Komatsu PW200-7 Plus Wheeled Excavators Shop Manual VENBM65000 PDF

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Komatsu PW200-7 Plus Wheeled Excavators Shop Manual VENBM65000  – PDF DOWNLOAD

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Komatsu PW200-7 Plus Wheeled Excavators Shop Manual VENBM65000  – PDF DOWNLOAD

Language : English
Pages : 1260
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu PW200-7 Plus Wheeled Excavators Shop Manual VENBM65000  – PDF DOWNLOAD

MACHINE MODEL SERIAL NUMBER

• PW200-7 PLUS        H55300 AND UP

VENBM65000 PW200-7Plus . 1
CONTENTS . 3
FOREWORD . 5
Safety notice 5
Important safety notice 5
General precautions 5
Preparations for work 5
Precautions during work 6
Foreword . 7
General 7
Structure and function . 7
Testing, adjusting and troubleshooting . 7
Disassembly and assembly . 7
Maintenance standard . 7
How to read the shop manual 8
Volumes 8
Distribution and updating 8
Filing method 8
Revised edition mark . 8
Revisions 8
Symbols 8
Hoisting instructions 9
Hoisting . 9
Wire Ropes . 9
Coating materials 10
Standard tightening torque . 12
Standard tightening torque of bolts and nuts . 12
Tightening torque of hose nuts . 13
Tightening torque of split flange bolts 13
Tightening torques for hoses (taper seal type and face seal type) 13
Tightening torque for 107 engine series (bolts and nuts) . 14
Tightening torque for 107 engine series (eye joints) . 14
Tightening torque for 107 engine series (tapered screws) . 14
Electric wire code . 15
Classification by thickness 15
Classification by color and code . 15
Conversion tables 16
Method of using the conversion table . 16
Units 22
GENERAL 23
Specification dimension drawings . 24
Dimensions . 24
1 Piece boom . 25
2 Piece boom . 26
Working ranges . 27
1 Piece boom . 27
2 Piece boom . 28
Specifications . 29
Weight table . 31
1 Piece boom . 32
2 Piece boom . 33
Fuel, coolant and lubricants . 34
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD . 37
Engine related parts . 38
Outline 38
Radiator – oil cooler – charge air cooler 39
Power train 40
Swing circle . 42
Specifications . 43
Swing machinery & motor 44
Swing motor 47
Operation of swing lock 50
Relief valve portion . 51
Operation 51
Undercarriage 52
Transmission . 54
Quick coupler control valve 58
Specification 58
Operation 58
Shematic . 59
ATT EPC valve assembly . 60
Travel motor . 61
Operation of travel motor 63
Clutch control circuit . 66
Function . 67
Axle . 68
Front axle . 68
Rear Axle 70
Suspension lock cylinder . 72
Circuit 72
Axle oscillation . 73
Braking system . 74
Structure and function . 75
Brake/steer pump . 76
Specifications . 76
Function . 76
Priority valve . 77
Specification 77
Function . 77
Power brake valve 78
Specifications . 78
Function . 79
Accumulator for brake valve 80
Steering system 81
Structure and function . 81
Steering column 82
Orbitrol valve . 83
Hydraulic equipment layout drawings 84
Hydraulic circuit diagram 86
Hydraulic tank . 87
Hydraulic pump . 88
HPV95 + 95 (PW200-7E0 ) 88
LS valve . 94
PC valve . 94
Pilot pressure control (PPC) system 109
Control valve 110
CLSS . 124
Outline of CLSS 124
Basic Principle 125
Main relief valve 127
Variable pressure compensation valve . 128
Centre swivel joint 130
Travel PPC pedal . 132
Work equipment – swing PPC valve . 134
Operation 136
Solenoid valve block . 138
Solenoid valve block . 142
2 Position 3 way valve . 142
ON / OFF Solenoid valves (4 way valve) . 144
Operation 144
Hi/ Lo Solenoid valve (4 way valve) 146
Operation 146
Attachment EPC valve . 148
Function . 149
Operation 149
Boom safety valve 152
Operation 153
Hydraulic cylinder . 154
Boom cylinder 154
Arm cylinder . 154
Bucket cylinder 154
Adjust cylinder 155
Outrigger cylinder . 156
Function . 157
Important – Depressurising the cylinder 157
Depressurise the cylinder before opening . 157
Dozer cylinder . 158
Work equipment . 160
Work Equipment . 161
1. Dimension of arm 162
2. Dimension of bucket . 164
Air conditioner 166
Air conditioner piping . 166
Electrical wiring diagram 167
Electrical system 168
Engine Control . 168
Function . 169
Engine controller 170
CN-CE01 170
CN-CE01 171
CN-CE02 171
CN-CE03 172
Pump controller 175
Input signals 176
Output signals . 177
Electronic control system 178
Machine control system diagram . 179
1. Engine and pump control function 180
Function . 181
2. Pump/Valve control function . 186
Function . 186
3. One-touch power maximizing function . 188
Function . 188
4. Auto-deceleration function 190
Function . 190
Operation 191
5 Auto-warm-up/Overheat and White Smoke prevention function 192
Function . 192
6. Swing control function 194
Function . 194
7. Travel control function . 196
Function . 196
8. ATT flow control, ATT direction control . 198
9. System component parts 199
Function . 199
Specifications . 200
Function . 200
Function . 201
Operation 201
Machine monitor system . 202
Monitor panel 203
Outline 203
Input and output signals . 204
Monitor control, display portion . 206
Monitor items and display 208
Monitor Gauge Displays . 210
Keypad layout 215
Declaration of switch function on keypad . 216
Overload warning device 218
Outline 218
Function . 218
Structure 218
Sensor . 219
Coolant temperature sensor . 220
Oil pressure switch 220
Rotation sensor 221
Boost pressure and temperature sensor 221
WIF (Water-In-Fuel detection) sensor . 222
Engine oil level sensor 222
Coolant level sensor . 223
Coolant temperature sensor . 224
