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Komatsu PC200,PC200LC-6 PC210LC-6 PC220LC-6 PC250LC-6 Hydraulic Excavator shop servie manual download

Komatsu PC200,PC200LC-6 PC210LC-6 PC220LC-6 PC250LC-6 Hydraulic Excavator shop servie manual

SERIAL NUMBERS

PC200-6 – A82001 and up
PC2OOLC-6 – A82001  and up
PC21OLC-6 – A82001 and up
PC22OLC-6 – A82001 and up
PC25OLC-6 – A82001 and up

This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding,  the manual is divided into the following sections. These sections are further divided into each main group of components.

GENERAL

This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts.

STRUCTURE AND FUNCTION

This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.

TESTING AND ADJUSTING

This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.

DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling each
component, as well as precautions to be taken for these operations.

MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.

Komatsu PC200,PC200LC-6 PC210LC-6 PC220LC-6 PC250LC-6 Hydraulic Excavator

PC200-6, PC200LC-6, PC21 OLC-6

HOW TO READ THE SHOP MANUAL

VOLUMES

Shop manuals are issued as a guide to carrying out repairs. They are divided as follows:
Chassis volume: Issued for every machine model
Engine volume: Issued for each engine series

Electrical volume: Each issued as one to cover all models

Attachment volume: Each issued as one to cover all models

These various volumes are designed to avoid duplication of information. Therefore to deal with all repairs for any model, it is necessary that chassis, engine electrical and attachment be available.

DISTRIBUTION AND UPDATING

Any additions, amendments or other changes will be sent to your distributors. Get the most up-to-date information before you start any work.

FILING METHOD

1.See the page number on the bottom of the page. File the pages in correct order.

2.Following examples show how to read the page number.

3.Additional pages: Additional pages are indicated by a hyphen (-) and numbered after the page number.

The Manual TABLE OF CONTENTS:

01 GENERAL 01-I

  • General assembly drawing (PC200-6, PC2OOLC-6, PC21OLC-6)
  • General assembly drawing (PC22OLC-6, PC25OLC-6) 
  • Specifications (PC200-6, PC2OOLC-6) 
  • Specifications (PC21 OLC-6) 
  • Specifications (PC220LC-6) 
  • Specifications (PC25OLC-6) 
  • Weight table (PC200-6, PC200LC-6) 
  • Weight table (PC21 OLC-6) 
  • Weight table (PC22OLC-6, PC25OLC-6) 
  • Fuel, coolants and lubricants

1O STRUCTURE AND FUNCTION IO-I

  • Enginerelatedparts IO -2
  • Radiator, oil cooler, aftercooler 10 -3
  • Powertrain 10 -4
  • Finaldrive 10 -5
  • Swingcircle 10 -7
  • Swingmachinery IO -8
  • Track frame, recoil spring IO -9
  • Trackshoe IO -10
  • Hydraulic piping drawing IO -13
  • Hydraulic circuit diagram 10 -14
  • Hydraulictank 10 -15
  • Hydraulicpump IO -16
  • Controlvalve IO -38
  • CLSS 10 -47
  • Swingmotor IO -92
  • Centerswiveljoint 10 -95
  • Travelmotor 10 -96
  • Valvecontrol IO-107
  • Work Equipment, Swing PPC valve 1 O-l 08
  • TravelPPCvalve IO-112
  • ServicePPCvalve IO-116
  • Safetylockvalve IO-119
  • PPCaccumulator IO-119
  • PPC shuttle, Travel junction valve 1 O-120
  • EPC,Solenoidvalve IO-127
  • Hydrauliccylinder IO-135
  • Additional filter for breaker 1 O-l 36
  • Overloadwarningdevice IO-137
  • Hose burst protection valve (boom) 1 O-141
  • Workequipment IO-144
  • Electrical circuit diagram 1 O-l 45
  • Engine control system 1 O-l 49
  • Electronic control system 1 O-l 54
  • Machine monitor system 1 O-l 79

20 TESTING AND ADJUSTMENT 20-I

  • Table of judgment standard values 20- 2
  • Standard value table for electrical parts 20-14
  • Tools for testing, adjusting and troubleshooting 20-23
  • Measuringenginespeed 20-24
  • Measuring intake manifold pressure 20-25
  • Measuring intake air restriction 20-26
  • Measuring lubricating oil pressure 20-27
  • Measuring fuel (filter) inlet restriction 20-28
  • Measuring blowby pressure 20-29
  • Measuring engine back pressure 20-30
  • Measuringexhaustcolor 20-31
  • Measuring coolant temperature 20-32
  • Measuringvalveclearance 20-33
  • Checking and adjusting belt tension for air conditioner compressor 20-34
  • Adjustingenginespeedsensor 20-35
  • Testing and adjusting governor motor lever stroke 20-36
  • Testing clearance of swing circle bearing 20-37
  • Testing and adjusting track shoe tension 20-38
  • Testing and adjusting hydraulic pressure in work equipment, swing, travel circuit 20-39
  • Testing and adjusting TVC valve output pressure (servo piston input pressure) 20-42
  • Testing and adjusting LS valve output pressure (servo pistion input pressure) and LS differential pressure 20-44
  • Testing and adjusting control pump circuit oil pressure 20-47
  • Testing EPC valve, solenoid valve output pressure 20-49
  • Measuring PPC valve output pressure and testing PPC shuttle valve 20-51
  • Adjusting work equipment l Swing PPC valve 20-53
  • Adjustingtravellever 20-54
  • Testing travel deviation 20-55
  • Testing location causing hydraulic drift of work equipment 20-56
  • Measuringoilleakage 20-58
  • Releasing remaining pressure in hydraulic circuit 20-59
  • Bleedingair 20-60
  • Troubleshooting 20-63

