SM PC200-7 SEBM024300 S - N 200001 Up
SM PC200-7 SEBM024300 S - N 200001 Up
SM PC200-7 SEBM024300 S - N 200001 Up
PC200, 200LC-7
PC220, 220LC-7
MACHINE MODEL
PC200-7
PC200LC-7
PC220-7
PC220LC-7
SERIAL NUMBER
00
00
00
00
200001 AND UP
200001 AND UP
60001 AND UP
60001 AND UP
00
00
00
00
This shop manual may contain attachments and optional equipment that are not available in your area. Please consult your local Komatsu distributor for those items you may
require.
Materials and specifications are subject to change without notice
2001
All Rights Reserved
Printed in USA 09-01
00-1
CONTENTS
No. of page
01
GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1
10
20
30
90
OTHERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1
00
00-2
SAFETY
SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The service and
repair techniques recommended by Komatsu and described in this manual are both effective
and safe. Some of these techniques require the use of tools specially designed by Komatsu for
the specific purpose.
GENERAL PRECAUTIONS
Mistakes in operation are extremely dangerous.
Read the Operation and Maintenance Manual carefully BEFORE operating the machine.
1. Before carrying out any greasing or repairs, read
all the precautions given on the decals which are
fixed to the machine.
2. When carrying out any operation, always
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons
missing.
00-3
SAFETY
00-4
SAFETY NOTICE
FOREWORD
GENERAL
FOREWORD
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 chapters; these chapters are further divided into the each main group of components.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Use the specifications given in the book with the latest date.
00-5
FOREWORD
VOLUMES
Shop manuals are issued as a guide to carrying out
repairs. They are divided as follows:
W h en a m an u a l is r e vis ed , a n e d itio n ma rk
(
....) is recorded on the bottom of the pages.
REVISIONS
These various volumes are designed to avoid duplicating the same information. Therefore, to deal with
all repairs for any model , it is necessary that chassis, engine, electrical and attachment volumes be
available.
DISTRIBUTION AND UPDATING
Any additions, amendments or other changes will be
sent to KOMATSU distributors. Get the most up-todate information before you start any work.
FILING METHOD
1. See the page number on the bottom of the page.
File the pages in correct order.
2. Following examples show how to read the page
number.
Example 1 (Chassis volume):
10 - 3
Item number (10. Structure and
Function)
Consecutive page number for each
item.
Example 2 (Engine volume):
12 - 5
Unit number (1. Engine)
Item number (2. Testing and Adjusting)
Consecutive page number for each
item.
3. Additional pages: Additional pages are indicated
by a hyphen (-) and number after the page
number. File as in the example.
Example:
12-203
10-4
12-203-1
10-4-1
Added pages
12-203-2
10-4-2
12-204
10-5
00-6
123
SYMBOLS
So that the shop manual can be of ample practical
use, important safety and quality portions are
marked with the following symbols.
Symbol
Item
Remarks
Safety
Caution
Weight
Tightening
torque
Coat
Oil, water
Drain
4
3
2
5
6
FOREWORD
HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
WIRE ROPES
1) Use adequate ropes depending on the
weight of parts to be hoisted, referring to
the table below:
Wire ropes
(Standard "Z" or "S" twist ropes
without galvanizing)
Rope diameter
Allowable load
mm
kN
tons
10
11.5
12.5
14
16
18
20
22.4
30
40
50
60
9.8
13.7
15.7
21.6
27.5
35.3
43.1
54.9
98.1
176.5
274.6
392.2
1.0
1.4
1.6
2.2
2.8
3.6
4.4
5.6
10.0
18.0
28.0
40.0
100%
88%
79%
71%
41%
SAD00479
The allowable load value is estimated to be onesixth or one-seventh of the breaking strength of
the rope used.
00-7
FOREWORD
Disconnection
1) Release the residual pressure from the hydraulic tan k. Fo r d e tails , se e TES TIN G AN D
ADJUSTING, Releasing residual pressure from
hydraulic tank.
2) Hold adapter (1) and push hose joint (2) into
mating adapter (3). (See Fig. 1)
The adapter can be pushed in about 3.5
mm.
Do not hold rubber cap portion (4).
3) After hose joint (2) is pushed into adapter (3),
press rubber cap portion (4) against (3) until it
clicks. (See Fig. 2)
4) Hold hose adapter (1) or hose (5) and pull it out.
(See Fig. 3)
Since some hydraulic oil flows out, prepare
an oil receiving container.
Connection
1) Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3), aligning them with each
other. (See Fig. 4)
Do not hold rubber cap portion (4).
2) After inserting the hose in the mating adapter
perfectly, pull it back to check its connecting
condition. (See Fig. 5)
When the hose is pulled back, the rubber
cap portion moves toward the hose about
3.5 mm. This does not indicate abnormality,
however.
00-8
Type 1
FOREWORD
Type 3
Disassembly
Type 2
Connection
00-9
FOREWORD
COATING MATERIALS
COATING MATERIALS
The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and assembly are listed below.
For coating materials not listed below, use the equivalent of products shown in this list.
Category
Komatsu code
Part No.
Q'ty
Container
LT-1A
790-129-9030
150 g
Tube
LT-1B
790-129-9050
20 g
(2 pcs.)
Polyethylene
container
LT-2
09940-00030
50 g
Polyethylene
container
LT-3
790-129-9060
(Set of
adhesive and
hardening
agent)
Adhesive:
1 kg
Hardenin
g
agent:
500 g
Can
LT-4
790-129-9040
250 g
Polyethylene
container
Holtz
MH 705
790-126-9120
75 g
Tube
Three bond
1735
790-129-9140
50 g
Polyethylene
container
2g
Polyethylene
container
Adhesives
Aron-alpha
201
790-129-9130
Loctite
648-50
79A-129-9110
50 cc
Polyethylene
container
LG-1
790-129-9010
200 g
Tube
LG-5
790-129-9070
1 kg
Can
Gasket
sealant
LG-6
790-129-9020
200 g
Tube
00-10
FOREWORD
Category
COATING MATERIALS
Komatsu code
Part No.
Q'ty
Container
LG-7
790-129-9070
1g
Tube
Three bond
1211
790-129-9090
100 g
Tube
LM-G
09940-00051
60 g
Can
Adhesives
Molybdenum
disulphide
lubricant
LM-P
09940-00040
200 g
Used to prevent seizure or scuffling of the thread when press fitting or shrink fitting.
Used as lubricant for linkage,
bearings, etc.
Tube
G2-LI
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
SYG2-160LI
SYGA-160CNLI
G2-CA
SYG2-400CA
SYG2-350CA
SYG2-400CA-A
SYG2-160CA
SYGA-160CNCA
Various
Various
Molybdenum
disulphide
lubricant
SYG2-400M
400 g
(10 per
case)
Belows type
Grease
Various
Various
00-11
FOREWORD
Width across
flats
mm
mm
6
8
10
12
14
10
13
17
19
22
16
18
20
22
24
24
27
30
32
36
27
30
33
36
39
41
46
50
55
60
Thread diameter
of bolt
Width across
flats
mm
mm
Nm
6
8
10
12
10
13
14
27
7.85 1.95
18.6 4.9
40.2 5.9
82.35 7.85
Nm
kgm
0 0.15
0 0.3
0 0.7
01
02
28.5 0 3
39 0 4
56 0 6
76 0 8.5
94.5 0 10.5
135 0 15
175 0 20
225 0 25
280 0 30
335 0 35
0 1.4
03
07
0 10
0 19
279 0 30
382 0 39
549 0 59
745 0 83
927 0 103
1320 0 140
1720 0 190
2210 0 240
2750 0 290
3290 0 340
1.35
3.2
6.7
11.5
18
13.2
31
66
113
177
kgm
0
0
0
0
0.8
1.9
4.1
8.4
0 0.2
0 0.5
0 0.6
0 0.8
Sealing surface
SAD00483
Thread diameter
mm
mm
Nm
kgm
14
18
22
24
30
33
36
42
19
24
27
32
36
41
46
55
24.5 4.9
49 19.6
78.5 19.6
137.3 29.4
176.5 29.4
196.1 49
245.2 49
294.2 49
2.5 0.5
5 2
8 2
14 3
18 3
20 5
25 5
30 5
00-12
Tightening torque
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
FOREWORD
Thread diameter
Tightening torque
mm
mm
Nm
kgm
10
12
16
14
17
22
65.7 6.8
112 9.8
279 29
0
0
0
6.7 0.7
11.5 1
28.5 3
0
0
Thread diameter
Tightening torque
mm
mm
Nm
14
20
24
33
42
Varies depending
on type of
connector.
34.3 4.9
93.1 9.8
142.1 19.6
421.4 58.8
877.1 132.3
Norminal No.
02
03, 04
05, 06
10, 12
14
kgm
0
0
0
0
0
0 0.5
01
02
06
0 13.5
3.5
9.5
14.5
43
89.5
Thread diameter
Tightening torque
mm
mm
Nm
kgm
08
10
12
14
16
18
20
24
30
33
36
42
52
14
17
19
22
24
27
30
32
32
n
36
n
n
7.35 1.47
11.27 1.47
17.64 1.96
22.54 1.96
29.4 4.9
39.2 4.9
49 4.9
68.6 9.8
107.8 14.7
127.4 19.6
151.9 24.5
210.7 29.4
323.4 44.1
0
0
0
0
0
0
0
0
0
0
0
0
0
0.75 0.15
1.15 0.15
1.8 0.2
2.3 0.2
3 0.5
4 0.5
5 0.5
7 1
11 1.5
13 2
15.5 2.5
21.5 3
33 4.5
Norminal No.
08
10
12
14
16
18
20
24
30
33
36
42
52
0
0
0
0
0
0
0
0
0
0
0
0
0
00-13
FOREWORD
Thread diameter
Tightening torque
mm
Nm
6
8
10
12
10 2
24 4
43 6
77 12
kgm
0
0
0
0
1.02
2.45
4.38
7.85
0 0.20
0 0.41
0 0.61
0 1.22
Thread diameter
Tightening torque
mm
Nm
6
8
10
12
14
8 2
10 2
12 2
24 4
36 5
kgm
0
0
0
0
0
0.81
1.02
1.22
2.45
3.67
0 0.20
0 0.20
0 0.20
0 0.41
0 0.51
Thread diameter
00-14
Tightening torque
mm
Nm
1 / 16
1/8
1/4
3/8
1/2
3/4
1
3 1
8 2
12 2
15 2
24 4
36 5
60 9
0
0
0
0
0
0
0
kgm
0.31
0.81
1.22
1.53
2.45
3.67
6.12
0 0.10
0 0.20
0 0.20
0 0.41
0 0.41
0 0.51
0 0.92
FOREWORD
CLASSIFICATION BY THICKNESS
Copper wire
Cable O.D.
(mm)
Current
rating
(A)
Applicable circuit
0.88
2.4
12
0.32
2.09
3.1
20
65
0.32
5.23
4.6
37
15
84
0.45
13.36
7.0
59
40
85
0.80
42.73
11.4
135
Starting
60
127
0.80
63.84
13.6
178
Starting
100
217
0.80
109.1
17.6
230
Starting
Norminal
number
Number of
strands
Dia. of
strands
(mm2)
Cross
section
(mm 2)
0.85
11
0.32
26
Primary
Charging
Ground
Starting
Lighting
Instrument
Signal
Other
Code
Color
White
Black
Black
Red
Yellow
Green
Blue
Code
WR
BW
RW
YR
GW
LW
2
Color White & Red
Code
WB
3
Color White & Black
Code
4
Auxiliary
WL
WG
5
Color White & Green
Code
6
Color
n
n
n
n
n
n
n
n
n
n
n
n
White & Black Red & White Rellow & Red Green & White Blue & White
BY
RB
YB
GR
LR
Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow
BR
RY
n
n
n
n
RG
YG
GY
LY
Yellow &
Green
Green &
Yellow
YL
GB
LB
Red & Green Yellow & Blue Green & Black Blue & Black
RL
YW
GL
n
n
00-15
FOREWORD
CONVERSION TABLE
CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE
The Conversion Table in this section is provided to enable simple conversion of figures. For details of the
method of using the Conversion Table, see the example given below.
EXAMPLE
Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
(1) Locate the number 50 in the vertical column at the left side, take this as , then draw a horizontal line
from .
(2) Locate the number 5 in the row across the top, take this as , then draw a perpendicular line down
from .
(3) Take the point where the two lines cross as . This point
gives the value when converting from millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.
