Description
Komatsu PC200LC-6 Hydraulic Excavator Shop Manual – SEBM010202
This is the complete Komatsu PC200LC-6 Hydraulic Excavator Shop Manual, publication SEBM010202, covering machines from serial number C10827 and up (PC200LC-6Z). Whether you are servicing, repairing, or rebuilding a PC200LC-6 excavator, this manual provides the detailed procedures, specifications, and reference data needed to do the job correctly.
File Details
- Manual Type: Shop / Service Manual
- Brand: Komatsu
- Model: PC200LC-6, PC200LC-6Z
- Serial Range: C10827 and up
- Publication Number: SEBM010202
- Language: English
- Page Count: 540
- File Format: PDF
Chapters Covered
The Komatsu PC200LC-6 Shop Manual is organized into six major sections that walk through every system on the machine:
Complete PDF Bookmark Tree
Complete Bookmarks
The complete bookmarks in the “Komatsu PC200LC-6 Hydraulic Excavator Shop Manual SEBM010202 – PDF Download” are as follows:
MAIN MENU
COVERp. 1
CONTENTSp. 2
+01 GENERALp. 3
SPECIFICATION DIMENSION DRAWINGSp. 4
SPECIFICATIONSp. 5
WEIGHT TABLEp. 7
FUEL, COOLANT AND LUBRICANTSp. 9
+10 STRUCTURE AND FUNCTIONp. 10
ENGINE RELATED PARTSp. 11
RADIATOR OIL COOLER AFTERCOOLERp. 12
ENGINE CONTROLp. 13
POWER TRAINp. 14
FINAL DRIVEp. 15
SWING CIRCLEp. 16
SWING MACHINERYp. 17
TRACK FRAME RECOIL SPRINGp. 18
TRACK SHOEp. 19
HYDRAULIC PIPING DRAWINGp. 20
HYDRAULIC CIRCUIT DIAGRAMp. 21
HYDRAULIC TANKp. 22
HYDRAULIC PUMPp. 23
IN-LINE FILTERp. 42
CONTROL VALVEp. 43
SELF-REDUCING PRESSURE VALVEp. 51
CLSSp. 56
SWING MOTORp. 90
CENTER SWIVEL JOINTp. 94
TRAVEL MOTORp. 96
VALVE CONTROLp. 104
WORK EQUIPMENT SWING PPC VALVEp. 105
TRAVEL PPC VALVEp. 109
SERVICE PPC VALVEp. 113
ACCUMULATORp. 116
STRAIGHT-TRAVEL SYSTEMp. 117
EPC SOLENOID VALVEp. 118
BOOM HOLDING VALVEp. 120
ADDITIONAL FILTER FOR BREAKERp. 123
WORK EQUIPMENTp. 124
ACTUAL ELECTRICAL WIRING DIAGRAMp. 125
ELECTRIC CIRCUIT SYSTEMp. 127
ELECTRIC CONTROL SYSTEMp. 129
MACHINE MONITOR SYSTEMp. 135
SENSORSp. 138
+20 TESTING AND ADJUSTINGp. 140
STANDARD VALVE TABLE FOR ENGINE RELATED PARTSp. 141
STANDARD VALVE TABLE FOR ENGINE CHASSIS RELATED PARTSp. 142
STANDARD VALVE TABLE FOR ENGINE ELECTRICAL SYSTEMp. 150
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTINGp. 153
MEASURING ENGINE SPEEDp. 154
MEASURING EXHAUST COLORp. 155
ADJUSTING VALVE CLEARANCEp. 156
MEASURING COMPRESSION PRESSUREp. 157
MEASURING BLOW BY PRESSUREp. 157
TESTING AND ADJUSTING FUEL INJECTION TIMINGp. 158
MEASURING ENGINE OIL PRESSUREp. 159
TESTING AND ADJUSTING FAN BELT TENSIONp. 160
TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSORp. 160
ADJUSTING ENGINE SPEED SENSORp. 161
ADJUSTING FUEL CONTROL LEVERp. 162
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUITp. 164
TESTING AND ADJUSTING PC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE)p. 167
TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSUREp. 168
TESTING AND ADJUSTING CONTROL CIRCUIT OIL PRESSUREp. 171
