Komatsu PC200-10M0 Hydraulic Excavator Shop Manual 2021 – SEN06867-01 PDF

Description

Komatsu PC200-10M0 Hydraulic Excavator Shop Manual – SEN06867-01 (2021)

The Komatsu PC200-10M0 Hydraulic Excavator Shop Manual (document number SEN06867-01, published 2021) is the complete workshop reference for the PC200-10M0 model. Every system is documented – the SAA4D107E-1 turbocharged diesel engine, the CLSS hydraulic system with its variable-displacement pumps and control valve, the electrical and electronic control architecture, the swing and travel drive groups, undercarriage, work equipment, and the ROPS cab. This is the same manual structure that Komatsu service technicians use for testing, adjustment, troubleshooting, and major component overhaul on the PC200-10M0.

File Details

• Manual type: Shop Manual (Workshop Service Manual)
• Brand: Komatsu
• Model: PC200-10M0 Hydraulic Excavator
• Document number: SEN06867-01
• Publication date: 2021
• Language: English
• Page count: 2,222 pages
• File format: PDF

Chapters Covered in the PC200-10M0 Shop Manual

• 00 Index and Foreword – Abbreviation list, safety notices, fire prevention, waste material disposal, hydraulic equipment handling, piping connection precautions, electrical equipment handling, fuel system and intake system precautions, connector handling, wire color code reading, standard tightening torque tables
• 01 Specification – Specification drawings, working range drawings, machine specifications, weight table, fuel/coolant/lubricant recommendations by ambient temperature
• 10 Structure and Function – Boot-up system, system operating lamp, battery disconnect switch, engine system (control, auto-deceleration, automatic warm-up, overheat prevention, turbocharger protection), cooling system, control system (machine monitor, KOMTRAX, pump controller, engine controller, PC-EPC resistor, CAN terminating resistor), hydraulic system (CLSS, main pump with LS and PC valves, LS-EPC and PC-EPC valves, control valve, pressure compensation, travel junction, swing control, work equipment, PPC lock, attachment oil flow adjuster), swing system (motor, machinery, swing circle), travel system (motor, final drive, PPC valve, center swivel joint), undercarriage, work equipment, cab related parts
• 20 Standard Value Table – Engine performance, air intake and exhaust, main body, lubrication, cooling system, machine performance, control valve spool strokes, lever strokes, operating efforts, work equipment/swing/travel oil pressures, LS differential pressures, swing, travel, hydraulic drift, speed of work equipment, time lag, oil leakage, pump performance
• 30 Testing and Adjusting – Tools, engine and cooling system tests (engine speed, boost pressure, exhaust gas color, valve clearance, compression pressure, blowby pressure, engine oil pressure, fuel pressure, fuel discharge/return/leakage, air bleeding, cylinder cut-out, no-injection cranking, air conditioner belt), power train, undercarriage, hydraulic system (release remaining pressure, test/adjust oil pressure in work equipment, swing, travel, control, pump PC and LS control circuits, solenoid valve, PPC valve, oil leakage, bleed air), cab related parts, electrical system (machine monitor operation, KOMTRAX startup, rearview camera angle, engine controller voltage circuit, test diodes, Pm Clinic)
• 40 Troubleshooting – Related information, precautions, sequence of events, checks, adapter connection to controllers and monitors, connector disconnection/connection, failure codes table, troubleshooting by failure code, electrical system (E-mode), hydraulic and mechanical systems (H-mode), engine (S-mode)
• 50 Disassembly and Assembly – Preparation (coolant, hydraulic oil, fuel, refrigerant), engine and cooling system (supply pump, injector, cylinder head, radiator, oil cooler, aftercooler, engine and main pump, front/rear oil seals, engine hood, fuel tank), power train (travel motor and final drive, swing motor and machinery, swing circle), undercarriage and frame (track, sprocket, idler, track roller, carrier roller, revolving frame, counterweight), hydraulic system (center swivel joint, hydraulic tank, main pump, control valve, PPC valves), work equipment (assembly, cylinder), cab related parts (operator cab, glass, front window, floor frame, air conditioner unit, seat, seatbelt, wiper), electrical system (controllers, monitor, KOMTRAX terminal)
• 60 Maintenance Standard – Engine mount, cooling system, swing circle, swing machinery, final drive, sprocket, track frame and idler cushion, idler, track roller, carrier roller, track shoe, triple shoe, swamp shoe, road liner, hydraulic tank, main pump, LS-EPC valve, PC-EPC valve, swing motor, travel motor, control valve, PPC valves, solenoid valve, attachment circuit selector valves, center swivel joint, work equipment linkage, arm and bucket dimensions, cylinders
• 80 Others – Air conditioner system (precautions, layout, specifications, refrigeration cycle, components, compressor, condenser, sensors, circuit diagram, troubleshooting, service tool connection, refrigerant handling, desiccant replacement)
• 90 Circuit Diagrams – Hydraulic circuit diagram with symbols, electrical circuit diagram (7 pages) with symbols and wire code reading

