Download - Sebm024300(General s&f)

© 2001 All Rights Reserved 00-1Printed in USA 09-01

SEBM024300

PC200, 200LC-7PC220, 220LC-7

• This shop manual may contain attachments and optional equipment that are not avail-able in your area. Please consult your local Komatsu distributor for those items you mayrequire. Materials and specifications are subject to change without notice

MACHINE MODEL SERIAL NUMBERPC200-7 00 200001 AND UP 00

PC200LC-7 00 200001 AND UP 00

PC220-7 00 60001 AND UP 00

PC220LC-7 00 60001 AND UP 00

CONTENTS

00-2

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-100

SAFETY SAFETY NOTICE

00-3

SAFETYSAFETY NOTICE

IMPORTANT SAFETY NOTICE

Proper service and repair is extremely important for safe machine operation. The service andrepair techniques recommended by Komatsu and described in this manual are both effectiveand safe. Some of these techniques require the use of tools specially designed by Komatsu forthe 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 danger-ous situation arises or may possibly arise, first consider safety, and take the necessary actionsto deal with the situation.

GENERAL PRECAUTIONS

Mistakes in operation are extremely dangerous.Read the Operation and Maintenance Manual care-fully BEFORE operating the machine.

1. Before carrying out any greasing or repairs, readall the precautions given on the decals which arefixed to the machine.

2. When carrying out any operation, alwayswear safety shoes and helmet. Do not wearloose work clothes, or clothes with buttonsmissing.

• Always wear safety glasses when hittingparts with a hammer.

• Always wear safety glasses when grindingparts with a grinder, etc.

3. If welding repairs are needed, always have atrained, experienced welder carry out the work.When carrying out welding work, always wearwelding gloves, apron, hand shield, cap andother clothes suited for welding work.

4. When carrying out any operation with two ormore workers, always agree on the operatingprocedure before starting. Always inform yourfellow workers before starting any step of theoperation. Before starting work, hang UNDERREPAIR signs on the controls in the operator'scompartment.

5. Keep all tools in good condition and learn thecorrect way to use them.

6. Decide a place in the repair workshop to keeptools and removed parts. Always keep the toolsand parts in their correct places. Always keepthe work area clean and make sure that there isno dirt or oil on the floor. Smoke only in the areasprovided for smoking. Never smoke while work-ing.

PREPARATIONS FOR WORK

7. Before adding oil or making any repairs, park themachine on hard, level ground, and block thewheels or tracks to prevent the machine frommoving.

8. Before starting work, lower blade, ripper, bucketor any other work equipment to the ground. Ifthis is not possible, insert the safety pin or useblocks to prevent the work equipment from fall-ing. In addition, be sure to lock all the controllevers and hang warning signs on them.

9. When disassembling or assembling, support themachine with blocks, jacks or stands beforestarting work.

10.Remove all mud and oil from the steps or otherplaces used to get on and off the machine.Always use the handrails, ladders or steps whengetting on or off the machine. Never jump on oroff the machine. If it is impossible to use thehandrails, ladders or steps, use a stand to pro-vide safe footing.

SAFETY SAFETY NOTICE

00-4

PRECAUTIONS DURING WORK

11.When removing the oil filler cap, drain plug orhydraulic pressure measuring plugs, loosenthem slowly to prevent the oil from spurting out.Before disconnecting or removing componentsof the oil, water or air circuits, first remove thepressure completely from the circuit.

12.The water and oil in the circuits are hot when theengine is stopped, so be careful not to getburned.Wait for the oil and water to cool before carry-ing out any work on the oil or water circuits.

13.Before starting work, remove the leads from thebattery. Always remove the lead from the nega-tive (–) terminal first.

14.When raising heavy components, use a hoist orcrane.Check that the wire rope, chains and hooks arefree from damage.Always use lifting equipment which has amplecapacity.Install the lifting equipment at the correct places.Use a hoist or crane and operate slowly to pre-vent the component from hitting any other part.Do not work with any part still raised by the hoistor crane.

15.When removing covers which are under internalpressure or under pressure from a spring,always leave two bolts in position on oppositesides. Slowly release the pressure, then slowlyloosen the bolts to remove.

16.When removing components, be careful not tobreak or damage the wiring. Damaged wiringmay cause electrical fires.

17.When removing piping, stop the fuel or oil fromspilling out. If any fuel or oil drips onto the floor,wipe it up immediately. Fuel or oil on the floorcan cause you to slip, or can even start fires.

18.As a general rule, do not use gasoline to washparts. In particular, use only the minimum ofgasoline when washing electrical parts.

19.Be sure to assemble all parts again in their origi-nal places.Replace any damaged parts with new parts.• When installing hoses and wires, be sure

that they will not be damaged by contactwith other parts when the machine is beingoperated.

20.When installing high pressure hoses, make surethat they are not twisted. Damaged tubes aredangerous, so be extremely careful when install-ing tubes for high pressure circuits. Also, checkthat connecting parts are correctly installed.

21.When assembling or installing parts, always usethe specified tightening torques. When installingprotective parts such as guards, or parts whichvibrate violently or rotate at high speed, be par-ticularly careful to check that they are installedcorrectly.

22.When aligning two holes, never insert your fin-gers or hand. Be careful not to get your fingerscaught in a hole.

23.When measuring hydraulic pressure, check thatthe measuring tool is correctly assembled beforetaking any measurements.

24.Take care when removing or installing the tracksof track-type machines.When removing the track, the track separatessuddenly, so never let anyone stand at eitherend of the track.

FOREWORD GENERAL

00-5

FOREWORDGENERALThis shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman anaccurate understanding of the product and by showing him the correct way to perform repairs and make judge-ments. 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 serviceworkshop. For ease of understanding, the manual is divided into the following chapters; these chapters are fur-ther divided into the each main group of components.

STRUCTURE AND FUNCTIONThis section explains the structure and function of each component. It serves not only to give an under-standing of the structure, but also serves as reference material for troubleshooting.In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and mainte-nance standards.

TESTING AND ADJUSTINGThis section explains checks to be made before and after performing repairs, as well as adjustments tobe made at completion of the checks and repairs.Troubleshooting charts correlating "Problems" with "Causes" are also included in this section.

DISASSEMBLY AND ASSEMBLYThis section explains the procedures for removing, installing, disassembling and assembling each com-ponent, as well as precautions for them.

MAINTENANCE STANDARDThis section gives the judgment standards for inspection of disassembled parts.The contents of this section may be described in STRUCTURE AND FUNCTION.

OTHERSThis 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 anyadvance notice. Use the specifications given in the book with the latest date.

FOREWORD HOW TO READ THE SHOP MANUAL

00-6

HOW TO READ THE SHOP MANUAL

VOLUMESShop manuals are issued as a guide to carrying outrepairs. They are divided as follows:

Chassis volume: Issued for every machine modelEngine volume: Issued for each engine series

Electrical volume:Attachments volume:

These various volumes are designed to avoid dupli-cating the same information. Therefore, to deal withall repairs for any model , it is necessary that chas-sis, engine, electrical and attachment volumes beavailable.

DISTRIBUTION AND UPDATINGAny additions, amendments or other changes will besent to KOMATSU distributors. Get the most up-to-date information before you start any work.

FILING METHOD1. 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 andFunction)Consecutive page number for eachitem.

Example 2 (Engine volume):

12 - 5

Unit number (1. Engine)Item number (2. Testing and Adjust-ing)Consecutive page number for eachitem.

3. Additional pages: Additional pages are indicatedby a hyphen (-) and number after the pagenumber. File as in the example.Example:10-410-4-110-4-210-5

REVISED EDITION MARK

When a manual is revised, an edit ion mark(123....) is recorded on the bottom of the pages.

REVISIONS

Revised pages are shown in the LIST OF REVISEDPAGES next to the CONTENTS page.

SYMBOLS

So that the shop manual can be of ample practicaluse, important safety and quality portions aremarked with the following symbols.

Symbol Item Remarks

¤ SafetySpecial safety precautionsare necessary when per-forming the work.

s Caution

Special technical precau-tions or other precautionsfor preserving standardsare necessary when per-forming the work.

4 Weight

Weight of parts of sys-tems. Caution necessarywhen selecting hoistingwire, or when working pos-ture is important, etc.

3 Tighteningtorque

Places that require specialattention for the tighteningtorque during assembly.

2 CoatPlaces to be coated withadhesives and lubricants,etc.

5 Oil, waterPlaces where oil, water orfuel must be added, andthe capacity.

6 DrainPlaces where oil or watermust be dra ined, andquantity to be drained.

}·

Each issued as onevolume to cover allmodels

12-20312-203-112-203-212-204

Added pages

FOREWORD HOISTING INSTRUCTIONS

00-7

HOISTING INSTRUCTIONS

HOISTING

¤ Heavy parts (25 kg or more) must be liftedwith a hoist, etc. In the DISASSEMBLYAND ASSEMBLY section, every partweighing 25 kg or more is indicated clearlywith the symbol4

• If a part cannot be smoothly removed from themachine by hoisting, the following checksshould 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 ROPES1) Use adequate ropes depending on the

weight of parts to be hoisted, referring tothe table below:

Wire ropes(Standard "Z" or "S" twist ropes

without galvanizing)

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

2) Sling wire ropes from the middle portion of thehook.

Slinging near the edge of the hook may causethe rope to slip off the hook during hoisting, anda serious accident can result. Hooks have max-imum strength at the middle portion.

3) Do not sling a heavy load with one rope alone,but sling with two or more ropes symmetricallywound onto the load.¤ Slinging with one rope may cause turning

of the load during hoisting, untwisting ofthe rope, or slipping of the rope from itsoriginal winding position on the load, whichcan result in a dangerous accident.

4) Do not sling a heavy load with ropes forming awide hanging angle from the hook.When hoisting a load with two or more ropes,the force subjected to each rope will increasewith the hanging angles. The table belowshows the variation of allowable load kN {kg}when hoisting is made with two ropes, each ofwhich is allowed to sling up to 9.8 kN {1000 kg}vertically, at various hanging angles.When two ropes sling a load vertically, up to19.6 kN {2000 kg} of total weight can be sus-pended. This weight becomes 9.8 kN {1000 kg}when two ropes make a 120° hanging angle.On the other hand, two ropes are subjected toan excessive force as large as 39.2 kN {4000kg} if they sling a 19.6 kN {2000 kg} load at alifting angle of 150°.

Rope diameter Allowable load

mm kN tons

1011.512.514161820

22.430405060

9.813.715.721.627.535.343.154.998.1176.5274.6392.2

1.01.41.62.22.83.64.45.6

10.018.028.040.0

SAD00479

41%71%79%88%100%

FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

00-8

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

¤ Before carrying out the following work, releasethe residual pressure from the hydraulic tank.For details, see TESTING AND ADJUSTING,Releasing residual pressure from hydraulictank.

¤ Even if the residual pressure is released fromthe hydraulic tank, some hydraulic oil flows outwhen the hose is disconnected. Accordingly,prepare an oil receiving container.

Disconnection1) Release the residual pressure from the hydrau-

l ic tank. For detai ls , see TESTING ANDADJUSTING, Releasing residual pressure fromhydraulic tank.

2) Hold adapter (1) and push hose joint (2) intomating 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 itclicks. (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.

Connection1) Hold hose adapter (1) or hose (5) and insert it in

mating adapter (3), aligning them with eachother. (See Fig. 4)★ Do not hold rubber cap portion (4).

2) After inserting the hose in the mating adapterperfectly, pull it back to check its connectingcondition. (See Fig. 5)★ When the hose is pulled back, the rubber

cap portion moves toward the hose about3.5 mm. This does not indicate abnormality,however.

Type 1

FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

00-9

Type 2 Type 3D

isas

sem

bly

1) Hold the mouthpiece of the tightening portionand push body (2) in straight until sliding pre-vention ring (1) contacts contact surface a ofthe hexagonal portion at the male end.

2) Hold in the condition in Step 1), and turnlever (4) to the right (clockwise).

3) Hold in the condition in Steps 1) and 2), andpull out whole body (2) to disconnect it.

1) Hold the mouthpiece of the tightening portionand push body (2) in straight until sliding pre-vention ring (1) contacts contact surface a ofthe hexagonal portion at the male end.

2) Hold in the condition in Step 1), and pushuntil cover (3) contacts contact surface a ofthe hexagonal portion at the male end.

3) Hold in the condition in Steps 1) and 2), andpull out whole body (2) to disconnect it.

Con

nect

ion

• Hold the mouthpiece of the tightening portionand push body (2) in straight until sliding pre-vention ring (1) contacts contact surface a ofthe hexagonal portion at the male end to con-nect it.

• Hold the mouthpiece of the tightening portionand push body (2) in straight until sliding pre-vention ring (1) contacts contact surface a ofthe hexagonal portion at the male end to con-nect it.

FOREWORD COATING MATERIALS

00-10

COATING MATERIALS

★ The recommended coating materials such as adhesives, gasket sealants and greases used for disassemblyand 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 Main applications, featuresr

Adhesives

LT-1A 790-129-9030 150 g Tube• Used to prevent rubber gaskets,

rubber cushions, and cock plugfrom coming out.

LT-1B 790-129-9050 20 g(2 pcs.)

Polyethylenecontainer

• Used in places requiring an imme-diately effective, strong adhesive.Used for plastics (except polyeth-ylene, polyprophylene, tetrafluor-oethlene and vinyl chlor ide),rubber, metal and non-metal.

LT-2 09940-00030 50 g Polyethylenecontainer

• Features: Resistance to heat andchemicals

• Used for anti-loosening and seal-ant purpose for bolts and plugs.

LT-3

790-129-9060(Set of

adhesive andhardening

agent)

Adhesive:1 kg

Hardening

agent:500 g

Can

• Used as adhesive or sealant formetal, glass and plastic.

LT-4 790-129-9040 250 g Polyethylenecontainer

• Used as sealant for machinedholes.

HoltzMH 705 790-126-9120 75 g Tube

• Used as heat-resisting sealant forrepairing engine.

Three bond1735 790-129-9140 50 g Polyethylene

container

• Quick hardening type adhesive• Cure time: within 5 sec. to 3 min.• Used mainly for adhesion of met-

als, rubbers, plastics and woods.

Aron-alpha201 790-129-9130 2 g Polyethylene

container

• Quick hardening type adhesive• Quick cure type (max. strength af-

ter 30 minutes)• Used mainly for adhesion of rub-

bers, plastics and metals.

Loctite648-50 79A-129-9110 50 cc Polyethylene

container

• Resistance to heat, chemicals• Used at joint portions subject to

high temperatures.

Gasketsealant

LG-1 790-129-9010 200 g Tube• Used as adhesive or sealant for

gaskets and packing of powertrain case, etc.

LG-5 790-129-9070 1 kg Can

• Used as sealant for variousthreads, pipe joints, flanges.

• Used as sealant for taperedplugs, elbows, nipples of hydrau-lic piping.

LG-6 790-129-9020 200 g Tube

• Features: Silicon based, resist-ance to heat, cold

• Used as sealant for flange sur-face, tread.

• mab Used as sealant for oil pan,final drive case, etc.

FOREWORD COATING MATERIALS

00-11

Category Komatsu code Part No. Q'ty Container Main applications, features

Adhesives

LG-7 790-129-9070 1 g Tube

• Features: Silicon based, quick hardening type

• Used as sealant for flywheelhousing, intake manifold, oil an,thermostat housing, etc.

Three bond1211 790-129-9090 100 g Tube

• Used as heat-resisting sealant forrepairing engine.

Molybdenumdisulphidelubricant

LM-G 09940-00051 60 g Can • Used as lubricant for sliding por-tion (to prevent from squeaking).

LM-P 09940-00040 200 g Tube

• Used to prevent seizure or scuf-fling of the thread when press fit-ting or shrink fitting.

• Used as lubricant for linkage,bearings, etc.

Grease

G2-LI

SYG2-400LISYG2-350LISYG2-400LI-ASYG2-160LISYGA-160CNLI

Various Various

• General purpose type

G2-CA

SYG2-400CASYG2-350CASYG2-400CA-ASYG2-160CASYGA-160CNCA

Various Various

• Used for normal temperature,light load bearing at places in con-tact with water or steam.

Molybdenumdisulphidelubricant

SYG2-400M400 g

(10 percase)

Belows type• Used for places with heavy load

FOREWORD STANDARD TIGHTENING TORQUE

00-12

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.

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 inthe table below.

Thread diameterof bolt

Width acrossflats

mm mm Nm kgm

68101214

1013171922

13.2 0 1.431 0 366 0 7

113 0 10177 0 19

1.35 0 0.153.2 0 0.36.7 0 0.711.5 0 118 0 2

1618202224

2427303236

279 0 30382 0 39549 0 59745 0 83927 0 103

28.5 0 339 0 456 0 6

76 0 8.594.5 0 10.5

2730333639

4146505560

1320 0 1401720 0 1902210 0 2402750 0 2903290 0 340

135 0 15175 0 20225 0 25280 0 30335 0 35

Thread diameterof bolt

Width acrossflats

mm mm Nm kgm

681012

10131427

7.85 0 1.9518.6 0 4.940.2 0 5.9

82.35 0 7.85

0.8 0 0.21.9 0 0.54.1 0 0.68.4 0 0.8

Thread diameter Width across flat Tightening torque

mm mm Nm kgm

1418222430333642

1924273236414655

24.5 0 4.949 0 19.6

78.5 0 19.6137.3 0 29.4176.5 0 29.4196.1 0 49245.2 0 49294.2 0 49

2.5 0 0.55 0 28 0 2

14 0 318 0 320 0 525 0 530 0 5

SAD00483

Sealing surface


00-13

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.

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.

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

101216

141722

65.7 0 6.8112 0 9.8279 0 29

6.7 0 0.711.5 0 128.5 0 3

Norminal No.Thread diameter Width across flat Tightening torque

mm mm Nm kgm

0203, 0405, 0610, 12

14

1420243342

Varies dependingon type ofconnector.

34.3 0 4.993.1 0 9.8

142.1 0 19.6421.4 0 58.8877.1 0 132.3

3.5 0 0.59.5 0 114.5 0 243 0 6

89.5 0 13.5

Norminal No.Thread diameter Width across flat Tightening torque

mm mm Nm kgm

08101214161820243033364252

08101214161820243033364252

141719222427303232n36nn

7.35 0 1.4711.27 0 1.4717.64 0 1.9622.54 0 1.96

29.4 0 4.939.2 0 4.949 0 4.9

68.6 0 9.8107.8 0 14.7127.4 0 19.6151.9 0 24.5210.7 0 29.4323.4 0 44.1

0.75 0 0.151.15 0 0.15

1.8 0 0.22.3 0 0.23 0 0.54 0 0.55 0 0.57 0 1

11 0 1.513 0 2

15.5 0 2.521.5 0 333 0 4.5


00-14

TIGHTENING TORQUE FOR 102 ENGINE SERIES (BOLT AND NUTS)Use these torques for bolts and nuts (unit: mm) of Cummins Engine.

TIGHTENING TORQUE FOR 102 ENGINE SERIES (EYE JOINTS)Use these torques for eye joints (unit: mm) of Cummins Engine.

TIGHTENING TORQUE FOR 102 ENGINE SERIES (TAPERED SCREWS)Use these torques for tapered screws (unit: inch) of Cummins Engine.

Thread diameter Tightening torque

mm Nm kgm

681012

10 0 224 0 443 0 6

77 0 12

1.02 0 0.202.45 0 0.414.38 0 0.617.85 0 1.22


mm Nm kgm

68101214

8 0 210 0 212 0 224 0 436 0 5

0.81 0 0.201.02 0 0.201.22 0 0.202.45 0 0.413.67 0 0.51


mm Nm kgm

1 / 161 / 81 / 43 / 81 / 23 / 4

1

3 0 18 0 212 0 215 0 224 0 436 0 560 0 9

0.31 0 0.100.81 0 0.201.22 0 0.201.53 0 0.412.45 0 0.413.67 0 0.516.12 0 0.92

FOREWORD ELECTRIC WIRE CODE

00-15

ELECTRIC WIRE CODEIn 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

CLASSIFICATION BY COLOR AND CODE

Norminalnumber

Copper wire

Cable O.D.(mm)

Currentrating

(A)Applicable circuit

Number ofstrands

Dia. ofstrands(mm2)

Crosssection(mm2)

0.85 11 0.32 0.88 2.4 12 Starting, lighting, signaletc.

2 26 0.32 2.09 3.1 20 Lighting, signal etc.

5 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

Priori-ty

Circuits

Classi-fication

Charging Ground Starting Lighting Instrument Signal Other

1 Pri-mary

Code W B B R Y G L

Color White Black Black Red Yellow Green Blue

2

Auxi-liary

Code WR n BW RW YR GW LW

Color White & Red n White & Black Red & White Rellow & Red Green & White Blue & White

3Code WB n BY RB YB GR LR

Color White & Black n Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow

4

Code WL n BR RY YG GY LY

Color White & Blue n Black & Red Red & Yellow Yellow &Green

Green &Yellow Blue & Yellow

5Code WG n n RG YL GB LB

Color White & Green n n Red & Green Yellow & Blue Green & Black Blue & Black

6Code n n n RL YW GL n

Color n n n Red & Blue Yellow & White Green & Blue n

FOREWORD CONVERSION TABLE

00-16

CONVERSION TABLE

METHOD OF USING THE CONVERSION TABLEThe Conversion Table in this section is provided to enable simple conversion of figures. For details of themethod of using the Conversion Table, see the example given below.

EXAMPLE• Method of using the Conversion Table to convert from millimeters to inches1. Convert 55 mm into inches.

(1) Locate the number 50 in the vertical column at the left side, take this as A, then draw a horizontal linefromA.

(2) Locate the number 5 in the row across the top, take this as B, then draw a perpendicular line downfromB.

(3) Take the point where the two lines cross asC. This pointC gives the value when converting from mil-limeters 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.

