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Komatsu PW210-1 Wheeled Excavator Shop Manual 10001 and up – PDF DOWNLOAD
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Komatsu PW210-1 Wheeled Excavator Shop Manual
Book Code: SEBM020K0102
MACHINE MODEL SERIAL N0.
PW210-1 10001 and up
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Description
Komatsu PW210-1 Wheeled Excavator Shop Manual
FILE DETAILS:
Komatsu PW210-1 Wheeled Excavator Shop Manual
Brands: Komatsu
Equipment Type: Wheeled Excavator
Manuals Type: Shop Manual
Machine Model: PW210-1
Serial Number: 10001 and up
Book Code: SEBM020K0102
Language: English
Pages: 477
File Format: Portable Document Format (PDF)
KOMATSU PW210-1 WHEELED EXCAVATOR SHOP MANUAL 10001 AND UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu PW210-1 Wheeled Excavator Shop Manual
FOREWORD:
GENERAL:
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the servicemen an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
- This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION:
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
TESTING AND ADJUSTING:
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also included in thissection.
DISASSEMBLY AND ASSEMBLY:
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD :
This section gives the judgement standards when inspecting disassembled parts.
TABLE OF CONTENTS:
Komatsu PW210-1 Wheeled Excavator Shop Manual
COVER.......................................................................................................................................... 1 CONTENTS....................................................................................................................................... 2 10 ENGINE...................................................................................................................................... 16 11 STRUCTURE AND FUNCTION.................................................................................................................. 16 AUTO-DECELERATION SYSTEM............................................................................................................... 17 12 TESTING AND ADJUSTING................................................................................................................... 25 TABLE OF JUDGEMENT STANDARD VALUE...................................................................................................... 26 TESTING AND ADJUSTING TOOL LIST........................................................................................................ 27 ADJUSTING VALVE CLEARANCE.............................................................................................................. 28 MEASURING COMPRESSION PRESSURE......................................................................................................... 29 ADJUSTING FUEL INJECTION TIMING........................................................................................................ 30 ADJUSTING DECELERATION CYLINDER........................................................................................................ 31 ADJUSTING FUEL CONTROL LEVER........................................................................................................... 32 13 DISASSEMBLY AND ASSEMBLY................................................................................................................ 34 STARTING MOTOR......................................................................................................................... 35 REMOVAL AND INSTALLATION........................................................................................................... 35 ALTERNATOR............................................................................................................................. 35 REMOVAL AND INSTALLATION........................................................................................................... 35 ENGINE OIL COOLER...................................................................................................................... 35 REMOVAL AND INSTALLATION........................................................................................................... 35 FUEL INJECTION PUMP.................................................................................................................... 37 REMOVAL AND INSTALLATION........................................................................................................... 37 AIR COMPRESSOR......................................................................................................................... 39 REMOVAL AND INSTALLATION........................................................................................................... 39 WATER PUMP............................................................................................................................. 39 REMOVAL AND INSTALLATION........................................................................................................... 39 NOZZLE HOLDER.......................................................................................................................... 41 REMOVAL AND INSTALLATION........................................................................................................... 41 TURBOCHARGER........................................................................................................................... 41 REMOVAL AND INSTALLATION........................................................................................................... 41 CYLINDER HEAD.......................................................................................................................... 43 REMOVAL............................................................................................................................ 43 INSTALLATION....................................................................................................................... 45 HYDRAULIC OIL COOLER................................................................................................................... 47 REMOVAL AND INSTALLATION........................................................................................................... 47 RADIATOR............................................................................................................................... 47 REMOVAL AND INSTALLATION........................................................................................................... 47 ENGINE,MAIN PUMP....................................................................................................................... 49 REMOVAL............................................................................................................................ 49 INSTALLATION....................................................................................................................... 51 DAMPER................................................................................................................................. 53 REMOVAL AND INSTALLATION........................................................................................................... 53 AUTO-DECELERATION CYLINDER............................................................................................................. 53 REMOVAL AND INSTALLATION........................................................................................................... 53 20 POWER TRAIN................................................................................................................................. 55 21 STRUCTURE AND FUNCTION.................................................................................................................. 55 POWER TRAIN............................................................................................................................ 56 TRAVEL AND SWING HYDRAULIC SYSTEM...................................................................................................... 58 TRAVEL AND SWING HYDRAULIC CIRCUIT DIAGRAM............................................................................................. 59 TRAVEL HYDRAULIC PIPING DIAGRAM........................................................................................................ 