Professional Documents
Culture Documents
PC200, 200LC-7
PC220, 220LC-7
MACHINE MODEL SERIAL NUMBER
PC200-7 00 200001 AND UP 00
• 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 may
require.
Materials and specifications are subject to change without notice
© 2001
All Rights Reserved 00-1
Printed in USA 09-01
CONTENTS
No. of page
01 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1
90 OTHERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1
00
00-2
SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The service and
repair techniques recommended by Komatsu and described in this manual are both effective
and safe. Some of these techniques require the use of tools specially designed by Komatsu for
the specific purpose.
To prevent injury to workers, the symbol ¤ is used to mark safety precautions in this manual.
The cautions accompanying these symbols should always be followed carefully. If any danger-
ous situation arises or may possibly arise, first consider safety, and take the necessary actions
to deal with the situation.
00-3
SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK 19.Be sure to assemble all parts again in their origi-
nal places.
11. When removing the oil filler cap, drain plug or Replace any damaged parts with new parts.
hydraulic pressure measuring plugs, loosen • When installing hoses and wires, be sure
them slowly to prevent the oil from spurting out. that they will not be damaged by contact
Before disconnecting or removing components with other parts when the machine is being
of the oil, water or air circuits, first remove the operated.
pressure completely from the circuit. 20.When installing high pressure hoses, make sure
12.The water and oil in the circuits are hot when the that they are not twisted. Damaged tubes are
engine is stopped, so be careful not to get dangerous, so be extremely careful when install-
burned. ing tubes for high pressure circuits. Also, check
Wait for the oil and water to cool before carry- that connecting parts are correctly installed.
ing out any work on the oil or water circuits. 21.When assembling or installing parts, always use
13.Before starting work, remove the leads from the the specified tightening torques. When installing
battery. Always remove the lead from the nega- protective parts such as guards, or parts which
tive (–) terminal first. vibrate violently or rotate at high speed, be par-
14.When raising heavy components, use a hoist or ticularly careful to check that they are installed
crane. correctly.
Check that the wire rope, chains and hooks are 22.When aligning two holes, never insert your fin-
free from damage. gers or hand. Be careful not to get your fingers
Always use lifting equipment which has ample caught in a hole.
capacity. 23.When measuring hydraulic pressure, check that
Install the lifting equipment at the correct places. the measuring tool is correctly assembled before
Use a hoist or crane and operate slowly to pre- taking any measurements.
vent the component from hitting any other part.
24.Take care when removing or installing the tracks
Do not work with any part still raised by the hoist
of track-type machines.
or crane.
When removing the track, the track separates
15.When removing covers which are under internal suddenly, so never let anyone stand at either
pressure or under pressure from a spring, end of the track.
always leave two bolts in position on opposite
sides. Slowly release the pressure, then slowly
loosen the bolts to remove.
16.When removing components, be careful not to
break or damage the wiring. Damaged wiring
may cause electrical fires.
17.When removing piping, stop the fuel or oil from
spilling out. If any fuel or oil drips onto the floor,
wipe it up immediately. Fuel or oil on the floor
can cause you to slip, or can even start fires.
18.As a general rule, do not use gasoline to wash
parts. In particular, use only the minimum of
gasoline when washing electrical parts.
00-4
FOREWORD GENERAL
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make 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 service
workshop. 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.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Use the specifications given in the book with the latest date.
00-5
FOREWORD HOW TO READ THE SHOP MANUAL
W h en a m an u a l is r e vis ed , a n e d itio n ma rk
VOLUMES
Shop manuals are issued as a guide to carrying out 123
( ....) is recorded on the bottom of the pages.
repairs. They are divided as follows:
SYMBOLS
These various volumes are designed to avoid dupli-
cating the same information. Therefore, to deal with So that the shop manual can be of ample practical
all repairs for any model , it is necessary that chas- use, important safety and quality portions are
sis, engine, electrical and attachment volumes be marked with the following symbols.
available.
4
number.
forming the work.
Example 1 (Chassis volume):
Weight of parts of sys-
10 - 3 tems. Caution necessary
Weight when selecting hoisting
3
Item number (10. Structure and wire, or when working pos-
Function) ture is important, etc.
Consecutive page number for each
Places that require special
2
item. Tightening
attention for the tightening
torque
torque during assembly.
Example 2 (Engine volume):
Places to be coated with
5
12 - 5 Coat adhesives and lubricants,
etc.
Unit number (1. Engine) Places where oil, water or
6
Item number (2. Testing and Adjust- Oil, water fuel must be added, and
ing) the capacity.
Consecutive page number for each
item. Places where oil or water
Drain m u s t b e d r a i n e d , a nd
quantity to be drained.
3. Additional pages: Additional pages are indicated
by a hyphen (-) and number after the page
number. File as in the example.
Example:
10-4 12-203
10-4-1 12-203-1
Added pages
10-4-2 12-203-2
10-5 12-204
00-6
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
4
with a hoist, etc. In the DISASSEMBLY a serious accident can result. Hooks have max-
AND ASSEMBLY section, every part imum strength at the middle portion.
weighing 25 kg or more is indicated clearly
with the symbol
¤
but sling with two or more ropes symmetrically
wound onto the load.
WIRE ROPES
Slinging with one rope may cause turning
1) Use adequate ropes depending on the
of the load during hoisting, untwisting of
weight of parts to be hoisted, referring to
the rope, or slipping of the rope from its
the table below:
original winding position on the load, which
can result in a dangerous accident.
Wire ropes
(Standard "Z" or "S" twist ropes
without galvanizing) 4) Do not sling a heavy load with ropes forming a
wide hanging angle from the hook.
When hoisting a load with two or more ropes,
Rope diameter Allowable load the force subjected to each rope will increase
mm kN tons
with the hanging angles. The table below
shows the variation of allowable load kN {kg}
10 9.8 1.0 when hoisting is made with two ropes, each of
11.5 13.7 1.4 which is allowed to sling up to 9.8 kN {1000 kg}
12.5 15.7 1.6 vertically, at various hanging angles.
