UEBM001901

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

PW220-7K 00 K40001 AND UP 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 00-1
Printed in Belgium (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 DIMENSIONS

PW200/220-7K 01-3
GENERAL DIMENSIONS

DIMENSIONS

2 PIECE BOOM

01-4 PW200/220-7K
GENERAL DIMENSIONS

PW200/220-7K 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
PW220-7
PW200-7 PW220-7
Machine model (Heavy duty
option)
Serial Number K40001 and up
Bucket capacity Arm size m³ 0.8 1.0
Operating weight (m) kg 19,900 20,400 21,160
1.8 138.3 {14,100}
2.4 (149.1 {15,200})
Max. digging force 138.3 {14,100}
kN {kg}
(using power max. function) 2.9 (149.1 {15,200})
163 {16,621}
3.5 (176 {17,947})
Swing speed rpm 12.4
Swing max. slope angle deg. 20
Cr : 0-2
Lo : 0-9
Travel speed km/h Hi : 10-35
Performance

(Germany :10-20)
deg. 35
Gradeability kPa {kg cm²} 36.3 {0.37}
Standard Tyre Width mm 10.00 - 20 11.00 - 20

01-8 PW200/220-7K
GENERAL SPECIFICATIONS

12
Machine model PW200-7 PW220-7
Serial Number K40001 and up
Model SAA6D102E-2-A
Type 4-cycle, water-cooled, in-line, vertical, direct
injection, with turbo charger
No. of cylinders - bore x stroke mm 6 - 102 x 120
Piston displacement l {cc} 5.883 {5,883}
Performance

Flywheel horsepower kW/rpm {HP/rpm} 106.7/1,950 {143/1,950}

Max. torque Nm/rpm {kgm/rpm} 610.0/1,500 {62.2/1,500}
Max. speed at no load rpm 2,150
Min. speed at no load rpm 1,030
Min. fuel consumption g/kWh {g/HPh} 215 {160}

Starting motor 24V, 4.5 kW

Alternator 24V, 45 A
Engine

Battery 12V, 110 Ah x 2

Radiator core type Triple Cooler
Hydraulic

Type x No. HPV95+95, variable displacement

Delivery l/min Piston type: 214 x 2
pump

Set pressure MPa (kg/cm²) Piston type: 37.2 {380}

Type x No. 1 Piece Boom 6-spool + 1 service spool type x 1 Hydraulic

Control
valve

Control
method 2 Piece Boom 7-spool + 1 service spool type x 1 Hydraulic

Travel motor A6VM140 HAXT/63W-V2B380A-SK, Piston type

Hydraulic

(with counter balance valve): x 1

motor

Swing motor KMF125ABE-5, Piston type

(with safety valve, holding brake): x 1

Type Boom Arm Bucket

Double act- Double acting Double acting
ing piston piston piston
1 Piece Boom

Inside diameter of cylinder mm 120 135 115

Diameter of piston rod mm 85 95 80
Stroke mm 1,334.5 1,490 1,120
Max. distance between pins mm 3,204.5 3,565 2,800
Min. distance between pins mm 1,870 2,075 1,680
Adjust Boom Arm Bucket
Type
Double L.H R.H
Double acting Double acting
acting Double act- piston piston
Hydraulic culinder

piston ing piston

2 Pice Boom

Inside diameter of cylinder 185 135 135 115

mm
Diameter of piston rod 120 95 95 80
Hydraulic system

mm
Stroke 626 966 1,490 1,120
mm
Max. distance between pins 1,824 2,521 3,565 2,800
mm
Min. distance between pins 1,198 1,555 2,075 1,680
mm
Hrdraulic tank Closed box type
Hydraulic filter Tank return side
Hydraulic cooler CF40-1 (Air cooled)

PW200/220-7K 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
PW220-7
Machine model PW200-7 PW220-7 (Heavy duty
option)
Serial Number K40001 and up
Engine assembly 749
• Engine 598
• Damper 6
• Hydraulic pump 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
Mechanical 38
Operator’s seat
Air Suspension 42
Counterweight 3,740 3,740 4,500
Swing machinery 160
Control valve 263
Swing motor 60
Travel motor 75
Center swivel joint 95

01-10 PW200/220-7K
GENERAL WEIGHT TABLE

12
1 PIECE BOOM
Unit: kg
Machine model PW200-7 PW220-7
Serial Number K40001 and up
Boom assembly 1,408
1.8m 523.56
2.4m 556.11
Arm assembly
2.9m 643.25
3.5m 740
Bucket assembly 628
Left Hand 250.21
Lift cylinder
Right Hand 250.79
Arm cylinder assembly 215.4
1.8m
159.8
Bucket cylinder 2.4m
135.4
assembly 2.9m
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 WEIGHT TABLE

