SEBMOlO202

Shop
Manual

HYDRAULIC EXCAVATOR

This material is proprietary to Komatsu America International Company and

is notto be reproduced, used,or
disclosed except in accordance with written authorization from Komatsu America International Company.

It is our policyto improve our products wheneverit is possible and practicalto do so. We reservethe right to make
changes or add improvements at any time without incurring any obligation to install such changes on productssold
previously.

Due to this continuous program of research and development, periodic revisions may betomade this publication.
It is recommendedthat customers contact their distributor for information
theon
latest revision.

Copyright 2000 Komatsu

July 2000
DataKom Publishing Corporation
 tD P 6) N 4 0
8 0 0 0 0 0

0 -I v) c)
-I rn -I rn
3: v, 3[1 2
rn 1 C rn
=R z 0 z
v, c) -I D
C r
b 3[1
2 rn
. U b
. B 2
U U
... c
. C
cn 0
-I 0
2 7
c) . -I
.. . rn
.. 2
m ' 8
...
8
..
.
m'
.
8
..
8
8 8
8
.. ..
. ..
8 . .
a *
8
..
a .. .
a
8
... . 8 .
8 0 .
..
8 a
8 . 8
..
8
a
8 m
. ..
8
8 . ..
. 8
8 . .
8 .
..
8 8 . 8 .
8 8
8 8
..
(0 P G3 h)
? ?
-L
?
.a
?
i

6
N
 .

01 GENERAL

Specification dimension drawings ............. 01- 2

Specifications ................................................
................ -..............
01- 4
Weight table 01- 6
..
Fuel. coolant and lubricants .._................01- 8

PC200-6Z 01-1
 .
GENERAL SPECIFICATION DIMENSION
DRAWINGS

SPECIFICATION DIMENSION DRAWINGS

Unit: m m

SVPO554 I

* The values marked Z are for shovel operations.

01 -2
 GENERAL SPECIFICATIONS

SPECIFICATIONS
Machine model
Serial Number
I PC200LC-62
C10827 and up
Bucket capacity
Operatingweight
Max. digging depth
I

f m3

kg
mm
0.8
2 1,300
6,620
rn
a
0)
Max. vertical wall depth mm 5,980
c
h Max. digging reach mm 9,875
J
U
Max. reach at ground level mm 9,700
E
g. Max. digging height mm 9,305
Max. dumping height mm 6,475

Max. digging force kN (kg) 11 1.7(1 1,400)

Swing speed rPrn 12.4
Swing max. slope angle deg. 20
Travel speed kmlh Lo: 3.8
Gradeability deg. 35
Ground pressure :Pa {kg/cmz 38.2 (0.39)

(standard triple grouser shoe width:700rnrn

Overall length (for transport) mrn 9,425

Overall width mm 2,800

Overall width of track mm 3,08 0

Overall height (for transport) mm 2,970

Overall height to chassis mm 2,905.

Ground clearance to bottom of upper structure mm 1,085
Min. ground clearance mm 440
Tail swing radius mm 2,750

Min. swing radius of work equipment mm 3,630

Height of work equipment at min. swing radiu: mm 7,570

Length of track on ground mm 3,640

I Track gauge mm 2,3 80

Ij L
Height of machine cab mrn 2,315 -

1 '01-4 f'C200-6Z
 .h

GENERAL SPECIFICATIONS

Model
Machine model
Serial Number
I
f PC2OOLC-6Z
C10827andup
S6D102-1
Type 4-cycle, water-cooled, in-line, vertical,
diredt injection, with turbocharger
No. of cylinders - bore x stroke 1 mm 6 - 102 X 120
Piston disdacement I Q kc) 5.883 (5,8831
Flywheel horsepower 102/2,000 {135/2,000}
0

2 Max. torque 548.8/1,350 {56/1,350)

Max. speed at no load 2,200
0
't, Min. speed at no load 97 0
0.
Min. fuel consumption 218 (160)
Starting motor 24V, 5.5 k W
Alternator 24V. 60A
Batterv 12V, 150 A h x 2
cw-4
2 on each side
Track roller 7 on each side
Track shoe Assembly-type
triple grouser, 45 on each side
Type x no. HPV95+95, variable displacement
piston type x 2
Delivery Q/min Piston type: 206 x 2
Type x No. 6-spool type x 1
27 Control method Hydraulic type .

0
Travel motor . HMVl10-,2, Piston type
i& (with brake valve, parking'brake) x 2
row

gg
r
Swing motor KMF90AB-3, Piston' type
(with safety valve, parking.brake1 x 1
1 I

I I. Boom . Arm . . Bucket

& Type Reciprocating Reciprocating Reciprocating
U piston piston piston
-C
.-
6 Inside
diameter of cylinder mm 130 135 115
=
0
3
Diameter of pistonrod mm 90 95 80
2 Stroke mm 1,285 1,490 1,120
U
Max. distance between pins mm 3.1 55 3,565 2,800
1 Min.distancebetween pins I mm 1,870 2,075 . - 1,680
Hydraulic tank Box-shaped, open
Hydraulic filter Tank return side
Hydraulic cooler Air cooled (CFT-1)

PC200-6Z 01-5
GENERAL WEIGHT TABLE

WEIGHT TABLE
A This weight table is for use when handling components or when transporting the machine.
Unit: kg
Machine model PC2OOLC-6Z
Serial Number C10827 and up
Engine assembly 742

Engine 535

- Damper 6

Hydraulic pump 145

Radiator, oil cooler assembly 124
~~

Hydraulic tank, filter assembly (excl. hydraulic oil) 136

Fuel tank (excl. fuel) 122
Revolving frame 1,556
Operator's cab 191
Operator's seat 13

Counterweight 3,750 ~

Swing machinery 164

Control valve 166
Swing I 53
Travel motor 98 x 2

Center swivel joint 42

Track frame assembly 4,898
Track frame 2,624
Swingcircle 27 6
Idler 140 x 2
Idlercushion 135 x 2
Carrierroller 21 x 4
Trackroller 38 x 14
Final drive (incl. travel motor) 340 x 2
L

01-6 PC200-6Z
 ,
GENERAL WEIGHT TABLE

Unit: kg
Machine model PC2OOLC-6Z
Serial Number C10827andup
Track shoe assembly
Triple grouser shoe (700 mm) 1,435 x 2

Boom assembly 1,334

Arm assembly 620

Bucket assembly 510 - 1,170 - .

Boom cylinder assembly 205 x 2

Arm cylinder assembly 244

Bucket cylinder assembly 148

Link assembly (large) 68

Link assembly (small) 22 x 2

Boom pin 43+10x2+25+10+20

Arm pin 10 x 2

Bucket pin 20 x 2

Link pin I 13 x 2

PC200-6Z 01 -7
 GENERAL FUEL, COOLANT AND LUBRICANTS

* FUEL, COOLANT AND LUBRICANTS

I CAPACITY (e)
~~

KIND OF AMBIENT TEMPERATURE

RESERVOIR ! 4 14 32 50 68 86 104'1
FLUID 1 -20 -10 0 10 20 30 4O'C

Engine oil pan 26.3 24.0

I
I
I

Damper case 0.75 -

Swing r n a c h i n e r y q 5.5 5.5

4.4 4.2

Idler (1 each) 0.07 - 0.08 0.07 - 0.08

Track roller (1 - e a c h ) l 0.19 - 0.21 0.19 - 0.21

Carrier roller (I each) 0.23 - 0.25 0.23 - 0.25

Hydraulic system 239 166

Hydraulic

I I
I
Fuel tank ...
Diesel
fuel
340 -

Cooling system Coolant

I
Add antifreeze 22.2

01-8 PC200-6Z
 .

10 STRUCTURE ANDFUNCTION

...............................
.
Engine related parts
Radiator oil cooler aftercooler
Engine control
10-2
10-3
........................................
10-4
.........
Power train .............................................
10-5
Final drive ...............................................
10-6
Swing circle ............................................
10-7
Swing machinery ...................................
10-8
Track frame recoil spring ..........
10-9
Track shoe ...............................................
10- 10
Hydraulic piping drawing ......................
10- 12
Hydraulic circuit diagram ........... 10- 13
Hydraulic tank .........................................
10- 14
Hydraulic pump ......................................
10- 15
In-line filter ..............................................
10- 33-1
Control valve ..........................................
10- 34
Self-reducing pressure valve ................10- 42
CLSS ........................................................ 10- 47
Swing motor ........................................... 10- 66
Center swivel joint ................................. 10- 70
Travel motor ........................................... 10- 72
Valve control ........................................... 10- 81
Work equipment swing PPC valve 10- 82 ....
Travel PPC valve .................................... 10- 86
Service PPC valve .................................. 10- 90
Accumulator ............................................
10- 93
Straight-travel system ............................ 10- 94
EPC solenoid valve ................................ 10- 95
Boom holding valve ............................... 10- 97
Additional filter for breaker ................... 10-100
Work equipment..................................... 10-101
Actual electrical wiring diagram ...........
10-102
Electrical circuit diagram ....................... 10-104
Electric control system .......................... 10-106
Machine monitor system .......................
10-112
Sensors ................................................... 10-115

..

PC200-6Z 10-1
 I I

0
I
0

Ln /

0
I
0

-
0

-.
v)
0)
rn
I
rn

Ln
D W
W
0
2
.I
Ln
W
m
 I

E N
8
6
N

.. ..

v)
>
’0
0
w
u
0
0
STRUCTURE AND FUNCTION ENGINE CONTROL

ENGINE CONTROL

SVPO5542

Lever position
1. Stopper @ Low idling
2. Engine control lever Q High idling
3. Control cable
4. Fuel injection pump

1n-A nrqnn ~7 i
a
AND STRUCTURE FINAL DRIVE

FINAL DRIVE
P A
1. Level plug
2. Drain plug
3. Cover
4. No. 2 sun gear (No. of teeth: 21)
5. No. 1 sun gear (No. of teeth: 10)
4. No. 1 planetary carrier
6. Cover
7. No. 2 planetary carrier
8. Sprocket
9. Floating seal
10. Travel motor
11. Hub
12. No. 2 planetary gear (No. of teeth: 36)
13. Ring gear (No. of teeth: 95)
14. No. 1 planetary gear (No. of teeth: 42)

SPECIFICATIONS

Reduction ratio: - (M) X (M+)

1
21 10
= -57.000

6 7 6 9

14 13 12 11
A- A
SAPO

10-6
I I
 50
(D
n
C
9
0
.
3
1

E!.
0
II h)
N
N
N+
-a
0
UI s .
I
X %
5
-1
cn
Y
 STRUCTURE AND FUNCTION -. FRAME
TRACK SPRING
RECOIL

TRACK FRAME RECOIL SPRING

A-A

SAPO2603

1. Idler The dimensions and number of track rollers

2. Track frame may differ according to the model, but the
3. Carrier roller basic structure is the same.
4. Final drive
5. Track roller No. of trackrollers: 9 (each side)
6. Track shoe
7. Center guard
8. Recoil spring
9. Front guard

PC200-62
10-9
STRUCTURE AND FUNCTION -- TRACK SHOE

TRACK SHOE
STANDARD SHOE

PC2OOLC-6Z
Shoe width
(triple shoe) 700 mm

Link pitch 190 mm

No. of shoe 49
(each side)

SELECTION OFTRACK SHOE

I PC~OOLC-~Z
Specifications Category
Standard 700 m m triple B

I I -
~~

Category
- . Use Precautions when usins
R o c k y ground, Travel in Lo speed when traveling on rough ground with obstacles
A normal river soil such as large boulders and fallen trees.
Cannot be used on rough groundwhere there are large obstacles
Normal soil, such as boulders and fallen trees.
B soft land Travel in Hi speed only on flat ground; when it .is impossible to
avoid traveling over obstacles, lower the travelspeed t o approx.
half o f Lo speed.
Use only for ground where 'A' and '6' sink and are impossible
t o use.
Extremely soft Cannot be used on rough ground where thereare large obstacles
C ground (swampy such as boulders and fallen trees.
ground) Travel in Hi speed only on flat ground; when it is impossible to
avoid traveling over obstacles, lower the travelspeed t o approx.
half of Lo speed.
D Paved surface The shoes are flat, so they have low gradeability.
The.shoes are made of rubber, so be careful when traveling on
E Paved surface rough ground.

* Categories 'B and .C0 are wide shoes, so * When selectingtheshoewidth,selectthe

narrowestshoepossible within the range
therearerestrictions on their use. There-
fore, before using, check the restrictions and that will give no problem with flotation and
consider carefully the conditions o f use be- ground pressure.
fore recommending a suitable shoe width. If If a wider shoe than necessary is used, there
necessary, givethecustomerguidance in will be a large load on the shoe, and this
their use. may lead to bending of theshoe, cracking of
the links, breakage of the pins, loosening of
the shoe bolts, or other problems.

10-10 PC3rn-X7
 1. Bucket cylinder
2. Arm cylinder
I 3. Boom cylinder
4. Hydraulic tank
5. Hydraulic filter
6. Filter (for breaker)
7. Swing motor
8. R.H. travel motor
\ 9. Hydraulic pump
S
I 10. Control valve
11. Junction box
12. Oil cooler
13. L.H. travel motor
14. Arm holding valve
15. Boom holding valve
16 16. L.H. PPC valve
17. RH. PPC valve
18. Center swivel joint
19. Travel PPC valve
19 20. Service PPC valve
21. Accumulator
10
22. EPC solenoid valve
22A.PPC lock solenoid valve
228. Swing brake solenoid valve
22C. 2 step relief solenoid valve
220. Travel speed solenoid valve
1

I I
L 3VPOllkl
LY - W C - ) Q v 1-u1
8092OdVS
1
 .
STRUCTURE AND FUNCTION HYDRAULIC PUMP
.-

HYDRAULIC PUMP

h i J k

m \
SAPO3204

1. Frontmain pump a. PdlF port (pump drain)

2. PC valve b. PenF port (front control pressure detection)
3. LS valve c. PBF port (pump pressure input)
4. Rearmain pump d. PAF port (front pump delivery)
5. PC-EPC valve e. PAR port (rear pump delivery)
f. PenR port (rear control pressure detection)
g. Psig port (LS set selector pilot)
Outline h. Irn (PC mode selector current)
This pump consists of 2 variablecapacity i. PLSR port (rear load pressure input)
- swashplate pumps,
piston
valve, and PC-EPC valve.
a PC valve, LS j.
k.
isig (LSsetselectorcurrent)
PLSF port (front load pressure input)
1. EPC basicpressuredetectionport
m. Ps port (pump suction)

PCZOO-6Z 10-15
? P?P P

m
n

m
u)
L-
O
0
r
N
II
m N
m
I I

0
I
0

v)
x-
Q
0
N
4
OI
4
STRUCTURE AND FUNCTION
Function
Therotationandtorquetransmittedtothe
pump shaft is converted into hydraulic en-
ergy, and pressurized oil is discharged ac-
cording to the load.
It is possible to change the discharge amount
by changing the swash plate angle.
Structure
Cylinderblock (7)issupportedtoshaft (1)
by a spline, and shaft (1) is supportedby the
front and rear bearings.
The tip of piston (6) is a concave ball, and
shoe (5)is caulked to it t o f o r m o n e unit.
Piston (6) and shoe (5)form a spherical bear-
ing.
1 n-18
HYDRAULIC PUMP
SAP03438
Rocker cam (4) has flat surface A, and shoe
(5) isalwayspressedagainstthissurface
while sliding in a circular movement.
Rocker cam (4) brings high pressure oil at
cylindrical surface B with cradle (21, which is
secured to thecase, and formsa static pres-
sure bearing when it slides.
Piston (6) carriesoutrelativemovement in
the axial direction inside each cylinder cham-
ber of cylinder block (7).
The cylinder block seals the pressure oil to
valve plate ( 8 ) and carries out relative rota-
tion. This surface is designed so that the oil
pressure balance is maintained ata suitable
level. The oil inside each cylinder chamber
ofcylinderblock (7) is sucked in and dis-
charged through valve plate (8).
PC7nn-A7
 STRUCTURE AND FUNCTION HYDRAULIC PUMP

Operation
1) Operation of pump
i) Cylinderblock (7)rotatestogether with
shaft (11, and shoe (5)slides on flat sur-
face A.
Whenthis happens, rockercam (4)
1
\
4 5
\ I /* /’
movesalongcylindrical surface B, so
angle a between center-tineX of rocker
cam (4) and the axial direction of cyfin-
der block (7)changes. (Angle a is called
the swash plate angle.)
ii) Centerline X of rockercam (4) main- \
tains swash plate angle o! in relation t o B
the axial direction of cylinder block (7), SDP01409
and flat surface A moves as a cam in
relation to shoe (5).
In this way, piston (6) slides on the in-
side of cylinder block (71, so a difference
between volumes E and F is created in-
side cylinder block (7).The suction and
discharge is carried out by this differ-
ence F - E.
In other words, when cylinder block (7)
rotates and the..volume of chamber E
becomes smaller, the oil is discharged
during that stroke. On the other hand, I E
the volume of chamber F becrmes larger, 7 SDPOlIIO
and as the volume becomes bigger, the
oil is sucked in. F
iii) If center line X of rocker cam (4) is in
line with the axial direction of cylinder
block (7) (swashplate angle = 01, the
_- difference between volumes E and F in-
side cylinder block( 7 ) becomes 0, so the
X

pump does not carry out any suction or

discharge of oil.
(Inactual fact, theswashplateangle
never becomes 0.)

PC200-6Z 10-19
STRUCTURE AND FUNCTION HYDRAULIC PUMP

2) Control of dischargeamount
If swashplate angle a becomes larger,
the difference between volumesE and F
becomes larger and discharge amount
Q increases.
Swash plate angle a is changed by servo
piston (12).
Servopiston (12) moves in a reciprocal
movement (H) according t o the signal
pressure from thePC and LS valves. This
straightlinemovementistransmitted
through rod (13) to rocker cam (41, and
rocker cam (4). which is supported by

ina rotating movement in direction (c).

the cylindricalsurface to cradle (21, slides

With servopiston (121, the area receiv-

SOP01412
ing the pressure is different on the left

i'
and right, so main pumpdischarge pres-
sure (self pressure) PP is alwaysbrought
to thechamber receiving the pressure at
the small diameter piston end.
Output pressure Pen of the LS valve is
brought to the chamber receivingthe
pressure at thelarge diameter piston end.
The relationship in the size of pressure
PP at the smalldiameter piston end and
pressure Pen a t the large diameter end,
and the ratiobetween the area receiving
the pressure of the small diameter pis-
ton and the large diameter piston con-
trols the movement of servo piston (12).

1 0-70 PC200-6Z
? PI, p p
W W W P W
0 0 0 0 0
aaaaa
STRUCTURE
HYDRAULIC
AND FUNCTION PUMP

Function
(1) LS valve
The LS valve detects the load and controls
the discharge amount.
This valvecontrolsmainpump discharge
amount Q according to differential pressure
-
APLS (=PP PLS) [called the LS differential
pressure](thedifferencebetweenmain
pump pressure PP and control valve outlet
port pressure PLS).
Main pumppressure PP, pressure PLS {called
the LS pressure) sent by the control valve
output, enter this valve. The relationship be- LS d i f f e r e n t i a lp r e s s u r e APLS
tween discharge amount 0 and differential SAPO3676
pressure APLS, (the difference between main
pump pressure PP and LS pressure PLS) (=
-
PP PLS) changes as shown in the diagram
on the right.

(2) PC valve
When the pump discharge pressure PPI (self-
pressure) andPP2 (other pump pressure) are
high, the PC valve controls the pump so that
no more oil than the constant flow (in ac-
cordance with the discharge pressure) flows
even if the stroke of the control valve be-
comes larger. In this way, it carries out equal
horsepower control so that the horsepower
absorbed by the pump does not exceed the
engine horsepower. PUMP d i s c h a r o e (PPI tPP2) 1 2
In other words, if the load duringthe opera- oressure averaoe
SAPO3440
tion becomes larger andthe pumpdischarge
pressure rises, it reduces thedischarge
amount from the pump; and if the pump
dischargepressure drops, it increases the
discharge amount from the pump. The rela-
tionship between the average of the front
and rear pump discharge pressures (aver-
age discharge amount of F, R pumps (PP1 +
PP2)/2) and pump discharge amount 0 is
shown on the right, with the current given
to the PC-EPC valvesolenoidshown as a
parameter. The pump controller senses the
actual speed of the engine, and if the speed
drops because of an increase in the load, it
reduces the pump discharge amount t o al-
low the speed t o recover. In other words,
whentheload increases andtheengine
speed drops below the set value, the com-
mand current to the PC-EPC valve solenoid
from the controller increases according t o
the drop in the engine speed t o reduce the
pump swash plate angle.

10-77 PC200-6Z
 i

D
I
D
.
STRUCTURE AND FUNCTION HYDRAULIC PUMP

U i n i n u nd i r e c t i o n SAPO4079

3) Operation in minimum direction for pump

discharge amount
The following explains the situation if servo
piston (11) moves to the left (the discharge
amount becomes smaller). When LS differ-
entialpressure APLS becomeslarger (for
example, when the area of opening of the
control valve becomessmallerand pump
pressure PP rises), pump pressure PP pushes
spool ( 6 ) to the left.
When spool ( 6 ) moves, main pump pressure
PP flows from port C to port D, and from
port K, it enters the large diameter end of
the piston.
Main pump pressure PP also enters port J a t
the small diameter end of the piston, but
because of the difference in area between
the large diameter end and the small diam-
eter end of servo piston (11). servo piston
(11) is pushed to the left.
As a result, the swash plate moves in the
direction to make angle smaller.

PC200-6Z
STRUCTURE AND FUNCTION
W i n i a u ad i r e c t i o n
4) When servo piston is balanced
Let us take the area receiving the pressure
at the large diameter end of the piston as
A l , the area receiving the pressure at the
small diameter end as AO, and the pressure
flowing into the large diameter end of the
piston as Pen. If the main pumppressure PP
of the LS valve and the combined force of
force 2 of spring (4) and LS pressure PLS
are balanced, and therelationship is A0 x PP
= A1 x Pen, servo piston (1 1) will stop in
that position, and the swash plate will be
kept at an intermediateposition. (Itwill stop
at a position where theopening of the throt-
tle from portD to port E and from port C to
port D of spool (6) is approximatelythe
same.)
1 I)-7c1
HYDRAULIC PUMP
SAPOIO~O
Atthis point, therelationshipbetweenthe
area receiving the pressure at both ends of
piston (11) is A0 :A1 = 1 :2, so the pressure
applied to bothends of the piston whenit is
balanced becomes PP : Pen = 2 : 1.
The position where spool (6)is balanced and
stopped is thestandard center, and the force
of spring (4) is adjusted so that it is deter-
mined when PP - PLS = 2.2 MPa (22.5 kg/
cm2).
 ,
FUNCTION
STRUCTURE AND HYDRAULIC PUMP

B ar
Minimum d i r e c t i o n

rC P r o l i x switch
Maximum d i r e c t i o n

PC-€PC Va I ve
r, --
I- %O N
OFF // PUlP
”
I /
.. controller

Resister
1 I
d SAPO3445

(2)PC valve
1) When pump controller is normal
a. When the load on the actuator is small and
pump pressures PP1 and PP2 are low
( i
JMovement of PC-EPC solenoid (1)
Thecommandcurrentfromthepump
controller flows to PC-EPC solenoid (1).
This command current acts on the PC-
EPC valve and outputs the signal pres-
sure. Whenthissignal pressureis re-
ceived, the force pushing piston (2) is
changed.
On the oppositeside to the force push-
ing this piston (2) is the springset pres-
sure of springs (4) and (6) andpump
pressure PP1 (selfpressure) and PP2
(other pumppressure) pushing spool (3).
4 Piston (2)stops at a position where the
combined force pushing spool 13) is bal-
anced, and the pressure (pressure of port
C) output from the PC valve changes ac-
cording to this position.
The size of command current X is deter-
mined by the nature of theoperation
(leveroperation), the selection of the
working mode, andthe setvalueand
actual value for the engine speed.
* Other pump pressure
This is the pressure of the pump at the
opposite end.
For the F pump, it is the R pump pres-
sure
For the R pump, it is the F pump pres-
sure

PC200-6Z 10-27
a

.
STRUCTURE
HYDRAULIC
AND FUNCTION PUMP

Port C of the PC valve is connected to

port E of the LS valve (see (1) LS valve).
Self pressure PP1 enters port B and the
small diameter end of servo piston (91,
and other pump pressure PP2 enters port
A.
When pump pressures PP1 and PP2 are
small, spool (3) is on the left. At this
point, port C and port D are connected,
and the pressure entering the LS valve
becomes drain pressure PT. The pres-
sure entering the large diameter end of
the pistonfromport J becomes drain
pressure PT, and servo piston (9) moves
to the right. In this way, the pump dis-
charge amount moves in the direction
of increase.
As servo piston (9) moves further, pis-
ton ( 7 ) is moved to the left by slider (8).
Springs (4) and (6)expand and the spring
force becomes weaker. When the spring
force becomes weaker, spool (3)moves
to the right, so the connection between
port C and port D is cut, and the pump
discharge pressure ports B and C are
connected. As a result, the pressure at
port C rises, andthe pressure at thelarge
diameter end of the piston also rises, so
the movement of piston (9) to the right
is stopped.
In other words, the stop position for pis-
ton (9) (= pump discharge amount) is
decided at the point where the force of
springs (4) and ( 6 )and the pushing force
from the PC-EPC valve solenoid and the
pushing force created by pressures PP1
and PP2 acting on spool (3)are in bal-
ance.

PC200-6Z 10-29

STRUCTURE AND FUNCTION
b. When load on actuator is large and pump
discharge pressure is high
Whentheloadis largeandpumpdis-
charge pressures PPI and PP2 are high,
the force pushing spool (3)to the left
becomes larger and spool (3) moves to
the position shown the in diagram above.
When thishappens, as shown i n the dia-
gram above, part of the pressurized oil
from port A flows out through the LS
valve from portC to portD and the pres-
surized oil flowing from port C to the LS
valvebecomesapproximatelyhalfof
main pump pressure PP.
When port E and port G of the LS valve
are connected(see (1) LS valve), the pres-
sure from port J enters the large diam-
eter end of servo piston (9), and servo
piston (9) stops.
10-30
,
HYDRAULIC PUMP
If main pump pressure PP increases fur-
ther and spool (3) moves further to the
left, main pump pressure PP1 flows to
port C and acts t o make the discharge
amount the minimum. When piston (9)
moves t o the left, piston (7) is moved to
the left. For this reason, springs (4) and
( 6 ) are compressed and push back spool
(3).When spool (3) moves t o the left,
the opening of port C and port D be-
comes larger. As a result, the pressure
at portC (= J) drops, and piston(9) stops
moving to the left.
Theposition in whichpiston (9) stops
when this happens is further to the left
than the position when pump pressures
PP1 and PP2 are low.
PC200-6Z
I&-01 29-0023d
STRUCTURE AND FUNCTION HYDRAULIC PUMP

_ . -

Maximum d i r e c t i o n

SAPO3450

2 ) When pump controller is abnormal and PC

prolix switch is ON
a. When load on main pump is light
If there is a failure in the pump control- At this point, port C is connected to the
ler, turn PC prolix switch ON to switch drain pressure of port D, and the large
t o t h e resistor side. Inthis case, the diameter end of the piston of servo pis-
power source is taken directly from the ton (9) also becomes the drain pressure
battery. But if the current isused as it is, PT through theLS valve. When this hap-
it is toolarge, so use the resistor t o con- pens, the pressure at the small diameter
trol the current flowing to PC-EPC valve end of the piston is large, so servo pis-
solenoid (1). ton (9) moves in the direction to make
When this is done, the current becomes the discharge amount larger.
constant, so the force pushing piston (2)
is also constant.
If main pump pressures PPI and PP2 are
low,thecombined forceofthe pump
pressure and the force of PC-EPC valve
solenoid (1) is weaker than the spring
set force, so spool (3)is balanced at a
position to theleft.

10-32 PC-700-A7
STRUCTURE
HYDRAULIC
AND FUNCTION PUMP

SAP03451

-
b. When main pump load is heavy
In the same way as in the previous item,
when the PC prolixswitch is ON, the
command current sent to PC-EPC valve
solenoid (1) becomes constant. For this
reason, the force of piston (2) pushing
spool (3) is constant.
If mainpump pressures PP1 and PP2
increase, spool (3)moves further to the
left than when the main pump load is
dischargeamount Q is determined as
shown in the d,iagram for..the value of
the current sent to thePC-EPC valve so-
lenoid through the resistor.
The curve when the PC prolix switch is
ON is curve @, which is to the left of
curve ( iJ
for when the pump controller is
normal.
I

light, and is balanced at the position in

the diagram above.
In this case, the pressure fromport A
flows to port C, so servo piston (9) moves
to theleft (to make the discharge amount
smaller) by the same mechanism as ex-
plained in Item 2)-b, and stops at a posi-
tion to the left of the position when the
load on the pump is light. In other words,
even when the PC prolix switch is ON,
the curve for the pump pressure PP and

PC200-6Z
TION AND STRUCTURE OIL flLTER

IN-LINE OIL FILTER

XlOBVU84

1. Pressure test ports Outline

2. Element 1x2) Onein-line oil filter is installed to discharge
3. Case side of the main pump to prevent the entry
of dirtanddust,andtoprotectthecircuit
A. To control valve and equipment.
B. From pump

10-33-1 P f7 m 4 7
I
STRUCTURE AND FUNCTION
CONTROL VALVE
- ..
1. Bspool valve
2. Cover 1
3. Cover 2
4. Junctionbox
a. Port PP1 (from rear main pump)
b. Port PP2 (from front main pump)
c. Port A6 (to arm cylinder head)
d. Port B6 (to arm cylinder bottom)
e. Port A5 (to L.H. travel motor)
f. Port B5 (to L.H. travel motor)
9. Port A4 (to swing motor)
h. Port B4 (to swing motor)
i. Port A3 (to boom cylinder bottom)
j. Port B3 (to boom cylinder head)
k. Port A2 (to R.H. travel motor)
I. Port B2 (to R.H. travel motor)
m. Port A I (to bucket cylinder head)
n. Port B1 (to bucket cylinder bottom)
u. Port T (to tank)
v. Port CP1 (to port CP3)
w. Port cP2 (to port CP4)
x. Port cP3 (to port CPI)
y. Port CP4 (to port CP2)
aa. Port PLSl (to rear pump control)
ab. Port PLS2 (to front pump control)
bb. Port TS (to tank)
cc. Port BP1 (PPC output pressure for boom
RAISE)
1 0-34
CONTROL VALVE
Outline
Thiscontrolvalveconsistsofthebspool
valve (an integrated composition).The junc-
tion box is installed to this.
Each valve isformedinto one unitby the
connection bolt, and the passages are inter-
nally connected, so the structureis compact
and is very easy to service.
This control valve consists of one spool for
one item of the work equipment, so it has a
simple structure.
dd. Port PX (from 2-stage relief solenoid
valve: pressure rise type)
ee. Port BP3 (from travel PPC valve)
ff. Port BP2 (from PPC valve)
pa. Port P12 (from arm PPC valve)
pb. Port P I 1 (from arm PPC valve)
PC. Port P I 0 (from L.H. travel PPC valve)
pd. Port P9 (from L.H. travel PPC valve)
pe. Port P8 (from swing PPC valve)
pf. Port P7 (from swing PPC valve)
pg. Port P6 (from boom PPC valve)
ph. Port P5 (from boom PPC valve)
pi. Port P4 (from R.H. travel PPC valve)
pj. Port P3 (from R.H. travel PPC valve)
pk. Port P2 (from bucket PPC valve)
pl. Port P1 (from bucket PPC valve)
pm. Port P-2 (from service PPC valve)
pn. Port P-1 (from service PPC valve)
PO. Port P-4 (from service PPC valve)
pp. Port P-3 (from service PPC valve)
pq. Port P-6 (from service PPC valve)
pr. Port P-5 (from service PPC valve)
PC200-6Z
AND STRUCTURE CONTROL V A L M

f i

h I n aa

u ~ b v vd f vh v i P I dd

bb W' a b b l
4 SAPO3966

K200-6Z 10-35
 Y

W
I
W
c

.
 STRUCTURE AND
FUNCTION VALVE CONTROL

I3 14 13 14 I3

13 14 I3 14 13
c-c SAP03214

1. Pressurecompensation valve(Arm) 8. L.H. travel spool

2. Pressure compensation valve (L.H. travel) 9. Swing spool
3. Pressurecompensation valve (Swing) 10. Boom spool
4. Pressurecompensation valve (Boom) 11. R.H. travel spool
5. Pressurecompensation valve (R.H. travel) 12. Bucket spool

- 6. Pressurecompensation
7. Arm spool
valve (Bucket) 13.
14.
Safety-suction valve
Suction valve

PC200-6Z 10-37
cb
03

..
-.
0
a
w
I .
z
r.
e

0
0
3

I.
2
E.
e

.
STRUCTURE AND FUNCTION COKTROL VALVE

’\

L- L K-K

M-M JJ-JJ SAPO3968

1. Unload spool
2. Main relief valve (Pressurerisetype)

PC200-62 10-39
STRUCTURE AND FUNCTION VALVE CONTROL

J-J

J
MM-MM

EE-EE

SAPO3199

1. LS shuttle valve
2. LS selectvalve
3. LS bypass valve

10-40 Dr3M.X7
STRUCTURE AND FUNCTION VALVE CONTROL

SAFETY-SUCTION VALVE FOR SERVICE VALVE

1. Suction valve
2. Main valve
3. Piston
4. Piston spring
5. Poppet
6. Poppet spring
7. Suction valve spring
8. Sleeve
9. Adjustment screw
10. Locknut
SBPoo19a

SPECIFICATION

Part NO. 1 pressure Set I Use

709-70-74800 I 20.58
MPa (210kg/cm2) at 190 Urnin I For breaker (Okada)

709-70-75100 20.09 MPa (205 kg/cm2)at 5 t h i n For breaker (Mitsubishi Krupp)

709-70-75300 16.66 MPa (170 kg/cm2)at 190 Urnin For breaker (Matsuda)

709-70-74600 24.5 MP (250 kg/cm2)a t 5 Umin For crusher (Okada)

PC200-6Z 10-41
STRUCTURE AND FUNCTION SELF-REDUCING
VALVE
PRESSURE

SELF-REDUCING PRESSURE VALVE

L J L J
e
a

E:

E:

SAP03258

a. Port P1 (from front pump)

b. Port PR (supply to. electromagnetic valve, PPC
valve, EPC valve)
c. Port T (to hydraulic tank)
d. Port PC (to front pump LS valve)

1 0-42
STRUCTURE AND FUNCTION SELF-REDUCING PRESSURE VALVE

I 7 6 5 4
A- A

IO 9
B-B SAPO3259

1. Control valve block 6. Spring (reducing valve pilot)

2. Valve (sequence valve) 7. Spring (reducing valve main)
3. Spring 8. Spring (reducing valve)
4. Screw 9. Spring (safety valve)
5. Poppet 10. Ball

PC200-6Z 10-43
 ,
FUNCTION
STRUCTURE
SELF-REDUCING
AND PRESSURE -
VALVE

Function
Thisvalvereduces thedischargepressure of
the main pump and supplies it as the control -
pressure for thesolenoid valve and PPC valve. P2

Operation
1. When engine is stopped
Poppet (5) is pushedagainsttheseat by
spring (61, and the passage from portPR 4
T is closed.
Valve ( 8 ) is pushed to the le& by spring (71, -----_-_____
--,--------,------,,---,!
PR,
and the passagefrom port P1 4PR is open.
I-----

HYDRAULIC CIRCUIT DIAGRU SAPO3299

Valve (2) is pushed to the left by spring (3).
so the passage betweenport P1 + P2 is
closed. (See Fig. 1)

(Fig. 1 ) SAP03300

10-44 PC200-6Z
ZOEhOdVS
I 3 A l V A lOMlN03
FUNCTION
STRUCTURE
AND SELF-REDUCING
VALVE
PRESSURE

4. When there is abnormal high pressure

When pressure PR of the self-reducing pressure
vatve becomes abnormally high, ball (IO)pushes
against the force of spring (91, separates from
the seat, and allows hydraulic oil to flow from
output portPR + T, so pressure PR goes down.
This action protects the equipment at the desti-
nation for the hydraulic pressure supply (PPC
valve, electromagnetic valve,etc.) from abnor-
mally high pressure. (See Fig. 4)

10 9
(F i e. 4 ) SAP03303

1 0-46 Pf7m-6z
0
W

.
 ,
STRUCTURE AND FUNCTION CLSS

Basic principle
1) Control of pump swash plate angle Actuator
The pump swashplateangle (pump dis-
charge amount) is controlled so that LS dif-
ferential pressure APLS (the difference be-
tween pump pressure PP and control valve
outlet port LS pressure PLS) (load pressure
o f actuator) is constant.
(LS pressure APLS = Pump discharge pres-
-
sure PP LS pressure PLS)
Pu
assage

I APu
II
I1 , 'I

1l.t .....",.
I I I r I

4
I l w
Small
PC v a l v e

current II Laroe current

SBP03454

If LS differentialpressure APLS becomes

lower than the set pressure of the LS valve
(when the actuator load pressure is high),
the pump swash plate moves towards the
maximum position; if it becomes higher than
the set pressure of the LS valve (when the
actuatorload pressure is low),the pump
swash plate moves towards the minimum
position.
-I
V
c
LS d i f f e r e n t i a l p r e s s u r e APLS

1 II- A 9
STRUCTURE AND FUNCTION CLSS

2) Pressure compensation
A pressure compensation valve is installed
to theoutlet port side of the control valve to
balance the load.
When two actuators are operated together,
this valve acts to make pressure difference
AP between the upstream (inlet port) and
downstream (outlet port) of the spool of each
valve the same regardless of the size of the
load (pressure).
In this way, the flow ofoil from the pump is
divided (compensated) in proportion to the
area of openings S1 and S2 of each valve.

Load

Pump

I]
1
SBP03456

PC200-6Z 1 0-49
N
\
 STRUCTURE FUNCTION CLSS

1. Main relief valve (2step relief)

Set pressure: 31.9 MPa (325 kg/cm3
2. Unload valve
Set pressure: 2.9 MPa {30 kglcmzl
3. Bucket spool
4. Pressure compensation valve
5. Safety-suction valve
Set pressure: 35.8 MPa (365 kg/cm3
6. LS shuttle valve
7 . R.H. travel spool
8. Suction valve
9. Boom spool
10. Check valve (for boom regeneration circuit)
11. Swing spool
- 12. L.H. travel spool
13. Arm spool
14. Check valve (for arm regeneration circuit)
15. LS select valve

A. To bucket cylinder
B. To R.H. travel motor
C. To boom cylinder
D. To swing motor
E. To L.H. travel motor
F. To arm cylinder

PC200-6Z 1 0-51
STRUCTURE CLSS

1A. Main pump 7A. Pump passage

1B. Main pump 7B. Pump passage
2A. Main relief valve 8. LS circuit
2B. Main relief valve 9A. Tank passage
3. Unload valve 9B. Tank passage
4. Junction block 10. Valve
5A. Control valve 11. Spring
5B. Control valve 12. LS bypassvalve
6A. Actuator
6B. Actuator

10-52 DCM L7
-
STRUCTURE AND FUNCTION CLSS

1. Unload valve
8 1 A

2 D E

Function
When the pump flow is merged and the con-
trol valve group onone side isactuated (with
the remaining control valve group at neu-
tral), the sub-unload valve drains the pump
flow to the group thatis at neutral.

Operation
The pressure in pump passages A is received
at the end portion of valve (1). The control
valve is at neutral, so the pressure in LS
circuit B is 0 MPa (0 kg/cm?.
The pressurized oil in pump passage A is
stopped by valve
cannot
(1) and escape, so A
the pressure rises. When this pressure be-
comes larger than the force of spring (2).
valve (11 moves to the left, ports C and D are
interconnected, and thepump pressure flows
t o tank passage E. In addition, the pressu-
rized oil in LS circuit B passes from orifice f
through port D and is drained to tank pas-
sage E. Therefore, in this operation, t S pres-
sure = tank pressure.
In thisunload operation, pump discharge
pressure - LS circuit pressure is greater than
the pump LS control pressure, so a signal is 2 t D E SBPO3110
sent to set the pump swashplate to the
minimum angle.

PC200-6Z 10-53
STRUCTURE AND FUNCTION CLSS

2. Introduction of LS pressure (LS shuttle valve)

SEP00123

1. Mainpump 4. Valve
2. Mainspool 5. Check valve
3. Pressure compensationvalve 6. LS shuttle valve

Function
LS pressure PLS isthe actuator load pres-
sure at the output side of the controlvalve.
Theupstreampressure (= spoolmeter-in
downstream pressure) of pressure compen-
sation valve (3)is taken inside main spool
(2) and goes t o LS shuttle valve (6).
When this happens, it connects actuator cir-
cuit A and LS circuit PLS through check valve
(51,and sets so that LS pressure PLS 4
tuator load pressure.
Introduction hole a inside main spool (2) has
a small diameter, so it also acts as a throttle.
Operation
When main spool (2) is operated, pump dis-
charge pressure PP starts t o f l o w tactuator
o
circuit A.
First, thispumpdischargepressure PP
passes through introduction hole a of main
spool (21, and is taken t o LS circuit PLS.
When actuator circuit pressure A rises to the
necessary pressure, pump pressure PP rises
and check valve (5) inside main spool (2)
opens. The high pressure of LS circuit PLS
then flows toactuator circuit A.
In this way, LS pressure PLS becomes ai-
most the same as actuator circuit pressure
A.

1 0-54 K200-62
STRUCTURE AND FUNCTION
3. LS bypass valve
1. Main pump
2. Mainspool
3. Pressure compensationvalve
4. LS shuttlevalve
5. LS bypass plug
PC200-6Z
CLSS
5 8 ~ 0 3 2 2I
Function
The residualpressure in LS circuit PLS is
released from orifices b and e.
This reduces the speed of the rise in the LS
pressure, and prevents any sudden change
in the oil pressure. Furthermore, a pressure
loss is generated by the circuit resistance
between LS shuttle valve (4) and throttle a
of main spool (2) according to the bypass
flow from LS bypass plug (5). As a result,
the effective LS differential pressure drops,
and the dynamic stability of the actuator is
increased.
10-55
ION STRUCTURE AND CLSS

4. Pressure compensation valve

Bl -pp
SBP03222

1. Mainpump
2. Valve
3. Shuttle valve
4. Piston
5. Spring
6. LS shuttlevalve

Function Operation ,

When the maximum load pressure is gener-
ated during compound operations and dur-
ing independent operations, andtheload
pressure is higher than other actuators, the
pressure compensation valve acts as a load
check valve t o prevent reverse flow in the
circuit.
If pump pressure PP and LS pressure PLS
are lower than actuator circuit B. shuttle valve
(3)inside the pressure compensation valve
moves to the left in the direction of the ar-
row to interconnect spring chamber c.
When this happens, piston (4) is pushed to
the right in the direction of the arrow by
spring (5).
As a results, valve (2) is also pushed to the
right in the direction of the arrow by piston
(41, so pumpoutletcircuit A closes. This
prevents the oil from flowing back from ac-
tuator circuit B t o pump outlet circuit A.

10-56 pc3m-x7
STRUCTURE AND FUNCTION
Function
During compound operations, if theload
pressure is lower than the other actuators
and the flow of oil starts to increase, the
pressurecompensationvalve carries out
compensation. In this case, it tries to make
theload pressure fortheother actuators
greater and reduce the flow of oil.
PCZOO-6Z
CLSS
Operation
Duringcompound operations, if theload
pressure for the otheractuators rises, the oil
flow in actuator circuit B tries to'r'ncrease.
When this happens, LS pressure.RLS for the
other actuator also increases, so this LS pres-
sure PLS pushes shuttle valve ( 3 b f i t h e pres-
sure compensation valve to the right in the
direction of the arrow, passes through the
passage inside piston (41, and flows tospring
chamber C.
As a results, piston (4) andvalve (2) are
pushed to the right in the direction of the
arrow, and the outlet side of pump circuit
PP is closed, so outlet portpressure A (spool
meter-in downstreampressure) becomes the
same as the outlet portpressure of the other
actuators.
Pumppressure PP (spool meter-in upstream
pressure) is the same between all actuators,
so pump pressure PP and outlet port pres-
sure A become the same between all spools
that are being operated. Therefore, the pump
flow is divided in proportion t o the area of
the opening of each valve.
10-57
 ,
STRUCTURE AND FUNCTION CLSS

5. Shuttle valve inside pressure compensation

valve (arm, swing, boom, bucket valve)

SBPO3224

1. Main pump Function

2. Valve When holding pressureat port A > LS pressure
3. Shuttle valve inside pressure compensation in spring chamber B
valve valve
Shuttle (3)is
pushed t o the right by
4.thePiston pressure circuit
of port
theA, and be-
tween ports A and PLS is shut off. In this
condition, the holding pressure at port A is
taken to spring chamber B, and pushes pis-
ton (4) to the left to prevent piston (4) and
valve ( 2 ) from separating.

10-58 PC200-6Z
 STRUCTURE AND FUNCTION CLSS

SBP03461

- <Surface area ratio of pressure compensation

valve>
The condition of the flow division changes ac-
cording to the ratio of the area of portion A1
and portion A2 of the pressure compensation
valve.
Area ratio = A2/A1.
When area ratio = 1:
Spool meter-in downstreampressure = Max.
load pressure, and oil flowis divided in pro-
portion to area of opening o f spool.
Whenratiq i s h o r e t h a n 1:
Spool meter-in downstreampressure > Max.
load pressure, and oil flow is divided i n a
proportion less than area of openingof
spool.
When ratio is less than 1:
Spool meter-in downstreampressure < Max.
load pressure, and oil flow is divided in a
proportionmorethan area ofopening of
spool.

PC200-6Z 10-59
STRUCTURE AND FUNCTION CLSS

6. Boom regenerationcircuit

1. Main pump Function

2. Mainspool 1) Cylinder
headpressure cylinder bottom
3A. Pressure compensation valve pressure (free fall, etc.)
38. Pressure compensation valve A returnflowcircuitisprovidedfrom the
4A. Suction valve (with safety) cylinder bottom to the cylinder head so that
48. Suction valve (with safety) when the bottom is lowered, the return flow
5. Check valve for boom regeneration circuit can be used toincrease the flow of oil the to
-. -
6. LS shuttlevalve
. - cylinder head.
-*
=:

Operation
When the cylinder head pressure < cylinder
bottom pressure, part of the pressurized oil
from the cylinder bottom passes through the
notch in spool (21, goes through port B, and
enters draincircuit T. Therest of the oil
entersregenerationcircuit C, opens check
valve (5). and passes through ports D and E
to flow back to the cylinder head.

10-60 K200-6Z
.
LY-WCA
29-0 1
E9-0L Z9-0OZX
SBBEOdVS
STRUCTURE AND FUNCTION CLSS

8. LS select vabre
* The diagram shows the situation when the
swing and lefttravel are operatedat the
same time. (BP pressure ON)

1. Valve
2. Spring
3. Piston
4. Piston
5. Swingspool
6. L.H. travelspool
7. Arm spool
8. L.H. shuttlevalve
9. LS circuit

9 SBPO2627
Function
Thisvalveis used to increase the ease of
operating the work equipment. It prevents
high pressure from being generated when
the swing is operated. It also prevents the
high LS pressure from the swingcircuit from
flowing into any other LS circuit when the
swing is operatedtogether with the work
BP
‘OFFJ
equipment.

Operation
When pilot pressure BP is OFF
Pilotpressure BP is OFF, so piston (3) is
T o LS s h u t t l e v a l v e
pushed t o the left by spring (2). If the swing
SBPO3466
isthen operated, swing LS pressure P1
passes through swing spool (5) and enters
port A. It pushes valve (1) to the left and
connects portsA and B. Therefore, swing LS
pressure Pi ff3w.s to LS shuttle valve (8).
When pilot pressure BP is ON
When pilot pressure BP is ON, piston (3)is
moved to the right against spring (2) by the
BP pressure. It pushes valve (1) to the right
and closes the circuit between ports A and
B. As a result, swing LS pressure P1 stops
flowing to LS shuttle valve (81, and even if
T o LS s h u t t l e v a l v e
swing LS pressure P1 rises to a high pres-
SBP03467
sure, it does not influence any other LS cir-
cuit.

10-64 Pc3rnA7
STRUCTURE AND FUNCTION 'CLSS

OPERATION OF CLSS SYSTEM AS A WHOLE

1. When all work equipment is at neutral
* The diagram shows the situation when all work equipment is at neutral.
* The valves and circuits that are not connected with the explanation of the operation of the CLSS
hydraulic system have been omitted.
* For details of this page, see page 90-15.

f
10-65-
1 Pf7nn-A7
 STRUCTURE AND FUNCTION CLSS

1. Hydrau1ic:tank Note: Groupsof control valves by main pump circuit

2A. Main pump (front) Bucket group: Bucket, R.H. travel, boom
28. Main pump (rear) Arm group:Swing, L.H. travel, arm
3A. PC valve (front)
38. PC valve (rear) Operation
4A.LS valve (front) When the levers are at neutral, the pump is
4B.LS valve (rear) at the minimum swash plate angle, and the
5 Junction block oil flow isdrained from unload valve (28A).
6. Bucket spool The LS pressure is connected to hydraulic
7. R.H. travel spool tank (1) by LS bypass valve (31). The LS
8. Boom spool differential pressure APLS (unload pressure
9. Swing spool -tank pressure) atthis point isM L S > pump
10. L.H. travel spool LS control pressure, so the pumpswash plate

- 11. Arm spoo!

12. Pressure compensation valve (bucket)
13. Pressure compensation valve (without
angle is the minimum.

shuttle valve) (R.H. travel)

14. Pressure compensation valve (boom)
15. Pressure compensation valve (swing)
16. Pressure compensation valve (without
shuttle valve) (L.H. travel)
17. Pressure compensation valve (arm)
18. Safety-suction valve
19. Suction valve
20. LS shuttle valve (bucket)
21. LS shuttle valve (R.H. travel)
22. LS shuttle valve (boom)
23. LS shuttle valve (L.H. travel)
24. LS shuttle valve (arm)
25. Check valve (for boom regeneration circuit)
26. Check valve (for arm regeneration circuit)
27. Main relief valve
28. Unload valve
L
29, L S select valve
30. LS check.valve
31.. LS bypass valve '
32. Self-reducing pressure valve

-, -_--
. -
.

PC200-6Z 10-65-2
 3
i
C
R
b
2
U
e
3a

1
n
n
.
 STRUCTURE AND FUNCTION CLSS

Operation -
1I- Bucket group
* When the bucket is operated, pressurized oil
from main pump (2B) flows to the bucket
group. The swash plate angle of main pump
(2B)i s controlled to match the operation of
bucket spool (6).
The LS pressure passing through the inside
of bucket spool ( 6 ) goes to unload spool
(281, and the unloadvalve is closed.

2) Arm group
When the pump flow is divided, all spools
are at neutral, so the oil flow fromthe mini-
.- mum swash'plate angle of main pump (2A)
is all drained from unload valve (28) of the
arm group. All spools in the arm group are
at neutral, so no LS pressure is generated.
-
If the pumppressure LS pressure becomes
greater than the set pressureof unload valve
(281, the unload valve is actuated andthe oil
is drained. The LS differential pressure APLS
at this pointisAPLS > pump LS control pres-
sure, so the pump swash plate angle is the
minimum.

PC200-6Z 10-65-4
STRUCTURE AND FUNCTION CLSS

3. Arm OUT, standard mode relief (cut-off control)

* The diagram shows the arm DUMP and standard mode relief.
* For details of this page, see page 90-19.

.I

10-65-5 w3nn-x7
STRUCTURE AND FUNCTION CLSS

Operation -
1) When pump swash plate angle is controlled

. t o minimum
When the arm is operated to OUT, if the
load increases, the LS pressure passing

. through the inside of arm spool (11) rises.

The LS pressure also goes to unload valve
(28) and unload valve (28) is closed. The
main circuitpressure rises and is relieved at
the standard mode relief pressure.

2) When thishappens, the pump pressuresen-

sor detects it and increases the PC-EPC cur-
rent (electroniccut-offcontrol) t o set the
pump swash plate angle to the minimum.

PC200-6Z 1 0-65-6
STRUCTURE AND FUNCTION .CLSS

4. Bucket DUMP, power max. relief

* The diagram shows bucket DUMP, relief.
* For details of this page, see page 90-21.

10-A.5-7 ~c3nn-x7
STRUCTURE AND FUNCTION CLSS

Operation 1
Relief valve (27) pilot pressure PB ON.

