1996 Komatsu PC200-6, PC200LC-6, PC210LC-6, PC220LC-6 & PC250LC-6 Hydraulic Excavator Chassis Shop Manual (P/N CEBMX20601)

Komatsu chassis shop manual Form No. CEBMX20601 covers the PC200-6, PC200LC-6, PC210LC-6, PC220LC-6, and PC250LC-6 hydraulic excavators, each with serial numbers A80001 and up.

• Hydraulic diagnosis: CLSS operation, TVC and LS valve testing, pump-controller troubleshooting, hydraulic drift checks, leakage measurements, and air-bleeding procedures.

• Pump and valve repair: HPV95+95 main-pump disassembly and assembly, control-valve service, pressure-compensation valves, PPC valves, and center swivel joint repair.

• Travel and swing systems: Final-drive overhaul, travel-motor repair, swing machinery service, and swing-circle bearing clearance checks, with separate PC250LC-6 final-drive procedures.

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

• Engine-related service: Compression and blowby testing, valve-clearance adjustment, injection-timing checks, cylinder-head removal and installation, and cooling-system component replacement.

• Electrical troubleshooting: Engine throttle controller, pump controller, and machine monitor diagnostics, supported by wiring diagrams, connector pin tables, and electrical test specifications.

Written for service personnel performing workshop repairs, this manual assumes access to the specified measuring equipment, lifting equipment, and special tools.

CLSS Diagnosis and Hydraulic Component Repair

The Testing and Adjustment section separates TVC output-pressure checks from LS output-pressure and differential-pressure checks. Symptom-based charts address slow work equipment, engine stalling under hydraulic load, travel deviation, and excessive swing overrun.

These charts connect machine symptoms with electrical checks and hydraulic measurements, helping technicians distinguish control faults from pump or actuator problems before selecting a repair.

Hydraulic circuit diagrams identify early and later serial-number configurations. Hydraulic piping drawings and flow-control characteristic charts support circuit tracing, while the air-bleeding section distinguishes work on pumps, cylinders, swing motors, and travel motors.

The HPV95+95 overhaul instructions include contact checks for the cradle, rocker cam, cylinder block, and valve plate. Incorrect rocker-cam and cradle positioning during piston tightening can damage both parts; the assembly section identifies this specific repair risk.

Controller Fault Tracing and Electrical Tests

Troubleshooting is divided into E, S, C, F, H, and M modes for the engine throttle controller, engine, pump controller, controller input signals, hydraulic/mechanical systems, and machine monitor.

Electrical circuit diagrams and the pump-controller judgment table connect service-code indications with relevant components and checks. Connector-location drawings and pin-number tables support harness testing, and the tool list identifies T-adapter kit 799-601-8000 for wiring and sensor diagnosis.

Final Drives, Undercarriage, and Cylinder Work

The PC250LC-6 has its own final-drive disassembly and assembly instructions, separate from the other covered models. Component inspection tables provide clearances, spring data, and repair limits for assessing dismantled parts.

General assembly drawings show machine and working-range dimensions. Work-equipment service extends to hydraulic-cylinder seals and packings, with separate removal and installation procedures for the boom, arm, bucket, and their cylinders.

Mechanics should always verify that systems are fully depressurized and physically secured before inspecting components or applying these factory specifications on the shop floor.

Engine Service and the Separate Engine Volume

Engine-related work includes fuel-injection pump, turbocharger, water-pump, thermostat, and cylinder-head removal and installation. Cooling-system procedures distinguish the radiator and hydraulic-oil-cooler arrangements used across the model groups.

This is the chassis volume. Komatsu specifies separate chassis and engine volumes for complete repair coverage. The separate engine shop manual is not included, so this file should not be selected as a complete internal engine-overhaul manual.

A Preview of Track-Tension and Electrical Test Data

The track-tension procedure specifies a clearance between the track frame and track shoe of 303 ± 20 mm with the track frame raised. Measurement locations differ by model and are identified alongside the specification.

For the fuel control dial, the electrical standard-value table gives 4–6 kΩ between pins 1 and 3 of the male E06 connector, with the starting switch off and the connector disconnected.

Searchable Text, Bookmarks, and Diagram Detail

Search and diagram access: Most manual text is searchable, but some diagram and troubleshooting pages lack searchable text. Embedded bookmarks cover the main sections and many individual procedures; some entries are misdirected, and the Main Menu link points to a separate file that is not included. Small wiring labels require zooming, and some hydraulic labels and linework remain faint.

Supplied as one printable, English-language, 722-page PDF: 720 manual pages, one introductory page, and one manual-revision request form. Both additional pages are included in the total.