Komatsu PC200LC-6Z Hydraulic Excavator Shop Manual - PDF DOWNLOAD by www.heydownloads.com

Shop Manual

SEBMOlO202

HYDRAULIC EXCAVATOR

This material is proprietary to Komatsu America International Company and is notto be reproduced, used,or disclosed except in accordance with written authorization from Komatsu America International Company. It is our policyto improve our products wheneverit is possible and practicalto do so. We reservethe right to make sold changes or add improvements at any time without incurring any obligation to install such changes on products previously. Due to this continuous program of research and development, periodic revisions may betomade this publication. It is recommendedthat customers contact their distributor for information theon latest revision.

July 2000

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01 GENERAL Specification dimension drawings ............. 01- 2 Specifications 01- 4 Weight table 01- 6 Fuel. coolant and lubricants .._................01- 8

................................................ ................ -.............. ..

PC200-6Z

01-1

DRAWINGS SPECIFICATION DIMENSION

GENERAL

SPECIFICATION DIMENSION DRAWINGS Unit: m m

* 01 -2

SVPO554 I

The values marked Z are for shovel operations.

GENERAL

SPECIFICATIONS

SPECIFICATIONS Machine model Serial Number Bucket capacity Operatingweight

Max. digging depth

PC200LC-62

C10827 and up 0.8 2 1,300

6,620

5,980

9,875

Max. reach at ground level

9,700

Max. digging height

9,305

Max. dumping height

6,475

kN (kg)

11 1.7(1 1,400)

Swing speed

rPrn

12.4

Swing max. slope angle

deg.

Travel speed

kmlh

Lo: 3.8

Gradeability

deg.

:Pa {kg/cmz

38.2 (0.39)

Overall length (for transport)

mrn

9,425

Overall width

2,800

Overall width of track

3,08 0

Overall height (for transport)

2,970

Overall height to chassis

2,905.

Ground clearance to bottom of upper structure

1,085

Min. ground clearance

440

Tail swing radius

2,750

Min. swing radius of work equipment

3,630

Height of work equipment at min. swing radiu:

7,570

Length of track on ground

3,640

Track gauge

2,3 80

Height of machine cab

mrn

2,315

rn a

Max. vertical wall depth

h Max. digging reach

J U

Max. digging force

Ground pressure (standard triple grouser shoe width:700rnrn

'01-4

f'C200-6Z

GENERAL

SPECIFICATIONS

Machine model Serial Number Model

No. of cylinders

- bore x stroke 1 I

2 0

C10827andup S6D102-1 4-cycle, water-cooled, in-line, vertical, diredt injection, with turbocharger

Type

Piston disdacement

PC2OOLC-6Z

6 - 102 X 120

Q kc)

5.883 (5,8831

Flywheel horsepower

102/2,000 {135/2,000}

Max. torque Max. speed at no load

548.8/1,350 {56/1,350) 2,200

't, 0.

Min. speed at no load Min. fuel consumption Starting motor Alternator

97 0

Batterv

218 (160) 24V, 5.5 k W 24V. 60A 12V, 150 A h x 2

Track roller

2 on each side 7 on each side

cw-4

Assembly-type triple grouser, 45 on each side

Track shoe

HPV95+95, variable displacement piston type x 2

Type x no. Delivery

6-spool type x 1 Hydraulic type

Control method Travel motor

i& row

KMF90AB-3, Piston' type (with safety valve, parking.brake1 x 1

Boom

& Type

Arm

Reciprocating Reciprocating piston piston

0 = 3

. HMVl10-,2, Piston type (with brake valve, parking'brake) x 2

gg Swing motor r .-C 6

Piston type: 206 x 2

Q/min

Type x No.

Bucket Reciprocating piston

Inside diameter of cylinder Diameter of pistonrod

mm mm

130

135

115

Stroke

1,285

1,490

1,120

3.1 55

3,565

2,800

1,870

2,075

Max. distance between pins

1 Min.distancebetween

Hydraulic tank

Hydraulic filter Hydraulic cooler

PC200-6Z

pins

. -

1,680

Box-shaped, open Tank return side Air cooled (CFT-1)

01-5

GENERAL

WEIGHT TABLE

A This weight table is for use when handling components or when transporting the machine.

Unit: kg

Machine model

PC2OOLC-6Z

Serial Number

C10827 and up 742

Engine assembly

Engine

535

Damper

6 145

Hydraulic pump

124

Radiator, oil cooler assembly ~~

Hydraulic tank, filter assembly (excl. hydraulic oil)

136

Fuel tank (excl. fuel)

122

Revolving frame

1,556

Operator's cab

191

Operator's seat

Counterweight

3,750

Swing machinery

164

Control valve

166

Swing

Travel motor

53 98 x 2

Center swivel joint Track frame assembly

4,898

Track frame

2,624

Swingcircle

27 6

Idler

140 x 2

Idlercushion

135 x 2

Carrierroller

21 x 4

Trackroller Final drive (incl. travel motor)

01-6

38 x 14 L

340 x 2

PC200-6Z

, WEIGHT TABLE

GENERAL

Unit: kg

Machine model

PC2OOLC-6Z

Serial Number

C10827andup

Track shoe assembly 1,435 x 2

Triple grouser shoe (700 mm) Boom assembly

1,334

620

Arm assembly Bucket assembly

510

- 1,170

205 x 2

Boom cylinder assembly Arm cylinder assembly

244

Bucket cylinder assembly

148

Link assembly (large)

Link assembly (small)

22 x 2 43+10x2+25+10+20

Boom pin Arm pin

10 x 2

Bucket pin

20 x 2

Link pin

PC200-6Z

- .

13 x 2

01 -7

FUEL, COOLANT AND LUBRICANTS

GENERAL

FUEL, COOLANT AND LUBRICANTS

RESERVOIR

KIND OF FLUID

-20

14 -10

Idler (1 each)

4O'C

24.0 I I

5.5

4.4

4.2

- 0.08

0.07

Diesel fuel Coolant

- 0.08

0.19 - 0.21 0.23

239 Hydraulic

5.5

- 0.21 0.23 - 0.25

Hydraulic system

01-8

104'1

0.19

Carrier roller (I each)

Cooling system

0.07

Track roller (1 - e a c h ) l

...

0.75

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

Fuel tank

50 10

26.3

Engine oil pan

Damper case

CAPACITY (e)

AMBIENT TEMPERATURE

- 0.25

166

I 340

I Add antifreeze

22.2

PC200-6Z

10 STRUCTURE ANDFUNCTION .

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

....

............................................

...........

.......................

PC200-6Z

10-1

Ln W m

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0 I 0

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â&#x20AC;&#x2122;0 0

STRUCTURE AND FUNCTION

ENGINE CONTROL

SVPO5542

1. 2. 3. 4.

Stopper Engine control lever Control cable Fuel injection pump

1n-A

Lever position

@ Low idling Q High idling

nrqnn

AND

FINAL DRIVE

STRUCTURE

FINAL DRIVE P

1. Level plug 2. Drain plug 3. Cover 4. No. 2 sun gear (No. of teeth: 21) 5. No. 1 sun gear (No. of teeth: 10) 4. No. 1 planetary carrier 6. Cover 7. No. 2 planetary carrier 8. Sprocket 9. Floating seal 10. Travel motor 11. Hub 12. No. 2 planetary gear (No. of teeth: 36) 13. Ring gear (No. of teeth: 95) 14. No. 1 planetary gear (No. of teeth: 42) SPECIFICATIONS Reduction ratio: - (M) X (M +) 1 21 10 = -57.000

10-6

A- A

11 SAPO

I I

0 UI

-a

N+

E!.

9 . 0

-1

. I

STRUCTURE AND FUNCTION

TRACK FRAME

FRAME TRACK

SPRING RECOIL

RECOIL SPRING

A-A

SAPO2603

1. Idler 2. Track frame 3. Carrier roller 4. Final drive 5. Track roller 6. Track shoe 7. Center guard 8. Recoil spring 9. Front guard

PC200-62

The dimensions and number of track rollers may differ according to the model, but the basic structure is the same.

No. of trackrollers: 9 (each side)

10-9

STRUCTURE AND FUNCTION

TRACK SHOE

TRACK SHOE STANDARD SHOE PC2OOLC-6Z Shoe width (triple shoe)

700 mm

Link pitch No. of shoe (each side)

190 mm

SELECTION OFTRACK SHOE

PC~OOLC-~Z Specifications

700 m m triple

Standard

Category .

Category

Use

Precautions when usins

R o c k y ground, normal river soil

Travel in Lo speed when traveling on rough ground with obstacles such as large boulders and fallen trees.

Normal soil, soft land

Cannot be used on rough groundwhere there are large obstacles such as boulders and fallen trees. Travel in Hi speed only on flat ground; when it .is impossible to avoid traveling over obstacles, lower the travelspeed t o approx. half o f Lo speed.

Extremely soft ground (swampy ground)

Paved surface

Use only for ground where 'A' and '6' sink and are impossible t o use. Cannot be used on rough ground where thereare large obstacles such as boulders and fallen trees. Travel in Hi speed only on flat ground; when it is impossible to avoid traveling over obstacles, lower the travelspeed t o approx. half of Lo speed. The shoes are flat, so they have low gradeability.

The.shoes are made of rubber, so be careful when traveling on rough ground.

Categories ' B and .C0 are wide shoes, so therearerestrictions on their use. Therefore, before using, check the restrictions and consider carefully the conditions o f use before recommending a suitable shoe width. If in necessary, givethecustomerguidance their use.

10-10

When selectingtheshoewidth,selectthe within the range narrowestshoepossible that will give no problem with flotation and ground pressure. If a wider shoe than necessary is used, there will be a large load on the shoe, and this may lead to bending of theshoe, cracking of the links, breakage of the pins, loosening of the shoe bolts, or other problems.

PC3rn-X7

S I

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

3VPOllkl

LY - W C - ) Q

v 1-u1

8092OdVS

HYDRAULIC PUMP

STRUCTURE AND FUNCTION .-

HYDRAULIC PUMP

Frontmain pump PC valve 3. LS valve 4. Rearmain pump 5. PC-EPC valve 1.

Outline This pump consists of 2 variablecapacity a PC valve, LS pumps, piston plate swash valve, and PC-EPC valve.

PCZOO-6Z

a. b. c. d. e. f.

g. h. i. j.

1. m.

\ SAPO3204

PdlF port (pump drain) PenF port (front control pressure detection) PBF port (pump pressure input) PAF port (front pump delivery) PAR port (rear pump delivery) PenR port (rear control pressure detection) Psig port (LS set selector pilot) Irn (PC mode selector current) PLSR port (rear load pressure input) isig (LSsetselectorcurrent) PLSF port (front load pressure input) EPC basicpressuredetectionport Ps port (pump suction)

10-15

? P?P P

0 N

r m

0 I

STRUCTURE AND FUNCTION

HYDRAULIC PUMP

SAP03438

Function

Therotationandtorquetransmittedtothe pump shaft is converted into hydraulic energy, and pressurized oil is discharged according to the load. It is possible to change the discharge amount by changing the swash plate angle.

Structure

Cylinderblock (7)issupportedtoshaft (1) by a spline, and shaft (1) is supportedby the front and rear bearings. The tip of piston (6) is a concave ball, and shoe (5)is caulked to it t o f o r m o n e unit. Piston (6) and shoe (5)form a spherical bearing.

1 n-18

Rocker cam (4) has flat surface A, and shoe (5) isalwayspressedagainstthissurface while sliding in a circular movement. Rocker cam (4) brings high pressure oil at cylindrical surface B with cradle (21, which is secured to thecase, and formsa static pressure bearing when it slides. Piston (6) carriesoutrelativemovement in the axial direction inside each cylinder chamber of cylinder block (7). The cylinder block seals the pressure oil to valve plate ( 8 ) and carries out relative rotation. This surface is designed so that the oil pressure balance is maintained ata suitable level. The oil inside each cylinder chamber (7) is sucked in and disofcylinderblock charged through valve plate (8).

PC7nn-A7

HYDRAULIC PUMP

STRUCTURE AND FUNCTION

Operation 1) Operation of pump i) Cylinderblock (7)rotatestogether with shaft (11, and shoe (5)slides on flat surface A. Whenthis happens, rockercam (4) movesalongcylindrical surface B, so angle a between center-tineX of rocker cam (4) and the axial direction of cyfinder block (7)changes. (Angle a is called the swash plate angle.) ii) Centerline X of rockercam (4) maintains swash plate angle o! in relation t o the axial direction of cylinder block (7), and flat surface A moves as a cam in relation to shoe (5). In this way, piston (6) slides on the inside of cylinder block (71, so a difference between volumes E and F is created inside cylinder block (7).The suction and discharge is carried out by this difference F - E. In other words, when cylinder block (7) rotates and the..volume of chamber E becomes smaller, the oil is discharged during that stroke. On the other hand, the volume of chamber F becrmes larger, and as the volume becomes bigger, the oil is sucked in. iii) If center line X of rocker cam (4) is in line with the axial direction of cylinder block (7) (swashplate angle = 01, the difference between volumes E and F inside cylinder block( 7 ) becomes 0, so the pump does not carry out any suction or discharge of oil. (Inactual fact, theswashplateangle never becomes 0.)

