Komatsu pc200 lc 6 hydraulic excavator service repair manual (a83000 and up)

SEP 1997 00-1-Î
CEBM001001
Shop
Manual
PC200LC-6
PC210LC-6
PC220LC-6
PC250LC-6
HYDRAULIC EXCAVATOR
MACHINE MODEL SERIAL NUMBERS
PC200LC-6 A83001 and up
This material is proprietary to Komatsu America International Company and is not to be reproduced, used, or disclosed
except in accordance with written authorization from Komatsu America International Company.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make
changes or add improvements at any time without incurring any obligation to install such changes on products sold
previously.
Due to this continuous program of research and development, periodic revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.

00-2
CONTENTS
01 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1
10 STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
20 TESTING, ADJUSTING AND TROUBLESHOOTING . . . . . . . . . . 20-1
30 DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 30-1
40 MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1

00-3
PRODUCT PUBLICATIONS INFORMATION
PC200LC-6
VARIOUS PRODUCT PARTS & SERVICE PUBLICATIONS ARE AVAILABLE TO ALL KOMATSU CONSTRUCTION
EQUIPMENT OWNERS, INCLUDING OPERATION & MAINTENANCE MANUALS, PARTS BOOKS AND SHOP
MANUALS.
SPECIAL PUBLICATIONS SUCH AS SERVICE TOOL, AIR CONDITIONING, AND TURBOCHARGER SHOP
MANUALS ARE ALSO AVAILABLE AS WELL AS SELECTED OPERATION & MAINTENANCE AND SHOP MANUALS
IN FOREIGN LANGUAGES.
THE PUBLICATIONS LISTED BELOW ARE AVAILABLE FOR THIS PARTICULAR MACHINE(S).
DESCRIPTION FORM NUMBER
PARTS BOOK - PAPER:
Engine and Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BEPB001701
PARTS BOOK - MICROFICHE:
Engine and Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BEPM001701
OPERATION & MAINTENANCE MANUAL:
Engine and Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CEAM001200
SHOP MANUAL:
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CEBM001000
SAFETY MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HE92-2
STANDARD MAN-HOUR GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CEKQ000300
PARTS AND SERVICE PUBLICATIONS CAN ONLY BE ACQUIRED BY AUTHORIZED KOMATSU DISTRIBUTORS,
USING THE KOMATSU AMERICA INTERNATIONAL COMPANY PARTS INFORMATION PROCESSING SYSTEM
(PIPS).
IF THE PIPS SYSTEM IS NOT AVAILABLE AT THE DISTRIBUTOR LOCATION, THEN THE FOLLOWING
REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS CAN BE USED. FORM KDC91D
IS SHOWN ON THE REVERSE SIDE OF THIS PAGE.
PC2006CA.PUB 102496

00-5
PC210LC-6
EQUIPMENT OWNERS, INCLUDING OPERATION & MAINTENANCE MANUALS, PARTS BOOKS AND SHOP MANUALS.
SPECIAL PUBLICATIONS SUCH AS SERVICE TOOL, AIR CONDITIONING, AND TURBOCHARGER SHOP MANUALS ARE
ALSO AVAILABLE AS WELL AS SELECTED OPERATION & MAINTENANCE AND SHOP MANUALS IN FOREIGN
LANGUAGES.
PARTS BOOK - PAPER:
Engine and Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BEPB001800
Engine and Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BEPM001800
Engine and Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CEAM001200
SHOP MANUAL:
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CEBM001000
SAFETY MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HE92-2
STANDARD MAN-HOUR GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CEKQ000300
PARTS AND SERVICE PUBLICATIONS CAN ONLY BE ACQUIRED BY AUTHORIZED KOMATSU DISTRIBUTORS, USING
THE KOMATSU AMERICA INTERNATIONAL COMPANY PARTS INFORMATION PROCESSING SYSTEM (PIPS).
IF THE PIPS SYSTEM IS NOT AVAILABLE AT THE DISTRIBUTOR LOCATION, THEN THE FOLLOWING REQUISITION FOR
TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS CAN BE USED. FORM KDC91D IS SHOWN ON THE
REVERSE SIDE OF THIS PAGE.
PC2006CA.PUB 102496

00-7
PC220LC-6
LANGUAGES.
PARTS BOOK - PAPER:
SHOP MANUAL:
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CEBM001000
SAFETY MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HE92-2
PC2006CA.PUB 102496

