Sebda2050508 SM PC220-5

SEBMA2050508
(SEBM02050508)
KOMRt bU
PC200,2OoLC-5
PC200,2ooLC-5
MIGHTY
PC220,22OLC-5
MACHINE MODEL
PC2004
PC2004 MIGHTY
PC2OOLC-5
PC2OOLC-5 MIGHTY
PC220-5
PC22OLC-5
SERIAL NO.
45001 and up
A70001 and up
58019 and up
45001 and up
A70001 and up
58019 and up
35001 and up
35001 and up
A70001 and up
0 Open Serial Numbers references (i.e. 45001 and up) apply to all machine Serial Numbers listed above.
Closed Serial Numbers references (i.e. 4500145003) apply only to those machine Serial Numbers.
l This shop manual may contain attachments and optional equipment that are not available in your area.
Please consult your local Komatsu distributor for those items you may require. Material and specification
are subject to change without notice.
l PC200, 2OOLG5, MIGHTY mount the S6D95L engine;
PC220, 22OLG5 mount the SA6D95L engine.
For details of the engine, see the 95 Series Engine Shop Manual.
FEB 92
00-l
@
CONTENTS
No. of page
10 STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . lo-1
20 TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . ~~-1
30 DISASSEMBLY AND ASSEMBLY . . . . . . : . . . . . 3o_1
40 MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . 4o_1
Not to be reproduced in whole or in part without the prior written permission of
KOMAl!BU, Tokyo, Japan.
The affected pages are indicated by the use of
the following marks. It is requested that necessary
actions be taken to these pages according to the
table below.
Mark Indication Action required
0 Page to be newly added Add
0 Page to be replaced Replace
(
) Page to be deleted Discard
Pages having no marks are those previously revised
or made additions.
Mark Page
Ti me of
revi si on
. oo- 1
. oo- 2
l oo- 2- l
. oo- 2- 2
l 00- 2- 3
l 00- 2- 4
l oo- 3
l oo- 4
l oo- 5
. 00- 6
. oo- 7
l 00- 8
l oo- 9
l 00- 10
. 00- 11
. 00- 12
l 00- 13
. 00- 14
l 00- 15
l 00- 16
0 00- 17
0 00- 18
0 00- 19
0 00- 20
0 00- 21
0 00- 22
0 00- 23
0 00- 24
LIST OF REVISED PAGES
Mark Page
Ti me of
revi si on
lo- 1
l o- 2
. I O- 3
0 l o- 3- 1
I O- 4
I O- 4- 1
I O- 4- 2
l I O- 5
l I O- 6
l o- 7
l o- 8
l o- 9
I O- I O
I O- 11
I O- 12
l I O- 13
0 I O- 14
10- 15
l l o- 16
. 10- 17
l I O- 18
I O- 19
0 10- 19- I
10- 20
10- 20- l
10- 20- 2
I O- 21
I O- 22
Mark Page
Ti me of
revi si on
I O- 23
I O- 24
I O- 25
l o- 26
l o- 27
l o- 28
10- 29
I O- 30
I O- 31
I O- 32
I O- 33
10- 34
10- 35
l o- 36
l I O- 37
. I O- 38
I O- 39
. I O- 40
I O- 41
I O- 42
I O- 43
10- 44
I O- 45
l 10- 45- I
10- 45- Z
1 o- 45- 3
10- 45- 4
10- 45- 5
Mark Page
Ti me of
revi si on
10- 45- 6
0 10- 45- 7
0 10- 45- 8
0 10- 45- g
0 1 O- 45- 10
0 1 o- 45- 11
0 1 O- 45- 12
I O- 46
10- 47
l o- 48
10- 49
10- 49- I
10- 50
1 o- 51
I O- 52
1 o- 53
1 o- 54
1 O- 56
10- 57
I O- 58
I O- 59
I O- 60
I O- 61
I O- 62
I O- 65
l I O- 66
I O- 67
I O- 68
Mark Page
Ti meof
revi si on
1 O- 69
. 10- 69- I
1 O- 69- 2
1 O- 69- 3
1 O- 69- 4
I O- 70
I O- 71
I O- 72
. I O- 73
. I O- 74
I O- 75
I O- 76
l I O- 77
1 o- 77- 1
l 1 O- 77- 2
. 1 o- 77- 3
10- 77- 4
. I O- 78
l I O- 79
I O- 80
l o- 81
I O- 82
l o- 83
. l o- 84
1 O- 85
l 1 O- 86
I O- 87
l 10- 88
Mark Page
Ti me of
revi si on
1 O- 89
l 1 O- 89- 1
1 O- 89- 2
l 1 O- 89- 3
1 O- 89- 4
1 O- 89- 5
. 1 O- 89- 6
0 1 O- 89- 8
1 O-90
l 1 o- 91
l 1 o-92
1 o-93
1 o-94
1 o-95
1 O- 96
1 o-97
1 O- 97- 1
1 o-97-2
l 1 o-97-3
1 O- 98
. 1 o-99
0 1 o-99-1
. 1 o-99-2
10-100
. 10-101
. 10- 102
. 10- 103
l I O- 104
I O- 105
I O- 106
0 I O- 107
I O- 109
10- 110
10- 111
I O- 112
10- 113
. 10- 114
. 10- 115
l o- 116
I O- 117
Vl ark Page
Ti me of
revi si on
0 I O- 118
10- 118- 1
10- 118- 2
l I O- 119
l 10- 120
0 10- 121
10- 122
l o- 123
l o- 124
10- 124- I
10- 124- 2
10- 124- 3
10- 124- 4
I O- 125
I O- 126
l I O- 127
. I O- 128
I O- 129
I O- 130
I O- 131
I O- 132
20- 1
20- 2
20- 3
20- 4
20- 5
. 20- 6
. 20- 7
20. 8
20- 9
20- 10
20- 11
20- 12
20- 13
20- 14
20- 15
20- 16
20- 18
Vl ark Page
Ti me of
Mark Page
Ti me of
revi si on revi si on
20- 19
0 20- 20
0 20- 21
0 20- 22
20- 23
0 20- 24
l 20- 25
20- 26
20- 27
l 20- 28
a 20- 28- I
20- 28- 2
20- 28- 3
20- 29
20- 30
20- 31
20- 32
20- 33
20- 33- I
20- 34
20- 35
20- 36
20- 37
20- 38
20- 39
20- 40
20- 41
20- 42
20- 43
20- 44
20- 45
20- 46
20- 47
20- 47- I
. 20- 47- 2
0 20- 48
0 20- 49
l 20- 49- l
. 20- 49- 2
20- 50
20- 51
20- 52
20- 53
20- 54
20- 55
20- 56
20- 57
20- 58
20- 59
20- 60
20- 61
20- 62
20- 63
20- 64
20- 65
20- 66
20- 67
l 20- 68
l 20- 69
l 20- 70
. 20- 71
0 20- 72
l 20- 73
. 20- 74
. 20- 75
. 20- 76
20- 77
0 20- 78
20- 79
20- 90
20- 91
20- 92
20- 93
20- 94
20- 95
20- 96
20- 97
20- 97- l
. 20- 98
. 20- 99
Mark Page
Ti me of
revi si on
0 20- 100
0 20- 101
20- 102
. 20- 103
20- 104
. 20- 104- I
20- 105
0 20- 106
20- 107
0 20- 107- l
20- 107- 2
20- 108
20- 109
20- 110
20- 111
20- 113
. 20- 114
20- 115
. 20- 116
0 20- 117
0 20- 117- l
0 20- 117- 2
0 20- 117- 3
0 20- 117- 4
20- 118
. 20- 119
. 20- 120
20- 121
20- 122
20- 123
20- 124
20- 126
20- 127
l 20- 128
20- 129
0 20- 129- l
20- 129- 2
0 20- 130
20- 131
20- 132
Mark Page
Ti me of
revi si on
20- 133
. 10- 133- I
20- 133- 2
20- 133- 3
20- 133- 4
0 20- 134
20- 135
. 20- 135- I
20- 135- 2
0 20- 136
20- 137
0 20- 137- l
20- 137- 2
l 20- 137- 3
20- 137- 4
20- 138
20- 139
l 20- 140
. 20- 141
. 20- 142
. 20- 142- I
. 20- 143
. 20- 144
. 20- 145
. 20- 146
. 20- 147
20- 148
20- 149
. 20- 150
. 20- 151
0 20- 152
. 20- 153
0 20- 154
20- 155
20- 156
20- 157
20- 158
20- 159
20- 160
20- 161
Mark Page
Ti me of
revi si on
Mark Page
Ti me of
Page
Ti me of
revi si on
Mark
revi si on
20- 162
20- 163
20- 164
20- 165
20- 166
20- 167
20- 169
. 20- 170
0 20- 171
l 20- 172
20- 173
20- 174
20- 175
20- 176
20- 177
20- 178
20- 179
20- 180
20- 181
20- 182
20- 183
20- 184
20- 185
20- 186
20- 187
20- 188
20- 189
20- 190
20- 192
20- 193
20- 194
20- 195
20- 196
20- 198
20- 199
20- 200
20- 201
20- 202
20- 203
20- 204
20- 205
20- 206
20- 207
20- 208
20- 209
20- 210
20- 211
20- 213
20- 214
20- 215
20- 216
20- 217
. 20- 218
20- 219
20- 220
20- 221
20- 222
20- 223
20- 224
20- 225
20- 226
20- 227
20- 228
20- 229
0 20- 230
20- 231
20- 232
20- 233
20- 234
20- 235
20- 236
20- 237
20- 238
20- 239
20- 240
20- 241
20- 242
20- 243
20- 244
0 20- 245
. 20- 246
. 30- 1
0 30. 2
30. 4
30. 5
30. 6
l 30. 7
30- 7- I
0 30- 7- 2
. 30- 8
. 30- 9
a 30- 10
( 30- 10- I )
0 30- 11
30- 12
30- 13
30- 14
30- 15
30- 16
30- 17
30- 18
30- 19
30- 20
30- 21
30- 22
30- 23
30- 24
30- 25
30- 26
30- 27
30- 28
30- 29
30- 30
30- 31
30- 32
30- 33
30- 34
30- 35
Mark Page
Ti me of
revi si on
30- 36
30- 37
30- 38
30- 39
30- 40
30- 41
. 30- 42
0 30- 42- I
0 30- 42- 2
0 30- 43
30- 43- 1
30. 43- 2
30- 43- 3
30- 43- 4
30- 43. 5
30- 43. 6
30- 43. 7
30- 43. 8
30. 43- 9
30- 43- 10
30- 43- 11
30- 43- 12
30- 43- 13
30- 43- 14
30- 44
30- 45
30- 45- I
30- 45- 2
30- 45- 3
30- 45- 4
30- 45- 5
30- 45- 6
30- 45- 7
30- 45- 8
30- 46
30- 47
30- 48
30- 49
30- 50
30- 51
00$3
i
Mark Page
Ti me of
revi si on
Mark Page
Ti me of
Mark Page
Ti me of
Mark Page
Ti me of
revi si on revi si on revi si on
30- 52
30- 53
30- 54
30- 55
30- 56
30- 57
30- 58
30- 59
30- 60
30- 61
30- 62
30- 63
30- 64
30- 65
30- 65- I
30- 65- 2
30- 65- 3
30- 65- 4
30- 65- 5
30- 65- 6
30- 65- 7
30- 65- 8
30- 65- g
30- 65- 10
30- 65- 11
30- 65- 12
30- 65- 13
30- 65- 14
30- 65- 15
30- 65- 16
30- 65- 17
30- 65- 18
30- 66
30- 67
30- 68
30- 69
30- 70
30- 71
30- 72
30- 73
30- 74
30- 75
. 30- 76
. 30- 77
0 30- 77- l
0 30- 77- 2
0 30- 77- 3
0 30- 77- 4
30- 78
30- 79
30- 80
30- 81
30- 82
30- 83
30- 83- l
30- 83- 2
30- 84
30- 85
30- 85- I
30- 85- 2
30- 86
30- 87
30- 88
30- 89
30- 90
30- 91
30- 92
30- 93
30- 94
30- 95
30- 95- l
30- 95- 2
30- 96
30- 97
30- 98
30- 99
30- 100
30- 101
30- 102
30- 103
30- 104
30- 105
30- 106
30- 107
40- 1
0 40. 2
40- 3
40- 4
40- 5
40- 6
40- 7
40- 8
40. 9
40- 10
40- 11
40- 12
40- 13
40- 13- 2
40- 14
0 40- 15
40- 16
40- 17
40- 18
40- 19
40- 20
40- 21
0 40- 21- 2
40- 21- 3
40- 21- 4
40- 21- 5
40- 21- 6
40- 21- 7
40- 21- 8
( 40- 21- 9)
0 40- 21- 10
0 40- 21- 11
0 40- 21- 12
0 40- 21- 13
0 40- 21- 14
0 40- 21- 15
0 40- 21- 16
0 40- 21- 17
40- 22
40- 23
40- 24
. 40- 25
. 40- 26
40- 27
. 40- 27- I
. 40- 27- 2
0 40- 28
40- 29
40- 30
40- 31
Mar. k Page
Ti me of
revi si on
oii-4
A
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for the safe operation of your machine.
The service and repair techniques recommended by Komatsu and described in this
manual are both effective and safe methods of operation. Some of these operations re-
quire the use of tools specially designed by Komatsu for the purpose.
A
YY
To prevent injury to workers, the symbols and
$
are used to mark safety pre-
cautions in this manual. The cautions accompanying these symbols should always be
followed carefully. If any dangerous situation arises or may possibly arise, first consider
safety, and take the necessary actions to deal with the situation.
A SAFETY
GENERAL PRECAUTIONS
Mistakes in operation are extremely dangerous.
Read the Operation and Maintenance Manual
carefully BEFORE operating the machine.
1. Before carrying out any greasing or repairs,
read all the precautions given on the
decals which are fixed to the machine.
2.When carrying out any operation, always
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons
missing.
l Always wear safety glasses when hitting
parts with a hammer.
. Always wear safety glasses when
grinding parts with a grinder, etc.
3. If welding repairs are needed, always have a
trained, experienced welder carry out the
work. When carrying out welding work,
always wear welding gloves, apron, glasses,
cap and other clothes suited for welding
work.
4.When carrying out any operation with two
or more workers, always agree on the op-
erating procedure before starting. Always
inform your fellow workers before starting
any step of the operation. Before starting
work, hang UNDER REPAIR signs on the
controls in the operators compartment.
5. Keep all tools in good condition and learn
the correct way to use them.
6. Decide a place in the repair workshop to
keep tools and removed parts. Always keep
the tools and parts in their correct places.
Always keep the work area clean and make
sure that there is no dirt or oil on the floor.
Smoke only in the areas provided for
smoking. Never smoke while working.
PREPARATIONS FOR WORK
7. Before adding oil or making any repairs,
park the machine on hard, level ground, and
block the wheels or tracks to prevent the
machine from moving.
8. Before starting work, lower blade, ripper,
bucket or any other work equipment to the
ground. If this is not possible, insert the
safety pin or use blocks to prevent the work
equipment from falling. In addition, be sure
to lock all the control levers and hang
warning signs on them.
9. When disassembling or assembling, sup-
port the machine with blocks, jacks or
stands before starting work.
10. Remove all mud and oil from the steps or
other places used to get on and off the
machine. Always use the handrails, ladders
or steps when getting on or off the
machine. Never jump on or off the machine.
If it is impossible to use the handrails,
ladders or steps, use a stand to provide safe
footing.
00-3
PRECAUTIONS DURING WORK
19. Be sure to assemble all parts again in their
original places.
11. When removing the oil filler cap, drain plug
or hydraulic pressure measuring plugs,
loosen them slowly to prevent the oil from
spurting out.
Before disconnecting or removing compo-
nents of the oil, water or air circuits, first
remove the pressure completely from the
circuit.
Replace any damaged parts with new parts.
. When installing hoses and wires, be
sure that they will not be damaged by
contact with other parts when the ma-
chine is being operated.
20. When installing high pressure hoses, make
sure that they are not twisted. Damaged
tubes are dangerous, so be extremely care-
ful when installing tubes for high pressure
circuits. Also, check that connecting parts
are correctly installed.
12.The water and oil in the circuits are hot
when the engine is stopped, so be careful
not to get burned.
Wait for the oil and water to cool before car-
rying out any work on the oil or water
circuits.
21
13. Before starting work, remove the leads from
the battery. Always remove the lead from
the negative (-1 terminal first.
14. When raising heavy components, use a
When assembling or installing parts, always
use the specified tightening torques. When
installing protective parts such as guards, or
parts which vibrate violently or rotate at
high speed, be particularly careful to check
that they are installed correctly.
hoist or crane.
Check that the wire rope, chains and hooks
are free from damage.
Always use lifting equipment which has
ample capacity.
Install the lifting equipment at the correct
places. Use a hoist or crane and operate
slowly to prevent the component from hit-
ting any other part. Do not work with any
part still raised by the hoist or crane.
15. When removing covers which are under in-
ternal pressure or under pressure from a
spring, always leave two bolts in position on
opposite sides. Slowly release the pressure,
then slowly loosen the bolts to remove.
16. When removing components, be careful not
to break or damage the wiring. Damaged
wiring may cause electrical fires.
17. When removing piping, stop the fuel or oil
from spilling out. If any fuel or oil drips on to
the floor, wipe it up immediately. Fuel or oil
on the floor can cause you to slip, or can
even start fires.
18.As a general rule, do not use gasoline to
wash parts. In particular, use .only the mini-
mum of gasoline when washing electrical
parts.
22. When aligning two holes, never insert your
fingers or hand. Be careful not to get your
fingers caught in a hole.
23. When measuring hydraulic pressure, check
that the measuring tool is correctly assem-
bled before taking any measurements.
24.Take care when removing or installing the
tracks of track-type machines.
When removing the track, the track sepa-
rates suddenly, so never let anyone stand at
either end of the track.
00-4
FOREWORD
This shop manual has been prepared as an aid to improve the quality of repairs by giving the
serviceman an accurate understanding of the product and by showing him the correct way to perform
repairs and make judgements. Make sure you understand the contents of this manual and use it to full
effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in
a service workshop.
For ease of understanding, the manual is divided into chapters for each main group of
components; these chapters are further divided into the following sections.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give
an understanding of the structure, but also serves as reference material for troubleshooting.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as
adjustments to be made at completion of the checks and repairs.
Troubleshooting charts correlating Problems to Causes are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or
assembling each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
NOTICE
The specifications contained in this shop manual are subject to change at any
time and without any advance notice. Contact your KOMATSU distributor for the
latest information.
I I
00-5
HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL
VOLUMES
Shop manuals are issued as a guide to carry-
ing out repairs. They are divided as follows:
Chassis volume: issued for every machine
model
Engine volume: Issued for each engine series
Electrical volume :
Attachments volume :
Each issued as
one volume to
cover all models
These various volumes are designed to avoid
duplicating the same information. Therefore to
deal with all repairs for any model, it is neces-
sary that chassis, engine, electrical and attach-
ment volumes are ready.
DISTRIBUTION AND UPDATING
Any additions, amendments or other
changes will be sent to KOMATSU distributers.
Get the most up-to-date information before
you start any work.
FILING METHOD
1. See the page number on the bottom of the
page. File the pages in correct order.
2. Following examples shows how to read the
page number.
Example 1 (Chassis volume):
10-3
TT
3.
Item number (IO. Structure
and Function)
Consecutive page number for
each item.
Example 2 (Engine volume):
12-410
t
Unit number (I. Engine)
Item number (2. Testing and
Adjusting)
Group No. (4. Fuel system)
Consecutive page No. (Page
10 of Group 4)
Additional pages: Additional pages are in-
dicated by a hyphen i-1 and number after the
page number. File as in the example.
Example:
1 o-4 12-203
REVISED EDITION MARK (a@)@ .... )
When a manual is revised, an edition mark is
recorded on the bottom outside corner of the
pages.
REVISIONS
Revised pages are shown at the LIST OF
REVISED PAGES on the between the title page
and SAFETY page.
SYMBOLS
So that the shop manual can be of ample
practical use, important places for safety and
quality are marked with the following symbols.
Symbol Item
*
el
kg
Q
Safety
Caution
Weight
Tighten-
ig torque
Coat
Xl. water
Drain
Remarks
Special safety precautions are
necessary when performing the
work.
Extra special safety precautions
are necessary when performing
the work because it is under
internal pressure.
Special technical precautions or
other precautions for
preserving standards are
necessary when performing the
work.
Weight of parts or systems.
Caution necessary when
selecting hoisting wire, or when
working posture is important,
etc.
Places that require special
attention for the tightening
torque during assembly.
Places to be coated with
adhesives and lubricants etc.
Places where oil, water or fuel
must be added, and the
capacity.
Places where oil or water must
be drained, and quantity to be
drained.
1 o-5 12-204
00-6
HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
A
Heavy parts (25 kg or more) must be
lifted with a hoist etc. In the Disassembly
and Assembly section, every part weigh-
ing 25 kg or more is indicated clearly with
the symbol &
1. If a part cannot be smoothly removed from
the machine by hoisting, the following
checks should be made:
. Check for removal of all bolts fastening
the part to the relative parts.
. Check for existence of another part
causing interference with the part to be
removed.
2. Wire ropes
I) Use adequate ropes depending on the
weight of parts to be hoisted, referring to
the table below:
Wire ropes
(Standard Z or S twist ropes
without galvanizing)
Rope diameter (mm) Allowable load (tons)
10 1 .o
11.2 1.4
12.5 1.6
14 2.2
16 2.8
18 3.6
20 4.4
22.4 5.6
30 10.0
40 18.0
50 28.0
60 40.0
The allowable load value is estimated to
be one-sixth or one-seventh of the
breaking strength of the rope used.
2) Sling wire ropes from the middle portion
of the hook.
Slinging near the edge of the hook may
cause the rope to slip off the hook during
hoisting, and a serious accident can result.
Hooks have maximum strength at the
middle portion.
100% 88% 79% 71% 41%
FSO064
3) Do not sling a heavy load with one rope
alone, but sling with two or more ropes
symmetrically wound on to the load.
A
Slinging with one rope may cause
turning of the load during hoisting,
untwisting of the rope, or slipping of
the rope from its original winding
position on the load, which can result
in a dangerous accident.
4) Do not sling a heavy load with ropes
forming a wide hanging angle from the
hook.
When hoisting a load with two or more
ropes, the force subjected to each rope
will increase with the hanging angles. The
table below shows the variation of
allowable load (kg) when hoisting is made
with two ropes, each of which is allowed
to sling up to 1000 kg vertically, at various
hanging angles.
When two ropes sling a load vertically, up
to 2000 kg of total weight can be
suspended. This weight becomes 1000 kg
when two ropes make a 120 hanging
angle. On the other hand, two ropes are
subjected to an excessive force as large as
4000 kg if they sling a 2000 kg load at a
lifting angle of 150.
60 90
Lifting angle : a
120 15o
FSO065
00-7
STANDARD TIGHTENING TORQUE
mm
1 STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS
The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in
sections of Disassembly and Assembly.
Thread diameter Width
of bolt across flat
(mm) (mm) 0
?
0
z
kgm
Nm
6 10 1.35kO.15 13.2* 1.4
8 13 3.2kO.3 31.4+-2.9
10 17 6.7 +0.7 65.7k6.8
12 19 11.5fl.O 112k9.8
14 22 18.Ok2.0 177*19
16 24 28.5*3 279&29
18 27 39+-4 383t39
20 30 56a6 549t58
22 32 76+8 745 & 78
24 36 94.5*10 927?98
27 41 135*15 1320t140
30 46 175*20 172Ok 190
33 50 225*25 221 O-+240
36 55 280?30 2750a 290
39 60 335*35 328Ok 340
This torque table does not apply to the bolts with which nylon packings or other non-
ferrous metal washers are to be used, or which require tightening to otherwise specified
torque.
Sr Nm (newton meter): 1 Nm & 0.1 kgm
2.TlGHTENlNG TORQUE OF SPLIT FLANGE BOLTS
Use these torques for split flange bolts.
Threaorj gianeter
(mm)
10
12
16
Width
across flats
(mm)
14
17
22
Tightening torque
kgm
Nm
6.7kO.7 65.7k6.8
11.5*1 1 12+9.8
28.5*3 279*29
00-8
Sealing surface
3.TlGHTENlNG TORQUE FOR NUTS OF FLARED
Use these torques for nut part of flared.
Thread diameter Width across flats
of nut part of nut part
(mm) (mm)
T
kgm
14 19 2.5i0.5
18 24 5k2
22 27 822
24 32 14+3
30 36 18*3
33 41 20+5
36 46 25+5
42 55 30-+5
Tightening torque
COATING MATERIALS
Nm
24.5 24.9
49* 19.6
78.5 k 19.6
137.3229.4
176.5229.4
196.1 -t49
245.2 *49
294.2249
The recommended coating materials prescribed in Komatsu Shop Manuals are listed below.
Nomenclature Komatsu code Applications
LT-IA
LT-1B
Used to apply rubber pads, rubber gaskets, and cork plugs.
Used to apply resin, rubber, metallic and
non-metallic parts when a fast, strong seal is needed.
LT-2
LT-3
Preventing bolts, nuts and plugs from loosening and leaking oil.
Provides an airtight, electrically insulating seal.
Used for aluminum surfaces.
LT-4
Used to coat plugs (plate shaped, bowl shaped) and holes, and
mating portion of shaft.
Sealant gasket
LG-1
LG-3
LG-4
LG-5
Used with gaskets and packings to increase sealing effect.
Heat-resistant gasket for precombustion chambers
and exhaust piping.
Used b itself on mounting surfaces on the final drive and transmission
cases. Thickness after tightening: Y 0.07 - 0.08 mm)
Used by itself to seal grease fittings, tapered screw fittings and tapered
screw fittings in hydraulic circuits of less than 50 mm in diameter.
Antifriction compound
(Lubricant including
molybdenum disulfide)
Grease
(Lithium grease)
LG-6
LG-7
LM-P
G2-LI
Silicon base type used in combination with LG-1 and LG-4.
Has a shorter curing time than LG-6, and is easier
to peel off.
Applied to bearings and taper shafts to facilitate press-fitting and to
prevent sticking, burning or rusting.
Applied to bearings, sliding parts and oil seals for lubrication, rust
prevention and facilitation of assembling work.
Vaseline
I
-
Used for protecting battery electrode terminals from corrosion.
l LT-2 is also called LOCTITE in the shop manuals.
00-9
ELECTRIC WIRE CODE
ELECTRIC WIRE CODE
In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Nominal
Copper wire
Cable O.D. Current rating
number Number / Dia. of strands/ Cross section (mm) I (A)
Applicable circuit
0.85
2
strands (mm) (mm?
11 0.32 0.88
26 0.32 2.09
2.4 12 Starting, lighting, signal etc.
3.1 20 Lighting, signal etc.
5 65 I-~ 0.32
I
5.23 1 4.6
I
37
I
Charging and signal
15
I
84
I
0.45
I
13.36 7.0
I
59 1 Starting (Glow plug)
40
60
85
127
0.80
0.80
42.73
63.84
11.4
13.6
135
178
Starting
Starting
100 217 0.80 109.1 17.6
I
230 Starting
CLASSIFICATION BY COLOR AND CODE
Lighting Instrument Signal Other
L R Y G
Red Yellow Green Blue
GW LW RW YR
Red &White Yellow & Red Green & White Blue &White
GR LR
Auxi_ Color White&Black - Black &Yellow
liary _
Code WL BR
Green & Red Blue & Red
LY GY
Green &Yellow
(GB)
I I I
Color White 81 Blue - Black & Red Blue &Yellow
(LB)
Red & Green Yellow & Blue (Green &Black) (Blue &Black)
(GL)
(Green & Blue)
-
-
00- l 0
CONVERSION TABLE
CONVERSION TABLE
Method of using the Conversion Table
The Conversion Table in this section is provided to enable simple conversion of figures. For details of the
method of using the Conversion Table, see the example given below.
Example
l Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
(1)
(2)
(3)
Locate the number 50 in the vertical column at the left side, take this as @, then draw a horizontal
line from @.
Locate the number 5 in the row across the top, take this as @J, then draw a perpendicular line
down from @.
Take the point where the two lines cross as 0. This point 0 gives the value when converting
from millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.
(1) The number 550 does not appear in the table, so divide by IO (move the decimal point one place
to the left) to convert it to 55 mm.
(2) Carry out the came 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
@
I
@--
0 1 2 3 4 5; 6
I
0 0.039 0.079 0.118 0.157 0.197 / 0.236
10 0.394 0.433 0.472 0.512 0.551 0.591 I 0.630
20 0.787 0.827 0.866 0.906 0.945 0.984 I 1.024
30 1.181 1.220 1.260 1.299 1.339 1.378 j 1.417
40 1.575 1.614 1.654 1.693 1.732 1.772 I 1.811
0 /
50 1.969 2.008 2.047 2.087 2.126 -----
-----_
12.165 2.205 -----__---_.---____________------..
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780
1 mm = 0.03937 in
7 8 9
0.276 0.315 0.354
0.669 0.709 0.748
1.063 1.102 1.142
1.457 1.496 1.536
1.850 1.890 1.929
2.244 2.283 2.323
2.638 2.677 2.717
3.032 3.071 3.110
3.425 3.465 3.504
3.819 3.858 3.898
00-l 1
CONVERSI ONTABLE
Millimeters to Inches
1 mm =O. O3937i n
1 3 4
0.039 0. 079 0. 118 0. 157 0. 197
0. 433 0. 472 0. 512 0. 551 0. 591
0. 827 0. 866 0. 906 0. 945 0. 984
1. 220 1. 260 1. 299 1. 339 1. 378
1. 614 1. 654 1. 693 1. 732 1. 772
50 1. 969 2. 008
60 2. 362 2. 402
70 2. 756 2. 795
80 3. 150 3. 189
90 3. 543 3. 583
2. 047
2. 441
2. 835
3. 228
3. 622
2. 087 2. 126 2. 165
2. 480 2. 520 2. 559
2. 874 2. 913 2. 953
3. 268 3. 307 3. 346
3. 661 3. 701 3. 740
l-
Ki l ogram 0 1 2 3 4 5
2. 20
24. 25
46. 30
68. 34
90. 39
4. 41 6. 61 8. 82
26. 46 28. 66 30. 86
48. 50 50. 71 51. 91
70. 55 72. 75 74. 96
92. 59 94. 80 97. 00
11. 02
33. 07
55. 12
77. 16
99. 21
112. 44
134. 48
156. 53
178. 57
200. 62
114. 64
136. 69
158. 73
180. 78
202. 83
116. 85
138. 89
160. 94
182. 98
205. 03
I
119. 05
141. 10
163. 14
185. 19
207. 24
121. 25 123. 46 125. 66
143. 30 145. 51 147. 71
165. 35 167. 55 169. 76
187. 39 189. 60 191. 80
209. 44 211. 64 213. 85
/
6 8 9
0. 236 0. 276 0. 315 0. 354
0. 630 0. 669 0. 709 0. 748
1. 024 1. 063 1. 102 1. 142
1. 417 1. 457 1. 496 1. 536
1. 811 1. 850 1. 890 1. 929
2. 205 2. 244 2. 283 2. 323
2. 598 2. 638 2. 677 2. 717
2. 992 3. 032 3. 071 3. 110
3. 386 3. 425 3. 465 3. 504
3. 780 3. 819 3. 858 3. 898
0
0
10
20
30
40
0.394
0. 787
1. 181
1. 575
Kilogram to Pound 1 kg =2. 2046 l b
I
I :
I
6 7 8 9
13. 23
35. 27
57. 32
79. 37
101. 41
15. 43
37. 48
59. 53
81. 57
103. 62
17. 64 19.84
39. 68 41. 89
61. 73 63.93
83. 78 85.98
105. 82 108. 03
127. 87 130. 07
149. 91 152. 12
171. 96 174. 17
194. 01 196. 21
216. 05 218. 26
10 22. 05
20 44. 09
30 66. 14
40 88. 18
50 110. 23
60 132. 28
70 154. 32
80 176. 37
90 198. 42
00- 12
CONVERSI ONTABLE
Liter to U.S. Gallon
1 g =0. 2642 U. S. Gal
t
I
I
I
1 2 3 4 5 6 7 8 9 0
10 2. 642
20 5. 283
30 7. 925
40 10. 567
50 13. 209
60 15. 850
70 18. 492
80 21. 134
90 23. 775
0. 264
2. 906
5. 548
8. 189
10. 831
0. 528
3. 170
5. 812
8. 454
11. 095
13. 473 13. 737
16. 115 16. 379
18. 756 19. 020
21. 398 21. 662
24. 040 24. 304
0.793 1. 057 1. 321 1. 585 1. 849 2. 113 2. 37E
3. 434 3. 698 3. 963 4. 227 4. 491 4. 755 5. 015
6. 076 6. 340 6. 604 6. 869 7. 133 7. 397 7. 661
8. 718 8. 982 9. 246 9. 510 9. 774 10. 039 10. 30:
11. 359 11. 624 11. 888 12. 152 12. 416 12. 680 12. 944
14. 001 14. 265 14. 529 14. 795 15. 058 15. 322 15. 586
16. 643 16. 907 17. 171 17. 435 17. 700 17. 964 18. 228
19. 285 i 9. 549 19. 813 20. 077 20. 341 20. 605 20. 870
21. 926 22. 190 22. 455 22. 719 22. 983 23. 247 23. 511
24. 568 24. 832 25. 096 25. 361 25. 625 25. 889 26. 153
l- L
Liter to U.K. Gallon
1 P=O. 21997 U. K. Gal
c
1 2 3 4 5 6 7 8 9 0
10 2. 200
20 4. 399
30 6. 599
40 8. 799
0. 220 0. 440 0. 660 0. 880 1. 100 1. 320 1. 540 1. 760 1. 980
2. 420 2. 640 2. 860 3. 080 3. 300 3. 520 3. 740 3. 950 4. 179
4. 619 4. 839 5. 059 5. 279 5. 499 5. 719 5. 939 6. 159 6.379
6. 819 7. 039 7. 259 7. 479 7. 969 7. 919 8. 139 8. 359 8.579
9. 019 9. 239 9. 459 9. 679 9. 899 10. 119 10. 339 10. 559 10. 778
50 10. 998 11. 281 11. 438
60 13. 198 13. 418 13. 638
70 15. 398 15. 618 15. 838
80 17. 598 17. 818 18. 037
90 19. 797 20. 017 20. 237
11. 658 11. 878 12. 098 12. 318 12. 528 12. 758 12. 978
13. 858 14. 078 14. 298 14. 518 14. 738 14. 958 15. 178
16. 058 16. 278 16. 498 16. 718 16. 938 17. 158 17. 378
18. 257 18. 477 18. 697 18. 917 19. 137 19. 357 19. 577
20. 457 20. 677 20. 897 21. 117 21. 337 21. 557 21. 777
L
00- 13
CONVERSION TABLE
kgm to ft.lb
1 kg. m=7. 233f t. l b
0 1 2 3 4 5 6 7 8 9
7. 2 14. 5 21. 7 28. 9 36. 2 43. 4 50. 6 57. 9 65. 1
10 72. 3 79. 6 86. 8 94. 0 101. 3 108. 5 115. 7 123. 0 130. 2 137. 4
20 144. 7 151. 9 159. 1 166. 4 173. 6 180. 8 188. 1 195. 3 202. 5 209. 8
30 217. 0 224. 2 231. 5 1 238. 7 245. 9 253. 2 260. 4 267. 6 274. 9 282. 1
40 289. 3 396. 6 303. 8 311. 0 318. 3 325. 5 332. 7 340. 0 347. 2 354. 4
50 361. 7 368. 9 376. 1 383. 4 390. 6 397. 8 405. 1 412. 3 419. 5 426. 8
60 434. 0 441. 2 448. 5 455. 7 462. 9 470. 2 477. 4 484. 6 491. 8 499. 1
70 506. 3 513. 5 520. 8 528. 0 535. 2 542. 5 549. 7 556. 9 564. 2 571. 4
80 578. 6 585. 9 593. 1 600. 3 607. 6 614. 8 622. 0 629. 3 636. 5 643. 7
90 651. 0 658. 2 665. 4 672. 7 679. 9 687. 1 694. 4 701. 6 708. 8 716. 1
100 723. 3 730. 5 737. 8 745. 0 752. 2 759. 5 766. 7 773. 9 781. 2 788. 4
110 795. 6 802. 9 810. 1 817. 3 824. 6 831. 8 839. 0 846. 3 853. 5 860. 7
120 868. 0 875. 2 882. 4 889. 7 896. 9 904. 1 911. 4 918. 6 925. 8 933. 1
130 940. 3 947. 5 954. 8 962. 0 969. 2 976. 5 983. 7 990. 9 998. 2 1005. 4
140 1012. 6 1019. 9 1027. 1 1034. 3 1041. 5 1048. 8 1056. 0 1063. 2 1070. 5 1077. 7
150 1084. 9 1092. 2 1099. 4 1106. 6 1113. 9 1121. 1 1128. 3 1135. 6 1142. 8 1150. 0
160 1157. 3 1164. 5 1171. 7 1179. 0 1186. 2 1193. 4 1200. 7 1207. 9 1215. 1 1222. 4
170 1129. 6 1236. 8 1244. 1 1251. 3 1258. 5 1265. 8 1273. 0 1280. 1 1287. 5 1294. 7
180 1301. 9 1309. 2 1316. 4 1323. 6 1330. 9 1338. 1 1345. 3 1352. 6 1359. 8 1367. 0
190 1374. 3 1381. 5 1388. 7 1396. 0 1403. 2 1410. 4 1417. 7 1424. 9 1432. 1 1439. 4
00- 14
CONVERSI ONTABLE
kg/cm* to lb/in*
1 kg/ cm' = 14. 22331b/ i n2
0 1 2 3 4 5 6 7 8 9
14. 2 28. 4 42. 7 56. 9 71. 1 85. 3 99. 6 113. 8 128. 0
10 142. 2 156. 5 170. 7 184. 9 199. 1 213. 4 227. 6 241. 8 256. 0 270. 2
20 284. 5 298. 7 312. 9 327. 1 341. 4 355. 6 369. 8 384. 0 398. 3 412. 5
30 426. 7 440. 9 455. 1 469. 4 483. 6 497. 8 512. 0 526. 3 540. 5 554. 7
40 568. 9 583. 2 597. 4 611. 6 625. 8 640. 1 654. 3 668. 5 682. 7 696. 9
50 711. 2 725. 4 739. 6 753. 8 768. 1 782. 3 796. 5 810. 7 825. 0 839. 2
60 853. 4 867. 6 881. 8 896. 1 910. 3 924. 5 938. 7 953. 0 967. 2 981. 4
70 995. 6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 2863 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 3124 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- l 5
CONVERSION TABLE
Temperature
Fahrenheit-Centigrade Conversion. -A simple way to convert a Fahrenheit temperture reading into a Centigrade
temperature reading or vice versa is to enter the accompanying table in the center or boldface column of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees,consider the center column as a table of Fahrenheit
temperatures and read the corresponding Centigrade temperature in the column at the left.
If it isdesired 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.
OC OF OC OF OC OF OC "F
40. 4 - 40 - 40. 0 - 11. 7 11 51. 8 7. 8 46 114. 8 27. 2 81 117. 8
- 37. 2 - 35 - 31. 0 - 11. 1 12 53. 6 8. 3 47 116. 6 27. 8 a2 179. 6
- 34. 4 - 30 - 22. 0 - 10. 6 13 55. 4 8. 9 48 I l a. 4 28. 3 83 181. 4
- 31. 7 - 25 - 13. 0 - 10. 0 14 57. 2 9. 4 49 120. 2 28. 9 84 183. 2
- 28. 9 - 20 - 4. 0 - 9. 4 15 59. 0 10. 0 50 122. 0 29. 4 85 185. 0
- 28. 3 - 19 - 2. 2 - 8. 9 16 60. 8 10. 6 51 123. 8 30. 0 a6 186. 8
- 27. 8 - 18 - 0. 4 - 8. 3 17 62.6 11. 1 52 125. 6 30. 6 87 188. 6
- 27. 2 - 17 1. 4 -7.8 18 64. 4 11. 7 53 127. 4 31. 1 88 190. 4
- 26. 7 - 16 3. 2 - 7. 2 19 66. 2 12. 2 54 129. 2 31. 7 89 192. 2
- 26. 1 - 15 5. 0 - 6. 7 20 68. 0 12. 8 55 131. 0 32. 2 90 194. 0
- 25. 6 - 14 6. 8 - 6. 1 21 69. 8 13. 3 56 132. 8 32. 8 91 195. 8
- 25. 0 - 13 8. 6 - 5. 6 22 71. 6 13. 9 57 134. 6 33. 3 92 197. 6
- 24. 4 - 12 10. 4 - 5. 0 23 73. 4 14. 4 58 136. 4 33. 9 93 199. 4
- 23. 9 - 11 12. 2 - 4. 4 24 75. 2 15. 0 59 138. 2 34. 4 94 201. 2
- 23. 3 - 10 14. 0 - 3. 9 25 77. 0 15. 6 60 140. 0 35. 0 95 203. 0
- 22. 8 - 9 15. 8 - 3. 3 26 78. 8 16. 1 61 141. 8 35. 6 96 204. 8
- 22. 2 - 8 17. 6 - 2. 8 27 80. 6 16. 7 62 143. 6 36. 1 97 206. 6
- 21. 7 -7 19.4 - 2. 2 28 82. 4 17. 2 63 145. 4 36. 7 98 208. 4
- 21. 1 - 6 21. 2 - 1. 7 29 84. 2 17. 8 64 147. 2 37. 2 99 210. 2
- 20. 6 - 5 23. 0 - 1. 1 30 86. 0 18. 3 65 149. 0 37. 8 100 212. 0
- 20. 0 - 4 24. 8 - 0. 6 31 87. 8 18. 9 66 150. 8 40. 6 105 221. 0
- 19. 4 - 3 26. 6 0 32 89. 6 19. 4 67 152. 6 43. 3 110 230. 0
- 18. 9 - 2 28. 4 0. 6 33 91. 4 20. 0 68 154. 4 46. 1 115 239. 0
- 18. 3 - 1 30. 2 1. 1 34 93. 2 20. 6 69 156. 2 48. 9 120 248. 0
- 17. 8 0 32. 0 1. 7 35 95. 0 21. 1 70 158. 0 51. 7 125 257. 0
- 17. 2 1 33. 8 2. 2 36 96. 8 21. 7 71 159. 8 54. 4 130 266. 0
- 16. 7 2 35. 6 2. 8 37 98. 6 22. 2 72 161. 6 57. 2 135 275. 0
- 16. 1 3 37. 4 3. 3 38 100. 4 22. 8 73 163. 4 60. 0 140 284. 0
- 15. 6 4 39. 2 3. 9 39 102. 2 23. 3 74 165. 2 62. 7 145 293. 0
- 15. 0 5 41. 0 4. 4 40 104. 0 23. 9 75 167. 0 65. 6 150 302. 0
- 14. 4 6 42. 8 5. 0 41 105. 8 24. 4 76 168. 8 68. 3 155 311. 0
- 13. 9 7 44. 6 5. 6 42 107. 6 25. 0 77 170. 6 71. 1 160 320. 0
- 13. 3 a 46. 4 6. 1 43 109. 4 25. 6 78 172. 4 73. 9 165 329. 0
- 12. 8 9 48. 2 6. 7 44 111. 2 26. 1 79 174. 2 76. 7 170 338. 0
- 12. 2 10 50. 0 7. 2 45 113. 0 26. 7 80 176. 0 79. 4 175 34z. o
00- 16
WEIGHT TABLE
A
This weight table is a guide for use when transporting or handling components.
PC200,2OOLC-5
Machine Model
Serial Numbers
Engine assembly
l Engine
l Damper
l Hydraulic pump
Radiator and oil cooler assembly
Hydraulic tank assembly
(without hydraulic oil)
Fuel tank (without fuel)
Revolving frame
Operators cab
Operators seat
Counterweight
Swing machinery
Control valve assembly
Swing motor assembly
Travel motor assembly
Center swivel joint
Track frame assembly
l Track frame
l Swing circle assembly
l Idler
l Idler cushion
0 Carrier roller
l Track roller
l Final drive
PC200-5
45001 and up
647
432
20
195
91
Unit: kg
PC2OOLC-5
45001andup
647
432
20
195
91
194 194
98 98
1,555 1,555
238 238
31.7 31.7
3,300 3,300
258 258
171 171
50 50
137x2 137x2
43 43
4,391 4,604
2,362 2,390
270 270
140x2 140x2
135x2 135x2
21 x4 21 x4
37x14 37x18
322x2 322x2
Unit: kg
Machine Model PC200-5 I PC2OOLC-5
Serial Numbers
I
45001 and up
I
45001 and up
Track shoe assembly
l Triple-grouser shoe (500 mm)
I 1
I
2,360
I
-
I
2,620
I
2,850
l Flat shoe (610 mm)
2,870 3,120
3,130 3,400
3,380 3,680
3,280
-
l Swamp shoe (860 mm)
2,900
-
Boom assembly
Arm assembly 628
Bucket assembly
I
646
I
646
Boom cylinder assembly
I
187x2
I
187x2
Arm cylinder assembly
I
251
I
251
Bucket cylinder assembly
Link (large) assembly
I
153
I
153
I
80
I
80
Link (small) assembly
I
22 x 2
I
22 x 2
Boom pin
Arm pin
Bucket pin
Link pin
43+10x2 43+10x2
+25+10+20 +25+10+20
10x2 10x2
20 x 2 20 x 2
18x2 18x 2
PC200,2OOLC-5 MIGHTY
Machine Model
Serial Numbers
Engine assembly
l Engine
l Damper
l Hydraulic pump
Radiator and oil cooler assembly
Fuel tank (without fuel)
PC200-5 MIGHTY PC2OOLC-5 MIGHTY
58019 and up 58019 and up
647 647
432 432
20 20
195 195
105 105
194 194
I
98
I
98
Revolving frame 1,923 1,923
Operators cab 238 238
Operators seat 31.7 31.7
Counterweight
Swing machinery
Center swivel joint
I
4,300
I
4,300
I
258
I
258
I
171
I
171
I
50
I
50
I
137 x 2
I
137x2
I
43
I
43
Track frame assembly 4, 391
l Track frame 2,362
l Swing circle assembly 270
l Idler 140x2
l Idler cushion 135x2
l Carrier roller 21 x4
l Track roller 37x 14
l Final drive 322 x 2
4,604
2,390
270
140x2
135x2
21 x4
37x18
322 x 2
Unit: kg
Machine Model 1 PC200-5 MIGHTY 1 PC2OOLC-5 MIGHTY
Serial Numbers
I
58019 and up
I
58019 and up
Track shoe assembly
l Rubber shoe (600 mm)
2,360
-
2,620 2,850
2,940
Boom assembly 1,362 1,362
Arm assembly 875 875
Bucket assembly
710 710
187x2 187x2
251 251
182 182
80 80
I
30 x 2
I
30 x 2
Boom pin
43+10x2 43+10x2
+25+ IO+20 +25+10+20
Arm pin
10x2
Bucket pin 20 x 2 20 x 2
Link pin 18x2 18 x 2
0k20
PC220,22OLC-5
Unit: kg
Machine Model PC220-5 PC22OLC-5
Serial Numbers 35001 and up 35001 and up
Engine assy 647 647
l Engine 432 432
l Damper 20 20
l Hydraulic pump 195 195
Radiator and oil cooler assembly 101
Fuel tank assembly (without fuel) 98 98
Revolving frame 1,840 1,840
Operators cab 238 238
Operators seat 31.7 31.7
Counterweight 4,300 4,300
Swing machinery
I
258
I
258
Center swivel joint
50 50
137x2 137x2
Track frame assembly
l Track frame
0 Swing circle
l Idler
l Idler cushion
0 Carrier roller
l Track roller
l Final drive
4,920 5,565
2,824 3,275
270 270
140x2 140x2
135x2 135x2
21 x4 21 x4
37x16 37x20
322x2
I
322x2
Unit: kg
Machine Model PC220-5 PC22OLC-5
Serial Numbers
I
35001 and up
I
35001 and up
Track shoe assembly
2,460
-
2,730 2,960
3,000 3,250
3,260 3,540
Boom assembly
Arm assembly
Bucket assembly
718 718
774 774
214x2 214x2
I
297 297
182 182 ::
g
80 80 z
22 x 2 22 x 2
Boom pin
51+10x2 51+10x2
+30+10+32 +30-I-10+32
Arm pin
I
10x2
I
10x2
Bucket pin 20 x 2 20 x 2
Link pin 18x 2 18x2
0022
LIST OF LUBRICANT AND WATER
PC200,2OOLC-5 Serial No: 45001 - 58018
PC220,22OLC-5 Serial No: 35001 - 36613
KIND OF
I
. _... -._.
RESERVOIR
FLUID
14 32
- 1l - l n
I ..~ -- I AMBIENT TEMPERATURE
CAPACITY ( Q )
50 68 86 F
10 20 30C
Specified Refill
Engine oil pan
Swing machinery case
Final drive case (each)
Damper case
Engine oil
Track roller (1 piece)
Idler (1 piece)
18.5 17.5
11.3 10
,:..:: . . ,: :.. ., . . ., . . . : 7.6 7.6
I 1.0
: :
..:. :
I
230
: .:.i:::.:~.:~:.:.:::jl:~~~:~::~...::~.,~ :, :, :I : :: ::: .A: . . . . . -&
170
j- ,: . .: . . ;.:,,, , 5w_4: _;,:y+ ::,;;_:: :; j :.
I , I I I
0.19 - 0.21 0.19 - 0.21
Gear oil 0.23 0.25 _ 0.23 _ 0.25
0.07 - 0.08 0.07 - 0.08
Fuel tank Diesel fuel
:: 3% ;:::.
310
-
. . . .
.;.. :... ,:.,
,S, ,,.,, . . . . ..j.. i > : ASTM D975 No. 2. : ~,, :,,,
I I I I
z
Cooling system Water Add antifreeze 19.7
-
0 _
2 x ASTM D975 No. 1
NOTE:
(I) When fuel sulphur content is less than 0.5%, (2)
change oil in the oil pan every periodic main-
tenance hours described in this manual.
Change oil according to the following table if
fuel sulphur content is above 0.5%.
I (3)
Fuel sulphur content
I
Change interval of oil in
engine oil pan
When starting the engine in an atmospheric
temperature of lower than OC, be sure to
use engine oil of SAEI OW, SAEI OW-30 and
SAE15W-40 even though an atmospheric
temperature goes up to 10C more or less in
the day time.
Use API classification CD as engine oil and if
API classification CC, reduce the engine oil
change interval to half.
ASTM: American Society of Testing and Material
SAE: Society of Automotive Engineers
Specified capacity: Total amount of oil including oil for components and oil in piping
Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance.
o623
PC200,2OOLC-5 Serial No: 58019 and up
PC200,22OLC-5 MIGHTY
PC220,22OLC-5 Serial No: 36614 and up
RESERVOIR
Engine oil pan
Swing machinery cast
Final drive case (each:
Damper case
Hydraulic system
Carrier roller (1 piece)
Track roller (1 piece)
Idler (1 piece)
Fuel tank
Cooling system
KIND OF
FLUID
AMBIENT TEMPERATURE
CAPACITY ( Q )
14 32 50 68 86 F
-10 0 IO 20 3oc
I-r
Specified Refill
Water
., ., . . . . . .
1 I I I
Add antifreeze
19.7
[20.2]
% ASTM D975 No. 1
NOTE:
(I) When fuel sulphur content is less than 0.5%,
change oil in the oil pan every periodic main-
tenance hours described in this manual.
Change oil according to the following table if
fuel sulphur content is above 0.5%.
Fuel sulphur content
Change interval of oil in
engine oil pan
ASTM: American Society of Testing and Material
SAE: Society of Automotive Engineers
(2)
(3)
18.5
9.3
7.6
t
t
I.1 9 - 0.21
8.23 - 0.25
.07 - 0.08
-
-
:
[ 1: PC200, 2OOLC-5 MIGHTY s
0
When starting the engine in an atmospheric
temperature of lower than 0C. be sure to
use engine oil of SAEI OW. SAEI OW-30 and
SAEl5W-40 even though an atmospheric
temperature goes up to 10C more or less in
the day time.
Use API classification CD as engine oil and if
API classification CC, reduce the engine oil
change interval to half.
Specified capacity: Total amount of oil including oil for components and oil in piping
Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance.
0024
10 STRUCTURE AND FUNCTION
Engine related parts and
engine mount ......................... lo- 2
Radiator, oil cooler and after-cooler ..... IO- 3
Fuel tank and piping ...................... IO- 4
Power train .............................. IO- 4-2
Final drive ................................. IO- 5
Swing circle ............................... IO- 7
Swing machinery ......................... IO- 8
Track frame and recoil spring ............ IO- 9
Idler ........................................ IO-I 0
Track roller, carrier roller ................. 1 O-l 1
Track shoe ................................. 1 O-l 2
Hydraulic piping ........................... IO-15
Hydraulic circuit diagram ................. IO-I 6
Hydraulic tank ............................. IO-20
OLSS (Open center Load Sensing
System) .............................. 10-20-I
Hydraulic pump ........................... lo-21
Control valve .............................. lo-40
Swing motor .............................. 1 O-50
Center swivel joint ........................ IO-54
Travel motor .............................. IO-56
Valve control .............................. IO-65
PPC valve .................................. 1 O-66
Accumulator ............................... IO-72
Safety lock valve .......................... 1 O-73
Solenoid valve assembly .................. 1 O-74
Shuttle valve ............................ 1 O-77-4
Boom holding valve ...................... 1 O-78
Hydraulic cylinder ......................... IO-82
Electrical wiring diagram ................. IO-84
Electrical circuit diagram ................. 1 O-86
Engine control system .................. 1 O-89-6
Governor motor linkage .................. IO-90
PEMC system ............................. 1 O-98
EMACC ................................... 1 O-l 25
10- l
8
Section A - A
Section B - B
I
205FO5005
Section C-C Section D - D Section E-E
1. Drive plate 7. Damper assembly
2. Torsion spring 8. Air cleaner
3. Stopper pin 9. Muffler
4. Friction plate l 10. Intake connector
5. Cone spring 11. Front engine mount
6. Friction washer 12. Rear engine mount
Out l i ne
l The damper assembly is a wet type.
Oil capacity: 1.80 Q
1 o-2
Gc
RADIATOR OIL COOLER AND AFTER-COOLER
PC200,2OOLC-5
PC220,22OLC-5
* The after-cooler attached only PC220,22OLC-5
ZI,
4 5 6 7 8 9
3
2
View Z
1. Fan shroud
2. Fan
3. Radiator outlet hose
4. Radiator inlet hose
5. Radiator
6. Radiator cap
7. Oil cooler
8. After -cooler
9. Oil cooler inlet hose
IO. Oil cooler outlet hose
1 1. Net
12. After-cooler inlet
13. After-cooler outlet
14. Sub-tank
205FO5006
SPECIFICATIONS
Radiator
PC200-5 Serial No: 45001 - 51419
PC220-5 Serial No: 35001 - 35928
CG-2
PC200-5 Serial No: 51420 and up
PC220-5 Serial No:,35929 and up
cwx-4
Oil cooler: SF-2
After-cooler: 6 rows
View 2
7. Oil cooler 1. Fan shroud
2. Fan
3. Radiator outlet hose
4. Radiator inlet hose
5. Radiator
6. Radiator cap
8 7 8
205FO5604
SPECIFICATIONS
8. Oil cooler inlet hose
9. Oil cooler outlet hose
10. Net
11. Sub-tank
Radiator: CWX-4
Oil cooler: SF-3
FUEL TANK AND PIPING
Section A-A
205FO5007
1. Drain valve
2. Fuel tank
3. Filler cap (with lock device)
4. Sight gauge
5. Fuel level sensor
1 o-4
DIAGRAM OF FUEL SYSTEM (with automatic air bleeding mechanism)
1. Fuel tank
2. Gauze filter
3. Priming pump
4. Feed pump
5. Fuel filter
6. Air bleed plug
7. Fuel injection pump
8. Fuel injection nozzle
9. Over-flow valve
6206F120- 1
Automatic bleeding of the fuel system
An overflow valve has been added to the
fuel injection pump to bleed any air that
has entered the fuel supply system during
replacement of the fuel filter, etc.
When cranking is carried out by the starting
motor, the feed pump starts to send fuel
under pressure. Because of this, the fuel
containing air is drained from the overflow
valve in the injection pump, and returns to
the fuel tank.
POWER TRAIN
1. Idler 7. Hydraulic pump
2. Center swivel joint 8. Swing brake solenoid valve
3. Control valve assembly 9. Travel speed solenoid valve
4. Final drive IO. Swing motor
5. Travel motor 1 1. Swing machinery
6. Engine 12. Swing circle
205FO5008
FINAL DRIVE
PC200,2OOLC-5 Serial No: 45001 - 58018
PC220,22OLC-5 Serial No: 35001 - 36613
1. Oil level plug
2. Drain plug
3. No. 1 sun (I 8 teeth) gear
5. No. 2 planetary carrier
6. Cover
8. Sprocket
9. Floating seal
10. Travel motor
ll.Hub
12. No.1 planet gear (31 teeth)
13. Ring gear (81 teeth)
14. No. 2 planet (34 teeth) gear
SPECIFICATIONS
Reduction ratio:
81 +I2
-
(
x 81 i-18
+1 =
12
)(
18
1
-41.625
14 13 12 11
205FO5009
- 10
1. Oil level plug
2. Drain plug
6. Cover
8. Sprocket
9. Floating seal
10. Travel motor
ll.Hub
12. No.1 planet gear (31 teeth)
14. No. 2 planet (34 teeth) gear
SPECIFICATIONS
Reduction ratio:
t
81 +I2
)i
81
-
+ 18 +1 =
12 18
)
-41.625
Section A - A
205FO5806
SWING CIRCLE
b
Section B - B
/
1. Swing circle outer race
2. Ball bearing
3. Swing circle inner race (I 10 teeth)
a. Inner race soft zone S
b. Outer race soft zone S
Section A- A
i
SPECIFICATIONS
110
Reduction ratio: - = 7.333
15
Grease volume: 21 Q (G2-LI)
205FO5010
10- 7
SWING MACHINERY
1. Swing pinion (I 5 teeth)
2. Cover
3. Cage
4. Planetary carrier
6. Bearing holder
7. Drive gear (15 teeth)
8. Swing motor
9. Bearing holder
10. Breather
1 1. Oil level gauge
12. Cover
13. Driven gear (76 teeth)
14. Planetary gear (24 teeth)
15. Sun (I 5 teeth) gear
16. Drain plug
SPECIFICATIONS
Reduction ratio: gx(63 A15) =
6
26.347
Section B - B
Section C - C
Section A - A
205FO5011
TRACK FRAME AND RECOIL SPRING
1
\
_.--A _
1. Idler
Depending on the model, the dimensions and
2. Track frame
number of track rollers is different, but the
3. Carrier roller
basic structure is the same. (The diagram
4. Final drive
shows PC2001
5. Track roller
Sr Number of track rollers
6. Track
PC200: 7 (each side)
7. Center guard
PC200LC: 9 (each side)
8. Recoil spring
PC220: 8 (each side)
9. Front guard
PC22OLC: 10 (each side)
9 8 7 6 5
205FO5012
1 o-9
IDLER
205FO5013
1. Lubricating plug
2. support
3. Idler
4. Floating seal
5. Idler shaft
6. Bushing
10- 10
TRACK ROLLER
205F2452
CARRIER ROLLER
1. Lubricating plug
2. Collar
3. Floating seal
4. Track roller
5. Bushing
6. Shaft
1. Shaft
2. Collar
3. Floating seal
4. Carrier roller
5. Ring
6. Cover
7. Lubricating plug
205FO5014
10- l 1
TRACK SHOE
1 2 3 4 5 6 7 8
1. Link
2. Shoe
3. Regular pin
4. Regular bushing
5. Regular dust seal
6. Master bushing
7. Master dust seal
8. Master pin
9. Shoe nut
10. Shoe bolt
205FO5015
Standard shoe specifications
PC200 600 mm triple-shoe
Link pitch: 190 mm
Number of shoe: 90
PC220 600 mm triple-shoe
Link pitch: 190 mm
Number of shoe: 94
PC2OOLC 700 mm triple-shoe
Link pitch: 190 mm
Number of shoe: 98
PC22OLC 700 mm triple-shoe
Link pitch: 190 mm
Number of shoe: 102
10- 12
SELECTION OF TRACK SHOE
l Select the most suitable track shoe f;om the following table.
0
z
2
PC220 PC22OLC
Specification
Cate-
Specification
Cate-
gory gory
500 mm
A
600 mm
triple shoe triple shoe
A
600 mm
A
700 mm
B
700 mm
B
800 mm
C
800 mm
I 1
C
-
triple shoe
610 mm
flat shoe
I I
D
-
600 mm
I I
D
-
rubber shoe
1 -
. Category
Cate-
gory
A
B
t
C
Use Precautions when using
Rocky ground, l Travel in Lo when traveling on rough ground with obstacles
normal river soil such as large boulders and fallen trees.
Normal soil,
soft land
Extremely short
ground
(swampy ground)
D
t
Paved surface
. Cannot be used on rough ground where there are large
obstacles such as boulders and fallen trees.
l Travel in Hi speed only on flat ground, and when it is
impossible to avoid traveling over obstacles,
lower the travel speed to approx. half of Lo. speed.
. Use only for ground where A and B sink and
are impossible to use.
l Cannot be used on rough ground where there are large
obstacles such as boulders and fallen trees.
l Travel in Hi speed only on flat ground, and when
it is impossible to avoid traveling over
obstacles, lower the travel speed to approx.
half of Lo speed.
l The shoe are flat, so they have low gradeability.
* Categories B and C are wide shoe, so
there are restrictions on their use. Therefore,
before using, check the restrictions and con-
sider carefully the conditions of use before
recommending a suitable shoe width. If
necessary, give the customer guidance in
their use.
* When selecting the shoe width, select the
narrowest shoe possible within the range
that will give no problem with flotation and
ground pressure.
If a wider shoe than necessary is used, there
will be a large load on the shoe, and this
may lead to bending of the shoe, cracking
of the links, breakage of the pins, loosening
of the shoe bolts, or other problems.
8
8
s1
1024
ADDITIONAL CIRCUIT
Circuit for 1 -pump - 1 -actuator (1 PI A)
Control valve
NCBF
--
NCALI _ : NCBL
I
.-
I.H. travel
El
Arm-Lo
I
Arm-Hi
+
AI R
I
Service 1
BAR
Boom-Lo
Boom-Hi
d=
I I
Arm. swing
PPC shuttle valve
i 1
I 1
j /
I I
1 I
Swing
1
I I
tiain relief valve
I
i
4
Travel shuttle valve
I
Main relief valve
-_ __
PL PF
P3
1
I
I
I
Shuttle valve
---------- A
3-way valve
j
I J
205FO5810
* 210 kg/cm2, 250 kg/cm2, 280 kg/cm2
Set (select) the set pressure of the safety valve to match the actuator.
Circuit for 2-pump-l-actuator (2PlA)
Control valve
Ncsr
r-
r
_~NCAR NCAL 1
XH. travel
El
L\rm-Lo
I
Gervice 1
=,
A I
I
I
.---A
Boom-Hi
Swing
I
4rm-Hi
I
A3u
I
BAR
Bucket
oom-Lo
El
.H. travel
I
Main relief valve
Arm. swing
PPC shuttle valve
Main relief valve
PF
l-pump. Z-pump
3-way valve
A I
d\ A
I
I
I
1 To accumulator, solenoid
valve assy
3-way
valve
>
1
1 205FO58 I2
+ 210 kg/cm2, 250 kg/cm2, 280 kg/cm2
Set (select) the set pressure of the safety valve to match the actuator.
10- &9- l
HYDRAULIC TANK
1. Bypass valve
2. Filter element
3. Bypass filter
4. Filter check valve
5. Filler cap
6. Lift check valve
7. Sight gauge
8. Strainer
9. Hydraulic tank
10. Filter case
1 1. Hydraulic oil level sensor
Section B-B
!
- 11
Section A- A
Section C - C
Section D-D
205FO5016A
SPECIFICATIONS
Tank capacity: 240 Q
Oil amount: 150 Q
Pressure valve
Relief set pressure: 0.17 kO.007 kg/cm2
Suction set pressure: 0 - 0.046 kg/cm2
Bypass valve set pressure: 1. 05 *0.2kg/cm2
Filter check valve set pressure:
1.82 *0.2kg/cm2
Lift check valve set pressure: 4.2kg/cm2
1 O-20
OLSS (Open center Load Sensing System)
Motor
Cylinder
I I I
F205C5006-1
OLSS (Open center Load Sensing System) is
an energy-saved system to reduce the fuel
consumption by means of controlling the
swash plate angle (delivery) of the variable-
displacement swash-plate type piston pump.
Therefore this system acts to reduce the hy-
draulic loss during operation, to increase the
fine control and to control the pump delivery.
o-~-l
1. EFFECTIVE USE OF ENGINE
HORSEPOWER
In H mode, the set speed of the engine
and the actual speed of the engine are
always detected. As a result, even if the
load changes during operation, the dis-
charge amount (swash plate angle) of the
pump is controlled so that the load on
the engine (engine speed) is always main-
tained constant, thus ensuring effective
use of the engine horsepower.
(Engine speed, oil pressure sensing
control)
2. CUT-OFF CONTROL
l The cut-off control is a function to re-
duce relief loss during operations.
If the load increases, the discharge
pressure of the main pump is in-
creased; if the load comes close to
the relief pressure, the discharge vo-
lume is decreased.
l This function is carried out with the
CO valve.
For details of the operation of the CO
valve, see HYDRAULIC PUMP.
3. FLOW CONTROL
PNC (pump neutral control)
l When the control levers are at neu-
tral, the pump discharge volume is
kept to the minimum to reduce the
wasteful flow of oil when the control
valve is at neutral.
PFC (pump fine control)
l When the lever is operated, the ne-
cesary flow is ordered to the pump
based on the flow command that
corresponds with the lever travel.
This reduces the wasteful flow of oil
that occurs during fine control.
l At the same time, by increasing the
pump discharge pressure to the opti-
mum value according to the lever tra-
vel, the fine control performance is
improved.
l This function is carried out with the
NC valve and jet sensor.
For details of the operation of the NC
valve and jet sensor, see HYDRAULIC
PUMP.
Main pump delivery
_
Pump delivery volume Q
205F05121A
(Note) H.0: Heavy duty operation mode,
G.0: General operation mode.
F.0: Finishing operation mode,
L.0: Lifting operation mode
Loss when there is no cut-off
Pump discharge volume (P/min.)
F205C5008
Lever travel (mm)
205FO5145
o-;o-2
HYDRAULIC PUMP
a
e
View Z
205FO5017
a. Jet sensor output pressure Pt IN port
b. Jet sensor output pressure Pd IN port
c. Jet sensor output pressure Pt IN port
d. Jet sensor output pressure Pd IN port
e. CO cancel pressure PSOR IN port
f. CO cancel pressure PSOF IN port
1. Front servo valve
2. Front CO l NC valve
3. Rear CO l NC valve
4. Rear servo valve
5. TVC valve
6. Charging pump
7. Rear main pump
8. Front main pump
1. FRONT MAIN PUMP AND REAR MAIN PUMP
(HPVOSO +0901
a
r? \
a.
b.
;:
e.
View Z
View X
Front main pump discharge PPI port
Front main pump discharge PP~ port
Suction PS port
Servo valve output pressure kls port
Charging pump pressure PCI port
b
9.
h.
i.
j.
k.
f. Front main pump output pressure Pal port I.
hij kl
View Y
205FO5018
Servo valve output pressure Pcin port
Servo valve output pressure Pc2n port
Front main pump output pressure PPI port
Rear main pump output pressure PP~ port
Charging pump pressure Pc 2 port
Servo valve output pressure Pcse port
1 o-22
cc
1. Front drive shaft
2. Front cradle
3. Front pump case
4. Front rocker cam
5. Front piston
6. Front cylinder
7. Front valve plate
8. Front end cap
9. Impeller
10. Coupling
11. Rear end cap
12. Rear valve plate
13. Rear cylinder
14. Rear piston
15. Rear rocker cam
16. Rear pump case
17. Rear cradle
18. Rear drive shaft
19. Servo piston
Section C - C
205FO5019
1 O-23
2. SERVO VALVE
* The drawing shows the servo valve for
front main pump
b c d
\ i
Section A-A
Section B-B
Section D-D Section E - E
a. Servo actuator port
b. Servo actuator port
c. Servo actuator port
d. NC valve output pressure Pi pick-up port
e. Servo valve drain Pdr OUT port
f. Rear main pump output pressure Pa2 IN port
g. Front main pump output pressure Pal IN
port
Section C -C
Section F - F Section G-G
205F65020
h. CO l NC valve drain Pdr IN port
i. CO * NC valve output pressure Pi IN port
j. Charging pump pressure Ppo OUT port
k. Rear main pump output pressure PP~ OUT
POfl
I. Front main pump output pressure PPI OUT
port
1. Lock nut 8. Pin
2. Cover 9. Control piston
3. Plug 10. Lock nut
4. Spring 1 1. Plug
5. Body 12. Lock nut
6. Spring 13. Cover
7. Arm 14. Sleeve
li 16
Section A- A
FUNCTION
Discharge volumes 01 and Q2 of main pumps
PPI and PP~ are controlled individually by
their own servo valve.
The relationship between pump discharge vo-
lume Q and input signal Pi sent to the
servo valve is as shown in the graph on the
right. Q changes in proportion to Pi.
205FO5021
15. Guide spool
16. Spring
17. Plug
18. Cover
19. Lock nut
(cc/rev) ,,Y
CO * NC valve output pressure Pi (kg/cm*)
205FO5022
OPERATION
1) Operation for increasing pump discharges (rocker cam angle changes to the large)
b Pi
NC valve
i
CO valve
TVC valve
Charging pump pressure PC is sent to port
a.
Signal pressure Pi from the NC valve is
sent from port b to chamber c.
As signal pressure Pi rises, the pressure in
chamber C pushes control piston (9) to
the left in the direction of the arrow. The
piston stops in a position where it is
balanced with the force of springs (4) and
(6).
At the same time, arm (7) uses servo piston
(20) as a fulcrum, moves to the left in the
same way as control piston (91, and while
fluctuating, moves guide spool (15) to the
left.
205F05023A
l The movement of guide spool (15) closes
port a and port d, and connects port d with
drain chamber e. As a result, servo piston
chamber f is also connected to chamber e
through port g and port d.
At the same time, port a and port h are
connected, and the flow passes through
port i to servo piston chamber j to push
servo piston (20) to the left in the direction
of the arrow. The rocker cam angle of the
main piston pump becomes larger, and the
pump discharge volume increases.
o Because of the movement of servo piston
(201, arm (7) rotates clockwise around pin
(81, moves guide spool (15) to the right, and
closes port a, port d, and port h, so the
discharge volume increases only by an
amount corresponding to signal pressure
Pi.
2) Operation for decreasing pump discharges (rocker cam angle changes to the small)
15 e h
Pi
l When signal pressure Pi drops, control
piston (9) moves to the right in the direction
of the arrow to a point where the hydraulic
pressure of chamber c is in balance with the
force of springs (4) and (6).
At the same time, arm (7) uses servo piston
(20) as a fulcrum, moves to the right in the
same way as control piston (9). and while
fluctuating, moves guide spool (I 5) to the
right.
l The movement of guide spool (15) closes
port a and port h, and connects port h with
drain chamber e. As a result, servo piston
chamber j is also connected to chamber e
through port i and port h.
205FO5024A
At the same time, port a and port d are
connected, and the flow passes through
port g to servo piston chamber f to push
servo piston (20) to the right in the
direction of the arrow. The rocker cam
angle of the main piston pump becomes
smaller, and the pump discharge volume
decreases.
l Because of the movement of servo piston
(201, arm (7) rotates counterclockwise
around pin (81, moves guide spool (15) to
the left, and closes port a, port d, and port
h, so the discharge volume decreases only
by an amount corresponding to signal
pressure Pi.
3. TVC VALVE
a b C
e d
a.
b.
c.
Charging pump pressure Ppo IN port
Front main pump output pressure PPI IN
Port
Rear main pump output pressure PP~ IN
POfl
d. TVC valve drain Pdr OUT port
d. TVC valve output pressure Pt2 OUT port
C--i B-i
fF
Section A- A
D-i
Section C-C Section D-D Section E-E
2.
3.
4.
Section B - B
Spring
Spool
Piston
Piston
Section F-F
205FO5025
5. Sleeve
6. Piston
7. Body
8. Solenoid
FUNCTION AND OPERATION
I) When command current from pump controller is small (when pump controller is normal)
De
Discharge
rease
PPI
TVC valve
P2
FUNCTION
When the pump controller is normal, the
main pump discharge volume can be
controlled as desired over a wide range
according to the command current from the
pump controller to carry out the power
mode function.
When the pump controller is abnormal,
hydraulic sensing is carried out to control
the main pump discharge volume according
to the load (pump discharge pressure) to
carry out the constant torque control
function (prolix function.)
For details, see PEMC SYSTEM.
WI 1 TVC prolix switch
Resistor
OPERATION
20j F05026A
l Because of the command current sent from
the controller, solenoid push pin (9) moves,
and piston (2) also moves. It stops at a
point where the sum of the force of spring
(1) and the force of push pin (9) and the
force of TVC output pressure Pt2 acting on
piston (3) is in balance. When this happens,
the command current is small, so piston (2)
balances at the bottom.
As a result, port a and port b are almost
completely open, and almost all the
pressurized oil from the charging pump is
output as TVC output pressure Pt2. Be-
cause of this, the pump discharge volume
is maximum.
1 O&29
2) When command current from pump controller is large (when pump controller is normal)
TVC valve
r
Servo valve
Fl
Servo piston
I I
Decrease - u Increase
Discharge
Resistor
l Because of the command current sent from
the controller, solenoid push pin (9) moves,
and the piston (2) also moves. It stops at
the point where it is balanced with the force
of spring (I). When this happens, the com-
mand current is large, so piston (2) is bal-
anced at the top. As a result, the flow of oil
sent from the charging pump is throttled at
port a and port b, and the area of the open-
ing at port b and port c (drain port) becomes
larger. Because of this, TVC valve output
pressure Pt2 drops and the pump discharge
volume is reduced.
205F05027A
3) Main oumo under light load (pump controller abnormal and TVC prolix switch ON)
Pi
r
I
Servo valve
_I
Servo piston
Decrease L@ - Increase
Discharge
NC
valve
co
valve
TVC valve
I .I lxx--l ,-,TT_
I
__.._. _..-.
TVC prolix switch
0
Resistor
Main pump discharge pressures PPI and
PP~ are low, so spool (2) is pushed down
by spring (1). As a result, charging pump
discharge pressure PC and TVC valve out-
put pressure Pt2 are equal.
When this happens, TVC valve output
pressure Ptz is maximum and the main
pump discharge volume is also maximum.
205F05028A
4) Main pump under heavy load (pump controller abnormal and TVC prolix switch ON)
TVC valve
-
co
valve
.:.:.
:.:.:
.:.>
$
:.y.:
(1:
. . . . .
g;i
:.:.:
.:.>
r--v
:.x
.:.:.
. ..i
Servo valve
Discharge
Resistor 205F05029A
l When main pump discharge pressure PPI
(or PPP) increases, spool (2) is moved up
by piston (4) or piston (6). As a result,
the flow at port a and port b is throttled
by the notch in the spool, and the area
of the opening at port b and port c (drain
port) becomes larger. Because of this,
TVC valve output pressure Pt2 drops and
the main pump discharge volume is
reduced.
4. CO l NC VALVE
a
d
b
a. Charging pump pressure PRO OUT port
b. Main pump output pressure PPI (PP~) OUT
port
c. Main pump output presure PP~ (PPI ) OUT
port
d. TVC valve output pressure Pt2 IN port
e. WC valve drain Pdr port
f. CO cancel pressure Pcf (Per) IN port
g. TVC valve output pressure Pt 2 F-R
connection port
h. Jet sensor output pressure Pd IN port
i. Jet sensor output pressure Pt IN port
Sr The diagram shows the CO l NC valve for
the front pump.
h
4 10
5
11
6
12
Section A- A
205FO5030
co VALVE NC VALVE
1. Plug 7. Plug
2. Piston 8. Sleeve
3. Spring 9. Piston
4. Spool 10. Spool
5. Piston 11. Spring
6. Plug 12. Plug
* ( I: For rear servo valve
1 o-33
@
FUNCTION AND OPERATION OF CO VALVE
1) When main pump discharge pressure is below relief pressure
Discharge
PF
:i.:.:...:
., ., .,
.- .
