANCE SCHEDULE CHART...142
23.1 MAINTENANCE SCHEDULE CHART...142
23.2 MAINTENANCE INTERVAL WHEN USING HYDRAULIC BREAKER...144
24.SERVICE PROCEDURE...145
24.1 INITIAL 250 HOURS SERVICE...145
24.2 WHEN REQUIRED...146
24.3 CHECK BEFORE STARTING...165
24.4 EVERY 100 HOURS SERVICE...169
24.5 EVERY 250 HOURS SERVICE...170
24.6 EVERY 500 HOURS SERVICE...175
24.7 EVERY 1000 HOURS SERVICE...181
24.8 EVERY 2000 HOURS SERVICE...182
SPECIFICATIONS...186
25.SPECIFICATIONS...187
OPTIONS,ATTACHMENTS...202
26.GENERAL PRECAUTIONS...203
26.1 PRECAUTIONS RELATED TO SAFETY...203
26.2 PRECAUTIONS WHEN INSTALLING ATTACHMENTS...204
27.HANDLING BUCKET WITH HOOK...205
27.1 CHECKING FOR DAMAGE TO BUCKET WITH HOOK...205
27.2 PROHIBITED OPERATIONS...205
27.3 PRECAUTIONS DURING OPERATIONS...205
28.USING SEAT BELT...206
28.1 SEAT BELT...206
29.OPERATION OF CAR RADIO(MACHINE EQUIPPED WITH CAB)...208
29.1 EXPLANATION OF CONTROLS...208
29.2 OPERATION METHOD...210
29.3 PRECAUTIONS FOR USE...212
29.4 SPECIFICATIONS...213
30.OPERATION OF WINDOW WASHER(MACHINE EQUIPPED WITH CAB)...214
30.1 OPERATION OF WINDOW WASHER...214
30.2 CHECK AND REFILLING OF WINDOW WASHER FLUID...214
31.HANDLING OF 1-WAY AND 2-WAY ...215
31.1 SELECTION OF 1-WAY AND 2-WAY...215
31.2 OPERATION OF PEDAL...215
32.INTRODUCTION OF ATTACHMENTS...216
32.1 SPECIFICATIONS AND USES...216
32.2 COMBINATIONS TABLE OF ATTACHMENTS...217
32.3 PRECAUTIONS FOR OPERATING WITH HYDRAULIC BREAKER...218
32.4 OPERATION OF QUICK BREAKER ARM...221
32.5 HANDLING POWER TILT,MECHANICAL ANGLE BLADE...238
SEBM010801 - Hydraulic Excavator PC20R-8, PC25R-8, PC27R-8 Shop Manual...241
COVER...241
CONTENTS...242
01 GENERAL...265
GENERAL ASSEMBLY DRAWING...266
SPECIFICATIONS...272
WEIGHT TABLE...278
LIST OF LUBRICANT AND WATER...280
10 STRUCTURE AND FUNCTION...282
POWER TRAIN...283
SWING CIRCLE...285
SWING MACHINERY...287
TRACK FRAME...288
RECOIL SPRING...291
HYDRAULIC PIPING ...292
HYDRAULIC CIRCUIT DIAGRAM...294
HYDRAULIC TANK...297
HYDRAULIC PUMP...299
CONTROL VALVE...322
CLSS...330
CENTER SWIVEL JOINT...353
SWING MOTOR...354
TRAVEL MOTOR...362
VALVE CONTROL...367
PPC VALVE...368
WORK EQUIPMENT...372
ELECTRICAL CIRCUIT DIAGRAM...373
MACHINE MONITOR SYSTEM...374
20 TESTING AND ADJUSTING...379
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS...380
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS...382
STANDARD VALUE TABLE FOR ELECTRICAL PARTS...397
TOOLS FOR TESTING,ADJUSTING,AND TROUBLESHOOTING...399
MEASURING ENGINE SPEED...400
MEASURING EXHAUST COLOR...401
ADJUSTING VALVE CLEARANCE...402
MEASURING COMPRESSION PRESSURE...403
TESTING AND ADJUSTING FUEL INJECTION TIMING...404
MEASURING ENGINE OIL PRESSURE...406
TESTING AND ADJUSTING ALTERNATOR FAN BELT TENSION...407
MEASURING SPROCKET WEAR...408
TESTING AND ADJUSTING TRACK SHOE TENSION...409
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT,SWING,TRAVEL CIRCUIT...410
TESTING AND ADJUSTING LS DIFFERENTIAL PRESSURE...414
ADJUSTING PC VALVE...418
TESTING AND ADJUSTING CONTROL CIRCUIT PRESSURE...419
MEASURING OUTPUT PRESSURE OF PPC LOCK VALVE AND TRAVEL BOOST VALVE...421
TESTING PPC VALVE OUTPUT PRESSURE AND SWING HOLDING BRAKE INLET PORT PRESSURE...422
ADJUSTING WORK EQUIPMENT,SWING PPC VALVE...426
TESTING AND ADJUSTING TRAVEL DEVIATION...427
MEASURING OIL LEAKAGE INSIDE CYLINDER...428
RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT...429
RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK...429
PRESSURIZING HYDRAULIC TANK...429
BLEEDING AIR...430
TROUBLESHOOTING...432
POINTS TO REMEMBER WHEN TROUBLESHOOTING...433
SEQUENCE OF EVENTS IN TROUBLESHOOTING...434
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE...435
CHECKS BEFORE TROUBLESHOOTING...443
TYPE OF CONNECTOR AND POSITION OF INSTALLATION...444
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...447
METHOD OF USING TROUBLESHOOTING CHARTS...457
TROUBLESHOOTING OF ELECTRICAL SYSTEM(E MODE)...460
E-MODE RELATED ELECTRICAL CIRCUIT DIAGRAM...461
E-1 ENGINE DOES NOT START...462
a) WHEN STARTING MOTOR DOES NOT TURN(STARTING SYSTEM)...462
b) WHEN STARTING MOTOR TURNS(ENGINE STOP SOLENOID SYSTEM)...464
E-2 ENGINE DOES NOT STOP...466
TROUBLESHOOTING OF HYDRAULIC,MECHANICAL SYSTEM(H MODE)...467
TABLE OF FAILURE MODES AND CAUSES...468
H-1 SPEEDS OF ALL WORK EQUIPMENT,SWING,TRAVEL ARE SLOW OR LACK POWER...470
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED,OR ENGINE STALLS...471
H-3 NO WORK EQUIPMENT,TRAVEL,SWING MOVE...471
H-4 ABNORMAL NOISE GENERATED(FROM AROUND PUMP)...472
H-5 FINE CONTROL ABILITY IS POOR OR RESPONSE IS POOR...472
H-6 BOOM IS SLOW OR LACKS POWER...473
H-7 ARM IS SLOW OR LACKS POWER...473
H-8 BUCKET IS SLOW OR LACKS POWER...474
H-9 BOOM SWING IS SLOW OR LACKS POWER...474
H-10 BLADE IS SLOW OR LACKS POWER...475
H-11 BOOM,ARM,BUCKET DO NOT MOVE(BOOM SWING,BLADE,TRAVEL AND SWING ARE NORMAL)...475
H-12 EXCESSIVE HYDRAULIC DRIFT(BOOM,ARM,BUCKET,BOOM SWING,BLADE)...476
a) BOOM...476
b) ARM,BUCKET...476
c) BOOM SWING...476
d) BLADE...477
H-13 EXCESSIVE TIME LAG(ENGINE AT LOW IDLING)...477
H-14 IN COMPOUND OPERATIONS,WORK EQUIPMENT WITH LARGER LOAD IS SLOW...477
H-15 TRAVEL DEVIATION...478
a) DEVIATION IN NORMAL TRAVEL...478
b) DEVIATION WHEN STARTING...478
H-16 TRAVEL SPEED IS SLOW OR LACKS POWER...479
H-17 STEERING DOES NOT TURN EASILY...479
H-18 TRAVEL SPEED DOES NOT SWITCH...480
H-19 TRAVEL DOES NOT MOVE(ONE SIDE ONLY)...480
H-20 SWING SPEED IS SLOW OR LACKS POWER...481
a) SPEED IS SLOW OR LACKS POWER IN BOTH DIRECTIONS...481
b) SPEED IS SLOW OR LACKS POWER IN ONE DIRECTION ONLY(LEFT OR RIGHT)...481
H-21 DOES NOT SWING...482
a) DOES NOT SWING IN EITHER DIRECTION...482
b) DOES NOT SWING IN ONE DIRECTION(LEFT OR RIGHT)...482
H-22 SWING ACCELERATION IS POOR...483
a) ACCELERATION IS POOR IN BOTH DIRECTIONS...483
b) ACCELERATION IS POOR IN ONE DIRECTION ONLY(LEFT OR RIGHT)...483
H-23 EXCESSIVE OVERRUN WHEN STOPPING SWING...484
a) OVERRUN WHEN STOPPING IS EXCESSIVE IN BOTH DIRECTIONS...484
b) OVERRUN WHEN STOPPING IS EXCESSIVE IN ONE DIRECTION ONLY(LEFT OR RIGHT)...484
H-24 EXCESSIVE SHOCK WHEN STOPPING SWING(IN ONE DIRECTION ONLY)...485
H-25 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING...485
H-26 EXCESSIVE HYDRAULIC DRIFT OF SWING...485
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM(M MODE)...486
ELECTRICAL CIRCUIT DIAGRAM FOR M MODE RELATED PARTS...487
M-1 WHEN THE STARTING SWITCH IS TURNED ON,NO DISPLAY IS GIVEN...488
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...488
M-3 WHEN STARTING SWITCH IS TURNED ON,SOME SELF CHECK LAMPS DO NOT LIGHT UP FOR 3 SECONDS...489
a) NO GAUGE LAMPS LIGHT UP(FUEL,COOLANT TEMPERATURE)...489
b) CAUTION LAMPS(ENGINE OIL PRESSURE,BATTERY CHARGE),PILOT LAMP(PREHEATING) DO NOT LIGHT UP...489
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...489
M-5 WHEN STARTING SWITCH IS ON(ENGINE STOPPED),ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP...490
M-6 WHEN STARTING SWITCH IS ON(ENGINE STOPPED),CHARGE CAUTION LAMP DOES NOT LIGHT UP...491
M-7 WHEN STARTING SWITCH IS TURNED TO HEAT,PREHEATING PILOT LAMP DOES NOT LIGHT UP...492
M-8 WHEN ENGINE IS RUNNING,ENGINE OIL PRESSURE CAUTION LAMP LIGHTS UP...492
M-9 WHEN ENGINE IS RUNNING,CHARGE CAUTION LAMP LIGHTS UP...493
M-10 ABNORMALITY IN COOLANT TEMPERATURE GAUGE...495
a) LEVEL DOES NOT RISE FROM SEGMENT C...495
b) LEVEL DOES NOT GO DOWN FROM SEGMENT H,OR ALL SEGMENTS GO OUT...495
c) COOLANT TEMPERATURE DOES NOT MATCH GAUGE DISPLAY...496
M-11 ABNORMALITY IN FUEL GAUGE...497
a) LEVEL DOES NOT RISE FROM SEGMENT E OR ALL SEGMENTS GO OUT...497
b) LEVEL DOES NOT GO DOWN FROM SEGMENT F...497
c) FUEL LEVEL DOES NOT MATCH GAUGE DISPLAY...498
M-12 DEFECTIVE OPERATION OF ALARM BUZZER...499
a) BUZZER DOES NOT SOUND...499
b) BUZZER CONTINUES TO SOUND AND DOES NOT STOP...499
M-13 WHEN ENGINE IS RUNNING,SERVICE METER DOES NOT ADVANCE...500
a) WHEN CHARGE CAUTION LAMP DOES NOT LIGHT UP...500
b) WHEN CHARGE CAUTION LAMP LIGHTS UP...500
c) PILOT LAMP DOES NOT FLASH(SERVICE METER IS ACTUATED)...500
M-14 NIGHT LIGHTING DOES NOT LIGHT UP...501
a) GAUGE LIGHTING DOES NOT LIGHT UP...501
b) SERVICE METER LIGHTING DOES NOT LIGHT UP...501
30 DISASSEMBLY AND ASSEMBLY...502
METHOD OF USING MANUAL...504
PRECAUTIONS WHEN CARRYING OUT OPERATION...505
SPECIAL TOOL LIST...507
SKETCHES OF SPECIAL TOOLS...511
STARTING MOTOR...516
REMOVAL AND INSTALLATION...516
ALTERNATOR...517
REMOVAL AND INSTALLATION...517
FUEL INJECTION PUMP...518
REMOVAL...518
INSTALLATION...519
NOZZLE HOLDER...520
REMOVAL AND INSTALLATION...520
WATER PUMP...521
REMOVAL...521
INSTALLATION...522
THERMOSTAT...523
REMOVAL AND INSTALLATION...523
ENGINE FRONT SEAL...524
REMOVAL AND INSTALLATION...524
ENGINE REAR SEAL...525
REMOVAL...525
INSTALLATION...526
CYLINDER HEAD...527
REMOVAL...527
INSTALLATION...528
RADIATOR...529
REMOVAL AND INSTALLATION...529
ENGINE,HYDRAULIC PUMP...530
REMOVAL...530
INSTALLATION...533
FUEL TANK...534
REMOVAL AND INSTALLATION...534
DAMPER...535
REMOVAL AND INSTALLATION...535
CENTER SWIVEL JOINT...536
REMOVAL AND INSTALLATION...536
DISASSEMBLY AND ASSEMBLY...537
