Komatsu PC200-7, PC200LC-7, PC200-7B, PC200LC-7B, PC220-7, PC220LC-7 Hydraulic Excavator Operation and Maintenance Manual (P/N SEAM041000T)

Komatsu's March 2002 GALEO Operation & Maintenance Manual, P/N SEAM041000T, covers the PC200-7, PC200LC-7, PC200-7B, PC200LC-7B, PC220-7 and PC220LC-7 hydraulic excavators within the serial ranges listed above.

Printable PDF with Search and Chapter Bookmarks

Text search and illustrated references: The main operating and maintenance text is searchable, with embedded bookmarks for chapters and individual procedures. The two emissions-information pages lack searchable body text, and the MAIN MENU bookmark requires a separate file. Small callouts in the connection drawings are readable when enlarged.

One printable, 311-page PDF, primarily in English. The total includes the front and back covers, two bilingual emissions-information pages and six memo pages.

Operating Controls, Routine Service and Attachment Setup

This selection of covered topics highlights the main operating and service sections. Trailer loading and long-term storage are further examples of the material included.

• Monitor and controls: Working modes, auto-deceleration, control-pattern illustrations, and oil-pressure, coolant and hydraulic-temperature warning displays.

• Fuel, air and cooling: Step-by-step instructions for water-separator service, air-cleaner maintenance, oil/filter changes and cooling-system flushing.

• Hydraulic maintenance: Pump, cylinder, swing-motor and travel-motor air bleeding, hydraulic filter replacement, tank-strainer cleaning and pressure-release guidance.

• Undercarriage and bucket: Track-tension adjustment, track-shoe bolt checks, bucket replacement/inversion, vertical- and horizontal-pin tooth replacement, and bucket-clearance adjustment with split shims.

• Attachment equipment: Breaker and crusher circuit selection, mounting/dismounting procedures, oil-flow settings, and operating guidance for trapezoidal and clamshell buckets.

• Troubleshooting and references: Electrical, chassis and engine fault charts, maintenance schedules, torque lists, wear-parts data and attachment compatibility tables.

The manual is intended for operators and maintenance personnel; Komatsu specifies that machine operation and maintenance require trained, authorized personnel.

Monitor Warnings and Fault Identification

The monitor section explains heavy-load, economy, fine-control and breaker modes, along with maintenance reminders and cold-weather starting and warm-up procedures.

The electronic-control table distinguishes E02 pump-control errors, E03 swing-brake faults, E05 governor faults and CALL warnings. Matching the display to its countermeasure entry helps identify the system involved and when Komatsu service is required. Emergency pump-drive and swing-brake cancel switches are described for temporary operation, not as completed repairs.

Fuse-capacity and circuit-name tables, fusible-link information and booster-cable connection drawings support basic electrical checks. Full-machine electrical wiring diagrams are not included.

The air-conditioner section includes sensor and damper self-diagnosis, refrigerant sight-glass checks and cabin-filter maintenance. Refrigerant replenishment is referred to a service provider.

Service Planning and Component Care

Daily walk-around checks and interval-service instructions give operators and maintenance personnel a common reference for planning routine work. Lubrication-point diagrams identify boom-cylinder, arm-cylinder and bucket-linkage locations; undercarriage checks include track rollers, sprockets and idlers.

Service instructions cover swing-machinery and final-drive oil changes, hydraulic-tank breather replacement, and cleaning radiator, oil-cooler and condenser fins. Fluid-selection charts, antifreeze mixing tables and KOWA oil-sampling guidance support lubricant and coolant planning.

Work referred to Komatsu service: Turbocharger checks, alternator and starting-motor service, valve-clearance adjustment, vibration-damper work and water-pump inspection or overhaul are service referrals, not detailed repair procedures. Fuel-injection pump faults appear in troubleshooting with distributor-directed remedies.

The fuel-filter instructions warn that overtightening can damage the packing and cause leakage.

Attachment Circuits and Hydraulic Precautions

For attachment-ready machines, the Hydraulic Circuit Connection drawings and Path of Oil illustrations accompany explanations of one-way breaker and two-way crusher circuits. Breaker use has a separate maintenance-interval graph because it accelerates hydraulic-oil deterioration.

Working-range charts and track-shoe selection tables help relate machine configuration to the job. The attachment guide also addresses accumulator handling and the clearance restrictions of extension-arm equipment.

Hydraulic air-bleeding instructions identify a specific risk: trapped air in the swing motor can damage its bearings. Always review the manual's high-pressure hydraulic precautions, safety-label diagrams and bucket-lifting guidance before maintenance.

Examples of Track and Compressor-Belt Check Data

The track-tension section specifies 10–30 mm (0.4–1.2 in) of deflection between the track top and the underside of a reference block spanning the idler and carrier roller, with the machine on firm, level ground.

For machines equipped with air conditioning, compressor-belt data specify 5–8 mm (0.20–0.31 in) of deflection under approximately 58.8 N (6 kgf), measured midway between the drive and compressor pulleys.