pc200 5

‘SEBM0205C503 SIO IM LAN INTOAN IL KOMATSU PC200-5 custom PC220-5 custom MACHINE MODEL SERIAL NO. PC200-5 45001 and up PC220-5 35001 and up © This shop manual may contain attachments and optional equipment that are not available in your area. Please consult your local Komatsu distributor for those items you may require. Materials and specifications are subject to change without notice. © PC200-5 mount the S6D9BL engine; PC220-5 mount the SABD9EL engine. For details of the engine, see the 95 Series Engine Shop Manual. © 1993 KOMATSU All Rights Reserved Printed in Japan 10-92(01}02606 00-110 20 30 40 CONTENTS No. of page STRUCTURE AND FUNCTION ................ 10-1 TESTING AND ADJUSTING .................. 20-1 DISASSEMBLY AND ASSEMBLY .. MAINTENANCE STANDARD................. 40-1 o205¢50208¢5 The affected pages are indicated by the use of the following marks, It is requested that necessary actions be taken to these pages according to the table below Mark ° Page to be replaced Indication oe Page to be deleted | | page to be newly added | Action required Aad Replace Discard Pages having no marks are those previously revised or made additions. LIST OF REVISED PAGES werk pone TET wre page TC] mark page Time] ware wane Time ot tn pape Time 1 3 on 103922 1089 © 107823 2 1 « we 3 roses 2 | « 16 3 | © 1079 3 2 war 3 03 wea 2 | + oe 3 1079 + 22 3 ose toass 2 | 2 wor 3 1080 + 23 3 018 woase 2 wore 3 |e wos 3 0: 3 1047 ° 10997 3 wera a | 6 wa 7 oo: 4 1018 © tess 3 | o 10684 3 | 6 10 3 00-5 1019 © 139 3 | + 0682 3 | 6 108 3 0-8 1020 © toss 3 | + 16 3 | 6 108 5 0-7 1021 © vse 3 ross © wes 3 00-8 1022 © vse 2 | + 108s 3 00-9 1023 + 1% 3 | © t0881 3 0010 102 oss + 1086 20.1 © 0122 102s 1042 1067 + 2 3 © 13 10262 1042 1068 + m9 5 + 0m 3 1027 ro4e toss 2 | me 8 ° 001s 3 1028 1046 + 107 3 28 1 1029 1047 © 10708 4 28 1 to 1030 1040 + 07 5 207 5 102 ot |e to 2 |e to 3 ze | 102 1032 | 1080 (1072) 29 1 wos woe 2 | toss + 107 3 |e zo 3 os 1095 ] tose + 07m 3 |e zon 3 we 1028 1058 + 1075 3 zo 10-7 1037 2 | 1054 © 10-76 a 20:13 2 a eee + 7 a [4 mom 8 we 1029 1057 + 0m 3 2015 00-2-1Mark Pose JME | mtork Page MBF atark Page MECN | mark Poue TPO] mark Page LECT 217g zosz} |e mer 3] + n04 8 3021 + ww 3 2053 mes 4 | + me 5 nom 2 2019 ross 2 | © me 3 20x27 3023 2020 «25 7 | © 2000 3 20128 3024 2021 © 20551 3 zoso1 2 | 6 019 3 3028 wo 2 | « 2ss2 3 | 20902 2 | © mr 3 3028 roi 2 | o 28a 3 | 20903 2 | © 201m 3 soar © 2222 3 | o 2osa i | 6 20004 20132 soz 2023) |e mose 3 zoos 2 | 6 201 3 3029 2028 2057 2 | 2091 20138 soso 2 (20:25) 2038 + wer 3 | © ms 3G gost + 2026 2060 + 983 20136 sos 2 20274 2061 29s | @ 20aa7® m2 2 + 02 @ zoe 1 | + 209 3 2oa% | oer 2029 2063 | 207 201391 3093 2030 ee 1 | 6 2008 3 20140} wut © 31 me | | 6 m0 3 20481 0382 20a 2086 | 20100 sot} 2003 2087 zo101 4 30952 2 ma P| #88 rrr 5 |e aor 3 3098 23s | #20693 vows | |e 32 3 pF © m1 8 20702 zo108 | woe) 3008 © 2352 2 |e zon 3 20108 | wo5 J 3039 + 228 2 no 2 20.108 a6 3040 + 03s 3 ora 2 zoaor | 3074 3041 © ar 3 zone 2 2008, op corsa as 3042 © 2008 zor 2% | «© zn 3 | + 9 3 3043 2039 2074 gor | |e a010 8 so4e + ma 2 2075! ma ¢ |e son 3 ao4s oar cb | © 207% 3 | © az 3 | o sot 3 | 6 soar 2 zoaz D | 6 2077 «ra 3 | o soe 3 | > some @ nas 2078 20115 | soz | | 6 30459 8 ross) | 2029 20017 goers} | 2 sous 8 245 2080 20118 | gow 1 | 0 3045s 3 246 nos 20119 sors || 8 tase 3 a7“ vez | | + 2010 3 sors || 8 30457 204g (2083) zor 2087 © 3046 2049 «20 9 | «mor 8 aoa 3047 2080 «m0 3 | 6 mon 3 2019 goss wer b> |. me S| 6 mm 8 302 soa 00-2-2 oz0scs02055 Mare Page TiMtOt] Mark Page Time ol | neark Page TES! | mark Pane [ME] Mark Page EOF t © 30401 3 | 6 aoeors 3 ao02 © 402041 4 > 90492 3 | o apeors 3 aoros || 6 doza42 3 e ssa 3 | o aoeo1s 3 sore 1 | © 402943 3 2 m4 3 | 6 a06o16 2 sors | | 2 402344 3 ee ee ee sors 1 | 6 402818 3 2 wae 3 | co asta 2 soror 1 | © 402318 3 © ws97 3 a7 sors 1 | ¢ 4023 o wae 3 2071 20109 4025 3050 won| 4028 i 2081 2073 4027 3059 2075 40.2 +0203 2085 son woe + 4030 | 3056 20-78 40.5 4091 3087 3079 40-6 4092 3058} | #3080 407 4029 3059 2081 408 soso; | o soe 3 40.9 goss; | > toga 3 4010 | sos a0e2 aon 2089 we | 4012 aoe 2088 soa 3065 2085 sons 3065 3088 | 4015 oe soar sor 2 2068 2088 4018 | 3069 3089 4019 | © apse1 3 2090 4020 o 30692 3 3091 40-21 | ° 30683 3 sos2 4022 | © snes 2 aoa 40.23 © sees 3 soe 1 |e aoza2 3 o soens 3 aos 4oza 2 © 30607 3 2098 40204 2 o 3698 3 007 4025 2 © 0699 3 2098 40236 2 306910 3 aoe 40237 2 © seer 3 30-100 40738 2 © 06012 3 30101 2 402040 3 00-2-3A IMPORTANT SAFETY NOTICE Proper service and repair is extremely important for the safe operation of your machine, The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe methods of operation. Some of these operations require the use of tools specially designed by Komatsu for the purpose. To prevent injury to workers, the symbol AM is used to mark safety precautions in this, ‘manual, The cautions accompanying these symbols should always be followed care fully. any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation A SAFETY GENERAL PRECAUTIONS Mistakes in operation are extremely dangerous Read the Operation and Maintenance Manual carefully BEFORE operating the machine. 1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine, 2.When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing ‘* Always wear safety glasses when hitting parts with a hammer. « Always wear safety glasses when grinding parts with a grinder, etc. 3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work 4.When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment. 5.Keep all tools in good condition and learn the correct way to use them, 6.Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking, Never smoke while working PREPARATIONS FOR WORK 7.Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving 8 Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. 9.When disassembling or assembling, support the machine with blocks, jacks or stands before starting work 10. Remove all mud and oil from the steps or other places used to get on and off the ‘machine. Always use the handrails, ladders or steps when getting on or off the ‘machine. Never jump on or off the machine If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing, 00-3PRECAUTIONS 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 carrying out any work on the oil or water circuits. 13. Before starting work, remove the leads from the battery, Always remove the lead from the negative (—) terminal first. 14.When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 15. When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove. 16.When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires. 17.When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately. Fuel or oil ‘on the floor can cause you to slip, or can even start fires, 18.As a general rule, do not use gasoline to wash parts. In particular, use only the minimum of gasoline when washing electrical parts. 00-4 19. 20, 21 22. 23 24. Be sure to assemble all parts again in their original places, Replace any damaged parts with new parts. + When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being operated. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. Also, check that connecting parts are correctly installed. When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole, When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurements. Take care when removing or installing the tracks of track-type machines. When removing the track, the track sepa- rates suddenly, so never let anyone stand at either end of the trackFOREWORD: This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. ‘This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into chapters for each main group of ‘components; these chapters are further divided into the following sections. STRUCTURE AND FUNCTION This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. TESTING AND ADJUSTING This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also included in this section. DISASSEMBLY AND ASSEMBLY This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations, MAINTENANCE STANDARD This section gives the judgement standards when inspecting disassembled parts. NOTICE shop manual are subject to change at any time and without any advance notice. Contact your KOMATSU distributor for the latest information. 00-5HOW TO READ THE SHOP MANUAL HOW TO READ THE SHOP MANUAL VOLUMES Shop manuals are issued as a guide to carrying out repairs. They are divided as follows: Chassis volume: Issued for every machine model Issued for each engine series Each issued as ‘one volume to cover all models Engine volume: Electrical volume Attachments volume These various volumes are designed to avoid duplicating the same information. Therefore to deal with all repairs for any model, it is necessary that chassis, engine, electrical and attach- ment volumes are ready. DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be sent to KOMATSU distributers. Get the most up-to-date information before you start any work. FILING METHOD 1. See the page number on the bottom of the age. File the pages in correct order. 2. Following examples shows how to read the page number. Example 1 (Chassis volume) 10-3 Item number (10. Structure and Function) Consecutive page number for each item. Example 2 (Engine volume): 12-410 U Unit number (1. Engine) Item number (2, Testing and Adjusting) ;— Group No. (4. Fuel system) ‘— Consecutive page No. (Page 10 of Group 4) 3. Additional pages: Additional pages are indicated by a hyphen (-) and number after the page number. File as in the example. Example: 10-4 12-203 10-81 12.208-1 Tora.g Added pages C43 203.2 05 12.208 00-6 REVISED EDITION MARK (()@ When a manual is revised, an edition mark is recorded on the bottom outside corner of the Pages. REVISIONS Revised pages are shown at the LIST OF REVISED PAGES on the between the title page and SAFETY page. SYMBOLS So that the shop manual can be of ample practical use, important places for safety and quality are marked with the following symbols. Symbol | item BD | sate Remarks Special safety precautions are necessary when performing the work, ‘Special technical precautions fr other precautions for preserving standards are necessary when performing the work, | caution Weight of parts or systems. Caution necessary when selecting hoisting wire, or when working posture Is Important, etc. (a) | Weight Places that require special attention for the tightening torque during assembly. Tighten ing torque| Places to be coated with “ Coat | adhesives and lubricants, etc. iP Places where oll, water or [Oil water| fuel must be added, and the capacity. Places where ol or water ‘must be drained, and quantity to be drained,HOISTING INSTRUCTIONS HOISTING INSTRUCTIONS Ay Heavy parts (25 kg or more) must be lifted with a hoist etc. In the Disassembly and Assembly section, every part weigh- ing 25 kg or more is indicated clearly with the symbol 1.If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: * Check for removal of all bolts fastening the part to the relative parts. * Check for existence of another part causing interference with the part to be removed. 2. Wire ropes 1)Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below Wire ropes (Standard "2" or “S" twist ropes. without galvanizing) Rope diameter (mm) | Allowable load (tons) 10 1.0 12 14 128 | 16 14 | 22 16 28 18 | 3.6 20 4a 224 56 30 10.0 40 18.0 50 28.0 60 40.0 The allowable load value is estimated to be one-sixth or one-seventh of the breaking strength of the rope used. 2) Sling wire ropes from the middle portion of the hook. Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result, Hooks have maximum strength at the middle portion. BESS ia 4195 3) Do not sling 2 heavy load with one rope alone, but sling with two or more ropes symmetrically wound on to the load. B Singing with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident. 4)Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load (kg) when hoisting is made with two ropes, each of which is allowed to sling up to 1000 kg vertically, at various hanging angles, When two ropes sling a load vertically, up to 2000 kg of total weight can. be suspended. This weight becomes 1000 kg when two ropes make a 120° hanging angle. On the other hand, two ropes are subjected to an excessive force as large as 4000 kg if they sling a 2000 kg load at a lifting angle of 150° 150" Lutung angie zo 30085 00-7STANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUE 1. STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in sections of “Disassembly and Assembly”. Thread diameter Width of bolt, across flat (mm) (mm) kgm. Nm 6 10 1.35+0.15 13.2414 8 13 3.2403 31.4429 10 17 67407 65.7468 12 19 11.5410 1129.8 14 22 18.0+2.0 177419 16 24 28.543 279429 18 27 3944 383439 20 30 56+6 | 54958. 22 32 16+8 | 745+78 24 36 94.5+10 | 927+98 27 at 135+15 | 1320+ 140 30 46 17520 1720190 33 50 225+25 2210240 36 55 280+30 2750-290 39 60 335+35 3280+340 This torque table does not apply to the bolts with which nylon packings or other non- ferrous metal washers are to be used, or which require tightening to otherwise specified torque. * Nm (newton meter): 1Nm 0.1 kgm. 2. TIGHTENING TORQUE OF SPLIT FLANGE BOLTS Use these torques for split flange bolts. Thread diameter Width Tightening torque of bolt across flats See (mm) (mm) kgm Nm 10 14 67+07 65.7+68 12 7 11.541 112498 16 22 28.5+3 27929 00-8STANDARD TIGHTENING TORQUE Sealing surtace Coun] 3. TIGHTENING TORQUE FOR NUTS OF FLARED —<[ eens Use these torques for nut part of flared a 30068 ‘Thread diameter | Width across flats Tightening torque 30 36 1823 | 176.5+294 42 55 30+5 1 (294.2+49 yd COATING MATERIALS The recommended coating materials prescribed in Komatsu Shop Manuals are listed below. Nomenclature Komatsu code ‘Applications ~ Used to apply resin, rubber, metalic and Used to apply rubber pads, rubber gaskets, and cork plugs ur1e | fonmeilepertewhene fost stony Seais needed Adhesives 1-2" | Preventing bots, nuts and plugs from loosening nd aking 5] Rrones an aright sacicaiywsaiaing eat urs Used tor shane sutates : a] Used oot pugs fle shaped bow shaped! and holes and tre ating partanal sor te Used with gaskets and packings to neease sealing eect ga ana asta Tor precombuston chambers — iss Didorheost no ie Iga | Used by self on mounting surfaces on the ral ave and Wansmission cose (hehveas afer hening OOP OOS md Ee] Uaed iy ano sal rans Tita, tapered serew fgg and apored es Soren tng in hydaute cout age tan SO minim Samat 166 Sion base type used combination withLG-1 and LG-4 Tass shore’ caring Wire an LGB aw aia — 17 to peeloi Aniiictan compound ‘obearngs and taper shale to falas press-Fitng and o {Cubrcon ncn uve | Able to bearings and taper shalt to facitate press -fiting and Aubricatincuding prevent stekng bring ousting Sreose Gaur] Appia Bean sing pars and at sels Tr aDTeaTOn AT ‘Lithium grease) Vaseline Drevention and factitation of assembling Work Used for protecting battery electrode terminals from corrosion “LT-2 is also callea LOCTITE in the shop manuals, 00-9ELECTRIC WIRE CODE ELECTRIC ELECTRIC WIRE CODE In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will help you understand WIRING DIAGRAMS. ‘SWB indicates a cable having a nominal number 5 and white coating with black stripe. Example: CLASSIFICATION BY THICKNESS rT — recede a rer ee [tose one | 2 | 12 | Storing tghing, signal ere 2 26 032 208 31 20 | Long, signal ere 3 5 082 52 a8 a7__| charang and onal 5 o O45 7336 70 30] Staring (Gow pg 0 3 080 ware [aie 135 | Staring 60 127 080 eae | 136 178 | Staring 700 2 80 | 08a 176 230 Stoning CLASSIFICATION BY COLOR AND CODE Prior- | classi Charging Ground ‘Starting Lighting Instrument. ‘Signal Other iv | fication ™ | Color] ‘White Black Black Red Yellow: Green Blue wa = ow mW ve ow ow 2 Color] White & Red - Black & White | Red & White | Yellow &Red | Green & White | Blue & White: * | oy. | abr) write Back | [Backs vetow| Reds wack |Velows Back| Geonated | Buen Red ary "Code WL - ‘BR RY YG GY Ly : [coior] wrie@aue | — | @ackenea | fede vetow [Volow & Geen] Green Yetow | Bus BVelow coae] we = = 7 % = 7 : Color | White & Green - - ‘Red &Green | Yellow & Blue | (Green & Black) | (Blue & Black) ae = = a Tw a s . | Color: - - - Red & Biue | Yellow & White | (Green & Blue) - 00-10CONVERSION 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 85 mm into inches (1) Locate the number 50 in the vertical column at the left side, take this as @, then draw a horizontal line trom @ {2) Locate the number 5 in the row across the top, take this as @, then draw a perpendicular line down from ©) (3) Take the point where the two lines crass as ©. This point © gives the value when converting from millimeters to inches. Therefore, 65 mm = 2165 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 10 5 mm, (2) Carry out the came procedure as above to convert 85 mm to 2.165 inches. (3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point one place to the right} to return to the original value. This gives 550 mm = 21.65 inches. Millimeters to inches ® 1 mm = 003897 in T ; T a T 1 T | | 10 | 9.294 | 0433 | 0472 | 0812 | 0551 | 0591 1) 0630 | 066s | 0709 0.748 20 | 0787 | 0827 | 066 | o906 | oas | 094] 1028 | 1063 | 1102 | 112 30 | 1481 | 1220 | 1260 | 1.299 | 1339 | aval) var7 | 3457 | 1496 | 1536 40 1575 | 1.614 | 1654 | 1.693 | 1.732 | 17723] 7.811 1.929 i ie! | 7 87, [2165] 2208 | 2248 | 2203 | 223 2402) 2aai [2.400 2520) 2569 | 2598 2638 | 2677 | 2717 60 | 2362 70 | 2758 | 2795 cea] emacs 2953 | 2982 | 3032 | 3071 | 3110 a | a1s0 | 3189 | 3228 | 3266 | 3207 | aus | aaes | 242s | 346s | 350s 90_| 3942 | 3589 | 3622 | 3661 | 3701 | a740 | 3700 | aa19 dese | Sse 00-17CONVERSION TABLE Millimeters to Inches 1mm = 0.03937 in of: [7 fe[«[sle T; [os ls r 7 ] | T : | osm oore | ore | arsr | ars | 0236 | o27e | oats | oase 20 | o7e7 | 0827 | 086s | ea0e | oss | ogee | so2e | 1002 | 1302 | 1142 so | tae | 1220 | 1260 | 1.299 | 1339 | 1378 | 1ar7 | 1as7 | 1496 | 1.596 co | 2362 | 2402 | 2441 | 2480 | 2520 | asso | 2soe | 2008 | 2077 | 2717 70 | 2756 | 2705 | 2895 | 2874 | 2913 | 2959 | 2992 | 2092 | 3071 | ant0 | 3150 | 3100 | a226 | a260 | 307 | 3346 | 3306 | szs | aes | 3500 Loe) Kilogram to Pound 1 kg = 2.2086 Ib ee ee =| aa] 661 | 987 | 102 | 1923 | 1543 | 1768 1988 10 | 2205 | 2425 | 2646 | 2806 | 30.86 | 2307 3527 | a4 | 2968 41.89 20 a | 4630 | 4850 | 5071 | 5191 | 5612 | 57.32 | 5953 | 61.73 | sass 20 66.14 | 68.34 yoss | 7275 | 7496 | 77.16 | 79.37 | 157 | 83.78 | 85.98 | | | 50 | 110.23 | 11244 | r1468 | 11685 | 119.05 | 121.25 , 12846 | 125.68 | 127.87 | 13007 vo | tsase | 15653 | 15373 roost | res.e | e635 | 1675 | 16076 | 17096 14.17 | 637 | 987 | e070 | 18298 | 19510 | 10720 | e060 | or90 | rotor 1621 | 00-12CONVERSION TABLE Liter to U.S. Gallon 1 €= 0.2642 US. Gal ae Tam! 0264 0528 0793 1057 1921 1585 1919 2113) 2378 10 2642) 2908 3170 3434 3608 2963 4.227. 4401 4755) 5018 20 5202 | ss4e| sei2| 6o76| 6240 6.604 6.069) 7133 7307/7661 20 7925 | 9.189 8454) 8.718 8982 9246 9510) 9.774 10029 | 10.303 40 ea a ae ae ae ae ee ae so | 12.209 | 13473 | 13797 | 14001 14.265 | 14.529 14795: 16058 18.322 15.505 60 | 15.50 | 16115 | 16.79 | 16.643! e907 | 17.171! 17.495 | 17.700 17.964 | 18.228 70 | 18492 | 18.756 | 19.020 | 19.285 | 19.549 | 19813 20077 | 20.341 20.608 | 20.870 80 21.134 | 21.398 | 21.662 | 21926 | 22.190 | 22455 22.719 22.989. 23.287) 23511 20 | 23.775 | 2an40 | 24.304 | 24568 | 24.832 25095 | 25.361 | 25629 25.809 | 26.159 | Liter to U.K. Gallon 1€= 021997 UK. Gal T T T ] 0 4 203 | 4 8 |e | 7 | 8 | 8 - + + + + | 0220, 0440 0600} om 1.100| 12%/ 1540) 1790) 1.980 0 2.200| 2420 2.640. 2960/3080) 3300) 3520| 3.740| 3.950) 4.179 20 | 4300 4510 4890 5050) 5270) samo | 5719| s000| e150) cave 30 6509 | 6ei9| 7039) 7260| 7479/ 7.969| 7919| 2139| 9259/9579 © | erm| oo.) em oa | 62 sa 119/100 sss 17 | | | 50 10.998 | 11.281 | 11.438 | 11.658 | 11.878 12098 | 12.918 | 12528, 12758] 12978 crs) rsom rasa | ras | seore vez seston) 1a78 70 | 18308 15.618 | 15.298 | 16058 | 16278 16498 16.718 | 16998) 17.158 | 17.978 | r7se8] s7a0| room | s02e7 | ta0r7| secor| sn0s7 | ros2r| vo2er| 19s 90 | 1997 | 20017 | 20237 | 20457 | 20.677 20ger | 21.117 21337) 21887 | 21777 LL poi it | 00-13CONVERSION TABLE kgm to ft.lb Vkg.m = 7.233 ftlb 7 of} 1] 2 a ea | ° T T 72| 148 a2 | 494 | s06| 79 | 65: 10 72a | 796| 08 toss | 1157 | 1230 | 1902 | 1974 20 | var | sor | 1591 wos | we | 1953 | 2028 | 2098 wo | ao | 2242} 2018 | 2832 | 2604 | 2676 | 2749 | 292.1 40 2003 | 2966 | 2038 | 3255 | 927 | s400 | 2472 | 3544 so | asi | ago | ares | aea4 | 2905) 2078 aos | aaa | ats a2se 60 4340 | 441.2 4485 | 455.7 | 4629 | 470.2 | 4774 | 4846 | 491.8 499.1 70 | 6063 | 135 | sos | soo | sas2| sas | 5497 | ss6g | 5642 574 80 578.6 | 585.9 | 593.1 | 6003 | 607.6 | 6148 | 6220 | 629.3 | 6365 643.7 0 — | e510 | 658.2 | cosa | 6727 | oreo | 697.1 | oo4s | 7016 | 7088 716: woo | 7233 | 7005 | 778 | 2450 | 7522 | 7595 | 7667 | 7739 | 7012 | 7e0 110 7956 | 9029 | s10.1 | 8173 | 6246 | e318 | 9390 | e463 9535 | 8607 r20 | s6s0 | ars2 | oaza | 0607 | exc | ons | otis | ote | casa | ont: a0 | 9403 | 9475 o548 | 9620 | 9602 | 9765 | 9607 | 909 | oo0.2 | 0054 140 | 10126 | roro9 | 1027.1 mes oe Yo18 | 0860 | 0882 | 0708 | 1777 150 1084.9 | 1092.2 | 1099.4 | 1106.6 | 1913.9 | 1121.1 | 1128.3 | 1135.6 | 1142.8 | 1150.0 vo | rsa96 | 1296.8 | 1264.1 | 12513 | 12585 | 12658 | 12730 | 1280.1 | 12875 | 1204.7 180 13019 | 1309.2 | tare 1323.6 | 1330.9 | 1338.1 | 1345.3 jee 1359.8 | 1367.0 veo fares | rers | rma | oso | vaaa | rena | a7 [ame /vzt | esoe | | | | | | 00-14CONVERSION TABLE kg/em? to Ib/in? 14.2233 ib/in® o 4 2 3 4 § 6 7 8.9 42 24427, S897. BHA G13 1280 10 1422 1565 17071849 199.1 2134 2278 ©2818 2580 2702 20 2845 208.7 9129 927.1 BIA 955.8 3698 38030834125 20 4267 4409 455.1 4604 4836 4978 51205269 HOS 8647 40 5689 583.2) 5974 611.6 6258 640.1 654.9 6685 682.7 «668 50 712 7254 | 7296 7528 768.1 78237965 810.7 2508292 60 853.4 867.6 881.8 896.1 910.3 9245 938.7 953.0 967.2 981.4 10 9956 1010 | 1028 1038 105910671081 1095. 1109 N18 80 1138 1152 | 1166 1181 1195 1209 1223 1237 1252 1266 90 | 1290 1208 | 1909 132819971981 138513801388 408 roo |r422 1437 145114651479 «1403=«1808«1522«1838 1880 110 1565 1879 | 1593 1607 1621 1636 1650 1664 1678 1693 120 | 7077217351748 176417781792 1808 teat 186 130 [191803 | 18771802 1908-1920 1994 1940 | 1969 | 1977 140 | 1991 2005 | 2020 20% © 2048-2062 2077 2081 2108. 2118 reo | 2276 2200 | 2908 «2318 | 2333847 | 2361 | 2375 | 2389 2404 ro Jamie ise auto aton 205 asso |soo_|asie [soa | ats 190 | 2560 | 2574 | 2589 | 2603 26172631 | 2646 | 2660 | 2674 | 2688 190 2702 ant 2731 2745 | 2759 2773 2788 | (2802 2816 2830 | 200 |zeis [aso | zars 2807 | 212016 | 200 | 20ea_| ase | 2079 210 2987 | 3001 | 3015 | 3030 3044 3088 | 3072 | 2086, jar Jans 220 3129 3143 3158 | 3172 3186 3200 3214 3229 3243 | 3257 230 |a271 | aze6 | 3300 aa aaze | 3343 3957 | 3371 | 9385 | 3390 zao ara 3420 | 242 gas | 3470 | a405 | 2499 | asia | 2527 | 3542 00-15CONVERSION TABLE ‘Temperature Fahrenheit-Centigrade Conversion, —A simple way to convert a Fahrenheit temperture reading into @ Centigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If itis desired to convert 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 lef If iv isdesired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right. ec ~ [le] [+ | * | | . T T T sow [owe fo [a | oe [oe fw [owe |e | ow | ove Sea me | Rsvol (trae eal feeaeh|| test ea eset (eed ta | io |e | “hs | Ses | eater ret eet |p oo sea fa Ma | SC | ae Jo | | ao | at) oe | os aaa | eae leat | atest] teoee caste geen e/a voce | see} |) et rece -26.7 16 32 12 19 | 66.2 122 54 129.2 a7) gg 192.2 26.1 15 50 67 20 68.0 128 58 131.0 322 | 194.0 -30 | -13 | 86 56 2 ns 139 87 1346 33 92 1976 ma | nz | wa | cso | a | aoe | wee | oe | ace | aoa | at | tne cog | erat peg | gee) aces ee | eee ese) sony |) || re as [0 wo] 3a] S| me | we | & | veo | ke | & | Ze ery Meee treet eee cent ier ees (eee ooh ee Bg er tea pet Ipeae | tee ee prep feet) seeds Bra apr iret meat orate poy fest) sesh | ee os | “3 | ao | m1 | 30 | ao | va [ee | smo | are | ww | ano Pm me (ree eae ona tere treats | el |[eeeee eager || eres Prats ea (aa |atong ese case licio |e cae festa | ro sta mee |e |e erg | oto eoee cea] on |e reed free |e | ae Tia] ct | go | sa | as | gaz | aoe | oo | annz | aoa | vz | 2000 cra | 0 | ao | ta Las] seo | an | | me | sna | te | aro Bee eee geen eee eent ete fon reee |) eee) eet ae =e | 2 | as6 | 28 | a7 | 996 | 222 | 72 | sere | sx2 | 128 | 2750 3 | ara | 33 | 38 | 10a | 228 | 73 | 1634 | oo | 140 2600 oe are ie soto tong | atta ee | eg |e fos 3) mo] Mt] | tate | ee | a | toro | ee | to | i shea olla lesieo o less fo lo loco |b eaya] see rena a | ecm) | eta pa | ora | foo |e | aa | os | as | tou | 25 | 7 | 1724 | 709 | 105 | 200 Be esas eect a Rreesi| cer | eta resonate fee fa exo ai cata st ced |Meat est ese ee L2| 00-16WEIGHT TABLE AX This weight table is a guide for use when transporting or handling components. Unit: kg Machine Model PC200-5 PC220-5 Serial Numbers 45001 and up 35001 and up Engine assembly 647 647 © Engine 432 432 * Damper 20 20 Hydraulic pump 195 195 Radiator and oil cooler assembly ” 101 Hydraulic tank assembly (without hydraulic oil) 14 “ Fuel tank (without fuel) 98 98 Revolving frame 1,855 1,840 Operator's cab 238 238 Operator's seat 317 317 Counterweight 3,300 4,300 Swing machinery 258 258 Control valve assembly im im ‘Swing motor assembly 50 50 Travel motor assembly 67 x2 137x2 Center swivel joint 43 43 Track frame assembly 4,307 4,836 © Track frame 2,362 2.824 ‘© Swing circle assembly 270 270 © Idler 140 x2 140.2 Idler cushion 135 x2 135x2 © Carrier roller 2x4 2x4 Track roller 37x14 37x16 *- Final drive 280 x 2 280 x 2 00-18 ‘o205cs,02055 Unit: kg Machine Model C2005 PC220-5 Serial Numbers 45001 and up 35001 and up Track shoe assembly Triple-shoe (500 mm) 2,360 2,460 Triple-shoe (600 mm) 2,620 2,730 Triple-shoe (700 mm) 2,870 3,000 Triple-shoe (600 mm) 3,120 3,260 Triple-shoe (800 mm) 3,380 = ‘Swamp shoe (860 mm) 3,280 = Flat shoe (610 mm) 2,900 = Boom assembly 1,362 1,550 ‘Arm assembly 628 78 Bucket assembly 646 774 Boom cylinder assembly 187 x2 2142 ‘Arm oylinder assembly 251 297 Bucket cylinder assembly 183 182 Link (large) assembly 20 80 Link (smail) assembly 2x2 2x2 , a3 + 10x2 51+ 10x2 Boom pin +25+10+20 | +30+10+32 Arm pin 102 10x2 Bucket pin 20x2 20x2 Link pin 1ex2 1ex2LIST OF LUBRICANT AND WATER PC200-5 Serial No: 45001 - 58018 PC220-5 Serial No: 35001 ~ 36013 KIND OF AMBIENT TEMPERATURE CAPACITY (2) RESERVOIR FLUID 14 32 50 68 86°F 08 EY Specitiea | Retin ia ae Engine oi pan ws | 75 i le OW: 30, Ie Tn SAE Tawa Damper ease 1 : Swing machinery ease | Engine oil OTE SAE RT 10 93 Final drive case (each) _ 4o | 40 Gof) ee SA (OW ca = Hydeaule system SRE a0 - Carrer roller (1 piece) [ 0.19-0.21 |o.19— 0.21 Trackrolier (V piece) | Gear oi TE SAE 140 ET TT 0.23 — 0.25 [0.28 — 028 tater (1 lace) 007 — 0.08 [0.07 — 0.08 Fuel tank Diesel fuel = — 230 180 ‘ASTM DBTENG.Z Cooling system Water ‘Ad antifreeze 16 = ASTM 0975 No. 1 NOTE: (1) When fuel sulphur content is less than 0.5%, change oil in the oil pan every periodic maintenance hours described in this manual. Change oil according to the following table if fuel sulphur content is above 0.5%. Change interval of oil in Fuel sulphur content eaaeeiese (2) When starting the engine in an atmospheric temperature of lower than 0°C, be sure to use engine oil of SAE1OW, SAE10W-30 and SAE15W-40 even though an atmospheric temperature goes up to 10°C more or less in the day time, (3) Use API classification CD as engine oil and if API classification CC, reduce the engine oil change interval to half. 0.5 t0 1.0% 1/2 of regular interval (4) There is no problem if single grade oil is mixed a with multigrade oil (SAE10W-30, 15W-40), but Above 1.0% 1/4 of regular interval be sure to add single grade oil that matches ASTM: American Society of Testing and Material SAE: Society of Automotive Engineers the temperature in the table on the left (5) We recommend Komatsu genuine oil which has been specifically formulated and approved for use in engine and hydraulic work equipment applications. Specified capacity: Total amount of oil including oil for components and oil in piping Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance. 00-20 o20scs20505, PC200-5 Serial No: 58019 and up PC220-5 Serial No: 36614 and up KIND OF AMBIENT TEMPERATURE CAPACITY ( & ) RESERVOIR: FLUID 4 32 50 68 86°F 16% SB BEE | Spectra | Retin E SAE 30 7 SAE TO | | Engine oil pan 195 | 185 ae “SAE 1030 7 SAE T8W40 Damper case ~} 1 4 10 ~ Swing machinery case| Engine oll SAE 30 10 93 _Final drive case (each) ——_| 40 40 SAE 100, Hydraulic system ‘SAE 100030 310 2 i SAE TEW-A0. Carrier rater (1 pieced [T [ 0190.21 0190.21 Track roller (1 piece) | Geo oil = [ITT TSE a0 0.23 — 0.25 |0.23— 0.25, Iler (1 piece) 0.07 — 0.08 |0.07 — 0.08 Fuel tank Diesel fue = 220 150 ‘ASTM D875 No.2 Cooling system Water ‘Add antifreeze 197 7 ® ASTM D975 No. 1 NOTE: (1) When fue! sulphur content is less than 0.5%, change oil in the oil pan every periodic maintenance hours described in this manual. Change oil according to the following table if fuel sulphur content is above 0.5%. Change interval of oil in Fuel suiphur content ‘ P engine oil pan 0.8 t0 1.0% 1/2 of regular interval Above 1.0% 1/4 of regular interval ASTM: American Society of Testing and Material SAE: Society of Automotive Engineers (2) When starting the engine in an atmospheric temperature of lower than 0°C, be sure to use engine oil of SAE1OW, SAE10W-30 and SAE15W-40 even though an atmospheric temperature goes up to 10°C more or less in the day time. (3) Use API classification CD as engine oil and if API classification CC, reduce the engine oil change interval to half. (4) There is no problem if single grade oil is mixed with multigrade oil (SAE10W-30, 15W-40), but be sure to add single grade oil that matches the temperature in the table on the left. (5) We recommend Komatsu genuine oil which has been specifically formulated and approved for use in engine and hydraulic work equipment applications. ‘Specified capacity: Total amount of oil including oil for components and oil in piping Re capacity: Amount of oil needed to refill system during normal inspection and maintenance. 00-21 310 STRUCTURE AND FUNCTION o20sc5, Power train Final drive . ‘Swing circle Swing machinery os Track frame and recoil spring Idler. . Track roller, carrier roller Track shoe Hydraulic piping Hydraulic circuit diagram . Hydraulic tank OLss Hydraulic pump. Control valve ‘Swing motor . Center swivel joint Travel motor Valve control PPC valve . oe : Accumulator, Safety lock valve ‘Swing lock solenoid vaive Shuttle valve Hydraulic cylinder Electrical circuit diagram Engine control system ... . EMACC ... - 10- 10- 10- 10- 10- 10- 10- 10- 10-11 10-12 10-13 10-14 10-17 10-34 10-46 10-49 10-50 10-57 10-58 10-64 10-65 10-66 10-67 10-69 10-71 10-79 10-1POWER TRAIN 1. Idler 2. Center swivel joint 3. Control valve assembly 4. Final drive 5. Travel motor 6.Engine 10-2 ‘D 1 Fz0scso01 7. Hydraulic pump 8. Swing lock solenoid valve 9. Swing motor 10. Swing machinery 11. Swing circle 2055,o205c5, FINAL DRIVE Coupling . Shaft Hub Sprocket . Gear (72 teeth) . No. 2 ring gear (72 teeth) No. 1 ring gear (PC200: 77 teeth) (PC220: 76 teeth) 8. Carrier 9. Cover 10. Sun gear (PC200: 13 teeth) 7 5 4 3 (PC220: 14 teeth) 11. Button 5) 12. Oil level plug 8 fc / 13. Lock nut 14, Pin 15, Planet gear (PC200: 32, 27 teeth) (PC220: 31, 27 teeth) 16. Drain plug 17. Floating seal Nogeeno SPECIFICATIONS, Teavel motor Reduction ratio: —69,892 a7 _— 2 78.714 10-3SWING CIRCLE were 10-4 Section BB Section A— A Feoscso02 ‘Swing circle outer race SPECIFICATIONS Ball bearing Reduction ratio: 119 = 7.333 ‘Swing circle inner race (110 teeth) 15 Grease volume: 218 (G2-LI) Inner race soft zone "S” Outer race soft zone "S” 2055205s SWING MACHINERY Section A—A 1. Swing pinion (15 teeth) 2. Cover 3. Cage 4. Planetary carrier 5. Ring gear (63 teeth) 6 Bearing holder 7. Drive gear (15 teeth) 8. Swing motor 9. Bearing holder 10. Breather 11. Oillevel gauge 12. Cover 13, Driven gear (76 teeth) 14, Planetary gear (24 teeth) 18. Sun gear (15 teeth) 16. Drain plug SPECIFICATIONS 76, (63 +15) _ Reduction ratio: Te x(°2 518) = 26.347 Section B—B Section C—C 20805011 10-5TRACK FRAME AND RECOIL SPRING OSV AMAONA 10-6 Idler . Track frame Carrier roller Final drive Track roller Track Center guard Recoil spring Front guard 20sF0s012 Depending on the model, the dimensions and number of track rollers is different, but the basic structure is the same. (The diagram shows PC200) Number of track rollers PC200: 7 leach side) PC220: 8 leach side) o205c5o205¢5 IDLER 208F05013, 1. Lubricating plug 2. Support 3. Idler 4, Floating seal 5. Idler shaft 6. Bushing 10-7TRACK ROLLER Lubricating plug Collar Floating seal Track roller Bushing Shaft eaaona 205F2452 CARRIER ROLLER Shaft Collar Floating seal Carrier roller Ring Cover Lubricating plug Nogaone 20sF0s014 10-8 o205¢5o208¢5 TRACK SHOE 1. Link 2.Shoe 3. Regular pin 4. Regular bushing 5. Regular dust seal 6. Master bushing 7. Master dust seal 8. Master pin 9. Shoe nut 10. Shoe bolt Standard shoe specifications C200 C220 500 mm triple-shoe Link pitch: 190 mm. Number of shoe: 90 500 mm triple-shoe Link pitch: 190 mm. Number of shoe: 94 205F08015, 10-9SELECTION OF TRACK SHOE * Select the most suitable track shoe from the following table. PC200 PC220 Specification | S°" | Specification | Cate gory gory 500 mm A 500 mm A __triple shoe triple shoe 600mm | 600 mm A _triple shoe triple shoe | 700 mm . 700 mm 5 triple shoe triple shoe 800mm | 800 mm A triple shoe triple shoe 200 mm a 610 mm D __triple shoe flat shoe 860 mm a i _swamp shoe 610 mm flat shoe 2 © Category Cate- gory ] Use Precautions when using ‘A | Rocky ground, normal river soil . Normal soil, | « soft land Cannot be used on rough ground when there are large obstacles such as boulders and fallen trees | Extremely short | * c ground |. | (swampy ground) Use only for ground where “A” and “B” sink and are impossible to use. Cannot be used on rough ground where there are large obstacles such as boulders and fallen trees. D | Pavedsurface | « The shoe are flat, so they have low gadeabi * Categories “B” and “C” are wide shoe, so there are restrictions on their use. There- fore, before using, check the restrictions and consider carefully the conditions of use before recommending a suitable shoe width. If necessary, give the customer guidance in their use. 10-10 * When selecting the shoe width, select the narrowest shoe possible within the range that will give no problem with flotation and ground pressure. If @ wider shoe than necessary is used, there will be a large load on the shoe, and this may lead to bending of the shoe, cracking of the links, breakage of the pins, loosening of the shoe bolts, or other problems. 0205502055 HYDRAULIC PIPING Ceronaene 10. 1 12 13, 14, 15. 16. 7. 18. 19, 20. 2 Bucket cylinder Arm cylinder Boom cylinder ‘Swing motor RU. travel motor Control valve Oil cooler ‘Arm swing PPC shuttle valve Boom bucket PPC shuttle valve Travel PPC block Hydraulic pump Hydraulic tank LH. travel motor Accumulator Oil filter Swing lock solenoid valve Safety lock valve Travel PPC valve LH. PPC valve Center swivel joint RH. PPC valve 10-11HYDRAULIC CIRCUIT DIAGRAM s9s0z0 Feoscsoo4-1 Fees Ht =A Buches evincee Aemertete Boom evi —— un a a 3 87 Bc rey its we yar tk 10-12 ®o205cs HYDRAULIC TANK Bypass valve Filter element Bypass filter Filter check valve Filler cap Lift check vaive Sight gauge Strainer Hydraulic tank 10. Filter case © ErNogeens (oe 381 I ey a 10 F205cs005 SPECIFICATIONS Tank capacity: 240% Oil amount: 1502 Pressure valve Relief set pressure: 0.170.007 kg/cm? Suction set pressure: 0 — 0.046 kg/cm? Bypass valve set pressure: 1.05 +0.2kg/em? Filter check valve set pressure: 1.82£0.2kg/em? Lift check valve set pressure: 4.2kg/cm? 10-13OLSS (Open center Load Sensing System) =a o m4 pum Servo vate 5 valve ; — sas revane F | 20505006 OLSS (Open center Load Sensing System) is an energy-saved system to reduce the fuel consumption by means of controlling the swash plate angle (delivery) of the variable- displacement swash-plate type piston pump. Therefore this system acts to reduce the hydraulic loss during operation, to increase the fine control and to control the pump delivery. 