SEBM02050508 SIO IMTAINTUA\ IL KOMATSU PC200,200LC-5 PC200,200LC-5. PC220,220LC-5 MACHINE MODEL SERIAL NO. PC200-5 45001 and up PC200-5 MIGHTY 58019 and up PC200LC-5 45001 and up PC200LC-5 MIGHTY 58019 and up PC220-5 35001 and up PC220LC-5 35001 and up * This shop manual may contain attachments and optional equipment that are not available in your area. Please consult your local Komatsu distributor for those items you may require. Materials and specifications are subject to change without notice PC200, 200LC-5, MIGHTY mount the S6D95L engine; C220, 220LC-5 mount the SAGD9EL engine. For details of the engine, see the 95 Series Engine Shop Manual Beer 00-110 20 30 40 CONTENTS STRUCTURE AND FUNCTION .............. * " TESTING AND ADJUSTING .................. 20-1 DISASSEMBLY AND ASSEMBLY ............ 30-1 MAINTENANCE STANDARD................. 40-1 Not to be reproduced in whole or in part without the prior written permission of U, Tokyo, Japan. 020505The affected pages are indicated by the use of the following marks. It is requested that necessary Mark Indication Action required] actions be taken to these pages according to the table below. Page to be newly added Add Sa © | Page to be replaced Replace ()] Page to be deleted Discard Pages having no marks are those previously revised or made additions. eS LIST OF REVISED PAGES Mark Page TCO! | Mark Page TE | Mork Page Timeot | Mark Page Tec! | mark Page Time of oor 8 1 1023 1058 6g ec o2 @ w2 © rom = & | 0 10457 @ | o ter @ s m2 © | © we ro 6 @ | 0 1058 10692 6 * m2 10-94 rox | 0 10459 @ 68s 6 8 eo m2 @ | wa 1027 @ | 0 14510 wee 6 8 eo m2 @ | wer 4 1028 @ | © tas wm 6 © © m3 war 6 2 «4 | 0 tae 6 on 2 04 jews «| wo © wes 6 wore © m5 ewe 8 | wa 4 wa 6 | @ om 8 © 006 10-7 1032 | 1048 é © 1078 8 © 07 8 2 1033 a 7s © we 109 1034 a oes eee 0 6 a * 09 10-10 10:35 | 108 . 07 @ © 10 10-11 1038 | 1st wr © ont tore a7 1052 © 072 © wx © 1019 @ #1038 1053 © 17a © 13 ewe @ 1038 woe we & © 018 wis 8 100 10-56 © oe @ © 005 © 1016 oa @ 1057 © 1079 © 006 07 @ | a 10.58 10-60 o 017 «@ | © 1048 [poole @ 10.59 wer ° ww | wa & | tome wo we ® oo 6G wis @ | tous 1061 wa © 0020 1020 | © s04s1 a 10-62 08 @ © 0021 | 10201 & 102 © | 6 @ | wes © ooze | 10202 10453 «06 a | © 086 00-28 | 10-21 10454 10-67 10-87 -~ om = =8® | we 10855 @ 1068 = @ | © 1088mak page Tm | man rage TES! | mark Page TITEST | wank Page TEESE | rk Page we =@ | + wie @ m9 @ 251 @® | © m0 @ © wae @ rore1 © | © 20 @ 2082 2 wi @ 1002 © 10.1182 wa ® 2083 nie ® © 1083 © torr n2 ® 2056 * 0103 10004 6 1020 23 @ 2055 r108 10s @ roa nw @ 2s @ | © mot @ © 10% @ sor ns © | m7 @ 20105 ® o 188 @ tons @ ne @ 2058 © 20106 @ wo ror ® na ® 2059 20-107 es =©@ | torr © | 6 mm @ 2060 © 2071 @ 2 2 =@ | 10102 © | © wer @ ws @ | 1072 0 ® wis 20282 @ 2082 2108 wo «® 101784 @ 3s @ 2063 @ | 20108 1095 wis = =© | m2 ® 2064 20110 10% 1018 ® ws @ 2085 2041 wr 017 ® 2031 2068 wi @ ws @ 10128 ® ne @ 2067 Le nia @ 972 © 1019 @ nu @ | « me @ 15) © 10973 @ 10130 31 @ | © me @ # ® toe ror ma @ | © m7 8 | © m7 ® 1099 @ to132 | 0 @ |e won = | ®t @ 10981 © ne «= @ |e wR 6 | @ wi & 2 082 @ wv @® | © m3 @ |e wis @ 10100 ® a1 @ nw =@® |e me © | © m4 ® 2 wr @ w2 ® wo D | «mm @ nas @ 2 002 ® 03 ® na ® |e mw nus @ © 10103 @ wa @ 2041 nn @ | © wm ® me) 25 ® 2082 rc a) win D wis @ |e m6 @ ma @ 2079 @ nim ® 10108 @ 7 @ 2048 no @ wi @ 2 0107 @ m8 @ 2048 2001 wim ® 10109 @ 209 2046 2092 ni @ 1010 20 «@ 20.47 2098 20.127 win @ wn ® rar @ 2094 + m1 @ wom ® we @ | © war @ 7095 ni @ 12 ® 2013 @ | «© 24 @ 7096 © 101 © swim @ wi @ | © 2049 ® ns @ 20-1292 D © 1015, mis D |e m1 @ wor @ |e 10 @ ro116 | 21 @ | « 20092 @ 28 8 @ nis @ 107 ® | 20-18 ® 20:50 © 2099 ® 212 | «D 00-2-2 @ 020505020805 Mark Page TIES" | Mark Page TITS OC | Mark Page [umS.°F | Mark Page ITF | Mark Page Time of wie t nie a 202052 | © 20286 235 om a v1 20208) 2027 ama 2 2168 8 20207 | 038 ® 2013337 201052 20-208 sore Ce ee eat) wid 1 201660 20098 poeple ce em 8 20167 nox 8 m0: 4 ma @ 1s S nos 8 20211 20:5 o 02 @ © 20151 @ | © mm @ 2029 30-6 Jo a1 @ 2019521 in 202 +07 (0 2 @ e018 8 wim 20.215 ee wit wm F ws | o 72 8 | ward @ © 2171 8 por wur t 6 8 8B | ae 2 © 21727 ns 6 ¥ |e ome 6 E |e ws maa @ © 201973 20.178 wz & |e wo © | mes © rosa wim m0 > 2010 | was 8 21% 2 2018 a nm b «wn 8 | mas & 20-139 pe 8 nm wt war? uo 8 20180 om 3013 | ae 9 wow 8 20181 poms 8 wu ware o ew 4 now 8 22s 8 wf wan 9 ere 6 20.189 20.226 woe san oie 8 2018 nr t | wort soa 5 ue 8 201882 met we soa 5 © mus 8 p18 8 mt aot sown 5 © m1 6 voir 3 | © 2020 8 2 somes rr 2018 2 wm wa was wes 20169 20282 2 4 4518 20-149 20190 2 nw > wae wae 8 © 20150 4 noi 4 20234 wom 304838 © 20361 20.199 2025 8 wot re) © ms 8 roi 2 2025 8 wo i sms 8 © m2 8 20-195 nm 3 pores was 5 © wise 8 20.1982 nome 8 3028 wa57 Ss 201985 4 201988 2s 7 2 woase 5 20198 1 201993 20208 3090 ome 20187 202008 za wot wart 20.188 za 3 m2 wat ome 20.189 22 8 223% oat wast 201608 20.203 roma wat wso nowt maa 2 | 0 moms 8 at ws 00-2-3mare page Tm®t | stark Peoe Tmect | mark Page TINO! | Mark Page Tue" | mark Page [ausion 2082 nm @ ore @ | 0 moans 3053 90-75 o 30-105 @ 40-21-15 2054 + 06 @ wi = | 0 doze 30-55 (30-77 ® 30-107 @ 40-21-17, 30-56 © 30771 @ 40-22 @ 30-57 0° 30772 € 40-23 & ws una © ore ou 8 ws wre @ |e a2 © 03 | no | @ 2078 oo 3 026 ® aver 20-79 404 027 @ we 3080 os & | © wm @ 20.63 na woe © one © 2004 20a 40.7 - 02 @ wes wa © 20.8 02 oss. ® nar @ “0.9 on © 0852 30602 @ 20-10 som 0853 @ me @ on 64 8 es @ won 3 30655 081 @ on ® 66 30852 @ 02 @ we? ® we | © 4one ee @ we 0 | + om © wes © wee | 4016 306510 2 | O 407 ses @ 0 «@ coe ss12 ns @ 2019 s0613 we @ 20-20 soe 353 @ «71 306515 ne ® |e ome @ 20-6516 ® 30-95 ® 40-213 ® 617 ® 0951 ® ane © 3065-18 & 30-95-2 @ 40215 @ 30-66 ® 30-96 ® 40-21-6 ® ner @ ne @ on7 4 30-68 D 30-98 @ 40-218 ® 30-69 D 30-99 @ 140-21-9) 30-70 o 30-100 @ oo 42110 @ 30-71 ® 30-101 @ oo 42-41 @ 30-72 @ 30-102 @ oo 40-2112 @ wna @ 10 @ | o wu ® 00-2-4 ® 020505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. To prevent injury to workers, the symbols i ond "A" are used to mark safety pre- cautions in this manual. The cautions accompanying these symbols should always be followed carefully any dangerous situation arses or may possibly aise, fst 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. Always wear safety glasses when hitting parts with a hammer. * Always wear safety glasses when grinding parts with a grinder, ete. 3.|f 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 operator's compartment. 5. Keep all tools in good condition and learn the correct way to use them. 6.Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working PREPARATIONS FOR WORK 7.Before adding oil or making any repairs, ark 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 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. 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, 13. Before starting work, remove the leads from the battery. Always remove the lead from the negative (—-) terminal first. 14.When raising heavy components, use a hoist or crane Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from 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- temal 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. 00-4 19. Be sure to assemble all parts again in their original places. Replace any damaged parts with new parts. ‘© When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the 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. 21.When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. 22, When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 23. When measuring hydraulic pressure, check that the measuring tool is correctly 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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. 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 Issued for each engine series Each issued as fone volume to cover all models Engine volume: Electrical volume: | Attachments volume | 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 Item number (10. Structure and Function) Consecutive page number for each item, Example 2 (Engine volume}: 12-410 Unit number (1. Engine) Item number (2. Testing and Adjusting) +— Group No. (4. Fuel system) | Consecutive page No. (Page 10 of Group 4) 3. Additional pages: Additional pages are in- dicated by a hyphen (-) and number after the page number. File as in the example. Example: 10-4 12-203 10-4-1 12-203-1 10-4-2 }~ Added pages —£ 13.293-2 10-6 12-204 00-6 REVISED EDITION MARK ((1 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. Synbot | Tem Remarks Special safety precautions ae A ac ale Rabee eh or Satety Envaapocilsfety precautions : bre neoary when prforting “a the ork becouse tf under internal pressure, ‘Special technical precautions or ‘other precautions for | Caution | preserving standards are necessary when performing the work. ‘Weight of parts or systems. Caution necessary when Weight | selecting hoisting wire, or when working posture is important, ete, 1. [Places that require special Ga | Fighter. | attention for the tightening ‘9 torque during assembly. Places to be coated with | coat 7 | Coat | adhesives and lubricants etc. Places where oll, water or fuel Oil, water | must be added, and the capacity. Places where oll or water must be drained, and quantity to be drained ws | DrainHOISTING INSTRUCTIONS HOISTING INSTRUCTIONS AL 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 1) Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below: Wire ropes (Standard “2” or “S" twist ropes without galvanizing) Rope diameter (mm) | Aliowable load (tons) 10 | 10 12 14 125 16 14 | 22 16 28 18 | 36 20 4a 224 56 30 10.0 40 18.0 50 280 60 400 st 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 8444 3)Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound on to the load. BA. Singing 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° 9 Load capacity Liting angle : 00-7STANDARD TIGHTENING TORQUE 1. STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS STANDARD TIGHTENING TORQUE The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in sections of "Disassembly and Assembly”. Thread diameter | —_ Wath oe of bolt across flat (mm) (mm) Ee — kgm Nm 6 10 1,35+0.15 13.2414 8 13 3.2+03 31.4429 10 7 6.7407 65.7468 12 19 11.5+1.0 112498 14 22 18.0+20 177419 16 24 28.543 27929 18 27 3924 383439 20 30 56+6 549-458 22 32 76+8 745+78 24 36 94.510 927+98 27 ai 135+15 1320+140 30 46 17520 1720190 33 50 225425 2210+240 36 55 280+30 2750+290 39 60 335435 3280+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. * Nm (newton meter): 1Nm + 0.1 kgm 2. TIGHTENING TORQUE OF SPLIT FLANGE BOLTS Use these torques for split flange bolts. Thread diameter Width Tightening torque Of bolt across flats (mm) (mm) kgm Nm 10 14 67+07 65.7+68 12 7 11541 112298 16 22 28543 279+29 00-8STANDARD TIGHTENING TORQUE feces Use these torques for nut part of flared, of ae Thread diameter | Width across flats Tightening torque of nut part a (mm) (oom) kgm Nm 4 19 | 24549 18 24 492196 22 27 7854196 24 32 137.2294 30 36 176.5+29.4 33 4a 196.149 36 46 245.2449 42 55 294.2449 COATING MATERIALS The recommended coating materials prescribed in Komatsu Shop Manuals are listed below. Nomenclature Komatsu code ‘Applications LTta Used to apply rubber pads, rubber gaskets, and cork plugs. Adhesives | Provides an airight, elestrcaly insulating seal ‘Used to coat plugs (plate shaped, bowl shaped) and holes, and a LG Used with gaskets and packings to increase sealing effect. ra eat-resistant gasket for precombustion chambers ee ee and exheust piping - _ ies Used by itself on mounting surfaces on the final drive and transmission cases. (Thickness after tightening: 0.07 — 0.08 mm) “Used by sell 10 seal grease Titings, tapered screw fittings and tapered 16-5 screw fittings in hydraulic circuits of less than 50 mm in diameter. LG-6 | Siicontese ype used in combination wth LG-1 ond LG Taso ajar cag We Won LOS, an war — G7 to peel off. ‘Antifriction compound lied to bearings and taper shafts to facilitate press-fitting and to abc cag ee | Appied to bearings and tape shat 1 ects pres-iting and molybdenum disulfide) eee isting. Grease Soe ee (Lithium grease) ae prevention and facilitation of assembling work. Vaseline = Used for protecting batery electrode terminels Yom corosion = “LT-2 is also called LOCTITE in the shop manuals, 00-9ELECTRIC WIRE CODE aH LH In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. ELECTRIC WIRE CODE 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 Strands | tml ‘re os | 032 088 2a 12 | Storing, thing, signal et. 2 2 | os 208 34 20 | Uahting, sgnalete 5 | om 328 a6 37__| Charging nd signal 75 3 a6 7336 70 59 | Staring (iow pia) 20 35 080 an |e 13s] Staring 60 127 080 wee | 18 178 | Staring 100 27 oa | 08 176 230 | Stoning CLASSIFICATION BY COLOR AND CODE ane lassi Charging | Ground Starting Lighting Instrument Signal Other on | eoae] Ww 3 3 a v t 7 mary | Color White Black ~ Black Red Yellow: Green Blue Goss] wr = ew aw F ow ow ; Coir] Whtet Red | — | Brack ewnte | Rede white | Yalow & fed | Gront Bh Whe Cove] wa = ay 7 8 oF aR 2 | a:[ Color] wawearBick | = [Baska Velow] ode aick |Velows Back | Geena Red | Aes Red wary Code WL = BR RY YG GY wy a [Coor[ wate save | — | Bockanea | Rea& vetiow | Yalow & Green | Green & Yellow | Blue &Yelow Sous] we = s 7 vr or oy . [Teeter] white &Green | _— E edt Green | Velow & Be [iGreen & sci | (Ble & Bick) cous = = 7 Ww © ics Ge = = Fed Bice _|Yolow& who] (Gren Bo) 00-10CONVERSION TABLE CONVERSION TABLE Method of using the Conversion Table The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below. Example + Method of using the Conversion Table to convert from millimeters to inches 1. Convert 56 mm into inches. (1) Locate the number 50 in the vertical column at the left side, take this as @), then draw a horizontal line from @), (2) Locate the number 5 in the row across the top, take this as @), then draw a perpendicular line down from @). (3) Take the point where the two lines cross as ©. This point ©) gives the value when converting from millimeters to inches. Therefore, 85 mm = 2.165 inches. 