Millimeters to inches

1 mm = 0.03937 in

0 1 2 3 4 5 6 7 8 9

010203040

5060708090

00.3940.7871.1811.575

1.9692.3622.7563.1503.543

0.0390.4330.8271.2201.614

2.0082.4022.7953.1893.583

0.0790.4720.8661.2601.654

2.0472.4412.8353.2283.622

0.1180.5120.9061.2991.693

2.0872.4802.8743.2683.661

0.1570.5510.9451.3391.732

2.1262.5202.9133.3073.701

0.1970.5910.9841.3781.772

2.1652.5592.9533.3463.740

0.2360.6301.0241.4171.811

2.2052.5982.9923.3863.780

0.2760.6691.0631.4571.850

2.2442.6383.0323.4253.819

0.3150.7091.1021.4961.890

2.2832.6773.0713.4653.858

0.3540.7481.1421.5361.929

2.3232.7173.1103.5043.898

B

A

C


00-17

Millimeters to Inches1 mm = 0.03937 in

Kilogram to Pound1 kg = 2.2046 lb

0 1 2 3 4 5 6 7 8 9

0

10

20

30

40

50

60

70

80

90

0

0.394

0.787

1.181

1.575

1.969

2.362

2.756

3.150

3.543

0.039

0.433

0.827

1.220

1.614

2.008

2.402

2.795

3.189

3.583

0.079

0.472

0.866

1.260

1.654

2.047

2.441

2.835

3.228

3.622

0.118

0.512

0.906

1.299

1.693

2.087

2.480

2.874

3.268

3.661

0.157

0.551

0.945

1.339

1.732

2.126

2.520

2.913

3.307

3.701

0.197

0.591

0.984

1.378

1.772

2.165

2.559

2.953

3.346

3.740

0.236

0.630

1.024

1.417

1.811

2.205

2.598

2.992

3.386

3.780

0.276

0.669

1.063

1.457

1.850

2.244

2.638

3.032

3.425

3.819

0.315

0.709

1.102

1.496

1.890

2.283

2.677

3.071

3.465

3.858

0.354

0.748

1.142

1.536

1.929

2.323

2.717

3.110

3.504

3.898

0 1 2 3 4 5 6 7 8 9

0

10

20

30

40

50

60

70

80

90

0

22.05

44.09

66.14

88.18

110.23

132.28

154.32

176.37

198.42

2.20

24.25

46.30

68.34

90.39

112.44

134.48

156.53

178.57

200.62

4.41

26.46

48.50

70.55

92.59

114.64

136.69

158.73

180.78

202.83

6.61

28.66

50.71

72.75

94.80

116.85

138.89

160.94

182.98

205.03

8.82

30.86

51.91

74.96

97.00

119.05

141.10

163.14

185.19

207.24

11.02

33.07

55.12

77.16

99.21

121.25

143.30

165.35

187.39

209.44

13.23

35.27

57.32

79.37

101.41

123.46

145.51

167.55

189.60

211.64

15.43

37.48

59.53

81.57

103.62

125.66

147.71

169.76

191.80

213.85

17.64

39.68

61.73

83.78

105.82

127.87

149.91

171.96

194.01

216.05

19.84

41.89

63.93

85.98

108.03

130.07

152.12

174.17

196.21

218.26


00-18

Liter to U.S. Gallon1l = 0.2642 U.S. Gal

Liter to U.K. Gallon1l = 0.21997 U.K. Gal

0 1 2 3 4 5 6 7 8 9

0

10

20

30

40

50

60

70

80

90

0

2.642

5.283

7.925

10.567

13.209

15.850

18.492

21.134

23.775

0.264

2.906

5.548

8.189

10.831

13.473

16.115

18.756

21.398

24.040

0.528

3.170

5.812

8.454

11.095

13.737

16.379

19.020

21.662

24.304

0.793

3.434

6.076

8.718

11.359

14.001

16.643

19.285

21.926

24.568

1.057

3.698

6.340

8.982

11.624

14.265

16.907

19.549

22.190

24.832

1.321

3.963

6.604

9.246

11.888

14.529

17.171

19.813

22.455

25.096

1.585

4.227

6.869

9.510

12.152

14.795

17.435

20.077

22.719

25.361

1.849

4.491

7.133

9.774

12.416

15.058

17.700

20.341

22.983

25.625

2.113

4.755

7.397

10.039

12.680

15.322

17.964

20.605

23.247

25.889

2.378

5.019

7.661

10.303

12.944

15.586

18.228

20.870

23.511

26.153

0 1 2 3 4 5 6 7 8 9

0

10

20

30

40

50

60

70

80

90

0

2.200

4.399

6.599

8.799

10.998

13.198

15.398

17.598

19.797

0.220

2.420

4.619

6.819

9.019

11.281

13.418

15.618

17.818

20.017

0.440

2.640

4.839

7.039

9.239

11.438

13.638

15.838

18.037

20.237

0.660

2.860

5.059

7.259

9.459

11.658

13.858

16.058

18.257

20.457

0.880

3.080

5.279

7.479

9.679

11.878

14.078

16.278

18.477

20.677

1.100

3.300

5.499

7.969

9.899

12.098

14.298

16.498

18.697

20.897

1.320

3.520

5.719

7.919

10.119

12.318

14.518

16.718

18.917

21.117

1.540

3.740

5.939

8.139

10.339

12.528

14.738

16.938

19.137

21.337

1.760

3.950

6.159

8.359

10.559

12.758

14.958

17.158

19.357

21.557

1.980

4.179

6.379

8.579

10.778

12.978

15.178

17.378

19.577

21.777


00-19

kgm to ft. lb1 kgm = 7.233 ft. lb

0 1 2 3 4 5 6 7 8 9

0

10

20

30

40

50

60

70

80

90

100

110

120

130

140

150

160

170

180

190

0

72.3

144.7

217.0

289.3

361.7

434.0

506.3

578.6

651.0

723.3

795.6

868.0

940.3

1012.6

1084.9

1157.3

1129.6

1301.9

1374.3

7.2

79.6

151.9

224.2

296.6

368.9

441.2

513.5

585.9

658.2

730.5

802.9

875.2

947.5

1019.9

1092.2

1164.5

1236.8

1309.2

1381.5

14.5

86.8

159.1

231.5

303.8

376.1

448.5

520.8

593.1

665.4

737.8

810.1

882.4

954.8

1027.1

1099.4

1171.7

1244.1

1316.4

1388.7

21.7

94.0

166.4

238.7

311.0

383.4

455.7

528.0

600.3

672.7

745.0

817.3

889.7

962.0

1034.3

1106.6

1179.0

1251.3

1323.6

1396.0

28.9

101.3

173.6

245.9

318.3

390.6

462.9

535.2

607.6

679.9

752.2

824.6

896.9

969.2

1041.5

1113.9

1186.2

1258.5

1330.9

1403.2

36.2

108.5

180.8

253.2

325.5

397.8

470.2

542.5

614.8

687.1

759.5

831.8

904.1

976.5

1048.8

1121.1

1193.4

1265.8

1338.1

1410.4

43.4

115.7

188.1

260.4

332.7

405.1

477.4

549.7

622.0

694.4

766.7

839.0

911.4

983.7

1056.0

1128.3

1200.7

1273.0

1345.3

1417.7

50.6

123.0

195.3

267.6

340.0

412.3

484.6

556.9

629.3

701.6

773.9

846.3

918.6

990.9

1063.2

1135.6

1207.9

1280.1

1352.6

1424.9

57.9

130.2

202.5

274.9

347.2

419.5

491.8

564.2

636.5

708.8

781.2

853.5

925.8

998.2

1070.5

1142.8

1215.1

1287.5

1359.8

1432.1

65.1

137.4

209.8

282.1

354.4

426.8

499.1

571.4

643.7

716.1

788.4

860.7

933.1

1005.4

1077.7

1150.0

1222.4

1294.7

1367.0

1439.4


00-20

kg/cm2 to lb/in2

1kg/cm2 = 14.2233 lb/in2

0 1 2 3 4 5 6 7 8 9

0

10

20

30

40

50

60

70

80

90

100

110

120

130

140

150

160

170

180

190

200

210

220

230

240

0

142.2

284.5

426.7

568.9

711.2

853.4

995.6

1138

1280

1422

1565

1707

1849

1991

2134

2276

2418

2560

2702

2845

2987

3129

3271

3414

14.2

156.5

298.7

440.9

583.2

725.4

867.6

1010

1152

1294

1437

1579

1721

1863

2005

2148

2290

2432

2574

2717

2859

3001

3143

3286

3428

28.4

170.7

312.9

455.1

597.4

739.6

881.8

1024

1166

1309

1451

1593

1735

1877

2020

2162

2304

2446

2589

2731

2873

3015

3158

3300

3442

42.7

184.9

327.1

469.4

611.6

753.8

896.1

1038

1181

1323

1465

1607

1749

1892

2034

2176

2318

2460

2603

2745

2887

3030

3172

3314

3456

56.9

199.1

341.4

483.6

625.8

768.1

910.3

1053

1195

1337

1479

1621

1764

1906

2048

2190

2333

2475

2617

2759

2901

3044

3186

3328

3470

71.1

213.4

355.6

497.8

640.1

782.3

924.5

1067

1209

1351

1493

1636

1778

1920

2062

2205

2347

2489

2631

2773

2916

3058

3200

3343

3485

85.3

227.6

369.8

512.0

654.3

796.5

938.7

1081

1223

1365

1508

1650

1792

1934

2077

2219

2361

2503

2646

2788

2930

3072

3214

3357

3499

99.6

241.8

384.0

526.3

668.5

810.7

953.0

1095

1237

1380

1522

1664

1806

1949

2091

2233

2375

2518

2660

2802

2944

3086

3229

3371

3513

113.8

256.0

398.3

540.5

682.7

825.0

967.2

1109

1252

1394

1536

1678

1821

1963

2105

2247

2389

2532

2674

2816

2958

3101

3243

3385

3527

128.0

270.2

412.5

554.7

696.9

839.2

981.4

1124

1266

1408

1550

1693

1835

1977

2119

2262

2404

2546

2688

2830

2973

3115

3257

3399

3542


00-21

TemperatureFahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Cen-tigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface col-umn 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 ofFahrenheit 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 ofCentigrade values, and read the corresponding Fahrenheit temperature on the right.

1°C = 33.8°F

°C °F °C °F °C °F °C °F

–40.4–37.2–34.4–31.7–28.9

–28.3–27.8–27.2–26.7–26.1

–25.6–25.0–24.4–23.9–23.3

–22.8–22.2–21.7–21.1–20.6

–20.0–19.4–18.9–18.3–17.8

–17.2–16.7–16.1–15.6–15.0

–14.4–13.9–13.3–12.8–12.2

–40–35–30–25–20

–19–18–17–16–15

–14–13–12–11–10

–9–8–7–6–5

–4–3–2–1

0

12345

6789

10

–40.0–31.0–22.0–13.0

–4.0

–2.2–0.4

1.43.25.0

6.88.6

10.412.214.0

15.817.619.421.223.0

24.826.628.430.232.0

33.835.637.439.241.0

42.844.646.448.250.0

–11.7–11.1–10.6–10.0

–9.4

–8.9–8.3–7.8–7.2–6.7

–6.1–5.6–5.0–4.4–3.9

–3.3–2.8–2.2–1.7–1.1

–0.600.61.11.7

2.22.83.33.94.4

5.05.66.16.77.2

1112131415

1617181920

2122232425

2627282930

3132333435

3637383940

4142434445

51.853.655.457.259.0

60.862.664.466.268.0

69.871.673.475.277.0

78.880.682.484.286.0

87.889.691.493.295.0

96.898.6

100.4102.2104.0

105.8107.6109.4111.2113.0

7.88.38.99.4

10.0

10.611.111.712.212.8

13.313.914.415.015.6

16.116.717.217.818.3

18.919.420.020.621.1

21.722.222.823.323.9

24.425.025.626.126.7

4647484950

5152535455

56575859

0

6162636465

6667686970

7172737475

7677787980

114.8116.6118.4120.2122.0

123.8125.6127.4129.2131.0

132.8134.6136.4138.2140.0

141.8143.6145.4147.2149.0

150.8152.6154.4156.2158.0

159.8161.6163.4165.2167.0

168.8170.6172.4174.2176.0

27.227.828.328.929.4

30.030.631.131.732.2

32.833.333.934.435.0

35.636.136.737.237.8

40.643.346.148.951.7

54.457.260.062.765.6

68.371.173.976.779.4

8182838485

8687888990

9192939495

96979899

100

105110115120125

130135140145150

155160165170175

117.8179.6181.4183.2185.0

186.8188.6190.4192.2194.0

195.8197.6199.4201.2203.0

204.8206.6208.4210.2212.0

221.0230.0239.0248.0257.0

266.0275.0284.0293.0302.0

311.0320.0329.0338.0347.0

FOREWORD UNITS

00-22

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}

01 GENERAL

01-1

Specification Dimension DrawingsPC200-7, PC200LC-7 . . . . . . . . . . . 01-2PC220-7, PC220LC-7 . . . . . . . . . . . 01-4

SpecificationsPC200-7, PC200LC-7 . . . . . . . . . . . 01-6PC220-7, PC220LC-7 . . . . . . . . . . . 01-8

Weight TablePC200-7, PC200LC-7 . . . . . . . . . . 01-10PC220-7, PC220LC-7 . . . . . . . . . . 01-12

Fuel, Coolant, And Lubricants. . . . . . . 01-14

PC200-7

GENERAL SPECIFICATION DIMENSION DRAWINGS

01-2 PC200-7

12SPECIFICATION DIMENSION DRAWINGSPC200-7, PC200LC-7

DIMENSIONS

WORKING RANGES


PC200-7 01-3

12DIMENSIONS

WORKING RANGES

Item Unit PC200-7 PC200LC-7

A Overall length mm 9,425 9,425

B Overall height mm 3,000 3,000

C Overall width mm 2,800 3,080

D Track shoe width mm 600 700

E Height of cab mm 3,000 3,000

F Tail swing radius mm 2,750 2,750

G Track overall length mm 4,080 4,450

H Length of track on ground mm 3,270 3,640

Min. ground clearance mm 440 440


A Max. digging reach mm 9,875 9,875

B Max. digging depth mm 6,620 6,620

C Max. digging height mm 10,000 10,000

D Max. vertical wall depth mm 5,980 5,980

E Max. dumping height mm 7,110 7,110

F Min. dumping height mm 2,645 2,645

G Max. reach at ground level mm 2,645 2,645


01-4 PC200-7

PC220-7, PC220LC-7

DIMENSIONS

WORKING RANGES


PC200-7 01-5

12DIMENSIONS

WORKING RANGES


A Overall length mm 9,885 9,885

B Overall height mm 3,160 3,160

C Overall width mm 2,980 3,280

D Track shoe width mm 600 700

E Height of cab mm 3,015 3,015

F Tail swing radius mm 2,940 2,940

G Track overall length mm 4,250 4,640

H Length of track on ground mm 3,460 3,845

Min. ground clearance mm 440 400


A Max. digging reach mm 10,180 10,180

B Max. digging depth mm 6,920 6,920

C Max. digging height mm 10,000 10,000

D Max. vertical wall depth mm 6,010 6,010

E Max. dumping height mm 7,035 7,035

F Min. dumping height mm 2,530 2,530

G Max. reach at ground level mm 10,020 10,020

GENERAL SPECIFICATIONS

01-6 PC200-7

SPECIFICATIONSPC200-7, PC200LC-7

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

Machine model PC200-7 PC200LC-7

Serial Number 200001 and up

Bucket capacity m³ 0.8 0.8

Operating weight kg 19,300 20,700

Per

form

ance

Wo

rkin

g r

ang

es

Max. digging depth

Max. vertical wall depth

Max. digging reach

Max. reach at ground level

Max. digging height

Max. dumping height

mm

mm

mm

mm

mm

mm

6,620

5,980

9,875

9,700

10,000

7,110

6,620

5,980

9,875

9,700

10,000

7,110

Max. digging force

(using power max. function)

Swing speed

Swing max. slope angle

Travel speed

Gradeability

Ground pressure

[standard shoe width]

kN {kg}

rpm

deg.

km/h

deg.

kPa {kg/cm²}

[mm]

138.3 {14,100}

(149.1 {15,200})

12.4

20

Lo: 3.0 ( Mi: 4.1)

Hi: 5.5

35

44.1 {0.45}

[600]

138.3 {14,100}

(149.1 {15,200})

12.4

20

Lo: 3.0 ( Mi: 4.1)

Hi: 5.5

35

36.3 {0.37}

[700]

Dim

ensi

on

s

Overall length (for transport)

Overall width

Overall width of track

Overall height (for transport)

Overall height to chassis

Ground clearance to bottom of upper structure

Min. ground clearance

Tail swing radius

Min. swing radius of work equipment

Height of work equipment at min. swing radius

Length of track on ground

Track gauge

Height of machine cab

mm

mm

mm

mm

mm

mm

mm

mm

mm

mm

mm

mm

mm

9,425

2,800

2,800

3,000

3,000

1,085

440

2,750

3,040

8,005

3,270

2,200

2,335

9,425

3,080

3,080

3,000

3,000

1,085

440

2,750

3,040

8,005

3,640

2,380

2,335


PC200-7 01-7

12



En

gin

e

ModelType

No. of cylinders - bore x strokePiston displacement

mm

llll {cc}

SAA6D102E-2-A4-cycle, water-cooled, in-line, vertical, direct

injection, with turbo charger6 - 102 x 1205.883 {5,883}

Per

form

ance

Flywheel horsepowerMax. torqueMax. speed at no loadMin. speed at no loadMin. fuel consumption

kW/rpm {HP/rpm}Nm/rpm {kgm/rpm}

rpmrpm

g/kWh {g/HPh}

106.7/1,950 {143/1,950}610.0/1,500 {62.2/1,500}

2,1501,030

215 {160}

Starting motorAlternatorBattery

24V, 4.5 kW24V, 35 A

12V, 110 Ah x 2

Radiator core type Corrugated CWX-4

Un

der

-ca

rria

ge

Carrier roller 2 on each side

Track roller 7 on each side 9 on each side

Track shoeAssembly-type triple grouser, 45 on each

side

Assembly-type triple grouser, 49 on each

side

Hyd

rau

lic s

yste

m

Hyd

rau

licp

um

p Type x No.DeliverySet pressure

llll/minMPa (kg/cm²)

HPV95+95, variable displacement

Piston type: 214 x 2Piston type: 37.2 {380}

Co

ntr

ol

valv

e Type x No.Control method

6-spool type x 1Hydraulic

Hyd

rau

licm

oto

r

Travel motor

Swing motor

HMV110ADT-2, Piston type(with brake valve, parking brake): x 2

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

Hyd

rau

lic c

ulin

der

Type

Inside diameter of cylinderDiameter of piston rodStrokeMax. distance between pinsMin. distance between pins

mmmmmmmmmm

Boom Arm Bucket

Double act-ing piston



12085

1,334.53,204.51,870

13595

1,4903,5652,075

11580

1,1202,8001,680

Hrdraulic tankHydraulic filterHydraulic cooler

Closed box typeTank return side

CF40-1 (Air cooled)


01-8 PC200-7

PC220-7, PC220LC-7

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



Bucket capacity m³ 1.0 1.0

Operating weight kg 22,700 24,130

Per

form

ance

Wo

rkin

g r

ang

es

Max. digging depth

Max. vertical wall depth

Max. digging reach

Max. reach at ground level

Max. digging height

Max. dumping height

mm

mm

mm

mm

mm

mm

6,920

6,010

10,180

10,020

10,000

7,035

6,920

6,010

10,180

10,020

10,000

7,035

Max. digging force

(using power max. function)

Swing speed

Swing max. slope angle

Travel speed

Gradeability

Ground pressure

[standard shoe width]

kN {kg}

rpm

deg.

km/h

deg.

kPa {kg/cm²}

[mm]

158.9 {16,200}

(171.6 {17,500})

11.7

25

Lo: 3.1 ( Mi: 4.2)

Hi: 5.5

35

50.0 {0.51}

[600]

158.9 {16,200}

(171.6 {17,500})

11.7

25

Lo: 3.1 ( Mi: 4.2)

Hi: 5.5

35

41.2 {0.42}

[700]

Dim

ensi

on

s

Overall length (for transport)

Overall width

Overall width of track

Overall height (for transport)

Overall height to chassis

Ground clearance to bottom of upper structure

Min. ground clearance

Tail swing radius

Min. swing radius of work equipment

Height of work equipment at min. swing radius

Length of track on ground

Track gauge

Height of machine cab

mm

mm

mm

mm

mm

mm

mm

mm

mm

mm

mm

mm

mm

9,885

2,980

2,980

3,160

3,015

1,110

440

2,940

3,450

8,110

3,460

2,380

2,390

9,885

3,280

3,280

3,160

3,015

1,110

440

2,940

3,450

8,110

3,845

2,580

2,390


PC200-7 01-9



En

gin

e

ModelType

No. of cylinders - bore x strokePiston displacement

mm

llll {cc}

SAA6D102E-2-C4-cycle, water-cooled, in-line, vertical, direct

injection, with turbo charger6 - 102 x 1205.883 {5,883}

Per

form

ance

Flywheel horsepowerMax. torqueMax. speed at no loadMin. speed at no loadMin. fuel consumption

kW/rpm {HP/rpm}Nm/rpm {kgm/rpm}

rpmrpm

g/kWh {g/HPh}

125/2,000 {167/2,000}686/1,500 {70/1,500}

2,2601,060

212 {153}

Starting motorAlternatorBattery

24V, 4.5 kW24V, 35 A

12V, 110 Ah x 2

Radiator core type Corrugated CF19-5

Un

der

-ca

rria

ge

Carrier roller 2 on each side

Track roller 8 on each side 10 on each side

Track shoeAssembly-type triple grouser, 47 on each

side

Assembly-type triple grouser, 51 on each

side

Hyd

rau

lic s

yste

m

Hyd

rau

licp

um

p Type x No.DeliverySet pressure

llll/minMPa (kg/cm²)

HPV95+95, variable displacement

Piston type: 214 x 2Piston type: 37.2 {380}

Co

ntr

ol

valv

e Type x No.Control method

6-spool type x 1Hydraulic

Hyd

rau

licm

oto

r

Travel motor

Swing motor

HMV110ADT-2, Piston type(with brake valve, parking brake): x 2

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

Hyd

rau

lic c

ulin

der

Type

Inside diameter of cylinderDiameter of piston rodStrokeMax. distance between pinsMin. distance between pins

mmmmmmmmmm

Boom Arm Bucket




13090

1,3353,2051,870

140100

1,6352,2353,870

13090

1,0202,6251,605

Hrdraulic tankHydraulic filterHydraulic cooler

Closed box typeTank return side

CF40-1 (Air cooled)

GENERAL WEIGHT TABLE

01-10 PC200-7

12WEIGHT TABLEPC200-7, PC200LC-7

This weight table is for use when handling components or when transporting the machine.

