PW220-7K Komatsu Hydraulic Excavator Service Repair Manual

PW200-7K PW220-7K

MACHINE MODELSERIAL NUMBER

PW200-7K K40001 AND UP

PW220-7K

K40001 AND UP

• 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.

01GENERAL

10STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

20TESTING AND ADJUSTING

30DISASSEMBLY AND ASSEMBLY

90OTHERS

SpecificationDimensionDrawings

1PieceBoom.................01-2

2PieceBoom.................01-4

Workingrange 1PieceBoom.................01-6

2PieceBoom.................01-7

DIMENSIONS

1 PIECE BOOM

2 PIECE BOOM

1 PIECE BOOM

PW200-7, PW220-7

MachinemodelPW200-7PW220-7PW220-7(Heavyduty option)

SerialNumberK40001andup

Max.diggingforce (usingpowermax.function)

(149.1{15,200})

2.9163{16,621} 3.5(176{17,947})

Swingspeedrpm12.4

Swingmax.slopeangledeg.20

Travelspeedkm/h

Gradeabilitydeg.

Cr:0-2

Lo:0-9

Hi:10-35 (Germany:10-20)

StandardTyreWidthmm10.00-2011.00-20

MachinemodelPW200-7PW220-7 SerialNumberK40001andup

Model Type

No.ofcylinders-borexstroke Pistondisplacement mm l {cc}

Max.torque

SAA6D102E-2-A 4-cycle,water-cooled,in-line,vertical,direct injection,withturbocharger 6-102x120 5.883{5,883}

PerformanceFlywheelhorsepower

Max.speedatnoload

Min.speedatnoload Min.fuelconsumption

Startingmotor Alternator Battery

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}

24V,4.5kW 24V,45A 12V,110Ahx2

Radiator core typeTriple Cooler

HydraulicpumpTypexNo. Delivery Setpressure l/min MPa(kg/cm²)

ControlvalveTypexNo. Control method

HydraulicmotorTravelmotor Swingmotor

HPV95+95,variabledisplacement Pistontype:214x2 Pistontype:37.2{380}

1PieceBoom6-spool+1servicespooltypex1Hydraulic 2PieceBoom7-spool+1servicespooltypex1Hydraulic

A6VM140HAXT/63W-V2B380A-SK,Pistontype (withcounterbalancevalve):x1 KMF125ABE-5,Pistontype (withsafetyvalve,holdingbrake):x1

PW200-7, PW220-7

This weighttableisforusewhenhandlingcomponentsorwhentransportingthemachine.

MachinemodelPW200-7PW220-7

SerialNumberK40001andup

Unit:kg

PW220-7 (Heavyduty option)

Radiatoroilcoolerassembly114

Hydraulictank,filterassembly(excludinghydraulicoil)139

Fueltank(excludingfuel)121

Revolvingframe2,070

Operator’scab286

Operator’sseat Mechanical38 AirSuspension42

Counterweight3,7403,7404,500

Swingmachinery160

Controlvalve263 Swingmotor60 Travelmotor75 Centerswiveljoint95

Unit:kg

MachinemodelPW200-7PW220-7

SerialNumberK40001andup

Boomassembly1,408

Armassembly 1.8m523.56 2.4m556.11 2.9m643.25 3.5m740

Bucketassembly628

Liftcylinder LeftHand250.21 RightHand250.79

Armcylinderassembly215.4

Linkassembly104.2

Boompin48+8x2+31+10+26

Armpin26

Bucketpin20.6

Linkpin20.6

Unit:kg

MachinemodelPW200-7PW220-7

SerialNumberK40001andup

Boomassembly 1stBoom656.48 2ndBoom1,050.07

Armassembly 1.8m523.56 2.4m556.11 2.9m643.25 3.5m740

Bucketassembly628

Liftcylinder LeftHand250.21 RightHand250.79

Adjustcylinder362.57

Armcylinderassembly215.4

Linkassembly104.2

Boompin 1stBoom26.5 2ndBoom26

Armpin26 Bucketpin20.6 Linkpin20.6

★ FortheH-046-HM,usetheoilrecommendedbyKomatsu.