TRAVEL MOTOR...538
REMOVAL AND INSTALLATION...538
DISASSEMBLY AND ASSEMBLY(PHV-190(FOR PC20R-8))...539
DISASSEMBLY AND ASSEMBLY(PHV-200(FOR PC25R-8),PHV-250(FOR PC27R-8))...550
SPROCKET...565
REMOVAL AND INSTALLATION...565
SWING MOTOR,SWING MACHINERY...566
REMOVAL...566
INSTALLATION...567
DISASSEMBLY...568
ASSEMBLY...571
SWING MOTOR(LMF16AB(FOR PC25R-8 AND PC27R-8)...574
DISASSEMBLY...574
ASSEMBLY...579
REVOLVING FRAME...587
REMOVAL...587
INSTALLATION...588
SWING CIRCLE...589
REMOVAL AND INSTALLATION...589
IDLER...590
REMOVAL AND INSTALLATION...590
DISASSEMBLY...591
ASSEMBLY...592
RECOIL SPRING...594
REMOVAL AND INSTALLATION...594
DISASSEMBLY AND ASSEMBLY...595
TRACK ROLLER...596
REMOVAL AND INSTALLATION...596
DISASSEMBLY...597
ASSEMBLY...598
CARRIER ROLLER...599
REMOVAL AND INSTALLATION...599
DISASSEMBLY AND ASSEMBLY...600
RUBBER SHOE...601
REMOVAL AND INSTALLATION...601
STEEL SHOE...602
REMOVAL AND INSTALLATION...602
HYDRAULIC TANK...603
REMOVAL AND INSTALLATION...603
HYDRAULIC COOLER...604
REMOVAL AND INSTALLATION...604
HYDRAULIC PUMP...605
REMOVAL AND INSTALLATION...605
MAIN PUMP(LPV-30(FOR PC25R-8 AND PC27R-8)...606
DISASSEMBLY...606
ASSEMBLY...614
CONTROL VALVE...625
REMOVAL...625
INSTALLATION...626
DISASSEMBLY...627
ASSEMBLY...632
PPC VALVE...639
REMOVAL AND INSTALLATION...639
DISASSEMBLY...640
ASSEMBLY...641
BOOM CYLINDER...642
REMOVAL...642
INSTALLATION...643
ARM CYLINDER...644
REMOVAL...644
INSTALLATION...645
BUCKET CYLINDER...646
REMOVAL...646
INSTALLATION...647
BOOM SWING CYLINDER...648
REMOVAL...648
INSTALLATION...649
BLADE CYLINDER...650
REMOVAL AND INSTALLATION...650
HYDRAULIC CYLNDER...651
DISASSEMBLY...651
ASSEMBLY...654
WORK EQUIPMENT...657
REMOVAL...657
INSTALLATION...658
BUCKET...659
REMOVAL AND INSTALLATION...659
ARM...660
REMOVAL...660
INSTALLATION...661
BUCKET,ARM...662
REMOVAL...662
INSTALLATION...663
BOOM...664
REMOVAL...664
INSTALLATION...665
BOOM SWING BRACKET...666
REMOVAL...666
INSTALLATION...667
BLADE...668
REMOVAL AND INSTALLATION...668
OPERATOR'S CAB...669
REMOVAL AND INSTALLATION...669
CANOPY...669
REMOVAL AND INSTALLATION...669
FLOOR FRAME...670
REMOVAL...670
INSTALLATION...671
40 MAINTENANCE STANDARD...672
SWING CIRCLE...673
SWING MACHINERY...675
TRACK FRAME,RECOIL SPRING...677
IDLER...678
CARRIER ROLLER...679
TRACK ROLLER...680
TRACK SHOE...681
HYDRAULIC PUMP...683
HYDRAULIC PUMP(LPV30)...684
CONTROL VALVE...685
CENTER SWIVEL JOINT...691
SWING MOTOR...692
TRAVEL MOTOR...694
PPC VALVE...695
HYDRAULIC CYLINDER...696
WORK EQUIPMENT...699
90 OTHERS...705
HYDRAULIC PIPING PC20R-8...706
HYDRAULIC PIPING PC25R,27R-8...707
HYDRAULIC CIRCUIT DIAGRAM PC20R-8...708
HYDRAULIC CIRCUIT DIAGRAM PC25R-8...709
HYDRAULIC CIRCUIT DIAGRAM PC27R-8...710
CLSS 10A. OPERATION OF THE SYSTEM AS A WHOLE PC20R-8...711
CLSS 10B. OPERATION OF THE SYSTEM AS A WHOLE PC25R,PC27R-8...712
ELECTRICAL CIRCUIT DIAGRAM PC20R,25R,27R-8...713
WEAM000101 - Hydraulic Excavator PC20R-8, PC27R-8 Operation & Maintenance Manual...714
1.1 FOREWORD...716
1.2 INFORMATION ON SAFETY...717
1.3 INTRODUCTION...719
1.3.1 INTENDED USES...719
1.3.2 IMPROPER OR UNAUTHORIZED USES...719
1.3.3 MAIN CHARACTERISTICS...720
1.3.4 RUNNING-IN...720
1.4 PRODUCT IDENTIFICATION...721
1.4.1 MACHINE SERIAL NUMBER...721
1.4.2 MACHINE IDENTIFICATION PLATE...721
1.4.3 ENGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE...722
1.4.4 TRAVEL REDUCTION GEAR SERIAL NUMBER...722
1.4.5 SWING MOTOR SERIAL NUMBER (for PC20R only)...723
1.4.6 SWING REDUCTION GEAR SERIAL NUMBER (for PC27R only)...723
1.4.7 CAB SERIAL NUMBER...723
1.4.8 SERIAL NUMBERS AND DEALER’S ADDRESS...724
TABLE OF CONTENTS...726
1.1 FOREWORD 1...726
1.2 INFORMATION ON SAFETY 2...726
1.3 INTRODUCTION 4...726
1.3.1 INTENDED USES 4...726
1.3.2 IMPROPER OR UNAUTHORIZED USES 4...726
1.3.3 MAIN CHARACTERISTICS 5...726
1.3.4 RUNNING-IN 5...726
1.4 PRODUCT IDENTIFICATION 6...726
1.4.1 MACHINE SERIAL NUMBER 6...726
1.4.2 MACHINE IDENTIFICATION PLATE 6...726
1.4.3 ENGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE 7...726
1.4.4 TRAVEL REDUCTION GEAR SERIAL NUMBER 7...726
1.4.5 SWING MOTOR SERIAL NUMBER (for PC20R only) 8...726
1.4.6 SWING REDUCTION GEAR SERIAL NUMBER (for PC27R only) 8...726
1.4.7 CAB SERIAL NUMBER 8...726
1.4.8 SERIAL NUMBERS AND DEALER’S ADDRESS 9...726
2.1 SAFETY, NOISE AND VIBRATION PLATES 20...726
2.1.1 POSITION OF THE SAFETY PLATES 20...726
2.1.2 PICTOGRAMS AND RELEVANT MEANINGS 22...726
2.1.3 POSITION OF THE NOISE PLATES ON MACHINES WITH CAB 26...726
2.1.4 POSITION OF THE NOISE PLATES ON MACHINES WITH CANOPY 27...726
2.1.5 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED 27...726
2.2 GENERAL PRECAUTIONS 28...726
2.2.1 GENERAL SAFETY RULES 28...726
2.2.2 SAFETY DEVICES AND GUARDS 28...726
2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS 28...726
2.2.4 UNAUTHORIZED MODIFICATIONS 29...726
2.2.5 LEAVING THE OPERATOR’S SEAT 29...726
2.2.6 GETTING ON AND OFF THE MACHINE 30...726
2.2.7 PREVENTING FIRES DUE TO FUEL AND OIL 30...726
2.2.8 PREVENTING BURNS 31...726
2.2.9 PREVENTING DAMAGE DUE TO ASBESTOS POWDER 31...726
2.2.10 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT 32...726
2.2.11 FIRE EXTINGUISHERS AND FIRST AID KIT 32...726
2.2.12 PRECAUTIONS CONCERNING THE CAB STRUCTURE 32...726
2.2.13 PRECAUTIONS CONCERNING THE EQUIPMENT 32...726
2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE 33...726
2.3.1 SAFETY ON THE WORK SITE 33...726
2.3.2 FIRE PREVENTION 33...726
2.3.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR'S CAB 33...726
2.3.4 ROOM VENTILATION 34...726
2.3.5 PRECAUTIONS TO BE TAKEN FOR THE LIGHTS 34...726
2.3.6 CLEANING THE WINDOWS - CHECKING THE WINDSHIELD WIPER BLADES 34...726
2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING 35...727
2.4.1 STARTING THE ENGINE 35...727
2.4.2 CHECK THE DIRECTION BEFORE STARTING THE MACHINE 35...727
2.4.3 CHECKS FOR TRAVELLING IN REVERSE 35...727
2.4.4 MOVING THE MACHINE 36...727
2.4.5 MOVING ON SLOPES 37...727
2.4.6 WORKING ON SLOPES 38...727
2.4.7 UNAUTHORIZED OPERATIONS 38...727
2.4.8 PREVENTING ELECTROCUTION 39...727
2.4.9 VISIBILITY 40...727
2.4.10 WORKING ON ICY OR SNOW-COVERED SURFACES 40...727
2.4.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT 40...727
2.4.12 WORKING ON LOOSE GROUND 40...727
2.4.13 PARKING THE MACHINE 41...727
2.5 TRANSPORTING THE MACHINE ON MOTOR VEHICLES 42...727
2.5.1 LOADING AND UNLOADING 42...727
2.5.2 TRANSPORT 42...727
2.6 BATTERY 43...727
2.6.1 PREVENTING RISKS THAT MAY BE DUE TO THE BATTERY 43...727
2.6.2 STARTING WITH BOOSTER CABLES 43...727
2.7 PRECAUTIONS FOR THE REMOVAL 44...727
2.8 PRECAUTIONS FOR MAINTENANCE 45...727
2.8.1 WARNING PLATES 45...727
2.8.2 TOOLS 45...727
2.8.3 PERSONNEL 45...727
2.8.4 EQUIPMENT 46...727
2.8.5 WORKING UNDER THE MACHINE 46...727
2.8.6 CLEANING THE MACHINE 46...727
2.8.7 USE OF THE ENGINE DURING MAINTENANCE OPERATIONS 47...727
2.8.8 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY 47...727
2.8.9 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION OR INSPECTION 47...727
2.8.10 RULES TO BE FOLLOWED DURING FUEL OR OIL TOPPING UP 48...727
2.8.11 CHECKING THE COOLANT LEVEL IN THE RADIATOR 48...727
2.8.12 USING LAMPS 48...727
2.8.13 PRECAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR 49...727
2.8.14 PRECAUTIONS CONCERNING THE STARTER 49...727
2.8.15 HANDLING HIGH-PRESSURE PIPES 50...727
2.8.16 PRECAUTIONS TO BE TAKEN WHEN HANDLING HIGH-PRESSURE OIL 50...727
2.8.17 PRECAUTIONS FOR MAINTENANCE OPERATIONS AT HIGH TEMPERATURES AND HIGH PRESSURE 50...727
2.8.18 COOLING FAN AND BELT 51...727
2.8.19 WASTE MATERIALS 51...727
2.8.20 PRECAUTIONS FOR THE USE OF THE synthetic biodegradable oil type HEES 51...727
3.1 SAFETY LOCKS 54...728
3.1.1 MACHINE LOCKS 54...728
3.2 GENERAL VIEWS 55...728
3.2.1 GENERAL VIEW OF THE MACHINE WITH CAB 55...728
3.2.2 GENERAL VIEW OF THE MACHINE WITH CANOPY 56...728
3.2.3 GENERAL VIEW OF THE DRIVER’S SEAT 57...728
3.3 INSTRUMENTS AND CONTROLS 58...728
3.3.1 INSTRUMENTS 58...728
3.3.2 WARNING LIGHTS 60...728
3.3.3 SWITCHES AND PUSH BUTTONS 62...728
3.3.4 ELECTRICAL ACCESSORIES 65...728
3.3.5 MACHINE CONTROLS 67...728
3.4 FUSES AND RELAYS 75...728
3.4.1 FUSES 75...728
3.4.1.1 EQUIPMENT FUSES 75...728
3.4.1.2 MAIN FUSE 76...728
3.4.2 RELAYS 77...728
3.5 GUARDS AND DRIVER’S SEAT 78...728
3.5.1 ENGINE HOOD 78...728
3.5.2 RIGHT COUNTERWEIGHT 79...728
3.5.3 CANOPY 79...728
3.5.4 CAB 80...728
3.5.5 VENTILATION AND HEATING 83...728
3.5.6 SEAT 84...728
3.5.7 SAFETY BELT 84...728
3.5.8 EMERGENCY EXIT 85...728
3.5.9 TECHNICAL DOCUMENTATION CASE 85...728
3.5.10 FIRE EXTINGUISHER 86...728
3.5.11 FIRST AID KIT 86...728
3.6 USE OF THE MACHINE 87...728
3.6.1 CHECKS BEFORE STARTING THE ENGINE 87...728
3.6.1.1 VISUAL CHECKS 87...728
3.6.1.2 DAILY CHECKS 87...728
3.6.1.3 OPERATIONAL CHECKS 88...728
3.6.2 STARTING THE ENGINE 89...728
3.6.2.1 STARTING WITH WARM ENGINE OR IN TEMPERATE CLIMATES 89...728
3.6.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES 90...728
3.6.3 WARMING THE ENGINE 91...728
3.6.4 HEATING THE HYDRAULIC OIL 91...728
3.6.5 HOW TO MOVE THE MACHINE 91...728
