Komatsu Pw200-7k Hydraulic Excavator Service Repair Manual Snk40001 And Up.pdf

UEBM001901

PW200-7K PW220-7K MACHINE MODEL PW200-7K PW220-7K

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•

SERIAL NUMBER 00

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K40001 AND UP K40001 AND UP

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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/PW220-7K mount the SAA6D102E-2 engine. For details of the engine, see the 102 Series Engine Shop Manual.

© 2003 All Rights Reserved Printed in Belgium

00-1 (1)

CONTENTS

No. of page 01

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1

10

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD . . . . . . . 10-1

20

TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1

30

DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1

90

OTHERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1 00

00-2

01

GENERAL Specification Dimension Drawings 1 Piece Boom . . . . . . . . . . . . . . . . . 01-2 2 Piece Boom . . . . . . . . . . . . . . . . . 01-4 Working range 1 Piece Boom. . . . . . . . . . . . . . . . . 01-6 2 Piece Boom . . . . . . . . . . . . . . . . . 01-7 Specifications. . . . . . . . . . . . . . . . . . . . . . 01-8 Weight Table . . . . . . . . . . . . . . . . . . . . . 01-10 Fuel, Coolant, And Lubricants . . . . . . . . 01-13

PW200/220-7K

01-1

GENERAL

SPECIFICATION DIMENSION DRAWINGS

12 SPECIFICATION DIMENSION DRAWINGS

DIMENSIONS 1 PIECE BOOM

01-2

PW200/220-7K

GENERAL

PW200/220-7K

DIMENSIONS

01-3

GENERAL

DIMENSIONS

DIMENSIONS 2 PIECE BOOM

01-4

PW200/220-7K

GENERAL

PW200/220-7K

DIMENSIONS

01-5

GENERAL

WORKING RANGES

WORKING RANGES 1 PIECE BOOM

Arm length mm (Tt/In)

1800

2400

2900

3500

A

Max. digging height

9467

9883

10003

10438

B

Max. dumping height

6704

7057

7229

7612

C

Max. digging depth

4791

5402

5917

6500

D

Min. swing radius

3906

3201

3143

3184

E’

Max. digging reach ay GL

8867

9438

9875

10478

E

Max. digging reach

9067

9651

10060

10642

01-6

PW200/220-7K

GENERAL

WORKING RANGES

2 PIECE BOOM

Arm length mm (Tt/In)

1800

2400

2900

3500

A

Max.digging height

9532

9842

10168

10434

B

Max.dumping height

6670

6982

7298

7574

C

Max digging depth

5166

5785

6285

6860

D

Min. swing radius

2594

3121

2745

2866

E’

Max. digging reach ay GL

8599

9144

9634

10156

E

Max. digging reach

8818

9348

9822

10338

PW200/220-7K

01-7

GENERAL

SPECIFICATIONS

12 SPECIFICATIONS

PW200-7, PW220-7 Machine model

PW200-7

Serial Number

K40001 and up

Bucket capacity Operating weight

Arm size (m)

m³

0.8

1.0

kg

19,900

20,400

1.8 Max. digging force (using power max. function)

2.4 2.9

kN {kg}

138.3 {14,100} (149.1 {15,200})

Performance

3.5 Swing speed

rpm

12.4

Swing max. slope angle

deg.

20

Travel speed

km/h

Cr : 0-2 Lo : 0-9 Hi : 10-35 (Germany :10-20)

Gradeability

deg. kPa {kg cm²}

35 36.3 {0.37}

Standard Tyre Width

mm

10.00 - 20

01-8

PW220-7

PW220-7 (Heavy duty option)

21,160

138.3 {14,100} (149.1 {15,200}) 163 {16,621} (176 {17,947})

11.00 - 20

PW200/220-7K

GENERAL

SPECIFICATIONS

12 Machine model

PW200-7

Serial Number

K40001 and up

Model Type

Flywheel horsepower Max. torque Max. speed at no load Min. speed at no load Min. fuel consumption

mm l {cc}

SAA6D102E-2-A 4-cycle, water-cooled, in-line, vertical, direct injection, with turbo charger 6 - 102 x 120 5.883 {5,883}

kW/rpm {HP/rpm} Nm/rpm {kgm/rpm} rpm rpm g/kWh {g/HPh}

106.7/1,950 {143/1,950} 610.0/1,500 {62.2/1,500} 2,150 1,030 215 {160}

Triple Cooler

Hydraulic pump

Radiator core type Type x No. Delivery Set pressure

Control valve

24V, 4.5 kW 24V, 45 A 12V, 110 Ah x 2

Type x No. Control method

Hydraulic motor

Starting motor Alternator Battery

Travel motor

1 Piece Boom

Engine

Performance

No. of cylinders - bore x stroke Piston displacement

2 Pice Boom

Hydraulic culinder

HPV95+95, variable displacement Piston type: 214 x 2 Piston type: 37.2 {380}

l/min

MPa (kg/cm²)

