Komatsu 27R8-7
Komatsu 27R8-7
Komatsu 27R8-7
40-28 PC15R-8
CONTENTS
PC27R-8 00-1
00-2 PC27R-8
The affected pages are indicated by the use of the
following marks. It is requested that necessary ac- Mark Indication Action required
tions be taken to these pages according to table
PC27R-8 00-2-1
Time of Time of Time of Time of Time of
Mark Page Mark Page Mark Page Mark Page Mark Page
revision revision revision revision revision
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30-69
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30-80
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40-9
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40-13
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40-16
40-17
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40-20
40-21
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40-23
40-24
40-25
40-26
40-27
40-28
40-29
40-30
00-2-2 PC27R-8
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for the safe operation of your machine.
The service and repair techniques recommended by Komatsu and describe in this manual are both ef-
fective and safe methods of operation. Some of these operations require the use of tools specially de-
signed by Komatsu for the purpose.
To prevent injury to workers, the symbols and are used to mark safety precautions in this man-
ual. The cautions accompanying these symbols should always be carefully followed. If any danger arises
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.
PC27R-8 00-3
13. Before starting work, remove the leads from the 24. Take sure when removing or installing tracks.
battery. Always remove the lead from the negative When removing the track, the track separates
( ± ) terminal first. suddenly, so never let anyone stand at either
end of the track.
14. When raising heavy components, use a hoist or
crane. Check that the wire rope, chains and hooks
are free from damage.
Always use lifting equipment which has ample ca-
pacity. Install the lifting equipment at the correct
places.
Use a hoist or crane and operate slowly to prevent
the component from hitting any other part.
Do not work with any part still raised by the hoist
or crane.
15. When removing covers which are under internal
pressure or under pressure from a spring, always
leave two bolts in position on opposite sides.
Slowly release the pressure, then slowly loosen
the bolts to remove.
16. When removing components, be careful not to
break or damage the wiring.
Damage wiring may cause electrical fires.
17. When removing piping, stop the fuel or oil from
spilling out. If any fuel or oil drips on to the floor,
wipe it up immediately.
Fuel or oil on the floor can cause you to slip, or
can even start fires.
18. As a general rule, do not use gasoline to wash
parts. In particular, use only the minimum of gaso-
line when washing electrical parts.
19. Be sure to assemble all parts again in their origi-
nal places. Replace any damage parts with new
parts.
When installing hoses and wires, be sure that
they will not be damaged by contact with other
parts when the machine is being operated.
20. When installing high pressure hoses, make sure
that they are not twisted. Damaged tubes are dan-
gerous, so be extremely careful when installing
tubes for high pressure circuits. Also, check that
connecting parts are correctly tightened.
21. When assembling or installing parts, always use
specified tightening torques.
When installing the parts which vibrate violently or
rotate at high speed, be particulary careful to
check that they are correctly installed.
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 PC27R-8
FOREWORD
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 distributor for the latest information.
PC27R-8 00-5
HOW TO READ THE SHOP MANUAL
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 RE-
VISED PAGES between the title page and SAFETY
page.
00-6 PC27R-8
HOISTING INSTRUCTIONS
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
PC27R-8 00-7
STANDARD TIGHTENING TORQUE
The following charts give the stardard tightening torques of bolts and nuts. Exceptions are given in sections of «Dis-
assembly 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 (0.737 lb.ft.)
00-8 PC27R-8
STANDARD TIGHTENING TORQUE
Sealing
Superficie surface
di tenuta
PC27R-8 00-9
COATING MATERIALS
COATING MATERIALS
The recommended coating materials prescribed in Komatsu Shop Manuals are listed below:
00-10 PC27R-8
ELECTRIC WIRE CODE
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
PC27R-8 00-11
WEIGHT TABLE
This weight table is a guide for use when transporting or handling components.
Unit: kg (lb.)
00-12 PC27R-8
TABLE OF OIL AND COOLANT QUANTITIES
AMBIENT TEMPERATURE CAPACITY
KIND OF ±30 ±20 ±10 0 10 20 30 40 50ëC
RESERVOIR
FLUID ±22 ± 4 14 32 50 58 85 104 122ëF 1st filling Change
SAE 10W
SAE 20W-20
SAE 30
OIL 5.2 , 5.2 ,
Engine oil pan SAE 40
. API CD (1.374 US.gall) (1.374 US.gall)
SAE 10W-30
SAE 15W-30
SAE 15W-40
OIL 48 , 29 ,
Hydraulic system SAE 10W
. API CD (12.7 US.gall) (7.66 US.gall)
Fuel
] 35 ,
FUEL Ð
tank ASTM D975 N. 2 (9.3 US.gall)
WATER+ 4,
Ð
ANTI-FREEZE (1.1 US.gall)
Engine coolant 4,
WATER Ð
system (1.1 US.gall)
PERMANENT 4,
Ð
LIQUID (1.1 US.gall)
] ASTM D975 N. 1
PC27R-8 00-13
PAGE INTENTIONALLY
LEFT BLANK
GROUP 10
40-28 PC15R-8
STRUCTURE AND FUNCTION
PC27R-8 10-1
POWER TRAIN
4 5 6 1 7
10
RKP01520
10-2 PC27R-8
SWING CIRCLE
3
4
Section A -- A
Sezione A A
1 2
3
4
5
Sezione
SectionB B
-B-B S
B
B
A
A
RKP01360
1. Outer race
2. Upper seal
3. Ball bearing
4. Inner race
5. Lower seal
PC27R-8 10-3
SWING MACHINERY
6
5
7
4
8
3
2
10
11
RKP01490
10-4 PC27R-8
FINAL DRIVE
1 2 3
9 8 7 RKP01370
1. Crankcase SPECIFICATIONS
2. No. 2 reduction gear Reduction ratio: 1 ± 53
3. No. 1 reduction gear
4. Cover
5. No. 1 sun gear
6. Oil drainage plug
7. No. 1 planetary gear
8. No. 2 sun gear (Z=16)
9. Housing
PC27R-8 10-5
TRACK FRAME
1 2 3 4 5
8 7 6
RKP01670
1. Idler 5. Sprocket
2. Track frame 6. Track roller
3. Sliding plate 7. Recoil spring
4. Travel motor 8. Track shoe
10-6 PC27R-8
RECOIL SPRING
1 2 3 4 5 6
A A
7 3 4
SectionAA- -AA
Sezione RKP01680
1. Idler 6. Nut
2. Support 7. Nipple
3. Cylinder
4. Rod
5. Recoil spring
PC27R-8 10-7
CARRIER ROLLER
7 1 2
4 3
RKP01400
1. Bearing 5. Cover
2. Gasket 6. Seal ring
3. Shaft 7. Roller
4. Spacer
TRACK ROLLER
1 2 3
4
RKP01410
1. Roller 4. Shoulder
2. Shaft 5. Seal ring
3. Bushing
10-8 PC27R-8
STEEL SHOE
4 5
3 2
RKP02010
1. Bushing SPECIFICATIONS
2. Pin
Width: 300 mm (11.82 in.)
3. Master housing
Pitch: 101.6 mm (4 in.)
4. Master pin
5. Cotter pin
6. Link
7. Shoe
PC27R-8 10-9
PAGE INTENTIONALLY
LEFT BLANK
10-10 PC27R-8
HYDRAULIC SYSTEM
7
4
1. Bucket cylinder
2. Arm cylinder
3. Boom swing cylinder
4. Control valve
8 5. R.H. PPC valve
6. Hydraulic tank
3
7. Hydraulic oil cooler
8. L.H. PPC valve
9. Hydraulic pump
2
10. Final drive
11. Servocontrol feed unit
9 12. Swivel joint
13. Blade cylinder
14. Swing motor
15. Boom cylinder
1 15
10
11
14
12
13
RKP03660
PC27R-8 10-11
PAGE INTENTIONALLY
LEFT BLANK
10-12 PC27R-8
HYDRAULIC CIRCUIT DIAGRAM
Reverse
DB
Swivel T2
joint
Right
P1
R/G
Left
G
F P2
A
Swing motor Forwards
C
240 o+5 Kg/cm2 H
D
Reverse
B
B M A P1
E
R/G
P2
T1
Forwards
Ps
P2 T B9 A9 PB9 B8 A8 PB8 B7 A7 PB7 B6 A6 PB6 B5 A5 B4 A4 B3 A3 B2 A2 B1 A1 PB1 LS
L.H. travel motor
30 Kg/cm2
Blade cylinder
2
240 Kg/cm
210 Kg/cm2
Forwards
Forwards
TS
Open
Lower
Close
Raise
Right
Right
1.5 ± 0.2 bar
Boom swing
C
Pi2
Reverse
Reverse
Curled
Bucket
equipment
Additional
L.H. swing
Open
R.H. travel
L.H. travel
Lower
Raise
Hydraulic tank
Left
Left
Oil cooler
Bucket
Boom
Arm
Cylinder block P1 P2
PPC valve A B
work equipment
0.2 0.2
T
T
S
E
P PS
P
ST1 solenoid valve MAX MIN
Accumulator
v = 0.35 ᐍ
PL S
T T Hydraulic
pump
P P
P3 P4 P1 P2 P1 P2 P4 P3
100 mesh
100 mesh
RKP04441
PC27R-8 10-13
HYDRAULIC PUMP
A
A
2 c
d RKP01130
10-14 PC27R-8
d
PDA P1 P2
PS
Max Min
Pen
PLS
SectionAA- A
Sezione -A
RKP01140
PC27R-8 10-15
1. Main pump
C
B C
A A
B RKP01200
1 2 3 4 5 6 7 8
SectionAA- -AA
Sezione Section
Sezione B
B -- B
B
1. Shaft
2. Oil seal
3. Case
4. Swash plate
5. Shoe
10 6. Piston
7. Cylinder block
8. Valve plate
9. Spring
Section C
Sezione C -- C
C 10. Servo piston RKP01150
10-16 PC27R-8
FUNCTION
. The rotation and torque transmitted to the pump
shaft is converted to hydraulic energy and pressur-
ized oil is discharged according to the load.
. It is possible to change the discharge amount by
changing the swash plate angle.
1 3 4 5 6 7 8
B A a
Section
SezioneAA--AA RKP01220
STRUCTURE
. Cylinder block (7) is supported to shaft (1) by a . Piston (6) carries out motion relative to the axial di-
spline, and shaft (1) is supported by the front and rection inside each cylinder chamber of cylinder
rear bearings. block (7).
. The end of piston (6) has a concave ball shape and . The cylinder block (7) carries out rotation relative to
shoe (5) is caulked to it to form one unit. valve plate (8) while sealing the pressurized oil, and
Piston (6) and shoe (5) form a spherical bearing. this surface ensures that the hydraulic balance is
. Rocker cam (4) has plane A, and shoe (5) is always maintained correctly.
pressed against this surface as it slides in a circle. The oil inside each cylinder chamber of cylinder
Rocker cam (4) forms a static bearing sending high block (7) is sucked in and discharged through valve
pressure oil at cylindrical surface B with to the plate (8).
case, and carries out a sliding movement.
PC27R-8 10-17
OPERATION
1. Pump operation
1 - The cylinder block (7) rotates together with the
shaft (1), and the shoe (5) slides on the flat sur-
face A.
At this time, the rocker cam (4) moves along 1 4 5 A 6 7 F
the cylindrical surface B, so the angle a be-
tween the center line X of the rocker cam (4)
and the inclination of the cylinder block (7) in
the axial direction changes.
This angle a is called the swash plate angle.
2 - When the center line X of the rocker cam (4)
maintains the swash plate angle a in relation
to the axial direction of the cylinder block (7),
the flat surface A acts as a cam for the shoe
(5). X
By this, the piston (6) slides on the inside of
the cylinder block (7), creates a difference be- B E RKP01240
10-18 PC27R-8
2. Control of discharge amount
. As the swash plate angle a becomes larger, dif-
ference between the capacities E and F be- 3 4 F
comes larger, so the discharge amount Q in-
creases.
The swash plate angle a is changed by the ser-
vo piston.
. The servo piston moves in a linear reciprocating
motion ( × ) under the signal pressure of TCC
and LS valve.
This linear motion is transmitted to the rocker
cam (4), which is supported by the cylindrical
surface of the case (3), and the rocker cam
slides in the semi-circular reciprocating direc-
tion ( ).
. The upper and lower pressure receiving area of
the servo piston are different from each other, E
and to the pressure chamber of the smaller pis- RKP01270
PC27R-8 10-19
2. TCC VALVE, LS VALVE, SERVO PISTON
1 a
2
6
3
7
4
9
c RKP01160
10-20 PC27R-8
LS VALVE
Function
. The LS valve controls the pump discharge amount
according to the amount of movement of the control
lever (that is the oil flow demanded by the actuator).
. The LS valve detects the oil flow demanded by the
actuator from the differential pressure DPLS be-
tween main pump discharge pressure PP and con-
trol valve outlet pressure PLS, and controls main
pump discharge amount Q.
(PP is called the pump pressure, PLS is called the
LS pressure, and DPLS is called the LS differential
pressure).
. In other words, the pressure loss (=LS differential
pressure DPLS) generated by the flow of oil from the
pump passing through opening area of the control
valve spool is detected.
By controlling pump discharge amount Q so that
this pressure loss remains constant, a pump dis-
charge amount is supplied in accordance with the
demands of the control valve by controlling pump
discharge amount Q.
. However, when carrying out fine control or in other
cases where the range does not exceed the maxi-
mum flow of the pump (the flow demanded by the
control valve is always supplied), the discharge
amount is the same as when the engine is at high
idling, even if the engine is at low idling.
To overcome this, a function has been added to
automatically lower the LS differential pressure
and reduce the discharge amount when the engine GH
is running at low idling.
. The engine speed is detected by pressures GH and
GL on both sides of the fixed throttle (metering
throttle) in the gear pump discharge passage.
This acts on LS valve No. 3 and No. 4 pressure re-
ceiving chambers a2 and b2, and changes the LS
setting. When the engine is running at low idling,
the gear pump discharge amount is reduced, so
pressures GH and GL on both sides of the metering
throttle become almost the same (the metering dif- b2
ferential pressure between GH and GL becomes a2 GL
lower).
On the other hand, when the engine is run at full
throttle, the gear pump discharge amount is in-
Pump discharge amount Q (ᐍ / min)
(US.gpm)
PC27R-8 10-21
OPERATION
1. When control valve is at HOLD position
M
Control valve
4 4
To actuator
PP
PLS
GH PP y
x GH GL
PLS
LS valve
8 a 6 b GL
c 6 e
RKP01291
d
. LS pressure PLS is brought from the control valve (Spring chamber a is connected to the drain circuit
outlet port to spring chamber a of the LS valve. through the control valve spool).
Pump pressure PP is brought to chamber b at the At the same time, pump pressure PP is held at the
tip of piston (6) on the opposite side. unload pressure of approx. 26 bar (377 psi).
. The position of piston (6) is determined by the size . For this reason, piston (6) is pushed to the left ( ),
of pump pressure PP, the combined force of LS port c and port d are interconnected, and pump
pressure PLS + force of spring (8), and the size pressure PP passes from port c to port d, and is
of the differential pressure (GH - GL) on both sides brought to chamber X at the large diameter end
of the gear pump metering throttle. of servo piston (4).
. Before the engine is started, servo piston (4) is . Pump pressure PP is always supplied to chamber Y
pushed to the left (direction of maximum swash at the small diameter end of servo piston (4), but
plate angle) by spring (1). the force applied to the large diameter end of servo
. After the engine is started, if all the control valves piston (4) is greater because of the difference in
are at the HOLD position, no pressure oil flows to area at both ends of the piston, so servo piston
the control valve outlet port, so LS pressure PLS (4) moves to the right ( ) in the direction of the
is 0 bar (0 psi). minimum swash plate angle.
10-22 PC27R-8
2. When opening area of control valve is maximum (lever operated freely)
M
Control valve
4
To actuator
PP
PLS
GH PP y
x GH GL
PLS
LS valve
8 a 6 b GL
c 6 e
RKP01251
d
. When control lever is operated fully (that is, when . At this point, port f of the TCC valve is drained in-
the area of opening of the control valve becomes side the pump case through the inside of the pis-
larger), the difference between pump pressure PP ton, so the pressure in chamber X at the large dia-
and LS pressure PLS (LS differential pressure meter end of servo piston (4) also becomes the
DPLS) becomes smaller. drain pressure.
. LS pressure PLS brought to spring chamber a of the . Because of this, servo piston (4) is moved to the left
LS valve becomes close to pump pressure PP, and ( ) in the direction of the maximum swash plate
piston (6) is pushed to the right ( ) by the combined angle by pump pressure PP acting on chamber Y
force of LS pressure PLS + force of spring (8). at the small diameter end of the piston.
This closes port c and interconnects port d and port e.
. 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.
PC27R-8 10-23
3. When opening area of control valve is small (small movement of lever)
M
Control valve
4
To actuator
PP
PLS
GH PP
GH GL
PLS
LS valve
6 b GL
c 6 e
RKP01281
d
10-24 PC27R-8
When engine is at low idling
. The LS set differential pressure of the LS valve is
taken as 7 bar (101.5 psi). In the area where the
LS differential pressure DPLS is more than 7 bar
(101.5 psi), the pump swash plate angle moves in
the minimum direction. If the area of opening of
the control valve is further increased and LS differ-
ential pressure DPLS goes below 7 bar (101.5 psi),
the pump swash plate angle is moved in the maxi-
mum direction. Even if the area of opening of the
control valve is the same, the LS set differential
pressure is lower than when the engine is running
at full throttle (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.
PC27R-8 10-25
4. When pump flow is amount demanded by control valve
M
Control valve
A1 4 A2
To actuator
PP
PLS
GH PP
x GH GL
PLS
LS valve
8 a 6 b
c 6 e
RKP01231
. Let us take the area receiving the pressure at the . As a result, port c, port d and port e open approxi-
large diameter end of servo piston (4) as A1, the mately the same amount, so the pump pressure
area receiving the pressure at the small diameter flows from port c to port d.
end as A2, the pressure acting on the large piston Part flows from port e to the tank case and is
diameter end as PEN and the pressure acting on the drained, so the pressure is reduced by approx. 1/2
small piston diameter end as PP. and flows to chamber X at the large diameter end
. When the flow of oil from the pump reaches the of servo piston (4).
flow demanded by the control valve, pump pres- . At this point, the relationship between the area re-
sure PP acting on port b of the LS valve and the ceiving the pressure at both ends of servo piston
combined force of LS pressure PLS + force of (4) is A2 : A1=1 : 2, so the pressure applied to both
spring (8) acting on spring chamber a are balanced, ends of servo piston (4) becomes PP : PEN=2 : 1.
so piston (6) stops at almost the central position. 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.
10-26 PC27R-8
. The force of the spring is adjusted so that
PP ± PLS=DPLS=16 bar (232 psi) at the point
where piston (6) is balanced.
. In other words, when the area of opening of control
valve is 1/2, the pump swash plate angle is also 1/2,
and when the area of opening of control valve is 1/4,
the pump swash plate angle is also 1/4. LS differen-
tial pressure DPLS is always held at 16 bar (232
psi), so the pump discharge amount is in accor-
dance with the area of opening of the control valve.
. For example, after balancing at an area of opening
1/4 of the control valve, if the system is operated to
3/4 of the area of opening of the control valve, LS
differential pressure DPLS will drop momentarily.
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 DPLS rises to 16 bar (232 psi), so it is ba-
lanced in this position.
PC27R-8 10-27
TCC VALVE
Function
. When discharge pressure PP becomes higher, the
area of opening of the control valve becomes lar-
ger, and even if the LS valve tries to increase pump
10-28 PC27R-8
OPERATION
1. When actuator load is large (pump discharge pressure PP is high)
3
M
Control valve
4 1
To actuator
PP
PLS
x y GH GL
f
PLS
c e
LS valve d
RKP01191
. When the load on the actuator becomes high and . If pump discharge PP rises further, piston (3) moves
pump discharge pressure PP rises, piston (3) is to the left ( ) and servo piston (4) moves to the
pushed to the left ( ). right ( ) in the direction of the minimum swash
. As a result, port f and chamber Y are intercon- plate angle because of the pressure in chamber X
nected, pump pressure PP flows from chamber Y at the large diameter end.
to port f, and at the same time, port f and the drain . When servo piston (4) moves to the right ( ) in
circuit are shut off. the direction of the minimum swash plate angle,
. If the LS valve takes action to increase the pump spring (1) is compressed, and piston (3) is moved
discharge amount, spool (6) of the LS valve is to the right ( ).
moved to the right ( ) and port d and port e are . When piston (3) is moved to the right ( ) and port
interconnected. f and chamber Y are shut off, servo piston (4) stops
. As a result, pump pressure PP from port f of the moving to the right.
TCC valve flows from port e of the LS valve to port . 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).
PC27R-8 10-29
2. When actuator load becomes smaller (pump discharge pressure PP drops)
3
M
Control valve
4 1
To actuator
PP
PLS
x y GH GL
f
PLS
c e
LS valve d
RKP01211
10-30 PC27R-8
3. Action of spring
3
M
Control valve
4 1
To actuator
PP
PLS
GH GL
LS valve
RKP01171
PC27R-8 10-31
. The position where piston (3) stops, in other words,
the pump absorption torque, is determined by the
position where the force of spring (1) + pump pres-
sure PP acting on piston (3) are in balance.
. In other words, if pump discharge pressure PP in-
creases, pump discharge amount Q is reduced;
and if pump discharge pressure PP goes down,
pump discharge amount Q is increased.
10-32 PC27R-8
PAGE INTENTIONALLY
LEFT BLANK
PC27R-8 10-33
CONTROL VALVE
s C
B
A
g
P P
f O O
dd
e M M ee
d r t
M M ff
c q L L u gg
p K K
v
n J J x
m H H
y
l G
w
G
k G G z
j F F aa
b
i bb hh
E E
a h cc
D D
A
B
C
ii
ll mm
RKP01590
10-34 PC27R-8
a. LS Port - From hydraulic pump (PLS Port)
b. PA1 Port - From L.H. PPC valve (P3 Port)
c. PA6 Port - From L.H. PPC valve (P1 Port)
d. PA7 Port - From R.H. PPC valve (P2 Port)
e. PA8 Port - From R.H. PPC valve (P3 Port)
f. PA9 Port - From work equipment PPC valve (P2 Port)
g. P2 Port - From hydraulic pump (P2 Port)
h. S Port - From hydraulic tank
i. B1 Port - To swing motor (A Port)
j. B2 Port - To swivel joint (D Port)
k. B3 Port - To swivel joint (A Port)
l. B4 Port - To boom swing cylinder (Head side)
m. B5 Port - To swivel joint (F Port)
n. B6 Port - To arm cylinder (Head side)
p. B7 Port - To boom cylinder (Bottom side)
q. B8 Port - To bucket cylinder (Bottom side)
r. B9 Port - To attachment (R.H. side)
s. Pi2 Port - To ST1 solenoid valve (P Port)
t. A9 Port - To attachment (L.H. side)
u. A8 Port - To bucket cylinder (Head side)
v. A7 Port - To boom cylinder (Head side)
x. A6 Port - To arm cylinder (Bottom side)
y. A5 Port - To swivel joint (E Port)
w. A4 Port - To boom swing cylinder (Head side)
z. A3 Port - To swivel joint (C Port)
aa. A2 Port - To swivel joint (B Port)
bb. A1 Port - To swing motor (B Port)
cc. P Port - From hydraulic pump (P1 Port)
dd. PB9 Port - From work equipment PPC valve (P1 Port)
ee. PB8 Port - From R.H. PPC valve (P4 Port)
ff. PB7 Port - From R.H. PPC valve (P1 Port)
gg. PB6 Port - From L.H. PPC valve (P2 Port)
hh. PB1 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
PC27R-8 10-35
7
5 8
3
10
2 11
SectionAA--AA
Sezione RKP01660
10-36 PC27R-8
1
10
Section B -- B
Sezione B B RKP01620
PC27R-8 10-37
9 10
8 11
7 12
13
6
14
5
4 15
16
3
17
2
18
19
1
20
Section
Sezione C
C -- C
C RKP01610
10-38 PC27R-8
1
3 4
6 5
SectionD D
Sezione -D-D Section
SezioneEE- -EE
7
10 11
14
13 12
9 8
Section G
Sezione G -- G
G
SectionFF- -FF
Sezione
RKP01640
SWING VALVE
7 - Spool
8 - Reducing pressure compensation valve
9 - Flow compensation valve
PC27R-8 10-39
5
1
3 2
SectionHH- H
Sezione -H
Section
Sezione JJ--JJ
7 8 12
6 11
13
16
10 9 14
15
Section
SezioneKK- K
-K Section L -- L
Sezione L L
RKP01600
10-40 PC27R-8
2 7
1 6
5 10
4 3 9 8
Section M -- M
Sezione M M Section NN-- N
Sezione N
11 12 13
Section OO--O
Sezione O Section PP-- P
Sezione P
RKP01630
PC27R-8 10-41
CLSS
1. OUTLINE
FEATURES
The term "CLSS" stand for the "Closed Center Load Sensing System" which has the following features.
a) Fine-controllability not affected by loads.
b) Controllability enabling digging even in the fine control mode.
c) Complex operability ensured by flow distribution determined according to the opening areas of spools during
complex operation.
d) Energy-saving feature using variable pump control.
STRUCTURE
. 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
PLS
Control valve
TCC valve
LS valve
PP
Servo
piston
RKP00661
10-42 PC27R-8
2. BASIC PRINCIPLE
1) Control of pump swash plate angle
. The pump swash plate angle (pump discharge amount) is so controlled that the LS differential pressure DPLS,
which is the difference between the pump discharge pressure PP and the LS pressure PLS at the outlet port of the
control valve (actuator load pressure), is maintained at a constant level.
(LS differential pressure DPLS=Pump discharge pressure PP ± pressure PLS).
. If the LS differential pressure DPLS becomes lower than the setting pressure of the LS valve, the pump swash
plate angle becomes larger, and if it becomes higher, the pump swash plate angle becomes smaller.
M For the details of this action, refer to the descriptions of «HYDRAULIC PUMP».
Actuator
Control valve
Main pump
LS passage
Min. Max.
Servo piston
∆ PLS
LS valve
Differential pressure
large (high) Differential
pressure
TCC valve small (low)
PC27R-8 10-43
2) Pressure compensation control
. Valves (pressure compensation valves) are installed at the inlet port side of the spools of the control valves to
balance the loads.
When the actuators are complex-operated, the pressure differences DP at the upstream (inlet) and downstream
(outlet) are made equal by these valves.
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
S1 S2
Pressure
Pressure compensation
compensation valve
valve
PUMP
RKP00681
10-44 PC27R-8
3. Functions and operation of each valve
NAMES OF HYDRAULIC CIRCUITS AND VALVES
1. Unload valve LS+16 bar
(232 psi)
P2
2. Safety valve: 206 bar
P2 (2988 psi)
8 3. Pressure compensation
T valve
B9
4. Suction valve
To hammer 5. Main relief valve:
A9
PA9
4 235 bar (3408 psi)
PB9
6. Back pressure check valve
3 (cracking pressure):
B8
0.45 bar (6.53 psi)
PA8 4 A8
7. Cooler by-pass valve
Bucket
PB8
(cracking pressure):
3 4 0.4 bar (5.8 psi)
B7
8. Pilot relief valve:
4 A7 29 bar (420.6 psi)
PA7 PB7 Boom
3 4 B6
PA6 4 A6
PB6 Arm
B5
A5
Blade
B4
A4 Boom
swing
3 Reverse
P1
B3
R.H. travel
A3
P2
Forwards
3 Reverse
P1
B2
L.H. travel
A2
P2
Forwards
3 Left
B
B1
Swing
A1 motor
PA1 A
PB1 Right
3
LS
1
P1 5 2
S
7
6
C T
RKP04481
PC27R-8 10-45
1. Unload valve
FUNCTION
1) When the control valve is at HOLD, pump discharge amount Q discharged by the minimum swash plate angle is
released to the tank circuit. When this happens, pump discharge pressure PP is set to 16 bar (232 psi) by spring
(2) inside the valve.
(LS pressure PLS=0 bar (0 psi)
1 PP PLS B S3 S2
S1 A T 2 T RKP00720
10-46 PC27R-8
2) During fine control of the control valve, when the demand flow for the actuator is within the amount discharged by
the minimum swash plate angle of the pump, pump discharge pressure PP is set to LS pressure PLS+16 bar (232
psi).
When the difference in pressure between pump discharge pressure PP and LS pressure PLS reaches the load of
spring (2) (16 bar (232 psi)) the unload valve opens, so LS differential pressure DPLS becomes 16 bar (232 psi).
OPERATION
1 PP PLS B S3 S2
S1 A T 2 T RKP00730
PC27R-8 10-47
3) When the control valve is being operated and the demand flow for the actuator becomes greater than the pump
discharge from the minimum swash plate angle, the flow of the oil out, to tank circuit T is shut off, and all of pump
discharge amount Q flows to the actuator circuit.
1 PP PLS B S3 S2
S1 A T 2 T RKP00740
OPERATION
Control valve operated
. When the control valve is operated to a larger . As a result, pump circuit PP and tank circuit T are
stroke, LS pressure PLS is generated and acts on shut off, and all the pump discharge amount Q
area S3 at the right end of spool (1). flows to the actuator circuit.
When this happens, the area of the opening of the
control valve spool is large, so the difference be-
tween LS pressure PLS and pump discharge pres-
sure PP is small.
. For this reason, the difference in pressure between
pump discharge pressure PP and LS pressure PLS
does not reach the load of spring (2) (19.6 9.8 bar
(290 142 psi)), so spool (1) is pushed to the left by
spring (2).
10-48 PC27R-8
2. Introduction of LS pressure
FUNCTION
. The LS pressure is the actuator load pressure at the outlet port end of the control valve.
. It actually reduces pump pressure PP at reducing valve (3) of the pressure compensation valve to the same pres-
sure as actuation circuit pressure A, and sends it to the LS circuit PLS.
. With the boom swing and blade valves, pump pressure PP is reduced to the same pressure as actuator circuit
pressure A by one reducing valve (3) used for both systems, and the pressure is sent to the LS circuit PLS.
A b a T
To PPC valve
PA
PLS1
2
3
C PLS
PP
4
T
RKP00392
OPERATION
1) Boom, arm, bucket, travel valve
. When spool (1) is operated, pump pressure PP . Actuator circuit pressure PA (=A) acts on the left
flows from control valve (2) and notch a in spool end of reducing valve (3); the reduced pump pres-
(1) through bridge passage b to actuator circuit A. sure PP acts on the other end.
. At the same time, reducing valve (3) also moves to . As a result, reducing valve (3) is balanced at a po-
the right, so pump pressure PP has its pressure re- sition where actuator circuit pressure PA and the
duced by the pressure loss at notch C. It is intro- pressure of spring chamber PLS1 are the same.
duced to LS circuit PLS, and then goes to spring Pump pressure PP reduced at notch C becomes ac-
chamber PLS1. tuator circuit pressure A and is taken to LS circuit
. When this happens, LS circuit PLS is connected to PLS.
tank circuit T from LS by-pass plug (4) (see the sec-
tion on the LS by-pass plug).
PC27R-8 10-49
1 7 3 T A b 5
d
e d
2
f
PP
PLS
4 RKP00620
10-50 PC27R-8
3. LS by-pass plug
FUNCTION
. It releases the residual pressure of LS pressure PLS.
. It makes the speed of the rise in pressure of LS pressure PLS more gentle. In addition, with this discharge
throttled flow, it creates a pressure loss in the throttled flow of the spool or shuttle valve, and increases the sta-
bility by lowering the effective LS differential pressure.
PLS 1 B
A T PP a T b RKP00750
OPERATION
. The pressurized oil for LS circuit PLS passes from
clearance filter a (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.
PP =Pump circuit
PLS=LS circuit
T =Tank circuit
A =To valves
B =To pump LS valve
PC27R-8 10-51
4. Pressure compensation valve
FUNCTION
. During compound operations, if the load pressure becomes lower than the other actuator and the oil flow tries to
increase, compensation is received. (When this happens, the other actuator being used for compound operation
(right side) is at a higher load than the actuator on this side (left side)).
W W
A a T PPA a T
PA
PA
PPA PLS1
1
2
PP
PLS RKP00403
OPERATION
. If the load pressure of the other actuator (right side) . Flow control valve (2) and reducing valve (1) are ba-
becomes higher during compound operations, the lanced in position where the difference in pressure
oil flow in actuator circuit A on this side (left side) between PLS and PA acting on both ends of redu-
tries to increase. cing valve (1) and the pressure loss between PP
and PPA on both sides of flow control valve (2) are
. If this happens, the LS pressure PLS of the other ac-
the same.
tuator acts on spring chamber PLS1, and reducing
valve (1) and flow control valve (2) are pushed to . In this way, the pressure difference between up-
the left ( ). stream pressure PPA and downstream pressure
PA of both spools used during compound opera-
. Flow control valve (2) throttles the area of opening
tions is the same, so the pump flow is divided in
between pump circuit PP and spool upstream
proportion to the area of opening of notch a of each
PPA, and pressure loss is generated between PP
spool.
and PPA.
10-52 PC27R-8
5. Area ratio of pressure compensation valve
FUNCTION
. The pressure compensation valve determines the compensation characteristics by carrying out fine adjustment
of the area ratio (S2/S1) between area S2 of reducing valve (1) and area S1 of flow control valve (2) to match the
characteristics of each actuator.
S1=Area of flow control valve (2) ± Area of piston (3).
S2=Area of reducing valve (1) ± Area piston (3).
A T
PPA
PA
S1
S2
PP 3 PLS 1
RKP00760
PC27R-8 10-53
6. Throttling LS introduction of pressure compensation valve
FUNCTION
. In the other actuator is relieved during compound operations, LS introduction throttle b of reducing valve (1) di-
vides the flow and sends more oil to the side receiving compensation.
OPERATION
W W
A a PPA a
PA
PA b
PPA PLS1
PLS2
1
1
PP
PLS
4
RKP00414
. If the other actuator (right side) is relieved during . PLS2 passes through LS introduction throttle b of
compound operations, each circuit pressure (PPA, reducing valve (1) and becomes PLS. PLS is con-
PA) of the other actuator becomes the same as nected to the tank circuit from LS by-pass plug
the pump circuit pressure (PP=relief pressure). (4), so pressure loss is generated at LS introduction
. In this case, spring chamber PLS2 of the other ac- throttle b (the condition becomes PLS<PLS2).
tuator (right side) becomes the same as pump cir- . As a result, even if the other actuator is relieved, a
cuit pressure PP because of the balance of redu- pressure differential is created between PP and
cing valve (1). PLS, so more oil flows to actuator circuit A on this
side (left side).
10-54 PC27R-8
7. L.H., R.H. travel junction circuit
FUNCTION
. To compensate for any difference in the oil flow in the left and right travel circuits when travelling in a straight
line, the junction circuit opens when the left and right travel spools are operated.
In this way, the flow of oil to the left and right travel motors is almost the same when travelling in a straight line, so
there is no travel deviation.
. When steering the machine, the difference in the load pressure returns the reducing valve of the travel on the
inside of the turn and the opening of the notch in the travel junction valve spool becomes smaller, so the machine
can be steered.
AL PAL AR PAR
T T
1L 1R
PLS
3 2 3 2
a
a
PP
c
RKP00423
a
OPERATION
When travelling in a straight lint
. When left and right travel spools (1) are operated,
the pump discharge flows from pump circuit PP
and circuits PAL and PAR to actuator circuits AL
and AR.
. When travelling in a straight line, to make actuator
circuits PAL and PAR equal, left and right reducing
valves (2) are pushed to the right by the same
amount, and notch a and the travel junction circuit
are opened.
. 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.
PC27R-8 10-55
LEFT TRAVEL RIGHT TRAVEL
AL PAL AR PAR
1L 1R
PLS
3 2 3 2
a
PP
b c
RKP00433
10-56 PC27R-8
8. Servocontrol reducing valve
FUNCTION
. This valve set servocontrol pressure to 29.5 bar (428 psi).
To servocontrol
solenoid valve 1 2
PC2
Gear pump
TS
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
(428 psi).
PC27R-8 10-57
PAGE INTENTIONALLY
LEFT BLANK
10-58 PC27R-8
SWIVEL JOINT
A
B B
e
1
b
f
2 c
4
SectionAA--AA
Sezione
A
k
j l
h
m
n
o RKP00260
SectionBB--BB
Sezione
PC27R-8 10-59
SWING MOTOR
A A
6 2
5 a
3
4
RKP01500
10-60 PC27R-8
8
7
9
d
13
10
12
11
Section
Sezione A
A -- A
A RKP01510
PC27R-8 10-61
TRAVEL MOTOR
a 1 2 3 4
8 7 6 5
b c d e
9 10
16 11
12
15
14 13
SectionAA- -AA
Sezione
RKP01380
10-62 PC27R-8
19 18 17
Section
SezioneBB
- B- B
RKP01390
PC27R-8 10-63
CYLINDER
BOOM
1 2
3 4 5 6 7 8 9 10 11 12
RKP01430
ARM
1 2
3 4 5 6 7 8 9 10
RKP01460
10-64 PC27R-8
BUCKET
1 2
3 4 5 6 7 8 9 10
RKP01450
BOOM SWING
1 2
3 4 5 6 7 8 9 10
RKP01440
PC27R-8 10-65
BLADE
1 2
3 4 5 6 7 8 9 10
RKP01420
Boom
Cylinder Arm Bucket Boom swing Blade
with canopy with cabin
45 mm 45 mm 40 mm 35 mm 40 mm 35 mm
Piston rod diameter
(1.773 in.) (1.773 in.) (1.576 in.) (1.379 in.) (1.576 in.) (1.379 in.)
75 mm 75 mm 70 mm 60 mm 60 mm 70 mm
Cylinder inside diameter
(2.955 in.) (2.955 in.) (2.758 in.) (2.364 in.) (2.364 in.) (2.758 in.)
10-66 PC27R-8
ACCUMULATOR
B
RKP00700
PC27R-8 10-67
PPC VALVE
WORK EQUIPMENT
a b
d c
E E
D D
e
B f
A C
C A RKP01070
10-68 PC27R-8
6
5 7
4
8
3
9
2 10
SectionAA- -AA
Sezione Section B -- B
Sezione B B
Section DD-- D
Sezione D
SectionC C
Sezione -C-C
Section EE--EE
Sezione
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
PC27R-8 10-69
FUNCTION
1. At neutral
Ports A and B of the control valve and ports P1 and
P2 of the PPC valve are connected to drain cham-
ber D through fine control hole f in spool (1). (Fig. 1)
D
f T
P
1
P3 (P1) P4 (P2)
A Control valve
B
RKP01091
FIG. 1
10-70 PC27R-8
3. During fine control (when the lever is returned)
When disc (5) starts to be returned, spool (1) is
pushed up by the force of centering spring (3) and
the pressure at port P1.
When this happens, fine control hole f is connected 5
to drain chamber D and the pressure oil at port P1
is released.
4
If the pressure at port P1 drops too far, spool (1) is
pushed down by metering spring (2), and fine con- 3
trol hole f is shut off from drain chamber D. At al-
most the same time, it is connected to pump pres- 2
sure chamber PP, and the pump pressure is sup- D
plied until the pressure at port P1 recovers to a f T
pressure that corresponds to the lever position.
When the spool of the control valve returns, oil in P
drain chamber D flows in from fine control hole f' f
in the valve on the side that is not working.
The oil passes through port P2 and enters chamber
1 PP
B to fill the chamber with oil. (Fig. 3)
P1 P2
A B
Control valve
FIG. 3 RKP01111
4. At full stroke
When disc (5) pushes down piston (4), and retainer
(7) pushes down spool (1), fine control hole f is shut
off from drain chamber D, and is connected with
pump pressure chamber PP. Therefore, the pilot
pressure from the control pump passes through fine
control hole f and flows to chamber A from port P1, 5
and pushes the control valve spool.
The oil returning from chamber B passes from port 4
P2 through fine control hole f' and flows to drain
chamber D. (Fig. 4) 9
D
f T
P
f
1 PP
P1 P2
A Control valve
B
FIG. 4 RKP01121
PC27R-8 10-71
PPC VALVE
HAMMER
5
4
c d 6
3 7
2
8
1
9
Section AA-- A
Sezione A
RKP00960
10-72 PC27R-8
FUNCTION
1. At neutral
Ports A and B of the control valve and ports P1 and
P2 of the PPC valve are connected to drain cham-
ber D through fine control hole f in spool (1). (Fig. 1)
D
T
f P
1
P1 P2
A Control valve B
RKP00971
FIG. 1
PC27R-8 10-73
3. During fine control (when the lever is returned)
When lever (5) starts to be returned, spool (1) is
pushed up by the force of centering spring (3) and
the pressure at port P1. 5
When this happens, fine control hole f is connected
to drain chamber D and the pressure oil at port P1
is released. 4
If the pressure at port P1 drops too far, spool (1) is
pushed down by metering spring (2), and fine con-
trol hole f is shut off from drain chamber D. At al-
most the same time, it is connected to pump pres- 7 D
sure chamber PP, and the pump pressure is sup-
plied until the pressure at port P1 recovers to a T
pressure that corresponds to the lever position. 2
When the spool of the control valve returns, oil in
drain chamber D flows in from fine control hole f' P
in the valve on the side that is not working. f
The oil passes through port P2 and enters chamber f'
B to fill the chamber with oil. (Fig. 3)
1 P1 P2 PP
A Control valve B
FIG. 3 RKP00991
4. At full stroke
When lever (5) pushes down piston (4), and retainer
(7) pushes down spool (1), fine control hole f is shut
off from drain chamber D, and is connected with
pump pressure chamber PP. Therefore, the pilot
pressure from the control pump passes through fine 5
control hole f and flows to chamber A from port P1,
and pushes the control valve spool. 4
The oil returning from chamber B passes from port
P2 through fine control hole f' and flows to drain
chamber D. (Fig. 4)
7 D
T
2
8
P
f
f'
1 P1 P2 PP
A Control valve B
FIG. 4 RKP01001
10-74 PC27R-8
SOLENOID VALVE
a b c d
1 2
RKP00810
PC27R-8 10-75
PAGE INTENTIONALLY
LEFT BLANK
10-76 PC27R-8
ELECTRICAL DIAGRAM (1/3)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
A2.5
2.1
A2.5 2 A2.5
2.1
X10 B - N1
3.9
G1
M - V1 2.12
H1 H2 H3 H4
FU2 FU9
3A 7.5A
R1 ACC BR R2 C
OFF ACC
R1
ST
HA1 S1 X6 1
S1 B X6 2
R1 10 X5 R1 X6 3
X6 4
X6 5
X5 H5 H6 H7 H8 H9
11 M1 X6 6
R - N2.5
B - G1 X6 7
R6
3 X10 12
X5 X6 9
X10
R1.5 X6 10
2.15
N1 X6 11
M1
M4
M - N1
A - R1
A - V1
X2
R - N2.5
X6
R - V1
R1
G1 12
B - N1 X6 13 P1 P2 P3
X11 2 X11 3
X-K1 2 4 13 X5 C/N1 X6 14
K1 KT1
3
t° q h
X5 X6
X5
R6
7 C - N1 15
X-K1 6
1 X10 X7 1 X5 X6 16
4
4
X-K1 X11 1 X11
A - R1
3
M4
FUG X-K1
S1
R - V1
B - G1
C - N1
60A
C/N1
N1
R6
1 2 3 9 2 4 5 4 8
X1 X1 X4 X4 X4 X4 X4 X4
X1 S2
R - N2.5
R35
S - N1
R6
L - R1
S1
00000 00 h
G1
A - R1
12 Vcc
M4
C - N1
C/N1
1
X3 X3
X28
1
M1 G2
30 50 X8
M V1 Y1
30
G S3 S4 R2
3
p t
U
31 31
R1 t
X8
N35
2
P4
N1
N1
31
2.1
RKP06570
PC27R-8 10-77
PAGE INTENTIONALLY
LEFT BLANK
10-78 PC27R-8
ELECTRICAL DIAGRAM (2/3)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
A2.5 A2.5
1.19 3.1
A2.5 A2.5
1.19 3.1
R1.5
1.3
G1
XS5 2 1 XS5 XS6 XS6 2 1 XS6
FU10 FU1 FU6 1 1 3 FU11 FU7 FU8 FU4
7.5 A 30 A 10 A 0 0 2
7.5A 7.5A 7.5A 10A
R - N1
G - N1.5
2
S5 A E
S6
X5 XS5 6 5 XS5 XS6 6
XS6 5
G - N1.5
A - N1.5
G/R1
C - L1
S7
R - V1
H - G1.5
R - N1.5
B - R1
V4
V - N1
R1.5
S8
G1
N1
1.12
3 1 2
K3 X5 X25 X25
1
X6
L - N1.5
L - R1.5
X5
7
B - R1.5
3.0
K2 X4
M - B1
S - G1
X6
R - N1.5
B - R1.5
C - L1
1 6
H - N1
H -R1
H -L1
X4 X4
V - N1
X16 X16 X16
4 3 2
N1.5
L - N1.5
L - R1.5
L - N1
1 2 3 4 1 2
X7 X7 A C B
KT2 X17 X19 X19 X19
X16 1 X23 X23 X23
M - B1
R1.5
V - N1
S - G1
S9
R - V1
2 1
1
2
N1
N1
N1
N1
N1
N1
N1.5
N1
31 31
1.19 3.1
RKP06580
PC27R-8 10-79
PAGE INTENTIONALLY
LEFT BLANK
10-80 PC27R-8
ELECTRICAL DIAGRAM (3/3)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
A2.5
2.19
A2.5
2.19
R - G1
S11 S14
S - N1.5
6 5 6 5
XS11 XS11 XS14 XS14
S12
B1.5
B1.5
S - N1.5
4
X5
B - R1.5 N1
2.19
R - G1
5
X5
R - G1
B - N1
1.12
B - N1
S13
5
X19
A/R1
C1.5
L1.5
B - N1
X19
A/R1
1 2 3 1
Y2 M R3
M3
V7
X27
X24 X26 3
2 1
N1.5
N1
N1
31
2.19
RKP06590
PC27R-8 10-81
10-82 PC27R-8
GROUP 20
40-28 PC15R-8
TESTING AND ADJUSTMENTS
Normal or standard technical data . . . . .. . . . . .. . . . .. . . 2 Control and adjustment of the track-shoe tension. . 28
Special tools . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 13 Control and regulation of the pressures in the
Checking the engine speed . .. . . . . .. . . . .. . . . . .. . . . .. . 15 hydraulic circuits .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 29
Adjustment of valve clearance . . . . .. . . . .. . . . . .. . . . .. . 16 Control and regulation of the LS differential
Measurement of the compression pressure .. . . . .. . 17 pressure and adjustment of the LS valve . .. . . . .. . . . 32
Control and adjustment of the tension Regulation of the PC valve .. . . . .. . . . . .. . . . . .. . . . .. . . . 34
of the fan belt .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 18 Control and regulation of the servo-control
Control and adjustment of the injection timing . . .. . 19 power supply . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 35
Control and adjustment of the accelerator stroke . . 21 Elimination of residual pressures - pressurisation
of the tank . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 36
Adjustment of the stroke of the blade
command lever . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 22 Bleeding air from the hydraulic circuits . . . .. . . . .. . . . 37
Adjusting the flexible cables .. . . . . .. . . . .. . . . . .. . . . .. . 23 Control of hydraulic drifts - analysis
of the causes of a drift . . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 39
Control and adjustment of the stroke of the
travel lever . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 24 Checking for any leakages inside the working
equipment cylinders. . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 45
Adjustment of the stroke of
the boom swing command pedal . .. . . . .. . . . . .. . . . .. . 25 Checking for any leakages inside
the swing motor . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 46
Adjustment of the PPC valve clearances . . . .. . . . .. . 26
Methods for testing for leakages inside the
Adjustment of the rubber pad and safety swivel joint . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 47
microswitch for servo-control engagement . .. . . . .. . 27
When carrying out controls, adjustments or analyses for troubleshooting, park the machine on firm, level
ground. Apply all the machine safety devices and use blocks to prevent any machine movement.
When more than one person is engaged in the work, use the prescribed notices that indicate that the machine
is undergoing maintenance. Do not allow any unauthorised persons to remain in the vicinity.
When checking the level of the cooling liquid, wait until this liquid has cooled. If the radiator cap is removed
while the liquid is still hot and under pressure, it may cause severe burns.
Take great care not to get entangled in moving parts (fan, alternator belt or any of the rotating elements).
PC27R-8 20-1
NORMAL OR STANDARD TECHNICAL DATA
. FOR THE ENGINE
Machine model PC27R-8
Engine 3D82AE-3FAE
mm 0.20
Intake valve (20ëC) (68ëF) (in.) (0.008) Ð
Valve clearance
Exhaust valve (20ëC) (68ëF) mm 0.20 Ð
(in.) (0.008)
Fuel injection Before top dead center (BTDC) degrees 14w1 14w1
timing
Deflection when mm 10 ± 15
Fan-belt tension pressed with finger (in.) (0.394 ± 0.591) Ð
force of approx. 6 kg (13.2 lb.)
20-2 PC27R-8
. FOR THE MACHINE
Bucket control
30 6 6 30 6 6
(1.182) (0.236) (0.236) (1.182) (0.236) (0.236)
Control valve
Swing control
RKP01970 mm
Work equipment control (in.)
ᐉ
Blade control a b
Travel control
RKP01980
PC27R-8 20-3
. FOR THE MACHINE
210 10 210 10
Boom
(2986 142) (2986 142)
210 10 210 10
Arm
(2986 142) (2986 142)
210 10 210 10
Bucket
(2986 142) (2986 142)
Hydraulic pressure
210 10 210 10
Travel
(2986 142) (2986 142)
. Relieve pressure on swing motor
215 5 215 5
Swing
(3057 71.1) (3057 71.1)
20-4 PC27R-8
. FOR THE MACHINE
15°
135° RKP01990 Degree 75ë Max. 90ë
Hydraulic drift of swing . Load in bucket: 135 kg (297.4 lb.) (mm) (194.7) (Max. 233.7)
(in.) (7.67) (Max. 9.208)
. Engine switched off
. Hydraulic oil temperature:
45 ± 55ëC (113 ±131ëF)
. Park the machine on a 15ë slope and posi-
tion the boom at 135ë with respect to the
ground surface.
. On the outer swing circle, mark the posi-
tion between revolving frame and track
frame. After 15 minutes measure the drift.
PC27R-8 20-5
. FOR THE MACHINE
Internal leakage from 45 ± 55ëC (113 ± 131ëF) ,/min 0.6 Max. 1.0
swing motor . Swing lock: engaged (US.gpm) (0.158) (Max. 0.264)
. Measure the leakage
. Pressurize circuit.
Measuring posture
Low speed
30.0 24 ± 36
High speed
. Hydraulic oil temperature:
45 ± 55ëC (113 ± 131ëF) 15.0 12 ± 18
. Rest the bucket on the ground,
raise one track-shoe, rotate one
turn, then measure time taken for
next.
Measuring posture
Low speed
45°
33.0 29 ± 37
45°
RKP01850
20m
10m
RKP01830
20-6 PC27R-8
. FOR THE MACHINE
30°
RKP02000
. Engine stopped.
. Hydraulic oil temperature:
45 ± 55ëC (113 ± 131ëF)
. Machine parked on sloping ground.
. Measure the drift after 5 minutes
. Engine speed: high idling
Leakage of travel motor . Hydraulic oil temperature: ,/min Ð Ð
45 ± 55ëC (113 ± 131ëF) (US.gpm)
. Lock shoe
15°
135° RKP01990
PC27R-8 20-7
. FOR THE MACHINE
Blade RKP01870
(measure the downward mm Max. 200 Max. 30
movement of the edge (in.) (Max. 7.88) (Max. 1.182)
of the blade)
. Engine stopped
. Hydraulic oil temperature:
45 ± 55ëC (113 ± 131ëF)
. Raise the blade to its maximum height and
measure the height of the edge from the
ground.
Measure the downward after 15 mins.
Boom 2 Max. 5
Internal cylinder
Arm
45 ± 55ëC (113 ± 131ëF) cm3/ 2 Max. 5
. Check leakages: on the cylinder on the min
side opposite to the one under pressure.
Bucket H Check one cylinder at a time 2 Max. 5
20-8 PC27R-8
. FOR THE MACHINE
Raise
2.3 1.8 ± 2.8
Bucket teeth on the ground
RKP01820
Lower
. Engine speed: high idling 2.3 1.8 ± 2.8
Cylinder fully extended
. Hydraulic oil temperature:
45 ± 55ëC (113 ± 131ëF)
. Measuring posture
Closed
Arm
3.0 2.4 ± 3.6
RKP01880
Inout
3.0 2.4 ± 3.6
Cylinder fully extended . Engine speed: high idling
. Hydraulic oil temperature:
45 ± 55ëC (113 ± 131ëF)
. Measuring posture
Dump
Bucket
2.2 1.7 ± 2.7
Work equipment
sec.
Curled
RKP01890
. Measuring posture
Boom swing
L.H.
. Measuring posture
Blade
Raise
RKP01900
Lower
PC27R-8 20-9
. FOR THE MACHINE
Measuring posture
RKP01920
Arm Max. 2 Max. 2
. Engine speed: low idling
. Hydraulic oil temperature:
Work equipment
RKP01930
Bucket Max. 2 Max. 2
. Engine speed: low idling
. Hydraulic oil temperature:
45 ± 55ëC (113 ± 131ëF)
. Bring the boom into a horizontal position.
Retract the bucket cylinder completely,
then extend it. Measure the time elapsing
from when the bucket stops at dead centre
until it starts to move again.
Measuring posture
20-10 PC27R-8
. FOR THE MACHINE
Test pressure
(psi) (426.6 71.1)
Nominal capacity
,/min 8.3
. Hydraulic oil temperature: (US.gall) (2.193)
45 ± 55ëC (113 ± 131ëF)
PC27R-8 20-11
Machine model PC27R-8
100
(26.42)
4
(28.92)
1
(7,23)
0
49 98 147 196 P(bar)
(711) (1421) (2132) (2843) (psi)
RKP04612
H When measuring deliveries with the pumps mounted on the machine, it is difficult to use the accelerator
to count the precise number of revs needed for this test.
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 (11.1 US.gall)
20-12
SPECIAL TOOLS
Measurement check points Symbol Code Name Q.ty Remarks
PC27R-8 20-13
PAGE INTENTIONALLY
LEFT BLANK
20-14 PC27R-8
TESTING AND ADJUSTMENTS CHECKING THE ENGINE SPEED
reading.
2 - Start the engine and check:
. Low idling without load (accelerator lever in "mini- MAX
MIN
mum" position).
. High idling without load (accelerator lever in
"maximum" position).
H Low idling: 1050w25 rpm
H High idling: 2785w25 rpm
PC27R-8 20-15
TESTING AND ADJUSTMENTS ADJUSTMENT OF VALVE CLEARANCE
1
1 - Remove the intake filter and the valve cover.
1
2 - Turn the drive shaft in the normal direction of rotation
until the line (1) marked as no. 1 on the flywheel is in
alignment with the reference notch (2) on the flywheel
housing. RKP06440
RKP06560
20-16 PC27R-8
TESTING AND ADJUSTMENTS MEASUREMENT OF THE COMPRESSION PRESSURE
RKPA2160
H Compression value:
Normal:
31w1 kg/cm2 (441w14.2 psi) at 250 rpm
(psi)
Compression pressure (kg/cm2)
Minimum permissible: 40
25w1 kg/cm2 (355.5w14.2 psi) at 250 rpm (569)
PC27R-8 20-17
CONTROL AND ADJUSTMENT OF THE
TESTING AND ADJUSTMENTS TENSION OF THE FAN BELT
RKPA2170
20-18 PC27R-8
TESTING AND ADJUSTMENTS CONTROL AND ADJUSTMENT OF THE INJECTION TIMING
1
RKPA3190
3 - Take off the clamp (3) and disconnect all the fuel de-
livery tubes (4) from the injection pump.
4
4 - Rotate the flywheel slowly in a counter-clockwise di-
rection (seen from the flywheel side), checking care-
fully the level of the fuel in the No. 1 union of the in-
jection pump. Stop the rotation when the fuel level 3
starts to rise.
RKPA2151
1/3
Notch
2
RKPA0011
PC27R-8 20-19
TESTING AND ADJUSTMENTS CONTROL AND ADJUSTMENT OF THE INJECTION TIMING
20-20 PC27R-8
CONTROL AND ADJUSTMENT
TESTING AND ADJUSTMENTS OF THE ACCELERATOR STROKE
H Test conditions:
. Engine: switched off.
1
. Working equipment: resting on the ground.
1 - Remove the inner cover of the control valve compart-
ment (1).
(For details, see «REMOVAL AND INSTALLATION»).
H If the sheathing (3) is to be substituted, before
proceeding with the adjustments, secure the
pump side of the sheathing in the intermediate
position.
RKPA2180
7
RKPB5492
RKPA2201
PC27R-8 20-21
ADJUSTMENT OF THE STROKE OF THE
TESTING AND ADJUSTMENTS BLADE COMMAND LEVER
H Test conditions:
. Engine: switched off.
1
. Working equipment: resting on the ground.
The adjustment, carried out on the power train, is aimed at
restoring the position of the command lever, keeping the
neutral position of the valve block spool.
The procedure is as follows:
1 - Remove the internal cover of the control valve com-
partment (1). (For details, see «30. REMOVAL AND
INSTALLATION»).
RKPA2180
3
RKPB5504
5
5 - Execute a full stroke in one of the two directions with
the lever (4).
H Make sure that the valve block spool executes the
full stroke. 4
6 - Tighten the lock-screw (3) until it rests on the lever
and then turn it for another half turn. Secure the posi-
tion with the nut (2). 8 7
7 - Repeat this lever adjustment (4) for the other direc- 9
tion. 6
RKPB5505
20-22 PC27R-8
TESTING AND ADJUSTMENTS ADJUSTING THE FLEXIBLE CABLES
H Test conditions:
. Engine: switched off.
. Working equipment: resting on the ground.
All adjustments that can be made to the flexible cables are
for the purpose of restoring the correct positions of the
control levers, while maintaining the neutral positions of
the control valve spools.
The procedure is as follows:
2
3
RKPA3200
[ ALIGNAMENT ERROR
A BETWEEN LEVER
IN NEUTRAL POSITION
0 ± 3 mm (0 ± 0.118 in.)
TRAVEL
LEVERS
= =
BOOM SWING
CONTROL PEDAL
2 4
RKP06630
[ A= for canopy: 200 mm (7.88 in.)
for cabin 220 mm (8.67 in.)
PC27R-8 20-23
CONTROL AND ADJUSTMENT OF THE STROKE
TESTING AND ADJUSTMENTS OF THE TRAVEL LEVER
1
RKPA2220
20-24 PC27R-8
ADJUSTMENT OF THE STROKE OF
TESTING AND ADJUSTMENTS THE BOOM SWING COMMAND PEDAL
1
RKPA2220
2 - Remove the caps (2) and loosen the nuts (3) and
screws (4).
3 - Push the pedal (5) to the end of its stroke in one direc- 2
5
tion. Keep this position and tighten the screw (4) until 4
it touches the support. Tighten the screw (4) by a final
half-turn.
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
6
4
4
3
3
RKP06640
PC27R-8 20-25
TESTING AND ADJUSTMENTS ADJUSTMENT OF THE PPC VALVE CLEARANCES
20-26 PC27R-8
ADJUSTMENT OF THE RUBBER PAD AND SAFETY
TESTING AND ADJUSTMENTS MICROSWITCH FOR SERVO-CONTROL ENGAGEMENT
RKPA3220
2 - Loosen the nut (2) and tighten the rubber pad (3) in
the lower plate (4) by several turns.
3 - Lower the servo-control engagement lever until the
pitch point of the roller (5) is roughly 3 mm from the 3
starting point of the cut-off slot.
2
4 - Keep this position and bring the rubber pad into con-
tact with the console (6). 6
RKPB5510
5
RKP06621
PC27R-8 20-27
TESTING AND ADJUSTMENTS CONTROL AND ADJUSTMENT OF THE TRACK-SHOE TENSION
A=10 ± 15 mm A=10 ± 30 mm
(A= 0.4 ± 0.6 in.) (A= 0.4 ± 1.18 in.)
RKPA3250
2. Adjustment
If the track-shoe tensions do not fall within permissible
limits, adjust them as follows:
RKPA3270
20-28 PC27R-8
CONTROL AND REGULATION OF THE PRESSURES
TESTING AND ADJUSTMENTS IN THE HYDRAULIC CIRCUITS
COOLER
SCAMBIATORE
4
TANK
SERBATOIO
DIESEL
DIESEL P1 P2
RKP06470
PC27R-8 20-29
CONTROL AND REGULATION OF THE PRESSURES
TESTING AND ADJUSTMENTS IN THE HYDRAULIC CIRCUITS
20-30 PC27R-8
CONTROL AND REGULATION OF THE PRESSURES
TESTING AND ADJUSTMENTS IN THE HYDRAULIC CIRCUITS
Valve adjustment
H The unloading valve cannot be re-adjusted, only sub-
stituted.
1
1. Adjustment of the main relief valve
If the pressures measured for the working equipment
and machine travel do not fall within normal values,
adjust the main relief valve (1) as follows:
2 - Loosen the lock nut (2) and rotate the adjusting
screw (3).
. To INCREASE pressure, turn in a CLOCK-
WISE direction. RKPA2280
RKP06360
RKP06430
PC27R-8 20-31
CONTROL AND REGULATION OF THE LS DIFFERENTIAL
TESTING AND ADJUSTMENTS PRESSURE AND ADJUSTMENT OF THE LS VALVE
Table 1
Position of LS differential pressu-
the travel re in bar (psi) NOTES
lever
20-32 PC27R-8
CONTROL AND REGULATION OF THE LS DIFFERENTIAL
TESTING AND ADJUSTMENTS PRESSURE AND ADJUSTMENT OF THE LS VALVE
LS valve adjustment
If the DPLS value is not the one indicated, adjust the LS
valve (1) as follows: 1
1 - Disconnect the tube (2). 2
2 - Loosen the lock nut (3) and turn the adjusting screw
(4).
. To INCREASE pressure, turn in a CLOCKWISE
direction.
. To DECREASE pressure, turn in a COUNTER-
CLOCKWISE direction.
H Each turn of the adjusting screw (4) varies the RKPA2400
pressure by about 13 bar (188.5 psi).
3 - Lock the nut (3).
Nut: 31w3.5 Nm (22.8w2.6 lb.ft.)
3
H After the adjustment, check the setting of the LS 4
valve (1) following the procedure used for the test.
RKP06510
PC27R-8 20-33
TESTING AND ADJUSTMENTS REGULATION OF THE PC VALVE
RKP06500
20-34 PC27R-8
CONTROL AND REGULATION OF THE
TESTING AND ADJUSTMENTS SERVO-CONTROL POWER SUPPLY
TANK».
PC27R-8 20-35
ELIMINATION OF RESIDUAL PRESSURES -
TESTING AND ADJUSTMENTS PRESSURISATION OF THE TANK
20-36 PC27R-8
TESTING AND ADJUSTMENTS BLEEDING AIR FROM THE HYDRAULIC CIRCUITS
Bleeding air Starting Bleeding Bleeding air Bleeding air Pressuris- Starting
from pumps engine air from from swing from travel ing tank tasks
cylinders motor motor
. Substitution of hydraulic oil p p p p p p p
. Cleaning tank filter ,1 ,1
. Substitution filter p p p
. Repair - substitution
pump p p p p p
. Removal of suction tube
. Substitution - repair
control valve p p p p
. Repair-Substitution
cylinders p p p p
. Removal of cylinders tube
. Repair - substitution
swing motor p p p
p
. Removal of tubes
from swing motor
. Repair - substitution
travel motor - joint
. Removal of tubes p p p p
from travel motor - joint
,1: Only bleed air from the swing and travel motors if the engine oil (casing) is to be drained.
1. Bleeding air from the pump
1 - Loosen and remove the cap (1) from the pump
body (2).
1
2 - Pour hydraulic oil through the hole until the entire
casing is full.
3 - Replace the cap (1).
Cap: 63.7w4.9 Nm (47w3.6 lb.ft.) 2
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.
RKPA2460
PC27R-8 20-37
TESTING AND ADJUSTMENTS BLEEDING AIR FROM THE HYDRAULIC CIRCUITS
20-38 PC27R-8
CONTROL OF HYDRAULIC DRIFTS -
TESTING AND ADJUSTMENTS ANALYSIS OF THE CAUSES OF A DRIFT
1. Test
To check on the extent of the hydraulic drifts of
individual components and the total hydraulic
drift, position the machine and follow the proce-
dures indicated in the «NORMAL TECHNICAL
DATA».
PC27R-8 20-39
CONTROL OF HYDRAULIC DRIFTS -
TESTING AND ADJUSTMENTS ANALYSIS OF THE CAUSES OF A DRIFT
2. Arm test
1 - Position the machine with the arm completely ex-
tended and with the bucket teeth on the ground.
2 - Stop the engine and release the residual hydrau-
lic pressures.
RKP05000
3 - Disconnect the hoses (1) and (2) from the arm cy-
linder and plug them to prevent the entry of impu-
rities.
4 - Plug the hole of the arm cylinder on the head
side and attach a provisional tube on the base
side to catch any oil leakages. 2
1
RKPA2480
RKP05010
20-40 PC27R-8
CONTROL OF HYDRAULIC DRIFTS -
TESTING AND ADJUSTMENTS ANALYSIS OF THE CAUSES OF A DRIFT
3. Bucket test
1 - Position the machine with the arm vertical and
the bucket resting on the ground in a horizontal
position. Put a weight in the bucket, or fill it with
earth.
2 - Stop the engine and release the residual hydrau-
lic pressures.
3 - Disconnect the bucket cylinder hoses (1) and (2)
and plug them to prevent the entry of impurities.
4 - Plug the hole of the bucket cylinder on the base
side and attach a provisional tube on the head
side to catch any oil leakages. RKP05020
RKPA2490
RKP05031
PC27R-8 20-41
CONTROL OF HYDRAULIC DRIFTS -
TESTING AND ADJUSTMENTS ANALYSIS OF THE CAUSES OF A DRIFT
RKP05040
RKPA2500
RKPA2510
135°
RKP05050
20-42 PC27R-8
CONTROL OF HYDRAULIC DRIFTS -
TESTING AND ADJUSTMENTS ANALYSIS OF THE CAUSES OF A DRIFT
5. Blade test
1 - Position the machine with the arm resting verti-
cally on the ground and with the bucket resting
on its back.
2 - Raise the blade completely and support it on a
centrally-positioned block.
3 - Stop the engine and release the residual hydrau-
lic pressures.
RKP04930
RKP04980
PC27R-8 20-43
CONTROL OF HYDRAULIC DRIFTS -
TESTING AND ADJUSTMENTS ANALYSIS OF THE CAUSES OF A DRIFT
15°
135°
RKP05050
20-44 PC27R-8
CHECKING FOR ANY LEAKAGES INSIDE
TESTING AND ADJUSTMENTS THE WORKING EQUIPMENT CYLINDERS
RKP04710
MAXIMUM
PRESSURE
RKP04751
PC27R-8 20-45
CHECKING FOR ANY LEAKAGES INSIDE
TESTING AND ADJUSTMENTS THE SWING MOTOR
H Test conditions: 2
. Engine: at working temperature.
. Hydraulic oil: 45 ± 55ëC (113 ± 131ëF). 1
. Turret: locked in place with the swing-locking pin.
1 - Disconnect the drainage tube (1) of the motor (2) and
plug it.
2 - Attach a provisional tube to catch the drainage oil.
3 - Start the motor and bring it up to maximum swing.
4 - Make sure that the turret is locked in place and push
the swing command lever to the end of its stroke. RKPA2302
20-46 PC27R-8
METHODS FOR TESTING FOR LEAKAGES
TESTING AND ADJUSTMENTS INSIDE THE SWIVEL JOINT
1. Functionality test
1 - When a lower actuator (blade, travel motor, travel
increment) is found to be defective, one of the
possible causes of failure is the swivel joint.
G Increment of travel speed
2 - In order to ascertain the cause of the defect it is
sufficient to by-pass the joint by connecting (using F Blade cylinder, base side - Descent
a length of additional tubing) the input and output
tubes of the joint of the line to be checked. E Blade cylinder, head side - Rise
If this corrects the defect, it is certainly due to the
swivel joint. D Travel motor to the left - Reverse
If the defect persists, it can be ascribed to other
causes, but definitely not to the swivel joint. C Travel motor to the right - Forward
these tests.
The test method consists of pressurising the line to be
checked and measuring any leakages from the adja-
cent lines according to the following tables:
TABLE A
Symbol Line to be controlled (under pressure) Adjacent line (possible leakages) Sym.
Travel motor to the left - Forward B
A Travel motor to the right - Reverse
External leak (visible) Ð
Travel motor to the right - Forward C
B Travel motor to the left - Forward
Travel motor to the right - Reverse A
Travel motor to the left - Reverse D
C Travel motor to the right - Forward
Travel motor to the left - Forward B
Blade cylinder, head side - Rise E
D Travel motor to the left - Reverse
Travel motor to the right - Forward C
Blade cylinder base side - Descent F
E Blade cylinder, head side - Rise
Travel motor to the left - Forward D
Descent Passage not used G
F Blade cylinder base side - Descent
Blade cylinder, head side - Rise E
The symbols correspond to the symbols stamped onto the input and output ports of the swivel joint.
PC27R-8 20-47
METHODS FOR TESTING FOR LEAKAGES
TESTING AND ADJUSTMENTS INSIDE THE SWIVEL JOINT
20-48 PC27R-8
GROUP 30
40-28 PC15R-8
REMOVAL AND INSTALLATION
PC27R-8 30-1
SWING CIRCLE BUCKET CYLINDER
Removal . . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . 47 Removal . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . . 59
Installation. . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . 47 Installation . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . . 59
RUBBER TRACK SHOES BOOM SWING CYLINDER
Removal . . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . 48 Removal . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . . 60
Installation. . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . 48 Installation . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . . 61
STEEL TRACK-SHOES BLADE CYLINDER
Removal . . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . 49 Removal . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . . 62
Installation. . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . 49 Installation . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . . 62
SPROCKET WHEEL WORK EQUIPMENT CYLINDERS
Removal . . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . 50 Disassembly . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . . 63
Installation. . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . 50 Assembly . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . . 63
FINAL DRIVE UPPER WORK EQUIPMENT
Removal . . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . 51 Removal . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . . 69
Installation. . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . 51 Installation . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . . 70
IDLER AND RECOIL SPRING ARM
Removal . . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . 52 Removal . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . . 71
Installation. . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . 52 Installation . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . . 72
SPRING RECOIL AND THRUST ARM ASSEMBLY
CYLINDER GROUPS Removal . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . . 73
Disassembly. .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . 53 Installation . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . . 73
Assembly . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . 53 BOOM
IDLER Removal . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . . 74
Disassembly. .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . 54 Installation . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . . 75
Assembly . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . 54 BOOM SWING SUPPORT
TRACK ROLLERS Removal . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . . 76
Removal . . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . 55 Installation . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . . 76
Installation. . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . 55 BLADE
BOOM CYLINDER Removal . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . . 77
Removal . . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . 56 Installation . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . . 77
Installation. . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . 57
ARM CYLINDER
Removal . . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . 58
Installation. . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . 58
30-2 PC27R-8
REMOVAL AND INSTALLATION HOW TO READ THE MANUAL
2. To the precautions to be taken during the removal or installation of the groups, must be added the specific
«PRECAUTIONS TO BE TAKEN DURING THE OPERATIONS».
Always make sure that these precautions are taken.
4. List of the tightening torques and weights, and the quantities oil, liquids or grease needed to fill
tanks and containers
(1) In the operating procedures, you will find the symbols , , , . In the following order, these
represent the values of «TIGHTENING TORQUES», «WEIGHT OF PARTS OR GROUPS», «QUANTITIES
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.
PC27R-8 30-3
REMOVAL AND INSTALLATION PRECAUTIONS TO BE TAKEN WHILE WORKING
H When dismantling or installing a part, always take the following general precautions.
30-4 PC27R-8
REMOVAL AND INSTALLATION SPECIAL TOOLS
SPECIAL TOOLS
Dynamometric wrench
2 ATR800190 with multiplier 1 Max. 400 kg (400 dNm)
ATR200740 Plunger éi 30 2
4 Mounting bushings on
cylinders and piston rod
ATR200750 Plunger éi 35 2
PC27R-8 30-5
REMOVAL AND INSTALLATION SPECIAL TOOLS
SPECIAL TOOLS
30-6 PC27R-8
REMOVAL AND INSTALLATION STARTER MOTOR
RKPA2560
6 5
RKPA2570
Screw: . . . . . . . . . . . . . . Nm (. . . . . . . . . . . . . . lb.ft.)
PC27R-8 30-7
REMOVAL AND INSTALLATION ALTERNATOR
RKPA2560
RKPA2580
H Adjust the tension of the fan belt. (For details, see «20.
CONTROLS AND ADJUSTMENTS»).
30-8 PC27R-8
REMOVAL AND INSTALLATION INJECTION PUMP
RKPA2161
7
3 - Disconnect from injection pump (3) fuel feeding pipes
(4) and return pipes (5).
4 5
4 - Disconnect injection pump (3) lubricating pipe (6).
5 - Disconnect high pressure pipes (7) from injection
pump (3). 6
RKPA2590
RKPA2600
11 X1
10 X2
RKP06390
PC27R-8 30-9
REMOVAL AND INSTALLATION INJECTION PUMP
12
RKPA2610
INSTALLATION OF INJECTION
PUMP
. To install, reverse the removal procedure.
30-10 PC27R-8
REMOVAL AND INSTALLATION NOZZLE HOLDER
RKPA2620
RKPA2630
RKPA2640
INSTALLATION OF THE
NOZZLE HOLDER
. To install, reverse the removal procedure.
PC27R-8 30-11
REMOVAL AND INSTALLATION WATER COOLANT PUMP
RKPA2421
5
4
RKPB6060
3 - Remove from the radiator the fan cover (7) and dis-
connect the fan-cooling conveyor (8).
RKPB6070
RKP06541
30-12 PC27R-8
REMOVAL AND INSTALLATION WATER COOLANT PUMP
12
15
12 RKP06551
INSTALLATION OF WATER
COOLANT PUMP
. To install, reverse the removal procedure.
PC27R-8 30-13
REMOVAL AND INSTALLATION CYLINDER HEAD
RKPA2620
6
5
RKPA2670
RKPA2631
RKP06400
30-14 PC27R-8
REMOVAL AND INSTALLATION CYLINDER HEAD
16
15
RKP06410
Exhaust side
Flywheel side
8 14 5
Fan side
2 12 9 3
INSTALLATION OF THE
CYLINDER HEAD
4 10 11 1
6 13 7
Screws:. . . . . . . . . . . . . . . . Nm (. . . . . . . . . . . lb.ft.)
Nuts: . . . . . . . . . . . . . . . . . . Nm (. . . . . . . . . . . lb.ft.)
Nut: . . . . . . . . . . . . . . . . . . . Nm (. . . . . . . . . . . lb.ft.)
Screw: . . . . . . . . . . . . . . . . . Nm (. . . . . . . . . . . lb.ft.)
7 1 10
Fan side
13 3 6
H Raise the cylinder head, keeping it horizontal, and 12
PC27R-8 30-15
REMOVAL AND INSTALLATION ENGINE HOOD
RKPA2730
INSTALLATION OF THE
ENGINE HOOD
. To install, reverse the removal procedure.
4 RKPA2740
30-16 PC27R-8
REMOVAL AND INSTALLATION CANOPY
REMOVAL OF CANOPY
Completely lower the working equipment until it is
resting on the ground and stop the engine and take
out the ignition key.
RKPA2750
INSTALLATION OF CANOPY
. To install, reverse the removal procedure.
RKPA2760
RKPA2770
PC27R-8 30-17
REMOVAL AND INSTALLATION CAB
REMOVAL OF CAB
Completely lower the working equipment until it is
resting on the ground and stop the engine and take
out the ignition key.
RKPA2780
INSTALLATION OF CAB
. To install, reverse the removal procedure.
RKPA279 0
30-18 PC27R-8
REMOVAL AND INSTALLATION HEATING FAN
RKPA2810
7 - Loosen screws (8) (No. 2), remove cover (9) and re-
move the complete fan (10).
H Accompany the tubes (6) and (7) to avoid to da-
10
mage them. 9
8
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). 11
13
10 - Remove the heating fan (13). 6
12
RKPA2830
PC27R-8 30-19
REMOVAL AND INSTALLATION HEATING FAN
30-20 PC27R-8
REMOVAL AND INSTALLATION COUNTERWEIGHT
2
RKPA2422
RKPA3180
INSTALLATION OF THE
COUNTERWEIGHT RKPA2840
PC27R-8 30-21
REMOVAL AND INSTALLATION FUEL TANK
1
RKPA2850
3
RKPA2860
8
9 RKPA2870
INSTALLATION OF THE
FUEL TANK
. To install, reverse the removal procedure.
1 - Fill up the tank.
30-22 PC27R-8
REMOVAL AND INSTALLATION HYDRAULIC TANK
4
5
RKPB6080
6
7
RKPB6090
RKPB6110
PC27R-8 30-23
REMOVAL AND INSTALLATION HYDRAULIC TANK
9
RKPB6100
10
RKPA2911
INSTALLATION OF THE
HYDRAULIC TANK
. To install, reverse the removal procedure.
Counterweight screws:
. . . . . . . . . . . . . . . . . . . Nm (. . . . . . . . . . . . . . . . lb.ft.)
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 PC27R-8
REMOVAL AND INSTALLATION OIL-COOLER - RADIATOR GROUP
4
5
RKPB6120
RKPB6070
RKPB6130
PC27R-8 30-25
REMOVAL AND INSTALLATION OIL-COOLER - RADIATOR GROUP
H Fill the hydraulic oil tank with oil up to its maximum le-
vel.
30-26 PC27R-8
REMOVAL AND INSTALLATION ENGINE-PUMP GROUP
RKPA2861
7 6
4
RKPA2930
RKZA2940
PC27R-8 30-27
REMOVAL AND INSTALLATION ENGINE-PUMP GROUP
15
RKPA2950
RKPA2811
RKPA2960
30-28 PC27R-8
REMOVAL AND INSTALLATION ENGINE-PUMP GROUP
RKPA2970
INSTALLATION OF THE
ENGINE-PUMP GROUP
. To install, reverse the removal procedure. 22
PC27R-8 30-29
REMOVAL AND INSTALLATION PUMP
30-30 PC27R-8
REMOVAL AND INSTALLATION ENGINE-PUMP COUPLING
RKPA2990
INSTALLATION OF THE
ENGINE-PUMP COUPLING
. To install, reverse the removal procedure. 2
3
PC27R-8 30-31
REMOVAL AND INSTALLATION LATERAL LOWER COVER
wiring harness.
4 - Disconnect the electrical socket connectors (3)
and take out the cover (2).
RKPA3010
4 7
RKPA2424
INSTALLATION OF THE
LATERAL LOWER COVER 5
. To install, reverse the removal procedure. 6
RKPA3020
30-32 PC27R-8
REMOVAL AND INSTALLATION INNER CONTROL VALVE BOX COVER
4 RKPA3030
INSTALLATION OF INNER
CONTROL VALVE BOX COVER
. To install, reverse the removal procedure.
RKPA3040
PC27R-8 30-33
REMOVAL AND INSTALLATION CONTROL VALVE
RKPA3050
RKPA3060
9
RKPA3070
30-34 PC27R-8
REMOVAL AND INSTALLATION CONTROL VALVE
RKPA3080
INSTALLATION OF THE
CONTROL VALVE
. To install, reverse the removal procedure.
PC27R-8 30-35
REMOVAL AND INSTALLATION LEFT-HAND PPC VALVE (ARM-BUCKET)
3 - Take out the screws (4) and remove the L.H. cover
(5). 8
4 - Remove the hose-clamp (6), remove the screws (7)
and remove the PPC valve (8).
7 6
RKPA4861
5 - Disconnect the six PPC valve tubes (9) and plug them
to prevent entry of impurities.
H Check that the tubes are marked to avoid exchan- 8
ging them during re-assembly.
9
INSTALLATION OF LEFT-HAND
PPC VALVE (ARM-BUCKET)
. To install, reverse the removal procedure. RKPA3110
P4
If the couplings are removed from the PPC valves,
make sure that the coupling with a filter is mounted
on input P. P3 P1
RKPA3120
30-36 PC27R-8
REMOVAL AND INSTALLATION RIGHT-HAND PPC VALVE (BOOM-BUCKET)
7
5
RKPA3140
5 - Take out the screws (6) and remove the PPC valve
(7).
6 - Disconnect the six PPC valve tubes (7) and plug them 8
to prevent entry of impurities.
H Check that the tubes are marked to avoid exchan-
ging them during re-assembly.
7
INSTALLATION OF RIGHT-HAND
PPC VALVE (BOOM-BUCKET)
To install, reverse the removal procedure.
RKPA3150
.
P4
If the couplings are removed from the PPC valves,
make sure that the coupling with a filter is mounted P3 P1
on input P. RKPA3160
PC27R-8 30-37
REMOVAL AND INSTALLATION SERVOCONTROL SOLENOID GROUP
1
RKPA2853
INSTALLATION OF THE
SERVOCONTROL SOLENOID GROUP
. To install, reverse the removal procedure.
30-38 PC27R-8
REMOVAL AND INSTALLATION PLATFORM
2
RKPA2425
RKPA3051
6
RKPB5572
9
RKPA3071
PC27R-8 30-39
REMOVAL AND INSTALLATION PLATFORM
11
10
RKPB5506
14
RKPA3131
18
RKPA3310
RKPA2812
30-40 PC27R-8
REMOVAL AND INSTALLATION PLATFORM
24
INSTALLATION OF THE
PLATFORM
. To install, reverse the removal procedure.
23
H Fill the tank with hydraulic oil up to the maximum le-
vel.
PC27R-8 30-41
REMOVAL AND INSTALLATION SWIVEL JOINT
RKZA3350
30-42 PC27R-8
REMOVAL AND INSTALLATION SWING MACHINERY
PANELS»).
3 - Disconnect the tubes (2) (No. 3)
RKPA3380
RKPA3390
RKPA3331
PC27R-8 30-43
REMOVAL AND INSTALLATION SWING MACHINERY
RKPA3321
INSTALLATION OF SWING 16
MACHINERY
13
. To install, reverse the removal procedure.
15
14
Platform screws: 130 Nm (95.8 lb.ft.)
Platform screws: Loctite 262
RKPA2303
30-44 PC27R-8
REMOVAL AND INSTALLATION REVOLVING FRAME
OF THE PLATFORM»).
7 - Disconnect the swing circle lubrication tube (2) and
remove the coupling (3). 6
2
8 - Remove the swing machinery (4). (For details, see
«REMOVAL OF SWING MACHINERY»).
5
9 - Disconnect the upper tubes (5) (No. 8) from the swivel
joint.
H Mark the tubes to avoid exchanging them during
re-assembly.
4
10 - Remove the bracket (6) of the joint. 3
11 - Loosen and remove the screws (7) that secure the re-
7
volving frame. RKPA3420
RKPA3430
PC27R-8 30-45
REMOVAL AND INSTALLATION REVOLVING FRAME
30-46 PC27R-8
REMOVAL AND INSTALLATION SWING CIRCLE
2
INSTALLATION OF THE
SWING CIRCLE RKPA3440
PC27R-8 30-47
REMOVAL AND INSTALLATION RUBBER TRACK SHOES
Direction
INSTALLATION OF RUBBER
TRACK-SHOES
. To install, reverse the removal procedure.
30-48 PC27R-8
REMOVAL AND INSTALLATION STEEL TRACK-SHOES
INSTALLATION OF
STEEL TRACK-SHOES
. To install, reverse the removal procedure.
PC27R-8 30-49
REMOVAL AND INSTALLATION SPROCKET WHEEL
INSTALLATION OF THE
SPROCKET WHEEL
. To install, reverse the removal procedure.
30-50 PC27R-8
REMOVAL AND INSTALLATION FINAL DRIVE
INSTALLATION OF THE
FINAL DRIVE 3
2
. To install, reverse the removal procedure.
PC27R-8 30-51
REMOVAL AND INSTALLATION IDLER AND RECOIL SPRING
2
RKPA3480
3
RKPA3490
30-52 PC27R-8
REMOVAL AND INSTALLATION SPRING RECOIL AND THRUST CYLINDER GROUPS
5 RKP06240
Assembly
. To re-assemble, reverse the dismantling procedure.
=
=
RKP06490
2 - Thrust cylinder
11
Disassembly 13
1 - Take out plate (8), valve 89) and nipple (10) from cy- 15
linder (7). 16
12
2 - Take out the piston (11) out of the cylinder. 7 14
3 - Take out the snap ring (12), the gasket (13), the
spacer (14), the anti-extrusion ring (15), and the O-
ring (16). 8
Assembly 9
. To re-assemble, reverse the dismantling procedure. 10 RKP06250
PC27R-8 30-53
REMOVAL AND INSTALLATION IDLER
RKPA3550
Oil: 70 cc.
2 1
2 - Tightening the cap (1). 4 5
RKP06260
30-54 PC27R-8
REMOVAL AND INSTALLATION TRACK ROLLERS
2
2 - Rotate the turret 90ë towards the removal side and
force the boom down to raise the lower track-frame RKPA3500
(2).
3
INSTALLATION OF THE RKPA3451
TRACK ROLLERS
. To install, reverse the removal procedure.
PC27R-8 30-55
REMOVAL AND INSTALLATION BOOM CYLINDER
4
2 - Remove the working beam (2).
3 - Stop the engine, release the pressures in the cylinder
by moving the right-hand PPC valve lever several
times.
RKPA3272
RKPA3520
30-56 PC27R-8
REMOVAL AND INSTALLATION BOOM CYLINDER
RKPA3540
MAX.1mm
RKP06270
(0.04 in.). 10
PC27R-8 30-57
REMOVAL AND INSTALLATION ARM CYLINDER
RKPA3570
INSTALLATION OF THE
ARM CYLINDER 1
5
4
H Adjust the shim thickness so that the clearance be-
tween cylinder and arm is below 1 mm (0.04 in.).
RKPA3580
. Start the engine and bleed the air from the cylinder.
(For details, see «20. CONTROLS AND ADJUST-
MENTS»).
MAX.1mm
MAX.1mm
RKP06290
30-58 PC27R-8
REMOVAL AND INSTALLATION BUCKET CYLINDER
A
RKPA3590
INSTALLATION OF THE
BUCKET CYLINDER
MAX.1mm
alignment.
PC27R-8 30-59
REMOVAL AND INSTALLATION BOOM SWING CYLINDER
tely.
H Bind the piston rod with wire to secure the fully re-
tracted position.
4 - Stop the engine and move the command pedal boom
swing cylinder several times to release residual pres-
sures. (For details, see «20. CONTROLS AND AD-
JUSTMENTS»).
3
2 1
RKPA3620
5
RKPA3411
RKPA3630
30-60 PC27R-8
REMOVAL AND INSTALLATION BOOM SWING CYLINDER
INSTALLATION OF THE
BOOM SWING CYLINDER
RKPA3640
RKP06320
MAX.1mm
MENTS»).
RKP06330
PC27R-8 30-61
REMOVAL AND INSTALLATION BLADE CYLINDER
INSTALLATION OF THE
BLADE CYLINDER
. To install, reverse the removal procedure.
30-62 PC27R-8
REMOVAL AND INSTALLATION WORK EQUIPMENT CYLINDERS
1 - Take off the guard rings (1) from both sides of the cy-
linder and from the piston rod. 1
H Make sure that the tube unions are not plugged.
1
RKP05230
23
RKPA1390
RKPA1400
2
RKPA1410
PC27R-8 30-63
REMOVAL AND INSTALLATION WORK EQUIPMENT CYLINDERS
5 - Raise the cylinder and hook the piston rod to the mo-
bile group of the tool C1.
6 - Extract the piston rod group (4) from the cylinder.
4
7 - Remove the cylinder (2) and the piston rod group.
C1
2
RKPA1420
30-64 PC27R-8
REMOVAL AND INSTALLATION WORK EQUIPMENT CYLINDERS
H Take great care not to damage the seal and the slid-
ing surfaces.
H Prepare each individual component before commen-
cing the final assembly. 7
1. Assembly of the cylinder head
1 - Position the guard ring (7) and, using a press and the C7
push rod C7, press it home in the head (3).
H Check the orientation carefully. 3 3
RKPA1440
C3
RKPA1450
7 9
RKZ05260
PC27R-8 30-65
REMOVAL AND INSTALLATION WORK EQUIPMENT CYLINDERS
2. Piston assembly
1 - Using the tool C8, mount the piston seal. Mount in se-
quence the rubber ring (13), the outer seal (14) and
the anti-extrusion rings (15). C8
13 14 15
RKPA1460
13
RKPA1470
C4
RKPA1480
RKPA1490
30-66 PC27R-8
REMOVAL AND INSTALLATION WORK EQUIPMENT CYLINDERS
Bevel
RKP06301
RKPA1500
8 - Mount the nut (5) that secures the piston and tighten
it with the socket wrench C6 and the dynamometric
tool with a multiplier C2.
Nut: Loctite 262
Nut:
Unit: Nm (lb.ft.)
Boom
Boom Arm Bucket Blade
swing
Cylinder 5 C6 C2
785w78 785w78 618w62 912w91 618w62
(578w57) (578w57) (455w46) (672w67) (455w46)
RKPA1431
4. Cylinder assembly
1 - Mount the tools C4 onto the apparatus C1.
2 - Position the bushing (22) and mount it onto the cylin- C4
der (2). 2
H Leave the cylinder in position, ready for the next C1
assembly operation.
22
RKPA1391
PC27R-8 30-67
REMOVAL AND INSTALLATION WORK EQUIPMENT CYLINDERS
RKPA1510
5 - Mount the piston rod group (4) onto the tool C1 and
raise the mobile part up to the end of its stroke.
6 - Put the cylinder (2) into a vertical position and guide 4
the piston into the tool C11.
7 - Lower the apparatus supporting the piston rod (4) in
order to insert the piston into the cylinder liner (2).
8 - Remove the tool C11 from the cylinder and then lower
the apparatus C1 even further, until the head (3) and
the piston rod approach the cylinder. C1
2
C11
30-68 PC27R-8
REMOVAL AND INSTALLATION UPPER WORK EQUIPMENT
RKPA3272
H Bind the piston rod with wire to secure the fully re-
tracted position. 3
7 - Stop the engine and release the residual hydraulic 4
pressures. (For details, see «20. CONTROLS AND RKPA3521
ADJUSTMENTS»).
8 - Disconnect the hoses (5) (No. 10); plug the tubes to
prevent entry of impurities. 5
H Remove the fixed working beam clips.
A
RKPA3670
7
RKPA3680
PC27R-8 30-69
REMOVAL AND INSTALLATION UPPER WORK EQUIPMENT
RKPA3690
. 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.
30-70 PC27R-8
REMOVAL AND INSTALLATION ARM
RKPA3720
RKPA3571
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).
11
RKPA3740
PC27R-8 30-71
REMOVAL AND INSTALLATION ARM
30-72 PC27R-8
REMOVAL AND INSTALLATION ARM ASSEMBLY
INSTALLATION OF THE
ARM ASSEMBLY
. To install, reverse the removal procedure.
7
Internal bushings: ASL800040
PC27R-8 30-73
REMOVAL AND INSTALLATION BOOM
2
8 - Start the engine and completely retract the piston rod
(5).
9 - Stop the engine and release the residual hydraulic
pressures. (For details, see «20. CONTROLS AND
ADJUSTMENTS»).
B
10 - Put a sling round the boom (2) and apply a slight ten-
sion to the cables. A
RKPA3770
4
5
RKPA3522
6 6
7
RKPA3780
30-74 PC27R-8
REMOVAL AND INSTALLATION BOOM
PC27R-8 30-75
REMOVAL AND INSTALLATION BOOM SWING SUPPORT
RKPA3830
mm (0.02 in.).
Supporting surfaces and shims: ASL800050
4 6
9
7
MAX.0,5mm
RKP06350
30-76 PC27R-8
REMOVAL AND INSTALLATION BLADE
PC27R-8 30-77
GROUP 40
40-28 PC15R-8
STANDARD MAINTENANCE
PC27R-8 40-1
SWING CIRCLE
RKP01530
Unit: mm (in.)
40-2 PC27R-8
SWING MACHINERY
1
25 Nm
(18.4 lb.ft.) 42 Nm
(30.9 lb.ft.)
2
750 ± 850 Nm
(552.8 ± 626.5 lb.ft.)
4
130 Nm
(95.8 lb.ft.)
20 ± 30 Nm
(14.7 ± 22.1 lb.ft.)
RKP01540
Unit: mm (in.)
Clearance between
2 0.15 (0.006) 0.35 (0.014)
planetary gear and ring gear
Replace
Clearance between
3 pinion and 0.30 (0.012) 0.70 (0.028)
swing circle teething
PC27R-8 40-3
FINAL DRIVE
120 Nm
(88.4 lb.ft.) 1 2
20 ± 30 Nm
(14.7 ± 22.1 lb.ft.)
RKP01371
Unit: mm (in.)
Backlash between
4 No. 1 sun gear and 0.10 (0.004) 0.30 (0.012)
No. 1 planetary gear
5 Axial play of sun gear 0.5 ± 1.5 (0.0197 ± 0.591) 2.5 (0.0985)
40-4 PC27R-8
SPROCKET
4
3
120 Nm
(88.4 lb.ft.)
2 1
RKP02050
Unit: mm (in.)
PC27R-8 40-5
TRACK FRAME AND RECOIL SPRING
RKP01671
Unit: mm (in.)
No. Check item Criteria Remedy
Standard
Item Repair limit Build up by
size
welding
Vertical width of Track frame 108 (4.255) 112 (0.158)
1
idler guide
Build up by
Idler support 106 (4.176) 102 (4.02) welding or
replace
Build up by
Track frame 161 (6.343) 165 (6.5)
welding
Horizontal width of
2 Build up by
idler guide
Idler support 159 (6.265) 155 (6.107) welding or
replace
Standard size Repair limit
Free Preloaded Installed Free Installed
length length load length load
3 Recoil spring Steel 206.4 2000 kg 241.8 1780 kg Replace
248 (9.77)
shoe (8.132) (4406 lb.) (9.527) (3921 lb.)
Rubber 248 188.4 2860 kg 241.8 2625 kg
shoe (9.771) (7.423) (6301 lb.) (9.527) (5783 lb.)
40-6 PC27R-8
IDLER
5 4 3
6
1
RKP01720
Unit: mm (in.)
Outer diameter
2 300 (11.82) 292 (11.5)
of tread Build up by
welding or
Width of track replace
3 28 (1.103) 20 (0.788)
shoe guide
Tolerance
Standard Standard Clearance
size clearance limit
Shaft Hole
Clearance between
6
bushing and idler ± 0.025 + 0.142 0.105 ±
35 (± 0.0001) (+ 0.0056) 0.206 1.5
Replace
(1.379) ± 0.064 + 0.080 (0.0041 ± (0.0591)
(± 0.0025) (+ 0.0032) 0.0081)
PC27R-8 40-7
CARRIER ROLLER
270 Nm
2 (199 lb.ft.)
RKP01401
Unit: mm (in.)
40-8 PC27R-8
TRACK ROLLER
7 4 3
6
170 Nm
(125.3 lb.ft.)
2 1
RKP01411
Unit: mm (in.)
Outer diameter
2 85 (3.349) 77 (3.034) Replace
of protusion
Tolerance
Standard Standard Clearance
size clearance limit
Shaft Hole
Clearance between
5
shaft and bushing 0 + 0.183
(0) (+0.0072)
25 (0.985) 0.2 (0.008) 0.3 (0.012)
± 0.013 + 0.144
(±0.0005) (+0.0057)
Replace
bushing
Tolerance
Standard Standard Interference
size interference limit
Shaft Hole
Interference between
6
roller and bushing + 0.073 + 0.039
(+0.0029) (+0.0015) 0.021 0.085
32
+ 0.048 +0 (0.00083) (0.00335)
(+0.0019) (+0)
PC27R-8 40-9
TRACK SHOE
STEEL SHOE
6
8
2
7 5
RKP02060
Unit: mm (in.)
40-10 PC27R-8
RUBBER SHOE
A
A
Section
Sezione A
A± A
-A RKP01730
Unit: mm (in.)
Wear of meshing
3 23 (0.906) 27 (1.064)
portion of sprocket
PC27R-8 40-11
HYDRAULIC PUMP
24.5w4.9 Nm 34.3w4.9 Nm
(18w3.6 lb.ft.) (25.3w0.2 lb.ft.)
30.9w3.4 Nm
(22.7w2.5 lb.ft.)
69.7w1.0 Nm
(51.4w0.74 lb.ft.)
13.3w1.5 Nm
22.1w2.5 Nm 22.1w2.5 Nm (9.8w1.1 lb.ft.)
(16.3w1.8 lb.ft.) (16.3w1.8 lb.ft.)
RKP01300
40-12 PC27R-8
CONTROL VALVE
11.3w1.5 Nm
31.9w2.5 Nm (8.3w1.1 lb.ft.)
(23.5w1.8 lb.ft.)
C
B
A
P P
O O
M M
L L
K K
J J
E E
A
B
C
11.3w1.5 Nm
(8.3w1.1 lb.ft.)
11.3w1.5 Nm
(8.3w1.1 lb.ft.)
RKP01591
PC27R-8 40-13
44.1w4.9 Nm
(32.5w3.6 lb.ft)
44.1w4.9 Nm
(32.5w3.6 lb.ft)
Section A -±AA
Sezione A
RKP01661
40-14 PC27R-8
1
8.3w1.5 Nm
(6.1w1.1 lb.ft.)
8.3w1.5 Nm
(6.1w1.1 lb.ft.)
Section
SezioneBB±- B
B RKP01621
Unit: mm (in.)
PC27R-8 40-15
1
1.5w0.2 Nm 2
(1.1w0.15 lb.ft.)
2
53.9w5.9 Nm 3
(39.7w4.3 lb.ft.)
139.7w22.1 Nm 139.7w22.1 Nm
(103w16.3 lb.ft.) (103w16.3 lb.ft.)
Section C± C
6
Sezione C -C RKP01611
Unit: mm (in.)
40-16 PC27R-8
147.1w9.8 Nm 53.9w5.9 Nm
(108.4w7.22 lb.ft.) (39.7w4.3 lb.ft.)
Section
SezioneEE±- E
E
22.1w2.5 Nm
(16.3w1.84 lb.ft.) 1
Section JJ -±JJ
Sezione Section
Sezione K
K±- K
K
44.1w4.9 Nm
(32.5w3.6 lb.ft) RKP02030
Unit: mm (in.)
PC27R-8 40-17
22.1w2.5 Nm 22.1w2.5 Nm
(16.3w1.84 lb.ft.) (16.3w1.84 lb.ft.)
1 1
Section LL -±LL
Sezione Section M -±MM
Sezione M
22.1w2.5 Nm
39.2w4.9 Nm (16.3w1.84 lb.ft.)
(28.9w3.6 lb.ft.) 2
Section O -±OO
Sezione O Section
SezionePP±- P
P
RKP02040
Unit: mm (in.)
40-18 PC27R-8
SWIVEL JOINT
RKP00500
Unit: mm (in.)
PC27R-8 40-19
SWING MOTOR
177w10 Nm 39w2 Nm
(130.4w7.4 lb.ft.) (28.7w1.5 lb.ft.)
A A
157w10 Nm
(115.7w7.4 lb.ft.)
8.8w1 Nm
(6.5w0.74 lb.ft.)
Section A -±AA
Sezione A RKP01550
Unit: mm (in.)
40-20 PC27R-8
PAGE INTENTIONALLY
LEFT BLANK
PC27R-8 40-21
TRAVEL MOTOR
63.7w5 Nm
(46.9w3.7 lb.ft.) 2
34.3w5 Nm
(25.3w3.7 lb.ft.)
3
B
240w5 Nm 31.9w2.5 Nm
(176.9w3.7 lb.ft.) (23.5w1.8 lb.ft.)
2.5w0.5 Nm
(1.84w0.37 lb.ft)
10w1 Nm
(7.4w0.74 lb.ft.) 2.5w0.5 Nm
(1.84w0.37 lb.ft.)
Section A
Sezione A -±AA
RKP01381
40-22 PC27R-8
53.7w5 Nm 5 53.7w5 Nm
(39.6w3.7 lb.ft.) (39.6w3.7 lb.ft.)
Section
Sezione B
B ±- B
B RKP01391
Unit: mm (in.)
PC27R-8 40-23
PPC VALVE
112.8w14.7 Nm
(83.1w10.8 lb.ft.)
13.2w1.5 Nm
(9.7w1.1 lb.ft.)
1
44.1w4.9 Nm
(32.5w3.6 lb.ft)
3
SectionAA- ±AA
Sezione Section
Sezione B
B ±- B
B
8.33w2.45 Nm
(6.1w1.8 lb.ft.)
2
Section D -±DD
Sezione D
3 6.37w2.45 Nm
(4.7w1.8 lb.ft.)
Section C±
Sezione C C
-C
Section EE-±EE
Sezione RKP01330
Unit: mm (in.)
40-24 PC27R-8
PPC VALVE
FOR HAMMER
13.23w1.47 Nm
(9.75w1.08 lb.ft.)
RKP01710
Unit: mm (in.)
PC27R-8 40-25
CYLINDER
M The figure represent arm cylinder
Boom: 569w57 Nm (419w42 lb.ft.) Boom: 785w78 Nm (578.5w57.5 lb.ft.) (Wrench size: 46 mm)
Arm: 539w54 Nm (397w39.8 lb.ft.) Arm: 785w78 Nm (578.5w57.5 lb.ft.) (Wrench size: 46 mm)
Bucket: 441w44 Nm (325w32.4 lb.ft.) Bucket: 618w62 Nm (455.5w45.7 lb.ft.) (Wrench size: 41 mm)
Boom swing: 588w59 Nm (433.3w43.5 lb.ft.) Boom swing: 912w91 Nm (672w67 lb.ft.) (Wrench size: 46 mm)
Blade: 539w54 Nm (397w39.8 lb.ft.) Blade: 618w62 Nm (455.5w45.7 lb.ft.) (Wrench size: 41 mm)
1 3
2
Loctite 262
RKP01470
Unit: mm (in.)
No. Check item Criteria Remedy
Misura Tolerance Standard Limit
Cylinder
standard Shaft Hole clearance clearance
± 0.025 + 0.039 0.025 ±
45 (±0.001) 0 0.126 0.426
Boom
(1.773) ± 0.087 (+0.0015 (0.001 ± (0.0168)
(±0.003) 0 ) 0.005)
± 0.025 + 0.039 0.025 ±
40 (±0.001) 0 0.126 0.426
Arm
(1.576) ± 0.087 (+0.0015 (0.001 ± (0.0168)
Clearance (±0.003) 0 ) 0.005)
between ± 0.025 + 0.039 0.025 ± Replace
1
piston rod and 35 (±0.001) 0 0.126 0.426 cylinder head
cylinder Bucket
(1.379) ± 0.087 (+0.0015 (0.001 ± (0.0168)
(±0.003) 0 ) 0.005)
± 0.025 + 0.039 0.025 ±
40 (±0.001) 0 0.126 0.426
Boom swing
(1.576) ± 0.087 (+0.0015 (0.001 ± (0.0168)
(±0.003) 0 ) 0.005)
± 0.025 + 0.039 0.025 ±
35 (±0.001) 0 0.126 0.426
Blade
(1.379) ± 0.087 (+0.0015 (0.001 ± (0.0168)
(±0.003) 0 ) 0.005)
± 0.025 + 0.142 0.105 ±
40 (±0.001) (+0.0056) 0.206 1
Boom
(1.576) ± 0.064 + 0.080 (0.004 ± (0.04)
(±0.002) (+0.0031) 0.008)
± 0.090 + 0.142 0.170 ±
35 (±0.004) (+0.0056) 0.272 1
Arm
(1.379) ± 0.130 + 0.080 (0.007 ± (0.04)
(±0.005) (+0.0031) 0.010)
Clearance ± 0.090 + 0.142 0.170 ±
between 35 (±0.004) (+0.0056) 0.272 1 Replace
2 Bucket
cylinder head (1.379) ± 0.130 + 0.080 (0.007 ± (0.04) bushing
bushing and pin (±0.005) (+0.0031) 0.010)
± 0.010 + 0.134 0.082 ±
40 (0.0004) (+0.0053) 0.184 1
Boom swing
(1.576) ± 0.050 + 0.072 (0.003 ± (0.04)
(±0.002) (+0.0028) 0.007)
± 0.090 + 0.142 0.170 ±
35 (±0.004) (+0.0056) 0.272 1
Blade
(1.379) ± 0.130 + 0.080 (0.007 ± (0.04)
(±0.005) (+0.0031) 0.010)
40-26 PC27R-8
Unit: mm (in.)
No. Check item Criteria Remedy
± 0.025 + 0.142 0.105 ±
40 (±0.001) (+0.0056) 0.206 1
Boom
(1.576) ± 0.064 + 0.080 (0.004 ± (0.04)
(±0.002) (+0.0031) 0.008)
± 0.090 + 0.142 0.170 ±
35 (±0.004) (+0.0056) 0.272 1
Arm
(1.379) ± 0.130 + 0.080 (0.007 ± (0.04)
(±0.005) (+0.0031) 0.010)
Clearance ± 0.090 + 0.142 0.170 ±
between 35 (±0.004) (+0.0056) 0.272 1 Replace
3 Bucket
cylinder bottom (1.379) ± 0.130 + 0.080 (0.007 ± (0.04) bushing
bushing and pin (±0.005) (+0.0031) 0.010)
± 0.010 + 0.134 0.082 ±
40 (0.0004) (+0.005) 0.184 1
Boom swing
(1.576) ± 0.050 + 0.072 (0.003 ± (0.04)
(±0.002) (+0.003) 0.007)
± 0.090 + 0.142 0.170 ±
35 (±0.004) (+0.0056) 0.272 1
Blade
(1.379) ± 0.130 + 0.080 (0.007 ± (0.04)
(±0.005) (+0.0031) 0.010)
PC27R-8 40-27
WORK EQUIPMENT
D
I
B
C
J
F A
N
G
E M
L
1 Section B
B -±BB Section CC-±CC
Sezione Section D
Sezione D -±DD
Sezione
Section
Sezione A
A± A
-A
Section F±
Sezione F - FF Section
SezioneG
G±- G
G
SectionEE- E
Sezione ±E RKP01741
40-28 PC27R-8
5
Section
SezioneHH±- H
H Section
Sezione II ±
- II Section J±
Sezione J - JJ
Section
SezioneKK±- K
K
4 6
Section L -±LL
Sezione L Section M
Sezione M-±MM Section
SezioneNN±-NN Section O -±OO
Sezione O
RKP01761
Unit: mm (in.)
PC27R-8 40-29
PC27R
40-30 PC27R-8