.:.:
. . . .
.+>
, j:j:j
I .::.
F T
205F05031A
FUNCTION
OPERATION
If the load increases during operation, and
the main pump discharge pressure in-
creases, when it becomes nearly the relief
pressure, the CO valve carries out the cut-
off function to reduce the discharge
amount of the pump and reduce the relief
loss.
At the same time, the pilot pressure of the
CO function cancel solenoid valve also has
the function of canceling the cut-off.
The CO valve is controlled by balancing the
spring with the sum of main pump dis-
charge pressure PP and CO valve output
pressure Pco.
0 Spool (4) is pushed down by spring (3).
As a result, port a and port b are com-
pletely open, and n/C valve output pres-
sure Pco are equal.
Because of this, CO valve otput pressure
Pco becomes maximum, and the dis-
charge volume of the main pump is also
maximum.
2) When the main pump discharge pressure is higher than the main relief pressure
Decrease -
Discharge
l When main pump discharge pressure PP
comes close to the relief pressure owing
to an increase in the load, piston (5) is
pushed by main pump discharge pressure
PP and at the same time piston (5) is
pushed by CO valve output pressure Pco.
When the force of spring (3) is overcome
by the pressing force of the pistons,
spool (4) moves upward.
As a result, the spool land restricts the oil
flow from port a to port b and at the same
time the opening areas of port b and port c
jdrain port) are made larger.
With angle reduced by the operation of the
servo valve, the main pump discharge is
reduced.
205F05032A
1 o-35
@
3) When cut-off function is canceled by CO cancel solenoid valve
Pi r-l _.A
Discharge
0 When the CO cancel solenoid valve is
switched, pilot pressure is taken to port
Pso and piston (2) is pushed down.
As a result, the setting of spring (3) be-
comes larger, so even when main pump
discharge pressure PP rises and reaches
the relief pressure, spool (4) is not actuat-
ed and CO valve output pressure Pco re-
mains at the maximum.
CO cancel
solenoid valve
205F05033A
FUNCTION AND OPERATION OF NC VALVE
1 I Control valve at neutral
Ii-n
I I
,Jfj Jet sqsor ,
Control valve
NC valve
PP.
1M#
FUNCTION
The NC valve controls the main pump dis-
charge volume according to the amount of
operation of the control valve spool, and
carries out the function of controlling the oil
flow to reduce the neutral loss and fine con-
trol loss.
The NC valve is controlled by balancing the
sum of jet sensor output pressure Pt and
NC valve output pressure Pi with the
sum of the force of NC valve spring (I 2)
and jet sensor output pressure Pd.
The jet sensor detects the flow of return oil
passing through the control valve and re-
turning to the tank, and takes it as NC valve
Pt and Pd.
l The differential pressure (Pt - Pd) of the
OPERATION
jet sensor reaches the maximum and jet
sensor output pressure Pt acting on piston
(101 becomes greater than the sum of the
force of spring (12) and jet sensor output
pressure Pd acting on the lower end of
spool (1 1).
As a result, spool (1 I) is pushed downward,
causing a restriction of the oil flow between
port c and port b and in turn opening port b
and port a (drain port).
Output pressure Pi of the NC valve is
then reduced to the minimum and the
main pump discharge is also reduced to
the mlnimum with the swash plate angle
minimized through the operation of the
servo valve.
2) When the control valve is operated
/iI
Jet sensor
Control valve
NC valve
205FO5035B
l With the jet sensor differential pressure (Pt
-
Pd) reduced according to the operation
of the control valve, spool (1 I) is pushed
upward, fully opening port c and port b.
Thus, the NC valve output pressure in-
creases. Together with the increase in the
main pump swash plate angle through the
servo valve operation, the main pump dis-
charge is also increased. That is to say, the
pump discharge increases as the stroke of
the lever increases.
o&38
5. CHARGING PUMP
Suction+
+
Discharge
1. Relief valve
2. Body
3. Cover
4. Drive gear
5. Driven gear
6. Filter
2
3
4
5
!!!J-
0
205FO5036
SPECIFICATIONS
Theoretical delivery: 25 cc/rev
Operating pressure: 32kglcm
1 o-39
CONTROL VALVE
PC200,2OOLC-5 Serial No: 45001 - 53192
PC220,22OLC-5 Serial No: 35001 - 36052
n
A-( q r s
mm
\
kk
U
205FO5037
1.
2.
Travel shuttle valve OUTLINE
4-spool valve (Built-in straight-travel valve,
arm throttle valve)
3. 5-spool valve (Built-in swing priority valve)
a.
b.
C.
d.
e.
f.
9.
h.
P3 port (From arm PPC valve)
PL port (From rear main pump)
PR port (From front main pump)
B~L port (To bucket cylinder bottom side)
B~L port (To boom cylinder head side)
BI L port (To L.H. travel motor PB port)
P5 port (From swing PPC shuttle valve)
P4 port (From boom bucket PPC shuttle
valve)
i. P6 port (To work equipment oil pressure
switch)
j.
k.
I.
m.
n.
0.
g
P-
::
q.
c\l r.
0
S.
t.
u.
V.
w.
X.
Y.
2.
Al L port (To L.H. travel motor PA port)
AWL port (To boom cylinder bottom side)
A3L port (To bucke cylinder head side)
P4AL port (From arm PPC valve)
P3AL port (From bucket PPC valve)
PZAL port (From boom PPC valve)
PEAL port (From L.H. travel PPC valve)
PRL port (From 2-stage relief solenoid valve)
PRR port (From 2-stage relief solenoid valve)
Pi AR port (From swing PPC valve)
P3AR port (Service)
P4AR port (From arm PPC valve)
P5AR port (From R.H. travel PPC valve)
A3R port (Service)
AI R port (To swing motor MA port)
Bl R port (To swing motor port MB)
B3R port (Service)
aa.
bb.
CC.
dd
ee.
ff.
99.
hh.
ii.
jj.
kk.
II.
mm.
nn.
00.
PP.
qq.
B4R port (To arm cylinder bottom side)
B5R port (To R.H. travel motor PA port)
T port (To tank)
A5R port (To R.H. travel motor PB port)
A4R port (To arm cylinder head side)
PtL port (To rear NC valve)
PdL port (To rear NC valve)
PtR port (To front NC valve)
PdR port (To front NC valve)
PI BL port (From L.H. travel PPC valve)
P2BL port (From boom PPC valve)
P3BL port (From bucket PPC valve)
Ts port (To tank)
P5BR port (From R.H. travel PPC valve)
P4BR port (From arm PPC valve)
PBBR port (Service)
PI BR port (From swing PPC valve)
l This control valve consists of a 4-spool
valve and a 5-spool valve. In addition, it also
has a travel shuttle valve.
It has a built-in straight-travel valve, arm
throttle valve and swing priority valve.
l The 4-spool valve and 5-spool valve are
connected by bolts to form one unit. The oil
flow merges inside the valve, so the valve is
compact and provides excellent ease of
maintenance.
10- 41
0
1. Spool return spring
2. Spool (L.H. travel)
3. Spool (Boom-Lo)
4. Spool (Bucket)
5. Spool (Arm-Hi)
7 6
Section A-A
Section B - B
6. Jet sensor orifice
7. Jet sensor relief valve
8. Main relief valve
9. Spool (Straight-travel)
IO. Spool (Arm throttle valve)
1042
6
Section C -C
10'
Section D - D
205F05039A
1. Spool return spring 6. Spool (R.H. travel)
2. Spool (Swing) 7. Jet sensor relief valve
3. Spool (Boom-Hi) 8. Jet sensor orifice
4. Spool (Service) 9. Main relief valve (5-spool)
5. Spool (Arm-Lo) 10. Spool (Swing priority)
1 o-g43
Section E - E
Section F - F
Section G-G
1. Check valve
2. Check valve spring
5. Spool (Swing priority)
6. Spool (Swing)
- 1
-2
Section H - H
7. Suction valve
8. Spool (Boom-Lo)
9. Check valve
10. Spool (Boom-Hi)
11. Safety-suction valve.
205FO5040
Section J-J
Section L-L
1. Safety-suction valve 6. Check valve
2. Spool (Bucket) 7. Spool (Arm-Lo)
3. Spool (Arm throttle) 8. Safety-suction valve
4. Spool (Service) 9. Check valve
5. Spool (Arm-Hi) 10. Spool RH. travel)
Section K - K
205FO5041
1 o-45
e f 9 h i
/
j
99,
ff.
hh
ii
5% F-l
II-
kk-
jj-

00
PP
qq
i I I I
ee dd c c bb aa
205FO5779
O-F-
1.
2.
Travel shuttle valve OUTLINE
4-spool valve (Built-in straight-travel valve,
arm throttle valve)
a.
b.
C.
d.
e.
f.
9.
h.
P3 port (From arm PPC valve)
B~L port (To bucket cylinder bottom side)
B~L port (To boom cylinder head side)
BI L port (To L.H. travel motor PB pot-t)
P4 port (From boom bucket PPC shuttle
valve)
i.
j.
k.
I.
m.
n.
0.
::
P.
:
q.
0
r.
S.
t.
U.
V.
w.
X.
Y.
2.
PS port (To work equipment - swing oil
pressure switch)
Al L port (To L.H. travel motor PA port)
AWL pot-t (To boom cylinder bottom side)
AWL port (To bucke cylinder head side)
PPAL port (From boom PPC valve)
Pl AL port (From L.H. travel PPC valve)
PRL port (From 2-stage relief solenoid valve)
PRR pot-t (From 2-stage relief solenoid valve)
Pi AR port (From swing PPC valve)
PBAR port (Service)
P4AR port (From arm PPC valve)
PBAR port (From R.H. travel PPC valve)
A3R port (Service)
AI R port (To swing motor MA port)
Bl R port (To swing motor port MB)
B3R port (Service)
aa.
bb.
cc.
dd.
ee.
ff.
99.
hh.
ii.
jj.
kk.
II.
mm.
nn.
00.
PP.
qq.
T port (To tank)
Pl BL port (From L.H. travel PPC valve)
PSBL port (From boom PPC valve)
Ts port (To tank)
P3BR port (Service)
Pl BR port (From swing PPC valve)
l This control valve consists of a 4-spool
valve and a 5-spool valve. In addition, it also
has a travel shuttle valve.
l The 4-spool valve and 5-spool valve are
connected by bolts to form one unit. The oil
flow merges inside the valve, so the valve is
compact and provides excellent ease of
maintenance.
1. Spool return spring 6. Jet sensor orifice
2. Spool (L.H. travel) 7. Jet sensor relief valve
3. Spool (Boom-Lo) 8. Main relief valve
4. Spool (Bucket) 9. Spool (Straight-travel)
5. Spool (Arm-Hi) 10. Spool (Arm throttle valve)
i
Section A - A
8
205FO5780
Section B - B
205FO5038
8 7
Section C - C
205FO578 I
10
Section D - D
2. Spool (Swing)
3. Spool (Boom-Hi)
4. Spool (Service)
5. Spool (Arm-Lo)
6. Spool (R.H. travel)
Section E - E
Section G - G
1. Check valve 6. Spool (Swing)
2. Check valve spring 7. Suction valve
3. Spool (L.H. travel) 8. Spool (Boom-Lo)
4. Spool (Straight-travel) 9. Spool (Boom-Hi)
5. Spool (Swing priority) 10. Safety-suction valve
Section F - F
Section H - H
205FO5782
1 2 3 4
5 8 7 8 9
Section J - J Section K - K
Section L - L
205FO5783
1. Safety-suction valve 6. Check valve
2. Spool (Bucket) 7. Spool (Arm-Lo)
3. Spool (Arm throttle) 8. Safety-suction valve
4. Spool (Service) 9. Check valve
5. Spool (Arm-Hi) IO. Spool (R.H. travel)
PC200,2OOLC-5 MIGHTY (with 2PlA circuit)
., t V
. .
JJ\
ii,
kk
qq
PP
00
nn
mm
rr
ss
205FO58 I4
1045-7
1. Travel shuttle valve
2. 5-spool valve (Built-in straight-travel valve,
arm throttle valve)
a.
b.
::
f.
9.
h.
in
i?
%
j
k.
I.
m.
n.
0.
P.
Cl.
r.
S.
t.
U.
V. PIAR port (From swing PPC valve)
W. PSAR port (Service 1)
X. P4AR port (From arm PPC valve)
Y.
P5AR port (From R.H. travel PPC valve)
Z. A3R port (Service 1)
P3 port (From arm PPC shuttle valve)
B6L port (Service 2)
B3L port (To bucket cylinder head side)
B2L port (To boom cylinder head side)
BIL port (To L.H. travel motor PB port)
P4 port (From boom, bucket PPC shuttle
valve)
P6 port (To work equipment, swing oil
pressure switch)
AIL port (To L.H. travel motor PA port)
A2L port (To boom cylinder bottom side)
A5L port (Service 2)
A3L port (To bucket cylinder bottom side)
P5AL port (Service 2)
P2AL port (From boom PPC valve)
PIAL port (From L.H. travel PPC valve)
PRL port (From 2-stage relief solenoid
valve)
PRR port (From 2-stage relief solenoid
valve)
OUTLINE
0 This control valve consists of a 5spool
valve and a 5-spool valve. In addition, it
also has a travel shuttle valve.
0 The 5-spool valve and 5spool valve are
connected by bolts to form one unit. The
oil flow merges inside the valve, so the
valve is compact and provides excellent
ease of maintenance.
aa.
bb.
z.
EY
99.
hh.
ii.
jj.
kk.
II.
mm.
nn.
00.
PP.
qq.
rr.
ss.
tt.
uu.
AIR port (To swing motor MA port)
BIR port (To swing motor MB port)
B3R port (Service 1)
T port (To tank)
PIBL port (From L.H. travel PPC valve)
PZBL port (From boom PPC valve)
P5BL port (Service 2)
T3 port (To tank)
P3BR port (Service 1)
PIBR port (From swing PPC valve)
1 O-&5-8
8
Section A - A
i
3. Spool (Boom-Lo)
4. Spool (Bucket)
5. Spool (Arm-Hi)
6. Spool (Service 2)
Section B - B
11. Spool (Arm throttle valve)
205FO58 I5
Section C - C
Section D - D
1. Spool return spring 6. Spool (R.H. travel)
2. Spool (Swing) 7. Jet sensor relief valve
3. Spool (Boom-Hi) 8. Jet sensor orifice
4. Spool (Service 1) 9. Main relief valve
5. Spool (Arm-Lo) 10. Spool (Swing priority)
205FO58 I6
o-Fo
Section E - E
3 4 5 6 7 8 9
Section G - G
1. Check valve
6. Spool (Swing)
7. Suction valve
8. Spool (Boom-Lo)
9. Spool (Boom-Hi)
10. Safety-suction valve
Section F - F
10
Section H - H
205FO58 I7
Section J - J Section K - K
Section L - L
205FO58 I8
2. Spool (Bucket)
3. Spool (Arm throttle)
6. Spool (Arm-Hi)
7. Check valve
8. Spool (Arm-Lo)
10. Check valve
12. Spool (R.H. travel)
TRAVEL SHUTTLE VALVE
a
I
e
Section A - A Section C - C
Section B - B
i
j
Section D - D
205FO5823
a. PS port (Oil pressureswitch) g. PT port (To tank) 1. Cover
b. P4 port (From boom - bucket h. PO port (To straight-travel valve) 2. Spool return spring
shuttle valve) i. PI port (From L.H. travel valve AIL 3. Body
c. P5 port (From swing shuttle valve)
port)
4. Spool
d. P3 port (From arm shuttle valve) j. P2 port (From L.H. travel valve BIL
e. P4a port (To arm throttle valve)
port)
f. P5a port (To swing priority valve)
FUNCTIONS
l The travel shuttle valve is installed to the
top of the 4-spool valve control valve. It
takes the PPC valve pressures from the left
travel, work equipment, and swing, and
sends pilot pressure to the straight-travel
valve when the travel and work equipment
or swing are operated at the same time.
OPERATION
Travel lever at FORWARD (other levers at
NEUTRAL)
l Pilot pressure oil flows to Pl port from the
left travel circuit and pushes the spool to
the rig ht.
Therefore, ports P3, P4, P5 and PO are con-
nected through the groove in the spool, and
are also connected to the straight-travel
valve. However, there is no flow of pilot
pressure oil from the shuttle valves of the
PPC valves, so the straight-travel valve is
not actuated.
(When operating in REVERSE, pressure
oil is sent to port P2, and pushes the spool
to the left.1
During simultaneous operation
When the arm and travel FORWARD are
operated at the same time, pilot pressure oil
flows from the left travel circuit to port PI
and pushes the spool to the right.
At the same time, when the arm is
operated, pilot pressure oil flows to port P3
from the shuttle valve of the arm PPC valve.
This passes through the groove in the spool
and port PO, and then flows to the
straight-travel valve.
The pilot pressure oil from the shuttle valve
of the swing PPC valve flows port P5b
port PO-straight-travel valve, and the
pilot pressure oil from the shuttle valve of
the boom and bucket PPC valves flows port
P4-port PO-straight-travel valve.
Fron
FORWARD circuit travel v&e REVERSE circuit
To arm
~~ c+ throttle valve
switch
From shuttle valve
of arm PPC valve valve of boom From shuttle
bucket PPC valve of swing
valve PPC valve
205F2032-2
From L.H From L.H. travel
REVERSE circuit
arm PPC valve
pressure switch
valve of From shuttle valve of
boom, bucket swing PPC valve
PPC valve
205F2033-2
1 o-&l7
STRAIGHT-TRAVEL VALVE
FUNCTION
l While operating the swing, boom, arm, or
bucket when traveling, the pressure oil
flowing to the R.H. and L.H. travel circuit
branches into the swing, boom, arm, or
bucket circuit.
Since the supply of pressure oil in a
branched travel circuit is less than that in
the circuit before the branch, the motor
naturally slows down, resulting in a turn.
l When the straight-travel valve is switched
over to establish continuity between the
R.H. and L.H. travel circuits, this undesired
turning is prevented by equalizing the
supply of pressure oil to the R.H. and L.H.
travel motors so that they rotate at the
same speed.
OPERATION
When traveling only
l Since no pilot hydraulic oil flows from the
shuttle valve in the PPC valve, no hydraulic
oil flows from the travel shuttle valve to the
straight-travel valve.
l Therefore, the circuit between port PR (R.H.
travel circuit) and port PL(L.H. travel circuit)
remains closed and both circuits remain
independent.
While operating the swing, boom, arm, or
bucket when traveling
l Spool (I 1 of the straight-travel valve is
pushed to the right by the pilot pressure
from the travel shuttle valve.
l Port PR and port PL then become connect-
ed to each other and an equal amount of
pressure oil is supplied to the R.H. and L.H.
travel motors, allowing both motors to
rotate at the same speed. The machine trav-
els thus in a straight line.
w
205FO5042
205FO5043
SWING PRIORITY VALVE
FUNCTION
When operating the swing and arm at the
same time, most of the oil flows to the arm,
which has less load. The flow of oil to the
swing circuit is reduced so the arm speed is
faster than the swing speed. This makes
combined operations difficult.
To prevent this, the swing priority valve is
switched to restrict the flow of pressure oil
to the arm-Lo control valve. This restricts
the arm speed and makes it easier to
operate the arm and swing at the same time.
OPERATION
When swing is at neutral
l No pilot pressure oil flows from the travel
shuttle valve, so the swing priority valve is
not switched. Because of this, the pressure
oil from the front main pump passes
through port PR and all the oil flows to the
arm-lo control valve.
When swing is operated
l When the swing is operated, spool (I) of
the swing priority valve is pushed to the left
by the pilot pressure from the travel shuttle
valve.
Because of this, the pressurized oil flowing
from front main pump - port PR to the
arm-Lo control valve is throttled, and the
arm speed is controlled, so the simultaneous
operation performance is improved.
1 Arm-Lo 1
205FO5044
Arm-Lo
205FO5045
ARM THROTTLE VALVE
FUNCTION
l When the arm control lever and boom
control lever are operated at the same time,
most of the pressure oil flows to the arm
circuit, where the load is less. The amount
of oil flowing to the boom circuit drops, so
the arm speed is faster than boom speed.
This makes combined operations difficult.
(particularly when using ARM OUT and
BOOM RAISE at the same time.)
When this happens, the arm throttle valve is
switched and the flow of oil to the arm-Hi
control valve is restricted. This regulates the
arm speed and makes combined operations
easier.
OPERATION
When arm is operated independently
l The pilot pressure does not flow from the
travel shuttle valve, so the arm throttle
valve is not actuated and the pressure oil
from the rear pump passes through port PL
and all flows to the arm Hi control valve.
Simulataneous operation
l When the arm is operated together with the
boom or bucket, the pilot pressure from the
travel shuttle valve pushes spool (I) of the
arm throttle valve to the left. When this hap-
pens, the flow of pressure oil from the rear
pump to the arm Hi control valve is throttled,
and the arm speed is controlled to improve
the ease of simultaneous operation.
l The arm is actuated by the merged oil flow
from two pumps, and the bucket is
actuated by the flow from one pump.
For this reason, when the arm and bucket
are operated together, the flow of oil to the
arm circuit is greater, so the arm moves
much faster than the bucket. This makes
combined operations difficult. (Particularly
when using ARM OUT and BUCKET
CURL at the same time.)
When this happens, the arm throttle valve is
switched and the flow of oil to the arm-Hi
control valve is restricted. This regulates the
arm speed and makes combined operations
easier.
[valve ]
205FO5046
valve
J
205FO5047
b
a
205F05048
a. Sport
b. MB port (From control valve)
c. MA port (From control valve)
d. T port (To tank)
e. B port (Swing brake solenoid valve)
SPECIFICATIONS
Type: KMFgOAB-2
Theoretical delivery:
87.8cclrev
Safety valve set pressure:
280 0 kg/cm* at 140 Q/min (PC200)
285 0 kg/cm* at 180 Q/min (PC220)
Rated speed:
2,132 rpm (PC200)
2,288 rpm (PC220)
Brake releasing pressure:
Max. 14kg/cm*
1 O-50
Go
H Section A- A
1. Brake spring
2. Drive shaft
3. Cover
4. Housing
5. Disc
6. Plate
7. Brake piston
8. End cover
9. Piston
13
Section I3 - B
112
10. Cylinder
11. Valve plate
12. Air bleeding plug
13. Center shaft
14. Center spring
15. Safety valve
16. Check valve
Section C-C
205FO5049
1 o- 51
.
SWING HOLDING BRAKE
OPERATION
I) When swing brake solenoid valve is
deactivated
When the swing brake solenoid valve is
deactivated, the pressurized oil from the
charging pump is shut off and pot-t B is con-
nected to the tank circuit.
Because of this, brake piston (7) is pushed
down in the direction of the arrow by brake
spring (I), so disc (5) and plate (6) are
pushed together and the brake is applied.
pump
2) When swing brake solenoid valve is
excited
When the swing brake solenoid valve is ex-
cited, the valve is switched, and the pressu-
rized oil from the charging pump enters
port B and flows to brake chamber a.
The pressurized oil entering chamber a
overcomes the force of brake spring (I),
and brake piston (7) is pushed up in the di-
rection of the arrow. Because of this, disc
(5) and plate (6) separate, and the brake is
released.
Pump
205FO5050 ::
::
z
205FO5051
1 o-52
SAFETY VALVE
FUNCTION
l The relief characteristics of this swing
motor safety valve consist of two stage as
shown in the diagram on the right.
It acts to reduce the shock when starting
ans stopping the swing.
kg/cm2 1
p2---_-__--
PI: 150 kg/cm2
P2: 280 kg/cm2
TI: 0.05 sec.
T2: 0.05 sec.
205FO5052
OPERATION
I) When circuit pressure is PO
The safety valve is not actuated.
205FO5053
2) When circuit pressure is PI
20 18 19 21
When the circuit pressure is PI, rod (18)
\ \ I I
pushes spring (I 91, so plunger (20) is open,
and the pressurized oil is relieved.
The time taken for rod (18) to contact bush-
ing (21) is TI, and the pressure during this
time remains at PI.
205FO5054
3) When circuit pressure is P2
After rod (I 8) contacts bushing (211, and
the pressure rises (PI -P2), the pressure
from hole a in rod (18) pushes piston (22)
and compresses spring (23) to increase the
set pressure.
The time taken to raise the set pressure is
T2, and the set pressure after the rise is P2.
18 23 22 a 21
205FO5055
CENTER SWIVEL JOINT
Section A- A
/A
--Cl
View Z
1. Cover
2. Body
3. Slipper seal
4. Oil seal
5. Shaft
Al : From control valve A5R port DI:
A2: To R.H. travel motor PB port D2:
BI : From control valve P 1 L port FI:
B2: To L.H. travel motor PB port F2:
Cl : From control valve B5R port TI:
C2: To R.H. travel motdr PA port T2:
I I \
B2 A2 c2
205F05056A
From control valve AI L port
To L.H. travel motor PA port
From travel speed solenoid valve
To L.H. and R.H. travel motor P port
To tank
From L.H. and R.H. travel motor T port
TRAVEL MOTOR
a. PB port (From control valve)
b. PA port (From control valve)
c. T port (To tank)
d. P port (From travel speed solenoid valve)
205FO5057
SPECIFICATIONS
Theoretical delivery:
Min. 100.5 cc/rpm (PC2001
109.0 cc/rpm (PC220)
Max. 160.8 cc/rpm
Rated pressure: 340 kg/cm2
Rated speed:
Min. I , 8 10 rpm (PC 200)
1,830 rpm (PC 220)
Max. 1,160 rpm (PC 200)
1,240 rpm (PC 220)
Brake releasing pressure: 12 *2kg/cm2
Hi-Lo switching pressure: 8 * 2kg/cm2
1 O-56
1. Output shaft
2. Motor case
3. Cradle
4. Rocker cam
5. Piston
6. Cylinder
7. Valve plate
Section A- A
Section 6 - B
205FO5058
8. End cover 15. Regulator piston
9. Regulator valve 16. Spring
10. Spring 17. Check valve spring
1 1. Brake spring 18. Check valve
12. Brake piston 19. Counterbalance valve
13. Plate 20. Spool return spring
14. Disc 2 1. Safety valve
Section C - C
1 o-57
MOTOR
OPERATION
I) At Lo speed (motor rocker cam angle at maximum)
Travel
control
.:.:.
:.:.:
.:.:.
:.:.:
.:.:.
::.:
.: :.
i:;:g
.:.:.
:.:.:
.:.:.
:.:.:
.:.:.
: :.:
:;:i
:.:.:
.:.:.
:.:.:
:::::
:>.>.
:
;i;i;
:;:i:
:.:.:
.:.:.
:.:.:
1.:.
:.: :
.:.:.
:.:.:
:; j:
:.:.:
.:.:.
:.:.:
.:.:.
:.:.:
. . . . . . .
:::::::
The solenoid valve is deactivated, so the 0
pilot pressure oil from the charging pump
does not flow to port P.
For this reason, regulator valve (9) is
pushed to the right in the direction of the 0
arrow by spring (I 0).
Because of this, it pushes check valve (221,
and the main pressure oil from the control
valve to end cover (8) passes through
passage a in regulator valve (91, enters
regulator piston (I 5a) at the top, and
pushes regulator piston (I 5a) to the right in
the direction of the arrow.
205FO5059
At the same time, the pressurized oil at
regulator piston (15b) at the bottom passes
through orifice b in regulator valve (9) and
is drained to the motor case.
As a result, rocker cam (4) moves in the
maximum rocker cam angle direction, the
motor capacity becomes maximum, and the
system is set to Lo speed.
1 O-58
2) At Hi speed (motor rocker cam angle at minimum)
15a
\
..I
0
:
0
15b
1 ravel
The solenoid valve is excited, so the pilot 0
pressure oil from the charging pump flows
to port P, and pushes regulator valve (9) is
pushed to the left in the direction of the
arrow. 0
Because of this, the main pressure oil from
the control valve passes through passage c
in regulator valve (9). enters regulator
piston (15b) at the bottom, and pushes
regulator piston (15b) to the right in the di-
rection of the arrow.
205FO5060
At the same time, the pressurized oil at
regulator piston (I 5a) at the top passes
through orifice d in regulator valve (91 and
is drained to the motor case.
As a result, rocker cam (4) moves in the
minimum rocker cam angle direction, the
motor capacity becomes minimum, and the
system is set to Hi speed.
1 o-59
PARKING BRAKE
OPERATION
I) When starting to travel
When the travel lever is operated, the
pressurized oil from the pump actuates
counterbalance valve spool (191, the circuit
to the parking brake is opened, and the oil
flows into chamber a of brake piston (I 21,
overcomes the force of spring (I I), and
pushes piston (12) to the right in the direc-
tion of the arrow.
When this happens, the force pushing plate
(I 3) and disc (I 4) together is lost, so plate
(I 3) and disc (I 4) separate and the brake is
released.
2) When stopping travel
When the travel lever is placed in neutral,
counterbalance valve spool (19) returns to
the neutral position and the circuit to the
parking brake is closed. The pressurized oil
in chamber a of brake piston (I 2) is drained
to the case from the orifice in the brake
piston, and brake piston (I 2) is pushed to
the left in the direction of the arrow by
spring (I I).
As a result, plate (I 3) and disc (14) are
pushed together, and the brake is applied.
205FO5061
14 13
al2 11
205FO5062
1 O-60
0
BRAKE VALVE
l The brake valve consists of a check valve,
counterbalance valve, and safety valve in a
circuit as shown in the diagram on the right.
(Fig. I)
l The function and operation of each compo-
nent is as given below.
II Counterbalance valve, check valve
Function
l When traveling down a slope, the weight of
the machine makes it try to travel faster
than the speed of the motor.
As a result, if the machine travels with the
engine at low speed, the motor will rotate
without load and will run away, which is ex-
tremely dangerous.
To prevent this, these valves act to make
the machine travel according to the engine
speed (pump discharge volume).
Operation when pressure is supplied
l When the travel lever is operated, the
pressurized oil from the control valve is sup-
plied to port PA. It pushes open check valve
(18a) and flows from motor inlet port MA
to motor outlet port MB. However, the
motor outlet port is closed by check valve
(I 8b) and spool (I 91, so the pressure at the
supply side rises. (Fig. 2)
l The pressurized oil at the supply side flows
from orifice El in spool (19) to chamber
Sl, and when the pressure in chamber Sl
goes above the spool switching pressure,
spool (I 9) is pushed to the right in the direc-
tion of the arrow.
As a result, port MB and port PB are con-
nected, the outlet port side of the motor is
opened, and the motor starts to rotate. (Fig.
3)
(Fig. I)
205FO5063
(Fig. 2)
205i05064A
Control valve
ljb
(Fig. 3 1
205FO5065
l o- 61
Operation of brake when traveling downhill
l If the machine tries to run away when travel-
ing downhill, the motor will turn under no
load, so the pressure at the motor inlet port
will drop, and the pressure in chamber SI
through orifice El will also drop.
When the pressure in chamber Sl drops
below the spool switching pressure, spool
(I 9) is returned to the left in the direction of
the arrow by spring (201, and outlet port
MB is throttled.
As a result, the pressure at the outlet port
side rises, resistance is generated to the ro-
tation of the motor, and this prevents run-
ning away.
In other words, the spool is moved to a posi-
tion where the pressure at outlet port MB
balances the pressure at the inlet port and
the force generated by the weight of the
machine. It throttles the outlet port circuit
and controls the speed according to the dis-
charge volume of the pump. (Fig. 4)
2) Safety valve
Function
l When travel is stopped (or when traveling
downhill), the circuit at the inlet and outlet
ports of the motor are closed by the coun-
terbalance valve, but the motor is rotated by
inertia, so the pressure at the oulet port of
the motor will become abnormally high and
damage the motor or piping. The safety
valve acts to release this abnormal pressure
and sent it to the inlet port side of the motor
to prevent damage to the equipment.
Operation
When stopping travel (or when traveling
downhill), chamber E in the outlet port cir-
cuit is closed by the check valve of the
counterbalance valve, but the pressure at
the outlet port rises because of inertia. (Fig.
51
If the pressure goes above the set pressure,
the force produced by the difference in area
between Dl and D2 [7r/4(Df - D$ x pres-
sure] overcomes the force of the spring and
moves the poppet to the right, so the oil
flows to chamber F in the circuit on the
opposite side. (Fig. 6)
:.:.
f
#
-- lflb
(Fig. 4)
205FO5066
I
(Fig. 5) 205F2044
(Fig. 6) 205F2045
1 O-62
VALVE CONTROL
Bucket dump Boom raiSe
1. L.H. travel control lever
2. R.H. travel control lever
3. R.H. PPC valve
4. R.H. work equipment control lever
5. Arm half flow solenoid valve
6. Control valve
7. Arm and swing shuttle valve
10
205FO5602
8. Boom, bucket and travel shuttle valve
9. Hydraulic pump
10. Accumulator
11. L.H. work equipment control lever
12. L.H. PPC valve
13. Safety lock valve
14. Travel PPC valve
1 O-65
0
PPC VALVE
PC200,2OOLC-5 Serial No: 45001 - 58018
PC220,22OLC-5 Serial No: 35001 - 36613
FOR WORK EQUIPMENT AND SWING
-
I
D
a
View Z
C d
a. P port (From charging pump)
b. T port (To tank)
c. P3 port (L.H.: arm in/R.H.: bucket dump)
d. P2 port (L.H.: R.H. swing/R.H.: boom lower)
e. P4 (L.H.: arm out/R.H.: bucket curl)
f. PI port (L.H.: L.H. swing/R.H.: boom raise)
205FO5068
7
6
9
5
10
4
11
3
12
2
1
Section A- A
Section E? - 6
1. Spool
7. Disc
2. Metering spring
8. Lever
3. Centering spring
9. Joint
4. Pilot piston
10. Plate
5. Pilot spring
1 1. Collar
6. Piston
12. Body
Section C-C
Section D - D
205FO5069
1 O-67
OPERATION
I) At neutral
Ports PI and P2 of the PPC valves in circuits
A and B of the control valve are connected
to drain chamber D through fine control
hole f in spool (I 1. (Fig. I)
2) Control lever operated slightly (fine
control)
When piston (6) starts to be pushed by disc
(71, retainer (I 31 is pushed. Spool (1) is also
pushed by spring (2) and moves down.
When this happens, fine control hole f is
shut off from drain chamber D. At almost
the same time it is connected to pump pres-
sure chamber Pp, and the pilot pressure of
the control valve is sent through fine control
hole f to port PI. When the pressure at port
PI rises, spool (I 1 is pushed back. Fine con-
trol hole f is shut off from pump pressure
chamber Pp. At almost the same time it is
connected to drain chamber D, so the pres-
sure at port PI escapes to drain chamber D.
Spool (I) moves up and down until the
force of spring (2) is balanced with the pres-
sure of port Pi.
The relationship of the positions of spool
(I) and body (I 21 (fine control hole f is in
the middle between drain hole D and pump
pressure chamber Pp), does not change
until damper piston (4) contacts piston (6).
Therefore, spring (2) is compressed in pro-
portion to the travel of the control lever, so
the pressure at port PI also rises in propor-
tion to the travel of the control lever. The
spool of the control valve moves to a posi-
tion where the pressure of port A (same as
pressure at port PI and the force of the
return spring of the control valve are bal-
anced. (Fig. 2)
(Fig. I) 205FO5072
(Fig. 2) 205FO5073
3)
::
::
c\l
0
4)
During fine control (control lever
returned)
When disc (7) starts to be returned, spool
(1) is pushed up by the force of centering
spring (3) and the pressure at port PI.
Because of this, fine control hole f is con-
nected to drain chamber D, and the pressu-
rized oil at port P 1 is released.
If the pressure at port PI drops too much,
spool (1) is pushed down by metering spr-
ing (2), so fine control hole f is shut off
from drain chamber D. At almost the same
time it is connected to pump pressure
chamber Pp, so the pressure at port PI
supplies the pump pessure until the pres-
sure recovers to a pressure equivalent to
the position of the lever.
When the control valve spool returns, oil in
drain chamber D from fine control hole f of
the valve on the side that is not moving
flows through port P2 and goes to chamber
B, so the oil is charged. (Fig. 3)
At full stroke
Disc (7) pushes down piston (6), but
damper piston (4) also follows this and
pushes down spool (1). Fine control hole f is
shut off from drain chamber D, and is con-
nected to pump pressure chamber Pp.
Therefore, the pilot pressure oil from the
charging pump passes through fine control
hole f and flows to chamber A from port PI
to push the control valve spool.
The return oil from chamber B passes from
port P2 through fine control hole f and
flows to drain chamber D.
With damper piston (4) that was following
piston (6). the pressurized oil in the spring
chamber flows out from orifice a, and
damper piston (4) and spool (I) are pushed
back by the force of metering spring (2) and
the hydraulic pressure at port Pl.
The time lag when the lever is suddenly
operated is prevented by damper piston (4).
(During fine control, damper piston (4) does
not follow piston (6), so the fine control per-
formance is maintained.) (Fig. 4)
205FO5074
(Fig. 4) 205FO5075
View 2
2OTFO1042
a. P port (From control pump)
b. T port (To tank)
c. P2 port (L.H.: Arm dump/R.H.: Boom lower)
d. P4 port (L.H.: Swing left/R.H.: Bucket curl)
e. PI port (L.H.: Arm curVl3.H.: Boom raise)
f. P3 port (L.H.: Swing right/R.H.: Bucket dump)
Section B - B
Section A - A
Section C - C
1. Spool
2. Metering spring
3. Centering spring
4. Piston
5. Disc
Sec t i on D - D
20TF01043
6. Nut
7. Joint
8. Plate
9. Retainer
10. Body
OPERATION
1) At neutral
Ports A and B of the control valve and ports PI
and P2 of the PPC valve are connected to drain
chamber D through fine control hole f in spool
(1). (Fig. 1)
2) During fine control (neutral - fine control)
When piston (4) starts to be pushed by disc (5)
retainer (9) is pushed; spool (1) is also pushed
by metering spring (2), and moves down.
When this happens, fine control hole f is shut
off from drain chamber D, and at almost the same
time, it is connected to pump pressure chamber
PP. so pilot pressure oil from the charging pump
passes through fine control hole f and goes from
port Pt to port A.
When the pressure at port Pt becomes higher,
spool (1) is pushed back and fine control hole
f is shut off from pump pressure chamber PP.
At almost the same time, it is connected to drain
chamber D to release the pressure at port PI.
When this happens, spool (1) moves up or down
so that the force of metering spring (2) is balanced
with the pressure at port PI. The relationship
in the position of spool (1) and body (10) (fine
control hole f is at a point midway between drain
hole D and pump pressure chamber PP) does not
change until retainer (9) contacts spool (1).
Therefore, metering spring (2) is compressed
proportionally to the amount of movement of the
control lever, so the pressure at port PI also rises
in proportion to the travel of the control lever.
In this way, the control valve spool moves to a
position where the pressure in chamber A (ttie
same as the pressure at port Pt) and the force
of the control valve spool return spring are
balanced. (Fig. 2)
20TF01044
(Fig.1)
2
f
*
; I.!
P t
20TF01045
(Fig.2)
1 O-$9-3
3) During fine control
(when control lever is returned)
When disc (5) starts to be returned, spool (1) is
pushed up by the force of centering spring (3)
and the pressure at port PI.
When this happens, fine control hole f is
connected to drain chamber D and the pressure
oil at port PI is released.
If the pressure at port PI drops too far, spool
(1) is pushed down by metering spring (2), and
fine control hole f is shut off from drain chamber
D. At almost the same time, it is connected to
pump pressure chamber PP, and the pump
pressure is supplied until the pressure at port
PI recovers to a pressure that corresponds to
the lever position.
When the spool of the control valve returns, oil
in drain chamber D flows in from fine control
hole f in the valve on the side that is not working.
The oil passes through port PZ and enters
chamber B to fill the chamber with oil. (Fig. 3)
ZOTF01046
(Fig.3)
4) At full stroke
When disc (5) pushes down piston (4) and
retainer (9) pushes down spool (l), fine control
hole f is shut off from drain chamber D, and is
connected with pump pressure chamber PP.
Therefore, the pilot pressure oil from the charging
pumppassesthroughfinecontrol holef andflows
to chamber A from port PI, and pushes the
control valve spool.
The oil returning from chamber B passes from
port P2 through fine control hole f and flows
to drain chamber D. (Fig. 4)
I I I I PP
2OTFO1047
(Fig.4)
o-9-4
FOR TRAVEL
a
a. P port (From charging pump)
b. T port (To tank)
c. P2 port (L.H. reverse)
d. P4 port RH. reverse)
e. PI port (L.H. forward)
f. P3 port RH. forward)
C d
f e
1 ago
Section A- A Section B - B
Section C-C
1. Spool
2. Metering spring
3. Centering spring
4. Piston
Section D - D
205FO507 1
5. Bolt
6. Plate
7. Collar
8. Body
10- g
ACCUMULATOR
1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
SPECIFICATION
Gas capacity: 300 cc
205FO5076
SAFETY LOCK VALVE
PC200,2OOLC-5 Serial No: 45001 - 49317
PC220,22OLC-5 Serial No: 35001 - 35568
i I \ \
2 3 4 5
205FO5077
PC200,200LC-5 Serial No: 49318 and up
1. Lever
2. Body
3. Seat
4. Ball
5. End cap
1. Lever
2. Body
3. Seat
4. Ball
5. End cap
F205C5018
0673
SOLENOID VALVE ASSEMBLY
PC200,2OOLC-5 Serial No: 45001 - 52783
PC220,22OLC-5 Serial No: 35001 - 36023
FOR 2-STAGE RELIEF l CO CANCEL, SWING BRAKE AND TRAVEL SPEED
e
F20505351
a. To L.H. and R.H. travel motor
b. To swing motor
c. To main relief valve, and front and rear CO
valve
1. Travel speed solenoid valve
2. Swing brake solenoid valve
3. 2-stage relief l CO cancel solenoid valve.
d. P port (From charging pump)
e. T port (To tank)
1 o-g4
1) FOR P-STAGE RELIEF l CO CANCEL AND TRAVEL SPEED
205FO50 79
1. Connector
2. Plunger
3. Coil
4. Push pin
5. Spool
6. Spring
7. Bracket
OPERATION
Solenoid deactivated
C
z 0
:
No signal current flows from the controller,
so solenoid is deactivated.
0 Because of this, port A is closed, and the
pressurized oil from the charging pump
does not flow to the actuator.
At the same time, the oil from the actuator
flows from port B to port C and is drained
to the tank.
205FO5080- 1
Solenoid excited
0 When the signal current flows from the
controller to solenoid, solenoid is excited.
As a result, the Dressurized oil from the
charging pump flows from port A to port B,
and to the actuator.
At the same time, port C is closed, and the
does not flow to the tank.
Actuator
205FO5081- 1
2) FOR SWING BRAKE
205FO5082
OPERATION
a No signal current flows from the controll-
er, so coil is deactivated.
Because of this, port P is closed, and the
does not flow to the swing motor.
At the same time, the oil from the swing
motor flows from port A to port T and is
drained to the tank.
Solenoid excited
l When the signal current flows from the
controller, coil is excited.
Because of this, port P and port A are inter-
connected, and the pressurized oil from the
charging pump flows to the swing motor.
At the same time, port T is closed, so the oil
does not flow to the tank.
1. Connector
2. Plunger
3. Coil
4. Spring
5. Spool
6. Body
7. Plug
l-l
Swing
motor
205FO5083-1
Exci
205FO5084-1
FOR 2-STAGE RELIEF * CO CANCEL, SWING BRAKE AND TRAVEL SPEED
a.
b.
C.
d.
e.
d e
205 F05826
To L.H. and R.H. travel motor
To swing motor
To main relief valve, and front and rear CO
valve
P port (From charging pump)
T port (To tank)
1. Travel speed solenoid valve
2. Swing brake solenoid valve
3. 2-stage relief * CO cancel solenoid valve
OPERATION T
l The signal current from the controller does
not flow, so coil is deactivated.
l As a result, port P is closed, and the press-
ure oil from the charging pump does not
flow to the actuator.
Deactiv;ted p? , ,
At the sarne time, the oil from the actuator
flows from port A to port T, and drains to
the tank.
1. Connector
2. Plunger
3. Coil
4. Push pin
5. Spring
6. Spool
7. Body
Section A - A
205FO5827
Solenoid excited
l When the signal current from the control-
ler flows to coil, coil is excited.
l Because of this, pressure oil from the
charging pump flows from port P to port
A, and then flows to the actuator.
At the same time, port T is closed, so the
oil does not flow to the tank.
Excite- , /
205FO5829
PC200,2OOLC-5 Serial No: 45001 - 52783
PC220,22OLC-5 Serial No: 35001 - 36052
FOR ARM HALF FLOW
OPERATION
0 No signal current flows from the controll-
er, so coil is deactivated.
Because of this, port P and port S are in-
terconnected, so the pressurized oil from
the PPC valve flows to the control valve.
Solenoid excited
l When the signal current flows from the con-
troller, coil is excited.
Because of this, port P is closed, and the
pressurized oil from the PPC valve does not
flow to the control valve.
At the same time, port S and Port T are in-
terconnected, so the pressurized oil from
the control valve is drained to the tank.
205FO5085
1. Connector
2. Plunger
3. Coil
4. Spring
5. Spool
6. Body
7. Plug
205FO5086
Exci
205FO5087
FOR ARM HALF FLOW
1 2 3 4 5 6 7
OPERATION
l The signal current from the controller does
not flow, so coil is deactivated.
1. Connector
2. Plunger
3. Coil
4. Push pin
5. Spring
6. Spool
7. Body
l As a result, port P and port A are intercon-
nected, and pressure oil from the PPC
valve flows to the control valve.
Solenoid excited
l When the signal current from the control-
ler flows to coil, coil is excited.
l Because of this, port P is closed, and the
pressure oil from the PPC valve does not
flow to the control valve.
At the same time, the oil from the control
valve flows from port A to port T, and
drains to the tank.
205FO5832
o-&7-3
SHUTTLE VALVE
FOR ARM AND SWING
a b c
9
Section A- A
FOR BOOM, BUCKET AND TRAVEL
h
Section A__A Section B-B
I-D
k--
,-
-i
I-
m-
j
n-
Section C - C
205FO5088
Section D- D
1. Plug
2. Body
3. Ball
a. PI B port (Swing right)
b. P5 port (Swing oil pressure switch)
c. P2B port (Swing Left)
d. P4B port (Arm in)
e. P6 port (travel shuttle valve)
f. P3B port (Arm out)
9.
P2A port (Swing left)
h. P 1 A port (Swing right)
i. P3A port (Arm out)
j.
P4A port (Arm in)
1. Plug
2. Body
3. Ball
a. P7Aport
b. PEA port
c. P2A port
d. PlAport
e. P9A port
f. P8A pot-t
g. P4A port
h. P3A port
i. PlOport
j. P5 port
k. P9B port
I. PUB pot-t
m. P4B port
n. P3B port
0. P7B port
p. P6~p0rt
q. P2Bport
r. PIB port
205FO5089
BOOM HOLDING VALVE
PC200,2OOLC-5 Serial No: 45001 - 53229
PC220,22OLC-5 Serial No: 35001 - 36052
Section B - B
Section A- A
205FO5090
2. Pilot spring
3. Pilot spool
4. Poppet spring
5. Poppet
PC200,200LC-5 MIGHTY
Section B - B
2. Pilot spring
3. Pilot spool
4. Poppet spring
5. Poppet
I I I I
Section A - A
205FO5784
OPERATION
I) At boom RAISE
When the boom is raised, the main pressure
from the control valve pushes up poppet (5)
in the direction of the arrow.
Because of this, the main pressure oil from
the control valve passes through the valve
and flows to the bottom end of the boom
cylinder.
2) Boom lever at NEUTRAL
When the boom is raised and the control
lever is returned to NEUTRAL, the circuit for
the holding pressure at the bottom end of
the boom cylinder is closed by poppet (51,
and at the same time, the circuit for the oil
flowing into poppet (5) through orifice a of
poppet (5) is closed by pilot spool (3).
As a result, the boom is held in position.
205FO5091
205FO5092
3) Boom LOWER
When the boom is lowered, the pilot pres-
sure from the PPC valve pushes pilot spool
(3) and the pressurized oil in chamber b
inside the poppet is drained.
When the pressure at port Cy rises because
of the pressurized oil from the bottom end
of the boom cylinder, the pressure of the
pressurized oil in chamber b is lowered be-
cause of orifice a.
If the pressure in chamber b drops below
the pressure at port V, poppet (5) opens,
the pressurized oil flows from port Cy to
port V, and then flows to the control valve.
If any abnormal pressure is generated in the
circuit at the bottom end of the boom cylin-
der, safety valve (I 1 is actuated.
205FO5093
HYDRAULIC CYLINDER
1. BOOM CYLINDER
1 2 3456 7
9 10 11 12 13 14 15 16
205FO5094
2. ARM CYLINDER
6
1' 8 1' 7
205FO5095
3. BUCKET CYLINDER
12 3456 7
10 11 12 13 14 15
205FO5096
1. Bottom side bushing
2. Piston rod
3. Cylinder head
4. Rod packing
5. Buffer ring
6. Wear ring
7. Cylinder 13. Piston
8. Head side tube 14. Piston nut
9. Head side cushion plunger 15. Bottom side tube
10. Ring 16. Bottom side bushing
1 1. Piston ring 17. Bottom side cushion plunger
12. Wear ring 18. Ball
SPECIFICATIONS
Unit: mm
1,
Item
Rod outside diameter
Cylinder inside diameter
Stroke
Maximum length
Minimum length
Piston nut width across flats
Boom
I
Arm
I
Bucket
PC200
120
85
1,285
3,160
1,875
85
ELECTRICAL WIRING DIAGRAM
9
8
i /
11
/
1\
23
18 I
17
/
16
205FO5744
View 2
1. Monitor panel
2. Window washer switch
3. Swing lock switch
4. Horn switch
5. Starting switch
6. Fuel control dial
7. Cigarette lighter
8. Service meter
9. Buzzer
10. Radio
11. NC prolix switch
12. Swing lock prolix switch
13. Pump controller
14. Engine throttle controller
15. TVC prolix resistor
16. Power maximizing switch
17. Wiper relay
18. Additional lamp relay
19. Heater Lo relay
20. Heater Hi relay
21. Speaker
22. Lamp relay
23. Fuse box
2-PUMP-I-ACTUATOR SYSTEM (PC200,2OOLC-5 MIGHTY)
1-pu
solenoid valve
CN-V9(X2)
To swing flusher
Fuse box
Pump selector switch
ON : Z-pump
OFF : l-pump
205FO5848
HORN (PC200,2OOLC-5 MIGHTY)
Horn (Hi) 348 Hz
s I. 25LR
Horn (Lo) 290 Hz
I7 1.25LR
205FO5849
10439-6
ENGINE CONTROL SYSTEM
i
1. Battery relay
2. Battery
3. Fuel control dial
4. Starting switch
5. Governor motor
6. Starting motor
7. Engine throttle controller
8. Fuel injection pump
/
View Z
205FO5104
OUTLINE
The engine can be started and stopped
simply by using the starting switch.
The engine speed can be controlled using a
dial control system for the fuel control.
The engine throttle controller also controls
the engine speed at the same time using
signals from the pump controller.
* For detail, see PEMC SYSTEM.
1 O-89-8
GOVERNOR MOTOR LINKAGE
Angle origin
(Position of stopper)
\
Full
-
FL20505391
1. Locknut
2. Yoke
3. Governor actuater
4. Spring assembly
5. Engine governor
1. OPERATION OF SYSTEM
PC200,2OOLC-5 Serial No: 45001 - 58018
PC220,220LC-5 Serial No: 35001 - 36613
Starting engine
l When the starting switch is turned to the
START position, the start signal flows to
the starting motor, and the starting motor
turns to start the engine.
Starting
When this happens, the engine throttle con-
troller checks the signal voltage from the
fuel control dial and sets the engine speed
to the set speed.
205FO51051
Engine speed control
l The fuel control dial sends a signal voltage
to the engine throttle controller according
to the position of the dial.
Starting
The engine throttle controller calculates the
angle of the governor motor according to
this signal voltage, and drives the governor
motor so that it is set to that position.
When this happens, it detects the operating
angle of the governor motor using a poten-
tiometer and observes the governor motor.
Stopping engine
l When the engine throttle controller detects
that the starting switch is at the STOP posi-
tion, it drives the governor motor to set it to
the NO INJECTION position, and stops the
engine.
Starting
When this happens, to maintain the electric
power in the system until the engine stops
completely, the engine throttle controller
itself drives the battery relay.
205FCi5 10 7-1
Starting engine
l When the starting switch is turned to the
START position, the start signal flows to
the starting motor, and the starting motor
turns to start the engine.
When this happens, the engine throttle con-
troller checks the signal voltage from the
fuel control dial and sets the engine speed
to the set speed.
Starting
205FO5752
Engine speed control
l The fuel control dial sends a signal voltage
to the engine throttle controller according
to the position of the dial.
Starting
The engine throttle controller calculates the
angle of the governor motor according to
this signal voltage, and drives the governor
motor so that it is set to that position.
When this happens, it detects the operating
angle of the governor motor using a poten-
tiometer and observes the governor motor.
205FO5753
Stopping engine
Starting
l When the engine throttle controller detects
F
that the starting switch is at theSTOP posi-
tion, it drives the governor motor to set it to
the NO INJECTION position, and stops the
engine.
When this happens, to maintain the electric
power in the system until the engine stops
completely, the engine throttle controller
itself drives the battery relay.
205FO5754
1 O&92
2. COMPONENT EQUIPMENT OF SYSTEM
1) ENGINE THROTTLE CONTROLLER
CN-El
0
v
View Z 1
1. Self-diagnostic display LEDs
205FO5108
Control function of controller
0
1)
2)
The engine throttle controller receives the
input signals shown in the diagram on the
right, processes these internally and sends
output signals to the pump controller,
governor motor, and battery relay.
Engine speed set function using fuel con-
trol dial
An output signal that matches input voltage
a corresponding to the position of the fuel
control dial is sent so that the governor
motor is set to turning angle b.
Turning angle b is fed back to the controller
by the potentiometer signal, and the opera-
tion of the governor motor is always
observed.
Engine speed control by No. 2 throttle
signal from pump controller
The pump controller controls the engine
speed directly using the No. 2 throttle signal
in order to carry out the PEMC system.
The engine throttle controller controls the
engine using the lower signal (higher vol-
tage) of the throttle signal from the fuel
control dial and the No. 2 throttle signal
from the pump controller.
Example:
Even if the fuel control dial is set to the
MAX. position, if LF.0 mode and S model is
selected for the working mode and power
set, the engine speed will automatically be
set to partial speed.
* For details, see PEMC SYSTEM.
(Input signal) (Output signal)
Pump controller
(Starting stop SIgnall IThrottle signall
(Potentmmeter stgnal)
205FO5 109
u
$
Controller output
,Hi-idling
characteristics
P /
.-
E%
=m
zm
@
0%
zal
E .E
2 $ Lo-idling
L-
z
8
output
output
205FO5110
1024
3) Auto-deceleration function using auto-
deceleration signal from pump controller
When the pump controller detects that all
levers are at neutral, it sends the auto-
deceleration signal to the engine throttle
controller. When this signal is received, the
engine throttle controller reduces the
engine speed to the deceleration position.
* For details, see PEMC SYSTEM.
4) Automatic warming-up function using
warming-up signal from monitor
After the engine is started, if the engine
water temperature is low, the monitor sends
the warming-up signal to the engine throttle
controller.
When this signal is received, the engine
throttle controller raises the engine speed
to carry out warming up.
+ For details, see PEMC SYSTEM.
51
::
::
(v
0
Engine stop function using starting
switch signal
When the starting switch is turned OFF, the
engine throttle controller detects this and
drives the battery relay to maintain the elec-
tric power. At the same time, it drives the
governor motor to pull back the fuel injec-
tion pump lever to the STOP position.
6) Self-diagnostic function
Three LEDs (red, green, red) light up and go
out to indicate that the machine is normal,
or to indicate the location of any failure
when any abnormality occurs.
+ For details., see the TROUBLE-
SHOOTING.
Starting switch xl oFF
Operation of
E=Lk
2.5 set
205F05111A
Voltage between connector CN-El (13) - (12).
(Battery relay drive signal)
Signal Voltage (VI)
ON-l 20 - 30
ON-2 18-28
I
OFF
I -15--30 I
Internal structure of controller
0
1)
2)
3)
The inside of the controller consists of the
-
input circuit, microcomputer, and drive cir-
1
6
cuit shown in the diagram on the right, and
6
-
k
U
al .Z
S
.= L
these have the various functions described
below.
$
-2
.f
-00
g .g
-0
5
8
- E
5 2
aB
2
-
.E
2
.>
z
G-e
.P 2
E
Input circuits r $
These receive the signals from the fuel con- G
trol dial (throttle signal), pump controller
-
(No. 2 throttle signal, auto-deceleration 205FO5112
signal), monitor (warming-up signal), and
starting switch (start signal), and send them
to the microcomputer. In this portion, the
noise in the signal is removed and the wave
pattern of the signal is regulated.
In addition, it makes the power source
(approx. 5V) for the governor motor poten-
tiometer and fuel control dial.
Microcomputer
The angle of the governor motor is calculat-
ed from the input signals sent from the
input circuits, and the pulse signal to drive
the governor motor is sent to the drive
circuit.
Drive circuit
The pulse signal sent from the micro-
computer is used to switch the direction of
1 the current flowing to the governor motor
to rotate the motor clockwise or
counterclockwise.
2) FUEL CONTROL DIAL
Machine
forward
Section A - A
FUNCTION
l This is installed under the monitor panel. A
potentiometer is installed under the knob,
and when the knob is turned, it rotates the
potentiometer shaft.
This rotation changes the resistance of the
variable resistor inside the potentiometer,
and sends the desired throttle signal to the
engine throttle controller. The shaded area
in the graph on the right shows the abnor-
mal detection area, and the engine speed is
set to low idling.
l There are detents at ten places on the knob
of the fuel control dial, but the knob can be
set at any desired position.
Composition of circuit
205FO5113
1. Knob
2. Dial
3. Spring
4. Ball
5. Potentiometer
6. Connector
s
! z
. I
n
0 0. 25 1 4 4. 75 5
Throttle voltage
characteristics (VI
205FO51 14
3) GOVERNOR MOTOR
1. Potentiometer
2. Cover
3. Shaft
4. Dust seal
5. Bearing
6. Motor
7. Gear
8. Connector
Section A- A
FUNCTION
l The motor is rotated and the governor lever
of the fuel injection pump is controlled by
the drive signal from the engine throttle
controller.
l A stepping motor is used for the motor
which provides the motive power.
In addition, a potentiometer to give feed-
back is installed to allow observation of the
operation of the motor.
The rotation of the motor is transmitted to
the potentiometer through a gear.
@ (E&3)
@ (jS{
205FO5115
OPERATION
Motor stationary
l Current is passing through both the
A-phase coil and B-phase coil of the motor.
Motor rotating
l A pulse current is applied to the A phase
and B phase by the engine throttle controller
to give synchronous rotation with the pulse.
OUTLINE OF OPERATION OF STEPPING
MOTOR
Fig. 1 shows a diagram of the stepping mo-
tor expanded in the direction of the circum-
ference.
It shows the relative positions of the teeth of
the rotor and stator, and the condition corre-
sponds to current drive pattern 1 in Table 1.
If the motor is changed from this condition
into current drive pattern 2, the relative posi-
tions of the stator and rotor will become as
shown by the dotted line in Fig. 1 (the stator
is fixed, so the rotor moves to the left).
When switched in the pattern 2 -+ 3 -+ 4 -1
. . . . the rotor also moves to the left in the
same way. If the current drive pattern is
changed 4 -+ 3 - 2 - 1 - 4 . . . . the
rotor moves to the right.
Fig. 1 Expanded diagram of stepping motor
Rotor (permanent magnet)
N S N S N S N S N S N
-1
--1
-7 --i
N S S I N
I
I
I
I
I
I
_J AA
I
I
I
I
I I
- - I _- I An . -_I
+i
t
Stator -i
r[ (
b b
A phase
B phase
Table 1
Current drive pattern Pattern 1
A-phase current +i
B-phase current -i
Pattern 2
+i
+i
Pattern 3
-i
+i
Pattern 4
-i
-i
4) LOOSE SPRING
PC200,2OOLC-5 Serial No: 45001 - 56525
PC220,220LC-5 Serial No: 35001 - 35437
r
L
1. Yoke
2. Pipe
3. Spring
4. Spring
5. Rod
205 F0585 1
1 2 3 4 5 1. Rod
2. Spring
3. Pipe
4. Spring
5. Joint
205FO5868
1 o-9&7-3
PEMC SYSTEM
I[t
l PEMC system: Pump and Engine Mutual Control System
The PEMC system is a system of total control to give a high level of both power and fuel economy
by controlling both the pump and engine.
Pump & engine mutual control system
Working mode selection function
Power set selection function
Pump flow control (PFC, PNC) function
i~*ZI~~~~~~~~~Zon
Power maximizing system
1
Auto-deceleration system
Lo
0
Engine automatic warming-up function
Engine automatic warming-up and
g
c*l
overheat prevention system
0
Engine overheat prevention function
I
Swing lock function
Swing control system
Swing holding brake function
(Pump control function
Travel control system
When machine is traveling)
Automatic Hi-Lo travel speed shift
function
Self-diagnostic function
I
205FO5116
PCZOO, 2OOLC-5 Serial No: 45001-49706
PC220,22OLC-5 Serial No: 35001-35661
Travel motor
Swing motor
&izz--b---! IArmthrottle I / j
-Main
relef alYe
L______--____J~
(switch
1
t
Swing
lock
switch
205FO5117B
10699
PC200,2OOLC-5 Serial No: 49707 - 58018
PC220,22OLC-5 Serial No: 35662 - 36613
Travel motor
Swing motor
------_ I Control valve
r
I
I
I
I
i
r-
Swing
lock
switch
wing
,ck
rolix
Nitch
01
;; s
Ic
P
s\
Power max
switch
207F@5@52-1
0Z9-
PC200,
PC200,
PC220,
2OOLC-5 Serial No: 58019 and up
2OOLC-5 MIGHTY
22OLC-5 Serial No: 36614 and up
Travel motor
I I
Swing motor
f39
Regulator, _ , Regulator
I
T
,_____,fL______
Control valve
I
I
_------,+--q.)
r-
-
I
, I
I
L--J
(Arm curl1
pres.
switch
Chargm
pump
Swing
lock
switch
lock
prolix
switch
Power max
switch
controller
205FO5755
1. PUMP AND ENGINE MUTUAL CONTROL SYSTEM (WORKING MODE SELECTION
AND POWER SET SELECTION)
Engine
Fuel injection Covernor
Engine throttle
controller
Travel control lever
PPC shuttle valve
(Travel lever signal1
Pump controller -
I
t _;.
HO GO FO LO
Fuel control dial 0000
,switci, s,gnali WORKING MODE @
(Switch signal) 5 6 (;
OUTLINE
l The changes in the engine speed caused by 0
the pump load are detected by the engine
speed sensor and fuel control dial output
signal. The pump controller calculates these
signals, and sends the results to the TVC
valve as a signal to control the pump dis-
charge volume. In this way, it canalways 0
give the optimum matching of the engine
torque and pump absorption torque.
Engine torque Engine horsepower
205FO5118A
The combination of the 4-level working
mode and 3-level power set makes it possi-
ble to choose a pump absorption torque
corresponding to the nature of the work, so
it is possible to use the engine more effec-
tively while also reducing fuel consumption.
Normally, the combination of the working
mode and power mode takes the working
mode as the basic mode, and the power
mode is automatically set according to the
selection of the working mode.
Main pump delivery
L.O + L G.O. F.O. L.0 + S
L.0 + L H
Engine speed N 205F0511 9A Engine speed N
205FO5 120A
Pump delivery volume 0
Note) H.0: Heavy duty operation mode, G.0: General operation mode,
205F05121A
F.0: Finishing operation mode, L.0: Lifting operation mode
CONTROL OF H MODE
When using H.O. G.O. F.0 or L.0 mode and H
mode
. Engine torque
Working mode:
Power set:
CO function:
Pump absorption
horsepower:
Same for any mode
Actuated
When the pump controller receives the
power set [HI signal from the monitor, it
sends out an electric command for the H
mode output setting to the engine throttle
controller.
The engine throttle controller receives this
and uses the governor motor to set the
engine governor lever to the FULL position.
If the pump load becomes too high and the
engine speed drops, the engine speed sens-
ing reduces the pump discharge amount,
and momentarily resets the engine speed to
the rated point. In this way, the engine
torque and pump absorption torque are
always matched at the rated point, and the
engine horsepower can be used to the
maximum.
The CO (Cut-off) function is actuated, and
when it reaches near the relief pressure, the
pump discharge amount is reduced to
reduce hydraulic loss and power loss.
Engine speed N
205FO5122
l Engine horsepower
Engine speed N
205FO5 123
l Main pump delivery
205FO5124
CONTROL OF S MODE
When using H.0 mode and S mode
Working mode: H.0
Power set: S
CO function: Actuated
Pump absorption At 80% partial
horsepower: output point
PC200 PC220
98.6 HP/2,050rpm 123.2 HP/2,200rpm
working mode lH.01 and power set [Sl
signal from the monitor, it sends out an
electric command for the S mode output
setting to the engine throttle controller.
governor lever to the FULL position.
The pump absorption horsepower and
engine speed are different, but the control
is basically the same as for [HI mode
(engine speed sensing at the matching
point).
When using G.0, F.0 or L.0 mode and S mode
l Working mode: G.O. F.0 or L.0
0 Power set: S
0 CO function: Actuated
l Pump absorption At 80% partial
PC200 PC220
98.6 HP/l ,900rpm 123.2 HP/2,000rpm
l When the pump controller receives the
working mode LG.01 (or fF.01 fL.01) and
power set El signal from the monitor, it
sends out an electric command for the S
mode output setting to the engine throttle
controller.
governor lever to the partial position.
l The pump absorption horsepower and
point).
l Engine torque l Engine horsepower
Engine speed N p
Lu
Engine speed N
205FO5125 205FO5126
Main pump delivery
Engine torque
205FO5133
Ei
0
Engine horsepower
Engine speed N
&
Engine speed N
205FO5128 205FO5129
al
205FO5136
O-LAO2
CONTROL OF L MODE
When using H.0 mode and L mode
l Working mode: H.0
0 Power set: L
PC200 PC220
83.8 HP/2,050rpm 1 103.5 HP/2,200rpm
working mode fH.01 and power set [Ll
signal from the monitor, it sends out an
electric command for the L mode output
governor lever to the FULL position.
::
z
point).
(\I
0
When using G.O. F.0 or L.0 mode and L mode
l Working mode: G.0 or F.0
0 Power set: L
PC200 PC220
83.8 HP/ 1,900rpm 103.5 HP/2,000rpm
working mode LG.01 (or tF.01) and power
set [LI signal from the monitor, it sends out
an electric command for the L mode output
governor lever to the partial position.
point).
l Engine torque
I \
Engine speed N
l Engine horsepower
a
L
b
3
E
I
b
_c
E
.-
1,1
P
w
Engine speed N
205FO5131 205FO5132
205FO5 127
l Engine torque
l Engine horsepower
Engine speed N Engine speed N
LLI
205FO5134 205FO5 135
Main pump delivery
205FO5 130
1 O-&O3
When using L.0 mode and L mode
Working mode: L.0
Power set: L
CO function: Actuated
Pump absorption At 62% partial
PC200 PC220
75.9 HP/l ,400rpm 96.6 HP/l ,500rpm
working mode IL.01 and power set [Ll signal
from the monitor, it sends out an electric
command for the L mode output setting to
the engine throttle controller.
and sets the governor lever to the partial
position.
The pump absorption horsepower and
point).
The area around the matching point is a
highly efficient area for engine fuel con-
sumption, so the fuel reduction effect is ex-
tremely large.
At the same time, by throttling the pump
output, it is possible to obtain a high level of
fine control performance to match fine con-
trol operation.
l Engine torque
Engine speed N
l Engine horsepower
205FO5137
Engine speed N
205FO5138
205FO5139
1 O-&O4
CONTROL OF POWER MAXIMIZING FUN-
CTION
l When the power max. switch is OFF
l Working mode:
0 Power set:
0 CO function:
l Pump absorption
horsepower:
H.0 or G.0
Same for any mode
Actuated
Depends on the
setting for working
mode and power set
a
l When power maximizing switch ON
l Working mode: H.0
0 Power set: H
0 CO function: Cancel
l Pump absorption At rated output point
horsepower:
0 Operation time: Even if the switch is
kept ON, it is auto-
matically canceled
after 8.5 seconds.
1
0
l When the working mode switch is at iH.01
or IG.01, and the power max. switch is
pushed ON, the following functions are ac-
tuated while the switch is being pressed.
II If either of the working modes and any
of the power sets is selected, the
system will switch to LH.01 and [HI.
2) The CO (cut-off) function is canceled,
and the flow at near relief pressure is
increased.
* For details, see PUMP CONTROL
SYSTEM.
* Even if the switch is kept pressed, the
above function is automatically canceled
after 8.5 seconds, and the system is
reset to the condition before the switch
was pressed.
t This function does not work when the
working mode switch is at iF.01 or tL.01.
l Engine torque
I \
Engine speed N
205FO5 122
l Engine horsepower
0 Main pump delivery
Engine speed N
205FO5123
205FO5 140
10- 105
0
CONTROL FUNCTIONS WHEN TRAVELING
0 When the travel is operated, even if any
working mode or power set is selected,
the working mode and engine speed will
stay as they are, and only the power set
is switched to the equivalent of H mode
(Pump control by engine speed sensing)
to increase the pump absorption torque.
CONTROL FUNCTION WHEN TVC PROLIX
SWITCH IS ON
l If any abnormality occurs in the controller or
sensors, a constant current flows from the
battery to the TVC valve so that the function
can be maintained through a pump absorp-
tion torque more or less equivalent to S
mode.
In this condition, only hydraulic sensing
using the TVC valve is used.
l Engine torque
Engine speed N
205FO5141
l Engine horsepower
w.
Engine speed N
205FO5142A
207FO5079
1 O-l 06
cc
2. PUMP CONTROL SYSTEM
Power max.
OUTLINE
F20505352
( (Sw$ch signal) ,
(Switch signal)
_ Pump (Drive signal)
controller
:(Drive signal):
i (Travel lever signal)
,, ,, ,,
By controlling the main pump discharge
volume according to the stroke of the con-
trol lever, it is possible to reduce the neutral
loss and fine control loss.
The half flow mode function that is auto-
matically set by the working mode provides
excellent fine control performance.
The cut-off function and cut-off cancel
function, together with the 2-stage relief
function provide both reduction of relief
loss and increase of digging power.
l o- l o?
0
I) FLOW CONTROL FUNCTION
PNC (Pump Neutral Control)
l When the control levers are at neutral,
the pump discharge volume is controlled
to the minimum to reduce the wasted
oil flow that occurs when the control
valve is at neutral.
PFC (Pump Fine Control)
l When the lever is operated, the control
for the necessary oil flow is sent to the
pump based on the flow command cor-
responding to the stroke of the lever. In
this way, the wasted oil flow that
occurs during fine control is reduced.
l At the same time, by increasing the
pump discharge volume by a suitable
amount to correspond to the stroke of
the lever, the fine control performance
is improved.
* For detail, see HYDRAULIC PUMP.
21 CUT-OFF (CO) FUNCTION
l When the load increases during opera-
tions and the main pump discharge
pressure rises, it reduces the pump dis-
charge volume when the pressure is
near the relief pressure, and acts to
reduce relief loss.
* For details, see HYDRAULIC PUMP.
3) CUT-OFF CANCEL FUNCTION
When the load increases during opera-
tions and the main pump discharge
pressure rises, the pump discharge
volume is not cut-off even when the
pressure is near the relief pressure. This
ensures the flow of oil and prevents any
drop in speed.
Actuation and cancelation of the cut-off
function is automatically determined by
the position of the power max. switch,
travel lever and swing lock switch.
Operation of switches and cut-off
function
Note I) This is only effective when the
working mode switch is at
IH.01 or LG.01.
Lever stroke L
205FO5145
Pump discharge volume Q
205FO5146
Pump discharge volume is
not cut-off.
Pump discharge volume 0
205FO5 147
* Quick warming up of hydraulic oil
when swing lock switch is ON
When the swing lock switch is turned
ON, the CO function is canceled.
In this condition, if the work equipment
is relieved, the hydraulic oil temperature
can be raised quickly to reduce the time
taken for warming up.
4) HALF FLOW MODE FUNCTION
When LF.01 or lL.01 is selected with the
working mode switch, the operation of the
control valve for the arm Hi (acceleration) is
stopped. The pumps actuating the boom
and arm are separated, so the digging
(finishing) operation is not affected by the
load on the other circuit. This improves the
fine control and finishing precision.
l Relationship between working mode
and pump discharge volume (during in-
dependent operation)
Ir The portion for one pump is taken as
100%.
-)r When the arm OUT and bucket are
operated simultaneously, the half flow
mode does not function.
5) 2-STAGE RELIEF FUNCTION
When the power max. switch is pushed ON
(Note I), or the travel,lever is operated, or
the swing lock switch is ON, the 2-stage
relief l CO cancel solenoid valve pilot pres-
sure raises the set pressure of the main
relief valve from 325 kg/cm2 to 340 kg/cm2
to increase the digging power and travel
force.
Note 1) This is only effective when the
working mode switch is at IH.01
or iG.01.
Power max.
Travel lever
Swing lock
switch (Note I) switch
OFF Operated Neutral ON OFF
Main relief
valve set 340
325 340 325 340 325
pressure
(kg/cm21
10- l 1. 1
0
3. POWER MAXIMIZING FUNCTION
t (Swtich yj>nal) ,
Engine speed signal) , t
1
(
Engine throttle (Thro?tlesignal)
controller (No. 2 thjottle signal)
= Pump controller
Control valve
--
I I
Swing (
( L.H. travel
(Drive signal)
r ,
t t ,:.
H.0 GO F.0 LO
000
0000
POWER
SET @
I
(Switch signal) (Switch signal) WoRKlNG MODE @
I
F20505353
OUTLINE
l By pressing the switch on the left work
equipment lever knob, the maximum digging
power is increased to give superior
production.
10- 112
a
l When the working mode is switched to
IH.01 or LG.01, and the power max. switch is
switched ON, the following functions are
actuated.
[
Working mode 1 H.0 or G.0 1 H.0
Power set Any mode H
Main relief
valve pressure 325 kgcm
340 kg/cm2
Length of _
operation
Even when pressed
continuously, it is
canceled after 8.5 set
i;l
0
* This function does not work if the working
mode switch is at IF.01 or fL.01.
4. AUTO DECELERATION SYSTEM
PC200,2OOLC-5 Serial No: 45001 - 49706
PC220,22OLC-5 Serial No: 35001 - 35661
Fuel control dial
F
Lo
7
Engine
i
E
g =
(Drive signal)
r-k
Sl
om
& 5
(Throttle signal) Engine throttle
- controller
R.H. control L.H. control
A
c-
I
.g
-:
ti
2
I
PPC shuttle valve
Y
S
Oil pres.
2
switch
(Work equipment
ON
\
(Swing lever signal)
~ Pump controller _
(Switch signal) 0
AUTO
DECEL 0,
/%
205FO5149
OUTLINE
l This is a fully electronic control type, and
when all the work equipment, swing and
travel levers are at neutral, and the pump
controller receives the signal, it sends a
command to the engine throttle controller.
When this is received, the engine throttle
controller drives the governor motor to
reduce the engine speed, thereby reducing
fuel consumption and noise.
Fuel control dial setting rpm
rpm
NO. 1
decel. position
100 I50
No. 2
-I_ 0.2
decel. position
(1400)
4
Max. 2 Max. 1
4 -
set
Control lever Neutral Control lever Operation
205FO5150
O-Al4
Engine
Fuel control dial
1
HI
c
Lo
7
r . ection
Governor
motor I
(Throttle signal)
Engine throttle
L.H. control R.H. control
controller
1
%
6)
.-
In
5
:
PPC shuttle valve ?
