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SM PC200-7 SEBM024300 S - N 200001 Up

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SEBM024300

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

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD. 10-1

20

TESTING AND ADJUSTING . . . . . . . . . . . . Will Be Issued 10-25-2001

30

DISASSEMBLY AND ASSEMBLY . . . . . . . . Will Be Issued 12-15-2001

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.

To prevent injury to workers, the symbol


is used to mark safety precautions in this manual.
The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions
to deal with the situation.

GENERAL PRECAUTIONS
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.

Always wear safety glasses when hitting


parts with a hammer.
Always wear safety glasses when grinding
parts with a grinder, etc.

3. If welding repairs are needed, always have a


trained, experienced welder carry out the work.
When carrying out welding work, always wear
welding gloves, apron, hand shield, cap and
other clothes suited for welding work.
4. When carrying out any operation with two or
more workers, always agree on the operating
procedure before starting. Always inform your
fellow workers before starting any step of the
operation. Before starting work, hang UNDER
REPAIR signs on the controls in the operator's
compartment.
5. Keep all tools in good condition and learn the
correct way to use them.

6. Decide a place in the repair workshop to keep


tools and removed parts. Always keep the tools
and parts in their correct places. Always keep
the work area clean and make sure that there is
no dirt or oil on the floor. Smoke only in the areas
provided for smoking. Never smoke while working.
PREPARATIONS FOR WORK
7. Before adding oil or making any repairs, park the
machine on hard, level ground, and block the
wheels or tracks to prevent the machine from
moving.
8. Before starting work, lower blade, ripper, bucket
or any other work equipment to the ground. If
this is not possible, insert the safety pin or use
blocks to prevent the work equipment from falling. In addition, be sure to lock all the control
levers and hang warning signs on them.
9. When disassembling or assembling, support the
machine with blocks, jacks or stands before
starting work.
10.Remove all mud and oil from the steps or other
places used to get on and off the machine.
Always use the handrails, ladders or steps when
getting on or off the machine. Never jump on or
off the machine. If it is impossible to use the
handrails, ladders or steps, use a stand to provide safe footing.

00-3

SAFETY

PRECAUTIONS DURING WORK


11. When removing the oil filler cap, drain plug or
hydraulic pressure measuring plugs, loosen
them slowly to prevent the oil from spurting out.
Before disconnecting or removing components
of the oil, water or air circuits, first remove the
pressure completely from the circuit.
12.The water and oil in the circuits are hot when the
engine is stopped, so be careful not to get
burned.
Wait for the oil and water to cool before carrying out any work on the oil or water circuits.
13.Before starting work, remove the leads from the
battery. Always remove the lead from the negative () terminal first.
14.When raising heavy components, use a hoist or
crane.
Check that the wire rope, chains and hooks are
free from damage.
Always use lifting equipment which has ample
capacity.
Install the lifting equipment at the correct places.
Use a hoist or crane and operate slowly to prevent the component from hitting any other part.
Do not work with any part still raised by the hoist
or crane.
15.When removing covers which are under internal
pressure or under pressure from a spring,
always leave two bolts in position on opposite
sides. Slowly release the pressure, then slowly
loosen the bolts to remove.
16.When removing components, be careful not to
break or damage the wiring. Damaged wiring
may cause electrical fires.
17.When removing piping, stop the fuel or oil from
spilling out. If any fuel or oil drips onto the floor,
wipe it up immediately. Fuel or oil on the floor
can cause you to slip, or can even start fires.
18.As a general rule, do not use gasoline to wash
parts. In particular, use only the minimum of
gasoline when washing electrical parts.

00-4

SAFETY NOTICE

19.Be sure to assemble all parts again in their original places.


Replace any damaged parts with new parts.
When installing hoses and wires, be sure
that they will not be damaged by contact
with other parts when the machine is being
operated.
20.When installing high pressure hoses, make sure
that they are not twisted. Damaged tubes are
dangerous, so be extremely careful when installing tubes for high pressure circuits. Also, check
that connecting parts are correctly installed.
21.When assembling or installing parts, always use
the specified tightening torques. When installing
protective parts such as guards, or parts which
vibrate violently or rotate at high speed, be particularly careful to check that they are installed
correctly.
22.When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers
caught in a hole.
23.When measuring hydraulic pressure, check that
the measuring tool is correctly assembled before
taking any measurements.
24.Take care when removing or installing the tracks
of track-type machines.
When removing the track, the track separates
suddenly, so never let anyone stand at either
end of the track.

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.

STRUCTURE AND FUNCTION


This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to
be made at completion of the checks and repairs.
Troubleshooting charts correlating "Problems" with "Causes" are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.

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

HOW TO READ THE SHOP MANUAL

HOW TO READ THE SHOP MANUAL

REVISED EDITION MARK

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.

Chassis volume: Issued for every machine model


Engine volume: Issued for each engine series
Each issued as one
Electrical volume:
Attachments volume: volume to cover all
models

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

Revised pages are shown in the LIST OF REVISED


PAGES next to the CONTENTS page.

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

Special safety precautions


are necessary when performing the work.

Caution

Special technical precautions or other precautions


for preserving standards
are necessary when performing the work.

Weight

Weight of parts of systems. Caution necessary


when selecting hoisting
wire, or when working posture is important, etc.

Tightening
torque

Places that require special


attention for the tightening
torque during assembly.

Coat

Places to be coated with


adhesives and lubricants,
etc.

Oil, water

Places where oil, water or


fuel must be added, and
the capacity.

Drain

Places where oil or water


m u s t b e d r a i n e d , a nd
quantity to be drained.

4
3
2
5
6

FOREWORD

HOISTING INSTRUCTIONS

HOISTING INSTRUCTIONS
HOISTING

Heavy parts (25 kg or more) must be lifted


with a hoist, etc. In the DISASSEMBLY
AND ASSEMBLY section, every part
weighing 25 kg or more is indicated clearly
with the symbol

If a part cannot be smoothly removed from the


machine by hoisting, the following checks
should be made:
1) Check for removal of all bolts fastening the
part to the relative parts.
2) Check for existence of another part causing
interference with the part to be removed.

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

Slinging near the edge of the hook may cause


the rope to slip off the hook during hoisting, and
a serious accident can result. Hooks have maximum strength at the middle portion.

100%

88%

79%

71%

41%
SAD00479

3) Do not sling a heavy load with one rope alone,


but sling with two or more ropes symmetrically
wound onto the load.
Slinging with one rope may cause turning
of the load during hoisting, untwisting of
the rope, or slipping of the rope from its
original winding position on the load, which
can result in a dangerous accident.

4) Do not sling a heavy load with ropes forming a


wide hanging angle from the hook.
When hoisting a load with two or more ropes,
the force subjected to each rope will increase
with the hanging angles. The table below
shows the variation of allowable load kN {kg}
when hoisting is made with two ropes, each of
which is allowed to sling up to 9.8 kN {1000 kg}
vertically, at various hanging angles.
When two ropes sling a load vertically, up to
19.6 kN {2000 kg} of total weight can be suspended. This weight becomes 9.8 kN {1000 kg}
when two ropes make a 120 hanging angle.
On the other hand, two ropes are subjected to
an excessive force as large as 39.2 kN {4000
kg} if they sling a 19.6 kN {2000 kg} load at a
lifting angle of 150.

The allowable load value is estimated to be onesixth or one-seventh of the breaking strength of
the rope used.

2) Sling wire ropes from the middle portion of the


hook.

00-7

FOREWORD

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

Before carrying out the following work, release


the residual pressure from the hydraulic tank.
For details, see TESTING AND ADJUSTING,
Releasing residual pressure from hydraulic
tank.
Even if the residual pressure is released from
the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly,
prepare an oil receiving container.

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

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

Type 3

1) Hold the mouthpiece of the tightening portion


and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of
the hexagonal portion at the male end.

1) Hold the mouthpiece of the tightening portion


and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of
the hexagonal portion at the male end.

2) Hold in the condition in Step 1), and turn


lever (4) to the right (clockwise).

2) Hold in the condition in Step 1), and push


until cover (3) contacts contact surface a of
the hexagonal portion at the male end.

3) Hold in the condition in Steps 1) and 2), and


pull out whole body (2) to disconnect it.

3) Hold in the condition in Steps 1) and 2), and


pull out whole body (2) to disconnect it.

Disassembly

Type 2

Hold the mouthpiece of the tightening portion


and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of
the hexagonal portion at the male end to connect it.

Connection

Hold the mouthpiece of the tightening portion


and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of
the hexagonal portion at the male end to connect it.

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

Main applications, featuresr

Used to prevent rubber gaskets,


rubber cushions, and cock plug
from coming out.

Used in places requiring an immediately effective, strong adhesive.


Used for plastics (except polyethylene, polyprophylene, tetrafluoroet hl ene and vi nyl chl or ide) ,
rubber, metal and non-metal.

Features: Resistance to heat and


chemicals
Used for anti-loosening and sealant purpose for bolts and plugs.

Used as adhesive or sealant for


metal, glass and plastic.

Used as sealant for machined


holes.

Used as heat-resisting sealant for


repairing engine.

Quick hardening type adhesive


Cure time: within 5 sec. to 3 min.
Used mainly for adhesion of metals, rubbers, plastics and woods.

Quick hardening type adhesive


Quick cure type (max. strength after 30 minutes)
Used mainly for adhesion of rubbers, plastics and metals.

Resistance to heat, chemicals


Used at joint portions subject to
high temperatures.

Used as adhesive or sealant for


gaskets and packing of power
train case, etc.

Used as sealant for various


threads, pipe joints, flanges.
Used as sealant for tapered
plugs, elbows, nipples of hydraulic piping.

Gasket
sealant

LG-6

790-129-9020

200 g

Tube

00-10

Features: Silicon based, resistance to heat, cold


Used as sealant for flange surface, tread.
mab Used as sealant for oil pan,
final drive case, etc.

FOREWORD

Category

COATING MATERIALS

Komatsu code

Part No.

Q'ty

Container

Main applications, features

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 as heat-resisting sealant for


repairing engine.

Used as lubricant for sliding portion (to prevent from squeaking).

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

Features: Silicon based, quick


hardening type
Used as sealant for flywheel
housing, intake manifold, oil an,
thermostat housing, etc.

General purpose type

Used for normal temperature,


light load bearing at places in contact with water or steam.

Used for places with heavy load

Various

00-11

FOREWORD

STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE


STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH)
In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in
the table below.
Thread diameter
of bolt

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

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS


In the case of flared nuts for which there is no
special instruction, tighten to the torque given in
the table below.

SAD00483

Thread diameter

Width across flat

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

STANDARD TIGHTENING TORQUE

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS


In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the
table below.

Thread diameter

Width across flat

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

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS


Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.

Thread diameter

Width across flat

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

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS


Unless there are special instructions, tighten the O-ring boss plugs to the torque below.

Thread diameter

Width across flat

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

STANDARD TIGHTENING TORQUE

TIGHTENING TORQUE FOR 102 ENGINE SERIES (BOLT AND NUTS)


Use these torques for bolts and nuts (unit: mm) of Cummins Engine.

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

TIGHTENING TORQUE FOR 102 ENGINE SERIES (EYE JOINTS)


Use these torques for eye joints (unit: mm) of Cummins Engine.

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

TIGHTENING TORQUE FOR 102 ENGINE SERIES (TAPERED SCREWS)


Use these torques for tapered screws (unit: inch) of Cummins Engine.

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

ELECTRIC WIRE CODE

ELECTRIC WIRE CODE


In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.

CLASSIFICATION BY THICKNESS

Copper wire
Cable O.D.
(mm)

Current
rating
(A)

Applicable circuit

0.88

2.4

12

Starting, lighting, signal


etc.

0.32

2.09

3.1

20

Lighting, signal etc.

65

0.32

5.23

4.6

37

Charging and signal

15

84

0.45

13.36

7.0

59

Starting (Glow plug)

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

CLASSIFICATION BY COLOR AND CODE


Circuits
Priority
Classification

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

Color White & Blue


Code

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

Black & Red Red & Yellow

n
n
n
n

RG

YG

GY

LY

Yellow &
Green

Green &
Yellow

Blue & Yellow

YL

GB

LB

Red & Green Yellow & Blue Green & Black Blue & Black
RL

YW

GL

Red & Blue Yellow & White Green & Blue

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

Liter to U.S. Gallon

1 = 0.2642 U.S. Gal

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

Liter to U.K. Gallon

1 = 0.21997 U.K. Gal

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

SPECIFICATION DIMENSION DRAWINGS

12

SPECIFICATION DIMENSION DRAWINGS


PC200-7, PC200LC-7
DIMENSIONS

WORKING RANGES

01-2

PC200-7

GENERAL

SPECIFICATION DIMENSION DRAWINGS

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

Track shoe width

mm

600

700

Height of cab

mm

3,000

3,000

Tail swing radius

mm

2,750

2,750

Track overall length

mm

4,080

4,450

Length of track on ground

mm

3,270

3,640

Min. ground clearance

mm

440

440

Unit

PC200-7

PC200LC-7

WORKING RANGES
Item
A

Max. digging reach

mm

9,875

9,875

Max. digging depth

mm

6,620

6,620

Max. digging height

mm

10,000

10,000

Max. vertical wall depth

mm

5,980

5,980

Max. dumping height

mm

7,110

7,110

Min. dumping height

mm

2,645

2,645

Max. reach at ground level

mm

2,645

2,645

PC200-7

01-3

GENERAL

SPECIFICATION DIMENSION DRAWINGS

PC220-7, PC220LC-7
DIMENSIONS

WORKING RANGES

01-4

PC200-7

GENERAL

SPECIFICATION DIMENSION DRAWINGS

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

Track shoe width

mm

600

700

Height of cab

mm

3,015

3,015

Tail swing radius

mm

2,940

2,940

Track overall length

mm

4,250

4,640

Length of track on ground

mm

3,460

3,845

Min. ground clearance

mm

440

400

Unit

PC220-7

PC220LC-7

WORKING RANGES
Item
A

Max. digging reach

mm

10,180

10,180

Max. digging depth

mm

6,920

6,920

Max. digging height

mm

10,000

10,000

Max. vertical wall depth

mm

6,010

6,010

Max. dumping height

mm

7,035

7,035

Min. dumping height

mm

2,530

2,530

Max. reach at ground level

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

Max. digging depth

mm

6,620

6,620

Max. vertical wall depth

mm

5,980

5,980

Max. digging reach

mm

9,875

9,875

Max. reach at ground level

mm

9,700

9,700

Max. digging height

mm

10,000

10,000

Max. dumping height

mm

7,110

7,110

kN {kg}

138.3 {14,100}

138.3 {14,100}

(149.1 {15,200})

(149.1 {15,200})

Max. digging force


(using power max. function)
Swing speed

rpm

12.4

12.4

Swing max. slope angle

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]

Overall length (for transport)

mm

9,425

9,425

Overall width

mm

2,800

3,080

Overall width of track

mm

2,800

3,080

Overall height (for transport)

mm

3,000

3,000

Overall height to chassis

mm

3,000

3,000

Ground clearance to bottom of upper structure

mm

1,085

1,085

Min. ground clearance

mm

440

440

Tail swing radius

mm

2,750

2,750

Min. swing radius of work equipment

mm

3,040

3,040

Height of work equipment at min. swing radius

mm

8,005

8,005

Length of track on ground

mm

3,270

3,640

Track gauge

mm

2,200

2,380

Height of machine cab

mm

2,335

2,335

Gradeability

Ground pressure
[standard shoe width]

Dimensions

PC200LC-7

: The "Mi" mode is on the multi-monitor specification machine only.

