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Komatsu PW200-7E0, PW220-7E0 Wheeled Excavator Shop Manual H55051, H65051 and up – PDF DOWNLOAD
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Komatsu PW200-7E0, PW220-7E0 Wheeled Excavator Shop Manual
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
FILE DETAILS:
Komatsu PW200-7E0, PW220-7E0 Wheeled Excavator Shop Manual
Brands: Komatsu
Equipment Type: Wheeled Excavator
Manuals Type: Shop Manual
Machine Model: PW200-7E0, PW220-7E0
Serial Number: H55051 and up, H65051 and up
Book Code: VEBM949100
Language: English
Pages: 1242
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu PW200-7E0, PW220-7E0 Wheeled Excavator Shop Manual
FOREWORD:
GENERAL :
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate 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. For ease of understanding, the manual is divided into the following sections. These sections are further divided into each main group of components.
GENERAL:
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts.
STRUCTURE AND FUNCTION:
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
TESTING, ADJUSTING AND TROUBLESHOOTING:
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY:
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD:
This section gives the judgement standards when inspecting disassembled parts.
TABLE OF CONTENTS:
Komatsu PW200-7E0, PW220-7E0 Wheeled Excavator Shop Manual
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
KOMATSU PW200-7E0, PW220-7E0 WHEELED EXCAVATOR SHOP MANUAL H55051, H65051 AND UP – PDF DOWNLOAD:
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