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KOMATSU PW200-7H PW220-7H SERVICE REPAIR MANUAL (SN:H50051 AND UP) – PDF DOWNLOAD
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- KOMATSU PW200-7H PW220-7H SERVICE REPAIR MANUAL
- SERIAL NUMBER
PW200-7H H50051 AND UP
PW220-7H H50051 AND UP - PUBLICATION NUMBER:VEBM370100
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Description
KOMATSU PW200-7H PW220-7H SERVICE REPAIR MANUAL (SN:H50051 AND UP)
KOMATSU PW200-7H PW220-7H SERVICE REPAIR MANUAL (SN:H50051 AND UP) – PDF DOWNLOAD:
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TABLE OF CONTENTS:
KOMATSU PW200-7H PW220-7H SERVICE REPAIR MANUAL (SN:H50051 AND UP)(SN:H50051 AND UP)
VEBM370100_PW200-7H-PW220-7H......................................................................................... 1 01 GENERAL........................................................................................................... 3 DIMENSIONS....................................................................................................... 6 2 PIECE BOOM................................................................................................. 6 WORKING RANGES................................................................................................... 8 1 PIECE BOOM................................................................................................. 8 2 PIECE BOOM................................................................................................. 9 SPECIFICATION DIMENSION DRAWINGS................................................................................. 4 DIMENSIONS....................................................................................................... 4 1 PIECE BOOM................................................................................................. 4 SPECIFICATIONS................................................................................................... 10 PW200-7, PW220-7............................................................................................. 10 WEIGHT TABLE..................................................................................................... 12 pW200-7, PW220-7............................................................................................. 12 1 PIECE boom................................................................................................. 13 2 PIECE boom................................................................................................. 14 FUEL, COOLANT AND LUBRICANTS..................................................................................... 15 Section 10........................................................................................................... 17 ENGINE RELATED PARTS............................................................................................. 18 RADIATOR . OIL COOLER . charge air cooler........................................................................ 19 POWER TRAIN...................................................................................................... 20 SWING CIRCLE..................................................................................................... 21 SWING MACHINERY & motor.......................................................................................... 23 SWING MOTOR...................................................................................................... 26 Operation of swing lock...................................................................................... 29 RELIEF VALVE PORTION......................................................................................... 30 Operation.................................................................................................... 30 UNDERCARRIAGE.................................................................................................... 32 TRANSMISSION..................................................................................................... 34 TRAVEL MOTOR..................................................................................................... 38 oPERATION OF TRAVEL MOTOR.................................................................................... 40 CLUTCH CONTROL CIRCUIT........................................................................................... 42 AXLE............................................................................................................. 44 sUSPENSION LOCK CYLINDER......................................................................................... 48 Braking System................................................................................................... 50 brake/steer pump................................................................................................. 52 PRIORITY VALVE................................................................................................... 53 SPECIFICATIONS............................................................................................... 54 FUNCTION..................................................................................................... 55 ACCUMULATOR for brake system..................................................................................... 56 STEERING sYSTEM.................................................................................................. 57 STEERING COLUMN.................................................................................................. 58 ORBITROL VALVE................................................................................................... 59 hydraulic equipment layout drawingS.............................................................................. 60 hydraulic CIRCUIT dIAgRAM........................................................................................ 62 HYDRAULIC TANK................................................................................................... 63 HYDRAULIC PUMP................................................................................................... 64 HPV95 + 95 (PW200-7H)........................................................................................ 64 LS VALVE..................................................................................................... 69 PC VALVE..................................................................................................... 69 LS valve..................................................................................................... 71 PC Valve..................................................................................................... 75 PILOT PRESSURE CONTROL (PPC) SYSTEM.............................................................................. 81 CONTROL VALVE.................................................................................................... 82 PW200 -220-7H................................................................................................ 82 CLSS............................................................................................................. 96 OUTLINE OF CLSS.............................................................................................. 96 MAIN RELIEF VALVE............................................................................................ 99 Function................................................................................................. 