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

• This 765-page English-language PDF is identified as Komatsu Manual No. SEBM02050309 and covers PC200/PC200LC-3 from S/N 20001, PC210/PC210LC-3K from K10001, PC220/PC220LC-3 from S/N 20001, PC240/PC240LC/PC240NLC-3 from S/N 10001, and PC240/PC240LC/PC240NLC-3K from K10001.
• Engine data is split between the S6D105-B-1 for PC200/PC210 listings and the S6D105-1 for PC220/PC240. Procedures cover compression and blow-by testing, injection-timing checks, valve adjustment, cylinder-head removal and installation, and engine/main-pump assembly removal and installation.
• Covers 2-stage and 3-stage mode-selector OLSS hydraulics through main-pump and charging-pump service, pressure testing, travel-deviation diagnosis, internal-leakage checks, air bleeding, control-valve work, and hydraulic-cylinder repair.
• Follows major power-train and undercarriage work from center-swivel-joint and travel-motor service through final-drive and swing-machinery disassembly, then covers recoil springs, idlers, rollers, and track-shoe removal and installation with maintenance standards.
• Provides EVMS and machine-monitor fault isolation, self-test display checks, E1-E6 electrical and H1-H16 hydraulic/mechanical troubleshooting charts, connector-pin tables, component-location views, and serial-specific wiring diagrams.
• Includes work-equipment, operator's cab, and counterweight removal/installation, plus specialty-tool listings, component-specific torque specifications, fluid and lubricant 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 Coverage

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, Hydraulic, and Drivetrain Repair Depth

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, oil cooler, injection pump, water pump, nozzle-holder, turbocharger, radiator, hydraulic oil cooler, and damper removal and installation. Standard and permissible tables organize performance, intake/exhaust, lubrication, fuel, and cooling-system data by engine family.

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. Repair depth extends to main-pump and control-valve disassembly, individual valve work, boom/arm/bucket cylinder overhaul, and complete work-equipment removal and assembly. Maintenance-standard sections add inspection limits for travel and swing parts, hydraulic components, and the undercarriage.

Diagrams, Diagnostics, and Shop Data

Named visual 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. Full-page reference sheets also include the 2-Stage and 3-Stage Mode Selector OLSS Function Chart, Connector Position for Troubleshooting, and a serial-specific Electrical Circuit Diagram.

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.

The center-swivel assembly cautions that careless rotor installation can damage the slipper-seal and oil-seal lips. The hydraulic-cylinder pages 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.

Scope and Safety Limits

Power Train Section 22, Testing and Adjusting, appears in the master contents but is absent from this PDF, which runs from Section 21 directly to Section 23. Engine coverage reaches cylinder-head and engine/main-pump assembly removal and installation, but it is not a complete bare-block overhaul manual for either covered S6D105 engine.

Working on heavy excavators involves serious physical hazards. Before hydraulic repair, stored pressure must be released and the work equipment secured. Removing the cab, counterweight, engine/main-pump assembly, cylinders, or track components requires suitable lifting and holding equipment; the testing sections also flag hot-coolant and rotating-fan hazards.