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Komatsu PC20R-8 Shop Manual
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Komatsu PC20R-8 Shop Manual

Komatsu PC20R-8 Shop Manual

Hydraulic excavator
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Summary of Contents for Komatsu PC20R-8

  • Page 3 40 MAINTENANCE STANDARD ..........40-1 00-1 PC20R-8 PC27R-8...
  • Page 4 00-2 PC20R-8 PC27R-8...
  • Page 5 20-46 30-23 10-20 10-61 20-6 20-47 30-24 10-21 10-62 20-7 20-48 30-25 10-22 10-63 20-8 20-49 30-26 10-23 10-64 20-9 20-50 30-27 10-24 10-65 20-10 20-51 30-28 10-25 10-66 20-11 20-52 30-29 10-26 10-67 20-12 20-53 30-30 00-2-1 PC20R-8 PC27R-8...
  • Page 6 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 00-2-2 PC20R-8 PC27R-8...
  • Page 7 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.
  • Page 8 22. When aligning two holes, never insert your fingers or hand. 23. When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurement. 00-4 PC20R-8 PC27R-8...
  • Page 9 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. 00-5 PC20R-8 PC27R-8...
  • Page 10 DISTRIBUTION AND UPDATING Special safety precautions are ne- Any additions, amendments or other changes will cessary when performing be sent to Komatsu Utility distributors. work. Get the most up-to-date information before you start any work. Safety Extra special safety precautions...
  • Page 11 2) Sling wire ropes from the middle portion of the hook. Slinging near the edge of the hook may cause the rope to slip off the hook during hoist- 00-7 PC20R-8 PC27R-8...
  • Page 12 320w35 3150w350 Ð 295w33 2900w330 410w45 4050w450 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 00-8 PC20R-8 PC27R-8...
  • Page 13 - 12 20w5 78.5w19.6 20w5 196.2w49 COATING MATERIALS The recommended coating materials prescribed in Komatsu Utility Shop Manuals are listed below: Nomenclature Code Applications Loctite 222 Used for low resistance locking of screws, check nuts and adjustment nuts. To prevent the loosening of bolts, nuts and plugs and the leakage of oil. Used for...
  • Page 14 Green ± Black ± ± ± COMPOSITION OF THE COLOURS The coloration of two-colour wires is indicated by the composition of the symbols listed. Example: G-V = Yellow-Green with longitudinal colouring. G/V = Yellow-Green with transversal colouring. 00-10 PC20R-8 PC27R-8...
  • Page 15 Track roller Idler assy. Final drive Sprocket Swing circle Shoe Steel shoe L= 300 mm Rubber shoe Swing bracket Boom Standard Long arm Bucket (standard) Blade Boom cylinder Arm cylinder Bucket cylinder Boom swing cylinder Blade cylinder 00-11 PC20R-8 PC27R-8...
  • Page 16 TABLE OF OIL AND COOLANT QUANTITIES < CAPACITY ( AMBIENT TEMPERATURE KIND OF RESERVOIR Specified Refill FLUID ±20 ±10 30ëC PC20R-8 PC27R-8 PC20R-8 PC27R-8 SAE 10W SAE 20W-20 Crankcase sump API CD SAE 30 SAE 40 SAE10W Hydraulic circuit API CD Final drive SAE 10W...
  • Page 17 GRUPPO...

  • Page 19: Table Of Contents

    Control valve ......... . 44 10-1 PC20R-8 PC27R-8...

  • Page 20: Power Train

    POWER TRAIN PC20R-8 RKP01340 1. Swing motor 7. Engine 2. Swing circle 8. Hydraulic pump 3. Track shoe idler 9. Servocontrol - travel speed increment solenoid valve 4. Control valve 5. Swivel joint 6. Travel motor 10-2 PC20R-8 PC27R-8...
  • Page 21 PC27R-8 RKP01520 1. Swing motor 7. Swivel joint 2. Swing machinery 8. Engine 3. Swing circle 9. Hydraulic pump 4. Track shoe idler 10. Servocontrol - travel speed increment solenoid valve 5. Control valve 6. Swivel joint 10-3 PC20R-8 PC27R-8...

  • Page 22: Swing Circle

    SWING CIRCLE PC20R-8 Sezione A - A Section A - A Section B - B Sezione B - B RKP01350 1. Outer race 2. Upper seal 3. Ball bearing 4. Inner race 5. Lower seal 10-4 PC20R-8 PC27R-8...
  • Page 23 PC27R-8 Section A - A Sezione A - A Sezione B - B Section B - B RKP01360 1. Outer race 2. Upper seal 3. Ball bearing 4. Inner race 5. Lower seal 10-5 PC20R-8 PC27R-8...

  • Page 24: Swing Machinery

    PC27R-8 RKP01490 1. Seal ring 9. Bearing 2. Oil drainage plug 10. Bearing 3. Crown (Z=72) 11. Pinion 4. Spacer SPECIFICATION 5. Sun gear (Z=10) Reduction ratio: 1:8.2 6. Planetary carrier 7. Planetary gear 8. Ring nut 10-6 PC20R-8 PC27R-8...

  • Page 25: Final Drive

    Reduction ratio: 1 ± 41.92 4. Cover PC27R-8 5. N . 1 sun gear Reduction ratio: 1 ± 53 6. Oil drainage plug 7. N . 1 planetary gear 8. N . 2 sun gear (Z=16) 9. Housing 10-7 PC20R-8 PC27R-8...

  • Page 26: Track Frame

    TRACK FRAME PC20R-8 RKP01690 1. Idler 5. Sprocket 2. Track frame 6. Track roller 3. Sliding plate 7. Recoil spring 4. Travel motor 8. Track shoe 10-8 PC20R-8 PC27R-8...
  • Page 27 PC27R-8 RKP01670 1. Idler 5. Sprocket 2. Track frame 6. Track roller 3. Sliding plate 7. Recoil spring 4. Travel motor 8. Track shoe 10-9 PC20R-8 PC27R-8...

  • Page 28: Recoil Spring

    RECOIL SPRING Section A - A Sezione A - A RKP01680 1. Idler 6. Nut 2. Support 7. Nipple 3. Cylinder 4. Rod 5. Recoil spring 10-10 PC20R-8 PC27R-8...

  • Page 29: Carrier Roller

    CARRIER ROLLER PC27R-8 RKP01400 1. Bearing 5. Cover 2. Gasket 6. Seal ring 3. Shaft 7. Roller 4. Spacer TRACK ROLLER RKP01410 1. Roller 4. Shoulder 2. Shaft 5. Seal ring 3. Bushing 10-11 PC20R-8 PC27R-8...

  • Page 30: Steel Shoe

    STEEL SHOE RKP02010 1. Bushing SPECIFICATIONS 2. Pin Width: 300 mm 3. Master housing Pitch: 101.6 mm 4. Master pin 5. Cotter pin 6. Link 7. Shoe 10-12 PC20R-8 PC27R-8...

  • Page 31: Hydraulic System

    5. R.H. PPC valve 6. Hydraulic tank 7. Hydraulic oil cooler 8. L.H. PPC valve 9. Hydraulic pump 10. Final drive 11. Servocontrol feed unit 12. Swivel joint 13. Blade cylinder 14. Swing motor 15. Boom cylinder RKP03650 10-13 PC20R-8 PC27R-8...
  • Page 32 PAGE INTENTIONALLY LEFT BLANK 10-14 PC20R-8 PC27R-8...
  • Page 33 5. R.H. PPC valve 6. Hydraulic tank 7. Hydraulic oil cooler 8. L.H. PPC valve 9. Hydraulic pump 10. Final drive 11. Servocontrol feed unit 12. Swivel joint 13. Blade cylinder 14. Swing motor 15. Boom cylinder RKP03660 10-15 PC20R-8 PC27R-8...
  • Page 34 PAGE INTENTIONALLY LEFT BLANK 10-16 PC20R-8 PC27R-8...

  • Page 35: Hydraulic Circuit Diagram

    Ø 2.0 Hydraulic pump ST1 solenoid valve Accumulator v = 0.35 Ø 1.0 R.H. PPC valve L.H. PPC valve Swing Bucket Boom Close Close Open Left Right Open Raise Lower 100 mesh 100 mesh RKP04401 10-17 PC20R-8 PC27R-8...
  • Page 36 PAGE INTENTIONALLY LEFT BLANK 10-18 PC20R-8 PC27R-8...
  • Page 37 Cylinder block PPC valve work equipment ST1 solenoid valve Accumulator v = 0.35 R.H. PPC valve L.H. PPC valve Bucket Boom Swing Open Close Raise Lower Close Open Left Right Hydraulic pump 100 mesh 100 mesh RKP04441 10-19 PC20R-8 PC27R-8...
  • Page 38 Port - From control valve (LS port) Displacement: 22 cc+2.75 cc d - S1 Port - From hydraulic tank Set pressure: - Main pump: 206 bar (210 kg/cm - Gear pump: 29 bar (30 kg/cm 1. Main pump 2. Gear pump 10-20 PC20R-8 PC27R-8...
  • Page 39 Sezione A - A RKP00070 1. Input shaft 8. Spring 2. Ball 9. Adjustment screw 3. Adjustment screw 10. Joint 4. Swash plate 11. Control piston 5. Piston 12. Sliding shoe 6. Cylinder block 13. Adjustment screw 7. Valve plate 10-21 PC20R-8 PC27R-8...
  • Page 40 (7), the angle of swash plate (4) is made smaller by total piston force F1 x a and is held at the position where the discharge pressure is balanced with the force of the spring. RKP00082 10-22 PC20R-8 PC27R-8...
  • Page 41 . Constant horsepower control is carried out with priority over load response control, so the dis- charge amount changes in the range below the flow at constant horsepower control. RKP00111 10-23 PC20R-8 PC27R-8...

