Description

Komatsu PC200-5, PC220-5 1993 Workshop Manual

You’ve got a PC200-5 or PC220-5 that’s lost its swing, or the hydraulic drift is pulling your hair out. The aftermarket PDF you pulled says “refer to factory spec” – but that’s exactly what you paid for and didn’t get. This 473-page OEM manual from Komatsu is what your shop needs on the bench. It’s not a reprint from some third-party copier; it’s the actual factory document, scanned from the original 1993 print. Every torque value, every clearance, every electrical pinout is Komatsu-sourced. I’ve watched guys chase boom drift for two days because they had a wrong spec from a forum. That doesn’t happen with this book.

Before you touch a wrench, read the SAFETY LOCK VALVE section and the ACCUMULATOR procedure. You’ll find them in the 10 STRUCTURE AND FUNCTION chapter. I’ve seen too many people skip the pressure release step and get a faceful of hydraulic oil. This manual shows you the sequence, including the tools you need: a 6000 psi gauge, a flow meter, and the Komatsu service tool adapter. If you don’t have those listed on page 20-2, stop and get them.

Structure and Function: Power Train, Swing Circle, and Track Frame

The manual opens with a thorough breakdown of every major assembly – from the FINAL DRIVE to the SWING CIRCLE. Each component has exploded views and torque callouts. Need to know the bolt torque for the sprocket? It’s in the TRACK FRAME AND RECOIL SPRING section. The SWING MACHINERY chapter includes shim selection for the swing gear backlash. You’ll also get the CENTER SWIVEL JOINT seal replacement procedure – a job that costs shops three hours of labor if they don’t have the correct O-ring dimensions. Every Valve in the control valve bank is labeled with its pilot pressure range. And the HYDRAULIC CYLINDER disassembly steps show you how to support the rod without damaging the chrome surface.

What Compression Pressure Should You Expect?

Section 20, TESTING AND ADJUSTING, starts with a table of judgement standard values. For the 6D105 engine, compression pressure at cranking speed should be 400–480 psi (28–34 kg/cm²). The valve clearance adjustment procedure on page 20-22 gives the intake (0.014 in) and exhaust (0.020 in) specs. If you’re resetting fuel injection timing, the manual walks you through the dial indicator method – not the BS guesswork you see on YouTube. Check the MEASURING COMPRESSION PRESSURE section for the exact gauge thread adapter (14 mm x 1.25).

473 Pages of OEM Data: Why Aftermarket Manuals Fail

I’ve had customers bring me copies of reprints that skip entire pages of the wiring diagram. This manual has every Electrical circuit in full – the ELECTRICAL CIRCUIT DIAGRAM covers the EMACC controller, the engine throttle controller, and the monitor panel. If you’re diagnosing a swing lock solenoid that won’t cancel, you’d use the Connector Connection Table on page 20-72 to check pin continuity. The Troubleshooting of Electrical System (C Mode) section lists C-1, C-2, and C-3 faults with step-by-step tests. The aftermarket books don’t have this depth. They leave out the self-diagnosis function action table. That’s how you waste a day chasing a bad relay when it’s actually the controller ground.

Hydraulic Pressure Testing: Work Equipment, Swing, Travel Circuit

When you’re setting main relief pressure, the manual says: connect a gauge to the pump output, run the engine at high idle, operate the work equipment to stall, and read the pressure. The standard is 4550 psi (320 kg/cm²) for the work equipment circuit. The table also lists swing motor relief at 3980 psi (280 kg/cm²). The TESTING AND ADJUSTING CHARGING PUMP PRESSURE procedure tells you to check the pilot pressure at the PPC valve – 430 psi (30 kg/cm²) at the outlet port. If you’re adjusting the MAIN PUMP CONTROL PRESSURE, you’ll need a 100 psi gauge and a 1/8” BSPT fitting. The manual doesn’t assume you already know; it tells you the exact port location, the wrench size, and the sequence for bleeding air after service.

Troubleshooting by the Numbers: E Mode, C Mode, H Mode

The troubleshooting section is where this manual really earns its keep. The E Mode (engine throttle controller) has ten fault codes: E-1 through E-10. For E-7 (engine does not start), the manual checks the fuel control dial voltage, the governor motor wiring, and the battery relay. For C Mode electrical faults, C-2 covers the swing lock not canceling: test the solenoid valve outlet port pressure (must be 0 psi when locked, 430 psi when unlocked). The H Mode hydraulic/mechanical section lists H-1 through H-13, including H-4 (work equipment lacks power) and H-10 (excessive hydraulic drift). Each fault has a judgement table and a flowchart. If you follow the sequence – check the pilot pressure first, then the main relief, then the cylinder bypass – you’ll find the problem in half the time. I’ve used these charts on a PC200-5 that had a stuck shuttle valve; the manual pointed me to the PPC SHUTTLE VALVE test on page 20-45.

Related manual you might need: Komatsu PC200 PC220-5 Workshop Manual. For the earlier models with more mechanical controls, see Komatsu PC200, PC200LC, PC220, PC200-5 Workshop Manual | 662 Pages. If you’re working on a wheel loader, Komatsu WA65-5 WA70-5 WA80-5 2005 Workshop Manual covers those power trains. For basic theory on Manual Transmission operation, you can find that online, but this manual has the specific torque specs for the final drive pinion nut (page 20-10).

One more thing about safety: the RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT procedure is on page 20-55. Do not skip that step. I’ve seen accumulator pressure hold for weeks. That section also tells you to cycle the attachment, let the engine cool, then crack the pilot line. The BLEEDING AIR procedure after cylinder replacement is equally important – a skipped bleed can cause foam in the oil and damage the pump.

Access the Factory Manual now and stop fighting with secondhand specs. This is the same book that Komatsu service departments use. If you’ve got a 1993 PC200-5 or PC220-5, this is the only manual you need.

Does this manual cover the PC220-5 as well?

Yes, it covers both PC200-5 and PC220-5.

Are torque values provided for the swing motor mounting bolts?

The manual includes a Table of Judgement Standard Value on page 20-1, which lists tightening torques for all major components including the swing motor, travel motor, and control valve. You’ll find specific ft-lb values for every threaded fastener in the hydraulic and powertrain assemblies. For example, the swing motor mounting bolts are torqued to 166 ft-lb (225 N·m) per the factory spec. This is not a generic range; it’s the exact value from Komatsu’s engineers.

What years does this manual apply to?

1993 model year, but covers all serial numbers within that production run.

Can I use this for troubleshooting electrical faults?

Yes. Section 10 contains the complete Electrical Circuit Diagram, and the Troubleshooting section (starting page 20-55) has self-diagnosis codes for the EMACC and engine throttle controller. The connector position tables are critical for pin-to-pin checks. The C Mode section alone covers three specific electrical faults with wiring diagrams.

Related manual: Komatsu PC200 PC220-5 Workshop Manual – also for Komatsu PC200, PC200LC, PC220, PC200-5 Workshop Manual | 662 Pages and Komatsu WA65-5 WA70-5 WA80-5 2005 Workshop Manual. For general knowledge on Manual Transmission theory, refer to trusted sources, but this manual has the actual Komatsu specs.