Unit: kg


Serial Number 200001 and up 200001 and up

Engine assembly

• Engine

• Damper

• Hydraulic pump

749

598

6

145

749

598

6

145

Radiator oil cooler assembly 110 110

Hydraulic tank, filter assembly (excluding hydraulic oil) 123 123

Fuel tank (excluding fuel) 121 121

Revolving frame 1,729 1,729

Operator’s cab 278 278

Operator’s 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

Center swivel joint 36 36

Track frame assembly

• Track frame

• Swing circle

• Idler

• Idler cushion

• Carrier roller

• Track roller

• Final drive (including travel motor)

4,194

2,179

273

99 x 2

130 x 2

16 x 4

36 x 14

343 x 2

4,712

2,534

273

99 x 2

135 x 2

16 x 4

36 x 18

343 x 2


PC200-7 01-11

12

Unit: kg



Track shoe assembly

• Standard triple grouser shoe (600 mm)


• Wide triple grouser shoe (800 mm)

• Road liner (rubber pad type) (600 mm)

1,215 x 2

1,405 x 2

1,530 x 2

1,470 x 2

1,325 x 2

1,530 x 2

1,670 x 2

1,600 x 2

Boom assembly 1,408 1,408

Arm assembly 653 653

Bucket assembly 628 628

Boom cylinder assembly 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

Boom pin 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


01-12 PC200-7

PC220-7, PC220LC-7

Unit: kg



Engine assembly

• Engine

• Damper

• Hydraulic pump

749

598

6

145

749

598

6

145

Radiator oil cooler assembly 119 119

Hydraulic tank, filter assembly (excluding hydraulic oil) 123 123

Fuel tank (excluding fuel) 121 121

Revolving frame 2,048 2,048

Operator’s cab 278 278

Operator’s 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

Center swivel joint 36 36

Track frame assembly

• Track frame

• Swing circle

• Idler

• Idler cushion

• Carrier roller

• Track roller

• Final drive (including travel motor)

4,828

2,558

293

99 x 2

135 x 2

16 x 4

36 x 16

362 x 2

5,460

3,046

293

99 x 2

135 x 2

16 x 4

36 x 20

362 x 2


PC200-7 01-13

12

Unit: kg



Track shoe assembly



• Wide triple grouser shoe (800 mm)

• Road liner (rubber pad type) (600 mm)

1,340 x 2

1,470 x 2

1,600 x 2

1,535 x 2

1,455 x 2

1,595 x 2

1,735 x 2

1,665 x 2

Boom assembly 1,825 1,825

Arm assembly 1,213 1,213

Bucket assembly 722 722

Boom cylinder assembly 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

Boom pin 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

GENERAL FUEL, COOLANT, AND LUBRICANTs

01-14 PC200-7

12FUEL, COOLANT, AND LUBRICANTS

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

RESERVOIRKIND OF

FLUID

AMBIENT TEMPERATURE CAPACITY (llll)

-22 -4 14 32 50 68 86 104°F-30 -20 -10 0 10 20 30 40°C

Specified Refill

Engine oil pan 26.3 24

Engineoil

SAE 30

SAE 10W

SAE 10W-30

SAE 15W-40

Damper case 0.75 —

Swing machinery case 6.6 6.6

Final drive case (each side) SAE 30 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

Carrier roller (1 each) 0.075-0.085 0.075-0.085

Hydraulic system 240 143

SAE 10W

SAE 10W-30

SAE 15W-40

Hydraulicoil

H046-HM (�)

Fuel tankDiesel

fuel400 —

ASTM D975 No. 2

ASTM D975A No.1

Cooling system Coolant Add antifreeze

PC200, PC200LC-7

PC200, PC200LC-7

22.4 22.4

PC220, PC220LC-7

PC220, PC220LC-7

30.9 30.9

10 STRUCTURE, FUNCTION, AND MAINTENANCE STANDARD

10-1

1252Engine Related Parts . . . . . . . . . . . . . .10-2Radiator • Oil Cooler • Aftercooler . . .10-3Power Train . . . . . . . . . . . . . . . . . . . . .10-4Final Drive . . . . . . . . . . . . . . . . . . . . . .10-6Swing Machinery

PC200-7, PC200LC-7. . . . . . . . . . . .10-8PC220-7, PC220LC-7. . . . . . . . . . .10-10

Swing CirclePC200-7, PC200LC-7. . . . . . . . . . .10-12PC220-7, PC220LC-7. . . . . . . . . . .10-13

Track Frame • Recoil Spring . . . . . . .10-14Idler. . . . . . . . . . . . . . . . . . . . . . . . . . .10-16Carrier roller. . . . . . . . . . . . . . . . . . . .10-18Track roller . . . . . . . . . . . . . . . . . . . . .10-19Track Shoe . . . . . . . . . . . . . . . . . . . . .10-20Hydraulic Equipment Layout Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-24Hydraulic Tank. . . . . . . . . . . . . . . . . .10-26Hydraulic Pump . . . . . . . . . . . . . . . . .10-28Control Valve

PC200-7, PC200LC-7. . . . . . . . . . .10-50PC220-7, PC220LC-7. . . . . . . . . . .10-64

CLSS . . . . . . . . . . . . . . . . . . . . . . . . . .10-80Self Pressure Reducing Valve. . . . . .10-83Swing Motor . . . . . . . . . . . . . . . . . . .10-86Reverse Prevention Valve. . . . . . . . .10-91Center Swivel Joint . . . . . . . . . . . . . .10-93Travel Motor . . . . . . . . . . . . . . . . . . .10-94Travel Junction Valve . . . . . . . . . . .10-103Travel PPC Shuttle Valve . . . . . . . .10-105Valve Control . . . . . . . . . . . . . . . . . .10-107Work Equipment • Swing PPC Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-108Travel PPC Valve . . . . . . . . . . . . . . .10-112Service PPC Valve . . . . . . . . . . . . . .10-121Solenoid Valve. . . . . . . . . . . . . . . . .10-124PPC Accumulator. . . . . . . . . . . . . . .10-126Return Oil Filter . . . . . . . . . . . . . . . .10-127Boom Hydraulic Drift Prevention Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-128Lift Check Valve . . . . . . . . . . . . . . . .10-131Attachment Circuit Selector Valve .10-132

Hydraulic CylinderPC200-7, PC200LC-7 . . . . . . . . . 10-134PC220-7, PC220LC-7 . . . . . . . . . 10-136

Work Equipment. . . . . . . . . . . . . . . 10-138Air Conditioner . . . . . . . . . . . . . . . . 10-146Engine Control . . . . . . . . . . . . . . . . 10-147Electronic Control System . . . . . . . 10-155Multi Monitor System . . . . . . . . . . 10-1807-Segment Monitor System . . . . . 10-202Sensor . . . . . . . . . . . . . . . . . . . . . . . 10-209

PC200-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ENGINE RELATED PARTS

10-2 PC200-7

12

ENGINE RELATED PARTS

1. Drive plate2. Torsion spring3. Stopper pin4. Friction plate

5. Damper assembly6. Muffler7. Rear engine mount8. Front engine mount

OUTLINE

• The damper assembly is a wet type.Oil capacity: 0.75 llll

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

PC200-7 10-3

RADIATOR • OIL COOLER •AFTERCOOLER

12

RADIATOR • OIL COOLER • AFTERCOOLER

SWP08671

1. Reservoir tank2. Oil cooler3. Radiator4. Fan5. Radiator inlet hose6. Radiator outlet hose7. Radiator cap8. Net9. Shroud10. Aftercooler

SPECIFICATIONS

Radiator : CWX-4 (PC200-7, PC200LC-7): CF19-5 (PC220-7, PC220LC-7)

Oil cooler : CF40-1

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD POWER TRAIN

10-4 PC200-7

12

POWER TRAIN

1. Idler2. Center swivel joint3. Control valve4. Final drive5. Travel motor (HMV 110ADT-2)6. Hydraulic pump (HPV95+95)

7. Engine (SAA6D102E-2)8. Travel speed solenoid valve9. Swing brake solenoid valve10. Swing motor (KMF125ABE-5)11. Swing machinery12. Swing circle

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD FINAL DRIVE

10-6 PC200-7

12

FINAL DRIVE

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD FINAL DRIVE

PC200-7 10-7

12

1. Level plug 2. Drain plug 3. Cover 4. No. 2 sun gear (No. of teeth: 21) 5. No. 1 sun gear (No. of teeth: 10) 4. No. 1 planetary carrier 6. Cover 7. No. 2 planetary carrier 8. Sprocket 9. Floating seal10. Travel motor11. Hub12. No. 2 planetary gear (No. of teeth: 36)13. Ring gear (No. of teeth: 95)14. No. 1 planetary gear (No. of teeth: 42)

SPECIFICATIONS

Reduction ratio:

Unit: mm

No. Check item Criteria Remedy

15Backlash between No. 1 sun gear and No. 1 planetary gear

Standard clearance Clearance limit

Replace

0.15 - 0.49 1.00

16Backlash between No. 1 planetary gear and ring gear

0.17 - 0.57 1.10

17Backlash between No. 1 planetary car-rier and motor

0.06 - 0.25 —


0.14 - 0.46 1.00


0.17 - 0.57 1.10

20Backlash between No. 2 planetary car-rier 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 Repair limit: 6Rebuild or replace23 Width of sprocket tooth

Standard size Repair limit

71 68

00.57121

952110

9510 −=+

+×

+−

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING MACHINERY

10-8 PC200-7

12

SWING MACHINERYPC200-7, PC200LC-7


PC200-7 10-9

12

1. Swing pinion (No. of teeth: 15)2. Spacer3. Case4. No. 2 planetary carrier5. No. 2 sun gear6. Ring gear7. No. 1 sun gear8. Swing motor9. Oil level gauge10. No. 1 planetary gear11. No. 1 planetary carrier12. No. 2 planetary gear 13. Drain plug

SPECIFICATIONS

Reduction ratio:

Unit: mm


14Backlash between swing motor shaft and No. 1 sun gear


Replace

0.18 - 0.28 —


0.16 - 0.50 1.00


0.18 - 0.59 1.10

17Backlash between No. 1 planetary carrier and No. 2 sun gear

0.39 - 0.71 1.20


0.16 - 0.50 0.90


0.18 - 0.59 1.00

20Backlash between No. 2 planetary carrier and swing pinion

0.07 - 0.23 —

21Backlash between swing pinion and swing circle

0.22 - 1.32 2.00

22Clearance between plate and planetary car-rier

0.66 - 1.14 —

23Wear of swing pinion surface contacting with oil seal

Standard size Repair limit Apply hard chrome plating, recondi-tion, or replace115

0—

-0.100

627.1818

581817

5817 =

+×

+


10-10 PC200-7

PC220-7, PC220LC-7


PC200-7 10-11

12

1. Swing pinion (No. of teeth: 13)2. Spacer3. Case4. No. 2 planetary carrier5. No. 2 sun gear6. Ring gear7. No. 1 sun gear8. Swing motor9. Oil level gauge10. No. 1 planetary gear11. No. 1 planetary carrier12. No. 2 planetary gear 13. Drain plug

SPECIFICATIONS

Reduction ratio:

Unit: mm


14Backlash between swing motor shaft and No. 1 sun gear


Replace

0.18 - 0.28 —


0.16 - 0.59 1.00


0.18 - 0.50 1.10

17Backlash between No. 1 planetary carrier and No. 2 sun gear

0.39 - 0.64 1.20


0.16 - 0.44 0.90


0.18 - 0.56 1.00

20Backlash between No. 2 planetary carrier and swing pinion

0.08 - 0.23 —

21Backlash between swing pinion and swing circle

0.23 - 1.37 2.00

22Clearance between plate and planetary car-rier

0.58 - 0.62 —

23Wear of swing pinion surface contacting with oil seal

Standard size Repair limit Apply hard chrome plating, recondi-tion, or replace115

0—

-0.100

689.2214

581417

5817 =

+×

+

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING CIRCLE

10-12 PC200-7

SWING CIRCLEPC200-7, PC200LC-7

1. Swing circle inner race (No. of teeth: 110)2. Ball3. Swing circle outer race

a. Inner race soft zone S positionb. Outer race soft zone S position

SPECIFICATIONS

Reduction ratio:

Amount of grease: 14.6 llll (G2-LI)

Unit: mm


4Axial clearance of bearing(when mounted on chassis)

Standard clearance Clearance limitReplace

0.5 - 1.6 3.2

333.715110 =

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING CIRCLE

PC200-7 10-13

12

PC220-7, PC220LC-7

S*P09097

1. Swing circle inner race (No. of teeth: 92)2. Ball3. Swing circle outer race

a. Inner race soft zone S positionb. Outer race soft zone S position

SPECIFICATIONS

Reduction ratio:

Amount of grease: 15.8 llll (G2-LI)

Unit: mm


4Axial clearance of bearing(when mounted on chassis)

Standard clearance Clearance limitReplace

0.5 - 1.6 3.2

077.71392 −=

−

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRACK FRAME • RECOIL SPRING

10-14 PC200-7

12

TRACK FRAME • RECOIL SPRING

1 Idler2 Track frame3 Carrier roller4 Final drive5 Track roller6 Track shoe7 Center guard8 Recoil spring9 Front guard

• The dimensions and the number of track rollers dependon the model, but the basic structure is not different.

• Number of track rollers

Model Q’ty

PC200-7 7

PC200LC-7 9

PC220-7 8

PC220LC-7 10


PC200-7 10-15

12

Standard shoe

ModelItem

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

No. on track (one side) 45 (pieces) 49 (pieces) 47 (pieces) 51 (pieces)

Unit: mm


10 Vertical width of idler guide

Standard size

Tolerance Repair limit

Rebuild or

replace

Track frame 107

Idler support 105

11Horizontal width of idler guide

Track frame 250

Idler support 247.4

12

Recoil spring


Replace

Free lengthx O.D.

Installation length

Installation load

Free length

Installation load

PC200-7 558 X 238 437108.8 kN

(11,100 kg)534

87.3 kN(8,900 kg)

PC200LC-7PC220-7PC22LC-7

603.5 X 239 466126.5 kN

(12,900 kg)576

100.9 kN(10,300 kg)


10-16 PC200-7

12

IDLER


PC200-7 10-17

12

Unit: mm


1 Outside diameter of protrudingStandard size Repair limit

Rebuild or

replace

538 —

2 Outside diameter of tread 500 488

3 Thickness of tread 26 20

4 Total width 159 —

5 Width of tread 37.5 43.5

6Clearance between shaft and bushing

Standard size

Tolerance Standard clearance

Clearance limit

Replace bushing

Shaft Hole

65-0.250-0.350

+0.074-0.036

0.214 - 0.424 1.5

7Interference between idler and bushing

Standard size

Tolerance Standard interference

Interference limitShaft Hole

72+0.089+0.059

-0.006-0.072

0.065 - 0.161 —


10-18 PC200-7

12

CARRIER ROLLER

Unit: mm


1 Outside diameter of flangeStandard size Repair limit

Replace

145 —


3 Width of tread 43 —

4 Thickness of tread 36.5 29.5

5 Width of flange 14 —

6Interference between shaft and bushing

Standard size



40-0.179-0.190

+0.284+0.169

0.339 - 0.474 —

7Interference between roller and bushing

47-0.061-0.036

0-0.040

0.036 - 0.101 —

8 Axial clearance of rollerStandard clearance Clearance limit

0.44 - 0.76 —


PC200-7 10-19

12

TRACK ROLLER

Unit: mm


1 Outside diameter of flangeStandard size Repair limit

Rebuild or

replace

188 —


3 Thickness of tread 44.5 38.5

4 Overall width 225 —

5 Inside width 85 —

6 Width of tread 44.5 —

7 Width of flange 25.5 —

8Clearance between shaft and bushing

Standard size

Tolerance Standard clearance

Clearance limit

Replace bushing

Shaft Hole

60-0.215-0.315

+0.195 0

0.215 - 0.510 1.5

9Interference between roller and bushing

Standardsize



67-0.153-0.053

+0.030 0

0.023 - 0.153 —

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRACK SHOE

10-20 PC200-7

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 shoe2.Road liner

3.Swamp shoe4.Flat shoe


PC200-7 10-21

12

: Dry type track link

Unit: mm

No.

Check item Criteria Remedy

1 Link pitchStandard size Repair limit

Reverse or replace

190.25 194.25

2 Bushing outside diameterStandard size

When turned

Normal load Impact load

59.3 — 54.3

3 Link heightStandard size Repair limit

Repair or replace

105 97

4Thickness of link metal(bushing press-fitting portion)

28.5 20.5

5

Shoe bolt pitch

160.4

Adjust or replace

6 62

7 18

8

Link

Inside width 84.8

9 Overall width 45.4

10 Tread width 39.6

11 Protrusion of pinRegular 2.5

Master 2.5

12Protrusion of bushing

Regular 4.85

Master 0.0

13Overall length of pin

Regular 212

Master 212

14Overall length of bushing

Regular 138.5

Master 128.7

15Thickness of bushing metal

Standard 10.4 Reverse or replace

When turned / Impact Load

5.4

16 Thickness of spacer —

—

17

Press-fitting force

Bushing 88.2 - 245 kN {9 - 25 ton}

18 Regular pin 127.4 - 274.4 kN {13 - 28 ton}

19Master pin 78.4 - 147 kN {8 - 15 ton}


10-22 PC200-7

12

: Dry type track link

Unit: mm


20Shoe bolt

a. Regular link

Tightening torque(Nm {kgm})

Additional tighteningangle (deg.)

Retighten

Triple shoe490 ± 49 {50 ± 5}

120 ± 10

Road liner(Rubber pad type)

549 ± 59 {56 ± 6}

—

b. Master link

Tightening torque (Nm {kgm})

Additional tighteningangle (deg.)

Lower limit torque(Nm {kgm})

— — —

No. of shoes (each side)PC200-7: 45, PC200LC-7: 49PC220-7: 47, PC220LC-7: 51

—

21Interference betweenbushing and link

Standardsize


Adjust or replace

Shaft Hole

59+0.304+0.394

+0.074 0

0.320 - 0.434

22Interference betweenregular pin and link

38+0.222+0.162

-0.138-0.200

0.300 - 0.422

23Clearance between regular pin and bushing

Standardsize

Tolerance Standard clearanceShaft Hole

38+0.222+0.162

+0.902+0.402

0.180 - 0.740

24Interference between master pin and bushing

Standardsize

Tolerance Standard interferenceShaft Hole

37.8+0.280+0.250

+0.062 0

0.188 - 0.280

25Clearance between master pin and bushing

Standardsize

Tolerance Standard clearanceShaft Hole

38-0.150-0.350

+0.902 +0.402

0.552 - 1.252

Height of grouser

Triple-grouserStandard size Repair limit Lug welding,

rebuild or replace26 16

Road liner 70 25 Replace


PC200-7 10-23

12TRIPLE GROUSER SHOE

SWAMP SHOE

Unit: mm


1 HeightStandard size Repair limit

Rebuild or replace

26 16

2 Thickness 8.5

3Length of base

26

4 19

5

Length at tip

20

6 14

7 19

8 ThicknessStandard size Repair limit

34.5 24.5

9 Height 102.5 90.5

10 Thickness 17 5


10-24 PC200-7

HYDRAULIC EQUIPMENT LAYOUTDRAWING

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


PC200-7 10-25

HYDRAULIC EQUIPMENT LAYOUTDRAWING

12

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC TANK

10-26 PC200-7

12HYDRAULIC TANK

1. Sight gauge2. Hydraulic tank3. Oil filler cap4. Filter element5. Strainer6. Bypass valve7. Suction strainer

SPECIFICATIONSTank capacity: 200 llllAmount of oil inside tank: 143 llllPressure valve

Relief cracking pressure:16.7 ± 6.9 kPa

{0.17 ± 0.07 kg/cm²}Suction cracking pressure:

0 - 0.49 kPa {0 - 0.005 kg/cm²}

Bypass Valve set pressure:150 ± 30 kPa

{1.5 ± 0.3 kg/cm²}

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP

10-28 PC200-7

12

HYDRAULIC PUMP

HPV95 + 95

1. Front main pump2. Rear main pump3. LS valve4. PC valve5. LS-EPC valve6. PC-EPC valve

IM : PC mode selector currentISIG : LS set selector currentPAF : Front pump delivery portPFC : Front pump delivery pres-

sure detection portPAR : Rear pump delivery portPRC : Rear pump delivery pressure

detection portPBF : Pump pressure input portPD1F: Case drain portPENF: Front pump control pressure

detection port

PENR : Rear pump control pressure detec-tion port

PLSF : Front load pressure input portPLSFC: Front load pressure detection portPLSR : Rear load pressure input portPLSRC: Rear load pressure detection portPS : Pump suction portPSIG : LS set selector pressure detection

portPM : PC set selector pressure detection

portPEPC : EPC basic pressure input port

Outline• This pump consists of 2 variable capacity swash plate

piston pumps, PC valve, LS valve, and EPC valve.


PC200-7 10-29

12

1. Shaft (Front)2. Cradle3. Case (Front)4. Rocker cam5. Shoe6. Piston

7. Cylinder block8. Valve plate9. End cap10. Shaft (Rear)11. Case (Rear)12. Servo piston


10-30 PC200-7

12

Function• The rotation and torque transmitted to the

pump shaft are converted into hydraulicenergy, and pressurized oil is dischargedaccording to the load.

• It is possible to change the discharge amountby changing the swash plate angle.

Structure• Cylinder block (7) is supported to shaft (1) by

a spline, and shaft (1) is supported by thefront and rear bearings.

• The tip of piston (6) is a concave ball, andshoe (5) is caulked to it to form one unit. Pis-ton (6) and shoe (5) form a spherical bearing.

• Rocker cam (4) has flat surface A, and shoe(5) is always pressed against this surfacewhile sliding in a circular movement.Rocker cam (4) brings high pressure oil at cyl-inder surface B with cradle (2), which issecured to the case, and forms a static pres-sure bearing when it slides.

• Piston (6) carries out relative movement inthe axial direction inside each cylinder cham-ber of cylinder block (7).

• The cylinder block seals the pressure oil tovalve plate (8) and carries out relative rota-tion. This surface is designed so that the oilpressure balance is maintained at a suitablelevel. The oil inside each cylinder chamber ofcylinder block (7) is sucked in and dischargedthrough valve plate (8).


PC200-7 10-31

12

Operation1) Operation of pump

i Cylinder block (7) rotates together withshaft (1), and shoe (5) slides on flat surfaceA.When this happens, rocker cam (4) movesalong cylindrical surface B, so angle αbetween center line X of rocker cam (4) andthe axial direction of cylinder block (7)changes. (Angle α is called the swash plateangle.)

ii Center line X of rocker cam (4) maintainsswash plate angle α in relation to the axialdirection of cylinder block (7), and flat sur-face A moves as a cam in relation to shoe(5).In this way, piston (6) slides on the inside ofcylinder block (7), so a difference betweenvolumes E and F is created inside cylinderblock (7). The suction and discharge is car-ried out by this difference F - E.In other words, when cylinder block (7)rotates and the volume of chamber Ebecomes smaller, the oil is discharged dur-ing that stroke. On the other hand, the vol-ume of chamber F becomes larger, and asthe volume becomes bigger, the oil issucked in.

iii If center line X of rocker cam (4) is in linewith the axial direction of cylinder block (7)(swash plate angle = 0), the differencebetween volumes E and F inside cylinderblock (7) becomes 0, so the pump does notcarry out any suction or discharge of oil.(In actual fact, the swash plate angle neverbecomes 0.)


10-32 PC200-7

122) Control of discharge amount• If the swash plate angle α becomes larger,

the difference between volumes E and Fbecomes larger and discharge amount Qincreases.

• Swash plate angle α is changed by servopiston (12).

• Servo piston (12) moves in a reciprocalmovement (↔) according to the signalpressure from the PC and LS valves. Thisstraight line movement is transmittedthrough rod (13) to rocker cam (4), androcker cam (4), which is supported by thecylindrical surface to cradle (2), slides in arotating movement in direction of arrow.

• With servo piston (12), the area receivingthe pressure is different on the left andthe right, so main pump discharge pres-sure (self pressure) PP is always broughtto the chamber receiving the pressure atthe small diameter piston end.

• Output pressure Pen of the LS valve isbrought to the chamber receiving thepressure at the large diameter end. Therelationship in the size of pressure PP atthe small diameter piston end and pres-sure Pen at the large diameter end, andthe ratio between the area receiving thepressure of the small diameter piston andthe large diameter piston controls themovement of servo piston (12).


