Komatsu PC200-7 & PC220-7 Excavator Shop Manual, 2005 (P/N SEBM024312)

Komatsu shop manual SEBM024312, cover-dated October 2005 and printed in Japan, covers PC200-7 and PC200LC-7 from serial 200001, plus PC220-7 and PC220LC-7 from serial 60001, with separate standard- and LC-undercarriage data.

PDF Search, Bookmarks, and Diagram Viewing

Text search and navigation: Much of the main text is searchable; some worksheet text and schematic labels are not. Embedded bookmarks cover the main sections; some individual links are missing or offset. Small wiring labels require zooming for clear reading.

The download contains one printable PDF with 810 pages, including the cover and five manufacturer revision-list pages.

Hydraulic Diagnosis and Workshop Repair: Selected Contents

This selected overview highlights the workshop coverage. Additional reference sections include tune-up service worksheets and push-pull coupler guidance.

• Engine testing: Speed adjustment, compression and blow-by checks, injection timing, lubrication checks, and symptom-based diagnosis of starting, smoke, and cooling faults.
• Hydraulic diagnosis: Pump-control checks, relief and pilot-pressure tests, cylinder-drift isolation, leakage measurement, and air bleeding after component work.
• Component repair: Step-by-step procedures for cylinder-head removal, final-drive and swing-machinery teardown, center-swivel service, and hydraulic-cylinder rebuilding.
• Undercarriage and structure: Track-tension adjustment, track and idler work, swing-circle and revolving-frame removal, work-equipment handling, and cab repairs.
• Electrical troubleshooting: Service-code diagnosis, monitor functions, controller and sensor tests, connector identification, and starting, charging, and air-conditioning circuits.
• Workshop references: Special-tool lists, component torque data, fluids and capacities, standard and service limits, adjustment specifications, and hydraulic and electrical test values.

Komatsu prepared this publication for service personnel performing workshop repairs. Hydraulic test equipment, electrical T-adapters, lifting gear, and model-specific tooling make it suited to technicians and experienced heavy-equipment mechanics familiar with safe machine isolation and component handling.

Engine Testing, Removal, and Cooling-System Work

The PC200 pair uses the SAA6D102E-2-A engine; the PC220 pair uses the SAA6D102E-2-C. Engine checks cover exhaust-gas color, valve clearance, compression, blow-by and oil pressure, fuel-injection timing, speed adjustment, and engine-speed sensor adjustment.

Removal and installation procedures cover the starting motor, fuel-injection pump, front and rear seals, cylinder head, radiator, oil cooler, and complete engine-and-pump group. For complete internal engine overhaul, Komatsu directs readers to the separate 102 Series Engine Shop Manual.

Hydraulic Controls, Drift Tests, and Seal Repairs

The hydraulic chapters explain the HPV95+95 pump, CLSS, PC/LS and EPC controls, six-spool main control valve and optional service valve, PPC valves, and boom, arm, and bucket cylinders. Swing and travel coverage includes the KMF125ABE-5 swing motor and HMV110ADT-2 travel motors.

Testing and adjustment includes main and swing relief pressures, control and PPC pressures, pump PC/LS circuits, cylinder and motor leakage, and air bleeding. Drift-isolation checks distinguish cylinder-packing leakage from control-valve faults, helping identify the component requiring attention.

Repair scope: Main-pump procedures cover removal, installation, and input-shaft seal replacement; a complete internal rebuild is outside their scope. Control-valve coverage includes removal, installation, pressure-compensation seal replacement, and reassembly precautions.

Control-valve notes warn that forcing a pressure-compensation piston before its seals are properly formed can damage them. Cylinder-rebuilding instructions flag excessive piston-ring expansion and incorrect end-gap positioning as causes of ring damage.

Final Drives, Swing Machinery, Undercarriage, and Cab

Chassis procedures cover final drives, swing motor and machinery, rollers, idler, recoil spring, tracks, swing circle, revolving frame, center swivel, hydraulic tank, and work equipment. Cab work includes glazing, front-window adjustment, monitor replacement, and controller replacement.

Serial-specific assembly: Swing-machinery procedures change at PC200/PC200LC serial 203890/203891 and PC220/PC220LC serial 60353/60354. The early procedure includes conversion from grease-lubricated to oil-lubricated bearing components. Work-equipment PPC-valve reassembly changes at PC200/PC200LC 202418/202419 and PC220/PC220LC 60239/60240.

Specifications separate dimensions, working ranges, weights, and cylinder data by model. Standard-machine entries use 600 mm base shoes; LC entries use 700 mm shoes.

Fault Codes, Monitor Functions, and Serial-Matched Wiring

Troubleshooting follows displayed service and failure codes, electrical E-mode, hydraulic/mechanical H-mode, and engine S-mode charts. It addresses controller power supplies, pump sensors, S-NET communication, EPC solenoids, weak work equipment, travel and swing faults, and engine starting, smoke, lubrication, and cooling complaints.

Monitor functions: Both multi-monitor and 7-segment sections explain live monitoring, service codes, governor adjustment, and attachment setup. Multi-monitor coverage also includes abnormality and maintenance records and pump-absorption-torque adjustment.

Electrical serial breaks occur at PC200/PC200LC 250000/250001 and PC220/PC220LC 65000/65001. Early machines have separate four-sheet circuits for multi-monitor and 7-segment configurations; later machines use a revised four-sheet set. Serial-matched machine and air-conditioner wiring helps avoid mixing early and late electrical builds.

Diagram references include the Hydraulic Equipment Layout Drawing, PC200 and PC220 Hydraulic Circuit Diagrams, Machine Control System Diagram, Monitor Panel System Circuit Diagram, and Governor and Pump Control System Circuit Diagrams. Connector Location Stereograms, pin tables, and wire-code references support component and terminal identification.

Special Tools and Component Handling

Tool tables identify 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. The repair sections specify residual-pressure release and secure support of raised components before opening circuits or removing major assemblies.

Selected Valve and Swing-Bearing Clearance Data

For the SAA6D102E-2 engines in all four models, the valve-clearance tables specify 0.25 mm intake and 0.51 mm exhaust at normal temperature.

The swing-circle maintenance standards list 0.5–1.6 mm standard axial bearing clearance, with the bearing mounted on the chassis, and a 3.2 mm clearance limit for all four models. A separate procedure explains the on-machine dial-gauge measurement.