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SEBM024300
PC20 0, 20 0LC-7PC220, 220LC-7
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CONTENTS
No. of page
01 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD. 10-1
20 TESTING AND ADJUSTING . . . . . . . . . . . . Will Be Issued 10-25-2001
30 DISASSEMBLY AND ASSEMBLY . . . . . . . . Will Be Issued 12-15-2001
90 OTHERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1
00
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SAFETY SAFETY NOTICE
SAFETYSAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The service and
repair techniques recommended by Komatsu and described in this manual are both effective
and safe. Some of these techniques require the use of tools specially designed by Komatsu for
the specific purpose.
To prevent injury to workers, the symbol ¤ is used to mark safety precautions in this manual.
The cautions accompanying these symbols should always be followed carefully. If any danger-
ous situation arises or may possibly arise, first consider safety, and take the necessary actions
to deal with the situation.
GENERAL PRECAUTIONS
Mistakes in operation are extremely dangerous.
Read the Operation and Maintenance Manual care-
fully BEFORE operating the machine.
1. Before carrying out any greasing or repairs, read
all the precautions given on the decals which are
fi d h hi
6. Decide a place in the repair workshop to keep
tools and removed parts. Always keep the tools
and parts in their correct places. Always keep
the work area clean and make sure that there is
no dirt or oil on the floor. Smoke only in the areas
provided for smoking. Never smoke while work-
ing.
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SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK
11.When removing the oil filler cap, drain plug or
hydraulic pressure measuring plugs, loosen
them slowly to prevent the oil from spurting out.
Before disconnecting or removing components
of the oil, water or air circuits, first remove the
pressure completely from the circuit.
12.The water and oil in the circuits are hot when the
engine is stopped, so be careful not to get
burned.
Wait for the oil and water to cool before carry-
ing out any work on the oil or water circuits.
13.Before starting work, remove the leads from the
battery. Always remove the lead from the nega-
tive (–) terminal first.
14.When raising heavy components, use a hoist or
crane.
Check that the wire rope, chains and hooks are
free from damage.
Always use lifting equipment which has ample
capacity.
Install the lifting equipment at the correct places.
Use a hoist or crane and operate slowly to pre
19.Be sure to assemble all parts again in their origi-
nal places.
Replace any damaged parts with new parts.
• When installing hoses and wires, be sure
that they will not be damaged by contact
with other parts when the machine is being
operated.
20.When installing high pressure hoses, make sure
that they are not twisted. Damaged tubes are
dangerous, so be extremely careful when install-
ing tubes for high pressure circuits. Also, check
that connecting parts are correctly installed.
21.When assembling or installing parts, always use
the specified tightening torques. When installing
protective parts such as guards, or parts which
vibrate violently or rotate at high speed, be par-
ticularly careful to check that they are installedcorrectly.
22.When aligning two holes, never insert your fin-
gers or hand. Be careful not to get your fingers
caught in a hole.
23.When measuring hydraulic pressure, check that
the measuring tool is correctly assembled before
taking any measurements
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FOREWORD GENERAL
FOREWORDGENERALThis shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judge-
ments. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are fur-ther divided into the each main group of components.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an under-
standing of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and mainte-
nance standards.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to
be made at completion of the checks and repairs.
Troubleshooting charts correlating "Problems" with "Causes" are also included in this section.
DISASSEMBLY AND ASSEMBLY
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FOREWORD HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL
VOLUMESShop manuals are issued as a guide to carrying out
repairs. They are divided as follows:
Chassis volume: Issued for every machine model
Engine volume: Issued for each engine series
Electrical volume:
Attachments volume:
These various volumes are designed to avoid dupli-
cating the same information. Therefore, to deal with
all repairs for any model , it is necessary that chas-
sis, engine, electrical and attachment volumes be
available.
DISTRIBUTION AND UPDATING
Any additions, amendments or other changes will be
sent to KOMATSU distributors. Get the most up-to-
date information before you start any work.
FILING METHOD
1. See the page number on the bottom of the page.
File the pages in correct order.
2 Following examples show how to read the page
REVISED EDITION MARK
When a manual is revised, an edi t ion mark( 1 2 3 ....) is recorded on the bottom of the pages.
REVISIONS
Revised pages are shown in the LIST OF REVISED
PAGES next to the CONTENTS page.
SYMBOLS
So that the shop manual can be of ample practical
use, important safety and quality portions are
marked with the following symbols.
Symbol Item Remarks
¤
Safety
Special safety precautions
are necessary when per-
forming the work.
s
Caution
Special technical precau-
tions or other precautions
for preserving standards
h
}·
Each issued as one
volume to cover all
models
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FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
¤ Heavy parts (25 kg or more) must be lifted
with a hoist, etc. In the DISASSEMBLY
AND ASSEMBLY section, every part
weighing 25 kg or more is indicated clearly
with the symbol 4
• If a part cannot be smoothly removed from the
machine by hoisting, the following checks
should be made:
1) Check for removal of all bolts fastening the
part to the relative parts.
2) Check for existence of another part causing
interference with the part to be removed.
WIRE ROPES
1) Use adequate ropes depending on the
weight of parts to be hoisted, referring to
the table below:
Wire ropes
(Standard "Z" or "S" twist ropes
without galvanizing)
Slinging near the edge of the hook may cause
the rope to slip off the hook during hoisting, and
a serious accident can result. Hooks have max-
imum strength at the middle portion.
3) Do not sling a heavy load with one rope alone,
but sling with two or more ropes symmetrically
wound onto the load.¤ Slinging with one rope may cause turning
of the load during hoisting, untwisting of
the rope, or slipping of the rope from its
original winding position on the load, which
can result in a dangerous accident.
4) Do not sling a heavy load with ropes forming a
wide hanging angle from the hook
SAD00479
41%71%79%88%100%
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FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
¤ Before carrying out the following work, releasethe residual pressure from the hydraulic tank.
For details, see TESTING AND ADJUSTING,
Releasing residual pressure from hydraulic
tank.
¤ Even if the residual pressure is released from
the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly,
prepare an oil receiving container.
Disconnection
1) Release the residual pressure from the hydrau-
l ic tank. For detai ls, see TESTING AND
ADJUSTING, Releasing residual pressure from
hydraulic tank.
2) Hold adapter (1) and push hose joint (2) intomating adapter (3). (See Fig. 1)
The adapter can be pushed in about 3.5
mm.
Do not hold rubber cap portion (4).
3) After hose joint (2) is pushed into adapter (3),
press rubber cap portion (4) against (3) until it
clicks. (See Fig. 2)
Type 1
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FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 2 Type 3
D i s a s s e m b l y
1) Hold the mouthpiece of the tightening portionand push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of
the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn
lever (4) to the right (clockwise).
1) Hold the mouthpiece of the tightening portionand push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of
the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and push
until cover (3) contacts contact surface a of
the hexagonal portion at the male end.
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FOREWORD COATING MATERIALS
COATING MATERIALS
The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and assembly are listed below.
For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code Part No. Q'ty Container Main applications, featuresr
Adhesives
LT-1A 790-129-9030 150 g Tube• Used to prevent rubber gaskets,
rubber cushions, and cock plugfrom coming out.
LT-1B 790-129-9050 20 g
(2 pcs.)Polyethylene
container
• Used in places requiring an imme-diately effective, strong adhesive.Used for plastics (except polyeth-ylene, polyprophylene, tetrafluor-oethlene and vinyl chloride),rubber, metal and non-metal.
LT-2 09940-00030 50 g Polyethylene
container
• Features: Resistance to heat andchemicals
• Used for anti-loosening and seal-ant purpose for bolts and plugs.
