Professional Documents
Culture Documents
: NG20-17-00
Machine Systems
PC200-10M0(CE)
Komatsu Ltd..
Techno Training Center
Komatsu City JAPAN
Manual Usage
2
Objective
Objectives
3
Table of Contents
A: Design 5
B: Fuel Saving 6 - 12
C: Durability Improvement 13 - 16
D: Serviceability Improvement 17 - 30
E: Condition Monitoring Improvement 31 - 35
F: ICT Tool Improvement 36 - 43
G: Expandability Points 44 - 46
H: Interchangeability 47 - 50
4
A: Design
PC200-10M0(CE)
PC200-8M0
5
B: Fuel Saving Technologies
Table of Contents
B: Fuel Saving Technologies
1. Engine 7-8
2. Swing Controls
(1). 2-stage Swing Relief Valve 9 - 12
6
B: Fuel Saving Technologies
1. Engine
Regarding PC200-10M0(CE)'s 4-
cylinder engine, blue color area
(shows low fuel) is wider than
PC200-8M0.
In addition, PC200-10M0(CE)
engine curve is used to be on more
fuel-efficient area (blue color area).
As the sacrifice of that, engine
speed is decreased and pump flow
is decreased, and then, productivity
is also decreased. Low fuel
consumption
(1). 4-cylinder
Improved fuel efficiency in the main
operating range and idle range by using
four cylinders2.
2. Swing Controls
(1). 2-Stage Swing Relief Valve
>This valve has 2 selectable setting for a set pressure.
>The set pressure of this valve is determined by the load at installed length of spring (4).
>During swing operation, the valve receives Pilot Pressure (PI) from the 2-stage swing
relief solenoid valve and reduces the relief (drain) quantity.
>According to Formula: (wasted) Energy = Pressure X Flow From 2-Stage
Swing Relief
Solenoid Valve (7)
1. Valve seat
2. Valve
3. Poppet
>Fuel Consumption is 4. Spring
greatly improved. 5. Spring
6. Piston
9
B: Fuel Saving Technologies
2. Swing Controls
(1). 2-Stage Swing Relief Valve
From Energy = Pressure X Flow
A) When Pilot Pressure is “Shut-Off” (Low Pressure Setting)
B) When Pilot Pressure is “Activated” (High Pressure Setting)
P: 28.4 MPa (constant)
Q1: 180L/Min
Q2: 70L/Min
2. Swing Controls
(1). 2-Stage Swing Relief Valve
During Swing Acceleration, the set pressure of the 2-Stage Swing Relief Valve is changed
to decrease the flow rate to hydraulic relief and improve the fuel consumption ratio.
2. Swing Controls
(1). 2-Stage Swing Relief Valve A: Flow rate at low pressure
setting
Table of Contents
C: Durability Improvement
1. Fuel System 14
2. PPC Hose - Face Seal 15
3. Removal of Greasing Tube at the Swing Circle 16
13
C: Durability Improvement
✔Improvement of fuel filtration number as one with the Engine. Mesh Size same with
Main Filter. Will issue PSN this November 2018.
Fuel filtration was changed according to region Effective for customers who refill bad fuel at clean
side during filter exchange.
(1)Strategic Area
Water separator Fuel filter
Fuel prefilter
Main filter
Additional Water
No vent CAP STD Pre-filter Feed pump
Pre-filter separator
+ Additional (for dust)
Breather
15
C: Durability Improvement
PC200-10M0(CE) PC200-8M0
16
D: Serviceability Improvement
Table of Contents
D: Serviceability Improvement
1. Single Oil Cooler 18
2. Easy Removal of Dust-Proof Net 19
3. Dust-Proof Net Mounting 20
4. Remote and Direct Drain for Fuel 21
5. Hand Priming Pump Change 22
6. PTO Oiling Method 23
7. Drain Port to Suction Pipe 24
8. Engine Hood Mechanical Lock Bar 25
9. Integration of Oil Level and Lubrication Pipes at 26
Swing Machinery
10. Service Pressure Sensor 27 - 29
11. Battery Disconnect Switch and System 30
Operation Lamp (Opt.)
17
D: Serviceability Improvement
The oil cooler core is changed from 2 sheets to 1 sheet to improve the cleaning
performance.
In addition, by adopting a new type of core, cooling efficiency is improved.
