Komatsu Wheeled Excavator PW210-1 Shop Manual SEBM020K0102 PDF
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Komatsu Wheeled Excavator PW210-1 Shop Manual SEBM020K0102 – PDF DOWNLOAD
MACHINE MODEL SERIAL No.
PW210-1 10001 and up
Description
Komatsu Wheeled Excavator PW210-1 Shop Manual SEBM020K0102 – PDF DOWNLOAD
FILE DETAILS:
Komatsu Wheeled Excavator PW210-1 Shop Manual SEBM020K0102 – PDF DOWNLOAD
Language : English
Pages :477
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Komatsu Wheeled Excavator PW210-1 Shop Manual SEBM020K0102 – PDF DOWNLOAD
MACHINE MODEL SERIAL No.
PW210-1 10001 and up
FOREWORD
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into chapters for each main group of components; these chapters are further divided into the following sections.
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.
This section explains checks to be made before and after performing repairs, as well
as adjustments to be made at completion of the checks and repairs.
Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.
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.
This section gives the judgement standards when inspecting disassembled parts.
TABLE OF CONTENTS:
Komatsu Wheeled Excavator PW210-1 Shop Manual SEBM020K0102 – PDF DOWNLOAD
MACHINE MODEL SERIAL No.
PW210-1 10001 and up
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 MACHINERY101
REMOVAL AND INSTALLATION101
DISASSEMBLY103
ASSEMBLY107
TRANSMISSION111
REMOVAL AND INSTALLATION111
DISASSEMBLY113
ASSEMBLY119
SWING MOTOR123
REMOVAL AND INSTALLATION123
DISASSEMBLY125
ASSEMBLY129
TRAVEL MOTOR133
REMOVAL AND INSTALLATION133
TRAVEL BRAKE VALVE133
REMOVAL AND INSTALLATION133
PISTON MOTOR135
DISASSEMBLY135
ASSEMBLY141
24 MAINTENANCE STANDARD149
TRAVEL MOTOR150
TRAVEL BRAKE VALVE151
TRAVEL SUCTION VALVE152
TRAVEL SHUTTLE VALVE153
TRANSMISSION154
SWING MOTOR155
SWING MACHINERY156
SWING CIRCLE157
40 STEERING SYSTEM158
41 STRUCTURE AND FUNCTION158
STEERING SYSTEM159
STEERING HYDRAULIC SCHEMATICS160
STEERING HYDRAULIC CIRCUIT DIAGRAM160
STEERING PUMP161
STEERING VALVE162
STEERING CYLINDER167
AXLE168
DRIVE SHAFT171
WHEEL171
BRAKE SYSTEM172
BRAKE AIR AND HYDRAULIC SYSTEM173
BRAKE AIR AND HYDRAULIC DIAGRAM174
BRAKE VALVE175
BRAKE LOCK SELECTOR VALVE(2-WAY CONTROL VALVE)177
SHUTTLE VALVE(DOUBLE CHECK VALVE)178
AIR MASTER179
WHEEL BRAKE181
PARKING BRAKE SYSTEM182
SUSPENSION SYSTEM188
SUSPENSION AIR AND HYDRAULIC SYSTEM189
SUSPENSION AIR AND HYDRAULIC CIRCUIT DIAGRAM190
SUSPENSION LOCK VALVE191
SUSPENSION RELIEF VALVE192
SUSPENSION LOCK CYLINDER195
SUSPENSION LOCK SELECTOR VALVE195
42 TESTING AND ADJUSTING196
TESTING AND ADJUSTING TOE-IN197
ADJUSTING MAXIMUM TURNING ANGLE OF FRONT WHEELS198
ADJUSTING PARKING BRAKE199
BLEEDING AIR FROM BRAKE CIRCUIT200
43 DISASSEMBLY AND ASSEMBLY201
STEERING CYLINDER202
REMOVAL AND INSTALLATION202
STEERING PUMP202
REMOVAL AND INSTALLATION202
FRONT AXLE204
REMOVAL AND INSTALLATION204
REAR AXLE206
REMOVAL AND INSTALLATION206
DIFFERENTIAL(FRONT)206
REMOVAL AND INSTALLATION206
DIFFERENTIAL(REAR)208
REMOVAL AND INSTALLATION208
DIFFERENTIAL210
DISASSEMBLY210
ASSEMBLY212
AIR MASTER216
REMOVAL AND INSTALLATION216
FRONT CALIPER218
REMOVAL AND INSTALLATION218
REAR CALIPER218
REMOVAL AND INSTALLATION218
CALIPER220
DISASSEMBLY AND ASSEMBLY220
FRONT FINAL DRIVE222
REMOVAL AND INSTALLATION222
FINAL DRIVE226
DISASSEMBLY226
ASSEMBLY228
PARKING BRAKE232
REMOVAL AND INSTALLATION232
SUSPENSION LOCK CYLINDER232
REMOVAL AND INSTALLATION232
DISASSEMBLY AND ASSEMBLY234
44 MAINTENANCE STANDARD236
STEERING PUMP237
STEERING CYLINDER238
FINAL DRIVE239
DIFFERENTIAL239
KING PIN,KNUCKLE AND TIE-ROD241
WHEEL BRAKE242
PARKING BRAKE243
SUSPENSION LOCK CYLINDER244
50 AIR SYSTEM245
51 STRUCTURE AND FUNCTION245
AIR PIPING DIAGRAM246
AIR SCHEMATICS248
AIR CIRCUIT DIAGRAM249
AIR GOVERNOR250
LOW PRESSURE INDICATOR SWITCH,PARKING CAUTION SWITCH AND SUSPENSION LOCK CAUTION SWITCH251
STOP LAMP SWITCH AND BRAKE LOCK CAUTION SWITCH252
60 HYDRAULIC SYSTEM253
61 STRUCTURE AND FUNCTION253
HYDRAULIC SYSTEM254
HYDRAULIC CIRCUIT DIAGRAM256
WORK EQUIPMENT CONTROL257
ARM THROTTLE VALVE261
PPC VALVE262
PPC SHUTTLE VALVE265
HYDRAULIC TANK267
HYDRAULIC PUMP268
CONTROL VALVE(4-SPOOL VALVE AND 5-SPOOL VALVE)285
2-STAGE AND 3-STAGE MODE SELECTOR OLSS(OPEN CENTER LOAD SENSING SYSTEM)290
ACCUMULATOR307
HYDRAULIC CYLINDER308
WORK EQUIPMENT311
OUTRIGGER311
DOUBLE CHECK VALVE312
62 TESTING AND ADJUSTING313
TABLE OF JUDGEMENT STANDARD VALUE314
TABLE OF ELECTRICAL JUDGEMENT STANDARD VALUE324
TESTING AND ADJUSTING TOOL LIST328
TESTING AND ADJUSTING MAIN RELIEF VALVE329
TESTING PRESSURE OF CONTROL CIRCUIT331
MEASURING DELIVERY OF MAIN PUMP333
MEASURING OIL LEAKAGE OF SWING,TRAVEL MOTOR334
AIR BLEEDING335
ADJUSTING OUTRIGGER CONTROL LEVER336
TROUBLESHOOTING337
CIRCUIT DIAGRAM338
CONNECTOR POSITION FOR TROUBLESHOOTING340
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS350
TROUBLESHOOTING PROCEDURE353
CHECKS BEFORE TROUBLESHOOTING354
ABNORMALITY DISPLAYS BY SELF CHECKER355
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 ASSEMBLY399
CHARGING PUMP400
REMOVAL AND INSTALLATION400
MAIN PUMP402
REMOVAL402
INSTALLATION404
MAIN PUMP INPUT SHAFT OIL SEAL406
REMOVAL AND INSTALLATION406
TVC VALVE408
REMOVAL AND INSTALLATION408
CO・NC VALVE408
REMOVAL AND INSTALLATION408
SERVO VALVE410
REMOVAL AND INSTALLATION410
MAIN PUMP412
DISASSEMBLY412
ASSEMBLY416
CONTROL VALVE426
REMOVAL426
INSTALLATION428
DISASSEMBLY AND ASSEMBLY430
JET SENSOR RELIEF VALVE434
REMOVAL AND INSTALLATION434
RELIEF VALVE434
REMOVAL AND INSTALLATION434
MAIN RELIEF VALVE436
REMOVAL AND INSTALLATION436
BOOM CYLINDER438
REMOVAL AND INSTALLATION438
ARM CYLINDER438
REMOVAL AND INSTALLATION438
BUCKET CYLINDER440
REMOVAL AND INSTALLATION440
OUTRIGGER CYLINDER440
REMOVAL AND INSTALLATION440
HYDRAULIC CYLINDER442
DISASSEMBLY442
ASSEMBLY446
WORK EQUIPMENT450
REMOVAL AND INSTALLATION450
BUCKET452
REMOVAL AND INSTALLATION452
ARM452
REMOVAL AND INSTALLATION452
BOOM454
REMOVAL AND INSTALLATION454
ARM AND BUCKET454
REMOVAL AND INSTALLATION454
64 MAINTENANCE STANDARD456
CHARGING PUMP457
CONTROL VALVE458
PPC SHUTTLE VALVE463
PPC VALVE464
WORK EQUIPMENT465
HYDRAULIC CYLINDER467
80 ELECTRIC AND ELECTRONIC SYSTEM468
81 STRUCTURE AND FUNCTION468
ELECTRICAL CIRCUIT DIAGRAM469
82 TESTING AND ADJUSTING470
CIRCUIT DIAGRAM471
TROUBLESHOOTING FOR MACHINE MONITOR472
M-1 CAUTION LAMPS DO NOT LIGHT UP WHEN STARTING SWITCH IS TURNED TO ON POSITION WITH ENGINE STOPPED(AIR PRESSURE:MAX45kg/cm2)472
A) ENGINE OIL PRESSURE LAMP DOES NOT LIGHT UP472
B) CHARGING LAMP DOES NOT LIGHT UP472
C) PARKING BRAKE LAMP DOES NOT LIGHT UP473
D) SUSPENSION LOCK LAMP DOES NOT LIGHT UP473
M-2 BUZZER DOES NOT SOUND WHEN STARTING SWITCH IS TURNED TO ON POSITION WITH ENGINE STOPPED(AIR PRESSURE:MAX45kg/cm2)474
M-3 CAUTION LAMPS DO NOT LIGHT UP WHEN STARTING SWITCH IS TURNED TO ON POSITION WITH ENGINE STARTED(AIR PRESSURE:MAX55kg/cm2)475
M-4 BUZZER DOES NOT STOP WHEN STARTING SWITCH IS TURNED TO ON POSITION WITH ENGINE STARTED(AIR PRESSURE:MAX55kg/cm2)476
M-5 ENGINE WATER TEMPERATURE GAUGE DOES NOT WORK476
M-6 FUEL GAUGE DOES NOT DISPLAY477
IMAGES PREVIEW OF THE MANUAL:
S.M 25/12/24