3.6.5.1 STEERING (CHANGING DIRECTION) 93...728
3.6.5.2 MOVING ON SLOPES 94...728
3.6.5.3 MAXIMUM IMMERSION DEPTH 95...728
3.7 PARKING THE MACHINE 96...729
3.7.1 PARKING ON LEVEL GROUND 96...729
3.7.2 PARKING ON SLOPES 97...729
3.8 STOPPING THE ENGINE 98...729
3.9 TRANSPORTING THE MACHINE ON MOTOR VEHICLES 99...729
3.9.1 LOADING AND UNLOADING THE MACHINE 99...729
3.9.2 TRANSPORT 100...729
3.10 LIFTING THE MACHINE 101...729
3.11 PRECAUTIONS TO BE TAKEN IN THE COLD SEASON 102...729
3.11.1 FUEL AND LUBRICANTS 102...729
3.11.2 COOLANT 102...729
3.11.3 BATTERY 102...729
3.11.4 OTHER PRECAUTIONS 103...729
3.11.5 PRECAUTIONS TO BE TAKEN AT THE END OF WORK 103...729
3.12 PRECAUTIONS TO BE TAKEN IN THE WARM SEASON 104...729
3.13 USING THE WORK EQUIPMENT 105...729
3.13.1 ORGANIZING THE WORK AREA 105...729
3.13.2 POSITIONING THE MACHINE FOR DIGGING OPERATIONS 106...729
3.13.3 DIGGING METHOD 107...729
3.13.4 CHANGING THE BUCKET 108...729
3.14 LONG PERIODS OF INACTIVITY 109...729
3.14.1 BEFORE THE PERIOD OF INACTIVITY 109...729
3.14.2 DURING THE PERIOD OF INACTIVITY 110...729
3.14.3 AFTER THE PERIOD OF INACTIVITY 110...729
3.15 TROUBLESHOOTING 111...729
3.15.1 OCCURRENCES THAT ARE NOT FAILURES 111...729
3.15.2 HOW TO REMOVE THE MACHINE 111...729
3.15.3 AFTER THE FUEL HAS RUN OUT 112...729
3.15.4 IF THE BATTERY IS DOWN 112...729
3.15.4.1 STARTING WITH BOOSTER CABLES 113...729
3.15.5 OTHER TROUBLES 114...729
3.15.5.1 ELECTRICAL CIRCUIT 114...729
3.15.5.2 HYDRAULIC SYSTEM 114...729
3.15.5.3 ENGINE 115...729
4.1 GUIDE TO MAINTENANCE 118...730
4.2 MAINTENANCE NOTES 120...730
4.2.1 NOTES REGARDING THE ENGINE 120...730
4.2.1.1 ENGINE OIL 120...730
4.2.1.2 COOLANT 120...730
4.2.1.3 FUEL 121...730
4.2.2 NOTES REGARDING THE HYDRAULIC SYSTEM 121...730
4.2.3 NOTES REGARDING THE ELECTRICAL SYSTEM 122...730
4.2.4 NOTES REGARDING LUBRICATION 122...730
4.2.5 PARTS SUBJECT TO WEAR THAT PERIODICALLY NEED CHANGING 123...730
4.3 FUEL, COOLANT AND LUBRICANTS 124...730
4.3.1 HOMOLOGATED HEES SYNTHETIC BIODEGRADABLE LUBRICANTS 126...730
4.4 DRIVING TORQUES FOR SCREWS AND NUTS 127...730
4.4.1 STANDARD DRIVING TORQUES 127...730
4.4.2 SPECIFIC DRIVING TORQUES 127...730
4.5 LUBRICATION 128...730
4.5.1 LUBRICATION DIAGRAM 128...730
4.6 PERIODICAL CHANGE OF THE COMPONENTS THAT ARE CONNECTED WITH SAFETY 129...730
4.6.1 CRITICAL PARTS FOR SAFETY 130...730
4.7 MAINTENANCE PLAN 133...730
4.7.1 WHEN REQUIRED 136...730
4.7.1.a WASHING THE COOLING CIRCUIT 136...730
4.7.1.b DRAINING THE FUEL TANK 137...730
4.7.1.c CHECKING THE ELECTRICAL SYSTEM 138...730
4.7.1.d CHECKING THE STEEL TRACK TENSION 138...730
4.7.1.e CHECKING THE RUBBER TRACKS 140...730
4.7.1.f CHECKING THE RUBBER TRACK TENSION 142...730
4.7.1.g CHANGING THE RUBBER TRACK 144...730
4.7.1.h CHECKING, CLEANING OR CHANGING THE AIR CLEANER CARTRIDGE 146...730
4.7.2 MAINTENANCE INTERVALS IN CASE OF USE OF THE DEMOLITION HAMMER (BREAKER) 147...730
4.7.2.a CHANGING THE HYDRAULIC OIL FILTER 147...730
4.7.2.b CHANGING THE HYDRAULIC OIL 147...730
4.7.3 CHECKS BEFORE STARTING 148...730
4.7.3.a VARIOUS CHECKS 148...730
4.7.3.b CHECKING THE COOLANT LEVEL 148...730
4.7.3.c CHECKING THE FUEL LEVEL 149...730
4.7.3.d CHECKING THE ENGINE OIL LEVEL 149...730
4.7.3.e CHECKING THE OIL LEVEL IN THE HYDRAULIC CIRCUIT 150...730
4.7.3.f CHECKING THE AIR CLEANER CLOGGING INDICATOR 151...730
4.7.3.g CHECKING THE FUEL FILTER FOR SEDIMENT AND WATER 151...730
4.7.4 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION (Only for machines in which the synthetic...730
4.7.5 MAINTENANCE EVERY 100 HOURS OF OPERATION 153...730
4.7.5.a LUBRICATING THE JOINTS AND THE BALL-BEARING RING 153...730
4.7.6 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION 155...731
4.7.7 MAINTENANCE EVERY 250 HOURS OF OPERATION 155...731
4.7.7.a ADJUSTING THE FAN BELT TENSION 155...731
4.7.7.b CHECKING THE BATTERY ELECTROLYTE LEVEL 156...731
4.7.7.c CHECKING THE OIL LEVEL IN THE TRAVEL REDUCTION GEARS 156...731
4.7.7.d CHANGING THE HYDRAULIC SYSTEM OIL FILTER 157...731
4.7.7.e CHANGING THE ENGINE OIL 158...731
4.7.8 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION (Only for machines in which the syntheti...731
4.7.9 MAINTENANCE EVERY 500 HOURS OF OPERATION 159...731
4.7.9.a CHANGING THE ENGINE OIL FILTER 159...731
4.7.9.b CHANGING THE FUEL FILTER 160...731
4.7.9.c CHANGING THE FUEL PUMP PRECLEANER 161...731
4.7.9.d CLEANING THE OUTSIDE OF THE RADIATORS 162...731
4.7.9.e DRAINING THE HYDRAULIC OIL TANK (Only for machines in which the synthetic biodegradable o...731
4.7.10 MAINTENANCE EVERY 1000 HOURS OF OPERATION 164...731
4.7.10.a CHANGING THE OIL IN THE TRAVEL REDUCTION GEARS 164...731
4.7.11 MAINTENANCE EVERY 2000 HOURS OF OPERATION 165...731
4.7.11.a CHANGING THE HYDRAULIC SYSTEM OIL AND CLEANING THE SUCTION FILTER 165...731
4.7.11.b CHANGING THE COOLANT 168...731
4.7.11.c CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE 169...731
4.7.11.d CHECKING THE ALTERNATOR AND THE STARTER 169...731
5.1 TECHNICAL DATA 172...731
5.1.1 STANDARD OVERALL DIMENSIONS (for model PC20R only) 172...731
5.1.2 TECHNICAL CHARACTERISTICS PC20R 173...731
5.1.3 STANDARD OVERALL DIMENSIONS (for model PC27R only) 174...731
5.1.4 TECHNICAL CHARACTERISTICS PC27R 175...731
5.1.5 LIFTING CAPACITY WITH CAB (for model PC20R only) 176...731
5.1.6 LIFTING CAPACITY WITH CANOPY (for model PC20R only) 177...731
5.1.7 LIFTING CAPACITY WITH CAB (for model PC27R only) 178...731
5.1.8 LIFTING CAPACITY WITH CANOPY (for model PC27R only) 179...731
6.1 AUTHORIZED OPTIONAL EQUIPMENT 182...732
6.1.1 PRECAUTIONS REGARDING SAFETY 182...732
6.1.2 PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT 183...732
6.1.3 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT 184...732
6.2 ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER (BREAKER) 185...732
6.2.1 DESCRIPTION AND CONTROL 185...732
6.2.2 USE OF THE DEMOLITION HAMMER AND RULES TO BE OBSERVED 185...732
6.2.3 INSTALLING AND REMOVING THE DEMOLITION HAMMER 189...732
6.2.3.1 INSTALLING THE HAMMER 189...732
6.2.3.2 REMOVING THE HAMMER 190...732
6.2.4 MAINTENANCE 190...732
6.3 ARRANGEMENT FOR THE OPERATION OF OPTIONAL EQUIPMENT 191...732
6.3.1 SELECTION VALVE (1) 191...732
6.3.2 CONTROL PEDAL (2) 192...732
6.3.3 ASSEMBLYING AND CONNECTING THE EQUIPMENT 193...732
6.3.4 MAINTENANCE 194...732
2.1 SAFETY, NOISE AND VIBRATION PLATES...735
2.1.1 POSITION OF THE SAFETY PLATES...735
2.1.2 PICTOGRAMS AND RELEVANT MEANINGS...737
2.1.3 POSITION OF THE NOISE PLATES ON MACHINES WITH CAB...741
2.1.4 POSITION OF THE NOISE PLATES ON MACHINES WITH CANOPY...742
2.1.5 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED...742
2.2 GENERAL PRECAUTIONS...743
2.2.1 GENERAL SAFETY RULES...743
2.2.2 SAFETY DEVICES AND GUARDS...743
2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS...743
2.2.4 UNAUTHORIZED MODIFICATIONS...744
2.2.5 LEAVING THE OPERATOR’S SEAT...744
2.2.6 GETTING ON AND OFF THE MACHINE...745
2.2.7 PREVENTING FIRES DUE TO FUEL AND OIL...745
2.2.8 PREVENTING BURNS...746
2.2.9 PREVENTING DAMAGE DUE TO ASBESTOS POWDER...746
2.2.10 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT...747
2.2.11 FIRE EXTINGUISHERS AND FIRST AID KIT...747
2.2.12 PRECAUTIONS CONCERNING THE CAB STRUCTURE...747
2.2.13 PRECAUTIONS CONCERNING THE EQUIPMENT...747
2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE...748
2.3.1 SAFETY ON THE WORK SITE...748
2.3.2 FIRE PREVENTION...748
2.3.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR'S CAB...748
2.3.4 ROOM VENTILATION...749
2.3.5 PRECAUTIONS TO BE TAKEN FOR THE LIGHTS...749
2.3.6 CLEANING THE WINDOWS - CHECKING THE WINDSHIELD WIPER BLADES...749
2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING...750
2.4.1 STARTING THE ENGINE...750
2.4.2 CHECK THE DIRECTION BEFORE STARTING THE MACHINE...750
2.4.3 CHECKS FOR TRAVELLING IN REVERSE...750
2.4.4 MOVING THE MACHINE...751
2.4.5 MOVING ON SLOPES...752
2.4.6 WORKING ON SLOPES...753
2.4.7 UNAUTHORIZED OPERATIONS...753
2.4.8 PREVENTING ELECTROCUTION...754
2.4.9 VISIBILITY...755
2.4.10 WORKING ON ICY OR SNOW-COVERED SURFACES...755
2.4.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT...755
2.4.12 WORKING ON LOOSE GROUND...755
2.4.13 PARKING THE MACHINE...756
2.5 TRANSPORTING THE MACHINE ON MOTOR VEHICLES...757
2.5.1 LOADING AND UNLOADING...757
2.5.2 TRANSPORT...757
2.6 BATTERY...758
2.6.1 PREVENTING RISKS THAT MAY BE DUE TO THE BATTERY...758
2.6.2 STARTING WITH BOOSTER CABLES...758
2.7 PRECAUTIONS FOR THE REMOVAL...759
2.8 PRECAUTIONS FOR MAINTENANCE...760
2.8.1 WARNING PLATES...760
2.8.2 TOOLS...760
2.8.3 PERSONNEL...760
2.8.4 EQUIPMENT...761
2.8.5 WORKING UNDER THE MACHINE...761
2.8.6 CLEANING THE MACHINE...761
2.8.7 USE OF THE ENGINE DURING MAINTENANCE OPERATIONS...762
2.8.8 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY...762
2.8.9 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION OR INSPECTION...762
2.8.10 RULES TO BE FOLLOWED DURING FUEL OR OIL TOPPING UP...763
2.8.11 CHECKING THE COOLANT LEVEL IN THE RADIATOR...763
2.8.12 USING LAMPS...763