Oil pres.
5
switch (Work equipment -
:
swing lever signal)
-
ON
0
Pump controller =
(Switch signal)
(Travel lever signal)
AUTO
DECEL I/l
/%
-
207KX-354
OPERATION
When auto-deceleration switch ON
1.
2.
3.
If the fuel control dial is set at a position
higher than 1500 rpm, and all control levers
are at neutral, the pump controller receives
the neutral signal and sends the auto-
deceleration signal to the engine throttle
controller.
When the engine throttle controller receives
the signal, it sends the drive signal to the
governor motor to drive the governor motor
and pull back the injection pump governor
lever to the No. 1 deceleration position. It
holds it at this position for approximately 4
seconds. When this happens, the engine
speed is lowered by about 100 rpm from
the dial setting.
After the levers have been at neutral for
more than 4 seconds, the drive signal is
again sent from the engine throttle control-
ler to the governor motor, and the governor
lever is pulled back and held in the No. 2
deceleration position.
The engine speed in this position is approx.
1400 rpm.
In the deceleration condition, if any control
lever is operated, the pump controller re-
ceives the signal and cancels the auto-
deceleration signal sent to the engine throt-
tle controller. When this happens, the
engine throttle controller sends a drive
signal to the governor motor to return the
governor lever to its original setting.
When auto-deceleration switch is OFF
l The engine speed can be set as desired
using the fuel control dial, and even if all the
levers are at neutral, the engine speed is not
reduced.
Engine
205FC5151.1
Enaine
Fuel d
205FO5152-1
Enaine
PPC shuttle valve
IX
Pump
controller
205FO5 153-l
l o- 116
0
5. ENGINE AUTOMATIC WARMING-UP AND OVERHEAT PREVENTION FUNCTION
Engine
Fuel control dial
Hi
f
Lo
t 1
5
(I)=
as-l
zz
2 .e
z.5, ~,
2 r\l
e
,, (Coolant temp. 102T signal)
z
(Coolant temp. 107C/105C signal)
(Drive signal)
(Working mode signal) Pump controller
w
(Power set signal)
OUTLINE
l After the engine is started, this raises the engine
speed automatically to warm up the engine. (Au-
tomatic warming-up function)
In addition, to protect the engine, if the coolant
temperature rises too high, it lowers the pump
load and engine speed to prevent overheating of
the engine. (overheat prevention function)
205FO5154
10- 117
/ 7
6
I )
l
21
l
AUTOMATIC WARMING-UP FUNCTION
Actuation table
\
Conditions
Coolant temperature: Less than 30C
Fuel control dial: Below set speed
[set speed: 1,200 rpml
* If all the above conditions are satisfied,
the automatic warming-up function
is actuated.
Coolant temperature: Above 30C
Fuel control dial: Held above 70% of high idling
for more than 3 sec.
Warming up time: At least 10 minutes
-k If any of the above conditions is applicable, the
automatic warming-up function is canceled.
OVERHEAT PREVENTION FUNCTION
Actuation table
PC200,2OOLC-5 Serial No: 45001 - 58018
PC220,22OLC-5 Serial No: 35001 - 36613
Action
Engine speed: 1,200 rpm
Engine speed: As desired
Conditions
Coolant temperature: 102 - 107C
(Coolant temperature gauge:
Red range)
Coolant temperature: Above 107C
Red range
Coolant temperature: Under 102C
Green range)
Ir Automatic reset
When coolant temperature is less
than 102C, return fuel control
dial to low idling position.
* Manual reset
Action
Power set:
Selected mode Action mode
H.0 and H,S mode H.0 and L mode
G.0 and H,S mode G.L and L mode
F.0 and H,S mode F.0 and L mode
L.0 and H,S mode L.0 and L mode
Engine speed: Default mode speed
Power set: L mode (same as No. 1 setting)
Engine speed: Low idlig
Warning lamp, buzzer: ON
Power set: Default mode
Engine speed: Fuel control dial set speed
(as desired)
O-A*
6. SWING CONTROL SYSTEM
PC200-5
PC220-5
Serial No: 45001 - 49706
Serial No: 35001 - 35661
Swing motor
L.H. control lever
OFF ON
/
$/
Pump controller
-
(Swing lever signal)
, ,l
,, //
205F05155B
OUTLINE
l The swing is controlled comprehensively
both when stopping and when operating
the swing, by the swing lock, swing holding
brake, and swing priority functions.
1o-A8-1
Swing motor
L.H. and R.H. control levers
Swing holding brake
7
Monitor panel
Swing brake
solenoid valve
vii
1
xes.
7
:ch
207F05055A
Conditions
Power set:
Action
Selected mode Action mode
H.0 and H,S mode H.0 and L mode
g Coolant temperature: 102 - 105C G.0 and H,S mode G.L and L mode
z
-0 7
B Red range)
F.0 and H,S mode F.0 and L mode
d
!i 2
2
L.0 and H.S mode L.0 and L mode
Warning lamp: ON
.E Coolant temperature: Above 105C Power set: L mode (same as No. 1 setting)
I (Coolant temperature gauge:
c*l
Engine speed: Low idlig
z
Red range Warning lamp, buzzer: ON
p Coolant temperature: Under 102C
=
5 (Coolant temperature gauge: Power set: Default mode
Green range) Engine speed: Default mode speed
-0 .*
2 z
Automatic reset
:
p
5 5
When coolant temperature is less
0 0,
z
than 102C, return fuel control
dial to low idling position.
Engine speed: Fuel control dial set speed
z
* Manual reset
(as desired)
OiF9
6. SWING CONTROL SYSTEM
PC200,2OOLC-5 Serial No: 45001 - 49706
PC220,22OLC-5 Serial No: 35001 - 35661
Swing motor
Swing holding brake
L.H. control lever
Swing
k
PPC shutlle
valve
Oi
SW
#
(Swing lock signal)
I
OUTLINE
l The swing is controlled comprehensively
both when stopping and when operating
the swing, by the swing lock, swing holding
brake, and swing priority functions.
.es.
7
:h
205F05155B
0-i20
PC200,2OOL-5 MIGHTY
Swing motor
L.H. and R.H. control levers
Swing holding brake
Monitor panel
) Sw,ing lock
Awing lock signa,tt, I{ :I OFF
res.
7
sh
207F05055A
11 SWlNG LOCK AND AUTOMATIC SWING
l Relationship between swing lock lamp and
21
HOLDING BRAKE SYSTEM
The swing lock (manual) and swing holding
brake (automatic) are employed to lock the
swing in the desired position and to prevent
hydraulic drift after stopping the swing.
the brake
Lock lamp Actuation
The swing brake is applied
approx. 4 seconds after the
swing control lever is placed
OFF (switch OFF) at neutral.
(Swing holding When the swing control
brake applied) lever is operated, the swing
brake is released and the
upper structure can swing
freely. (Note)
The upper structure is held
in place by the swing brake,
3N (switch ON) and even if the control lever
[Swing lock applied) is operated, the swing brake
is not canceled, so the upper
structure does not swing.
Note:
On the following machines, both the work g
equipment control levers are interconnected:
z
PC200-5 Serial No.: 40707 and up
2
Sr Swing lock prolix switch function Actuation table
When the pump controller is abnormal
and the swing holding brake function
does not work normally, the swing lock
prolix switch cancels the swing brake
and operates the swing.
+I Even when the swing lock prolix switch
is turned ON, the swing lock switch
stays ON and the swing brake is not
canceled.
Sr When the swing brake is canceled, the
swing has only a hydraulic brake operat-
ed by the safety valve, so if the swing is
stopped on a slope, there may be hy-
draulic drift.
HYDRAULIC OIL QUICK WARM-UP
FUNCTION WHEN SWING LOCK
SWITCH IS ON
t For details, see PUMP CONTROL
SYSTEM.
1 O-&22
7. TRAVEL CONTROL SYSTEM
Travel motor
(Throttle signal)
Engine throttle
controller
(Swing signal)
c
205FO5 156
OUTLINE
l This increases the pump absorption torque
and drawbar pull when traveling.
l The travel performance is improved by
switching the travel speed manually or
automatically.
o-A23
II PUMP CONTROL FUNCTION WHEN
TRAVELING
When traveling, the following functions are
actuated.
l If any of the working mode and power
set are selected, the working mode and
engine speed stay as they are and the
power set only is switched to the
equivalent of H mode.
* For details, see ENGINE AND PUMP
MUTUAL CONTROL SYSTEM.
2) TRAVEL SPEED SWITCHING FUNCTION
The switching of the travel speed can be
carried out manually or automatically, and
has the following functions.
i)
ii)
iii)
When the travel speed switch is
switched, the solenoid valve is
switched. The action of the pilot pres-
sure then changes the motor rocker
cam angle and changes the travel speed.
If the speed setting of the fuel control
dial is set to less than approx. 1400
rpm:
l When traveling in Lo, even if it is
switched to Hi, the transmission is
not shifted.
l When traveling in Hi, the transmis-
sion is automatically shifted to Lo.
Automatic switching between Hi and Lo
according to pump discharge pressure
When traveling with the travel speed
switch at Hi, if the machine travels up a
slope and the pressure in the travel cir-
cuit goes above 310 kg/cm2 for more
than 1.0 second, the solenoid valve is
deactivated (closed) and the travel
speed is switched to Lo. If the machine
continues to travel at Lo (with the travel
speed switch still at Hi) and it comes
again to flat ground or travels downhill,
and the pressure in the travel circuit
drops below 210 kg/cm2 for more than
1.0 second, the solenoid is excited
(opened) and the speed is switched
again to high speed.
* Detection of the pressure in the
travel circuit when only the travel is
being operated is made by sensing
the pressure for both the front
pump and the rear pump, and taking
the higher value; for compound op-
erations, only the sensor for the rear
pump pressure is used.
(Travel speed
switch at Hi)
(Travel pressure
continues at
more than 3 10
kg/cm2 for
more than 1 .O
seconds)
(Travel pressure
(Travel speed
continues at
less than 2 10
kg/cm2 for
more than 1 .O
seconds)
switch at Hi)
o-A24
8.
1)
SYSTEM COMPONENT EQUIPMENT
PUMP CONTROLLER
CN-C3 CN-C2 CN-Cl
84:
1. Self-diagnostic
display window
Section A- A
205FO5 157
2) ENGINE SPEED SENSOR
3)
4)
5)
61
9
i i
___
6
0
1. Magnet
2. Terminal
3. Case
4. Boot
5. Connector
ENGINE THROTTLE CONTROLLER, FUEL
CONTROL DIAL AND GOVERNOR
MOTOR
* For detail see ENGINE CONTROL
SYSTEM.
MONITOR PANEL
* For detail, see EMACC.
TVC VALVE
* For detail, see HYDRAULIC PUMP.
2-STAGE RELIEF *CO CANCEL SOLE-
NOID VALVE
TRAVEL SPEED SOLENOID VALVE
ARM HALF FLOW SOLENOID VALVE
Ir For detail, see SOLENOID VALVE
ASSEMBLY.
205FO5158A
z
FUNCTION
z
l The engine speed sensor is installed to the
z
ring gear of the engine flywheel, and acts to
count electrically the number of gear teeth
that pass in front of the sonsor. This detec-
tion is carried out magnetically, and the
sensor contains a magnet and detection coil.
7) PUMP PRESSURE SENSOR
_l& (=-J ii- igY_
4. Flange
5. Detect module of oil pressure
6. Introduction pipe of oil pressure
Amplifier
I
OUTLINE
l The pump discharge pressure is converted
to a voltage, and the signal is sent to the
pump controller.
FUNCTION
l The voltage output is proportional to the
pressure.
Oil pressure P (kg/cm?
205FO5161
l Relationship between output voltage V (v)
and pressure P (kg/cm2).
V = 0.008 x P + 1 .O
205FO5159A
OPERATION
Isolation
To amplifier seam
t
Oil pressure
205FO5160
When the pressurized oil entering from
pressure introduction pipe (61 is pressurized
by the diaphragm of pressure sensor
module (51, the diaphragm shape changes.
A bridge is formed on the opposite face of
this diaphragm by a strain gauge, and the
deflection of the diaphragm is converted
from a resistance value of the strain gauge
to the bridge output voltage and is sent to
the voltage amplifier (amp).
The voltage is further amplified by the
amplifier, and is output to the controller.
o-i4-3
8) WORK EQUIPMENT OIL PRESSURE SWITCH, SWING OIL PRESSURE SWITCH,
TRAVEL OIL PRESSURE SWITCH
123456 7
202FO5 I65
1. Plug
2. Diaghragm
3. Back up spring
4. Pin
5. Guide pin
6. Movable contacts
7. Connector
SPECIFICATIONS
Actuation pressure: 5.0 2 1 .O kg/cm2
Reset pressure: 3.0 f 0.5 kg/cm2
EMACC (ELECTRONIC MONITOR AND CONTROL CONSOLE)
Sensor signal
I=
Monitor panel
7
Sensor
Power
source
1
Battery
Relay Electrical parts
Engine throttle controller
Warming-up signal
Q=
Buzzer signal
II
Pump controller
II
Switch signal
Coolant temp. signal
Buzzer
205FO5162
l The electronic monitor and control console
(EMACC) observes the condition of the ma-
chine through the sensors installed to vari-
ous parts of the machine, and processes
this information quickly. The system informs
the operator of the condition of the machine
by displaying the condition on the panel.
The content of the panel displays can be
broadly divided into the following.
1. Monitor portion that gives warnings
when any abnormality occurs in the
machine.
l Various modes selector switches are built
into the monitor panel, and it acts as the
control portion of the machine control
system.
2. The gauge portion (coolant temperature,
fuel level) that always informs the condi-
tion of the machine.
1. MONITOR PANEL
OUTLINE
l The monitor panel has the switch functions
for the electrical parts, mode selection, and
monitor display functions.
It has a built-in CPU (Central Processing
Unit), and processes the data and outputs
the display.
The monitor display uses a liquid crystal dis-
play (LCD). The switches are flat sheet
switches.
205FO5 163
MONITOR
PC200,2OOLC-5 Serial No: 45001 - 58018
PC220,22OLC-5 Serial No: 35001 - 36613
1. Coolant temperature gauge
2. Engine oil level caution lamp
3. Coolant level lamp
4. Coolant temperature caution lamp
5. Coolant level caution lamp
6. Engine oil pressure caution lamp
7. Fuel level caution lamp
8. Charge level caution lamp
9. Engine preheat pilot lamp
10. Hydraulic oil level caution lamp
11. Fuel level guage
i P 7 205FO5164
Item
Condition for displaying
abnormalities
Description
Classifi-
cation of
indicatior
Symbol
Below low level Coolant level
Engine oil level
Hydraulic oil level
indicates when placing the starting
switch to ON before starting the
engine.
If it is normal, the lamp goes off.
If it is an abnormality, the lamp
flashes.
Below low level
Below low level
0.5 kg/cm2 max. Engine oil pressure
Indicates while the engine is running
and the starting switch is set to ON.
flashes and the buzzer sounds.
Coolant level Below low level
Coolant temperature 107C min.
Charge level When charging system fails.
Indicates when the engine is running
flashes.
Fuel level Below low level
67 76 83 90 97 102 107C
Appropriate place (one place)
lights up.
Coolant temperature
All light up below appropriate
level
Fuel level
When the starting switch is turned to
HEAT position, this pilot lights for 30
seconds, then flashes (for 10
seconds) to indicate the preheating
is finished.
Preheat When preheating
o-227
1 2 3 4 5
1. Coolant temperature gauge
2. Engine oil level caution lamp
3. Coolant level lamp
4. Coolant temperature caution lamp
5. Coolant level caution lamp
6. Engine oil pressure caution lamp
7. Fuel level caution lamp
8. Charge level caution lamp
9. Engine preheat pilot lamp
10. Hydraulic oil level caution lamp
11. Fuel level guage
1
Classifi-
cation of Symbol
indication
Item
205FO5164
Condition for displaying
abnormalities
Description
:
%
8
Indicates when placing the starting
switch to ON before starting the
;I=
0
engine.
Ifs -
Engine oil level Below low level
_
If it is normal, the lamp goes off. ._.
VI- -
I
Z
1 If it is an abnormality,thk lamp
Hydraulic oil level Below low level
flashes.
0
c
L
G
b Engine oil pressure 0.5 kg/cm2 max.
Indicates while the engine is running
8
Q
Coolant temperature
102C (Flash) flashes and the buzzer sounds.
105C (Buzzer)
m Charge level When charging system fails.
@
Fuel level Below low level
Indicates when the engine is running
flashes.
67 76 83 90 97102 105C
8
I /
Coolant temperature
ai:d d
.;.
.:.
:.:.
0 00
Appropriate place (one place)
j:
:j:
lights up.
0-10
C t-l
9 57 76 98 122 145 176 192 215 236 31OP
Fuel level
All light up below appropriate
level
When the starting switch is turned to
-00-
HEAT position, this pilot lights for 30
Preheat
When preheating seconds, then flashes (for 10
seconds) to indicate the preheating
is finished.
O-k2*
SWITCH
1. Heater fan switch
2. Power set selection switch
3. Working mode selection switch
4. Buzzer cancel switch
5. Travel speed switch
6. Lamp switch
7. Auto-deceleration switch
8. Wiper switch
9. Swing lock lamp
9 8 7
205FO5165
l The switches consist of four mode selector Switch actuation table
switches and four electrical component
switches; every time the switch is pressed,
Item Action
the condition of the machine changes. The
present condition is displayed by the light-
ing up of the LED above the switch.
Working mode G.0 - H.0 - L.0 - F.0
Power set S -H-L
Auto decel ON -OFF
Travel speed Lo -Hi
Fan OFF-Lo-Hi
Wiper OFF-Lo-Hi
Lamp OFF-l -2
Buzzer cancel OFF -ON
* The bold letters indicate the default values
when the starting switch is truned ON.
l o- 129
0
2.
0
SENSOR
The signals from the sensors are input
directly to the monitor panel.
One of the contact points of the sensors
with contacts is always connected to the
chassis GND.
Classification
of indicatinn
I
Type of sensor Sensing type Normal Abnormal
Coolant level
CHECK
Contact type ON (close) OFF (open)
MONITOR Engine oil level ON (close)
GROUP
Contact type OFF (open)
Hydraulic oil level Contact type ON (close) OFF (open)
CAUTION Engine oil pressure Contact type OFF (open) ON (close)
Coolant temperatrue Resistance type
- -
GAUGE GROUP
Fuel level Resistance type
- -
1) COOLANT LEVEL SENSOR
1. Sub-tank
2. Float
3. Sensor
4. Connector
205FO5166
10- 130
2) ENGINE OIL LEVEL SENSOR
205FO5167A
3) HYDRAULIC OIL LEVEL SENSOR
205FO5168
4) ENGINE OIL PRESSURE SENSOR
1. Connector
2. Bracket
3. Float
4. Switch
1. Connector
2. Plug
3. Switch
4. Float
1. Plug
2. Contact ring
3. Contact
4. Diaphragm
5. Spring
6. Terminal
205FO5169
10- 131
5) COOLANT TEMPERATURE SENSOR
2 3
1. Connector
2. Plug
3. Thermister
205FO5170A
6) FUEL LEVEL SENSOR
8
EMPTY
1 \
Float
Connector
Cover
Variable resistance
i ;I
Section A- A
205FO5171
l o- 132
20 TESTING AND ADJUSTING
Table of judgement standard value ........................
Standard value table for electrical system ..................
Tools for testing, adjusting, and troubleshooting .............
Adjusting valve clearance ...............................
Measuring compression pressure .........................
Testing and adjusting fuel injection timing ..................
Testing and adjusting travel of governor motor lever .........
Inspection of swing circle bearing clearance ................
Adjusting engine speed sensor ...........................
Testing and adjusting hydrauic pressure in
...................... 20- 2
...................... 20-I 8
...................... 20-29
...................... 20-30
...................... 20-31
...................... 20-32
...................... 20-33
..................... 20-33-I
...................... 20-34
work equipment, swing, travel circuit ................... ............
Testing and adjusting charging pump pressure .............. ............
Testing and adjusting main pump control pressure ........... ............
Measuring stroke of servo piston ......................... ............
Measuring output pressure of PPC valve ................... ............
Adjusting work equipment, swing PPC valve ................ ............
Testing PPC shuttle valve ................................ ............
Measuring solenoid valve output port pressure .............. ............
Testing locations causing hydrauic drift of work equipment .... ............
Bleeding air ........................................... ............
Releasing remaining pressure in hydraulic circuit ............ ............
Troubleshooting ....................................... ............
........ 20-35
........ 20-38
........ 20-40
........ 20-47
........ 20-48
........ 20-49
........ 20-50
........ 20-51
........ 20-52
........ 20-54
........ 20-56
........ 20-57
ABefore performing inspection, adjustment or faultfinding, park the machine on level ground and
A
check the safety pin and chock.
When performing joint work, make appropriate signals and allow only authorized personnel near
the machine.
A When checking the water level, allow the engine to cool down before removing the radiator cap to
prevent the risk of being scalded by hot water which may spurt out if the engine is hot.
A Take great care to avoid getting caught in rotating parts such as the fan, etc.
TABLE OF JUDGEMENT STANDARD VALUE
. FOR ENGINE
Machine model PC200-5 PCZZO-5
Engine S6D95L-1 SA6D95L-1
. Standard
WI ue
Permissible
value
Item Measurement conditions Unit
Engine speed
High idling
rpm 2,250 i 70
Low idling
rpm 870 + 50
Rated speed
rpm 2,050
2,410 + 70 -
870+ 50 -
2,200
-
Max. 5.5 7.5
1 .o 2.0
Exhaust gas color
At sudden acceleration
Bosch
index
At high idling
Bosch
index
Max. 5.5 7.5
Max. 1 .O 2.0
0.35
I
-
0.50
-
Valve clearance
(normal temperature)
Intake valve
Exhaust valve
mm
mm
0.35
-
0.50
-
Compression pressure
(SAE 30 oil)
Oil temperature: 40-60C kg/cm Min. 28
(Engine speed) (rpm) (320 - 360) (3202-0360,
Min. 28
(320 - 360) (320 y360)
N;_lj
(Coolant temperature:
Operating range) mmH,O
At rated output
Blowby pressure
(SAE oil)
Max. 75 150
I I
(Coolant temperature:
Operating range)
At high idling (SAESO)
At low idling (SAE30)
At low idling (SAElOW)
kg/cm
kg/cm
kg/cm
3.5 - 6.0 2.4
3.5 - 6.0 2.4
Min 1 .O 0.7
Min 0.8 0.7
Oil pressure
Min. 1 .O 0.7
Min. 0.8 0.7
Oil temperature
Whole speed range
(inside oil pan)
OC 80- 110 120 80- 110 120
Fuel injection timing B.T.D.C.
0
18*1 18*1 18~ 1 18i 1
8 6- 10 8 6- 10
Belt tension (alternator)
Deflection when pressed
with finger force of
approx. 6 kg.
mm
0 FOR CHASSIS
* The standard values and permissible values shown in this table are all values for H.0 (heavy-duty
operation) and H mode.
1
Machine model
PC200 - 220-5
Classif
cation
Unil Standard value
i-
Item
At l-pump relief
Measurement conditions
Hydraulic oil temperature: 45 _ 551
Engine oil pressure:
Within operating range
. Coolant temperature:
At 2-pump relief
Within operating rangr
. l-pump relief: Bucket relief
2pump relief: Arm relief
-
PC200 PC220
-
I
-
Speed when CO
function canceled
* H.0 and H mode
- Engine at high idling
* Arm relief
Speed when auto-
deceleration is
actuated
Fuel control dial at MAX.
. Control lever at neutral
-
1,400t 120
P a b
-
9.5to.5 9.520.5
Boom-Lo control
valve
Boom-Hi control
valve
I
r
P
Arm-Lo control valve
Arm-Hi control valve mm
Bucket control valve
Swing control valve
Travel control valve
202F2302
65*10
Max. 75
Min. 55
Boom control lever
Arm control lever
Center of lever knob
Read max. value to end of travel
Engine stopped
Except for neutral play
Max. 75
Min. 55
65+10
Bucket control lever
1
65rlO
mm
Swing control lever 65-clO
Travel control lever 120*11
Max. 75
Min. 55
-
kg
Max. 75
Min. 55
Max. 131
Min. 119
Play of travel lever Max. 15 Max. 10
2.3iO.3 Max. 3.1
1.8*0.3
Max. 2.6
i
travel
1 .BiO.3
Bucket control lever
Max. 2.6
Max. 3.1
Max. 4.0
Max. 11
Swing control lever 2.3i0.4
1
Lever 2.5r0.7
Pedal
7kl.8
Machine model
PC206 .226-5
Unit Standard value
pc200
I t em Permissible value
pc200
Max. 340
Min.310
. Oil temperature: 45 - 55C
. Relief pressure with engine at
high idling
(Relieve only circuit to be
measured)
H.0 and H mode
. ( ) : When using power
maximizing (reference)
At outlet of pump
*I: Oil pressure when travel is re-
lieved on one side.
*2: When the travel lever is ope-
rated, the CO is canceled.
Boom
Arm
Bucket
325:;,
(340:;)
Max. 300
Min. 285
Max. 365
Min. 325
Max. 36
Min. 25
29o;;o
34o+O
-15
Swing
Trave I
Charging pump 32;:
T
Control lever at
neutral
23*1 24tl
. Oil temperature:
45 - 55C
. Engine at high
idling
. H.0 and
H mode
Max. 18 Max. 18
I
1 -pump relief
[2pump average
oil pressure1
P, +P
1
2
=160-l 7c
kg/cd
TVC valve output
pressure
Max. 17 Max. 18
Min. 14 Min. 15
17+1 16+1
g/cm
I
. Oil temperature:
45 - 55C
. Engine at high
idling
. Ii.0 and H mode
. Measure at NC
valve outlet port
Control lever at
neutral
E;;!z;J
Travel lever at
full, track rotating
freely
1
Max. 5.5 Max. 5.5
Min. 17
CO - NC valve
output pressure
Min. 17
(actuated
J
Pump relief
Max. 5.5 Max. 5.5
16*3
. Engine at high idling
. Control lever at neutral
Max. 19
Min. 13
Lever at
neutral
et sensor
ifferential
ressure
Lever at end
of travel
. Control lever at end of travel
(Pump discharge pressure as
desired)
Max. 2 Max. 2
Machine model PC200 .220-5
Classi,
cation
Item Measurement conditions Unit Standard value Permissible value
Working equipment Max. reach
PC200 PC220 PC220
Max. 130 Max. 120
3.2 i 0.3 Max. 3.4
4.6 ? 0.5 Max. 5.1
pas-
Engine at high idling
Hydraulic oil temperature: 45 - 55~
Stop after swinging one turn
and measure distance that swing
circle moves
( 1: Distance of movement on
outside circumference of
swing circle
Swing brake angle
Max. 160 Max. 90
2.8 ? 0.3
4.2 + 0.4
Nork equipment Max. reach 1
90 Max. 3.8
Time taken to start
swing
20x2123
sec.
Hydraulic oil temperature:
45 - 55Oc
H.0 and H mode
Time taken from starting
position to swing 90 and
180
180 Max. 5.5
Work equipment
posture
Max. reach
Time taken to swing 25 ? 2 24 + 2 Max. 30 Max. 30 sec.
Engine at high idling 202~2~~
Hydrau lit oil temperature:
45 - 55Oc
H.0 and H mode
Swing one turn, and measure time
taken to swing next 5 turns
Engine stopped
45 - 55Oc
Set machine on 15 slope, and set
upper structure at 90 to the side.
Make match marks on swing circle
outer race and track frame.
Measure distance that match
marks move apart after 5 minutes.
Hydraulic dri!t of
swing mm
45 - 55Oc
Swing lock switch ON
Relieve swing circuit.
Leakage from swing
motor
Max. 5 Max. 10
Item
Unit Standard value Permissible value
Classifi-
cations
Measurement conditions
PC200 PC220 PC200 PC220
C200:
18.1 t3
C2OOLC:
j2.4*3
PC200:
Max. 54.1
Min. 45.1
PC200 LC :
Max. 58.6
Min. 49.4
PC220:
Max. 53.5
Min. 44.3
PC22OLC:
Max. 57.3
Min. 48.3
PC220:
47.3i3
PC22OLC:
51.3*3
PC220:
29.2*2
PC22OLC
31.7?2
LO
Travel speed (I)
sec.
45- 55Oc
H.0 and H mode
t Raise track on one side
at a time, rotate one turn,
then measure time taken
for next 5 turns.
C200 :
28.0*2
?C2OOLC:
30.5+2
PC200:
Max. 32.0
Min. 26.0
PC200LC:
Max. 34.5
Min. 28.5
PC220:
Max. 33.2
Min. 27.2
PC22OLC:
Max. 35.7
Min. 29.7
Hi
Max. 26.5
Min. 20.5
Max. 25.2
Min. 19.2
22.522 21.2i2
Lo
sec.
mm
Travel speed (2)
0
::
Max. 17.1
Min. II .I
:
45- 55C
H.0 and H mode
Run up for at least IO m,
and measure time taken to
travel next 20 m on flat
ground.
Hi
-
Max. 17.1
Min. 11.1
13.1*2 13.1?2
205F2409
. Hydraulic oil temperature:
45 - 55C
Run up for at least 10 m, and
measure deviation when travel-
ing next 20 m on flat ground.
*Use a hard horizontal surface
Travel deviation Max. 200 Max. 220
205F2402
l Measure dimension x
Classifi
cation
Measurement conditions Unit
-
Standardvalue Permissible value
Hydraulic drift of
travel
0 0
. Engine stopped
45- 55Oc
Stop machine on 12 slope
with sprocket facing straight
up the slope.
Measure the distance the
machine moves in 5 minutes.
Leakage of travel
motor
!/mir
Max. 13.6 Max. 27.2
45-555Oc
. Lock shoes and relieve travel
circuit.
Work equipment posture
Total work equip-
ment (hydraulic
drift at tip of
bucket teeth)
Max. 900
Max. 600
Boom cylinder
(amount of
retraction of
cylinder)
Max. 27 Max. 18
Place in above posture and
measure extension or retraction
of cylinder and downward
movement at tip of bucket teeth.
Bucket: Rated load
Horizontal, flat ground
Levers at neutral
Engine stopped
45 - 55Oc
Start measuring immediately
after setting.
Measure hydraulic drift for each
5 minutes, and judge from results
for 15 minutes.
mm
Arm cylinder
(amount of
extension of
cylinder)
Max. 160
Max. 240
Bucket cylinder
(amount of
retraction of
cylinder)
Max. 35 Max. 53
T
Classif
cation
Measurement conditions Unit
Sec.
Standard value Permissible value
PC200 PC220
3.1kO.3
PC200
Max. 3.9
PC220
Max. 3.9
3.OkO.3 Max. 3.4 Max. 3.3
4.1 io.4 Max. 5.0 Max. 4.8
Boom
Bucket teeth in
contact with
ground
s
cylinder fully
extended
3.1 to.3
45-55C
2.7i-0.3
H.0 and H mode
45-!xc
Arm
Cylinder fully
retracted
4
fully extended
3.8t0.4
2.8kO.3 3.1to.4 Max. 3.8 Max. 3.7
Max. 4.3 Max. 4.8
::
0
z
Max. 2.7 Min.3.1
H.0 and H mode
3.610.4 4.oto.4
But ket
Cylinder fully
retracted
s
h.illy extended
205F2423
45 - 55%
H.0 and H mode
2.1 kO.3 2.420.3
i
Lower bucket to ground and
measure time taken for chassis
to rise from ground
. Engine: Low idling
45-555OC
Boom
Max. 1 .O Max. 1.2
Arm
Max. 1.0
Max. 2.8
Amount of time when arm stops
for a moment.
Engine: Low idling
45-55Oc
20-8
0
Unit Stand value Permissible value
P
i
F
Max. 3.6 Sec.
-
Max. 1 .o
. Amount of time when bucket
stops for a moment.
Engine: Low idling
45 - 55OC
45-555Oc
. Relieve circuit to be measured
Cylinders
4.5 20
Center swivel
joint
10 50
45-55Oc
l Use a hard horizontal surface.
20m
Travel deviation
(travel and work
equipment)
Max. 200 Max. 220
205F2402
l Measure dimension x
-
lmin
PC200 PC220
45-555Oc
. Measure with engine running at
rated speed.
. At relief valve set pressure
(32 kg/cm )
Charging pump
Min. 47.0 flin. 43.3 vlin. 39.5 Min. 429
Piston pump See next page
See next page
20-9
Classifi-
cation
Discharge volume of PC200 main piston pump (H.0 + H mode)
IWO Luo 300
Pump discharge pressure = v (kg/cm?
F20505459
Pump rated speed: 2,050 rpm
Discharge pressure Discharge pressure Average Pressure
Standard value
Judgement standard
Check point
of test pump of other pump
for discharge
value
amount
(kglcm* 1 (kg/cm 1
(kg/cm)
Q WminJ
0 (Urnin)
As desired
P, P,
PI + P,
See graph
See graph
(Lower limit)
f
*
Bring discharge pressure P, and P2 for the pump as close as possible to the average pressure
when measuring.
The error is greatest around the area where the graph bends, so avoid measuring at these points.
When measuring with the pump mounted on the machine, if it is not possible to set the engine
to the specified speed with the fuel control dial, use the engine speed and pump discharge
amount as a base to calculate the pump discharge amount at the specified speed.
Clanifi-
cation
Discharge volume of PC200 main piston pump (H.0 + S mode)
Upper limit
Lower limit
100 200 300
F20505460
I I I
As desired
PI P,
p,
See graph
See graph
2
(Lower limit)
k Bring discharge pressure P, and P? for the pump as close as possible to the average pressure
when measuring.
k When measuring with the pump mounted on the machine, if it is not possible to set the engine
Classifi-
cation
Discharge volume of PC200 main piston pump (H.0 + L mode)
Lower limit
Upper limit
loo 200 300
Pump discharge pressure = 2
+ (kglcn-?)
F20505461
Standard value
Check point
for discharge
Judgement standard
value
amount
(k&m2 I (kg/cm*) (kg/cm 2 ) 0 (Urnin
d (Urnin)
As desired
P, P,
PI + P,
2
See graph
See graph
(Lower limit)
* Bring discharge pressure P, and P2 for the pump as close as possible to the average pressure
when measuring.
* When measuring with the pump mounted on the machine, if it is not possible to set the engine
20; 2
Classifi-
cati on
Discharge volume of PC220 main piston pump (H.0 + H mode)
100 200 300
F20505462
Standard value
Check point
Discharge pressure Discharge Pressure Average press&
Judgement standard
for discharge
value
amount
(kg/cm* ) (kg/cm)
(kg/cm 1 Q (Urnin) Q bUmin)
As desired P, P,
P, + P,
2
see graph
See graph
(Lower limit)
t Bring discharge pressure P, and P2 for the pump as close as possible to the average pressure
when measuring.
The error is greatest around the area where the graph bends, so avoid measuring at these points:
20; 3
L
Clatsifi-
cations Discharge volume of PC220 main piston pump (H.0 + S mode)
100 200 300
Pump discharge pressure = v (kg/cm2)
F20505463
Discharge pressure Discharge pressure *erage p;essure
Standard value
Judgement standard
Check point of test pump of other pump
for discharge
amount
value
(kg/cm * ) (kg/cm* 1 (kg/cm )
Q (Qlmin) Q (Qlmin)
As desired PI P,
P +P
1
2
See graph
See graph
(Lower limit)
* Bring discharge pressure P, and P, for the pump as close as possible to the average pressure
when measuring.
20- 14
0
Classifi-
cations
Discharge volume of PC220 main piston pump (H.0 + L mode)
100 200 300
PI + P2
Pump discharge pressure = 2 (kg/cm)
F20505464
Pump rated speed: 2.200 rpm
Standard value
for discharge
Judgement standard
Check point
of test pump of other pump value
(kg/cm)
amount
(kg/cm ) (kg/cm,) Q (Urnin) Q (Urnin)
As desired
P, P*
PI + P,
See graph
See graph
2
(Lower limit)
* Bring discharge pressure P, and P, for the pump as close as possible to the average pressure
when measuring.
20- 15
0
TABLE OF SPEEDS FOR S, L MODES
* The values in this table are reference values for the speed of the work equipment, swing, and travel when switching from H.0 and
H mode to other modes
Classifi-
c at i on
.
I t em
Boom
(Bucket teeth in
contact with
ground *cylinder
fully extended)
Arm
(Cylinder fully
retracted tf fully
extended)
Bucket
(Cylinder fully
retracted +
fully extended)
Time taken to
swing
Travel speed
Travel deviation
Measur ement c ondi t i on
. Measure full stroke for each
cylinder (for boor only,
measure time taken to lower
to the ground)
. Set the machine on a flat
horizontal surface.
. No load in bucket
45-55Oc
. When measuring boom: arm,
bucket cylinders fully retracted
. When measuring arm: top
surface of boom horizontal
bucket cylinder fully
retaracted
. When measuring bucket: top
surface of boom horizontal,
arm cylinder fully retracted
No load in bucket
. Swing one turn, then measure
time taken to swing next
two turns.
45.- E&o c
Raise track on one side at a time,
rotate one turn, then measure
time taken to rotate the next
two turns.
. Amount of deviation when
traveling 20 m as shown below
* Us a hard horizontal surface.
20m
Uni t
SW.
Sec.
Sec.
mm
?C200-5
3io.4 3.3+0.4 4.3f0.4
I I
I I
9f0.3 2.9rto.3 3.4*0.:
i I
I
1 f0.4 6.8 f0.7 7.6z!cO.8
I I
I I
.0*0.3 3.0f0.3 3.3*9.:
I I
I I
.8*0.413.8f0.414.610.t
.3f0.2 2.3kO.2 2.8fO.Z
I I
0.8 10.8 13.2
lto.5 f0.5 *0.7
I I
I
.6&1.4 9.6jz1.4 ;1,,
1 I
Max. 200
PC220-5
;.O+S F.O+S L.O+L
node mode mode
t
5Ito.4 3.5kO.4 4.5*0.5
.2f0.33.2*0.3 3.710.4
I I
.5f0.4 3.5*0.4 4.1 f0.4
I 1
I I
.3*0.4 4.3kO.4 5.3f0.5
I I
.6*0.3 2.610.3 3.2kO.3
I I
0.3 10.3
12.6
*0.5 10.5 10.6
t
.2*1.3 9.2i1.3
11.4
11.6
I /
m. 2*0. 916. 2kO. 9j 7. 6kl .l
Max. 200
205F2402
t Measure dimension3
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM
+ Note 1: (Male) and (Female) in the Connector No. column indicates the matina at the terminal
(pin). (For details, see CONNECTION TABLE FOR CONNECTORS).
2: The figure in ( ) in the Judgement table column indicates the pin number.
Classi
catiol
I f i -
ns
1
Fuel control dial
Potentiometer
Motor
Power source
voltage
Fuel control dial
(Throttle signal)
Governor
Potentiometer
Connector No
E6 (Male)
E4 (Male)
E5 (Male)
El
Judgement table
If the condition is as shown in the
table below, it is normal
7
1
Between (1) - (2) 4-9.Q
Between (3) - (4) 4-9R
Between (1) - (3) No continuity
(1 ) - chassis No continuity
(3) - chassis No continuity
WI
table below, it. is normal
Fi
Between (6) - (16) 4.75 - 5.25V
Measurement
conditions
I) Turn starting
switch OFF.
2) Disconnect
Connector.
I) Turn starting
switch OFF.
2) Disconnect
connector.
I) Turn starting
switch OFF
2) Disconnect
connector
1) Turn starting
switch ON.
2) Insert
T-adapter.
1) Turn starting
switch ON.
2) Insert
T-adapter.
I) Turn starting _
switch ON.
2) Insert
T-adapter.
Classi
catior
Connector No. Judgment table
Measurement
conditions
1) Turn starting
switch ON.
2) Insert
T-adapter
If the condition is asshown in the
tabe below, it is normal
No. 2 throttle
signal
Between (9) - (19) 0.25 -44.75V
If the condition is as shown in
the table below, it is normal
1) Turn starting
switch ON.
2) Insert
T-adapter.
Warming-up
signal
1) Turn starting
switch ON.
2) Insert
T-adapter.
Auto-deceleration
signal
Between
(11) - (12)
When decelerating Max. 1 V
When canceled 8- 12v
If the condition is as shown in
the table below, it is normal.
1) Turn starting
switch ON.
2) Insert
Tdapter
El
Governor motor
Battery relay
Between (3) - (14)
Between (4) - (15)
2.8 - 6.3V
2.8 - 6.3V
1) Turn starting
switch ON.
2) Insert
T-adapter
Between (13) - (12) 20 - 3ov
*This is only for 2.5 seconds after
turning the starting switch ON -+ OFF.
At other times, it is 0 V.
) Turn starting
switch OFF.
!I Disconnect
connector.
Between
(17) - (12)
PC200
PC220
Continuity
No continuity
Model selection
Classif
cation
Component Connector No. Judgment table
Measurement
conditions
i-
Throttle signal
(engine throttle
controller)
Engine speed sensor
Nork equipment oil
xessure switch
PCZOO, ZOOLC-5
No.: 45001 - 49706
PC220, 220LC-5
1 ,No.: 35001 - 35661
Nork equipment .
wing oil pressure
switch
C200,2OOLC-5
\lo.: 49707 and up
C200, 2OOLC-5 MIGHT
C220,22OLC-5
\o.: 35662 and up
Swing oil pressure
switch
PC200,2OOLC-5
1
No.: 45001 - 49706
PC220,22OLC-5
No.: 35001 - 35661
1
Travel oil pressure
swicth
20620
1) Turn starting
table below, it is normal.
switch ON.
Between (20) - (10) 0.25 - 4.75
2) Insert
T-adapter
c2
1) Turn starting
switch OFF.
2) Disconnect
connector.
Between (1) - (2) 500 - 1,000.Q
Between (2) - chassis
Min. 1 Ma
1) Start engine
2) Insert T-
adapter.
Measure at AC range
Between (I) - (2)
I
0.5 - 3.ov
E7
1) Screw in speed sensor until it contacts
ring gear, then turn back one turn.
2) Work normally after carrying out above
adjustment.
For boom, arm, bucket, and swing control levers
1) Start engine.
(Charge
accumulator)
2) Disconnect
connector.
All levers at neutral Min. 1Mn
Between (I) - (2)
One or more levers
operated
Max, , n
Sl (Male)
Between (1). (2) chassis Mtn. 1 MS2
1) Start engine.
(Charge
accumulator)
2) Disconnect
connector.
For swing control lever
Lever at neutral Min. 1 MR
Between (1) - (2)
Lever operated Max. la
S2 (Male)
Between (1). (2) - chassis Min. 1 Ma
I
For travel control lever
1) Start engine.
(Charge accumu-
lator).
2) Disconnect
connector.
S4 (Male)
Between (1). (21 - chassis Min. 1 Ma
I
Judgment table
Measurement
conditions
Classifi-
cations
Component Connector No.
IllSpeC-
tion
method
1) Start engine.
2) Fuel control
dial at MAX.
3) Insert
T-adapter
Between (1) - (2) 18 - 28V
Pump pressure sensor
c7 (Rear)
C8 (Front)
All levers
at neutral
I ) Turn stan-
ing switch
OFF.
Switch OFF Min. IMR
Between (81 - (41
Switch ON Max. IR
Swing lock switch C2 (Female)
21 Disconnect
connector
CN2.
1) Turn TVC
prolix switch
OFF.
2) Turn start-
ing switch
OFF.
3) Disconnect
connector C4
I
Between (1) - (2)
I
10 - 22Q
I
TVC solenoid valve C4 (Male)
Between (2) - chassis Min. 1MQ
I
I ) Turn stan-
ing switch
OFF.
21 Disconnect
connector
VI.
PCZOO, 2OOLC-5 Serial No.: 45001 - 52783
PC220,22OLC-5 Serial No.: 35001 - 36023
r
Between (1) - (2)
I
10 - 350
I
Between (2) - chassis Min. IMR
Swing brake
solenoid valve
Vl (male)
Between (1) - (2)
24 - 4662
Min. 1MQ
I ) Turn start-
ing switch
OFF.
21 Disconnect
connector
v2.
PC200,2OOLC-5 Serial No: 45001 - 52783
PC220,22OLC-5 Serial No: 35001 - 36023
Between (1) - (2)
50 - IOOR
Min. IMQ
Travel speed
solenoid valve
V2 (male)
PC200; 2OOLC-5 MIGHTY
I
Between (1) - (2)
I
24 - 46R
I
Between (21 - chassis Min. IMR
Classifi
cation!
Z-stage relief l
co cancel
solenoid valve
Arm half flow
solenoid valve
Connector No.
V7 (Male)
V5 (Male)
I
IllSPt?C-
tion
nethod
Judgment table
PC200,200LC-5 Serial No: 45001 - 52783
PC220,22OLC-5 Serial No: 35001 - 36023
Between (I) - (2) 50 - 1000
Between (2) - chassis Min. 1MR
table below, It is normal.
Between (1) - (2)
Between (2) - chasiis
24 - 46R
Min. 1MR
PC200,200LC-5 Serial No: 45001 - 52783
PC220,22OLC-5 Serial No: 35001 - 36052
Between (I) - (2) 10-350
Between (I) - (2)
24 - 46R
Min. IMR
Measurement
conditions
I ) Turn stan-
ing switch
OFF.
2) Disconnect
connector
v7.
1) Turn start-
ing switch
OFF.
2) Disconnect
connector
v5.
20622
Cl assi f i
c at i on:
Connector No.
hpec-
t i on
net hod
J udgment t abl e
Measur ement
c ondi t i ons
I ) Turn start-
ing switch
OFF.
2) Insert
T-adapter.
Power source
voltage
Cl
1 Between (12). (13) - 13). (4)l 20 - 3ov
I
l i Turn start-
ing switch
ON.
21 Insert
T-adaoter.
Between (8) - (14) 10 - 13v
H.0 mode
Between (8) - (151 O-IV
Between (8) - (14) IO - 13v
G.0 mode
Between (8) - (15) 10 - 13v
Between 18) - (14) 0 - 1v
F.0 mode
Between (8) - (15) 10 - 13v
Working mode
switch
c 2
1 L.0 mode -1
1) Turn start
ing switch
ON.
2) Insert
T-adapter.
) H mode -1
Power set switch c2
l 10 - 13V when working mode is L.0 mode
1) Turn start-
ing switch
ON.
2) Insert
T-adaoter.
Auto-deceleration
switch
c2
Switch OFF
Between
10 - 13v
Switch ON
(8) - (7)
o- 1v
1) Turn start-
ing switch
ON.
2) Insert
T-adapter.
Switch at Lo
Between
10 - 13v
Switch at Hi
181 - (3)
o- 1v
Travel speed
switch
c2
1) Turn stan-
ing switch
ON.
2) Insert
T-adaoter.
Power maximizing
switch
c2 Switch OFF
Between
20 - 28V
Switch ON
(8) - (12)
0 - 1v
Classifi
cation:
Connector No. Judgment table
Measurement
conditions
PC200,2OOLC-5 Serial No: 45001 - 58018
PC220,22OLC-5 Serial No: 35001 - 36613
1) Turn start-
ing switch
ON.
21 Insert
T-adapter.
5xJant temperature
signal
c2
I I I
Coolant temperature
Between (8) - (17) O-IV
above 105C
Between (8) - (18) o- 1v
I ) Turn start-
ing switch
ON.
2) Insert
T-adapter.
Wodel
xlection
c2
I ) Turn start-
ing switch
ON.
2) Insert
T-adapter.
<erosene mode c2
1) Start engine.
2) Insert
T-adapter.
3) All levers
at neutral
kto-deceleration
utput signal
Auto-decelera-
tion switch OFF
8- 12v
Between
Auto-decelera-
(21) - 1191
tion switch ON
0 - 1v
c2
Classifi
cation:
IllSPfX-
tion
nethod
Judgment table
T
PC200,200LC-5 Serial No: 45001 - 58018
PC220,22OLC-5 Serial No: 35001 - 36613
11 Turn start-
ing switch
ON.
[Coolant
temperature
gauge is within
green range]
2) Insert
T-adapter.
Between
(21) - (11)
PC200 PC220
H.0 mode
or H mode
0.75 - l.OV 0.75 - l.OV
G.0, F.O. L.0
and S mode,
G.0, F.0 and
1.25 - 1.55V 1.35 - 1.65V
L mode
L.0 and L mode 2.06 - 2.36V 2.18 - 2.48V
When coolant
temperature is 4.0 - 4.25V 4.0 - 4.25V
above 107~C
No. 2 throttle signal c2
Between
(211 - (11)
PC200 PC220
H.0 mode
or H mode
0.75 - l.OV 0.75 - l.OV
G.O. F.O. L.0
and S mode,
G.O. F.0 and
1.25 - 1.55V 1.35 - 1.65V
L mode
L.0 and L mode 2.06 - 2.36V 2.18 - 2.48V
When coolant
temperature is 4.0 - 4.25V 4.0 - 4.25V
above 105~C
swing brake
;olenoid
I) Start engine
!I Turn swing
lock switch
OFF.
$1 Turn swing
lock prolix
switch OFF.
1) Insert
T-adapter
I!
Approx. 4 set after I
placing swng lever 1 20-30V /
Cl
at neutral
Swing lever
operated
Between
(8) - (121, (13)
0 - 3v
1) Start engine.
2) Insert
T-adapter
3) Fuel control
dial at MAX.
4) Travel on
flat ground
Travel speed
solenoid
Travel speed
switch at Lo
Between
20 - 3ov
Travel speed
(161 - (12). (13)
switch at Hi
0 - 3v
Cl
1) Turn start-
Ing switch
ON.
2) Insert
T-adapter.
Z-stage relief * CO
cancel solenoid
(2.stage relief)
2-stage relief. CO
cancel solenoid
(CO cancel)
Travel lever
at neutral
Travel lever
operated
Between
(15) - (12). (13)
20 - 3ov
0 - 3v
Cl
1) Turn start-
ing switch
ON.
2) Insert
T-adapter.
Cl
Swing lock
switch OFF
20 - 3ov
Between
Swing lock
(7) - (121, (131
switch ON
0 - 3v
Classif
cation
Arm half flow
Connector No.
Cl
Il-lSpeC-
tion
method
H.0, G.O. mode
Between
20 - 3ov
F.O. L.0 mode
(6) - (12), 113)
0 - 3v
Measur ement
conditions
I ) Turn start-
ing switch
ON.
2) Insert
T-adapter
Classi
catior
InSpeC-
tion Judgment table
method
the condition is as shown in Table 1, Table 2, and Table 3, the monitor panel is
0mlal.
able 1 (CHECK, CAUTION group)
Measurement
conditions
CHECK, CAUTION
group
Buzzer signal
The voltage for H
and L in the table
are as follows.
*l. Engine oil
pressure signal
H: 3.5 - 30V
L: Approx. OV
*2. Starting signal
H: 7 - 30V
L: Approx. OV
The starting signal
is H once, but after
that it becomes L.
However, until the
starting switch is
turned OFF, the
Starting signal is
held in the memory
inside the monitor
panel as H.
*3. Alternator
signal
H: 20 - 30V
L: Max. 5v
*4. Sensor signal
H: 3.5 - 30V
L: Approx. OV
I ) Start engine.
21 Insert T-adapter.
Monitor auxiliary signal input
kgnai_i it~;~~~or
item
I
PI (16) PI (8) Pl (7)
Monitor
display
Flashing
OFF
Zoolant lever
I (17)
lngine oil
ever
1 (18)
Flashing
hydraulic oil
---I
ever
1 (IO)
Flashing
OFF
Flashing
OFF
reheat Engine oil pressure signal
1 (9) L and starting signal L
Flashing
OFF
Flashing
OFF
Flashing
OFF
:uel level
1 (5) I
Flashing
:harge
1 (7)
Engine oil pressure signal
H and starting signal H
:001ant level
OFF
Flashing
OFF
Flashing
OFF
Flashing
OFF
ble 2 (Buzzer signal)
Pl (4)
P2 II), (2). (14). (15)
Open (no connecting wiring)
Pl (1) - (3)
(+24V input)
Starting switch ON
20 - 3ov
Starting switch OFF
ov
PI (11) (Alarm buzzer output) - (3) Remove connector, and buzzer sounds
Disconnect P8 (coolant level sensor) or the following cycle is repeated.
I
Connect short connector to P8 Over 20V: 0.8 set
3V: 0.8 set
When short connector is connected,
buzzer stops or voltage is OV.
Classifi
cation!
GAUGE group
Coolant temperature
IllSpeC-
Connector No.
I I
tion Judgment table
method
able 3 (GAUGE group)
Measure resistance
between coolant
temperature gauge
Pl (female)
(6) - (3)
Measure resistance
between fuel
level gauge
PI (female)
(5) - (3)
P2
Position of
gauge display
Starting switch
ON
Right
side
All OFF
t 8
7
Dis-
play 6
posi-
tion t 5
4
J 3
Left
side
Right
side 10
9
T 8
7
Dis-
play 6
posi-
tion ! 5
4
3
i
2
1
Left
side
All OFF
Display level resistance (kR)
(Monitor panel input resistance)
Starting switch OFF
Min. - Max.
0 - 0.7
0.5 - 3.245
3.015 - 3.665
3.419 - 4.222
3.946 - 5.092
4.764 - 6.248
5.844 - 7.713
7.086 - 10.17
9.455 - Disconnection
0 - 14.24
11.23 - 20.87
17.51 - 27.32
23.52 - 34.07
29.98 - 39.55
35.15 - 44.38
39.70 - 49.45
44.47 - 61.60
55.89 - 79.36
72.52 - 691.63
611.82 - Disconnection
PC200,2OOLC-5 Serial No: 45001 - 58018
PC220,22OLC-5 Serial No: 35001 - 36613
t
Measurement
conditions
1) Turn starting
switch OFF,
insert dummy
resistance, or
measure resist-
ance (kni
(Monitor panel
input resistance)
2) Turn starting
switch ON, and
check display.
3) Connect socket.
1) Turn starting
switch ON.
2) Insert
T-adapter.
20628
Classii
cation
Component Connector No
IllSpeC.
tion
n&hoc
Judgment table
Measurement
1) Turn starting
switch ON.
2) InsertT-adapter.
PC200,200LC-5 Serial No: 58019 and up
Coolant Between (12) - (16) IO-13v
temperature
below 102C Between (13) - (16) 10 - 13v
Coolant
temperature
Between (12) - (16) 0 - 1v
a hove 102~C.
below 105C
Between (13) - (16) 10 - 13v
Coolant Between (12) - (16) o- 1v
temperature
above 105X Between (13) - (16) O-IV
Coolant temperatur, P2
I ) Turn starting
switch ON.
2) Insert
T-adapter. P2
Coolant temper-
ture below IOC
Coolant temper-
ture below 5OC
Between
(11) - (16)
Max. 1V
8- 12V
Narming-up signal
1) Turn starting
switch ON.
2) Insert
T-adapter.
table below.
Between (8) - (16) 10 - 13v
H.0 mode
Between (9) - (16) o- 1v
Between (8) - (16) 10 - 13v
G.0 mode .
Between (9) - (16) 10 - 13v
Between (8) - (16) 0 - 1v
F.0 mode
Between 19) - (16) 10 - 13v
L.0 mode
rVorking mode
:witch
P2
1) Turn start-
ing switch
ON.
2) Insert
T-adapter.
Between (5) - (16) 10 - 13v
H mode
Between (6) - (16) IO-13v
S mode
Between (6) - (16) IO-13v
Between (5) - (16) *o-w
L mode
Between (6) - (16) o-1v
* 10 - 13V when working mode is L.0 mode
I
ON
Between
Max. 1V
OFF
(7) - (16)
8- 12V
f ower set switch P2
r
1) Turn stan-
ing switch
ON.
2) Insert
T-adapter.
I
\uto-deceleration
witch
P2
1.
20-;8- 1
Classifi
cations
Connector No.
P2
tibn
nethod
Between
alternator
terminal R
- chassis
Judgment table
If thecondition is as shown in the
When engine is running (112 throttle or above):
27.5 - 29.5v
* If the battery is old, or after starting in cold areas,
the voltage may not rise for some time.
Measurement
conditions
I ) Turn start-
ing switch
ON.
2) insert
T-adapter.
1) Start engine.
20;$8-2
Classifi
cations
Coolant level sensor
Engine oil level
sensor
Coolant temperature
sensor
Engine oil pressure
sensor
Fuel level sensor
Hydraulic oil level
gauge
Connector No.
P8 (Male)
P7 (Male)
P7 (Male)
-
P6 (Male)
P9 (Male)
Measurement conditions and standard values
1) Turn starting switch OFF.
2) Disconnect connector P8.
3) Insert T-adapter into connector at sensor end and measure resistance value
Sub-tank water level at LOW level
or above
Sub-tank water level at LOW level
nr hnlnw,
Max. 1R
Min. IMR
3) Drain oil and remove sensor.
4) Insert T-adapter into sensor and measure resistance value.
* Connect the
T-adapter to the
connector and
; zs
? Raise
Max. 1Q
float
sensor flange.
$ p_. Lower
1 float
Min. IMR
3) Insert T-adapter into connector at sensor end and measure resistance value
Normal temperature (25-C) Approx. 37 - 50kQ
100x Approx. 3.5 - 4.0kQ
1) Install oil pressure measurement gauge.
2) Remove wiring harness terminal.
3) Start engine.
4) Put tester in contact between chassis and sensor terminal screw, and measure
resistance value.
Engine oil pressure: 0.7 kg/cm2 or above Min. IMR
Engine oil pressure: 0.3 kg/cm or below Max. 10
3) Drain fuel and remove sensor.
4) Insert T-adapter into sensor and measure resistance value.
* Connect the
T-adapter to the
connector and
sensor flange.
Raise
float to
f
stopper
Max. approx. 12Q
Lower
-;
float to Approx. 85 - 1 lo<>
J stopper
2) Disconnect P9.
3) Drain oil and remove sensor.
4) Insert T-adapter into sensor and measure resistance Value.
4,
c3
4
=Jt
Raise
float
J-
w
3 1
Lower
float
Max. lL1
Min. 1MQ
20-;8-3
J
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
Check or
measurement item
S
Engine speed
Water and oil
temperatures
Hydraulic pressure
Compression pressure
Blow-by pressure
Valve clearance
Exhaust color
Operating force
Stroke, hydraulic drift
Work equipment speed
Pump performance
Troubleshooting of
wiring harnesses and
sensors
Troubleshooting of
voltage and resistance
values
Engine oil pressure
;ym bol Part No. Part Name Remarks
1 799- 203- 8000 Multi-tachometer Digital display L: 60 - 2,OOOrpm
H: 60 - 19,999rpm
A 799-203-8901 Clamp set
2
6210-81-4111 Gear box
Degital temperature _50 _, 2ooC
gauge
I
799- 101- 5001 Hydraulic tester
Pressure gauge
20, 60, 400, 600 kg/cm*
l--
790-261-1201 Digital hydraulic
tester
Pressure gauge 700kg/cm2
C . 790-261-1310 Both male and female:
14 x 1.5 (female PT l/8)
2 . 790-261-1320 Adapter Both male and female:
. 790-261-1330
Both male and female:
1 795-502-I 590 Compression guage 0 - 70 kg/cm*
Kit Part No. 795-502-1205
D -
2 l 795-502-1370 Adapter
E 799-201-1504 Blow-by checker 0 - 500mmH,O
F
Commercially
available
Feeler gauge
-
799-201-9000
Handy smoke Discoloration 0 - 70%
G
checker (with standard color)
Commercially
Smoke meter
(Discoloration % x l/IO
available = Bosch index)
I-
-. H -, 79A-264-0020 Push-pull scale
I
-
I
Commercially
available
Scale
-
J
Commercially
available
Stop watch
-
K 790-303-I 002 Flowmeter Kit
I I
1 799-601-2600 T-adapter box
M 79A-264-0210 Tester
N 799-401-2320 Hydraulic guage 1 Okg/cm*
20629
ADJUSTING VALVE CLEARANCE
1.
2.
3.
4.
*
0
Remove the cylinder head cover.
Rotate the crankshaft in the normal direction to
align pointer (2) with 1.6 TOP line (I) on the
crankshaft pulley. When rotating, check the
movement of the intake valve of No. 6 cylinder.
When No. 1 cylinder is at top dead center,
adjust the valves marked l . Next, rotate the
crankshaft one turn (360) in the normal direc-
tion and adjust the valve clearance of the re-
maining valves marked o.
* Valve arrangement
To adjust the valve clearance, loosen locknut
(6). then insert tool F between rocker arm (3)
and valve stem (4). and turn adjustment screw
(5) until the clearance is a sliding fit. Then tight-
en locknut (61 to hold the adjustment screw in
position.
w Locknut: 4.5 f 0.5 kgm
After adjusting No. 1 cylinder at top dead
center, it is also possible to turn the crankshaft
120 each time and adjust the valve clearance
of each cylinder according to the firing order.
l Firing order: 1 - 5 - 3 - 6 - 2 - 4
After tightening the locknut, check the clear-
ance again.
205FO521C
1
0
205FO5211
0
z
20-30
0
A
When measuring the compression pressure,
be careful not to touch the exhaust mainfold
or muffler, or to get your clothes caught in
the fan, fan belt or other rotating parts.
1.
2.
3.
4.
5.
6.
Adjust the valve clearance.
For details, see ADJUSTING
CLEARANCE.
VALVE
Warm up the engine to make the oil temperature
40 - 60C.
Remove the nozzle holder assembly from the
cylinder to be measured.
Install adapter D2 in the mount of the nozzle
holder, then connect pressure gauge Dl .
Set tachometer A in position.
Disconnect the fuel control rod, place the con-
trol lever of the injection pump in the NO INJEC-
TION position, then crank the engine with the
starting motor and measure the compression
pressure.
Measure the compression pressure at the point
where the pressure gauge indicator remains
steady.
When measuring the compression pressure,
measure the engine speed to confirm that it is
within the specified range.
After measuring the compression pressure, in-
stall the nozzle holder assembly.
20-3 1
TESTING AND ,ADJUSTING FUEL INJECTION TIMING
1. Rotate the crankshaft in the normal direction to
align pointer (2) with 18 line (1 I on the crank-
shaft pulley.
2. Disconnect fuel injection pipe (3) of No. 1
cylinder.
3. Remove delivery valve holder (41, take out deliv-
ery valve (51 and spring (61, then install delivery
valve holder (4) again.
4. Place the governor lever at the FULL position.
5. Loosen the nut in the oblong hole of the mount-
- ing flange of the fuel injection pump, then
loosen injection pump mounting bolts (7).
6.Move the fuel injection pump towards the out-
side, then move the injection pump towards the
cylinder block a little at a time while operating
the priming pump, and stop at the point where
the fuel stops flowing from the delivery valve
holder.
* If the fuel does not stop whichever way the
injection pump is moved, rotate the crank-
shaft one more turn.
* Adjust the fuel injection timing by moving
the fuel injection pump as follows.
To RETARD timing, move towards
OUTSIDE.
To ADVANCE timing, move towards CYLIN-
DER BLOCK.:
7.Tighten injection pump mounting bolts (7) in
turn.
8. Tighten the nut in the oblong hole of the mount-
ing flange of the fuel injection pump.
9. Remove delivery valve holder (4). assemble
delivery valve (5) and spring (61, then install
delivery valve holder (4) again.
m Delivery valve holder: 3.3 * 0.2 kgm
10. Connect fuel injection pipe (3).
m Sleeve nut: 2.4 f 0.1 kgm
205FO5214
L
I
I
205FO5216
F2050539r
c.
TESTING AND ADJUSTING TRAVEL OF GOVERNOR MOTOR
LEVER
1. Inspection
1) Set each switch in the following condition
* Condition Starting switch: ON
Working mode: H.0
Power mode: H
Auto-deceleration: OFF
Fuel control dial: MAX
2) In the above condition, check the two fol-
lowing points regarding the governor lever
and spring rod.
i) Check that the injection pump gover-
nor lever is contacting the FULL
stopper.
ii) Check that there is a clearance of at
least 1 mm between the yoke welding
bead and the end face of spring rod
(2).
+ If the clearance is too small, grind
the welding bead to ensure a clear-
ance of at least 1 mm.
Adjusting
Ir Carry out adjustment with the starting
switch OFF.
Pull out pin (I), and disconnect spring rod
(2) from the injection pump governor
lever.
Set governor motor lever (3) and injection
pump governor lever (4) in contact with
the FULL stopper, adjust the length of spr-
ing rod (2), and connect again.
From the above position, turn back rod (5)
3.5 turns (approx. 4.4 mm) (extend the
rod), then secure with locknut (6).
I 205F05220A
L
--c-- Min. 1 mm
Detail P
FO20205032
INSPECTION OF SWING CIRCLE
Method of inspecting swing circle bearing clear-
ance on machine
1. Fix a dial gauge equipped with a magnet to the
outer race (or inner race ) of the swing circle, and
put the probe in contact with the end face of the
inner race (or outer race).
Set the dial gauge at the front or rear.
2. Set the work equipment to the
reach with the tip of the bucket at
of the bottom surface of the frame.
maximum
the height
In this condition, the front of the upper struc-
ture will go down, and the rear will go up.
3. Set the dial gauge to the 0 point.
4. Set the arm at 90 perpendicular to the
ground surface, then lower the boom until
the front of the track comes off the ground.
The front of the upper structure will go up,
and the rear will go down.
5. With the machine in this condition, read the
value on the dial gauge.
This reading of the dial gauge is the clear-
ance of the swing circle bearing.
AWhen carrying out the measurement, do
not put your hands or feet under the un-
dercarriage.
6. Return the machine to the condition in Step
2, and check that the dial gauge has returned
to the 0 point. If the dial gauge has not re-
turned to the 0 point, repeat Steps 2 - 5.
Revolving frame
I G=l
Revolving frame
Ime
F20505395
F20505396
F20505397
20$3- l
ADJUSTING ENGINE SPEED SENSOR
1.
2.
3.
Screw in so that the tip of sensor (I) contacts
gear (2).
When sensor (I 1 contacts gear (21, turn it back
one turn.
Tighten locknut (3).
Ir When connecting the wiring, be careful to
prevent any excessive force from bearing
on the wiring of the sensor.
* Be careful not to scratch the top of the
sensor or to get any metal powder stuck to
it.
Engine speed sensor
\L%
205FO5221
205FO5222 j
20-34
0
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK
EQUIPMENT, SWING, TRAVEL CIRCUIT
1. Measuring
*
Y Y
*
11
2)
Oil temperature when measuring:
Lower the work equipment to the ground
and stop the engine. Operate the control
levers several times to release the remaining
pressure in the hydraulic piping. Then
loosen the oil filler cap slowly to release the
pressure inside the hydraulic tank.
Put the safety lock lever in the LOCK
position.
Remove pressure pick-up plug (I) or (2)
(Thread dia. = 1 Omm, Pitch = 1.25mm)
from the circuit to be measured, then install
oil pressure gauge Cl (600 kg/cm2).
Start the engine, set to the H.0 and H mode,
and measure the main relief pressure with
the engine at high idling.
l Condition of actuator to be measured
45 - 55C
i)
ii1
iii)
Table 1
For the work equipment, set each
cylinder to the end its stroke.
For swing, turn the swing lock
switch ON.
For travel, fit block 0 under the
track shoe grouser. Or fit block @
between the sprocket and frame to
lock the track shoe. Measure one
side at a time.
lug Pump Actuator controlled
l Arm cylinder
I
1 Front pump
l Boom cylinder
0 Swing motor %
l R.H. travel motor
l Arm cylinder
1 l L.H. travel motor
i i 205FO5223
I 205FO5224
205FO5225 205FO5226
% The set pressure of the safety valve for the
boom head end and swing motor is lower
than the set pressure of the main relief valve,
so be careful.
2. Adjusting
Main relief valve
I) Adjusting high set pressure
i) Loosen locknut (3) and turn holder (4)
to adjust.
+ Adjust the holder as follows.
l To INCREASE pressure, turn
CLOCKWISE
l To DECREASE pressure, turn
COUNTERCLOCKWISE
w Locknut: 6.0 f 0.5 kgm
* When the high set pressure is ad-
justed, the low set pressure also
changes so always adjust the low
set pressure also.
2) Adjusting low set pressure
i) Loosen locknut (5).
+ Check that elbow (6) moves.
ii) Loosen locknut (7) and turn holder (8)
to adjust.
CLOCKWISE
COUNTERCLOCKWISE
+ Amount of adjustment for one turn
of holder: 128 kg/cm2
m Locknut: 4.5 +- 0.5 kgm
Ir Normally, the pressure applied to port PR is
approx. 13 kg/cm2 or less, and at high set
pressure, is approx. 30 kg/cm2.
Swing motor safety valve
1) Loosen locknut (9) and turn adjustment
screw (I 01 to adjust.
+ Adjust the adjustment screw as follows.
CLOCKWISE
COUNTERCLOCKWISE
* After adjusting, repeat the procedure in
Step 1 to check again.
m Safety valve: 18.0 + 1 .O kgm
* Adjustment of the safety valve set pressure
is only for the swing motor. Do not try to
adjust the safety valve set pressure for any
other part.
l-4 /
For rear pump
For\front pump
205FO5227
3 4 Pa 5
205FO5664
205FO522:
1
205FO5230 ,
20-36
0
Precautions when measuring hydraulic pressure
I) Measuring hydraulic pressure under normal
operation
Relieve the boom, arm, and bucket cylinders
when measuring.
* Do not operate the power max. switch.
2) Measuring hydraulic pressure when 2-stage
relief is actuated
Relieve the travel circuit to measure.
* When the travel circuit is relieved, the
2-stage relief solenoid valve and the CO
cancel solenoid valve are actuated.
+ When the CO valve is canceled, the relief
pressure is different when one side is
relieved and when both sides are relieved.
TESTING AND ADJUSTING CHARGING PUMP PRESSURE
1. Measuring
*
I )
2)
*
Oil temperature when measuring: 45 -
55C
Remove pressure pick-up plug (I) (Thread
dia. = 1 Omm, Pitch = 1.25mm), and install
Start the engine and measure with the
engine at high idling.
When testing for internal leakage of the
equipment in the control circuit, use the
parts given below to shut off the circuit for
the following sections when measuring the
relief pressure.
,,c. Section of hydraulic Component that
circuit shut off canbechecked
1
Piston pump inlet
Port
Piston pump
2 Charging pump
outlet port
Charging pump
3 Solenoid valve Solenoid valve
4 IT
ravel PPC valve Travel PPC valve
+ For Items No. 2 and below, it is possible
to check if the equipment above it is
normal.
* Use the following parts to shut off the
circuit.
l For elbow
Sleeve nut:
07221-20210,07221-20315
0722 I-20422
Plug:
07222-00210,07222-50315
07222-00414
l For hose
Plug:
07376-50210,07376-50315
07376-50422
205FO5231
Sleevie
205FO5233
Piston pump Solenoid valve
Ih
Travel PPC valve
Charging pump
(0
:@
R.H. PPC valve
2
r-
t
Safety lock
valve
L.H. PPC valve
205FO5234
20-38
0
2. Adjusting
I) Loosen locknut (2) and turn adjustment
screw (3) to adjust.
Sr Adjust the adjustment screw as follows.
CLOCKWISE
COUNTERCLOCKWISE
Sr Amount of adjustment for one turn of
adjustment screw: 5.4 kg/cm2
m Locknut: 6.5 + 1 .O kgm
+ After completion of adjustment, repeat
the procedure in Step 1 to check the set
pressure again.
205FO5235
20-39
0
TESTING AND ADJUSTING MAIN PUMP CONTROL PRESSURE
1. TVC valve output pressure
Measuring
*
*
sr
1)
2)
Measure the relief pressure of the charging
pump first, and check that it is normal.
The TVC valve output pressure varies ac-
cording to the average pressure for the
pump discharge pressure (
PI + P2
2
=
average pressure), so before measuring,
always adjust the main relief pressure to the
specified pressure.
Remove pressure pick-up plug (I) (Thread
dia. = 1 Omm, Pitch = 1.25mm), and install
Set to heavy-duty and H mode, run the
engine at high idling, and measure the hy-
draulic pressure with the control lever at
neutral and at pump relief.
45 - 55C
[Reference]
a) The average pressure at one pump relief is
approx. 170 kg/cm2. (The discharge pres-
sure of the pump being relieved is 320
kg/cm2, and the discharge pressure of the
pump not being relieved is approx. 20
kg/cm2.)
b) For the relationship between the change in
the TVC valve output pressure and the
pump discharge amount, see graphs 1 and
2.
L
205FO5236
205FO5237
Graph 1
100 200 300
Pump discharge pressure
Pl +P2
- = Average pressure (kg/c,+)
2
205F0523E
1 Graph 2
TVC valve control area
When CO function is canceled
co valve
control area
Pump discharge pressure
Pl +P2 _
- - Average pressure (kgicr+)
2
205FO5239
20-40
0
Adjusting
Ir If the results of the measurement show that the
hydraulic pressure is not within the standard,
adjust as follows.
I) Loosen locknut (2).
2) Turn adjustment screw (3) to adjust.
* If the adjustment screw is stiff, do not use
excessive force. If excessive force is used
to turn the screw, the tip may break.
3) Adjust the adjustment screw as follows.
l To INCREASE pressure, turn CLOCKWISE
l To DECREASE pressure, turn COUNTER-
CLOCKWISE
205FO5240
It Amount of adjustment for one turn of ad-
justment screw: Approx. 3.5 kg/cm2
f After adjusting with the adjustment screw,
repeat the procedure in measuring to check the
3
output pressure.
* If the adjustment screw is stiff and excessive
force is used to turn it, the tip may break, so in
this case, remove the TVC valve assembly,
remove the cover assembly, and put lubricant
:
on the screw before trying to move it.
-
0
g
205FO5241
20-4 1
a
Output pressure of CO valve and NC valve
[Reference1
The output pressure of the NC valve controls
the discharge amount of the piston pump flow-
ing to the servo valve.
The oil flows TVC valve - CO valve -NC valve -
servo valve, and the ouput pressure changes as
follows according to the movement of the con-
trol lever or work equipment.
* Control levers at neutral
The NC valve is actuated by the differential
pressure of the jet sensor, and the output
pressure drops below 5.5 kg/cm2.
(The pump discharge amount is the minimum)
+ When hydraulic cylinder is relieved
The CO valve is actuated, and lowers the
pressure of the oil entering the NC valve to
below 5.5 kg/cm2. The NC valve supplied
this pressure as it is to the servo valve.
(The pump discharge amount in this case is
the minimum)
+ Work equipment, swing, travel actuated
The output pressure of the TVC valve is not
affected by the CO valve and NC valve, and
is supplied as it is to the servo valve.
(The discharge amount of the pump varies
between the maximum and the point where
the CO valve is actuated.)
Measuring
+
l
1)
Olil temperature when measuring:
45 - 55C
Remove pressure pick-up plug (41 (Thread
dia. = 1 Omm, Pitch = 1.25 mm), and install
Ir This is at the body side of the servo
valve.
Pressure when NC valve is actuated
Set to H.0 and H mode, run the engine at
high idling, and measure the pressure when
all control levers are at neutral.
* Turn the auto-deceleration switch OFF.
* If the output pressure is more than 5.5
kg/cm2, measure the differential pres-
sure of the jet sensor.
205FO5242
I
i
205FO5243
205FO5244
2)
3)
Pressure when CO valve is actuated
Run the engine at high idling and measure
the hydraulic pressure when any of the
boom (except LOWER), arm, or bucket are
relieved.
Pressure when work quipment or swing are
actuated
A
The work equipment is actuated
when the pressure is measured, so
be careful of the surrounding area.
Measure the hydraulic pressure when reliev-
ing the swing (front pump) or when rotating
the track under no load (front, rear pump) at
the same time as measuring the output pres-
sure of the TVC valve.
Sr Measure the swing relief with the swing
lock switch OFF.
j, Rotate the track under no load one side
at a time.
* If there is a big difference from the TVC
valve output pressure, the operation of
the CO valve or NC valve is probably
defective.
Adjusting
I) CO valve
* If the set pressure of the CO valve is high,
the discharge amount is not reduced when
the circuit is relieved, so the relief pressure
becomes high. For this reason, always
adjust the pressure to the specified
pressure.
i) Loosen locknut (5) and turn adjustment
+ Adjust the adjustment screw as follows.
CLOCKWISE
COUNTERCLOCKWISE
+ Amount of adjustment for one turn of
adjustment screw: 41.25 kg/cm2.