(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the
left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
A
B
B
Millimeters to inches
1 mm = 0.03937 in
00-16
0
10
20
30
40
0
0.394
0.787
1.181
1.575
0.039
0.433
0.827
1.220
1.614
0.079
0.472
0.866
1.260
1.654
0.118
0.512
0.906
1.299
1.693
0.157
0.551
0.945
1.339
1.732
0.197
0.591
0.984
1.378
1.772
0.236
0.630
1.024
1.417
1.811
0.276
0.669
1.063
1.457
1.850
0.315
0.709
1.102
1.496
1.890
0.354
0.748
1.142
1.536
1.929
50
60
70
80
90
1.969
2.362
2.756
3.150
3.543
2.008
2.402
2.795
3.189
3.583
2.047
2.441
2.835
3.228
3.622
2.087
2.480
2.874
3.268
3.661
2.126
2.520
2.913
3.307
3.701
2.165
2.559
2.953
3.346
3.740
2.205
2.598
2.992
3.386
3.780
2.244
2.638
3.032
3.425
3.819
2.283
2.677
3.071
3.465
3.858
2.323
2.717
3.110
3.504
3.898
FOREWORD
CONVERSION TABLE
0.264
0.528
0.793
1.057
1.321
1.585
1.849
2.113
2.378
10
2.642
2.906
3.170
3.434
3.698
3.963
4.227
4.491
4.755
5.019
20
5.283
5.548
5.812
6.076
6.340
6.604
6.869
7.133
7.397
7.661
30
7.925
8.189
8.454
8.718
8.982
9.246
9.510
9.774
10.039
10.303
40
10.567
10.831
11.095
11.359
11.624
11.888
12.152
12.416
12.680
12.944
50
13.209
13.473
13.737
14.001
14.265
14.529
14.795
15.058
15.322
15.586
60
15.850
16.115
16.379
16.643
16.907
17.171
17.435
17.700
17.964
18.228
70
18.492
18.756
19.020
19.285
19.549
19.813
20.077
20.341
20.605
20.870
80
21.134
21.398
21.662
21.926
22.190
22.455
22.719
22.983
23.247
23.511
90
23.775
24.040
24.304
24.568
24.832
25.096
25.361
25.625
25.889
26.153
0.220
0.440
0.660
0.880
1.100
1.320
1.540
1.760
1.980
10
2.200
2.420
2.640
2.860
3.080
3.300
3.520
3.740
3.950
4.179
20
4.399
4.619
4.839
5.059
5.279
5.499
5.719
5.939
6.159
6.379
30
6.599
6.819
7.039
7.259
7.479
7.969
7.919
8.139
8.359
8.579
40
8.799
9.019
9.239
9.459
9.679
9.899
10.119
10.339
10.559
10.778
50
10.998
11.281
11.438
11.658
11.878
12.098
12.318
12.528
12.758
12.978
60
13.198
13.418
13.638
13.858
14.078
14.298
14.518
14.738
14.958
15.178
70
15.398
15.618
15.838
16.058
16.278
16.498
16.718
16.938
17.158
17.378
80
17.598
17.818
18.037
18.257
18.477
18.697
18.917
19.137
19.357
19.577
90
19.797
20.017
20.237
20.457
20.677
20.897
21.117
21.337
21.557
21.777
00-18
FOREWORD
CONVERSION TABLE
kgm to ft. lb
1 kgm = 7.233 ft. lb
7.2
14.5
21.7
28.9
36.2
43.4
50.6
57.9
65.1
10
72.3
79.6
86.8
94.0
101.3
108.5
115.7
123.0
130.2
137.4
20
144.7
151.9
159.1
166.4
173.6
180.8
188.1
195.3
202.5
209.8
30
217.0
224.2
231.5
238.7
245.9
253.2
260.4
267.6
274.9
282.1
40
289.3
296.6
303.8
311.0
318.3
325.5
332.7
340.0
347.2
354.4
50
361.7
368.9
376.1
383.4
390.6
397.8
405.1
412.3
419.5
426.8
60
434.0
441.2
448.5
455.7
462.9
470.2
477.4
484.6
491.8
499.1
70
506.3
513.5
520.8
528.0
535.2
542.5
549.7
556.9
564.2
571.4
80
578.6
585.9
593.1
600.3
607.6
614.8
622.0
629.3
636.5
643.7
90
651.0
658.2
665.4
672.7
679.9
687.1
694.4
701.6
708.8
716.1
100
723.3
730.5
737.8
745.0
752.2
759.5
766.7
773.9
781.2
788.4
110
795.6
802.9
810.1
817.3
824.6
831.8
839.0
846.3
853.5
860.7
120
868.0
875.2
882.4
889.7
896.9
904.1
911.4
918.6
925.8
933.1
130
940.3
947.5
954.8
962.0
969.2
976.5
983.7
990.9
998.2
1005.4
140
1012.6
1019.9
1027.1
1034.3
1041.5
1048.8
1056.0
1063.2
1070.5
1077.7
150
1084.9
1092.2
1099.4
1106.6
1113.9
1121.1
1128.3
1135.6
1142.8
1150.0
160
1157.3
1164.5
1171.7
1179.0
1186.2
1193.4
1200.7
1207.9
1215.1
1222.4
170
1129.6
1236.8
1244.1
1251.3
1258.5
1265.8
1273.0
1280.1
1287.5
1294.7
180
1301.9
1309.2
1316.4
1323.6
1330.9
1338.1
1345.3
1352.6
1359.8
1367.0
190
1374.3
1381.5
1388.7
1396.0
1403.2
1410.4
1417.7
1424.9
1432.1
1439.4
00-19
FOREWORD
CONVERSION TABLE
kg/cm2 to lb/in2
1kg/cm2 = 14.2233 lb/in2
14.2
28.4
42.7
56.9
71.1
85.3
99.6
113.8
128.0
10
142.2
156.5
170.7
184.9
199.1
213.4
227.6
241.8
256.0
270.2
20
284.5
298.7
312.9
327.1
341.4
355.6
369.8
384.0
398.3
412.5
30
426.7
440.9
455.1
469.4
483.6
497.8
512.0
526.3
540.5
554.7
40
568.9
583.2
597.4
611.6
625.8
640.1
654.3
668.5
682.7
696.9
50
711.2
725.4
739.6
753.8
768.1
782.3
796.5
810.7
825.0
839.2
60
853.4
867.6
881.8
896.1
910.3
924.5
938.7
953.0
967.2
981.4
70
995.6
1010
1024
1038
1053
1067
1081
1095
1109
1124
80
1138
1152
1166
1181
1195
1209
1223
1237
1252
1266
90
1280
1294
1309
1323
1337
1351
1365
1380
1394
1408
100
1422
1437
1451
1465
1479
1493
1508
1522
1536
1550
110
1565
1579
1593
1607
1621
1636
1650
1664
1678
1693
120
1707
1721
1735
1749
1764
1778
1792
1806
1821
1835
130
1849
1863
1877
1892
1906
1920
1934
1949
1963
1977
140
1991
2005
2020
2034
2048
2062
2077
2091
2105
2119
150
2134
2148
2162
2176
2190
2205
2219
2233
2247
2262
160
2276
2290
2304
2318
2333
2347
2361
2375
2389
2404
170
2418
2432
2446
2460
2475
2489
2503
2518
2532
2546
180
2560
2574
2589
2603
2617
2631
2646
2660
2674
2688
190
2702
2717
2731
2745
2759
2773
2788
2802
2816
2830
200
2845
2859
2873
2887
2901
2916
2930
2944
2958
2973
210
2987
3001
3015
3030
3044
3058
3072
3086
3101
3115
220
3129
3143
3158
3172
3186
3200
3214
3229
3243
3257
230
3271
3286
3300
3314
3328
3343
3357
3371
3385
3399
240
3414
3428
3442
3456
3470
3485
3499
3513
3527
3542
00-20
FOREWORD
CONVERSION TABLE
Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface column of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1C = 33.8F
40.4
37.2
34.4
31.7
28.9
40
35
30
25
20
40.0
31.0
22.0
13.0
4.0
11.7
11.1
10.6
10.0
9.4
11
12
13
14
15
51.8
53.6
55.4
57.2
59.0
7.8
8.3
8.9
9.4
10.0
46
47
48
49
50
114.8
116.6
118.4
120.2
122.0
27.2
27.8
28.3
28.9
29.4
81
82
83
84
85
117.8
179.6
181.4
183.2
185.0
28.3
27.8
27.2
26.7
26.1
19
18
17
16
15
2.2
0.4
1.4
3.2
5.0
8.9
8.3
7.8
7.2
6.7
16
17
18
19
20
60.8
62.6
64.4
66.2
68.0
10.6
11.1
11.7
12.2
12.8
51
52
53
54
55
123.8
125.6
127.4
129.2
131.0
30.0
30.6
31.1
31.7
32.2
86
87
88
89
90
186.8
188.6
190.4
192.2
194.0
25.6
25.0
24.4
23.9
23.3
14
13
12
11
10
6.8
8.6
10.4
12.2
14.0
6.1
5.6
5.0
4.4
3.9
21
22
23
24
25
69.8
71.6
73.4
75.2
77.0
13.3
13.9
14.4
15.0
15.6
56
57
58
59
0
132.8
134.6
136.4
138.2
140.0
32.8
33.3
33.9
34.4
35.0
91
92
93
94
95
195.8
197.6
199.4
201.2
203.0
22.8
22.2
21.7
21.1
20.6
9
8
7
6
5
15.8
17.6
19.4
21.2
23.0
3.3
2.8
2.2
1.7
1.1
26
27
28
29
30
78.8
80.6
82.4
84.2
86.0
16.1
16.7
17.2
17.8
18.3
61
62
63
64
65
141.8
143.6
145.4
147.2
149.0
35.6
36.1
36.7
37.2
37.8
96
97
98
99
100
204.8
206.6
208.4
210.2
212.0
20.0
19.4
18.9
18.3
17.8
4
3
2
1
0
24.8
26.6
28.4
30.2
32.0
0.6
0
0.6
1.1
1.7
31
32
33
34
35
87.8
89.6
91.4
93.2
95.0
18.9
19.4
20.0
20.6
21.1
66
67
68
69
70
150.8
152.6
154.4
156.2
158.0
40.6
43.3
46.1
48.9
51.7
105
110
115
120
125
221.0
230.0
239.0
248.0
257.0
17.2
16.7
16.1
15.6
15.0
1
2
3
4
5
33.8
35.6
37.4
39.2
41.0
2.2
2.8
3.3
3.9
4.4
36
37
38
39
40
96.8
98.6
100.4
102.2
104.0
21.7
22.2
22.8
23.3
23.9
71
72
73
74
75
159.8
161.6
163.4
165.2
167.0
54.4
57.2
60.0
62.7
65.6
130
135
140
145
150
266.0
275.0
284.0
293.0
302.0
14.4
13.9
13.3
12.8
12.2
6
7
8
9
10
42.8
44.6
46.4
48.2
50.0
5.0
5.6
6.1
6.7
7.2
41
42
43
44
45
105.8
107.6
109.4
111.2
113.0
24.4
25.0
25.6
26.1
26.7
76
77
78
79
80
168.8
170.6
172.4
174.2
176.0
68.3
71.1
73.9
76.7
79.4
155
160
165
170
175
311.0
320.0
329.0
338.0
347.0
00-21
FOREWORD
UNITS
UNITS
In this manual, the measuring units are indicated with Internatinal System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses {
Example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}
kW/rpm {HP/rpm}
g/kWh {g/HPh}
00-22
}.
01
GENERAL
Specification Dimension Drawings
PC200-7, PC200LC-7 . . . . . . . . . . . 01-2
PC220-7, PC220LC-7 . . . . . . . . . . . 01-4
Specifications
PC200-7, PC200LC-7 . . . . . . . . . . . 01-6
PC220-7, PC220LC-7 . . . . . . . . . . . 01-8
Weight Table
PC200-7, PC200LC-7 . . . . . . . . . . 01-10
PC220-7, PC220LC-7 . . . . . . . . . . 01-12
Fuel, Coolant, And Lubricants. . . . . . . 01-14
PC200-7
01-1
GENERAL
12
WORKING RANGES
01-2
PC200-7
GENERAL
12
DIMENSIONS
Item
Unit
PC200-7
PC200LC-7
Overall length
mm
9,425
9,425
Overall height
mm
3,000
3,000
Overall width
mm
2,800
3,080
mm
600
700
Height of cab
mm
3,000
3,000
mm
2,750
2,750
mm
4,080
4,450
mm
3,270
3,640
mm
440
440
Unit
PC200-7
PC200LC-7
WORKING RANGES
Item
A
mm
9,875
9,875
mm
6,620
6,620
mm
10,000
10,000
mm
5,980
5,980
mm
7,110
7,110
mm
2,645
2,645
mm
2,645
2,645
PC200-7
01-3
GENERAL
PC220-7, PC220LC-7
DIMENSIONS
WORKING RANGES
01-4
PC200-7
GENERAL
12
DIMENSIONS
Item
Unit
PC220-7
PC220LC-7
Overall length
mm
9,885
9,885
Overall height
mm
3,160
3,160
Overall width
mm
2,980
3,280
mm
600
700
Height of cab
mm
3,015
3,015
mm
2,940
2,940
mm
4,250
4,640
mm
3,460
3,845
mm
440
400
Unit
PC220-7
PC220LC-7
WORKING RANGES
Item
A
mm
10,180
10,180
mm
6,920
6,920
mm
10,000
10,000
mm
6,010
6,010
mm
7,035
7,035
mm
2,530
2,530
mm
10,020
10,020
PC200-7
01-5
GENERAL
SPECIFICATIONS
SPECIFICATIONS
PC200-7, PC200LC-7
Machine model
PC200-7
Performance
Working ranges
Serial Number
200001 and up
Bucket capacity
0.8
0.8
Operating weight
kg
19,300
20,700
mm
6,620
6,620
mm
5,980
5,980
mm
9,875
9,875
mm
9,700
9,700
mm
10,000
10,000
mm
7,110
7,110
kN {kg}
138.3 {14,100}
138.3 {14,100}
(149.1 {15,200})
(149.1 {15,200})
rpm
12.4
12.4
deg.
20
20
Travel speed
km/h
Lo: 3.0 (
Mi: 4.1)
Lo: 3.0 (
Mi: 4.1)
Hi: 5.5
Hi: 5.5
deg.
35
35
kPa {kg/cm}
44.1 {0.45}
36.3 {0.37}
[mm]
[600]
[700]
mm
9,425
9,425
Overall width
mm
2,800
3,080
mm
2,800
3,080
mm
3,000
3,000
mm
3,000
3,000
mm
1,085
1,085
mm
440
440
mm
2,750
2,750
mm
3,040
3,040
mm
8,005
8,005
mm
3,270
3,640
Track gauge
mm
2,200
2,380
mm
2,335
2,335
Gradeability
Ground pressure
[standard shoe width]
Dimensions
PC200LC-7
01-6
PC200-7
GENERAL
SPECIFICATIONS
12
Machine model
PC200-7
Serial Number
200001 and up
Model
Type
Performance
Engine
l {cc}
SAA6D102E-2-A
4-cycle, water-cooled, in-line, vertical, direct
injection, with turbo charger
6 - 102 x 120
5.883 {5,883}
kW/rpm {HP/rpm}
Nm/rpm {kgm/rpm}
rpm
rpm
g/kWh {g/HPh}
106.7/1,950 {143/1,950}
610.0/1,500 {62.2/1,500}
2,150
1,030
215 {160}
mm
Starting motor
Alternator
Battery
24V, 4.5 kW
24V, 35 A
12V, 110 Ah x 2
Corrugated CWX-4
2 on each side
Track shoe
Assembly-type triple
grouser, 45 on each
side
Assembly-type triple
grouser, 49 on each
side
Hydraulic
pump
9 on each side
Type x No.
Delivery
Set pressure
Control
valve
7 on each side
Type x No.
Control method
Hydraulic
motor
Track roller
Travel motor
l/min
MPa (kg/cm)
Swing motor
Hrdraulic tank
Hydraulic filter
Hydraulic cooler
PC200-7
Type
Hydraulic culinder
Undercarriage
Carrier roller
Hydraulic system
PC200LC-7
mm
mm
mm
mm
mm
Boom
Arm
Bucket
120
85
1,334.5
3,204.5
1,870
135
95
1,490
3,565
2,075
115
80
1,120
2,800
1,680
01-7
GENERAL
SPECIFICATIONS
PC220-7, PC220LC-7
Machine model
PC220-7
Performance
Working ranges
Serial Number
60001 and up
Bucket capacity
1.0
1.0
Operating weight
kg
22,700
24,130
mm
6,920
6,920
mm
6,010
6,010
mm
10,180
10,180
mm
10,020
10,020
mm
10,000
10,000
mm
7,035
7,035
kN {kg}
158.9 {16,200}
158.9 {16,200}
(171.6 {17,500})
(171.6 {17,500})
rpm
11.7
11.7
deg.
25
25
Travel speed
km/h
Lo: 3.1 (
Mi: 4.2)
Lo: 3.1 (
Mi: 4.2)
Hi: 5.5
Hi: 5.5
deg.
35
35
kPa {kg/cm}
50.0 {0.51}
41.2 {0.42}
[mm]
[600]
[700]
mm
9,885
9,885
Overall width
mm
2,980
3,280
mm
2,980
3,280
mm
3,160
3,160
mm
3,015
3,015
mm
1,110
1,110
mm
440
440
mm
2,940
2,940
mm
3,450
3,450
mm
8,110
8,110
mm
3,460
3,845
Track gauge
mm
2,380
2,580
mm
2,390
2,390
Gradeability
Ground pressure
[standard shoe width]
Dimensions
PC220LC-7
01-8
PC200-7
GENERAL
SPECIFICATIONS
Machine model
PC220-7
Serial Number
60001 and up
Model
Type
Performance
Engine
l {cc}
SAA6D102E-2-C
4-cycle, water-cooled, in-line, vertical, direct
injection, with turbo charger
6 - 102 x 120
5.883 {5,883}
kW/rpm {HP/rpm}
Nm/rpm {kgm/rpm}
rpm
rpm
g/kWh {g/HPh}
125/2,000 {167/2,000}
686/1,500 {70/1,500}
2,260
1,060
212 {153}
mm
Starting motor
Alternator
Battery
24V, 4.5 kW
24V, 35 A
12V, 110 Ah x 2
Corrugated CF19-5
2 on each side
Track shoe
Assembly-type triple
grouser, 47 on each
side
Assembly-type triple
grouser, 51 on each
side
Hydraulic
pump
10 on each side
Type x No.
Delivery
Set pressure
Control
valve
8 on each side
Type x No.
