1996 Komatsu PC200-6, PC200LC-6, PC210LC-6, PC220LC-6, and PC250LC-6 Excavator Chassis Shop Manual (P/N CEBMX20601)

Komatsu chassis shop manual CEBMX20601, March 1996, covers PC200-6, PC200LC-6, PC210LC-6, PC220LC-6, and PC250LC-6 excavators, each from serial number A80001 and up. It combines system explanations with workshop testing, repair procedures, and inspection standards.

• Engine service: Valve-clearance adjustment, fuel injection timing, compression and blowby testing, injection-pump removal, and cylinder-head removal and installation.

• Hydraulic diagnosis: CLSS pressure tests, TVC and LS valve adjustment, main-pump delivery checks, hydraulic-drift diagnosis, and pump, cylinder, swing-motor, and travel-motor bleeding procedures.

• Hydraulic component repair: HPV95+95 main-pump disassembly and assembly, control-valve service, center swivel joint overhaul, and hydraulic-cylinder disassembly and seal installation.

• Travel, swing, and undercarriage: Final-drive overhaul, HMV160 travel-motor repair, swing machinery disassembly, swing-circle inspection, and recoil spring, idler, and roller service.

• Electrical troubleshooting: Engine throttle and pump controller fault charts, monitor diagnostics, connector pin tables, wiring diagrams, and voltage and resistance checks.

• Inspection standards: Component-specific clearances, wear limits, spring specifications, tightening torques, and fluid-capacity tables for evaluating parts and planning service work.

Written for service technicians performing workshop repairs, this manual calls for hydraulic test equipment, electrical meters, and specialized lifting and component-repair tools for the relevant operations.

Engine Service and Chassis-Volume Scope

Repair coverage: This is the chassis volume. Komatsu specifies that both chassis and engine volumes are needed for complete repair coverage; the separate engine volume is not included.

The engine-related procedures cover cylinder-head removal and installation, crankshaft oil-seal replacement, and service removal of the injection pump, nozzle holders, and turbocharger. Compression, blowby, oil-pressure, and injection-timing checks support diagnosis before major components are removed.

Cooling-system work includes water-pump and thermostat replacement, radiator and hydraulic-oil-cooler removal, and separate procedures for the aftercooler-equipped PC220LC-6 and PC250LC-6 arrangements.

CLSS Diagnosis and Hydraulic Component Repair

The closed-center load sensing system section explains how pump control, pressure compensation, and the merge-divider circuit interact. Structure drawings distinguish the standard six-spool control valve from seven- and nine-spool layouts with additional service valves.

Fault isolation: Hydraulic-drift tests distinguish cylinder-packing leakage from control-valve and boom-holding-valve faults. Together with the TVC and LS pressure checks, these procedures help narrow the suspect component before committing to a pump or cylinder teardown.

General assembly drawings and hydraulic piping drawings locate assemblies and connections. The hydraulic circuit diagrams separate early and later serial-number configurations, so the circuit must be matched to the machine before tracing a fault.

Main-pump assembly instructions extend to rocker-cam contact checks, valve-plate inspection, washer selection, and rotating-torque checks. The manual warns that striking the pump valve plate during assembly can damage its sliding surface or distort the plate.

Before diagnostic work or opening high-pressure hydraulic lines, follow the manual’s pressure-release and work-equipment support precautions.

Controller Fault Charts and Electrical Tests

The troubleshooting section separates engine throttle control, engine symptoms, pump control, pump input signals, hydraulic/mechanical faults, and machine-monitor faults. Its judgment tables connect symptoms and service codes to the appropriate diagnostic path, helping distinguish an electrical fault from a hydraulic or mechanical problem.

Engine Throttle Controller System and Pump Controller System circuit diagrams work alongside connector-location drawings, pin-number tables, and monitor bit-pattern charts. The tool list identifies T-adapter kit 799-601-8000 for harness and sensor testing.

Final Drives, Swing Machinery, and Undercarriage

The PC250LC-6 has its own final-drive disassembly and assembly procedures, separate from those for the other covered models. Travel-motor overhaul instructions are specifically labeled for the HMV160 with brake and include cylinder-block contact checks and shaft end-play adjustment.

Swing coverage includes motor removal, reduction-gear disassembly, swing-circle replacement, and bearing-clearance measurement. Recoil spring, idler, carrier roller, and track roller procedures are supported by maintenance standards for assessing wear. Hydraulic-cylinder and work-equipment sections cover seals, pins, bushings, and boom, arm, and bucket removal.

Examples of Pump and Travel-Motor Assembly Clearances

For the HPV95+95 front pump, the shaft assembly section specifies a 1.45–1.60 mm clearance between the installed lock washer’s end face and the snap-ring groove. A washer-selection table accompanies this assembly check.

For the HMV160 travel motor with brake, shaft-to-bearing end play is specified at 0.05–0.25 mm during the assembly check with the parking-brake spring and O-ring omitted. The associated spacer table supports adjustment to that range.

Search, Bookmarks, and Foldout Diagrams

Finding procedures and reading circuits: Text search works through most chapters, although some diagrams and troubleshooting pages lack searchable text. Embedded bookmarks cover chapters and individual procedures; the legacy “MAIN MENU” shortcut points to a separate file that is not included. Small wiring and connector labels require magnification.

One printable English PDF contains 722 pages: 721 pages of manual material, including the one-page revision-request form, plus one introductory page.