LT-3
790-129-9060(Set of
adhesive andhardening
agent)
Adhesive:1 kg
Hardening
agent:500 g
Can
• Used as adhesive or sealant formetal, glass and plastic.
LT 4 790 129 9040 250 Polyethylene
t i
• Used as sealant for machined
h l
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FOREWORD COATING MATERIALS
Category Komatsu code Part No. Q'ty Container Main applications, features
Adhesives
LG-7 790-129-9070 1 g Tube
• Features: Silicon based, quickhardening type
• Used as sealant for flywheelhousing, intake manifold, oil an,thermostat housing, etc.
Three bond1211
790-129-9090 100 g Tube • Used as heat-resisting sealant for
repairing engine.
Molybdenumdisulphidelubricant
LM-G 09940-00051 60 g Can • Used as lubricant for sliding por-
tion (to prevent from squeaking).
LM-P 09940-00040 200 g Tube
• Used to prevent seizure or scuf-fling of the thread when press fit-ting or shrink fitting.
• Used as lubricant for linkage,bearings, etc.
Grease
G2-LI
SYG2-400LI
SYG2-350LISYG2-400LI-ASYG2-160LISYGA-160CNLI
Various Various
• General purpose type
G2-CA
SYG2-400CASYG2-350CASYG2-400CA-ASYG2-160CASYGA-160CNCA
Various Various
• Used for normal temperature,light load bearing at places in con-tact with water or steam.
M l bd 400 U d f l ith h l d
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FOREWORD STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH)
In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in
the table below.
Thread diameterof bolt
Width acrossflats
mm mm Nm kgm
6
8
10
12
14
10
13
17
19
22
13.20
1.4
310
3
660
7
113 0 10
1770
19
1.350
0.15
3.20
0.3
6.70
0.7
11.5 0 1
180
2
16
18
2022
24
24
27
3032
36
2790
30
3820
39
5490
597450
83
9270
103
28.50
3
390
4
560
6760
8.5
94.50
10.5
27
30
33
36
39
41
46
50
55
60
13200
140
17200
190
22100
240
27500
290
32900
340
1350
15
1750
20
2250
25
2800
30
3350
35
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FOREWORD STANDARD TIGHTENING TORQUE
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS
In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the
table below.
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS
Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
10
12
16
14
17
22
65.70
6.8
1120
9.8
2790
29
6.70
0.7
11.50
1
28.50
3
Norminal No.
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
02
03, 04
05 06
14
20
24
Varies depending
t f
34.30
4.9
93.1 0 9.8
142 1 19 6
3.50
0.5
9.5 0 1
14 5 2
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FOREWORD STANDARD TIGHTENING TORQUE
TIGHTENING TORQUE FOR 102 ENGINE SERIES (BOLT AND NUTS)Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
TIGHTENING TORQUE FOR 102 ENGINE SERIES (EYE JOINTS)
Use these torques for eye joints (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
mm Nm kgm
68
10
12
100
2240
4
430
6
770
12
1.020
0.202.450
0.41
4.380
0.61
7.850
1.22
Thread diameter Tightening torque
mm Nm kgm
6
8
80
2
100
2
0.810
0.20
1.020
0.20
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FOREWORD ELECTRIC WIRE CODE
ELECTRIC WIRE CODEIn the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Norminalnumber
Copper wire
Cable O.D.(mm)
Currentrating(A)
Applicable circuitNumber of
strands
Dia. ofstrands(mm2)
Crosssection(mm2)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signaletc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting
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FOREWORD CONVERSION TABLE
CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE
The Conversion Table in this section is provided to enable simple conversion of figures. For details of the
method of using the Conversion Table, see the example given below.
EXAMPLE
• Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
(1) Locate the number 50 in the vertical column at the left side, take this as A , then draw a horizontal line
from A .
(2) Locate the number 5 in the row across the top, take this as B , then draw a perpendicular line down
from B .
(3) Take the point where the two lines cross as C . This point C gives the value when converting from mil-
limeters to inches. Therefore, 55 mm = 2.165 inches.2. Convert 550 mm into inches.
(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the
left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
B
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FOREWORD CONVERSION TABLE
Liter to U.S. Gallon
1l
= 0.2642 U.S. Gal
Liter to U.K. Gallon
0 1 2 3 4 5 6 7 8 9
0
10
20
30
40
50
60
70
80
90
0
2.642
5.283
7.925
10.567
13.209
15.850
18.492
21.134
23.775
0.264
2.906
5.548
8.189
10.831
13.473
16.115
18.756
21.398
24.040
0.528
3.170
5.812
8.454
11.095
13.737
16.379
19.020
21.662
24.304
0.793
3.434
6.076
8.718
11.359
14.001
16.643
19.285
21.926
24.568
1.057
3.698
6.340
8.982
11.624
14.265
16.907
19.549
22.190
24.832
1.321
3.963
6.604
9.246
11.888
14.529
17.171
19.813
22.455
25.096
1.585
4.227
6.869
9.510
12.152
14.795
17.435
20.077
22.719
25.361
1.849
4.491
7.133
9.774
12.416
15.058
17.700
20.341
22.983
25.625
2.113
4.755
7.397
10.039
12.680
15.322
17.964
20.605
23.247
25.889
2.378
5.019
7.661
10.303
12.944
15.586
18.228
20.870
23.511
26.153
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FOREWORD CONVERSION TABLE
kgm to ft. lb1 kgm = 7.233 ft. lb
0 1 2 3 4 5 6 7 8 9
0
10
20
30
40
50
60
70
80
90
100
110
120
130
140
0
72.3
144.7
217.0
289.3
361.7
434.0
506.3
578.6
651.0
723.3
795.6
868.0
940.3
1012.6
7.2
79.6
151.9
224.2
296.6
368.9
441.2
513.5
585.9
658.2
730.5
802.9
875.2
947.5
1019.9
14.5
86.8
159.1
231.5
303.8
376.1
448.5
520.8
593.1
665.4
737.8
810.1
882.4
954.8
1027.1
21.7
94.0
166.4
238.7
311.0
383.4
455.7
528.0
600.3
672.7
745.0
817.3
889.7
962.0
1034.3
28.9
101.3
173.6
245.9
318.3
390.6
462.9
535.2
607.6
679.9
752.2
824.6
896.9
969.2
1041.5
36.2
108.5
180.8
253.2
325.5
397.8
470.2
542.5
614.8
687.1
759.5
831.8
904.1
976.5
1048.8
43.4
115.7
188.1
260.4
332.7
405.1
477.4
549.7
622.0
694.4
766.7
839.0
911.4
983.7
1056.0
50.6
123.0
195.3
267.6
340.0
412.3
484.6
556.9
629.3
701.6
773.9
846.3
918.6
990.9
1063.2
57.9
130.2
202.5
274.9
347.2
419.5
491.8
564.2
636.5
708.8
781.2
853.5
925.8
998.2
1070.5
65.1
137.4
209.8
282.1
354.4
426.8
499.1
571.4
643.7
716.1
788.4
860.7
