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STRUCTURE AND FUNCTION EPC . SOLENOID VALVE

3) At boom LOWER
When the boom is lowered, the pilot pressure
from the PPC valve pushes pilot spool (3) and the
pressurized oil in chamber b inside the poppet is
drained.
When the pressure at port C, rises because of
the pressurized oil from the bottom end of the
boom cylinder, the pressure of the pressurized
oil in chamber b is lowered by orifice a.
If the pressure in chamber b drops below the pres-
sure at port V, poppet (5) opens, the pressurized
oil flows from port C, to port V, and then flows to
the control valve.
If any abnormal pressure is generated in the circuit
at the bottom end of the boom cylinder, safety valve
(1) is actuated.

iYgg?J
XlODD056

1 o-1 34
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STRUCTURE AND FUNCTION HYDRAULIC CYLINDER

HYDRAULIC CYLINDER
SPECIFICATIONS
Unit: mm

Boom Arm Bucket

PC200-6
Item PC200LC-6 PC22OLC-6
PC21 OLC-6 PC25OLC-6

Outside diameter of 130 140 135 140 115 130

piston rod I I-

Inside diameter of 90 100 95 100 80 90

cylinder
I

Stroke 1,285 1,285 1,490 1,635 1,120 1,020

Max. stroke 3,565 3,870 2,800 2,625

Min. stroke 2,075 2,235 1,680 1,605

Width across flats 95 95 95 95 95 95

of piston nut

1 O-l 35
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STRUCTURE AND FUNCTION ADDITIONAL FILTER FOR BREAKER

ADDITIONAL FILTER FOR BREAKER

* FOR MACHINES EQUIPPED WITH BREAKER

XlOBV051

I. Head cover SPECIFICATIONS

2. Element Rated pressure : 6.86 MPa (70 kg/cm?
3. Case Flow . 107Plmin
4. Drain plug Relief valve .
5. Valve cracking pressure : 0.34 + 0.049 MPa
6. Spring (3.5 f 0.5 kg/cm?
7. Spring set plug Filter mesh size : 6w
Filtering area : 3160 cm*

1 O-l 36
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STRUCTURE AND FUNCTION OVERLOAD WARNING DEVICE

OVERLOAD WARNING DEVICE

1. OUTLINE

Battery Buzzer
-.-

Boom control
valve
Hydraulic
pu/mps
/

XO8BTOOl

FUNCTION
l This device is installed to warn the operator
when the machine is close to tipping over when
it lifts an excessive weight while being used
as a crane.
STRUCTURE
l When an excessive weight is lifted, the oil
pressure goes up at the bottom side of the
boom cylinders. When this happens, the
pressure switch senses the rising pressure,
turns the pressure switch on, and lights the
monitor lamp to warn the operator. When the
monitor lamp lights, immediately lower the
weight to the ground or bring the arm closer
in to the operator to prevent the machine from
tipping over.

1O-l 37
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STRUCTURE AND FUNCTION

OVERLOAD WARNING DEVICE

Control panel

I 4

Overload warning pilot lamp

r’=.8Bs88
‘\
\ i
\

XllAH003

1 O-l 38

STRUCTURE AND FUNCTION
2. OPERATION
0 Hose (2) directs the oil pressure from
the bottom side of the boom cylinders
to pressure switch (3).
a. When the boom is in the lowest position
l When boom (5) is in the lowest position,
lever (4) takes position A in Fig. 1 and the
pressure to activate its switch (closed and
open) becomes 60 kg/cm’.
b. When the boom is in the highest position
l When the boom is in the highest position,
lever (4) takes position B in Fig. 1 and the
pressure to activate the switch becomes
360 kg/cm’.
C. When the boom is in an arbitrary position
l When the boom is in a position anywhere
between the lowest and the highest points,
the operating pressure of switch (3) will be
somewhere between 60 kg/cm* and 360 kg/cm’,
based on the boom position.
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OVERLOAD WARNING DEVICE
For instance, when the boom is in a certain
position between the lowest and the highest points,
lever (4) takes a position which corresponds to that
boom position.
If lever (4) is in the position to make the operating
pressure of the pressure switch 150 kg/cm* (which
is the same pressure as the bottom side of the
boom cylinder), the pressure switch will turn on
when excessive weight is lifted by the boom and the
oil pressure of the bottom of the boom cylinders
exceeds 150 kg/cm*.
A When the machine is performing any kind of opera-
tion other than lifting loads, fasten the pressure
switch lever (4) with the bolt (6) to prolong the life
at the pressure switch.
XOSBTOO2
1o-1 39
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STRUCTURE AND FUNCTION OVERLOAD WARNING DEVICE

3. ADJUSTING PRESSURE OF THE OIL

PRESSURE SWITCH
l Screw D: Pressure range adjustment screw
To make an adjustment so that the
oil pressure switch acts normally
when checking the operation of the
overload warning device.
Turning to the left makes the pres-
sure range wider.
l Screw E: Zero point adjustment screw
Turning to the right one complete
turn raises the pressure by 57 kg/cm*.
Each complete turn to the left lowers
the pressure by 57 kg/cm’.
A When an adjustment is required, contact your
Komatsu distributor and have him make the
adjustment.