10-14 0208¢5,205s CONSTANT TORQUE CONTROL © Constant torque control is a function to maintain the pump absorption torque at a constant level If the pump load {pressure} goes up, the pump discharge volume is decreased; on the other hand, if the pump load (pressure) goes down, the pump discharge volume is increased. © This function is carried out with the TVC valve For details of the operation of the TVC valve, see HYDRAULIC PUMP. 2. CUT-OFF CONTROL © The cut-off control is a function to reduce relief loss during operations. If the load increases, the discharge pressure of the main pump is increased; if the load comes close to the relief pressure, the discharge volume is decreased. © This function is carried out with the CO valve For details of the operation of the CO valve, see HYDRAULIC PUMP. 3. FLOW CONTROL PNC (pump neutral control} ‘© When the control levers are at neutral, the pump discharge volume is kept to the minimum to reduce the wasteful flow of oil when the control valve is at neutral. PFC (pump fine control) © When the lever is operated, the ne- cesary flow is ordered to the pump based on the flow command that corresponds with the lever travel This reduces the wasteful flow of oil that occurs during fine control © At the same time, by increasing the pump discharge pressure to the opti mum value according to the lever travel, the fine control performance is improved. * This function is carried out with the NC valve and jet sensor. For details of the operation of the NC valve and jet sensor, see HYDRAULIC PUMP. Engine torque Pump absorption paa toraue Torque (har) Engine speed (rpm) Fa0scsce Loss when there is no cutoff curort é Pump discharge volum= [¢/min J Lever travel (mm) Fr0scse Pump discharge volume (kg/n 205F05146 10-15,0205¢5, HYDRAULIC PUMP meaoge Jet sensor output pressure Pt IN port Jet sensor output pressure Pd IN port Jet sensor output pressure Pt IN port Jet sensor output pressure Pd IN port Per port Por port PNOgTaONS 205F05017 Front servo valve Front CO +NC valve Rear CONC valve Rear servo valve TVC valve Charging pump Rear main pump Front main pump 10-171, FRONT MAIN PUMP AND REAR MAIN PUMP (HPVO90 +090) Front main pump discharge PA1 port Front main pump discharge PA2 port Suction PS port Servo valve output pressure Psv1B port Charging pump pressure Psv1 port Front main pump output pressure Pat port 10-18 crore 205F05018 Servo valve output pressure Psv1A port Servo valve output pressure Psv2A port Front main pump output pressure Pat port Rear main pump output pressure Pa2 port Charging pump pressure Psv2 port Servo valve output pressure Pv2B port 20552055 Se Pg 8 9 10 U, " 12 19 14 15 18 17 1. Front drive shaft 2. Front cradle 3. Front pump case 4. Front rocker cam 5. Front piston 6. Front cylinder 7. Front valve plate 8. Front end cap 9. Impetter 10. Coupling 11. Rear end cap 12. Rear valve plate 13. Rear cylinder 14. Rear piston 15. Rear rocker cam 16. Rear pump case 17. Rear cradle 18. Rear drive shaft 19. Servo piston 18 Section C—C 205F05019, 10-192. SERVO VALVE tf o20 | P| * The drawing shows the servo valve for front main pump. NLT] Section 8—B Section C—C ] 1 «Le i & — a s bu—Os| Lf O8 SectionD-D Section EE SectionF—F SectionG—G ——sograggg0 Servo actuator port hh. CO*NC valve drain Pdr IN port ‘Servo actuator port i. CO*NC valve output pressure Pecn IN port Servo actuator port i. Charging pump pressure Ppo OUT port NC valve output pressure Pecn pick-up port k. Rear main pump output pressure Paz OUT Servo valve drain Pdr OUT port Rear main pump output pressure Pa2 IN port Front main pump output pressure Pat IN port ereaoge 10-20 port Front main pump output pressure Pat OUT port o205¢5,o205c5 Section A—A 20808021 1. Lock nut 8.Pin 15. Guide spool 2. Cover 8. Control piston 16. Spring 3.Plug 10. Lock nut 17.Plug 4. Spring 11.Plug 18. Cover 5. Body 12. Lock nut 19. Lock nut 6. Spring 13. Cover 7.Arm 14. Sleeve FUNCTION Discharge volumes Q1 and Q2 of main pumps PA1 and PA2 are controlled individually by their own servo valve. The relationship between pump discharge volume Q and input signal Pecn sent to the servo valve is as shown in the graph on the right. Q changes in proportion to Peen. Pump delivery amount Q (cc/rev)| CO*NC valve output pressure Pecn (kg/em’) 208F08022 10-21OPERATION 1) Operation for increasing pump discharges (rocker cam angle changes to the large) se bh \ \\ Psv Pecn NC valve @ Charging pump pressure Psv is sent to port a Signal pressure Pecn from the NC valve is sent from port b to chamber e. ‘@ As signal pressure Pecn rises, the pressure in chamber C pushes control piston (9) to the left in the direction of the arrow. The piston stops in a position where it is balanced with the force of springs (4) and (6), At the same time, arm (7) uses servo piston (20) as a fulcrum, moves to the left in the same way as control piston (9), and while fluctuating, moves guide spool (15) to the loft. 10-22 20505023 The movement of guide spool (15) closes port a and port d, and connects port d with drain chamber e. As a result, servo piston chamber f is also connected to chamber & through port g and port d At the same time, port a and port h are connected, and the flow passes through port i to servo piston chamber j to push servo piston (20) to the left in the direction of the arrow. The rocker cam angle of the main piston pump becomes larger, and the pump discharge volume increases. Because of the movement of servo piston (20), arm (7) rotates clockwise around pin (8), moves guide spool (15) to the right, and closes port a, port d, and port h, so the discharge volume increases only by an amount corresponding to signal pressure Pecn. 020505o20scs 2) Operation for decreasing pump iSeen ah yoy oy charges (rocker cam angle changes to the small) i CO valve @ When signal pressure Pecn drops, control piston (9) moves to the right in the direction of the arrow to a point where the hydraulic pressure of chamber ¢ is in balance with the force of springs (4) and (6). At the same time, arm (7) uses servo piston (20) as a fulcrum, moves to the right in the same way as control piston (9), and while fluctuating, moves guide spool (15) to the right. @ The movement of guide spool (15) closes port a and port h, and connects port h with drain chamber @. As a result, servo piston chamber j is also connected to chamber e through port i and port h 205F08024 At the same time, port a and port d are connected, and the flow passes through port g to servo piston chamber f to push servo piston (20) to the right in the direction of the arrow. The rocker cam angle of the main piston pump becomes smaller, and the pump discharge volume decreases. Because of the movement of servo piston (20), arm (7) rotates counterclockwise around pin (8), moves guide spool (15) to the left, and closes port a, port d, and port h, so the discharge volume decreases only by an amount corresponding to signal pressure Pecn. 10-233. TVC VALVE {8 © Section B—8 Section AA a fe 7 le | \[od Section C—C Section D-D —SectionE-€ Section F—F 205605025 . Charging pump pressure Ppo IN port 1. Spring 5. Sleeve b. Front main pump output pressure Pat IN 2. Spool 6. Piston port 3. Piston 7. Body ¢. Rear main pump output pressure Paz IN 4. Piston 8. Solenoid port d. TVC valve drain Pdr OUT port d. TVC valve output pressure Pe OUT port 10-24 20550205¢5 FUNCTION AND OPERATION 1) Main pump under —— Serve valve ‘Servo piston — TI = Trerease Discharge Pal] M FUNCTION © The TVC valve is controlled by balancing the sum of main pump discharge pressure PA1 and PA2 and TVC valve output pressure against the force of spring (1). Te valve Resistor Feoscso0s OPERATION Main pump discharge pressures PAT and PAZ are low, so spool (2) is pushed down by spring (1). As a result, charging pump discharge pressure Psv and TVC valve output pressure Pe are equal. When this happens, TVC valve output pressure Pe is maximum and the main pump discharge volume is also maximum. 10-252) Main pump under heavy load Te valve ng | co. vaive | Valve Servo piston owls] Tnerease Disetorge Control valve ‘nro! © Mahe Resistor Pat M 2058010 © When main pump discharge pressure PA1 (or PA2) increases, spool (2) is moved up by piston (4) of piston (6). As a result, the flow at port a and port b is throttled by the notch in the spool, and the area of the opening at port b and port ¢ (drain port) becomes larger. Because of this, TVC valve output pressure Pe drops and the main pump discharge volume is reduced, 10-26 @ 0205¢5020505, 4. e@reo CO + NC VALVE Charging pump pressure PRO OUT port Main pump output pressure Pat (Paz) OUT port Main pump output pressure Pa2(Pat) OUT port TVC valve output presure Pe IN port TVC valve drain Pdr port Por (Pcr) port TVC valve output pressure Pe F-R connection port Jet sensor output pressure Pd IN port Jet sensor output pressure Pt IN port %* The diagram shows the CO+NC valve for the front pump. Section A—A 20808030 CO VALVE NC VALVE 1. Plug 7. Plug 2. Piston 8.Sleeve 3. Spring 9.Piston 4. Spool 10. Spool 5. Piston 11. Spring 6.Plug 12.Plug + ( }: Forrear servo valve 10-27,FUNCTION AND OPERATION OF CO VALVE 1) When main pump discharge pressure is below relief pressure Serve valve Servo piston Decrease Tnarease Disclara Contrar valve Control valve FUNCTION © If the load increases during operation, and the main pump discharge pressure increases, when it becomes nearly the relief pressure, the CO valve carries out the cutoff function to reduce the discharge amount of the pump and reduce the relief loss. © The CO valve is controlled by balancing the spring with the sum of main pump discharge pressure PA and CO valve output pressure Pec. 10-28 Feoscsot1 OPERATION © Spool (4) is pushed down by spring (3). As a result, port a and port b are completely open, and TVC valve output pressure Pec are equal Because of this, CO valve output pressure Pec becomes maximum, and the discharge volume of the main pump is also maximum. o205cs0208¢5 2) When the main pump discharge pressure is higher than the main relief pressure Pec Pel wo bev Servo piston jecrease = Ly] Trerease meee ole Control fm © When main pump discharge pressure PA comes close to the relief pressure owing to an increase in the load, piston (5) is pushed by main pump discharge pressure PA and at the same time piston (5) is pushed by CO valve output pressure Pec. When the force of spring (3) is overcome by the pressing force of the pistons, spool (4) moves upward. As a result, the spool land restricts the oil flow from port a to port b and at the same time the opening areas of port b and port (drain port) are made larger. With angle reduced by the operation of the servo valve, the main pump discharge is reduced PAY Feoscsor2 10-29FUNCTION AND OPERATION OF NC VALVE 1) Control vaive at neutral | Pecrésse——L I increase = Servo piston FUNCTION © The NC valve controls the main pump discharge volume according to the amount of operation of the control valve spool, and caries out the function of controlling the oil flow to reduce the neutral loss and fine control loss. © The NC valve is controlled by balancing the sum of jet sensor output pressure Pt and NC valve output pressure Pecn with the sum of the force of NC valve spring (12) and jet sensor output pressure Pd © The jet sensor detects the flow of return oil Passing through the control valve and returning to the tank, and takes it as NC valve Ptand Pd. 10-30 Jet sensor 205F05024 OPERATION © The differential pressure (Pt — Pd) of the jet sensor reaches the maximum and jet sensor output pressure Pt acting on piston (10) becomes greater than the sum of the force of spring (12) and jet sensor output. Pressure Pd acting on the lower end of spool (11). As a result, spool (11) is pushed downward, causing a restriction of the oil flow between port ¢ and port b and in turn opening port b and port a (drain port). Output pressure Pt of the NC valve is then reduced to the minimum and the main pump discharge is also reduced to the minimum with the swash plate angle minimized through the operation of the servo valve. 0205¢5o205¢5 2) When the control vaive is operated Jet sensor Control valve [ severe \. Servo piston TJ—=increase Decrease © With the jet sensor differential pressure (Pt — Pd) reduced according to the operation of the control valve, spool (11) is pushed upward, fully opening port ¢ and port b. Thus, the NC valve output pressure increases. Together with the increase in the main pump swash plate angle through the servo valve operation, the main pump discharge is also increased. That is to say, the Pump discharge increases as the stroke of the lever increases. 10 Wf Pec/co tye |Psv valve | valve Li 12 20505095, 10-315. CHARGING PUMP . Relief valve Body Cover Drive gear Driven gear Filter OE PENa 10-32 205F05036 SPECIFICATIONS Theoretical delivery: 25 cc/rev Operating pressure: 32kg/cm? 20505CONTROL VALVE PC200-5 Serial No: 45001 - 53433, PC220-5 Serial No: 35001 - 36066 10-34 @ 2055o205¢5 e yessooge N io ) < Rareea i zi "= Hi OF AY Leet S aren Section € 6 Oo) Section DD Faoscsor4 6. Spool (R.H. travel) 7. Jet sensor relief valve 8. Jet sensor orifice 8. Main relief vaive 10. Spool (Swing priority) 10-39-10 ®Section E-E —— Section G-G Check valve Check valve spring Spool (LH. travel) Spool (Straight-travel) Spool (Swing priority) Spool (Swing) 10-39-11 ® Section F~F Section H-H 2055102 7. Safety-suction valve 8. Spool (Boom-Lo) 9. Check valve 10. Spool (Boom-Hi) 11. Safety-suction valve ‘0205¢52055, Section kK ~ K 10 ° oO}; (oe 7 Section L-L Froscs1t3 Safety-suction valve 6. Check valve Spool (Bucket) 7. Spool (Arm-Lo) |. Spool (Arm throttle) 8. Safety-suction valve Spool (Service) 9. Check valve Spool (Arm-Hi) 10. Spool (RH. travel) 10-39-12TRAVEL SHUTTLE VALVE = Section C— 4 Section D—D a. Peport Pr port (To tank) 1 b. Paport (From boom + bucket Poport (To straight-travel valve) 2. shuttle valve) P1 port (From LH. travel control 3. ©. Psport (From swing shuttle valve) _—_valve), 4. d._P3port (From arm shuttle valve) P2 port (From LH. travel control e. Paaport (To arm throttle valve) valve) f. Psaport (To swing priority valve) 10-40 ® 205F05623 Cover Spool return spring Body Spool oz0scs0205¢5 FUNCTIONS © The travel shuttle vaive is installed to the top of the 4-spool valve control valve. It takes the PPC valve pressures from the left travel, work equipment, and swing, and sends pilot pressure to the straight-travel valve when the travel and work equipment or swing are operated at the same time. OPERATION Travel lever at “FORWARD” (other levers at “NEUTRAL") ‘@ Pilot pressure oil flows to P1 port from the left travel circuit and pushes the spool to the right Therefore, ports P3, P4, PS and PO are connected through the groove in the spool, and are also connected to the straight-travel valve. However, there is no flow of pilot pressure oil from the shuttle valves of the PPC valves, so the straight-travel valve is not actuated. (When operating in “REVERSE”, pressure oil is sent to port P2, and pushes the spool to the left) During simultaneous operation © When the arm and travel FORWARD are operated at the same time, pilot pressure oil flows from the left travel circuit to port P1 and pushes the spool to the right. @ At the same time, when the arm is operated, pilot pressure oil flows to port PS from the shuttle valve of the arm PPC valve This passes through the groove in the spool and port PO, and then flows to the straight-travel valve © The pilot pressure oil from the shuttle valve of the swing PPC valve flows port P5—~ Port PO—straight-travel valve, and the pilot pressure oil from the shuttle valve of the boom and bucket PPC valves flows port P4— port PO— straight-travel valve. From LH. travel FORWARD circuit travel valve To auto- <> = deceleration a ollpressure | switch j Pp Pad From shuttle valve From shuttle ‘ofarm PPC valve val bucket PPC. val From LH travel To straight- FORWARD circuit travel vealve Toauto- = deceleration Pe bil pressure Switehy Ped From shuttle valve of oy From shuttle valve of arm PPC valve From iH travel REVERSE circuit Toarm = ep throttle valve FFELP To swing [Psa priority valve a ‘ofboom From shuttle valve of swing PPC valve 208F2032-2 FromLH. travel REVERSE crit, Toarm D> throttle valve [FED To swing [Pee priority valve ae From shuttle valve of ‘boom, bucket swing PPC valve PPC valve 208F2032-2 10-41STRAIGHT-TRAVEL VALVE FUNCTION @ While operating the swing, boom, arm, or bucket when traveling, the pressure oil flowing to the RH. and LH. travel circuit branches into the swing, boom, arm, or bucket circuit. Since the supply of pressure oil in a branched travel circuit is less than that in the circuit before the branch, the motor naturally slows down, resulting in a turn, @ When the straight-travel vaive is switched over to establish continuity between the RH. and LH. travel circuits, this undesired turning is prevented by equalizing the supply of pressure oil to the RH. and LH. travel motors so that they rotate at the same speed. OPERATION When traveling only ‘@ Since no pilot hydraulic oil flows from the shuttle valve in the PPC valve, no hydraulic il flows from the travel shuttle valve to the straight-travel valve. @ Therefore, the circuit between port PR (RH. travel circuit) and port PLILH. travel circuit) remains closed and both circuits remain independent. While operating the swing, boom, arm, or bucket when traveling © Spool (1) of the straight-travel valve is Pushed to the right by the pilot pressure from the travel shuttle valve. © Port PR and port PL then become connected to each other and an equal amount of pressure oil is supplied to the RH. and LH. travel motors, allowing both motors to rotate at the same speed. The machine trav- els thus in a straight line. 10-42 2osFos082 Ml Be Kecovel’s (poate 205F05043, 0205¢5o208¢5 SWING PRIORITY VALVE FUNCTION © When operating the swing and arm at the same time, most of the oil flows to the arm, which has less load. The flow of oil to the swing circuit is reduced so the arm speed is faster than the swing speed. This makes combined operations difficult © To prevent this, the swing priority valve is switched to restrict the flow of pressure oil to the arm-Lo control valve. This restricts the arm speed and makes it easier to operate the arm and swing at the same time. OPERATION ‘When swing is at neutral @ No pilot pressure oil flows from the travel shuttle valve, so the swing priority valve is not switched. Because of this, the pressure oil from the front main pump passes through port Pr and all the oil flows to the arm-Lo control valve. When swing is operated @ When the swing is operated, spool (1) of the swing priority vaive is pushed to the left by the pilot pressure from the travel shuttle valve Because of this, the pressurized oil flowing from front main pump ~ port Pr to the arm-Lo control valve is throttled, and the arm speed is controlled, so the simultaneous operation performance is improved. aaa valve: 205F0s044 205F05048, 10-43ARM THROTTLE VALVE FUNCTION @ When the arm control lever and boom control lever are operated at the same time, most of the pressure oil flows to the arm circuit, where the load is less. The amount Of oil flowing to the boom circuit drops, so the arm speed is faster than boom speed. This makes combined operations difficult. (particularly when using "ARM OUT” and “BOOM RAISE” at the same time.) When this happens, the arm throttle valve is ‘switched and the flow of oil to the arm-Hi control valve is restricted. This regulates the arm speed and makes combined operations easier. OPERATION When arm is operated independently © The pilot pressure does not flow from the travel shuttle valve, so the arm throttle valve is not actuated and the pressure oil from the rear pump passes through port Pt and all flows to the arm Hi control valve, Simulataneous operation ‘¢ When the arm is operated together with the boom or bucket, the pilot pressure from the travel shuttle valve pushes spool (1) of the arm throttle valve to the left. When this hap- Pens, the flow of pressure oil from the rear Pump to the arm Hi control valve is throttled, and the arm speed is controlled to improve the ease of simultaneous operation 10-44 © The arm is actuated by the merged oil flow from two pumps, and the bucket is actuated by the flow from one pump. For this reason, when the arm and bucket are operated together, the flow of oil to the arm circuit is greater, so the arm moves much faster than the bucket. This makes ‘combined operations difficult. (Particularly when using “ARM QUT” and “BUCKET CURL" at the same time.) ‘When this happens, the arm throttle valve is. switched and the flow of oil to the arm-Hi control valve is restricted. This regulates the arm speed and makes combined operations easier. ‘arm-Hi [Seoign-vavay) Travel abate) 205F0S046 208F05087 o20sc5,SWING MOTOR S port MB port (From control valve) MA port (From control valve) T port (To tank) B port (From swing lock solenoid valve) peaose 10-46 F20scso15 SPECIFICATIONS Type: KMF9OAB-2 Theoretical delivery: 87.8cc/rev Safety valve set pressure: 290 kg/cm? Rated speed: 2,132 rpm (PC200) 2,288 rpm (PC220) Brake releasing pressure: Max. 14kg/cm? 0205¢5020505 Section 8-8 1. Brake spring 2. Drive shaft 3. Cover 4, Housing 5.Dise 6 Plate 7. Brake piston 8. End cover 9. Piston Section €~ C 20505016 10. Cylinder 11. Valve plate 12. Air bleeding plug 13. Center shaft 14. Center spring 18. Safety valve 16. Check valve 17. Check valve spring 10-47‘SWING HOLDING BRAKE OPERATION 1) When swing lock solenoid valve is deactivated When the swing lock solenoid valve is deactivated, the pressurized oil from the charging pump is shut off and port B is connected to the tank circuit. Because of this, brake piston (7) is pushed down in the direction of the arrow by brake spring (1), so disc (5) and plate (6) are pushed together and the brake is applied. 2) When swing lock solenoid valve is excited When the swing lock solenoid valve is excited, the valve is switched, and the pressurized oil from the charging pump enters port B and flows to brake cham: ber a. The pressurized oil entering chamber a ‘overcomes the force of brake spring (1), and brake piston (7) is pushed up in the direction of the arrow. Because of this, disc (5) and plate (6) separate, and the brake is released, 10-48 _ aA ‘Charging ‘Swing lock pump solenotd valve 205F05050 Excited ) 1 Charging Swing lock pump soleneid vane 205F05051 o205c50205¢5 CENTER SWIVEL JOINT gReNe Cover Body Slipper seal Oil seal Shaft AL A2 Bi Ba: cr c2: From control valve ASR port To RH. travel motor PB port From control valve P1L port To LH. travel motor PB port From control valve BSR port To RH. travel motor PA port D1 D2: Fl F2: " 72. oO U 208F05056 From control valve A1L port ToLH. travel motor PA port (Blind) (Blind) To tank From LH. and RH. travel motor T port 10-49 3%TRAVEL MOTOR a, PA port (From control valve) b. PB port (From control valve) ¢. T port (To tank) 10-50 206F2036A SPECIFICATIONS Type: KMFS0ADC-2 Theoretical delivery: 87.8 co/rev Safety valve set pressure: 360 kg/cm? Rated speed: 2,150 kg/cm? Brake releasing pressure: 11 + 2 kg/cm? Spool switching pressure: 8.5 + 1.2 kg/cm? o205¢50205¢5 SN emeenas Section AA Section8 — B - Housing Brake piston Plate Disc Brake case Output shaft Center shaft Valve plate 9. Piston 10. Cylinder block 11. Center ball 12. Spring 13. Spool return spring 14. Counterbalance valve spool 15. Housing 16. Check valve spring Section ~ 0 205F20408 17. Check valve 18. Adjustment screw 19. Lock nut 20. Sleeve 21. Safety valve spring 22. Pilot piston 23, Safety valve 10-51PARKING BRAKE OPERATION 1, Travel control lever moved from “neutral” to “travel” position: The pressure oil from the main pump passes through the travel control valve and is sent to the travel motor and travel brake valve, The pressure oil which flows to the travel brake valve moves the counterbalance spool of the travel brake valve, and flows to the parking brake The pressure oil which enters chamber F of the parking brake is connected to the tank drain circuit. ‘Counterbel E \ Sontol valve -> neo Sa f / / Travel brake valve 10-52 To motor U However, it is restricted by throttle C, so the pressure rises and pushes brake piston (2) to the left For this reason, the force pushing discs (4) and plates (3) are removed, and output shaft (6) which is meshed with the discs is released. Therefore, the travel motor can rotate. In addition, brake piston (2) is pushed against housing (1), so the outlet port of throttle C is closed and the parking brake is kept free. i I 205050205¢5 2. Travel control lever moved back from “travel” to “neutral”: The flow of oil from the travel control valve to the travel motor and travel brake valve stops, so the counterbalance valve spool of the travel brake valve tries to re turn to the neutral position. When this happens, the pressure in parking brake pressure chamber F drops and brake piston (2) is pushed back by springs (12). When brake piston (2) is pushed back, a gap is formed between the brake piston and housing (1). counterbalance valve 29001 Travel orake valve The output port of throttle C is connected to the inside of housing (1), and the oil is drained. (The inside of the housing is connected to the tank drain circuit.) For this reason, brake piston (2) is pushed back by springs (12), and plates (3) and discs (4) are pushed against the brake case. As a result, output shaft (6) cannot rotate and the brake is applied. 3 ste! 4 (Oise) 10-53BRAKE VALVE 1) Counterbalance valve Function When driving the machine downhill, the sprocket rotates more quickly than the revolution of travel motor due to its own weight, thus tending to accelerate motors. However, with the employment of the counterbalance valve, load is applied to the motor so that the machine will travel in confirmity with the engine speed. Operation When oil starts flowing: When the travel control lever is changed either to “F" or “R", oil from the main pump enters the Pa port via the travel control valve, and pushes check valve C1 When the hydraulic pressure applied to check vaive C1 is increased, check valve C1 is moved and oil flows to motor outlet port MB via motor inlet port MA, and then to the opposing side of the spool. However, the outlet (PB port) is closed with check valve C2; therfore, the oil flow stops. As a result, the travel motors do not rotate. And the oil pressure is further increased, the oil pressure in chamber Et at the left of spool (14), increases. When the oil pressure is boosted to 7.3 — 9.7 kg/em®, spool (14) moves to the right, allowing the oil to flow out from Dz of spool (14) to PB port. The oil finally returns to the hydraulic tank. In this way, the travel motor starts rotating. When the machine is traveling downhill: Due to its own weight, the travel motor rotates quickly than the revolution of motor normally with the oil. Therefore, the oil pressure on the inlet side MA of the motor decreases. When the oil pressure in chamber E1 decreases to less than 7.3 — 9.7 ka/ m?, spool (14) moves to the left, thus blocking the oil from flowing out from D2 of spool (14). As a result, the oil pressure on the outlet side MB of the motor rises. As this oil pressure works as a resistance to the motor, the machine is prevented from traveling at a speed higher than the engine speed. As it is clear from the above, the machine cannot travel at a higher speed other than that conforms to the regulated engine speed. 10-54 ~o AF conwotvaive |* a o205c50205¢5, 2) Safety valve Function When stopping the machine or driving downhill, the circuit for motor outlet port is closed or throttled by the counterbalance valve, but the motor trys to rotate by inertia so that the oil pressure on the outlet side of the motor rises. And this may damage the motor and piping. So the oil pressure on the motor outlet side relieves to the motor inlet side. Operation When stopping the machine or driving downhill, the circuit for motor outlet port E is closed or throttled by the counterbal ance valve, but the oil pressure of motor outlet port E rises by the inertia of motor. © When the pressure in chamber E reaches the safety valve spring force (set pressure), @ differential pressure occurs between chamber E and G (according to the difference between D1 and D2), moving safety valve (11) to the right. This allows the oil in chamber E to flow into chamber F. 10-55o205c5, VALVE CONTROL Nogeena 5 ee at eee a Berd LM. swing ory) LH. travel control valve RH. travel control valve RH. PPC valve R.H. work equipment control lever Control lever ‘Arm swing PPC shuttle valve Boom « bucket PPC shuttle valve Feoscso17 8. Hydraulic pump 9. Travel PPC block 10. Accumulator 11. Safety lock valve 12. Travel PPC valve 13. LH. work equipment control valve 14. LH. PPC valve 10-57PPC VALVE PC200-5 Serial No: 45001 - 58018 PC220-5 Serial No: 35001 - 36613 FOR WORK EQUIPMENT AND SWING P port (From charging pump) T port (To tank) P3 port (LH.: arm in/RH.: bucket dump) P2 port (LH: RH. swing/R.H.: boom lower) Pa (LH. arm out/RH.: bucket curl) Pt port (LLH.: LH. swing/RH.: boom raise) seaoge 10-58 @ 205F05068 205s2055 Section A~A 1. Spool 2. Metering spring 3. Centering spring 4. Pilot piston 5. Pilot spring 6 Piston Section C—C Section 8—B Section D-D 205F08069 7.Dise 8. Lever 9. Joint 10. Plate 11. Collar 12. Body 10-59OPERATION 1) Atneutral Ports P1 and P2 of the PPC valves in circuits A and B of the control valve are connected to drain chamber D through fine control hole f in spool (1). (Fig. 1) 2) Control lever operated slightly (fine control) When piston (4) starts to be pushed by disc (2), retainer (7) is pushed. Valve (10) is also pushed by spring (9) and moves down. When this happens, fine control hole f is shut off from drain chamber D. At almost the same time it is connected to pump pres sure chamber Pp, and the pilot pressure of the control valve is sent through fine control hole f to port P1. When the pressure at port Pt rises, valve (10) is pushed back. Fine control hole f is shut off from pump pressure chamber Pp. At almost the same time it is connected to drain chamber D, so the pressure at port P1 escapes to drain chamber D. Valve (10) moves up and down until the force of spring (9) is balanced with the pressure of port P1 The relationship of the positions of spool (1) and body (12) (fine control hole f is in the middle between drain hole D and pump Pressure chamber Pp), does not change Until damper piston (4) contacts piston (6) Therefore, spring (8) is compressed in pro- Portion to the travel of the contro! lever, so the pressure at port P1 also rises in proportion to the travel of the control lever. The ‘spool of the control valve moves to a position where the pressure of port A (same as pressure at port P1 and the force of the return spring of the control valve are balanced. (Fig. 2) 10-60 Control valve Fig. 205605072 20805073 0205¢50205¢5 3) During fine contro! (control lever returned) When disc (7) starts to be retumed, spool! (1) is pushed up by the force of centering spring (2) and the pressure at port P1 Because of this, fine control hole f is connected to drain chamber D, and the pressurized oil at port P1 is released. If the pressure at port P1 drops too much, spool (1) is pushed up by metering spring (2), so fine control hole f is shut off from drain chamber D. At almost the same time it is connected to pump pressure chamber Pp, 80 the pressure at port P1 supplies the pump pressure until the pressure recovers to a pressure equivalent to the position of the lever. When the control valve spool returns, oil in drain chamber D from fine control hole f' of the valve on the side that is not moving flows through port P2 and goes to chamber B, so the oil is charged. (Fig. 3) 4) At full stroke Disc (7) pushes down piston (6), but damper piston (4) also follows this and pushes down spool (1). Fine control hole f is shut off from drain chamber D, and is connected to pump pressure chamber Pp Therefore, the pilot pressure oil from the charging pump passes through fine control hole f and flows to chamber A from port P1 to push the control valve spool. The return oil from chamber B passes from port P2 through fine control hole 1” and flows to drain chamber D. With damper piston (4) that was following piston (6), the pressurized oil in the spring chamber flows out from orifice a, and damper piston (4) and spool (1) are pushed back by the force of metering spring (2) and the hydraulic pressure at port P1 The time lag when the lever is suddenly operated is prevented by damper piston (4) (During fine control, damper piston (4) does not follow piston (6), so the fine control performance is maintained.) (Fig. 4) Control valve Control valve Fig. 4) Fig. 3) 208F05074 205F05075 10-61 3PC200-5 Serial No: 58019 and up PC220-5 Si No: 36614 and up FOR WORK EQUIPMENT AND SWING 10-61-1 @ seacge zorr0%082 P port (From control pump) T port (To tank) Pz port (L.H.: Arm dump/R.H.: Boom lower) Pa port (L.H.: Swing left/R.H.- Bucket curl) 1 port (L.H.: Arm curl/R.H.: Boom raise) 3 port (LH.: Swing right/R.H.: Bucket dump) 0205¢50205¢5 Section € — See re 10-61-2 aOPERATION 1) Atneutral Ports A and B of the control valve and ports P1 and P2 of the PPC valve are connected to drain ‘chamber D through fine control hole f in spool (1). Fig. 1) 2) During fine control (neutral ~ fine contro!) When piston (4) starts to be pushed by disc (6), retainer (9) is pushed; spool {1) is also pushed by metering spring (2), and moves down, ‘When this happens, fine control hole f is shut off from drain chamber D, and at almost the same time, it is connected to pump pressure chamber Pp, so pilot pressure oil from the charging pump passes through fine control hole f and goes from port P1 to port A. When the pressure at port P1 becomes higher spool (1) is pushed back and fine contro! hole {is shut off from pump pressure chamber PP At almost the same time, itis connected to drain. chamber D to release the pressure at port Pt When this happens, spool (1) moves up or down sothat the force of metering spring 2) is balanced with the pressure at port P1. The relationship in the position of spool (1) and body (10) (fine control hole fis at a point midway between drain hole D and pump pressure chamber Pr} does not change until retainer (9) contacts spool (1) Therefore, metering spring (2) is compressed proportionally to the amount of movement of the control lever, so the pressure at port Pt also rises in proportion to the travel of the control lever. In this way, the control valve spool moves to 8 position where the pressure in chamber A (the same as the pressure at port Pt) and the force of the control valve spool return spring are balanced. (Fig. 2) 10-61-3 o (Fig.2) 0205¢5ozoscs 3 4) During fine control (when control lever is returned) ‘When disc (5) starts to be returned, spool (1) is pushed up by the force of centering spring (3), and the pressure at port Pt When this happens, fine control hole f is connected to drain chamber D and the pressure oil at port Pr is released If the pressure at port P1 drops too far, spoot (1) is pushed down by metering spring (2), and fine control hole fis shut off from drain chamber D. At almost the same time, it is connected to pump pressure chamber Pr, and the pump pressure is supplied until the pressure at port Pi recovers to @ pressure that corresponds to the lever position. When the spool! of the control valve returns, oil in drain chamber D flows in from fine control hole fin the 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) At full stroke When disc (8) pushes down piston (4), and retainer (9) pushes down spo! (1), fine control hole f is shut off from drain chamber D, and is connected with pump pressure chamber Pr Therefore, the pilot pressure oil fom the charging pump passes through fine control hole f and flows to chamber A from port P1, and pushes the control valve spool The oil returning from chamber B passes from port P2 through fine control hole f° and flows to drain chamber D. (Fig. 4) Pi Pa] (Fig.3) (Fig 4) 10-61-4 3FOR TRAVEL P port (From charging pump) T port (To tank) . P2 port (LH. reverse) P4 port (RH. reverse) Pt port (LH. forward) P3 port (RH. forward) seaoge 10-62 ®@ 205F05070, o205¢5o205c5, BONG Section AA i Q ot bel Le “buy <4 Spool ‘Metering spri Section C—C ing Centering spring Piston exo Bolt Plate Collar Body PP) P) Pp] | Section 8-8 © ©) © ©) Section D—D 208505071 10-63 5ACCUMULATOR Gas plug Shell Poppet Holder Bladder Oil port OORONa SPECIFICATION Gas capacity: 300 ce 20805076 SAFETY LOCK VALVE Lever Body Seat Ball . End cap gReNe Faoscsoi8 10-64 o205cs,20505, SWING LOCK SOLENOID VALVE 1 No: 45001 - 58018 1 No: 36001 - 36613 Connector Plunger Coil Spring Spool Body Plug Nogaene 208F05082 OPERATION Solenoid deactivated ‘* No signal current flows from the switch, so coil (3) is deactivated. As a result, spool (6) is kept in the neutral Position by spring (4) Because of this, port P is closed, and the pressurized oil from the charging pump does not flow to the swing motor. At the same time, the oil from the swing motor flows from port A to port T and is drained to the tank. Solenoid excited When the signal current flows from the ‘Swing switch, coil (3) is excited, and plunger (2) is r ov 4 ce pushed to the right in the direction of the arrow. As a result, spool (5) is also pushed to the right in the direction of the arrow. Because of this, port P and port A are in- terconnected, and the pressurized oil from the charging pump flows to the swing motor. At the same time, port T is closed, ‘so the oil does not flow to the tank. 205F05084 10-65PC200-5 Serial No: 58019 and up PC220-5 Serial No: 36614 and up Section A~ A 205F05627 OPERATION Solenoid deactivated ‘* The signal current from the controller does not flow, so coil is deactivated. * Asa result, port P is closed, and the press. ure il from the charging pump does not flow to the actuator. At the same time, the oil from the actuator flows from port A to port T, and drains to the tank, Solenoid excited © When the signal current from the controller flows to coil, coil is excited. * Because of this, pressure oil from the charging pump flows from port P to port A, and then flows to the actuator. At the same time, port T is closed, so the oil does not flow to the tank. 10-65-1 @ Connector Plunger Coil Push pin Spring Spool Body Nogsene Deactivated Excited Swing motor 205F 05828 T 205F 05829 oz0scsSHUTTLE VALVE FOR BOOM AND BUCKET of Section AA SectionB — 8 Fa0scsor9 FOR ARM AND SWING OQ) Section A~A 205F05088 10-66 Plug Ball Body Plug AEN P1A port (Bucket dump} P3A port (Bucket curl) PAA port (Boom raise) P2A port (Boom lower) P5 port (Travel shuttle vaive) P3B port (Bucket curl) P1B port (Bucket dump} 2B port (Boom lower) P4B port (Boom raise} rzereapge Plug Body Ball P1B port (Swing right) PS port (Swing oil pressure switch) P2B port (Swing Left) PAB port (Arm in} P6 port (travel shuttle valve) P3B port (Arm out) |. P2A port (Swing left) P1A port (Swing right) P3A prt (Arm out) PAA port (Arm in) o205cso20scs HYDRAULIC CYLINDER 1. BOOM CYLINDER 205FOSO94 18 "7 20sF05095 1 2 38 45 6 1 10 11 12:13 14 18 208705096 1. Bottom side bushing 7.Cylinder 13 Piston 2. Piston rod 8 Head side tube 14, Piston nut 3. Cylinder head 9. Head side cushion plunger 15, Bottom side tube 4. Rod packing 10. Ring 16, Bottom side bushing 5. Buffer ring 11. Piston ring 17. Bottom side cushion plunger 6. Wearing 12. Wear ring 18. Ball 10-67SPECIFICATIONS Unit: mm oS Cylinder Boom 7 Arm Bucket Item Pc200 | Pc220 | Pc200 | Pc220 | Pc200 | Pc220 Rod outside diameter 120 130 135 140 115 130 Cylinder inside diameter 85 “80 95 100 80 90 Stroke 1,285 1275 | 1490 | 1,635 | 1,120 | 1,020 Maximum length 3,160 | 3,135 | 3,565 ‘3870 2,800 | 2,625 Minimum length 1.875 | 1.860 | 2078 2,235 | 1,680 | 1,605 - Piston nut width across flats 85 95 95 95 85 95 10-68 205sELECTRICAL CIRCUIT DIAGRAM ‘connector type, Number of ins PC200-5 Serial No: 45001 - 56338 cn-CLY) ( PC220-5 Serial No: 35001 - 36437 Basic code Not dined one _ Connector No This ms ele on , —— traci or trouterhotng) She asine and in ower! [Tight Wper__—]__Fuse box connection table ee Governor motor S| == J eit We rita ong eet pe EGR, og itstfan Pyemonee : Head lam — 38 cr Sane PS te 3 = 7 nes Ie mes pS $ F = t - qemeot erst, || fm GES) wet aa sf] 87] Sd Working ln J | Sb EB aS] a8 == S8lz ' \ i 7 ‘ Engine rote i | ay a a4 | {]| speaker U } = j cy-mu.2) : ale Oe be Cy ies oy) iid] - cal eee 8 | Fusibte nk | | oe 9 PATH Shas —_ fh ; Room lamp “ 8 yo Foe cont 3 es ey Z — Hmm SH = sae e Staring awitch a paces teri mit 3 or a heater | Magntc tach af compressor = 5 for goon or cer =, ee 1 esse z Eyl: i La Woringbuzer ey -Larty 1 [n—ittéee¢ —t-L ans He cuts owe 5 contat , Wing motor esa) HESS) iat senor Fae (3 t rad 2 Perea fae = jercwzaone) | ‘CN-M27 —{- SE 4% |Rovolving Floor —_ a . sane - ee Sie See ALPBOKA Coot el ner f mt ea oases = | ol Js) Sit a Free sled cwmeswesa) | | 2 fe poset ste || E ese EEE gay + an | 2\ tonatloner 5) | a + aial eee i Bud : 3 ) ae orem E boas ight relay Hester. Heater per relay |___Manat~ = Ugh reley it relay Lo relay ae ~ a Faoscsm0 -—-10-69 2C2005 PC220-5 Seri Fuse box connection table No: 56339 - 58018 No: 36438 - 36613, Monitor panel switch output w Connector type, Number of pins a q-no ( Fee. : ale eter panes’ ee ee Sane eee aoe + ; = “ON o fy] machine or in troubleshooting) ‘the machine and in troubleshooting) : Pe pee! By s Batter relay % wa geet fog Swing lock 2 {Shel j epi ( $1 solenoid valve 7 a tier leva cum) ay ae ee : T| speaker Fusible link \- ne Anema | ea 3 | Engine + | ‘TVC valve [ fais fp | | EG & 7 Peers te [ [see | GeMONR Mo, ! a | } _— wm (Q5 ea cere | G o Opie iL ovr) worse go ter TH : :) — ‘ai | i 4 _ | Feat es | cease) | owes |swee orpesix [Het ) = ror F set | dee Lae | co, per motor Kes as) E = se oe : | PTX?) sensor NS SES | EE / 1 ek) i 1 fi ‘ T ~ Ve eLepate | e mgm cu Oe pressure sensor a aed | eer) feet _ — oe | ee OO ae” | oh \ Se eae 5 fe =a sae/ a) nets = @ fF : | erg) Fo esr I | L as | F eae mau me 3 aw eotioer o coor Semis any WE Cee ET eng ont on-D3 Ls tu 4 t L 2 rel Hester Heater jiper rel \htrelay relay Lo relay ees CN MIG CN-MI7 o205c50205¢5 lo: 58019 and up No: 36614 and up Fuse box connection table Monitor pane! switch output Connector type, Number of pine oa ee qr | : bese code Wot dgayed on enact oie number i tye on er = r dine etvtauienarg!” aan roan Suse 3} eee an 2 caer ty Sing a See e j - ome ME, pexieny aa : Fusibie Wok ag [lave cr _ — HY i ‘ TWewene SS Hor | I | __ | bs dav ° Head amp io] I rd: 388 I lif 1 | |~retectrical intake Pal | | [eee GMO mmo, ! Hh Pee ae : : so | il Hh of or silt cn-Mia(ss) CAPSIXL) cums comune ea ‘cP TOKe) sensor Fee) | 9 te Window washer [es jenn | sien caveqoee) Coot lel ear Z Sl g ee 7 es) g a Stentor pane EDS 4 “I Light retoy ie, Tees, Wiper relay _ ae Faosco114 10-70-1 ®2085 ENGINE CONTROL SYSTEM PC200-5 Serial No: 45001 - 56338 PC220-5 Serial No: 35001 - 36437 ELECTRICAL CONTROL TYPE Engine Sarg mower tf Fuel control dia signal) per ote Starting switch Mrrotte signal) Engine throne controller |” (starting switch ON signal) Monitor pane! (Power source) (Warming-up signa!) OUTLINE * The engine can be started and stopped simply by using the starting switch. * The engine speed can be controlled using @ dial control system for the fuel control. '* The engine control system is provided with an automatic warming-up function that raises the engine speed to warm up the engine after the engine is started, 20805021 10-71 3GOVERNOR MOTOR LINKAGE r ety Full speed = Fa0scsts Locknut Yoke Governor motor Spring assembly Engine governor Pens 10-72 © o205¢50205¢5 1. OPERATION OF EACH FUNCTION 1) OPERATION OF ENGINE START, STOP, SPEED CONTROL Starting engine @ When the starting switch is tumed to the START position, the start signal flows to the starting motor, and the starting motor turns to start the engine. When this happens, the engine throttle controller checks the signal voltage from the fuel control dial and sets the engine speed to the set speed. Engine speed control ‘@ The fuel contro! dial sends a signal voltage to the engine throttle controller according to the position of the dial The engine throttle controller calculates the angle of the governor motor according to this signal voltage, and drives the governor motor so that it is set to that position. When this happens, it detects the operating angle of the governor motor using @ potentiometer and observes the governor motor Stopping engine @ When the engine throttle controller detects that the starting switch is at the STOP position, it drives the governor motor to set it to the NO INJECTION position, and stops the engine. When this happens, to maintain the electric power in the system until the engine stops completely, the engine throttle controller itself drives the battery relay. 