933.1
1005.4
1077.7
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FOREWORD CONVERSION TABLE
kg/cm2 to lb/in2
1kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0
10
20
30
40
50
60
70
80
90
100
110
120
130
140
0
142.2
284.5
426.7
568.9
711.2
853.4
995.6
1138
1280
1422
1565
1707
1849
1991
14.2
156.5
298.7
440.9
583.2
725.4
867.6
1010
1152
1294
1437
1579
1721
1863
2005
28.4
170.7
312.9
455.1
597.4
739.6
881.8
1024
1166
1309
1451
1593
1735
1877
2020
42.7
184.9
327.1
469.4
611.6
753.8
896.1
1038
1181
1323
1465
1607
1749
1892
2034
56.9
199.1
341.4
483.6
625.8
768.1
910.3
1053
1195
1337
1479
1621
1764
1906
2048
71.1
213.4
355.6
497.8
640.1
782.3
924.5
1067
1209
1351
1493
1636
1778
1920
2062
85.3
227.6
369.8
512.0
654.3
796.5
938.7
1081
1223
1365
1508
1650
1792
1934
2077
99.6
241.8
384.0
526.3
668.5
810.7
953.0
1095
1237
1380
1522
1664
1806
1949
2091
113.8
256.0
398.3
540.5
682.7
825.0
967.2
1109
1252
1394
1536
1678
1821
1963
2105
128.0
270.2
412.5
554.7
696.9
839.2
981.4
1124
1266
1408
1550
1693
1835
1977
2119
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FOREWORD CONVERSION TABLE
Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Cen-
tigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface col-umn of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4
–37.2
–34.4
–31.7
–28.9
–28.3 –27.8
–27.2
–26.7
–26.1
–25.6
–25.0
–40
–35
–30
–25
–20
–19 –18
–17
–16
–15
–14
–13
–40.0
–31.0
–22.0
–13.0
–4.0
–2.2 –0.4
1.4
3.2
5.0
6.8
8.6
–11.7
–11.1
–10.6
–10.0
–9.4
–8.9 –8.3
–7.8
–7.2
–6.7
–6.1
–5.6
11
12
13
14
15
1617
18
19
20
21
22
51.8
53.6
55.4
57.2
59.0
60.862.6
64.4
66.2
68.0
69.8
71.6
7.8
8.3
8.9
9.4
10.0
10.611.1
11.7
12.2
12.8
13.3
13.9
46
47
48
49
50
5152
53
54
55
56
57
114.8
116.6
118.4
120.2
122.0
123.8125.6
127.4
129.2
131.0
132.8
134.6
27.2
27.8
28.3
28.9
29.4
30.030.6
31.1
31.7
32.2
32.8
33.3
81
82
83
84
85
8687
88
89
90
91
92
117.8
179.6
181.4
183.2
185.0
186.8188.6
190.4
192.2
194.0
195.8
197.6
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FOREWORD UNITS
UNITS
In this manual, the measuring units are indicated with Internatinal System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.
Example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}
kW/rpm {HP/rpm}
g/kWh {g/HPh}
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01 GENERAL
Specification Dimension DrawingsPC200-7, PC200LC-7 . . . . . . . . . . . 01-2PC220-7, PC220LC-7 . . . . . . . . . . . 01-4
SpecificationsPC200-7, PC200LC-7 . . . . . . . . . . . 01-6PC220-7, PC220LC-7 . . . . . . . . . . . 01-8
Weight TablePC200-7, PC200LC-7 . . . . . . . . . . 01-10PC220-7, PC220LC-7 . . . . . . . . . . 01-12
Fuel, Coolant, And Lubricants. . . . . . . 01-14
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GENERAL SPECIFICATION DIMENSION DRAWINGS
12DIMENSIONS
Item Unit PC200-7 PC200LC-7
A Overall length mm 9,425 9,425
B Overall height mm 3,000 3,000
C Overall width mm 2,800 3,080
D Track shoe width mm 600 700
E Height of cab mm 3,000 3,000
F Tail swing radius mm 2,750 2,750G Track overall length mm 4,080 4,450
H Length of track on ground mm 3,270 3,640
Min. ground clearance mm 440 440
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GENERAL SPECIFICATION DIMENSION DRAWINGS
PC220-7, PC220LC-7
DIMENSIONS
WORKING RANGES
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GENERAL SPECIFICATION DIMENSION DRAWINGS
12DIMENSIONS
Item Unit PC220-7 PC220LC-7
A Overall length mm 9,885 9,885
B Overall height mm 3,160 3,160
C Overall width mm 2,980 3,280
D Track shoe width mm 600 700
E Height of cab mm 3,015 3,015
F Tail swing radius mm 2,940 2,940
G Track overall length mm 4,250 4,640
H Length of track on ground mm 3,460 3,845
Min. ground clearance mm 440 400
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GENERAL SPECIFICATIONS
SPECIFICATIONS
PC200-7, PC200LC-7
Machine model PC200-7 PC200LC-7
Serial Number 200001 and up
Bucket capacity m³ 0.8 0.8
Operating weight kg 19,300 20,700
P e r f o
r m a n c e
W o r k i n g r a
n g e s
Max. digging depth
Max. vertical wall depth
Max. digging reach
Max. reach at ground level
Max. digging height
Max. dumping height
mm
mm
mm
mm
mm
mm
6,620
5,980
9,875
9,700
10,000
7,110
6,620
5,980
9,875
9,700
10,000
7,110
Max. digging force
(using power max. function)
Swing speed
Swing max. slope angle
Travel speed
Gradeability
Ground pressure
kN {kg}
rpm
deg.
km/h
deg.
kPa {kg/cm²}
138.3 {14,100}
(149.1 {15,200})
12.420
Lo: 3.0 ( Mi: 4.1)
Hi: 5.5
35
44 1 {0 45}
138.3 {14,100}
(149.1 {15,200})
12.420
Lo: 3.0 ( Mi: 4.1)
Hi: 5.5
35
36 3 {0 37}
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GENERAL SPECIFICATIONS
12
Machine model PC200-7 PC200LC-7
Serial Number 200001 and up
E n g i n
e
Model
Type
No. of cylinders - bore x stroke
Piston displacement
mm
l ll l {cc}
SAA6D102E-2-A
4-cycle, water-cooled, in-line, vertical, direct
injection, with turbo charger
6 - 102 x 120
5.883 {5,883}
P e r f o r m a
n c e
Flywheel horsepower
Max. torque
Max. speed at no load
Min. speed at no load
Min. fuel consumption
kW/rpm {HP/rpm}
Nm/rpm {kgm/rpm}
rpm
rpm
g/kWh {g/HPh}
106.7/1,950 {143/1,950}
610.0/1,500 {62.2/1,500}
2,150
1,030
215 {160}
Starting motor
Alternator
Battery
24V, 4.5 kW
24V, 35 A
12V, 110 Ah x 2
Radiator core type Corrugated CWX-4
U n d e r -
c a r r i a g e
Carrier roller 2 on each side
Track roller 7 on each side 9 on each side
Track shoe
Assembly-type triple
grouser, 45 on each
side
Assembly-type triple
grouser, 49 on each
side
c HPV95+95, variable displacement
GENERAL SPECIFICATIONS
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GENERAL SPECIFICATIONS
PC220-7, PC220LC-7
Machine model PC220-7 PC220LC-7 Serial Number 60001 and up
Bucket capacity m³ 1.0 1.0
Operating weight kg 22,700 24,130
P e r f o
r m a n c e
W o r k i n g r a
n g e s
Max. digging depth
Max. vertical wall depth
Max. digging reach
Max. reach at ground level
Max. digging height
Max. dumping height
mm
mm
mm
mm
mm
mm
6,920
6,010
10,180
10,020
10,000
7,035
6,920
6,010
10,180
10,020
10,000
7,035
Max. digging force
(using power max. function)
Swing speed
Swing max. slope angle
Travel speed
Gradeability
Ground pressure
kN {kg}
rpm
deg.
km/h
deg.
