KOMATSU-VEBM949100 Komatsu PW200-7E0, PW220-7E0 wheeled excavator pdf shop manual
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Komatsu PW200-7E0, PW220-7E0 wheeled excavator pdf shop manual

KOMATSU-VEBM949100
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Format: PDF

Pages: 1242

File size: 33.05 MB

Language: English

Models: PW200-7E0 SN H55051 and up, PW220-7E0 SN H65051 and up

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Table of Contents for KOMATSU-VEBM949100 manual

  • PW200/220-7E0 VEBM949100
  • CONTENTS
  • FOREWORD
    • Safety
    • List of revised pages
    • General
    • How to read the shop manual
    • Hoisting instructions
    • Coating materials
    • Standard tightening torque
    • Electric wire code
    • Conversion tables
    • Units
  • GENERAL
    • Specification dimension drawings
    • Working ranges
    • Specifications
    • Weight table
  • STRUCTURE AND FUNCTION, MAINTENANCE STANDARD
    • Engine related parts
    • Radiator - Oil cooler - Charge air cooler
    • Power train
    • Swing circle
    • Swing machinery and motor
    • Swing motor
    • Undercarriage
    • Transmission
    • Travel motor
    • Clutch control circuit
    • Axle
    • Suspension lock cylinder
    • Braking system
    • Brake/steer pump
    • Priority valve
    • Power brake valve
    • Accumulator for brake system
    • Steering system
    • Steering column
    • Orbitrol valve
    • Hydraulic equipment layout drawings
    • Hydraulic circuit diagram
    • Hydraulic tank
    • Hydraulic pump
    • Pilot pressure control (PPC) system
    • Control valve
    • CLSS
    • Centre swivel joint
    • Travel PPC pedal
    • Work equipment - Swing PPC valve
    • Solenoid valves
    • Boom Safety valve
    • Hydraulic cylinder
    • Outrigger cylinder
    • Dozer cylinder
    • Work equipment
    • Air conditioner
    • Electrical wiring diagram
    • Electrical system
    • Engine control system
    • Machine monitor system
    • Overload warning device
    • Sensor
    • 1st attachment circuit hydraulic performance (main valve bypassed)
    • Travel circuit
    • Steering system
    • Service brake and suspension system
    • Quick coupler control valve
    • ATT EPC valve assembly
    • KOMTRAX terminal system
    • Standard value table for engine related parts
    • Standard value table for chassis related parts
    • Flow control characteristic of PC valve (STD)
  • TESTING AND ADJUSTING
    • Preparations for troubleshooting of electrical system
  • TESTING AND ADJUSTING
    • Measuring engine speed
    • Measuring intake air pressure (boost pressure)
    • Measurement of exhaust gas color
    • Adjusting valve clearance
    • Measuring compression pressure
    • Measurement of blow-by pressure
    • Measure engine oil pressure
    • Handling fuel system parts
    • Releasing residual pressure from fuel system
    • Measuring fuel pressure
    • Measuring fuel return rate and leakage
    • Bleeding air from fuel circuit
    • Checking fuel circuit for leakage
    • Checking and adjusting air conditioner compressor belt tension
    • Replacing the fan belt
    • Measurement of clearance in swing circle bearings
    • Inspection and adjustment of hydraulic oil pressure in hydraulic circuit for work equipment, swing and travel
    • Inspection and adjustment of control circuit oil pressure
    • Inspection and adjustment of pump pc (valve inlet) control oil pressure
    • Inspection and adjustment of pump ls valve control oil pressure
    • Measurement of solenoid valve output pressure
    • Measurement of PPC valve output pressure
    • Adjustment of work equipment and swing PPC valve
    • Measuring and adjusting quick coupler control valve output pressure
    • Testing travel motor relief pressure
    • Adjusting travel motor relief pressure
    • Testing propshaft speed
    • Testing transmission clutch control circuit
    • Inspection of locations of hydraulic drift of work equipment
    • Release of remaining pressure in hydraulic circuit
    • Measurement of oil leakage amount
    • Air bleeding of various parts
    • Inspection procedures for diode
    • Special function of monitor panel
    • Procedure for turning on KOMTRAX terminal
  • TESTING AND ADJUSTING
    • Troubleshooting
    • Points to remember when troubleshooting
    • Sequence of events in troubleshooting
    • Points to remember when carrying out maintenance
    • Checks before troubleshooting