2. Convert 550 mm into inches (1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the left) to convert it to 5 mm (2) Carry out the came procedure as above to convert 56 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 11mm = 0.03937 in ° 1 2 3 sf sje | 7 8 8 0197 ] 0236 | 0276 | oa8 | 0350 20 | 0787 a) tao |e 0.984 *| 1024 | 0.663 | 0709 | 0748 1063 | 1.102 | 1.142 30 | tar | 1.220 | 1.260 1.299 | 1.339 | 1.378!) 1.417 | 1.457 | 1496 | 1536 49 | 1575 | 1.614 | 1654 | 1.693 ol 2oe7 | 2126 |ra765"] 2.208 2.490" | 2520" | 2559 | 2598 2e7 | 2913 | 2953 | 2892 | 3032 | 3071 | 3110 20 | 3180 | 3169 | 3228 | 326 | 3907 | 3246 | 336 | 3425 | 3465 | asoa 90 | 3549 | 3589 | 3622 | 3681 | 3701 | 3740 | 3720 | sara | anse | 398 224a | 2.263 | 2923 | 2638 | 2677 | 2.717 1732 eoglts 1890 | 1929 00-11CONVERSION TABLE Millimeters to Inches Timm 03937 in O 4) 9 2 3 aj s | 6 7 8 9 | | | | | | 0 030 | 0070 | ore | oxs7 | oor | 0236 | 0.276 | oats | ose 10 | ose | 0433 | 0472 | osi2 | asst | 0591 | 0690 | 0669 | 0709 | 0.748 20 0.787 0.827 | 0.866 | 0906 | 0.945 | 0.984 1.024 1.063 1.102 1.142 so | ier 1220 | 1260 | 1.209 | 1339 | 1378 | 147, 1457 | 1496 | 1.836 co | sie) ner | vse | 1003 | s9se 1972 | sett | sao | 00 1920 a 50 1969 | 2008 | 2047 | 2087 | 2126 | 2.165 | 2205 | 2.244 | 2.283 | 2.923 7 2756 | 2795 | 2835 | 2974 | 2913 | 2953 | 2992 | 3032 | 3071 | 3.10 eo | aso | 3189 3208 | 3268 | 3307 | 3246 3.086 9425 | anes 350d co | sea) 3583 | asze | a601 | a7or 2740 7a. asta | 3058 3008 | ij Kilogram to Pound 1g = 2.2086 1 t + t 220} 441) 661) 882 1323 | 1543 | 17.64! 1986 20 | eon | 4520 | aes0 | sor | stor | sao | o7a2| sasa | oi72 exee wo | e614) oo | yoss | 7275 | 7896 | 77.16) 7937 | 8157 | 378 85.98 j | | so | 110.23 | 112.44 | 114.64 | 11685 | 11905 | 121.25 | 12348 | 12566 | 127.87 | 13007 0 | ts228 | 13448 | 13669 | 138.09 | 141.10 142.30 | 14551 | 147.71 149.91 | 152.12 80 176.37 | 17857 | 190.78 | 182.98 | 185.19 | 187.39 | 189.60 | 191.80 | 194.01 | 196.21 9 | 19942 | 0062 | 20209 | 20503 | 20724 | 2004 | avt.6t | 21285 (21605 21828 ' | | | 00-12CONVERSION TABLE Liter to U.S. Gallon 2682 US. Gal L ° 1 2 3 | 4 L | 6 7 | 8 9 ; 1 1 | ozs | 0526) 079) 1057| 1321) ssa5| re | ase) 2976 10 262 | 2906| 3.170| 434 | 2609) 3969) 4.227) a41| 4755 | 5019 20 5283} 5543) 5812! 6076| 6340| 6604! oa60! 7133| 7.397) 7.661 v0} 7925| a.180| sas) e718 8982) 9.246) 9510) 9774 10.009 | 10.200 40 10.567 | 10.831 , 11.095 Ucee ia ed 11.888 | 12.152} 12.416 | 12.680 | 12.944 \ \ 80 13.200 | 13473 | 13737 | 14001 | 14.205 | 14529 | 14.795 | 15058 15.922 | 18.506 60 15.980 | 16.115 | 16379 | 16.643, 18907 | 17.171 17.495) 17,700 17.998 | 18228 70 48492 | 18756 | 19020 | 19.285 | 19.549 | 19813 | 20077 | 20.341 | 20.605 | 20870 20 21.134 | 21.998 | 21.682 | 21926 22.190 | 22.455 22.719 22.983. 23.287 | 23511 90 a7 | 24040 | zeae | aeson seam asc | zeae1 25625 | 25.00 | 20182 1 i: 1 Liter to U.K. Gallon 0.21997 UK. Gal - | r T o | 4 2 3 4 5 6 7 8 ° 4 1 | T e220 | oso) oso] ose | 1.100) 1520] 1540| 1700/1000 10 2.200! 2420] 2640| 2860) 3080; 3300} 3520] 3740 3950] 4.179 20 4399) 4610 | | 5059 | 5279/ 5499 s719| 5930) 6159/6379 » ese | cei) 7030| 7250| 7.470] 7960) 7919) 2130) 350| as70 40 8799 a019| 9.239] 9459| 9679) 9.899] 10.119 | 10330] 10.5859 | 10.778 50 10.998 | 11.281 | 11.438 viasa | snar0 12.098 | 12.318 | 12.528 | 12.758 | 12978 60 13198 13.418 | 13638 | 13858 | 14078 | 14298 | 14518 | 14.738 | 14.958) 16.178, 70 | 16398 | 15.618 | 15836 16058 | 16.278 | 16496 | 16718 | 16938 | 17.188 | 17378 80 17.598 | 17.818 | 18037 | 18257 18.477 | 18697 | 18.917) 19.197 | 19.957) 19577 0 19.797 | 20017 | 20.237 | 20487 | 20.677 | 20.897 | 24.117 | 21.397 | 21.887) 21.777 i 00-13CONVERSION TABLE kgm to ft.lb 1 kg.m = 7.233 ftlb, T T T Bee eee eee ee eee ee lr fede 1 i ) v2] ws] 22 ws v2 | aa] soe | sro] oss 10 723 | 736} 968| 940| 1019 | 108s | 1157 | 1230 | 1302 | 197.4 20 uaz | 1519 | 1501 | 1664 | 1736 | 1808 | 1901 | 1953 | 2025 | 2098 30 2170 | 2282 | 2315 | 2387 | 2459 | 2532 | 2604 | 2676 | 2749 | 2821 | | | 50 3617 | 3689 | 9761 | 3834 3906 | 3978 | 4051 | 4123 | 4195 | 4268 © ago | aar2 | aaa | 45.7 | 4029 | 702) 774 | 4046 | 4019 | e991 70 5063 | 8135 | 5208 5280 | 5352 | 5475 | S497 | S559 | so42 | S714 w | sms seo | sans | cova | ars [ccs | mie ema fue eae % e510 658.2 | 6654 | 6727 | 6799 | 687.1 | Goa | 7016 | 7088 | 7161 | | H I 110 795.6 | 8029 | 810.1 | 817.3 926.6 | 8318 | 8390 8453 | 8535 | 8607 120 868.0 | 875.2 | 8824 889.7 i 896.9 | 904.1 oa 918.6 | 925.8 j 933.1 1x0 | 9403 | 9475 | 9548 | 9620! 9002 9768 | 983.7 o909 | 9982 | 10054 140 10126 | 10199 | 1027.1 | 10243 | 10415 | 10488 | 19500 1063.2 | 10705 | 1077.7 | feree (esa oeeeal eatitnesel inraea| evil meet iareeed ra |= 160 | 11873 | 688 | 11717 | 11790 | 11862 | 11934 1200.7 | 12079 1215.1 | 1222.8 qo | 1329.6 12968 | 1204.1 | 1251.3 | 12585 | 1265.8 , 12730 | 1280.1 | 12875 | 12987 reo | 19019 | 1309.2 | 13164 | 19236 | 13909 | 1938.1 | 1345.3 | 1952.6 | 19598 | 1367.0 190 | 13743. 19615 | 13887 | 1396.0 | 14032 | 1410.4 | wre 14249 | 1432.1 | 1439.4 | I 00-14CONVERSION TABLE kg/cm? to tb/in? 1 kg/em? = 14.2293 Ib/in? T , of+]f2])a]+]ele]>tele i | | 142) 24| 427) s69| 711] 953) 996] 1138 | 1280 20 284.5 | 298.7 | 3129 | 327.1 3414 | 355.6 | 369.8 | 384.0 | 398.3 | 4125, go | 427 | ato | ass | 4604 | 40368 | 4978 | 5120 | 5263 | s40s | 5547 «o | sea | sea2| sora | oie | case | 540.1 | 0543 | 6585 6827 | 6969 50 711.2 | 7254 | 7396 | 753.8 | 768.1 782.3 796.5 | 810.7 825.0 | 839.2 co | asa4 | e676 acre aac | 9103 | 9245 | 0987 | 9530 | 9672 | 0614 70 | g956 | 1010 1024 1038 | 1058 | 1067 | 1081 | 1098 | t109 | 1128 80 vga | 1152, 166 tet | 1195 | 1209 1223 | 1237 | 1252 | 1266 90 1280 | 1294 | 1309 1323. | 1337 | 1351 | 1368 | 1380 | 1394 | 1408. | | | 10 | 865 | 1579 1583 1607 1621 | 1698 | 1650 | 1664 | r67e | 1009 yo favor 721795749 | x70 | 1778792 | 1808 | aB21 | 1895 130 1849 2863 1877 1892 | 1906 1920 | 1934 | 1949 1963 1977 rao | 1991 | 2005 2020 2004 | 2088 | 2062 | 2077 | 2001 | 2105 | 2119 | | 1502194 214821622176 | 2190 2205 2219 | 2233 | 2047 | 2062 vo |aa7e 2200 zt are [ass zor asst |za75 | 289 2008 170 2418 | 2432 2448-2460 | 2475 | 2489 2503 | 2518 | 2532 | 2546 veo | 2560 | 2574 2589-2603 | 2017 | 2631 2616 | 2660 | 2674 2688 yo | 27022717 ara 274827582773 -2788 | 2802 | 2816 2830 200 | 2085 2659 28737072001 -2916 2090-2044 | 20582873 210 | 2887 gor a015 3000 | soe 208 3072 ste | 31013118 220.3129) 3143 3158 -3172-| 9186 © 320031283229 3433087 200 fas | seus sa00 ase aes aes sae? sat | as05 amo wo |e [uz | tse | 0 owes jar | aux | soa | 3428 00-15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 itis desired to convert fram 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 itis desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right. : a z 7 + | <1 7 0.4 40 40.0 | 117 " 518 18 46 1148 22 a | ne -289 -20 4.0 94 15 59.0 10.0 50, 122.0 24 | 85 | 1850 278 | -18 4 -23 | 7 626 ua | 52 1286 306 87 | 1886 25.0 13 86 5.6 2 | 16 139 | 57 134.6 Ba 92 197.6 ma | 12 | wo | 50 7 7 | 734 | 104 [= | vs ssa | 90 | to04 23.9 1 122 44 | a | 52 15.0 59 138.2 44 4 201.2 172 | 1 338 22 36 96.8 27 ” 159.8 4 130 266.0 -1 | 3 34 33 38 100.4 | 139 | 7 448 5B 42 107.6 13350 8 464 61 43 109.4 00-16020805, WEIGHT TABLE A This weight table is a guide for use when transporting or handling components. PC200, 200LC-5 Unit: kg Machine Model PC200-5 PC2001LC-5 Serial Numbers 45001 and up 45001 and up Engine assembly 647 647 © Engine 432 432 © Damper 20 20 © Hydraulic pump 195 195 Radiator and oil cooler assembly 2 2 Hydraulic tank assembly (without hydraulic cil) 194 194 Fuel tank (without fuel) 98 | 98 Revolving frame 1,555, 1,555 Operator's cab 238 | 238 ee po Operator's seat 317 317 | ——+ Counterweight 3,300 | 3,300 Swing machinery 258 258 Control vaive assembly im im Swing motor assembly 50 50 Travel motor assembly 137x2 | 137x2 Center swivel joint 43 43 Track frame assembly 4391 4,604 fe Track frame 2,362 2,390 Swing circle assembly 270 270 Idler 1402 140x2 @ Idler cushion 135 x2 135 x2 © Carrier roller 2x4 21x4 Track roller 37x14 37x18 © Final drive 322x2 3222 00-17 aUnit: kg Machine Model PC200-5 PC200LC-5 Serial Numbers 45001 and up 45001 and up Track shoe assembly © Triple-grouser shoe (500 mm) 2,360 - * Triple-grouser shoe (600 mm) 2,620 2,850 © Triple-grouser shoe (700 mm) 2,870 3,120 © Triple-grouser shoe (800 mm) 3,130 3,400 © Triple-grouser shoe (900 mm) 3,380 3,680 © Swamp shoe (860 mm) 3,280 - © Flat shoe (610 mm) 2,900 - Boom assembly 1,362 1,362 ‘Arm assembly 628 628 Bucket assembly 646 646 Boom cylinder assembly 187 x2 1872 ‘Arm cylinder assembly 251 251 Bucket cylinder assembly 153 153 Link (large) assembly 80 80 Link (small) assembly 222 22x2 Boom pin 43+ 10x2 43 +10x2 +25 +10 +20 +25 +10 +20 Arm pin 10x2 10x2 Bucket pin 20x2 | 20x2 Link pin 18x2 18x2 00-18 @ 020505,020605, PC200, 200LC-5 MIGHTY Unit: kg Machine Model PC200-5 MIGHTY PC200LC-5 MIGHTY Serial Numbers 58019 and up 58019 and up Engine assembly 647 647 © Engine 432 432 * Damper 20 20 * Hydraulic pump 195 195 Radiator and oil cooler assembly 105 105 Hydraulic tank assembly (without hydraulic oi!) at ™ Fuel tank (without fuel) 98 98 Revolving frame 1,923 1,923, Operator's cab 238 238 Operator's seat 37 317 Counterweight 4,300 4,300 ‘Swing machinery 258 258 Control vaive assembly Ta in Swing motor assembly 50 50 Travel motor assembly 137 x2 137 x2 Center swivel joint 43 43 Track frame assembly 4,391 4,604 © Track frame 2,362 2,390 * Swing circle assembly 270 270 * Idler 140 x2 140 x2 Idler cushion 135 x2 135 x2 * Carrier roller rx 2x4 # Track roller 37x14 37x18 * Final drive 322x2 3222Unit: kg Machine Model PC200-5 MIGHTY | PC200LC-5 MIGHTY Serial Numbers 58019 and up 58019 and up Track shoe assembly * Triple-grouser shoe (500 mm) 2,360 - * Triple-grouser shoe (600 mm) 2,620 2,850 ‘* Rubber shoe (600 mm) 2,940 | - Boom assembly 1,362 1,362 ‘Arm assembly 875 | 375 Bucket assembly 710 710 Boom cylinder assembly 187x2 | 187 x2 Arm cylinder assembly 251 251 Bucket cylinder assembly 182 182 Link (large) assembly 80 80 Link (small) assembly 30x20 30%2 Boom pin - 43 +102 43+ 10x2 + 25+ 10+ 20 +25 +10 + 2 ‘Arm pin 10x2 10x2 Bucket pin 20x2 20x2 Link pin 18x2 18x2 00-20 @ 020505020505 C220, 220LC-5 Unit: kg Machine Model PC220-5 PC2201C-5 Serial Numbers 35001 and up 35001 and up Engine ass'y 647 | 647 © Engine 432 432 © Damper 20 20 © Hydraulic pump 195 195 Radiator and oil cooler assembly 101 101 Hydraulic tank assembly (without hydraulic oil) ned te Fuel tank assembly (without fuel) 98 98 Revolving frame 1,840 | 1,840 Operator's cab 238 238 Operator's seat 317 | 37 Counterweight 4,300 4,300 ‘Swing machinery 258 | 258 Control valve assembly im im ‘Swing motor assembly 50 50 Travel motor assembly 1372 137x2 Center swivel joint 43 43 Track frame assembly 4,920 5,565 © Track frame 2,824 3.275 © Swing circle 270 270 © Idler 140x2 140x2 Idler cushion 135 x2 135x2 @ Carrier roller 2x4 2x4 @ Track roller 37x16 37x20 Final drive 322x2 322x2 00-21 %Unit: kg Machine Model Serial Numbers PC220-5 PC220LC-5 35001 and up 36001 and up Track shoe assembly * Triple-grouser shoe (500 mm) ‘* Triple-grouser shoe (600 mm) * Triple-grouser shoe (700 mm) *_Triple-grouser shoe (800 mm) 2,460 - 2,730 2,960 3,000 3,250 3,260 3,540 Boom assembly 1,550 1,550 ne ne ‘Arm assembly Bucket assembly - 774 714 Boom cylinder assembly 214x2 nax2 ‘Arm cylinder assembly 297 297 Bucket cylinder assembly 182 182 Link (large) assembly 80 80 22x2 22x2 Link (small) assembly Boom pin S14+10x2 | 81+ 102 +30+10+32 | +30+10+32 ‘Arm pin 10x2 \ 10x2 Bucket pin [ [x2 | axa Link pin 18x2 18x2 00-22 ® 020508020505, LIST OF LUBRICANT AND WATER C200, 200LC-5 Serial No: 45001 - 58018 C220, 220LC-5 Serial No: 35001 - 36613 (1) 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 suiphur content | Change interval of oitin engine oil pan 0.5 10 1.0% 1/2 of regular interval ‘Above 1.0% 1/4 of regular interval ASTM: American Society of Testing and Material SAE: Society of Automotive Engineers KIND OF ‘AMBIENT TEMPERATURE CAPACITY () RESERVOIR KIND ¢ “ 50 68 (a6TF aM So $8 SE | Specita | Ren SAE SO Engine oil pe wes | 178 co SAE 10W35 E ST SAE Tow-ao ‘Swing machinery case| 13 10 Final drive case {each)| Engine oi ‘SAE 30. 