Description

Komatsu PC200LC-6 2000 Workshop Manual – The Only Factory Spec Source

If you have ever wasted a morning tearing down a hydraulic pump only to find a bad solenoid, or torqued a head bolt to a guess and watched it leak oil and coolant, you understand the value of having the original factory documentation. This is not a reprint from some aftermarket house that copies blurred pages and leaves out the footnotes. This is the Komatsu PC200LC-6 2000 Workshop Manual, 540 pages of OEM data printed for the PC200LC-6 serial numbers C10827 and up. I have used these manuals on excavators for twenty years. They save your back, your wallet, and your reputation.

Fuel, Coolant and Lubricants – Don’t Guess the Specs

Section 01 spells out the exact fluids your machine needs. Page 01-8 lists the fuel, coolant and lubricants by type, viscosity grade, and capacity. That includes engine oil, hydraulic oil (the CLSS system is picky about viscosity), gear oil for the swing and travel drives, and grease for the track adjusters. Using the wrong hydraulic fluid on a PC200LC-6 can wreck the self-reducing pressure valve or the PPC valves. The manual also gives the weight table on page 01-6 so you can ballast the machine correctly for towing. Skip this part and you are guessing what goes in the tank.

Adjusting Valve Clearance: The Factory Method

Section 20 covers testing and adjusting. Under “ADJUSTING VALVE CLEARANCE” the manual walks you through the whole job. You need a feeler gauge and a torque wrench for the lock nuts. The procedure: bring the engine to TDC on the compression stroke for each cylinder, check the clearance, adjust using the adjusting screw, then torque the lock nut to the spec in the standard valve table. The manual gives intake and exhaust clearances in metric (0.25 mm and 0.35 mm respectively). Do not assume these are the same as a car engine. The Komatsu 6D102 diesel has specific thermal expansion rates. If you skip this step you will get valve lash noise and burnt seats.

Komatsu PC200LC-6 2000 Workshop Manual: What You Get in 540 Pages

This is not a condensed guide. Every subsystem has its own chapter: structure and function, hydraulic piping drawing, actual electrical wiring diagram, electric circuit system, electric control system, machine monitor, sensors. You get the hydraulic circuit diagram with all pressure test points labelled. You get the full troubleshooting section for the engine system (S mode) and electrical system (E mode) with failure codes. Need to test the PC valve output pressure? The manual tells you the tool to use, the port to tap, and the acceptable range. No diagrams missing, no pages cut out. Compare that to a third-party PDF where half the connectors are labeled “N/A”. That is why I only trust OEM documents.

3 Critical Fuel System Checks Before Starting

Section 20 also includes “TESTING AND ADJUSTING FUEL INJECTION TIMING” and “MEASURING COMPRESSION PRESSURE”. Before you pull the injector pump, do these three checks: (1) measure engine blow by pressure to rule out ring damage; (2) measure fuel injection timing with a timing light or dial indicator; (3) test the fuel control lever adjustment. The manual gives the exact timing spec in degrees. If you skip blow by measurement you could rebuild the pump for nothing. Also check the fuel filter (in-line filter is covered in section 10). Contaminated fuel can damage the EPC solenoid valve. The manual’s sequence of events for troubleshooting (page S-1) tells you exactly what to check first.

Hydraulic Pressure Testing: Step-by-Step Procedure

“TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT” is a chapter you will reference often. The manual lists the required tools – pressure gauges, test hoses, a tachometer – and then gives the test sequence: release residual pressure (see the separate procedure), install gauges at the pump output, the PC valve, and the LS valve. Run the engine at high idle, operate each function, record the pressures. The manual includes standard valve tables for engine related parts and chassis parts so you can compare. If your swing motor drifts or the travel deviation is off, the troubleshooting charts on page E-1 narrow it down. I have used these charts to trace a failed straight-travel system to a stuck EPC solenoid in under an hour.

Related Manuals for the PC200-6 Series

• Komatsu PC200-6 PC250LC-6 1996 Service Manual
• PC200-6 PC250LC-6 Electrical Wiring Diagram
• Komatsu PC200-6 PC220-6 1997 Service Manual – 560 Pages of Factory Specs

For more background on hydraulic systems, see the Manual Transmission article at Wikipedia, or the Manual Transmission resource at the manufacturer site.

FAQ – Common Questions About This Manual

Does this manual cover the PC200LC-6 with a breaker attachment?

Yes. Section 10 includes an additional filter for breaker and the hydraulic piping for work equipment. The manual addresses accumulator and boom holding valve circuits used with breakers.

What is the torque spec for the cylinder head bolts?

The manual provides the torque sequence and final torque value in the standard valve table for engine related parts. You need to follow the tightening steps exactly – do not use a generic spec from a car forum.

Can I use this manual to rebuild the final drive?

Yes, section 10 covers final drive, swing circle, swing machinery, and track frame. The procedures include disassembly, inspection, and assembly with torque values for nuts and bolts. Page 20-? gives the track shoe tension adjustment.

Are wiring diagrams included?

Yes. The manual contains actual electrical wiring diagrams, electric circuit system diagrams, and connector pin number connection tables. That is essential for diagnosing failure codes like E-1 (PC-EPC control system abnormality).

If you are tired of chasing ghosts with aftermarket binders or blurred photocopies, get the real thing. Access the Factory Manual from AutoRepairManuals and start working with the same data the dealer techs use. No guesswork, no wasted shifts. Just OEM specs you can trust.