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

Komatsu’s March 2002 chassis shop manual (P/N CEBM005802) covers the PC200LC-7L and PC220LC-7L hydraulic excavators, both from serial number A86001 and up.

PDF Search, Bookmarks, and Wiring Detail

Text search and navigation: The main text is searchable. Labels inside many diagrams, including the electrical foldouts, are outside the text search. Embedded bookmarks cover the main sections and many procedures, though some entries are mislabeled. Small connector labels, pin numbers, and wire codes on the foldouts are easier to read when zoomed in.

The download is one printable English PDF with 639 pages. That total includes the cover, one supplemental front page, three blank pages, 17 memorandum pages, six revision-list pages, one publication-information page, and two forms for publication orders and revision requests.

Hydraulic Troubleshooting, Final Drive Repair, and Electrical Testing

Selected workshop topics appear below. The manual also covers revolving-frame removal and installation and diagnosis of air-conditioning faults.

• 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 and LS control tests, control-circuit and solenoid pressure checks, work-equipment drift tests, 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 assembly, and PPC valve reassembly precautions.

• Travel and swing: Step-by-step procedures for final drive disassembly and assembly, plus travel motor leakage testing, swing machinery repair, and swing circle bearing clearance measurement.

• Undercarriage and work equipment: Idler and recoil spring repair, roller reassembly precautions, track shoe removal and track 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 wiring diagrams.

• Cooling and cab: Radiator and hydraulic oil cooler removal and installation, plus procedures for removing and reinstalling the air conditioner unit and operator’s cab.

The manual is written for service technicians, with procedures that call for hydraulic test equipment, special tools, and lifting gear for heavy assemblies.

Engine Service and the Separate Engine Manual

The chassis manual covers removal and installation of the engine and hydraulic pump assembly, along with checks before and after repair. For internal engine work, including cylinder head, injection pump, and turbocharger disassembly, Komatsu directs technicians to the separate Engine Shop Manual SEBM010011. This download contains the chassis manual only.

CLSS Hydraulics and Component Repair

The closed-center load-sensing system (CLSS) section explains pump control, pressure compensation, and combined operations. The hydraulic and mechanical system chart and PC valve flow-control curves give technicians references for investigating weak digging, slow travel, engine stalling under load, and excessive drift.

Main control valve cross-sections show oil paths, spool arrangements, and compensation valves. The repair section details pressure-compensation valve seal replacement and the cushion components in the boom, arm, and bucket cylinders. The pump seal procedure flags the input shaft as vulnerable to damage when prying out the old seal.

Final Drive, Swing Machinery, and Undercarriage

The final drive procedures cover planetary carriers, sun gears, hub bearing adjustment, and floating seals. The bearing instructions warn that direct loading or impact can damage the resin retainer. Swing machinery assembly includes gear indexing and thrust washer precautions.

Model-specific tables distinguish track layouts, swing assemblies, and work equipment dimensions. The special-tool list identifies final drive wrench 796-427-1200 and recoil spring compressors 790-600-2001 or 791-685-8006.

Multi Monitor Diagnostics and Circuit Diagrams

The service menu covers live readings, electrical and mechanical fault histories, governor motor adjustment, and pump absorption torque adjustment. Service-current settings address machines with and without attachments. Separate E217 test tables show how to check the model selection circuit for each excavator.

Connector locations, troubleshooting flowcharts, and expected electrical readings help isolate wiring, sensor, and solenoid faults before a controller is replaced. Wiring references include the monitor panel M circuit, the engine start, stop, and charging diagrams, and the governor pump controller’s swing and parking brake circuit. Eight electrical foldouts support wire tracing across systems.

Workshop Reference Tables and Precautions

Reference tables give component weights, fluid capacities, conversion factors, and tightening torques for fasteners and hydraulic fittings. Maintenance standards include wear limits, clearances, spool return spring loads, and hydraulic and electrical test values. Follow the manual’s precautions for residual hydraulic pressure, suspended assemblies, and recoil springs.

Final Drive Assembly Specifications in the Manual

For both models, the final drive bearing procedure specifies a maximum tangential force of 294 N (66 lbf) at the start of hub rotation relative to the motor case.

The final drive cover bolts have a two-stage tightening specification of 98 Nm (72.2 lbf ft) followed by an 80–90° turn.