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Komatsu Pw200-7H,Pw220-7H Wheeled Excavator Operation & Maintenance Manual SN H50051 And Up – PDF DOWNLOAD
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Komatsu Pw200-7H,Pw220-7H Wheeled Excavator Operation & Maintenance Manual
Book Code : VEAM370101
SERIAL NUMBER:
PW200-7H H50051 and up
PW220-7H H50051 and up
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Description
Komatsu Pw200-7H,Pw220-7H Wheeled Excavator Operation & Maintenance Manual
FILE DETAILS:
Komatsu Pw200-7H,Pw220-7H Wheeled Excavator Operation & Maintenance Manual
Model Specification: Pw200-7H,Pw220-7H Wheeled Excavator
Language: English
File Format: PDF
Total Pages: 408
Requirements: Adobe PDF Reader
ZOOM IN/OUT: YES
Downloadable: YES
KOMATSU PW200-7H,PW220-7H WHEELED EXCAVATOR OPERATION & MAINTENANCE MANUAL SN H50051 AND UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu Pw200-7H,Pw220-7H Wheeled Excavator Operation & Maintenance Manual
FOREWORD:
- This manual provides rules and guidelines which will help you use this machine safely and effectively. Keep this manual handy and have all personnel read it periodically. If this manual has been lost or has become dirty and can not be read, request a replacement manual from Komatsu or your Komatsu distributor.
- If you sell the machine, be sure to give this manual to the new owners. Continuing improvements in the design of this machine can lead to changes in detail which may not be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information for your machine or for questions regarding information in this manual.
Guide to Reduce Vibration Levels on Machine
The following guides can help an operator of this machine to
reduce the whole body vibration levels:
1. Use the correct equipment and attachments.
2. Maintain the machine according to this manual
Q Tire pressures (for wheeled machines)
Q Brake and steering systems
Q Controls, hydraulic system and linkages
3. Keep the terrain where the machine is working and traveling
in good condition
Q Remove any large rocks or obstacles
Q Fill any ditches and holes
Q Site manager should provide machine operators with
machine and schedule time to maintain terrain conditions
TABLE OF CONTENTS:
Komatsu Pw200-7H,Pw220-7H Wheeled Excavator Operation & Maintenance Manual
FOREWORD.................................................................................................. 3 SAFETY INFORMATION........................................................................................ 5 SAFETY MESSAGES....................................................................................... 5 NOISE................................................................................................. 6 VIBRATION............................................................................................. 6 Guide to Reduce Vibration Levels on Machine....................................................... 7 EMERGENCY STEERING.................................................................................... 8 EMERGENCY BRAKING..................................................................................... 8 INTRODUCTION.............................................................................................. 9 INTENDED USE.......................................................................................... 9 FEATURES.............................................................................................. 9 BREAKING IN YOUR NEW MACHINE.......................................................................... 10 LOCATIONS OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR............................................ 11 MACHINE SERIAL NO. PLATE POSITION..................................................................... 11 ENGINE SERIAL NO. PLATE POSITION...................................................................... 11 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR............................................................. 11 MACHINE SERIAL PLATES................................................................................. 12 STANDARD SERIAL PLATE............................................................................. 12 SAFETY.................................................................................................... 19 GENERAL PRECAUTIONS................................................................................... 20 PRECAUTION DURING OPERATION........................................................................... 28 BEFORE STARTING ENGINE............................................................................ 28 OPERATING MACHINE................................................................................. 29 TRANSPORTATION.................................................................................... 36 BATTERY........................................................................................... 37 TOWING............................................................................................ 38 BUCKET WITH HOOK OR BUCKET LINK WITH LIFTING EYE.................................................. 40 GENERAL PRECAUTIONS........................................................................... 40 PRECAUTIONS FOR LIFTING OPERATION............................................................. 42 HANDLING OF FLUIDS................................................................................ 43 PRECAUTIONS FOR MAINTENANCE........................................................................... 44 BEFORE CARRYING OUT MAINTENANCE................................................................... 44 DURING MAINTENANCE................................................................................ 47 POSITION FOR ATTACHING SAFETY LABELS.................................................................. 50 POSITION FOR ATTACHING SAFETY LABELS.............................................................. 50 LIFTING CAPACITY CHART PW200-7H....................................................................... 58 ONE PIECE BOOM Lift capacity tables for 2.5 metre undercarriage................................... 58 ONE PIECE BOOM Lift capacity tables for 2.75 metre undercarriage.................................. 65 TWO PIECE BOOM Lift capacity tables for 2.5 metre undercarriage................................... 72 TWO PIECE BOOM Lift capacity tables for 2.75 metre undercarriage.................................. 79 LIFTING CAPACITY CHART PW220-7H....................................................................... 86 ONE PIECE BOOM Lift capacity tables for 2.75 metre undercarriage and heavy duty counterweight..... 86 ONE PIECE BOOM Lift capacity tables for 2.75 metre undercarriage.................................. 