99 Variable pressure compensation valve.........................................................................100 CENTre SWIVEL JOINT..............................................................................................102 TRAVEL PPC PEDAL.................................................................................................103 WORK EQUIPMENT . SWING PPC VALVE.................................................................................106 SERVICE PPC VALVE................................................................................................111 SOLENOID VALVES..................................................................................................116 SOLENOID VALVE BLOCK.........................................................................................119 2 Position 3 way valve...................................................................................119 2 Position 4 way valve...................................................................................121 LS (PC)-EPC VALVE............................................................................................124 attachment epc valve.........................................................................................128 Boom safety valve................................................................................................132 HYDRAULIC CYLINDER...............................................................................................134 pw200-7, pw220-7.............................................................................................134 BOOM CYLINDER............................................................................................134 ARM CYLINDER.............................................................................................134 BUCKET CYLINDER..........................................................................................134 ADJUST CYLINDER..........................................................................................135 Outrigger CYLINDER...............................................................................................136 dozer CYLINDER...................................................................................................138 work equipment...................................................................................................140 Pw200/220-7..................................................................................................141 Work Equipment...........................................................................................141 1. DIMENSION OF ARM..........................................................................................142 2. Dimension of bucket.......................................................................................144 air conditioner..................................................................................................146 air conditioner piping.......................................................................................146 electrical wiring diagram........................................................................................147 engine control system............................................................................................148 Governor motor...............................................................................................151 Engine throttle and pump controller..........................................................................154 ELECTRONIC CONTROL SYSTEM........................................................................................156 machine control system diagram...............................................................................158 machine MONITOR SYSTEM...........................................................................................182 Monitor panel................................................................................................184 LIQUID CRYSTAL MONITOR ADJUSTMENT SWITCH.....................................................................202 OVERLOAD WARNING DEVICE..........................................................................................208 OUTLINE......................................................................................................208 SENSOR...........................................................................................................210 1st attachment circuit hydraulic performance (main valve bypassed)...............................................217 TRAVEL CIRCUIT...............................................................................................218 oPERATIONAL AND CONTROL FEATURES.............................................................................219 SteeRING system..................................................................................................238 Operating principles.........................................................................................238 SERVICE BRAKE AND SUSPENSION SYSTEM..............................................................................248 bRAKING SYSTEM...............................................................................................248 operation....................................................................................................252 Section 20...........................................................................................................255 INSPECTION AND ADJUSTMENT OF ENGINE RPM..........................................................................272 MEASUREMENT OF EXHAUST GAS COLOR.................................................................................274 ADJUSTMENT OF VALVE CLEARANCE....................................................................................276 3MEASUREMENT OF COMPRESSION PRESSURE.............................................................................278 MEASUREMENT OF BLOW-BY PRESSURE..................................................................................279 INSPECTION AND ADJUSTMENT OF FUEL INJECTION TIMING...............................................................280 MEASUREMENT OF ENGINE OIL PRESSURE...............................................................................282 EMERGENcy sEtting iF FAILURE occurs IN ENGINE CONTROL SYSTEM.....................................................284 MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS................................................................285 INSPECTION AND ADJUSTMENT OF HYDRAULIC OIL PRESSURE IN HYDRAULIC CIRCUIT FOR WORK EQUIPMENT, SWING AND TRAVEL....286 INSPECTION AND ADJUSTMENT OF CONTROL CIRCUIT OIL PRESSURE........................................................290 INSPECTION AND ADJUSTMENT OF PUMP PC (Valve INLET) CONTROL OIL PRESSURE(PW200/220)...............................292 INSPECTION AND ADJUSTMENT OF PUMP LS valve CONTROL OIL PRESSURE(pW200/220).......................................295 MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE....................................................................299 7 - Stage solenoid block.....................................................................................301 4 - Stage solenoid block.....................................................................................303 2 - Stage solenoid block.....................................................................................304 MEASUREMENT OF PPC VALVE OUTPUT PRESSURE.........................................................................305 ADJUSTMENT OF WORK EQUIPMENT AND SWING PPC VALVE.................................................................307 testing travel motor relief pressure.............................................................................308 adjusting travel motor relief pressure...........................................................................309 Testing propshaft speed..........................................................................................310 TESTING TRANSMISSION CLUTCH CONTROL CIRCUIT......................................................................311 INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK EQUIPMENT.....................................................313 RELEASE OF REMAINING PRESSURE IN HYDRAULIC CIRCUIT...........................................................315 MEASUREMENT OF OIL LEAKAGE AMOUNT................................................................................316 INSPECTION PROCEDURES FOR DIODE..................................................................................320 SPECIAL FUNCTION OF MONITOR PANEL................................................................................321 OPERATION OF OPERATORS MENU AND DISPLAY (OUTLINE)............................................................323 TABLE FOR ERROR AND FAILURE CODE NO..........................................................................329 OPERATION AND DISPLAY OF SERVICE MENU........................................................................333 Way of switching to Service Menu.........................................................................333 Table for Monitoring Items...............................................................................336 PREPARATIONS FOR TROUBLESHOOTING ELECTRICAL SYSTEM...............................................................351 