76 76 Damper cose 10 = z "Sat Tow | Hydraulic system 230 170 + - | Carrer roller (1 piece) I | 0.19 -0.21]0.19 0.21 Trackroller (1 piece) | Gearoit «= [EET wT 0.23 ~0.25|o.23 — 0.25 Idler (1 piece) r 0.07 - 0.08|0.07 — 0.08 5 +— + Fuel tank Diesel fue! — l si | ‘ASTM D975 No.2 Cooling system Water ‘Add antifreeze 197 ‘» ASTM D975 No.1 NoTE: (2) When starting the engine in an atmospheric temperature of lower than 0°C, be sure to use engine oil of SAETOW, SAE10W-30 and SAE15W-40 even though an atmospheric temperature goes up to 10°C 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 ic 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. 00-23 aC200, 200LC-5 Serial No: 58019 and up C200, 220LC-5 MIGHTY C220, 220L.C-5 Serial No: 36614 and up nD Or ‘AMBIENT TEMPERATURE CAPACITY( ©) RESERVOIR erUIA Fa GensBe teen ¥( 10 0 10 20 a0" Specitied | Refit [ ET TSA wo T Engine oil pan 195 185 SAE z Te SAE 10W30 se Ee SAE IO Swing machinory case| i 10 93 Final drive case (each)| Engine oi Et oa | 7s 76 Damper case T 40 * an sar we : SAE OWS =] 2 | 1 SE sa a Carir caller (1 piece Ti Track roller (¥ piece) | Gear oil (EEE ET OTSAE aE later (1 piece) Hydraulic system r 0.19 -0.21/0.19- 0.21 0.23 — 0.25|0.23 0.25 T 0.07 — 0,080.07 ~ 0.08 Fuel tank Diesel fuel a0 TTASTM D975 No. z Cooling system Water Aad antifreeze | 0) | 1: PC200, 200LC- ene (J: PC200, 200L¢-5 MIGHTY NOTE: (1) When fuel sulphur content is less than 0.5% (2) When starting the engine in an atmospheric change oil in the oil pan every periodic main- temperature of lower than O°C, be sure to tenance hours described in this manual use engine oil of SAETOW, SAE10W-30 and Change oil according to the following table if SAE15W-40 even though an atmospheric fuel sulphur content is above 0.5%. temperature goes up to 10°C more or less in the day time. (3) Use API classification CD as engine oil and if Fuel sulphur content | henge intervet of oitin API classification CC, reduce the engine oil engine oil pan change interval to half. 05 to 1.0% 1/2 of regular interval Above 1.0% 1/4 of regular interval 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. 00-24 02050510 STRUCTURE AND FUNCTION 020505 Engine related parts and engine mount ....... 10-2 Radiator, oil cooler and after-cooler ..... 10- 3 Fuel tank and piping .... 10-4 Power train 10- 42 Final drive ... 10-5 ‘Swing circle .. 10-7 ‘Swing machinery ....... soveeseee 10° 8 Track frame and recoil spring ... +109 Idler . 10-10 Track roller, carrier roller 1011 Track shoe . + 10-12 Hydraulic piping .. . = 10-15 Hydraulic circuit diagram - 10-16 Hydraulic tank .. 10-20 OLSS (Open center Load Sensing System) 10-204 Hydraulic pump = 10-21 Control valve = 10-40 ‘Swing motor 10-50 Center swivel joint .........-seccecceeeees 10-54 Travel motor 10-56 Valve control = 10-65 PPC valve 10-66 ‘Accumulator . 10-72 Safety lock valve . ceeeseeeseees 10°73 Solenoid valve assembly ..... 10-74 Shuttle valve 10-77-84 Boom holding valve 10-78 Hydraulic cylinder ......... 10-82 Electrical wiring diagram oo 10-84 Electrical circuit diagram 10-86 Engine control system ........+.se-se-++ 1089-6 Governor motor linkage 10-90 PEMC system 10-98 EMACC . 10-125 10-1ENGINE RELATED PARTS AND ENGINE MOUNT 405 6 1 2 " pe ie ‘ Section B-B i Section C-C Section D-D Section E-E 205F08005, 1. Drive plate 7. Damper assembly Outline 2. Torsion spring 8. Air cleaner © The damper assembly is a wet type. 3. Stopper pin 9. Muffler Oil capacity: 1.80 £ 4. Friction plate « 10. Intake connector 5. Cone spring 11. Front engine mount 6. Friction washer 12. Rear engine mount 10-2 020505020505 RADIATOR OIL COOLER AND AFTER-COOLER PC200, 200LC-5 * The after-cooler attached only PC220, 220LC-5 PC220, 220LC-5 z> B— we View Z 205F05008 1. Fan shroud 8. After -cooler SPECIFICATIONS 2. Fan 9. Oil cooler inlet hose Radiator 3.Radistor outlet hose _—_10. Oil cooler outlet hose C2005 Serial No: 45001 — 61419 4. Radiator inlet hose 11.Net PC220-5 Serial No: 35001 — 35928 8. Radiator 12. After-cooler inlet cG2 6. Radiator cap 13. After-cooler outlet PC 200-5 Serial No: 51420 and up 7. Oil cooler 14. Sub-tank PC220-5 Serial No: 35929 and up CWX-4 Oil cooler: SF-2 After-cooler: 6 rows 10-3C200, 200LC-5 MIGHTY View Z 2osroseos 1. Fan shroud 7. Oil cooler SPECIFICATIONS 2. Fan 8. Oil cooler inlet hose Radiator: CWX-4 3. Radiator outlet hose 8. Oil cooler outlet hose Oil cooler: SF-3 4, Radiator inlet hose 10. Net 8. Radiator 11, Sub-tank 6. Radiator cap 10-3-1 © 020505FUEL TANK AND PIPING Section A—A EN 208F05007 Drain valve Fuel tank . Filler cap (with lock device) Sight gauge . Fuel level sensor gReNe 10-4 020505020505 FINAL DRIVE PC200, 200LC-5 Serial No: 45001 - 58018 PC220, 220LC-5 Serial No: 35001 - 36613 1h 8 1 it 1. Oil level plug 2.Drain plug 3.No. 1 sun gear (18 teeth) 4. No. 2 sun gear (12 teeth) 5. No. 2 planetary carrier 6. Cover 7.No. 1 planetary carrier 8 Sprocket 9. Floating seal 10. Travel motor 11. Hub 12.No.1 planet gear (31 teeth) 13. Ring gear (81 teeth) 14. No. 2 planet gear (34 teeth) 208F05009 SPECIFICATIONS Reduction ratio: 81 +12) /81 +18), , = gta title= —41.625 10 10-5 @PC200, 200LC-5 Serial No: 58019 and up C200, 200LC-5 MIGHTY C220, 220LC-5 Serial No: 36614 and up a 1.Oillevel plug 2. Drain plug 3.No. 1 sun gear (18 teeth) 4. No. 2 sun gear (12 teeth) 5.No. 2 planetary carrier 6.Cover 7.No. 1 planetary carrier 8 Sprocket 9 Floating seal 10. Travel motor 11. Hub 12.No.1 planet gear (31 teeth) 13. Ring gear (81 teeth} 14. No. 2 planet gear (34 teeth) SPECIFICATIONS Reduction ratio: 81 +12) /81 +18), , _ EEE Eas « 41.625 10 -205F 05806 020505,020505 SWING CIRCLE wpe Section B-B 2 Pa 3 Section A~A Li 208F05010 ‘Swing circle outer race SPECIFICATIONS Ball bearing Reduction ratio: 110 = 7.333 ‘Swing circle inner race (110 teeth) Grease volume: 212 (G2-LI) Inner race soft zone "S” Outer race soft zone “S' 10-7SWING MACHINERY Section A—A 1. Swing pinion (15 teeth) 2.Cover 3.Cage 4,Planetary carrier 5. Ring gear (63 teeth) 6. Bearing holder 7. Drive gear (15 teeth) 8. Swing motor 9. Bearing holder 10. Breather 11. Oil level gauge 12. Cover 18. Driven gear (76 teeth) 14, Planetary gear (24 teeth) 15. Sun gear (15 teeth) 16. Drain plug SPECIFICATIONS Reduction rato: 72 x(@2 18) = 26.347 Section C—C 208F05011 020805020505 TRACK FRAME SON SOM ANS Section AA Idler Track frame Carrier roller Final drive Track roller Track Center guard Recoil spring Front guard AND RECOIL SPRING 208F05012 Depending on the model, the dimensions and number of track rollers is different, but the basic structure is the same. (The diagram shows PC200} Number of track rollers PC200: 7 (each side) PC200LC: 9 (each side) PC220: 8 (each side) PC220LC: 10 (each side} 10-9IDLER 1. Lubricating plug 2. Support 3. Idler 4. Floating seal 5. Idler shaft 6. Bushing 10-10 205F05013 020505020505, TRACK ROLLER Lubricating plug Collar Floating seal Track roller Bushing Shaft Onsen 2osF2852 Shaft Collar Floating seal Cartier roller Ring Cover Lubricating plug NOOSeNa 208F06016 10-11TRACK SHOE 1. Link 2.Shoe 3. Regular pin 4. Reguler bushing 5. Regular dust seal 6. Master bushing 7. Master dust seal 8. Master pin 9. Shoe nut 10. Shoe bolt 10-12 208F05015 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 PC200LC 700 mm triple-shoe Link pitch: 190 mm Number of shoe: 98 PC220LC 700mm triple-shoe Link pitch: 190 mm Number of shoe: 102 020505020505 SELECTION OF TRACK SHOE ® Select the most suitable track shoe from the following table. C200 PC200LC [__PC200 MIGHTY PC200LC MIGHTY : Cate- Cate- | Cate- Cate- Speciation | ory _| Specification | Cory | Specification | CO | Specitcation | Cate 500 mm A 600 mm A s00mm | A 500 mm A triple shoe triple shoe triple shoe triple shoe 600 mm a 7oomm |p 600 mm a 600 mm 5 triple shoe triple shoe triple shoe triple shoe 700 mm iF 800 mm 00mm |g _ Z triple shoe triple shoe “rubber shoe 800 mm a 900 mm E - - = triple shoe triple shoe |S 900 mm e 860 mm a 7 7 = triple shoe swamp shoe | ‘860 mm ¢ _ = | : i _ swamp shoe : 610 mm i - = _ _ flat shoe ° _ 600 mm 7 _ - _ _ rubber shoe? PC220 PC220LC Cate- | Cate- Specification | C36" | Specification | C2te 500 mm 600 mm tripe shoe | * | tipleshoe | ® _ 600 mm 700 mm triple shoe | 4 | tipleshoe | 8 700 mm 5 800 mm e triple shoe triple shoe 800 mm a - triple shoe 610 mm _ a flat shoe a 600 mm rubber shoe 10-13, a© Category Cate 7 ui Precautions when usi gory | Ise | recautions when using | Rocky ground, Travel in Lo when traveling on rough ground with obstacles | normalriversoil_ | "such as large boulders and fallen trees. | | e Cannot be used on rough ground where there are large Normatsoi, | _ Sbstacles such as boulders and fallen trees | Normelscil, | Travelin Hi speed oniy on flat ground, and when itis impossible to avoid traveling over obstacles, lower the travel speed to approx. half of Lo. speed. oe @ Use only for ground where “A” and “B” sink and are impossible to use. ¢ Cannot be used on rough ground where there are large obstacles such as boulders and fallen trees. Extremely short | | CF ae ng) #Tavelin Hi speed ony on fet ground, and when | itis impossible to avoid traveling over | obstacles, lower the travel speed to approx. half of Lo speed, D_| Pavedsurface | 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 020805 of the links, breakage of the pins, loosening of the shoe bolts, or other problems.020508 HYDRAULIC PIPING 1. Bucket cylinder 2. Arm cylinder 3.Boom cylinder 4. Swing motor 5.RH. travel motor 6.Control vaive 7.Oil cooler 8. Arm, swing shuttle valve 9.Boom, bucket, travel shuttle valve 10. Hydraulic pump 11. Hydraulic tank 12, Accumulator 13. LH. travel motor 14, Hydraulic filter 18. Solenoid valve assembly 16. Solenoid valve assembly 17.LH. PPC valve 18, Safety lock valve | 19. Travel PPC valve | 20. Boom holding valve 21. RH. PPC valve 22. Center swivel joint :208F05600 10-15 ©HYDRAULIC CIRCUIT DIAGRAM C200, 200LC-5 Si s0s00 # 2 - 5 ii a % 3 g 8 bio [dt Pn . Bs eae be 33 Be 3 ba 88 H ERE ane = Teaat motor FC200: 1005160 8 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. 2 (ce/rev) CO- NC valve output pressure Pi (kg/em*) 208F05022 10-25OPERATION 1) Operation for increasing pump oe bh ischarges (rocker cam angle changes to the large) a Section B—8 SOB — | o es oe QI pe, lo fs : Gl ° 55 { Da Section 6 Sl a. Charging pump pressure Ppo IN port b. Front main pump output pressure Pet IN Port c. Rear main pump output pressure Pz IN port d. TVC valve drain Pdr OUT port d. TVC valve output pressure Ptz OUT port 10-28 ® eRe 205F06025 Spring 5. Sleeve Spool 6. Piston Piston 7. Body Piston 8. Solenoid 020805020605 FUNCTION AND OPERATION 1) When command current from pump controller is small (when pump controlle! M J normal) TVC valve iS Nc |co vaive | valve Servo valve Servo piston se Lj] = increase Discharge {Control ae Fivalve: PIF vawve Pry Pr2 — Pe 4 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. ‘él —— i Pa TE faa nfs] Pe: Pra) De TVC prolix switch Res OPERATION © 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 Ptz 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 Ptz. Be- cause of this, the pump discharge volume is maximum, 205050264, 10-29 @2) When command current from pump controller is large (when pump controller is normal) Ne | co valve | valve Servo valve Servo piston Decrease =— Lj] Increase Discharge Ton | year valve _{3/*{ valve th © 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 (1). 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 ¢ (drain port) becomes larger. Because of this, TVC valve output Pressure Ptz drops and the pump discharge volume is reduced. 10-30 3 a TVC valve Pump id Resistor 2056050274 TVC prolix switeh 020505020805 3) Main pump under light load (pump controller abnormal and TVC prolix switch ON) TVC valve rT Lil NC co Valve | Valve i Pes | servo valve | — Pea) | Servo piston L ~ Decrease Li = Increase Discharge Prs Pez Dany fo ME _{ if IN VC prolx switen Wty —~ Resistor 208F05028A @ Main pump discharge pressures Pr1 and Pr2 are low, so spool (2) is pushed down by spring (1). As a result, charging pump discharge pressure Pe and TVC valve out- put pressure Ptz are equal When this happens, TVC valve output pressure Ptz is maximum and the main pump discharge volume is also maximum. 10-31 é4) Main pump under heavy load (pump controller abnormal and TVC prolix switch ON) VC valve Pi NC valve co valve Servo valve Servo piston Decrease = TJ —trerease Discharge cantor valve: (Control valve. Pry Po Pump — Lorry [controtter M = TVC prolix switch Resistor 208050288 © When main pump discharge pressure Pet (or Pr2) 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 ¢ (drain port) becomes larger. Because of this, TVC valve output pressure Ptz drops and the main pump discharge volume is reduced. 