Description

Komatsu PC200, PC200LC, PC220, PC200-5, PC200LC-5 Workshop Manual

I’ve got a drawer full of aftermarket manuals that look pretty on the shelf but leave you guessing on a critical torque spec. This one is different. The Komatsu PC200, PC200LC, PC220, PC200-5, PC200LC-5 Workshop Manual is the exact same document the dealer’s techs pull up when they’re diagnosing a no-start or a hydraulic drift. 662 pages of OEM content, not a third-party reprint. If you’re working on an S6D95L or SA6D95L engine, this is the only source you need.

Engine and Fuel System Coverage

Section 10 dives into the engine related parts and mount, radiator, oil cooler, after-cooler, and the complete fuel tank and piping. You want to know how the OLSS (Open Center Load Sensing System) interacts with the hydraulic pump? It’s in there. The governor motor linkage adjustment procedure is spelled out with travel specifications. Valve clearance adjustment is under Testing and Adjusting – they give you the cold clearance for intake and exhaust. Forget the generic numbers; these are the Komatsu factory figures.

7 Systems Covered in the Structure and Function Section

• Final drive, swing circle, swing machinery
• Track frame, recoil spring, idler, rollers, track shoe
• Hydraulic piping, circuit diagram, tank, pump, control valve
• Center swivel joint, travel motor, valve control, PPC valve
• Accumulator, safety lock valve, solenoid valve assembly, shuttle valve
• Boom holding valve, hydraulic cylinder
• Electrical wiring diagram, circuit diagram, engine control system, PEMC, EMACC

That’s not a table of contents – that’s what you’ll be referencing when a solenoid valve sticks or the swing brake won’t release.

Testing and Adjusting: Real Procedures with Real Numbers

Section 20 starts with a table of judgment standard values – the numbers they use to decide if a component is within spec. You get the standard value table for the electrical system, a list of required tools, then step-by-step for adjusting valve clearance, measuring compression pressure, testing and adjusting fuel injection timing. Page 20-13 covers the governor motor lever travel adjustment. I’ve seen techs skip that step and chase a surging engine for hours. Don’t be that guy.

Hydraulic Pressure Testing: Charging Pump and Main Pump Control

Need to test and adjust hydraulic pressure in the work equipment, swing, and travel circuit? It’s right after the engine speed sensor adjustment. They walk you through charging pump pressure, main pump control pressure, stroke of the servo piston, travel deviation, PPC valve output pressure. There’s even a procedure for releasing remaining pressure in the hydraulic circuit before you crack a line. Safety first – they mean it.

Troubleshooting: E-Mode and C-Mode Diagnostics

The troubleshooting section is 40+ pages deep. Engine throttle controller system (E mode) covers 12 fault codes from E-1 (power source abnormality) through E-12 (automatic warm-up defective). Each one has a diagnostic flowchart. Pump controller system (C mode) covers codes C-1 through C-8 – solenoid valve short circuits, swing brake issues, TVC solenoid problems. The connector position diagrams and connection tables make electrical diagnosis possible even if you’re not an electrical specialist. You can find the specific connector, probe it with your multimeter, and know whether the controller or the harness is at fault.

Audience Fit: Who Actually Needs This Manual?

If you own a PC200-5, PC200LC-5, PC220-5, or PC220LC-5, you need this manual. Home garage enthusiasts who take on hydraulic repairs will appreciate the disassembly and assembly section (Section 30). Professional mechanics who bill by the hour cannot afford to guess on piston ring end gap or swing circle bearing clearance. The maintenance standard section (Section 40) gives wear limits and replacement criteria. If you’re a shop owner, having this in your library means your techs stop calling the dealer hotline for basic torque values.

Source Validity: Why OEM Beats Aftermarket

I’ve bought aftermarket manuals that swapped a torque value by 10 ft-lb because they copied from a different engine. This manual is from Komatsu, printed in Japan, with revision marks indicating every page update. The list of revised pages in the front shows you exactly which pages have been corrected. That level of traceability doesn’t exist in any third-party PDF found on a forum. If you care about doing the job right, pay for the real thing. You can find related factory documents like Komatsu PC200 PC200LC Workshop Manual and KOMATSU PC200 PC210 Hydraulic Excavator Parts Catalog for parts lookup. For later models, check Komatsu PC200 PC220-7 Service Manual. External references on general Manual Transmission theory might help, but for Komatsu specifics, nothing beats this OEM document.

FAQ

Does this manual cover the fuel injection pump overhaul?

It covers testing and adjusting fuel injection timing, but full pump disassembly is in the engine-specific 95 Series Shop Manual. This manual references that document.

What torque values are listed for cylinder head bolts?

The manual provides torque values in both ft-lb and N·m. For exact values, see the maintenance standard section and the structure and function section. Page 20-10 has the compression pressure spec.

Is the wiring diagram in color?

Black and white line drawings with connector pin numbers. Not as pretty as color but every wire gauge and connector ID is legible. Use the connection table to decode harness plugs.

Can I use this manual on a PC200LC-5 Mighty?

Yes. The front cover lists PC200-5 Mighty serial numbers 58019 and up, and PC200LC-5 Mighty same range. Identical content except for the serial number prefix.

Stop burning billable hours on guesswork. Access the Factory Manual from AutoRepairManuals and get the actual Komatsu procedures on your screen. 662 pages, OEM verified, ready to print or view on any device.