14 21.6 2.2 When two ropes sling a load vertically, up to
16 27.5 2.8 19.6 kN {2000 kg} of total weight can be sus-
18 35.3 3.6
pended. This weight becomes 9.8 kN {1000 kg}
20 43.1 4.4
22.4 54.9 5.6
when two ropes make a 120° hanging angle.
30 98.1 10.0 On the other hand, two ropes are subjected to
40 176.5 18.0 an excessive force as large as 39.2 kN {4000
50 274.6 28.0 kg} if they sling a 19.6 kN {2000 kg} load at a
60 392.2 40.0 lifting angle of 150°.
00-7
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
¤
tank.
Disconnection
1) Release the residual pressure from the hydrau-
lic tan k. Fo r d e tails , se e TES TIN G AN D
ADJUSTING, Releasing residual pressure from
hydraulic tank.
Connection
1) Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3), aligning them with each
other. (See Fig. 4)
★ Do not hold rubber cap portion (4).
00-8
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 2 Type 3
1) Hold the mouthpiece of the tightening portion 1) Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end. the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn 2) Hold in the condition in Step 1), and push
lever (4) to the right (clockwise). until cover (3) contacts contact surface a of
the hexagonal portion at the male end.
Disassembly
3) Hold in the condition in Steps 1) and 2), and 3) Hold in the condition in Steps 1) and 2), and
pull out whole body (2) to disconnect it. pull out whole body (2) to disconnect it.
• Hold the mouthpiece of the tightening portion • Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end to con- the hexagonal portion at the male end to con-
nect it. nect it.
Connection
00-9
FOREWORD COATING MATERIALS
COATING MATERIALS
★ The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and assembly are listed below.
★ For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code Part No. Q'ty Container Main applications, featuresr
00-10
FOREWORD COATING MATERIALS
Category Komatsu code Part No. Q'ty Container Main applications, features
00-11
FOREWORD STANDARD TIGHTENING TORQUE
mm mm Nm kgm
mm mm Nm kgm
6 10 0
7.85 1.95 0.8 0 0.2
8 13 0
18.6 4.9 1.9 0 0.5
10 14 0
40.2 5.9 4.1 0 0.6
12 27 0
82.35 7.85 8.4 0 0.8
Sealing surface
mm mm Nm kgm
14 19 0
24.5 4.9 0
2.5 0.5
18 24 0
49 19.6 5 2 0
22 27 0
78.5 19.6 8 2 0
24 32 0
137.3 29.4 14 3 0
30 36 0
176.5 29.4 18 3 0
33 41 0
196.1 49 20 5 0
36 46 0
245.2 49 25 5 0
42 55 0
294.2 49 30 5 0
00-12
FOREWORD STANDARD TIGHTENING TORQUE
mm mm Nm kgm
10 14 0
65.7 6.8 0
6.7 0.7
12 17 112 9.80 11.5 1 0
16 22 279 290 28.5 3 0
02 14 0
34.3 4.9 3.5 0 0.5
03, 04 20 Varies depending 0
93.1 9.8 9.5 01
05, 06 24 on type of 0
142.1 19.6 14.5 02
10, 12 33 connector. 0
421.4 58.8 43 06
14 42 0
877.1 132.3 89.5 0 13.5
08 08 14 0
7.35 1.47 0.75 0.15 0
10 10 17 0
11.27 1.47 1.15 0.15 0
12 12 19 0
17.64 1.96 1.8 0.2 0
14 14 22 0
22.54 1.96 2.3 0.2 0
16 16 24 0
29.4 4.9 3 0.5 0
18 18 27 0
39.2 4.9 4 0.5 0
20 20 30 0
49 4.9 5 0.5 0
24 24 32 0
68.6 9.8 7 1 0
30 30 32 0
107.8 14.7 11 1.5 0
33 33 n 0
127.4 19.6 13 2 0
36 36 36 0
151.9 24.5 15.5 2.5 0
42 42 n 0
210.7 29.4 21.5 3 0
52 52 n 0
323.4 44.1 33 4.5 0
00-13
FOREWORD STANDARD TIGHTENING TORQUE
mm Nm kgm
6 0
10 2 1.02 0 0.20
8 0
24 4 2.45 0 0.41
10 0
43 6 4.38 0 0.61
12 0
77 12 7.85 0 1.22
mm Nm kgm
6 0
8 2 0.81 0 0.20
8 0
10 2 1.02 0 0.20
10 0
12 2 1.22 0 0.20
12 0
24 4 2.45 0 0.41
14 0
36 5 3.67 0 0.51
mm Nm kgm
1 / 16 0
3 1 0.31 0 0.10
1/8 0
8 2 0.81 0 0.20
1/4 0
12 2 1.22 0 0.20
3/8 0
15 2 1.53 0 0.41
1/2 0
24 4 2.45 0 0.41
3/4 0
36 5 3.67 0 0.51
1 0
60 9 6.12 0 0.92
00-14
FOREWORD ELECTRIC WIRE CODE
CLASSIFICATION BY THICKNESS
Copper wire
Norminal Cable O.D. Current
number Dia. of Cross (mm) rating Applicable circuit
Number of strands section (A)
strands
(mm2) (mm 2)
Circuits
Priori- Charging Ground Starting Lighting Instrument Signal Other
ty Classi-
fication
Code W B B R Y G L
Pri-
1 mary
Color White Black Black Red Yellow Green Blue
Code WR n BW RW YR GW LW
2
Color White & Red n White & Black Red & White Rellow & Red Green & White Blue & White
Code WB n BY RB YB GR LR
3
Color White & Black n Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow
Code WL n BR RY YG GY LY
4 Auxi-
liary
Color White & Blue n Black & Red Red & Yellow
Yellow &
Green
Green &
Yellow
Blue & Yellow
Code WG n n RG YL GB LB
5
Color White & Green n n Red & Green Yellow & Blue Green & Black Blue & Black
Code n n n RL YW GL n
6
Color n n n Red & Blue Yellow & White Green & Blue n
00-15
FOREWORD CONVERSION TABLE
CONVERSION TABLE
EXAMPLE
• Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
A
(1) Locate the number 50 in the vertical column at the left side, take this as , then draw a horizontal line
A
from .