01-6

PC200-7

GENERAL

SPECIFICATIONS

12
Machine model

PC200-7

Serial Number

200001 and up

Model
Type

Performance

Engine

No. of cylinders - bore x stroke


Piston displacement
Flywheel horsepower
Max. torque
Max. speed at no load
Min. speed at no load
Min. fuel consumption

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

Radiator core type

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

HPV95+95, variable displacement

l/min
MPa (kg/cm)

HMV110ADT-2, Piston type


(with brake valve, parking brake): x 2
KMF125ABE-5, Piston type
(with safety valve, holding brake): x 1

Swing motor

Inside diameter of cylinder


Diameter of piston rod
Stroke
Max. distance between pins
Min. distance between pins

Hrdraulic tank
Hydraulic filter
Hydraulic cooler

PC200-7

Piston type: 214 x 2


Piston type: 37.2 {380}
6-spool type x 1
Hydraulic

Type
Hydraulic culinder

Undercarriage

Carrier roller

Hydraulic system

PC200LC-7

mm
mm
mm
mm
mm

Boom

Arm

Bucket

Double acting piston

Double acting piston

Double acting piston

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

Closed box type


Tank return side
CF40-1 (Air cooled)

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

Max. digging depth

mm

6,920

6,920

Max. vertical wall depth

mm

6,010

6,010

Max. digging reach

mm

10,180

10,180

Max. reach at ground level

mm

10,020

10,020

Max. digging height

mm

10,000

10,000

Max. dumping height

mm

7,035

7,035

kN {kg}

158.9 {16,200}

158.9 {16,200}

(171.6 {17,500})

(171.6 {17,500})

Max. digging force


(using power max. function)
Swing speed

rpm

11.7

11.7

Swing max. slope angle

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]

Overall length (for transport)

mm

9,885

9,885

Overall width

mm

2,980

3,280

Overall width of track

mm

2,980

3,280

Overall height (for transport)

mm

3,160

3,160

Overall height to chassis

mm

3,015

3,015

Ground clearance to bottom of upper structure

mm

1,110

1,110

Min. ground clearance

mm

440

440

Tail swing radius

mm

2,940

2,940

Min. swing radius of work equipment

mm

3,450

3,450

Height of work equipment at min. swing radius

mm

8,110

8,110

Length of track on ground

mm

3,460

3,845

Track gauge

mm

2,380

2,580

Height of machine cab

mm

2,390

2,390

Gradeability

Ground pressure
[standard shoe width]

Dimensions

PC220LC-7

: The "Mi" mode is on the multi-monitor specification machine only.

01-8

PC200-7

GENERAL

SPECIFICATIONS

Machine model

PC220-7

Serial Number

60001 and up

Model
Type

Performance

Engine

No. of cylinders - bore x stroke


Piston displacement
Flywheel horsepower
Max. torque
Max. speed at no load
Min. speed at no load
Min. fuel consumption

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

Radiator core type

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

HPV95+95, variable displacement

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

Inside diameter of cylinder


Diameter of piston rod
Stroke
Max. distance between pins
Min. distance between pins

Hrdraulic tank
Hydraulic filter
Hydraulic cooler

PC200-7

Piston type: 214 x 2


Piston type: 37.2 {380}

MPa (kg/cm)

Type
Hydraulic culinder

Undercarriage

Carrier roller

Hydraulic system

PC220LC-7

mm
mm
mm
mm
mm

Boom

Arm

Bucket

Double acting piston

Double acting piston

Double acting piston

130
90
1,335
3,205
1,870

140
100
1,635
2,235
3,870

130
90
1,020
2,625
1,605

Closed box type


Tank return side
CF40-1 (Air cooled)

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

Radiator oil cooler assembly

110

110

Hydraulic tank, filter assembly (excluding hydraulic oil)

123

123

Fuel tank (excluding fuel)

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

Track frame assembly

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

Final drive (including travel motor)

343 x 2

343 x 2

Revolving frame

Center swivel joint

01-10

PC200-7

GENERAL

WEIGHT TABLE

12

Unit: kg
Machine model

PC200-7

PC200LC-7

Serial Number

200001 and up

200001 and up

Track shoe assembly

Standard triple grouser shoe (600 mm)

1,215 x 2

1,325 x 2

Standard triple grouser shoe (700 mm)

1,405 x 2

1,530 x 2

Wide triple grouser shoe (800 mm)

1,530 x 2

1,670 x 2

Road liner (rubber pad type) (600 mm)

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

Arm cylinder assembly

226

226

Bucket cylinder assembly

136

136

Link assembly (large)

81

81

Link assembly (small)

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 cylinder 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

Radiator oil cooler assembly

119

119

Hydraulic tank, filter assembly (excluding hydraulic oil)

123

123

Fuel tank (excluding fuel)

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

Track frame assembly

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

Final drive (including travel motor)

362 x 2

362 x 2

Revolving frame

Center swivel joint

01-12

PC200-7

GENERAL

WEIGHT TABLE

12

Unit: kg
Machine model

PC220-7

PC220LC-7

Serial Number

60001 and up

60001 and up

Track shoe assembly

Standard triple grouser shoe (600 mm)

1,340 x 2

1,455 x 2

Standard triple grouser shoe (700 mm)

1,470 x 2

1,595 x 2

Wide triple grouser shoe (800 mm)

1,600 x 2

1,735 x 2

Road liner (rubber pad type) (600 mm)

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

Arm cylinder assembly

262

262

Bucket cylinder assembly

161

161

Link assembly (large)

82

82

Link assembly (small)

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

FUEL, COOLANT, AND LUBRICANTs

12

FUEL, COOLANT, AND LUBRICANTS

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

Track roller (1 each)

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

Carrier roller (1 each)


SAE 10W
SAE 10W-30
Hydraulic system
SAE 15W-40
Hydraulic
oil

Fuel tank

H046-HM ()
ASTM D975 No. 2

Diesel
fuel
ASTM D975A
No.1

Cooling system

Coolant

Add antifreeze

For the H-046-HM, use the oil recommended by Komatsu.

01-14

PC200-7

10
1252
Engine

STRUCTURE, FUNCTION, AND


MAINTENANCE STANDARD

Related Parts . . . . . . . . . . . . . .10-2


Radiator Oil Cooler Aftercooler . . .10-3
Power Train . . . . . . . . . . . . . . . . . . . . .10-4
Final Drive . . . . . . . . . . . . . . . . . . . . . .10-6
Swing Machinery
PC200-7, PC200LC-7 . . . . . . . . . . . .10-8
PC220-7, PC220LC-7 . . . . . . . . . . .10-10
Swing Circle
PC200-7, PC200LC-7 . . . . . . . . . . .10-12
PC220-7, PC220LC-7 . . . . . . . . . . .10-13
Track Frame Recoil Spring . . . . . . .10-14
Idler. . . . . . . . . . . . . . . . . . . . . . . . . . .10-16
Carrier roller. . . . . . . . . . . . . . . . . . . .10-18
Track roller . . . . . . . . . . . . . . . . . . . . .10-19
Track Shoe . . . . . . . . . . . . . . . . . . . . .10-20
Hydraulic Equipment Layout Drawing
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-24
Hydraulic Tank . . . . . . . . . . . . . . . . . .10-26
Hydraulic Pump . . . . . . . . . . . . . . . . .10-28
Control Valve
PC200-7, PC200LC-7 . . . . . . . . . . .10-50
PC220-7, PC220LC-7 . . . . . . . . . . .10-64
CLSS . . . . . . . . . . . . . . . . . . . . . . . . . .10-80
Self Pressure Reducing Valve. . . . . .10-83
Swing Motor . . . . . . . . . . . . . . . . . . .10-86
Reverse Prevention Valve . . . . . . . . .10-91
Center Swivel Joint . . . . . . . . . . . . . .10-93
Travel Motor . . . . . . . . . . . . . . . . . . .10-94
Travel Junction Valve . . . . . . . . . . .10-103
Travel PPC Shuttle Valve . . . . . . . .10-105
Valve Control . . . . . . . . . . . . . . . . . .10-107
Work Equipment Swing PPC Valve
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-108
Travel PPC Valve . . . . . . . . . . . . . . .10-112
Service PPC Valve . . . . . . . . . . . . . .10-121
Solenoid Valve. . . . . . . . . . . . . . . . .10-124
PPC Accumulator. . . . . . . . . . . . . . .10-126
Return Oil Filter . . . . . . . . . . . . . . . .10-127
Boom Hydraulic Drift Prevention Valve
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-128
Lift Check Valve . . . . . . . . . . . . . . . .10-131
Attachment Circuit Selector Valve .10-132

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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

ENGINE RELATED PARTS

12

ENGINE RELATED PARTS

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

The damper assembly is a wet type.


Oil capacity: 0.75 l

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

RADIATOR OIL COOLER


AFTERCOOLER

12

RADIATOR OIL COOLER AFTERCOOLER

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

: CWX-4 (PC200-7, PC200LC-7)


: CF19-5 (PC220-7, PC220LC-7)
Oil cooler : CF40-1

10-3

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

FINAL DRIVE

12

FINAL DRIVE

10-6

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

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

Backlash between No. 1 planetary gear


and ring gear

0.17 - 0.57

1.10

17

Backlash between No. 1 planetary carrier and motor

0.06 - 0.25

18

Backlash between No. 2 sun gear and


No. 2 planetary gear

0.14 - 0.46

1.00

19

Backlash between No. 2 planetary gear


and ring gear

0.17 - 0.57

1.10

20

Backlash between No. 2 planetary carrier and No. 1 sun gear

0.38 - 0.66

1.00

21

End play of sprocket shaft

0.00 - 0.10

22

Amount of wear on sprocket tooth

23

Replace

Repair limit: 6
Standard size

Repair limit

71

68

Width of sprocket tooth

PC200-7

Rebuild or
replace

10-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

SWING MACHINERY

12

SWING MACHINERY
PC200-7, PC200LC-7

10-8

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

SWING MACHINERY

12

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.

Swing pinion (No. of teeth: 15)


Spacer
Case
No. 2 planetary carrier
No. 2 sun gear
Ring gear
No. 1 sun gear
Swing motor
Oil level gauge
No. 1 planetary gear
No. 1 planetary carrier
No. 2 planetary gear
Drain plug

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

Backlash between No. 1 sun gear and No. 1


planetary gear

0.16 - 0.50

1.00

16

Backlash between No. 1 planetary gear and


ring gear

0.18 - 0.59

1.10

17

Backlash between No. 1 planetary carrier


and No. 2 sun gear

0.39 - 0.71

1.20

18

Backlash between No. 2 sun gear and No. 2


planetary gear

0.16 - 0.50

0.90

19

Backlash between No. 2 planetary gear and


ring gear

0.18 - 0.59

1.00

20

Backlash between No. 2 planetary carrier


and swing pinion

0.07 - 0.23

21

Backlash between swing pinion and swing


circle

0.22 - 1.32

2.00

22

Clearance between plate and planetary carrier

0.66 - 1.14

Standard size

Repair limit

23

Wear of swing pinion surface contacting


with oil seal

14

Backlash between swing motor shaft and


No. 1 sun gear

15

PC200-7

115

0
-0.100

Replace

Apply hard chrome


plating, recondition, or replace

10-9

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

SWING MACHINERY

PC220-7, PC220LC-7

10-10

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

SWING MACHINERY

12

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.

Swing pinion (No. of teeth: 13)


Spacer
Case
No. 2 planetary carrier
No. 2 sun gear
Ring gear
No. 1 sun gear
Swing motor
Oil level gauge
No. 1 planetary gear
No. 1 planetary carrier
No. 2 planetary gear
Drain plug

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

Backlash between No. 1 sun gear and No. 1


planetary gear

0.16 - 0.59

1.00

16

Backlash between No. 1 planetary gear and


ring gear

0.18 - 0.50

1.10

17

Backlash between No. 1 planetary carrier


and No. 2 sun gear

0.39 - 0.64

1.20

18

Backlash between No. 2 sun gear and No. 2


planetary gear

0.16 - 0.44

0.90

19

Backlash between No. 2 planetary gear and


ring gear

0.18 - 0.56

1.00

20

Backlash between No. 2 planetary carrier


and swing pinion

0.08 - 0.23

21

Backlash between swing pinion and swing


circle

0.23 - 1.37

2.00

22

Clearance between plate and planetary carrier

0.58 - 0.62

Standard size

Repair limit

23

Wear of swing pinion surface contacting


with oil seal

14

Backlash between swing motor shaft and


No. 1 sun gear

15

PC200-7

115

0
-0.100

Replace

Apply hard chrome


plating, recondition, or replace

10-11

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

SWING CIRCLE

SWING CIRCLE
PC200-7, PC200LC-7

1. Swing circle inner race (No. of teeth: 110)


2. Ball
3. Swing circle outer race
a. Inner race soft zone S position
b. Outer race soft zone S position

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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

SWING CIRCLE

12

PC220-7, PC220LC-7

S*P09097

1. Swing circle inner race (No. of teeth: 92)


2. Ball
3. Swing circle outer race
a. Inner race soft zone S position
b. Outer race soft zone S position

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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

TRACK FRAME RECOIL SPRING

12

TRACK FRAME RECOIL SPRING

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

The dimensions and the number of track rollers depend


on the model, but the basic structure is not different.
Number of track rollers
Model

Qty

PC200-7

PC200LC-7

PC220-7

PC220LC-7

10

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

TRACK FRAME RECOIL SPRING

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

No. on track (one side)

Unit: mm
No.

Check item

Criteria
Standard
size

10

11

Vertical width of idler guide

Horizontal width of idler


guide

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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

TRACK FRAME RECOIL SPRING

12

IDLER

10-16

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

TRACK FRAME RECOIL SPRING

12

Unit: mm
No.

Check item

Outside diameter of protruding

Criteria

Remedy

Standard size

Repair limit

538

Outside diameter of tread

500

488

Thickness of tread

26

20

Total width

159

Width of tread

37.5

43.5

Clearance between shaft and


bushing

Standard
size
65

Interference between idler and


bushing

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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

TRACK FRAME RECOIL SPRING

12

CARRIER ROLLER

Unit: mm
No.

Check item

Criteria

Remedy

Standard size

Repair limit

145

Outside diameter of flange

Outside diameter of tread

120

106

Width of tread

43

Thickness of tread

36.5

29.5

Width of flange

14

Interference between shaft


and bushing

Interference between roller


and bushing

Axial clearance of roller

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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

TRACK FRAME RECOIL SPRING

12

TRACK ROLLER

Unit: mm
No.

Check item

Criteria

Remedy

Standard size

Repair limit

188

Outside diameter of flange

Outside diameter of tread

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

Clearance between shaft and


bushing

Standard
size
60

Interference between roller


and bushing

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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

TRACK SHOE

12

TRACK SHOE
TRIPLE GROUSER SHOE, ROAD LINER, SWAMP SHOE, FLAT SHOE

P portion shows the link of bushing press fitting end.

1.Triple-grouser shoe
2.Road liner

10-20

3.Swamp shoe
4.Flat shoe

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

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

Bushing outside diameter

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

Shoe bolt pitch

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

88.2 - 245 kN {9 - 25 ton}

Regular pin

127.4 - 274.4 kN {13 - 28 ton}

Master pin

78.4 - 147 kN {8 - 15 ton}

: Dry type track link

PC200-7

10-21

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

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

Clearance between regular pin


and bushing

Tolerance

Standard
size

Interference between master


pin and bushing

Clearance between master pin


and bushing

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

PC200-7: 45, PC200LC-7: 49


PC220-7: 47, PC220LC-7: 51

No. of shoes (each side)

Interference between
bushing and link

Retighten

Additional tightening Lower limit torque


angle (deg.)
(Nm {kgm})

21

Remedy

: Dry type track link

10-22

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

TRACK SHOE

12

TRIPLE GROUSER SHOE

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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

HYDRAULIC EQUIPMENT LAYOUT


DRAWING

12

HYDRAULIC EQUIPMENT LAYOUT DRAWING


1. Bucket cylinder
2. Arm cylinder
3. Boom cylinder
4. Hydraulic tank
5. Hydraulic filter
6. R.H. travel motor
7. Swing motor
8. Hydraulic pump
9. Control valve
10. Oil cooler
11. L.H. travel motor
12. Multi-pattern selector valve
13. L.H. PPC valve
14. Safety lever (electric type)
15. Center swivel joint
16. R.H. PPC valve
17. Travel PPC valve
18. Attachment circuit selector valve
19. Holding valve
20. Accumulator
21. Solenoid valve assembly
21A PPC lock solenoid
21B Travel junction solenoid
21C Pump merge/divider solenoid
21D Travel speed solenoid
21E Swing brake solenoid
21F 2-stage relief solenoid

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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

HYDRAULIC EQUIPMENT LAYOUT


DRAWING

12

PC200-7

10-25

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

HYDRAULIC PUMP

12

HYDRAULIC PUMP
HPV95 + 95

1.
2.
3.
4.
5.
6.