  • Page 42: Hydraulic Pump

    - PS Port - From hydraulic tank 2. Main pump b - P2 Port - To control valve (P2 port) c - P1 Port - To control valve (P port) d - P Port - To control valve (LS port) 10-24 PC20R-8 PC27R-8...
  • Page 43 . The main pump is an integrated unit consisting of the pump, servo piston, TCC valve and LS valve. The explanation of the structure and function is di- vided into separate sections: 1. Main pump 2. TCC valve 3. LS valve 10-25 PC20R-8 PC27R-8...
  • Page 44 Sezione B - B 1. Shaft 2. Oil seal 3. Case 4. Swash plate 5. Shoe 6. Piston 7. Cylinder block 8. Valve plate 9. Spring Section C - C Sezione C - C 10. Servo piston RKP01150 10-26 PC20R-8 PC27R-8...
  • Page 45 (7) is sucked in and discharged through valve Rocker cam (4) forms a static bearing sending high plate (8). pressure oil at cylindrical surface B with to the case, and carries out a sliding movement. 10-27 PC20R-8 PC27R-8...
  • Page 46 (In actual fact, the swash plate angle never be- comes 0). RKP01260 4 - In other words, discharge amount of the pump is directly proportional to the swash plate an- 10-28 PC20R-8 PC27R-8...
  • Page 47 (lower), output pressure P of the LS valve is introduced. Movement of the servo piston is controlled by the relationship between pressures P and the proportion of the pressure receiving areas of the smaller and larger pistons. 10-29 PC20R-8 PC27R-8...
  • Page 48 - GH Port - Gear pump pressure inlet port 2. Spacer c - P Port - From control valve (LS port) 3. Piston 4. Servo piston LS VALVE 5. Piston 6. Piston 7. Sleeve 8. Spring 9. Union 10-30 PC20R-8 PC27R-8...
  • Page 49 (GH and GL) are brought to the LS valve. (kg /cm The relationship between pump discharge amount Differential pressure RKP01321 Q and LS differential pressure DP changes as shown in the diagram on the right. 10-31 PC20R-8 PC27R-8...
  • Page 50 HOLD position, no pressure oil flows to (4) moves to the right ( ) in the direction of the the control valve outlet port, so LS pressure P minimum swash plate angle. is 0 bar (0 kg/cm 10-32 PC20R-8 PC27R-8...
  • Page 51 . As the result, the pressurized oil acting on chamber X at the large diameter end of servo piston (4) flows from port d to port e and is connected to port f of the TCC valve. 10-33 PC20R-8 PC27R-8...
  • Page 52 ), so servo piston (4) is moved to the right tion. ) in the direction of the minimum swash plate angle. In other words, the LS set differential pressure of 10-34 PC20R-8 PC27R-8...
  • Page 53 (even when the lever is operated to the same halfway position), so the discharge flow is reduced below the level when the engine is run- ning at full throttle. 10-35 PC20R-8 PC27R-8...
  • Page 54 This makes the force acting on both ends of servo piston (4) 1 : 1, so servo piston (4) stops in that po- sition and the pump discharge amount is balanced with the oil flow demanded by the control valve. 10-36 PC20R-8 PC27R-8...
  • Page 55 As a result, the LS valve is actuated and the pump discharge amount is increased, but when the pump swash plate angle rises to 3/4 the LS differential pressure DP rises to 16 bar (16 kg /cm ), so it is balanced in this position. 10-37 PC20R-8 PC27R-8...
  • Page 56 P goes down, pump discharge amount Q is increased. Pump discharge pressure P . The relationship between pump discharge pressure RKP01181 and pump discharge amount Q is as shown in the diagram on the right. 10-38 PC20R-8 PC27R-8...
  • Page 57 . The position where servo piston (4) stops is higher d, enters chamber X at the large diameter end of (closer to the minimum swash plate angle) than servo piston (4), and stops the movement of servo when the pump discharge pressure is low. piston (4). 10-39 PC20R-8 PC27R-8...
  • Page 58 LS valve. . For this reason, servo piston (4) is moved to the left ) in the direction of the maximum swash plate angle by the pressure in chamber Y at the small diameter end. 10-40 PC20R-8 PC27R-8...
  • Page 59 . The pump absorption torque curve, which shows the relationship between pump discharge pressure and discharge amount Q, is a bent curve as shown in the diagram on the right because spring Pump discharge pressure P (1) has different spring pitches. RKP01181 10-41 PC20R-8 PC27R-8...
  • Page 60 (3) are in balance. . In other words, if pump discharge pressure P creases, pump discharge amount Q is reduced; and if pump discharge pressure P goes down, pump discharge amount Q is increased. 10-42 PC20R-8 PC27R-8...
  • Page 61 PAGE INTENTIONALLY LEFT BLANK 10-43 PC20R-8 PC27R-8...

  • Page 62: Control Valve

    CONTROL VALVE RKP01590 10-44 PC20R-8 PC27R-8...
  • Page 63 Port - From L.H. PPC valve (P2 Port) hh. P Port - From L.H. PPC valve (P4 Port) ii. TS Port - To hydraulic tank ll. T Port - To hydraulic tank mm. C Port - To exchange oil cooler 10-45 PC20R-8 PC27R-8...
  • Page 64 9 - Suction valve (Close arm) 4 - Suction valve (L.H. Boom swing) 10 - Suction valve (R.H. Travel forward) 5 - Suction valve (Raise boom) 11 - Suction valve (L.H. Travel forward) 6 - Suction valve (Close bucket) 10-46 PC20R-8 PC27R-8...
  • Page 65 6 - Spool (boom swing) 2 - Spool (bucket) 7 - Spool (R.H. travel) 3 - Spool (boom) 8 - Spool (L.H. travel) 4 - Spool (arm) 9 - Spool (swing) 5 - Spool (blade) 10 - Main relief valve 10-47 PC20R-8 PC27R-8...
  • Page 66 15 - Boom swing and blade 6 - Arm 16 - R.H. Travel 7 - Boom 17 - L.H. Travel 8 - Bucket 18 - Swing 9 - Attachment 19 - LS bypass plug 20 - Cooler check valve 10-48 PC20R-8 PC27R-8...
  • Page 67 12 - Reducing pressure compensation valve 5 - LS bypass plug 13 - Flow compensation valve 6 - Unload valve 14 - Spool SWING VALVE 7 - Spool 8 - Reducing pressure compensation valve 9 - Flow compensation valve 10-49 PC20R-8 PC27R-8...
  • Page 68 BLADE VALVE 13 - Suction valve (lower) 5 - Spool 14 - Reducing pressure compensation valve 15 - Flow compensation valve ARM VALVE 16 - Spool 6 - Spool 7 - Check valve 8 - Suction valve 10-50 PC20R-8 PC27R-8...
  • Page 69 3 - Reducing pressure compensation valve 8 - Reducing pressure compensation valve 4 - Flow compensation valve 9 - Flow compensation valve 5 - Spool 10 - Spool 11 - Plug 12 - Cover 13 - Pilot relief valve: 10-51 PC20R-8 PC27R-8...

  • Page 70: Clss

    . The CLSS consists of a variable displacement single piston pump, control valve and actuators. . The pump body consists of the main pump, TCC valve and LS valve. Actuator Control valve TCC valve LS valve Servo piston RKP00661 10-52 PC20R-8 PC27R-8...
  • Page 71 M For the details of this action, refer to the descriptions of «HYDRAULIC PUMP». Actuator Control valve Pump passage Main pump LS passage Min. Max. Servo piston ∆ LS valve Differential pressure large (high) Differential pressure small (low) TCC valve Pump pressure high Pump pressure low RKP00651 10-53 PC20R-8 PC27R-8...
  • Page 72 In this way, the flow from the pump are distributed in proportion to the opening areas S1 and S2 of each valve. Load Load Actuator Actuator ∆ P ∆ P Pressure Pressure compensation compensation valve valve PUMP RKP00681 10-54 PC20R-8 PC27R-8...
  • Page 73 0.45 bar (4.5 kg/cm 7. Cooler by-pass valve Bucket (cracking pressure): 0.4 bar (4 kg/cm 8. Pilot relief valve: 29 bar (30 kg/cm Boom Blade Boom swing Reverse R.H. travel Forwards Reverse L.H. travel Forwards Left Swing motor Right RKP04481 10-55 PC20R-8 PC27R-8...
  • Page 74 S2+spring force of spring (2), spool (1) is moved to the right. Pump circuit P is then connected to tank circuit T through the drill hole. . In this way, pump discharge pressure P is set to 16 bar (16 kg/cm 10-56 PC20R-8 PC27R-8...
  • Page 75 . When the difference in pressure between pump discharge pressure P and LS pressure P reaches the load of spring (2), spool (1) moves to the right, and pump circuit P and tank circuit T are connected. 10-57 PC20R-8 PC27R-8...
  • Page 76 . For this reason, the difference in pressure between pump discharge pressure P and LS pressure P does not reach the load of spring (2) (19.69.8 bar (2010 kg/cm )), so spool (1) is pushed to the left by spring (2). 10-58 PC20R-8 PC27R-8...
  • Page 77 A and is taken to LS circuit chamber P . When this happens, LS circuit P is connected to tank circuit T from LS by-pass plug (4) (see the sec- tion on the LS by-pass plug). 10-59 PC20R-8 PC27R-8...
  • Page 78 . At the same time, the actuator circuit pressure passes through notch f in hammer spool (6), then goes through passage d, and acts on the left end of piston (7). Piston (7) and reducing valve (3) then move to the right. 10-60 PC20R-8 PC27R-8...
  • Page 79 (formed by the clearance between LS by-pass plug (1) and the valve body) through or- ifice b and flows to the tank circuit T. =Pump circuit =LS circuit T =Tank circuit A =To valves B =To pump LS valve 10-61 PC20R-8 PC27R-8...
  • Page 80 P and spool upstream proportion to the area of opening of notch a of each , and pressure loss is generated between P spool. and P 10-62 PC20R-8 PC27R-8...
  • Page 81 (=A) and oil flow to side receiving compensation is divided in a proportion more than area of opening of spool. Ratio of area S1 and S2 Valve Ratio Valve Ratio 0.98 Boom swing 0.98 Travel 1.00 Blade 0.98 Boom 0.95 Hammer 1.00 Bucket 1.00 Swing 0.95 10-63 PC20R-8 PC27R-8...
  • Page 82 . As a result, even if the other actuator is relieved, a cuit pressure P because of the balance of redu- pressure differential is created between P cing valve (1). , so more oil flows to actuator circuit A on this side (left side). 10-64 PC20R-8 PC27R-8...
  • Page 83 . In this way, the left and right travel actuator circuits are interconnected by the travel junction circuits, so if any difference occurs in the flow of oil to the left and right travel motors, the compensation is carried out to prevent any deviation in travel. 10-65 PC20R-8 PC27R-8...
  • Page 84 . Damper b is provided in the circuit to dampen any excessive characteristics in the opening or closing of the travel junction circuit if the spool is operated suddenly. 10-66 PC20R-8 PC27R-8...
  • Page 85 Gear pump RKP00641 OPERATION . The discharge pressure from the gear pump enter- ing chamber A acts on the bottom of valve (1). The gear pump discharge pressure is set to 29.5 bar (30 kg/cm 10-67 PC20R-8 PC27R-8...
  • Page 86 PAGE INTENTIONALLY LEFT BLANK 10-68 PC20R-8 PC27R-8...