    • Classification and steps for troubleshooting
    • Connector location chart and electrical circuit diagram by system
    • Connection table for connector pin numbers
    • Information contained in troubleshooting table
    • Failure code [6B2JMA] - Abnormality in travel PPC switch hydraulics
    • Failure code [989L00] - Engine controller lock caution 1
    • Failure code [989M00] - Engine controller lock caution 2
    • Failure code [989N00] - Engine controller lock caution 3
    • Failure code [AA10NX] - Air cleaner clogging
    • Failure code [AB00KE] - Charging voltage abnormally low
    • Failure code [B@BAZG] - Abnormally lowered engine oil pressure
    • Failure code [B@BAZK] - Abnormally lowered engine oil level
    • Failure code [B@BCNS] - Engine cooling water overheating
    • Failure code [B@BCZK] - Abnormally low radiator water level
    • Failure code [B@HANS] - Hydraulic oil overheating
    • Failure code [CA111] - EMC critical internal failure
    • Failure code [CA115] - Engine neutral and backup speed sensor error
    • Failure code [CA122] - Chg air press sensor high error
    • Failure code [CA123] - Chg air press sensor low error
    • Failure code [CA131] - Throttle sensor high error
    • Failure code [CA132] - Throttle sensor low error
    • Failure code [CA144] - Coolant temp sens high error
    • Failure code [CA145] - Coolant temp sens low error
    • Failure code [CA153] - Chg air temp sensor high error
    • Failure code [CA154] - Chg air temp sensor low error
    • Failure code [CA155] - Chg air temp high speed derate
    • Failure code [CA187] - Sens supply 2 volt low error
    • Failure code [CA221] - Ambient press sens high error
    • Failure code [CA222] - Ambient press sens low error
    • Failure code [CA227] - Sens supply 2 volt high error
    • Failure code [CA234] - Eng overspeed
    • Failure code [CA238] - Ne speed sens supply volt error
    • Failure code [CA271] - IMV/PCV1 short error
    • Failure code [CA272] - IMV/PCV1 open error
    • Failure code [CA322] - Inj #1 (L#1) open/short error
    • Failure code [CA323] - Inj #5 (L#5) open/short error
    • Failure code [CA324] - Inj #3 (L#3) open/short error
    • Failure code [CA325] - Inj #6 (L#6) open/short error
    • Failure code [CA331] - Inj #2 (L#2) open/short error
    • Failure code [CA332] - Inj #4 (L#4) open/short error
    • Failure code [CA342] - Calibration code incompatibility
    • Failure code [CA351] - Injectors drive circuit error
    • Failure code [CA352] - Sens supply 1 volt low error
    • Failure code [CA386] - Sens supply 1 volt high error
    • Failure code [CA428] - Water in fuel sensor high error
    • Failure code [CA429] - Water in fuel sensor low error
    • Failure code [CA435] - Eng oil press sw error
    • Failure code [CA441] - Battery voltage low error
    • Failure code [CA442] - Battery voltage high error
    • Failure code [CA449] - Rail press very high error
    • Failure code [CA451] - Rail press sensor high error
    • Failure code [CA452] - Rail press sensor low error
    • Failure code [CA488] - Chg air temp high torque derate
    • Failure code [CA553] - Rail press high error
    • Failure code [CA559] - Rail press low error
    • Failure code [CA689] - Eng ne speed sensor error
    • Failure code [CA731] - Eng bkup speed sens phase error
    • Failure code [CA757] - All continuous data lost error
    • Failure code [CA778] - Eng G speed sensor error
    • Failure code [CA1633] - KOMNET datalink timeout error
    • Failure code [CA2185] - Throttle sensor supply voltage high error
    • Failure code [CA2186] - Throttle sensor supply voltage low error
    • Failure code [CA2249] - Rail press very low error
    • Failure code [CA2311] - IMV solenoid error
    • Failure code [CA2555] - Grid htr relay volt high error
    • Failure code [CA2556] - Grid heater relay volt low error
    • Failure code [D110KB] - Short-circuiting in battery relay
    • Failure code [D19JKZ] - Personal code relay abnormality
    • Failure code [D862KA] - GPS antenna discon
    • Failure code [DA25KP] - Press. sensor power abnormality
    • Failure code [DA2RMC] - Pump comm. abnormality
    • Failure code [DA2SKA] - Disconnection of S-NET signal
    • Failure code [DA2SKQ] - Abnormality in inputting model code
    • Failure code [DA2SKQ] - Abnormality in inputting model code
    • Failure code [DAF0KT] - Abnormal data in error history
    • Failure code [DAFRMC] - Monitor comm. abnormality