B
(2) Locate the number 5 in the row across the top, take this as , then draw a perpendicular line down
B
from .
C
(3) Take the point where the two lines cross as . This point C 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.
B
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
C
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
A 50
60
1.969
2.362
2.008
2.402
2.047
2.441
2.087
2.480
2.126
2.520
2.165
2.559
2.205
2.598
2.244
2.638
2.283
2.677
2.323
2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
00-16
FOREWORD CONVERSION TABLE
Millimeters to Inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to Pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-17
FOREWORD CONVERSION TABLE
0 1 2 3 4 5 6 7 8 9
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
0 1 2 3 4 5 6 7 8 9
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
00-18
FOREWORD CONVERSION TABLE
kgm to ft. lb
1 kgm = 7.233 ft. lb
0 1 2 3 4 5 6 7 8 9
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-19
FOREWORD CONVERSION TABLE
kg/cm2 to lb/in2
1kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
00-20
FOREWORD CONVERSION TABLE
Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a 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 of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
00-21
FOREWORD UNITS
UNITS
In this manual, the measuring units are indicated with Internatinal System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.
Example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}
kW/rpm {HP/rpm}
g/kWh {g/HPh}
00-22
01 GENERAL
PC200-7 01-1
GENERAL SPECIFICATION DIMENSION DRAWINGS
12
SPECIFICATION DIMENSION DRAWINGS
PC200-7, PC200LC-7
DIMENSIONS
WORKING RANGES
01-2 PC200-7
GENERAL SPECIFICATION DIMENSION DRAWINGS
12
DIMENSIONS
WORKING RANGES
PC200-7 01-3
GENERAL SPECIFICATION DIMENSION DRAWINGS
PC220-7, PC220LC-7
DIMENSIONS
WORKING RANGES
01-4 PC200-7
GENERAL SPECIFICATION DIMENSION DRAWINGS
12
DIMENSIONS
WORKING RANGES
PC200-7 01-5
GENERAL SPECIFICATIONS
SPECIFICATIONS
PC200-7, PC200LC-7
Machine model PC200-7 PC200LC-7
Travel speed km/h Lo: 3.0 ( Mi: 4.1) Lo: 3.0 ( Mi: 4.1)
Hi: 5.5 Hi: 5.5
Gradeability deg. 35 35
01-6 PC200-7
GENERAL SPECIFICATIONS
12
Model SAA6D102E-2-A
Type 4-cycle, water-cooled, in-line, vertical, direct
injection, with turbo charger
No. of cylinders - bore x stroke mm 6 - 102 x 120
Piston displacement l {cc} 5.883 {5,883}
Type x No.
pump
Delivery
l/min Piston type: 214 x 2
Set pressure
MPa (kg/cm²) Piston type: 37.2 {380}
Control
PC200-7 01-7
GENERAL SPECIFICATIONS
PC220-7, PC220LC-7
Travel speed km/h Lo: 3.1 ( Mi: 4.2) Lo: 3.1 ( Mi: 4.2)
Hi: 5.5 Hi: 5.5
Gradeability deg. 35 35
01-8 PC200-7
GENERAL SPECIFICATIONS
Model SAA6D102E-2-C
Type 4-cycle, water-cooled, in-line, vertical, direct
injection, with turbo charger
No. of cylinders - bore x stroke mm 6 - 102 x 120
Piston displacement l {cc} 5.883 {5,883}
Type x No.
pump
Delivery
l/min Piston type: 214 x 2
Set pressure
MPa (kg/cm²) Piston type: 37.2 {380}
Control
PC200-7 01-9
GENERAL WEIGHT TABLE
12
WEIGHT TABLE
PC200-7, PC200LC-7
This weight table is for use when handling components or when transporting the machine.
Unit: kg
• Damper 6 6
• Idler 99 x 2 99 x 2
• Carrier roller 16 x 4 16 x 4
• Track roller 36 x 14 36 x 18
01-10 PC200-7
GENERAL WEIGHT TABLE
12
Unit: kg
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
PC200-7 01-11
GENERAL WEIGHT TABLE
PC220-7, PC220LC-7
Unit: kg
• Damper 6 6
• Idler 99 x 2 99 x 2
• Carrier roller 16 x 4 16 x 4
• Track roller 36 x 16 36 x 20
01-12 PC200-7
GENERAL WEIGHT TABLE
12
Unit: kg
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
PC200-7 01-13
GENERAL FUEL, COOLANT, AND LUBRICANTs
12
FUEL, COOLANT, AND LUBRICANTS
SAE 30
SAE 10W
Engine oil pan 26.3 24
SAE 10W-30
SAE 15W-40
SAE 10W
SAE 10W-30
Hydraulic system 240 143
SAE 15W-40
Hydraulic
H046-HM (★)
oil
PC200, PC200,
PC200LC-7 PC200LC-7
22.4 22.4
Cooling system Coolant Add antifreeze
PC220, PC220,
PC220LC-7 PC220LC-7
30.9 30.9
01-14 PC200-7
10 STRUCTURE, FUNCTION, AND
MAINTENANCE STANDARD
1252
Engine Related Parts . . . . . . . . . . . . . .10-2 Hydraulic Cylinder
Radiator • Oil Cooler • Aftercooler . . .10-3 PC200-7, PC200LC-7 . . . . . . . . . 10-134
Power Train . . . . . . . . . . . . . . . . . . . . .10-4 PC220-7, PC220LC-7 . . . . . . . . . 10-136
Final Drive . . . . . . . . . . . . . . . . . . . . . .10-6 Work Equipment. . . . . . . . . . . . . . . 10-138
Swing Machinery Air Conditioner . . . . . . . . . . . . . . . . 10-146
PC200-7, PC200LC-7 . . . . . . . . . . . .10-8 Engine Control . . . . . . . . . . . . . . . . 10-147
PC220-7, PC220LC-7 . . . . . . . . . . .10-10 Electronic Control System . . . . . . . 10-155
Swing Circle Multi Monitor System . . . . . . . . . . 10-180
PC200-7, PC200LC-7 . . . . . . . . . . .10-12 7-Segment Monitor System . . . . . 10-202
PC220-7, PC220LC-7 . . . . . . . . . . .10-13 Sensor . . . . . . . . . . . . . . . . . . . . . . . 10-209
Track Frame • Recoil Spring . . . . . . .10-14
Idler. . . . . . . . . . . . . . . . . . . . . . . . . . .10-16
Carrier roller. . . . . . . . . . . . . . . . . . . .10-18
Track roller . . . . . . . . . . . . . . . . . . . . .10-19
Track Shoe . . . . . . . . . . . . . . . . . . . . .10-20
Hydraulic Equipment Layout Drawing
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-24
Hydraulic Tank . . . . . . . . . . . . . . . . . .10-26
Hydraulic Pump . . . . . . . . . . . . . . . . .10-28
Control Valve
PC200-7, PC200LC-7 . . . . . . . . . . .10-50
PC220-7, PC220LC-7 . . . . . . . . . . .10-64
CLSS . . . . . . . . . . . . . . . . . . . . . . . . . .10-80
Self Pressure Reducing Valve. . . . . .10-83
Swing Motor . . . . . . . . . . . . . . . . . . .10-86