PC200-7 10-33

12

LS VALVE

PC VALVE

1. Plug2. Locknut3. Sleeve4. Spring5. Seat6. Spool7. Piston8. Sleeve

PP : Pump portPDP : Drain portPLP : LS control pressure output portPLS : LS pressure input portPPL : PC control pressure input portPSIG : LS mode selection pilot port

1. Servo piston assembly2. Plug3. Pin4. Spool5. Retainer6. Seat7. Cover8. Wiring

PP1 : Pump portPP2 : Pump pressure pilot portPT : Drain portPM : PC mode selector pressure pilot portPPL : PC control pressure output portPLP : LS control pressure output port


10-34 PC200-7

12Function(1) LS valve

The LS valve detects the load and controls thedischarge amount.This valve controls main pump dischargeamount Q according to differential pressure∆PLS (=PP - PLS) [called the LS differentialpressure] (the difference between main pumppressure PP and control valve outlet portpressure PLS).Main pump pressure PP, pressure PLS {calledthe LS pressure} coming from the controlvalve output, and pressure Psig {called theLS selector pressure} from the proportionalsolenoid valve enter this valve. The relation-ship between discharge amount Q and differ-ential pressure ∆PLS, (the difference betweenmain pump pressure PP and LS pressurePLS) (= PP - PLS) changes as shown in thediagram at the right according to LS pressureselector current isig of the LS-EPC valve.When isig changes between 0 and 1A, the setpressure of the spring changes according tothis, and the selector point for the pump dis-charge amount changes at the rated centralvalve between 0.69 ↔ 2.2 MPa {7 ↔ 22 kg/cm²}.

(2) PC valveWhen the pump discharge pressure PP1(self-pressure) and PP2 (other pump pres-sure) are high, the PC valve controls thepump so that no more oil than the constantflow (in accordance with the discharge pres-sure) flows even if the stroke of the controlvalve becomes larger. In this way, it carriesout equal horsepower control so that thehorsepower absorbed by the pump does notexceed the engine horsepower.In other words, If the load during the opera-tion becomes larger and the pump dischargepressure rises, it reduces the dischargeamount from the pump; and if the pump dis-charge pressure drops, it increases the dis-charge amount from the pump. Therelationship between the average of the frontand rear pump discharge pressures (averagedischarge amount of F, R pumps (PP1 +PP2)/2) and pump discharge amount Q isshown on the right, with the current given tothe PC-EPC valve solenoid shown as a param-eter. The controller senses the actual speed ofthe engine, and if the speed drops because ofan increase in the load, it reduces the pumpdischarge amount to allow the speed torecover. In other words, when the loadincreases and the engine speed drops below

the set value, the command current to the PC-EPC valve solenoid from the controllerincreases according to the drop in the enginespeed to reduce the pump swash plate angle.


PC200-7 10-35

12OPERATION

(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 theinlet port of the control valve brought tospring chamber B, and main pump dischargepressure PP brought to port H of sleeve (8).The size of this LS pressure PLS + force Z ofspring (4) and the main pump pressure (selfpressure) PP determines the position ofspool (6). However, the size of the outputpressure PSIG (the LS selection pressure) ofthe EPC valve for the LS valve entering port Galso changes the position of spool (6). (Theset pressure of the spring changes).

• Before the engine is started, servo piston (11)is pushed to the right. (See the diagram onthe right)

• When the engine is started and the controllever is at the neutral position, LS pressurePLS is 0 MPa {0 kg/cm²}. (It is interconnectedwith the drain circuit through the controlvalve spool.)

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 differ-ence in the area of the piston (11).

SDP08884


10-36 PC200-7

12

2) Operation in increase direction for pumpdischarge amount

• When the difference between the main pumppressure PP and LS pressure PLS, in otherwords, LS differential pressure ∆PLS,becomes smaller (for example, when the areaof opening of the control valve becomeslarger and pump PP drops), spool (6) ispushed to the right by the combined force ofLS pressure PLS and the force of spring (4).

• When spool (6) moves, port D and port E arejoined and connected to the PC valve. Whenthis happens, the PC valve is connected to thedrain port, so circuit D - K becomes drainpressure PT. (The operation of the PC valve isexplained later).

• For this reason, the pressure at the largediameter end of servo piston (12) becomesdrain pressure PT, and pump pressure PPenters port J at the small diameter end, soservo piston (12) is pushed to the right. There-fore, the swash plate moves in the directionto make the discharge amount larger. If theoutput pressure of the EPC valve for the LSvalve enters port G, this pressure creates aforce to move piston (7) to the left. If piston(7) is pushed to the left, it acts to make the setpressure of spring (4) weaker, and the differ-ence between PLS and PP changes whenports D and E of spool (6) are connected.

SDP08885


PC200-7 10-37

12

3) Operation in decrease direction forpump discharge amount

• The following explains the situation if theservo piston (12) moves to the left (the dis-charge amount becomes smaller). When LSdifferential pressure ∆PLS becomes larger(for example, when the area of opening of thecontrol valve becomes smaller and pumppressure PP rises), pump pressure PPpushes spool (6) to the left.

• When spool (6) moves, main port pressurePP flows from port C and port D and fromport K, it enters the large diameter end of thepiston.

• Main pump pressure PP also enters port J atthe small diameter end of the piston, butbecause of the difference in area between thelarge diameter end and the small diameterend of servo piston (12), servo piston (12) ispushed to the left.

• As a result, the swash plate moves in thedirection to make angle smaller.

• If LS selection pressure PSIG enters port G, itacts to make the set pressure of spring (4)weaker.

SDP08886


10-38 PC200-7

12

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 smalldiameter end as A0, and the pressure flowinginto the large diameter end of the piston asPen. If the main pump pressure PP of the LSvalve and the combined force of force Z ofspring (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, andthe swash plate will be kept at an intermedi-ate position. (It will stop at a position wherethe opening of the throttle from port D to portE and from port C to port D of spool (6) isapproximately the same.)

• At this point, the relationship between thearea receiving the pressure at both ends ofpiston (12) is A0 : A1 = 1:2, so the pressureapplied to both ends of the piston when it isbalanced becomes PP : Pen = 2:1.

• The position where spool (6) is balanced andstopped is the standard center, and the forceof spring (4) is adjusted so that it is deter-mined when PP - PLS = 2.2 MPa {22 kg/cm²}.However, if PSIG (the output pressure of 0 ↔2.9 MPa {0 ↔ 30 kg/cm²} of the EPC valve ofthe LS valve) is applied to port G, the balancestop position will change in proportion topressure PSIG between PP - PLS = 2.2 ↔0.69 MPa {22 ↔ 7 kg/cm²}.

SDP08887


PC200-7 10-39

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 low➀ 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 PC-EPC valve and outputs the signal pres-sure. When this signal pressure isreceived, the force pushing piston (2) ischanged.

• On the opposite side to the force pushingthis piston (2) is the spring set pressure ofsprings (4) and (6) and pump pressurePP1 (self pressure) and PP2 (other pumppressure) pushing spool (3). Piston (2)stops at a position where the combinedforce pushing spool (3) is balanced, and

• the pressure (pressure of port C) outputfrom the PC valve changes according tothis position.

• The size of command current X is deter-mined by the nature of the operation(lever operation), the selection of theworking mode, and the set value andactual value for the engine speed.

� Other pump pressureThis is the pressure of the pump at the opposite end.

For the F pump, it is the R pump pressureFor the R pump, it is the F pump pressure


10-40 PC200-7

12

➁ Action of spring• The spring load of springs (4) and (6) in the

PC valve is determined by the swash plateposition.

• If piston (9) moves to the left, spring (6) iscompressed, and if it moves further to the left,spring (6) contacts seat (5) and is fixed inposition. In other words, the spring load ischanged by piston (9) extending or compress-ing springs (4) and (6).

• If the command circuit input to PC-EPC valvesolenoid (1) changes further, the force push-ing piston (2) changes, and the spring load ofsprings (4) and (6) also changes according tothe valve of the PC-EPC valve solenoid com-mand current.

SDP08889


PC200-7 10-41

12

• Port C of the PC valve is connected to port Eof the LS valve (see (1) LS valve). Self pres-sure PP1 enters port B and the small diame-ter end of servo piston (9), and other pumppressure PP2 enters port A.

• When pump pressures PP1 and PP2 aresmall, spool (3) is on the left. At this point,port C and D are connected, and the pressureentering the LS valve becomes drain pressurePT. If port E and port G of the LS valve areconnected (see (1) LS valve), the pressureentering the large diameter end of the pistonfrom port J becomes drain pressure PT, andservo piston (9) moves to the right. In thisway, the pump discharge amount moves inthe direction of increase.

• As servo piston (9) moves further, springs (4)and (6) expand and the spring force becomesweaker. When the spring force becomesweaker, spool (3) moves to the right, so theconnection between port C and port D is cut,and the pump discharge pressure ports B andC are connected. As a result, the pressure atport C rises, and the pressure at the largediameter end of the piston also rises, so themovement of piston (9) to the right isstopped.

• In other words, the stop position for piston (9)(= pump discharge amount) is decided at thepoint where the force of springs (4) and (6)and the pushing force from the PC-EPC valvesolenoid and the pushing force created by thepressures PP1 and PP2 acting on the spool(3) are in balance.


10-42 PC200-7

12

b. When load on actuator is large andpump discharge pressure is high• When the load is large and pump dis-

charge pressures PP1 and PP2 are high,the force pushing spool (3) to the leftbecomes larger and spool (3) moves tothe position in the diagram above. Whenthis happens, as shown in the diagramabove, part of the pressurized oil fromport B flows out through port C where theLS valve is actuated to port D, and thepressurized oil flowing from port C to theLS valve becomes approximately half ofmain pump pressure PP.

• When port E and port G of the LS valveare connected (see (1) LS valve), the pres-sure from port J enters the large diameterend of servo piston (9), and servo piston(9) stops.

• If main pump pressure PP increases fur-ther and spool (3) moves further to theleft, main pump pressure PP1 flows toport C and acts to make the dischargeamount the minimum. When piston (9)moves to the left, springs (4) and (6) arecompressed and push back spool (3).When spool (3) moves to the left, theopening of port C and port D becomeslarger. As a result, the pressure at port C(= J) drops, and piston (9) stops movingto the left.

• The position in which piston (9) stopswhen this happens is further to the leftthan the position when pump pressuresPP1 and PP2 are low.


PC200-7 10-43

12

• The relation of average pump pressure(PP1 + PP2)/2 and the position of servopiston (9) forms a bent line because ofthe double-spring effect of springs (4)and (6). The relationship between aver-age pump pressure (PP1 + PP2)/2 andpump discharge amount Q is shown inthe figure at the right.

• If command voltage X sent to PC-EPCvalve solenoid (1) increases further, therelationship between average pumppressure (PP1 + PP2)/2, and pump dis-charge amount Q is proportional to thepushing force of the PC-EPC valve sole-noid and moves in parallel. In otherwords, the pushing force of PC-EPCsolenoid (1) is added to the force push-ing to the left because of the pump pres-sure applied to the spool (3), so therelationship between the average pumppressure (PP1 + PP2)/2 and Q movesfrom ➀ to ➁ in accordance with theincrease in X.


10-44 PC200-7

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 toswitch to the resistor side. In this case, thepower source is taken directly from thebattery. But if the current is used as it is, itis too large, so use the resistor to controlthe current flowing to PC-EPC valve sole-noid (1).

• When this is done, the current becomesconstant, so the force pushing piston (2)is also constant.

• If the main pump pressure PP1 and PP2are low, the combined force of the pumppressure and the force of PC-EPC valvesolenoid (1) is weaker than the spring setforce, so spool (3) is balanced at a posi-tion to the left.

• At this point, port C is connected to thedrain pressure of port D, and the largediameter end of the piston of servo piston(9) also becomes the drain pressure PTthrough the LS valve. When this happens,the pressure at the small diameter end ofthe piston is large, so servo piston (9)moves in the direction to make the dis-charge amount larger.


PC200-7 10-45

12

b. When main pump load is heavy• In the same way as in the previous item,

when the emergency pump drive switchis ON, the command current sent to PC-EPC valve solenoid (1) becomes constant.For this reason, the force of piston (2)pushing spool (3) is constant.

• If main pump pressures PP1 and PP2increase, spool (3) moves further to theleft than when the main pump load islight, and is balanced at the position inthe diagram above.

• In this case, the pressure from port Aflows to port C, so servo piston (9) movesto the left (to make the discharge amountsmaller) by the same mechanism asexplained in item 2)-b, and stops at aposition to the left of the position whenthe load on the pump is light. In otherwords, even when the emergency pumpdrive switch is ON, the curve for thepump pressure PP

and discharge amount Q is determined asshown in the diagram for the valve of thecurrent sent to the PC-EPC valve solenoidthrough the resistor.The curve when the PC prolix switch isON is curve ➁, which is to the left of curve➀ for when the pump controller is normal.


10-46 PC200-7

12

LS(PC)-EPC VALVE

1. Body2. Spool3. Spring4. Rod

5. Coil6. Plunger7. Connector

PSIG(PM) : To LS(PC) valvePT : To tankPEPC : From self-reducing pressure valve


PC200-7 10-47

12O

FUNCTION

• The EPC valve consists of the proportionalsolenoid portion and the hydraulic valveportion.

• When it receives signal current i from thepump controller, it generates the EPC out-put pressure in proportion to the size of thesignal, and outputs it to the LS valve.

OPERATION

1. When signal current is 0 (coil deener-gized)• When there is no signal current flowing

from the controller to coil (5), coil (5) isgeneralized.

• For this reason, spool (2) is pushed to theright in the direction of the arrow by spring(3).

• As a result, port PEPC closes and the pres-surized oil from the main pump does notflow to the LS valve.At the same time, the pressurized oil fromthe LS valve passes from port PSIG(PM)through port PT and is drained to the tank.

08890


10-48 PC200-7

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 propul-sion force is generated which pushesplunger (6) to the left.

• Push pin (4) pushes spool (2) to the left,and pressurized oil flows from port PEPCto port PSIG(PM).

• When the pressure at port PSIG(PM) risesand the load of spring (3) + the force actingon surface a of spool (2) becomes greaterthan the propulsion force of plunger (6),spool (2) is pushed to the right. The circuitbetween port PEPC and port PSIG(PM) isshut off, and at the same time, portPSIG(PM) and port PT are connected.

• As a result, spool (2) is moved up or downuntil the propulsion force of plunger (6) isbalanced with the load of spring (3) + pres-sure of port PSIG(PM).

• Therefore, the circuit pressure between theEPC valve and the LS valve is controlled inproportion 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 ofplunger (6) is also at its maximum.

• For this reason, spool (2) is pushed fully tothe left by push pin (4).

• As a result, the maximum flow of pressur-ized oil from port PEPC flows to portPSIG(PM), and the circuit pressurebetween the EPC valve and LS valvebecomes the maximum.At the same time, port PT closes and stopsthe oil from flowing to the tank.

08891

08892

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE

10-50 PC200-7

12CONTROL VALVEPC200-7, PC200LC-7

A1 : To bucket cylinder headA2 : To left travel motorA3 : To boom cylinder bottomA4 : To swing motorA5 : To right travel motorA6 : To arm cylinder headA-1 : To attachmentB1 : To bucket cylinder bottomB2 : To left travel motorB3 : To bottom cylinder headB4 : To swing motorB5 : To right travel motorB6 : To arm cylinder bottomB-1 : To attachmentP1 : From bucket PPC valveP2 : From bucket PPC valveP3 : From left travel PPC valveP4 : From left travel PPC valveP5 : From boom PPC valveP6 : From boom PPC valveP7 : From swing PPC valveP8 : From swing PPC valve

P9 : From right travel PPC valveP10 : From right travel PPC valveP11 : From arm PPC valveP12 : From arm PPC valveP-1 : From service PPC valveP-2 : From service PPC valveBP1 : Boom RAISE PPC output pressureBP5 : From attachment circuit selector solenoid

valvePLS1 : To rear pump controlPLS2 : To front pump controlPP1 : From rear main pumpPP2 : From front main pumpPR : To solenoid valve, PPC valve, EPC valvePS : From pump merge-divider solenoid valvePST : From travel junction valvePX1 : From 2-stage solenoid valvePX2 : From 2-stage solenoid valveSA : Pressure sensor fitting portSB : Pressure sensor fitting portT : To tankTS : To tankTSW : To swing motor

1. 6-spool valve2. Cover 13. Cover 24. Pump merge-divider valve5. Back pressure valve6. Boom lock valve7. Service valve

OUTLINE

• This control valve consists of a 6-spoolvalve (unit type), 1 service valves, a pumpmerge-divider valve, a back pressure valve,and a boom hydraulic drift preventionvalve.

• Since all the valves are assembled togetherwith connecting bolts and their passes areconnected to each other inside the assem-bly, the assembly is small in size and easyto maintain.

• Since one spool of this control valve isused for one work equipment unit, its struc-ture is simple.


PC200-7 10-51

127-spool valve(6-spool valve + 1 service valves)

(1/9)


10-52 PC200-7

12(2/9)

S*P09099


PC200-7 10-53

12

1. Unload valve2. 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)

9. Pressure compensation valve (Service)10. Pressure compensation valve (Bucket CURL)11. Pressure compensation valve (Left travel for-

ward)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

(3/9)


10-54 PC200-7

12

1. Spool (Arm)2. Spool (Right travel)3. Spool (Swing)4. Spool (Boom)5. Spool (Left travel)

6. Spool (Bucket)7. Spool (Service)8. Unload valve9. Main relief valve10. Spool return spring

(4/9)

Unit: mm


11 Spool return spring


If damaged or deformed, replace

spring

Free length x Outside diameter

Installed length

Installed load

Free length

Installed load

54.2 x 34.8 51.2416.5 N{42.5 kg}

—333.2 N{34 kg}

12 Spool return spring 54.6 x 34.8 51.2429.9 N{43.9 kg}

—336.1 N{34.3 kg}

13 Spool return spring 54.5 x 34.8 51.2393 N

{40.1 kg}—

314.6 N{32.1 kg}


PC200-7 10-55

12

1. Safety-suction valve (Arm OUT)2. Suction valve (Right travel reverse)3. Suction valve (Boom RAISE)4. Suction valve (Left travel reverse)5. Safety-suction valve (Bucket DUMP)6. Safety-suction valve (Service)7. Safety-suction valve (2-stage) (Service)8. Safety-suction valve (Bucket CURL)9. Suction valve (Left travel forward)10. Safety-suction valve (Boom LOWER)11. Suction valve (Right travel forward)

12. Safety-suction valve (Arm IN)13. LS shuttle valve (Arm)14. LS shuttle valve (Right travel)15. LS select valve16. LS shuttle valve (Boom)17. LS shuttle valve (Left travel)18. LS shuttle valve (Bucket)19. LS shuttle valve (Service)20. LS check valve21. Pressure relief plug

(5/9)

Unit: mm


22 Check valve spring



spring


Installed length

Installed load

Free length

Installed load

11.5 x 4.6 8.51.5 N

{0.15 kg}—

1.2 N{0.12 kg}


10-56 PC200-7

12

(6/9)

1. Unload valve2. Main relief valve3. Safety valve (Boom

RAISE)4. Lift check valve

ARM CONTROL VALVE

5. Safety-suction valve6. Spool7. Pressure compensation valve

(OUT)8. LS shuttle valve9. Pressure compensation valve

(IN)10. Safety-suction valve11. Check valve for regeneration cir-

cuit

R. H. TRAVEL CONTROL VALVE

12. Suction valve13. Spool14. Pressure compensation valve

(Reverse)15. LS shuttle valve16. Pressure compensation valve

(Forward)17. Suction valve


PC200-7 10-57

Unit: mm


18 Relief spring



spring


Installed length

Installed load

Free length

Installed load

30.7 x 9.6 25.9406.7 N{41.5 kg}

—325.6 N{33.2 kg}

19 Valve spring 24.3 x 8 19.569.6 N{7.1 kg}

—55.7 N{5.7 kg}

20 Unload spring 31.5 x 10.2 26.970.6 N{7.2 kg}

—56.4 N{5.8 kg}

21Regeneration valve spring

31.5 x 10.3 196.2 N

{0.6 kg}—

4.9 N{0.5 kg}

22 Piston return spring 48.1 x 10.8 2817.5 N{1.8 kg}

—14.0 N{1.4 kg}


—63.5 N{6.5 kg}

24 Piston return spring 36.9 x 11.1 2829.4 N{3 kg}

—23.5 N{2.4 kg}


10-58 PC200-7

BUCKET CONTROL VALVE

1. Safety-suction valve2. Spool3. Pressure compensation valve (DUMP)4. LS shuttle valve5. Pressure compensation valve (CURL)6. Safety-suction valve

SERVICE VALVE

7. Safety-suction valve8. Spool9. Pressure compensation valve10. LS shuttle valve11. Pressure compensation valve12. Safety-suction valve

Unit: mm


13 Piston return spring



spring


Installed length

Installed load

Free length

Installed load

48.1 x 10.8 2817.5 N{1.8 kg}

—14.0 N{1.4 kg}


—23.5 N{2.4 kg}

(7/9)


10-60 PC200-7

12

(8/9)

SWING CONTROL VALVE

1. Spool2. Pressure compensation

valve (Left)3. LS select valve4. Pressure compensation

valve (Right)

BOOM CONTROL VALVE

5. Suction valve6. Spool7. Pressure compensation

valve (RAISE)8. Hydraulic drift prevention

valve9. LS shuttle valve10. Pressure compensation

valve (Lower)11. Safety-suction valve12. Check valve for regeneration

circuit

L. H. TRAVEL CONTROL VALVE

13. Pump merge-divider valve (Travel junction valve)

14. Return spring15. Suction valve16. Spool17. Pressure compensation

valve (Reverse)18. LS shuttle valve19. Pressure compensation

valve (Forward)20. Suction valve


PC200-7 10-61

Unit: mm


21 Regeneration valve spring



spring


Installed length

Installed load

Free length

Installed load

31.5 x 10.3 196.2 N

{0.6 kg}—

4.9 N{0.5 kg}


—14.0 N{1.4 kg}


—23.5 N{2.4 kg}

24 Load spring 30.4 x 16.7 27428.3 N{43.7 kg}

—343 N

{35.0 kg}

25 Check valve spring 13.6 x 5.5 103.0 N

{0.3 kg}—

2.4 N{0.25 kg}

26 Check valve spring 33.0 x 12.0 2635.3 N{3.6 kg}

—28.2 N{2.9 kg}

27 Check valve spring 16.4 x 8.9 11.513.7 N{1.4 kg}

—11.0 N{1.1 kg}

28 Spool return spring 30.7 x 20.5 2350.0 N{5.1 kg}

—40.0 N{4.1 kg}


10-62 PC200-7

12

1. Unload valve2. Main relief valve3. Pump merge-divider valve (Main)4. Return spring5. Pump merge-divider valve (For LS)6. Return spring7. Valve (Sequence valve)8. Spring (Sequence valve)

9. LS bypass plug10. Screw11. Poppet12. Spring (Pressure reducing valve pilot)13. Spring (Pressure reducing valve main)14. Valve (Pressure reducing valve)15. Spring (Safety valve)16. Ball

(9/9)


PC200-7 10-63

Unit: mm


17 Valve spring



spring


Installed length

Installed load

Free length

Installed load

24.3 x 8 19.569.6 N{7.1 kg}

—55.7 N{5.7 kg}

18 Unload spring 31.5 x 10.2 2683.4 N{8.5 kg}

—66.7 N{6.8 kg}

19 Check valve spring 11.5 x 4.6 8.51.5 N

{0.15 kg}—

1.2 N{0.12 kg}


—125.5 N{12.8 kg}


—142.0 N{14.5 kg}

22 Sequence valve spring 70.9 x 18.0 59199.8 N{20.4 kg}

—160.0 N{16.3 kg}


—8.3 N

{0.8 kg}

24 Relief spring 34.7 x 10.4 32.3430.2 N{43.9 kg)

—344.2 N{35.1 kg}


10-64 PC200-7

CONTROL VALVEPC220-7, PC220LC-7

A1 : To bucket cylinder headA2 : To left travel motorA3 : To boom cylinder bottomA4 : To swing motorA5 : To right travel motorA6 : To arm cylinder headA-1 : To attachmentB1 : To bucket cylinder bottomB2 : To left travel motorB3 : To bottom cylinder headB4 : To swing motorB5 : To right travel motorB6 : To arm cylinder bottomB-1 : To attachmentP1 : From bucket PPC valveP2 : From bucket PPC valveP3 : From left travel PPC valveP4 : From left travel PPC valveP5 : From boom PPC valveP6 : From boom PPC valveP7 : From swing PPC valveP8 : From swing PPC valve

P9 : From right travel PPC valveP10 : From right travel PPC valveP11 : From arm PPC valveP12 : From arm PPC valveP-1 : From service PPC valveP-2 : From service PPC valveBP1 : Boom RAISE PPC output pressureBP5 : From attachment circuit selector solenoid

valvePLS1 : To rear pump controlPLS2 : To front pump controlPP1 : From rear main pumpPP2 : From front main pumpPR : To solenoid valve, PPC valve, EPC valvePS : From pump merge-divider solenoid valvePST : From travel junction valvePX1 : From 2-stage solenoid valvePX2 : From 2-stage solenoid valveSA : Pressure sensor fitting portSB : Pressure sensor fitting portT : To tankTS : To tankTSW : To swing motor

1. 6-spool valve2. Cover 13. Cover 24. Pump merge-divider valve5. Back pressure valve6. Boom lock valve7. Service valve

OUTLINE

• This control valve consists of a 6-spoolvalve (unit type), 1 service valves, a pumpmerge-divider valve, a back pressure valve,and a boom hydraulic drift preventionvalve.