  • Page 87: Swivel Joint

    G Port - From ST1 solenoid valve d. g Port - To travel motors (PS Port) (B Port) e. e Port - To blade cylinder (Head side) o. A Port - From control valve (B3 Port) 10-69 PC20R-8 PC27R-8...

  • Page 88: Swing Motor

    SWING MOTOR PC20R-8 RKP00940 a. T Port - To hydraulic tank SPECIFICATION b. B Port - From control valve (A1 Port) Displacement: 195 rev. A Port - From control valve (B1 Port) 1. Safety valve 10-70 PC20R-8 PC27R-8...
  • Page 89 12 - Bearing 4 - Valve plate 13 - Bearing 5 - Valve 14 - Pinion 6 - Valve housing 15 - Valve 7 - Pin 16 - Cartridge 8 - Balancing plate 17 - Spring 9 - Ball 10-71 PC20R-8 PC27R-8...
  • Page 90 PC27R-8 RKP01500 1. Valve plate 9. Check valve spring 2. Cylinder 10. Check valve 3. Piston 11. Plug 4. Disc 12. Cylinder 5. Shoe 13. Safety valve 6. Spring 7. Safety valve spring 8. Plug 10-72 PC20R-8 PC27R-8...
  • Page 91 Sezione A - A RKP01510 a. DB Port - To hydraulic tank b. A Port - From control valve (A1 port) M Port - To control valve (C port) d. B Port - From control valve (B1 port) 10-73 PC20R-8 PC27R-8...

  • Page 92: Travel Motor

    TRAVEL MOTOR B B B Section A - A Sezione A - A RKP01380 10-74 PC20R-8 PC27R-8...
  • Page 93 18. Spool return spring (travel increment) . Low speed: 18.00 cm /rev. 19. Counterbalance valve spring (travel increment) Swing speed: . High speed: PC20R-8: 2645 rpm PC27R-8: 3275 rpm . Low speed PC20R-8: 1323 rpm PC27R-8: 1637 rpm 10-75 PC20R-8 PC27R-8...
  • Page 94 PAGE INTENTIONALLY LEFT BLANK 10-76 PC20R-8 PC27R-8...

  • Page 95: Cylinder

    7. Ring 11. Piston 4. Head 8. Spacer 12. Nut 9 10 RKP01460 1. Bushing (Head side) 5. Gasket 9. Piston 2. Bushing (Bottom side) 6. Cylinder 10. Nut 3. Rod 7. Piston gasket 4. Head 8. Ring 10-77 PC20R-8 PC27R-8...
  • Page 96 3. Rod 7. Piston gasket 4. Head 8. Ring BOOM SWING RKP01440 1. Bushing (Head side) 5. Gasket 9. Piston 2. Bushing (Bottom side) 6. Cylinder 10. Nut 3. Rod 7. Piston gasket 4. Head 8. Ring 10-78 PC20R-8 PC27R-8...
  • Page 97 PC27R-8 Boom Cylinder Bucket Boom swing Blade with canopy with cabin Piston rod diameter Cylinder inside diameter Piston stroke Max. cylinder length 1417 1385 1330 1215 1299 Min. cylinder length Piston nut width across flat 10-79 PC20R-8 PC27R-8...
  • Page 98 PAGE INTENTIONALLY LEFT BLANK 10-80 PC20R-8 PC27R-8...

  • Page 99: Accumulator

    B. . If the oil under in line B falls below the maximum calibration pressure (even after intensive use), the rubber bag (1) will expand due to pressure from the nitrogen it. 10-81 PC20R-8 PC27R-8...

  • Page 100: Ppc Valve

    T Port - To ST1 solenoid valve (T port) e. T Port - To control valve (TS port) P Port - From ST1 solenoid valve (A port) P Port - From ST1 solenoid valve (A port) 10-82 PC20R-8 PC27R-8...
  • Page 101 Sezione C - C Section E - E Sezione E - E RKP01080 1. Spool 7. Joint 2. Adjusting spring (internal) 8. Cover 3. Return spring (external) 9. Pin 4. Plunger 10. Body 5. Disc 6. Nut 10-83 PC20R-8 PC27R-8...
  • Page 102 A (the same as FIG. 2 RKP01101 pressure at port P1) and the force of the control valve spool return spring are balanced. (Fig. 2) 10-84 PC20R-8 PC27R-8...
  • Page 103 A from port P1, and pushes the control valve spool. The oil returning from chamber B passes from port P2 through fine control hole f' and flows to drain chamber D. (Fig. 4) Control valve FIG. 4 RKP01121 10-85 PC20R-8 PC27R-8...

  • Page 104: Ppc Valve

    2. Adjusting spring (internal) P1 Port - To control valve (P port) 3. Return spring (external) d. P2 Port - To control valve (P port) 4. Plunger 5. Lever 6. Cover 7. Stopper 8. Body 9. Filter (100 mesh) 10-86 PC20R-8 PC27R-8...
  • Page 105 Control valve where the pressure in chamber A (the same as pressure at port P1) and the force of the control FIG. 2 RKP00981 valve spool return spring are balanced. (Fig. 2) 10-87 PC20R-8 PC27R-8...
  • Page 106 A from port P1, and pushes the control valve spool. The oil returning from chamber B passes from port P2 through fine control hole f' and flows to drain chamber D. (Fig. 4) Control valve FIG. 4 RKP01001 10-88 PC20R-8 PC27R-8...
  • Page 107 A Port - To PPC valve (P port) 2. Y1 Travel increment B Port - To swivel joint (G port) d. P Port - From control valve (P port) e. T Port - To hydraulic tank 10-89 PC20R-8 PC27R-8...
  • Page 108 PAGE INTENTIONALLY LEFT BLANK 10-90 PC20R-8 PC27R-8...
  • Page 109 2-WAYS CONNECTOR DEUTSCH (NOT USED) LEVEL INDICATOR X10 4-WAYS CONNECTOR OIL LEVEL WARNING LIGHT COUNTER-HOUR X11 4-WAYS CONNECTOR (NOT USED) INSTRUMENT PANEL X28 1-WAY CONNECTOR POSITION LIGHT WARNING LIGHT PRE-HEATER X-K1 4-WAYS CONNECTOR (NOT USED) WATER TEMPERATURE WATER 10-91 PC20R-8 PC27R-8...
  • Page 110 PAGE INTENTIONALLY LEFT BLANK 10-92 PC20R-8 PC27R-8...
  • Page 111 LIGHT SWITCH X16 4-WAYS CONNECTOR FU11 FUSE 7.5A (WORKING BEAM) PUSH-BUTTON X17 2-WAYS CONNECTOR HAMMER SOLENOID VALVE X19 5-WAYS CONNECTOR MARK PUSH-BUTTON X20 2-WAYS CONNECTOR DEUTSCH N.A. PUSH-BUTTON X21 2-WAYS CONNECTOR DEUTSCH S10 PRESSOSTAT X23 3-WAYS CONNECTOR DEUTSCH 10-93 PC20R-8 PC27R-8...
  • Page 112 PAGE INTENTIONALLY LEFT BLANK 10-94 PC20R-8 PC27R-8...
  • Page 113 X24 2-WAYS CONNECTOR DEUTSCH S12 ARM REST MICRO X26 4-WAYS CONNECTOR S13 SERVOCONTROL MICRO X27 3-WAYS CONNECTOR S14 SWITCH A VENTILATOR XS11 CONNECTOR FOR SWITCH MERIT SERVOCONTROL SOLENOID VALVE DIODE XS14 CONNECTOR FOR SWITCH MERIT SERVOCONTROL SOLENOID VALVE 10-95 PC20R-8 PC27R-8...
  • Page 114 10-96 PC20R-8 PC27R-8...
  • Page 115 GRUPPO...
  • Page 117 Adjustment of valve clearance ...... . 26 Regulation of the PC valve (PC20R-8) ....46 Normal or standard tech .
  • Page 118 Engine oil Whole speed range ëC Max. 120 Max. 120 temperature Fuel injection Before top dead center (BTDC) degrees 14w1 14w1 timing Deflection when Fan-belt tension pressed with finger 10 ± 15 Ð force of approx. 6 Kg 20-2 PC20R-8 PC27R-8...
  • Page 119 1050 1025 ± 1075 2600 Ð Max. 0.5 Max. 1.0 0.20 Ð 0.20 Ð 31w1 25w1 (250) (250) Ð Ð ±0.5 Ð Min. 1.0 Ð Ð Ð Max. 120 Max. 120 14w1 14w1 10 ± 15 Ð 20-3 PC20R-8 PC27R-8...
  • Page 120 17 ± 23 pedal Swing LH Travel control Forward Neutral 90 ± 110 lever Backward Accelerator lever Min. Ð Max. 160 ± 200 Work equipment, Max. 5 Max. 8 swing Play of control lever Travel Max. 10 Max. 15 20-4 PC20R-8 PC27R-8...
  • Page 121 2575 ± 2675 < < 60 ± 80 60 ± 80 60 ± 80 60 ± 80 40 ± 60 17 ± 23 90 ± 110 160 ± 200 Max. 5 Max. 8 Max. 10 Max. 15 20-5 PC20R-8 PC27R-8...
  • Page 122 Relieve pressure on swing motor Hydraulic oil temperature: All levers at HOLD Max. 35 Max. 35 45 ± 55ëC LS differential Engine speed: max. pressure Differential pressure= Travel rotating freely, pump delivery travel lever at half-way pressure ± LS pressure position 20-6 PC20R-8 PC27R-8...
  • Page 123 1.7 ± 2.3 1.7 ± 2.3 1.7 ± 2.3 1.7 ± 2.3 7.0 ± 9.0 2.5 ± 3.5 1.7 ± 2.3 1.2 ± 1.8 1.0 ± 1.4 Max. 35 Max. 35 Max. 35 Max. 35 20-7 PC20R-8 PC27R-8...
  • Page 124 Max. 210 Hydraulic drift of swing (75ë) (Max. 90ë) (Degree) Load in bucket: PC20R-8: 126 kg PC27R-8: 135 kg Engine switched off Hydraulic oil temperature: 45 ± 55ëC Park the machine on a 15ë slope and posi- tion the boom at 135ë with respect to the ground surface.
  • Page 125 . FOR THE MACHINE PC27R-8 Standard Permissible value value 20ë Max. 24ë (52) (Max. 62.3) 1.7 ± 2.1 3.1 ± 3.9 34.0 Max. 38.0 194.7 Max. 233.7 (75ë) (Max. 90ë) 20-9 PC20R-8 PC27R-8...
  • Page 126 Engine speed: high idling Hydraulic oil temperature: 45 ± 55ëC Travel deviation Max. 500 Max. 550 Travel 20 metres on flat ground and mea- sure the deviation. The surface must be firm and horizontal. RKP01830 Measure dimension «X» 20-10 PC20R-8 PC27R-8...
  • Page 127 . FOR THE MACHINE PC27R-8 Standard Permissible value value Max. 1.0 30.0 24 ± 36 15.0 12 ± 18 33.0 29 ± 37 16.0 14 ± 18 Max. 500 Max. 550 20-11 PC20R-8 PC27R-8...
  • Page 128 Long arm Max. 300 Max. 350 RKP01860 Bucket: rated load: Short arm Max. 20 Max. 30 PC20R-8: 126 kg Boom cylinder PC27R-8: 135 kg (Retraction) In this position, measure ex- tension or retraction of each Max. 20 Max. 33 Long arm...
  • Page 129 Ð Max. 300 Max. 340 Max. 300 Max. 350 Max. 20 Max. 30 Max. 20 Max. 33 Max. 20 Max. 30 Max. 20 Max. 33 Max. 20 Max. 20 Max. 15 Max. 20 Max. 15 Max. 22 20-13 PC20R-8 PC27R-8...
  • Page 130 Max. 5 Engine speed: high idling Hydraulic oil temperature: 45 ± 55ëC Max. 5 Check leakages: on the cylinder on the side opposite to the one under pressure. H Check one cylinder at a time Bucket Max. 5 20-14 PC20R-8 PC27R-8...
  • Page 131 . FOR THE MACHINE PC27R-8 Standard Permissible value value Max. 20 Max. 30 Max. 5 Max. 5 Max. 5 20-15 PC20R-8 PC27R-8...
  • Page 132 Cylinder fully extended Hydraulic oil temperature: 45 ± 55ëC Measuring posture Blade 1.0 ± 1.4 Blade on the ground RKP01900 1.0 ± 1.4 Blade raised to Engine speed: high idling max. height Hydraulic oil temperature: 45 ± 55ëC 20-16 PC20R-8 PC27R-8...
  • Page 133 . FOR THE MACHINE PC27R-8 Standard Permissible value value 1.8 ± 2.8 1.8 ± 2.8 2.4 ± 3.6 2.4 ± 3.6 1.7 ± 2.7 1.7 ± 2.7 6.0 ± 8.0 6.0 ± 8.0 1.0 ± 1.4 1.0 ± 1.4 20-17 PC20R-8 PC27R-8...
  • Page 134 RKP01940 Engine speed: low idling Hydraulic oil temperature: 45 ± 55ëC Raise the blade to its max. height, then lower it. Measure the time that it takes to raise the machine after the blade touches the ground 20-18 PC20R-8 PC27R-8...
  • Page 135 . FOR THE MACHINE PC27R-8 Standard Permissible value value Max. 2 Max. 2 Max. 2 Max. 2 Max. 2 Max. 2 Max. 1 Max. 1 20-19 PC20R-8 PC27R-8...
  • Page 136 Permissible Check item Test condition Unit cation value value Theoretical flow 2.75 Motor speed 2600 Gear pump P2 Test pressure kg/cm Nominal capacity /min Hydraulic oil temperature: 45 ± 55 ëC Piston pump P1 See next page 20-20 PC20R-8 PC27R-8...
  • Page 137 Make delivery measurements with the engine running at a speed close to the test speed and then make a proportional calculation. Example: MEASUREMENT Engine speed: 2525 rpm Delivery: 42 /min PROPORTIONAL DELIVERY AT 2600 rpm (42x2600)/2525= 43.2 /min 20-21 PC20R-8 PC27R-8...
  • Page 138 Permissible Check item Test condition Unit cation value value Theoretical flow 3.44 Motor speed 2600 Gear pump P2 Test pressure kg/cm Nominal capacity /min Hydraulic oil temperature: 45 ± 55 ëC Piston pump P1 See next page 20-22 PC20R-8 PC27R-8...
  • Page 139 Make delivery measurements with the engine running at a speed close to the test speed and then make a proportional calculation. Example: MEASUREMENT Engine speed: 2525 rpm Delivery: 42 /min PROPORTIONAL DELIVERY AT 2600 rpm (42x2600)/2525= 43.2 /min 20-23 PC20R-8 PC27R-8...
  • Page 140 Scale 60 bar ATR800140 Compression gauge Scale 400 bar ATR800010 Compression gauge Scale 600 bar Hydraulic pressure Servocontrol kit ATR800200 Ð (Differential pressure) 3F3055600 Elbow P2 Pressure Included in the Track shoe tension 823001135 Grease nipple machine tool kit 20-24 PC20R-8 PC27R-8...

