Komatsu Hydraulic Excavator Pc20r 27r 8 Shop Manual
Komatsu Hydraulic Excavator Pc20r 27r 8 Shop Manual
Komatsu Hydraulic Excavator Pc20r 27r 8 Shop Manual
This is the cut pages sample. Download all 298 page(s) at: ManualPlace.com
40-28 PC15R-8
CONTENTS
30-31 40-6
30-32 40-7
30-33 40-8
30-34 40-9
30-35 40-10
30-36 40-11
30-37 40-12
30-38 40-13
30-39 40-14
30-40 40-15
30-41 40-16
30-42 40-17
30-43 40-18
30-44 40-19
30-45 40-20
30-46 40-21
30-47 40-22
30-48 40-23
30-49 40-24
30-50 40-25
30-51 40-26
30-52 40-27
30-53 40-28
30-54 40-29
30-55 40-30
30-56 40-31
30-57 40-32
30-58 40-33
30-59
30-60
30-61
30-62
30-63
30-64
30-65
30-66
30-67
30-68
30-69
30-70
30-71
30-72
30-73
30-74
30-75
30-76
30-77
30-78
30-79
30-80
30-81
40-1
40-2
40-3
40-4
40-5
Proper service and repair is extremely important for the safe operation of your machine.
The service and repair techniques recommended by Komatsu Utility and describe in this manual are
both effective and safe methods of operation. Some of these operations require the use of tools specially
designed by Komatsu Utility for the purpose.
To prevent injury to workers, the symbols and are used to mark safety precautions in this ma-
nual. The cautions accompanying these symbols should always be carefully followed. If any danger ari-
ses or may possibly arise, first consider safety, and take necessary steps to face.
SAFETY
GENERAL PRECAUTIONS PREPARATIONS FOR WORK
Mistakes in operation extremely dangerous. 7. Before adding or making any repairs, park the ma-
Read all the Operation and Maintenance Manual care- chine on hard, level ground, and block the tracks
fully BEFORE operating the machine. to prevent the machine from moving.
1. Before carrying out any greasing or repairs, read 8. Before starting work, lower blade, bucket or any
all the precautions written on the decals which other work equipment to the ground. If this is
are suck on the machine. not possible, use blocks to prevent the work
equipment from falling down. In addition, be sure
2. When carrying out any operation, always wear sa- to lock all the control levers and hang warning
fety shoes and helmet. Do not wear loose work sign on them.
clothes, or clothes with buttons missing.
9. When disassembling or assembling, support the
. Always wear safety glasses when hitting parts
machine with blocks, jacks or stands before star-
with a hammer.
ting work.
. Always wear safety glasses when grinding
parts with a grinder, etc. 10. Remove all mud and oil from the steps or other
places used to get on and off the machine. Always
3. If welding repairs are needed, always have a trai- use the handrails, ladders or steps when getting
ned, experienced welder carry out the work. on or off the machine.
When carrying out welding work, always wear Never jump on or off the machine.
welding gloves, apron, glasses, cap and other clo- If it is impossible to use the handrails, ladders or
thes suited for welding work. steps, use a stand to provide safe footing.
4. When carrying out any operation with two or more
workers, always agree on the operating procedure
before starting. Always inform your fellow workers PRECAUTIONS DURING WORK
before starting any step of the operation. Before
11. When removing the oil filler cap, drain plug or hy-
starting work, hang UNDER REPAIR signs on
draulic pressure measuring plugs, loosen them
the controls in the operator's compartment.
slowly to prevent the oil from spurting out.
5. Keep all tools in good condition and learn the cor- Before disconnecting or removing components of
rect way to use them. the hydraulic circuit and engine cooling circuit,
first remove the pressure completely from the cir-
6. Decide a place in the repair workshop to keep
cuit.
tools and removed parts. Always keep the tools
and parts in their correct places. Always keep 12. The water and oil in the circuits are not hot when
the work area clean and make sure that there is the engine in stopped, so be careful not to get
no dirt or oil on the floor. burned.
Smoke only in the areas provided for smoking. Wait for the oil water to cool before carrying out
Never smoke while working. any work on the cooling water circuits.