60 TRAVEL HYDRAULIC CIRCUIT DIAGRAM....................................................................................................... 61 CENTER SWIVEL JOINT(FOR HYDRAULIC AND PNEUMATIC)....................................................................................... 62 TRAVEL MOTOR........................................................................................................................... 63 TRAVEL SHUTTLE VALVE................................................................................................................... 70 TRANSMISSION........................................................................................................................... 71 FORWARD-REVERSE SELECTOR LEVER......................................................................................................... 74 SOLENOID VALVE(FOR FORWARD-REVERSE SELECTION).......................................................................................... 75 TRANSMISSION SELECTOR VALVE............................................................................................................ 76 TRAVEL PPC VALVE....................................................................................................................... 78 SWING HYDRAULIC PIPING DIAGRAM......................................................................................................... 79 SWING CONTROL CIRCUIT.................................................................................................................. 80 SWING PRIORITY VALVE................................................................................................................... 81 SWING MOTOR............................................................................................................................ 82 SWING MECHANICAL BRAKE................................................................................................................. 86 SWING MACHINERY........................................................................................................................ 90 SWING CIRCLE........................................................................................................................... 92 23 DISASSEMBLY AND ASSEMBLY................................................................................................................ 94 CENTER SWIVEL JOINT.................................................................................................................... 95 REMOVAL AND INSTALLATION........................................................................................................... 95 DISASSEMBLY AND ASSEMBLY........................................................................................................... 97 SWING CIRCLE........................................................................................................................... 99 REMOVAL AND INSTALLATION........................................................................................................... 99 SWING MACHINERY........................................................................................................................101 REMOVAL AND INSTALLATION...........................................................................................................101 DISASSEMBLY........................................................................................................................103 ASSEMBLY...........................................................................................................................107 TRANSMISSION...........................................................................................................................111 REMOVAL AND INSTALLATION...........................................................................................................111 DISASSEMBLY........................................................................................................................113 ASSEMBLY...........................................................................................................................119 SWING MOTOR............................................................................................................................123 REMOVAL AND INSTALLATION...........................................................................................................123 DISASSEMBLY........................................................................................................................125 ASSEMBLY...........................................................................................................................129 TRAVEL MOTOR...........................................................................................................................133 REMOVAL AND INSTALLATION...........................................................................................................133 TRAVEL BRAKE VALVE.....................................................................................................................133 REMOVAL AND INSTALLATION...........................................................................................................133 PISTON MOTOR...........................................................................................................................135 DISASSEMBLY........................................................................................................................135 ASSEMBLY...........................................................................................................................141 24 MAINTENANCE STANDARD....................................................................................................................149 TRAVEL MOTOR...........................................................................................................................150 TRAVEL BRAKE VALVE.....................................................................................................................151 TRAVEL SUCTION VALVE...................................................................................................................152 TRAVEL SHUTTLE VALVE...................................................................................................................153 TRANSMISSION...........................................................................................................................154 SWING MOTOR............................................................................................................................155 SWING MACHINERY........................................................................................................................156 SWING CIRCLE...........................................................................................................................157 40 STEERING SYSTEM.............................................................................................................................158 41 STRUCTURE AND FUNCTION..................................................................................................................158 STEERING SYSTEM........................................................................................................................159 STEERING HYDRAULIC SCHEMATICS..........................................................................................................160 STEERING HYDRAULIC CIRCUIT DIAGRAM.....................................................................................................160 STEERING PUMP..........................................................................................................................161 STEERING VALVE.........................................................................................................................162 STEERING CYLINDER......................................................................................................................167 AXLE...................................................................................................................................168 DRIVE SHAFT............................................................................................................................171 