Control method
Hydraulic
motor
Track roller
Travel motor
l/min
6-spool type x 1
Hydraulic
HMV110ADT-2, Piston type
(with brake valve, parking brake): x 2
KMF125ABE-5, Piston type
(with safety valve, holding brake): x 1
Swing motor
Hrdraulic tank
Hydraulic filter
Hydraulic cooler
PC200-7
MPa (kg/cm)
Type
Hydraulic culinder
Undercarriage
Carrier roller
Hydraulic system
PC220LC-7
mm
mm
mm
mm
mm
Boom
Arm
Bucket
130
90
1,335
3,205
1,870
140
100
1,635
2,235
3,870
130
90
1,020
2,625
1,605
01-9
GENERAL
WEIGHT TABLE
12
WEIGHT TABLE
PC200-7, PC200LC-7
This weight table is for use when handling components or when transporting the machine.
Unit: kg
Machine model
PC200-7
PC200LC-7
Serial Number
200001 and up
200001 and up
Engine assembly
749
749
Engine
598
598
Damper
Hydraulic pump
145
145
110
110
123
123
121
121
1,729
1,729
Operators cab
278
278
Operators seat
35
35
Counterweight
3,735
3,735
Swing machinery
160
160
Control valve
263
263
Swing motor
60
60
Travel motor
98 x 2
98 x 2
36
36
4,194
4,712
Track frame
2,179
2,534
Swing circle
273
273
Idler
99 x 2
99 x 2
Idler cushion
130 x 2
135 x 2
Carrier roller
16 x 4
16 x 4
Track roller
36 x 14
36 x 18
343 x 2
343 x 2
Revolving frame
01-10
PC200-7
GENERAL
WEIGHT TABLE
12
Unit: kg
Machine model
PC200-7
PC200LC-7
Serial Number
200001 and up
200001 and up
1,215 x 2
1,325 x 2
1,405 x 2
1,530 x 2
1,530 x 2
1,670 x 2
1,470 x 2
1,600 x 2
1,408
1,408
Arm assembly
653
653
Bucket assembly
628
628
172 x 2
172 x 2
226
226
136
136
81
81
22 x 2
22 x 2
48 + 8 x 2 + 31 + 10 + 26
48 + 8 x 2 + 31 + 10 + 26
Arm pin
11 + 8
11 + 8
Bucket pin
20 x 2
20 x 2
Link pin
13 x 2
13 x 2
Boom assembly
Boom pin
PC200-7
01-11
GENERAL
WEIGHT TABLE
PC220-7, PC220LC-7
Unit: kg
Machine model
PC220-7
PC220LC-7
Serial Number
60001 and up
60001 and up
Engine assembly
749
749
Engine
598
598
Damper
Hydraulic pump
145
145
119
119
123
123
121
121
2,048
2,048
Operators cab
278
278
Operators seat
35
35
Counterweight
5,056
5,056
Swing machinery
237
237
Control valve
263
263
Swing motor
60
60
Travel motor
98 x 2
98 x 2
36
36
4,828
5,460
Track frame
2,558
3,046
Swing circle
293
293
Idler
99 x 2
99 x 2
Idler cushion
135 x 2
135 x 2
Carrier roller
16 x 4
16 x 4
Track roller
36 x 16
36 x 20
362 x 2
362 x 2
Revolving frame
01-12
PC200-7
GENERAL
WEIGHT TABLE
12
Unit: kg
Machine model
PC220-7
PC220LC-7
Serial Number
60001 and up
60001 and up
1,340 x 2
1,455 x 2
1,470 x 2
1,595 x 2
1,600 x 2
1,735 x 2
1,535 x 2
1,665 x 2
Boom assembly
1,825
1,825
Arm assembly
1,213
1,213
722
722
195 x 2
195 x 2
262
262
161
161
82
82
22 x 2
22 x 2
50 + 10 x 2 + 31 + 10 + 26
50 + 10 x 2 + 31 + 10 + 26
Arm pin
11 + 10
11 + 10
Bucket pin
20 x 2
20 x 2
Link pin
17 x 2
17 x 2
Bucket assembly
Boom cylinder assembly
Boom pin
PC200-7
01-13
GENERAL
12
RESERVOIR
KIND
OF
FLUID
CAPACITY (l)
AMBIENT TEMPERATURE
-22 -4
-30 -20
14
-10
32
0
50
10
68
20
86
30
104F
40C
Specified
Refill
26.3
24
0.75
6.6
6.6
4.7
4.5
Idler (1 each)
0.07-0.08
0.07-0.08
0.19-0.20
0.19-0.20
0.075-0.085
0.075-0.085
240
143
400
PC200,
PC200LC-7
PC200,
PC200LC-7
22.4
22.4
PC220,
PC220LC-7
PC220,
PC220LC-7
30.9
30.9
SAE 30
SAE 10W
Engine oil pan
SAE 10W-30
SAE 15W-40
Damper case
Swing machinery case
Final drive case (each side)
Engine
oil
SAE 30
Fuel tank
H046-HM ()
ASTM D975 No. 2
Diesel
fuel
ASTM D975A
No.1
Cooling system
Coolant
Add antifreeze
01-14
PC200-7
10
1252
Engine
PC200-7
Hydraulic Cylinder
PC200-7, PC200LC-7 . . . . . . . . .
PC220-7, PC220LC-7 . . . . . . . . .
Work Equipment. . . . . . . . . . . . . . .
Air Conditioner . . . . . . . . . . . . . . . .
Engine Control . . . . . . . . . . . . . . . .
Electronic Control System . . . . . . .
Multi Monitor System . . . . . . . . . .
7-Segment Monitor System . . . . .
Sensor . . . . . . . . . . . . . . . . . . . . . . .
10-134
10-136
10-138
10-146
10-147
10-155
10-180
10-202
10-209
10-1
12
1.
2.
3.
4.
Drive plate
Torsion spring
Stopper pin
Friction plate
10-2
5.
6.
7.
8.
Damper assembly
Muffler
Rear engine mount
Front engine mount
OUTLINE
PC200-7
12
SWP08671
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Reservoir tank
Oil cooler
Radiator
Fan
Radiator inlet hose
Radiator outlet hose
Radiator cap
Net
Shroud
Aftercooler
PC200-7
SPECIFICATIONS
Radiator
10-3
POWER TRAIN
12
POWER TRAIN
1.
2.
3.
4.
5.
6.
Idler
Center swivel joint
Control valve
Final drive
Travel motor (HMV 110ADT-2)
Hydraulic pump (HPV95+95)
10-4
7.
8.
9.
10.
11.
12.
Engine (SAA6D102E-2)
Travel speed solenoid valve
Swing brake solenoid valve
Swing motor (KMF125ABE-5)
Swing machinery
Swing circle
PC200-7
FINAL DRIVE
12
FINAL DRIVE
10-6
PC200-7
FINAL DRIVE
12
1.
2.
3.
4.
5.
4.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Level plug
Drain plug
Cover
No. 2 sun gear (No. of teeth: 21)
No. 1 sun gear (No. of teeth: 10)
No. 1 planetary carrier
Cover
No. 2 planetary carrier
Sprocket
Floating seal
Travel motor
Hub
No. 2 planetary gear (No. of teeth: 36)
Ring gear (No. of teeth: 95)
No. 1 planetary gear (No. of teeth: 42)
SPECIFICATIONS
Reduction ratio:
10 + 95 21+ 95
+ 1 = 57.00
10 21
Unit: mm
No.
15
Check item
Backlash between No. 1 sun gear and
No. 1 planetary gear
Criteria
Remedy
Standard clearance
Clearance limit
0.15 - 0.49
1.00
16
0.17 - 0.57
1.10
17
0.06 - 0.25
18
0.14 - 0.46
1.00
19
0.17 - 0.57
1.10
20
0.38 - 0.66
1.00
21
0.00 - 0.10
22
23
Replace
Repair limit: 6
Standard size
Repair limit
71
68
PC200-7
Rebuild or
replace
10-7
SWING MACHINERY
12
SWING MACHINERY
PC200-7, PC200LC-7
10-8
PC200-7
SWING MACHINERY
12
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
SPECIFICATIONS
Reduction ratio:
17 + 58 18 + 58
= 18.627
17 18
Unit: mm
No.
Check item
Criteria
Remedy
Standard clearance
Clearance limit
0.18 - 0.28
0.16 - 0.50
1.00
16
0.18 - 0.59
1.10
17
0.39 - 0.71
1.20
18
0.16 - 0.50
0.90
19
0.18 - 0.59
1.00
20
0.07 - 0.23
21
0.22 - 1.32
2.00
22
0.66 - 1.14
Standard size
Repair limit
23
14
15
PC200-7
115
0
-0.100
Replace
10-9
SWING MACHINERY
PC220-7, PC220LC-7
10-10
PC200-7
SWING MACHINERY
12
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
SPECIFICATIONS
Reduction ratio:
17 + 58 14 + 58
= 22.689
17 14
Unit: mm
No.
Check item
Criteria
Remedy
Standard clearance
Clearance limit
0.18 - 0.28
0.16 - 0.59
1.00
16
0.18 - 0.50
1.10
17
0.39 - 0.64
1.20
18
0.16 - 0.44
0.90
19
0.18 - 0.56
1.00
20
0.08 - 0.23
21
0.23 - 1.37
2.00
22
0.58 - 0.62
Standard size
Repair limit
23
14
15
PC200-7
115
0
-0.100
Replace
10-11
SWING CIRCLE
SWING CIRCLE
PC200-7, PC200LC-7
SPECIFICATIONS
110
Reduction ratio:
= 7.333
15
Amount of grease: 14.6 l (G2-LI)
Unit: mm
No.
10-12
Check item
Axial clearance of bearing
(when mounted on chassis)
Criteria
Remedy
Standard clearance
Clearance limit
0.5 - 1.6
3.2
Replace
PC200-7
SWING CIRCLE
12
PC220-7, PC220LC-7
S*P09097
SPECIFICATIONS
92
Reduction ratio: = 7.077
13
Amount of grease: 15.8 l (G2-LI)
Unit: mm
No.
PC200-7
Check item
Axial clearance of bearing
(when mounted on chassis)
Criteria
Remedy
Standard clearance
Clearance limit
0.5 - 1.6
3.2
Replace
10-13
12
1
2
3
4
5
6
7
8
9
Idler
Track frame
Carrier roller
Final drive
Track roller
Track shoe
Center guard
Recoil spring
Front guard
10-14
Qty
PC200-7
PC200LC-7
PC220-7
PC220LC-7
10
PC200-7
12
Standard shoe
Model
PC200-7
PC200LC-7
PC220-7
PC220LC-7
Shoe width
600 mm
700 mm
600 mm
700 mm
Link pitch
190 mm
190 mm
190 mm
190 mm
45 (pieces)
49 (pieces)
47 (pieces)
51 (pieces)
Item
Unit: mm
No.
Check item
Criteria
Standard
size
10
11
Track frame
107
Idler support
105
Track frame
250
Idler support
247.4
Standard size
Recoil spring
12
PC200-7
PC200LC-7
PC220-7
PC22LC-7
PC200-7
Remedy
Tolerance
Repair limit
Rebuild
or
replace
Repair limit
Free length
x O.D.
Installation
length
Installation
load
Free
length
Installation
load
558 X 238
437
108.8 kN
(11,100 kg)
534
87.3 kN
(8,900 kg)
603.5 X 239
466
126.5 kN
(12,900 kg)
576
100.9 kN
(10,300 kg)
Replace
10-15
12
IDLER
10-16
PC200-7
12
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Repair limit
538
500
488
Thickness of tread
26
20
Total width
159
Width of tread
37.5
43.5
Standard
size
65
Standard
size
72
PC200-7
Tolerance
Shaft
Hole
-0.250
-0.350
+0.074
-0.036
Tolerance
Shaft
Hole
+0.089
+0.059
-0.006
-0.072
Rebuild
or
replace
Standard
clearance
Clearance
limit
0.214 - 0.424
1.5
Standard
interference
Interference
limit
0.065 - 0.161
Replace
bushing
10-17
12
CARRIER ROLLER
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Repair limit
145
120
106
Width of tread
43
Thickness of tread
36.5
29.5
Width of flange
14
10-18
Standard
size
Tolerance
Standard
interference
Interference
limit
Shaft
Hole
40
-0.179
-0.190
+0.284
+0.169
0.339 - 0.474
47
-0.061
-0.036
0
-0.040
0.036 - 0.101
Standard clearance
Clearance limit
0.44 - 0.76
Replace
PC200-7
12
TRACK ROLLER
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Repair limit
188
156
144
Thickness of tread
44.5
38.5
Overall width
225
Inside width
85
Width of tread
44.5
Width of flange
25.5
Standard
size
60
Standard
size
67
PC200-7
Tolerance
Shaft
Hole
-0.215
-0.315
+0.195
0
Tolerance
Shaft
Hole
-0.153
-0.053
+0.030
0
Rebuild
or
replace
Standard
clearance
Clearance
limit
0.215 - 0.510
1.5
Standard
interference
Interference
limit
0.023 - 0.153
Replace
bushing
10-19
TRACK SHOE
12
TRACK SHOE
TRIPLE GROUSER SHOE, ROAD LINER, SWAMP SHOE, FLAT SHOE
1.Triple-grouser shoe
2.Road liner
10-20
3.Swamp shoe
4.Flat shoe
PC200-7
TRACK SHOE
12
Unit: mm
No
.
1
Check item
Criteria
Remedy
Standard size
Repair limit
190.25
194.25
Link pitch
When turned
Standard size
Normal load
Impact load
54.3
59.3
3
Standard size
Repair limit
105
97
28.5
20.5
Reverse
or
replace
Link height
Thickness of link metal
(bushing press-fitting portion)
4
5
Repair or
replace
160.4
62
18
8
9
Inside width
84.8
Overall width
45.4
Tread width
39.6
Regular
2.5
Master
2.5
Protrusion of
bushing
Regular
4.85
Master
0.0
Overall length of
pin
Regular
212
Master
212
Overall length of
bushing
Regular
138.5
Master
128.7
Standard
10.4
When turned /
Impact Load
5.4
Link
10
11
12
13
14
15
16
Protrusion of pin
Thickness of
bushing metal
Thickness of spacer
17
18
19
Reverse
or
replace
Bushing
Press-fitting
force
Adjust or
replace
Regular pin
Master pin
PC200-7
10-21
TRACK SHOE
12
Unit: mm
No.
Check item
Criteria
Tightening torque
(Nm {kgm})
a. Regular link
Shoe bolt
20
b. Master link
Additional tightening
angle (deg.)
Triple shoe
490 49
{50 5}
120 10
Road liner
(Rubber pad type)
549 59
{56 6}
Tightening torque
(Nm {kgm})
22
23
Interference between
regular pin and link
Tolerance
Standard
size
59
+0.304
+0.394
+0.074
0
0.320 - 0.434
38
+0.222
+0.162
-0.138
-0.200
0.300 - 0.422
Tolerance
Standard
size
Shaft
Hole
+0.222
+0.162
+0.902
+0.402
Tolerance
Standard
size
Shaft
Hole
+0.280
+0.250
+0.062
0
Standard
clearance
0.180 - 0.740
Shaft
Hole
-0.150
-0.350
+0.902
+0.402
0.188 - 0.280
Standard
clearance
0.552 - 1.252
Standard size
Repair limit
26
16
Lug welding,
rebuild or
replace
70
25
Replace
Triple-grouser
Road liner
Adjust or
replace
Standard
interference
Tolerance
Standard
size
38
Height of
grouser
Standard
interference
Hole
37.8
25
Shaft
38
24
Interference between
bushing and link
Retighten
21
Remedy
10-22
PC200-7
TRACK SHOE
12
SWAMP SHOE
Unit: mm
No.