When the bucket is being operated, if the

power max. button is turned ON, pilot pres-
sure PB acts on relief valve (271, so the set
pressure of the relief valve is raised.

When the bucket is operated to DUMP and

the load increases, pump pressure P1 and
LS pressure PLSl both rise. When this hap-
pens, pilot pressure PB controls relief valve
(27) to the same relief pressure as when the
power max. button is operated.

f'C200-6Z 10-65-8
r*
J
5'
x
m
(D

UJ
(0
(D

x
a
(P
(0

zw
 STRUCTURE AND FUNCTION CLSS

Operation -
Whentheboom RAISE is operated, main
pumps (2A) and (2B) are both a t the maxi-
m u m swash plate angle, and unload valve
(28A) is closed.
Atthis point, forthe meter-inopening of
boom spool (81, even if both pumps are at
the maximum swash plate angle, the LS dif-
ferential pressure is set to be smaller than
the pump LS control pressure.
In other words, LS differential pressure APLS
is APLS e pump LS control pressure, so the
pump swash plate angle becomes the maxi-

- mum.
Inadditidn,-theflow of mainpump (2A)
passes through junction block (5) and flows
t o boom spool (8).

PCZOO-6Z 10-65-10
 .
STRUCTURE AND FUNCTION CLSS

6. Swing operatedindependently
* For details of this page, see page 90-25.

10-65-1 1
STRUCTURE AND FUNCTION CLSS

Operation -
When the swingisoperated,unloadvalve
(28) is closed.
When this happens, the oil flow from main
pumps (a, 2B) is controlled by the LS dif-
ferential pressure and is discharged to match
the area of opening of the meter-in of the
swing spool.

PC200-6Z 12
1 0-65-
 .
STRUCTURE AND FUNCTION CLSS

7. Travel operated independently

f For details of this page, see page 90-27.

:
3
1 0-65-1 Pr3nn-x7
 STRUCTURE AND FUNCTION CLSS

Operation -

11
When the straight travel is operated, an oil
flow supplied from the mainpump to match
the amount of movement of left and right
travel spools (10).and (7).
Main pump (2A) oil flow:
To left travel spool (10) (arm group)
Main pump (28) oil flow:
To right travel spool (7) (bucket group)
The ability to travel in a straight line is en-
sured by actuating the pressure compensa-

- tion valves and interconnecting theright

traveland l e f t travel through the pistons of
pressure control valves (13) and (16) and
through the external piping.

2)
From the above condition 1). if the steering
control levers are returned (the oil flow is
reduced) or operated in opposite directions
(FORWARD,and REVERSE), the travel junc-
tion circuit through,,the above piston is cut
off, and the leftand right sides are operated
independently to enable the steering to be
operated.

PC200-62 14
10-65-
STRUCTURE AND FUNCTION CLSS

Operation
1) . When the arm and boom are operated si-
multaneously, the swash plate angle for both
pumps becomes the maximum.
When this happens, the load pressure at the
boom RAISE side is higher than at the arm
side, so the LS pressure passes through ports
E and F of boomspool (81, enters LS shuttle
valve (22) and is sent to the LS circuit. This
LS pressure is transmitted to port G of arm
pressure compensation valve (171, and acts
to increase the set pressure of the pressure
compensation valve. Because of this, the
pressure betyeen port H of arm spool (11)
and port -1 of pressure compensation valve
(17) rises; and spool meter-in LS differential
-
pressure (pump pressure LS pressure =
APLS) becomes the same asthat at the boom
end.

2) Because of theabove operation, the oil flow

is divided in proportion to the size of the
opening area of boom spool ( 8 ) andthe
opening area of arm spool (11).
Meter-in L S differential pressure APLS dur-
ing boom RAISE + arm IN is APLS e boom
LS control pressure, so the main pump
swash plate angle is set to maximum.

K200-6Z 10-65-
16
AND STRUCTURE MOTOR

SWING MOTOR
KMFWAB-3 1

n P

- e d C
SAPO3230

a. Port S SPECIFICATIONS
c. Port M B (from controlvalve)
e. Port M A (from controlvalve)
d. Port T (to tank)
e. Port B (froon;.&ing
valve)
solenoid
brake 87.8 cclrev
Safety valve set 27.9 MPa
pressure (285 kglcrn’)

speed
Rated I 2,260 rprn

Brake releasing 2.1 MPa

(21 kglcrnz) pressure

1 0-66 PC200-6Z
d - /- n
STRUCTURE AND FUNCTION SWING MOTOR

Operation of swing lock

When swing lock solenoid valve is deacti-
vated
When theswing lock solenoid valve is deac-
tivated, the pressurized oil from the main
pump is shut off and port B is connected to
the tank circuit.
As a result, brake piston (7) is pushed down
by brake spring (11, discs (5) and plates (6)
are pushed together, and the brake is ap-
plied.

U SAPO3471

When swing lock solenoid valve is excited

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

W SAP03472

W3M. X 7
 STRUCTURE AND
FUNCTION MOTOR

RELIEF VALVE PORTION

1) Outline
The relief valve portion consists of check
valves (2) and (31,shuttle valves (4) and (51,
and relief valve (1).
2. Function
When the swing is stopped, the outlet port
circuit of the motor fromthe controlvalve is
closed, but the motor continues to rotate
under inertia, so the pressure at.the output
side of the motor becomes abnormally high,
and this may damage the motor.
To prevent this, the abnormally high pres-

- sure oil isreljeved to portS from the outlet

portofthgmotor (high-pressure side) to pre-
vent any damage to the motor.

3. Operation
1) When starting swing
When the swing control lever is operated to
.swing right, the pressure oil from the pump
passes through the controlvalve and is sup-
plied to port MA. As a result, the pressure at
port M A rises, the starting torque is gener- SAPO3473
ated in the motor, and the motor starts to
rotate. The oil from the outlet port of the Froa p o r t S
motor passes from portM B through the con-
trol valve and returns to the tank. (Fig. 1)
2) When stopping swing
When the swing control lever is returned to
neutral, the supply of pressure oil from the
pump to port M A is stopped. With the oil
&
from the outlet port of themotor, the return
circuit to the tank is closed by the control
valve, so the pressure at port MB rises. As a
result, rotation resistance is generated in the
motor, so the braking effect starts.
If the pressure at port M B becomes higher
than thepressure at port MA, it pushes shut-
tle valve A (4) and chamber C becomes the
same pressure as port MB. The oil pressure
rises further until it reaches the set pressure
of relief valve (1). As a result, a high braking
torque acts.on the motor and stops the mo-
tor. (Fig. 2F - F
When the relief valve (1) is being actuated,
the relief oil and oilfromport S passes
through check valve B (3)and is supplied to
port MA. This prevents cavitation at port MA.

PC200-6Z 10-69
 ,
STRUCTURE AND FUNCTION CENTER SWIVEL JOINT

CENTER SWIVEL JOINT

4-PORT SWIVEL

A1

c1

El

E2

A-A

T1 T2 D2
\

B2 A2 c2
Z
SBPW249
-
s
~

.
I

1. Cover 82. To. L.H. travel motor port PA

2. Body C1. From control valve port A2
3. Slipper seal C2. To R.H. travel motor port PA
4. O-ring Dl. From control valve port A5
5. Shaft D2. To L.H. travel motor port PB
El. From travel speed solenoid valve
A l . From control valve port B2 E2. To L.H. and R.H. travel motors port P
A2. To R.H. travel motor port PB T1. To tank
B1. From control valve port B5 T2. From L.H. and R.H. travel motors port T

1 n-7n PC7cx)-6Z
JOINT STRUCTURE
SWIVEL CENTER
AND FUNCTION

&PORT SWIVEL

’\ El

AI

CI

G2
GI

A-A

TI

Z F2 82E2 A2
SBP02643

1. Cover C2. To R.H. travel motor port PA

2. Body Dl. From control valve port A5
3. Slipper seal 5 D2. To L.H. travel motor port PB
4. Oil seal E l . From control valve port A3
5. Shaft E2. Blind
F1. From control valve port B3
A l . From control valve port B2 F2. Blind
A2.To R.H. travel motor port PB G1. From travel speed solenoid valve
B1. From control valve port 85 G2.To L.H. and R.H. travel motors port P
&

B2. To. L.H. travel motor port PA T1. To tank

C1. From control valve port A2 T2. From L.H. and R.H. travel motors port T

FC200-6Z 10-71
p ? pfu
w www
0 0 0 0
aaaa

PW

I
I I
1 . . .

\
fY
STRUCTURE AND FUNCTION TRAVEL MOTOR

\i

\b 9
A-A c-c

23 22 21 20
E-E D-D SAPO2754

. -
-+
7 :

1. Regulator piston 9. Check valve spring 17. Valve plate

2. Spring 10. Output shaft 18. Counterbalance valve
3. Regulator valve 11. Swash plate 19. Ring
4. Spring 12. Retainer guide 20. Spool return spring
5. Motor case 13. Pin 21. Brake piston
6. Suction safety valve spring 14. Piston 22. Plate
7. Suction safety valve 15. Retainer 23. Disc
8. Check valve 16. Cylinder 24. Ball

PCZOO-6Z 1 0-73
 ,
STRUCTURE AND FUNCTION TRAVEL MOTOR

OPERATION OF MOTOR
1) Motor swash plate angle (capacity)at maxi-
mum

The solenoid valve is deactivated, so the pi- * At the same time, the pressurized oil at regu-
lot pressure oilfromthemainpumpdoeslatorpiston (15) passes through orifice c in
not
flow :a port P. valve
regulator (9) and is drained to the
Forthis reason, regulatorvalve (9)ispushedmotor
to the right in thedirectionofthearrow
spring (10).
by - case.
As a result, swash plate (4) moves in the
angle plate
maximum swash direction, the
Because of this, it pushes check valve (22). motor capacity becomes maximum.
and the mainpressure oil from the control
valve going to end cover ( 8 ) is shut off by
regulator vzlve (9).
Fulcrum a of swash plate (4) is eccentric to
point offorce b of the combined force of the
propulsion forceof cylinder (61, so the com-
bined force of the piston propulsion force
acts as a moment toangle swash plate(4) in
the direction of the maximum swash plate
angle.

10-74 PC200-6Z
. .

J
AND STRUCTURE FUNCTION TRAVEL MOTOR

OPERATION OF'PARKING BRAKE

1) When starting to travel
When the travellever is operated, the pres-
surized oil from the pump actuates counter-
balance valve spool(191, opens the circuitto
the parkingbrake, and flows into chamberA
of brake piston (12).
It overcomes the force of spring (111, and
pushes piston(12) to the left in the direction
of the arrow.
When this happens, the force pushing plate
(13) and disc (14) together is lost, so plate
(13) and disc (14) separate and the brake is
released. -

SAP03480

2) When stopping travel

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

II 14 13 12 SAPO348 I
 STRUCTURE AND FUNCTION TRAVEL MOTOR

I
Trrvsl control v a l v s

OPERATION OF BFMKE VALVE

The brake valve consists of a suction safety
valve (18A), counterbalance valve (18) in a
circuit as shown in the diagram onthe right.
(Fig. 1)
The function and operation of each compo-
nent is as given below.

1) Counterbalance valve, check valve

Function
When traveling downhill, the weight of the
machine makes it try to travel faster than
the speed of the motor.
As a result,=if the machine travels with the
engine at low speed, the motor will rotate

u
without loadand the machine will run away,
which is extremely dangerous.
To prevent this, these valvesact to make the T r a v a l control rrlrr
machine travelaccording to the engine speed
(pump discharge amount).

Operation when pressure oil is supplied

When the travel lever is operated, the pres- IdA
surized oil from the control valve is supplied
t o port PA. It pushes open suction safety
valve (18A) and flows from motor inlet port
M A to motor outlet port MB.
However, the motor outlet port isclosed by
suction safety valve (18B) and spool (191, so
the pressure at the supply siderises. (Fig. 2 )

/
19

. The pressurized oil at the supply side flows

from orifice El and E2 in spool (19) to cham-
ber S1. When the pressure in chamber S1
goesabovethespoolswitching pressure,
spool (19) is pushed to theright 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, fid?he motor starts to rotate. (Fig.
3)

PC200-6Z 10-77
AND STRUCTURE TRAVEL MOTOR

Operation of brake when traveling downhill

If the machine triestorun away when
traveling downhill, the motorwill turn under
no load, so the pressure at the motor inlet
port will drop, and the pressure in chamber
S1 through orifices E l and E2 will also drop.
Whenthe pressure in chamber S1 drops
below the spool switching pressure, spool
(19) is returned to theleft in the direction of
the arrow by spring (201, and outlet portMB
is throttled.
As a result, the pressure at the outlet port
side rises, resistance is generated to the ro- t
tation of the motor, and this prevents the
machine from running away.
In other words, the spool moves to a posi-
tion where the pressure at outlet port MB
balances the pressure at the inlet port and 19
the force generated by the weight of the
machine. theIt throttles circuit
outlet port SAP03405
and controls the travel speed according to
the amount of oildischarged from the pump.
(Fi.9 4)
2) Safety valve
Function
When travel is stopped (or when traveling
downhill), the circuits at the inlet and outlet
ports of the motor are closed by the coun-
terbalance valve, but the motor is rotated by
inertia, so the pressure at the outlet port of
the motor will become abnormally high and
damage the motor or piping. The safety valve
acts to release this abnormal pressure and
send it to the: inlet port side of the motor to S I
prevent damage to the equipment.
Operation
t
1) When travel is stopped (or when traveling
downhill, rotating t o right)
When the motorinletport pressure (pres-
sure PA) goes down, the pressure in cham-
ber S1 also goes down. When it goes below
the switching pressure of the spool, spool
I
AI
w
IF i e. 5)
--'* ' SAPO3486
(19) is returned to the left by spring (201,
and outlet port passage B1 is throttled. When
this happens,&e motor continues to rotate
under ineda: so the outlet pressure (pres-
sure MB) rises. (Fig. 5)
If the pressure goes above the set pressure
of suction-safety valve (18A1, the poppet
opens.The oilthen passes through large
notch A1 in counterbalance valve spool (19)
and flows to chamber M A in the circuit on
the opposite side. (Fig. 6 )
MA
2) When rotating t o left
The operation is the reverse of when rotat- (F I 0. 6) SAP03487
ing to the right.
1 n-752 PC7N-X7
 .
STRUCTURE AND FUNCTION TRAVEL MOTOR

31 Whenstartingtravel(orduringnormal
travel)
When the travel lever is operated, the pres-
sure oil from the pump moves counterbal-
ance valve spool (19) to theright. When this
happens, the passage to the suction-safety
valve becomes the circuit flowing through 1IA
the small notch in thecounterbalance valve
spool. As a result, a big difference in pres-
sure is created, and the pump pressure rises
to provide a powerful drawbar pull. (Fig. 7)

W
(F i e. 7)

PC200-6Z 10-79
 ,
STRUCTURE AND FUNCTION VALVE CONTROL

VALVE CONTROL +

SVPO5544

.
-*
-
Lever positions
7. Travel P P f valve 9. Hydraulic pump @ HOLD @ Swing RIGHT
2. Service PPC valve 10. Junction box 0 Boom RAISE @ Swing LEFT
3. Service pedal 11. Accumulator @ Boom LOWER @ NEUTRAL
4. L.H. travel lever 12. EPC solenoid valve 0 Bucket DUMP @ Travel REVERSE
5. R.H. travel lever 13. L.H. work equipment 0 Bucket CURL @ Travel FORWARD

-- 6.
7.
R.H. PPC valve
R.H. work equipment
lever
lever
14. L.H.PPC valve
15. Safety lock lever
@ HOLD
0A r m IN
@ Arm OUT
@ LOCK
@ FREE

8. Control valve

PCZOO-6Z 10-81
4

? 71'11'1197171
00 0 0 0 0 0 0
h) aaaaaa
STRUCTURE AND FUNCTION WORK EQUIPMENT SWING PPC VALVE

-u
i’ A- A c-c

/-----
11

D-D

B-B

E-E
SBPW274

1. Spool --- 7. Joint

2. Metering &ring 8. Plate
3. Centeringspring 9. Retainer
4. Piston 10. Body
5. Disc 11. Filter
6. Nut (for connecting lever)

PC200-6Z 10-83
STRUCTURE AND FUNCTION WORK EQUIPMENT SWING PPC VALVE

OPERATION
1) At neutral
Ports A and B of the controlvalve and ports
P1 and P2 of thePPC valve are connected to
drain chamber D through fine control holef
in spool (1). (Fig. 1)

2) During fine control(neutralfinecontrol)

When piston (4) starts t o be pushed by disc
(5).retainer (9) is pushed; spool (1) is also
pushed by metering spring (21, and moves (Fie. 1)
down. SBPO3493
When this happens, fine control hole f is
shut off from drain chamber D, and at al-
most thesame time, it is connected to pump
pressure chamber PP, so pilot pressure oil
from the main pump passes throughfine
control hole f and goes from portP1 to port
A.
Whenthepressureatport P1 becomes
higher,spool (1) ispushed back andfine
control hole f is shut off from pump pres-
sure chamber PP. At almost the same time,
it is connected to drain chamber D t o re-
lease the pressure at port P1. When this h a p
pens, spool (1) moves up or down so that
the force of metering spring (2) is balanced
with the pressure at port P1. The relation-
ship in the position of spool (1) and body
(10) (fine control holef is at a point midway
between drain hole D and pump pressure
chamber PBt 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 a t port
P1 also rises in proportion to the travel of
the control lever. In this way, the control
valve spool moves to a position where the
pressure i n chamber A (the same as the pres- ( F i e . 2) SBP03494
sure at port P1) and the force of the control
valvespoolreturnspring are balanced.
(Fig.2)

1 0-8A PC7047
STRUCTURE
FUNCTION
AND WORK EQUIPMENT SWING PPC VALVE

3) During fine control

(when controllever is returned)
When disc ( 5 )starts to be returned, spool (1)
is pushed up by the force of centering spring
(3)and the pressure at port P1.
When this happens, fine control hole f is
connected to drain chamber D and the pres-
sure oil at port P1 is released.
If the pressure at portP I drops too far, spool
(1) is pushed down by metering spring (21,
and fine control hole f is shut off from drain
chamber D. At almost the same time, it is
connected to pump pressure chamber PP,
and the pump pressure is supplied until the
pressure at port PI recovers to a pressure
that corresponds to the lever position.
When thespool of the controlvalve returns,
oil in drain chamber D flows in from fine
control holef' in the valve on the side that is
not working. The oil passes through port P2
and enters chamber B to fill the chamber
with oil. (Fig. 3)

(F ia. 3)
SBP03495

4) A t full stroke
When disc (5) pushes down piston (41, and
retainer (9) pushes down spool (11, fine con-
trol hole f is shut off from drain chamber D,
and isconnected with pump pressure cham-
ber PP. Therefore, the pilot pressure oil from
the main pump passes through fine control
holef and flows to chamber A from port P1,
and pushes the control valve spool.
The oil returning from chamber B passes
from portP2 through finecontrol hole f' and
flows to drain chamber D. (fig. 4)

(F i a. 4)
SBP03496

PC200-6Z 10-85
4

? N
CK, w w w w w w
0 0 0 0 0 0
0. aaaaaa
STRUCTURE AND FUNCTION TRAVEL PPC VALVE

OPERATlON
1) At neutral
Ports A and B of the control valve and ports
P1 andP2 of the PPC valve are connected t o
drain chamber D through fine control holef
in spool (I). (Fig. 1)

2 ) Fine contrd (neutral + fine control)

When pistonj 4 ) starts to be pushed by disc
(51, retainer (9) is pushed. Spool (1) is also
pushed by metering spring (2) and moves (Fie. 1).
SBP03497
down.
When this happens, finecontrolhole f is
shut off from drain chamber D. At almost
the same time, it is connected to pumppres-
sure chamber PP, and the pilot pressure of
the main pump is sent from port A through
fine control holef to port P1.
When the pressure at port P1 rises, spool (1)
is pushed back. Fine control hole f is shut
off from pump pressure chamber PP. At al-
most the sametime, it is connected to drain
chamber D, so the pressure at port P1 es-
capes.
As a result, spool (1) moves up and down
until the force of metering spool (2) is bal-
anced with the pressure of port P1.
The relationship of the position of spool (1)
and body (10) (fine control hole f is in the
middle between drainhole D and pump pres-
sure chamber PPI does not change until re-
tainer ( 9 ) contacts spool (1).
Therefore, metering spring (2) is compressed
in proportion to the travel of the control le-
ver, so the pressure at port P1 also rises in
proportion to the travel of the controllever.
In this way, the spool of the control valve (F i 0. 2)
moves to a_ w s i t i o n where the pressure of SBP03498
chamber A' (Same as pressure at port P1)
andtheforceofthereturn spring of the
control valve spool are balanced. (Fig.2)

Pf700-A7
 STRUCTURE AND FUNCTION VALVETRAVEL PPC

3) Fine control (control lever returned)

When disc (5)starts to be returned, spool (1)
is pushedup by theforce of centering spring
(3)and the pressure at port PI.
Because of this, fine control hole f is con-
nected t o drain chamber D, and the pressu-
rized oil at port P I is released.
If the pressure a t port P I drops too much,
spool ( 7 ) is pushed up by metering spring
(21, 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 P I supplies the
pump pressure until the pressure recovers
to a pressure equivalent to the position of
the lever.
When the control valve returns, oil in drain
chamber D flows in from fine control hole 'f
of the valve on the side that is not moving.
It passes through portP2 and goesto cham-
ber B t o charge the oil.
(Fig. 3) & i o . 3)
SBP03499

4) A t full stroke
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 to pump pressure chamber PP.
Therefore, the pilot pressure oil from the
main pump passes through fine control hole
f and flows to chamber A from port P l 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 cham-
ber D. (Fig. 4)

(F i 0. 4)
SBP03695

PC200-6Z 10-89
3

IP
UW
v-uvv
0 0 0 0
aaaa

5
U
 ,
STRUCTURE AND FUNCTION SERVICE PPC VALVE

OPERATION
A t neutral
The pressurized oil from the control pump
enters from port P and is blocked by spool
(9).
Ports A and B of'the control valve and ports
a and.b of the PPC valve are connected to
drain port T through fine control hole X of
spool (9).

SBP03500

-
When operated
When cam (2) is moved, metering spring ( 8 )
is pushed by ball (31,piston (41, and sleeve
(61, and spool (9) is pushed down by this.
As a result, fine control hole X is shut off
from the drain circuit. At almost the same
time, fine controlportion Y is connected with
port a, and the pressurized oil from port P
flows from port a to port A of the control
valve.

SBP03501

PC200-6Z 1 0-91
STRUCTURE AND FUNCTION SERVICE PPC VALVE

When the pressure at port a becomes higher,

spool (9) is pushed back by the force acting
on the end of the spool. When fine control
portion Y closes, fine control hole X is con-
nected to the drain circuit at almostthe same
time.
As a result, spool (9) moves up and down to
balance the force at port a and the force at
metering spring (8).
Therefore, metering spring ( 8 )is compressed
in proportion to the amount the control le-
veris moved. The spring force becomes
larger, so the pressureat port a also in-
creases in proportion to the amount the con-
trol lever is operated.
In this way, the control valve spool moves
to a position where the pressure of port A
(the same as the pressure at port a) is bal-
anced with the force of the return spring of
the valve spool. SBP03502

10-92 PC200-6Z
 STRUCTURE AND FUNCTION ACCUMULATOR

-
ACCUMULATOR
FOR PPC VALVE

1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oilport

Specifications
Type of gas : Nitrogen gas
Gas volume : 300 cc

SDPO I626

Function
Theaccumulatorisinstalledbetweenthe
main pump and the PPC valve. Even if the
engine is stopped with the work equipment
raised, pilot oil pressure is sent to the main
control valveby the pressure of the nitrogen
gas compressed inside the accumulator, so
it is possible to lower the work equipment
under its ownweight.

Operation
Before actuation
After
actual ion
After the engine stops, when the PPC valve
is at neutral, chamber A inside the bladder A A
is compressed by the oil pressure in cham-
ber B.
If the PPC v%lGSis operated, the oil pressure
in chamber B becomes less than 2.9 MPa
(30 kg/cmq, so the bladder expands under 0 0
the pressure of the nitrogen gas in chamber
A. The oil entering chamberB is sent as the
pilot pressure to actuate the main control
c valve.

SEPO1628

PC200-6Z 10-93
FUNCTION
STRUCTURE AND STRAIGHT-TRAVEL SYSTEM

STRAIGHT-TRAVEL SYSTEM

L H. t r a v e l motor R. H. t r a v e l rotor

I
j
r-
-
- -I

I I

j I
j I
I i
T r a v e l PPC v a l v e

Pressur v a l v e

J SAP03081

Function
This system interconnects the pressure corn-
pensation valves for L.H. and R.H. travel
FORWARD and REVERSE with external pip-
ing to ensuf&he ability to travel in a straight
Travel
line. Pressure
As shown in the diagram on the right, the compensation

leftandrightports are interconnected

through passage a insidetravel pressure
compensation valve (11.
By setting the throttle in junction circuit a to
a suitable value, it is possible to fulfill the I I I SAPO3504
requirements for steering ability and the abil-
ity to maintain a straight line.

1n - O A PC200-6Z
STRUCTURE AND FUNCTION EPC SOLENOID VALVE

EPC SOLENOID VALVE

FOR PPC LOCK, SWING BRAKE, EPC SOLENOID VALVE 2-STAGE RELIEF

AI

1 2 3

ACC

A1 A3A4 At

ACC PI

\
T SVPO5552

1. PPC lock EPC solenoid valve Al. To PPC valve

2. 2-Stage velief solenoid valve A2. To main valve (2-stage relief valve)
3. Swing brake EPC solenoid valve A3. To swing motor swing brake
ACC. To accumulator
P1. From mainpump
T. To tank

PC200-6Z
10-95
FUNCTION
STRUCTURE AND EPC SOLENOID VALVE

I 1. Connector
\ 2. Movable core
3. Coil
4. Cage
5. Spool
6. Block
7. Spring

7 6

SAP03237

Operation
When solenoid is deactivated
When the signal current does not flow from
the PPC lock switch or swing lock switch,
solenoid (3)is deactivated.
For this reason, spool (5)is pushed fully to
the right by spring (6).
As a result, the circuit between ports P and
A closes and the pressurized oil from the
main pump does not flow to ,the actuator.
At the same time, the pressurized oil from
the actuator flows from portA to port T, and
is then drained to the tank.
SAPO3888
When solenoid is excited
When the signal current flows from the PPC
lock switch or swing lock switch to solenoid
(3). solenoid (3)i s excited.
For this reason, spool (5)is pushed to the
left in the direction of thearrow.
As a result, the pressurized oil fromthe main
pump flows from port P through the inside
of spool (5)to portA, and then flowst o the
actuator. At the sametime, port T is closed,
and this stops the oil from flowing to the
tank.

SAP03889

10-96 PC200-6Z
STRUCTURE AND FUNCTION BOOM HOLDING VALVE

BOOM HOLDING VALVE

.k For machine equipped with arm holding valve, the structure and function of arm holding valve is
the same as this valve.

2 3
a b
\ /

0-0
A-A

tA "-1

d
/

SDPO I32 I

1. Safety-suction valve a. Port T (totank)

2. Pilot spring b. Port Pi (from boom LOWER PPC valve)
3. Pilotspool c. Port Cy (to boom cylinder bottom)
4. Poppet spring d. Port V (from boom control valve)
5. Poppet

PC200-6Z 10-97
STRUCTURE AND FUNCTION BOOM HOLDING VALVE

OPERATION
1) At boom RAISE
When the boom israised, the main pressure
from the control valve pushes poppet (5) up
in the direction of the arrow.
Because of this, the main pressure from the
control valve passes through the valve and
flows to the bottomend of the boom cylin-
der.

21 Boom lever a t NEUTRAL

When the boom is raised and the control
lever is returned to NEUTRAL, the circuit for
the holding pressure at the bottom end of
the boom cylinder is closed by poppet (5),
and at the same time, the oil flowing into
poppet (5)through orifice a of poppet (5) is
closed. by pilot spool (3).
As a result, the boom is held in position.

SBPO3508

10-98 PC200-6Z
 STRUCTURE AND FUNCTION BOOM HOLDING VALVE

3) At 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 in-
side the poppet is drained.
When the pressure at port B 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 by
orifice a.
If the pressure in chamber b drops below
the pressure at port A, poppet (5) opens the
pressurized oil flows from port B to port A,
and then flows to the control valve.
L
If any abwrinal pressure is generated in the
circuit at the bottomend of the boom cylin-
der, safety valve (1) is actuated.

SBPO3509

PC200-6Z 10-99
 STRUCTURE
FUNCTION
ADDITIONAL
AND FILTER FOR BREAKER

ADDITIONAL FILTER FOR BREAKER

* FOR MACHINEEQUIPPED WITH BREAKER

I ' ' I I

i
SBP02669

1. Head cover SPECIFICATIONS

2. Element Ratedpressure : 6.86 MPa (70 kg/cm2)
Case
3. Flow : 102 Umin
4. Drain plug; T- Relief valve cracking pressure:
5. Valve 0.34 f 0.049 MPa
6. Spring (3.5 f 0.5 kg/cm2)
7 . Spring setplug Filter mesh size : 6 pm
Filtering area : 3160 crnz

10-100 PC200-6Z
.
STRUCTURE AND FUNCTION ACTUAL ELECTRICAL WRING DIAGRAM

ACTUAL ELECTRICAL WIRING DIAGRAM

f For details of this page, see page 90-7.

SVPO5545

10-102 PC200-6Z
 >
' I
.I
1. Fuel level sensor
2. Working lamp
33 3. PC control EPC solenoid valve
4. Rear lamp
5. Engine speed sensor
32 \ . .
6. Engine oil pressure switch
7. Washer rank
8. Travel alarm
9. Horn (high tone)
10. Horn (low tone)
11. Battery relay
12. Battery
13. Front lamp
14. PPC lock solenoid valve
15. Swing brake solenoid valve
16. -
V 17. -
18. Engine water temperature sensor
19. Electrical Intakeair heater
20. Air conditioner compressor magnetswitch
21. Engine oil level sensor
22. Alternator
23. Starting motor
24. R.H. additional front lamp
25. Room lamp
26. LH. additional front lamp
27. Wiper motor
28. Alarm buzzer
29. Pump controller
30. Horn.awitch
31. -
32. Monitor panel
33. Starting switch
34. Fuse box
36. -
SVPO5546
36. Wiper switch
37. Swing lock switch
38. Optional lamp switch
39. PPC lock switch
40. Heater
41. Light relay
42. Heater relay
43. -
STRUCTURE AND FUNCTION ELECTRICAL CIRCUIT DIAGRAM

ELECTRICAL CIRCUIT-DIAGRAM
( 1/ a
* For detailIs of this page, see page 90-11.

-"
c
.-
0
c
c
0

OLO

10-104 PC200-6Z
x

.
 .
STRUCTURE AND FUNCTlON ELECTRIC CONTROL SYSTEM

ELECTRIC CONTROL SYSTEM

TOTAL SYSTEM DIAGRAM

L. n.
PPC
va Ive

'C l o c k
l a i t rwitch
R. n.
PPC
va I v e

Travel
PPC !
vs I r e

Engine

7
I

I Main
I
I DUDD
Servo Servo f

I
I valve v Iv I
I
I
I-

Monitor vanel

relay

SVPO5547

10-1 06 K200-62
-1

s
 ,
FUNCTION AND
STRUCTURE ELECTFtIC CONTROL SYSTEM

Function
The pump controller sets the pump absorp-
tion torque to match the engine speed.
When the engine is running at high speed, it
raises the pump absorption torque to boost
the productivity. When the engine is run-
ning at low speed, it throttles the pumpab-
sorption torque to prevent the engine from
stalling.

L
Enrinc srced
\
L

SAP03896

10-108 PC7rn-A7
STRUCTURE AND FUNCTION ELECTRIC CONTROL SYSTEM

Pump controller

CONTROLLER, T V C
SERIAL NO. ma

CN-CO f
/

SAP03228

Input/output signals

1 1 I
CN-COl
Pin No. Name of signal Input/output
1 Pow_erspurce (24V) Input Input
2 NC - Pinio. Name of signal -
InpuVoutput

