UEBM001901
PW200-7K PW220-7K MACHINE MODEL PW200-7K PW220-7K
•
•
SERIAL NUMBER 00
00
K40001 AND UP K40001 AND UP
00
00
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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