WHEEL..................................................................................................................................171 BRAKE SYSTEM...........................................................................................................................172 BRAKE AIR AND HYDRAULIC SYSTEM.........................................................................................................173 BRAKE AIR AND HYDRAULIC DIAGRAM........................................................................................................174 BRAKE VALVE............................................................................................................................175 BRAKE LOCK SELECTOR VALVE(2-WAY CONTROL VALVE).........................................................................................177 SHUTTLE VALVE(DOUBLE CHECK VALVE)......................................................................................................178 AIR MASTER.............................................................................................................................179 WHEEL BRAKE............................................................................................................................181 PARKING BRAKE SYSTEM...................................................................................................................182 SUSPENSION SYSTEM......................................................................................................................188 SUSPENSION AIR AND HYDRAULIC SYSTEM....................................................................................................189 SUSPENSION AIR AND HYDRAULIC CIRCUIT DIAGRAM...........................................................................................190 SUSPENSION LOCK VALVE..................................................................................................................191 SUSPENSION RELIEF VALVE................................................................................................................192 SUSPENSION LOCK CYLINDER...............................................................................................................195 SUSPENSION LOCK SELECTOR VALVE.........................................................................................................195 42 TESTING AND ADJUSTING...................................................................................................................196 TESTING AND ADJUSTING TOE-IN...........................................................................................................197 ADJUSTING MAXIMUM TURNING ANGLE OF FRONT WHEELS........................................................................................198 ADJUSTING PARKING BRAKE................................................................................................................199 BLEEDING AIR FROM BRAKE CIRCUIT........................................................................................................200 43 DISASSEMBLY AND ASSEMBLY................................................................................................................201 STEERING CYLINDER......................................................................................................................202 REMOVAL AND INSTALLATION...........................................................................................................202 STEERING PUMP..........................................................................................................................202 REMOVAL AND INSTALLATION...........................................................................................................202 FRONT AXLE.............................................................................................................................204 REMOVAL AND INSTALLATION...........................................................................................................204 REAR AXLE..............................................................................................................................206 REMOVAL AND INSTALLATION...........................................................................................................206 DIFFERENTIAL(FRONT)....................................................................................................................206 REMOVAL AND INSTALLATION...........................................................................................................206 DIFFERENTIAL(REAR).....................................................................................................................208 REMOVAL AND INSTALLATION...........................................................................................................208 DIFFERENTIAL...........................................................................................................................210 DISASSEMBLY........................................................................................................................210 ASSEMBLY...........................................................................................................................212 AIR MASTER.............................................................................................................................216 REMOVAL AND INSTALLATION...........................................................................................................216 FRONT CALIPER..........................................................................................................................218 REMOVAL AND INSTALLATION...........................................................................................................218 REAR CALIPER...........................................................................................................................218 REMOVAL AND INSTALLATION...........................................................................................................218 CALIPER................................................................................................................................220 DISASSEMBLY AND ASSEMBLY...........................................................................................................220 FRONT FINAL DRIVE......................................................................................................................222 REMOVAL AND INSTALLATION...........................................................................................................222 FINAL DRIVE............................................................................................................................226 DISASSEMBLY........................................................................................................................226 ASSEMBLY...........................................................................................................................228 PARKING BRAKE..........................................................................................................................232 REMOVAL AND INSTALLATION...........................................................................................................232 SUSPENSION LOCK CYLINDER...............................................................................................................232 REMOVAL AND INSTALLATION...........................................................................................................232 DISASSEMBLY AND ASSEMBLY...........................................................................................................234 44 MAINTENANCE STANDARD....................................................................................................................236 STEERING PUMP..........................................................................................................................237 STEERING CYLINDER......................................................................................................................238 FINAL DRIVE............................................................................................................................239 DIFFERENTIAL...........................................................................................................................239 