Section 30...........................................................................................................677 HOW TO READ THIS MANUAL..........................................................................................679 REMOVAL AND INSTALLATION OF ASSEMBLIES.......................................................................679 DISASSEMBLY AND ASEMBLY OF ASSEMBLIES........................................................................679 SPECIAL TOOLS....................................................................................................680 SKETCHES.....................................................................................................680 LIST OF TOOLS................................................................................................681 PRECAUTIONS WHEN PERFORMING OPERATION............................................................................682 GOVERNOR MOTOR ASSEMBLY..........................................................................................684 REMOVAL......................................................................................................684 STARTING MOTOR ASSEMBLY..........................................................................................685 REMOVAL......................................................................................................685 INSTALLATION.................................................................................................685 FUEL INJECTION PUMP ASSEMBLY.....................................................................................686 ENGINE FRONT SEAL................................................................................................690 ENGINE REAR SEAL.................................................................................................692 CYLINDER HEAD ASSEMBLY...........................................................................................694 COMBINATION COOLER...............................................................................................700 ENGINE AND HYDRAULIC PUMP ASSEMBLIES.............................................................................704 TRANSMISSION AND TRAVEL MOTOR ASSEMBLY...........................................................................709 TRANSMISSION ASSEMBLY............................................................................................711 TRAVEL MOTOR ASSEMBLY............................................................................................724 SWING MOTOR AND SWING MACHINERY ASSEMBLY.........................................................................728 SWING MOTOR AND SWING MACHINERY ASSEMBLY.........................................................................729 FRONT AXLE ASSEMBLY..............................................................................................736 FRONT AXLE ASSEMBLY..............................................................................................738 REAR AXLE ASSEMBLY...............................................................................................787 REAR AXLE ASSEMBLY...............................................................................................789 PROPSHAFT ASSEMBLY...............................................................................................811 WHEEL ASSEMBLY...................................................................................................812 SUSPENSION LOCK CYLINDER ASSEMBLY................................................................................813 SUSPENSION LOCK ASSEMBLY.........................................................................................814 OUTRIGGER ASSEMBLY...............................................................................................815 OUTRIGGER ASSEMBLY...............................................................................................816 DOZER BLADE ASSEMBLY.............................................................................................817 DOZER BLADE ASSEMBLY.............................................................................................818 SWING CIRCLE.....................................................................................................819 ASSEMBLY.........................................................................................................819 REVOLVING FRAME ASSEMBLY.........................................................................................820 CENTRE SWIVEL JOINT ASSEMBLY.....................................................................................823 CENTRE SWIVEL JOINT ASSEMBLY.....................................................................................826 HYDRAULIC TANK ASSEMBLY..........................................................................................828 FUEL TANK ASSEMBLY...............................................................................................831 CONTROL VALVE ASSEMBLY...........................................................................................833 LS SELECT VALVE ASSEMBLY.........................................................................................836 LS SHUTTLE VALVE ASSEMBLY........................................................................................837 PRESSURE COMPENSATION VALVE ASSEMBLY.............................................................................838 MAIN RELIEF VALVE ASSEMBLY.......................................................................................839 LS CONTROL EPC VALVE ASSEMBLY....................................................................................840 EPC SOLENOID VALVE ASSEMBLY......................................................................................841 PPC VALVE BLOCK ASSEMBLY.........................................................................................842 MANIFOLD BLOCK ASSEMBLY..........................................................................................843 OIL SEAL IN HYDRAULIC PUMP INPUT SHAFT...........................................................................844 WORK EQUIPMENT PPC VALVE ASSEMBLY................................................................................845 HYDRAULIC CYLINDER ASSEMBLY......................................................................................847 MONOBOOM WORK EQUIPMENT ASSEMBLY.................................................................................853 2 PIECE BOOM WORK EQUIPMENT ASSEMBLY.............................................................................856 AIR CONDITIONER UNIT ASSEMBLY....................................................................................859 COUNTERWEIGHT ASSEMBLY...........................................................................................863 OPERATOR CAB ASSEMBLY............................................................................................865 MONITOR ASSEMBLY.................................................................................................868 GOVERNOR / PUMP CONTROLLER ASSEMBLY..............................................................................870 Section 90...........................................................................................................873 90 OTHERS........................................................................................................873 HYDRAULIC CIRCUIT DIAGRAM 1/3....................................................................................875 HYDRAULIC CIRCUIT DIAGRAM 2/3....................................................................................877 HYDRAULIC CIRCUIT DIAGRAM 3/3....................................................................................879 ELECTRICAL CIRCUIT DIAGRAM 1/5...................................................................................881 ELECTRICAL CIRCUIT DIAGRAM 2/5...................................................................................883 ELECTRICAL CIRCUIT DIAGRAM 3/5...................................................................................885 ELECTRICAL CIRCUIT DIAGRAM 4/5...................................................................................887 ELECTRICAL CIRCUIT DIAGRAM 5/5...................................................................................889
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