Reverse Prevention Valve . . . . . . . . .10-91
Center Swivel Joint . . . . . . . . . . . . . .10-93
Travel Motor . . . . . . . . . . . . . . . . . . .10-94
Travel Junction Valve . . . . . . . . . . .10-103
Travel PPC Shuttle Valve . . . . . . . .10-105
Valve Control . . . . . . . . . . . . . . . . . .10-107
Work Equipment • Swing PPC Valve
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-108
Travel PPC Valve . . . . . . . . . . . . . . .10-112
Service PPC Valve . . . . . . . . . . . . . .10-121
Solenoid Valve. . . . . . . . . . . . . . . . .10-124
PPC Accumulator. . . . . . . . . . . . . . .10-126
Return Oil Filter . . . . . . . . . . . . . . . .10-127
Boom Hydraulic Drift Prevention Valve
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-128
Lift Check Valve . . . . . . . . . . . . . . . .10-131
Attachment Circuit Selector Valve .10-132
PC200-7 10-1
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ENGINE RELATED PARTS
12
ENGINE RELATED PARTS
10-2 PC200-7
RADIATOR • OIL COOLER •
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD AFTERCOOLER
12
RADIATOR • OIL COOLER • AFTERCOOLER
SWP08671
PC200-7 10-3
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD POWER TRAIN
12
POWER TRAIN
10-4 PC200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD FINAL DRIVE
12
FINAL DRIVE
10-6 PC200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD FINAL DRIVE
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 seal
10. Travel motor
11. Hub
12. 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:
10 + 95 21+ 95
− × + 1 = −57.00
10 21
Unit: mm
Backlash between No. 1 sun gear and Standard clearance Clearance limit
15
No. 1 planetary gear 0.15 - 0.49 1.00
Backlash between No. 1 planetary gear
16 0.17 - 0.57 1.10
and ring gear
PC200-7 10-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING MACHINERY
12
SWING MACHINERY
PC200-7, PC200LC-7
10-8 PC200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING MACHINERY
12
SPECIFICATIONS
Reduction ratio:
17 + 58 18 + 58
× = 18.627
17 18
Unit: mm
Backlash between swing motor shaft and Standard clearance Clearance limit
14
No. 1 sun gear 0.18 - 0.28 —
Backlash between No. 1 sun gear and No. 1
15 0.16 - 0.50 1.00
planetary gear
Backlash between No. 1 planetary gear and
16 0.18 - 0.59 1.10
ring gear
Backlash between No. 1 planetary carrier
17 0.39 - 0.71 1.20
and No. 2 sun gear
Backlash between No. 2 sun gear and No. 2 Replace
18 0.16 - 0.50 0.90
planetary gear
Backlash between No. 2 planetary gear and
19 0.18 - 0.59 1.00
ring gear
Backlash between No. 2 planetary carrier
20 0.07 - 0.23 —
and swing pinion
Backlash between swing pinion and swing
21 0.22 - 1.32 2.00
circle
Clearance between plate and planetary car-
22 0.66 - 1.14 —
rier
Standard size Repair limit
Apply hard chrome
Wear of swing pinion surface contacting
23 0 plating, recondi-
with oil seal 115 — tion, or replace
-0.100
PC200-7 10-9
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING MACHINERY
PC220-7, PC220LC-7
10-10 PC200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING MACHINERY
12
SPECIFICATIONS
Reduction ratio:
17 + 58 14 + 58
× = 22.689
17 14
Unit: mm
Backlash between swing motor shaft and Standard clearance Clearance limit
14
No. 1 sun gear 0.18 - 0.28 —
Backlash between No. 1 sun gear and No. 1
15 0.16 - 0.59 1.00
planetary gear
Backlash between No. 1 planetary gear and
16 0.18 - 0.50 1.10
ring gear
Backlash between No. 1 planetary carrier
17 0.39 - 0.64 1.20
and No. 2 sun gear
Backlash between No. 2 sun gear and No. 2 Replace
18 0.16 - 0.44 0.90
planetary gear
Backlash between No. 2 planetary gear and
19 0.18 - 0.56 1.00
ring gear
Backlash between No. 2 planetary carrier
20 0.08 - 0.23 —
and swing pinion
Backlash between swing pinion and swing
21 0.23 - 1.37 2.00
circle
Clearance between plate and planetary car-
22 0.58 - 0.62 —
rier
Standard size Repair limit
Apply hard chrome
Wear of swing pinion surface contacting
23 0 plating, recondi-
with oil seal 115 — tion, or replace
-0.100
PC200-7 10-11
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING CIRCLE
SWING CIRCLE
PC200-7, PC200LC-7
Reduction ratio:
110
a. Inner race soft zone S position = 7.333
15
b. Outer race soft zone S position
Unit: mm
10-12 PC200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING CIRCLE
12
PC220-7, PC220LC-7
S*P09097
PC200-7 10-13
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRACK FRAME • RECOIL SPRING
12
TRACK FRAME • RECOIL SPRING
PC220-7 8
PC220LC-7 10
10-14 PC200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRACK FRAME • RECOIL SPRING
12
Standard shoe
Model
PC200-7 PC200LC-7 PC220-7 PC220LC-7
Item
Shoe width 600 mm 700 mm 600 mm 700 mm
Unit: mm
Standard
Tolerance Repair limit
size
10 Vertical width of idler guide
Track frame 107 Rebuild
or
Idler support 105
replace
Horizontal width of idler Track frame 250
11
guide Idler support 247.4
PC200LC-7
126.5 kN 100.9 kN
PC220-7 603.5 X 239 466 576
(12,900 kg) (10,300 kg)
PC22LC-7
PC200-7 10-15
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRACK FRAME • RECOIL SPRING
12
IDLER
10-16 PC200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRACK FRAME • RECOIL SPRING
12
Unit: mm
PC200-7 10-17
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRACK FRAME • RECOIL SPRING
12
CARRIER ROLLER
Unit: mm
3 Width of tread 43 —
5 Width of flange 14 —
10-18 PC200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRACK FRAME • RECOIL SPRING
12
TRACK ROLLER
Unit: mm
PC200-7 10-19
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRACK SHOE
12
TRACK SHOE
10-20 PC200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRACK SHOE
12
Unit: mm
No
Check item Criteria Remedy
.