Systems and Components Documented

The engine section of this Komatsu PC200-10M0 shop manual deals with the SAA4D107E-1, a 4-cylinder, water-cooled, in-line, direct-injection diesel with turbocharger and air-cooled aftercooler. Bore and stroke are 107 mm x 124 mm, total displacement 4.46 litres. Engine control covers auto-deceleration, automatic warm-up, overheat prevention, and turbocharger protection, with test procedures for boost pressure, compression pressure, blowby pressure, oil pressure, and fuel pressure.

The hydraulic system coverage is built around CLSS (Closed-center Load Sensing System) and includes the main pump assembly (two variable-displacement piston pumps), the control valve with pressure compensation, unload valve, merge-divider, travel junction, swing stroke control, boom and arm regeneration circuits, and the full set of PPC valves. Testing procedures for pump discharge pressure, LS differential pressure, PC valve outlet pressure, LS valve outlet pressure, LS-EPC and PC-EPC valve output, and solenoid valve output are included with standard values and adjustment procedures.

Swing and travel drive groups are documented with structure, function, disassembly, assembly, and maintenance standards. The swing motor (with parking brake, 2-stage relief valve, shuttle valve, suction valve) and swing machinery (two-stage planetary reduction) are covered, as is the travel motor (variable displacement, counterbalance valve, suction safety valve, parking brake) and final drive (two-stage planetary reduction). The center swivel joint, travel PPC valve, and travel junction valve are also included.

Electrical troubleshooting spans the full failure-code list, E-mode symptom-based diagnosis (60 numbered E-code entries covering engine starting, preheating, monitors, gauges, sensors, solenoids, wipers, alarms, cameras, and quick coupler), H-mode hydraulic/mechanical troubleshooting, and S-mode engine troubleshooting. The electrical circuit diagram is presented in seven segments with connector pin identification.

Key Specifications Found in This Manual

Machine weight 19,800 kg, bucket capacity 0.8 m3, rated engine output 110 kW (148 HP) at 2000 rpm, three travel speed ranges (3.0 / 4.1 / 4.9 km/h), maximum digging depth 6,515 mm, maximum digging reach 9,860 mm, maximum digging height 10,065 mm, main pump discharge volume 219.5 L/min x 2, set pressure 37.2 MPa (380 kg/cm2), and a comprehensive set of tightening torques, clearances, and service limits for every major assembly.

Who This Komatsu PC200-10M0 Shop Manual Is For

This manual is written for the technician who needs the correct specification and procedure rather than a guess. It covers the full arc of ownership: routine maintenance intervals and fluid capacities, preventive testing and adjustment, fault-code diagnosis for the electronic control system, complete teardown and reassembly instructions for the engine, hydraulics, swing and travel groups, undercarriage, work equipment, and cab, plus the maintenance standards needed to judge wear limits during overhaul. Independent repair shops, fleet maintenance departments, and owner-operators working on the PC200-10M0 will find the same depth of information here that a factory service technician would use.

Having the exact procedure and the exact value matters when you are setting pump pressures, adjusting valve clearances, checking a cylinder bore, or diagnosing a failure code. This Komatsu PC200-10M0 Hydraulic Excavator Shop Manual gives you the specifications and the step-by-step sequences to do the job correctly the first time.

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Delivered as an instant PDF download, the manual is available immediately after payment. No shipping, no waiting. It can be viewed on any device, searched for the section you need, and printed page by page for use in the workshop. The file works on laptops, tablets, phones, and desktop computers – open it in any PDF reader and you have the full 2,222-page Komatsu PC200-10M0 Hydraulic Excavator Shop Manual at your fingertips.