2.8.13 PRECAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR...764
2.8.14 PRECAUTIONS CONCERNING THE STARTER...764
2.8.15 HANDLING HIGH-PRESSURE PIPES...765
2.8.16 PRECAUTIONS TO BE TAKEN WHEN HANDLING HIGH-PRESSURE OIL...765
2.8.17 PRECAUTIONS FOR MAINTENANCE OPERATIONS AT HIGH TEMPERATURES AND HIGH PRESSURE...765
2.8.18 COOLING FAN AND BELT...766
2.8.19 WASTE MATERIALS...766
2.8.20 PRECAUTIONS FOR THE USE OF THE synthetic biodegradable oil type HEES...766
3.1 SAFETY LOCKS...769
3.1.1 MACHINE LOCKS...769
3.2 GENERAL VIEWS...770
3.2.1 GENERAL VIEW OF THE MACHINE WITH CAB...770
3.2.2 GENERAL VIEW OF THE MACHINE WITH CANOPY...771
3.2.3 GENERAL VIEW OF THE DRIVER’S SEAT...772
3.3 INSTRUMENTS AND CONTROLS...773
3.3.1 INSTRUMENTS...773
3.3.2 WARNING LIGHTS...775
3.3.3 SWITCHES AND PUSH BUTTONS...777
3.3.4 ELECTRICAL ACCESSORIES...780
3.3.5 MACHINE CONTROLS...782
LEVER 1 (BASIC MANOEUVRES)...783
LEVER 2 (BASIC MANOEUVRES)...783
LEVER 1 (COMBINED MANOEUVRES)...784
LEVER 2 (COMBINED MANOEUVRES)...784
3.4 FUSES AND RELAYS...790
3.4.1 FUSES...790
3.4.1.1 EQUIPMENT FUSES...790
3.4.1.2 MAIN FUSE...791
3.4.2 RELAYS...792
3.5 GUARDS AND DRIVER’S SEAT...793
3.5.1 ENGINE HOOD...793
3.5.2 RIGHT COUNTERWEIGHT...794
3.5.3 CANOPY...794
3.5.4 CAB...795
3.5.5 VENTILATION AND HEATING...798
3.5.6 SEAT...799
3.5.7 SAFETY BELT...799
3.5.8 EMERGENCY EXIT...800
3.5.9 TECHNICAL DOCUMENTATION CASE...800
3.5.10 FIRE EXTINGUISHER...801
3.5.11 FIRST AID KIT...801
3.6 USE OF THE MACHINE...802
3.6.1 CHECKS BEFORE STARTING THE ENGINE...802
3.6.1.1 VISUAL CHECKS...802
3.6.1.2 DAILY CHECKS...802
3.6.1.3 OPERATIONAL CHECKS...803
3.6.2 STARTING THE ENGINE...804
3.6.2.1 STARTING WITH WARM ENGINE OR IN TEMPERATE CLIMATES...804
3.6.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES...805
3.6.3 WARMING THE ENGINE...806
3.6.4 HEATING THE HYDRAULIC OIL...806
3.6.5 HOW TO MOVE THE MACHINE...806
3.6.5.1 STEERING (CHANGING DIRECTION)...808
3.6.5.2 MOVING ON SLOPES...809
3.6.5.3 MAXIMUM IMMERSION DEPTH...810
3.7 PARKING THE MACHINE...811
3.7.1 PARKING ON LEVEL GROUND...811
3.7.2 PARKING ON SLOPES...812
3.8 STOPPING THE ENGINE...813
3.9 TRANSPORTING THE MACHINE ON MOTOR VEHICLES...814
3.9.1 LOADING AND UNLOADING THE MACHINE...814
3.9.2 TRANSPORT...815
3.10 LIFTING THE MACHINE...816
3.11 PRECAUTIONS TO BE TAKEN IN THE COLD SEASON...817
3.11.1 FUEL AND LUBRICANTS...817
3.11.2 COOLANT...817
3.11.3 BATTERY...817
3.11.4 OTHER PRECAUTIONS...818
3.11.5 PRECAUTIONS TO BE TAKEN AT THE END OF WORK...818
3.12 PRECAUTIONS TO BE TAKEN IN THE WARM SEASON...819
3.13 USING THE WORK EQUIPMENT...820
3.13.1 ORGANIZING THE WORK AREA...820
3.13.2 POSITIONING THE MACHINE FOR DIGGING OPERATIONS...821
3.13.3 DIGGING METHOD...822
3.13.4 CHANGING THE BUCKET...823
3.14 LONG PERIODS OF INACTIVITY...824
3.14.1 BEFORE THE PERIOD OF INACTIVITY...824
3.14.2 DURING THE PERIOD OF INACTIVITY...825
3.14.3 AFTER THE PERIOD OF INACTIVITY...825
3.15 TROUBLESHOOTING...826
3.15.1 OCCURRENCES THAT ARE NOT FAILURES...826
3.15.2 HOW TO REMOVE THE MACHINE...826
3.15.3 AFTER THE FUEL HAS RUN OUT...827
3.15.4 IF THE BATTERY IS DOWN...827
3.15.4.1 STARTING WITH BOOSTER CABLES...828
3.15.5 OTHER TROUBLES...829
3.15.5.1 ELECTRICAL CIRCUIT...829
3.15.5.2 HYDRAULIC SYSTEM...829
3.15.5.3 ENGINE...830
4.1 GUIDE TO MAINTENANCE...833
4.2 MAINTENANCE NOTES...835
4.2.1 NOTES REGARDING THE ENGINE...835
4.2.1.1 ENGINE OIL...835
4.2.1.2 COOLANT...835
4.2.1.3 FUEL...836
4.2.2 NOTES REGARDING THE HYDRAULIC SYSTEM...836
4.2.3 NOTES REGARDING THE ELECTRICAL SYSTEM...837
4.2.4 NOTES REGARDING LUBRICATION...837
4.2.5 PARTS SUBJECT TO WEAR THAT PERIODICALLY NEED CHANGING...838
4.3 FUEL, COOLANT AND LUBRICANTS...839
LUBRICATION WITH GREASE...839
4.3.1 HOMOLOGATED HEES SYNTHETIC BIODEGRADABLE LUBRICANTS...841
4.4 DRIVING TORQUES FOR SCREWS AND NUTS...842
4.4.1 STANDARD DRIVING TORQUES...842
4.4.2 SPECIFIC DRIVING TORQUES...842
4.5 LUBRICATION...843
4.5.1 LUBRICATION DIAGRAM...843
4.6 PERIODICAL CHANGE OF THE COMPONENTS THAT ARE CONNECTED WITH SAFETY...844
4.6.1 CRITICAL PARTS FOR SAFETY...845
FUEL SUPPLY SYSTEM...845
HYDRAULIC SYSTEM...846
4.7 MAINTENANCE PLAN...848
4.7.1 WHEN REQUIRED...851
4.7.1.a WASHING THE COOLING CIRCUIT...851
4.7.1.b DRAINING THE FUEL TANK...852
4.7.1.c CHECKING THE ELECTRICAL SYSTEM...853
4.7.1.d CHECKING THE STEEL TRACK TENSION...853
4.7.1.e CHECKING THE RUBBER TRACKS...855
4.7.1.f CHECKING THE RUBBER TRACK TENSION...857
4.7.1.g CHANGING THE RUBBER TRACK...859
4.7.1.h CHECKING, CLEANING OR CHANGING THE AIR CLEANER CARTRIDGE...861
4.7.2 MAINTENANCE INTERVALS IN CASE OF USE OF THE DEMOLITION HAMMER (BREAKER)...862
4.7.2.a CHANGING THE HYDRAULIC OIL FILTER...862
4.7.2.b CHANGING THE HYDRAULIC OIL...862
4.7.3 CHECKS BEFORE STARTING...863
4.7.3.a VARIOUS CHECKS...863
4.7.3.b CHECKING THE COOLANT LEVEL...863
4.7.3.c CHECKING THE FUEL LEVEL...864
4.7.3.d CHECKING THE ENGINE OIL LEVEL...864
4.7.3.e CHECKING THE OIL LEVEL IN THE HYDRAULIC CIRCUIT...865
4.7.3.f CHECKING THE AIR CLEANER CLOGGING INDICATOR...866
4.7.3.g CHECKING THE FUEL FILTER FOR SEDIMENT AND WATER...866
4.7.4 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION (Only for machines in which the synthetic...867
4.7.5 MAINTENANCE EVERY 100 HOURS OF OPERATION...868
4.7.5.a LUBRICATING THE JOINTS AND THE BALL-BEARING RING...868
4.7.6 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION...870
4.7.7 MAINTENANCE EVERY 250 HOURS OF OPERATION...870
4.7.7.a ADJUSTING THE FAN BELT TENSION...870
4.7.7.b CHECKING THE BATTERY ELECTROLYTE LEVEL...871
4.7.7.c CHECKING THE OIL LEVEL IN THE TRAVEL REDUCTION GEARS...871
4.7.7.d CHANGING THE HYDRAULIC SYSTEM OIL FILTER...872
4.7.7.e CHANGING THE ENGINE OIL...873
4.7.8 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION (Only for machines in which the syntheti...874
4.7.9 MAINTENANCE EVERY 500 HOURS OF OPERATION...874
4.7.9.a CHANGING THE ENGINE OIL FILTER...874
4.7.9.b CHANGING THE FUEL FILTER...875
4.7.9.c CHANGING THE FUEL PUMP PRECLEANER...876
4.7.9.d CLEANING THE OUTSIDE OF THE RADIATORS...877
4.7.9.e DRAINING THE HYDRAULIC OIL TANK (Only for machines in which the synthetic biodegradable o...878
4.7.10 MAINTENANCE EVERY 1000 HOURS OF OPERATION...879
4.7.10.a CHANGING THE OIL IN THE TRAVEL REDUCTION GEARS...879
4.7.11 MAINTENANCE EVERY 2000 HOURS OF OPERATION...880
4.7.11.a CHANGING THE HYDRAULIC SYSTEM OIL AND CLEANING THE SUCTION FILTER...880
4.7.11.b CHANGING THE COOLANT...883
4.7.11.c CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE...884
4.7.11.d CHECKING THE ALTERNATOR AND THE STARTER...884
5.1 TECHNICAL DATA...887
5.1.1 STANDARD OVERALL DIMENSIONS (for model PC20R only)...887
MACHINE WITH CAB...887
MACHINE WITH CANOPY...887
5.1.2 TECHNICAL CHARACTERISTICS PC20R...888
5.1.3 STANDARD OVERALL DIMENSIONS (for model PC27R only)...889
MACHINE WITH CAB...889
MACHINE WITH CANOPY...889
5.1.4 TECHNICAL CHARACTERISTICS PC27R...890
5.1.5 LIFTING CAPACITY WITH CAB (for model PC20R only)...891
5.1.6 LIFTING CAPACITY WITH CANOPY (for model PC20R only)...892
5.1.7 LIFTING CAPACITY WITH CAB (for model PC27R only)...893
5.1.8 LIFTING CAPACITY WITH CANOPY (for model PC27R only)...894
6.1 AUTHORIZED OPTIONAL EQUIPMENT...897
6.1.1 PRECAUTIONS REGARDING SAFETY...897
6.1.2 PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT...898
6.1.3 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT...899
6.2 ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER (BREAKER)...900
6.2.1 DESCRIPTION AND CONTROL...900
6.2.2 USE OF THE DEMOLITION HAMMER AND RULES TO BE OBSERVED...900
FOR A CORRECT USE, IT IS NECESSARY TO:...900
ALWAYS AVOID THE FOLLOWING INCORRECT USES:...902
6.2.3 INSTALLING AND REMOVING THE DEMOLITION HAMMER...904
6.2.3.1 INSTALLING THE HAMMER...904
6.2.3.2 REMOVING THE HAMMER...905
6.2.4 MAINTENANCE...905
6.3 ARRANGEMENT FOR THE OPERATION OF OPTIONAL EQUIPMENT...906
6.3.1 SELECTION VALVE (1)...906
6.3.2 CONTROL PEDAL (2)...907
6.3.3 ASSEMBLYING AND CONNECTING THE EQUIPMENT...908
6.3.4 MAINTENANCE...909
WEAM003100 - Hydraulic Excavator PC27R-8 Operation & Maintenance Manual...910
COVER...910
1.1 FORWARD...911
1.2 INFORMATION ON SAFETY...912
1.3 INTRODUCTION...914
1.3.1 INTENDED USES...914
1.3.2 IMPROPER OR UNAUTHORIZED USES...914
1.3.3 MAIN CHARACTERISTICS...915
1.3.4 RUNNING-IN...915
1.4 PRODUCT IDENTIFICATION...916
1.4.1 MACHINE SERIAL NUMBER ...916
1.4.2 MACHINE IDENTIFICATION PLATE...916
1.4.3 ENGINE SERIAL NUMBER AND EMISSION LABEL...917
1.4.4TRAVEL REDUCTION GEAR SERIAL NUMBER...917
1.4.5 SWING REDUCTION GEAR SERIAL NUMBER...918
1.4.6 CAB SERIAL NUMBER...918
1.4.7 SERIAL NUMBERS AND DEALER'S ADDRESS...919
TABLE OF CONTENTS...920
SAFETY AND ACCIDENT PREVENTION...927
2.1 SAFETY PLATES...928
2.1.1 POSITION OF THE SAFETY PLATES...928
2.1.2 POSITION OF THE PICTOGRAMS...944
2.1.3 PICTOGRAMS AND REVELANT MEANINGS...946
2.1.4 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED...947
2.2 GENERAL PRECAUTIONS...948
2.2.1 GENERAL SAFETY RULES...948
2.2.2 SAFETY DEVICES AND GUARDS...948
2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS...948
2.2.4 UNAUTHORIZED MODIFICATIONS...949
