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Komatsu PW200-7E0 PW220-7E0 Excavator Shop Manual PDF
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Komatsu PW200-7E0 PW220-7E0 Wheeled Excavator Shop Manual VEBM949100 – PDF DOWNLOAD
MACHINE MODEL SERIAL NUMBER
PW200-7E0 H55051 AND UP
PW220-7E0 H65051 AND UP
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Description
Komatsu PW200-7E0 PW220-7E0 Wheeled Excavator Shop Manual VEBM949100 – PDF DOWNLOAD
FILE DETAILS:
Komatsu PW200-7E0 PW220-7E0 Wheeled Excavator Shop Manual VEBM949100 – PDF DOWNLOAD
Language : English
Pages : 1242
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Komatsu PW200-7E0 PW220-7E0 Wheeled Excavator Shop Manual VEBM949100 – PDF DOWNLOAD
MACHINE MODEL SERIAL NUMBER
PW200-7E0 H55051 AND UP
PW220-7E0 H65051 AND UP
PW200/220-7E0 VEBM949100 1
CONTENTS 3
FOREWORD 5
Safety 7
Safety notice 7
General precautions 7
Preparations for work 8
Precautions during work 8
List of revised pages 11
General 17
General 17
Structure and function 17
Testing, adjusting and troubleshooting 17
Disassembly and assembly 17
Maintenance standard 17
How to read the shop manual 18
Volumes 18
Distribution and updating 18
Filing method 18
Revised edition mark 18
Revisions 19
Symbols 19
Hoisting instructions 20
Hoisting 20
Coating materials 22
Standard tightening torque 24
Standard tightening torque of bolts and nuts 24
Tightening torque of hose nuts 25
Tightening torque of split flange bolts 25
Tightening torques for hoses (taper seal type and face seal type) 26
Tightening torque for 107 engine series (bolts and nuts) 26
Tightening torque for 107 engine series (eye joints) 27
Tightening torque for 107 engine series (tapered screws) 27
Electric wire code 28
Classification by thickness 28
Classification by color and code 28
Conversion tables 29
Method of using the conversion table 29
Temperature 34
Units 35
GENERAL 37
Specification dimension drawings 39
Dimensions 39
1 Piece boom 39
Dimensions 41
2 Piece boom 41
Working ranges 43
1 Piece boom 43
2 Piece boom 44
Specifications 45
PW200-7E0, PW220-7E0 45
Weight table 47
W200-7E0, PW220-7E0 47
1 Piece boom 48
2 Piece boom 49
Fuel, coolant and lubricants 50
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD 53
Engine related parts 55
Radiator – Oil cooler – Charge air cooler 56
Power train 57
Swing circle 58
Swing machinery and motor 60
Swing motor 63
Operation of swing lock 66
Relief valve portion 67
Operation 67
Undercarriage 68
Transmission 70
Travel motor 73
Operation of travel motor 75
Clutch control circuit 78
Axle 80
Front axle 80
Rear Axle 82
Suspension lock cylinder 84
Circuit 84
Axle oscillation 85
Braking system 86
Brake/steer pump 88
Priority valve 89
Power brake valve 90
Accumulator for brake system 92
Steering system 93
Steering column 94
Orbitrol valve 95
Hydraulic equipment layout drawings 96
Hydraulic circuit diagram 98
Hydraulic tank 99
Hydraulic pump 100
HPV95 + 95 (PW200-7E0 ) 100
LS valve 106
PC valve 106
Pilot pressure control (PPC) system 121
Control valve 122
PW200E0/220-7E0 122
CLSS 136
Outline of CLSS 136
Basic Principle 137
Main relief valve 139
Variable pressure compensation valve 140
Centre swivel joint 142
Travel PPC pedal 143
Work equipment – Swing PPC valve 145
Solenoid valves 150
Solenoid valve block 154
2 Position 3 way valve 154
2 Position 4 way valve 156
LS (PC)-EPC valve 158
Attachment EPC valve 161
Boom Safety valve 164
Hydraulic cylinder 166
PW200-7E0, PW200-7E0 166
Boom cylinder 166
Arm cylinder 166
Bucket cylinder 166
Adjust cylinder 167
Outrigger cylinder 168
Dozer cylinder 170
Work equipment 172
PW200-7E0/PW220-7E0 173
Work equipment 173
1 Dimension of arm 174
2 Dimension of bucket 176
Air conditioner 178
Air conditioner piping 178
Electrical wiring diagram 180