1. Body
2. Bourdon tube
3. Eccentric disc
4. Microswitch
5. Lever and roller
6. Adjustment screw (E)
7. Adjustment screw (D)

\
Screw E XO8BTOO4

IO-140
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STRUCTURE AND FUNCTION HOSE BURST PROTECTION VALVE (BOOM)

HOSE BURST PROTECTION VALVE (BOOM)

High pressure from

control valve (v port)

Pilot signal
(Pi port)

To tank (T port)

&3Jpad caution

1. Body
2. Spool
3. Relief valve
4. Check valve

To cylinder port
KY port) XlOBH175

FUNCTION

l This valve prevents sudden uncontrolled

lowering of the boom, when lifting, due to
the burst of a hose in the boom cylinder line.
In such a condition this valve will hold the
load until the operator lowers the boom in a
controlled way using the normal wrist control.

IO-141
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STRUCTURE AND FUNCTION HOSE BURST PROTECTION VALVE (BOOM!

v port
OPERATION
BOOM RAISE
l During boom raising the pilot signal from
wrist control operates control valve spool to
direct high pressure oil to port V of hose
burst valve.
l This pressure lifts check valve (4) from seat
and high pressure oil flows in the bottom of the
cylinder, raising the boom

Boom control

.~,:.~._:.:,
~_.,...____.._
:.:_>>:.:..,:.:
......._..
.....,.......
:c:.:.:.:.:.: ..A...... . . . . . . . . . . ..‘.....I....-‘”

w XlODD057

BOOM LOWER
l During boom lowering, the pilot signal reverses
the front through the control valve spool. High
pressure oil flows to the head side of the cylinder.
Oil in the bottom side of the cylinder flows through
the port C, of the valve but cannot flow past the
check valve. The pilot signal also opens the spool
(2) of the hose burst valve and allows oil to flow
back to tank.

XlODD058

IO-142
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STRUCTURE AND FUNCTION HOSE BURST PROTECTION VALVE (BOOM)

When hose burst occurs (Operation to lower safety)

v port
l The sudden loss of pressure at port V will cause \
check valve (4) to re-seat and so the valve is
locked.
l The boom can be lowered in a controlled way by
operating the wrist control in the normal way.

mtrol

IO-143
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WORK EQUIPMENT
STRUCTURE AND FUNCTION

WORK EQUIPMENT

X1722023

1. Arm
2. Bucket cylinder
3. Arm cylinder
4. Boom
5. Boom cylinder
6. Bucket

IO-144
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ELECTRICAL CIRCUIT DIAGRAM (112) FOLDOUT 24

(TO
2/2)

CNWHOI ?=
BLUE
EN- HO IO-145
LTO (TO 0
I 2/2) 2/2) 2/2) 2 2) 2/2 1 2/2)
ELECTRICAL CIRCUIT DIAGRAM (2/2) c
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-
(TO
l/2)
-

-
-

t -_-_ ---___ _________

- -
Z
- I
1 I

(TO
l/2)

(TO
1/21

(TO
l/2)

IO-146
0
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ELECTRICAL WIRING DIAGRAM FOLDOUT 11
PC200-6, PC200LC-6
PC21 OLC-6, PC22OLC-6
PC25OLG6

12

13

14

15
i /

16

P ‘/;i _
26 l9

IO-147
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FOLDOUT 12

1. Fuel level sensor 36. Fuse box

2. Working lights 37. Caution buzzer
3. Hydraulic oil level sensor 38. Starting switch
4. LS control EPC valve 39. Fuel control dial
5. Rear pump pressure sensor 40. Cigarette lighter
6. Front pump pressure sensor 41. Swing lick switch
7. Rear pump TVC valve 42. Wiper switch
8. Front pump TVC valve 43. Light switch
9. Rear working light 44. Buzzer cancel switch
48 10. Governor motor 45. Service meter
3 11. Engine speed sensor 46. Speaker
12. Engine oil pressure sensor (Hi) 47. Kerosene mode connector
13. Engine oil pressure sensor (Lo) 48. Air conditioner control panel
14. Air cleaner clogging sensor 49. Engine throttle controller
15. Coolant level sensor 50. Pump controller
16. Window washer motor 51. Radio
17. Travel alarm 52. TVC prolix resistor
18. Horn (high tone) 53. Wiper motor controller
19. Horn (low tone) 54. Additional light relay
20. Battery relay 55. Light relay
21. R.H. head light 56. Monitor panel
22. Battery 57. Swing lock prolix switch
23. Wiper motor 58. TVC prolix switch
24. Horn switch 59. Swing oil pressure switch
25. R.H. additional light 60. Bucket CURL oil pressure switch
\55 26. Room lamp 61. Bucket DUMP oil pressure switch
27. L.H. additional light 62. Arm IN oil pressure switch
56 28. L.H. knob switch 63. Boom LOWER oil pressure switch
29. Alternator 64. Arm OUT oil pressure switch
30. Coolant temperature sensor 65. Travel oil pressure switch
$8 X 31. Electrical intake air heater 66. Boom RAISE oil pressure switch
205FO629 I 32. Engine oil level sensor 67. Swing brake solenoid valve
68. Travel speed solenoid valve
69. Pump merge-divider solenoid valve
70. 2-stage relief solenoid valve
71. LS select solenoid valve

67
205F06292 1 O-l48
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STRUCTURE AND FUNCTION ENGINE CONTROL SYSTEM

ENGINE CONTROL SYSTEM

X12BV078

1. Battery relay FUNCTION

2. Battery l The engine can be started and stopped simply
3. Starting switch by using the starting switch.
4. Fuel control dial l A dial type engine control is used to control the
5. Governor motor engine speed. The engine throttle controller
6. Starting motor receives the control signal from the fuel control
7. Engine throttle controller dial, sends a drive signal to the governor motor,
8. Fuel injection pump and controls the angle of the governor lever in the
fuel injection pump.
l At the same time, the engine throttle controller
also receives signals from other controllers to
control the engine speed.

IO-149