kPa {kg/cm²}
158.9 {16,200}
(171.6 {17,500})
11.725
Lo: 3.1 ( Mi: 4.2)
Hi: 5.5
35
50 0 {0 51}
158.9 {16,200}
(171.6 {17,500})
11.725
Lo: 3.1 ( Mi: 4.2)
Hi: 5.5
35
41 2 {0 42}
GENERAL SPECIFICATIONS
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GENERAL SPECIFICATIONS
Machine model PC220-7 PC220LC-7
Serial Number 60001 and up
E n g i n e
Model
Type
No. of cylinders - bore x stroke
Piston displacement
mm
l ll l {cc}
SAA6D102E-2-C
4-cycle, water-cooled, in-line, vertical, direct
injection, with turbo charger
6 - 102 x 120
5.883 {5,883}
P e r f o r m a n c
e Flywheel horsepower
Max. torque
Max. speed at no load
Min. speed at no load
Min. fuel consumption
kW/rpm {HP/rpm}
Nm/rpm {kgm/rpm}
rpm
rpm
g/kWh {g/HPh}
125/2,000 {167/2,000}
686/1,500 {70/1,500}
2,260
1,060
212 {153}
Starting motor
Alternator
Battery
24V, 4.5 kW
24V, 35 A
12V, 110 Ah x 2
Radiator core type Corrugated CF19-5
U n d e r -
c a r r i a g e
Carrier roller 2 on each side
Track roller 8 on each side 10 on each side
Track shoe
Assembly-type triple
grouser, 47 on each
side
Assembly-type triple
grouser, 51 on each
side
GENERAL WEIGHT TABLE
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GENERAL WEIGHT TABLE
12WEIGHT TABLE
PC200-7, PC200LC-7
This weight table is for use when handling components or when transporting the machine.
Unit: kg
Machine model PC200-7 PC200LC-7
Serial Number 200001 and up 200001 and up
Engine assembly
• Engine
• Damper
• Hydraulic pump
749
598
6
145
749
598
6
145
Radiator oil cooler assembly 110 110
Hydraulic tank, filter assembly (excluding hydraulic oil) 123 123
Fuel tank (excluding fuel) 121 121
Revolving frame 1,729 1,729
Operator’s cab 278 278
Operator’s seat 35 35
Counterweight 3,735 3,735
Swing machinery 160 160
GENERAL WEIGHT TABLE
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GENERAL WEIGHT TABLE
12
Unit: kg
Machine model PC200-7 PC200LC-7
Serial Number 200001 and up 200001 and up
Track shoe assembly
• Standard triple grouser shoe (600 mm)
• Standard triple grouser shoe (700 mm)
• Wide triple grouser shoe (800 mm)
• Road liner (rubber pad type) (600 mm)
1,215 x 2
1,405 x 2
1,530 x 2
1,470 x 2
1,325 x 2
1,530 x 2
1,670 x 2
1,600 x 2
Boom assembly 1,408 1,408
Arm assembly 653 653
Bucket assembly 628 628
Boom cylinder assembly 172 x 2 172 x 2
GENERAL WEIGHT TABLE
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GENERAL WEIGHT TABLE
PC220-7, PC220LC-7
Unit: kg
Machine model PC220-7 PC220LC-7
Serial Number 60001 and up 60001 and up
Engine assembly
• Engine
• Damper
• Hydraulic pump
749
598
6
145
749
598
6
145
Radiator oil cooler assembly 119 119
Hydraulic tank, filter assembly (excluding hydraulic oil) 123 123
Fuel tank (excluding fuel) 121 121
Revolving frame 2,048 2,048Operator’s cab 278 278
Operator’s seat 35 35
Counterweight 5,056 5,056
Swing machinery 237 237
Control valve 263 263
Swing motor 60 60
GENERAL WEIGHT TABLE
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GENERAL WEIGHT TABLE
12
Unit: kg
Machine model PC220-7 PC220LC-7
Serial Number 60001 and up 60001 and up
Track shoe assembly
• Standard triple grouser shoe (600 mm)
• Standard triple grouser shoe (700 mm)
• Wide triple grouser shoe (800 mm)
• Road liner (rubber pad type) (600 mm)
1,340 x 2
1,470 x 2
1,600 x 2
1,535 x 2
1,455 x 2
1,595 x 2
1,735 x 2
1,665 x 2
Boom assembly 1,825 1,825
Arm assembly 1,213 1,213
Bucket assembly 722 722
Boom cylinder assembly 195 x 2 195 x 2
GENERAL FUEL, COOLANT, AND LUBRICANTs
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GENERAL FUEL, COOLANT, AND LUBRICANTs
12FUEL, COOLANT, AND LUBRICANTS
RESERVOIRKINDOF
FLUID
AMBIENT TEMPERATURE CAPACITY (l ll l )
-22 -4 14 32 50 68 86 104°F-30 -20 -10 0 10 20 30 40°C
Specified Refill
Engine oil pan 26.3 24
Engine
oil
SAE 30
SAE 10W
SAE 10W-30
SAE 15W-40
Damper case 0.75 —
Swing machinery case 6.6 6.6
Final drive case (each side) SAE 30 4.7 4.5
Idler (1 each) 0.07-0.08 0.07-0.08
Track roller (1 each) 0.19-0.20 0.19-0.20
Carrier roller (1 each) 0.075-0.085 0.075-0.085
SAE 10W
SAE 10W 30
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10 STRUCTURE, FUNCTION, AND
MAINTENANCE STANDARD
1252Engine Related Parts . . . . . . . . . . . . . .10-2Radiator Oil Cooler • Aftercooler . . .10-3Power Train . . . . . . . . . . . . . . . . . . . . .10-4
Final Drive . . . . . . . . . . . . . . . . . . . . . .10-6Swing Machinery
PC200-7, PC200LC-7. . . . . . . . . . . .10-8PC220-7, PC220LC-7. . . . . . . . . . .10-10
Swing CirclePC200-7, PC200LC-7. . . . . . . . . . .10-12PC220-7, PC220LC-7. . . . . . . . . . .10-13
Track Frame • Recoil Spring . . . . . . .10-14Idler. . . . . . . . . . . . . . . . . . . . . . . . . . .10-16Carrier roller. . . . . . . . . . . . . . . . . . . .10-18Track roller . . . . . . . . . . . . . . . . . . . . .10-19Track Shoe . . . . . . . . . . . . . . . . . . . . .10-20Hydraulic Equipment Layout Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-24Hydraulic Tank . . . . . . . . . . . . . . . . . .10-26
Hydraulic CylinderPC200-7, PC200LC-7 . . . . . . . . . 10-134PC220-7, PC220LC-7 . . . . . . . . . 10-136
Work Equipment. . . . . . . . . . . . . . . 10-138Air Conditioner . . . . . . . . . . . . . . . . 10-146Engine Control . . . . . . . . . . . . . . . . 10-147Electronic Control System . . . . . . . 10-155Multi Monitor System . . . . . . . . . . 10-1807-Segment Monitor System . . . . . 10-202Sensor . . . . . . . . . . . . . . . . . . . . . . . 10-209
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STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
RADIATOR OIL COOLER •
AFTERCOOLER
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, ,
12
RADIATOR • OIL COOLER • AFTERCOOLER
SWP08671
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD POWER TRAIN
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12
POWER TRAIN
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STRUCTURE, FUNCTION, & MAINTENANCE STANDARD FINAL DRIVE
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12
FINAL DRIVE
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD FINAL DRIVE
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12
1. Level plug
2. Drain plug
3. Cover
4. No. 2 sun gear (No. of teeth: 21)
5. No. 1 sun gear (No. of teeth: 10)
4. No. 1 planetary carrier
6. Cover
7. No. 2 planetary carrier
8. Sprocket
9. Floating seal
10. Travel motor
11. Hub12. No. 2 planetary gear (No. of teeth: 36)
13. Ring gear (No. of teeth: 95)
14. No. 1 planetary gear (No. of teeth: 42)
SPECIFICATIONS
Reduction ratio:
00.57121
9521
10
9510−=+
+×
+−
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING MACHINERY
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12
SWING MACHINERYPC200-7, PC200LC-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING MACHINERY
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12
1. Swing pinion (No. of teeth: 15)2. Spacer
3. Case
4. No. 2 planetary carrier
5. No. 2 sun gear
6. Ring gear
7. No. 1 sun gear
8. Swing motor
9. Oil level gauge
10. No. 1 planetary gear11. No. 1 planetary carrier
12. No. 2 planetary gear
13. Drain plug
SPECIFICATIONS
Reduction ratio:
627.1818
5818
17
5817=
+×
+
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING MACHINERY
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PC220-7, PC220LC-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING MACHINERY
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12