    • Failure code [DDC3KZ] - Outrigger switch select abnormality
    • Failure code [DDHPAKP] - Abnormality in pump pressure sensor
    • Failure code [DDP4KX] - Abnormality in travel PPC pressure switch
    • Failure code [DDWCKZ] - Abnormality in travel direction control switch
    • Failure code [DFB1KZ] - Service lever potentio 1 abnormality
    • Failure code [DFB2KZ] - Service lever potentio 2 abnormality
    • Failure code [DFB3L8] - Service lever 1 potentio error
    • Failure code [DFB4L8] - Service lever 2 potentio error
    • Failure code [DGH2KB] - Hydr oil sensor short
    • Failure code [DH10KS] - Abnormality in pressure sensor power source
    • Failure code [DHPAKP] - Abnormality in F pump pressure sensor
    • Failure code [DHPAMA] - Abnormality in F pump pressure sensor
    • Failure code [DHPBMA] - Abnormality in R pump pressure sensor
    • Failure code [DHS5KX] - Abnormality in travel PPC sensor
    • Failure code [DHX1MA] - Abnormality in overload caution sensor
    • Failure code [DLE2MA] - Abnormality in engine rotation sensor in governor (pump controller system)
    • Failure code [DLT4KA] - Disconnection in transmission speed sensor in governor (pump controller syste)m)
    • Failure code [DW27KA] - Disconnection in transmission clutch solenoid
    • Failure code [DW27KB] - Short-circuiting in transmission clutch solenoid
    • Failure code [DW4CKA] - Disconnection in PPC lock solenoid
    • Failure code [DW4CKB] - PPC lock sol. S/C
    • Failure code [DW44KA] - Disconnection of travel F/R solenoid
    • Failure code [DW44KB] - Short-circuiting of travel F/R solenoid
    • Failure code [DW45KA] - Disconnection in swing parking brake solenoid
    • Failure code [DW4MKA] - Disconnection in creep solenoid
    • Failure code [DW4MKB] - Short-circuiting in creep solenoid
    • Failure code [DW91KA] - Disconnection in travel neutral solenoid
    • Failure code [DW91KB] - Short-circuiting in travel neutral solenoid
    • Failure code [DWK0KA] - Disconnection in 2-stage relief solenoid
    • Failure code [DWK0KB] - Short-circuiting in 2-stage relief solenoid
    • Failure code [DWK2KA] - Disconnection in 2-stage back pressure solenoid
    • Failure code [DWK2KB] - Short circuiting in 2-stage back pressure solenoid
    • Failure code [DXA0KA] - Disconnection in PC-EPC solenoid system
    • Failure code [DXE0KA] - Disconnection in LS-EPC solenoid system
    • Failure code [DXE0KB] - Short-circuiting in LS-EPC solenoid
    • Failure code [DXE4KA] - Service current EPC1 discon
    • Failure code [DXE4KB] - Service current EPC1 short
    • Failure code [DXE7KA] - Service current EPC2 disco
    • Failure code [DXE7KB] - Service current EPC2 short
    • Failure code [DXE8KA] - Service current EPC3 discon
    • Failure code [DXE8KB] - Service current EPC3 short
    • Failure code [DXE9KA] - Service current EPC4 discon
    • Failure code [DXE9KB] - Service current EPC4 short
    • Failure code [DY20KA] - Wiper working abnormality
    • Failure code [DY20MA] - Wiper parking abnormality
    • Failure code [DY2CKB] - Washer drive S/C
    • Failure code [DY2DKB] - Wiper drive (for) S/C
    • Failure code [DY2EKB] - Wiper drive (rev) S/C
  • TESTING AND ADJUSTING
    • Troubleshooting when service code "Electrical system" and failure code "Mechanical system" are indicated
    • Information contained in troubleshooting table
    • E-1 - Engine does not start (engine does not rotate)
    • E-5 - Auto-decelerator does not work
    • E-6 - Auto engine warm-up device does not work
    • E-7 - Preheater does not operate
    • E-8 - All work equipment, swing and travel do not move
    • E-9 - One-touch power max switch does not work
    • E-10 - No display in monitor panel at all
    • E-11 - Part of display on monitor panel is missing
    • E-12 - Monitor panel displays contents irrelevant to the model
    • E-13 - Fuel level monitor red lamp lights up while engine is running
    • E-14 - Engine coolant temperature gauge does not indicate normally
    • E-15 - Hydraulic oil temperature gauge does not display correctly
    • E-16 - Fuel gauge does not display correctly
    • E-17 - Swing lock monitor does not display correctly
    • E-18 - When the monitor switch is operated, no display appears
    • E-19 - Windshield wiper and window washer do not operate
    • E-20 - Alarm buzzer cannot be stopped
    • E-21 - "Boom/stabiliser RAISE" is not correctly displayed in monitor function
