2007 and Up Komatsu PC200-8, PC200LC-8, PC220-8, PC220LC-8 Excavator Shop Manual (P/N SEN00084-07)

Komatsu shop manual SEN00084-07 covers the 2007 and newer PC200-8, PC200LC-8, PC220-8, and PC220LC-8 GALEO hydraulic excavators. This chassis volume combines structural information, maintenance standards, testing, troubleshooting, and repair procedures.

• Engine and fuel system: Removal and installation of the fuel supply pump, fuel injectors, cylinder head, engine seals, and engine assembly.

• Cooling system: Radiator, hydraulic oil cooler, aftercooler, and fuel cooler removal and installation, with component specifications.

• Hydraulic service: Pressure testing, air bleeding, cylinder and center swivel joint disassembly and assembly, plus control-valve removal and reassembly precautions.

• Drivetrain and undercarriage: Final-drive and swing-machinery disassembly and assembly, with idler, recoil-spring, carrier-roller, and track-roller service.

• Electrical systems: Failure-code tables, wiring diagrams, and removal and installation of the engine controller, pump controller, monitor, and KOMTRAX communication modem.

• Cab and accessories: Operator's cab and front-window removal, bonded-glass replacement, air-conditioner diagnosis, and air-conditioner unit removal and installation.

This manual suits heavy-equipment technicians familiar with hydraulic and electrical diagnosis and equipped to use the specified gauges, service adapters, and lifting equipment.

Engine, Fuel System, and Cooling

Testing procedures cover valve-clearance adjustment, compression and blow-by measurements, fuel-return and leakage tests, fuel-circuit air bleeding, and fan-belt replacement. Radiator and aftercooler specifications accompany the cooling-system repair information.

Engine coverage: The chassis volume includes cylinder-head and crankshaft-seal removal and installation. Full internal engine overhaul requires the separate engine volume, which is not included.

Fuel-system cautions address contamination of common-rail components and internal hose-adapter damage during removal.

Hydraulic Diagnosis and Component Work

The HPV95+95 pump and CLSS sections explain PC/LS regulation, solenoid outputs, and PPC controls. Hydraulic-drift tests distinguish cylinder-packing leakage from control-valve faults, helping identify which assembly needs attention before teardown.

Pump service includes removal and input-shaft oil-seal replacement. Control-valve instructions cover pressure-compensation valve seal replacement and reassembly precautions; the work-equipment and travel PPC valve chapters are limited to assembly precautions.

Center-swivel reassembly cautions explain how rotor installation can damage the dust seal and O-ring. Working on this equipment involves high hydraulic pressures and heavy loads; follow the manual's pressure-release and lifting precautions.

Final Drives, Swing Gear, and Undercarriage

Travel motors, final drives, and swing machinery have structural references, while separate final-drive repair procedures distinguish the PC200/PC200LC and PC220/PC220LC assemblies.

Maintenance tables give clearances, interference fits, and wear limits for the swing circle and undercarriage components, including the track frame, idlers, recoil springs, and rollers. Service procedures supply component-specific tightening torques.

Track-shoe tension checks and swing-circle bearing-clearance measurements are also covered.

Electrical Fault Tracing and Diagrams

Failure-code charts connect symptoms to sensor, harness, and controller checks. Intake-air/boost-pressure sensor diagnosis uses voltage and wiring-resistance tests; machine-monitor service functions support engine, pump-control, and KOMTRAX troubleshooting.

The drawings include separate PC200/PC200LC and PC220/PC220LC hydraulic circuits, the main electrical circuit, connector arrangements, and the air-conditioner circuit. Hydraulic equipment layouts, machine-dimension drawings, and working-range diagrams provide additional reference.

A Preview of Recoil-Spring and Swing-Bearing Standards

These examples are a small selection of the manual's component inspection data.

Recoil-spring standard installation load is 109.3 kN at an installed length of 417 mm for PC200-8. PC200LC-8, PC220-8, and PC220LC-8 use 126.5 kN at 433 mm.

With the swing circle mounted on the chassis, all four models have a standard bearing axial clearance of 0.5–1.6 mm and a clearance limit of 3.2 mm.

PDF Search, Bookmarks, and Diagram Viewing

Finding text and circuit detail: Text search works through the main written sections, but many diagram labels and connector tables are not searchable. Embedded bookmarks link to sections and procedures; small labels in the large circuit drawings require zooming.

The manual is supplied as one printable, English-language 1,082-page PDF. That total already includes the original cover, 35 section title pages, 35 publication pages, and 42 blank or header/footer-only pages.