PC200-6Z

/â&#x20AC;&#x2122;

\ I /*

SDP01409

SDPOlIIO

10-19

STRUCTURE AND FUNCTION

HYDRAULIC PUMP

2) Control of dischargeamount

If swashplate angle a becomes larger, the difference between volumesE and F becomes larger and discharge amount Q increases. Swash plate angle a is changed by servo piston (12). Servopiston (12) moves in a reciprocal movement (H) according t o the signal pressure from thePC and LS valves. This straightlinemovementistransmitted through rod (13) to rocker cam (41, and rocker cam (4). which is supported by the cylindricalsurface to cradle (21, slides ina rotating movement in direction With servopiston (121, the area receiving the pressure is different on the left and right, so main pumpdischarge pressure (self pressure) PP is alwaysbrought to thechamber receiving the pressure at the small diameter piston end. Output pressure Pen of the LS valve is brought to the chamber receivingthe pressure at thelarge diameter piston end. The relationship in the size of pressure PP at the smalldiameter piston end and pressure Pen a t the large diameter end, and the ratiobetween the area receiving the pressure of the small diameter piston and the large diameter piston controls the movement of servo piston (12).

(c).

1 0-70

SOP01412

i '

PC200-6Z

aaaaa

0 0 0 0 0

W W W P W

? PI, p p

STRUCTURE HYDRAULIC AND FUNCTION

Function (1) LS valve The LS valve detects the load and controls the discharge amount. This valvecontrolsmainpump discharge amount Q according to differential pressure APLS (=PP PLS) [called the LS differential pressure](thedifferencebetweenmain pump pressure PP and control valve outlet port pressure PLS). Main pumppressure PP, pressure PLS {called the LS pressure) sent by the control valve output, enter this valve. The relationship between discharge amount 0 and differential pressure APLS, (the difference between main pump pressure PP and LS pressure PLS) (= PP PLS) changes as shown in the diagram on the right.

PUMP

LS d i f f e r e n t i a lp r e s s u r e

APLS

SAPO3676

(2) PC valve When the pump discharge pressure PPI (selfpressure) andPP2 (other pump pressure) are high, the PC valve controls the pump so that no more oil than the constant flow (in accordance with the discharge pressure) flows even if the stroke of the control valve becomes larger. In this way, it carries out equal horsepower control so that the horsepower absorbed by the pump does not exceed the engine horsepower. In other words, if the load duringthe operation becomes larger andthe pumpdischarge pressure rises, it reduces thedischarge amount from the pump; and if the pump dischargepressure drops, it increases the discharge amount from the pump. The relationship between the average of the front and rear pump discharge pressures (average discharge amount of F, R pumps (PP1 + PP2)/2) and pump discharge amount 0 is shown on the right, with the current given to the PC-EPC valvesolenoidshown as a parameter. The pump controller senses the actual speed of the engine, and if the speed drops because of an increase in the load, it reduces the pump discharge amount t o allow the speed t o recover. In other words, whentheload increases andtheengine speed drops below the set value, the command current to the PC-EPC valve solenoid from the controller increases according t o the drop in the engine speed t o reduce the pump swash plate angle.

10-77

PUMP d i s c h a r o e

oressure averaoe

(PPI tPP2) 1 2 SAPO3440

PC200-6Z

STRUCTURE AND FUNCTION

HYDRAULIC PUMP

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

SAPO4079

3) Operation in minimum direction for pump

discharge amount The following explains the situation if servo piston (11) moves to the left (the discharge amount becomes smaller). When LS differentialpressure APLS becomeslarger (for example, when the area of opening of the control valve becomessmallerand pump pressure PP rises), pump pressure PP pushes spool ( 6 ) to the left. When spool ( 6 ) moves, main pump pressure PP flows from port C to port D, and from port K, it enters the large diameter end of the piston.

PC200-6Z

Main pump pressure PP also enters port J a t the small diameter end of the piston, but because of the difference in area between the large diameter end and the small diameter end of servo piston (11). servo piston (11) is pushed to the left. As a result, the swash plate moves in the direction to make angle smaller.

STRUCTURE AND FUNCTION

HYDRAULIC PUMP

W i n i a u ad i r e c t i o n

servo piston is balanced Let us take the area receiving the pressure at the large diameter end of the piston as A l , the area receiving the pressure at the small diameter end as AO, and the pressure flowing into the large diameter end of the piston as Pen. If the main pumppressure PP of the LS valve and the combined force of force 2 of spring (4) and LS pressure PLS are balanced, and therelationship is A0 x PP = A1 x Pen, servo piston (1 1) will stop in that position, and the swash plate will be kept at an intermediateposition. (Itwill stop at a position where theopening of the throttle from portD to port E and from port C to port D of spool (6) is approximatelythe same.)

4) When

1 I)-7c1

SAPOIO~O

Atthis point, therelationshipbetweenthe area receiving the pressure at both ends of piston (11) is A0 :A1 = 1 :2, so the pressure applied to bothends of the piston whenit is balanced becomes PP : Pen = 2 : 1. The position where spool (6)is balanced and stopped is thestandard center, and the force of spring (4) is adjusted so that it is determined when PP - PLS = 2.2 MPa (22.5 kg/ cm2).

, FUNCTION STRUCTURE AND

HYDRAULIC PUMP

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

PC-â&#x201A;ŹPC Va I ve ..

I- %O N r,

OFF

Maximum d i r e c t i o n

PUlP

controller

Resister

I /

â&#x20AC;?

I SAPO3445

(2)PC valve

1) When pump controller is normal a. When the load on the actuator is small and pump pressures PP1 and PP2 are low ( i J Movement of PC-EPC solenoid (1)

Thecommandcurrentfromthepump controller flows to PC-EPC solenoid (1). This command current acts on the PCEPC valve and outputs the signal pressure. Whenthissignal pressureis received, the force pushing piston (2) is changed. On the oppositeside to the force pushing this piston (2) is the springset pressure of springs (4) and (6) andpump pressure PP1 (selfpressure) and PP2 (other pumppressure) pushing spool (3). Piston (2)stops at a position where the combined force pushing spool 13) is balanced, and the pressure (pressure of port

PC200-6Z

C) output from the PC valve changes according to this position. The size of command current X is determined by the nature of theoperation (leveroperation), the selection of the working mode, andthe setvalueand actual value for the engine speed. Other pump pressure This is the pressure of the pump at the opposite end. For the F pump, it is the R pump pressure For the R pump, it is the F pump pressure

10-27

STRUCTURE HYDRAULIC AND FUNCTION

PUMP

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

PC200-6Z

10-29

, STRUCTURE AND FUNCTION

b. When load on actuator is large and pump discharge pressure is high Whentheloadis largeandpumpdischarge pressures PPI and PP2 are high, the force pushing spool (3)to the left becomes larger and spool (3) moves to the position shown the in diagram above. When thishappens, as shown i n the diagram above, part of the pressurized oil from port A flows out through the LS valve from portC to portD and the presC to the LS surized oil flowing from port valvebecomesapproximatelyhalfof main pump pressure PP. When port E and port G of the LS valve are connected(see (1) LS valve), the pressure from port J enters the large diam(9), and servo eter end of servo piston piston (9) stops.

10-30

HYDRAULIC PUMP

If main pump pressure PP increases further and spool (3) moves further to the left, main pump pressure PP1 flows to port C and acts t o make the discharge amount the minimum. When piston (9) moves t o the left, piston (7) is moved to the left. For this reason, springs (4) and ( 6 ) are compressed and push back spool (3).When spool (3) moves t o the left, C and port D bethe opening of port comes larger. As a result, the pressure at portC (= J) drops, and piston(9) stops moving to the left. Theposition in whichpiston (9) stops when this happens is further to the left than the position when pump pressures PP1 and PP2 are low.

PC200-6Z

I&-01

29-0023d

STRUCTURE AND FUNCTION

HYDRAULIC PUMP

_ . -

Maximum d i r e c t i o n

SAPO3450

2 ) When pump controller is abnormal and PC prolix switch is ON a. When load on main pump is light If there is a failure in the pump controller, turn PC prolix switch ON to switch t o t h e resistor side. Inthis case, the power source is taken directly from the battery. But if the current isused as it is, it is toolarge, so use the resistor t o control the current flowing to PC-EPC valve solenoid (1). When this is done, the current becomes constant, so the force pushing piston (2) is also constant. If main pump pressures PPI and PP2 are low,thecombined forceofthe pump pressure and the force of PC-EPC valve solenoid (1) is weaker than the spring set force, so spool (3)is balanced at a position to theleft.

10-32

At this point, port C is connected to the drain pressure of port D, and the large diameter end of the piston of servo piston (9) also becomes the drain pressure PT through theLS valve. When this happens, the pressure at the small diameter end of the piston is large, so servo piston (9) moves in the direction to make the discharge amount larger.

PC-700-A7

PUMP

STRUCTURE HYDRAULIC AND FUNCTION

b. When main pump load is heavy In the same way as in the previous item, when the PC prolixswitch is ON, the command current sent to PC-EPC valve solenoid (1) becomes constant. For this (2) pushing reason, the force of piston spool (3) is constant. If mainpump pressures PP1 and PP2 increase, spool (3)moves further to the left than when the main pump load is light, and is balanced at the position in the diagram above. In this case, the pressure fromport A C, so servo piston (9) moves flows to port to theleft (to make the discharge amount smaller) by the same mechanism as explained in Item 2)-b, and stops at a position to the left of the position when the load on the pump is light. In other words, even when the PC prolix switch is ON, the curve for the pump pressure PP and PC200-6Z

SAP03451

dischargeamount Q is determined as shown in the d,iagram for..the value of the current sent to thePC-EPC valve solenoid through the resistor. The curve when the PC prolix switch is ON is curve @, which is to the left of i J for when the pump controller is curve ( normal. I

TION

OIL flLTER

AND STRUCTURE

IN-LINE OIL FILTER

XlOBVU84

1. Pressure test ports 2. Element 1x2) 3. Case

A. To control valve B. From pump

10-33-1

Outline

Onein-line oil filter is installed to discharge side of the main pump to prevent the entry of dirtanddust,andtoprotectthecircuit and equipment.

P f7 m 4 7

CONTROL VALVE

STRUCTURE AND FUNCTION

CONTROL VALVE

- .. 1. Bspool valve 2. Cover 1 3. Cover 2 4. Junctionbox

a. Port PP1 (from rear main pump) b. Port PP2 (from front main pump) c. Port A6 (to arm cylinder head) d. Port B6 (to arm cylinder bottom) e. Port A5 (to L.H. travel motor) f. Port B5 (to L.H. travel motor) 9. Port A4 (to swing motor) h. Port B4 (to swing motor) i. Port A3 (to boom cylinder bottom) j. Port B3 (to boom cylinder head) k. Port A2 (to R.H. travel motor) I. Port B2 (to R.H. travel motor) m. Port A I (to bucket cylinder head) n. Port B1 (to bucket cylinder bottom) u. Port T (to tank) v. Port CP1 (to port CP3) w. Port cP2 (to port CP4) x. Port cP3 (to port CPI) y. Port CP4 (to port CP2) aa. Port PLSl (to rear pump control) ab. Port PLS2 (to front pump control) bb. Port TS (to tank) cc. Port BP1 (PPC output pressure for boom RAISE)

1 0-34

Outline Thiscontrolvalveconsistsofthebspool valve (an integrated composition).The junction box is installed to this. Each valve isformedinto one unitby the connection bolt, and the passages are internally connected, so the structureis compact and is very easy to service. This control valve consists of one spool for one item of the work equipment, so it has a simple structure.

dd. Port PX (from 2-stage relief solenoid valve: pressure rise type) ee. Port BP3 (from travel PPC valve) Port BP2 (from PPC valve) pa. Port P12 (from arm PPC valve) pb. Port P I 1 (from arm PPC valve) PC. Port P I 0 (from L.H. travel PPC valve) pd. Port P9 (from L.H. travel PPC valve) pe. Port P8 (from swing PPC valve) pf. Port P7 (from swing PPC valve) pg. Port P6 (from boom PPC valve) ph. Port P5 (from boom PPC valve) pi. Port P4 (from R.H. travel PPC valve) pj. Port P3 (from R.H. travel PPC valve) pk. Port P2 (from bucket PPC valve) pl. Port P1 (from bucket PPC valve) pm. Port P-2 (from service PPC valve) pn. Port P-1 (from service PPC valve) PO. Port P-4 (from service PPC valve) pp. Port P-3 (from service PPC valve) pq. Port P-6 (from service PPC valve) pr. Port P-5 (from service PPC valve)

ff.

PC200-6Z

AND

STRUCTURE

CONTROL V A L M

f i

vh v i P I

u ~ b v vd f

K200-6Z

b b l

SAPO3966

10-35

FUNCTION STRUCTURE AND

VALVE

c-c

1. 2. 3. 4. 5. 6.

Pressurecompensation Pressure compensation Pressurecompensation Pressurecompensation Pressurecompensation Pressurecompensation 7. Arm spool

PC200-6Z

valve(Arm) valve (L.H. travel) valve (Swing) valve (Boom) valve (R.H. travel) valve (Bucket)

8. 9. 10. 11. 12. 13. 14.

CONTROL

SAP03214

L.H. travel spool Swing spool Boom spool R.H. travel spool Bucket spool Safety-suction valve Suction valve

10-37

E. e

I .

z r. e

a I .