1
2
Check item
Criteria
Remedy
Standard size
Repair limit
26
16
Height
Thickness
8.5
26
Length of base
19
20
Rebuild or replace
Length at tip
14
7
8
19
Height
10
Thickness
PC200-7
Standard size
Repair limit
34.5
24.5
102.5
90.5
17
Thickness
10-23
12
10-24
PC200-7
FOREWORD
CONVERSION TABLE
Millimeters to Inches
1 mm = 0.03937 in
0.039
0.079
0.118
0.157
0.197
0.236
0.276
0.315
0.354
10
0.394
0.433
0.472
0.512
0.551
0.591
0.630
0.669
0.709
0.748
20
0.787
0.827
0.866
0.906
0.945
0.984
1.024
1.063
1.102
1.142
30
1.181
1.220
1.260
1.299
1.339
1.378
1.417
1.457
1.496
1.536
40
1.575
1.614
1.654
1.693
1.732
1.772
1.811
1.850
1.890
1.929
50
1.969
2.008
2.047
2.087
2.126
2.165
2.205
2.244
2.283
2.323
60
2.362
2.402
2.441
2.480
2.520
2.559
2.598
2.638
2.677
2.717
70
2.756
2.795
2.835
2.874
2.913
2.953
2.992
3.032
3.071
3.110
80
3.150
3.189
3.228
3.268
3.307
3.346
3.386
3.425
3.465
3.504
90
3.543
3.583
3.622
3.661
3.701
3.740
3.780
3.819
3.858
3.898
Kilogram to Pound
1 kg = 2.2046 lb
0
0
2.20
4.41
6.61
8.82
11.02
13.23
15.43
17.64
19.84
10
22.05
24.25
26.46
28.66
30.86
33.07
35.27
37.48
39.68
41.89
20
44.09
46.30
48.50
50.71
51.91
55.12
57.32
59.53
61.73
63.93
30
66.14
68.34
70.55
72.75
74.96
77.16
79.37
81.57
83.78
85.98
40
88.18
90.39
92.59
94.80
97.00
99.21
101.41
103.62
105.82
108.03
50
110.23
112.44
114.64
116.85
119.05
121.25
123.46
125.66
127.87
130.07
60
132.28
134.48
136.69
138.89
141.10
143.30
145.51
147.71
149.91
152.12
70
154.32
156.53
158.73
160.94
163.14
165.35
167.55
169.76
171.96
174.17
80
176.37
178.57
180.78
182.98
185.19
187.39
189.60
191.80
194.01
196.21
90
198.42
200.62
202.83
205.03
207.24
209.44
211.64
213.85
216.05
218.26
00-17
12
PC200-7
10-25
HYDRAULIC TANK
12
HYDRAULIC TANK
1.
2.
3.
4.
5.
6.
7.
Sight gauge
Hydraulic tank
Oil filler cap
Filter element
Strainer
Bypass valve
Suction strainer
10-26
SPECIFICATIONS
Tank capacity: 200 l
Amount of oil inside tank: 143 l
Pressure valve
Relief cracking pressure:
16.7 6.9 kPa
{0.17 0.07 kg/cm}
Suction cracking pressure:
0 - 0.49 kPa
{0 - 0.005 kg/cm}
Bypass Valve set pressure:
150 30 kPa
{1.5 0.3 kg/cm}
PC200-7
HYDRAULIC PUMP
12
HYDRAULIC PUMP
HPV95 + 95
1.
2.
3.
4.
5.
6.
IM
ISIG
PAF
PFC
:
:
:
:
PAR :
PRC :
PBF :
PD1F:
PENF:
Outline
This pump consists of 2 variable capacity swash plate
piston pumps, PC valve, LS valve, and EPC valve.
10-28
PC200-7
HYDRAULIC PUMP
12
1.
2.
3.
4.
5.
6.
Shaft (Front)
Cradle
Case (Front)
Rocker cam
Shoe
Piston
PC200-7
7.
8.
9.
10.
11.
12.
Cylinder block
Valve plate
End cap
Shaft (Rear)
Case (Rear)
Servo piston
10-29
HYDRAULIC PUMP
12
Function
The rotation and torque transmitted to the
pump shaft are converted into hydraulic
energy, and pressurized oil is discharged
according to the load.
It is possible to change the discharge amount
by changing the swash plate angle.
Structure
Cylinder block (7) is supported to shaft (1) by
a spline, and shaft (1) is supported by the
front and rear bearings.
The tip of piston (6) is a concave ball, and
shoe (5) is caulked to it to form one unit. Piston (6) and shoe (5) form a spherical bearing.
10-30
PC200-7
HYDRAULIC PUMP
12
Operation
1) Operation of pump
i Cylinder block (7) rotates together with
shaft (1), and shoe (5) slides on flat surface
A.
When this happens, rocker cam (4) moves
along cylindrical surface B, so angle
between center line X of rocker cam (4) and
the axial direction of cylinder block (7)
changes. (Angle is called the swash plate
angle.)
ii Center line X of rocker cam (4) maintains
swash plate angle in relation to the axial
direction of cylinder block (7), and flat surface A moves as a cam in relation to shoe
(5).
In this way, piston (6) slides on the inside of
cylinder block (7), so a difference between
volumes E and F is created inside cylinder
block (7). The suction and discharge is carried out by this difference F - E.
In other words, when cylinder block (7)
rotates and the volume of chamber E
becomes smaller, the oil is discharged during that stroke. On the other hand, the volume of chamber F becomes larger, and as
the volume becomes bigger, the oil is
sucked in.
iii If center line X of rocker cam (4) is in line
with the axial direction of cylinder block (7)
(swash plate angle = 0), the difference
between volumes E and F inside cylinder
block (7) becomes 0, so the pump does not
carry out any suction or discharge of oil.
(In actual fact, the swash plate angle never
becomes 0.)
PC200-7
10-31
HYDRAULIC PUMP
10-32
PC200-7
HYDRAULIC PUMP
12
LS VALVE
1.
2.
3.
4.
5.
6.
7.
8.
Plug
Locknut
Sleeve
Spring
Seat
Spool
Piston
Sleeve
PP :
PDP :
PLP :
PLS :
PPL :
PSIG :
Pump port
Drain port
LS control pressure output port
LS pressure input port
PC control pressure input port
LS mode selection pilot port
PP1
PP2
PT
PM
PPL
PLP
Pump port
Pump pressure pilot port
Drain port
PC mode selector pressure pilot port
PC control pressure output port
LS control pressure output port
PC VALVE
1.
2.
3.
4.
5.
6.
7.
8.
PC200-7
:
:
:
:
:
:
10-33
HYDRAULIC PUMP
12
Function
(1) LS valve
The LS valve detects the load and controls the
discharge amount.
This valve controls main pump discharge
amount Q according to differential pressure
PLS (=PP - PLS) [called the LS differential
pressure] (the difference between main pump
pressure PP and control valve outlet port
pressure PLS).
Main pump pressure PP, pressure PLS {called
the LS pressure} coming from the control
valve output, and pressure Psig {called the
LS selector pressure} from the proportional
solenoid valve enter this valve. The relationship between discharge amount Q and differential pressure PLS, (the difference between
main pump pressure PP and LS pressure
PLS) (= PP - PLS) changes as shown in the
diagram at the right according to LS pressure
selector current isig of the LS-EPC valve.
When isig changes between 0 and 1A, the set
pressure of the spring changes according to
this, and the selector point for the pump discharge amount changes at the rated central
valve between 0.69 2.2 MPa {7 22 kg/
cm}.
(2) PC valve
When the pump discharge pressure PP1
(self-pressure) and PP2 (other pump pressure) are high, the PC valve controls the
pump so that no more oil than the constant
flow (in accordance with the discharge pressure) flows even if the stroke of the control
valve becomes larger. In this way, it carries
out equal horsepower control so that the
horsepower absorbed by the pump does not
exceed the engine horsepower.
In other words, If the load during the operation becomes larger and the pump discharge
pressure rises, it reduces the discharge
amount from the pump; and if the pump discharge pressure drops, it increases the discharge amount from the pump. The
relationship between the average of the front
and rear pump discharge pressures (average
discharge amount of F, R pumps (PP1 +
PP2)/2) and pump discharge amount Q is
shown on the right, with the current given to
the PC-EPC valve solenoid shown as a parameter. The controller senses the actual speed of
the engine, and if the speed drops because of
an increase in the load, it reduces the pump
discharge amount to allow the speed to
recover. In other words, when the load
increases and the engine speed drops below
10-34
the set value, the command current to the PCEPC valve solenoid from the controller
increases according to the drop in the engine
speed to reduce the pump swash plate angle.
PC200-7
HYDRAULIC PUMP
12
OPERATION
SDP08884
(1) LS valve
1) When control valve is at neutral position
The LS valve is a three-way selector valve,
with pressure PLS (LS pressure) from the
inlet port of the control valve brought to
spring chamber B, and main pump discharge
pressure PP brought to port H of sleeve (8).
The size of this LS pressure PLS + force Z of
spring (4) and the main pump pressure (self
pressure) PP determines the position of
spool (6). However, the size of the output
pressure PSIG (the LS selection pressure) of
the EPC valve for the LS valve entering port G
also changes the position of spool (6). (The
set pressure of the spring changes).
Before the engine is started, servo piston (11)
is pushed to the right. (See the diagram on
the right)
When the engine is started and the control
lever is at the neutral position, LS pressure
PLS is 0 MPa {0 kg/cm}. (It is interconnected
with the drain circuit through the control
valve spool.)
PC200-7
10-35
HYDRAULIC PUMP
12
SDP08885
10-36
PC200-7
HYDRAULIC PUMP
12
SDP08886
PC200-7
10-37
HYDRAULIC PUMP
12
SDP08887
10-38
PC200-7
HYDRAULIC PUMP
12
(2) PC Valve
1) When pump controller is normal
a. When the load on the actuator is small
and pump pressures PP1 and PP2 are
low
Movement of PC-EPC solenoid (1)
The command current from the pump
controller flows to PC-EPC solenoid
(1).This command current acts on the PCEPC valve and outputs the signal pressure. When this signal pressure is
received, the force pushing piston (2) is
changed.
On the opposite side to the force pushing
this piston (2) is the spring set pressure of
springs (4) and (6) and pump pressure
PP1 (self pressure) and PP2 (other pump
pressure) pushing spool (3). Piston (2)
stops at a position where the combined
force pushing spool (3) is balanced, and
PC200-7
10-39
HYDRAULIC PUMP
12
SDP08889
Action of spring
The spring load of springs (4) and (6) in the
PC valve is determined by the swash plate
position.
If piston (9) moves to the left, spring (6) is
compressed, and if it moves further to the left,
spring (6) contacts seat (5) and is fixed in
position. In other words, the spring load is
changed by piston (9) extending or compressing springs (4) and (6).
10-40
PC200-7
HYDRAULIC PUMP
12
PC200-7
10-41
HYDRAULIC PUMP
12
10-42
If main pump pressure PP increases further and spool (3) moves further to the
left, main pump pressure PP1 flows to
port C and acts to make the discharge
amount the minimum. When piston (9)
moves to the left, springs (4) and (6) are
compressed and push back spool (3).
When spool (3) moves to the left, the
opening of port C and port D becomes
larger. As a result, the pressure at port C
(= J) drops, and piston (9) stops moving
to the left.
The position in which piston (9) stops
when this happens is further to the left
than the position when pump pressures
PP1 and PP2 are low.
PC200-7
HYDRAULIC PUMP
12
PC200-7
10-43
HYDRAULIC PUMP
12
10-44
PC200-7
HYDRAULIC PUMP
12
PC200-7
10-45
HYDRAULIC PUMP
12
LS(PC)-EPC VALVE
1.
2.
3.
4.
Body
Spool
Spring
Rod
10-46
5. Coil
6. Plunger
7. Connector
PC200-7
HYDRAULIC PUMP
12O
FUNCTION
OPERATION
1. When signal current is 0 (coil deenergized)
When there is no signal current flowing
from the controller to coil (5), coil (5) is
generalized.
For this reason, spool (2) is pushed to the
right in the direction of the arrow by spring
(3).
As a result, port PEPC closes and the pressurized oil from the main pump does not
flow to the LS valve.
At the same time, the pressurized oil from
the LS valve passes from port PSIG(PM)
through port PT and is drained to the tank.
PC200-7
08890
10-47
10-48
HYDRAULIC PUMP
08891
08892
PC200-7
CONTROL VALVE
12
CONTROL VALVE
PC200-7, PC200LC-7
1.
2.
3.
4.
5.
6.
7.
6-spool valve
Cover 1
Cover 2
Pump merge-divider valve
Back pressure valve
Boom lock valve
Service valve
OUTLINE
A1
A2
A3
A4
A5
A6
A-1
B1
B2
B3
B4
B5
B6
B-1
P1
P2
P3
P4
P5
P6
P7
P8
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
10-50
P9
P10
P11
P12
P-1
P-2
BP1
BP5
PLS1 :
PLS2 :
PP1 :
PP2 :
PR :
PS :
PST :
PX1 :
PX2 :
SA :
SB :
T
:
TS :
TSW :
PC200-7
CONTROL VALVE
12
7-spool valve
(6-spool valve + 1 service valves)
(1/9)
PC200-7
10-51
CONTROL VALVE
12
(2/9)
S*P09099
10-52
PC200-7
CONTROL VALVE
12
(3/9)
1. Unload valve
2. Pressure compensation valve (Arm OUT)
3. Pressure compensation valve (Right travel
Reverse)
4. Pressure compensation valve (Left swing)
5. Pressure compensation valve (Boom RAISE)
6. Pressure compensation valve (Left travel
reverse)
7. Pressure compensation valve (Bucket DUMP)
8. Pressure compensation valve (Service)
PC200-7
10-53
CONTROL VALVE
12
(4/9)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Spool (Arm)
Spool (Right travel)
Spool (Swing)
Spool (Boom)
Spool (Left travel)
Spool (Bucket)
Spool (Service)
Unload valve
Main relief valve
Spool return spring
Unit: mm
No.
Check item
Criteria
Standard size
11
Remedy
Repair limit
Free length x
Outside diameter
Installed
length
Installed
load
Free
length
Installed
load
54.2 x 34.8
51.2
416.5 N
{42.5 kg}
333.2 N
{34 kg}
12
54.6 x 34.8
51.2
429.9 N
{43.9 kg}
336.1 N
{34.3 kg}
13
54.5 x 34.8
51.2
393 N
{40.1 kg}
314.6 N
{32.1 kg}
10-54
If damaged or
deformed, replace
spring
PC200-7
CONTROL VALVE
12
(5/9)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
Unit: mm
No.
Check item
Criteria
Standard size
22
PC200-7
Remedy
Repair limit
Free length x
Outside diameter
Installed
length
Installed
load
Free
length
Installed
load
11.5 x 4.6
8.5
1.5 N
{0.15 kg}
1.2 N
{0.12 kg}
If damaged or
deformed, replace
spring
10-55
CONTROL VALVE
12
(6/9)
10-56
5. Safety-suction valve
6. Spool
7. Pressure compensation valve
(OUT)
8. LS shuttle valve
9. Pressure compensation valve
(IN)
10. Safety-suction valve
11. Check valve for regeneration circuit
R. H. TRAVEL CONTROL
VALVE
12. Suction valve
13. Spool
14. Pressure compensation valve
(Reverse)
15. LS shuttle valve
16. Pressure compensation valve
(Forward)
17. Suction valve
PC200-7
CONTROL VALVE
Unit: mm
No.