3 = 3 208F05108-1 Starting oy ee t © | = | | — Fuel dial “ 208F05107-12) OPERATION OF AUTOMATIC ENGINE WARMING-UP FUNCTION Actuated Canceled Conditions. Coolant temperature: Less than 30°C Fuel control dial: Below set speed [set speed: 1,200 rpm] ‘* — Ifall the above conditions are satisfied, the automatic warming-up function is actuated Coolant temperature: Above 30°C Fuel control dial: Held above 70% of high idling for more than 3 sec. Warming up time: At least 10 minutes % If any of the above conditions is applicable, the ‘automatic warming-up function is canceled. Action Engine speed: 1,200 rpm Engine speed: As desired 10-74 0205¢50205C5 2. COMPONENT EQUIPMENT OF SYSTEM 1) ENGINE THROTTLE CONTROLLER View2 1 1. Self-diagnostic display LEDs 205F05108 Input and output signals Pin No, Nome of signet eet Tein No Name of signal co 1 Power source + vB Input | 12 | Power source ground GND Input 2_| Sterting switch ON signal KON | Input | 13 | Battery relay drive Br [output 3 | Motor drive A A [output] 14 | Motor drive & % [output | 4 | Motordrive 8 8 [output] 15 | Motordived S_[ouput| 5 | Potentiometersigns! __APSIG [Output] 16 | PotentiometerGND AP [Output 6 | Potentiometer power ap. loutput| 17. | Model selection SEL | Input ae cients oon sP+ [output] 18 | Potentiometer GND SP — [Output 8 Potentiometer signal SPSiG | Input | 19 | No.2 throttle PC— | Input 8 | No.2 throttle Pc+ | input | 20 | Throwte sA— [Output 10 = i = [21 | Warming-up signal TL | input Ww - - = Lo 10-75Control function of controller © The engine throttle controller receives the input signals shown in the diagram on the right, processes these internally and sends output signals to the governor motor, and battery relay. 1) Engine speed set function using fuel control dial ‘An output signal that matches input voltage a corresponding to the position of the fuel control dial is sent so that the governor motors set to turning angle b. ‘Turning angle b is fed back to the controller by the potentiometer signal, and the operation of the governor motor is always observed 2) Automatic warming-up function using warming-up signal from monitor After the engine is started, if the engine water temperature is low; the monitor sends the warming-up signal to the engine throttle controller. When this signal is received, the engine throttle controller raises the engine speed to carry out warming up. 3) Engine stop switch signal When the starting switch is turned OFF, the engine throttle controller detects this and drives the battery relay to maintain the electric power. At the same time, it drives the governor motor to pull back the fuel injection pump lever to the STOP position. function usi 4) Self-diagnostic function Three LEDs (red, green, red) light up and go out to indicate that the machine is normal, or to indicate the location of any failure when any abnormality occurs. * For details, see the SHOOTING. ‘TROUBLE- 10-76 ® input signal) (Output signal Engine throttle Governor motor turning angle Fzoscs0z2 Controller output characteristics / ising {engine speed) 7 Fuel contro dial output voltage (V) 20} {Governor motor| Fuel control dial output ‘operating range | characterstics Fuel control dal position 208F05110 Starting switch —2% __ Operation of governor motor Battery relay] oF = drive signal 250 205F05111 o205¢50205¢5 Internal structure of controller © The inside of the controller consists of the input circuit, microcomputer, and drive circuit shown in the diagram on the right, and these have the various functions described below. 1) Input circuits These receive the signals from the fuel control dial {throttle signal), monitor (warming-up signal), and starting switch (start signal), and send them to the microcomputer. In this portion, the noise in the signal is removed and the wave pattern of the signal is regulated. In addition, it makes the power source (approx. 5V) for the governor motor potentiometer and fuel control dial 2) Microcomputer The angle of the governor motor is calculat- ed from the input signals sent from the input circuits, and the pulse signal to drive the governor motor is sent to the drive circuit 3) Drive circuit The pulse signal sent from the microcomputer is used to switch the direction of the current flowing to the governor motor to rotate the motor clockwise or counterclockwise. Sensor di Hey Itt Input circuit Microcomputer Drive circuit Governor motor, etc. 205F05112 10-772) FUEL CONTROL DIAL Machine _forward FUNCTION ‘© This is installed under the monitor panel. A potentiometer is installed under the knob, and when the knob is turned, it rotates the potentiometer shaft. This rotation changes the resistance of the variable resistor inside the potentiometer, ‘and sends the desired throttle signal to the engine throttle controller. The shaded area in the graph on the right shows the abnormal detection area, and the engine speed is set to low idling, 10-78 } a Perens ee Composition of circuit Dial angle 205F08113, Throttle voltage characteristics (V) Knob Dial Spring Ball Potentiometer Connector IS 205F05114 0205¢502055 3) GOVENOR MOTOR Potentiometer Cover Shaft Dust seal Bearing Motor Gear Connector @VETAONG Section A— A G3 FUNCTION @ The motor is rotated and the governor lever Of the fuel injection pump is controlled by the drive signal from the engine throttle controller. © A stepping motor is used for the motor which provides the motive power. In addition, @ potentiometer to give feed- back is installed to allow observation of the operation of the motor. The rotation of the motor is transmitted to the potentiometer through a gear a — Composition of circuit 20508115 OPERATION Motor stationary © Both A phase and B phase of the motor are continuous. Motor rotating © A pulse current is applied to the A phase and B phase by the engine throttle controller to give synchronous rotation with the pulse. 10-78-14) LOOSE SPRING 10-78-2 ® 208F 05853 ep ReNe Yoke Pipe 9 Spring Rod 0205¢50208¢5 PC200-5 Serial No: 56339 and up PC220-5 Serial No: 36438 and up, MECHANICAL CONTROL TYPE Full laling ‘stop 1 1. Cable 2. Fuel control lever 3. Engine 4. Fuel injection pump 208Fcos00! 10-78-3 a0205¢5 EMACC (ELECTRONIC MONITOR AND CONTROL CONSOLE) Monitor pane! Sensor signal Sensor Battery © The electronic monitor and control console (EMACC) observes the condition of the machine through the sensors installed to various parts of the machine, and processes this information quickly. The system informs the operator of the condition of the machine by displaying the condition on the panel. The content of the panel displays can be broadly divided into the following. 1. Monitor portion that gives warnings when any abnormality occurs in the machine. 2. The gauge portion (coolant temperature, fuel level) that always informs the condition of the machine. et Relay Electrical parts Engine throtte controller Werming-up signal Buzzer signal 2055023 © Various switches are built into the monitor panel, and it acts as the control portion of the machine. 10-791. MONITOR PANEL cnpr NP OUTLINE ‘The monitor panel has the switch functions for the electrical parts, mode selection, and monitor display functions, It has a built-in CPU (Central Processing Unit), and processes the data and outputs the display. The monitor display uses a liquid crystal display (LCD). The switches are flat sheet switches. 10-80 Input and output signal cN-P1 Pepe 2055024 ‘205s2055, MONITOR No: 45001 - 58018 No: 35001 ~ 36613 Coolant temperature gauge Coolant level lamp Coolant temperature caution lamp Coolant level caution lamp Engine oil pressure caution lamp Fuel level caution lamp Charge level caution lamp Engine preheat pilot lamp Fuel level gauge Condition fo diepleving ator ot Syme item Description ater sel fz Indicates when placing the starting Sg | urth's ON hefors saring the 5 a oS $2 mathe mp goes ot Ss Iiitisan abnormality We tarp 3 oO | | flashes. CAUTION MONITOR, GROUP joe | Engine oil pressure Coolant level 0.5 kg/em? max. Below low level Indicates while the engine is tunning and the starting switch is set to ON. Hit is normal, the lamp goes off Ititis an abnormality, the lamp 2 & | Coolant temperature Charge level Fuel level Coolant temperature 107°C min. When charging system fails. Below low level Qui flashes and the buzzer sounds. Indicates when the engine is running and the starting switch is set to ON. If itis normal, the lamp goes off itis an abnormality, the lamp flashes. Appropriate place (one place) s |e lights up. 2 & | 8 ee 3] gd | roti ty Aap bow prorat | When the starting switch is turned to e | HEAT position, this pilot lights for 30 3 | Preheat When preheating Seconds, then flashes (for 10 zz} seconds} to indicate the preheating is finished 10-81 3PC200-5 Serial No: 58019 and up PC220-5 Serial No: 36614 and up 1. Coolant temperature gauge 2. Coolant level lamp 3. Coolant temperature caution lamp 4. Coolant level caution lamp 5, Engine oil pressure caution lamp 6. Fuel level caution lamp 7. Charge level caution lamp 8. Engine preheat pilot lamp 9. Fuel level gauge a 8 7 6 3 ee etame| i ‘abnormalities, Descriot & Indicates when placing the starting ee | switch to ON before starting the Be |S | cootnt ive Below ow ave | Wien the ame goss of CAUTION MONITOR GROUP Engine oil pressure 0.5 kg/cm? max Indicates while the engine is tunning | Coolant level Below iow level ‘and the starting switch is set to ON. If itis normal, the lamp goes off. If itis an abnormality, the lamp Coolant temperature Charge level Fue! level 102°C (Flash) 105°C (Buzzer) When charging system f Below low level flashes and the buzzer sounds. Indicates when the engine is running and the starting switch is set to ON. If itis normal, the lamp goes off. Ifitis an abnormality, the lamp flashes. Coolant temperature 67 76 a3 50 97 102 105-¢ ith ‘Appropriate place (one place) o | lights up. 3 Se Ses 2 | I, 8 | iy | rut SSA | ansontup veiw aseopnete | (0) ieel wa) be | HEAT position, this pilot lights for 30 3 | Oo | Preheat When preheating seconds, then flashes (for 10 is finished. 10-82 ® 0205¢50205¢5 SWITCH © The switches consist of four electrical component switches; every time the switch is pressed, the condition of the machine changes. The present condition is displayed by the lighting up of the LED above the switch. Buzzer cancel switch Lamp switch Wiper switch ‘Swing lock lamp. Heater fan switch paeNs Feoscsoz6 Switch actuation table Item Action Fan OFF + Lo ~ Hi "Wiper OFF Lo + Hi Lamp 2 OFF 1-2 Buzzer cancel OFF -- ON. 10-83 32. SENSOR @ The signals from the sensors are input directly to the monitor panel. One of the contact points of the sensors with contacts is always connected to the chassis GND. CasaTeaTon Tee oF enaor Sensing we Normal | Abnowra GREGK MONTOR GROUP | Coolant evel Coniactiype | ON ose) | OFF open) CAUTION | Engine ol pressure Conactioe | OFF Gren) | ON onl Coolant temperate Resistance type = = GAUGE GROUP : —_| Fuel level Resistance type | — | = 1) COOLANT LEVEL SENSOR 1. Sub-tank 2. Float 3. Sensor 4. Connector eo nm jab e : ~o_] @ 20505166 o205¢5o20scs 2) ENGINE OIL PRESSURE SENSOR Plug Contact ring Contact Diaphragm Spring : Terminal Composition of circuit 20505169) 3) COOLANT TEMPERATURE SENSOR 1. Connector 2. Plug 3. Thermister Composition of circuit F20scs027 10-85 34) FUEL LEVEL SENSOR FULL Float Connector Cover Variable resistance BEND yw b> Ne Cot a = Aa ®, Pre Composition of circuit / \ | \ a i Section A—A 208605171 0205¢520 TESTING AND ADJUSTING o205¢5 Table of judgement standard value 20-2 Tools for testing, adjusting, and troubleshooting 20-18 Adjusting valve clearance ..... aco Measuring compression pressure 20-20 Testing and adjusting fuel injection timing... eee 20-21 Testing and adjusting travel of governor motor lever 20-22 Testing and adjusting hydraulic pressure in ‘work equipment, swing, travel circuit .. 20-23 Testing and adjusting charging pump pressure eee eer 20-26 Testing and adjusting main pump control pressure -.. 20-28 Measuring stroke of servo piston : 20-35 Measuring output pressure of PPC valve . 20-36 Adjusting work equipment, swing PPC valve ... 20-37 Testing PPC shuttle valve -- 20-38 Measuring solenoid valve output port pressure so 20-38 Testing locations causing hydraulic drift of work equipment ... ses 20-39 Bleeding air... ; 20-40 Releasing remaining pressure in hydraulic circuit 20-42 ‘Troubleshooting 20-43 Ad Before performing inspection, adjustment or faultfinding, park the machine on level ground and check the safety pin and chock When performing joint work, make appropriate signals and allow only authorized personnel near the machine. Adwhen checking the water level, allow the engine to cool down before removing the radiator cap to prevent the risk of being scalded by hot water which may spurt out if the engine is hot. Take great care to avoid getting caught in rotating parts such as the fan, etc.TABLE OF JUDGEMENT STANDARD VALUE © FOR ENGINE Mechine mel e200 poz20s Emine sepssi.a sasoost.a Surana] Pemmibe | Senderd | Peminibe wen Mernrementcondions | une | Stuiud | Pemimibie [ Standid [Peis tng wm | 220270} - | aaiosrm - Engine speed | Gow tins | em | “errs0 | = 'a70: 50 E | red wnt om | 2030 = | 2x0 | : [ aumosnaavomien [2 | ues | os | wes | cn Exhaust ga color | Ie | | at high idling Boe | Max.1.0 20 10 | 20 vate crane isa abe | om | 098 : 025 : thors mre) Espero mm | O30 = 20 = compreianprenue or sempre: 40-806 | toon | atin.ae | 20 | aan. 8 0 Reso | Eraenoes! tom | eto” 360) | ¢220™360) | (2202600 | «220 360) iow pesre (Coons emperor aes ce T (cron temperate Operating age schon ing sam | 35-60 | 24 | asso | 24 on peur Actom ising sae90) | agin? | ming | 07 | mao | a7 Atiowising Saetow) | igem | Minos | 07 | mnos | 87 ot empernve | Woe ome ange w-r0 | 120 | e-m0 | 120 Flinn ing eros, s fosesr | weer seer) nase Orfecon when resis fats wrsionaereor wh fg foc ot om | 8 s-0 | 8 6-10 approx. 6 ks, 20-2 2 o205¢5o205¢5 © FOR CHASSIS Machine model C200 2205 Chast. cae = os es 7 7 Trait ot Tanawaure a5 = ST Posmolea is rcenolal|ircoonl | teraz 7 Reena eat i pea | eee | : raceme met | romee eee) = ee pees a i ieee al Boom-Lo control T LE _| a ES : Acm-Lo.control velve { +2 cele — Fay | & Arm-Hi control vaive ia mm - |as:os/95:05 |9.5+0.5| 9.5:0.5 t— ee | | & ° Min. 15 " Read max. value to end of travel t Engine opoed | Arm conto ivr Except for petra lay ro0.18 Mon 145 g_ | Bueket conto! ever yoo mes z os ie = | swing conto! ever sao Won 45 e tie £ om a 3 | reset control iver a tito é [- — 5 Play of av ever Won 18 Yon 20 ‘Stop Low ot es 7 Low s+ High v0 “36 80 736 owt “e f Boom contol ever | «Engine a high ding 23:03 tox 3.1 Ot remperatre 45~55°C fem contol eer onto ier kno tomessure 22:03 Mo 31 : _ Measure max, value to end ot a z ‘al | pucker contr ivr r9203 Max 26 : & ‘Swing control lever 1820.3 Max. 26 i Lever 2ss07 oe 40 EB | trawtconwot iver i Peas ate won 1 Sto + Low / Stop = Low 2509/3512 Mon 70 + Fue contrl ever, - ow - igh / Low = Hon asit6 1708 Mex 90 > 36399 and op No 36438 and UP 20-3Machine model 200-2085 ciasit] Ca tom Measurement conditions Unit | Standard vatve ermine value Oi emperasure: 45 ~ 55°C cao | rcz20 | Pcz00 | c220 Rete pressure wih engine at i : : nigh cing (Faieve ont circuit tobe em messed) ox 340 _] Router ot pume mate Bucket <4 30 yan 300 Seing 2019 Meats ewe! sit, Me 00 Charging ume ai aes oun emperature: | Control ever at Engine a gh z ‘ing sur vloh VC vaie cutout [pum were | pene ail presure | 5 wor | Mocs | mae as i ver [ts Mini | Minas : - — kalom* _ Oi temperature: | Contol ever at $555 | Co vate not “gapeneh | (sce ] Wax 70 ex 30 edu sine | wave actuated ‘alvo cuit port [Travel lvor CO-NCvave ey re output prewure {cOvaWe, NC) vos Min 14 [ieee ctates Pump et {covane seated, No Max 55 Mox. 88 sve nat Leetated Laverat | "Qi temperature: 45 ~ 55°C engine thigh iin sea Men 3p neural | Sonal lot atta . Mins Jet sensor - siteronit one i womperature: 45 ~ 55°C Lover arena |“ Enaine a ih ling oreo! Control ever tend of vel Max? Max? {ump dicharge pressure a8 onsrec) 20-4 o205¢5o205¢5 Clos Unit Pc200 - 2205 Standard value Permisibe value swing ‘Swing broke sngle Working equipment poet, Noload Engine at high ieting Hydeoule oi temperature: 45 — 85°C ‘Stop after swinging one ture and measure distance thet swing rele moves 1: Distance of movement on outside eoumference of fi swing ence Wax reach os) revo | P20 prom yeerr Max 90° | Max. 120 Pc200pcz20, Max 120 Mae 16 Time taken to start oun Wark equipment Wax Hydraulic ol temperature: 45 = 55°C Time taken from starting ottion 0 sing 90" and a0" zea | az0a 180° oa | 47005 Max3S Max. 38 Max.52 | Max.56 Time taken to swing Work equioment Pe Engin st high idling Hyrauie oi temperature: Swing one tutn, and meature time taken to swing next 9 torre v2 | ae Max 31 | Max 92 Hydraulic dit of swing Engine stopped + Hydraulic oi! temperature + Set machine on 15° slope, and eet Upper structure at 90° to the side + Make maten marks on swing circle cuter race and track frame. + Measure distance that mates marks move apart after 5 minutes. Leakage from swing Engine at high ing * Hydraulic oil temperature 45 55°C ‘Swing tock switch ON Feliove swing circu imin Max. 10Machine model c200-2205 Clas eae \emuramant conditions unit | Standard value Permissible value pe2vo | pcz20 | Pc200 | Pc2z0 ‘Travel speed (1) wee. | 3019 wes | Mac | Max so Engine at high ting i Mines Hydraulic ol temperature: 45-55C FRaiee track on one side then measure time taken 205F05263, 2. Install oil pressure gauge C1 (60 kg/cm’) to the r — Solenoid block 0205¢5TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF ‘WORK EQUIPMENT * If there is any hydraulic drift in the work equip- — o205cs ment (cylinders), check as follows to determine if the cause is in the cylinder packing or in the control valve. Checking for defective cylinder packing 1) Checking boom and bucket cylinders i) Set in the same posture as when measuring hydraulic drift, and stop the engine. ii) Operate the boom contro! lever to RAISE or the bucket control lever to ‘CURL. If the lowering speed increases, the packing is defective. @ Ifthere is no change, the control valve is defective 2) Checking arm cylinder i) Operate the arm cylinder to move the arm in fully, then stop the engine. ii] Operate the arm control lever to IN © If the lowering speed increases, the packing is defective. If there is no change, the contro! valve is defective. If the pressure in the accumulator has been lost, run the engine for approx. 10 seconds to charge the accumulator again before operating, [Reference] If the cause of the hydraulic drift is in the packing, and the above operation is carried out, the downward movement becomes faster because of the following reasons. 1) If the work equipment is set to the above posture (holding pressure applied to the bottom end), the oil at the bottom end leaks to the head end. However, the volume at the head end is smaller than the volume at the bottom end by the volume of the rod, so the internal pressure at the head end increases because of the oil flowing in from the bottom end 2) When the internal pressure at the head end increaes, the balance is maintained by a certain pressure (this differes according to the amount of leakage) in proportion to it, | rear rasor0 es) PC220: 11620k3 Co 2o5r0s266 aosroszes | 3) When the pressure is balanced, the downward movement becomes slower. If the lever is then operated according to the procedure given above, the circuit of the head endis openedto the drain circuit the bottom end is closed by the check valve), so the oil atthe head end flows to the drain circuit and the downward movement becomes faster. 2. Checking PPC valve If the hydraulic drift differs when the safety lock lever is in the LOCK or FREE position, (engine running), the PPC valve is defective.BLEEDING AIR Procedure for bleeding the air Tr bioedna tom Ti bieding procedure i z 3 2 = = — ee lr 7 Ghagehyarvic oh T + Tt a + Clean strainer ° o 7° 7 wotay” © ior Replace return iter tment o 1% o : Reece oe a * Reolece or epsircontolvahe ob 0 5 Oo ° ‘+ Replace cylinder ~ - 5 + Remove cvinder piping oe ees — ca + Replace swing motor 1 T > + Remove sing motor piping (ic 2 ° + Fogle ravel oir or st > Remwve tavel eter orsoivel o ~——— 0 - 0 peng L L 1 i Note: Bleed the air from the swing and travel motors only when the oil inside the motor case has been drained 1. Bleeding air from pump 1) Loosen air bleed plug (1), and check that oil oozes out from the plug 2) When oil oozes out, tighten plug (1) =a Plug: 7+ 1 kgm * If oil does not ooze out from the air bleed plug 3) Leave plug (1) loosened, then remove hose (2) and elbow (3) 4) Add oil through the elbow mounting hole until oil comes out from plug (1) 5) Fit elbow (3), install hose (2). 6) Tighten air bleed plug (1) SD Plug: 7+ 1 kgm ‘Precautions when starting the engine When starting the engine after carrying out the above operation, run at low idling for 10 minutes. + If the water temperature is low and warming-up operation is carried out, cancel the automatic warming-up with the fuel control dial after starting the engine. (For machine equipped with fuel contro! dial) 20-40 © 0205¢50205¢5 2. Bleeding air from cylinders 1) Start the engine and run it at low idling for approx. 5 min. 2) Run engine at low idling, and raise and lower boom 4 — 5 times in succession. * Stop the piston rod approx. 100 mm before the end of the stroke. Do not relieve the circuit 3) Run the engine at full throttle and repeat Step 2). After this, run the engine at low idling and operate the piston rod to the end of its stroke to relieve the circuit. 4) Carry out the procedure in Steps 2) and 3) for both the arm and bucket cylinders, Bleeding air from swing motor 1) Run the engine at low idling, loosen air bleed plug (4), and check that oil oozes out from the plug. * If oil does not ooze out from the air bleed plug 2) Stop the engine, and fill the pump case with oil through plug (4) 3) Tighten air bleed plug (4) =D Plug: 17.0+2.0 kgm Bleeding air from travel motor 1) Run the engine at low idling, loosen air bleed plug (5), and if oil flows out, tighten the air bleed plug again. Sz Plug: 8+ 1kgm F20scs047 Fa0scs04e 20-41RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT * If the piping between the hydraulic cylinder and the control valve is disconnected, remove the remaining pressure from the circuit as follows. The travel circuit is an open circuit, so there is no remaining pressure. Itis enough to remove the oil filler cap. Loosen the oil filler cap slowly to release the pressure inside the tank. 2. Operate the control levers. ‘* When the levers are operated 2-3 times, the Pressurestored inthe accumulatoris removed, 3. Start engine, run at low idling for approx. 5 min. utes, then stop the engine and operate the control levers, * Repeat the above operation 2 - 3 times to release all the remaining pressure. 20-42 20550205¢5 TROUBLESHOOTING Points to remember when troubleshooting ... Sequence of events in troubleshooting Precautions when carrying out maintenance Checks before troubleshooting Electrical circuit diagram... Position of connectors for troubleshooting Connection table for connector Handling connectors ... Display method for monitor panel, pump controller and engine throttle controller Action of self-diagnostic function and symptoms on machine Method of proceeding with troubleshooting .. Method of using judgement table .. Method of using troubleshooting charts... Troubleshooting of engine throttle controller system {E model... Troubleshooting of electrical system (C mode) . Troubleshooting of hydraulic and mechanical system (H mode) .... Troubleshooting of monitor system (P mode)... 20. 20- 20- 20: 20: 20- 20- 20: 20- 20: 20- 20- 44 45 46 53 5a 56 59 67 68 69 70 n 20-72-1 20: 73 20-90-1 20- 91 20-117 20-43 2POINTS TO REMEMBER WHEN TROUBLESHOOTING ‘Ave Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted. ‘© When carrying out the operation with two or more workers, Keep sickly tv tle ayreed signals, and do no allow any unauthorized person to come near. @ Be extremely careful not to touch any hot parts or to get caught in any rotating parts. ¢ When disconnecting wiring, always disconnect the negative (—) terminal of the battery first. “AX e When removing the plug from a location which is under pressure from oil, water, or air, always + release the internal pressure first. When installing measuring equipment, be sure to connect it properly. ‘© The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence of the failure. When carrying out troubleshooting, and important point is of course to understand the structure and function. However, a short cut to effective troubleshooting is to ask the operator vari- ‘ous questions to form some idea of possible cases of the failure that would produce the reported symptoms. 1. When carrying out troubleshooting, do not hurry to disassemble the components. If components are disassembled immediately any failure occurs: Parts that have no connection with the failure or other unnecessary parts will be disassembled. @ It will become impossible to find the cause of the failure. It will also cause @ waste of manhours, Parts, or oil or grease, and at the same time, will also lose the confidence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed procedure. 2. Points to ask user or operator 1) Have any other problems occured apart from the problem that has been reported? 2) Was there anything strange about the machine before the failure occurred? 3) Did the failure occur suddenly, or were there problems with the machine cond tion before this? 4) Under what conditions did the failure occur? 5) Had any repairs been carried out before ‘the failure? ‘When were these repairs carried out? 6) Has the same kind of failure occurred before? 3. Check before troubleshooting 1) Check the oil level. 2) Check for any external leakage of oil from the piping or hydraulic equipment. 20-44 3) Check the travel of the control levers. 4) Check the stroke of the contro! valve spool. 5) Other maintenance items can be checked externally, so check any item that is considered to be necessary. 4. Confirming failure © Confirm the extent of the failure your- self, and judge whether to handle it as a teal failure or as a problem with the ‘method of operation, etc ‘* When operating the machine to re- enact the torubleshooting symptoms, do not carry out any investigation or measurement that may make the problem worse. 5, Troubleshooting © Use the results of the investigation and inspection in Items 2 — 4 to narrow ‘down the causes of failure, then use the troubleshooting flowchart to locate the Position of the failure exactly. * The basic procedure for troublesh- oting is as follows. 1) Start from the simple points. 2) Start from the most likely points. 3) Investigate other related parts or information 6. Measures to remove root cause of failure © Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will occur again. To prevent this, always investigate why the problem occurred. Then, remove the root cause. o205¢5,0205¢5 SEQUENCE OF EVENTS IN TROUBLESHOOTING Office, shop, Jobsite cap rms (cove 20-45PRECAUTIONS 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 repairs must be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the quality of repairs. For this purpose, it gives sections on “Handling elecric equipment” and “Handling hydraulic equipment” (particlularly hydraulic oil) 1, PRECAUTIONS WHEN HANDLING ELECTRIC EQUIPMENT 1) Handling wiring harnesses. and connectors Wiring harnesses consist of wiring connecting one component to another component, connectors used for connecting and disconnecting one wire from another wire, and protector or tubes used for protecting the wiring. Compared with other electrical ‘components fitted in boxes or cases, wiring harnesses are more likely to be affected by the direct effects of rain, water, heat. or vibration. Furthermore, during inspection and repair operations they are frequently removed and installed again, so they are likely to suffer deformation or damage. For this reason, it is necessary to be extremely careful when handling wiring harnesses. Main failures occurring in wiring harness (1) Defective contact of connectors (defective contact between male and female) Problems with defective contact are likely to occur because the male connector is not properly inserted into the female connector, or because one or both of the connectors is deformed or the position is not correctly aligned, or because there is corrosion or oxidization of the contact surfaces. 20-46 20505201 Improper insertion 20805202 o205¢5o205¢5 {2) Detective compression or soldering of connectors The pins of the male and female connectors are in contact at the compressed terminal or soldered portion, but there is excessive force on the wiring, and the plating peels to cause improper correction or breakage. 3 Disconnections in wiring If the wiring is held and the connectors are pulled apart, or components are lifted with a crane with the wiring still connected, or 2 heavy object hits the wiring, the compression of the connector may be lost, or the soldering may be damaged, or the wiring may be broken, (4) High pressure water entering connector The connector is designed to make it difficult for water to enter (drip-proof structure), but if high-pressure water is sprayed directly on the connector, water may enter the connector depending on the direction of the water jet. The connector is designed to prevent water from entering, but at the same time, if the water does enter, it is difficult for it to be drained, Therefore, if water should get into the connector, the pins will be short-circuited by the water, 80 if any water gets in, immediately dry the connector or take other appropriate action before passing electricity through it. (8) Oil or dirt stuck to connector If oil or grease are stuck to the connector and an oil film is formed on the mating surface between the male and female pins, the oil will not let the electricity pass, so there will be defective contact If there is oil or grease or dirt stuck to the connector, wipe it off with a dry cloth or blow dry with air, and spray it with a contact restorer. * When wiping the mating portion of the connector, be careful not to use excessive force or deform the pins. 56103079 aN F20805208 F 20805205, 20508206 20-472) Removing, If there is water or oil in the air, it will increase the contamination of the points, so clean with air from which all the water and oil has been removed. stalling, and drying connectors and wiring harnesses Dis a (2) connecting connectors Hold the connectors when disconnecting, When disconnecting the connectors, hold the connectors and not the wires. For connctors held by a screw, loosen the screw fully, then hold the male and female connectors in each hand and pull apart. For connectors which have a lock stopper, press down the stopper with your thumb and pull the connectors apart. Action to take after removing connectors After removing any connector, cover it with a vinyl bag to prevent any dust, dirt, oil, or water from getting in the connector portion. Connecting connectors ay 20-48 oO Check the connector visually. a. Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). b. Check that there is no deformation, defective contact, corrosion, or damage to the connector pins. ©. Check that there is no damage or breakage to the outside of the connector. + If there is any oil, water, or dirt stuck to the connector, wipe it off with a dry cloth. If any water has got inside the connector, warm the inside of the wiring with a dryer, but be careful not to make it too hot as this will cause short circuits. + If there is any damage or breakage, replace the connector. Press lightly when removing Lock stopper EY Oo 20508207 20505208 o208¢50208¢5 (2) 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, (3) Correct any protrusion of the boot and any misalignment of the wiring hanress For connectors fitted with boots, correct any protrusion or the boot. In addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position. + When blowing with dry air, there is danger that the oil in the air may cause improper contact, so clean with air from which all the water and oil has been removed. Drying wiring harness If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high pressure water or steam directly ‘on the wiring harness. If water gets directly on the connector, do as follows. (1) Disconnect the connector and wipe off the water with a dry cloth. + If the connector is blown dry with air, there is the risk that oil in the air may cause defective contact, so avoid blowing with air. (2) Dry the inside of the connector with a dryer. If water gets inside the connector, use a dryer to dry the connector. Hot air from the dryer can be used, but be careful not to make the connector or related parts too hot. as this will cause deformation or damage to the connector. Cliks into position F20505209 Ul F20505210 F20505211 F20508212 20-49(3) Carry out a continuity test on the connector. After drying, leave the wiring harness disconnected and carry out a continuity test to check for any short circuits between pins caused by water. * After completely drying the connector, blow it with contact restorer and reassemble. (1) The control box contains a microcomputer and electronic control circuits. These control all of the electronic circuits on the machine, so be extremely careful when handling the control box (2) Do not open the cover of the contro! box unless necessary. (3) Do not place objects on top of the control box. (4) Cover the control connectors with tape ora vinyl bag. (5) During rainy weather, do not leave the control box in a place where it is ex- posed to rain, (6) Do not place the contro! 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 connectors connected to the control box. Fit an are welding ground close to the welding point. a 20-50 _T-adapter F20505213, F20505214 F20s0s215 F20s05216 0205¢50205¢5 2. POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in the hydraulic cirucit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, itis necessary to be particularly careful 1) Be careful of the operating environment. Avoid adding hydraulic cil, replacing filters, or repairing the machine in rain or high winds, or places where there is a lot of dust. 2) 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 the equip- ‘ment. It is also difficult to confirm the performance after repairs, so it is desirable to use unit exchange. Disassembly and maintenance of hydraulic equipment should be carried out in a specially prepared dustproof workshop, and the performance should be confirmed with special test equipment. 