0 w

STRUCTURE AND FUNCTION

COKTROL VALVE

â&#x20AC;&#x2122;\

L- L

K-K

M-M

JJ-JJ

SAPO3968

Unload spool

2. Main relief valve (Pressurerisetype)

PC200-62

10-39

STRUCTURE AND FUNCTION

VALVE

CONTROL

J-J

MM-MM

EE-EE

SAPO3199

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

10-40

Dr3M.X7

STRUCTURE AND FUNCTION

VALVE

CONTROL

SAFETY-SUCTION VALVE FOR SERVICE VALVE

SBPoo19a

SPECIFICATION Part NO. 709-70-74800

pressure 20.58 MPa

Set (210kg/cm2) at 190 Urnin

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

Use For breaker (Okada)

709-70-75100

20.09 MPa (205 kg/cm2)at 5 t h i n

For breaker (Mitsubishi Krupp)

709-70-75300

16.66 MPa (170 kg/cm2)at 190 Urnin

For breaker (Matsuda)

709-70-74600

24.5 MP (250 kg/cm2)a t 5 Umin

For crusher (Okada)

PC200-6Z

10-41

STRUCTURE AND FUNCTION

SELF-REDUCING VALVE PRESSURE

SELF-REDUCING PRESSURE VALVE

L J

E: E:

SAP03258

Port P1 (from front pump) Port PR (supply to. electromagnetic valve, PPC valve, EPC valve) c. Port T (to hydraulic tank) d. Port PC (to front pump LS valve) a. b.

1 0-42

STRUCTURE AND FUNCTION

SELF-REDUCING PRESSURE VALVE

A- A

1. Control valve block 2. Valve (sequence valve) 3. Spring 4. Screw 5. Poppet

PC200-6Z

B-B

6. 7. 8. 9. 10.

Spring Spring Spring Spring

Ball

SAPO3259

(reducing valve pilot) (reducing valve main) (reducing valve) (safety valve)

10-43

VALVE

FUNCTION STRUCTURE SELF-REDUCING AND PRESSURE

Function Thisvalvereduces thedischargepressure of the main pump and supplies it as the control pressure for thesolenoid valve and PPC valve. Operation 1. When engine is stopped Poppet (5) is pushedagainsttheseat by spring (61, and the passage from portPR 4 T is closed. Valve ( 8 ) is pushed to the le& by spring (71, and the passagefrom port P1 4PR is open. Valve (2) is pushed to the left by spring (3). so the passage betweenport P1 + P2 is closed. (See Fig. 1)

-----_-_____

--,--------,------,,---,! PR, I-----

HYDRAULIC

CIRCUIT DIAGRU

(Fig. 1 )

10-44

SAPO3299

SAP03300

PC200-6Z

ZOEhOdVS

I 3 A l V A lOMlN03

FUNCTION STRUCTURE AND

SELF-REDUCING VALVE PRESSURE

4. When there is abnormal high pressure

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

1 0-46

(F i e. 4 )

SAP03303

Pf7m-6z

CLSS

STRUCTURE AND FUNCTION

Basic principle 1) Control of pump swash plate angle The pump swashplateangle (pump discharge amount) is controlled so that LS differential pressure APLS (the difference between pump pressure PP and control valve outlet port LS pressure PLS) (load pressure o f actuator) is constant. (LS pressure APLS = Pump discharge pressure PP LS pressure PLS)

Actuator

assage

APu

.....",. I

4 I l w

1.tl

PC v a l v e

Small

If LS differentialpressure APLS becomes lower than the set pressure of the LS valve (when the actuator load pressure is high), the pump swash plate moves towards the maximum position; if it becomes higher than the set pressure of the LS valve (when the actuatorload pressure is low),the pump swash plate moves towards the minimum position.

-I

1 II- A 9

current

Laroe current

c LS d i f f e r e n t i a l p r e s s u r e APLS

SBP03454

CLSS

STRUCTURE AND FUNCTION

2) Pressure compensation A pressure compensation valve is installed to theoutlet port side of the control valve to balance the load. When two actuators are operated together, this valve acts to make pressure difference AP between the upstream (inlet port) and

downstream (outlet port) of the spool of each valve the same regardless of the size of the load (pressure). In this way, the flow ofoil from the pump is divided (compensated) in proportion to the area of openings S1 and S2 of each valve.

Load

I Pump

1 SBP03456

PC200-6Z

1 0-49

STRUCTURE

FUNCTION

CLSS

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

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

PC200-6Z

1 0-51

CLSS

STRUCTURE

1A. 1B. 2A. 2B. 3. 4. 5A. 5B. 6A. 6B.

Main pump Main pump Main relief valve Main relief valve Unload valve Junction block Control valve Control valve Actuator Actuator

10-52

7A. 7B. 8. 9A. 9B. 10. 11. 12.

Pump passage Pump passage LS circuit Tank passage Tank passage Valve Spring LS bypassvalve

M L7 C D

CLSS

STRUCTURE AND FUNCTION

1. Unload valve 1

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

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

PC200-6Z

SBPO3110

10-53

STRUCTURE AND FUNCTION

CLSS

Introduction of LS pressure (LS shuttle valve)

SEP00123

1. 2. 3.

Mainpump Mainspool Pressure compensationvalve

Function LS pressure PLS isthe actuator load pressure at the output side of the controlvalve. Theupstreampressure (= spoolmeter-in downstream pressure) of pressure compensation valve (3)is taken inside main spool (2) and goes t o LS shuttle valve (6). When this happens, it connects actuator circuit A and LS circuit PLS through check valve (51,and sets so that LS pressure PLS 4 tuator load pressure. Introduction hole a inside main spool (2) has a small diameter, so it also acts as a throttle.

1 0-54

4. Valve 5. Check valve 6. LS shuttle valve

Operation

When main spool (2) is operated, pump discharge pressure PP starts t o f l o w tactuator o circuit A. First, thispumpdischargepressure PP passes through introduction hole a of main spool (21, and is taken t o LS circuit PLS. When actuator circuit pressure A rises to the necessary pressure, pump pressure PP rises and check valve (5) inside main spool (2) opens. The high pressure of LS circuit PLS then flows toactuator circuit A. In this way, LS pressure PLS becomes aimost the same as actuator circuit pressure A. K200-62

STRUCTURE AND FUNCTION

CLSS

3. LS bypass valve

5 8 ~ 0 3 2 2I

1. Main pump 2. Mainspool 3. Pressure compensationvalve 4. LS shuttlevalve 5. LS bypass plug

PC200-6Z

Function The residualpressure in LS circuit PLS is released from orifices b and e. This reduces the speed of the rise in the LS pressure, and prevents any sudden change in the oil pressure. Furthermore, a pressure loss is generated by the circuit resistance between LS shuttle valve (4) and throttle a of main spool (2) according to the bypass flow from LS bypass plug (5). As a result, the effective LS differential pressure drops, and the dynamic stability of the actuator is increased.

10-55

ION

STRUCTURE AND

CLSS

Pressure compensation valve

Bl 1. 2. 3. 4. 5. 6.

-pp

SBP03222

Mainpump Valve Shuttle valve Piston Spring LS shuttlevalve

Function When the maximum load pressure is generated during compound operations and during independent operations, andtheload pressure is higher than other actuators, the pressure compensation valve acts as a load check valve t o prevent reverse flow in the circuit.

10-56

Operation If pump pressure PP and LS pressure PLS are lower than actuator circuit B. shuttle valve (3)inside the pressure compensation valve moves to the left in the direction of the arrow to interconnect spring chamber c. When this happens, piston (4) is pushed to the right in the direction of the arrow by spring (5). As a results, valve (2) is also pushed to the right in the direction of the arrow by piston (41, so pumpoutletcircuit A closes. This prevents the oil from flowing back from actuator circuit B t o pump outlet circuit A. ,

pc3m-x7

STRUCTURE AND FUNCTION

Function During compound operations, if theload pressure is lower than the other actuators and the flow of oil starts to increase, the pressurecompensationvalve carries out compensation. In this case, it tries to make theload pressure fortheother actuators greater and reduce the flow of oil.

PCZOO-6Z

CLSS

Operation Duringcompound operations, if theload pressure for the otheractuators rises, the oil flow in actuator circuit B tries to'r'ncrease. When this happens, LS pressure.RLS for the other actuator also increases, so this LS pressure PLS pushes shuttle valve ( 3 b f i t h e pressure compensation valve to the right in the direction of the arrow, passes through the passage inside piston (41, and flows tospring chamber C. As a results, piston (4) andvalve (2) are pushed to the right in the direction of the arrow, and the outlet side of pump circuit PP is closed, so outlet portpressure A (spool meter-in downstreampressure) becomes the same as the outlet portpressure of the other actuators. Pumppressure PP (spool meter-in upstream pressure) is the same between all actuators, so pump pressure PP and outlet port pressure A become the same between all spools that are being operated. Therefore, the pump flow is divided in proportion t o the area of the opening of each valve.

10-57

STRUCTURE AND FUNCTION

, CLSS

Shuttle valve inside pressure compensation valve (arm, swing, boom, bucket valve)

SBPO3224

Main pump

2. Valve 3. Shuttle valve inside pressure compensation valve

4.thePiston

10-58

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

PC200-6Z

STRUCTURE AND FUNCTION

CLSS

SBP03461

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

PC200-6Z

10-59

STRUCTURE AND FUNCTION

CLSS

Boom regenerationcircuit

1. Main pump 2. Mainspool 3A. Pressure compensation valve 38. Pressure compensation valve 4A. Suction valve (with safety) 48. Suction valve (with safety) 5. Check valve for boom regeneration circuit 6. LS shuttlevalve . -

-. -*

Function 1) Cylinder head pressure cylinder bottom pressure (free fall, etc.) A returnflowcircuitisprovidedfrom the cylinder bottom to the cylinder head so that when the bottom is lowered, the return flow can be used toincrease the flow of oil the to cylinder head.

10-60

Operation When the cylinder head pressure < cylinder bottom pressure, part of the pressurized oil from the cylinder bottom passes through the notch in spool (21, goes through port B, and enters draincircuit T. Therest of the oil C, opens check entersregenerationcircuit valve (5). and passes through ports D and E to flow back to the cylinder head. K200-6Z

LY-WCA

29-0 1

E9-0L

Z9-0OZX

SBBEOdVS

STRUCTURE AND FUNCTION

CLSS

LS select vabre The diagram shows the situation when the swing and lefttravel are operatedat the same time. (BP pressure ON) 1. Valve 2. Spring 3. Piston 4. Piston 5. Swingspool 6. L.H. travelspool 7. Arm spool 8. L.H. shuttlevalve 9. LS circuit

Function Thisvalveis used to increase the ease of operating the work equipment. It prevents high pressure from being generated when the swing is operated. It also prevents the high LS pressure from the swingcircuit from flowing into any other LS circuit when the swing is operatedtogether with the work equipment. Operation When pilot pressure BP is OFF Pilotpressure BP is OFF, so piston (3) is pushed t o the left by spring (2). If the swing isthen operated, swing LS pressure P1 passes through swing spool (5) and enters port A. It pushes valve (1) to the left and connects portsA and B. Therefore, swing LS pressure Pi ff3w.s to LS shuttle valve (8). When pilot pressure BP is ON When pilot pressure BP is ON, piston (3)is moved to the right against spring (2) by the BP pressure. It pushes valve (1) to the right and closes the circuit between ports A and B. As a result, swing LS pressure P1 stops flowing to LS shuttle valve (81, and even if swing LS pressure P1 rises to a high pressure, it does not influence any other LS circuit.

10-64

SBPO2627

â&#x20AC;&#x2DC;OFFJ

T o LS s h u t t l e v a l v e SBPO3466

T o LS s h u t t l e v a l v e

SBP03467

Pc3rnA7

STRUCTURE AND FUNCTION

'CLSS

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

* * *

f 10-651

Pf7nn-A7

STRUCTURE AND FUNCTION

Hydrau1ic:tank

2A. Main pump (front)

28. Main pump (rear) 3A. PC valve (front) 38. PC valve (rear) 4A.LS valve (front) 4B.LS valve (rear) 5 Junction block 6. Bucket spool 7. R.H. travel spool 8. Boom spool 9. Swing spool 10. L.H. travel spool 11. Arm spoo! 12. Pressure compensation valve (bucket) 13. Pressure compensation valve (without shuttle valve) (R.H. travel) 14. Pressure compensation valve (boom) 15. Pressure compensation valve (swing) 16. Pressure compensation valve (without shuttle valve) (L.H. travel) 17. Pressure compensation valve (arm) 18. Safety-suction valve 19. Suction valve 20. LS shuttle valve (bucket) 21. LS shuttle valve (R.H. travel) 22. LS shuttle valve (boom) 23. LS shuttle valve (L.H. travel) 24. LS shuttle valve (arm) 25. Check valve (for boom regeneration circuit) 26. Check valve (for arm regeneration circuit) 27. Main relief valve 28. Unload valve 29, L S select valve 30. LS check.valve 31 LS bypass valve ' 32. Self-reducing pressure valve

CLSS

Note: Groupsof control valves by main pump circuit Bucket group: Bucket, R.H. travel, boom Arm group:Swing, L.H. travel, arm

Operation

When the levers are at neutral, the pump is at the minimum swash plate angle, and the oil flow isdrained from unload valve (28A). The LS pressure is connected to hydraulic tank (1) by LS bypass valve (31). The LS differential pressure APLS (unload pressure -tank pressure) atthis point isM L S > pump LS control pressure, so the pumpswash plate angle is the minimum.

-, -_-. .