Standard size Repair limit
1 Link pitch
190.25 194.25
Reverse
When turned or
Standard size replace
2 Bushing outside diameter Normal load Impact load
59.3 — 54.3
5 160.4
7 18
16 Thickness of spacer —
PC200-7 10-21
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRACK SHOE
12
Unit: mm
490 ± 49
a. Regular link Triple shoe 120 ± 10
{50 ± 5}
— — —
10-22 PC200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRACK SHOE
12
TRIPLE GROUSER SHOE
SWAMP SHOE
Unit: mm
2 Thickness 8.5
3 26
Length of base
4 19
5 20
Rebuild or replace
6 Length at tip 14
7 19
10 Thickness 17 5
PC200-7 10-23
HYDRAULIC EQUIPMENT LAYOUT
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD DRAWING
12
HYDRAULIC EQUIPMENT LAYOUT DRAWING
1. Bucket cylinder
2. Arm cylinder
3. Boom cylinder
4. Hydraulic tank
5. Hydraulic filter
6. R.H. travel motor
7. Swing motor
8. Hydraulic pump
9. Control valve
10. Oil cooler
11. L.H. travel motor
12. Multi-pattern selector valve
13. L.H. PPC valve
14. Safety lever (electric type)
15. Center swivel joint
16. R.H. PPC valve
17. Travel PPC valve
18. Attachment circuit selector valve
19. Holding valve
20. Accumulator
21. Solenoid valve assembly
21A PPC lock solenoid
21B Travel junction solenoid
21C Pump merge/divider solenoid
21D Travel speed solenoid
21E Swing brake solenoid
21F 2-stage relief solenoid
10-24 PC200-7
HYDRAULIC EQUIPMENT LAYOUT
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD DRAWING
12
PC200-7 10-25
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC TANK
12
HYDRAULIC TANK
10-26 PC200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
HYDRAULIC PUMP
HPV95 + 95
1. Front main pump IM : PC mode selector current PENR : Rear pump control pressure detec-
2. Rear main pump ISIG : LS set selector current tion port
3. LS valve PAF : Front pump delivery port PLSF : Front load pressure input port
4. PC valve PFC : Front pump delivery pres- PLSFC: Front load pressure detection port
5. LS-EPC valve sure detection port PLSR : Rear load pressure input port
6. PC-EPC valve PAR : Rear pump delivery port PLSRC: Rear load pressure detection port
PRC : Rear pump delivery pressure PS : Pump suction port
detection port PSIG : LS set selector pressure detection
PBF : Pump pressure input port port
PD1F: Case drain port PM : PC set selector pressure detection
PENF: Front pump control pressure port
detection port PEPC : EPC basic pressure input port
Outline
• This pump consists of 2 variable capacity swash plate
piston pumps, PC valve, LS valve, and EPC valve.
10-28 PC200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
PC200-7 10-29
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
Function
• The rotation and torque transmitted to the • Rocker cam (4) has flat surface A, and shoe
pump shaft are converted into hydraulic (5) is always pressed against this surface
energy, and pressurized oil is discharged while sliding in a circular movement.
according to the load. Rocker cam (4) brings high pressure oil at cyl-
• It is possible to change the discharge amount inder surface B with cradle (2), which is
by changing the swash plate angle. secured to the case, and forms a static pres-
Structure sure bearing when it slides.
• Cylinder block (7) is supported to shaft (1) by • Piston (6) carries out relative movement in
a spline, and shaft (1) is supported by the the axial direction inside each cylinder cham-
front and rear bearings. ber of cylinder block (7).
• The tip of piston (6) is a concave ball, and • The cylinder block seals the pressure oil to
shoe (5) is caulked to it to form one unit. Pis- valve plate (8) and carries out relative rota-
ton (6) and shoe (5) form a spherical bearing. tion. This surface is designed so that the oil
pressure balance is maintained at a suitable
level. The oil inside each cylinder chamber of
cylinder block (7) is sucked in and discharged
through valve plate (8).
10-30 PC200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
Operation
1) Operation of pump
i Cylinder block (7) rotates together with
shaft (1), and shoe (5) slides on flat surface
A.
When this happens, rocker cam (4) moves
along cylindrical surface B, so angle α
between center line X of rocker cam (4) and
the axial direction of cylinder block (7)
changes. (Angle α is called the swash plate
angle.)
ii Center line X of rocker cam (4) maintains
swash plate angle α in relation to the axial
direction 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 of
cylinder block (7), so a difference between
volumes E and F is created inside cylinder
block (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 E
becomes smaller, the oil is discharged dur-
ing that stroke. On the other hand, the vol-
ume of chamber F becomes larger, and as
the volume becomes bigger, the oil is
sucked in.
iii If center line X of rocker cam (4) is in line
with the axial direction of cylinder block (7)
(swash plate angle = 0), the difference
between volumes E and F inside cylinder
block (7) becomes 0, so the pump does not
carry out any suction or discharge of oil.