3) Sealing openings After any piping or equipment is removed, the openings should be sealed with caps, tapes, or vinyl bags to prevent any dirt or dust from entering. If the opening is left open or is blocked with a rag, there is danger of dirt entering or of the surrounding area being made dirty by leaking oil so never do this. Do not simply drain oil out on to the ground, collect it and ask the customer to dispose of it, or take it back with you for disposal. 4) Do not let any dirt or dust get in during refilling operations. Be careful not to let any dirt or dust get in when refilling with hydraulic oil, Always keep the oil filler and the area around it clean, and also use clean pumps and oil con- tainers. If an oil cleaning device is used, itis possible to filter out the dirt that has collect ed during storage, so this is an even more effective method. F20505218 F20508219 20-515) Change hydra ture is high. When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil, so itis best to change the oil when itis still warm. When changing the oil, as much as possible of the old hydraulic oil must be drained out. (D0 not drain the oil from the hydraulic tank; also drain the oil from the filter and from the drain plug in the Circuit) If any old oils left, the contaminants and sludge in it will mix with the new oil and will shorten the life of the hydraulic ol. when the tempera- 6) Flushing operations After disassembling and assembling the equipment, or changing the oil, use flushing oil to remove the contaminants, sludge, and old oil from the hydraulic circuit. Normally, flushing is carried out twice: pri- mary flushing is carried out with flushing oil, and secondary flushing is carried out with the specified hydraulic oil. 7) Cleaning operations After repairing the hydraulic equipment (pump, control vaive, ete.) or when running the machine, carry out oil cleaning to remove the sludge or contaminants in the hydraulic oil circuit The oil cleaning equipment is used to remove the ultrafine (about 34) particles that the filter built into the hydraulic equipment cannot remove, so it is an extremely effective device. 20-52 20505220 20505221 205s0205¢5 CHECKS BEFORE TROUBLESHOOTING (1, Checks before starting, 2. Other check items) (switch starting switch from on to off) Item | pescemeny Remedy 1. Check fuel level | = ‘Add fuel 2] 2 check for dirt or water in fuel | = Clean, drain 2 3. Check hydraulic oil level | = Add oil i 3 4. Check hydraulic oil strainer | - Clean, drain B/S] 5. check swing machinery cil evel . Add oll B/ 3 | 6 Check engine oillevel (Level of oilin oil pan) = Add oil $15] 7. check cooling water level 7 Add water &| | 9, Check forloose or corroded battery - Tighten or replace 2} % terminals : i to. Sheek for loose or corroded atemator Z oo a g} heck for loose or corroded starting motor _ Tighten or replace Check for abnormal noise or smell = Repair Check for oil leakage = Repair Bleed air from system Bleed air Check battery voltage (engine stopped! 0 — 30V Replace 2 Check level of battery electrolyte S Add or replace 2 |, | 17. Check for discolored, burnt, or bare wiring = Replace Z i | 19, Cheek formissing wing clamps, hanging 7 Repair =|) 3/8 Checks for water leaking onto wiring Disconnect = | 19. (check carefully water leakage at connectors connector and 3 and terminals) dry connection | 20. check for broken or corroded fuses = Replace 21. Gagine runing at ove half throttle) 278 — 296V Replace 22, Noise when battery relay is operated _ an 20-53ELECTRICAL CIRCUIT DIAGRAM ENGINE THROTTLE CONTROLLER SYSTEM PC200-5 Serial Ne 5001 ~ 56338 C220-5 Serial No: 35001 - 36437 Starting switch BBRIRTRAC mutica) Battery (Nsi20) OFF 0) 258 ‘SwR 7 608. TT S08. HEAT] cis ie —— 18224 =) eezyphay a pesebon wre) w2owe) seatbelt a ‘Monitor panel can _-Lpetameie) io | miss) ES(MB) Fuel conto il bil aaa ‘dr $ 2H (eS 3 § —PC200 only Engine throtie 3 mia(ss) Enawicen BE oe 1 Sah | Governor motor 20-54 @ [ ‘ cei = aa Feoscso4e 0208¢57 PUMP AND SWING LOCK SYSTEM PC200-5 Serial No: 45001 - 58018 PC220-5 Serial No: 35001 - 36613 Mont oan Suing lok sch SESFIEICAEICS Tonyoro] [Oro] ism lore ‘ofr ify! an 2] eres Be (amezo)— > (AMPi6) | | nestor Sing tok M3 (si2) oie) Samm, vigce) onto || | Coats Lone | tit f 8 eee | pea al 8 [ 8g ne | [38 | TsxG@t¥ed Weve : seat (17 1 x miatse) 3 aoe yedee a BE lmincc2y Copan a Z ary asst hi ener ray aosscostee 20-55 3PC200-5 Serial No: 58019 and up PC220-5 Serial No: 36614 and up Swing lock switch 2[3]4 [516 tO] [OO] [ tock, OO Fre | | sw we | ‘Swing lock M3 (SI2) swe M2) solenaidvatve —VI(X2) wa EA mee (3 t ae LL D2 [ PSeke hua Q2)__Reawe ue seep (sft rustle ase Miatse) af eye — CS Wiccan M7(2) a 4 swe 20505120 20-55-1 ® 0205¢50208¢5 MONITOR SYSTEM PC200-5 Serial No: 45001 ~ 56338 PC220-5 Serial No: 35001 - 36437 Serica mater Promes2y OF a GQ a : “ape sp ; | ‘M2cx2) Lagi lingnal oof ga, ve | 38 a “ eth ae erss toy || eget 1 cowl Engine ol prossure sensor { ‘| 2) peasy CoO lvl ensr . sare i] = 35 f Fuel level sensor wpe A = : t FEB solace ysis ) lend valve Sing ick ste I SITE RsTe |= su oe La Sol ool=r wom Working ere wane Neeser att 6) 20550650 20-55-2 ®PC200-5 Serial No: 56339 - 58018 PC220-5 Serial No: 36438 - 36613 jowesa a iKESA) MaiKeSS) MSM) See sisio) PaiaMPis) Hl He wou 20805103 20550205¢5 PC200-5 Serial No: 58019 and up PC220-5 Serial No: 36614 and up r (KES4) MaiKES@) MS(Ma) ‘Bamery NSI20 {6 8 Sa ae (§ cee S| a prixas Son - | BR ih} a a | ana —# iolpemes msisias|| vioxz) selena C# Swing lock saten Warns buzzer operas | | M29 mot a fh | | i I 2 M2BIKES2) Motor : age weir t | 2 wou Wortina amp aun Mead lam zvocore 20-55-4POSITION OF CONNECTORS FOR TROUBLESHOOTING T T ICN No.) ELECTRICAL COMPONENT) Type No. off toca-| PS - P6 Fuel level sensor pr Coalant temperature P8 Coolant level sensor P9 = P10 | Service meter Vi Swing ck solenoid valve |X Mt [Saringewics fm | «es 2 Starting motor x) 28 M3__ Intermediate connector s 12 | &7 | Ma Intermediate connector |KES| 4 | C1 | Ms _[intrmedite connector | M | «| 82 M6 _ Intermediate connector m | 6 T Fe 17 ntermediate connector | t | 2 | #7 18 | Head ame wf) ws ug | Working lamp mf | H3 10 [Intermediate connector Te Mit Fosble fink Th? pe M12 Heater Kes| 3 Fa M3” Speaker wes| 2 [a ‘M14 | Intermediate connector s | 8 Fe oe 20-56 ® 'o,of]tece-| [ew no. [ELECTRICAL COMPONENT Type No, of] Lace ca | TVCvalve x | 2 | ne M16. [Horn (High tone) Tees) 1 [is C8 | TC resisior w | 2 | & | | mir |Homdowtone) sf 1 8 “£1 | Engine throttle controller | MIC | 21 &3 M21 | Radio KES. 4 T K2 *E2 | Governor motor s | 12 |e M26 [Power source for service |KES| 4 | Fa Tex [covrerpomsenewr |X [3 [w8| | er memedswnio: | wa) * 5 | Governor motor L* 4 NB M29_ | Window washer switch M 2 J2 £6 _| Fuel control dial m3 | o7 1 [Wiper relay 6 | 86 £8 | Intermediate connec stor swe) 8 cy ‘R2 | Heater Lo relay 6 Be P1_| Monitor panel AMP) 20 | C7 | | RS [Heater Hirelay 6 | AS ea usierearl eves og Te Las | Pa _| Waring buzzer +: For machine equipped with fuel control dial o205cs0205¢5 CONNECTION TABLE FOR CONNECTOR No. of X TYPE CONNECTOR: a Male connector Female connector aa le | 2S @ 1 ae 205F05309 208F05310 2 208f09311 20505312 3 20sF05919 2osr0s314 3 1 4 i | 5) | OLE ug 2 4 a 205F05315 205F05316 20-59No. off M TYPE CONNECTOR ees Male connector Female connector a = ‘| eT) ff | Ge 205F05317 | aosrosai8 2 1 20508319 205F05320 8 2 3 [> | y 1 20805921 20sF0s922 1 3 a 1 CTS} 4 a] aE —— 2 42 20sr09323 20sF09924 20-60 © 0208¢50205¢5 So ee = pins Male connector Female connector 4 1 \ / \ if tee 8 per] a a i \ 6 3 205F08325 20805326 20-61No. off ‘S TYPE CONNECTOR Lud ‘Male connector I Female connector 8 205608927 20508328 1 6 10 — bg __Se z : a ami 510 20505329 6 4 oF 12 my oa) a 5 20808531 205608332 16 l 20805333 208605934 20-62 oO 0208¢50205¢5 No. of ‘AMPO40 TYPE CONNECTOR 7 Pins Male connector Female connector 18 16 [ ie Te 3 20809395 205f05336 2 20 205F08337 20808938 20-63 ©SWP TYPE CONNECTOR No. of | fa Male connector Female connector 44 6 6 43 aosrosa3e zosr05a40 1 i 8 Silk ea oo48 zosrosaas aosross2 20-64 o 0205¢5o205¢5 MIC CONNECTOR: No. of pins Female connector Male connector 4 } 1 5 9 ¢ 3 c 4 20805969 L = aosrosaee 7 : a | arene vaaeeis 1 " Selesalale cele i pejlece|l ficeclea 1% 7 [}" 1426 | aan 20-65No. of] N-SLC CONNECTOR pins Female connector ] Male connector 1, f= . io ' azaeo49 20F980 eases 4 n0r382 exarasa 20-66 o205¢5o208c5 HANDLING CONNECTORS 1. When removing the connectors from the clips, pull the connector in a parallel direction to the clip. * If the connector is twisted to the left and right or up and down, the housing may break 2. When disconnecting male and female connectors, release the lock and pull in Parallel with both hands. * Never try to pull out with one hand. 3. When the wiring harness clamp of the connector has been removed, always return it to its original condition and check that there is no looseness of the clamp. 205F08610 208F05611 20505612 20-67DISPLAY METHOD FOR MONITOR PANEL AND ENGINE THROTTLE CONTROLLER 1, MONITOR PANEL Approximately 2 seconds after the starting switch is turned ON, all monitor and gauge lamps light up and the buzzer sounds for approximately 1 second. This is the self-diagnostic function of the monitor panel. After this, the display returns to normal. 2. ENGINE THROTTLE CONTROLLER PC200-5 Serial No: 45001 - 56338 PC220-5 Serial No: 35001 - 36437 1) Mode! code display function (normal display) When the starting switch is turned ON, the model code is displayed for approximately 5 seconds on the controller display panel * After 5 seconds, the model code display changes to the normal display or the abnormal display (self-diagnostic display). * The display for the wrist contro! type is the opposite (left becomes right) of the display for the long lever control type. 2) Self-diagnostic display _—_ (abnormal display) ¢ The abnormal display consists of 3 LEDs, and the ON/OFF combination of these displays the type of abnormality (abnormal system), If two or more abnormalityes occur at the same time, the abnormalities are displayed in the order of priority shown in the table on the right. © Once the starting switch is turned OFF, the self-diagnostic display is reset. Check the abnormal display with the starting switch ON. © When the abnormality is removed, isplay is automatically reset, so if the abnormality occurs intermit- tently, the abnormal display and normal display will appear alternately, and the display may appear to be the flashing. 20-6! @ © Model code display Modet LEDS (Light Emitting Diodes! Fed Green Rea Pc200 eoo ON OFF FF Red Green fed Pc220 oe °o OFF ON FF Rea Green Aes Normal display Omer ZO OFF ON OFF © Self-diagnostic display pnority | (Light Emitting Diodes) ve Red Groen Red 1 power source eystem 1 pene ‘0r controller system 2 | 0 @ | coven motr 3 e@oo } 6 | SSS" S| sovemermoter 5 | @ © oO | manrrreetgne Axnormatty inf 8] 8 8 S| crmratdat ores ON ON ON vystem o205¢5,) o205cs ACTION OF SELF-DIAGNOSTIC FUNCTION AND SYMPTOMS ON MACHINE @ ENGINE THROTTLE CONTROLLER SYSTEM PC200-5 Ser No: 45001 - 56338 PC220-5 Serial No: 35001 - 36437 Display code System with abnormality Details of abnormality Consition when normal voltage, current, resistance values! 1. Controller power source system Action of contoler when abnormality detected ‘Symptoms shown by machine when there is ‘abnormality Motor drive current: 06 TWOisconnection in wningharmess between E1 (1) ~ fuse 2) Red Green Red | power source system Disconnection in wing harness between E1 (2) ~ M20 (3) ~ 20 (4) | 1. Between 1 (1) and Et (12). 20 ~ 30V cn 1. Engine can be started, but remins at low idling O © O | éreomroter oNparting switch 2 Between 1 (2) andE1 (121, 20 — 30V 2 Engine does not stop. OFF OFF OFF Disconnection in wiring harness between £1 (12) ~ chassis 2 Detectwve controter 3. Detective contact of comector E1 1. Short cireuitinside governor motor a Fersimeewate] | Makes motor crve current O 1. During operation 2 Short rut of wing harness between €1 (2) ~ €2(3) ~ €5 (1}with | [Beineenc— ira | Seieenn—a Tse || (Abram display asappears when starting 11 Speed drops to low ing fed Groon Red | snort crcuitin Ra ee eat aeaes aimee Between) eeineenl ie] «=o —) | Switenis ured OFF) 21 Engine dows not stop © © [governor motor system| 3. Short crcuitof wiring harness between E1 (8) ~ £2 (B)—€5 (3) with, Geiwecn= a | Hin wil || i the fare location is reset during operation, | 2, When engine stops. ON OFF ON wring harness between 1(18) ~ £219) ~ €5 (4) Betwent iar | Betwoon l= (a) | Win THAT the display returns to the normal splay (The | 1! Engine starts bu stays at low idling 4, Wiring harness in tem 20° 3 in contact with ground [i Bereenanenan Tui ame applies fo other fur aso} 21 Engine does not stop efter starting. Red Greon Rea e000 ON OFF OFF fea Green Red Oo OFF OFF ON fed Green Red e eo ON ON OFF Short circuit in battery relay system Disconnection in ‘governor motor system ‘Abnormality in governor potentiometer system ‘When excess current flows betwoen €1 (13) — battery relay + Occures only when engine is stopped and starting switchs turned OFF Stariegewich © fo yah, Disconnection inside governor motor Disconnection in wiring harness between E1 (3}~ E2 (9) ~ E6 (1) Disconnection in wiring harness between E1 (4) 2 (8) -E5 (3) Disconnection in wiring harness between €1 (14) ~E2 (4) -E5 (2) Disconnection in wiring haeness between E1 (15) £2 (7) -E5 (4) Defective contact of connectors, £1. €2, €5 1 Berwoon E1 (13} and chassis. 20 ~ 30V 4 Is held for approx. 40 sec after starting ‘switen is turned OFF. Battery relay deve currents sotto 0 Engine does not star. ‘Same as short crcuitin governor motor system No particular action taken 1. disconnection occurs simultaneously for both ‘Apphase and B phaso, its the same as for 8 ‘short carcuttin the governor motor system 2. there isa disconnection nether A phase or B phase 41 Engine does not stop. 2] Stops moving at position just before failure occurred, so engine speed cannot be controled Short circuit n wiring harness between E1 (5) ~ (6) (6) ~ (16!, (5) ~ U6) Ta [iver [oae — 278 T= we] —— | = ar [aas — 625 ‘a= ve] =} @- w]oas— «rs ‘61 [= oa a7 fer nal = ars 835 (s) —(8) =~ Jo2s — 475 Controls by calculating the positon of the motor {rom the voltage value ust before occurrence of the abnormality 1 The accuracy of th rep Forexample the following cases may occur 1 Engine does nat run at hgh ding fa tle too low! 2] Engine does not run at lw icing (ate too tah. 3] Automatic warming-up speed is defective {too high ar to0 low, 4] Engine does not stop. ‘* The governor motor moves in the direction {o'stop the engine, but the motor may not the position where stops completely Red Groen Red ON ON ON Abnormality in fuel control dial system 1 2 Short crcuitin wining harness betwoon E2 (1) ~ (2, (2) ~ (6). (1) ~ (7) 3. Short circuitin wiring harness betwoen E4 (1) — (21, (2) — (3), (11 — 3) 4. Shor circutin wiring harness between E6 (1) — (21, (2) — (3) (11 — @) 5, Short circuitin wiring harness betwoen E1 (7) ~ (8), (B) — (18), (7) ~ 18) 6, Disconnection in winng harness between E1 (6) — £2 (1) - €4 0) 7 Disconnection in wiring harness between E115) — E2 (2) ~ 4 (2), 8 Disconnection in wining harness betweon E1 (18) — €2 (6) ~ 4 (3) 8, Defective governor potentiometer 10, Detective contact of connectors, £1, £2, £6 Ergine trons eontoter re ey Governor Short circuit in wining harness between €1 (7) ~ (18), (7) ~ (8) 18) ~ (18) Short cicuit in wiring harness between E6 (1) ~ (2) (1) — (3). (21 ~ (3) Disconnection in wiring harness between E1 (71 — €6 (1) Disconnection in wiring harness betwean E1 (8) — £6 (2) Disconnection in wiring harness between €1 (18) ~ ES (3) Detective fuel control cial Detective contact of connectors E1, £6 Fuel control dial AIMAX. 0.25 — 10V AUMIN: 40 — 4 75V Holds the engine speed atthe fuel control dial postion just before the abnormalty oceutes. 1, When itis at MAX it does not move to partial 2 When ii at partial, it does nat mave to MAX. 20-69 @METHOD OF PROCEEDING WITH TROUBLESHOOTING * If any abnormalities occur in the machine, use the flow chart below to judge which troubleshooting needs to be carried out, then proceed to actual troubleshooting, 45001 - 56338 No: 35001 - 36437 Troubleshooting (Engine related Is fluc in alec: tial system oF Tee Taagaront table for engine thvots conti {etecticl system UEogine system) — mode ‘Sea engine shop Hs sojeted pers [Electrical system] —4 ¢ mode Ts olre 1 fue ino sponses LL tran eel —] fee Sawert serene | roane ne | g Tee Tasperemt— haa! sito had afar : mentor res) EH te PC200-5 Serial No: 56339 and up PC220-5 Serial No: 36438 and up Trowiesooina teogine sites Sas engine shop 7 Ue sytem! — ¢ mode ire Beate Baton svaine chassis, LL chugs alates) —] sr yaraue or enn ae amt meV moc epee Sc BE Eromom See age (Mono sete P made 20-70 2) 0205c5,0205¢5 METHOD OF USING JUDGEMENT TABLE This judgement table is a tool to determine if the problem with the machine is caused by an abnormal ity in the electrical system or by an abnormality in the hydraulic or mechanical system. The symptoms are then used to decide which troubleshooting table (E-OO , C- OO, H-OC) matches the symptoms. The presence of any self-diagnostic display given in the judgement table indicates which troubleshooting table to use. * The abnormality display (warning) given by the monitor panel leads directly to troubleshooting of the vehicle monitor (P-O0). (See the contents for troubleshooting of the vehicle monitor system) 1, Judgement table for engine throttle controller, engine related parts PC200-5 Serial No: 45001-56338 PC 220-5 Serial No: 35001 - 36437 © If the self-diagnostic display gives an abnormal display, go to the troubleshooting code (E-0) given on the bottom line of the judgement table. (There is a @ given in the column where the feilure mode and self-diagnostic display, go to the troubleshooting code {E-O or engine shop manual) given in the column on the right of the judgement table for that failure mode < Example > Failure mode “Engine does not start” [Procedure] Check the three LEDs on the side face of the controller to see if their ON/OFF combination gives an abnormal display for the self-diagnostic display. [Judgement] If there is an abnormal display (for example, '* © ©!) on the self-diagnostic display: Go to troubleshooting E-2 of the electrical system If there is no abnormal display on the self-diagnostic display: Go to troubleshooting of [-—— Starting motor rotates: mechanical system (see engine shop manual) ‘@ Check that the starting —| motor rotates — Starting motor does not rotate Go to troubleshooting E-8 of electrical system 20-712. Judgement table for electrical system and hydraulic, mechanical system [Procedure 1] Locate the failure mode. ‘Ask the operator questions and try to re-enact the failure (check the failure symptoms on the actual machine). Use this information to locate the appropriate failure symp- tom from Failure Modes No. 1- No. 24 in the Judgement Table. [Procedure 2] Judge if the failure is in the electrical system, or in the hydraulic or mechanical system. 1) Connect a T-adapter or socket between the wiring harness and connector for sole- noids marked with a © in the Judgement Table, then follow the troubleshooting procedures and measure the voltage for each to check if itis the normal voltage. 2) Is the voltage the same as in the table (when normal)? Voltage is same as in table (when normal) +> go to appropriate troubleshooting (H- 00 ) for hydraulic or mechanical system. If voltage is different from table (when normal) —> go to appropriate troubleshooting (C- 00 } for electrical system. [Procedure 3] Carry out appropriate troubleshooting (YES/NO troubleshooting). 02085o205cs METHOD OF USING TROUBLESHOOTING CHARTS 1. Category of troubleshooting code number Troubleshooting Component Code No, 2 | Troubleshooting of engine throttl oe Troubleshooting of engine throttle €00 Troubleshooting of elect #00 Troubleshooting of hydraulic, © mechanical system P00 ‘Troubleshooting of monitor system 2. Method of using troubleshooting table @ Troubleshooting code number and problem The top left of the troubleshooting chart gives the troubleshooting code number and the problem with the machine. ® Distinguishing condition Even with the same problem the method of troubleshooting may differ according to the mode component, or problem. In such cases, the troubleshooting chart is further divided into sections marked with small letters (for example, a)), s0 go to the appropriate section to carry out troubleshooting Hf the troubleshooting table is not divided into sections, start troubleshooting from the first check item Method of following troubleshooting chert ‘@ Check or measure the item inside the box, and according to the answer follow either the YES line or the NO line to go to the next box. (Note: The number written at the top right corner of the box is an index number; it does not indicate the order to follow.) ‘© Following the YES or NO lines according to the results of the check or measurement will lead finally to the Cause column. Check the cause and take the action given in the Remedy column on the right. ‘© Below the box there are the methods for inspection or measurement, and the judgement values. If the judgement values below the box are correct or the answer to the question inside the box is YES, follow the YES line; if the judgement value is not correct, or the answer to the question is NO, follow the NO line. © Below the box is given the preparatory work needed for inspection and measurement, and the judgement values. If this preparatory work is neglected, or the method of operation or handling is mistaken, there is danger that it may cause mistaken judgement, or the equip- ‘ment may be damaged. Therefore, before starting inspection or measurement, always read the instructions carefully, and start the work in order from Item 1). General precautions ‘When using the troubleshooting chart, precautions that apply to all items are given at the top of the page and marked with *. The precautions marked * are not given in the box, but must always be followed when carrying out the check inside the box ) Troubleshooting tools When carrying out the troubleshooting, prepare the necessary troubleshooting tools. For details, see TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING ®© Installation position, pin number A diagram or chart is given for the connector type, installation position, and connector pin number connection table, so when carrying out troubleshooting, see this chart for details of the connector pin number and location for details of the connector pin number and locations for inspection and measurement of wiring connector number © © appearing in the troubleshooting flow chart. < Example > © E2 | @O@ || short circuit in governor motor] is displayed ® (There are cases where the troubleshooting is divided into Sections a), b) etc.) * If this happens during operation, because of the force of the spring: 1) Engine speed changes to low idling 2) Engine does not stop If the problem occured when the engine was stopped: 1) Engine starts but remains at low idling 2) Engine starts, but does not stop A Stop the engine (place the fuel lever of the injection pump in the NO INJECTION position) before carrying out any checks. ® % 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. Cause Remedy coo EE ee foe 20-72-2 @ 0205¢5o205c5 TROUBLESHOOTING OF ENGINE THROTTLE CONTROLLER SYSTEM (E MODE) PC200-5 Serial No: 45001 - 56338 PC220-5 Serial No: 35001 - 36437 Judgement table for engine throttle controller and engine relative parts Points to remember when carrying out troubleshooting on engine throttle controller system Failure mode Self-diagnostic display E14 £2 3 4 5 £6 [=] [Abnormality in power source system or controller displayed (All lamps OFF) [£=4] [short circuit in governor motor] is displayed [= 5-5] [Abnormality in battery relay) is displayed [Disconnection in wiring harness of governor motor] is displayed [=] [Abnormality in governor potentiometer] is displayed [259] [Abnormality in fuel control dial] is displayed No self-diagnostic display 7 £8 Engine does not start Engine rotation is irregular or lack of output power (max. engine speed is too low) Engine does not stop ‘Automatic warming-up operation is defective 20-74 20-75 20-76 20-78 20-79 20-80 20-81 20-82 20-84 20-86 20-88 20-90 20-73JUDGEMENT TABLE FOR ENGINE THROTTLE CONTROLLER AND ENGINE RELATIVE PARTS splay abnormality display) 7 Power oreonoler Watarting motor d [13] Excarsive consumption offer | 12 0 reer amo ghee |] wn noni aro Ie e |e |e |e | es | ee isi) ev 20-74 oO 0208¢5o20scs POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING ON ENGINE THROTTLE CONTROLLER SYSTEM ‘The engine on the PC200, 220 is controlled by an engine throttle controller. The problems that may arise with this system are as follows Low idling speed in too high (low) High idling speed is too low Automatic warming-up speed is too high (low) There is hunting Engine does not stop opens fan abnormality occurs and the abnormality is displayed by the self-diagnostic display, use the charts to goto the applicable troubleshooting flowchart E-1-E-6. However, if there is no self-diagnostic display, and there is an abnormality in the machine, it is necessary to determine if the problem is in the mechanical system or in the electrical system, For example, if there is defective adjustment of the linkage between the governor motor and injection pump, the above problems 1 — 6 may occur. Therefore, if any of the above problems 1 — 6 occurs, carry out the following troubleshooting procedure. “es fe Osten a "See TESTING AND ADJUSTING. 1 gyitem E710, After disconnecting or adjusting the linkage as shown above, go to the troubleshooting flow chart for the mechanical system or electrical system, + For details of the procedure for adjusting the linkage, see TESTING AND ADJUSTING,E-1 [5 ‘= 5] [Abnormality in power source system or controller] is displayed (All lamps OFF) ‘* Ittuses Z and 9 are not blown, If they are blown, check for a short circuit in the wiring hamess between fuse — controller or starting switch, * If battery is normal. * Before carrying out troubleshooting, check that all the related connectors are properly inserted. ‘* Always connect any disconnected connectors before going on to the next step. 4 ves. [phere cgneinarey ves| a | [feria 8 eae] : 2 | ae welertivecemisy CN nol iece an Seo ean oa We Gen BS 4} tase 1 vs ora 44 zoey suring owen muir | @ Engine hone [Ne r =) { ENMIC2!) misisi2) 2 mn \ G 1 = ey) | fuse 3 4 \;— —_— lero /@ ® : - ; ry” / @ (9), | (702) Bateryreley 2) F205cs129 20-76 0205¢5MK cause Remesy Detective engine rors | epiace Setaen'€ 7 Hemate) Reis eat) Defective contact, or Rarness between £1 fomae) (21 D4 — Mi (3) - 20 NT 2) starting saith terminal BR Detective starting switch Defective contact oF Sisconnection in wring hamess between £1 (femate (1) M5 (1) se 2 outet port Detective batery relay Defective contact, ot Sisconnecton in wing harness botwoen staring wren terminal 98 = Mz S10. MT (2) batery relay 20-77 @E-2 |< ‘%s''%| (Short circuit in governor motor] is displayed + If this happens during operation, because of the force of the spring 1) Engine speed changes to low idling. 2). Engine does not stop % Ifthe problem occured when the engine was stopped: 1) Engine starts but remains at low idling 2) Engine starts, but does not stop Ay Stop the engine (place the governor lever of the injection pump in the NO INJECTION position) before carrying out any checks. + 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. a Green ec5e ON. OFF ON eae) eSimwel Tiina Faan ae wi-@ aa rer (3) @) (a) = (95) [4-90 8) a) in ate ‘ait int Becamen gi TT, —] Sere 1, yaar BG a ceans | Seas Seha | Engire trot contr Eumicai e2si2) £5(x4) — aw @ S i ac) ( (4) @ @ © @ | 8 {?) @ 20:78 Fooscs0se 205s[Abnormality in battery relay] is displayed ~ Note: This occurs only when the engine is stopped and the starting switch is turned to the OFF position 2, The engine dues not stop. AiStop the engine (place the governor lever of the injection pump in the NO INJECTION position) before carrying out any checks. + 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. Tad Geen Ree Detective batcry cay | Retace ~ fon of ore [Peete Meamsrasne [aca a. ts sig gammy | aia eratensring ae chs wn TW 2) en amp i g via) eo 8 String switch iMz0ma) 8 * i 8 a @ t fu Ba) @ 51512) evwacen le) M72) eatery say aay =) a @ 1 2 *) Engine tote conan pO Hoo Fe0sesi2a when ON (approx. 24) sot To betery relay BR totes} \290"0% 240) Senmateg seuss, (Non To battery relay BR | ot atin. 40 6 205F05354 Note: When the starting switch is ON, the controller is OFF, but a voltage of 20 — 30V is always flowing from the starting switch BR, so if the measurement is made at E1 (13), the voltage is ~ 20 — 30Vv. 20-79 ®£-4 |S > 5° 3 | [Disconnection in wiring harness of governor motor] is displayed 4 During operation: 1) If there is disconnection simultaneously in the A phase and B phase: Engine speed changes to low idling Engine does not stop 2) If there is a disconnection in either A phase or B phase: The engine speed stays the same as immediately before the problem occured. * If the problem occurred when th engine was stopped: 1). Engine starts but remains at low idling 2). Engine does not stop Stop the engine (place the governor lever of the injection pump in the NO INJECTION position) before carrying out any checks. * 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. Tar Gan Rtmcetororoslonsin | pepair or Co0e® Sa ee ean oe Syeene ie PEs, a ones = ES (male) [Et Wemater [Resistance valve GRE TP ee | Mo EN(MIC2I) E2(Si2) E5(X4) Governor aw\ @ 3 i a) Ac) \¢ 1a) @ aw (@ ® g «7 B-)/ @ O @ F20scs0s4 20-80 o20scsE-5 [Abnormality in governor potentiometer] is displayed 4 Bofore carrying out troubleshooting, chock that all the related connectors are properly inserted * Always connect any disconnected connectors before going on the next step. cause Remedy avs eer les 17] crbsween sachin On on of [| acim [| « Bcnscces 8 Eximaie) [Ev emai) | Resance valve ma) | 8 Twa Cas oa78 | e270 ‘Between {71 (8) | ~ (18) ~ chassis Min TMi Engine trot contoler EWMiCal) 2(S12) :4(X3) € i i 3 2 2 Governor potentiometer € € g 20-81[Abnormality in fuel control dial] is displayed % Before carrying out troubleshooting, check that all the related connectors are properly inserted, Always connect any discannacted connectors before going on the next step. 2 ves Cause Remedy L) sTnzagre «ONO Tablet 6 imal o-@ a O) 2a ‘e-11) Resistance value | fees 0) chase Win. ng throte contr Evimicai) Misisi2) E6(M3) ® (2) r ® (2) 2 @ 9 3 Fue contol al F20scs067 oz0scsE-7 Engine does not start + When the starting motor does not turn, + Check that fuse 9 ie not blown before starting troubleshooting * 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. 4 ves g | [seme nermr |] ves] soumor™” |] Apmantaag "ren O% Beonosts sus no) rains $s [| ee af] esebenae 1 ves nee eat ng ee s a L] sesciateatien [J fetes? L_tley ends Varnae wo] ‘emina’8 eee Seminal 8. RS Ree + Connect -) pole of Bin 26, ‘tester to (I terminal SS no ar caswrs) — Miais mzo(vea) [fusible link *] (-) la @mnee L ool ——] FJ aE D@ uma savery Battery oy M7W2) >) starting i |}--€o88}— a 2 @ wich 2 7 7 Tose Froscsi24 20-84 @ 205sSetary sorminal Starting mavor terminal 8 fanaa ares i alten (perwenn Mirminaene) Detective batery Detective contact of Detective contact, ot ‘econnectonn wing hamess between starting Site terminal BRM "020" B10 M72) battery relay terminal BR fitch (oeraeen Mirna 888) Tinevaing tse tink) arery capacity t00 iow. Defective consact of 20-85 ©E-8 Engine rotation is irregular or lack of output power (max. engine speed is too low) * Before storting troubleshooting, check the model code. * Before carrying out troubleshooting, check that all the related connectors are properly inserted. * Always connect any disconnectd connectors before going on to the next step. avs See TERT SAND Rees Wormingupsional_§ ves 1 ire Tao ee vel ete “Typ rerioo se Potentiomenet 4 Seer ean severe eer ves] eereceter || L FL iinet wf Pease 28V ND ay wuoway Staring wien 8 é Engine tote 2 eo “eluwican 1 isis ess) -oelcona J TI a3 sins | @ g raat at iscr | G| 5 e —* Fuca | @ 9 a |Warming up y 8) £403) Governor re Jono 2S D Potemionetr (SIG) 2) 2) Penton 5 5 Pziuicen 1) | Warming-up raosestes 20-86 ® 0205¢5o20scs Detective adjustment Detective njction oie: iomate 2 or dotective starting switch 20-87E-9 Engine does not stop. AStop the engine (place the governor lever of the injection pump in the NO INJECTION position) before carrying out any checke. * Before starting troubleshooting, check the model code. oo" 85 °s"'s| * 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. 1 STOP Moppe”? “Saring een Potentiometer _§ YES an tnege | ves] eaten orr || No], Sajuneea? af] viene” ABUsring: “N° Serina vane _a |] slovenia, |] peaeg $2-43 no] ar ss When ON (approx. 28V) Voltage from starting swnteh (E¥ (2) i To battery relay BR Voltage output from controller when starting switeh is OFF When ON Contraler circuit __tNote) J (@P9r0x. 24V) To battery relay BR actuated (ET (13) — OFF wae Sve ine Max: 7 sc (when tis impossibie to sat 10 NO INJECTION because of falure of the motor) 205F08966 Note: When the starting switch is ON, the controller is OFF, but 2 voltage of approx. 20 — 30V is always flowing from the starting switch BR, so if the measurement is made at E1 (13), the voltage is 20 — 30V. 20-88 © 0205¢50208C5 Detective contact of detective staring owtch (oe) starting ewiten / * S pire — fer) Barry relay Engin rele love Foe mzomas fe» | @ ) t ® ae oer é 5 \ F205cs126 20-89 ®E-10 Automatic warming-up operation is defecxtive ‘* Warming-up is not carried out when the coolant temperature is under 30°C, or does not stop when, the coolant temperature goes above 30°C. (When it is canceled by the fuel contro! dial, there is no change in the voltage.) * Conditions for carrying out warming-up’ 1) Coolant temperature below 30°C 2) Fuel control dial set at about 50% or below (warming-up signal: Max. 1V) * Conditions for canceling warming-up: 1) Coolant temperature above 30°C 2) Fuel control dial raised to above 70% and kept there for at least 3 seconds (see Note 1) * Before carrying out troubleshooting, check that all the related connectors are properly inserted. ‘* Always connect any disconnected connectors before goir.g on to the next step. Note 1:When the fuel contro! dial is turned up to cancel warming-up, warming-up will not start again unless the starting switch is turned OFF and then turned ON again, 2:When the fuel control dial is turned up to cancel warming-up, the voltage of E1 (21) does not change. ves Detective engine rrorle (Seonowe2) 9 Sontctae Reniace Soeraton not | terweetes con Lf i: ET norma? YES sos p-ar 1 verre ase ge Disconnection in wiring + Fee ntot iat “| Bi apm hamess between €1 apatt or Ee 2 femal @ir=mas 6) | Fegaee : ‘i “Gurpearanaenrten | “PD tomate) im oF 4s atecive ensine throttle | aes ere : No seep-17 Engine tote Wining harne Restance value enti Monitor panel Begaeer 1 Hertel NT san, a euMican P2ioso161 Beneeen EF Gamal i) ox we ‘oo | Seal Met | sey | nome gy {6 | F20scsos0 20-90 o20scsTROUBLESHOOTING OF ELECTRICAL SYSTEM (C MODE) Judgement table for electrical system or hydraulic, mechanical system .a.cnnsnnenen 20-90-2 Failure mode C-1. There is excessive drop in engine speed, or engine stalls .... 20-90-3, C2 Does not swing (swing lock is not canceled).. 20-90-4 C-3 Swing lock is not actuated ..... 20-90-5 0208C5 20-90-1 ®JUDGEMENT TABLE FOR ELECTRICAL SYSTEM OR HYDRAULIC, MECHANICAL SYSTEM “gaa peu oa eSStoreceneal ten coho 1 Spee ot wot al 7 er | we ws we we rire mieten 76] Teva ts pee fr sped is com) ~e 17 | Meche doe re neve ov ie on [Cer 18 Goer sng vig nk a ei 2 cr 4 aa 3 ca | ua | 20-90-2 @ 0205C50205C5 C-1 There is excessive drop in engine speed, or engine stalls solenoid. If there is @ disconnection in the solenoid, resistor, or wiring harness, no current flows to the If pin (2) of the solenoid is short circuited with the ground, the solenoid is actuated normally. + 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. 0 Cause famed Detective contact. of ves] sicomecton to | pep Terese oT eee ated Me replace ves} Seong |] | Soma 3 [| cetiematl #8 Detective contact. oF is reste Sema Gecomecton msring | Repair or rollemees STumsara — %2) homes between ce | reace mai andi F] ston OFF temas 68 2 | norma Bonween wiring | teal (2 ves] PSndiasner” L] “Setcn ore’ NOL galas ta Detective reser replace ‘haute 304-360, haeness and 1) Lchases? += Disconnect 06, chowsis, Min, 1 Mia Turn string + Bissatneet Ce te swaching of 1] swien OFF wee Detective TVC solenoid | Renlace swing look nor H «392207 Ne mal Disconnect C8 Detective contactor Snean Seroansbenween uso’? | Repair o ‘Maa —certematey | solace, ‘ahor Mo date tal= Maia chases caixa) iatse) Masi 7 < © ® ® r came) Resistor fuse L__t/ |__| TORT 2osecosiosC-2 Does not swing (swing lock not canceled) ‘If there is a disconnection in the solenoid or wiring harness, the solenoid is not actuated, If pin (2) of the solenoid is short circuited with the ground, the solenoid stays actuated, Bafore carrying out troubleshooting, check that all the related connectors are properly inserted. ‘* Always connect any disconnected connectors before going on to the next step. cause Remedy ves Seo H-9 [Does not Swing) Detective contact. oF ais 4ves| Romase wean | Repel or ves} toon Van eee ees cheats a shor Te conti be ffemate c) - M3.) 1] Sach On Te renwance be |] LOrme Detective swing lock fps or te radeonee Ue. | | sTerpemtieg — NB] ont pice Te vonage st so} tnvsna a witch OFF foutiet of fase 4 °| Showa intabie 27] | ¢ Switch OW: rormal? Re concmiy “Tun serine nol Suir OFt” | ogtcive swing took wen} Riace = 5 ‘Switch OFF ‘Continuity : rn wa sDiconnest' vt. «Baconnett ich Ot Duby win, Detective contact, or arnass Dexwoon fuse 1 | Repair o¢ x wai cviemaes | 9sce in Table 1 ‘Swing look switch | Voltage Remarks ON (Locked) | 20 30V | Solenoid not actuated OFF (Freo) | Max. 1V_| Solenoid actuated Table 2 “Boor SOTE | PERS Sora Nov STS and Up V1 (male) 38001 - 36613 | PC220-5 serial No: 36614 and up -2@) a 24-46 0 (1,2) — chassis Min. 1 Mo. Sing lock switch Tz] s[a[sTe ‘ON [ORO] TOPO] [toc forF| [OHO Free fuse Montor pana = 2104016) ono 31812) 2 L weiixey ‘Swing lock solenoid miaise) @ d Cop + e : 205508107 20-90-4 ® 0208C50205¢5 C-3 Swing lock is not actuated If there is @ disconnection in the solenoid or wiring harness, the solenoid is not actuated. If pin (2) of the solenoid is short circuited with the ground, the solenoid stays actuated. 