00-9
PC250LC-6
LANGUAGES.
PARTS BOOK - PAPER:
SHOP MANUAL:
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CEBM001000
SAFETY MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HE92-2
PC2006CA.PUB 102496

SAFETY FORWARD
00-11
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for the safe operation of your machine. The service and repair
techniques recommended and described in this manual are both effective and safe methods of operation.
Some of these operations require the use of tools specially designed for the purpose.
To prevent injury to workers, the symbols and are used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises
or may possibly arise, first consider safety, and take the necessary actions to deal with the situation.
GENERAL PRECAUTIONS PREPARATIONS FOR WORK
Mistakes in operation are extremely dangerous. Read the 7. Before adding oil or making repairs, park the
OPERATION & MAINTENANCE MANUAL carefully machine on hard, level ground, and block the wheels
BEFORE operating the machine. or tracks to prevent the machine from moving.
1. Before carrying out any greasing or repairs, read all 8. Before starting work, lower blade, ripper, bucket or
the precautions given on the decals which are fixed to any other work equipment to the ground. If this is not
the machine. possible, insert the safety pin or use blocks to prevent
2. When carrying out any operation, always wear safety to lock all the control levers and hang warning signs
shoes and helmet. Do not wear loose work clothes, on them.
or clothes with buttons missing.
9. When disassembling or assembling, support the
! Always wear safety glasses when hitting parts with
a hammer.
! Always wear safety glasses when grinding parts
with a grinder, etc. 10. Remove all mud and oil from the steps or other
3. If welding repairs are needed, always have a trained, use the handrails, ladders or steps when getting on or
experienced welder carry out the work. When off the machine. Never jump on or off the machine.
carrying out welding work, always wear welding If it is impossible to use the handrails, ladders or
gloves, apron, glasses, cap and other clothes suited steps, use a stand to provide safe footing.
for welding work.
4. When carrying out any operation with two or more
workers, always agree on the operating procedure 11. When removing the oil filler cap, drain plug or
before starting. Always inform your fellow workers hydraulic pressure measuring plugs, loosen them
before starting any step of the operation. Before slowly to prevent the oil from spurting out. Before
starting work, hang UNDER REPAIR signs on the disconnecting or removing components of the oil,
controls in the operator's compartment. water or air circuits, first remove the pressure
5. Keep all tools in good condition and learn the correct
way to use them. 12. The water and oil in the circuits are hot when the
6. Decide a place in the repair workshop to keep tools Wait for the oil and water to cool before carrying out
and removed parts. Always keep the tools and parts any work on the oil or water circuits.
in their correct places. Always keep the work area
clean and make sure that there is no dirt or oil on the 13. Before starting work, remove the leads from the
floor. Smoke only in the areas provided for smoking. battery. ALWAYS remove the lead from the negative
Never smoke while working. (-) terminal first.
the work equipment from falling. In addition, be sure
machine with blocks, jacks or stands before starting
work.
places used to get on and off the machine. Always
PRECAUTIONS DURING WORK
completely from the circuit.
engine is stopped, so be careful not to get burned.

FORWARD SAFETY
00-12
14. When raising heavy components, use a hoist or
crane. Check that the wire rope, chains and hooks
are free from damage. Always use lifting equipment
which has ample capacity. Install the lifting
equipment at the correct places. Use a hoist or crane
and operate slowly to prevent the component from
hitting any other part. Do not work with any part still
raised by the hoist or crane.
15. When removing covers which are under internal
pressure or under pressure from a spring, always
leave two bolts in position on opposite sides. Slowly
release the pressure, then slowly loosen the bolts to
remove.
16. When removing components, be careful not to break
or damage the wiring, Damaged wiring may cause
electrical fires.
17. When removing piping, stop the fuel or oil from
spilling out. If any fuel or oil drips on to the floor, wipe
it up immediately. Fuel or oil on the floor can cause
you to slip, or can even start fires.
18. As a general rule, do not use gasoline to wash parts.
In particular, use only the minimum of gasoline when
washing electrical parts.
19. Be sure to assemble all parts again in their original
places. Replace any damaged part with new parts.
! When installing hoses and wires, be sure that
they will not be damaged by contact with other
parts when the machine is being operated.
20. When installing high pressure hoses, make sure that
they are not twisted. Damaged tubes are dangerous,
so be extremely careful when installing tubes for high
pressure circuits. Also check that connecting parts
are correctly installed.
21. When assembling or installing parts, always use the
specified tightening torques. When installing
protective parts such as guards, or parts which
vibrate violently or rotate at high speed, be partic-
ularly careful to check that they are installed
correctly.
22. When aligning two holes, never insert your fingers or
hand. Be careful not to get your fingers caught in a
hole.
23. When measuring hydraulic pressure, check that the
measuring tool is correctly assembled before taking
any measurements.
24. Take care when removing or installing the tracks of
track-type machines. When removing the track, the
track separates suddenly, so never let anyone stand
at either end of the track.