PC200-6Z

10-65-2

1 n n

STRUCTURE AND FUNCTION

CLSS

Operation 1I- Bucket group *

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

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

PC200-6Z

10-65-4

CLSS

STRUCTURE AND FUNCTION

3. Arm OUT, standard mode relief (cut-off control) The diagram shows the arm DUMP and standard mode relief.

* *

For details of this page, see page 90-19.

10-65-5

w3nn-x7

STRUCTURE AND FUNCTION

Operation

CLSS

1) When pump swash plate angle is controlled t o minimum When the arm is operated to OUT, if the load increases, the LS pressure passing through the inside of arm spool (11) rises. The LS pressure also goes to unload valve (28) and unload valve (28) is closed. The main circuitpressure rises and is relieved at the standard mode relief pressure.

. .

2) When thishappens, the pump pressuresensor detects it and increases the PC-EPC current (electroniccut-offcontrol) t o set the pump swash plate angle to the minimum.

PC200-6Z

1 0-65-6

STRUCTURE AND FUNCTION

* *

.CLSS

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

10-A.5-7

~c3nn-x7

STRUCTURE AND FUNCTION

Operation

CLSS

Relief valve (27) pilot pressure PB ON.

When the bucket is being operated, if the power max. button is turned ON, pilot pressure PB acts on relief valve (271, so the set pressure of the relief valve is raised. When the bucket is operated to DUMP and the load increases, pump pressure P1 and LS pressure PLSl both rise. When this happens, pilot pressure PB controls relief valve (27) to the same relief pressure as when the power max. button is operated.

f'C200-6Z

10-65-8

x zw

(0 (D

STRUCTURE AND FUNCTION

Operation

CLSS

Whentheboom RAISE is operated, main pumps (2A) and (2B) are both a t the maxim u m swash plate angle, and unload valve (28A) is closed. Atthis point, forthe meter-inopening of boom spool (81, even if both pumps are at the maximum swash plate angle, the LS differential pressure is set to be smaller than the pump LS control pressure. In other words, LS differential pressure APLS is APLS e pump LS control pressure, so the pump swash plate angle becomes the maximum. Inadditidn,-theflow of mainpump (2A) passes through junction block (5) and flows t o boom spool (8).

PCZOO-6Z

10-65-10

. STRUCTURE AND FUNCTION

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

10-65-1 1

CLSS

STRUCTURE AND FUNCTION

CLSS

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

PC200-6Z

1 0-6512

STRUCTURE AND FUNCTION

CLSS

7. Travel operated independently f For details of this page, see page 90-27.

1 0-65-1 3

Pr3nn-x7

STRUCTURE AND FUNCTION

Operation 11

CLSS

When the straight travel is operated, an oil flow supplied from the mainpump to match the amount of movement of left and right travel spools (10).and (7). Main pump (2A) oil flow: To left travel spool (10) (arm group) Main pump (28) oil flow: To right travel spool (7) (bucket group) The ability to travel in a straight line is ensured by actuating the pressure compensation valves and interconnecting theright traveland l e f t travel through the pistons of pressure control valves (13) and (16) and through the external piping.

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

PC200-62

10-6514

STRUCTURE AND FUNCTION

CLSS

Operation

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

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

K200-6Z

10-6516

AND

MOTOR

STRUCTURE

SWING MOTOR KMFWAB-3

Port S Port M B (from controlvalve) Port M A (from controlvalve) d. Port T (to tank) e. Port B (froon;.&ing valve) solenoid brake

a. c. e.

SPECIFICATIONS

87.8 cclrev

Safety valve set pressure speed Rated Brake releasing

1 0-66

SAPO3230

27.9 MPa (285 kglcrnâ&#x20AC;&#x2122;)

2,260 rprn 2.1 MPa (21 kglcrnz)

pressure

PC200-6Z

d - /n

STRUCTURE AND FUNCTION

SWING MOTOR

Operation of swing lock When swing lock solenoid valve is deactivated When theswing lock solenoid valve is deactivated, the pressurized oil from the main pump is shut off and port B is connected to the tank circuit. As a result, brake piston (7) is pushed down by brake spring (11, discs (5) and plates (6) are pushed together, and the brake is applied.

SAPO3471

SAP03472

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

W3M. X 7

MOTOR

STRUCTURE AND FUNCTION

RELIEF VALVE PORTION 1) Outline

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

3. Operation

1) When starting swing

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

PC200-6Z

SAPO3473

Froa p o r t S

10-69

, STRUCTURE AND FUNCTION

CENTER SWIVEL JOINT

CENTER SWIVEL JOINT 4-PORT SWIVEL

A-A T1

Z ~

. I

1. Cover 2. Body 3. Slipper seal 4. O-ring 5. Shaft

A l . From control valve port B2 A2. To R.H. travel motor port PB B1. From control valve port B5 1 n-7n

c2 SBPW249

82. To. L.H. travel motor port PA C1. From control valve port A2 C2. To R.H. travel motor port PA Dl. From control valve port A5 D2. To L.H. travel motor port PB El. From travel speed solenoid valve E2. To L.H. and R.H. travel motors port P T1. To tank T2. From L.H. and R.H. travel motors port T PC7cx)-6Z

JOINT

STRUCTURE SWIVEL CENTER AND FUNCTION

&PORT SWIVEL

â&#x20AC;&#x2122;\

A-A

Z 1. Cover 2. Body 3. Slipper seal 5 4. Oil seal 5. Shaft

A l . From control valve port B2 A2.To R.H. travel motor port PB B1. From control valve port 85 B2. To. L.H. travel motor port PA C1. From control valve port A2

FC200-6Z

82E2

SBP02643

C2. To R.H. travel motor port PA Dl. From control valve port A5 D2. To L.H. travel motor port PB E l . From control valve port A3 E2. Blind F1. From control valve port B3 F2. Blind G1. From travel speed solenoid valve G2.To L.H. and R.H. travel motors port P T1. To tank T2. From L.H. and R.H. travel motors port T

10-71

w www 0 0 0 0 aaaa

p ? pfu

I I

TRAVEL MOTOR

STRUCTURE AND FUNCTION

\i \b

c-c

A-A

23 22

1. 2. 3. 4. 5.

E-E

D-D

SAPO2754

Regulator piston Spring Regulator valve Spring Motor case 6. Suction safety valve spring 7. Suction safety valve 8. Check valve

PCZOO-6Z

9. 10. 11. 12. 13. 14. 15. 16.

Check valve spring Output shaft Swash plate Retainer guide Pin Piston Retainer Cylinder

17. Valve plate 18. Counterbalance valve 19. Ring 20. Spool return spring 21. Brake piston 22. Plate 23. Disc 24. Ball

1 0-73

, TRAVEL MOTOR

STRUCTURE AND FUNCTION

OPERATION OF MOTOR

1) Motor swash plate angle (capacity)at maximum

The solenoid valve is deactivated, so the pilot pressure oilfromthemainpumpdoeslatorpiston :a port P. not flow Forthis reason, regulatorvalve (9)ispushedmotor by to the right in thedirectionofthearrow spring (10). Because of this, it pushes check valve (22). and the mainpressure oil from the control valve going to end cover ( 8 ) is shut off by regulator vzlve (9). Fulcrum a of swash plate (4) is eccentric to point offorce b of the combined force of the propulsion forceof cylinder (61, so the combined force of the piston propulsion force acts as a moment toangle swash plate(4) in the direction of the maximum swash plate angle.

10-74

At the same time, the pressurized oil at regu(15) passes through orifice c in (9) and is drained to the valve regulator case. As a result, swash plate (4) moves in the direction, the angle plate maximum swash motor capacity becomes maximum.

PC200-6Z

AND

STRUCTURE

TRAVEL MOTOR

FUNCTION

OPERATION OF'PARKING BRAKE

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

SAP03480

2) When stopping travel When the travel lever is placed in neutral, counterbalance valve spool (19) returns to the neutral position and the circuit t o the parking brake is closed. The pressurized oil in chamber A of brake piston (12) is drained to the case from the orifice in the brake piston, and brake piston (12) is pushed to the right in the direction of the arrow by spring (11). As a result,plate (13) and disc (14) are pushed together, and the brake is applied. A time delay is providedby having thepressurized oil pass through a throttle in slow return valve (22) when the brake piston returns, and this ensures that the brake still effective aâ&#x201A;Źter-lhe machine stops.

SAPO348 I

TRAVEL MOTOR

STRUCTURE AND FUNCTION

I Trrvsl

OPERATION OF BFMKE VALVE

control v a l v s

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

1) Counterbalance valve, check valve Function When traveling downhill, the weight of the machine makes it try to travel faster than the speed of the motor. As a result,=if the machine travels with the engine at low speed, the motor will rotate without loadand the machine will run away, which is extremely dangerous. To prevent this, these valvesact to make the machine travelaccording to the engine speed (pump discharge amount).

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

u T r a v a l control rrlrr

The pressurized oil at the supply side flows from orifice El and E2 in spool (19) to chamber S1. When the pressure in chamber S1 goesabovethespoolswitching pressure, spool (19) is pushed to theright in the direction of the arrow. As a result, port MB and port PB are connected, the outlet port side of the motor is opened, fid?he motor starts to rotate. (Fig.

PC200-6Z

10-77

AND

TRAVEL MOTOR

STRUCTURE

Operation of brake when traveling downhill If the machine triestorun away when traveling downhill, the motorwill turn under no load, so the pressure at the motor inlet port will drop, and the pressure in chamber S1 through orifices E l and E2 will also drop. Whenthe pressure in chamber S1 drops below the spool switching pressure, spool (19) is returned to theleft in the direction of the arrow by spring (201, and outlet portMB is throttled. As a result, the pressure at the outlet port side rises, resistance is generated to the rotation of the motor, and this prevents the machine from running away. In other words, the spool moves to a position where the pressure at outlet port MB balances the pressure at the inlet port and 19 the force generated by the weight of the machine. theIt throttles circuit outlet port and controls the travel speed according to the amount of oildischarged from the pump. (Fi.9 4) 2) Safety valve Function When travel is stopped (or when traveling downhill), the circuits at the inlet and outlet ports of the motor are closed by the counterbalance valve, but the motor is rotated by inertia, so the pressure at the outlet port of the motor will become abnormally high and damage the motor or piping. The safety valve acts to release this abnormal pressure and send it to the: inlet port side of the motor to S I prevent damage to the equipment. Operation 1) When travel is stopped (or when traveling downhill, rotating t o right) When the motorinletport pressure (pressure PA) goes down, the pressure in chamber S1 also goes down. When it goes below the switching pressure of the spool, spool (19) is returned to the left by spring (201, and outlet port passage B1 is throttled. When this happens,&e motor continues to rotate under ineda: so the outlet pressure (pressure MB) rises. (Fig. 5) If the pressure goes above the set pressure of suction-safety valve (18A1, the poppet opens.The oilthen passes through large notch A1 in counterbalance valve spool (19) and flows to chamber M A in the circuit on the opposite side. (Fig. 6 ) 2) When rotating t o left The operation is the reverse of when rotating to the right. 1 n-752

SAP03405

w IF i e. 5)

--'* '

SAPO3486

MA (F I 0. 6)

SAP03487

PC7N-X7

TRAVEL MOTOR

STRUCTURE AND FUNCTION

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

(F i e. 7)

PC200-6Z

10-79

STRUCTURE AND

FUNCTION

VALVE CONTROL

SVPO5544

-* Travel P P f valve Service PPC valve Service pedal L.H. travel lever R.H. travel lever R.H. PPC valve R.H. work equipment lever Control valve .

7. 2.

4. 5. 6. 7.

PCZOO-6Z

9. Hydraulic pump 10. Junction box 11. Accumulator 12. EPC solenoid valve 13. L.H. work equipment lever 14. L.H.PPC valve 15. Safety lock lever

Lever positions

@ HOLD 0 Boom RAISE @ Boom LOWER 0 Bucket DUMP 0 Bucket CURL @ HOLD 0A r m IN @ Arm OUT

@ @ @ @ @

Swing RIGHT Swing LEFT NEUTRAL Travel REVERSE Travel FORWARD @ LOCK @ FREE

10-81

71'11'1197171

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0 0 0 0 0 0

STRUCTURE AND FUNCTION

iâ&#x20AC;&#x2122;

WORK EQUIPMENT SWING PPC VALVE

-u

A- A

c-c

/-----

D-D

B-B

E-E SBPW274

1. Spool --Metering &ring 3. Centeringspring 4. Piston 5. Disc 6. Nut (for connecting lever)

PC200-6Z

7. Joint 8. Plate 9. Retainer

10. Body 11. Filter

10-83

STRUCTURE AND FUNCTION

WORK EQUIPMENT SWING PPC VALVE

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

2) During fine control(neutralfinecontrol) When piston (4) starts t o be pushed by disc (5).retainer (9) is pushed; spool (1) is also pushed by metering spring (21, and moves down. When this happens, fine control hole f is shut off from drain chamber D, and at almost thesame time, it is connected to pump pressure chamber PP, so pilot pressure oil from the main pump passes throughfine control hole f and goes from portP1 to port A. Whenthepressureatport P1 becomes higher,spool (1) ispushed back andfine control hole f is shut off from pump pressure chamber PP. At almost the same time, it is connected to drain chamber D t o release the pressure at port P1. When this h a p pens, spool (1) moves up or down so that the force of metering spring (2) is balanced with the pressure at port P1. The relation(1) and body ship in the position of spool (10) (fine control holef is at a point midway between drain hole D and pump pressure chamber PBt does not change until retainer (9) contacts spool (1). Therefore,â&#x20AC;&#x2122;metering spring (2) is compressed proportionally to the amount of movement of the control lever, so the pressure a t port P1 also rises in proportion to the travel of the control lever. In this way, the control valve spool moves to a position where the pressure i n chamber A (the same as the pressure at port P1) and the force of the control are balanced. valvespoolreturnspring (Fig.2)

1 0-8A

(Fie. 1)

( F i e . 2)

SBPO3493

SBP03494

PC7047

STRUCTURE FUNCTION AND

WORK EQUIPMENT SWING PPC VALVE

3) During fine control

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

SBP03495

4) A t full stroke

When disc (5) pushes down piston (41, and retainer (9) pushes down spool (11, fine control hole f is shut off from drain chamber D, and isconnected with pump pressure chamber PP. Therefore, the pilot pressure oil from the main pump passes through fine control holef and flows to chamber A from port P1, and pushes the control valve spool. The oil returning from chamber B passes from portP2 through finecontrol hole f' and flows to drain chamber D. (fig. 4)

(F i a. 4)

PC200-6Z

SBP03496

10-85

CK,

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0 0 0 0 0 0

w w w w w w

STRUCTURE AND FUNCTION

TRAVEL PPC VALVE

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

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

(Fie. 1).