Electrical system 181
Engine control 181
Engine controller 183
CN-CE01 183
CN-CE01 184
CN-CE02 184
CN-CE03 185
Engine control system 188
Machine control system diagram 190
1 Engine and pump control function 192
2 Pump/valve control function 197
3 One-touch power maximizing function 199
4 Auto-deceleration function 201
5 Auto-warm-up/overheat and white smoke prevention function 203
6 Swing control function 205
7 Travel control function 207
8 ATT flow control, circuit selector function (option) 209
9 System component parts 210
Machine monitor system 213
Monitor panel 214
Monitor gauge displays 218
Keypad layout 221
Liquid crystal monitor adjustment switch 232
Overload warning device 238
Outline 238
Sensor 239
Coolant temperature sensor 240
Oil pressure switch 240
Rotation sensor 241
Boost pressure and temperature sensor 241
WIF (Water-In-Fuel detection) sensor 242
Engine oil level sensor 242
Coolant level sensor 243
Coolant temperature sensor 243
Hydraulic oil temperature sensor 244
Fuel level sensor 244
Air cleaner clogging sensor 245
Overload Caution sensor 245
Swing proximity sensor 245
Travel PPC sensor 245
PPC pressure sensor 246
Park brake pressure sensor 246
Brake accumulator low pressure sensor 246
Brake stop light sensor 246
1st attachment circuit hydraulic performance (main valve bypassed) 247
Travel circuit 248
Operational and control features 249
1 Travel motor 251
2 Travel pedal 259
3 Forward/neutral/reverse switch (F-N-R) 260
4 Forward/reverse travel solenoid 261
5 Travel/neutral solenoid 262
6 Travel creep solenoid 263
7 2-stage relief solenoid 264
8 Hi/Lo solenoid valve 266
9 Back pressure solenoid 267
Steering system 268
Operating principles 268
Condition 1 269
Condition 2 269
Condition 3 270
Condition 4 270
Condition 5 271
Condition 6 271
OLS priority valve 272
Load sensing steering unit 272
Service brake and suspension system 278
Braking system 278
Operation 281
Quick coupler control valve 284
Specification 284
Operation 284
Shematic 285
ATT EPC valve assembly 286
KOMTRAX terminal system 287
KOMTRAX terminal 288
Standard value table for engine related parts 293
Standard value table for chassis related parts 294
Flow control characteristic of PC valve (STD) 307
TESTING AND ADJUSTING 291
Preparations for troubleshooting of electrical system 430
TESTING AND ADJUSTING 309
Measuring engine speed 311
Measuring intake air pressure (boost pressure) 313
Measurement of exhaust gas color 315
Adjusting valve clearance 317
Measuring compression pressure 319
Measurement of blow-by pressure 322
Measure engine oil pressure 324
Handling fuel system parts 325
Releasing residual pressure from fuel system 326
Measuring fuel pressure 327
Measuring fuel return rate and leakage 329
Bleeding air from fuel circuit 332
Checking fuel circuit for leakage 333
Checking and adjusting air conditioner compressor belt tension 335
Replacing the fan belt 336
Measurement of clearance in swing circle bearings 337
Inspection and adjustment of hydraulic oil pressure in hydraulic circuit for work equipment, swing and travel 338
Inspection and adjustment of control circuit oil pressure 343
Procedure for pressure reducing adjustment 345
Inspection and adjustment of pump pc (valve inlet) control oil pressure 346
Inspection and adjustment of pump ls valve control oil pressure 350
Measurement of solenoid valve output pressure 357
7 – Stage solenoid block 359
4 – Stage solenoid block 361
2 – Stage solenoid block 362
Measurement of PPC valve output pressure 363
Checking Proportional Control PPC Circuit 364
Adjustment of work equipment and swing PPC valve 365
Measuring and adjusting quick coupler control valve output pressure 366
Testing travel motor relief pressure 368
Measuring travel motor Relief pressure 368
