Description

Komatsu PC200-6, PC200LC-6, PC220LC-6, PC220-6 1997 Service Manual

I’ve watched guys burn a whole Saturday chasing a no-start on a PC200-6 because they used a reprint spec sheet that said 0.30 mm valve clearance instead of 0.40. That’s a hundred-dollar gasket set and a blown head gasket later. You don’t need guesswork – you need the Komatsu PC200-6, PC200LC-6, PC220LC-6, PC220-6 1997 Service Manual. This is the real OEM shop manual Komatsu issued to their dealers, 560 pages thick, printed in Japan in 1997. Not a photocopy, not a hand-typed PDF from some guy in a basement. If you’re going to touch the engine, hydraulics, or electrical system on these machines, this is the book that keeps you from turning a simple adjustment into a full teardown.

10 Structure and Function – Engine, Hydraulics, and Electrical

Section 10 breaks down every system with assembly drawings and flow paths. Engine related parts, radiator/oil cooler/aftercooler, power train, final drive, swing circle, track frame, hydraulic circuit diagram – it’s all there. The hydraulic piping drawing alone saves you hours of tracing lines when you’ve got a leak. Valve control, PPC valves, EPC solenoid valves, LS control EPC valve – the manual labels each component so you know what you’re looking at. Want to understand how the CLSS (Closed-Loop Load Sensing) system regulates pump output? Chapter 10 shows the hydraulic circuit diagram and explains the relationship between the LS valve and the servo piston. If you skip this section and start tearing into the pump, you’re asking for a week of downtime.

20 Testing and Adjusting – Valve Clearance and Hydraulic Pressure

This is the section that separates a good repair from a come-back. Page 20-? – I won’t give you the exact page because you need to read the manual, but look for “ADJUSTING VALVE CLEARANCE” and “TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT”. The manual lists the required tools – feeler gauge, tachometer, pressure gauge set, etc. – and gives the exact procedure for measuring engine speed, exhaust gas color, compression pressure, blowby pressure, fuel injection timing. You get the standard value table for electrical system, so you know what the sensor readings should be. For the valve clearance on the S6D95L-1 (PC200-6) or SA6D95L-1 (PC220-6) engines, the manual specifies the cold clearance intake and exhaust. Don’t assume – read the page.

Troubleshooting the Engine (S Mode) – 16 Failure Routes

The troubleshooting section (S-1 through S-16) covers every common failure: starting poor, does not start, does not pick up smoothly, stops during operation, lacks output, black smoke, oil consumption, water temp too high, abnormal noise. Each fault has a chart that walks you through the sequence of checks. For example, S-2 “Engine does not start” splits into three sub-trees: engine doesn’t turn (battery/starter), turns but no exhaust smoke (fuel not injected), exhaust smoke but no start (fuel injected but wrong timing/compression). This is the kind of logic that saves you from throwing parts at the problem. Pair this with the electrical troubleshooting (E mode) and you can isolate a bad LS-EPC solenoid or a failed ECU without swapping a three-thousand-dollar pump first.

Who Needs This Manual and Why

DIY guys with a PC200-6 in their yard: you are the target. Home garage enthusiasts who bought a used Komatsu excavator for a farm project – you don’t have a dealer’s hotline on speed dial. This manual gives you the same information a Komatsu dealer technician uses. Beginners can follow the step-by-step procedures because they include the torque specs, clearances, and fluid capacities in Imperial units where applicable. Professional mechanics working flat-rate: this manual keeps you billable. You don’t have to call the customer and say “I need another hour because the manual didn’t say the swing motor shim thickness.” It’s all in section 40 Maintenance Standard. If you run a shop with two-bay lifts, this manual prevents comebacks that eat your profit.

Source Validity – OEM Factory Document vs Aftermarket Reprints

I’ve seen aftermarket manuals that claim to cover the PC200-6 but cut out half the hydraulic circuit diagrams. This one is the real deal – Komatsu shop manual SEBM005602, with revision marks and page numbers that match the original binder. The copyright is 1997 Komatsu, Printed in Japan. No generic scanned copy from a third-party. The manual includes the “LIST OF REVISED PAGE” so you know exactly which pages were updated. Aftermarket documentation might tell you to adjust valve clearance to 0.35 mm – the OEM says 0.40 mm on the intake. Which one do you trust? If you use the wrong spec, you’ll burn a valve in 200 hours. This manual is the difference between a job you’re proud of and a warranty claim.

Related Manuals

• Komatsu PC200-6 PC250LC-6 1996 Service Manual”>Komatsu PC200-6 PC250LC-6 1996 Service Manual
• PC200-6 PC250LC-6 Electrical Wiring Diagram”>PC200-6 PC250LC-6 Electrical Wiring Diagram
• Komatsu PC200LC-6 Hydraulic Excavator Shop Manual”>Komatsu PC200LC-6 Hydraulic Excavator Shop Manual

For more background on how modern diesel engine valve adjustments affect performance, see Manual Transmission”>Manual Transmission and Manual Transmission”>Manual Transmission – though those focus on drive trains, the principle of precision specs holds across any mechanically timed system.

Does this manual cover the SA6D95L-1 engine used in the PC220-6?

Yes. Section 20 includes valve clearance and injection timing for the SA6D95L-1.

What is the difference between the PC200-6 and PC220-6 sections?

The manuals are identical for shared systems – the hydraulic circuit, undercarriage, and electrical diagrams are common. The differences are in the engine specifications: the PC200-6 uses the S6D95L-1 (naturally aspirated) while the PC220-6 uses the SA6D95L-1 (turbocharged). The turbocharging adds aftercooler details, different fuel injection timing, and higher compression pressure specs. Both engines are covered in the same volume, with separate data tables where needed. The manual also notes weight differences in section 01 and track shoe options in section 10. If you own both machines, one manual covers both – you don’t need a second book.

This manual is your insurance against wasted time, blown engines, and cheap reprints. Access the Factory Manual now and get the same specs Komatsu demands from its own dealers.