Front main pump


Rear main pump
LS valve
PC valve
LS-EPC valve
PC-EPC valve

IM
ISIG
PAF
PFC

:
:
:
:

PAR :
PRC :
PBF :
PD1F:
PENF:

PC mode selector current


LS set selector current
Front pump delivery port
Front pump delivery pressure detection port
Rear pump delivery port
Rear pump delivery pressure
detection port
Pump pressure input port
Case drain port
Front pump control pressure
detection port

PENR : Rear pump control pressure detection port


PLSF : Front load pressure input port
PLSFC: Front load pressure detection port
PLSR : Rear load pressure input port
PLSRC: Rear load pressure detection port
PS
: Pump suction port
PSIG : LS set selector pressure detection
port
PM : PC set selector pressure detection
port
PEPC : EPC basic pressure input port

Outline
This pump consists of 2 variable capacity swash plate
piston pumps, PC valve, LS valve, and EPC valve.

10-28

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

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

Rocker cam (4) has flat surface A, and shoe


(5) is always pressed against this surface
while sliding in a circular movement.
Rocker cam (4) brings high pressure oil at cylinder surface B with cradle (2), which is
secured to the case, and forms a static pressure bearing when it slides.
Piston (6) carries out relative movement in
the axial direction inside each cylinder chamber of cylinder block (7).
The cylinder block seals the pressure oil to
valve plate (8) and carries out relative rotation. This surface is designed so that the oil
pressure balance is maintained at a suitable
level. The oil inside each cylinder chamber of
cylinder block (7) is sucked in and discharged
through valve plate (8).

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD


12
2)

HYDRAULIC PUMP

Control of discharge amount


If the swash plate angle becomes larger,
the difference between volumes E and F
becomes larger and discharge amount Q
increases.
Swash plate angle is changed by servo
piston (12).
Servo piston (12) moves in a reciprocal
movement () according to the signal
pressure from the PC and LS valves. This
straight line movement is transmitted
through rod (13) to rocker cam (4), and
rocker cam (4), which is supported by the
cylindrical surface to cradle (2), slides in a
rotating movement in direction of arrow.
With servo piston (12), the area receiving
the pressure is different on the left and
the right, so main pump discharge pressure (self pressure) PP is always brought
to the chamber receiving the pressure at
the small diameter piston end.
Output pressure Pen of the LS valve is
brought to the chamber receiving the
pressure at the large diameter end. The
relationship in the size of pressure PP at
the small diameter piston end and pressure Pen at the large diameter end, and
the ratio between the area receiving the
pressure of the small diameter piston and
the large diameter piston controls the
movement of servo piston (12).

10-32

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

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.

Servo piston assembly


Plug
Pin
Spool
Retainer
Seat
Cover
Wiring

PC200-7

:
:
:
:
:
:

10-33

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

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

At this point, spool (6) is pushed to the left,


and port C and port D are connected. Pump
pressure PP enters the large diameter end of
the piston from port K and the same pump
pressure PP also enters port J at the small
diameter end of the piston, so the swash plate
is moved to the minimum angle by the difference in the area of the piston (11).

10-35

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

HYDRAULIC PUMP

12

SDP08885

2) Operation in increase direction for pump


discharge amount
When the difference between the main pump
pressure PP and LS pressure PLS, in other
words, LS differential pressure PLS,
becomes smaller (for example, when the area
of opening of the control valve becomes
larger and pump PP drops), spool (6) is
pushed to the right by the combined force of
LS pressure PLS and the force of spring (4).
When spool (6) moves, port D and port E are
joined and connected to the PC valve. When
this happens, the PC valve is connected to the
drain port, so circuit D - K becomes drain
pressure PT. (The operation of the PC valve is
explained later).

10-36

For this reason, the pressure at the large


diameter end of servo piston (12) becomes
drain pressure PT, and pump pressure PP
enters port J at the small diameter end, so
servo piston (12) is pushed to the right. Therefore, the swash plate moves in the direction
to make the discharge amount larger. If the
output pressure of the EPC valve for the LS
valve enters port G, this pressure creates a
force to move piston (7) to the left. If piston
(7) is pushed to the left, it acts to make the set
pressure of spring (4) weaker, and the difference between PLS and PP changes when
ports D and E of spool (6) are connected.

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

HYDRAULIC PUMP

12

SDP08886

3) Operation in decrease direction for


pump discharge amount
The following explains the situation if the
servo piston (12) moves to the left (the discharge amount becomes smaller). When LS
differential pressure PLS becomes larger
(for example, when the area of opening of the
control valve becomes smaller and pump
pressure PP rises), pump pressure PP
pushes spool (6) to the left.
When spool (6) moves, main port pressure
PP flows from port C and port D and from
port K, it enters the large diameter end of the
piston.

PC200-7

Main pump pressure PP also enters port J at


the small diameter end of the piston, but
because of the difference in area between the
large diameter end and the small diameter
end of servo piston (12), servo piston (12) is
pushed to the left.
As a result, the swash plate moves in the
direction to make angle smaller.
If LS selection pressure PSIG enters port G, it
acts to make the set pressure of spring (4)
weaker.

10-37

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

HYDRAULIC PUMP

12

SDP08887

4) When servo piston is balanced


Let us take the area receiving the pressure at
the large diameter end of the piston as A1,
the area receiving the pressure at the small
diameter end as A0, and the pressure flowing
into the large diameter end of the piston as
Pen. If the main pump pressure PP of the LS
valve and the combined force of force Z of
spring (4) and LS pressure PLS are balanced,
and the relationship is A0 x PP = A1 x Pen,
servo piston (11) will stop in that position, and
the swash plate will be kept at an intermediate position. (It will stop at a position where
the opening of the throttle from port D to port
E and from port C to port D of spool (6) is
approximately the same.)

10-38

At this point, the relationship between the


area receiving the pressure at both ends of
piston (12) is A0 : A1 = 1:2, so the pressure
applied to both ends of the piston when it is
balanced becomes PP : Pen = 2:1.
The position where spool (6) is balanced and
stopped is the standard center, and the force
of spring (4) is adjusted so that it is determined when PP - PLS = 2.2 MPa {22 kg/cm}.
However, if PSIG (the output pressure of 0
2.9 MPa {0 30 kg/cm} of the EPC valve of
the LS valve) is applied to port G, the balance
stop position will change in proportion to
pressure PSIG between PP - PLS = 2.2
0.69 MPa {22 7 kg/cm}.

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

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

the pressure (pressure of port C) output


from the PC valve changes according to
this position.
The size of command current X is determined by the nature of the operation
(lever operation), the selection of the
working mode, and the set value and
actual value for the engine speed.
Other pump pressure
This is the pressure of the pump at the
opposite end.
For the F pump, it is the R pump pressure
For the R pump, it is the F pump pressure

10-39

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

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

If the command circuit input to PC-EPC valve


solenoid (1) changes further, the force pushing piston (2) changes, and the spring load of
springs (4) and (6) also changes according to
the valve of the PC-EPC valve solenoid command current.

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

HYDRAULIC PUMP

12

Port C of the PC valve is connected to port E


of the LS valve (see (1) LS valve). Self pressure PP1 enters port B and the small diameter end of servo piston (9), and other pump
pressure PP2 enters port A.
When pump pressures PP1 and PP2 are
small, spool (3) is on the left. At this point,
port C and D are connected, and the pressure
entering the LS valve becomes drain pressure
PT. If port E and port G of the LS valve are
connected (see (1) LS valve), the pressure
entering the large diameter end of the piston
from port J becomes drain pressure PT, and
servo piston (9) moves to the right. In this
way, the pump discharge amount moves in
the direction of increase.
As servo piston (9) moves further, springs (4)
and (6) expand and the spring force becomes
weaker. When the spring force becomes
weaker, spool (3) moves to the right, so the
connection between port C and port D is cut,
and the pump discharge pressure ports B and
C are connected. As a result, the pressure at
port C rises, and the pressure at the large
diameter end of the piston also rises, so the
movement of piston (9) to the right is
stopped.
In other words, the stop position for piston (9)
(= pump discharge amount) is decided at the
point where the force of springs (4) and (6)
and the pushing force from the PC-EPC valve
solenoid and the pushing force created by the
pressures PP1 and PP2 acting on the spool
(3) are in balance.

PC200-7

10-41

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

HYDRAULIC PUMP

12

b. When load on actuator is large and


pump discharge pressure is high
When the load is large and pump discharge pressures PP1 and PP2 are high,
the force pushing spool (3) to the left
becomes larger and spool (3) moves to
the position in the diagram above. When
this happens, as shown in the diagram
above, part of the pressurized oil from
port B flows out through port C where the
LS valve is actuated to port D, and the
pressurized oil flowing from port C to the
LS valve becomes approximately half of
main pump pressure PP.
When port E and port G of the LS valve
are connected (see (1) LS valve), the pressure from port J enters the large diameter
end of servo piston (9), and servo piston
(9) stops.

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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

HYDRAULIC PUMP

12

The relation of average pump pressure


(PP1 + PP2)/2 and the position of servo
piston (9) forms a bent line because of
the double-spring effect of springs (4)
and (6). The relationship between average pump pressure (PP1 + PP2)/2 and
pump discharge amount Q is shown in
the figure at the right.

If command voltage X sent to PC-EPC


valve solenoid (1) increases further, the
relationship between average pump
pressure (PP1 + PP2)/2, and pump discharge amount Q is proportional to the
pushing force of the PC-EPC valve solenoid and moves in parallel. In other
words, the pushing force of PC-EPC
solenoid (1) is added to the force pushing to the left because of the pump pressure applied to the spool (3), so the
relationship between the average pump
pressure (PP1 + PP2)/2 and Q moves
from to in accordance with the
increase in X.

PC200-7

10-43

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

HYDRAULIC PUMP

12

2) When pump controller is abnormal and


PC prolix switch is ON
a. When load on main pump is light
If there is a failure in the pump controller,
turn emergency pump drive switch ON to
switch to the resistor side. In this case, the
power source is taken directly from the
battery. But if the current is used as it is, it
is too large, so use the resistor to control
the current flowing to PC-EPC valve solenoid (1).
When this is done, the current becomes
constant, so the force pushing piston (2)
is also constant.
If the main pump pressure PP1 and PP2
are low, the combined force of the pump
pressure and the force of PC-EPC valve
solenoid (1) is weaker than the spring set
force, so spool (3) is balanced at a position to the left.

10-44

At this point, port C is connected to the


drain pressure of port D, and the large
diameter end of the piston of servo piston
(9) also becomes the drain pressure PT
through the LS valve. When this happens,
the pressure at the small diameter end of
the piston is large, so servo piston (9)
moves in the direction to make the discharge amount larger.

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

HYDRAULIC PUMP

12

b. When main pump load is heavy


In the same way as in the previous item,
when the emergency pump drive switch
is ON, the command current sent to PCEPC valve solenoid (1) becomes constant.
For this reason, the force of piston (2)
pushing spool (3) is constant.
If main pump pressures PP1 and PP2
increase, spool (3) moves further to the
left than when the main pump load is
light, and is balanced at the position in
the diagram above.
In this case, the pressure from port A
flows to port C, so servo piston (9) moves
to the left (to make the discharge amount
smaller) by the same mechanism as
explained in item 2)-b, and stops at a
position to the left of the position when
the load on the pump is light. In other
words, even when the emergency pump
drive switch is ON, the curve for the
pump pressure PP

PC200-7

and discharge amount Q is determined as


shown in the diagram for the valve of the
current sent to the PC-EPC valve solenoid
through the resistor.
The curve when the PC prolix switch is
ON is curve , which is to the left of curve
for when the pump controller is normal.

10-45

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

HYDRAULIC PUMP

12

LS(PC)-EPC VALVE

1.
2.
3.
4.

Body
Spool
Spring
Rod

10-46

5. Coil
6. Plunger
7. Connector

PSIG(PM) : To LS(PC) valve


PT
: To tank
PEPC
: From self-reducing pressure valve

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

HYDRAULIC PUMP

12O
FUNCTION

The EPC valve consists of the proportional


solenoid portion and the hydraulic valve
portion.
When it receives signal current i from the
pump controller, it generates the EPC output pressure in proportion to the size of the
signal, and outputs it to the LS valve.

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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD


2. When signal current is very small (coil
energized)
When a very small signal current flows to
coil (5), coil (5) is energized, and a propulsion force is generated which pushes
plunger (6) to the left.
Push pin (4) pushes spool (2) to the left,
and pressurized oil flows from port PEPC
to port PSIG(PM).
When the pressure at port PSIG(PM) rises
and the load of spring (3) + the force acting
on surface a of spool (2) becomes greater
than the propulsion force of plunger (6),
spool (2) is pushed to the right. The circuit
between port PEPC and port PSIG(PM) is
shut off, and at the same time, port
PSIG(PM) and port PT are connected.
As a result, spool (2) is moved up or down
until the propulsion force of plunger (6) is
balanced with the load of spring (3) + pressure of port PSIG(PM).
Therefore, the circuit pressure between the
EPC valve and the LS valve is controlled in
proportion to the size of the signal current.
3. When signal current is maximum (coil
energized)
When the signal current flows to coil (5),
coil (5) is energized.
When this happens, the signal current is at
its maximum, so the propulsion force of
plunger (6) is also at its maximum.
For this reason, spool (2) is pushed fully to
the left by push pin (4).
As a result, the maximum flow of pressurized oil from port PEPC flows to port
PSIG(PM), and the circuit pressure
between the EPC valve and LS valve
becomes the maximum.
At the same time, port PT closes and stops
the oil from flowing to the tank.

10-48

HYDRAULIC PUMP

08891

08892

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

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

:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:

To bucket cylinder head


To left travel motor
To boom cylinder bottom
To swing motor
To right travel motor
To arm cylinder head
To attachment
To bucket cylinder bottom
To left travel motor
To bottom cylinder head
To swing motor
To right travel motor
To arm cylinder bottom
To attachment
From bucket PPC valve
From bucket PPC valve
From left travel PPC valve
From left travel PPC valve
From boom PPC valve
From boom PPC valve
From swing PPC valve
From swing PPC valve

10-50

P9
P10
P11
P12
P-1
P-2
BP1
BP5

This control valve consists of a 6-spool


valve (unit type), 1 service valves, a pump
merge-divider valve, a back pressure valve,
and a boom hydraulic drift prevention
valve.
Since all the valves are assembled together
with connecting bolts and their passes are
connected to each other inside the assembly, the assembly is small in size and easy
to maintain.
Since one spool of this control valve is
used for one work equipment unit, its structure is simple.
:
:
:
:
:
:
:
:

PLS1 :
PLS2 :
PP1 :
PP2 :
PR :
PS :
PST :
PX1 :
PX2 :
SA :
SB :
T
:
TS :
TSW :

From right travel PPC valve


From right travel PPC valve
From arm PPC valve
From arm PPC valve
From service PPC valve
From service PPC valve
Boom RAISE PPC output pressure
From attachment circuit selector solenoid
valve
To rear pump control
To front pump control
From rear main pump
From front main pump
To solenoid valve, PPC valve, EPC valve
From pump merge-divider solenoid valve
From travel junction valve
From 2-stage solenoid valve
From 2-stage solenoid valve
Pressure sensor fitting port
Pressure sensor fitting port
To tank
To tank
To swing motor

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

CONTROL VALVE

12
7-spool valve
(6-spool valve + 1 service valves)
(1/9)

PC200-7

10-51

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

CONTROL VALVE

12
(2/9)

S*P09099

10-52

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

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

9. Pressure compensation valve (Service)


10. Pressure compensation valve (Bucket CURL)
11. Pressure compensation valve (Left travel forward)
12. Pressure compensation valve (Boom LOWER)
13. Pressure compensation valve (Right swing)
14. Pressure compensation valve (Right travel
forward)
15. Pressure compensation valve (Arm IN)
16. Main relief valve

10-53

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

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

Spool return spring

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

Spool return spring

54.6 x 34.8

51.2

429.9 N
{43.9 kg}

336.1 N
{34.3 kg}

13

Spool return spring

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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

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.

Safety-suction valve (Arm OUT)


Suction valve (Right travel reverse)
Suction valve (Boom RAISE)
Suction valve (Left travel reverse)
Safety-suction valve (Bucket DUMP)
Safety-suction valve (Service)
Safety-suction valve (2-stage) (Service)
Safety-suction valve (Bucket CURL)
Suction valve (Left travel forward)
Safety-suction valve (Boom LOWER)
Suction valve (Right travel forward)

Safety-suction valve (Arm IN)


LS shuttle valve (Arm)
LS shuttle valve (Right travel)
LS select valve
LS shuttle valve (Boom)
LS shuttle valve (Left travel)
LS shuttle valve (Bucket)
LS shuttle valve (Service)
LS check valve
Pressure relief plug

Unit: mm
No.