1. Swing pinion (No. of teeth: 13)2. Spacer
3. Case
4. No. 2 planetary carrier
5. No. 2 sun gear
6. Ring gear
7. No. 1 sun gear
8. Swing motor
9. Oil level gauge
10. No. 1 planetary gear11. No. 1 planetary carrier
12. No. 2 planetary gear
13. Drain plug
SPECIFICATIONS
Reduction ratio:
689.2214
5814
17
5817=
+×
+
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING CIRCLE
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SWING CIRCLEPC200-7, PC200LC-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING CIRCLE
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12
PC220-7, PC220LC-7
S*P09097
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRACK FRAME • RECOIL SPRING
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12
TRACK FRAME • RECOIL SPRING
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRACK FRAME • RECOIL SPRING
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12
Standard shoe
Model
ItemPC200-7 PC200LC-7 PC220-7 PC220LC-7
Shoe width 600 mm 700 mm 600 mm 700 mm
Link pitch 190 mm 190 mm 190 mm 190 mm
No. on track (one side) 45 (pieces) 49 (pieces) 47 (pieces) 51 (pieces)
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRACK FRAME • RECOIL SPRING
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12
IDLER
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STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRACK FRAME • RECOIL SPRING
12
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12
CARRIER ROLLER
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRACK FRAME • RECOIL SPRING
12
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12
TRACK ROLLER
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRACK SHOE
12
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12
TRACK SHOE
TRIPLE GROUSER SHOE, ROAD LINER, SWAMP SHOE, FLAT SHOE
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRACK SHOE
12
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12
Unit: mm
No
.Check item Criteria Remedy
1 Link pitchStandard size Repair limit
Reverse
or
replace
190.25 194.25
2 Bushing outside diameterStandard size
When turned
Normal load Impact load
59.3 — 54.3
3 Link heightStandard size Repair limit
Repair or
replace
105 97
4Thickness of link metal
(bushing press-fitting portion)28.5 20.5
5
Shoe bolt pitch
160.4
6 62
7 18
8
Link
Inside width 84.8
9 Overall width 45.4
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRACK SHOE
12
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12
Unit: mm
No. Check item Criteria Remedy
20Shoe bolt
a. Regular link
Tightening torque
(Nm {kgm})
Additional tightening
angle (deg.)
Retighten
Triple shoe 490 ± 49 {50 ± 5}
120 ± 10
Road liner
(Rubber pad type)
549 ± 59
{56 ± 6}—
b. Master link
Tightening torque
(Nm {kgm})
Additional tightening
angle (deg.)
Lower limit torque
(Nm {kgm})
— — —
No. of shoes (each side)PC200-7: 45, PC200LC-7: 49
PC220-7: 47, PC220LC-7: 51—
21Interference between
bushing and link
Standard
size
Tolerance Standard
interferenceShaft Hole
59+0.304
+0.394
+0.074
00.320 - 0.434
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STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
HYDRAULIC EQUIPMENT LAYOUT
DRAWING
12
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HYDRAULIC EQUIPMENT LAYOUT DRAWING
1. Bucket cylinder
2. Arm cylinder
3. Boom cylinder
4. Hydraulic tank
5. Hydraulic filter
6. R.H. travel motor
7. Swing motor
8. Hydraulic pump
9. Control valve
10. Oil cooler
11. L.H. travel motor
12. Multi-pattern selector valve
13. L.H. PPC valve
14. Safety lever (electric type)
15. Center swivel joint
16. R.H. PPC valve
17. Travel PPC valve
18. Attachment circuit selector valve
FOREWORD CONVERSION TABLE
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Millimeters to Inches
1 mm = 0.03937 in
Kilogram to Pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0
10
20
30
40
50
60
70
80
90
0
0.394
0.787
1.181
1.575
1.969
2.362
2.756
3.150
3.543
0.039
0.433
0.827
1.220
1.614
2.008
2.402
2.795
3.189
3.583
0.079
0.472
0.866
1.260
1.654
2.047
2.441
2.835
3.228
3.622
0.118
0.512
0.906
1.299
1.693
2.087
2.480
2.874
3.268
3.661
0.157
0.551
0.945
1.339
1.732
2.126
2.520
2.913
3.307
3.701
0.197
0.591
0.984
1.378
1.772
2.165
2.559
2.953
3.346
3.740
0.236
0.630
1.024
1.417
1.811
2.205
2.598
2.992
3.386
3.780
0.276
0.669
1.063
1.457
1.850
2.244
2.638
3.032
3.425
3.819
0.315
0.709
1.102
1.496
1.890
2.283
2.677
3.071
3.465
3.858
0.354
0.748
1.142
1.536
1.929
2.323
2.717
3.110
3.504
3.898
0 1 2 3 4 5 6 7 8 9
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
HYDRAULIC EQUIPMENT LAYOUTDRAWING
12
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STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC TANK
12HYDRAULIC TANK
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HYDRAULIC TANK
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STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
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HYDRAULIC PUMP
HPV95 + 95
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
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STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
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Function
• The rotation and torque transmitted to the
pump shaft are converted into hydraulic
• Rocker cam (4) has flat surface A, and shoe
(5) is always pressed against this surface
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
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Operation
1) Operation of pump
i Cylinder block (7) rotates together withshaft (1), and shoe (5) slides on flat surface
A.
When this happens, rocker cam (4) moves
along cylindrical surface B, so angle αbetween center line X of rocker cam (4) and
the axial direction of cylinder block (7)
changes. (Angle α is called the swash plate
angle.)ii Center line X of rocker cam (4) maintains
swash plate angle α in relation to the axialdirection of cylinder block (7), and flat sur-
face A moves as a cam in relation to shoe
(5).
In this way, piston (6) slides on the inside of
cylinder block (7), so a difference between
volumes E and F is created inside cylinder
block (7). The suction and discharge is car-
ried out by this difference F - E.
In other words, when cylinder block (7)
rotates and the volume of chamber E
becomes smaller, the oil is discharged dur-
ing that stroke. On the other hand, the vol-
ume of chamber F becomes larger, and as
the volume becomes bigger the oil is
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
122) Control of discharge amount
If th h l t l b l
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• If the swash plate angle α becomes larger,the difference between volumes E and F
becomes larger and discharge amount Q
increases.
• Swash plate angle α is changed by servopiston (12).
• Servo piston (12) moves in a reciprocal
movement (↔) according to the signalpressure from the PC and LS valves. This
straight line movement is transmitted
through rod (13) to rocker cam (4), and
rocker cam (4), which is supported by the
cylindrical surface to cradle (2), slides in a
rotating movement in direction of arrow.
• With servo piston (12), the area receiving
the pressure is different on the left and
the right, so main pump discharge pres-
sure (self pressure) PP is always brought
to the chamber receiving the pressure at
the small diameter piston end.