2.2.5 LEAVING THE OPERATORS SEAT...949
2.2.6 GETTING ON AND OFF THE MACHINE...950
2.2.7 PREVENTING FIRES DUE TO FUEL AND OIL...950
2.2.8 PREVENTING BURNS...951
2.2.9 PREVENTING DAMAGE DUE TO ASBESTOS POWER ...951
2.2.10 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT...952
2.2.11 FIRE EXTINGUISHERS AND FIRST AID KIT...952
2.2.12 PRECAUTIONS CONCERNING THE CAB STRUCTURE...952
2.2.13 PRECAUTIONS CONCERNING THE EQUIPMENT...952
2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE...953
2.3.1 SAFETY ON THE WORK SITE...953
2.3.2 FIRE PREVENTION...953
2.3.3 PRECAUTIONS TO BE TAKEN FROM THE OPERATOR'S CAB...953
2.3.4 ROOM VENTILATION...954
2.3.5 PRECAUTIONS TO BE TAKEN FOR THE LIGHTS...954
2.3.6 CLEANING THE WINDOWS - CHECKING THE WINDSHEILD WIPER BLADES...954
2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING...955
2.4.1 STARTING THE ENGINE...955
2.4.2 CHECK THE DIRECTION BEFORE STARTING THE MACHINE ...955
2.4.3 CHECKS FOR TRAVELLING IN REVERSE...955
2.4.4 MOVING THE MACHINE...956
2.4.5 MOVING ON SLOPES...957
2.4.6 WORKING ON THE SLOPES...958
2.4.7 UNAUTHORIZED OPERATIONS...958
2.4.8 PREVENTING ELECTROCUTION...959
2.4.9 VISIBILITY...960
2.4.10 WORKING ON ICY OR SNOW-COVERED SURFACES ...960
2.4.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT...960
2.4.12 WORKING ON THE LOOSE GROUND ...960
2.4.13 PARKING THE MACHINE...961
2.5 TRANSPORTING THE MACHINE ON OTHER VEHICLES...962
2.5.1 LOADING AND UNLOADING...962
2.5.2 TRANSPORT...962
2.6 BATTERY...963
2.6.1 PREVENTING RISKS THAT MAY BE DUE TO THE BATTERY...963
2.6.2 STARTING WITH BOOSTER CABLES...963
2.7 PRECAUTIONS FOR EMERGENCY RECOVERY...964
2.8 PRECAUTIONS TO BE TAKEN DURING MAINTENANCE...965
2.8.1 WARNINGS PLATES...965
2.8.2 TOOLS...965
2.8.3 PERSONNEL...966
2.8.4 EQUIPMENT...966
2.8.5 WORKING THE MACHINE...966
2.8.6 CLEANING THE MACHINE...966
2.8.7 USE OF THE ENGINE DURING MAINTENANCE OPERATIONS...967
2.8.8 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY...967
2.8.9 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION OR INSPECTION...967
2.8.10 RULES TO BE FOLLOWED DURING FUEL OR OIL TOPPING UP...968
2.8.11 CHECKING THE COOLANT LEVEL IN THE RADIATOR...968
2.8.12 USING LAMPS...968
2.8.13 PRECAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR...969
2.8.14 PRECAUTIONS CONCERNING THE STARTER...969
2.8.15 HANDLING HIGH-PRESSURE PIPES...970
2.8.16 PRECAUTIONS TO BE TAKEN WHEN HANDLING HIGH-PRESURE OIL...970
2.8.17 PRECAUTIONS FOR MAINTENANCE OPERATIONS AT HIGH TEMPERATURES AND HIGH PRESSURE...970
2.8.18 COOLING FAN AND BELT...971
2.8.19 WASTE MATERIALS...971
DESCRIPTION AND USE OF THE MACHINE...973
3.1 SAFETY LOCKS...974
3.1.1 MACHINE LOCKS...974
3.2 GENERAL VIEWS...975
3.2.1 GENERAL VIEW OF THE MACHINE WITH CAB...975
3.2.2 GENERAL VIEW OF THE MACHINE WITH CANOPY...976
3.2.3 GENERAL VIEW OF THE DRIVER'S SEAT...977
3.3 INSTRUMENTS AND CONTROLS...978
3.3.1 INSTRUMENTS, WARNING LIGHTS AND PUSH BUTTONS...978
3.3.2 MACHINE CONTROLS...984
3.4 FUSES AND RELAYS...993
3.4.1 FUSES...993
3.4.1.1 EQUIPMENT FUSES...993
3.4.1.2 MAIN FUSE...994
3.4.2 RELAYS...995
3.5 GUARDS AND DRIVER'S SEAT...996
3.5.1 ENGINE HOOD...996
3.5.2 CANOPY CAB ...997
3.5.3 CAB...997
3.5.4 VENTILATION AND HEATING...1000
3.5.5 SEAT...1000
3.5.6 SAFETY BELT...1001
3.5.7 EMERGENCY EXIT...1001
3.5.8 TECHNICAL DOCUMENTATION CASE...1002
3.5.9 FIRE EXTINGUISHER...1002
3.5.10 FIRST AID KIT...1002
3.6 USE OF THE MACHINE...1003
3.6.1 CHECKS BEFORE STARTING THE ENGINE...1003
3.6.1.1 VISUAL CHECKS...1003
3.6.1.2 DAILY CHECKS...1003
3.6.1.3 OPERATIONAL CHECKS...1004
3.6.2 STARTING THE ENGINE...1005
3.6.2.1 STARTING WITH WARM ENGINE OR IN TEMPERATE CLIMATES...1005
3.6.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES...1006
3.6.3 WARMING THE ENGINE...1007
3.6.4 HEATING THE HYDRAULIC OIL...1007
3.6.5 HOW TO MOVE THE MACHINE...1007
3.6.5.1 STEERING (CHANGING DIRECTION)...1009
3.6.5.2 MOVING ON SLOPES...1010
3.6.5.3 MAXIMUM IMMERSION DEPTH...1011
3.7 PARKING THE MACHINE...1012
3.7.1 PARKING ON LEVEL GROUND...1012
3.7.2 PARKING ON SLOPES...1013
3.8 STOPPING THE ENGINE...1014
3.9 TRANSPORTING THE MACHINE ON OTHER VEHICLES...1015
3.9.1 LOADING AND UNLOADING THE MACHINE...1015
3.9.2 TRANSPORT...1016
3.10 LIFTING THE MACHINE...1017
3.11 PRECAUTIONS TO BE TAKEN IN THE COLD SEASON...1018
3.11.1 FUEL AND LUBRICANTS...1018
3.11.2 COOLANT...1018
3.11.3 BATTERY...1018
3.11.4 OTHER PRECAUTIONS...1019
3.11.5 PRECAUTIONS TO BE TAKEN AT THE END OF WORK...1019
3.12 PRECAUTIONS TO BE TAKEN IN THE WARM SEASON...1020
3.13 USING THE WORK EQUIPMENT...1021
3.13.1 ORGANIZING THE WORK AREA...1021
3.13.2 POSITIONING THE MACHINE FOR DIGGING OPERATIONS...1022
3.13.3 DIGGING METHOD...1023
3.13.4 CHAGING THE BUCKETT...1024
3.14 LONG PERIODS OF INACTIVITY...1025
3.14.1 BEFORE THE PERIOD OF INACTIVITY...1025
3.14.2 DURING THE PERIOD OF INACTIVITY...1026
3.14.3 AFTER THE PERIOD OF INACTIVITY...1026
3.15 TROUBLESHOOTING...1027
3.15.1 OCCURRENCES THAT ARE NOT FAILURES...1027
3.15.2 HOW TO REMOVE THE MACHINE...1027
3.15.3 AFTER THE FUEL HAS RUN OUT...1028
3.15.4 IF THE BATTERY IS DOWN...1028
3.15.4.1 STARTING WITH BOOSTER CABLES...1029
3.15.5 OTHER BOOSTER CABLES...1030
3.15.5.1 ELECTRIC CIRCUIT...1030
3.15.5.2 HYDRAULIC SYSTEM...1030
3.15.5.3 ENGINE...1031
MAINTENANCE...1033
4.1 GUIDE TO MAINTENANCE...1034
4.2 MAINTENANCE NOTES...1036
4.2.1 NOTES REGARDING THE ENGINE...1036
4.2.1.1 ENGINE OIL...1036
4.2.1.2 COOLANT...1036
4.2.1.3 FUEL...1037
4.2.2 NOTES REGARDING THE HYDRAULIC SYSTEM...1037
4.2.3 NOTES REGARDING THE ELECTRICAL SYSTEM...1038
4.2.4 NOTES REGARDING LUBRICATION...1038
4.2.5 PARTS SUBJECT TO WEAR THAT PERIODICALLY NEED CHANGING...1039
4.3 FUEL, COOLANT AND LUBRICANTS...1040
4.4 NUT AND BOLT TIGHTENING TORQUES...1044
4.4.2 SPECIFIC TIGHTENING TORQUES...1044
4.5 LUBRICATION...1045
4.5.1 LUBRICATION DIAGRAM...1045
4.6 PERIODICAL CHANGE OF THE COMPONENTS THAT ARE CONNECTED WITH SAFETY...1046
4.7 MAINTENANCE PLAN...1050
4.7.1 WHEN REQUIRED...1050
4.7.1.A WASHING THE COOLANT CIRCUIT...1052
4.7.1.B DRAINING THE FUEL TANK...1053
4.7.1.C CHECKING THE ELECTRICAL SYSTEM...1053
4.7.1.D CHECKING THE STEEL TRACK TENSION...1054
4.7.1.E CHECKING THE RUBBER TRACKS...1056
4.7.1 F CHECKING THE RUBBER TRACK TENSION...1058
4.7.1.G CHANGING THE RUBBER TRACK...1060
4.7.1.H CHECKIJNG,CLEANING OR CHANGING THE AIR CLEANER CARTRIDGE...1062
4.7.2 MAINTENANCE INTERVALS IN CASE OF USE OF THE DEMOLITION HAMMER(BREAKER)...1063
4.7.2.A CHANGING THE HYDRAULIC OIL FILTER...1063
4.7.2.B CHANGING THE HYDRAULIC OIL...1063
4.7.3 CHECKS BEFORE STARTING...1064
4.7.3.A VARIOUS CHECKS...1064
4.7.3.B CHECKING THE COOLANT LEVEL...1064
4.7.3.C CHECKING THE FUEL LEVEL...1065
4.7.3.D CHECKING THE ENGINE OIL LEVEL...1065
4.7.3.E CHECKING THE OIL LEVEL IN THE HYDRAULIC CIRCUIT...1066
4.7.3.F CHECKING THE AIR CLEANER CLOGGING INDICATOR...1067
4.7.3.G CHECKING THE FUEL FILTER FOR SEDIMENT AND WATER...1067
4.7.4 MAINTENANCE EVERY 100 HOURS OF OPERATION...1068
4.7.4.A LUBRICATING THE JOINTS AND THE BALL-BEARING RING...1068
4.7.5 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION...1070
4.7.6 MAINTENANCE EVEY 250 HOURS OF OPERATION...1070
4.7.6.A ADJUSTING THE FAN BELT TENSION...1070
4.7.6.B CHECKING THE BATTERY ELECTROLYTE LEVEL...1071
4.7.6 C CHECKING THE OIL LEVEL IN THE TRAVEL REDUCTION GEARS...1071
4.7.6.D CHANGING THE HYDRAULIC SYSTEM OIL FILTER...1072
4.7.6 E CHANGING THE ENGINE OIL...1073
4.7.7 MAINTENANCE EVERY 500 HOURS OF OPERATION...1074
4.7.7.A CHANGING THE ENGINE OIL FILTER...1074
4.7.7.B CHANGING THE FUEL FILTER ...1075
4.7.7.C CHANGING THE FUEL PUMP PRECLEANER...1076
4.7.7.D CLEANING THE OUTSIDE OF THE RADIATORS...1077
4.7.8 MAINTENANCE EVERY 1000 HOURS OF OPERATION...1078
4.7.8. A CHANGING THE OIL IN THE TRAVEL REDUCTION GEARS...1078
4.7.9 MAINTENANCE EVERY 2000 HOURS OF OPERATION...1079
4.7.9.A CHANGING THE HYDRAULIC SYSTEM OIL AND CLEANING THE SUCTION FILTER...1079
4.7.9.B CHANGING THE COOLANT...1081
4.7.9.C CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE...1081
4.7.9.D CHECKING THE ALTERNATOR AND THE STARTER...1081
TECHNICAL SPECIFICATIONS...1083
5.1 TECHNICAL DATA...1084
5.1.1 STANDARD OVERALL DIMENSIONS...1084
5.1.2 TECHNICAL CHARACTERISTICS...1086
5.1.3 LIFTING CAPACITY WITH CAB...1087
5.1.4 LIFTING CAPACITY WITH CANOPY...1088
AUTHORIZED OPTIONAL EQUIPMENT...1089
6.1 AUTHORIZED OPTIONAL EQUIPMENT...1090
6.1.1 PRECAUTIONS REGARDING SAFETY...1090
6.1.2 PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT...1091
6.1.3 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT...1092
6.2 ARRANGEMENT FOR THE INSTALLATION OF THE DEOLITION HAMMER (BREAKER)...1093
6.2.1 DESCRIPTION AND CONTROL...1093
6.2.2 USE OF THE DEMOLITION HAMMER AND RULES TO BE OBESERVED...1093
6.2.3 INSTALLING AND REMOVING THE DEMOLITION HAMMER...1097
6.2.3.1 INSTALLING THE HAMMER...1097
6.2.3.2 REMOVING THE HAMMER...1098
6.2.4 MAINTENANCE...1098
6.3 ARRANGEMENT FOR THE OPERATION OF OPTIONAL EQUIPMENT...1099
6.3.1 SELECTION VALVE (1)...1099
6.3.2 CONTROL PEDAL (2)...1100
6.3.3 ASSEMBLYING AND CONNECTING THE EQUIPMENT...1101