+ If the hydraulic pressure does not drop
even when the adjustment screw is ad-
justed, there is probably a defect inside
the CO valve.
ii) After adjusting, repeat the procedure in
measuring to check the set pressure again.
co valve
205FO5245
205FO5246
J
2) NC valve
* The NC valve is actuated by the dif-
ferential pressure of the jet sensor, so
when adjusting it, always check first
that the differential pressure of the jet
sensor is correct.
i) Loosen locknut (7) and turn adjustment
* Adjust the adjustment screw as
follows.
CLOCKWISE
CLOCKWISE
205FO5247
* Amount of adjustment for one turn
of holder: Approx. 4.3 kg/cm2.
20-44
3. Defferential pressure of jet sensor
[Reference]
High pressure and low pressure (high pressure
- low pressure = differential pressure) is
formed at the outlet port of the control valve,
and this differential pressure controls the NC
valve.
The differential pressure is at its maximum
when the control levers are at neutral, and is at
its minimum when the control levers are operat-
ed to the end of their travel.
Measuring
*y Loosen the oil filler cap slowly to
release the pressure inside the hydraulic
+
1)
2)
3)
4)
tank.
45 - 55C
Remove pressure pick-up plugs (91 (high
pressure side) and (I 0) (low pressure side)
(PT l/8).
* For both front and rear, the side nearest
the engine is the high pressure side.
* The clearance between the pressure
pick-up plug and cover is small, so use
one of the following adapter.
l Adapter:
790-261-1231
(PT l/8 x PT l/8 90 elbow)
790-261-1310
(Type to insert between hose
and elbow)
Install oil pressure gauge Cl (60 kg/cm2 at
high pressure side, 25 kg/cm2 at low pres-
sure side).
Set to H.0 and H mode, run the engine at
high idling, and measure the differential
pressure with the control levers at neutral.
Sr High pressure (Pt) - low pressure (Pd)
= Differential pressure
Using the work equipment, raise the track
frame on one side, and measure the dif-
ferential pressure with the track rotating
freely (control lever operated to the end of
its travel).
*
*
Any actuator can be measured, but it is
easiest to measure the free rotation of
the track because the measurement
time can be chosen as desire.
The differential pressure is the minimum
(below 1 .O kg/cm2).
Relationship between travel of
control lever and differential
pressure of jet sensor
I
O Control lever travel (mm)
205FO5249
/ /
iO5FO5250
I
Elbbws
205FO5251
20-45
0
Adjusting
*
I )
*
If the results of the measurement show that
the differential pressure is not within the
standard value, adjust as follows.
Loosen locknut (I I) and turn adjustment
* Adjust the adjustment screw as follows.
CLOCKWISE
COUNTERCLOCKWISE
Sr Amount of adjustment for one turn of
adjustment screw:
Approx. 16.6 kg/cm2
m Locknut: 7.0 f 1.0 kgm
After adjusting the adjustment screw,
repeat the procedure in measuring to check
the differential pressure again.
205FO5252
F2050539E
20-46
@
MEASURING STROKE OF SERVO PISTON
*
1.
2.
If the output pressure of the NC valve is normal,
and it is considered that the pump performance
is defective, inspect as follows to determine if
the servo valve is defective or not.
Prepare the tool
Make up gauge 0 from the following parts.
1) Servo piston cap (side which has spring)
2) Dump truck brake wear measurement
gauge (566-98-41120)
3) Tap PT l/4 threads in the center of the cap,
and install the gauge.
Measuring
1)
21
3)
4)
Remove the cap (with the spring) from the
side to be measured.
t The cap is pushed by the spring, so use
bolt (01016-31070) and a nut.
Fit the shims that were removed, and install
gauge @.
4 Do not let the shims catch on the
threaded portion of the bolt.
Stop the engine, push the rod in fully, then
measure the dimension of the rod.
Raise the track shoe on the side where the
gauge is installed, and measure the dimen-
sion of the rod when the engine is run at
high idling and the track is rotated freely.
t Standard stroke: Approx. 7.2 mm
* When the track shoe is rotated freely,
push the rod by hand, and check at the
same time that the rod moves smothly
in accordance with the travel of the con-
trol lever.
I 205FO5254
205FO5255
20-47
0
TESTING AND ADJUSTING TRAVEL DEVIATION
* When traveling on fiat ground
1. Measuring when traveling
1) Set the machine in the travel posture.
J, When setting the machine in the travel
posture, extend the bucket and arm cyl-
inder rod fully, and hold the boom at 45.
2) Travel for 10 m, then measure the deviation
when traveling for the next 20 m.
* Set to the H.0 and H mode, and measure
with the engine at high idling.
Travel posture
202F2322
20 m
0 Travel for 10 m
Travel straight
through without
stopping
\ \
Make a mark
\
Make a mark at
Make a mark
the 10 m midpoint
~~r~~n?Jn~~~:I-^.rk
this deviation
Mark
202F5258
2o-i7-1
2. Adjusting
If the result of the measurement shows that the
value is not within the standard value, adjust as
follows.
t Adjustment procedure
.
1)
2)
If the travel deviation is still not within the
standard value even after carrying out this
adjustment, see TROUBLESHOOTING, Travel
deviation is excessive.
Loosen 4 bolts (I).
Ir The shims are split shims, so do not
remove the cap.
Add shim (2) of a thickness that matches the
amount of deviation, then tighten bolts (1).
* Add maximum of 0.3 mm of shim.
W Mounting bolt: 6.75 2 0.75 kgm
* Amount of travel deviation and thickness
of shim to add
PC200
20
15
10
5
0
Thickness of shim to add (mm)
F205C5118
PC220
F205C5117
Thickness of shim to add (mm)
F205C5119
2047-2
MEASURING OUTPUT PRESSURE OF PPC VALVE
*
1.
2.
3.
4.
45 - 55C
Disconnect the hose (see diagram below) from
the circuit to be measured.
install adapter C2 between the hose and elbow.
Install oil pressure gauge Cl (60 kg/cm7 to
adapter C2.
Run the engine at high idling, operate the con-
trol lever for the circuit to be measured, and
measure the hydraulic pressure.
PC200,2OOLC-5 Serial No: 45001 - 52783
PC220,22OLC-5 Serial No: 35001 - l
R.H. PPC valve P,
205F05684
205FO5266B
* Color code
B: Black, Br: Brown, W: White, Y: Yellow
BU: Blue, G: Green, R: Red
PC220,22OLC-5 Serial No: l and up
R.H PPC valve
I D
L.H
205FO5880
20649
ADJUSTING WORK EQUIPMENT, SWING PPC VALVE
PC200,2OOLC-5 Serial No: 45001 - 58018
PC220,22OLC-5 Serial No: 35001 - 36613
* If there is excessive play in the work equipment
or swing lever, adjust as follows.
*y Lower the work equipment to the ground
Set the safety lock lever to the LOCK po-
sition.
1.
2.
3.
Remove the boot, loosen the lever mounting
bolt, then remove the lever.
Hold down disc (I 1, and loosen locknut (2).
Turn disc (I 1 and adjust the clearance.
sr
i)
ii)
iii)
iv)
*
Adjust the clearance with the disc as
follows.
l To DECREASE clearance, turn
CLOCKWISE
l To INCREASE clearance,
COUNTERCLOCKWISE
turn
When adjusting the clearance, adjust four
pistons (3) separately. (Two pistons in the
front-to-rear direction (A - a) and two pis-
tons in the left-to-right direction (B - b)).
Set disc (I) so that it contacts one of the
pistons in the front-to-rear direction (A -
a), then adjust the clearance between disc
(I) and piston (3) on the opposite side to
0.3 - 0.5 mm.
After adjusting in the front-to-rear direction,
adjust in the left-to-right direction (B - b).
If the clearance exceeds 0.5 mm, change
the position of disc (I) or change the
mounting position of piston (31, then check
again.
w Locknut: 11.5 * 1.5 kgm
If no clearance is made, even when the lever
is at neutral, the work equipment will move,
or the hydraulic drift will increase, so
always provide a clearance.
0.3 - 0.5 mm
1
3
20- $9- l
PCZOO, 2OOLC-5 Serial No: 58019 and up
f- If there is excessive play in the work equip-
ment or swing lever, adjust as follows.
*qLower the work equipment to the ground and
stop the engine. Operate the control levers
several timesto release the remaining pressure
in the hydraulic piping. Then loosen the oil
filler cap slowly to release the pressure inside
the hydraulic tank. Set the safety lock lever to
the LOCK position.
1.
2.
3.
4.
5.
*
z
z
8
Remove the PPC valve.
Remove boot (1).
Loosen locknut (2), and screw in disc (3) until
it contacts the head of 4 pistons (4).
Ir When adjusting, do not operate the pis-
tons.
Hold disc (3) in position and tighten locknut
(2) to the specified tightening torque.
w Locknut: 11 & 1 kgm
Install boot (I).
With this adjustment, the clearance between
disc (3) and piston (4) is made 0.
20TF011.29
20-&9-2
TESTING PPC SHUTTLE VALVE
*
-k
1.
2.
3.
If the auto-deceleration does not work, the
swing brake is not canceled, the travel lacks
power, or if there is any other problem, and the
pressure switch is normal, check the operation
of the PPC shuttle valve as follows. (Check first
that the electrical system is normal.)
Oil temperature when testing:
45 - 55C
Remove the pressure switch from the circuit to
be tested.
I) Work equipment, swing pressure switch (I)
2) Travel pressure switch (2)
Install pressure gauge Cl (60 kg/cm?.
Run the engine at high idling, operate the fol-
lowing control lever, and measure the hydraulic
pressure.
In the case of switch (1). operate the work
equipment or swing lever.
In the case of switch (21, operate the travel
lever.
205FO5259
20-50
MEASURING SOLENOID VALVE OUTLET PORT PRESSURE
Measure each solenoid valve at the following
places.
INO. I
Solenoid Measurement location
I
Solenoid valve
outlet port
Disconnect the hose, and install adapter C2 be-
tween the measurement point and the hose.
* Adapter
Size
02
03
04
Part No.
790-261-1310
790-261-I 320
790-261-I 330
Install oil pressure gauge Cl (60 kg/cm21 to the
adapter.
Run the engine at high idling and measure the
hydraulic pressure under the following
conditions.
1)
21
3)
4)
Arm half flow solenoid valve
If the working mode switch is set to heavy-
duty or general mode, and the arm is operat-
ed, the PPC valve output pressure is sup-
plied; if the working mode switch is set to
finishing or lifting mode, the pressure
should be 0 kg/cm2.
Swing brake soleoid valve
Operate the swing.
Travel speed solenoid valve
Set the travel speed switch to Hi.
2-stage relief *CO cancel solenoid valve
Turn the swing lock switch ON or push the
power max. switch ON.
205FO5260
205FO5261
205FO5262
205FO5263
TESTING LOCATIONS CAUSING
WORK EQUIPMENT
*
1.
If there is any hydraulic drift in the work equip-
ment (cylinders), check as follows to determine
if the cause is in the cylinder packing or in the
control valve.
Checking for defective cylinder packing
I ) Checking boom and bucket cylinders
i) Set in the same posture as when
measuring hydraulic drift, and stop the
engine.
ii) Operate the boom control lever to
RAISE or the bucket control lever to
CURL.
l If the lowering speed increases, the
packing is defective.
l If there is no change, the holding
valve (boom) or the control valve
(bucket) is defective.
2) Checking arm cylinder
i) Operate the arm cylinder to move the
arm in fully, then stop the engine.
ii) Operate the arm control lever to IN.
l If the lowering speed increases, the
packing is defective.
l If there is no change, the control
valve is defective.
* If the pressure in the accumulator has been
lost, run the engine for approx. 10 seconds
to charge the accumulator again before
operating.
[Reference1
I )
2)
If the cause of the hydraulic drift is in the
packing, and the above operation is carried
out, the downward movement becomes
faster because of the following reasons.
If the work equipment is set to the above
posture (holding pressure applied to the
bottom end), the oil at the bottom end leaks
to the head end. However, the volume at the
head end is smaller than the volume at the
bottom end by the volume of the rod, so the
internal pressure at the head end increases
because of the oil flowing in from the
bottom end.
When the internal pressure at the head end
increaes, the balance is maintained by a cer-
tain pressure (this differes according to the
amount of leakage) in proportion to it.
HYDRAULIC DRIFT OF
PC200: 1,260 kg (. 1
PC220: 1,620 kg
r -7
205FO5264
205FO5265
3) When the pressure is balanced, the down-
ward movement becomes slower. If the
lever is then operated according to the
procedure given above, the circuit of the
head end is opened to the drain circuit (the
bottom end is closed by the check valve),
so the oil at the head end flows to the drain
circuit and the downward movement be-
comes faster.
20-52
Checking boom holding valve
*y Set the work equipment at the maximum
reach, and the top of the boom horizon-
tal, then stop the engine.
Lock the work equipment control levers
and release the pressure inside the hy-
draulic tank.
1)
2)
3)
Disconnect pilot hose (I) of the boom hold-
ing valve, and install a blind plug in the hose.
* Blind plug: 07376-50315
* Leave the holding valve end open.
Start the engine, charge the accumulator,
then stop the engine.
Operate the boom control lever to the
LOWER position.
* If any oil leaks from the port that is left
open, the holding valve is defective.
Checking PPC valve
If the hydraulic drift differs when the safety
lock lever is in the LOCK or FREE position,
(engine running), the PPC valve is defective.
20-53
BLEEDING AIR
Procedure for bleeding the air
Air bleeding item Air bleeding procedure
Bleed air from Bleed air from Bleed air from Bleed air from
Neutral of work travel motor
Start operations
l Charge hydraulic oil
l Clean strainer
+ o + + (Note? (Not$+
I
l Replace return filter element
0
I
> 0
l Replace or repair pump
l Remove suction piping
* Replace or repair control valve
- Replace cylinder
l Remove cylinder piping
0 J+ 0
I
) 0
l Replace Swing motor
l Remove swing motor piping
0 -0 -0
. Replace travel motor or swivel
l Remove travel motor or swivel
0 ) 0 + 0
piping
Note: Bleed the air from the swing and travel motors only when the oil inside the motor case
has been drained.
1. Bleeding air from pump
I) Loosen air bleed plug (II, and check
that oil oozes out from the plug.
2) When oil oozes out, tighten plug (I).
m Plug: 1.75 * 0.25 kgm
* If oil does not ooze out from the air
bleed plug:
3) Leave plug (I) loosened, then remove
hose (2) and elbow (3).
4) Add oil through the elbow mounting
hole until oil comes out from plug (I 1.
5) Fit elbow (31, install hose (2).
6) Tighten air bleed plug (I 1.
m Plug: 1.75 f 0.25 kgm
* Precautions when starting the engine
When starting the engine after carrying
out the above operation, run at low
idling for 10 minutes.
* If the water temperature is low and
warming-up operation is carried out,
cancel the automatic warming-up with
the fuel control dial after starting the
engine.
2. Bleeding air from cylinders
1) Start the engine and run it at low idling
for approx. 5 min.
2) Run engine at low idling, and raise and
lower boom 4 - 5 times in succession.
* Stop the piston rod approx. 100
mm before the end of the stroke. Do
not relieve the circuit.
3) Run the engine at full throttle and repeat
Step 2). After this, run the engine at low
idling and operate the piston rod to the
end of its stroke to relieve the circuit.
4) Carry out the procedure in Steps 2) and
3) for both the arm and bucket cylinders.
* If the hydraulic cylinder has been re-
placed, it is better to bleed the air be-
fore connecting the work equipment
again.
(In particular, for the LOWER end of
the boom cylinder, if it contacts the
boom, the cylinder cannot be operat-
ed to the end of its stroke.)
3. Bleedina air from swing motor I
I )
*
2)
3)
Run the engine at low idling, loosen air
bleed plug (41, and check that oil oozes
out from the plug.
If oil does not ooze out from the air
bleed plug :
Stop the engine, and fill the pump case
with oil through plug (4).
Tighten air bleed plug (4).
w Plug: 17.0 + 2.0 kgm
4. Bleeding air from travel motor
I) Run the engine at low idling, loosen air
bleed plug (51, and if oil flows out, tight-
en the air bleed plug again.
w Plug: 0.9 f 0.1 kgm
1
s
205FO5608
sr
1.
2.
3.
If the piping between the hydraulic cylinder and
the control valve is disconnected, remove the
remaining pressure from the circuit as follows.
The travel circuit is an open circuit, so there is
no remaining pressure. It is enough to remove
the oil filler cap.
Loosen the oil filler cap slowly to release the
pressure inside the tank.
Operate the control levers.
t When the levers are operated 2 - 3 times,
the pressure stored in the accumulator is
removed.
Start engine, run at low idling for approx. 5 mi-
nutes, then stop the engine and operate the
control levers.
+ Repeat the above operation 2 - 3 times to
release all the remaining pressure.
TROUBLESHOOTING
Points to remember when troubleshooting. .................................
Sequence of events in troubleshooting .....................................
Precautions when carrying out maintenance ................................
Checks before troubleshooting ............................................
Electrical circuit diagram ..................................................
Position of connectors for troubleshooting .................................
Connection table for connector ............................................
Explanation of functions of control mechanism of electrical system ...........
Display method for monitor panel, pump controller and engine throttle controller
Action of self-diagnostic function and symptoms on machine ................
Method of ,using judgement table ..........................................
Method of using troubleshooting charts ....................................
Troubleshooting of engine throttle controller system (E mode) ................
Troubleshooting of pump controller system (C mode) .......................
Troubleshooting of pump controller input signal system (F mode) .............
Troubleshooting of hydraulic and mechanical system (H mode) ...............
Troubleshooting of monitor system (P mode) ...............................
. . 20- 58
. 20- 59
. . 20- 60
. 20- 67
. 20- 68
. 20- 72
. 20- 90
. 20- 98
. . 20-I 01
. 20- 105
. 20- 108
. . 20-I 10
. . 20-I 13
. . 20-I 39
. . 20-I 69
. . 20-I 81
. . 20-213
20-57
0
POINTS TO REMEMBER WHEN TROUBLESHOOTING
a
l Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are
securely fitted.
l When carrying out the operation with two or more workers, keep strickly to the agreed signals,
and do no allow any unauthorized person to come near.
l Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
l When disconnecting wiring, always disconnect the negative (-1 terminal of the battery first.
*A,o When removing the plug from a location which is under pressure from oil, water, or air, always
4
release the internal pressure first. When installing measuring equipment, be sure to connect it
properly.
l The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs
swiftly, and to prevent reoccurrence of the failure.
When carrying out troubleshooting, and important point is of course to understand the struc-
ture and function. However, a short cut to effective troubleshooting is to ask the operator vari-
ous questions to form some idea of possible cases of the failure that would produce the report-
ed symptoms.
1. When carrying out troubleshooting, do not
hurry to disassemble the components.
If components are disassembled immediate-
ly any failure occurs:
l Parts that have no connection with the
failure or other unnecessary parts will
be disassembled.
l It will become impossible to find the
cause of the failure.
It will also cause a waste of manhours,
parts, or oil or grease, and at the same time,
will also lose the confidence of the user or
operator.
For this reason, when carrying out trou-
bleshooting, it is necessary to carry out
thorough prior investigation and to carry
out troubleshooting in accordance with the
fixed procedure.
2. Points to ask user or operator
I) Have any other problems occured apart
from the problem that has been
reported?
2) Was there anything strange about the
machine before the failure occurred?
3) Did the failure occur suddenly, or were
there problems with the machine condi-
tion before this?
4) Under what conditions did the failure
occur?
5) Had any repairs been carried out before
the failure?
When were these repairs carried out?
6) Has the same kind of failure occurred
before?
3. Check before troubleshooting
I) Check the oil level.
2) Check for any external leakage of oil
from the piping or hydraulic equipment.
3) Check the travel of the control levers.
4) Check the stroke of the control valve
spool.
5) Other maintenance items can be
checked externally, so check any item
that is considered to be necessary.
4. Confirming failure
l Confirm the extent of the failure your-
self, and judge whether to handle it as a
real failure or as a problem with the
method of operation, etc.
* When operating the machine to re-
enact the torubleshooting symp-
toms, do not carry out any investiga-
tion or measurement that may make
the problem worse.
5. Troubleshooting
l Use the results of the investigation and
inspection in Items 2 - 4 to narrow
down the causes of failure, then use the
troubleshooting flowchart to locate the
position of the failure exactly.
* The basic procedure for troublesh-
ooting is as follows.
1) Start from the simple points.
2) Start from the most likely points.
3) Investigate other related parts or
information.
6. Measures to remove root cause of failure
l Even if the failure is repaired, if the root
cause of the failure is not repaired, the
same failure will occur again.
To prevent this, always investigate why
the problem occurred. Then, remove the
root cause.
20-58
SEQUENCE OF EVENTS IN TROUBLESHOOTING
a Jobsite
step 1
[Examination. confirmation of symptoms 1
1) When a request for repairs is received,
first ask the following points.
* Name of customer
Type. senal number of machine
. Details of jobsite, etc.
2) Ask questions to gain an outline of the
problem.
+ Condition of fallure
Work being carried out at the time
\
Ring! Ring!
--------
----____
3
of the failure
Operating environment
Past hlstory, details of maintenance,
etc.
step 2
Determining probable location of cause
1) Look at the troubleshooting section of the
shop manual to find locations of possible
caSeS
step 3
[Preparation of troubleshooting tools]
Look at the table of troubleshooting tools
in the shop manual and prepare the
necessary tools.
* T-adapter
* Hydraulic pressure gauge kit, etc.
Look in the parts book and prepare the
necessary replacement parts.
* Decide action to take
1) Before starting troubleshooting, locate and
repair simple failures. n 0,
* Check before starting items
* Other check items
2) See the Troubleshooting Section of the
shop manual, select a troubleshootinq
flowchart that matches the symptonx. and
carry out troubleshooting_
Step 6
Reenacting failure
I f Driveand operate the machine to confirm
the condition and judge if there is really a
failure
I
20-59
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
To maintain the performance of the machine
over a long period, and to prevent failures or
other troubles before they occur, correct opera-
tion, maintenance and inspection, troubleshoot-
ing, and repairs must be carried out. This section
deals particularly with correct repair procedures
for mechatronics and is aimed at improving the
quality of repairs. For this purpose, it gives sec-
tions on Handling elecric equipment and
Handling hydraulic equipment (particlularly
hydraulic oil).
1. PRECAUTIONS WHEN HANDLING
ELECTRIC EQUIPMENT
I) Handling wiring harnesses and
connectors
Wiring harnesses consist of wiring connect-
ing one component to another component,
connectors used for connecting and discon-
necting one wire from another wire, and
protector or tubes used for protecting the
wiring. Compared with other electrical
components fitted in boxes or cases, wiring
harnesses are more likely to be affected by
the direct effects of rain, water, heat, or vi-
bration. Furthermore, during inspection and
repair operations they are frequently re-
moved and installed again, so they are likely
to suffer deformation or damage. For this
reason, it is necessary to be extremely care-
ful when handling wiring harnesses.
Main failures occurring ir! wiring harm-
(1) Defective contact of connect&
(defective contact between male and
female)
Problems with defective contact are
likely to occur because the male connec-
tor is not properly inserted into the
female connector, or because one or
both of the connectors is deformed or
the position is not correctly aligned, or
because there is corrosion or oxidization
of the contact surfaces.
F20505201
Improper insertion
F20505202
20-60
(2) Defective compression or soldering of
connectors
The pins of the male and female
connectors are in contact at the
compressed terminal or soldered
portion, but there is excessive force on
the wiring, and the plating peels to
cause improper correction or breakage.
(31 Disconnections in wiring
If the wiring is held and the connectors
are pulled apart, or components are
lifted with a crane with the wiring still
connected, or a heavy object hits the
wiring, the compression of the
connector may be lost, or the soldering
may be damaged, or the wiring may be
broken.
Improper compression
F56103079
(4) High pressure water entering connector
The connector is designed to make it
difficult for water to enter (drip-proof
structure), but if high-pressure water is
sprayed directly on the connector,
water may enter the connector depend-
ing on the direction of the water jet.
The connector is designed to prevent
water from entering, but at the same
time, if the water does enter, it is diffi-
cult for it to be drained. Therefore, if
water should get into the connector, the
pins will be short-circuited by the water,
so if any water gets in, immediately dry
the connector or take other appropriate
action before passing electricity
through it.
(5) Oil or dirt stuck to connector
If oil or grease are stuck to the connec-
tor and an oil film is formed on the
mating surface between the male and
female pins, the oil will not let the elec-
tricity pass, so there will be defective
contact.
If there is oil or grease or dirt stuck to
the connector, wipe it off with a dry
cloth or blow dry with air, and spray it
with a contact restorer.
* When wiping the mating portion of
the connector, be careful not to use
excessive force or deform the pins.
F2050520A
F20505205
F20505206
20- 61
0
* If there is water or oil in the air, it
will increase the contamination of
the points, so clean with air from
which all the water and oil has been
removed.
2) Removing, installing, and drying connec-
tors and wiring harnesses
Disconnecting connectors
(I)
(2)
Hold the connectors when discon-
necting.
When disconnecting the connectors,
hold the connectors and not the wires.
For connctors held by a screw, loosen
the screw fully, then hold the male and
female connectors in each hand and pull
apart. For connectors which have a lock
stopper, press down the stopper with
your thumb and pull the connectors
apart.
Action to take after removing
connectors
After removing any connector, cover it
with a vinyl bag to prevent any dust,
dirt, oil, or water from getting in the
connector portion.
Connecting connectors
(I) Check the connector visually.
a. Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portionI.
b. Cherr. that there is nn ~dwcoa~~,?~,
defective contact, corrosion, or
damage to the connector pins.
c. Check that there is no damage or
breakage to the outside of the
connector.
* If there is any oil, water, or dirt stuck
to the connector, wipe it off with a
dry cloth. If any water has got inside
the connector, warm the inside of
the wiring with a dryer, but be care-
ful not to make it too hot as this will
cause short circuits.
* If there is any damage or breakage,
replace the connector.
Lock
v
F20505207
F20505208
20-62
(2) Fix the connector securely.
Align the position of the connector cor-
rectly, then insert it securely.
For connectors with lock stopper
Push in the connector until the stopper
clicks into position.
(3) Correct any protrusion of the boot and
any misalignment of the wiring hanress
For connectors fitted with boots, correct
any protrusion or the boot. In addition, if
the wiring harness is misaligned, or the
clamp is out of position, adjust it to its
correct position.
* When blowing with dry air, there is
danger that the oil in the air may
cause improper contact, so clean
with air from which all the water
and oil has been removed.
Drying wiring harness
If there is any oil or dirt on the wiring har-
ness, wipe it off with a dry cloth. Avoid
washing it in water or using steam. If the
connector must be washed in water, do not
use high pressure water or steam directly
on the wiring harness. If water gets directly
on the connector, do as follows.
(I) Disconnect the connector and wipe off
the water with a dry cloth.
+ If the connector is blown dry with
air, there is the risk that oil in the air
may cause defective contact, so
avoid blowing with air.
(2) Dry the inside of the connector with a
dryer.
If water gets inside the connector, use a
dryer to dry the connector.
Ir Hot air from the dryer can be used,
but be careful not to make the
connector or related parts too hot,
as this will cause deformation or
damage to the connector.
Cliks into position
II
F20505209
I I
F20505210
F20505211
F20505212
2043
0
(3) Carry out a continuity test on the
connector.
After drying, leave the wiring harness
disconnected and carry out a continuity
test to check for any short circuits be-
tween pins caused by water.
* After completely drying the connec-
tor, blow it with contact restorer
and reassemble.
3) Handling control box
( I ) The control box contains a micro-
computer and electronic control circuits.
These control all of the electronic cir-
cuits on the machine, so be extremely
careful when handling the control box.
(2) Do not open the cover of the control
box unless necessary.
(3) Do not place objects on top of the con-
trol box.
(4) Cover the control connectors with tape
or a vinyl bag.
(5) During rainy weather, do not leave the
control box in a place where it is ex-
posed to rain.
(6) Do not place the control box on oil,
water, or soil, or in any hot place, even
for a short time. (Place it on a suitable
dry stand)
(7) Precautions when carrying out arc
welding
When carrying out arc welding on the
body, disconnect all wiring harness
connectors connected to the control
box. Fit an arc welding ground close to
the welding point.
T-adapter
\\\
F20505213
F20505214
z
0_
z
F20505215
F20505216
20-64
2. POINTS TO REMEMBER WHEN
HANDLING HYDRAULIC EQUIPMENT
With the increase in pressure and precision of
hydraulic equipment, the most common cause
of failure is dirt (foreign material) in the hydrau-
lic cirucit. When adding hydraulic oil, or when
disassembling or assembling hydraulic equip-
ment, it is necessary to be particularly careful.
1)
21
::
z
cv
0
3)
41
Be careful of the operating environment.
Avoid adding hydraulic oil, replacing filters,
or repairing the machine in rain or high
winds, or places where there is a lot of dust.
Disassembly and maintenance work in
the field
If disassembly or maintenance work is car-
ried out on hydraulic equipment in the field,
there is danger of dust entering the equip-
ment. It is also difficult to confirm the per-
formance after repairs, so it is desirable to
use unit exchange. Disassembly and mainte-
nance of hydraulic equipment should be car-
ried out in a specially prepared dustproof
workshop, and the performance should be
confirmed with special test equipment.
Sealing openings
After any piping or equipment is removed,
the openings should be sealed with caps,
tapes, or vinyl bags to prevent any dirt or
dust from entering. If the opening is left
open or is blocked with a rag, there is
danger of dirt entering or of the surrounding
area being made dirty by leaking oil so
never do this.
Do not simply drain oil out on to the ground,
collect it and ask the customer to dispose
of it, or take it back with you for disposal.
Do not let any dirt or dust get in during
refilling operations.
Be careful not to let any dirt or dust get in
when refilling with hydraulic oil. Always
keep the oil filler and the area around it
clean, and also use clean pumps and oil con-
tainers. If an oil cleaning device is used, it is
possible to filter out the dirt that has collect-
ed during storage, so this is an even more
effective method.
F20505217
F20505218
F20505219
20-65
5) Change hydraulic oil when the tempera-
ture is high.
When hydraulic oil or other oil is warm, it
flows easily. In addition, the sludge can also
be drained out easily from the circuit togeth-
er with the oil, so it is best to change the oil
when it is still warm. When changing the oil,
as much as possible of the old hydraulic oil
must be drained out. (Do not drain the oil
from the hydraulic tank; also drain the oil
from the filter and from the drain plug in the
circuit.) If any old oil is left, the contaminants
and sludge in it will mix with the new oil and
will shorten the life of the hydraulic oil.
6) Flushing operations
After disassembling and assembling the
equipment, or changing the oil, use flushing
oil to remove the contaminants, sludge, and
old oil from the hydraulic circuit.
Normally, flushing is carried out twice: pri-
mary flushing is carried out with flushing
oil, and secondary flushing is carried out
with the specified hydraulic oil.
7) Cleaning operations
After repairing the hydraulic equipment
(pump, control valve, etc.) or when running
the machine, carry out oil cleaning to
remove the sludge or contaminants in the
hydraulic oil circuit.
The oil cleaning equipment is used to
remove the ultrafine (about 34 particles
that the filter built into the hydraulic equip-
ment cannot remove, so it is an extremely
effective device.
F20505220
F20505221
20-66
CHECKS BEFORE TROUBLESHOOTING
(1. Checks before starting, 2. Other check items)
T
Item
1. Check fuel level
2. Check for dirt or water in fuel
3. Check hydraulic oil level
4. Check hydraulic oil strainer
5. Check swing machinery oil level
6. Check engine oil level (Level of oil in oil pan)
7. Check cooling water level
8. Check condition of dust indicator
9, Check for loose or corroded battery
terminals
IO.
Check for loose or corroded alternator
terminals
, , . Check for loose or corroded starting motor
terminals
12. Check for abnormal noise or smell
13. Check for oil leakage
14. Bleed air from system
15. Check battery voltage (engine stopped)
16. Check level of battery electrolyte
17. Check for discolored, burnt, or bare wiring
1 8. Check for missing wiring clamps, hanging
wires
Checks for water leaking onto wiring
19. (check carefully water leakage at connector:
and terminals)
20. Check for broken or corroded fuses
21. Check alternator voltage
(engine running at over half throttle)
22. Noise when battery relay is operated
(switch starting switch from on to off)
Judgement
standard
-
-
-
-
-
-
-
-
-
20 - 3OV
-
-
-
27.5 - 29.6V
Remedy
Add fuel
Clean, drain
Add oil
Clean, drain
Add oil
Add oil
Add water
Clean or replace
Tighten or replace
Tighten or replace
Tighten or replace
Repair
Repair
Bleed air
Replace
Add or replace
Replace
Repair
Disconnect
connector and
dry connection
Replace
Replace
Replace
20-67
ELECTRICAL CIRCUIT DIAGRAM
ENGINE THROTTLE CONTROLLER SYSTEM
PC200,2OOLC-5 Serial No: 45001 - 48283
PC220,22OLC-5 Serial No: 35001 - 35447
Starting switch
0.85GY
Fuse
0.85WR
I
Ml468)
1
(NSl20)
I
Battery relay
Governor motor
controller
E6(M3) Fuel control dial
__._. __._
Auto-deceleration \
; 0.5L
Throttle (+I
,. 0.5w
r\ GWD
l--In
PC200 only
.Jvv
-I- 5
0.518 6
Power set a
_____
0.5L
Power set b
0.5LW .
7 Auto-deceleration
~ 8
05G
Working mode a
g
Working mode b
Coolant 102C signal
Coolant 107C signal
16 \GND
--
PC200,2OOLC-5 Serial No: 48284 - 58018
PC220,22OLC-5 Serial No: 35448 - 36613
Starting switch
starting motor Alternator
Governor motor
Fuel control
p&
dial
3
205FO5757
Starting switch
Fuse
M37CMI) M38L2)
2WR
Fusible link
0 85GY
IOA 2
5WR
Iti- I
608
Fusible link
Banery relay
--A
205FO5757
DIO
%,b
2
E6CM3
r
Kerosene mode
20-&O
PUMP CONTROLLER SYSTEM
PC200,2OOLC-5 Serial No: 45001 - 49706
PC220,22OLC-5 Serial No: 35001 - 35661
1 tuse &,
Swing lock switch
l-l
M6EIO)
Arm half flow
L-stage relief CO
cancel solenoid valve
L-ITilw
Travel speed
) solenoid valve
T"C prolix
reslstor
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
-izing swit .h
PC200,2OOLC-5 Serial No: 49707 - 58018
PC220,22OLC-5 Serial No: 35662 - 36613
Swing lock
prolix switch
Battery relay
Battery (NSl20)
Fusible link
r
M3(Sl6)
D9
r-i&J 2-stage relief . CO
I I I I I I I I ' - I L1 Travel weed
solenoid valve
I Enqine throttle controller
_-
I I
I
1,
Swing brake
20-&2
-I
-_-
Monitor panel
J
/e
B switch
Engine speed sensor
Swing lock
prolix switch
Battery (~~120)
Swing lock switch
r-----l I I
IllI/ -85-l Arm half flow
I M6(SIO) I I I I I
solenoid valve
Z-stage relief . CO
V7(X2) cancel solenoid valve
I I I L\ Travel soeed
V2(X2) solenoid valve
Swing brake
I-1
i 4 0.5GW I I I I I I I I I
05w
5 nK,L1
I
I-I
Monitor panel
1
t
Power maximizing switch
Engine speed sensor
8YR
. . ,. ,._,, ,
tiaunmi+r, 8 0.5GR
205FO5761B
MONITOR SYSTEM
PC200,2OOLC-5 Serial No: 45001 - 58018
PC220,22OLC-5 Serial No: 35001 - 36613
Service meter
M7lL2) Mll(L2)
WR w/R
J
g motor
Alternator
Wlper motor
Light
relay
air heater
I
P5(Xl)
Engine oil level sensor
Heater
Hi relay
III
Overload
P7(x2j Coolant temperature sensor
r-1
L!.rr!i
Heater
Lo relay
warnmq dewce
III
Engine oil pressure sensor
Wiper
relay
oo,y~~ Coolant level sensor
Tl I i I I I I I I I
P6IXI)
is I I
R
I
Pump controller
r-1
B:dy
earth
P4(M2)
Warn-T
Startina switch
Window washer
R.H. head lamp
205FQ5705
Service meter
_
Wiper motor IYCEA,
D3
Light
relay
I I
Electrical intake l
air heater
Heater
Hi relay
Heater
Lo relay
R2
P5(X,) Engine oil level sensor
P7(X2) Coolant temperature sensor
r-1
l.T?_i Overload warning device
y-1
Wiper
relay
Engine oil pressure sensor
_
-
Fuel level sensor
P6(XI) r- 2- -
Pump controller
-_-
05GW
0%
I ]
1.258 ZsLp
Engine loom lamp
c
Window washer
Startinq switch
T@
Boom lamp
R.H.
head lamp
205FO5763
POSITION OF CONNECTORS FOR TROUBLESHOOTING
PC200,2OOLC-5 Serial No: 45001 - 58018
PC220,22OLC-5 Serial No: 35001 - 36613
C
I-
air conditioner
No. o
pins
1
4
M TYPE CONNECTOR
Male connector Female connector
205FO5317 205FO5318
205FO5319
i
205FO5321 205FO5322
1 3
el
205FO5323 205FO5324
2
i
205FO5320
20-9 1
0
No. o
pins
6
f
T
Male connector
M TYPE CONNECTOR
1 4
ci 6
205FO5325
Female connector
6 3
205FO5326
20-92
No. (
pin:
S TYPE CONNECTOR
Male connector
Female connector
8
205FO532: 205~05328
6 1
10
h I
205FO5329
!
12
l $ 5
205FO5332
s i
205FO533
8 1
16 7
16
1; Ii
205FO5334 205FO5333
20-93
No. o
pins
16
20
fl
AMP040 TYPE CONNECTOR
Male connector
i il
205FO5335
\ w
i i l
205FO5337
Female connector
205FO5336
11 i
205FO5338
20-94
No. c
pins
6
8
If I
SWP TYPE CONNECTOR
Male connector
1
\ !
/ \
3 6
205FO5339
4 8 8 i
205FO5341
Female connector
4 1
\
H
I I
6 3
205FO5340
205FO5342
20-95
fl
MIC CONNECTOR
No. o
pins
9
.I7
21
Female connector Male connector
205FO5343 205FO5344
142F414 142F415
142F416 142F417
20-96
No. of 1
X TYPE CONNECTOR
Male connector Female connector
205FO5309 205FO5310
205FO5311 205FO5312
i
205FO53 13 205FO5314
205FO53 15 205FO5316
1
HANDLING CONNECTORS
1. When removing the connectors from the
clips, pull the connector in a parallel direc-
tion to the clip.
* If the connector is twisted to the left
and right or up and down, the housing
may break.
2. When disconnecting male and female
connectors, release the lock and pull in
parallel with both hands.
Ir Never try to pull out with one hand.
3. When the wiring harness clamp of the
connector has been removed, always return
it to its original condition and check that
there is no looseness of the clamp.
205FO5609
I 205FO5610
205FO5611
205FO5612
20- 27- l
EXPLANATION OF FUNCTIONS OF CONTROL MECHANISM
OF ELECTRICAL SYSTEM
This section gives the functions and details of checks for the monitor panel, pump controller,
engine throttle controller needed to carry out troubleshooting of the electrical system.
1. Explanation of functions
and
The control mechanism for the electrical system consists of the monitor panel, pump controller,
and engine throttle controller. It carries out control by changing the absorption torque of the pump
(power mode) or by changing the output of the engine (working mode).
Monitor panel and both the controllers i) each input the necessary signals, and ii) combined with
the signals selected by the monitor panel, the controllers input and output the necessary signals to
control the absorption torque of the pump and the engine output.
l Input and output signal system of monitor panel and both controllers (Fig. I)
PC200,2OOLC-5 Serial No: 45001 - 49706
PC220,22OLC-5 Serial No: 35001 - 35661
Monitor panel
r 3
Eng,ne 011 level
Worktng mode watch signal
-A CL
Power mode swatch slgnal
Engine
throttle ~
controller L
Swng Oli
@
pressure swtch
Travel 011
@
pressure switch
Pump
@
pressure sensor
Power max
swtch signal
205F05345A
The pump controller and engine throttle controller have a self-diagnostic display function and if any
electrical abnormality (disconnection, contact with ground, internal short circuit, or short circuit be-
tween wires) occurs in the output signals (input signal for the receiving controller) for numbers 0 -
@ in Fig. 1, the content of the abnormality is displayed.
l If 01 - 09, or 25 are displayed (if a short circuit or other fault causes a current above the
specified level to flow to the controller, the controller stops the operation of that system).
l If 1 1 - 28 are displayed, there is a disconnection (the operation of that system stops) or there
is contact of the No. 2 pin of the solenoid with the ground (the solenoid continues to operate).
Even if there is any abnormality in the input signal system for @ - 0, the abnormality is not displayed
in the display area, but the pump controller has a built-in monitor function to check the input signals.
The controller starts to work only when there is an input signal, and it gives a display on the display
panel.
Therefore, when investigating if the cause is in the electrical system or in the hydraulic or mechanical
system in the case of There is no abnormality display on the display panel, but there is an abnormality
in the movement of the unit, the first step when carrying out troubleshooting is to use the method of
checking the operation of the electrical systm in Item 2 to check if the necessary signal is being output
to the pump controller correctly.
Monitor panel
c J
i
, -I
,
Swng l ock sagnal
c
1_- _ .=.. _.
Coolant temperafre
107C/105C signal (Note)
AutomaW
wamxng-up signal
Note:
205F05714
107C signal PC200, 2OOLC-5 Serial No.: 49707 - 58018 105C signal PC200, 2OOLC-5 Serial No.: 58019 and up
PC220, 22OLC-5 Serial No.: 35662 - 36613 PC200,2OOLC-5 MIGHTY
PC220, 22OLC-5 Serial No.: 36614 and up
20699
2. Checking operation of electrical system
When the Set of operations given below is carried out in the order given, and the action of the
monitor panel, pump controller, and engine throttle controller are as given in the table, the monitor
panel (EMACCI and both the controllers are normal.
c The IH.1./ and other displays given in the table are the monitor displays given by the controller if
the input and output signals are normal.
o The monitor display of the pump controller is displayed for 1.5 seconds after the signal is
input, and after that the operaton mode is displayed.
c For items 0, 0, and 0, the system automatically enters the auto-deceleration mode, so set
the auto-deceleration switch on the monitor panel OFF.
PC200,2OOLC-5 Serial No: 45001 - 49706 PC220,22OLC-5 Serial No: 35001 - 35661
Operation procedure and condition of
machine
Items for confirmation (when normal)
Monitor panel Pump Controller Engine throttle controller
\I:
* Turn starting switch OFF.
* Turn fuel control dial to MlN
All lamps OFF All lamps OFF All lamps OFF
a is displayed
_
Display lamps light up
2 Turn starting switch ON. G.0 and S mode is
display
start engine
3
If coolant temperature is below 30C.
carry out automatx warming up and
+
increase engine speed.
[Operating model
Decimal pant flashes
After 5 s?c. normal display
10 l (\ is displayed
. Turn fuel control dial to MAX
Raise engine speed I FULL speed of
Engme speed rises (fuel
4
G.0 mode.
control dial, governor
. Set auto-deceleratlo swtch OFF
potentiometer systems normal1
* Set working mode to H.0 mode
5,
Raise engine speed from FULL speed of
G.0 mode to FULL speed of H.0 mode.
- :~,:,~y~,
Set auto-deceleratlo switch OFF
m is displayed ~i+~~~~~~~~t!$ 2
(
. Set working mode to L.0 mode
6
Lower engine speed from FULL speed
of H 0 mode to FULL speed of L.0 mode.
- Ldi~p~~~e~mode * j:_.-:l is displayed ~[~{;~~~:~I?~~:? 2
* Set working mode to G 0 mode
7
Raise engine speed from FULL speed of
L.0 mode to FULL speed of G 0 mode
* Set auto-deceleration swtch OFF
3 rises agal ,IUO
pal system
8, -
Press power marimwng swatch
!$ Swtch travel speed swtch between HI and Lo )
Travel speed Hi -Lo
IS dlsplayed
11 - 1.5 secl
:
Cancel deceleration and raise engine
Opfyk equip-_
Operate work equpment lever, and move
sw,ng lever slightly to left and right.
m Isdisplayed 1
Switch auto-decelerat!on switch ON.
Iz
Engine speed drops to deceleration
speed after a few seconds.
I I
____
@ Switch swing lock switch ON and OFF.
Swing lock lamp OFF
. and ON is displayed
@ Operate travel lever slightly. 4
jj)
Return fuel control dial to MIN
H I
Engine speed drops (fuel
Engine speed drops to low idling. control dial system normal)
@ Turn starting switch OFF.
Engine stops
(battery relay system normal)
Operation procedure and condition of Items for confirmation (when normal1
I
machine
1 Monitor panel 1
;I;
* Turn starting switch OFF
* Turn fuel control dial to MIN.
$
Display lamps light up
Turn starting switch ON G.0 and S mode IS
display
Start engine
9
If coolant temperature IS below 30C.
carry out automatic warming up and
increase engine speed.
. Turn fuel control dial to MAX.
n
Raiseengine speed in FULL speed of
G.0 mode I-4
. Set auto-deceleration switch OFF
* Set working mode to H.0 mode
3
Raise engine speed from FULL speed of H.0 and H mode
G 0 mode to FULL speed of H.0 mode. IS dIsplayed
* Set auto-deceleration switch OFF
. Set working mode to L 0 mode
B
Lower engine speed from FULL speed
L.0 and L mode 15
-+
of H.0 mode to FULL speed of L.0 mode.
displayed
* Set working mode to G.0 mode
a
Rae engme speed from FULL speed of G 0 and S mode
L.0 mode to FULL speed of G 0 mode. is displayed
* Set auto-deceleration switch OFF.
D
Press power maximizing switch
I 1
!$ Switch travel speed switch between HI and LO
Travel speed Hi -Lo
is displayed
B
Operate work equipment or swng levers
Cancel deceleration and raise engine
speed.
Switch auto-deceleration switch ON
B
Engine speed drops to deceleration
Deceleration is
speed after a few seconds
displayed
I
@ Switch swng lock switch ON and OFF.
Swing lock lamp OFF
and ON is displayed
Return fuel control dial to MIN.
Turn starting switch OFF.
Pump controller
All lamps OFF
j is displayed
[Operating model
Decimal point flashes
m 1s displayed
:_.-:/ is dIsplayed
All lamps OFF
pc200,G vll is displaved
PC220~~a (model displayed
for 5 set)
After 5 sec. normal disblay
&I= is displayed
Engine speed rises (fuel
control dial, governor
potentiometer systems normal
Engine speed rise (No. 2
throttle signal system
normal1
Engine speed drops (No. 2
normal)
Engine speed rises again (No.
2 throttle signal system
normal)
Engine speed drops (fuel
control dial system normal)
Engine stops
(battery relay system normal)
7
20401
DISPLAY METHOD FOR MONITOR PANEL, PUMP
CONTROLLER AND ENGINE THROTTLE CONTROLLER
1.
2.
MONITOR PANEL
Approximately 2 seconds after the starting
switch is turned ON, all monitor and gauge
lamps light up and the buzzer sounds for
approximately 1 second. This is the
self-diagnostic function of the monitor
panel. After this, the display returns to
normal.
ENGINE THROTTLE CONTROLLER
I) Model code display function (normal
display)
When the starting switch is turned ON,
the model code is displayed for approxi-
mately 5 seconds on the controller dis-
play panel.
* After 5 seconds, the model code
display changes to the normal
display or the abnormal display
(self-diagnostic display).
Ir The display for the wrist control
type is the opposite (left becomes
right) of the display for the long
lever control type.
2) Self-diagnostic
display)
display (abnormal
l The abnormal display consists of 3
LEDs, and the ON/OFF combination
of these displays the type of
abnormality (abnormal system).
. If two or more abnormalityes occur
at the same time, the abnormalities
are displayed in the order of priority
shown in the table on the right.
l Once the starting switch is turned
OFF, the self-diagnostic display is
reset.
Check the abnormal display with
the starting switch ON.
0 When the abnormality is removed,
the display is automatically reset, so
if the abnormality occurs intermit-
tently, the abnormal display and
normal display will appear alternate-
ly, and the display may appear to be
flashing.
. Model code display
Model LEDs (Light Emitting Diodes)
Red Green Red
PC200
0 0 0
OFF OFF ON
Red Green Red
PC220
0 0 0
OFF ON OFF
Normal display
Red Green Red
0 0 0
OFF ON OFF
l Self-diagnostic display
Order of LEDs
priority (Light Emitting Diodes)
Abnormal system
Red Green Red
1 0 0 0
Power source system
OFF OFF OFF
or controller sytem
Red Green Red Short circuit in
2 0 0 0
governor motor
ON OFF ON system
Red Green Red
3 3 0 0
Short circuit in
OFF OFF ON
battery relay system
Red Green Red
Disconnection in
4 0 c
k-j governor motor
ON OFF OFF
system
Red Green Red
Abnormality In gover-
5 0 0 0
nor motor potentiomete
sytem, or motor is
OFF ON ON step out
Red Green Red
6 0 0 0
Abnormality in fuel
ON ON ON
control dial system
Red Green Red
7 0 0 0
Abnormaltiy in No. 2
ON ON OFF
*O-io2
3. PUMP CONTROLLER
I) Model code display function (normal
display)
When the starting switch is turned ON,
the model code is displayed for approxi-
mately 0.5 seconds on the controller
display panel.
2) Operation mode display function
(normal display)
The operation mode is displayed unless
there is any change or abnormality in
the input or output system for the pump
controller on controller.
l Model code display
mi
l Operation mode display
Power set
selection system Working mode selection system
mi
Power source
monitor
Lights up when
power is ON
Engine speed signal monitor
When engine speed signal is
input
Flashes
(At 2,000 rpm, approx.
20 times/l 0 set)
3) Input signal display function (normal
l Input signal display
display)
When the input signal to the controller
is switched, the input signal is displayed
for approx. 1 - 1.5 sec.
* If it is not displayed, there is an
abnormality in the input signal
system.
Sr After the input signal is displayed
for 1 - 1.5 set, the display
changes to the operation mode
display.
input signal
Travel speed switch Lo - Hi
Travel speed switch Hi - Lo
Auto-deceleration switch OFF - ON
Code Displa!
Hi
!I-:. t
Lo
!I- .cI
Ad
r\ t
J-u2
Swing lock switch OFF - ON
Work equipment oil pressure switch
bS -
!rB!3
I
OFF - ON P., 17 ,
PCZOO, 200LC-5 No.: 45001 - 49706
.I-. %
PC220,220LC-5 No.: 35001 - 35661
I
Swing oil pressure switch
b
PCZOO, 2OOLC-5 No.: 45001 - 49706
C220, 22OLC-5 No.: 35001 - 35661 I
OFF - ON
Work equipment . swing oil
pressure switch
PC200,200LC-5 No.: 49707 and
1
up
PC220,22OLC-5 No.: 35662 and
1
up
Service oil pressure switch 1, 2 OFF - ON
Travel oil pressure switch OFF - ON
Power max. switch OFF - ON UP
\ I 1-t
.u.r
Free swing FS -- :- .IJ
*O-iAo3
4) Self-diagnostic display function (abnor-
mal display)
l If there is any abnormality in the
controller output signal system and
sensor system, the abnormal display
and operation mode display are
shown alternately.
+ If two or more abnormalities
occur at the same time, all of the
abnormality displays and opera-
tion mode display are shown in
turn.
. If 01 - 09, 25 are displayed, there
is danger that the controller may be
broken, so the controller automati-
cally stops the output to the system
where the abnormality has occurred.
l Once the starting switch is turned
OFF, the abnormal display is reset,
so check with the starting switch
ON.
Ir If the starting switch is turned
OFF, re-enact the abnormal dis-
play as follows.
n System
Turn the starting switch ON.
0 System
Turn starting switch ON
(Engine stopped) and oper-
ate the control lever.
n System
Start the engine and operate
the control lever
l If no signal comes from the engine
speed sensor (engine stopped,
defective clearance at sensor, etc.).
the central decimal point does not
flash.
I Example of display
a) H.0 and H mode when normal
b) Same as a) but throttle signal
system abnormal
Short circuit in 2
No. 2 throttle signal system
20- 104
0
POSITION OF SELF-DIAGNOSTIC DISPLAY FOR EACH CONTROLLER
For pump contl
For engine throttle controller
0
TROUBLESHOOTING PROCEDURE WHEN ABNORMALITY OCCURS
::
c*l
0
Engi
Is problem in en-
gine or hydraulic
system?
I
L
Hydraulic
swtem
F20505400
2 YES
Does engine
throttle controller
give abnormal
display?
I
Does pump con-
troller g,ve abnor-
mal display
4
4
Is monitor display
of pump controller
NO inputs;q~al
I 1
* See table for checkina
operation of electrical
system.
Note: Items (1). (4). (15).
(16) do not apply.
5 YEI
f there is abnormality in
tern 12). (3), 15) - 17). (9J.
:121, (13)
NC
If there is abnormality in
Item (8). 11% 111). (141.
Remedy
Go to troubleshooting for
engine throttle controller
svstem
Problem in engine, mechani
Cal system
pump controller system
Go to troubleshooting for H
mode hydraulic and me-
chanical system
applicalble item in C mode
applable Item in P mode
30 to troubleshooting for
Ppplicable (tern in F mode
20-ki?4-
2. Judgement table for pump controller, hydraulic related parts
l If the self-diagnostic display gives an abnormal display, go to the troubleshooting code (C-c
c) given on the bottom line of the judgement table.
(There is a l given in the column where the failure mode and self-diagnostic display come
together.)
l For any problem where there is no abnormal display given by the self-diagnostic display, check
the chart for the place where the failure mode and input signal display come together (place
marked c).
If the display is normal, go to the troubleshooting code (H-c c) given in the column on the
right of the judgement table.
If the input signal is not displayed, go to the troubleshooting code (F-c c) given on the
bottom line.
<Example > Failure mode Auto-deceleration does not work
[Procedure]
Check if an abnormal display is given by the self-diagnostic display, or if the numbers on the side face
of the controller are flashing.
[J
If there is an abnormal display (for example, 28) on the self-diagnostic display:
Go to troubleshooting C-21 of the electrical syste
!m.
If there is no abnormal display on the self-diagnostic display, and the auto-deceleration does not work:
I-
Di spl ay given: . . . . . . . . . . . . . . . . . .
l Check the monitor for the pu.mp
--I
controller input signal
Go to troubleshooting of
hydraulic system H-7
L No di spl ay given: . . . . . . . . . . . . . . . .
Go to troubleshooting of
electrical system Fl , 2,3, or 6
20- 109
METHOD OF USING TROUBLESHOOTING CHARTS
1. Category of troubleshooting code number
Troubleshooting
Code No.
Component
E_cccontroller system
Troubleshooting of engine throttle
c-cc
Troubleshooting of pump controller
system
F-CC
Troubleshooting of pump controller
input signal system
H-cc
Troubleshooting of hydraulic,
mechanical system
P-G c ) Troubleshooting of monitor system
2. Method of using troubleshooting table
Troubleshooting code number and problem
The top left of the troubleshooting chart gives the troubleshooting code number and the prob-
lem with the machine.
Distinguishing condition
Even with the same problem the method of troubleshooting may differ according to the model,
component, or problem. In such cases, the troubleshooting chart is further divided into sections
marked with small letters (for example, a)), so go to the appropriate section to carry out
z
troubleshooting.
0
CJ
If the troubleshooting table is not divided into sections, start troubleshooting from the first
0
check item.
Method of following troubleshooting chart
Check or measure the item inside the box, and according to the answer follow either the
YES line or the NO line to go to the next box. (Note: The number written at the top right
corner of the box is an index number; it does not indicate the order to follow.)
Following the YES or NO lines according to the results of the check or measurement will
lead finally to the Cause column. Check the cause and take the action given in the Remedy
column on the right.
Below the box there are the methods for inspection or measurement, and the judgement
values. If the judgement values below the box are correct or the answer to the question
inside the box is YES, follow the YES line; if the judgement value is not correct, or the
answer to the question is NO, follow the NO line.
Below the box is given the preparatory work needed for inspection and measurement, and
the judgement values. If this preparatory work is neglected, or the method of operation or
handling is mistaken, there is danger that it may cause mistaken judgement, or the equip-
ment may be damaged. Therefore, before starting inspection or measurement, always read
the instructions carefully, and start the work in order from Item I).
General precautions
When using the troubleshooting chart, precautions that apply to all items are given at the top
of the page and marked with +. The precautions marked + are not given in the box, but must
always be followed when carrying out the check inside the box.
Troubleshooting tools
When carrying out the troubleshooting, prepare the necessary troubleshooting tools. For
details, see TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING.
20- 110
0 Installation position, pin number
A diagram or chart is given for the connector type, installation position, and connector pin
number connection table, so when carrying out troubleshooting, see this chart for details of the
connector pin number and location for details of the connector pin number and locations for in-
spection and measurement of wiring connector number o o appearing in the troubleshooting
flow chart.
< Example >
o E_2 mi
[Short circuit in governor motor1 is displayed
@ (There are cases where the troubleshooting is divided into Sections a), b) etc.)
+ If this happens during operation, because of the force of the spring:
I ) Engine speed changes to low idling
2) Engine does not stop
+ If the problem occured when the engine was stopped:
I) Engine starts but remains at low idling
2) Engine starts, but does not stop
A Stop the engine (place the fuel lever of the injection pump in the NO INJECTION posi-
tion) before carrying out any checks.
@ or Before carrying out troubleshooting, check that all the related connectors are properly
inserted.
Sr Always connect any disconnected connectors before going on to the next step.
YE
t
Red Green led
l 0 0
I* resistance be-
tween each pin of
H
E5 (male),and
ON OFF ON
each pin-chassis
as shown in Table
17
I .Trn starting
switch OFF.
. Disconnect ES.
2 YES
c
.Trn starting
snitch OFF.
i Disconnect El:
Short circuit in wiring
harmx* for problem
pEi;_NEOjj(between El-
See Fig. 7
20- 111
POINTS TO REMEMBER
TROUBLESHOOTING ON
SYSTEM
WHEN CARRYING OUT
The engine on the PC200, 220 is controlled by an engine throttle controller.
The problems that may arise with this system are as follows.
1. Low idling speed in too high (low)
2. High idling speed is too low
3. Auto-deceleration speed is too high (low)
4. Automatic warming-up speed is too high (low)
5. There is hunting
6. Engine does not stop
If an abnormality occurs and the abnormality is displayed by the self-diagnostic display, use the charts
to go to the applicable troubleshooting flowchart G-l - G-7. However, if there is no self-diagnostic
display, and there is an abnormality in the machine, it is necessary to determine if the problem is in the
mechanical system or in the electrical system.
For example, if there is defective adjustment of the linkage between the governor motor and injection
pump, the above problems 1 - 6 may occur.
Therefore, if any of the above problems
procedure.
1 - 6 occurs, carry out the following troubleshooting
YES 2
_ YES
Defective adjustmenr of governor
1
Doer oper at i on Of
d mof or linkage
_ governor motor
See TESTING AND ADJUSTING.
Does condition
beCOme normal
return to normal - when linkage
when linkage
befwee governor
motor and injeCtion
between governor pump is dirconnecred
Go to troubleshooting of electrical
motor and
NO
sYstem E-9 - E-l 1.
injection pump is _ . Set starting switch
di&onnected. and
pump governor
lever is operated
by hand or is
secured with
at ON p&ion and
operate fuel control dial
and working mode switch.
See Engine shop manual
NO
I If the engine does
not stop. push the
governor lever to
the STOP position
and check if the
engine stops.
After disconnecting or adjusting the linkage as shown above, go to the troubleshooting flow chart for
the mechanical system or electrical system.
* For details of the procedure for adjusting the linkage, see TESTING AND ADJUSTING.
E-l I? %?I [Abnormality in power source system or controller] is
displayed (All lamps OFF)
PC200,200LC-5 Serial No: 45001 - 48283
PC220,22OLC-5 Serial No: 35001 - 35447
When fuse 9 is not blown
(If it is blown, check for any short circuit with the ground in the circuit to the starting switch.)
If battery is normal.
Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Always connect any disconnected connectors before going on to the next step.
3 YES
I I I
gqotl
YES
!
Disconnect connect
YES tar El and replace
2- fuse 2. Does it blow
7 again
Repalce fuse 2. *
. Does it blow again? -
Turn starting
NO
switch ON.
I I
. Turn starting
switch ON.
NO
Does working lamp
light up?
NO
II
Y
5
YES
Is voltage between
- El (11 and El (12) .
normal?
* 20 - 3ov
4 . Turn starting
switch ON.
ES
I
NC
7 YES
Is there continuity
YES
between El
- (female1 (12) and -
6
battery relay termi-
nal E?
9 Turn starting NO
Is voltage between swtch OFF.
El (21 and chassis - . Disconnect El.
normal7
8 YES
* 20 - 3ov
* Turn starong
Is voltage between
switch ON.
starting switch ter-
NO
minal BR and
chassis normal?
. 20 - 3ov
. Turn starting
switch ON.
NO
* I urn stamng
switch ON.
YES
9s
Is voltage between
battery relay term,-
NO
al BR and chassis
normal
10 YES
-
* zo-3ov
Is voltage between
* Turn starting
L starting switch ter-
switch ON.
NO
minal BR and chas-
sis normal?
M20lM4)
* 20 - 3ov
* Turn starting
switch ON.
NO
Engine thronle controller
EI(MlCZI)
Starting switch MI(M~)
DIO
I ;
FUX
Ml4681
Battery
relay
I3
M7CL21 Battery relay
Battery
BR; b
+t-+/~/
774 F20505465
Already reset
Defective enigne throttle
controller
Defective contact, 01
disconnection in wiring
harness between El
(female) (12) - Ml4 (8) -
chassis ground
Defective contact, Or
harness between El
(female) (2) - M20 - Ml (21
- starting switch terminal
BR
Defective starbng switch
Defecwe contact. or
harness between El
(female) 11) and fuse 2
Outlet
Defective battery relay
Defective contact. or
harness between startina
switch terminal BFi - MleL2)
- M20 - D10 - M7 (2) -
battery relay terminal BR
Defective starting switch
Remedy
Inspect, repair
Replace
Repair or
reDlace
R+3W
Replace
Repair or
iepk%e
Replace
PC200,2OOLC-5 Serial No: 48284 - 58018
PC220,22OLC-5 Serial No: 35448 - 36613
+ When fuse 9 is not blown
j, If battery is normal.
+ Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Ir Always connect any disconnected connectors before going on to the next step.
Red Green Red
000
OFF OFF OFF
is fuse 2 blown?
ES
NO
3 YES
Disconnect connec-
YES tar El and replace
2 -
fuse 2. Does it blow
p agan?
Repalce fuse 2. . Turn starting
Does 11 blow again switch ON.
NO
* Turn starting
switch ON.
NO
Yl
4
Does working lamp
. Turn starttng
switch ON.
L
10
7 YES
Is rhere cont~~fy
YES
between El
- (femalei 112) and -
barrery relay terml
6
nal ET
. Turn starting NO
YES
Is voltage between switch OFF.
- E, (2) and chass,s - * Disconnect El.
!lOKlWi?
5--
fl YES
. 20 3ov
P . Turn starnng
Is voltage between
swtch ON
sfarnng swtch ter-
Is voltage between - m,nai ER and
El (11 and El (121
NO
- chassis normal?
normal?
. 20 - 3ov
NO
. 20 - 3ov
. Turn starttng
. Turn starttng
swlrch ON.
watch ON.
NO
9
Is voltage between
battery relay termi-
El
nal BR and chassis
normal7
* 20 - 3ov
* Turn starting
switch ON.
I
10 YES
. 20 - 3ov NO
. Turn staritng
switch ON.
F20505466
20-d7-1
Cause
/ Short circuit I wiring
harness between fuse 2 and
Controller
Remedy
Abnormality in engine
throttle controller
Already reset
Defecwe enigne throttle
controller
Defectwe contact. or
disconnection in wring
harness between El
(female) (12) - Ml4 181 -
chassis ground
Defective contact, or
harness between El
(female) (2) - D14 - M20
- Ml (2) - starting switch
terrmna, BR
Defective starting switch
Defective contact, 01
harness between El
(female) (1) and fuse 2
outlet
harness between starting
switch terminal BR - M1 (2)
- M20 - DlO - M7 (2) -
battery relay fermlnal BR
Defective stamng swlfch
Inspect. repail
Rf?plaC.?
ReplaCe
Replace
ReplaCe
20-1cA7-2
*
t
*
*
When fuse 9 is not blown
If battery is normal.
3 YES
Disconnect connec-
YES mr El and replace
2-
fuse 2. Does it blow
1 agan?
YES Repax fuse 2. . Turn starting
NO
_ Does it blow again? - switch ON.
. Turn starting
switch ON.
NO
Red Green Red
000
OFF OFF OFF
il
Is fuse 2 blown?
Is voltage between
El Ill and El 112)
switch ON.
6 1 b.;;;; relay term]- 1 Lo
. Turn starring
Y j
Is voltage between switch OFF.
- El (21 and chaws - . Disconnect El.
normal?
8 YES
- 20 - 3ov
. Turn starting
switch ON
Is voltage between
starnng swtch ter-
- m,nal ER and
NO
chaws normal
. 20 - 3ov
. Turn staeing
switch ON.
NO
Does working
light up?
* Turn starting
switch ON.
lamp
I
YES
9 I
* 20 - 3ov
. Turn starting
switch ON.
NO
I I/
Stamng switch MI(M~)
010
_
I=20505467
C~XSIS ground
disconnection in wring
harness between El
(female) (21 - D14 - M20 -
Ml (21 - starttng switch
terminal BR
. Defective starting switch
disconnectlon in wtrlng
harness between El
(female) (1) and fuse 2
$1 Defective battery relay
Remedy
Inspect. repaIr
20- !;8 7-4
-2
E-2 m [Short circuit in governor motor] is displayed
sr
*
A
*
*
If this happens during operation, because of the force of the spring:
I) Engine speed changes to low idling.
If the problem occured when the engine was stopped:
2) Engine starts, but does not stop
Stop the engine (place the governor lever of the injection pump in the NO INJECTION position)
before carrying out any checks.
1 Red Green Red
I.00
ON OFF ON
2 YES
Is resistance bet-
YES ween each pin of
, - El (female), and c
each pin - chassis
Is resistance be- as shown in Table
fween each pin of l?
- E5 (mae),and
each pin- chassis
- *Turn starting
as shown in Table
switch OFF.
I?
. Disconnect El.
l Turn starting
switch OFF. NO
0 Disconnect E5.
Table 1
E5 (male) El (female) Resistance value
(I) - (2) (3) - (14) 4-9R
(3) - (4) (4) - (15) 4-9.Q
(1) - (3) (3) - (4) Min. 1 Ma
(I) - (4) (3) - (15) Min. 1 Ma
Between pins (1). Between pins (3), (4),
(2). (3). (4) -chassis
(14), (15) -chassis
Min. 1 MA?.
Fig. 1
(MIC21)
\ 1
A (+I\ ti
CaUSe Remedy
Defective engi ne t hr ot t l e
c O t r Ol l er
Short c i r c ui t i n w i r i na
harness for problem -
pin No. (between El-
E2- E5)
* See Fig. 1
Def ec t i ve gover nor
mot or
ReplZXe
Repai r or
r epl ac e
ReplaCe
E2(Sl2) E5(X4)
Governor
motor
205FO5352-2
20- 118
0
E-3 m [Abnormality in battery relay] is displayed
PCZOO, ZOOLC-5 Serial No: 45001 - 58018
PC220,22OLC-5 Serial No: 35001 - 36613
Note: This occurs only when the engine is stopped and the starting switch is turned to the OFF position.
* The engine does not stop.
Astop the engine (place the governor lever of the injection pump in the NO INJECTION position)
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on to the next step.
Red Gr een Red -
1 YES
000 -
I s r esi st anc e bet w een
El (f emal e) (13)-
bat t er y r el ay t er mi nal -
OFF OFF ON
BR, w i r i ng har ness-
c hassi s nor mal ?
I 1
NO
I
.Bet w een El (13)-bat t er r el av BR: Max . l f l I
l Bet w een w i r i ng har ness - c has& : Mi n. 1 Ma
* Tur n st ar f i nq sw i t c h OFF. I
l Di sc onnec t El and bat t er y r el ay BR.
I
Def ec t i ve bat t er y r el ay
1) Cont ac t of w i r i ng
har ness bet w een El
(f emal e) (13) - M7
(2) - bat t er y r el ay B
w i t h ot her w i r i ng
har ness
2) When l amp i s
c onnec t ed
FL?0505468
When ON (appr ox . 24V)
Repai r or
rePlaCe
sw i t c h (El (2))
OFF
Vol t age out put f r om c ont r ol l er w hen st ar t i ng
When ON
- sw i t c h i s OFF
(appr ox . 24V)
Cont r ol l er c i r c ui t (Not e)
ac t uat ed (El (13))
To bat t er y r el ay 8 R
OFFJ
_ - Mi n.: 4.0 set
Dr i ve t i me Max .: 7 set (w hen i t i s i mpossi bl e t o set t o NO I NJ ECTI ON
bec ause of f ai l ur e of t he mot or )
205FO5354
Note: When the starting switch is ON, the controller is OFF, but a voltage of 20 - 30V is always
flowing from the starting switch BR, so if the measurement is made at El (I 31, the voltage is
20 - 3ov.
20- 119
' C
PCZOO, 2OOLC-5 Serial No: 58019 and up
Note: This occurs only when the engine is stopped and the starting switch is turned to the OFF position.
Ir The engine does not stop.
AStop the engine (place the governor lever of the injection pump in the NO INJECTION position)
. Between El (13)-battery relay (+) : Max. I.$2
l Between wiring harness - chassis: Min. 1 MR
*Turn starting switch OFF.
. Disconnect El and battery relay (+I
1) Contact of wiring
harness between El
(female) (13) - M7
(2) - battery relay I+)
with other wiring
harness
2) When lamp is
connected
m
N
Ml(M4)
Starting switch
M20
(M 4)
Battery relay
El(MIC21)
ReDlaCe
Repair or
replace
When ON (approx. 24V)
voltage from starting
switch (El (2))
To battery relay (+I
OFF
t from controller when starting
Controller circuit (Note)
actuated (El (13))
To battery relay (+I
OFF1
L 4 - Min.: 4.0 set
Drive time Max.: 7 set (when it is impossible to set to NO INJECTION
because of failure of the motor)
205FO5354
Note: When the starting switch is ON, the controller is OFF, but a voltage of 20 - 30V is always
flowing from the starting switch BR, so if the measurement is made at El (13). the voltage is
20 - 3ov.
20-A20
E-4 l;e. [Disconnection in wiring harness of governor
inotor] is displayed
Sr During operation:
I) If there is disconnection simultaneously in the A phase and B phase:
Engine speed changes to low idling
Engine does not stop
2) If there is a disconnection in either A phase or B phase:
The engine speed stays the same as immediately before the problem occured.
* If the problem occurred when th engine was stopped:
+ Always connect any disconnected connectors before going on to the next step.
2 YES
I 15 rerirtance I I
switch OFF.
. Disconnect E5.
Table 1
E5 (male) El (female) Resistance value
(1) - (2) (3) - (14) 4-9$?.
(3) - (4) (4) - (15) 4-9.Q
(1) - (3) (3) - (4) Min. 1 MS2
(1) - (4) (3) - (15) Min. 1 MSt
Between pins (11, (2). Between pins (3). (41,
(3), (4) - chassis (14). (15) -chassis
Min. 1 Ma
Fig 1
E I (MIC21)
Cat l se
Defective engine throttle
controller
harness for problem Pin
No. (between El - E2
-E5)
* See Fig. 1
Defective governor
m0tor
Remedy
ReplCXe
Repair or
r l 3pl aCe
Repl aCe
205FO5352-2
E-5 m [Abnormality in governor potentiometer] is
displayed
+ If the pump controller displays only 22, go to troubleshooting C-l 8.
Ir Before carrying out troubleshooting, check that all the related connectors are properly inserted.
+, Always connect any disconnected connectors before going on the next step.
Red Green Red
OFF ON ON
Governor mot or
potentiometer
display and pump
controller
display [221
Check display of
pump controller.
Gover nor motor
potentiometer
display only
.4.
Is resistance bet-
YES ween El (female)
- (6) - (6), (5) - -
3
(16). (6) - (16) as
shown in Table I?
I* resistance
between E4
- Turn starting
YES (male) (1) - (21, _
switch OFF.
- (1) - (3). (2) -
* Disconnect El
2
(3) as shown in
Table 17
Is re51stance
between El ifemale)
* Turn starting
- (10) - (20). and
switch OFF.
-
between (10). (20)
* Disconnect E4. ~0
-chaws normal?
1
. $$%_l Ma No
switch OFF.
-Disconnect El and C2.
8 YES
IS re$i*face
between each pin
YES
Qt El Ifemale)
7 - (6w(1610r between each
Is resistance
Pi - ctla**is as
between E4
ShDW in Table 17
(male) (1 I - (2).
- Turn starting
NO
- (1) - (31, (2) -
_
switch OFF.
(31 as shown in . Disconnect El.
L Table 17
* Turn starting
switch OFF.
* Disconnect E4.
NO
E I (lVlIC21)
C2(MIC21)
Pump controller
Fuel control dial
Governor potentiometer
source 5V
E2612) E4(X3)
F20505357
20- 122
0
6 YES
Is resistance bet-
ween El (female)
(7) - (81, (8) - -
(18). (7) - (18) as
shown in Table I? ND
_ ---
* Turn starting
switch OFF.
NO
. Disconnect E6.
NO
Controller
Wiring harness between
El (female) (7) - E6
(female) (I 1 in contact
with ground, or contact
with other wiring harness
Defective fuel
control dial
El (female) (6)-~2 (1)
-E4 (female) (1) in
contact with ground, or
contact with other
wiring harness.
Defective governor
motor
harness between E 1
(female) (10). (20) -
c2 (f&lalit) (IO), (20).
or contact with ground
Defective engine
throttle controller
Defective wiring
har ness in system where
resistance value is
defective
Defective governor
motor
Table I
E4 (male) E6 (male) El (female) El (female) Resistance value (Kn)
Between (I) - (3) Between (1) - (3) Between (6) - (16) Between (7) - (18) 4-6
Between (I) - (2) Between (I) - (2) Between (6) - (5) Between (7) - (8) 0.25 - 7.0
Between (2) - (3) Between (2) - (3) Between (5) - (16) Between (8) - (18) 0.25 - 7.0
- _
B;ty; (6) (5) (16) Between (7) (8) (18)
Min. 1 M.Q
- - chassis
Replace
Repair or
replace
Replace
Repair or
replace
Replace
Repair or
reDlace
Replace
Repair or
xplace
Replace
20- 123
0
E-6 VI [Abnormality in fuel control dial] is displayed
* When the relevant abnormality is displayed,
Pump controller abnormality display 22 is also dis-
played at the same time.
* Always connect any disconnected connectors before going on the next step.
YE
Red Gr een Red
ON ON ON
A . Tur n st ar t i ng
sw i t c h OFF.
. Di sc onnec t E6.
YI
2
w een El (f emal e)
(7) - (8). (7) -
(18). (8) - (18) as
show n i n Tabl e l ?
. Tur n st ar t i ng
sw i t c h OFF.
. Di sc onnec t El .
3 YE
m=
* Mi n. 100k .Q NI
* Bet w een w i r i ng
har ness - c hassi s:
Mi n. 1Ma
.* Tur n st ar t i ng
sw i t c h OFF.
* Di sc onnec t El and C:
\I 0
Tabl e 1
Fig. 1
E I (MlC21)
I
I
Def ec t i ve engi ne t hr ot t l e
c ont r ol l er
Shor t c i r c ui t i n w i r i ng
(f emal e) (101, (20) -
C2 (f emal e) (10). (20).
or c ont ac t w i t h ground
Def ec t i ve w i r i ng
har ness i n syst em w her e
r esi st anc e val ue i s
def ec t i ve
Def ec t i ve f uel c ont r ol
di al
C2(MIC21)
I / I
m
I
Sensor powe
(source kV 1
Remedv
Repl aCe
Repair or
re!Aace
Repair or
replaCe
Repl f l Ce
Pump controller
Fuel control dial
F20505358
2o-A24
E-7 j, [Abnormality in No. 2 throttle signal] is displayed
4 YES
Red Green Red
ON ON OFF
(19) -chassis as
shown in Table l?