Adjusting travel motor relief pressure 369
Testing propshaft speed 370
Measuring rotating speed of propshaft 370
Testing transmission clutch control circuit 371
Description 371
Inspection of locations of hydraulic drift of work equipment 373
Release of remaining pressure in hydraulic circuit 375
Measurement of oil leakage amount 377
Air bleeding of various parts 380
Inspection procedures for diode 382
Special function of monitor panel 384
Operation of operators menu and display (outline) 387
Table for failure code no 394
Operation and display of service menu 398
Way of switching to Service Menu 398
Table for monitoring items 401
Procedure for turning on KOMTRAX terminal 419
KOMTRAX terminal lamp indications 423
TESTING AND ADJUSTING 433
Troubleshooting 433
Points to remember when troubleshooting 435
Sequence of events in troubleshooting 437
Points to remember when carrying out maintenance 438
Points to remember when handling electric equipment 438
Points to remember when troubleshooting electric circuits 444
Points to remember when handling hydraulic equipment 444
Checks before troubleshooting 446
Classification and steps for troubleshooting 447
Steps for troubleshooting 447
Connector location chart and electrical circuit diagram by system 454
Connection table for connector pin numbers 479
T-boxes and T-adapters table 508
Information contained in troubleshooting table 515
Relative electrical circuit diagram 516
Failure code [6B2JMA] – Abnormality in travel PPC switch hydraulics 517
Failure code [989L00] – Engine controller lock caution 1 518
Failure code [989M00] – Engine controller lock caution 2 518
Failure code [989N00] – Engine controller lock caution 3 519
Failure code [AA10NX] – Air cleaner clogging 520
Failure code [AB00KE] – Charging voltage abnormally low 522
Failure code [B@BAZG] – Abnormally lowered engine oil pressure 524
Failure code [B@BAZK] – Abnormally lowered engine oil level 526
Failure code [B@BCNS] – Engine cooling water overheating 528
Failure code [B@BCZK] – Abnormally low radiator water level 530
Failure code [B@HANS] – Hydraulic oil overheating 532
Failure code [CA111] – EMC critical internal failure 534
Failure code [CA115] – Engine neutral and backup speed sensor error 535
Failure code [CA122] – Chg air press sensor high error 536
Failure code [CA123] – Chg air press sensor low error 538
Failure code [CA131] – Throttle sensor high error 540
Failure code [CA132] – Throttle sensor low error 542
Failure code [CA144] – Coolant temp sens high error 544
Failure code [CA145] – Coolant temp sens low error 546
Failure code [CA153] – Chg air temp sensor high error 548
Failure code [CA154] – Chg air temp sensor low error 550
Failure code [CA155] – Chg air temp high speed derate 552
Failure code [CA187] – Sens supply 2 volt low error 554
Failure code [CA221] – Ambient press sens high error 556
Failure code [CA222] – Ambient press sens low error 558
Failure code [CA227] – Sens supply 2 volt high error 560
Failure code [CA234] – Eng overspeed 562
Failure code [CA238] – Ne speed sens supply volt error 564
Failure code [CA271] – IMV/PCV1 short error 566
Failure code [CA272] – IMV/PCV1 open error 568
Failure code [CA322] – Inj #1 (L#1) open/short error 570
Failure code [CA323] – Inj #5 (L#5) open/short error 572
Failure code [CA324] – Inj #3 (L#3) open/short error 574
Failure code [CA325] – Inj #6 (L#6) open/short error 576
Failure code [CA331] – Inj #2 (L#2) open/short error 578
Failure code [CA332] – Inj #4 (L#4) open/short error 580
Failure code [CA342] – Calibration code incompatibility 582
Failure code [CA351] – Injectors drive circuit error 584
Failure code [CA352] – Sens supply 1 volt low error 586
Failure code [CA386] – Sens supply 1 volt high error 588
Failure code [CA428] – Water in fuel sensor high error 590