10STRUCTURE,FUNCTIONAND MAINTENANCESTANDARD

1stAttachmentCicuitHydraulicPerfomance (MainValveBypassed).................10-178 1stAttachmentCicuitHydraulicPerfomance (ViaMainValve)......................10-180

ENGINE RELATED PARTS

1.Driveplate5.Damperassembly 2.Torsionspring6.Muffler 3.Stopperpin7.Rearenginemount 4.Frictionplate8.Frontenginemount 9Brake/Steerpump10Oilcatchertube 11Breatherhose12Breathercap

OUTLINE

•Thedamperassemblyisawettype.

Oilcapacity: 0.75l

1.Reservoirtank6.OilCoolerinlettube11.ChargeAirOilCoolerinlethose

2.Oilcooler7.Radiatoroutlethose12.Net

3.Radiator8.Radiatorinlethose13.Shroud

4.ChargeAirCooler9.Fan14.RadiatorCap

5.OilCooleroutlettube10.ChargeAirOilCooleroutlethose

SPECIFICATIONS: CombinationCooler

1.Centreswiveljoint10.Accumulators

2.Hydraulictank11.Powerbrakevalve

3.Mainpump12.Swingcircle

4.Engine13.Swingmotor/machinery

5.Gearpump14.Rearaxle

6.Priorityvalve15.Propshaft

7.Maincontrolvalve16.Travelmotor

8.Travelspeedsolenoidvalve17.Transmission

9.Clutchcontrolvalve18.Frontaxle

1Swingcircleinnerrace(No.ofteeth:92)

2Ball

3Swingcircleouterrace

aInnerracesoftzoneSposition

bOuterracesoftzoneSposition

SPECIFICATIONS

Reductionratio:

18.627X-92 =-142.807 12

Amountofgrease:15.8l(G2-LI)

NoCheckitemCriteriaRemedy

4AxialclearanceofbearingStandardclearanceClearancelimitReplace (whenmountedonchassis)

SWING MACHINERY & MOTOR

1.Swingmachinery

2.Swingmotor

3.Swingpinnion

4.Dipstick

1Swingpinion(No.ofteeth:12)

2)Spacer

3)Case

4)No.2planetarygear

5)No.2sungear

6)Ringgear

7)No.1sungear

8)Swingmotor

9)Oillevelgauge

10)No.1planetarygear

11)No.1planetarycarrier

12)No.2planetarycarrier

13)Drainplug

SPECIFICATIONS

Reductionratio:

15BacklashbetweenNo.1sungearandNo.1plane-tarygear0.15~0.511.00

16BacklashbetweenNo.1planetarygearandring gear 0.17~0.601.10

17BacklashbetweenNo.1planetarycarrierandNo.2 sungear 0.40~0.751.20

14BacklashbetweenswingmotorshaftandNo.1sun gear Standard clearanceClearancelimit Replace 0.18~0.28—

18BacklashbetweenNo.2sungearandNo.2plane-tarygear0.16~0.551.00

19BacklashbetweenNo.2planetarygearandring gear

0.17~0.601.10

20Backlashbetweencouplingandswingpinion0.08~0.25—

21Backlashbetweenswingpinionandswingcircle0.00~1.212.00

22Clearancebetweenplateandcoupling0.57~1.09—

23Wearofswingpinionsurfacecontactingwithoilseal

StandardsizeRepairlimitApplyhard chromeplating, recondition,or replace 145 0 -0.100 17+58 X 18+58=18.627 1718

KMF125ABE-5

BFromswinglocksolenoidvalve

SFromcontrolvalve

TTotank

MAFromcontrolvalve

MBFromcontrolvalve

SPECIFICATIONS

PW200-7PW220-7

ModelKMF125ABE-5

Theoreticaldisplacement125.0cm³/rev

Safetyvalvesetpressure28.4MPa{290kg/cm²}

Ratedrevolvingspeed1,694rpm1,879rpm

Brakereleasepressure1.9MPa{19kg/cm²}