J
* Turn startina
switch OFF.-
. Disconnect El.
(female) (9). (19)
- C2 (f emal e)
(11). (21) aSShoW
i n Tabl e 17
Turn starting
switch OFF.
Disconnect El
and C2.
between El
(female) (9) -
(19) as shown in
. Turn starting
switch OFF.
- Disconnect El.
. Turn startingswitch ON.
+ Switch working mode switch.
NO
Table 1
El (female)
El (female) -
C2 (female)
Resistance value
Engine throttle controller Pump controller
Between (9) - (19)
EI(MIC21) C2tMIC21)
-
Min. 1 MO.
Between (9)-chassis
-
Min. 1 MR
Between 119) -
0
-
chassis
Max. 1R
Between (9) - (11) Max. 1 s2
-
Between (19) - (21) Max. 1 n
205FO5358
Table 2 Voltage (V)
Condition when measuring PC200 PC220
(1) When overheating 4.0 - 4.25 4.0 - 4.25
(4) Heavy-duty mode
or H mode
Engine speed (rpm)
205FO5359
20-A26
Cont ac t of w i r i ng
(f emal e) (91, (19) -
c 2 (f emal e) (11). (21)
Di sc onnec t i on i n w i r i ng
(f emal e) (9). (19)-C2
(f emal e) (11). (21)
Wi r i ng har ness bet w een
El (f emal e) (9). (19)-
C2 (f emal e) (11). (21) i n
c ont ac t w i t h gr ound
I
Remedy
Repl ac e
r
Repl ac e
I ReDair or
I
Repai r or
r epl ac e
Repai r or
r epl ac e
20- 127
E-8 Engine does not start
PC200,2OOLC-5 Serial No: 45001 - 58018
PC220,22OLC-5 Serial No: 35001 - 36613
Sr When the starting motor does not turn.
* Check that fuse 9 is not blown before starting troubleshooting.
Sr Before carrying out troubleshooting, check that all the related connectors are properly inserted.
1
IS battery
voltage and
specific gravity
normal?
- Voltage:
Min. 24V
Specific
gravity:
Min. 1.26
YEE
. Turn starting
p,:Ih tosTA:T;\&[[
- Turn starting switch to START.
. Approx. 24\j
battery relay
when starting
switch is turned
- Turn starting
switch ON-OFF
Yl
6
starting switch
terminal 6
normal?
9 YES
Is there con-
YES tinuity between
8
- battery terminal -
(-) - battery
I* resistance of relay terminal-b?
YES
wiring harness
between starting
NO
7
switch BR-
battery relay BR
0
normal?
Is there ContinuitY * Between starting
S between starting _ switch BR- batter,,
NO
r switch terminal B relay BR: Max. 1 a
- terminal BR? * Between wiring harness- chassis: Min. 1 Ma
- * Disconnect at both starting switch and battery
* Turn starting
relay ends.
switch ON.
* Remove terminal B. NO
tester to (-) ierminz
of battery.
.20-29v
NO
Starting
motor
M 2(X 2) E8CSWP8) M14CS8)
P?
Fusible link
Starting
switch
205FO589 I
20- 128
8
Defective contact Of
wiring harness between
battery terminal (+) -
starting motor terminal 6
switch terminal C-Ml
(4)-Ml4 (l)-ES cl)-
M2 (1 j-starting motor
terminal S
1 zictive battery
Repl aCe
Repair
switch terminal BR - Ml
I
(2l- M20 - DIO - M7 (2) -
battery relay terminal BR
I
20- 129
Cc
* When the starting motor does not turn.
+ Check that fuse 9 is not blown before starting troubleshooting.
* Before carrying out troubleshooting, check that all the related connectors are properly inserted
Is battery
El
voltage and
specific gravity
normal?
. Voltage:
Min. 24V
Specific
gravity:
Min. 1.26
Starting
motor
battery rebf
when starting
switch is turned
- Turn starting
switch ON-OFF
P 1(
Yl
3
Is there any
sound of
starting motor
pinion moving
out?
4 YES
IS voltage between
; starting motor
terminal B -
chassis normal?
NO
+ Turn starting switch ON.
* Approx. 24V
5 YES
- Turn starting
switch to START.
Is voltage between
starting switch
ND terminal c -
chassis normal?
NO
* Turn starting switch to START.
. Approx. 24V
9 YES
Is there con-
YES
tinuity between
8 r battery terminal -
(-) - revolving
Is resistance of frame ground?
YES
wiring harness
between Starting
NO
::
7
r switch ER-
battery rew (+I
g
normal?
r*I
0
Is there continuity
YES between starting
* Between starting NO
_ switch BR - battery
switch terminal B relay (+) : Max. 1 Cl
6 -
terminal BR? * Between wiring harness- chassis: Min. 1 MO_
- * Disconnect at both starting switch and batterv
IS voltage at
* Turn starting relay ends.
starting switch _ switch ON.
terminal B
* Remove terminal B. NO
normal?
i
. connect (-) Pole ot
tester to (-) terminal
of battery.
- zo-29v
NO
3
M 2(X 2) E8CSWP8) M14CS8)
/ I pT9 :usible link
M37CMl) Fuse
M l(M 4)
aanery
I, M 7 CL 2)
Starting
switch
205FO5892
20- 1$9- l
1 Defective contact of
Defective starting
switch (between
terminals B- C)
Defective battery
relay
Defective contact of
battery terminal i-1 -
revolving frame ground?
switch terminal BR - Ml
(2) - M20 - DlO - M7 (21
battery relay terminal (+I
Defective starting
,.
SWl f Ch ,between
terminal B- BR)
harness between battery
termnal (+I - M38 -
M37 (1) -Ml (1) -
starting switch terminal
B (including fusible link)
. Battery capacity too low
Repair
Repair or
replace
Repl aCe
?eDlaCe
3epair or
eplace
Repair or
.ep lace
Replace
FIepair Or
-ep1ace
20- l=i9-2
E-9 Engine rotation is irregular
PC200,2OOLC-5 Serial No: 45001 - 48283
PC220,22OLC-5 Serial No: 35001 - 35447
al Idling rotation is irregular
* Before starting troubleshooting, check the model code.
+
*
Always connect any disconnectd connectors before going on to the next step.
YI
1
posi t i on w hen
l i nk age i s di s-
c onnec t ed?
* Tur n st ar t i ng sw i t c l
OFF.
2 YES
Adjust linkage
between governor
motor and injec-
tion pump. IDOe5
it become
nOrlTlal? NO
l See TESTI NG AND
ADJ USTI NG.
War mi ng-up si gnal 6 YES
I S vol t age I
Pot ent i omet er 1
- (16) normal
H zo-3ot i _ LO
bet w een El
normal and
PC200: 2.8V
pc220: 2.9v
NO
st abl e?
. At MI N.: I
4.0 - 4.75v
. At MAX.:
I
Ll n
0.25 - l .OV
M20(M4)
Fuel control dial
205FO5722
*O-A30
CaUSe
t-- Defective adjustment
of linkage
Defective injection
Pump
Defective governor
motor
See E-12
Defectwe contact of
starttng switch BR - Ml
(2) - M20 14). (3) -
El (female) (2). or
defective starting swtch
See E-5
see E-6
F
Remedy
Adjust
;ee Engine sho
nanual
20- 131
a
b)
*
*
*
Ther e i s hunt i ng
Before starting troubleshooting, check the model code.
IS lwtclr lever
aligned with dial
position when
linkage is dis-
connected?
* Turn starting
switch ON.
* Move fuel control Is voltage between
dial from MIN. to YES El (9) - (19) stable
MAX. and stop on and as shown in
the way.
Potentiometer 4
Tabl e 21
(ES
r
2 YES
Adjust l i nk age
bet w een gover nor
mot or and i n& x -
t i on pump. Does
i t bec ome
nor mal ?
Fuel control dial 3
IS voltage
between El
(8) - (18)
normal and
stable?
At MIN.:
4.0 - 4.75.v
At MAX.:
0.25 - l.OV
Y
No. 2 throttle
signal 5
I s vol t age bet w een
El 15) - (161 nor mal
and st abl e, and as
show n i n Tabl e 17
YES
Starting signal 7
IS voltaae
I normal and 1 1
stable?
I - When auto-decele-
ration operating: A
Max. 1 V
NO
. When auto-deceleration
canceled: 8 - 12V
NO
Table 1 Voltage (V)
Condition
At high idling
PC200 PC220
2.6-3.0 1 2.7-3.1
At low idling 0.5 - 0.9 0.5 - 0.9
When decelerating Approx. 1.9 Approx. 2.1
When warming-up Approx. 2.2 Approx. 2.4
Table 2 Voltage (V)
(1) When overheating 4.0 - 4.25 4.0 - 4.25
(2) 1 L.0 and L mode 2.06 - 2.36 2.18 - 2.48
I I
(3) G.O. F.O. L.0 and S mode
1.25 - 1.55 1.35 - 1.65
G.O. F.0 and L mode
(4) H.0 mode or H mode 0.75 - 1 .o 0.75 - 1 .o
Engine speed (rpm)
20-A32
205FO5362
Warming-up signal 8 YES
IS voltage
between El
- (21) - (12) -
normal and
stable?
. When warming-up NO
operating: Max. 1V
. When warming-up
canceled: 6 - 12V
Defective adjustment
of linkage
Defective injection
pump
Defective governor
motor
See E-l 2
starting switch BR - Ml
12) - M20 (4). (3) - El
(female) (2) - starting
switch, or defective
starting switch
see P-19
See E-7
See E-5
See E-6
Fuel control dial
Remedy
Adj usf
jee Engine she
nanual
Repl aCe
Repair or
replace
20- 133
' 7
a)
Ir
*
*
Idling rotation is irregular
Before carrying out troubleshooting, check that all the related connectors are properly inserted
Always connect any disconnectd connectors before going on to the next step.
2 YES
1 Adjust l i nk age I I
between governor
motor and i nj ec -
t i on pump. Doe*
it become H
ADJUSTING.
IS Voltaue I I
* Turn starting switct
OFF.
1 Is voltage
II
* Ah-- ooeratina: I
YES
rl
between El ( 51
- ( 16) normal
and stabl e?
.llrlI
_ 20-3( Iti - ho
NO
between El
normal and
At low idling
PC200: 2.8V
PC220: 2.9v
h
4.0 - 4.75v
. At MAX.:
I
0.25 - l.OV
NO
Starting
Ml(M4) Switch Ml(M4)
Engine throttle
Controller
El (MIC21)
Start signal
ISig)
Dial
PotentioniSig)
meter
(6)
potentiometer
F20505470
20-iz3-1
Remedy
of linkage
-,
starbng switch BR - Ml
(2) - M20 141. (3) - D14 -
El (female) (2). or
defective starting switch
See E-5
see E-6
Defective injection
Pump
Defective governor
motor
See E-l 2
Adjust
See Engine sho
nanual
Replace
20- 133- 2
b)
*
There is hunting
PC200 I PC220
1 I I
aligned with dial
position when
linkage is dis-
connected?
? YES
Adjust linkage
YES
betwean governor
motor and injec-
tion pump. Doer
it become
normal?
. Turn starting
switch ON.
. Move fuel control
dial from MIN. to
MAX. and stop on
the way.
YES
No. 2 throttle r
YES
Starting signal
I 7, r
Deceleration
Is voltage
between El
(2) - (12)
signal
I 5, I
1 ::czand 11
- When auto-decele-
2 4.0 -
%
: 3.0 -
%
k
.-
; 2.0 -
i;
;
4 P l.O-
Engine speed kpm)
205FO5362
ration operating: a
Max. TV
NO
* When auto-deceleration
canceled: 8 - 12V
YES
Is voltage between
El (9) - (19) stable
c and as shown in
Potentiometer 4
Table 2?
Is voltage between
YES El (9) - (16) normal _
and stable, and as
Fuel control dial 3
shown in Table l?
Is voltage
between El
-

18) - (181
normal and
NO
stable?

At MIN.:
4.0 - 4.75v
At MAX.:
I
0.25 - 1 .OV
NO
Table 1 Voltage IV)
Condition PC200 1 PC220
Table 2 Voltase (V)
(1) When overheating , 4.0 - 4.25 4.0 - 4.25
(2) L.0 and L mode 2.06 - 2.36 2.18 - 2.48
(3) G.0, F.O. L.0 and S mode 1.25 - 1.55 1.35 - 1.65
G.O. F.0 and L mode
(4) l-l.0 mode or H mode 0.75 - 1 .o 0.75 - 1 .o
20-23-3
Is voltage
between El
- (21) - (12) -
normal and
stable?
. When warming-up NO
operating: Max. 1 V
* When warming-up
canceled: 8 - 12V
n
CalEe
of linkage
Defective injection
pump
Defective governor
motor
See E-l 2
(2) - M20 141. (3) - Dl4
- El (female) (21 -
starting switch, or defec-
tive starting switch
see P-19
see E-7
See E-5
See E-6
Fuel control dial
F20505471
Remed,
Adjust
See Engine
lUUZ4l
ReDlace
Repair or
replace
E-10 Lack of output power (max. engine speed is too low)
PC200,2OOLC-5 Serial No: 45001 - 48283
PC220,22OLC-5 Serial No: 35001 - 35447
*
*
-k
mi
contact with
FULL stopper?
. Start engine.
- Fuel control dial
at MAX
- Heavy-duty
+H mode
Y
n
L
Is adjustment of
linkage between
governor motor
- injection Pump
normal? I
Yt
Potentiometer 4
YES
Is voltage between
El (6) - 116) normal
and stable, and as
Fuel control dial 3
shown in Table 17
Is voltage between
El (8) - (18)
normal and stable?
* At MIN.:
4.0 - 4.7511
Yl
No. 2 throttle
signal
5
El (9) - (19) stable
and as shown in
YES
Deceleration
Is voltage between
El (1:) - (12)
normal and stable,
ration operating: L
Max. 1V NO
* When auto-deceleration
canceled: S-12V
IO
. At MAX.: 1
0.2.5 - l.OV NO
YES
I Adiustlinkaqe I I
be;ween go&w
motor - iniec- Ll
. See TESTING AND
ADJUSTING.
Table 1 Voltage (V)
I Condition I PC200 I PC220 I
At high idling 2.6 - 3.0 2.7 - 3.1
At low idling 0.5 - 0.9 0.5 - 0.9
When warming-up Approx. 2.2 Approx. 2.4
Table 7 Voltage (V)
Engine speed (rpm)
205FO5364
20-ik34
Starting
Engine throttle
controller
E I ,MIC2,)
, I1
Cause
Defective injection
pump
Defective governor
motor
See E-l 2
Defectwe contact of
12) - M20 (4). (31 -
El (female) (2). or
defective starting switch
see P-19
See E-7
See E-5
See E-6
Defective adjustment of
governor motor linkage
Defective injection Pump
Remedy
ee Engine sho
IanUal
qeplace
Repair or
,eplaCe
Adjust
;ee Engine sto
nanual
205F05723A
20- 135
0
t Before starting troubleshooting, check the model code.
m
r
* start engine.
. Fuel control dial
at MAX
- Heavy-duty
in mclae
YI
Fuel control dial 3
YES Is voltage between
-El (8) - (18)
normal and stable?
2- . At MIN.:
_
Is adjustment of
4.0 - 4.75v
linkage between
. At MAX.:
- governor motor - o.*5 - 1.0
- injection pump
normal?
; 4.0
I
- 1
P
z 3.0
YES
Deceleration r
signal
6
YES lS Voltage between
No. 2 throttle
- El (ll)-(121 -
signal
5
normal and stable,
Is voltage between
* When auto-decele-
YES
El (9) - I191 stable ration operating: _ _
and as shown I Max. 1v NO
Potentiometer 4
Table Z? . When auto-deceleration
I I I
canceled: 8- 12
Is voltage between
El (5) - (16) normal
and stable, and as
shown in Table 17
t
NO
IO
YES
Adjust linkage
between 9oeror
L motor - injec- _
NO fion Pump. Does
it becqme
normal? NO
l See TESTING AND
ADJUSTING.
Table 1 Voltage (V)
When warming-up 1 Approx. 2.2 1 Approx. 2.4
Table 2
Engine speed (rpm)
205FO5364
2o-25-1
Warming-up signal fl YES
IS voltage I I
CaLI
/
Defective injection
pump
Defective governor
IllotCIr
See E-l 2
Defective contact of wiring
switch BR -Ml (2) - M20
(4). (3) - D14 - El Ifemale)
IZ), or defective ?.tart~ng
switch
see P-19
See E-7
See E-6
;I
Defective injection pump
Fuel control dial
Pump controller
F20505471
Remedy
;ee Engine she
WlllUal
3ep1ace
idjust
ee Engine sto
1aIlual
20- 1, 352
7,
E-l 1 Engine does not stop.
PC200,2OOLC-5 Serial No: 45001 - 48283
PC220,22OLC-5 Serial No: 35001 - 35447
* Before starting troubleshooting, check the model code.
I PC200 I PC220 I
YES
1
Has lever of
YES
governor stopped
in c~ntacf with
STOP stopper?
2
* Starting switch
Potentiometer 5 YES
ON-OFF
. Does engine
return to normal
When starting
_ when linkage is _
YES switch is OFF, is
NO adjusted?
Relay drive
4
- voltage between -
. Is loose spring When afarting -
El (5) - (16)
normal?
free of twisting? switch is OFF,
YES doe5 voltage
. When engine is NO
~~J~SST~~G~ AND Starting signal
between El (13) stopped:
3 - (12) change as pc200: 3.7-4.1v
shcw in Table l?
When starting
PC220: 3.8-4.2V
switch is OFF, is
- voltage between -
NO El (2) - (12)
NO
normal?
. Max. 1 v
NO
Table 1
y;kta;e(::;l;;arting ~(pprox 24v) To battery re,ay BR
OFF
(Note)
-----___
_ Voltage output from controller when starting switch is OFF
When ON
Controller circuit
actuated (El (13))
(approx. 24V)
OFF_
To battery relay BR
Min.: 4.0 set
Drive time
-Max.: 7 set (when it is impossible to set to NO INJECTION
205FO5366
Note: When the starting switch is ON, the controller is OFF, but a voltage of approx. 20 - 30V is
always flowing from the starting switch BR, so if the measurement is made at El (I 31, the vol-
tage is 20 - 30V.
20-T 36
8
GUSEZ
DlO
Defective injection
Pump
of linkage
Defective governor
motor
see E-5
Defective engine
throttle controller
Defectwe contact of
w,r,g harness between
starmg switch BR - Ml
12) - M20 (41. (31 -
El (female1 121. or
defectwe startmg swttch
i
Remedy
See Engine shol
nanu.3
Adiust
Replace
Repl aCe
El (MIC21)
Start signal
2.
Battery relay
drive
13
M20 (M4)
Ml(M4)
4 -2 Starting switch
Governor (Sig) 5
potentiometer
(6) 16
IC
Battery relay
F20505472
PC200,2OOLC-5 Serial No: 48284 - 58018
PC220,22OLC-5 Serial No: 35448 - 36613
PC200 PC220
Has lever of
governor stopped
L-t
in contact with
STOP stopper?
* Starting switch
ON-OFF
1
\I0
ES
YES
Does engine
return to normal
when linkage is
adjusted?
Is loose spring
free of twisting?
I
. See TESTING AND
ADJUSTING.
h
Starting signal 3
switch is OFF, is
voltage between
El (2) - (12)
. Max. 1V
I
Potentiometer 5 YES
NO
Table 1
~;~;;;e~~;;;;arxig .~(pprox~ 24v To battery relay BR
OFF
(Note)
______~_ _ Voltage output from controller when starting switch is OFF
When ON
Controller circuit
~_ ---1 (El (13))
(approx. 24V)
OFF
I
To battery relay BR
Min.: 4.0 set
- Max.: 7 set (when it is impossible to set to NO INJECTION
205FO5366
Note: When the starting switch is ON, the controller is OFF, but a voltage of approx. 20 - 30V is
always flowing from the starting switch BR, so if the measurement is made at El (I 31, the vol-
tage is 20 - 30V.
20- 137- l
014
El (MIC21)
Start signal
Battery relay
drive
Governor (Sigl
potentiometer
(-)
GND
L
M2OCM4)
Defective injection
pump
of linkage
Defective governor
motor
see E-5
Defective engine
throttle controller
switch BR - Ml (2) - M20
(4). (3) - D14 - El (female)
121, or defective starting
switch
i
Remedy
see Engine sho
nanuai
Adiust
Fi epl SX
E2612) E4(X3)
1
5
-2
16 3
DlO
2
I
M7(L2)
1 :
Battery relay
F20505473
*O-g7-*
Sr Before starting troubleshooting, check the model code.
governor stopped
in contact with
STOP stopper?
I
Potentiometer 5 YES
ON-OFF
NC
. Does engine
return to normal
When starting
when linkage is
YES switch is OFF, is
, adjusted?
Relay drive
4
- voltage between -
. Is loose spring
El (5) - (16)
When starting
_
free of twisting?
normal?
YES
switch is OFF,
_ does voltage
- When engine is NO
l ~&~ssT~~G. *ND Starting signal
between El (13) stopped:
3 - (12) change as pc200: 3.7-4.1v
-
When starting
3.8-4.2V show in Table I? PC220:
switch is OFF, is
- voltage between -
NC El (2) - (12)
NO
L
Table 1
YES
normal?
f Max. IV
When ON (approx. 24V)
Voltage from starting -,
switch (El (2))
I
- To battery relay (+j
OFF
(Note)
--_--___
1 When ON
- Voltage OUtPUt from controller when starting switch is OFF
Controller circuit
actuated (El (13))
(approx. 24V)
OFF_
To battery relay I+)
Min.: 4.0 sac
Drive time
- Max.: 7 set (when it is impossible to set to NO INJECTION
205F053E
Note: When the starting switch is ON, the controller is OFF, but a voltage of approx. 20 - 30V i
always flowing from the starting switch BR, so if the measurement is made at El (13). the vol
tage is 20 - 30V.
20-27-3
Defective injection
pump
Defective adjtistment
of linkage
Defective governor
motor
See E-5
Defective engine
throttle controller
harness between start,ng
switch BR - Ml (2) - M20
14). (3) - D14 - El (female)
12). or defective stafling
switch
D14 - -M2O(M4)
1 2 @@
El(MIC21)
I h 1 ,I. n \
Start signal 4
Battery relay
drie i7
A\ 1-Q Starting switch
1 Governor (Sig) 1 *
111 I \ 7,
,I -
-
lv/
E2 612) E4(X3)
1
=kBI
2 2
7 3
M7(L2)
\ I
25
See Engine she
nanual
ReDlace
ReplaCe
Repair or
replace
F20505474
20- 137- 4
0
E-l 2 Automatic warming-up operation is defective
* Warming-up is not carried out when the coolant temperature is under 3OC, or does not stop when
the coolant temperature goes above 30C.
(When it is canceled by the fuel control dial, there is no change in the voltage.)
Sr Conditions for carrying out warming-up:
I) Coolant temperature below 30C
2) Fuel control dial set at about 50% or below (warming-up signal: Max. 1 VI
* Conditions for canceling warming-up:
1) Coolant temperature above 30C
2) Fuel control dial raised to above 70% and kept there for at least 3 seconds in power set switch
H or S mode (see Note I)
+r Always connect any disconnected connectors before going on to the next step.
Note 1 :When the fuel control dial is turned up to cancel warming-up, warming-up will not start again
unless the starting switch is turned OFF and then turned ON again.
2:When the fuel control dial is turned up to cancel warming-up, the voltage of El (211 does not
change.
operation does
Table 1
Warming-up
operation is not
canceled
YES
(See Note 2)
21
* Start engine.
- Turn startina switch
OFF. -
- Disconnect El and
c2.
4 YES
* Warming-up: Max. 1 V
* Fuel control dial at MIN.
* Start engine.
E I (MIC21)
Wiring harness
Between El (feti6le) (21)
- chassis
CtW.ES
controller
see P-21
Disconnection in wirina
harness between El
(female) (21)- P2
(female) (11). or contact
with ground
controller
see P-2 1
Remedy
FC3plWX
Repair or
replaD
R@Z!Ce
Monitor panel
P2(04016)
Between El (female) (21)
- P2 (female) (11)
1 Max. 1 SL 1
205FO5368
20-l 38
0
PCZOO, 2OOLC5 Serial No: 58019 and up
Ir Check if fuse 1 is blown. If the fuse is blown, check if the wiring harness between the fuse 1 - Cl
(3) (4) is in contact with the ground.
YES Defective pump
controller
Repl Xe I
OFF
* 20-30V
. Turn starting
switch ON.
,s o,ta__ ^. _..*1,.*
end of .___
* 20-30V
_ I.._^ r*..l+:.%n
Is voltage berween
I-l I z1 -
M7 (1) - fuse 1
I
Pump controller
I
_ =- Ly
switch ON.
. 20- 3ov
- Turn starting
&itch ON.
Defective contact, or discon-
nection in wiring harness
(female) (1) - battery relay -
Repair or
repl aCe
n
Fusible link
relay
Battery
205FO57 7 I
*o-122-1
c-2 [ ?
.-.
,I [Short circuit in 2-stage relief . CO cancel
.
solenoid valve, 2-stage relief system] is displayed
When an abnormality occurs, [Oil and LO71 are displayed.
If the starting switch is turned OFF after the abnormality occurred, turn the starting switch ON, set
the power max. switch to ON, and check that 1011 and 1071 are displayed. (If they are not displayed,
the system has been reset.)
It is also possible to operate the travel lever (in this case, with the engine at high idling), or to turn
the swing lock switch ON.
* Disconnect Cl.
To P
Table 1
A-
3 YES
Is resistance
between VJ
(male) (1) - (2) -
as shown in
Table 17
NO
* Turn starting switch
OFF.
* Disconnect V7.
Serial No. Cl (female) VJ (male) Resistance value
PC200: 4500, _ 52JB3 Between 13)(4) - (15) Between (I) - (2) 50 - IOOR
PC220: 3500 - 36023 Between (15) - chassis Between (2) - chassis Min. 1MR
I
PC200: 52784 and up
PC200 MIGHTY
Between (3K4) - (15) Between (1) - (2) 24- 46Q
PC220: 36024 and up Between (15) -chassis Between (2) - chassis Min. IMR
Cause Remedy
Defective pump
controller
Contact between wiring
yarness of power source
and wiring harness
setween Cl (female)
:15j - v7 (female) (2)
3efective 2-stage relief *
:O cancel solenoid valve
M20(M4)
Repl aCe
qepair or
.epl Xe
3eL3l ace
2-stage
relief. CO
cancel
solenoid
valve
Z-stage
relief
solenoid D9
C-3 Is.3 1 [Sh or circuit in arm half flow solenoid valve t
*
*
-k
I
system] is displayed
If the starting switch is turned OFF after the abnormality occurs, turn the starting switch ON, set
the working mode switch to F.0 mode, and check that the display is [031. (If it is not displayed, the
system has been reset.)
c
\-\
.\A
w een Cl (f emal e)
(31 (4) - (6). (6)
- c hassi s as show n
OFF.
* Disconnect Cl.
2 YES
Interchange with
1
Table I?
* Turn starting
switch OFF.
* Disconnect V5.
Table 1
I Serial No. I Cl (female) I M3 (female) I M6 (female) I V5 (male) / Resistance value I
* I terchange V5 and V4.
a Turn starting switch ON.
* Turn working mode
switch to finishing mode.
VO
NC
1 To A
YES
41
. Turn starting NC
switch OFF.
- Disconnect M6.
j
I
I
I
I
I
s
CaW.e
Defective pump
Controller
Contact between
wiring harness of
power sorca and
wiring harness
between Cl (female)
(6)- M3 (female) (5)
harness of power sourca
and wiring harness
between M6 (female)
(6) - V5 (female) (2)
harness of power source
and wiring harness
between M3 (male) (5)
-M6 (male) (6)
3efective arm half f l ow
i ol enoi d val ve
Remedy
Replace
qepair or
ePlaCe
qepair or
eplace
?epair or
Wace
?eplace
Pc200: 45001 _ 52783 Betwee (3)(4) - (6) 1
Between (3) - (5) Between (7) - (6) Between (1) - (2) 10 - 35Q
Pc220: 35001 - 36052 Between (6) _ chassis
Between (5) - chassis Between (6) - chassis Between (2) - chassis Min. IMQ
PC200: 52784 and up Between (31(4) - (6) Between (3) - (5) Between (7) - (6) Between (I) - (2) 24 - 46R
PC200 MIGHTY
PC220: 36053 and up Between (6) - chassis Between (5) - chassis Between (6) - chassis Between (2) - chassis Min. 1MR
Pump controller
205FO5371-1
20- 144
0
c-4 [.I-\.--\
m \I [Short circuit in swing brake solenoid valve
* If the starting switch is turned OFF after the abnormality occurs, start the engine, operate the
swing, and check that the display is [04l. (If it is not displayed, the system has been reset.)
2 YES
~,
* Turn starting
switch OFF.
- Disconnect Cl.
operate swing.
1 WTOA
NO
YE
* Turn starting
switch OFF. NO
* Disconnect VI.
. Set swing lock
switch OFF
fl
PC220: 35001- 36023 between ( 8) - chassi s
PC200: 52784 and up Between (3)(4) - (8)
PC200 MIGHTY
PC220: 36024 and up Between (8) - chassis
between M3
(male) (1) - (9).
or between (1)
or (9) -chassis
in Table l?
switch OFF.
* Disconnect M3.
* Between (11 or (91
chassis: Min. 1MR
. Turn starting switch OFF.
. Disconnect M3.
I Defective swing
. Set swing lock switch OFF
zrake solenoid
lalve
~1
i \
I
EL
[
NC
-
CXSe
Defective pump
controller
and wiring harness
between Cl (female) (8)-
M3 (female) (9).
and wiring harness
between M3 (female)
cl)-VI (female) (2) ,
Defective swing lock
switch
a Contact between wiring
and wiring harness
between M3 (male) (l)-
lock switch-M3 (male)
(9)
Swing lock Swing lock
prolix switch switch
ON ~9 OFF ON 99 OFF
VI(X2)
I-
Remedy
Repl Xe
Repair or
.eplace
Repair or
-qace
Replace
Repair or
replace
RePl aCe
Fuse
M20(M4)
205FO5372- I A
c-5 1s.q
[Short circuit in travel speed solenoid valve system] is
displayed
* If the starting switch is turned OFF after the abnormality occurs, turn the starting switch ON, set
the fuel control dial to MAX. and the travel speed switch to Hi, and check that the display is [OS].
(If it is not displayed, the system has been reset.)
A- Always connect any disconnected connectors before going on to the next step.
2 YES
I nt er c hange w i t h
-. I ^
r el i ef sol enoi d
- I I I S r esi st anc e bet - 1
val ve. I s LO51
H LIA
H
ween CI (female)
I
(3) (4) - (16). (16)
. I nt er c hange V2 and V3.
- c hassi s gr ound as
show n i n Tabl e 17
H
- Tur n st ar t i ng sw i t c h ON.
7
- Pl ac e t r avel speed sw i t c h at Hi .
* Tur n st ar t i ng
sw i t c h OFF.
I
t c ToA
a Di sc onnec t Cl . No
3 YES
A-
I s r esi st anc e
bet w een V2
(mal e) (1) - (2) -
as show n i n
Tabl e I ?
. Tur n st ar t i ng NO
sw i t c h OFF.
- Di sc onnec t V2.
Table 1
~~220: 36024 and up Bet w een (16) - chassis Between (2) - chassis
Cause Remedy
Def ec t i ve pump
c ont r ol l er
Sont ac t bet w een w i r i ng
,ar ness of pow er sour c e
3nd w i r i ng har ness
x w .w een Cl (f emal e)
116)-V2 (f emal e) (2)
3ef ec t i ve t r avel speed
zol enoi d val ve
ReDlaCe
Pump controller
- M20IM4)
M3Bl6)
(i)@
I I 1
Fuse
Cl (MICl7)
I r-u I
3
L
I
_
solenoid
205FO5373-1
2o-A46
C-6 [.$-\]
[Short circuit in 2-stage relief l CO cancel
solenoid valve, CO cancel system] is displayed
* When an abnormality occurs LO1 1 and 1071 are displayed.
* If the starting switch is turned OFF after the abnormality occurred, turn the starting switch ON, set
the power max. switch to ON, and check that 1011 and [071 are displayed. (If they are not displayed,
the system has been reset.)
It is also possible to operate the travel lever (in this case, with the engine at high idling), or to turn
the swing lock switch ON.
\-\ \-\
i
J-L \
llnterchange with *[ v
~ ~TOA
* Disconnect Cl. No-
3 YES
1
* Turn starting NO
switch OFF.
Table 1
* Disconnect V7.
Serial No.
I
Cl (female)
I
V7 (male) Resistance value
I
Defective pump
controller
and wirina harness
between cl (female)
(7) - v7 (female) (2)
Defective 2.stage relief .
CO cancel solenoid
valve
PC200: 45001 _ 62783 Between (31(4) - (7) Between (1) - (2) 50 - IOOR
PC220: 35001 - 36023 Between (7) _ chassis
PC200: 52784 and up Between (3)(4) - (7) Between (1) - (2) 24 - 460
PC200 MIGHTY
PC220: 36024 and up Between (71 - chassis Between (2) - chassis Min. 1MR
M20(M4)
Pump controller
P359
I I
Fuse
FilZplaCe
1 2-stage
205FO5725
C-7 [.z::] [Short circuit in TVC solenoid sysem (I)] is displayed
* If the starting switch is turned OFF after the abnormality occurs, turn the starting switch ON, and
check that the display is 1081. (If it is not displayed, the system has been reset.)
* Turn the TVC prolix switch OFF.
switch OFF
. Disconnect C4.
*._&~
* Turn starting
switch OFF.
* Disconnect C5.
Table 1
4 YE! j
between C5
(male) (1) - (3).
(2) - (4) as shown
- Turn starting
switch OFF.
NC
* Disconnect C5.
IO
,
Cause
Defective pump controlls
Defective TVC solenoid
Wirino harness between
Cl (female) (9)-c5
(female) (1) in contact
with ground, or in contac
with GND wiring
* Wiring harness between
C5 (male) (I)-prolix
switch-C5 (male) (3)
in contact with g;ound,
or in contact with GND
wiring
* Defective TVC prolix
switch
C5 (female) (3)-C4
with ground, or in confac
with GND wiring
Cl (female) C5 (female) C4 (male) Resistance value
Between (9) - (17) Between (3) - (4) Between (1) - (2) lo-222a
Between (17) -chassis Between (4) - chassis Between (2) - chassis Min. 1 MR
Between C5 (male) (1) - (3). (2) - (4) Max. 1 D
n
I I
TVC prolix switch
ON OOFF
.
C5(M6)
5:
Fuse
o
$)
I
4
$g
C4fX7)
I:( ( 3 Resistor
Remedy
RePlXe
ReDlXX
Repair or
replace
Repair or
eplXe
lVC valve
CI(MICl7)
1 t-1 (4, 1
Pump controller
205FO5375-1
20- 148
0
C-8 [.z!z] [Short circuit in TVC solenoid valve system ( 211 is
displayed
+ If the starting switch is turned OFF after the abnormality occurs, turn the starting switch ON, and
check that the display is [091. (If it is not displayed, the system has been reset.)
+ Turn the TVC prolix switch OFF.
YE
1
\-\ \-\
H
Is resistance
between C4
.,_, . 1, (male) (1). - (2)
es shown I
Table l?
Table 1
. Turn starting
switch OFF.
* Disconnect C4.
2 YES
lZjZJH__,.,
. Turn starting switch
ClFF -.
- Disconnect Cl.
4 YE!
A -
Is resistance bet-
YES ween C5 (female)
3 - (I) -(3),(2) - -
1s resistance *
(4) es shown in
Table I?
between C5
N
(female1 13) - a Turn starting switch
chassis. (3) - (5) - OFF.
es shown in
* Disconnect C5.
Table I?
OFF.
. Disconnect C5.
NO
Defective pump ContrOllE
Cl (female) (9)-C5
with ground, or in contac
with GND wiring
* Wiring harness between
C5 (male) (1 )-prolix
switch- C5 (male) (3)
in contact with ground,
or in contact with GND
wiring
* Defective TVC prolix
switch
Niring harness between
35 (male) (3)-C4 (fernall
1) in contact with groum
)r in contact with GND
wiring
I
Cl (female)
I
C5 (female)
I
C4 (male) 1 Resistancevalue 1
I I I
Between (9) - (17) Between (3) - (4) Between (1) - (2) lo-22s1
Between (17) - chassis 1 Between (4) - chassis Between (2) - chassis I Min. 1 Ma
I
Between C5 (male) (1) - (3). (2) - (4) Max. 1 n
TVC prolix switch
tzzlM20(M41
Remedy
Replace
Replace
Repair or
X?Pl?G?
Repair or
reDlace
qepair or
x!place
CI(MICl7)
I I
Pump controller
20%05375-l
20- 149
0
c-9 [. \. :]
[Disconnection in 2-stage relief . CO cancel
solenoid valve, 2-stage relief system] is displayed
* Display and location of abnormality
1) When [I 71 is displayed at the same time
i) If there is a disconnection in the solenoid or up to portion (a) of the wiring harness, the sole-
noid does not work.
ii) If solenoid pin (2) is in contact with the ground, the solenoid remains actuated.
2) When [I 11 only is displayed
If there is a disconnection in portion (b) of the wiring harness, the solenoid works normally.
check that the display is [I 1 I. (If it is not displayed, the system has been reset.)
* If [I 11 is displayed, start the engine, and if there no difference in the digging force between when
the power maximizing is actuated and when the switch is not actuated, start troubleshooting from
Item 4 in the flow chart below.
YE
1
\ \
H
Is voltage betweer
. 1.
Cl (15) - chassis
normal?
. Lever at neutral: 20 -30v
- Lever operated: Max. 3V
. Turn starting switch ON.
l Travel lever operated,
power maximizing switch
ON, or set swing lock
switch ON.
Table 1
2 YES
ElT
YES
I
NO
3
Is resistance
between Cl
_ (female) (3) (4) _
- (15). (15) -
4 YE
chassisasshown ~ -
in Table 17 Is resistance
~ between V7
. Turn starting switch,
OFF.
NO
(male) (1) - (2) -
* Disconnect Cl.
as shown in
Table l?
I\
OFF.
* Disconnect V7.
I Serial No.
C1(female 4
PC200: 52784 and UP Between (3)(4) - (15)
2220: 36024 e,,d up &.tWeen (15) -chassis Between (2) - chassis Min. IMQ
CaLIS?
Defective pump controller
Already reset
3isconnection in wiring
,aress between Cl
:female) (3). (4). (15)-
V7 (female) (1) (2). or
Niring harness between Cl
Ifemale) (15)-V7 (female
I2) in contact with ground
Iaefective 2-stage relief *
:o cancel solenoid valve
Remedy
Pump controller
CI(MICl7)
V7(X2)
205FO5377-1
c-1 0 [. :.s]
[Disconnection in arm half flow solenoid valve
* If there is a disconnection in the solenoid or wiring harness, the circuit up to the solenoid is not ac-
tuated. If pin (2) of the solenoid is short circuiting with the ground, the circuit up to the solenoid
stays actuated.
check that the display is [I 31. (If it is not displayed, the system has been reset.)
* If [I 31 is displayed, start the engine, and if there is no difference in the ARM IN speed between F.0
mode and G.0 mode, start troubleshooting from A in the flow chart below.
jr Before carrying out troubleshooting, check that all the related connectors are properly inserted.
2 YES
$$jZ?LJ~
1 -\ _
.
Is voltage
- Turn starting switch
,. LX
between Cl (6) _,
ON.
- chassis
norlal?
NO 3 YES
. Turn starting switch ON. Is resistance
. Finishing, lifting
between c1
mode: Max. 3V
_ (female) (3) (4)
. Heavy-duty, general
- (6). (6) -
mode: 20 - 30V
chassis as show
in Table 17 NO
Turn starting switch
- To A
OFF
- oi&..t 0,.
A--r
YES
between M3
5-
(male) (3) -
(5). (5) - chassis
as show in
Is resistance bet- Table I?
YES wee MS (female)
&
I- (7) - (6), (6) -
a Turn starting switch
-
chassis as shown in
OFF.
4
- Table l?
* Disconnect M3.
Is resistance bet-
ween V5 (male)
- Turn starting switct-
(I) - (2). (2) - - OFF.
* Disconnect M6.
NO
chassis as shown in
Table l?
OFF.
* Disconnect V5. ND
Defective pump
controller
Already reset
Disconnection in wiring
harness between Cl
(female) (3)(4)-M3
(female) (3)(5), or
Cl (female) (6)-M3
with ground
harness between M3
(male) (3)(5)-~6
(male) (7)(6), or wiring
harness between M6
(female) (5)- M6 (male)
(6) in contact with
ground
larness between M6
Ifemale) (7) (6) - V5
[female) (1) (2). or wiring
harness between M6
Ffemale) (7) - V5 (female
2) in contact with grounc
Defective arm half
flow solenoid valve
Remedv
Replace
qepair or
ep1ace
qepair or
eplace
leplace
Table
Serial No. Cl (female) M3 (female) M6 (female) V5 (male) Resistance value
PC200: 45001 _ 52783 Between (3)(4) - (6) Between (3) - (5) Between (7) - (6) Between (1) - (2) 10 - 350
PC2201 35001 - 36052 Between (6) _ chassis
Between (5) - chassis Between (6) - chassis Between (21 - chassis Min. 1MR
PC200: 52784 and up
PC200 MIGHTY
Between (3)(4) - (6) Between (3) - 15) Between (7) - (6) Between (1) - (2) 24 - 46R
PC220: 36053 and up Between (6) - chassis Between (5) - chassis Between (6) - chassis Between (2) - chassis Min. lM62
Pump controller
205FO5371.1
r ,
C-l 1 /_ \J-\ i [Disconnection in swing brake solenoid valve system]
c
is displayed
If there is a disconnection in the solenoid or wiring harness, the circuit up to the solenoid is not ac-
tuated. If pin (21 of the solenoid is short circuiting with the ground, the circuit up to the solenoid
stays actuated.
If the sta,rting switch is turned OFF after the abnormality occurs, turn the starting switch ON, and
Always turn the swing lock prolix switch OFF, and set the swing lock switch at OFF before starting
to check.
If [I 41 is displayed, start the engine, and if the swing holding brake is not released when the swing
is operated, start troubleshooting from Item 4 in the flow chart below.
2 YES Defective pump
tn same condi- I 1 A
controller
\\ \_
IS voltage
ON.
between Cl (8) _
. Turn swing lock
. \ . -\ ;os%;
switch 0 F F.
YES
- Lever at neutral: 20 - 3ov
3
* Lever operated: Max. 3v
Is resistance
* Turn swing lock switch OFF.
between Cl
* Turn starting switch ON. NG (femae) (3) (4) -
- (8). (8) -
chassis a* show
4 YE:
in Table l? 15 resistance
A
j
TO A
between 1
: ;e%;v$gal~; switch OFF. NC
(male) (1) -
(2). (2) -
chassis as shown
in Table 17 N
OFF.
c I
* Disconnect Vl.
6 YE:
[
t
it
c Iround
YES
Is resistance be-
_ tween M3 (male) _
5 (1) - 19). (1) or (91
Is resistance
- chassis normal?
between M3
Nl 3 .
A-
(female) (3) - * Turn staning switch OFF.
(1). (1) - - . Disconnect M3.
chassis as shown * Between (11 - (9): Max. lr
in Table 17
\ . Between (1) or (91 -
. Turn Startina switch chassis: Min. 1Mn
OFF. -
5
- 1
* Disconnect M3. No
Y
F
>isconnection in
viring harness between
d3 (female) (1). (3)
-Vl (female) (l)(2),
)r wiring harness
etwee M3 (female)
l)-Vl (female) (2)
n contact with ground
CaUSe
3efective swing brake
;olenoid
Jisconnectio in wiring
,amess between Cl
female) (8)- M3 (female)
9). or contact with
~;~c;tive swing lock
harness between M3
(male) (I) - lock switch
- M3 (male) (9). or
contact with ground
Table 1
Serial No. Cl (female) M3 (female) VI (male) Resistance value
PC200: 45001 _ 52783 Between (3)(4) - (8) Between (3) - (1) Between (I) - (2) 10 - 35R
Between (1) - chassis Between (2) -chassis Min. IMQ
PC200: 52784 and up
Between (3K4) - (8) Between (3) - (1)
PC200 MIGHTY
Between (1) - (2) 24 - 46R
PC220: 36024 and up Between (8) - chassis Between (I) - chassis Between (2) - chassis Min. IMR
swng lock
pro,,x 5Wleh
;v$;t l0Ek
ON QJ OFF
Already reset
Remedy
=i?plaCe
qi?plaCe
7epair or
ep1ace
c-12 [. :.q
[Disconnection in travel speed solenoid valve system]
L
is displayed
If there is a disconnection in the solenoid or wiring harness, the circuit up to the solenoid is not ac-
tuated. If pin (2) of the solenoid is short circuiting with the ground, the circuit up to the solenoid
stays actuated.
If the starting switch is turned OFF after the abnormality occurs, turn the starting switch ON, set
the travel speed switch to Lo, and check that the display is [I 51. (If it is not displayed, the system
has been reset.)
If II 51 is displayed, start the engine, and if the speed does not become Hi when the travel speed
switch is set to Hi and the engine is at high idling, start troubleshooting from A in the flow chart
below.
1 \-
--t
. L,\
2 YES
I same condition
YES as when measuring
r Item 1, is [151
t
1 1
displayed7
NO A
Is voltage between ON.
- Cl (16) -chassis -
nromal?
3 YES
* At Lo: ZO-30V
Is r esi st anc e
* At Hi: Max. 3V
between Cl
- Switch travel
I (female) (3) (4)
NO
- (16). (16) - -
speed switch.
chassis as show
in Table 17 NO
ON.
-
OFF.
* Disconnect Cl.
To A
4 YE
A----El
OFF.
. Disconnect V2.
Table 1
PCZOO: 52784 and UP Between (3)(4) - (16)
pC220: 36024 and up Between 116) - chassis
Cause Remedy
Defective pump
30tr011er
Qplace
Already reset
-,arness between Cl
(female) (3) (4) (16) -
V2 (female) (1) (2). or
airing harness between
Cl (female) (161 - V2
with ground
Defective travel speed
.olenoid valve
Pump controller
M20tM4)
M3(Sl6)
Fuse
Repair or
.eplace
SeplXe
Cl (MICl7)
TGWel
speed
solenoid
205FO5373-1
20-;53
d
C-l 3 1 :J-:] [Disconnection in Z-stage relief l CO cancel
c . J
solenoid valve, CO cancel system] is displayed
Display and location of abnormality
1) When [I 11 is displayed at the same time
i) If there is a disconnection in the solenoid or up to portion (a) of the wiring harness, the sole-
noid does not work.
ii) If solenoid pin (2) is in contact with the ground, the solenoid remains actuated.
2) When [I 71 only is displayed
If there is a disconnection in portion (b) of the wiring harness, the solenoid works normally.
If the starting switch is turned OFF after the abnormality occurs, turn the starting switch ON, turn
the swing lock switch ON, and check that the display is [I 71. (If it is not displayed, the system has
been reset.)
If [I 71 is displayed, start the engine, and if there no difference in the digging force between when
the swing lock switch is ON and when the swing lock switch is OFF, start troubleshooting from
A in the flow chart below.
Item 1, is 1171
1
displayed?
NO
\ \-\
Is voltage between ON.
. \. \ - ::r::,; chassis - NO
3 YES
* At swing lock switch 15 resistance
ON: Max.3V tx?*ween Cl
At swing lock switch _ (female) (3) (4) _
OFF: 20 - 30V
- (7). (71 -
chassis as show
ON.
in Table 17 NO
c TOA
OFF.
. Disconnect Cl.
4 YE
A~-----~[
OFF.
Table 1
* Disconnect V7
Serial No. I Cl (female) I v7 (male) I Resistance value
pC200: 4500, _ 52763 Between (3)(4) - (7)
Between (I) - (2) 50 - loon
Between (2) - chassis Min. IMQ
PC200: 52764 and p Between (3)(4) - (7) Between (I) - (2) 24 - 46Q
PC200 MIGHTY
PC220: 36024 and up
Between (7) - chassis Between (2) - chassis Min. 1MQ
CaUSe Remedy
Defective pump
controller
Alreadv reset
larness between Cl
ifemale) (3) (4) (7) -
v7 (female) (1) (21, or
miring harness between
Cl (female) (7) - V7
rfemale) (2) in contact
Nith ground
Zlefective 2-stage relief .
:O cancel solenoid valve
n
Pump controller
CIwICl7)
\ I
mq-g
Replace
V7(X2)
I5 D9
205FO5381-1
C-M- [. m]
\ -\ [Disconnection in TVC solenoid valve system] is
displayed
Sr If there is a disconnection in the solenoid or wiring harness, the circuit up to the solenoid is not ac-
tuated. If pin (2) of the solenoid is short circuiting with the ground, the current (approx. IA) con-
tinues to flow to the solenoid.
Sr If the starting switch is turned OFF after the abnormality occurs, turn the starting switch ON, and
* Turn the TVC prolix switch OFF.
I
OFF.
- Disconnect C4.
NO
a Disconnect C5.
* Disconnect C5.
I
Defective pump
controller
TO A
harness between C5
(female) (3). (4)-C4
(female) (l), (2), or
C5 (female) (4)-C4
with ground
harness between C5
(female) (1). (2kCl
(female) (9). (17). or
C5 (female) (2)-Cl
with ground
Defective TVC prolix
switch, or defective
switch-C5
Table 1
Cl (female) c5 (female) c4 (male)
Resistance value
cs2,
Between (9) - (17) Between (3) - (4) Between (1) - (2) 10-22
Between (17) - chassis Between (4) - chassis Between (2) - chassis Min. 1 MS2
Between C5 (male) (1) - (3). (2) - (4) Max. 1
TVC prolix switch
M20(M4)
Remedy
Replace
Repair or
replaCe
Replace
Repair or
replace
Repair or
replace
ON
Resistor
Pump controller
205FO5375-1
20- 155
0
c-15 [.2. q
[Abnormality in No. 2 throttle signal system] is
displayed
check that the display is 121 I. (If it is not displayed, the system has been reset.)
i Always connect any disconnected connectors before going on to the next step.
Yl
. Min. IMKL
* Disconnect C2 and
El.
* Turn starting Switch
OFF.
3 YE
Is same condition
- Item 2, is [211
2
displayed?
h
IS voltage
, between C2(11) _
ON.
- (12) as show
in Table 11
4 YE
- Turn starting switch Remove El. Is
ON. voltage between
* Switch working L El (female) (19) -
mode switch. ND - (9) as shown in
Table 17
I\
ON.
- Switch working
mode switch.
* Disconnect El.
I O
4 4.0 - 0
i!
: 3.0 -
5
._
:
z 2.0 -
i
I
N
p 1.0 -
CC+JSE!
Defective pump
COntrOllar
Already wsaf
Defective engine
throttle ContrOller
Defective pump controller Replace
Disconnection in wiring har-
ness between C2 (female)
(11). (21) - El (female) (91,
(19). or contact with ground
Remedy
Repl aCe
ReplaCe
Repair or
WJlace
El (MIC
Pump controller
C2(MIC21)
205F05383-K
Engine speed (rpm)
C-16 [_z_z] [Abnormality in throttle signal system] is displayed
* If an abnormality is displayed for the engine throttle controller, go first to troubleshooting E-6.
+I Always connect any disconnected connectors before going on to the next step.
2 YES
I same condition
- item 1, is [221 -
1
displayed?
NO
-\ -\ IS voltage
ON.
.K .\z
- between C2 (10) -
- (20) normal?
3 YES
. 0.25-4.75V
. Turn starting switch ON.
* Fuel control dial
Is voltage
MIN.-MAX.
N; between El (10) -
- (20) normal?
t-=-Y=
Defective pump
controller
ReplaCe
Already reset
harness between C2
(female) (lo), (20) - El
(female) (10). (20). or
C2 (female) (10) - Ml5
(1) - El (female) (10) in
contact with ground
Pump controller Engine throttle controller
Repair or
replace
205F05385A
20- 157
0
c-1 7 [.2.3]
[Abnormality in front pump pressure sensor signal
check that the display is [231. (If it is not displayed, the system has been reset.)
i Always connect any disconnected connectors before going on to the next step.
2 YES
In same condition
as when measuring
Item 1, is 1231 -
displaYed?
NO
* Turn startina switch
YI
* 0.5 - 4.5 v
. Start engine.
(High idling)
+
* Repeat arm relief.
Pump controller
ON.
5 YES
- Start engine.
(High idling)
+
* Min. 1MG?. 1
- Turn starting
switch OFF.
;;:
NO
- Disconnect C3
and C8.
z
C3IMIC9) C8(X3)
Front pump
pressure sensor
Rear pump
pressure sensor
205FO5386-1
Defective pump
controller
Already reset
disconnection in
C3 (female) cl)-C8
(female) (1)
Defective front pump
oressure sensor
I disconnection in wirmg
harness between C3
(female) (3)-C8 (female)
(2)
harness between C3
(female) (6). cl)-C7. C8
(female) (3), (1). or
contact with ground
Replace
Repair or
reDlace
ReplaCe
Repair or
replace
Repair or
reDleG?
20- 159
C- 18 I.2 _4] [Abnormality in rear pump pressure sensor signal
2 YES
In fame conditions
- Item 1, is [241 -
displayed?
NO
ON.
T-t
7 \ \
\- -\
e-0
1
5 YES
Is voltage
- betweenc3 (7) -
- (21 normals YES
IS voltage
4
- between C7 (3) -
- ( 1) normal?
* 0.5-4.5v
* Start engine.
(High idling)
YES IS VOltage between
- c7 (2) - (1)
- 0.5-4.5v NO
+
3
normal?
* Start engine.
* Repeat arm relief. p
(High idling)
Is resistance
+
between c3
* 18-28V
- (female) (7)
NO
- (2). (71 -
_ . ;;.n starting switch-N0
chassis normal?
- Min. IMQ.
* Turn starting L
switch OFF. NO
* Disconnect C3
and C7.
Pump controller
C3IMIC9) C8(X3)
pressure sensor
205FO5386-1
20- 160
0
disconnectin in
wring harness
between C3 (female)
(2) - C7 (female) 11)
Defective rear pump
pressure sensor
disconnection in
C3 (female) (3)- C7
Ifemale) (2)
Short clrcut m wiring
harness between C3
(female) (7). (2) -
C7-C8 (female) (3).
(1). or contact with
I
ground
Repl ac e
Repair or
eplace
Replace
qepair or
eplace
qepair or
epl ac e
*O-2
C-19 [_s.=,] [Ab normality in pressure sensor power source,
check that the display is 1251. (If it is not displayed, the system has been reset.1
YES
2 I
. 18-28V
ON.
ES
r[
Is same conditi-
ons as when
measuring
Item 1, is I251
displayed?
NO
Disconnect C8.
. 18-28V
. Turn startina switch
ON. -
Disconnect C7.
Is voltage
between C3 (3)
- 12) normal?
I
YES
AI
H
* Disconnect ~7. L
- 18-28V NO
* Turn starting switch CnaSSlS normal
ON.
_.
a Disconnect C3, C7.
and C8.
Pump controller
C3IMIC9) C8(X3)
Front pump
pressure sensor
Rear pump
205FO5386-1
20- 162
0
Cat I %?
Defective pump
controller
Already reset
Defective front pump
pressure sensor
Defective rear PumP
pressure sensor
Defective pump
controller
Dwonnecton in wnng
harness between C3 (fe-
male1 (1) and C8 (female)
(1 I, C3 (female1 (31 and
C8X7 (female) (2). C3
(female) (2) and C7 (fe-
male) (1). or contact
with ground
*O-P3
c-20 [.2.;J)
[Abnormality in engine speed sensor system] is
displayed
Ir If the starting switch is turned OFF after the abnormality occurs, turn the starting switch ON, and
Note: If the decimal point on the pump controller self-diagnostic monitor display does not flash when I
the engine is started, go to troubleshooting F-8.
Call% Remedy
3 YES
Defective pump
controller
YES
When engine is
2
- started, is [261 -
displayed?
Is resistance
Already reset
YES
between C3 * Start engine.
NC, (see Note)
Note
1
- (female) (8) - -
(4) normal?
Dlscoectlo Ill wlrlng
Is resistance
harness between C3 (female)
between E7 _
(male) (1) -
(2) normal?
Pump controller
C3(MIC9) M3@16) E2 (St21 E7(X21
Engine
speed
sensor
205FO5389-2
20- 164
0
c-21 [.28] [Abnormality in auto-deceleration signal output
* When the auto-deceleration switch is ON.
* If the starting switch is turned OFF after the abnormality occurs, turn the starting switch ON, turn
the auto-deceleration switch ON, then operate the control lever (Neutral - operated), and check
that the display is [281. (If it is not displayed, the system has been reset.)
2 YES
Iln same conditions1
Item 1, is [281 -
1
OFF.
- I&symect C2 and
Table 1
Defective pump
controller
Already reset
Defective engine
throttle controller
Disconnection in
C2 (female) (19)-El
(female) (11). or
contact with ground
Operation Voltage between C2 (female) (19) - chassis
Auto-deceleration switch ON. lever at neutral I O-l v
1 Auto-deceleration switch OFF, lever at neutrall 8-12V
I
Replace
Replace
Repair or
.epklce
Table 2
connector Resistance value
Between C2 (female) (19) - El (female) (11) Max. la
Between C2 (female) (19) -chassis Min. 1 Ma
Pump controller Engine throttle controller
C2(MIC21)
Auto-
deceleration @
EI(MIC21)
P\
12 GND
205F05390A
20-l 6$
0
c-22 [.a.q [Abnormality in overheat signal system] is displayed
Sr If [291 is displayed again when engine is restarted.
jr Always connect any disconnected connectors before going on to the next step.
CaWX Remedy
YES See Engine shop
1
manual
-\ 1-1 _
Does monitor
\- -\
panel display - YES
overheating?
Defective Pump Repl aCe
2
c ont rol l er
.-.-
. Turn starting
switch ON.
Is voltage between
N; C2 (l7), (18) - (8) -
normal?
3 YES Defective monitor
Is resistance bet-
panel
RepleCe
p
. When normal:
ween P2 (female)
lo-13v
- (12). (13) - (16), -
* When overheated:
ND (12) (13) -
chassis normal?
harness between C2
o--1v (female) (171, (18)-
Repair or
* Start engine
- Min. IMQ P2 (female) (12). (131,
repl aCe
- Disconnect C2 end or contact with ground
P2.
PC200-5 Serial No.: 45001 - 58018
PC220-5 Serial No.: 35001 - 36613
Pump controller Monitor panel
C2IMIC 21) P2(040 16)
205FO5391 A
C2(MIC21) P2(040 16)
205FO5391 A
c-23 I%$$$ [Controller abnormal system] is displayed
CEUSS? Remedy
Defective pumP
controller
ReplaCe
20- 167
TROUBLESHOOTING OF PUMP CONTROLLER
INPUT SIGNAL SYSTEM
(F MODE)
Failure mode
F- 1 Pump controller monitor does not display [PI 1 . . . . . . .
F- 2 Pump controller monitor does not display [P21 . . . . . . . .
F- 3 Pump controller monitor does not display [P61 . . . . . .
F- 4 Pump controller monitor does not display Lb51 . . . . . . .
F- 5 Pump controller monitor does not display [Hi or Lo1 . . . .
F- 6 Pump controller monitor does not display [AdI . . . . . . . .
F- 7 Pump controller monitor does not display [UP1 . . . . . . .
F- 8 Pump controller monitor does not display LC. 1 . . . . . .
F- 9 Pump controller working mode display does not switch .
F-l 0 Pump controller power mode display does not switch . . .
. .
. .
. .
. .
.
. .
. .
. .
20-170
20-171
20-173
. 20-174
20-175
. 20-176
20-177
20-178
. 20-179
20-180
20-A69
F-l Pump controller monitor does not display
equipment oil pressure switch]
PC200,200LC-5 Serial No: 45001 - 49706
PC220,22OLC-5 Serial No: 35001 - 35661
*
*
A
*
sr
+
\2 \
.\ . \
J
[Work
After starting the engine, and operating the work equipment (boom, arm, bucket) levers, it is dis-
played for approx. 1 sec.
If it is not displayed for any of the boom, arm, or bucket systems when the control lever is operated,
carry out the troubleshooting below.
If it is not displayed for only one or two of the systems, the shuttle valve in that circuit is defective.
When measuring with the engine started, operate the levers without moving the work equipment.
When measuring with the engine stopped, charge the accumulator before measuring.
Is voltage betweer
L-
Cl (1) - (121,
(13) normal?
- Lever at neutral:
zo-3ov
* Lever (boom,
arm, bucket)
operated:
Max. 1 V
* Start engine.
CalATe Remedy
2 YES
In same conditi-
ons as when
measuring Item 1,
is [PI 1displayed?
* Start engine. NO
* Operate lever
(boom, arm,
bucket)
4 VFS
Already reset
Defective pump
cOntrOller
Defective contact. dlscon-
nectnn I w,r,nq harness
Replace
Repair or
WPlXZ
.-_
IS resistance between
between Cl (female1 (1 21,
YES Sl (femaleI 12) - Cl
1131 - Sl (female) (11.
3 - (female) (1) normal
-
_ and IS circuit insulated
Defectwe contact, dlscon-
Is resistance
between S1
from chassis, NO
nect,on I w,r,ng harness
(male) (1) - (2)
between C 1 (female) 12) -
_
, nOrmal and is
_ * Between Sl and Cl: Max. Ifi
- Between wiring harness and
Sl (fern&l 11). ~rc~ntact
circuit insulated
from chassis?
chassis: Min. 1 Ma
wth ground
* Disconnect Sl and Cl.
. Lever operated:
Max. 1 .Q
NO
Defective work
* Lever at neutral :
equipment oil pressure
Min. 1 Ma
switch
. Start engine. * If the condition does
- Disconnect Sl. not become normal
* It is also possible to fit a short connecfor to make judgement.
even when the switch
In this case, proceed as follows after checking the voltage between Cl (I) - 112).
is replaced, go to H-7.
(13) in Step 1.
. If voltage is 20 - 3OV. answer YES and go to Item 2.
. If voltage is IV or below, answer NO and go to Item 3.
Repair or
replace
Replace
Pump controller
Cl (MICl7)
/
205FO5392-1
F-2 Pump controller monitor does not display [F _s] [Swing oil
pressure switch (Work equipment*swing oil pressure switch)]
PC200,2OOLC-5 Serial No: 45001 - 49706
PC220,22OLC-5 Serial No: 35001 - 35661
l Swing oil pressure switch
Sr After starting the engine, and operating the swing lever while operating the arm or bucket levers, it
is displayed for approx. 1 sec.
t Always connect any disconnected connectors before going on to the next step.
A Before operating the swing lever, turn the swing lock switch ON.
YE
Is voltage between
C3 (5) - chassis
. Lever at neutral:
20-30V
. Swing lever
operated :
Max. 1 V
* Start engine. h
2 YES
In same condi-
tions as when
measuring Item 1,
is [PZI displayed?
- Start engine.
* Operate swing
lever
NO
YE
n
(male) (1) - (21
nor mal and is
circuit insulated
from chassis?
Lever operated :
Max. 1 a
- Lever at neutral:
Min. 1Ma
* Start engine.
. Disconnect 52.
4 YES
/Z%Z&jHT
* Between S2 and C3: Max. 1.Q
* Between wiring harness and chassis:
Min. 1 MQ.
* Disconnect S2 and C3.
IO
A I read y reset
Defective pump
controller
Defectwe contact, dls-
connection in wiring
harness between Cl
(female) (12). (I 31 -
s2 (female) (1). or
contact wtth ground
Defective contact, dls-
harness between C3
(female) (5) - S2
(female) (2). or
contact with ground
Defective swing oil
pressure switch
* If the condition
does not become
normal even when
the switch is
replaced, go to H-7.
* It is also possible to fit a short connector to make judgement.
I
In this case. proceed as follows after checking the voltage between C3 (5) and the
chassis in Step 1.
* If voltage is 20 - 3OV. answer YES and go to Item 2.
. If voltage is 1V or below, an?.wer NO and go to Item 3.
Pump controller
Remedy
Replace
Repair or
replace
Replace
Swing oil
pressure switch
205FO5393-1
20-A71
0 Work equipment -swing oil pressure switch
* After starting the engine, and operating the swing lever or work equipment levers, it is displayed
for approx. 1 sec.
*
A
Always connect any disconnected connectors before going on to
Before operating the swing lever, turn the swing lock switch ON.
the next step.
YE
1
Is voltage between
C3 151 - chassis
. Lever at neutral:
20 - 3ov
. Lever operated:
Max. 1V
. Start engine.
N
2 YES
I
I same condl-
I
t,os as when
measunng Item 1,
IS [P21 displayed?
Start en&e.
NO
Operatelever
YES
3 r
Between Sl and C3: Max. IQ
Between wiring harness and chassis:
Disconnect Sl and C3
. Lever operated:
Max. 1 R
. Lever at neutral:
Min. 1 MR
. Start engine.
. Disconnect Sl.
NO
* It is also possible to fit a short connector to make judgement.
In this case, proceed as follows after checking the voltaae between C3 (5) and the
chassis in Step 1.
* If voltage is 20 - 30V. answer YES and go to rtem 2.
+ If voltage is 1V or below, answer NO and go to Item 3.
Call%?
Already reset
Defective pump controller
Defectwe contact. dlscon-
echo I w,nng harness
between S 1 (female1 ill
and Cl (female) (121. 1131,
Defectwe contact, dlscon-
actlo I wnng harness
between C3 (female1 151 -
Sl (female) 121. or contact
wth ground
Defective work
equlpment~ swing oil
pressure switch
* If the condltlon does
not become normal
even when the swtch
IS replaced, go to H-7
Remedy
Pump controller
Work equipment.
swing oil pressure switch
205FO5728
.
F-3 Pump controller monitor does not display
pressure switch]
.? .& [Travel oil
I
*
*
*
*
After starting the engine, and operating the travel lever, it is displayed for approx. 1 sec.
A
Before operating the travel lever, check that the surrounding area is safe.
If it is not displayed when operating the travel lever on one side, the PPC shuttle valve is defective.
YE
1
Is voltage between
C2 (1) - chassis
. Lever et neutral :
20 - 3ov
. Travel lever
operated: Max. 1 L
* Start engine.
I\
2 YES
I I I
In same conditi-
ons es when
measuring Item 1,
is [P61 displayed?
i
I I I
* Start engine. NO
* Operate-travel
lever
I
Is resistance
between s4
(male) (1) - (2)
normal and is
circuit insulated
from chassis?
* Lever operated:
Max. 1n
* Lever et neutral:
Min. 1 Ma
* Start engine.
. Disconnect 54.
4 YES
* Between wiring harness and chassis:
J - Disconnect 54 and C2.
NO
* It is also possible to fit a short connector to make judgemat.
In this case. proceed as follows after checking the voltage between C2 (1) and the
chassis in Step 1.
* If voltage is 20 - 3OV. answer YES and go to Item 2.
* If voltage is IV or below, answer NO and go f~ Item 3.
Already reset
Defective pump
controller
Defective contact. dis-
connection in w&g
harness between S4
(female1 (11 - Cl
(female) (12). (13). or
cOntact with ground
Defective contact, dis-
harness between C2
(female) (2) - M3 (13)
- s4 (female) (2). or
contact with ground
Defective travel oil
pressure switch
l If the condition does
not become normal
eve when the switch
is replaced, go to H-7.
Repl i 3Ce
Repair or
E?PlaCe
Repair or
F3PlZVX
Replace
Pump controller
Cl (MICl7)
S4(X2)
pressure switch
205FO5394-1
20-A73
F-4 Pump controller monitor does not display [:I(L,] [Swing lock
switch]
* After starting the engine, and turning the swing lock switch ON, it is displayed for approx. 1 sec.
Sr If the monitor panel display is normal (if the swing lock lamp on the panel does not light up, go to
P-22).
+ Always connect any disconnected connectors before going on the next step.
CWXW
I
I
Remedy
2 YES
In same condi-
YES tions as when
measuring Item 1,
1
is Lb51 displayed?
* Swing lock switch NO
Is voltage between
ON-OFF
C2 (4) - (8)
lXXll?
3 YES
* Swing lock switch
ON: Max. 1V
IS there continuity
L between C2 (female)
OFF l8 - 28v NO (4) -wing lock
* Turn starting
switch ON.
swtch Ll)?
. Turn starting NO
switch OFF
* Disconnect C2.
Already reset
Defective pump
controller
- Defective swing
lock switch
* Dlsconnectvx I wrmg
harness between C2
(female) (8) - swng
lock swtch (1 I. or
contact wth ground
harness between C2
(female) (4) - lock
switch (1)
Replace
Repair or
replace
Repair or
replace
Pump
M20W4) v
controller
(Q@
Fuse
CI(MICl7P) M3E161
I
I
Swing brake
1
Swing brake
solenoid valve
C2(MIC21) Swing lock
prolix switch
Swing lock @
Swing lock
switch
GND @
1
205F05730A
20-&74
F-5 Pump controller monitor does not display [.b\. ,] or [!,_.,-,] [Travel
speed switch]
* After starting the engine, and switching the travel speed switch to Hi or Lo, it is displayed for
approx. 1 sec.
Sr If the monitor panel display is normal (if the panel display is not normal, go to P-20).
2 YES
In same conditi-
YES ons as when
- measuring Item 1, -
is [Hi] or [Lo1
1
displayed?
NO
Is voltage between
C2 (3) - (8) as -
shown in table 17
3 YES
* Turn starting Disconnect P2. Is
switch ON. voltage between
* Travel speed switch- ~2 (female) (4) - -
Hi-Lo ND (16)asshown
below? NO
ON.
* P2 disconnected:
10 - 13v
Already reset
Defective pump
controller
Defective monitor
panel
Defective contact,
disconnection in
wiring harness
between C2 (female)
(3) - P2 (female)
(4). or contact with
ground
Replace
Repair or
reDlace
Repair or
replace
Table 1
Travel speed switch Lo 10 - 13V
Travel speed switch Hi 1 Max. 1V
Pump controller
Monitor panel
C2(MIC21) P2 (04016)
205FO5396
20-&75
F-6 Pump controller monitor does not display [!&J,]
[Auto-deceleration switch]
* After starting the engine, and set auto-deceleration switch to ON, it is displayed for approx. 1 sec.
* If the monitor panel display is normal (if the auto-deceleration display on the panel does not
change, go to P-l 9).
2 YES
In same conditi-
YES 0s es when
measuring Item 1,
1
is [Ad] displayed?
YES
I
. P2 disconnected:
10 - 13v
I
I
I
c
- t
I
Cause
Al read Y reset
Defective pump
controller
3efective monitor
>ane1
Iefective contact, or
jisconnection in wiring
harness between C2
female) (7) - P2
female) (7)
Remedy
Replace
Repair or
replace
Table 1
Auto-deceleration switch ON Max. 1 v
Auto-deceleration switch OFF lo- 13v
Pump controller
Monitor panel
C2UvllC2l) P2 (040161
205FO5397
20- 176
0
F-7 Pump controller monitor does not display [_,l:l] [Power
maximizing switch]
* After starting the engine, and pressing the power maximizing switch, it is displayed for approx. 1
sec.
+ Always connect any disconnected connectors before going on the next step.
not press,
20 - 3ov
* When swi
pressed :
I I I
IL4
. When switch is
?d:
Is resistance
between switch _
tch is
NO (1) - (2)
Max. 1v
normal?
..-
I
Cause
I
Remedy
I
2 YES
Already reset
Defective pump
controller
ReplaCe
Defective contactT
or disconnection !n
Repair or
replSX
C2 (female) (12). (8)
- switch
Defective power
. . . Rc?l.%?e
* When switch is not ND
pressed: Min. 1 MR
* When switch is
pressed: Max. 1.Q
Pump controller
C2(MIC21)
..__ -
Power maximizing switch
205FO5398
F-8 Pump controller monitor does not display [pQ$JQ] hJecimal
point of [Engine speed sensor]
+ The display flashes when the engine is started.
Yf
* 500 - 1ooo.Q
* Turn starting switcl
OFF.
- Disconnect C3.
F
YES
~:
I I
- Measure with
AC range.
. 0.5 - 3v
* Start engine.
4 YES
NO
- Between (1) and (2):
500 - 1oooa
- Between (1) and
chassis: Min. 1 Ma
OFF.
- Disconnect E7.
C3lJ S.e Remedy
engine speed sensor
Defective pump
controller
Defective engine speed
SeSOr
Defective contact, dis-
harness between C3
(female) (8). (4) - M3
(1 2). (4) - E2 (I I),
(I 21 - E7 (female1 (2).
(1). or contact with ground
Defective speed sensor
ReplXe
Redace
Redace
Pump controller
C3(MIC9) M3(Sl6) E2(Sl2) E7(X2)
0
Engine
speed
@J
sensor
205FO5389-1
20-l 78
a
F-9 Pump controller working mode display does not switch
I
\ 7 -\ \ \
\ \= 3 7
1
* The working mode is displayed approx. 1 set after the starting switch is turned ON.
* If the monitor panel display is normal and the working mode does not switch, go to
Troubleshooting M-l 7.
Yl
1
IS voltage bet -
w een c 2 (14)
L-l
(15) and (8) as
show n i n Tabl e
l ?
sw i t c h ON.
. Sw i t c h w or k i ng
mode on r
moni t or panel
2 YES
under r ame c on-
di ?l O L as w hen
meaw r ,ng I t er n
* 7, doeswokring 3
mode monifor
dilplay w.Jircll
OUTallV?
. Sw i t c h w or k i ng NO
mode on
moni t or panel
3 YES
sw i t c h ON.
. When P2 i s
NO
di sc onnec t ed:
10 - 13v
Tabl e 1
G.0 10 - 13v 10 - 13v C2 (MIC21)
I \ I
CaUSe Remedy
Def ec t i ve pump
c ont r ol l er
Def ec t i ve moni t or Panel
Def ec t i ve c ont ac t or
di sc onnec t i on i n w i r i ng
har ness bet w een C2
(f emal e) (14) - P2
(f emal e) (8). and
bet w een C2 (f emal e)
(15) - P2 (f emal e) (9).
Monitor panel
P2 (04016)
F.0 o-1v 10 - 13v
L.0 o-1v 0 - 1v
205FO5627
2o-i79
F-l 0 Pump controller power set display does not switch
t The power set is displayed approx. 1 set after the starting switch is turned ON.
Ir If the monitor panel display is normal and the power set does not switch, go to Troubleshooting
M-l 8.
However, if the coolant temperature gauge on the monitor panel is showing the red range (over
102C), the pump controller displays L mode.
Y
1
I I
* Turn starting
switch ON.
. Switch power
mode on
monitor panel.
* Switch power
mode on
monitor panel
YES
I
switch ON. -
. When P2 is
disconnected:
10 - 13v
Table ?
r-\IBa.mBcl
l 10 - 13V when working mode is
L.0 mode
Already reset
Defective pump
controller
Defective monitor panel
disconnection in
C2 (female) (5) - P2
(female) (5). and bet-
w?en C2 (female) (6)
-
P2 (female) (6).
Remedy
RePlaCe
F7epl.Sl2
Repair or
reDlace
C2 (MIC21) P2 (04016)
205FO5628
TROUBLESHOOTING OF HYDRAULIC AND
MECHANICAL SYSTEM
(H MODE)
Failure mode
Work equipment, travel, swing system
H- 1 Speeds of work equipment, travel, swing are all slow ...................
H- 2 There is excessive drop in engine speed, or engine stalls ................
H- 3 Work equipment, travel, swing do not move, or speed is extremely slow .
H- 4 Work equipment, travel, swing lack power .............................
H- 5 Power mode selection system does not switch ........................
H- 6 Abnormal noise generated (from around pump) ........................
H- 7 Auto-deceleration does not work
.....................................
Work equipment system
H- 8 Boom, arm speed is extremely slow
...................................
H- 9 Work equipment (boom, arm, bucket) speed is slow ....................
H-l 0 When boom and arm are operated simultaneously, boom is slow ........
H-l 1 Work equipment (boom, arm, bucket) lacks power .....................
H-l 2 Excessive hydraul,ic drift
.............................................