Check item

Criteria
Standard size

22

Check valve spring

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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

CONTROL VALVE

12
(6/9)

ARM CONTROL VALVE


1. Unload valve
2. Main relief valve
3. Safety valve (Boom
RAISE)
4. Lift check valve

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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

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

Piston return spring

48.1 x 10.8

28

17.5 N
{1.8 kg}

14.0 N
{1.4 kg}

23

Piston return spring

56.4 x 11.9

45

79.4 N
{8.1 kg}

63.5 N
{6.5 kg}

24

Piston return spring

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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

CONTROL VALVE

(7/9)

BUCKET CONTROL VALVE

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

Piston return spring

Piston return spring

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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

CONTROL VALVE

12

(8/9)

SWING CONTROL VALVE

BOOM CONTROL VALVE

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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

CONTROL VALVE

Unit: mm
No.

Check item

Criteria
Standard size

21

Regeneration valve spring

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

Piston return spring

48.1 x 10.8

28

17.5 N
{1.8 kg}

14.0 N
{1.4 kg}

23

Piston return spring

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

Check valve spring

13.6 x 5.5

10

3.0 N
{0.3 kg}

2.4 N
{0.25 kg}

26

Check valve spring

33.0 x 12.0

26

35.3 N
{3.6 kg}

28.2 N
{2.9 kg}

27

Check valve spring

16.4 x 8.9

11.5

13.7 N
{1.4 kg}

11.0 N
{1.1 kg}

28

Spool return spring

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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

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

Check valve spring

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

Spool return spring

46.6 x 21.8

3.3

156.8 N
{16.0 kg}

21

Spool return spring

64.5 x 32.3

63

177.5 N
{18.1 kg}

142.0 N
{14.5 kg}

22

Sequence valve spring

70.9 x 18.0

59

199.8 N
{20.4 kg}

160.0 N
{16.3 kg}

23

Spool return spring

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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

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

:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:

To bucket cylinder head


To left travel motor
To boom cylinder bottom
To swing motor
To right travel motor
To arm cylinder head
To attachment
To bucket cylinder bottom
To left travel motor
To bottom cylinder head
To swing motor
To right travel motor
To arm cylinder bottom
To attachment
From bucket PPC valve
From bucket PPC valve
From left travel PPC valve
From left travel PPC valve
From boom PPC valve
From boom PPC valve
From swing PPC valve
From swing PPC valve

10-64

P9
P10
P11
P12
P-1
P-2
BP1
BP5

This control valve consists of a 6-spool


valve (unit type), 1 service valves, a pump
merge-divider valve, a back pressure valve,
and a boom hydraulic drift prevention
valve.
Since all the valves are assembled together
with connecting bolts and their passes are
connected to each other inside the assembly, the assembly is small in size and easy
to maintain.
Since one spool of this control valve is
used for one work equipment unit, its structure is simple.
:
:
:
:
:
:
:
:

PLS1 :
PLS2 :
PP1 :
PP2 :
PR :
PS :
PST :
PX1 :
PX2 :
SA :
SB :
T
:
TS :
TSW :

From right travel PPC valve


From right travel PPC valve
From arm PPC valve
From arm PPC valve
From service PPC valve
From service PPC valve
Boom RAISE PPC output pressure
From attachment circuit selector solenoid
valve
To rear pump control
To front pump control
From rear main pump
From front main pump
To solenoid valve, PPC valve, EPC valve
From pump merge-divider solenoid valve
From travel junction valve
From 2-stage solenoid valve
From 2-stage solenoid valve
Pressure sensor fitting port
Pressure sensor fitting port
To tank
To tank
To swing motor

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

CONTROL VALVE

12
7-spool valve
(6-spool valve + 1 service valves)

(1/9)

PC200-7

10-65

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

CONTROL VALVE

12
(2/9)

S*P09102

10-66

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

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

9. Pressure compensation valve (Service)


10. Pressure compensation valve (Bucket CURL)
11. Pressure compensation valve (Left travel forward)
12. Pressure compensation valve (Boom LOWER)
13. Pressure compensation valve (Right swing)
14. Pressure compensation valve (Right travel
forward)
15. Pressure compensation valve (Arm IN)
16. Main relief valve

10-67

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

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

Spool return spring

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

Spool return spring

54.6 x 34.8

51.2

429.9 N
{43.9 kg}

336.1 N
{34.3 kg}

13

Spool return spring

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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

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.

Safety-suction valve (Arm OUT)


Suction valve (Right travel reverse)
Suction valve (Boom RAISE)
Suction valve (Left travel reverse)
Safety-suction valve (Bucket DUMP)
Safety-suction valve (Service)
Safety-suction valve (2-stage) (Service)
Safety-suction valve (Bucket CURL)
Suction valve (Left travel forward)
Safety-suction valve (Boom LOWER)
Suction valve (Right travel forward)

Safety-suction valve (Arm IN)


LS shuttle valve (Arm)
LS shuttle valve (Right travel)
LS select valve
LS shuttle valve (Boom)
LS shuttle valve (Left travel)
LS shuttle valve (Bucket)
LS shuttle valve (Service)
LS check valve
Pressure relief plug

Unit: mm
No.

Check item

Criteria
Standard size

22

Check valve spring

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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

CONTROL VALVE

12
(6/9)

S*P09105

ARM CONTROL VALVE


1. Unload valve
2. Main relief valve
3. Safety valve (Boom
RAISE)
4. Lift check valve

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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

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

Piston return spring

48.1 x 10.8

28

17.5 N
{1.8 kg}

14.0 N
{1.4 kg}

23

Piston return spring

56.4 x 11.9

45

79.4 N
{8.1 kg}

63.5 N
{6.5 kg}

24

Piston return spring

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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

CONTROL VALVE

(7/9)

BUCKET CONTROL VALVE

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

Piston return spring

Piston return spring

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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

CONTROL VALVE

12

(8/9)

SWING CONTROL VALVE

BOOM CONTROL VALVE

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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

CONTROL VALVE

Unit: mm
No.

Check item

Criteria
Standard size

21

Regeneration valve spring

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

Piston return spring

48.1 x 10.8

28

17.5 N
{1.8 kg}

14.0 N
{1.4 kg}

23

Piston return spring

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

Check valve spring

13.6 x 5.5

10

3.0 N
{0.3 kg}

2.4 N
{0.25 kg}

26

Check valve spring

33.0 x 12.0

26

35.3 N
{3.6 kg}

28.2 N
{2.9 kg}

27

Check valve spring

16.4 x 8.9

11.5

13.7 N
{1.4 kg}

11.0 N
{1.1 kg}

28

Spool return spring

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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

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

Check valve spring

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

Spool return spring

46.6 x 21.8

3.3

156.8 N
{16.0 kg}

21

Spool return spring

64.5 x 32.3

63

177.5 N
{18.1 kg}

142.0 N
{14.5 kg}

22

Sequence valve spring

70.9 x 18.0

59

199.8 N
{20.4 kg}

160.0 N
{16.3 kg}

23

Spool return spring

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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

CONTROL VALVE

MAIN RELIEF VALVE

1. Spring
2. Poppet

FUNCTION

The relief valve set pressure is set to 2 stages.


When power is needed, pilot pressure P is turned ON and the pressure is set to high pressure.

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.

When pilot pressure P is OFF: Low-pressure setting


The set pressure is determined by the installed load of spring (1).

2. When pilot pressure P is ON: High-pressure setting


In addition to the installed load of spring (1), pilot pressure P is applied to poppet diameter d1, so the
set pressure becomes higher.

10-78

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

CONTROL VALVE

12

VARIABLE PRESSURE COMPENSATION VALVE

PC200-7

10-79

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

CLSS

12

CLSS
OUTLINE OF CLSS

FEATURES

STRUCTURE

CLSS stands for Closed center Load Sensing


System, and has the following features.

1) Fine control not influenced by load


2) Control enabling digging even with fine control
3) Ease of compound operation ensured by flow
divider function using area of opening of
spool during compound operations
4) Energy saving using variable pump control

10-80

The CLSS consists of a main pump (2


pumps), control valve, and actuators for the
work equipment.
The main pump body consists of the pump
itself, the PC valve and LS valve.

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

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)

If LS differential pressure PLS becomes


lower than the set pressure of the LS valve
(when the actuator load pressure is high),
the pump swash plate moves towards the
maximum position; if it becomes higher
than the set pressure of the LS valve (when
the actuator load pressure is low), the
pump swash plate moves towards the minimum position.

PC200-7

10-81

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

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

In this way, the flow of oil from the pump is


divided (compensated) in proportion to the
area of opening S1 and S2 of each valve.

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

SELF PRESSURE REDUCING VALVE

SELF PRESSURE REDUCING VALVE


FUNCTION

This value reduces the discharge pressure


of the main pump and supplies it as control
pressure for the solenoid valves, PPC
valves, etc..

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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

SELF PRESSURE REDUCING VALVE

2. When in neutral or load pressure P2 is


low (When boom is lowered and arm is in IN
position and they are moving down under
own weight)
Note: When load pressure A2 is lower than self-pressure reducing valve output pressure PR.

Valve (7) receives the force of spring (8) and


PR pressure (which is 0 MPa {0 kg/cm} when
the engine is stopped) in the direction to close
the circuit between ports P2 and A2. If the
hydraulic oil flows in port P2, the dx P2 pressure becomes equal to the total of the force of
spring (8) and the value of area of d x PR
pressure, then the area of the pass between
ports P2 and A2 is so adjusted that the P2
pressure will be kept constant above the PR
pressure.
If the PR pressure rises above the set level,
puppet (11) opens and the hydraulic oil flows
from the PR port through orifice "a" in spool
(14) and open part of puppet (11) to seal drain
port TS.
Accordingly, differential pressure is generated
between before and after orifice "a" in spool
(14) and then spool (14) moves to close the
pass between port P2 and PR. The P2 pressure is controlled constant (at the set pressure) by the area of the oil pass at this time
and supplied as the PR pressure. (See Fig. 2.)

3. When load pressure P2 is high


If load pressure A2 rises and the pump discharge increases because of operation of the
work equipment, the dx P2 pressure rises
higher than the total of the force of spring (8)
and the value of d x PR pressure, and then
valve (7) moves to the right stroke end.
As a result, the area of the pass between ports
P2 and A2 increases and the pass resistance
lowers and the loss of the engine power is
reduced.
If the PR pressure rises above the set pressure, puppet (11) opens and the hydraulic oil
flows from the PR port through orifice "a" in
spool (14) and open part of puppet (11) to seal
drain port TS.
Accordingly, differential pressure is generated
between before and after orifice "a" in spool
(14) and then spool (14) moves to close the
pass between port P2 and PR. The P2 pressure is controlled constant (at the set pressure) by the area of the oil pass at this time
and supplied as the PR pressure. (See Fig. 3.)

10-84

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

SELF PRESSURE REDUCING VALVE

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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

SWING MOTOR

12

SWING MOTOR
KMF125ABE-5

B :
S :
T :
MA :
MB :

From swing lock solenoid valve


From control valve
To tank
From control valve
From control valve

SPECIFICATIONS

PC200-7
Model

KMF125ABE-5

Theoretical displacement

125.0 cm/rev

Safety valve set pressure

28.4 MPa {290 kg/cm}

Rated revolving speed


Brake release pressure

10-86

PC220-7

1,694 rpm

1,879 rpm

1.9 MPa {19 kg/cm}

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

SWING MOTOR

12

Unit: mm
No.

Check item

Criteria
Standard size

Check valve spring

Shuttle valve spring

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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

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.

2. When swing lock solenoid valve is excited


When the swing lock solenoid valve is excited,
the valve is switched and the pressure oil from
the main pump enters port B and flows to brake
chamber a.
The pressure oil entering chamber a overcomes
brake spring (1) and pushes brake piston (7) up.
As a result, discs (5) and plates (6) are separated
and the brake is released.

PC200-7

10-89

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

SWING MOTOR

12

RELIEF VALVE PORTION


1) Outline
The relief portion consists of check valves
(2) and (3), shuttle valves (4) and (5), and
relief valve (1).
2. Function
When the swing is stopped, the outlet port
circuit of the motor from the control valve
is closed, but the motor continues to rotate
under inertia, so the pressure at the output
side of the motor becomes abnormally
high, and this may damage the motor.
To prevent this, the abnormally high pressure oil is relieved to port S from the outlet
port of the motor (high-pressure side) to
prevent any damage.
3. Operation
1) When starting swing
When the swing control lever is operated
to swing right, the pressure oil from the
pump passes through the control valve and
is supplied to port MA. As a result, the
pressure at port MA rises, the starting
torque is generated in the motor, and the
motor starts to rotate. The oil from the outlet port of the motor passes from port MA
through the control valve and returns to
the tank. (Fig. 1)
2) When stopping swing
When the swing control lever is returned to
neutral, the supply of pressure oil from the
pump to port MA is stopped. With the oil
from the outlet port of the motor, the return
circuit to the tank is closed by the control
valve , so the pressure at port MB rises. As
a result, rotation resistance is generated in
the motor, so the braking effect starts.
If the pressure at port MB becomes higher
than the pressure at port MA, it pushes
shuttle valve A (4) and chamber C
becomes the same pressure as port MB.
The oil pressure rises further until it
reaches the set pressure of relief valve (1).
As a result, a high braking torque acts on
the motor and stops the motor. (Fig.2)
When relief valve (1) is being actuated, the
relief oil and oil from port S passes
through check valve B (3) and is supplied to
port MA. This prevents cavitation at port
MA.

10-90

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

REVERSE PREVENTION VALVE

12

REVERSE PREVENTION VALVE


Operation diagram

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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

REVERSE PREVENTION VALVE

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.

2) After motor stops


The motor is reversed by the closing pressure generated at port MB. (1st reversal)
When this happens, reversal pressure is
generated at port MA. Pressure MA goes
to chamber a, so spool (2) pushes spring (3)
and moves to the right, and MA is connected to B. At the same time, b is connected to f through the drill hole in spool
(5), so the reversal pressure at port MA is
bypassed to port T to prevent the 2nd
reversal.

10-92

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

CENTER SWIVEL JOINT

12

CENTER SWIVEL JOINT

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

A1. To L.H. travel motor port PB


A2. From control valve port A5
C1. To R.H. travel motor port PA
B2. From control valve port B5
D1. To R.H. travel motor port PB
E. To L.H. and R.H. travel motors port P

Unit: mm
No.

Check Item

Clearance between rotor


and shaft

PC200-7

Criteria

Remedy

Standard Size

Standard clearance

Repair limit

80

Replace

10-93

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

TRAVEL MOTOR

TRAVEL MOTOR
HMV110-2

P :
T :
PA :
PB :
MA:
MB:

From travel speed solenoid valve


To tank
From control valve
From control valve
MA pressure pickup port
MB pressure pickup port

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

37.3 MPa {380 kg/cm}


Min.
Capacity

2,805 rpm

3,046 rpm

Max.
capacity

1,842 rpm

1,588 rpm

Rated speed

10-94

Brake releasing pressure

1.2 MPa {12 kg/cm}

Travel speed
switching
pressure

0.8 MPa {8 kg/cm}

Differential
pressure

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

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

9. Check valve spring


10. Output shaft
11. Rocker cam
12. Retainer guide
13. Pin
14. Piston
15. Retainer
16. Cylinder

17. Valve plate


18. Counterbalance valve
19. Ring
20. Spool return spring
21. Brake piston
22. Plate
23. Disc
24. Ball

10-95

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

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}

Check valve spring

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}

Regulator valve spring

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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

TRAVEL MOTOR

OPERATION OF MOTOR
1) Motor swash plate angle at maximum

SJP08742
OR
08893

The solenoid valve is deactivated, so the pilot


pressure oil from the main pump does not
flow to port P.
For this reason, regulator valve (9) is pushed
to the right in the direction of the arrow by
spring (10).
Because of this, it pushes check valve (22),
and the main pressure oil from the control
valve going to end cover (8) is shut off by regulator valve (9).
Fulcrum a of rocker cam (4) is eccentric to
point of force b of the combined force of the
propulsion force of cylinder (6), so the combined force of the piston propulsion force acts
as a moment to angle rocker cam (4) in the
direction of the maximum swash plate angle.