1 1; 1 fi"~vlo~~lecicif I 1
~ ~~~ ,

L I 1 i
3 Engine speed sensor Input
4 Engine speed sensor GND Input Input
5 Model selection 1 Input resistance Prolix GND Input
I I I I 1 I ~~ I
~~~ i

6 Model selection 2 Input 13 EPC solenoid (-1 output

7 EPC solenoid (+) output

PC200-6Z 10-109
 I

d.
N
STRUCTURE AND FUNCTION ELECTRIC CONTROL SYSTEM

Operation
1) Swing lock function
The swing can be locked at any position
desired by using the swing lock switch

- (manual).
Operation of swing lock switch

Lock switch I Pilot lamp I Function Operation

Swing lock Swing lock is always actuated, and upper structure

ON Lights up
ON does not swing even when swing lever is operated

OFF Goes out

lock Swing lock is canceld, and upper structure swings Swing
OFF when swing lever is operated

2) PPC lock function

The PPC lockswitchis interconnected
with the safetylock lever. When the
safety lock lever is at theLOCK position,
the PPC lock switch is turnedOFF.
When the PPC lock switch is turned OFF,
the electric currentgoing to thePPC lock
solenoid valve is shut off, and the work
equipment will not moveeven if the work
equipment control levers are operated.

PC200-6Z 10-111
 STRUCTURE
MONITOR
MACHINE
FUNCTlONAND SYSTEM

MACHINE MONITOR SYSTEM

buzzer

Switch sional

U Work Iirht
Heater

Battery
SBP03898

FUNCTION
Themachinemonitorsystemmonitorsthe In addition,themonitorpanelisequipped
machine conditions with sensors mounted with switches for each electrical device.
o n each part of the machine, and processes
anddisplayg-theconditiondata t o inform
the operator of the condition.
Details oftheinformationdisplayed on the
monitor panel are as follows:
1. Monitorsectionwhichgivesanalarm
when abnormalityoccurs in the machine.
2. Pilotsectionwhichdisplaysthecondi-
tion of the machine when operated.
3. Gauge section which always displays the
machine condition.

10-112 PC200-6Z i
 I .

STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM

MONITOR PANEL

SXPOOO44

OUTLINE Input and output signal

The monitor panelhasmonitor/displayfunc- CN-P1 (Monitor panel)
r
.- tion and switch function for electrical
de- f No Signal name I
10
vices.
CPU (Central Processing Unit) is mountedin Engine oil- pressure Input
the panel, which processes, displays and out- Charge level Input
puts the data.
The gauge displayuses a liquid crystaldis-
- -
play (LCD) and the monitor display uses ~ Swing lock Input
lamps. ~

Prehearing--- Input

l - -

lo!i 1
i Buzzer output
Night light Input

CN-B (Heater switch)

10.1 Signal name [;.iG1i;nal name ;1
2 Work light 2 Heater Hi Outpul
3 Night light output 3 Heater Lo Outpul
4 +24V

PC200-6Z 10-113
 .
STRUCTURE AND FUNCTiClN MACHINE MONITOR SYSTEM

I 2 3

t
1. Service meter lamp
6. Preheating
pilot
2. Coolant temperature gauge 7. Swing lock pilot lamp
3. Fuel level gauge 8. caution
Charge
level lamp !
4.switch
Light pressure
caution
9. oil
Engine lamp
5. Heater switch

10-114 PC200-6Z
 STRUCTURE AND FUNCTION SENSORS

SENSORS

The signalsfromthe sensorsare input di-

rectly to the panel.
One side of the contact-typesensors is al-
ways connected to the chassis GND.

Classification of indication Type of sensor Sensing type Normal Abnormal

CAUTION ON
Contact type Engine oil pressure OFF

Coolant temperature Resistance type - -

GAUGEGROUP
Fuel level Resistance type - -
d

1) Engine oil pressure sensor

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

-
5. Spring
6. Terminal

S t r u c t u r e of c i r c u i t
Operations (ON) pressure:
49 -c 19.6 kPa (0.5 3 0.2 kg/cm2?
SBDO1537

2) Coolant temperature sensor

1. Connector
2 3
2. Plug
3. Thermistor

Structure of c i r c u i t
SBDOl53B

PCZOO-6Z 10-115
d

.
 ,

20 TESTING AND ADJUSTING

Standard value table for engine related parts .... 20- 2 Testing and adjusting PC valve output
Standard value table for chassis related parts ... 20- 3 pressure (servo piston input pressure) 20-1 15 ....
Standard value table for electrical system ......... 20- 11 Testing and adjusting LS valve output pressure
Tools for testing, adjusting, (servo piston input pressure) and LS

- and troubleshooting
engine
Measuring
...................................
...................................
speed
20-101
20-102
differential pressure
Testing and adjusting control
...................................
20-1 17

Measuring exhaust color .................................. 20-103 circuit-oil pressure .......................................

20-120
Adjusting valve clearance ................................. 20-104 Testing solenoid valve output pressure 20-121 ..........
Measuring compression pressure .......... 20-105 Measuring PPC valve output pressure 20-122 ............
Measuring blow-by pressure ............................ 20-105 Adjusting work equipment, swing PPC valve 20-124 ..
Testing and adjusting fuel injection timing.... 20-106 Testing travel deviation .....................................
20-125
Measuring engine oilpressure' ............ 20-107 Testing locations causing hydraulic drift
Testing and adjusting fan belt tension ........... 20-108 of work equipment .....................................
20-126
Testing and adjusting belttension for air Measuring oil leakage .......................................
20-128 $
conditioner compressor ............................. 20-108 Releasing remaining pressure
Adjusting engine speed sensor ........................ 20-109 in hydraulic circuit ......................................
20-130
Adjusting fuel control lever .............................. 20-1 10 Testing clearance of swing circle bearing 20-131 ......
Testing and adjusting hydraulic pressure in Testing and adjusting track shoe tension ....... 20-132
work equipment, swing, travel circuit...... 20-1 12 Bleeding air ........................................................
20-133
Troubleshooting ..................................................
20-201

.f Notethefollowing when makingjudgementsusingthe standardvalue tables for testing, adjusting, or

troubleshooting.

1. The standard value for a new machine given in the table is the value used when shipping the machine from
the factory and is given for reference. It is used as a guideline for judging the progress of wear after the
machine has been operated, and as a reference value when carrying out repairs.

2. The service limit value given in the tables is theestimated value for the shipped machine based on theresults
of various tests. It is used for reference together with the state of repair and the history of operation to judge
if there is a failure.

3. These standa_rcjvalues are not the standards used in dealing with claims.
1 .~

A When carrying out testing, adjusting, or troubleshooting, park themachine on levelground, insert thesafety
pins, and use blocks t o prevent the machinefrom moving.
When carrying out work togetherwith other workers, always use signals anddo not let unauthorized
people
near the machine.
- A When checking the water level, always wait for the watert o cool down. If the radiator cap is removed when
the water is stillhot, the water will spurt out andcause burns.
A Be careful n o t t oget caught in the fan, fan belt or other rotatingparts.

PC200-6Z 20-1
 .
TESTING AND ADJUSTING
STANDARD
VALUE TABLE
FOR ENGINE RELATED PARTS

STANDARD VALUE TABLE FOR ENGINE RELATED PARTS

Machine model PC200-6Z

Engine S6D102-1

Measurement condition Unit Standard

Item value value

High idling
I I 2,200 70 -
Engine speed Low idling rPm 970 = 50 - 'I
Rated speed 2,000

At sudden acceleration Max. 5.5

Exhaust gas color
At high idling index Max. 0.5
(normal temperature)

-- I
Intake valve 0.25
Valve clearance
Exhaust valve 0.51

t
Difference
between
Oil temperature:
-
40 60°C kzF:2 Min. 2.4
{Min. 24.6) cylinders

r
Compression pressure Min. 1.0
(engine speed: 250rpm) {Min. 10.3)
(SAE15W-40oil)
~~

(Coolant temperature:
Blow-by pressure operating range) kPa Max. 1.2
At rated'output (mmHnO1 (Max. 123)
(SAE30 oil)
(Coolant temperature:
operating range)

At high idling MPa 0.34 0.52 -

Oil pressure (SAE15W-40) {kg/cml (3.5 5.3) -
At low idling Min. 0.1

1
(SAE15W-40) {Min. 1.0)

1 I
I I
1 I

Oil temperature Whole speed range "C 80-110 120

(inside oil pan)

I
Before top deadcenter
'
O
Fuel injection timing (B.T.D.C.) ldegreei l7 17 2 1

Fan-tension Min. 10
pressed 1 8 Max. 6
tension
Belt with finger
force of
approx.
Fan- I
air conditioner
mm I
compressor
5-8 5-8

70-7 i
PC200-6Z I
 TESTING AND ADJUSTING STANDARD VALUE TABLE
FOR CHASSIS RELATED PARTS

STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS

Machine model PCZOO-6Z

1
I
Item Unit Standard value Permissiblevalue
Measurement conditions
- Hydraulic oil temperature:
45 - 55°C
At 2-pump relief
- Coolant temperature: 2,000t100
2,ooOtlOO
Within operating range
. 2-pump relief: Arm relief

Boom control valve e a b e a b

Arm control valve

Bucket control valve mm

9.5*0.5 9.520.5 - 9.520.5 9.520.5
Swing control valve

Travel control valve BLpoo101 I

- Center of lever knob i
- Read max. value to end of
__t__
Boom control lever 100 f 10 100 f 10

Arm control lever travel loo 10

2 100 t 10
Engine stopped
Bucket control lever
. Excluding neutral play

Swing control lever mm 100 t 10 100 * 10

Travel control lever

Play of control lever

Work equipment,
swing I Max. 5 I Max. 5

Travel Max. 10 Max. 10

Boom control lever - Engine at high idling

. Oil temperature: 45 - 55°C
Arm control lever - Fit push-pull scale to center 15.7 t 3.9 15.7 -c 3.9
of control lever knob to (1.6 t 0.4) (1.6 t 0.41
measure 13.7 2 21
.3
9.7 t 2.9
Bucket control lever
- Measure max. value to end
of travel
Swing control lever

Travel confroliever
24.5 t 5.9 24.5 t 5.9
(2.5t 0.6) (2.5 t 0.6)

PC200-6Z 20-3
TESTING AND ADJUSTING STANDARD
VALUE
TABLE
FOR
CHASSIS
RELATED PAWS

Machine model PC200-6Z

cate Item Measurement conditions Unit Standard value Permissible value

gory
- Hydraulic oil temperature:
45 - 55°C 3.9 2 1.0 3.9 f 1.0
Unload pressure . Engine at high idling *
(40 10) (40 f 10)
. All levers at neutral
. Pump output pressure
Boom - Hydraulic oil temperature:
45 - 55°C
5 Arm .Relief pressure with engine
a . . at high idling (Relieve only
En circuit to be measured) MPa
-u Bucket
- Pump outlet port pressure (kgl
3 t: For travel, measure oil cmzl
2 Swing Dressure for relief on one

setf-reckrdng pressurevalve
. Hydraulic oil I Levers at

70-A Pr3M-h7
TESTING AND ADJUSTING
STANDARD
VALUE TABLE FOR CHASSIS RELATED PARTS

Applicable model
T- PC200-62
~

Measurement conditions Unit Standard value 'ermissible value

Work equipment
Max.
reach
-
posture

Swing brake angle deg.

Max. 100 Max. 130
TKPO1115 :mm:
. Engine at high idling
. Hydraulic oil temperature: 45-55°C
. Stop after m'nging one turn and
measure distance that .wn
ig circle
moves -
reach posture

9V Max. 3.7

TKPOl116 SeC.
. Engine at high idling
. Hydraulic oil temperature:
45 - 55°C Max. 5.6
. In WO mode + H mode
. Time taken to swing 90" and
180" from starting position
-
Work
equipment
Max.
reach
posture

Time taken t o swing see. 24 2 3.5 Max. 30

TKPOtllS
. Engine at high idling
. Hydraulic oil temperature: 45-55°C
. In H/O mode + H mode
. Swing one turn, and measure time
taken to swing next 5 turns
-

Hydraulic-drift of swing Engine stopped mm 0 0

I .
- Hydraulic oil temperature: 45-55°C
. Set machine on 15" slope, and set
upper structure at 9
0' to the side.
. Make match marks on swing circle
outer race and track frame.
. Measure distance that match
marks move apart after 5 minutes.
~

. Engine at high idling

Leakage from swing Hydraulic oil temperature: 45-55% /min.
motor . Swing lock switch ON Max. 5 Max. 10
I
- Relieve swing circuit.

PC200-6Z 20-5
TESTING AND ADJUSTING STANDARD
VALUE TABLE FOR CHASSIS
RELATED
PARTS

-T
Applicable model PC200-62

Item Measurement conditions Unit Standard value 'ermissible value

STD STD:
40.5 2 5 -
35.5 48.5
LC LC
44.0 2 5 39.0 * 52.0
BKp#)tOb
Travel speed (1)
- Engine at high idling SeC.
Hydraulic oil temperature:
-
45 55%
- STD STD
- 31.5
- In H/O mode
Raise track on one side ata
27.5 2 2
LC
25.5
LC
time, rotate one turn, then
measure time taken for
30 2 2.5 27.5 - 35
next 5 turns with no load.
t
21 2 2.5 18.5 - 24.5

Travel speed (2) Engine at high idling

- Hydraulic.oil temperature:
45 - 55%
In H/O mode
Run up for at least 10 m, 132 1 12 - 15
and measure time taken to
travel next 20 m on flat
ground.

. Engine at high idling

. Hydraulic oil temperature:
45 - 55°C
. Run up for at least 10 m, and
Travel deviation measure deviation when Max. 200 300
traveling next 20 m on flat
-. - _- ground.
t Use a hard horizontal surface.

* Measure dimension X .
W3M L 7 i
TESTING AND ADJUSTING STANDARD VALUE
TABLE FOR CHASSIS RELATED PARTS

Applicable model PC200-6Z

-
Item Measurement conditions Uni Standard value Permissible value
-

Hydraulic drift of travel mm 0 0

Engine stopped
- Hydraulic oil temperature:
45 - 55°C
. Stop machine on 12" slope
with sprocket facing straight
up theslope.
- Measure the distance the
machine moves in 5 minutes.
-

Leakage of travel rnoto Lock pin !/min 13.6 27.2

TKPO11 I7
8 Engine at high idling
e Hydraulic oil temperature:
45 - 55°C
' Lock shoes and relieve travel
circuit.
-
Work equipment posture
Total work equip-
ment Max. 960 Max. 1,440
(hydraulic drift at
tip of bucket teeth)

Boom cylinder BKPOollO

(amount of retrac- Max. 50 Max. 75
tion of cylinder)
Place in above posture and
measure extension or retrac-
tion of each cylinder and
downward movement at tip of
bucket teeth. mm
Arm cylinder
(amownrof exten- Bucket: Rated load Max. 160
sion of cylinder) Horizontal, flat ground
Levers at neutral
Engine stopped
Hydraulic oil temperature:
45 - 55°C
Start measuring immediately
Bucket cylinder after setting.
(amount of retrac- Max. 35 Max. 53
Measure hydraulic drift every 5
tion of cylinder) minutes, and judge from
results for 15 minutes.

PC200-6Z 20-7
TESTING AND ADJUSTING STANDARD
VALUE
TABLE FOR CHASSIS
RELATED
PARTS

1
-F

Applicable model PC200-62

Boom
Item
I Measurement conditions Unit
- Standard value 'ermissible value

4.020.4 Max. 4.8

Bucket teeth in
contact with grounc
3 -'Engine at high idling
Cylinder fully . Hydraulic oil temperature: 3.0203 Max. 3.4
extended
. In H/O mode
-
45 55'C

Arm 3.620.4 Max. 4.5

Cylinder fully
retracted
3 TKPOI I19
- Engine at high idling
Fully extended Hydraulic oil temperature: 2.920.3 Max. 3.5

- In WO mode
-
45 55'C
I

Bucket 2.820.4 Max. 3.5

Cylinder fully
retracted
3 TKPOlI20
Engine at high idling
Fully extended . Hydraulic oil temperature: see 2.120.3 Max. 2.7
-
45 55°C

J
.......................
BKPOO114
Boom Max. 1.0 Max. 1.2
. Lower boom and measure time
taken from point where bucket
contacts ground to point where
chassis rises from ground
. Engine at low idling
Hydraulic oil temperature:
-_ 45 55°C -

Arm Max. 1.0 Max. 2.8

BKPOO115
- Stop arm suddenly and measure
time taken for arm to stop
Engine at low idling
Hydraulic oil temperature:
45 - 55°C
i
w7m-67
TESTING AND ADJUSTING
STANDARD
VALUE
TABLE FOR CHASSIS
RELATED PARTS

-T
Applicable model PC200-6Z

Item
~~

Measurement conditions
t
Unii Standard value Permissible value

Bucket sec. Max. 1.0 Max. 3.6

- Stop bucket suddenly and

measure time taken for bucket
to stop at bottom and then
start again.
-
- Engine at low idling
Hydraulic oil temperature:
-
45 55'C
-
Cylinders - Hydraulic oil temperature:
45 - 55°C
4.5 20
- Engine at high idling &ni F
Center swivel joint - Relieve circuit to be measured 10 50

c - Engine at high idling

.-0 . Hydraulic oil temperature:
+
m
zQ 45 - 55°C
0
f Use a hard horizontalsurface.

Travel deviation when 20m

work equipment + mm Max. 200 Max. 220
travel are operated

* Measure dimension X.
-

Piston pump See next page See next page

PC200-6Z 20-9 6
TESTING AND ADJUSTING
TSTANDARD VALUE TABLE
FOR CHASSIS RELATED
PARTS

PC200-62 Discharge amount of main piston pump

9. 8 19. 6 29. 4 34.3 39.I 2

( 1001 (2001 ( 3001 ( 3501 (41301
P u m p discharoe o r e s s u r e

Pump speed: At 2000 rpm, PC current 260 m A

Test pump Standard value

Average Discharge Judgement
discharge pressure of pressure for discharge standard lower
Check Point pressure other pump amount Q limit Q
(MPa {kg/cmz)) (MPa (kg/cm2))
(Urnin) (MPa (kglcmz))
(Umin)
P1 + P2
As desifed, P1 P2 See graph See graph
2

* As far as possible, bring pump discharge pressure P I and P2 as close as possible to the
average pressure when measuring.
The error is large near the point where the graph cutves, so avoid measuring at this point.

70-1 0 Pr71K)-A7
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR
ELECTRICAL SYSTEM

STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM

t- Name of
component

Swing lock switch

:onnector
No.

X05
(male)
If the condition is as shown in the table
below. it is normal

When switch Between 0

is OFF

When switch
is
Between @

Between @
-@
-@
Between 0 - @
-@
Max. 1 R
Min. 1 MR

Min. 1 MR
Max. 1 R
Measurement
conditions
1) Turn starting
switch OFF.
2) Disconnect
connector X 0 5

I ~

If the condition is within the range shown in 1) Turn pump

the table below, it is normal prolix switch
OFF.
PC-EPC SQlenoid
C13
(male) I Between 0 - 0 I 7-14R I 2) Disconnect
connector C13.
Between @ - chassisMin. 1 MR
--
If the condition is within the
range shown in 1) Turn starting
the table below, it is normal switch OFF.
2) Disconnect
Swing holding
brake solenoid
V04
(male) I Between 0 - 0 1 20-60 R connector V04.
valve
Gens- 1 I
~~

chassis Min. 1MR

$
If thecondition is within therange shown in 1) Turn starting
the table below, it is normal switch OFF.
PPC oil pressure V07 2) Disconnect
lock solenoid valvc (male) Between 0 -0 20 - 60 R connector V07.
Between @ - chassis Min. 1 M R
- ~ ~ ~~~ ~

If the condition is within the range shown in 1) Turn starting

the table below, it is normal switch OFF.
1 2) Disconnect
Model selection cog 4 0 1 connector.
3) Connect
T-adapter to
section 2 harness side.

-1

f'C200-6Z 20-11
 ,
TESTING
AND
ADJUSTING
. STANDARD
VALUE TABLE FOR ELECTRICAL PARTS

r
n
Name of
component

Power source
voltage

-
I Connectol

col
No. ..

g
29
....-
Judgment table

If the condition is as shown in the table

below, it is normal
20 - 30 V
Measurement
conditions
1) Turn starting
switch ON.
2) Insert
T-adapter.

I
If the condition is as shown in the table 1) Turn starting
below, it is normal switch ON.

I
2) Set throttle
Between @ - @I 320 t 80 mA lever to FULL
solenoid
:@
m t 3) Turn pump
gz prolix switch
OFF.
-
-
L.
m 4) Place all levers
e
c.-
at HOLD.
'S
8 If the condition is as shown in the table 1) Turn starting

2 -2 below, it is normal switch OFF.

2) Disconnect

I -@
3
3
Q
Model Model selection 1 @ No continuity connector.
selection C 3) Connect
col 6 Model selection 2 @-0 Continuity T-adapter to
wiring harness
end.
-
If the condition is as shown in the table 1) Turn starting
-2 below, it is normal switch OFF.
2) Disconnect I
Kerosene
mode
co1
3

C
In normal mode @-@ No continuity connector.
3) Connect
@-@
,
6 In kerosene mode Continuity T-adapter to
wiring harness
end.
I

I Between E3 o) When engine is running (1/2 throttle or above 1) Start engine.

alternator UJ -
+ 27.5 29.5 V
Atternator terminal L gg 3k If the battery is old, or after starting in colc
and areas, the voltage may not rise for some
time.
I
chassis
If the condition is as shown in the table 1) Turn starting
m below. it is normal switch OFF.
2g 2) Disconnect
Coolant
PO7 2m Normaltemperature (25°C) Approx.37 - 50 ki2 connector W7.
temperature
sensor (male) 3:. 3) Insert
=2 100°C Approx. 3.5 - 4.0 kR T-adapter in
connector at
sensor end.
If the condition is as shown in the table 1) Install oil
below, it is normal pressure
measurement
Engine oil pressure gauge.
Min. 1 MO
above 70 kPa (0.7 kg/cm21 2) Remove wiring
harness
Engine oil pressure
sensor - sll terminal.
_7
Man. 1 R 3) Start engine. I
4) Contact tester
between
sensor
terminal and
chassis ground

70-1 2 PC700-6Z i
TESTING AND ADJUSTING STANDARD VALUE TABLE
ELECTRICAL
FOR PARTS

-t
Name of Zonnector lnspecba Measurement
component Judgment table
conditions
~-
If the condition is as shown in the table 1) Turn starting
below, it is normal switch OFF.
2) Disconnect
connector PO6.
3) Drain fuel and
remove fuel
level sensor.
Fuel level sensor 4) Insert
T-adapter in
sensor.
% Connect the
T-adapter to
the connector
and sensor
flange.
If the condition isas shown in the table 1) Turn starting
below, it is normal switch OFF.
I Between @ - @ I50-1,WOR I 2) Disconnect
connector E07.
Between @ - chassis
Min. 1 MR

Engine speed Measure with AC range

sensor 1) insert
T-adapter.
2) Start engine.

Y
u)
1) Screw in until speed sensor contacts ring
gear, then turn back 1 1/6 turn.
2) Sensor should work normally when ad-
justed as above.

PC200-6Z 20- 13
 TESTlNG AND ADJUSTING
TOOLS FOR TESTING,
ADJUSTING, AND TROUBLESHOOTING

TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING

- ~~

Check or measurement item iymbo Part No. Part N a m e Remarks

799-203-8001 Multi-tachometer - . , k 60 2.000 rom
Diaital disDIav -
Engine speed A or H: 60 l9.99grrpm -
- 799-608-1000Tachometer(electricaltype) -
0 3,000 rpm
Coolant and oil temperatures B 799-101-1502 I Digital temperature gauge -99 - 1,299"C
Pressure gauge
799-101-5002 Hydraulic tester 2.5,5.9,39.2, 58.8 MPa
1
(25, 60.
400. 600 kg/cm2)

- 790-261-1203 I Digitalhydraulic tester 1I pr~@~$$kg/cmz)

2 799-401-2320 I Hydraulic
gauge 1.0 MPa {lo kg/cm2)
-
.790-261-1311 Both male and female
14 x 1.5 (female PT 1/81
Both male andfemale
I
Oil pressure c 3 18 x 1.5 (female PT 1/81
0790-261-1331 Both male and female
- 22 x 1.5 (female PT 1/8)
4
- 799-401-2700 I Differentialpressuregauge I (12V)
790-261-1360 Adapter Both male and female
14 x 1.5 (female PT 1/81
790-261-1370 Nut xFor 14 1.5 blind
5
07003-31419 Gasket For blind

-- 07040-11409 I Plug I For 14 x 1.5 blind

l 0 - 6.9 MPa (0-70 kg/cm2}
Compressian pressure' D-
--2
1 Blow-by checker
~ ~~~ ~~

1 799-201-1504 10 - 4.9 MPa (0 - 500mmHzO)

E -
2 795-790-1950 I Nozzle I Orifice
diameter 0 5.613 m m

q
Valve clearance F
-
799-201-9000 1 Handy Smoke Checker
Discoloration 0 70% (with
standard color)

I
Exhaust color I
(Discoloration % x 1/10 =
c0
avaabye
rcially Smoke meter Bosch index)
Air supply pressure
(boost pressure) H 799-401-2201 I Pressure gauge
79A-264-0020 0 - 294Nkg)
(0 - 30
Operating effort J Push-pull scale
79A-264-0090 {O - 50
0 - 490Nkg)

Stroke, hydraulic drift

-
K
Work equipment speed L
Measuring voltage and
resistance values-- M
799-601-7100 T-adapter assembly
799-601-2720 For MIC 13P
Troubleshooting of wiring
harnesses and sensors 799-601-7330 Adapter For S 16P (White)

-
799-601-7360 For relay 5P
Measuring wear of sprockel P 190796-427-1
gauge Wear -
Fuel in'ection timing and
valve dearance 130 Q 795-799-1 Adapter -

PC200-6Z 20-101
 TESTING AND
ADJUSTING MEASURING
SPEED ENGINE

MEASURING ENGINE'SPEED
A w h e n removingorinstallingthe measuring
equipment, be careful not to touch any high
temperature parts.
* Measure the engine speed under the following
conditions.
Coolant temperature: Within operating range
-
Hydraulic oil temperature : 45 55°C

1. Installation of tachometer
1) Mechanical meter
i) Remove the cover under the front pul-
ley, then set probe @ of tachometer A
on stand @ facing pulley (1).
ii) Stick silver paper to pulley (1) at one
place.
iii)Connect probe 0 and tachometerA with
the cable.
A w h e n measuring the speed, be careful
not t o touch any rotating part or high
temperature part.

2) Electric meter
i) Install T-adapter N1 to connector CN-EO7
(2) of the engine speed sensor.
ii) Connect the power source cable to the
battery (24V). BLPO2 114

2. Start the engine, and measure the engine speed

when it is set to the conditions for measuring.
1) Measuring at low idling and high idling:
Measure the engine speed with the fuel con-
trol lever set to low idling and high idling.
2)' Measuring speed at pump relief:
Run the engine at f u l l throttle and measure
the engine speed when the pump isrelieved.
3) Measure the speed at near the rated speed.
Run the engine at full throttle, operate the
arm lever, and measure the speed when the
arm circuit is relieved.

20- 102 Pt70-rs7 I

 TESnNG AND ADJUSTING
MEASURING
EXHAUST GAS COLOR

MEASURING EXHAUST GAS

COLOR
When measuring in the field when there is no
air or power supply, use smoker checker G1,
when recording official data, use smoke meter
G2.
* Raise the coolant temperature t o the operating
range before measuring.
A W h e n removingorinstallingthe measuring
equipment,becareful not to touchanyhigh
temperature parts.

- 1. Measuring with handysmoke checker G1

1) Fit filter paper in tool G1.
2 ) Insert the exhaustgasintake port into the
exhaust pipe, accelerate the engine suddenly,
and at thesame time operate the handle of
tool G1 to catch the exhaust gas on the filter
paper.
3) Remove the filterpaper and compare it with
the scale provided to judge thecondition.

2. Measuring with smoke meter G2

Insert-probe @ into the outlet port of ex-
haust pipe, then tighten the clip tosecure it
to the exhaust pipe.
Connect the probe hose, accelerator switch
plug, and air hose to tool G2.
*
The pressure of the air supply shouldbe
less than 1.47 MPa (15 kg/cm2).
Connect the power cord to the AC outlet.
*
When connecting theport, check first that
the power switchof tool 6 2 is OFF.
Loosen the cap nut of the suction pump, BLPO2 I I 6
then fit the filter paper.
*
Fit the filter paper securely so that the
exhaust gas does not leak.
Turn the power switch of toolG2 ON.
Accelerate the engine suddenly, and at the
same tiime, depress the accelerator pedal of
tool G2 and catch the exhaust gas color on
the filter paper.
Lay the filter paperused to catch the ex-
haust gas color on top of unused filter pa-
pers (IO sheets or more) insidethe filter pa-
per holder, and read the indicated value.

BLPO? I 1 7
I

PC200-6Z 20-103
 ,
TESTING AND
VALVE
ADJUSTING
ADJUSTING CLEARANCE

ADJUSTINGVALVE "

CLEARANCE
1. Remove the cylinder head cover.

2. Using cranking tool Q, rotate the crankshaft i n

the normal direction until timing pin (1) enters
the hole in the gear.
* This position is the No. 1 cylinder compres-
sion top dead center.

3. When No.'l cylinder is atcompression top dead

center, adjust the valves marked 0. Next, rotate
I V a l v e arrrusement diarrrr

the crankshaft one turn (360") in the normal di-

rection and adjust the valve clearance of the
remaining valves marked 0.
* Make match marks on the crankshaft pulley
or damper, then rotate 360".

P
4. To adjustthevalve clearance, loosen locknut TKP00738
(61, then insert feeler gauge F between rocker
lever (3) andvatvestem (41, and turn adjust-
ment screw (5)until the clearance is a sliding fit.
Then tighten locknut (6) to hold the adjustment 4 3 6
screw in position.
Locknut :44.1 t 4.9 Nm I4.5 t 0.5 kgml

* After adjusting No. 1 cylinder at compression

top dead center, it is also possible to turn the
crankshaft 180" each time and adjust the valve
clearance of each cylinder according to the fir-
ing order.
- -
Firing order : 1 - 5 - 3 - 6 2 4
* After tightening the locknut, check the valve .PO2 I 19
clearance again.
* There is no timing mark on the front pulley,
so set t o compression top dead center as
follows.
i) If the-firing order is followed, thenext
cylhder after No. 1 cylinder is No. 5 cyl-
inder, so watchthe movement of the
No. 2 cylinder valves and rotate in the
normal direction.
ii) Whenthe clearance ofboth the intake
and exhaust valves of the No. 2 cylinder
is 0, the No. 5 cylinder is at compression
top dead center. (For the No. 3 cylinder,
watch 5 - 2 movement of the No. 4 cylin-
der V B ' 5 . )
I

20- 1 04 pc700-A7 I
 MEASURING BLOW-BY PRESSURE
TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE

MEASURING COMPRESSION
PRESSURE
A When measuring thecompression pressure, be
careful not to touch the exhaust manifold or
muffler, or to get your clothes caught in the fan,
fan belt or otherrotating parts.
1. Adjust the valve clearance.
For details, see ADJUSTING VALVE CLEARANCE.
2. Warm up the engine to make the oil tempera-
ture 40 - 60°C.
3. Remove the nozzle holder assembly from the older assembly
cylinder to be measured. TLPO I002
4. Install adapter D2 in the mount of the nozzle
holder, then connect pressure gauge Dl.
- 5. Set tachometer A in position.
6. Disconnect the fuel control rod, place the gover-
nor lever of the injection pump in the NO IN-
JECTION position, then crank the engine with
the starting motor and measure the compres-
sion pressure.
* Measure the compression pressure at the point
wherethepressure gauge indicatorremains
steady.
* When measuring the compression pressure,
measure the engine speed to confirm that it is
within the specified range.
* After measuring the compression pressure, in-
stall the nozzle holder assembly.

MEASURING BLOW-BY
PRESSURE
*
8

Measure the blow-bypressure under the follow-

ing conditions.
Coolant temperature: Within operating range
Hydraulic oil temperature: 50 - 80°C.
1. Install nozzle E2 of blow-by checker E to blow-
by hose.
2. Connect the nozzle and gauge with the hose.
3. Run the engine at high idling and relievethe
arm circuit.
4. Measuretheblow-by at thepointwherethe
gauge indicator remains steady.
- - 1

PC200-6Z 20- 105

TESTING AND ADJUSllNG TESTING AND ADJUSTING FUEL INJECTION TIMING

TESTING AND ADJUSTING

FUEL INJECTION TIMING
1. Testing
1) Using cranking tool Q, rotate the crankshaft
in the normal direction until timing pin (1)
enters the hole in the gear.
2) Remove plug (21, reverse timing pin (3).and
check that pin (3)is meshed with timing pin
pointer (4) at the injection pump side.

2. Adjusting -:
If the timing pin does not mesh
i) Remove the fuel injection pump.
For details, see REMOVAL OFFUEL INJEC-
TION PUMP ASSEMBLY.
ii) Rotate the camshaft of theinjection pump
andmesh timing pin (3) with timing pin
pointer (4).
iii) Install the fuel injection pump assembly.
For details, see INSTALLATION OF FUEL IN-
JECTION PUMP ASSEMBLY.

70-1 0 A Pf700-6Z i
TESTING AND ADJUSTING MEASURING ENGINE OIL PRESSURE

MEASURING ENGINE OIL

PRESSURE
-k Measure the engine oil pressure under the fol-
lowing conditions.
* Coolant temperature: Within operating range

1. Remove engine oil low pressure sensor (1), then

install the adapter of oil pressure gauge kit C1
and oilpressure gauge C2 (1.0 MPa (10 kg/cm2).

2. Start the engine, and measure the oil pressure

at the low pressure end with the engine at low
idling andatthehighpressureend with the
I \ x12ADo92
engine at high idling.

PC200-6Z 20- 107

 TESTING AND ADJUSTING FAN BELT TENSION
TESTING AND ADJUSTING TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONERCOMPRESSOR

TESTING AND ADJUSTING

FAN BELT TENSION
Testing
Check the deflection of the belt when the belt is
pressed with a finger force of approx. 58.8 N (6
kg) at a point midway between the tension pul-
ley and fan pulley.

Adjusting
1. Loosen mounting bolts (2) and (31,bolt (41, nut
(51, and belt tension adjustment bolt (6) of ten-
sion pulley (1).
2. Move tension pulley (1) and watch the tension
of the fan. belt through the clearance from the
cylinder block. Whenthetensionis correct,
tighten adjustment bolt (6) first, then tightenten-
sion pulley mounting bolts (2) and (31,and nut
(5).
3. After adjusting the belt tension, check again to
confirm that the belt tensionwithin
is the stand-
ard value.
* After adjusting the belt, run the engine for at
least 15 minutes, then measure the deflection of
the belt again.

TESTING AND ADJUSTING I Bar

BELT TENSION FOR AIR
CONDITIONER COMPRESSOR
* tf the deflection of the belt when it is pressed at
a point midway between the drive pulley and
the compressor pulley is not within the stand-
ard value, or when carrying out maintenance
after replacing the belt, adjust the belt tension 2
as follows.
1. Loosen bolts (1) and (2). I TLP01003

2. Lever with a bar between (3)and (4) to adjust

the belt tension.
3. When the position of the compressor is fixed,
tighten bolts (2) and (1) to secure in position.
5-0nm
4. After adjustingthe belttension, repeat the above I
procedure to check that thebelt tension is within
the standard value.

BLP07118

20- 1 08
SURING
DJUSTING
AND TESTING SENSOR SPEED

MEASURING SPEED SENSOR

1. Screw in until the tip of sensor (1) contacts gear
(2).
2. When gear (2) contacts sensor (11, turn back 1 f
1/6 turn. (a: clearance)
3. Tightenlocknut (3).
* Be particularly careful whensecuring the sensor
wiring t o ensurethat no excessive forceis
brought tobear on the wiring.
* Be careful not t o let the tip ofthe sensor be
scratched or to letany iron particles stick to the
sensor tip.

BEPOll49

PC200-4Z 20- 1 09
.
TESTING
ADJUSING
AND ADJUSTING
LEVER
CONTROL
FUEL

Set the operator's seat to rear end position.

1. Adjust the mounting dimensionof yoke (2) of
cable (1) t o dimension a. (Both the clutch and
engine ends)
* Yoke mounting dimension a: 12 m m
2. Set fuel control lever (3)to the idling position,
then adjust the mounting dimension of cable (1)
to dimension b.
* Cable mounting dimension b 217 m m
3. Check thatgovernor lever (4) is in theidling
range, then install thecable at theengine end to
dimension c. (If it is not withinthe idling range,
adjust with nut d or e.), then adjust stopper bolt
(5)so that the clearance between fuel control
lever (3)Snd stopper bolt (5) is 0.
f Basic dimension f of stopper bolt: 11 m m
f After adjusting, fighten the locknut ofthe
stopper boltsecurely.
* Cable mounting dimension c: 239 m m
4. Check the engine speed when fuel control lever
(3) is at theidling position.
* Engine idling speed: 970 2 50 rpm
(If it is not within the idling range, repeat
Step 3 t o adjust.)
5. Move fuel control lever (3)(including the play)
towards the FULL position until governor lever
(4) comes to theSTOP position, then adjust s t o p
per bolt (6) so that the clearance between fuel
control lever (3)and stopper bolt (6) is 0.
* Basic dimension g of stopper bolt: 25 m m
* After adjusting, tightenthe locknut ofthe
stopper bolt securely.

PC200-6Z 70-1 1 1
 TESTING AND ADJUSTING HYDRAULIC PRESSURE
TESTING AND ADJUSTING IN WORK EQUIPMENT,
SWING,
TRAVEL
CIRCUIT

TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK

EQUIPMENT, SWING, TRAVEL CIRCUIT
1. Measuring
* Hydraulic oil temperature when measuring: I 2 1
45 - 55°C
A L o w e r the work equipment to the ground and
stop the engine. Loosen the oil filler cap slowly
t o release the pressure inside the hydraulic tank.
Then put the safety lock lever in the LOCK posi-
tion. Install oil pressure gauge C1 (58.8 MPa
(600 kg/cmz}) to the quick disconnect (1) or (2)
for the circuit to be measured.
a. Measuring main unload pressure
i. Unloadpressurewhenfront and rear
pump flows are merged. Measure the
oil pressure with the engine at high idling
and the control levers at neutral.
* With this procedure, the unload pressure of
the unload valve of the leftand right control
valves is measured.
 TESTING AND ADJUSTING HYDRAULIC PRESSURE
TESTING AND ADJUSTING IN WORK
EQUIPMENT,
SWING, TRAVEL CIRCUIT

b. Measuring pump relief pressure

1) Low setting (oil pressure: 31.9 MPa (325 kg/
cm2))
i) Measure the pressure when each actua-
tor except the travel actuator is relieved
with the engine atfull throttle.
* Notethatthe setpressure of the
safety valvefor the swing motor and
head end of the boom is lower than
the main relief low set pressure, so
the value measured will be the relief
pressure of the safety valve.
* Whenmeasuringtheswingrelief
pressure, measure with theswing
5 lock turned switch ON.

2) High setting (oil pressure: 34.8 MPa (355 kg/

cm3)
i) Whentravelis operated
Measure the oil pressure when thetravel
P
is relieved on each side separately with
the engine at full throttle.
* To relieve the travelcircuit, put block
@ under the track shoe grouser, or
put block @ I
between the sprocket
and frame to lock the track. BLpoo170 BLpoo171

PC200-6Z 20-1 13 e
 TESTING AND ADJUSTINGHYDRAULIC PRESSURE
TESTING
AND ADJUSTING IN WORK EQUIPMENT,
SWING,
TRAVEL
CIRCUIT

2. Adjusting
e (1): For front pump
I ,
e (2): For rear pump adjusting high pressure set-
Y .

ting.
Loosen locknut (31, then ’turn holder (4) to
adjust.
* Turn the holder to adjust as follows:
To INCREASE pressure, turn CLOCKWISE.
To DECREASE pressure,turn COUNTERCLOCKWISE.
* Amount of adjustment for one turn of holder.
approximately 12.5 MPa {128kg/cmz)
Locknut: 53.5 2 4.9 Nm (5.5 2 0.5 kgml
* When the high pressure setting is adjusted, the
low pressure setting will also change, so adjust
the low piessure setting also.
a. Adjusting low pressure setting. Loosen
locknut (51, then turn holder (6) to adjust. 4 6 I
0 Turn the holder to adjust as follows:
To INCREASE pressure, turn CLOCKWISE.
To DECREASE pressure,turn COUNTERCLOCKWISE.
* Amount of adjustment for one turn of holder:
Approximately 12.5 MPa (128 kglcm’l
Locknut: 53.5 2 4.9 Nm (5.5 2 0.5 kgml
* Normally, the pressure applied to port PX1 is 0
Mpa (0 kg/cm2); atthe high pressure setting,it is ‘3 s
2.9 MPa (30 kg/cm2). XlOUo4S
b. Swing motor safetyvalve.Loosenlocknut
I 1 ), then turn adjustment screw ( 2 1 to ad-
just.
* Turn the adjustment screw to adjust as follows.
To INCREASE pressure, turn CLOCKWISE.
To DECREASE pressure,turn COUNTERCLOCKWISE.
* Amount of adjustment for one turn of holder:
Approximately 6.7 MPa (68.4 kg/cm2).
Locknut:
90.6 2 12.3 Nm (9.25 2 1.25 kgml

70-1 l d w3nn-x7
 TESTING AND ADJUSTING PC VALVE OUTPUT
TESTING AND ADJUSTING PRESSURE (SERVO PISTON INPUT PRESSURE)

-
TESTING AND ADJUSTING PC
VALVE OUTPUT PRESSURE
(SERVO PISTON INPUT
PRESSURE)
1. Measuring
* Oil temprature when measuring: 45 55°C. -
0 Measure the oil pressure when the circuit is re-
lieved in the pressure rise mode.
a. Install oil pressuregauge C1 t o quick dis-
connects (11, (21, (31, and (4).
* Install a 39.2 MPa (400 kg/cm3gauge t o t h e
I -70
servo valve end, and a 58.8 MPa (600 kg/cm2)
gauge to thepump outlet port end.
b. Turn the swing lock switch ON.
c. Set the working mode to H/O mode.
d. Runengineat full throttle,turntheknob
switch ON, andmeasuretheoilpressure
when the arm (IN) circuit is relieved.
* Check that the servo pistoninput pressure is 1/2
of the pump discharge pressure.
Note: If there is any abnormality in the LS valve or
servo piston, the servo piston input pressure
will be 0 or almost the same as the pump
discharge pressure.
2. Adjusting
* If theloadbecomes larger, theengine speed
will drop. Or if the engine speed remains nor-
mal, the work equipment speed will drop. In
such cases, if the pump discharge pressure and
LS differential pressure are normal, adjsut the
PC valve as follows.
a. Loosenlocknut (41, and if theequipment
speed is-slow, turn screw (5) to the right; if
the engine speed drops, turn the screw t o
the left.
* If the screw is turned to the right, the pump
absorption torque will be increased, and if it is
turned to the left, the pump absorption torque
will be reduced.
* The adjustment range for the screw is a maxi-
mum of 1 turn to the left and 180" to the right.
* The amount of adjustment for one turn of the
screw: 1.5 mm ofservopiston stroke move-
ment. 4 5 3
b. After cdmpleting the adjustment, tighten the
locknuts.
Locknut (3):
34.3 2 4.9 N m (3.5 & 0.5 kgm}
Locknut (4):
100.5 2 12.3 N m (10.25 2 1.25 kgm}

X30AVt98

PC200-6Z 20-115
 TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE
TESTING AND ADJUSTING (SERVO PISTON INPUT PRESSURE) AND LSDIFFERENTIALPRESSURE

TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO

PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE
* oil temperature when measuring: 45 - 55°C 2 1
1. Measuring LS valve output pressure (servo pis-
ton input pressure).
a. Installoil pressure gauge C1 to quick dis-
connects (11, (21, (3)and (4).
f Install a 39.2 MPa (400 kg/cm2) gauge t o the
pump outlet port end.
0 Oil pressurewhentravel isrotatingunderno
load on one side.
i. Usetheworkequipment to raise the track
assembly on one side.
ii. Run the engine at full throttle and operate
the travel lever to the end of its stroke and
measure the oil pressure with the track ro-
e tatingunder
no load.

Table1
Pump Servo in'et
Working Travel pressure Remarks
mode lever (MPa pressure
(MPa {kglcmV
{kgcm?)
About the
WO 3.72 f 0.69 3.72 2 0.69 same as
mode {3a i 71 (38 2 7) Pump
pressure
About
WO Full 6.86 0.98 3.43 2 0.49 60% Of
mode (70 f 10) I35 * 5) Pump
pressure

PC200-6Z 20-1 17
 TESTING AND ADJUSTING LS VALVE OUTPUTPRESSURE ,
TESTING AND ADJUSTING (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE

2. Measuring LS differential pressure

a. Measuring with a differential pressure gauge.
i. Installoneline of differential pressure
gauge C4 to the main pressure port of
the front (or rear) pump.
ii. Install the second line of pressure gauge
to the quick disconnects on the LS lines at
the main control valve. (The LS lines are
color coded at eachend.Makesure to
use the same LS line on both the pump
end and the main valve end.)
iii. Set the conditions in Table 2 and meas-
ure the LS differential pressure.

Table 2
2 1
Fuel LS differential
control Operation pressure
lever (MPa{kg/cm2))
MAX 1 Levers neutral
at I 2.94 2 0.98
{30 5 10)~-
MAX Travel circuit under no load 2.16 5 0.1
(lever half operated) {22 2 11

20-1 18
 TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE
TESTING AND ADJUSTING (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE

3. Adjusting LS valve
When the differential pressure is measured un-
der the conditions above, and the results show 1 4 6
that the differential pressure is not within the
standard value, adjust as follows.
a. Loosen locknut (4) and turn screw (5) to ad-
just the differential pressure.
0 Turn thescrew to adjustthedifferential pres-
sure as follows: I
To INCREASE pressure, turn CLOCKWISE.
To DECREASE pressure, turn COUNTERCLOCKWISE. XWAV299
f Amount of adjustment (LSdifferential pressure)
for one turn of screw: 0.65 MPa (6.6 kg/cm2L
b. After adjusting, tighten locknut (4).
*
Locknut 56.4 & 7.4 Nm (5.75 0.75kgm).
Note: Alwaysmeasure the differential pressure while
adjusting.

PC200-6Z 20-1 19
TESTING AND ADJUSTING
TESTING
AND
ADJUSTING
CONTROL
CIRCUIT
OILPRESSURE

TESTING AND ADJUSTING

CONTROL CIRCUIT OIL I

PRESSURE
1. Measuring
* Oil temperature when measuring: 45 55°C-
A L o w e r the work equipment to the ground and
stop the engine. Loosen the oil filler cap slowly
to release the pressure inside the hydraulic tank.
Then set the safety lock leverto the LOCK posi-
tion.
a. Install oil pressuregauge C1 (5.8MPa (60
kg/crn% to quick disconnect nipple.
b. Start the engine and measurewith the enigne
at full$hrottle.

20- 1 20
 TESTING
ADJUSTING
AND TESTING
SOLENOID
VALVE
OUTPUT
PRESSURE

TESTING SOLENOID -VALVE

OUTPUT PRESSURE
Measuring
* Oil temperature when measuring: 45 55°C -
Measuring output pressure of ON-OFF solenoid
va Ive
1) Disconnect output hose (2) of the solenoid
valve, then use adapter C3 in the oil pres-
sure gauge kit to install oil pressure gauge
C1 (5.9 MPa (60 kg/cmZ)).
2) Measure the solenoid valve output pressure
under the conditions in Table 1.

Table 1
1 Name of
;olenoid

PPC
hydraulic
lock
I
-
Measurement
conditions

Safety lock lever at FREE

Hydraulic pressure
in PPC valve
circuit
NOhydraulic
I
/Operating condition m n o f k Oil pressure
solenoid MPa {kg/cmq)

ON
Min. 2.7
{Min. 28)
I Remarks
k
BLPO2 1 4 7

Safety lock lever at LOCK pressure in PPC OFF 0 {OI

valve circuit
Swing or work equipment .iever Brake canceled ON !.Win. 2.7
Swing operated {Min. 28)

I I I
holdino
brake
" 1 All levers
except
travel at neutral
I
Brake
(5 sec after returning to neutral)
actuated
OFF 0 {O)

Min. 2.7 Motor swash

Travel
speed
selector
switch at Hi
Travel
speed Hi ON {Min. 281 plate angle at
Travel [ minimum
I I
I I I
speed Motor swash
Travelspeedselectorswitch at Lo
I Travel speed Lo OFF 0 {01
I plate angle at
maximum

Travel lever operated Pressure rise ON Min. 2.7

2-stage {Min. 281
relief
OFF 0 (01
Note 1: Operation of solenoid valve
ON: Energized (oil pressure generated), OFF: Deenergized (oil pressure: 0 )
- Note 2: The measurement conditions in the table are the typical conditions for measuring the output
pressure.
In some cases, the solenoid valve may be actuated (ON/OFF) in conditions other than the
measurement conditions.
A W h e n operating the levers, operate slightly and be careful not to move the machine.

PC200-6Z 20-1 21 i
TESTING AND ADJUSTING MEASURING
VALVE
PPC OUTPUT PRESSURE

MEASURING PPC VALVE

OUTPUT PRESSURE
J, Oil temperature when measuring: 45 - 55°C

1. Measuring PPC valve output pressure

Disconnect hose(1) of the circuit to meas-
be
ured.
Install adapter C3 between hose (1) and el-
bow (2).
Install oil pressure gauge C1 (5.9 MPa (60
kg/cm2N t o adapter C3.
Run the engine at full throttle, operate the
control lever of the circuit to be measured,
and measure the oil pressure.
If the output at the control valve end low,is
measure the input pressure of PPC the valve.
If it is normal, there is defective actuation of
the PPC valve.

20- 1 22 pc7nn-x7
 ADJUSTING
TESTING
AND
MEASURING OUTPUT
VALVE
PRESSURE
PPC

Plug location diagram

Interruption block seen from rear of machine

Arm I N

T(CN-SO
r a v e l I )scw
ht$i

R. H. w i n o

Bucket DUMP

Bucket CURL

Boom LOWER

.-

TKP01007

PC200-6Z 20- 1 23
TESTING AND ADJUSTING ADJUSTING WORK EQUIPMENT SWING PPC VALVE

ADJUSTING WORK
EQUIPMENT SWING PPC
VALVE
f If there is excessive play in the work equipment
or swing lever, adjust as follows.
A L o w e r the work equipment to the ground and
stop the engine. Loosen the oil filler capslowly
t o release the pressure inside the hydraulic tank.
Then set thesafety lock lever to the LOCK posi-
tion.

1. Remove the PPC valve.

2. Removeboot (1).
3. Loosen loeknut (21, then screw in disc (3)until it
contacts the 4 heads of piston (4).
f When doing this, do not move the piston.
4. Screw disc (3) in position, then tighten locknut
(2) to the specified torque.
=
Locknut: 107.8 9.8 Nm 111 5 1 kgrn}
5. Installboot (1).
f With the above adjustment, the clearance
between disc (3)and piston (4) becomes 0.

7fL17A
 .
DEVIATION
TESTING
TRAVEL
AND
TESTING
ADJUSTING

TESTING TRAVEL DEVIATION

* When traveling on level ground. Travel Posture
1. Set the machine in the travel posture.
*
For the travel posture, extend the bucket and
arm cylinder rods fully, and hold the boom
angle at 45".
2. Travel for 10 m, then measure the deviation A
when traveling for the next 20 m.
*
Measure with the engine at high idling.
*
Installthehydraulic pressure gaugeand
measure the pump discharge pressureat the
same time.
TDP00328

M a k e a m aMrakk e a m ataMrhtakek e a mark

!Om m i d w a y P o i n t

L ao yu t a string 10m m i d w aPyo i n t

20m Point

Mark
a p & & rk
Mark
M e a s u r e t h e a m o u n t of
distance A at this Point
TEPOO329

PC200-6Z 20-1 25
 TESTING LOCATIONS CAUSING
TESTING
ADJUSTlNG
AND
HYDRAULIC DRIFT OF WORK EQUIPMENT

TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK

EQUIPMENT
* If there is any hydraulic drift in the work equip-
ment (cylinders), check as follows to determine
if the cause is in the cylinder packing or in the
control valve.
1. Checking for defective cylinder packing
1) Checking boom and bucket cylinders
i) Set in the same posture as when meas-
uring hydraulic drift, andstop the en-
gine.
ii) Operate the boom control lever t o RAISE
or the bucket control lever to CURL.
If thelowering speedincreases, the
packing is defective. I TDPOO333

If there is no change, the boom hold- PC200-6: 1,260kg

-ingvalve (boom) or the controlvalve
(bucket) is defective.
2) Checking armcylinder
i) Operate thearmcylinder to move the
arm in fully, then stop the engine.
ii) Operate the control lever to arm IN.
If the lowering speed increases, the
packing is defective.
If there is no change, thecontrol
valve is defective.
* If the pressure in the accumulator
hasdropped, runtheenginefor
approx. 10 seconds t o charge the BKpoo159
accumulator again before operating.
[Reference] If the cause of the hydraulic drift is
in the packing, and the above op-
erations is carried out, the down-
ward movement becomes faster for
the following reasons.
If the work equipment is set to the above
posture (holdingpressure applied to thebot-
tom end), the oil at the bottom end leaks to
the head end. However, the volume at the
head end is smaller than the volume at the
bottom end bythe volume of therod, so the
internal pressure at the head end increases
because of the oil flowing in from the bot-
tom end.
When the internal pressure a t the head end
increases, the pressure at the bottom end
also rises in proportion to this. The balance
is maintained at a certain pressure (this dif-
fers according to the amount of leakage) by
repeating this procedure.
When the pressure is balanced, the down-
ward movement becomes slower. If the le-
ver is then operated according to the proce-
duregiven above, thecircuit at the head
end is opened to the drain circuit (the bot-
tom end is closed by the check valve), so
the oil at the head end flows to the drain
circuitandthedownwardmovementbe-
comes faster.
 TESTING LOCATIONS CAUSING
TESTING AND ADJUSTING HYDRAULIC
DRIFT OF WORK EQUIPMENT

A Checking
2. boom holding valve
Set the work equipment at
and the top of the boom
the maximum reach,
horizontal, then stop
the engine.
Lock the work equipment control levers and re-
lease the pressure inside the hydraulic tank.
A T 0 prevent danger, never stand under the work
equipment.
7 ) Disconnect pilot hose (1) of the boom hold-
ing valve, andinstall a blind plug in the
hose.
* Blind plug: 07376-50315
* Leave the boom holding valve end open.
* If any oil leaks from the port that is left
open, the boom holding valve is defec-
tive.

3. Checking PPC valve

If the hydraulic drift differs when thesafety lock
lever is in the LOCK or FREE position, (engine
running), the PPC valve is defective.

f'C200-6Z 20-1 27
TESTING AND ADJUSTING MEASURING OIL LEAKAGE

MEASURING OIL LEAKAGE

f Hydraulic oil temperature when measuring: P o s t u r ef o rm e a s u r i n gb o o mc y l i n d e r
-
45 55°C
1. Work equipment cylinder
f If the hydraulic drift of the work equipment is
outside the standard value, measure the leak-
age inside the cylinder as follows, and judge if
. the cause of the hydraulic drift is in the cylinder
or in the control valve.
If the leakage is with in the standard value,
the problem is in the control 'valve.
If the leakage is greater then the standard
value, the problem is in the cylinder. TEP00334

1) Fully extend the rod of the cylinder t o be

measured, then stop the engine.
2) Disconnect piping (1) at the head end, then P o s t u r ef o rm e a s u r i n g arm. b u c k e tc y l i n d e r
block the piping at the chassis end with a
blind plug.
A B e careful not t o disconnect the piping
at the bottom end.
3) Start the engine and apply the relief pres-
sure to the bottom end of the cylinder with
the engine at high idling.
4) Continue this condition for 30 seconds, then
measure the oil leakage for the next one
minute.
TEP00335

Boom F Y Ii n d c r I \ I I I

I Arm c y l i n d e r

L TLPOO74f

!
7n-1 78 D P - M L7 i
 I I

K
&
N

-4
rn
Q
0
0
Y
Ly
rl
 MEASURING OIL LEAKAGE
TESTING
AND ADJUSTING RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT

2. Swing motor
1) Disconnectdrain hose (1) from the swing
motor, then fit a blind plug at the tank end.
2) Set the swing lock switch ON.
3) Start the engine and operate the swing re-
lief with the engine at high idling.
4) Continue this condition for 30 seconds, then
measurethe oil leakage for the next one
minute.
* After measuring, swing 180" and measure
again.
54
3. Travel motor
1) Disconnectdrain hose (2) from the travel
motof, then fit a blind plug atthe hose end.
2) Fit block ( iJ the track shoe grouser, or
under
fit block @ between the sprocket and frame
t o lock the track.
3) Start the engine and operate the travel .relief
with the engine at high idling.
A W h e n measuringthe oil leakage from
the travel motor;mistaken operation of
the control lever may lead to a serious
accident, so always use signals and check
when carrying out thisoperation.
4) Continue this condition for 30 seconds, then
measurethe oil leakage for thenextone
minute.
*When measuring, movethemotorslightly
(to change the position between the valve
plate and cylinder, and piston and cylinder),
and measure several times.

RELEASING REMAINING
PRESSURE IN HYDRAULIC
CIRCUIT
* If the piping between the hydraulic cylinder and
the control valve is disconnected, release the
remaining pressure from the circuit as follows.
BLpoO170
I BLP00171

The travel ciucuit is an open circuit, so there is

no remaining pressure. It is enough to remove
the oil filler cap.
1. Loosen theloil filler cap slowly to release the
pressure inside the tank.
2. Operate the control levers.
* When the levers are operated 2 - 3 times,
the pressure stored in the accumulator is
removed.
3. Start the engine, run at low idling for approx. 5
minutes, then stop the engine and operate the
control levers.
* Repeat the above operation 2 - 3 times to
release all the remaining pressure.

30- 1 30 Dr3nnA7
 TESTING AND ADJUSTING TESTING CLEARANCE OF SWING CIRCLE
BEARING

TESTING CLEARANCE OF
SWING CIRCLE BEARING I

Method of testing clearance of swing circle bearing

when mounted on machine
1. Fix a magnet-type dial gauge to the outer circle
(or inner circle) of the swing circle, and put the
tip of the probe in contact with the inner circle
(or outer circle). f r ame
Set the dial gauge at the front or rear.

D i a l sauae
TEP00339

- Extend the work equipment to the maximum

reach, and set thetip of the bucket t o the same
height as the bottom ofthe revolving frame.
When this is done, the upper structure will tilt
forward, so the front will go down and the rear
will rise.

3. Set the dial gauge to the zero point.

J
’//////////////////

BKPW173

4. Set the arm more or less at right angles to the

ground surface, then lower the boom until the
front of the machine comes off the ground.
When this is done, the upper structure will tilt
back, so the front will rise and the rear will go
.C
down.

5. Read the value on the dial gauge at this point.

The value on the dial gauge is the clearance of
the swing circle bearing.

Whencarryingoutthe measurement, do not I BKFW174

put your hand or feet under the undercarriage.

6. Return to the condition i n Step 2, and check that

the dial gauge has returned to the zero point. If
it has not returned to the zero point, repeat Step
2 to 5.

PCZOO-6Z 20-131
TESTING
ADJUSTING
AND =STING
ADJUSTING
AND TRACK SHOE TENSION

TESTING AND ADJUSTING

TRACK SHOE TENSION
TESTING
1. Raise the track frame using the arm and boom,
and measure the clearance between the bottom
of the track frame and the top of the track
shoe.
Clearance a: 303 -c 20 mm
Measurement position
PC200-6 : 5th track roller from the sprocket. I o
ADJUSTING
f If the track shoe tension is notwithin the stand-
ard value, adjust as follows.
.
1 When the tension is too high:
Loosen plug (1) gradually,andreleasethe
grease.
A T h e r e i s danger that the plug may fly out
u n der t he high internalpressureofthe
grease, so never loosen plug (11 more than
7 turn.
f If the grease doesnot come outeasily, move
the machine backwards or forwards slowy.

2. If track is too loose:

Pump in grease through grease fitting (2).
f If the grease cannot be pumped in easily, 2
move the machine backwards and forwards
slowly.

20-132
R BLEEDING
TESTING AND ADJUSTING

BLEEDING AIR
Order for operation and porocedure for bleeding air

procedure
bleedingAir item
bleedingAir
1 2 3 4 5 6
Bleeding Bleeding Bleeding Bleeding
air from Start engine air from air from air from
Nature of work Pump cylinder 'swing motor travel motor 'perations

- Replace hydraulic oil

Clean strainer o +
I
o +
I
o I+ o oiNotel)l+I o
I
Replace return
filter element I l o ' I
I* 0
- Replace, repair pump
Remove suction piping 0 ~ 0 I
1
~ 0 I* 0

- -
I
Replace, repair control
- valve O L O 0
- Replace cylinder
I I
Remove cyltnder piping o l o I I> 0
Replace swing motor
Remove swing motor piping 0-0 I > 0

Note 1: Bleed the air from the swing and travelmotors only whenthe oil inside the motorcase has been drained.

1. Bleeding air from pump

Loosen air bleed plug (11, and check that oil
oozes out from the plug.
When oil oozes out, tighten plug (1).
Plug:
17.15 z 2.45 N m 11.75 t 0.25 kgm)
If no oil oozes out from the air bleed plug:
Leavepl.ug (1) loosened and remove hose
(2)and elbow (3).
Pour in oil through the elbow mount hole
until oil oozes out from plug (1).
Fit elbow (3) and install hose (2).
Tighten air bleed plug (1).
Plug: I XlOZO7l
17.15 t 2.45 N m (1.75 3 0.25 kgm)
Precautions when staring the engine
After completing the above procedure and
starting the engine, run the engine at low
idling for- _10 minutes.
- -
I .

BLPOZ I58

PC200-6Z 20- 1 33
TESTING AND ADJUSTING BLEEDING AIR

2. Bleeding air from hydraulic cylinders

1) Start the engine and run at idling for approx.
5 minutes.
2) Run the engine at low idling, then raise and
lower the boom4 - 5 times in succession.
* Operate the piston rod to approx. 100
mm before the end of its stroke. Do not
relievethecircuit under any circum-
stances.
3) Run the engine at full throttle and repeat
Step 2). After that, run the engine at low
idling, and operate the piston rod to the end
of its stroke to relieve the circuit.
4) Repeat Steps 2) and 3)to bleed the air from
the arm andbucket cylinders.
f When the cylinder has been replaced, bleed
the air before connecting the piston rod.
Be particularly careful not to operate the cyl-
inder to the end of its stroke when the pis-
ton rod has been connected to the LOWER
end of the boom cylinder.

3. Bleeding air from swing motor

1) Run the engine at low idling, loosen air bleed
plug (11, and check that oil oozes out.
f If no oil oozes out from the air bleed plug:
2) Stop the engine, and pour oil into the motor
case from plug (1).
3) Tighten air bleed plug (1).
Plug : 166.6 f 19.6 Nm I17 2 kgrnl

4. Bleeding air from travel motor

Run the engine at low idling, loosen air bleed
plug (21, and when oil oozesout, tighten the
plug again’. -

20-134
 Points to remember when troubleshooting ....................................................................................... 20-202
Sequence of events in troubleshooting .............................................................................................. 20-203
Precautions when carrying out maintenance..................................................................................... 20-204
Checks before troubleshooting ..................:......................................................................................... 20-212
Connector types and mounting locations .......................................................................................... 20-214
Connection table for connector pin numbers .................................................................................... 20-220
Method of using troubleshooting charts ............................................................................................ 20-230
Troubleshooting of engine system (S mode) .................................................................................... 20-301
Troubleshooting of electrical system (E mode) ................................................................................. 20-351
Troubleshooting of hydraulic and mechanical system (H mode) .................................................... 20-401
Troubleshooting of machine monitor system (M mode) .................................................................. 20-451

PCZOO-6Z 20-201
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING

POINTS TO REMEMBER WHEN TROUBLESHOOTING

A Stop the machinei n a level place, and check that thesafety pin, blocks, and parking brake are securely fined.
A When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not
allow any unauthorized person to come near.
A If the radiator cap is removed when the engine ishot, hot water may spurt out and cause burns, so wait for
the engine to cool downbefore starting troubleshooting.
A Be extremely careful not to touch any hot partsor to get caught in any rotating parts.
A When disconnecting wiring, always disconnect the negative (-1 terminal of the battery first.
A When removing theplug or cap from a location which isunder pressurefrom oil, water, or air, always release
the internal pressure first. When installing measuring equipment, be sure t o connect it properly.

The aim of-troubleshooting is to pinpoint the basic cause of the failure, t o carry out repairs swiftly, and to
prevent reoccurrence of the failure.
When cartying out troubleshooting, and important point is of course t o understand the structure andfunction.
However, a short cut toeffective troubleshooting is t o ask the operator various questions to form some idea
of possible causes of the failure that would produce the reported symptoms.

1. When carrying out troubleshooting, do not hurry
t o disassemble the components.
If components are disassembled immediately any
failure occurs:
Parts that have no connection withthe fail-
ure or other unnecessary parts will be disas-
sembled.
It will becomeimpossible to find the cause
of thefailure.
It will also cause a waste of manhours, parts, or
oil or grease, and at thesame time, will also lose
the confidence of the user or operator.
For this reason, when carrying out troubleshoot-
ing, it is necessary t o carry out thorough prior
investigation and t o carry out troubleshooting i n
accordance with the fixed procedure.
2. Points t o ask user or operator
1) Have any other problems occurred apart from
the problem that has been reported?
2) Was thereanything strange aboutthe ma-
chine before the failureoccurred?
3) Did the failure occur suddenly, or were there
problems with the machine condition before
this?
4) Under what conditions did the failure occur?
5) Had anyrepairs been carried out before the
failure?
When were these repairs carried out?
6) Has the same kindof failureoccurred be-
fore?
3. Check beforetroubleshooting
1) Check the oil level
2) Check for anyexternal leakage of oil from
the piping or hydraulic equipment.
3) Check the travel of the control levers.
4) Check the stroke of the control valve spool.
5) Other maintenance items can be checked ex-
ternally, so check any item that is considered
t o be necessary.
4. Confirming failure
Confirmthe extent ofthe failure yourself,
and judge whether to handle it as a real fail-
ure or as a problem with the method of op-
eration, etc.
* Whenoperating the machine to reenact
the troubleshooting symptoms, do not
carry out any investigation or measure-
ment that maymake the problem worse.
5. Troubleshooting
Use the results of the investigation and in-
-
spection in Items 2 4 to narrow down the
causes of failure, then use the troubleshoot-
ing flowchart t o locate the positionof the
failure exactly.
* The basic procedure for troubleshooting
is as follows.
1) Start from the simple points.
2) Start from the most likely points.
3) Investigate other related parts or in-
formation.
6. Measures to remove root cause of failure
Even if thefailure is repaired, if the root cause
of thefailure is not repaired, the same failure
will occur again.
To prevent this, always investigate why the
problem occurred. Then, remove theroot
cause.

20-202 W?M L7
SEQUENCE OF EVENTS IN TROU,BLESHOOTfNG

Office, shop Jobsite

Step 1
[Examination, confirmation of symptoms I
1) When a reguest for repairs is received, first

--
ask the following points.
Name of customer

-
Type, serial number of machine
Details of jobsits, ac.
2) &k questions to gain an outline of the prob-
lem.
--
Condition of failure
2 a
Wort baing carried out 8 theltime
Oof the
) m R T
W

-
failure
Operating environment

rn76 3
Past history,details of mintemma, etc.
i

Step 2
[Determining probable location of c a u q lEWOO183

1)Look at the troubleshooting section of the

shop manual tofind locations of possible :::E;? i
causes.

Repair pboite at
TEWOOlsI

Step 3
[Preparation of troubleshooting tools1
TEW00185
1) LDok at the table of troubleshooting tools in
the shop manual and prepare the necessaTy

--
(step 7
-
1'-
1001s. Pinpoint locations of failure (carry out
T-adapter
Hydraulic pressuregaugekit,etc.
2) took in the parts book and prepare the nec-
- troubleshooting)
Decide action to take

essary replacement 1) Before starting troubleshooting,locate and

repair simple failures.

- Check before darting items

Other check items
2) See the Troubleshooting Section of tha shop
manual. select a troubleshooting flowchart
that matches the symptoms, and carry out
troubleshooting.
TEWWlE?

f Step 6
[Reenacting failure]

* Drive and operate the machine to confirm

the condition and judge if there is really a
L failure.

Step 4
f-[
I
Was there anything strange about the ma-
chine before the failure occurred?
Did the failure occur suddenly?
Had any repairs bean carried out beforethe
TEW189

F'C200-6Z 20-203
TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

To maintain the performance of the machine over a long period, and to prevent failures or other
troubles before they occur, correct operation, maintenance and inspection, troubleshooting, and re-
pairs must be carriedout. This section deals particularly with correct repair procedures for mechatronics
and is aimed a t improving the quality of repairs. For this purpose, it gives sections on ”Handling
electric equipment” and “Handling hydraulic equipment” (particularly gear oil and hydraulic oil).

1. POINTS TO REMEMBER WHEN HANDLING

ELECTRIC EQUIPMENT

1) Handling wiring harnesses and connectors

Wiring harnesses consist of wiring connecting
one component t o another component, connec-
tors used for connecting and disconnecting one
wire from another wire, and protectors or tubes
used for protecting thewiring.
Compared with other electrical components fit-
ted in boxes or cases, wiring harnesses are more
likely to beaffected by the direct effects of rain,
water, heat, or vibration. Furthermore, during
inspection and repair operations, they are fre-
quently removed and installed again, so they
are likely to suffer deformation or damage. For
this reason, it is necessary t o be extremely care-
ful when handling wiring harnesses.

Main failures occurring in wiring harness

@ Defectivecontact of connectors (defective
contact between male and female)
Problems with defective contact are likely to
occur because the male connectoris not
properly inserted into the female connector,
or because one or both ofthe connectors is
w
I Improper insertion
I
deformedorthepositionis not correctly
aligned, or becausethereiscorrosion or
oxidization of the contact surfaces.

I TEwool92 I

@ Defective crimping or solderingof connec-

tors
The pins of the male andfemale connectors
are in contactat the crimpedterminalor
solderedportion, but if there is excessive
force brought to bear on the wiring, the plat-
ing at the jointwill peel and cause improper
connection or breakage.

I TEW00193

70-7nA
 TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

3J Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, o r components are lifted with a
crane with the wiring still connected, or a
heavy object hits the wiring, the crimping of
the connector may separate, or the solder-
ing may be damaged, or the wiring may be
broken.

a High-pressure water entering connector

The connector is designed to make it diffi-
cult for waterto enter (dripproof structure), I 1
s
but if high-pressure water issprayed directly
on the connector, water may enter the con-
nector,dependingonthedirection of the
water jet.
As already said, the connector is designed
to prevent water from entering, but at the
same time, if water does enter, it is difficult
for it to be drained. Therefore, if water should
get into the connector, the pins will be short-
I ?
TEW00195
circuited by the water, so if any water gets
in, immediately dry the connector or take
other appropriate action before passing elec-
tricity through it.

3 Oil or dirt stuck to connector

If oil or grease are stuck to the connector
1
and an oil film is formed on the mating sur-
face between the male and femalepins, the
o i l will not let the electricity pass, so there
will be defective contact.
If there is oil orgrease stuck to the connec-
tor, wipe it off with a dry cloth or blowit dry
with compressed air andspray it with a con-
tact restorer.
* When wiping the mating portion of the
connector, be careful not t o use exces-
sive force or deform the pins.
* If there is oil or waterin the compressed
air; the contactswill become even dirtier,
so remove the oil andwater from the
compressed air completely before clean-
ing with compressed air.

PC200-6Z 20-205
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

2) Removing, installing, and drying connectors and

wiring harnesses

0 Disconnectingconnectors
( iJ
Hold the connectors when disconnecting.
When disconnecting the connectors, hold the Press lightly
when removing
connectors and not the wires. For connec-
tors held by a screw, loosen the screw fully, .ock *opper, -
then hold the male and female connectors
in each hand and pull apart. For connectors
which have a lock stopper, press down the
stopper with your thumb and pull the con-
nectors apart.
* Never pull with one hand.

@ When removing from clips

When removinga cmnector froma clip, pull
the connector in a parallel direction t o the
clip.
* If the connector is twisted up and down
or to the left or right, the housing may
break.

@ Action to take after removing connectors

After removing any connector, cover it with
a vinyl. bag to prevent any dust, dirt, oil, or
water from getting in the connector portion.
f If the machine is left disassembled for a
long time, it is particularly easy for im-
proper contact to occur, so always cover
the connector.

7n-70~ PC7m-67
 TROUBLESHOOTING POINTS TO REMEMBER WHEN
CARRYING OUT MAINTENANCE

e Connectingconnectors
@ Check the connector visually.
1) Check that there is no oil, dirt, or water
stuck to the connector pins (mating por-
tion).
2) Check that there is no deformation, de-
fective contact, corrosion, or damage to
the connector pins.
3) Check that there is no damage or break-
a g e to the outside of the connector.
* If there is any oil, water, or dirt stuck to
the connector,wipe it off with a dry cloth.
If any water has got inside the connec-
tor, warm the insideof the wiring with a
.- dryer, but be careful not to make it too
hot as thiswill cause short circuits.
* If -there is any damage or breakage, re-
place the connector.

@ Fix the connector securely.

Align the position of the connector correctly,
then insert it securely.
For connectors with lock stopper, push in
the connector until the stopper clicks into
position.

@ Correct any protrusion of the boot and any

misalignment of the wiring harness
For connectors fitted with boots, correct any
protrusion of t h e boot. In addition, if the
wiring harness is misaligned, or the clamp
is out of position, adjust it to its correct po-
sition.
- * If the connector cannot be corrected eas-
ily, removetheclampandadjustthe
position.

@ If the connector clamp has been removed,

be sure to return it to its original position.
Check also that there are no loose clamps.

PC200-6Z 20-207
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

0 Drying wiring harness

If there is any oil or dirt on the wiring harness,
wipe it off with a dry cloth. Avoid washing it in
water or using steam. If the connector must be
washed i n water, do not use high-pressure wa-
ter or steam directly on the wiring harness.

If water gets directly on the connector, do as

follows.
( iJ Disconnect the connector and wipe off the
water with a dry cloth.
* If the connector is blown dry with com- TEWOO196
pressed air, there is the risk that oil in
the air may cause defective contact, so
remove all oil and water from thecom-
pressed air before blowing with air.

@ Dry the inside ofthe connector with a dryer.

If water gets inside the connector, use a dryer
to dry theconnector.
* Hot air from the dryer can be used, but
regulate the time that the hot air is used
in order not to make the connector or
related parts too hot, as this will cause
deformation or damage t o the connec-
tor.

@ Carry out a continuity test on the connector.

After drying, leave the wiring harness dis-
connected-and carry out a continuity test to
check for any shortcircuitsbetweenpins
caused by water.
* Aftercompletelydryingthe connector,
blow it with contact restorer and reas-
semble.

20-208 PC200-6Z
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

3) Handling control box

@ The control box containsamicrocomputer
and electronic control circuits. These control
all of the electronic circuits on the machine,
so be extremely careful when handling the
control box.
0 Do not open the cover of the control box
unless necessary.

@ Do not place objects on top of the control

box.
@ Cover the control connectors with tape or a
vinyl bag.
Never touchthe connector contactswith your
hand.
@ During rainy weather, do not leave the con-
trol box in a place where it is exposed to
rain.

@ Do not place the control box on oil, water,

or soil, or in any hot place, even for a short
time.
(Place it on a suitable dry stand).
@ Precautions when carrying out arc welding
When carrying out arc welding on the body,
disconnect all wiring harness connectorscon-
nected to the control box. Fit an arc welding
ground close to the welding point.

2. Points to remember when troubleshooting electric circuits

1) Always turn the power OFF before disconnecting or connect connectors.
2) Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Disconnect and connect the related connectors several times to check.
3)Always connect any disconnected connectors before going on to the next step.
* If the power is turned ON with the connectors still disconnected, unnecessary abnormality
displays will be generated.
4) When carrying out troubleshooting of circuits (measuring thevoltage, resistance, continuity, or
current), move the related wiring and connectors several times and check that there is no
change in the reading of t h e tester.
* If there is any change, there is probably defective contact in that circuit.

20-209
I

PC200-6Z
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

3. POINTS TO REMEMBER WHEN HANDLING

HYDRAULIC EQUIPMENT

With the increase in pressure and precision of hy-

draulic equipment, the most common cause of fail-
ure is dirt (foreign material) in the hydraulic circuit.
When adding hydraulic oil, or when disassembling
or assembling hydraulic equipment, it is necessary
to be particularly careful.

Be careful of the operating environment.

Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or
places where there is a lot of dust.

Disassembly and maintenance work in the field

If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering theequipment. It is also
difficult to confirmthe performance after repairs,
so it is desirable t o use unit exchange. Disas-
semblyand main-tenance ofhydraulic equip-
ment should be carried out in a specially pre-
pared dustproofworkshop, and the performance
should be confirmed with special test equipment.

Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags t o prevent any dirt or dust from en-
tering. If the opening is left open or is blocked
with a rag, there is danger of dirt entering or of
the surrounding area being made dirty by leak-
ing oil so never do this.
Do not simply drain oil out on to the ground,
collect it and ask the customer to dispose of it,
or take it back with you for disposal.

Do not let any dirt or dust getin during refilling

operations.
Be careful-not.to letany dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.

I TEW00209 I

20-2 10 PC200-6Z
1
I
 TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

5) Change hydraulic oil when the temperature is

high.
When hydraulic oil orother oil is warm, it flows
easily. In addition, the sludge can also be drained
out easily from the circuit together with the oil,
so it is best to change the oil when it is still
warm. When changing the oil, as much as pos-
sible of the old hydraulic oil must be drained
out. (Drain the oil from the hydraulic tank; also
drain the oil from the filter and from the drain
plug in the circuit.) If any oldoil is left, the
contaminants and sludge in it will mix with the
new oil andwill shorten the life of the hydraulic
oil.

6) Flushingoperations
After disassembling and assembling the equip
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil oil
from the hydraulic circuit.
Normally, flushing is carried out twice: primary
flushing is carried out with flushingoil, and sec-
ondary flushing iscarried out withthe specified
hydraulic oil.

TEwooZlO

7) Cleaningoperations I

After repairing the hydraulic equipment (pump,

control valve,etc.) or whenrunningthe ma-
chine, carry out oil cleaning to remove the sludge
or contaminants in the hydraulic oil circuit.
- The oil cleaning equipment is used t o remove
the ultrafine (about 3 ~ particles
) that the filter
built into thehydraulicequipmentcannot re-
move, so it is an extremely effective device.

PC200-6Z 20-211
TROUBLESHOOTING TROUBLESHOOTING
CHECKS BEFORE

CHECKS BEFORE TROUBLESHOOTING

Item Action

1. Check fuel level, type of fuel Add fuel

2. Check for impurities in fuel Clean, drain
3. Check hydraulic oil level Add oil
4. Check hydraulic strainer Clean, drain
5. Check swing machinery oil level Add oil
6. Check engine oil level (oil pan oil level), type of oil Add oil
7. Check coolant level Add water
8. Check dust indicator for clogging Clean or replace
9. Check hydraulic filter Replace

1. Check for looseness, corrosion of battery terminal, wiring Tighten or replace

2. Check for looseness, corrosion of alternator terminal, wiring Tighten or replace
3. Check for looseness, corrosion of starting motor terminal, wiring Tighten or replace

1. Check for abnormal noise, smell Repair

2. Check for oil leakage Repair
3. Carry out air bleeding Bleed air

1. Check battery voltage (engine stopped) 20 - 30v Replace

2. Check batteryelectrolytelevel - Add or replace
3. Check for discolored, burnt, exposed wiring - Replace
4. Check for missing wiring clamps, hanging wiring - Repair
5. Check for water leaking on wiring (be particularly careful attention - Disconnect
to water leaking on connectors or terminals) connector and dry
6. Check for blown, corroded fuses - Replace
7. Check alternator voltage (engine running at 1/2 throttle or above) 4fter running Replace
for several
minutes:
27.5 - 29.5 V
8. Check operating sound of battery relay (when switch is turned ON/OFF) - Replace

20-2 12 PC3CULh7
 TROUBLESHOOTING CONNECTOR
TYPES AND MOUNTING LOCATIONS

CONNECTOR TYPES AND MOUNTING LOCATIONS

Con- No. Add- Con- No.

Add-
nector Type of Mounting location res nector Type of Mounting location
ress
No. Dins No. I Dins I
IKESl / I Heater I K-3
1 - I

I BR /Terminal / 1 / Battewrelay terminal BR I R-8 1 M12 3

CO1 MIC 13 Pump regulator e-2 M14 L 2 Fusible link D-3

C05 M 6 Pump prolix switch G-2 M16 Terminal 1 Horn (high tone) E-4
~CO9 M 1 / 3 I Model selection connector I K-2 / M17 M 6 Wiper motor 1-1
I C13 /X / 2 I Pump EPC solenoid valve I A-6 I M18 M 3 Wiper switch K-2
DO1 KESl 2 window washer circuit K-4 For M I 9 IM I 2 / Wiper switch 1 K-2 I
DO5 KESl 2 For swing lock solenoid K-4 M20 Terminal 1 Horn (low tone) E-4
I DO7 IKESl / / Fortravel speed selector solenoidcircuit [ K-3 1
~~ ~~~

2 M21 PA 9 Radio K- 1
I DO8 I KESl I 2 I For heater / K-6 I M22 ZL,,, 1 Horn switch 6-3
M23 :r&,,, 1 Horn switch speaker G-4
H-4
M24 2ktDr1 SpeakerH-4 H-4
M26 M 6 Air conditioner unit F-7
I I
M27 zLN 1 Room lamp G-4 L

I E l1 1 Terminal I 1 / Electricalintakeairheaterrelay I P-7 I

E12 X 2 Alternator P-1 M31 KESO 4 Wiper motor
E13 Terminal 1 Starting motor relay terminal 0-9 M31 ZA,,, 1 Option power source
/ E14 /Terminal I 1 1 Electricalintakeairheaterrelay / P-8 I M32 M 2 Airconditionerunitpower source
I E15 /Terminal I 1 / Electrical intake air heater I R-4 I
FO1 X 2 Travel alarm (option) E-5 M35 X 2 Air conditioner condenser E-8
FB1 Box 2 Fuse box 1-5 M36 M 1 mode selector switch K-5 Kerosene
c
/ 1 I 1-1 I
I I I I I

H02 IS (blue)/ 16 Left stand wiring harness M38 M 2 Travel Hi-Lo switch J-1
L I
H03 S (white1' 16 Right stand wiring harness H-2 M40 M 1 Additional right front lamp (opt) G-8
H05 L 2 Right stand wiring harness H-2 M41 M 1 Additional left front lamp (opt) G-7
H06 S 8 Right stand wiring harness 1-1 M42 zk, 1 Additional rear lamp (option) A-8
M02 X 2 Starting motor relay R-6 M43 ,!z%w 1 Option power source E-4
M06 KESl - 4 Heater switch 1-5 PO1 040 16 Monitor panel H-4
PO2 I KESl I 4 I Light
switch 1 14-5 I
M08 M 1 Right front lamp D-3
M09 M 1 Boom working lamp A- 4
M10 M 1 Boom working lamp E-3
M11 L 2 Fusible link D-3 RE
[Terminal I 1 I Battery relay terminal B I R-8 I

20-2 1 4 PC200-6Z I
 TROUBLESHOOTING
CONNECTOR TYPES AND MOUNTING LOCATIONS

Con- No. Add- Con- No.

Add-
nector Type of Mounting location res nector Type of Mounting location ress
No. pins No. pins

I
I Travel pressure switch (for travel alarm) I M-4 I I 1 - 1
I I
I SO1 IX I 2 I I 1
If S11 lTerminaI1
I I
1 I Engine oil pressure
1 -
switch I
I R-3 I I
I 1
I
I
I
I
1
I
I
I
I
I

- S12 Zkr 1 PPC hydraulic lock switch 1-1

S13 %Lr1 PPC hydraulic lock switch J-1

S14 M 2 PPC hydraulic lock switch K-1

I I I

I TO6 (Terminal I 1 I Starting switch (B) I I

- '
I ~~~

PC200-6Z 20-2 15
wo Q CIJ

TO6 W26
107
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS

PC200-6Z 20-2 17
t
d
0
IL
-1

03

rn rn

rn
0

6
N
e
TROUBLESHOOTING CONNECTION
FOR
TABLE CONNECTOR PIN NUMBERS

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

.k The terms male and female refer to the pins, while the terms male housing and female housing
refer to the mating portion of the housing.

No. X type connector

of
pins Male (female housing) Female (male housing)

BEH00148 8EH00149

1
1

2'
'2

moo221 TEwoo222

3 1

i 2

I TEWOO223 I TNV00224

1 3
3 1

2 4 4 2

lEWW225 TEW00226

20-220 PC200-6Z
 I

2
a, a,

0 0 0 0 0

c--l

-1
0 a,

w -1
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR
PIN NUMBERS

NO. M type connector

of
pins Male (female housing) Female (male housing)

2 2

3 2

‘1
rrwoO243 TEWWZU

1 3 3 1

2 4 2
TEW24S TEWW246

1 4 4 1

3 6 6 3 TEW00248
TEW00247

4 1 1 4

8 5
BLPOOOU) 5 8 BLpoooIl

20-222 PC200-6Z
 !

,
3grn a,
X o z
m m
2 -"?
m -1

P -1

w
u) VI
TROUBLESHOOTING CONNECTIONFOR
TABLE CONNECTOR PIN NUMBERS

No.
of
pins
r Male (female housing)
AMP040 type connector

Female (male housing)

4 8
8 4

5 1 BLPOOOY

12 6

"\ )2

12

7 1

8
\ /"

i
16 8

16

9 1
1 9
BLpDoo57 TEW00232

10
\ ?O 20 10

20

ii 1
11 TEWW234
BLpooo58

PC200-6Z 20-225
 h)

h)
\ n
(P
3
D
3
E
5
0
C
3.
3
'p,
 I

P 0 P.. z
2 "P

m
0 m
I rn
0 s
0 0
rn - 0
Ln -
Ln
0
E @
I
w
w

m
rn
I
0
N 0
I"
-.
Y ul
E -
 m

A
Hq
P
 T-
~~

No. PA connector
of
pins Male (female housing) Female (male housing)

9
BEH00157
9 5
8EH00156

PC200-6Z 20-229
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS

METHOD OF USING TROUBLESHOOTING CHARTS

1. Category of troubleshooting code number

I
~~ ~~~~ ~~

Troubleshooting Code No. Component

SO0 Troubleshooting of engine related parts
E-OO Troubleshootingof electrical system
H-00 Troubleshooting of hydraulic, mechanical system
M-OO I Troubleshooting of machine monitor

2. Method of using troubleshooting table for each troubleshooting mode

1) Troubleshooting code number and problem
The title of thetroubleshooting chart gives the troubleshooting code, service code, and failure
mode (problem with the machine). (See Example (1))
2) Distinguishingconditions
Even with thesame failure mode (problem), the method of troubleshooting may differ accord-
ing to the model, component, or problem. In such cases, the failure mode(problem) is further
divided into sections marked with small letters (for example, a), so go to the appropriate
section t o carry out troubleshooting. (See Example (2)) If the troubleshooting table is not
divided into sections, start troubleshooting from the firstcheck item in the failure mode.
3) Method of following troubleshooting chart
Check or measure the item inside
YES line or the NO line to go to the next 0.
e, and according to the answer follow either the
(Note: The number written at the top right
corner of the 0is an index number; it does not indicate the order t o follow.)
Following the YES or NO lines according to the results of the check or measurement will
lead finally to theCause column. Check the cause and take the action given in the Remedy
column on the right. (See Example (3))
Below the 0there are the methods for inspection or measurement, and the judgement
values. If the judgement values below the 0are correct or the answer to the question
inside the 0is YES, follow the YES line; if the judgement value is not correct, or the
answer t o the question is NO, follow the NO line.
Below the 0is given the preparatory work needed for inspection and measurement, and
the judgement values. If this preparatory work isneglected, or the method ofoperation or
handling is mistaken, there is danger that it may cause mistaken judgement, or the equip-
ment may be damaged. Therefore, before starting inspectionor measurement, always read
t h e instructions carefully, and start the work in order from Item 1).
4) General precautions
When carrying out troubleshooting for the failure mode(problem), precautions that apply to all
items are given at the top of the page and marked with -k (See Example (4)) .
The precautions marked *
are not given in the I but
, mustalways be followedwhen
carrying out the check inside the I .
5) Troubleshootingtools
When carrying out the troubleshooting, prepare the necessary troubleshooting tools. For de-
tails, see TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING.

20-230 PC200-6Z
TROUBLESHOOTING
METHOD OF USING TROUBLESHOOTING
CHARTS

6 ) Installation position, pin number

A diagram or chart is given for the connector type, installation position, and connector pin
number connection. When carrying out troubleshooting, see this chart for details of the con-
nector pin number and locationforinspection andmeasurement of the wiring connector
number appearing in the troubleshooting flow chart for each failure mode (problem).

<Example>
(1) M-4 Abnormality in PPC oil pressure lock solenoid system

(4) * Before carrying out troubleshooting, check that all the related connectors are prop-
erly inserted.
* Always connect any disconnected connectors before going on the next step.
* Check that fuses 2 is normal.

(2) a) Is not actuated (safety lock is not released)

Divided into sections a) and b)
b) Remains actuated (safetu lock is not applied)

Cause Remedy

4 YE5
Go to A
Is voltage
- between S12and -
- chassis normal?
Defective contact or
disconnection in wiring
Repair or
-
Is voltage harness between V07
-
-h

YES between V07 (1) *Turn startingswitch

ON.
NC Ifemale) (2) HO2 (7) - replace

Is resistance
- and chassis
normal?
Smhg lock lever
-
LOCK 20 30 V
RELEASE: Max. 1 V
514 (1)-S12
Defective contact or
YES between S12 and - *Turn starting disconnection in wiring Repair or
S13 asshown in ON. NO harness between fuse 2 - replace
1 Table 17 -20-30V -
H06 (4) V07 (female) 11)
Is resistance
-
*Turn starting Defective PPC oil
between V07 switch OFF. Replace
pressure lock switch
(male) (1) and 12) -Disconnect s12 NO
normal? and S13.
* Check PPC oil pressure l o c k
-Turn starting
switch as individual part. Defective PPC oil

-switch OFF.
Disconnect V07.
-20-6oR
No
pressure lock solenoid
switch
Replace

5 YE!
Go to H mode (H-3)

Defective contact or
chassis normal? disconnection in wiring
Repair or
harness between S13 - replace
-Turn
starting NC -
S14 (2) H02 15) -
- switch OFF.
Disconnect S13.
* Max.1 R
chassis ground

Table 1
Safety lock lever Resistance value
OFF Max. 1 R
- LOCK Min. 1 M R

PC200-6Z 20-23 1
. TROUBLESHOOTING OF ENGINE SYSTEM
(S MODE)

Method of using troubleshootingcharts ............................................................................................. 20-302

s- 1 Starting performance is poor (startingalways takes time) .................................................. 20-306
s- 2 Engine does not start ............................................................................................................... 20-307
(1) Engine does not turn.......................................................................................................... 20-307
(2) Engine turns but no exhaust smoke comes out (fuel is not being injected) ..............20-308
(3) Exhaust smoke comes out. but engine does not start (fuel is being injected) ........... 20-309
s- 3 Engine does not pick up smoothly (follow-up is poor) ........................................................ 20-310
.s-4 Engine stops during operations .............................................................................................. 20-311
s- 5 Engine does not rotate smoothly (hunting) ........................................................................... 20-312
S- 6 Engine lacks output (no power) ............................................................................................... 20-313
s- 7 Exhaust smoke is black (incomplete combustion) ................................................................ 20-314
S- 8 Oil consumption is excessive (or exhaust gas is blue) ......................................................... 20-315
s- 9 Oil becomes contaminated quickly ......................................................................................... 20-316
s-10 Fuel consumption is excessive ................................................................................................ 20-317
s-11 Oil is in cooling water. or water spurts back. or water level goes down .......................... 20-318
s-12 Oil pressure caution lamp lights up (drop in oil pressure) .................................................. 20-319
S-13 Oil level rises (water. fuel in oil) ............................................................................................. 20-320
S-14 Water temperature becomes too high (overheating) ............................................................ 20-321
S-15 Abnormal noise is made .......................................................................................................... 20-322
S-16 Vibration is excessive ............................................................................................................... 20-323

PC200-6Z 20-301
TESTING AND ADJUSTING METHOD OF USING TROUBLESHOOTING
CHARTS

METHOD OF USING TROUBLESHOOTING CHARTS

This troubleshooting chart is divided into three

sections: questions, check items, and troubleshoot-
ing. Thequestions and check items are used to
pinpoint high probability causes that can be located
from thefailure symptoms or simple inspeciton with-
out using troubleshooting tools.
Next, troubleshooting tools or direct inspection
are used to check the high probability causes to
make final confirmation.

[Questionsl
Sections @ +@ I i n the
I chart on the right corre-
sponds to the items where answers can be ob-
tained from the user. The items in @ are items
that can be obtained from the user, depending
on the user's level.
[Check itemsl
The serviceman carries out simple inspection to
narrow down thecauses. The items under @ in
the chart on the rightcorrespond to this.
The serviceman narrows down the causes from
information @ that he has obtained from the
user and the results of @ that he has obtained
from his own inspection.
ITroubleshootingl
Troubleshooting is carried out in the order of
probability, starting with the causes that have
been marked as having the highest probability
from information gained from [Questions] and
[Check items].

20-302 PC200-6Z
 TESTING AND ADJUSTING METHOD OF USING TROUBLESHOOTING CHARTS

The basic method ofusing the troubleshootingchart

is as follows.
Items listed for [Questions] and [Check items] that
have a relationship with the Cause items are marked
with 3, and of these, causes that have a high prob-
ability are marked with Q.
Check each of the [Questions] and [Check items] in
turn, and marked the 0 or Q i n the chart for items
where the problem appeared. The vertical column
(Causes) that has the highest number of points is
the most probable cause, so start troubleshooting

f l . For [Confirm recentrepairhistory] in the

[Questionsl Section, ask the user, and mark
,- the Cause column with A to use as reference
for locating the cause of the failure. How-
ever, do not use this when making calcula-
tions to narrowdown the causes.
XC2. Use the a in the Cause column as reference
for [Degree of use (Operated for long pe-
riod)] in the [Questions] section as reference.
As a rule, do not use it when calculating the
points for locating the cause, but it can be
included if necessary t o determine the order
f o r troubleshooting.

PC200-6Z 20-303
TESTING AND ADJUSTING METHOD OF USING TROUBLESHOOTING
CHARTS

- Example of troubleshooting when exhaust gas is black

Let us assume that [Clogged air cleaner1 is taken to be the cause of black exhaust gas. Three
symptoms have causal relationship with this problem: [Exhaust gas slowly became black], [Power
slowly became weaker], and [Dust indicator is red].
If we look from these three symptoms to findthe causes, we find thatthere is a relationship with
five causes. Let us explain here the method of using this causal relationship t o pinpoint the most
probable cause.

s 7 Exhaust gas is black (incomplete combustion)

General causes why exhaust gas is black
Insufficient intake of air
Improperconditionoffuelinjection
Excessive injectionoffuel

Legmd

20-304 PC200-6Z
TESTING
ADJUSTING
AND METHOD OF USING TROUBLESHOOTING
CHARTS

,,, lr
I

Five causes

Step 1
Clarify the relationship between the three
symptoms in the [Questions] and[Check items]
section andthe fiveCause items in the vertical
column.

Three symptoms

t "

I
1

L
7 SteD 2
Add up the totalof Oand Omarkswhere the
horizontal linesfor the threesymptoms and the
vertical columns for the.causes intersect.
(1) Clogged air cleaner element: 600
(2) Air leakage between turbocharger
and head: 00
(3) Clogged, seized injection nozzle: 0
(4) Defective contact ofvalve, valve seat: 0
(5)Worn
piston ring, cylinder: 0

Step 3
The calculationin Step 2 show that the closest
relationship iswith [Clogged aircleaner
element]. Follow this column down to the
I troubleshooting area and carry out the
troubleshooting item marked0 . The Remedy is
given as [Clean], so carry out cleaning, and the
I exhaust gas color should returnto normal.

PC200-6Z 20-305
TESTING AND ADJUSTING S1

S-1 Starting performance is poor (starting always takes time)

General causes why exhaust smoke comes out but
engine takes time to start
Defectiveelectricalsystem
Insufficientsupplyoffuel
Insufficientintake o f air
Improperselection of fuel
(At ambienttemperatureof 1O'C or below,use
ASTM D975 No. 1)

-
*
-a
n+
Batterychargingrate
-1

20°C
0"c
~~

100% 90% 80% 75% 70%

1.24 1.26
1.23 1.28
1.22
1.23 1.24 1.25 1.27 1.29
-1 0°C 1.24
1.25
1.26
1.28
1.30
The specific gravity should exceed the value
for the chargingrate of 70% in the above table.
In cold areas thespecificgravitymust ex-
ceed the value for the charging rate of 75%
in the above table.

20-306 PC200-6Z
TESTING s-2

S-2 Engine does not start

(1) Engine does not turn I Causes /
General causes why engine does not turn
Internal parts ofengineseized
f If internal parts of theengineareseized,
carry out troubleshooting for "Engine
stops during operations".
Defective electrical system

Legend
0:Possible causes(judging from Questions and check items)
~:
:
p r
& b l
e ca u rc l
c l
o d g i
f
rw n ~ d c h e d ri
l
e m s )
:Possible causes dueto length of use (used for a long period)
0 :hems toconfirm tho caw.
1 Confirm recent repair history
I Degree of useofmachine I ODeratedfor
long
period In1 InI I I I
.- Condition of horn when Horn sounds

-a starting switchis turned ON Horn does not sound or volume is l o w 0

Speed is slow 0
When starting switchis
Makes grating noise
turned toSTART, pinion
Soon disengages again
moves out, but
Makes rattlina noise anddoes not turn c
I When starting switch is turnedto START, pinion does not move out 101 I I I I I
5m When starting switch is turned to ON, there is no clicking sound 0
r
u Batteryterminal is loose
When batteryis checked, battery electrolyte is found to below

Specificgravity of.electrolyte. voltage of battery is low .I

For the following conditions1) - 5). turn the starting switch
OFF, connect the cord, and carry out troubleshooting
ONat
I
1) When terminal6 and terminal C of starting switch are
connected, engine starts
2) When terminal 6 and terminal C of starting motor are
connected, engine starts
3) When terminal 6 and terminal C of safety relay are
connected. engine starts
4) Engine starts when safety switch terminal and starting
motor B terminal is connected
5 ) There is no 24V between battery relay terminalM and
terminal E
When ring gear is inspected directly. tooth surface is
found to be chiooed

PC200-6Z
I :1 Remedy
a

20-307
TESTING AND ADJUSTING s-2

(2)Engine turns but no exhaust smoke comes

out (fuel is not being injected1

f Check that the monitor panel does not dis-

play any abnormalityin the governor control
system.
General causes why engine turns but no ex-
haust smoke comes out
Supplyoffuel impossible
Supply of fuel is extremelysmall
Improper selection of fuel (particularly in win-
ter)

* Standards for use of fuel

20-308 PC200-6Z
 TESTING AND ADJUSTING
s-2

(3)Exhaust smoke comes out but engine does

not start
(Fuel is being injected)

Ir General causes why exhaustsmokecomes

out but engine does not start
Lackof rotatingforcedue todefectiveelec-
trical system
Insufficientsupplyoffuel
Insufficientintake ofair
Improper selection of fuel andoil

Legend
0 :Possiblemusets (judgingfrom Ouostho and check items)

PC200-6Z
20-309
TESTING AND ADJUSTING s-3

S-3 Engine does not pick up smoothly (follow-up is poor)

causes /
Gel
. 'I 1st

Legend
0:Possible causes (judging from Questions and check items)
~:~probabb~(iudgingfromoue+liomMdcheckitems)
:Possible causes dueto length of use (used for a long period)
:hems to confirmthe cause.

Rust and water are found when fuel tank is drained Il0lol I I I I I I I I
Dust indicator is red 0 w
Noise of interference is heard from around turbocharger 0
Engine pick-up suddenly becamepoor 0 0 00
Blue under light load
Color of exhaust gas
Black la1 I la1 I la1 I I lo
I Clanging sound is heard from around cylinder head I I I I l I I l a l I I I
I Mud is stuck to fuel tank cap I I I I I I I I l 0 l I I
There is leakage from fuel piping 0
High idlingspeed underno load is normal,
but speed suddenly drops when load is applied
00 0
There is hunting from engine (rotation is irregular) 000 0
When exhaust manifold is touched immediately after
starting engine, temperature of somecylinders is low
00
I 20. Blowby gas is excessive I I I I l l o l I I I I I
When aircleanerelement is inspected dirdy, it is found to be dogged 0
When
fudClter, mainerarrinspnteddirdy.meyarefoundtobeclossed
_. -
I I I I I I I I I I I
When feed pump strainer is inspested directly,it is found to be clogged 0
Speed does not
change
when
operation of certain
cylinders is stopped a
When
control
rack is pushed, it is found to be heavy, or does not
return a
When compression pressure is measured,
is it found to be lo\ a a
I When turbocharger is rotated by hand, it is found to beheavy1 I I 1 1 1 .1 I I I I I
When fuel cap is inspected directly,
is it found to
clogged
be a
When
pump
feed is operated,
operation
is too light or t w heavy a
, um s z c .
- r0 m
Remedy ::2 m
5 E 5g xu
m m
~x ~
~ c
0
~
~ z an a
_ m
o b

20-310 PC200-6Z
 TESTING AND ADJUSTING S-4

S-4 Engine stops during operations

General causes why engine stops during opera-
tions
Seized partsinside engie
Insufficientsupplyoffuel
overheating
* If there is overheating and the engine stops,
carry out troubleshooting for overheating.
Failure in main pistonpump
* If the engine stops because of a failure in the
main piston pump, carry out troubleshooting
for the hydraulic system (H MODE).

When oil pan is removed and inspection is madedirectly,

it is foundto be abnormal

When head cover is removed and inspection is made directly,

co
.E
e
it is found to be abnormal

When gear train isinspected, it does not turn

fa
5 When fuel filter, strainer are inspected directly,
2
2 they are found to be clogged
I-
When feed pump nrainer is inspected directly,it is found to be clogged
Inspect feed pump directly
When control rack is pushed, it is found to be heavy, or does not return

1
Remedy

PCZOO-6Z 20-31 1
TESTING AND s-5

S-5 Engine does not rotate smoothly (hunting)

General causes why engine does not rotate
smoothly I Causes

Air in fuel system

Defectivegovernor mechanism
Defectiveelectricgovernor mechanism
Ir tf hunting does not occur when the rod be-
tween the governor motor and the injection
pump is disconnected, troubleshoot by us-
ing the electrical system troubleshooting (E
mode).

Rust, water are found when fuel tank is drained

Leakage from fuel piping

;I€
When feed pump isoperated,
1) No response, light, return is quick

2) No response, light, return is normal

Engine speed sometimes rises too far
Engine i
s sometimes difficult to stop
Seal on iniection oumo has come off

When governor lever is moved it isfound to be stiff

When injection pump istested, governoris found to be

When control rack is pushed, it is foundto be heavy, or

does not return
When fuel cap is inspecteddirectly, it is found to be clogged I I I Ie
When feed pump strainer is inspected directly,it is found to
be clogged
When fuel filter. strainer are inspected directly, they are
found to be clogged

Remedy

20-3 12 PC200-6Z
TESTING AND ADJUSTING S-6

S-6 Engine lacks output (no power)

General causes why engine lacks output
Insufficient intake of air
Insufficient supply of fuel
Impropercondition of fuel injection
Improper fuelused / Causes /
(if non-specified fuel is used, output drops)
Lack of outputdueto overheating
* If there is overheatingand insufficient output,
carry out troubleshooting for overheating.

Legend
0 :Possible causes(judging from Questions and check i t e m s )
O:Mastprobsbkcaurer(judgiifrwnOuestionssndcheclritnns)
A :Possible causes dueto length of use (used for a long period)

PCZOO-6Z 20-3 13
 TESTING AND s-7

S-7 Exhaust smoke is black

(incomplete combustion)
I Causes I
General causes why exhaust smoke is black
Insufficientintakeofair
Impropercondition of fuelinjection
Excessiveinjectionoffuel

Legend
0 :Possiblecauses (judging from Questions and checkitems)
Q:Mostprobablecauses~udgingfrom&estiusandCheckinms)
A :PossiMecauses due to length of use (usedfora long period)
:kerns to confirm the cause.
Confirm recent repair history 1 1 1 1 1 1 1 1 1 1 1 1

Color of exhaust gas

I
excessive is Blow-by gas 8
Engine
pickup
is poor and combustion is irregular 0 0 000 0
When exhaustmanifold istouched immediately after
starting engine, temperature of some cylinders is low
0 0
Timing block on fuel injection pump are out of alignment

Clanging soundis heard from around cylinder head

Muffler is crushed

20-3 1 4 PC200-6Z i
TESTING AND ADJUSTING S-8

S-8 Oil consumption is excessive (or exhaust smoke is blue)

* Do not run the engine at idlingfor more than
20 minutes continuously. (Both lowand high
idling)
General causes why oil consumption is exces-
sive
Abnormalcombustion of oil
External leakage of oil
Wear of lubrication system
I Causes I

estions and checkitems)

Qlenions and Check items)
so (used for a long period)

When compression pressure is measured, it is found to be l o w

When breather element is inspected. it is found to be clogged with dirty oil
Y) There is external l e a b g e of oil from engine

.=E
2 -
Pressorbtightness test of oil cooler shows there is leakage
Excessive play ofturbocharger shaft
”c . Inspect rear seal directly
When intake manifoldis removed, dust is found inside
When intake manifold is removed, insideis found to be dirty with oil

Remedy

PC200-6Z 20-315
 ODOOB ~
Troubleshooting I Check items Questions .. *.....

P
3
a
i

Replace
Clean
Replace
Replace
Clean
Clean
Replace
Replace
I
.

Carry out trout tshootina for EXHAU!

TESTING AND ADJUSTING s-lo

S-10 Fuel consumption is excessive

General causes why fuel consumption is exces-
sive
Leakage of fuel
Improperconditionof fuelinjection
Excessive injectionof fuel

Legend
0:
Possible causes (judging from Questions and check items)
,~:ModprobabkcauseS(jUdgingfranQuestiomandChCdCitemJ)
A :Possiblecauses due to length of use (used for a long period)
0 :hems to confirm the cause.
Confirm recentrepair history
Degree of use of machine
C

Gradually increased
Suddenly increased
I I I I

I I I I

Injection pump measurement shows that injection amount is excessive (.

cn
.E
I
Speed does not changewhen operation of ceRaincylindersis stopped 0
0
2
-m
When control rack is pushed, it is found to be heavy, or does not return 0
2= . Whencheckis made, injeclion timing is found
to be incorrect 0
,O Remove head cover and inspect directly
I-
Remove feed pump and inspect directly
When engine speed is measured, low idling speed is found tobe high

PC200-6Z 20-3 17
TESTING AND ADJUSTING s-I1

S-11 Oil is in cooling water, or water spurts back, or water level goes down
General causes why oil is in cooling water
Internal leakage in lubrication system
Internal leakage in coolingsystem

Legend
0 :Possible causes (judgingfrom Questions andcheck items1
~:MaaprobaMecSux*i(iudgingfromQwstiomandchsdcitems)
A:Possiblecauses due to lengthof use (usedfor a long period)
:h e m to confirm the cause.
Confirm recent repair history

Pressure-tightness testof oil cooler shows there is leakage

Pressuretightness testof cylinder head shows there leakage
is

3a Remove cylinder head and inspect directly 0

g Remove oil panand inspect directly e.
I

20-318 PC200-6Z
TESTING AND ADJUSTING s-12

S-12 Oil pressure caution lamp lights up (drop in oil pressure)

General causes why oil pressure lamp lights up
Leakage, clogging,wear of lubricating system
Defective oil pressure control
Improper oil used(improperviscosity)
Deterioration of oil due to overheating

* Standards for engine oil selection

Ambient temperature
Type of oil
-4 14 32 50 68 86 104'F

/ Causes /
Engine oil

Legend

Replacement of filters has not been carriedout according

to Omration Manual
~~~