• Output pressure Pen of the LS valve is
brought to the chamber receiving thepressure at the large diameter end. The
relationship in the size of pressure PP at
the small diameter piston end and pres-
sure Pen at the large diameter end, and
the ratio between the area receiving the
pressure of the small diameter piston and
the large diameter piston controls the
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
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LS VALVE
1. Plug
2. Locknut
3. Sleeve4. Spring
5. Seat
6. Spool
7. Piston
8. Sleeve
PP : Pump port
PDP : Drain port
PLP : LS control pressure output portPLS : LS pressure input port
PPL : PC control pressure input port
PSIG : LS mode selection pilot port
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12Function
(1) LS valve
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(1) LS valve
The LS valve detects the load and controls the
discharge amount.
This valve controls main pump discharge
amount Q according to differential pressure∆PLS (=PP - PLS) [called the LS differentialpressure] (the difference between main pump
pressure PP and control valve outlet port
pressure PLS).
Main pump pressure PP, pressure PLS {called
the LS pressure} coming from the control
valve output, and pressure Psig {called the
LS selector pressure} from the proportional
solenoid valve enter this valve. The relation-
ship between discharge amount Q and differ-
ential pressure ∆PLS, (the difference betweenmain pump pressure PP and LS pressure
PLS) (= PP - PLS) changes as shown in the
diagram at the right according to LS pressure
selector current isig of the LS-EPC valve.
When isig changes between 0 and 1A, the set
pressure of the spring changes according tothis, and the selector point for the pump dis-
charge amount changes at the rated central
valve between 0.69 ↔ 2.2 MPa {7 ↔ 22 kg/ cm²}.
(2) PC valve
When the pump discharge pressure PP1
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12OPERATION
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SDP08884
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
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SDP08885
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STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
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SDP08887
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
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STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
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SDP08889
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
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• Port C of the PC valve is connected to port E
of the LS valve (see (1) LS valve). Self pres-
sure PP1 enters port B and the small diame-
ter end of servo piston (9), and other 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 D are connected, and the pressureentering the LS valve becomes drain pressure
PT. If port E and port G of the LS valve are
connected (see (1) LS valve), the pressure
entering the large diameter end of the piston
from port J becomes drain pressure PT, and
servo piston (9) moves to the right. In this
way, the pump discharge amount moves in
the direction of increase.
• As servo piston (9) moves further, 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
C i d h h l
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
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STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
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• The relation of average pump pressure
(PP1 + PP2)/2 and the position of servo
piston (9) forms a bent line because of
the double-spring effect of springs (4)
and (6). The relationship between aver-
age pump pressure (PP1 + PP2)/2 and
pump discharge amount Q is shown in
the figure at the right.
• If command voltage X sent to PC-EPC
valve solenoid (1) increases further, the
relationship between average pump
pressure (PP1 + PP2)/2, and pump dis-
charge amount Q is proportional to the
pushing force of the PC-EPC valve sole-
noid and moves in parallel. In other
words, the pushing force of PC-EPCsolenoid (1) is added to the force push-
ing to the left because of the pump pres-
sure applied to the spool (3), so the
relationship between the average pump
pressure (PP1 + PP2)/2 and Q moves
from ➀ to ➁ in accordance with the
increase in X.
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
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STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
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STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
LS(PC)-EPC VALVE
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LS(PC)-EPC VALVE
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12O
FUNCTION
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FUNCTION
• The EPC valve consists of the proportional
solenoid portion and the hydraulic valve
portion.
• When it receives signal current i from the
pump controller, it generates the EPC out-
put pressure in proportion to the size of the
signal, and outputs it to the LS valve.
OPERATION
1. When signal current is 0 (coil deener-
gized)
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
2. When signal current is very small (coil
energized)
• When a very small signal current flows to
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• When a very small signal current flows to
coil (5), coil (5) is energized, and a propul-
sion force is generated which pushes
plunger (6) to the left.• Push pin (4) pushes spool (2) to the left,
and pressurized oil flows from port PEPC
to port PSIG(PM).
• When the pressure at port PSIG(PM) rises
and the load of spring (3) + the force acting
on surface a of spool (2) becomes greater
than the propulsion force of plunger (6),
spool (2) is pushed to the right. The circuit
between port PEPC and port PSIG(PM) is
shut off, and at the same time, port
PSIG(PM) and port PT are connected.
• As a result, spool (2) is moved up or down
until the propulsion force of plunger (6) is
balanced with the load of spring (3) + pres-
sure of port PSIG(PM).
• Therefore, the circuit pressure between the
EPC valve and the LS valve is controlled inproportion to the size of the signal current.
3. When signal current is maximum (coil
energized)
• When the signal current flows to coil (5),
coil (5) is energized.
08891
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STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
12CONTROL VALVEPC200-7, PC200LC-7
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A1 : To bucket cylinder head
A2 : To left travel motor
A3 : To boom cylinder bottom
A4 : To swing motor
A5 : To right travel motor
A6 : To arm cylinder head
A-1 : To attachment
B1 : To bucket cylinder bottom
B2 : To left travel motor
B3 : To bottom cylinder head
P9 : From right travel PPC valve
P10 : From right travel PPC valve
P11 : From arm PPC valve
P12 : From arm PPC valve
P-1 : From service PPC valve
P-2 : From service PPC valve
BP1 : Boom RAISE PPC output pressure
BP5 : From attachment circuit selector solenoid
valve
PLS1: To rear pump control
1. 6-spool valve
2. Cover 1
3. Cover 2
4. Pump merge-divider valve
5. Back pressure valve
6. Boom lock valve
7. Service valve
OUTLINE
• This control valve consists of a 6-spool
valve (unit type), 1 service valves, a pump
merge-divider valve, a back pressure valve,
and a boom hydraulic drift prevention
valve.
• Since all the valves are assembled together
with connecting bolts and their passes are
connected to each other inside the assem-
bly, the assembly is small in size and easyto maintain.
• Since one spool of this control valve is
used for one work equipment unit, its struc-
ture is simple.
