Komatsu PC200, PC210-3, PC220, PC240-3 Excavator 1995–2008 Shop Manual (P/N SEBM02050309)

This Komatsu factory shop manual, P/N SEBM02050309, covers PC200/PC200LC-3, PC210/PC210LC-3K, PC220/PC220LC-3, and PC240/PC240LC/PC240NLC-3 and -3K. Check the serial-number coverage above against your machine.

PDF Search, Bookmarks, and Diagram Detail

Search and navigation limits: PDF text search is not available. Numbered page bookmarks provide limited navigation, but section-tab entries have no active destinations and appended-sheet bookmarks are unlabeled. Small wiring and hydraulic schematic labels require zooming.

One printable English-language PDF contains 765 pages, including the original cover, revision lists, blank pages, 10 revision-form/reverse pages, and a 22-page appended diagram/reference section.

Engine Tests, OLSS Hydraulics, and Component Repair

The selected coverage below highlights major shop procedures rather than reproducing the full contents. Further topics include exhaust-smoke measurement and fuel-control-lever sensor adjustment.

• Engine service: Compression and blow-by testing, injection-timing checks, valve adjustment, cylinder-head removal/installation, and engine/main-pump assembly removal/installation.

• OLSS hydraulics: 2-stage and 3-stage mode-selector systems, pressure testing, main-pump and charging-pump service, internal-leakage checks, air bleeding, and control-valve repair.

• Travel and swing: Step-by-step center-swivel-joint and travel-motor service, final-drive and swing-machinery disassembly, swing-circle replacement, and bearing adjustment.

• Undercarriage: Recoil-spring disassembly/assembly, idler and roller replacement, track-shoe removal/installation, and component maintenance standards.

• Electrical diagnosis: EVMS fault isolation, self-test display checks, E2–E6 electrical charts, H1–H14 and H16 hydraulic/mechanical charts, connector-pin tables, and serial-specific wiring diagrams.

• Cylinders and major assemblies: Boom, arm, and bucket cylinder repair; work-equipment, cab, and counterweight removal/installation; component-specific torques, fluid data, clearances, and wear limits.

Because the procedures assume hydraulic test equipment, specialty adapters, precision measurement, and controlled lifting of major assemblies, this factory shop manual is suited to professional technicians and experienced heavy-equipment mechanics.

Serial-Specific Procedures and Schematics

For pages 11-1 and later, the cover adds PC210-3 to the PC200-3 S/N 21464-and-up listing and PC240-3 to the PC220-3 S/N 26365-and-up listing. Machine-monitor coverage changes at PC200-3 S/N 30310 and PC220-3 S/N 22628.

Hydraulic schematic applicability has separate breaks. OLSS sheets split at PC200-3 S/N 26988 and PC220-3 S/N 21818, while a wrist-control/long-lever sheet starts at PC200-3 S/N 24684 and PC220-3 S/N 21135. These distinctions help match the diagnostic chart, connector layout, and valve arrangement to the machine.

Engine Service and Repair Limits

Engine data is split between the S6D105-B-1 for PC200/PC210 listings and the S6D105-1 for PC220/PC240. Standard and permissible-value tables organize performance, intake/exhaust, lubrication, fuel, and cooling-system data by engine family.

Engine structure coverage identifies the mounts and attached parts, radiator and cooler, damper, fuel tank and piping, engine control, and optional auto-deceleration system. Separate procedures cover starter, alternator, engine oil cooler, injection pump, water pump, nozzle-holder, turbocharger, radiator, hydraulic oil cooler, and damper removal and installation.

Engine overhaul scope: Coverage reaches cylinder-head and engine/main-pump assembly removal and installation, but this is not a complete bare-block overhaul manual for either covered S6D105 engine.

Pump, Valve, and Cylinder Repair

The hydraulic chapters explain work-equipment control, the front and rear main-pump system, PPC pilot circuits, TVC/CO/NC pump-control valves, the accumulator, and valve banks.

Main-pump repair: Step-by-step procedures cover the HPV090 + 090 assembly, including bearing and shim adjustments, swash-plate settings, and contact checks between the cylinder block and valve plate and between the rocker cam and cradle. Charging-pump references identify the BAR25.

Valve and cylinder work: Repair depth extends to control-valve disassembly, individual valve work, boom/arm/bucket cylinder overhaul, and complete work-equipment removal and assembly. Maintenance standards add inspection limits for hydraulic components and work-equipment joints.

The travel-deviation diagnosis distinguishes center-swivel sealing faults from pump, control-valve, and travel-motor faults, linking the symptom to the component requiring further inspection.

Drivetrain and Undercarriage Details

Swing-motor procedures distinguish assemblies with and without a swing mechanical brake. Final-drive assembly instructions separate shim-type and spacer-type bearing-clearance adjustment by machine serial number. Maintenance standards cover travel and swing parts as well as the undercarriage.

Power-train scope: Section 22, Testing and Adjusting, is not included in this PDF; the power-train material runs from Section 21 directly to Section 23.

Circuit Diagrams and Fault Isolation

Named references include the Travel and Brake System circuit and sectional views, Hydraulic Piping – Wrist Control Type, and Hydraulic Schematics – Wrist Control/Long Lever Control Type.

Appended reference sheets include the 2-Stage and 3-Stage Mode Selector OLSS Function Chart, Connector Position for Troubleshooting, and serial-specific Electrical Circuit Diagrams. The diagnostic material connects self-test displays and electrical measurements with hydraulic/mechanical fault charts; machine-monitor troubleshooting has separate earlier and later serial-number sections.

Special Tools and Assembly Precautions

Factory tool tables identify the multi-tachometer P/N 799-203-8000, engine pressure measuring kit P/N 799-203-2002, and cylinder repair stands P/N 790-502-2000 or 790-502-1001. Hydraulic diagnostics also list the tester, thermistor kit, measuring cylinder, replacement valves, and KES plugs and adapters.

Careless center-swivel rotor installation can damage the slipper-seal and oil-seal lips. The hydraulic-cylinder procedures warn that reversed packing, a forced slipper seal, or careless press-fitting can damage packing, dust seals, O-rings, or deform the cylinder-head bushing.

Hydraulic repair requires stored-pressure release and secured work equipment. Cab, counterweight, engine/main-pump, cylinder, and track-component handling requires suitable lifting and holding equipment; testing sections also address hot-coolant and rotating-fan hazards.

Valve-Clearance and Compression Data Preview

For the covered S6D105-B-1 and S6D105-1 engines, the valve-clearance tables specify 0.25 mm intake and 0.45 mm exhaust at 20°C.

Compression-test tables give a standard minimum of 31.5 kg/cm² and a permissible value of 22 kg/cm² at 320–360 rpm, with engine oil at 40–60°C. These entries accompany the compression-testing procedure and its measurement conditions.