  • Page 141: Checking The Engine Speed

    Low idling without load (accelerator lever in "mini- mum" position). High idling without load (accelerator lever in "maximum" position). H Low idling: PC20R-8: 950w25 rpm PC27R-8: 1050w25 rpm H High idling: PC20R-8: 2780w25 rpm PC27R-8: 2785w25 rpm H If the minimum and maximum speeds do not fall...

  • Page 142: Adjustment Of Valve Clearance

    (8), and the O-rings (9). Thoroughly clean the contact surface on the cylinder heads. 2 - Replace the valve cover (8) and mount the O-rings (9) and the lock nuts (10). Lock nuts for cover: 25w3 Nm RKP06560 20-26 PC20R-8 PC27R-8...

  • Page 143: Measurement Of The Compression Pressure

    C1 or C2. If the speed does not correspond with the control value, check it against the diagram. RKP06370 H Compression value: Normal: PC20R-8: 32w1 kg/cm at 250 rpm PC27R-8: 31w1 kg/cm at 250 rpm PC20R...

  • Page 144: Control And Adjustment Of The Tension

    20 hours of operation. Crankshaft Puleggia pulley albero motore Screws fastening the alternator to the timing system cover: 45 ± 54 Nm RKP04800 Screws locking the support: 25 ± 32 Nm 20-28 PC20R-8 PC27R-8...

  • Page 145: Control And Adjustment Of The Injection Timing

    15° H In order to determine the degrees of intermediate 20° fuel injection timing, sub-divide the space be- 10° tween 10ë and 15ë. 15° H Normal fuel injection timing: 14w1ë 10° Notch RKPA0011 20-29 PC20R-8 PC27R-8...
  • Page 146 H After adjustment of the fuel injection timing: 8 - Connect the fuel delivery tubes (4) to the pump and replace the clamp (3). Delivery tube couplings: 31.85w2.45 Nm 9 - Bleed any air from the fuel circuit. 20-30 PC20R-8 PC27R-8...

  • Page 147: Control And Adjustment Of The Accelerator Stroke

    4 - Push the accelerator control lever (2) to the end of its stroke in the maximum position, until the lever (4) rests against the maximum-adjustment screw (6). 5 - Tighten the screw (6) until it is 0.1 mm from the lever (2) and then tighten the lock-nut. RKPA2201 20-31 PC20R-8 PC27R-8...

  • Page 148: Adjustment Of The Stroke Of The

    Before starting the engine to check the adjust- ment, make sure that the valve block spool re- turns to its neutral position each time the lever RKPB5505 (4) is released. 8 - Re-assemble the inner cover of the control valve com- partment (1). 20-32 PC20R-8 PC27R-8...

  • Page 149: Adjusting The Flexible Cables

    (4). 4 - Firmly tighten the nuts (2). RKPA3200 ALIGNAMENT ERROR BETWEEN LEVER IN NEUTRAL POSITION 0 ± 3 mm TRAVEL LEVERS BOOM SWING CONTROL PEDAL RKP06630 [ A= for canopy: 200 mm for cabin 220 mm 20-33 PC20R-8 PC27R-8...

  • Page 150: Control And Adjustment Of The Stroke Of The Travel Lever

    5 - Keeping the position of the lever (4), tighten the nut (2). 6 - Repeat the same operations for the other direction RKPA3280 and for the other lever. Before starting the engine, check that the levers and the valve block spools return to their neutral position. 20-34 PC20R-8 PC27R-8...

  • Page 151: Adjustment Of The Stroke Of The Boom Swing Command Pedal

    4 - Hold the pedal (5) in position and lock the nut (3). 5 - Repeat the same operations for the other working di- rection of the pedal. Before starting the engine, check that the pedal and control valve spools return to their neutral positions. RKPA3280 RKP06640 20-35 PC20R-8 PC27R-8...

  • Page 152: Adjustment Of The Ppc Valve Clearances

    4 push-rods (4). H During this adjustment, take care not to acti- vate any of the push-rods (4) individually. 4 - Secure this position by tightening the retaining nut (2) to the specific torque. Retaining nut: 113w15 Nm RKP06380 20-36 PC20R-8 PC27R-8...

  • Page 153: Adjustment Of The Rubber Pad And Safety Microswitch For Servo-Control Engagement

    4 - Tighten the microswitch (9) until it depresses the push-button by 3w0.5 mm. 5 - Put the console (6) into its 'safe' position and lock the nut (8). 6 - Connect the connectors (7) and replace the cover (1). RKPA3240 20-37 PC20R-8 PC27R-8...

  • Page 154: Control And Adjustment Of

    4 - Force the boom downwards until the track-shoe to be checked is completely raised. 5 - Measure the distance «A» in the following posi- tions: PC20R-8: Between the 2 sprocket track roller and the track shoe. PC27R-8: Between the 3 sprocket track roller and the track shoe.

  • Page 155: Control And Regulation Of The Pressures In The Hydraulic Circuits

    A4 - B4 Blade (Raise - Lower) A5 - B5 Arm (Close - Open) A6 - B6 RKP06460 Boom (Lower - Raise) A7 - B7 Bucket (Dump - Curl) A8 - B8 Hammer (Suction - Delivery) A9 - B9 20-39 PC20R-8 PC27R-8...
  • Page 156 "A" between the chassis and the sprocket wheel. To check the pressures of the swing, insert the swing lock. H Normal pressures: Working equipment and travel: 210 10 kg/cm (206 10 bar) Swing: 155 5 kg/cm (151.9 5 bar) RKPA3870 20-40 PC20R-8 PC27R-8...
  • Page 157 PPC valve to the end of its stroke and with the pressure stabilized. H Normal pressure: 215 5 kg/cm (211 5 bar) 6 - Restore the setting of the main relief valve. RKPA2270 20-41 PC20R-8 PC27R-8...
  • Page 158 To DECREASE pressure, turn in a COUN- TER-CLOCKWISE direction. 3 - Lock the nut (3) and replace the cap nut (2). H After the adjustments, check the setting of the safety valves following the same procedure used for the measurements. RKP04920 20-42 PC20R-8 PC27R-8...
  • Page 159 WISE direction. To DECREASE pressure, turn in a COUN- TER-CLOCKWISE direction. H Each turn of the adjusting screw (3) varies the pressure by about 100 bar (102 kg/cm 2 - Lock the nut (2). Nut: 8.8w1 Nm RKP06430 20-43 PC20R-8 PC27R-8...