KING PIN,KNUCKLE AND TIE-ROD...........................................................................................................241 WHEEL BRAKE............................................................................................................................242 PARKING BRAKE..........................................................................................................................243 SUSPENSION LOCK CYLINDER...............................................................................................................244 50 AIR SYSTEM..................................................................................................................................245 51 STRUCTURE AND FUNCTION..................................................................................................................245 AIR PIPING DIAGRAM.....................................................................................................................246 AIR SCHEMATICS.........................................................................................................................248 AIR CIRCUIT DIAGRAM....................................................................................................................249 AIR GOVERNOR...........................................................................................................................250 LOW PRESSURE INDICATOR SWITCH,PARKING CAUTION SWITCH AND SUSPENSION LOCK CAUTION SWITCH................................................251 STOP LAMP SWITCH AND BRAKE LOCK CAUTION SWITCH.........................................................................................252 60 HYDRAULIC SYSTEM............................................................................................................................253 61 STRUCTURE AND FUNCTION..................................................................................................................253 HYDRAULIC SYSTEM.......................................................................................................................254 HYDRAULIC CIRCUIT DIAGRAM..............................................................................................................256 WORK EQUIPMENT CONTROL.................................................................................................................257 ARM THROTTLE VALVE.....................................................................................................................261 PPC VALVE..............................................................................................................................262 PPC SHUTTLE VALVE......................................................................................................................265 HYDRAULIC TANK.........................................................................................................................267 HYDRAULIC PUMP.........................................................................................................................268 CONTROL VALVE(4-SPOOL VALVE AND 5-SPOOL VALVE).........................................................................................285 2-STAGE AND 3-STAGE MODE SELECTOR OLSS(OPEN CENTER LOAD SENSING SYSTEM)................................................................290 ACCUMULATOR............................................................................................................................307 HYDRAULIC CYLINDER.....................................................................................................................308 WORK EQUIPMENT.........................................................................................................................311 OUTRIGGER..............................................................................................................................311 DOUBLE CHECK VALVE.....................................................................................................................312 62 TESTING AND ADJUSTING...................................................................................................................313 TABLE OF JUDGEMENT STANDARD VALUE......................................................................................................314 TABLE OF ELECTRICAL JUDGEMENT STANDARD VALUE...........................................................................................324 TESTING AND ADJUSTING TOOL LIST........................................................................................................328 TESTING AND ADJUSTING MAIN RELIEF VALVE................................................................................................329 TESTING PRESSURE OF CONTROL CIRCUIT....................................................................................................331 MEASURING DELIVERY OF MAIN PUMP........................................................................................................333 MEASURING OIL LEAKAGE OF SWING,TRAVEL MOTOR............................................................................................334 AIR BLEEDING...........................................................................................................................335 ADJUSTING OUTRIGGER CONTROL LEVER......................................................................................................336 TROUBLESHOOTING........................................................................................................................337 CIRCUIT DIAGRAM....................................................................................................................338 CONNECTOR POSITION FOR TROUBLESHOOTING.............................................................................................340 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS.........................................................................................350 TROUBLESHOOTING PROCEDURE..........................................................................................................353 CHECKS BEFORE TROUBLESHOOTING......................................................................................................354 ABNORMALITY DISPLAYS BY SELF CHECKER...............................................................................................355 TROUBLESHOOTING(EXCEPT TROUBLESHOOTING FOR MACHINE MONITOR)........................................................................356 TROUBLESHOOTING FOR ELECTRIC SYSTEM(E1-E6).........................................................................................362 TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEM(H1-H16)........................................................................381 63 DISASSEMBLY AND ASSEMBLY................................................................................................................399 CHARGING PUMP..........................................................................................................................400 REMOVAL AND INSTALLATION...........................................................................................................400 MAIN PUMP..............................................................................................................................402 REMOVAL............................................................................................................................402 INSTALLATION.......................................................................................................................404 MAIN PUMP INPUT SHAFT OIL SEAL.........................................................................................................406 REMOVAL AND INSTALLATION...........................................................................................................406 TVC VALVE..............................................................................................................................408 REMOVAL AND INSTALLATION...........................................................................................................408 CO・NC VALVE............................................................................................................................408 