(F i 0. 2)

SBP03497

SBP03498

Pf700-A7

STRUCTURE AND FUNCTION

VALVETRAVEL PPC

3) Fine control (control lever returned) When disc (5)starts to be returned, spool (1)

is pushedup by theforce of centering spring (3)and the pressure at port PI. Because of this, fine control hole f is connected t o drain chamber D, and the pressurized oil at port P I is released. If the pressure a t port P I drops too much, spool ( 7 ) is pushed up by metering spring (21, so fine control hole f is shut off from drain chamber D. At almost the same time, it is connected to pump pressure chamber PP, so the pressure at port P I supplies the pump pressure until the pressure recovers to a pressure equivalent to the position of the lever. When the control valve returns, oil in drain chamber D flows in from fine control hole 'f of the valve on the side that is not moving. It passes through portP2 and goesto cham3) the oil. (Fig. ber B t o charge

& i o . 3)

SBP03499

4) A t full stroke

Disc (5)pushes down piston (4). and retainer (9) pushes down spool (1). Fine control hole f is shut off from drain chamber D, and is connected to pump pressure chamber PP. Therefore, the pilot pressure oil from the main pump passes through fine control hole f and flows to chamber A from port P l to push the control valve spool. The return oil from chamber B passes from port p2 through fine control hole f' and flows to drain chamber D. (Fig. 4)

(F i 0. 4)

PC200-6Z

SBP03695

10-89

5 U

0 0 0 0

aaaa

v-uvv

I P

STRUCTURE AND FUNCTION

SERVICE PPC VALVE

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

SBP03500

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

SBP03501

PC200-6Z

1 0-91

STRUCTURE AND FUNCTION

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

10-92

SERVICE PPC VALVE

SBP03502

PC200-6Z

STRUCTURE AND FUNCTION

ACCUMULATOR

ACCUMULATOR FOR PPC VALVE

Gas plug Shell Poppet Holder Bladder Oilport

1. 2. 3. 4. 5. 6.

Specifications Type of gas Gas volume

: Nitrogen gas : 300 cc

SDPO I626

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

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

ion

After actual Before actuation A

SEPO1628

PC200-6Z

10-93

STRAIGHT-TRAVEL SYSTEM

FUNCTION STRUCTURE AND

STRAIGHT-TRAVEL SYSTEM L H. t r a v e l motor

R. H. t r a v e l rotor

-I

j j

T r a v e l PPC v a l v e

Pressur v a l v e

SAP03081

Function

This system interconnects the pressure cornpensation valves for L.H. and R.H. travel FORWARD and REVERSE with external piping to ensuf&he ability to travel in a straight line. As shown in the diagram on the right, the leftandrightports are interconnected through passage a insidetravel pressure compensation valve (11. By setting the throttle in junction circuit a to a suitable value, it is possible to fulfill the requirements for steering ability and the ability to maintain a straight line.

1n - O A

Travel

Pressure

compensation

I I

SAPO3504

PC200-6Z

STRUCTURE AND FUNCTION

EPC SOLENOID VALVE

EPC SOLENOID VALVE FOR PPC LOCK, SWING BRAKE, EPC SOLENOID VALVE

2-STAGE RELIEF

ACC A1 A3A4

ACC

PPC lock EPC solenoid valve

2. 2-Stage velief solenoid valve

3. Swing brake EPC solenoid valve

PC200-6Z

Al.

A2.

SVPO5552

To PPC valve To main valve (2-stage relief valve)

A3. To swing motor swing brake ACC. To accumulator P1. From mainpump T. To tank

10-95

FUNCTION STRUCTURE AND

EPC SOLENOID VALVE

1. 2. 3. 4. 5. 6. 7.

Connector Movable core Coil Cage Spool

Block

Spring

SAP03237

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

SAPO3888

SAP03889

10-96

PC200-6Z

BOOM HOLDING VALVE

STRUCTURE AND FUNCTION

BOOM HOLDING VALVE .k

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

a \

0-0

tA "-1

A-A

SDPO I32 I

1. Safety-suction valve 2. Pilot spring 3. Pilotspool 4. Poppet spring 5. Poppet

PC200-6Z

Port T (totank) b. Port Pi (from boom LOWER PPC valve) c. Port Cy (to boom cylinder bottom) d. Port V (from boom control valve) a.

10-97

STRUCTURE AND FUNCTION

BOOM HOLDING VALVE

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

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

SBPO3508

10-98

PC200-6Z

STRUCTURE AND FUNCTION

BOOM HOLDING VALVE

3) At boom LOWER

When the boom is lowered, the pilot 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 B rises because of the pressurized oil from the bottom end of the boom cylinder, the pressure of the pressurized oil in chamber b is lowered by orifice a. If the pressure in chamber b drops below the pressure at port A, poppet (5) opens the pressurized oil flows from port B to port A, and then flows to the control valve. If any abwrinal pressure is generated in the circuit at the bottomend of the boom cylinder, safety valve (1) is actuated.

SBPO3509

PC200-6Z

10-99

FILTER FOR BREAKER

STRUCTURE FUNCTION ADDITIONAL AND

ADDITIONAL FILTER FOR BREAKER

FOR MACHINEEQUIPPED WITH BREAKER

I '

' I

i SBP02669

1. Head cover 2. Element Case 3. 4. Drain plug; T5. Valve 6. Spring 7 . Spring setplug

10-100

SPECIFICATIONS Ratedpressure : 6.86 MPa (70 kg/cm2) Flow : 102 Umin Relief valve cracking pressure: 0.34 f 0.049 MPa (3.5 f 0.5 kg/cm2) Filter mesh size : 6 pm Filtering area : 3160 crnz

PC200-6Z

STRUCTURE AND

FUNCTION

ACTUAL ELECTRICAL WRING DIAGRAM

ACTUAL ELECTRICAL WIRING DIAGRAM f

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

SVPO5545

10-102

PC200-6Z

' I

. .

SVPO5546

Horn.awitch

Monitor panel Starting switch Fuse box

43.

Wiper switch Swing lock switch 38. Optional lamp switch 39. PPC lock switch 40. Heater 41. Light relay 42. Heater relay

30. 31. 32. 33. 34. 36. 36. 37.

29. Pump controller

4. Rear lamp 5. Engine speed sensor 6. Engine oil pressure switch 7. Washer rank 8. Travel alarm 9. Horn (high tone) 10. Horn (low tone) 11. Battery relay 12. Battery 13. Front lamp 14. PPC lock solenoid valve 15. Swing brake solenoid valve 16. 17. 18. Engine water temperature sensor 19. Electrical Intakeair heater 20. Air conditioner compressor magnetswitch 21. Engine oil level sensor 22. Alternator 23. Starting motor 24. R.H. additional front lamp 25. Room lamp 26. LH. additional front lamp 27. Wiper motor 28. Alarm buzzer

3. PC control EPC solenoid valve

1. Fuel level sensor 2. Working lamp

STRUCTURE AND FUNCTION

ELECTRICAL CIRCUIT DIAGRAM

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

-" c

c c 0

OLO

10-104

PC200-6Z

ELECTRIC CONTROL SYSTEM

STRUCTURE AND FUNCTlON

ELECTRIC CONTROL SYSTEM TOTAL SYSTEM DIAGRAM

L. n.

PPC va Ive

'C l o c k

l a i t rwitch

R. n. PPC

va I v e

Travel PPC vs I r e

! Engine

7 I I I I

I I

I-

Main Servo

valve

DUDD

Servo v Iv

Monitor vanel

relay

SVPO5547

10-1 06

K200-62

, FUNCTION AND STRUCTURE

ELECTFtIC CONTROL SYSTEM

Function The pump controller sets the pump absorption torque to match the engine speed. When the engine is running at high speed, it raises the pump absorption torque to boost the productivity. When the engine is running at low speed, it throttles the pumpabsorption torque to prevent the engine from stalling. L

10-108

Enrinc srced

SAP03896

PC7rn-A7

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

Pump controller

CONTROLLER, T V C SERIAL NO.

CN-CO f

SAP03228

Input/output signals CN-COl Name of signal

Pin No.

Input/output

Pow_erspurce (24V)

Engine speed sensor

Input

Engine speed sensor GND

Input

Model selection 1

Model selection 2

EPC solenoid (+)

PC200-6Z

Input

Input Input

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

Pinio.

~~~

Name of signal

InpuVoutput

Input

resistance Prolix 1

EPC solenoid (-1

GND

~~~

Input

output

10-109

ELECTRIC CONTROL SYSTEM

STRUCTURE AND FUNCTION

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

Lock switch

Pilot lamp

Lights up

OFF

Goes out

Function

Operation

Swing lock ON

Swing lock is always actuated, and upper structure does not swing even when swing lever is operated

lock

OFF

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

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

PC200-6Z

10-111

SYSTEM

MONITOR MACHINE STRUCTURE FUNCTlONAND

MACHINE MONITOR SYSTEM buzzer

Switch sional

Work Iirht Heater

Battery

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

10-112

SBP03898

In addition,themonitorpanelisequipped with switches for each electrical device.

PC200-6Z

MACHINE MONITOR SYSTEM

STRUCTURE AND FUNCTION

MONITOR PANEL

SXPOOO44

OUTLINE The monitor panelhasmonitor/displayfunc.-

tion and switch function for electrical devices. CPU (Central Processing Unit) is mountedin the panel, which processes, displays and outputs the data. The gauge displayuses a liquid crystaldisplay (LCD) and the monitor display uses lamps.

Input and output signal CN-P1 (Monitor panel)

Signal name

I 1 0

Engine oilpressure

Input

Charge level

Input

Swing lock

Input

Prehearing--l i Buzzer

10.1

Signal name

2 Work light

3 Night light

lo!i

output

Night light

Input

output Input

CN-B (Heater switch) [;.iG1i;nal 2

name

Heater Hi

3 Heater Lo

Outpul Outpul

4 +24V

PC200-6Z

10-113

STRUCTURE AND FUNCTiClN

1. Service meter 2. Coolant temperature gauge 3. Fuel level gauge 4.switch Light 5. Heater switch

10-114

MACHINE MONITOR SYSTEM

lamp 6. Preheating pilot 7. Swing lock pilot lamp 8. caution Charge level lamp pressure caution 9. oil Engine lamp

PC200-6Z

SENSORS

STRUCTURE AND FUNCTION

SENSORS sensorsare input diThe signalsfromthe rectly to the panel. One side of the contact-typesensors is always connected to the chassis GND.

Sensing type

Normal

Coolant temperature

Resistance type

Fuel level

Resistance type

Type of sensor

Classification of indication CAUTION GAUGEGROUP

Abnormal

ON Contact type Engine oil pressure

OFF

1) Engine oil pressure sensor

Plug Contact ring Contact Diaphragm Spring 6. Terminal

1. 2. 3. 4. 5.

S t r u c t u r e of c i r c u i t

SBDO1537

Operations (ON) pressure: 49 -c 19.6 kPa (0.5 3 0.2 kg/cm2?

2) Coolant temperature sensor

Structure of c i r c u i t

PCZOO-6Z

1. Connector 2. Plug 3. Thermistor

SBDOl53B

10-115

20 TESTING AND ADJUSTING

.... 20- 2 ... 20- 3 ......... 20- 11

Standard value table for engine related parts Standard value table for chassis related parts Standard value table for electrical system Tools for testing, adjusting, and troubleshooting engine Measuring speed

................................... 20-101 20-102 ................................... Measuring exhaust color .................................. 20-103 Adjusting valve clearance ................................. 20-104 Measuring compression pressure .......... 20-105 Measuring blow-by pressure ............................ 20-105 Testing and adjusting fuel injection timing.... 20-106 Measuring engine oilpressure' ............ 20-107 Testing and adjusting fan belt tension ........... 20-108 Testing and adjusting belttension for air conditioner compressor Adjusting engine speed sensor Adjusting fuel control lever Testing and adjusting hydraulic pressure in work equipment, swing, travel circuit......

............................. 20-108 ........................ 20-109

..............................