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. Caue Remesy oetecve actuation ot | pepace 1 sclentd vale Te vaage be een @) and Wing harness between Shoei shown Viiemaierai- man” | Repar or intevie? Toot wen a) ehon ee | role Siteg nim groma TSian eae teow ing ek 9 nb] such shone amy Detective swing tock | peplace STunsatpa wien ben OFF Senten ON tore Necontnuny Sater OFF Table ‘Swing lock switch | Voltage Remarks ON iLockea) | 20-30V | Solenoid not actuated OFF (Free) | Max 1V | Solenoid actuated Swing took switch Ses on JOFO JOFO] [tected OFF tol TOPOL Free fuse} Monto panel 10 2104016) v2 Swing tok \@ waisian p> ono @ WIX2) ging lock soloed masa i [oa rte : 208F05107 20-90-5 @oz0scs TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE) Failure mode Work equipment, travel, swing system H+ 1 Speeds of work equipment, travel, swing are all slow H- 2 There is excessive drop in engine speed, or engine stalls H- 3. Work equipment, travel, swing do not move, or speed is extremely slow H- 4 Work equipment, travel, swing lack power H- 5 Abnormal noise generated (from around pump) Work equipment system H- 6 Boom, arm speed is extremely slow H- 7 Work equipment (boom, arm, bucket) speed is slow H- 8 When boom and arm are operated simultaneously, boom is slow H- 9 Work equipment (boom, arm, bucket) lacks power H-10 Excessive hydraulic drift H-11_ Excessive time lag H-12_ When arm and swing are operated simultaneously, arm is slow Travel system H-13 When machine is traveling, it deviates naturally to one side a) Deviates in same direction both in forward and reverse b)_ Deviates in different direction in forward and reverse H-14 Excessive deviation during compound operations H-15 Excessive deviation when starting H-16 Travel lacks power or speed is slow H-17 Machine does not move (one side only! ‘Swing system H-18 Does not swing H-19 Swing speed is slow or acceleration is poor H-20 Excessive overrun when stopping swing H-21 Excessive shock when stopping swing H.22 Excessive abnormal noise when stopping swing H-23 Excessive hydraulic drift of swing H-24 When operated simultaneously with arm, swing speed is slow ‘TABLE OF FAILURE MODES AND CAUSES 20- 92 20- 94 20- 96 20- 98 20- 98 20- 99 20- 99 20-100 20-100 20-100 20-101 20-101 20-102 20-104 20-105 20-106 20-108 20-108 20-110 20-112, 20-113 20-113 20-114 20-114 20-114 20-115 20-91 qH-1 Speeds of work equipment, travel, swing are all slow % If there are other problems, such as travel deviation or low bucket or swing speed, go to H-13. “1. Ifthe pressure is not at least 27 kg/cm’, the spool of the acceleration (Hi) end is not fully actuated. *2. The discharge pressure of the pump has an effect on the TVC valve set pressure, so check it before adjusting the TVC valve set pressure, *2 Couse Remedy 1 murainagectoume | Rese tres Drtenp sonnet imam | paar 4 20. 0205¢5H-2 There is excessive drop in engine speed, or engine stalls 20-94 @ oz0scs20-95H-3 Work equipment, travel, swing do not move, or speed is extremely slow ‘* When there is a big difference from the permissible value. 2 ves|iehin Fla Crank with va 1 ‘motor. BNC inser nL setremaiy stow |} T¥E vo +0 78 kalem? Fig, 1 Control circuit Piston puma Charging pump 5 ves No] wher ne vane Solenoid valve Travel PPC vaive of uf oh g Saloty lock valve + aS YP 20-96 LM PPC valve 208F05300 0205¢50205¢5 Detective chorsina pump 20-97 ©H-4 Work equipment, travel, swing lack power x Insome cases, the work equipment speed may not be slow, but it feels that the work equipment lacks If the set pressure of the main relief valve drops, this will also cause the work equipment speed to drop. pressure nermat [| Drop in sat pressure of aa NO main relist valve H-5 Abnormal noise generated (from around pump) 2 fF] Sem” pss Lectepioingclame | Tahun 4p J toon ti , 4 mars ne] 425) petecve pump eplnce SEE Mocone [See 20-98 ® o205c5H-6 Boom, arm speed is extremely slow ~ When the travel, swing, and bucket speeds are normal 1 vs Detective operation Twaneanopet 50 H-7 Work equipment (boom, arm, bucket) speed is slow * When the travel and swing speeds are normal (However, if there is any travel deviation and the bucket or boom speed is slow when operated individually, go first to “H-13 When machine is traveling, it deviates naturally to one side” ) a 8 cause Remedy 2 ves Detecne apron ot nest elce YES] oe rssrg ot 1 Detesive FCae ropes wien NO no Bate inp rice ovonsa” [] tus peeseeereeest tates Bucket [Nox 88 Tareas [Evinaer] Gorar end aren") —[ Head end tgiem: Boom —[Sefety ~ suction vaive (266) Sofory — wvetion vaive BO) Bucket [Safety ~ suction valve [985] Setery — wetion valve BS) 20-99 3H-8 When boom and arm are operated simultaneously, boom is slow. %* When there is no travel deviation during simultaneous operations. (If there is excessive travel deviation, go to H-14,) cause Remedy H-9 Work equipment (boom, arm, bucket) lacks power ‘* When the travel and swing speeds are normal, cause Femeay tvs yp me ae Ine feo a ‘fortalewe (NO HT heal Tobie en Tween [cs fm | ian 260 Buck | Mn 58 H-10 Excessive hydraulic drift Goto H-7, Item 3. 20-100 ® 0208¢5o20scs H-11 Excessive time lag If the work equipment speed is normal (if the speed is slow, go first to H-7, Item 2), H-12 When arm and swing are operated simultaneously, arm is slow 4 When there is no travel deviation during simultaneous operations. (f there is excessive travel devia tion, go to H-14.) 20-101 iH-13 When machine is traveling, it deviates naturally to one side ‘* When the travel speed is normal. a) Deviates in same direction both in forward and reverse Sus ; ve] seem gion ves | Bement ‘ car BE ve ADJUSTING. ‘When track is rota- e fe branes en \ Figen 30 +8 kgiem Note: When the track is rotated freely, if the output pressure of the NC valve is the same as the output pressure of the TVC valve, both the jet sensor and NC valve are normal 20-102 oO 0208¢50208¢5 clean or 20-103 “b)_Deviates in di ifferent rection in forward and reverse (See Fig. 1) ves| 1 = ao saree [ni Engine at high iting 20-104 ® 2 ves Figen *0 30 7B kgiem Fig t Joint pacing snd cirect'on Rear right (Ab Frant left oes not deviate © | ia! From right (Cl Rear ett ceverse ont fete (0 u u 0) “ Fight reverse and Tett forward Right forward and 020552055 H-14 Excessive deviation du + Ifindividuel travel is normal, 1g compound operations 2 ves IF] Setvemove FT 25 sagem * See TESTING PPC SHUTTLE VALVE, and measure work equipment PPC pilot pressure. cause Remedy 20-105 @H-15 Excessive deviation when starting * When the travel speed is normal % If there ig aleo deviation during normal travel, go to “H-13 When machine is traveling, it deviates naturally to one side.” For deviation during simultaneous operations with the work equipment, go first to “H-14 Excessive deviation during compound operations.” % Bleed all air completely from the circuit. ves 2 4s ( prinupee ) haere ave | nt 7 Hh 4 festa 320mm bus 5 [| es si sasten caneona || seaege,.N ™ a mace at co tows 2 kar? L 20-106 oO o205c5o208¢5 20-107 qH-16 Travel lacks power (or speed is slow) %* When there is no travel deviation. (If there is travel deviation, go to H-13.) %* If the main relief pressure has dropped, the work equipment lacks power even for normal work Detective CO valve H-17 Machine does not move (one side only) “ao motorsatety waive ate 20-108 oO 0208¢5H-18 Does not swing © When other work equipment and travel speeds are normal ‘Tum ewing lock switch OFF. vies [ Dom not swing ] | [ Does not swing NGL woneanecnon 20-110 ® ‘ ete ites 4 - Does contro! ves] atte vo) sce iat i" 25 — SOO Kglem™ no. ie Ingerchanged, Bago 5 ~ 300 kg/em* o205c50205¢5 20-111H-19 Swing speed is slow or acceleration is poor * When other work equipment and travel speeds are normal. (If there is also deviation (to right) during normal travel, go first to “H-13 When machine is traveling, it deviates naturally to one side”) 20-112 oO sgl on es orm ned ts * il 288 ~ 300 kgfem" Detective safety vaive 0208¢5H-20 Excessive overrun when stopping swing * If the speed is slow or the acceleration is poor, go first to H-19. 1 yes" Both let ana Aeolace motor “Sema 5 oan Detective satan valve PES 185 8 , , g H-21 Excessive shock when stopping swing & When the swing speed is normal. + Turn the swing lock switch OFF cau 1123] petecveswinamecrior | pepe Peta Daecive swing matot | pesace [Both left and right! ae " 1 Shock both Datectvn ening Nock | maples {One arection ony: eteve salty vate | Replace 20-113H-22 Excessive abnormal noise when stopping swing ‘* When the swing speed is normal. sincera tvs acres |e H-23 Excessive hydraulic drift of swing When swing lock switch is ON. (if the hydraulic drift is excessive when the swing lock switch is OFF, go first to Troubleshooting H-18.) 1 ves H-24 When operated simultaneously with arm, swing speed is slow @ When the usual swing speed is normal Cause 20-114 ® oz0scso205c5, TABLE OF FAILURE MODES AND CAUSES i Pomp 1ve Controlvaive hsor Swing motor | Travel motor Parts causing fire | | A ] | ~ g | oN ls] | 3 | § Faiure mode oe) eleielelei8//sieielelelsseiz/e flelel se gi sleleleieig elgicisielelg) 3 8ialel5/5|8/3 S/S|F|8/a)5| 25/8) E Ele slslSlzZala lS [slSlzislFle/F/5/8] | [ Seeeds of workeavipment evel swing ae all sow Tofo To} To I rt LEPC pop 2 &| There is excessive drop in engine speed, or engine stalls, ° _je ol wz 2 | Work equipment travel, ewing do not move o| fol ff | | ira ~ : 2 & | Speedis extremely slow Gfitis greatly outside permissible range) ° eee L TEE _ LE & Work cauipment, wave swing lack power ott 7 3 - ka 3 E Abn egen - of fo Tho ~ He ‘speed is extremely slow 7 7 ° ~ He ¢ |Boomspecdissiow o| fofo alee ole ° 2 | Arm speedis slow = ” | fol lofo ° ° 47 =. | Bucket speed is slow z of fofo ° - ° E | When boom and arm are operated simultaneously, boom is slow ° [ He & | Work equipment (boom, arm, bucket) lacks power i o| lolo - ° a of [| [| ¥s z Excessive hydraulic drift 7 Oo o|O | { = Oo H-10 3 [Excessive time log _ [ - ° Z a at ‘When arm and swing are operated simultaneously, arm is slow ° I | 12 : Deviates in same direction both in forward andreverse [0/00 | ° o| Jofo ° [ ofo] Jo Hs a) € | 2 | Deviates indifferent direction in forward and reverse CT] o| fo ° #513 & | 2 | Excessive deviation dung compound operations Z ° of of [oe 3 Excessive deviation when starting olo | o| [ole 3 ofo Has £ Lacks power (or speed is slow) = oO oO = ~ _ 7 H-A16 Machine does not move (one side only) | | o}o ° o H-17 ~ «Both left and right ° [ olo °| ° Cea One direction only | ” oO Oo 7 8 ‘Swing speed is slow or | Both left and right ° ° olo ny acceleration is poor ‘One direction only oO | | jo | § | excessive overun _[Bothietand ight ° azo @ | when stopping swing | One direction only oO _ 5 | Excessive shock when | Both left and right ojo ° fey © | stopping swing ‘One direction only [oO | I Excessive abnormal noise when stopping swing elo ° ° H22 Excessive hydraulic drift of swing _ | 23 When operated simultaneously with arm, swing speed is slow ° H26 20-1150208¢5 TROUBLESHOOTING OF MONITOR SYSTEM (P MODE) Failure mode P- 1 Monitor panel lamps do not light up for 3 seconds when starting switch is turned ON 20-118 a) No monitor panel lamps light up 20-118 b)_ Some monitor panel lamps do not light up 20-118 P- 2. Monitor panel lamps all ight up when starting switch is tured ON, but do not go out 20-119 P- 3. When starting switch is turned ON (engine stopped), CHECK items flash 20-120 a) Coolant level flashes 20-120 P- 4 Preheating is not being used, but preheating display lights up 20-121 P. 5 When starting switch is turned ON and engine is started, CHECK items flash 20-122 a) Alternator system 20-122 b)_Engine oil pressure system 20-122 P- 6 When starting switch is tured ON (engine stopped). CAUTION items flash 20-123 P- 7 When starting switch is turned ON and engine is started, CAUTION items flash 20-124 a) Engine oil pressure flashes 20-124 b) Coolant level flashes 20-124 ©} Coolant temperature flashes : 20-125 d) Charge flashes 20-125 e) Fuel level flashes 20-126 P.8 a) When starting switch is turned ON (engine stopped), buzzer does not sound for 1 second 20-127 CAUTION item is flashing but buzzer does not sound, 20-127 b). There is no abnormality display on the monitor, but the buzzer sounds 20-127 P- 9 Panel lighting of monitor panel does not light up 20-128 P-10 Coolant temperature shows abnormally low temperature 20-129 P-11 Coolant temperature gauge gives no display 20-129 P-12 Fuel gauge always displays FULL 20-130 P-13 Fuel gauge gives no display 20-130 P14 a) Lamps do not light up 20-131 b) Lamps light up even when lamp switch is not operated 20-131 P15 a) Wipers do not work 20-133 b) Wipers work even when wiper switch is not operated 20-133 P16 a) Fan does not work 20-135 b)_ Fan works even when fan switch is not operated 20-135 P17 Warming-up operation is not carried out below 30°C, or warming-up ‘operation is not canceled even when temperature goes above 30°C 20-137 P-18 Defective swing lock ...... . : 2 20-138 P-18 Fuel level sensor system defective beveeeeees 20-139 P-20 Coolant temperature system defective : coc 20-140 P-21. Coolant level sensor system defective trey cece 20-141 20-117P-1 Monitor panel lamps do not light up for 3 seconds when starting switch is turned ON a) No monitor panel lamps light up 2 ves “Voroge 20 soy NO tYornge 20—a0y [No Monitor panel Pil04020) Q fese ; . : 4 b)_ Some monitor panel lamps do not light up 20-118 oO Coetective o20scs,o205¢5 P-2 Monitor panel lamps all light up when starting switch is turned ON, but do not go out 20-119P-3 When starting switch is turned ON (engine stopped), CHECK. items flash (Levels for CHECK items are as specified) a) 8| (Coolant levell flashes * Check that the coolant is at the specified level before carrying out the troubleshooting ves seca - 1 Cher shoe 3 ves Detective monitor pane! | Reptace ‘Sonate Pa ves| freer Sate eared 8 2 fT Shown in peer eee a ae | Lis no Serer a un] Sim, Se tence aginst |S anesang anconmect Serneen Peer sate 1 Sonzamerore PS evar eas an thera + Bicones #8 ne rear Monitor pena Pil04020) Mate) Paix2) D D c re 20-120 ® Faoscsi27 o20scso208¢5 P-4 Preheating is not being used, but preheating display lights up esto) chase sound nonmait [| NO a ves iatt wan saev. | teplace Miia Gnatel yaa ay | At nspes ov " P1(04020) Monitor panel miatse) Mum) La) ER(swPe) tev suse Cn) ) 3) a) {3) | [Teneo ce | eater 208F05204 20-121P-5 When starting switch is turned ON and engine is started, CHECK items flash * Check both the alternator system and engine oil pressure system. a) Alternator system b) Engine oil pressure system % When the engine oil pressure is normal. P1(04020) MI4(S8) «EB SWPB) forminal Reo 1) mal [yet ewalel 07 Bronnure sessor — £8 (8) ered i) 2) (tema) G18) with ona grouns Detective monitor panei | Repl Monitor panei) (} ® ‘O} rotor tarminal 20-122 ® Engine of Faoscst28 0205520505 P-6 When starting switch is turned ON (engine stopped), CAUTION items flash * When the engine oil pressure is normal. as a peS____ I vetective atternator Rep 5 le achat | x0 bos at 2 rater] | | Etec aomas sta comeacd repair Items) Po4oz0) mIaise)—«E@{SWPE) q Monitor pave' } (6) 0 Alternator terminal R 2055128P-7 When starting switch is turned ON and engine is started, CAUTION items flash (When there is no abnormality in CHECK items or engine) a) [s@e| (Engine oil pressure) flashes ! Jon pressure 2 ves nay Sepegee L PI(04020) MI4(S8) EB(SWPB) | 2058129 re) 1 ») | | (Coolant tevell flashes | 20-124 ® o205c50205¢5 a ? {Coolant temperature) flashes ; if so Detective monitor pane! | Replace PI(04020) Mi4(Ss) E8(SWP8) _P7(X2) Cook - Monitor panet) © (6) / L tre B\ - t 4 205F05307A, ) fo (Charge) flashes a Remedy, 2 ws, Defective monitor panel | Replace rrvoiaeseosmm|| sore Sirona oy gic Fao, | | ee ., eae Puoaoz0) Mia(se) EB(SWP8) Monitor pane!) (P (2) | ) © Aternator terminal R 208F0S308-1 20-125 @i ) | HB (Fuct ievell flashes ‘* Check that there is fuel before carrying out troubleshooting, 2 ves efi fal seen tad ane < areongine. IMAI foransrox. 2 minutes P104020), Meme) PEI sssvet sensor +B ty Froscso62 20-126 ® 0205¢5P-8 (a) When starting switch is turned ON (engine stopped), buzzer does not sound for 1 second 7 CAUTION item is flashing but buzzer does not sound. * Of the CAUTION item, the buzzer does not sound if there is any abnormality in the charge or fuel level 1 vs Detecrive monitor pane! | Replace no hy eet fh utee Ten staninavaien ; P-8 (b) There is no abnormality display on the monitor, but 8 the buzzer sounds ae Contact of enastie Ce aeeer 3 Monitor pan r +24v | pame) P1(04020) \{7 eurrer ty | a @ 2) ct 205F0S310A 20-127P-9 Panel lighting of monitor panel does not light up (liquid crystal display is normal) 1 yes TRenove a NO etective monitor panel + Ghee talon ot 20-128 o 0205¢5P-10 Coolant temperature shows abnormally low temperature Ifthe coolant temperature actually remains low, check the engine system. Fan or P-11 Coolant temperature gauge gives no display (during operation, no level of gauge is displayed) H coo meres . Eco |] ontectve moniter ane! |Resice Tape TNS P-10,11 Related electrical circuit diagram Pi(04020) miaise) ERISWPA) P7(x2) Pues i 2 coum umperat enor Manson) | ®\ +o = 2osr083114 20-129 6P-12 Fuel gauge always displays FULL * Check first if the fuel tank is actually full before carrying out troubleshooting, : ive fue vel sansor] wanen Pee oT) no 2 ves Comite hemeet te." [attr inspection raved? fneen'?6 Hemme) (1) — propa or STanRarTa Ten] | ae cntiy is ert Pee on Semeestrt” P-13 Fuel gauge gives no display * Check if there is any fuel before carrying out troubleshooting. Le P-12,13 Related electrical circuit diagram Monitor parat Pu04020) Me(Me) Pex!) ivan (setectve] §—P) -—Pel 20-130 ® Tyme (4) — [replace al (3) Feoscso6 205sP-14 (a) Lamps do not light up wes ne ea per 10 a ws Dararrgeton crete orien 1 ts sere any aie ‘moniter panel amiss corner | Jctoan (cerective| ia aoe rack vay RE Jonas or 3 S P-14 (b) Lamps light up even when lamp switch is not operated couse 7 oe Srecal aee es val any, || ipa lay Ra) or | role at Ile ee |eeen 72" : a 20-131 @P1(04020), 3} Mio(MD, Mo(Mi) MacMi) LS) won ere 20-132 1 2 (Ra) o) £3) sees Froscs06e 0205¢50208¢5 P-15 (a) Wipers do not work 2 ho 3 [| feemaie (2 4 ves] ie) (a mab 2) P-15 (b) Wipers work even when wiper switch is not operated zea JSoneace pair ves} cosnnaity on. Tare wiper switen RD 20-133 3+2av MS(Ma) —_M4cxesa)_ikese) PI onl 5bG6 COOUG Oe @ @ 205F08914 20-134 ® 2055020505, P-16 (a) Fan does not work P-16 (b) Fan works even when fan switch is not operated 20-135 3+2av “al e Lg 2\} | pl Ae rT 205F08315, 20-136 205sP-17 Warming-up operation is not carried out below 30°C, or warming-up operation is not canceled even when nt temperature goes above 30°C 200-5 Serial No: 45001 - 56338 PC220-5 Serial No: 35001 - 36437 * Carry out troubleshooting first for E-10 Automatic warming-up is defective 1 rexel TER . ' Scggeasrrer g cna Teaeocommany | | turner ter se ter | retoce er Latha ron oe uring operation) | Ma 1¥ ‘Aare warming? | sav (Note) PI(04020) — MIG(SB)_ EBISWPB) P7IX2) ac umperaturesontor Monitor panel } e}—E (6) t ANN ° T° - 205608207-1 20-137 3P-18 Defective swing lock a) Even when swing lock switch is turned ON (LOCK), swing lock lamp on monitor panel does not light up. % Only carry out this troubleshooting if the swing lock is actually applied. ies Detective monitor panel | Replace irene || ‘Swing lock switch ON [20 ~ 300 b) Swing lock does not work, or is not canceled % Swing lock lamp is normal. cause Toned eS 2 ves BOBRSE A | sear L coteeenvgtocenien | Se rez Volage ‘Swing ok owen ON] Wax 1 ‘Sint lock switch OFF | 20 — 30 Tables Resistance ‘Swing lock switch ON | Min. TA ‘Swint lock switch OFF | Max 12 20-138 o20scs0205¢5 P-19 Fuel level sensor system defective Note 1: Difference between fuel level and gauge display If the gauge display position is "10", the fuel level display is 78% or 100%; if it is “1”, the fuel level display is less than 14.5%. If the machine is on a slope, the display and actual fuel level will be different. Therefore, when checking, always stop the machine on. level ground and wait for at least two minutes before reading the gauge. (The fluid level changes when the machine is moving, so a time delay is provided to give a stable display.) * Remove the fuel level sensor when carrying out this troubleshooting 3s arercewmnsenor | noe 7) ese 1 eT | L oeteoeeersrtune 2s | nevace Gee |) Tablet FULL #0908" | aporon Yi ors EMPTY 0700" approx. 5 — 1108 20208083 Note 2: There is probably interference with the sensor inside the tank, or defective installation Install carefully when replacing Note 3: Check for any vibration at the connector mount, and take the necessary action if the vibration is excessive. 20-139P-20 Coolant temperature sensor system defective aan rE rae | 0s | RETO | (se FE sense fl Tobie | peveture (25°0 | Approx 97 S088 1o0"e ‘pron 35-4 0x Connector some b 1 } Note 1: If the problem occurs again, the connector (female) at the chassis end is probably defective, so replace the connector (harness) at the chassis end. Note 2: Check for any vibration at the connector mount, and take the necessary action if the vibration is excesive. 20-140 oO 0205¢5o20scs P-21 Coolant level sensor system defective Note 1: Variations in coolant level The coolant level changes according to the angle and swaying of the machine, so if any abnormal display is given, stop the machine on flat ground and check the coolant level before carrying out the check again. 4 Remove the coolant level sensor when carrying out this troubleshooting i eeerererd ee star 3 yes Fesanance of mount Nowe 2) | Replace sensor 1 9 ise 4 Table 1 Float UF | Maxie Fiost OOWN | Min. Ma 20208086 Note 2: There is a strong possibility that the mount is resonating, so check the mount of the sub: tank. Note 3: Check for any vibration at the connector mount, and take the necessary action if the vibration is excessive. 20-141 i30 DISASSEMBLY AND ASSEMBLY 2055 METHOD OF USING MANUAL PRECAUTIONS WHEN CARRYING OUT OPERATION ‘SPECIAL TOOL LIST WEIGHT TABLE TIGHTENING TORQUES AND STANDARD VALUES TABLE LUBRICANT AND COOLANT TABLE STARTING MOTOR Removal and Installation ALTERNATOR Removal and Installation ENGINE OIL COOLER Removal and installation FUEL INJECTION PUMP Removal and Installation WATER PUMP. Removal and Installation NOZZLE HOLDER Removal and Installation TURBOCHARGER Removal and Installation THERMOSTAT Removal and Installation ENGINE FRONT SEAL Removal and Installation ENGINE REAR SEAL Removal and Installation GOVERNOR MOTOR Removal and Installation CYLINDER HEAD Removal and installation AFTER-COOLER Removal and installation HYDRAULIC COOLER Removal and Installation REDIATOR, HYDRAULIC COOLER Removal and installation 30- 4 30- 5 30-7 30-9 30-10 30-11-2 30-12 30-12 30-14 30-14 30-16 30-16 30-18 30-18 30-20 30-20 30-22 30-24 30-26 30-26 30-28 ENGINE, HYDRAULIC PUMP Removal and Installation DAMPER Removal and installation CENTER SWIVEL JOINT Removal and Installation Disassembly and Assembly FINAL DRIVE Removal and Installation Disassembly Assembly TRAVEL MOTOR Disassembly Assembly ‘SPROCKET Removal and Installation SWING MOTOR Removal and Installation Disassembly Assembly ......- SWING MACHINERY Removal and Installation Disassembly Assembly REVOLVING FRAME Removal and Installation SWING CIRCLE Removal and Installation IDLER, RECOIL SPRING Removal and Installation Disassembly and Assembly TRACK ROLLER Removal and installation CARRIER ROLLER, Removal and Installation ‘TRACK SHOE Removal and Installation CHARGING PUMP Removal and Installation 30-30 30-32 30-32 30-34 30-34 30-36 30-40 - 30-45-1 30-45-4 30-46 30-48 + 30-49-1 30-49-4 30-48 30-50 30-52 30-58 30-60 30-60 30-62 30-64 30-64 30-66 30-68HYDRAULIC PUMP Removal and Installation Disassembly Assembly MAIN PUMP INPUT SHAFT OIL SEAL Removal and Installation CONTROL VALVE Removal and Installation Disassembly Assembly MAIN RELIEF VALVE Removal and Installation Disassembly and Assembly TVC VALVE Removal and Installation CO+NC VALVE Removal and Installation SERVO VALVE Removal and Installation .. WORK EQUIPMENT PPC VALVE Removal and Installation Disassembly and Assembly TRAVEL PPC VALVE Removal and Installation Disassembly and Assembly PPC SHUTTLE VALVE Removal and Installation BOOM CYLINDER: Removal and Installation 30-2 ® 30-68 + 30-69-1 30-69-6 30-70 30-70 30-72 30-74 30-76 30-76 30-78 30-78 30-78 30-80 30-80 30-82 30-82 30-84 30-84 ARM CYLINDER Removal and Installation BUCKET CYLINDER Removal and Installation HYDRAULIC CYLINDER Disassembly Assembly WORK EQUIPMENT Removal and Installation BUCKET Removal and Installation ARM Removal and Installation ‘ARM, BUCKET Removal and Installation Boom Removal and Installation CAB Removal and Installation COUNTERWEIGHT Removal and Installation ENGINE THROTTLE CONTROLLER Removal and Installation MONITOR PANEL Removal and Installation PROCEDURE FOR FLUSHING HYDRAULIC CIRCUIT .- 30- 30- 30- 30- 30- 30- 30- 86 86 88 90 92 94 94 96 96 98 98 30-100 30-100 30-102 0205¢5METHOD OF USING MANUAL 1. When removing or installing unit assemt (1) When removing or installing a unit assembly, the order of work and techniques used are given for the removal operation; the order of work for the installation operation is not given. (2) Any special techniques applying only to the installation procedure are marked) 1|, and the ‘same mark is placed after the relevant step in the removal procedure to indicate which step in the installation procedure it applies to. (Example) REMOVAL OF OOO ASSEMBLY Tilte of operation A vee Precautions related to safety when carrying out the operation TVXXKK (Noo cceecees Step in operation * everrreereenn Technique or important point to remember when removing XXXX (1). 2 A640) [#1 Indicates that a technique is listed for use during installation 3. OO C Cassembly (3) = : See Lubricant and Coolant Table INSTALLATION OF © 0 OASSEMBLY ..... Title of operation + Carry out installation in the reverse order to removal. fer Technique used during installation * Technique or important point to remember when installing A A A (2) + Adding water, oil socssssses Step in operation * Point to remember when adding water or oil 2. General precautions when carrying out installation or removal (disassembly or assembly) of units are given together as PRECAUTIONS WHEN CARRYING OUT OPERATION, so be sure to follow these precautions when carrying out the operation. 1g of special tools (1) For details of the description, part number, and quantity of any tools (A,, etc.) that appear in the operation procedure, see the SPECIAL TOOLS LIST given in this manual. isting of tighter 1g torque, weight, refill amount for oil and water (1) If symbols such as © , [ip], or ‘dl! appear in the operation procedure, See TIGHTENING TORQUES AND STANDARD VALUES TABLE, MAINTENANCE STANDARD TABLE, WEIGHT TABLE, and LUBRICANT AND COOLANT TABLE for details of the values. 30-4 0205¢5o208c5 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 necessary places before removal to prevent any mistake when assembling + To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. + Fit wires and hoses with tags to show their installation position to prevent any mistake when installing + Check the number and thickness of the shims, and keep in a safe place. + When raising components, be sure to use lifting equipment of ample strength + When using forcing screws to remove any components, tighten the forcing screws alternately. * Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering after removal. * Precautions when handling piping during disassembling Fit the following blind plugs into the piping after disconnecting it during disassembly operations. 1) Hoses and tubes using sleeve nuts Nominal | umber | PM 2 ors 03078 (07221-20210 (ul, 07222-00210 Pui (07221-20816 INutl, 07222-00312 Pig) 08 (07221-20422 ut, 07222-00414 Pug) 05 2 t),07222.00515 (Piug) 08 07221-20628 (Nutl,07222-00616 Pug) 10 77221-21034 (Null, 07222-01018 Pug) 12 07376-51294 | 07221-21296 (Nut, 07222-01219 Plug) 2) Split flange type hoses and tubes Nominal Sleeve head 1 Nomina | Flange hose ena) | Sleeve hea Split flange. (os | 07379.00800__| _07378-104¢ (07371-30400 ‘05 | 07379-00800 | 07378-10800 | 07371-30500 3) If the part is not under hydraulic pressure, the following corks can be used Nomina Dimensions Nominal) Partnumber me (06 _[ovoss-oos08| 6 | = | 8 7 a |o704e.00811| 8 lovoss-o1012] 10 | e812 wl Taper 19 6s jo7oea.orave] 12 | 10 18 jovoao-orara| 14 [115 18 lo7o4s-01620] 16 [a5 70 1 18 [o7oss.ove22) 18 | 15 22 20 07049-02025 20 | 172s 22 jov04s.02229| 22 [185] 28 ao2r200s 24 [o7048-02430| 24 | 20 | 30 27_07049.02734| 27 [225 | 34 30-5Precautions for installation operations Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque. Install the hoses without twisting or interference. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts. Bend the cotter pin or lock plate securely. ‘When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2 — 3 drops of adhesive. ‘When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no dirt or damage, then coat uniformly with gasket sealant. Clean all parts, and correct any damage, dents, burrs, or rust. Coat rotating parts and sliding parts with engine oil ‘When press fitting parts, coat the surface with antifriction compound (LM-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 fully, and align the direction of the hook. ‘When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side. Precautions when completing the operations If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run the engine to circulate 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, such as hydraulic cylinders, pumps, or motors, have been removed for repair, always bleed the air from the system after reassembling the parts. % For details, see TESTING AND ADJUSTING, Bleeding air. Add the specified amount of grease (molybdenum disulphide grease) to the work equpment related parts. 30-6 o205¢50205¢5 SPECIAL TOOL LIST Nature of work Symbol | Part No. Part Name Qty Remarks Disassembly, Serena | «| 2 drive assembly | 1 790 102 1831 | Nut wrench | 790-101-1102 | Pump. |_| 790-431-2100 | Plate Ass'y 1 791-600-2001 | Compressor A 1 or eer 791-685-8003 Compressor 8 i Disassembly, ee assembly of recoil 8 ~—_—‘791-635-3160 | Extension 1 Spring assembly en __j___| 790-101-1600 Cylinder (70 t) 1 790-101-1102 | Pump M4 > | 791-630-3000 | Remover & installer | 1 isassembly, Removal, press fittn, visas ee Yiack | | 790-101-1300 | Cylinder 1000 | 1 _| Removal press fiting shoe assembly esas or of master pin 790-101-1102 | Pump 1 + Removal, instal- | lation of charging | pump assembly . | r = pump assembly” | 796.750.1410 | Oil stopper a lation of main pump assembly | 1 | 790-502-1002 | Repair stand 1 | ‘Arm cylinder (Socket (PC200, 220) 790-302-1450 | (width across flats: | 1 | Boom, bucket | 85mm) |" eylinder | Removal, ; (#220) installa = tion of | Socket Boom, bucket | nylon nut 790-302-1350 | (width across flats: | 1 cylinder | | 85mm) (PC200) Disassembly, 790-101-1102 | Pump 1 | assembly of oT : sesemity e [2 | 790-720-1000 | Expander 1 [Eagension of cylinder assembly | -—-— — so [| en2a0-60 | i Rang | (bez00, 1 | |(PC200, 220) lArm cylinder | Comp: | 8 | 796-720-1670 | ring 1 [amc ression | Bucket cylin- | Of piston _ _ der (PC220)_|"""9 | Bucket cyli | 796-720- i wicket cylin= | || | 796-720-1660 | ring + [Bucesesysr . 1 = _ + Removal, instal- | Removal insta 796-900-1200 | Remover 1 assembly a = + Removal, instal: | F | 790-101-3800 | Puller (50 t) | + | Failing out boo lation of work —E——Eeee—r——eES |} equipment marae eae equipmen 790-101-1102_| Pump 1Nature of work | symbol | Par No. Part Name ary Remarks 790-507-5000 | Repeir stand 1 1 790-901-2280 | Plate 1 795-690-1803 | Torque wrench set 1 Disassembly assembly of travel | G | 2 | 796-720-2220 | Socket 1 motor assembly 796-730-2120 | Screwdriver 1 3 | 796-730-2000 | Wrench 1 « | 7967512300 | Holder 1 790-501-5000 | Repair stand 1 1 790-901-2110 Bracket 1 | 790-901-2280 | Piao 1 2 799-301-1600 Oil leak tester kit 1 | Removal of brake piston oe | 796.790.2120 | Screwdriver 1 motor assembly Removal, instalation 3 | 7967202220 | Socket a | Removal 796-690-1803 | Torque wrench set 1 4 | 790-4452910 | Holder 1 | Installation of conter shat py |e eel | eed 1 | Measurement of rotating 795-630-1803, Torque wrench set 1 torque 780-507-5000 | Repair stand 1 1 | 7909012110 | Bracket 1 79007-2150 | Plate 1 [2 [700-245-1000 | Pie 1 | 790730-2120 |” serewariver 1 a | 796-720-2000 | Socket 1 | Removal, instalation of Disassembly, “na assembly of x |__| 79520-1808 | Toraue wrench set 1 hydraulic pump Measurement of shoe ateembly + | 7904452610 | Hook 1 | essuren 5 |_ 1987202210 | Scrondriver Tees 790-720-2220 ‘Socket ‘ of impeller & | 70-45-6100 | Gauge (Max. anal side) | 1 | aajustmon of stroke of 7 790-445-2900, Gauge (Min. angle side} 1 seelcaeen 8 pecnereoe) eet u Measurement of rotating 795-630-1803 ‘Torque wrench set 1 an 30-8 ® i0208C5 WEIGHT TABLE Unit: kg Machine model PC200-5 PC220-5 Serial No. a 45001 and up 35001 and up Cylinder head assembly 40 40 « | Hydraulic cooler assembly 55 55 & | Radiator, hydraulic cooler assembly 80 80 “Air cleaner assembly (with bracket) 35 35 Engine, main pump assembly 750 750 Center swivel joint assembly 45 45 ; Final drive assembly 340 340 5 | Sprocket : 40 40 '5 | Swing motor assembly 55 55 _ 8 | swing machinery assembly 280 280 | Revolving frame assembly 4,400 4,400 Pence a romeeeeaees 3 | Idler, recoil spring assembly 270 270 5 | Recoil spring assembly 140 140 5 | idler assembly _ 130 130 | Main pump assembly 210 210 & | Control valve assembly - 180 180 - 2 | Boom cylinder assembly _ 130 220 & | Armeylinder assembly _ 250 300 =| Bucket cylinder assembly 160 190 2 | Work equipment assembly "3,400 4,000 € Bucket assembly 650 800 § | Arm assembly 1,000 1,150 © | arm, bucket assembly 1,650 2,000 5 | Boom assembly 1,750 2,000 3 | Operator's cab assembly 240 240 | Sperator's cect assembly 7 oa 3 | counterweight - 3,400. 4,350 30-9TIGHTENING TORQUES AND STANDARD VALUES TABLE ; nad: eee Machine model Hl | PC200-5 6220-5 1 | Head cover mounting bolt 0.9401 09401 2 | Rocker arm assembly mounting bolt, nut 25408 25205 3 | Rocker arm locknut —_ kgm 45405 | 45205 4 Cylinder head mounting bolt 1st step [7 7#1 2nd step 11408 1405 g 3rd step ° 905° 90°37 2 |S | Rear seal assembly | 1) Flywheel mounting bolt 1st step _| kgm 943 943 2nd step_| wi2 | 1Be2 Senate om | 088 os 6 | Engine mounting bolt kam | 28543 28.543 1 | Damper assembly mounting bolt 7282075 | 7.254075 2 | Final drive assembly [- 1). Carrier pin mounting nut 3525 3525 2). Gear plate mounting bolt 3.15 = 0.38 3.15 + 0.36 ['3) Gear assembly mounting bolt 3922 3922 | 4) Starting force Max. 30 Max. 30 | | 5) Cover mounting bolt 2823 2843 | 6) Final drive assembly mounting bolt _| |eeaazaete 2843 3 | Travel motor assembly | S| | 1) Safety valve 2643 2643 EL 5 kgm 5 | | 21 Counterbalance valve mounting bolt | 6.75 + 0.75 6.75 + 0.75 3 | | 3) Shett rotating torque 0.48 - 0.60 0.45 0.60 “| Tay Retainer mounting bok tet time a | 2nd time _| 050.1 05 £0. | 3rd time | [| aoto1 | 1008 a] ene rer ceca in 1)_ Plug of check vaive 3845 3845 2) Safety valve 1841 1821 3) Retainer mounting screw 1st step | Max. 0.1 Max. 0.1 2nd step o5:01 | 05+01 3rd stop 1.35 £0.15 1.35 £0.15 | 4) Brake case assembly mounting bolt 1842 1842 30-10 ® 0208¢50205¢5 Machine model oo Unt Pc200-5 Pe220-5 5 Swing machinery assembly 1)_ Carrier gear pin mounting bolt | 11.25 + 1.25 11.25 + 1.25 4 2) Carrier assembly plate mounting bolt 39.254 4.25 | 39.25 + 4.25 5 | _3) Bearing cage mounting bolt yo I é + When adjusting preload (only 4 bolts) _20 i 20 + After adjusting | 6.75 + 0.75 6.75 + 0.75 6 Revolving frame assembly mounting bolt men me ] [1 Recoit spring assembly ae ; = | _1)_ Installed toad of spring 11,100 12,900 3 | 2) Free length of spring 558 603.5 5 3)_ Installed length of spring =m 437 | 466 1 Hydraulic pump assembly 1) Mounting bolt of main pump input ___ shaft housing assembly 3154035 | 3.1540.35 2) Plate bolt of cradie 3.15 4 0.35 3.15 £ 0.35 3) Bearing retainer screw 1.35 £0.15 1.35 # 0.15 4) Housing mounting bolt 3.15 + 0.35 3.15 2 0.35 5) Pump sub-assembly mounting bolt 11521 11541 6) End cap mounting bolt (Front) ial (Rear) | | 7) impetier mounting bolt € | __8) Servo piston mounting bolt % | | 9) Servo valve assembly mounting bolt 3.18 + 0.36 3.15 0.35 2 10) Rear pump assembly mounting nut kam 28543 28543 2 11) CO-NC valve mounting bolt (Front pump) (32403 3.2403 = 12) TVC and CO.NC vaive mounting bolt - (Rear pump) 32403 32203 13) Tube joint bolt 1.8202 18202 |___14) Sleeve nut of hose B22 822 12 | Control vaive assembly | i 11) Check vaive mount plug 20+2 2042 (2) Safety-suction valve Wt? 1422 3)_Jet sensor relief valve 55 +05 55t05 4) Main relief valve “95 £05 95 +05 3 | Work equipment PPC valve assembly 1)_ Joint | 11.25 + 1.25 11.25 + 1.28 2) Nut 115218 115215 30-11 ai ] item Unit Machine model j PC200-5 PC220-5 4] Hydraulic cylinder assembly &| | 1) Bucket cylinder Head mounting bolt 27544 21544 2g Piston nut 720 £72 720 £72 | 2) Arm cylinder or 3855 38455 g} Piston nut 1040 + 108 1,040 + 104 =) [3 Boom cylinder Head mounting bolt 25 +4 25+4 Piston nut _ 72072 1,040 + 104 30-11-1 ® 208so20scs LUBRICANT AND COOLANT TABLE Unit: & Machine model PC200-5 PC220-5 Remarks Serial No. 45001 and up 35001 and up Cooling water 156 156 Engine oil pan 175 75 Swing machinery case 93 93 Final drive case 37 37 Each side _ Hydraulic tank 170 170 _ PTO case 18 18 Note: The values for oil volumes are the values for normal oil changes during inspection and maintenance.REMOVAL OF STARTING MOTOR ASSEMBLY Ar Disconnect the cable from the negative (—) terminal of the battery. 1. Governor motor assembly + Remove governor motor assembly. For details, see REMOVAL OF GOVER- NOR MOTOR ASSEMBLY. 2. Heater switch (1) (See F1) 3. Governor motor bracket (2) (See F1) 4. Wiring (3) (See F2) 5. Wiring connector (4) (See F2) 6. Starting motor assembly (5) (See F2) INSTALLATIN OF STARTING MOTOR ASSEMBLY * Carry out installation in the reverse order to removal 30-12 O REMOVAL OF ALTERNATOR ASSEMBLY A disconnect the cable from the negative ( terminal of the battery. 1. Wiring (1) (See F3) 2. Adjustment bolt (2) (See F3) * Loosen mounting bolts and nuts (3). +3. Fan belt (4) (See F3) #1) 4, Mounting bolts and nuts (3) (See F3) 5. Alternator assembly (5) (See F3) INSTALLATION OF ALTERNATOR ASSEMBLY + Carry out installation in the reverse order to removal faa + Adjust the fan belt tension. For details, see Standard Value Table for Engine, 0208¢50205¢5 F 20505303, F2 30-13 pREMOVAL OF ENGINE OIL COOLER ASSEMBLY 1. Draining cooling water 2. Dust indicator hose (1), intake pipe (2) (See Fy 3. Turbocharger heat insulator plate (3) (See Fi) Lubrication tube (4) (See F2) Oil level gauge guide (5) (See F2) Oil cooler assembly (6) (See F2) [#1 oop INSTALLATION OF ENGINE OIL COOLER ASSEMBLY + Carry out installation in the reverse order to removal, a1 ~~. Oil cooler assembly: Gasket sealant (LG-7) + Refilling with water ‘%* Add water to the specified level, and run the engine to circulate the water through the system. Then check the water level again. 