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
12
7-spool valve
(6-spool valve + 1 service valves)
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(1/9)
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
12
(2/9)
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S*P09099
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
12
(3/9)
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STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
12
(4/9)
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(4/9)
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
12
(5/9)
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STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
12
(6/9)
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STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
Unit: mm
No Check item Criteria Remedy
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No. Check item Criteria Remedy
18 Relief spring
Standard size Repair limit
If damaged or
deformed, replace
spring
Free length x
Outside diameter
Installed
length
Installed
load
Free
length
Installed
load
30.7 x 9.6 25.9406.7 N
{41.5 kg}—
325.6 N
{33.2 kg}
19 Valve spring 24.3 x 8 19.569.6 N
{7.1 kg}—
55.7 N {5.7 kg}
20 Unload spring 31.5 x 10.2 26.970.6 N
{7.2 kg}—
56.4 N
{5.8 kg}
21Regeneration valve
spring31.5 x 10.3 19
6.2 N
{0.6 kg}—
4.9 N
{0.5 kg}
22 Piston return spring 48.1 x 10.8 2817.5 N
{1.8 kg}—
14.0 N {1.4 kg}
23 Piston return spring 56.4 x 11.9 4579.4 N
{8.1 kg}—
63.5 N
{6.5 kg}
24 Piston return spring 36.9 x 11.1 2829.4 N
{3 kg}
—23.5 N
{2.4 kg}
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
(7/9)
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BUCKET CONTROL VALVE
1. Safety-suction valve
2 Spool
SERVICE VALVE
7. Safety-suction valve
8 Spool
(7/9)
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STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
12
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(8/9)
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
Unit: mm
No. Check item Criteria Remedy
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y
21 Regeneration valve spring
Standard size Repair limit
If damaged ordeformed, replace
spring
Free length x
Outside diameter
Installed
length
Installed
load
Free
length
Installed
load
31.5 x 10.3 196.2 N
{0.6 kg}—
4.9 N
{0.5 kg}
22 Piston return spring 48.1 x 10.8 2817.5 N
{1.8 kg}—
14.0 N {1.4 kg}
23 Piston return spring 36.9 x 11.1 2829.4 N
{3 kg}—
23.5 N
{2.4 kg}
24 Load spring 30.4 x 16.7 27428.3 N
{43.7 kg}—
343 N
{35.0 kg}
25 Check valve spring 13.6 x 5.5 103.0 N
{0.3 kg}—
2.4 N {0.25 kg}
26 Check valve spring 33.0 x 12.0 2635.3 N
{3.6 kg}—
28.2 N
{2.9 kg}
27 Check valve spring 16.4 x 8.9 11.513.7 N
{1.4 kg}
—11.0 N
{1.1 kg}
28 Spool return spring 30.7 x 20.5 2350.0 N
{5.1 kg}—
40.0 N {4.1 kg}
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
12
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(9/9)
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
Unit: mm
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No. Check item Criteria Remedy
17 Valve spring
Standard size Repair limit
If damaged ordeformed, replace
spring
Free length x
Outside diameter
Installed
length
Installed
load
Free
length
Installed
load
24.3 x 8 19.569.6 N
{7.1 kg}—
55.7 N
{5.7 kg}
18 Unload spring 31.5 x 10.2 2683.4 N
{8.5 kg}—
66.7 N
{6.8 kg}
19 Check valve spring 11.5 x 4.6 8.51.5 N
{0.15 kg}—
1.2 N {0.12 kg}
20 Spool return spring 46.6 x 21.8 3.3156.8 N
{16.0 kg}—
125.5 N
{12.8 kg}
21 Spool return spring 64.5 x 32.3 63177.5 N
{18.1 kg}—
142.0 N
{14.5 kg}
22 Sequence valve spring 70.9 x 18.0 59199.8 N
{20.4 kg}—
160.0 N
{16.3 kg}
23 Spool return spring 29.9 x 11.0 10.710.4 N
{1.1 kg}—
8.3 N
{0.8 kg}
24 Relief spring 34.7 x 10.4 32.3430.2 N
{43.9 kg)—
344.2 N
{35.1 kg}
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
CONTROL VALVEPC220-7, PC220LC-7
1 6 spool valve OUTLINE
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A1 : To bucket cylinder head
A2 : To left travel motor
A3 : To boom cylinder bottom
A4 : To swing motorA5 : To right travel motor
A6 : To arm cylinder head
A-1 : To attachment
B1 : To bucket cylinder bottom
B2 : To left travel motor
B3 : To bottom cylinder head
B4 T i t
P9 : From right travel PPC valve
P10 : From right travel PPC valve
P11 : From arm PPC valve
P12 : From arm PPC valveP-1 : From service PPC valve
P-2 : From service PPC valve
BP1 : Boom RAISE PPC output pressure
BP5 : From attachment circuit selector solenoid
valve
PLS1: To rear pump control
PLS2 T f t t l
1. 6-spool valve
2. Cover 1
3. Cover 24. Pump merge-divider valve
5. Back pressure valve
6. Boom lock valve
7. Service valve
OUTLINE
• This control valve consists of a 6-spoolvalve (unit type), 1 service valves, a pump
merge-divider valve, a back pressure valve,
and a boom hydraulic drift prevention
valve.
• Since all the valves are assembled together
with connecting bolts and their passes are
connected to each other inside the assem-
bly, the assembly is small in size and easy
to maintain.
• Since one spool of this control valve is
used for one work equipment unit, its struc-
ture is simple.
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
12
7-spool valve
(6-spool valve + 1 service valves)
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(1/9)
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
12
(2/9)
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S*P09102
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
12
(3/9)
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STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
12
(4/9)
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S*P09104
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
12
(5/9)
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STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
12
(6/9)
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S*P09105
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
Unit: mm
No. Check item Criteria Remedy
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18 Relief spring
Standard size Repair limit
If damaged or
deformed, replace
spring
Free length xOutside diameter
Installedlength
Installedload
Freelength
Installedload
34.7 x 10.4 32.3430.2 N
{43.9 kg}—
344.2 N
{35.1 kg}
19 Valve spring 10.45 x 7 4.83.1 N
{0.32 kg}—
2.5 N {0.26 kg}
20 Unload spring 31.5 x 10.2 26.970.6 N
{7.2 kg}—
56.4 N
{5.8 kg}
21Regeneration valve
spring31.5 x 10.3 19
6.2 N
{0.6 kg}—
4.9 N
{0.5 kg}
22 Piston return spring 48.1 x 10.8 2817.5 N
{1.8 kg}—
14.0 N {1.4 kg}
23 Piston return spring 56.4 x 11.9 4579.4 N
{8.1 kg}—
63.5 N
{6.5 kg}
24 Piston return spring 36.9 x 11.1 2829.4 N
{3 kg}—
23.5 N
{2.4 kg}
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
(7/9)
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BUCKET CONTROL VALVE
1. Safety-suction valve
2 Spool
SERVICE VALVE
7. Safety-suction valve
8 Spool
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STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
12
(8/9)
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(8/9)
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
Unit: mm
N Ch k it C it i R d
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No. Check item Criteria Remedy
21 Regeneration valve spring
Standard size Repair limit
If damaged ordeformed, replace
spring
Free length x
Outside diameter
Installed
length
Installed
load
Free
length
Installed
load
31.5 x 10.3 196.2 N
{0.6 kg}—
4.9 N
{0.5 kg}
22 Piston return spring 48.1 x 10.8 2817.5 N
{1.8 kg}—
14.0 N
{1.4 kg}
23 Piston return spring 36.9 x 11.1 28 29.4 N {3 kg}
— 23.5 N {2.4 kg}
24 Load spring 30.4 x 16.7 27428.3 N
{43.7 kg}—
343 N
{35.0 kg}
25 Check valve spring 13.6 x 5.5 103.0 N
{0.3 kg}—
2.4 N
{0.25 kg}
26 Check valve spring 33.0 x 12.0 2635.3 N
{3.6 kg}—
28.2 N
{2.9 kg}
27 Check valve spring 16.4 x 8.9 11.513.7 N
{1.4 kg}—
11.0 N {1.1 kg}
28 Spool return spring 30.7 x 20.5 2350.0 N
{5.1 kg}—
40.0 N
{4.1 kg}
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
12
(9/9)
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STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
Unit: mm
No Check item Criteria Remedy
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No. Check item Criteria Remedy
17 Valve spring
Standard size Repair limit
If damaged ordeformed, replace
spring
Free length x
Outside diameter
Installed
length
Installed
load
Free
length
Installed
load
10.45 x 7 4.83.1 N
{0.32 kg}—
2.5 N
{0.26 kg}
18 Unload spring 31.5 x 10.2 26.870.6 N
{7.2 kg}—
56.4 N
{5.8 kg}
19 Check valve spring 11.5 x 4.6 8.5 1.5 N {0.15 kg}
— 1.2 N {0.12 kg}
20 Spool return spring 46.6 x 21.8 3.3156.8 N
{16.0 kg}—
125.5 N
{12.8 kg}
21 Spool return spring 64.5 x 32.3 63177.5 N
{18.1 kg}—
142.0 N
{14.5 kg}
22 Sequence valve spring 70.9 x 18.0 59199.8 N
{20.4 kg}—
160.0 N
{16.3 kg}
23 Spool return spring 29.9 x 11.0 10.710.4 N
{1.1 kg}—
8.3 N {0.8 kg}
24 Relief spring 34.7 x 10.4 32.3430.2 N
{43.9 kg)—
344.2 N
{35.1 kg}
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
MAIN RELIEF VALVE
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FUNCTION
• The relief valve set pressure is set to 2 stages.