Non-specified oil is beins used

I
~~

Lights up at low idling

Condition when oil I Lights up
at low, high idling
pressure lamplights up I Lightsuponslope
I Sometimes lights up
There is clogging, leakagefrom hydraulic piping (external)

o) When oil filter is inspected directly, it is found to be clogged e@

5 Remove oil pan and inspect directly
II) Oil pump rotation is heavy, there is play
5
0
There is catching of relief valve or regulator valve, spring or
valve guide is broken
When oil pressure is measured, it is found to be within
I standard value

PCZOO-6Z 20-3 1 9
TESTING AND ADJUSTlNG S-13

S-13 Oil level rises (water, fuel in oil)

* If there is oil in the cooling water, carry out
troubleshooting for "Oil is in cooling water".
General causes why oil level rises
Water in oil
Causes
Fuel in oil (diluted, andsmellsofdiesel fuel)
Entryofoil from othercomponent

Pressure-tightness test of oil cooler shows there is leakage

Pressure-tightness testof cylinder head shows there is leakage 1.1 I
When compression pressure is measured, it is found to be low I le1
Remove rear seal and inspect directly

Remove injection pump and inspect directly

Remove oil pan and check directly

20-320 PC200-6Z
TESTING AND ADJUSTING S-14

S-14 Water temperature becomes too high (overheating)

General causes why water temperature becomes too
high
/
- Lack of cooling air (deformation, damage of fan)
Drop in heatdissipation efficiency
Defective coolingcirculation system
Causes

Temperature difference between top and bonom radiator

tanks is excessive ~~~

Temperature difference between top and bonom radiator

tanks is slight

-
a
.-
0
When water filler port is inspected, core is found to be clogged
When function test is carried out onthermostat, it does not

-g . open even at crackingtemperature

n
3 When water temperature is measured, it is found to be normal
2
I- When oil cooler is inspected directly, it is found to be clogged

cap tester, set

When measurement is made with radiator
Dressure is found tobe low ~~ ~

When compression pressure is measured, it is found to be low

Remove oil pan and inspect directly

Remedy

PC200-6Z 20-321
TESTING AND ADJUSTING S-15

S-15 Abnormal noise is made i

*
Causes
Judge if the noise is an internal noise or an
external noise.
General causes why abnormal noise is made
Abnormalityduetodefectiveparts
Abnormalcombustion
Air sucked in from intakesystem

20-322 PC200-6Z
TESTING AND ADJUSTING S-16

S-16 Vibration is excessive

* If there is abnormal noise together with the
vibration, carry out troubleshooting for "Ab-
normal noise is made".
General causes why vibration is excessive
Defectiveparts(abnormal wear, breakage)
Improper alignment
Abnormal combustion

PC200-6Z 20-323
 TROUBLESHOOTING OF ELECTRICAL SYSTEM
(E MODE)

Judgement table forelectrical, hydraulic, and mechanical systems ................................................ 20-352

Electrical circuit diagram for each system .......................................................................................... 20-354
Failure codes
E-1 Abnormality in PC-€PC control system
a) Engine stops even when throttle lever is not returned to STOP position.
................................................................... 20-355
When sudden load is applied, engine stalls.
b) Lacks power when throttle lever is at FULL, work equipment speed is slow ............20-356
E-2 Abnormality in travel speed selector system (travel speed does not switch) ................... 20-358
E-3 Abnormality in swing holding brake solenoid system
a) Swing holding brake solenoid is not actuated (cannot swing) ..................................... 20-359
b) Remains actuated (swing cannot be locked) ................................................................... 20-360 .
E-4 Abnormality in PPC oil pressure lock solenoid system
a) Solenoid is not actuated (safety lock is not canceled) ................................................... 20-361
b) Remains actuated (safety lock is not actuated) ............................................................... 20-362
E-5 Abnormality in engine starting system (engine does not start) .......................................... 20-364

PC200-6Z 20-351
 JUDGEMENT TABLE FOR ELECTRICAL,
TROUBLESHOOTING SYSTEMS
MECHANICAL
ANDHYDRAULIC,

JUDGEMENT TABLE FOR ELECTRICAL, HYDRAULIC, AND

MECHANICAL SYSTEMS
Pump regulator Solenoid valve
Parts causing failure Travel Hi-Lo solenoid

1. Insert T-adapter in pump 1. Insert T-adapter in Hi-Lo

regulator connector (CO1). solenoid connector (V06).
2. Turn starting switch to 2. Turn starting switch ON.
START. 3. Is voltage between V06
3. Turn pump prolix switch (1) and chassis as shown
OFF. in table below?
4. Place all levers at HOLD.
5. Is voltage between CO1
(13) and (10) as shown in
table below?

(When normal)
Voltage
Hi-Lo switch I
Failure mode
\
Speeds of all work equipment, swing, travel are slow or lack power
There is excessive droo in enaine soeed. or enaine stalls
At low idling
At full

0
0
I 0.8 - 0.97 V I
I 0.24 - 0.4 V I
High
Low
20 - 30 V
ov

No work eauipment. travel, swina move

Abnormal noise generated (around pump)
Fine control ability is poor orresponse is poor
Boom is slow or lacks power
A r m is slow or lacks Dower
Bucket is slow or lacks Dower
Boom does not move
Arm does not move
Bucket does not move
Excessive hvdraulic drift
Excessive time laa (enaine at low idlina)
Cthev equipment moves when single circuit is relieved
In compound operations, work equipment with larger load isslow
In swing + boom (RAISE), boom is slow
In swing + travel, travel speed drops excessively
Excessive deviation during normaltravel
Travel deviation
Excessive deviation when startina
Travel speed is slow
Steering does not turn easily or lacks power
Travel does not move (one side only)
Travel soeed does not switch 0
Both left and right
Does not swing
One direction onlv
Swing acceleration is poor Both left and right
or swing speed is slow One direction only
Excessive overrun when Both left and right
stopping swing One direction onlv
Excessive shock when stomina swina (one direction onlv)
Excessive abnormal noise when stopping swing
Excessivehydraulic When swing
holding brake is applied
drift of swing When
swing
holding
brake is canceled
Troubleshooting No. for electrical system E-1 E-2

20-352 PC200-6Z i
 JUDGEMENT TABLE FOR ELECTRICAL,
TROUBLESHOOTING HYDRAULIC, AND MECHANICAL SYSTEMS

Solenoid valve
holding
Swing brake solenoid I PPC hydraulic
solenoid
1. Insert 1-adapter in swing holding brake 1. Insert T-adapter in PPC hydraulic lock solenoid
connector
solenoid (V04). connector (V07).
2. Turn starting switch ON. 2. Turn starting switch ON.
3. Is voltage between V04 (1) and (2) as shown 3. ISvoltage between V07 (1) and (2) as shown
below?in table below? i n table

normal) (When (When normal)

measurement
Release 20-3ov 20 Release - 30 V
Lock ov
H-1
H-2
H-3
H-4
H-5
H-6
H-7
H-8

H-9

H-10
H-11
H-12
H-13
H-14
H-15

H-16

H-17
H-18
H-19
H-20

H-21

H-22

H-23

H-24
I I
H-25

H-26
1
I
E-3 E-4

PC200-6Z 20-353
 r
r---------
1

I I

J I

!i
0
V
-4
'e
L
TROUBLESHOOTING E-1

E-1 Abnormality in PC-EPC control system

* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on to the next step.
* Check that fuse 2 is normal.
* Check that the pump prolix switch is OFF.

a) Engine stops even when throttle lever is not returned to STOP position. When sudden load is
applied, engine stalls.

CaUSe Remedy

Replace or
Troubleshooting of turn pump
Is voltage pump regulator prolix switch
Short circuit.dironnection, ON.
(female) (1) and defective contact in wiring
(8)normal? harness between -
fuse (2) Repair or
HO6 14)- Cot (female)( 1 1 , ~ replace
1 switch ON. between COl (female)(8)
Disconnect COT. and chassis ground
Does LED of
pump regulator - -20-30V
Is continuity
I YES
I Go t o H mode (H-2)

-
go out?
YES between COI
* Turn staning -
(female) 15) (10). Shon circuit,
- disconnection. or defective
-
switch ON. 3 (61 (10) normal? Repair or
I contact in wiring harness
Turn Sartinp switch OFF. NO
between CO1 (female) (5) - replace
- 1sregulator
LED of Pump

NO flashing?
-- *DisconnectCot.
No continuity between(5)and (10)
-Continuity between(6) and (10)
-
(10). (6) (10)

5 YES
- Turn starting
switch ON.
Is resistance

c - 1 Failure of solenoid Replace

-Turn starringswitch NO
- OFF
DisconnectC13.
-7-14R Replace or
7 YES Abnormality in pump turn pump
Is resistance regulator prolix switch
Disconnection in wiring 3N.
(female) (7) and harness between CO1
(13) normal? -
(female)(7)-COS (1) (3) - qepair or
C13 (female)(1). between
-
C13 (female)12) COS (4) - 'eplace

chassis normal?
-
12) CO1 (female)(13)
Wiring harness betweenCO1
* Disconnect CO1. I - - -
[female)( 7 ) C05 (11 (3) qepair or
* Min. 1 Mi2 NO C13 (female)(1).or batween 'eplace
-
C13 (female)(2) COS (4)-
-
12) CO1 ifernale) (13)shon
:ircuiting with chassis
around

PC200-6Z 20-355
TROUBLESHOOTING E-1

b) Lacks power when throttle lever is at FULL, work equipment speed is slow

Cause Remedy

3 YES Troubleshooting of
I
pump regulator Replace
Is resistance
-
YES between CO1 - Short circuit

--
2 (female) (3)and disconnection, or defective

- - Turn
(4) normal? contact in wiring harness Repair or
-
Is resistance
between CO1 (female) (3)

--
YES between E07 starting NO and E07 (female) (1). or
replace
(male) (1) and (2) switch OFF. between CO1 (female) (41
normal? Disconnect COl. and E07 (female)(2)
-500-1OOOR
-
Is LED of pump Turn starting Troubleshooting of

-
I Replace
regulator switch OFF. NO speedtensor
flashing? Disconnect €07.
-500-1OOOR
Turn starting 4 YES Abnormality in pump
- switch ON. I Replace
regulator
Set throttle lever
to,FULL. -
NO
Is continuin, befween
COl (female)15) and
(10). (61 and (101
- Short circuit,
disconnection, or
normal?
- I
defective contactin Repair or
Turn starting NO wiring harness between replace
switch OFF. CO1 (female) (5) and (101,
* Disconnect CO1. or between (6)and (10)
No continuity between (5)
and (10)
Continuity between (6)
and (10)

20-356 PC200-6Z i
TROUBLESHOOTING E-2

E-2 Abnormality in travel speed selector system (travel speed does

not switch)

* Beforecarryingout troubleshooting, check that all the re- Remedy

lated connectors are properly inserted.
* Always connect any disconnected connectors before going
on to thenext step.
* Check that fuse 5 is normal. 3
YES
Go t o H mode (H-20)
Is voltage
w ; between VO6 (1)
and chassis
, normal? Does condition
-
4 YES Defective travel Hi-Lo
relay
Replace

Turn starting become normal

. switch ON.
Turn Hi-Lo switch
ON.
NO whentravel
Hi-Lo
relay isreplaced?
*Turn starting switch NO Go t o A
020-30V
- OFF.
Replace relay.
-Turn starting switch ON.
*Turn Hi-Lo switch ON. H~-L~
Defective travel Replace
SO r e k y switch

Disconnect VO6. Lo Defective travel Hi-Lo

solenoid valve
Replace
*20-60R
Defective contact or
disconnection in wiring
harness betweenM30 Repair or
Is voltage -
(female) (1) HO2 (1) H06 - replace
-
(2) R05 (female) (11
Defective contactor
chassis normal? disconnection in wiring
Repair or
harness betweenfuse (5) -
switch ON.
-
H06 (8) H02 (9) M38 - replace
(female) 12). and between
*20-30V
Tabte.1 R05 (female) (5) - H03 (15)

Travel Hi-Lo switch Resistance value

HIGH Max. 1 S2 Travel speed switch
LOW Min. 1 MR
1 2
E-2 Related electrical circuit diagram

V06 ( X 2 )

= a - T r a v esl p e e d
- 3 solenoid v a l v e

007 I

-3
-3
TKPOlOlO

20-358 PC200-6Z
 TROUBLESHOOTING E-3

E-3 Abnormality in swing holding brake solenoid system

* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
f Always connect any disconnected connectors before going on the next step.
* Check that fuse 2 is normal.

F
a) Swing holding brake solenoid is not actuated (cannot swing)

GOto H-21
Is voltage
n Defective contact or
and chassis disconnection in wiring
harness between V04
Turn starting N(
-
(female) (2) HO2 (3)
X05 (female) (4,
- Repair or
replace
switch ON.
Swing lock
switch LOCK:
- -
between X05 (female) (3)
HOZ (5) chassis
ground
20-3ov
* Swing lock switch Defective contact or
CANCEL: Max. 1 V disconnection in wiring Repair or
40 harness betwean fuse 2 - replace
1
-
H06 (4) V04 (female) (1)
* Turn $tatting
switch OFF.
Defective swing lock Replace
switch

- switch OFF.
Disconnect V04.
-20-60Q NO
Defective swing iock
solenoid valve Replace

Table 1
- Swing holding brake switch
CANCEL
Resistance value
Max. 1 B
LOCK Min. 1 MR

E-3 a) Related electric circuit diagram

Fuse H06 (S8) V04 ( X 2 1

BDP00258

PC200-6Z 20-359
TROUBLESHOOTING E-3

b) Remains actuated (swing cannot be locked)

Cause

Go to H Mode (H-21)

I IS rm-stance
(female)(4) and
chassis normal7 H Short ciucuit withchassis
ground in wiring harness
between VO4 (female) (2) Repair or
- -
H02 (3) X05 (female) replace
(4)

Defective swing holding Replace

brake switch

'I
I
Defective operation of
Turn starting

-
swing holdingbrake
rm'tch OFF. NO solenoid valve(short Replace
Disconnect V04.
circuit with ground
at (2))
-20-60n

Table 1
Swing holding brake switch Resistance value
CANCEL Max. 1 R
LOCK Min. 1 MR

E-3 b) Related electric circuit diagram

Fuse H06 ( S 8 ) V04 ( X 2 1

S w i n eh o l d i n g
brake solenoid

8DP00258

20-360 PCZOO-6Z
 TROUBLESHOOTING E-4

E-4 Abnormality in PPC oil pressure lock solenoid system

* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
* Check that fuses 2 is normal.

a) Solenoid is n o t actuated (safety lock is n o t canceled)

Remedv

I 4 YEA
Go to A

--
Is voltage
between S f 2 and
chassis normal?
- Defective contact or
disconnection ,inwiring
Is voltage Repair or
YES - between V07 (1) *Turn starting switch N( -
harness between'V07
- ceplace
-
(female) (2) H02 (71
2
and chassis ON.
Safety lofk lever -
S14 (1) S12
Is resistance
normal? -
LOCK: 20 30 V Defective contact or
-
RELEASE: Max. 1 V
YE ; b e m e n s12 and - T u r n starting disconnection in wiring Repair or
st3 asshown in switch ON. . NO harness between fuse 2 - replace
1 Table 17 -20-30V -
H06 (41 V07 (female) (11
Is resistance -Turn starting Defective PPC oil
between V07 switch OFF. Replace
pressure lock switch
(male1 (11 and (2) -Disconnect S12 NO
- and S13.
Check PPC oil pressure lock
Turn staning
I Defective
-
switch 8s individual part. PPC oil
switch OFF. Replace
Disconnect V07. JO pressure lock switch
-20-60Q

' Defective contact or

chassis normal? disconnection in wiring
harness between S13 - Repair or
-Turn
starting NC -
S14 (21 H02 (51 - replace

-switch OFF.
Disconnect S13.
Max.1 f2
chassis ground

c
Table 1
Swing holding brake switch Resistance value
RELEASE Max. 1 R
LOCK Min. 1 MR -

E-4 a) Related electric circuit diagram

Fuse H06 (S8) V07 (X021

PPC o i l Dressure
lock switch
S 1 4 (M2) H02 (SI61
I /
I 1
- D20
LI

SI3
BDPOO257

PC200-6Z 20-36 1
TROUBLESHOOTING E-4

b) Remains actuated (safety lock is not actuated]

Cause

Short ciucuitwith chassis

ground in wiring harness
1 YES Replace wiring
between V07 (female) (2)
Is resistance - H02 ( 7 )- S14 (1) and harness
between S12 and s12
S13 as shown in
table 17 Defective PPC oil
Replace
Turn starting NO pressure switch

- switch OFF.
Disconnect SI2
and S13.