• Since all the valves are assembled togetherwith connecting bolts and their passes areconnected to each other inside the assem-bly, the assembly is small in size and easyto maintain.

• Since one spool of this control valve isused for one work equipment unit, its struc-ture is simple.


PC200-7 10-65

127-spool valve(6-spool valve + 1 service valves)

(1/9)


10-66 PC200-7

12(2/9)

S*P09102


PC200-7 10-67

12

1. Unload valve2. 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)

9. Pressure compensation valve (Service)10. Pressure compensation valve (Bucket CURL)11. Pressure compensation valve (Left travel for-

ward)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

(3/9)


10-68 PC200-7

12

1. Spool (Arm)2. Spool (Right travel)3. Spool (Swing)4. Spool (Boom)5. Spool (Left travel)

6. Spool (Bucket)7. Spool (Service)8. Unload valve9. Main relief valve10. Spool return spring

(4/9)

S*P09104

Unit: mm


11 Spool return spring



spring


Installed length

Installed load

Free length

Installed load

54.2 x 34.8 51.2416.5 N{42.5 kg}

—333.2 N{34 kg}


—336.1 N{34.3 kg}

13 Spool return spring 54.5 x 34.8 51.2393 N

{40.1 kg}—

314.6 N{32.1 kg}


PC200-7 10-69

12

1. Safety-suction valve (Arm OUT)2. Suction valve (Right travel reverse)3. Suction valve (Boom RAISE)4. Suction valve (Left travel reverse)5. Safety-suction valve (Bucket DUMP)6. Safety-suction valve (Service)7. Safety-suction valve (2-stage) (Service)8. Safety-suction valve (Bucket CURL)9. Suction valve (Left travel forward)10. Safety-suction valve (Boom LOWER)11. Suction valve (Right travel forward)

12. Safety-suction valve (Arm IN)13. LS shuttle valve (Arm)14. LS shuttle valve (Right travel)15. LS select valve16. LS shuttle valve (Boom)17. LS shuttle valve (Left travel)18. LS shuttle valve (Bucket)19. LS shuttle valve (Service)20. LS check valve21. Pressure relief plug

(5/9)

Unit: mm





spring


Installed length

Installed load

Free length

Installed load

11.5 x 4.6 8.51.5 N

{0.15 kg}—

1.2 N{0.12 kg}


10-70 PC200-7

12

(6/9)

S*P09105

1. Unload valve2. Main relief valve3. Safety valve (Boom

RAISE)4. Lift check valve

ARM CONTROL VALVE

5. Safety-suction valve6. Spool7. Pressure compensation valve

(OUT)8. LS shuttle valve9. Pressure compensation valve

(IN)10. Safety-suction valve11. Check valve for regeneration cir-

cuit

R. H. TRAVEL CONTROL VALVE

12. Suction valve13. Spool14. Pressure compensation valve

(Reverse)15. LS shuttle valve16. Pressure compensation valve

(Forward)17. Suction valve


PC200-7 10-71

Unit: mm


18 Relief spring



spring


Installed length

Installed load

Free length

Installed load

34.7 x 10.4 32.3430.2 N{43.9 kg}

—344.2 N{35.1 kg}

19 Valve spring 10.45 x 7 4.83.1 N

{0.32 kg}—

2.5 N{0.26 kg}


—56.4 N{5.8 kg}

21Regeneration valve spring

31.5 x 10.3 196.2 N

{0.6 kg}—

4.9 N{0.5 kg}


—14.0 N{1.4 kg}


—63.5 N{6.5 kg}


—23.5 N{2.4 kg}


10-72 PC200-7

BUCKET CONTROL VALVE

1. Safety-suction valve2. Spool3. Pressure compensation valve (DUMP)4. LS shuttle valve5. Pressure compensation valve (CURL)6. Safety-suction valve

SERVICE VALVE

7. Safety-suction valve8. Spool9. Pressure compensation valve10. LS shuttle valve11. Pressure compensation valve12. Safety-suction valve

Unit: mm


13 Piston return spring



spring


Installed length

Installed load

Free length

Installed load

48.1 x 10.8 2817.5 N{1.8 kg}

—14.0 N{1.4 kg}


—23.5 N{2.4 kg}

(7/9)


10-74 PC200-7

12

SWING CONTROL VALVE

1. Spool2. Pressure compensation

valve (Left)3. LS select valve4. Pressure compensation

valve (Right)

BOOM CONTROL VALVE

5. Suction valve6. Spool7. Pressure compensation

valve (RAISE)8. Hydraulic drift prevention

valve9. LS shuttle valve10. Pressure compensation

valve (Lower)11. Safety-suction valve12. Check valve for regeneration

circuit

L. H. TRAVEL CONTROL VALVE

13. Pump merge-divider valve (Travel junction valve)

14. Return spring15. Suction valve16. Spool17. Pressure compensation

valve (Reverse)18. LS shuttle valve19. Pressure compensation

valve (Forward)20. Suction valve

(8/9)


PC200-7 10-75

Unit: mm


21 Regeneration valve spring



spring


Installed length

Installed load

Free length

Installed load

31.5 x 10.3 196.2 N

{0.6 kg}—

4.9 N{0.5 kg}


—14.0 N{1.4 kg}


—23.5 N{2.4 kg}

24 Load spring 30.4 x 16.7 27428.3 N{43.7 kg}

—343 N

{35.0 kg}

25 Check valve spring 13.6 x 5.5 103.0 N

{0.3 kg}—

2.4 N{0.25 kg}

26 Check valve spring 33.0 x 12.0 2635.3 N{3.6 kg}

—28.2 N{2.9 kg}


—11.0 N{1.1 kg}


—40.0 N{4.1 kg}


10-76 PC200-7

12

1. Unload valve2. Main relief valve3. Pump merge-divider valve (Main)4. Return spring5. Pump merge-divider valve (For LS)6. Return spring7. Valve (Sequence valve)8. Spring (Sequence valve)

9. LS bypass plug10. Screw11. Poppet12. Spring (Pressure reducing valve pilot)13. Spring (Pressure reducing valve main)14. Valve (Pressure reducing valve)15. Spring (Safety valve)16. Ball

(9/9)


PC200-7 10-77

Unit: mm


17 Valve spring



spring


Installed length

Installed load

Free length

Installed load

10.45 x 7 4.83.1 N

{0.32 kg}—

2.5 N{0.26 kg}


—56.4 N{5.8 kg}

19 Check valve spring 11.5 x 4.6 8.51.5 N

{0.15 kg}—

1.2 N{0.12 kg}


—125.5 N{12.8 kg}


—142.0 N{14.5 kg}

22 Sequence valve spring 70.9 x 18.0 59199.8 N{20.4 kg}

—160.0 N{16.3 kg}


—8.3 N

{0.8 kg}

24 Relief spring 34.7 x 10.4 32.3430.2 N{43.9 kg)

—344.2 N{35.1 kg}


10-78 PC200-7

MAIN RELIEF VALVE

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 theset pressure becomes higher.

1. Spring2. Poppet


PC200-7 10-79

12

VARIABLE PRESSURE COMPENSATION VALVE

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CLSS

10-80 PC200-7

12

CLSS

OUTLINE OF CLSS

FEATURES

• CLSS stands for Closed center Load SensingSystem, and has the following features.

1) Fine control not influenced by load2) Control enabling digging even with fine con-

trol3) 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

STRUCTURE

• The CLSS consists of a main pump (2pumps), control valve, and actuators for thework equipment.

• The main pump body consists of the pumpitself, the PC valve and LS valve.


PC200-7 10-81

Basic principle1) Control of pump swash plate• The pump swash plate angle (pump dis-

charge amount) is controlled so that LS dif-ferential pressure ∆PLS (the differencebetween pump pressure PP and controlvalve outlet port LS pressure PLS) (loadpressure of actuator) is constant.(LS pressure ∆PLS = Pump discharge pres-sure PP – LS pressure PLS)

• If LS differential pressure ∆PLS becomeslower than the set pressure of the LS valve(when the actuator load pressure is high),the pump swash plate moves towards themaximum position; if it becomes higherthan the set pressure of the LS valve (whenthe actuator load pressure is low), thepump swash plate moves towards the min-imum position.


10-82 PC200-7

2) Pressure compensation• A pressure compensation valve is installed to

the outlet port side of the control valve to bal-ance the load.

• When two actuators are operated together,this valve acts to make pressure difference ∆Pbetween the upstream (inlet port) and down-stream ( outlet port) of the spool of each valvethe same regardless of the size of the load(pressure).

In this way, the flow of oil from the pump isdivided (compensated) in proportion to thearea of opening S1 and S2 of each valve.

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SELF PRESSURE REDUCING VALVE

PC200-7 10-83

SELF PRESSURE REDUCING VALVE

FUNCTION

• This value reduces the discharge pressureof the main pump and supplies it as controlpressure for the solenoid valves, PPCvalves, etc..

OPERATION

1. When engine is stopped• Puppet (11) is pressed by spring (12)

against the seat and port PR is not con-nected to TS.

• Valve (14) is pressed by spring (13) againstthe left side and port P2 is connected to PR.

• Valve (7) is pressed by spring (8) againstthe left side and port P2 is not connected toA2.(See Fig. 1.)


10-84 PC200-7

2. When in neutral or load pressure P2 islow (When boom is lowered and arm is in INposition and they are moving down underown weight)

Note: When load pressure A2 is lower than self-pres-sure reducing valve output pressure PR.

• Valve (7) receives the force of spring (8) andPR pressure (which is 0 MPa {0 kg/cm²} whenthe engine is stopped) in the direction to closethe circuit between ports P2 and A2. If thehydraulic oil flows in port P2, the φdx P2 pres-sure becomes equal to the total of the force ofspring (8) and the value of area of ∅d x PRpressure, then the area of the pass betweenports P2 and A2 is so adjusted that the P2pressure will be kept constant above the PRpressure.

• If the PR pressure rises above the set level,puppet (11) opens and the hydraulic oil flowsfrom the PR port through orifice "a" in spool(14) and open part of puppet (11) to seal drainport TS.Accordingly, differential pressure is generatedbetween before and after orifice "a" in spool(14) and then spool (14) moves to close thepass between port P2 and PR. The P2 pres-sure is controlled constant (at the set pres-sure) by the area of the oil pass at this timeand supplied as the PR pressure. (See Fig. 2.)

3. When load pressure P2 is high• If load pressure A2 rises and the pump dis-

charge increases because of operation of thework equipment, the φdx P2 pressure riseshigher than the total of the force of spring (8)and the value of ∅d x PR pressure, and thenvalve (7) moves to the right stroke end.

• As a result, the area of the pass between portsP2 and A2 increases and the pass resistancelowers and the loss of the engine power isreduced.

• If the PR pressure rises above the set pres-sure, puppet (11) opens and the hydraulic oilflows from the PR port through orifice "a" inspool (14) and open part of puppet (11) to sealdrain port TS.Accordingly, differential pressure is generatedbetween before and after orifice "a" in spool(14) and then spool (14) moves to close thepass between port P2 and PR. The P2 pres-sure is controlled constant (at the set pres-sure) by the area of the oil pass at this timeand supplied as the PR pressure. (See Fig. 3.)


PC200-7 10-85

12

4. When abnormally high pressure isgenerated

• If the PR pressure on the self-pressurereducing valve rises high abnormally, ball(16) separates from the seat against theforce of spring (15) and the hydraulic oilflows from output port PR to TS. Accord-ingly, the PR pressure lowers. By this oper-ation, the hydraulic devices (PPC valves,solenoid valves, etc.) are protected fromabnormal pressure. (See Fig. 4.)

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING MOTOR

10-86 PC200-7

12

SWING MOTOR

KMF125ABE-5

B : From swing lock solenoid valveS : From control valveT : To tankMA: From control valveMB : From control valve

SPECIFICATIONS

PC200-7 PC220-7

Model KMF125ABE-5

Theoretical displacement 125.0 cm³/rev

Safety valve set pressure 28.4 MPa {290 kg/cm²}

Rated revolving speed 1,694 rpm 1,879 rpm

Brake release pressure 1.9 MPa {19 kg/cm²}


PC200-7 10-87

12

1. Brake spring2. Drive shaft3. Spacer4. Case5. Disc6. Plate7. Brake piston

8. Housing9. Piston10. Cylinder block11. Valve plate12. Reverse prevention valve13. Center shaft14. Center spring

15. Safety valve16. Check valve17. Check valve spring18. Shuttle valve19. Shuttle valve spring


10-88 PC200-7

12

Unit: mm





spring


Installed length

Installed load

Free length

Installed load

62.5 x 20.0 353.5 N

{0.36 kg}—

2.8 N{0.29 kg}

2 Shuttle valve spring 16.4 x 8.9 11.513.7 N{1.4 kg}

—10.8 N{1.1 kg}


PC200-7 10-89

12

Operation of swing lock1. When swing lock solenoid valve is deacti-

vatedWhen the swing lock solenoid valve is deacti-vated, the pressurized oil from the main pump isshut off and port B is connected to the tank cir-cuit.As a result, brake piston (7) is pushed down bybrake spring (1), discs (5) and plates (6) arepushed together, and the brake is applied.

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


10-90 PC200-7

12

RELIEF VALVE PORTION

1) OutlineThe relief portion consists of check valves(2) and (3), shuttle valves (4) and (5), andrelief valve (1).

2. FunctionWhen the swing is stopped, the outlet portcircuit of the motor from the control valveis closed, but the motor continues to rotateunder inertia, so the pressure at the outputside of the motor becomes abnormallyhigh, and this may damage the motor.To prevent this, the abnormally high pres-sure oil is relieved to port S from the outletport of the motor (high-pressure side) toprevent any damage.

3. Operation1) When starting swing• When the swing control lever is operated

to swing right, the pressure oil from thepump passes through the control valve andis supplied to port MA. As a result, thepressure at port MA rises, the startingtorque is generated in the motor, and themotor starts to rotate. The oil from the out-let port of the motor passes from port MAthrough the control valve and returns tothe tank. (Fig. 1)

2) When stopping swing• When the swing control lever is returned to

neutral, the supply of pressure oil from thepump to port MA is stopped. With the oilfrom the outlet port of the motor, the returncircuit to the tank is closed by the controlvalve , so the pressure at port MB rises. Asa result, rotation resistance is generated inthe motor, so the braking effect starts.

• If the pressure at port MB becomes higherthan the pressure at port MA, it pushesshuttle valve A (4) and chamber Cbecomes the same pressure as port MB.The oil pressure rises further until itreaches the set pressure of relief valve (1).As a result, a high braking torque acts onthe motor and stops the motor. (Fig.2)

• When relief valve (1) is being actuated, therelief oil and oil from port S passesthrough check valve B (3) and is supplied toport MA. This prevents cavitation at portMA.

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD REVERSE PREVENTION VALVE

PC200-7 10-91

12

REVERSE PREVENTION VALVE

Operation diagram

1. Valve body2. Spool (MA side)3. Spring (MA side)4. Plug5. Spool (MB side)6. Spring (MB side)7. Plug

Explanation of effect

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD REVERSE PREVENTION VALVE

10-92 PC200-7

12

OutlineThis valve reduces the swing back genera-tion in the swing body by the inertia of theswing body, the backlash and rigidity of themachinery system, and the compression ofthe hydraulic oil when the swing isstopped. This is effective in preventingspillage of the load and reducing the cycletime when stopping the swing (the posi-tioning ability is good and it is possible tomove swiftly to the next job.

Operation1) When brake pressure is being gener-

ated 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 connectedto e.When this happens, pressure MA is belowthe set pressure of spring (3), so spool (2)does not move. For this reason, the pres-sure oil is closed by spool (2), and the brak-ing force is ensured.

2) After motor stops• The motor is reversed by the closing pres-

sure generated at port MB. (1st reversal)When this happens, reversal pressure isgenerated at port MA. Pressure MA goesto chamber a, so spool (2) pushes spring (3)and moves to the right, and MA is con-nected to B. At the same time, b is con-nected to f through the drill hole in spool(5), so the reversal pressure at port MA isbypassed to port T to prevent the 2ndreversal.

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CENTER SWIVEL JOINT

PC200-7 10-93

12

CENTER SWIVEL JOINT

1. Cover2. Body3. Slipper seal4. O-ring5. Shaft

A1. To L.H. travel motor port PBA2. From control valve port A5C1. To R.H. travel motor port PAB2. From control valve port B5D1. To R.H. travel motor port PBE. To L.H. and R.H. travel motors port P

T2. To tankT1. From L.H. and R.H. travel motors port TD2. From control valve port B2B1. To L.H. travel motor port PAC2. From control valve port A2

Unit: mm

No. Check Item Criteria Remedy

6Clearance between rotor

and shaftReplace

Standard Size Standard clearance Repair limit

80 — —

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL MOTOR

10-94 PC200-7

TRAVEL MOTOR

HMV110-2

P : From travel speed solenoid valveT : To tankPA : From control valvePB : From control valveMA: MA pressure pickup portMB: MB pressure pickup port

SPECIFICATIONS

ModelItem

PC200-7 PC220-7

Type HMV110-2

TheoreticalDelivery

Min. 78.6 cm³/rev 74 cm³/rev

Max. 106.2 cm³/rev 110.7 cm³/rev

Set pressure 37.3 MPa {380 kg/cm²}

Rated speed

Min.Capacity

2,805 rpm 3,046 rpm

Max.capacity

1,842 rpm 1,588 rpm

Brake releasing pressure 1.2 MPa {12 kg/cm²}

Travel speed switching pressure

Differential pressure

0.8 MPa {8 kg/cm²}


PC200-7 10-95

12

1. Regulator piston2. Spring3. Regulator valve4. Spring5. Motor case6. Suction safety valve spring7. Suction safety valve8. Check valve

9. Check valve spring10. Output shaft11. Rocker cam12. Retainer guide13. Pin14. Piston15. Retainer16. Cylinder

17. Valve plate18. Counterbalance valve19. Ring20. Spool return spring21. Brake piston22. Plate23. Disc24. Ball


10-96 PC200-7

12

Unit: mm


1Check valve spring


If damaged or deformed,

replace spring


Installed length

Installed load

Free length

Installed load

PC200-7 31.6 x 6.5 24.22.55 N

{0.26 kg}—

1.96 N{0.2 kg}

PC220-7 31.6 x 6.5 24.27.16 N

{0.73 kg}—

5.73 N{0.58 kg}


—1.57 N

{0.16 kg}

3 Return spring 58.43 x 30 42.6411 N

{41.9 kg}—

329 N{33.5 kg}

4 Regulator valve spring 21.5 x 11.1 17.155 N

{5.6 kg}—

44 N{4.5 kg}


PC200-7 10-97

OPERATION OF MOTOR1) Motor swash plate angle at maximum

• The solenoid valve is deactivated, so the pilotpressure oil from the main pump does notflow to port P.For this reason, regulator valve (9) is pushedto the right in the direction of the arrow byspring (10).

• Because of this, it pushes check valve (22),and the main pressure oil from the controlvalve going to end cover (8) is shut off by reg-ulator valve (9).

• Fulcrum a of rocker cam (4) is eccentric topoint of force b of the combined force of thepropulsion force of cylinder (6), so the com-bined force of the piston propulsion force actsas a moment to angle rocker cam (4) in thedirection of the maximum swash plate angle.

• At the same time, the pressurized oil at regu-lator piston (15) passes through orifice c inregulator valve (9) and is drained to the motorcase.

• As a result, rocker cam (4) moves in the maxi-mum swash plate angle direction, the motorcapacity becomes maximum.

SJP08742

OR

08893


10-98 PC200-7

12

2) Motor swash plate angle at minimum

• When the solenoid valve is excited, the pilotpressure oil from the main pump flows toport P, and pushes regulator valve (9) to theleft direction of the arrow.

• Because of this, the main pressure oil fromthe control valve passes through passage d inregulator valve (9), enters regulator piston(15) at the bottom, and pushes regulator pis-ton (15) to the right in the direction of thearrow.

• As a result, rocker cam (4) moves in the mini-mum swash plate angle direction, the motorcapacity becomes minimum.

SJP08743

OR

08894


PC200-7 10-99

12

OPERATION OF PARKING BRAKE1) When starting to travel

When the travel lever is operated, the pres-surized oil from the pump actuates coun-terbalance 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 direc-tion 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 travelWhen 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 pis-ton returns, and this ensures that the brake is still effective after the machine stops.