TESTING SOLENOID VALVE OUTPUT PRESSUREp. 172
MEASURING PPC VALVE PUTPUT PRESSUREp. 173
ADJUSTING WORK EQUIPMENT, SWING PPC VALVEp. 175
TESTING TRAVEL DEVIATIONp. 176
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENTp. 177
MEASURING OIL LEAKAGEp. 179
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUITp. 181
TESTING CLEARANCE OF SWING CIRCLE BEARINGp. 182
TESTING AND ADJUSTING TRACK SHOE TENSIONp. 183
BLEEDING AIRp. 184
+TROUBLESHOOTINGp. 186
POINTS TO REMEMBER WHEN TROUBLESHOOTINGp. 187
SEQUENCE OF EVENTS IN TROUBLESHOOTINGp. 188
PRECAUTIONS WHEN CARRYING OUT MAINTENANCEp. 189
CHECKS BEFORE TROUBLESHOOTINGp. 197
CONNECTOR TYPES AND MOUNTING LOCATIONSp. 198
CONNECTION TABLE FOR CONNECTOR PIN NUMBERSp. 203
METHOD OF USING TROUBLESHOOTING CHARTSp. 213
+TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)p. 215
METHOD OF USING TROUBLESHOOTING CHARTSp. 216
S-1 STARTING PERFORMANCE IS POOR (ALWAYS TAKES TIME)p. 220
+S-2 ENGINE DOES NOT STARTp. 221
(1) ENGINE DOES NOT RUNp. 221
(2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)p. 222
(3) EXHAUST SMOKE COMES OUT, BUT ENGINE DOES START (FUEL IS BEING INJECTED)p. 223
S-3 ENGINE DOES NOT PICK SMOOTHY (FOLLOW-UP IS POOR)p. 224
S-4 ENGINE STOPS DURING OPERATIONSp. 225
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)p. 226
S-6 ENGINE LACKS OUTPUT (NO POWER)p. 227
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTIONp. 228
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE)p. 229
S-9 OIL BECOMES CONTAMINATED QUICKLYp. 230
S-10 FUEL CONSUMPTION IS EXCESSIVEp. 231
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWNp. 232
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)p. 233
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)p. 234
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)p. 235
S-15 ABNORMAL NOISE IS MADEp. 236
S-16 VIBRATION IS EXCESSIVEp. 237
+TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)p. 238
JUDGEMENT TABLE FOR ELECTRICAL, HYDRAULIC, AND MECHANICAL SYSTEMSp. 239
ELECTRICAL CIRCUIT DIAGRAM FOR SYSTEMp. 241
+FAILURE CODESp. 242
+E-1 ABNORMALITY IN PC-EPC CONTROL SYSTEMp. 242
A) ENGINE STOPS EVEN WHEN THROTTLE LEVER IS NOT RETURNED TO STOP POSITION. WHEN SUDDEN LOAD IS APPLIED, ENGINE STALLSp. 242
B) LACKS POWER WHEN THROTTLT LEVER IS AT FULL, WORK EQUIPMENT SPEED IS SLOWp. 243
E-2 ABNORMALITY IN TRAVEL SPEED SELECTOR SYSTEM (TRAVEL SPEED DOES NOT SWITCH)p. 245
+E-3 ABNORMALITY IN SWING HOLDING BRAKE SOLENOID SYSTEMp. 246
A) SWING HOLDING BRAKE SOLENOID IS NOT ACTUATED (CANNOT SWING)p. 246
B) REMAINS ACTUATED (SAFETY LOCK IS NOT ACTUATED)p. 247
+E-4 ABNORMALITY IN PPC OIL PRESSURE LOCK SOLENOID SYSTEMp. 248
A) SOLENOID IS NOT ACTUATED (SAFETY LOCK IS NOT CANCELED)p. 248
B) REMAINS ACTUATED (SAFETY LOCK IS NOT ACTUATED)p. 249
E-5 ABNORMALITY IN ENGINE STARTING SYSTEM (ENGINE DOES NOT START)p. 250
+TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)p. 253
TABLE OF FAILURE MODES AND CAUSESp. 254