10-32 @ 020505,020805 4.CO + NC VALVE Charging pump pressure PRO OUT port Main pump output pressure Pet (Pp2) OUT port Main pump output presure Pr2 (Prt) OUT port TVC valve output pressure Ptz IN port TVC valve drain Pdr port CO cancel pressure Pef (Per) IN port TVC valve output pressure Pt F-R connection port Jet sensor output pressure Pd IN port Jet sensor output pressure Pt IN port * The diagram shows the CO+NC valve for the front pump. Section A~A 20805030 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 * (_ }: For rear servo valveFUNCTION AND OPERATION OF CO VALVE 1), When main pump discharge pressure is below relief pressure Servo valve L Servo piston l Decrease L.I—= Inerease Discharge onirolly|p{Control efiaese effete FUNCTION @ 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 Pr and CO valve output pressure Peo. 10-34 COeancst | J) s2eretd ave | 205F05031A OPERATION © Spool (4) is pushed down by spring (3). As a result, port a and port b are com- pletely open, and TVC valve output pres- sure Peo are equal. Because of this, CO valve otput pressure Pco becomes maximum, and the dis- charge volume of the main pump is also maximum. 020808020505 2) When the main pump discharge pressure is higher than the main relief pressure valve [COcancet ~) Solenoid valve 1 7 Servo valve a — Servo piston Decrease = UJ Increase Discharge {€ontrot valve © When main pump discharge pressure PP comes close to the relief pressure owing to an increase in the load, piston (6) 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 ¢ (drain port) are made larger. With angle reduced by the operation of the servo valve, the main pump discharge is reduced. 208050224 10-35 a3) When cut-off function is canceled by CO cancel solenoid valve Servo valve ‘Servo piston Decrease [j]—= Increase Discharge {Control} [Control © 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 Peo re- mains at the maximum. 10-36 @ ICO cancel solenoid valve 205F050034, 020805020505 FUNCTION AND OPERATION OF NC VALVE 1) Control vaive at neutral Servo vale 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- trot loss. © The NC vaive 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 (12) 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 Pad. (4 co | we valve | valve [fae sae] 205050348 OPERATION © The differential pressure (Pt — Pd) of the jet sensor reaches the maximum and jet ‘sensor output pressure Pt acting on piston (10) becomes greater than the sum of the force of spring (12) and jet sensor output pressure Pd acting on the lower end of spool (11), As a result, spool (11) is pushed downward, causing a restriction of the oil flow between port ¢ 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 minimum with the swash plate angle minimized through the operation of the servo valve. 10-37, ®2) When the control valve is operated set sensor Control valve Servo valve aco |tve jPe Servo piston — ee © With the jet sensor differential pressure (Pt = Pd) reduced according to the operation of the control valve, spool (11) is pushed upward, fully opening port ¢ 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. 10- re 2osF050388 020505020505, 5. CHARGING PUMP Onsen Relief valve Body Cover Drive gear Driven gear Filter 2 Discharge 20sF0s036 SPECIFICATIONS. Theoretical delivery: 25 cc/rev Operating pressure: 32kg/cm* 10-39CONTROL VALVE C200, 200LC-5 Serial No: 45001 - 53192 C220, 220LC-5 Serial No: 35001 - 36052 ee dd cc bb aa 205F08037| 10-40 ® 020505020805 yosee0gR wo wexescerenapesgrre Travel shuttle valve 4-spool valve (Built-in straight-travel valve, arm throttle valve) 5-spool valve (Buil in swing priority valve) 3 port (From arm PPC valve) PL port (From rear main pump) PR port (From front main pump) B3L port (To bucket cylinder bottom side} Bai port (To boom cylinder head side) B1L port (To LH. travel motor PB port) PS port (From swing PPC shuttle valve) P4 port (From boom bucket PPC shuttle valve) P6 port (To work equipment oil pressure switch) AIL port (To LH. travel motor PA port) A2L port (To boom cylinder bottom side) ‘A3L port (To bucke cylinder head side) PAA port (From arm PPC valve) P3AL port (From bucket PPC valve) P2AL port (From boom PPC valve} P1AL port (From LH. travel PPC valve) PRL port (From 2-stage reliet solenoid valve) PRR port (From 2-stage relief solenoid valve) P1AR port (From swing PPC valve) P3aR port (Service) PAAR port (From arm PPC valve) PSAR port (From RH. travel PPC valve) ABR port (Service) A1R port (To swing motor MA port) BiR port (To swing motor port MB) B3R port (Service) Bak port (To arm cylinder bottom side) BSR port (To RH. travel motor PA port) T port (To tank) ASR port (To RH. travel motor PB port) ‘aR port (To arm cylinder head side) PAL port (To rear NC valve} Pat port (To rear NC valve} PtA port (To front NC valve) PaR port (To front NC valve} P1BL port (From LH. travel PPC valve) P2BL port (From boom PPC valve) P3BL port (From bucket PPC valve] Ts port (To tank) PSBR port (From RH. travel PPC valve) PABR port (From arm PPC valve) P3BR port (Service) P1BR port (From swing PPC valve) OUTLINE @ 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 @ built-in straight-travel valve, arm throttle valve and swing priority valve. @ 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 3Section A—A Section B-| 1. Spool return spring 2. Spool (LH. travel) 3. Spool (Boom-Lo} 4. Spool (Bucket! 5. Spool (Arm-Hi) 10-42 8 205F05038 6. Jet sensor orifice 7. Jet sensor relief valve 8. Main relief vaive 9. Spool (Straight-travel) 10. Spool (Arm throttle valve) 020805020508 Section C—C Section D-D 205F050308 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-spoo!) 5. Spool (Arm-Lo) 10. Spool (Swing priority) 10-43 @Section E-E Section G~G 1. Check valve 2. Check valve spring 3. Spool (LH. travel) 4. Spool (Straight-travel) 8. Spool (Swing priority) 6 Spool (Swing) 10-44 ® Section F—F Section H—H 205F05040 7. Suction valve 8. Spool (Boom-Lo} 9. Check valve 10. Spool (Boom-Hi) 11. Safety-suction valve 020505,020505 Section L—L 1. Safety-suction valve 2. Spool (Bucket) 3. Spool (Arm throttle) 4. Spool (Service) 5. Spool (Arm-Hi) Section K—k 205F05041 6. Check valve 7. Spool (Arm-Lo) 8. Safety-suction valve 9. Check valve 10. Spool (R.H. travel) 10-45PC200, 200LC-5 Serial No: 53193 and up PC200, 200LC-5 MIGHTY C220, 220LC-5 Serial No: 36053 and up 10-45-1 @ 020505,020505 ye+paoge wo N deceleration Po} | ilpressure || ‘switehy From shuttle valve of arm PPC valve From LH. travel To straight FORWARD circuit travel vealve| REVERSE circurt Toatm > throttle valve => To swing Priority valve Toswing mechanical pemes From shute prone eich valve of boom From shuttle bucket PPC valve of swing valve PPC valve 205*2092-2 ~~ LE LILLE Pe From LH. travel REVERSE creuit Toauto- y leceleration P| orm olpressue ES throttovahe Setial z => To swing pr priority valve To swing p mechanical eal Pe brake ol From shuttle valve of From shuttle pressure switch ‘arm PPC valve valve of From shuttle vaive af ‘boom, bucket swing PPC val PPC valve 208F2023-2 10. 47STRAIGHT-TRAVEL VALVE FUNCTION ‘© While operating the swing, boom, arm, or bucket when traveling, the pressure oil flowing to the RH. and LH. 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. @ When the straight-travel valve is switched over to establish continuity between the RH. and LH. travel circuits, this undesired turning is prevented by equalizing the supply of pressure oil to the RH. and LH. travel motors so that they rotate at the same speed. OPERATION ‘When traveling only © Since no pilot hydraulic oil flows from the shuttle valve in the PPC valve, no hydraulic oil flows from the travel shuttle vaive to the straight-travel valve. © Therefore, the circuit between port PR (RH. travel circuit) and port PLILH. travel circuit) remains closed and both circuits remain independent. operating the swing, boom, arm, or bucket when traveling © Spool (1) of the straight-travel valve is pushed to the right by the pilot pressure from the travel shuttle valve. © Port PR and port PL then become connect- ed to each other and an equal amount of pressure oil is supplied to the RH. and LH. travel motors, allowing both motors to rotate at the same speed. The machine trav- els thus in a straight line. 10-48 ® m1 ELRH wavel Travel sti) [ave ‘emt Bucket Boom:Lo 205F05042 205F05043, 020505020505 ‘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 ‘© 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 © When the swing is operated, spool (1) 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 vaive is throttled, and the arm speed is controlled, so the simultaneous operation performance is improved. ree a (Travel shut valve 20sro5044 Travel shutia valve. ? 205F05085, 10-49 éARM THROTTLE VALVE FUNCTION @ 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 © 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 @ When the arm is operated together with the boom or bucket, the pilot pressure from the travel shuttle valve pushes spool (1) of the arm throttle valve to the left. When this hap- ens, 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 10-49-1 © 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. ‘Ar-H Pi] 205F05086 Pc [Susian-vavel 205F05047 020505020505 | Section CC 14 13 ” Section B—8 2osF05049 1. Brake spring 10. Cylinder 2.Drive shaft 11. Valve plate 3. Cover 12. Air bleeding plug 4. Housing 13. Center shaft 5. Disc 14, Center spring 6.Plate 15, Safety valve 7. Brake piston 16. Check valve 8. End cover 17. Check valve spring 9. Piston 10-51SWING HOLDING BRAKE OPERATION 1) 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 port 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 (1), so disc (5) and plate (6) are pushed together and the brake is applied. 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 (1), 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 10-52 charging pump 205F05050 Excited at e) Charging pump 205F05051 020805020805 SAFETY VALVE FUNCTION © 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 Pu: 150 kg/em® Pa: 280 kg/cm? Tr: 0.08 see. Ta! 0.08 sec. 205F05052 OPERATION 1) When circuit pressure is PO The safety valve is not actuated. 20505059 2) When circuit pressure is P1 nae orn When the circuit pressure is P1, rod (18) io pushes spring (19), so plunger (20) is open, \ ] and the pressurized oil is relieved. lee The time taken for rod (18) to contact bush- t ing (21) is T1, and the pressure during this time remains at P1 = SS | 205F05054 3) When circuit pressure is P2 After rod (18) contacts bushing (21), and the pressure rises (P1-~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 72, and the set pressure after the rise is P2. 205F05055 10-53CENTER SWIVEL JOINT Cover Body Slipper seal Oil seal Shaft gReNe 10-54 @ AY A2: B1 Ba: cr C2: From control valve ASR port To RH. travel motor PB port From control valve P1L port To LH. travel motor PB port From control valve BSR port To RH. travel motor PA port 205F05056A, D1: From control valve A1L port D2: To LH. travel motor PA port F1: From travel speed solenoid valve F2: ToLH. and RH. travel motor P port Ti: To tank 72: From LH. and R.H. travel motor T port 020505,TRAVEL MOTOR PB port (From contro! valve) PA port (From control valve) T port (To tank) P port (From travel speed solenoid valve) aege 10-56 208F05087 SPECIFICATIONS Theoretical delivery Min. 100.5 ce/rpm (PC200) 109.0 co/rpm (PC220) Max. 160.8 ce/rpm Rated pressure: 340 kg/cm? Rated speed Min. 1,810 rpm (PC 200) 1,830 rpm (PC 220) Max. 1,160 rpm (PC 200) 1,240 rpm (PC 220) Brake releasing pressure: 12 2kg/em? Hi-Lo switching pressure: 8 2kg/em? 020505020805 Section B—B 1. Output shaft 2.Motor case 3. Cradle 4. Rocker cam 5.Piston 6. Cylinder 7. Valve plate 8.End cover 9. Regulator valve 10. Spring 11. Brake spring 12. Brake piston 13.Plate 14, Disc Section CC 205F05058 15, Regulator piston 16. Spring 17. Check valve spring 18. Check valve 19. Counterbalance valve 20. Spool return spring 21. Safety valve 10-57MOTOR OPERATION 1) At Lo speed (motor rocker cam angle at maximum) Traveling speed solenoid valve xt] The solenoid valve is deactivated, so the 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 arrow by spring (10). © Because of this, it pushes check valve (22), and the main pressure oil from the control valve to end cover (8) passes through passage @ in regulator valve (9), enters regulator piston (15a) at the top, and Pushes regulator piston (15a) to the right in the direction of the arrow. 10-58 205F05059 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 020505020505, 2) At Hi speed (motor rocker cam angle at minimum) © The solenoid valve is excited, so the pilot 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. © Because of this, the main pressure oil from the control valve passes through passage ¢ 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. Traveling speed| solenoid valve Travel control P valve 205F05060 © At the same time, the pressurized oil at regulator piston (15a) at the top passes through orifice d in regulator valve (9) 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. 