6.3.4 MAINTENANCE...1102
WEAM003102 - Hydraulic Excavator PC27R-8 Deluxe Operation & Maintenance Manual...1103
COVER...1103
1.1 FOREWORD...1104
1.2 INFORMATION ON SAFETY...1105
1.3 INTRODUCTION...1107
1.3.1 INTENDED USES...1107
1.3.2 IMPROPER OR UNAUTHORIZED USES...1107
1.3.3 MAIN CHARACTERISTICS...1108
1.3.4 RUNNING-IN...1108
1.4 PRODUCT IDENTIFICATION...1109
1.4.1 MACHINE SERIAL NUMBER...1109
1.4.2 MACHINE IDENTIFICATION PLATE...1109
1.4.3 ENGINE SERIAL NUMBER AND EMISSION LABEL...1110
1.4.4 TRAVEL REDUCTION GEAR SERIAL NUMBER...1110
1.4.5 SWING REDUCTION GEAR SERIAL NUMBER...1111
1.4.6 CAB SERIAL NUMBER...1111
1.4.7 SERIAL NUMBERS AND DEALER’S ADDRESS...1112
TABLE OF CONTENTS...1113
SAFETY AND ACCIDENT PREVENTION...1120
2.1 SAFETY PLATES...1121
2.1.1 POSITION OF THE SAFETY PLATES...1121
2.1.2 POSITION OF THE PICTOGRAMS...1137
2.1.3 PICTOGRAMS AND RELEVANT MEANINGS...1139
2.1.4 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED...1140
2.2 GENERAL PRECAUTIONS...1141
2.2.1 GENERAL SAFETY RULES...1141
2.2.2 SAFETY DEVICES AND GUARDS...1141
2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS...1141
2.2.4 UNAUTHORIZED MODIFICATIONS...1142
2.2.5 LEAVING THE OPERATOR’S SEAT...1142
2.2.6 GETTING ON AND OFF THE MACHINE...1143
2.2.7 PREVENTING FIRES DUE TO FUEL AND OIL...1143
2.2.8 PREVENTING BURNS...1144
2.2.9 PREVENTING DAMAGE DUE TO ASBESTOS POWDER...1144
2.2.10 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT...1145
2.2.11 FIRE EXTINGUISHERS AND FIRST AID KIT...1145
2.2.12 PRECAUTIONS CONCERNING THE CAB STRUCTURE...1145
2.2.13 PRECAUTIONS CONCERNING THE EQUIPMENT...1145
2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE...1146
2.3.1 SAFETY ON THE WORK SITE...1146
2.3.2 FIRE PREVENTION...1146
2.3.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR'S CAB...1146
2.3.4 ROOM VENTILATION...1147
2.3.5 PRECAUTIONS TO BE TAKEN FOR THE LIGHTS...1147
2.3.6 CLEANING THE WINDOWS - CHECKING THE WINDSHIELD WIPER BLADES...1147
2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING...1148
2.4.1 STARTING THE ENGINE...1148
2.4.2 CHECK THE DIRECTION BEFORE STARTING THE MACHINE...1148
2.4.3 CHECKS FOR TRAVELLING IN REVERSE...1148
2.4.4 MOVING THE MACHINE...1149
2.4.5 MOVING ON SLOPES...1150
2.4.6 WORKING ON SLOPES...1151
2.4.7 UNAUTHORIZED OPERATIONS...1151
2.4.8 PREVENTING ELECTROCUTION...1152
2.4.9 VISIBILITY...1153
2.4.10 WORKING ON ICY OR SNOW-COVERED SURFACES...1153
2.4.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT...1153
2.4.12 WORKING ON LOOSE GROUND...1153
2.4.13 PARKING THE MACHINE...1154
2.5 TRANSPORTING THE MACHINE ON OTHER VEHICLES...1155
2.5.1 LOADING AND UNLOADING...1155
2.5.2 TRANSPORT...1155
2.6 BATTERY...1156
2.6.1 PREVENTING RISKS THAT MAY BE DUE TO THE BATTERY...1156
2.6.2 STARTING WITH BOOSTER CABLES...1156
2.7 PRECAUTIONS FOR EMERGENCY RECOVERY...1157
2.8 PRECAUTIONS TO BE TAKEN DURING MAINTENANCE...1158
2.8.1 WARNING PLATES...1158
2.8.2 TOOLS...1158
2.8.3 PERSONNEL...1159
2.8.4 EQUIPMENT...1159
2.8.5 WORKING UNDER THE MACHINE...1159
2.8.6 CLEANING THE MACHINE...1159
2.8.7 USE OF THE ENGINE DURING MAINTENANCE OPERATIONS...1160
2.8.8 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY...1160
2.8.9 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION OR INSPECTION...1160
2.8.10 RULES TO BE FOLLOWED DURING FUEL OR OIL TOPPING UP...1161
2.8.11 CHECKING THE COOLANT LEVEL IN THE RADIATOR...1161
2.8.12 USING LAMPS...1161
2.8.13 PRECAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR...1162
2.8.14 PRECAUTIONS CONCERNING THE STARTER...1162
2.8.15 HANDLING HIGH-PRESSURE PIPES...1163
2.8.16 PRECAUTIONS TO BE TAKEN WHEN HANDLING HIGH-PRESSURE OIL...1163
2.8.17 PRECAUTIONS FOR MAINTENANCE OPERATIONS AT HIGH TEMPERATURES AND HIGH PRESSURE...1163
2.8.18 COOLING FAN AND BELT...1164
2.8.19 WASTE MATERIALS...1164
2.8.20 PRECAUTIONS FOR THE USE OF THE synthetic biodegradable oil type HEES...1164
THE MACHINE AND ITS OPERATIONS...1166
3.1 SAFETY LOCKS...1167
3.1.1 MACHINE LOCKS...1167
3.2 GENERAL VIEWS...1168
3.2.1 GENERAL VIEW OF THE MACHINE WITH CAB...1168
3.2.2 GENERAL VIEW OF MACHINE WITH CANOPY...1169
3.2.3 GENERAL VIEW OF THE DRIVER'S SEAT...1170
3.3 INSTRUMENTS AND CONTROLS...1171
3.3.1 INSTRUMENTS...1171
3.3.2 WARNING LIGHTS...1173
3.3.3 SWITCHES AND PUSH BUTTONS...1175
3.3.4 ELECTRICAL ACCESSORIES...1178
3.3.5 MACHINE CONTROLS...1180
3.4 FUSES AND RELAYS...1193
3.4.1 FUSES...1193
3.4.1.1 EQUIPMENT FUSES...1193
3.4.1.2 MAIN FUSE...1194
3.4.2 RELAYS...1195
3.5 GUARDS AND DRIVER'S SEAT...1196
3.5.1 ENGINE HOOD...1196
3.5.2 RIGHT COUNTERWEIGHT...1197
3.5.3 CANOPY...1197
3.5.4 CAB...1198
3.5.5 VENTILATION AND HEATING...1201
3.5.6 SEAT...1202
3.5.7 SAFETY BELT...1202
3.5.8 EMERGENCY EXIT...1203
3.5.9 TECHNICAL DOCUMENTATION CASE...1203
3.5.10 FIRE EXTINGUISHER...1204
3.5.11 FIRST AID KIT...1204
3.6 USE OF THE MACHINE...1206
3.6.1 CHECKS BEFORE STARTING THE ENGINE...1206
3.6.1.1 VISUAL CHECKS...1206
3.6.1.2 DAILY CHECKS...1206
3.6.1.3 OPERATIONAL CHECKS...1207
3.6.2 STARTING THE ENGINE...1208
3.6.2.1 STARTING WITH WARM ENGINE OR IN TEMPERATE CLIMATES...1208
3.6.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES...1209
3.6.3 WARMING THE ENGINE...1210
3.6.4 HEATING THE HYDRAULIC OIL...1210
3.6.5 HOW TO MOVE THE MACHINE...1210
3.6.5.1 STEERING (CHANGING DIRECTION)...1212
3.6.5.2 MOVING ON SLOPES...1213
3.6.5.3 MAXIMUM IMMERSION DEPTH...1214
3.7 PARKING THE MACHINE...1215
3.7.1 PARKING ON LEVEL GROUND...1215
3.7.2 PARKING ON SLOPES...1216
3.8 STOPPING THE ENGINE...1217
3.9 TRANSPORTING THE MACHINE ON OTHER VEHICLES...1218
3.9.1 LOADING AND UNLOADING THE MACHINE...1218
3.9.2 TRANSPORT...1219
3.10 LIFTING THE MACHINE...1220
3.11 PRECAUTIONS TO BE TAKEN IN THE COLD SEASON...1221
3.11.1 FUEL AND LUBRICANTS...1221
3.11.2 COOLANT...1221
3.11.3 BATTERY...1221
3.11.4 OTHER PRECAUTIONS...1222
3.11.5 PRECAUTIONS TO BE TAKEN AT THE END OF WORK...1222
3.12 PRECAUTIONS TO BE TAKEN IN THE WARM SEASON...1223
3.13 USING THE WORK EQUIPMENT...1224
3.13.1 ORGANIZING THE WORK AREA...1224
3.13.2 POSITIONING THE MACHINE FOR DIGGING OPERATIONS...1225
3.13.3 DIGGING METHOD...1226
3.13.4 CHANGING THE BUCKET...1227
3.14 LONG PERIODS OF INACTIVITY...1228
3.14.1 BEFORE THE PERIOD OF INACTIVITY...1228
3.14.2 DURING THE PERIOD OF INACTIVITY...1229
3.14.3 AFTER THE PERIOD OF INACTIVITY...1229
3.15 TROUBLESHOOTING...1230
3.15.1 OCCURENCES THAT ARE NOT FAILURES...1230
3.15.2 HOW TO REMOVE THE MACHINE...1230
3.15.3 AFTER THE FUEL HAS RUN OUT...1231
3.15.4 IF THE BATTERY IS DOWN...1231
3.15.4.1 STARTING WITH BOOSTER CABLES...1232
3.15.5 OTHER TROUBLES...1233
3.15.5.1 ELECTRICAL CIRCUIT...1233
3.15.5.2 HYDRAULIC SYSTEM...1233
3.15.5.3 ENGINE...1234
MAINTENANCE...1236
4.1 GUIDE TO MAINTENANCE...1237
4.2 MAINTENANCE NOTES...1239
4.2.1 NOTES REGARDING THE ENGINE...1239
4.2.1.1 ENGINE OIL...1239
4.2.1.2 COOLANT...1239
4.2.1.3 FUEL...1240
4.2.2 NOTES REGUARDING THE HYDRAULIC SYSTEM...1240
4.2.3 NOTES REGUARDING THE ELECRICAL SYSTEM...1241
4.2.4 NOTES REGUARDING LUBRICATION...1241
4.2.5 PARTS SUBJECT TO WEAR THAT PERIODICALLY NEED CHANGING...1242
4.3 FUEL, COOLANT AND LUBRICANTS...1243
4.3.1 HOMOLOGATED HEES SYNTHETIC BIODEGRADABLE LUBRICANTS...1247
4.4 NUT AND BOLT TIGHTENING TORQUES...1248
4.4.1 STANDARD TIGHTENING TORQUES...1248
4.4.2 SPECIFIC TIGHTENING TORQUES...1248
4.5 LUBRICATION...1249
4.5.1 LUBRICATION DIAGRAM...1249
4.6 PERIODICAL CHANGE OF THE COMPONENTS THAT ARE CONNECTED WITH SAFETY...1250
4.6.1 CRITICAL PARTS FOR SAFETY...1251
4.7 MAINTENANCE PLAN...1254
4.7.1 WHEN REQUIRED...1257
4.7.1.a WASHING THE COOLING CIRCUIT...1257
4.7.1.b DRAINING THE FUEL TANK...1258
4.7.1.c CHECKING THE ELECTRICAL SYSTEM...1259
4.7.1.d CHECKING THE STEEL TRACK TENSION...1259
4.7.1.e CHECKING THE RUBBER TRACKS...1261
4.7.1.f CHECKING THE RUBBER TRACK TENSION...1263
4.7.1.g CHANGING THE RUBBER TRACK...1265
4.7.1.h CHECKING, CLEANING OR CHANGING THE AIR CLEANER CARTRIDGE...1267
4.7.2 MAINTENANCE INTERVALS IN CASE OF USE OF THE DEMOLITION HAMMER (BREAKER)...1268
4.7.2.a CHANGING THE HYDRAULIC OIL FILTER...1268
4.7.2.b CHANGING THE HYDRAULIC OIL...1268
4.7.3 CHECKS BEFORE STARTING...1269
4.7.3.a VARIOUS CHECKS...1269
4.7.3.b CHECKING THE COOLANT LEVEL...1269
4.7.3.c CHECKING THE FUEL LEVEL...1270
4.7.3.d CHECKING THE ENGINE OIL LEVEL...1270
4.7.3.e CHECKING THE OIL LEVEL IN THE HYDRAULIC CIRCUIT...1271
4.7.3.f CHECKING THE AIR CLEANER CLOGGING INDICATOR...1272
4.7.3.g CHECKING THE FUEL FILTER FOR SEDIMENT AND WATER...1272
4.7.4 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION (ONLY FOR MACHINES IN WHICH THE SYNTHETIC BIODEGRADABLE OIL TYPE HEES...1273
4.7.5 MAINTENANCE EVERY 100 HOURS OF OPERATION...1274
4.7.5.a LUBRICATING THE JOINTS AND THE BALL-BEARING RING...1274
4.7.6 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION...1276
4.7.7 MAINTENANCE EVERY 250 HOURS OF OPERATION...1276
4.7.7.a ADJUSTING THE FAN BELT TENSION...1276
4.7.7.b CHECKING THE BATTERY ELECTROLYTE LEVEL...1277
4.7.7.c CHECKING THE OIL LEVEL IN THE TRAVEL REDUCTION GEARS...1277
4.7.7.d CHANGING THE HYDRAULIC SYSTEM OIL FILTER...1278