Fuel level sensor 224
Air cleaner clogging sensor 225
Overload Caution sensor 225
Swing proximity sensor . 226
Travel PPC sensor 226
PPC pressure sensor 226
Park brake pressure sensor . 227
Brake accumulator low pressure sensor 227
Brake stop light sensor 227
1st Attachment circuit hydraulic performance (main valve bypassed) . 228
Travel system 229
Travel circuit . 229
1. Travel motor 230
2. Travel pedal 239
3. Forward / Neutral / Reverse switch (F-N-R) 240
4. Forward / Reverse travel solenoid . 241
5. Travel / Neutral solenoid . 242
6. Travel creep solenoid . 243
7. 2-Stage relief solenoid . 244
8. Hi/Lo solenoid valve 246
9. Back pressure solenoid 247
Steering system 248
Operating principles . 248
Dynamic steering . 248
2 – Stage principle 248
1. Condition 1 . 249
2. Condition 2 . 250
3. Condition 3 . 251
4. Condition 4 . 252
5. Condition 5 . 253
6. Condition 6 . 254
7. OLS Priority valve 255
8. Load sensing steering unit 256
Service brake and suspension system 261
Braking system . 261
Operation 264
Komtrax terminal system 268
Central lubrication system (CLS) . 270
Auto-grease pump . 270
Overview . 271
Display and control unit . 271
LED-display 272
Push buttons . 272
Three-digit LED display 273
Check central lubrication system, fill up grease . 274
Lubrication diagram 275
Standard value table for engine related parts 279
Standard value table for chassis related parts . 280
Flow control characteristic of PC valve 293
STANDARD VALUE TABLE . 277
Measuring engine speed . 296
Measuring intake air pressure (boost pressure) . 297
Measurement of exhaust gas colour 298
Adjusting valve clearance 300
Measuring compression pressure . 302
Measuring blow-by pressure . 304
Measuring engine oil pressure 305
Handling fuel system parts . 306
Releasing residual pressure from fuel system . 307
Measuring fuel pressure 308
Measuring fuel return rate and leakage . 310
Bleeding air from fuel circuit . 312
Air bleeding route of fuel circuit . 313
Checking fuel circuit for leakage 314
Checking and adjusting air conditioner compressor belt tension . 315
Checking . 315
Adjusting 315
Replacing the fan belt . 316
Measurement of clearance in swing circle bearings 317
Inspection and adjustment of hydraulic oil pressure in hydraulic circuit for work equipment, swing and travel 318
Measurement 318
Adjustment . 320
Inspection and adjustment of control circuit oil pressure 322
Measurement 322
Procedure for pressure reducing adjustment . 323
Inspection and adjustment of pump PC (valve inlet) control oil pressure 324
Measurement 324
Adjustment . 326
Inspection and adjustment of pump LS valve control oil pressure 327
Measurement 327
Adjustment . 331
Measurement of solenoid valve output pressure 332
7 – Stage solenoid block . 334
4 – Stage solenoid block . 336
2 – Stage solenoid block . 337
Measurement of PPC valve output pressure . 338
Checking proportional control PPC circuit 339
Adjustment of work equipment and swing PPC valve . 340
Measuring and adjusting quick coupler control valve output pressure 341
Testing travel motor relief pressure . 343
Measuring travel motor relief pressure . 343
Adjusting travel motor relief pressure . 344
Testing propshaft speed 345
Measuring rotating speed of propshaft 345
Testing transmission clutch control circuit 346
Description 346
Inspection of locations of hydraulic drift of work equipment . 348
Release of remaining pressure in hydraulic circuit . 350
Measurement of oil leakage . 351
Air bleeding of various parts 354
Inspection procedures for diode 356
Special function of monitor panel 357
Changing the lubrication interval times 412
TESTING AND ADJUSTING 295
TROUBLESHOOTING 413
Troubleshooting 413
Points to remember when troubleshooting 414
Sequence of events in troubleshooting 415
Points to remember when carrying out maintenance . 416
1. Points to remember when handling electric equipment . 416
2. Points to remember when troubleshooting electric circuits . 422
3. Points to remember when handling hydraulic equipment 423
Checks before troubleshooting 425
Classification and steps for troubleshooting . 426
Classification of troubleshooting 426
Steps for troubleshooting 426
Failure-looking phenomenon and troubleshooting no 427
How to read electric wire code . 430
Connector location chart and circuit diagram by system . 435
Connector table 436
Connection table for connector pin numbers . 449
T-boxes and T-adapters table . 477
Before carrying out troubleshooting when failure code is displayed . 484
Information contained in troubleshooting table . 486
Relative circuit diagram . 487
Failure code [2G00MA] – Brake oil pressure abnormality . 488
Circuit diagram related to brake oil pressure switch . 488
Failure code [6B2JMA] – Travel hydraulic abnormality . 489
Failure code [989L00] – Engine controller lock caution 1 . 489
Failure code [989M00] – Engine controller lock caution 2 . 490
Failure code [989N00] – Engine controller lock caution 3 . 490
Failure code [AA10NX] – Air cleaner clogging . 491
Failure code [AB00KE] – Charge voltage low . 492
Failure code [B@BAZG] – Engine oil pressure low 493
Failure code [B@BAZK] – Engine oil level low . 493
Failure code [B@BCNS] – Engine water overheat 494
Failure code [B@BCZK] – Engine coolant level low . 494
Failure code [B@HANS] – Hydraulic oil overheat . 495
Failure code [CA111] – EMC critical internal failure . 495
Failure code [CA115] – Engine neutral and backup speed sensor error 496