H-13 Excessivetimelag ..................................................
H-l 4 Does not enter finishing operation mode
..............................
H-l 5 When arm and swing are operated simultaneously, arm is slow ..........
Travel system
H-16
al
b1
H-17
H-18
H-19
H-20
H-21
When machine is traveling, it deviates naturally to one side
Deviates in same direction both in forward and reverse .
Deviates in different direction in forward and reverse . .
Excessive deviation during compound operations . . . . . .
Excessive deviation when starting . . . . . . . . . . . . . . . . .
Travel lacks power or speed is slow . . . . . . . . . . . . . .
Travel speed does not switch . . . . . . . . . . . . . . . . . . .
Machine does not move (one side only) . . . . . . . . . . . . .
Swing system
H-22 Doesnotswing ............................................
H-23 Swing speed is slow or acceleration is poor.
..................
H-24 Excessive overrun when stopping swing
.....................
H-25 Excessive shock when stopping swing
.......................
H-26 Excessive abnormal noise when stopping swing ..............
H-27 Excessive hydraulic drift of swing
...........................
H-28 When operated simultaneously with arm, swing speed is slow . .
TABLE OF FAILURE MODES AND CAUSES .............................
. .
.
.
. .
.
. .
.
.
.
.
.......
......
......
......
......
......
......
......
. 20-182
20-184
20-186
20-188
. 20-188
20-189
20-189
20- 190
20- 192
20- 194
20- 194
20- 194
20-I 96
20-I 96
20- 196
20-I 98
20-200
20-20 1
20-202
20-204
20-204
20-205
. . 20-206
20-208
. 20-209
. 20-209
. 20-210
. 20-210
. 20-210
. 20-211
20- 181
H-l Speeds of work equipment, travel, swing are all slow
* If there are other problems, such as travel deviation or low bucket or swing speed, go to H-l 6.
% 1. If the pressure is not at least 27 kg/cm2, the spool of the acceleration (Hi) end is not fully actuated.
x2. The discharge pressure of the pump has an effect on the TVC valve set pressure, so check it
before adjusting the TVC valve set pressure.
Yl
1
Is relief pressure
at charging pump
normal?
* Engine at high
idling
. 30 TE kg/cm2
*1
4 YES
v
Is engine speed . When normal relieved:
YES normal when
- pump is relieved -
PC200 2150 * 60 rpm
PC220 2300 * 60 rpm
3
with CO canceled?
. When CO canceled: NO
YES
IS set pressure
PC200 2050 ? 60 rpm PC220 2200 + 60 rpm
- at Tvcvalve -
* H.0 + H mode
normal?
. Arm relief
5 YES
2
. PC200: 16 ; Does condition
kg/cm
_ become normal
+1
Is relief pressure
* pc220: 17_2
ND when TVC Valve
is adjusted?
. of F. R Pump - kg/&
normal?
.,^
. H.0 + H mode
NU
. l-pump relief
- At normal relief: * Engine at high idling
310 - 340 kg/cm
- At 2-stage relief:
6 YES
335 - 365 kg/cm=
- H.0 + H mode
DOS condition
* Engine at high
_ become nOrmal _
idling
NO when main relief
valve is adjusted?
%2
NO
20- 182
0
I CalKX
Leakage inside
Pump
21 See Engine shop manual
fl/ Defective TVC valve
Defective main relief
valve
(Go to H-3, Item 3)
Remedy
Replace pump
assembly
Adjust
Replace
4djus.t
Replace
20- 183
H-2 There is excessive drop in engine speed, or engine stalls
YES
I
+1
* PCZOO: 16 -2
kg/cm
+1
. PC220: 17 _2
kg/cm2
* l-pump relief
* H.0 + H mode
* Engine at high 1
idling
. set pressure
YES
becomes
.r
normal
. Problem does
4 I L
not cnange
Does condition
. Set pressure
become normal
i
becomes
L when TVCvalve -- orma
v set pressure is
. Condition also
adjusted?
becomes
normal 1
2 I
When pump is
relieved, is
OUtpUt pressure Of
co valve normal?
Y,
3
a At normal relief:
Max. 5.5 kg/cm
Does output
a When CO canceled: _
pres$ure become
normal when CO
Same pressure at NO valve is
TVC pressre adjusted?
* Engine at high idling
. H.0 + H mode
Y,
f Output pres-
sure becomes
nor mal
- * Condition also
becomes
normal J
* output pres-
sure does not
become
I
-
normal
. Set pressure
does not
become
normal
20- 184
0
Cause Remedy
A
See Engi ne shop manual -
Def ec t i ve adj ust ment of
c o val ve
Adj ust
( Def ec t i ve CD val ve
Repl ac e
Def ec t i ve adj ust ment of
TVC val ve
Adj ust
. Def ec t i ve TVC val ve
Repl Xe
M-3 Work equipment, travel, swing do not move, or speed
is extremely slow
* When there is a big difference from the permissible value.
* Auto-deceleration is normal.
* Mode selection is H.0 and H mode.
n
motor.
- Disconnect
gcwernor lOtOr
I
connector, and set h
governor lever
to NO INJECTION.
Do not move, or
speed is extremely
Speed is
extremely slow
3
YES
YES
3-
Block circuit (1) -
(6) in Fig. 1. Is
-charging pump -
relief pressure 4 YES
normal?
_ Is any foreign
* 30 E kg/cm2
material found in
_
oil drained from -
* Engine at high
NO charging pump
outlet strainer?
idling
NO
YES
5
L To I tern 3 above
IS set pressure of
- TVCvalve
6 YES
normal?
Does condition
. 14 - 17 kg/cm*
become normal
_
::
. H.0 + H mode
NO when TVC valve
is adjusted? ::
NO
z
Fig. 1 Control circuit
Solenoid valve
_Y
Charging pump
Safety lock valve
Travel PPC valve
4
9tJ+
R.H. PPC valve
5
w
L.H. PPC valve
205FO5300
20- 186
0
Defective charging
. Defectwe damper
iPT0)
_ - Defective mm pump
(broken shaft, etc 1
Defective set pressure
of TVC valve
Remedy
Wplace relief
ralve
Idj ust
20- 187
0
H-4 Work equipment, travel, swing lack power
Y
1
Does the problem
cxcur when
digging force is
maximized, or
during normal
ES
NO
When digging
force is
maximized
YI
2
* At travel relief:
335 - 365 kg/cm*
. Engine at high
idling
,
3 YE
Outlet Port Of
solenoid valve
* See conditions for N
Item 4 below.
4 YE
solenoid valve
- At travel relief and N
when digging force
is maximized:
25 - 35 kg/cm
. During normal
operation: 0 kg/cm
* It is also possible to hold the solenoid
During normal
3
valve outlet hose by hand to judge.
operation
CaUSe
Defective CO valve
Defective CO cancel
solenoid valve
Drop in set pressure of
main relief valve
Defective 2.stage
relief solenoid valve
Drop in set pressure
of main relief valve
H-5 Power set selection system does not switch
Remedy
correct or
reDlace
ReplaCe
Adjust or
,ep1ace
Replace
4djust or
.ep1ace
1
When TVC valve 1 YES
solenoid is remov-
ed, and mode
selection switch is
operated with con-
nector still conne-
cted, does spool .
of solenoid move? NO
I) Turn starting
switch ON.
Cause
Defective TVC valve
Remedy
Repl aCe
RePlaCe
20- 188
0
H-6 Abnormal noise generated (from around pump)
Is oil level in
hydraulic tank
2
3
Is problem
removed when
piping between
tank and pump is
4 YE
oil is drained, are
any metal wear
particles found?
CaUSe
Clogged strainer
Loose piping clamp
Defective pump
Operate for a time
and watch any
changes in symptoms
Lack of oil
H-7 Auto-deceleration does not work
CaUSe
t-
1 YES Defective travel shuttle
Is hydraulic
Valve
pressure at inlet
port of travel -
shuttle valve
normal? Defective PPC shuttle
- 25 - 35 kg/cm ND
valve
Remedy
Clean
Tighten
Replace
Inspect again
Depending on
changes
in symptoms)
Add hydraulic
oil
Remedy
Repair or
reDlaCe
Repair or
replace
20- 189
H-8 Boom, arm speed is extremely slow
l Mode selection is H.0 and H mode.
* When the travel, swing, and bucket speeds are normal.
C.WSl 2 Remedy
1 YES
Does travel shuttle
valve spool move -
smoothly?
*Valve on top of NO
control valve
Defective operation Repair or
of straight-travel valve repl aCe
Defective operation of Repair or
travel shuttle valve replace
20- 190
0
H-9 Work equipment (boom, arm, bucket) speed is slow
* When the travel and swing speeds are normal
(However, if there is any travel deviation and the bucket or boom speed is slow when operated indi-
vidually, go first to H-l 4 When machine is traveling, it deviates naturally to one side.)
I
Arm only
[ Bucket only
3 YES
Is operation of
- boom holding -
valve normal?
NO
. Check movement of
valve with your hand.
4 YES
Is hydraulic
pressure at Outlet
] - port of arm half -
flow solenoid
valve normal?
NO
. F.0 or L.0 mode: 0 kg/cm2
. Normal operation: 25 - 36 kg/cm2
l It is also possible to hold the solenoid valve outlet
hose by hand to judge.
J
1
Is hydraulic drift
* ;li~b/c-
* Engine at high
1
of slow cylinder _
within standard
ValUe?
NO
5
Does hydraulic
drift become
faster when
YES
lever is
operated?
NO 6
* See TESTING AND
ADJUSTING.
r[ Arm, bucket ]
* 20 cc/min
* For details of the
* When relieved
type of safety
valve, see
4
NO 7 YES
Table 1.
II
L
[ BoomonlY
1
Is boom holding
valve normal?
H
* Check movement NO
of valve with your
hand.
Table 1 Table of locations and types of safety valves used for
each cylinder
( ) : Set pressure
Cylinder Bottom end (kg/cm2) Head end (kg/cm 2 )
Boom Safen/ -suction valve (355) Safety -suction valve (290)
Arm Safety - suction valve (355) Safety valve (355)
Bucket Safety - suction valve (355) Safetv -suction valve (3551
20- 192
0
I
Cause Remedy
Def ec t i ve oper at i on of
c ont r ol val ve spool
(boom)
Def ec t i ve oper at i on
of boom hol di ng val ve
Def ec t i ve oper at i on of
c ont r ol val ve spool (ar m)
Def ec t i ve ar m hal f f l ow
sol enoi d val ve
)I Def ec t i ve PPC val ve
Def ec t i ve saf et y (suc t i on)
val ve
Def ec t i ve oi l -t i ght ness
of c ont r ol val ve spool
Repai r or
replaCe
control valve
assembl y
Repai r or
replaCe
Repai r or
r epl ac e
Cont r ol valve
assembl y
20- 193
H-10 When boom and arm are operated simultaneously,
boom is slow.
l When usual operation is normal.
F-i-i
Defective arm throttle
valve
Repair or
repl aCe
H-l 1 Work equipment (boom, arm, bucket) lacks power.
* When the travel and swing speeds are normal.
YES
r
1
Does this problem
occur when digging
force is maximized,
I-
or during normal
operation?
j_ ( During normal
~0 i operation
2 YES
i I I
i
Is main relief
pressure normal
at travel relief?
H
I
-w NO
YES
3r
power at both
head end and
bottom end, or
NO
4 YES
I 1 I
One end only ]
Table 1 mm
H-l 2 Excessive hydraulic drift
+I Go to H-9, Item 5.
20-l 94
a
Cause Remedy
Defective operation of
1 CO cancel solenoid
valve
ReplaCe
Defective OperatiOn Of
*-stage relief solenoid
Valve
ReplaCe
- (Go to H-9, Item 2)
(Go to H-9, Item 5)
Defective safety
(suction) valve
Replace
20- 195
H-13 Excessive time lag
* If the work equipment speed is normal (if the speed is slow, go first to H-9, Item 2).
CaUSi?
of suc t i on val ve
H-14 Does not enter F.0 mode (Half flow functiuon)
CaUSe
of ar m hal f f l ow
sol enoi d val ve
Remedy
Repl ac e
Ti me l ag set
Remedy
ReplaCe
H-15 When arm and swing are operated simultaneously, arm
is slow
* If the operation of the auto-deceleration is normal (if the auto-deceleration is defective, go first to
H-7).
C.NSe
Def ec t i ve Oper at i On of
sw i ng pr i or i t y val ve
Remedy
Repai r or
r epl .3Ce
20- 196
0
H-l 6 When machine is traveling,
side
* When the travel speed is normal.
it deviates naturally to one
a) Deviates in same direction both in forward and reverse
When pump out l e
hoses ar e c hanged
bet w een F and R,
does di r ec t i on of
devi at i on c hange?
YES
1
t
L
NO
Di r ec t i on of
devi at i on
c hanges
Di r ec t i on of
devi at i on does
not c hange
* For det ai l s, see
TESTI NG AND
ADJ USTI NG.
I
ES
41L
. For det ai l s, see NO
YES I s OUt pUt pr eSS r e
TESTI NG AND
- of NC val ve
ADJ USTI NG.
nor mal ?
YES
* When t r ac k i s r ot a-
6-
t ed f r eel y or dur i ng
nor mal t r avel ,
I s di f f er ent i al
-
sensor nor ma!?
I s mai n r el i ef
t he TVC out put
pressure nor mal ?
pr essur e.
* Lever at neut r al :
* Lever at neut r al :
Max . 5.5 k g/c m
13 - 19 k g/c m No
* Engi ne at hi gh i dl i ng . See Nore.
I s out put pr esw r e
of PPC val ve
. 30 g kg/cm2
10
Ar e met al par t i c l es
YES f ound i n oi l
_ dr ai ned f r om f i nal _
YES
dr i ve on si de
w hi c h devi at es?
11 r
p Doesdi r ect i on Of
devi ar i o" change when
9
_ l ef t and r i gi l *t mr es _
NO bet wee" C0"t r . d "he
and I Wi ". I j oi nt ar e
i t sr c hsnged7
YES Does c ont r ol val ve
spool move
smoot hl y?
NO
I I
NO
Note: When the track is rotated freely, if the output pressure of the NC valve is the same as the
output pressure of the TVC valve, both the jet sensor and NC valve are normal.
20-:98
CCV_lSC? Remedy
of pump
See TESTING
AND
ADJUSTING
Leakage of inside
pump
Repl aCe
Defective operation
of servo valve
Replace
Defective operation
of NC valve
Adjust or
replace
7 YES
Does condition
becc~me normal
when relief valve
of jet sensor is
interchanged or
adjusted?
. never operated: NO
Max. 2 kg/cm
Drop in set pressure
of jet sensor relief valve
Defective jet sensor
orifice
Drop in set pressure Of
main relief valve
Adjust
Clean or
repl aCe
Adjust or
replace
-
Defective final
drive
Repair or
replace
Defective control
valve body
Replace
Defective swivel
joint
Defective travel
rncltor
Replace
Replace motor
assembly
Defective Operation Of
COntrOl valve spool
Replace
Defective PPC valve Replace
20- 199
b) Deviates in different direction in forward and reverse (See Fig. 1 I
2 YES
YES lS OUfpUt pWssW
, - of PPC valve
__ normal?
Defective swivel
joint packing
Is relief pressure - - Defective PPC valve
normal at travel - . 30 E kg/,-+ NO
relief?
a Engine at high idling
. 335 - 365 kg/cm2
. Engine at high idlint
ND Drop in set pressure
of travel motor Safety
valve
replace
Repair or
replace
Replace safetv
valve assembly
Fig. 1
Location of defective swivel
joint packing and direction
of deviation in travel
20-200
0
H-l 7 Excessive deviation during compound operations
* If individual travel is normal.
CS_lSC? Remedy
2 YES Defective operation Repair or
of straight-travel valve replaCe
YES
Does spool of
1 -
travel shuttle
valve mclve
smoothly?
Is oil pressure at
Repair or
inlet port of travel NO
- travel shuttle valve repIS
shuttle valve
normal?
.25 - 36 kg/cm*
NO
PPC shuttle valve
* If the pressure in Item 1 is lost, the auto-deceleration also will not work.
*O-$O
H-l 8 Excessive deviation when starting
* When the travel speed is normal
* If there is also deviation during normal travel, go to H-l 6 When machine is traveling, it deviates
naturally to one side.
For deviation during simultaneous operations with the work equipment, go first to H-l 7 Excessive
deviation during compound operations.
* Bleed all air completely from the circuit.
\
1
Does machine
deviate at lever
El
full stroke, or
during fine
control?
. 220mm/20m
IES
I
NO
Deviates at
full stroke
Machine deviates
when starting,
regardless of N -
fine control, or
_ N - Full stroke
4 YES
NO
6 YES
7
is OUtpUt
YES_ pressure at NC
valve at fast end
5
normal?
Is differential - Control lever at NO
pressure of jet neutral: Max.5.5 kg/cm=
- sensor at fast - * Traqk rotating freely: Min. 18 kg/cm*
side (outside of
turn) normal?
7 YES
- ,s,::99 lever at
13 - 19 kg/cm2
- Control lever at
full stroke
Max. 2 kg/cm=
problem reversed?
NO
20-202
0
Defective OperatiOn
of servo valve
Defective control
valve
Defective swivel joint
Defective travel motor
servo valve
NC valve
Defective jet sensor
relief valve
Defective jet SenSOr
orifice
Remedy
20-203
H-19 Travel lacks power (or speed is slow)
Ir The mode selection is H.0 and H mode.
* When there is no travel deviation.
* If the main relief pressure has dropped, the work equipment lacks power even for normal work. If
the CO cancel and 2-stage relief valve systems are defective, the work equipment lacks power for
work using the power maximizing function.
2 YES
Is hydraulic
YES preSSre at Outlet
- port of co cancel -
solenoid valve
1 Il0rlllal?
* See conditions for NO
Is main relief Item 3 below.
pressure at travel -
relief normal?
3 YES
At travel relief:
335 - 365 kg/cm*
Is hydraulic
pressure at Outlet
Engine at high N& port of 2.stage -
idling relief solenoid
valve normal?
I I I
. At travel relief and NO
with power
maximized:
25 - 35 kg/cm
. During normal
operation: 0 kg/cm
H-20 Travel speed does not switch
* When the travel speed is normal at Hi or Lo.
1 YES
Is hydraulic
pressure at
outlet port of -
travel weed
solenoih normal?
* At Hi: NO
25 - 35 kg/cm
At Lo: 0 kg/cm
1:
Cause
Defective CO valve
Defective CO cancel
solenoid valve
main relief valve
Defective 2.stage relief
solenoid valve
Defective travel motor
. Speed change servo
valve
Defective travel speed
solenoid valve
Remedy
Repair or
replace
Replace
4djust or
replace
replace
Remedy
Replace motor
assv
Replace
20-204
0
H-21 Machine does not move (one side only)
I
CaUSe Remedy
2 YES
Defective final drive
Is any foreign
YES material found in _
oil drained from
I
final drive?
NO
Is main relief
pressure at motor -
relief normal? .
3 YES
. At travel relief:
Is hydraulic pressure
325 - 365 kg/cm
normal at motor
* Engine at high - relief when safety -
idling NO va,ves are
interchanged?
. For standard value, NO
see Item 1.
Travel motcar brake
dragging
Defective travel
mtxclr safety valve
Defective travel
motor
Repair 0,
replace
I
Replace motor
assern b I y
I Replace safety
valve
Replace motor
assembly
H-22 Does not swing
l When other work equipment and travel speeds are normal
* Turn swing lock switch OFF.
YES
r
Does not swing in
either direction, or
in one direction
Does not swing
in either
direction
YES
4
Is any foreign
YES material found in
oil drained from
swing machinery? 5 YES
3-
Does control
Is hydraulic
L valve spool move
YES
_ pressure et left
NO
smoothly?
and right relief
2
normal?
NO
-1
_
Is hydraulic .285 - 300 kg/cm2
pressure et swing
brake solenoid
H
* Engine at high
idling
NO
valve Outlet port
normal?
I
. Lever operated:
25 - 36 kg/cm2
- Lever at neutral:
NO
0 ka/cm
l It is a?so possible to hold the solenoid valve outlet hose by hand to judge.
6 YES
When left and
I
Does not swing
right safety valves
o
~0 in one direction
l-
are interchanged, -
0
is problem
reVet?Xd?
NO
z
l IS also possible to measure
the hydraulic pressure to
judge.
* 285 - 300 kg/cm2
- Engine at high idling
20-206
0
CaLI% Remedy
Repair or
Defective swing machinery rep,ace
Defective motor brake
Replace motor
assembly
control valve spool
Defective swing motor
Replace motor
assembly
Defective operation Of
swing brake solenoid
valve
Replace
- Defective safety valve Replace
. Defective PPC valve Replace
20-207
H-23 Swing speed is slow or acceleration is poor
+ When other work equipment and travel speeds are normal. (If there is also deviation (to right)
during normal travel, go first to H-l 6 When machine is traveling, it deviates naturally to one side.)
YI
both left and
right, or in one
direction only?
- Time taken to start
swing (set) (90) :
PCZOO: Max. 3.4
sec.
PC220: Max. 3.8
* Time taken for
swing (secK5 turns)
Both PC200 and
220: Max. 30 NO
Both left and
right
One direction
only
YE
2
* Must be the same a!
TVC valve outpf
pressure
* At relief:
I\
Max. 5.5 kg/cm
. Measure at NC valw
* Is also possible to
measure the hydraL
pressure to judge.
.285 - 300 kg/cm2
Does spool move
smoothly when
NC
4 YES
become normal
when CO valve is
For standard value, NC
see Item 2.
6 YES
F[
. For standard value, NC
see Item 5.
NO
c
3 YES
-Engine at high idling
CaUSe
Excessive leakage inside
swing motor, or brake
dragging
control Valve spool
co valve
Defective operation Of
co valve
safety Valve
Defective safety valve
Defective PPC valve
Remedy
7ep1ace motor
assembly
Adjust
Repl aCe
Adjust
qeplace
GDlaCe
20-208
0
H-24 Excessive overrun when stopping swing
* If the speed is slow or the acceleration is poor, go first to H-23.
excessive to both
left and right, or
in onidirection
* Overrun when
VES
C
NO
sropp,ng swl~g:
* PC200: 120
* PC220: 160
-.
- tngune at nagll ldllng
[ Both left and
L right
r One direction
I only
Cause
. Leakage inside motor
0
t3
S+
H-25 Excessive shock when stopping swing
* When the swing speed is normal.
Is shock excessive
on both left and
i
right, or in one
direction only?
NO
. Lever operated: 25 - 36 kg/cm NO
a Lever et neutral: 0 kg/cm
*When the swing is operated and the lever
is returned to neutral, the hydraulic
pressure becomes 0 after approx. 6 sec.
One direction 1
OlllY
J
C&US=
Defective Swing
machinery
brake
Defective swing brake
solenoid valve
Remedy
Replace motor
assemblv
Replace or
adjust
Remedy
Repair
Replace
Replace
ReDlaCe
20-209
0
H-26 Excessive abnormal noise when stopping swing
* When the swing speed is normal.
YES
on both left and
right, or in one
direction only?
L
NO
Both left and
right
One direction
OlV
2 YES
Is any foreign I
1
material found in
oil drained from
swing machinery?
H
1
NO
become normal
when safetv
interchanged?
3
1
YES
I
NO
H-27 Excessive hydraulic drift of swing
1 YES
Is hydraulic
pressure et swing
brake solenoid -
valve Outlet port
normal?
. never at neutral: NO
0 kg/cm
* Lever operated:
25 - 36 kg/cm2
CaUSe Remedy
3efective swing
nachinery
Defective lift check
Valve
3efective suction valve
CaUSe Remedy
Replace motor
brake
assem b I v
Defective swing brake
solenoid valve
Replace
H-28 When operated simultaneously with arm, swing
is slow
l When the usual swing speed is normal.
CCdUSe
swing priority valve
t
Remedy
Repair or
,ep1ace
3epair
3ePlXe
3ep1ace
3eplace
speed
20- 210
0
TROUBLESHOOTING OF MONITOR SYSTEM
(P MODE)
Failure mode
P- 1
P- 2
P- 3
P- 4
P- 5
P- 6
P- 7
:: P- 8
::
2
P- 9
P-IO
P-l 1
P-12
P-13
P-14
P-15
P-16
P-17
P-18
P-19
P-20
P-21
P-22
Monitor panel lamps do not light up for 3 seconds when starting
SwitchisturnedON _..........................._....................___...
a) No monitor panel lamps light up.. . . . . . . . . . . . . . . . . . . . . . . _ .
b) Some monitor panel lamps do not light up . . . . . . . . . . . . . . . . . .
Monitor panel lamps all light up when starting switch is turned ON,
20-2 14
20-214
20-2 14
butdonotgoout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-2 15
When starting switch is turned ON (engine stopped), CHECK items flash . .
20-216
a) Coolant level flashes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-2 16
b) Engineoillevelflashes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .._ 20-217
c) Hydraulic oil level flashes . . . . . . . . . . . . . . . . . . . . . . _ . . . . . . . . . . 20-218
Preheating is not being used, but preheating display lights up . . . . . . . . . . . .
20-219
When starting switch is turned ON and engine is started, CHECK items flash .
20-220
a) Alternatorsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-220
b) Engineoilpressuresystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-220
When starting switch is turned ON (engine stopped), CAUTION items flash 20-22 1
When starting switch is turned ON and engine is started, CAUTION items flash .
20-222
a)
b)
cl
d1
e)
Engine oil pressure flashes ......... y ............................
Coolant level flashes ............................................
Coolant temperature flashes .....................................
Chargeflashes.. ...............................................
Fuellevelflashes ...............................................
20-222
20-222
. 20-223
20-223
20-224
a)
b)
When starting switch is turned ON (engine stopped),
buzzer does not sound for 1 second . . . . . . . . . . . . . . . . .
CAUTION item is flashing but buzzer does not sound.. . . . . . .
There is no abnormality display on the monitor, but the buzzer sounds
. 20-225
. 20-225
20-225
Panel lighting of monitor panel does not light up ................................. : 20-226
Coolant temperature shows abnormally low temperature ........................... 20-227
Coolant temperature gauge gives no display ...................................... 20-227
Fuel gauge always displays FULL ................................................ 20-228
Fuel gauge gives no display ..................................................... 20-228
a) Lamps do not light up .......................................................
20-229
b) Lamps light up even when lamp switch is not operated ......................... 20-229
a) Wipers do not work. ........................................................
20-231
b) Wipers work even when wiper switch is not operated .......................... 20-23 1
a) Fandoesnotwork .......................................................... 20-233
b) Fan works even when fan switch is not operated ............................... 20-233
Working mode does not switch .................................................
20-235
Power mode selection system does not switch .................................... 20-236
Auto-deceleration does not switch
(Does not enter auto-deceleration; auto-deceleration is not canceled) ............ 20-237
Travel speed does not switch between Hi and Lo .................................. 20-238
Warming-up operation is not carried out below 3OC, or warming-up
operation is not canceled even when temperature goes above 30C ............. 20-239
Even when swing lock switch is turned ON (LOCK),
swing lock lamp on monitor panel does not light up ............................ 20-240
20- 213
P-l Monitor panel lamps do not light up for 3 seconds
when starting switch is turned ON
a) No monitor panel lamps light up
2 YES
YES Is voltage between
1
- Pl (female) (1) - -
(3) ormal7
Is voltage between
terminals of fuse
* Voltage 20 - 30V NO
3 - chassis ground
- . Turn starting switch
OWllal?
ON.
* Voltage 20 - 30v NO
ON.
Monitor panel
PI (04020)
205FO5300
b) Some monitor panel lamps do not light up
Cause
Defective contact. Or
harness between fuse 3 -
Pl (female) (1) or Pl
(female) (3) - M6 (9) -
chassis ground
Disconnection in fuse
Remedy
Replace
Clea
(defective
contact) or
r epl ac e
&place after
Ispecting caus<
If disconnectio
replace
20- 214
P-2 Monitor panel lamps all light up when starting switch is
turned ON, but do not go out
*
CFl USe Remedy
Def ec t i ve moni t or panel ReplaCe
20- 215
P-3 When starting switch is turned ON (engine stopped). CHECK
items flash (Levels for CHECK items are as specified)
jr Check that the coolant is at the specified level before carrying out the troubleshooting.
Does display go off
when short connec-
tor is connected to
P8 (fern&l?
Is there continuity
_ between P8
(female) (2) - -
chassis ground?
Table
- Dieconnect W
3 YES
1SHT
* Connect and disconnect
short connector to P8
(female).
- ?urn &ting switch
OFF.
. Disconnect Pl
Defective coolant level
sensor system
(See P-26)
Defective monitor panel Repl.WX
Defective contact, or dis-
connection in wiring harnes
between P8 (female) (1) -
M6 (1) - Pl (female) (17)
harness between P8
(female) (2) - chassis
ground
-
Clean (defectiv
contact) or
rE+NX
Clean (defectiv
:ontact) or
replaCe
Pl (04020)
P8 (X2)
Coolant level sensor
I
205FO5894
20-2 16
0
bl $ (Engine oil level) flashes
cl
* Use the dipstick to check that the engine oil is at the specified level before carrying out the
troubleshooting.
CZilSe Remedy
YES
1 1
Defective engine oil !evel
*ensx system
-
(See P-25)
2 YES
, Defective monitor panel ReplaCe
Table
P5 (female:
ground.
. Disconnect Pl, P5
. Turn starting switch OFF
1 6~14 (5) - Pl (female) 1
I I
Clean (defective
contact) or
reDlace
I
Pl (04020) Ml4 68) E8GWP8) P5CXl) Engine oil
level sensor
205FO5896
20- 217
0
cl
L!?-d
L (Hydraulic oil level) flashes
PC200,2OOLC-5 Serial No: 45001 - -
PC220,22OLC-5 Serial No: 35001 - *
when short connec-
tor is connected to
* Turn starting
switch ON.
ES
3 YES
I I I
~
. Connect and disconnect shoR connector
OFF
1 Disconnect P9
NO
Table
v
Monitor
1
Does display go out
when P9 (female)
(1) is grounded to
* Turn starting
switch ON.
* Disconnect P9.
r
PI (04020) M3 (S16) P9 (X2)
Hydraulic oi
level sensor
Table
ES
C.%JSC?
PC200,2OOLC-5 Serial No: - and up
PC220,22OLC-5 Serial No: * and up
Between P9 (female)
and (3)
continuity
Defective hydraulic oil
level sensor
(See P-27)
harness between P9
(female) ( 1) - M3 (1) -
Pl (female) (10)
Defective contact, or discon-
nection in wiring harness
between P9 (female) (21 -
M3 (11) - Ml4 (8) -chassis
ground
Remedy
Check that P9
?ot defective
Icontact, inser-
tion), check
weration of
iensor accordir
to Standard
~aluesTable fo
electrical
:ompoets,
then replace
Replace
Clean (defecti\
contact) or
reDlace
Clean (defectiv
contact) or
rep I ace
2 YES
I
Is continuity
between Pl (famale)
(10) and (3) es
shown in Table?
1
* Turn starting NO
switch ON.
* Disconnect Pl.
205FO5898
Cause
DefectEve hydraulic oil level
sensor system (See M-27)
DefectEve contact. or
disconnection in wirinq
harness between P9 -
(female) (1) - M3 (7) - PI
(female) (101
ReplXE
ClFXVl
(defective
contact) or
r&%X
Connected
I
Yes
Hydraulic oil
level sensor
P9CXl ) Not connected No Pl (O4020) M3CS16)
205FO5899
*O-i *
P-4 Preheating is not being used, but preheating display
lights up
c

1
Is voltage bet w een
st ar t i ng sw i t c h
El
t er mi nal Rl w i r i ng
_
c hassi s i s gr ound
O l XJ ?
. ov
* Tur n st ar t i ng sw i t c
ON.
Def ec t i ve moni t or panel Repl ac e
j I S Vol t age bet w een
i
Pl (9) - c hassi s
gr ound nor mal ?
H
- ov
a Tur n st ar t i ng sw i t c h
ON.
NO 3 YES
Is voltage between
_ Ml 4 (3). (4) -
c hassi s gr ound
_
nor mal ?
* ov NO
. Tur n st ar t i nq sw i t c h
heat er r el ay - E8 (3) -
Ml 4 (4) - Pl (female)
(9) i n c ont ac t w i t h +24V.
or def ec t i ve heat er r el ay
Ml 4 (mal e) (3) - Ml (3)
-
st ar t i ng sw i t c h i n
c ont ac t w i t h +24V
Af t er i nspec -
t i on, r epai r or
r epl ac e
Af t er i nspec -
t i on, r epai r or
r epl ac e
Af t er i nspec -
t i on, r epai r or
r epl ac e
PI (04020)
Ml4tS8)
+24V
Heater relay Electrical
intake air
heater
205FO5304
20- 219
a
P-5 When starting switch is turned ON and engine is started,
CHECK items flash
* Check both the alternator system and engine oil pressure system.
Call*= Remedy
a) Alternator system
2 YES
. Defective monitor panel ReplaCe
Is voltage between
YES PI (female) (7) -
1-
chassis ground
p normal?
Is voltage be-
Defective cony! or dis-
connection in wlrlng
Clean (defective
tween alternator
.26-30V
t harness between alternator Contact) or
terminal R -
NO
- terminal R - E8 (2)- Ml4 replace
chassis ground
. Start engine, and
run et half
(2) - Pl (female) (7)
normal?
thcottle or above. ,
* 26-30V
. Start engine, and NO
_ Defective alternator Replace
run et half
throttle or above.
Check that
b)
terminal is not
Engine oil pressure system
defective (con-
* When the engine oil pressure is normal.
tact, insertion),
check operation
of sensor ac-
cording to
YES
Standard Values
1
Defective engine oil
Table for elect-
pressure sensor
Doer display go off
rical
compoents,
when wiring
harness terminal
then replace
of engine oil
PreSSWe senror is
.NO
Contact of wiring harness
2 YES
between engine oil
removed?
ti pressure sensor - E8 (8)
After inspection,
repair or replace
- Is there conti-
- Ml4 (7) - Pl (female)
* Turn starting switch nuity between
(16) with chassis ground
ON. - Pl (female) (16) -
- chassis ground?
NO
* Remove wiring harness
Defective monitor panel ReplaCe
terminal of engine oil
pressure sensor.
* Disconnect Pl
Pl (04020) Ml4 68)
o Alternator terminal R
Engine oil
pressure sensor
205FO5950
20-220
a
P-6 When starting switch is turned ON (engine stopped),
CAUTION items flash
* When the engine oil pressure is normal.
YI
1
Is there continuity
between M 14
L-t
(female) (7) -
chassis ground?
f Turn starang switch
OFF.
* Disconnect Ml4
3
Is voltage between
YES_ alternator terminal _
R - chassis ground
20 - 3OV?
2-
_ * Do not start
Is there continuity engine.
; between PI - Remove alternator
(female) (16) - - terminal R wiring.
(3)?
OFF.
YES
NO 4 YE!
- Remove al ternator
terminal R wiring.
* Disconnect P1
I
NO
* Disconnect Ml4
,
j
3
Cat I S?
Defective alternator Replace
Nirina harness be-
tween al ternator
terminal R - ES (2) -
~14 (2) - Pl (female)
yd4i; contact with
disconnection in Wiring
harness between E8
(male) (8) - Ml4 (7) -
Pl (female) (16)
Defective engine Oil
pressure sensor
harness between Ml4
(female) (7) - ES (8) -
engine oil pressure Sensor
Remedy
\fter inspectic
epair or replal
SeplXX
:lean (defecti\
:ontact),repai!
3r replace
Repair or
repke
Pl (04020) M1468)
o Alternator terminal R
Engine oil
pressure sensor
205FO5950
P-7 When starting switch is turned ON and engine is started,
CAUTION items flash
(When there is no abnormality in CHECK items or engine)
a) & (Engine oil pressure) flashes
r-l
1
Does display go
off when wiring
harness of engine -
oil pressure
sensor is removed?
2 YES
* Start engine. Is there continuity
- between Pl
NO (female) (16) - W?
NO
* Disconnect Pl
PI (04020)
Monitor
panel
MI4681
Engine oil
pressure
sensor
rfi
F205C5 I29
(Coolant level) flashes
I
Defective engine oil
pressure sensor
Contact of chassis
ground with wiring
harness between E8
(male) (6) - Ml4 (7)
- PI (female) (16)
*O-i**
cl
B--l
(Coolant temperature) flashes
2 YES
Does displav go
YES
off when short
, - connector is
connected to P7
IS cOOlat
- (female)?
NO
* Start engine.
tWTlpW.3tW!
gauge within red
range?
Defective cool.ant tempe-
rature Sensor system
_
(See P-24)
Defective monitor panel FkpbX
. Start engine, and
yy;;;;,lf throttle NO . Defective monitor Panel ReplaCe
PI (04020) M I4(S8) E8ISWP8)
P 7(X2)
Coolant temperature sensor
Monitor panel @
I
205F05307A
d) m (Charge) flashes
I
2 YES
Is voltage be-
YEz K%A7) - -
1
chassis ground
Is voltage be-
normal?
tween alternator
terminal R -
20 -30V NO
-
chassis ground
* Start engine.
normal?
*20-30V
. Start engine, and
run at half throttle No
Defective monitor oanel Replace
disconnection in
alternator terminal R
- EB (2) - Ml4 (2) - P
(female) (7)
Defective alternator
1
Clean (defec
contact) or
replaCe
Replace
Pl(O4020)
Monitor panel
Ml4(S8)
I
3 0 Alternator terminal R
205FO5308-1
20-223
0
e) @ (Fuel level) flashes
L-l
* Check that there is fuel before carrying out troubleshooting.
* The surface of the fuel varies, so there is a
delay built info the display for the fuel level.
Cat l s.2 Remedy
Defective fuel level
sensor system
(See P-23)
-
Defective monitor panel i3.3piWG.5
* Defective monitor panel ReplaCe
PI (040201 M6(SIO) P6(XI)
Fuel level sensor
Monitor panel
205F05309A
2Q-:24
P-8 (a)
t Of the
level.
When starting switch is turned ON (engine stopped),
buzzer does not sound for 1 second
CAUTION item is flashing but buzzer does not sound.
CAUTION item, the buzzer does not sound if there is any abnormality in the charge or fuel
1 YES
Does buzzer sound
when Pl (female)
(I 1) and chassis
- turn starting switch
ON.
harness between Pl
(female) (I 1) - P4 (2)
_ buzzer C-J, or between
+24V - P4 (7) - buzzer
(+), or defective buzzer
Remedy
ReplaCe
P-8 (b) There is no abnormality display on the monitor, but
the buzzer sounds
1 YES
Does buzzer
sound when Pl is -
removed?
* Remove PI. NO
- turn starting switch
ON.
r-
+24V
Monitor
Cause
Contact of chassis ground
with wiring harness
between Pl (female)
(11) - buzzer (-1
Remedy
4fter inspection
.epai r or
.epiace
ReplaCe
205FO531 OA
20-225
a
P-9 Panel lighting of monitor panel does not light up (liquid
crystal display is normal)
1 YES
I s bul b br ok en or
i s t her e def ec t i ve -
c ont ac t ?
- Remove bulb. NO
* Chec k c ondi t i on of
bul b vi sual l y.
CalKGe
Bul b br ok en or def ec t i ve
c ont ac t
Def ec t i ve moni t or panel
Remedy
Repl ac e bul b, 0
:l ean (def ec t i ve
:ont ac t )
Repl aCe
20-226
P-IO Coolant temperature shows abnormally low
temperature
* If the coolant temperature actually remains low, check the engine system.
YES
1 I
Does display of all .I I
1 is connected f~ P7? 1 1 ~0
- Turn starting switch OFF.
Defective coolant
temperature sensor system
(See P-24)
Defective monitor panel ZeplaCf2
harness between Pl
(female) (6) - Ml4 (6) -
E8 (6) - P7 (female) (I)
or P7 (female) (2) - ES
(7) - chassis ground
lean (defectiv
3ntact) or
?place
P-l 1 Coolant temperature gauge gives no display (during
operation, no level of gauge is displayed)
Does display of
coolant tem-
l-t
perature gauge
appear when P7
is removed?
ON.
ES
Defective coolant tempe-
ratre sensor system
(See P-24)
OFF. -
P-l 0, 11 Related electrical circuit diagram
PI (04020) M 14(S8) ES(SWP8) P 7(X2)
Coolant temperature Sensor
Monitor panel
6
-
I
After inspectior
repair,or replace
205FO5311A
20-227
0
P-12 Fuel gauge always displays FULL
* Check first if the fuel tank is actually full before carrying out troubleshooting.
YES
Does display of
fuel gauge go off d
when P6 is
relClWd?
NO 2 YES
* Turn starting switc IS there continuity
ON. between Pl 15) - -
. Wait for approx. 2 chassis ground?
minutes.
NO
. Disconnect Pl, P6
. The surface of the fuel varies, so there is a delay built into
the display for the fuel level.
CaUSe
sensor system
(See P-23)
ontact of chassis ground
,vith wiring harness be-
tween P6 (female) (1) -
M6 (4) - Pl (female) (5)
Defective monitor panel IepiaCe
Remedy
P-l 3 Fuel gauge gives no display
* Check if there is any fuel before carrying out troubleshooting.
-
ifter inspection
zpair, or
?oleCe
sensor system
(See P-23)
* Turn StaRing switch
OFF.
- Disconnect P1. P6
ES
Defective monitor Panel
1 harness between P6
1 (female) (1) - M6 (4) -
P1 (female) (5)
P-l 2, 13 Related electrical circuit diagram
ReplaCe
clean (defective
contact) or
replace
PI (04020) M6C30)
Monitor panel
@- -3
1
P6(XI)
Fuel level sensor
I
205FO5312A
20-228
0
P-14 (a) Lamps do not light up
Does lamp light UP
YES when PI (female)
- (14) and chassis -
ground are con-
NO
nected?
l - Is there any dis-
- . Turn starting switch
connection or
ON.
Do LEDs on
defective contact
. Disconnect P,
monitor panel -
in lamp?
light up?
- Check visually.
- Turn startinq switch
ON. -
* Turn lamp switch
ON.
YES
n I
3 YES
NO
NO
Disconnection, defective
contact in lamp
harness between Pl
(female) (14) - lamp
relay R4 (2). between
lamp relay R4 (1) - fuse
(5). between !amp relay
R4 (5) - M6 (3) - MS
(1). or between M6 (3)
-
Ml0 (1) - M9 (1)
P-14 (b) Lamps light up even when lamp switch is not
operated
;epl aCe
lean (defective
ontact) or
,place
:lean (defective
ontact) or
Dplace
leplace
3 YES
Is there
YES
continuity
2 - between PI
_ (female) (14) -
chassis ground?
NO
YES
Does lamp light
- up when PI is
-
removed?
OFF.
1
* Disconnect Pl.
Are LEDs on
monitor panel -
ON.
NO
out?
ON.
* Turn lamp switch NO
OFF
s
with wiring harness bet-
ween Pl (female) (14) -
lamp relay R4 (2). or
defective lamp relay
\Ei ,r,ng harness between M6
lfemalel 131 - M8 ifemale)
(1) or M6 (female1 (3) -
MlO(ll -MS(femalel(l)
I contact with +24V
After inspec-
tion, repair or
rl?plXZ
After inspec-
tion, repair or
replace
Replace
Replace
20-229
a
PC200,2OOLC-5 Serial No: 45001 - 58018
PC220,22OLC-5 Serial No: 35001 - 36613
+24V
M6c3IO) M 8tMI)
I
Lamp relay (R4)
MI0
TmT Boom head lamp
205FO5313-1
Monitor
M8tMI)
lamp
Boom head lamp
7+r
M4l(MIl
Head lamp (L.H.)
on cab
l
M40tM I)
Head lamp
on cab
(R.H.)
205FO5772
20-$30
P-15 (a) Wipers do not work
DO LEDS on
moni t or panel
* Tur n st ar t i ng sw i t c l
ON.
. Tur n w i per sw i t c h
ON.
ES
1
h
N
2
goes w i per w or k
w hen Pl (f emal e)
(15) and c hassi s
* Tur n st ar t i ng sw i t c h
ON.
* Disconnect Pl
4 YE
~
TgYNmarringswirchI
* Turn w i per sw i t c h
NO
ON.
* 20 - 3ov
* Di sc onnec t M4
Cal AX
Def ec t i ve w i per mot or
Def ec t i ve c ont ac t l or di s-
c onnec t i on i n w nng
har ness bet w een PA4
(f emal e) (2) - M5 (2)
- c hassi s gr ound
Def ec t i ve w i per r el av,
or def ec t i ve c ont ac t ,
or di sc onnec t i on i n
w i r i ng har ness bet w een
w i per r el ay Rl (3) -
M5 (1) - M4 (f emal e)
(1)
P-15 (b) Wipers work even when wiper switch is not
operated
Ar e LEDs on
moni t or panel
* Tur n.st ar t i ng sw i t c l
ON.
* Tur n w i per sw i t c h
OFF
3 YES
I s t her e
YES c ont i nui t y
2 - bet w een Pl
(f emal e) (15) -
Does w i per w or k - Di sc onnec t Pl . NO
_
w hen Pl i s r emoved - Tur n st ar t i ng sw i t c h
OFF.
. Tur n st ar t i ng sw i t c h NO
ON.
CaUSe
Cont ac t of c hassi s gr ound
w i t h w i r i ng har ness
bet w een Pl (f emal e) (15)
--).vi per r el ay Rl (f emal e)
w i per r el ay Rl (3) -
M5 (1) - M4 (1) i n
c ont ac t w i t h +24V, or
def ec t i ve w i per r el ay
Remedy
Repl ac e
Repl ac e
Cl ean (def ec t i ve
c ont ac t ) or
replace
Cl ean (def ec t i vr
c ont ac t ) r epai r
or r epl ac e
REQISX
A
re
TE
A
r e
r e
R
R
RemedV
f t er i nspec t i on
i pai r or
!pl ac e
f t er i nspec t i on
#pai r or
,p I ace
ep1ac e
eDlaCe
+24V
M SM4)
M4tKES4) (KES4)
(CN-Rl)
205FO5314
20-232
P-l 6 (a) Fan does not work
Cal Se Remedy
v ES
- Turn starting switc,
ON.
* Turn fan switch
ON.
h
N(
Does fan work
when PI (female)
(12) (or (13)) -
chassis ground
are connected?
I
ON.
* Disconnect Pl
YES
Ii
R2 (female) (3)
(Lo side) or R3
(female) (3) (Hi
side) - chassis
* Turn starting
switch ON.
4
Is there con-
tinuity between
R2 (female) (3)
- Ml 2 (female)
(2), or between
R3 (female) (3)
Gjy12 (female)
* Turn startinq switch
ON. -
* Turn heater switch
Defective heater
3efective contaFt! or dis-
:onnection in wrang
>eress between PI
Ifemale) (12) - heater
x4aY R2 (2). between PI
.female) (13) - heater
clay R3 (2). between Ml i
.female) (2) - heater
xlay R2 (3). or between
Ml2 (female) (3) heater
,elay R3 (3)
Defective heater relay
Jisconnection in wirina
,arness between R2 -
:female) (2) -PI (12)
:female), or between R3
ifemale) (2) -PI (13)
,female)
Replace
Replace
Clean (defectivm
contact) or
replace
Replace
Repair or
replace
Replace
P-16 (b) Fan works even when fan switch is not operated
Cause Remedy
3 YES
Is there continuity
YES between P1
2 - (female) (12) (or -
_ (13)) -chassis
ground?
NO
YES Does fan work when - Turn starting switch
Pl is removed?
1
- OFF.
with wiring harness
between Pl (female) (12) After inspec-
heater relay R2 (2). oi
. between PI (female) (13)
tion, repair or
replace
- heater relay R3 (2)
Contact of chassis
ground with wiring
harness between heater
After inspec-
. - Ml2 (2) (or (3)) - tion, repair or
heater relay R2 (3) or R3
(3). or defective heater
replace
relay R2 or R3
Are LED% on
monitor paner -
ON.
NO
. Defective monitor panel Replace
out?
ON.
- Turn fan switch ND
OFF.
. Defective monitor panel Replace
20-233
a
+ 24V
M 12
205FO5315
20-234
P-17 Working mode does not switch
I
CaLlW!
I
Remedy
a) Even when monitor panel switch is pressed, mode
display (LED) above switch does not change.
b) When monitor panel switch is pressed, mode
display (LED) above switch changes.
harness between C2
(14) - P2 (8) or
between C2 (15) - P2
(9). or short circuit
with GND
Tabl e 1
Table 27
NO
* Turn starting switch I
ON.
Working mode 1 Between (14) - (8) 1 Between (15) - (8)
H.0 1 12V (Note) Max. IV
G.0 12V (Note) 12V (Note)
F.0 Max. 1v 12V (Note)
L-0 Max. 1 v Max. 1V
See troubleshooting of
ReplaCe
correct or
replaCe
Replace
Table 2
Working mode
H.0
G.0
Between (8) - (16) Between (9) - (16)
12V (Note) Max. 1V
12V (Note) 12V (Note)
F.0 Max. 1V 12V (Note)
L.0 Max. 1 V 1 Max. 1V
Note: If the voltage is not 12V and is unstable, take the answer
as YES.
C2 (MIC21)
P2 (04016)
205FO5627
20-232
0
P-18 Power set does not switch
a) Even when monitor panel switch is pressed, mode
display (LED) above switch does not change.
b) When monitor panel switch is pressed, mode display (LED)
above switch changes.
YES
1 I
Is voltage between
C2 (5) - (8) and
between (6) - (8) -
as shown in Table
2 YES
I?
Is voltage between
- Turn starting Switc
P2 (5) - (16) and
ON.
9 between (6) - -
ND (16) as shown in
Tadle 27 NO
ON.
harness between C2 (5)
- P2 (5) or between C2
(6) - P2 (6). or short
circuit with GND
Table 1 Table 2
Between (5) - (8) Between (6) - (8)
Note: If the voltage is not 12V and is unstable,
take the answer as YES.
C2 (M IC21) P2 (04016)
Remedy
Replace
3epair or
xplace
3eplace
205FO5628
20-236
0
P-19 Auto-deceleration does not switch (Does not enter
auto-deceleration; auto-deceleration is not canceled)
Cause Remedy
a) Even when monitor panel switch is pressed, ON-OFF display
(LED) above switch does not change.
_ Defective monitor panel ReplaCe
bl When monitor panel switch is pressed, ON-OFF display
(LED) above switch changes.
YES
1
pump controller
system
Is voltage between
C2 (7) - (8) es
- harness between C2
shown in Table l?
2 YES
~ s (7) _ P2 (7). or
correct or
contacf with chassis
replaCe
- Turn starting switch Is Itage betwee
ON.
L P2 (7) - (16) as
ground
-
ND shown in Table I?
NO
Defective monitor panel ReplaCe
ON.
Table 1
. Voltage
Auto-deceleration
switch ON
Max. 1 V
Auto-deceleration
switch OFF
12V (Note)
Note: If the voltage is not 12V and
is unstable, take the answer as
YES.
205F05397A
20-237
o-
P-20 Travel speed does not switch between Hi and Lo
a) Even when monitor panel switch is pressed,
(LED) above switch does not change.
Lo -Hi display
b) When monitor panel switch is pressed, Lo - Hi display
(LED) above switch changes.
L b
ON.
Ci Xl Se
)efective monitor panel
ice troubleshooting of
lump controller systenl
>isconnection in wiring
harness between C2 (3)
- P2 (4). or contact
vith chassis ground
lefective monitor panel
Table 1
r-1
Not e: If the voltage is not 12V
and is unstable, take the
answer as YES.
C2uvlIC21) f2 (04016)
~_fj$jzj
205F05396A
Remedy
ReplaCe
%PlaCe
20-238
0
P-21 Warming-up operation is not carried out below 3OC,
or warming-up operation is not canceled even when
temperature goes above 30C
* Carry out troubleshooting first for E-l 2 Automatic warming-up is defective
Is voltage betweer
P2 (11) - (16j.a~
shown in Table l?
- Turn starting switcl
ON.
.I
Warming-up
5 operation is
not carries
Ot
LI
NO
Warming-up
operation is
not canceled
YES
71
. Turn starting switch NO
OFF.
. Disconnect Pl, P7
YES
21
I -1 I
l-
Can warming-up
be canceled when
short connector is
connected to P7
3 YES
Is there continuity
. Start engine.
between Pl (female)
Ng (6) -chassis ground -
when short connector
is connected 10 P7.
IL
. Turn starting switch NO
OFF.
f Disconnect Pl, P7
See E-12
Defective coolant tern-
perature sensor
Pl (female) (6) - M6
(6) - P7 (1) in contact
with chassis ground or
other GND wiring
Defective coolant tem-
perature sensor
harness between Pl
(female) (6) - M6 (6)
-
P7 (I)
Remedy
Repair or
replace
Repair or
replace
RePl aCe
Note: If the voltage is not 12V and
is unstable, take the answer
as YES.
PI (040201 M14K381 E86WP8) P7(X2)
Coolant temperature sensor
Monitor panel
@
205FO5307-1
20-;39
P-22 Even when swing lock switch is turned ON (LOCK),
swing lock lamp on monitor panel does not light up
Sr Only carry out this troubleshooting if the swing lock is actually applied.
1 YES
Is voltage between
PZ (3) - (16) as -
show n i n Tabl e I ?
NO
* Tur n st ar t i ng sw i t c h
ON.
CWSe
Def ec t i ve moni t or panel Repl ac e
Di sc onnec t i on i n w i r i ng
harness between swing
lock switch (1) - P2 (3)
Swing lock switch
Monitor
P2(04016)
panel
Remedy
correct or
r epl ac e
205FO5741
20-240
0
P-23 Fuel level sensor system defective
Note 1: Difference between fuel level and gauge display
If the gauge display position is lo, the fuel level display is 78% or 100%; if it is "1 ,
the fuel level display is less than 14.5%. If the machine is on a slope, the display and
actual fuel level will be different. Therefore, when checking, always stop the machine on
level ground and wait for at least two minutes before reading the gauge. (The fluid level
changes when the machine is moving, so a time delay is provided to give a stable display.)
+ Remove the fuel level sensor when carrying out this troubleshooting.
resistance between
Connector 11) and
flange as shown in
3 YES
I1
NO
4 YES
Check wiring
. harness visually. Is -
it broken?
NO
CaLIS
Interference with sensor
inside tank
Defective contact of connector
Defective sensor (Note 2)
harness (Note 3)
(Defective clamp)
(Outside force applied)
Defective sensor
Remedy
%?PlKZ
:Note 2)
Clean COnnectOr
or replace
Replace
Repalce sensor
Reolace
F20205053
Note 2: There is probably interference with the sensor inside the tank, or defective installation.
Install carefully when replacing.
Note 3: Check for any vibration at the connector mount, and take the necessary action if the vibration
is excessive.
20- 241
0
P -24 Coolant temperature sensor system defective
c
YES I
Defectwe contact of COnneCtOr Clean COnneCtOr
(Note 1) or replace sen*cJr
harness INore 2)
(Defective clamp)
Replace sen*cJr
1
bs,~siS~t~nce
temperatre SenSOr
03nneCtor (male) (1) -
and (2) as shown I
2 YES
P ,-
Table 1 ?
P Check wiring
- harness VISUBIIY. Is -
NO
it broken?
NO
Table 1
Normal tem-
perature (25C
Approx. 37 - 50ki2
100C Approx. 3.5--4.Okfl
Defective sewor ReplaCe
Sensor
F20205054
Note 1: If the problem occurs again, the connector (female) at the chassis end is probably defective,
so replace the connector (harness) at the chassis end.
is excesive.
20-242
0
P-25 Defective engine oil level sensor system
Note 1: Variations in oil level
The oil level changes according to the angle of the machine, the engine speed, and the oil
temperature, so if any abnormal display is given, stop the machine on flat ground and check the
oil level again.
+ Remove the oil level sensor when carrying out this troubleshooting.
L
YES
Is any dirt or dust
- stuck to movable -
part of float?
3 YES
Is float badly
1
- cracked, chipped. or -
Move the float up
NO damaged?
and down. Is the
resistance between -
connector (1) and
flange as shown in
Table l?
NO
4 YES
Check wiring
L harness visually. Is -
NO
,t broken?
NO
Table 1
Aiizfzs
Note 2:
Note 3:
Note 4:
Defective movement of
float caused by dirt
connector (Note 2)
harness (Note 3)
(Defective clamp)
Defective sensor Replace
F20205055
Remedy
Clean
Replace
sensor (Note
41
Clean or
repl.Xe
connedor
If the problem occurs again, the connector (female side) at the chassis end is probably
defective, so check the connector and wiring harness at the chassis end.
Check for any vibration at the connector mount, and take the necessary action if the vibration
is excessive.
The installation is probably defective, so be careful when installing. If the problem occurs
again, check for any vibration at the connector mount, and take the necessary action if the
vibration is excessive.
P-26 Coolant level sensor system defective
Note 1: Variations in coolant level
The coolant level changes according to the angle and swaying of the machine, so if any
abnormal display is given, stop the machine on flat ground and check the coolant level
before carrying out the check again.
* Remove the coolant level sensor when carrying out this troubleshooting.
Move the float up
and down. Is the
resistance between
connector 11) and
flange as shown in
Tahlr 1,
I
YES
2
Defective movement Of float
because of dirt
stuck in float?
3 YES
- Is float badly
_ cracked, chipped, or -
NO damaged?
Resonance of nlODf
NO
Defective contact
of connector
(Note 2)
4
Is wiring of wiring
harness broken? is
. resistance between
connector (1). (2)
and sensor below
IsI?
Table 1
Float UP Max. lC2
1 Float DOWN 1 Min. lMS2 1
YES
I
NO
Cause
DisconneCfion in wiring
harness (Note 3)
(Defective clamp)
Defective tensor
Remedy
Clean
Replace sensor
(Note 41
Clean connector
or replace
Repalce sensor
RePl aCe
F20205056
Note 2: If the problem occurs again, the connector (female side) at the chassis end is probably
is excessive.
Note 4: The installation is probably defective, so be careful when installing. If the problem occurs
20-244
a
P-27 Hydraulic oil level sensor system defective
PC200,2OOLC-5 Serial No: 45001 - -
PC220,220LC-5 Serial No: 35001 - -
Note 1 : Variations in hydraulic oil level
The hydraulic oil level changes according to the angle and swaying of the machine, so if any
abnormal display is given, stop the machine on flat ground and check the hydraulic oil level
before carrying out the check again.
* Remove the hydraulic oil level sensor when carrying out this troubleshooting.
YES Is any dirt or dust
- stuck in float?
3 YES
- Is float badly
1
- cracked, chipped. or _
Move the float up
NO damaged,
and down. Is the
resistance between NO
tonnector (1) and
(21 as shown in
Table?
4
YES
Is wring of wiring 1
harness broken? Is
_ resrstance between _
NO connector (1). (2)
a$ensor below
NO
Tabl e 1
Note 2:
Note 3:
Note 4:
C.3U.W
Defective movement of float
because of dtrt
Resonance of mount
Defective contact
of connector
(Note 21
harness (Note 3)
(Defective clamp)
Defective sensor
F20505366
If the problem occurs again, the connector (female side) at the chassis
Remedy
Clean
Replace Sensor
(Note 41
Clean Connector
or replace
l?epalce sesor
ReplXe
end is probably
Check for any vibration at the connector mount, and take the necessary action if the vibration
is excessive.
The installation is probably defective, so be careful when installing. If the problem occurs
20-i45
PC200,2OOLC-5 Serial No: * and up
PC220,22OLC-5 Serial No: - and up
Note 1: Variations in hydraulic oil level
The hydraulic oil level changes according to the angle and swaying of the machine, so if any
abnormal display is given, stop the machine on flat ground and check the hydraulic oil level
again.
+ Remove the hydraulic oil level sensor when carrying out this troubleshooting.
and down. Is the
resistance between
connector (1) and
flange as shown in
Y ES
1
i
10
YES
2
Is any dirt or dust
stuck to movable -
part of float? 3 YES
1
- Is float badly
- cracked, chipped, or _
NO damaged?
NO
Cause
I==
4 YES
Check wiring
harness visually. Is -
it broken?
NO
Table 1
z%zJz%G
Defective movement 01
float caused by dirt
Resonance at mount
connector (Note 2)
harness (Note 3)
(Defective clamp)
Defect,ve sensor
Remedy
Clean
Replace
sensor (Note
4)
Clean or
replace
connector
ReplaCe
sensor
Replace
F20205055
Note 2: If the problem occurs again, the connector (female side) at the chassis end is probably
is excessive.
Note 4: The installation is probably defective, so be careful when installing. If the problem occurs
30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL.. .
PRECAUTIONS WHEN
CARRYING OUT OPERATION .
SPECIAL TOOL LIST . . . . . . . . . . .
WEIGHT TABLE . . . . . . _ . . . . .
TIGHTENING TORQUES AND
STANDARD VALUES TABLE . .
LUBRICANT AND COOLANT TABLE
STARTING MOTOR
Removal and Installation
z
ALTERNATOR
::
:
ENGINE OIL COOLER
FUEL INJECTION PUMP
WATER PUMP
NOZZLE HOLDER
TURBOCHARGER
THERMOSTAT
ENGINE FRONT SEAL
ENGINE REAR SEAL
GOVERNOR MOTOR
CYLINDER HEAD
AFTER-COOLER
HYDRAULIC COOLER
30- 4
30- 5
30- 7
30- 7-2
30-
30-
9
11
. . . . . . . . . . 30-
. . . .
12
. 30-12
. 30-14
. 30-14
. 30-16
. 30-16
30-18
30-18
. 30-20
30-20
. 30-22
30-24
30-26
. 30-26
REDIATOR, HYDRAULIC COOLER
Removal and Installation . . . . . . . . 30-28
ENGINE, HYDRAULIC PUMP
DAMPER
CENTER SWIVEL JOINT
.......... 30-30
.......... 30-32
.......... 30-32
Disassembly and Assembly ........ 30-34
FINAL DRIVE
Removal and Installation .......... 30-34
Disassembly ..................... 30-36
Assembly ........................ 30-38
SPROCKET
Removal and Installation .......... 30-42-I
TRAVEL MOTOR
Disassembly .................. 30-43-I
Assembly ..................... 30-43-5
SWING MOTOR
Disassembly .................... 30-45
Assembly ..................... 30-45-3
SWING MACHINERY
Removal and Installation ........ 30-45-8
Disassembly .................... 30-46
Assembly ....................... 30-48
REVOLVING FRAME
SWING CIRCLE
IDLER, RECOIL SPRING
Disassembly and Assembly. ....... 30-58
TRACK ROLLER
CARRIER ROLLER
TRACK SHOE
CHARGING PUMP
HYDRAULIC PUMP
Disassembly .................. 30-65-I
Assembly ..................... 30-65-6
MAIN PUMP INPUT SHAFT OIL SEAL
CONTROL VALVE
Disassembly ..................... 30-68
Assembly ........................ 30-70
MAIN RELIEF VALVE
TVC VALVE
CO l NC VALVE
SERVO VALVE
WORK EQUIPMENT PPC VALVE
Disassembly and Assembly ........ 30-77-I
TRAVEL PPC VALVE
BOOti HOLDING VALVE
PPC SHUTTLE VALVE
BOOM CYLINDER
Removal and Installation . . . . . . . . 30-83-I
ARM CYLINDER
Removal and Installation . . . . . . . 30-84
BUCKET CYLINDER
Removal and Installation . . . . . . 30-85-I
HYDRAULIC CYLINDER
Disassembly . . . . . . . . . 30-86
Assembly.. . . . . . . 30-88
WORK EQUIPMENT
Removal and Installation . . . . . . 30-90
BUCKET
Removal and Installation . . . . 30-92
ARM
ARM, BUCKET
Removal and Installation . . . . . _ . . 30-94
BOOM
Removal and Installation . . . . . . 30-95-I
CAB
COUNTERWEIGHT
Removal and Installation . . . . . . . . 30-96
Removal and Installation . . . . . . . 30-98
PUMP CONTROLLER
MONITOR PANEL
Removal and Installation . . . . . . 30-98
METHOD OF USING MANUAL
1. When removing or installing unit assemblies
( I ) When removing or installing a unit assembly, the order of work and techniques used are given
for the removal operation; the order of work for the installation operation is not given.
(2) Any special techniques applying only to the installation procedure are markedm, and the
same mark is placed after the relevant step in the removal procedure to indicate which step in
the installation procedure it applies to.
(Example)
REMOVAL OF 00 0 ASSEMBLY ......
a ................................
1. XXXX(1) ........................
* ...............................
2. AAA(2): . . . . . . . . . . . . . . . . . . . . . .
Tilte of operation
Precautions related to safety when carrying out the
operation
Step in operation
Technique or important point to remember when
removing XXXX !I ).
m Indicates that a technique is listed for use
during installation
3. 0 0 0 0 assembly (31
:
_ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Lubricant and Coolant Table
INSTALLATION OF 0 0 OASSEMBLY . Title of operation
.
Carry out installation in the reverse order to removal.
I.. . . . . . . . . . . . . . . . . Technique used during installation
* . . . . . . . . . . . . . . . . . . Technique or important point to remember when in-
stalling A A A (2).
.
Adding water, oil _ . . . . . . Step in operation
sr . . . . . . . . . . . . . . . . . Point to remember when adding water or oil
2. General precautions when carrying out installation or removal (disassembly or assembly) of units
are given together as PRECAUTIONS WHEN CARRYING OUT OPERATION, so be sure to follow
these precautions when carrying out the operation.
3. Listing of special tools
(1) For details of the description, part number, and quantity of any tools (A,, etc.) that appear in
the operation procedure, see the SPECIAL TOOLS LIST given in this manual.
4. Listing of tightening torque, weight, refill amount for oil and water
( I ) If symbols such as m ,
&,or%@ appear in the operation procedure, See TIGHTENING
TORQUES AND STANDARD VALUES TABLE, MAINTENANCE STANDARD TABLE, WEIGHT
TABLE, and LUBRICANT AND COOLANT TABLE for details of the values.
PRECAUTIONS WHEN CARRYING OUT OPERATION
[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the
general precautions given below when carrying out the operation.]
1.
.
.
.
.
.
.
.
.
.
.
+
Precautions when carrying out removal work
If the coolant contains antifreeze, dispose of it correctly.
After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from
entering.
When draining oil, prepare a container of adequate size to catch the oil.
Confirm the match marks showing the installation position, and make match marks in the neces-
sary places before removal to prevent any mistake when assembling.
To prevent any excessive force from being applied to the wiring, always hold the connectors when
disconnecting the connectors.
Fit wires and hoses with tags to show their installation position to prevent any mistake when
installing.
Check the number and thickness of the shims, and keep in a safe place.
When raising components, be sure to use lifting equipment of ample strength.
When using forcing screws to remove any components, tighten the forcing screws alternately.
Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt
from entering after removal.
Precautions when handling piping during disassembling
Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
I) Hoses and tubes using sleeve nuts
Nominal
Plug (nut end)
Sleeve nut (elbow end)
number Use the two items below as a set
02 07376-50210 07221-20210 (Nut), 07222-00210 (Plug)
03 1 07376-50315 1 07221-20315 (Nut), 07222-00312 (Plug)
04 / 07376-50422 07221-20422 (Nut), 07222-00414 (Plug)
05 1 07376-50522 1 07221-20522 (Nut), 07222-00515 (Plug)
06 07376-50628 07221-20628 (Nut), 07222-00616 (Plug)
10 07376-51034 07221-21034 (Nut), 07222.01018 (Plug)
12 07376-51234 07221-21234 (Nut).07222-01219 (Plus)
2) Split flange type hoses and tubes
Nominal
Flange (hose end)
Sleeve head
number (tube end)
Split flange
04 07379-00400 07378-I 0400 0737 I-30400
05 07379-00500 07378-l 0500 0737l-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
A
A
Taper 1I8
202F2001
24 /07049-024301 24 1 20 / 30
27 /07049-027341 27 1 22.5 1 34
Precautions for installation operations
Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
Install the hoses without twisting or interference.
Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
Bend the cotter pin or lock plate securely.
When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded
portion with 2 - 3 drops of adhesive.
When coating with gasket sealant, clean the surface and remove all oil and grease, check that
there is no dirt or damage, then coat uniformly with gasket sealant.
Clean all parts, and correct any damage, dents, burrs, or rust.
Coat rotating parts and sliding parts with engine oil.
When press fitting parts, coat the surface with antifriction compound (LM-PI.
After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then con-
nect securely.
When using eyebolts, check that there is no deformation or deterioration, screw them fully, and
align the direction of the hook.
When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
Precautions when completing the operations
If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run g
the engine to circulate the water through the system. Then check the water level again.
g
If the hydraulic equipment has been removed and installed again, add engine oil to the specified 0
level. Run the engine to circulate the oil through the system. Then check the oil level again.
If the piping or hydraulic equipment, such as hydraulic cylinders, pumps, or motors, have been re-
moved for repair, always bleed the air from the system after reassembling the parts.
t For details, see TESTING AND ADJUSTING, Bleeding air.
Add the specified amount of grease (molybdenum disulphide grease) to the work equpment related
parts.
SPECIAL TOOL LIST
Nature of work Symbol Part No. Part Name
Installer
oty
Remarks
1 Installation of floating seal 1 791-545-l 510
Disassembly,
assembly of final
drive assembly
A 2
t
3
796- 540- I 110
790- 331- I 110
791-600-2001
791-6:;-8003
B 791-635-3160
Disassembly,
assembly of recoil
spring assembly
Extension II I
790-I 01-l 600 1 : rZJll:er (70 t)
790-I 01-l 102
791-630-3000 Remover & installer 1
Cylinder (100 t) 1
Removal, press fitting
of master pin
Pump 1
Disassembly,
assembly of track
shoe assembly
C 790-I 01-l 300
790-I 01-I 102
. Removal,
installation of
charging pump
assembly
* Removal, instal-
lation of main
pump assembly
Oil stopper D 796- 750- 1410
Socket
(width across flats:
95 mm)
790-502-I 002
Arm cylinder
(PC200, 220)
Boom, bucket
cylinder
(PC220)
Boom, bucket
cylinder
(PC200)
790-302-I 450
Removal,
installation
of nylon
nut
1
Socket
(width across flats:
85 mm)
790-302-I 350
Pump
I 1 I I Disassembly,
assembly of
hydraulic
cylinder assembly
790-I 01-l 102
790-720-I 000 Expander
Ring
I
1
Expansion of
piston ring
1
Arm cylinder
(PC220)
E
2
796-720-I 680
3 796-720-I 670 Ring
Ring
Clamp
1
Bucket cylin-
der (PC220)
1 All cylinders
796-720-I 660
07281- 01279
. Removal, instal-
lation of boom
assembly
. Removal, instal-
lation of work
equipment
assembly
796-900-I 200
790-I 01-3800 F
790-I 01-l 102 Pump
Nature of work Symbol Part No. Part Name Oty Remarks
Disassembly,
assembly of travel
motor assembly
G
c
Disassembly,
assembly of swing
motor assembly
Disassembly,
assembly of
hydraulic pump
assembly
H
-
K
I I I I
790-501-5000 Repair stand 1
1 790-901-21 IO Bracket 1
790-901-I 350 Plate 1
2 1 799-301-1600 1 Oil leak tester
I I
1 Removal of brake piston
3 790-445-3810 Push tool 1
Press fitting of bearing
4 790-445-3870 Push tool 1 inner race
5 790-445-3820 Plate 1 Transporting
790-501-5000 Repair stand 1
1 790-901-2110 Bracket 1
790-901-2290 Plate
r 1
1
2 1 799-301-1600 1 Oil leak tester kit
I I
1 Removal of brake piston
3 11 Re;z,vJ, installation of
795-630-I 803 Torque wrench set 1
4 790-445-3910 Holder 1 Installation of center shaft
796- 730- 2000 Wrench 1
F
Measurement of rotating
d
795-630-I 803 Torque wrench set 1
torque
790-501-5000 Rapair stand 1
1 790-901-2110 Bracket 1
790-901-2150 Plate 1
2 790-345-I 020 Plate 1
796-730-2120 Screwdriver 1
Removal, installation of
bearing retainer
I, installation of
790-445-6100
orque wrenc
Measurement of rotating
30- g- l
WEIGHT TABLE
Unit: kg
Machine model PC200,2OOLC-5 PC200, 2OOLC5 MIGHTY
Serial No.
Cylinder head assembly
45001 and up
40
58019 and up
40
Hydraulic cooler assembly 55 55
.: p Radiator, hydraulic cooler assembly 80 94
L Air cleaner assembly (with bracket) 35 35
Engine, main pump assembly 750 750
Center swivel joint assembly 45 45
.& Final drive assembly 460 460
r! Sprocket 40 40
&
3 Swing motor assembly 55 55
l?
Swing machinery assembly 280 280
Revolving frame assembly
I
4,400
I
4,770
% Idler, recoil spring assembly 270 270
-;
2 Recoil spring assembly 140 140
u
3 Idler assembly 130 130
E Hydraulic pump assembly 210 210
aI
F Control valve assembly 180 180
cn
.u Boom cylinder assembly 190 190
?I
s Arm cylinder assembly 250 250
>
I Bucket cylinder assembly 160 190
; Work equipment assembly 3,400 3,750
E Bucket assembly 650 715
g Arm assembly 1,000 1,250
;i
, Arm, bucket assembly 1,650 2,000
z
E Boom assembly 1,750 1,750
g
w
Operators assembly cab 240 240
+ Operators seat assembly 30 30
0
3 Counterweight 3,400 4,400
Unit: kc
Machine model I
PC2205 I
Serial No. I 35001 and up I
1 Cylinder head assembly I 40 I
Hydraulic cooler assembly 55
?
F Radiator, hydraulic cooler assembly 80
w
Air cleaner assembly (with bracket) 35
Engine, main pump assembly
I
750
I
Center swivel joint assembly
I
45
I
.G
Final drive assembly
r!! Sprocket
&
3 Swing motor assembly
0
a Swing machinery assembly
460
40
55
280
Revolving frame assembly
I
4,400
I
% Idler, recoil spring assembly
.;
g Recoil spring assembly
m
3 Idler assembly
270
140
130
TIGHTENING TORQUES AND STANDARD VALUES TABLE
1
-
2
3
4
5
-
6
1
2
3
Item
L
Unit
PC200,2OOLC-5
PC220,22OLC-5
Head cover mounting bolt
Rocker arm assembly mounting bolt, nut
Rocker arm locknut
0.9 f 0. 1 0.9 + 0. 1
2.5 k 0.5 2.5 f 0.5
km
4.5 * 0.5
I
4.5 f 0.5
Cylinder head mounting bolt 1 st step
2nd step :
3rd step
0
90 +30
0
I
90 30
0
Rear seal assembly
1) Flywheel mounting bolt 1 st step
2nd step
km
9+3 9*3
I
18i 2
I
181 2
2) Face runout, radial runout of
flywheel
Engine mounting bolt
Damper assembly mounting bolt
Final drive assembly
1) Retainer mounting bolt
2) Retainer mounting bolt
3) Starting torque
I
7.25 +0.75
I
7.25 f 0.75
11.25 k 1.25 11.25 k 1.25
kgmk
4) Carrier mounting bolt 11.25 i 1.25 13.25 i 1.25
5) Carrier mounting bolt
I
6.75 i- 0.75 6.75 + 0.75
6) Cover mounting bolt
Initial tightening torque
Additional tightening
angle
I
8.0
I
8.0
7) Final drive assembly mounting bolt
*
1) Cradle mounting bolt
kgm
28 k 3
I
28 k3
2) End cover mounting bolt
I
56 f 6
I
56 + 6
I
Machine model
6
1
0 Safety valve
Machine model
PC200, 2OOLC- 5
PC200, 2OOLC- 5 MI GHTY
PC220, 22OLC- 5
28 f 3 28 i 3
13 f1.5 13 i 1.5
Swing machinery assembly
1) Carrier gear pin mounting bolt
2) Carrier assembly plate mounting b,olt
3) Bearing cage mounting bolt
11.25 & 1.25 11.25 f 1.25
39.25 + 4.25 39.25 f 4.25
* When adjusting preload (only 4 bolts)
* After adjusting
1) Plug of check valve
knm
2.0
6.75 + 0.75
38 & 5
2.0
6.75 f 0.75
38 f 5
18+ 1
Max. 0.1
0.5 & 0.1
1.35 f 0.15
18, 2
111 f 11
2) Safety valve
3) Retainer mounting screw 1 st step
2nd step
3rd step
4) Brake case assembly mounting bolt
Revolving frame assembly mounting bolt
Recoil spring assembly
1) Installed load of spring
kg
11,100
2) Free length of spring
3) Installed length of spring
12,900
603.5
466
Machine model
Item
Hydraulic pump assemblv
i) Mounting bolt of main pump input shaft
housing assembly
2) Plate bolt of cradle
Uni t PC200, 2OOLC- 5
PC200, 2OOLC- 5 MI GHTY pc220r 220LC- 5
-k :gm
1
3) Bearing retainer screw
4) Housing mounting bolt
5) Pump sub-assembly mounting bolt
6) End cap mounting bolt (Front)
(Rear)
7) Impeller mounting bolt
8) Servo piston mounting bolt
9) Servo valve assembly mounting bolt
10) Rear pump assembly mounting nut
11) CO * NC valve mounting bolt (Front pump)
12) TVC and CO * NC valve mounting bolt
(Rear pump)
13) Tube joint bolt
14) Sleeve nut of hose
1) Check valve mount plug
2
2) Safety-suction valve
3) Set sensor relief valve
4) Main relief valve
Work equipment PPC valve assembly
1) Joint
3
2) Nut
4 Boom lock valve assembly
1) Safetv valve 19f 1 19f 1
4 t 0.5 4 * 0.5
6.75 i 0.75 6.75 f 0.75
27.5 + 4 27.5 + 4
720 f 72 720 + 72
38 f 5.5 38 -c 5.5
1,040 + 104 1,040 * 104
27.5 k 4 27.5 + 4
720 f 72 1,040 f 104
2) Spool mount plug
3) Check valve body mounting bolt
Hydraulic cylinder assembly
1) Bucket cylinder Head mounting bolt
Piston nut
5
2) Arm cylinder Head mounting bolt
Piston nut
3) Boom cylinder Head mounting bolt
Piston nut
REMOVAL OF STARTING REMOVAL OF ALTERNATOR
MOTOR ASSEMBLY ASSEMBLY
A Disconnect the cable from the negative (-1
terminal of the battery.
