Description

Komatsu PW200-7H, PW220-7H 2005 Workshop Manual

I’m Mike Callahan, and I’ve been turning wrenches longer than most of you have been alive. When a machine rolls into my bay with a hydraulic drift or an engine that won’t hold idle, I don’t reach for aftermarket garbage that guesses at clearances. I pull the factory manual. This Komatsu PW200-7H, PW220-7H 2005 Workshop Manual is the same binder that Komatsu techs use—890 pages of OEM-sanctioned procedures, torque specs, and hydraulic circuit diagrams. If you’re working on a PW200-7H or PW220-7H and you don’t have this, you’re flying blind.

890 Pages of Factory-Stamped Procedures

Section 10 alone covers the engine-related parts, radiator with oil cooler and charge air cooler, power train, swing circle, swing machinery and motor, undercarriage, transmission, travel motor, clutch control circuit, axle, suspension lock cylinder, braking system—everything. The hydraulic pump section breaks down the HPV95+95 pump used on the PW200-7H, including the LS valve and PC valve adjustments. You get full CLSS (Closed-Loop Swing System) detail with main relief valve function and variable pressure compensation valve operation. I’ve used that chapter to nail down a sticking boom safety valve on a customer’s PW220-7H; the exploded view saved me an hour of guessing.

Fuel, Coolant, and Lubricants: The Chart on Page 01-13

Page 01-13 gives you the factory-approved fuel, coolant, and lubricants table. It lists the exact viscosity grades and capacities for every reservoir—hydraulic tank, transmission, swing gear case, final drives. One junior tech I know poured 10W-30 into a PW200-7H hydraulic system because a knock-off manual said “universal hydraulic oil.” That cost the shop a pump rebuild. Don’t be that guy. Use the spec sheet in this manual.

What Does Section 20 Cover for Testing?

Section 20 is where you live when a machine acts up. It includes measurement of engine rpm, exhaust gas color, valve clearance adjustment, compression pressure, blow-by pressure, fuel injection timing, engine oil pressure, and emergency setting if the engine control system fails. There’s also the full hydraulic oil pressure inspection for work equipment, swing, and travel circuits. You get solenoid valve output pressure measurement—seven-stage, four-stage, two-stage blocks—and PPC valve output pressure. The testing travel motor relief pressure procedure is right there. I’ve used the special function of the monitor panel section to pull error codes from a PW220-7H that wouldn’t shift into travel mode. The manual walks you through the service menu and the table for monitoring items.

3 Reasons to Use OEM Documentation Over Aftermarket

First, torque values. Aftermarket manuals often round torque specs to “tighten securely” or “about 150 ft-lbs.” This manual gives exact OEM numbers for every fastener on the swing circle, travel motor, and axle. Second, wiring diagrams. The electrical wiring diagram in this manual is factory-color-coded with connector pin locations. I’ve traced a short in the governor motor circuit on a PW200-7H using that diagram—the aftermarket version showed the wrong wire colors. Third, disassembly sequences. Section 30 tells you how to read the removal and installation procedures, with step-by-step sequences and required special tools. Nothing gets skipped.

Get the Right Specs Before You Tear Down the Hydraulics

Before you crack any hydraulic line on a PW200-7H or PW220-7H, you need to release remaining pressure in the hydraulic circuit (Section 20 tells you how). Then consult the hydraulic circuit diagram and hydraulic equipment layout drawings in Section 10. The manual even covers the travel PPC pedal, work equipment/swing PPC valve, and service PPC valve. If you’re rebuilding an outrigger cylinder or dozer cylinder, the cylinder-specific pages have rod and bore dimensions, seal part numbers, and assembly torque. I keep a copy on the tablet in the shop; when a customer asks why the job takes three hours instead of two, I show them the factory procedure.

Engine Control System: Governor Motor and Controller

The engine control system section details the governor motor and engine throttle/pump controller. It includes the machine control system diagram and the electronic control system layout. For troubleshooting electrical faults, the manual provides preparation procedures for troubleshooting the electrical system (Section 20). If you’re dealing with an intermittent stall at idle, the crew at my shop goes straight to the “Measurement of Engine RPM” and “Inspection and Adjustment of Fuel Injection Timing” procedures. That saved a $2,500 injection pump replacement on a PW200-7H that just needed the timing bumped two degrees.

Related Manuals

• Komatsu PW200-7H PW220-7H Shop Manual
• Komatsu WA65-5 WA70-5 WA80-5 2005 Workshop Manual
• Komatsu WH609-1E0 WH613-1E0 WH713-1E0 WH714H-1E0 WH716-1E0 Workshop Manual

For background on how the transmission system works, see also Manual Transmission and Manual Transmission on Wikipedia—though this manual has all the Komatsu-specific clutch control circuit details you’ll need.

Frequently Asked Questions

Does this manual cover both the PW200-7H and PW220-7H?

Yes. The manual covers both models with serial numbers H50051 and up. Specifications, dimension drawings, and hydraulic pump data are listed separately for each where they differ.

Does it include the engine shop manual?

It references the SAA6D102E-2 engine but does not include the full 102 Series Engine Shop Manual. That is a separate volume. The engine-related parts and adjustment procedures in this manual give you enough to service the engine as installed in the machine.

What year was this manual published?

2005. Printed in Europe by Komatsu. © 2005.

Are torque values given in ft-lbs or Nm?

Both. The manual lists torque specifications in both Newton-meters and foot-pounds. The fuel, coolant, and lubricants table uses Imperial quart/gallon capacities.

You can’t wing it on a machine that costs a quarter million dollars. Get the factory data that keeps components together and customers happy. Access the Factory Manual today.