30-14 ® REMOVAL OF FUEL INJECTION PUMP ASSEMBLY 1. Fuel injection pipe (1) (See F3) [#1 2. Control rod (2) (See F3) Mark the mounting hole of the clevis pin 3. Heater switch (3) (See F3) * Remove the heater switch mounting bolts, and move the heater switch towards the rear. 4, Spill hose (4) (See F3) 5. Fuel hose (5) (See F3) 6. Lubrication tube (6) (See F3) 7. Bracket (7) (See F3) 8. Fuel injection pump assembly (8) (See F3) (m2) ‘* Remove 5 front end mounting bolts and 1 pump end mounting bolt. INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY + Carry out installation in the reverse order to removal #1] S=) Sleeve nut: See Tightening Torques and Standard Values Table (we * Install the injection pump as follows, 1) Set No. 1 cylinder at compression top dead center. * Rotate the crankshaft in the normal direction and align the pointer with the 1.6 TOP line on the crankshaft pulley. (See F4) Hf no match mark can be seen on the idler gear, rotate the crankshaft one more turn 2) Replace the normal bolt with bolt ®, and lock drive gear (9) in position. (See F5) 3)_ Injection pump assembly * Insert pin @ (64.0 — 4.5 mm, length = approx. 100 mm) through cover mounting bolt hole @, and check that the pin enters the casting hole in the drive gear smoothly. (See F6) 4) Remove bolt () and tighten the normal bolt again. (See F5) + Adjust the fuel timing and bleed the air from the fuel circuit. For details, see TESTING AND ADJUST- ING 0208¢50208¢5 ‘ew fom fyb 20505305 (01408107 30-15 LREMOVAL OF WATER PUMP ASSEMBLY 1. Draining cooling water 2. Wiring connector (1) (See F1) 3. Hose (2) (See F1) 4. Fan belt (3) (See F1) [#1] %* Loosen the mounting bolts and nuts of the alternator assembly, then remove the adjustment bolt, and move the alternator assembly towards the block. 5. Plate (4) (See F1) 6. Water pump assembly (5) (See F1) INSTALLATION OF WATER PUMP ASSEMBLY + Carry out installation in the reverse order to removal. (ei + Adjust the fan belt tension. For details, see Standard Value Table for Engine. + Refilling with water * Add water to the specified level, and run the engine to circulate the water through the system. Then check the water level again. 30-16 REMOVAL OF NOZZLE HOLDER ASSEMBLY Fuel injection pipe (1) (See F2) [#1] Spill hose (2) (See F2) Holder (3) (See F2) [ 2) Nozzle holder assembly (4) (See F2) |# 3 * When removing the nozzle holder assembly, be careful not to let any dirt or dust get in. PON INSTALLATION OF NOZZLE HOLDER ASSEMBLY + Carry out installation in the reverse order to removal eat = Sleeve nut: For details, see Tightening Torques and Standard Values Table [#2] 321 Mounting bolt For details, see Tightening Torques and Standard Values Table 3) % When installing the nozzle holder assembly, check and clean the nozzle mount, then instal 0205¢5sosozo 30-17REMOVAL OF TURBOCHARGER ASSEMBLY 1. Dust indicator hose (1), intake pipe (2) (See Ft) 2. Turbocharger heat insulator plate (3) (See Fi) 3. Lubrication drain tube (4) (See F1) Hose (5) (See F2) ‘* Disconnect the hose, and move it towards the intake connector. Lubrication inlet tube (6) (See F2) Muffler heat insulator plate (7) (See F2) U-bolt (8) (See F2) Bracket (9) (See F2) ‘Turbocharger assembly (10) (See F2) %* Remove the turbocharger mounting nuts, pull out the muffler drain hose, move the muffler assembly towards the counterweight, then remove the turbocharger assembly. > eaxoe INSTALLATION OF TURBOCHARGER ASSEMBLY + Carry out installation in the reverse order to removal. 30-18 > REMOVAL OF THERMOSTAT ASSEMBLY 1. Draining cooling water 2. Connector (1) (See F3) 3. Thermostat assembly (2) (See F3) INSTALLATION OF THERMOSTAT ASSEMBLY + Carry out installation in the reverse order to removal. + Refilling with water %* Add water to the specified level, and run the engine to circulate the water through the system. Then check the water level again. 0205¢5| Z 20805310 30-19 5REMOVAL OF ENGINE FRONT SEAL 1, After cooler assembly (PC220 6 only) + Remove after-cooler assembly. 2. Radiator, hydraulic cooler assembly + Remove radiator and hydraulic cooler assembly. For details, see REMOVAL OF RADIA- TOR, HYDRAULIC COOLER ASSEMBLY Fan (1) (See F1) Vibration damper (2) (See F1) Fan belt (3) (See F1) [#1 + Loosen the mounting bolts and nuts of the alternator assembly, then remove the adjustment bolts, and move the alternator assembly towards the block. 6. Pulley (4) (See F2) * Using puller (D, remove the pulley, then remove the collar. 7. Front seal (5) (See F3) [#2 sae INSTALLATION OF ENGINE FRONT SEAL + Carry out installation in the reverse order to removal, a + Adjust the fan belt tension. For details, see Standard Value Table for Engine. (#21 ~~ Lip of oil seal: Grease (G2-LI) + Press fit the front seal so that it is level with the surface of the front cover. 30-20 REMOVAL OF ENGINE REAR SEAL 1. Damper accembly + Remove damper assembly. For details, see REMOVAL OF DAMPER ASSEMBLY. 2. Flywheel (1) (See F4) [#1] The pilot of the flywheel is shallow, and may suddenly come out, so be careful not to get your fingers caught. 3. Rear seal (2) (See F5) #2 * Measure the dimension from housing end face. INSTALLATION OF ENGINE REAR SEAL + Carry out installation in the reverse order to removal. fea) ‘Tightening order of mounting bolts (See F5) =] Mounting bolt: For details, see Tightening Torques and Standard Values Table. + Use dial gauge ‘ to measure the face runout and radial runout of the flywheel (See F6) For details, see Tightening Torques and Standard Values Table. (#2 * When assembling, check the wear groove of the seal lip contact portion of the crankshaft, and if necessary, slide to flywhh side until housing end face. <= Lip of oil seal: Grease (G2-LI) o205c50208¢5 oe ra ts Vv i i ° "es A Aye x 6 Ng @ rE = SS 3} 2 ae oe pa 30-21 aREMOVAL OF GOVERNOR MOTOR ASSEMBLY PC200-5 Serial No: 45001 - 56338 PC220-5 Serial No: 35001 - 36437 Ardisconnect the cable from the negative (—) terminal of the battery 1. Control rod (1) (See F1) %* Remove the clevis pins at the governor motor end. 2. Wiring connector (2) (See F1) 3. Governor motor assembly (3) (See F1) INSTALLATION OF GOVERNOR MOTOR ASSEMBLY PC200-5 Serial No: 45001 - 56338 PC220-5 Serial No: 35001 - 36437 + Carry out installation in the reverse order to removal 30-2: ® 205502055 20805311 30-23 1REMOVAL OF CYLINDER HEAD ASSEMBLY 1. Water pump assembly + Remove water pump assembly. 2. Turbocharger assembly + Remove turbocharger assembly. 3.Wiring (1) (See F1) 4. Intake connector (2) (See F1) 5. Breather hose (3) (See F1) 6. Fuel filter assembly (4) (See F1) * Disconnect the fuel filter assembly, and move it towards the fan. 7. Fuel injection pipe (5) (See F1) (# 1) 8. Spill hose (6) (See F1) 9.Nozzle holder assembly (7) (See F1) [#2 * Remove 6 nozzle holder assemblies together with the spill hoses 10. Head cover (8) (See F1) [# 3] 11. Rocker arm assembly (9) (See F2) [2 4 %* Loosen the locknut, then loosen the adjustment screw 2 — 3 turns. 12. Push rod (10) (See F2) 13. Cylinder head assembly (11) (See F3) | 5 (ks) See Weight Table INSTALLATION OF CYLINDER HEAD ASSEMBLY + Carry out installation in the reverse order to removal Go] S=E Sleeve nut: See Tightening Torques and _ Standard Values Table #2 32] Mounting bolt: See Tightening Torques and Standard Values Table (3) =] Mounting bolt See Tightening Torques and Standard Values Table 30-24 ) (ea) * Tighten the mounting bolts and nuts starting from the center and working out in order to the outside. (See F4) %* Check that the ball of the adjustment screw is fitted securely in the socket of the push rod. + Adjust the valve clearance. For details, see TESTING AND ADJUST- ING, Adjusting valve clearance. = Mounting bolt, nut See Tightening Torques and Standard Values Table SD Locknut: See Tightening Torques and Standard Values Table (es + If rust can be found of which beyond the confines of 5 mm square, replace the head bolt with new one. * Be careful to check that there is no dirt or dust on the mounting surface of the cylinder head or inside the cylinder. ‘* When installing the gasket, check that the grommets have not come out. %* Tighten the cylinder head mounting bolts 2 — 3 turns by hand, then tighten in the order given in the diagram << Mounting bolt: ‘Anti-friction compound (LM- P) 30 Mounting bolt: ‘See Tightening Torques and ‘Standard Values Table * After tightening, make one punch mark on the bolt head to indicate the number of times it has been tightened. + If any bolt already has five punch marks, do not reuse it. Replace it with a new bolt. © Refilling with coolant. ‘* Refill coolant to the specified level and run the engint to circulate the coolant through the system. Then check the coolant level again 20550205¢5 e ‘ SB Sab FONE Ae BS eS oe Wg or es a 1 209F05407 Extaust sie (Orde for tghtening head bolts 62084014 30-25 TREMOVAL OF AFTER-COOLER ASSEMBLY (PC220 only) 1. Hose (1) (See F1) 2. After-cooler assembly (2) (See F1) * Sling the after-cooler assembly, and remove the mounting bolts, then lower the after-cooler assembly and pull it out. INSTALLATION OF AFTER-COOLER ASSEMBLY (PC220 only) * Carry out installation in the reverse order to removal 30-26 REMOVAL OF HYDRAULIC COOLER ASSEMBLY “AS Lower the work equipment to the ground and stop the engine. Then loosen the oll filercep gradually toreplessethe internal pressure ofthe hydraulic reservoir 1. After-cooler assembly (PC220 only) + Remove after-cooler assembly. For details, see REMOVAL OF AFTER-COOLER ASSEMBLY. 2. Hose (1) (See F2) 3. Hydraulic cooler assembly (2) (See F3) Sling the hydraulic cooler assembly, and remove mounting bolts, then lower the hydraulic cooler assembly and pull it out fis) See Weight Table INSTALLATION OF HYDRAULIC COOLER ASSEMBLY + Carry out installation in the reverse order to removal + Refilling with oil * Add oil to the specified level, and run the engine to circulate the oil through the system. Then check the oil level again o205¢502065 30-27REMOVAL OF RADIATOR, HYDRAULIC COOLER ASSEMBLY “B" Lower the work equipment to the ground and stop the engine. Then loosen the oil filler cap gradually to replease the internal pressure of the hydraulic reservoir. 1. After-cooler assembly (PC220-5 only) + Remove after-cooler assembly. For details, see REMOVAL OF AFTER- COOLER ASSEMBLY Draining water Hose (1) (See F1) Hose (2) (See F2) Hose (3) (See F2) Shroud (4) (See F2) % Remove the shroud and move it towards the engine. 7. Radiator and hydraulic cooler assembly (5) (See F3) + Sling the radiator and hydraulic cooler assembly, then remove the mounting bolts, and lift off the radiator and hydraulic cooler assembly. pa pen (is) See Weight Table INSTALLATION OF RADIATOR, HYDRAULIC COOLER ASSEMBLY + Carry out installation in the reverse order to removal. + Refilling with oil + Run the engine to circulate the oil through the system. Then check the oil level again. + Refilling with water %* Run the engine to circulate the water through the system. Then check the water level again 0205s205F05409 30-29REMOVAL OF ENGINE, HYDRAULIC PUMP ASSEMBLY PC200-5 Serial No: 45001 - 56338 PC220-5 Serial No: 35001 - 36437 Ad Disconnect the cable from the negative ( terminal of the battery. “AE Lower the work equipment to the ground and stop the engine. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank + Remove hydraulic tank strainer, and use 1001 D to stop the oil. (See F1) + When not using tool D, remove drain plug and drain the oil from hydraulic tank and piping ‘ weer See Lubricant and Coolant Table * After removing the piping, mark with tags to prevent mistakes when installing, 1. Draining water 2.Aircleaner cover (1) (See F2) 3. Air cleaner assembly (2) (See F2) % Remove the air cleaner cover, then remove the air cleaner assembly together with the bracket (se) See Weight Table 4, Muffler heat insulator plate (3) (See F2) 5. Dust indicator hose (4) (See F2) 6.Hose (5) (See F2) 7. Tube (6) (See F2) 8.Hose (7) (See F3) 9. Wiring connectors (8), (9) (See F3, Fa) 10. Wiring (10) (See F4) 11. Fuel hose (11) (See F4) 12. Hose (12) (See Fa) 13.Fan and vibration damper assembly (13) (See F4) %* Remove vibration damper mounting bolts, and move fan assembly towards radiator. 14. Intake pipe (14) (See F4) 30-30 @ 18. Wiring connector (15) (See F5) 16. Ground connection (16) (See F5) 17.Engine and hydraulic pump assembly (17) (See F6) [# i) ‘* When removing the engine and hydraulic pump assembly, do not forget to disconnect the piping and wiring, and check that there is no interference at any point when removing See Weight Table INSTALLATION OF ENGINE, HYDRAULIC PUMP ASSEMBLY PC200-5 Serial No: 45001 - 56338 PC220-5 Serial No: 35001 - 36437 * Carry out installation in the reverse order to removal, i) 3) Mounting bolt: See Tightening Torques and Standard Values Table ing oll and coolant + Refill oil and coolantto the specified level. “wi See Lubricant and Coolant Table. + Bleeding air ‘* Bleed the air from fuel system. + Bleed the air from the main pump For details, see TESTING AND ADJUST- ING, Bleeding air. %* When finished, check the level of hydraulic tank and radiator (sub-tank} 20550208¢5 A F2. Lt 208F05411 £3. 205F0s412| Fa. 205-0543) 30-31REMOVAL OF ENGINE, HYDRAULIC PUMP ASSEMBLY PC200-5 Serial No: 56339 and up PC220-5 Serial No: 36438 and up Ay Disconnect the cable from the negative (-) vias terminal of the battery. "A" Lower the work equipment to the ground and stop the engine. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. + Remove hydraulic tank strainer, and use tool D to stop the oil. (See F1) * When not using tool D, remove drain plug and drain the oil from hydraulic tank and piping. wate See Lubricant and Coolant Table * Afterremoving the piping, mark with tags to prevent mistakes when installing. Draining water Air cleaner cover (1) (See F2) Air cleaner assembly (2) (See F2) ‘%* Remove the air cleaner cover, then remove the air cleaner assembly together with the bracket. [ie] See Weight Table }. Muffler heat insulator plate (3) (See F2) 3 Dust indicator hose (4) (See F2) 3. Hose (5) (See F2) . Tube (6) (See F2) 3. Hose {7) (See F3) Wiring connector (8) (See F3) Fuel contro! cable (9) (See FA) 30-31-1 @ 11. Wiring (10) (See F5) 12. Fuel hose (11) (See FS) 13. Hose (12) (See F5) 14. Fan and vibration damper assembly (13) (See F5) * Remove vibration damper mounting bolts, and move fan assembly towards radiator, 16. Intake pipe (14) (See F5) 16. Wiring connector (15) (See F6) 17. Ground connection (16) (See F6) 18. Engine and hydraulic pump assembly (17) (See F7) (#1) ‘When removing the engine and hydraulic pump assembly, do not forget to disconnect the piping and wiring, and check that there is no interference at any point when removing. (is) See Weight Table INSTALLATION OF ENGINE, HYDRAULIC PUMP ASSEMGBLY PC200-5 Serial No: 56339 and up PC220-5 Serial No: 36438 and up * Carry out installation in the reverse order to removal, 1) = Mounting bolt: See Tightening Torques and Standard Values Table + Filling oit and coolant * Refill oil and coolant to the specified level. see Lubricant and Coolant Table. + Bleeding air * Bleed the air from fuel system, %* Bleed the air from the main pump. For details, see TESTING AND ADJUST- ING, Bleeding air. ‘%* When finished, check the level of hydraulic tank and radiator (sub-tank). o20sc50205¢5 FI | £9879) aostcosnss 2 fs : ] 1 | aostosert const Fs "7 a 2oeFo0s152 30-31-2 2REMOVAL OF DAMPER ASSEMBLY 1. Hydraulic pump assembly + Remove hydraulic pump assembly. For details, see REMOVAL OF HYDRAU- LIC PUMP ASSEMBLY. 2. Damper assembly (1) (see F1) (#1) INSTALLATION OF DAMPER ASSEMBLY + Carry out installation in the reverse order to removal. [wa] a“ Damper spline Anti-friction compound (LM-G) = Mounting bolt: See Tightening Torques and Standard Values Table 30-32 D REMOVAL OF CENTER SWIVEL JOINT ASSEMBLY “A Lower the work equipment to the ground and release the remaining pressure in the circuit. For details, see TESTING AND ADJUSTING, Releasing pressure in hydraulic circuit for machines with PPC valve Hoses (1), (2) (See F2) Elbow (3) (See F2) Hose (A) (See F3) Link (5) (See F3) Center swivel assembly (6) (See Fa) geene [xs] See Weight Table INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY + Carry out installation in the reverse order to removal + Bleeding air % Bleed the air from travel motors. For details, see TESTING AND ADJUST- ING, Bleeding air. + When finishing, check the oil level of hydraulic tank. 0205¢50208¢5 30-33 CDISASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY Remove cover (1). (See F1) 2. Remove snap ring (2). (See F1) 3. Using push-puller 1), pull out swivel rotor (4) and ring (3) from swivel shaft (5). (See F1,F2) 4. Remove snap ring (6), then remove oil seal (7) and slipper seal (8). (See F1) ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY 1. Assemble slipper seal (8) to swivel rotor (4) (See F1) 2. Using push tool ®, press fit oil seal (7) to swivel rotor (4), and install snap ring (6) (See F1, F3) Lip of oil seal: Grease (G2-L) 3. Set swivel shaft (5) on block, then using push tool, tap swivel rotor (4) with a plastic hammer and install. (See F1) ‘* When installing the rotor, be extremely careful not to damage the lips of the slipper seal and the oil seal 4. Install ring (3), and secure with snap ring (2). (See F1) 5. Fit O-ring and install cover (1). (See F1) 30-34 @ 0205¢50205¢5 20505420 £3 205F05421) 20sF0s422 30-35 ®@REMOVAL OF TRAVEL MOTOR ASSEMBLY “BF Lower the work equipment completely to the ground and stop the engine. Operate the control levers several times to release the remaining pressure in the hydraulic piping. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. 1. Drain oil, (See F1) + Remove drain plug (1), and drain oll from the final drive case, ‘ water See Lubricant and Coolant Table 2. Cover (2). (See F2) 3. Hoses (3), (4), and (5). (See F3) After removing the hoses, fit blind plugs. 4. Mounting bolts (6). (See F3) Remove 2 mounting bolts 5. Travel motor assembly (7). (See F4) Fit guide bolt (®) (Thread dia. = 16 mm, Pitch = 2 mm, Length = 300 mm) in the mounting hole of the travel motor, and pull out the travel motor assembly + Using eyebolts ©) (Thread dia. = 10 mm, Pitch = 1.5 mm), remove travel motor assembly (7) See Weight Tabie INSTALLATION OF TRAVEL MOTOR ASSEMBLY * Carry out installation in the reverse order to removal + Refilling with oil Add oil to the specified level. See Lubricant and Coolant Table + Bleeding air * Bleed the air from the motor. For details, see TESTING AND ADJUST- ING, Bleeding air from travel motor. * After bleeding the air from the motor, check the level of the hydraulic tank 30-35-1 o REMOVAL OF TRAVEL MOTOR, FINAL DRIVE ASSEMBLY “AS Lower the work equipment completely to the «ground and stop the engine. Operate the control levers several times to release the remaining pressure in the hydraulic piping. Then loosen the oil filer cap slowly to re lease the pressure inside the hydraulic tank. 1. Remove track shoe assembly For details, see REMOVAL OF TRACK SHOE ASSEMBLY 2. Sprocket (2). (See F5) % Using hydraulic jack © (30 0), raise the track frame, then remove 20 mounting bolts (1), and remove sprocket (2) Cover (3). (See F6) Hoses (4), (5), and (6). (See F7) 5. Remove travel motor and final drive assom- bly (7). (See FB) [#1 4%. Sling the travel motor and final drive assembly, and remove 18 mounting bolts (8), then lift off travel motor and final drive assembly (7) % Be extremely careful that the travel motor does not hit the track frame, as (i) See Weight Table INSTALLATION OF TRAVEL MOTOR, FINAL DRIVE ASSEMBLY * Carry out installation in the reverse order to removal #1 G2 Mounting bolt: See Tightening Torques and Standard Values Table + Bleeding air + Bleed the alr from the motor For details, see TESTING AND ADJUST- ING, Bleeding air from travel motor. * After bleeding the air from the motor, check the level of the hydraulic tank. 02055,, sosoz0 , ’DISASSEMBLY OF FINAL DRIVE ASSEMBLY Draining oil Remove drain plug (1) and drain oil from final, drive case. (See F1) : vets Final drive case: See Lubricant and Coolant Table. 2. Travel motor assembly 1) Remove 2 mounting bolts (2). (See F2) 2) Remove travel motor assembly (3), by using eyebolts (D). (See F3) 16°] Travel motor assembly See Weight Table. 3. Coupling, sun gear 1) Remove coupling (4). (See F4) 2) Remove sun gear (5). (See F4) 4. Cover 1) Make match marks on cover (7), ring gear (9) and hub (20). (See F5) 2) Remove mounting bolt (6) and then remove cover (7). (See F5) 3) Remove button (8) from cover. (See F6) 5. Ring ges Remove ring gear (9). (See F7) 6. Spacer Remove spacer (10). (See F7) 7. Carrier assembly Remove carrier assembly (11), by using eye: bolts (7). (See F8) 8. Spacer Remove spacer (12). (See F9) 9. Gear assembly 1) Remove 18 mounting bolts (13). (See F9) 2) Take out gear assembly (14). (See F10) There are knock-pins fitted in the gear assembly, so if itis difficult to remove the assembly, put a block in contact with the knock-pin position and hit with a hammer to remove. 0208¢50205¢5 Feoscso76 eer Feoscs072 Feoses077 Fa. FS, 4 “5 __Faeseso73 L Feoscsore totem mores 0 LL Feoscso7e Froscs07s F20sc80783) Disassemble gear assembly as the way of below. i) Remove mounting bolt (15), then remove plate (16). (See F1) ii) Remove inner gear (17) from outer gear (18). (See F2) 10. Shim Remove shim (19). (See F3) %* Check the number and thickness of the shims, and keep in a safe place. 11. Hub assembly 1). Using tool A, and puller (2), remove hub assembly (20) from shaft (21). (See F4, F5) 2) Remove hub assembly (20) by using eyebolts (@). (See FS) 12. Floating seal, bearing 1) Remove floating seal (22) from shaft (21) (See F6) 2) Remove floating seal (23), then remove bearings (24) and (25) from hub (26). (See FT) DISASSEMBLY OF CARRIER ASSEMBLY 13. Nut 1) Set carrier assembly on block @). (See F8) 2) Bend lock washer (27) back, then remove nut (28) with tool A,. (See F8, F9) 14. Collar Remove lock washer (27) and collar (29). (See F10) 15. Pin Set carrier assembly (30) in a press, then using push tool (3), remove pin (31). (See Fup 16. Gear assembly 1) Remove gear assembly (32) from carrier (33). (See F12) 2) Remove bearings (35), (36) and spacer (37) from gear (34). (See F13) 3) Remove bearing outer race (38) from gear. (See F14) o205c50205¢5 Fz0scs090 _Fzescso81| Fe0scs0ee F20scs082 F205c5008 |_ 2055002 Fz0scs095 Fa0scs093 30.39ASSEMBLY OF FINAL DRIVE ASSEMBLY ASSEMBLY OF CARRIER ASSEMBLY 1. Gear assembly 1) Using push too! @), press fit bearing outer race (38) on gear. (See F1, F2) 2) Assemble bearing (36), spacer (37) and bearing (35) on gear (34), then set gear assembly (32) on carrier (33). (See F3, FA) 2. Pin Set carrier assembly in a press, then using push tool (7), press fit pin (31). (See F5) When press fitting the pin, rotate the gear and pay careful attention to the angle of the pin. 3. Collar Assemble collar (28) and lock washer (27). (See F6) 4. Nut 1) Using tool A,, tighten nut (28). (See F7, F8) <%= Nut For details, see Tightening Torques and Standard Val- ues Table 2). Bend lock washer (27) securely. (See F8) 30-40 WHOLE ASSEMBLY OF FINAL DRIVE ASSEMBLY 5. Bearing, floating seals 1) Using push tool, press fit bearings (25) and (24) on hub (26). (See F9) 2). Install floating seal (23). (See F9) 3). Install floating seal (22) on shaft (21), (See F10) Install floating seals after degreasing O- ring and contact face of O-ring and drying. % When installing the floating seals, coat the sliding face of the seal thinly with engine oil. 6. Hub assembly Using eyebolts (3), set hub assembly (20) on shaft (21), then using push tool, tap bearing to press fit. (See F11) 7. Adjusting bearing clearance 1) Rotate the hub 2 or 3 turns to settle the bearing 2). Using tool A,, hold the bearing and press fit on the shaft securely. 32 Plate mounting bolt: 1.28 + 0.25 kgm, 0205¢50208¢5 FI F2. Fo F10 F20scs099 £20505005 Fa F20scs092 Faoscsone Froscso8e 7 Feoscs0e? | 30-41 ®DAdjusting spacer type i) Using a depth micrometer. measure stepped difference “h”, between the end face of the shaft and the end face of the bearing inner race. (See F1) * When measuring stepped difference “hn”, measure at three places around the circumference and take the minimum value. ii) Take value "h” measured in step i) and select spacers to give a value of (h-0.10) to (h - 0.15) mm. % There are seven types of spacer and select the spacer to give the above thickness. 3) Assemble selected shim or spacer (19). (See F2) Gear assembly 1) Assemble gear assembly as follows. i) Assemble inner gear(17) to outer gear (18). (See F3) ii) Fit plate (16), then tighten mounting bolts (15). (See FA) < Thread of bolt: Adhesion (LT-2) =) Mounting bolt: For details, see Tight- ening Torques and Standard Values Table. 2) Set gear assembly (14) in hub as below. (See F5) i Align position of dowel pin of gear assembly. ii) Temporarily tighten with 2 mounting bolts. iil) Knock in 2 dowel pins. * When installing, be careful that the shim doesn't slip out of position. 3) Tighten 18 mounting bolts. Thread of bolt: Adhesion (LT-2) I Mounting bolt: For details, see Tightening Torques and Standard Values Table. 30-42 oO 4) Check adjustment of bearing clearance again Hook spring balance (8) in the tap hole for the sprocket mounting bolt, rotate the hub against the shaft, and measure the starting force. (See F6) + Starting force: 30 kg and below ‘If the starting force exceeds the above value, it is necessary to adjust it again because of the preload of bearing. 9. Spacer Install spacer (12). (See F7) 0205¢50205510. Carrier assembly Using evebolts (1), raise carrier assembly (11). Align as shown in diagram below, then fit sun gear (5) and install. (See F1}). * Always match the stamped numbers. If the gear are assembled int the wrong combina- tions, the gears may be damaged. planetary gear, set the three 11 marks facing in the same direct that the lines of the ‘sun gear and planet gears are centered land meshed as shown in the figure before installing IT the stamped numbers cannot be aligned at the center rotate the planet {gear which cannot be aligned 120° to the left or right, and the numbers to be aligned will appear. in, and cheek fon the sun gear comes between the } | stamped numbers on the planet gears. 11. Spacer Install spacer (10). (See F2) 12, Ring gear Coat mounting surface with gasket sealant, align match marks made when disassembling, and install ring gear (9). (See F2) ~X Contact face: Gasket sealant (LG-6) Install ring gear as the marking facing the cover. 4 Remove sun gear (5) assembled in step 10 to align teeth. (See F1) ‘When assembling the ‘The stamped number | 13. Cover 1). Install button (8) on cover. (See F3) 2) Coat mounting surface with gasket sealant, align match marks made when disassembling, then set cover (7) on ring gear and tighten mounting bolts (6). (See Fa) ~~ Contact face: Gasket sealant (LG-6) 32) Mounting bolt: For details, see Tight- ening Torques and Standard Values Table. 14, Sun gear, coupling 1) Install sun gear (5). (See F5) 2) Install coupling (4). (See F5) 15. Travel motor assembly 1) Using eyebolts (1), raise travel motor assembly (3). Fit O-ring and install on shaft. | (See F6) 2) Tighten 2 mounting bolts (2). (See F7) 16. Refilling with oll Tighten drain plug (1) and add engine oil through oil filler (38) to the specified level. (See F8) 4 Finaldrive case: See Lubricant and Coolant Table Check the level again at the specified place after installing the final drive case assembly to the machine body. 0205¢50205¢5 Foscease Fr0sc9076DISASSEMBLY OF TRAVEL MOTOR ASSEMBLY © Preparatory work Using a block, set the swing motor assembly (1) at an angle of 25°. 1. Brake case assembly Using eye bolt (Dia. 10 mm, Pitch 1.5 mm), lift off brake case assembly (2). 2. Brake piston Set brake case assembly on unit repair stand G1, then remove brake piston (3), 3. Disc, plate Remove disc (4) and plate (5). 30-45-1 a F205¢5130 20505133 20550208¢5 4, Piston assembly 1) Using tools G2, remove screw, then remove retainer (6). 2) Remove both piston assembly (7) and holder. 5. Output shaft ‘Turn over brake case assembly, remove nut (8) with too! G3, then remove output shaft (9). 6. Bearing 1) Remove snap ring (10), then remove spacer (11) and ring (12). 2) Remove oil seal (13) and bearing (14). . Cylinder block Remove four big springs (16) and four small springs from housing (15), then remove center shaft (17) and cylinder block (18). 20505198 30-45-2 ®8 Plate Remove plate (19). 9. Counterbalance valve, check valve 1) Remove plate (20), then remove spool switching spring (21), retainer (22) and counterbalance vaive spo! (23). 2) Remove seat (24), then remove check valve spirng (25) and check valve (26). 10. Safety valve Remove safety valve (27). 30-45-3 ® _-_¢F20scs139| B® www Froscstao 28 ) LT wo TD 25 28 el 20505141 0208¢50208¢5 ASSEMBLY OF TRAVEL MOTOR ASSEMBLY 1. Safety valve Fit O-ring and backup ring, and install safety valve assembly (27) GE Safety valve: See Tightening Torques and Standard Values Table 2. Counterbalance valve, check valve 1) Assemble check vaive (26) and spring (25), then fit backup ring and O-ring to seat (24) and install 2) Assemble counterbalance valve spool (23) and retainer (22), then fit O-ring and install plate (20). 2 Bolt: See Tightening Torques and Standard Values Table 3. Plate Turn over housing, align dowel, then install plate (19). (A Q (Oo 3 QW eS KO (7 {( 4. Cylinder block 1) Install cylinder block (18), assemble center shaft (17), then use tool Gé to secure center shaft. | 4% Coat end face of cylinder block with | engine oil. 2) Install four big springs and four small springs in housing. raowcea5. Bearing 1) Press fit bearing (28) on shaft (9). 2). Press fit outer races (29) and (30) in brake case. 3) Assemble output shaft (9) in brake case, then press fit bearing (14) and oil seal (15). 4) Fitspacer(11), then install snap ring (10). 5) Fit O-ring and install ring (12), then par- tially tighten nut (8). 7X. Oil seal face: Grease (G2-L!) Nut and pre-pressure adjustment Tighten up nut (8) using toot G3 while measuring the rotation torque using tool G2. * Rotate the shaft at the rate of about one revolution every five seconds. If the rotational torque becomes higher than the specified value, slacken off the nut completely to make the rotational torque zero, then retighten the nut. Rotational torque of shaft: See Tightening Torques and Stan- dard Values Table %* After adjusting the rotational torque, bend the lock plate. Ifthe lock does not line up with the groove inthe nut, either tighten up the nut within the range of the specified rotational torque or slacken it, 30-45-5 ® Froscsta 20505149 0205¢50205¢5 7. Piston assembly 1) Install holder (31) on piston (7) and set assembly on retainer (6). 2) Install center ball (32) and holder (33) on shaft + Clean the spherical face of the shaft and coat lightly with engine oil 3) Assemble piston (7) to retainer (6), align with holder and set on shaft % Coat the hole in the retainer for the mounting bolt with thread tightener (L-2), then completely remove any thread tightener or oil from the side of the retainer. 4) Following the order in 208F255, tighten retainer mounting bolts with wrench to the following tightening torque. 35) Retainer mounting bolt: See Tightening Torques and Standard Values Table ‘* Completely remove all oil or grease from the mountig bolts before installing, * After tightening the mounting bolts, check ‘that the piston moves freely and falls under its own weight. ‘* If the piston does not move smoothly, loosen the mounting bolts, then tighten and check again. ‘* No thread tightener should come out after the bolts are tightened, . Disc, plate Install plates (5) and disc (4). F20505134 206r2559. Brake piston Fit O-ring and install brake piston (3). 10. Brake case assembly Fit O-ring, then using eye bolt (Dia. 10 mm, Pitch 1.5 mm), lift brake case assembly (2). Align piston assembly with cylinder block and install. * Set housing at about 25°, % Remove too! G4 after installing the brake case assembly. 0-45-7 . ® ___r0se5191 0205¢5REMOVAL OF SPROCKET Track shoe assembly + Remove track shoe assembly For details, see REMOVAL OF TRACK SHOE ASSEMBLY. 2. Jacking up machine * Swing the work equipment 90° to jack up the machine, then set block <1) between the track frame and the track shoe. (See F1) 3. Sprocket (1). (See F1) (#1) %* Sling the sprocket, then remove the mounting bolts, and lift off the sprocket. "| See Weight Table INSTALLATION OF SPROCKET + Carry out installation in the reverse order to removal fq) <> Mounting bolt: Thread tightener (LT-2) <=) Mounting bolt: See Tightening Torques and ‘Standare Values Table 30-46 o20scssog0z0 30-47REMOVAL OF SWING MOTOR ASSEMBLY “A Lower the work equipment to the ground and release the remaining pressure in the circuit. For details, see TESTING AND ADJUSTING, Releasing pressure in hydraulic circuit for machines with PPC valve 1, Hoses (1), (See F1) % Disconnect 7 hoses. 2. Swing motor assembly (2). (See F2) ig the swing motor assembly, and remove the mounting bolts [te] See Weight Table INSTALLATION OF SWING MOTOR ASSEMBLY + Carry out install removal + Refilling with oil ‘* Add oil to the specified level, and run the engine to circulate the oil through the system. Then check the oil level again nin the reverse order to 30-48 D REMOVAL OF SWING MACHINERY ASSEMBLY 1. Swing motor assembly + Remove swing motor assembly. 2. Swing machinery assembly (1). (See F3) % Sling the swing machinery assembly, then using forcing screws, and remove the swing machinery assembly. tg) See Weight Table INSTALLATION OF SWING MACHINERY ASSEMBLY + Carry out installation in the reverse order to removal + Refilling with oil % Run the engine to circulate the oil through the system, Then check the oil level again. 0208¢5) ) sos0z0 30-49DISASSEMBLY OF SWING MOTOR ASSEMBLY (KMF90-2 (AB)) 1. Brake case assembly 1) Using a block, set the swing motor assembly (1) at an angle of approx 25°. 2) Lift off brake case assembly (2). 2. Brake piston Set brake case assembly (2) in tool H1, then use tool H2 to remove brake piston (3) % If the air pressure is high, the brake piston will fly out, so be careful. 3. Piston assembly 1) Using tool H3, remove screw, then remove retainer (4). 2) Remove piston assembly (5) and center ball (6) + The screw is not permitted to be reused, so scrap it. 4, Disc, plates Remove disc (7) and plates (8) and (9). 30-49-1 ® 20205296 0208¢50208¢5 6. Drive shaft 5. Cover Remove snap ring (12), then remove cover (13). * Lever the groove with a screwdriver. 20208295 1) Remove snap ring (17), then remove spacer (16) 2) Push down drive shaft (15) with press and remove. 3} Remove bearing (18), then remove outer race (19), and remove seat (20) and spring (21), * The outer race can be pulled out by hand. 1S 20208296 20205297 30-49-27. Spring Remove spring (26). 8. Cylinder block assembly 1) Remove cylinder block (28) together with center shaft from housing (27). 2) Remove center shaft (30), center ring (31), and spring (29) from cylinder block (28). 9. Valve plate Remove valve plate (32). 10. Safety valve Remove safety valve (33) 11. Check valve Remove plug (34), then remove spring (35) and valve (36) 30-49-3 © F20s05428 205sASSEMBLY OF SWING MOTOR ASSEMBLY (KMF90-2 (AB)) Precautions when assembling 1) Clean all parts, check for dirt or damage, and repair any burrs. 2) Coat the rotating and sliding surfaces of all parts with engine oil (E010-CD) before installing, 1. Bearing Press fit bearing (37) in housing (27. * Check that the bearing is completely press fitted up to the end face. 2. Check valve Assemble valve (36) and spring (35), then fit O-ring and install plug (34). = Plug: See Tightening Torques Standard Values Table X= Plug: Thread tightener (LT-2) and 208s 3. Safety valve Fit O-ring and install safety valve (33) Gz Safety valve: See Tightening Torques and dard Values Table Stan- 4. Valve plate Turn over housing, then align valve plate (32) with dowel pin, and install. * Check that there is no clearance (play) at the mounting surface with the housing. Fa0sos4ae5. Cylinder block assembly 1) Install cylinder block (28). 2) Assemble spring (29) and center ring (31) in cylinder block, then install center shaft (30). 3) Using tool H4 secure center shaft (30). Pulling force: 150 ~ 200 kg * When doing this, check that the cylin der block cannot be rotated by hand. | ra0zes0s| Se || S| 4a 6. Bearing aa Press fit bearing (25) to drive shaft (15). 7. Outer race Press fit outer race (24) in brake case (23) 7 RI 8. Assembly of drive shaft assembly i 1) Assemble shaft (15) in brake case (28), T)- and put piston mounting side on block ©. 2) Install spring (21). % Align the spring so that the outside 1 circumference opens. 3) Align with spring, and install seat (20) 4) Install outer race (19). l ~ 1 20205308 5) Press fit bearing (18) : ] + Press fit carefully and make sure that Lt spring (21) does not come away from ) the seat. : * From the point where the bearing roller contacts the outer race, rotate the | | shaft while press fitting it * Press-fitting load: 748 — 1606 kg ] | 20208300 30-49-5 ® o208¢s02055 6) Assemble spacer (16) of thickness of 5.4 mm, and install snap ring (17) * Check that the snap ring is fitted securely in the ring groove. (if it does not fit, replace it with a 5.0 mm spacer.) 20205296 9. Measuring procedure for clearance (portion 2 ) between seat (20) and brake case 1) Push out drive shaft (15) from piston mount until bearing inner race (22), spacer (16), and snap ring (17) are in close contact. + Pushing force: 288 ~ 1144 kg i (Force can be applied up to 2000 kg) 2) After the above parts come into close contact, apply a load of 2000 kg. * Check that the spacer cannot be rotated by hand. 3) Fit dial gauge 2 to brake case, push drive shaft (15) with 500 — 2000 kg, and measure amount of movement of shaft. + Movement: 0.1— 0.4mm + If the amount of movement is not within the standard range: + If it is more than 0.4 mm, replace with a 0.58 mm spacer (706-7E- i | 11320) : If it is smaller than 0.1 mm, replace with a 0.5 mm spacer (706- 86-4030) 20205912 | + After replacing the spacer, measure a : the amount of movement again. a @ 1) Apply ample oil to bearing. 2) Using tool H5, rotate at approx. 