10-59PARKING BRAKE OPERATION 1) When starting to travel When the travel lever is operated, the Pressurized oil from the pump actuates counterbalance valve spool (19), the circuit to the parking brake is opened, and the oil flows into chamber a of brake piston (12), overcomes the force of spring (11), and pushes piston (12) to the right in the direc- tion of the arrow. When this happens, the force pushing plate (13) and disc (14) together is lost, so plate (13) and disc (14) separate and the brake is released 2) When stopping travel When the travel lever is placed in neutral, counterbalance valve spoo! (19) returns to the neutral position and the circuit to the parking brake is closed. The pressurized oil in chamber @ of brake piston (12) is drained to the case from the orifice in the brake piston, and brake piston (12) is pushed to the left in the direction of the arrow by spring (11) As a result, plate (13) and disc (14) are Pushed together, and the brake is applied. 10-60 d [control valve aor dS 208F05061 Sal i = La il 208F05062 020505020805 BRAKE VALVE @ 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. 1) © The function and operation of each compo- nent is as given below. 1) Counterbalance valve, check valve Function © 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 @ When the travel lever is operated, the pressurized oil from the control valve is sup- lied 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 (18b} and spool (19), so the pressure at the supply side rises. (Fig. 2) © The pressurized oil at the supply side flows from orifice E1 in spool (19) to chamber S1, and when the pressure in chamber $1 goes above the spool switching pressure, spool (19) 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) | Control valve i J cmervne| A Counterbalance L} | valve 208F05083 (Fig. 2) Control valve 205F05064 205F05085 10-61Operation of brake when traveling downhill @ 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 $1 through orifice E1 will also drop. When the pressure in chamber $1 drops below the spool switching pressure, spool (19) is returned to the left in the direction of the arrow by spring (20), and outlet port MB is throttled. As a result, the pressure at the outlet port side rises, resistance is generated to the 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 @ 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. 5) © If the pressure goes above the set pressure, the force produced by the difference in area between D1 and D2 [77/4(D} — D3) 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) 10-62 Control valve 18h Pa 205F0S066 a D (Fig. 6) 020508VALVE CONTROL 5 ~ Boom lower “\cur! AQ RH. swing Armin m. LON 2 Rog ‘i eA 3 Y 7 3 2 8 10 8 - ny 2osrosso2 1. LH. travel control lever 8. Boom, bucket and travel shuttle valve 2. RH. travel control lever 9. Hydraulic pump 3. RH. PPC valve 10. Accumulator 4, RH. work equipment control lever 11. LH. work equipment control lever 5. Arm hal flow solenoid valve 12. LH. PPC valve 6. Control valve 13. Safety lock valve 7. Arm and swing shuttle valve 14, Travel PPC valve 10-65 @PPC VALVE C200, 200LC-5 Serial No: 45001 - 58018 C220, 220LC-5 Serial No: 35001 - 36613 FOR WORK EQUIPMENT AND SWING View Z f P port (From charging pump) T port (To tank) P3 port (LH.: arm in/RH.: bucket dump) P2 port (LH. LH. swing/RH.: boom lower) Pa (LH. arm out/RH.: bucket curl) PI port (L.H.: LH. swing/RH.: boom raise) 205F05068 020605020505 1. Spool 2. Metering spring 3. Centering spring 4. Pilot piston 5. Pilot spring 6.Piston Section B—B Section D—D Section C—C 205F05069, 7.Dise 8.Lever 9. Joint 10. Plate 11. Collar 12. Body 10-67OPERATION 1) Atneutral Ports P1 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 (1). (Fig. 1) 2) Control lever operated slightly (fine control) When piston (6) starts to be pushed by disc (7), retainer (13) 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 P1. When the pressure at port P1 rises, spool (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 Pt escapes to drain chamber D. Spool (1) moves up and down until the force of spring (2) is balanced with the pres- sure of port P1. The relationship of the positions of spool (1) and body (12) (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 P1 also rises in propor- tion to the travel of the control lever. The ‘spool of the control vaive moves to a posi- tion where the pressure of port A (same as pressure at port P1 and the force of the return spring of the control valve are bal- anced. (Fig. 2) 10-68 © Fig. 17 205F05072, Control valve (Fig. 2) 208F08073, 020508020505 3) 4) During fine contro! (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 P1 Because of this, fine control hole f is con- nected to drain chamber D, and the pressu- rized oil at port P1 is released. If the pressure at port P1 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 P1 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, oi 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 P1 to push the control valve spool. The return oil from chamber B passes from port P2 through fine control hole f* and flows to drain chamber D. 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 (1) are pushed back by the force of metering spring (2) and the hydraulic pressure at port P1 The time lag when the lever is suddenly operated is prevented by damper piston (4) (Ouring fine control, damper piston (4) does not follow piston (6), so the fine control per- formance is maintained. (Fig. 4) (Fg. 3) 2osF0s074 — i —w alll Fig 4) 20805075 10-69 6C200, 200LC-5 Serial No: 58019 and up C200, 200LC-5 MIGHTY C220, 220LC-5 Serial No: 36614 and up FOR WORK EQUIPMENT AND SWING 10-69-1 @ 2oo1082 P port (From contro! pump) T port (To tank) 2 port (LH.: Arm dump/R.H.: Boom lower) Pa port (LH.: Swing left/R.H.: Bucket curl) Pt port (LH. Arm curl/R.H.: Boom raise) 3 port (L.H.: Swing right/R.H.: Bucket dump) 020805020805 Retainer 10-69-2 ®OPERATION 1) Atneutral Ports A and B of the control valve and ports P1 and P2 of the PPC valve are connected to drain chamber D through fine control hole f in spool (1). ig. 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 P1 becomes higher, ‘spool (1) is pushed back and fine control hole f is shut off from pump pressure chamber Pp. At almost the same time, itis connected to drain chamber D to release the pressure at port P1 ‘When this happens, spool (1) moves up or down so that the force of metering spring (2) is balanced with the pressure at port Pr. The relationship in the position of spool (1) and body (10) (fine control hole fis 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 Pt also rises in proportion to the travel of the control lever. In this way, the control valve spool moves to a position where the pressure in chamber A (the ‘same as the pressure at port P1) and the force ‘of the control valve spool return spring are balanced. (Fig. 2) 10-69-3 ® (Fig.1) 020505020805 3) 4 During fine control (when control lever is returned) When disc (6) starts to be returned, spool (1) is pushed up by the force of centering spring (3) and the pressure at port Pr. When this happens, fine control hole f is connected to drain chamber D and the pressure oil at port P1 is released. If the pressure at port P1 drops too far, spool (1) is pushed down by metering spring (2), and fine control hole f is shut off from drain chamber D. At almost the same time, it is connected to pump pressure chamber Pr, and the pump pressure is supplied until the pressure at port P1 recovers to a pressure that corresponds to the lever position. ‘When the spool of the control valve returns, oil in drain chamber D flows in from fine control hole fin the vaive on the side that is not working The oil passes through port P2 and enters chamber B to fill the chamber with oil. (Fig. 3) At full stroke ‘When disc (5) pushes down piston (4), and retainer (9) pushes down spool (1), fine control hole f is shut off from drain chamber D, and is. connected with pump pressure chamber PP. Therefore, the pilot pressure oil from the charging ump passes through fine control hole f and {lows to chamber A from port P1, and pushes the control valve spool The oil returning from chamber B passes from port P2 through fine control hole f* and flows to drain chamber D. (Fig. 4) A Oo o T Hl ~ ~Pe PL P| conotvaive MB (Fig.3) ee) Fig.4) 10-69-4 ®FOR TRAVEL Gq °o © P port (From charging pump) . T port (To tank) P2 port (LH. reverse) |. Pa port (RH. reverse} Pt port (LH. forward) P3 port (R.H. forward) a, b. ce 4 e f 20805070 020505020505 PON Spool Metering spring Centering spring Piston @nog Section B-8 Section D—D 205F05071 Bolt Plate Collar Body 10-71 6ACCUMULATOR Gas plug Shell Poppet Holder Bladder Oilport PA RON> SPECIFICATION Gas capacity: 300 ce 20805076 020505SAFETY LOCK VALVE PC200, 200LC-5 Serial No: 45001 ~ 49317 PC220, 220LC-5 Serial No: 35001 ~ 35568 Te 7S [I Lever Body Seat Ball End cap gpene 20508077 020505 PC200, 200LC-5 Serial No: 49318 and up PC200, 200LC-5 MIGHTY C220, 220LC-5 Serial No: 35569 and up Lever Body Seat Ball End cap Froscso1a 10-73 8SOLENOID VALVE ASSEMBLY C200, 200LC-5 Serial No: 45001 - 52783 C220, 220LC-5 Serial No: 35001 - 36023 FOR 2-STAGE RELIEF + CO CANCEL, SWING BRAKE AND TRAVEL SPEED — o a. ToLH.and RH. travel motor b. To swing motor cc. To main relief valve, and front and rear CO valve 4. P port (From charging pump) fe. Tport (To tank) 10-74 o 20805351 1. Travel speed solenoid valve 2. Swing brake solenoid valve 3. 2-stage relief + CO cancel solenoid valve. 020805020505 1) FOR 2-STAGE RELIEF + CO CANCEL AND TRAVEL SPEED OPERATION Solenoid deactivated © No signal current flows from the controller, 0 solenoid is deactivated. 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. Solenoid excited © When the signal current flows from the controller to solenoid, solenoid is excited. As a result, the pressurized oil from the charging pump fiows from port A to port B, and to the actuator. At the same time, port C is closed, and the pressurized oil from the charging pump does not flow to the tank. 205F05079 NOE RONS Connector Plunger Coil Push pin Spoot Spring Bracket Actuator 2osFos0K04 ro Actuator 205F0508-12) FOR SWING BRAKE OPERATION Solenoid deactivated © No signal current flows from the controll- er, so coil is deactivated. Because of this, port P is closed, and the pressurized oil from the charging pump 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 © 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. 10-76 Nogpens 208F05082 Connector Plunger Coil Spring Spool Body Plug ‘Swing motor Deactivated, ‘Swing motor 205F05003-1 020505020505 C200, 200LC-5 Serial No: 52784 and up PC200, 200LC-5 MIGHTY C220, 220LC-5 Serial No: 36024 and up FOR 2-STAGE RELIEF - CO CANCEL, SWING BRAKE AND TRAVEL SPEED To LH. 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) 205F05826 1. Travel speed solenoid valve 2. Swing brake solenoid valve 3. 2-stage relief - CO cancel solenoid valve 10-77Section A— A, 20505827 OPERATION Solenoid deactivated ‘* The signal current from the controller does not flow, so coil is deactivated. * Asa result, port P is closed, and the press- ure oil from the charging pump does not flow to the actuator. At the sarne time, the oil from the actuator flows from port A to port T, and drains to the tank, Solenoid excited ‘+ When the signal current from the control- ler flows to coil, coil is excited. * 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. 10-77-1 1. Connector 2. Plunger 3. Coil 4. Push pin 5. Spring 6. Spool 7. Body rt / Deactivated / Actuator zosroseza ; Excite Actuator 2205 F-05829 020805020505 C200, 200LC-5 Serial No: 45001 - 52783 C220, 220LC-5 Serial No: 35001 - 36052 FOR ARM HALF FLOW ees ee OPERATION Solenoid deactivated '@ No signal current flows from the controll- er, so coil is deactivated. Because of this, port P and port $ are in- terconnected, so the pressurized oil from the PPC valve flows to the control valve. Solenoid excited © 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 $ and Port T are in- terconnected, so the pressurized oil from the control valve is drained to the tank Connector Plunger Coil Spring Spool Body Plug NMogaene 205F05085 Deactivated. Ss. Excited LL bh ; | > =| ) i Tt 10-77-2 ®PC200, 200LC-5 Serial No: 52784 and up C200, 200LC-5 MIGHTY C220, 220LC-5 Serial No: 36053 and up FOR ARM HALF FLOW 205F05830 OPERATION Solenoid deactivated * The signal current from the controller does not flow, so coil is deactivated, © Asa result, port P and port A are intercon- nected, and pressure oil from the PPC valve flows to the control valve. Solenoid excited © When the signal current from the control- ler flows to coil, coil is excited. * 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. 