Check item
Criteria
Standard size
18
Relief spring
Remedy
Repair limit
Free length x
Outside diameter
Installed
length
Installed
load
Free
length
Installed
load
30.7 x 9.6
25.9
406.7 N
{41.5 kg}
325.6 N
{33.2 kg}
24.3 x 8
19.5
69.6 N
{7.1 kg}
55.7 N
{5.7 kg}
19
Valve spring
20
Unload spring
31.5 x 10.2
26.9
70.6 N
{7.2 kg}
56.4 N
{5.8 kg}
21
Regeneration valve
spring
31.5 x 10.3
19
6.2 N
{0.6 kg}
4.9 N
{0.5 kg}
22
48.1 x 10.8
28
17.5 N
{1.8 kg}
14.0 N
{1.4 kg}
23
56.4 x 11.9
45
79.4 N
{8.1 kg}
63.5 N
{6.5 kg}
24
36.9 x 11.1
28
29.4 N
{3 kg}
23.5 N
{2.4 kg}
PC200-7
If damaged or
deformed, replace
spring
10-57
CONTROL VALVE
(7/9)
SERVICE VALVE
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Safety-suction valve
Spool
Pressure compensation valve (DUMP)
LS shuttle valve
Pressure compensation valve (CURL)
Safety-suction valve
Safety-suction valve
Spool
Pressure compensation valve
LS shuttle valve
Pressure compensation valve
Safety-suction valve
Unit: mm
No.
Check item
Criteria
Standard size
13
14
10-58
Free length x
Outside diameter
Remedy
Repair limit
Installed
length
Installed
load
Free
length
Installed
load
28
17.5 N
{1.8 kg}
14.0 N
{1.4 kg}
48.1 x 10.8
36.9 x 11.1
28
29.4 N
{3 kg}
23.5 N
{2.4 kg}
If damaged or
deformed, replace
spring
PC200-7
CONTROL VALVE
12
(8/9)
1. Spool
2. Pressure compensation
valve (Left)
3. LS select valve
4. Pressure compensation
valve (Right)
5. Suction valve
6. Spool
7. Pressure compensation
valve (RAISE)
8. Hydraulic drift prevention
valve
9. LS shuttle valve
10. Pressure compensation
valve (Lower)
11. Safety-suction valve
12. Check valve for regeneration
circuit
10-60
L. H. TRAVEL CONTROL
VALVE
13. Pump merge-divider valve
(Travel junction valve)
14. Return spring
15. Suction valve
16. Spool
17. Pressure compensation
valve (Reverse)
18. LS shuttle valve
19. Pressure compensation
valve (Forward)
20. Suction valve
PC200-7
CONTROL VALVE
Unit: mm
No.
Check item
Criteria
Standard size
21
Remedy
Repair limit
Free length x
Outside diameter
Installed
length
Installed
load
Free
length
Installed
load
31.5 x 10.3
19
6.2 N
{0.6 kg}
4.9 N
{0.5 kg}
22
48.1 x 10.8
28
17.5 N
{1.8 kg}
14.0 N
{1.4 kg}
23
36.9 x 11.1
28
29.4 N
{3 kg}
23.5 N
{2.4 kg}
343 N
{35.0 kg}
24
Load spring
30.4 x 16.7
27
428.3 N
{43.7 kg}
25
13.6 x 5.5
10
3.0 N
{0.3 kg}
2.4 N
{0.25 kg}
26
33.0 x 12.0
26
35.3 N
{3.6 kg}
28.2 N
{2.9 kg}
27
16.4 x 8.9
11.5
13.7 N
{1.4 kg}
11.0 N
{1.1 kg}
28
30.7 x 20.5
23
50.0 N
{5.1 kg}
40.0 N
{4.1 kg}
PC200-7
If damaged or
deformed, replace
spring
10-61
CONTROL VALVE
12
(9/9)
1.
2.
3.
4.
5.
6.
7.
8.
Unload valve
Main relief valve
Pump merge-divider valve (Main)
Return spring
Pump merge-divider valve (For LS)
Return spring
Valve (Sequence valve)
Spring (Sequence valve)
10-62
9.
10.
11.
12.
13.
14.
15.
16.
LS bypass plug
Screw
Poppet
Spring (Pressure reducing valve pilot)
Spring (Pressure reducing valve main)
Valve (Pressure reducing valve)
Spring (Safety valve)
Ball
PC200-7
CONTROL VALVE
Unit: mm
No.
Check item
Criteria
Standard size
17
Valve spring
Remedy
Repair limit
Free length x
Outside diameter
Installed
length
Installed
load
Free
length
Installed
load
24.3 x 8
19.5
69.6 N
{7.1 kg}
55.7 N
{5.7 kg}
18
Unload spring
31.5 x 10.2
26
83.4 N
{8.5 kg}
66.7 N
{6.8 kg}
19
11.5 x 4.6
8.5
1.5 N
{0.15 kg}
1.2 N
{0.12 kg}
125.5 N
{12.8 kg}
20
46.6 x 21.8
3.3
156.8 N
{16.0 kg}
21
64.5 x 32.3
63
177.5 N
{18.1 kg}
142.0 N
{14.5 kg}
22
70.9 x 18.0
59
199.8 N
{20.4 kg}
160.0 N
{16.3 kg}
23
29.9 x 11.0
10.7
10.4 N
{1.1 kg}
8.3 N
{0.8 kg}
24
Relief spring
34.7 x 10.4
32.3
430.2 N
{43.9 kg)
344.2 N
{35.1 kg}
PC200-7
If damaged or
deformed, replace
spring
10-63
CONTROL VALVE
CONTROL VALVE
PC220-7, PC220LC-7
1.
2.
3.
4.
5.
6.
7.
6-spool valve
Cover 1
Cover 2
Pump merge-divider valve
Back pressure valve
Boom lock valve
Service valve
OUTLINE
A1
A2
A3
A4
A5
A6
A-1
B1
B2
B3
B4
B5
B6
B-1
P1
P2
P3
P4
P5
P6
P7
P8
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
10-64
P9
P10
P11
P12
P-1
P-2
BP1
BP5
PLS1 :
PLS2 :
PP1 :
PP2 :
PR :
PS :
PST :
PX1 :
PX2 :
SA :
SB :
T
:
TS :
TSW :
PC200-7
CONTROL VALVE
12
7-spool valve
(6-spool valve + 1 service valves)
(1/9)
PC200-7
10-65
CONTROL VALVE
12
(2/9)
S*P09102
10-66
PC200-7
CONTROL VALVE
12
(3/9)
1. Unload valve
2. Pressure compensation valve (Arm OUT)
3. Pressure compensation valve (Right travel
Reverse)
4. Pressure compensation valve (Left swing)
5. Pressure compensation valve (Boom RAISE)
6. Pressure compensation valve (Left travel
reverse)
7. Pressure compensation valve (Bucket DUMP)
8. Pressure compensation valve (Service)
PC200-7
10-67
CONTROL VALVE
12
(4/9)
S*P09104
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Spool (Arm)
Spool (Right travel)
Spool (Swing)
Spool (Boom)
Spool (Left travel)
Spool (Bucket)
Spool (Service)
Unload valve
Main relief valve
Spool return spring
Unit: mm
No.
Check item
Criteria
Standard size
11
Remedy
Repair limit
Free length x
Outside diameter
Installed
length
Installed
load
Free
length
Installed
load
54.2 x 34.8
51.2
416.5 N
{42.5 kg}
333.2 N
{34 kg}
12
54.6 x 34.8
51.2
429.9 N
{43.9 kg}
336.1 N
{34.3 kg}
13
54.5 x 34.8
51.2
393 N
{40.1 kg}
314.6 N
{32.1 kg}
10-68
If damaged or
deformed, replace
spring
PC200-7
CONTROL VALVE
12
(5/9)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
Unit: mm
No.
Check item
Criteria
Standard size
22
PC200-7
Remedy
Repair limit
Free length x
Outside diameter
Installed
length
Installed
load
Free
length
Installed
load
11.5 x 4.6
8.5
1.5 N
{0.15 kg}
1.2 N
{0.12 kg}
If damaged or
deformed, replace
spring
10-69
CONTROL VALVE
12
(6/9)
S*P09105
10-70
5. Safety-suction valve
6. Spool
7. Pressure compensation valve
(OUT)
8. LS shuttle valve
9. Pressure compensation valve
(IN)
10. Safety-suction valve
11. Check valve for regeneration circuit
R. H. TRAVEL CONTROL
VALVE
12. Suction valve
13. Spool
14. Pressure compensation valve
(Reverse)
15. LS shuttle valve
16. Pressure compensation valve
(Forward)
17. Suction valve
PC200-7
CONTROL VALVE
Unit: mm
No.
Check item
Criteria
Standard size
18
Relief spring
Remedy
Repair limit
Free length x
Outside diameter
Installed
length
Installed
load
Free
length
Installed
load
34.7 x 10.4
32.3
430.2 N
{43.9 kg}
344.2 N
{35.1 kg}
10.45 x 7
4.8
3.1 N
{0.32 kg}
2.5 N
{0.26 kg}
19
Valve spring
20
Unload spring
31.5 x 10.2
26.9
70.6 N
{7.2 kg}
56.4 N
{5.8 kg}
21
Regeneration valve
spring
31.5 x 10.3
19
6.2 N
{0.6 kg}
4.9 N
{0.5 kg}
22
48.1 x 10.8
28
17.5 N
{1.8 kg}
14.0 N
{1.4 kg}
23
56.4 x 11.9
45
79.4 N
{8.1 kg}
63.5 N
{6.5 kg}
24
36.9 x 11.1
28
29.4 N
{3 kg}
23.5 N
{2.4 kg}
PC200-7
If damaged or
deformed, replace
spring
10-71
CONTROL VALVE
(7/9)
SERVICE VALVE
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Safety-suction valve
Spool
Pressure compensation valve (DUMP)
LS shuttle valve
Pressure compensation valve (CURL)
Safety-suction valve
Safety-suction valve
Spool
Pressure compensation valve
LS shuttle valve
Pressure compensation valve
Safety-suction valve
Unit: mm
No.
Check item
Criteria
Standard size
13
14
10-72
Free length x
Outside diameter
Remedy
Repair limit
Installed
length
Installed
load
Free
length
Installed
load
28
17.5 N
{1.8 kg}
14.0 N
{1.4 kg}
48.1 x 10.8
36.9 x 11.1
28
29.4 N
{3 kg}
23.5 N
{2.4 kg}
If damaged or
deformed, replace
spring
PC200-7
CONTROL VALVE
12
(8/9)
1. Spool
2. Pressure compensation
valve (Left)
3. LS select valve
4. Pressure compensation
valve (Right)
5. Suction valve
6. Spool
7. Pressure compensation
valve (RAISE)
8. Hydraulic drift prevention
valve
9. LS shuttle valve
10. Pressure compensation
valve (Lower)
11. Safety-suction valve
12. Check valve for regeneration
circuit
10-74
L. H. TRAVEL CONTROL
VALVE
13. Pump merge-divider valve
(Travel junction valve)
14. Return spring
15. Suction valve
16. Spool
17. Pressure compensation
valve (Reverse)
18. LS shuttle valve
19. Pressure compensation
valve (Forward)
20. Suction valve
PC200-7
CONTROL VALVE
Unit: mm
No.
Check item
Criteria
Standard size
21
Remedy
Repair limit
Free length x
Outside diameter
Installed
length
Installed
load
Free
length
Installed
load
31.5 x 10.3
19
6.2 N
{0.6 kg}
4.9 N
{0.5 kg}
22
48.1 x 10.8
28
17.5 N
{1.8 kg}
14.0 N
{1.4 kg}
23
36.9 x 11.1
28
29.4 N
{3 kg}
23.5 N
{2.4 kg}
343 N
{35.0 kg}
24
Load spring
30.4 x 16.7
27
428.3 N
{43.7 kg}
25
13.6 x 5.5
10
3.0 N
{0.3 kg}
2.4 N
{0.25 kg}
26
33.0 x 12.0
26
35.3 N
{3.6 kg}
28.2 N
{2.9 kg}
27
16.4 x 8.9
11.5
13.7 N
{1.4 kg}
11.0 N
{1.1 kg}
28
30.7 x 20.5
23
50.0 N
{5.1 kg}
40.0 N
{4.1 kg}
PC200-7
If damaged or
deformed, replace
spring
10-75
CONTROL VALVE
12
(9/9)
1.
2.
3.
4.
5.
6.
7.
8.
Unload valve
Main relief valve
Pump merge-divider valve (Main)
Return spring
Pump merge-divider valve (For LS)
Return spring
Valve (Sequence valve)
Spring (Sequence valve)
10-76
9.
10.
11.
12.
13.
14.
15.
16.
LS bypass plug
Screw
Poppet
Spring (Pressure reducing valve pilot)
Spring (Pressure reducing valve main)
Valve (Pressure reducing valve)
Spring (Safety valve)
Ball
PC200-7
CONTROL VALVE
Unit: mm
No.
Check item
Criteria
Standard size
17
Valve spring
Remedy
Repair limit
Free length x
Outside diameter
Installed
length
Installed
load
Free
length
Installed
load
10.45 x 7
4.8
3.1 N
{0.32 kg}
2.5 N
{0.26 kg}
18
Unload spring
31.5 x 10.2
26.8
70.6 N
{7.2 kg}
56.4 N
{5.8 kg}
19
11.5 x 4.6
8.5
1.5 N
{0.15 kg}
1.2 N
{0.12 kg}
125.5 N
{12.8 kg}
20
46.6 x 21.8
3.3
156.8 N
{16.0 kg}
21
64.5 x 32.3
63
177.5 N
{18.1 kg}
142.0 N
{14.5 kg}
22
70.9 x 18.0
59
199.8 N
{20.4 kg}
160.0 N
{16.3 kg}
23
29.9 x 11.0
10.7
10.4 N
{1.1 kg}
8.3 N
{0.8 kg}
24
Relief spring
34.7 x 10.4
32.3
430.2 N
{43.9 kg)
344.2 N
{35.1 kg}
PC200-7
If damaged or
deformed, replace
spring
10-77
CONTROL VALVE
1. Spring
2. Poppet
FUNCTION
OPERATION
The relief valve set pressure is determined by the installed load of spring (1). (First stage)
It is unnecessary to set the first and second stage individually.
The second stage is set when the first stage is set.
1.
10-78
PC200-7
CONTROL VALVE
12
PC200-7
10-79
CLSS
12
CLSS
OUTLINE OF CLSS
FEATURES
STRUCTURE
10-80
PC200-7
CLSS
Basic principle
1) Control of pump swash plate
The pump swash plate angle (pump discharge amount) is controlled so that LS differential pressure PLS (the difference
between pump pressure PP and control
valve outlet port LS pressure PLS) (load
pressure of actuator) is constant.
(LS pressure PLS = Pump discharge pressure PP LS pressure PLS)
PC200-7
10-81
2) Pressure compensation
A pressure compensation valve is installed to
the outlet port side of the control valve to balance the load.
When two actuators are operated together,
this valve acts to make pressure difference P
between the upstream (inlet port) and downstream ( outlet port) of the spool of each valve
the same regardless of the size of the load
(pressure).
10-82
CLSS
PC200-7
OPERATION
1. When engine is stopped
Puppet (11) is pressed by spring (12)
against the seat and port PR is not connected to TS.
Valve (14) is pressed by spring (13) against
the left side and port P2 is connected to PR.
Valve (7) is pressed by spring (8) against
the left side and port P2 is not connected to
A2.
(See Fig. 1.)
PC200-7
10-83
10-84
PC200-7
12
4. When abnormally high pressure is
generated
If the PR pressure on the self-pressure
reducing valve rises high abnormally, ball
(16) separates from the seat against the
force of spring (15) and the hydraulic oil
flows from output port PR to TS. Accordingly, the PR pressure lowers. By this operation, the hydraulic devices (PPC valves,
solenoid valves, etc.) are protected from
abnormal pressure. (See Fig. 4.)