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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

TRAVEL MOTOR

12

2) Motor swash plate angle at minimum

SJP08743
OR
08894

When the solenoid valve is excited, the pilot


pressure oil from the main pump flows to
port P, and pushes regulator valve (9) to the
left direction of the arrow.
Because of this, the main pressure oil from
the control valve passes through passage d in
regulator valve (9), enters regulator piston
(15) at the bottom, and pushes regulator piston (15) to the right in the direction of the
arrow.
As a result, rocker cam (4) moves in the minimum swash plate angle direction, the motor
capacity becomes minimum.

10-98

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

TRAVEL MOTOR

12

OPERATION OF PARKING BRAKE


1) When starting to travel
When the travel lever is operated, the pressurized oil from the pump actuates counterbalance valve spool (19), opens the
circuit to the parking brake, and flows into
chamber A of the brake piston (12).
It overcomes the force of spring (11), and
pushes piston (12) to the left in the direction of the arrow.
When this happens, the force pushing plate
(13) and disc (14) together is lost, so plate
(13) and disc (14) separate and the brake is
released.

1. When stopping travel


When the travel lever is placed in neutral,
counterbalance valve spool (19) returns to
the neutral position and the circuit to the
parking brake is closed.
The pressurized oil in chamber A of brake
piston (12) is drained to the case from the
orifice in the brake piston, and brake piston
(12) is pushed to the right in the direction
of the arrow by spring (11).
As a result, plate (13) and disc (14) are
pushed together, and the brake is applied.
A time delay is provided by having the
pressurized oil pass through a throttle in
slow return valve (22) when the brake piston returns, and this ensures that the brake
is still effective after the machine stops.

PC200-7

SJP08744
OR
08895

SJP08745
OR
08896

10-99

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

TRAVEL MOTOR

OPERATION OF BRAKE VALVE


The brake valve consists of a suction safety
valve (18A), counterbalance valve (18) in a
circuit as shown in the diagram on the
right. (Fig. 1)
The function and operation of each component is as given below.
1) Counterbalance valve, check valve
Function
When traveling downhill, the weight of the
machine makes it try to travel faster than
the speed of the motor.
As a result, if the machine travels with the
engine at low speed, the motor will rotate
without load and the machine will run
away, which is extremely dangerous.
To prevent this these valves act to make the
machine travel according to the engine
speed (pump discharge amount).

SAP03482
OR
08897

Operation when pressure oil is supplied


When the travel lever is operated, the pressurized oil from the control valve is supplied to port PA. It pushes open suction
safety valve (18A) and flows from motor
inlet port MA to motor outlet port MB.
However, the motor outlet port is closed by
suction safety valve (18B) and spool (19),
so the pressure at the supply side rises.
(Fig. 2)

The pressurized oil at the supply side flows


from orifice E1 and E2 in spool (19) to
chamber S1. When the pressure in chamber S1 goes above the spool switching
pressure, spool (19) is pushed to the right
in the direction of the arrow.
As a result, port MB and port PB are connected, the outlet port side of the motor is
opened, and the motor starts to rotate. (Fig.
3)

10-100

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

TRAVEL MOTOR

Operation of brake when traveling downhill


If the machine tries to run away when traveling downhill, the motor will turn under no
load, so the pressure at the motor inlet port
will drop, and the pressure in chamber S1
through orifices E1 and E2 will also drop.
When the pressure in chamber S1 drops
below the spool switching pressure, spool
(19) is returned to the left, in the direction of
the arrow by spring (20), and outlet port MB
is throttled.
As a result, the pressure at the outlet port
side rises, resistance is generated to the rotation of the motor, and this prevents the
machine from running away.
In other words, the spool moves to a position
where the pressure at the outlet port MB balances the pressure at the inlet port and the
force generated by the weight of the
machine. It throttles the outlet port circuit
and controls the travel speed according to
the amount of oil discharged from the pump.
(Fig. 4)
2) Safety valve
Function
When travel is stopped (or when traveling
downhill), the circuits at the inlet and outlet
ports of the motor are closed by the counterbalance valve, but the motor is rotated by
inertia, so the pressure at the outlet port of
the motor will become abnormally high and
damage the motor or piping. The safety
valve acts to release this abnormal pressure
and send it to the inlet port side of the motor
to prevent damage to the equipment.
Operation
1. When travel is stopped (or when traveling downhill, rotating to right)
When the motor inlet port pressure (pressure
PA) goes down, the pressure in chamber S1
also goes down. When it goes below the
switching pressure of the spool, spool is
returned to the left by spring (20), and outlet
port passage B1 is throttled. When this happens, the motor continues to rotate under
inertia, so the outlet pressure (pressure MB)
rises. (Fig. 5)
If the pressure goes above the set pressure
of suction-safety valve (18A), the poppet
opens. The oil then passes through large
notch A1 in counterbalance valve spool (19)
and flows to chamber MA in the circuit on
the opposite side. (Fig. 6)
2. When rotating to left
The operation is the reverse of when rotating
to the right.
PC200-7

10-101

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

TRAVEL MOTOR

2) When starting travel (or during normal


travel)
When the travel lever is operated, the pressure oil from the pump moves counterbalance valve spool (19) to the right. When
this happens, the passage to the suctionsafety valve becomes the circuit flowing
through the small notch B2 in the counterbalance valve spool. As a result, a big difference in pressure is created, and the
pump pressure rises to provide a powerful
drawbar pull. (Fig. 7)

10-102

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

TRAVEL JUNCTION VALVE

TRAVEL JUNCTION VALVE


Function
This valve connects both travel circuits to each
other so that the hydraulic oil will be supplied
evenly to both travel motors and the machine will
travel straight.
When the machine is steered, outside pilot pressure PST closes the travel junction valve to secure
high steering performance.

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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

When pilot pressure is turned OFF


If pilot pressure PST from the solenoid valve is 0, travel junction spool
(13) is pressed by the force of spring
(14) against the right side and the
pass between ports PTL and PTR is
open.

TRAVEL JUNCTION VALVE

If the oil flow rates in both travel motors


become different from each other, the oil
flows through the route between port PTL,
travel junction spool (13), and port PTR so
that the oil flow rates will be equalized again.

SU(V)P08731
OR
08899

10-104

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

TRAVEL PPC SHUTTLE VALVE

TRAVEL PPC SHUTTLE VALVE


Function
If the boom lever is set to the "RAISE" position or the arm lever is set in the "IN" or
"OUT" position or the bucket lever is set in the
"CURL" or "DUMP" position while the
machine is travelling up a sharp slope, the
travel PPC shuttle valve regulates the spool
strokes of the boom, arm, and bucket control
valves with the travel PPC pressure to limit
the flow of the oil into the boom, arm, and
bucket cylinders.
When the strokes of the boom, arm, and
bucket are regulated, the travel PPC pressure

PC200-7

is applied through the circuit in the control


valve.
Operation
1 When travel lever is in neutral

The oil in stroke regulation signal chamber


"a" is drained through orifices (5) and (6) of
pistons (3) and (4) in the travel spring case
and the travel PPC valve.If the boom lever is
set to the "RAISE" position (or the arm lever is
set in the "IN" or "OUT" position or the bucket
lever is set in the "CURL" or "DUMP" position), spool (1) moves to the left until it
reaches the end of spring case (2) (st0).

10-105

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD


12
2. When travel lever is operated
If the right travel lever is set in the reverse (or
forward) direction, the right travel reverse (or
forward) PPC pressure pushes spool (7) to the
left (or right).
Spool (7) pushes piston (3) to close orifice (5)
and shut off stroke regulation signal chamber
"a" from the drain circuit of the travel PPC
valve.

10-106

TRAVEL PPC SHUTTLE VALVE

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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

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"

(9) Swing "RIGHT"


(10) Swing "LEFT"
(11) Neutral
(12) Travel "REVERSE"
(13) Travel "FORWARD"

10-107

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

WORK EQUIPMENT SWING PPC


VALVE

WORK EQUIPMENT SWING PPC VALVE

P: From main pump


T: To tank

10-108

P1:
P2:
P3:
P4:

Left: Arm OUT / Right: Boom LOWER


Left: Arm IN / Right: Boom RAISE
Left: Swing RIGHT / Right: Bucket CURL
Left: SwingLEFT / Right: Bucket DUMP

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

WORK EQUIPMENT SWING PPC


VALVE

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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

WORK EQUIPMENT SWING PPC


VALVE

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)

2) During fine control (neutral fine


control)
When piston (4) starts to be pushed by disc
(5), retainer (9) is pushed; spool (1) is also
pushed by metering spring (2), and moves
down.
When this happens, fine control hole f is
shut off from drain chamber D, and at
almost the same time, it is connected to
pump pressure chamber PP, so pilot pressure oil from the main pump passes
through fine control hole f and goes from
port P1 to port A.
When the pressure at port P1 becomes
higher, spool (1) is pushed back and fine
control hole f is shut off from pump pressure chamber PP. At almost the same time,
it is connected to drain chamber D to
release the pressure at port P1. When this
happens, spool (1) moves up or down so
that the force of metering spring (2) is balanced with the pressure at port P1. The
relationship in the position of spool (1) and
body (10) (fine control hole f is at a point
midway between drain hole D and pump
pressure chamber PP) does not change
until retainer (9) contacts spool (1).
Therefore, metering spring (2) is compressed proportionally to the amount of
movement of the control lever, so the pressure at port P1 also rises in proportion to
the travel of the control lever. In this way,
the control valve spool moves to a position
where the pressure in chamber A (the
same as the pressure at port P1) and the
force of the control valve spool return
spring are balanced. (Fig. 2)

10-110

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

WORK EQUIPMENT SWING PPC


VALVE

12

3) During fine control (when control


lever is returned)
When disc (5) starts to be returned, spool
(1) is pushed up by the force of centering
spring (3) and the pressure at port P1.
When this happens, fine control hole f is
connected to drain chamber D and the
pressure oil at port P1 is released.
If the pressure at port P1 drops too far,
spool (1) is pushed down by metering
spring (2), and fine control hole f is shut off
from drain chamber D. At almost the same
time, it is connected to pump pressure
chamber PP, and the pump pressure is supplied until the pressure at port P1 recovers
to a pressure that corresponds to the lever
position.
When the spool of the control valve
returns, oil in drain chamber D flows in
from fine control hole f in the valve on the
side that is not working. The oil passes
through port P2 and enters chamber B to
fill the chamber with oil. (Fig. 3)

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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

TRAVEL PPC VALVE

TRAVEL PPC VALVE

P : From main pump


T : To tank
P1 : Left reverse
P2 : Left forward

10-112

P3
P4
P5
P6

: Right reverse
: Right forward
: Travel signal
: Steering signal

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

TRAVEL PPC VALVE

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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

TRAVEL PPC VALVE

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}

Steering signal spring

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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

TRAVEL PPC VALVE

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)

2) Fine control (neutral fine control)


When piston (4) starts to be pushed by disc
(5), retainer (9) is pushed. Spool (1) is also
pushed by metering spring (2), and moves
down.
When this happens, fine control hole f is
shut off from drain chamber D. At almost
the same time, it is connected to pump
pressure chamber PP, and the pilot pressure of the main pump is sent from port A
through fine control hole f to port P1.
When the pressure at port P1 rises, spool
(1) is pushed back. Fine control hole f is
shut off from pump pressure chamber PP.
At almost the same time, it is connected to
drain chamber D, so the pressure at port
P1 escapes.
As a result, spool (1) moves up and down
until the force of metering spool (2) is balanced with the pressure at port P1.
The relationship of the position of spool (1)
and body (10) (fine control hole f is in the
middle between drain hole D and pump
pressure chamber PP) does not change
until retainer (9) contacts spool (1).
Therefore, metering spring (2) is compressed in proportion to the travel of the
control lever, so the pressure at port P1
also rises in proportion to the travel of the
control lever. In this way, the spool of the
control valve spool moves to a position
where the pressure of chamber A (same as
pressure at port P1) and the force of the
return spring of the control valve spool are
balanced. (Fig. 2)

PC200-7

10-115

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

TRAVEL PPC VALVE

12

3) Fine control (control lever returned)


When lever (5) starts to be returned, spool
(1) is pushed up by the force of centering
spring (3) and the pressure at port P1.
Because of this, fine control hole f is connected to drain chamber D, and the pressurized oil at port P1 is released.
If the pressure at port P1 drops too much,
spool (1) is pushed up by metering spring
(2), so fine control hole f is shut off from
drain chamber D. At almost the same time,
it is connected to pump pressure chamber
PP, so the pressure at port P1 supplies the
pump pressure until the pressure recovers
to a pressure equivalent to the position of
the lever.
When the control valve returns, oil in drain
chamber D flows in from fine control hole f
of the valve on the side that is not moving.
It passes through port P2 and goes to chamber B to charge the oil. (Fig. 3)

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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

TRAVEL PPC VALVE

2. Travel signal/Steering function


Travel signal
If either of the travel levers is operated, the maximum PPC output pressure on both sides is output as
the travel signal. Accordingly, if the machine is traveling is judged by the signal of port P5.
Steering signal
If the operation quantities of both levers are different from each other as in the steering operation, the
higher one of the PPC output pressures on both sides is output as the steering signal.
Any signal is not output from port P6 while the machine is travelling straight (forward or reverse) or in
neutral.
Accordingly, if the machine is being steered is judged by the signal of port P6.
Operation
1) While in NEUTRAL
The signals of the output ports (P1 - P4), travel signal (Port P5), and steering signal (Port P6) are not output.

PC200-7

10-117

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

TRAVEL PPC VALVE

2) While travelling straight


(The following drawing shows the circuit for traveling straight forward.)
While the left motor is operating for forward travel (the signal of port P2 is output) and the right motor
is also operating for forward travel (the signal of port P4 is output), the pressures in left spring chamber
(k) and right spring chamber (l) of steering signal valve (j) are set high. Accordingly, the steering signal
valve is kept in neutral and the steering signal (Port P6) is not output.

10-118

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

TRAVEL PPC VALVE

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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

TRAVEL PPC VALVE

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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

SERVICE PPC VALVE

SERVICE PPC VALVE

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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

SERVICE PPC VALVE

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

When lever (5) is moved, metering spring


(2) is pushed by piston (4) and retainer (7),
and spool (1) is pushed down by this.
As a result, fine control portion Y is connected with port a, and the pressurized oil
from port P flows from port a to port A of
the control valve.

10-122

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

SERVICE PPC VALVE

When the pressure at port a becomes


higher, spool (1) is pushed back by the
force acting on the end of the spool, and
fine control portion Y closes.
As a result, spool (1) moves up and down
to balance the force at port a and the force
at metering spring (2).
Therefore, metering spring (2) is compressed in proportion to the amount the
control lever is moved. The spring force
becomes larger, so the pressure at port a
also increases in proportion to the amount
the control lever is operated.
In this way, the control valve spool moves
to a position where the pressure of port A
(the same as the pressure at port a) is balanced with the force of the return spring of
the control valve spool.

PC200-7

10-123

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

SOLENOID VALVE

SOLENOID VALVE
PPC lock, 2-stage relief, travel speed, swing brake, merge-divider, travel junction solenoid valves

1. PPC lock solenoid valve


2. Travel junction solenoid
valve
3. Merge-divider solenoid valve
4. Travel speed solenoid valve
5. Swing brake solenoid valve
6. 2-stage relief solenoid valve

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

A6 : To main valve (2-stage relief


valve)
P1 : From main pump
ACC: To accumulator

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

SOLENOID VALVE

12
1.
2.
3.
4.
5.
6.

Connector
Moving core
Coil
Spool
Block
Spring

OPERATION

WHEN SOLENOID IS TURNED OFF

Since the signal current does not flow from


the controller, solenoid (3) is turned off.
Accordingly, spool (4) is pressed by spring
(6) against the left side.
By this operation, the pass from P to A is
closed and the hydraulic oil from the main
pump does not flow into the actuator.
At this time, the oil from the actuator is
drained through ports A and T into the
tank.

WHEN SOLENOID IS TURNED ON


The signal current flows from the controller
to solenoid (3), and the latter is turned on.
Accordingly, spool (4) is pressed against to
the right side.
By this operation, the hydraulic oil from the
main pump flows through port P and spool
(4) to port A, then flows into the actuator.
At this time, port T is closed and the oil
does not flow into the tank.