10-77-3 ® NOReeNS Connector Plunge! Coil Push pi Spring Spool Body in Be] Controt valve valve Excited 205F0se31 Be] Contr! vate Pec 20505832 020508SHUTTLE VALVE FOR ARM AND SWING Section A—A 205F05088 020505 FOR BOOM, BUCKET AND TRAVEL oh ot © Gla = Section A~. ogo| PA | Polo oR Section D-D 205F05089| a SectionB—B Section CC ere verse seaege Plug Body Ball P 1B port (Swing right) P5 port (Swing oil pressure switch) P28 port (Swing Left) P4B port (Arm in) P6 port (travel shuttle valve) P38 port (Arm out) P2A port (Swing left! P1A port (Swing right) P3A port (Arm out) P4A port (Arm in) 1. Plug Body Ball oN P7A port PBA port PA port PAA port P9A port PBA port PAA port P3A port P10 port PS port P98 port Pep port P48 port P38 port P7B port Pee port P28 port P1B port neposgr re -se>80008 10-77-4 6BOOM HOLDING VALVE C200, 200LC-5 Serial No: 45001 - 53229 C220, 220LC-5 Serial No: 35001 - 36052 a —fh | D il ! i a= ) als ee O 32 205F05090, Safety-suction valve Pilot spring Pilot spool Poppet spring Poppet 1 2. 3. 4. 5. 10-78 @ 020505020508 PC200, 200LC-5 Serial No: 53230 and up PC200, 200LC-5 MIGHTY PC220, 220LC-5 Serial No: 36053 and up fo | Safety-suction valve Pilot spring Pilot spool Poppet spring Poppet Section A — A, — Sy] 73 oo a oO arOrO) 10-79 8OPERATION 1) Atboom 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. 205F05091 2) Boom lever at NEUTRAL When the boom is raised and the control lever is returned to NEUTRAL, the circuit for Ain) the holding pressure at the bottom end of ie a the boom cylinder is closed by poppet (5), and at the same time, the circuit for the oil flowing into poppet (5) through orifice a of poppet (5) is closed by pilot spoo! (3) As a result, the boom is held in position. 205F05092 10-80 > 020805020505 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 (1) is actuated. 205F05093 10-81 6HYDRAULIC CYLINDER 1. BOOM CYLINDER 3, BUCKET CYLINDER 1. Bottom side bushing 2.Piston rod 3. Cylinder head 4. Rod packing 5. Buffer ring 6. Wear ring 10-82 © 10 11:12 13 14 15 ey 8 9 10 111213 14 16 \\\itfoo He viae) 205F08094 | / / 20805095, 7..Cylinder 8. Head side tube 9. Head side cushion plunger 10.Ring 11. Piston ring 12. Wear ring 205F05096 13.Piston 14. Piston nut 15. Bottom side tube 16. Bottom side bushing 17. Bottom side cushion plunger 18. Ball 020505,020808 SPECIFICATIONS Unit: mm ~ Cylinder Boom Arm Bucket Item Pc200 | Pc220 | Pc200 | Pc220 | Pc200 | PC220 Rod outside diameter 120 130 135 140) 118 130 Cylinder inside diameter 85 90 9 | 100 80 90 "Stroke 1285 | 1.278 | 1490 | 1635 1,120 | 1,020 Maximum tength 3,160 | 3,195 3565 | 2,800 2,625 "Minimum length 1875 | 1,860 2075 | 2.235 | 1.680 | 1,605 Piston nut width across flats 85 95 “| 95 05 85 95 10-83 6ELECTRICAL WIRING DIAGRAM - Monitor panel Window washer switch . Swing lock switch Horn switch Starting switch Fuel control dial . Cigarette lighter Service meter Buzzer 10. Radio 11. TVC prolix switch 12. Swing lock prolix switch ©PNOZEeNs 10-84 ®@ View 2 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 2osFosz44 020805020805, 205F050080 24. Working lamp 25. Head lamp 26.Battery 27. Additional head lamp 28. uel level sensor 29. Arm half flow solenoid valve 30. Front pump pressure sensor 31.Coolant level sensor 32.Rear pump pressure sensor 33. Work equipment oil pressure switch PC200 Serial No: 45001 — 49706 PC220 Serial No: 35001 — 35661 Work equipment + swing oil pressure switch C200 Serial No: 49707 and up PC220 Serial No: 35662 and up 34. Coolant temperature sensor 35. Altemator 36. Swing oil pressure switch 37. Engine oil pressure sensor 38. Governor motor 39. Starting motor 40. Engine oil level sensor 41. TVC valve 42, Travel oil pressure switch 43. Hydraulic oil level sensor 44. Service oil pressure switch 45, Service oil pressure switch 46, 2-stage relief «CO cancel solenoid valve 47. Travel speed solenoid valve 48. Swing brake solenoid valve 49, Horn (Low tone) 50. Horn (High tone) 51. Battery relay 10. -85ELECTRICAL CIRCUIT DIAGRAM C200, 200LC-5 Serial No: 45001 - 48283, C220, 220LC-5 Serial No: 35001 - 35447 7 _Meritor pane switch output Wierkng ode Master fn Fuse box connection tbe Sensce meter u=PIOLKES2) p ODF 4) Werirs buze" oy paint) Ul cna (Kes 4) (es a) cues ws 2sage Staring sentch oF IO ites Fal col dat 3 cw. woaewe) xn? fi se) 7 g Giese 5 1 TF carr a ir ve ey u = oe E So So Fy foce tyrmute TE TW prox ol ievel” poe Senos Ere Sencar fessor Vater "PC220 only GRECTTX3) PPO on ‘cu-iiat’se) # 1022 cn-metsio) ase To 22) cn-esixesa) fora ‘F05637-1 c 4 10-86 020505,020505, working amp Boor ovgztsia) am | [_gewo = = ¢ — . th a = tgne rom fj | fhe Laces tra ae Lee fy ‘rote cone NEI, Festi pea = i fore fae | | HE Pare 1 eee engine i oun am! Jue) se cn-yiri.g) 100.21) fier cn-atse) Tova) ower ew-esixy Eran tet crap ht H ‘cooant Temperature sensa To wal tage) gaa e-M7 205F05634.1 ESSE SE ALPHABETICAL INDEX 2s ale algialelg PARTS NAME Plage rebel» CO cancel eT aE ir condone or e50ler Batery Batery ay Clarets iahiar crt cH oer owe CHF 0 CHES D2 DE DE 09 NEL 16 Be 3 re wa te co co cS RE ‘ar ‘a ‘of rs Er or ‘CN S10 ONSITE wz Wrst rss ‘elelelelelala CNVE CNV CRT CHE CHWS, Conder Control valve Coston vel sacar — Coolant Temperature Sensor [Emergency sop Swick Engine Engine ground Engine ot evel nase Ean eoe Engine sped sensor sedis alelslsleldelalelalaleiala Engine tote controler se ee a sgt panera Sr eet es oe ao HE ee 2 ie s Toes ; Hoe 4 coer = hee = maa = —— # a # soos = ee 3 2 Rect 3 a a Be SEP ania # tates atom e otras # er : tet reat 2 1 TE a 3 Be : g SE ccna g teres aaa a ate = there a eters S eee g Shea s Eee 2 slneae % 2 camarsemnme tr Soe 10-87 ®C200, 200LC-5 Serial No: 48284 - 49706 C220, 220LC-5 Serial No: 35448 - 35661 T___Menior piel switch Peng conor 7 fue box connection ie nr - - = Bonoff Sow ze 3 5 a 3s 1 ly : i Jott sia) vasa wea DE kas eos = EI tes] zi T _cNcetxs) Comma val Breeze Re a Seeb : eat oom ome = 7 eg ms |) j “PE220 ory CR=CTT 3) Choe thr 3] servic meter $ (POUKESA) ono? 4 Starng swich Worma ban ype) eee PERO or q . or {o eueMLe) eral ace [O40 ) to 22) weer mer es a) (KES a) - cums r ee zl { : flea dt : > “ “ = oan b) 5 Wied water x 7 cncegiwe) i ae i gtgwstsio. Wwe ‘Sentch oN-M2BiKESZ)—] (M2) f F to @al ovo} L__ =i Ht UG cvateonese ao ; | oreo 3 | ion 1 eae 20sF08637-1 — TT S [sane gar F Ey = EET =I z =a ._. 10-88 @, 020508,020505, moses ougatsi2y Enon tote controler OW tame | Eu(Mic2). aa cysna2) xpi To t12) ONesm Len To) ise! | By Engine “cMi7 208F08634-1 7 w ’___ EE ALPHABETICAL INDEX ARTS sage eit CO cance oieno vas ‘ir condone or fooler ‘akernator “raha a aan Va Baer ery ay igaratiebghlr ener ox Ne CN NC CRDT NDT NOTE NOTE THE COS [: sae ADRESS anf ews er arf ees a ert ows? er ef owe a er owes er ee Rv a ef er a er ene a ‘ef env a ‘ef ene os ma Sr eons sr | onre sak ts Sr Cooter et aor ca St Caan tempers oor 3 | Ceca ate a a fe 9 [Emerge sop sh a or ena 7 Se te 5 | Engi of ave sasr | 100 | Engine ci sressure wich ia Tor engine voor ar 7 102 Engine spe6d sense fe Tos [Engine toute contr 7 Tod Fou ane oF 108 [Fron ump eat saa te taal cana at = Fastin OF Fase bor bs Fase bo SSRETOT BE co or fe eat Ra or eaterCos97 | orn gh 0 oF Horn ow 370 Pr Host with er yaa oi ava Sona e erossn mode connec * UH fsa imp co Tighe cr agree SEN oT CORSET Er ont gana A Mant spe ET BE ae 128 wots fa 126 Mar a 127 | Oven warn OTS or 12 Potton * 128 Power nt Sa 35 150] resi rh Nr T3t | Pr eoeer s Taz Ri head os Tae as Raa ar [at Rea op pret naar te 135, Revoing ame we 135] Room an 38 “art Sones near ae 7 | Sens of roars waRERT os as | sere o piste Such 6 “ao Span 55 “wa | String ef 1 Seng ae aT 5 Tar] Sings pra oa 1 a5 Singlet sch He a6 | Sug o prasae or a se a 1a Trav a pease oe spa sled vt a we Pec o We pa eer 1s Westen ae a 153 Waring bars a Tse] Wino water ae 158 | Wet ator ae 156 | Wise tr 157 | Wort sqioneat ong a pai aomen—[s 150 Wrdg tmp Goor. MePC200, 200L.C-5 Set C220, 220LC-5 Seri No: 49707 - 58018 No: 35662 - 36613 Montor panel swith [ Woning mode Hote Fuse vo einmnan le oom le Clore Wane 1 (tee ual Gonadal cn-moeTRESeI— Jin) en a cN-MatKESS) cN-MBIIM3) ow CRE NRT Hireley Lo reloy E I = r aa 5 HEE: Sung fe” Haat ve Te Fels ews rose Teanmzouay or Sees Pe200 ON 3,13 Bah bit 298 3) To 22h ered Youn ONMUMS) ose ose Yo 22) CN MesiKES@) an a a e Ea a # aT rT a I 020508oweatsie) Goverer motor [a ca-ealoxs) Potentonerer Geom | ome ' ) ore ron eno aren ae | “ ee Toe - | | gS) 8 ee re ; cso g ae fore Eaoh & : | 2 Re -£7(X2) —— te 3 Yo (12) $e Be H ) Soe N-DIa pan fp cmitiey ' Le | yo 1121) sae = cup Cage of wet _ CHES |iswPia) Z Po —— He: i as act ——= oad Ppp Sete ue suo oe = ea cues ‘Veco se, H shee a Sar Ene of ee cnix9 ¥ = vow Se REHU fDi = — =) : 4 an thon aaonal Raw 70H sofia ==" bag - : pee. Ty chew — | overload warning os cores , s x | osroseaa.t a Fr ALPHABETICAL INDEX PARTS RANE 2 slge tell CO areal wa va ‘ie eonioner oF eae ‘erator al TW SRR a Batery Baier ea Cigarete ight cwcr N = ADDRESS co #7 Be cS os = ts Ks Ke AE a a5 [ROC PARTS Nae RODRESS 80 | CSO) or ar] cesT 6 [raz] ewse or a5 cWSe er aa] cHe = er BS CNT ~ FB a [one i a7 | cnvs ee a8 | Nv? ai cue 80 | Nv 7 | Condenser Ni 32 | Cont va 16 33 | Coolant vel Sor Re 4 | Coolant emperatue naar Fa 35 Elecesimate a air 7 36 | Emergency stop swich 6 37] Engi 6 98 | Engine roura 38] Engi ol level naar —— BS TOOT Engine ol pressure sich Re TOT Engine room Tp Mr TOE] Engine spe6d senso RS “aa | Engine trot contol Mz Toa | For tame oF 1 | Fron pup peas sensor i 106 | Foe conta i es 17 [Fue level sensor oO 106 | Fare box 6 10 | Fare tox comnaTN BIE TO Fuse int ‘or TT] Governor maior ci 2] Restor at 113 Heater Ray % a Hester Lore Br 18] Horn igh 440 aT oF 16] Horn tow 370 Ha Pr Tr Honanih - Ba 1a | Ryarauie oi val zangor ee [iis Petrosene mode eomectr ie 120] LH Reed mp We 121] pit reay a {22 | Magnet ehich oT compresar fe 128 | Wenitor panel a 124 Montor pene! Swi Opa cc 725] Motor 26 | Motor aE 127 | Overton warring EVE oF 12a [Fotentoreter ie 129 | Power max_ewGh 85 130] Presure sch i 131 Pump conker wo aE RH heed or os 133 Reso aT 13 | Rear puma press. sensor te 135 Revolving Tame Wz 196 | Room ap 76 157 [Service meer a5. 138 | Sevier nase aweh ce 130] Service oi pressure sich? 3 [iso Spencer 6 Tar} Storing moor Fe a2] Storing owt Ee 143 Sing brane oro 144 | Swing oc prot Swick rs 125 Swing lock swith ia 16 | Swi al pressure Sg or 1a Switch a 1 | Travel 3 proamue ba he 8 | Travel speed slenod wah 8 50 TVC Prot steh 7 [SST -1VC prticresistor cs 152 TC sono valve ro 153 Warning Bue me 154 Window washer ae 18 | Wiper motor = 180 Wiser Er Fis? | Work equpment owing oT presureswch —[ Be 188] Working tap on] co 10-89-2 ®PC200, 200LC-5 PC200, 200LC-5 MIGHTY No: 36614 and up : 58019 and up Fone box conna CN-PIOKKES2) oo? 2 = ° PER only (ott ite | } oxo] e233 [ i SE ) 4 SLaaal le ttt e oF lech ‘Addins! Lght relay — Heater lane reley ay Oe eter Wiper lay 020505ALPHABETICAL INDEX d Governor motor 7 (pan ———————rpprse) RH. ead lamp gehen beats) omg tes) re Fatage eat: CO cancel ano VANS a2 LON STO! Tyga "PE" cy yy fee te | steele S {evn a ae ea fi Sea see oon am, gsten ase Stier aes e oe ea z — cat | a5] 21 4 shar aes i Sone o— i St ee: it f ar eae et ea i —— ——— 5 + ae | eM) Too | Engine ground FE fae ee em io tamieieamam orsegg, | | serene e re oe! OO Ta ree a te Tae [Engine speed sor i ie = , —. ae ae Hd | ae =o ae e d = J cuemauxey 1 (248) or | Frat pump oer e ap 1g sat tee ‘ eteet— th] | TEP cin ne gee rhs || |) |\I)I)]) EGS | fl Tf Sete % elise eset ty ip * is Ta at aie is | Jecore 1 eine ie ne q fs ir LI Fei i po i i a a rt | i Te i | I 1 eater relay Last 2 118] Horn Itow. 379 Ra Pr 5 | | is eh Se? 4 g | | : SPRL rere % oo ll a E Py ne q 1 |] | [ ‘Magnetic catch of compressor Motor a ar i HHH tartresobona ores ‘Overload warning device oF cov — amar a | p——_Fy} 4 Power mak ooh 3 team i ee et ) eae : eee aoa % roa) ett eee i | opeg ay SRF STE RH Pend mp = CN-MI4(S8) ~ — A 1} | ‘pump prass. sensor 16 i = | mh jevalving tame Nz Eee I oer cee eae! eS i town EEE [ a @ 3 —= =) Tar | Serves ot restore IER? Be i Se | vot ga = = Tn oo en x ir) Poor jae a — a os “Yeo ‘ : 7 F trame th fra Ta5]| Swing brake solenoid valve 77 |= Garena | To Te cuneate coe = % Taio Hie Seat a cveguat rT eh a re eae rorua joe i eh = se ass] 150] Travel oll pressure switch é =i | eS ‘i ee $ Air condition oF Overload tom OMG 182 TVE a ih 7 cooler warning] 153, Prolix resistor cy cng ee ‘device (High. 390 He) Floor renistor 1 Ey Tbe] TE solenoid valve rc) a ane | @ 155] Warning buzzer aa yoivar{ 32ers — Pr was || “156 | Window washer” ro 2 co Yj) | u | sal 787 | Wet ator ca =| | ‘Thermstet) 15S | Wiper relay. emus = 1 a aang TTT ) sonata = = 360 Working ump oor) cu 10-89-4LOWER WIPER SYSTEM Wiper relay iver) JCN-M3I(M3) CN-M33 SJ 20505387 FREE SWING SYSTEM \ foe ming te feet es) eco ® ef foo ) Oy ; tT x PT : Pit Z WI ey [2235 Jew-mseimay switch Foot switch F 20505988, 10-89-5 TRAVEL ALARM SYSTEM ‘Travel alarm relay o.sw . 