2002 Komatsu PC200LC-7L & PC220LC-7L Hydraulic Excavator Factory Shop Manual (P/N CEBM005802)

Komatsu chassis shop manual CEBM005802, dated March 2002, covers 2002 PC200LC-7L and PC220LC-7L hydraulic excavators, both from serial number A86001 and up.

Text search, navigation, and wiring detail: The main text supports PDF search; text within many diagrams, including the electrical foldouts, is not searchable. Bookmarks cover the main sections, although some destinations are incorrect. Small wiring labels require zooming.

• Engine testing: SAA6D102E-2 compression and blow-by checks, valve-clearance adjustment, fuel-injection timing, engine oil-pressure testing, and engine-speed sensor adjustment.

• Hydraulic diagnosis: HPV95+95 pump PC/LS control tests, control-circuit and solenoid pressures, work-equipment drift checks, internal-leakage measurements, and air bleeding.

• Hydraulic component repair: Main control valve seal replacement, pump input-shaft seal service, center swivel joint overhaul, hydraulic cylinder disassembly, and PPC valve assembly precautions.

• Travel and swing: Final-drive planetary gear disassembly and assembly, bearing adjustment, swing machinery repair, travel-motor testing, and swing-circle inspection.

• Undercarriage and work equipment: Idler and recoil-spring repair, roller assembly precautions, track-shoe removal and tension adjustment, plus work-equipment removal and installation.

• Electronic controls: Multi monitor service functions, governor pump controller diagnosis, service-code testing, electrical symptom charts, and connector-specific circuit diagrams.

• Cooling and cab: Radiator and hydraulic oil cooler removal, air conditioner unit replacement, operator's cab removal, and related installation procedures.

Written for service workshop personnel, the procedures call for hydraulic test equipment, special tools, and lifting equipment for heavy assemblies.

Engine Service and the Separate Engine Manual

Engine and hydraulic pump assembly removal and installation are documented, along with governor motor adjustment and engine checks before and after repair.

Engine overhaul scope: Internal engine repair and component disassembly, including the cylinder head, injection pump, and turbocharger, are referred to the separate Engine Shop Manual SEBM010011, which is not included.

CLSS Hydraulics and Component Repair

The Closed-center Load Sensing System (CLSS) section explains pump control, pressure compensation, and combined operations. The System Chart for Hydraulic and Mechanical Systems and Flow Control Characteristic of PC Valve reference tables support diagnosis of weak digging, slow travel, engine stalling under load, and excessive hydraulic drift.

Hydraulic circuit diagrams and main control valve cross-sections show oil paths, spool arrangements, and compensation valves. Repair coverage extends to pressure-compensation valve seals and the boom, arm, and bucket cylinders, with separate assembly details for their cushion components.

The pump input-shaft seal procedure warns that careless seal removal can damage the shaft. Pump service coverage here includes removal, installation, and shaft-seal replacement.

Final Drive, Swing Machinery, and Undercarriage

Final-drive instructions cover planetary carriers, sun gears, hub bearings, floating seals, and rotational-resistance checks. Swing machinery assembly includes gear indexing and thrust-washer precautions.

The final-drive bearing instructions flag the resin retainer as vulnerable to direct loading or impact during assembly. Special-tool tables identify equipment by job, including final-drive wrench 796-427-1200 and recoil-spring compressors 790-600-2001 or 791-685-8006.

Model-specific maintenance tables distinguish track layouts, swing assemblies, and work-equipment dimensions. Carrier and track roller sections provide reassembly precautions; the idler and recoil spring have disassembly and assembly procedures.

Multi Monitor Diagnostics and Circuit Diagrams

The service menu covers live monitoring, electrical and mechanical fault histories, governor adjustment, pump absorption torque, and attachment service-current settings. Separate E217 model-code tests address the two machine models, while service-circuit settings distinguish machines with and without attachments.

Troubleshooting flowcharts outline fault isolation, while test tables pair suspected causes with connector checks and expected electrical values. This helps a technician distinguish harness, sensor, or solenoid faults from controller problems before selecting parts for a repair.

Electrical references include the Monitor Panel System Circuit Diagram (M Circuit), engine start/stop/charging diagrams, and the governor pump controller's swing/parking-brake circuit. Connector location drawings and eight electrical foldouts support wire tracing.

Factory Specifications and Workshop Precautions

Reference material includes dimension drawings, component weights, fuel/coolant/lubricant capacities, conversion tables, and tightening torques for fasteners and hydraulic fittings. Maintenance standards provide wear limits, clearances, spool return spring loads, hydraulic test specifications, and electrical test values.

Working on pressurized heavy machinery carries inherent physical risks. Follow the manual's precautions for residual hydraulic pressure, suspended assemblies, and recoil springs.

English PDF and Included Pages

One printable English PDF contains 639 pages total. This includes the manual cover, one dealer-branding page, three blank pages, 17 memorandum pages, six revision-list pages, one publication-information page, and two forms for publication orders and revision requests. All are already included in the total.