18
D: Serviceability Improvement
A-A
19 PC200-10M0(CE) PC200-8M0
D: Serviceability Improvement
20
D: Serviceability Improvement
Operate drain
cock
at pump room
22
D: Serviceability Improvement
Breather/Oiling Port
PC200-10M0(CE) PC200-8M0
No Drain Port
Hydraulic
Fluid
Temperature
Sensor Port
Suction
Drain Port
PC200-10M0(CE) PC200-8M0
25
D: Serviceability Improvement
PC200-10M0(CE) PC200-8M0
26
D: Serviceability Improvement
Plug
Wiring Harness and Connector No. P49 is
found beside the inner RHS Frame
of the Pump Room
Example: R-pump, LS Pressure
Measurement
28
D: Serviceability Improvement
Go to PUMP Menu and search for Search as well the Rear Pump Long Press Check Icon Button (F6)
Service Pressure Sensor Item (01141) Pressure Item (01101) or input both and start monitoring.
Number Codes directly
Procedures for Set-Up
>Data communication
occurs in controller when
this light is tuned ON. Turn
OFF battery disconnect
switch ONLY when there is
no light, some Data might
be lost.
30
E: Condition Monitoring Improvement
Table of Contents
E: Condition Monitoring Improvement
1. Blowby Pressure Sensor 32 - 33
2. Hydraulic Return Oil Filter Clogging Sensor 34
3. Breaker Filter Clogging Switch 35
31
E: Condition Monitoring Improvement
Note: If disconnected or
damaged, Error Code:DHE5MA
and Action Code:L0a is
generated (Error Info sent to
KOMTRAX but no Buzzer Sound)
32
E: Condition Monitoring Improvement
Display the following monitoring screen from the service menu and execute:
>Swing Lock: ON, ARM DIG Relief + 1 Touch Power and Monitor Value.
>The failure judgment reference value is 1.96 kPa and it is the same with the current
one (PC200-8M0).
33
E: Condition Monitoring Improvement
> If sensor is disconnected or damaged, error code: DKR2MA appears. (Action code is not displayed.)
>No Calibration is required if replacement is done.
>Bypass Valve Set Pressure: 250 +- 50 KPa (Same with PC210-10M0)
Note: The exchange of filter is based on conventional time interval. However, when filter clogging is detected, replacement is
needed to prevent contaminated oil to flow downstream in order to prevent failure.
34
E: Condition Monitoring Improvement
Table of Contents
F: ICT Tool Improvement
1. Maintenance Screen Items 37
2. Maintenance Screen Actual Monitor 38
3. Language Selection Improvement 39
4. E-Mode Adjustment Function 40
5. Remaining Hours of Breaker Filter 41
6. Blowby Pressure Measurement Monitoring 42
7. Monitoring Item List 43
36
F: ICT Tool Improvement
1. Maintenance Screen Items Double the Time for Replacement: 500 H → 1000 H
PC200-10M0(CE) PC200-8M0
Maintenance item Default maintenance Time remaining until Default maintenance Time remaining until
time setting (h) maintenance time setting (h) maintenance
Engine oil filter change 500 500 500 (*1) 500 (*1)
*1: The interval is set for only that specification machine. *2:The replacement interval may become shortened depending on dust situation of application.
New/Updated Maintenance
EVERY 4000 HOURS MAINTENANCE Items are in Red Colors
METHOD FOR REPLACING RADIATOR CAP ................................................ 4-89
METHOD FOR REPLACING COOLANT FILTER CARTRIDGE............................ 4-90
METHOD FOR CHANGING COOLANT.......................................................... 4-90
37
F: ICT Tool Improvement
2500 2498
2500 2498
38
F: ICT Tool Improvement
39
F: ICT Tool Improvement
Main Monitor Panel Screen Press F6. Select Machine Setting and Press F6
to choose for Different Working Mode
40
F: ICT Tool Improvement
41
F: ICT Tool Improvement
Table of Contents
G: Expandability Points
1. Breaker Operation and Maintenance 45
2. Breaker Operation and Maintenance 46
from OMM
44
G: Expandability Points
45
G: Expandability Points
46
H: Interchangeability
47
H: Interchangeability
48
H: Interchangeability
49
H: Interchangeability
50
KLTD TTC Ref. No.: NG20-17-00
Machine Systems
PC200-10M0(CE)
Komatsu Ltd..
Techno Training Center
Komatsu City JAPAN