PC200-7
10-85
SWING MOTOR
12
SWING MOTOR
KMF125ABE-5
B :
S :
T :
MA :
MB :
SPECIFICATIONS
PC200-7
Model
KMF125ABE-5
Theoretical displacement
125.0 cm/rev
10-86
PC220-7
1,694 rpm
1,879 rpm
PC200-7
SWING MOTOR
12
1.
2.
3.
4.
5.
6.
7.
Brake spring
Drive shaft
Spacer
Case
Disc
Plate
Brake piston
PC200-7
8.
9.
10.
11.
12.
13.
14.
Housing
Piston
Cylinder block
Valve plate
Reverse prevention valve
Center shaft
Center spring
15.
16.
17.
18.
19.
Safety valve
Check valve
Check valve spring
Shuttle valve
Shuttle valve spring
10-87
SWING MOTOR
12
Unit: mm
No.
Check item
Criteria
Standard size
10-88
Free length x
Outside diameter
Remedy
Repair limit
Installed
length
Installed
load
Free
length
Installed
load
35
3.5 N
{0.36 kg}
2.8 N
{0.29 kg}
62.5 x 20.0
16.4 x 8.9
11.5
13.7 N
{1.4 kg}
10.8 N
{1.1 kg}
If damaged or
deformed, replace
spring
PC200-7
SWING MOTOR
12
Operation of swing lock
1. When swing lock solenoid valve is deactivated
When the swing lock solenoid valve is deactivated, the pressurized oil from the main pump is
shut off and port B is connected to the tank circuit.
As a result, brake piston (7) is pushed down by
brake spring (1), discs (5) and plates (6) are
pushed together, and the brake is applied.
PC200-7
10-89
SWING MOTOR
12
10-90
PC200-7
12
1. Valve body
2. Spool (MA side)
3. Spring (MA side)
4. Plug
5. Spool (MB side)
6. Spring (MB side)
7. Plug
Explanation of effect
PC200-7
10-91
12
Outline
This valve reduces the swing back generation in the swing body by the inertia of the
swing body, the backlash and rigidity of the
machinery system, and the compression of
the hydraulic oil when the swing is
stopped. This is effective in preventing
spillage of the load and reducing the cycle
time when stopping the swing (the positioning ability is good and it is possible to
move swiftly to the next job.
Operation
1) When brake pressure is being generated at port MB
Pressure MB passes through the notch and
goes to chamber d, spool (5) pushes spring
(6) according to the difference in area D1 >
D2, moves to the left, and MB is connected
to e.
When this happens, pressure MA is below
the set pressure of spring (3), so spool (2)
does not move. For this reason, the pressure oil is closed by spool (2), and the braking force is ensured.
10-92
PC200-7
12
1. Cover
2. Body
3. Slipper seal
4. O-ring
5. Shaft
T2. To tank
T1. From L.H. and R.H. travel motors port T
D2. From control valve port B2
B1. To L.H. travel motor port PA
C2. From control valve port A2
Unit: mm
No.
Check Item
PC200-7
Criteria
Remedy
Standard Size
Standard clearance
Repair limit
80
Replace
10-93
TRAVEL MOTOR
TRAVEL MOTOR
HMV110-2
P :
T :
PA :
PB :
MA:
MB:
SPECIFICATIONS
Model
Item
Type
Theoretical
Delivery
PC200-7
PC220-7
HMV110-2
Min.
78.6 cm/rev
74 cm/rev
Max.
106.2 cm/rev
110.7 cm/rev
Set pressure
2,805 rpm
3,046 rpm
Max.
capacity
1,842 rpm
1,588 rpm
Rated speed
10-94
Travel speed
switching
pressure
Differential
pressure
PC200-7
TRAVEL MOTOR
12
1. Regulator piston
2. Spring
3. Regulator valve
4. Spring
5. Motor case
6. Suction safety valve spring
7. Suction safety valve
8. Check valve
PC200-7
10-95
TRAVEL MOTOR
12
Unit: mm
No.
Check item
Criteria
Standard size
Check valve
spring
Remedy
Repair limit
Free length x
Outside diameter
Installed
length
Installed
load
Free
length
Installed
load
PC200-7
31.6 x 6.5
24.2
2.55 N
{0.26 kg}
1.96 N
{0.2 kg}
PC220-7
31.6 x 6.5
24.2
7.16 N
{0.73 kg}
5.73 N
{0.58 kg}
13.0 x 6.5
9.5
1.96 N
{0.2 kg}
1.57 N
{0.16 kg}
Return spring
58.43 x 30
42.6
411 N
{41.9 kg}
329 N
{33.5 kg}
21.5 x 11.1
17.1
55 N
{5.6 kg}
44 N
{4.5 kg}
10-96
If damaged or
deformed,
replace spring
PC200-7
TRAVEL MOTOR
OPERATION OF MOTOR
1) Motor swash plate angle at maximum
SJP08742
OR
08893
PC200-7
At the same time, the pressurized oil at regulator piston (15) passes through orifice c in
regulator valve (9) and is drained to the motor
case.
As a result, rocker cam (4) moves in the maximum swash plate angle direction, the motor
capacity becomes maximum.
10-97
TRAVEL MOTOR
12
SJP08743
OR
08894
10-98
PC200-7
TRAVEL MOTOR
12
PC200-7
SJP08744
OR
08895
SJP08745
OR
08896
10-99
TRAVEL MOTOR
SAP03482
OR
08897
10-100
PC200-7
TRAVEL MOTOR
10-101
TRAVEL MOTOR
10-102
PC200-7
Operation
When pilot pressure is turned ON
If the pilot pressure from the travel junction solenoid valve becomes higher than the force of
spring (14), travel junction spool (13) moves to the
left stroke end and the junction circuit between
port PTL (Left travel circuit) and PTR (Right travel
circuit) is closed.
SU(V)P08730
OR
08898
PC200-7
10-103
SU(V)P08731
OR
08899
10-104
PC200-7
PC200-7
10-105
10-106
At this time, the right travel reverse (or forward) PPC pressure is applied through orifice
(6) of piston (4) to the left end of piston (8) to
push piston (8) to the right.
When boom RAISE, arm IN, OUT, bucket
CURL, DUMP are operated, spool (1) moves
to the left, but the maximum stroke of the
spool is limited to st1, the amount of movement (st2) of piston (8).
PC200-7
VALVE CONTROL
VALVE CONTROL
Lever positions
1. Travel PPC valve
2. Service PPC valve
3. Service pedal
4. L.H. travel lever
5. R.H. travel lever
6. R.H. PPC valve
7. R.H. work equipment control lever
PC200-7
8. Solenoid valve
9. Accumulator
10. Control valve
11. Hydraulic pump
12. Junction box
13. L.H. work equipment control lever
14. L.H. PPC valve
(1) Hold
(2) Boom "RAISE"
(3) Boom "LOWER"
(4) Bucket "DUMP"
(5) Bucket "CURL"
(6) Hold
(7) Arm "IN"
(8) Arm "OUT"
10-107
10-108
P1:
P2:
P3:
P4:
PC200-7
12
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Spool
Metering spring
Centering spring
Piston
Disc
Nut (For connection of lever)
Joint
Plate
Retainer
Body
Filter
Unit: mm
No.
Check item
Criteria
Standard size
12
Centering spring
(For P3 and P4)
Remedy
Repair limit
Free length x
Outside diameter
Installed
length
Installed
load
Free
length
Installed
load
42.5 x 15.5
34
17.6 N
{1.8 kg}
13.7 N
{1.4 kg}
13
Centering spring
(For P3 and P4)
44.5 x 15.5
34
29.4 N
{3.0 kg}
23.5 N
{2.4 kg}
14
Metering spring
26.5 x 8.2
24.9
16.7 N
{1.7 kg}
13.7 N
{1.4 kg}
PC200-7
If damaged or
deformed,
replace spring
10-109
OPERATION
1) At neutral
Ports A and B of the control valve and
ports P1 and P2 of the PPC valve are connected to drain chamber D through fine
control hole f in spool (1). (Fig. 1)
10-110
PC200-7
12
4) At full stroke
When disc (5) pushes down piston (4), and
retainer (9) pushes down spool (1), fine
control hole f is shut off from drain chamber D, and is connected with pump pressure chamber PP. Therefore, the pilot
pressure oil from the main pump passes
through fine control hole f and flows to
chamber A from port P1, and pushes the
control valve spool.
The oil returning from chamber B passes
from port P2 through fine control hole f
and flows to drain chamber D. (Fig. 4)
PC200-7
10-111
10-112
P3
P4
P5
P6
: Right reverse
: Right forward
: Travel signal
: Steering signal
PC200-7
12
1.
2.
3.
4.
5.
Plate
Body
Piston
Collar
Metering spring
PC200-7
6.
7.
8.
9.
10.
Centering spring
Valve
Damper
Steering signal
Steering signal valve spring
10-113
12
Unit: mm
No.
Check item
Criteria
Standard size
Metering spring
Remedy
Repair limit
Free length x
Outside diameter
Installed
length
Installed
load
Free
length
Installed
load
26.5 x 8.15
24.7
16.7 N
{1.7 kg}
13.7 N
{1.4 kg}
Centering spring
48.1 x 15.5
32.5
108 N
{11 kg}
86.3 N
{8.8 kg}
12.8 x 7.3
8.5
8.8 N
{0.9 kg}
7.1 N
{0.72 kg}
10-114
If damaged or
deformed,
replace spring
PC200-7
12
OPERATION
1) At neutral
Ports A and B of the control valve and
ports P1 and P2 of the PPC valve are connected to drain chamber D through fine
control hole f in spool (1). (Fig. 1)
PC200-7
10-115
12
4) At full stroke
Lever (5) pushes down piston (4), and
retainer (9) pushes down on spool (1). Fine
control hole f is shut off from drain chamber
D, and is connected to pump pressure
chamber PP. Therefore, the pilot pressure
oil from the main pump passes through fine
control hole f and flows to chamber A from
port P1 to push the control valve spool. The
return oil from chamber B passes from port
P2 through fine control hole f and flows to
drain chamber D. (Fig. 4)
10-116
PC200-7
PC200-7
10-117
10-118
PC200-7
12
3) When steered or pivot-turned
(The following drawing shows the circuit for left forward (slow) and right forward (fast) operation.)
If the operation quantities of both levers are different from each other as in the steering operation (If the
difference of the pilot pressure between both sides is higher than a certain level), the pilot pressure is
output as the steering signal.
In the case of the following drawing, the pressure in left spring chamber (k) of steering signal valve (j) is
P2. The pressure in right spring chamber (l) is P4.
If (P4 - P2) x (Sectional area of spool) > Set spring load, the spool is changed to the direction of the
arrow and the higher one of both PPC output pressures (the pressure of port P4 in this drawing) is output as the steering signal to port P6.
PC200-7
10-119
12
4) When pivot-turned
(The following drawing shows the circuit for left reverse and right forward operation.)
While the left motor is operating for reverse travel (the signal of port P1 is output) and the right motor is
operating for forward travel (the signal of port P4 is output), only the pressure in right spring chamber
(l) of steering signal valve (j) is set high. Accordingly, the steering signal valve moves to the left and
outputs the steering signal (port P6).
10-120
PC200-7
1. Spool
2. Metering spring
3.
4.
5.
6.
7.
8.
Centering spring
Piston
Lever
Plate
Retainer
Body
T
P
P1
P2
: To tank
: From main pump
: Port
: Port
Unit: mm
No.
Check item
Criteria
Standard size
10
PC200-7
Centering spring
Metering spring
Remedy
Repair limit
Free length x
Outside diameter
Installed
length
Installed
load
Free
length
Installed
load
33.9 x 15.3
28.4
124.5 N
{12.7 kg}
100 N
{10.2 kg}
22.7 x 8.1
22
16.7 N
{1.7 kg}
13.7 N
{1.4 kg}
If damaged or
deformed,
replace spring
10-121
OPERATION
At neutral
The pressurized oil from the main pump
enters from port P and is blocked by spool
(1).
Ports A and B of the control valve and
ports a and b of the PPC valve are connected to drain port T through fine control
hole X of spool (1).
WHEN OPERATED
10-122
PC200-7
PC200-7
10-123
SOLENOID VALVE
SOLENOID VALVE
PPC lock, 2-stage relief, travel speed, swing brake, merge-divider, travel junction solenoid valves
10-124
T : To tank
A1 : To PPC valve
A2 : To main valve (Travel junction valve)
A3 . To main valve (Mergedivider valve)
A4 : To both travel motors
A5 : To swing motor
PC200-7
SOLENOID VALVE
12
1.
2.
3.
4.
5.
6.
Connector
Moving core
Coil
Spool
Block
Spring
OPERATION
PC200-7
10-125
PPC ACCUMULATOR
PPC ACCUMULATOR
1
1.
2.
3.
4.
5.
6.
Gas plug
Shell
Poppet
Holder
Bladder
Oil port
SPECIFICATIONS
Gas capacity:300 cc (for PPC)
SBP00290
10-126
PC200-7
SPECIFICATIONS
1.
2.
3.
4.
5.
Drain plug
Element
Case
Head cover
Relief valve
PC200-7
Rated pressure:
6.9 MPa {70 kg/cm2}
Flow
:
200 l/min
Relief valve cracking pressure:
0.34 0.05 MPa
{3.5 0.5 kg/cm2}
Filter mesh size: 6 m
Filtering area :
4,570 cm2
10-127
08900
10-128
PC200-7
Function
This valve prevents the oil in the boom cylinder bottom from leaking through spool (1)
and the boom from lowering under its weight
while the boom lever is not operated.
Operation
1. When boom lever is in "RAISE" position
If the boom lever is set in the "RAISE" position, the pressure of the main hydraulic oil is
applied toward the left to area "A" of the ring
formed by the difference between outside
diameter d1 of puppet (5) and seat diameter
d2 (= Area of d1 - Area of d2). At this time,
if this pressure is higher than the force of
spring (4), puppet (5) moves to the left. By this
operation, the main hydraulic oil from the
control valve flows through the open part of
puppet (5) to the boom cylinder bottom.
2. When boom lever is in neutral
If the control lever is returned to the neutral
position while the boom is raised, the oil in
puppet (5) which has flowed through orifice
"a" is sealed by pilot piston (2).
PC200-7
10-129
10-130
PC200-7
PC200-7
10-131
1. Spool
2. Spring
V :
T :
ATT:
ACC:
P1 :
TS :
To control valve
To hydraulic tank
To attachment
To accumulator
From attachment circuit selector solenoid valve
To hydraulic tank
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Spool return
spring
Repair limit
Free length x
Outside Dia.
Installed
length
Installed
load
Free length
Installed
load
132.0 x 29
114.5
833 N
{85.0 Kg}
--
666 N
{68.0 Kg}
Replace spring if
any damages or
deformations are
found
Function
10-132
PC200-7
PC200-7
08901
08902
10-133
HYDRAULIC CYLINDER
HYDRAULIC CYLINDER
PC200-7, PC200LC-7
BOOM CYLINDER
ARM CYLINDER
BUCKET CYLINDER
10-134
PC200-7
HYDRAULIC CYLINDER
12
100 HOURS GREASING
Unit: mm
No.
