1992 Komatsu PC200-5, PC200-5 MIGHTY, PC200LC-5, PC200LC-5 MIGHTY, PC220-5 & PC220LC-5 Excavator Shop Manual (P/N SEBM02050508)

Komatsu Shop Manual P/N SEBM02050508, printed 02-92, covers the 1992 PC200-5 and PC220-5 excavator families, including their LC versions and the PC200-5/PC200LC-5 MIGHTY variants. Coverage follows the model-specific serial ranges listed above.

Bookmarked PDF and Diagram Detail

Search, navigation and small labels: Embedded bookmarks provide access to the main chapters and component sections. PDF text search is not available. Small wire codes and connector labels on the large electrical circuit diagrams require zooming.

The download contains one printable 662-page PDF, including 28 preliminary pages with the original cover, contents, revision lists, safety information and reference tables. These pages are already included in the total.

Hydraulic Controls, Diagnostics and Component Repair

The following is a selection of covered topics. Further examples include lower-wiper circuitry and the horn circuit for PC200 MIGHTY machines.

• Hydraulic control testing: OLSS operation, TVC and CO/NC valve pressure checks, jet-sensor differential-pressure testing, PPC valve adjustment and work-equipment drift diagnosis.

• Electrical troubleshooting: PEMC and EMACC systems, controller self-diagnostic displays, E/C/F/H/P troubleshooting charts, connector locations and pin-connection tables.

• Pump and valve repair: Step-by-step procedures for HPV090+090 pump disassembly and assembly, control-valve service, PPC valve repair and boom holding valve overhaul.

• Final drive and swing: Final-drive teardown, bearing-clearance adjustment, travel-motor and swing-motor reassembly, swing machinery repair and swing-circle removal.

• Undercarriage and work equipment: Track-shoe removal, idler and recoil-spring service, roller replacement, hydraulic-cylinder rebuilding and boom, arm and bucket removal.

• Engine-related service: Valve-clearance adjustment, compression testing, fuel-injection timing checks, cylinder-head removal and installation, and engine assembly removal.

Written for service personnel carrying out workshop repairs, the manual includes operations requiring Komatsu special tools, hydraulic test equipment and suitable lifting equipment.

OLSS Testing and Fault Isolation

Structure and function explanations connect the variable-displacement pumps, control valves, travel motors and swing machinery with the checks used before and after repairs. Pump delivery-volume charts, cut-off control graphs and spool cross-section views explain how pump output changes with operating conditions.

Diagnostic judgement tables distinguish electrical faults from hydraulic or mechanical causes before component disassembly. Dedicated work-equipment drift checks help separate cylinder-packing faults from control-valve and boom holding valve problems.

The TVC adjustment section warns that forcing a stiff adjustment screw can break its tip.

Rebuild Checks and Serial-Specific Hardware

Main-pump instructions distinguish the front and rear servo pistons and cover matched component sets, contact-pattern inspection and shim selection. The special-tool list identifies the 790-445-2610 hook used for piston-shoe clearance checks.

Final-drive reassembly includes bearing-clearance and starting-force checks, together with the serial-specific cover-bolt replacement requirement listed above. The HMV160 travel-motor and KMF90-2 (AB) swing-motor sections cover internal assembly and brake components.

Center-swivel joint instructions identify the risk of damaging the slipper-seal and oil-seal lips during rotor installation. Undercarriage maintenance standards provide inspection criteria for track-frame guides, idlers, rollers, track links and pin/bushing fits.

Engine Scope, Fluids and Hydraulic Cleanup

Engine-related procedures include fuel-injection pump, nozzle-holder, turbocharger, thermostat, water-pump and crankshaft-seal replacement. For detailed internal engine repair, the cover directs users to the separate 95 Series Engine Shop Manual, which is not included in this download.

Lubricant and coolant charts distinguish specified capacities from refill quantities and separate serial-dependent data. Ambient-temperature charts support fluid selection.

Hydraulic flushing procedures distinguish metal contamination, component repair without metal debris, and reassembly after transportation. They include piping arrangements, filter requirements and PPC-circuit flushing.

Always observe standard shop safety protocols and completely relieve system pressure before interacting with hydraulic lines.

Preview of Valve Clearances and Travel-Motor End Play

Engine checks: For the S6D95L-1 and SA6D95L-1 engines, the judgement table lists valve clearances of 0.35 mm intake and 0.50 mm exhaust at normal temperature.

Travel-motor assembly: The HMV160 reassembly section specifies shaft end play of 0.05–0.25 mm and explains spacer selection when the measured clearance falls outside that range.