1 Piece Boom

6-spool + 1 service spool type x 1 Hydraulic

2 Piece Boom

7-spool + 1 service spool type x 1 Hydraulic

Swing motor

A6VM140 HAXT/63W-V2B380A-SK, Piston type (with counter balance valve): x 1 KMF125ABE-5, Piston type (with safety valve, holding brake): x 1

Type

Boom

Arm

Bucket

Double acting piston

Double acting piston

Double acting piston

120 85 1,334.5 3,204.5 1,870

135 95 1,490 3,565 2,075

115 80 1,120 2,800 1,680

Adjust

Boom

Arm

Bucket

Double acting piston

L.H

Double acting piston

Double acting piston

185 120 626 1,824 1,198

135 95 966 2,521 1,555

135 95 1,490 3,565 2,075

115 80 1,120 2,800 1,680

Inside diameter of cylinder Diameter of piston rod Stroke Max. distance between pins Min. distance between pins

mm mm mm mm mm

Type

Hydraulic system

PW220-7

Inside diameter of cylinder Diameter of piston rod Stroke Max. distance between pins Min. distance between pins

Hrdraulic tank Hydraulic filter Hydraulic cooler

PW200/220-7K

mm mm mm mm mm

R.H

Double acting piston

Closed box type Tank return side CF40-1 (Air cooled)

01-9

GENERAL

WEIGHT TABLE

12 WEIGHT TABLE

PW200-7, PW220-7 This weight table is for use when handling components or when transporting the machine.

Unit: kg Machine model

PW200-7

Serial Number

K40001 and up

Engine assembly • Engine • Damper • Hydraulic pump

749 598 6 145

Radiator oil cooler assembly

114

Hydraulic tank, filter assembly (excluding hydraulic oil)

139

Fuel tank (excluding fuel)

121

Revolving frame

2,070

Operator’s cab

286

Operator’s seat

Mechanical Air Suspension

PW220-7 (Heavy duty option)

3,740

4,500

38 42

Counterweight

3,740

Swing machinery

160

Control valve

263

Swing motor

60

Travel motor

75

Center swivel joint

95

01-10

PW220-7

PW200/220-7K

GENERAL 12 1 PIECE

WEIGHT TABLE

BOOM Unit: kg

Machine model

PW200-7

Serial Number

K40001 and up

Boom assembly

Arm assembly

1,408 1.8m

523.56

2.4m

556.11

2.9m

643.25

3.5m Bucket assembly Lift cylinder

740 628

Left Hand

250.21

Right Hand

250.79

Arm cylinder assembly

215.4

1.8m Bucket cylinder assembly

PW220-7

2.4m 2.9m

159.8 135.4 135.4

3.5m Link assembly

104.2

Boom pin

48 + 8 x 2 + 31 + 10 + 26

Arm pin

26

Bucket pin

20.6

Link pin

20.6

PW200/220-7K

01-11

GENERAL 12 2 PIECE

WEIGHT TABLE

BOOM Unit: kg

Machine model

PW200-7

Serial Number

K40001 and up

Boom assembly

Arm assembly

1st Boom

656.48

2nd Boom

1,050.07

1.8m

523.56

2.4m

556.11

2.9m

643.25

3.5m

740

Bucket assembly Lift cylinder

628 Left Hand Right Hand

250.21 250.79

Adjust cylinder

362.57

Arm cylinder assembly

215.4

1.8m Bucket cylinder assembly

2.4m 2.9m

159.8 135.4 135.4

3.5m Link assembly Boom pin

01-12

PW220-7

104.2 1st Boom

26.5

2nd Boom

26

Arm pin

26

Bucket pin

20.6

Link pin

20.6

PW200/220-7K

GENERAL

FUEL, COOLANT AND LUBRICANTS

12 FUEL, COOLANT AND LUBRICANTS

KIND OF FLUID

RESERVOIR

CAPACITY (l)

AMBIENT TEMPERATURE -22 -4 -30 -20

14 -10

32 0

50 10

68 20

86 30

104°F 40°C

Specified

Refill

26.3

26.3

0.75

—

6.6

6.6

190

166

370

—

23

—

Wide

13.5

—

Narrow

11.5

—

14

—

12

—

2.9

2.9

2.85

—

2.0

—

SAE 30 SAE 10W Engine oil pan SAE 10W-30 SAE 15W-40 Engine oil

Damper case

SAE 30

Swing machinery case SAE 10W SAE 10W-30 Hydraulic system

SAE 15W-40 Hydraulic oil Diesel fuel

Fuel tank

Cooling system

ASTM D975 No. 2 ASTM D975A No.1

Water Front

Axles Rear Transmission Hubs

H046-HM (H)

Wide Narrow

Add antifreeze

Fuchs titan hydra 20W-40 Multi oil BP traction 8

Front

Fuchs titan hydra 20W-40

Rear

★ For the H-046-HM, use the oil recommended by Komatsu.