(In actual fact, the swash plate angle never
becomes 0.)
PC200-7 10-31
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
2) Control of discharge amount
• If the swash plate angle α becomes larger,
the difference between volumes E and F
becomes larger and discharge amount Q
increases.
• Swash plate angle α is changed by servo
piston (12).
• Servo piston (12) moves in a reciprocal
movement (↔) according to the signal
pressure from the PC and LS valves. This
straight line movement is transmitted
through rod (13) to rocker cam (4), and
rocker cam (4), which is supported by the
cylindrical surface to cradle (2), slides in a
rotating movement in direction of arrow.
• With servo piston (12), the area receiving
the pressure is different on the left and
the right, so main pump discharge pres-
sure (self pressure) PP is always brought
to the chamber receiving the pressure at
the small diameter piston end.
• Output pressure Pen of the LS valve is
brought to the chamber receiving the
pressure at the large diameter end. The
relationship in the size of pressure PP at
the small diameter piston end and pres-
sure Pen at the large diameter end, and
the ratio between the area receiving the
pressure of the small diameter piston and
the large diameter piston controls the
movement of servo piston (12).
10-32 PC200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
LS VALVE
PC VALVE
PC200-7 10-33
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
Function
(1) LS valve
The LS valve detects the load and controls the
discharge amount.
This valve controls main pump discharge
amount Q according to differential pressure
∆PLS (=PP - PLS) [called the LS differential
pressure] (the difference between main pump
pressure PP and control valve outlet port
pressure PLS).
Main pump pressure PP, pressure PLS {called
the LS pressure} coming from the control
valve output, and pressure Psig {called the
LS selector pressure} from the proportional
solenoid valve enter this valve. The relation-
ship between discharge amount Q and differ-
ential pressure ∆PLS, (the difference between
main pump pressure PP and LS pressure
PLS) (= PP - PLS) changes as shown in the
diagram at the right according to LS pressure
selector current isig of the LS-EPC valve.
When isig changes between 0 and 1A, the set
pressure of the spring changes according to
this, and the selector point for the pump dis-
charge amount changes at the rated central
valve between 0.69 ↔ 2.2 MPa {7 ↔ 22 kg/
cm²}.
(2) PC valve
When the pump discharge pressure PP1
(self-pressure) and PP2 (other pump pres-
sure) are high, the PC valve controls the
pump so that no more oil than the constant
flow (in accordance with the discharge pres-
sure) flows even if the stroke of the control
valve becomes larger. In this way, it carries
out equal horsepower control so that the
horsepower absorbed by the pump does not
exceed the engine horsepower.
In other words, If the load during the opera-
tion becomes larger and the pump discharge
pressure rises, it reduces the discharge
amount from the pump; and if the pump dis-
charge pressure drops, it increases the dis-
charge amount from the pump. The
relationship between the average of the front
and rear pump discharge pressures (average
discharge amount of F, R pumps (PP1 +
PP2)/2) and pump discharge amount Q is
shown on the right, with the current given to
the PC-EPC valve solenoid shown as a param-
eter. The controller senses the actual speed of
the engine, and if the speed drops because of
an increase in the load, it reduces the pump the set value, the command current to the PC-
discharge amount to allow the speed to EPC valve solenoid from the controller
recover. In other words, when the load increases according to the drop in the engine
increases and the engine speed drops below speed to reduce the pump swash plate angle.
10-34 PC200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
OPERATION
SDP08884
PC200-7 10-35
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
SDP08885
2) Operation in increase direction for pump • For this reason, the pressure at the large
discharge amount diameter end of servo piston (12) becomes
• When the difference between the main pump drain pressure PT, and pump pressure PP
pressure PP and LS pressure PLS, in other enters port J at the small diameter end, so
words, LS differential pressure ∆PLS, servo piston (12) is pushed to the right. There-
becomes smaller (for example, when the area fore, the swash plate moves in the direction
of opening of the control valve becomes to make the discharge amount larger. If the
larger and pump PP drops), spool (6) is output pressure of the EPC valve for the LS
pushed to the right by the combined force of valve enters port G, this pressure creates a
LS pressure PLS and the force of spring (4). force to move piston (7) to the left. If piston
• When spool (6) moves, port D and port E are (7) is pushed to the left, it acts to make the set
joined and connected to the PC valve. When pressure of spring (4) weaker, and the differ-
this happens, the PC valve is connected to the ence between PLS and PP changes when
drain port, so circuit D - K becomes drain ports D and E of spool (6) are connected.
pressure PT. (The operation of the PC valve is
explained later).
10-36 PC200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
SDP08886
PC200-7 10-37
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
SDP08887
10-38 PC200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
(2) PC Valve
1) When pump controller is normal
a. When the load on the actuator is small
and pump pressures PP1 and PP2 are
low
➀ Movement of PC-EPC solenoid (1)
• The command current from the pump • the pressure (pressure of port C) output
controller flows to PC-EPC solenoid from the PC valve changes according to
(1).This command current acts on the PC- this position.
EPC valve and outputs the signal pres- • The size of command current X is deter-
sure. When this signal pressure is mined by the nature of the operation
received, the force pushing piston (2) is (lever operation), the selection of the
changed. working mode, and the set value and
• On the opposite side to the force pushing actual value for the engine speed.
this piston (2) is the spring set pressure of ★ Other pump pressure
springs (4) and (6) and pump pressure This is the pressure of the pump at the
PP1 (self pressure) and PP2 (other pump opposite end.
pressure) pushing spool (3). Piston (2) For the F pump, it is the R pump pressure
stops at a position where the combined For the R pump, it is the F pump pressure
force pushing spool (3) is balanced, and
PC200-7 10-39
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
SDP08889
➁ Action of spring
• The spring load of springs (4) and (6) in the • If the command circuit input to PC-EPC valve
PC valve is determined by the swash plate solenoid (1) changes further, the force push-
position. ing piston (2) changes, and the spring load of
• If piston (9) moves to the left, spring (6) is springs (4) and (6) also changes according to
compressed, and if it moves further to the left, the valve of the PC-EPC valve solenoid com-
spring (6) contacts seat (5) and is fixed in mand current.
position. In other words, the spring load is
changed by piston (9) extending or compress-
ing springs (4) and (6).