H-1 SPEEDS OF ALL WORK EQUIPMENT, TRAVEL, SWING ARE SLOW OR LACKS POWERp. 258
H-2 THERE IS NOT EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLSp. 260
H-3 NO WORK EQUIPMENT, TRAVEL, SWING MOVEp. 261
H-4 ABNORMAL NOISE GENERATED (AROUND PUMP)p. 261
H-5 FINE CONTROL ABILITY IS POOR OR RESPONSE IS POORp. 262
H-6 BOOM IS SLOW OR LACKS POWERp. 263
H-7 ARM IS SLOW OR LACKS POWERp. 265
H-8 BUCKET IS SLOW OR LACKS POWERp. 267
H-9 WORK EQUIPMENT (BOOM, ARM, BUCKET) DOES NOT MOVE (BUT TRAVEL AND SWING ARE NORMALp. 267
H-10 EXCESSIVE HYDRAULIC DRIFT (BOOM, ARM, BUCKET)p. 268
H-11 EXCESSIVE TIME LAG (ENGINE AT LOW IDLING)p. 269
H-12 OTHER EQUIPMENT MOVES WHEN SINGLE CIRCUIT IS RELIEVEDp. 269
H-13 IN COMPUND OPERATIONS, WORK EQUIPMENT WITH LARGER LOAD IS LOWp. 269
H-14 IN SWING + BOOM RAISE, BOOM RAISE IS SLOWp. 270
H-15 IN SWING + TRAVEL, TRAVEL SPEED DROPS EXCESSIVELYp. 270
+H-16 TRAVEL DEVIATIONp. 271
A) DEVIATION IS EXCESSIVE IN NORMAL TRAVELp. 271
B) DEVIATION IS EXCESSIVE WHEN STARTINGp. 271
H-17 TRAVEL SPEED IS SLOWp. 272
H-18 STEERING DOES NOT TURN EASILY OR LACKS POWERp. 273
H-19 TRAVEL DOES NOT MOVE (ONE SIDE ONLY)p. 274
H-20 TRAVEL SPEED DOES NOT SWITCHp. 274
+H-21 DOES NOT SWINGp. 275
A) DOES NOT SWING TO EITHER LEFT OR RIGHTp. 275
B) DOES NOT SWING IN ONE DIRECTIONp. 275
H-22 SWING ACCELERATION IS POOR OR SWING SPEED IS LOWp. 276
+H-23 EXCESSIVE OVERRUN WHEN STOPPING SWINGp. 278
A) ONE DIRECTION ONLYp. 278
B) BOTH DIRECTIONSp. 278
H-24 EXCESSIVE SHOCK WHEN STOPPING SWING (ONE DIRECTION ONLY)p. 279
H-25 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWINGp. 279
+H-26 EXCESSIVE HYDRAULIC DRIFT OF SWINGp. 280
A) WHEN SWING LOCK IS ONp. 280
B) WHEN SWING LOCK IS OFFp. 280
+TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)p. 281
+MONITOR SYSTEM ELECTRICAL CIRCUIT DIAGRAMp. 282
M-1 WHEN THE STARTING SWITCH IS TURNED ON, NO DISPLAY IS GIVEN (LAMPS DO NOT LIGHT UP FOR 3 SECONDS)p. 283
M-2 WHEN THE STARTING SWITCH IS TURNED ON, LAMPS LIGHT UP FOR 3 SECONDS, BUT THEN DO NOT GO OUTp. 283
+M-3 WHEN STARTING SWITCH IS TURNED ON, SOME LAMPS DO NOT LIGHT UP FOR 3 SECONDSp. 284
A) NO GAUGE LAMP LIGHTS UP (CAUTION LAMPS LIGHT UPp. 284
B) SWING LOCK PREHEATING LAMPS DO NOT LIGHT UP (ALL GAUGE LAMPS LIGHT UP)p. 284
C) CHARGE CAUTION LAMP DOES NOT LIGHT UPp. 284
D) ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UPp. 284
M-4 WHEN POWER IS ON (BEFORE ENGINE IS STARTED), CHARGE CAUTION LAMP DOES NOT LIGHT UPp. 285
M-5 WHEN POWER IS TURNED ON (BEFORE ENGINE IS STARTED), ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UPp. 285
M-6 DURING PREHEATING, PREHEATING PILOT LAMP DOES NOT LIGHT UPp. 286
M-7 WHEN SWITCH IS OPERATED, SWING LOCK LAMP DOES NOT LIGHT UPp. 286
M-8 ENGINE OIL PRESSURE CAUTION LAMP LIGHTS UP WHEN ENGINE IS RUNNING (ENGINE OIL PRESSURE IS NORMAL)p. 287
M-9 CHARGE CAUTION LAMP LIGHTS UP WHEN ENGINE IS RUNNINGp. 287
+M-10 ABNORMALITY IN COOLANT TEMPERATURE GAUGEp. 288