  • Page 160: Control And Regulation Of The Ls Differential Pressure And Adjustment Of The Ls Valve (Pc20R-8)

    CONTROL AND REGULATION OF THE LS DIFFERENTIAL TESTING AND ADJUSTMENTS PRESSURE AND ADJUSTMENT OF THE LS VALVE (PC20R-8) CONTROL AND REGULATION OF THE LS DIFFERENTIAL PRESSURE AND ADJUSTMENT OF THE LS VALVE (PC20R-8) Test 1. Test method with differential pressure gauge E3 1 - Remove the plugs (1) and (2), mount the elbow E5 and mount two pressure adapters.
  • Page 161 CONTROL AND REGULATION OF THE LS DIFFERENTIAL TESTING AND ADJUSTMENTS PRESSURE AND ADJUSTMENT OF THE LS VALVE (PC20R-8) LS valve adjustment If the DP value is not the one indicated, adjust the LS valve (1) as follows: 1 - Disconnect the tube (2).

  • Page 162: Regulation Of The Pc Valve (Pc20R-8)

    TESTING AND ADJUSTMENTS REGULATION OF THE PC VALVE (PC20R-8) REGULATION OF THE PC VALVE (PC20R-8) H If the engine speed decreases when an increase in pressure or delivery is requested, or when the speed of the working equipment is low, even though the en-...

  • Page 163: Control And Regulation Of The Ls Differential Pressure And Adjustment Of The Ls Valve (Pc27R-8)

    4. Make a note of the value read. 7 - Subtract the LS pressure from the delivery pres- sure of the pump (P ) in order to obtain the differ- ential pressure value DP ± LS=DP H DP normal= 34.3 bar (35 kg/cm RKPA2370 20-47 PC20R-8 PC27R-8...
  • Page 164 RKPA2400 pressure by about 13 bar (13 kg/cm 3 - Lock the nut (3). Nut: 31w3.5 Nm H After the adjustment, check the setting of the LS valve (1) following the procedure used for the test. RKP06510 20-48 PC20R-8 PC27R-8...

  • Page 165: Regulation Of The Pc Valve (Pc27R-8)

    If the engine rpm suffer an abnormal drop, turn RKPA2410 the screw (3) in a COUNTER-CLOCKWISE direc- tion to DECREASE the torque absorption. 3 - After adjustment, tighten the check-nut (2). RKP06500 20-49 PC20R-8 PC27R-8...

  • Page 166: Control And Regulation Of The Servo-Control

    To INCREASE pressure, rotate in a CLOCK- WISE direction. To DECREASE pressure, rotate in a COUN- TER-CLOCKWISE direction. H Each turn of the screw (5) varies the pressure by 56 kg/cm (55 bar). 2 - Lock the nut (4). Nut: 22w2.5 Nm RKP06420 20-50 PC20R-8 PC27R-8...

  • Page 167: Elimination Of Residual Pressures - Pressurisation

    2 - Stop the engine, loosen the tank cap (1) and then close it again. H This operation lets air into the tank when the level of the remaining oil is at minimum. RKP04720 3 - Start the engine and lower the working equipment to the ground. 20-51 PC20R-8 PC27R-8...

  • Page 168: Bleeding Air From The Hydraulic Circuits

    2 - Pour hydraulic oil through the hole until the entire casing is full. 3 - Replace the cap (1). Cap: PC20R-8: 16.7w2.5 Nm PC27R-8: 63.7w4.9 Nm H After filling the casing, start the engine and al- low it to run at low idling for about 10 minutes before proceding to bleed the air from the cir- cuits.
  • Page 169 H This method must be used for all the optional working equipment, unless otherwise indi- cated. RKP04690 1 - Each time an item of optional working equipment is installed, operate the equipment repeatedly, with the engine at low idling, until all air has been completely eliminated. 20-53 PC20R-8 PC27R-8...

  • Page 170: Control Of Hydraulic Drifts - Analysis Of The Causes

    8 - Stop the engine and check the position of the boom for 15 minutes. If the boom moves downwards the drift is due to the cylinder gaskets. If the boom does not move, the drift is due to the control valve. RKP04990 20-54 PC20R-8 PC27R-8...
  • Page 171 6 - Stop the engine and check the position of the arm for 15 minutes. If the arm moves downwards the drift is due to the cylinder gaskets. If the arm does not move, the drift is due to the control valve. RKP05010 20-55 PC20R-8 PC27R-8...
  • Page 172 6 - Stop the engine and check the position of the bucket for 15 minutes. If the bucket makes an opening movement the drift is due to the cylinder gaskets. If the bucket does not move, the drift is due to the control valve. 50 cm RKP05030 20-56 PC20R-8 PC27R-8...
  • Page 173 7 - Stop the engine and check the position of the boom for 15 minutes. If the boom makes a rotating movement the drift is due to the cylinder gaskets. If the boom does not move, the drift is due to the control valve. RKP05050 20-57 PC20R-8 PC27R-8...
  • Page 174 1 - Position the machine with boom, arm and bucket raised as in the figure and with the revolving frame turned 135ë to the left. 2 - Stop the engine and release the residual hydrau- lic pressures. RKP04980 20-58 PC20R-8 PC27R-8...
  • Page 175 If the revolving frame rotates the drift is due to either the safety valve or the control valve. RKPA2530 H To establish the cause of the drift, install a PC27R-8 new safety valve. RKPA2301 RKP05050 20-59 PC20R-8 PC27R-8...

  • Page 176: Checking For Any Leakages Inside The Working

    4 - After 30 seconds, wait for a full minute to collect any leakages from the free tube. POSITION FOR THE ARM AND BUCKET TEST RKP04710 DELIVERY TUBE HEAD BOTTOM SIDE SIDE MAXIMUM PRESSURE RKP04751 20-60 PC20R-8 PC27R-8...
  • Page 177 6 - Bring the motor back to low speed and repeat the reading for the other direction of swing. 7 - Check that the average between the two readings falls within normal values (See «TECHNICAL DATA»). 8 - Re-assemble the hydraulic drainage circuit. RKPA2302 20-61 PC20R-8 PC27R-8...

  • Page 178: Methods For Testing For Leakages Inside The Swivel Joint

    Travel motor to the left - Forward Descent Passage not used Blade cylinder base side - Descent Blade cylinder, head side - Rise The symbols correspond to the symbols stamped onto the input and output ports of the swivel joint. 20-62 PC20R-8 PC27R-8...
  • Page 179 If oil leaks out of one of the two tubes of the tested actuators (adjacent lines), it means that there is a leakage of the intermediate gasket be- tween the high pressure line and the adja- cent line. RKP04761 20-63 PC20R-8 PC27R-8...
  • Page 180 TESTING AND ADJUSTMENTS 20-64 PC20R-8 PC27R-8...
  • Page 181 GRUPPO...
  • Page 183 Installation......... . 47 Installation ......... 24 30-1 PC20R-8 PC27R-8...
  • Page 184 Installation ......... 79 Installation......... 59 30-2 PC20R-8 PC27R-8...

  • Page 185: How To Read The Manual

    OF OIL OR LIQUIDS TO BE INTRODUCED», «SCREW LOCKING MATERIAL, SEALANTS AND LUBRICA- TION», «LUBRICATING GREASE». NOTE If no symbol is indicated, the values to be used are those given in the introductory sections of this manual. 30-3 PC20R-8 PC27R-8...

  • Page 186: Precautions To Be Taken

    H For details, see «20. TESTING AND ADJUSTMENTS». After having re-assembled cylinder joints or cylinders, or work equipment articulations, lubricate thoroughly. 30-4 PC20R-8 PC27R-8...

  • Page 187: Special Tools

    Gauge for cylinder é 50 Gauge for cylinder é 55 Gauging piston gasket ATR200990 Gauge for cylinder é 60 ATR201000 Gauge for cylinder é 70 Bushing for piston rod é 30 Mounting head Bushing for piston rod ATR201150 é 35 30-5 PC20R-8 PC27R-8...
  • Page 188 Nature of work Symbol Code Description Q.ty Notes Bushing for piston é 50 Bushing for piston é 55 Disassembly - assembly Assembling cylinders piston - cylinder ATR201190 Bushing for piston é 60 ATR201200 Bushing for piston é 70 30-6 PC20R-8 PC27R-8...

  • Page 189: Removal

    Screw: ........Nm 30-7 PC20R-8 PC27R-8...

  • Page 190: Removal

    6 - Free the pulley (8) from the fan-belt and remove alter- nator (9). RKPA2580 INSTALLATION OF THE ALTERNATOR To install, reverse the removal procedure. H Adjust the tension of the fan belt. (For details, see «20. CONTROLS AND ADJUSTMENTS»). 30-8 PC20R-8 PC27R-8...

  • Page 191: Installation

    H Before removing pump driving gear, mark posi- tion compared to idling gear. H For removal, use a puller (X1) and tighten its screws (X2) directly in the gear (10). H During removal be careful not let key drop (11) in the housing. RKP06390 30-9 PC20R-8 PC27R-8...

  • Page 192: Installation

    Nuts:........Nm Pump lock nuts: 25.5 Nm 1 - Check fuel injection timing. (For details, see «20. CONTROLS AND ADJUST- MENTS»). 30-10 PC20R-8 PC27R-8...

  • Page 193: Nozzle Holder

    RKPA2630 3 - Loosen nuts (5) and remove clips (6). 4 - Remove the complete injection nozzles. RKPA2640 INSTALLATION OF THE NOZZLE HOLDER To install, reverse the removal procedure. High-pressure pipe union: 31.85w2.45 Nm Nuts: 7.84w0.98 Nm 30-11 PC20R-8 PC27R-8...

  • Page 194: Water Coolant Pump

    RKPB6070 4 - Loosen the screws (9), remove the cooling fan (10) and the spacer (11). Take out the fan-cooling con- veyor (8). Loosen the alternator drive belt and disengage the pulley of the water pump. RKP06541 30-12 PC20R-8 PC27R-8...

