Komatsu PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0 Hydraulic Excavator Shop Manual SEN06109-00

Description

Komatsu PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0 Hydraulic Excavator Shop Manual

This Komatsu PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0 Hydraulic Excavator Shop Manual (Form No. SEN06109-00) is the complete service reference for the PC200-8M0, PC200LC-8M0, PC220-8M0, and PC220LC-8M0 excavators. It covers serial numbers 400001 and up for the PC200-8M0 and PC200LC-8M0, and 100001 and up for the PC220-8M0 and PC220LC-8M0. All four models share the Komatsu SAA6D107E-1 engine and the HPV95+95 hydraulic pump, and this manual details every system on the machine from the engine and cooling system through the hydraulic circuits, undercarriage, electrical system, and work equipment. Whether you are performing routine maintenance, diagnosing a failure code, or rebuilding a final drive, this Komatsu shop manual gives you the procedures, specifications, and component information needed to do the job correctly.

File Details

• Manual Type: Shop Manual
• Brand: Komatsu
• Models Covered: PC200-8M0, PC200LC-8M0, PC220-8M0, PC220LC-8M0
• Document Number: SEN06109-00
• Edition / Date: 07-12 (01) — July 2012
• Language: English
• Page Count: 1,252
• File Format: PDF

Chapters Covered

• 00 Index and Foreword — Index, foreword, safety and general information, how to read the shop manual, explanation of terms for maintenance standard, handling of fuel system devices, handling of intake system parts, handling of hydraulic equipment, push-pull coupler procedures, handling of electrical equipment, electric wire codes, precautions, KOMTRAX, tightening torque tables, abbreviations, conversion tables
• 01 Specification — Specification dimension drawings, working range diagram, specifications, weight table, fuel/coolant/lubricant table
• 10 Structure, Function and Maintenance Standard — Engine and cooling system, power train (final drive, swing machinery, swing circle), undercarriage and frame (track frame, recoil spring, idler, carrier roller, track roller, track shoe), hydraulic system (hydraulic tank and filter, hydraulic pump, control valve, CLSS, swing motor, travel motor, PPC valve, solenoid valve, PPC accumulator, return oil filter, attachment circuit selector valve, hydraulic cylinder), work equipment, electrical system (engine control, electrical control system, machine monitor system, sensor, KOMTRAX system)
• 20 Standard Value Table — Standard service value tables for engine and chassis related parts
• 30 Testing and Adjusting — Tools, engine speed, intake air pressure, exhaust gas color, valve clearance, compression pressure, blowby pressure, engine oil pressure, fuel system handling and testing, air conditioner belt, alternator belt, swing circle bearing clearance, track tension, work equipment/swing/travel oil pressures, control circuit source pressure, pump PC and LS control circuit pressures, solenoid valve output pressures, PPC valve output pressures, hydraulic drift, oil leakage, air bleeding, cab tipping stopper, mirrors, rear view camera
• 40 Troubleshooting — Failure code table and fuse locations, general troubleshooting information, troubleshooting by failure code (Parts 1–5), electrical system troubleshooting (E-mode), hydraulic and mechanical system troubleshooting (H-mode), engine troubleshooting (S-mode)
• 50 Disassembly and Assembly — General information, engine and cooling system, power train, undercarriage and frame, hydraulic system, work equipment, cab and attachments, electrical system
• 80 Appendix — Air conditioner system
• 90 Diagrams and Drawings — Hydraulic diagrams and drawings, electrical diagrams and drawings

What This Manual Enables You to Do

With this Komatsu PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0 shop manual, a technician can perform the full range of service work on these excavators. Engine service includes valve clearance adjustment, compression testing, fuel system diagnostics, injector removal and installation, cylinder head removal and installation, and front and rear oil seal replacement. The hydraulic section covers the HPV95+95 pump, CLSS control valve, swing motor, travel motor, PPC valves, and hydraulic cylinders with complete disassembly and assembly procedures.

The manual also provides the testing and adjusting values needed to verify system performance — relief pressures, LS differential pressures, PC-EPC and LS-EPC output pressures, PPC valve output pressures, servo piston pressures, and control circuit source pressure. Troubleshooting is organized by failure code, electrical symptom (E-mode), hydraulic/mechanical symptom (H-mode), and engine symptom (S-mode), with detailed flowcharts and connector references so you can trace a fault to its source rather than replacing parts by guesswork.

Models, Engine, and Serial Coverage

• PC200-8M0 — Serial number 400001 and up
• PC200LC-8M0 — Serial number 400001 and up
• PC220-8M0 — Serial number 100001 and up
• PC220LC-8M0 — Serial number 100001 and up
• Engine: SAA6D107E-1 — 4-cycle, water-cooled in-line, direct injection with turbocharger and air-cooled aftercooler, 6 cylinders, 107 x 124 mm bore x stroke, 6.69 L displacement

Why This Manual Matters

Komatsu designed the PC200-8M0, PC200LC-8M0, PC220-8M0, and PC220LC-8M0 with electronically controlled hydraulic and engine systems, including the CLSS (Closed-center Load Sensing System), PC and LS valve control, and the KOMTRAX system. Using the correct service procedures and specifications is essential — incorrect adjustment of the PC valve, LS valve, or main relief valve can reduce performance, increase fuel consumption, or damage hydraulic components. The testing and adjusting chapter gives the exact pressure values, torque figures, and measurement conditions needed to keep these systems within specification.

For rebuilds, the disassembly and assembly chapter includes component weights, special tool part numbers, tightening torques, coating materials, and step-by-step procedures for the final drive, swing machinery, swing circle, hydraulic pump, control valve, travel motor, swing motor, and hydraulic cylinders. The structure and function chapter explains how each system operates, which is invaluable when diagnosing intermittent or complex failures.

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The Komatsu PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0 Hydraulic Excavator Shop Manual is delivered as a PDF download immediately after payment. There is no shipping, no waiting, and no physical book to store. You can view it on a laptop, tablet, or smartphone, print the pages you need for the workshop, and keep the complete manual on hand for every service job. This is the same comprehensive document used by professional technicians to service the PC200-8M0, PC200LC-8M0, PC220-8M0, and PC220LC-8M0 excavators.