A) AFTER ENGINE IS STARTED, LEVEL STAYS AT BOTTOM (WHITE RANGE) AND DOES NOT MOVEp. 288
B) AFTER ENGINE IS STARTED, LEVEL IMMEDIATELY RISES ENGINE IS NOT OVERHEATING BUT INDICATOR ENTERS RED RANGEp. 288
C) COOLANT TEMPERATURE GAUGE GOES OUTp. 288
+M-11 ABNORMALITY IN FUEL GAUGEp. 289
A) ALL FUEL GAUGE SEGMENTS GO OUTp. 289
B) EVEN WHEN FUEL LEVEL GOES DOWN, FUEL GAUGE CONTINUES TO SHOW FULLp. 289
C) EVEN WHEN TANK IS FILLED, FUEL GAUGE DOES NOT SHOW FULLp. 289
+M-12 DEFECTIVE OPERATION OF ALARM BUZZERp. 291
A) BUZZER DOES NOT SOUNDp. 291
B) BUZZER CONTINUES TO SOUND AND DOES NOT STOPp. 291
+M-13 ENGINE IS RUNNING, BUT SERVICE METER DOES NOT MOVEp. 292
A) CHARGE CAUTION LAMP LIGHTS UPp. 292
B) CHARGE CAUTION LAMP DOES NOT LIGHT UPp. 292
+M-14 NIGHT LIGHTING DOES NOT LIGHT UPp. 293
A) GAUGE LIGHTING DOES NOT LIGHT UPp. 293
B) SERVICE METER LIGHTING DOES NOT LIGHT UP (SERVICE METER IS WORKING NORMALLY)p. 293
+M-15 WIPER DOES NOT MOVE, OR DOES NOT STOP MOVINGp. 294
A) WIPER DOES NOT MOVE WHEN WIPER SWITCH IS TURNED ONp. 294
B) WIPER MOVES EVEN WHEN WIPER SWITCH IS NOT TURNED ONp. 294
+M-16 HEATER DOES NOT WORK AT EITHER HI OR LOp. 296
A) DOES NOT WORK AT EITHER HI OR LOp. 296
B) DOES NOT WORK AT LO ONLYp. 296
C) DOES NOT WORK AT HI ONLYp. 296
+30 DISASSEMBLY AND ASSEMBLYp. 297
METHOD OF USING MANUALp. 299
PRECAUTIONS WHEN CARRYING OUT OPERATIONp. 300
SPECIAL TOOL LISTp. 302
SKETCHES OF SPECIAL TOOLSp. 306
+STARTING MOTOR ASSEMBLYp. 307
REMOVAL AND INSTALLATIONp. 307
+ALTERNATIVE ASSEMBLYp. 308
REMOVAL AND INSTALLATIONp. 308
+AIR CONDITIONER COMPRESSOR ASSEMBLYp. 309
REMOVAL AND INSTALLATIONp. 309
+CONDENSER ASSEMBLYp. 310
REMOVAL AND INSTALLATIONp. 310
+ENGINE OIL COOLER CORE ASSEMBLYp. 311
REMOVAL AND INSTALLATIONp. 311
+FUEL INJECTION PUMP ASSEMBLYp. 312
REMOVALp. 312
INSTALLATIONp. 315
+WATER PUMP ASSEMBLYp. 317
REMOVAL AND INSTALLATIONp. 318
+NOZZLE HOLDER ASSEMBLYp. 319
REMOVAL AND INSTALLATIONp. 319
+TURBOCHARGER ASSEMBLYp. 320
REMOVAL AND INSTALLATIONp. 320
+THERMOSTAT ASSEMBLYp. 321
REMOVAL AND INSTALLATIONp. 322
+CYLINDER HEAD ASSEMBLYp. 323
REMOVALp. 323
INSTALLATIONp. 327
+RADIATOR – HYDRAULIC COOLER ASSEMBLYp. 330
REMOVALp. 330
INSTALLATIONp. 332
+ENGINE – MAIN PUMP ASSEMBLYp. 333
REMOVALp. 333
INSTALLATIONp. 337
+DAMPER ASSEMBLYp. 338
REMOVAL AND INSTALLATIONp. 338
+FUEL TANK ASSEMBLYp. 339
REMOVAL AND INSTALLATIONp. 339
+CENTER SWIVEL JOINT ASSEMBLYp. 340
REMOVAL AND INSTALLATIONp. 341
DISASSEMBLY AND ASSEMBLYp. 342
+FINAL DRIVE ASSEMBLYp. 343
REMOVAL AND INSTALLATIONp. 343
DISASSEMBLYp. 344
ASSEMBLYp. 347
+SPROCKETp. 352
REMOVAL AND INSTALLATIONp. 352
+SWIMG MOTOR, SWING MACHINERYp. 353
REMOVAL AND INSTALLATIONp. 354
DISASSEMBLYp. 355
ASSEMBLYp. 359
+REVOLVING FRAME ASSEMBLYp. 364
REMOVALp. 364
INSTALLATIONp. 365
+SWING CIRCLE ASSEMBLYp. 366
REMOVALp. 366
INSTALLATIONp. 367
+IDLER – RECOIL SPRING ASSEMBLYp. 368
REMOVAL AND INSTALLATIONp. 368
+RECOIL SPRING ASSEMBLYp. 369
DISASSEMBLYp. 369