Check item
Criteria
Cylinder
Clearance between
piston rod and bushing
Clearance between
piston rod support
pin and bushing
Clearance between
cylinder bottom
support pin and
bushing
Standard
size
Tolerance
Shaft
Hole
Remedy
Standard clearance
Clearance
limit
Boom
85
-0.036
-0.090
+0.222
+0.047
0.083 ~ 0.312
0.412
Arm
95
-0.036
-0.090
+0.222
+0.047
0.083 ~ 0.312
0.412
Bucket
80
-0.030
-0.076
+0.258
+0.048
0.078 ~ 0.334
0.434
Boom
80
-0.030
-0.060
+0.457
+0.370
0.400 ~ 0.517
1.0
Arm
80
-0.030
-0.076
+0.457
+0.370
0.400 ~ 0.533
1.0
Bucket
70
-0.030
-0.076
+0.424
+0.350
0.380 ~ 0.500
1.0
Boom
70
-0.030
-0.060
+0.424
+0.350
0.380 ~ 0.484
1.0
Arm
80
-0.030
-0.076
+0.457
+0.370
0.400 ~ 0.523
1.0
Bucket
70
-0.030
-0.076
+0.424
+0.350
0.380 ~ 0.500
1.0
Replace bushing
Replace pin or
bushing
Check item
Criteria
Cylinder
Clearance between
piston rod and bushing
Clearance between
piston rod support
pin and bushing
Clearance between
cylinder bottom
support pin and
bushing
PC200-7
Standard
size
Tolerance
Shaft
Hole
Remedy
Standard clearance
Clearance
limit
Boom
85
-0.036
-0.090
+0.222
+0.047
0.083 ~ 0.312
0.412
Arm
95
-0.036
-0.090
+0.222
+0.047
0.083 ~ 0.312
0.412
Bucket
80
-0.030
-0.076
+0.257
+0.048
0.078 ~ 0.334
0.447
Boom
80
-0.030
-0.060
+0.190
+0.070
0.100 ~ 0.250
---
Arm
80
-0.030
-0.076
+0.175
+0.075
0.105 ~ 0.251
---
Bucket
70
-0.030
-0.076
+0.170
+0.070
0.100 ~ 0.246
---
Boom
70
-0.030
-0.060
+0.165
+0.045
0.075 ~ 0.225
---
Arm
80
-0.030
-0.076
+0.175
+0.075
0.105 ~ 0.251
---
Bucket
70
-0.030
-0.060
+0.170
+0.070
0.100 ~ 0.230
---
Replace bushing
Replace pin or
bushing
10-135
HYDRAULIC CYLINDER
PC220-7, PC220LC-7
BOOM CYLINDER
ARM CYLINDER
BUCKET CYLINDER
10-136
PC200-7
HYDRAULIC CYLINDER
12
100 HOURS GREASING
Unit: mm
No.
Check item
Criteria
Cylinder
Clearance between
piston rod and bushing
Clearance between
piston rod support
pin and bushing
Clearance between
cylinder bottom
support pin and
bushing
Standard
size
Tolerance
Shaft
Hole
Remedy
Standard clearance
Clearance
limit
Boom
90
-0.036
-0.090
+0.257
+0.048
0.084 ~ 0.347
0.447
Arm
100
-0.036
-0.090
+0.257
+0.047
0.083 ~ 0.347
0.447
Bucket
90
-0.030
-0.090
+0.257
+0.048
0.084 ~ 0.347
0.447
Boom
80
-0.030
-0.060
+0.457
+0.370
0.400 ~ 0.517
1.0
Arm
80
-0.030
-0.076
+0.457
+0.370
0.400 ~ 0.533
1.0
Bucket
80
-0.030
-0.076
+0.457
+0.370
0.400 ~ 0.533
1.0
Replace bushing
Replace pin or
bushing
Boom
80
-0.030
-0.076
+0.457
+0.370
0.400 ~ 0.533
1.0
Arm
80
-0.030
-0.076
+0.457
+0.370
0.400 ~ 0.533
1.0
Bucket
80
-0.030
-0.076
+0.457
+0.370
0.400 ~ 0.533
1.0
Check item
Criteria
Cylinder
Clearance between
piston rod and bushing
Clearance between
piston rod support
pin and bushing
Clearance between
cylinder bottom
support pin and
bushing
PC200-7
Standard
size
Tolerance
Shaft
Hole
Remedy
Standard clearance
Clearance
limit
Boom
90
-0.036
-0.090
+0.257
+0.048
0.084 ~ 0.347
0.447
Arm
100
-0.036
-0.090
+0.257
+0.047
0.083 ~ 0.347
0.447
Bucket
90
-0.036
-0.090
+0.257
+0.048
0.084 ~ 0.347
0.447
Boom
80
-0.030
-0.060
+0.190
+0.070
0.100 ~ 0.250
---
Arm
80
-0.030
-0.076
+0.175
+0.075
0.105 ~ 0.251
---
Bucket
80
-0.030
-0.076
+0.175
+0.075
0.105 ~ 0.251
---
Replace bushing
Replace pin or
bushing
Boom
80
-0.030
-0.060
+0.190
+0.070
0.100 ~ 0.250
---
Arm
80
-0.030
-0.076
+0.175
+0.075
0.105 ~ 0.251
---
Bucket
80
-0.030
-0.076
+0.175
+0.075
0.105 ~ 0.251
---
10-137
WORK EQUIPMENT
WORK EQUIPMENT
10-138
PC200-7
WORK EQUIPMENT
PC200-7, PC200LC-7
100 HOURS GREASING
Unit: mm
No.
Check item
Criteria
Standard
size
Tolerance
Remedy
Standard clearance
Clearance
limit
Shaft
Hole
90
-0.036
-0.071
+0.342
+0.269
0.305 ~ 0.412
1.0
90
-0.036
-0.071
+0.153
+0.097
0.133 ~ 0.224
1.0
70
-0.030
-0.076
+0.335
+0.275
0.305 ~ 0.411
1.0
80
-0.030
-0.076
+0.337
+0.273
0.303 ~ 0.413
1.0
80
-0.030
-0.076
+0.337
+0.273
0.303 ~ 0.413
1.0
70
-0.030
-0.076
+0.335
+0.275
0.303 ~ 0.411
1.0
Replace
Check item
Criteria
Standard
size
Tolerance
Remedy
Standard clearance
Clearance
limit
+0.131
+0.074
0.110 ~ 0.202
1.0
Shaft
Hole
90
-0.036
-0.071
90
-0.036
-0.071
+0.166
+0.074
0.110 ~ 0.237
1.0
70
-0.030
-0.076
+0.158
+0.078
0.108 ~ 0.234
1.0
80
-0.030
-0.076
+0.137
+0.074
0.104 ~ 0.213
1.0
80
-0.030
-0.076
+0.166
+0.086
0.116 ~ 0.242
1.0
80
-0.030
-0.076
+0.154
+0.074
0.104 ~ 0.230
1.0
PC200-7
Replace
10-139
WORK EQUIPMENT
PC220-7, PC220LC-7
100 HOURS GREASING
Unit: mm
No.
Check item
Criteria
Standard
size
Tolerance
Remedy
Standard clearance
Clearance
limit
Shaft
Hole
90
-0.036
-0.071
+0.342
+0.269
0.305 ~ 0.412
1.0
90
-0.036
-0.071
+0.153
+0.097
0.133 ~ 0.224
1.0
80
-0.030
-0.076
+0.335
+0.275
0.305 ~ 0.411
1.0
80
-0.030
-0.076
+0.337
+0.273
0.303 ~ 0.413
1.0
80
-0.030
-0.076
+0.337
+0.273
0.303 ~ 0.413
1.0
80
-0.030
-0.076
+0.335
+0.275
0.303 ~ 0.411
1.0
Replace
Check item
Criteria
Standard
size
Tolerance
Remedy
Standard clearance
Clearance
limit
+0.186
+0.074
0.110 ~ 0.239
1.0
Shaft
Hole
100
-0.036
-0.071
90
-0.036
-0.071
+0.166
+0.074
0.110 ~ 0.237
1.0
80
-0.030
-0.076
+0.166
+0.084
0.116 ~ 0.242
1.0
80
-0.030
-0.076
+0.137
+0.074
0.104 ~ 0.213
1.0
80
-0.030
-0.076
+0.166
+0.086
0.116 ~ 0.242
1.0
80
-0.030
-0.076
+0.166
+0.066
0.096 ~ 0.232
1.0
10-140
Replace
PC200-7
WORK EQUIPMENT
1. DIMENSION OF ARM
10-142
PC200-7
WORK EQUIPMENT
12
Unit: mm
Model
No.
80 +0.1
0
80 +0.1
0
109.3 +1.5
0
109.3 +1.5
0
0
305.5 -0.5
0
305.5 -0.5
90 -0.036
-0.071
90 -0.036
-0.071
402.1 1
419.9 1
187.2 0.5
206.1 0.5
829.1 1
918.6 1
2,919
3,037.6
2,630.5 1
2,562.8 1
10
410 1
465 1
11
640 0.2
585 0.2
12
600 0.5
600 0.5
13
458.1
446.3
14
1,486
1,551.7
15
80
80
16
326.5 1
326.5 1
17
80
80
0
311-0.5
0
311-0.5
325
325
Min.
1,680
1,605
Max.
2,800
2,625
19
PC200-7
PC220-7, PC220LC-7
18
PC200-7, PC200LC-7
10-143
WORK EQUIPMENT
12
2.DIMENSION OF BUCKET
10-144
PC200-7
WORK EQUIPMENT
12
Unit: mm
Model
PC200-7, PC200LC-7
PC220-7, PC220LC-7
457.6 0.5
442.4 0.5
22 0.5
59.2 0.5
92 48
96 52
458.1
446.3
1,477.3
1,540.5
158.6
185.7
7 37
No.
+0.1
80 0
80 +0.2
0
10
326.5 1
326.5 1
11
56
59
12
106
104
13
470
470
14
23.5
23.5
15
140
140
16
190
190
17
132
155
18
129
135
19
107
107
20
85
82
21
22
PC200-7
358.5 +2
0
38
358.5 +2
0
37
10-145
AIR CONDITIONER
AIR CONDITIONER
AIR CONDITIONER PIPING
1.
2.
3.
4.
5.
6.
7.
8.
10-146
A. Fresh air
B. Recirculated air
C. Hot air/cold air
PC200-7
ENGINE CONTROL
ENGINE CONTROL
OUTLINE
1.
2.
3.
4.
5.
6.
7.
8.
9.
Battery relay
Battery
Starting switch
Fuel control dial
Linkage
Starting motor
Engine throttle and pump controller
Fuel injection pump
Governor motor
PC200-7
10-147
ENGINE CONTROL
12
1. OPERATION OF SYSTEM
Starting engine
When the starting switch is turned to the
START position, the starting signal flows to
the starting motor, and the starting motor
turns to start the engine.
When this happens, the engine throttle and
pump controller checks the signal from the
fuel control dial and sets the engine speed
to the speed set by the fuel control dial.
Stopping engine
When the starting switch is turned to the
STOP position, the engine throttle and
pump controller drives the governor motor
so that the governor lever is set to the NO
INJECTION position.
When this happens, to maintain the electric
power in the system until the engine stops
completely, the engine throttle and pump
controller itself drives the battery relay.
10-148
08903
08904
08905
PC200-7
ENGINE CONTROL
12
1. COMPONENT
Fuel control dial
1. Knob
2. Dial
3. Spring
4. Ball
5. Potentiometer
6. Connector
Function
The fuel control dial is installed under the
monitor panel, and a potentiometer is
installed under the knob. The potentiometer shaft is turned by turning the knob.
As the potentiometer shaft is turned, the
resistance of the variable resistor in the
potentiometer changes and a throttle signal is sent to the engine throttle and pump
controller.
The hatched area in the graph shown at
right is the abnormality detection area.
PC200-7
10-149
ENGINE CONTROL
Governor motor
1.
2.
3.
4.
5.
6.
7.
8.
Potentiometer
Cover
Shaft
Dust seal
Bearing
Motor
Gear
Connector
Function
The motor is turned according to the drive
signal from the engine throttle and pump
controller to control the governor lever of the
fuel injection pump.
This motor used as the motive power source
is a stepping motor.
10-150
Operation
While motor is stopped
Electric power is applied to both phases A
and B of the motor.
While motor is running
The engine throttle and pump controller supplies a pulse current to phases A and B, and
the motor revolves, synchronizing to the
pulse.
PC200-7
ENGINE CONTROL
10-152
PC200-7
ENGINE CONTROL
12
Input and output signals
CN-1
CN-2
Pin
Signal name
No.
1 Boom bottom pressure sensor
Input/
output
Input
CN-3
Pin
No.
1 NC
Signal name
Input/
output
Output
Pin
Signal name
No.
1 VB (controller power)
Input/
output
Input
Input
Input
Input
NC
Input
Input
Signal GND
Input
232C_RxD
Input
Output
Input
Input
Output
Input
LS-EPC
Output
NC
Input
Model selection 4
Input
Output
Input
Output
NC
Output
Input
NC
Output
Input
10
NC
Input
10
Input
10
Signla GND
Input
11
NC
Output
11
VB (controller power)
Input
11
Knob SW
Input
12
CAN shield
12
Input
12
NC
Input
13
Model selection 5
Input
13
13
Input
14
232C_TxD
Output
14
KEY_SIG
14
Input
15
NC
Input
15
Output
15
NC
Output
16
SENS_PWR
17
Input
Input
Input
16
Input
16
PC-EPC
Output
17
Model selection 3
Input
17
Output
Input
18
Output
18
Output
18
NC
Input
19
NC
Output
19
Input
19
Throttle potentiometer
Input
20
NC
Input
20
Input
20
NC
Input
S_NET
21
21
Input/
output
22
22
POT_PWR
CAN0_L
23
23
Input/
output
24
KEY_SIG
24
23
CAN1_L
Input/
output
25
26
Output
24
Input
27
Output
28
Output
25
NC
Input
29
Input
26
NC
Input
30
Input
27
Model selection 2
Input
31
28
NC
Input
32
29
33
30
NC
34
NC
31
Output
Input
21
22
32
33
34
PC200-7
Input
Input
Input
Output
35
Output
NC
Output
CAN0_H
Input/
output
36
37
Output
CAN1_H
Input/
output
38
NC
Output
39
Input
40
Input
35
Input
36
NC
Input
37
Input
38
Input
39
40
Input
10-153
Control function
1
Engine/Pump composite control function
2
Pump/Valve control function
3
One-touch power maximizing function
4
Auto-deceleration function
5
Auto-warm-up/Overheat prevention function
Self-diagnosis function
PC200-7
10-155
10-156
PC200-7
PC200-7
10-157
SJP08754
OR
08908
10-158
PC200-7
FUNCTION
SJP08755
OR
08909
SJP08756
OR
08910
SJP08757
OR
08911
PC200-7
10-159
12
Model
Mode A
PC200-7, PC220-7
OR
106.6 kW/1,900 rpm {143 HP/1,900 rpm}
08912
SJP08759
OR
08913
SJP08760
OR
08914
10-160
PC200-7
12
L)
Digging
Breaker
Finishing
85%
75%
70%
SJP08761
OR
08915
Model
PC200-7, PC220-7
Mode E
Mode B
(Mode L)
99 HP / 1,800 RPM
SJP08762
OR
08916
SJP08763
OR
08917
PC200-7
10-161
12
2) Function to control pump during
travel
If the machine travels in mode A, either of
engine speed and pump absorption torque
does not change.
If the machine travels in mode E or B, the
working mode does not change, but the
engine speed and pump absorption torque
rise to the same value as in mode A.
SJP08764
OR
08920
If the machine travels in mode L, the working mode and engine speed do not change,
but the pump absorption torque is
increased.
: The L mode is on the multi-monitor specification machine only.
10-162
PC200-7
12
2. Pump/Valve control function
SJP08765
OR
08921
Function
The machine is matched to various types of
work properly with the 2-stage relief function
to increase the digging force, etc.