Failure code [CA429] – Water in fuel sensor low error 592
Failure code [CA435] – Eng oil press sw error 594
Failure code [CA441] – Battery voltage low error 596
Failure code [CA442] – Battery voltage high error 600
Failure code [CA449] – Rail press very high error 602
Failure code [CA451] – Rail press sensor high error 604
Failure code [CA452] – Rail press sensor low error 606
Failure code [CA488] – Chg air temp high torque derate 608
Failure code [CA553] – Rail press high error 608
Failure code [CA559] – Rail press low error 609
Failure code [CA689] – Eng ne speed sensor error 612
Failure code [CA731] – Eng bkup speed sens phase error 614
Failure code [CA757] – All continuous data lost error 616
Failure code [CA778] – Eng G speed sensor error 618
Failure code [CA1633] – KOMNET datalink timeout error 620
Failure code [CA2185] – Throttle sensor supply voltage high error 622
Circuit diagram related to fuel control dial 622
Failure code [CA2186] – Throttle sensor supply voltage low error 623
Circuit diagram related to fuel control dial 623
Failure code [CA2249] – Rail press very low error 624
Failure code [CA2311] – IMV solenoid error 626
Failure code [CA2555] – Grid htr relay volt high error 628
Failure code [CA2556] – Grid heater relay volt low error 630
Failure code [D110KB] – Short-circuiting in battery relay 632
Failure code [D19JKZ] – Personal code relay abnormality 634
Failure code [D862KA] – GPS antenna discon 636
Failure code [DA25KP] – Press sensor power abnormality 638
Failure code [DA2RMC] – Pump comm abnormality 640
Failure code [DA2SKA] – Disconnection of S-NET signal 642
Failure code [DA2SKQ] – Abnormality in inputting model code 644
Failure code [DA2SKQ] – Abnormality in inputting model code 646
Failure code [DAF0KT] – Abnormal data in error history 648
Failure code [DAFRMC] – Monitor comm abnormality 650
Failure code [DDC3KZ] – Outrigger switch select abnormality 652
Failure code [DDHPAKP] – Abnormality in pump pressure sensor 654
Failure code [DDP4KX] – Abnormality in travel PPC pressure switch 656
Failure code [DDWCKZ] – Abnormality in travel direction control switch 658
Failure code [DFB1KZ] – Service lever potentio 1 abnormality 660
Failure code [DFB2KZ] – Service lever potentio 2 abnormality 662
Failure code [DFB3L8] – Service lever 1 potentio error 664
Failure code [DFB4L8] – Service lever 2 potentio error 665
Failure code [DGH2KB] – Hydr oil sensor short 667
Failure code [DH10KS] – Abnormality in pressure sensor power source 668
Failure code [DHPAKP] – Abnormality in F pump pressure sensor 670
Failure code [DHPAMA] – Abnormality in F pump pressure sensor 672
Failure code [DHPBMA] – Abnormality in R pump pressure sensor 674
Failure code [DHS5KX] – Abnormality in travel PPC sensor 676
Failure code [DHX1MA] – Abnormality in overload caution sensor 678
Failure code [DLE2MA] – Abnormality in engine rotation sensor in governor (pump controller system) 680
Failure code [DLT4KA] – Disconnection in transmission speed sensor in governor (pump controller syste)m) 682
Failure code [DW27KA] – Disconnection in transmission clutch solenoid 684
Failure code [DW27KB] – Short-circuiting in transmission clutch solenoid 686
Failure code [DW4CKA] – Disconnection in PPC lock solenoid 688
Failure code [DW4CKB] – PPC lock sol S/C 690
Failure code [DW44KA] – Disconnection of travel F/R solenoid 692
Failure code [DW44KB] – Short-circuiting of travel F/R solenoid 694
Failure code [DW45KA] – Disconnection in swing parking brake solenoid 696
Failure code [DW4MKA] – Disconnection in creep solenoid 698
Failure code [DW4MKB] – Short-circuiting in creep solenoid 700
Failure code [DW91KA] – Disconnection in travel neutral solenoid 702
Failure code [DW91KB] – Short-circuiting in travel neutral solenoid 704