GENERAL FORWARD
00-13
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate
understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure
you understand the contents of this manual and use it to full effect at every opportunity.
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.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any advance
notice. Contact your distributor for the latest information.

ALTERNATOR DISASSEMBLY AND ASSEMBLY
30-15 Î
ALTERNATOR
Removal
Disconnect the cable from the negative (-) terminal of
the battery.
1. Open engine hood.
2. Remove fan guard (1) and right fan guard mounting bracket
(2).
3. Disconnect wiring (3).
4. Using wrench Î, raise tensioner (6) and remove belt (7).
Be extremely careful not to get your fingers caught
when removing the belt.
5. Remove alternator mounting bolts (8) and (9), then remove
alternator assembly (10).
Installation
! Carry out installation in the reverse order to removal.

DISASSEMBLY AND ASSEMBLY AIR CONDITIONER COMPRESSOR
30-16 Î
AIR CONDITIONER COMPRESSOR
Removal
Under pressure, precautions must be taken to protect
eyes and skin. Never loosen any part of the refrigerant
circuit while charged with gas. The air conditioner
system should only be serviced by qualified personnel.
1. Remove refrigerant gas (R134a) using discharge ports (1).
Don't release gas into the atmosphere.
2. Remove fan guard (2).
3. Disconnect hoses (3) and (4) and disconnect electrical
connector.
4. Loosen bolts (5) and (6) and rotate compressor about bolt
(5) towards the engine and remove drive belt (7).
5. Remove bolts (8) then remove air conditioner compressor
(9).
Installation
! Carry out installation in reverse order of removal.
i Check O-rings of hoses are not damaged or deteriorated.
i Adjust the belt tension (see TESTING AND ADJUSTING).
! Fill with refrigerant (R-134a).

AIR CONDITIONER CONDENSER DISASSEMBLY AND ASSEMBLY
30-17 Î
AIR CONDITIONER CONDENSER
Removal
1. Open forward left side cover and remove top cover.
2. Remove overfill tank bracket (2) by removing bolts and
washers (1).
3. Disconnect electrical connector and hoses (3) and (4).
i Loosen the sleeve nut slightly and release the refrigerant
(R134a) completely before disconnecting hoses and tubes.
i Fit plugs to hoses and tubes to prevent ingress of moisture,
dust or dirt.
4. Remove condenser assembly (5) by removing bolts and
washers (6).
Installation
i Check that the O-ring is not damaged or deteriorated.
! Fill with refrigerant (R134a).

DISASSEMBLY AND ASSEMBLY DRY RECEIVER
30-18 Î
DRY RECEIVER
Removal
1. Open forward left side cover and remove top cover.
2. Disconnect hose (1) and (2) of dry receiver.
i Loosen the sleeve nut slightly and release the refrigerant
(R143a) completely before disconnecting hoses.
i Fit blind plugs into the hoses to prevent the entry of
moisture, dust or dirt.
3. Remove dry receiver assembly (3).
Installation
i Check that the O-rings are not damaged or deteriorated,
then connect the hoses.
! Fill with refrigerant (R-134a).

FUEL INJECTION PUMP DISASSEMBLY AND ASSEMBLY
30-19 Î
FUEL INJECTION PUMP
Removal
Disconnect the cable from the negative (-) terminal of
the battery.
2. Remove cover (1) on top of condenser, then remove stay
(2) at the counterweight.
3. Remove fan guard (3) and left bracket (4).
4. Disconnect coolant temperature sensor connector (5).
5. For machines with air conditioning, remove bracket (6) for
compressor hose clamp.
i Tighten together with the fuel inlet hose clamp.
6. Remove lock clips (8) (2 places) and lock bracket (7) of
dipstick guide.
7. Disconnect governor motor rod (9) at governor end.
i Rotate the shaft of the governor motor and do not
stop it suddenly.
i Always disconnect the guide motor connector before
disconnecting the rod.
8. Disconnect the 6 delivery tubes (10). See engine
shop manual for details.
9. Disconnect the return fuel hose (11).
i Fuel will flow out when the hose is disconnected, so plug
hose to prevent the fuel from leaking.

DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP
30-20 Î
10. Disconnect tube (12) between fuel filter and fuel injection
pump.
11. Remove lubrication tube (13).
12. Remove mounting bolt (14) of support bracket at bottom of
fuel injection pump.
13. Using tool A2, rotate engine in normal direction, and push
No. 1 cylinder compression top dead center positioning pin
(15) into gear.
i Push the pin lightly against the gear and rotate the engine
slowly.
i After determining the TDC position, check if the meshing of
the timing pin has come out.
14. Remove 2 fan belts (16), then move fan tension
pulley (17) and adjustment bar (18) towards fan
shaft.
i Loosen mounting bolt (19) of adjustment bolt bottom
bracket (20), then loosen adjustment bolt (21).
15. Turn cap (22) and remove.
16. Remove fuel injection pump. For details, see engine shop
manual.

FUEL INJECTION PUMP DISASSEMBLY AND ASSEMBLY
30-21 Î
Installation
i Adjust the governor lever. For details, see TESTING AND
ADJUSTING, Adjusting governor motor lever stroke.
Delivery tube sleeve nut (10) : 24 ± 4 Nm (2.45 ± 0.41
kgm)
i Adjust the belt tension. For details, see TESTING AND
ADJUSTING, Testing and adjusting the fan belt tension.
! Bleed air from fuel system.

DISASSEMBLY AND ASSEMBLY WATER PUMP
30-22 Î
WATER PUMP
Removal
1. Drain coolant.
3. Remove fan guard (1), then remove left and right side
covers (2) and (3) of fan guard mount.
4. Using wrench Î, raise tensioner (4), then remove belt (5).
5. Loosen adjustment bar (7) of fan tension pulley (6),
then loosen fan belt (8).
6. Loosen mounting bolt (11) of fan pulley (10) and fan shaft
(9) 2 - 3 mm, then move towards radiator.

WATER PUMP DISASSEMBLY AND ASSEMBLY
30-23 Î
7. Remove water pump assembly (12).
Installation
i Adjust the belt tension. For details, see TESTING AND
ADJUSTING, Testing and adjusting of fan belt tension.
i Add coolant through the coolant filler to the specified level.
Run the engine to circulate the coolant through the system.
Then check the coolant level again.

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DISASSEMBLY AND ASSEMBLY NOZZLE HOLDER
30-24 Î
NOZZLE HOLDER
Removal
2. Disconnect delivery tube (1) at nozzle holder
assembly end.
3. Remove spill tube (2)
4. Remove nozzle holder assembly (3).
i If it is difficult to remove the nozzle holder assembly, use
tool A4 to remove it.
i Be careful not to let dirt or dust get into the nozzle holder
assembly mount.
Installation
Delivery tube sleeve nut: 30 ± 5 Nm (3.06 ± 0.51 kgm)
Joint bolt: 8 ± 2 Nm (0.81 ± 0.20 kgm)
Nozzle holder assembly: 60 ± 5 Nm (6.12 ± 0.51 kgm)
Nozzle holder assembly thread portion: Seizer
prevention compound (Molycoat 1000)
i When assembling the nozzle holder, clean the nozzle
mount, and check that there is no dirt or dust inside the
sleeve before assembling.

TURBOCHARGER DISASSEMBLY AND ASSEMBLY
30-25 Î
TURBOCHARGER
Removal
1. Open engine hood, and remove turbocharger shield (1).
2. Remove turbocharger. See engine shop manual for details.
Installation

DISASSEMBLY AND ASSEMBLY THERMOSTAT
30-26 Î
THERMOSTAT
Removal
1. Drain coolant.
2. Open engine hood, and remove fan guard (1) and right side
guard mounting bracket (2).
3. Using wrench Î, raise tensioner (3), then remove fan belt
(4).
4. Remove alternator assembly top mounting bolt (5) from
bracket, then alternator assembly (6) towards partition plate
end.
i Loosen the mounting bolts at the bottom of the alternator
assembly.
5. Disconnect radiator inlet hose (7) and aeration hose (8).
6. Remove alternator bracket (9).
7. Remove thermostat. For details, see engine shop manual.

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Komatsu pc200 lc 6 hydraulic excavator service repair manual (a83000 and up)