93 TWO PIECE BOOM Lift capacity tables for 2.75 metre undercarriage and heavy duty counterweight.....100 TWO PIECE BOOM Lift capacity tables for 2.75 metre undercarriage..................................107 OPERATION.................................................................................................117 GENERAL VIEW..........................................................................................118 GENERAL VIEW OF MACHINE...........................................................................118 GENERAL VIEW OF CONTROLS AND GAUGES...............................................................119 EXPLANATION OF COMPONENTS.............................................................................120 MACHINE MONITOR...................................................................................120 BASIC OPERATION OF MACHINE MONITOR............................................................121 BASIC CHECK ITEMS.................................................................................123 CAUTION ITEMS.................................................................................125 EMERGENCY STOP ITEMS..........................................................................129 METER DISPLAY PORTION.........................................................................132 METERS........................................................................................134 MONITOR SWITCHES..............................................................................138 SWITCHES..............................................................................................151 CONTROL LEVERS, PEDALS................................................................................159 FRONT WINDOW......................................................................................165 EMERGENCY EXIT FROM OPERATOR'S CAB................................................................169 CAP, COVER WITH LOCK..............................................................................171 METHOD OF OPENING AND CLOSING CAP WITH LOCK (For the fuel tank filler port)...................171 METHOD OF OPENING AND CLOSING COVER WITH LOCK (cover with lock)...............................171 FUSE..............................................................................................172 LUGGAGE TRAY......................................................................................173 ASHTRAY...........................................................................................173 CUP HOLDER........................................................................................173 HOT AND COOL BOX..................................................................................173 CAB RADIO.........................................................................................174 PRECAUTION OF USE.............................................................................174 POWER PICK-UP PORT................................................................................174 HANDLING AIR CONDITIONER..........................................................................175 GENERAL LOCATIONS OF CONTROL PANEL............................................................175 METHOD OF OPERATION...........................................................................179 PRECAUTIONS WHEN USING AIR CONDITIONER........................................................186 CHECK, MAINTAIN MACHINE EQUIPPED WITH AIR CONDITIONER.........................................187 OTHER FUNCTIONS...............................................................................187 FUSIBLE LINK......................................................................................188 CONTROLLER........................................................................................188 TOOL BOX..........................................................................................189 REFUELLING PUMP...................................................................................189 SAFETY........................................................................................189 PROCEDURE.....................................................................................189 MAINTENANCE...................................................................................190 WARNING LAMPS.....................................................................................191 HANDLING ACCUMULATORS.............................................................................192 OPERATION.............................................................................................194 CHECK BEFORE STARTING ENGINE......................................................................194 WALK-AROUND CHECK.............................................................................194 CHECK BEFORE STARTING.........................................................................196 ADJUSTMENT BEFORE OPERATION OPERATOR’S SEAT (AIR SUSPENSION SEAT).............................201 SEAT BELT.....................................................................................203 ADJUSTMENT BEFORE OPERATION OPERATOR’S SEAT (MECHANICAL SEAT).................................204 SEAT BELT.....................................................................................204 OPERATIONS AND CHECKS BEFORE STARTING ENGINE..........................................................205 STARTING ENGINE...................................................................................207 NORMAL STARTING...............................................................................207 STARTING IN COLD WEATHER......................................................................208 OPERATIONS AND CHECKS AFTER STARTING ENGINE...................................................210 WARMING UP OPERATION..........................................................................210 IN COLD AREAS (AUTOMATIC WARMING-UP OPERATION)................................................213 MOVING MACHINE OFF................................................................................216 MOVING MACHINE FORWARD........................................................................216 STEERING..........................................................................................219 TRAVELLING ON PUBLIC HIGHWAY......................................................................220 STOPPING & PARKING................................................................................222 STOPPING MACHINE (EMERGENCY)..................................................................223 SWINGING (Slewing the upper carriage).............................................................224 OPERATION OF WORK EQUIPMENT.......................................................................225 WORKING MODE SELECTION............................................................................227 PROHIBITIONS FOR OPERATION........................................................................229 