0 lo =. & ossw O85LR, 0.858 ( To swing flasher 0206052-PUMP- 1-ACTUATOR SYSTEM (PC200, 200LC-5 MIGHTY) CN=v90x2) > of 0858 o \2 oo s3 ‘pump: 2pump selector ae CN-ve(K2) CN-VKQX2) 2 oloessr_| | osscr{, \ o] 0.858 e \? oroescr. oascel, )* Sfoescy | CN-FI(M4) | va CN-DB _ Toswing usner ( 2 Sl25 es 40 usy Pump selector switch ONY zoom OFF pomp Fuse box : (egesequsaceregupan see ry asaaai As aaah \ e 1256 8 aosroseas HORN (PC200, 200LC-5 MIGHTY) Horn (Hi) 348 Hz CAEMIE | sie Horn (Lo) 290 Hz CACMIT oir 20505849 10-89-6 @020805 ENGINE CONTROL SYSTEM ov omeone 6 0 View Z 205F08104 Battery relay OUTLINE Battery @ The engine can be started and stopped Fuel control dial simply by using the starting switch, Starting switch © The engine speed can be controlled using a Governor motor dial control system for the fuel control. Starting motor @ The engine throttle controller also controls Engine throttle controller the engine speed at the same time using Fuel injection pump. signals from the pump controller. * For detail, see PEMC SYSTEM 10-89-8 @GOVERNOR MOTOR LINKAGE Angle origin (Position of stopper) Locknut Yoke . Governor actuater Spring assembly . Engine governor gaeye 10-90 3 2005991 020805020505 1. OPERATION OF SYSTEM C200, 200LC-5 Serial No: 45001 - 58018 C220, 220LC-5 Serial No: 35001 - 36613 Starting engine @ When the starting switch is tumed 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, Engine speed control © The fuel control dial sends a signal voltage to the engine throttle controller according to the position of the dial The engine throttle controller calculates the angle of the governor motor according to this signal voltage, and drives the governor motor so thatit 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 engi © 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. 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. Foal gal Engine Staring Switch [Eegine wwrone} sono a Storting Starting __[togise throttle) ~ 20sF0s1074 10-91 éC200, 200LC-5 Serial No: 58019 and up PC200, 200LC-5 MIGHTY C220, 220LC-5 Serial No: 36614 and up Starting engine © 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. Engine speed control © The fuel control dial sends a signal voltage to the engine throttle controller according to the position of the dial. 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 @ 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. 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. 10-92 rom mest Starting Fue diol Engine teh “ starting = {foo trorie} Teiercgn” [sorter jae Engine Fuel dial ts nied ol 020508020505, 2, COMPONENT EQUIPMENT OF SYSTEM. 1) ENGINE THROTTLE CONTROLLER 1 Self-diagnostic display LEDs 205F05108, 10-93Control function of controller © 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. 1) 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, 2) Engine speed contro! 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 (F.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. Ainput signe {Output signa Tange Tap oR] ‘Sire op : creat | Learn | fone ——1__| = (tagraworeewpson| |B Governor pees ty ev 20508109 Controller output _sharacteristics Governor motor turing ang (engine speed) 7 Fuel control dial output F" voltage Vh a 2 4 & sal #Bovernor motor] Fuel nil ds output : opetating range cherscteses 205F05110 020505,020805 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. 5) Engine stop function using starting switch signal When the starting switch is tured 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 SHOOTING. TROUBLE- Starting switch —ON Operation of soveror motor —. lon-2 Battery relay OFF drive signal 25 sec 205051114, Voltage between connector CN-E1 (13) — (12). (Battery relay drive signal) a —voreas | om 20-30 | ‘ON? 18-28 10-95Internal structure of controller @ The inside of the controller consists of the input circuit, microcomputer, and drive cir- cuit shown in the diagram on the right, and these have the various functions described below. 1) Input circuits These receive the signals from the fuel con- trol dial (throttle signal), pump controller (No. 2 throttle signal, auto-deceleration signal), monitor (warming-up signall, 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 2) 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 3) Drive circuit The pulse signal sent from the micro- computer is used to switch the direction of the current flowing to the governor motor to rotate the motor clockwise or counterclockwise. 10-96 © Heid Input circuit Microcomputer Drive circuit Governor motor, etc. 208F08112 020508020505 2) FUEL CONTROL DIAL Knob Dial Spring Ball Potentiometer Connector OR eN> Section A~A : Composition of circuit —s) ie ey 3 20508119 FUNCTION 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. There are detents at ten places on the knob Throttle voltage of the fuel control dial, but the knob can be Sharacterates Ma srasi16 set at any desired position. 10-97 ©3) GOVERNOR MOTOR FUNCTION @ The motor is rotated and the governor lever of the fuel injection pump is controlled by the drive signal from the engine throttle controller. © 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. 10-97-1 6 1. Potentiometer 2. Cover 7 3. Shaft | 4. Dust seal 5. Bearing 6. Motor 7. Gear b | 8. Connector NT Tm \ l 7 iA Section AA ca) (me —30 2 EE") E> ecm Composition of circuit 205f05115 OPERATION Motor stationary © Current is passing through both the A:phase coil and B-phase coil of the motor. Motor rotating © A pulse current is applied to the A phase and B phase by the engine throttle controller to give synchronous rotation with the pulse. 020805020805 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+ 3-241 4 .., the rotor moves to the right, Fig. 1 Expanded diagram of stepping motor Rotor (permanent magnet) sfistiat}sfiyt]s|in dis |{nlis | N 7 -4 s s]} wv] | i if i} t t | h eu z =) oH Stator A phase 8 phase aesosana Table + Current drive pattern Pattern? | Pattern 2 | Pattern 3 Pattern 4 B-phase current “i ti | +i “i4) LOOSE SPRING C200, 200LC-5 Serial No: 45001 - 56525 C220, 220LC-5 Serial No: 35001 - 35437 20505851 C200, 200LC-5 Serial No: 56526 and up C200, 200LC-5 MIGHTY C220, 220LC-5 Serial No: 35438 and up 10-97-3 yeeros gaeNe Yoke Pipe Spring Spring Rod Rod Spring Pipe Spring Joint 020505PEMC SYSTEM [Pump & engine mutual control system] wn mode selection function Pump control system Power maximizing system ‘Auto-deceleration system PEMC system Engine automatic warming-up and] loverheat prevention system ‘Swing control system “Travel control system Power set selection function Pump flow control (PFC, PNC) function ‘Cut-off (CO) function Cut-off cancel funetion Half flow function Ho ‘automatic warming-up function Engine overheat prevention function Ho lock function ‘Swing holding brake function (Pump control function ‘When machine is traveling) ‘Automatic Hi-Lo travel speed shift function Self-diagnostic function © 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. 10-98 a 20908116 020505,C200, 200LC-5 Ser PC220, 220LC-5 Ser No: 45001 - 49706 1 No: 35001 - 35661 Swing motor —z ia] toe ; equotorT____— JReavator l L PPC snutte valve be LT r ; nt Son 1 [ese We ! A. travel ee it | | | EL amis fa--- ‘Arm throttle HH tl i Serviee B] to c re lb = 1 | €]Sen pony eft fe] | Ly bp i Geom fa Srommemea |p A ' Th ral tut | oY i in 3 I lexe 8 "3 bene” atch 8 ae me are | onfpr Engine thotle ae ah | conroier rower max | | fock nc, pat | | Pome 205F051178 10-99 ®C200, 200LC-5 Serial No: 49707 - 58018 C220, 220LC-5 Serial No: 35662 - 36613 Travel motor Swing motor Oo Reguiatol__,_ —“FRegulator t t i i | Ena] | a] it 1 | neve 1 fama Fee tft | | &Lamto fae ‘em throttle He i Service Ef san LS rere | fsa py E{somie || [itt 11 Beem Straight eavei a eee i | Bf Swing fa TH ave tou 1 a | it tie wh =| F = sera Engine thot Resistor Pump of 2 10-99-1 ® 207F08082-1 020505020505 C200, 200LC-5 Serial No: 58019 and up .00LC-5 MIGHTY -20LC-5 Serial No: 36614 and up Travel motor 6 rotor $2 Ue sre eguiatoT__,_—JReuiator PC shuttle valve ub &, aan amie fa--+ I i I i i ! Senvice a | | essen pr fa 4 1 | [oeseme ba Sragt wawia | 1 j ef See fa CH travel 1 I Lo Engine onaor panel [C= ; ahah) “UBT | Le || aaa "| | 3 Fuel conta Engine throtte sel | conaier Pump ‘controler 20sr08 755,1. PUMP AND ENGINE MUTUAL CONTROL SYS" AND POWER SET SELECTION) TEM (WORKING MODE SELECTION Engine Fel ineetion Feel iieet on coven Travel control ever PPC shuttle valve it pressure switeh [treet teers | | i { fSeeepgarn | i [eeeegennee “HE Enging throtte a <2] Pump controller jee Fuel contro! dial ag OUTLINE ‘@ The changes in the engine speed caused by . 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 can always . give the optimum matching of the engine torque and pump absorption torque. (Throttle signal) Engine torque Engine horsepower LOFL GO,FO,LO+S ae / | GO,FO+L \ A Engine torque T 8 MN Engine speedN 2056051198 Engine speed N Note) HO: Heavy duty operation mode, G.0: General operatio [Switch signal) 208F0S118 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 La Ly 0.F0,LO+S & | Vsoro+t 3 ‘Vwors £ Ho+L F 5 208F051208 Pump delivery volume Q n mode, 205r051214 F.O: Finishing operation mode, L.O: Lifting operation mode 10-100 @ 020508020805 CONTROL OF H MODE ‘When using H.0, G.0, F.0 or L.O mode and H mode © Working mode: Same for any mode © Power set H @ CO function: Actuated © Pump absorption At rated output horsepower: point Pc200 C220 123.3 HP/2,050rpm | 152.8 HP/2,200rpm @ 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 torque Engine torque T Engine speed N 209F05122 ‘© Engine horsepower : g Engine speed N 20805123, ‘© Main pump delivery = =| é Pump delivery volume 20sfos124 10-101 8CONTROL OF S MODE ‘When using H.0 mode and S mode © Working mode: HO © Power set s © CO function: Actuated © Pumpabsorption At 80% partial horsepower: output point PC200 C220 ‘98.6 HP/2,050rpm | 123.2 HP/2,200rpm. @ When the pump controller receives the working mode [H.O) and power set [S) signal from the monitor, it sends out an electric command for the S mode output setting to the engine throttle controller. The engine throttle controller receives this, ‘and uses the governor motor to set the governor lever to the FULL position, @ The pump absorption horsepower and engine speed are different, but the control is basically the same as for [H] mode (engine speed sensing at the matching point), ‘When using G.0, F.0 or L.O mode and Smode @ Workingmode: — G.0, FO or LO © Power set: s © CO function Actuated © Pumpabsorption At 80% partial horsepower: output point Pc200 PC220 ‘98.6 HP/1,900rpm | 123.2 HP/2,000rpm_ © When the pump controller receives the working mode [G.0] (or [F.0] [L.Ol) and power set [S] signal from the monitor, it sends out an electric command for the S mode output setting to the engine throttle controller. The engine throttle controller receives this and uses the governor motor to set the governor lever to the partial position. @ The pump absorption horsepower and engine speed are different, but the control is basically the same as for (H) mode (engine speed sensing at the matching point) 10-102 © Engine torque © Engine horsepower = g) si ; : al 8 2 g/ & gf \ Engine speed N B Enoine speed 208F05128 208F08126 ‘© Main pump delivery 7 BL "Pump delivery volume Q 2osF05133 © Engine torque 4 Engine horsepower | : el \ 3| 5 5) i | 3] / Engine speed N 2 Engine speed N 2osrostz8 2osF0s129 © Main pump delivery Pump delivery volume Q. 205F08136 020505020505 CONTROL OF L MODE When using H.0 mode and L mode @ Working mode: HO © Power set L © CO function: Actuated @ Pump absorption At 68% partial horsepower: output point C200 PC220 83.8 HP/2,050rpm | 103.5 HP/2,200rpm. @ When the pump controller receives the working mode [H.O] 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. The engine throttle controller receives this and uses the governor motor to set the governor lever to the FULL position. @ The pump absorption horsepower and engine speed are different, but the control is basically the same as for (H] mode {engine speed sensing at the matching point) ‘When using G.0, F.0 or L.O mode and L mode © Working mode: G.0 or F.0 © Power set ie @ CO function: Actuated @ Pump absorption At 68% partial horsepower: output point C200 C220 ‘83.8 HP/1,900rpm [103.5 HP/2,000rpm. @ When the pump controller receives the working mode [G.0] (or [F.0]) and power set [L] signal from the monitor, it sends out an electric command for the L mode output setting to the engine throttle controller. The engine throttle controller receives this, ‘and uses the governor motor to set the ‘governor lever to the partial position. © The pump absorption horsepower and engine speed are different, but the control is basically the same as for [H] mode engine speed sensing at the matching point). © Engine torque Engine horsepower e - a [earns [cnn rca) he 20508147 Note 1) This is only effective when the working mode switch is at {H.0] or (G.O]. 