Komatsu Wheeled Excavator PW200-7 Plus service & repair manual

Description Komatsu Wheeled Excavator PW200-7 Plus service & repair manual

Komatsu Wheeled Excavator PW200-7 Plus pdf workshop service repair manual

Serial number H55300 and up

Specifications, testing, troubleshooting, maintenance, technical documentation, electrical diagrams, hydraulic schematics, adjusting, assembly, disassembly, removal, installation instructions and other information

MANUAL CONTENT:
FOREWORD
Safety notice
Foreword
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
Fuel, coolant and lubricants

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD
Engine related parts
Radiator – oil cooler – charge air cooler
Power train
Swing circle
Swing machinery & motor
Swing motor
Undercarriage
Transmission
Quick coupler control valve
ATT EPC valve assembly
Travel motor
Operation of travel motor
Clutch control circuit
Axle
Suspension lock cylinder
Braking system
Brake/steer pump
Priority valve
Power brake valve
Accumulator for brake valve
Steering system
Steering column
Orbitrol valve
Hydraulic equipment layout drawings
Hydraulic circuit diagram
Hydraulic tank
Hydraulic pump
LS valve
PC valve
Pilot pressure control (PPC) system
Control valve
CLSS
Outline of CLSS
Main relief valve
Variable pressure compensation valve
Centre swivel joint
Travel PPC pedal
Work equipment – swing PPC valve
Solenoid valve block
ON / OFF Solenoid valves (4 way valve)
Attachment EPC valve
Boom safety valve
Hydraulic cylinder
Outrigger cylinder
Dozer cylinder
Work equipment
1.Dimension of arm
2.Dimension of bucket
Air conditioner
Air conditioner piping
Electrical wiring diagram
Electrical system
Engine Control
Engine controller
Pump controller
Electronic control system
Machine control system diagram
Machine monitor system
Monitor panel
Overload warning device
Outline
Sensor
1st Attachment circuit hydraulic performance (main valve bypassed)
Travel system
Travel circuit
Steering system
Operating principles
Service brake and suspension system
Braking system
Operation
Komtrax terminal system
Central lubrication system (CLS)
Lubrication diagram

STANDARD VALUE TABLE
Standard value table for engine related parts
Standard value table for chassis related parts
Flow control characteristic of PC valve

TESTING AND ADJUSTING
Measuring engine speed
Measuring intake air pressure (boost pressure)
Measurement of exhaust gas colour
Adjusting valve clearance
Measuring compression pressure
Measuring blow-by pressure
Measuring 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
Air bleeding route of 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
Measurement
Procedure for pressure reducing adjustment
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
7 - Stage solenoid block
4 - Stage solenoid block
2 - Stage solenoid block
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
Measuring rotating speed of propshaft
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
Air bleeding of various parts
Inspection procedures for diode
Special function of monitor panel
Changing the lubrication interval times

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
Classification of troubleshooting
Failure-looking phenomenon and troubleshooting no
Connector location chart and circuit diagram by system
Connection table for connector pin numbers
Troubleshooting when failure code is indicated
Troubleshooting of electrical system (E-Mode)
Troubleshooting of electrical system (Error checking of items without monitor codes)
Troubleshooting of hydraulic, mechanical and central lubrication system
Troubleshooting when failure code is indicated
Troubleshooting of electrical system (E-Mode)
Troubleshooting of electrical system (Error checking of items without monitor codes)
Troubleshooting of hydraulic, mechanical and central lubrication system

DISASSEMBLY AND ASSEMBLY
How to read this manual
Removal and installation of assemblies
Coating materials list
Special Tools
Sketches of special tools
List of 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
Disassembly of steering cylinder
Assembly of steering cylinder
Disassembly of epicyclic reduction gear and brake
Assembly of epicyclic reduction gear and brake
Disassembly of joint box
Assembly of joint box
Disassembly of beam trumpet and differential unit
Assembly of beam trumpet and differential unit
Disassembly of pinion group
Assembly of pinion group
Toe-in adjustment
Removal and installation of rear axle
Disassembly and assembly of rear axle
Removal of epicyclic reduction gear and brake
Installation of epicyclic reduction gear and brake
Disassembly of beam trumpet and differential unit
Installation of beam trumpet and differential unit
Disassembly of pinion group
Installation of pinion group
Removal and installation of propshaft
Removal and installation of wheel
Removal and installation of suspension lock cylinder
Disassembly and assembly of suspension lock cylinder
Change rod seal
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 PPC valve
Disassembly and assembly of hydraulic cylinder
Disassembly of arm and bucket cylinders
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

OTHER
Hydraulic circuit diagram
Circuit diagram
Connector diagram
Connector table for revolving frame harness
Connector table for operator‘s cab wiring harness
Connector table various wiring harness

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