20-1 10 20-1 12

when makingjudgementsusingthe

Testing and adjusting PC valve output 20-1 15 pressure (servo piston input pressure) Testing and adjusting LS valve output pressure (servo piston input pressure) and LS differential pressure 20-1 17 Testing and adjusting control 20-120 circuit-oil pressure Testing solenoid valve output pressure 20-121 Measuring PPC valve output pressure 20-122 Adjusting work equipment, swing PPC valve 20-124 Testing travel deviation 20-125 Testing locations causing hydraulic drift of work equipment 20-126 Measuring oil leakage 20-128 Releasing remaining pressure in hydraulic circuit 20-130 Testing clearance of swing circle bearing 20-131 Testing and adjusting track shoe tension ....... 20-132 Bleeding air 20-133 Troubleshooting 20-201

....

................................... .......................................

.......... ............ ..

..................................... ..................................... ....................................... ......................................

......

........................................................

..................................................

Notethefollowing troubleshooting.

standardvalue

tables for testing, adjusting, or

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

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

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

- A

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

A Be careful n o t t oget caught PC200-6Z

in the fan, fan belt or other rotatingparts.

20-1

TESTING AND ADJUSTING STANDARD VALUE

TABLE FOR

ENGINE RELATED PARTS

STANDARD VALUE TABLE FOR ENGINE RELATED PARTS Machine model

PC200-6Z

Engine

S6D102-1

Measurement condition

Item

High idling

Low idling

Engine speed

Unit

Compression pressure

Blow-by pressure

Exhaust valve Oil temperature: 40 60Â°C (engine speed: 250rpm) (SAE15W-40oil)

(Coolant temperature: operating range)

Min. 2.4 {Min. 24.6)

At low idling (SAE15W-40)

MPa 0.34 0.52 {kg/cml (3.5 5.3)

1 I I

Whole speed range (inside oil pan)

Fuel injection timing

Before top deadcenter (B.T.D.C.) ldegreei

70-7

Min. 0.1 {Min. 1.0)

Oil temperature

tension Belt

Difference between cylinders Min. 1.0 {Min. 10.3)

Max. 1.2 kPa (mmHnO1 (Max. 123)

(Coolant temperature: operating range)

At high idling (SAE15W-40)

-- I

0.25 0.51

kzF:2

At rated'output (SAE30 oil)

I 1

= 50

Max. 0.5

(normal temperature) Intake valve

Oil pressure

Max. 5.5

index

At high idling

value

2,000

At sudden acceleration

Valve clearance

2,200 970

rPm

Rated speed Exhaust gas color

Standard value

"C O

Fan-tension pressed 1 with finger Fanmm force of air conditioner approx. compressor

80-110 l7

' 8

120

17 2 1 Min. 10 Max. 6

I 5-8

5-8

PC200-6Z

TESTING AND ADJUSTING

CHASSIS RELATED PARTS

STANDARD VALUE TABLE FOR

STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS Machine model Item

At 2-pump relief

Measurement conditions

- Hydraulic oil temperature: 45 - 55Â°C

- Coolant temperature: .

I PCZOO-6Z

Unit

Standard value

Permissiblevalue

2,000t100 2,ooOtlOO

Within operating range 2-pump relief: Arm relief

Boom control valve

9.5*0.5 9.520.5

Arm control valve Bucket control valve

Swing control valve Travel control valve Boom control lever Arm control lever Bucket control lever

BLpoo101

- Center of lever knob - Read max. value to end of .

Work equipment, swing

Play of control lever

Arm control lever Bucket control lever Swing control lever Travel confroliever

PC200-6Z

Travel

- Engine at high idling . Oil temperature: 45 - 55Â°C - Fit push-pull scale to center

of control lever knob to measure Measure max. value to end of travel

100 f 10

100 t 10

100 * 10

loo

Travel control lever

Boom control lever

__t__

travel Engine stopped Excluding neutral play

Swing control lever

9.520.5 9.520.5

Max. 5 Max. 10

15.7 t 3.9 (1.6 t 0.4) 13.7 2 21 .3 9.7

15.7 -c 3.9 (1.6 t 0.41 t 2.9

24.5 t 5.9 (2.5t 0.6)

24.5 t 5.9 (2.5 t 0.6)

20-3

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS RELATED

PC200-6Z

Machine model

cate

Measurement conditions

Item

gory

a .

. Engine at high idling . All levers at neutral . Pump output pressure

-u

Boom Arm

- 55°C

Swing

setf-reckrdng pressurevalve

Standard value

Permissible value

3.9 2 1.0 (40 10)

3.9 f 1.0 (40 f 10)

- Hydraulic oil temperature: 45 - 55°C .Relief pressure with engine

. at high idling (Relieve only

Bucket

70-A

Unit

- Hydraulic oil temperature:

Unload pressure

PAWS

circuit to be measured)

- Pump outlet port pressure

t: For travel, measure oil Dressure for relief on one

. Hydraulic oil I

MPa

(kgl cmzl

Levers at

Pr3M-h7

TABLE FOR CHASSIS RELATED PARTS

TESTING AND ADJUSTING STANDARD VALUE

Applicable model Measurement conditions Work equipment Max. reach posture

Swing brake angle

TKPO1115

. Engine at high idling . Hydraulic oil temperature: 45-55째C

. Stop after m'nging one turn and measure distance that .wn ig moves

reach

circle

T-

Unit

deg. :mm:

PC200-62 ~

Standard value

'ermissible value

Max. 100

Max. 130

posture

9V TKPOl116

. Engine at high idling

. Hydraulic oil temperature: 45 - 55째C . In WO mode + H mode . Time taken to swing 90" and 180" from starting position

Work equipment Max. reach posture

Time taken t o swing

TKPOtllS

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

Hydraulic-drift of swing I

- Hydraulic oil temperature: 45-55째C Engine stopped

Max. 3.7 SeC.

Max. 5.6

see.

3.5

Max. 30

/min.

Max. 5

Max. 10

. Set machine

on 15" slope, and set 0 ' to the side. upper structure at 9 Make match marks on swing circle outer race and track frame. . Measure distance that match marks move apart after 5 minutes.

. ~

Leakage from swing motor I

PC200-6Z

. Engine at high idling

Hydraulic oil temperature: 45-55%

. Swing lock switch ON - Relieve swing circuit.

20-5

TESTING AND ADJUSTING

STANDARD VALUE

Applicable model Item

Measurement conditions

TABLE FOR CHASSIS RELATED PARTS

-T Unit

PC200-62 Standard value

'ermissible value

STD 40.5 2 5

STD: 35.5 48.5

44.0

Travel speed (1)

BKp#)tOb

- Engine at high idling -

Travel speed (2)

Hydraulic oil temperature: 45 55% In H/O mode Raise track on one side ata time, rotate one turn, then measure time taken for next 5 turns with no load.

- _-

SeC.

STD 27.5 2 2

30 2 2.5

STD

25.5

27.5

2.5

18.5

132 1

- 31.5

- 35

- 24.5

Engine at high idling

. Engine at high idling . Hydraulic oil temperature:

- Hydraulic.oil temperature:

45 - 55% In H/O mode Run up for at least 10 m, and measure time taken to travel next 20 m on flat ground.

Travel deviation

39.0 * 52.0 LC

- 15

- 55Â°C

. Run up for at least 10 m, and

measure deviation when traveling next 20 m on flat ground. t Use a hard horizontal surface.

Max. 200

300

* Measure dimension X . W3M L 7

TESTING AND ADJUSTING

STANDARD VALUE TABLE

Applicable model Item

Hydraulic drift of travel

Measurement conditions

Engine stopped

- Hydraulic oil temperature: 45 - 55°C . Stop machine on 12" slope -

Leakage of travel rnoto

Lock

Boom cylinder (amount of retraction of cylinder)

Arm cylinder (amownrof extension of cylinder)

Bucket cylinder (amount of retraction of cylinder)

PC200-6Z

TKPO11 I7

Total work equipment (hydraulic drift at tip of bucket teeth)

with sprocket facing straight up theslope. Measure the distance the machine moves in 5 minutes.

Engine at high idling Hydraulic oil temperature: 45 - 55°C Lock shoes and relieve travel circuit.

Work equipment posture

Uni -

PC200-6Z Standard value

Permissible value

13.6

27.2

Max. 960

Max. 1,440

Max. 50

Max. 75

!/min

BKPOollO

Place in above posture and measure extension or retraction of each cylinder and downward movement at tip of bucket teeth. Bucket: Rated load Horizontal, flat ground Levers at neutral Engine stopped Hydraulic oil temperature: 45 - 55°C Start measuring immediately after setting. Measure hydraulic drift every 5 minutes, and judge from results for 15 minutes.

FOR CHASSIS RELATED PARTS

mm Max. 160

Max. 35

Max. 53

20-7

TESTING AND ADJUSTING

FOR CHASSIS RELATED PARTS

STANDARD VALUE TABLE

-F

PC200-62

Applicable model Item Boom

Measurement conditions

Unit -

Bucket teeth in contact with grounc

Cylinder fully extended

. .

-'Engine at high idling Hydraulic oil temperature: 45 55'C In H/O mode

Arm Cylinder fully retracted

Fully extended

'ermissible value

4.020.4

Max. 4.8

3.0203

Max. 3.4

3.620.4

Max. 4.5

2.920.3

Max. 3.5

TKPOI I19

- Engine at high idling -

Hydraulic oil temperature: 45 55'C In WO mode

Bucket Cylinder fully retracted

Standard value

TKPOlI20 Engine at high idling . Hydraulic oil temperature: 45 55°C

see

2.820.4

Max. 3.5

2.120.3

Max. 2.7

Max. 1.0

Max. 1.2

Max. 1.0

Max. 2.8

J ....................... BKPOO114

Boom

. Lower boom and measure time -_

Arm

taken from point where bucket contacts ground to point where chassis rises from ground . Engine at low idling Hydraulic oil temperature: 45 55°C

- Stop arm suddenly and measure BKPOO115

time taken for arm to stop Engine at low idling Hydraulic oil temperature: 45

- 55°C w7m-67

FOR CHASSIS RELATED

TESTING AND ADJUSTING STANDARD VALUE TABLE

Applicable model ~~

Item

Measurement conditions

Bucket

-T t

PARTS

PC200-6Z

Unii

Standard value

Permissible value

sec.

Max. 1.0

Max. 3.6

4.5

Max. 200

Max. 220

- Stop bucket suddenly and Cylinders Center swivel joint

measure time taken for bucket to stop at bottom and then start again. Engine at low idling Hydraulic oil temperature: 45 55'C

- Hydraulic oil temperature: 45 - 55°C - Engine at high idling - Relieve circuit to be measured

- Engine at high idling . Hydraulic oil temperature:

0 .+ m zQ

Travel deviation when work equipment + travel are operated

PC200-6Z

- 55°C

Use a hard horizontalsurface. 20m

* Measure dimension X.

Piston pump

&ni

See next page

20-9

TESTING AND ADJUSTING TSTANDARD

VALUE TABLE FOR

CHASSIS RELATED PARTS

PC200-62 Discharge amount of main piston pump

9. 8

19. 6 (2001

( 1001

29. 4

( 3001

34.3

( 3501

39.I 2

(41301

P u m p discharoe o r e s s u r e

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

Test pump discharge pressure

pressure of other pump

As desifed,

Standard value Average Discharge Judgement standard lower for discharge pressure limit Q amount Q (MPa {kg/cmz)) (MPa (kg/cm2)) (Urnin) (MPa (kglcmz)) (Umin) P1 + P2 2

See graph

* As far

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

70-1 0

Pr71K)-A7

TESTING AND ADJUSTING

SYSTEM

STANDARD VALUE TABLE FOR ELECTRICAL

STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM Name of component

No.

If the condition is as shown in the table below. it is normal

Swing lock switch

Measurement conditions

:onnector

X05 (male)

-@ -@ Between 0 - @

When switch Between 0 is OFF Between @ When switch is Between @

PC-EPC SQlenoid

C13 (male)

-Swing holding brake solenoid valve

PPC oil pressure

lock solenoid valvc

V04 (male)

Max. 1 R

Min. 1 MR Min. 1 MR Max. 1 R

If the condition is within the range shown in the table below, it is normal

I Between 0 - 0 Between @

- chassisMin.