Table 1
Swing holding brake switch Resistance value
RELEASE Max. 1 R
LOCK Min. 1 M R

E-4 b) Related electric circuit diagram

Fuse H06 6 8 ) V07 (X021

T 3
A
PPC oi I
p r e s s u r e lock
m
I /
solenoid valve
PPC oil pressure
lock s w i t c h

8DP00257

70-1362 PC200-6Z !
TROUBLESHOOTING E-5

E-5 Abnormality in engine starting system (engine does not start)

* When the starting motor does not turn.

* Check that fuse 1 is normal.
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.

YES

YES -
3
r
w Is there sound of
starting motor
pinion engaging?
- 6
Is voltage between
Turn starting
- terminal S and -
YES safety relay

switch to START. chassis normal?

3x- Same conditions

-
Is voltage between as in Step 5.
YES starting switch

-
I-
terminalcand
chassis normal?
4 NO
* Turn starting
*Is voltage between-
- "
switch toSTART.
1
L starting motor
When starting NO terminal B and -
2o 30
Yt switch is turned chassis normal? NO
OFF. is sound heard
from battery relay? * Turn starting
switch ON.
* Turn starting -20-30V
switch ON + NO
OFF.

12 YES
h resistance of wiring
1

1 ,, -
YES harnssbetwm
starting switchBR and
battery relay BR
-
- switch terminal B - -
Is voltage
and normal?

F
there continuity
Is
specific gravity of YES men Between starting NO
starting
battery normal?
-
- - ~ ~ ~ $ , ~ ~1 R
M ~ ~~ &
. :

-
and 0R7 Between wiring harness and chassis: Min.1 R
~~

*20-30V. Is voltage of Disconnect both endsof starting switch and battery

Specific gravity:
Min. 1.26
starting switch - *Turn starting
switch ON. NO
relay.
NO terminal B
normal? -Remove terminal B.
* Connect ( 4 end
of tester to
battery terminal NO
(-1
-20-30V

NO

20-364 PC200-6Z I
TROUBLESHOOTING E-5

Cause Remedy

Defective starting motor Repair or

(motor proper) replace

YES Defective starting motor Rspair or

(magnetic switch) replace
7

-
Is voksge b a r n e n Defective contact or
narring motor disconnection in wiring
terminal C and YES harness between safety Repair or
chassis normal? ' a -
relay terminal C T13 (1I replace
Is voltage between -starting motor terminal
331 Same conditions
as in Step5. NO safew relay
terminal C and
- 9 YES
C
chassis normal? Defective safety relay Replace
-
~,
Is voltage
Q Same conditions between M02
as in Step 5. NO (female) 12) and

-
chassis normal?
Defective alternator Replace
Turn
starting NO

- switch ON.
Max. 13 V
Defective contact or
disconnection in wiring
harness between startins Repair or
switch terminal C H03 -
- -
(3) M02 (1) safety
replace

relay terminal S
Defective starting switch
(between terminals E Replace
and Cl
Defective contactof wiring
hemess betweenbattery Repair or
-
terminal ( 4 battery relay
terminal B -terminal M - replace
starting motor terminal B

Defective battery relay Replace

Defective contact or
disconnection in wiring
harness between startins
Repair wiring
switch terminalBR H03 - harness
(1) -battery relay
terminal BR

Defective starting switch

(between E and ER) Replace
Defective contact or
dixonnecfion in wiring
harness between banery
---
relay terminal( 4 banery Repair wiring
relay terminalB M11 (1). I2 harness
- H03 (2) -fuse 1 starting
switch terminalB (including
fusible link)
Charge or
Lack of battery capacity
replace

PC200-6Z 20-365
TROUBLESHOOTING E-5

E-5 Related electric circuit diagram

S t a t t i n o switch Fuse

Fusible l i n k

TKP0101 I

20-366 PC200-6Z
 TROUBLESHOOTING OF HYDRAULIC AND
MECHANICAL SYSTEM
(H MODE)

Table of failure modes and causes ...*.................................................................................................. 20-402

H-l Speeds of all work equipment, travel, swing are slow or lacks power.. ....................... 20-406
H-2 There is excessive drop in engine speed, or engine stalls .............................................. 20-408
H-3 No work equipment, travel, swing move ......................................................................................... 20-409
H-4 Abnormal noise generated (around pump) ....................................................................... 20-409
H-5 Fine control ability is poor or response is poor ................................................................ 20-409
H-6 Boom is slow or lacks power .............................................................................................. 20-412
H-7 Arm is slow or lacks power ................................................................................................. 20-414
H-8 Bucket is slow or lacks power ............................................................................................. 20-416
H-9 Work equipment (boom, arm, bucket) does not move
(but travel and swing are normal) ...................................................................................... 20-416
H-10 Excessive hydraulic drift (boom, arm, bucket) .................................................................. 20-417
H-11 Excessive time lag (engine at low idling) .......................................................................... 20-418
H-12 Other equipment moves when single circuit is relieved .................................................. 20-418
H-13 In compound operations, work equipment with larger load is slow ............................. 20-418
H-14 In swing + boom RAISE, boom RAISE is slow .................................................................. 20-419
H-15 In swing + travel, travel speed drops excessively ............................................................ 20-419
H-16 Travel deviation ..................................................................................................................... 20-420
a) Deviation is excessive in normal travel ....................................................................... 20-420
b) Deviation is excessive when starting ........................................................................... 20-420
H-17 Travel speed is slow ............................................................................................................. 20-421
H-18 Steering does not turn easily or lacks power .................................................................... 20-422
H-19 Travel does not move (one side only) ................................................................................ 20-423
H-20 Travel speed does not switch .............................................................................................. 20-423
H-21 Does not swing ..................................................................................................................... 20-424
a ) Does not swing to either left or right .......................................................................... 20-424
b) Does not swing in one direction ................................................................................... 20-424
H-22 Swing acceleration is poor or swing speed is slow ......................................................... 20-426
H-23 Excessive overrun when stopping swing ........................................................................... 20-428
a) One direction only .......................................................................................................... 20-428
b) Both directions ................................................................................................................ 20-428
H-24 Excessive shock when stopping swing (one direction only). .......................................... .20-429
H-25 Excessive abnormal noise when stopping swing ............................................................. 20-429
H-26 Excessive hydraulic drift of swing ...................................................................................... 20-430
a) When swing lock is ON ................................................................................................. 20-430
b) When swing lock is OFF ................................................................................................ 20-430

PC200-6Z 20-401 :
FAILURE
TROUBLESHOOTING
OF TABLE MODES AND CAUSES

TABLE OF FAILURE MODES AND CAUSES (1/2)

T
Piston pump -e
9

i
6 Speeds of all work equipment, swing, travel areslow or lack power
iz.% There is excessive drop in engine speed. or engine stalls
No work equipment, travel, swing move
Abnormal noise generated (around pump)
Fine control ability is poor or response is poor
Boom is slow or lacks power
Arm is slow or lacks power
Bucket is slow or lacks power
Boom does not m w e
Arm does not m w e
f Bucket does not move
Excessive hydraulic drift
Excessive time lag (engine at l:,w idling)
I Other equipment moves when single circuit is relieved
u-
5 I InIn-compound operations, work equipment with larger load is slow
swing + boom (RAISE), boom is slow
In swing + travel, travel speed drops excessively
Deviation is excessive during normal travel
Travel deviation
Deviation is excessive when starting
Travel speed is slow
Steering does not turn or lack power
Does not move (one side only)
Travel speed does not switch
Both left and right
Does not swing
One direction only
Swing acceleration is poor Both left and right

c
or swing speed is slow One direction only
Excessive overrun Both left and right
when sttaaoina swino One direction onlv
Excessive shock when stopping swing (one direction only)
Excessive abnormal noise when stopping swing
Excessive hydraulic Whenbrake ON
drift of swing Whenbrake OFF

* In the failure modes, modes for compound operations are used when independent operations are normal
A: When there is an abnormality for both front and rear

20-402 PC200-6Z ;
 I I
1 b Main relief valve
i b Unload valve
~ ~~~

1 Pressure compensation valve

Main circuit check valve
LS circuit check valve
0
LS shuttle valve J
valveLS select 3
<
LS circuit throttle L
m
Arm counterblance valve

Suction valve
PPC valve
Travel PPC shuttle (built-in PPC valve)
Swing PPC slow return valve
Swivel joint

-I
a
E
M
5
I
s
0
n
P
TROUBLESHOOTING FAILURE OF TABLE MODES AND CAUSES

TABLE OF FAILURE MODES AND CAUSES (2/2)

motor

= Speeds of all work equipment, swing. travel are slow orlack power
.fs .E? There is excessive drop in engine speed, or engine stalls
o
x
-- . No work equipment. travel, swing move
55 Abnormal noise generated (around pump)
Fine control ability is poor or response is poor
Boom is slow or lacks power
Arm is slow or lacks power
E Bucket is slow or lacks power
k
.- Boom does not move
% Arm does not move
Bucket does not move
s
5
Excessive hydraulic drift
Excessive time lag (engine at low idling)
Other equipment moves when single circuit is relieved
5s
U "
Incompound operations, work equipment with larger load is slow
g'g
88
In swing + boom (RAISE). boom is slow
In swing + travel, travel speed drops excessively

-55
Deviation is excessive during normal travel
Travel deviation
Deviation is excessive
when starting
Travel speed isslow
Steering does not turn or lacks power
D o e s not move (one side only)
t -
Travel speed does not switch
Both left and right
Does not swing
One direction only
Swing acceleration is poor Both left and right

$ or swing speed isslow One direction only

Both left and right
Z Excessive overrun
2; when stopping swing One direction only
rn
Excessive shock when stopping swing (one direction only)
.$
v) Excessive abnormal noise when stopping swing
Excessive hydraulic When brake ON
drift of swina When brake OFF

In the failure modes, modes for compound operations are used when independent operations are normal
A: When there is an abnormality for both front and rear

20-404 PC200-6Z
.
TROUBLESHOOTING H-1

H-1 Speeds of all work equipments, travel, swing are slow or lacks
power
* Check that there is no abnormal normal from the mainpump before starting troubleshooting.
(If there is any abnormal noise, carry out Troubleshooting H-4.)

YES
4 -
Does condition
YES become normal
when PC valve is 5 YES
adjusted? Does condition
- NZ P C v h assembly is -
3 * For details, see become normal when
7
TESTINGAND
Is servo piston input
YES_ pressurerpprox. I R
of main circuit
- ADJUSTING. replaced)
NO
pressure?

Engine at high 6 YES

idling

- -
Arm IN relieved Does
become normal when
-
YES Is main pump
relief pressure
normal?
- NO LS valve assembly is
replaced)
Distribution NO
between LS
-
30.4 33.8 MPa
valve andpiston pump(servo piston).
-
(310 345 kglcm? YES
* Engine at high
l+ t
relieved Does condition
-
--
become normal
NO when main relief a YES

8 Check and
- -
30.4 33.8 MPa
-
(310 345
become normal
NO when unload
measure circuit valve is replaced?
oil pressure. kslcmq
For details,see €Wine at high -3.9 f 1.0 MPa NO
idling (40f 10 kg/cm’)
TESTING AND
ADJUSTING. * Arm INrelieved Engineat highidling
Arm IN relieved -
NO

Note 1:Measuring servo piston input pressure

Measure the input pressure to the large diameter end of the servo piston when the arm is
relieved. (Approx. 15.7 MPa (Approx. 160 kg/cm21)
[Basically the pressure at the large diameter end is approx. 1/2 that of the small diameter
end. (For details, see TESTING AND ADJUSTING.)]

20-406 PC200-6Z i
 TROUBLESHOOTING H-1

I Cause Remedy

Defective adjustment of
PC valve Adjust

Defective PC valve Repair or

assembly replace

Repair or
Defective piston pump
replace

Defective LS valve Repair or

assembly replace

Defective piston pump Repair or

(servo piston) reDlace

Defective adjustment of
main relief valve Adjust

Defective operation of
unload valve Replace

Defective operation of
main relief valve Replace

Defective hydraulic
- equipment in self- Adjust or
reducing pressure valve replace
output circuit
(For details, see TESTING
AND ADJUSTING.)

PC200-6Z 20-407
 TROUBLESHOOTING H-2

H-z I nere IS excesswe arop In engrne speea, or englne stalls

* Check that the main relief pressure is normal.

Cause Remedy
~ ~~

Clogged throttle inside

servo or filter inside Clean

I Servo Adjust or

1
YES replace PC
3 Defective PC valve valve
Das condition assembly
servo or filter
n become normal
-
inside servo
clogged?
whenPCvalve
assembly is
replaced? Does condition
-
4 YES Defective LS valve
Adjust or
replace LS
valve
I 2
become normal
L when LS valve
NO assembly is
- assembly
Replace
Is engine speed replaced?
(piston pump
normal at arm NO Defective servo piston assembly)

% See below. See troubleshooting for

N -
engine (S mode)

Note 1:Replace the defective servo valve assemblywith a new pac. If the engine speed is lower than
the reference value given below, go t o troubleshooting for S mode.
If it is higher, the servo valve system is defective, so replace it.
Note 2:Engine speed at arm relief when engine and pump are normal (reference value)

ef arm at I
speedEngine I Conditions
~~ ~ ~~~ ~ _ _ _ _ _
I
Engine at high idling.
Min. 1900 rpm With arm at end of stroke, move lever slowly to high
idling and read engine speedat point where there is
maximum drop in speed.

20-408 PC200-6Z
 TROUBLESHOOTING H-3, H-4

H-3 N o work equipment, travel, swing move

Cause Remedy

Defective self-reducing
2 YES pressure valve or Replace

-
When main pump
-
defective control circuit
YES pressure pickup

--
1 plugisremoved,
does oil come out?
Is PFC l o c k
solenoid valve - * Crank
with
starting motor.
NO
working
Defective damper Replace

- -
properly?
Hold outlethose
by hand
and NO
Defective operation of
PPC lock solenoid valve
or safety lock lever
Adjust
operate l o c k
lever.

H-4 Abnormal noise generated (around pump)

Cause Remedy

Do bubbles
engine is
Change
Improper hydraulic oil
hydraulic oil

- bubbles inside -
YES Are there
hydraulic tank? YES Clogged by external
Remove
P
4 object (cloth. etc.)
(strainer)
1 - Is suction strainer
clogged by
NO external object?
_ Is.suctionstrainer 5 YE! Repair or
Defect inside pump
Is hydraulic tank - .External
clogged with
-
replace
oil level normal? object:
Cloth, etc. Ns
metalpanicles or
are metal
particles stuck to
- Operate for a short time
and watch for any
Inspect again
(depending on
drain plug?
N( change in symptoms changes in
symptoms)

I Lack of hydraulic oil Add hydraulic

NO oil

PC200-6Z 20-409
TROUBLESHOOTING H-5

H-5 Fine control ability is poor or response is poor

F=
Cause

Clogged throttle in LS
circuit
Is throttle in LS
circuit clogged?
DefectiveLS valve, or
defective servo piston

20-410 PC200-6Z
2
0I

i
 TROUBLESHOOTING H-6

Cause Remedy

Defective boom cylinder Correct or

piston packing replace

Defective operation of LS Correct or

shuttle valve ( L s shuttle replace
for R.H. travel or bucket)

Defective safety &

suction valve Replace

-
Defective operation of Correct or
boom regeneration valve replace

Defective operation of
pressure compensation Correct or
valve or pressure replace
compensation piston

Defective operation of Correct or

control vakre spool replace

Defective PPC valve Replace

PC200-6Z 20-413
TROUBLESHOOTING H-7

H-7 Arm is slow or lacks power

Ir When travel and swing speeds are normal.

6 YES
IS leakage from
YES
,- arm cylinder -
normal?
-
- valve
Does LS shuttle
move - *Max.20cc/min NO
Engine at high
4 smoothly?
idling
-
Are relief pressure
YES of F and R w m p
normal am, - Check Ls shuttle
for LH. travel,
~

NO
3 circuit is relieved? boom, R.H.
IS p I K I u n
i
travel and
- 33.8 MPa
-
YES companution VJIW
um~mul.ordoes
toc
- 30.4
(310-315 kg/cm2, NO
bucket
P-recompbn-hn * Engine at high
Phil mOY* SllWMhb? idling
Does control * It is also possible
YES vatve spoolfor
arm move
- to interchange
with other NO
smoothly? compensation
valve.
See Note 1.
pressure of PPC
valve normal? NO

* Min. 2.7 MPa

- {28.kg/cm?
Engine at high
idling
NO

Note 1: After inspection, do not forget to return the interchanged valves to the original position.

20-414 PC200-6Z i
TROUBLESHOOTING H-7

Cause Remedy

Defective operation of
arm regeneration valve Correct or
or arm counterbalance replace
valve

Defective arm cylinder Correct or

piston packing replace

Defective operation of LE
shuttle valve (LS shuttle Correct or
for L.H. travel, boom, replace
R.H. travel or bucket)

Defective safety-suction
valve for arm Replace

Defective operation of
arm pressure
Correct or
compensation valve or
pressure compensation replace
piston

Defective operation of Correct or

control valvespool replace

Defective PPC valve Replace

PC200-6Z 20-415
 TROUBLESHOOTING
H-8, 9

H-8 Bucket is slow or lacks power

* When travel and swing speeds are normal.

I I 1

1 rl
4 MS Defective operation of

1
YES Is leakage from
safety-suction valvefor
bucket
Repair or
replace

Defective bucket cylinder Repair or

YE NO pistonpacking replace

Does control
2 does pressure
lmmwnsationokton II Engine at high
idlina I Defective operation of
pressure compensation
.
-,
valve spool for valve for bucket or Repair or
bucket move pressure compensation replace
* smoothly? with other compensation valve. piston
Is output
pressure of PPC
valve normal?
- See Note 1. Defective operation of
control valve spoolfor
Correct or
replace
bucket
Min. 2.7 MPa
(28 kgkrn? I Defective PPC valve Replace
Engine at high NO
idling

Note 1: After inspection, do not forget to return the interchanged valves to the original position.

H-9 Work equipment (boom, arm, bucket) does not move (but travel
and swing are normal)
* Whenboom, arm, andbucket areeach operated inde-
pendently.

K Cause

Defective control valve Correct or

spool replace
Is output
pressure of PPC
-
valve normal?
- Min. 2.7 MPa
d

NO -1 Defective PPC valve Replace

- (28 kg/cm2)
Engine at high
idling

20-41 6 PC200-6Z
 TROUBLESHOOTING H-10

H-10 Excessive hydraulic drift (boom, arm, bucket)

1) Excessive hydraulic drift of boom

1 1
YES
I Defective hydraulic
cylinder piston packing
Replace

-
Does speed of
dcwnwardmovemeot

-
becomefanerwhen 2 YES Defective operation of
lever is operated) 'DOeSCOndition safety-suction valve Replace
See TESTING
AND
become normal when
N ( j "'"W-sUcti" valve n
-
ADJUSTING. mtefchanged? Correct or
Defective operation of
It is also possible NO boom lock valve replace

- to measure
leakage of
cylinder.

- Max. 20 c d m i n
At relief
Engine at high
idling

21 Excessive hydraulic drift of armor bucket

T
Cause
--
'ES Defective hydraulic
Replace
cylinder piston packing

downward mwement YES Defective operation of

become faster when 21 Replace
safety-suction valve
lever is operated?
* See TESTING
[Does condition
become normal
-1 I
AND when safety- Defective control valve
- ADJUSTING.
It is also possible
t o measure
compensation valve
spool Replace

Damaged slipper seal of

leakage of Or does pressure

---
pressure compensation ICorrect or
cylinder. compensation piston valve, or defective
Max. 20 c d m i n move smoothly? revlace
At relief operation of pressure
* It is also possible to interchange with compensation piston
Engine at high
other compensation valve.
idling
See Note 1.

Note 1: After inspection, donot forget to return the interchanged valves to the original position.

PC200-6Z 20-417
TROUBLESHOOTING H-11, H-12, H-13

H-11 Excessive time lag (engine at low idling)

Cause Remedy

Defective safety-suction
valve, or defective Replace
regeneration valve
YE

Bucket Defective safety-suction

valve Replace

- it is also possible
to interchange .-
Defective omration of
pressure compensation
valve or pressure
Correct or
replace
with other I compeniation piston

- compensation valve.
See Note 1.
I I
Note 1: After inspection, do not forget to return the interchanged valves to the original position.

2
H-12 Other equipment moves when single circuit is relieved

Remedy
I
Defective operation of
pressure compensation
valve slipper seal
(The slipper seal in the Replace
pressure compensation
valve of the circuit that
moved isdefective.)

H-13 In compound operations, work equipment with larger load is slow

Cause Remedy
Defective operation of pressure Replace (replace pressure compensation
compensation valve valve on side where load is lower)

Combination of compound operation Side where load is larger

1 Boom RAISE + arm IN Boom RAISE
2 Boom RAISE + arm OUT Arm OUT
3 Boom RAISE + bucket CURL Boom RAISE
4 + bucket CURL
A r m OUT Arm OUT
5 Boom LOWER + arm OUT Arm OUT

20-41 8 PC200-62
I t

4
TROUBLESHOOTING H-16

H-16 Travel deviation (deviation is excessive in normal travel and

when starting)
a) Deviation is excessive in normal travel

I
Cause Remedy

4YEE Defective travel motor Correct or

assembly replace
- control valve
Does spool of
-
3move smoothly?
--
- Does travel
YES pressure
compensation valva
- NO
Defective operation of
control valve spool
Correct or
replace

2 rnovermoothly?
k travel speed Defective operation of
YES normal when
rotating under no
- Check as
individual pan. NO
travel pressure
compensation valve
Correct or
replace
load?
For conditions Adjust or
and standard Defective LS valve
values, see
NO replace
TESTING AND
ADJUSTING.
Defective PPC valve Replace

- of
I5 output pressure
self-reduu'ng

N 1 pressurevalve
-
normal? Defective self-reducing
Replace
Min. 3.3 MPa No pressure valve

- (Min. 34 kg/cm')
Engine athigh
idling

b) Deviation is excessive when starting

Cause
Defective operation of travel
Remedy
I
Correct or replace
counterbalance valve
Clogged throttle inside servo of
Correct or replace
bottom or R pump

20-420 PC200-6Z
TROUBLESHOOTING
H-17

H-17 Travel speed is slow

* Check that the spool of the travel PPC valve is moving the full stroke before carrying out trouble-
shooting.

Cau- Remedy

4 YE! Defective operation of

control valve suction Correct or
Does condition
- valve replace
YES become normal
3 when suction
valve is replaced?
-
-
Defective travel motor Correct or
YES n- V0 ma hu l , o r d w s - assembly replace

-
N(
2 pr.wrecDmpenvtion
pkmnmn YnooChb?
YES -
Does control
valve spool move - * It is also possible
to check by
Defective operation of
pressure compensation Correct or
replace
smoothly? NO compensation valve. valve or pressure
interchangingwith other
Note: After checking, alwaysreturn to original compensation piston
positions.
Defective operation of Correct or
right PPC valves
NO control valve spool replace
normal. and is output
pressure normal?
* Difference
5 YES
Defective PPC valve Replace
between output IS output pressure
pressure in of self-reducing -
FORWARD and
REVERSE: vNO
ela
v;;;;~
:,
Within 0.4 MPa .Output
pressure: NO
Defective self-reducing
pressure valve
Replace

- (4 kglcm?
Output pressure:
Min. 2.7 MPa
Min. 3.3 MPa
(34kg/cm’)
* Engine at high
(28 kg/cm2} idling
Engine at high
idling
* Relieve travel
circuit

PC200-6Z 20-421
TROUBLESHOOTING H-18

H-18 Steering does not turn easily or lacks power

Remedy

YES Defective control valve

Replace
2 suction valve
Does condition

valve -
y ~- become
swhen suction
normal
of control valve is 3 YES Defective travel motor Correct or

- 1-
intorchangod?
* Interchange left -
become n m a l
when suaion valve -
check valve replace

Is travel relief and rightspools.NO of travel motor is

interchanged? Defective travel motor
pressure normal? Replace
NO safew valve

-
i
3.8::; MPa
(3551
;: kglcm’b
Engine a t high
idling
’NO Defective main relief
va Ive
Replace

20-422 PC200-62
TROUBLESHOOTING H-19, H-20

H-19 Travel does not move (one side only)

k
Cause Remedy

YES Defective final drive Correct or

replace
1
Is any foreign Defective operation of
3 YES
material found in suction valve of control Replace

-
Dosr condition
oil drained from
final drive?
y ~ become
2
s nonnd when
lehand right d o n
valves con no^ valw
- valve

Defective operation of
-
ISamount of oil ar0imerrh.ng.d’
-
I

counterbalance valveor Replace

drained from NO
travel motor safety valve
NO travel motor

--
normal?
Max. 30 Umin Defective travel motor Replace
Engine athigh NO

- idling
Relieve travel
circuit.

H-20 Travel speed does not switch

Cause Remedy

Defective operation of
2 YES
I travel motor speed Replace
Is output pressure
- selector solenoid -
YES of travef speed
selector servo piston

--
1
valve normal? Defective operation of
Correct or
Is travel speed travel speed selector
selector electrical - ’
NO
* Mi’. 2-7 MPa
solenoid valve
replace
circuit normal?
- - (28 kg/cmq

-
Set travel speed
selector switch toHi. Defective travel speed
Disconnect Correct or
selector switch or relay,
connector V06. NO chassis wiring harness
replace

-
* Start engine.
Set travel speed
switch to Hi
Use tester t o
check that
voltage at
chassis wiring
harness end of
connector VO6 (1)
is 21.5 - 29.5 V.

PC200-6Z 20-423
 TROUBLESHOOTING H-21

H-21 Does not swing

a) Does not swing to either left or right

I Cause Remedy

Defective swing Repair or

foreign Is any machinery replace

oil drained from

Defective swing holding Repair or
of swing holding motor brake or swing replace
brake solenoid
Ivatve normal?

- (28 kglcm?
Min. 2.7 MPa ‘ ‘ 1 1 solenoid
holding brake
Defectivevalve
operation
cancelof
replace Or
* Swing lock
switch OFF

b) Does.not swing in one direction

-
Cause Remedy

Defective swing motor

safety valve or suction Replace
Does control valve

swing move
Defective operation of
Correct or
Is PPC valve control valve spoolfor
swing replace
. .oressure
outDut
normal?

Min. 2.7 MPa Defective PPC valve Replace

(28 kg/cm?
* Swing lock
switch OFF

20-424 PC200-6Z
TROUBLESHOOTING H-22

H-22 Swing acceleration is poor or swing speed is slow

* If condition is normal when work equipment is operated independently.

2 YES

- Both left
and right -
Does LS shuttle
valve move -
srnoothty?

NO

6 YES
IDoerconamon 1

acceleration poor
- - k m e normal
YES when left and right
safety vahres of

-:ompenrat
5 ming motor are
in both directions
interchanged?
or in one
- ai=
pressure
YES for ming normel,
don pressure
It is possible to
measure relief
NO

- -
4
- -
Compensationpiston prsuure ofnuin9 motor.

YES i
Does control
for - - move moothlv?
k is also possible
to interchange
Relief pressure: 27.5 30.4
u80-310 k~m’l
NO *See Note 1.
swing move with other
3 smoothly? compensation valve.
See Note 1.
- One -output pressure -
direction Is PPC valve
I
only NO
(left or right) norral?

* Min. 2.7 MPa

(28 kg/cmz) I
Engine at high NO
idling
Swing lock
switch OFF

Note 1: After inspection, do not forget to return the interchanged valves to the original position.

20-426 PC200-6Z
TROUBLESHOOTING H-22

Cause Remedy

Defective swing motor

Replace
assembly

Defective operation of LS
Correct or
shuttle valve (all LS
replace
shuttles)

Defective operation of
swing motor safety valve Replace

Defective swing motor

Replace
suction valve

Defective operation of
pressure compensation Correct or
valve or compensation replace
piston
Defective operation of
control valve spool for Correct or
swing replace

Defective PPC valve Replace

PC200-6Z 20-427
TROUBLESHOOTING
H-23

H-23 Excessive overrun when stopping swing

a) One direction only

Cause Remedy

3 YES Defective swing PPC Correct or

slow return valve replace

returnvalves are

Defective PPC valve Replace

NO

valve spool for

swing move
- 1
NO
Defective swing motor
safety valve Replace
smoothly?
Defective operation of
control valve spool for Zorrect or
swing I-eplace

b) Both directions

Cause Remedy
Defective swing motor Repair or replace

20-428 PC200-6Z
 TROUBLESHOOTING H-24, H-25

H-24 Excessive shock when stopping swing (one direction only)

Remedy

Defective swing'PPC
slow return v a l w k h e c k Correct or
valve) replace

Defective PPC valve Replace

H-25 Excessive abrormal noise when stopping swing

Cause Remedy

Defective operation of
Replace
swing motor safety valve
1
Is output pressure
of swing motor YES Defective swing motor
solenoid valve - 1 suction valve Replace

become normal
Defective swing Repair or
h
machinery replace
Is foreign
material found in

Defective back pressure Correct or

NO valve replace

PC200-62 20-429
TROUBLESHOOTING H-26

H-26 Excessive hydraulic drift of swing

a) When swing lock is ON

Cause Remedy

1 YES Defective operation of Repair or

Ls output pressure swing holding brake replace
of swing holding
brake solenoid
v a l v e normal? Defective operation of
I I swing lock solenoid Correct or
Min 2.7 MPa NO va Ive replace
128 kglcrn?
Turn swinglock
switch OFF.

b) When swing lock is OFF

Cause Remedy

3 YE! Defective swing motor

Replace
safety valve

-- Is problem reversed
YES when lef! and right
2 satetyvalves are
-
--
Is pressure interchanged? Defective swing motor Correct or
rdirection
One only - c~nsationvalveon
~~m$e-l*or
cwnpenwt'mpinon
N(
suction valve replace

,move rrnoothlv? Defective pressure

compensation valve, or Correct or
NO defective operationof replace
pressure compensation
piston
Defective control valve Replace
spool
Is drain amount

Repair or
Defective swing motor replace
- 1 0 Ulmin NO
-Engine at high
idling
-Relieve swing
circuit

20-430 PC200-6Z
.. TROUBLESHOOTING OF
MACHINE MONITOR SYSTEM
(M MODE)

Monitor system electrical circuit diagram ...........................................................................................

20-452
M- 1 When the starting switch is turnedON. no display is given
(lamps do notlight up for 3 seconds) .............................................................................. 20-453
M- 2 When starting switch is turnedON. lamps light up f o r 3 seconds.
but then do not go out ......................................................................................................
20-453
M- 3 When starting switch is turnedON, some lamps do not light up for 3 seconds ....... 20-454
a) No gauge lamps light up (caution lamps light up) ..................................................
20-454
b) Swing lock. preheating lamps do not light up (all gauge lamps light up) 20-454 ...........
c) Charge caution lamp does not light up .....................................................................
20-454
. d) Engine oil pressure caution lamp does not light up ................................................
20-454
M- 4 When power is turned on (before engine isstarted). charge caution lamp
does not light up ................................................................................................................
20-455
M- 5 When power is turned on (before engine isstarted), engine oil pressure
caution lamp does not light up ......................................................................................... 20-455
M- 6 During preheating, preheating pilot lamp does notlight up ......................................... 20-456
M- 7 When switch is operated. swing lock lamp does not light up ...................................... 20-456
M- 8 Engine oil pressure caution lamp lightsup when engine is running
(engine oil pressure is normal)......................................................................................... 20-457
M- 9 Charge caution lamp lightsup when engine is running................................................ 20-457
M-10 Abnormality in coolant temperature gauge.................................................................... 20-458
a) After engine is started, level stays at bottom (white range) and
does not move.............................................................................................................. 20-458
b) After engine is started, level immediately rises
Engine is not overheatingbut indicator enters red range....................................... 20-458
c) Coolant temperature gauge goes out ........................................................................ 20-458
M-11 Abnormality in fuel gauge ................................................................................................. 20-459
a) All fuel gauge segments go out ................................................................................. 20-459
b) Even when fuel level goes down, fuel gauge continues to show FULL ............... 20-459
. c) Even when tank is filled, fuel gauge does not show FULL ..................................... 20-459
M-12 Defective operation of alarm buzzer ................................................................................. 20-461
a) Buzzer does not sound ................................................................................................ 20-461
b) Buzzer continues to sound and doesnot stop .......................................................... 20-461
M-13 Engine is running. but service meter does not move.................................................... 20-462
a) Charge caution lamp lights up ................................................................................... 20-462
b) Charge caution lamp does not light up ..................................................................... 20-462
M-14 Night lighting does not light up ........................................................................................ 20-463
a) Gauge lighting does not light up ............................................................................... 20-463
b) Service meter lighting does not light up (service meter is working normally).... 20-463
M-15 Wiper does not move. or does not stop moving............................................................2 0.464
a) Wiper does not move when wiper switchis turned to ON ..................................... 20-464
b) Wiper moves even when wiper switch is not turned to ON ................................... 20-464
M-16 Heater does not work......................................................................................................... 20-465
a) Does not work at either Hi or Lo ................................................................................ 20-465
b) Does not work at Lo only ............................................................................................ 20-465
c) Does not work at Hi only ............................................................................................ 20-465

PC200-6Z 20-451
 n
c
3
m
- 0
r- 2
I -
0
= 0 0
c = i
i m
j
L .

3
TROUBLESHOOTING M-1, M-2

M-1 When the starting switch is turned ON, no display is gken (lamps
doe not light up for 3 seconds)

* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.

Cause Remedy

Defective monitor panel Replace

I1s -age 'I I Defective contact or

disconnection in wiring
harness between Pol
W 2 ) and fuse 2, or Repair or
-
between PO1 (3)(4) H03 replace
(11) - chassis ground
Replace fuse
-20-30v after inspecting
Blown fuse 2 and repairing
NO cause of blown

M-1 Related electrical circuit diagram

I fuse
PO 1
Moni t o r P a n e l (0401 6) Fuse

VB
VB
GND H03 (St 6)
GND

B O P O O ~

M-2 When starting switch is turned ON, lamps light up for 3 seconds,
but then do not go out

* Before carrying out troubleshooting, check that

all the related connectors are properly inserted.
* Always connectanydisconnectedconnectors
before going on the next step.
* Check the fuses 2 before troubleshooting.

_i
Cause Remedy

Defective monitor panel Replace

PC200-62 20-453
TROUBLESHOOTING M-3

M-3 When starting switch is turned ON, some lamps do not light up
for,3 seconds
* Before carrying gout troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
* Check the fuse before troubleshooting.

a) No gauge lamps light up (caution lamps light up)

CaUSe Remedy

Defective monitor panel Replace

b) Swing lock, preheating lamps do not light up

(all gauge lamps light up)
1 YES Blown bulb in lamp
which does not light up Replace
Is there
disconnection in
lamp whichdoes
-
not lightup?
Defective monitor panel Replace
Check visually for NO
blown bulb.

c) Charge caution lamp does not light up

1 YES Blown bulb of charge

caution lamp Replace
Is there
disconnection in -
lamp?

- Check visually for NO

blown buib:.?
GO to M-b.

dl Engine oil pressure caution lamp does not light up

1 YES Blown bulb of engineoil

presusure caution lamp Replace
Is there
disconnection in

GO to M-5.
Check visually far NO
blown bulb.

20-454 PC200-6Z
 TROUBLESHOOTING M I , M-5

.-

M-4 When power is turned on (before engine is started), charge

caution lamp does not light up
* Beforecarryingout troubleshooting, check thatall CaUSe Remedy
the related connectors are properly inserted.
* Always connect any disconnected connectors before
going on the nextstep.
YES
Lamp bulb is blown . Repbce
1
Is voltage Defective contact or
disconnection in wiring
between P O 1 (10) ov harness between PO1

-
and PO1 (3).(4)
normal? 2- - -
(female) (10) H03 0)-
Repair or
replace
7 M02 (2) -E08 (1) E12
Turn starting between P O 1
NO (female) (10) -
- (1) -alternator terminal L

-
switch ON. 3 YES
*O -SV Defective D l 4 Replace
-(3). (4) normal?
Disconnect Wl. I
between
-Turn starting 0 - 1ov alternator Land
-
-
I

switch ON. chassis normal?

Max. 10 V -Turn starting NO Defective alternator Replace
switch ON.
Disconnect P o l and D14.
Max. 10 V
diagram
circuit
electric
M-4 Related Alternator

E l 2 (X21

TKP01013

M-5 When power .isturned on (before engine is started), engine oil

- pressure
caution
lamp does not light up
* Beforecarryingout troubleshooting, check thatallthe re-

=-I
lated connectors are properly inserted.
* Always connect any disconnected connectors before going
Remedy
on the nextstep.
* Check for blown lamp bulb before starting troubleshooting.
2 YES
Defective monitor panel Replace
I IScontinuitv
Defective contact or
disconnection in wiring
Repair or
harness between P o l
(female) ( 9 )- H03 (10)- replace
E08 (male) ( 8 )

Defective engine oil

pressure sensor Replace
aMax.0-5R

ram circuit electric

M-4 Related I I
Engine o i l
M o n i t o r oanel PO1 (04016) H03(SIGwhite) Dressure s w i t c h
TROUBLESHOOTING M-6, M-7

M-6 During preheating, preheating pilot lamp does not light up

t Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
* If the lamps do not light up for3 seconds when the starting switch is turned ON, go to M-2.

1YES I Defective monitor panel Replace

ts voltage
betwean PO1 (13)
and 13)(4)
- Defective contact or
disconnection in wiring
-
normal?
harness between PO1
Repair or
replace
-Turn starting NO (female) (13) and
switch to HEAT. starting switch R1. or
-20-30v defective starting switch

M-6 Related electrical circuit diagram

PO 1 Starting switch
M o n i t o r P a n e l (040 1 6 )

H03 6 1 6)

BDP00266

M-7 When switch is operated, swing lock lamp does not light up
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* A,lways.connect any disconnected connectors before going on the next step.

I Cause Remedy

2 YES I
~ ~~~ ~~~

Defective monitor panel Replace

Is therecontinuity
YES between PO1
1 (female) (12) and
- Defective contact or
disconnection in wiring
chassis normal? harness between PO1 Repair or
(female) (12) - H03 ( 9)-
between X05 * Disconnect Po1 NO -
HOZ (10) XOS (female)
replace
(1). or XOS (female) (2) -
- H02 (5) - chassis ground
Disconnect X=. Defective swing lock Replace
-Turn swing lock NO switch
switch ON.

M-7 Related eleccl- kat circuit diagram

20-456 PC200-6Z I
I
TROUBLESHOOTING M-8, M-9

M-8 Engine oil pressure caution lamp lights up when engine is running
(engine oil pressure is normal)
* Before carrying out troubleshooting, check that all the re-
Remedy
lated connectors are properly inserted. CaUSe

* Always connect any disconnected connectors before go-

ing on the next step.
YES Defective engine oil
l t Replace
pressure sensor switch

Does engine oil

pressure caution
Defective monitor p a n e l Replace
PO1 Ifemale) (9)
Contact of chassis wiring

- terminal or E08.
Start engine.
.
T~~~startingNO
switch OFF.
harness with wiring
harness between PO1
-
Ifemale) (9) H03 (10) -
Repair or
replace

Check continuity between Wl E08 (mala) (8)

(female) (9) and chassis ground.
Min. 1 Mn

M-8 Related electric circuit diagram

Engine o i l
Wonitor P a n e l POI (04016) H03 (SI6 w h i t e) Dressure s n i t c h
I I

Engine oil Pressure @

- @
1-
I I
TKP01014

M-9 Charge caution lamp lights up when engine is running

* Before carrying out troubleshooting, check that all the re-
lated connectors are properly inserted.
* Always connect any disconnected connectors before go-
ing on the next step.
2
YES
I Defective monitor panel Replace

Is voltage Contact of chassis ground

YES between Po1
(female) (10) and
- 3 YES
with wiring harness
Repair or
between PO1 (female)(10)
(3)(4) normal7 Is rninance - H03 (7) - E08 (2) - replace

Is Mkage &tween
~- Stan engine.
-
1
.20 - 30 v
-
between alternator
terminal L (wiring - alternator terminal L

akernator terminal
L and chassis
- NO harness end),
normal?
Defective contact or
disconnection in wiring Repair or
harness between P O 1
- replace

-ground normal? *Disconnect NO (female) (10) H03 (7) -

alternator terminal E08 (2) -alternator
Stan engine.
-20-30V
1 and Pol.
Min. 1 MR - terminal L
Defective generation of Replace
NO electricity by alternator

I I
M-9 Related electric circuit diagram
Alternator

Mon i t o r Dane1 PO I (04016) H03 (SI6 w h i t e ) E 0 8 1( X)

9 L
charotnorate
-
TKPOIOIS

PC200-6Z 20-457
TROUBLESHOOTING M-10

M-10 Abnormality in coolant temperature gauge

f Before carrying out troubleshooting, check that all the related connectors are properly inserted.
f Always connect any disconnected connectors before going on the next step.

a) After engine is started, level stays at bottom (whiterange) and does not move

Remedy
~~

YES Defective coolant

I
Replace
1 1 temperature sensor
pEGzGq Defective contactor
one at a time and disconnection in wiring

Turn starting
v- one at a time and
2 YES harness betweenPO1
- -
(female) ( 6 ) H03 (5)-
E08 (6) PO7 (female) (11,
Repair or
replace
or between PO7 (female)
switch ON. N 6 findball (2) -chassis ground
Connect short
connector to PO7 . segments go out?
,.T
,, &aina - NO Defective monitor panel Replace
(female).
- switch ON.
Short circuit P O 1
(6)and (3)(4).

b) After engine is started, level immediately rises

Engine is not overheating but indicator enters red range
2 YES
Defective monitor panel Replace

-
k resistance
YES between m7
1 r (male) (1) and (2)
I normal? J
Defective coolant Replace
between P O 1 -DisconnectPO7. NO temperature sensor

Defective contact

-
After
Start engine. between PO1 (female) inspection,
Max. 0.1. V NO (3N4)- H03 (11) -chassis repair
ground
cl Coolant temperature gauge goes out
YES Defective coolant
Replace
temperature sensor

light up? 2 YES

Defective monitor panel Replace
Is resistance
Turn starting between PO1
Contact chassisground
with wiringharness
--
* Remove PO7 (3)(4) normal? Repair or
between P O 1 (female) (6)
Disconnect Pol.
Resistance:
NO -
- H03 ( 5 ) E08 ( 6)- PO7 replace
(female) (1). or leak
Min. 1 lrll

M-10 Relatedelectricalcircuit diagram

Enoine water
Won i t o r p a n e l PO 1 (0401 6) H03 (Sl6whi t e ) PO7 (X21 t e m p e r a t u r e sensor

TKPOlOlB

20-458 f'C200-6Z
 TROUBLESHOOTING M-11

M-11 Abnormality in fuel gauge

* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.

a) all fuel gauge segments go out

Cause Remedy

Defective fuel level

YES
sensor (failure in Replace
1 disconnection mode)
Does fuel gauge
give FULL display
(all segments
- 2 YES
Defeaive contact or
disconnection in wiring
Repair or
harness between PO1

- -
lighted up)? replace
Does fuel gauge (female) (7) H06 (6)
Turn starting give FULL display -PO6 (female) (1)
switch ON. NO (all segments
.- lighted up?
Connect PO6
(female)
-Turn
to starting NO Defective monitor panel Replace
w&.h ON
-
chassis ground.
Wait for approx. Short circuit PO1 (7) and (3).
1 minute. -Wait forapprox. 1 minute.

b) Even when fuel level goes down, fuel gauge continues to show FUL

Defective monitor panel Replace

Contact chassisground
with wiringharness

- - - Turn starting
Repair or
No between PO1 (female) (7)
YES fuel
Is resistance of
level sensor - -
H06 ( 6 ) PO6 (female) replace
1 normal? (1)

- :. - switch ON.
~

Is voltage
Removesensor Wait for approx.1 minute. Defective fuel level
between PO1 Replace
Movsfloatby NO sensor
(3)(4) and chassis
!ground normal? I hand and

-
measure resistance betweenPO6 (male) and chassis ground. Defective contactor
* F position : Max. approx. 12 R disconnection in wiring
Start engine. After
* Max. 0.1 V
-
E position :Approx. 85 110 R
harness between PO1 inspection,
NO -
(female) (3)(4) H03 (11) repair
-chassis ground

c ) Even when tank is filled, fuel gauge does not show FULL

YES
1 Defective monitor panel Replace

Is resistance of
fuel level sensor - 2 YES
Defective contactor
disconnection in wiring After
normal? harness between PO1 inspection,

- Measure
resistance NO
Is voltage
between PO1
(3)(4) and chassis
- -chassis ground
-
(female) (3)(4) H03 (11) repair

-.
between PO6 ground normal? Defective fuel level
Replace
(male) -chassis Start engine. NO sensor

- ground
F position :Max.
approx. 12 n
Max. 0.1 V

PC200-6Z 20-459
 n
I 5
m
0
V
0
0
N UI
-I 0
0 -l

.
 TROUBLESHOOTING M-12

M-12 Defective operation of alarm buzzer

f Before carrying out troubleshooting, check that all the related connectors are properly..inserted.
f Always connect any disconnected connectors before going on the next step.

a) Buzzer does not sound

CaUSe Remedy

YES
Defective monitor panel Replace
1
Does buzzer Defective contact or
sound when PO1 disconneuion in wiring
(female) (15) and

- -
(3)are connected?
Connect PO1 -.~6 --
between PO4 (2)
2 YES harnessbetween PO4
(female) (1) and P O 1
(female) (15). or defective
buzzer
Repair or
replace

(female) (15) and chassis

- and (3).
Turn
starting
switch ON.
ground normal?
Turn starting
switch ON.
NO
Defective contact or
disconnection in wiring
harness between !use 2
Repair or
replace
and W4 (female) (2)
.20-3Ov

b) Buzzer continues ?o sound and does not stop

M-12 Relatedelectricalcircuitdiagram

BDP0027 I

PC200-6Z 20-461
TROUBLESHOOTING M-13

M-13 Engine is running,. but service meter does not move

f Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnectedconnectors before going on the next step.
a) Charge caution lamp lights up
Cause Remedy

YES
2 1 Defective monitor panel Replace

Defective contactor
disconnection in wiring
harness betweenPol Repair or
- -
(10) H03 (7) E08 (2) - replace
alternator terminal L
Contact of chassis
ground with wiring Repair or
harness betweenP O 1
-
(female) (10) H03 (7) -
replace
-
Start engine.
-20-30v I terminal L and W1.
Min. 1 MSI
E08 (2) alternator
terminal L
Defective generationof
Replace
electricity by alternator

I
b) Charge caution lamp does not light up

Cause

Defective monitor Dane1 Replace

M-13Related electrical circuit diagram

Alternator

20-462 PC200-6Z
TROUBLESHOOTlNG M-14

M-14 Night lighting does not light up

* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.

a) Gauge lighting does not light up

Bulb of night lifhting

,YES (inside monitor panel) Replace
blown
Defective contact or
disconnection in wiring
harness between PO1 Repair or
(female) (16) and PO2 replace
-Turn starting (female) (3)
between PO2 (3)
Defective light switch Replace
ON.
-20-3ov - Turn starting
switch ON. N
Is voltage
between PO2 (4)
aand I:hassis Disconnection in wiring
Turn light switch-'-lground normal? harness between PO2 Repair or
ON. (female) (4) and fuse 4, replace
NO
-.u. or blown fuse
-20-30V

b) Service meter lighting does not light up (service meter is working normally)

Cause Remedy

Defective monitor panel Replace

M-14 Related electrical circuitdiagram

PO2
PO 1 (KES1, 4 ) Lam0 s w i t c h
Monitor panel (04016) To w o r k i n g lam0 <

H03 ( S 1 6)

Fuse

BDP00272

f'C200-6Z 20-463
 ***

'
C

I
z
0

k'
a
!3
r,

3
Ip
n
s
0
2
 I i i

4
x
’D
0
TROUBLESHOOTING M-16

M-I6 Heater does not work

* Before carrying out troubleshooting, check that allthe
related connectors are properly inserted.
* Always connect any disconnected connectors before go- Remedy
ing on the next step.
a) Does not work at either Hi or Lo
2 YES
I IS there continuity I I
Go to troubleshooting of
heater
-
..
Defective contactor
disconnection in wiring
Repair or
betmtntcnninals - *Turn starting
switch OFF.
NO
harness between M06
ffemale) (4)and chassis replace

I'
of M06 (male) as ground
lshown in Table 17 I
Turn starting
switch OFF. NO Defective heaterswitch Replace
Disconned M06.

Table 1
Switch position Continuous terminal
Lo Between (3) (4) - Cause Remedy
Hi Be-n (2) (4) -
b) Does not work at Lo only
Go to troubleshooting of
heater
-
(female) (2) and Defective contactor

-
chassis ground? disconnection in wiring
harness between M06 Repair or
between M06 Disconnect M12. NO (female) (3) and M12 replace
(female) (2)

-Turn NO I Defective heaterswitch Replace

-switch OFF.
Heater switch at Lo.

c) Does not work at Hi only

2 YES Go to troubleshooting of -
Is there continuity
-
heater
YES between M12 - Defective contact or

I
(female)(3)and

- -
chassis ground? disconnection in wiring
harness between M06 Repair or
betmen M06 Disconnect MIZ. NO (female) (2) and M12 replace
(male) 17' (female) (3)

Disconnect M06.
[ - Heater switch at Hi.
Turn startina NO Defective heaterswitch Replace
switch OFF-
* Heater switch at Si.

M-15 Related electrical circuitdiagram

switch Heater H06 (KES14) M l 2 (KES13)

Heater H i -
H e a l e r Lo Heater
H05 (L2)
1
Fuse

-
BKP02453

20-466 PC200-6Z
.

30 DISASSEMBLY AND ASSEMBLY

METHOD OF USING MANUAL ...................

30- 3 CENTER SWIVEL JOINT ASSEMBLY
PRECAUTIONS WHEN CARRYING OUT Removal and Instaltation ..........30-44
. OPERATION ............................................ 30- 4 Disassembly and Assembly ................
30-46
SPECIAL TOOL LIST ....................................
30- 6 FINAL DRIVE ASSEMBLY
SKETCHES OF SPECIAL TOOLS ............... 30-10 Removal and Installation ..........30-47
STARTING MOTOR ASSEMBLY Disassembly ...........................................
30-48
Removal and Installation .................... 30-11 Assembly ................................................
30-51
ALTERNATOR ASSEMBLY SPROCKET
Removal and Installation .................... 30-12 Removal and Installation ...........
30-56
AIR CONDITIONER COMPRESSOR ASSEMBLY SWING MOTOR. SWING MACHINERY
Removal and Installation .................... 30-13 ASSEMBLY
CONDENSER ASSEMBLY Removal and Installation ...........
30-57
Removal and Installation .................... 30-14 Disassembly ...........................................
30-59
ENGINE OIL COOLER CORE ASSEMBLY Assembly ................................................
30-63
Removal and Installation .................... 30-15 REVOLVING FRAME ASSEMBLY
FUEL INJECTION PUMP ASSEMBLY Removal ..................................................
30-68
Removal ................................................. 30-16 Installation ..............................................
30-69
Installation ............................................ 30-19 SWING CIRCLE ASSEMBLY
WATER PUMP ASSEMBLY Removal .................................................. 30-70
Removal and Installation .................... 30-21 Installation ..............................................
30-71
NOZZLE HOLDER ASSEMBLY IDLER RECOIL SPRING ASSEMBLY
- Removal and Installation .................... 30-23 Removal and Installation...................... 30-72
TURBOCHARGER ASSEMBLY RECOIL SPRING ASSEMBLY
Removal and Installation .................... 30-24 Disassembly ........................................... 30-73
THERMOSTAT ASSEMBLY Assembly ................................................30-74
Removal and Installation .................... 30-25 IDLER ASSEMBLY
CYLINDER HEAD ASSEMBLY Disassembly ........................................... 30-75
Removal ................................................. 30-27 Assembly ................................................ 30-76
Installation ............................................ 30-31 TRACK ROLLER ASSEMBLY
RADIATOR HYDRAULIC OIL COOLER Removal and Installation...................... 30-78
ASSEMBLY Disassembly ........................................... 30-79
Removal ................................................. 30-34 Assembly ................................................ 30-81
Installation ............................................ 30-36 CARRIER ROLLER ASSEMBLY
ENGINE MAIN PUMP ASSEMBLY Removal and Installation...................... 30-83
Removal ................................................. 30-37 Disassembly ........................................... 30-84
Installation ............................................ 30-41 Assembly ................................................ 30-86
DAMPER ASSEMBLY TRACK SHOE ASSEMBLY
Removal and Installation .................... 30-42 Removal and Installation...................... 30-88
FUEL TANK ASSEMBLY
.
.
Removal and Installation .................... 30-43

PC200-6Z 30-1
HYDRAULIC TANK ASSEMBLY BOOM CYLINDER ASSEMBLY
Removal ................................................
30- 89 Removal ................................................ 30-122
Installation ............................................
30- 90 Installation ............................................ 30-123
MAIN PUMP ASSEMBLY ARM CYLINDER ASSEMBLY
Removal ................................................
30- 91 Removal ................................................ 30-124
Installation 93............................................
30- Installation ............................................ 30-125
MAIN PUMP INPUT SHAFT OIL SEAL BUCKET CYLINDER ASSEMBLY
Removal and Installation 30- 94 .......... Removal ................................................ 30-126
CONTROL VALVE ASSEMBLY Installation ............................................ 30-127
Removal ................................................
30- 95 HYDRAULIC CYLINDER ASSEMBLY
Installation ............................................
30- 97 Disassembly ....................................... 30-128
Disassembly ........................................
30- 98 Assembly .............................................. 30-131
Assembly ..............................................
30-103 WORK EQUIPMENT ASSEMBLY
MAIN RELIEF VALVE ASSEMBLY Removal ................................................ 30-135
Disassembly and Assembty 30-109 ................ Installation ............................................ 30-136
PC VALVE ASSEMBLY BUCKET ASSEMBLY
Removal and Installation 30-110.......... Removal ................................................ 30-137
LS VALVE ASSEMBLY Installation ............................................ 30-138
Removal and Installation 30-172.......... ARM ASSEMBLY
PC-EPC VALVE ASSEMBLY Removal ................................................ 30-139
Removal and Installation ..........
30-1 13 Installation ............................................ 30-1 40
SOLENOID VALVE ASSEMBLY BUCKET ARM ASSEMBLY
Removal and Installation 30-114.......... Removal ................................................ 30-1 41
WORK EQUIPMENT SWING PPC VALVE Installation ............................................ 30-142 I
ASSEMBLY BOOM ASSEMBLY
Removal and Installation 30-1 15 .......... Removal ................................................ 30-143
Disassembly .........................................
30-116 Installation ............................................
44 30-1
I

Assembly ..............................................
17 30-1 OPERATOR'S CAB ASSEMBLY
TRAVEL PPC VALVE ASSEMBLY Removal and Installation .......... 30-145
Removal and Installation 30-118 .......... COUNTERWEIGHT ASSEMBLY
Disassembly and Assembly 30-119 ................ Removal and Installation .......... 30-146
BOOM LOCK VALVE ASSEMBLY MONITOR ASSEMBLY
Removal and Installation .......... 30-121 Removal and Installation .......... 30-147

PC200-6Z
 DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL

METHOD OF USING MANUAL

1. When removing or installing unit assemblies
@ When removing or installing a unit assembly, the order of work andtechniques used are given
for the removaloperation; the order of work for the installation operation is notgiven.
@ Any special techniques applying only to the installation procedure are marked and the m,
same mark is placed after the relevant step in the removal procedure t o indicate which step in
the installation procedure it applies to.