1 turn/5 sec, and measure rotating torque of drive shaft, * Rotating torque: 0.1 — 0.16 kgm % if it is not within the standard value, | 10. Measuring rotating torque of drive shaft | replace the bearing with a new part.11, Cover 1) Install oil seal (14) to cover (13). X= Lip surface of oil seal: Grease (G2-L!) 2) Fit O-ring and install cover (13). 3) Install snap ring (12). 12.Discs, plates Assemble plate (9), then assemble plates (8) and discs (7) in turn. * Align the discs at three places with the notched tooth on the spline. | 13, Piston assembly 1) Set ball (6) of cener shaft to shaft. 2) Assemble piston (5) to retainer (4), and install as one unit to shaft. 20205298] 30-49-7 ® 20208314 20205295 0208¢5205s 3) Using tool H3, tighten screws (7) in order shown in diagram. Qx Screw: Thread tightener (LT-2) @=5 Screw: See Tightening Torques and Standard Values Table + Remove all grease from the thread, then dry it and coat with thread tightener. Wipe off any thread tightener that is squeezed out. * After tightening, check that the big end of the piston and the center ball move smoothly. * After tightening, check that the play in the axial direction of the piston assembly is within 0.35 mm, 14. Brake piston Fit O-ring and install brake piston (3) + Assembie so that the piston pin groove is aligned with the dowel pin of the end cover. 15. Brake case assembly 1) Set housing (27) so that cylinder block is perpendicular. * Before assembling spring (26), it is better to assemble brake case assembly (2) in the housing, and align the brake piston and dowel pin. 2) Install spring (26) to housing 3} Face hole of center ball in direction of center shaft, then fit O-ring to brake case. 4) Align pin groove of brake piston with dowel pin, and install brake case assembly (2) + Tighten the mounting bolts uniformly. If the mounting bolts become heavy, do not forcibly tighten; remove the brake case assembly and start again == Mounting bolt: See Tightening Torques and Standard Values Table * When finally tightening the mounting bolts, set in tool H1 AD Mating surface of case: Gasket sealant (LG-1) 20708917DISASSEMBLY OF SWING MACHINERY ASSEMBLY 1 Draining ott Remove drain plug and drain oll from swing machinery case ’ watew Swing machinery case: See Lubricant and Coolant Table Cover assembly 1) Remove mounting bolts, then using eyebolts (1), remove cover assembly (1). (See F1) * There are 9 mounting bolts at the top and 3 mounting bolts at the bottom, 2) Disassembly of cover assembly ’) Remove cages (2) and (3). (See F2) * Check =the == number and thickness of the shims, and keep in a safe place. ii) Remove outer races (4) and (5) from cage. (See F3, FA) iil) Remove mounting bolts, then remove cover (6). (See F5) iv) Remove gear assemblies (7) and (8). (See F6) v) Remove bearings (9) and (10) from gear. (See F7, F8) 30-50 oO vi) Remove inner races (12) and (13) from case (11). (See F9) . Shaft Remove shaft (14). (See F10) . Ring gear Remove ring gear (15). (See F10) Carrier assembly 1) Remove mounting bolts, then remove carrier assembly (16). (See F11) 2) Disassembly of carrier assembly i) Remove mounting bolts (17), then remove holder. (See F12) ii) Set carrier assembly (16) in press, and using push tool (2), remove pin (18), then remove gear assembly (19). (See F12, F13) ii) Remove holder (20). (See F13) 0205¢5FL 205F0s452 208F05453, Fz 205F05455, Fu 20sF054s4 Fa 205F05456 2o5F0585| 2osrosaa?| Fe 205F05449 205Fosaea F3 20505446] sosozo 20505448 #7 208F05450 30-51iv) Remove bearing (22) and spacer (23) from gear (21). (See F1) v)_ Remove inner race (24). (See F1) 6. Shaft assembly 1), Remove mounting bolts (25). (See F2) 2) Set shaft and case assembly (26) in press, and using push tool ‘3), remove shaft assembly (27). (See F3) 3) Disassembly of shaft assembly i) Remove spacer (29) from shaft (28). (See F4) ii) Remove bearing (30). (See F4) iii) Remove cover (31). (See F5) iv) Remove oil seal (32) from cover. (See F6) 7. Case assembly Remove bearing (33). (See F7) 30-52 oO ASSEMBLY OF SWING MACHINERY ASSEMBLY 1. Case assembly 1) Using push tool, press fit bearing (33). (See F8) 2) Assemble spacer (29). (See F9) 3) Using push tool, press fit bearing (30). (See F9) 2. Shaft assembly 1) Assembly of shaft assembly i) Using push tool ), press fit oil seal (32). (See F10, F11 <>. Outer circumference of oil seal Adhesive (LG-6) ii) Assemble cover (31) to shaft (28). (See F12) 7. Lip of oil seal: Grease (G2-LI) iii) Set case assembly in press, and press fit shaft assembly (27). (See F13) iv) Tighten mounting bolts (25). (See F13) ~~ Cover mountig surface: Adhesive (LG-6) 3. Carrier assembly 1) Assembly of carrier assembly * Assemble the same marked tapered roller bearing because one set of tapered roller bearing consists of inner race, outer race and spacer. i) Using push tool, press fit inner race (24). (See F14) ii) Assemble spacer (23) and bearing (22) to gear (21). (See F14) 02055o205c5 205F08460 SO osroses7 2 Fa Fio Fu As 3 6 “0 - : | j ee \ | { | | L 7 J _zosrosase 20308459) 0st0s46s aostosasa Fe 208F05462 208F05463 205F05457| 30-53iii)’ Assemble holder (20). (See F1) iv) Set carrier assembly (16) in press, then assemble gear assembly (19), and using push tool 2, press fit pin (18). (See F2) * Be careful to keep the pin straight, and rotate the gear when press fitting the pin ‘* After press fitting the pin, check that the gear rotates smoothly. v) Fit holder and tighten with mounting bolts (17). (See F3) ~~ Mounting bolt: Thread tightener (LT-2) = Mounting bolt: See Tightening Torques and Standard Values Table 2) Fit carrier assembly (16), and tighten with mounting bolts. (See F4) ~~ Mounting bott: Thread tightener (LT-2) 35 Mounting bolt: See Tightening Torques and Standard Values Table 4. Ring gear Install ring gear (15). (See F5) ~~. Ring gear mounting surface: Thread tightener (LG-6) 5. Shaft Assemble shaft (14). (See F5) 6. Cover assembly 1) Assembly of cover assembly i) Using push tool, press fit inner races. (13) and (12) in case (11). (See F6) 30-54 ii) Using push tool ©, press fit bearing (10) in gear (See F7) ili) Using push tool @), press fit bearing (9) in gear. (See F8) iv) Install gear assemblies (8) and (7). (See F9) v) Fit cover (6) and tighten with mounting bolts. (See F10) “Cover mounting surface: Adhesive (LG-6) vi) Using push tool, press fit outer races (5) and (4) in cage. (See F11, F12) . Adjusting preload of bearing 1) Remove O-ring, and install cages (3) and (2). (See F13) % Install 2 bolts each at a and b. * Rotate the spline shaft for the motor mount 5 — 6 turns, then tighten the bolts to the specified torque. Sx Bolt: See Tightening Torques and Standard Values Table 20505,0208C5 A F2 20sF0s467| 20sros6a 205F05469| 20805470) F3. Fa. F10 t 205F05455, 205F0s456 L 2osFo5a2a| 2osrose4a F5. Fu F12 | | | 205F05453| 205F05447 205F05446 | 6 F13 ] 205F05452 205F05471 30-552) Selecting shims Measure points "c” and "d” with a feeler gauge, then select shims from the table below. clear [Above [02 os [os fos |10/12 [14/16 22 [24 sted [eeow [os los [oe (io [12|14|16/18 2.4 [26 Shinthickness [06 [07 [08 [oo |ro|11 12/13 is fra % Types of shims: 3) Remove cages (3) and (2). (See F1) 4) Fit O-rings and install cages (3) and (2) (See Fi) 35 Mounting bolt See Tightening Torques and Standard Values Table + Check that the spline shaft for the motor mount rotates smoothly by and 5) Using eyebolts (1), install cover assembly (1). (See FI) << Cover assembly mounting surface: Adhesive (LG-6) . Refilling with Tighten drain plug and add engine oil through oi filler. 4M? Swing machinery case: See Lubricant and Coolant Table 30-56 oO 0208¢50208¢5 30-57REMOVAL OF REVOLVING FRAME ASSEMBLY Boom cylinder assembly + Remove boom cylinder assembly. Work equipment assembly + Remove work equipment assembly. For details, see REMOVAL OF WORK EQUIPMENT ASSEMBLY. Counterweight assembly + Remove counterweight assembly. Cab assembly + Remove cab assembly. For details see REMOVAL OF OPERA- TOR'S CAB ASSEMBLY. Hoses (1). (See F1) Link (2). (See F1) Revolving frame assembly (3). (See F2) [#1] %* For the mounting bolts marked #, move the control box assembly, remove the grommets, then remove the bolts. % When removing the mounting bolts, leave 2 bolts each at the front and rear. Using lever block, adjust the balance of the revolving frame assembly to the front and rear, and left and right, remove the remaining bolts, then lift off. * When removing the revolving frame assembly, be careful not to hit the center swivel joint assembly. (9) See Weight Table 30-58 INSTALLATION OF REVOLVING FRAME ASSEMBLY + Carry out installation in the reverse order to removal. (#1) * The dimensions of the mounting bolts, diameter of the washers, and thickness of the washers differs according to the mounting position, so refer to the table and diagram below when installing. (See F4) ameter rhickness 1 ' “This indicates the size of bolts used only on the PC220. >. Mating surface of swing circle a Gasket sealant (LG-1) Mounting bolt Thread tightener (LT-2) S32 Mounting bolt: See Tightening Torques and Standard Values Table o20scs0208¢5 208F08475 205F05876| 30-59 ;REMOVAL OF SWING CIRCLE ASSEMBLY 1. Revolving frame assembly + Remove revolving frame assembly. For details, see REMOVAL OF REVOLVING FRAME ASSEMBLY. 2. Swing circle assembly (1). (See F1) [#1] * Remove 36 mounting bolts. ("45") See Weight Table INSTALLATION OF SWING CIRCLE ASSEMBLY * Carry out installation in the reverse order to. removal (eT % Install swing circle assembly with the inside softzone "S” mark facing the outside soft zone (plug) as shown in figure. (See F2) <\ Mounting bolt: Thread tightener (LT-2) =I Mounting bolt: See Tightening Torques and Standard Values Table Os Circle teeth surface: Grease (G2-L!) Volume: 218 30-60 REMOVAL OF IDLER, RECOIL SPRING ASSEMBLY 1. Track shoe assembly + Remove track shoe assembly. 2. Idler and recoil spring assembly (1). (See F3) * Sling the idler and recoil spring assembly, and pull out to the front to remove. (is") See Weight Table 3. Disconnection of idler and recoil spring assembly Secure recoil spring with block @, then sling idler assembly, remove mounting bolts, and disconnect idler assembly (2) and recoil spring assembly (3). (See F4) + Make match marks on the matching surface of the idler and the recoil spring. (kr) See Weight Table INSTALLATION OF IDLER, RECOIL SPRING ASSEMBLY + Carry out installation in the reverse order to removal. 0205¢50205¢5 £3 2 20505318 FA. F20s0sa19 208F05478 30-61DISASSEMBLY OF RECOIL SPRING ASSEMBLY 1. Remove piston assembly (2) trom recoil spring assembly (1). (See F1) isassembly of recoil spring assembly 1) Set recoil spring assembly (1) to tool B. (See F2) “A The spring is under large installed load, so be sure to set the tool properly. Failure to do this is dangerous. * Spring installed load: See Tightening Torques and Stan- dard Values Table 2) Apply hydraulic pressure slowly to compress spring, then remove lock plate (3), and remove nut (4). (See F1) * 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: See Tightening Torques and Stan- dard Values Table 3) Remove yoke (6), cylinder (7), and dust seal (8) from spring (5). (See F1) 3. Disassembly of piston assembly 1) Remove lock plate (10) from piston (), then remove valve (11). (See F1) 2) Remove snap ring (12), then remove U- packing (13) and ring (14). (See F1) 2 30-62 ASSEMBLY OF RECOIL SPRING ASSEMBLY 1. Assembly of piston assembly 1) Assemble ring (14) and U-packing (13) to piston (9), and secure with snap ring (12). (See F1) 2) Fit valve (11) and secure with lock plate (10). (See F1) Assembly of recoil spring assembly 1) Assemble dust seal (8) to cylinder (7) (See F1) Lip of dust seal: Grease (G2-LI) 2) Assemble cylinder (7) and yoke (6) to spring (6), and set in tool C. (See F1) 3) Apply hydraulic pressure slowly to compress spring, tighten nut (4) so that installed length of spring is dimension "a", then secure with lock plate (3) (See F3) + Installed length of spring: See Tightening Torques and Standard Values Table 4) Remove recoil spring assembly (1) from tool B. (See F2) Assemble piston assembly (2) to recoil spring assembly (1). (See F1) 72. Piston: Grease (G2-LI) * Assemble the cylinder assembly so that the mounting position of the valve is exactly at side. 0205¢50205¢5 20805480 | 30-63REMOVAL OF TRACK ROLLER ASSEMBLY 4. Lubricator (1). (See F1) * Loosen the lubricator, and loosen the track shoe tension. “A The adjustment cylinder is under extremely high pressure. Never loosen the lubricator more than one turn. If the track tension is not relieved, move the machine backwards and forwards. 2. Track roller assembly (2). (See F2) [#1 * Remove the mounting bolts of the track roller, then swing the work equipment 90°, jack up the machine, and remove the track roller assembly [ie] See Weight Table INSTALLATION OF TRACK ROLLER ASSEMBLY + Carry out istallation in the reverse order to removal. (er %* Set the track roller assembly to the mounting position, then operate the control levers to lower the machine slowly, and tighten the mounting bolts ‘temporarily. ~\. Mounting bolt: Thread tightener (LT-2) * Operate the control levers to lower the machine completely to the ground, then tighten the mounting bolts fully 30-64 REMOVAL OF CARRIER ROLLER ASSEMBLY 1, Track shoe assembly * Using hydraulic jack @, push up the track to a position where the carrier roller assembly can be removed. (See Fa) 2. Carrier roller assembly (1). (See F3) [#1 INSTALLATION OF CARRIER ROLLER ASSEMBLY + Carry out installation in the reverse order to removal, 1) >. Mounting bolt: Thread tightener (LT-2) o205¢50205¢5 Ft F3. ~ 20808320 20505322 Fz, ia) | 5 [- | Hiei [2 \ 15 F20505321 | 30-65REMOVAL OF TRACK SHOE ASSEMBLY * Stop the machine in a position where the track can be laid out to the rear when the master pin is pulled, then loosen lubricator (1) to relieve the track tension. “A The adjustment cylinder is under ex- ‘tremely high pressure. Never loosen the lubricator more than ‘one turn. If the track tension is not relieved, move the machine backwards and forwards. 2. Master pin (2) [#1] * Using tool C, pull out the master pin. (See F2, F3) 3. Track shoe assembly (3) [#2 % Move the machine forward so that the Position of the temporary pin is at the front of the idler, then put block (@) in contact with the grouser, pull out temporary pin (2), and remove the dust seal. (See F3) * Drive the machine in reverse to lay out the track. INSTALLATION OF TRACK SHOE ASSEMBLY Carry out installation in the reverse order to removal. ai) * Using tool C, press fit the master pin. (#2) ‘* Deflection of track: See Tightening Torques and Stan- dard Values Table 30-66 © 20550208¢5 20808320 20808323 20508328 30-67 tREMOVAL OF CHARGING PUMP ASSEMBLY “BE Lower the work equipment to the ground and stop the engine. Operate the control levers several times to release the remaining Pressure in the hydraulic piping. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. + Remove hydraulic tank strainer, and use tool D to stop the oil. (See F1) * When not using tool D, remove drain plug and drain the oil from hydraulic tank and piping. . ‘wy See Lubricant and Coolant Table 1. Hoses (1). (See F2) 2. Tube (2). (See F2) 3. Charging pump assembly (3). (See F2) INSTALLATION OF CHARGING PUMP ASSEMBLY + Carry out installation in the reverse order to removal, + Refilling with oil * Refill to the specified level, and run the engine to circulate the oil through the system. Then check the oil level again. 4@ See Lubricant and Coolant Table REMOVAL OF HYDRAULIC PUMP ASSEMBLY “BF Lower the work equipment to the ground and stop the engine. Operate the control levers several times to release the remaining pressure in the hydraulic piping. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank + Remove hydraulic tank strainer, and use tool D to stop the oil. (See F3) + When not using tool D, remove drain plug and drain the oil from hydraulic tank and piping ‘ watey See Lubricant and Coolant Table + Draining oil from damper chamber ’ was See Lubricant and Coolant Table Muffler heat insulator plate (1). (See F4) Muffler assembly (2). (See F4) Muffler bracket (3). (See F4) Tubes (4). (See F4) Hoses (5), (6). (See Fa) + Disconnect 2 hoses (6) Wiring connector (7). (See F5) Hoses (8). (See F5) 8. Hydraulic pump assembly (9). (See F6) gaene xo Cis) See Weight Table INSTALLATION OF HYDRAULIC PUMP ASSEMBLY + Filling oil Refill damper case oil to the specified level. a See Lubricant and Coolant Table. + Bleeding air * Refill to the specified level then see TEST- ING AND ADJUSTING, “Bleeding Air” and bleed air from main pump. ‘* When finished, check the level of hydraulic tank. ozoses,30-69DISASSEMBLY OF HYDRAULIC PUMP ASSEMBLY (HPV090 + 090) Note) The procedure for disassembly is basi- cally the same for both front and rear pumps, so this section describes the disassembly of the front pump only. When there are differences, however, they will be noted at the appropriate place in the description 1, TVC and CO, NC valve assembly oo a 1) Set pump assembly (1) in tool K1. | | 1 = 2005420] 2) Remove hose (2) 3) Remove tube (3) | 4) Disconnect wiring, then remove TVC and CO, NC vaive assembly (5). (Rear pump) 5) Remove CO, NC valve assembly (6). (Front pump} 2. Rear pump assembly 1) Sling rear pump assembly (7). 2) Remove 4 nuts at front pump assembly end, then remove rear pump assembly (7). ‘* Disconnect at the middle of the end caps. 3. Servo valve assembly Remove servo valve assembly (8) F20506422) 30-69-1 ® 0205¢502055 Impeller Using tool KS, remove bolt (9), then remove plate (10), washer (10A) and impeller (11) %* Check the number and thickness of the shims, and keep in a safe place. + Be careful not to lose plate (10). . End cap Remove end cap (13). * The force of the spring is bearing on the valve plate, so loosen the mounting bolts uniformly. Valve plate Remove valve plate (15) + For a pump which has been operated, the valve plate will have become stuck to the cylinder block, so twist it carefully without causing scratches, Note) If the cylinder block and valve plate will be reused, store them as a set Pump sub-assembly Support cylinder block and shaft, then remove pump sub-assembly (17) F 20505435), —————— ees 20205325 30-69-2 3s8. Servo piston 1) 2) 3) 4) Using forcing screws © (Dia. — 10 mm, Pitch — 1.5 mm) and nut @, remove cap (18) and shim (20) Remove spring (22) Repeat Step 1) and remove cap (19) and shim (21). Remove servo piston (23) * The servo pistons used for the front and rear are not the same part, so mark them to distinguish them. DISASSEMBLY OF PUMP. SUB-ASSEMBLY 9. Slider Remove slider (24). 10. Cylinder block 1) Remove cylinder block (25). 2) Disassemble cylinder block as follows. i) Using bolt @ (10 mm or 12 mm) and washers @, compress spring (26). + Installed load: Approx. 130 kg ii) Remove snap ring (27) iil) Loosen nut @ slowly, and allow spring to expand until tension is removed. iv) Remove washers (28A) and (288), and spring (26). 30-69-3 ® a Fs0ss40) 20205929 2A 26 288 27 t iy AS ji ® \ 20205390 0205¢50205¢5 11. Drive shaft assembly 1) Screw in forcing screws, and remove housing (29) and shim * Check the number and thickness of the shims, and keep in a safe place. * The charging pump is removed for the rear pump, but there is no shim. 2) Remove snap ring (30) 3) Knock out drive shaft (31) from piston end to remove. 12. Piston Use tool K3 to remove 4 screws (43), then remove bearing retainer (44), shoe retainer (45), spacer (46), and piston (47). 20205323 Faososest | L,_—8 20703017 30-69-4 aWHEN REUSING PUMP DRIVE SHAFT AND END CAP + Removal of inner race from pump drive shaft 1) Remove snap ring (38), then remove washer (37), inner race (40), and bearing (41), 2) Using bearing race puller inner race (42). remove 30-69-5 ® 1 _4 | | 20205335 o205¢502055 ASSEMBLY OF HYDRAULIC PUMP ASSEMBLY (HPV0390 + 090) Precautions at time of assembly 1) Clean each part thoroughly and remove all sharp edge and rough edges. 2) Apply engine oil (EO10-CD) to the rotating and sliding parts before assemblying them * Be sure to use the following parts as a set. i) Cradle and rocker cam ii) Cylinder block and valve plate Note) The procedure for assembly is basi- cally the same for both front and rear pumps, so this section describes the assembly of the front pump only. When there are differences, however, they will be noted at the appropriate place in the description. ASSEMBLY OF PUMP. SUB-ASSEMBLY 1. Piston assembly 1) Fit dowel pin (50) to cradle, set rocker cam (49) in position, then install plate (48) * The side of the rocker cam with the groove faces the oil hole side of the cradle. >= Plate bolt: Thread tightener (LT-2) (Loctite #262) ami Plate bolt: See Tightening Torques and Standard Values Table + After tightening the bolts, check that the rocker cam moves smoothly. F20205338| 30-69-6 32) Select the spacer thickness as follows. SSS i) Assemble shoe retainer (45) to piston (47), put on the level block, then 45 | measure distance ® to top surface of shoe retainer. li) Select spacer thickness as follows. Spacer thickness — distance @ + (0.03 to 0.07 mm) * There are three types of spacer. 3) Install spacer (46) selected in Step 2)-i) and ii), then install piston (47), shoe re- | 47 tainer (45) and bearing retainer (44). au Using tool K3, install screws(43). rt) DAs Bearing retainer screw: Thread tightener (LT-2) == Bearing retainer screw: — l~—48 See Tightening Torques and Standard Values Table Rocker cam Feovesez2 1] 4) Hold rocker cam in position, then using — Rockercam SY tool K4 pull piston (47) with a force of 2 3. kg, and measure clearance ® between piston shoe and rocker cam + Measure the clearance with the rocker cam at position a or b, and measure for all nine piston * Clearance: 0.03 ~ 0.07 mm + If clearance @ is not within the standard range, adjust the spacer again. Retainer bearing 20703021 Le ~ Rocker cam| 30-69-7 @ 2055oz0scs 2. Drive shaft assembly 1) Press fit inner race (42) to drive shaft (31). 2) Install bearing (41), inner race (40) and washer (37) Select washer as follows. i) Install inner race (40), then install snap ring (38) * Check that the snap ring is not deformed or damaged, and correct any burrs before installing. Install with the cut inside part facing the opposite direction from the inner race. ii) Using a thickness gauge, measure clearance * between snap ring (38) and inner race (40). * Push the snap ring securely into the Groove on the opposite side from the inner race it) Install selected washer (37). Washer thickness ~ clearance « + (0 10.0.1 mm) 3) Install snap ring (38) * Check that there is no play beteen the snap ring and the washer. There are three types of washer. 20205342 | 30-69-8 e5) Press fit drive shaft (31) to cradle (36). 6) Install snap ring (30). 7), Install oil seal (35) to housing (29). AD Lip of oil seal: Grease (G2-L!) 8) Fit O-ring and shim (34) selected in step 9), and install housing (29) to cradle. = Mounting bolt: See Tightening Torques and Standard Values Table * Wind the shaft with tape to prevent damage to the oil seal lip surface + Install cover to rear pump. 30-69-9 ® 20208346 20205387 Fr0so54as 0208¢502055, 9) Select shim for housing as follows. i) Push drive shaft (31) in completely, and measure dimension » of end face of bearing outer race (33) and cradle. ii) Measure dimension © of housing (32) iii) Select. shim to give following thickness. * Shim thickness: » ~ s = © + 0.05 ~ 0.15 mm, * Therefore, there is a clearance of 0.05 — 0.15 mm at portion «. * Threre is no shim at the rear pump, 3. Cylinder block 1) Assemble cylinder block as follows. i) Assemble washer (284), spring (26) and washer (28B). * Assemble the washer facing in the direction shown in the diagram. ii) Using bolts @ (10 mm or 12 mm), washers @ and nut ©, compress spring (26). iil) Install snap ring (27). 2) Align with drive shaft and piston, and install cylinder block (25) * Always install the valve plate (which forms a set with the cylinder) together with the cylinder, or makr a mark and be careful not to make any mistake. [eA | ® a LL Te i 20k 26 288.27 20205330 l F20205353 30-69-10 ®4. Servo piston 1) Set pump case (32) in tool K1 2) Install servo piston (23). + The servo pistons used for the front and rear are not the same part, so be careful not to make any mistake when assembling them. ‘* The length from the center is different for the end with the spring and the end without the spring. 3) Adjust servo piston as follows. Max. swash plate angle side i) Align toot K6 with dowel pin and groove g for servo valve arm of servo piston, and set tool K6 in position. + As seen from the rear of the front pump, the right side (the top when mounted on the machine; the side with the spring) is the maximum swash plate angle side. (maximum flow side) Note: For the rear pump, use the same tool turned over. ii) Measure distance @ between servo piston and case. 30-69-11 Front pump. F20s054so Faososea7 Rear pump Faososcas F 2050544 | o20scso205cs, iii) Measure distance » of cap (18). iv) Select shim thickness as follows. © £0.05 mm * After adjusting the shim, put it in a set with the cap. Min. swash plate angle side %* To adjust the minimum swash plate angle, replace tool K7 with the tool for the minimum angle, and repeat the same procedure as in Steps i) iv). Note that the case faces in the opposite direction from the maximum. swash plate angle side. 5. Pump sub-assembly » 2) 3) Install slider and O-ring %* Fit the O-ring in the pilot portion and the joint portion. Install 2 joints on case. %* Install with the small hole facing the cradle side. Align the slider with the servo piston, and install pump sub-assembly (17) * Be careful that the O-ring is not caught. Also, be careful not to drop the cylinder. = Mounting bolt: See tightening Torques and Standard Values Table * Assemble rear pump using tool K2. Icap a Pump case F 20208956 Servo valve ~ cap 8 Jove pion all cine | clearance ‘at Servo vaive| rrounting 20208325 30-69-1 26. Endcap 1) Press fit bearing (14) to end cap (13). 2), Install joint and O-ring, + Install the joint with the large hole facing the end cap. 3) Coat with engine oil, align with pin and bearing, and install vaive plate (15). * Check that it is aligned with the end cap port, and that there is no interference with the pin and bearing. 4) Install end cap (13). =5 Mounting bolt: See Tightening Torques and Standard Values Table == Mounting nut: See Tightening Torques and Standard Values Table * There is the force of the spring inside the cylinder block, so tighten the mounting bolts uniformly. 7. Impeller 1) Adjust clearance between impeller and end cap portion @ as follows. i) Measure thickness ® of plate (10). ii) Assemble plate (10) to coupling, and install impeller. * Check that impeller (11) and end cap portion ® are in contact. iii) Measure dimension © from end face of coupling (11) to plate (10). 30-69-13 ® Fossa F208 06636 Faososes | Fr0s05469, 208s0208¢5 iv) Measure dimension 4 from end face of coupling to shaft (31) v) Use measured values *, <, and » as follows to select shim. a—(e tops shim thickness (05 + 0.1) mm = 2) Assemble plate (10) to coupling (11A), then fit shim (12) selected in Step 1) and washer (10A), then using tool KB, install impeller (11) ~< Mounting bolt: Thread tightener (LT-2) (Loctite #262) == Mounting bolt: See Tightening Tor- ques and Standard Values Table 3) Check interference or impeller (11) and rear end cap as follows. i) Measure dimension of end face of rear end cap to end face of front end cap portion * ii) Measure protrusion dimension 1 of impeller vane from front end cap. iii) Check that measured dimension is o> + If the above dimension is + >», there is no clearance at portion , so the impeller vane will contact the rear end cap at the time of assembly. To prevent this, repeat the procedure at step 7-1) and adjust the shim (12) again, fzos0sse¢ " 1 Vera 9 | J 2. |i | ____F2os054ss: 30-69-1 48. Servo piston cap 1) 2) Install spring (22) on the right as seen from the rear of the pump. Fit Oring, and shims (20) and (21) selected in step 4, then install caps (18) and (19). * When installing cap (18) at spring end, use 2 forcing screws @ (Thread dia. = 10 mm, Pitch = 1.25 mm) and 2 nuts ®. 35 Mounting bolt: See Tightening Torques and Standard Values Table + After installing the cap, measure the rotating torque of pump using tool ks. i) There must be no variation in the rotating torque (Range of variation: Max. 0.3 kgm) and the rotating torque must be less than 1.4 kgm. ii) If the rotating torque or range of variation are not within the standard value, disassemble the pump assembly and assemble it again. 9. Servo valve assembly Fit O-ring, align arm with servo piston, then install servo valve assembly (8). * Be careful not to let the O-ring drop out. Tighten the bolts gradually on opposite sides in turn, 35 Mounting bolt: See Tightening Torques and Standard Values Table 10.Rear pump assembly y 2) Install O-rings to front and rear end caps. Raise rear pump assembly (7), align spline, and install. = Mounting nut: See tightening Torques and Standard Values Table 30-69-15 ® 20505456 Fas064s7 Frososs22 o205cs02055 11. TVC and CO, NC valve assembly 1) Fit O-ring and install CO, NC valve assembly (6}. (Front pump) Mounting bolt: See Tightening Torques and Standard Values Table 2) Fit O-ring, install TVC and CO, NC valve assembly (5), then clamp wiring. (Rear pump) S35 Mounting bolt: See Tightening Torques and Standard Values Table 3) Fit O-ring and install tube (3) = Joint bolt: See Tightening Torques and Standard Values Table 4) Install strainer, then install hose (2). <=) Sleeve nut: See Tightening Torques and Standard Values Table * After completion of assembly, check the quality of the parts. After completing the assembly of the pump assembly, use a test stand (A type or C type) to check the quality. + For details of the procedure for checking quality, see TESTING METHODS. 20508491}CHECKING CONTACT BETWEEN CYLINDER BLOCK AND VALVE PLATE, AND ROCKER CAM AND CRADLE 1. Checking contact between cylinder block and valve plate. 1) Make @ centering tool for the cylinder Cylinder block Centering too! block and valve plate. + The tool can be made of a soft material such as plastic or bakelite 2) Remove grease from the parts to be checked * Do not wipe with a cloth. 3) Set the tool in position, and coat the cylinder block side with inspection paint. * Apply the paint thinly. 4) Put the vaive plate on top, push with a force of 4 — 5 kg, and rotate 2 — 3 times. 5) Remove the valve plate, transfer the contact surface to tape, and check the contact surface. * The standards for the contact surface are as follows. Valve pate | a. Seal Min. 80% 20703037 vines biock | 2, Seal [Min 60% Valve plate Cylinder block 20709038 30-69-17, ® 205s,0205¢5 2. Checking contact between rocker cam and cradle 1) Remove grease from the parts to be checked. * Do not wipe with a cloth. 2) Set the tool in position, and coat the cradle side with inspection paint + Apply the the paint thinly. Put the rocker cam on top, push with a force of 4 — 5 kg, and move 2 ~ 3 time from the stopper contact position to the maximum angle. Remove the rocker cam, transfer the contact surface to tape, and check the contact surface. * The standard for the contact surface are 3) 4) as follows. [Pump] Ommansone | Contact] Conc hom |_Mose_| °"\mmi”* | Sinece | “sroouede -y 090 7 Min. 20% | Min Som + If there is no contact at the center but only at the outside, the contact is no good. Rocker cam 20703039 Reference! If the contact is not within the contact standard value, when carrying, always lap both parts together. * Parts with scratches cannot be reused. 30-69-18REMOVAL OF MAIN PUMP INPUT SHAFT OIL SEAL 1. Hydraulic pump assembly + Remove hydraulic pump assembly For details, see REMOVAL OF HYDRAU- LIC PUMP ASSEMBLY. 2, Housing assembly (1). (See F1) [#1 + Using forcing screws, remove the housing assembly and the shims. 3. Oil seal (2). (See F2) (#2) + Remove oil seal from housing. INSTALLATION OF MAIN PUMP INPUT SHAFT OIL SEAL + Carry out installation in the reverse order to removal. ai = Mounting bolt: See Tightening Torques and Standard Values Table = | % Using tool ‘D), press fit oil seal (2) in housing (1). (See F3) lip ofoilseal: Grease (G2-L) 30-70 REMOVAL OF CONTROL VALVE ASSEMBLY ower the work equipment to the ground and release the remaining pressure in the circuit. For details, see TESTING AND AD- JUSTING, Releasing pressure in hydraulic circuit for machines with PPC valve. %* Mark the piping with tags to prevent mistakes in position when assembling. 1. Wiring connector (1). (See F4) 2.Hoses (3). (See F4) + For hose (3), remove 8 PPC hoses. 3. Hose (4). (See F5) 4,Hose (5). (See F5) 5. Tube (6). (See F5) %* Remove the tube together with the bracket. 6.Hose (7). (See F5) 7.Hoses (8), (9). (See F5) * For hose (8), remove 3 PPC hoses. For hose (9), remove 4 PPC hoses. 8. Tubes (10). (See F5) * Disconnect 4 tubes together with the bracket, and remove the 2 remaining tubes. 9. Hose (11). (See F6) 10. Wiring connector (13). (See Fé) 11. Clamp (14), (See F6) 12. Control valve assembly (15). (See F7) * Remove the control valve assembly together with the frame. [Cis] See Weight Table INSTALLATION OF CONTROL VALVE ASSEMBLY * Carry out installation in the reverse order to removal + Bleeding air % Refillto the specified level, then see TEST- ING AND ADJUSTING, "Bleeding Air” and bleed air from charging pump. + When finished, check the level of hydrau- lig tank, 0205¢50205¢5 205F05486 nee 20UFO1210-K F3. 20uF01211-%. F 20505328) 30-71DISASSEMBLY OF CONTROL VALVE ASSEMBLY * The set pressure of the safety valve cannot be adjusted when the safety valve is installed on the machine, so do not disassemble it The following explanation uses the left control valve as the example. Main relief valve, jet sensor relief valve Remove main relief valve (1) and jet sensor relief valve (2). (See F1) Safety-suction valve Remove safety-suction valve (3), (4), and (5). (See F1) Check vaive Remove plug (6), then remove spring (7) and check valve (8). (See F1) LH. travel valve 1) Remove case (9), then remove retainer (10), spring (11), retainer (12), spring (13), and retainer (14), and pull out spool (15). (See F1) 2) Remove case (16), then remove retainer (17), spring (18), retainer (19), spring (20), and retainer (21). (See F1) * This is applicable for the swing, RH. travel, boom-Lo, and boom-Hi spools. Retainer (19) is not assembled in the boom-Lo spool, * Boom-Hi spool i) There is @ shim inserted in the spring, 50 be careful when removing, ii) In place of parts (16) — (21) in Step 2),a plate is installed. ‘Arm throttle valve 1) Remove plug (22), the remove washer (23), spring (24), and washer (25). (See Ft) 2) Remove plate (26), then pull out spool (27). (See F1) The swing priority valve is installed assembled in the opposite direction to the arm throttle valve. 30-72 6. Bucket valve 1) Remove case (28), then remove spring (29) and retainer (30). (See F1) 2) Remove case (31), then remove spring (32) and retainer (33), and pull out spool (34). (See F1) ‘* This is applicable for the arm-Lo, service, and arm-Hi spools, * Shim (35) is installed in the spring of the arm-Hi valve, so be careful when removing, |. Straight-travel valve 1) Remove plate (36), then remove spring (37). (See F1) 2) Remove plug (38), pull out spool (39) (See F1) o205¢50208¢5 ead ea 0 & c 24 Dy ona 208605687 205605408 30-73ASSEMBLY OF CONTROL VALVE ASSEMBLY 1, Straignt-travel valve 1) Assemble spool (39), then fit O-ring and install plug (38). (See F1) 2) Fit spring (37) and install plate (36). (See F1) 2. Bucket valve 1) Assemble spool (34), fit retainer (33) and spring (32), then fit O-ring and install case (31). (See F1) 2) Fit retainer (30) and spring (29), then fit O-ring and install case (28). (See F1) * This is applicable for the arm-Lo, service, and arm-Hi spools. * Shim (35) is installed in the spring of the arm-Hi valve spool, so be careful of the position when installing. 3. Arm throttle valve 1) Assemble spool (27), then fit O-ring and install plate (26). (See F1) 2) Fit washer (25), spring (24), and washer (23), then fit O-ring and install plug (22). (See F1) * The swing priority valve is installed assembled in the opposite direction to the arm throttle valve. 4. LH. travel vaive 1) Install retainer (21), spring (20), retainer (19), spring (18), and retainer (17), then fit O-ring and install case (16). (See F1) 2) Assemble spool (15), install retainer (14), spring (13), retainer (12), spring (11), and retainer (10), then fit O-ring and install case (9), (See F1) ‘* This is applicable for the swing, RH travel, boom-Lo, and boom-Hi spools. * Retainer (19) is not assembled in the boom-Lo spool. * Boom-Hi spool i) Shim is installed in the spring of the boom-Hi valve spool, so be careful of the position when installing. ji) In place of parts (21) — (16) in Step 1), plate is installed. 30-74 Oo 5. Check valve Install check vaive (8) and spring (7), then fit O-ring and install plug (6). (See F1) =) Plug: See Tightening Torques and Standard Values Table Safety-suction valve Install safety-suction valve (61, (4), and (3) (See F1) = Safety-suction valve. See Tightening Torques and Standard Values Table Jet sensor relief valve, main relief valve Install jet sensor relief valve (2) and main relief valve (1). (See F1) S35) Jet sensor relief valve: See Tightening Torques and Standard Values Table SD Main relief valve: See Tightening Torques and Standard Values Table ozoscs0205¢5 205F05407 205F0s488 30-75REMOVAL OF MAIN RELIEF VALVE ASSEMBLY “BE Lower tne work equipmunt to the yround and stop the engine. Operate the control Tovers several ies to release the remaining pressure in the hydrauic piping ‘Then loosen the il filer cap slowly to release the pressure inside the hydraulic tank 1. RH. control valve main relief valve (1). (See Ft) [1 2. LH. control valve main relief valve (2). (See F1) [2] INSTALLATION OF MAIN RELIEF VALVE ASSEMBLY + Carry out installation in the reverse order to removal (=) #21 S== Main relief valve See Tightening Torques and Standard Values Table + After installing the main relief valve on the machine, adjust the set pressure. For details, see TESTING AND ADJUST- ING, Adjusting main relief valve 30-76 DISASSEMGLY OF MAIN RELIEF VALVE ASSEMBLY 4. Losen nut (1), and pull out adjustment screw (2), then remove retainer (3), spring (4), and poppet (5). (See F2) H_ Before loosening nut (1), measure the protrusion dimension of screw (2) from the end face of the nut 2. Loosen nut (6), and remove holder (7). (See F2) 3. Pull out seat (9), spring (10), and valve (11) from sleeve (8). (See F2) 4, Remove snap ring (12) from sleeve (8). (See F2) 5. Remove O-ring and backup ring (13) from seat (9). (See F2) 6. Remove O-ring and backup ring (14) from sleeve (8). (See F2) ASEMBLY OF MAIN RELIEF VALVE ASSEMBLY 1, Assemble backup ring (14) and O-ring in sleeve (8). (See F2) 2. Assemble backup ring (13) and O-ring to seat (9). (See F2) 3. Install snap ring (12) to sleeve (8). (See F2) 4, Assemble valve (11), spring (10), and seat (9) in sleeve (8). (See F2) 5. Assemble nut (6) and O-ring to holder (7), and assemble in sleeve (8), then assemble poppet (5), spring (4), retainer (3), and O-ring. (See F2) 6. Screw adjustment screw (2) into holder (7), adjust so that protrusion dimension from end face of locknut (1) is the same as when it was disassembled, then secure with locknut (1). (See F2) 205¢5F2 FA 999020 30-77REMOVAL OF TVC VALVE ASSEMBLY 1, Wiring connector (1). (See F1) 2. TVC valve assembly (2). (See F1) INSTALLATION OF TVC VALVE ASSEMBLY + Carry out installation in the reverse order to removal REMOVAL OF CO-NC VALVE ASSEMBLY . Wiring connector (1). (See F2) . Hose (2). (See F2) Tube (3). (See F2) CO+NC valve assembly (4). (See F2) + Remove the rear pump CO-NC valve together with the TVC valve. PONS INSTALLATION OF CO-NC VALVE ASSEMBLY + Carry out installation in the reverse order to removal 30-78 REMOVAL OF SERVO VALVE ASSEMBLY 1. CO-NC valve assembly + Remove CO + NC valve assembly. For details, see REMOVAL OF CO+NC VALVE. 