Failure code [DWK0KA] – Disconnection in 2-stage relief solenoid 706
Failure code [DWK0KB] – Short-circuiting in 2-stage relief solenoid 708
Failure code [DWK2KA] – Disconnection in 2-stage back pressure solenoid 710
Failure code [DWK2KB] – Short circuiting in 2-stage back pressure solenoid 712
Failure code [DXA0KA] – Disconnection in PC-EPC solenoid system 714
Failure code [DXE0KA] – Disconnection in LS-EPC solenoid system 716
Failure code [DXE0KB] – Short-circuiting in LS-EPC solenoid 718
Failure code [DXE4KA] – Service current EPC1 discon 720
Failure code [DXE4KB] – Service current EPC1 short 722
Failure code [DXE7KA] – Service current EPC2 disco 724
Failure code [DXE7KB] – Service current EPC2 short 726
Failure code [DXE8KA] – Service current EPC3 discon 728
Failure code [DXE8KB] – Service current EPC3 short 730
Failure code [DXE9KA] – Service current EPC4 discon 732
Failure code [DXE9KB] – Service current EPC4 short 734
Failure code [DY20KA] – Wiper working abnormality 736
Failure code [DY20MA] – Wiper parking abnormality 738
Failure code [DY2CKB] – Washer drive S/C 740
Failure code [DY2DKB] – Wiper drive (for) S/C 742
Failure code [DY2EKB] – Wiper drive (rev) S/C 744
TESTING AND ADJUSTING 511
Troubleshooting when service code “Electrical system” and failure code “Mechanical system” are indicated 511
Information contained in troubleshooting table 749
Relative electrical circuit diagram 750
E-1 – Engine does not start (engine does not rotate) 751
E-5 – Auto-decelerator does not work 755
E-6 – Auto engine warm-up device does not work 757
E-7 – Preheater does not operate 758
E-8 – All work equipment, swing and travel do not move 760
E-9 – One-touch power max switch does not work 762
E-10 – No display in monitor panel at all 763
E-11 – Part of display on monitor panel is missing 764
E-12 – Monitor panel displays contents irrelevant to the model 764
E-13 – Fuel level monitor red lamp lights up while engine is running 765
E-14 – Engine coolant temperature gauge does not indicate normally 766
E-15 – Hydraulic oil temperature gauge does not display correctly 768
E-16 – Fuel gauge does not display correctly 769
E-17 – Swing lock monitor does not display correctly 770
E-18 – When the monitor switch is operated, no display appears 772
E-19 – Windshield wiper and window washer do not operate 774
E-20 – Alarm buzzer cannot be stopped 776
E-21 – “Boom/stabiliser RAISE” is not correctly displayed in monitor function 777
E-22 – “Boom/stabiliser LOWER” is not correctly displayed in monitor function 778
E-23 – “Arm DIGGING” is not correctly displayed in monitor function 779
E-24 – “Arm DUMPING” is not correctly displayed in monitor function 780
E-25 – “Bucket DIGGING” is not correctly displayed in monitor function 781
E-26 – “Bucket DUMPING” is not correctly displayed in monitor function 782
E-27 – “SWING” is not correctly displayed in monitor function 784
E-28 – “TRAVEL” is not correctly displayed in monitor function 786
E-29 – “2 piece boom” is not correctly displayed in monitor function 788
E-30 – Air conditioner does not work 790
E-31 – Travel reverse alarm does not sound 792
E-32 – KOMTRAX system does not operate normally 794
TESTING AND ADJUSTING 747
Troubleshooting of electrical system (E-Mode) 747
Information contained in troubleshooting table 799
Radio cassette and telephone socket 800
PPC lock circuit 802
Brake light circuit 804
Undercarriage attachments – Mode selection 806
Undercarriage attachments – Front left outrigger 808
Undercarriage attachments – Front right outrigger 810
Undercarriage attachments – Rear left outrigger 812
Undercarriage attachments – Rear right outrigger 814
Heated seat does not warm up 816
Suspension lock 818
Lower wiper does not work (optional fitment) 820