(Example)
REMOVAL OF 0000ASSEMBLY ............Title of operation
A ....................................................................... the Precautions related to safety when carrying out
operation
1. X X X X ( 1 ) ..................................................... Stepinoperation
f ................................................................... Technique or important point to remember
- removing when XXXX (1).
2. A A A A (2): ............................................... Indicates that a techniqueislisted for use
during installation
3. 00 00 assembly (3)
b
............................................................ Quantity of oil or water drained

INSTALLATION OF 0003 ASSEMBLY ....Title of operation

Carry out installation in the reverse order to removal.
.............................................................. Technique used during installation
f ................................................................... Technique or important point toremember when
installing A A A A (2).
Adding water, oil ................................. Step in operation
* ............................................................ Point to remember when adding water or oil
@......................................................... Quantity when filling with oil and water
2. General precautions when carrying out installation or removal (disassembly or assembly) of units
are given together as PRECAUTIONS WHEN CARRYING OUT OPERATION, so be sure to follow
these precautions when carrying outthe operation.

3. Listing of special tools

@ For details of the description, part number, and quantity of any .tools(AI, etc.) thdt agpear in
the operation procedure, see the SPECIAL TOOLS LIST given in this manual.

PC200-6Z 30-3
 PRECAUTIONS
DISASSEMBLY AND ASSEMBLY WHEN CARRYING OUT OPERATION

PRECAUTIONS WHEN CARRYING OUT OPERATION

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the
general precautions given below when carrying out the operation.]

..
1. Precautions when carrying out removal work
If the coolant contains antifreeze, dispose of it correctly.
After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from
entering.
When draining oil, prepare a container of adequate size to catch the oil.
Confirm the match marks showing the installation position, and make match marks in the neces-

. sary places before removal to prevent any mistake when assembling.

To prevent any excessiveforce from being applied to the wiring, always hold theconnectors when
disconnecting the connectors. DO not pull the wires.
Fit wires and hoses with tags to show their installation position to prevent any mistake when
installing.

. Check the number and thickness of the shims, and keep in a safe place.
When raising components, be sure to use lifting equipment of ample strength.
When using forcing screws to remove any components, tighten the forcing screws uniformly in
turn.
Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt
from entering after removal.
* Precautions when handling piping during disassembly
Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
1) Hoses and tubes using sleeve nuts
Nominal Plug (nut end) Sleeve nut (elbow end) Use the two items below as a set
number
02 07376-50210 07221-20210 (Nut), 07222-00210 (Plug)
03 07376-50315 07221-20315 (Nut), 07222-00312 (Plug)
04 07376-50422 07221-20422 (Nut), 07222-00414 (Plug)
05 07376-50522 07221-20522 (Nut), 07222-00515 (Plug)
06 07376-50628 07221-20628 (Nut), 07222-00616 (Plug)
10 07376-51034 07221-21034 (Nut), 07222-01018 (Plug)
12 07376-51234 07221-21234 (Nut), 07222-01219 (Plug)

2) Split flange type hoses and tubes

Nominal Sleeve head (tube end) Split flange
Flange (hose end)
number
04 0737 1-30400 07378-10400 07379-
05 07371-30500 07378-10500 07379-00

%R
3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part Number
number D l d I L
~~

06 07049-00608 6 5 8
08 07049-0081 1 8 11 6.5
10 07049-01012 8.5 10
12
12 07049-01215 10 12
15
14 07049-01418 14
11.5 18 Taper 1/8
16 07049-01620 16 13.5 20
18 07049-01822 15 18
22
20 07049-02025 20 17 25
22 07049-02228 22
18.5 28
24 07049-02430 20 24
30
27 07049-02734 27
22.5 34 DEW401

30-4 f'C200-6Z
DISASSEMBLY AND ASSEMBLY
PRECAUTIONS WHEN CARRYING OUT OPERATION

.
2. Precautionswhen carrying out installation work
Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
Install the hoses without twisting or interference.
Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
Bend the cotter pins and lock plates securely.
When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded
portion with 2 - 3 drops of adhesive.
When coatingwith gasket sealant, clean the surface and remove all oil and grease, check that there
is no dirt or damage, then coat uniformly with gasket sealant.
Clean all parts, and correct any damage, dents, burrs, or rust.
Coat rotating parts and sliding parts with engine oil.
When press fitting parts, coat the surface with anti-friction compound (LM-P).
After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then
connect securely.
When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and
align the direction of the hook.
When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one
side.

* When operating the hydraulic cylinders for the first time afterreassembling cylinders, pumps and
other hydraulic equipment removed for repair, always bleed the air as follows:
1. Stan the engine and run a t low idling.
2. Operate thework equipmentcontrol lever to operate the hydrauliccylinder 4 - 5 times,
stopping the cylinder 100 mm from the end of its stroke.
3. Next, operate the hydraulic cylinder 3 - 4 times t o the end of its stroke.
4. After doing this, run the engine at normal speed.
* Whenusingthe machine for thefirsttimeafterrepair or long storage, followthe same
procedure.

3. Precautions when completing the operation

If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run
the engine tocirculate the water through the system. Then check the water level again.
If the hydraulic equipment has been removed and installed again, add engine oil to the specified
level. Run the engine to circulate the oil through the system. Then check the oil level again.
If the piping or hydraulic equipment have been removed, always bleed the air from the system
after reassembling the parts.
* For details, seeTESTINGANDADJUSTING, Bleeding air.
Add thespecified amount of grease (molybdenum disulphidegrease) to the work equipment parts.

PC200-6Z 30-5
LIST DISASSEMBLY
TOOL SPECIAL
AND ASSEMBLY

SPECIAL TOOL LIST

* Tools with part number790T-0000000cannot be supplied (they are items
t o be locally manufac-
tured).
* Necessity: H: Cannot be substituted, shouldalwaysbeinstalled (used)
* useful if available, can
0: Extremely be
substituted with commercially available part
* New/remodel:N: Tools with new part numbers, newly developed for this model.
* R: Tools with upgradedpart numbers, remodeled from
items
already available for
other models.
* Blank Tools alreadyavailable for other models, used without any modification.
* Tools marked 0in the Sketch column are tools introducedin special sketches (See SKETCHES OF
SPECIAL TOOLS).

Component Symbol Pan.No. I Part Name ;ketchlNature of work,

remarks

Removal, installa-
tion of cylinder
I
790-331-1 110 Wrench Tightening of
cylinder head bolt
assembly
Removal, insralla- Barring
tion of fuel injection
pump assembly ~ Removal of drive
lgear

Removal, installa- 4
tion of nozzle holder
assembly

Engine, main pump

assembly
Radiator, hydraulic
cooler assembly
Control. pump
assembly B 796-460-1210 Oil stopper
Main pump assem-
bly',
Removal, installa-
tion of. secvo valve
assembly

-790-101-2520 -Screw

,791-112-1180 -Nut
Disassembly
of center swivel joint D ,790-101-2540
.Washer
assembly
,790-101-2630 -Leg

,790-101-2570 -Plate

790-101-2560 -Nut

-
! 790-101-2650 (-Adapter

Disassembly, F 796-426-1120 Push tool Press fitting of

as-:.r.mbly of swing bearing
m : . :cinery

PC200-6Z
 DISASSEMBLY AND ASSEMBLY
SPECIAL TOOL LIST
x

Component Symbol Part No. 1 Part Name I I

siw Q'ty IreNmeoWd/ellSketch( Nature Of work*
NeCeS-
remarks
796-427-1200 Wrench m 1 Removal, installa-
tion of round nut
796T-427-1221 Push tool m 1 0
790-101-2510 Block m 1
792-104-3940~~~ ~

2 05180-11613
Disassembly, assem- 01643-31645 Washer Press fitting of
bly of final drive bearing inner race
assembly Washer
01643-32060 m 2 -
790-105-2100 Jack m 1

- 790-101-1 102 Pump m 1

3 790-331-1110 Wrench I 1 Tightening of final
drive cover mount-
ing bolt
Installation of

w
791-545-1510 Installer m 1 floating seal
Compressor (A)
791-600-2001
-
or

1
791-6858005 Compressor (B) m 1
Removal, press
fitting of master pin
791-635-3160 Extension m 1
Removal, installation
of recoil spring 790-101-1600 Cylinder(b%.NOUtonl) 1
assembty 790-101-1102 Pump m 1
790-201-1500 Push tool kit 0 1
-790-201-1620 -Plate 1 Installation of dust
2 seal on recoil
-790-101-5021 -Grip 1 spring piston
-01010-50816 -Bolt 1
79 1-63O-3OOO Remover & Installer 1
Removal, installation Removal, press
of track shoe I 79C-101-1300 Cylii(980tN~lWtonll 1 fitting of master pin
790-101-1102 Pump m 1
Removal, installation 09007-01760 Hexagonal wrench 1 Widthflats:
across 17 rnm
of road liner (rubber
pad w e ) Commercialyavailablcsocket
Hexagonal 1 17 mm
Installation of
790-434-1630 Installer m 1 floating seal

111 1
Assembly of idler
assembly 790-101-1000 Charging with oil,

790-434-1 640 Installer

floating seal

4-z
Disassembly, assem- 791-601-1000 Oil pump with Charging oil,
-
bly of track roller
assembly K t I ichecking for air
leakage
Tightening
790-331-1110
3 Wrench of track
roller assembly
mounting bolt

K200-6Z 30-7
DISASSEMBLY
TOOL SPECIAL
AND ASSEMBLY LIST

~ ~~~

Component Symbol Nature of work,

remarks
~~ ~ ~~~ ~-
Removal, installa-
tion of nut
Press fitting of
Disassembly, assem- bearing
bly of carrier roller L 3F
assembly Installation of
Roatina seal
Charging with oil,
4 hecking for air leakage
Installation of track Tightening of track
roller M roller bolt

Replacement of pump N
shaft oil seal

1
-
lemoval. installation
If piston assembly
2
3eplacement pin for
- wrench assembly
Expansion of piston
3 .ing

Disassembly, assem-

7
bly of hydraulic
cylinder - 07281-01159 Clamp 1
790-201-1702 Pushkit
tool 1 Bucket
*790-201-1831 -Push tool 1
.790-101-5021 .Grip 1
*01010-50816 .Bolt 1
790-201-1702 Pushkit
tool 1
.790-201-1930 .Push tool 1
5
~790-101-5021 .Grip 1
.01010-50816 .Bolt 1
790-201-1702 Push tool
kit 1
*790-201-1940 *Push tool 1
.790-101-5021 -Grip 1
,01010-50816 *Bolt 1

PCZOO-6Z
 1 . . I

6
N

gz W
0
-3
'00 5
5.2
0,
U
0
5 Insertion of dust seal
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS

SKETCHES OF SPECIAL TOOLS

Note: Komatsu cannot accept any responsibility for special tools
manufactured according to these sketches.
G 2 Push tool

150

CKPO4076
MATERIAL
TREATMENT
HEAT
0000000000 STKH13A
PART NAME

v
PUSH TOOL

I 796T-427-1220 A

30-10 PC7 0 n - A 7
 DISASSEMBLY AND ASSEMBLY MOTOR STARTING

REMOVAL OF STARTING
MOTOR ASSEMBLY
A Disconnect the cable from the negative (-1 ter-
minal of the battery.

1. Openenginehood.

2. Disconnect 3 wires (1).

3. Remove 2 bolts (2).

4. Remove starting motor assembly (3). CLPO3201

INSTALLATION OF STARTING
MOTOR ASSEMBLY

- Carry outinstallation
removal.
in thereverseorderto

Starting motor mounting bolt :

43 6 Nm I4.38 2 0.61 kgm}

Both faces of starting motor gasket :

Gasket sealant (LG-1)

PC200-6Z 30-1 1
AND DISASSEMBLY ASSEMBLY ALTERNATOR

REMOVAL OF ALTERNATOR
ASSEMBLY
A Disconnect the cable from the negative (-) ter-
minal of the battery.

1. Open engine hood.

2. Remove fan guard(1) and rightfan guard mount-

ing bracket (2).

k
3. Disconnect wiring (3) and connector (41, and re-
move X-connector (5) from bracket.

CLPO3204

4. Using wrench@, raise tensioner ( 6 )and remove

a
belt (7).
Be extremely careful not to get your fingers
caught when removing the belt.

I=1 CLPO3205 I
5. Remove alter? ':,r mounting bolts (8) and (9),
then remove L ' - rnator assembly (IO).

Car: outin.
' ;tion in the reverse order to
re:-: val.

PC200-6Z
 DISASSEMBLY AND ASSEMBLY AIR CONDITIONER COMPRESSOR

REMOVAL OF AIR
CONDITIONER COMPRESSOR
ASSEMBLY
A Loosen the flangemountingbolts of theair
conditioner hose, and release the refrigerant (R-
134a) slowly.

1. Open engine hood.

2. Remove fan guard (1).

3. Disconnectconnector (2).

4. Disconnecthoses (3).

5. Loosen adjustment bolt (4) and remove belt (5).

6. Remove 4 mounting bolts (6).then remove com-

pressor assembly (7).

INSTALLATION OF AIR
CONDITIONER COMPRESSOR
ASSEMBLY
Carry outinstallationinthe reverse order to
removal.

* When installing the hoses, check that the 0-

rings are not damaged or deteriorated, then
connect the hoses.

* Adjust the belt tension.

- For details, see
TESTING AND ADJUSTING,
Testing and adjustingair conditioner belt ten-

- sion.
Fill with refrigerant (R-134a).

PCZOO-6Z 30-13
CONDENSER
DISASSEMBLY AND ASSEMBLY

REMOVAL OF CONDENSER
ASSEMBLY
1. Open engine hood (1) and side cover (2) at left
side of chassis.

2. Remove cover (3)on top of condenser.

I
I3803
I

3. Disconnect air conditioner hose (41, thendis- r

connect hose (5)at receiver drier end and hose
(6) at condenser end.
* Loosenhoses (41, (5) and (6) slightly and
release the refrigerant (R-134a) completely
before disconnecting hoses.
* Fit blind plugs into the condenser po'rt and
hoses to prevent the entryof moisture, dust
o r dirt.

4. Remove receiver drier (7) together with bracket.

5. Remove condenser assembly (8).

INSTALLATION OF
CONDENSER ASSEMBLY
Carryout installation in thereverseorderto
removal.

p
T
J
* Check that the O-rings are not damaged or
deteriorated, then connect the hoses.

Fill withrefrigerant (R-134a).

30-1 4 PC200-6Z
 DISASSEMBLY AND ASSEMBLY ENGINE OIL COOLER CORE

REMOVAL OF ENGINE OIL

COOLER CORE ASSEMBLY
1. Open engine hood.

2. Remove adiabatic cover (1).

3. Remove turbocharger lubrication hose (2) and

oil filter (3).

4. Disconnect connector (41 with alternator wiring,

and remove connector bracket (5) of intermedi-
ate clamp.

- 5. Remove oil cooler cover assembly (6).

6. Remove cooler core (7) from oil cooler cover

assembly (6).

CLPO3214

INSTALLATION OF ENGINE OIL

COOLER CORE ASSEMBLY
Carry outinstallationin the reverse orderto
removal.

w Sleeve nut (2) of turbocharger lubrica-

tion hose :
24 4 Nm {2.45 f 0.41 kgm}
I d ’
Oil filter (3): 13 2 Nm I1.33 0.20 kgm} CLPO3228
f Or bring the seal surface into contact, then
tighten 314 turns.

.f Tighten in the order (1) - (14) as shown in

the diagram.
w Mounting bolt (6)of oil cooler cover as-
sembly : 24 = 4 lilm i2.45 = 0.41 kgm}

CLPO3715

PC200-6Z 30- 15
 DISASSEMBLY AND ASSEMBLY INJECTION FUEL PUMP

REMOVAL OF FUEL INJECTION

PUMP ASSEMBLY
A Disconnect the cable from, the negative (-1 ter-
minal of the battery.

1. Open engine hood.

2. k m o v e cover (1) on top of condenser, then

remove stay (2) at counterweight.

3. Remove fan guard (3) and left bracket (4).

4. Disconnect water temperature sensor connector

(5).

5. Remove bracket (6)for compressor hose clamp.

* Tightentogether with thefuelinlet hose
clamp.

7 . Disconnect governor motor rod ( 9 ) at governor

end.
Ir Rotate the shaft of the governor motor and
a
do not stop it suddenly.
* Always disconnect the guide motor connec-
tor before disconnecting the rod.

6. :'isconnect 6 deik ?-i tubes (10).

c ~
.,.- x. n n e c t fue! :.. r $y hose (11) and returnhose
-I.

-gel will li,: :'3t when the hoses are dis-

..onnected, .nsert wooden plugs in the
mes to p: -:Ithe fuel from leaking.

\ \
\ \
12 II
CLPO3119
 DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP

10. Disconnect tube clamp (15) (4 places) and tubes

(13)and (14) between fuel filter and fuel injec-
tion pump.

11. Remove lubrication tube (16).

12. Remove mounting bolt (17) of support bracket

at bottom of fuel injection pump.

- 13. Usingtool A 2 , rotateengine innormal direc-

tion, and push No. 1 cylinder compression top
dead center positioning pin (18)into gear.
f Push thepinlightly againstthegearand
rotate the engine slowly.
f After determining the TDC position, check if
the meshing of the timing pinhas come out.

14. Remove 2 fan belts (19). then move fan tension

pulley (20) and adjustment bar (21) towards fan
shaft.
f Loosen mounting bolt (23)of adjustment bolt

- bottom bracket.(22), then loosen adjustment

bolt (24).

15. Turn cap (25)and remove.

CLP03226

16. Remove washer (27) and nut (26)inside case.

* Be extremely careful not to dropthe nut and

washer inside the case when removing.

21

PC200-6Z 30- 1 7
 DISASSEMBLY FUEL
AND ASSEMBLY INJECTION PUMP

INSTALLATION OF FUEL
INJECTION PUMP ASSEMBLY
Carry out installation in the reverse order to
removal.

* Adjust the governor lever.

For details, see TESTING AND ADJUSTING,
Adjusting governor motor lever stroke.

Delivery tube sleeve nut (10) :

24 t 4 Nm 12.45 t 0.41 kgm}

* Adjust the belt tension.

For details, see TESTING AND ADJUSTING,
Testing and adjusting fan belt tension.

a Drive nut (26) :

=
95 10 Nrn I9.7 t 1.01 kgrn}

Installthefuel injection pump assembly as

follows.
1) Check that the No. 1 cylinder is at compres-
sion top dead center.
A
* For details, see RemovalStep13.

2) Remove plug (30), then remove timing pin

(311.

3) Reverse the position of timing pin (31). align

the timing pin groove with pointer (32)in-
side the pump, then temporarily tighten plug
(30).
* If the toothof pointer (32) cannot be
aligned with the timing pin hole, rotate
the shaft of the fuel injection pump to
align the pointer tooth.

30
CLPO3232 CLP03733

PC200-6Z 30-1 9
DISASSEMBLY
INJECTION FUEL
AND ASSEMBLY PUMP

4) Align pump camshaft with pump drive gear

and install fuel injection pump assembly(29).
then tighten nut (28).
Nut (28) :
43 f: 6 Nrn 14.38 t 0.61 kgrn)

\\
CLP03230

5) Assemble washer (271, and tighten nut (26)

temporarily.
*
Be extremely careful not to drop the nut
and wash.er inside the casewhen install-
ing.
Temporary tightening of nut (26) :
12.5 t 2.5 Nm (1.27f: 0.25 kgm}
*
This is not the final torque value.
* To prevent damage to the timing pin, be
careful not to tighten the nut to more
than the above tightening torque.

6) Remove meshing of engine timing pin (18).

I ' I I CLP03235

7) Remove plug (301, reverse position of tim-

ing pin (311, then assemble and install plug
to fuel injection pump.
Plug : 14.7 Nrn 11.5 kgrnl

8) Tighten nut (26) of fuel injection pump fully.

Nut (26) :
95 t 10 Nm I9.7 t 1.01 kgm)

9) For remaining installation,carry out in re-

verse order to removal.

Bleeding air
* Bleed the air from fuel system.
CLPO3236

30-20 DP?fUlX7
AND DISASSEMBLY ASSEMBLY WATER PUMP

REMOVAL OF WATER PUMP

ASSEMBLY
1. Drain coolant.

2. Open engine hood.

3. Remove f a n guard (11, then remove left and right

side covers (2) and (3)of fan guard mount.

- 4. Using wrench 0, raise tensioner (41, then re-

move belt (5). I
A Be extremely careful not toget your fingers
caught when removing the belt.

39

5. Loosen adjustment bar (7) of fan tension pulley

(6).then loosen fan belt ( 8 ) . I \ s a

\ ' CLPO3240

6. Loosen mounting bolt (11) of fan pulley (10) and

fan shaft (9) 2 - 3 mm, then move towards ra-
diator.

PC200-6Z 30-2 1
 ,
DISASSEMBLY AND ASSEMBLY WATER PUMP

7. Remove water pump assembly (12).

INSTALLATION OF WATER
PUMP ASSEMBLY
Carry out installation in the reverse order to
removal.

a* Adjust the belt tension.

For details, see TESTING AND ADJUSTING,
Testing and adjusting of fan belt tension.

Refilling with water

* Add water through the water filler to the
specified level.
Run the engine to circulate the water
through
the system. Then check the water level again.
I.

30-22
 DISASSEMBLY AND ASSEMBLY NOZZLE HOLDER

REMOVAL OF NOZZLE
HOLDER ASSEMBLY
1. Openengine hood.

2. Disconnect delivery tube (1) a t nozzle holder as-

sembly end.

3. Remove spill tube (2).

4. Remove nozzle holder assembly (3).

* If it is difficult to remove the nozzle holder
assembly, use tool A4 to remove it. I
* Be careful not to let dirt or dust get into the
CLPO3243

nozzle holder assembly mount.

INSTALLATION OF NOZZLE ,3
HOLDER ASSEMBLY
Carry out installation in the reverse orderto
removal.
CLP03244

Delivery tube sleeve nut :

30 2 5 Nm 13.06 2 0.51 kgm}

Joint bolt :8 t 2 Nm I0.81 t 0.20 kgm}

-
Nozzle holder assembly :
60 t. 5 Nm I6.12 2 0.51 kgm}
a Nozzle holder assembly thread portion :
Seizure prevention compound
(Molycoat 1000)
* When assembling the nozzle holder, clean
the nozzle holder mount, and checkthat there
is no dirt or dust inside the sleeve before
assembling.

PC200-6Z 30-23
DISASSEMBLY AND ASSEMBLY TURBOCHARGER

REMOVAL OF
TURBOCHARGER ASSEMBLY
1. Open engine hood, and remove adiabatic cover
(1) of turbocharger assembly.

2. Remove air cleaner intake connector (2) and air

supplytube (3) between turbocharger and
aftercooler.

3. Remove connector clamp (4).

4. Removelubrication inlet tube (5) andlubrica-

~~

CL603245
tion return tube (61, then remove turbocharger
assembly (7).
* Afterremovingthelubrication tube,close
all the ports to prevent the entry of mud or
dirt.

I CLPO3246

INSTALLATION OF
TURBOCHARGER ASSEMBLY
Carryoutinstallation in thereverseorder to
removal.

- Intake tube bandclip :

10 t: 2 Nm 11.02 t: 0.21 kgml

w Lubrication inlet tube sleeve nut :

35 t: 5 Nm I3.6 t 0.5 kgml
Lubrication return tube mountingbolt :
24 t: 4 Nm (2.45 t: 0.41 kgm}
Turbocharger assembly mounting nut :
I O 2 2 Nm 11.02 t: 0.20 kgm}

30-24 vr3nn-x7
D THERMOSTAT
DISASSEMBLY ASSEMBLY

REMOVAL OF THERMOSTAT
ASSEMBLY
1. Drain coolant.

2. Open engine hood, and remove fan guard (1)

and right side guard mounting bracket (2).

- 3. Using wrench 0, raise tensioner (31,then re-

move fan belt (4).
A Be extremely careful notto get your fingers
caught when removing the belt.

4. Remove .alternator assembly top mounting bolt

(5) from bracket, then move alternator assembly
( 6 )towards partition plate end.
* Loosen the mounting bolts at the bottom of
the alternator assembly.

I I CLPO3250

5. Disconnect radiator inlet hose (7)and aeration

hose ( 8 ) .

6. Remove alternator bracket (9).

^.

51

PC200-6Z 30-25
 ,
THERMOSTAT
DISASSEMBLY AND ASSEMBLY

7. Remove thermostat housing (10).

IO

8. Remove thermostat (11).

CLP03253

INSTALLATION OF
THERMOSTAT ASSEMBLY
Carry out installation in the reverse order to
removal.

Thermostat housing mounting bolt :

24 t 4 Nm (2.45 2 0.41 kgm}

Refilling with water

* Add water through the waterfiller to the
specified level.
Run the engine t o circulate thewater through
the system. Then check the water level again.

30-26 pc3m-x7
 DISASSEMBLY AND ASSEMBLY HEAD CYLINDER

REMOVAL OF CYLINDER HEAD

ASSEMBLY
A Disconnect the cable from the negative (-1 ter-
minal of the battery.

1. Drain coolant.

2. Open engine hood.

3. Remove fan guard(1). then remove left and right

side covers (2) and (3)of fan guard mount.
8
4. Remove turbocharger assembly.
For details, see REMOVAL OF TURBOCHARGER
- ASSEMBLY.

5. Remove exhaust manifold cover (4).

6. Remove adiabatic plate mountingbracket (5) for

turbocharger.
* In order t o remove mounting bolt (61, do as
follows.
- 1) Remove muffler drain pipe. (main pump
end)
2) Loosen muffler mounting U-bolt.
Rotate connector (7) at the muffler end
up slightly to a position where it is pos-
sible to remove the mounting bolts.

7. Remove
exhaust
manifold (8). a
8. Disconnect electrical intake air heater wiring (91,
water temperature sensor connector (101, and
compressor connector (1 ).1

9. Remove mounting bracket (12) of intermediate

clampforwiring andairconditionerhose at
engine end.

10. Remove air conditioner belt (131, then remove

compressor assembly(14) together with bracket,
- and move
towards countenweight.

11. Remove mounting plate (16) and clamp (15) of I3 II CLPO3258

dipstick guide.

PC200-6Z 30-27 !.
4
0

W
 DISASSEMBLY
CYLINDER
AND ASSEMBLY HEAD

17. Remove intake connector (28).

- 18. Remove 6 deliverytubes (29).

19. Disconnect tubes (30) and (31) between fuel fil-

ter and fuel injection
pump, then disconnect fuel
return
hose (32) at fuelfilter end. EpJ
20. Remove fuel filter assembly (33) together with
bracket.

I -
CLPO3264

21. Remove intermediate clamps (34) (3 places) of

fuelreturn hose (32). then removespilltube
(35).

22. Remove nozzle holder assembly (36).

-

23. Remove head cover (37).

PC200-6Z 30-29 I:
HEAD DISASSEMBLY
CYLINDER
AND ASSEMBLY

24. Remove rocker arm assembly (38).

25 Remove pushrod (39).

26. Remove mabunting bolts of cylinder head in or-

der shown in diagram. E3

L CE100394

27. Lift off cylinder head assembly (40).

&I Cylinderheadassembly: 52 kg
f0
28. Remove cylinder
head
gasket (41). 1x141

I
.. CLPO3269

30-30 PC200-6Z
 ,
HEAD DISASSEMBLY
CYLINDER
AND ASSEMBLY

-
INSTALLATION OF CYLINDER
HEAD ASSEMBLY I
Carry out installation in thereverse orderto
removal.

-
Muffler mounting U-bolt :
12 t 2.5 Nm 1122 t 0.26 kgm)

* Tighten the mounting bolts in the order @ -

@ shown in the diagram on the right. I CDW00396
Exhaust manifold mounting bolt :
43 t 6 Nm 14.38 t 0.61 kgm}

* Adjust the belt tension.

For details, see TESTING AND ADJUSTING,
Testing and adjusting air conditioner
belt ten-
sion.

Pulley hub mounting bolt :

33 t 5 Nrn 13.37 t 0.51 kgm}
w Tensioner bracket mounting bolt :
24 2 4 Nm 12.45 t 0.41 kgm}

Exhaust hose clamp :

*
10 2 Nm 11.02 t 0.20 kgm}

Sleeve nut at injection pump end :

-- 24 t 4 Nm 4.45 t 0.41 kgm}
Sleeve nut at nozzle holder end :
30 t 5 Nm 9.06 t 0.51 kgm}

Fuel tube joint bolt (301,(31) :

24 2 4 Nm 12.45 2 0.41 kgml
Fuel hose joint bolt (32):
. 30 2 5 Nm 13.06 2 0.51 kgm}

PC200-6Z 30-31
LY AND DISASSEMBLY CYLINDER HEAD

p
J
Spill tube joint bolt:
8 t 2 Nm 10.81 t 020 kgml

Nozzle holder assembly :

60 t 9 Nm 16.12 t 0.92 kgm}

Head cover mounting bolt :

24 t 4 Nm 4.45 t 0.41 kgml

rn E 1
Install the rocker arm assembly and cylinder
head assembly as follows.
to
* Check that there is no dirt or dust on the
cylinder mount surface or inside the cylin-
der.
1) Setcylinder head gasket (41) t o cylinder
block.
* Check that the gasket is aligned correctly
with the holes in the block.

2) Raise cylinder head assembly (40) and set to ..

cylinder block. I CLPO3269

3) Assemblepush rod (39).

e Add engine oil (15W-40) to the push
rod socket portion.

4) Fit rocker arm assembly (381,and tighten

mounting bolts by hand.
.k Check that the ball portion of the adjust-
ment screw is fitted securely in thesocket
portion of the push rod.
6 Put engine oil (15W-401 on the seat
surface and thread of the 8 m m and
12 rnm diameter mounting bolts.

30-32 PC200-6Z
 DISASSEMBLY
CYLINDER
AND ASSEMBLY HEAD

5) Tighten cylinder head mounting bolts in or-

der shown in diagram.
6 Put engine oil (15W-40) on the seat
surface and thread of the mounting
bolts.
Cylinder head mounting bolt :

1st step: Tighten in order @ - @ to 90 t 5 Nm

(9.18 t 0.51 kgml.
2nd step: Tighten in order 0,@, @, @, 0,@ to
120 t 5 Nm I12.24 t 0.51 kgm).
3rd step: i) When using tool A1 I CEW00394 I
Using angle tightening wrench
(tool A l l , tighten bolts a further
SO" in order @ - @.
iil When not using tool A1
Makematch marks with a felt
pen on bolt andhead, then At
tighten bolt a further 90".

I CLPO4084

B
6 ) Tighten rocker arm assembly mounting bolts I

(diameter: 8 mm). Uake m a r k s on c r l l n d e r

headan6 bolt
Rocker a r m mounting bolt :
24 z 4 Nm 4.25 0.41 kgm)
.-
7) Adjustvalve clearance.
For details, see TESTING AND ADJUSTING,
Adjusting valve clearance.

DKP00485

- Refilling with water

* Refill to the specifiedlevel,and run the I
engine to circulate the waterthrough the
system. Then check the water level again.

f'C200-6Z 30-33
 RADIATOR
DISASSEMBLY AND ASSEMBLY HYDRAULIC OIL COOLER

REMOVAL OF RADIATOR,
HYDRAULIC OIL COOLER
ASSEMBLY

-
A Lower the work equipment completely to the
loosenthe oil
ground and stop the engine. Then
filler cap slowly to release the pressure inside
the hydraulic tank.

. Remove the hydraulic tank strainer, and using

tool B, stop the oil.
When not using tool B, remove the drain
plug,anddrain the oil from the hydraulic CLPO3276
tank and inside the system.
b
& Hydraulic tank :Approx. 170

. Drain coolant.

1. Remove condenser assembly.

For details, see REMOVAL OF CONDENSER AS-
SEMBLY. 3

2. Remove undercoverat bottom of condenser and

bottom of radiator.
* Set a container under the machine to catch
the oil.

3. Disconnect hoses(1). then remove sub-tank (2).

4. Remove sub-tank mounting bracket (3).

5. Disconnect oil cooler hoses (4) and (5).

i
30-34 P f7rx)-A7
 DISASSEMBLY
AND ASSEMBLY
RADIATOR COOLER
HYDRAULIC
OIL

8. Remove f a n guard (10).

9. Disconnect radiator upper hose (1 1).

-- 10. Disconnectradiatorlower hose (12) andheater

hose (131, then remove intermediate clamp (14)
of radiator lower hose.

282

11. Remove 2 ctamps (16) of heater hose (15).

12. Disconnect left and right support rods (17) of

radiator.

13. Sling radiator and hydraulic oil cooler assembly

(18), removebottommounting bolts, thenlift
off radiator and hydraulic oil cooler assembly
slowly.
* When raising the radiatorand hydraulic oil
cooler assembly, be extremely careful n o t t o
hit the fan.

& Radiator hydraulic oil cooler assembly:

112 kg

PCZOO-6Z 30-35
DISASSEMBLY AND ASSEMBLY
RADIATOR HYDRAULIC
OIL COOLER

INSTALLATION OF RADIATOR,
HYDRAULIC OIL COOLER
ASSEMBLY
Carry out installation in the reverse order to
removal.

r q 1.1 Coupling : 16.7 t 2 Nm 11.7 2 0.2 kgm)

[fl
Radiator hose band clip :
8.83 f 0.98 Nm iO.9 t 0.1 kgm}

Refilling with water

* Add water through the water filler to the
specified level.
Run the engine to circulate the water through
the system. Then check the water levelagain.

Refilling with oil (hydraulictank)

* Add oil throughthe oil filler to the specified
level.
Run the engine to circulate the oil through
the system. Then check the oil level again.

30-36 Pf7m-x7
 DISASSEMBLY AND ASSEMBLY ENGINE MAIN PUMP

REMOVAL OF ENGINE MAIN

PUMP ASSEMBLY
A Disconnect the cable from the negative (-1 ter- A
minal of the battery.
A Lower the work equipment completely to the
ground and stop the engine. Then loosen the oil
filler cap slowly t o release the pressure inside
the hydraulic tank.

Remove the hydraulic tank strainer, and using

tool B, stop the oil.
Whennotusingtool B, remove thedrain
plug, and drain the oil from thehydraulic
tank and inside the system.
- b
& Hydraulic tank : Approx. 170 e

After disconnecting the piping, fit tags to distin-

guish the mounting position.

Drain coolant.

1. Remove engine hood (1).

I ICLPO3299

2. Remove main pump top cover (2).

3. Remove right side cover (3)together with cover

mounting frame (4).
- *Remove the cover a t the bottom of the main
pump and the cover at the bottom of the
engine, then set a container under the main
pump t o catch the oil.

4. Remove connector (5) from bracket, then dis-

connect.

\\ \ I CLPO3812

PC200-6Z 30-37
DISASSEMBLY AND ASSEMBLY ENGINE
PUMP MAIN

5. Disconnect F and R pump dischargehoses (6)

and (7). F and R LS pressure hoses (8) and (9),
and EPC basic pressure hose (10).
* Protect with the sleeve nut t o prevent dam-
age to the nipple or elbow taper seal por-
tion.

6. Disconnect pump servo pressure hose (11) and

pump drain hose (121, and remove intermediate
clamp (13) of hose.
* Protect with the sleeve nut t o prevent dam-
age to the nipple or elbow taper seal por-
tion.

7. Disconnect suction tube (14) at pump end.

*Cover the suction tube port portion
with plas-
tic.

, . , CcPOS814

8. Removeenginepartition plates (151, (161, and

(17).

9. Remove bracket (18) at counterweight end.

I O . Remove fan guard (191, then remove left and

right side brackets (20)and (21) of fan guard
mount.

30-38 pr7nn-x7
B
8
6
N
w N
P
0
P
0

c
 DISASSEMBLY AND ASSEMBLY ENGINE MAIN PUMP

INSTALLATION OF ENGINE,
MAIN PUMP ASSEMBLY
Carry outinstallation in the reverse orderto
removal.

* Set the engine mount rubber as shown in

the diagram, then install theengine and main
pump assembly.
Engine mount bolt :
277 2 32 Nm (28.3 t 3.3 kgm}

Refilling with water

I Enoine rear s l d e Enoine front side
DKP00487

_-
* Add water through the
specified level.
waterfiller t o the

Run the engine to circulate thewater through

the system. Then check the water level again.

Refilling with oil(hydraulictank)

* Add oil through the oil filler to the specified
level.
Run the engine to circulate the oil through
the system. Then check the oil level again.

Bleeding
air
* Bleed the air from the main pump.
For details, see TESTING AND ADJUSTING,
Bleeding air.

PC200-6Z 30-41
DISASSEMBLY AND ASSEMBLY DAMPER

REMOVAL OF DAMPER
ASSEMBLY I

1. Removemain pump assembly.

For details, see REMOVAL OF MAIN PUMP AS-
SEMBLY.

2. Remove damperassembly (1).

INSTALLATION OF DAMPER
ASSEMBLY
Carry outinstallation in thereverseorder to
removal.

30-42 PC200-6Z
TANK DISASSEMBLY
FUEL AND ASSEMBLY

REMOVAL OF FUEL TANK

ASSEMBLY
A Disconnect the cable from the negative (-) ter-
minal of the battery.

1. Loosen drainvalve (1) of fuel tank and drain

fuel.
b
& Fuel tank :
Approx. 340 (when tank is full)

2. Disconnect fuel supply hose (2) and return hoses 0

(3)and (4).

3. Remove handrail (51,battery case (61, and cover

(7).

& Battery case : 28 kg

4. Disconnect fuel sensor connector (81, then re-

move wiring from clamp.

5. Sling fuel tank assembly (91, then remove mount-

ing bolts, and lift off fuel tank assemblv (9).
I

a
& Fuel tank assembly : 122 kg

INSTALLATION OF FUEL TANK

ASSEMBLY
Carry outinstallation in the reverse order to
removal.

Fuel tank mounting bolt :

277 2 3 2 N m (28.3 z 3.2 kgml

Refilling with fuel(fueltank)

Add fuel.

PC200-6Z 30-43
DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT

REMOVAL OF CENTER SWIVEL

JOINT ASSEMBLY
A Release the remaining pressure in the hydraulic
circuit. For details, see TESTING AND ADJUST-
ING, Releasing remaining pressure from hydrau-
lic circuit.
* Mark all the piping with tags to prevent mis-
takes in the mounting position wheninstalling.
1. Disconnect hoses (1). (21, (31,and (4) between
travel motor and swivel joint.

2. Remove elbow (5).

3. Disconnect drain hose (6).

4. Disconnect hoses (7) and (8) between control
valve and swivel joint.
5. Disconnect travel speed selector hose (9).
6. Disconnect plate (10).

7 . Remove center swivel joint assembly (11).

& Center swivel joint assembly : 45 kg

I ' '
' I
CLPO5177

30-44 PC200-6Z
 DISASSEMBLY ,ANDASSEMBLY
SWIVEL CENTER JOINT

-.

INSTALLATION OF CENTER
SWIVEL JOINT ASSEMBLY I
Carry outinstallationin the reverse order to
removal.

* Assemble the center swivel as shown in the

Center swivel.
diagram below. joint
Refilling with oil (hydraulic tank)
* Add oil through the oilfiller to the specified
c Sprocket

level. Run the engine to circulatethe oil

through thesystem. Then check the oil level
again. QKP00488
Bleeding air
* Bleed the air form the travel motor. For de-
tails, see TESTINGAND ADJUSTING, Bleed-
ing air.

PCZOO-6Z 30-45
DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT

DISASSEMBLY OF CENTER
SWIVEL JOINT ASSEMBLY
t
1. Removecover (1).

2. Remove snap ring (2). 0

3. Using tool D, pull out swivel rotor (4) and ring
(3)from swivel shaft (5).

4. RemoveO-ring (6) and slipper seal ( 7 ) from

swivel rotor.

7
ASSEMBLY OF CENTER
SWIVEL JOINT ASSEMBLY
1. Assemble slipper seal ( 7 )and O-ring (6) t o swivel
rotor.

2. Set swivel shaft (5) t o block, then using push

5
tool, tap swivel rotor (4) with a plastic hammer
I
t o install. i
CLPO384 1
Contact surface of rotor, shaft :
Grease (G2-LI)
-f When installing the rotor, be extremely care-
ful not to damage the slipper seal and the
O-ring.

3. Install ring (3) and secure with snap ring (2).

4. Fit O-ring and install cover (1).

Mounting bolt :
31.36 2 2.94 Nm 13.2 2 0.3 kgm)

M CLPO3842

30-46 PC200-6Z
AND DISASSEMBLY ASSEMBLY FINAL DRIVE

REMOVAL OF FINAL DRIVE

ASSEMBLY
1. Remove sprocket. For details, see REMOVAL OF

a SPROCKET.
Lower the work equipment completely
ground and stop the
to the
engine. Then loosen the oil
/I

filler cap slowly t o release the pressure inside

the hydraulic tank.

2. Remove cover (1).

3. Disconnect 4 travel motor hoses (21, and lift off CLpol413

final drive assembly (3).
f Be extremely careful not to damage the nip-
-. ple tool surface of the hose mount.
&
f
Final drive assembly : 300 kg
Never use tap hole for cover when slinging
final drive assembly.

INSTALLATION OF FINAL
DRIVE ASSEMBLY
Carry outinstallation in the reverse order to
removal.

Final drive mounting bolt:

- 276.8 2 31.8 Nm 128.25 2 3.25 kgml

Bleedingair
f Bleed the air from the travel motor. For de-
tails, see TESTING AND ADJUSTING, Bleed-
ing air.

Refilling with oil (hydraulictank)

f Add oil through the oil filler to the specified
level. Run theengine to circulatetheoil
through the system. Then check the oil level
again.

PC200-6Z 30-47
DRIVE
AND DISASSEMBLY
FINAL ASSEMBLY

DISASSEMBLY OF FINAL
DRIVE ASSEMBLY
1. Draining oil
Remove drain plug and drainoil from final drive
case.
b
Final drive case : Approx. 4.2 e
2. Cover
Remove mounting bolts, then remove cover (1) 12
using eyebolts 0.
Ir When raising ring gear (12) and cover (1) a s CLPO1427
o n e unit, tap the ring gear with a wooden
hammer to remove thering gear.

3. Spacer
Remove spacer (2).

CLPOI4l7

4. No. 1 carrierassembly
1) Remove No. 1 carrier assembly (3). 3

CLPO1418

2) Disassemble No. 1 carrier assembly a s fol-

lows.
i) Push in pin (41, and pull outshaft (5)
I
from carrier (6).
* After removing the shaft, remove pin
(4).
ii) Remove thrust washer (71, gear (8).bear-
ing (91, and thrust washer (10).

d O
I 5

CLPOI4I9

30-48 K200-6Z
i

n n
DRIVE DISASSEMBLY
FINAL AND ASSEMBLY

11. Nut
1) Remove lock plate (241.
2) Using tool G1, remove nut (25).

I
I I
CLPO1433

12. Hub assembly

1) Using eyebolts 0,remove hub assembly (26)
from travel motor.

26

CLPO1434

2) Disassemble hub assembly as follows.

i) Remove floating seal (27). I 28.
ii) Remove bearings (28) and (29) from hub
(30).
* When removing bearing (281, do not hit
the resin retainer of the bearing.

30
CLPO1435

3) Remove floating seal (31) from travel motor

(32).

30-50 PC200-6Z
 DISASSEMBLY
FINAL AND ASSEMBLY DRIVE

ASSEMBLY OF FINAL DRIVE

ASSEMBLY
28 23
* Clean all parts, and check for dirt or damage.
Coat the sliding surfaces of all parts with engine
oil before installing.

1. Hub assembly
1) Using push tool, press fit bearings (28) and
(29)t o hub (30).

'30
CLPO1435

- 2) Using tool 64, install floating seal (26).

*Remove all oil and grease from the 0-
ring and O-ring contact surface, and dry
thepartsbeforeinstallingthefloating
seal.
"'\
*Afterinstallingthefloating seal, check
thattheangleofthefloatingsealis
within 1 mm.
*After installing the floating seal, coat the
sliding surface thinly with engine oil.
I I

CKP03843

3) Usingtool 64, installfloating seal (31) to

travel motor (32).
* The procedure forinstallation is the same
as in Step 2) above.

CLPO1436

4) Using eyebolts @, set hub assembly (26) t o

travel motor, then using push tool, tap t o
press fit bearing portion.

26

u CLPOI434

PC200-6Z 30-51
AND DISASSEMBLY ASSEMBLY FINAL DRIVE

2. Nut G2
1) Install nut as follows.
i) Using tool 62, push bearing inner race
portion.
* Do notheatthebearing with a
burner, or directly push or hit the
resin retainer.
* Pushing force:
8.82 - 12.74 kN (0.9 - 1.3 ton}
* Rotate t h e hub 2 - 3 times before
applying the pushing forcetothe
bearing inner race. CLPO3844
ii) Measure dimension a in the condition in
Step i) above.
iii) Measure thickness b of nut itself.
iv) Calculate a - b = c.
v) Using tool GI, tighten nut (25) to a point
where dimension d is c$.,.

CLPOI437

vi) Using push-pull scale @, measure tan-

gential force in direction of rotation of
hub in relation to motor case.
*Tangential force : Max. 294 N (30kg1
*The tangential force is the maximum
force when starting rotation.

vii) Install lock plate (24). I

30-52 PC200-6Z
DRIVE DISASSEMBLY
FINAL AND ASSEMBLY

* Installthelock plate as shown inthe

diagram.
Thread of mounting bolt: BAD .
Thread tightener (LT-21
* Do not coatthetapportionofthe
nut with thread tightener (LT-2).

there i s no c a s t i n rn o t c h .
B r i n el o c k D late and s D I i n e

- 3. No. 2 carrier assembly

1) Assemble No. 2 carrier assembly as follows.
. . f Replace thrust washers (201, (23) and pin
(17) with new ones.
* There are the remains ofthe caulking
when the pin is insetted at the end face
of hole h at the side of the carrier, so
remove the caulked metal from the in-
side diameter of the hole before starting
t o assemble.
i) Assemblebearing (22) to gear (21). fit
top and bottom thrust washers (20) and CLPO1439
(231, andset gear assembly in carrier
(19).

I
ii) Align position of pin holes of shaft and
carrier, then tap with a plastic hammer
t o install shaft (18).
* When installing the shaft, rotate the
't
planetary gear. Becareful not todam-
age the thrust washer.
iii) Insert pin (17).
* After inserting the pin, caulk the pin
portion of the carrier.
*
II
Afterassemblingthe carrier assembly,
check that gear (21) rotates smoothly. I'
CLPO1440

2) Install No. 2 carrier assembly (16).

* Align the position so that the three tips
of the gear shafts of carrierassembly
(16) enter the three hollows in the end
face of the motor case, then install.

CLPOI44I

K200-6Z 30-53
DISASSEMBLY AND ASSEMBLY FINAL DRIVE

4. Thrustwasher
Install thrust washer (15). 1 1. 14

5. No. 2 sun gear

Install No. 2 sun gear (14).

6. Thrust washer
Install thrust washer (13).

7. No. 1 sun gear shaft

Install No. 1 sun gear shaft (11).
CLPOI442

8. No. 1 cam'er assembly

1) Assemble No. 1 carrier assembly as follows.
f Replace thrust washers (71, (10) and pin
(4) with new ones.
h
\
9
I B
* Therearetheremainsofthecaulking
when the pin is inserted at the endface
of hole h at the side of the carrier, so
remove the caulked metal from the in-
side diameter of the hole before starting
to assemble.
i) Assemble bearing (9) t o gear ( 8 ) , fit top
and bottom thrust washers (7)and (lo), CLP01422
and set gear assembly in carrier (6).

ii) Align position of pin holes of shaft and

carrier, then tap with a plastic hammer
t o install shaft (5).
* When installing the shaft, rotate the
planetary gear. Be careful not to dam-
age the thrust washer.
iii) Insert pin (4).
* After inserting the pin, caulk the pin
portion of thecarrier.
* Afterassemblingthecarrier assembly, 5'
check that gear (8)rotates smoothly.
CLPO1423

2) Install No. 1 carrier assembly (3).

9. Spacer
Install spacer (2).

CLPO1443

30-54 PC200-6Z
 DISASSEMBLY AND ASSEMBLY FINAL DRIVE

10. Ring gear

Fit O-ring to hub end, then using eyebolts 0,
align position of bolt holes ofhub and ring gear
(121, and install.
f Remove all grease and oil from the mating
surface of the ring gear and hub.
f Do not put any gasket sealant on the mating
surface of the ring gear and hub under any
circumstances.

I W CLPO I444

- 11. Cover
Usingeyebolts 0, fit cover (11, thentighten
mountingbolts with angletighteningwrench
63.
Mounting surface of cover :
Gasket sealant (LG-6)
Mounting bolt :
1st pass: 98 Nm {lo kgm)
2nd pass: Turn 80 90" -

CLPO1445

12. Refilling with oil

Tighten drain plug and add engine oil through
oil filler.

- & Final drive case : Approx. 4.2

* Carry out a final check of the oil level at the
determined position after installing the final
drive assembly to the chassis.

I CLPOl446

PC200-6Z 30-55
 4

Q
F
r+
0

E8
&
N
 DISASSEMBLY AND ASSEMBLY SWtNG MOTOR AND SWING MACHINERY

REMOVAL OF SWING. MOTOR,

SWING MACHINERY
ASSEMBLY
A Lower the work equipment to the ground and
stop the engine. Loosen the hydraulic tank oil
filler cap slowly to release the pressure inside
the hydraulictank. Then set the safety lock lever
to the LOCK position.

1. Remove hose clamps (1) and (2) (2 places each).

2. Disconnect swing motor inlet and outlet hoses

(3)and (41, and disconnect suction hose (5).

- 3. Remove hose clamp (6).