PRECAUTIONS FOR OPERATION.........................................................................231 RECOMMENDATIONS FOR TRAVELLING....................................................................232 PRECAUTIONS WHEN TRAVELLING UP OR DOWN HILLS......................................................233 HOW TO ESCAPE FROM MUD............................................................................235 WHEN ONE SIDE IS STUCK........................................................................235 WHEN BOTH SIDES ARE STUCK.....................................................................235 WORK POSSIBLE USING HYDRAULIC EXCAVATOR...........................................................236 BACKHOE WORK..................................................................................236 SHOVEL WORK...................................................................................236 DITCHING WORK.................................................................................236 LOADING WORK..................................................................................237 LEVELLING WORK................................................................................237 REPLACEMENT AND INVERSION OF BUCKET...............................................................238 REPLACEMENT...................................................................................238 INVERSION.....................................................................................238 STOPPING ENGINE...................................................................................240 CHECK AFTER FINISHING WORK........................................................................240 CHECK AFTER STOPPING ENGINE...........................................................................241 LOCKING...........................................................................................241 OVERLOAD WARNING DEVICE...........................................................................241 HANDLING THE WHEELS...............................................................................242 TRANSPORTATION........................................................................................246 LOADING, UNLOADING WORK...........................................................................246 PRECAUTIONS FOR LOADING...........................................................................248 HOW TO LIFT THE MACHINE.......................................................................249 PRECAUTIONS FOR TRANSPORTATION....................................................................251 TRAVELLING POSTURE................................................................................252 COLD WEATHER OPERATION................................................................................253 PRECAUTIONS FOR LOW TEMPERATURE...................................................................253 FUEL AND LUBRICANTS...........................................................................253 BATTERY.......................................................................................255 PRECAUTIONS AFTER COMPLETION OF WORK..............................................................256 AFTER COLD WEATHER................................................................................256 LONG-TERM STORAGE.....................................................................................257 BEFORE STORAGE....................................................................................257 DURING STORAGE....................................................................................257 AFTER STORAGE.....................................................................................258 STARTING MACHINE AFTER LONG-TERM STORAGE..........................................................258 TROUBLESHOOTING.......................................................................................259 PHENOMENA THAT ARE NOT FAILURES...................................................................259 METHOD OF TOWING MACHINE..........................................................................260 PRECAUTIONS ON PARTICULAR JOBSITES................................................................260 DISCHARGED BATTERY................................................................................261 REMOVAL AND INSTALLATION OF BATTERY...........................................................262 BATTERY CHARGES...............................................................................262 STARTING ENGINE WITH BOOSTER CABLES...........................................................263 OTHER TROUBLE.....................................................................................265 ELECTRICAL SYSTEM.............................................................................265 CHASSIS.......................................................................................266 ENGINE........................................................................................267 ELECTRONIC CONTROL SYSTEM.....................................................................269 MAINTENANCE...............................................................................................271 GUIDES TO MAINTENANCE.................................................................................272 OUTLINE OF SERVICE....................................................................................275 USE OF BIO-DEGRADEABLE OIL........................................................................275 Filter changes................................................................................275 Oil changes...................................................................................276 OUTLINE OF OIL, FUEL, COOLANT.....................................................................276 OIL...........................................................................................276 FUEL..........................................................................................277 COOLANT.......................................................................................277 GREASE........................................................................................278 CARRYING OUT KOWA (Komatsu Oil Wear Analysis).................................................278 STORING OIL AND FUEL..........................................................................279 FILTERS.......................................................................................279 OUTLINE OF ELECTRIC SYSTEM........................................................................280 OUTLINE OF HYDRAULIC SYSTEM.......................................................................280 WEAR PARTS LIST.......................................................................................282 USE FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE.....................................283 PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS..................................................283 USE FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE CONT................................285 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS........................................................287 INTRODUCTION OF NECESSARY TOOLS...................................................................287 TIGHTENING TORQUE SPECIFICATIONS......................................................................288 TIGHTENING TORQUE LIST............................................................................288 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS.........................................................289 SAFETY CRITICAL PARTS.............................................................................290 MAINTENANCE SCHEDULE CHART............................................................................291 KEY TO LUBRICATION POINTS.........................................................................295 SERVICE PROCEDURE.....................................................................................297 INITIAL 50 HOURS SERVICE..........................................................................297 CHECK AND TIGHTEN WHEEL NUTS......................................................................297 INITIAL 250 HOURS SERVICE.........................................................................297 WHEN REQUIRED.....................................................................................298 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT..................................................298 CLEAN INSIDE OF COOLING SYSTEM................................................................303 CLEAN INSIDE OF COOLING SYSTEM................................................................304 CHECKING COOLANT LEVEL............................................................................307 DRAINING THE SYSTEM...........................................................................307 CLEANING THE SYSTEM...........................................................................308 FILLING THE SYSTEM............................................................................308 REFILLING AN OVERHEATED SYSTEM................................................................309 CLEANING THE RADIATOR.........................................................................309 THERMOSTAT....................................................................................310 FAN...........................................................................................310 CHECK AND TIGHTEN WHEEL NUTS......................................................................310 CHECK ELECTRICAL INTAKE AIR HEATER................................................................311 CHECK ALTERNATOR..................................................................................311 CHECK START MOTOR.............................................................................312 REPLACE BUCKET SIDE CUTTERS.......................................................................312 REPLACE BUCKET TEETH..............................................................................313 REPLACE BUCKET TEETH (VERTICAL PIN TYPE)......................................................313 REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)....................................................316 ADJUST BUCKET CLEARANCE...........................................................................317 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID........................................................318 CHECK AND ADJUST AIR CONDITIONER..................................................................319 CHECK LEVEL OF REFRIGERANT (GAS)..............................................................319 DRAIN ENGINE BREATHER OIL CATCHER.................................................................320 CHECK BEFORE STARTING.............................................................................321 CHECK COOLANT LEVEL, ADD WATER....................................................................321 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL....................................................322 CHECK FUEL LEVEL, ADD FUEL....................................................................323 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL....................................................324 CHECK AIR CLEANER FOR CLOGGING................................................................324 CHECK ELECTRIC WIRING.........................................................................325 CHECK FOR WATER AND SEDIMENT IN SEDIMENTOR. DRAIN WATER AND SEDIMENT..........................326 CHECK FOR WATER IN PRIMARY FUEL FILTER, DRAIN WATER...........................................326 EVERY 50 HOURS....................................................................................327 DRAIN WATER AND SEDIMENT FROM FUEL TANK.......................................................327 EVERY 100 HOURS SERVICE...........................................................................328 LUBRICATING...................................................................................328 CLEANING FRESH AIR FILTER.....................................................................333 EVERY 250 HOURS MAINTENANCE.......................................................................334 CHECK OIL LEVEL IN MACHINERY CASE, ADD OIL....................................................334 CHECK OIL LEVEL IN WHEEL HUBS, ADD OIL (Front Axle)...........................................334 CHECK OIL LEVEL IN WHEEL HUBS, ADD OIL (Rear Axle)............................................335 CHECK OIL LEVEL IN AXLES, ADD OIL.............................................................335 CHECK OIL LEVEL IN TRANSMISSION, ADD OIL......................................................336 CHECK LEVEL OF BATTERY ELECTROLYTE............................................................336 BELTS, GENERAL................................................................................337 CHECK FAN BELT TENSION, ADJUST TENSION........................................................338 CHECK, ADJUST TENSION OF AIR CONDITIONER COMPRESSOR BELT......................................339 EVERY 500 HOURS SERVICE...........................................................................340 REPLACE FUEL FILTER CARTRIDGE.................................................................340 CHECK SWING PINION GREASE LEVEL, ADD GREASE...................................................341 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE.............................342 CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS AND CONDENSER FINS...........................344 CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER SYSTEM.............................345 CLEANING RECIRCULATED AIR FILTER..............................................................345 REPLACE HYDRAULIC TANK BREATHER ELEMENT.......................................................346 EVERY 1000 HOURS SERVICE..........................................................................347 REPLACE HYDRAULIC FILTER ELEMENT..............................................................347 CHANGE OIL IN SWING MACHINERY CASE............................................................348 CHECK ALL TIGHTENING PARTS OF TURBOCHARGER....................................................350 CHECK PLAY OF TURBOCHARGER ROTOR..............................................................350 CHECK & ADJUST VALVE CLEARANCE................................................................350 CHECK FAN BELT TENSIONER BEARING BELT AND FAN HUB.............................................350 CHECK FAN BELT TENSION........................................................................350 CHANGE OIL IN AXLES...........................................................................351 CHANGE OIL IN HUBS............................................................................352 CHANGE OIL IN TRANSMISSION ASSEMBLY...........................................................353 CHANGE OIL IN DAMPER..........................................................................354 EVERY 2000 HOURS SERVICE..........................................................................355 CLEAN HYDRAULIC TANK STRAINER.................................................................355 CLEAN THE STRAINER OF THE BRAKE FILTER........................................................356 CLEAN, CHECK TURBOCHARGER.....................................................................357 CHECK ALTERNATOR, STARTING MOTOR..............................................................357 CHECK VIBRATION DAMPER........................................................................357 CHANGE ANTIFREEZE.............................................................................357 CHECK AND ADJUST VALVE CLEARANCE..............................................................357 EVERY 4000 HOURS SERVICE..........................................................................358 CHECK WATER PUMP..............................................................................358 EVERY 5000 HOURS SERVICE..........................................................................359 CHANGE OIL IN HYDRAULIC TANK AND REPLACE STEER/BRAKE CIRCUIT STRAINER.........................359 SPECIFICATIONS............................................................................................363 SPECIFICATIONS........................................................................................364 1 - PIECE BOOM....................................................................................365 2 - PIECE BOOM....................................................................................367 WORKING RANGE: ONE PIECE BOOM.....................................................................369 WORKING RANGE: TWO PIECE BOOM.....................................................................370 OPTIONS, ATTACHMENTS......................................................................................371 GENERAL PRECAUTIONS...................................................................................372 PRECAUTIONS RELATED TO SAFETY.....................................................................372 PRECAUTIONS WHEN INSTALLING ATTACHMENTS...............................................................373 HANDLING BUCKET WITH HOOK.............................................................................375 CHECKING FOR DAMAGE TO BUCKET WITH HOOK...........................................................375 PROHIBITED OPERATIONS.............................................................................375 PRECAUTIONS DURING OPERATIONS.....................................................................375 MACHINES READY FOR ATTACHMENTS........................................................................376 GENERAL LOCATIONS.................................................................................376 HANDLING THE CLAMSHELL BUCKET.....................................................................378 How to install clamshell bucket...............................................................378 HOW TO OPERATE................................................................................379 OPERATION.........................................................................................380 WHEN USING BREAKER............................................................................380 METHOD FOR RELEASING PRESSURE IN CONTROL CIRCUIT OF MACHINES EQUIPPED WITH ACCUMULATOR............381 LONG-TERM STORAGE.................................................................................381 SPECIFICATIONS................................................................................381 INTRODUCTION OF ATTACHMENTS AND EXTENDING MACHINE SERVICE LIFE........................................382 HYDRAULIC BREAKER.................................................................................382 POWER RIPPER......................................................................................385 FORK GRAB.........................................................................................387 GRAPPLE BUCKET....................................................................................389 SCRAP GRAPPLE.....................................................................................391 CRUSHER & SMASHER.................................................................................393 HYDRAULIC PILE DRIVER.............................................................................395 HYDRAULIC EXCAVATOR WITH MULTIPURPOSE CRANE.......................................................396 GENERAL VIEW OF CONTROLS......................................................................398 LEFT CONTROL LEVER (with auto-deceleration device)............................................399 RIGHT CONTROL LEVER (with auto-deceleration device)...........................................399 UPPER BOOM CONTROL PEDAL......................................................................400 EXCAVATOR’S WORK..............................................................................400 REPLACEMENT OF BUCKET.........................................................................402 HANDLING THE TRAPEZOIDAL BUCKET (If equipped).................................................403 INDEX.....................................................................................................405
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R Bronson –
Easy to use, manual appears to be complete.