10-110 ® 020505020508 * 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 [F.0] or [LO] is selected with the working mode switch, the operation of the control vaive 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 © Relationship between working mode and pump discharge volume (during in- dependent operation) % —Aetustor]| Boom ‘arm Travel Mwornina~—PReize [Lower| in | our Pucker Swing | HO 200 | 100 | 200 | 200 | 100 | 100 | 100 | 100 60 FO : | 200 | 100 | 100 | 200 | 100 | 100 | 100 | 100 Lo | + The portion for one pump is taken as 100%. * 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 Power max 5 Tock] (Note 1), or the travel lever is operated, or lewiteh (Note 1), Travellever | SWing tock! the swing lock switch is ON, the 2-stage FON | OFF foperstea[Neurai[On | OFF reliet + CO cancel solenoid valve pilot pres- | sure raises the set pressure of the main Mainveliel reliet valve from 325 kg/cm? to 340 kg/cm? | pressure | 240 | 928 | 340 | 325 |340| 326 to increase the digging power and travel | ikg/em*) force. Note 1) This is only effective when the working mode switch is at (H.0] or (6.0). lief i 1 1 10-111 ®3. POWER MAXIMIZING FUNCTION Control valve ——_ hsor| [28hsor RH. travel EE am & E] Amtlo [@ E] Armthrottle [a | EL Service EF oBucket f@ E] Swing priority [a | Boom-lo f@ i Boom-Hi [a | Straight travel | [swing [teva] | | eel SET WD Engine | Fuel Governor| TWecuon S0ven | i io Seve | a t (C0 vaive=e{cO valve 5] 3] | g} 3] rexel ONE 2| 2 Seiten | Ls | & Ss — = & (Swtich signal) Eine spoedsignat Engine thro! ~ Throttle signal) "| 5. controlter (Orive signal) controller (No. 2 throttle signal) P } Wo GOO Lo 000 SO88 EN" Jiswitth signa (Switch signa)| workin move OUTLINE © By pressing the switch on the left work ‘equipment lever knob, the maximum digging power is increased to give superior Production. 10-112 ® 20805353 020505020505 © When the working mode is switched to [H.0] or [G.0], and the power max. switch is switched ON, the following functions are actuated. Foner 7 Mode~2teh] oF on funoton Working mode] 10 or 6.0 Ho Power set | Any mode H cotunction | Actusted | Cancels Lc Maint! 1395 kgiem* Jem? valve pressure 325 kg) 340 kg! Lenatmot | | Eontinuoushritis operation | canceled after 8.5 sec. * This function does not work if the working made switch is at [F.0] or [LO].4, AUTO DECELERATION SYSTEM C200, 200LC-5 Si C220, 220LC-5 Seri No: 45001 - 49706 No: 35001 - 35661 Engine Fuel control diat (Throttle signal) Engine throttle | controller RH. control LH. control lever lever Travel control lever A 3) (8/8 " 3 PPC shuttle valve 3 Oilpres. 2 switch (Work equipment lever signal . (Swing eversignal) | pump controler | (Switeh signa) O L_ "ea sone| Pump controli ‘AUTO A (Travel lever signal). | pEceL ZY Ld aosrostas OUTLINE ‘This is a fully electronic control type, and when all the work equipment, swing and travel levers are at neutral, and the pump eres controller receives the signal, it sends a 1 command to the engine throttle controler. No.2 When this is received, the engine throttle ‘decel. position (1400), controller drives the governor motor to reduce the engine speed, thereby reducing 4 Mox.t fuel consumption and noise u Conteoilever Neutra Controllever Operation 20505150 10- 020505C200, 200L.C-5 Serial No: 49707 and up C200, 200LC-5 MIGHTY C220, 220LC-5 Serial No: 35662 and up “ee Fuel control dial F cmre Hy | eS Fuelinection rotor Lo 3 E (Drive signal (Throttle signal) Engine throttle LH. control R.H. control Goucees iver Ree pe control lever fl li Tne! 2 2 els la 2 8 Tt 17 TI g 8 3 8 PPC shuttle valve $ Giipres. 2 switch (Work equipment - ‘swing lever signal) Pumpcontrotier |-=\Swtch sonal (Travel lever signal) 10-115 ®OPERATION ‘When auto-deceleration switch ON 1. 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. 2. 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. 3. 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 © The engine speed can be set as desired using the fuel contro! dial, and even if all the levers are at neutral, the engine speed is not reduced, 10-116 ® Al coy | Fut contol dil o>} i wr ies Bebe taamalerae, seo fa) work Fut contol cal ge wets 208F05153.1 020805020505 5. ENGINE AUTOMATIC WARMING-UP AND OVERHEAT PREVENTION FUNCTION |Coolant temp. sensor Governor {Coolant temperature signal) Seno Sano valve valve INC vatve [Nc vaive [co vaive] [co valve} CL TW Monitor pane! Fuelcontoldal == BL pas : 5 ala 2 2 B to s| 3 é Q| 3 oe z ! T | eL,_] Engine trot (Worming-up signet Engine te signal (No. 2 throttle (Coolant temp. 102°C signel) (Coolant temp. 107° C/10S°C signal (Working mode signal) | Purp controller Bowersetsignah | (Drive signal! OUTLINE ‘© 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) 205F0515¢ 10-117 61) AUTOMATIC WARMING-UP FUNCTION © Actuation table Conditions Coolant temperature: Less than 30°C Fuel contro! dial: Below set speed * — Ifall the above conditions are satisfied, the automatic warming-up function is actuated Actuated Coolant temperature: Above 30°C Fuel control dial for more than 3 sec. Warming up time: At least 10 minutes Canceled [set speed: 1,200 rpm] Held above 70% of high idling * If any of the above conditions is applicable, the ‘automatic warming-up function is canceled. Action Engine speed: 1,200 rpm Engine speed: As desired 2) OVERHEAT PREVENTION FUNCTION © Actuation table C200, 200LC-5 Serial No: 45001 - 58018 C220, 220LC-5 Serial No: 35001 - 36613 i ™— Conditions Action ; con A | Power set [Selected mode | Action mode cess 2 HOandH.S mode | HO andl mode = | Coolant temperature: 102° ~ 107°C | | ———_ > | & | (Coolant temperature gauge: GOandHSmode | GLandL mode 215 ran see bon s|s Redrange) | | 5.0 anaH,S mode | Foanat mode 3] | [LoangHs mode | LOandtmode | | Engine speed: Default mode speed £ | Coolant temperature: Above 107°C | Power set: L mode (same as No. 1 setting) 8 | (Coolant temperature gauge: | Engine speed: Low idlig et Redrange | Waming lamp, buzzer: ON £ | Coolant temperature: Under 102°C | | (Coolant temperature gauge | Power set: Default mode = Green range) | Engine speed: Default mode speed Bl S| * Automatic reset B\2 & | 2 When coolant temperature is less S | § | than 102°C, return fuel contro! Lanegan caer | dial to low idling position. Dean eeeed Geo ace eva eee 3 | * Manual reset | (as desire 10-118 @ 020505020505 C200, 200LC-5 Serial No: 58019 and up C200, 200LC-5 MIGHTY C220, 220LC-5 Serial No: 36614 and up | Conditions ‘Action | Power set ) | Selected mode ‘ction mo | [HOandHSmode | HOandi mode | | € | Coolant temperature: 102° — 105°C GOandHSmode | GLandt mode = | 2 | (Coolant temperature gauge: 1 2B] | Red range) | | FOandH.Smode | FO andi mode z|*| LOanasmode | LOandi mode | ts Engine speed: Default mode speed Warning lamp: ON E | coolant temperature: Above 105°C | Power set: L mode (same as No. 1 setting! | 8 | (Coolant temperature gauge: Engine speed: Low idlig Mes Red range | Warning lamp, buzzer: ON 2 - | 2 | Coolant temperature: Under 102°C | | (Coolant temperature gauge: Power set: Default mode al Green range) | Engine speed: Default mode speed BR) g * Automatic reset ' BF tmenggeeruemmauress ess ponerse: ooo mae | & | diate tow idling position, | Eroine speed: Fuel contro cal set speed | * Manual reset | 10-1196. SWING CONTROL SYSTEM C200, 200LC-5 Serial No: 45001 - 49706 C220, 220LC-5 Serial No: 35001 - 35661 LH. control lever f ‘Swing motor ‘Swing holding brake Swing PPC shutlle |__ ‘Swing brake valve ores Swing lock switch (Lock signal “Drive signal T {Swing lock signal) { Pump controller (Swing lever signal) 205F05 1558 OUTLINE @ The swing is controlled comprehensively both when stopping and when operating ‘the swing, by the swing lock, swing holding brake, and swing priority functions. 10-120 ® 020508C200, 200LC-5 Serial No: 49707 and up C200, 200L-5 MIGHTY C220, 220LC-5 Serial No: 35662 and up ‘Swing motor LH and RH. controtlevers Swing holding brake oe en = || Bae [Pec shutne [Swing brake PRC Shute ores solenoid valve H l when M Leesa Swing tock a +s 8 000 3 aha sg Seas Joo au a ala) 2/3 50_]50_[oo 3/3 [Swing lock signal) (Work equipment = ‘swing lever signal) [4 Pump controller 207F050558, 10-121 ®@1) SWING LOCK AND AUTOMATIC SWING @ Relationship between swing lock lamp and HOLDING BRAKE SYSTEM the brake 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 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! Lock lamp ‘Actuation ‘The upper structure is held in place by the swing brake, ON (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 equipment control levers are interconnected PC200-5 Serial No.: 40707 and up PC220-6 Serial No.: 35662 and up * Swing lock prolix switch function Actuation table ‘When the pump controller is abnormal aaa SE EE and the swing holding brake function protrsmcn |__ OR" Sonoma oanenty does not work normally, the swing lock ‘Sinaiock | oy a " om prolix switch cancels the swing brake and operates the swing * Even when the swing lock prolix switch is turned ON, the swing lock switch stays ON and the swing brake is not canceled. ‘* 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. 2) HYDRAULIC OIL QUICK WARM-UP FUNCTION WHEN SWING LOCK SWITCH IS ON %* For details, see PUMP CONTROL ‘SYSTEM. 0205057. TRAVEL CONTROL SYSTEM Travel control ever Travel motor =“ = Control Controt 4 : tool Tomine 7 Fu contol il 5 8 ' alz : el a? howe stznal engine rotie| |B conor 22 e§ trot signal] §| & HE Pump controller [* (Drive signal) (Swing signal Travel ever signal [swinesionay | [, —Ztreveever signa 208F05158 OUTLINE © This increases the pump absorption torque and drawbar pull when traveling. @ The travel performance is improved by switching the travel speed manually or automatically. 10-123 ©” 2) PUMP CONTROL FUNCTION WHEN TRAVELING ‘When traveling, the following functions are actuated. © 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. TRAVEL SPEED SWITCHING FUNCTION The switching of the travel speed can be carried out manually or automatically, and has the following functions. i) 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. il) Hf the speed setting of the fuel control dial is set to less than approx. 1400 tpm: @ When traveling in Lo, even if it is switched to Hi, the transmission is not shifted. @ When traveling in Hi, the transmis- sion is automatically shifted to Lo. iii) 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/cm? 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/cm? 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. High speed travel |= | venison (Travel speed (Travel pressure v seconds) 020505,020505 8. SYSTEM COMPONENT EQUIPMENT 1) PUMP CONTROLLER ener 1 Self-diagnostic display window Section AA 205F081572) ENGINE SPEED SENSOR Magnet Terminal Case Boot Connector gaeRe 3) ENGINE THROTTLE CONTROLLER, FUEL CONTROL DIAL AND GOVERNOR MOTOR * For detail see ENGINE CONTROL SYSTEM, 4) MONITOR PANEL * For detail, see EMACC. 6) TVC VALVE ‘* For detail, see HYDRAULIC PUMP. 6) 2-STAGE RELIEF +CO CANCEL SOLE- NOID VALVE ‘TRAVEL SPEED SOLENOID VALVE ARM HALF FLOW SOLENOID VALVE * For detail, see SOLENOID VALVE ASSEMBLY. 10-124-2 © r -—Th o7stc o7ste Composition of circuit 205F05158A, FUNCTION © The engine speed sensor is installed to the 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 020505020505 7) PUMP PRESSURE SENSOR Amplifier Cord Connector Flange Detect module of oil pressure Introduction pipe of oil pressure Pe Rens Amplifier |p en 2 )Input (+24Vv) 3/ Out put (1 — SV) Composition of circuit Ke OUTLINE pump controller. To amplifier {solation ie © The voltage output is proportional to the {Stainless} pressure. Oil pressure ee @ When the pressurized oil entering from pressure introduction pipe (6) is pressurized by the diaphragm of pressure sensor module (5), the diaphragm shape changes. aS 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 © Relationship between output voltage V (v} to the bridge output voltage and is sent to and pressure P (kg/cm) the voltage amplifier (amp). V = 0.008 xP + 1.0 © The voltage is further amplified by the amplifier, and is output to the controller. ‘Sensor output voltage V (V) Oil pressure P {kg/cm*) 20505161 10-124-3 ©8) WORK EQUIPMENT OIL PRESSURE SWITCH, SWING OIL PRESSURE SWITCH, TRAVEL OIL PRESSURE SWITCH Mogaons 10-124-4 € Plug Diaghragm Back up spring Pin Guide pin Movable contacts Connector arth &:B a Composition of circuit 2ozrosi6s SPECIFICATIONS Actuation pressure: 5.0 + 1.0 kg/em* Reset pressure: 3.0 0.5 kg/em? 020505020505 EMACC (ELECTRONIC MONITOR AND CONTROL CONSOLE) Monitor panel Sensor signal Sensor Power © 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, 2. The gauge portion (coolant temperature, fuel level) that always informs the condi- tion of the machine. Buzzer signal Relay Electrical parts \—8—=9 Engine throttle controller ‘Warming-up signal ‘Switch signal Coolant temp. signal Buzzer Ge 205F08162 @ Various modes selector switches are built into the monitor panel, and it acts as the control portion of the machine control system.