Komatsu PC200 & PC220 Excavator Factory Service Manual (P/N SEBM024312)

• An 810-page PDF of Komatsu shop manual SEBM024312, cover-dated October 2005 and printed in Japan.
• Coverage is serial-specific: PC200-7 and PC200LC-7, serial 200001 and up; PC220-7 and PC220LC-7, serial 60001 and up, with separate standard- and LC-undercarriage data.
• Hydraulic sections explain the HPV95+95 pump, CLSS, PC/LS and EPC controls, six-spool main control valve and optional service valve, PPC valves, KMF125ABE-5 swing motor, HMV110ADT-2 travel motors, and boom, arm, and bucket cylinders, together with pressure, drift, leakage, and air-bleeding tests.
• Major repair procedures cover engine-and-pump removal, cylinder-head service, final-drive and swing-machinery teardown, center-swivel and control-valve overhaul, hydraulic-cylinder rebuilding, undercarriage work, and work-equipment removal.
• Electrical diagnosis uses multi-monitor and 7-segment service functions, service/failure-code charts, connector-location stereograms, pin tables, and system circuits for the governor/pump controller, sensors, solenoids, starting and charging, and air conditioning.
• Factory reference material includes special-tool lists and part numbers, standard and service limits, component-specific torque data, fluids and capacities, adjustment specifications, hydraulic and electrical test values, and serial-matched schematics.

Systems, Testing, and Troubleshooting

Komatsu prepared this publication for service personnel performing workshop repairs. Its reliance on hydraulic test equipment, electrical T-adapters, lifting gear, and model-specific tooling makes it suited to technicians and experienced heavy-equipment mechanics who already understand safe machine isolation and component handling.

The specifications identify the SAA6D102E-2-A engine in the PC200 pair and the SAA6D102E-2-C in the PC220 pair. They also separate dimensions, working ranges, weights, and cylinder data by model; the standard machines have 600 mm base shoe-width entries, while the LC versions are listed with 700 mm shoes.

Engine-related checks include speed adjustment, exhaust-gas color, valve clearance, compression and blow-by pressure, fuel-injection timing, oil pressure, and engine-speed sensor adjustment. Chassis procedures cover swing-circle bearing clearance, track tension, main and swing relief testing, control and PPC pressure checks, pump PC/LS circuit diagnosis, hydraulic drift isolation, cylinder and motor leakage measurement, and air bleeding.

Troubleshooting is organized around displayed service and failure codes plus electrical E-mode, hydraulic/mechanical H-mode, and engine S-mode charts. Fault coverage reaches from controller power supplies, pump sensors, S-NET communication, and EPC solenoids to weak work equipment, travel or swing faults, engine starting, smoke, lubrication, and cooling complaints. Multi-monitor and 7-segment service functions provide live monitoring, abnormality records, maintenance records, governor adjustment, attachment setup, and pump-absorption-torque adjustment.

Serial Breaks, Control Systems, and Diagrams

The electrical documentation changes at PC200 serial 250000/250001 and PC220 serial 65000/65001. Early machines receive separate four-sheet circuits for multi-monitor and 7-segment configurations; later machines use a revised four-sheet set. Swing-machinery teardown is also divided at PC200 serial 203890/203891 and PC220 serial 60353/60354, while work-equipment PPC-valve assembly changes at PC200 serial 202418/202419 and PC220 serial 60239/60240.

Named visual references include the Hydraulic Equipment Layout Drawing, PC200 and PC220 Hydraulic Circuit Diagrams, Machine Control System Diagram, Monitor Panel System Circuit Diagram, Governor and Pump Control System Circuit Diagrams, and Connector Location Stereograms. Serial-matched whole-machine and air-conditioner wiring diagrams support circuit tracing without mixing early and late electrical builds.

Repair Scope, Special Tools, and Cautions

Engine and cooling work covers the starting motor, fuel-injection pump, front and rear seals, cylinder head, radiator, oil cooler, and removal of the complete engine-and-pump group. Chassis work extends to final drives, swing motor and machinery, rollers, idler, recoil spring, tracks, swing circle, revolving frame, center swivel, hydraulic tank, and control valve. Separate procedures address hydraulic cylinders, work equipment, the cab, glazing, monitor, and controller.

This chassis manual does not contain a complete internal engine overhaul; Komatsu directs the reader to the separate 102 Series Engine Shop Manual for detailed SAA6D102E-2 work. Main-pump coverage includes structure and operation, test and adjustment procedures, removal and installation, and input-shaft seal service, but not a full internal pump rebuild.

The tool tables identify equipment such as hydraulic gauge kit 799-101-5002, fuel-injection-pump puller 795-799-1390, track-shoe remover/installer 791-630-3000, and cylinder repair stand 790-502-1003. Control-valve notes warn that forcing the pressure-compensation piston before its seals are properly formed can damage them; the cylinder section flags piston-ring overexpansion and incorrect end-gap positioning as causes of ring damage during assembly. Residual hydraulic pressure must be released and raised components securely supported before circuits or major assemblies are opened.