Work lights (operator cab front left) 822
Work lights (operator cab front right) 823
Work lights (operator cab rear) 824
Work lights (boom, arm and counterweight) 826
Cab and counterweight beacon light 828
Air seat compressor (option – air suspension seat) 830
Operator cab interior light 832
Cigar lighter 834
Park brake (not activating) 836
Park brake (displayed symbol) 838
RH PPC lever clamshell roller switch pushed to the LH position 840
RH PPC lever clamshell roller switch pushed to the RH position 842
RH PPC lever clamshell roller switch pushed to the RH or LH position 844
Horns 846
Swing lock – Normal operation 848
Swing lock – Emergency operation 850
Neutral start (engine) 852
Neutral start (engine) cont’d (A) 853
Neutral start (engine) cont’d (B) 854
Neutral start (engine) cont’d (C) 855
Emergency travel control – Forward 858
Emergency travel control – neutral 860
Emergency travel control – Reverse 863
Emergency travel control – Reverse cont’d 864
Driving lights – Main beam 866
Driving lights – Main beam flash 868
Driving lights – Main beam dipped 870
Driving lights – Position lights 872
Driving lights – Position lights cont’d (1) and (2) 874
Indicators – Right hand 876
Indicators – Left hand 878
Hazard warning lights 880
Hazard warning lights cont’d (A) 882
Swing lock proximity switch 884
TESTING AND ADJUSTING 797
Troubleshooting of electrical system (Error checking of items without monitor codes) 797
System chart for hydraulic and mechanical systems 889
Information contained in troubleshooting table 893
H-1 – All work equipment lacks power, or travel and swing speeds are slow 894
H-2 – Engine speed sharply drops or engine stalls 895
H-3 – No work equipment, travel or swing move 896
H-4 – Abnormal noise is heard from around hydraulic pump 897
H-5 – Auto-decelerator does not work 898
H-6 – Fine control mode does not function 899
H-7 – Boom moves slowly or lacks power 900
H-8 – Arm moves slowly or lacks power 901
H-9 – Bucket moves slowly or lacks power 902
H-10 – Work equipment does not move in its single operation 903
H-11 – Work equipment hydraulic drift is too fast 904
H-12 – Work equipment has big time lag 905
H-13 – Other work equipment moves when relieving single circuit 906
H-14 – One-touch power max switch does not operate 907
H-15 – In compound operation, work equipment with larger load moves slowly 908
H-16 – In swing and boom RAISE operation, boom moves slowly 909
H-17 – In swing and travel, travel speed drops sharply 910
H-18 – Travel speed does not switch 911
H-19 – Travel speed does not shift, or it is too slow or fast 912
H-20 – Machine does not swing 913
H-21 – Swing acceleration is poor, or swing speed is slow 914
H-22 – Excessive overrun when stopping swing 915
H-23 – There is big shock when stopping swing 916
H-24 – There is loud abnormal noise caused when stopping swing 917
H-25 – Swing natural drift is too big 918
H-26 – Swing speed is faster than specified swing speed 919
Troubleshooting of engine (S-mode) 920
Method of using troubleshooting chart 920
S-1 – Starting performance is poor 923
S-2 – Engine does not start 924
S-3 – Engine does not pick up smoothly 927
S-4 – Engine stops during operations 928
S-5 – Engine does not rotate smoothly 929
S-6 – Engine lack output (or lacks power) 930
S-7 – Exhaust smoke is black (incomplete combustion) 931
S-8 – Oil consumption is excessive (or exhaust smoke is blue) 932
S-9 – Oil becomes contaminated quickly 933
S-10 – Fuel consumption is excessive 934
S-11 – Oil is in coolant (or coolant spurts back or coolant level goes down) 935
S-12 – Oil pressure drops 936
S-13 – Oil level rises (entry of coolant/fuel) 937
S-14 – Coolant temperature becomes too high (overheating) 938
S-15 – Abnormal noise is made 939
S-16 – Vibration is excessive 940