1. Spring2. Poppet
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
12
VARIABLE PRESSURE COMPENSATION VALVE
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STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CLSS
12
CLSS
OUTLINE OF CLSS
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STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CLSS
Basic principle
1) Control of pump swash plate
• The pump swash plate angle (pump dis-
charge amount) is controlled so that LS dif
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charge amount) is controlled so that LS dif-
ferential pressure ∆PLS (the differencebetween pump pressure PP and control
valve outlet port LS pressure PLS) (load
pressure of actuator) is constant.
(LS pressure ∆PLS = Pump discharge pres-sure PP – LS pressure PLS)
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CLSS
2) Pressure compensation
• A pressure compensation valve is installed to
the outlet port side of the control valve to bal-
ance the load.
In this way, the flow of oil from the pump is
divided (compensated) in proportion to the
area of opening S1 and S2 of each valve.
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• When two actuators are operated together,this valve acts to make pressure difference ∆Pbetween the upstream (inlet port) and down-
stream ( outlet port) of the spool of each valve
the same regardless of the size of the load
(pressure).
p g
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SELF PRESSURE REDUCING VALVE
SELF PRESSURE REDUCING VALVE
FUNCTION
• This value reduces the discharge pressure
f th i d li it t l
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of the main pump and supplies it as control
pressure for the solenoid valves, PPCvalves, etc..
OPERATION
1. When engine is stopped
• Puppet (11) is pressed by spring (12)
against the seat and port PR is not con-
nected to TS.
• Valve (14) is pressed by spring (13) against
the left side and port P2 is connected to PR.
• Valve (7) is pressed by spring (8) against
the left side and port P2 is not connected to
A2.
(See Fig. 1.)
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STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SELF PRESSURE REDUCING VALVE
12
4. When abnormally high pressure is
generated
• If the PR pressure on the self-pressure
reducing valve rises high abnormally, ball
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reducing valve rises high abnormally, ball
(16) separates from the seat against theforce of spring (15) and the hydraulic oil
flows from output port PR to TS. Accord-
ingly, the PR pressure lowers. By this oper-
ation, the hydraulic devices (PPC valves,
solenoid valves, etc.) are protected from
abnormal pressure. (See Fig. 4.)
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING MOTOR
12
SWING MOTOR
KMF125ABE-5
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STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING MOTOR
12
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STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING MOTOR
12
Operation of swing lock
1. When swing lock solenoid valve is deacti-
vated
When the swing lock solenoid valve is deacti-
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vated, the pressurized oil from the main pump isshut off and port B is connected to the tank cir-
cuit.
As a result, brake piston (7) is pushed down by
brake spring (1), discs (5) and plates (6) are
pushed together, and the brake is applied.
2. When swing lock solenoid valve is excited
Wh h i l k l id l i i d
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING MOTOR
12
RELIEF VALVE PORTION
1) Outline
The relief portion consists of check valves
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The relief portion consists of check valves
(2) and (3), shuttle valves (4) and (5), and
relief valve (1).
2. Function
When the swing is stopped, the outlet port
circuit of the motor from the control valve
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 is relieved to port S from the outlet
port of the motor (high-pressure side) to
prevent any damage.
3. Operation
1) When starting swing
• When the swing control lever is operatedto swing right, the pressure oil from the
pump passes through the control valve and
is supplied to port MA. As a result, the
pressure at port MA rises, the starting
torque is generated in the motor, and the
motor starts to rotate The oil from the out-
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD REVERSE PREVENTION VALVE
12
REVERSE PREVENTION VALVE
Operation diagram
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1. Valve body
2. Spool (MA side)
3. Spring (MA side)
4. Plug
5. Spool (MB side)
6. Spring (MB side)
7. Plug
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD REVERSE PREVENTION VALVE
12
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Outline
This valve reduces the swing back genera-
tion in the swing body by the inertia of the
swing body, the backlash and rigidity of the
machinery system, and the compression of
the hydraulic oil when the swing is
stopped. This is effective in preventing
spillage of the load and reducing the cycle
time when stopping the swing (the posi-tioning ability is good and it is possible to
move swiftly to the next job.
Operation
1) When brake pressure is being gener-
ated at port MB
• Pressure MB passes through the notch and
goes to chamber d, spool (5) pushes spring
(6) according to the difference in area D1 >
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CENTER SWIVEL JOINT
12
CENTER SWIVEL JOINT
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STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL MOTOR
TRAVEL MOTOR
HMV110-2
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STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL MOTOR
12
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STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL MOTOR
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STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL MOTOR
OPERATION OF MOTOR
1) Motor swash plate angle at maximum
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SJP08742
OR
08893
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL MOTOR
12
2) Motor swash plate angle at minimum
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SJP08743
OR
08894
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL MOTOR
12
OPERATION OF PARKING BRAKE
1) When starting to travel
When the travel lever is operated, the pres-
i d il f th t t
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surized oil from the pump actuates coun-terbalance valve spool (19), opens the
circuit to the parking brake, and flows into
chamber A of the brake piston (12).
It overcomes the force of spring (11), and
pushes piston (12) to the left in the direc-
tion of the arrow.
When this happens, the force pushing plate
(13) and disc (14) together is lost, so plate
(13) and disc (14) separate and the brake isreleased.
1. When stopping travel
When the travel lever is placed in neutral,
counterbalance valve spool (19) returns to
SJP08744
OR
08895
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL MOTOR
OPERATION OF BRAKE VALVE
• The brake valve consists of a suction safety
valve (18A), counterbalance valve (18) in a
circuit as shown in the diagram on the
right. (Fig. 1)
• The function and operation of each compo-
nent is as given below
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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 rotatewithout load and the machine will run
away, which is extremely dangerous.
To prevent this these valves act to make the
machine travel according to the engine
speed (pump discharge amount).
Operation when pressure oil is supplied
• When the travel lever is operated, the pres-surized oil from the control valve is sup-
plied to port PA. It pushes open suction
safety valve (18A) and flows from motor
inlet port MA to motor outlet port MB.
However, the motor outlet port is closed by
suction safety valve (18B) and spool (19),
SAP03482
OR
08897
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL MOTOR
Operation of brake when traveling downhill
• If the machine tries to run away when travel-
ing downhill, the motor will turn under no
load, so the pressure at the motor inlet port
will drop and the pressure in chamber S1
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will drop, and the pressure in chamber S1through orifices E1 and E2 will also drop.
When the pressure in chamber S1 drops
below the spool switching pressure, spool
(19) is returned to the left, in the direction of
the arrow by spring (20), and outlet port MB
is throttled.
As a result, the pressure at the outlet port
side rises, resistance is generated to the rota-
tion of the motor, and this prevents themachine from running away.
In other words, the spool moves to a position
where the pressure at the outlet port MB bal-
ances the pressure at the inlet port and the
force generated by the weight of the
machine. It throttles the outlet port circuit
and controls the travel speed according to
the amount of oil discharged from the pump.(Fig. 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 counter
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL MOTOR
2) When starting travel (or during normal
travel)
• When the travel