SJP08744

OR

08895

SJP08745

OR

08896


10-100 PC200-7

OPERATION OF BRAKE VALVE• The brake valve consists of a suction safety

valve (18A), counterbalance valve (18) in acircuit as shown in the diagram on theright. (Fig. 1)

• The function and operation of each compo-nent is as given below.

1) Counterbalance valve, check valveFunction• When traveling downhill, the weight of the

machine makes it try to travel faster thanthe speed of the motor.As a result, if the machine travels with theengine at low speed, the motor will rotatewithout load and the machine will runaway, which is extremely dangerous.To prevent this these valves act to make themachine travel according to the enginespeed (pump discharge amount).

Operation when pressure oil is supplied• When the travel lever is operated, the pres-

surized oil from the control valve is sup-plied to port PA. It pushes open suctionsafety valve (18A) and flows from motorinlet port MA to motor outlet port MB.However, the motor outlet port is closed bysuction safety valve (18B) and spool (19),so the pressure at the supply side rises.(Fig. 2)

• The pressurized oil at the supply side flowsfrom orifice E1 and E2 in spool (19) tochamber S1. When the pressure in cham-ber S1 goes above the spool switchingpressure, spool (19) is pushed to the rightin the direction of the arrow.As a result, port MB and port PB are con-nected, the outlet port side of the motor isopened, and the motor starts to rotate. (Fig.3)

SAP03482

OR

08897


PC200-7 10-101

Operation of brake when traveling downhill• If the machine tries to run away when travel-

ing downhill, the motor will turn under noload, so the pressure at the motor inlet portwill drop, and the pressure in chamber S1through orifices E1 and E2 will also drop.When the pressure in chamber S1 dropsbelow the spool switching pressure, spool(19) is returned to the left, in the direction ofthe arrow by spring (20), and outlet port MBis throttled.As a result, the pressure at the outlet portside rises, resistance is generated to the rota-tion of the motor, and this prevents themachine from running away.In other words, the spool moves to a positionwhere the pressure at the outlet port MB bal-ances the pressure at the inlet port and theforce generated by the weight of themachine. It throttles the outlet port circuitand controls the travel speed according tothe amount of oil discharged from the pump.(Fig. 4)

2) Safety valveFunction• When travel is stopped (or when traveling

downhill), the circuits at the inlet and outletports of the motor are closed by the counter-balance valve, but the motor is rotated byinertia, so the pressure at the outlet port ofthe motor will become abnormally high anddamage the motor or piping. The safetyvalve acts to release this abnormal pressureand send it to the inlet port side of the motorto prevent damage to the equipment.

Operation1. When travel is stopped (or when travel-

ing downhill, rotating to right)• When the motor inlet port pressure (pressure

PA) goes down, the pressure in chamber S1also goes down. When it goes below theswitching pressure of the spool, spool isreturned to the left by spring (20), and outletport passage B1 is throttled. When this hap-pens, the motor continues to rotate underinertia, so the outlet pressure (pressure MB)rises. (Fig. 5)

• If the pressure goes above the set pressureof suction-safety valve (18A), the poppetopens. The oil then passes through largenotch A1 in counterbalance valve spool (19)and flows to chamber MA in the circuit onthe opposite side. (Fig. 6)

2. When rotating to left The operation is the reverse of when rotating

to the right.


10-102 PC200-7

2) When starting travel (or during normal travel)

• When the travel lever is operated, the pres-sure oil from the pump moves counterbal-ance valve spool (19) to the right. Whenthis happens, the passage to the suction-safety valve becomes the circuit flowingthrough the small notch B2 in the counter-balance valve spool. As a result, a big dif-ference in pressure is created, and thepump pressure rises to provide a powerfuldrawbar pull. (Fig. 7)

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL JUNCTION VALVE

PC200-7 10-103

TRAVEL JUNCTION VALVE

Function• This valve connects both travel circuits to each

other so that the hydraulic oil will be suppliedevenly to both travel motors and the machine willtravel straight.

• When the machine is steered, outside pilot pres-sure PST closes the travel junction valve to securehigh steering performance.

OperationWhen pilot pressure is turned ON• If the pilot pressure from the travel junction sole-

noid valve becomes higher than the force ofspring (14), travel junction spool (13) moves to theleft stroke end and the junction circuit betweenport PTL (Left travel circuit) and PTR (Right travelcircuit) is closed.

SU(V)P08730

OR

08898

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL JUNCTION VALVE

10-104 PC200-7

When pilot pressure is turned OFF• If pilot pressure PST from the sole-

noid valve is 0, travel junction spool(13) is pressed by the force of spring(14) against the right side and thepass between ports PTL and PTR isopen.

• If the oil flow rates in both travel motorsbecome different from each other, the oilflows through the route between port PTL,travel junction spool (13), and port PTR sothat the oil flow rates will be equalized again.

SU(V)P08731

OR

08899

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL PPC SHUTTLE VALVE

PC200-7 10-105

TRAVEL PPC SHUTTLE VALVE

Function• If the boom lever is set to the "RAISE" posi-

tion 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 themachine is travelling up a sharp slope, thetravel PPC shuttle valve regulates the spoolstrokes of the boom, arm, and bucket controlvalves with the travel PPC pressure to limitthe flow of the oil into the boom, arm, andbucket cylinders.

• When the strokes of the boom, arm, andbucket are regulated, the travel PPC pressure

is applied through the circuit in the controlvalve.

Operation1 When travel lever is in neutral• The oil in stroke regulation signal chamber

"a" is drained through orifices (5) and (6) ofpistons (3) and (4) in the travel spring caseand the travel PPC valve.If the boom lever isset to the "RAISE" position (or the arm lever isset in the "IN" or "OUT" position or the bucketlever is set in the "CURL" or "DUMP" posi-tion), spool (1) moves to the left until itreaches the end of spring case (2) (st0).

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL PPC SHUTTLE VALVE

10-106 PC200-7

122. When travel lever is operated• If the right travel lever is set in the reverse (or

forward) direction, the right travel reverse (orforward) PPC pressure pushes spool (7) to theleft (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 PPCvalve.

• At this time, the right travel reverse (or for-ward) PPC pressure is applied through orifice(6) of piston (4) to the left end of piston (8) topush piston (8) to the right.

• When boom RAISE, arm IN, OUT, bucketCURL, DUMP are operated, spool (1) movesto the left, but the maximum stroke of thespool is limited to st1, the amount of move-ment (st2) of piston (8).

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD VALVE CONTROL

PC200-7 10-107

VALVE CONTROL

1. Travel PPC valve2. Service PPC valve3. Service pedal4. L.H. travel lever5. R.H. travel lever6. R.H. PPC valve7. R.H. work equipment con-

trol lever

8. Solenoid valve 9. Accumulator10. Control valve11. Hydraulic pump12. Junction box13. L.H. work equip-

ment control lever14. L.H. PPC valve

Lever positions

(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"


10-108 PC200-7

WORK EQUIPMENT • SWING PPCVALVE

WORK EQUIPMENT • SWING PPC VALVE

P: From main pumpT: To tank

P1: Left: Arm OUT / Right: Boom LOWERP2: Left: Arm IN / Right: Boom RAISEP3: Left: Swing RIGHT / Right: Bucket CURLP4: Left: SwingLEFT / Right: Bucket DUMP


PC200-7 10-109


12

1. Spool2. Metering spring3. Centering spring4. Piston5. Disc6. Nut (For connection of lever)

7. Joint8. Plate9. Retainer10. Body11. Filter

Unit: mm


12Centering spring(For P3 and P4)



replace spring


Installed length

Installed load

Free length

Installed load

42.5 x 15.5 3417.6 N{1.8 kg}

—13.7 N{1.4 kg}

13Centering spring(For P3 and P4)

44.5 x 15.5 3429.4 N{3.0 kg}

—23.5 N{2.4 kg}

14 Metering spring 26.5 x 8.2 24.916.7 N{1.7 kg}

—13.7 N{1.4 kg}


10-110 PC200-7


OPERATION1) At neutral

Ports A and B of the control valve andports P1 and P2 of the PPC valve are con-nected to drain chamber D through finecontrol 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 alsopushed by metering spring (2), and movesdown.When this happens, fine control hole f isshut off from drain chamber D, and atalmost the same time, it is connected topump pressure chamber PP, so pilot pres-sure oil from the main pump passesthrough fine control hole f and goes fromport P1 to port A.When the pressure at port P1 becomeshigher, spool (1) is pushed back and finecontrol hole f is shut off from pump pres-sure chamber PP. At almost the same time,it is connected to drain chamber D torelease the pressure at port P1. When thishappens, spool (1) moves up or down sothat the force of metering spring (2) is bal-anced with the pressure at port P1. Therelationship in the position of spool (1) andbody (10) (fine control hole f is at a pointmidway between drain hole D and pumppressure chamber PP) does not changeuntil retainer (9) contacts spool (1).Therefore, metering spring (2) is com-pressed proportionally to the amount ofmovement of the control lever, so the pres-sure at port P1 also rises in proportion tothe travel of the control lever. In this way,the control valve spool moves to a positionwhere the pressure in chamber A (thesame as the pressure at port P1) and theforce of the control valve spool returnspring are balanced. (Fig. 2)


PC200-7 10-111


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 centeringspring (3) and the pressure at port P1.When this happens, fine control hole f isconnected to drain chamber D and thepressure oil at port P1 is released.If the pressure at port P1 drops too far,spool (1) is pushed down by meteringspring (2), and fine control hole f is shut offfrom drain chamber D. At almost the sametime, it is connected to pump pressurechamber PP, and the pump pressure is sup-plied until the pressure at port P1 recoversto a pressure that corresponds to the leverposition.When the spool of the control valvereturns, oil in drain chamber D flows infrom fine control hole f in the valve on theside that is not working. The oil passesthrough port P2 and enters chamber B tofill the chamber with oil. (Fig. 3)

4) At full strokeWhen disc (5) pushes down piston (4), andretainer (9) pushes down spool (1), finecontrol hole f is shut off from drain cham-ber D, and is connected with pump pres-sure chamber PP. Therefore, the pilotpressure oil from the main pump passesthrough fine control hole f and flows tochamber A from port P1, and pushes thecontrol valve spool.The oil returning from chamber B passesfrom port P2 through fine control hole fand flows to drain chamber D. (Fig. 4)

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL PPC VALVE

10-112 PC200-7

TRAVEL PPC VALVE

P : From main pumpT : To tankP1 : Left reverseP2 : Left forward

P3 : Right reverseP4 : Right forwardP5 : Travel signalP6 : Steering signal


PC200-7 10-113

12

1. Plate2. Body3. Piston4. Collar5. Metering spring

6. Centering spring7. Valve8. Damper9. Steering signal10. Steering signal valve spring


10-114 PC200-7

12

Unit: mm


1 Metering spring



replace spring


Installed length

Installed load

Free length

Installed load

26.5 x 8.15 24.716.7 N{1.7 kg}

—13.7 N{1.4 kg}

2 Centering spring 48.1 x 15.5 32.5108 N{11 kg}

—86.3 N{8.8 kg}

3 Steering signal spring 12.8 x 7.3 8.58.8 N

{0.9 kg}—

7.1 N{0.72 kg}


PC200-7 10-115

12

OPERATION1) At neutral

Ports A and B of the control valve andports P1 and P2 of the PPC valve are con-nected to drain chamber D through finecontrol 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 alsopushed by metering spring (2), and movesdown.When this happens, fine control hole f isshut off from drain chamber D. At almostthe same time, it is connected to pumppressure chamber PP, and the pilot pres-sure of the main pump is sent from port Athrough fine control hole f to port P1.When the pressure at port P1 rises, spool(1) is pushed back. Fine control hole f isshut off from pump pressure chamber PP.At almost the same time, it is connected todrain chamber D, so the pressure at portP1 escapes.As a result, spool (1) moves up and downuntil the force of metering spool (2) is bal-anced with the pressure at port P1.The relationship of the position of spool (1)and body (10) (fine control hole f is in themiddle between drain hole D and pumppressure chamber PP) does not changeuntil retainer (9) contacts spool (1).Therefore, metering spring (2) is com-pressed in proportion to the travel of thecontrol lever, so the pressure at port P1also rises in proportion to the travel of thecontrol lever. In this way, the spool of thecontrol valve spool moves to a positionwhere the pressure of chamber A (same aspressure at port P1) and the force of thereturn spring of the control valve spool arebalanced. (Fig. 2)


10-116 PC200-7

12

3) Fine control (control lever returned)When lever (5) starts to be returned, spool(1) is pushed up by the force of centeringspring (3) and the pressure at port P1.Because of this, fine control hole f is con-nected to drain chamber D, and the pressur-ized 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 fromdrain chamber D. At almost the same time,it is connected to pump pressure chamberPP, so the pressure at port P1 supplies thepump pressure until the pressure recoversto a pressure equivalent to the position ofthe lever.When the control valve returns, oil in drainchamber D flows in from fine control hole fof the valve on the side that is not moving.It passes through port P2 and goes to cham-ber B to charge the oil. (Fig. 3)

4) At full strokeLever (5) pushes down piston (4), andretainer (9) pushes down on spool (1). Finecontrol hole f is shut off from drain chamberD, and is connected to pump pressurechamber PP. Therefore, the pilot pressureoil from the main pump passes through finecontrol hole f and flows to chamber A fromport P1 to push the control valve spool. Thereturn oil from chamber B passes from portP2 through fine control hole f and flows todrain chamber D. (Fig. 4)


PC200-7 10-117

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 asthe travel signal. Accordingly, if the machine is traveling is judged by the signal of port P5.

• Steering signalIf the operation quantities of both levers are different from each other as in the steering operation, thehigher 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 inneutral.Accordingly, if the machine is being steered is judged by the signal of port P6.

Operation1) While in NEUTRAL The signals of the output ports (P1 - P4), travel signal (Port P5), and steering signal (Port P6) are not out-

put.


10-118 PC200-7

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 motoris 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 signalvalve is kept in neutral and the steering signal (Port P6) is not output.


PC200-7 10-119

123) 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 thedifference of the pilot pressure between both sides is higher than a certain level), the pilot pressure isoutput as the steering signal.In the case of the following drawing, the pressure in left spring chamber (k) of steering signal valve (j) isP2. 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 thearrow and the higher one of both PPC output pressures (the pressure of port P4 in this drawing) is out-put as the steering signal to port P6.


10-120 PC200-7

124) 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 isoperating 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 andoutputs the steering signal (port P6).

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SERVICE PPC VALVE

PC200-7 10-121

SERVICE PPC VALVE

1. Spool2. Metering spring3. Centering spring4. Piston5. Lever6. Plate7. Retainer8. Body

T : To tankP : From main pumpP1 : PortP2 : Port

Unit: mm


9 Centering spring



replace spring


Installed length

Installed load

Free length

Installed load

33.9 x 15.3 28.4124.5 N{12.7 kg}

—100 N

{10.2 kg}

10 Metering spring 22.7 x 8.1 2216.7 N{1.7 kg}

—13.7 N{1.4 kg}


10-122 PC200-7

OPERATIONAt 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 andports a and b of the PPC valve are con-nected to drain port T through fine controlhole 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 con-nected with port a, and the pressurized oilfrom port P flows from port a to port A ofthe control valve.


PC200-7 10-123

• When the pressure at port a becomeshigher, spool (1) is pushed back by theforce acting on the end of the spool, andfine control portion Y closes.

• As a result, spool (1) moves up and downto balance the force at port a and the forceat metering spring (2).

• Therefore, metering spring (2) is com-pressed in proportion to the amount thecontrol lever is moved. The spring forcebecomes larger, so the pressure at port aalso increases in proportion to the amountthe control lever is operated.In this way, the control valve spool movesto a position where the pressure of port A(the same as the pressure at port a) is bal-anced with the force of the return spring ofthe control valve spool.

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SOLENOID VALVE

10-124 PC200-7

SOLENOID VALVE

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

1. PPC lock solenoid valve2. Travel junction solenoid

valve3. Merge-divider solenoid valve4. Travel speed solenoid valve5. Swing brake solenoid valve6. 2-stage relief solenoid valve

T : To tankA1 : To PPC valveA2 : To main valve (Travel junc-

tion valve)A3 . To main valve (Merge-

divider valve)A4 : To both travel motorsA5 : To swing motor

A6 : To main valve (2-stage relief valve)

P1 : From main pumpACC: To accumulator

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SOLENOID VALVE

PC200-7 10-125

12

1. Connector2. Moving core3. Coil4. Spool5. Block6. Spring

OPERATION

WHEN SOLENOID IS TURNED OFF

• Since the signal current does not flow fromthe 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 isclosed and the hydraulic oil from the mainpump does not flow into the actuator.At this time, the oil from the actuator isdrained through ports A and T into thetank.

WHEN SOLENOID IS TURNED ON

The signal current flows from the controllerto solenoid (3), and the latter is turned on.Accordingly, spool (4) is pressed against tothe right side.By this operation, the hydraulic oil from themain 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 oildoes not flow into the tank.

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD PPC ACCUMULATOR

10-126 PC200-7

PPC ACCUMULATOR

1

2

3

4

5

6

SBP00290

1. Gas plug2. Shell3. Poppet4. Holder5. Bladder6. Oil port

SPECIFICATIONSGas capacity:300 cc (for PPC)

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD RETURN OIL FILTER

PC200-7 10-127

RETURN OIL FILTER

FOR BREAKER

1. Drain plug2. Element3. Case4. Head cover5. Relief valve

SPECIFICATIONS

Rated pressure: 6.9 MPa {70 kg/cm2}Flow : 200 llll/minRelief valve cracking pressure:

0.34 ± 0.05 MPa{3.5 ± 0.5 kg/cm2}

Filter mesh size: 6 µmFiltering area : 4,570 cm2


10-128 PC200-7

BOOM HYDRAULIC DRIFTPREVENTION VALVE

BOOM HYDRAULIC DRIFT PREVENTION VALVE

When boom control valve is at RAISE

When boom control valve is at NEUTRAL

08900


PC200-7 10-129


Function

• This valve prevents the oil in the boom cylin-der bottom from leaking through spool (1)and the boom from lowering under its weightwhile the boom lever is not operated.

Operation

1. When boom lever is in "RAISE" positionIf the boom lever is set in the "RAISE" posi-tion, the pressure of the main hydraulic oil isapplied toward the left to area "A" of the ringformed by the difference between outsidediameter d1 of puppet (5) and seat diameterd2 (= Area of ∅d1 - Area of ∅d2). At this time,if this pressure is higher than the force ofspring (4), puppet (5) moves to the left. By thisoperation, the main hydraulic oil from thecontrol valve flows through the open part ofpuppet (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 inpuppet (5) which has flowed through orifice"a" is sealed by pilot piston (2).

The main hydraulic oil is shut off from theholding pressure on the boom cylinder bot-tom side.

• At this time, the holding pressure on theboom cylinder bottom side is applied towardthe right to area "A" of the ring formed by thedifference between outside diameter d1 ofpuppet (5) and seat diameter d2 (= Area of∅d1 - Area of ∅d2). The total of this pressureand the force of spring (4) closes puppet (5) toshut off the main hydraulic oil from the hold-ing pressure on the boom cylinder bottom.Accordingly, the boom is held.

3. When boom lever is in "LOWER" positionIf the boom lever is set in the "LOWER" posi-tion, pilot spool (2) is pushed by the pilotpressure from the PPC valve and the hydrau-lic oil in chamber "b" in the puppet is drainedthrough orifice "c".The oil on the boom bottom side flows fromorifice "a" through chamber "b" and orifice "c"to the drain hole, and the oil pressure inchamber "b" lowers.If the pressure in chamber "b" lowers belowthe pressure at port B, puppet (4) opens andthe hydraulic oil from port B flows throughport A to the control valve.


10-130 PC200-7


4. When abnormally high pressure is gener-ated

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

• If the hydraulic drift prevention valve for thearm cylinder head circuit is installed(optional), the hydraulic oil in the boom cylin-der bottom circuit or that in the arm cylinderhead circuit, having higher pressure, pushescheck valve (6 or 6A) open, then safety valve(3) operates.

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD LIFT CHECK VALVE

PC200-7 10-131

LIFT CHECK VALVE

Function

This valve applies back pressure to the draincircuit to prevent generation of negative pres-sure on the hydraulic devices for the workequipment (motors, cylinders, etc.)

Operation

1. While engine is stoppedAny oil is not supplied from the pump tothe self-pressure reducing valve and valve(1) is pressed by only the force of spring (2)toward the right and drain circuit "a" of thecontrol 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 con-trol valve to spring chamber "c" of the backpressure valve.

• Output pressure PR applied to springchamber "c" is applied to the left end ofvalve (1) (area of ∅d) to push valve (1) tothe right.

• At this time, pressure PA of drain circuit "a"of the control valve is applied to the rightend of valve (1) (area of ∅d1) to push valve(1) to the left.

• Valve (1) is balanced so that the back pres-sure PA will be as follows.PA = {(Area of ∅d) x PR + Force of spring(2)} / (Area of ∅d1)


10-132 PC200-7

ATTACHMENT CIRCUIT SELECTORVALVE

ATTACHMENT CIRCUIT SELECTOR VALVE

Function

1. Spool2. Spring

V : To control valveT : To hydraulic tankATT: To attachmentACC: To accumulatorP1 : From attachment circuit selector solenoid valveTS : To hydraulic tank

Unit: mm


3Spool return spring


Replace spring if any damages or deformations are found

Free length x Outside Dia.

Installed length

Installed load

Free lengthInstalled

load

132.0 x 29 114.5833 N

{85.0 Kg}--

666 N{68.0 Kg}


PC200-7 10-133

ATTACHMENT CIRCUIT SELECTORVALVE

When a breaker is installed, the return oil fromthe breaker does not pass through the mainvalve, but returns directly to the hydraulic tank.When other attachments (crusher, etc.) areinstalled, the attachment and the main valve areinterconnected.

Operation

1. When attachment other than breaker is installedSpool (1) is pushed fully to the left by theforce of spring (2), ATT port and port V areinterconnected, and ATT port and port T areshut off, so the attachment and main valve areinterconnected.

2. When breaker is installedWhen the pilot pressure from the attachmentcircuit selector solenoid valve overcomes theforce of spring (2), the spool (1) moves fully tothe right. ATT port and port V are shut off andATT port and port T are interconnected, so theoil returning from the breaker does not passthrough the main valve, but passes throughport T and returns directly to the hydraulictank.