This shop manual has been prepared as an aid to improve the quality of repairs by giving the operator an ac-
curate 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.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any
notice.
Contact your Komatsu Utility distributor for the latest information.
VOLUMES SYMBOLS
Shop manual are issued as a guide to carry out re- In order to make the shop manual greatly chelpful,
pairs. These various volumes are designed to avoid important points about safety and quality are marked
duplicating the same information. with the following symbols.
REVISIONS
Revised pages are shown on the LIST OF REVI-
SED PAGES between the title page and SAFETY pa-
ge.
HOISTING INSTRUCTIONS
WIRE ROPES
(Standard «S» or «Z» twist ropes
without galvanizing)
4) Do not sling a heavy load with ropes forming a
Rope diameter (mm) Allowable load (tons) wide hanging angle from the hook.
When hoisting a load with two or more ropes,
10 1.0 the force subjected to each rope will increase
with the hanging angles.
11.2 1.4 The table below shows the variation of allowa-
ble load (kg) when hoisting is made with two ro-
12.5 1.6 pes, each of which is allowed to sling up to
1000 kg vertically, at various handing angles.
14 2.2 When two ropes sling a load vertically, up to
16 2.8 2000 kg of total weight can be suspended.
This weight becomes 1000 kg when two ropes
18 3.6 make a 120ë hanging angle.
On the other hand, two ropes are subjected to
20 4.4 an excessive force as large as 4000 kg if they
sling a 2000 kg load at a lifting angle of 150ë.
22.4 5.6
30 10.0
40 18.0
50 28.0
60 40.0
The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in sections of «Di-
sassembly and Assembly».
This torque table does not apply to bolts or nuts which have to fasten nylon or other parts non-ferrous metal washer.
. Nm (Newton meter): 1 Nm = 0.102 kgm
COATING MATERIALS
The recommended coating materials prescribed in Komatsu Utility Shop Manuals are listed below:
In the wiring diagrams various colours and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: R -N 1.5 indicates a cable having a nominal number 1.5 and red coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire
Nominal Cable O.D. Current rating
Number ù of strands Cross section Applicable circuit
number (mm) (A)
strands (mm) (mm2)
1 14 0.30 0.99 2.80 11 Warning light, light etc.
1.5 21 0.30 1.48 3.35 14 Working beam, solenoid valve, etc.
2.5 35 0.30 2.47 3.80 20 Control panel, etc.
4 56 0.30 3.95 4.60 28 Pre-heating
6 84 0.30 5.93 5.20 37 Control panel
35 266 0.40 9.20 12.20 125 Battery - Ground
This weight table is a guide for use when transporting or handling components.
Unit: kg
SAE 10W
SAE 20W-20
OIL
Crankcase sump 3.6 5.2 3.6 5.2
. API CD SAE 30
SAE 40
OIL SAE10W
Hydraulic circuit 48 48 29 29
. API CD
Fuel ]
FUEL 35 35 Ð Ð
tank ASTM D975 N. 2
WATER+
4 4 Ð Ð
ANTI-FREEZE
Engine coolant
WATER 4 4 Ð Ð
system
PERMANENT
4 4 Ð Ð
LIQUID
] ASTM D975 N. 1
NOTE:
(1) When fuel sulphur content is less than 0.5%, (2) When starting the engine is weathers temperature
change oil in the oil pan ebery periodic maintenan- below 0ëC, be sure to use engine oil SAE 10W,
ce hours described in operation and maintenance SAE 20W-20, even if weather temperature goes
manual. up to 10ëC day time.
Change oil according to the following table if fuel (3) Use classification CD as engine oil, if use classifi-
sulphur content is above 0.5%. cation CC, reduce the engine oil change interval to
half.
Oil change interval in engine oil
Fuel sulphur content (4) Use original products, which have characteristics
pan
specifically formulated and approved for the engi-
0.5 to 1.0% 1/2 of regular interval ne, the hydraulic circuit of equipment and for re-
ductions.
Above 1.0% 1/4 of regular interval
POWER TRAIN
PC20R-8
3 4 5 1 6
9
RKP01340
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