Failure code [CA122] – Charge air press sensor high error 498
Circuit diagram related to boost pressure/temperature sensor (combination sensor) 499
Failure code [CA123] – Charge air press sensor low error . 500
Circuit diagram related to boost pressure/temperature sensor (combination sensor) 501
Failure code [CA131] – Throttle sensor high error 502
Circuit diagram related to fuel control dial . 503
Failure code [CA132] – Throttle sensor low error . 504
Circuit diagram related to fuel control dial . 505
Failure code [CA144] – Coolant temperature sensor high error . 506
Circuit diagram related to coolant temperature sensor 507
Failure code [CA145] – Coolant temp sensor low error . 508
Circuit diagram related to coolant temperature sensor 509
Failure code [CA153] – Charge air temperature sensor high error 510
Circuit diagram related to boost pressure/temperature sensor (combination sensor) 511
Failure code [CA154] – Charge air temperature sensor low error . 512
Circuit diagram related to boost pressure/temperature sensor (combination sensor) 513
Failure code [CA155] – Charge air temperature high speed derate 514
Failure code [CA187] – Sensor supply 2 voltage low error . 516
Circuit diagram related to sensor power supply 2 . 517
Failure code [CA221] – Ambient press sensor high error . 518
Circuit diagram related to ambient pressure sensor . 519
Failure code [CA222] – Ambient press sensor low error 520
Circuit diagram related to ambient pressure sensor . 521
Failure code [CA227] – Sensor supply 2 volt high error . 522
Circuit diagram related to sensor power supply 2 . 522
Failure code [CA234] – Engine overspeed 523
Failure code [CA238] – NE speed sensor supply voltage error 524
Circuit diagram related to engine NE speed sensor 524
Failure code [CA271] – IMV/PCV1 short circuit error 525
Circuit diagram related to supply pump actuator (metering unit) 525
Failure code [CA272] – IMV/PCV1 open error . 526
Circuit diagram related to supply pump actuator (metering unit) 526
Failure code [CA322] – Injector #1 (L#1) open/short circuit error 528
Circuit diagram related to no. 1 injector 529
Failure code [CA324] – Injector #3 (L#3) open/short circuit error 530
Circuit diagram related to no. 3 injector 531
Failure code [CA331] – Injector #2 (L#2) open/short circuit error 532
Circuit diagram related to no. 4 injector 535
Failure code [CA342] – Calibration code incompatibility 536
Failure code [CA351] – Injectors drive circuit error . 538
Circuit diagram related to engine controller . 539
Failure code [CA352] – Sensor power supply 1 voltage low error . 540
Circuit diagram related to sensor power supply 1 . 541
Failure code [CA386] – Sensor power supply 1 voltage high error 542
Circuit diagram related to sensor power supply 1 . 542
Failure code [CA428] – Water-in-fuel sensor high error . 544
Circuit diagram related to water-in-fuel sensor 545
Failure code [CA429] – Water-in-fuel sensor low error 546
Circuit diagram related to water-in-fuel sensor 547
Failure code [CA435] – Engine oil pressure switch error 548
Circuit diagram related to engine oil pressure switch 548
Failure code [CA441] – Battery voltage low error . 549
Circuit diagram related to engine controller power supply 551
Failure code [CA442] – Battery voltage high error 552
Circuit diagram related to engine controller power supply 553
Failure code [CA449] – Common rail pressure very high error 554
Failure code [CA451] – Common rail pressure sensor high error 556
Circuit diagram related to common rail pressure sensor . 557
Failure code [CA452] – Common rail pressure sensor low error . 558
Circuit diagram related to common rail pressure sensor . 559
Failure code [CA488] – Charge air temperature high torque derate . 560
Failure code [CA553] – Common rail pressure high error . 560
Failure code [CA559] – Common rail pressure low error 561
Failure code [CA689] – Engine Ne speed sensor error 562
Circuit diagram related to engine Ne speed sensor 563
Failure code [CA731] – Engine G speed sensor phase error . 564
Failure code [CA757] – All continuous data lost error 566
Circuit diagram related to engine controller power supply 567
Failure code [CA778] – Engine G speed sensor error . 568
Circuit diagram related to engine G speed sensor . 569
Failure code [CA1633] – KOMNET Datalink timeout error 570
Circuit diagram related to CAN communication . 571
Failure code [CA2185] – Throttle sensor supply voltage high error 572
Circuit diagram related to fuel control dial . 572
Failure code [CA2186] – Throttle sensor supply voltage low error . 573
Circuit diagram related to fuel control dial . 573
Failure code [CA2249] – Common rail pressure very low error 574
Failure code [CA2311] – IMV solenoid error . 576
Circuit diagram related to supply pump actuator (metering unit) 577
Failure code [CA2555] – Grid heater relay volt high error 578
Circuit diagram related to engine preheater/starting motor/charging system . 579
Failure code [CA2556] – Grid heater relay volt low error . 580
Circuit diagram related to engine preheater/starting motor/charging system . 581
Failure code [D110KB] – Short circuit in battery relay . 582
Circuit diagram for battery relay – Pump controller 583
Failure code [D19JKZ] – Personal code relay abnormality 584
Circuit diagram related to engine preheater/starting motor/charging system . 585
Failure code [D862KA] – GPS antenna disconnection 586
Configuration diagram of KOMTRAX system 586
Failure code [DA22KK] – Pump solenoid power supply voltage low error . 588