10-40 PC200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
PC200-7 10-41
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
10-42 PC200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
PC200-7 10-43
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
10-44 PC200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
PC200-7 10-45
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
LS(PC)-EPC VALVE
10-46 PC200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12O
FUNCTION
OPERATION
PC200-7 10-47
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
10-48 PC200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
12
CONTROL VALVE
PC200-7, PC200LC-7
1. 6-spool valve OUTLINE
2. Cover 1
3. Cover 2 • This control valve consists of a 6-spool
4. Pump merge-divider valve valve (unit type), 1 service valves, a pump
5. Back pressure valve merge-divider valve, a back pressure valve,
6. Boom lock valve and a boom hydraulic drift prevention
7. Service valve valve.
• Since all the valves are assembled together
with connecting bolts and their passes are
connected to each other inside the assem-
bly, the assembly is small in size and easy
to maintain.
• Since one spool of this control valve is
used for one work equipment unit, its struc-
ture is simple.
10-50 PC200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
12
7-spool valve
(6-spool valve + 1 service valves)
(1/9)
PC200-7 10-51
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
12
(2/9)
S*P09099
10-52 PC200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
12
(3/9)
PC200-7 10-53
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
12
(4/9)
Unit: mm
10-54 PC200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
12
(5/9)
Unit: mm
PC200-7 10-55
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
12
(6/9)
10-56 PC200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
Unit: mm
PC200-7 10-57
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
(7/9)
Unit: mm
10-58 PC200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
12
(8/9)
10-60 PC200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
Unit: mm
PC200-7 10-61
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
12
(9/9)
10-62 PC200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
Unit: mm
PC200-7 10-63
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
CONTROL VALVE
PC220-7, PC220LC-7
1. 6-spool valve OUTLINE
2. Cover 1
3. Cover 2 • This control valve consists of a 6-spool
4. Pump merge-divider valve valve (unit type), 1 service valves, a pump
5. Back pressure valve merge-divider valve, a back pressure valve,
6. Boom lock valve and a boom hydraulic drift prevention
7. Service valve valve.
• Since all the valves are assembled together
with connecting bolts and their passes are
connected to each other inside the assem-
bly, the assembly is small in size and easy
to maintain.
• Since one spool of this control valve is
used for one work equipment unit, its struc-
ture is simple.
10-64 PC200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
12
7-spool valve
(6-spool valve + 1 service valves)
(1/9)
PC200-7 10-65
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
12
(2/9)
S*P09102
10-66 PC200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
12
(3/9)
PC200-7 10-67
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
12
10-68 PC200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MULTI MONITOR SYSTEM
MAINTENANCE OPERATION
PC200-7 10-195
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MULTI MONITOR SYSTEM
ADJUSTMENT METHOD
02 Contrast
03 Brightness
10-196 PC200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MULTI MONITOR SYSTEM
PASSWORD FUNCTION
PC200-7 10-197
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MULTI MONITOR SYSTEM
08942
10-198 PC200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MULTI MONITOR SYSTEM
PC200-7 10-199
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MULTI MONITOR SYSTEM
10-200 PC200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MULTI MONITOR SYSTEM
08946
PC200-7 10-201
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD 7-SEGMENT MONITOR SYSTEM
SJP08775
OR
08931
• The monitor system monitors the condition • The monitor panel also has various mode
of the machine with sensors installed on vari- selector switches and functions to operate the
ous parts of the machine. It processes and machine control system.
immediately displays the obtained informa-
tion on the panel notifying the operator of the
condition of the machine.
The panel is roughly divided as follows.
1. Monitor section to output alarms when
the machine has troubles
2. Gauge section to display the condition
constantly (Coolant temperature, hydrau-
lic oil temperature, fuel level, etc.)
10-202 PC200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD 7-SEGMENT MONITOR SYSTEM
12
1. Monitor panel
PC200-7 10-203
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD 7-SEGMENT MONITOR SYSTEM
10-204 PC200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD 7-SEGMENT MONITOR SYSTEM
Air cleaner clogging When clogged Goes off. Flashes when abnormal.
SAP00521
PC200-7 10-205
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD 7-SEGMENT MONITOR SYSTEM
12
10-206 PC200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD 7-SEGMENT MONITOR SYSTEM
12
5. Demo-mode
1) In the demo-mode, the time is set to 250h,
the elapsed time is set to 240h, and
replacement of oil is displayed when the
key is turned on. The elapsed time does
not increase, however. The time can be
reset in this mode. Turn on the key 3
times in this mode, and the time interval
is automatically set to "Not set" at the 4th
time and after. The elapsed time is set to
"0h" and counting of elapsed time is
started.
PC200-7 10-207
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD 7-SEGMENT MONITOR SYSTEM
12
Mode selector switches
• There are 4 sets of the mode selector Operations table of switch section
switches on the switch section. Each time one
switch is pressed, the machine condition ★ The bold letters are the positions of the
changes. The current condition is indicated switches reset when the starting switch is
by the lighting of the LED above the switch. turned on.
• The initial setting of only the work mode after Item Operation
the starting switch is turned on can be
changed. Work mode A↔E↔B
★ For how to change the setting, see "Work Auto-deceleration ON↔OFF
mode default setting mode" in TROUBLE-
SHOOTING-Display and special functions of Wiper OFF↔Intermittent↔ON
monitor panel.
Travel speed Hi↔Lo
10-208 PC200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SENSOR
SENSOR
• The signals from the sensors are input to the
panel directly. Either side of a sensor of con-
tact type is always connected to the chassis
ground.