08901

08902

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC CYLINDER

10-134 PC200-7

HYDRAULIC CYLINDERPC200-7, PC200LC-7

BOOM CYLINDER

ARM CYLINDER

BUCKET CYLINDER


PC200-7 10-135

12100 HOURS GREASING

500 HOURS GREASING

Unit: mm


1Clearance between piston rod and bush-ing

CylinderStandard

size

Tolerance Standard clear-ance

Clearance limit

Replace bush-ing

Shaft Hole

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

2Clearance between piston rod support pin and bushing

Boom 80-0.030-0.060

+0.457+0.370

0.400 ~ 0.517 1.0

Replace pin or bushing

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

3

Clearance between cylinder bottom support pin and bushing

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

Unit: mm



CylinderStandard

size


Clearance limit

Replace bush-ing

Shaft Hole

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 ---

3


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 ---


10-136 PC200-7

PC220-7, PC220LC-7

BOOM CYLINDER

ARM CYLINDER

BUCKET CYLINDER


PC200-7 10-137

12100 HOURS GREASING

500 HOURS GREASING

Unit: mm



CylinderStandard

size


Clearance limit

Replace bush-ing

Shaft Hole

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

3


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

Unit: mm



CylinderStandard

size


Clearance limit

Replace bush-ing

Shaft Hole

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 ---

3


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 ---

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD WORK EQUIPMENT

10-138 PC200-7

WORK EQUIPMENT


PC200-7 10-139

PC200-7, PC200LC-7

100 HOURS GREASING

500 HOURS GREASING

Unit: mm


1Clearance between connecting pin and bushing of revolving frame and boom

Standard size


Clearance limit

Replace

Shaft Hole

90-0.036-0.071

+0.342+0.269

0.305 ~ 0.412 1.0

2Clearance between connecting pin and bushing of boom and arm

90-0.036-0.071

+0.153+0.097

0.133 ~ 0.224 1.0

3Clearance between connecting pin and bushing of arm and link

70-0.030-0.076

+0.335+0.275

0.305 ~ 0.411 1.0

4Clearance between connecting pin and bushing of arm and bucket

80-0.030-0.076

+0.337+0.273

0.303 ~ 0.413 1.0

5Clearance between connecting pin and bushing of link and bucket

80-0.030-0.076

+0.337+0.273

0.303 ~ 0.413 1.0

6Clearance between connecting pin and bushing of link and link

70-0.030-0.076

+0.335+0.275

0.303 ~ 0.411 1.0

Unit: mm



Standard size


Clearance limit

Replace

Shaft Hole

90-0.036-0.071

+0.131+0.074

0.110 ~ 0.202 1.0


90-0.036-0.071

+0.166+0.074

0.110 ~ 0.237 1.0


70-0.030-0.076

+0.158+0.078

0.108 ~ 0.234 1.0


80-0.030-0.076

+0.137+0.074

0.104 ~ 0.213 1.0


80-0.030-0.076

+0.166+0.086

0.116 ~ 0.242 1.0


80-0.030-0.076

+0.154+0.074

0.104 ~ 0.230 1.0


10-140 PC200-7

PC220-7, PC220LC-7

100 HOURS GREASING

500 HOURS GREASING

Unit: mm



Standard size


Clearance limit

Replace

Shaft Hole

90-0.036-0.071

+0.342+0.269

0.305 ~ 0.412 1.0


90-0.036-0.071

+0.153+0.097

0.133 ~ 0.224 1.0


80-0.030-0.076

+0.335+0.275

0.305 ~ 0.411 1.0


80-0.030-0.076

+0.337+0.273

0.303 ~ 0.413 1.0


80-0.030-0.076

+0.337+0.273

0.303 ~ 0.413 1.0


80-0.030-0.076

+0.335+0.275

0.303 ~ 0.411 1.0

Unit: mm



Standard size


Clearance limit

Replace

Shaft Hole

100-0.036-0.071

+0.186+0.074

0.110 ~ 0.239 1.0


90-0.036-0.071

+0.166+0.074

0.110 ~ 0.237 1.0


80-0.030-0.076

+0.166+0.084

0.116 ~ 0.242 1.0


80-0.030-0.076

+0.137+0.074

0.104 ~ 0.213 1.0


80-0.030-0.076

+0.166+0.086

0.116 ~ 0.242 1.0


80-0.030-0.076

+0.166+0.066

0.096 ~ 0.232 1.0


10-142 PC200-7

1. DIMENSION OF ARM


PC200-7 10-143

12

Unit: mm

Model No.

PC200-7, PC200LC-7 PC220-7, PC220LC-7

1 ∅ 80 +0.1 0 ∅ 80 +0.1 0

2 109.3 +1.5 0 109.3 +1.5 0

3 305.5 0 -0.5 305.5 0 -0.5

4 ∅ 90 -0.036 -0.071 ∅ 90 -0.036 -0.071

5 402.1 ±1 419.9 ±1

6 187.2 ±0.5 206.1 ±0.5

7 829.1 ±1 918.6 ±1

8 2,919 3,037.6

9 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

18Arm as individual part 311 0 -0.5 311 0 -0.5

When pressfitting bushing 325 325

19Min. 1,680 1,605

Max. 2,800 2,625


10-144 PC200-7

12

2.DIMENSION OF BUCKET


PC200-7 10-145

12

Unit: mm

Model No.

PC200-7, PC200LC-7 PC220-7, PC220LC-7

1 457.6 ±0.5 442.4 ±0.5

2 22 ±0.5 59.2 ±0.5

3 92° 48’ 96° 52’

4 458.1 446.3

5 1,477.3 1,540.5

6 158.6 185.7

7 — —

8 0 7° 37’

9 ∅ 80 +0.1 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

21 358.5 +2 0 358.5 +2 0

22 38 37

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD AIR CONDITIONER

10-146 PC200-7

AIR CONDITIONER

AIR CONDITIONER PIPING

1. Hot water pickup piping2. Air conditioner compressor3. Refrigerant piping4. Condenser5. Receiver tank6. Hot water return piping7. Air conditioner unit8. Duct

A. Fresh airB. Recirculated airC. Hot air/cold air

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ENGINE CONTROL

PC200-7 10-147

ENGINE CONTROL

1. Battery relay2. Battery3. Starting switch4. Fuel control dial5. Linkage6. Starting motor7. Engine throttle and pump controller8. Fuel injection pump9. Governor motor

OUTLINE

• The engine can be started and stopped withonly starting switch (3).

• The engine throttle and pump controller(7)reveives the signal of fuel control dial (4) andtransmits the drive signal to governor motor(9) to control the governor lever angle of fuelinjection pump (8) and control the enginespeed.


10-148 PC200-7

12

1. OPERATION OF SYSTEMStarting engine• When the starting switch is turned to the

START position, the starting signal flows tothe starting motor, and the starting motorturns to start the engine.When this happens, the engine throttle andpump controller checks the signal from thefuel control dial and sets the engine speedto the speed set by the fuel control dial.

Engine speed control• The fuel control dial sends a signal to the

engine throttle and pump controlleraccording to the position of the dial. Theengine throttle and pump controller calcu-lates the angle of the governor motoraccording to this signal, and sends a signalto drive the governor motor so that it is atthat angle.When this happens, the operating angle ofthe governor motor is detected by thepotentiometer, and feedback is sent to theengine throttle and pump controller, sothat it can observe the operation of thegovernor motor.

Stopping engine• When the starting switch is turned to the

STOP position, the engine throttle andpump controller drives the governor motorso that the governor lever is set to the NOINJECTION position.

• When this happens, to maintain the electricpower in the system until the engine stopscompletely, the engine throttle and pumpcontroller itself drives the battery relay.

08903

08904

08905


PC200-7 10-149

121. COMPONENT

Fuel control dial

1. Knob2. Dial3. Spring4. Ball5. Potentiometer6. Connector

Function• The fuel control dial is installed under the

monitor panel, and a potentiometer isinstalled under the knob. The potentiome-ter shaft is turned by turning the knob.

• As the potentiometer shaft is turned, theresistance of the variable resistor in thepotentiometer changes and a throttle sig-nal is sent to the engine throttle and pumpcontroller.The hatched area in the graph shown atright is the abnormality detection area.


10-150 PC200-7

Governor motor

1. Potentiometer2. Cover3. Shaft4. Dust seal5. Bearing6. Motor7. Gear8. Connector

Function• The motor is turned according to the drive

signal from the engine throttle and pumpcontroller to control the governor lever of thefuel injection pump.This motor used as the motive power sourceis a stepping motor.

• A potentiometer for feedback is installed tomonitor the operation of the motor.

• Revolution of the motor is transmittedthrough the gear to the potentiometer.

OperationWhile 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 sup-

plies a pulse current to phases A and B, andthe motor revolves, synchronizing to thepulse.


10-152 PC200-7

Engine throttle and pump controller


PC200-7 10-153

12Input and output signals

CN-1 CN-2 CN-3

PinNo.

Signal name Input/output

PinNo.


PinNo.


1 Boom bottom pressure sensor Input 1 NC Output 1 VB (controller power) Input

2 R pump pressure sensor Input 2 Swing emergency switch Input 2 VIS (solenoid power) Input

3 Arm angle potentiometer Input 3 NC Input 3 SOL_COM (solenoid common gnd)

4 Signal GND Input 4 232C_RxD Input 4 Battery relay drive Output

5 Abnormality in auto-greasing con-troller Input

5 Overload sensor (ON/OFF) Input 5 Governor motor A phase (+) Output

6 Overload alarm valid switch Input 6 LS-EPC Output

6 NC Input 7 Model selection 4 Input 7 Travel junction SOL Output

7 Overload sensor (analog) Input 8 Attachment circuit selector signal Output 8 NC Output

8 F boom pressure sensor Input 9 NC Output 9 Bucket CURL pressure SW Input

9 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 Input

14 Boom head pressure sensor Input 15 NC Input 15 Governor motor A phase (-) Output

15 NC Input 16 Travel steering signal pressure SW Input 16 PC-EPC Output

16 SENS_PWR Output 17 Model selection 3 Input 17 Pump merge/divider solenoid Output

17 Key Switch (Terminal C) 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 Input21 S_NET Input/

output21 GND (controller GND)

21 GND (analog GND) 22 VIS (solenoid PWR) Input

22 POT_PWR Output22 CAN0_L Input/

output23 SOL_COM (solenoid common gnd)

23 Key switch (terminal ACC) Input 24 KEY_SIG Input

24 Arm crane relay actuation observa-tion Input 23 CAN1_L Input/

output25 Governor motor B phase (+) Output

26 Service flow adjustment EPC (1) Output

24 Flash memory write permission sig-nal 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 Input 34 NC

31 GND (S_NET GND) 35 Governor motor B phase (-) Output

32 CAN0_H Input/output

36 NC Output

37 Swing parking brake solenoid Output

33 CAN1_H Input/output

38 NC Output

39 Travel pressure switch Input

34 GND (232C GND)40 Arm OUT pressure switch Input

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

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM

PC200-7 10-155

ELECTRONIC CONTROL SYSTEM

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

1Control function

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 system6

Swing control function

7

Travel control function

8

ATT flow control, circuit selector function (option)

Self-diagnosis function


10-156 PC200-7

MACHINE CONTROL SYSTEM DIAGRAM


PC200-7 10-157


10-158 PC200-7

1. Engine and Pump control function

SJP08754

OR

08908


PC200-7 10-159

FUNCTION

• The operator can set the work mode switchon the monitor panel to mode A, E, or B (or

L) and select proper engine torque andpump absorption torque according to thetype of work.

• The engine throttle and pump controllerdetects the speed of the engine governorset with the fuel control dial and the actualengine speed and controls them so that thepump will absorb all the torque at each out-put point of the engine, according to thepump absorption torque set in each mode.

: The L mode is on the multi-monitor specifi-cation machine only.

SJP08755

OR

08909

SJP08756

OR

08910

SJP08757

OR

08911


10-160 PC200-7

12

1) Control method in each modeMode A• Matching point in mode A: Rated speed

• If the pump load increases and the pressurerises, the engine speed lowers.At this time, the controller lowers the pumpdischarge so that the engine speed will benear the full output point. If the pressure low-ers, the controller increases the pump dis-charge so that the engine speed will be nearthe full output point.By repeating these operations, the controllerconstantly uses the engine near the full out-put point.

Model PC200-7, PC220-7

Mode A 106.6 kW/1,900 rpm {143 HP/1,900 rpm}

SJP08758

OR

08912

SJP08759

OR

08913

SJP08760

OR

08914


PC200-7 10-161

12

Mode E / Mode B / (Mode L)

• At this time, the controller keeps the pumpabsorption torque along the constant horse-power curve and lower the engine speed bythe composite control of the engine andpump.By this method, the engine is used in the lowfuel consumption area.

: The L mode is on the multi-monitor specifica-tion machine only.

Mode Digging Breaker Finishing

Partial output point 85% 75% 70%

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

SJP08761

OR

08915

SJP08762

OR

08916

SJP08763

OR

08917


10-162 PC200-7

12

2) Function to control pump during travel

• If the machine travels in mode A, either ofengine speed and pump absorption torquedoes not change.

• If the machine travels in mode E or B, theworking mode does not change, but theengine speed and pump absorption torquerise to the same value as in mode A.

• If the machine travels in mode L, the work-ing mode and engine speed do not change,but the pump absorption torque isincreased.

: The L mode is on the multi-monitor specifi-cation machine only.

3) Function to control when emergency pump drive switch is turned ON

• Even if the controller or a sensor has atrouble, the functions of the machine canbe secured with pump absorption torquealmost equivalent to mode E by turning onemergency pump drive switch (10).In this case, a constant current flows fromthe battery to the EPC valve for PC and theoil pressure is sensed by only the EPCvalve for PC.

SJP08764

OR

08920


PC200-7 10-163

122. Pump/Valve control function

Function• The machine is matched to various types of

work properly with the 2-stage relief functionto increase the digging force, etc.

SJP08765

OR

08921


10-164 PC200-7

12

1) LS control function• The change point (LS set differential pressure)

of the pump discharge in the LS valve ischanged by changing the output pressurefrom the LS-EPC valve to the LS valve accord-ing to the operating condition of the actuator.

• By this operation, the start-up time of thepump discharge is optimized and the com-posite operation and fine control perfor-mance is improved.

2) Cut-off function• When the cut-off function is turned on, the

PC-EPC current is increased to near the maxi-mum value.By this operation, the flow rate in the reliefstate is lowered to reduce fuel consumption.

• Operating condition for turning on cut-offfunction

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/cm²}. If the 2-stage relief func-tion is turned on, however, the relief pressurerises to about 37.2 MPa {380 kg/cm²}.By this operation, the hydraulic force isincreased further.

• Operating condition for turning on 2-stagerelief function

Condition

• The average value of the front and rearpressure sensors is above 27.9 MPa {285kg/cm²} and the one-touch power maximiz-ing function is not turned on

Condition Relief pressure

• During travel• When swing lock switch is

turned on• When boom is lowered• When one-touch power maxi-

mizing function is turned on• When mode is operated

34.8 MPa{355 kg/cm²}

⇓37.2 MPa

{380 kg/cm²}

08922


PC200-7 10-165

12

3. One-touch power maximizing function

FUNCTION

• Power can be increased for a certain time byoperating the left knob switch.

SJP08766

OR

08923


10-166 PC200-7

12

1) One-touch power maximizing function• When the operator needs more digging force

to dig up a large rock, etc., if the left knobswitch is pressed, the hydraulic force isincreased about 7% to increase the diggingforce.

• If the left knob switch is turned on in workingmode "A" or "E", each function is set automat-ically as shown below.

⇓Software cut-off function

Working mode

Engine/Pump control

2-stage relief function Operation time

A, EMatching at rated output point

34.8 MPa {355 kg/cm²}⇓

37.2 MPa {380 kg/cm²}

Automatically reset at 8.5 sec

Cancel


PC200-7 10-167

12

4. Auto-deceleration function

FUNCTION

• If the all control levers are set in NEUTRALwhile waiting for a dump truck or work, theengine speed is lowered to the medium levelautomatically to reduce the fuel consumptionand noise.

• If any lever is operated, the engine speedrises to the set level instantly.

SJP08767

OR

08924


10-168 PC200-7

12

OPERATION

WHEN CONTROL LEVERS ARE SET IN NEU-TRAL

• If all the control levers are set in NEUTRALwhile the engine speed is above the decelera-tor operation level (about 1,400 rpm), theengine speed lowers instantly to the firstdeceleration level about 100 rpm lower thanthe set speed.

• If 4 more seconds pass, the engine speedlowers to the second deceleration level(about 1,400 rpm) and keeps at that level untilany lever is operated again.

WHEN ANY CONTROL LEVER IS OPERATED

• If any control lever is operated while theengine speed is kept at the second decelera-tion level, the engine speed rises instantly tothe level set with the fuel control dial.


PC200-7 10-169

12

1. Auto-warm-up/Overheat prevention function

FUNCTION

• After the engine is started, if the engine cool-ing water temperature is low, the enginespeed is raised automatically to warm up theengine. If the engine cooling water tempera-ture rises too high during work, the pumpload is reduced to prevent overheating.

SJP08768

OR

08925


10-170 PC200-7

12

1) Auto-warm-up function• After the engine is started, if the engine cool-

ing water temperature is low, the enginespeed is raised automatically to warm up theengine.

2) Overheat prevention function• If the engine cooling water temperature rises

too high during work, the pump load andengine speed are reduced to prevent over-heating.

• This function is turned on when the watertemperature rises above 95°C.

Operating condition (All) Operated

Water temperature: Below 30°C.Engine speed: Max. 1,200 rpm ⇒ Engine speed: Max. 1,200 rpm

⇓Resetting condition (Any one)

⇒Reset

AutoWater temperature: Above 30°C

Engine speed: Any levelAuto-warm-up operation time: Min. 10 minutes

ManualFuel control dial: Kept at 70% of full level for 3 sec. or longer

Operating condition Operation/Remedy Resetting condition

Water temperature: Above 105°C ⇒

Work mode: Any modeEngine speed: Low idleMonitor alarm lamp: Lights upAlarm buzzer: Sounds

⇒Water temperature: Below 105°CFuel control dial: Return to low idle position once.• Under above condition, controller

is set to condition before operationof function. (Manual reset)


Water temperature: Above 102°C ⇒

Work mode: Mode A, E, OR BEngine speed: Keep as is.Monitor alarm lamp: Lights up.Lower pump discharge.

⇒Water temperature: Below 102°C• Under above condition, controller

is set to condition before operationof function. (Automatic reset)


Water temperature: Above 100°C ⇒ Work mode: Mode A

Engine speed: Keep as is.Lower pump discharge.




Water temperature: Above 95°C ⇒ Work mode: Travel

Engine speed: Keep as is.Lower travel speed.




PC200-7 10-171

12

6. Swing control function

FUNCTION

The swing lock and swing holding brake func-tions are installed.

SJP08769

OR

08926


10-172 PC200-7

12

1) Swing lock and swing holding brake functions

• The swing lock function (manual) is used tolock machine from swinging at any position.The swing holding brake function (automatic)is used to prevent hydraulic drift after themachine stops swinging.

• Swing lock switch and swing lock/holdingbrake

Operation of swing holding brake release switch

• If the controller, etc. has a problem, the swingholding brake does not work normally, andthe machine cannot swing, the swing lock canbe reset with the swing holding brake releaseswitch.

� Even if the swing holding brake releaseswitch is turned on, if the swing lock switch isturned on, the swing brake is not released.

� If the swing lock is reset, swinging is stoppedby only the hydraulic brake of the safetyvalve. Accordingly, if swinging is stopped ona slope, the upper structure may drift hydrau-lically.

2) Quick hydraulic oil warm-up function when swing lock switch is turned on

• If swing lock switch (4) is turned on, thepump-cut function is cancelled and the reliefpressure rises from 34.8 MPa {355 kg/cm²} to37.2 MPa {380 kg/cm²}. If the work equipmentis relieved under this condition, the hydraulicoil temperature rises quickly and the warm-uptime can be shortened.

Lock switch

Lock lamp

Function Operation

OFF OFFSwing 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.

ON ONSwing 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.

Swing hold-ing brake release switch

ON(When control has

trouble)

OFF(When controller is nor-

mal)Swing lock switch

ON OFF ON OFF

Swing brakeSwing lock is turned on.

Swing lock is canceled.

Swing lock is turned on.

Swing hold-ing brake is turned on.


PC200-7 10-173

12

7. Travel control function

FUNCTION

• The pumps are controlled and the travelspeed is changed manually or automatically,to secure proper travel performance matchedto the type of work and jobsite during travel.

SJP08770

OR

08927


10-174 PC200-7

121) Pump control function during travel• If the machine travels in a work mode other

than mode A, the work mode and the enginespeed are kept as they are and the pumpabsorption torque is increased.

� For details, see ENGINE/PUMP COMPOSITECONTROL FUNCTION.

1. Travel speed change functioni) Manual change with travel speed switch

If the travel speed switch is changedbetween Lo, ( Mi), and Hi, the governor/pump controller controls the pump capac-ity and motor capacity at each gear speedas shown at right to change the travelspeed.

ii) Automatic change by engine speedIf the engine speed is lowered to 1,500rpm or less with the fuel control dial dur-ing travel;

• the travel speed does not change even ifthe travel speed switch is changed fromLo, ( Mi) to Hi,

• the travel speed changes to Mi level auto-matically if the travel speed has been Hi.

iii) Automatic change by pump dischargepressureWhile the machine is traveling with thetravel speed switch at Hi, if the load isincreased because of an upslope ground,etc. and the travel pressure keeps above24.5 MPa {250 kg/cm²} for 0.5 seconds, thetravel motor capacity is changed automat-ically and the travel speed is lowered (tothe Mi level) (The travel speed switch iskept at Hi, however).While the machine is travelling at Milevel, if the load is reduced on a flat ordownslope ground, etc. and the travelpressure keeps below 14.7 MPa {150 kg/cm²} for 0.5 seconds, the travel motorcapacity is changed automatically and thetravel speed is set to Hi again.

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

Travel speed switch

Lo (Low speed)

( Mi) (Mid-dle Speed)

Hi (High speed)

Pump capacity (%)

60 90 100

Motor capacity Max. Max. Min.

Travel speed (km/h)

3.0 4.1 5.5

08928


PC200-7 10-175

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

FUNCTION

This function is available only with the ATT speci-fication. 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.


10-176 PC200-7

9. System component parts1) Engine revolution sensor

1. Sensor2. Locknut3. Wiring harness4. Connector

FUNCTION

• The engine revolution sensor is installed tothe ring gear of the engine flywheel. It electri-cally calculates the number of the gear teethwhich pass in front of it and transmits theresult to the engine throttle and pump con-troller.

• A magnet is used to sense the gear teeth.Each time a gear tooth passes in front of themagnet, a current is generated.


PC200-7 10-177

12

2) PPC oil pressure switch

1. Plug2. Switch3. Connector

SPECIFICATIONS

Type of contacts: Normally open contactsOperating (ON) pressure: 0.5 ± 0.1 MPa

{5.0 ± 1.0 kg/cm²}Resetting (OFF) Pressure: 0.3 ± 0.5 MPa

{3.0 ± 0.5 kg/cm²}

FUNCTION

• The junction block has 9 pressure switches,which check the operating condition of eachactuator by the PPC pressure and transmit itto the governor/pump controller.


10-178 PC200-7

12

3) Pump pressure sensor

1. Sensor2. Connector

FUNCTION

• The pump pressure sensor is installed to theinlet circuit of the control valve. It convertsthe pump discharge pressure into a voltageand transmits it to the governor/pump con-troller.

OPERATION

• The oil pressure applied from the pressureintake part presses the diaphragm of the oilpressure sensor, the diaphragm is deformed.