ASSEMBLYp. 370
+IDLER ASSEMBLYp. 371
DISASSEMBLYp. 371
ASSEMBLYp. 372
+TRACK ROLLER ASSEMBLYp. 374
REMOVAL AND INSTALLATIONp. 374
DISASSEMBLYp. 375
ASSEMBLYp. 377
+CARRIER ROLLER ASSEMBLYp. 379
REMOVAL AND INSTALLATIONp. 379
DISASSEMBLYp. 380
ASSEMBLYp. 382
+TRACK SHOE ASSEMBLYp. 384
REMOVAL AND INSTALLATIONp. 384
+HYDRAULAIC TANK ASSEMBLYp. 385
REMOVALp. 385
INSTALLATIONp. 386
+MAIN PUMP ASSEMBLYp. 387
REMOVALp. 387
INSTALLATIONp. 389
+MAIN PUMP INPUT SHAFT OIL SEALp. 390
REMOVAL AND INSTALLATIONp. 390
+CONTROL VALVE ASSEMBLYp. 391
REMOVALp. 391
INSTALLATIONp. 393
DISASSEMBLYp. 394
ASSEMBLYp. 399
+MAIN RELIEF VALVE ASSEMBLYp. 405
DISASSEMBLY AND ASSEMBLYp. 405
+PC VALVE ASSEMBLYp. 406
REMOVAL AND INSTALLATIONp. 407
+LS VALVE ASSEMBLYp. 408
REMOVAL AND INSTALLATIONp. 408
+PC-EPC VALVE ASSEMBLYp. 409
REMOVAL AND INSTALLATIONp. 409
+SOLENOID VALVE ASSEMBLYp. 410
REMOVAL AND INSTALLATIONp. 410
+WORK EQUIPMENT – SWING PPC VALVE ASSEMBLYp. 411
REMOVAL AND INSTALLATIONp. 411
DISASSEMBLYp. 412
ASSEMBLYp. 413
+TRAVEL PPC VALVE ASSEMBLYp. 414
REMOVAL AND INSTALLATIONp. 414
DISASSEMBLY AND ASSEMBLYp. 415
ASSEMBLYp. 416
+BOOM LOCK VALVE ASSEMBLYp. 417
REMOVAL AND INSTALLATIONp. 417
+BOOM CYLINDER ASSEMBLYp. 418
REMOVALp. 418
INSTALLATIONp. 419
+ARM CYLINDER ASSEMBLYp. 420
REMOVALp. 420
INSTALLATIONp. 421
+BUCKET CYLINDER ASSEMBLYp. 422
REMOVALp. 422
INSTALLATIONp. 423
+HYDRAULIC CYLINDER ASSEMBLYp. 424
DISASSEMBLYp. 424
ASSEMBLYp. 427
+WORK EQUIPMENT ASSEMBLYp. 431
REMOVALp. 431
INSTALLATIONp. 432
+BUCKET ASSEMBLYp. 433
REMOVALp. 433
INSTALLATIONp. 434
+ARM ASSEMBLYp. 435
REMOVALp. 435
INSTALLATIONp. 436
+BUCKET – ARM ASSEMBLYp. 437
REMOVALp. 437
INSTALLATIONp. 438
+BOOM ASSEMBLYp. 298
REMOVALp. 298
INSTALLATIONp. 298
+OPERATOR'S CAB ASSEMBLYp. 439
REMOVAL AND INSTALLATIONp. 439
+COUNTERWEIGHT ASSEMBLYp. 440
REMOVAL AND INSTALLATIONp. 440
+MONITOR ASSEMBLYp. 441
REMOVAL AND INSTALLATIONp. 441
+40 MAINTENANCE STANDARDp. 442
SWING MACHINERYp. 443
SWING CIRCLEp. 445
FINAL DRIVEp. 446
TRACK FRAME – RECOIL SPRINGp. 448
IDLERp. 449
CARRIER ROLLERp. 451
TRACK ROLLERp. 452
TRACK SHOEp. 453
HYDRAULIC PUMPp. 458
CONTROL VALVEp. 459
SELF-REDUCING PRESSURE VALVEp. 466
SWING MOTORp. 467
TRAVEL MOTORp. 468
WORK EQUIPMENT – SWING PPC VALVEp. 469
TRAVEL PPC VALVEp. 470
SERVICE PPC VALVEp. 471
CENTER SWIVEL JOINTp. 472
BOOM HOLDING VALVEp. 474
HYDRAULIC CYLINDERp. 475
WORK EQUIPMENTp. 477
DIMENSION OF WORK EQUIPMENTp. 479
+90 OTHERSp. 483
HYDRAULIC PIPING DRAWINGp. 484
HYDRAULIC CIRCUIT DIAGRAMp. 490
ACTUAL ELECTRICAL WIRING DIAGRAM (1/2)p. 492
ACTUAL ELECTRICAL WIRING DIAGRAM (2/2)p. 496
ELECTRICAL CIRCUIT DIAGRAM (1/2)p. 500
ELECTRICAL CIRCUIT DIAGRAM (2/2)p. 504
+OPERATION OF CLSS SYSTEM AS A WHOLEp. 508
1. WHEN ALL WORK EQUIPMENT IS NEUTRALp. 508
2. ONE SIDE ACTUATED, OTHER SIDE NEUTRALp. 512
3. ARM OUT, STANDARD MODE RELIEF (CUT-OFF CONTROL)p. 516
4. BUCKET DUMP, POWER MAX RELIEFp. 520
5. BOOM RAISEp. 524