7-14R

1 MR

If the condition is within the range shown in the table below, it is normal

I Between 0 - 0

Gens-

chassis

V07 (male)

1) Turn starting switch OFF. 2) Disconnect connector X 0 5

20-60

Min. 1MR

-0 Between @ - chassis -

~~~

- 60 R

1) Turn starting switch OFF. 2) Disconnect connector V04.

Min. 1 M R

If the condition is within the range shown in the table below, it is normal 1

Model selection

OFF.

2) Disconnect connector C13.

1) Turn starting switch OFF. 2) Disconnect connector V07.

If thecondition is within therange shown in the table below, it is normal Between 0

1) Turn pump prolix switch

cog 4 0 1

section 2

1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect T-adapter to harness side.

-1

f'C200-6Z

20-11

TESTING AND ADJUSTING

Name of component

Power source voltage

Connectol No.

col

g 29

If the condition is as shown in the table below, it is normal

m t

Model selection

3 Q

Between @

c.-

20 - 30 V

If the condition is as shown in the table below, it is normal

solenoid L.

col

I Between

alternator terminal L and chassis

Atternator

Coolant temperature sensor

PO7 (male)

In kerosene mode

E3 o) UJ

2m 3:.

at HOLD.

In normal mode

-@ @-0

No continuity

Continuity

-@ @-@ @

No continuity Continuity

When engine is running (1/2 throttle or above + 27.5 29.5 V 3k If the battery is old, or after starting in colc areas, the voltage may not rise for some time.

If the condition is as shown in the table below. it is normal Normaltemperature (25Â°C) Approx.37 100Â°C

Approx. 3.5

- 50 ki2 - 4.0 kR

If the condition is as shown in the table below, it is normal Engine oil pressure above 70 kPa (0.7 kg/cm21 Engine oil pressure sensor

70-1 2

sll

1) Turn starting switch ON. 2) Set throttle lever to FULL 3) Turn pump prolix switch

OFF.

If the condition is as shown in the table below, it is normal

1) Turn starting switch ON. 2) Insert T-adapter.

4) Place all levers

Model selection 2

-2

320 t 80 mA

Model selection 1 @

- @I

If the condition is as shown in the table below, it is normal

-2

co1

Kerosene mode

Measurement conditions

Judgment table

.. ....-

TABLE FOR ELECTRICAL PARTS

STANDARD VALUE

Min. 1 MO Man. 1 R

1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect T-adapter to wiring harness end. 1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect T-adapter to wiring harness end.

I ,

1) Start engine.

1) Turn starting

switch OFF. 2) Disconnect connector W7. 3) Insert T-adapter in connector at sensor end. 1) Install oil pressure measurement gauge. 2) Remove wiring harness terminal. 3) Start engine. 4) Contact tester between sensor terminal and chassis ground

PC700-6Z

STANDARD VALUE TABLE ELECTRICAL FOR PARTS

TESTING AND ADJUSTING

Name of component

-t Zonnector lnspecba

Measurement conditions

Judgment table

If the condition is as shown in the table below, it is normal

Fuel level sensor

If the condition isas shown in the table below, it is normal

I Between @ - @ Between @ Engine speed sensor

- chassis Min.

I50-1,WOR

switch OFF. 2) Disconnect connector PO6. 3) Drain fuel and remove fuel level sensor. 4) Insert T-adapter in sensor. % Connect the T-adapter to the connector and sensor flange.

1) Turn starting switch OFF. 2) Disconnect connector E07.

1 MR

Measure with AC range

1) Turn starting

1) insert

T-adapter. 2) Start engine.

1) Screw in until speed sensor contacts ring gear, then turn back 1 1/6 turn.

2) Sensor should work normally when adjusted as above.

PC200-6Z

20- 13

FOR TESTING, ADJUSTING,

TESTlNG AND ADJUSTING TOOLS

AND TROUBLESHOOTING

TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING Check or measurement item Engine speed Coolant and oil temperatures

iymbo

Part N a m e

Part No.

799-203-8001 Multi-tachometer or 799-608-1000Tachometer(electricaltype)

799-101-1502

- 790-261-1203 I Digitalhydraulic gauge 2 799-401-2320 I Hydraulic -

tester

.790-261-1311

Oil pressure

4 -

-Compressian pressure'

D-

Exhaust color Air supply pressure

(boost pressure)

Operating effort Stroke, hydraulic drift Work equipment speed Measuring voltage and resistance values--

Adapter

790-261-1370

Nut

07003-31419

Gasket

07040-11409

795-790-1950

H J

799-201-9000 avaabye c0 rcially 799-401-2201 79A-264-0020 79A-264-0090

Both male and female 14 x 1.5 (female PT 1/81 Both male andfemale 18 x 1.5 (female PT 1/81 Both male and female 22 x 1.5 (female PT 1/8) Both male and female 14 x 1.5 (female PT 1/81

xFor 14

1.5 blind

For blind

1 Blow-by checker

10 - 4.9 MPa (0 - 500mmHzO)

I Nozzle

1 I I

Handy Smoke Checker Smoke meter

I Pressure gauge Push-pull scale

0 - 6.9 MPa (0-70 kg/cm2} ~

~~~

I Orifice diameter

0 5.613 m m

Discoloration 0 70% (with standard color) (Discoloration % x 1/10 = Bosch index)

- 30 0 - 490Nkg) {O - 50

0 - 294Nkg) (0

K L

799-601-7100 T-adapter assembly 799-601-2720 799-601-7330

For MIC 13P Adapter

795-799-1

For S 16P (White) For relay 5P

P 190796-427-1 gauge Wear

Fuel in'ection timing and 130 Q valve dearance

PC200-6Z

pr~@~$$kg/cmz) 1.0 MPa {lo kg/cm2)

I For 14 x 1.5 blind

799-601-7360 Measuring wear of sprockel

60.

I Plug

1 799-201-1504

- 1,299"C

Pressure gauge 58.8 MPa 2.5,5.9,39.2, 400. 600 kg/cm2) (25,

I Differentialpressuregauge I (12V)

790-261-1360

Troubleshooting of wiring harnesses and sensors

799-401-2700

--2 E -

Valve clearance

0790-261-1331

-99

Hydraulic tester

Diaital disDIav . , k 60 2.000 rom H: 60 l9.99grrpm 0 3,000 rpm

I Digital temperature gauge

799-101-5002

Remarks

Adapter

20-101

ADJUSTING TESTING AND

MEASURING SPEED ENGINE

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

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

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

BLPO2 114

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

20- 102

Pt70-rs7

GAS COLOR

TESnNG AND ADJUSTING MEASURING EXHAUST

MEASURING EXHAUST GAS

COLOR

When measuring in the field when there is no air or power supply, use smoker checker G1, when recording official data, use smoke meter

G2.

Raise the coolant temperature t o the operating range before measuring. A W h e n removingorinstallingthe measuring equipment,becareful not to touchanyhigh temperature parts.

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

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

* *

BLPO2 I I 6

PC200-6Z

BLPO? I 1 7

20-103

, TESTING AND VALVE ADJUSTING ADJUSTING

ADJUSTINGVALVE CLEARANCE

CLEARANCE

1. Remove the cylinder head cover.

Using cranking tool Q, rotate the crankshaft i n the normal direction until timing pin (1) enters the hole in the gear. This position is the No. 1 cylinder compression top dead center.

3. When No.'l cylinder is atcompression top dead center, adjust the valves marked 0. Next, rotate the crankshaft one turn (360") in the normal di-

V a l v e arrrusement diarrrr

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

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

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

- -

* *

TKP00738

.PO2 I 19

20- 1 04

pc700-A7

TESTING AND ADJUSTING

MEASURING BLOW-BY PRESSURE MEASURING COMPRESSION PRESSURE

MEASURING COMPRESSION PRESSURE

A When measuring thecompression pressure, be careful not to touch the exhaust manifold or 1.

3. 4.

5. 6.

* * *

muffler, or to get your clothes caught in the fan, fan belt or otherrotating parts. Adjust the valve clearance. For details, see ADJUSTING VALVE CLEARANCE. Warm up the engine to make the oil temperature 40 - 60Â°C. Remove the nozzle holder assembly from the cylinder to be measured. Install adapter D2 in the mount of the nozzle holder, then connect pressure gauge Dl. Set tachometer A in position. Disconnect the fuel control rod, place the governor lever of the injection pump in the NO INJECTION position, then crank the engine with the starting motor and measure the compression pressure. Measure the compression pressure at the point wherethepressure gauge indicatorremains steady. When measuring the compression pressure, measure the engine speed to confirm that it is within the specified range. After measuring the compression pressure, install the nozzle holder assembly.

older assembly TLPO I002

MEASURING BLOW-BY PRESSURE

Measure the blow-bypressure under the follow-

ing conditions.

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

PC200-6Z

- 1

20- 105

TESTING AND ADJUSllNG

TESTING AND ADJUSTING FUEL INJECTION TIMING

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

2. Adjusting -: If the timing pin does not mesh i) Remove the fuel injection pump.

For details, see REMOVAL OFFUEL INJECTION PUMP ASSEMBLY. ii) Rotate the camshaft of theinjection pump andmesh timing pin (3) with timing pin pointer (4). iii) Install the fuel injection pump assembly. For details, see INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY.

70-1 0 A

Pf700-6Z

MEASURING ENGINE OIL PRESSURE

TESTING AND ADJUSTING

MEASURING ENGINE OIL PRESSURE

-k Measure the engine oil pressure under the fol-

lowing conditions. Coolant temperature: Within operating range

1. Remove engine oil low pressure sensor (1), then install the adapter of oil pressure gauge kit C1 and oilpressure gauge C2 (1.0 MPa (10 kg/cm2). 2.

Start the engine, and measure the oil pressure at the low pressure end with the engine at low idling andatthehighpressureend with the engine at high idling.

PC200-6Z

x12ADo92

20- 107

TESTING AND ADJUSTING

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

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

Adjusting 1. Loosen mounting bolts (2) and (31,bolt (41, nut (51, and belt tension adjustment bolt (6) of tension pulley (1). 2. Move tension pulley (1) and watch the tension of the fan. belt through the clearance from the cylinder block. Whenthetensionis correct, tighten adjustment bolt (6) first, then tightentension pulley mounting bolts (2) and (31,and nut

(5). 3. After adjusting the belt tension, check again to

confirm that the belt tensionwithin is the standard value. After adjusting the belt, run the engine for at least 15 minutes, then measure the deflection of the belt again.

TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR

3. 4.

tf the deflection of the belt when it is pressed at a point midway between the drive pulley and the compressor pulley is not within the standard value, or when carrying out maintenance after replacing the belt, adjust the belt tension as follows. Loosen bolts (1) and (2). Lever with a bar between (3)and (4) to adjust the belt tension. When the position of the compressor is fixed, tighten bolts (2) and (1) to secure in position. After adjustingthe belttension, repeat the above procedure to check that thebelt tension is within the standard value.

Bar

2 TLP01003

5-0nm

BLP07118

20- 1 08

SURING DJUSTING AND TESTING

SENSOR SPEED

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

* *

BEPOll49

PC200-4Z

20- 1 09

TESTING ADJUSING AND

ADJUSTING LEVER CONTROL FUEL

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

* *

PC200-6Z

70-1 1 1

TESTING AND ADJUSTING

TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT

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

TESTING AND ADJUSTING

TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT

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

2) High setting (oil pressure: 34.8 MPa (355 kg/ cm3) i) Whentravelis operated Measure the oil pressure when thetravel is relieved on each side separately with the engine at full throttle. To relieve the travelcircuit, put block @ under the track shoe grouser, or put block @ between I the sprocket and frame to lock the track.

PC200-6Z

BLpoo170

BLpoo171

20-1 13

TESTING AND

ADJUSTING

TESTING AND ADJUSTINGHYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT

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

* *

‘3

XlOUo4S

70-1 l d

w3nn-x7

TESTING AND ADJUSTING PC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE)

TESTING AND ADJUSTING

TESTING AND ADJUSTING PC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE)

1. Measuring Oil temprature when measuring: 45 55Â°C. 0 Measure the oil pressure when the circuit is relieved in the pressure rise mode. a. Install oil pressuregauge C1 t o quick disconnects (11, (21, (31, and (4). Install a 39.2 MPa (400 kg/cm3gauge t o t h e servo valve end, and a 58.8 MPa (600 kg/cm2) gauge to thepump outlet port end. b. Turn the swing lock switch ON. c. Set the working mode to H/O mode. d. Runengineat full throttle,turntheknob switch ON, andmeasuretheoilpressure when the arm (IN) circuit is relieved. Check that the servo pistoninput pressure is 1/2 of the pump discharge pressure. Note: If there is any abnormality in the LS valve or servo piston, the servo piston input pressure will be 0 or almost the same as the pump discharge pressure. 2. Adjusting If theloadbecomes larger, theengine speed will drop. Or if the engine speed remains normal, the work equipment speed will drop. In such cases, if the pump discharge pressure and LS differential pressure are normal, adjsut the PC valve as follows. a. Loosenlocknut (41, and if theequipment speed is-slow, turn screw (5) to the right; if the engine speed drops, turn the screw t o the left. If the screw is turned to the right, the pump absorption torque will be increased, and if it is turned to the left, the pump absorption torque will be reduced. The adjustment range for the screw is a maximum of 1 turn to the left and 180" to the right. The amount of adjustment for one turn of the stroke movescrew: 1.5 mm ofservopiston ment. b. After cdmpleting the adjustment, tighten the locknuts. Locknut (3): 34.3 2 4.9 N m (3.5 & 0.5 kgm} Locknut (4): 100.5 2 12.3 N m (10.25 2 1.25 kgm}

-70

* *

* * *

X30AVt98

PC200-6Z

20-115

TESTING AND ADJUSTING

TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LSDIFFERENTIALPRESSURE

TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE

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

Table1

Working mode

Travel lever

mode

PC200-6Z

{kgcm?)