PW200/220-7K

01-13

10

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

Engine Related Parts . . . . . . . . . . . . . . . . . . . . . 10-2 Radiator • Oil Cooler • Charge air cooler . . . . . . 10-3 Power Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4 Swing Circle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6 Swing Machinery . . . . . . . . . . . . . . . . . . . . . . . . 10-8 Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12 Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . 10-17 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20 Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-23 Clutch Control Circuit . . . . . . . . . . . . . . . . . . . . 10-25 Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-29 Suspension Lock Cylinder . . . . . . . . . . . . . . . . 10-33 Braking System . . . . . . . . . . . . . . . . . . . . . . . . 10-35 Brake/Steer Pump . . . . . . . . . . . . . . . . . . . . . . 10-37 Priority Valve . . . . . . . . . . . . . . . . . . . . . . . . . . 10-38 Power Brake Valve . . . . . . . . . . . . . . . . . . . . . 10-39 Accumulator for Brake System . . . . . . . . . . . . 10-40 Steering Train . . . . . . . . . . . . . . . . . . . . . . . . . 10-41 Steering Column . . . . . . . . . . . . . . . . . . . . . . . 10-42 Orbitrol Valve . . . . . . . . . . . . . . . . . . . . . . . . . . 10-43 Hydraulic Layout Drawing . . . . . . . . . . . . . . . . 10-44 Hydraulic Circuit Diagram . . . . . . . . . . . . . . . . 10-47 Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . 10-48 Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . 10-49 Pilot Pressure Control System . . . . . . . . . . . . . 10-66 Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . 10-67

PW200/220-7K

CLSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80 Centre Swivel Joint . . . . . . . . . . . . . . . . . . . . . 10-81 Travel PPC Pedal . . . . . . . . . . . . . . . . . . . . . . 10-82 Work Equipment • Swing PPC Valve . . . . . . . 10-85 Service PPC Pedal . . . . . . . . . . . . . . . . . . . . . 10-90 Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . 10-94 Travel-Boom-Stabilizer Solenoid Valve . . . . . 10-96 Boom Safety Valve . . . . . . . . . . . . . . . . . . . . 10-104 Hydraulic Cylinder (Boom-Arm-Bucket) . . . . 10-106 Outrigger Cylinder. . . . . . . . . . . . . . . . . . . . . 10-108 Dozer Cylinder . . . . . . . . . . . . . . . . . . . . . . . 10-110 Work Equipment . . . . . . . . . . . . . . . . . . . . . . 10-112 Air Conditioner . . . . . . . . . . . . . . . . . . . . . . . 10-118 Electrical Wiring Diagram . . . . . . . . . . . . . . . 10-119 Engine Control System . . . . . . . . . . . . . . . . . 10-120 Electronic control System . . . . . . . . . . . . . . . 10-127 Machine Monitor System . . . . . . . . . . . . . . . 10-152 Overload Warning Device . . . . . . . . . . . . . . . 10-173 Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-174 1st Attachment Cicuit Hydraulic Perfomance (Main Valve Bypassed) . . . . . . . . . . . . . . . . . 10-178 1st Attachment Cicuit Hydraulic Perfomance (Via Main Valve) . . . . . . . . . . . . . . . . . . . . . . 10-180 Travel System . . . . . . . . . . . . . . . . . . . . . . . . 10-182 Steering System . . . . . . . . . . . . . . . . . . . . . . 10-202 Service Brake and Suspension System . . . . 10-212

10-1

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

ENGINE RELATED PARTS

ENGINE RELATED PARTS

5

6

12

6

A

11

A

7

10 8 9

1. Drive plate

5. Damper assembly

2. Torsion spring

6. Muffler

3. Stopper pin

7. Rear engine mount

4. Friction plate

8. Front engine mount

9

10 Oil catcher tube

Brake/Steer pump

11 Breather hose

10-2

12 Breather cap

OUTLINE •

The damper assembly is a wet type. Oil capacity: 0.75l

PW200/220-7K

STRUCTURE, FUNCTION, & MAINTENANCE STANDARDRADIATOR • OIL COOLER • CHARGE AIR COOLER

RADIATOR • OIL COOLER • CHARGE AIR COOLER 3

2

8

14 4

12 10

13

A

View A

9

5 1 4

2

3

7

1.