PC200-7

10-125

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

RETURN OIL FILTER

RETURN OIL FILTER


FOR BREAKER

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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

BOOM HYDRAULIC DRIFT


PREVENTION VALVE

BOOM HYDRAULIC DRIFT PREVENTION VALVE


When boom control valve is at RAISE

08900

When boom control valve is at NEUTRAL

10-128

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

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

BOOM HYDRAULIC DRIFT


PREVENTION VALVE

The main hydraulic oil is shut off from the


holding pressure on the boom cylinder bottom side.
At this time, the holding pressure on the
boom cylinder bottom side is applied toward
the right 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). The total of this pressure
and the force of spring (4) closes puppet (5) to
shut off the main hydraulic oil from the holding pressure on the boom cylinder bottom.
Accordingly, the boom is held.
3. When boom lever is in "LOWER" position
If the boom lever is set in the "LOWER" position, pilot spool (2) is pushed by the pilot
pressure from the PPC valve and the hydraulic oil in chamber "b" in the puppet is drained
through orifice "c".
The oil on the boom bottom side flows from
orifice "a" through chamber "b" and orifice "c"
to the drain hole, and the oil pressure in
chamber "b" lowers.
If the pressure in chamber "b" lowers below
the pressure at port B, puppet (4) opens and
the hydraulic oil from port B flows through
port A to the control valve.

10-129

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

4. When abnormally high pressure is generated


If abnormally high pressure is generated in
the boom cylinder bottom circuit, the hydraulic oil in port B pushes check valve (6) open,
then safety valve (3) operates.

10-130

BOOM HYDRAULIC DRIFT


PREVENTION VALVE

If the hydraulic drift prevention valve for the


arm cylinder head circuit is installed
(optional), the hydraulic oil in the boom cylinder bottom circuit or that in the arm cylinder
head circuit, having higher pressure, pushes
check valve (6 or 6A) open, then safety valve
(3) operates.

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

LIFT CHECK VALVE

LIFT CHECK VALVE


Function
This valve applies back pressure to the drain
circuit to prevent generation of negative pressure on the hydraulic devices for the work
equipment (motors, cylinders, etc.)
Operation
1. While engine is stopped
Any oil is not supplied from the pump to
the self-pressure reducing valve and valve
(1) is pressed by only the force of spring (2)
toward the right and drain circuit "a" of the
control valve is connected through orifice
"b" of valve (1) to port T.

2. While engine is running


Output pressure PR of the self-pressure
reducing valve is applied through the control valve to spring chamber "c" of the back
pressure valve.
Output pressure PR applied to spring
chamber "c" is applied to the left end of
valve (1) (area of d) to push valve (1) to
the right.
At this time, pressure PA of drain circuit "a"
of the control valve is applied to the right
end of valve (1) (area of d1) to push valve
(1) to the left.
Valve (1) is balanced so that the back pressure PA will be as follows.
PA = {(Area of d) x PR + Force of spring
(2)} / (Area of d1)

PC200-7

10-131

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

ATTACHMENT CIRCUIT SELECTOR


VALVE

ATTACHMENT CIRCUIT SELECTOR VALVE

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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

ATTACHMENT CIRCUIT SELECTOR


VALVE

When a breaker is installed, the return oil from


the breaker does not pass through the main
valve, but returns directly to the hydraulic tank.
When other attachments (crusher, etc.) are
installed, the attachment and the main valve are
interconnected.
Operation
1. When attachment other than breaker is
installed
Spool (1) is pushed fully to the left by the
force of spring (2), ATT port and port V are
interconnected, and ATT port and port T are
shut off, so the attachment and main valve are
interconnected.

2. When breaker is installed


When the pilot pressure from the attachment
circuit selector solenoid valve overcomes the
force of spring (2), the spool (1) moves fully to
the right. ATT port and port V are shut off and
ATT port and port T are interconnected, so the
oil returning from the breaker does not pass
through the main valve, but passes through
port T and returns directly to the hydraulic
tank.

PC200-7

08901

08902

10-133

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

HYDRAULIC CYLINDER

HYDRAULIC CYLINDER
PC200-7, PC200LC-7
BOOM CYLINDER

ARM CYLINDER

BUCKET CYLINDER

10-134

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

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

500 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

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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

HYDRAULIC CYLINDER

PC220-7, PC220LC-7
BOOM CYLINDER

ARM CYLINDER

BUCKET CYLINDER

10-136

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

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

500 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

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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

WORK EQUIPMENT

WORK EQUIPMENT

10-138

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

WORK EQUIPMENT

PC200-7, PC200LC-7
100 HOURS GREASING
Unit: mm
No.

Check item

Clearance between connecting


pin and bushing of revolving
frame and boom

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

Clearance between connecting


pin and bushing of boom and arm

90

-0.036
-0.071

+0.153
+0.097

0.133 ~ 0.224

1.0

Clearance between connecting


pin and bushing of arm and link

70

-0.030
-0.076

+0.335
+0.275

0.305 ~ 0.411

1.0

Clearance between connecting


pin and bushing of arm and
bucket

80

-0.030
-0.076

+0.337
+0.273

0.303 ~ 0.413

1.0

Clearance between connecting


pin and bushing of link and
bucket

80

-0.030
-0.076

+0.337
+0.273

0.303 ~ 0.413

1.0

Clearance between connecting


pin and bushing of link and link

70

-0.030
-0.076

+0.335
+0.275

0.303 ~ 0.411

1.0

Replace

500 HOURS GREASING


Unit: mm
No.

Check item

Clearance between connecting


pin and bushing of revolving
frame and boom

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

Clearance between connecting


pin and bushing of boom and arm

90

-0.036
-0.071

+0.166
+0.074

0.110 ~ 0.237

1.0

Clearance between connecting


pin and bushing of arm and link

70

-0.030
-0.076

+0.158
+0.078

0.108 ~ 0.234

1.0

Clearance between connecting


pin and bushing of arm and
bucket

80

-0.030
-0.076

+0.137
+0.074

0.104 ~ 0.213

1.0

Clearance between connecting


pin and bushing of link and
bucket

80

-0.030
-0.076

+0.166
+0.086

0.116 ~ 0.242

1.0

Clearance between connecting


pin and bushing of link and link

80

-0.030
-0.076

+0.154
+0.074

0.104 ~ 0.230

1.0

PC200-7

Replace

10-139

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

WORK EQUIPMENT

PC220-7, PC220LC-7
100 HOURS GREASING
Unit: mm
No.

Check item

Clearance between connecting


pin and bushing of revolving
frame and boom

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

Clearance between connecting


pin and bushing of boom and arm

90

-0.036
-0.071

+0.153
+0.097

0.133 ~ 0.224

1.0

Clearance between connecting


pin and bushing of arm and link

80

-0.030
-0.076

+0.335
+0.275

0.305 ~ 0.411

1.0

Clearance between connecting


pin and bushing of arm and
bucket

80

-0.030
-0.076

+0.337
+0.273

0.303 ~ 0.413

1.0

Clearance between connecting


pin and bushing of link and
bucket

80

-0.030
-0.076

+0.337
+0.273

0.303 ~ 0.413

1.0

Clearance between connecting


pin and bushing of link and link

80

-0.030
-0.076

+0.335
+0.275

0.303 ~ 0.411

1.0

Replace

500 HOURS GREASING


Unit: mm
No.

Check item

Clearance between connecting


pin and bushing of revolving
frame and boom

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

Clearance between connecting


pin and bushing of boom and arm

90

-0.036
-0.071

+0.166
+0.074

0.110 ~ 0.237

1.0

Clearance between connecting


pin and bushing of arm and link

80

-0.030
-0.076

+0.166
+0.084

0.116 ~ 0.242

1.0

Clearance between connecting


pin and bushing of arm and
bucket

80

-0.030
-0.076

+0.137
+0.074

0.104 ~ 0.213

1.0

Clearance between connecting


pin and bushing of link and
bucket

80

-0.030
-0.076

+0.166
+0.086

0.116 ~ 0.242

1.0

Clearance between connecting


pin and bushing of link and link

80

-0.030
-0.076

+0.166
+0.066

0.096 ~ 0.232

1.0

10-140

Replace

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

WORK EQUIPMENT

1. DIMENSION OF ARM

10-142

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

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

Arm as individual part


When pressfitting bushing

19

PC200-7

PC220-7, PC220LC-7

18

PC200-7, PC200LC-7

10-143

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

WORK EQUIPMENT

12

2.DIMENSION OF BUCKET

10-144

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

AIR CONDITIONER

AIR CONDITIONER
AIR CONDITIONER PIPING

1.
2.
3.
4.
5.
6.
7.
8.

Hot water pickup piping


Air conditioner compressor
Refrigerant piping
Condenser
Receiver tank
Hot water return piping
Air conditioner unit
Duct

10-146

A. Fresh air
B. Recirculated air
C. Hot air/cold air

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

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

The engine can be started and stopped with


only starting switch (3).
The engine throttle and pump controller(7)
reveives the signal of fuel control dial (4) and
transmits the drive signal to governor motor
(9) to control the governor lever angle of fuel
injection pump (8) and control the engine
speed.

10-147

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

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.

Engine speed control


The fuel control dial sends a signal to the
engine throttle and pump controller
according to the position of the dial. The
engine throttle and pump controller calculates the angle of the governor motor
according to this signal, and sends a signal
to drive the governor motor so that it is at
that angle.
When this happens, the operating angle of
the governor motor is detected by the
potentiometer, and feedback is sent to the
engine throttle and pump controller, so
that it can observe the operation of the
governor motor.

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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

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

A potentiometer for feedback is installed to


monitor the operation of the motor.
Revolution of the motor is transmitted
through the gear to the potentiometer.

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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

ENGINE CONTROL

Engine throttle and pump controller

10-152

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

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

R pump pressure sensor

Input

Swing emergency switch

Input

VIS (solenoid power)

Arm angle potentiometer

Input

NC

Input

SOL_COM (solenoid common gnd)

Input

Signal GND

Input

232C_RxD

Input

Battery relay drive

Output

Abnormality in auto-greasing controller

Input

Overload sensor (ON/OFF)

Input

Governor motor A phase (+)

Output

Overload alarm valid switch

Input

LS-EPC

Output

NC

Input

Model selection 4

Input

Travel junction SOL

Output

Overload sensor (analog)

Input

Attachment circuit selector signal

Output

NC

Output

F boom pressure sensor

Input

NC

Output

Bucket CURL pressure SW

Boom angle potentiometer

Input

10

NC

Input

10

Boom RAISE pressure SW

Input

10

Signla GND

Input

11

NC

Output

11

VB (controller power)

Input

11

Knob SW

Input

12

CAN shield

12

VIS (solenoid power)

Input

12

NC

Input

13

Model selection 5

Input

13

SOL_COM (solenoid common gnd)

13

Governor motor FB potentiometer

Input

14

232C_TxD

Output

14

KEY_SIG

14

Boom head pressure sensor

Input

15

NC

Input

15

Governor motor A phase (-)

Output

15

NC

Output

16

SENS_PWR

17

Key Switch (Terminal C)

Input

Input

Input

16

Travel steering signal pressure SW

Input

16

PC-EPC

Output

17

Model selection 3

Input

17

Pump merge/divider solenoid

Output

Input

18

Relay drive signal for arm crane

Output

18

Heater relay drive

Output

18

NC

Input

19

NC

Output

19

Bucket DUMP pressure switch

Input

19

Throttle potentiometer

Input

20

NC

Input

20

Boom LOWER pressure switch

Input

20

NC

Input

GND (controller GND)

GND (analog GND)

S_NET

21

21

Input/
output

22

VIS (solenoid PWR)

22

POT_PWR

SOL_COM (solenoid common gnd)

Key switch (terminal ACC)

CAN0_L

23

23

Input/
output

24

KEY_SIG

24

Arm crane relay actuation observaInput


tion

23

CAN1_L

Input/
output

25

Governor motor B phase (+)

26

Service flow adjustment EPC (1)

Output

24

Flash memory write permission signal

Input

27

Travel Hi/Lo selector solenoid

Output

28

2-stage relief solenoid

Output

25

NC

Input

29

Swing pressure switch

Input

26

NC

Input

30

Arm IN pressure switch

Input

27

Model selection 2

Input

31

GND (controller GND)

28

NC

Input

32

GND (controller GND)

29

GND (pulse GND)

33

GND (controller GND)

30

NC

34

NC

31

GND (S_NET GND)

Output
Input

21
22

32
33
34

PC200-7

Input

Input
Input
Output

35

Governor motor B phase (-)

Output

NC

Output

CAN0_H

Input/
output

36
37

Swing parking brake solenoid

Output

CAN1_H

Input/
output

38

NC

Output

39

Travel pressure switch

Input

40

Arm OUT pressure switch

Input

GND (232C GND)

35

Service valve pressure switch

Input

36

NC

Input

37

Model selection switch 1

Input

38

Swing lock switch

Input

39

GND (pulse GND)

40

Engine speed sensor

Input

10-153

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

ELECTRONIC CONTROL SYSTEM

ELECTRONIC CONTROL SYSTEM

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

Electronic control system


6
Swing control function
7
Travel control function
8
ATT flow control, circuit selector function (option)

Self-diagnosis function

For the self-diagnosis function, see "TROUBLE SHOOTING".

PC200-7

10-155

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

ELECTRONIC CONTROL SYSTEM

MACHINE CONTROL SYSTEM DIAGRAM

10-156

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

PC200-7

ELECTRONIC CONTROL SYSTEM

10-157

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

ELECTRONIC CONTROL SYSTEM

1. Engine and Pump control function

SJP08754
OR
08908

10-158

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

ELECTRONIC CONTROL SYSTEM

FUNCTION

The operator can set the work mode switch


on the monitor panel to mode A, E, or B (or
L) and select proper engine torque and
pump absorption torque according to the
type of work.
The engine throttle and pump controller
detects the speed of the engine governor
set with the fuel control dial and the actual
engine speed and controls them so that the
pump will absorb all the torque at each output point of the engine, according to the
pump absorption torque set in each mode.
: The L mode is on the multi-monitor specification machine only.

SJP08755
OR
08909

SJP08756
OR
08910

SJP08757
OR
08911

PC200-7

10-159

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

ELECTRONIC CONTROL SYSTEM

12

1) Control method in each mode


Mode A
Matching point in mode A: Rated speed
SJP08758

Model
Mode A

PC200-7, PC220-7
OR
106.6 kW/1,900 rpm {143 HP/1,900 rpm}
08912

If the pump load increases and the pressure


rises, the engine speed lowers.
At this time, the controller lowers the pump
discharge so that the engine speed will be
near the full output point. If the pressure lowers, the controller increases the pump discharge so that the engine speed will be near
the full output point.
By repeating these operations, the controller
constantly uses the engine near the full output point.

SJP08759
OR
08913

SJP08760
OR
08914

10-160

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

ELECTRONIC CONTROL SYSTEM

12

Mode E / Mode B / (Mode


Mode
Partial output point

L)

Digging

Breaker

Finishing

85%

75%

70%

SJP08761
OR
08915

Model

PC200-7, PC220-7

Mode E

123 HP / 1,750 RPM

Mode B

108 HP / 1,650 RPM

(Mode L)

99 HP / 1,800 RPM

At this time, the controller keeps the pump


absorption torque along the constant horsepower curve and lower the engine speed by
the composite control of the engine and
pump.
By this method, the engine is used in the low
fuel consumption area.
: The L mode is on the multi-monitor specification machine only.

SJP08762
OR
08916

SJP08763
OR
08917

PC200-7

10-161

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

ELECTRONIC CONTROL SYSTEM

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.

3) Function to control when emergency


pump drive switch is turned ON
Even if the controller or a sensor has a
trouble, the functions of the machine can
be secured with pump absorption torque
almost equivalent to mode E by turning on
emergency pump drive switch (10).
In this case, a constant current flows from
the battery to the EPC valve for PC and the
oil pressure is sensed by only the EPC
valve for PC.

10-162

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

ELECTRONIC CONTROL SYSTEM

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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

ELECTRONIC CONTROL SYSTEM

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

The average value of the front and rear


pressure sensors is above 27.9 MPa {285
kg/cm} and the one-touch power maximizing function is not turned on

The cut-off function does not work, however,


while the machine is travelling in mode A or the
arm crane operation width swing lock switch is
turned on.
1. 2-stage relief function
The relief pressure in the normal work is 34.8
MPa {355 kg/cm}. If the 2-stage relief function is turned on, however, the relief pressure
rises to about 37.2 MPa {380 kg/cm}.
By this operation, the hydraulic force is
increased further.
Operating condition for turning on 2-stage
relief function
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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

ELECTRONIC CONTROL SYSTEM

12

3. One-touch power maximizing function

SJP08766
OR
08923

FUNCTION

Power can be increased for a certain time by


operating the left knob switch.