4. Disconnect drain hoses (7) and (81, then discon-

nect pilot hose (9).

5. Remove 12 mounting bolts (10) at swing ma-

chinery end, then lift off swing motor and swing
machinery assembly (11).
* When removing the swing motor and swing
- machinery assembly, be careful not to dam-

e
l age the hoses, and lift off slowly.
Swing motor, swing machinery assem-
bly : 225 kg

PC200-6Z 30-57
DISASSEMBLY AND ASSEMBLY SWING MOTOR
AND SWING MACHINERY

INSTALLATION OF SWING
MOTOR, SWING MACHINERY
ASSEMBLY
Carry out installation in the reverse order to
removal.

Swing machinery mounting bolt :

549 2 59 Nm (56 z 6 kgm)

Refilling with oil (hydraulic tank)

* Add oil through the oil filler tothe specified
level.
Run the engine to circulate the oil through
the system. Then check the oil level again.

*
Bleeding air
Bleed the air from the swing motor.
For details, see TESTING AND ADJUSTING,
Bleeding air.

30-58 PC200-6Z
 DISASSEMBLY AND ASSEMBLY SWING MACHINERY

DISASSEMBLY OF SWING
MACHINERY ASSEMBLY
1. Draining oil
Loosen drain plug and drain oil from swing ma-
chinery case.
b
Swing machinery case : Approx. 5.5

2. Swing motor assembly

1) Set swing motor and swing machinery as-
sembly t o block @.
2 ) Remove mounting bolts, then remove swing
motor assembly (1).
-
3. No. 1 thrust washer
Remove No. 1 thrust washer (2).

\WWWl&A CLP02924

4. No. 1 sungear
Remove No. 1 sun gear (3).

CLPO2925

5. No. 1 carrierassembly
1) Remove No. 1 carrier assembly (4).

CLP07976

PC200-6Z 30-59
Po
hl
Y

i
Z
A ?
0
Y A

0 (u
0. D;' In
3
-*,

/-
/-

n
r
0
V L
N
W
N
4
DISASSEMBLY AND ASSEMBLY . SWING MACHINERY

9. Bolt
Remove holder mounting bolt (13). 13

10. No. 2 carrier assembly

1) Remove No. 1 carrier assembly (14).

CL.PO2931

Disassemble No. 2 carrier assembty as fol-

lows.
i) Push in pin (151, and knock shaft (16) out '7, / l6
from carrier (17).
Ir After removing the shaft, remove pin
(15).
ii) Remove thrust washer (181, gear (191,
bearing (201, and thrust washer (21).
iii) Remove plate (22).

I 22 -1 5
CLPO2932

11. Shaft assembly

1) Remove mounting bolts (23).
2) Set shaft and case assembly to press, then
using push tool @, remove shaft assembly
(24) from case assembly (25).

Zj
CLPO2933 CLPO2934

3) Disassemble shaft assembly as follows.

i) Usingpushtool @, removecover as-
sembly (26) and bearing (27) from shaft
(28).
ii) Remove oil seal (29) from cover (30).
26

27

CLP02935 CLPO2936

PC200-6Z 30-61
d
AND DISASSEMBLY ASSEMBLY SWING MACHINERY

ASSEMBLY OF SWING
MACHINERY ASSEMBLY
* Cleanallpartsand check fordirtor damage.
Coat the slidingsurfaces of all parts with engine
oil before installing.

1. Bearing
Using push tool0,press fit bearing (27)to case
(32).

CLPO2938

- 2. Cover
assembly
I
1) Using push tool 0,press fit oil seal (29) to
cover (30).
Outside circumference of oil seal :
Gasket sealant (LG-6)
* Be careful not to let the gasket sealant
(LG-6) get on the oil seal lip when press
fitting.

1 CLPO2939

2) Fitcover assembly (26) to case (32), and

tighten mounting bolts (23). 26\ ,2 3 I
a Cover mounting surface :
Gasket sealant (LG-6)
Q i
3 Mounting bolt :
66.2 t 7.4 N m i6.75 t 0.75 kgm)
Lip. of oil seal : Grease (G2-LII

CLP02940

3. Case Assembly
Set case assembly (25) to shaft (28). then using
push tool 0, press fit bearing inner race por-
tion.
* When setting the case assembly to the shaft,
be extremely careful not to damage the oil
seal.

C l PO294 1

PC200-6Z 30-63
DISASSEMBLY AND ASSEMBLY SWING MACHINERY

4. Bearing
Using tool F, press fit bearing (31).
* Press the bearing inner race and outer race
at the same time when press fitting.Do not
press only the innerrace when press fitting.
* After press fitting the bearing, check that the -11
case rotates smoothly.

CLP02942

5. No. 2 carrierassembly
1) Assemble No. 2 carrier assembly as follows.
* There are theremainsofthecaulking
17
\ /I*
when the pin is inserted at the end face
of hole h at the side of the carrier, so
remove the caulked metal from the in-
side diameter of the hole before starting
t o assemble.
i) Assemble plate (22) t o carrier (17).

I
ii) Assemblebearing (20) t o gear (191, fit
top and bottom thrust washers (18) and 22-
(21) and set gear assembly to carrier(17). CLPO.7943
iii) Align with position of pin holes of shaft
and carrier, then tap with a plastic ham-
mer to install shaft(16).
* When installing the shaft, rotate the
planetary gear, and be careful not to
damage the thrustwasher.
/I6
iv) Insert pin (15).
* After inserting the pin, caulk the pin
portion of the carrier.

15 h
CLPO2944

2) Install No. 2 carrier assembly (14).

13
6. Bolt
Tighten bolt (13).
Mounting bolt :
Thread tightener ILT-2)
Mounting bolt :
176.5 2 19.6 Nm I18 2 2.0 kgm)

L L PO2931

30-64 PC200-6Z
 DISASSEMBLY AND ASSEMBLY SWING MACHINERY

7. No. 2 sun gear

Install No. 2 sun gear (12).

12930

- 8. No. 2 thrust washer

Install No. 2 thrust washer (11).

12929

9. Ringgear r
Install ring gear (10).
Case side mounting surface :
Gasket sealant (LG-6)

10. No. 1 carrier assembly

1) Assemble No. 1 carrier assembly as follows.
* There are the remains of the caulking at
8
I
the end face of carrier side hole k made
when inserting the pin, so remove the
remainsofthecaulkingontheinside
diameter of the hole before starting as-
sembly.
i) Assemble bearing ( 8 )t o gear (7).then fit
top and bottom thrust washers (9)and
set gear assembly to carrier.
CLPO2945

PC200-6Z 30-65
DISASSEMBLY AND ASSEMBLY SWING MACHINERY

ii) Align pin holeposition of carrierand

shaft, then tap with plastic hammer and
install shaft (6).
* Rotate the planet gear when install-
ing the shaft, and be careful not to
damage the thrustwasher.
iii) Insert pin (5).
* After inserting the pin, caulk the pin
portion of the carrier.

II 6
CLP02946

iv) Install No. 1 carrier assembly (4).

CLPO2926

11. No. 1 sun gear I

Install No. 1 sun gear (3).

CLPO2925

12. No. 1 thrust washer

Install No. 1 thrust washer (2).

CLPO2924

30-66 PC200-6Z
DISASSEMBLY AND ASSEMBLY SWING MACHINERY

13. Swing motor assembly

Install swing motor assembly (1).
Ring gear side mounting surface :
Gasket sealant ILG-6)

GLP02923

* Coat the outside diameter of the hole only

at the holein the ring gear where there is a
distinguishing protrusion on the case. (See
?he diagram on the right.)
Mounting bolt :
*
176.5 t: 19.6 Nm 118 2.0 kgm)

14. Refilling with oil

! Path for
I iauidoasket

P r o j e c t i o nf o r
Tightendrain plug andadd engine oilthrough identification
oil filler to specifiedlevel.

PC200-6Z 30-67
AND DISASSEMBLY ASSEMBLY REVOLVING FRAME

REMOVAL OF REVOLVING
FRAME ASSEMBLY
1. Remove 2 boom cylinder assemblies. For de-
tails, seeREMOVAL OF BOOM CYLINDERAS-
SEMBLY.

2. Remove work equipment assembly. For details,

see REMOVAL OF WORK EQUIPMENT ASSEM-
BLY.

3. Remove counterweightassembly. For details,see

REMOVAL OF COUNTERWEIGHT ASSEMBLY.

4. Disconnect top mounting hoses (l), (21, and (3)

of swivel joint assembly at swivel joint assem-
bly end.

5. Remove stopper link (4).

6. Remove mounting bolts, then lift off revolving

frame assembly (5).
* Leave 2 bolts @ each at the front and rear,
use a lever block to adjust the balance of the
revolving frame assembly to the front and
rear, andleft and right,thenremovethe
remaining bolts, and lift off.
A When removing the revolving frameas-
sembly, be careful not to hit the center
swivel joint assembly.

& Revolving frame assembly: 5,200 kg UJ CLPO3849

30-68 PC200-6Z
AND DlSASSEMBLY
REVOLVINGASSEMBLY FRAME

INSTALLATION OF REVOLVING
FRAME ASSEMBLY
Carry out installation in the reverse order to
removal.

Mating surface of swing circle :

Gasket sealant (LG-1)
Thread of revolving frame mounting
bolt : Thread tightener (LT-2)
Revolving frame mounting bolt :

Mounting bolt

I PC200-6 I 20- 110 I I

32
1st: 294 (301
2nd: Tighten 60" I
Refilling with oil (hydraulic tank)
Ir Add oil throughthe oil filler to the speci-
fied level. Run the engine to circulate
the oil through the system. Then check
the oil level again.

Bleeding air
* Bleed the air.Fordetails, seeTESTING
AND ADJUSTING, Bleeding air.

PC200-6Z 30-69
DISASSEMBLY AND ASSEMBLY SWING CIRCLE

REMOVAL OF SWING CIRCLE

ASSEMBLY
1. Remove revolving frame assembly. For details,
see REMOVAL OF REVOLVING FRAME ASSEM-
BLY.

2. Remove swing circle mounting bolts (11, leaving

1 bolt each in front and rear direction.
.k Swingcircle assembly mounting bolts: 32
pcs.

3. Sling swing circle assembly (2) at three points, I-\

CLPO3850
then remove remaining mounting bolts.

4. Lift off swing circle assembly (2).

&I Swing circle assembly : 280 kg

30-70 PC200-6Z
 I

AND DSASSEMBLY ASSEMBLY SWING CIRCLE

INSTALLATION OF SWING
CIRCLE ASSEMBLY

B+
Carry out installation in the reverse order to S u i n ec i r c l es t a r tm a r t

removal. Socket

a Thread of swing circle mounting bolt :

start m a r t

Sac t e t
48'f5

Thread tightener (LT-2)

P o s i t i o n of
Swing circle mounting bolt : s u i a ec i r c l e
1st pass: en4 aSa or kcskteatr t mark

Tighten to 191.2 t 19.6 Nm 119.5 t 2 kgm)

DKPO049 I
2nd pass:
1) Using the angle of the bolt head as the
base, make start marks on the swing cir-
cle and socket. Innerrace
2) Make an end mark at a point (on swing ,soft zone
circle) 4 8 ~ 5 "from the start mark. r race
zone
3) Tighten so thatthe startmark onthe
socket is aligned with the end mark on
the swing circle at the 484" position.

Set the soft zone S mark on the inside ring

f
of the inner race facing the right side as
shown in the diagram, then install to the
track frame. DLP00492
6 Swing circle : Grease (G2-LII 211

PC200-6Z 30-71
DISASSEMBLY AND
IDLER
ASSEMBLY SPRING
RECOIL

REMOVAL OF IDLER.. RECOIL

SPRINGlASSEMBLY
1. Remove track shoe assembly.Fordetails, see
REMOVAL OF TRACK SHOE ASSEMBLY.

2. Sling idler and recoil spring assembly (I), and

pull out to the front toremove.

&IIdler recoil spring assembly :275 kg

3. Disconnect recoil spring assembly (3)from idler

assembly (2).

&
J Idler assembly : 140 kg ~

& Recoil spring assembly : 135 kg

3
\
INSTALLATION OF IDLER
RECOIL SPRING ASSEMBLY
Carry outinstallation in the reverse order to
removal.
I CLPO3855

J, When installing the idler assembly and re-

coil spring assembly, assemble so that the
position of the greasing plug on the idler is
on the outside for the right side of the ma-
chine and on the inside for the left side of
the machine.

30-72 PC20-67
DISASSEMBLY AND ASSEMBLY RECOIL SPRING

2. Disassembly of recoil spring assembly

1) Set recoil spring assembly (1) to tool H1.
A The recoil spring is under large installed
load, so be sure to set the tool properly.
Failure to do this is dangerous.
* Installed load of spring
: 126.5 kN (12,900 kg)

* Compress the spring to a point where

the nut becomes loose.
* Release the'hydraulic pressure slowly
and release the tension of the spring.
* Free length of spring : 603.5 mm

3) Remove yoke (6), cylinder (71, and dust seal

( 8 ) from spring (5).

3. Disassembly of piston assembly

1) Remove lock plate (10) from piston (9).then
remove valve (11).
2) Remove snap ring (121,then remove U-pack-
ing (13) and ring (14).

PC200-6Z 30-73
DISASSEMBLY AND ASSEMBLY RECOIL SPRING

ASSEMBLY OF RECOIL SPRING

ASSEMBLY
H2
1. Assembly of piston assembly
1)Assemble ring (14) andU-packing (13) to
piston (9), and secure with snap ring (12).
2) Tightenvalve (11) temporarily,and secure
with lock plate (10).

2. Assembly of recoil spring assembly

1) Using tool HZ, install dust seal (8)to cylin-
der (7).
CLPO3858
2) Assemble cylinder (7) and yoke ( 6 ) t o spring
(51, and set in tool H1.
& Sliding portion of cylinder :
Grease (G2-LI)

3) Apply hydraulic pressure slowly tocompress

spring, and tighten nut ( 4 ) so that installed
length of spring is dimension "a", then se-
cure with lock plate (3).
* Installed length "a" of spring : 466 mm

4) Remove recoil spring assembly (1) from tool

H1.
CLPO3859
3. Assemble piston assembly (2) to recoil spring
assembly (1).
xf_Ls Sliding portion of piston, wear ring:
Grease (G2-LI)
* Assemble the cylinder assembly so that the
mounting position of the valve is 90" t o the
side.
* Fill the inside of the cylinder with 300 cc of
grease (G2-LI), then bleed the air and check
that grease comes out of the grease hole.

30-74 PC200-6Z
IDLER DISASSEMBLY AND ASSEMBLY

-
DISASSEMBLY OF IDLER
ASSEMBLY
1. Remove dowel pin (11, then remove support (2). 7

2. Remove floating seal (3)from support (2) and

idler (4).

3. Pull out idler (4) from shaft (5) and support (7)
assembly.
* It is filledwith 80 cc. of oil, so drain the oil at
this point or lay a cloth to prevent the area
from becoming dirty.

2
CLPO3860

4. Remove floating seal ( 6 ) on opposite side from

idler (4) and shaft (5)and support (7) assembly. 4 6

CLPO3861

5. Remove dowel pin (81, then remove support (7)

from shaft (5).

6. Remove bushings (9) and (10) from idler (4).

CLPO3862 CLPO3863

PC200-6Z 30-75
DISASSEMBLY ASSEMBLY IDLER

ASSEMBLY OF IDLER
ASSEMBLY I I 1

1. Press fit bushings (9) and (10) t o idler (4).

10

CLPO2209 CLP022 IO

2. Fit O-ring and install support(7)t o shaft (5)with

dowel pin (8).

3. Using tool J1, install floating seal (6)to idler (4)

and shaft (5) and support (7)assembly.
*Coat the sliding surface of the floating seal 5
with oil, and be carefd not to let anydirt or
dust get stuck t o it.
* Remove all grease and oil from the contact
surface of the O-ring and the floating seal.
a
' CLPO3861

I I

CKP03867

4. Assemble shaft (5) land support (7) assembly to

idler (4).
4

CLPO3868

30-76 Dr3M-X7
 DISASSEMBLY AND ASSEMBLY IDLER

5. Using tool J1, install floating seal (3)to idler (4)

and support (2).
.k Coat the sliding surface of the floating seal
with oil, and be careful not tolet any dirt or 2 3
dust get stuck t o it.
* Remove all grease and oil from the contact
surface of the O-ring and the floating seal.

I CLPO3869

Jt
\

CKP03870

6. Install O-ring, then install support ( 2 )with dowel

pin (1).

7 . Add oil and tighten plug.

-
Oil : Approx. 80 cc (SAESO)

Plug : 205.8 2 49 Nm (21 2 5 kgm)

2
CLPO3860

PC200-6Z 30-77
DISASSEMBLY AND ASSEMBLY TRACK ROLLER

REMOVAL OF TRACK ROLLER

ASSEMBLY
1. Lower work equipment,then loosen lubricator
(11, and relieve track tension.
The adjustment cylinder is under extremely
high pressure. Never loosen the lubricator
-
more than one turn. If the grease does not
come out easily, move the machine back-
wards and forwards.
2. Remove mountingboltsof track roller, then
swing work equipment 90". jack up machine,
and remove track roller assembly (2) towards CLP03872
outside of machine.

Track roller assembly : 40 kg

INSTALLATION OF TRACK
ROLLER ASSEMBLY
Carry outinstallation in the reverse order to
removal.

* Adjustthe track tension. For details, see

TESTING AND ADJUSTING, Testing and ad-
justing track tension.

* Place the plug on the outside of the chassis,

andsetthetrackroller assembly inthe
mounting position.
* Operate the work equipment levers to lower
the machine slowly, then tighten the mount-
ing bolts temporarily.
* Operate the work equipment levers to lower M
the machine completely tothe ground, then
tighten the mounting bolts fully.
CLPO3871
Track roller assembly mounting bolt:
1st pass :
Tighten to 196 t 19.6 Nm (20 t. 2 kgml
2nd pass : Track r o l l e r
1. Whenusingtool M. s t a r t mark
Usingan
angle
tightening
wrench, tighten bolt 90 2 5". Socket
start
I
2. When not using tool M.
1) Using the angle of the bolt head
as the base, make start marks on
the track roller and socket.
2) Make an end mark at a point 90 2 t r a c kr o l l e r
5" from the start mark. / m a r ks t aeSrnotdc kme at r k
3) Tighten so that the start mark on Socket
DLP00493
the socket is aligned with the end
markonthe track roller at the
9025" position.
33-78 PC7CK)-A7
 DISASSEMBLY AND ASSEMBLY TRACK ROLLER

DISASSEMBLY OF TRACK
ROLLER ASSEMBLY
1. Remove pin (11, then remove collar (2).

CLP022 19

2. Remove floating seal (3)from collar (2) and roller

(4).

CLPO2220 CLP0222 I

3. Pull out roller (4) from shaft (5).

* It is filled with 190 - 215cc. of oil, so drain
the oil at this point or lay a cloth to prevent
the area from becoming dirty. 5
4. Remove floating seal ( 6 ) on opposite side from
roller (4) and shaft (5).
4

CLPO2222 CLPO2223

PC200-6Z 30-79
w
0
63
0

0
I-
V
O
N
N
N
A
 DISASSEMBLY AND ASSEMBLY TRACK ROLLER

-
ASSEMBLY OF TRACK ROLLER
ASSEMBLY
1. Using push tool 0, press fit bushings (9) and
(10) to roller (4).

2.' Assemble collar ( 8 ) t o shaft (51,and install pin

(7).

3. Using tool K1, install floating seal (6) to shaft

(5).
* When assembling the floatingseal, clean the 1 9 IO 8
contact surface of O-ring ( 6 c ) and floating CLPOO803
seal (6a), remove all grease and oil, and dry
it. Make sure that no dirt or dust sticks to
A the contact
surface of
the
floating seal.

4. Using tool K1, install floating seals (6) and (3) to

roller (4).
* For details of the precautions when install-
ing floating seals (6b) and (6d). and (3b) and
(3d), see the precaution for Step3.

5. Assemble shaft (5) to roller (4).

6. Turn over roller (4) and shaft (5)assembly.

CLPO2226 CLPO3885
7. Using tool K I , install floating seal (3)to collar
(2).
* For details of the precautions when install-
ing floating seals (3a) and ( 3 ~ ) see
. the pre-
caution for Step 3.
. K1

CLPO3886

CL~ 0 3 ~ 8 8 CLP03889

PC200-6Z 30-81
 U N

0
r
V
0
w
i: m
Lo
0
ROLLER DISASSEMBLY
CARRIERAND ASSEMBLY

REMOVAL OF CARRIER
ROLLER ASSEMBLY
1. Lower work equipment, thenloosenlubricator
(1).relieve
A
and
track tension.
The adjustment cylinder is under extremely
a
high pressure. Never loosen the lubricator
more than one turn. If the grease does not
come out, move the machine backwards and
forwards.

2. Using hydraulic jack 0,push up track to a posi-

tion wherecarrierroller assembly canbe re- CLPO3872
moved, then remove carrier roller assembly (2).
a
INSTALLATION OF CARRIER
ROLLER ASSEMBLY
Carryoutinstallationin the reverse orderto
removal.

* Adjustthetrack tension. For details, see I CLPO3894

TESTING AND ADJUSTING, Testing and ad-
justing track tension.

Thread of carrier roller assembly mounting bolt:

Thread tightener (LT-2)

PC200-6Z 30-83
ROLLERDISASSEMBLY
CARRIER
AND ASSEMBLY

DISASSEMBLY OF CARRIER
ROLLER ASSEMBLY
1. Remove plug (1) anddrainoil.
b
Carrier roller assembly : 230 - 250 cc
2. Set carrier roller assembly on stand 0.
3. Remove cover (2).
4. Remove ring (3).

U W
CLPO3896 CLPO3897

5. UsingtoolL1,remove nut (4).

6. Usingpushtool @, pull outshaftassembly (5)
from roller ( 6 ) withpress, thenremoveinner
race (7). 7
Ll

CLPO3898 CLPO3899

7. Remove outer races ( 8 ) and (9)from roller ( 6 ) .

8. Disassembly of shaftassembly
1) Usingpuller @, removeinnerrace (10).
I

6 3 z9

CLPO3900 CLPO3901

30-84 PC200-6Z
DISASSEMBLY AND ASSEMBLY ROLLER CARRIER

2) Remove floating seals (11).

3) Using push tool 0,remove collar (12) from
shaft (13).

L
-
+- CLPO3903

PC200-6Z 30-85
DISASSEMBLY AND ASSEMBLY CARRIER ROLLER

ASSEMBLY OF CARRIER
ROLLER ASSEMBLY
1. Using push tool @, press fit outer races ( 8 ) and
(9) to roller (6).

2. Assembly of shaft assembly

1) Using push tool @, press fit collar (12) t o
shaft (13).
*When press fitting, be careful that there
is no scuffing.
Fitting portion of shaft : SAE30
2 ) Using tool L3, assemble floating seals (11).
*
CLP03904 I CLPO3905
When assembling the floatingseal, clean
the contact surface of O-ring ( l l c ) and
floating seal (lla), remove allgrease and
oil, and dry it. Make sure that no dirt or
dust sticks to the contact surface of the
n
floating seal.
3) Assemble floating seals (111, then using tool
L2, press fit inner race (10).
*For details of the precautions when in-
stalling floatingseals ( l l b )and (lld),see
the precaution for Step 2).

3. Assemble roller (6) t o shaft assembly (5).

4. Using tool K, press fit inner race (7).

* W h e n press fitting the bearing, rotatethe 7
roller,andpress fit t o a pointwherethe 5 L1
rotation becomes slightly heavier.

5. Using tool L1, tighten nut (4) to a point where 6

drill hole in shaft is aligned with drill hole in
nut.
U CLPOI
448
I
CLP03898

6. Install ring (3).

7. Usingpush-pull scale @, check that it rotates

smoothly.

CtPO3909 CLP03897

30-86 PC200-6Z
 DISASSEMBLY AND ASSEMBLY ROLLER CARRIER

8. Fit O-ring and install cover (2).

/
CLPO3910

- 9. Usingtool L4, apply basic pressure to rolleroil

filler port,and check for leakage of air from
seal.
* Basic pressure : 0.1 MPa (1 kg/cm21
* Methodof checking
The basic pressure shall be maintained for
10 seconds and the indicator of the gauge
shall not go down.

I CLPO391 I

IO. Using tool L4, fill carrier roller assembly with I

oil, then tighten plug (1).

Carrier roller oil : 230 - 250 cc (SAE30)

t
To o i l DUHD i
To vacuum t a n k
DLP00494

PC200-6Z 30-87
DISASSEMBLY AND ASSEMBLY TRACK SHOE

REMOVAL OF TRACK SHOE

ASSEMBLY
1. Stopmachine at a pointwheremaster pin is
midway betweenidlerandcarrierroller,and
where there is space to lay out track assembly
on ground.

2. Lowerwork equipment, then loosenlubricator

(11, and relieve track tension.
A The adjustment cylinder is under extremely
high pressure. Never loosen the lubricator
more than one turn. If the grease does not CLP03872
come out, move the machine backwards and
forwards.
3. Using tool I, pull out master pin (2).

4. Remove tool I, and move machine forward so

that position of temporary pin @ is at front of
idler, and set block @ in position.

5. Remove temporary pin0,and remove dustseal,

then drive machine in reverse to lay out track
(3).

INSTALLATION OF TRACK
SHOE ASSEMBLY
p g
* Adjustthe tracktension. For details, see
TESTING AND ADJUSTING, Testing and ad-
justing track tension.

* Use tool I and press fit so that the protru-

sion of the master pin is dimension "a".
Protrusion "a" of master pin : 4 2 2 m m

* Whenassemblingthedust seal, coatthe

bushing contact surface with grease (G2-LI).
* Replace the shoes with new ones when rubber
pads get worn to the same height (or lower) as
the heads of their mounting bolts.
It is impossible to remove or install mounting
bolts once the heads get damaged, crushed or
deformed.

30-88 PC200-6Z
 DISASSEMBLY
HYDRAULIC
AND ASSEMBLY TANK

REMOVAL OF HYDRAULIC
TANK ASSEMBLY
1. Drain
oil from hydraulic tank. p g
b
Hydraulic tank : Approx. 170 e
2. Remove engine hood (11, pump top cover (21,
and control valve top cover (3).

3. Remove right side cover (4) together with cover

mounting frame (5).

- 4. Remove engine partition plates ( 6 ) and ( 7 ) and

mounting bracket for partition plate on hydrau-
lic tank side.

5. Disconnect hydraulic oil return tube (8).

6. Remove pump suction tube (9) together with

joint hose (10).

7 . Remove LS pressure hose clamp (11).

8. Disconnect 7 hydraulic tank return hoses (12).

* After disconnecting the hoses, fit tags to dis-
tinguish them.
* Protect with the sleeve nut to prevent dam-
age to the nipple or elbow taper seal por-
tion.

19

9. Sling hydraulic tank assembly (131, then remove

mounting bolts, and lift off hydraulic tank as-
sem bly.

Hydraulic tank assembly : 136 kg

CLP03670

PC200-6Z 30-89
DISASSEMBLY
HYDRAULIC
AND ASSEMBLY TANK

--
INSTALLATION OF HYDRAULIC
TANK ASSEMBLY
Carry outinstallation in the reverse order to
removal.

Hydraulic tank drain plug :

68.5 t 10 Nm l6.98 z 1.01 kgm}

Hydraulic tank mounting bolt :

277 232 Nm {28.3 t 3.2 kgm}

Refilling with oil (hydraulictank)

* Add oil through theoil filler to the specified
level.
Run the engine t o circulate the oil through

a the system. Then check the oil level again.

Hydraulictank :Approx. 170

Bleeding
air
.k Bleed the air.
For details, see TESTING AND ADJUSTING,
Bleeding air.

30-90 PC200-6Z
DISASSEMBLY AND ASSEMBLY PUMP MAIN

REMOVAL OF MAIN PUMP

ASSEMBLY
A Disconnect the cable from the negative (-1 ter-
minal of the battery.
A Lower the work equipment completely to the
ground and stop the engine. Then loosen the oil
filler cap slowly to release the pressure inside B
the hydraulic tank.

Removethehydraulictank strainer, andusing

tool B, stop the oil.
Whennot using tool B, remove the drain
plug, and drain the oil from the hydraulic
I CLPO3276

tank and inside the system.

b
& Hydraulic tank : Approx. 170

Drainoilfrom damper case.

1. Remove engine hood cover (1).

2. Remove main pump top cover (2).

3. Remove right side cover (3) together with cover

mounting frame (4).

4. Remove connector (5)from bracket and discon-

nect.

I \\ \ I CLPO38 I2

5. Disconnect F and R pump discharge hoses ( 6 )

and (7).F and R LS pressure hoses ( 8 ) and (91,
and EPC basic pressure hose (10).
* Protect with the sleeve nut to prevent dam-
age to the nipple or elbow taper seal por-
tion.

PC200-6Z 30-91
 DISASSEMBLY AND ASSEMBLY MAIN PUMP

6. Disconnect pump servo pressure hose (11) and

pump drain hose (121, and remove intermediate
clamp (13) of hose.
* Protect with the sleeve nut to prevent dam-
age to the nipple or elbow taper seal por-
tion.

7. Disconnect suction tube (14) at pump end.

* with plas-
Cover the suction tube port portion
tic.

8. Removeenginepartition plates (15), (161, and

(17).

9. Removemufflerdrainpipe (18) andclamp

mounting bracket (19). 18

19

03 8 1 6

10. Remove main p u m p assembly (20) as follows.

1) Leaving 2 - 3 mounting bolts, remove other
mounting bolts.
2) Slingmain pump assemblyandinstall 2
guidebolts ( iJ
ondiametricallyopposite
sides.
3) Remove remaining mounting bolts, then pull
out slowly until main pump assembly sepa-
rates from spline shaft.
4) Lift off main pump assembly.

&I Main pump assembly : 150 kg /I7

30-92 PC200-6Z
DISASSEMBLY AND ASSEMBLY MAIN PUMP

INSTALLATION OF MAIN
PUMP ASSEMBLY
Carry outinstallationin the reverse order t o
removal.

6 Involute spline of main pump :

Anti-friction compound (LM-G)
Mating surface of main pump case :
Gasket sealant ILG-6)

Refilling with oil (damper)

* Add engine oil through the oil filler to the
specified level. Run the engine t o circulate
the oil through thesystem. Wait for at least
15 minutes, then check the oil level again.

Damper :Approx. 0.7

Refilling with oil (hydraulictank)

* Add oil through the oilfiller to the specified
level.
Run the engine to circulate the oil through
the system. Then check the oil level again.

Bleeding
air
t Bleed the air from main pump.
For details, see TESTING AND ADJUSTING,
Bleeding air.

PC200-6Z 30-93
DISASSEMBLY AND ASSEMBLY INPUT
PUMP
MAIN SHAFT OIL SEAL

REMOVAL OF MAIN PUMP

INPUT SHAFT OIL SEAL
1. Remove main pump assembly. For details, see
REMOVAL OF MAIN PUMP ASSEMBLY.

2. Remove snap ring (11, then remove spacer (2).

3. Lever up oil seal (3) with a screwdriver to re-

move. p g
*Whenremovingtheoil seal, be extremely
careful not to damage the shaft.
I/ CLPO3916

INSTALLATION OF MAIN
PUMP INPUT SHAFT OIL SEAL
CarFy outinstallation in the reverse order to
removal.

a6 Lip of oil seal : Grease (G2-LI)

6 Coat the outside circumference of the oil
seal with grease (G2-LI) thinly, then Dress
fit.
* Using tool N, press fit oil seal (3).

CLPO3917

30-94 PC200-6Z
CONTROL ASSEMBLY
DISASSEMBLY AND

REMOVAL OF CONTROL
VALVE ASSEMBLY
A Run the engine at low idling, operate the cylin-
der to the end of its stroke without relieving the
circuit, then lower the work equipment to the
ground.
For details, see TESTING AND ADJUSTING, Re-
Ieasing pressure in hydraulic circuit.
After stopping the engine, do as follows.

Loosen theoilfillercap slowly t o release the

pressure inside thetank.
Operate thecontrol levers.
* Operate the control levers several times to
release the pressure in the accumulator.
Start the engine and run at low idling for approx.
5 seconds, then stop theengine and operate the
control levers.
f Repeat the above operation several times to
release the remaining pressure completely.

1. Open engine hood, and remove valve top cover

(1) and air deaner top cover(2).

2. Removepartitionplate covers (3) and (4) be-

tween engine and control valve, move partition
plate cover (5) under intake hose towards en-
gine.

3. Disconnect pump discharge hoses (6) and (71,

and remove hose clamp (8).

4. Remove self-reducing pressure valve (9).

._-
* The length of the mounting bolts is differ-
ent. See below.
Left side mounting bolts (2 bolts) :
L = 120 mm
Right side mounting bolts (2 bolts) :
L = 125 m m

5. Disconnect hoses (10) between control valve and

relay block, hose (1 1) between controlvalve and
timing valve, travel valve pilot hose (12),2 boom
valve pilot hoses (131, and 2 relief valve pilot
hoses (14).
* After disconnecting the hoses, fit tags to dis-
tinguish them.
Ir Protect with the sleeve nut to prevent dam-
age t o the nipple or elbow taper seal por-
tion.

PC200-6Z 30-95
DISASSEMBLY AND ASSEMBLY CONTROL VALVE

6. Disconnect 2 travel valve junction hoses (15).

7. Disconnect 2 LS pressure pilot hoses (16).

f After disconnecting the hoses, fit tags to dis-
tinguish them.

8. Disconnect 10 hoses (19) connected t o each

valve.
f After disconnecting thehoses, fit tags to dis-
tinguish them.
f Protect with the sleeve nut to prevent dam-
age to the nipple or elbow taper seal por-
tion.

I I9 CLPO3828

9. Disconnect 2 each of bucket valve tube (20),

boom valve tube (211, and arm valve tube (22).

10. Disconnect 2 each of right travel valve hose (23),

swing valve hose (241, and left travel valve hose
(25).

11. Disconnect 2 LS select valve pilot hoses (26).

m?7% CLP03829

12. Sling control valve assembly (27), then remove

mounting bolts, and lift off control valve assem-
bly.

fi Control valve assembly : 170 kg

30-96 PC200-6Z
DISASSEMBLY AND ASSEMBLY CONTROL VALVE

INSTALLATION OF CONTROL
VALVE ASSEMBLY
Carryoutinstallation in the reverse order to
removal.

Refilling with oil (hydraulic tank)

* Add oil through the oil filler tothe specified
level.
Run the engine to circulate the oil through
the system. Then check the oil level again.

Bleeding
air
* Bleed the airfrom thecircuitbetweenthe
valve and the hydraulic cylinder.
For details, see TESTING AND ADJUSTING,
Bleeding air.

PC200-6Z 30-97
 r-
O T
m

.I

0
x
73
0
v
m
N X
m
 W
*\

D
1
D

w \

:'
-0
n

0
DISASSEMBLY AND ASSEMBLY COMROL VALVE

Bucket

RH t r a

Boon

f L-L \ Swine
1 2
LH t r a

Arm

2 8-8

79

24 21

25' 20

26 19

18 60
c-c

J-J

50 49 AA-AA 48 47

DKP00528

30-100 PC200-6Z
 CONTROL VALVE

The set pressure of the safety valve cannot be

adjusted when it is installed on the machine, so
do not disassemble.
This section explains the procedure for the 6-
spool valve.

1. Main reliefvalve
Remove main relief valve (2).

2. Unload valves, safety-suction valves.suction

valves
1) Remove unload valves (1) and (17).
2) Remove safety-suction valves (23). (221,(271,
(18). and (20).
3) Remove suction valves (251,(241,(211, (261,
and (19).

3. Pressure compensation valves

* Beforeremoving any pressure compensa-
tion valve, check and mark its mounting po-
sition.
1) Remove bucket DUMP pressure compensa-
tion valve (81, R.H. travel REVERSE pressure
compensation valve (71, boom RAISE.pres-
surecompensation valve (61,rightswing
pressure compensation valve (51, L.H. travel
REVERSE pressure compensation valve (41,
and arm OUT pressure compensation valve
(3).
2) Remove bucket CURL pressure compensa-
tion valve (101, R.H. travel FORWARD pres-
sure compensation valve (111, boom LOWER
pressure cornpensation valve(121, left swing
.-
pressure compensation valve (131, L.H. travel
FORWARDpressurecompensationvalve
(741, and arm IN pressurecompensation
valve (15).
* After removing the pressure compensation
valves, remove check valve (35) from each
pressure compensation valve mount.

4. LS select valve
Remove LS select valve (38).

f'C200-6Z 30-101
DISASSEMBLY AND ASSEMBLY CONTROLVALVE

5. LS shuttle valves, pump merge/divider valve, 10. Boom control valve

boom regeneration valve
1) Remove LS shuttle valves (79) and (81).
2) Remove block (80). then remove boom
regenerationspring (61) and boom re-
generation valve (62).
6. Remove covers (9) and (16).
1) Remove case (571, then removespring
(55) and retainer (60).
2) Remove case (641, thenremovespring
(53) and retainer (63).
3) Remove spool assembly (54).
* Do not disassemble spool assembly
(54).

7. Arm control valve 11. Bucket control valve

1) Remove case (701, then remove spring
(74) and retainer (69).
2) Remove case (661, then remove spring
(67) and retainer (78).
3) Remove spool assembly (68).
*Do not disassemble spool assembly
(68).
1) Remove case (301, then removespring
(31) and retainer (32).
2) Remove case (341, then remove spring
(28) and retainer (33).
3) Remove spool assembly (29).
* Do not disassemble spool assembly
(29).

8. Swing control valve

1) Remove case (401, then remove spring
(39) and retainer (41).
2) Remove case (431, then remove spring
(36) and retainer (42).
3) Remove spool assembly (37).
*Do not disassemble spool assembly
(37).

9. RH. travel, L.H. travel control valves

1) Remove case (471, then remove spring
(46) and retainer (48).
2)Remove case(50). spring (44). and re-
tainer (49).
3) Remove spool assembly (45).
* Do not disassemble spool assembly
(45).

30-1 02 PC200-6Z
VALVE
DISASSEMBLY
CONTROL
AND ASSEMBLY

ASSEMBLY OF CONTROL
VALVE ASSEMBLY
W3)

9
\

/ \
l6 t 2
Z

DKP00526

FC200-6Z 30-103
ul
4

"\

c'
0

t
I t I

c
I m
c I
m

.
VALVEDISASSEMBLY
CONTROL
AND ASSEMBLY

Coat the sliding surfaces of all parts with
engine oil before installing.
1 Bucket control valve spool
7 ) Assemble spool assembly (29) t o valve
body.
2) Assembleretainer (33)and spring (281,
then fit O-ring t o case (34) and install.
Case mounting bolt :
30.87 t 3.43 Nm (3.15t 0.35 kgm}
3) Assembleretainer (32) and spring (31)
to spool, then fit O-ring to case (30) and
install.
Case mounting bolt :
30.87 2 3.43 Nm 6.15 t 0.35 kgm}
2. Boom control valve spool
1) Assemble SPCOI assembly (54) to valve
body.
2) Assembleretainer (63) and spring (53).
then fit O-ring t o case (64) and install.
3)Assembleretainer (41) and spring (39),
then fit O-ring t o case (40) and install.
Case mounting bolt :
30.87 t 3.43 Nrn {3.15t 0.15 kgm}
5. Arm control valve
1) Assemble spool assembly ( 6 8 ) to valve
body.
2) Assembleretainer (78)andspring (67).
then fit O-ring t o case (66) and install.
Case mounting bolt :
30.87 t 3.43 Nm (3.15t 0.15 kgm}
3) Assembleretainer (69) andspring (741,
then fit O-ring to case (70) and install.
QE3 Case mounting bolt :
30.87 3.43 Nm 13.15 0.15 kgm}

-
QE3 Case mounting bolt :
=
30.87 3.43 Nm 13.15 t 0.35 kgm)
3) Assemblespring (56) and piston (591,
then install plug (58).
Plug :
= *
107.8 14.7 Nm (11.0 1.5 kgm}
4) Assembleretainer (60) and spring (551,
then install case (57).

-
Case mounting bolt :
=
30.87 3.43 Nrn (3.15t 0.15 kgm}

3. R.H. travel, L.H. travel control valves

1) Assemble spool assembly (45) to valve
body.
2) Assemble retainer (49) and spring (441,
then fit O-ring t o case (50) and install.
Case mounting bolt :
30.87 2 3.43 Nm 13.15 t 0.15 kgm}
3)Assemble retainer (48) and spring (46)
to spool, then fit O-ring to case (47) and
install.
Case mounting bolt :
30.87 2 3.43 Nm 13.15 t 0.15 kgm}

4. Swing control valve spool

1) Assemblespool assembly (37) to valve
body.
2) Assemble retainer (42) and spring (36),
then fit O-ring to case (43) and install.
Case mounting bolt :
30.87 2 3.43 Nm 13.15 t 0.15 kgml

30-1 06 PC200-6Z
DISASSEMBLY
CONTROL
AND ASSEMBLY VALVE

6. Covers
1) Fit O-ring to cover (161, then install.
2) Fit O-ring to cover (91, then install.
Mating surface of covers (161, (9) :
Seal end 242 or equivalent
* Tighten the mounting bolts in the order
shown in the diagram on the right.
Mounting bolt :
166.6 t 9.8 Nm I17 1 kgm}

7. LS shuttle valves, pump mergejdivider valve,

boom regeneration valve CKpQo8M

1) Assemble boom regeneration valve (62) and

spring (61) to valve body, then install block
(801.
* Tighten the mounting bolts in the order
shown in the diagram on the right.
Mounting bolt :
=
166.6 t 9.8 Nm (17 1 kgm}
2) Install LS shuttle valves (81) and (79).
Mounting bolt :
66.15 t 7.35 Nm (6.75z 0.75 kgm}

8. LSselectvalve
Install LS select valve (38).
LS select valve :
127.4 = 19.6 Nm (13* 2 kgm}

.
9. Pressurecompensation valves
Check themarksmade on each pressure
compensation valve during disassembly, and
install in the correct position.
1) Beforeinstallingpressurecompensation
valves below, install check valve (35).
2) Fit O-ring, then install armIN pressure com-
pensation valve (151,L.H. travel FORWARD
pressure compensation valve(141, left swing
pressurecompensationvalve (131, boom
LOWER pressure compensation valve (121,
R.H. travel FORWARD pressure compensa-
tion valve (11). and bucket CURL pressure
compensation valve (10).
w Pressure compensation valves :
392 2 19.6 Nm I40 t 2 kgm}
3) Fit O-ring, theninstallarm OUT pressure
compensation valve (31,L.H. travel REVERSE
pressure compensationvalve (41, right swing
pressurecompensationvalve 151, boom
RAISE pressure compensation valve (61, R.H.
travel REVERSE pressurecompensation
valve (71, and bucket DUMP pressure com-
pensation valve (8).
Pressure compensation valves :
392 t 19.6 Nm I40 2 2 kgm)

PC200-6Z 30-107
VALVE
DISASSEMBLY
CONTROL
AND ASSEMBLY

10. Unload valves,safety-suctionvalves,suction

valves
FitO-rings and install suction valves (191,
(261, (211, (241, and (25).
Suction valve :
147 2 9.8 N m I15 t 1 kgm}
Fit O-rings and install safety-suction valves
(18). (271,(221, and (23).
Safety-suction valve :
147 t 9.8 Nm I15 t 1 kgm)
Fit O-ringsand install unload valves(17)and
(1). I u<woB20
Unload valve assembly :
*
166.6 19.6 Nm I17 t 2 kgm}

11. Main relief valve

FitO-ring and install mainrelief valve as-
sembly (2).
Main relief valve :
53.9 t 4.9 Nm i5.5 t 0.5 kgm}

30-1 08 PC200-6Z
 DISASSEMBLY AND ASSEMBLY VALVE
MAIN RELIEF

DISASSEMBLY OF MAIN
RELIEF VALVE ASSEMBLY

I CKPO39 I9

1. Loosenlocknut (91, removeplug (81, then re-

move retainer (6).
2. Locsenlocknut (101, then remove holder (71,
spring (111, seat (121, and poppet (5).
3. Remove ring (11, thenremovevalve (3)and
spring (4).
* If anyabnormalityisfoundinanypart after
disassembly, replace the wholemain relief valve
assembly.

ASSEMBLY OF MAIN RELIEF

VALVE ASSEMBLY

--
.-_
Coat the sliding surfaces with engineoil.

1. Assemble spring (4) and valve (31,then install

ring (1).
2. Install seat (121, poppet (51, spring (111, and
holder (71, and secure in position with locknut
(10).
Locknut : 53.9 2 4.9 Nm (5.5 2 0.5 kgm}
3. Fitretainer (61, then install plug ( 8 ) and secure
in position with locknut (9).
Locknut : 39.7 2 4.9Nm (4.0 0.5 kgm}
* After installing main reliefvalve to control valve
assembly, adjustpressurereferring to section
TESTING AND ADJUSTING, testing and adjust-
ing hydraulic pressure in work equipment, swing,
travel circuit.

PC200-6Z 30-109
DISASSEMBLY AND ASSEMBLY PC VALVE

REMOVAL OF PC VALVE
ASSEMBLY
Disconnect the cable from the negative (-1 ter- J
a minal of the battery.
Lower the work equipment completely to the
ground andstop the engine. Then loosen the oil
filler cap slowly to release the pressure inside B
the hydraulic tank.

Remove the hydraulic tank strainer,and using

tool B, stop the oil.
When not using tool B, remove the drain CLPO3276
plug, and drain the oil from the hydraulic
tank and inside the system.
b
& Hydraulic tank : Approx. 170 fl

There are PC valve assernblies installed to both

the front pumpand the rear pump, but the pro-
cedure for removal is the same.

1. Remove nut (11, then remove hoseassembly

(2). a
2. Installlocknut @ (708-2L-28290).
Locknut :
100.5 2 12.5 Nm (10.25 2 1.25 kgm}

3. Turnnut (3)in directionof loosening, then

tighten at locknut (iJend.
* Angle of turning for nut (3):Approx. 30"

4. Fit tool to widthacross flats (22 mm) of hexago-

nal portion of sleeve (41, then loosenandre-
move PC valve assembly (5). a
CKPO37 I9

30-1 10 PC200-6Z B
 DISASSEMBLY AND ASSEMBLY PC VALVE

INSTALLATION OF PC VALVE
ASSEMBLY
Carry outinstallation in the reverse order to
removal.

Nut (2):
100.5 2 12.5 Nm t10.25 t 1.25 kgm}

* After installing the PC valve'assembly,re-

move locknut @.

& * Adjust
the PC valve assembly.
For details, see TESTING AND ADJUSTING,
Testing and adjusting PC valve output pres-
sure (servo piston inlet pressure).
Nut (3):
100.5 f 12.5 Nm (10.25 t 1.25 kgm}

Refilling with oil (hydraulic tank)

* Add oil through theoil filler to the specified
level.
Run the engine to circulate the oil through
the system. Then check the oil level again.

PC200-6Z 30-1 1 1
DISASSEMBLY AND ASSEMBLY LS VALVE

REMOVAL OF LS VALVE
ASSEMBLY
A Disconnect the cable from the negative (-1 ter-
minal of the battery.
A Lower the work equipment completely to the
ground and stop the engine. Then loosen theoil
filler cap slowly to release the pressure inside
the hydraulic tank.

Remove thehydraulic tank strainer, andusing

tool B, stop the oil.
When not usingtool 6, remove the drain
plug, and drain the oil from the hydraulic
CLPO3276 I
tank and inside thesystem.
b
& Hydraulic tank :Approx. 170

There are LS valve assemblies installed to both

the front pump and the rear pump, but the pro-
cedure for removal is the same.

1. Disconnecthose (1).
2
2. Fit t o o l t owidth across flats (30mm) of hexago-
nal portion of sleeve, then loosen and remove
LS valve assembly (2).

INSTALLATION OF LS VALVE
ASSEMBLY
Carry outinstallationinthe reverse order to
removal.

.A. Adjust the LS valve assembly.

For details, see TESTING AND ADJUSTING,
Testing and adjusting LS valve output pres-
sure (servo piston inletpressure) and LS dif-
ferential pressure.
Sleeve :
139.7 12.3 N m f14.752 1.25 kgm)

Refilling with oil {hydraulictank)

t Add oil through the oil filler to the specified
level.
Run the engine to circulate the oil through
the system. Then check the oil level again.

30-1 12 PC200-6Z
 DISASSEMBLY AND ASSEMBLY PCEPC VALVE

REMOVAL OF PC-EPC VALVE

ASSEMBLY
A Disconnect the cable from the negative (-1 ter-
minal of the battery.
A Lower the work equipment completely to the
ground and stop the engine. Then loosen the oil
filler cap slowly to release the pressure inside
the hydraulic tank.

1. Remove the main pump bottom cover.

2. Disconnect wiring connectors (1) (2 places). \\\ - 1 CLPO3831

* After disconnecting the connectors, fit tags
to distinguish them.
&

3. Disconnecthose (2).

4. Remove PC-EPC valve assembly (3).

--
INSTALLATION OF PC-EPC
VALVE ASSEMBLY
Carry out installation in the reverse order t o
removal.

Hose sleeve nut :

- 24.5 t 4.9 Nm 4 . 5 t 0.5 kgm)

PC-EPC valve assembly mounting bolt :

13.3 2 1.5 N m {1.35 2 0.15 kgm)

PC200-6Z 30-1 13
 DISASSEMBLY
VALVE AND ASSEMBLY
SOLENOID

REMOVAL OF SOLENOID
VALVE ASSEMBLY
Disconnect the cable from the negative (-) ter-
minal of the battery.

1. Remove 3 solenoid wiring connectors (1) from

clip and disconnect.
* Mark the male and female ends of each con-
nector with tags to prevent mistakes when
connecting.

2. Disconnect 2 hoses (2) installed to bottomof

va Ive.
* After disconnecting the hoses, fit tags to dis-
tinguish them.

3. Disconnect 4 hoses (3)installed to top of valve.

* After disconnecting the hoses, fit tags to dis-
tinguish them.

4. Remove mounting bolts, then remove solenoid

valve assembly (4).

When removing solenoid valve as an individual

Part
i) When washing valve,loosen mounting bolt
(5)and remove. a

INSTALLATION OF SOLENOID
VALVE ASSEMBLY

a
Bolt : 3.9 z 0.39 Nrn I0.4 t 0.04 kgm)

CKPO I453

30-1 14 PC200-6Z
 DISASSEMBLY AND ASSEMBLY
WORK EQUIPMENT SWING PPC VALVE

REMOVAL OF WORK
EQUIPMENT SWING PPC
VALVE ASSEMBLY
3 I /I
A Lower the work equipment completely to the
ground andstop the engine. Then loosen the oil
filler cap slowly to release the pressure inside
the hydraulic tank.

1. Remove control stand case.

For details, see REMOVAL OF CONTROL STAND
CASE.

2. Remove joint bolt(11, and disconnect hose (2).

- p g
3. Remove mounting bolts, raise PPC valve assem-
bly (31,then disconnect hoses (4) and (51, and
remove. 1121
* Before disconnecting the hoses, make match
marks to show the connecting position.

INSTALLATION OF WORK
EQUIPMENT SWING PPC
VALVE ASSEMBLY
Carry out installation in the reverse order to
removal.
-

Hose mount joint bolt:

29.4 t 4.9 Nm (3.0 t 0.5 kgm}

Hose mount joint bolt :

39.2 f 4.9 N m I4.0 t 0.5 kgm}
* If there is excessive play in the control le-
vers, adjust the PPC valve.
For details, see TESTING AND ADJUSTING,
Adjusting PPC valve.

f'C200-6Z 30-1 15 i
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT SWING PPC VALVE

DISASSEMBLY OF WORK
EQUIPMENT SWING PPC
VALVE ASSEMBLY
1. Remove nut (11, then remove disc (2) and boot
(3).

2. Remove bolts, then remove plate (5).

* Do notremove joint (4) unless it is to be
replaced.

3. Remove seal (6) and collar ( 7 ) .

4. Pull out piston (8). andremoveretainer (91,

springs (10) and (111, and shim (12).
* Spring (10) consists of a set of two types of
springs withdifferent installedloads, so
check the mounting position (oil port) and
mark with tags to prevent mistakes when
installing.

5. Pull out valve (13) from body (14).

CLPO3924

30-1 16 PC200-6Z 1
 DISASSEMBLY AND ASSEMBLY WORK EQUPMENT SWING PPC VALVE

-
ASSEMBLY OF WORK
EQUIPMENT SWING PPC
VALVE ASSEMBLY
1. Assemble valve (13) to body (14).