Circuit diagram related to solenoid power supply . 589
Failure code [DA25KP] – Pressure sensor power abnormality 590
Circuit diagram related to pressure sensor power supply of pump controller . 591
Failure code [DA26KP] – 5V sensor 2 power abnormality 592
Circuit diagram related to 5V sensor . 592
Failure code [DA29KQ] – Model selection abnormality 594
Circuit diagram related to model selection abnormality . 595
Failure code [DA2RMC] – CAN disconnection (Pump controller detected 596
Circuit diagram related to CAN communication . 597
Failure code [DAF8KB] – Short circuit in camera power supply . 598
Circuit diagram related to camera power supply . 599
Failure code [DAFGMC] – GPS module operation error . 600
Failure code [DAFRMC] – CAN disconnection (monitor detected 602
Circuit diagram related to CAN communication . 603
Failure code [DDP4KX] – Disconnection in travel PPC pressure switch 604
Circuit diagram for travel PPC pressure switch . 605
Failure code [DDWCKZ] – Disconnection in direction control switches 606
Circuit diagram for travel direction control switch (S/N H60051 – H60103) 607
Circuit diagram for travel direction control switch (S/N H60104 and up) 607
Failure code [DFB1KZ] – Service lever potentiometer 1 abnormality 608
Circuit diagram for PPC control switches . 609
Failure code [DFB2KZ] – 2nd ATT service lever main potentio 2 abnormality 610
Circuit diagram for PPC control switches . 611
Failure code [DFB3L8] – RH Lever potentiometer (for 1st ATT) has failure . 612
Failure code [DFB4L8] – 2nd ATT service lever potentio 2 error . 613
Failure code [DFB5KZ] – 1st ATT service lever main potentio 1 abnormality 614
Circuit diagram for PPC control switches . 615
Failure code [DFB6KZ] – Service lever potentiometer 2 abnormality 616
Circuit diagram for PPC control switches . 617
Failure code [DGH2KB] – Hydraulic oil temperature sensor short circuit . 618
Circuit diagram related to hydraulic oil temperature sensor 619
Failure code [DH10KS] – Abnormality in 24V sensor power source . 620
Circuit diagram for 24V sensor power source 621
Failure code [DHPAMA] – F pump press sensor abnormality 622
Circuit diagram related to pump pressure sensor of pump controller . 623
Failure code [DHS5KX] – Abnormality in travel PPC sensor . 624
Circuit diagram related to Travel PPC sensor . 625
Failure code [DHX1MA] – Overload sensor abnormality (analog) . 626
Circuit diagram for overload caution . 627
Failure code [DLT4KA] – Disconnection in transmission speed sensor . 628
Circuit diagram for transmission speed sensor power source . 629
Failure code [DW27KA] – Disconnection in transmission clutch solenoid 630
Circuit diagram for transmission clutch solenoid in pump controller 631
Failure code [DW27KB] – Short circuit in transmission clutch solenoid 632
Circuit diagram for transmission clutch solenoid . 633
Failure code [DW4AKA] – Disconnection in suspension lock solenoid 634
Circuit diagram for suspension lock solenoid in pump controller 635
Failure code [DW4AKB] – Short circuit in suspension lock solenoid 636
Circuit diagram for suspension lock solenoid in pump controller 637
Failure code [DW4CKA] – Disconnection in PPC lock solenoid . 638
Circuit diagram for PPC lock solenoid in pump controller . 639
Failure code [DW4CKB] – PPC lock sol. S/C 640
Circuit diagram related to swing holding brake solenoid of pump controller . 641
Failure code [DW4MKA] – Disconnection in creep solenoid 642
Circuit diagram for creep solenoid in pump controller 642
Failure code [DW4MKB] – Short circuit in creep solenoid 643
Circuit diagram for creep solenoid in pump controller 643
Failure code [DW44KA] – Disconnection in travel F/R solenoid . 644
Circuit diagram for travel F/R solenoid 645
Failure code [DW44KB] – Short circuit in travel F/R solenoid . 646
Circuit for travel F/R solenoid in pump controller . 647
Failure code [DW45KA] – Disconnection in swing parking brake solenoid 648
Circuit diagram for swing and parking brake solenoid in pump controller 649
Failure code [DW45KB] – Swing holding brake solenoid short circuit . 650
Circuit diagram related to swing holding brake solenoid of pump controller . 651
Failure code [DW91KA] – Disconnection in travel neutral solenoid . 652
Circuit diagram for travel neutral solenoid 653
Failure code [DW91KB] – Short circuit in travel neutral solenoid . 654
Circuit diagram for travel neutral solenoid 655
Failure code [DWB1KA] – Disconnection in outrigger operation solenoid 656
Circuit diagram for outrigger operation solenoid . 657
Failure code [DWB1KB] – Short circuit in outrigger operation solenoid 658
Circuit diagram for outrigger operation solenoid . 659
Failure code [DWB2KA] – Disconnection in 1st outrigger solenoid 660
Circuit diagram for outrigger solenoid . 661
Failure code [DWB2KB] – Short circuit in 1st outrigger solenoid 662
Circuit diagram for outrigger solenoid . 663
Failure code [DWB3KA] – Disconnection in 2nd outrigger solenoid 664
Circuit diagram for outrigger solenoid . 665
Failure code [DWB3KB] – Short circuit in 2nd outrigger solenoid 666
Circuit diagram for outrigger solenoid . 667
Failure code [DWB4KA] – Disconnection in 3rd outrigger solenoid 668
Circuit diagram for outrigger solenoid . 669
Failure code [DWB4KB] – Short circuit in 3rd outrigger solenoid 670
Circuit diagram for outrigger solenoid . 671
Failure code [DWB5KA] – Disconnection in 4th outrigger solenoid 672
Circuit diagram for outrigger solenoid . 673
Failure code [DWB5KB] – Short circuit in 4th outrigger solenoid 674
Circuit diagram for outrigger solenoid . 675
Failure code [DWK0KA] – Disconnection in 2-stage relief solenoid . 676
Circuit diagram for 2-stage relief solenoid in pump controller . 676
Failure code [DWK0KB] – Short circuit in 2-stage relief solenoid . 677
Electric circuit diagram for 2-stage relief solenoid in pump controller 677
Failure code [DWK2KA] – Disconnection in 2-stage back pressure solenoid 678
Circuit diagram for 2-stage back pressure solenoid in pump controller 678
Failure code [DWK2KB] – Short circuit in 2-stage back pressure solenoid 679
Circuit diagram for 2-stage back pressure solenoid in pump controller 679
Failure code [DXA8KA] – Disconnection in PC-EPC (F) solenoid system 680
Circuit diagram for PC-EPC solenoid in pump controller . 681
Failure code [DXA8KB] – Short circuit in PC-EPC (F) solenoid . 682
Circuit diagram for PC-EPC solenoid in pump controller . 683
Failure code [DXE0KA] – Disconnection in LS-EPC solenoid system 684
Circuit diagram for LS-EPC solenoid in pump controller . 684
Failure code [DXE0KB] – Short circuit in LS-EPC solenoid . 685
Circuit diagram for LS-EPC solenoid in pump controller . 685
Failure code [DXEAKA] – Service Current EPC1 Open Circuit (left hand) 686
Circuit diagram related to the 1st and 2nd service EPC solenoids . 687
Failure code [DXEAKB] – Service current EPC1 solenoid short (left hand) 688
Circuit diagram related to the 1st and 2nd service EPC solenoids . 689
Failure code [DXE7KA] – Service current EPC2 solenoid disconnection (right hand) . 690
Circuit diagram related to the 1st and 2nd service EPC solenoids . 691
Failure code [DXE7KB] – Service current EPC solenoid short (right hand) 692
Circuit diagram related to the 1st and 2nd service EPC solenoids . 693
Failure code [DXE8KA] – Service current EPC solenoid disconnection (left hand) . 694
Circuit diagram related to the 1st and 2nd service EPC solenoids . 695
Failure code [DXE8KB] – Service current EPC3 solenoid short (left hand) 696
Circuit diagram related to the 1st and 2nd service EPC solenoids . 697
Failure code [DXE9KA] – Service current EPC solenoid disconnection (right hand) 698
Circuit diagram related to the 1st and 2nd service EPC solenoids . 699
Failure code [DXE9KB] – Service current EPC solenoid short (right hand) 700
Circuit diagram related to the 1st and 2nd service EPC solenoids . 701
Failure code [DXK3KA] – Travel pedal throttle EPC solenoid open circuit 702
Circuit diagram related to travel pedal EPC valve 702
Failure code [DXK3KB] – Travel pedal throttle EPC solenoid short circuit . 703
Circuit diagram related to travel pedal EPC valve 703
Failure code [DY20KA] – Wiper working abnormality 704
Circuit diagram related to wiper motor of machine monitor 705
Failure code [DY20MA] – Wiper parking abnormality 706
Circuit diagram related to wiper motor of machine monitor 707
Failure code [DY2CKA] – Window washer drive system disconnection . 708
Circuit diagram related to wiper motor of machine monitor 709
Failure code [DY2CKB] – Washer drive short circuit . 710
Circuit diagram related to window washer motor of machine monitor 711
Failure code [DY2DKB] – Wiper drive (fwd) short circuit 712
Circuit diagram related to wiper motor of machine monitor 713
Failure code [DY2EKB] – Wiper drive (rev) short circuit 714
Circuit diagram related to wiper motor of machine monitor 715
TROUBLESHOOTING 481
Troubleshooting when failure code is indicated . 481
Circuit diagram related to no. 2 injector 533
Failure code [CA332] – Injector #4 (L#4) open/short circuit error 534
Preparations for troubleshooting of electrical system 718
Troubleshooting of electrical system (E-mode) 722
Before carrying out troubleshooting of electrical system . 722
Location of fusible links 724
Location of fuse box and fuse numbers 724
Information contained in troubleshooting table . 725
E-1 When starting switch turned ON, machine monitor displays nothing . 726
Circuit diagram related to machine monitor power supply 727
E-2 When starting switch turned ON (before starting engine), basic check item lights up 728
Circuit diagram related to radiator coolant level switch . 728
Circuit diagram related to engine oil level switch . 729
E-3 Engine does not start (engine does not rotate) . 730
Circuit diagram for engine start, stop and battery charging 732
E-4 Preheater does not operate . 734
Circuit diagram related to engine preheater 735
E-5 Automatic warm-up system does not operate (in cold season) . 736
E-6 All work equipment, swing and travel mechanism do not move or cannot be locked . 738
Circuit diagram for PPC lock solenoid 739
E-7 Precaution lights up while engine is running . 740
Circuit diagram related to engine preheater/starting motor/charging system . 741
Circuit diagram related to air cleaner clogging switch . 743
E-8 Emergency stop item lights up while engine is running 746
Circuit diagram related to 2-stage relief solenoid . 747
E-9 Engine coolant temperature gauge does not indicate normally 748
E-10 Hydraulic oil temperature gauge does not indicate normally 749
E-11 Fuel level gauge does not indicate normally . 752
Circuit diagram related to fuel level sensor . 752
E-12 Contents of display by machine monitor are different from applicable machine 754
E-13 Machine monitor does not display some items . 754
E-14 Function switch does not work . 754
E-15 Auto-decelerator does not operate normally 755
E-16 Working mode does not change 756
E-17 Travel speed does not change 757
Circuit diagram related to travel speed shifting solenoid 757
E-18 Alarm buzzer cannot be stopped 758
Circuit diagram for Quick Coupler system . 759
E-19 Windshield wiper and window washer do not operate . 760
Circuit diagram related to windshield and window washer 761
E-20 Power maximising function does not operate normally . 762
E-21 Swing holding brake does not operate normally . 763
Circuit diagram for Swing Lock switch 764
E-21 – “Boom/Stabiliser RAISE” is not correctly displayed in monitor function 765
Circuit diagram for boom RAISE PPC hydraulic switch 765
E-22 Travel alarm does not sound or does not stop sounding . 766
Circuit diagram for travel PPC hydraulic switch and travel alarm . 767
E-23 Air conditioner does not operate normally (including air conditioner abnormality record) 768
Circuit diagram related to air conditioner . 778
E-24 When starting switch is turned OFF, service meter is not displayed 779
E-25 Machine monitor cannot be set in service mode . 779
E-26 Monitoring function does not display lever control signal normally 780
Circuit diagram for boom RAISE PPC hydraulic switch 780
Circuit diagram for boom LOWER PPC hydraulic switch 781
Circuit diagram for arm DIGGING PPC hydraulic switch . 782
Circuit diagram for arm DUMPING PPC hydraulic switch . 783
Circuit diagram for bucket DIGGING PPC hydraulic switch 784
Circuit diagram for bucket DUMPING PPC hydraulic switch 785
Circuit diagram for right and left swing PPC hydraulic switches 787
Circuit diagram for travel PPC hydraulic switch and travel alarm . 789
Circuit diagram for 2-piece boom PPC hydraulic switch 791
E-27 KOMTRAX system does not operate normally 792
TROUBLESHOOTING 717
Troubleshooting of electrical system (E-Mode) 717
Information in troubleshooting table . 797
12V socket . 798
Radio 799
PPC lock circuit . 800
Circuit diagram for PPC lock circuit . 801
Brake light circuit 802
Circuit diagram for brake light circuit 803
Undercarriage attachments – Mode selection . 804
Circuit diagram for undercarriage attachments – Mode selection . 805
Undercarriage attachments – Mode activation 806
Circuit diagram for undercarriage attachments – Mode activation 807
Undercarriage attachments – Front left outrigger . 808
Circuit diagram for undercarriage attachments – Mode selection . 809
Undercarriage attachments – Front right outrigger 810
Circuit diagram for undercarriage attachments – Mode selection . 811
Undercarriage attachments – Rear left outrigger 812
Circuit diagram for undercarriage attachments – Mode selection . 813
Undercarriage attachments – Rear right outrigger . 814
Circuit diagram for undercarriage attachments – Mode selection . 815
Heated seat does not warm up . 816
Circuit diagram for the heated seat 817
Suspension lock 818
Circuit diagram for suspension lock 819
Lower wiper does not work (optional fitment) . 820
Circuit diagram for lower wiper 821
Work lights (operator cab front left) 822
Circuit diagram for work lights – Work light switch (1) 823
Work lights (operator cab front right) . 824
Circuit diagram for work lights – Work light switch (1) 825
Work lights (operator cab rear) 826
Circuit diagram for work lights – work light switch (2) 827
Work lights (Boom – left hand) . 828
Circuit diagram for work lights – Work light switch (1) 829
Work lights (Boom – right hand) 830
Circuit diagram for work lights – Work light switch (1) 831
Work lights (Revolving frame – left hand) 832
Circuit diagram for work lights – Work light switch (1) 833
Work lights (Revolving frame – right hand) . 834
Circuit diagram for work lights – Work light switch (1) 835
Work lights (Counterweight – left hand) 836
Circuit diagram for work lights – work light switch (2) 837
Work Lights (Counterweight – right hand) . 838
Circuit diagram for work lights – work light switch (2) 839
Work Lights (Oil tank – side mount) 840
Circuit diagram for work lights – work light switch (2) 841
Flashing beacon (operator’s cabin mount) . 842
Circuit diagram for cabin, counterweight & fuel tank beacon light 843
Flashing beacon (Counterweight mount) 844
Circuit diagram for cab, counterweight & fuel tank beacon light 845
Flashing beacon (Fuel tank mount) 846
Circuit diagram for cab, counterweight & fuel tank beacon light 847
Air seat compressor (option – air suspension seat) . 848
Circuit diagram for air seat compressor (option – air suspension seat) . 849
Operator’s cab interior light 850
Circuit diagram for operator’s cab interior light 851
Cigarette lighter 852
Circuit diagram for cigarette lighter 853
Park brake (not activating) 854
Circuit diagram for park brake . 855
Park brake (displayed symbol) 856
Circuit diagram for park brake . 857
RH PPC Lever clamshell roller switch pushed to the RH position . 858
Circuit diagram for clamshell control 859
RH PPC Lever clamshell roller switch pushed to the RH or LH position . 860
Circuit diagram for clamshell control 861
Horns 862
Circuit diagram for horn . 863
Swing lock – Normal operation 864
Circuit diagram for swing lock . 865
Swing lock – Emergency operation . 866
Circuit diagram for swing lock . 867
Neutral start (engine) . 868
Circuit diagram for neutral start (engine) . 869
Neutral start (engine) cont’d (A) 870
Circuit diagram for neutral start (engine) . 871
Neutral start (engine) cont’d (B) 872
Circuit diagram for neutral start (engine) . 873
Neutral start (engine) cont’d (C) 874
Circuit diagram for neutral start (engine) . 875
Emergency travel control – Forward . 876
Circuit diagram for travel direction control . 877
Emergency travel control – Neutral . 878
Circuit diagram for travel direction control . 879
Emergency travel control – Reverse . 880
Circuit diagram for travel direction control . 881
Driving lights – Main beam . 882
Circuit diagram for driving lights . 883
Driving lights – Main beam flash . 884
Circuit diagram for driving lights . 885
Driving lights – Main beam dipped 886
Circuit diagram for driving lights . 887
Driving lights – Position lights . 888
Driving lights – Position lights cont’d (1) and (2) 889
Circuit diagram for driving lights . 890
Indicators – Right hand 892
Circuit diagram for indicators & hazard warning 893
Indicators – Left hand . 894
Circuit diagram for indicators & hazard warning 895
Hazard warning lights 896
Hazard warning lights cont’d (A) . 897
Circuit diagram for indicators & hazard warning 898
Swing lock proximity switch 900
Brake and swing lock proximity switches 901
TROUBLESHOOTING 795
Troubleshooting of electrical system (Error checking of items without monitor codes) . 795
System chart for hydraulic and mechanical systems 904
Information contained in troubleshooting table . 908
H-1 – All work equipment lacks power, or travel and swing speeds are slow 909
H-2 – Engine speed sharply drops or engine stalls 910
H-3 – No work equipment, travel or swing move 911
H-4 – Abnormal noise is heard from around hydraulic pump . 911
H-5 – Auto-decelerator does not work . 912
H-6 – Fine control mode does not function 912
H-7 – Boom moves slowly or lacks power . 913
H-8 – Arm moves slowly or lacks power 914
H-9 – Bucket moves slowly or lacks power . 915
H-10 – Work equipment does not move in its single operation 915
H-11 – Work equipment hydraulic drift is too fast 916
H-12 – Work equipment has big time lag . 917
H-13 – Other work equipment moves when relieving single circuit 917
H-14 – One-touch power max. switch does not operate 918
H-15 – In compound operation, work equipment with larger load moves slowly . 918
H-16 – In swing + boom RAISE operation, boom moves slowly 918
H-17 – In swing + travel, travel speed drops sharply . 919
H-18 – Travel speed does not switch 920
H-19 – Travel speed does not shift, or it is too slow or fast 921
H-20 – Machine does not swing 922
H-21 – Swing acceleration is poor, or swing speed is slow 923
H-22 – Excessive overrun when stopping swing . 924
H-23 – There is big shock when stopping swing 925
H-24 – There is loud abnormal noise caused when stopping swing . 925
H-25 – Swing natural drift is too big 926
H-26 – Swing speed is faster than specified swing speed 926
Troubleshooting of engine (S-MODE) . 929
Method of using troubleshooting chart 929
S-1 – Starting performance is poor . 932
S-2 – Engine does not start 933
S-3 – Engine does not pick up smoothly . 936
S-4 – Engine stops during operations . 937
S-5 – Engine does not rotate smoothly 938
S-6 – Engine lacks output (or lacks power) . 939
S-7 – Exhaust smoke is black (incomplete combustion) . 940
S-8 – Oil consumption is excessive (or exhaust smoke is blue) 941
S-9 – Oil becomes contaminated quickly . 942
S-10 – Fuel consumption is excessive . 943
S-11 – Oil is in coolant (or coolant spurts back or coolant level goes down) . 944
S-12 – Oil pressure drops 945
S-13 – Oil level rises (Entry of coolant/fuel) . 946
S-14 – Coolant temperature becomes too high (overheating) 947
S-15 – Abnormal noise is made 948
S-16 – Vibration is excessive 949
Troubleshooting of central lubrication system (CLS) 950
Trouble 950
Troubleshooting during grease pump operation . 952
Pump element . 953
Check power supply . 954
Changing the control unit 954
Troubleshooting – grease system faults . 955
Venting of the system 956
TROUBLESHOOTING 903
Troubleshooting of hydraulic, mechanical and central lubrication system 903
Quick coupler 927
How to read this manual 961
Removal and installation of assemblies . 961
Special tools 961
Removal of parts . 962
Installation of parts 962
Sketches of special tools 962
Coating materials list . 963
Special Tools 966
Sketches of special tools 969
E1 push tool . 969
E5 push tool . 969
F2 push tool . 970
List of tools 971
Precautions when performing operation 972
Removal and installation of starting motor . 976
Removal 976
Installation . 976
Removal and installation of fuel pump assembly . 977
Removal 977
Installation . 980
Removal and installation of fuel injector assembly . 981
Special tools 981
Removal 981
Installation . 986
Removal and installation of engine front seal 990
Special tools 990
Removal 990
Installation . 992
Removing and installation of engine rear seal 993
Special tools 993
Removal 993
Installation . 994
Removal and installation of cylinder head assembly . 996
Special tools 996
Removal 996
Installation .1004
Removal and installation of combination cooler .1011
Removal 1011
Installation .1014
Removal and installation of engine and hydraulic pump assemblies .1015
Special tools 1015
Removal 1015
Installation .1020
Removal and installation of fuel cooler assembly .1022
Removal 1022
Installation .1022
Removal and installation of transmission and travel motor 1023
Removal 1023
Installation .1025
Disassembly and assembly of transmission .1026
Special tools 1026
Disassembly 1026
Removal of travel motor 1026
Installation of travel motor .1027
Removal of transmission input shaft 1028
Installation of transmission input shaft .1038
Removal of output shaft 1039
Installation of output shaft .1042
Removal of pump shaft 1043
Installation of pump shaft .1045
Disassembly and assembly of travel motor assembly 1046
Disassembly 1047
Assembly .1049
Removal and installation of swing motor and swing machinery assembly .1051
Removal 1051
Installation .1052
Disassembly and assembly of swing motor and swing machinery assembly .1053
Special tools 1053
Disassembly 1053
Assembly .1056
Removal and installation of front axle .1062
Removal 1062
Installation .1063
Disassembly and assembly of front axle .1064
Disassembly of steering cylinder .1064
Assembly of steering cylinder 1069
Disassembly of epicyclic reduction gear and brake 1076
Assembly of epicyclic reduction gear and brake .1082
Disassembly of joint box .1091
Assembly of joint box 1098
Disassembly of beam trumpet and differential unit 1106
Assembly of beam trumpet and differential unit .1111
Disassembly of pinion group 1118
Assembly of pinion group .1121
Toe-in adjustment 1130
Removal and installation of rear axle 1132
Removal 1132
Installation .1133
Disassembly and assembly of rear axle 1134
Special tools 1134
Removal of epicyclic reduction gear and brake 1134
Installation of epicyclic reduction gear and brake .1141
Disassembly of beam trumpet and differential unit 1151
Installation of beam trumpet and differential unit .1155
Disassembly of pinion group 1156
Installation of pinion group .1160
Removal and installation of propshaft 1168
Removal 1168
Installation .1168
Removal and installation of wheel 1169
Removal 1169
Installation .1169
Removal and installation of suspension lock cylinder .1170
Removal 1170
Installation .1170
Disassembly and assembly of suspension lock cylinder .1171
Change rod seal 1171
Removal and installation of outrigger 1172
Removal 1172
Installation .1173
Disassembly and assembly of outrigger 1174
Disassembly 1174
Assembly .1175
Removal and installation of dozer blade 1176
Removal 1176
Installation .1176
Disassembly and assembly of dozer blade 1177
Disassembly 1177
Assembly .1178
Removal and installation of swing circle assembly 1179
Removal 1179
Installation .1179
Removal and installation of revolving frame assembly .1181
Removal 1181
Installation .1184
Removal and installation of centre swivel joint 1185
Removal 1185
Installation .1188
Disassembly and assembly of centre swivel joint 1189
Special tools 1189
Disassembly 1189
Assembly .1190
Removal and installation of hydraulic tank .1191
Removal 1191
Installation .1194
Removal and installation of fuel tank 1195
Removal 1195
Installation .1196
Removal and installation of control valve 1197
Removal 1197
Installation .1201
Removal and installation of LS select valve assembly .1202
Removal 1202
Installation .1202
Removal and installation of LS shuttle valve assembly 1203
Removal 1203
Installation .1203
Removal and installation of pressure compensation valve assembly .1204
Removal 1204
Installation .1204
Removal and installation of main relief valve assembly .1205
Removal 1205
Installation .1205
Removal and installation of LS control EPC valve assembly 1206
Removal 1206
Installation .1206
Removal and installation of EPC solenoid valve assembly 1207
Removal 1207
Installation .1207
Removal and installation of PPC valve block assembly .1208
Removal 1208
Installation .1208
Removal and installation of manifold block assembly 1209
Removal 1209
Installation .1209
Removal and installation of oil seal in hydraulic pump input shaft .1210
Special tools 1210
Removal 1210
Installation .1210
Disassembly and assembly of work equipment ÜPPC valve 1211
Assembly .1212
Disassembly and assembly of hydraulic cylinder .1213
Special tools 1213
Disassembly of arm and bucket cylinders 1214
Assembly .1216
Removal and installation of monoboom work equipment 1221
Special tools 1221
Removal 1221
Installation .1223
Removal and installation of 2 piece boom work equipment 1224
Special tools 1224
Removal 1224
Installation .1226
Removal and installation of air conditioner unit .1227
Special tools 1227
Removal 1227
Installation .1231
Removal and installation of counterweight 1232
Removal 1232
Installation .1233
Removal and installation of operator cab assembly 1234
Removal 1234
Installation .1236
Removal and installation of monitor assembly .1237
Removal 1237
Installation .1238
Removal and installation of governor/pump controller assembly 1239
Removal 1239
Installation .1240
Removal and Installation of KOMTRAX terminal .1241
Removal 1241
Installation .1241
DISASSEMBLY AND ASSEMBLY . 957
OTHER 1243
Hydraulic circuit diagram (1/3) 1245
Hydraulic circuit diagram (2/3) 1246
Hydraulic circuit diagram (3/3) 1247
Circuit diagram (cabin 1/5) 1248
Circuit diagram (cabin 2/5) 1249
Circuit diagram (cabin 3/5) 1250
Circuit diagram (cabin 4/5) 1251
Circuit diagram (cabin 5/5) 1252
Circuit diagram (machine 1/4) 1253
Circuit diagram (machine 2/4) 1254
Circuit diagram (machine 3/4) 1255
Circuit diagram (machine 4/4) 1256
Connector diagram 1257
Connector table for revolving frame harness 1257
Connector table for operator‘s cab wiring harness (Part 1/2) .1258
Connector table for operator‘s cab wiring harness (Part 2/2) .1259
Connector table various wiring harness .1260

DESCRIPTION:

Komatsu PW200-7 Plus Wheeled Excavators Shop Manual VENBM65000  – PDF DOWNLOAD

MACHINE MODEL SERIAL NUMBER

• PW200-7 PLUS        H55300 AND UP

G.B 28/12/24