  • Page 195: Installation

    Fan screws: ......Nm H Check the gaskets: Pump screws: ......Nm 30-13 PC20R-8 PC27R-8...
  • Page 196 7 - Remove the valves cover (11). RKPA2631 8 - Remove the rocker-arm shaft (12). H Loosen the lock nuts and unscrew the valve tap- pets by 2-3 turns. 9 - Take out the rocker-arm control rods (13). RKP06400 30-14 PC20R-8 PC27R-8...

  • Page 197: Cylinder Head

    H Raise the cylinder head, keeping it horizontal, and place it on the gasket without shifting anything. H Lubricate the screw-threadings with engine oil. H Tighten the screws in the sequence indicated. (See figure). Intake side Cylinder head screws: 68.6w1.96 Nm RKP05141 30-15 PC20R-8 PC27R-8...

  • Page 198: Removal

    RKPA2730 INSTALLATION OF THE ENGINE HOOD To install, reverse the removal procedure. H Check the alignment of the outside edges, the center- ing and the adjustment of the closing mechanism (4). RKPA2740 30-16 PC20R-8 PC27R-8...

  • Page 199: Installation

    2 - Loosen and remove the screws (2) and (3). 3 - Remove the canopy. Canopy: 73 kg RKPA2750 INSTALLATION OF CANOPY To install, reverse the removal procedure. Screw (2): 180 Nm Screw (3): 67 Nm RKPA2760 RKPA2770 30-17 PC20R-8 PC27R-8...
  • Page 200 3 - Attach the cab (4) to some hoisting tackle. 4 - Loosen the cab lock crews (N . 10). 5 - Take out the cab (4). Cab: 208 kg INSTALLATION OF CAB To install, reverse the removal procedure. Screw: 67 Nm RKPA279 0 30-18 PC20R-8 PC27R-8...
  • Page 201 H Take care not to take out completely the tube (6) and (7) from engine box. 8 - Disconnect the connector (11). RKPB5530 9 - Loosen the clips (12) and take out the tubes (6) and (7). 10 - Remove the heating fan (13). RKPA2830 30-19 PC20R-8 PC27R-8...

  • Page 202: Heating Fan

    1 - Make sure that the heating cock is fully open. 2 - Fill up the coolant circuit. Coolant: approx. 4 3 - Start the engine to circulate the coolant and check that there are no leaks. 4 - Stop the engine and top up the level. 30-20 PC20R-8 PC27R-8...

  • Page 203: Removal

    4 - Attach the counterweight (5) to some hoisting tackle, remove the screws, and pull out the counterweight (5). INSTALLATION OF THE COUNTERWEIGHT RKPA2840 To install, reverse the removal procedure. Lateral counterweight screws: 180 Nm Counterweight screws: Loctite 262 Counterweight screws: 300 Nm 30-21 PC20R-8 PC27R-8...

  • Page 204: Removal

    Fuel tank: 14 kg RKPA2870 INSTALLATION OF THE FUEL TANK To install, reverse the removal procedure. 1 - Fill up the tank. Tank: max. 35 2 - Bleed the air from the fuel pipes and start the engine. 30-22 PC20R-8 PC27R-8...

  • Page 205: Removal

    3 - Remove the pipe (6) from oil cooler and exhaust pipe (8). RKPB6090 4 - Remove the exhaust pipe (8) (PC20R-8 N .2 - PC27R-8 . 3) in the tank. H Mark the tubes to avoid exchanging them during re-installation.

  • Page 206: Hydraulic Oil Tank

    Counterweight screws: 180 Nm 2 - Start the engine at low idling to circulate the oil throughout the system. 3 - Pressurise the tank and bleed air from all circuits. (For details, see «20. CONTROLS AND ADJUST- MENTS»). 30-24 PC20R-8 PC27R-8...

  • Page 207: Removal

    3 - Disconnect pipe (5). RKPB6120 4 - Disconnect the delivery and drainage coolant pipes (6) and (7). RKPB6070 5 - Loosen the lower screws (8) and upper screws (9) and remove them. RKPB6130 30-25 PC20R-8 PC27R-8...
  • Page 208 H Make sure that the heating cock is fully open in the cab version. 2 - Pressurise the tank and bleed air. (For details, see «20. CONTROLS AND ADJUSTMENTS»). 3 - Stop the engine, check the level and, if necessary, top it up. 30-26 PC20R-8 PC27R-8...

  • Page 209: Removal

    6 - Disconnect the accelerator cable (16) and its sleeve. 7 - Disconnect the clips (9), the connector (10), the pre- heating cable (11), the temperature sensor cables (12), the oil pressure indicator (13) and the grounding plait (14). 13 14 RKZA2940 30-27 PC20R-8 PC27R-8...
  • Page 210 11 - Attach the fixed hood (19) to hoisting tackle and take out it. H Check that the motor swings completely free while it is being raised, and that no other parts are damaged. Fixed hood: 60 kg RKPA2960 12 - Remove the exhaust terminal (20). 30-28 PC20R-8 PC27R-8...

  • Page 211: Engine-Pump Group

    4 - Stop the engine, check the levels and, if necessary, top them up. 5 - Bleed air from the hydraulic circuits and pressurise the tank. (For details, see «20. CONTROLS AND AD- JUSTMENTS»). 30-29 PC20R-8 PC27R-8...

  • Page 212: Removal

    (4) and the suction tube (6). 5 - Attach the pump to some hoisting tackle and apply a slight tension to the cable. 6 - Loosen the screws (7) (PC20R-8 në 2 - PC27R-8 në 4) and remove the pump (8). Pump: PC20R-8 19 kg...

  • Page 213: Removal

    3 - Stop the engine, check the oil level and, if necessary, top it up. 4 - Bleed the air from the hydraulic circuits and pressur- ise the tank. (For details, see «20. CONTROLS AND ADJUSTMENTS»). 30-31 PC20R-8 PC27R-8...

  • Page 214: Removal

    2 - Loosen the screw (5) and take out the general fuse (6). 3 - Loosen the lock screws (N . 6) and take out the cover (7). RKPA2424 INSTALLATION OF THE LATERAL LOWER COVER To install, reverse the removal procedure. RKPA3020 30-32 PC20R-8 PC27R-8...

  • Page 215: Removal

    CONTROL VALVE BOX COVER To install, reverse the removal procedure. 1 - Fixed the control block cylinder support and make sure that the travel control lever, blade control lever and boom swing control pedal are locked. RKPA3040 30-33 PC20R-8 PC27R-8...
  • Page 216 3 - Remove the floor mat (5) and the covers (6). RKPA3060 4 - Disconnect the lever command cable from the cables (7). 5 - Disconnect the cables (8) and (9) from travel control lever, from boom swing control pedal and from brack- RKPA3070 30-34 PC20R-8 PC27R-8...

  • Page 217: Installation

    3 - Pressurise the tank and bleed air from all circuits. (For details, see «20. CONTROLS AND ADJUST- MENTS»). H Adjust the travel control lever, blade control lever and boom swing control pedal stroke. (For detail, see 20. CONTROLS AND ADJUST- MENTS). 30-35 PC20R-8 PC27R-8...

  • Page 218: Left-Hand Ppc Valve (Arm-Bucket)

    H Check carefully the positions for re-connecting the tubes. Position White White Green Green Blue Blue If the couplings are removed from the PPC valves, make sure that the coupling with a filter is mounted on input P. RKPA3120 30-36 PC20R-8 PC27R-8...

  • Page 219: Right-Hand Ppc Valve (Boom-Bucket)

    H Check carefully the positions for re-connecting the tubes. Position White White Yellow Yellow If the couplings are removed from the PPC valves, make sure that the coupling with a filter is mounted on input P. RKPA3160 30-37 PC20R-8 PC27R-8...

  • Page 220: Servocontrol Solenoid Group

    H Plug the tubes to prevent entry of impurities. 4 - Take out the screws (7) and remove the solenoid group (8) complete with accumulator. RKPB5570 INSTALLATION OF THE SERVOCONTROL SOLENOID GROUP To install, reverse the removal procedure. 30-38 PC20R-8 PC27R-8...

  • Page 221: Platform

    4 - Disconnect (4) and (5) from EV solenoid valve (6). H Disconnect the connectors travel increment pedal control and the equipment PPC valve pipes. RKPB5572 5 - Disconnect the cables (8) and (9) of the travel motor command e boom swing. RKPA3071 30-39 PC20R-8 PC27R-8...
  • Page 222 11 - Only for cabin version. H Drain the coolant. Coolant: Approx.4 12 - Disconnect the return and delivery pipes (19) and (20) to the heating fan. H Plug the tubes to prevent entry of impurities. RKPA2812 30-40 PC20R-8 PC27R-8...
  • Page 223 H Adjust the travel control lever and boom swing control pedal stroke (For details, see «20. CONTROLS AND ADJUSTMENTS»). H Adjust accelerator control lever and blade control lever stroke (For details, see «20. CONTROLS AND ADJUSTMENTS»). Platform screws: 320 Nm 30-41 PC20R-8 PC27R-8...

  • Page 224: Removal

    1 - Start the engine to circulate the oil, bleed air from the lower circuits and check that tubes are leaktight. 2 - Stop the engine and check the level of the tank. 3 - Pressurise the tank. 30-42 PC20R-8 PC27R-8...
  • Page 225 (For details, see «REMOVAL OF THE SIDE LOWER RKPA2853 PANELS»). 3 - Disconnect the tubes (2) (N . 3) RKPA3380 4 - Remove the hose-clamp (3). RKPA3390 5 - Only for canopy version. Loosen the screws (4) and remove the cover (5). RKPA3331 30-43 PC20R-8 PC27R-8...

  • Page 226: Swing Machinery

    H Mark the tubes to avoid exchanging them during re-assembly. H Plug the tubes to prevent entry of impurities. 10 - Take out the screws (15) (N . 6) and remove the swing machinery (16). Swing machinery: 32 kg RKPA2303 30-44 PC20R-8 PC27R-8...
  • Page 227 3 - Stop the engine, check the oil hydraulic level and, if necessary, top it up. 4 - Bleed air from the hydraulic circuits and pressurise the tank. (For details, see «20. CONTROLS AND AD- JUSTMENTS»). 30-45 PC20R-8 PC27R-8...

  • Page 228: Removal

    H Adjust the length of the cables to balance the group. 13 - Loosen and remove the two turret screws (7) left in position for safety. 14 - Remove the revolving frame (8). Revolving frame: PC20R-8: 1000 kg PC27R-8: 1400 kg RKPA3430 30-46 PC20R-8 PC27R-8...
  • Page 229 4 - Bleed air from the hydraulic circuits. (For details, see «20. CONTROLS AND ADJUSTMENTS»). 5 - Stop the engine, check the levels and cooling circuit and eventually top them up. 6 - Pressurise the hydraulic oil tank. (For details, see «20. CONTROLS AND ADJUSTMENTS»). 30-47 PC20R-8 PC27R-8...

