Description

Komatsu PC200, PC210, PC220, PC230, 200LC-7 Technical Manual

You’ve got a Komatsu PC200 or PC210 on the lift with a dead main pump. The aftermarket PDF you found shows a different pump layout. Now you’re staring at the EPC valve assembly wondering which line goes where. That’s where this factory Komatsu PC200, PC210, PC220, PC230, 200LC-7 Technical Manual comes in. Thirty pages of pure disassembly and assembly procedure for the HPV95+95 pump. Every step, every special tool, every sequence – lifted straight from Komatsu’s publication SEBH800700. No reverse-engineered garbage.

Special Tools: What You Need Before Starting

The first thing you’ll notice in this manual is the List of Special Tools (page 2). It’s not a suggestion – it’s a requirement. Komatsu specifies a unit repair stand (790-501-5000 for 100V), specific plates, push tool kits, and collars for retracting PC valve seals. If you skip the tool list, you’ll fight the pump housing and likely damage the needle bearings. I’ve seen techs try to press out seals with a socket – that’s how you score the bore. The manual even provides rough sketches for each special tool (page 3), so if you’re in a remote shop you can fabricate your own. But Komatsu makes it clear: they don’t take responsibility if you machine it wrong. Pay attention to the ‘Necessity’ column – some tools are mandatory, others are convenient. The tool part numbers are genuine Komatsu, with N/R designations to show what’s new or revised. This is the kind of detail you won’t find in a generic guide.

Main Pump Disassembly Sequence

The disassembly procedure for the main pump assembly starts on page 4. Step one: mount the plate for the front pump on the stand using tool W1 (plate 796T-467-1130). Then set the hydraulic pump assembly – weight 160 kg – onto the stand. You’ll need a hoist rated for that. Then remove the PC-EPC valve assembly, then the front LS-EPC valve assembly, then the rear pump by removing 6 mounting bolts. Each step is laid out in order. The manual doesn’t skip the small stuff like removing checking port plugs or snap rings from the end cap. That kind of detail keeps you from breaking a $400 coupling. The valve body components are called out with specific tool numbers – the manual tells you exactly which wrench to use for shaft rotating torque measurement (wrench assembly 796-751-1500).

EPC Valve Assembly: Factory Procedure

The EPC valve assembly is a common failure point on these pumps. The manual walks you through removal of the PC-EPC and LS-EPC valves. After removal, you access the end cap assembly. Sub-steps: remove three checking port plugs (8), then remove needle bearing (9) and snap ring (10), then coupling (12), then needle bearing (13). If you’re not following this order, you’ll trap pressure in the cap and risk getting sprayed with hydraulic oil. Safety warning: bleed the system first. The manual assumes you know that, but I’ll say it anyway – depressurize the hydraulic circuit before you crack any line. The valve body internals are precision-machined, much like the internals of a Manual Transmission – you can’t force components together. Understanding the sequencing is similar to learning how a Manual Transmission works; each part has a specific order.

30 Pages of Focused Procedure

You might think 30 pages isn’t enough for a hydraulic pump. But consider what this manual covers: it’s a single pump model – the HPV95+95 – applied to five excavator models: PC200, 200LC-7, PC210, PC220, PC230, and the PC228US variants. Every page is dedicated to disassembly and reassembly. No chapters on engine, hydraulics, or electrical. That focus means you get the exact sequence without flipping through irrelevant sections. Compare that to a generic service manual that tries to cover everything and buries the pump procedure on page 423. This manual is built for the technician who needs to rebuild one pump and get back to trench digging. The special tool rough sketches are included so you can see exactly what the stand or pusher looks like – no guesswork on dimensions.

OEM Documentation vs Aftermarket Schematics

This manual is a direct reproduction of the factory Komatsu publication – SEBH800700. That part number matters. Aftermarket repair guides often reverse-engineer the pump layout and miss critical details like the orientation of the coupler or the exact depth for pressing a needle bearing. I’ve had to redo jobs because a generic manual said ‘install bearing flush’ when the factory spec was 2 mm below flush. The OEM manual gives you the disassembly sequence, the part numbers for special tools, and the rough sketches. There’s a reason field techs keep these in their work trucks. If you want to rebuild a Komatsu pump right, start with the factory data. Pair it with the Komatsu PC200 PC200LC Workshop Manual for the full machine, the KOMATSU PC200 PC210 Hydraulic Excavator Parts Catalog for part numbers, and the Komatsu PC200 PC220-7 Service Manual for torque specs and adjustments.

Frequently Asked Questions

Does this manual include torque specifications?

No. It covers disassembly/assembly only.

What models are covered?

This technical manual applies to Komatsu PC200, PC200LC-7 (serial #200001 and up), PC210, PC210LC-7 (#40001~), PC220, PC220LC-7 (#60001~), PC230, PC230LC-7 (#11001~), and PC228US, PC228USLC-3 (#20001~). The pump itself is the HPV95+95, used in work equipment, swing, and travel circuits. The manual’s 30 pages include procedures for the main pump assembly, EPC valves, rear pump, and cylinder block. It does not cover installation or adjustment – those are in the service manual.

If you’re rebuilding an HPV95+95 pump, don’t trust a reprint from a third-party site. Get the actual factory document here. Access the Factory Manual and put it on your tablet or print the key pages. Your pump will thank you, and you’ll save the cost of a second rebuild.