Komatsu PC200-7 Refurbished: The Step-by-Step Process of Full Machine Rebuild for Construction
You walk into a workshop in Guangzhou. On the floor sits a Komatsu PC200-7 with 12,000 hours on the meter. The paint is scratched, hoses are cracked, and the undercarriage looks tired. But the frame is straight, and the bones are good. Here's how our team turns this used machine into a reliable excavator for your next job.
Step 1 – Full dismantling
We strip everything. Engine, hydraulic pumps, swing motor, travel motors, control valves, cab, wiring harness - all removed. The bare chassis goes on heavy stands. Every component gets tagged and inspected.
Step 2 – Engine and hydraulic rebuild
The Komatsu SAA6D102E-2 diesel engine is completely opened. We replace piston rings, bearings, gaskets, and seals with OEM-grade parts. Injectors go to the test bench for recalibration. After reassembly, we run compression and oil pressure tests.
The hydraulic system is just as critical. Main pumps are disassembled. Every seal and O-ring is renewed. Flow is set to Komatsu's factory spec: 2 × 214 L/min at operating pressure. Hoses and steel lines are checked one by one - any crack or leak means replacement.
Step 3 – Undercarriage and structure
Track links, rollers, idlers, sprockets - we measure wear with calipers. Anything below tolerance gets swapped. The boom, arm, and bucket are inspected for weld cracks. The cab's AC, joysticks, and gauges are tested; if they don't work, they're replaced.
Step 4 – Reassembly and painting
We bolt everything back following factory torque specs. New hoses, clamps, and electrical connectors go in. Then comes the fresh coat of Komatsu yellow. Decals and safety labels are reapplied.
Step 5 – Functional testing
Cold start first. Then idle stability. Then full hydraulic cycle: boom up and down, arm in and out, bucket curl, swing left and right, travel forward and reverse. We run it under full pressure and check for leaks. Every test is recorded on video - you get the footage. An SGS pre-shipment inspection is available on request.
Why this matters to you
A fully rebuilt PC200-7 costs 40–60% less than a new machine. You get documented test results, a short-term warranty on engine and pumps, and a machine that's proven itself on our test yard. For contractors in Africa, Southeast Asia, or Latin America, that means putting a reliable 20-ton excavator on site without paying new equipment prices.
When that refurbished PC200-7 fires up at your job site - smooth hydraulics, clean exhaust, no leaks - you'll know it was worth the rebuild.