6. SWING OPERATED INDEPENDENTLYp. 528
7. TRAVEL OPERATED INDEPENDENTLYp. 532
8. COMPOUND OPERATIONp. 536
- 01 GENERAL – Specification dimension drawings, machine specifications, weight table, fuel, coolant, and lubricant recommendations
- 10 STRUCTURE AND FUNCTION – Engine related parts, radiator oil cooler aftercooler, engine control, power train, final drive, swing circle, swing machinery, track frame recoil spring, track shoe, hydraulic piping and circuit diagrams, hydraulic tank, hydraulic pump, in-line filter, control valve, self-reducing pressure valve, CLSS, swing motor, center swivel joint, travel motor, valve control, work equipment swing PPC valve, travel PPC valve, service PPC valve, accumulator, straight-travel system, EPC solenoid valve, boom holding valve, additional filter for breaker, work equipment, actual electrical wiring diagram, electrical circuit diagram, electric control system, machine monitor system, sensors
- 20 TESTING AND ADJUSTING – Standard value tables for engine, chassis, and electrical systems, testing and adjusting tools, measuring engine speed, exhaust color, adjusting valve clearance, measuring compression pressure, blow-by pressure, fuel injection timing, engine oil pressure, fan belt tension, air conditioner compressor belt tension, adjusting engine speed sensor and fuel control lever, testing and adjusting hydraulic pressure in work equipment, swing, and travel circuits, PC valve output pressure, LS valve output pressure and LS differential pressure, control circuit oil pressure, solenoid valve output pressure, PPC valve output pressure, travel deviation, hydraulic drift, oil leakage measurement, releasing remaining pressure, swing circle bearing clearance, track shoe tension, bleeding air, and troubleshooting
- 30 DISASSEMBLY AND ASSEMBLY – Starting motor, alternator, air conditioner compressor, condenser, engine oil cooler core, fuel injection pump, water pump, nozzle holder, turbocharger, thermostat, cylinder head, radiator and hydraulic oil cooler, engine main pump, damper, fuel tank, center swivel joint, final drive, sprocket, swing motor and swing machinery, revolving frame, swing circle, idler, recoil spring, track roller, carrier roller, track shoe, hydraulic tank, main pump, control valve, main relief valve, PC valve, LS valve, PC-EPC valve, solenoid valve, work equipment swing PPC valve, travel PPC valve, boom lock valve, boom cylinder, arm cylinder, bucket cylinder, hydraulic cylinder, work equipment, bucket, arm, bucket arm, operator’s cab, counterweight, and monitor
- 40 MAINTENANCE STANDARD – Wear limits, clearances, and service standards for swing machinery, swing circle, final drive, track frame, recoil spring, carrier roller, track roller, idler, track shoe, hydraulic pump, control valve, self-reducing pressure valve, swing motor, travel motor, work equipment swing PPC valve, travel PPC valve, service PPC valve, center swivel joint, boom holding valve, hydraulic cylinder, work equipment, and work equipment dimensions