4.7.7.e CHANGING THE ENGINE OIL...1279
4.7.8 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION (ONLY FOR MACHINES IN WHICH THE SYNTHETIC BIODEGRADABLE OIL TYPE HEE...1280
4.7.9 MAINTENANCE EVERY 500 HOURS OF OPERATION...1280
4.7.9.a CHANGING THE OIL FILTER...1280
4.7.9.b CHANGING THE FUEL FILTER...1281
4.7.9.c CHANGING THE FUEL PUMP PRECLEANER...1282
4.7.9.d CLEANING THE OUTSIDE OF THE RADIATORS...1283
4.7.9.e DRAINING THE HYDRAULIC OIL TANK (ONLY FOR MACHINES IN WHICH THE SYNTHETOC BIODEGRADABLE OIL TYPE HEES IS USED)...1284
4.7.10 MAINTENANCE EVERY 1000 HOURS OF OPERATION...1285
4.7.10.a CHANGING THE OIL IN THE TRAVEL REDUCTION GEARS...1285
4.7.11 MAINTENANCE EVERY 2000 HOURS OF OPERATION...1286
4.7.11.a CHANGING THE HYDRAULIC SYSTEM OIL AND CLEANING THE SUCTION FILTER...1286
4.7.11.b CHANGING THE COOLANT...1289
4.7.11.C CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE...1290
4.7.11.d CHECKING THE ALTERNATOR AND THE STARTER...1290
TECHNICAL SPECIFICATIONS...1292
5.1 TECHNICAL DATA...1293
5.1.1 STANDARD OVERALL DIMENSIONS...1293
5.1.2 TECHNICAL CHARACTERISTICS...1295
5.1.3 LIFTING CAPACITY WITH CAB...1296
5.1.4 LIFTING CAPACITY WITH CANOPY...1297
AUTHORIZED OPTIONAL EQUIPMENT...1298
6.1 AUTHORIZED OPTIONAL EQUIPMENT...1299
6.1.1 PRECAUTIONS REGARDING SAFETY...1299
6.1.2 PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT...1300
6.1.3 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT...1301
6.2 ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER (BREAKER)...1302
6.2.1 DESCRIPTION AND CONTROL...1302
6.2.2 USE OF THE DEMOLITION HAMMER AND RULES TO BE OBSERVED...1302
6.2.3 INSTALLING AND REMOVING THE DEMOLITION HAMMER...1306
6.2.3.1 INSTALLING THE HAMMER...1306
6.2.3.2 REMOVING THE HAMMER...1307
6.2.4 MAINTENANCE...1307
6.3 ARRANGEMENT FOR THE OPERATION OF OPTIONAL EQUIPMENT...1308
6.3.1 SELECTION VALVE (1)...1308
6.3.2 CONTROL PEDAL (2)...1309
6.3.3 ASSEMBLYING AND CONNECTING THE EQUIPMENT...1310
6.3.4 MAINTENANCE...1311
WEBM000200 - Hydraulic Excavator PC20R-8, PC27R-8 Shop Manual...1312
WEBM000201 - Hydraulic Excavator PC20R-8, PC27R-8 Shop Manual...1608
COVER...1608
CONTENTS...1610
LIST OF REVISED PAGES...1612
SAFETY...1614
FOREWORD...1616
HOW TO READ THE SHOP MANUAL...1617
HOISTING INSTRUCTIONS...1618
STANDARD TIGHTENING TORQUE...1619
COATING MATERIALS...1620
ELECTRIC WIRE CODE...1621
WEIGHT TABLE...1622
TABLE OF OIL AND COOLANT QUANTITIES...1623
10.STRUCTURE AND FUNCTION...1626
POWER TRAIN...1627
SWING CIRCLE...1629
SWING MACHINERY PC27R-8...1631
FINAL DRIVE...1632
TRACK FRAME...1633
RECOIL SPRING...1635
CARRIER ROLLER PC27R-8...1636
TRACK ROLLER...1636
STEEL SHOE...1637
HYDRAULIC SYSTEM PC20R-8...1638
HYDRAULIC SYSTEM PC27R-8...1640
HYDRAULIC CIRCUIT DIAGRAM PC20R-8...1642
HYDRAULIC CIRCUIT DIAGRAM PC27R-8...1644
HYDRAULIC PUMP PC20R-8...1645
HYDRAULIC PUMP PC27R-8...1649
TCC VALVE, LS VALVE, SERVO PISTON...1655
CONTROL VALVE...1669
CLSS...1677
SWIVEL JOINT...1694
SWING MOTOR...1695
TRAVEL MOTOR...1699
CYLINDER...1702
ACCUMULATOR...1706
PPC VALVE...1707
PPC VALVE...1711
SOLENOID VALVE...1714
ELECTRICAL DIAGRAM (1/3)...1716
ELECTRICAL DIAGRAM (2/3)...1718
ELECTRICAL DIAGRAM (3/3)...1720
20.TESTING AND ADJUSTMENT...1724
NORMAL OR STANDARD TECHNICAL DATA...1725
SPECIAL TOOLS...1747
CHECKING THE ENGINE SPEED...1748
ADJUSTMENT OF VALVE CLEARANCE...1749
MEASUREMENT OF THE COMPRESSION PRESSURE...1750
CONTROL AND ADJUSTMENT OF THE TENSION OF THE FAN BELT...1751
CONTROL AND ADJUSTMENT OF THE INJECTION TIMING...1752
CONTROL AND ADJUSTMENT OF THE ACCELERATOR STROKE...1754
ADJUSTMENT OF THE STROKE OF THE BLADE COMMAND LEVER...1755
ADJUSTING THE FLEXIBLE CABLES...1756
CONTROL AND ADJUSTMENT OF THE STROKE OF THE TRAVEL LEVER...1757
ADJUSTMENT OF THE STROKE OF THE BOOM SWING COMMAND PEDAL...1758
ADJUSTMENT OF THE PPC VALVE CLEARANCES...1759
ADJUSTMENT OF THE RUBBER PAD AND SAFETY MICROSWITCH FOR SERVO-CONTROL ENGAGEMENT...1760
CONTROL AND ADJUSTMENT OF THE TRACK-SHOE TENSION...1761
CONTROL AND REGULATION OF THE PRESSURES IN THE HYDRAULIC CIRCUITS...1762
CONTROL AND REGULATION OF THE LS DIFFERENTIAL PRESSURE AND ADJUSTMENT OF THE LS VALVE (PC20R-8)...1767
REGULATION OF THE PC VALVE (PC20R-8)...1769
CONTROL AND REGULATION OF THE LS DIFFERENTIAL PRESSURE AND ADJUSTMENT OF THE LS VALVE (PC27R-8)...1770
REGULATION OF THE PC VALVE (PC27R-8)...1772
CONTROL AND REGULATION OF THE SERVO-CONTROL POWER SUPPLY...1773
ELIMINATION OF RESIDUAL PRESSURES - PRESSURISATION OF THE TANK...1774
BLEEDING AIR FROM THE HYDRAULIC CIRCUITS...1775
CONTROL OF HYDRAULIC DRIFTS - ANALYSIS OF THE CAUSES OF A DRIFT...1777
CHECKING FOR ANY LEAKAGES INSIDE THE WORKING EQUIPMENT CYLINDERS...1783
CHECKING FOR ANY LEAKAGES INSIDE THE SWING MOTOR...1784
METHODS FOR TESTING FOR LEAKAGES INSIDE THE SWIVEL JOINT...1785
30.REMOVAL AND INSTALLATION...1790
HOW TO READ THE MANUAL...1792
PRECAUTIONS TO BE TAKEN WHILE WORKING...1793
SPECIAL TOOLS...1794
STARTER MOTOR...1796
ALTERNATOR...1797
INJECTION PUMP...1798
NOZZLE HOLDER...1800
WATER COOLANT PUMP...1801
CYLINDER HEAD...1803
ENGINE HOOD...1805
CANOPY...1806
CAB...1807
HEATING FAN...1808
COUNTERWEIGHT...1810
FUEL TANK...1811
HYDRAULIC TANK...1812
OIL-COOLER - RADIATOR GROUP...1814
ENGINE-PUMP GROUP...1816
PUMP...1819
ENGINE-PUMP COUPLING...1820
LATERAL LOWER COVER...1821
INNER CONTROL VALVE BOX COVER...1822
CONTROL VALVE...1823
LEFT-HAND PPC VALVE (ARM-BUCKET)...1825
RIGHT-HAND PPC VALVE (BOOM-BUCKET)...1826
SERVOCONTROL SOLENOID GROUP...1827
PLATFORM...1828
SWIVEL JOINT...1831
SWING MACHINERY...1832
REVOLVING FRAME...1835
SWING CIRCLE...1837
RUBBER TRACK SHOES...1838
STEEL TRACK-SHOES...1839
SPROCKET WHEEL...1840
FINAL DRIVE...1841
IDLER AND RECOIL SPRING...1842
SPRING RECOIL AND THRUST CYLINDER GROUPS...1843
IDLER...1844
TRACK ROLLERS...1845
BOOM CYLINDER...1846
ARM CYLINDER...1848
BUCKET CYLINDER...1849
BOOM SWING CYLINDER...1850
BLADE CYLINDER...1852
WORK EQUIPMENT CYLINDERS...1853
UPPER WORK EQUIPMENT...1859
BUCKET...1861
ARM...1862
ARM ASSEMBLY...1864
BOOM...1865
BOOM SWING SUPPORT...1867
BLADE...1868
40.STANDARD MAINTENANCE...1872
SWING CIRCLE...1873
SWING MACHINERY PC27R-8...1874
FINAL DRIVE...1875
SPROCKET...1876
TRACK FRAME AND RECOIL SPRING...1877
IDLER...1878
CARRIER ROLLER PC27R-8...1879
TRACK ROLLER...1880
TRACK SHOE...1881
HYDRAULIC PUMP...1883
CONTROL VALVE...1885
SWIVEL JOINT...1891
SWING MOTOR...1892
TRAVEL MOTOR...1895
PPC VALVE...1897
CYLINDER...1899
WORK EQUIPMENT PC20R-8...1901
WORK EQUIPMENT PC27R-8...1903
WEBM002900 - Hydraulic Excavator PC27R-8 Shop Manual...1906
COVER...1906
CONTENTS...1907
FOREWARD...1910
FOREWARD...1912
HOW TO READ THE SHOP MANUAL...1913
HOISTING INSTRUCTIONS...1914
STANDARD TIGHTENING TORQUE...1915
COATING MATERIALS...1917
ELECTRIC WIRE CODE...1918
WEIGHT TABLE...1919
TABLE OF OIL AND COOLANT QUANTIES...1920
10 STRUCTURE AND FUNCTION...1922
POWER TRAIN...1923
SWING CIRCLE...1924
SWING MACHINERY...1925
FINAL DRIVE...1926
TRACK FRAME...1927
RECOIL SPRING...1928
CARRIER ROLLER...1929
TRACK ROLLER...1929
STEEL SHOE...1930
HYDRAULIC SYSTEM...1931
HYDRAULIC CIRCUIT DIAGRAM...1932
HYDRAULIC PUMP...1934
CONTROL VALVE...1952
CLSS...1960
SWIVEL JOINT...1977
SWING MOTOR...1978
TRAVEL MOTOR...1980
CYLINDER...1982
ACCUMULATOR...1985
PPC VALVE...1990
SOLENOID VALVE...1993
ELECTRICAL DIAGRAM (1/3)...1995
ELECTRICAL DIAGRAM (2/3)...1996
ELECTRICAL DIAGRAM (3/3)...1997
20 TESTING AND ADJUSTING...1999
NORMAL OR STANDARD TECHNICAL DATA...2000
SPECIAL TOOLS...2011
CHECKING THE ENGINE SPEED...2012
ADJUSTMENT OF VALVE CLEARANCE...2013
MEASUREMENT OF THE COMPRESSOR PRESSURE...2014
CONTROL AND ADJUSTMENT OF THE TENSION OF THE FAN BELT...2015
CONTROL AND ADJUSTMENT OF THE INJECTION TIMING...2016
CONTROL AND ADJUSTMENT OF THE ACCELERATOR STROKE ...2018
ADJUSTMENTOF THE STROKE OF THE BLADE COMMAND LEVER...2019
ADJUSTING THE FLEXIBLE CABLES...2020
CONTROL AND ADJUSTMENT OF THE STROKE OF THE TRAVEL LEVER...2021
ADJUSTMENT OF THE STROKE OF THE BOOM SWING COMMAND PEDAL...2022
ADJUSTMENT OF THE PPC VALVE CLEARANCES...2023
ADJUSTMENT OF THE RUBBER PAD AND SAFETY MICROSWITCH FOR SERVO-CONTROL ENGAGEMENT...2024
CONTROL AND ADJUSTMENTOF THE STROKE OF THE TRACK-SHOE TENSION...2025
CONTROL AND REGULATION OF THE PREEURES IN THE HYDRAULIC CIRCUTIS...2026
CONTROL AND REGULATION OF THE LS DIFFERENTIAL PRESSURE AND ADJUSTMENT OF THE LS VALVE...2029
REGULATION OF THE PC VALVE...2031
CONTROL AND REGULATION O THE SERVO-CONTROL POWER SUPPLY...2032
ELIMINATION OF RESIDUAL PRESSURES - PRESSURISATION OF THE TANK...2033
BLEEDING AIR FROM THE HYDRAULIC CIRCUITS...2034
CONTROL OF HYDRAULIC DRIFTS - ANALYSIS OF THE CAUSES OF A DRIFT...2036
CHECKING FOR ANY LEAKAGES INSIDE THE WORKING EQUIPMENT CYLINDERS...2042
CHECKING FOR ANY LEAKAGES INSIDE THE SWING MOTOR...2043
METHODS FOR TESTING FOR LEAKAGES INSIDE THE SWIVEL JOINT...2044
30 REMOVAL AND INSTALLATION...2047
HOW TO READ THE MANUAL...2049
PRECAUTIONS TO BE TAKEN WHILE WORKING...2050
SPECIAL TOOLS...2051
STARTER MOTOR...2053
REMOVAL...2053
INSTALLATION...2053
ALTERNATOR...2054