30 DISASSEMBLY AND ASSEMBLY 30-I

  • METHOD OF USING MANUAL 30-4
  • PRECAUTIONS WHEN CARRYING OUT OPERATION 30-5
  • SPECIAL TOOL LIST 30-7
  • REMOVAL 30-I 1
  • AIR CONDITIONER COMPRESSOR 30-I 1
  • INSTALLATION 30-I 1
  • REMOVAL 30-I 2
  • CONDENSER ASSEMBLY 30-12
  • INSTALLATION 30-12
  • REMOVAL 30-I 3
  • GOVERNOR MOTOR 30-I 3
  • INSTALLATION 30-I 3
  • REMOVAL 30-14
  • HYDRAULIC OIL COOLER 30-14
  • INSTALLATION 30-14
  • REMOVAL 30-I 5
  • RADIATOR HYDRAULIC OIL COOLER 30-15
  • INSTALLATION 30-16
  • REMOVAL 30-I 7
  • HYDRAULIC 30-17
  • INSTALLATION 30-20
  • 30-21
  • DAMPER 30-21
  • INSTALLATION 30-21
  • REMOVAL 30-22
  • FUEL TANK 30-22
  • INSTALLATION 30-22
  • REMOVAL 30-23
  • CENTER SWIVEL JOINT 30-23
  • INSTALLATION 30-23
  • DISASSEMBLY 30-24
  • ASSEMBLY 30-24
  • REMOVAL 30-25
  • FINAL DRIVE 30-25
  • INSTALLATION 30-25
  • DISASSEMBLY OF FINAL DRIVE ASSEMBLY
  • PC200-6, PC2OOLC-6, PC21OLC-6,
  • TRAVEL MOTOR 30-41
  • ASSEMBLY 30-46
  • REMOVAL 30-54
  • SPROCKET 30-54
  • INSTALLATION 30-54
  • REMOVAL 30-55
  • SWlNG MOTOR 30-55
  • INSTALLATION 30-55
  • REMOVAL 30-56
  • SWING MACHINERY 30-56
  • INSTALLATION 30-56
  • DISASSEMBLY 30-57
  • ASSEMBLY 30-60
  • REMOVAL 30-64
  • REVOLVING FRAME 30-64
  • INSTALLATION 30-65
  • REMOVAL 30-66
  • SWING CIRCLE 30-66
  • INSTALLATION 30-67
  • REMOVAL 30-68
  • RECOIL SPRING _ 30-68
  • INSTALLATION _ 30-68
  • DISASSEMBLY 30-69
  • RECOIL SPRING 30-69
  • ASSEMBLY 30-70
  • DISASSEMBLY 30-71
  • IDLER 30-71
  • ASSEMBLY 30-72
  • REMOVAL 30-74

40 MAINTENANCE STANDARD 40-I

  • Final drive (PC200-6, PC2OOLC-6, PC21 OLC-6, PC220LC-6) 
  • Final drive (PC25OLC-6) 
  • Swing machinery 
  • Swingcircle 
  • Track frame, recoil spring (PC200-6, PC200LC-6, PC21 OLC-6, PC22OLC-6)
  • Track frame, recoil spring (PC25OLC-6) 
  • Idler (PC200-6, PC2OOLC-6, PC21 OLC-6, PC220LC-6) 
  • Idler (PC250LC-6) 
  • Carrier roller (PC200-6, PC200LC-6, PC21 OLC-6, PC22OLC-6) 
  • Carrier roller (PC25OLC-6) 
  • Track roller (PC200-6, PC2OOLC-6, PC21 OLC-6, PC220LC-6) 
  • Track roller (PC25OLC-6) 
  • Track shoe (PC200-6, PC2OOLC-6, PC21 OLC-6, PC22OLC-6) 
  • Trackshoe(PC250LC-6) 
  • Hydraulicpump 
  • Controlvalve 
  • Safety-suction valve for service valve 
  • Swing motor 
  • Travel motor (PC200-6, PC200LC-6, PC21 OLC-6, PC22OLC-6) 
  • Travel motor (PC25OLC-6) 
  • Work equipment, swing PPC valve 
  • Travel PPCvalve 
  • Service PPC valve 
  • PPC shuttle, travel junction valve 
  • EPCsolenoidvalve 
  • Center swivel joint 
  • Boom holdingvalve 
  • Hydraulic cylinder (PC200-6, PC2OOLC-6, PC21 OLC-6) 
  • Hydraulic cylinder (PC22OLC-6, PC25OLC-6) 
  • Workequipment

♦ omatsu PC200,PC200LC-6 PC210LC-6 PC220LC-6 PC250LC-6 Hydraulic Excavator shop manual.pdf (51.0 MB )

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October 1996 published

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