- 90 OTHERS – Hydraulic piping drawing, hydraulic circuit diagram, actual electrical wiring diagrams, electrical circuit diagrams, and a detailed explanation of the CLSS system operation as a whole including neutral, one-side actuated, arm out, bucket dump, boom raise, swing, travel, and compound operation modes
This Komatsu PC200LC-6 shop manual is far more than a basic owner’s guide. It is the same comprehensive technical resource used by professional diesel mechanics and heavy equipment technicians to diagnose faults, perform complete component overhauls, and verify that every repair meets Komatsu’s original specifications. The manual covers the S6D102-1 engine, the HPV95+95 hydraulic pump, the HMV110-2 travel motor, the KMF90AB-3 swing motor, and every major mechanical, hydraulic, and electrical system on the PC200LC-6Z excavator.
What This Komatsu PC200LC-6 Shop Manual Enables You to Do
With the Komatsu PC200LC-6 Hydraulic Excavator Shop Manual SEBM010202, you can confidently tackle work that would otherwise require guesswork or expensive dealer visits. The Testing and Adjusting section alone provides the standard values and service limits needed to diagnose hydraulic pressure problems, engine performance issues, swing and travel faults, and electrical malfunctions. The Disassembly and Assembly section gives step-by-step procedures for removing and reinstalling major components, from the fuel injection pump and turbocharger to the final drive and swing machinery.
Because this manual includes the Maintenance Standard chapter, you can measure wear on track components, check backlash in the swing and final drive gearing, verify hydraulic cylinder clearances, and determine whether parts are within service limits or need replacement. This is the information that separates a proper repair from a temporary fix.
Why the Right Manual Matters for the PC200LC-6
The Komatsu PC200LC-6 is a robust 21,300 kg class excavator, but like any hydraulic machine, it depends on precise pressures, torques, and clearances to operate reliably. Using incorrect specifications can lead to premature component failure, poor performance, or unsafe operating conditions. This manual provides the exact values and procedures that Komatsu specifies for the PC200LC-6Z, including torque values, hydraulic pressure settings, and wear limits that are not available in generic repair guides.
Instant PDF Delivery
The Komatsu PC200LC-6 Shop Manual SEBM010202 is delivered as an instant PDF download after purchase. There is no shipping, no waiting, and no physical book to lose. You can access the manual on any device – laptop, tablet, or smartphone – and print the pages you need for the workshop. Whether you are in the field or in a fully equipped service bay, the information you need is always available.
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