1. Governor motor assembly
l Remove governor motor assembly.
For details, see REMOVAL OF GOVER-
NOR MOTOR ASSEMBLY.
2. Heater switch (I 1 (See Fl)
3. Governor motor bracket (2) (See Fl 1
4. Wiring (3) (See F2)
5. Wiring connector (4) (See F2)
6. Starting motor assembly (5) (See F2)
1. Wiring (I) (See F3)
2. Adjustment bolt (2) (See F3)
t Loosen mounting bolts and nuts (3).
3. Fan belt (4) (See F3) m
4. Mounting bolts and nuts (3) (See F3)
5. Alternator assembly (5) (See F3)
INSTALLATIN OF
STARTING MOTOR
ASSEMBLY
INSTALLATION OF
ALTERNATOR ASSEMBLY
l Carry out installation in the reverse order to
removal.
B
.
removal.
Adjust the fan belt tension.
For details, see Standard Value Table
for Engine.
::
:
0
30- 12
0
Fl
F2050530 1
F2
F20505302
3023
REMOVAL OF ENGINE OIL REMOVAL OF FUEL
COOLER ASSEMBLY INJECTION PUMP ASSEMBLY
1.
2.
3.
.Draining cooling water
Dust indicator hose (I), intake pipe (2) (See
Fl)
Turbocharger heat insulator plate (3) (See
Fl)
4. Lubrication tube (4) (See F21
5. Oil level gauge guide (5) (See F2)
6. Oil cooler assembly (6) (See F21 m
INSTALLATION OF ENGINE
OIL COOLER ASSEMBLY
removal.
& Oil cooler assembly:
Gasket sealant (LG-7)
l Refilling with water
t Add water to the specified level, and run
the engine to circulate the water
through the system. Then check the
water level again.
1.
2.
3.
4.
5.
6.
7.
8.
Fuel injection pipe (I 1 (See F3) m
Control rod (2) (See F31
+ Mark the mounting hole of the clevis pin.
Heater switch (3) (See F3)
Ir Remove the heater switch mounting
bolts, and move the heater switch to-
wards the rear.
Spill hose (4) (See F3)
Fuel hose (5) (See F3)
Lubrication tube (6) (See F3)
Bracket (7) (See F31
Fuel injection pump assembly (8) (See F3)
m
* Remove 5 front end mounting bolts and
1 pump end mounting bolt.
INSTALLATION OF FUEL
INJECTION PUMP ASSEMBLY
removal.
m
QZI Sleeve nut:
See Tightening Torques and
Standard Values Table
m
l Install the injection pump as follows.
1) Set No. 1 cylinder at compression
top dead center.
Sr Rotate the crankshaft in the
normal direction and align the
pointer with the 1.6 TOP line on
the crankshaft pulley. (See F4)
If no match mark can be seen on
the idler gear, rotate the crank-
shaft one more turn.
2) Replace the normal bolt with bolt
0, and lock drive gear (9) in posi-
tion. (See F5) .
3) Injection pump assembly
* Insert pin @ (+4.0 - 4.5 mm,
length = approx. 100 mm)
through cover mounting bolt
hole a, and check that the pin
enters the casting hole in the
drive gear smoothly. (See F6)
4) Remove bolt @ and tighten the
normal bolt again. (See F5)
l Adjust the fuel timing and bleed the air
from the fuel circuit.
For details, see TESTING AND ADJUST-
ING.
30- 14
0
Fl
F205053Of
F2
F20505305
I-
:3
F
I
205FO5400
' 4
mark C
(View from flywheel)
014OF107
F5
1
9.
F6
I -- 20UF01206.KC
REMOVAL OF WATER
PUMP ASSEMBLY
1. Draining cooling water
2. Wiring connector (I 1 (See Fl)
3. Hose (2) (See Fl I
4. Fan belt (3) (See Fl) m
+ Loosen the mounting bolts and nuts of
the alternator assembly, then remove
the adjustment bolt, and move the alter-
nator assembly towards the block.
5. Plate (4) (See Fl 1
6. Water pump assembly (51 (See Fl)
INSTALLATION OF WATER
PUMP ASSEMBLY
removal.
m
l Adjust the fan belt tension.
For details, see Standard Value Table
for Engine.
* Add water to the specified level,
and run the engine to circulate the
water through the system. Then
check the water level again.
REMOVAL OF NOZZLE
HOLDER AS$EMBLY
1. Fuel injection pipe (I) (See F2) m
2. Spill hose (2) (See F2)
3. Holder (3) (See F2) m
4. Nozzle holder assembly (4) (See F2) m
+ When removing the nozzle holder as-
sembly, be careful not to let any dirt or
dust get in.
INSTALLATION OF NOZZLE
HOLDER ASSEMBLY
removal.
m Sleeve nut:
For details, see Tightening
Torques and Standard Values
Table
/
g
w Mounting bolt:
Z
Z
Table
m
* When installing the nozzle holder as-
sembly, check and clean the nozzle
mount, then install.
30- 16
0
F20505307
30617
REMOVAL OF REMOVAL OF
TURBOCHARGER ASSEMBLY THERMOSTAT AhSEMBLY
1.
2.
Dust indicator hose (I), intake pipe (2) (See
FII
Turbocharger heat insulator plate (3) (See
FII
3. Lubrication drain tube (4) (See Fl)
4. Hose (51 (See F2)
6.
6.
7.
8.
9.
* Disconnect the hose, and move it to-
wards the intake connector.
Lubrication inlet tube (61 (See F2)
Muffler heat insulator plate (7) (See F2)
U-bolt (8) (See F2)
Bracket (9) (See F2)
Turbocharger assembly (I 0) (See F2)
* Remove the turbocharger mounting
nuts, pull out the muffler drain hose,
move the muffler assembly towards the
counterweight, then remove the tur-
bocharger assembly.
INSTALLATION OF
TURBOCHARGER ASSEMBLY
removal.
1. Draining cooling water
2. Connector (1 I (See F3)
3. Thermostat assembly (2) (See F3I
INSTALLATION OF
THERMOSTAT ASSEMBLY
Carry out installation in the reverse order to
removal.
Refilling with water
-f Add water to the specified level, and run
the engine to circulate the water
through the system. Then check the
water level again.
3028
F2
::
F20505309
s
m
0
/ F20505310
3029
REMOVAL OF ENGINE REMOVAL OF ENGINE
FRONT SEAL REAR SEAL
1.
2.
3.
4.
5.
6.
After-cooler assembly (PC220-5 only)
l Remove after-cooler assembly.
Radiator, hydraulic cooler assembly
l Remove radiator and hydraulic cooler
assembly.
For details, see REMOVAL OF RADIA-
TOR, HYDRAULIC COOLER ASSEMBLY.
Fan (I) (See Fl)
Vibration damper (2) (See Fl)
Fan belt (3) (See Fll a
* Loosen the mounting bolts and nuts of
the alternator assembly, then remove
the adjustment bolts, and move the al-
ternator assembly towards the block.
Pulley (4) (See F2)
* Using puller 0, remove the pulley, then
remove the collar.
7. Front seal (5) (See F3) a
INSTALLATION
FRONT SEAL
OF ENGINE
removal.
l Adjust the fan belt tension.
For details, see Standard
for Engine.
jn21
Value Table
a Lip of oil seal: Grease (G2-LI)
-k Press fit the front seal so that it is level
with the surface of the front cover.
1. Damper assembly
l Remove damper assembly.
For details, see REMOVAL OF DAMPER
ASSEMBLY.
2. Flywheel (I 1 (See F4) /nl
A
The pilot of the flywheel is shallow, and
may suddenly come out, so be careful
not to get your fingers caught.
3. Rear seal (2) (See F5) m
REAR SEAL
removal.
111/
* Tightening order of mounting bolts (See
F5)
m Mounting bolt:
.
m
*
Table.
Use dial gauge @ to measure the face
runout and radial runout of the flywheel.
(See F6)
For details, see Tightening Torques and
Standard Values Table.
When assembling, check the wear
groove of the seal lip contact portion of
the crankshaft, and if necessary, move
the seal approx. 2 mm (change a from
20 mm to 22 mm) towards the flywheel
before assembling. (See F7)
&I& Lip of oil seal: Grease (G2-LI)
30-20
a
1
I -1
705FWi 401 ---. -_ ._.
F2
r
205FO5402
F3
205FO5403
F
205FO5404
F5
6143F105
F6
6140F287A
7
a
I
202FO5415
REMOVAL OF GOVERNOR
MOTOR ASSEMBLY
A Disconnect the cable from the negative (- 1
1. Control rod (I) (See Fl)
Sr Remove the clevis pins at the governor
motor end.
2. Wiring connector (21 (See Fl I
3. Governor motor assembly (3) (See Fl 1
INSTALLATION OF
GOVERNOR MOTOR
ASSEMBLY
removal.
30;22
Fl
r
REMOVAL OF CYLINDER
HEAD ASSEMBLY
1. Water pump assembly
l Remove water pump assembly.
2. Turbocharger assembly
l Remove turbocharger assembly.
3. Wiring (I 1 (See Fl)
4. Intake connector (2) (See Fl I
5. Breather hose (3) (See Fl 1
6. Fuel filter assembly (41 (See Fl I
* Disconnect the fuel filter assembly, and
move it towards the fan.
7. Fuel injection pipe (5) (See Fl) m
8. Spill hose (6) (See Fl)
9. Nozzle holder assembly (7) (See Fl) m
* Remove 6 nozzle holder assemblies
together with the spill hoses.
10. Head cover (8) (See F I) /
11. Rocker arm assembly (9) (See F21 @!%!
J, Loosen the locknut, then loosen the ad-
justment screw 2 - 3 turns.
12. Push rod (I 0) (See F2)
13. Cylinder head assembly (I I) (See F3) m
&
kg See Weight Table
INSTALLATION OF
CYLINDER HFAD ASSEMBLY
removal.
m
m Sleeve nut:
m
w Mounting bolt:
m
m Mounting bolt:
m
Jr Tighten the mounting bolts and nuts
starting from the center and working
out in order to the outside. (See F41
+ Check that the ball of the adjustment
screw is fitted securely in the socket of
the push rod.
l Adjust the valve clearance.
ING, Adjusting valve clearance.
w Mounting bolt, nut: 0
See Tightening Torques and 0
Z
w Locknut:
m
jl Be careful to check that there is no dirt
or dust on the mounting surface of the
cylinder head or inside the cylinder.
Jc When installing the gasket, check that
the grommets have not come out.
Ir Tighten the cylinder head mounting
bolts 2 - 3 turns by hand, then tighten
in the order given in the diagram.
a Mounting bolt:
Anti-friction compound (LM-
PI
m Mounting bolt:
Sr After tightening, make one punch mark
on the bolt head to indicate the number
of times it has been tightened. (See F5)
l If any bolt already has five punch
marks, do not reuse it. Replace it
with a new bolt.
nn
205FO5405
F2
205FO5406
1
-I
205FO5407
4
Exhaust side
Front tii Rear
Order for tightening head bolts
6206F401 A
F5
I-
Make marks on bolt and cylinder hand
@$jY I) @+To
F621201067A
REMOVAL OF
AFTER-COOLER ASSEMBLY
(PC220 only)
1. Hose (I) (See Fl)
2. After-cooler assembly (2) (See Fl I
t Sling the after-cooler assembly, and
remove the mounting bolts, then lower
the after-cooler assembly and pull it out.
INSTALLATION
AFTER-COOLER
(PC220 only)
OF
ASSEMBLY
removal.
REMOVAL OF HYDRAULIC
COOLER ASSEMBLY
1. After-cooler assembly (PC220 only)
For details, see REMOVAL OF
AFTER-COOLER ASSEMBLY.
3. Net (2) (See F2)
4. Hydraulic cooler assembly (3) (See F3)
* Sling the hydraulic cooler assembly, and
remove mounting bolts, then lower the
hydraulic cooler assembly and pull it out.
&
kg See Weight Table
INSTALLATION OF
HYDRAULIC COOLER
ASSEMBLY
removal.
l Refilling with oil
* Add oil to the specified level, and run
the engine to circulate the oil through
::
the system. Then check the oil level
g
again.
:
30-26
0
F
I I
F205053 12
2
:
i
~ F20505313
L
F3
1
F20505314
REMOVAL OF RADIATOR,
HYDRAULIC COOLER
ASSEMBLY
1. After-cooler assembly (PC220-5 only)
For details, see REMOVAL OF AFTER-
COOLER ASSEMBLY
2. Draining water
3. Hose (I) (See Fl 1
4. Hose (2) (See F2)
6. Shroud (4) (See F2I
Ir Remove the shroud and move it
towards the engine.
7. Radiator and hydraulic cooler assembly (5)
(See F3)
+ Sling the radiator and hydraulic cooler
assembly, then remove the mounting
bolts, and lift off the radiator and
hydraulic cooler assembly.
&I
kg See Weight Table
INSTALLATION OF
RADIATOR, HYDRAULIC
COOLER ASSEMBLY
removal.
. Refilling with oil
Ir Run the engine to circulate the oil
through the system.
Then check the oil level again.
Sr Run the engine to circulate the water
through the system.
Then check the water level again.
30-28
0
Fl
I I
205FO5408
F2
205FO5409
F3
205FO5410 1
30-29
a
REMOVAL OF ENGINE,
HYDRAULIC PUMP
ASSEMBLY
15. Wiring connector (15) (See F5)
16. Ground connection (16) (See F5)
*yLower the work equipment to the ground
and stop the engine. Then loosen the oil
filler cap slowly to release the pressure
inside the hydraulic tank.
l Remove hydraulic tank strainer, and use
tool D to stop the oil. (See Fl)
l When not using tool D, remove drain
plug and drain the oil from hydraulic
tank and piping.
:
_ See Lubricant and Coolant Table
* After removing the piping, mark with tags
to prevent mistakes when installing.
1. Draining water
2. Air cleaner cover (I 1 (See F21
3. Air cleaner assembly (2) (See F2)
Ir Remove the air cleaner cover, then
remove the air cleaner assembly
together with the bracket.
17. Engine and hydraulic pump assembly (I 7)
(See F6) m
* When removing the engine and hydrau-
lic pump assembly, do not forget to dis-
connect the piping and wiring, and
check that there is no interference at
any point when removing.
&
kg See Weight Table
4. Muffler heat insulator plate (3) (See F2)
5. Dust indicator hose (4) (See F2)
7. Tube (6) (See F2)
9. Wiring connectors (81, (9) (See F3, F4)
10. Wiring (I 0) (See F4)
11. Fuel hose (I I) (See F4)
12. Hose (I 2) (See F4)
13. Fan and vibration damper assembly (I 3)
(See F4)
Ir Remove vibration damper mounting
bolts, and move fan assembly towards
radiator.
14. Intake pipe (I 4) (See F4)
b
kg See Weight Table
INSTALLATION OF ENGINE,
HYDRAULIC PUMP
ASSEMBLY
removal.
m Mounting bolt:
Refilling with oil
* Run the engine to circulate the oil
through the system.
Q See Lubricant and Coolant Table
Refilling with water
+ Run the engine to circulate the water
through the system.
Then check the water level again.
30630
Fl
I
F9879
F2
205FO5411
205FO541
F4
I
11
205FO541
F6
I I
205FO5415
30$31
REMOVAL OF DAMPER REMOVAL OF CENTER
ASSEMBLY SWIVEL JOINT ASSEMBLY
1. Hydraulic pump assembly
l Remove hydraulic pump assembly.
For details, see REMOVAL OF HYDRAU-
LIC PUMP ASSEMBLY.
2. Damper assembly (I 1 (see Fl 1 m
INSTALLATION OF DAMPER
ASSEMBLY
removal.
m
a) Damper spline:
Anti-friction compound (LM-G)
w Mounting bolt:
*A& Lower the work equipment to the ground
4
and release the remaining pressure in the
circuit. For details, see TESTING AND
ADJUSTING, Releasing pressure in
hydraulic circuit for machines with PPC
valve.
1. Hoses (1). (2). (3) (See F2)
2. Elbow (4) (See F21
4. Link (6) (See F31
5. Center swivel assembly (7) (See F4)
fi
kg
See Weight Table
INSTALLATION OF CENTER
SWIVEL JOINT ASSEMBLY
removal.
;3
m
0
N
through the system.
Then check the oil level agian.
0
F2
205FO5416 205FO.50
F3
I
5
F4
30-33
0
DISASSEMBLY OF CENTER REMOVAL OF FINAL DRIVE
SWIVEL JOINT ASSEMBLY ASSEMBLY
1.
2.
3.
4.
Remove cover (I 1. (See Fl)
Remove snap ring (2). (See Fl)
Using push-puller 0, pull out swivel rotor
(4) and ring (3) from swivel shaft (5). (See
Fl, F2)
Remove snap ring (61, then remove oil seal
(7) and slipper seal (8). (See Fl)
I. Sprocket
l Remove sprocket.
*A, Loosen the oil filler cap slowly to
* release the pressure inside the hy-
draulic tank.
3. Final drive assembly (2) (See F5) m
* Sling the final drive assembly, then
remove the mounting bolts, and lift off
the final drive assembly.
ASSEMBLY OF CENTER
SWIVEL JOINT ASSEMBLY
1.
2.
3.
4.
5.
Assemble slipper seal (8) to swivel rotor (4).
(See Fl I
Using push tool 0, press fit oil seal (7) to
swivel rotor (4), and install snap ring (6).
(See Fl , F3)
&I& Lip of oil seal: Grease (G2-LI)
Set swivel shaft (5) on block, then using
push tool, tap swivel rotor (4) with a plastic
hammer and install. (See Fl)
* When installing the rotor, be extremely
careful not to damage the lips of the
slipper seal and the oil seal.
Install ring (31, and secure with snap ring
(2). (See Fl 1
Fit O-ring and install cover (I 1. (See Fl)
See Weight Table
INSTALLATION OF FINAL
DRIVE ASSEMBLY
removal.
&I& Mounting bolt:
Thread tightener (LT-2)
w Mounting bolt:
l Bleeding air
Bleed the air from the motor.
For details, see TESTING AND
ADJUSTING, Bleeding air from travel
motor.
After bleeding the air from the motor,
check the level of the hydraulic tank.
30-34
0
Fl
P
-6s
t1
205FO5420
F2
205FO542 1
F3
205FO5423
205FO5424
30635
DISASSEMBLY OF FINAL
DRIVE ASSEMBLY
1.
2.
3.
4.
5.
6. Ring gear
Draining oil
Remove drain plug and drain oil from final
drive case.
:
- Final drive case:
See Lubricant and Coolant Table
Cover
7.
8.
9.
Remove ring gear (I 2). (See F6)
No. 2 sun gear
Remove sun gear (I 3). (See F6)
Thrust washer
Remove thrust washer (I 4). (See F7)
No. 2 carrier assembly
1) Remove carrier assembly (I 5). (See F7)
Using forcing screws and eyebolts 0,
remove cover (I 1. (See F I)
Thrust washer
Remove thrust washer (2). (See F2)
No. 1 sun gear shaft
Remove sun gear shaft (3). (See F2)
I) Remove carrier assembly (4). (See F2)
2) Disassembly of carrier assembly
i) Remove mounting bolts (5). then
remove holder. (See F3)
ii) Set carrier assembly (4) in press,
then using push tool 0, pull out pin
(61, and remove gear assembly (7).
(See F41
i1 Remove mounting bolts (I 61, then
remove holder. (See F8I
ii) Set carrier assembly (I 5) in press,
then using push tool 0, pull out pin
(171, and remove gear assembly
(I 8). (See F9)
iii1 Remove bearing (20) and spacer
(21) from gear (19). (See FIO)
iv) Remove outer race (221. (See FIO)
iii) Remove bearing (9) and spacer (IO)
from gear (8). (See F5)
iv) Remove outer race (I I). (See F5)
10. Retainer
Remove mounting bolts (23) and (241, then
remove retainer (25). (See Fl I)
11. Spacer
Remove spacer (26). (See F12)
30;36
Fl F6 F7
12
13
205FO5425
F2
205FO5430 205FO5431
F8 F9
m I 205F0542E i
F4 FI O
205FO5427 205FO5428
F!
r
Fl l F12
205FO5429 205FO5435 205FO5436
ASSEMBLY OF FINAL
DRIVE ASSEMBLY
12. Hub assembly
I ) Using eyebolts @I, remove hub
assembly (27) from travel motor. (See
Fl)
1. Hub assesmbly
1) Using push tool, press fit bearings (3 I)
and (30). (See F4)
2) Using tool A,, install floating seal (29).
(See F41
3) Using tool A,, install floating seal (28).
(See F5, F6)
2) Remove floating seal (28). (See F2)
3) Remove floating seal (291. (See F3)
4) Remove bearings (30) and (31). (See F3)
Sr When installing the floating seals,
remove all oil and grease from the
O-ring and O-ring contact surface,
and dry completely before installing.
* After installing the floating seals,
coat the sliding surfaces thinly with
engine oil.
4) Using eyebolts 0, set hub assembly
(27) on travel motor, then using push
tool, tap to press fit bearing. (See F7)
30G38
I
27
0
I
205FO5437 205FO5439 205FO5438
F2 F3
8
205FO5438 205FO5439
F
i
F5
6
8
205FO5509
F7
\
I
205FO5437
30639
2. Adjusting bearing clearance
I) Using tool A,, hold bearing, and
temporarily tighten 2 bolts. (See Fl)
2) Rotate hub 2 - 3 turns to settle bearing.
3) Loosen bolts of tool A,, and then
tighten again to a torque of 2.0 kgm.
(See Fl)
4) Using a depth micrometer, measure
stepped difference a between end face
of shaft and inner race, and dimension b
of gear coupling. (See F2)
* Measure two places and take the
average value.
5) Calculate difference (cl between
dimension b and stepped difference a
(b - a = c).
6) Select a spacer to give a value of
C
- 0. 05
- 0. 15 mm
* Select the suitable thickness of
spacer from the 8 types of spacer.
3. Retainer
I I Fit retainer (25). and tighten with mount-
ing bolts (24) and (25). (See F4)
a Mounting bolt:
B Mounting bolt (24):
B Mounting bolt (23):
2) Check adjustment of bearing clearance
again.
Hook spring balance @ in the tap hole
for the sprocket mounting bolt, pull to
rotate the hub on the shaft and measure
the starting force. (See F5)
* Starting force:
See Tightening Torques and Stan-
dard Values Table
Ir If the starting force is higher than
the standard value, there is a preload
on the bearing, so adjust again.
4. No. 2 carrier assembly
I) Assembly of carrier assembly
i1 Using push tool, press fit outer race
(22) to gear (191. (See F6)
ii) Assemble spacer (21) and bearing
(20). (See F6)
iii)
iv)
Set carrier assembly (I 5) in press,
then assemble gear assembly (I 8).
and using push tool 0, press fit pin
(I 7). (See F7)
+ Be careful to keep the pin
straight, and rotate the gear
when press fitting the pin.
Fit holder and tighten with mounting
bolts (I 6). (See F8)
J+I& Mounting bolt:
m Mounting bolt:
See Tightening Torques
and Standard Values
Table
5.
6.
7.
8.
21 Install carrier assembly (I 5). (See F9)
Thrust washer
Assemble thrust washer (I 4). (See F9)
No. 2 sun gear
Assemble sun gear (I 3). (See FIO)
Ring gear
Align with teeth surface of carrier, and in-
stall ring gear (I 2). (See FIO)
a Ring gear mounting surface:
Thread tightener (LG-6)
I ) Assembly of carrier assembly
i) Using push tool, press fit outer race
(I I ) to gear (8). (See Fl I )
ii) Assemble spacer (IO) and bearing
(9). (See Fl I)
30-40
0
Fl
F20505367
F2
Gear coupling
k
I
F20505368
F 3 F4
205FO5436 205FO5435 205FO5431 1 205FO5430
24
205F2469A
F6
1
F
F
22
20
7 F8
I
205FO5441 205FO5432
9 FIO
205FO5434
Fl 1
1
/ 205FO5429
30- 41
0
iii) Set carrier assembly (4) in press,
then assemble gear assembly (7),
and using push tool 0, press fit
pin (6). (See Fl)
jr Be careful to keep the pin
iv) Fit holder and tighten with mount-
ing bolts (5). (See F2)
& Mounting bolt:
m Mounting bolt:
and Standard Values
Table
2) Align with teeth surface of ring gear,
and install carrier assembly (4). (See
F3)
9. No. 1 sun gear shaft
Assemble sun gear shaft (3). (See F3)
10. Thrust washer
Assemble thrust washer (2). (See F3)
11. Cover
Using eyebolts 0, install cover (1). (See
F4).
& Cover mounting surface:
.
1)
Procedure for tightening cover mount-
ing bolts
Tightening method when using angle
tightening wrench
i) Tighten bolts to specified initial
torque.
m Mounting bolt:
and Standard Values
Table
ii) Using tool A3, tighten bolts to
specified tightening angle. (See
F5)
w Mounting bolt:
and Standard Values
Table
2) Tightening method when not using
angle tightening wrench
0
ii)
iii)
iv)
Tighten bolts to specified initial
torque.
m Mounting bolt:
and Standard Values
Table
Make start mark on cover and
socket in accordance with angle of
hexagon of bolt. (See F6)
Make end mark at specified tight-
ening angle from start mark. (See
F6)
* Make the end mark on the
cover only.
B Mounting bolt:
and Standard Values
Table
Tighten until start mark on socket
is aligned with end mark on
cover. (See F6)
+ When carrying out disassembly and
assembly of the final drive on the fol-
lowing serial numbers, replace mount-
ing bolt 0 with bolt @I, and tighten
according to procedures 1) or 2)
above. (See F7)
- PC200,2OOLC-5
Serial No: 45001 - 61725
- PC220,22OLC-5
Serial No: 35001 - 36986
12. Refilling with oil
Tighten drain plug and add engine oil
through oil filler.
%
Final drive case:
*
See Lubricant and Coolant
Table
After installing the final drive assem-
bly to the body, check the oil level
again at the specifid position.
30642
Fl F2
F3
4 6 II--
0
7
/
205FO5442
1
205FO5427
205FO5426
F4
1.
205FO5425
F5
lousing
_.
205FO59 I I
F
Start mark
on cover
Mounting bolt
205FO59 I2
Start mark
on socket
F7
r
Bolt @I
Bolt @
2rJ5FO59 I3
30-i2-1
REMOVAL OF SPROCKET
1. Track shoe assembly
* Remove track shoe assembly.
For details, see REMOVAL OF TRACK
SHOE ASSEMBLY.
2. Jacking up machine
+ Swing the work equipment 90 to jack
up the machine, then set block 0 be-
tween the track frame and the track
shoe. (See Fl)
3. Sprocket (1). (See Fl) m
* Sling the sprocket, then remove the
mounting bolts, and lift off the
sprocket.
&
kg See Weight Table
INSTALLATION OF
SPROCKET
. Carry out installation in the reverse order
to removal.
m
& Mounting bolt:
w Mounting bolt:
3042-2
Fl
I 1
30643
DISASSEMBLY OF TRAVEL MOTOR ASSEMBLY (HMVIGO)
1.
2.
3.
4.
Motor assembly
Remove motor assembly from final drive as-
sembly.
* For details, see DISASSEMBLY OF FINAL
DRIVE ASSEMBLY.
Spring, pistons
Remove spring (1) and pistons (2) and (3).
* Mark match marks on the case and the
piston.
Set motor assembly (4) in tool Gl.
End cover assembly, valve plate
1) Remove end cover assembly (5)
2) Remove valve plate (6).
* If the valve plate is to be used again,
keep it in a safe place and be careful
not to damage the cylinder block
mounting surface.
3) Using gear puller 0, remove outer race
(7) and spacer (8).
+ Check the thickness of the spacer.
F2050541E , F2050541E
3 F20505412
Gl
P \
/
F20505413
F20505"' , '
r
4) Disassemble end cover as follows
0
ii)
iii)
iv)
v)
A
Remove safety valve assembly (10).
* The set pressure is higher than the
set pressure of the main relier
valve, so do not disassemble it.
Remove plug (II), then remove spring
(12) and valve (13).
Remove plug (14), then remove spool
(15), spring (16), and plate (17).
Remove plug (18), then remove ball
(19).
Remove plug (20), then remove spring
(21), retainer (22), and spool (23).
A force of approx. 40 kg is brought to
bear on the plug, so push the installa-
tion tool perpendicularly against the
plug when loosening it.
5. Spring
Remove spring (24).
6.
7.
Piston assembly
Using tool G2, blow in air, and remove
brake piston (25).
+ If the air pressure is high, the brake pis-
ton will fly out, so be careful.
Disc, plate
Remove disc (26), Plates (27) and (28).
11
F20505417
F20505418
24
25
F20505419
8.
9.
Bearing
Using bearing race puller 0 and gear puller
0 remove bearing (29).
+ Be careful not to contact the bearing rol-
ler portion with the puller.
+ If the cylinder block is to be used again,
put a gasket or paper on the valve plate
contact surface to protect the surface.
* The puller must not be allowed to scratch
or damage the cylinder block sliding sur-
face.
Cylinder block, piston assembly
1) Remove cylinder block (30) and piston as-
sembly (31) as one unit.
2) Disassemble into cylinder block (30), re-
tainer guide (33), shoe retainer (34), and
piston (35), and remove spring (44) and
shim (45) from retainer guide.
* Check the number and thickness of
the shims, and keep in a safe place.
10. Rocker cam
Remove rocker cam (36).
F20505421
F20205262
I
33 44
30
34 35
45
F20205263
F20505422
30-&3-3
11. Cradle
Remove 4 bolts from final drive end, then
remove cradle (37).
12. Shaft assembly
Remove shaft assembly (38).
F2050542:
30-&3-4
1.
2.
3.
4.
Set motor case (39) to tool Gl.
Bearing outer race
Using push tool 0, press fit bearing outer
race (40) in case.
Oil seal
Using push tool, press fit oil seal (41) in
case.
Shaft assembly
1) Using tool 63, press fit bearing (42) to
shaft (43).
2) Install shaft assembly (38).
5. Cradle
ASSEMBLY OF TRAVEL MOTOR ASSEMBLE (HMV 160)
Precautions when assembling
1) Clean all parts, check for dirt or damage,
and repair any burrs.
2) Coat the rotating and sliding surfaces of
all parts with engine oil (EOIO-CD) before
installing.
* Always use the following parts as a set.
i) Cradle and rocker cam
ii) Cylinder block and valve plate
Align with dowel pin, and set cradle (37) in
position.
m Mounting bolt:
dard Values Table
J, It is not permitted to use the seal washer
again, so always replace it with a new
part.
41
F20505424
F20205272
F20505423
6. Rocker cam
Align with cradle groove, and install rocker
cam (36).
t Install the rocker cam with the thick stop-
per facing the case mating surface which
has two drill holes.
7. Cylinder block, piston assembly
1) Assemble cylinder block and piston as-
sembly as follows.
i) Assemble piston (35) to shoe retainer
(34).
* The variation between the thick-
ness of the shoe lips must be
within 0.005 mm.
(Spare parts are supplied in a kit
within these dimensions.)
ii) Assemble spring (44) and shim (45) to
retainer guide (33).
I F20505425
F20205274
F20205275
t Assemble the springs as shown in
the diagram, then select shims and
assemble so that the dimension in
the diagram is 141.90 rfr 0.10 mm.
* Assemble the thick shim at the
spring end.
Spring
iii) Set retainer guide (33) to cylinder
block (30).
Shim
Spring
F20205276
iv) Assemble piston assembly (31) in cy-
linder block (30).
31
F20205277
2) Align cylinder block (30) and piston as-
sembly (31) wit.h spline of shaft, then in-
stall.
I \ F20205262 1
30-4$3-7
8. Shim adjustment of retainer guide
1)
2)
3)
4)
z
5)
z
:
Install valve plate (6) with cylinder block
end facing straight up.
Put a steel scale in contact with case
(39), and measure dimension 0 between
case and valve plate.
* The shaft is an outboard type and is
at an angle, so make it as perpendicu-
lar as possible, measure at several
places, and take the average.
* Do not push down on the valve plate.
Select shim (45) for retainer guide so that
dimension 0 is 2.30 + 0.41 mm.
* When changing the thickness of shim
(45), disassemble to the condition in
7-I)-ii).
After adjusting dimension 0, check that
dimension of clearance 0 from end cover
(5) is 1.7 f 0.1.
* The dimension for portion @ is 4 mm.
After completing selection of shim,
remove end cover and valve plate.
9. Plate, disc, piston
1) Assemble plate (28), then assemble plate
(27) and disc (26) in order.
* There are 6 plates and 5 discs.
* Align the discs at three places with
the notched tooth on the spline.
2) Fit O-ring and backup ring, then install
brake piston (25).
* Assemble so that the piston groove is
aligned with the dowel pin in the end
cover.
* Assemble the backup ring in the di-
rection shown in the diagram.
F2020527a
A clearan
1.7 i 0.1
mm is
formed
,
F20205297
Backup ring
O-ring
Backup ring
F20205298
10. Adjustment of shaft end play
1)
2)
3)
4)
Using tool G4 and puller, press fit bear-
ing (29) to shaft (38).
Assemble spacer
stall bearing (7).
(8) in end cover, and in-
Sr Assemble the same spacer as was
removed.
Install end cover (5) to motor case.
* This is temporarily stopped, so do not
install the spring and O-ring of the
parking brake.
m Mounting bolt:
Fit dial gauge @ to motor case, then
move shaft in axial direction, and
measure movement of shaft in axial di-
rection (end play).
+ End play: 0.05 - 0.25 mm
n Puller
F20205281
F20505415
J
30-&3-9
5) If dimension is not within standard range,
adjust again as follows.
i) Remove end cover.
ii) Remove outer race.
For details, see disassembly step 4-3).
iii) Set outer race to bearing measure
dimension 0 from case and end face
of outer race, then decide spacer @
from following formula.
@=14.35-@
iv) Select spacer from Table.
b mm
1.60 1. 70 1. 80 1. 90 2. 00 2. 10 2. 20 2. 30 2. 40
~ 1. 69 - 1. 79 - 1. 89 ~ 1. 99 - 209 - 2. 19 - 2. 29 - 2. 39 - 2. 49
Sel ected 708. SH 708. SH 708. 8H 708. 8H 70%8H 708. 8H 70%8H 708- W 708. 8H
spacer - 12290 - 12280 - 12220 - 12230 - 12240 - - 1216O - 12250 - 72270 - - 12210
VI
vi)
Assemble selected spacer, assemble
again according to assembly proce-
dure 10-2) - 4), and measure end
play.
After completion of adjustment,
remove end cover.
11. End cover assembly
1) Assemble end cover assembly as follows.
+ Precautions when installing the plug.
Remove all the grease from the plug,
then coat the thread with two drops
of adhesive. (Adhesive: Loctite #638)
i) Assemble spool (23), retainer (22), and
spring (21) in turn, then fit O-ring and
install plug (20).
A A force of approx 40 kg is brought
to bear on the plug, so push the
installation tool perpendicularly
against the plug when tightening
it.
m Plug: See Tightening Torques
and Standard Values Table
Outer race
F20205284
I
12
11
F70! i 05417
F20505418
ii) Assemble ball (19), then fit O-ring
and install plug (18).
W Plug: See Tightening Torques
and Standard Values
Table
iii) Assemble plate (17), spring .(16), and
spool (15) in order, then fit O-ring
Qa Plug: See Tightening Torques
and Standard Values
Table
iv) Assemble valve (13) and spring (12),
then fit O-ring and install plug (11).
m Plug: See Tightening Torques
and Standard Values
Table
v) Fit O-ring and install safey valve as-
sembly (10).
m Safety valve assembly:
2) Install end cover assembly as follows.
i) Install spring (24) for parking brake.
* Assemble the spring so that the
outside circumference is in the
open direction.
ii) Align with dowel pin, and install valve
plate (6) to end cover.
6
24
F20505426 F20205286
iii) Fit O-ring, and align dowel pin with
piston groove, then install end cover
assembly (5).
w Mounting bolt:
12. Pistons, spring
Align match mark, and install pistons (3) and
(2), and spring (1).
* Assemble the piston with no spring at
the discharge port end.
. When storing or transporting the motor
assembly, install tool G5 to the oil seal
end.
Ir When doing this, coat the lip surface of
the oil seal with engine oil using your
finger tip.
F20505412
\
1
F20205287
30-g-12
CHECKING CONTACT BETWEEN CYLINDER
BLOCK AND VALVE PLATE, AND ROCKER CAM
AND CRADLE
1. Checking contact between cylinder block
and valve plate
1)
2)
3)
4)
5)
*
Make a centering tool for the cylinder
block and valve plate.
* The tool can be made of a soft ma-
terial such as plastic or bakelite.
Remove grease from the parts to be
checked.
* Do not wipe with a cloth.
Set the tool in position, and coat the cy-
linder block side with inspection paint.
t Apply the paint thinly.
Put the valve plate on top, push with a
force of 4 - 5 kg and rotate 2 - 3
times.
Remove the valve plate, transfer the con-
tact surface to tape, and check the con-
tact surface.
The standards for the contact surface are
as follows.
Valve plate a. Seal Min. 80%
Cylinder block a. Seal Min. 80%
Cylinder block Centering tool
F20703037
z
0
:
Valve plate
Cylinder block
FL0703038
2. Inspection of contact of rocker cam and
cradle
1)
2)
3)
4)
Remove grease from parts to be in-
spected.
+ Do not wipe off with waste cloth.
Coat cradle with inspection paint.
t Coat with paint thinly.
Put rocker cam on top, push down with a
force of 4 - 5 kg, and move 2 - 3 times
between min. tilt angle and max. tilt
angle.
Remove rocker cam, then transfer contact
surface to tape and inspect contact pat-
tern.
* The standard for the contact pattern
is as shown in below.
* The part fails the inspection if there is
no contact at the center but only con-
tact at the outside.
[Reference]
If the contact is not within the standard
range and lapping is carried out, always
lap the mating parts together.
* Any part that is scratched must not
be reused.
/
Contact less
than 50%
/Contact 50% -
? ;;;tna;; yore
I
OrJ
55 77
Contact 50% -
4F-
I Cmm&ss
0
90%
90%
~
k-
Crade F20205290
30- 4d?- 14
REMOVAL OF SWING
MOTOR ASSEMBLY
* AC Lower the work equipment to the ground
A
+ and release the remaining pressure in the
circuit. For details, see TESTING AND AD-
JUSTING, Releasing pressure in hydraulic
circuit for machines with PPC valve.
1. Hoses (1).
-k Disconnct 7 hoses.
2. Swing motor assembly (2).
* Sling the swing motor assembly,
remove the mounting bolts.
&I
kg See Weight Table
and
I,NSTALLATION OF SWING
MOTOR ASSEMBLY
0 Carry out installation in the reverse order to
removal.
0 Refilling with oil
* Add oil to the specified level, and run
again.
8;
F20505317
DISASSEMBLY OF SWING MOTOR ASSEMBLY (KMF90-2 (AB))
1.
2.
3.
Brake case assembly
1) Using a block, set the swing motor as-
sembly (1) at an angle of approx 25.
2) Lift off brake case assembly (2).
Brake piston
Set brake case assembly (2) in tool HI, then
use tool H2 to remove brake piston (3).
* If the air pressure is high, the brake pis-
ton will fly out, so be careful.
Piston assembly
1)
2)
Using tool H3, remove screw, then
remove retainer (4).
Remove piston assembly (5) and center
ball (6).
J, The screw is not permitted to be, re-
used, so scrap it.
4. Disc, plates
Remove disc (7) and plates (8) and (9).
F20205291
F20205292
F20205293
I
F2020.5294
5. Cover
Remove snap ring (12), then remove
(13).
* Lever the groove with a screwdriver.
6. Drive shaft
i
1)
2)
3)
cover
Remove snap ring (17), then remove
spacer (16).
F20205295
F20205296
Push down drive shaft (15) with press
and remove.
F20205297
Remove bearing (18), then remove outer
race (19), and remove seat (20) and
spring (21).
* The outer race can be pulled out by
hand.
F20205298
7.
8.
Spring
Remove spring (26).
Cylinder block assembly
1) Remove cylinder block (28) together with
center shaft from housing (27).
2) Remove center shaft (30), center ring
(31), and spring (29) from cylinder block
(28).
9. Valve plate
Remove valve plate (32).
10. Safety valve
Remove safety valve (33).
11. Check valve
Remove plug (34), then remove spring (35)
and valve (36).
_w-m_ J
\ /
F20505427
F20205300
F20505428
3044- 2
ASSEMBLY OF SWING MOTOR ASSEMBLY (KMF90-2 (AB))
Precautions when assembling
1.
2.
3.
1) Clean all parts, check for dirt or damage,
and repair any burrs.
2) Coat the rotating and sliding surfaces of
all parts with engine oil (EOIO-CD) before
installing.
Bearing
Press fit bearing (37) in housing (27).
* Check that the bearing is completely
press fitted up to the end face.
Check valve
Assemble valve (36) and spring (35), then fit
O-ring
G=
Plug: See Tightening Torques and
Plug: Thread tightener (LT-2)
Safety valve
Fit O-ring and install safety valve (33).
w Safety valve:
dard Values Table
h I.
F20205303
@\
35
,34
I F20505428
4. Valve plate
Turn over housing, then align valve plate
(32) with dowel pin, and install.
* Check that there is no clearance (play) at
the mounting surface with the housing.
30-65-3
5. Cylinder block assembly
1) Install cylinder block (28).
2) Assemble spring (29) and center ring (31)
in cylinder block, then install center shaft
(30).
3) Using tool H4 secure center shaft (30).
* Pulling force: 150 - 200 kg
* When doing this, check that the cylin-
der block cannot be rotated by hand.
6. Bearing
Press fit bearing (25) to drive shaft (15).
7. Outer race
Press fit outer race (24) in brake case (23).
8. Assembly of drive shaft assembly
II
2)
3)
4)
5)
Assemble shaft (15) in brake case (28),
and put piston mounting side on block
0.
Install spring (21).
* Align the spring so that the outside
circumference opens.
Align with spring, and install seat (20).
Install outer race (19).
Press fit bearing (18).
* Press fit carefully and make sure that
spring (21) does not come away from
the seat.
* From the point where the bearing rol-
ler contacts the outer race, rotate the
shaft while press fitting it.
t Press-fitting load: 748 - 1606 kg
~ 28
F20205305
F202053061j I I &==?v/ Fi
15 28
/
I =20205308
F20205309
6) Assemble spacer (16) of thickness of 5.4
mm, and install snap ring (17).
* Check that the snap ring is fitted se-
curely in the ring groove.
(If it does not fit, replace it with a 5.0
mm spacer.)
9. Measuring procedure for clearance (portion
@I) between seat (20) and brake case
Push out drive shaft (15) from piston
mount until bearing inner race (22),
spacer (16), and snap ring (17) are in
close contact.
* Pushing force: 288 - 1144 kg
(Force can be applied up to 2000 kg)
After the above parts come into close
contact, apply a load of 2000 kg.
f Check that the spacer cannot be ro-
tated by hand.
Fit dial gauge 0 to brake case, push
drive shaft (15) with 500 - 2000 kg, and
measure amount of movement of shaft.
* Movement: 0.1 - 0.4 mm
t If the amount of movement is not
within the standard range:
* If it is more than 0.4 mm, replace
with a 0.58 mm spacer (706-7E-
11320)
- If it is smaller than 0.1 mm, re-
place with a 0.5 mm spacer (706-
86-40030)
* After replacing the spacer, measure
the amount of movement again.
10. Measuring rotating torque of drive shaft
1)
2)
Apply ample oil to bearing.
Using tool H5, rotate at approx. 1 turn/5
set, and measure rotating torque of drive
shaft.
* Rotating torque: 0.1 - 0.16 kgm
* if it is not within the standard value,
replace the bearing with a new part.
F20205296
0205311
F20205312
F20205313
1
30-i5-5
11. Cover
1) Install oil seal (14) to cover (13).
a Lip surface of oil seal:
Grease (G2-LI)
2) Fit O-ring and install cover (13).
3) Install snap ring (12).
12. Discs, plates
Assemble plate (9), then assemble plates (8)
and discs (7) in turn.
sr Align the discs at three places
notched tooth on the spline.
13. Piston assembly
1) Set ball (6) of cener shaft to shaft.
2) Assemble piston (5) to retainer (4),
stall as one unit to shaft.
with the
and in-
F20205314
F20205295
F20205294
\k----q
F2020529:
L
1
I
30-$5-6
3) Using tool H3, tighten screws (7) in order
shown in diagram.
PCE& Screw: Thread tightener (LT-2)
w Screw: See Tightening Torques
and Standard Values Table
* Remove all grease from the thread, then
dry it and coat with thread tightener.
Wipe off any thread tightener that is
squeezed out.
-f After tightening, check that the big end
of the piston and the center ball move
smoothly.
Ir After tightening, check that the play in
the axial direction of the piston assembly
is within 0.35 mm.
14. Brake piston
Fit O-ring and install brake piston (3).
* Assemble so that the piston pin groove is
aligned with the dowel pin of the end
cover.
15. Brake case assembly
1)
2)
3)
4)
Set housing (27) so that cylinder block is
perpendicular.
-rt Before assembling spring (26), it is
better to assemble brake case assem-
bly (2) in the housing, and align the
brake piston and dowel pin.
Install spring (26) to housing.
Face hole of center ball in direction of
center shaft, then fit O-ring to brake case.
Align pin groove of brake piston with
dowel pin, and install brake case assem-
bly (2).
+ Tighten the mounting bolts uniformly.
If the mounting bolts become heavy,
do not forcibly tighten; remove the
brake case assembly and start again.
w Mounting bolt:
* When finally tightening the mounting
bolts, set in tool HI.
& Mating surface of case:
@
F-20205317

F20505429
- F20505427
F20205291
3045-7
REMOVAL OF SWING
MACHINERY ASSEMBLY
1. Swing motor assembly
(For details, see REMOVAL OF SWING
MOTOR ASSEMBLY)
1) Disconnect 7 hoses (1).
2) Remove swing motor assembly (2).
2. Swing machinery assembly (1).
* Sling the swing machinery assembly, then
using forcing screws, and remove the
swing machinery assembly.
63
kg See Weight Table
INSTALLATION OF SWING
MACHINERY ASSEMBLY
F20505317
0 Carry out installation in the reverse order to
removal.
0 Refilling with oil
through the system.
DISASSEMBLY OF SWING
MACHINERY ASSEMBLY
1.
2.
vi) Remove inner races (I 2) and (13)
from case (I I). (See F9)
Draining oil
Remove drain plug and drain oil from swing
machinery case.
:
_ Swing machinery case:
Cover assembly
I) Remove mounting bolts, then using
eyebolts 0, remove cover assembly
(I). (See Fl)
Sr There are 9 mounting bolts at the
top and 3 mounting bolts at the
bottom.
3. Shaft
2) Disassembly of cover assembly
Remove cages (2) and (3). (See F2)
Remove shaft (I 4). (See FIO)
* Check the number and
4. Ring gear
thickness of the shims, and
Remove ring gear (I 5). (See FIO)
keep in a safe place.
Remove outer races (4) and (5) from
cage. (See F3, F4)
iii) Remove mounting bolts, then
remove cover (6). (See F5)
iv) Remove gear assemblies (7) and (8).
(See F61
ti
5. Carrier assembly
I ) Remove mounting bolts, then remove
carrier assembly (I 61. (See Fl I)
i) Remove mounting bolts (I 7). then
remove holder. (See F12)
v) Remove bearings (9) and (IO) from
gear. (See F7, F8)
ii1 Set carrier assembly (I 6) in press,
and using push tool 0, remove pin
(181, then remove gear assembly
(I 9). (See F12, F13)
iii) Remove holder (20). (See F13)
Fl F2
205FO5444
F3
! 4
205FO5446
F5 F
-
/ 205FO5448 205FO5449
F7 8 F 13
I 205FO545C
L
205FO5445
4
205FO5447
6
1
10
205FO5451
9
H u
205FO5452
: I 1 F12
205FO5454 205FO5455
205FO5453
20
205FO5456
ASSEMBLY OF SWING
MACHINERY ASSEMBLY
iv) Remove bearing (22) and spacer
(23) from gear (21). (See Fl)
v) Remove inner race (24). (See Fl 1
I. Case assembly
I) Using push tool, press fit bearing (33).
(See F8)
2) Assemble spacer (29). (See F9)
31 Using push tool, press fit bearing (30).
(See F9)
6. Shaft assembly
I) Loosen mounting botls (251. (See F2)
2) Set shaft and case assembly (26) in
press, and using push tool 0, remove
shaft assembly (27). (See F3)
2. Shaft assembly
I ) Assembly of shaft assembly
i) Using push tool 0, press fit oil seal
(32). (See FIO, Fl I)
a Outer circumference of oil
seal: Adhesive (LG-6)
3) Disassembly of shaft assembly
i) Remove spacer (29) from shaft
(28). (See F4)
ii) Remove bearing (30). (See F4)
iii) Remove cover (31). (See F5)
ii1
iii)
iv)
Assemble cover (31) to shaft (28).
(See F12)
ET& Lip of oil seal: Grease (LG-6)
Set case assembly in press, and
press fit shaft assembly (27). (See
F13)
Tighten mounting bolts (25). (See
F13)
&?k Cover mountig surface:
Adhesive (LG-6)
iv) Remove oil seal (32) from cover.
(See F6)
7. Case assembly
Remove bearing (33). (See F7)
3. Carrier assembly
I) Disassembly of carrier assembly
i) Using push tool, press fit inner race
(24). (See F14)
ii) Assemble spacer (23) and bearing
(221 to gear (21). (See F14)
30-48
0
Fl
205FO5457 205FO5463 205FO5464
F2 : 3 ' 10 F : I 1 F
32
205FO5458
205FO546; 205FO5465
205FO5459
F12 FE 13
28
31
28
31
205FO5460 205FO5461 205FO5461 205FO5466
F6 7 F14
32
205FO5462 205FO5463 205FO5457
iii) Assemble holder (20). (See Fl)
iv) Set carrier assembly (I 61 in press,
then assemble gear assembly (191,
and using push tool 0, press fit pin
(18). (See F2)
+ Be careful to keep the pin
* After press fitting the pin, check
that the gear rotates smoothly.
v) Fit holder and tighten with mounting
bolts (I 7). (See F3)
KY& Mounting bolt:
m Mounting bolt:
and Standard Values
Table
2) Fit carrier assembly (I 61, and tighten
with mounting bolts. (See F4)
&& Mounting bolt:
W Mounting bolt:
4. Ring gear
Install ring gear (I 5). (See F51
&III& Ring gear mounting surface:
Thread tightener (LG-6)
5. Shaft
Assemble shaft (I 4). (See F5)
6. Cover assembly
I) Assembly of cover assembly
i) Using push tool, press fit inner races
(I 3) and (I 2) in case (I I). (See F6)
ii) Using push tool 8, press fit bearing
(I 0) in gear. (See F7)
iii) Using push tool 0, press fit bearing
(9) in gear. (See F8)
iv) Install gear assemblies (8) and (7).
(See F9)
VI Fit cover (6) and tighten with
mounting bolts. (See FIO)
a Cover mounting surface:
Adhesive (LG-6)
vi) Using push tool, press, fit outer
races (5) and (4) in cage. (See Fl 1,
F12)
7. Adjusting preload of bearing
1) Remove O-ring, and install cages (3)
and (2). (See F13)
Ir Install 2 bolts each at a and b.
Sr Rotate the spline shaft for the
motor mount 5 - 6 turns, then
tighten the bolts to the specified
torque.
m Bolt:
and Standard Values
Table
30-50
a
Fl F2 F7 F8
205FO5467 205F0546E
F
_
205FO5455 205FO5454
4
205FO5453 205FO5447 205FO5446
I -
205FO5452
205FO5469
9
Fl l F 12
F 13
10
.6
205FO5448
30- 51
a
8.
2) Selecting shims
Measure points c and d with a
feeler gauge, then select shims from the
table below.
*
3)
4)
5)
Types of shims:
t = 0.4, t = 0.5, t = 0.6
t = 0.7, t = 0.8
Remove cages (3) and (2). (See Fl 1
Fit O-rings and install cages (3) and (2).
(See Fl)
m Mounting bolt:
* Check that the spline shaft for the
motor mount rotates smoothly by
hand.
Using eyebolts 0, install cover assem-
bly (I). (See Fl)
a Cover assembly mounting
surface: Adhesive (LG-6)
Refilling with oil
Tighten drain plug and add engine oil
through oil filler.
Q
Swing machinery case:
Fl
I
il
205FO5472
F2
I
205FO5444
30-53
0
REMOVAL OF REVOLVING
FRAME ASSEMBLY
1. Boom cylinder assembly
l Remove boom cylinder assembly.
2. Work equipment assembly
l Remove work equipment assembly.
For details, see REMOVAL OF WORK
EQUIPMENT ASSEMBLY.
3. Counterweight assembly
l Remove counterweight assembly.
4. Cab assembly
l Remove cab assembly.
For details see REMOVAL OF OPERA-
TORS CAB ASSEMBLY.
5. Hoses (I). (See Fl)
6. Link (2). (See Fl)
7. Revolving frame assembly (3). (See F2) m
* For the mounting bolts marked %
move the control box assembly, remove
the grommets, then remove the bolts.
J, When removing the mounting bolts,
leave 2 bolts each at the front and rear.
* Using lever block, adjust the balance of
the revolving frame assembly to the
front and rear, and left and right,
remove the remaining bolts, then lift off.
* When removing the revolving frame as-
sembly, be careful not to hit the center
swivel joint assembly.
&?I
kg See Weight Table
INSTALLATION OF
REVOLVING FRAME
ASSEMBLY
removal.
(
* The dimensions of the mounting bolts,
diameter of the washers, and thickness
of the washers differs according to the
mounting position, so refer to the table
and diagram below when installing. (See
F4)
Bolt Bolt size
Diameter Thickness
of washer of washer
Oty
a 24 - 105 48 6 4
b 24 - 105 48 9 2
c 24 - 60 48 6 2
Others 24 - 60 48 6 18
% 24 - 70 48 6 4
x :This indicates the size of bolts used only on the
PC220.
&I?+ Mating surface of swing circle:
Gasket sealant (LG- I)
AFL Mounting bolt:
::
z
m Mounting bolt:
2
30-54
0
Fl F4
I I 205FO5473 1
F2
z
205FO5474 /
::
g F3
F
I
205FO5476
205FO5475
30-55
0
REMOVAL OF SWING
CIRCLE ASSEMBLY
1. Revolving frame assembly
l Remove revolving frame assembly.
For details, see REMOVAL OF
REVOLVING FRAME ASSEMBLY.
2. Swing circle assembly (I 1. (See Fl 1 m
Ir Remove 36 mounting bolts.
&
kg See Weight Table
INSTALLATION OF SWING
CIRCLE ASSEMBLY
removal.
Ir Install swing circle assembly (I) with
the inside soft zone (S) mark facing 90
to the left. (See F2)
& Mounting bolt:
m Mounting bolt:
&I& Circle teeth surface:
Grease (G2-LI)
Volume: 21 Q
REMOVAL OF IDLER,
RECOIL SPRING ASSEMBLY
I ,
2.
3.
Track shoe assembly
l Remove track shoe assembly.
Idler and recoil spring assembly (I 1. (See F31
* Sling the idler and recoil spring
assembly, and pull out to the front to
remove.
&
kg
See Weight Table
Disconnection of idler and recoil spring
assembly
Secure recoil spring with block 0, then
sling idler assembly, remove mounting
bolts, and disconnect idler assembly (2) and
recoil spring assembly (3). (See F4)
J, Make match marks on the matching sur-
face of the idler and the recoil spring.
6
kg See Weight Table
INSTALLATION OF IDLER,
RECOIL SPRING ASSEMBLY 0
0
g
removal.
30-56
a
Fl
\L/
F20505318
z
F20505319
::
$
F3
I I
205FO5477
F
205FO5478
30657
DISASSEMBLY OF RECOIL
SPRING ASSEMBLY
1. Remove piston assembly (2) from recoil
spring assembly (I 1. (See Fl)
2. Disassembly of recoil spring assembly
I ) Set recoil spring assembly (I) to tool B.
(See F2)
*yThe spring is under large installed
load, so be sure to set the tool prop-
erly. Failure to do this is dangerous.
* Spring installed load:
dard Values Table
2) Apply hydraulic pressure slowly to
compress spring, then remove lock
plate (31, and remove nut (4). (See Fl)
* Compress the spring to a point
where the nut becomes loose.
+ Release the hydraulic pressure
slowly and release the tension of
the spring.
* Free length of spring:
dard Values Table
3) Remove yoke (61, cylinder (71, and dust
seal (8) from spring (5). (See Fl)
3. Disassembly of piston assembly
I) Remove lock plate (I 0) from piston (91,
then remove valve (I I). (See Fl 1
2) Remove snap ring (I 21, then remove U-
packing (I 31 and ring (I 4). (See Fl)
ASSEMBLY OF RECOIL
SPRING ASSEMBLY
1. Assembly of piston assembly
I) Assemble ring (14) and U-packing (I 3)
to piston (91, and secure with snap ring
(12). (SeeFl)
2) Fit valve (1 I ) and secure with lock plate
(IO). (See Fl)
2. Assembly of recoil spring assembly
I) Assemble dust seal (8) to cylinder (7).
(See Fl)
a Lip of dust seal: Grease (G2-LI)
2) Assemble cylinder (7) and yoke (6) to
spring (51, and set in tool C. (See Fl)
3) Apply hydraulic pressure slowly to
compress spring, tighten nut (4) so that
installed length of spring is dimension
, then secure with lock plate (3).
(lee F3)
* Installed length of spring:
4) Remove recoil spring assembly (I) from
tool B. (See F2)
3. Assemble piston assembly (2) to recoil
spring assembly (I 1. (See Fl)
ALI& Piston: Grease (G2-LI)
* Assemble the cylinder assembly so that
the mounting position of the valve is
exactly at side.
30;58
205FO547!
F3
481
1
30659
REMOVAL OF TRACK
ROLLER ASSEMBLY
1. Lubricator (I I. (See Fl)
* Loosen the lubricator, and loosen the
track shoe tension.
*,The adjustment cylinder is under ex-
tremely high pressure.
Never loosen the lubricator more than
one turn.
If the track tension is not relieved, move
the machine backwards and forwards.
2. Track roller assembly (21. (See F2) m
Ir Remove the mounting bolts of the track
roller, then swing the work equipment
90. jack up the machine, and remove
the track roller assembly.
6
kg See Weight Table
INSTALLATION OF TRACK
ROLLER ASSEMBLY
l Carry out istallation in the reverse order to
removal.
+ Set the track roller assembly to the
mounting position, then operate the
control levers to lower the machine
slowly, and tighten the mounting bolts
temporarily.
A?+ Mounting bolt:
Thread tightener (LT-21
* Operate the control levers to lower the
machine completely to the ground, then
tighten the mounting bolts fully.
REMOVAL OF CARRIER
ROLLER ASSEMBLY
1. Track shoe assembly
Ir Using hydraulic jack 0, push up the
track to a position where the carrier
roller assembly can be removed. (See
Fl)
2. Carrier roller assembly (I 1. (See F3) 1
INSTALLATION OF CARRIER
ROLLER ASSEMBLY
removal.
1
& Mounting bolt:
30660
Fl
F20505320
F2
3
F20505322
30;6 1
REMOVAL OF TRACK SHOE
ASSEMBLY
1. Positioning track
Sr Stop the machine in a position where
the track can be laid out to the rear
when the master pin is pulled, then
loosen lubricator (I) to relieve the track
tension.
*F The adjustment cylinder is under ex-
tremely high pressure.
Never loosen the lubricator more than
one turn.
If the track tension is not relieved, move
the machine backwards and forwards.
2. Master pin (2) m
+I Using tool C, pull out the master pin.
(See F2, F3)
3. Track shoe assembly (3) m
* Move the machine forward so that the
position of the temporary pin is at the
front of the idler, then put block @ in
contact with the grouser, pull out
temporary pin 0, and remove the dust
seal. (See F3)
Sr Drive the machine in reverse to lay out
the track.
INSTALLATION OF TRACK
SHOE ASSEMBLY
removal.
m
* Using tool C, press fit the master pin.
(
Ir Deflection of track:
dard Values Table
F20505320
F2
0
F2050532:
0
2 F3
I
F20505324
REMOVAL OF CHARGING REMOVAL OF HYDRAULIC
PUMP ASSEMBLY PUMP ASSEMBLY
%&Lower the work equipment to the ground *&Lower the work equipment to the ground
Remove hydraulic tank strainer, and use
tool D to stop the oil. (See Fl)
* When not using tool D, remove drain
tank and piping.
:
4
.
Remove hydraulic tank strainer, and use
tool D to stop the oil. (See F3)
+ When not using tool D, remove drain
1.
2.
3.
w See Lubricant and Coolant Table
Hoses (I 1. (See F2)
Tube (2). (See F2)
Charging pump assembly (3). (See F2)
INSTALLATION OF
CHARGING PUMP
ASSEMBLY
removal.
* Refill to the specified level, and run the
engine to circulate the oil through the
system. Then check the oil level again.
Q
.
1.
2.
3.
4.
5.
6.
7.
8.
tank and piping.
:
_ See Lubricant and Coolant Table
Draining oil from damper chamber
:
U See Lubricant and Coolant Table
Muffler heat insulator plate (I). (See F4)
Muffler assembly (2). (See F4)
Muffler bracket (3). (See F4)
Tubes (4). (See F4)
Hoses (51, (6). (See F4)
* Disconnect 2 hoses (6).
Wiring connector (7). (See F5)
Hoses (8). (See F51
Hydraulic pump assembly (9). (See F6)
E!?l
kg See Weight Table
INSTALLATION OF
HYDRAULIC PUMP
ASSEMBLY
.
Carry out installation in the reverse order to
removal.
Refilling with oil
* Refill to the specified level, and run the
system. Then check the oil level agian.
Ir Add oil to the damper chamber to the
specified level.
Q
Fl
I
L/
F9879
F2
I
F3
L/
F9879
F4
I /
205FO5483
F5
r
205FO5484
1
205F05485
30-65
0
DISASSEMBLY OF HYDRAULIC PUMP ASSEMBLY
(HPV090 + 090)
Note) The procedure for disassembly is basi-
cally the same for both front and rear
pumps, so this section describes the dis-
assembly of the front pump only. When
there are differences, however, they will
be noted at the appropriate place in the
description.
1. WC and CO, NC valve assembly
1) Set pump assembly (1) in tool Kl.
a
3)
4)
5)
Remove hose (2).
Remove tube (3).
Disconnect wiring, then remove TVC and
CO, NC valve assembly (5). (Rear pump)
Remove CO, NC valve assembly (6).
(Front pump)
2.
3.
Rear pump assembly
1)
2)
Sling rear pump assembly (7).
Remove 4 nuts at front pump assembly
end, then remove rear pump assembly
(7).
* Disconnect at the middle of the end
caps.
Servo valve assembly
Remove servo valve assembly (8).
i
F20505430
I F20505431
? I 8
5432
4.
5. End cap
6.
Impeller
Using tool K5, remove bolt (9), then remove
plate (IO), washer (IOA) and impeller (11).
t Check the number and thickness of the
shims, and keep in a safe place.
t Be careful not to lose plate (10).
Remove end cap (13).
* The force of the spring is bearing on the
valve plate, so loosen the mounting bolts
uniformly.
Valve plate
Remove valve plate (15).
* For a pump which has been operated,
the valve plate will have become stuck to
the cylinder block, so twist it carefully
without causing scratches.
Note) If the cylinder block and valve plate
will be reused, store them as a set.
7. Pump sub-assembly
Support cylinder block and shaft, then
remove pump sub-assembly (17).
F2050543311 F20505434
30-$5-2
15
F30. 505436
8. Servo piston
1)
2)
3)
4)
Using forcing screws 0 (Dia. = 10 mm,
Pitch = 1.5 mm) and nut 0, remove cap
(18) and shim (20).
Remove spring (22).
Repeat Step 1) and remove
shim (21).
Remove servo piston (23).
* The servo pistons used
cap (19) and
for the front
and rear are not the same part, so
mark them to distinguish them.
DISASSEMBLY OF PUMP
SUB-ASSEMBLY
9. Slider
Remove slider (24).
IO. Cylinder block
1) Remove cylinder block (25).
2) Disassemble cylinder block as follows.
U
ii)
iii)
iv)
Using bolt -0 (10 mm or 12 mm) and
washers 0, compress spring (26).
* Installed load: Approx. 130 kg
Remove snap ring (27).
Loosen nut 0 slowly, and allow
spring to expand until tension is
removed.
Remove washers (28A) and (28B),
and spring (26).
\
23
F20505439 11 F20505440
F20205329
29A 29 29e 27
w F2020533j 1
A
3o-k5-3
11. Drive shaft assembly
1) Screw in forcing screws, and remove
housing (29) and shim.
* Check the number and thickness
the shims, and keep in a safe place.
* The charging pump is removed
the rear pump, but there is no shim.
2) Remove snap ring (30).
3) Knock out drive
end to remove.
12. Piston
of
for
shaft (31) from piston
Use tool K3 to remove 4 screws (43), then
remove bearing retainer (44), shoe retainer
(45), spacer (46), and piston (47).
I F2020533
43
F20505441
1
-46
F20703017
WHEN REUSING PUMP DRIVE SHAFT AND
END CAP
- Removal of inner race from pump
shaft
drive
1) Remove snap ring (38), then remove
washer (37), inner race (40), and bearing
(41).
F20205335
2) Using bearing race puller 0, remove
inner race (42).
F20205336
30-g-5
ASSEMBLY OF HYDRAULIC PUMP ASSEMBLY
(HPV090 + 090)
Precautions at time of assembly
1) Clean each part thoroughly and remove
all sharp edge and rough edges.
2) Apply engine oil (EOIO-CD) to the rotat-
ing and sliding parts before assemblying
them.
* Be sure to use the following parts as a
set.
i) Cradle and rocker cam
ii) Cylinder block and valve plate
Note) The procedure for assembly is basi-
cally the same for both front and rear
pumps, so this section describes the
assembly of the front pump only.
When there are differences, however,
they will be noted at the appropriate
place in the description.
ASSEMBLY OF PUMP
SUB-ASSEMBLY
1. Piston assembly
1) Fit dowel pin (50) to cradle, set rocker
cam (49) in position, then install plate
(46).
* The side of the rocker cam with the
groove faces the oil hole side of the
cradle.
48
xI1, Plate bolt: Thread tightener
(LT-2)
(Loctite #262)
m Plate bolt:
+r After tightening the bolts, check that
the rocker cam moves smoothly.
50
F20205338
2) Select the spacer thickness as follows.
i) Assemble shoe retainer (45) to piston
(47), put on the level block, then
measure distance 0 to top surface of
shoe retainer.
ii) Select spacer thickness as follows.
Spacer thickness = distance 0 +
(0.03 to 0.07 mm)
+ There are three types of spacer.
3) Install spacer (46) selected in Step 2)-i)
and ii), then install piston (47), shoe re-
tainer (45) and bearing retainer (44).
Using tool K3, install screws(43).
& Bearing retainer screw:
m Bearing retainer screw:
4) Hold rocker cam in position, then using
tool K4 pull piston (47) with a force of 2
- 3 kg, and measure clearance 0 be-
tween piston shoe and rocker cam.
* Measure the clearance with the rocker
cam at position a or b, and measure
for all nine piston.
* Clearance: 0.03 - 0.07 mm
* If clearance 0 is not within the stan-
dard range, adjust the spacer again.
Rocker cam
F20703022-1
Rocker cam
Retainer bearing
F20703021
Pull
K4
F20505442
Rocker cam
3o-F-7
2. Drive shaft assembly
1) Press fit inner race (42) to drive shaft
(31).
2) Install bearing (41), inner race (40) and
washer (37).
Select washer as follows.
i)
+
ii)
iii)
Install inner race (40), then install
snap ring (38).
Check that the snap ring is not de-
formed or damaged, and correct any
burrs before installing. Install with the
cut inside part facing the opposite di-
rection from the inner race.
Using a thickness gauge, measure
clearance 0 between snap ring (38)
and inner race (40).
Push the snap ring securely into the
groove on the opposite side from the
inner race.
Install selected washer (37).
Washer thickness = clearance 0 + (0
to 0.1 mm)
31
r------------ --------\
/
I--..
-_
3
__--
F20205342
37
F2050544:
F20505444
I
40
F20205344
* Check that there is no play beteen the
snap ring and the washer. There are
three types of washer.
30-$5-8
5) Press fit drive shaft (31) to cradle (36).
7) Install oil seal (35) to housing (29).
6 Lip of oil seal: Grease (G2-LI)
F20205348
8) Fit O-ring and shim (34) selected in step
9), and install housing (29) to cradle.
w Mounting bolt:
* Wind the shaft with tape to prevent
damage to the oil seal lip surface.
* Install cover to rear pump.
9) Select shim for housing as follows.
i)
ii)
Push drive shaft -(31) in completely,
and measure dimension 0 of end face
of bearing outer race (33) and cradle.
Measure dimension @ of housing (32).
iii) Select shim to give following thick-
ness.
* Shim thickness: @ - 0 = 0 +
0.05 - 0.15 mm.
* Therefore, there is a clearance of
0.05 - 0.15 mm at portion @I.
+ Threre is no shim at the rear
pump.
3. Cylinder block
1)
Assemble cylinder block as follows.
2)
*
i)
ii)
iii)
Assemble washer (28A), spring (26)
and washer (28B).
+ Assemble the washer facing in the
direction shown in the diagram.
Using bolts 0 (IO mm or 12 mm),
washers @I and nut 0, compress
spring (26).
Install snap ring (27).
Align with drive shaft and piston, and in-
stall cylinder block (25).
Always install the valve plate (which
forms a set with the cylinder) together
with the cylinder, or makr a mark and be
careful not to make any mistake.
F20205351
F70505446
28A 26 288 27
F20205330
F2020535: 3
4. Servo piston
1) Set pump case (32) in tool Kl.
2) Install servo piston (23).
* The servo pistons used for the front
and rear are not the same part, so be
careful not to make any mistake when
assembling them.
* The length from the center is different for
the end with the spring and the end
without the spring.
3) Adjust servo piston as follows.
- Max. swash plate angle side
i) Align tool K6 with dowel pin and
groove g for servo valve arm of servo
piston, and set tool K6 in position.
* As seen from the rear of the front
pump, the right side (the top when
mounted on the machine; the side
with the spring) is the maximum
swash plate angle side. (maximum
flow side)
Note: For the rear pump, use the
same tool turned over.
ii) Measure distance 0 between servo
piston and case.
Rear pump
F20505448
1 1 F20505449
F2050545C 1
3o-F
iii) Measure distance @ of cap (18).
iv) Select shim thickness as follows.
@ - 0 = 0 + 0.05 mm
* After adjusting the shim, put it in
a set with the cap.
. Min. swash plate angle side
* To adjust the minimum swash plate
angle, replace tool K7 with the tool
for the minimum angle, and repeat
the same procedure as in Steps i) -
iv).
Note that the case faces in the oppo-
site direction from the maximum
swash plate angle side.
5. Pump sub-assembly
1)
2)
3)
Install slider and O-ring.
* Fit the O-ring in the pilot portion and
the joint portion.
Install 2 joints on case.
t Install with the small hole facing the
cradle side.
Align the slider with the servo piston,
and install pump sub-assembly (17).
J, Be careful that the O-ring is not
caught. Also, be careful not to drop
the cylinder.
m Mounting bolt:
See tightening Torques and
* Assemble rear pump using tool K2.
F2020535E
Clearance C
\
Servo piston Clearance C
F20703026
Clearanc
(a
Servo valve
mounting
surface
Pump case
F20703027
6. End cap
1) Press fit bearing (14) to end cap (13).
2) Install joint and O-ring.
-f Install the joint with the large hole
facing the end cap.
3) Coat with engine oil, align with pin and
bearing, and install valve plate (75).
or Check that it is aligned with the end
cap port, and that there is no inter-
ference with the pin and bearing.
4) Install end cap (13).
m Mounting bolt:
m Mounting nut:
* There is the force of the spring inside
the cylinder block, so tighten the
mounting bolts uniformly.
7. Impeller
1) Adjust clearance between impeller and
end cap portion 0 as follows.
i) Measure thickness @ of plate (IO).
ii) Assemble plate (10) to coupling, and
install impeller.
* Check that impeller (11) and end
cap portion 0 are in contact.
iii) Measure dimension 0 from end face
of coupling (IIA) to plate (IO).
F20505452
2)
3)
iv)
v)
Measure dimension @ from end face
of coupling to shaft (31).
Use measured values @I, 0, and @ as
follows to select shim.
* k3 - (0 + 63) + (0.5 * 0.1) mm =
shim thickness
Assemble plate (10) to coupling (IIA),
then fit shim (12) selected in Step 1) and
washer (IOA), then using tool K5, install
impeller (11).
& Mounting bolt:
m Mounting bolt:
Thread tightener
(LT-2)
(Loctite #262)
See Tightening Tor-
ques and Standard
Values Table
Check interference or impeller (11) and
rear end cap as follows.
i)
ii)
iii)
Measure dimension of end face of
rear end cap to end face of front end
cap portion 0.
Measure protrusion dimension 0 of
impeller vane from front end cap.
Check that measured dimension is
0 > 0.
* If the above dimension is
0 > 0, there is no clearance at
portion @I, so the impeller vane
will contact the rear end cap at
the time of assembly. To prevent
this, repeat the procedure at step
7 -1) and adjust the shim (12)
again.
F20505454 11
F20505434 F20505433
10A
Front end c
12
F20505455
30-6&l 4
8.
9.
Servo piston cap
1) Install spring (22) on the right as seen
from the rear of the pump.
2) Fit O-ring, and shims (20) and (21) se-
lected in step 4, then install caps (18)
and (19).
Ir
*
i)
ii)
When installing cap (18) at spring end,
use 2 forcing screws 0 (Thread dia.
= 10 mm, Pitch = 1.25 mm) and 2
nuts 0.
D Mounting bolt:
After installing the cap, measure the
rotating torque of pump using tool
KS.
There must be no variation in the ro-
tating torque (Range of variation:
Max. 0.3 kgm) and the rotating torque
must be less than 1.4 kgm.
If the rotating torque or range of vari-
ation are not within the standard
value, disassemble the pump assem-
bly and assemble it again.
Servo valve assembly
Fit O-ring, align arm with servo piston, then
install servo valve assembly (8).
* Be careful not to let the O-ring drop out.