PC200-7

10-165

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

ELECTRONIC CONTROL SYSTEM

12

1) One-touch power maximizing function


When the operator needs more digging force
to dig up a large rock, etc., if the left knob
switch is pressed, the hydraulic force is
increased about 7% to increase the digging
force.
If the left knob switch is turned on in working
mode "A" or "E", each function is set automatically as shown below.

Software cut-off function


Working
mode
A, E

10-166

Engine/Pump
control

2-stage relief function

Operation time

Matching at rated
output point

34.8 MPa {355 kg/cm}

37.2 MPa {380 kg/cm}

Automatically
Cancel
reset at 8.5 sec

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

ELECTRONIC CONTROL SYSTEM

12

4. Auto-deceleration function

SJP08767
OR
08924

FUNCTION

If the all control levers are set in NEUTRAL


while waiting for a dump truck or work, the
engine speed is lowered to the medium level
automatically to reduce the fuel consumption
and noise.
If any lever is operated, the engine speed
rises to the set level instantly.

PC200-7

10-167

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

ELECTRONIC CONTROL SYSTEM

12

OPERATION
WHEN CONTROL LEVERS ARE SET IN NEUTRAL

If all the control levers are set in NEUTRAL


while the engine speed is above the decelerator operation level (about 1,400 rpm), the
engine speed lowers instantly to the first
deceleration level about 100 rpm lower than
the set speed.
If 4 more seconds pass, the engine speed
lowers to the second deceleration level
(about 1,400 rpm) and keeps at that level until
any lever is operated again.

WHEN ANY CONTROL LEVER IS OPERATED

If any control lever is operated while the


engine speed is kept at the second deceleration level, the engine speed rises instantly to
the level set with the fuel control dial.

10-168

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

ELECTRONIC CONTROL SYSTEM

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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

ELECTRONIC CONTROL SYSTEM

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

Water temperature: Below 30C.


Engine speed: Max. 1,200 rpm

Engine speed: Max. 1,200 rpm

Resetting condition (Any one)

Reset

Water temperature: Above 30C


Auto
Auto-warm-up operation time: Min. 10 minutes
Manual

Fuel control dial: Kept at 70% of full level for 3 sec.


or longer

2) Overheat prevention function


If the engine cooling water temperature rises
too high during work, the pump load and
engine speed are reduced to prevent overheating.

Operating condition

Water temperature:
Above 105C

Operating condition
Water temperature:
Above 102C

Operating condition
Water temperature:
Above 100C

10-170

This function is turned on when the water


temperature rises above 95C.

Operation/Remedy

Resetting condition

Work mode: Any mode


Engine speed: Low idle
Monitor alarm lamp: Lights up
Alarm buzzer: Sounds

Water temperature: Below 105C


Fuel control dial: Return to low idle
position once.
Under above condition, controller
is set to condition before operation
of function. (Manual reset)

Operation/Remedy

Resetting condition

Work mode: Mode A, E, OR B


Engine speed: Keep as is.
Monitor alarm lamp: Lights up.
Lower pump discharge.

Water temperature: Below 102C


Under above condition, controller
is set to condition before operation
of function. (Automatic reset)

Operation/Remedy

Operating condition
Water temperature:
Above 95C

Work mode: Mode A


Engine speed: Keep as is.
Lower pump discharge.

Resetting condition

Operation/Remedy

Engine speed: Any level

Work mode: Travel


Engine speed: Keep as is.
Lower travel speed.

Water temperature: Below 100C


Under above condition, controller
is set to condition before operation
of function. (Automatic reset)

Resetting condition

Water temperature: Below 95C


Under above condition, controller
is set to condition before operation
of function. (Automatic reset)

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

ELECTRONIC CONTROL SYSTEM

12

6. Swing control function

SJP08769
OR
08926

FUNCTION
The swing lock and swing holding brake functions are installed.

PC200-7

10-171

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

ELECTRONIC CONTROL SYSTEM

12

1) Swing lock and swing holding brake


functions
The swing lock function (manual) is used to
lock machine from swinging at any position.
The swing holding brake function (automatic)
is used to prevent hydraulic drift after the
machine stops swinging.
Swing lock switch and swing lock/holding
brake
Lock
switch

OFF

ON

Lock
lamp

Function

Operation

OFF

Swing
holding
brake

If swing lever is set in neutral,


swing brake operates in
about 5 sec. If swing lever is
operated, brake is released
and machine can swing freely.

Swing
lock

Swing lock operates and


machine is locked from
swinging. Even if swing lever
is operated, swing lock is not
reset and machine does not
swing.

ON

2) Quick hydraulic oil warm-up function


when swing lock switch is turned on
If swing lock switch (4) is turned on, the
pump-cut function is cancelled and the relief
pressure rises from 34.8 MPa {355 kg/cm} to
37.2 MPa {380 kg/cm}. If the work equipment
is relieved under this condition, the hydraulic
oil temperature rises quickly and the warm-up
time can be shortened.

Operation of swing holding brake release


switch
If the controller, etc. has a problem, the swing
holding brake does not work normally, and
the machine cannot swing, the swing lock can
be reset with the swing holding brake release
switch.

Swing holding brake


release switch
Swing lock
switch
Swing brake

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.

Even if the swing holding brake release


switch is turned on, if the swing lock switch is
turned on, the swing brake is not released.
If the swing lock is reset, swinging is stopped
by only the hydraulic brake of the safety
valve. Accordingly, if swinging is stopped on
a slope, the upper structure may drift hydraulically.

10-172

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

ELECTRONIC CONTROL SYSTEM

12

7. Travel control function

SJP08770
OR
08927

FUNCTION

The pumps are controlled and the travel


speed is changed manually or automatically,
to secure proper travel performance matched
to the type of work and jobsite during travel.

PC200-7

10-173

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

ELECTRONIC CONTROL SYSTEM

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)

Mi) (Middle Speed)

Hi (High
speed)

Pump capacity
(%)

60

90

100

Motor capacity

Max.

Max.

Min.

3.0

4.1

5.5

Travel speed
(km/h)

ii) Automatic change by engine speed


If the engine speed is lowered to 1,500
rpm or less with the fuel control dial during travel;
the travel speed does not change even if
the travel speed switch is changed from
Lo, ( Mi) to Hi,
the travel speed changes to Mi level automatically if the travel speed has been Hi.
iii) Automatic change by pump discharge
pressure
While the machine is traveling with the
travel speed switch at Hi, if the load is
increased because of an upslope ground,
etc. and the travel pressure keeps above
24.5 MPa {250 kg/cm} for 0.5 seconds, the
travel motor capacity is changed automatically and the travel speed is lowered (to
the Mi level) (The travel speed switch is
kept at Hi, however).
While the machine is travelling at Mi
level, if the load is reduced on a flat or
downslope ground, etc. and the travel
pressure keeps below 14.7 MPa {150 kg/
cm} for 0.5 seconds, the travel motor
capacity is changed automatically and the
travel speed is set to Hi again.
: The "Mi" mode is on the multi-monitor specification machine only.

10-174

08928

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

ELECTRONIC CONTROL SYSTEM

8. ATT flow control, circuit selector function (option)

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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

ELECTRONIC CONTROL SYSTEM

9. System component parts


1) Engine revolution sensor

1.
2.
3.
4.

Sensor
Locknut
Wiring harness
Connector

FUNCTION

The engine revolution sensor is installed to


the ring gear of the engine flywheel. It electrically calculates the number of the gear teeth
which pass in front of it and transmits the
result to the engine throttle and pump controller.
A magnet is used to sense the gear teeth.
Each time a gear tooth passes in front of the
magnet, a current is generated.

10-176

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

ELECTRONIC CONTROL SYSTEM

12

2) PPC oil pressure switch

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

The junction block has 9 pressure switches,


which check the operating condition of each
actuator by the PPC pressure and transmit it
to the governor/pump controller.

PC200-7

10-177

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

ELECTRONIC CONTROL SYSTEM

12

3) Pump pressure sensor

1. Sensor
2. Connector
FUNCTION

The pump pressure sensor is installed to the


inlet circuit of the control valve. It converts
the pump discharge pressure into a voltage
and transmits it to the governor/pump controller.

OPERATION

The oil pressure applied from the pressure


intake part presses the diaphragm of the oil
pressure sensor, the diaphragm is deformed.
The gauge layer facing the diaphragm measures the deformation of the diaphragm by
the change of its resistance, then converts the
change of the resistance into a voltage and
transmits it to the amplifier (voltage amplifier).
The amplifier amplifies the received voltage
and transmits it to the governor/pump controller.
Relationship between pressure P (MPa {kg/
cm}) and output voltage (V) is as follows.
V = 0.08 [0.008] x P + 0.5

10-178

SJP08774
OR
08930

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

MULTI MONITOR SYSTEM

MULTI MONITOR SYSTEM

SJP08775
OR
08931

The monitor system monitors the condition


of the machine with sensors installed on various parts of the machine. It processes and
immediately displays the obtained information on the panel notifying the operator of the
condition of the machine.
The panel is roughly divided as follows.
1. Monitor section to output alarms when
the machine has troubles
2. Gauge section to display the condition
constantly (Coolant temperature, hydraulic oil temperature, fuel level, etc.)

10-180

The monitor panel also has various mode


selector switches and functions to operate the
machine control system.

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

MULTI MONITOR SYSTEM

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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

MULTI MONITOR SYSTEM

Input and output signals


CN-1

CN-2

Pin
No.
1 Key ON

Signal name

Input/
output
Input

Key ON

Washer motor output

Starting signal

Input

Limit switch (W)

Input

GND

Input/
output
Input

Pin
No.
1 NC

Signal name

Input/
output
Input

Input

Fuel level

Input

NC

Input

Output

Radiator water level

Input

NC

Input

(Hydraulic oil level)

Input

NC

Input

Air cleaner clogging

Input

NC

Input

NC

Input

NC

Input

Engine oil pressure

Input

RS230C CTS

Input

Engine oil level

Input

RS230C RXD

Input

GND

VB +

Wiper motor (+)

Output

10

Wiper motor (-)

Output

11

Buzzer ON signal

Input

12

Limit switch (P)

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

Hydraulic oil temperature (analog)

Input

12

NC

Input

13

GND (for analog signal)

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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

MULTI MONITOR SYSTEM

MONITOR CONTROL, DISPLAY PORTION


MONITOR PORTION

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.

Fuel level monitor


Hydraulic oil temperature monitor
Power max. monitor
Auto-deceleration monitor
Radiator water level caution
Battery charge caution
Engine oil pressure caution
Engine oil level caution
Air cleaner clogging
Maintenance time warning caution

10-183

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

MULTI MONITOR SYSTEM

MONITOR ITEMS AND DISPLAY

Symbol

Display item

Swing lock

Display method

Swing lock switch

Swing holding brake


release switch

Swing lock monitor

OFF

OFF

OFF

ON

OFF

ON

OFF

ON

Flashes

ON

ON

ON

Continuous set time

Preheating monitor status

Up to 30 sec.

ON

From 30 sec. to 40 sec.

Flashes

More than 40 sec.

OFF

Power Max. switch status

Power max. monitor status

Being pressed

Lights up but goes out after


approx. 9 sec. when kept pressed

Not being pressed

Flashes

Preheating

Power Max.

Engine water
temperature
Hydraulic oil
temperature

See gauge display on the next page

Fuel level

10-184

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

Gauge

Engine water temperature (C)

Hydraulic oil temperature (C)

MULTI MONITOR SYSTEM

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

Fuel level (L)

PC200-7

10-185

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

MULTI MONITOR SYSTEM

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 engine is running

Engine oil pressure

--

When abnormal,
lights up and buzzer
sounds

Battery charge

--

Lights up when abnormal

Radiator water level

Lights up when abnormal

When abnormal,
lights up and buzzer
sounds

Engine oil level

Lights up when abnormal

--

Air cleaner clogging

--

Lights up when abnormal

Maintenance

Lights up when there is a warning. Lights up for


only 30 sec. after key is turned ON, then goes
out.

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.

Condition of hydraulic oil

Color of symbol

Low temperature (below B6 or equivalent)

Black on white background

Normal (B6 - B2)

No display

High temperature (below B2)

White on red letters

10-186

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

Display category

Symbol

Display item

MULTI MONITOR SYSTEM

Display range
ON

INT

Display method
OFF

Wiper

Displays set condition

Working
mode

Displays set
mode

Travel speed

Displays set
speed

Monitor

Service meter

PC200-7

Auto-deceleration

ON OFF

Displays actuation status

Service
meter indicator

When service meter is working

Lights up when
service meter is
working

10-187

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

MULTI MONITOR SYSTEM

SWITCHES

1.
2.
3.
4.
5.
6.
7.
8.
9.

Working mode selector switch


Selector switch
Display brightness, contrast adjustment switch
Control switch
Window washer switch
Wiper switch
Maintenance switch
Travel speed selector switch
Auto-deceleration switch

10-188

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

Working mode selector switch


The condition of the machine changes according to the switch that is pressed (A, E, L, B). It
is possible to check the condition on the working mode monitor display. The relationship
between each working mode and the monitor
display is shown in the table on the right.

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.

Travel speed selector switch


Each time the travel speed selector switch is
pressed, the travel speed changes.
Lo Mi Hi Lo . . . . . .
Use the travel speed monitor display to check
the present condition.
The relationship between the set speed and
the monitor display in the table on the right.

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

MULTI MONITOR SYSTEM

Switch that is
pressed

Display

Working mode status after setting

[A]

A mode (default)

[E]

E mode

[L]

L mode

[B]

B mode

Display

Setting

Crawler symbol + Lo

Low speed (default)

Crawler symbol + Mi

Medium speed

Crawler symbol + Hi

High speed

Display

Setting

Wiper actuation
status

None

OFF

Stowing stopped
or now stowing

Wiper symbol + INT

INT

Intermittent actuation

Wiper symbol + ON

ON

Continuous actuation

10-189

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

Window washer switch


While the switch is being pressed, window
washer liquid is sprayed out. There is a time
delay before the wiper starts.

Control switch
This is used for control when using the maintenance function or select function.
(For details, see each function.)

Display brightness, contrast adjustment


switch
Use this switch when adjusting the display
brightness and contrast.
(For details, see each function.)

10-190

MULTI MONITOR SYSTEM

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

MULTI MONITOR SYSTEM

SELECT MODE FUNCTION

This is used when setting the flow in each


working mode. It is possible to make the setting when genuine attachment piping is
installed and the initial value setting function
on the service menu has been used to set to
ATTACHMENT INSTALLED.
It is possible to check on the working mode
monitor if this function can be set.

Working mode

Monitor display

A mode

[A] + crusher symbol

E mode

[E] + crusher symbol

B mode

[B] + flow symbol

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

Flow level bar graph


retracts to the left

3) After completing the level selection, press


input confirmation switch (3).
The selection flow level is confirmed and
the screen moves to the normal screen.
From the moment that the flow level is
selected, the content of the selection is
reflected for the attachment flow.
Before the input confirmation switch
is pressed, the flow levelis not confirmed, so press return switch (4) to
return to the normal screen. This function can be used to return to the previously set flow.
The relationship between the set flow
level and the flow value is as shown in
the table on the right.

PC200-7

Flow level

Flow (L/min.)

Remarks

430

Default

350

250

170

140

115

90

30

10-191

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

MULTI MONITOR SYSTEM

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.

10-key pad operation

01

02

03

3) After completing the level selection, press


input confirmation switch (3).
The selected flow level is selected.
Before the input confirmation switch
is pressed, the flow level is not confirmed, so press return switch (4) to
return to the operator screen. This
function can be used to return to the
previously set flow.
4) After the flow level is confirmed, the
screen changes to the screen shown in
the diagram on the right.
With this screen, it is possible to make
fine adjustment to the flow.

No.

Flow level (L/min.)

Remarks

01

180

Default

02

140

03

100

5) Press control switch (2) and select the


flow level.