12
2 PIECE BOOM
Unit: kg
Machine model PW200-7 PW220-7
Serial Number K40001 and up
1st Boom 656.48
Boom assembly
2nd Boom 1,050.07
1.8m 523.56
2.4m 556.11
Arm assembly
2.9m 643.25
3.5m 740
Bucket assembly 628
Left Hand 250.21
Lift cylinder
Right Hand 250.79
Adjust cylinder 362.57
Arm cylinder assembly 215.4
1.8m
159.8
Bucket cylinder 2.4m
135.4
assembly 2.9m
135.4
3.5m
Link assembly 104.2
1st Boom 26.5
Boom pin
2nd Boom 26
Arm pin 26
Bucket pin 20.6
Link pin 20.6

01-12 PW200/220-7K
GENERAL FUEL, COOLANT AND LUBRICANTS

12
FUEL, COOLANT AND LUBRICANTS

KIND AMBIENT TEMPERATURE CAPACITY (l)

RESERVOIR OF -22 -4 14 32 50 68 86 104°F
FLUID Specified Refill
-30 -20 -10 0 10 20 30 40°C

SAE 30

SAE 10W
Engine oil pan 26.3 26.3
SAE 10W-30

SAE 15W-40
Engine
Damper case oil SAE 30 0.75 —
Swing machinery case 6.6 6.6

SAE 10W

SAE 10W-30
Hydraulic system 190 166
SAE 15W-40

Hydraulic
H046-HM (H)
oil

Diesel ASTM D975 No. 2

Fuel tank 370 —
fuel ASTM D975A
No.1

Cooling system Water Add antifreeze 23 —

Wide 13.5 —
Front
Narrow 11.5 —
Axles
Wide Fuchs titan hydra 20W-40 14 —
Rear
Narrow Multi oil 12 —
Transmission BP traction 8 2.9 2.9

Front Fuchs titan hydra 20W-40 2.85 —

Hubs
Rear 2.0 —
★ 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

6
12

A
11

10

8
9

1. Drive plate 5. Damper assembly

2. Torsion spring 6. Muffler
3. Stopper pin 7. Rear engine mount OUTLINE
4. Friction plate 8. Front engine mount
• The damper assembly is a wet type.
9 Brake/Steer pump 10 Oil catcher tube
Oil capacity: 0.75l
11 Breather hose 12 Breather cap

10-2 PW200/220-7K
STRUCTURE, FUNCTION, & MAINTENANCE STANDARDRADIATOR • OIL COOLER • CHARGE AIR COOLER

RADIATOR • OIL COOLER • CHARGE AIR COOLER

2 3
8 14
4
12

10
13

View A

5
1
4 3 2

7 11 6

1. Reservoir tank 6. Oil Cooler inlet tube 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

Oil Coolant Air

Max working pressure. bar 10 0.6 1.38
Max working temperature oC
100 100 155
Cooler volume l. 8.5 8 12

PW200/220-7K 10-3
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD POWER TRAIN

POWER TRAIN

1 2 3

11 5

10 9 8

13
12

18 15 17 16 15 14

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 PW200/220-7K
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING CIRCLE

SWING CIRCLE

10-6 PW200/220-7K
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING CIRCLE

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

SPECIFICATIONS

Reduction ratio:
18.627 X - 92 = -142.807
12

Amount of grease: 15.8l (G2 - LI)

No Check item Criteria Remedy

Axial clearance of bearing Standard clearance Clearance limit
4 Replace
(when mounted on chassis)

PW200/220-7K 10-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING MACHINERY & MOTOR

SWING MACHINERY & MOTOR

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 Swing pinion (No. of teeth: 12)

2) Spacer
3) Case
4) No. 2 planetary gear
5) No. 2 sun gear
6) Ring gear
7) No. 1 sun gear
8) Swing motor
9) Oil level gauge
10) No. 1 planetary gear
11) No. 1 planetary carrier
12) No. 2 planetary carrier
13) Drain plug

SPECIFICATIONS

Reduction ratio:

17 + 58 X 18 + 58 = 18.627
17 18

Unit: mm

No. Check item Criteria Remedy

Standard
Backlash between swing motor shaft and No. 1 sun Clearance limit
14 clearance
gear
0.18 ~ 0.28 —
Backlash between No. 1 sun gear and No. 1 plane-
15 0.15 ~ 0.51 1.00
tary gear
Backlash between No. 1 planetary gear and ring
16 0.17 ~ 0.60 1.10
gear
Backlash between No. 1 planetary carrier and No. 2
17 0.40 ~ 0.75 1.20 Replace
sun gear
Backlash between No. 2 sun gear and No. 2 plane-
18 0.16 ~ 0.55 1.00
tary gear
Backlash between No. 2 planetary gear and ring
19 0.17 ~ 0.60 1.10
gear
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 Apply hard
chrome plating,
23 Wear of swing pinion surface contacting with oil seal 0
145 — recondition, or
-0.100 replace

PW200/220-7K 10-11
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING MOTOR

SWING MOTOR
KMF125ABE-5

SPECIFICATIONS

B From swing lock solenoid valve PW200-7 PW220-7

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 1,879 rpm
Brake release pressure 1.9 MPa {19 kg/cm²}

10-12 PW200/220-7K
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