2. Assemble shim (12) andspring (11) to valve

(13).
* When assembling spring (111, set the end
with the small coil diameter(insidediam-
eter) at shim (12) end.

u
3. Assemble spring (101, retainer (91, and piston (8).
*The number of loops in the coil for spring
(10) is different for each of thehydraulic
ports below, so be careful when installing.

Position of port Free length of spring

P1, P2 44.4 mm

P3, P4 42.4 mm

* The position of each port is marked on the

bottom of the valve body.
Piston : Grease (G2-LI)
* When assemblingpiston (81, coat the out-
side of the pistonand the inside of the hole
in the body with grease.

4. Fit O-ring to collar(7)and assemble in body

(14). then install seal (6).

& 5. Install
plate (5).
Mounting bolt :
1323 t 1.47 Nm (1.35 t 0.15 kgm}

6. Install joint (4).

Sliding portion of joint :
Grease (G2-LII, 2 - 4 cc
Female thread of body :
Thread tightener (LT-2)
* Coat two places on the female thread with
one drop each of Loctite as shown in the
diagram.
Joint : 44.1 t 4.9 N m (4.5 t 0.5 kgm}
* Keep strictly to the tightening torque.

7. Assemble boot (3)and disc (2). and tighten with

nut (1).
Contact surface of piston and disc :
Grease (G2-LI1, 0.3 - 0.8 cc
Nut : 112.7 = 14.7 N m (11.5 2 1.5 kgm}
* After assembling the disc, adjust the height
of the disc. For details, see TESTING AND
ADJUSTING, Adjusting PPC valve.

PC200-62 30-1 17
 ASSEMBLY
DISASSEMBLYTRAVEL
AND PPC VALVE

REMOVAL OF TRAVEL PPC

VALVE ASSEMBLY
A Lower the work equipment completely to the
loosen the oil
ground andstop the engine. Then
filler cap slowly to release the pressure inside
the hydraulic tank.

1. Remove travel PPC valve undercover.

2. Removefloor mat.

3. Remove pedals (1) and levers (2).

4. Removecover (3).

5. Remove covers (41,then remove springs (5).

6. Disconnect 6 PPC hoses (71,then remove travel

PPC valve assembly (8). p g

I CEP00427

INSTALLATION OF TRAVEL
PPC VALVE ASSEMBLY
Carryoutinstallation in the reverse order t o
removal.

Cover mounting bolt :

19.6 t 1.96 Nrn {2.0 t 0.2 kgrn} I 5 CEPW428

Hose mount joint bolt :

(width across flats : 30 mm) : CJ

39.2 t 4.9 Nrn 14.0 t 0.5 kgrn}

Hose mount elbow :
(width across flats : 22 rnrn) :
34.3 t 4.9 Nrn 13.5 t 0.5 kgm} -8
QECI Hose mount joint bolt :
(width across flat : 17 m m ) :
=
24.5 4.9 Nrn I2.5 t 0.5 kgrn}

CEP00429

30-1 18 PC200-6Z
 DISASSEMBLYTRAVEL
AND ASSEMBLY PPC VALVE

DISASSEMBLY OF TRAVEL PPC

VALVE ASSEMBLY
1. Remove screws (1). then remove levers (2).

2. Remove mounting bolts (31, then remove case

and shaft assembly (4).

3. Remove mounting bolts (51,then remove plate

(6) and damper assembly (7) as one unit.
* Check the thickness and mounting position
of washer (18).
* Never disassemble damper assembly (7).

4. Remove mounting bolts (81, then remove damper

- assembly ( 7 )from plate (6).

5. Remove seal (9) and collar (10).

6. Pull out piston (111, andremoveretainer (121,

springs (13) and (141, and shims (15).
* Check the number and thickness of shims
(15) for each mounting position, and keep in
a safe place.
F
7. PUII out valve (16) from body (17).

CLPO3926

PC200-6Z 30-1 19 d
 AND ASSEMBLY
DISASSEMBLYTRAVEL PPC VALVE

ASSEMBLY OF TRAVEL PPC

VALVE ASSEMBLY
I. Assemble valve (16) in body (17).

2. Assembleshim (15) andspring (14) to valve

*
(16).
Assemblethesamenumberand thickness
of shim (15) as was removed during disas-
sembly.
Standard shim thickness : 0.3 m m
* Spring (14) is not symmetricalatthe top
and bottom, so assemble with the small coil
diameter (inside diameter) at the shim end.

3. Assemble spring (131, retainer (121, and piston

(11).
Outside circumference of piston,
body hole : Grease (G2-LI)

4. Fit O-ring t o collar (10) and assemble in body

(171, then install seal (9).

5. Install damper assembly (7) to plate (61, then

tighten mounting bolts (8).
a Mounting bolt :Thread tightener (LT-2)
Mounting bolt:
4.41 = 0.49 Nrn i0.45 f 0.05 kgm}

6. Install plate (6) and damper assembly (7) as one

unit, then tighten mounting bolts(5).
* Check the thickness of washer (18) and as-
semble in the position checked during dis-
assembly.
Mounting bolt:
=
30.87 3.43 Nm I3.15 L 0.35 kgm}

7. Install case and shaft assembly (4). then tighten

mounting bolts (3).
* Check thatthe out-of-parallel of shaft and
CLPO3926
damper assembly (7) of case and shaft as-
sembly (4) is less than 0.5.
Q Rocking portion of shaft,
connection of lever and piston :
Grease (G2-LI)
Mounting bolt:
27.93 = 3.43 Nm 12.85 z 0.35 kgm)

8. Install levers (2). then tighten screws (1).

* Adjust so that lever (2) can slightly move.
Rocking portion of lever pin and plate :
Grease (G2-LI)
Screw : 8.82 z 0.98 N m IO.9 z 0.1 kgm}

30-1 20 PC200-6Z
DISASSEMBLY AND ASSEMBLY BOOM LOCK VALVE

REMOVAL OF BOOM LOCK

VALVE ASSEMBLY
A Lower the work equipment completely to the
ground, then release the remaining pressure in
the hydraulic circuit. For details, see TESTING
AND ADJUSTING, Releasing remaining pressure
in hydraulic circuit.

1. Disconnect tube (1) and hoses (2).

2. Disconnect tube (3).

'CLPO3927
3. Remove mounting bolts of bracket (4). then re-
move boomlock valve (5) together with bracket
(4).

INSTALLATION OF BOOM
LOCK VALVE ASSEMBLY
Carryoutinstallation in the reverse order to
removal.
4
Refilling with oil (hydraulictank) I CLPO3928

It Add oil through the oil filler to

the specified
level. Run theengine t o circulatethe oil
through thesystem. Then check the oil level
again.

Bleeding
air
J, Bleed the air. For details, see TESTING AND
ADJUSTING, Bleeding air.

PC200-6Z 30-121
 DISASSEMBLY AND ASSEMBLY BOOM CYLINDER

REMOVAL OF BOOM
CYLINDER ASSEMBLY
a Extend the armand bucketfully, lower the work
equipment completely to the ground, and put
the safety lock lever in the LOCK position.

1. Disconnect grease hose (1).

2. Sling boom cylinder assembly (2). and remove

lock bolt (3).

3. Remove plate, then remove head pin (4).

Ir Thereareshimsinstalled, so check the
number and thickness, and keep in a safe
place.

4. Start engine, andretractpiston rod, then tie

piston rod with wire to prevent it from coming
out.
* Setstand 0 underthecylinder assembly,
and adjust the position for slinging.
A Release the remaining pressure in the hy-
draulic circuit. For details, seeTESTING AND
ADJUSTING, Releasing remaining pressure
in hydraulic circuit.

5. Disconnect hoses (5).

6. Remove plate, then using forcing screws 0,re-

move bottom pin (61, and remove boom cylin-
assembly der
*
(2).
Thereareshims installed, so check the
a
number and thickness, and keep in a safe
place.

&I Boom cylinder assembly : 205 kg

30-1 22 PC200-6Z
 DISASSEMBLY AND ASSEMBLY BOOM CYLINDER

INSTALLATION OF BOOM
CYLINDER ASSEMBLY
Carry out installation in the reverse orderto
removal.

* When tightening thelocknut, tighten so that

clearance a between the plate andnut is 0.5
- 1.5 mm.
+ I
a
A Inside surface of bushing when CKP03932
assembling pin :

- Greasing
Anti-friction compound (LM-P)
assembling
after pin :
Grease (LM-G)
A When aligning the position of the pin hole,
never insert your fingers in the pin hole.
* Adjust the shim thickness so that clearance
b between cylinder rod (7) and plate (8) is
below 1 mm.
* Standardshim thickness : 0.8 mm, 1.5
mm

Inside surface of bushing when

assembling pin : I CLPO3933

Anti-friction compound (LM-P)

Greasing after assembling pin :
Grease (LM-G)
A When aligning the position of the pin hole,
never insert your fingers in thepin hole.
- * Adjust the shim thickness so that clearance
c between cylinder bottom (9) and bracket
(10) is below 1 mm.
* Standard shim thickness : 0.8 mm, 1.5
rnm

Refilling with oil (hydraulictank)

* Add oil through the oil filler to the
specified
C IO
CLPO3934
level. Run theengine t o circulatetheoil
through thesystem. Then check the oil level
again.

Bleeding
air
* Bleed the air from the cylinder. For details,
see TESTING AND ADJUSTING, Bleeding air
from hydraulic cylinder.

PC200-6Z 30-1 23
DISASSEMBLY AND ASSEMBLY LINDER ARM CY

REMOVAL OF ARM CYLINDER

ASSEMBLY
A Extend the arm cylinder piston rodcompletely
approx. 200
to
mm, lower the work equipment
the ground, then set the remaining safety lock
lever to the LOCK position.

between arm cylinder and boom.

1. Set block (iJ

2. Remove plate, then remove head:pin (1).

3
3. Start engine, and retract piston rod, thentie CLPO3935
piston rod with wire to prevent it from coming
out.
A Release the remaining pressure in the hy-
draulic circuit. For details,see TESTINGAND
ADJUSTING, Releasing remaining pressure
in hydraulic circuit.

4. Disconnect hoses (2).

5. Disconnect grease hose (3).

6. Raise arm cylinder assembly, remove plate, re-

move bottom pin (41, then remove a r m cylinder
assembly (5).
Ir There areshimsinstalled, so check the
number and thickness,andkeep in a safe
place.

& Arm cylinder assembly : 265 kg

30-124 PC200-6Z
AND DISASSEMBLY ARM CYLINDER

&

INSTALLATION OF ARM
CYLINDER ASSEMBLY
Carry out installation in the reverse order to
removal.

& Inside surface of bushing when

assembling pin :
Anti-friction compound (LM-P)
& Greasing after assembling pin :
Grease (LM-G)
AWhen aligning the position of the pin hole, CLP03936
never insert your fingers in the pin hole.

- m
& Inside surface of bushing when
assembling pin :
Anti-friction compound (LM-P)
& Greasing after assembling pin :
Grease (LM-G)
AWhen aligning the position of the pin hole,
never insert your fingers in the pin hole.
*Adjust the shim thickness so that clearance
a between cylinder bottom ( 6 ) and bracket
(7)is below 1 mm.
*Standard shim thickness : 0.8 mm, 1.5
mm

Refilling with oil (hydraulictank)

* Add oil through the oil filler tothe specified
level. Run the engine to circulate theoil
through the system. Then check the oil level
again.

Bleeding air
* Bleed the air from the cylinder. For details,
see TESTINGAND ADJUSTING, Bleeding air
from hydraulic cylinder.

PC200-6Z 30-125
AND DISASSEMBLY
BUCKET ASSEMBLY CYLINDER

REMOVAL OF BUCKET
CYLINDER ASSEMBLY
A Extend the bucket cylinder piston rod approx.
200 mm, lower the work equipment completely
to the ground, then set the safety lock lever to
the LOCK position.

1. Set block @ under arm top.

2. Set block @ between link and arm, and block @

bolt
between bucket cylinder andarm.
3. lock
Remove (1).
4. Remove plate, then remove head pin (2).
a
f Thereareshims installed, so check the
number and thickness, and keep in a safe
place.
5. Start engine, andretractpiston rod, then tie
piston rod with wire to prevent it from coming .4
out.
A Release the remaining pressure in the hy-
draulic circuit. For details, see TESTINGAND
ADJUSTING, Releasing remaining pressure
in hydraulic circuit.
6. Disconnect 2 hoses (3).
7 . Raise bucket cylinder assembly, remove plate,
remove bottom pin(41, then remove bucket cyl-
inder assembly (5). pJ CLPO3938
f Thereareshimsinstalled, so check the
number and thickness, and keep i n a safe

dace- Bucket cylinder assembly : 165 kg

30-1 26 PC200-6Z
 DISASSEMBLY AND ASSEMBLY CYUNDER BUCKET

INSTALLATION OF BUCKET
CYLINDER ASSEMBLY
Carry out installation in the reverse order to
removal.

f When tightening the locknut, tighten so that

clearance a between the plate and nut is 0.5
- 1.5 mm.
+ I
m Inside surface of bushing when
a
CKP03932
assembling pin :
Anti-friction compound (LM-P)
a Grease after assembling pin :
b
Grease (LM-G)
A When aligning the position of the pin hole,
-I-

never insert your fingers in thepin hole.

* Adjust the shim thickness so that clearance
b between link (6) and link ( 7 ) is below 1
rnm.
* Standard shim thickness : 0.8 rnm, 1.5
mm

7
6 Inside surface of bushing when 1

CLP03939
assembling pin :
Anti-friction compound (LM-P)
6 Grease after assembling pin :
Grease (LM-GI
AWhen aligning the position of the pin hole,
9
never insert your fingers in the pinhole.
- *Adjust the shim thickness so that clearance
c between cylinder bottom ( 8 ) and bracket
( 9 ) is below 1 mm.
* Standardshim thickness : 0.8 mm, 1.5
mm

- Refilling with oil (hydraulictank)

* Add oil through the oilfiller to the specified CLPO3940
level. Run the engine to circulate theoil
through the system. Then check the oil level
again.

Bleeding
air
* Bleed the air from the cylinder. For details,
see TESTING AND ADJUSTING, Bleeding air
from hydraulic cylinder.

Pc200-6Z 30-127
 AND ASSEMBLY
CYLINDERHYDRAULIC
DISASSEMBLY

DISASSEMBLY OF HYDRAULIC
CYLINDER ASSEMBLY
1. Piston rod assembly
1) Remove piping from cylinder assembly.
2) Remove mounting bolts and disconnect head
assembly (1).
3) Pull out piston rod assembly (2).
* Place a container under the cylinder to
catch the oil.

-
CLPO3941

4) Disassemble piston rod assembly as follows.

i) Set piston rod assembly (2) in tool 01.

ii) Remove stopper screw (3) of piston as-

sembly. ,3
* Common screw size for boom, arm,
and bucketcylinder: M12 x Pitch 1.75

CLP03779

* Ifthe caulking of screw (3)istoo

strongand it cannot be removed,
tighten the screw fully, then fit a tap
to thethread and remove the screw.

I DKP00498 I

30-1 28 PC200-6Z
 I

c)
r
0
0
w -
4 -
CD
L

.
w
0
I
4
w
0

N
MBLY AND DISASSEMBLY

ASSEMBLY OF HYDRAULIC
CYLINDER ASSEMBLY
* Be careful notto damage the packings,dust
seals, and O-rings.
* Do not try to force the backup ring into position.
-
Warm it in warm water (50 60°C) before fitting
it.

1. Assembly of head assembly

1) Using tool 0 5 , press fit bushing (20).
2) Assemble buffer ring (19).
3) Assemble rod packing (18). CLPO3786
CLPO3787
4) Using tool 06, install dust seal(171, and se-
cure with snap ring (16).
c 5) Install backup ring and O-ring (15).

15

17

CLPO2322

2. Assembly of piston assembly

1) Using tool 03, expand piston ring (13).
f Set the piston ring on tool 0 3 , and turn
-
the handle 8 10 times to expand the
ring.
.-
2) Set tool 0 4 in position, and compress piston
ring (13).

CKPO3788 CLPO3789 I

3) Install backup ring and O-ring (14).

4) Assemble wear ring (12).
5) Assemble ring (11).
.k Be careful not to open the endgap of
the ring too wide.
Ring groove : Grease (G2-LI)

I CLPO3784

PC200-6Z 30-131
DISASSEMBLY
CYLINDERHYDRAULIC
AND ASSEMBLY

3. Piston rod assembly

1) Set piston rod assembly (2) to tool 01.

2 ) Assemble head assembly (7).

3) Fit O-ring and backup ring to collar (61, then

assemble.
Boomandarm cylinderonly

4) Assembleplunger (5).
Boomandarm cylinderonly
* Check thatthere is a small amount of
play at thetip of the plunger.
Arm cylinderonly

5) Set cushion plunger (10) to piston rod, then

assemble 12 balls (9) and secure with cap
(8).
Arm cylinderonly

CXPO3783

6) Assemble piston assembly (4) as follows.

Whenusingrod and piston again:
Ir Washthoroughly and removeall
metal particles and dirt.
i) Screw in piston assembly (41, then
use tool 0 2 to tighten piston assem-
bly (2) so thatposition of screw
thread hole matches.
* Remove all burrs and flashes with
a file.
ii) Tighten screw (3).
Screw (3) : I OLP00499
=
66.2 7.35 Nm (6.75 f: 0.75 kgml

30-132 PC200-6Z
BLY AND DISASSEMBLY

iii) Caulk thread at 2 places with punch.

I 3
When using a new part for either or both
of rod or piston assembly (2)
* For therod with bottom cushion,
mark the cushion plug position on
PunchI
the end face of the rod.
Armcylinderonly

DKP00500

i) Screw in until piston assembly (4)

contacts end face of rod, then use
tool 0 2 to tighten.
Piston assembly (4):
294 t 29.4 Nm I30 t 3.0 kgm}
* After tightening the piston, check
that there is play in plunger (5).
Boom, arm cylinderonly

DKP00501

ii) Machine one of holes used to install

screw (3).
* Align a drill horizontal with the
V-groove of the thread of rod (2)
andpiston (41, then carry out
machining.
* For the cylinder with bottom
cushion (arm cylinder), avoid the
cushion plug position when ma-
chining.
Screw machining dimension
4mm)
Drill I CLPO3792

iii) After machining, wash thoroughly to

remove all metal particles and dust.

iv) Tighten screw (3).

Screw (3) :
66.2 2 7.35 Nm 16.75 2 0.75 kgm)

v) Caulk thread a t 2 places with punch.

C I Po3779

PC200-6Z 30- 133

DISASSEMBLY
CYLINDERHYDRAULIC
AND ASSEMBLY

7) Assemble piston rod assembly (2).

Seal portion : Grease (G2-Ll)
* Set the end gap of the ring horizontal (at
side position), align axial center of cylin-
der tube, then insert.
* After inserting, check that the ring is not
broken and has not come out, then push
in fully.

DLP00502

8 ) Tighten head assembly (1) withmounting I

bolts.
Mounting bolt :

Cylinder Tightening torque

Bucket 270-+39Nm
{27.5*4.0kgm)
Arm I 373254Nm
<38.0*5.5kgm)
Boom I 27039Nm (27.5a4.Okgm)

9) Install piping.
I CLPO394 1

30-134 PC200-6Z
 DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
._-

REMOVAL OF WORK.
EQUIPMENT ASSEMBLY
A Extend the arm andbucket fully, lower the work
equipment to the ground, and set the safety
lock lever to theLOCK position.

1. Disconnect grease hose (1).

2. Sling boom cylinder assembly (21, and remove

lock bolt (3).

3. Remove plate, then remove head pin (4)

f Thereareshims installed, so checkthe

- number and thickness, and keep in a safe

place.

4. Start engine,and retract piston rod, thentie

piston rod with wire to prevent it from coming
out, and lower it onto block.
f Disconnect the boom cylinder on the oppo-
site side in the same way.
A Release the remaining pressure in the hy-
draulic circuit. For details, see TESTINGAND
ADJUSTING, Releasing remaining pressure
in hydraulic circuit.

5. Disconnect hoses (51, and secure it to valve with

rope.
* Hoses (6) are for machines equipped with
an additional attachment circuit.

6. Disconnect wiring connector ( 6 ) forworking

lamp.
A

7. Sling work equipment assembly, remove plate,

then remove foot pin ( 7 ) using tool P, and re-
movework equipment assembly (8). m
* Thereareshims installed, so checkthe
number and thickness, and keep in a safe
place. II 11 CLPO4028

&I Work equipment assembly : 3,300 kg

CLP040?9

PC200-6Z 30-1 35 f
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT

INSTALLATION OF WORK
EQUIPMENT ASSEMBLY
Carryoutinstallation in the reverse order to
removal.

f When tightening the locknut, tighten so that

clearance a between the plate and nut is 0.5
- 1.5 mm.

a
e Inside surface of bushing when CKP03932
assembling pin :
Anti-friction compound (LM-P)
Grease after assembling pin :
Grease (LM-G)
A When aligning the position of the pin hole,
never insert your fingers inthe pin hole.
f Adjust the shim thickness so that clearance
b between cylinder rod (10) and plate (11) is
below 1 mm.
f Standard shim thickness : 0.8 mm, 1.5
mm

a Inside surface of bushing when I CLPO3947

assembling pin :
Anti-friction compound (LM-P)
Grease after assembling pin :
Grease (LM-GI
A When aligning the position of the pin hole,
never insert your fingers in the pin hole.
f Adjust the shim thickness so that clearance
c between boom (12) and bracket (13) is be-
low l mm.
f Standard shim thickness :
0.8 mm, 1.0 mm, 1.5 m m
+
C
Refilling with oil (hydraulic tank)
* Add oil through the oil filler to the specified CLPO3948
level. Run the engine t o circulate theoil
through the system. Then check the oil level
again.

Bleeding air
* Bleed the air from the cylinder. For details,
see TESTING AND ADJUSTING, Bleeding air
from hydraulic cylinder.

30-1 36 PC200-6Z
 DISASSEMBLY AND ASSEMBLY BUCKET

REMOVAL OF BUCKET
ASSEMBLY
A Set the back of the bucket facing down, lower
the ground,
the work equipment completely to
and set the safety lock lever to the LOCK posi-
tion.

1. Remove lock bolt (1). m

2. Removeconnecting pin (2) betweenlink and
bucket.
* Thereare shims installed, so check the
number and thickness, and keep in a safe
place.

3. Start engine, andretractpiston rod, thentie

piston rod with wire to prevent it from coming
out.

4. Remove lock bolt (3).

5. Remove plate (41, the remove connectingpin (5)

between arm and bucket.
* Thereareshims installed, so check the
number and thickness, and keep in a safe
place.

6. After raising work equipment, swing to discon-

nect bucket assembly (6).

&I Bucket assembly :650 kg

&

PC200-6Z 30-1 37
DISASSEMBLY AND ASSEMBLY BUCKET

INSTALLATION OF BUCKET
ASSEMBLY
Carry outinstallation in the reverse order to
removal.

lfl E l
* When tightening the locknut, tighten so that
clearance a between the plate and nut is0.5
- 1.5 mm.
- + - I
a
Inside surface of bushing when CKP03932
assembling pin :
Anti-friction compound (LM-P)

I
Grease after assembling pin :
Grease (LM-G) , b
A When aligning the position of thepin hole,
never insertyour fingers in the pin hole.
* Adjust the shim thickness so that clearance
b between bucketboss ( 7 ) and link ( 8 ) is
below 1 mm.
* Standard shim thickness : 0.8 mm, 1.5
mm

E l
a Inside surface of bushing when
assembling pin :
I 7
CLPO3952

Anti-friction compound (LM-P)

Grease after assembling pin :
Grease (LM-G) I , c

A When aligning the position of the pin hole,

never insert your fingers in the pin hole.
* Set the O-ring at the end face of the bucket
boss securely.
* Adjust the shim thickness so that clearance
c between armtop (9) and spacer (IO) is 0.5
- 1.0 mm.
* Standardshim thickness : 0.5 mm, 1.0
mm
CLP03953

30-138 PC200-62
 DISASSEMBLY ASSEMBLY ARM

REMOVAL OF ARM ASSEMBLY

I I
1. Remove bucket assembly. For details, see RE-
MOVAL OF BUCKET ASSEMBLY.

2. Secure front link to arm with wire. 2

3. Pull in arm so that it is easy to remove pin at
arm cylinder head, then lower arm and bucket
assembly (1) on to block 0.
Set the safety lock lever to the LOCK posi-
tion.

4. Set block @ between arm cylinder and boom. cLP05 I8 I

- 5. Remove plate, then remove arm cylinder head

pin (2).

6. Start engine, andretractpiston rod, thentie

piston rod with wire to prevent it from coming
out.
A Release the remaining pressure in the hy-
draulic circuit. For details, see TESTINGAND
ADJUSTING, Releasing remaining pressure
in hydraulic circuit.

7. Disconnect 2 hoses (3).

* Install blind plugs atthe male end and in the
disconnected hoses.

8. Remove plate, thenremove connecting pin (4)

between arm and boom.
Ir Thereareshims installed, so check the
number and thickness, and keep in a safe
-. place.

9. After raising boom, swing to remove armand

bucket cylinder assembly (1).

6 Arm, bucket cylinder assembly : 950 kg

K200-6Z 30-139
ARM DISASSEMBLY AND ASSEMBLY

INSTALLATION OF ARM
ASSEMBLY
Carry out installation in the reverse order to
removal.

a Inside surface of bushing when

assembling pin :
Anti-friction compound (LM-P)
Grease after assembling pin :
Grease (LM-GI
A When aligning the position of the pin hole,
(I CLPO3955
never insert your fingers in the pin hole.

Inside surface of bushing when

assembling pin :
Anti-friction compound (LM-P)
6 Grease after assembling pin :
Grease (LM-G)
AWhen aligning the position of the pin hole,
never insert your fingers in the pin hole.
*Adjust the shim thickness so that clearance
a between boom top ( 6 ) and arm bottom (7)
is below 1.0 mm.
f Standard shim thickness : 0.8 mm

Refilling with oil (hydraulic tank)

* Add oil through the oil filler to the specified
level. Run the engine to circulate the oil
through the system. Then check theoil level
again.

Bleeding air
* Bleed the air from the cylinder. Fordetails,
see TESTING AND ADJUSTING, Bleeding air
from hydraulic cylinder.

30-140 PC200-6Z i
 DISASSEMBLY AND ASSEMBLY
BUCKET ARM

-
REMOVAL OF BUCKET ARM
ASSEMBLY
A Extend the arm cylinder piston rodapprox. 200
mm, lower the work equipment completely to
the ground, thenset the safety lock lever to the
LOCK position.

1. Set block @ between arm cylinder and boom.

2. Remove plate, then remove arm cylinder head

pin (1). pig
CLPO3956
3. Startengine,and retractpiston rod, thentie

- piston rod with wire to prevent it from coming

out.
A Release the remaining pressure in the hy-
draulic circuit. For details, see TESTINGAND
ADJUSTING, Releasing remaining pressure
in hydraulic circuit.

4. Disconnect hoses (2)and (3).

* Install blind plugs at themale end and in the
disconnected hoses.

5. Raise bucket and arm assembly, remove plate,

then remove connecting pin (4) betweenarm
and boom, and remove bucket and arm assern-
bly (5).
* There are shims installed, so check the
number and thickness, and keep in a safe
place.

.A
& Bucket, arm assembly : 1,650 kg

PCXX)dZ 30-141
 ,
DISASSEMBLY
BUCKET
AND ASSEMBLY ARM

INSTALLATION OF BUCKET
ARM ASSEMBLY
Carry out installation in the reverse order to
removal.

p g
Inside surface of bushing when
assembling pin :
Anti-friction compound (LM-P)
6 Grease after assembling pin :
A
'Grease (LM-GI
When aligning the position of the pin hole,
never insert your fingers i n the pin hole.
I CLPO3955

Inside surface of bushing when

assembling pin :
Anti-friction compound (LM-P)
Grease after assembling pin :
Grease (LM-G)
A When aligning the position of the pin hole,
never insert your fingers in the pin hole.
* Adjust the shim thickness so that clearance
a between boom top(6) and arm bottom ( 7 )
is below 1 mm.
* Standard shim thickness : 0.8 mm

Refilling with oil (hydraulictank)

* Add oil through the oil filler to the specified
level.Run the engine to circulatethe oil
through the system. Then checkthe oil level
again.

Bleeding
air
* Bleed the air from the cylinder. For details,
see TESTING ANDADJUSTING, Bleeding air
from hydraulic cylinder.

30-1 42 PC200-6Z
 ,
DISASSEMBLY AND ASSEMBLY CAB OPERATOR'S

REMOVAL OF OPERATORS
CAB ASSEMBLY
A Disconnect the cable from the negative ( 4 ter-
minal of thebattery.

1. Remove floor mat.

2. Disconnect speaker wiring (11, room lamp wir-

ing (2), antenna wiring (31,and washer hose (4).
f Fit tags to mark the male and female ends
of the connectors t o prevent mistakes when
connecting.

3. Disconnect wiper motor wiring connector (5).

-
4. Remove 9 cab mounting bolts.
f Check thepositionof the chassis ground
connection.

5. Lift off operator's cab asseembly (6).

& Operator's cab assembly : 250 kg

CLPO4022

INSTALLATION OF
OPERATOR'S CAB ASSEMBLY
Carry outinstallation in the reverse order t o
removal.

CLP04023

L CLPO4, 0 2 4
I I

PC200-6Z 30-145
DISASSEMBLY AND ASSEMBLY COUNTERWEIGHT

REMOVAL OF
COUNTERWEIGHT ASSEMBLY
I. Set eyebolts @ to counterweight assembly (11,
and sling.

2. Remove mounting bolts (2) and (3).

f Be careful not to lose the shimswhenre-
moving.

3. Lift off counterweight (1) horizontally with wire

or chain block.
f Be careful not to hit the engine, radiator and
d o l e r assembly.
Countenveight assembly : 3,430 kg

INSTALLATION OF
COUNTERWEIGHT ASSEMBLY
Carry out installation in the reverse order to
removal.
p g
Thread of counterweight mounting bolt:
Thread tightener (LT-2)
Counterweight mounting bolt :
1,323 t 147 Nm t135 z 15 kgm)

* Installing andadjustingcounterweight
1) Sling counterweight with craneandset
in position on frame.
2) Push counterweight and install shim and
mounting bolts (2) and (3). and adjustto
following dimensions.
Clearance from revolving frame :

-
10 A 5 mm (left and right)
Clearance from bodywork door : U n i t :nn
10 A 5 mm (left and right) /Door
Steppeddifference b from revolving Counterneioht
frame in left-to right direction :
Max. 5 mm
Steppeddifference a from bodywork a = 1 Oi4
door in left-to right direction :
10 k 4 m m
Steppeddifference c from bodywork
top cover in up-down direction : -b=0i5
Max. 5 mm \
Revolvino frame DKP00503

30-146 PC200-6Z
 DISASSEMBLY AND ASSEMBLY MONITOR

REMOVAL OF MONITOR
ASSEMBLY
A Disconnect the cable from the negative (-) ter-
minal of the battery.

1. Removeboot (2) from cover ( l ) , raise t o top,

then remove lever (3).
* Check the direction of the lever.

2. Disconnecthornwiring.

3. Remove cover (11, and disconnect 3 connectors

(4).
wCLPO4025

- 4. Removemonitor assembly (5) from cover (1).

-I

INSTALLATION OF MONITOR
ASSEMBLY
Carry outinstallationinthe
removal.
reverse order to
I
I /I CLPO4026

Mounting nut of monitor assembly :

8.33 2 0.49 Nm I0.85 2 0.05 kgm}

PC200-6Z 30-147
.

40 MAINTENANCESTANDARD

Swing machinery .........................................

40-2
Swing circle .................................................
40-4
....................................................
Final drive
.
Track frame Recoil spring
Idler
40-6
........................
40-8
................................................................
40-10
Carrier roller ................................................
40-12
Track roller ...................................................
40-13
Track shoe ....................................................
40-14
Hydraulic pump ..........................................
40-19
Control valve ...............................................
40-20
Self-reducing pressure valve ...................... 40-27
Swing motor ................................................
40-28
................................................
Travel motor
.
Work equipment Swing PPC valve ..........40-30
Travel PPC valve ..........................................
40-29

40-31
Service PPC valve ........................................ 40-32
Center swivel joint .....................................
40-33
Boom holding valve .....................................
40-35
Hydraulic cylinder ......................................
40-36
Work equipment .........................................
40-38
.
Dimension of work equipment .................
40-40

PC200-6Z 40-1
 P
e
0

6.
N
MAINTENANCE STANDARD SWING MACHINERY

Unit: mm

Check item Criteria Remedy

I
Standard clearance Clearance limit
Backlash between swing motor
shaft and No. 1 sun gear
0.18 - 0.29 -
Backlash between No. 1 sun gear
and No. 1 planetary gear 0.15 - 0.47 1.00

Backlash between No. 1 planetary

gear and ring gear 0.17 - 0.55 1.10

Backlash between No. 1 planetary

carrier and No. 2 sun gear 0.36 - 0.63 1.20
Replace
Backlash between No. 2 sun gear
and No. 2 planetary gear 0.14 - 0.44 0.90
Backlash between No. 2 planetary
gear and ring gear 0.16 - 0.51 1 .oo

Backlash between No. 2 planetary

carrierswing
pinion
and I 0.09 - 0.20
Backlash between swing pinion and
-
circle swina I
I
0.22 - 1.32 I
2.00
Clearance between plate and
planetary carrier 0.68 - 1.12 -
4pply hard
Standard size Repair limit :hrome
Wear of swing pinion surface
contacting with oil seal dating
0 .econdition.
lZ5-0.100 124.7
3r reolace

PC200-6Z 40-3
MAINTENANCE STANDARD SWING CIRCLE

SWING CIRCLE

------1.
1’/-.,
!

/ L

lst:191.3kl9.6Nm 1 s t :294.2k29.4Nm
(19.5k2koml (30t3koml
2nd :40+5’ 2nd:60+6‘

A-A
SAP02736

Unit: m m

No. Check i t e m Criteria Remedy

’ Axial clearance of bearing

(when mounted on chassis)
Standard clearance Clearance limit
Replace
0.5 - 1.6 3.2

40-4 PC200-6Z
P
0
b
D
r
U
3
7
m

i:
j
i
j
I

3
3 i
L -i
.
i
0
8
N
 MAlNTrNANCE STANDARD DRIVE FINAL

Unit: mm

No. Check item Criteria Remedy

- Standard clearance Clearance limit

Backlash between No. 1 sun gear and
No. 1 planetary gear
0.15 - 0.49 1-00

Backlash between No. 1 planetary

gear and ring gear 0.17 - 0.57 1.10

Backlash between No. 1 planetary

carrier and motor 0.06 - 0.25 -
Replace
Backlash between No. 2 sun gear and
No. 2 planetary gear
0.14 - 0.46 1-00

Backlash between No. 2 planetary

gear and ring gear 0.17 - 0.57 1.10

Backlash between No. 2 planetary

carrier and No. 1 sun gear 0.38 - 0.66 1.oo

7 End play of sprocket shaft 0 - 0.10 -

8 Amount of wear on sprocket tooth Repair limit: 6

Rebuild or
Standard size Repair limit replace
9 Width of sprocket tooth
71 68

PC200-6Z 40-7
MAINTENANCE STANDARD TRACK FRAME
SPRING
RECOIL

TRACK FRAME RECOIL SPRING

*

SAPO2737

Unit: mm

No. Check item Remedy

- Criteria

Tolerance

1 Vertical width of idler guide Track frame

I '07 I I
Rebuild or
Idler support 105 replace
~~

Track frame 250

2 Horizontal width of idler guide

-
Standard size Repair limit

Free length Installation Installation Free installation

3 Recoil spring x O.D. length load length load Replace
126.5 kN 100.9 kN
'03.5 x 239 466 576
{12,900 kg} {10,300 kg)

40-8 PC200-6Z
P
0
-1

1
MAINTENANCE STANDARD IDLER

Unit: m m
D
Check item Criteria Remedy

Standard size Repair limit

1 Outside diameter of protruding
560 -
2 Outside diameter of tread 520 508
Rebuild or
replace
3 Width of protrusion 85 -
-

,
Total width 164

1 1 1
5 Width of tread 39.5 45.5
- I I I
Tolerance
tnd
Sa r;: Standard Ck;raxe
clearance
Clearance between shaft and Replace
6 bushing

65 I -0.250
-0.350
-1 +0.074
-0.036 I 1 1.5
bushing

Clearance between shaft and -0.250 -0.110 0.03 - -

65 0.180 Replace
support -0.290 -0.220

Tolerance
Standard Standard Interference
Interference between idler and size interference limit
8 bushing

+0.089 -0.006 0.065 - - Replace

12 +0.059 -0.072 0.161 bushing

Standard clearance Clearance limit

Side clearance of idler (each)
0.39 - 1.00 1.5

PC200-6Z 40-11 b
P m
0
-1

B8
6.
N
1
I .
 ,
MAINTENANCE STANDARD TRACK ROLLER

TRACK ROLLER
.6Nm

SBP02740
F
Unit: rnrn

No. I Check item Criteria Remedy

' Outside diameter of flange

(outside)
Standard size Repair limit

188 -
- 2 Outside diameter of tread
~ -~

156 144
Rebuild or
replace
i-

3 Width of tread 44.5 52

4 Width of I ,J?~z 25.5 -

I
.x-

I
Tolerance
Standard Standard Clearance
5 Clearance F J I J - ~ I ?shaft
~ and size clearance limit
bushing

60
-0.21 5 +0.195 0.215 - 1.5
43-315 0 0.510
Replace
bushing
Tolerance
Standard Standard Interference
Interference between roller and interference limit
bushing

1 -
~ ~~

+0.030 0.023
0.153

- Standard clearance Clearance limit

Side clearance of : d e r Seplace
0.5 - 1.0 1.5

PC200-6Z 40-1 3 i
P -I
? =R
-1 '0
P 0
2.
0
3
u)

.
 ,
MAINTENANCE STANDARD TRACK SHOE

- Unit: m m

Remedy
Check item Criteria
-
No.
~~ ~~ ~~ ~~

Standard size Repair limit

1 Link pitch
194.25 190.25

- - - Standard size
When turned I Reverse or
replace

2 Bushing outside diameter Impact

load
Normal
load

59.3

Standard size Repair limit

Repair or
3 Link height replace

Thickness of link metal

4 28.5
(bushing press-fitting portion)
-
5 160.4
Replace
6 Shoe bolt pitch 62
_.

7 18
-
8 Inside width 84.8

Overall 9
-
Link width 45.5 I Repair or
replace

10 40.3
I
11 Protrusion of pin 4
-
12 Protrusion of regular bushing
~~ ~
4.85 I
13 Overall length of pin 220
1 Adjust or
replace
14 Overall length of bushing 128.7

15 Thickness of bGhing metal 10.4

-
16 Thickness of spacer -
17 Bushing 88.2 - 245 kN (9 - 25 ton)
-
- 18 Press-fitting force 127.4 - 274.4 kN {13 - 28 ton) -
.x.
I
~

19 Master pim 78.4 - 147 kN (8 - 15 ton)

% : Dry type track link

PC200-6Z 40-1 5 e
MAINTENANCE STANDARD TRACK SHOE

IO 2 7 17 25 19 15

3 20,
SBP03974

* P portion shows the link of bushing press fitting end.

i

40- 1 6 PC200-6Z i
NDARD MAINTENANCE TRACK SHOE

~--
Unit mm

Check item Criteria Remedy

Tightening torque Additinal tightening

(Nm IkgmH angle (deg.)
a. Regular link
490*49 (50t5) 120*10
Shoe bolt Retighten
20 Tightening torque Additinal tightening Lower limit torque
(Nm IkgmH angle (deg.) (Nm fkgm))
b. Master link
- - -
No. of shoes (each side) 45

Tolerance
Standard Standard
Interference between size I interference
21
bushing and link
+0.304
- . 59
+0.264
+0.074
0 0.190 - 0.314
Interference between
-
22
reaular Din and link 38 +0.222
+0.072
-0.138
-0.200 0.210 - 0.422
Tolerance
Standard Standard
Clearance between size clearance
23
regular pin and bushing
I I I
+0.222 +0.902 Adjust or
38 +0.072 +0.402 0.180 - 0.830 replace

Tolerance
Standard Standard
% size interference
24 Interference between
master pin and link

37.8 I +0*230
+0.200 I +;'O6' I 0.138 - 0.230
Tolerance
Standard Standard
x-
- 25 Ilearance between
naster pin and bushing
size clearance

I I I
-0.200 +0.902
38
-0.400 +0.402 0.602 - 1.302
-x- : Dry type track link
f'C200-6Z 40- 17
MAINTENANCE STANDARD TRACK SHOE

TRIPLE GROUSER SHOE

-.. -

SDDOl629

Unit: mrn

No. Check item Criteria Remedy

Standard size Repair limit

1 Height
26 16

2 Thickness 10

3 1 I 27
__I Length of base I Rebuild or
replace
4 22

5 21
-
6 Length at tip 14
-
7 19

40- 1 8 PC200-6Z i
6
N

-0 u, U
U
in
>
0
0
W
N
VI
t
0
N
.
P
0
LJ
0

.
MAINTENANCE STANDARD VALVE CONTROL

B-0

SAPO3976

- Unit: mm

No.
- Check item

.-~
Criteria Remedy

Standard size Repair, limit

1 SPOOI
return spring Installed
x O.D. length length
Replace
120.6 N - 96.1 N spring if any
54.5 X 34.8 53.5
(12.3 kg) (9.8 kg) damages or
~ ~~

deformations
- 111.8 N are found.
Spool return spring 54.6 X 34.8 53.5 139.3 N
~~
(14.2 kg) (11.4 kg)
I
85.3 N 68.6 N
3 Spool return spring 54.2 x 34.0 53.5
(8.7 kg}
- {7 kg}

PC200-6Z 40-21
MAINTENANCE STANDARD VALVE CONTROL

392.3f I9.6Nm
( 4 0 t 2b.1
I

-6

\
;47.1 f9.8Nm 392.3t 19.6Nm 392.3f 19.6Nm 392.3 f 19.6Nm
(15flk.l (40*2kpnl (40f 2k.l (40f2ked
0-D E-E F-F

SAPO3253

40-22 PC200-6Z
MAINTENANCE STANDARD VALVE CONTROL

- Unit: m m

No Check item Criteria Remedy

-
Standard size Repair limit

Free length Installed Installed Free Installed

1 Piston return spring x O.D. length load length load
I I 1

- Replace
.
17.6 N 13.7 N
2 Piston return spring (1.8 kg) {1.4 kg) spring if
any
428.3 N damages
3 Load spring (33 (43.7 kg) kg) ~ or defor-
mations
1.5N are found.
Check valve spring 13.6 x 5.5 (0.2 kg) {0.15 kg)

Piston return spring 50.4 x 17 39

158.8 N
(16.2 kg)
- 127.4N
(13 kg}
17.6 N - 13.7 N
-
6 Piston return spring 40.8 x 22.4 21
(1.8 kg) U.4 kg)

PC200-6Z 40-23
 x
I
x

U \ \

rg Fg
2
' ' Z

C
2.
r?
3
3
 c
L
I
c
L

I
I
I
I
I

PW
*"
Oh.
 ,
MAINTENANCE STANDARD VALVE CONTFiOL

SAFETY-SUCTION VALVE
- r (FOR SERVICE VALVE)

SAP02748

Unit mm
~~

No. Check item Criteria Remedy

Standard size Repair limit

Free length Installed Installed Free

Installed
1 Suction valve spring x 0 .D. load load
length length
Replace
16.3 x 21.3 9.5
2.1 N
(0.21 kg}
- 1.6 N
(0.16 kg1

2 Piston spring 20 x 7 14
2.1 N - 1.6 N i
(0.21 kg) (0.16 kg}
i
40-26 PC200-6Z
 MAINTENANCE STANDARD VALVEPRESSURE
SELF-REDUCING

SELF-REDUCING PRESSURE VALVE

0-0 \ I
A- A

SAP03294

Unit: mm

-
Spring (safety valve) 16.1 x 7.8 13.4
61.7 N
(6.3 kg) - I 58.0 N
16 kg) I
PC200-6Z 40-27
A X

cc
o w

a
MAINTENANCE STANDARD TRAVEL MOTOR

TRAVEL MOTOR
HMVl lO-2
- -

8-0 c-c

SAP01750

No. Check item Criteria Remedy

Standard size Repair limit

Free length Installed Installed Free Installed Replace

1 Check valve spring x O.D. load load spring if
length length

31.6 x 6.5 24.2

2.55 N
(0.26 kg}
- 2-06N
Io.’ kg}
Zages
or defor-

2 Check valve spring 13.0 x 6.5 9.5

1.96 N
[0.2 kg)
- 1.57 N
{0.16 kg)
mations
are found.

411 N - 329 N
3 Return spring 58.43 x 30 42.6 i41.9 kg) (33.5 kg)

PC200-6Z 40-29
P A
0
w N
&
0

W D
I I
[D D

W
W
0
sfz
W
m
I
rn

K C
2.
r?
3
3!&
N 3
I

fl

t
MAINTENANCE STANDARD SERVICE PPC VALVE

SERVICE PPC VALVE

- -

Unit: m m

No. Check item Criteria Remedy

Standard size Repair limit

Replace
Free length Installed Installed Free Installed spring
if
1 Centering spring x 0 .D. load load
length length any
46.1 N 44.1 N damages
64.8 x 16.6 40.5 (62.9) or defor-
(4.7 kg) (4.5 kg)
mations
25.5 N 24.5 N are found.
2 Metering spring 26.0 x 10.5 25.0 (25'2)
{2.6 kg) (2.5 kg}

40-32 PC200-6Z
c
P
?
G3
b

cn
m
Y
0

-4
-
.n
W

3
0
8
N
 ,
MAINTENANCE STANDARD BOOM HOLDING VALVE

-.

BOOM HOLDING VALVE

* For machine equipped with arm holding valve, the Maintenance Standard of arm holding valve is
the same as this valve.

B-0

tA
1 4/7 t lONm A-A
( 1 5 * Ibrl

SDPO I354

Unit: m m

No. Check item Criteria Remedy

Standard size Repair limit

Replace
Free length Installed Installed Free Installed spring if
1 Pilot valve spring x O.D. load load any
length length
damages
4.7 N - 3.7 or defor-
26.5 x 11.2 25'0 ( 0 . 3 kg)
(0.48 kg) mations
are found.
2 Check valve spring 37.2 x 16.2 30.0
35.3 N - 28.4
13.6 kg) (2.9 kg)

PC200-6Z 40-35
STANDARD MAINTENANCE CYLINDER

- Unit: mm

No Check item Criteria Remedy

Cylinder

Clearance between
1 piston rod and
Boom 90
-0.036 4.257 0.084 - Replace
bushing -0.090 4.048 0.347

I 1
I I

Arm 95
-0.036
4.090
+0.222
4.047 -
0.3 12
0.412

-0.030 +0.258 0.078 -

'1 .-
80
- Bucket -0.076 +0.048 0.334 0.434

80 -0.030 +0.457 0.400 - 1.0

4.060 4.370 0.517
- I
I
Clearance between -0.030 4.457 0-400
2 piston rod support -0.076 4.370 0.533 1.0
pin and bushing
-
-
-0.030 +0.424 0.380
1.o

I1
Replace

1
Bucket -0.076 +0.350 0.500
pin or
-0.030 4.451 0.380 - bushing
-0.060 +0.370 0.484

I
Clearancebetwe,en
cylinder bottom
3 support pin and
-0.030
-0.076
+0.457
+0.370
0.400
0.523
- I
1.0
bushing
-0.030 +0.424 0.380 -
Bucket 1.o
-0.076 +0.350 0.500
z

PC200-6Z 40-37
P
0
/-
I)

m 0 D
I
I I
rn 0 D

w Gn

x R n
I I I
x R n

r
I
n
D
-a
0
is N
x 4
l
o
B w
0.
N
 MAINTENANCE STANDARD WORK EQUIPMENT

SEP02762

Unit: rnm

No. Check item Criteria Remedy

Clearance between connecting pin

frame
revolving
ofbushing
1 and Shaft Hole
and boom I I I I
-0.036 +0.342 0.305 -
90 A-.-. .
1.0n7'1 0.412 +0.269

Clearance between connecting pin

90
-0.036 +0.153 0.133 - 1.0
and bushing of boom and arm -0.071 +0.097 0.224
.
Clearance between connecting pin
70
-0.030 +0.335 0.305 - 1.0
Replace
and bushing of arm and link -0.076 +0.275 0.41 1
Clearance between connecting pin -0.030 +0.337 0.303 -
and bushing of arm and bucket 80 +0.273 -0.076 0.413 1.0

Clearance between connecting pin

80
-0.030 +0.337 0.303 - 1.0
and bushing of link and bucket +0.273 -0.076 0.413
Clearance between connecting pin -0.030 +0.335 0.303 -
and bushing of link and link 70 1.o
+0.275 -0.076 0.41 1

PC200-6Z 40-39
MAINTENANCE STANDARD DIMENSION OF WORK EQUIPMENT

DIMENSION OF WORK EQUIPMENT

1. ARM PORTION

I 7

16 18

1 1

3
2

W
Y-Y x-x SAPO2764

40-40 PC200-6Z
 MAINTENANCE STANDARD
DIMENSION OF WORK EQUIPMENT '

U n i t mm

PC200-6

1 I

4 090-0.036
-0.071

5 361.7t1

6 187.2a0.5
~~ ~~

7 829.1t1

8 2,919

9 2,631.3a1

10 410al
-.
11 640t0.2

12 600*0.5

13 458.1

14 1,486
~ ~ ~ ~ _ _ _ _ _ _ ~

15 080

16 326.5*1

17 080

18
I Arm as
individual pan I 0
311-0.5
When press-
fitting bushing 325

- 19
Min. 1,680

Max. 2,800

PC200-6Z 40-41
 MAINTENANCE STANDARD DIMENSION OF WORK EQUIPMENT

Unit: mm

PC200-6Z

1 469.39 - 470.41
2 I 326.14 - 327.66
3 I 022.35 Thru 038.10 Spotface
lineboring)
(after

-
~~ ~ ~~ ~ ~~

5 442.90 444.50
6 190.50 diameter
7 0110.01 - 110.21 Linebore Fit. front only
- 8 - M20 X 2.5mm thru, 4 holes equally spaced on 150.11 diameter between centers
9 -
326.14 327.66
10 022.35 Thru 0 38.10 Sprotface (after lineboring)
11 59.18
-
469.36 470.41 12
13 96.27
14 -
457.20 458.72
15 080.01 - 80.21 TYP.
16 I 1449.58
17 1 1370.08

PC200-6Z 40-43
.

90 OTHERS

Hydraulic piping drawing ........................................................................... go- 3

Hydraulic circuit diagram ........................................................................... go- 5
. Actual electrical wiring diagram (1/2) ....................................................... go- 7
Actual electrical wiring diagram (2/2) .......................................................
90-9
Electrical circuit diagram (1/2) ................................................................... 90-11
Electrical circuit diagram (2M)................................................................... 90-13
Operation of CLSS system as a whole
1 . When all work equipment is at neutral ......................................... 90-15
2. One side actuated. other side neutral ............................................90-17
.
3 A r m OUT. standard mode relief (cut-off controll) ........................ 90-19
4 . Bucket DUMP, power max. relief .................................................... 90-21
.
5 Boom RAISE...................................................................................... 90-23
6. Swing operated independently....................................................... 90-25
.
7 Tavel operated independently ........................................................ 90-27
8. Compound operation....................................................................... 90-29

PC200-6Z 90- 1
DataKom Publishing Corporation
440 North Fairway Drive
Vernon Hills, IL 60061-8112 U S A .
Attn: Service Publications PROPOSAL FOR MANUAL OR CSS REVISION
Fax No. (847) 970-4186

DATE: FOR INTERNAL USE ONLY -- NO. PMR

P CITY: NAME OF COMPANY:

R
0 STATE OR PROVINCE::
P
DEPARTMENT: COUNTRY:
S
E
NAME: FAX NO:
R

~ U A DESCRIPTION:
L ICSS PROGRAM - e.g: Lookup, Parts or Service

MANUAL OR CSS CD NO: CSS PROGRAM RELEASE VERSION:

MANUAL OR CSS CD ISSUE DATE: CSS BOOK PUBLISHER:

BOOK DESCRIPTION
MACHINE MODEL& S/N:
MANUAL SECTION/PAGE NUMBERS OR CSS REFERENCE
& PAGE NUMBERS:

PROBLEM:

Attach photo or sketch.

If more spaceis needed, use another sheet.

FOR INTERNALUSE ONLY

CORRECTIVE ACTION: