Komatsu PW200-7E0 and PW220-7E0 service and repair manual

Shop Manual MACHINE MODEL SERIAL NUMBER PW200-7E0 H55051 AND UP PW220-7E0 H65051 AND UP VEBM949100 PW200-7E0 PW220-7E0 • This shop manual may contain attachments and optional equipment that are not available in your area. Please consult your local Komatsu distributor for those items you may require. • Materials and specifications are subject to change without notice. • PW200/PW220-7E0 mount the SAA6D107E-1 engine. • For details of the engine, see the 107 Series Engine Shop Manual. © 2008 All Rights Reserved Printed in Europe 2008-07

PW200/PW220-7E0 VEBM949100 TOC-1 CONTENTS 00 FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-1 01 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1 10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 20 TESTING AND ADJUSTING. . . . . . . . . . . . . . . . . . . . . . . . 20-1 20 TESTING AND ADJUSTING. . . . . . . . . . . . . . . . . . . . . . 20-101 20 TESTING AND ADJUSTING Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-301 20 TESTING AND ADJUSTING Troubleshooting when service code "Electrical system" and failure code "Mechanical system"are indicated . . . . . . . . . . . . . . . 20-401 20 TESTING AND ADJUSTING Troubleshooting of electrical system (E-Mode) . . . . . 20-701 20 TESTING AND ADJUSTING Troubleshooting of electrical system (Error checking of items without monitor codes) . . . . 20-801 20 TESTING AND ADJUSTING Troubleshooting of hydraulic and mechanical system (H-Mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-901 30 DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . 30-1 90 OTHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1 No. of page

TOC-2 PW200/PW220-7E0 VEBM949100 Blank for technical reason

PW200/PW220-7E0 VEBM949100 FOREWORD Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-3 Safety notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-3 General precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-3 Preparations for work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-4 Precautions during work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-4 List of revised pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-7 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-13 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-13 Structure and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-13 Testing, adjusting and troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-13 Disassembly and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-13 Maintenance standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-13 How to read the shop manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-14 Volumes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-14 Distribution and updating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-14 Filing method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-14 Revised edition mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-14 Revisions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-15 Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-15 Hoisting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-16 Hoisting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-16 Coating materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-18 Standard tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-20 Standard tightening torque of bolts and nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-20 Tightening torque of hose nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-21 Tightening torque of split flange bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-21 Tightening torques for hoses (taper seal type and face seal type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-22 Tightening torque for 107 engine series (bolts and nuts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-22 Tightening torque for 107 engine series (eye joints) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-23 Tightening torque for 107 engine series (tapered screws) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-23 Electric wire code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-24 Classification by thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-24 Classification by color and code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-24 Conversion tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-25 Method of using the conversion table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-25 Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-30 Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-31 00 00-1

FOREWORD PW200/PW220-7E0 VEBM949100 Blank for technical reason 00-2

FOREWORD Safety PW200/PW220-7E0 VEBM949100 Safety Safety notice IMPORTANT SAFETY NOTICE Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques recommended and described in this manual are both effective and safe methods of operation. Some of these operations require the use of tools specially designed for the purpose. To prevent injury to workers, the symbol is used to mark safety precautions in this manual. The cautions accompa- nying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation. General precautions Mistakes in operation are extremely dangerous. Read the OP- ERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine. 1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine. 2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. • Always wear safety glasses when hitting parts with a hammer. • Always wear safety glasses when grinding parts with a grinder, etc. 3. If welding repairs are needed, always have a trained, experi- enced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work. 4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Al- ways inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment. 5. Keep all tools in good condition and learn the correct way to use them. 00-3

Safety FOREWORD PW200/PW220-7E0 VEBM949100 6. Decide a place in the repair workshop to keep tools and re- moved parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the are- as provided for smoking. Never smoke while working. Preparations for work 1. Before adding oil or making repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving. 2. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. 3. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work. 4. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe foot- ing. Precautions during work 1. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit. 2. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out any work on the oil or water circuits. 3. Before starting work, remove the leads from the battery. AL- WAYS remove the lead from the negative (-) terminal first. 4. When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample ca- pacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the compo- nent from hitting any other part. Do not work with any part still raised by the hoist or crane. 5. When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in posi- tion on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove. 00-4

FOREWORD Safety PW200/PW220-7E0 VEBM949100 6. When removing components, be careful not to break or damage the wiring, Damaged wiring may cause electrical fires. 7. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires. 8. As a general rule, do not use gasoline to wash parts. In par- ticular, use only the minimum of gasoline when washing electrical parts. 9. Be sure to assemble all parts again in their original places. Replace any damaged part with new parts. • When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being operated. 10. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. Also check that connecting parts are correctly installed. 11. When assembling or installing parts, always use the speci- fied tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. 12. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 13. When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measure- ments. 14. Take care when removing or installing the tracks of track- type machines. When removing the track, the track sepa- rates suddenly, so never let anyone stand at either end of the track. 00-5

Safety FOREWORD PW200/PW220-7E0 VEBM949100 Blank for technical reason 00-6

Komatsu PW200-7E0 and PW220-7E0 service and repair manual

You're Reading a Preview

Recently Viewed