Reservoir tank

6.

Oil Cooler inlet tube

11

6

11. Charge Air Oil Cooler inlet hose

2.

Oil cooler

7.

Radiator outlet hose

12. Net

3.

Radiator

8.

Radiator inlet hose

13. Shroud

4.

Charge Air Cooler

9.

Fan

14. Radiator Cap

5.

Oil Cooler outlet tube

10. Charge Air Oil Cooler outlet hose

SPECIFICATIONS: Combination Cooler

Max working pressure. bar Max working temperature Cooler volume l.

PW200/220-7K

oC

Oil

Coolant Air

10

0.6

1.38

100

100

155

8.5

8

12

10-3

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

POWER TRAIN

POWER TRAIN 1

2

3

4

11

5

7

10

9

8

13

12

6

18

15

17

16

15

1.

Centre swivel joint

10.

Accumulators

2.

Hydraulic tank

11.

Power brake valve

3.

Main pump

12.

Swing circle

4.

Engine

13.

Swing motor / machinery

5.

Gear pump

14.

Rear axle

6.

Priority valve

15.

Propshaft

7.

Main control valve

16.

Travel motor

8.

Travel speed solenoid valve

17.

Transmission

9.

Clutch control valve

18.

Front axle

10-4

14

PW200/220-7K

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

SWING CIRCLE

SWING CIRCLE

10-6

PW200/220-7K

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

1

Swing circle inner race (No. of teeth: 92)

2

Ball

3

Swing circle outer race

a

Inner race soft zone S position

b

Outer race soft zone S position

SWING CIRCLE

SPECIFICATIONS Reduction ratio: 18.627 X - 92 = 12

-142.807

Amount of grease: 15.8l (G2 - LI)

No 4

Check item Axial clearance of bearing (when mounted on chassis)

PW200/220-7K

Criteria Standard clearance

Remedy Clearance limit

Replace

10-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

SWING MACHINERY & MOTOR

SWING MACHINERY & MOTOR

4

2

1

3

1.

Swing machinery

2.

Swing motor

3.

Swing pinnion

4.

Dipstick

10-8

PW200/220-7K

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

SWING MACHINERY & MOTOR

12

10-10

PW200/220-7K

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

SWING MACHINERY & MOTOR

12

1 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) 13)

Swing pinion (No. of teeth: 12) Spacer Case No. 2 planetary gear No. 2 sun gear Ring gear No. 1 sun gear Swing motor Oil level gauge No. 1 planetary gear No. 1 planetary carrier No. 2 planetary carrier Drain plug

SPECIFICATIONS Reduction ratio: 17

+ 58 X 18 + 58 = 18.627 17 18

Unit: mm No.

Check item

Criteria

Remedy

Standard clearance

Clearance limit

0.18 ~ 0.28

—

0.15 ~ 0.51

1.00

Backlash between No. 1 planetary gear and ring gear

0.17 ~ 0.60

1.10

17

Backlash between No. 1 planetary carrier and No. 2 sun gear

0.40 ~ 0.75

1.20

18

Backlash between No. 2 sun gear and No. 2 planetary gear

0.16 ~ 0.55

1.00

19

Backlash between No. 2 planetary gear and ring gear

0.17 ~ 0.60

1.10

20

Backlash between coupling and swing pinion

0.08 ~ 0.25

—

21

Backlash between swing pinion and swing circle

0.00 ~ 1.21

2.00

22

Clearance between plate and coupling

0.57 ~ 1.09

—

Standard size

Repair limit

23

Wear of swing pinion surface contacting with oil seal

14

Backlash between swing motor shaft and No. 1 sun gear

15

Backlash between No. 1 sun gear and No. 1 planetary gear

16

PW200/220-7K

145

0 -0.100

—

Replace

Apply hard chrome plating, recondition, or replace

10-11

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

SWING MOTOR

SWING MOTOR KMF125ABE-5

SPECIFICATIONS B

From swing lock solenoid valve

S

From control valve

Model

KMF125ABE-5

T

To tank

Theoretical displacement

125.0 cm³/rev

MA

From control valve

Safety valve set pressure

28.4 MPa {290 kg/cm²}

MB

From control valve

Rated revolving speed

1,694 rpm

PW200-7

Brake release pressure

10-12

PW220-7

1,879 rpm

1.9 MPa {19 kg/cm²}

PW200/220-7K

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