TESTING AND ADJUSTING 887
Troubleshooting of hydraulic and mechanical system (H-Mode) 887
How to read this manual 945
Removal and installation of assemblies 945
Special tools 945
Removal of parts 946
Installation of parts 946
Sketches of special tools 946
Coating materials list 947
Special Tools 950
Sketches of special tools 953
E1 push tool 953
E5 push tool 953
F2 push tool 954
List of tools 955
Precautions when performing operation 956
Removal and installation of starting motor 960
Removal 960
Installation 960
Removal and installation of fuel pump assembly 961
Removal 961
Installation 964
Removal and installation of fuel injector assembly 965
Special tools 965
Removal 965
Installation 970
Removal and installation of engine front seal 974
Special tools 974
Removal 974
Installation 976
Removing and installation of engine rear seal 977
Special tools 977
Removal 977
Installation 978
Removal and installation of cylinder head assembly 980
Special tools 980
Removal 980
Installation 988
Removal and installation of combination cooler 995
Removal 995
Installation 998
Removal and installation of engine and hydraulic pump assemblies 999
Special tools 999
Removal 999
Installation 1004
Removal and installation of fuel cooler assembly 1006
Removal 1006
Installation 1006
Removal and installation of transmission and travel motor 1007
Removal 1007
Installation 1009
Disassembly and assembly of transmission 1010
Special tools 1010
Disassembly 1010
Removal of travel motor 1010
Installation of travel motor 1011
Removal of transmission input shaft 1012
Installation of transmission input shaft 1022
Removal of output shaft 1023
Installation of output shaft 1026
Removal of pump shaft 1027
Installation of pump shaft 1029
Disassembly and assembly of travel motor assembly 1030
Disassembly 1031
Assembly 1033
Removal and installation of swing motor and swing machinery assembly 1035
Removal 1035
Installation 1036
Disassembly and assembly of swing motor and swing machinery assembly 1037
Special tools 1037
Disassembly 1037
Assembly 1040
Removal and installation of front axle 1046
Removal 1046
Installation 1047
Disassembly and assembly of front axle 1048
Disassembly of steering cylinder 1048
Assembly of steering cylinder 1053
Disassembly of epicyclic reduction gear and brake 1060
Assembly of epicyclic reduction gear and brake 1066
Disassembly of joint box 1075
Assembly of joint box 1082
Disassembly of beam trumpet and differential unit 1090
Assembly of beam trumpet and differential unit 1095
Disassembly of pinion group 1102
Assembly of pinion group 1105
Toe-in adjustment 1114
Removal and installation of rear axle 1116
Removal 1116
Installation 1117
Disassembly and assembly of rear axle 1118
Special tools 1118
Removal of epicyclic reduction gear and brake 1118
Installation of epicyclic reduction gear and brake 1125
Disassembly of beam trumpet and differential unit 1135
Installation of beam trumpet and differential unit 1139
Disassembly of pinion group 1140
Installation of pinion group 1144
Removal and installation of propshaft 1152
Removal 1152
Installation 1152
Removal and installation of wheel 1153
Removal 1153
Installation 1153
Removal and installation of suspension lock cylinder 1154
Removal 1154
Installation 1154
Disassembly and assembly of suspension lock cylinder 1155
Change rod seal 1155
Removal and installation of outrigger 1156
Removal 1156
Installation 1157
Disassembly and assembly of outrigger 1158
Disassembly 1158
Assembly 1159
Removal and installation of dozer blade 1160
Removal 1160
Installation 1160
Disassembly and assembly of dozer blade 1161
Disassembly 1161
Assembly 1162
Removal and installation of swing circle assembly 1163
Removal 1163
Installation 1163
Removal and installation of revolving frame assembly 1165