  • Page 230: Removal

    1 - Remove the evolving frame (For details, see «RE- MOVAL OF THE REVOLVING FRAME»). 2 - Take out the screws (1) that secure the swing circle (2). 3 - Remove the swing circle (2). Swing circle: PC20R-8: 25 kg PC27R-8: 33 kg RKPA3440 INSTALLATION OF THE SWING CIRCLE To install, reverse the removal procedure.

  • Page 231: Rubber Track Shoes

    4 - Insert three steel pipes into the track-shoe and then reverse the track-shoe until the first pipe is above the idler. 5 - Push the track-shoe (2) outwards and remove it. Track-shoe: PC20R-8: 88 kg PC27R-8: 117 kg Direction Steel tube...

  • Page 232: Steel Track-Shoes

    (4) and lay it on the ground. 5 - Push down with the boom in order to raise the lower track-frame and pull out the track-shoe (4). Track-shoe: PC20R-8: 159 kg PC27R-8: 172 kg RKP06650 INSTALLATION OF STEEL TRACK-SHOES To install, reverse the removal procedure.

  • Page 233: Sprocket Wheel

    4 - Take out the screws (1) and their washers. 5 - Remove the sprocket wheel (2). RKP05241 Sprocket wheel: 7 kg INSTALLATION OF THE SPROCKET WHEEL To install, reverse the removal procedure. Screws: Loctite 262 Screws: 120 Nm RKPA3460 30-51 PC20R-8 PC27R-8...

  • Page 234: Final Drive

    To install, reverse the removal procedure. Final drive screws: Loctite 262 Final drive screws: 120 Nm 1 - Start the engine and bleed air from the travel motors. (For details, see «20. CONTROLS AND ADJUST- MENTS»). RKPA2551 30-52 PC20R-8 PC27R-8...

  • Page 235: Installation

    2 - Pull the idler (2) and recoil spring (3) out of the lower track-frame (1). RKPA3480 RKPA3490 INSTALLATION OF IDLER AND RECOIL SPRING To install, reverse the removal procedure. H Restore tension to the track-shoe. (For details, see «20. CONTROLS AND ADJUSTMENTS). 30-53 PC20R-8 PC27R-8...

  • Page 236: Spring Recoil And Thrust Cylinder Groups

    2 - Take out the piston (11) out of the cylinder. 3 - Take out the snap ring (12), the gasket (13), the spacer (14), the anti-extrusion ring (15), and the O- ring (16). Assembly To re-assemble, reverse the dismantling procedure. RKP06250 30-54 PC20R-8 PC27R-8...

  • Page 237: Idler

    4 - Remove the bushings (8). ASSEMBLY OF THE IDLER To re-assemble, reverse the dismantling procedure. H Use a press for the final assembly. 1 - Fill up with oil. Oil: 70 cc. 2 - Tightening the cap (1). RKP06260 30-55 PC20R-8 PC27R-8...

  • Page 238: Track Rollers

    H Slowly lower the lower track-frame (2) until the rollers (5) rest fully on the track-shoe, then finish tightening the screws (4). Roller screws: Loctite 262 Roller screws: 170 Nm H Restore the track-shoe tension. (For details, see RKPA3272 «20. CONTROLS AND ADJUSTMENTS»). 30-56 PC20R-8 PC27R-8...

  • Page 239: Boom Cylinder

    7 - Disconnect the tubes (6) and plug them. Also plug the holes in the cylinder to prevent entry of impurities. 9 - Remove the pin (7). RKPA3530 10 - Remove the cylinder (4). Boom cylinder: PC20R-8: 20 kg PC27R-8: 25 kg 30-57 PC20R-8 PC27R-8...

  • Page 240: Installation

    Internal bushings: ASL800050 1 - Start the engine and bleed the air from the cylinder. (For details, see «20. CONTROLS AND ADJUST- MENTS»). H After bleeding the air, check the level of oil in the tank. RKP06280 30-58 PC20R-8 PC27R-8...

  • Page 241: Arm Cylinder

    6 - Disconnect the tubes (4) and plug them. Also plug the holes in the cylinder to prevent the entry of impurities. 7 - Remove the pin (5). 8 - Remove the cylinder (1). Arm cylinder: PC20R-8: 20 kg PC27R-8: 28 kg RKPA3570 INSTALLATION OF THE ARM CYLINDER To install, reverse the removal procedure.

  • Page 242: Bucket Cylinder

    RKPA3600 6 - Put a sling round the cylinder (1). 7 - Remove the pin (5). 8 - Remove the cylinder (1). Bucket cylinder: PC20R-8: 11 kg PC27R-8: 12 kg INSTALLATION OF THE MAX.1mm BUCKET CYLINDER To install, reverse the removal procedure.
  • Page 243 H Disconnect first the negative terminal (±) and then the positive terminal (+). RKPA3411 7 - Disconnect the hoses (4) and plug them. Also plug the holes in the cylinder to prevent the entry of impu- rities. RKPA3630 30-61 PC20R-8 PC27R-8...

  • Page 244: Boom Swing Cylinder

    9 - Put a sling round the cylinder (10) and apply a slight tension to the cables. 10 - Take out the pin (11) and remove the cylinder (10). Boom swing cylinder: PC20R-8: 17 kg PC27R-8: 22 kg INSTALLATION OF THE...

  • Page 245: Removal

    Do not insert fingers in the holes to check alignment. Internal bushings: ASL800040 Start the engine and bleed the air from the cylinder. (For details, see «20. CONTROLS AND ADJUST- MENTS»). H After bleeding the air, check the oil level in the tank. 30-63 PC20R-8 PC27R-8...
  • Page 246 3 - Attach the special wrench C5 (adjusted to fit the cylin- der) to the head (3) and apply the dynamometric tool RKPA1400 4 - Unscrew the head (3) and extract it completely from the cylinder (2). RKPA1410 30-64 PC20R-8 PC27R-8...
  • Page 247 Boom Bucket Blade swing Model PC20R-8 PC27R-8 RKPA1430 10 - Take all the groups to pieces and remove all the seals, guard rings and guide rings. The seals, guard rings, and guide rings cannot be used again. 30-65 PC20R-8 PC27R-8...
  • Page 248 4 - Mount the O-ring (10), the anti-extrusion ring (11) and the O-ring (12) onto the cylinder head (3). 11 12 H Only for the boom cylinders. In sequence mount the anti-extrusion ring (17), the O-ring (18) and the 2nd anti-extrusion ring (17). RKZ05260 30-66 PC20R-8 PC27R-8...
  • Page 249 3 - Mount the pilot boss C10 adapted to the diameter onto the extremity of the piston rod. 4 - Slide the head (3) onto the piston rod (4). 5 - Remove the pilot boss C10 from the extremity of the piston rod. RKPA1490 30-67 PC20R-8 PC27R-8...
  • Page 250 REMOVAL AND INSTALLATION WORK EQUIPMENT CYLINDERS 6 - For the boom cylinders. Mount the brake bushing (19). H For the boom cylinder for the PC20R-8, also 19 20 mount the spacer (20). H Carefully check the orientation of the chamfer on the brake bushing.
  • Page 251 Boom Boom Bucket Blade swing Model PC20R-8 490w49 490w49 412w41 539w54 490w49 PC27R-8 490w49 490w49 412w41 539w54 490w49 12 - Mount the guard rings (1) on both sides of the cylin- der and the piston rod. RKPA1401 30-69 PC20R-8 PC27R-8...
  • Page 252 H Remove the fixed working beam clips. RKPA3670 9 - Put a sling around the equipment and apply a slight tension to the cables. H Adjust the length of the cables to balance the load. RKPA3680 30-70 PC20R-8 PC27R-8...

  • Page 253: Installation

    10 - Take away the pin (8). Remove the working equip- ment (9). H Check and make a note of the position of the shim. Working equipment: PC20R-8: 230 kg PC27R-8: 310 kg RKPA3690 INSTALLATION OF THE UPPER WORK EQUIPMENT MAX.1mm...
  • Page 254 2 - Take out the safety pin (5) and remove the pin (6) that connects the bucket (3) to the arm (7). 3 - Remove the bucket (3). RKPA3700 Bucket: PC20R-8: 40 kg PC27R-8: 50 kg INSTALLATION OF THE BUCKET To install, reverse the removal procedure.
  • Page 255 10 - Put a sling round the arm (10) and apply a slight ten- sion to the cables. 11 - Remove the pin (11) and take out the arm (10). Arm: PC20R-8: 35 kg PC27R-8: 50 kg Long arm: PC20R-8: 48 kg PC27R-8: 70 kg RKPA3740 30-73 PC20R-8 PC27R-8...
  • Page 256 Start the engine to circulate the oil and bleed the air MAX.1mm from the cylinder. RKP06340 H After bleeding the air, stop the engine and check the oil level in the tank. 30-74 PC20R-8 PC27R-8...

  • Page 257: Arm Assembly

    6 - Disconnect the delivery and exhaust equipment tubes (5). H Plug the tubes to prevent entry of impurities. 7 - Remove the pin (6) and take out the arm complete (7). Arm complete: PC20R-8: 115 kg PC27R-8: 160 kg RKPA3572 INSTALLATION OF THE ARM ASSEMBLY To install, reverse the removal procedure.

  • Page 258: Boom

    11 - Disconnect the hoses (6) (N . 10); plug the tubes to prevent entry of impurities. H Remove the wiring harness lock clips. 12 - Remove the pin (7) and remove the boom (2). Boom: PC20R-8: 80 kg PC27R-8: 126 kg RKPA3522 RKPA3780 30-76...
  • Page 259 Start the engine to circulate the oil and bleed the air from the cylinder. H After bleeding the air, stop the engine and check the oil level in the tank. 30-77 PC20R-8 PC27R-8...

  • Page 260: Boom Swing Support

    7 - Take out the bracket (5), remove the pin (6) and re- move the boom swing support (4). H Make a note of the position of the spacer (7) and the quantity of shims (8). Boom swing support: PC20R-8: 37 kg PC27R-8: 52 kg RKPA3830 INSTALLATION OF THE BOOM SWING SUPPORT To install, reverse the removal procedure.
  • Page 261 H Adjust the length of the cables to balance the group. 4 - Take out the pin (3). RKPA3800 5 - Remove the blade (4). Blade: PC20R-8: 100 kg PC27R-8: 137 kg INSTALLATION OF THE BLADE To install, reverse the removal procedure. Internal bushings: ASL800050...
  • Page 262 REMOVAL AND INSTALLATION 30-80 PC20R-8 PC27R-8...
  • Page 263 GRUPPO...
  • Page 265 Track shoe..........10 Work equipment ........30 40-1 PC20R-8 PC27R-8...