PC200-7
10-163
12
1) LS control function
The change point (LS set differential pressure)
of the pump discharge in the LS valve is
changed by changing the output pressure
from the LS-EPC valve to the LS valve according to the operating condition of the actuator.
By this operation, the start-up time of the
pump discharge is optimized and the composite operation and fine control performance is improved.
2) Cut-off function
When the cut-off function is turned on, the
PC-EPC current is increased to near the maximum value.
By this operation, the flow rate in the relief
state is lowered to reduce fuel consumption.
Operating condition for turning on cut-off
function
08922
Condition
During travel
When swing lock switch is
turned on
When boom is lowered
When one-touch power maximizing function is turned on
When mode is operated
10-164
Relief pressure
34.8 MPa
{355 kg/cm}
37.2 MPa
{380 kg/cm}
PC200-7
12
SJP08766
OR
08923
FUNCTION
PC200-7
10-165
12
10-166
Engine/Pump
control
Operation time
Matching at rated
output point
Automatically
Cancel
reset at 8.5 sec
PC200-7
12
4. Auto-deceleration function
SJP08767
OR
08924
FUNCTION
PC200-7
10-167
12
OPERATION
WHEN CONTROL LEVERS ARE SET IN NEUTRAL
10-168
PC200-7
12
1. Auto-warm-up/Overheat prevention
function
SJP08768
OR
08925
FUNCTION
After the engine is started, if the engine cooling water temperature is low, the engine
speed is raised automatically to warm up the
engine. If the engine cooling water temperature rises too high during work, the pump
load is reduced to prevent overheating.
PC200-7
10-169
12
1) Auto-warm-up function
After the engine is started, if the engine cooling water temperature is low, the engine
speed is raised automatically to warm up the
engine.
Operating condition (All)
Operated
Reset
Operating condition
Water temperature:
Above 105C
Operating condition
Water temperature:
Above 102C
Operating condition
Water temperature:
Above 100C
10-170
Operation/Remedy
Resetting condition
Operation/Remedy
Resetting condition
Operation/Remedy
Operating condition
Water temperature:
Above 95C
Resetting condition
Operation/Remedy
Resetting condition
PC200-7
12
SJP08769
OR
08926
FUNCTION
The swing lock and swing holding brake functions are installed.
PC200-7
10-171
12
OFF
ON
Lock
lamp
Function
Operation
OFF
Swing
holding
brake
Swing
lock
ON
ON
(When control has
trouble)
ON
OFF
OFF
(When controller is normal)
ON
OFF
Swing
Swing
Swing lock Swing holdlock is
lock is
is turned
ing brake is
turned on. canceled. on.
turned on.
10-172
PC200-7
12
SJP08770
OR
08927
FUNCTION
PC200-7
10-173
12
1) Pump control function during travel
If the machine travels in a work mode other
than mode A, the work mode and the engine
speed are kept as they are and the pump
absorption torque is increased.
For details, see ENGINE/PUMP COMPOSITE
CONTROL FUNCTION.
1. Travel speed change function
i) Manual change with travel speed switch
If the travel speed switch is changed
between Lo, ( Mi), and Hi, the governor/
pump controller controls the pump capacity and motor capacity at each gear speed
as shown at right to change the travel
speed.
Travel speed
switch
Lo (Low
speed)
Hi (High
speed)
Pump capacity
(%)
60
90
100
Motor capacity
Max.
Max.
Min.
3.0
4.1
5.5
Travel speed
(km/h)
10-174
08928
PC200-7
FUNCTION
This function is available only with the ATT specification. The function acts as follows according to
the flow command and working mode from the
monitor.
1) It throttles the ATT PPC pressure and controls
the flow when the pedal is depressed fully.
2) In mode B and the other modes, it switches to
ATT single acting (B) or double acting (other
modes).
: The ATT flow control adjustment function is
on the multi-monitor specification machine
only.
PC200-7
10-175
1.
2.
3.
4.
Sensor
Locknut
Wiring harness
Connector
FUNCTION
10-176
PC200-7
12
1. Plug
2. Switch
3. Connector
SPECIFICATIONS
Type of contacts: Normally open contacts
Operating (ON) pressure: 0.5 0.1 MPa
{5.0 1.0 kg/cm}
Resetting (OFF) Pressure: 0.3 0.5 MPa
{3.0 0.5 kg/cm}
FUNCTION
PC200-7
10-177
12
1. Sensor
2. Connector
FUNCTION
OPERATION
10-178
SJP08774
OR
08930
PC200-7
SJP08775
OR
08931
10-180
PC200-7
12
1. Monitor panel
OUTLINE
The monitor panel has the functions to display various items and the functions to
select modes and electric parts.
The monitor panel has a CPU (Central Processing Unit) in it to process, display, and
output the information.
The monitor display unit consists of LCD
(Liquid Crystal Display). The switches are
flat sheet switches.
PC200-7
10-181
CN-2
Pin
No.
1 Key ON
Signal name
Input/
output
Input
Key ON
Starting signal
Input
Input
GND
Input/
output
Input
Pin
No.
1 NC
Signal name
Input/
output
Input
Input
Fuel level
Input
NC
Input
Output
Input
NC
Input
Input
NC
Input
Input
NC
Input
NC
Input
NC
Input
Input
RS230C CTS
Input
Input
RS230C RXD
Input
GND
VB +
Output
10
Output
11
Buzzer ON signal
Input
12
Input
10-182
CN-3
Pin
Signal name
No.
1 Engine water temperature
Input
N/W signal
Input/
Output
RS230C RXD
Input/
Output
10
N/W signal
Input/
Output
10
RS230C RXD
Input/
Output
11
Battery charge
Input
11
BOOTSW
Input
12
Input
12
NC
Input
13
13
GND
14
Buzzer drive
Input
14
CAN (SHIELD)
Input
15
Limit SW (window)
Input
15
CAN (+)
Input
16
Buzzer cancel
Input
16
CAN (-)
Input
17
Swing lock
Input
18
Preheat
Input
19
Light switch
Input
20
N/W GND
PC200-7
08932
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Wiper motor
Preheating monitor
Swing lock monitor
Engine water temperature monitor
Hydraulic oil temperature gauge
Engine water temperature gauge
Working mode monitor
Service monitor
Travel speed monitor
Fuel gauge
PC200-7
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
10-183
Symbol
Display item
Swing lock
Display method
OFF
OFF
OFF
ON
OFF
ON
OFF
ON
Flashes
ON
ON
ON
Up to 30 sec.
ON
Flashes
OFF
Being pressed
Flashes
Preheating
Power Max.
Engine water
temperature
Hydraulic oil
temperature
Fuel level
10-184
PC200-7
Gauge
Range
Temperature, volume
Indicator
Buzzer sound
A1
105
Red
A2
102
Red
A3
100
Green
A4
80
Green
A5
60
Green
A6
30
White
B1
105
Red
B2
102
Red
B3
100
Green
B4
80
Green
B5
40
Green
B6
20
White
C1
289
Green
C2
244.5
Green
C3
200
Green
C4
100
Green
C5
60
Green
C6
41
Red
PC200-7
10-185
Checks before starting (caution lamps all light up), when maintenance interval is exceeded.
If the checks before starting or maintenance interval is exceeded items light up, the display of the hydraulic
oil temperature gauge and the hydraulic oil temperature monitor are stopped, and the following cautions
are displayed.
Symbol
Display item
Check before
starting item
When engine is
stopped
--
When abnormal,
lights up and buzzer
sounds
Battery charge
--
When abnormal,
lights up and buzzer
sounds
--
--
Maintenance
The problems that have occurred are displayed in order from the left.
When the above cautions are displayed, if the hydraulic oil temperature is high or low, only the symbol is
displayed.
Color of symbol
No display
10-186
PC200-7
Display category
Symbol
Display item
Display range
ON
INT
Display method
OFF
Wiper
Working
mode
Displays set
mode
Travel speed
Displays set
speed
Monitor
Service meter
PC200-7
Auto-deceleration
ON OFF
Service
meter indicator
Lights up when
service meter is
working
10-187
SWITCHES
1.
2.
3.
4.
5.
6.
7.
8.
9.
10-188
PC200-7
Selector switch
This is used when making detailed settings in
each working mode. (For details, see ATTACHMENT FLOW CONTROL FUNCTION for modes
A and E.)
Maintenance switch
Check the condition of the maintenance
items. (For details, see MAINTENANCE FUNCTION.)
Auto-deceleration switch
Each time the auto-deceleration switch is
pressed, the auto-deceleration function is
switched ON/OFF.
Use the auto-deceleration monitor display to
check the present condition.
When the working mode switch is operated to
switch the working mode, it is automatically
set to ON.
Wiper switch
Each time the wiper switch is pressed, the
wiper setting changes OFF INT ON
OFF . . . . . .
Use the wiper monitor display to check the
present condition.
The relationship between the wiper setting
and the monitor display is as shown in the
table on the right.
PC200-7
Switch that is
pressed
Display
[A]
A mode (default)
[E]
E mode
[L]
L mode
[B]
B mode
Display
Setting
Crawler symbol + Lo
Crawler symbol + Mi
Medium speed
Crawler symbol + Hi
High speed
Display
Setting
Wiper actuation
status
None
OFF
Stowing stopped
or now stowing
INT
Intermittent actuation
Wiper symbol + ON
ON
Continuous actuation
10-189
Control switch
This is used for control when using the maintenance function or select function.
(For details, see each function.)
10-190
PC200-7
Working mode
Monitor display
A mode
E mode
B mode
METHOD OF USE
Carry out the setting on the normal screen
1. A mode, E mode
1) Press select switch (1) on the monitor to
move to the adjustment screen.
2) Press control switch (2) to select the flow
level.
Control switch
Actuation
Flow level bar graph
extends to the right
PC200-7
Flow level
Flow (L/min.)
Remarks
430
Default
350
250
170
140
115
90
30
10-191
2. B mode
1) Press select switch (1) on the monitor to
move to the screen for selecting the 3stage flow level.
2) Press control switch (2), or input [01] - [03]
with the numeral 10-key pad to choose
one on the three flow levels.
No.
01
02
03
No.
Remarks
01
180
Default
02
140
03
100
Control switch
Actuation
Flow level bar graph
extends to the right
10-192
PC200-7
PC200-7
Flow
level
When
flow is
100 L/
min.
When
flow is
140 L/
min.
When
flow is
180 L/
min.
130
170
210
120
160
200
110
150
190
100
140
180
90
130
170
80
120
160
70
110
150
Remarks
Default
Display level
200 or 210
180 or 190
160 or 170
140 or 150
120 or 130
100 or 110
80 or 90
70
10-193
MAINTENANCE FUNCTION
When the maintenance time for replacement,
inspection, or filling has approached for the 10
maintenance items, press maintenance switch (1)
and the caution display (yellow or red) appears
on the monitor display for 30 seconds after the
key is turned ON to remind the operator to carry
out lubrication maintenance.
Maintenance items
No.
Item
Replacement
interval (hours)
01
Engine oil
500
02
500
03
Fuel filter
500
04
Hydraulic filter
1000
05
500
06
Corrosion resistor
(1000)
07
1000
08
2000
09
1000
10
Hydraulic oil
5000
Display
Condition
None
10-194
PC200-7
PC200-7
10-195
Symbol
Content
01
Return mark
Return
02
Contrast
03
Brightness
Actuation
Flow level bar graph
extends to the right
10-196
08937
PC200-7
PASSWORD FUNCTION
08941
PC200-7
10-197
10-198
PC200-7
When the starting switch is at the OFF position, keep return switch (1) and control switch
(2) of the monitor pressed at the same time,
and the service meter is shown on the display.
This display is shown only while the two
switches are being pressed. When the
switches are released, the display goes out.
Note that it takes 3 - 5 seconds after the
switches are pressed for the service meter
display to appear.
On the password input screen or on the normal screen, if monitor return switch (1) and
working mode (A) switch are kept pressed at
the same time, all the LCD display will light
up and the whole screen will become white,
so the display can be checked.
If any part of the display is black, the LCD is
broken.
PC200-7
08943
10-199
10-200
PC200-7
If there is more than one service code or failure code, the display switches every 2 seconds and displays all the service codes/failure
codes that caused the user code to be displayed.
Even if service codes/failure codes have
occurred, if they did not cause the user code
to be displayed, this function does not display
them.
PC200-7
08947
08948
10-201
SJP08775
OR
08931
10-202
PC200-7
12
1. Monitor panel
OUTLINE
The monitor panel has the functions to display various items and the functions to select
modes and electric parts.
The monitor panel has a CPU (Central Processing Unit) in it to process, display, and output the information.
The monitor display unit consists of LCD (Liquid Crystal Display) and LED (Light Emitting
Diode). The switches are flat sheet switches.
PC200-7
CN-P02
Signal neme
Pin
No.
Signal Name
Fuel
NC
Wiper contact W
GND
NC
GND
VB + (24 V)
Network signal
10
10
Network signal
11
11
Charge level
12
Wiper contact P
12
NC
13
14
NC
15
16
Buzzer cancel
17
Swing lock
18
Preheating
19
Limit switch
20
Network (GND)
10-203
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
10-204
PC200-7
When engine is
stopped
Lights when normal.
(Goes off when
engine is started.)
Displayed item
Display range
When clogged
Goes off.
Charge level
When charge is
abnormal
When swing is
locked
Oil maintenance
Preheating
When preheated
Coolant temperature
Fuel level
SAP00521
SAP00523
SAT00098
SAP00526
PC200-7
Goes off.
10-205
12
10-206
PC200-7
12
PC200-7
10-207
12
Mode selector switches
10-208
Operation
Work mode
AEB
Auto-deceleration
ONOFF
Wiper
Travel speed
OFFIntermittentON
HiLo
PC200-7
SENSOR
SENSOR
Sensor
name
Type of sensor
When
normal
When
abnormal
Engine oil
level
Contact
ON
(Closed)
OFF
(Open)
Engine oil
pressure
Contact
OFF
(Open)
ON
(Closed)
Hydraulic
oil temperature
Resistance
Coolant
temperature
Resistance
Fuel level
Resistance
Contact
OFF
(Closed)
ON
(Open)
Air cleaner
clogging
PC200-7
10-209
SENSOR
12
1. Plug
2. Contact ring
3. Contact
4. Diaphragm
5. Spring
6. Terminal
1. Thermistor
2. Body
3. Tube
10-210
4. Tube
5. Wire
6. Connector
PC200-7
SENSOR
12
1. Float
2. Connector
3. Cover
4. Variable resistor
PC200-7
10-211
90
OTHERS
Hydraulic Circuit Diagram
PC200-7, PC200LC-7. . . . . . . . . . . . 90-3
PC220-7, PC220LC-7. . . . . . . . . . . . 90-5
Electrical Circuit Diagram (1/5)
PC200-7, PC200LC-7. . . . . . . . . . . . 90-7
PC220-7, PC220LC-7. . . . . . . . . . . . 90-9
Electrical Circuit Diagram (2/5). . . . . 90-11
Electrical Circuit Diagram (3/5). . . . . 90-13
Electrical Circuit Diagram (4/5). . . . . 90-15
Electrical Circuit Diagram (5/5). . . . . 90-17
Electrical Circuit Diagram For Air
Conditioner . . . . . . . . . . . . . . . . . . . . 90-19
PC200-7
90-1
OTHERS
PC200-7
90-3
OTHERS
PC200-7
90-5
OTHERS
PC200-7
90-7
OTHERS
PC200-7
90-9
OTHERS
PC200-7
90-11
OTHERS
PC200-7
90-13
OTHERS
PC200-7
90-15
OTHERS
PC200-7
90-17
OTHERS
PC200-7
90-19