Hydraulic
oil tempera- Resistance — —
ture
Coolant
Resistance — —
temperature
PC200-7 10-209
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SENSOR
12
1. Connector
2. Bracket
3. Float
4. Switch
1. Plug
2. Contact ring
3. Contact
4. Diaphragm
5. Spring
6. Terminal
1. Thermistor 4. Tube
2. Body 5. Wire
3. Tube 6. Connector
10-210 PC200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SENSOR
12
1. Float
2. Connector
3. Cover
4. Variable resistor
PC200-7 10-211
90 OTHERS
PC200-7 90-1
OTHERS HYDRAULIC CIRCUIT DIAGRAM
PC200-7 90-3
OTHERS HYDRAULIC CIRCUIT DIAGRAM
PC200-7 90-5
OTHERS ELECTRICAL CIRCUIT DIAGRAM (1/5)
PC200-7 90-7
OTHERS ELECTRICAL CIRCUIT DIAGRAM (1/5)
PC200-7 90-9
OTHERS ELECTRICAL CIRCUIT DIAGRAM (2/5)
PC200-7 90-11
OTHERS ELECTRICAL CIRCUIT DIAGRAM (3/5)
PC200-7, PC200LC-7
PC220-7, PC220LC-7
PC200-7 90-13
OTHERS ELECTRICAL CIRCUIT DIAGRAM (4/5)
PC200-7, PC200LC-7
PC220-7, PC220LC-7
PC200-7 90-15
OTHERS ELECTRICAL CIRCUIT DIAGRAM (5/5)
PC200-7 90-17
OTHERS ELECTRICAL CIRCUIT DIAGRAM FOR AIR CONDITIONER
PC200-7 90-19
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MULTI MONITOR SYSTEM
MAINTENANCE OPERATION
PC200-7 10-195
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MULTI MONITOR SYSTEM
ADJUSTMENT METHOD
02 Contrast
03 Brightness
10-196 PC200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MULTI MONITOR SYSTEM
PASSWORD FUNCTION
PC200-7 10-197
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MULTI MONITOR SYSTEM
08942
10-198 PC200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MULTI MONITOR SYSTEM
PC200-7 10-199
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MULTI MONITOR SYSTEM
10-200 PC200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MULTI MONITOR SYSTEM
08946
PC200-7 10-201
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD 7-SEGMENT MONITOR SYSTEM
SJP08775
OR
08931
• The monitor system monitors the condition • The monitor panel also has various mode
of the machine with sensors installed on vari- selector switches and functions to operate the
ous parts of the machine. It processes and machine control system.
immediately displays the obtained informa-
tion on the panel notifying the operator of the
condition of the machine.
The panel is roughly divided as follows.
1. Monitor section to output alarms when
the machine has troubles
2. Gauge section to display the condition
constantly (Coolant temperature, hydrau-
lic oil temperature, fuel level, etc.)
10-202 PC200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD 7-SEGMENT MONITOR SYSTEM
12
1. Monitor panel
PC200-7 10-203
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD 7-SEGMENT MONITOR SYSTEM
10-204 PC200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD 7-SEGMENT MONITOR SYSTEM
Air cleaner clogging When clogged Goes off. Flashes when abnormal.
SAP00521
PC200-7 10-205
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD 7-SEGMENT MONITOR SYSTEM
12
10-206 PC200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD 7-SEGMENT MONITOR SYSTEM
12
5. Demo-mode
1) In the demo-mode, the time is set to 250h,
the elapsed time is set to 240h, and
replacement of oil is displayed when the
key is turned on. The elapsed time does
not increase, however. The time can be
reset in this mode. Turn on the key 3
times in this mode, and the time interval
is automatically set to "Not set" at the 4th
time and after. The elapsed time is set to
"0h" and counting of elapsed time is
started.
PC200-7 10-207
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD 7-SEGMENT MONITOR SYSTEM
12
Mode selector switches
• There are 4 sets of the mode selector Operations table of switch section
switches on the switch section. Each time one
switch is pressed, the machine condition ★ The bold letters are the positions of the
changes. The current condition is indicated switches reset when the starting switch is
by the lighting of the LED above the switch. turned on.
• The initial setting of only the work mode after Item Operation
the starting switch is turned on can be
changed. Work mode A↔E↔B
★ For how to change the setting, see "Work Auto-deceleration ON↔OFF
mode default setting mode" in TROUBLE-
SHOOTING-Display and special functions of Wiper OFF↔Intermittent↔ON
monitor panel.
Travel speed Hi↔Lo
10-208 PC200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SENSOR
SENSOR
• The signals from the sensors are input to the
panel directly. Either side of a sensor of con-
tact type is always connected to the chassis
ground.
Hydraulic
oil tempera- Resistance — —
ture
Coolant
Resistance — —
temperature
PC200-7 10-209
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SENSOR
12
1. Connector
2. Bracket
3. Float
4. Switch
1. Plug
2. Contact ring
3. Contact
4. Diaphragm
5. Spring
6. Terminal
1. Thermistor 4. Tube
2. Body 5. Wire
3. Tube 6. Connector
10-210 PC200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SENSOR
12
1. Float
2. Connector
3. Cover
4. Variable resistor
PC200-7 10-211
90 OTHERS
PC200-7 90-1
OTHERS HYDRAULIC CIRCUIT DIAGRAM
PC200-7 90-3
OTHERS HYDRAULIC CIRCUIT DIAGRAM
PC200-7 90-5
OTHERS ELECTRICAL CIRCUIT DIAGRAM (1/5)
PC200-7 90-7
OTHERS ELECTRICAL CIRCUIT DIAGRAM (1/5)
PC200-7 90-9
OTHERS ELECTRICAL CIRCUIT DIAGRAM (2/5)
PC200-7 90-11
OTHERS ELECTRICAL CIRCUIT DIAGRAM (3/5)
PC200-7, PC200LC-7
PC220-7, PC220LC-7
PC200-7 90-13
OTHERS ELECTRICAL CIRCUIT DIAGRAM (4/5)
PC200-7, PC200LC-7
PC220-7, PC220LC-7
PC200-7 90-15
OTHERS ELECTRICAL CIRCUIT DIAGRAM (5/5)
PC200-7 90-17
OTHERS ELECTRICAL CIRCUIT DIAGRAM FOR AIR CONDITIONER
PC200-7 90-19