2. Servo valve assembly (1). (See F3) INSTALLATION OF SERVO VALVE ASSEMBLY + Carry out installation in the reverse order to removal. o208c5| £20508: 30-79REMOVAL OF WORK EQUIPMENT PPC VALVE ASSEMBLY “AY Lowerthe work equipment to ground and * stop the engine. Operate the control lev- ere 2 oF 3 times, then loosen the oil filer cap gradually to release the internal pres: ‘sure of the hydraulic tank. Lever assembly (1). (See F1) Bolt (2). (See F1) Stand (3). (See F1) Hoses (4). (See F1) + Disconnect 6 hoses. PPC vaive assembly (6). (See F1) pene * INSTALLATION OF WORK EQUIPMENT PPC VALVE ASSEMBLY + Carry out installation in the reverse order to removal DISASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY PC200-5 Serial No: 45001 - 58018 PC220-5 Serial No: 35001 - 36613 1. Remove nut (1), then remove disc (2). (See F2) 2. Remove joint (3), then remove plate (4) (See F2) 3. Remove piston assembly (5). (See F2) 4, Disassembly of piston assembly Remove the following parts from piston (6). (See F2) 1) Remove collar (7), then remove dust seal (8). (See F2) 2) Remove collar (9), then remove seal (10). (See F2) 3) Remove piston (11), and spring (12) (See F2) 5. Remove valve assembly (13), then remove spring (14). (See F2) 6. Disassembly of valve assembly Push retainer (16) to remove collar (15), ‘then remove retainer (16), spring (17), and shim (18) from vaive (19). (See F2) 30-80 @ ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY PC200-5 Serial No: 45001 ~ 5801s PC220-5 Serial No: 35001 - 36613 1. Assembly of valve assembly Assemble shim (18), spring (17), and retain er (16) to valve (19), and push down retainer (16) to install collar (15). (See F2) 2. Assemble spring (14) and install valve assembly (13). (See F2) 3. Assembly of piston assembly Assemble the following parts to piston (6). 1) Assemble spring (12) and piston (11) (See F2) ~~ Piston: Grease (G2-LI) 2) Fit seal (10) to collar (9) and assemble. (See F2) 3) Fit dust seal (8) to collar (7) and assemble. (See F2) Install piston assembly (6). (See F2) Fit plate (4) and install joint (3). (See F2) SED Joint See Tightening Torques and Standard Values Table 6. Fitdisc (2) and install nut (1). (See F2) + Adjust the clearance between disc (2) and piston (6), For details, see TESTING AND ADJUST- ING, Adjusting PPC valve for work equipment. Nut See Tightening Torques and Standard Values Table ae 0205¢50208¢5 FL £2. oreosers| 006 Ge 0 aan 4 40 §) Pane 205F05493 30-81DISASSEMBLY OF PPC VALVE ASSEMBLY PC200-5 Serial No: 58019 and up PC220-5 Serial No: 36614 and up 1. Remove nut (1), then remove disc (2) and - boot (3). 2. Remove joint (4), then remove plate (5) 3. Remove seal (6) and collar (7). 4. Pull out piston (8), and remove retainer (9), springs (10) and (11), and shim (12). %* Spring (10) consists of two sets of two types of spring with different installed loads, so check the installation position (hydraulic port) and fit tags to prevent mistakes when installing, 5. Pull out valve (13) from body (14). 30-81-1 @ 0208¢50205¢5 ASSEMBLY OF PPC VALVE ASSEMBLY PC200-5 Serial No: 58019 and up PC220-5 Serial No: 36614 and up 1 2. Assemble valve (13) to body (14). ‘Assemble shitn (12) and spring (11) to valve (13). Assemble spring (10}, retainer (9), and piston (8), * Spring (10) consists of spring with a different number of coils for each hydraulic port. The number of coils and position of use are as follows. Port | Number of coils on spring Pt, P2 " P3, Pa 9 % The position of each port is stamped on the bottom of the valve body. ~~ Piston: Grease (LG-2) ‘% When assembling piston (18), coat the outer circumference of the piston and the inner circumference of the body hole with grease. Fit O-ring to collar (7), then assemble in body (14), and install seal (6) Install plate (5) 32) Mounting bolt: See MAINTENANCE STANDARDS. Install joint (4). <—~ Sliding portion of joint Grease (LG-2) 72 Joint: Thread tightener (LT-2) So Joint: See MAINTENANCE STAN- DARDS. * Keep strictly to the standard value for the tightening torque of the joint. Assemble disc (2), and tighten with nut (1), =) Nut See MAINTENANCE STAN- DARDS, %* After assembling the disc, adjust the assembled height of the disc. For details, see TESTING AND ADJUSTING, Adjust- ing PPC vaive. G+» > CO gE ¢ caso oe (QO O( 30-81-2 3REMOVAL OF TRAVEL PPC VALVE ASSEMBLY “BH Lower the work equpment to the ground and stop the engine. Operate the control levers several times to release the remaining pressure in the hydraulic piping. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. 1. Yokes (1). (See F1) 2. Hose (2). (See F1) * Disconnect 6 hoses. 3. Travel PPC valve assembly (3). (See F1) INSTALLATION OF TRAVEL PPC VALVE ASSEMBLY + Carry out installation in the reverse order to removal. 30-82 D DISASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY 1. Remove plate (1), then remove piston assembly (2). (See F2) 2. Disassembly of piston assembly Remove collar (4) from piston (3), then remove seal (5). (See F2) 3. Remove valve assembly (6), then remove spring (7). (See F2) 4. Disassembly of valve assembly Push retainer (8) to remove collar (8), then remove retainer (9), spring (10), and shim (11) from vaive (12). (See F2) ASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY 1. Assembly of vaive assembly Assemble shim (11), spring (10), and retainer (9) in valve (12), then push down retainer (9) to install collar (8). (See F2) 2. Assemble spring (7), and install valve assembly (6). (See F2) 3. Assembly of piston assembly Assemble seal (5) to collar (4), and install to piston (3). (See F2) 4. Assemble piston assembly (2), and install plate (1). (See F2) 0205¢50208¢5 are 80 ano D ) Z, 20505495 30-83 7REMOVAL OF PPC SHUTTLE VALVE ASSEMBLY “Bl Lower the work equipment to the ground * and stop the engine. Operate the control levers several times to release the remaining pressure in the hydraulic piping. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. 1. PPC shuttle valve assembly for arm, swing 1) Hoses (1). (See F1) + Disconnect 4 hoses. 2) Hoses (2). (See F1) + Disconnect 6 hoses. 3) PPC shuttle valve assembly (3) for arm, swing. (See F1) 2. PPC shuttle valve assembly for boom bucket, travel 1) Hoses (4). (See F1) + Disconnect 8 hoses. 2) Hoses (5). (See F1) * Disconnect 10 hoses. 3) PPC shuttle valve assembly (6) for boom, bucket, travel. (See F1) INSTALLATION OF PPC SHUTTLE VALVE ASSEMBLY + Carry out installation in the reverse order to removal. 30-84 oO REMOVAL OF BOOM CYLINDER ASSEMBLY MExtend the arm and bucket fully, lower the ‘work equipment to the ground, and operate the control levers 2 or 3 times. 1. Hose (1). (See F2) 2. Lock bolt (2). (See F2) [# 1] 3. Pin (3). (See F2) [#2 * Sling the boom cylinder assembly, and remove the pin Start the engine, and retract the rod of the boom cylinder, tie the rod with wire to prevent it from coming out, then lower it onto the block. “AF Release the remaining pressure in the circuit. For details, see TESTING AND ADJUSTING, Releasing pressure in hydraulic circuit for machines with PPC valve. 4, Hose (4). (See F3) 5. Pin (5). (See F4) * Sling the boom cylinder assembly, then use forcing screws (1) to remove the pin 6. Boom cylinder assembly (6). (See F4) (ts) See Weight Table INSTALLATION OF BOOM CYLINDER ASSEMBLY + Carry out installation in the reverse order to removal. (fw) % Tighten with the locknut so that the clearance between the boom boss and nutis 0.5 — 1.5 mm. (See F5) (2) When aligning the position of the pin hole, run the engine at low idling. Never insert your fingers in the pin hole. + Bleeding air ‘Bleed the air from the cylinder. For details, see TESTING AND ADJUST- ING, Bleeding air from hydraulic cylinder. %* After bleeding the air from the cylinder, ‘check the level of the oil in the hydraulic tank, 20550205C5 F2 osfossge.c 20sF0s499 0.5 — 1.5mm 208F6065 30-85REMOVAL OF ARM CYLINDER ASSEMBLY Set block @ between the arm and the boom, then extend the arm fully, lower the work equipment to the ground, and operate the control levers 2 or 3 times. Sling the arm cylinder assembly. 1. Pin (1), (See F1) (#1) Start the engine, and retract the rod of the arm cylinder, then tie the rod with wire to prevent it from coming out. AS Release the remaining pressure in the circuit. For details, see TESTING AND ADJUSTING, Releasing pressure in hydraulic circuit for machines with PPC valve. Hose (2). (See F1) Hose (3). (See F1) Pin (4). (See F1) ‘Arm cylinder assembly (5). (See F1) geen [om] See Weight Table INSTALLATION OF ARM CYLINDER ASSEMBLY + Carry out installation in the reverse order to removal. AdWhen aligning the position of the pin hole, run the engine at low idling. Never insert your fingers in the pin hole. + Bleeding air + Bleed the air from the cylinder. For details, see TESTING AND ADJUST- ING, Bleeding air from hydraulic cylinder. + After bleeding the air from the cylinder, check the level of the oil in the hydraulic tank REMOVAL OF BUCKET CYLINDER ASSEMBLY Adextond the arm ana bucket fully, lower the work equipment to the ground, and operate the control levers 2 or 3 times. Set block (D between the link and the arm, ‘and sling the bucket cylinder assembly. 1. Lock bolt (1). (See F2) #1] 2. Pin (2), (See F2) A Start the engine, and retract the rod of the bucket cylinder, then tie the rod with wire to prevent it from coming out “A Release the remaining pressure in the circuit. For details, see TESTING AND ADJUSTING, Releasing pressure in hydraulic circuit for machines with PPC valve. 3. Hose (3). (See F2) 4. Pin (4). (See F2) 5, Bucket cylinder assembly (6). (See F2) ("ke") See Weight Table INSTALLATION OF BOOM CYLINDER ASSEMBLY + Carry out installation in the reverse order to removal #1) + Tighten with the locknut so that the clearance between the link boss and nut is 0.5 — 1.5mm. (See F3) (w2) Awren aligning the position of the pin hole, run the engine at low idling. Never insert your fingers in the pin hole. + Bleeding air * Bleed the air from the cylinder. For details, see TESTING AND ADJUST- ING, Bleeding air from hydraulic cylinder. + After bleeding the sir from the cylinder, check the level of the oil in the hydraulic tank. o205¢53 - “__ Frososaa4 20505335, 0205¢5 30.87DISASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY 1. Cylinder assembly 1) Remove mounting bolts, and disconnect head assembly (1). (See F1) 2) Pull out piston rod assembly (2). (See Ft) ‘* Place a container to catch the oil under the cylinder. 2. Piston rod assembly 1) Set piston rod assembly (2) in tool Ex (See F2) 2) Using hydraulic pump, remove nut (3) (See F2) % Width across flats of nut Cylinder | e Boom | Arm | Bucket Model — C200 as | 95 | 95 C220 so | 95 | 95 3) Remove piston assembly (4). (See F3) 4) Remove retainer (5) and plunger (6). (See F3) + Retainer (6) is for PC220 boom cylinder only. + Plunger (6) is for PC200, PC220 boom, arm cylinders only. 5) Remove collar (7). (See F3) * For PC200, PC220 boom, arm cylinders only 6) Remove head assembly (8). (See F3) 7) Remove cap (9), and pull out 12 balls (10), then remove plunger (111). (See F4) + For PC200, PC220 arm cylinder only 30-88 oO . Disassembly of piston assembly 1) Remove ring (19) (See F5) 2) Remove wear ring (13). (See F5) 3) Remove piston ring (14). (See F5) . Disassembly of cylinder head assembly 1) Remove snap ring (15), then remove dust seal (16). (See F6) 2) Remove rod packing (17). (See F6) 3) Remove buffer ring (18). (See F6) 4) Remove bushing (19). (See F6) 0208¢50205¢5 12. aE 4 | | 13 12 F2 ‘2onrosae 2o2F09a08 3 202F0s483, +--+ 202F0S601-KASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY 4 De careful not to damage the packings, dust seals, and O-rings. 1, Assembly of head assembly 1) Press fit bushing (19). (See F1) 2) Assemble buffer ring (18). (See F1) 3) Assemble rod packing (17). (See F1) 4) Assemble dust seal (16), and secure with snap ring (1). (See F1) 2. Assembly of piston assembly 1) Using tool E2, expand piston ring (14), (See F2) Set the piston ring in tool E2,and tum the handle 8 — 10 tums to expand 2) Set tool Es in position, and compress piston ring (14). (See F3) 3) Assemble wear ring (13). (See F4) 4) Assemble ring (12). (See F4) %* Be careful not to open the end gap of the ring too far. ~\ Ring groove: Grease (G2-L!) 3. Piston rod assembly 1) Set plunger (11) in piston rod, then assemble 12 balls (10), and secure with cap (9). (See F5) ‘* Check that there is a certain amount of plug at the tip of the plunger. + For PC200, PC220 arm cylinder only 30-90 2) 3) 4) 5) 6) 7 Assemble head assembly (8). (See F6) Assemble collar (7). (See F6) + For PC200, PC220 boom, arm cylinders only Assemble plunger (6) and retainer (5) (See F6) + Plunger (6) is for PC200, PC220 boom, arm cylinders only. + Retainer (5) is for PC220 boom cylinder only. Assemble piston assembly (4). (See F6) Set piston rod assembly (2) in tool Ey (See F7) Using hydraulic pump, tighten nut (3) <>. Nut: Thread tightener (LT-3) Se Nut: See Tightening Torques and Standard Values Table 4. Cylinder assembly v 2 Assemble piston rod assembly (2). (See F9) “O~ Seal: Grease (G2-LI) ‘* Set the end gap of the ring at the horizontal (side) position, align the center of shaft and cylinder tube, then insert. (See F8) %* After inserting, check that the ring is not broken and has not come out, then push in fully. Tighten head assembly (1) with mounting bolts. (See F9) 32) Mounting bolt; See Tightening Torques and Standard Values Table 0208¢50208¢5 Ft Fo i a | fom» 7 ed Ke aoarosses F2 F3 co i 1 I € ee \ wu iM | fn, L Fa Fs 1 12. M | MM { 12 iO nd gop of rng aoxroness 2e2r05000| 8 Fo 10, / MW . aoroseorx| — | 2onrosaet| 30-91 ©REMOVAL OF WORK EQUIPMENT ASSEMBLY AXcatend the arm and the bucket fully and lower the work equipment completely, then operate the control levers 2 or 3 times. 1, Hose (1). (See F1) 2. Lock bolt (2). (See F1) [1] 3. Pin (3), (See F1) [2] * Sling the boom cylinder assembly and remove the pin. Start the engine and retract the boom cylinder rod fully, then tie the rod with wire to prevent it from coming out, and lower it onto the block. + Disconnect the boom cylinder on the opposite side in the same way. “Ae Release the remaining pressure in * the circuit. For details, see TESTING AND ADJUSTING, Releasing pressure in hydraulic circuit for machines with PPC valve. 4, Hoses (4). (See F2) 5. Wiring (5). (See F2) 6. Pin (6), (See F3) % Sling work equipment assembly (7), then using tool F, remove the pin. (See F3) 7. Work equipment assembly (7). (See F4) [te] See Weight Table INSTALLATION OF WORK EQUIPMENT ASSEMBLY + Carry out installation in the reverse order to removal (ei) When tightening the locknut, tighten so that the clearance between the boss of the boom and the nut is “0.5 — 1.5 mm”. (See F5) #2] Awien aligning the position of the pin hole, run the engine at low idling, and align slowly. Never insert your fingers in the pin hole. + Bleeding air + Bleed the air from the cylinder For details, see TESTING AND ADJUST- ING, Bleeding air from hydraulic cylinder. + After bleeding the air from the cylinder, check the level of the hydraulic tank. 0205¢50205¢5 208F6085 30-93REMOVAL OF BUCKET ASSEMBLY ASet the back of the bucket facing down, lower the work equpment to the ground, and operate the control levers 2 or 3 times. Lock bolt (1). (See F1) [#1] Plate (2). (See F1) [#2 Pin (3). (See F1) (#3) Lock bolt (4). (See F1) [#4 Pin (5). (See F1) Bucket assembly (6). (See F1) + Raise the work equipment and discon- ect the arm from the bucket. papeNe See Weight Table INSTALLATION OF BUCKET ASSEMBLY + Carry out installation in the reverse order to removal. | ea % Tighten with the locknut so that the clearance between the bucket boss and nutis 0.5 — 1.5 mm. (See F2) % Adjust the shim thickness so that the clearance between bucket boss (7) and spacer (8) is 0.5 - 1.0 mm. (See F3} * When aligning the position of the pin hole, run the engine at low idling. Never insert your fingers in the pin hole. 30-94 © REMOVAL OF ARM ASSEMBLY 1. Bucket assembly + Remove bucket assembly. For details, see REMOVAL OF BUCKET ASSEMBLY. 2. Work equipment set * Secure the bucket cylinder assembly to ‘the arm, pull in the arm, and lower it onto block ‘D. (See F4) 3. Pin (4), (See Fa) [#1] %* Sling the arm cylinder assembly, and remove the pin. Start the engine, and retract the rod of ‘the arm cylinder, then tie the rod with wire to prevent it from coming out. A"Release the remaining pressure in the Circuit. For details, see TESTING AND ADJUSTING, Releasing pressure in hydraulic circuit for machines with PPC valve. 4. Hose (2). (See F4) Pin (3). (See F4) 6. Arm assembly (4). (See Fa) * Raise the boom and disconnect the boom from the arm. (xe) See Weight Table INSTALLATION OF ARM ASSEMBLY + Carry out installation in the reverse order to removal. J Awoen aligning the position of the pin hole, run the engine at low idling. Never insert your fingers in the pin hole. + Bleeding air % Bleed the air from the cylinder. For details, see TESTING AND ADJUST- ING, Bleeding air from hydraulic cylinder. % After bleeding the air from the cylinder, check the level ofthe oil in the hydraulic tank ei o205¢5,20805336 205F6085 205s 20805397 30.95REMOVAL OF ARM, BUCKET ASSEMBLY AdExtend the arm and bucket fully, lower the work equipment to the ground, and operate the control levers 2 or 3 times. 1, Pin (1). (See F1) (1) %® Set block (1) between the arm and the boom, then sling the arm cylinder assembly, and remove the pin. (See F1) AiSitart the engine, and retract the rod of the arm cylinder, then tie the rod with wire to prevent it from coming out. Release the remaining pressure in the circuit. For details, see TESTING AND ADJUSTING, Releasing pressure in hydraulic circuit for machines with PPC valve. 2. Hose (2). (See F2) 3. Pin (3). (See F2) + Sling the arm and bucket assembly, then remove the pin 4. Arm and bucket assembly (4) (ie) See Weight Table INSTALLATION OF ARM, BUCKET ASSEMBLY + Carry out installation in the reverse order to removal. =I] When aligning the position of the pin hole, run the engine at low idling. Never insert your fingers in the pin hole. * Bleeding air Bleed the air from the cylinder. For details, see TESTING AND ADJUST- ING, Bleeding air from hydraulic cylinder. * After bleeding the air from the cylinder, check the level of the oil in the hydraulic tank. 30-96 © REMOVAL OF BOOM ASSEMBLY 1. Arm and bucket assembly + Remove arm and bucket assembly. For details, see REMOVAL OF ARM, BUCKET ASSEMBLY. 2. Hose (1), (See F3) 3. Lock bolt (2). (See F3) [#1] 4. Pin (3). (See F3) [#2] + Sling the boom bylinder assembly, and remove the pin. Start the engine, and retract the rod of ‘the boom cylinder, tie the rod with wire to prevent it from coming out, then lower it onto the block. + Disconnect the boom cylinder assembly ‘on the opposite side in the same way. “Ak Release the remaining pressure in the * circuit. For details, see TESTING AND ADJUSTING, Releasig pressure in hydraulic circuit for machines with PPC valve. 5. Hose (4). (See F4) 6. Wiring (5). (See Fa) 7. Pin (6). (See F5) + Sling the boom assembly, then use tool F to remove the pin. (See F5) 8. Boom assembly (7). (See F6) |} See Weight Table INSTALLATION OF BOOM ASSEMBLY (eI + Tighten with the locknut so that the clearance between the boom boss and nutis 0.5 — 1.5 mm, (x2) When aligning the position of the pin hole, run the engine at low idling. Never insert your fingers in the pin hole. + Bleeding air + Bleed the air from the cylinder. For details, see TESTING AND ADJUST- ING, Bleeding air from hydraulic cylinder. + After bleeding the air from the cylinder, check the level of the oil in the hydraulic tank. 208s0208¢5 205F05499 20508340 20508501REMOVAL OF OPERATOR'S CAB ASSEMBLY 1. Seat assembly (1). (See F1) [xs] See Weight Table 2. Wiper motor wiring (2). (See F1) 3. Antenna wiring (3). (See F2) 4. Room lamp wiring (4). (See F2) 5. Ground connection (5). (See F2) 6. Instrument panel assembly (6). (See F2) % Remove the cover, then loosen the mounting bolts, and move the instrument panel assembly towards the inside. 7. Cab assembly (7). (See F3) ts] See Weight Table INSTALLATION OF OPERATOR'S CAB ASSEMBLY + Carry out installation in the reverse order to removal 30.98 REMOVAL OF COUNTERWEIGHT 1. Counterweight (1). (See F4) [3 1] ‘* Using eyebolts, sling the counterweight, then remove the mounting bolts. %* Width across falts of bolt: 41 mm. S's] See Weight Table INSTALLATION OF COUNTERWEIGHT + Carry out installation in the reverse order to removal. (wt =I Mounting bolt: See Tightening Torques and Standard Values Table 0208¢50208¢5 30-99REMOVAL OF ENGINE THROTTLE CONTROLLER PC200-5 Serial No: 45001 - 56338 PC220-5 Serial No: 35001 - 36437 1. Wiring connector (1). (See F1) 2. Engine throttle controller assembly (2). (See Fi) INSTALLATION OF ENGINE THROTTLE CONTROLLER PC200-5 Serial No: 45001 - 56338 PC220-5 Serial No: 35001 - 36437 + Carry out installation in the reverse order to removal. 30-100 REMOVAL OF MONITOR PANEL ASSEMBLY 1. Screws (1). (See F2) + Remove 4 screws, and move the monitor panel assembly upward. Wiring connector (2). (See F2) . Monitor panel assembly (3). (See F2) ex INSTALLATION OF MONITOR PANEL ASSEMBLY + Carry out installation in the reverse order to removal 0205¢5399020 30-101PROCEDURE FOR FLUSHING HYDRAULIC CIRCUIT * When carrying out flushing to remove the dirt in the hydraulic circuit, use the following procedure. Select one of the patterns below to match the level of contamination in the hydraulic circuit. Flushing No. Contamination level nate 1 | Hydraulic equipment is broken; there are i metal particles in the circuit Parts in the circuit have been disassembled 2 | and assembled {there are no metal particles in the circuit) eI 3 | Periodic flushing 4_| After assembly at jobsite following | e disassembly and transportation 1. Parts to prepare * The figures in the table below show the number of parts required. T Flushing pattern No, Part Name Part No, T AlBic 1. | Flushing element 209-60-31130 | 2 | 1 | 1 2 | Standard element | 07063-01210 1) 1/4 3 | Pilot filter 704-28-02751 | 2 1 | 1 4 | Small strainer | 206-60-41221 1 | 1 | 1 «5 | Flange for snort 07377-00615 6 | - | 3 sirouiting piping 205-62-74730 | 1 | — | 1 | Main vaive blind plug 07222-00312 | 4 | 4 and sleeve nut 07221-20315 7 Extension nipple for Gallpec ecu 07102-20340 | 4,4a)- Extenion nipple for ] | St pecan 217-04-11580 [4/4] - + Inadcition to these, a stopper is also needed as a blind plug for the hydraulic tank filter case. * For details, see "Installation of filter element.” 30-102 oO o205cs0205¢5 x Order of operations The following explanation describes the procedure for short-circuiting the piping, installation of the filter element, cleaning of the cylinder, and flushing of the PPC circuit that is carried out in the operation for each flushing pattern. 1). Short-circuiting the piping Using the piping short-circuiting flange, short circuit the following piping. Posi- Attach- tion ment Hose connection PartNo. | Q'ty 2 | Arm | (C)and (0) 205-62-74730] 1 poy" | “| | 3 | Bucket | (A) and (®) [07377-00615] 1 | ae 4 | swing | (1 and UW) [07377-00615] 1 | | tk) and iL) 5 | Travel | (Mage) [07877-00615 | 2 Method for short circuiting piping All the hydraulic circuit, including the hoses and tubes is flushed, so short circuit the supply and return pipes in the circuit wee | [2 20905978 20508979 30-1032) Installation of filter element * When removing the element from the return filter, use the stopper to prevent the dirt inside the filter case from entering the tank + Inside diameter of hole: 35.7 mm * When parts have been removed for short circuiting, clean the individual parts and blow with air, then mask with tape to pre- 4 vent dirt from entering, and store in a safe i place until 30-104 Relief valve ~ ‘Small Strainer steiner (lean) (Clean) Flashing - element (instal) Pilot filter Stopper —_ Fitter case] | (Replace with new one) 20508380 |__-tlement 35.7mm yssembling again. 20505361 0208¢5o205c5 3) Cleaning cylinder * a ii) iw) Disassemble all cylinders and clean them. Remove cylinder head, then pull out piston rod: Fix cylinder at an angle, then use a pump to clean with flushing fluid. * If no pump is available, use 2 crane, collect the flushing fluid at the bottom end, shake well, then drain the flushing fluid, and blow with air. Apply flushing fluid to the cylinder head and piston and brush well with a nylon brush, then blow with air. % Dirt is likely to collect particularly in the inset portions, so clean these parts well Check inside of cylinder for damage. + Any vertical scratches in cylinder. + Any breakage or seizure of wear rings or piston rings. + Scratches on piston. * If there is any scuffing of the piston or cylinder, replace the assembly. + If only the wear ring or piston ring are damaged, replace the damaged part with a new part, and use again. Wear Piston Wear ring ng 20508384 | ring F2050s982 Flushing fluid | 20505383 Piston Nut 20508385, 30-105 a4) Flushing PPC circuit Disconnect PPC hose from Itis not necessary to remove ‘main valve, then fit noses for port P and port T. blind plug in main valve Use nipple to connect hose Replace element and clean Using extension hose, small strainer return PPC circuit hose directly to hydraulic filter case Hydraulic tank F20s0se6 i) Disconnect PPC circuit hose from control valve, and return directly to hydraulic tank filter case. * Carry out the operation for one PPC valve. ii) Run the engine at high idling, operate the control lever in each direction and hold it for 2 minutes in each position. iil) Repeat the procedure in Step ii) at least 5 times. iv) Carry out the procedure in Steps i), ii, and iil) for each PPC circuit. 30-106 o205¢50208¢5 3. Flushing pattern [A] iD 2 3) Disassembly, cleaning, reassembly i) Failed parts * If any part is badly damaged, replace it. Hydraulic tank Suction strainer Oil cooler If excessive amounts of dirt and dust are stuck in the core, replace vl Cylinder * For details, see cylinder” vi) Other hydraulic equipment “Cleaning Preparatory work for flushing ’) Install the flushing element, clean the small strainer, then install it as it is, Replace the pilot filter with a new part. * For details, see “Installing filter element" ii) Short circuit the cylinder circuit, swing motor circuit, and travel motor circuit * For details, see "Short circuiting piping” iii) Add hydraulic oil to the specified level iv) Bleed the air from the main pump. Flushing cylinder circuit, swing motor circuit, travel motor circuit i) Run the engine at low idling for 30, minutes. ‘* The control levers must not be moved during this time. ii) Run the engine at midrange speed for 30 minutes. * The control levers must not be moved during this time. If the oil temperature is low, increase the length of the operation in Steps i) and ii) to raise the temperature. The oil temperature should be 50 — 80°C. 4 5) iil) Run the engine at high idling and carry out the following operation. + Operating pattern Boom RAISE ~ Boom LOWER - Arm IN - Arm QUT ~ Bucket CURL ~ Bucket DUMP - Right swing ~ Left swing ~ Left travel Right travel + Operating time Hold the lever in each position for 2 minutes. + Number of times of operation Repeat the above pattern at least 5 times. Restoring cylinder circuit, swing motor circuit i) Restore the cylinder circuit and swing motor circuit to the standard circuit. %* Keep the travel motor circuit short-circuited. ii) Add hydraulic oil to the specified level. iil) Bleed the air from the main pump, cylinders, and swing motor. Flushing center swivel joint i) Run the engine at high idling and carry out the following operation. + Operation pattern Left and right FORWARD +90° swing Left and right REVERSE +90° swing * Swing 90° to either the left or right, but swing in the same direction each time. + Operating time Hold the lever in each position for 2 minutes. + Number of times of operation Repeat the above pattern 4 times, and rotate the swing one turn. %* The purpose of swinging 90° each is to remove the dirt inside the center swivel for the whole circumference of the oil groove on the rotor side and shatt side. 30-107 i8) Restoring travel circuit i) Restore the travel circuit to the standard circuit ii) Replace the flushing element with a new part * For details, see “installing filter element” Bleed the air from the travel motor. 7)Flushing PPC circuit i) Flush the PPC circuit + For details, see “Flushing PPC circuit”. 8)Restoring PPC circuit i) Restore the PPC circuit to the standard circuit. 9) Flushing during actual operation i) With the flushing element installed, carry out normal operations for 10 — 20 hours. ‘* If the oil temperature is low, carry out the operation warming-up 10) Replacing element i) Replace the retum filter with a standard element, clean the small strainer and install it as itis. Replace the pilot filter with a new part. * For details, see “Installing filter element”, ii) Add hydraulic oil to the specified level. iii) Bleed the air from the main pump. 30-108 @ Flushing pattern (B) v 2) 3) 4) 5) Preparatory work for flushing Install the flushing element * For details, see "Installing filter element”, Flush PPC circuit Flush the PPC circuit * For details, see “Flushing PPC circuit” Restoring PPC circuit Restore the PPC circuit to the standard circuit. Flushing during actual operation With the flushing element installed, carry out normal operations for 10 — 20 hours. + If the oil temperature is low, carry out the warming-up operation Replacing element Replace the return filter with a standard element, clean the small strainer and install it as itis. Replace the pilot filter with a new part. * For details, see “Installing filter element” 0208¢52055 y 2) Hf the cylinder piping is connected and the cylinder is operated before the system flushed, there is danger that the dirt that entered during assembly operations will circulated inside the cylinder. Therefore, do not flush the system after completion of assembly; carry out flushing before connecting the piping to the cylinder Preparatory work for flushing i) Short circuit the cylinder circuit. + For details, see "Short-circuiting piping” ii) Install the flushing element. * For details, see “Installing filter elemen Flushing i) Run the engine at low idling for 30 minutes. + The control levers must not be moved during this time ii) Run the engine at midrange speed for 30 minutes. ‘* The control levers must not be moved during this time. ili) Run the engine at high idling and carry out the following operation. + Operating pattern Boom RAISE ~ Boom LOWER ~ ‘Arm IN — Arm OUT ~ Bucket CURL Bucket DUMP + Operating time Hold the lever in each position for 2 minutes, + Number of times of operation Repeat the above pattern at least 5 times. 3) 4) 5) Restoring evlinder circuit i) Restore the cylinder circuit to the standard circuit Add hydraulic oil to the specified level ii) Bleed the air from the main pump and cylinders. Flushing during actual operation i) With the flushing element installed, carry out normal operations for 10 — 20 hours. + If the oil temperature is. low. carry out the warming-up operation Replacing element i) Replace the return filter with a standard element, clean the small strainer and install it as itis. Replace the pilot filter with a new part * For details, see “Installing filter element” ii) Add hydraulic oil to the specified level. ) Bleed the air from the main pump. 30-109 @40 MAINTENANCE STANDARD 0205¢5 Final drive Swing machinery ‘Swing circle Track frame and recoil spring. Idler. Track roller Carrier roller Track shoe Hydraulic pump. ee Charging pump and relief valve Control valve : Travel shuttle valve Swing motor Center swivel joint Travel motor PPC valve Hydraulic cylinder Work equipment . 40-1FINAL DRIVE 28 + 6.5 kgm —_ 1 ) d — ge 1 j ie d c d _ | | c Leal eal — Hatt ( f / Mm Mm j if em | {| | ! hy i 0 355 28 kom i yf - nd Lik OO 205F2203A 40-2 o205¢5Unit a No Check tem Criteria Remedy Standard cleoranca Clearance imi 1 | Backash between sun gear and _ planet gear ore om | oo pca00:022~080 | 110 2 | Backlash between planet gear and 2 No ting gear 220: 0.20 ~ 08 110 — Backlash between planet goar and ~ 3 | No. 2 ring gear casio aa 7 | Beckiash between No.2 ing gear —— a and geor 5 | End ply of sprocket shaft o-oa - 6 | Amount of weer on sprocket oth Repsir iit: 6 = : i Dutup Standard size Repair iit welding or 7 | wicth of sprocket tooth Li 1 a 260 1 20kGm 8 35 170 20kgm 32) 38.0 = 50kam raoscsmea Unit: mm No. Check iter Crteria Remedy Standard size Repair tint | repiaceit Freelength | Installed | instatea | Free | instaled | 2x¥ deme 1 | check vaive spring 00. | "tength | “lod” | length | toed Seforma- i tone are = | | | 40-25CENTER SWIVEL JOINT 20508775, Unit: mm. No. Check item Criteria Remedy Standard size | Standard clearance | Clearance limit 1 | Clearance between Replace rotor and shaft 90 0.086 — 0.108 ort 40-26 0205¢50208¢5 TRAVEL MOTOR G18 + 02 kgm \ 35 = £05 kgm Section ~ C Seeeer nea) 208F2202 Unit: mm No. ‘Check tem Criteria Remedy Standard size Repair fimit Free length] Installed | installed Installed 1 | spool tum spring NOD. | length | toad Freelenat| "iggy? | Replace or 51x295 | 347 | 285kg | 477 | 228kg | deformation is found. 2 | Check valve spring 514x173] 305 O.2kg 472 | o16kg 40-27PPC VALVE PC200-5 Serial No: 45001 - 58018 PC220-5 Serial No: 35001 - 36613 FOR WORK EQUIPMENT AND SWING G15 + 1.5 kam 4 Ca GEN 25 + 1.0kam 111.5 + 1.0 kgm 4 Lind GABE 25105 kom _ GD 18 + O.4kgm 205F05198 Unit: mm No. | Check item Criteria Remedy ‘Standard size Repair limit Freelength | installed | Installed | Free | Installed 1 | Pilot spring | x0D. | length load length toad _| replace it T any dama- 126x385] 11.9 |0018kg | 0.16kg | gesor deforma ~ tions are 2 | Metering spring 314x74| 294 | 1.7k9 = 1.4kg | found 3 | Centering spring (For P3,P 4) 531x174) 36.5 57 ko S 46kg 4 | Centering spring (For P1,P2) s31x174| 365 73kg S 58kg 40-28 @ 0205¢5PC200-5 Serial No: 58019 and up PC220-5 Serial No: 36614 and up FOR WORK EQUIPMENT AND SWING oa / n 8 mH 05h 3 futon B= Unit mm No Check tem Grea Remedy Standard oe Repel i Free enoth] Insaled | Treated | Fee | Intalea ontrng svi : - aed | iat + | Seren seri 8" Viera | “toad” | tenath — cent 4a5x155| 34 23k9 - 1Bkg | any dama | See 1 ——|— Bers 2 | Metering spring 265%82| 269 1.7kg = 14kg | are found Genigigg son | 40-29 3FOR TRAVEL fq ( 1 = aR 2 | j ls 3315 — 35tam GE 25105 tam oo, |cn| oT I e G18 £04 kom a0srosi99 Unit: mm No. Check item Criteria Remedy Standerd size Repair limit Freetength] Instaled | instated | Free | Installed | Replaceit 1 | Metering spring OD. | length | load” | ength | "load | any dama- — i gesor aiax7a| 204 | ire | - | rane | setorme: }—— found 2 | centering spring frsxr99) 268 | 29% | - | 18h0 o205csHYDRAULIC CYLINDER PC200-5 ‘* The drawing shows boom cylinder FE Boom: 27.5 + 40kgm FE Boom: 720 + 72 kgm Width across flats: 85) Arm: 380+ 55kgm Arm: 1040 * 104 kgm (Width across flats: 95) Bucket: 27.5 + 40kgm Bucket: 720 +t 72 kgm (Width across fats: 85) Cylinder Standard | Tolerance | standard | Clearance sJseresteater [soon | es | =8885 | $8325 | °°8%i2 | one | rena “ am | 95 | =9888 | £0383 [om88.;, | onte aucket | 80 $9288 | 0073— | aaa Boon | 80 4958 [ona [10 : aor supp am | 80 333% [3855 | 12 | aucret | 70 $8535 [05850 | 1 | rapes ven | 70 19425 [°°82a,| 10 [Phe Clears | 167 2 |epinarbotem” | am | ao | ~9089 | t2482 |oAga=. | 10 owaer | 70 | =9099 | tg826 [omggs, | 10 40-30 205s~~ PC220-5 * The drawing shows boom cylinder ZA Boom: 27.5 + 40 kgm GED Boom: 1040 + 104 kgm Width across flats: 95) Am: 380*55kgm Arm: 1040 * 104 kgm (Width across flats: 95), Bucket 27.5 * 40kgm Bucket: 1040 + 104 kgm (Width across fats: 95! / Cylinder | Standard inclerenice, Standard | Clearance + foemmezanrmen [soon | 0 [9888 | 293% [PCa | O47 |e - " tm | 00 | 0885 | 2988 [Ebay | ome wen | 90 | 70085 [ 28880 [28a | ome | soon | oo | 28888 | 382 [88a [ve | Clearance between t ] 04 2 patanred spear Arm | 90 | =oo78 | $0300 [°"0saa |_| swan | 00 | 8088 | 28552 [ERs [0 [ag wom [oo | 00mg | 38588 [o-tas, [10 |e Clears betwe rn 030 | 2 are, [am | co | 08a | 2838 [Othe | +0 suse | co | 0088 | 2238 [ARR |e 40-31WORK EQUIPMENT Section A-A = Section B—8 Section C—C Section D—D 40-32 Section E-E Section F—F Pa Section G—G 4 Section K—K 205F05203A o20sc5,‘o205c5, Unit: mam No. Check item Criteria Remedy Standard roman! Standard | Clearance Clearance between bushing and a See eae 1 | connecting pin of revolving Shaft Hole frame and boom 1 By -0036 | +0342 |o305— | =0071 | 40269 | 0.412 2 | Clearance between bushing and aa —0.036 | +0343 [0.307 — connecting pin of boom and arm =0071 | +0271 | "0.413 Se ee = Replace 3g | Clearance between bushing and | 70 (PC200)| —0.030 | +0337 connecting pin of arm and link | 80 (PC220)| —0.076 | +0275 14 | Clearance between bushing and ao | -9.030 | +0337 connecting pin of arm and bucket =0076 | +0273 55 | Clearance between bushing and go | -9.030 | +0337 Connecting pin of link and bucket =0076 | +0273 6g | Clearance between bushing and | 70 (PC200)| —0.030 | +0335 connecting pin of link andlink | 80 (PC220)| —0-76 | +0.273 40-33

pc200 5

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

pc200 5

Uploaded by

Copyright:

Available Formats

You might also like