    • E-22 - "Boom/stabiliser LOWER" is not correctly displayed in monitor function
    • E-23 - "Arm DIGGING" is not correctly displayed in monitor function
    • E-24 - "Arm DUMPING" is not correctly displayed in monitor function
    • E-25 - "Bucket DIGGING" is not correctly displayed in monitor function
    • E-26 - "Bucket DUMPING" is not correctly displayed in monitor function
    • E-27 - "SWING" is not correctly displayed in monitor function
    • E-28 - "TRAVEL" is not correctly displayed in monitor function
    • E-29 - "2 piece boom" is not correctly displayed in monitor function
    • E-30 - Air conditioner does not work
    • E-31 - Travel reverse alarm does not sound
    • E-32 - KOMTRAX system does not operate normally
  • TESTING AND ADJUSTING
    • Troubleshooting of electrical system (E-Mode)
    • Information contained in troubleshooting table
    • Radio cassette and telephone socket
    • PPC lock circuit
    • Brake light circuit
    • Undercarriage attachments - Mode selection
    • Undercarriage attachments - Front left outrigger
    • Undercarriage attachments - Front right outrigger
    • Undercarriage attachments - Rear left outrigger
    • Undercarriage attachments - Rear right outrigger
    • Heated seat does not warm up
    • Suspension lock
    • Lower wiper does not work (optional fitment)
    • Work lights (operator cab front left)
    • Work lights (operator cab front right)
    • Work lights (operator cab rear)
    • Work lights (boom, arm and counterweight)
    • Cab and counterweight beacon light
    • Air seat compressor (option - air suspension seat)
    • Operator cab interior light
    • Cigar lighter
    • Park brake (not activating)
    • Park brake (displayed symbol)
    • RH PPC lever clamshell roller switch pushed to the LH position
    • RH PPC lever clamshell roller switch pushed to the RH position
    • RH PPC lever clamshell roller switch pushed to the RH or LH position
    • Horns
    • Swing lock - Normal operation
    • Swing lock - Emergency operation
    • Neutral start (engine)
    • Neutral start (engine) cont'd (A)
    • Neutral start (engine) cont'd (B)
    • Neutral start (engine) cont'd (C)
    • Emergency travel control - Forward
    • Emergency travel control - neutral
    • Emergency travel control - Reverse
    • Emergency travel control - Reverse cont'd
    • Driving lights - Main beam
    • Driving lights - Main beam flash
    • Driving lights - Main beam dipped
    • Driving lights - Position lights
    • Driving lights - Position lights cont'd (1) and (2)
    • Indicators - Right hand
    • Indicators - Left hand
    • Hazard warning lights
    • Hazard warning lights cont'd (A)
    • Swing lock proximity switch
  • TESTING AND ADJUSTING
    • Troubleshooting of electrical system (Error checking of items without monitor codes)
    • System chart for hydraulic and mechanical systems
    • Information contained in troubleshooting table
    • H-1 - All work equipment lacks power, or travel and swing speeds are slow
    • H-2 - Engine speed sharply drops or engine stalls
    • H-3 - No work equipment, travel or swing move
    • H-4 - Abnormal noise is heard from around hydraulic pump
    • H-5 - Auto-decelerator does not work
    • H-6 - Fine control mode does not function
    • H-7 - Boom moves slowly or lacks power
    • H-8 - Arm moves slowly or lacks power
    • H-9 - Bucket moves slowly or lacks power
    • H-10 - Work equipment does not move in its single operation
    • H-11 - Work equipment hydraulic drift is too fast
    • H-12 - Work equipment has big time lag
    • H-13 - Other work equipment moves when relieving single circuit
    • H-14 - One-touch power max. switch does not operate
    • H-15 - In compound operation, work equipment with larger load moves slowly
    • H-16 - In swing and boom RAISE operation, boom moves slowly
    • H-17 - In swing and travel, travel speed drops sharply
    • H-18 - Travel speed does not switch
    • H-19 - Travel speed does not shift, or it is too slow or fast
    • H-20 - Machine does not swing
    • H-21 - Swing acceleration is poor, or swing speed is slow
    • H-22 - Excessive overrun when stopping swing
    • H-23 - There is big shock when stopping swing
    • H-24 - There is loud abnormal noise caused when stopping swing
    • H-25 - Swing natural drift is too big
    • H-26 - Swing speed is faster than specified swing speed
    • Troubleshooting of engine (S-mode)