REMOVAL...2054
INSTALLATION...2054
INJECTION PUMP...2055
REMOVAL...2055
INSTALLATION...2056
NOZZLE HOLDER...2057
REMOVAL...2057
INSTALLATION...2057
WATER COOLANT PUMP...2058
REMOVAL...2058
INSTALLATION...2059
CYLINDER HEAD...2060
REMOVAL...2060
INSTALLATION...2061
OIL COOLER...2062
REMOVAL...2062
INSTALLATION...2062
RADIATOR...2063
REMOVAL...2063
INSTALLATION...2063
ENGINE HOOD...2064
REMOVAL...1907
INSTALLATION...1907
CANOPY...2065
REMOVAL...2065
INSTALLATION...2065
CAB...2066
REMOVAL...2066
INSTALLATION...2066
HEATING FAN...2067
REMOVAL...2067
INSTALLATION...2068
COUNTERWEIGHT...2069
REMOVAL...2069
INSTALLATION...2069
DIESEL FUEL TANK...2070
REMOVAL...2070
INSTALLATION...2070
HYDRAULIC OIL TANK...2071
REMOVAL...2071
INSTALLATION...2072
OIL-COOLER-RADIATOR GROUP...2073
REMOVAL...2073
INSTALLATION...2074
ENGINE-PUMP GROUP...2075
REMOVAL...2075
INSTALLATION...2077
PUMP...2078
REMOVAL...2078
INSTALLATION...2078
ENGINE-PUMP COUPLING...2079
REMOVAL...2079
INSTALLATION...2079
SIDE LOWER PANELS...2080
REMOVAL...2080
INSTALLATION...2080
INNER CONTROL VALVE BOX COVER...2081
REMOVAL...2081
INSTALLATION...2081
CONTROL VALVE...2082
REMOVAL...2082
INSTALLATION...2083
LEFT-HAND PPC VALVE (ARM-BUCKET)...2084
REMOVAL...2084
INSTALLATION...2084
RIGHT-HAND PPC VALVE (BOOM-BUCKET)...2085
REMOVAL...2085
INSTALLATION...2085
SERVOCONTROL SOLENOID GROUP...2086
REMOVAL...2086
INSTALLATION...2086
PLATFORM...2087
REMOVAL...2087
INSTALLATION...2089
SWIVEL JOINT...2090
REMOVAL...2090
INSTALLATION...2090
SWING MACHINERY...2091
REMOVAL...2090
INSTALLATION...2092
REVOLVING FRAME...2093
REMOVAL...2093
INSTALLATION...2094
SWING CIRCLE...2095
REMOVAL...2095
INSTALLATION...2095
RUBBER TRACK SHOES...2096
REMOVAL...2096
INSTALLATION...2096
STEEL TRACK-SHOES...2097
REMOVAL...2097
INSTALLATION...2097
SPROCKET WHEEL...2098
REMOVAL...2098
INSTALLATION...2098
FINAL DRIVE...2099
REMOVAL...2099
INSTALLATION...2099
IDLER AND RECOIL SPRING ASSEMBLY...2100
REMOVAL...2100
INSTALLATION...2100
SPRING RECOIL AND THRUST CYLINDER GROUPS...2101
DISASSEMBLY...2101
ASSEMBLY...2101
IDLER...2102
DISASSEMBLY...2102
ASSEMBLY...2102
TRACK ROLLERS...2103
REMOVAL...2103
INSTALLATION...2103
BOOM CYLINDER...2104
REMOVAL...2104
INSTALLATION...2105
ARM CYLINDER...2106
REMOVAL...2106
INSTALLATION...2106
BUCKET CYLINDER...2107
REMOVAL...2107
INSTALLATION...2107
BOOM SWING CYLINDER...2108
REMOVAL...2108
INSTALLATION...2109
BLADE CYLINDER...2110
REMOVAL...2110
INSTALLATION...2110
WORKING EQUIPMENT CYLINDERS...2111
DISASSEMBLY...2111
ASSEMBLY...2113
UPPER WORKING EQUIPMENT...2117
REMOVAL...2117
INSTALLATION...2118
ARM...2119
REMOVAL...2119
INSTALLATION...2120
ARM ASSEMBLY...2121
REMOVAL...2121
INSTALLATION...2121
BOOM...2122
REMOVAL...2122
INSTALLATION...2123
BOOM SWING SUPPORT...2124
REMOVAL...2124
INSTALLATION...2124
BLADE...2125
REMOVAL...2125
INSTALLATION...2125
40 MAINTENANCE STANDARD...2127
SWING CIRCLE...2128
SWING MACHINERY...2129
FINAL DRIVE...2130
SPROCKET...2131
TRACK FRAME AND RECOIL SPRING...2132
IDLER...2133
CARRIER ROLLER...2134
TRACK ROLLER...2135
TRACK SHOE...2136
HYDRAULIC PUMP...2138
CONTROL VALVE...2139
SWIVEL JOINT...2145
SWING MOTOR...2146
TRAVEL MOTOR...2147
PPC VALVE (FOR BOOM, ARM, BUCKET, SWING)...2149
PPC VALVE (FOR HAMMER)...2150
CYLINDER...2151
WORK EQUIPMENT...2153
WEBM003800 - Hydraulic Excavator PC27R-8 Deluxe Shop Manual...2156
COVER...2156
CONTENTS...2158
SAFETY...2162
FOREWORD...2164
HOW TO READ THE SHOP MANUAL...2165
HOISTING INSTRUCTIONS...2166
STANDARD TIGHTENING TORQUE...2167
COATING MATERIALS...2169
ELECTRIC WIRE CODE...2170
WEIGHT TABLE...2171
TABLE OF OIL COOLANT QUANTITIES...2172
10. STRUCTURE AND FUNCTION...2176
POWER TRAIN...2177
SWING CIRCLE...2178
SWING MACHINERY...2179
FINAL DRIVE...2180
TRACK FRAME...2181
RECOIL SPRING...2182
CARRIER ROLLER...2183
TRACK ROLLER...2183
STEEL SHOE...2184
HYDRAULIC SYSTEM...2186
HYDRAULIC CIRCUIT DIAGRAM...2188
HYDRAULIC PUMP...2189
CONTROL VALVE...2209
CLSS...2217
SWIVEL JOINT...2234
SWING MOTOR...2235
TRAVEL MOTOR...2237
CYLINDER...2239
ACCUMULATOR...2242
PPC VALVE...2243
SOLENOID VALVE...2250
ELECTRICAL DIAGRAM (1/3)...2252
ELECTRICAL DIAGRAM (2/3)...2254
ELECTRICAL DIAGRAM (3/3)...2256
20. TESTING AND ADJUSTING...2260
NORMAL OR STANDARD TECHNICAL DATA...2261
SPECIAL TOOLS...2272
CHECKING THE ENGINE SPEED...2274
ADJUSTMENT OF VALVE CLEARANCE...2275
MEASUREMENT OF THE COMPRESSION PRESSURE...2276
CONTROL AND ADJUSTMENT OF THE TENSION OF THE FAN BELT...2277
CONTROL AND ADJUSTMENT OF THE INJECTION TIMING...2278
CONTROL AND ADJUSTMENT OF THE ACCELERATOR STROKE...2280
ADJUSTMENT OF THE STROKE OF THE BLADE COMMAND LEVER...2281
ADJUSTING THE FLEXIBLE CABLES...2282
CONTROL AND ADJUSTMENT OF THE STROKE OF THE TRAVEL LEVER...2283
ADJUSTMENT OF THE STROKE OF THE BOOM SWING COMMAND PEDAL...2284
ADJUSTMENT OF THE PPC VALVE CLEARANCE...2285
ADJUSTMENT OF THE RUBBER PAD AND SAFETY MICROSWITCH FOR SERVO-CONTROL ENGAGEMENT...2286
CONTROL AND ADJUSTMENT OF THE TRACK-SHOE TENSION...2287
CONTROL AND REGULATION OF THE PRESSURES IN THE HYDRAULIC CIRCUITS...2288
CONTROL AND REGULATION OF THE LS DIFFERENTIAL PRESSURE AND ADJUSTMENT OF THE LS VALVE...2291
REGULATION OF THE PC VALVE...2293
CONTROL AND REGULATION OF THE SERVO-CONTROL POWER SUPPLY...2294
ELIMINATION OF RESIDUAL PRESSURES - PRESSURIATION OF THE TANK...2295
BLEEDING AIR FROM THE HYDRAULIC CIRCUITS...2296
CONTROL OF HYDRAULIC DRIFT - ANALYSIS OF THE CAUSES OF A DRIFT...2298
CHECKING FOR ANY LEAKAGES INSIDE THE WORKING EQUIPMENT CYLINDERS...2304
CHECKING FOR ANY LEAKAGES INSIDE THE SWING MOTOR...2305
METHODS FOR TESTING FOR LEAKAGES INSIDE THE SWIVEL JOINT...2306
30. REMOVAL AND INSTALLATION...2310
HOW TO READ THE MANUAL...2312
PRECAUTIONS TO BE TAKEN WHILE WORKING...2313
SPECIAL TOOLS...2314
STARTER MOTOR...2316
REMOVAL...2316
INSTALLATION...2316
ALTERNATOR...2317
REMOVAL...2317
INSTALLATION...2317
INJECTION PUMP...2318
REMOVAL...2318
INSTALLATION...2319
NOZZLE HOLDER...2320
REMOVAL...2320
INSTALLATION...2320
WATER COOLANT PUMP...2321
REMOVAL...2321
INSTALLATION...2322
CYLINDER HEAD...2323
REMOVAL...2323
INSTALLATION...2324
ENGINE HOOD...2325
REMOVAL...2325
INSTALLATION...2325
CANOPY...2326
REMOVAL...2326
INSTALLATION...2326
CAB...2327
REMOVAL...2327
INSTALLATION...2327
HEATING FAN...2328
REMOVAL...2328
INSTALLATION...2329
COUNTERWEIGHT...2330
REMOVAL...2330
INSTALLATION...2330
FUEL TANK...2331
REMOVAL...2331
INSTALLATION...2331
HYDRAULIC TANK...2332
REMOVAL...2332
INSTALLATION...2333
OIL-COOLER - RADIATOR GROUP...2334
REMOVAL...2334
INSTALLATION...2335
ENGINE-PUMP GROUP...2336
REMOVAL...2336
INSTALLATION...2338
PUMP...2339
REMOVAL...2339
INSTALLATION...2339
ENGINE-PUMP COUPLING...2340
REMOVAL...2340
INSTALLATION...2340
LATERAL LOWER COVER...2341
REMOVAL...2341
INSTALLATION...2341
INNER CONTROL VALVE BOX COVER...2342
REMOVAL...2342
INSTALLATION...2342
CONTROL VALVE...2343
REMOVAL...2343
INSTALLATION...2344
LEFT-HAND PPC VALVE (ARM-BUCKET)...2345
REMOVAL...2345
INSTALLATION...2345
RIGHT-HAND PPC VALVE (BOOM-BUCKET)...2346
REMOVAL...2346
INSTALLATION...2346
SERVOCNTROL SOLENOID GROUP...2347
REMOVAL...2347
INSTALLATION...2347
PLATFORM...2348
REMOVAL...2348
INSTALLATION...2350
SWIVEL JOINT...2351
REMOVAL...2351
INSTALLATION...2351
SWING MACHINERY...2352
REMOVAL...2352
INSTALLATION...2353
REVOLVING FRAME...2354
REMOVAL...2354
INSTALLATION...2355
SWING CIRCLE...2356
REMOVAL...2356
INSTALLATION...2356
RUBBER TRACK SHOES...2357
REMOVAL...2357
INSTALLATION...2357
STEEL TRACK SHOES...2358
REMOVAL...2358
INSTALLATION...2358
SPROCKET WHEEL...2359
REMOVAL...2359
INSTALLATION...2359
FINAL DRIVE...2360
REMOVAL...2360
INSTALLATION...2360
IDLER AND RECOIL SPRING...2361
REMOVAL...2361
INSTALLATION...2361
SPRING RECOIL AND THRUST CYLINDER GROUPS...2362
DISASSEMBLY...2362
ASSEMBLY...2362
IDLER...2363
DISASSEMBLY...2363
ASSEMBLY...2363
TRACK ROLLERS...2364
REMOVAL...2364
INSTALLATION...2364
BOOM CYLINDER...2365
REMOVAL...2365
INSTALLATION...2366
ARM CYLINDER...2367
REMOVAL...2367
INSTALLATION...2367
BUCKET CYLINDER...2368
REMOVAL...2368
INSTALLATION...2368
BOOM SWING CYLINDER...2369
REMOVAL...2369
INSTALLATION...2370
BLADE CYLINDER...2371
REMOVAL...2371
INSTALLATION...2371
WORK EQUIPMENT CYLINDERS...2372
DISASSEMBLY...2372
ASSEMBLY...2374
UPPER WORK EQUIPMENT...2378
REMOVAL...2378
INSTALLATION...2379
ARM...2380
REMOVAL...2380
INSTALLATION...2381
ARM ASSEMBLY...2382
REMOVAL...2382
INSTALLATION...2382
BOOM...2383
REMOVAL...2383
INSTALLATION...2384
BOOM SWING SUPPORT...2385
REMOVAL...2385
INSTALLATION...2385
BLADE...2386
REMOVAL...2386
INSTALLATION...2386
40. STANDARD MAINTENANCE...2390
SWING CIRCLE...2391
SWING MACHINERY...2392
FINAL DRIVE...2393
SPROCKET...2394
TRACK FRAME AND RECOIL SPRING...2395
IDLER...2396
CARRIER ROLLER...2397
TRACK ROLLER...2398
TRACK SHOE...2399
HYDRAULIC PUMP...2401
CONTROL VALVE...2402
SWIVEL JOINT...2408
SWING MOTOR...2409
TRAVEL MOTOR...2411
PPC VALVE (FOR BOOM, ARM, BUCKET, SWING)...2413
PPC VALVE (FOR HAMMER)...2414
CYLINDER...2415
WORK EQUIPMENT...2417
Komatsu Hydraulic Excavator PC20R, PC25R, PC27R Repair Service Manuals
