Komatsu PW200-7K PW220-7K Shop Manual PDF – Wheeled Excavator Repair & Service Guide K40001-Up

Description

This Komatsu PW200-7K PW220-7K Shop Manual is the complete service and repair documentation for these wheeled excavators, covering serial numbers K40001 and up. Published under document number UEBM001801, this 848-page shop manual gives technicians, fleet managers and equipment owners the full factory service information needed to maintain, diagnose and overhaul the PW200-7K and PW220-7K wheeled excavators. The manual mounts the SAA6D102E-2 engine and directs readers to the 102 Series Engine Shop Manual for internal engine details.

File Details

• Manual Type: Shop Manual
• Brand: Komatsu
• Models: PW200-7K, PW220-7K
• Serial Numbers: K40001 and up
• Engine: SAA6D102E-2
• Language: English
• Pages: 848
• Format: PDF
• Document Number: UEBM001801

Chapters Covered

• 01 GENERAL
• 10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
• 20 TESTING AND ADJUSTING
• 30 DISASSEMBLY AND ASSEMBLY
• 90 OTHERS

01 General

Specification dimension drawings for both the 1 piece boom and 2 piece boom configurations, working range charts, complete machine specifications, a component weight table for handling and transport, and the fuel, coolant and lubricants chart with ambient temperature ranges, capacities and refill quantities.

10 Structure, Function and Maintenance Standard

The largest chapter of the manual, covering the engine and related components, radiator, oil cooler and charge air cooler, power train layout, swing circle, swing machinery and swing motor, undercarriage, transmission, travel motor, clutch control circuit, front and rear axle, suspension lock cylinder, braking system, brake and steer pump, priority valve, power brake valve, accumulator, steering train, steering column, orbitrol valve, hydraulic layout and circuit diagrams, hydraulic tank, hydraulic pump with PC and LS valves and EPC control, pilot pressure control system, control valve with CLSS, centre swivel joint, travel PPC pedal, work equipment and swing PPC valves, service PPC pedal, solenoid valves, travel-boom-stabilizer solenoid valve, boom safety valve, hydraulic cylinders for boom, arm, bucket, outrigger and dozer, work equipment, air conditioner, electrical wiring diagrams, engine control system, electronic control system, machine monitor system, overload warning device, sensors, 1st attachment circuit hydraulic performance, travel system, steering system, and service brake and suspension system.

20 Testing and Adjusting

Standard value tables for engine related parts and chassis related parts, followed by detailed inspection and adjustment procedures. Topics include engine RPM inspection and adjustment, exhaust gas colour measurement, valve clearance adjustment, compression pressure and blow-by pressure measurement, fuel injection timing, engine oil pressure, engine speed sensor adjustment, air compressor belt tension, emergency settings for engine control system failure, swing circle bearing clearance, hydraulic oil pressure for work equipment, swing and travel, control circuit oil pressure, pump PC and LS control circuit oil pressure, solenoid valve output pressure, PPC valve output pressure, work equipment and swing PPC valve adjustment, travel motor relief pressure adjustment, release of remaining pressure, oil leakage measurement, air bleeding, diode inspection, and the special functions of the monitor panel including service menu, monitoring, abnormality record, maintenance record, default settings and adjustments. The troubleshooting section covers both electrical system (E-mode) and hydraulic/mechanical system (H-mode) diagnostics with service codes, failure codes and step-by-step flowcharts.

30 Disassembly and Assembly

Removal and installation procedures for major assemblies and components including the governor motor, starting motor, fuel injection pump, engine front seal, engine rear seal, cylinder head, combination cooler, engine and hydraulic pump assemblies, transmission and travel motor, swing motor and swing machinery, front axle, rear axle, propshaft, wheels, suspension lock cylinder, outrigger, dozer blade, swing circle, revolving frame, centre swivel joint, hydraulic tank, fuel tank, control valve, LS select valve, LS shuttle valve, pressure compensation valve, main relief valve, LS control EPC valve, EPC solenoid valve, PPC valve block, manifold block, oil seal in hydraulic pump input shaft, work equipment PPC valve, travel pedal valve, hydraulic cylinder, monoboom assembly, 2 piece boom assembly, air conditioner unit, counterweight, operator’s cab, monitor assembly and governor pump controller. Each procedure includes special tools, tightening torques, sealants and assembly precautions.

90 Others

Hydraulic circuit diagram (2 sheets) and electrical circuit diagram (3 sheets) for reference during diagnostics and repair.

Systems and Components Covered in Detail

The Komatsu PW200-7K PW220-7K shop manual provides complete service coverage for the SAA6D102E-2 engine installation, including damper assembly, engine mounts, radiator and combination cooler, fuel system, air intake and exhaust, and engine control system. The power train section covers the transmission with its two clutches and epicyclic gearbox, propshafts, front and rear axles with differential and final drives, and the travel motor with counterbalance valve and speed control. Hydraulic coverage spans the variable displacement piston pumps with PC and LS valve control, EPC valves, control valve with pressure compensation and LS shuttle valves, PPC valves, hydraulic cylinders for all work equipment, and the complete hydraulic circuit diagram. Braking and steering systems include the fully hydraulic service brake with accumulators, parking brake integrated into the transmission, priority valve, orbitrol valve, and steering cylinder on the front axle. Electrical coverage includes the engine throttle and pump controller, monitor panel with LCD display and service menu, sensors, solenoid valves, and complete wiring diagrams.

Who This Manual Is For

This Komatsu PW200-7K PW220-7K workshop manual is written for professional diesel technicians, fleet maintenance managers, equipment owners and operators who need accurate specifications and procedures for these wheeled excavators. Whether you are performing routine maintenance, diagnosing a hydraulic fault, rebuilding a cylinder, repairing the transmission, troubleshooting an electrical issue, or carrying out a full component overhaul, this manual provides the standard values, torque figures, clearances, service limits and step-by-step procedures needed to complete the job correctly. The testing and adjusting chapter is particularly valuable for diagnosing performance complaints, with standard value tables covering engine and chassis systems, and the troubleshooting chapter gives structured diagnostic flowcharts for both electrical and hydraulic/mechanical problems.

Get the Complete Komatsu PW200-7K PW220-7K Shop Manual

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With 848 pages covering every major system on the PW200-7K and PW220-7K wheeled excavators, this Komatsu shop manual PDF gives you the same technical information used for professional service and repair. The manual covers serial numbers K40001 and up, so it applies across the production range. Every procedure includes the correct specifications, tightening torques, special tools and safety precautions — eliminating guesswork and reducing the risk of damage from incorrect assembly or adjustment. Delivered as an instant PDF download after payment, the manual can be viewed on any device, searched for specific topics, and printed for use in the workshop. Whether you need to look up a hydraulic pressure setting, identify a service code, or follow a complete disassembly procedure, this Komatsu PW200-7K PW220-7K shop manual provides the answers.