Komatsu PC200LC-7L PC220LC-7L Hydraulic Excavator Shop Manual – Chassis Repair PDF
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Complete Komatsu chassis shop manual for PC200LC-7L and PC220LC-7L hydraulic excavators (serial A86001 and up). Covers structure and function, testing and adjusting, troubleshooting, and full disassembly and assembly procedures for the SAA6D102E-2 engine, hydraulic pump, control valve, swing and travel motors, final drive, undercarriage, work equipment, and electrical system.
Description
Komatsu PC200LC-7L PC220LC-7L Chassis Shop Manual
This Komatsu PC200LC-7L PC220LC-7L hydraulic excavator shop manual is the chassis-volume workshop reference for the -7L series machines, issued under form number CEBM005802 in March 2002. It covers both the PC200LC-7L and PC220LC-7L from serial number A86001 upward, and it is the same technical reference Komatsu distributors use when diagnosing, adjusting, and rebuilding these excavators in the service bay.
Where most generic excavator guides stop at routine maintenance, this volume takes the technician the whole way through: how each system is built, how it is supposed to behave, how to test and adjust it, how to isolate faults, and how to pull it apart and put it back together to the correct clearances and torques.
File Details
- Manual type: Chassis Shop Manual (service / repair)
- Brand: Komatsu
- Models covered: PC200LC-7L, PC220LC-7L
- Serial number range: A86001 and up
- Document number: CEBM005802
- Publication date: March 2002
- Language: English
- Page count: 638 pages
- File format: PDF
Chapters Covered
The manual is organised into five top-level sections, each split into component groups:
- 01 GENERAL
- Specification dimension drawings
- Dimensions and working ranges
- Machine specifications
- Weight table
- Fuel, coolant and lubricants
- Standard tightening torques
- Electric wire code
- Conversion tables
- 10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
- Engine, damper and cooling system
- Power train layout
- Final drive and travel motor (HMV110ADT-2)
- Swing motor (KMF125ABE-5) and swing machinery
- Swing circle
- Undercarriage: idler, carrier roller, track roller, track chain and shoe
- Hydraulic pump (HPV95+95) — PC valve, LS valve, PC-EPC valve
- CLSS closed-centre load sensing system
- Main control valve, pressure compensation, relief and safety valves
- Self pressure reducing valve
- Boom drift prevention valve, lift check valve
- PPC valves (work equipment, travel)
- Solenoid valve assembly
- Accumulator and hydraulic filter
- Electronic control system, engine throttle and pump controller
- Monitor panel, sensors and switches
- Air conditioner
- 20 TESTING, ADJUSTING AND TROUBLESHOOTING
- Standard value tables (engine and chassis)
- Engine rpm, exhaust gas colour, valve clearance, compression pressure
- Blow-by pressure, fuel injection timing, engine oil pressure
- Engine speed sensor, air conditioner belt
- Swing circle bearings, track shoe tension
- Equipment, swing and travel pressures
- Control circuit, pump PC and pump LS control circuit pressures
- Solenoid valve, PPC valve output pressures
- Work equipment drift, oil leakage, bleeding air
- Multi monitor panel functions and service menu
- Electrical system service codes (E mode) and mechanical system failure codes (H mode)
- Circuit diagram by system and connector tables
- 30 DISASSEMBLY AND ASSEMBLY
- Radiator, hydraulic oil cooler
- Engine and hydraulic pumps removal and installation
- Final drive disassembly and assembly
- Swing motor and swing machinery
- Carrier roller, track roller, idler, recoil spring
- Sprocket, track shoe, swing circle
- Revolving frame, centre swivel joint, hydraulic tank
- Control valve and pressure compensation valve seal replacement
- Hydraulic pump and input shaft oil seal
- Work equipment PPC valve, travel PPC valve
- Hydraulic cylinders (boom, arm, bucket)
- Work equipment removal and installation
- Air conditioner unit, counterweight, operator’s cab
- Monitor, governor pump controller
- 90 OTHER
- Full electrical circuit diagram sheets (4 sheets)
What This Komatsu Shop Manual Gives You
Read as a whole, this PC200LC-7L and PC220LC-7L chassis shop manual is a full-service reference for the -7L excavator platform. It opens with the machine’s real dimensions, working ranges and weight breakdown, then moves into the structure and function of every major system — pump, valves, motors, cylinders, swing, travel, undercarriage, and the electronic control layer that manages them. From there it hands over the numbers a technician actually works with: standard value tables, pressure and speed tolerances, spool strokes, lever forces, drift limits, leakage allowances, and torque values.
The troubleshooting section is one of the strongest parts of the book. Faults are grouped into display codes (E mode for the electrical system and H mode for the hydraulic and mechanical systems), each with a symptom-to-cause flow, testing reference, and expected reading. This lets you work from a code on the monitor panel down to a specific circuit or component without guessing.
The disassembly and assembly section picks up where diagnosis ends, giving the removal, teardown, inspection, and reassembly sequence for major assemblies, along with special-tool part numbers, tightening torques, and sealant or thread-locker call-outs throughout.
Covered Models and Engine
- PC200LC-7L — operating weight 20,700 kg, bucket capacity 0.8 m³
- PC220LC-7L — operating weight 24,130 kg, bucket capacity 1.0 m³
- Engine: SAA6D102E-2, 4-cycle water-cooled in-line vertical, direct injection, turbocharged, 6 cylinders, 102 x 120 mm bore and stroke, 5.883 L displacement
- Hydraulic pump: HPV95+95 variable displacement twin pump
- Swing motor: KMF125ABE-5 piston type with safety valve and holding brake
- Travel motor: HMV110ADT-2 piston type with brake valve and parking brake
Jobs This Manual Supports
- Diagnosing slow, weak, or drifting boom, arm, and bucket circuits
- Testing and adjusting main relief, PC valve, LS valve, and swing safety valve pressures
- Reading and clearing service codes and failure codes through the monitor panel
- Removing and re-installing the engine and hydraulic pump assembly as a unit
- Rebuilding the final drive, swing motor, swing machinery, and hydraulic cylinders
- Setting track shoe tension and inspecting undercarriage components
- Adjusting lever play and PPC valve output on work equipment and travel circuits
- Tracing faults through the full electrical circuit diagram and connector tables
- Replacing the pressure compensation valve seal and input-shaft oil seal
- Measuring engine compression, blow-by, injection timing, and valve clearance
Why This Manual Matters
The PC200LC-7L and PC220LC-7L are closed-centre load-sensing machines with electronic pump control. Getting them right means using the specified pressures, tolerances, and adjustment procedures rather than rule-of-thumb settings, because the pump, valve, and controller work as a matched system. A torque value or a small clearance taken from the wrong source can put an assembly back together in a way that runs fine for a week and then fails. This manual supplies the numbers, the sequence, and the safety notes for the chassis side of the machine, so repairs are carried out to spec the first time.
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Instant PDF Delivery
This Komatsu PC200LC-7L PC220LC-7L shop manual is delivered as a downloadable PDF immediately after purchase — no waiting for shipping, no physical book to handle. Open it on a workshop laptop, tablet, or desktop, search and print the pages you need for the job in front of you, and keep it on hand for the next repair. Whether you are a Komatsu owner doing your own maintenance, an independent mechanic servicing a customer’s -7L machine, or a fleet technician working from a service truck, this chassis shop manual is the reference you want on the shelf and on the screen.
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