• The gauge layer facing the diaphragm mea-sures the deformation of the diaphragm bythe change of its resistance, then converts thechange of the resistance into a voltage andtransmits it to the amplifier (voltage ampli-fier).

• The amplifier amplifies the received voltageand transmits it to the governor/pump con-troller.

• Relationship between pressure P (MPa {kg/cm²}) and output voltage (V) is as follows.V = 0.08 [0.008] x P + 0.5

SJP08774

OR

08930

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MULTI MONITOR SYSTEM

10-180 PC200-7

MULTI MONITOR SYSTEM

• The monitor system monitors the conditionof the machine with sensors installed on vari-ous parts of the machine. It processes andimmediately displays the obtained informa-tion on the panel notifying the operator of thecondition of the machine.The panel is roughly divided as follows.1. Monitor section to output alarms when

the machine has troubles2. Gauge section to display the condition

constantly (Coolant temperature, hydrau-lic oil temperature, fuel level, etc.)

• The monitor panel also has various modeselector switches and functions to operate themachine control system.

SJP08775

OR

08931


PC200-7 10-181

12

1. Monitor panel

OUTLINE

• The monitor panel has the functions to dis-play various items and the functions toselect modes and electric parts.The monitor panel has a CPU (Central Pro-cessing Unit) in it to process, display, andoutput the information.The monitor display unit consists of LCD(Liquid Crystal Display). The switches areflat sheet switches.


10-182 PC200-7

Input and output signals

CN-1 CN-2 CN-3

PinNo.


PinNo.


PinNo.


1 Key ON Input 1 Engine water temperature Input 1 NC Input

2 Key ON Input 2 Fuel level Input 2 NC Input

3 Washer motor output Output 3 Radiator water level Input 3 NC Input

4 Starting signal Input 4 (Hydraulic oil level) Input 4 NC Input

5 Limit switch (W) Input 5 Air cleaner clogging Input 5 NC Input

6 GND 6 NC Input 6 NC Input

7 GND 7 Engine oil pressure Input 7 RS230C CTS Input

8 VB + Input 8 Engine oil level Input 8 RS230C RXD Input

9 Wiper motor (+) Output 9 N/W signal Input/

Output 9 RS230C RXD Input/Output10 Wiper motor (-) Output

11 Buzzer ON signal Input10 N/W signal Input/

Output 10 RS230C RXD Input/Output12 Limit switch (P) Input

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 10-183

MONITOR CONTROL, DISPLAY PORTION

MONITOR PORTION

1. Wiper motor2. Preheating monitor3. Swing lock monitor4. Engine water temperature monitor5. Hydraulic oil temperature gauge6. Engine water temperature gauge7. Working mode monitor8. Service monitor9. Travel speed monitor10. Fuel gauge

11. Fuel level monitor12. Hydraulic oil temperature monitor13. Power max. monitor14. Auto-deceleration monitor15. Radiator water level caution16. Battery charge caution17. Engine oil pressure caution18. Engine oil level caution19. Air cleaner clogging20. Maintenance time warning caution

08932


10-184 PC200-7

MONITOR ITEMS AND DISPLAY

Symbol Display item Display method

Swing lock

Swing lock switchSwing holding brake

release switchSwing lock monitor

OFF OFF OFF

ON OFF ON

OFF ON Flashes

ON ON ON

Preheating

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.

Power Max. switch status Power max. monitor status

Being pressedLights up but goes out after

approx. 9 sec. when kept pressed

Not being pressed Flashes

Engine water temperature

See gauge display on the next pageHydraulic oil temperature

Fuel level


PC200-7 10-185

Gauge RangeTemperature, vol-

umeIndicator Buzzer sound

Engine water tem-perature (°C)

A1 105 Red ❍

A2 102 Red

A3 100 Green

A4 80 Green

A5 60 Green

A6 30 White

Hydraulic oil tem-perature (°C)

B1 105 Red

B2 102 Red

B3 100 Green

B4 80 Green

B5 40 Green

B6 20 White

Fuel level (L)

C1 289 Green

C2 244.5 Green

C3 200 Green

C4 100 Green

C5 60 Green

C6 41 Red


10-186 PC200-7

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.

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.

Symbol Display itemCheck before starting item

When engine is stopped

When engine is run-ning

Engine oil pressure � --When abnormal,

lights up and buzzer sounds

Battery charge � --Lights up when abnor-

mal

Radiator water level �Lights up when abnor-

mal

When abnormal, lights up and buzzer

sounds

Engine oil level �Lights up when abnor-

mal--

Air cleaner clogging � --Lights up when abnor-

mal

MaintenanceLights up when there is a warning. Lights up for

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

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


PC200-7 10-187

Display category Symbol Display item Display range Display method

Monitor

WiperON INT OFF

Displays set con-dition

Working mode

Displays set mode

Travel speedDisplays set speed

Auto-deceler-ation

ON ⇔ OFFDisplays actua-tion status

Service meterService meter indica-tor

When service meter is workingLights up when service meter is working


10-188 PC200-7

SWITCHES

1. Working mode selector switch2. Selector switch3. Display brightness, contrast adjustment switch4. Control switch5. Window washer switch6. Wiper switch7. Maintenance switch8. Travel speed selector switch9. Auto-deceleration switch


PC200-7 10-189

• Working mode selector switchThe condition of the machine changes accord-ing to the switch that is pressed (A, E, L, B). Itis possible to check the condition on the work-ing mode monitor display. The relationshipbetween each working mode and the monitordisplay is shown in the table on the right.

• Selector switchThis is used when making detailed settings ineach working mode. (For details, see ATTACH-MENT FLOW CONTROL FUNCTION for modesA and E.)

• Maintenance switchCheck the condition of the maintenanceitems. (For details, see MAINTENANCE FUNC-TION.)

• Auto-deceleration switchEach time the auto-deceleration switch ispressed, the auto-deceleration function isswitched ON/OFF. Use the auto-deceleration monitor display tocheck the present condition. When the working mode switch is operated toswitch the working mode, it is automaticallyset to ON.

• Travel speed selector switchEach time the travel speed selector switch ispressed, the travel speed changes.Lo → Mi → Hi → Lo . . . . . .Use the travel speed monitor display to checkthe present condition.The relationship between the set speed andthe monitor display in the table on the right.

• Wiper switchEach time the wiper switch is pressed, thewiper setting changes OFF → INT → ON →OFF → . . . . . . Use the wiper monitor display to check thepresent condition.The relationship between the wiper settingand the monitor display is as shown in thetable on the right.

Switch that is pressed

DisplayWorking mode sta-

tus after setting

[A] A A mode (default)

[E] E E mode

[L] L L mode

[B] B B mode

Display Setting

Crawler symbol + Lo Low speed (default)

Crawler symbol + Mi Medium speed

Crawler symbol + Hi High speed

Display SettingWiper actuation

status

None OFFStowing stopped or now stowing

Wiper symbol + INT INTIntermittent actu-

ation

Wiper symbol + ON ONContinuous actu-

ation


10-190 PC200-7

• Window washer switchWhile the switch is being pressed, windowwasher liquid is sprayed out. There is a timedelay before the wiper starts.

• Control switchThis is used for control when using the main-tenance function or select function.(For details, see each function.)

• Display brightness, contrast adjustmentswitchUse this switch when adjusting the displaybrightness and contrast.(For details, see each function.)


PC200-7 10-191

SELECT MODE FUNCTION

• This is used when setting the flow in eachworking mode. It is possible to make the set-ting when genuine attachment piping isinstalled and the initial value setting functionon the service menu has been used to set toATTACHMENT INSTALLED.

• It is possible to check on the working modemonitor if this function can be set.

METHOD OF USE

� Carry out the setting on the normal screen1. A mode, E mode

1) Press select switch (1) on the monitor tomove to the adjustment screen.

2) Press control switch (2) to select the flowlevel.

3) After completing the level selection, pressinput confirmation switch (3).The selection flow level is confirmed andthe screen moves to the normal screen.From the moment that the flow level isselected, the content of the selection isreflected for the attachment flow.� Before the input confirmation switch

is pressed, the flow levelis not con-firmed, so press return switch (4) toreturn to the normal screen. This func-tion can be used to return to the previ-ously set flow.The relationship between the set flowlevel and the flow value is as shown inthe table on the right.

Working mode Monitor display

A mode [A] + crusher symbol

E mode [E] + crusher symbol

B mode [B] + flow symbol

Control switch Actuation

Flow level bar graph extends to the right

Flow level bar graph retracts to the left

Flow level Flow (L/min.) Remarks

8 430 ❈ Default

7 350

6 250

5 170

4 140

3 115

2 90

1 30


10-192 PC200-7

2. B mode

1) Press select switch (1) on the monitor tomove to the screen for selecting the 3-stage flow level.

2) Press control switch (2), or input [01] - [03]with the numeral 10-key pad to chooseone on the three flow levels.

3) After completing the level selection, pressinput confirmation switch (3).The selected flow level is selected.� Before the input confirmation switch

is pressed, the flow level is not con-firmed, so press return switch (4) toreturn to the operator screen. Thisfunction can be used to return to thepreviously set flow.

4) After the flow level is confirmed, thescreen changes to the screen shown inthe diagram on the right.With this screen, it is possible to makefine adjustment to the flow.

5) Press control switch (2) and select theflow level.

No. 10-key pad operation

01

02

03



Flow level bar graph retracts to the left

No. Flow level (L/min.) Remarks

01 180 ❈ Default

02 140

03 100


PC200-7 10-193

6) After completing the level selection, pressinput confirmation switch (3).The selected flow level is confirmed andthe screen moves to the operator screen.From the moment that the flow level isselected, the content of the selection isreflected for the attachment flow.� Before the input confirmation switch

is pressed, the flow level is not con-firmed, se press return switch (4) toreturn to the normal screen. This func-tion can be used to return to the previ-ously set flow.The relationship between the set flowlevel and the flow value is as shown inthe table on the right.

7) Check the set value with the workingmode monitor.The relationship between the displaylevel and the set value is as shown in thetable on the right, and it is possible tocheck the level of the flow that can be set.

Flow level

When flow is 100 L/min.



Remarks

7 130 170 210

6 120 160 200

5 110 150 190

4 100 140 180 ❈ Default

3 90 130 170

2 80 120 160

1 70 110 150

Display level Set value (llll/min.)

8 200 or 210

7 180 or 190

6 160 or 170

5 140 or 150

4 120 or 130

3 100 or 110

2 80 or 90

1 70


10-194 PC200-7

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

❈ Option, so not set

� The above replacement intervals are set foreach item, and the time remaining to mainte-nance is reduced as the machine is operated.The content of the caution display differsaccording to the ramaining time. The relation-ship is as shown in the table below.

No. ItemReplacement

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

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


PC200-7 10-195

METHOD OF CHECKING STATUS MAINTENANCE ITEMS

� Operate as follows when on the operatorscreen.

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 mainte-nance item to select the item.� The cursor moves and the item is high-

lighted.� The display method is the same as

described on the previous page (relation-ship between remaining time and cautiondisplay). If the remaining time is less than30 hours, the item is displayed in yellow,and if it is less than 0 hours, it is displayedin 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 inlarge letters.

� The background color of the symbol forthe item where the maintenance tiem wasreset is the same as the background of thescreen, so it is possible to check that it hasbeen reset.


10-196 PC200-7

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 operatorscreen.

1. Press display brightness/contrast adjustment switch (1) and switch to the adjustment screen.

� Relationship between menu symbol and con-tent.

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 bright-ness and contrast as desired.

No. Symbol Content

01 Return mark Return

02 Contrast

03 Brightness



Flow level bar graph retracts to the left 08937


PC200-7 10-197

PASSWORD FUNCTION

• If a passport is input, the engine will not startunless the password is input correctly whenstarting.

• When setting this function or when changingthe password, it is necessary to go from thenormal screen to the setting screen and inputthe password.This becomes posssible 10 minutes after thestarting switch is turned ON and the monitorscreen has changed to the normal screen.

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.

08941


10-198 PC200-7

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.

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 dif-

ferent from the number input the firsttime, the password will not be confirmedand the screen will return to the firstscreen, so input the same 4-digit pass-word 2 times in succession.

08942


PC200-7 10-199

SERVICE METER CHECK FUNCTION

• When the starting switch is at the OFF posi-tion, keep return switch (1) and control switch(2) of the monitor pressed at the same time,and the service meter is shown on the dis-play.

• This display is shown only while the twoswitches are being pressed. When theswitches are released, the display goes out.Note that it takes 3 - 5 seconds after theswitches are pressed for the service meterdisplay to appear.

DISPLAY LCD CHECK FUNCTION

• On the password input screen or on the nor-mal screen, if monitor return switch (1) andworking mode (A) switch are kept pressed atthe same time, all the LCD display will lightup and the whole screen will become white,so the display can be checked.

• If any part of the display is black, the LCD isbroken.

08943


10-200 PC200-7

USER CODE DISPLAY FUNCTION

• If there is any problem in operating themachine, the user code is displayed on themonitor to advise the operator of the steps totake.This code display appears on the operatorscreen.

• On the operator screen, the user code is dis-played on the portion for the hydraulic oiltemperature gauge.

• If more than one user code is generated at thesame time, the user codes are displayed inturn for 2 seconds each to display all the usercodes.

08945


PC200-7 10-201

• While the user code is being displayed, if theinput confirmation switch is pressed, the ser-vice code and failure code can be displayed.

• If there is more than one service code or fail-ure code, the display switches every 2 sec-onds and displays all the service codes/failurecodes that caused the user code to be dis-played.Even if service codes/failure codes haveoccurred, if they did not cause the user codeto be displayed, this function does not displaythem.

• If the telephone number has been set usingthe telephone number input on the servicemenu, it is possible to switch on the servicecode/failure code and display the telephonesymbol and telephone number.For details of inputting and setting the tele-phone number, see SPECIAL FUNCTIONS OFMONITOR PANEL in the TESTING ANDADJUSTING section.

08946

08947

08948

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD 7-SEGMENT MONITOR SYSTEM

10-202 PC200-7

7-SEGMENT MONITOR SYSTEM

• The monitor system monitors the conditionof the machine with sensors installed on vari-ous parts of the machine. It processes andimmediately displays the obtained informa-tion on the panel notifying the operator of thecondition of the machine.The panel is roughly divided as follows.1. Monitor section to output alarms when

the machine has troubles2. Gauge section to display the condition

constantly (Coolant temperature, hydrau-lic oil temperature, fuel level, etc.)

• The monitor panel also has various modeselector switches and functions to operate themachine control system.

SJP08775

OR

08931


PC200-7 10-203

121. Monitor panel

OUTLINE

• The monitor panel has the functions to dis-play various items and the functions to selectmodes and electric parts.The monitor panel has a CPU (Central Pro-cessing Unit) in it to process, display, and out-put the information.The monitor display unit consists of LCD (Liq-uid Crystal Display) and LED (Light EmittingDiode). The switches are flat sheet switches.

INPUT AND OUTPUT SIGNALS

CN-P01 CN-P02Pin No. Signal neme Pin

No. Signal Name

1 Key switch (Battery) 1 Engine water temperature

2 Key switch (Battery) 2 Fuel

3 Washer motor output 3 Radiator water level

4 Key switch (Terminal C) 4 NC

5 Wiper contact W 5 Air cleaner clogging sensor

6 GND 6 NC

7 GND 7 Engine oil pressure sensor

8 VB + (24 V) 8 Engine oil level sensor

9 Wiper motor (+) 9 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)


10-204 PC200-7

Display section of monitor

1. Service meter display2. Coolant temperature gauge3. Coolant temperature caution4. Digital meter display (Service code and user

code are displayed when trouble occurs5. Fuel level caution6. Fuel level gauge7. Engine oil level caution lamp8. Preheating pilot lamp9. Swing holding brake pilot lamp10. Oil maintenance pilot lamp11. Battery charge caution lamp12. Air cleaner clogging caution lamp13. Engine oil pressure caution lamp


PC200-7 10-205

Monitored items and display

Symbol Displayed item Display rangeWhen engine is stopped

While engine is running

Engine oil pressure

Max. 1,500 rpmMax. 0.05 MPa {0.5 kg/cm²}Min. 1,500 rpmMax. 0.15 MPa {1.5 kg/cm²}

Lights when normal.(Goes off when engine is started.) Flashes and buzzer

sounds when abnormal.

Air cleaner clogging When clogged Goes off. Flashes when abnormal.

Charge levelWhen charge is abnormal

Lights when normal.(Goes off when engine is started.) Flashes when abnormal.

Engine oil level Below low levelFlashes when abnor-mal.

Goes off.

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 preheatedLights up for 30 sec. when starting switch is set to HEAT. Then, flashes for 10 sec. to indicated completion of preheating.

Coolant temperatureFlashes at 102°C or higher. Flashes and buzzer sounds at 105°C or higher.

Fuel level Flashes when below low level.

SAP00521

SAP00523

SAT00098

SAP00526


10-206 PC200-7

12

Oil maintenance function

1. Function and operationAt 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 func-tion to indicate the phone number of the place to make contact for service on the LCD unit is installed, too.

1) Check of elapsed timeNothing is displayed normally until pointB shown in the figure at right after thisfunction is reset. If the key is turned onwith the buzzer cancel switch processed(for 2.5 seconds), however, the elapsedtime is displayed on the service metersection.

2) Display of replacement of oilIf time passes point B after this function isreset, the elapsed time is displayed on theservice meter section and the LED flasheswhen the key is turned on.

2. Setting of time interval1) The time interval is set in the interval set-

ting mode. It can be set to "125h", "250h","500h", "Not set", or "Demo-mode". Thedefault is "Not set".

2) To enter the interval setting mode, pressand hold the clock switch for 2.5 seconds.

3) If the buzzer cancel switch is pressed inthe interval setting mode, the clock dis-play section changes to "—" → "125" →"250" → "500" → " d" in order. ("—" corre-sponds to "Not set" and " d" correspondsto "Demo-mode".)

4) To save the time interval, set a desiredtime (mode) on the monitor panel andpress and hold the clock switch for 2.5seconds.


PC200-7 10-207

12

3. Timing and contents of display1) When replacement of oil is displayed

The elapsed time is displayed for 10 sec-onds after all segments are turned on.Phone number is displayed for the next 10seconds.If the phone number has not been input,however, the elapsed time is displayed for20 seconds after all segments are turnedon.

2) When elapsed time is checkedThe elapsed time is displayed for 10 sec-onds after all segments are turned on.

4. Resetting elapsed time1) When the replacement of oil and elapsed

time are displayed, press the buzzer can-cel switch 10 seconds after all segmentsare turned on (while the elapsed time isdisplayed) and hold for 3 seconds. Theelapsed time is reset. After this operation,"0h" is displayed for 1 second.

2) When the set time is changed, the elapsedtime is reset to "0h".

5. Demo-mode1) In the demo-mode, the time is set to 250h,

the elapsed time is set to 240h, andreplacement of oil is displayed when thekey is turned on. The elapsed time doesnot increase, however. The time can bereset in this mode. Turn on the key 3times in this mode, and the time intervalis automatically set to "Not set" at the 4thtime and after. The elapsed time is set to"0h" and counting of elapsed time isstarted.


10-208 PC200-7

12Mode selector switches

• There are 4 sets of the mode selectorswitches on the switch section. Each time oneswitch is pressed, the machine conditionchanges. The current condition is indicatedby the lighting of the LED above the switch.

• The initial setting of only the work mode afterthe starting switch is turned on can bechanged.

� For how to change the setting, see "Workmode default setting mode" in TROUBLE-SHOOTING-Display and special functions ofmonitor panel.

Operations table of switch section

� The bold letters are the positions of theswitches reset when the starting switch isturned on.

1. Travel speed switch2. Auto-deceleration switch3. Wiper switch4. Work mode selector switch

Item Operation

Work mode A↔E↔B

Auto-deceleration ON↔OFF

Wiper OFF↔Intermittent↔ON

Travel speed Hi↔Lo

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SENSOR

PC200-7 10-209

SENSOR

• The signals from the sensors are input to thepanel directly. Either side of a sensor of con-tact type is always connected to the chassisground.

Sensor name

Type of sensorWhen

normalWhen

abnormal

Engine oil level

ContactON

(Closed)OFF

(Open)

Engine oil pressure

ContactOFF

(Open)ON

(Closed)

Hydraulic oil tempera-ture

Resistance — —

Coolant temperature

Resistance — —

Fuel level Resistance — —

Air cleaner clogging

ContactOFF

(Closed)ON

(Open)


10-210 PC200-7

12

Engine oil level sensor

Engine oil pressure sensor (For low pressure)

Coolant temperature sensorHydraulic oil temperature sensor

1. Connector2. Bracket3. Float4. Switch

1. Plug2. Contact ring3. Contact4. Diaphragm5. Spring6. Terminal

1. Thermistor2. Body3. Tube

4. Tube5. Wire6. Connector


PC200-7 10-211

12

Fuel level sensor

Air cleaner clogging sensor

1. Float2. Connector3. Cover4. Variable resistor

90 OTHERS

90-1

Hydraulic Circuit DiagramPC200-7, PC200LC-7. . . . . . . . . . . . 90-3PC220-7, PC220LC-7. . . . . . . . . . . . 90-5

Electrical Circuit Diagram (1/5)PC200-7, PC200LC-7. . . . . . . . . . . . 90-7PC220-7, PC220LC-7. . . . . . . . . . . . 90-9

Electrical Circuit Diagram (2/5). . . . .90-11Electrical Circuit Diagram (3/5). . . . .90-13Electrical Circuit Diagram (4/5). . . . .90-15Electrical Circuit Diagram (5/5). . . . .90-17Electrical Circuit Diagram For Air Conditioner . . . . . . . . . . . . . . . . . . . .90-19

PC200-7

PC200-7 90-3

OTHERS HYDRAULIC CIRCUIT DIAGRAM

HYDRAULIC CIRCUIT DIAGRAMPC200-7, PC200LC-7

PC200-7 90-5

OTHERS HYDRAULIC CIRCUIT DIAGRAM

HYDRAULIC CIRCUIT DIAGRAMPC220-7, PC220LC-7

PC200-7 90-7

OTHERS ELECTRICAL CIRCUIT DIAGRAM (1/5)

ELECTRICAL CIRCUIT DIAGRAM (1/5)FOR MULTI MONITORPC200-7, PC200LC-7

PC200-7 90-9


ELECTRICAL CIRCUIT DIAGRAM (1/5)FOR MULTI MONITORPC220-7, PC220LC-7

PC200-7 90-11


ELECTRICAL CIRCUIT DIAGRAM (2/5)FOR MULTI MONITOR

PC200-7, PC200LC-7PC220-7, PC220LC-7

PC200-7 90-13



PC200-7, PC200LC-7 PC220-7, PC220LC-7

PC200-7 90-15



PC200-7, PC200LC-7 PC220-7, PC220LC-7

PC200-7 90-17



PC200-7, PC200LC-7PC220-7, PC220LC-7

PC200-7 90-19

OTHERS ELECTRICAL CIRCUIT DIAGRAM FOR AIR CONDITIONER

ELECTRICAL CIRCUIT DIAGRAM FOR AIR CONDITIONER