1998 Komatsu PC200-6 Hydraulic Excavator Shop Manual (P/N SEBM010201K)

The 1998 Komatsu PC200-6 Hydraulic Excavator Shop Manual, SEBM010201K, is the February 1998 edition for machines with serial numbers C10001 and up.

Supplied as one 531-page PDF in English.

• Engine testing and repair: Compression and blow-by checks, valve clearance and injection timing adjustments, plus cylinder head, fuel injection pump, turbocharger and water pump removal and installation.

• Hydraulic diagnosis: Main pump, PC/LS and PPC valve pressure tests, work equipment drift checks, swing and travel motor leakage measurements, and hydraulic system air bleeding.

• Power train and undercarriage: Final drive and swing machinery disassembly and assembly, center swivel repair, track roller and recoil spring service, and track shoe removal and installation.

• Control valves and cylinders: Control valve and hydraulic cylinder disassembly and assembly, main relief valve service, and boom, arm and bucket removal and installation.

• Electrical troubleshooting: Pump control, travel speed, swing brake, PPC lock and machine monitor diagnostics, supported by connector locations, pin tables and wiring diagrams.

• Maintenance standards: Component-specific wear limits, clearances, torque tables, fluid capacities, electrical test values and work equipment dimensions.

Written for service technicians performing workshop repairs, the manual identifies the test equipment and special tools required for individual procedures.

CLSS Hydraulics and Fault Isolation

Hydraulic coverage explains the Closed-center Load Sensing System (CLSS), HPV95+95 main pumps, pressure compensation, and regeneration circuits for the arm and boom. Hydraulic piping drawings and hydraulic circuit diagrams accompany CLSS operating diagrams for independent and combined functions.

Troubleshooting is divided into engine (S), electrical (E), hydraulic/mechanical (H) and machine monitor (M) groups. Work equipment drift tests help distinguish cylinder packing leakage from control valve or boom holding valve faults before an assembly is removed for repair.

Coverage distinguishes four-port and six-port center swivel joints. The structure-and-function sections also address the arm holding valve and additional breaker filter where fitted.

Engine Repair and Coverage Limits

Reference values for the 102-series S6D102-1 engine cover fuel consumption and performance baselines, alongside oil-pressure testing. Cooling-system procedures include radiator, hydraulic oil cooler and thermostat removal and installation.

Repair scope: This machine/chassis volume covers engine removal and cylinder head replacement, but not a complete internal engine overhaul. Main pump procedures cover removal, installation and input shaft oil seal replacement, with separate PC, LS and PC-EPC valve procedures; a complete pump overhaul is not included.

Fuel injection pump installation cautions explain how excessive tightening torque while the timing pins are engaged can damage a timing pin.

Final Drive, Swing and Undercarriage Repair

Final drive repair details include planetary carriers, bearing adjustment and floating seals. Swing circle installation identifies the bearing soft-zone orientation. Track frame, idler, roller and track link tables supply inspection limits.

Roller assembly procedures include air-leak testing. The final drive bearing instructions warn against burner heat or direct force on the resin retainer, which can damage the bearing.

Electrical Diagrams and Connector References

Actual electrical wiring diagrams and electrical circuit diagrams accompany connector mounting locations and pin-number tables. The electrical section maps out wire thickness and color-code classifications. These charts help technicians quickly trace circuits when evaluating the machine monitor and electronic controls.

Fault charts address starting failures, travel-speed switching, swing holding brakes and PPC hydraulic locks, plus abnormal gauge, warning-lamp and service-meter operation.

Technical Data and Workshop Preparation

Conversion tables accompany standard tightening torques for metric bolts, hose nuts and split flange connections, with dedicated tables for the 102-series engine. The manual lists capacity values for the engine oil pan, hydraulic system, and cooling system. It also provides ambient temperature viscosity recommendations.

Maintenance data include cylinder dimensions, piston rod diameters and stroke lengths for the boom, arm and bucket. Main and safety-suction valve pressure specifications, pin and bushing clearances, and specification dimension drawings provide further inspection references.

Special tool lists identify required tools, alternatives and locally fabricated tools, including gear-barring tool 795-799-1130 for engine timing work. Safety precautions address hydraulic pressure release and support of raised equipment.

File Format and Readability

The total includes the one-page cover, the 27-page diagram appendix (including 12 additional enlarged detail pages), and a one-page manual-revision proposal form.

Text search: An embedded OCR layer supports searches through most text sections. The 15 schematic and detail pages at PDF pages 506–510 and 513–522 have no searchable text; OCR errors can also affect exact searches elsewhere.

Navigation: Embedded bookmarks cover chapters and individual procedures. The MAIN MENU bookmark points to a separate file that is not included.

Diagram readability: Small wiring labels, connector numbers and hydraulic annotations are best read with zooming; enlarged detail pages are included.