    • S-1 - Starting performance is poor
    • S-2 - Engine does not start
    • S-3 - Engine does not pick up smoothly
    • S-4 - Engine stops during operations
    • S-5 - Engine does not rotate smoothly
    • S-6 - Engine lack output (or lacks power)
    • S-7 - Exhaust smoke is black (incomplete combustion)
    • S-8 - Oil consumption is excessive (or exhaust smoke is blue)
    • S-9 - Oil becomes contaminated quickly
    • S-10 - Fuel consumption is excessive
    • S-11 - Oil is in coolant (or coolant spurts back or coolant level goes down)
    • S-12 - Oil pressure drops
    • S-13 - Oil level rises (entry of coolant/fuel)
    • S-14 - Coolant temperature becomes too high (overheating)
    • S-15 - Abnormal noise is made
    • S-16 - Vibration is excessive
  • TESTING AND ADJUSTING
    • Troubleshooting of hydraulic and mechanical system (H-Mode)
    • How to read this manual
    • Sketches of special tools
    • Precautions when performing operation
    • Removal and installation of starting motor
    • Removal and installation of fuel pump assembly
    • Removal and installation of fuel injector assembly
    • Removal and installation of engine front seal
    • Removing and installation of engine rear seal
    • Removal and installation of cylinder head assembly
    • Removal and installation of combination cooler
    • Removal and installation of engine and hydraulic pump assemblies
    • Removal and installation of fuel cooler assembly
    • Removal and installation of transmission and travel motor
    • Disassembly and assembly of transmission
    • Disassembly and assembly of travel motor assembly
    • Removal and installation of swing motor and swing machinery assembly
    • Disassembly and assembly of swing motor and swing machinery assembly
    • Removal and installation of front axle
    • Disassembly and assembly of front axle
    • Removal and installation of rear axle
    • Disassembly and assembly of rear axle
    • Removal and installation of propshaft
    • Removal and installation of wheel
    • Removal and installation of suspension lock cylinder
    • Disassembly and assembly of suspension lock cylinder
    • Removal and installation of outrigger
    • Disassembly and assembly of outrigger
    • Removal and installation of dozer blade
    • Disassembly and assembly of dozer blade
    • Removal and installation of swing circle assembly
    • Removal and installation of revolving frame assembly
    • Removal and installation of centre swivel joint
    • Disassembly and assembly of centre swivel joint
    • Removal and installation of hydraulic tank
    • Removal and installation of fuel tank
    • Removal and installation of control valve
    • Removal and installation of LS select valve assembly
    • Removal and installation of LS shuttle valve assembly
    • Removal and installation of pressure compensation valve assembly
    • Removal and installation of main relief valve assembly
    • Removal and installation of LS control EPC valve assembly
    • Removal and installation of EPC solenoid valve assembly
    • Removal and installation of PPC valve block assembly
    • Removal and installation of manifold block assembly
    • Removal and installation of oil seal in hydraulic pump input shaft
    • Disassembly and assembly of work equipment ÜPPC valve
    • Disassembly and assembly of hydraulic cylinder
    • Removal and installation of monoboom work equipment
    • Removal and installation of 2 piece boom work equipment
    • Removal and installation of air conditioner unit
    • Removal and installation of counterweight
    • Removal and installation of operator cab assembly
    • Removal and installation of monitor assembly
    • Removal and installation of governor/pump controller assembly
    • Removal and Installation of KOMTRAX terminal
  • DISASSEMBLY AND ASSEMBLY
  • OTHER
    • Lubrication
    • Hydraulic circuit diagram (1/3)
    • Hydraulic circuit diagram (2/3)
    • Hydraulic circuit diagram (3/3)
    • Electrical circuit diagram (1/7)
    • Electrical circuit diagram (2/7)
    • Electrical circuit diagram (3/7)
    • Electrical circuit diagram (4/7)
    • Electrical circuit diagram (5/7)
    • Electrical circuit diagram (6/7)
    • Electrical circuit diagram (7/7)
Document type
Shop manual
Language
English
Machinery type
wheeled excavator
KOMATSU-VEBM949100-preview.pdf - 496.7KB

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