Tighten the bolts gradually on opposite
sides in turn.
w Mounting bolt:
10. Rear pump assembly
1)
2)
Install O-rings to front and rear end caps.
Raise rear pump assembly (7), align
spline, and install.
D Mounting nut:
See tightening Torques and
22
F20505438 " F205054371
/
21
F. 20505456
F20505457
F20505432
30-62- 15
11. TVC and CO, NC valve assembly
1)
2)
3)
4)
Fit O-ring and install CO, _ NC valve as-
sembly (6). (Front pump)
m Mounting bolti
Fit O-ring, install TVC and CO, NC valve
assembly (5), then clamp wiring. (Rear
pump)
B Mounting bolt:
Fit O-ring and install tube (3).
m Joint bolt:
Install strainer, then install hose (2).
m Sleeve nut:
J, After completion of assembly, check
the quality of the parts.
After completing the assembly of the
pump assembly, use a test stand (A
type or C type) to check the quality.
* For details of the procedure for check-
ing quality, see TESTING METHODS.
I F20505431
30-g- 16
CHECKING CONTACT BETWEEN CYLINDER
BLOCK AND VALVE PLATE, AND ROCKER
CAM AND CRADLE
1. Checking contact between cylinder block
and valve plate.
1)
2)
3)
41
51
*
Make a centering tool for the cylinder
block and valve plate.
* The tool can be made of a soft ma-
terial such as plastic or bakelite.
checked.
Set the tool in position, and coat the cy-
linder block side with inspection paint.
* Apply the paint thinly.
Put the valve plate on top, push with a
force of 4 - 5 kg, and rotate 2 - 3
times.
Remove the valve plate, transfer the con-
tact surface.
The standards for the contact surface are
as follows.
Valve plate a. Seal
Cylinder block a. Seal
Min. 80%
Min. 80%
Cylinder block
Centering tool
\
........ .............. . ... . . .....
................
...............................
...................
j::::::::::::::::::::~::::::::::
. . . . . . . ... . . ... ... ... . ..........
................
...... ...........................
.....................
..................
:.:.:.: ..........................
. . ..I.. ... . . ... .................
:::::::::::::::::::~::::::~:::::
::
::
F20703037 g
Valve plate
Cylinder block
F20703038
2. Checking contact between rocker cam and
cradle
1)
2)
3)
4)
*
checked.
Set the tool in position, and coat the
cradle side with inspection paint.
* Apply the the paint thinly.
Put the rocker cam on top, push with a
force of 4 - 5 kg, and move 2 - 3 time
from the stopper contact position to the
maximum angle.
Remove the rocker cam, transfer the con-
tact surface.
The standard for the contact surface are
as follows.
Pump Dimension a
Model (mm)
HPV 090 72
Contact
surface
Min. 80%
Contact b from
a to outside
Min. 50%
* If there is no contact at the center but
only at the outside, the contact is no
good.
Reference:
F20703039
If the contact is not within the contact
standard value, when carrying, always lap
both parts together.
* Parts with scratches cannot be reused.
30-62- 18
REMOVAL OF MAIN PUMP
INPUT SHAFT OIL SEAL
1. Hydraulic pump assembly
l Remove hydraulic pump assembly.
For details, see REMOVAL OF HYDRAU-
LIC PUMP ASSEMBLY.
2. Housing assembly (I 1. (See Fl) m
Jr Using forcing screws, remove the hous-
ing assembly and the shims.
3. Oil seal (2). (See F2) B
l Remove oil seal from housing.
INSTALLATION OF MAIN
PUMP INPUT SHAFT OIL
SEAL
removal.
m Mounting bolt:
m
* Using tool 0, press fit oil seal (2) in
housing (I 1. (See F3)
a Lip of oil seal: Grease (G2-LII
REMOVAL OF CONTROL
VALVE ASSEMBLY
*FLower the work equipment to the ground
* Mark the piping with tags to prevent mis-
takes in position when assembling.
1. Wiring connector (I 1. (See F4)
2. Hoses (21, (3). (See F4)
* For hose (31, remove 8 PPC hoses.
3. Hose (4). (See F5)
4. Hose (5). (See F51
5. Tube (6). (See F5)
* Remove the tube together with the
bracket.
6. Hose (7). (See F5)
7. Hoses (81, (9). (See F5)
.+ For hose (81, remove 3 PPC hoses.
For hose (9). remove 4 PPC hoses.
8. Tubes (I 0). (See F5)
+ Disconnect 4 tubes together with the
bracket, and remove the 2 remaining
tubes.
9. Hose (I I). (See F61
IO. Solenoid valve (I 2). (See F6)
11. Wiring connector (I 3). (See F6)
12. Clamp (I 4). (See F6)
13. Control valve assembly (I 5). (See F7)
* Remove the control valve assembly
together with the frame.
&
kg See Weight Table
INSTALLATION OF
CONTROL VALVE
ASSEMBLY
removal.
Ir Add oil to the specified level, and run
again.
F4
Fl
205FO5486
F2
F
20UF01210-K
3
/a
20UF01211-K
i
F5
\ T F2050532E
6
F7
/ F20505328
i
30-67
a
DISASSEMBLY OF
CONTROL VALVE
ASSEMBLY
*
.
1.
2.
3.
4.
The set pressure of the safety valve cannot
be adjusted when the safety valve is in-
stalled on the machine, so do not disassem-
ble it.
The following explanation uses the left con-
trol valve as the example.
Main relief valve, jet sensor relief valve
Remove main relief valve (I) and jet sensor
relief valve (2). (See Fl )
Safety-suction valve
Remove safety-suction valve (31, (41, and
(5). (See Fl 1
Check valve
Remove plug (61, then remove spring (7)
and check valve (8). (See Fl)
L.H. travel valve
I )
2)
*
*
*
Remove case (9). then remove retainer
(IO), spring (I I), retainer (I 2). spring
(I 3). and retainer (141, and pull out
spool (I 5). (See Fl)
Remove case (I 61, then remove retainer
(171, spring (18). retainer (I 9), spring
(201, and retainer (21). (See Fl 1
This is applicable for the swing, M-l.
travel, boom-Lo, and boom-Hi spools.
Retainer (19) is not assembled in the
boom-Lo spool.
Boom-Hi spool
i) There is a shim inserted in the
spring, so be careful when removing.
ii) In place of parts (I 61 - (21) in Step
21, a plate is installed.
5. Arm throttle valve
I )
2)
*
Remove plug (221, the remove washer
(231, spring (241, and washer (251. (See
Fl)
Remove plate (261, then pull out spool
(271. (See Fl)
The swing priority valve is installed as-
sembled in the opposite direction to the
arm throttle valve.
6. Bucket valve
I )
2)
*
*
Remove case (281, then remove spring
(29) and retainer (30). (See Fl)
Remove case (31). then remove spring
(32) and retainer (331, and pull out
spool (34). (See Fl)
This is applicable for the arm-Lo, ser-
vice, and arm-Hi spools.
Shim (35) is installed in the spring of
the arm-Hi valve, so be careful when
removing.
7. Straight-travel valve
I) Remove plate (36). then remove spring
(371. (See Fl)
21 Remove plug (38). pull out spool (39).
(See Fl)
Fl
2---
205FO5487
205FO5488
30-69
a
ASSEMBLY OF CONTROL
VALVE ASSEMBLY
1. Straight-travel valve
I) Assemble spool (391, then fit O-ring
and install plug (38). (See Fl)
2) Fit spring (37) and install plate (36).
(See Fl)
2. Bucket valve
I )
2)
*
*
Assemble spool (34). fit retainer (33)
and spring (321, then fit O-ring and in-
stall case (3 I). (See F I)
Fit retainer (30) and spring (29). then fit
O-ring and install case (28). (See Fl)
This is applicable for the arm-Lo, ser-
vice, and arm-Hi spools.
Shim (35) is installed in the spring of
the arm-Hi valve spool, so be careful of
the position when installing.
3. Arm throttle valve
I )
2)
*
Assemble spool (271, then fit O-ring
and install plate (26). (See Fl)
Fit washer (251, spring (241, and washer
(231, then fit O-ring and install plug
(22). (See Fl)
The swing priority valve is installed as-
sembled in the opposite direction to the
arm throttle valve.
4. L.H. travel valve
1) Install retainer (211, spring (201, retainer
(I 9). spring (I 81, and retainer (I 71, then
fit O-ring and install case (I 6). (See Fl)
2) Assemble spool (I 51, install retainer
(141, spring (I 3). retainer (I 2). spring
(I I), and retainer (IO), then fit O-ring
and install case (9). (See Fl)
Sr This is applicable for the swing, R.H.
travel, boom-Lo, and boom-Hi spools.
* Retainer (19) is not assembled in the
boom-Lo spool.
* Boom-Hi spool
i)
ii)
Shim is installed in the spring of the
boom-Hi valve spool, so be careful
of the position when installing.
In place of parts (21) - ( I 6) in Step
1 I, a plate is installed.
5.
6.
7.
Check valve
Install check valve (8) and spring (71, then
fit O-ring and install plug (61. (See Fl )
633 Plug:
Safety-suction valve
Install safety-suction valve (5). (41, and (3).
(See Fl)
W Safety-suction valve:
Jet sensor relief valve, main relief valve
Install jet sensor relief valve (2) and main
relief valve (I I. (See Fl)
m Jet sensor relief valve:
m Main relief valve:
30-70
a
Fl
1
38
205FO5487
3:
-d
205FO5488
30671
REMOVAL OF MAIN RELIEF DISASSEMBLY OF MAIN
VALVE ASSEMBLY RELIEF VALVE ASSEMBLY
*y Lower the work equipment to the ground
pressure in the hydraulic piping.
Then loosen the oil filler cap slowly to
tank.
1. Hoses (I). (See Fl)
2. R.H. control valve main relief valve (2). (See
Fl) m
3. L.H. control valve main relief valve (3). (See
Fl) m
INSTALLATION OF MAIN
RELIEF VALVE ASSEMBLY
removal.
II 1x1
m Main relief valve:
l After installing the main relief valve on
the machine, adjust the set pressure.
ING, Adjusting main relief valve.
1. Loosen nut (21, and remove plug (I). (See
F3)
t Before loosening the nut, measure prot-
rusion dimension a of the plug from the
end face of the nut. (See F2)
2. Remove retainer (3). (See F3)
3. Loosen nut (51, and remove holder (4). (See
F3)
+ Before loosening the nut, measure prot-
rusion dimension b of the holder from
the end face of the nut. (See F2)
4. Remove spring (6) and poppet (7). (See F31
5. Remove sleeve (8). then remove seat (9).
backup ring (I 01, spring (I I), and valve
(I 2). (See F3)
6. Remove snap ring (14) from sleeve (I 3).
(See F3)
7. Remove backup ring (151 from sleeve (13).
(See F3)
ASSEMBLY OF MAIN
RELIEF VALVE ASSEMBLY
1.
2.
3.
4.
5.
6.
7.
Assemble backup ring (I 5) and O-ring in
sleeve (I 3). (See F3)
Install snap ring (I 4) to sleeve (I 3). (See F3)
Assemble backup ring (IO) and O-ring to
seat (91, then install valve (I 2). spring (I I),
seat (91, and sleeve (81 to sleeve (13). (See
F3)
Assemble poppet (7) and spring I6). (See
F3)
Assemble nut (5) and O-ring to holder (41,
and install to sleeve (I 3). (See F3)
* Adjust so that protrusion dimension b
of the holder from the end face of the
nut is the same as when it was dis-
assembled, then secure with the nut.
(See F2)
Assemble retainer (3). (See F3)
Assemble nut (21 and O-ring to plug (I I, and
install to sleeve (I 3). (See F3)
* Adjust so that protrusion dimension a
of the plug from the end face of the nut
is the same as when it was disassem-
bled, then secure with the nut. (See F2)
30-72
0
-----
205FO5489
a
b
205FO5490
F3
205FO5491
30-73
a
REMOVAL OF TVC VALVE
ASSEMBLY
1. Wiring connector (I 1. (See Fl)
2. TVC valve assembly (2). (See Fl I
INSTALLATION OF TVC
VALVE ASSEMBLY
removal.
REMOVAL OF SERVO
VALVE ASSEMBLY
1. CO l NC valve assembly
l Remove CO l NC valve assembly.
For details, see REMOVAL OF CO l NC
VALVE.
2. Servo valve assembly (I 1. (See F3)
INSTALLATION OF SERVO
VALVE ASSEMBLY
removal.
REMOVAL OF CO-NC
VALVE ASSEMBLY
1. Wiring connector (I). (See F2)
2. Hose (2). (See F2)
3. Tube (3). (See F2)
4. CO l NC valve assembly (4). (See F2)
+ Remove the rear pump CO *NC valve
together with the TVC valve.
INSTALLATION OF CO-NC
VALVE ASSEMBLY
removal.
30674
Fl
F3
\
F20505330
30675
REMOVAL OF WORK
EQUIPMENT PPC VALVE
ASSEMBLY
*qLower the work equipment to the ground
levers several times to release the re-
maining pressure in the hydraulic piping.
Then loosen the oil filler cap slowly to
tank.
1. Plate (1). (See Fl)
2. Seat assembly (2). (See Fl)
3. Wiring connector (3). (See F2)
4. Lever assembly (4). (See F2)
5. Cover (5). (See F2) m
6. Bracket (6). (See F3)
* Remove the mounting bolts, and
move the bracket towards the win-
dow.
7. Hoses (7). (See F3)
* Disconnect 6 hoses.
8. PPC valve assembly (8). (See F3)
jr Remove the mounting bolts, then
remove the valve assembly together
with the hose.
INSTALLATION OF WORK
EQUIPMENT PPC VALVE
ASSEMBLY
* Carry out installation in the reverse order
to removal.
a
* Fit the slide stopper securely into the
inside lever.
30676
Fl
F20505369 1
F2
I
F3
I
F20505371
30677
DISASSEMBLY OF WORK ASSEMBLY OF WORK
EQUIPMENT PPC VALVE EQUIPMENT PPC VALVE
ASSEMBLY ASSEMBLY
PC200,2OOLC-5 Serial No: 45001 - 58018 PC200,2OOLC-5 Serial No: 45001 - 58018
PC220,22OLC-5 Serial No: 35001 - 36613 PC220,22OLC-5 Serial No: 35001 - 36613
1.
2.
3.
4.
5.
6.
Remove nut (I), then remove disc (2).
(See Fl)
Remove joint (3), then remove plate (4).
(See Fl)
Remove piston assembly (5). (See Fl)
Disassembly of piston assembly
Remove the following parts from piston
(6). (See Fl)
1) Remove collar (7), then remove dust
seal (8). (See Fl)
2) Remove collar (9), then remove seal
(10). (See Fl)
3) Remove piston (11) and spring (12).
(See Fl)
Remove valve assembly (13), then remove
spring (14). (See Fl)
Disassembly of valve assembly
Push retainer (16) to remove collar (15),
then remove retainer (16), spring (17),
and shim (18) from valve (19). (See Fl)
1.
2.
3.
Assembly of valve assembly
Assemble shim (IS), spring (17), and re-
tainer (16) to valve (19), and push down
retainer (16) to install collar (15). (See
Fl)
Assemble spring (14) and install valve
assembly (13). (See Fl)
Assembly of piston assembly
Assemble the following parts to piston
(6).
1)
2)
3)
Assemble spring (12) and piston (11).
(See Fl)
& Piston: Grease (G2-LI)
Fit seal (10) to collar (9) and as-
semble. (See Fl)
Fit dust seal (8) to collar (7) and as-
semble. (See Fl)
4. Install piston assembly (5). (See Fl)
5. Fit plate (4) and install joint (3). (See Fl)
W Joint:
6.
Fit disc (2) and install nut (1). (See Fl)
* Adjust the clearance between disc (2)
and piston (6).
For details, see TESTING AND AD-
JUSTING, Adjusting PPC valve for
work equipment.
m Nut:
30-z7-1
Fl
r
I- -
@-8
@
o -7
- 10
@j-9
0
A
s
S/l2
g,ll
@--15
@-1s
g.17
,>18
fi
-19
1
/5
, 13
205FO5493
DISASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY
1. Remove nut (I), then remove disc (2) and
boot (3).
2. Remove joint (4), then remove plate (5).
3. Remove seal (6) and collar (7).
4. Pull out piston (8), and remove retainer (9),
springs (10) and (1 I), and shim (12).
* Spring (10) consists of two sets of two
types of spring with different installed
loads, so check the installation position
(hydraulic port) and fit tags to prevent
mistakes when installing.
5. Pull out valve (13) from body (14).
20TF01235
30-&7-3
ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY
1.
2.
Assemble valve (13) to body (14).
Assemble shim (12) and spring (11) to valve
(13).
3. Assemble spring (IO), retainer (9), and piston
(8).
Sr Spring (10) consists of spring with a dif-
ferent number of coils for each hydraulic
port. The number of coils and position of
use are as follows.
*
* The position of each port is stamped on
the bottom of the valve body.
& Piston: Grease (LG-2)
jr When assembling piston (18), coat the
outer circumference of the piston and the
inner circumference of the body hole with
grease.
4. Fit O-ring to collar (7), then assemble in
body (14), and install seal (6).
5. Install plate (5).
m Mounting bolts: See MAINTENANCE
STANDARDS.
6. Install joint (4).
a Sliding portion of joint: Grease (LG-2)
& Joint: Thread tightener (LT-2)
m Joint: See MAINTENANCE STANDARDS.
* Keep strictly to the standard value for the
tightening torque of the joint.
7. Assemble disc (2), and tighten with nut (1).
w Nut: See MAINTENANCE STANDARDS.
or After assembling the disc, adjust the assem-
bled height of the disc:For details, see TEST-
ING AND ADJUSTING, Adjusting PPC valve.
a
t
es9
ZOTF01235
30-z7-4
U&Lower the work equpment to the ground
4
1.
2.
3.
Yokes (I 1. (See Fl)
Hose (2). (See Fl I
Travel PPC valve assembly (3). (See Fl)
REMOVAL OF TRAVEL PPC DISASSEMBLY OF TRAVEL
VALVE ASSEMBLY PPC VALVE ASSEMBLY
1.
2.
3.
4.
Remove plate (I), then remove piston as-
sembly (2). (See F21
INSTALLATION OF TRAVEL
PPC VALVE ASSEMBLY
removal.
Disassembly of piston assembly
Remove collar (4) from piston (31, then
remove seal (5). (See F2)
Remove valve assembly (61, then remove
spring (7). (See F2)
Disassembly of valve assembly
Push retainer (9) to remove collar (81, then
remove retainer (9). spring (10). and shim
(I I) from valve (I 2). (See F2)
ASSEMBLY OF TRAVEL
PPC VALVE ASSEMBLY
1.
2.
3.
4.
Assembly of valve assembly
Assemble shim (1 I), spring (I 01, and retain-
er (9) in valve (I 21, then push down retainer
(91 to install collar (8). (See F2)
Assemble spring (71, and install valve as-
sembly (6). (See F2)
g
Assembly of piston assembly
g
Assemble seal (5) to collar (41, and install to
z
piston (31. (See F2)
Assemble piston assembly (21, and install
plate (I 1. (See F2)
205FO5494
2
2-
6-
4
L
r
4
205FO5495
30-79
0
REMOVAL OF BOOM DISASSEMBLY OF BOOM
HOLDING VALVE ASSEMBLY HOLDING VALVE ASSEMBLY
%&Lower the work equipment to the ground
4
1.
2.
3.
Hoses (I 1. (See Fl)
Tubes (2). (See Fl)
Boom holding valve assembly 13). (See Fl)
+
1.
2.
3.
The set pressure of the safety valve cannot
be adjusted when the safety valve is in-
stalled on the machine, so do not disassem-
ble it.
Remove safety valve assembly (I 1. (See F2)
Remove plug (2). then remove spacer (3).
spring (4). seat (51, and spool (6). (See F2)
Remove body (71, then remove spring (8)
and check valve (9). (See F2)
INSTALLATION OF BOOM
HOLDING VALVE ASSEMBLY
removal.
Sr Refill to the specified level, and run the
system. Then check the oil level again.
ASSEMBLY OF BOOM
HOLDING VALVE ASSEMBLY
1. Assemble check valve (9) and spring (81,
then fit O-ring and install body (7). (See F2)
W Mounting bolt:
See Standard Value Table for
Tightening Torques
2. Fit seat (5) to spool (6) and insert in body
(71, then install spring (4). spacer (31, plug
(2) and O-ring. (See F2)
W Plug:
3. Fit O-ring and install safety valve (I). (See
F2)
m Safety valve:
30-80
0
Fl
205FO.5496
1
205FO5497
30- 81
0
REMOVAL OF PPC INSTALLATION OF PPC
SHUTTLE VALVE ASSEMBLY SHUTTLE VALVE ASSEMBLY
*yLower the work equipment to the ground
1. PPC shuttle valve assembly for arm,
swing
I) Hoses (II. (See Fl)
+ Disconnect 4 hoses.
2) Hoses (2). (See Fl 1
3) PPC shuttle valve assembly (3) for arm,
swing. (See Fl)
removal.
2. PPC shuttle valve assembly for boom
bucket, travel
I ) Hoses (4). (See Fl)
2) Hoses (5). (See Fl)
3) Pressure switch (6). (See Fl)
4) PPC shuttle valve assembly (7) for
boom, bucket, travel. (See F 1)
Fl
I I
205FO5498
REMOVAL OF BOOM
CYLINDER ASSEMBLY
A
Extend the arm and bucket fully, lower the
work equipment to the ground, and operate
the control levers 2 or 3 times.
1. Hose (1). (See Fl)
2. Lock bolt (2). (See Fl) 1
3. Pin (3). (See Fl) ml )I I=1
* Sling the boom cylinder assembly, and
A
remove the pin.
Start the engine, and retract the rod of
the boom cylinder, tie the rod with wire
to prevent it from coming out, then
lower it onto the block.
*Release the remaining pressure in the
ADJUSTING, Releasing pressure in hy-
draulic circuit for machines with PPC
valve.
4. Hose (4). (See F2)
5. Pin (5). (See F3) WI WI
* Sling the boom cylinder assembly, then
use forcing screws 0 to remove the
pin.
6. Boom cylinder assembly (6). (See F3)
&
kg
See Weight Table
CYLINDER ASSEMBLY
removal.
+ Tighten with the locknut so that the
clearance between the boom boss and
nut is 0.5 - 1.5 mm. (See F4)
m
A
When aligning the position of the pin
hole, run the engine at low idling. Never
insert your fingers in the pin hole.
Adjust with shims so that the clear-
ance between cylinder rod (7) and
plate (8) is less than 1 mm. (See F5)
* There are two type of shim thick-
ness: 0.8 mm, 1.5 mm
ance between cylinder bottom (9) and
bracket (IO) is less than 1 mm.
(See F6)
Inside surface of bushing: LM-P
For grease, use LM-G.
l Bleeding air
* Bleed the air from the cylinder.
ING, Bleeding air from hydraulic cylinder.
* After bleeding the air from the cylinder,
check the level of the oil in the hydraulic
tank.
30- : 3- l
F2
F20505332
F3
F20505333
F4
I I
0. 5 - 1. 5 mm
2OSF6065
F20505401
F20505402 1
30-:3-2
REMOVAL OF ARM INSTALLATION OF ARM
CYLINDER ASSEMBLY CYLINDER ASSEMBLY
A
Set block @ between the arm and the l Carry out installation in the reverse order to
removal.
*
1.
2.
3.
4.
5.
boom, then extend the arm fully, lower the
Sling the arm cylinder assembly.
Pin (1). (See Fl) ml j]
A
the arm cylinder, then tie the rod with
wire to prevent it from coming out.
?&Release the remaining pressure in the
valve.
Hose (2). (See Fl 1
Hose (3). (See Fl)
Pin (4). (See Fl) ia ml
Arm cylinder assembly (5). (See Fl)
&
kg
See Weight Table
AWhen aligning the position of the pin
m
* Adjust with shims so that the clear-
bracket (7) is less than 1 mm.
(See F2)
m
& Inside surface of bushing: LM-P
* For grease, use LM-G.
l Bleeding air
tank.
Fl
I
I
F20505334
F2
REMOVAL OF BUCKET
CYLINDER ASSEMBLY
A
A
Set block @ between the link and the arm,
and sling the bucket cylinder assembly.
1. Lock bolt (1). (See Fl) m
2. Pin (2). (See Fl) mj PI jE5)
A
the bucket cylinder, then tie the rod
with wire to prevent it from coming out.
*y Release the remaining pressure in the
valve.
3. Hose (3). (See Fl)
4. Pin (4). (See Fl) WI 1x1
5. Bucket cylinder assembly (5). (see Fl)
fi
kg See Weight Table
INSTALLATION OF BUCKET
CYLINDER ASSEMBLY
removal.
* Tighten with the locknut so that the
clearance between the link boss and nut
is 0.5 - 1.5 mm. (See F2)
m
A
n31
t Adjust with shims so that the clear-
ance between link (6) and link (7) is
less than 1 mm. (See F3)
m
bracket (9) is less than 1 mm.
(See F4)
m
xrz1, Inside surface of bushing: LM-P
l Bleeding air
+ Bleed the air from the cylinder.
tank.
30- g- 1
Fl
F20505335
F2
-4--I
0. 5 - 1. 5 mm
2OSF6065
F3
6 7
mm
F20505404 1
F4
3o-k5-2
DISASSEMBLY OF
HYDRAULIC CYLINDER
ASSEMBLY
1. Cylinder assembly
I ) Remove mounting bolts, and disconnect
head assembly (I). (See Fl)
2) Pull out piston rod assembly (2). (See
FII
* Place a container to catch the oil
under the cylinder.
3. Disassembly of piston assembly
1) Remove ring (12). (See F5)
2) Remove wear ring (13). (See F5)
3) Remove piston ring (14). (See F5)
2. Piston rod assembly
I ) Set piston rod assembly (21 in tool EI.
(See F2)
2) Using hydraulic pump, remove nut (3).
(See F2)
* Width across flats of nut
mm
4. Disassembly of cylinder head assembly
1) Remove snap ring (I 51, then remove
dust seal (I 6). (See F6)
2) Remove rod packing (I 7). (See F6)
3) Remove buffer ring (I 8). (See F6)
4) Remove bushing (I 9). (See F6)
3) Remove piston assembly (4). (See F3)
4) Remove retainer (5) and plunger (6).
(See F3)
l Retainer (5) is f6r PC220 boom
cylinder only.
l Plunger (6) is for PC200, PC220
boom, arm cylinders only.
5) Remove collar (7). (See F3)
l For PC200, PC220 boom, arm cylin-
ders only
6) Remove head assembly (8). (See F3)
7) Remove cap (9), and pull out 12 balls
(I 01, then remove plunger (I I ) . (See F4)
l For PC200, PC220 arm cylinder only
30-86
0
Fl
202FO548
M
202FO5482 202FO5486
202FO5483
F4
I 202FO5501 -K
I
202FO5485
12
F5.i
13
14
13
12
6
19
18
16
17
15
30-87
0
ASSEMBLY OF HYDRAULIC
CYLINDER ASSEMBLY
* Be careful not to damage the packings, dust
seals, and O-rings.
I . Assembly of head assembly
I) Press fit bushing (I 91. (See Fl)
2) Assemble buffer ring (I 8). (See Fl)
3) Assemble rod packing (I 7). (See Fl)
4) Assemble dust seal (I 61, and secure
with snap ring (I 5). (See Fl)
2. Assembly of piston assembly
11 Using tool E2, expand piston ring (14).
(See F2)
* Set the piston ring in tool E2. and
turn the handle 8 - 10 turns to
expand.
21 Set tool E3 in position, and compress
piston ring (I 4). (See F3)
3) Assemble wear ring (I 3). (See F4)
4) Assemble ring (I 2). (See F4)
jr Be careful not to open the end gap
of the ring too far.
& Ring groove: Grease (G2-LI)
3. Piston rod assembly
I) Set plunger (I 1) in piston rod, then
assemble 12 balls (IO), and secure with
cap (9). (See F5)
+ Check that there is a certain amount
of plug at the tip of the plunger.
l For PC200, PC220 arm cylinder only
21 Assemble head assembly (8). (See F6)
3) Assemble collar (7). (See F6)
l For PC200, PC220 boom, arm cylin-
ders only
4) Assemble plunger (6) and retainer (5).
(See F6)
l Plunger (6) is for PC200, PC220
boom, arm cylinders only.
l Retainer (5) is for PC220 boom
cylinder only.
5) Assemble piston assembly (4). (See F6)
6) Set piston rod assembly (2) in tool El.
(See F7)
71 Using hydraulic pump, tighten nut (3).
Xn, Nut: Thread tightener (LT-3)
@a Nut:
4. Cylinder assembly
I) Assemble piston rod assembly (2). (See
FS)
& Seal: Grease (G2-LI)
jr Set the end gap of the ring at the
horizontal (side) position, align the
center of shaft and cylinder tube,
then insert. (See F8I
+ After inserting, check that the ring is
not broken and has not come out,
then push in fully.
2) Tighten head assembly (I) with mount-
ing bolts. (See FSI
W Mounting bolt;
30-88
a
Fl
202F0548E
u
202FO548;
F4
A-4
202FO5488
12
12
: m
202FO5485
F5
202FO5501 -K
6
: 7
8
9
6
202FO5483
M
202FO5482
202FO5489
202FO5481
30;89
REMOVAL OF WORK
EQUIPMENT ASSEMBLY
A
Extend the arm and the bucket fully and
lower the work equipment completely, then
operate the control levers 2 or 3 times.
1. Hose (1). (SeeFl)
2. Lock bolt (2). (See Fl 1 m
3. Pin (3). (See Fl) ml 1-1 [m
* Sling the boom cylinder assembly and
remove the pin.
A
Start the engine and retract the
boom cylinder rod fully, then tie the
rod with wire to prevent it from
coming out, and lower it onto the
block.
t Disconnect the boom cylinder on the
opposite side in the same way.
*A&Release the remaining pressure in
* the circuit. For details, see TESTING
AND ADJUSTING, Releasing pres-
sure in hydraulic circuit for machines
with PPC valve.
4. Hoses (4). (See F2)
5. Wiring (5). (See F2)
6. Pin (6). (See F3) ml mi
Sr Sling work equipment assembly (7),
then using tool F, remove the pin. (See
F3)
7. Work equipment assembly (7). (See F4)
fi
kg See Weight Table
INSTALLATION OF WORK
EQUIPMENT ASSEMBLY
removal.
+ When tightening the locknut, tighten so
that the clearance between the boss of
the boom and the nut is 0.5 - 1.5
mm. (See F5)
m
A
hole, run the engine at low idling, and
align slowly. Never insert your fingers in
the pin hole.
m
t Adjust with shims so that the clear-
a
ance between boom (10) and bracket
(11) is less than 1 mm. (See F7)
m
a Inside surface of bushing: LM-P
l Bleeding air
+ After bleeding the air from the cylinder,
check the level of the hydraulic tank.
Fl F5
\
205FO5499
205FO5500
F3
205FO5501
F4.
II
205FO5502
0.5 - 1.5mm
2OSF6065
F20505406
F7
\o \
Max. 1 mm
F20505407
REMOVAL OF BUCKET REMOVAL OF ARM
ASSEMBLY ASSEMBLY
A
Set the back of the bucket facing down, 1. Bucket assembly
1.
2.
3.
4.
5.
6.
lower the work equpment to the ground,
and operate the control levers 2 or 3 times.
Lock bolt (1). (See Fl) 1
Plate (2). (See Fl 1 m
Pin (3). (See Fl) m
Lock bolt (4). (See Fl) m
Pin (5). (See Fl) m
Bucket assembly (6). (See Fl)
Ir Raise the work equipment and discon-
nect the arm from the bucket.
+I
kg See Weight Table
INSTALLATION OF BUCKET
ASSEMBLY
removal.
Tighten with the locknut so that the
clearance between the bucket boss and
nut is 0.5 - 1.5 mm. (See F2)
Adjust the shim thickness so that the
clearance between bucket boss (7) and
spacer (8) is 2 mm. (See F3)
2.
3.
4.
5.
6.
l Remove bucket assembly.
For details, see REMOVAL OF BUCKET
ASSEMBLY.
Work equipment set
* Secure the bucket cylinder assembly to
the arm, pull in the arm, and lower it
onto block 0. (See F4)
Pin (4). (See F4) m
+ Sling the arm cylinder assembly, and
A
remove the pin.
y &wire to prevent it from coming out.
* Release the remaining pressure in the
valve.
Hose (2). (See F4)
Pin (3). (See F4)
Arm assembly (4). (See F4)
* Raise the boom and disconnect the
boom from the arm.
::
&
kg See Weight Table
0
zr
INSTALLATION OF ARM
ASSEMBLY
removal.
m
A When aligning the position of the pin
m
ance between boom (5) and arm (6) is
* There is only one type of shim thick-
ness: 0.8 mm
j
& Inside surface of bushing: LM-P
l Bleeding air
+ After bleeding the air from the cylinder,
tank.
30&92
Fl
F 2
0.-11.5mm
2OSF6065
F3
7 8 Shim
d
_[_
Clearance 2 mm
F20505337
F20505338
F5
F20505408
REMOVAL OF ARM,
BUCKET ASSEMBLY
A
1. Pin (1). (See Fl) m FFi
* Set block @ between the arm and the
boom, then sling the arm cylinder as-
A
sembly, and remove the pin. (See Fl)
wire to prevent it from coming out.
*yRelease the remaining pressure in the
valve.
2. Hose (2). (See F2)
3. Pin (3). (See F2) wti m
Sr Sling the arm and bucket assembly,
then remove the pin.
4. Arm and bucket assembly (4)
r?YI
kg See Weight Table
INSTALLATION OF ARM,
BUCKET ASSEMBLY
removal.
w
A
m
ance between boom (5) and arm (6) is
t There is only one type of shim
thickness: 0.8 mm
m
x11, Inside surface of bushing: LM-P
l Bleeding air
tank. 0
Lo
0
z
Fl
I
I
I
II
I
F2
u
F20505340
F3
6 5
30-95
@
REMOVAL OF BOOM
ASSEMBLY
ASSEMBLY
1.
2.
3.
4.
5.
6.
7.
8.
Arm and bucket assembly
l Remove arm and bucket assembly.
For details, see REMOVAL OF ARM,
BUCKET ASSEMBLY.
Hose (1). (See Fl)
Lock bolt (2). (See Fl) m
Pin (3). (See Fl) ml mj jr1
t Sling the boom bylinder assembly, and
A
remove the pin.
the boom cylinder, tie the rod with wire
to prevent it from coming out, then
lower it onto the block.
Sr Disconnect the boom cylinder assembly
on the opposite side in the same way.
*y Release the remaining pressure in the
ADJUSTING, Releasig pressure in hy-
valve.
Hose (4). (See F2)
Wiring (5). (See F2)
Pin (6). (See F5) m] m
* Sling the boom assembly, then use tool
F to remove the pin. (See F3)
Boom assembly (7). (See F4)
&
kg See Weight Table
l Carry out installation in the reverse order
to removal.
Sr Tighten with the locknut so that the
clearance between the boom boss and
nut is 0.5 - 1.5 mm.
m
A
pziJ
*
m
*
ance between boom (10) and bracket
(11) is less than 1 mm (See F6)
0
0
l Bleeding air
Sr Bleed the air from the cylinder.
-k After bleeding the air from the cylinder,
tank.
30-g5- 1
Fl
r
205FO5499
F2
205FO5.500
F3
I I
205FO5501
F4
F20505341
F5
F6
Max. 1 mm
F.20505411
30-:5-2
REMOVAL OF OPERATORS REMOVAL OF
CAB ASSEMBLY COUNTERWEIGHT
1. Seat assembly (I 1. (See F I)
2.
3.
4.
5.
6.
6
kg See Weight Table
Wiper motor wiring (2). (See Fl)
Antenna wiring (3). (See F2)
Room lamp wiring (4). (See F2)
Ground connection (5). (See F2)
Instrument panel assembly (6). (See F2)
J, Remove the cover, then loosen the
7.
mounting bolts, and move the instru-
ment panel assembly towards the inside.
Cab assembly (7). (See F3)
b
kg See Weight Table
INSTALLATION OF
OPERATORS CAB
ASSEMBLY
removal.
1. Counterweight (I 1. (See F4) m
* Using eyebolts, sling the counterweight,
then remove the mounting bolts.
+ Width across falts of bolt: 41 mm
fi
kg See Weight Table
INSTALLATION OF
COUNTERWEIGHT
removal.
/
m Mounting bolt:
.See Tightening Torques and
30-96
a
Fl
r
F
_
- 1
.2
I
F20505372
: 2
205FO5504
F3
205FO5505
I-
--
/
===xzE
/--- I/
d
. k20505342
30-97
0
REMOVAL OF ENGINE REMOVAL OF MONITOR
THROTTLE CONTROLLER PANEL ASSEMBLY
1.
2.
3.
4.
5.
6.
Pump controller assembly. 1. Screws (I 1. (See F5)
For details, see REMOVAL OF PUMP CON- Sr Remove 4 screws, and move the moni-
TROLLER ASSEMBLY. tor panel assembly upward.
Wiring connector (I 1. (See Fl) 2. Wiring connector (2). (See F5)
* Disconnect the connector from the 3. Monitor panel assembly (3). (See F5)
wiring clamp.
Bracket (2). (See Fl)
Wiring connector (3). (See Fl I
Bracket (4). (See Fl 1
* Remove the mounting bolts, and move
INSTALLATION OF
MONITOR PANEL
ASSEMBLY
the bracket towards the inside.
Egnine throttle controller assembly (5). (See
F2)
removal.
THROTTLE CONTROLLER
removal.
REMOVAL OF PUMP
CONTROLLER ASSEMBLY
1. Box assembly (I 1. (See F31
Sr Disconnect the antenna wiring of the
radio, the wiring connectors, and the
ground connection, then remove togeth-
er with the radio.
2. Wiring connector (2). (See F4)
3. Pump controller assembly (3). (See F4)
INSTALLATION OF PUMP
CONTROLLER ASSEMBLY
removal.
30-98
0
Fl
\
/I
F2050.5373
F2
F20505374
F20505375
2 3
F20505376
F20505377
PROCEDURE FOR FLUSHING HYDRAULIC CIRCUIT
* When carrying out flushing to remove the dirt in the hydraulic circuit, use the following procedure.
Select one of the patterns below to match the level of contamination in the hydraulic circuit.
Contamination level
Flushing
nattern
I I
1
Hydraulic equipment is broken; there are
metal particles in the circuit I
A
Parts in the circuit have been disassembled
2 and assembled
(there are no metal particles in the circuit)
B
3 Periodic flushing
4
After assembly at jobsite following
disassembly and transportation
C
1. Parts to prepare
+ The figures in the table below show the number of parts required.
No. Part Name
Flushing pattern
Part No.
A B C
1 Flushing element 209-60-31130 2 1 1
2 Standard element 07063-01210 1 1 1
3 Pilot filter 704-28-02751 2 1 1
4 Is
mall strainer / 206-60-41221 1 1 / 1 [ 1
5
Flange for short-
circuiting piping
6
Main valve blind plug
and sleeve nut
07222-00312 4 4
-
07221-20315
7
Extension nipple for
PPC circuit
07 102-20340
1414/-
Extenion nipple
PPC circuit
for
21 T-04-1 1580
l In addition to these, a stopper is also needed as a blind plug for the hydraulic tank filter case.
* For details, see Installation of filter element.
30-l 00
0
2. Order of operations
The following explanation describes the procedure for short-circuiting the piping, installation of
the filter element, cleaning of the cylinder, and flushing of the PPC circuit that is carried out in the
operation for each flushing pattern.
I) Short-circuiting the piping
Using the piping short-circuiting flange, short circuit the following piping.
osi-
tion
Method for short circuiting piping
All the hydraulic circuit, including the
hoses and tubes is flushed, so short cir-
cuit the supply and return pipes in the
2 / Arm 1 (Cl and (D) 1205-62-747301 1
3 1 Bucket / (A) and (B) 107377-00615 1 1
4 Swing ( I ) and (J) 07377-00615 1
I I I
5 ) Travel ) ~,1~~&~ )07377-00615 / 2
I I I I
circuit.
L
Flange
F2050537I 3
F20505379
30201
2) Installation of filter element
(Replace with new one)
F20505380
When removing the element from the return
filter, use the stopper to prevent the dirt
inside the filter case from entering the tank.
l Inside diameter of hole: 35.7 mm
When parts have been removed for short
circuiting, clean the individual parts and
blow with air, then mask with tape to pre-
vent dirt from entering, and store in a safe
place until assembling again.
Stopper
Filter case
F20505381
3) Cleaning cylinder
Ir Disassemble all cylinders and clean
them.
i) Remove cylinder head, then pull out
piston rod.
ii) Fix cylinder at an angle, then use
pump to clean with flushing fluid.
Sr If no pump is available, use
a
a
crane, collect the flushing fluid
at the bottom end, shake well,
then drain the flushing fluid, and
blow with air.
iii) Apply flushing fluid to the cylinder
head and piston and brush well with
a nylon brush, then blow with air.
Ir Dirt is likely to collect particularly
in the inset portions, so clean
these parts well.
iv) Check inside of cylinder for damage.
Any
vertical
cylinder.
scratches in
Any breakage or seizure of wear
rings or piston rings.
Scratches on piston.
If there is any scuffing of the
piston or cylinder, replace the
assembly.
If only the wear ring or piston
ring are damaged, replace the
damaged part with a new part,
and use again.
Cylinder Rod Head
I \ /
F20505382
Cylinder
\
Pump
Flushing fluid
F20505383
Rod Piston Sunken
F20505384
Wear Piston Wear
30-Ao3
F20505385
4) Flushing PPC circuit
Use nipple to connect hose
D
1
Using extension hose,
Replace element and clean
return PPC circuit hose
small strainer
directly to hydraulic filter case
From
pump
It is not necessary to remove
noses for port P and port T.
Disconnect PPC hose from
main valve, then fit
nd plug in main valve
F20505386
i) Disconnect PPC circuit hose from
control valve, and return directly to
hydraulic tank filter case.
Sr Carry out the operation for one
PPC valve.
ii) Run the engine at high idling, oper-
ate the control lever in each direction
and hold it for 2 minutes in each
position.
iii) Repeat the procedure in Step ii) at
least 5 times.
iv) Carry out the procedure in Steps i),
ii), and iii) for each PPC circuit.
30-l 04
0
3. Flushing pattern [Al
1) Disassembly, cleaning, reassembly
i) Failed parts
* If any part is badly damaged, re-
place it.
ii) Hydraulic tank
iii) Suction strainer
iv) Oil cooler
* If excessive amounts of dirt and
dust are stuck in the core,
replace.
VI Cylinder
+ For details, see Cleaning
cylinder.
vi) Other hydraulic equipment
2) Preparatory work for flushing
i) Install the flushing element, clean
the small strainer, then install it as it
is. Replace the pilot filter with a new
part.
* For details, see Installing filter
element.
ii) Short circuit the cylinder circuit,
swing motor circuit, and travel
motor circuit.
* For details, see Short circuiting
piping.
iii) Add hydraulic oil to the specified
level.
iv) Bleed the air from the main pump.
3) Flushing cylinder circuit, swing motor
circuit, travel motor circuit
i) Run the engine at low idling for 30
minutes.
* The control levers must not be
moved during this time.
ii) Run the engine at midrange speed
for 30 minutes.
J, The control levers must not be
* If the oil tempefature is low, increase
the length of the operation in Steps
i) and ii) to raise the temperature.
The oil temperature should be 50 -
80C.
iii) Run the engine at high idling and
carry out the following operation.
l Operating pattern
Boom RAISE - Boom LOWER -
Arm IN - Arm OUT - Bucket
CURL - Bucket DUMP - Right
swing - Left swing - Left travel
-Right travel
l Operating time
Hold the lever in each position
for 2 minutes.
l Number of times of operation
Repeat the above pattern at
least 5 times.
4) Restoring cylinder circuit, swing motor
circuit
i) Restore the cylinder circuit and
swing motor circuit to the standard
circuit.
Jr Keep the travel motor circuit
short-circuited.
ii) Add hydraulic oil to the specified
level.
iii) Bleed the air from the main pump,
cylinders, and swing motor.
5) Flushing center swivel joint
i) Run the engine at high idling and
l Operation pattern
Left and right FORWARD +90
swing
Left and right REVERSE +90
swing
Ir Swing 90 to either the left
or right, but swing in the
same direction each time.
l Operating time
for 2 minutes.
Repeat the above pattern 4
times, and rotate the swing one
turn.
Sr The purpose of swinging
90 each is to remove the
dirt inside the center swivel
for the whole circumference
of the oil groove on the rotor
side and shaft side.
30-l 05
0
4. Flushing pattern [Bl
1)
2)
3)
4)
5)
Preparatory work for flushing
Install the flushing element.
Sr For details, see Installing filter
element.
Flush PPC circuit
Flush the PPC circuit
or For details, see Flushing PPC
circuit.
Restoring PPC circuit
Restore the PPC circuit to the standard
circuit.
Flushing during actual operation
With the flushing element installed,
carry out normal operations for 10 -
20 hours.
* If the oil temperature is low, carry
out the warming-up operation.
Replacing element
Replace the return filter with a standard
element, clean the small strainer and in-
stall it as it is.
Replace the pilot filter with a new part.
Sr For details, see Installing filter ele-
ment.
0
z
z
6) Restoring travel circuit
i) Restore the travel circuit to the stan-
dard circuit.
ii) Replace the flushing element with a
new part.
Ir For details, see Installing filter
element.
iii) Bleed the air from the travel motor.
7) Flushing PPC circuit
i) Flush the PPC circuit
Jr For details, see Flushing PPC
circuit.
8) Restoring PPC circuit
i) Restore the PPC circuit to the stan-
dard circuit.
9) Flushing during actual operation
i) With the flushing element installed,
carry out normal operations for 10
- 20 hours.
Sr If the oil temperature is low,
carry out the warming-up
operation.
IO) Replacing element
i) Replace the return filter with a stan-
dard element, clean the small strain-
er and install it as it is.
Replace the pilot filter with a new
part.
Ir For details, see Installing filter
element.
level.
iii) Bleed the air from the main pump.
30- 106
0
5. Flushing pattern [Cl
_* If the cylinder piping is connected and
the cylinder is operated before the
system flushed, there is danger that the
dirt that entered during assembly opera-
tions will circulated inside the cylinder.
Therefore, do not flush the system after
completion of assembly; carry out flush-
ing before connecting the piping to the
cylinder.
1) Preparatory work for flushing
i) Short circuit the cylinder circuit.
Ir For details, see Short-circuiting
piping.
ii) Install the flushing element.
element.
2) Flushing
i) Run the engine at low idling for 30
minutes.
* The control levers must not be
ii) Run the engine at midrange speed
for 30 minutes.
Sr The control levers must not be
iii) Run the engine at high idling and
l Operating pattern
Boom RAISE - Boom LOWER -
Arm IN - Arm OUT - Bucket
CURL -Bucket DUMP
l Operating time
for 2 minutes.
Repeat the above pattern at
least 5 times.
3) Restoring cylinder circuit
i) Restore the cylinder circuit to the
standard circuit.
level.
iii) Bleed the air from the main pump
and cylinders.
4) Flushing during actual operation
i) With the flushing element installed,
carry out normal operations for 10
- 20 hours.
* If the oil temperature is low,
carry out the warming-up
operation.
5) Replacing element
i) Replace the return filter with a stan-
dard element, clean the small strain-
er and install it as it is.
Replace the pilot filter with a new
part.
element.
level.
iii) Bleed the air from the main pump.
30- 107
0
40 MAINTENANCE STANDARD
Final drive . . . . .
Swing machinery.. .
Swing circle . . . .
Track frame and recoil sprig
Idler . . . . . . . .
Track roller . . . . . .
Carrier roller . . . . .
Track _______.___.____._____.
Hydraulic pump . .
Charging pump and relief valve
Control valve . .
Swing motor _..___._..___.__
Center swivel joint
Travel motor . . . . . .
PPC valve . . . . . . . . .
Boom holding valve . . .
Hydralic cylinder _ . . . . . . . .
Work equipment . . . . . . .
40- 2
40- 4
. 40- 6
. 40- 7
40- 8
40-10
40-11
40-12
40- 13-2
40-14
40-15
40-22
40-23
. 40-24
. 40-25
. 40-27
. 40-28
. 40-30
40- l
a
FINAL DRIVE
-47.5 + 2.5 kam
m Initial tightening torque: 80 kgm
Additional tightening angle: 9r+i
kgm_
11.25 f 1.25 kgrn~duh
-11.25 +I.25 kgm
205FO5182-1
Unit: mm
No. Check item Criteria
Standard clearance Clearance limit
i
Backlash between No. 1 sun
gear and No. 1 planet gear
0.19 - 0.54 1 .oo
I I I
I
2 Backlash between No. 1 planet 0.21 - 0.62 1.10
gear and No. 1 ring gear
8 Backlash between No. 1 planetary 0.06 - 0.22 -
carrier and idle gear
4 Backlash between No. 2 sun -
gear and No. 2 planet gear
0.19 0.54 1. 00
5
Backlash between No. 2 planet
0.21 - 0.62 1.10
gear and ring gear
between No. 2
6 Backlash planetary 0.40 - 0.70 1.20
carrier and No. 1 sun gear
7 End play of sprocket shaft 0.05 - 0.15
-
8 Amount of wear on sprocket tooth Repair limit: 6
Standard size Repair limit
9
I
Width of sprocket tooth
Remedy
Replace
Rebuild
or
replace
71 68
SWING MACHINERY
205FO5 183
40-4
Unit: mm
Check item Criteria
shaft and drive gear
0.07 - 0.18
een sun gear
0.17 - 0.49
contacting with oil seal
0.08 - 0.32
SWING CIRCLE
94.5 2 10 kgm
Section A-A
205FO5184
Unit: mm
No. Check item Criteria Remedy
Standard size Clearance limit
Axial clearance of bearing
1
(When mounted on machine)
Replace
0.5 - 1.6 3.2
40-6
0
TRACK FRAME AND RECOIL SPRING
-
NO.
1
-
2
3 Recoil spring
2
k
* The drawing shows the PC200-5
,
\
3
205FO5185
Unit: mm
Check item Criteria
Vertical width of idler guide
Horizontal width of idler guide
PC200
PC2OOLC
PC220
PC22OLC
c
Standard size Tolerance Repair limit
Track frame 107
Idler support 105
Track frame 250
I I
I I /
Idler support
Free Installation Installation Free Installation
length length load length load
j58 x 238 437 11,100 kg 534 8,900 kg
603.5 x
239 466 12,900 kg 576 10,300 kg
Remedy
Rebuild or
replace
Replace
40-7
IDLER
2
205FO5186
40-8
Unit: mm
No.
::
1
Z
hl
0
2
3
4
5
6
7
8
9
Check item Criteria Remedy
Outside diameter of protrusion
560
-
Outside diameter of tread
Width of protrusion
520 508
85
-
Total width
I
164
-
Width of tread 39.5 45.5
Clearance between shaft and
bushing
I
- -
65 0.250 +0.074 0.214
- 0.350 - 0.035 0.424
1. 5
Clearance between shaft and -
65
0.250 -0.110 0.030 -
- support - 0.290 - 0.220 0.180
Standard
Tolerance
Standard Interference
Interference between idler and
bushing
E:Ghylearance of idler
size
Shaft Hole
interference limit
72
+0.089 -0.006 0.065 -
+0.059 - 0.072 0.161 -
Standard clearance Clearance limit
0.39 - 1.00 1.5
Rebuild or
replace
Replace
bushing
Replace
Replace
bushing
40-9
TRACK ROLLER
w 44.5 * 4.5 kgm
No
7
A. I I I
/_ 3 _14_1
.I
205FO5187
Check item
Outside diameter of flange
(outside)
Width of tread
Width of flange
Clearance between shaft and
bushing
Interference between
roller and bushing
Ezzh;learance of roller
Criteria
Unit: mm
::
Remedy
Z
g
Standard size
I
Repair limit
I
186
I
-
154 142
44.5 52
24.5
-
Standard
size
Tolerance
Shaft Hole
Standard Clearance
clearance limit
60 -0.215 +0.195 0.215
-
-0.315 0 0.510
1.5
Standard
size
Tolerance
Shaft Hole
Standard Interference
interference limit
67 +0.153 +0.030 0.023
-
+0.053 0 0.153 -
Standard clearance
0.41 - 0.95
Clearance limit
1.5
Replace
bushing
Replace
40- 10
CARRIER ROLLER
No
-
1
5
6
205FO5188
Unit: mm
Check item
Outside diameter of flange
(outside)
Width of tread 43 50
Clearance between
shaft and bearing
Standard
size
Tolerance
Shaft Hole
Standard
clearance
Interference between
roller and bushing
50 0 0 -0.016 -
-0.016 -0.012 0.012
80 0 -0.021 0.008 -
-0.013 -0.051 0.05 1
I
Side clearance of roller
Criteria
Standard size
165
Repair limit
-
140
I
130
Clearance
limit
-
Standard size
I
Repair limit
0.01 - 0.18
I
-
Remedy
Rebuild or
replace
Replace
40- 11
TRACK SHOE
B
1
h
2@5FO5189- 1
40- 12
0
Unit: mm
1 Link pitch
190.25 194.25 Turn or
replace
2 Outside diameter of bushing 59.3 54.3
Triple 26 16 Lug wel-
3 Height of grouser
ding,
rebuild or
Swamp 102.5 90.5 replace
4 Height of link 105 97 Rebuild or
replace
6 interference of regular pin and link 38 +0.222 -0.138 0.210
-
+0.072 - 0.200 0.422
0.140
7 Interference of master pin +0.230 +0.062 0.138
Replace
-
and link
37.8
+0.200 0 0.230
0.130 with larger
one
8 1 Protrusion of bushing
I
4.85
I
9 Tightening torque of shoe bolt
Initial tightening torque: 40 f 4 kgm
Additional tightening angle: 120 f 10
Tighten
HYDRAULIC PUMP
n
m m w B
18 + 0.4 kgm 3.15 + 0.35 kgm 5.5* 0.5 kgm 14.25 + 2.25 kgm
m
1.75 f 0.25 kgm 11. 25 + 1. 25 kgm 8 + 2 kgm 1.15 f 0.
-7:1 kgm -7: 1 kgm
205FO5773
15 kgm
4o-k?-2
CHARGING PUMP AND RELIEF VALVE
-11.5 k 1Okgm
\
No
1
-
2
3
4
5 Charging relief valve spring
5 m5.5 * 0.5 kgm
205FO5190
Unit: mm
Check item
Top clearance of gear
Standard size
0.090 - 0.130
Criteria
Repair limit
0.145
Side clearance of
gear 0.055 - 0.075
0.105
Clearance between gear shaft
and bushing
0.045 - 0.076
0.13
Delivery
Engine oil
CLASS-CD SAEI OW
50 -t 5C
30 kg/cm2
I
Standard value Repair limit
Revolution Delivery Revolution
speed (rpm) (Urnin)
Delivery
speed (rpm) (Urnin)
3,200
I
72
I
3,200
I
68
Free length Installed Installed Free Installed
x O.D. length load length load
32.3 x 13.0 26.4 14.6 kg - 13.1 kg
Remedy
Replace
Replace
spring if
any dama-
ges or
deforma-
tions are
found
40- 14
CONTROL VALVE
PC200,2OOLC-5 Serial No: 45001 - 53192
PC220,22OLC-5 Serial No: 35001 - 36052
m 3.0 f 0.5 kgm
/
D 0.9 * 0.1 kgm
w 6.0 * 1.O kgm.
205FO5191
40- 15
(@
1 .O kgm
No. Check item
1
-
2
3
4
5
6
Section B - B
m 3.0 * 0.5 kgm
5.5 1+0.5 kgm 5.5 f 0.5 kgm
Section A- A
205FO5192
g
L3
g
Unit: mm
Main relief valve
pilot poppet spring
Main relief valve
main valve spring
Jet sensor relief valve
pilot poppet spring
main valve spring
Spool return spring
(Straight-travel valve)
Spool return spring
(Arm throttle valve)
Criteria Remedy
Standard size
I
Repair limit
Free length
x O.D.
30.7 x 9.6
26.0 x 9.2
26.3 x 8.0
23.8 x 7.8
71.7x20.3
$7.5 x 28.0
L
Installed Installed
length load
26.8 33.1 kg
20.0 3.2 kg
26.1 0.39 kg
18.1 2.41 kg
45.0 11.4kg
35.5 16.2 kg
Free
length
-
-
-
-
-
-
installed
load
26.5 kg
2.56 kg
0.31 kg
1.93 kg
9.1 kg
13.0 kg
Replace
spring if
any dama-
ges or
deforma-
tions are
found
40- 16
m 10.0 * l.Okgm 1
3
m 5.5 * 0.5 kgm m 5.5 -t 0.5 kgm
-
No
-
1
2
-
3
4
-
5
-
& 14.5
Section D -D
Section C - C
205FO5193
Unit: mm
Check item
Main relief valve
pilot poppet spring
Main relief valve
main valve spring
pilot poppet spring
main valve spring
Spool return spring
(Swing priolity valve)
Criteria Remedy
30.7 x 9.6 26.8
26.0 x 9.2 20.0
26.3 x 8.0 26.1
23.8 x 7.8 18.1
33.1 kg -
3.2 kg -
0.39 kg -
2.41 kg -
26.5 kg
Replace
2.56 kg spring if
any dama-
ges or
deforma- 0.31 kg
tions are
found
1.93 kg
37.5 x 28.0 36.5 8.1 kg - 6.5 kg
40-17
m 20.0 f 2.0 kgm
w 20.072.0 kgm
&I 20.0 * 2.0 kgm W
1 m 20.0 * 2.0 kgm
Section E - E
Section F - F
m 11 .O * 1.5 kgm 11 .O f 1.5 kgm
m w
14.5 % 2.0 kgm 3 4 7 2.3 f 0.2 kgm 4
15.0 * 1 .O kgm 6
5
W
11 .O f 1.5 kgm
Section G - G
Section H-H
40- 18
205FO5 194
Unit: mm
No. Check item
1 Check valve spring
3
4
5
6
Spool return spring
Spool return spring
Spool return spring
Spool return spring
Criteria
I
Remedy
24.5 x 1 1. 6 14.5 0.76 kg - 0.61 kg
31.8 x 7.6 26.5 0.1 kg - 0.08 kg
. Replace
spring if
29.8 x 28.1 27.0 17.1 kg - 13.7 kg any dama-
ges or
def orma-
41.4x 29.5 40.0 17.1 kg - 13.7 kg tions are
found
5 1 .O x 29.6 50.0 8.6 kg - 6.9 kg
,..:;:I
40- 19
5
1 -15.0* l.Okgm
m
15.0 * 1.0
bm 1 1
m 2.3 * 0.2 kgm
.O
kgm/ \
\
1
B 2.3 * 0.2 kgm 2
Section J-J
Section K - K
11.0 2 1.5 kgm
Section L - L
40-20
205FO5195
Unit: mm
No
1
-
2
3
Check item
Spool return spring
Spool return spring
Spool return spring
Criteria Remedy
51 .O x 29.6 50.0 8.6 kg - 6.9 kg Replace
spring if
I I I anv dama-
50.8 x 29.5 50.0 7.6 kg - 6.1 kg ges or
deforma-
tions are
41.4x 29.5 40.0 17.1 kg - 13.7 kg found
4
I
Spool return spring 129.8x28.1 1 27.0 1 17.1 kg 1 - 1 13.7kg 1
5 Check valve srping 46.8 x 26.2 25.0 0.76 kg - 0.61 kg
40-2 1
PC200, 2OOLC-5 Serial No: 53193 and up
PC200, 2OOLC-5 MIGHTY
PC220, 22OLC-5 Serial No: 36053 and up
w 3. 0 k 0. 5 kgm'
cd
I-E
A-l
A-i,-/
w 6. 0 t 1. 0 kgm
m 0. 9 - t 0. 1 kgm
205FO57.35
40-2 1-2
\E>
m
2
1 10.0 ir
\ I /
1 .O kgm
No. Check item
3
4
5
6
3,0 _ o.5 kgm
+
Section A - A
205=05766
Main relief valve
pilot poppet spring
Main relief valve
main valve spring
pilot poppet spring
main valve spring
Spool return spring
(Straight-travel valve)
Spool return spring
(Arm throttle valve)
Section B - B
Criteria
Standard size
Free length Installed Installed
x O.D. length load
30.7 x 9.6 26.8 33.1 kg
26.0 x 9.2 20.0 3.2 kg
26.3 x 8.0 26.1 0.39 kg
23.8 x 7.8 18.1 2.41 kg
71.7x20.3 45.0 1 1.4 kg
37.5 x 28.0 35.5 16.2 kg
Repair limit
-
0.31 kg
-
1.93 kg
A-
-
9.1 kg
-
13.0 kg
205FO5 IS2
T
Unit: mm
Remedy
Replace
spring if
any dama-
ges or
deforma-
tions are
found
No. Check item
1
2
3
-
4
5
m
10.0 + 1.0 kgm
! ?
w
14.5 i 2.0
m 5.5 & 0.5 kim 5.5 + 0.5 kgm \
m 14.5 k 2.0 kgm
Section C - C
Section D - D
205FO5787
Unit: mm
Main relief valve
pilot poppet spring
Main relief valve
main valve spring
pilot poppet spring
main valve spring
Spool return spring
I
:
.
-L
Criteria Remedy
Replace
spring if
any dama-
ges or
deforma-
tions are
found
m 20.0 k 2.0 kgm
/=2.0 kgm
A-1
3.5 k 0.5 kgm
v 1 w 20.0 i 2.0 kgm
m
I \- 20.0 + 2.0 kgm
1 B 20.0 * 2.0 kgm
Section E - E
w
w 7.0 k 1.0 kgm m 7.0 k 1.0 kgm 13.0+ 1.0 kgm 3
Section G - G
Section F - F
w
4
2.3 & 0.2 kgm 4
m
13.O+l.bkgm 6 5
Section H - H
w
7.0 i 1.0 kgm
205FO5788
Unit: mm
No. Check item
2
-
3
4
5
6 Spool return spring
Check valve spring
Spool return spring
Spool return spring
Spool return spring
Criteria
Standard size
I
Repair limit
Free length
x O.D.
24.5 x 1 1. 6
31.8 x 7.6
29.8 x 28.1
41.4 x 29.5
5 1 .O x 29.6
32.0 x 13.1
Installed
length
14.5
26.5
27.0
40.0
50.0
32.0
Installed
load
0.76 kg
0.1 kg
17.1 kg
17.1 kg
8.6 kg
0 kg
Free
length
-
-
-
-
-
31
Installed
load
0.61 kg
0.08 kg
13.7 kg
13.7 kg
6.9 kg
-
F
Remedy
Replace
spring if
any dama-
ges or
deforma-
tions are
found
w 13. 0i l . Okgm
i l . 0 kgm
2. 3 k 0. 2 kgm 13. 0 i 1. 0
Secti on J - J
m 7. 0 * 1. 0 kgm
Secti on L - L
7. 0 i 1. 0 kgm
i m 2. 3 + 0. 2 kgm
i
kgm
Secti on K - K
205FO5789
Unit: mm
No. Check item
1
2
-
3
4
-
5
Spool return spring
Spool return spring 50.8 x 29.5 1 50.0 1 7.6 kg 1 - 6.1 kg
Spool return spring 414x29.51 40.0 1 17.1kg / - 1 13.7kg
Spool return spring
Check valve srping
Criteria Remedy
Free length installed Installed Free Installed
51.0x29.61 50.0 1 8.6kg / - 1 6.9kg
29.8 x 28.1 27.0 17.1 kg - 13.7 kg
46.8 x 26.2 25.0 0.76 kg - 0.61 kg
Replace
spring if
any dama-
ges or
deforma-
tions are
found
PC200,2OOLC-5 MIGHTY (with 2PlA circuit)
w \
w 0.9 O.lkgm
205FO5854
4 3w
Qa Qz
5.5i0.5kgm
5.5+0.5kgm 3.010.5kgm
Section A - A
Section B - B
- 1.Okgm
205F05855
z
z
Unit: mm
1
Main relief valve Free length Installed Installed Free Installed
pilot poppet spring x O.D. length load length load
30.7 x 9.6 26.8 33.1 kg - 26.5 kg
Replace
2 Main relief valve
main valve spring
26.0 x 9.2 20.0 3.2 kg - 2.56 kg spring if
any dama-
ges or
3 Jet sensor relief valve
26.3 x 8.0
26.1 0.39
kg
deforma-
-
pilot poppet spring
0.31
kg tions are
found
main valve spring 23.8 x 7.8 18.1 2.41 kg - 1.93 kg
(Straight-travel valve) 7 1.7 x 20.3 45.0 11.4kg - 9.1 kg
(Arm throttle valve) 37.5 x 28.0 35.5 16.2 kg - 13.0 kg
m
10. 0 / l . Okgm
\
. 3kgm-
m 5. 5 r 0. 5k; , , ,
& 5. 5 0. 5kgr r i
' 1
- 14. 5 ' Z. Okgnl
Section C - C Section D - D
205FO5856
Unit: mm
1
Main relief valve Free length Installed Installed Free Installed
pilot poppet spring x O.D. length load length load
30.7 x 9.6 26.8 33.1 kg - 26.5 kg
Replace
2 Main relief valve
main valve spring
26.0 x 9.2 20.0 3.2 kg 2.56 kg spring if -
any dama-
ges or
pilot poppet spring
26.3 x 8.0 26.1 0.39 kg 0.31 kg deforma- -
tions are
found
4
I
main valve spring
I
23.8 x 7.8 18.1 2.41 kg - 1. 93 kg
I
5
I
Spool return spring
I
37.5 x 28.0 36.5 8.1 kg - 6.5 kg
I
w 20. 0 ' 2. 0kgm
B
20. 0' 2. 0kgw
20. 0. 2. 0kgm
1 \
1
w 20. 0 ~2. 0kgm
Section E - E
m 7. 0 1 l . Okj i wm 13. 0t l . Okgm 3
3--
4
Section G - G
Section H - H
-3
4
Section F - F
w
4
2. 3- 0. 2kgnl 4
m/
13. O?l . Okgm
. Okgm
205FO5857
4o-z-13
Unit: mm
No.
-
3
4
-
5
-
6
Check item
Check valve spring
Check valve spring
Spool return spring
Spool return spring
Spool return spring
Spool return spring
Criteria
5
24.5 x 1 1.6 14.5 0.76 kg - 0.61 kg
31.8 x 7.6 26.5 0.1 kg - 0.08 kg
29.8 x 28.1 27.0 17.1 kg - 13.7 kg
41.4 x 29.5 40.0 17.1 kg - 13.7 kg
51.0x29.6 50.0 8.6 kg - 6.9 kg
32.0x 13.1 32.0
0 kg 31 -
Remedy
Replace
spring if
any dama-
ges or
deforma-
tions are
found
40- G- 14
. O+_l . Okgm 1
1w w
i
ti 2. 3' 0. 2kgm
2. 3+0. 2kgm 13. 01 1 . Okgm
Section J - J
Section K - K
5 1 m 13. 0 f l.Okgrn
\
I
7. 0 1 l.Okgnr
Section L - L
205FO5858
Unit: mm
No.
-
3
4
5
-
Check item Criteria Remedy
I
Standard size
I
Repair limit
Spool return spring
Spool return spring
Spool return spring
Spool return spring
Check valve srping
5 1 .O x 29.6 50.0 8.6 kg - 6.9 kg
50.8 x 29.5 50.0 7.6 kg - 6.1 kg
41.4 x 29.5 40.0 17.1 kg - 13.7 kg
29.8 x 28.1 27.0 17.1 kg - 13.7 kg
46.8 x 26.2 25.0 0.76 kg - 0.61 kg
Replace
spring if
any dama-
ges or
deforma-
tions are
found
TRAVEL SHUTTLE VALVE
m 2.25 + 0.25 kgm
/
w 2.25 + 0.25 kgm
I
m 2.25 k 0.25 kgm
205FO5863
Unit: mm
Replace
spring if
Fry$;$h Installed Installed Free installed
any dama-
length load length load
ges or
deforma-
tions are
53.7 x 13.4 34.0 4.6 kg 3.7 kg
found
SWING MOTOR
No
1
1
-18.0 r+ 1.O kgm
m 17.0 2 2.0 kgm
m 38.0 k5.0 kgm
205FO5196
Check item
Check valve spring
Criteria
Free length Installed Installed Free installed
62.5 x 20.0 35 0.36 kg - 0.29 kg
I
Unit: mm
Remedy
Replace if
any dama-
ges or
deforma-
tions are
found
CENTER SWIVEL JOINT
Unit: mm
Standard size Standard clearance Clearance limit
1 Clearance between
rotor and shaft
Replace
90 0.056 - 0.105 0.1 11
40-23
0
TRAVEL MOTOR
m 1.15 2 0.15 kgm
\
m
4.0 k 0.5 kgm
w
0.9 * 0.1 kgm
6.0 kgm
/
m
2.4 k 0.4 kgm
/
w 28.0 ? 3.0 kgm
4.7 kgm
m 7.5 f 1.0 kgm
w 12.8 f 1.7 kgm
205FO5197
Unit: mm
1 Spool selector spring
Replace if
any dama-
49.8 x 33.0 42.0 43.1 kg - 34.9 kg ges or
deforma-
tions are
2 Check valve spring 5 1.4 x 17.3 30.5 0.2 kg - 0.16 kg found
3 Regulator piston spring 55.0 x 9.0 50.0 lO.Okg - 8.0 kg
PPC VALVE
PC200,2OOLC-5 Serial No: 45001 - 58018
PC220,22OLC-5 Serial No: 35001 - 36613
No.
4
Check item
Pilot spring
Metering spring
Centering spring (For Ps, P4)
Centering spring (For P 1, P 2)
.5 * 1.5 kgm
.5 * 1 .O kgm
1 .O kgm
1.8 -t 0.4 kgm
F 3.5 I 0.5 kgm
205FO5 198
Unit: mm
Criteria
12.6 x 3.85 11.9 0.018 kg - 0.16 kg
31.4x7.4 29.4 1.7kg - 1.4 kg
47.4 x 16.8 36.5 2.3 kg - 1.8 kg
45.2 x 16.8 36.5 3.8 kg - 3.0 kg
Remedy
Replace if
any dama-
ges or
deforma-
tions are
found
40625
PC200,2OOLC-5 Serial No: 58019 an up
11. 5 + 1. 5 kgm
1. 35 i 0. 5 kgm
1. 8 k 0
Sec t i on A - A Sect i on B - B
m 4+ 0. 5 kgm
Section 0 - D
20TF01075
Unit: mm
Section C - C
1 t
t
44.6 x 15.5
26.5 x 8.2
43.2 x 15.5
Installed
length
Installed
load
2.3 kg
1.7 kg
3.8 kg
Free
length
Installed
load
1.8 kg
1.4 kg
3.0 kg
Centering spring
(for P,, P, ports)
1
Replace
spring if
any dama-
3
es or de-
ormations
are found
2 Metering spring
Centering spring
(for P,, P, ports)
FOR TRAVEL
l -
2-
km
D Min. 3 kgm
.8 f 0.4 kgm
205FO5199
Unit: mm
No. Check item
1 Metering spring
2 Centering spring
Criteria Remedy
Free length Installed lnstaled Free Installed Replace if
x O.D. length load length load any dama-
ges or
31.4 x 7.4 29.4 1.7 kg - 1.4 kg
deforma-
tions are
found
47.4 x 16.8 36.5 2.3 kg - 1.8 kg
BOOM HOLDING VALVE
PC200,2OOLC-5 Serial No: 45001 - 53229
PC220,22OLC-5 Serial No: 35001 - 36052
Section A-A
No
-19.0 i l.Okgm SectionB-B
205FO5200
Unit: mm
Check item
Criteria Remedy
Pilot valve spring
Check valve spring
Free length Installed Installed Free Installed Replace if
x O.D. length load length load any dama-
ges or
38.2 x 17.0 36.0 1.1 kg - 0.88 kg
def orma-
tions are
found
26.5 x 1 1.2 25.0 0.48 kg - 0.38 kg
Section B - B
1
-A
Section A - A
m 15.0 3~1.0 kgm
205FO5790
Unit: mm
No.
I
Check item
1 Pilot valve spring
)
I
Criteria
Free length installed installed Free installed
38.2 x 17.0 36.0 1.1 kg - 0.88 kg
26.5 x 1 1.2 25.0 0.48 kg - 0.38 kg
Remedy
Replace if
any dama-
ges or
deforma-
tions are
found
4027-2
i
HYDRAULIC CYLINDER
PC200,2OOLC-5
* The drawing shows boom cylinder
QS3 Boom: 27.5 * 4.0 kgm w Boom: 720 F 72 kgm (Width across flats: 85)
Arm: 38.0 * 5.5 kgm Arm: 1040 * 104 (Width flats: 95) kgm across
Bucket: 27.5 k 4.0 kgm Bucket: 720 * 72 (Width across flats: 85) kgm
No.
1
-
2
-
3
-
Check item
Clearance between
piston rod and
bushing
Clearance between
piston rod support
and bushing
Clearance between
cylinder bottom
support and bushing
205FO5201 A
Criteria
::
Unit: mm g
N
0
Remedy
Cylinder Standard
Tolerance
Standard Clearance
name size
Shaft Hole
clearance limit
Boom 85
-
0.036 +0.222 0.083
-
0.412 Replace
- 0.090 +0.047 0.312
bushing
Arm 95 -0.036 +0.222 0.083
-
- 0.090 +0.047 0.312
0.412
Bucket 80
-
0.030 +0.258 0.073
-
-0.076 +0.048 0.334
0.434
Boom 80
-
0.030 +0.457 0.400
-
- 0.060 +0.370 0.517
1 .o
80
-
Arm 0.030 +0.457 0.400
-
- 0.076 +0.370 0.533
1 .o
Bucket 70
Boom 70
-
0.030
- 0.076
- 0.030
- 0.060
+0.424 0.380
-
+0.350 0.500
1 .o
Replace
pin and
+0.424 0.380 -
+0.350 0.484
1 .o bushing
-
Arm 80 0.030 +0.457 0.400
-
-0.076 +0.370 0.523
1 .o
Bucket 70
-
0.030 +0.424 0.380
-
-0.076 +0.350 0.500
1 .o
PC220 * 22OLC-5
+ The drawing shows boom cylinder
w Boom:
Arm:
Bucket:
27.5 f 4.0 kgm B Boom: 1040 k 104 kgm (Width across flats:
38.0 f 5.5 kgm Arm: 1040 f 104 kgm (Width across flats:
27.5 f 4.0 kgm Bucket: 1040 -t 104 kgm (Width across flats:
205F05202A
Unit: mm
No
1
2
-
3
Clearance between
piston rod and
Clearance between
piston rod support
and bushing
Clearance between
cylinder bottom
support and bushing
Remedy
Replace
bushing
Replace
pin and
bushing
WORK EQUIPMENT
Section A- A
Section B-B
Section C - C
Section D-D
Section G - G
Section E-E
Section F - F
5
\
Section K - K
205F05203A
4oci30
No. Check item
Clearance between bushing and
1 connecting pin of revolving
frame and boom
2 Clearance between bushing and
connecting pin of boom and arm
connecting pin of arm and link
connecting pin of arm and bucket
5
6
7
-
8
connecting pin of link and bucket
connecting pin of link and link
Bucket clearance (a)
Bucket clearance (b) 2.0
Criteria
~
0.5 - 1 .o
Unit: mm
Remedy
Replace
Shim
Idjust
Komatsu America international Company
440 North Fairwav Drive
I 1
Vernon Hills, IL 66061-8112 U.S.A.
Attn: Technical Publications
PROPOSAL FOR MANUAL REVlslON
Fax No. (847) 970-4186
PFMRl 081696
FOR INTERNAL USE ONLY -- No. PMR
2 NAME OF COMPANY:
:
:
S DEPARTMENT:
E
R NAME:
LOCATION:
PHONE NO:
DATE:
MANUAL NAME:
MANUAL NO:
MACHINE MODEL:
S/N IF APPLICABLE:
PAGE NO:
PROBLEM:
Attach photo or sketch.
If more space is needed, use another sheet.
1 FOR INTERNAL USE ONLY
CORRECTIVE ACTION:

Sebda2050508 SM PC220-5

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Sebda2050508 SM PC220-5

Uploaded by

Copyright:

Available Formats

SEBMA2050508

You might also like