Control switch

Actuation
Flow level bar graph
extends to the right

Flow level bar graph


retracts to the left

10-192

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

6) After completing the level selection, press


input confirmation switch (3).
The selected flow level is confirmed and
the screen moves to the operator screen.
From the moment that the flow level is
selected, the content of the selection is
reflected for the attachment flow.
Before the input confirmation switch
is pressed, the flow level is not confirmed, se press return switch (4) to
return to the normal screen. This function can be used to return to the previously set flow.
The relationship between the set flow
level and the flow value is as shown in
the table on the right.
7) Check the set value with the working
mode monitor.
The relationship between the display
level and the set value is as shown in the
table on the right, and it is possible to
check the level of the flow that can be set.

PC200-7

MULTI MONITOR SYSTEM

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

Set value (ll/min.)

200 or 210

180 or 190

160 or 170

140 or 150

120 or 130

100 or 110

80 or 90

70

10-193

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

MULTI MONITOR SYSTEM

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

Engine oil filter

500

03

Fuel filter

500

04

Hydraulic filter

1000

05

Hydraulic tank breather

500

06

Corrosion resistor

(1000)

07

Damper case oil

1000

08

Final case oil

2000

09

Machinery case oil

1000

10

Hydraulic oil

5000

Option, so not set

The above replacement intervals are set for


each item, and the time remaining to maintenance is reduced as the machine is operated.
The content of the caution display differs
according to the ramaining time. The relationship is as shown in the table below.

Display

Condition

None

Remaining time for


maintenance for all
items is more than 30
hours

Notice display (black


symbol displayed on
yellow background)

There is one or more


items with less than 30
hours remaining time
for maintenance

Warning display (wiper


symbol displayed on red
background)

There is one or more


items with less than 0
hours remaining time
for maintenance

10-194

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

MULTI MONITOR SYSTEM

METHOD OF CHECKING STATUS


MAINTENANCE ITEMS
Operate as follows when on the operator
screen.
1. Press maintenance switch (1) and switch to
the maintenance list display screen.
The maintencance items are displayed as
symbols on the screen.
2. Press control switch (2), or use the 10-key pad
to input the number (01 - 10) of the maintenance item to select the item.
The cursor moves and the item is highlighted.
The display method is the same as
described on the previous page (relationship between remaining time and caution
display). If the remaining time is less than
30 hours, the item is displayed in yellow,
and if it is less than 0 hours, it is displayed
in red.
MAINTENANCE OPERATION
1.

After completing the selection, press input


confirmation switch (3).
The screen will change to the maintenance
reset screen.
2. Use the maintenance reset screen to check
the content, and if there is any problem, press
input confirmation switch (3) to move to the
check screen.
If the wrong item is selected, press return
switch (4) to return to the maintenance list
screen.
3. Check the content on the check screen, and if
there is no problem, press input confirmation
switch (3) to reset the maintenance time.
After the reset is completed, the screen
returns to the maintenance list display
screen. To check the remaining time, or if the
wrong item is selected, press return switch (4)
to return to the maintenance list screen.
The check screen shows the symbol for
the maintenance item and the set time in
large letters.
The background color of the symbol for
the item where the maintenance tiem was
reset is the same as the background of the
screen, so it is possible to check that it has
been reset.

PC200-7

10-195

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

MULTI MONITOR SYSTEM

BRIGHTNESS, CONTRAST ADJUSTMENT


FUNCTION
This function is used to adjust the brightness and
contrast of the display.
ADJUSTMENT METHOD
Operate as follows when on the operator
screen.
1. Press display brightness/contrast adjustment
switch (1) and switch to the adjustment
screen.
Relationship between menu symbol and content.
No.

Symbol

Content

01

Return mark

Return

02

Contrast

03

Brightness

2. Press control switch (2), or use the 10-key pad


to input the number (00 - 02) to select either
contrast or brightness.
After completing the selection, press input
confirmation switch (3) and return to the
adjustment screen.
Then press return switch (4) or use the 10-key
pas to set to [00] and press input confirmation
switch (3) to return to the normal screen.
3. Press control switch (2) and adjust the brightness and contrast as desired.
Control switch

Actuation
Flow level bar graph
extends to the right

Flow level bar graph


retracts to the left

10-196

08937

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

MULTI MONITOR SYSTEM

PASSWORD FUNCTION

If a passport is input, the engine will not start


unless the password is input correctly when
starting.
When setting this function or when changing
the password, it is necessary to go from the
normal screen to the setting screen and input
the password.
This becomes posssible 10 minutes after the
starting switch is turned ON and the monitor
screen has changed to the normal screen.

08941

METHOD OF SETTING, CHANGING


PASSWORD
1.

Turn the starting switch ON, keep starting


switch (2) pressed, use the 10-key pad to input
7 2 9 7 2 9 in succession, and the
screen will change to the 8-digit numeral
input screen.

2. On the input screen, use the 10-key pad to


input an 8-digit number [19210513]. When the
final digit [number 3] is input, the screen will
change to the Valid/Invalid screen for the
password function.

PC200-7

10-197

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

MULTI MONITOR SYSTEM

3. Press control switch (1) or (2) to set to Valid/


Invalid.
The diagram on the right shows the screen
when control switch (1) is pressed and the
screen is set to [Valid].

If [Invalid] is selected and input confirmation


switch (3) is pressed, the password function
will be made invalid, and the screen will
return to the normal screen.
If [Valid] is selected and input confirmation
switch (3) is pressed, the password function
will be made valid, and the screen will change
to the screen for inputting the 4-digit number.
08942

4. Input a 4-digit number on the input screen


(the lock and key symbol are displayed), then
press input confirmation switch (3).
When the input confirmation switch is
pressed, you will be requested to input the
same 4-digit number again, so input the same
4-digit number, then press input confirmation
switch (3) to confirm the password.
Numerals 1 and 2 are displayed at the top
right corner of the screen to distinguish
between the 1st input screen and the 2nd
input screen.
When the password is confirmed, the screen
will return to the normal screen.
If the number input the second time is different from the number input the first
time, the password will not be confirmed
and the screen will return to the first
screen, so input the same 4-digit password 2 times in succession.

10-198

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

MULTI MONITOR SYSTEM

SERVICE METER CHECK FUNCTION

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.

DISPLAY LCD CHECK FUNCTION

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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

MULTI MONITOR SYSTEM

USER CODE DISPLAY FUNCTION

If there is any problem in operating the


machine, the user code is displayed on the
monitor to advise the operator of the steps to
take.
This code display appears on the operator
screen.
On the operator screen, the user code is displayed on the portion for the hydraulic oil
temperature gauge.

If more than one user code is generated at the


same time, the user codes are displayed in
turn for 2 seconds each to display all the user
codes.
08945

10-200

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

MULTI MONITOR SYSTEM

While the user code is being displayed, if the


input confirmation switch is pressed, the service code and failure code can be displayed.
08946

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.

If the telephone number has been set using


the telephone number input on the service
menu, it is possible to switch on the service
code/failure code and display the telephone
symbol and telephone number.
For details of inputting and setting the telephone number, see SPECIAL FUNCTIONS OF
MONITOR PANEL in the TESTING AND
ADJUSTING section.

PC200-7

08947

08948

10-201

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

7-SEGMENT MONITOR SYSTEM

7-SEGMENT MONITOR SYSTEM

SJP08775
OR
08931

The monitor system monitors the condition


of the machine with sensors installed on various parts of the machine. It processes and
immediately displays the obtained information on the panel notifying the operator of the
condition of the machine.
The panel is roughly divided as follows.
1. Monitor section to output alarms when
the machine has troubles
2. Gauge section to display the condition
constantly (Coolant temperature, hydraulic oil temperature, fuel level, etc.)

10-202

The monitor panel also has various mode


selector switches and functions to operate the
machine control system.

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

7-SEGMENT MONITOR SYSTEM

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

INPUT AND OUTPUT SIGNALS


CN-P01
Pin
No.

CN-P02
Signal neme

Pin
No.

Signal Name

Key switch (Battery)

Engine water temperature

Key switch (Battery)

Fuel

Washer motor output

Radiator water level

Key switch (Terminal C)

NC

Wiper contact W

Air cleaner clogging sensor

GND

NC

GND

Engine oil pressure sensor

VB + (24 V)

Engine oil level sensor

Wiper motor (+)

Network signal

10

Wiper motor (-)

10

Network signal

11

(Buzzer ON signal input)

11

Charge level

12

Wiper contact P

12

NC

13

GND (For analog signal)

14

NC

15

Wind limit switch

16

Buzzer cancel

17

Swing lock

18

Preheating

19

Limit switch

20

Network (GND)

10-203

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

7-SEGMENT MONITOR SYSTEM

Display section of monitor

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.

10-204

Service meter display


Coolant temperature gauge
Coolant temperature caution
Digital meter display (Service code and user
code are displayed when trouble occurs
Fuel level caution
Fuel level gauge
Engine oil level caution lamp
Preheating pilot lamp
Swing holding brake pilot lamp
Oil maintenance pilot lamp
Battery charge caution lamp
Air cleaner clogging caution lamp
Engine oil pressure caution lamp

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

7-SEGMENT MONITOR SYSTEM

Monitored items and display


Symbol

When engine is
stopped
Lights when normal.
(Goes off when
engine is started.)

Displayed item

Display range

Engine oil pressure

Max. 1,500 rpm


Max. 0.05 MPa
{0.5 kg/cm}
Min. 1,500 rpm
Max. 0.15 MPa
{1.5 kg/cm}

Air cleaner clogging

When clogged

Goes off.

Flashes when abnormal.

Charge level

When charge is
abnormal

Lights when normal.


(Goes off when
engine is started.)

Flashes when abnormal.

Engine oil level

Below low level

Flashes when abnormal.

Packing (Swing lock)

When swing is
locked

Lights up when swing is locked. Flashes when


swing holding brake release switch is turned on.

Oil maintenance

See "OIL MAINTENANCE FUNCTION" on next page.

Preheating

When preheated

Coolant temperature

Flashes at 102C or higher. Flashes and


buzzer sounds at 105C or higher.

Fuel level

Flashes when below low level.

While engine is running

Flashes and buzzer


sounds when abnormal.

SAP00521

SAP00523

SAT00098

SAP00526

PC200-7

Goes off.

Lights up for 30 sec. when starting switch is set


to HEAT. Then, flashes for 10 sec. to indicated
completion of preheating.

10-205

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

7-SEGMENT MONITOR SYSTEM

12

Oil maintenance function


1. Function and operation
At a set time after the engine oil is replaced, the
oil maintenance function is turned on to notify
the operator by the LED lamp on the monitor
panel that it is time to replace the oil. The function to indicate the phone number of the place to
make contact for service on the LCD unit is
installed, too.
1) Check of elapsed time
Nothing is displayed normally until point
B shown in the figure at right after this
function is reset. If the key is turned on
with the buzzer cancel switch processed
(for 2.5 seconds), however, the elapsed
time is displayed on the service meter
section.
2) Display of replacement of oil
If time passes point B after this function is
reset, the elapsed time is displayed on the
service meter section and the LED flashes
when the key is turned on.
2. Setting of time interval
1) The time interval is set in the interval setting mode. It can be set to "125h", "250h",
"500h", "Not set", or "Demo-mode". The
default is "Not set".
2) To enter the interval setting mode, press
and hold the clock switch for 2.5 seconds.
3) If the buzzer cancel switch is pressed in
the interval setting mode, the clock display section changes to "" "125"
"250" "500" " d" in order. ("" corresponds to "Not set" and " d" corresponds
to "Demo-mode".)
4) To save the time interval, set a desired
time (mode) on the monitor panel and
press and hold the clock switch for 2.5
seconds.

10-206

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

7-SEGMENT MONITOR SYSTEM

12

3. Timing and contents of display


1) When replacement of oil is displayed
The elapsed time is displayed for 10 seconds after all segments are turned on.
Phone number is displayed for the next 10
seconds.
If the phone number has not been input,
however, the elapsed time is displayed for
20 seconds after all segments are turned
on.
2) When elapsed time is checked
The elapsed time is displayed for 10 seconds after all segments are turned on.
4. Resetting elapsed time
1) When the replacement of oil and elapsed
time are displayed, press the buzzer cancel switch 10 seconds after all segments
are turned on (while the elapsed time is
displayed) and hold for 3 seconds. The
elapsed time is reset. After this operation,
"0h" is displayed for 1 second.
2) When the set time is changed, the elapsed
time is reset to "0h".
5. Demo-mode
1) In the demo-mode, the time is set to 250h,
the elapsed time is set to 240h, and
replacement of oil is displayed when the
key is turned on. The elapsed time does
not increase, however. The time can be
reset in this mode. Turn on the key 3
times in this mode, and the time interval
is automatically set to "Not set" at the 4th
time and after. The elapsed time is set to
"0h" and counting of elapsed time is
started.

PC200-7

10-207

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

7-SEGMENT MONITOR SYSTEM

12
Mode selector switches

1. Travel speed switch


2. Auto-deceleration switch
3. Wiper switch
4. Work mode selector switch

There are 4 sets of the mode selector


switches on the switch section. Each time one
switch is pressed, the machine condition
changes. The current condition is indicated
by the lighting of the LED above the switch.

The initial setting of only the work mode after


the starting switch is turned on can be
changed.
For how to change the setting, see "Work
mode default setting mode" in TROUBLESHOOTING-Display and special functions of
monitor panel.

10-208

Operations table of switch section


The bold letters are the positions of the
switches reset when the starting switch is
turned on.
Item

Operation

Work mode

AEB

Auto-deceleration

ONOFF

Wiper
Travel speed

OFFIntermittentON
HiLo

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

SENSOR

SENSOR

The signals from the sensors are input to the


panel directly. Either side of a sensor of contact type is always connected to the chassis
ground.

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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

SENSOR

12

Engine oil level sensor


1. Connector
2. Bracket
3. Float
4. Switch

Engine oil pressure sensor (For low pressure)

1. Plug
2. Contact ring
3. Contact
4. Diaphragm
5. Spring
6. Terminal

Coolant temperature sensor


Hydraulic oil temperature sensor

1. Thermistor
2. Body
3. Tube

10-210

4. Tube
5. Wire
6. Connector

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

SENSOR

12

Fuel level sensor

1. Float
2. Connector
3. Cover
4. Variable resistor

Air cleaner clogging sensor

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

HYDRAULIC CIRCUIT DIAGRAM

HYDRAULIC CIRCUIT DIAGRAM


PC200-7, PC200LC-7

PC200-7

90-3

OTHERS

HYDRAULIC CIRCUIT DIAGRAM

HYDRAULIC CIRCUIT DIAGRAM


PC220-7, PC220LC-7

PC200-7

90-5

OTHERS

ELECTRICAL CIRCUIT DIAGRAM (1/5)

ELECTRICAL CIRCUIT DIAGRAM (1/5)


FOR MULTI MONITOR
PC200-7, PC200LC-7

PC200-7

90-7

OTHERS

ELECTRICAL CIRCUIT DIAGRAM (1/5)

ELECTRICAL CIRCUIT DIAGRAM (1/5)


FOR MULTI MONITOR
PC220-7, PC220LC-7

PC200-7

90-9

OTHERS

ELECTRICAL CIRCUIT DIAGRAM (2/5)

ELECTRICAL CIRCUIT DIAGRAM (2/5)


FOR MULTI MONITOR
PC200-7, PC200LC-7
PC220-7, PC220LC-7

PC200-7

90-11

OTHERS

ELECTRICAL CIRCUIT DIAGRAM (3/5)

ELECTRICAL CIRCUIT DIAGRAM (3/5)


FOR MULTI MONITOR
PC200-7, PC200LC-7
PC220-7, PC220LC-7

PC200-7

90-13

OTHERS

ELECTRICAL CIRCUIT DIAGRAM (4/5)

ELECTRICAL CIRCUIT DIAGRAM (4/5)


FOR MULTI MONITOR
PC200-7, PC200LC-7
PC220-7, PC220LC-7

PC200-7

90-15

OTHERS

ELECTRICAL CIRCUIT DIAGRAM (5/5)

ELECTRICAL CIRCUIT DIAGRAM (5/5)


FOR MULTI MONITOR
PC200-7, PC200LC-7
PC220-7, PC220LC-7

PC200-7

90-17

OTHERS

ELECTRICAL CIRCUIT DIAGRAM FOR AIR CONDITIONER

ELECTRICAL CIRCUIT DIAGRAM FOR AIR CONDITIONER

PC200-7

90-19

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