  • Page 266: Swing Circle

    SWING CIRCLE M The figure represent PC20R-8 130 Nm with Loctite 262 130 Nm with Loctite 262 RKP01530 Unit: mm Check item Criteria Remedy Standard clearance Clearance limit Axial bearing clearance Replace 40-2 PC20R-8 PC27R-8...

  • Page 267: Swing Machinery

    Clearance between 0.15 0.35 planetary gear and ring gear Replace Clearance between pinion and 0.30 0.70 swing circle teething Standard size Repair limit Size of pinion in the zone of contact with the sealing ring 49.5 0.19 40-3 PC20R-8 PC27R-8...

  • Page 268: Final Drive

    Backlash between Replace . 2 sun gear and 0.10 0.30 . 2 planetary gear Backlash between . 1 sun gear and 0.10 0.30 . 1 planetary gear Axial play of sun gear 0.5 ± 1.5 40-4 PC20R-8 PC27R-8...

  • Page 269: Sprocket

    344.3 ± 2 Wear at tips of Build up by 386.2 w1.5 sprocket teeth solder or replace Face width at tips of Ð sprocket teeth Face width at base +0.5 of sprocket teeth ± 1 40-5 PC20R-8 PC27R-8...

  • Page 270: Track Frame And Recoil Spring

    Idler support welding or replace Standard size Repair limit Free Preloaded Installed Free Installed length length load length load Recoil spring Replace Steel 206.4 2000 kg 241.8 1780 kg shoe Rubber 188.4 2860 kg 241.8 2625 kg shoe 40-6 PC20R-8 PC27R-8...

  • Page 271: Idler

    Width of tread Tolerance Standard Standard Clearance size clearance limit Clearance between Shaft Hole bushing and idler ± 0.025 + 0.142 0.105 ± Replace ± 0.064 + 0.080 0.206 Standard size Repair limixt Clearance between shaft and support 0.25 40-7 PC20R-8 PC27R-8...

  • Page 272: Carrier Roller

    CARRIER ROLLER PC27R-8 270 Nm RKP01401 Unit: mm Check item Criteria Remedy Standard size Repair limit Outer diameter of tread Replace Width of tread Ð Standard tolerance Clearance limit Axial play of roller Replace 0 ± 0.5 40-8 PC20R-8 PC27R-8...

  • Page 273: Track Roller

    Replace bushing Tolerance Standard Standard Interference size interference limit Interference between Shaft Hole roller and bushing + 0.073 + 0.039 0.021 0.085 + 0.048 Standard size Repair limit Axial play of roller Replace 0 ± 1.17 1.17 40-9 PC20R-8 PC27R-8...

  • Page 274: Track Shoe

    0.22 +0.12 + 0.05 Interference between +0.15 0.07 0.15 Replace pin and link +0.12 + 0.05 Interference between +0.02 0.02 0.12 master pin and link +0.07 + 0.05 Standard size Clearance limit Clearance between link joint faces 40-10 PC20R-8 PC27R-8...
  • Page 275 RUBBER SHOE Section A ± A Sezione A - A RKP01730 Unit: mm Check item Criteria Remedy Standard size Repair limit Wear of lug height Replace Wear of roller guard portion Wear of meshing portion of sprocket 40-11 PC20R-8 PC27R-8...

  • Page 276: Hydraulic Pump

    HYDRAULIC PUMP PC20R-8 30.4w2.9 Nm (3.1w0.3 kgm) 63.7w4.9 Nm (6.5w0.5 kgm) 57.9w6.9 Nm (5.9w0.7 kgm) View Z Vista Z RKP00061 40-12 PC20R-8 PC27R-8...
  • Page 277 PC27R-8 24.5w4.9 Nm 34.3w4.9 Nm (2.5w0.5 kgm) (3.5w0.5 kgm) 30.9w3.4 Nm (3.15w0.35 kgm) 69.7w1.0 Nm (7w1 kgm) 13.3w1.5 Nm 22.1w2.5 Nm 22.1w2.5 Nm (1.35w0.15 kgm) (2.25w0.25 kgm) (2.25w0.25 kgm) RKP01300 40-13 PC20R-8 PC27R-8...

  • Page 278: Control Valve

    CONTROL VALVE 11.3w1.5 Nm 31.9w2.5 Nm (1.15w0.15 kgm) (3.25w0.25 kgm) 11.3w1.5 Nm (1.15w0.15 kgm) 11.3w1.5 Nm (1.15w0.15 kgm) RKP01591 40-14 PC20R-8 PC27R-8...
  • Page 279 44.1w4.9 Nm (4.5w0.5 kgm) 44.1w4.9 Nm (4.5w0.5 kgm) Section A ± A Sezione A - A RKP01661 40-15 PC20R-8 PC27R-8...
  • Page 280 (1.84 kg) is found, replace the Spool return spring 98 N 78.4 N 46.2x20 25.4 Ð spring (boom, blade) (10 kg) (8 kg) Spool return spring 74.5 N 59.6 N 42x20 25.4 Ð (travel) (7.6 kg) (6.1 kg) 40-16 PC20R-8 PC27R-8...
  • Page 281 Cooler check valve spring 29.1x18.7 Ð (8.4 kg) (6.7 kg) Back pressure check 78.8 N 63 N 27.2x13.2 Ð valve spring (8.04 kg) (6.43 kg) 22.6 N 18.1 N Spool return spring (hammer) 29x17.5 28.5 Ð (2.3 kg) (1.84 kg) 40-17 PC20R-8 PC27R-8...
  • Page 282 Repair limit When damage or Free length Installed Installed Free Installed Check valve spring deformation x é.D. length load length load (arm) is found, replace the 1.96 N 1.57 N 21.9x5 15.8 Ð spring (0.2 kg) (0.16 kg) 40-18 PC20R-8 PC27R-8...
  • Page 283 é.D. length load length load deformation 1.96 N 1.57 N is found, 21.9x5 15.8 Ð (0.2 kg) (0.16 kg) replace the spring 83.3 N 66.6 N Pilot relief valve spring 32.4x10.4 Ð (8.5 kg) (6.8 kg) 40-19 PC20R-8 PC27R-8...

  • Page 284: Swivel Joint

    SWIVEL JOINT RKP00500 Unit: mm Check item Criteria Remedy Standard size Standard clearance Clearance limit Clearance between Replace rotor and shaft 0.055 ± 0.085 0.090 40-20 PC20R-8 PC27R-8...

  • Page 285: Swing Motor

    Sezione A - A Unit: mm Check item Criteria Remedy Standard size Repair limit When damage or Free length Installed Installed Free Installed deformation Suction valve spring x é.D. length load length load is found, replace the spring 40-21 PC20R-8 PC27R-8...
  • Page 286 30.1 15.7 2.3 N 25.5 1.6 N Standard clearance Clearance limit Clearance between piston and cylinder 0.03 ± 0.15 Replace Clearance between 0.01 ± 0.02 shoe and piston 40-22 PC20R-8 PC27R-8...
  • Page 287 PAGE INTENTIONALLY LEFT BLANK 40-23 PC20R-8 PC27R-8...

  • Page 288: Travel Motor

    TRAVEL MOTOR 63.7w5 Nm 34.3w5 Nm B B B 31.9w2.5 Nm 240w5 Nm 2.5w0.5 Nm 2.5w0.5 Nm 10w1 Nm Section A ± A Sezione A - A RKP01381 40-24 PC20R-8 PC27R-8...
  • Page 289 15.7 7.8 N 13.9 6.3 N is found, replace the Braking valve return spring 24.7 60 N 28.1 48 N spring Travel increment 29.5 68 N 34.7 54 N spool return spring 40-25 PC20R-8 PC27R-8...

  • Page 290: Ppc Valve (For Boom, Arm, Bucket, Swing)

    (1.0 kg) (0.8 kg) is found, replace the Centering spring 17.7 N 14.1 N spring 42.5x15.5 Ð (P1 and P2 port) (1.8 kg) (1.44 kg) 16.7 N 13.7 N Metering spring 26.5x9.2 24.9 Ð (1.7 kg) (1.4 kg) 40-26 PC20R-8 PC27R-8...

  • Page 291: Ppc Valve (For Hammer)

    Installed Installed Free Installed Centering spring x é.D. length load length load Replace 308.7 N 277.5 N 54.4x21.2 40.5 53.1 (31.5 kg) (28.3 kg) 24.5 N 21.6 N Metering spring 25.9x11.0 25.0 25.8 (2.5 kg) (2.2 kg) 40-27 PC20R-8 PC27R-8...

  • Page 292: Cylinder

    0.170 ± Bucket cylinder bottom ± 0.130 + 0.080 0.247 bushing and pin ± 0.010 + 0.134 0.082 ± Boom swing ± 0.050 + 0.072 0.184 ± 0.090 + 0.142 0.170 ± Blade ± 0.130 + 0.080 0.272 40-28 PC20R-8 PC27R-8...
  • Page 293 0.170 ± Bucket cylinder bottom ± 0.130 + 0.080 0.272 bushing and pin ± 0.010 + 0.134 0.082 ± Boom swing ± 0.050 + 0.072 0.184 ± 0.090 + 0.142 0.170 ± Blade ± 0.130 + 0.080 0.272 40-29 PC20R-8 PC27R-8...

  • Page 294: Work Equipment

    Sezione B - B Section A ± A Sezione A - A Section G ± G Section F ± F Sezione G - G Sezione F - F Section E ± E Sezione E - E RKP01750 40-30 PC20R-8 PC27R-8...
  • Page 295 + 0.117 0.170 ± and mounting pin of bucket ± 0.130 + 0.080 0.247 and link Clearance between bushing ± 0.090 + 0.145 0.170 ± and mounting pin of track ± 0.130 + 0.080 0.275 frame and blade 40-31 PC20R-8 PC27R-8...
  • Page 296 Sezione B - B Section A ± A Sezione A - A Section G ± G Section F ± F Sezione G - G Sezione F - F Section E ± E Sezione E - E RKP01740 40-32 PC20R-8 PC27R-8...
  • Page 297 + 0.142 0.170 ± and mounting pin of bucket ± 0.130 + 0.080 0.272 and link Clearance between bushing ± 0.090 + 0.142 0.170 ± and mounting pin of track ± 0.130 + 0.080 0.272 frame and blade 40-33 PC20R-8 PC27R-8...
  • Page 298 40-34 PC20R-8 PC27R-8...

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