REMOVAL AND INSTALLATION...........................................................................................................408 SERVO VALVE............................................................................................................................410 REMOVAL AND INSTALLATION...........................................................................................................410 MAIN PUMP..............................................................................................................................412 DISASSEMBLY........................................................................................................................412 ASSEMBLY...........................................................................................................................416 CONTROL VALVE..........................................................................................................................426 REMOVAL............................................................................................................................426 INSTALLATION.......................................................................................................................428 DISASSEMBLY AND ASSEMBLY...........................................................................................................430 JET SENSOR RELIEF VALVE................................................................................................................434 REMOVAL AND INSTALLATION...........................................................................................................434 RELIEF VALVE...........................................................................................................................434 REMOVAL AND INSTALLATION...........................................................................................................434 MAIN RELIEF VALVE......................................................................................................................436 REMOVAL AND INSTALLATION...........................................................................................................436 BOOM CYLINDER..........................................................................................................................438 REMOVAL AND INSTALLATION...........................................................................................................438 ARM CYLINDER...........................................................................................................................438 REMOVAL AND INSTALLATION...........................................................................................................438 BUCKET CYLINDER........................................................................................................................440 REMOVAL AND INSTALLATION...........................................................................................................440 OUTRIGGER CYLINDER.....................................................................................................................440 REMOVAL AND INSTALLATION...........................................................................................................440 HYDRAULIC CYLINDER.....................................................................................................................442 DISASSEMBLY........................................................................................................................442 ASSEMBLY...........................................................................................................................446 WORK EQUIPMENT.........................................................................................................................450 REMOVAL AND INSTALLATION...........................................................................................................450 BUCKET.................................................................................................................................452 REMOVAL AND INSTALLATION...........................................................................................................452 ARM....................................................................................................................................452 REMOVAL AND INSTALLATION...........................................................................................................452 BOOM...................................................................................................................................454 REMOVAL AND INSTALLATION...........................................................................................................454 ARM AND BUCKET.........................................................................................................................454 REMOVAL AND INSTALLATION...........................................................................................................454 64 MAINTENANCE STANDARD....................................................................................................................456 CHARGING PUMP..........................................................................................................................457 CONTROL VALVE..........................................................................................................................458 PPC SHUTTLE VALVE......................................................................................................................463 PPC VALVE..............................................................................................................................464 WORK EQUIPMENT.........................................................................................................................465 HYDRAULIC CYLINDER.....................................................................................................................467 80 ELECTRIC AND ELECTRONIC SYSTEM..............................................................................................................468 81 STRUCTURE AND FUNCTION..................................................................................................................468 ELECTRICAL CIRCUIT DIAGRAM.............................................................................................................469 82 TESTING AND ADJUSTING...................................................................................................................470 CIRCUIT DIAGRAM........................................................................................................................471 TROUBLESHOOTING FOR MACHINE MONITOR....................................................................................................472 M-1 CAUTION LAMPS DO NOT LIGHT UP WHEN STARTING SWITCH IS TURNED TO ON POSITION WITH ENGINE STOPPED(AIR PRESSURE:MAX.4.5kg/cm2)....472 A) ENGINE OIL PRESSURE LAMP DOES NOT LIGHT UP..................................................................................472 B) CHARGING LAMP DOES NOT LIGHT UP.............................................................................................472 C) PARKING BRAKE LAMP DOES NOT LIGHT UP........................................................................................473 D) SUSPENSION LOCK LAMP DOES NOT LIGHT UP......................................................................................473 M-2 BUZZER DOES NOT SOUND WHEN STARTING SWITCH IS TURNED TO ON POSITION WITH ENGINE STOPPED(AIR PRESSURE:MAX.4.5kg/cm2)............474 M-3 CAUTION LAMPS DO NOT LIGHT UP WHEN STARTING SWITCH IS TURNED TO ON POSITION WITH ENGINE STARTED(AIR PRESSURE:MAX.5.5kg/cm2)....475 M-4 BUZZER DOES NOT STOP WHEN STARTING SWITCH IS TURNED TO ON POSITION WITH ENGINE STARTED(AIR PRESSURE:MAX.5.5kg/cm2).............476 M-5 ENGINE WATER TEMPERATURE GAUGE DOES NOT WORK...................................................................................476 M-6 FUEL GAUGE DOES NOT DISPLAY....................................................................................................477
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