Removal 1165
Installation 1168
Removal and installation of centre swivel joint 1169
Removal 1169
Installation 1172
Disassembly and assembly of centre swivel joint 1173
Special tools 1173
Disassembly 1173
Assembly 1174
Removal and installation of hydraulic tank 1175
Removal 1175
Installation 1178
Removal and installation of fuel tank 1179
Removal 1179
Installation 1180
Removal and installation of control valve 1181
Removal 1181
Installation 1185
Removal and installation of LS select valve assembly 1186
Removal 1186
Installation 1186
Removal and installation of LS shuttle valve assembly 1187
Removal 1187
Installation 1187
Removal and installation of pressure compensation valve assembly 1188
Removal 1188
Installation 1188
Removal and installation of main relief valve assembly 1189
Removal 1189
Installation 1189
Removal and installation of LS control EPC valve assembly 1190
Removal 1190
Installation 1190
Removal and installation of EPC solenoid valve assembly 1191
Removal 1191
Installation 1191
Removal and installation of PPC valve block assembly 1192
Removal 1192
Installation 1192
Removal and installation of manifold block assembly 1193
Removal 1193
Installation 1193
Removal and installation of oil seal in hydraulic pump input shaft 1194
Special tools 1194
Removal 1194
Installation 1194
Disassembly and assembly of work equipment ÜPPC valve 1195
Assembly 1196
Disassembly and assembly of hydraulic cylinder 1197
Special tools 1197
Disassembly of arm and bucket cylinders 1198
Assembly 1200
Removal and installation of monoboom work equipment 1205
Special tools 1205
Removal 1205
Installation 1207
Removal and installation of 2 piece boom work equipment 1208
Special tools 1208
Removal 1208
Installation 1210
Removal and installation of air conditioner unit 1211
Special tools 1211
Removal 1211
Installation 1215
Removal and installation of counterweight 1216
Removal 1216
Installation 1217
Removal and installation of operator cab assembly 1218
Removal 1218
Installation 1220
Removal and installation of monitor assembly 1221
Removal 1221
Installation 1222
Removal and installation of governor/pump controller assembly 1223
Removal 1223
Installation 1224
Removal and Installation of KOMTRAX terminal 1225
Removal 1225
Installation 1225
DISASSEMBLY AND ASSEMBLY 941
OTHER 1227
Lubrication 1229
Hydraulic circuit diagram (1/3) 1233
Hydraulic circuit diagram (2/3) 1234
Hydraulic circuit diagram (3/3) 1235
Electrical circuit diagram (1/7) 1236
Electrical circuit diagram (2/7) 1237
Electrical circuit diagram (3/7) 1238
Electrical circuit diagram (4/7) 1239
Electrical circuit diagram (5/7) 1240
Electrical circuit diagram (6/7) 1241
Electrical circuit diagram (7/7) 1242
DESCRIPTION:
Komatsu PW200-7E0 PW220-7E0 Wheeled Excavator Shop Manual VEBM949100 – PDF DOWNLOAD
MACHINE MODEL SERIAL NUMBER
PW200-7E0 H55051 AND UP
PW220-7E0 H65051 AND UP
GENERAL PRECAUTIONS :
Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine.
1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine.
2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.
● Always wear safety glasses when hitting parts with a hammer.
● Always wear safety glasses when grinding parts with a grinder, etc.
3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work.
4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator’s compartment.
5. Keep all tools in good condition and learn the correct way to use them.
6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
PREPARATIONS FOR WORK:
1. Before adding oil or making repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving.
2. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them.
3. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work.
4. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.
S.V 26/12/24
