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Komatsu PW200-7K PW220-7K Wheeled Excavator Operation & Maintenance Manual – PDF Download
Original price was: $62.95.$19.95Current price is: $19.95.
- Komatsu PW200-7K PW220-7K Wheeled Excavator Operation & Maintenance Manual
- PUBLICATION NUMBER:UEAM003700
- SERIAL NUMBER
PW200-7K – K40146 and up
PW220-7K – K40146 and up
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Description
Komatsu PW200-7K PW220-7K Wheeled Excavator Operation & Maintenance Manual
Description:
- Komatsu PW200-7K PW220-7K Wheeled Excavator Operation & Maintenance Manual
- 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.
Table of Contents:
Komatsu PW200-7K PW220-7K Wheeled Excavator Operation & Maintenance Manual
FOREWORD.................................................................................................. 3 SAFETY INFORMATION........................................................................................ 4 SAFETY MESSAGES....................................................................................... 4 NOISE................................................................................................. 5 VIBRATION............................................................................................. 5 EMERGENCY STEERING.................................................................................... 6 INTRODUCTION.............................................................................................. 7 INTENDED USE.......................................................................................... 7 FEATURES.............................................................................................. 7 BREAKING IN YOUR NEW MACHINE.......................................................................... 8 LOCATIONS OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR............................................ 9 MACHINE SERIAL NO. PLATE POSITION..................................................................... 9 ENGINE SERIAL NO. PLATE POSITION...................................................................... 9 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR............................................................. 9 MACHINE SERIAL PLATES................................................................................. 10 STANDARD SERIAL PLATE............................................................................. 10 GERMANY SERIAL PLATE.............................................................................. 10 ITALIAN SERIAL PLATE.............................................................................. 11 SAFETY.................................................................................................... 19 GENERAL PRECAUTIONS................................................................................... 20 PRECAUTION DURING OPERATION........................................................................... 26 BEFORE STARTING ENGINE............................................................................ 26 OPERATING MACHINE................................................................................. 27 TRANSPORTATION.................................................................................... 33 BATTERY........................................................................................... 34 TOWING............................................................................................ 35 BUCKET WITH HOOK OR BUCKET LINK WITH LIFTING EYE.................................................. 36 GENERAL PRECAUTIONS........................................................................... 36 PRECAUTIONS FOR LIFTING OPERATION............................................................. 37 PRECAUTIONS FOR MAINTENANCE........................................................................... 39 BEFORE CARRYING OUT MAINTENANCE................................................................... 39 DURING MAINTENANCE................................................................................ 42 POSITION FOR ATTACHING SAFETY LABELS.................................................................. 45 POSITION FOR ATTACHING SAFETY LABELS.............................................................. 45 LIFTING CAPACITY CHART PW200-7K....................................................................... 53 ONE PIECE BOOM Lift capacity tables for 2.5 metre undercarriage................................... 53 ONE PIECE BOOM Lift capacity tables for 2.75 metre undercarriage.................................. 60 TWO PIECE BOOM Lift capacity tables for 2.5 metre undercarriage................................... 67 TWO PIECE BOOM Lift capacity tables for 2.75 metre undercarriage.................................. 74 LIFTING CAPACITY CHART PW220-7K....................................................................... 81 ONE PIECE BOOM Lift capacity tables for 2.75 metre undercarriage and heavy duty counterweight..... 81 ONE PIECE BOOM Lift capacity tables for 2.75 metre undercarriage.................................. 88 TWO PIECE BOOM Lift capacity tables for 2.75 metre undercarriage and heavy duty counterweight..... 95 TWO PIECE BOOM Lift capacity tables for 2.75 metre undercarriage..................................102 OPERATION.................................................................................................111 GENERAL VIEW..........................................................................................112 GENERAL VIEW OF MACHINE...........................................................................112 GENERAL VIEW OF CONTROLS AND GAUGES...............................................................113 EXPLANATION OF COMPONENTS.............................................................................114 1. MACHINE MONITOR................................................................................114 BASIC OPERATION OF MACHINE MONITOR............................................................115 BASIC CHECK ITEMS.................................................................................117 CAUTION ITEMS.................................................................................119 EMERGENCY STOP ITEMS..........................................................................123 METER DISPLAY PORTION.........................................................................126 METERS........................................................................................128 MONITOR SWITCHES..............................................................................131 SWITCHES..............................................................................................146 CONTROL LEVERS, PEDALS................................................................................154 FRONT WINDOW......................................................................................159 EMERGENCY EXIT FROM OPERATOR'S CAB................................................................163 DOOR LOCK.........................................................................................164 CAP, COVER WITH LOCK..............................................................................165 METHOD OF OPENING AND CLOSING CAP WITH LOCK (For the fuel tank filler port)...................165 METHOD OF OPENING AND CLOSING COVER WITH LOCK (cover with lock)...............................165 FUSE..............................................................................................166 LUGGAGE TRAY......................................................................................167 ASHTRAY...........................................................................................167 CUP HOLDER........................................................................................167 HOT AND COOL BOX..................................................................................167 CAB RADIO.........................................................................................168 PRECAUTION OF USE.............................................................................168 POWER PICK-UP PORT................................................................................168 HANDLING AIR CONDITIONER..........................................................................169 GENERAL LOCATIONS OF CONTROL PANEL............................................................169 METHOD OF OPERATION...........................................................................173 PRECAUTIONS WHEN USING AIR CONDITIONER........................................................180 CHECK, MAINTAIN MACHINE EQUIPPED WITH AIR CONDITIONER.........................................181 OTHER FUNCTIONS...............................................................................181 FUSIBLE LINK......................................................................................182 CONTROLLER........................................................................................182 TOOL BOX..........................................................................................183 REFUELLING PUMP...................................................................................183 SAFETY........................................................................................183 PROCEDURE.....................................................................................183 MAINTENANCE...................................................................................184 WARNING LAMPS.....................................................................................185 HANDLING ACCUMULATORS.............................................................................186 OPERATION.............................................................................................187 CHECK BEFORE STARTING ENGINE......................................................................187 WALK-AROUND CHECK.............................................................................187 CHECK BEFORE STARTING.........................................................................189 ADJUSTMENT BEFORE OPERATION OPERATOR’S SEAT (AIR SUSPENSION SEAT).............................194 SEAT BELT.....................................................................................196 ADJUSTMENT BEFORE OPERATION OPERATOR’S SEAT (MECHANICAL SEAT).................................197 SEAT BELT.....................................................................................198 OPERATIONS AND CHECKS BEFORE STARTING ENGINE..........................................................199 STARTING ENGINE...................................................................................201 NORMAL STARTING...............................................................................201 STARTING IN COLD WEATHER......................................................................202 OPERATIONS AND CHECKS AFTER STARTING ENGINE...................................................204 WARMING UP OPERATION..........................................................................204 IN COLD AREAS (AUTOMATIC WARMING-UP OPERATION)................................................207 MOVING MACHINE OFF................................................................................210 MOVING MACHINE FORWARD........................................................................210 STEERING..........................................................................................213 TRAVELLING ON PUBLIC HIGHWAY......................................................................214 STOPPING & PARKING................................................................................215 STOPPING MACHINE (EMERGENCY)..................................................................216 SWINGING (Slewing the upper carriage).............................................................217 OPERATION OF WORK EQUIPMENT.......................................................................218 WORKING MODE SELECTION............................................................................221 PROHIBITIONS FOR OPERATION........................................................................222 PRECAUTIONS FOR OPERATION.........................................................................223 PRECAUTIONS WHEN TRAVELLING UP OR DOWN HILLS......................................................225 HOW TO ESCAPE FROM MUD............................................................................226 WHEN ONE SIDE IS STUCK........................................................................226 WHEN BOTH SIDES ARE STUCK.....................................................................226 WORK POSSIBLE USING HYDRAULIC EXCAVATOR...........................................................226 BACKHOE WORK..................................................................................226 SHOVEL WORK...................................................................................227 DITCHING WORK.................................................................................227 LOADING WORK..................................................................................227 LEVELLING WORK................................................................................227 REPLACEMENT AND INVERSION OF BUCKET...............................................................228 REPLACEMENT...................................................................................228 INVERSION.....................................................................................228 STOPPING ENGINE...................................................................................230 CHECK AFTER FINISHING WORK........................................................................230 CHECK AFTER STOPPING ENGINE...........................................................................231 LOCKING...........................................................................................231 OVERLOAD WARNING DEVICE...........................................................................231 HANDLING THE WHEELS...............................................................................231 TRANSPORTATION........................................................................................235 LOADING, UNLOADING WORK...........................................................................235 PRECAUTIONS FOR LOADING...........................................................................237 HOW TO LIFT THE MACHINE.......................................................................238 PRECAUTIONS FOR TRANSPORTATION....................................................................239 TRAVELLING POSTURE................................................................................240 COLD WEATHER OPERATION................................................................................241 PRECAUTIONS FOR LOW TEMPERATURE...................................................................241 FUEL AND LUBRICANTS...........................................................................241 BATTERY.......................................................................................242 PRECAUTIONS AFTER COMPLETION OF WORK..............................................................243 AFTER COLD WEATHER................................................................................243 LONG-TERM STORAGE.....................................................................................244 BEFORE STORAGE....................................................................................244 DURING STORAGE....................................................................................244 AFTER STORAGE.....................................................................................245 STARTING MACHINE AFTER LONG-TERM STORAGE..........................................................245 TROUBLESHOOTING.......................................................................................246 PHENOMENA THAT ARE NOT FAILURES...................................................................246 METHOD OF TOWING MACHINE..........................................................................247 PRECAUTIONS ON PARTICULAR JOBSITES................................................................247 DISCHARGED BATTERY................................................................................248 REMOVAL AND INSTALLATION OF BATTERY...........................................................248 BATTERY CHARGES...............................................................................249 STARTING ENGINE WITH BOOSTER CABLES...........................................................250 OTHER TROUBLE.....................................................................................252 ELECTRICAL SYSTEM.............................................................................252 CHASSIS.......................................................................................253 ENGINE........................................................................................254 ELECTRONIC CONTROL SYSTEM.....................................................................256 MAINTENANCE...............................................................................................257 GUIDES TO MAINTENANCE.................................................................................258 OUTLINE OF SERVICE....................................................................................261 USE OF BIO-DEGRADEABLE OIL........................................................................261 Filter changes................................................................................261 Oil changes...................................................................................261 If an abnormality is found in the characteristics of the oil, change the oil immediately..........261 OUTLINE OF OIL, FUEL, COOLANT.....................................................................262 OIL...........................................................................................262 FUEL..........................................................................................262 COOLANT.......................................................................................263 GREASE........................................................................................263 CARRYING OUT KOWA (Komatsu Oil Wear Analysis).................................................263 STORING OIL AND FUEL..........................................................................264 FILTERS.......................................................................................265 OUTLINE OF ELECTRIC SYSTEM........................................................................266 OUTLINE OF HYDRAULIC SYSTEM.......................................................................266 WEAR PARTS LIST.......................................................................................268 USE FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE.....................................269 PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS..................................................269 USE FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE CONT................................271 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS........................................................273 INTRODUCTION OF NECESSARY TOOLS...................................................................273 TIGHTENING TORQUE SPECIFICATIONS......................................................................274 TIGHTENING TORQUE LIST............................................................................274 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS.........................................................275 SAFETY CRITICAL PARTS.............................................................................276 MAINTENANCE SCHEDULE CHART............................................................................277 KEY TO LUBRICATION POINTS.........................................................................281 SERVICE PROCEDURE.....................................................................................283 INITIAL 250 HOURS SERVICE.........................................................................283 WHEN REQUIRED.....................................................................................284 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT..................................................284 CLEAN INSIDE OF COOLING SYSTEM................................................................289 CLEAN INSIDE OF COOLING SYSTEM................................................................290 CHECKING COOLANT LEVEL............................................................................292 DRAINING THE SYSTEM...........................................................................292 CLEANING THE SYSTEM...........................................................................293 FILLING THE SYSTEM............................................................................293 REFILLING AN OVERHEATED SYSTEM................................................................293 CLEANING THE RADIATOR.........................................................................294 THERMOSTAT....................................................................................294 FAN...........................................................................................294 CHECK AND TIGHTEN WHEEL NUTS......................................................................295 CHECK ELECTRICAL INTAKE AIR HEATER................................................................295 CHECK ALTERNATOR..................................................................................295 CHECK START MOTOR.............................................................................296 REPLACE BUCKET SIDE CUTTERS.......................................................................296 REPLACE BUCKET TEETH..............................................................................297 REPLACE BUCKET TEETH (VERTICAL PIN TYPE)......................................................297 REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)....................................................300 ADJUST BUCKET CLEARANCE...........................................................................301 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID........................................................302 CHECK AND ADJUST AIR CONDITIONER..................................................................303 CHECK LEVEL OF REFRIGERANT (GAS)..............................................................303 DRAIN ENGINE BREATHER OIL CATCHER.................................................................304 CHECK BEFORE STARTING.............................................................................305 CHECK COOLANT LEVEL, ADD WATER....................................................................305 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL....................................................305 CHECK FUEL LEVEL, ADD FUEL....................................................................306 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL....................................................307 CHECK AIR CLEANER FOR CLOGGING................................................................307 CHECK ELECTRIC WIRING.........................................................................308 CHECK FOR WATER AND SEDIMENT IN SEDIMENTOR. DRAIN WATER AND SEDIMENT..........................308 CHECK FOR WATER IN PRIMARY FUEL FILTER, DRAIN WATER...........................................309 EVERY 50 HOURS....................................................................................309 DRAIN WATER AND SEDIMENT FROM FUEL TANK.......................................................309 EVERY 100 HOURS SERVICE...........................................................................309 LUBRICATING...................................................................................309 CLEANING FRESH AIR FILTER.....................................................................314 EVERY 250 HOURS MAINTENANCE.......................................................................315 CHECK OIL LEVEL IN MACHINERY CASE, ADD OIL....................................................315 CHECK OIL LEVEL IN WHEEL HUBS, ADD OIL (Front Axle)...........................................315 CHECK OIL LEVEL IN WHEEL HUBS, ADD OIL (Rear Axle)............................................316 CHECK OIL LEVEL IN AXLES, ADD OIL.............................................................316 CHECK OIL LEVEL IN TRANSMISSION, ADD OIL......................................................317 CHECK LEVEL OF BATTERY ELECTROLYTE............................................................317 BELTS, GENERAL................................................................................318 CHECK FAN BELT TENSION, ADJUST TENSION........................................................318 CHECK, ADJUST TENSION OF AIR CONDITIONER COMPRESSOR BELT......................................319 EVERY 500 HOURS SERVICE...........................................................................320 LUBRICATE SWING CIRCLE (2 POINTS).............................................................320 REPLACE FUEL FILTER CARTRIDGE.................................................................321 CHECK SWING PINION GREASE LEVEL, ADD GREASE...................................................322 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE.............................323 CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS AND CONDENSER FINS...........................324 CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER SYSTEM.............................325 CLEANING RECIRCULATED AIR FILTER..............................................................326 REPLACE HYDRAULIC TANK BREATHER ELEMENT.......................................................327 EVERY 1000 HOURS SERVICE..........................................................................328 REPLACE HYDRAULIC FILTER ELEMENT..............................................................328 CHANGE OIL IN SWING MACHINERY CASE............................................................329 CHECK ALL TIGHTENING PARTS OF TURBOCHARGER....................................................329 CHECK PLAY OF TURBOCHARGER ROTOR..............................................................330 CHECK & ADJUST VALVE CLEARANCE................................................................330 CHECK FAN BELT TENSIONER BEARING BELT AND FAN HUB.............................................330 CHECK FAN BELT TENSION........................................................................330 CHANGE OIL IN AXLES...........................................................................330 CHANGE OIL IN HUBS............................................................................331 CHANGE OIL IN TRANSMISSION ASSEMBLY...........................................................333 EVERY 2000 HOURS SERVICE..........................................................................334 CLEAN HYDRAULIC TANK STRAINER.................................................................334 CLEAN, CHECK TURBOCHARGER.....................................................................334 CHECK ALTERNATOR, STARTING MOTOR..............................................................334 CHECK VIBRATION DAMPER........................................................................334 CHANGE ANTIFREEZE.............................................................................334 CHECK AND ADJUST VALVE CLEARANCE..............................................................335 EVERY 4000 HOURS SERVICE..........................................................................335 CHECK WATER PUMP..............................................................................335 EVERY 5000 HOURS SERVICE..........................................................................336 CHANGE OIL IN HYDRAULIC TANK..................................................................336 SPECIFICATIONS............................................................................................339 SPECIFICATIONS........................................................................................340 1 - PIECE BOOM....................................................................................341 2 - PIECE BOOM....................................................................................343 WORKING RANGE: ONE PIECE BOOM.....................................................................345 WORKING RANGE: TWO PIECE BOOM.....................................................................346 OPTIONS, ATTACHMENTS......................................................................................347 GENERAL PRECAUTIONS...................................................................................348 PRECAUTIONS RELATED TO SAFETY.....................................................................348 PRECAUTIONS WHEN INSTALLING ATTACHMENTS...............................................................349 HANDLING BUCKET WITH HOOK.............................................................................351 CHECKING FOR DAMAGE TO BUCKET WITH HOOK...........................................................351 PROHIBITED OPERATIONS.............................................................................351 PRECAUTIONS DURING OPERATIONS.....................................................................351 MACHINES READY FOR ATTACHMENTS........................................................................352 GENERAL LOCATIONS.................................................................................352 HANDLING THE CLAMSHELL BUCKET.....................................................................354 How to install clamshell bucket...............................................................354 HOW TO OPERATE................................................................................355 OPERATION.........................................................................................355 WHEN USING BREAKER............................................................................356 METHOD FOR RELEASING PRESSURE IN CONTROL CIRCUIT OF MACHINES EQUIPPED WITH ACCUMULATOR............357 LONG-TERM STORAGE.................................................................................357 SPECIFICATIONS................................................................................357 INTRODUCTION OF ATTACHMENTS AND EXTENDING MACHINE SERVICE LIFE........................................358 HYDRAULIC BREAKER.................................................................................358 POWER RIPPER......................................................................................361 FORK GRAB.........................................................................................362 GRAPPLE BUCKET....................................................................................363 SCRAP GRAPPLE.....................................................................................364 CRUSHER & SMASHER.................................................................................366 HYDRAULIC PILE DRIVER.............................................................................367 HYDRAULIC EXCAVATOR WITH MULTIPURPOSE CRANE.......................................................368 GENERAL VIEW OF CONTROLS......................................................................370 LEFT CONTROL LEVER (with auto-deceleration device)............................................371 RIGHT CONTROL LEVER (with auto-deceleration device)...........................................371 UPPER BOOM CONTROL PEDAL......................................................................372 EXCAVATOR’S WORK..............................................................................372 REPLACEMENT OF BUCKET.........................................................................374 HANDLING THE TRAPEZOIDAL BUCKET (If equipped).................................................375
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KOMATSU PW200-7K PW220-7K WHEELED EXCAVATOR OPERATION & MAINTENANCE MANUAL – PDF DOWNLOAD:
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