3.72 f 0.69 {3a i 71

mode

Pump pressure (MPa

Full

6.86

0.98

(70 f 10)

Servo in'et Remarks pressure (MPa {kglcmV 3.72 2 0.69 (38 2 7) 3.43

0.49

I35 * 5)

About the same as Pump pressure About 60% Of Pump pressure

20-1 17

TESTING AND ADJUSTING

TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE

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

Table 2 Fuel control lever MAX

Operation Levers neutral at

MAX Travel circuit under no load (lever half operated)

20-1 18

LS differential pressure (MPa{kg/cm2)) 2.94 2 0.98 {30 5 10)~-

2.16 5 0.1 {22 2 11

TESTING AND ADJUSTING

TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE

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

I XWAV299

PC200-6Z

20-1 19

TESTING AND ADJUSTING TESTING AND ADJUSTING CONTROL CIRCUIT OIL PRESSURE

TESTING AND ADJUSTING CONTROL CIRCUIT OIL PRESSURE 1. Measuring

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

20- 1 20

TESTING ADJUSTING AND TESTING SOLENOID VALVE OUTPUT PRESSURE

TESTING SOLENOID -VALVE OUTPUT PRESSURE

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

BLPO2 1 4 7

Table 1 Name of ;olenoid

PPC hydraulic lock

Swing holdino brake

Travel speed

2-stage relief

I -

Safety lock lever at FREE

NOhydraulic pressure in PPC valve circuit

OFF

Swing or work equipment .iever Brake canceled operated

Safety lock lever at LOCK

All levers except travel at neutral Brake (5 sec after returning to neutral)

Travel speed selector switch

/Operating condition m n o f k Oil pressure solenoid MPa {kg/cmq) Hydraulic pressure Min. 2.7 in PPC valve ON {Min. 28) circuit

Measurement conditions

Travelspeedselectorswitch Travel lever operated

actuated

at Hi Travel speed at Lo

Travel speed Lo Pressure rise

OFF

0 {OI

OFF

!.Win. 2.7 {Min. 28) 0 {O)

Min. 2.7 {Min. 281

Remarks

0 {01

Min. 2.7 {Min. 281

OFF

0 (01

I [

Motor swash plate angle at minimum Motor swash plate angle at maximum

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

PC200-6Z

20-1 21

TESTING AND ADJUSTING

MEASURING VALVE PPC

OUTPUT PRESSURE

MEASURING PPC VALVE OUTPUT PRESSURE J,

Oil temperature when measuring: 45 - 55Â°C

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

20- 1 22

pc7nn-x7

ADJUSTING TESTING AND MEASURING

OUTPUT VALVE PRESSURE PPC

Plug location diagram Interruption block seen from rear of machine

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

H. w i n o

Bucket DUMP

Bucket CURL

Boom LOWER

TKP01007

PC200-6Z

20- 1 23

TESTING AND ADJUSTING

ADJUSTING WORK EQUIPMENT SWING PPC VALVE

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

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

7fL17A

DEVIATION TESTING TRAVEL AND TESTING ADJUSTING

TESTING TRAVEL DEVIATION

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

Travel Posture

* *

M a k e a m aMrakk e L ao yu t 20m Point a

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

PC200-6Z

a mark

10m m i d w aPyo i n t

Mark &

M e a s u r e t h e a m o u n t of distance A at this Point

TDP00328

Mark

TEPOO329

20-1 25

TESTING LOCATIONS CAUSING DRIFT OF WORK EQUIPMENT

TESTING ADJUSTlNG AND HYDRAULIC

TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT

If there is any hydraulic drift in the work equipment (cylinders), check as follows to determine if the cause is in the cylinder packing or in the control valve. 1. Checking for defective cylinder packing 1) Checking boom and bucket cylinders i) Set in the same posture as when measuring hydraulic drift, andstop the engine. ii) Operate the boom control lever t o RAISE or the bucket control lever to CURL. If thelowering speedincreases, the packing is defective. If there is no change, the boom hold-ingvalve (boom) or the controlvalve (bucket) is defective. 2) Checking armcylinder i) Operate thearmcylinder to move the arm in fully, then stop the engine. ii) Operate the control lever to arm IN. If the lowering speed increases, the packing is defective. If there is no change, thecontrol valve is defective. If the pressure in the accumulator hasdropped, runtheenginefor approx. 10 seconds t o charge the accumulator again before operating. [Reference] If the cause of the hydraulic drift is in the packing, and the above operations is carried out, the downward movement becomes faster for the following reasons. If the work equipment is set to the above posture (holdingpressure applied to thebottom end), the oil at the bottom end leaks to the head end. However, the volume at the head end is smaller than the volume at the bottom end bythe volume of therod, so the internal pressure at the head end increases because of the oil flowing in from the bottom end. When the internal pressure a t the head end increases, the pressure at the bottom end also rises in proportion to this. The balance is maintained at a certain pressure (this differs according to the amount of leakage) by repeating this procedure. When the pressure is balanced, the downward movement becomes slower. If the lever is then operated according to the proceduregiven above, thecircuit at the head end is opened to the drain circuit (the bottom end is closed by the check valve), so the oil at the head end flows to the drain circuitandthedownwardmovementbecomes faster.

TDPOO333

PC200-6: 1,260kg

BKpoo159

TESTING AND ADJUSTING

TESTING LOCATIONS CAUSING OF WORK EQUIPMENT HYDRAULIC DRIFT

boom holding valve A Checking Set the work equipment at the maximum reach, and the top of the boom horizontal, then stop 2.

the engine. Lock the work equipment control levers and release the pressure inside the hydraulic tank. A T 0 prevent danger, never stand under the work equipment. 7 ) Disconnect pilot hose (1) of the boom holding valve, andinstall a blind plug in the hose. Blind plug: 07376-50315 Leave the boom holding valve end open. If any oil leaks from the port that is left open, the boom holding valve is defective.

* * *

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

f'C200-6Z

20-1 27

TESTING AND ADJUSTING

MEASURING OIL LEAKAGE

MEASURING OIL LEAKAGE f

P o s t u r ef o rm e a s u r i n gb o o mc y l i n d e r

Hydraulic oil temperature when measuring: 45 55Â°C

1. Work equipment cylinder f If the hydraulic drift of the work equipment is outside the standard value, measure the leakage inside the cylinder as follows, and judge if . the cause of the hydraulic drift is in the cylinder or in the control valve. If the leakage is with in the standard value, the problem is in the control 'valve. If the leakage is greater then the standard value, the problem is in the cylinder. 1) Fully extend the rod of the cylinder t o be measured, then stop the engine. 2) Disconnect piping (1) at the head end, then block the piping at the chassis end with a blind plug. A B e careful not t o disconnect the piping at the bottom end. 3) Start the engine and apply the relief pressure to the bottom end of the cylinder with the engine at high idling. 4) Continue this condition for 30 seconds, then measure the oil leakage for the next one minute.

TEP00334

P o s t u r ef o rm e a s u r i n g

arm. b u c k e tc y l i n d e r

TEP00335

Boom F Y Ii n d c r

\ I

L 7n-1 78

Arm c y l i n d e r

TLPOO74f

D P - M

0 0

-4

TESTING AND

ADJUSTING

MEASURING OIL LEAKAGE RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT

Swing motor 1) Disconnectdrain hose (1) from the swing motor, then fit a blind plug at the tank end. 2) Set the swing lock switch ON. 3) Start the engine and operate the swing relief with the engine at high idling. 4) Continue this condition for 30 seconds, then measurethe oil leakage for the next one minute. After measuring, swing 180" and measure again.

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

RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT

If the piping between the hydraulic cylinder and the control valve is disconnected, release the remaining pressure from the circuit as follows. The travel ciucuit is an open circuit, so there is no remaining pressure. It is enough to remove the oil filler cap. 1. Loosen theloil filler cap slowly to release the pressure inside the tank. 2. Operate the control levers. When the levers are operated 2 - 3 times, the pressure stored in the accumulator is removed. 3. Start the engine, run at low idling for approx. 5 minutes, then stop the engine and operate the control levers. Repeat the above operation 2 - 3 times to release all the remaining pressure.

BLpoO170

I BLP00171

* *

30- 1 30

Dr3nnA7

TESTING AND ADJUSTING

TESTING CLEARANCE OF SWING CIRCLE BEARING

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

f r ame

D i a l sauae

TEP00339

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

3. Set the dial gauge to the zero point.

â&#x20AC;&#x2122;////////////////// BKPW173

Set the arm more or less at right angles to the ground surface, then lower the boom until the front of the machine comes off the ground. When this is done, the upper structure will tilt back, so the front will rise and the rear will go down.

Read the value on the dial gauge at this point. The value on the dial gauge is the clearance of the swing circle bearing.

Whencarryingoutthe measurement, do not put your hand or feet under the undercarriage.

BKFW174

6. Return to the condition i n Step 2, and check that the dial gauge has returned to the zero point. If it has not returned to the zero point, repeat Step 2 to 5.

PCZOO-6Z

20-131

TRACK SHOE TENSION

TESTING ADJUSTING AND =STING ADJUSTING AND

TESTING AND ADJUSTING TRACK SHOE TENSION TESTING 1. Raise the track frame using the arm and boom, and measure the clearance between the bottom of the track frame and the top of the track shoe. Clearance a: 303 -c 20 mm Measurement position PC200-6 : 5th track roller from the sprocket.

ADJUSTING f If the track shoe tension is notwithin the standard value, adjust as follows. 1 When the tension is too high: Loosen plug (1) gradually,andreleasethe grease. A T h e r e i s danger that the plug may fly out under the high internalpressureofthe grease, so never loosen plug (11 more than 7 turn. f If the grease doesnot come outeasily, move the machine backwards or forwards slowy.

2. If track is too loose: Pump in grease through grease fitting (2). f If the grease cannot be pumped in easily,

move the machine backwards and forwards

slowly.

20-132

BLEEDING TESTING AND ADJUSTING

BLEEDING AIR Order for operation and porocedure for bleeding air procedure bleedingAir

item bleedingAir

Nature of work

- -

Replace hydraulic oil Clean strainer Replace return filter

element

Replace, repair pump Remove suction piping

Bleeding air from Pump

Start engine

I I o + o + o I+ o

Replace cylinder Remove cyltnder piping

0-0

Bleeding air from 'swing motor

Bleeding air from cylinder

Replace, repair -control valve

Replace swing motor Remove swing motor piping

Bleeding air from travel motor

'perations

oiNotel)l+I o I*

I I

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

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

XlOZO7l

- I

BLPOZ I58

PC200-6Z

20- 1 33

TESTING AND ADJUSTING

2. Bleeding air from hydraulic cylinders

1) Start the engine and run at idling for approx.

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

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

Bleeding air from travel motor Run the engine at low idling, loosen air bleed plug (21, and when oil oozesout, tighten the plug againâ&#x20AC;&#x2122;. -

20-134

BLEEDING AIR

....................................................................................... .............................................................................................. Precautions when carrying out maintenance..................................................................................... Checks before troubleshooting ..................:......................................................................................... Connector types and mounting locations .......................................................................................... Points to remember when troubleshooting

20-202

Sequence of events in troubleshooting

20-203

Connection table for connector pin numbers ....................................................................................

............................................................................................ Troubleshooting of engine system (S mode) .................................................................................... Troubleshooting of electrical system (E mode) ................................................................................. Troubleshooting of hydraulic and mechanical system (H mode) .................................................... Troubleshooting of machine monitor system (M mode) .................................................................. Method of using troubleshooting charts

20-204 20-212 20-214 20-220 20-230 20-301 20-351 20-401 20-451

PCZOO-6Z

20-201

TROUBLESHOOTING

POINTS TO REMEMBER WHEN TROUBLESHOOTING

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

The aim of-troubleshooting is to pinpoint the basic cause of the failure, t o carry out repairs swiftly, and to prevent reoccurrence of the failure. When cartying out troubleshooting, and important point is of course t o understand the structure andfunction. However, a short cut toeffective troubleshooting is t o ask the operator various questions to form some idea of possible causes of the failure that would produce the reported symptoms. 1.

When carrying out troubleshooting, do not hurry t o disassemble the components. If components are disassembled immediately any failure occurs: Parts that have no connection withthe failure or other unnecessary parts will be disassembled. It will becomeimpossible to find the cause of thefailure. It will also cause a waste of manhours, parts, or oil or grease, and at thesame time, will also lose the confidence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary t o carry out thorough prior investigation and t o carry out troubleshooting i n accordance with the fixed procedure. Points t o ask user or operator 1) Have any other problems occurred apart from the problem that has been reported? 2) Was thereanything strange aboutthe machine before the failureoccurred? 3) Did the failure occur suddenly, or were there problems with the machine condition before this? 4) Under what conditions did the failure occur? 5) Had anyrepairs been carried out before the failure? When were these repairs carried out? 6) Has the same kindof failureoccurred before? Check beforetroubleshooting 1) Check the oil level 2) Check for anyexternal leakage of oil from the piping or hydraulic equipment. 3) Check the travel of the control levers.

20-202

Check the stroke of the control valve spool. Other maintenance items can be checked externally, so check any item that is considered t o be necessary. Confirming failure Confirmthe extent ofthe failure yourself, and judge whether to handle it as a real failure or as a problem with the method of operation, etc. Whenoperating the machine to reenact the troubleshooting symptoms, do not carry out any investigation or measurement that maymake the problem worse. 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 t o locate the positionof the failure exactly. The basic procedure for troubleshooting is as follows. 1) Start from the simple points. 2) Start from the most likely points. 3) Investigate other related parts or information. Measures to remove root cause of failure Even if thefailure is repaired, if the root cause of thefailure is not repaired, the same failure will occur again. To prevent this, always investigate why the problem occurred. Then, remove theroot cause. 4) 5)

W?M L7

SEQUENCE OF EVENTS IN TROU,BLESHOOTfNG Office, shop Step 1 [Examination, confirmation of symptoms

Jobsite

1) When a reguest for repairs is received, first ask the following points. Name of customer Type, serial number of machine Details of jobsits, ac. 2) &k questions to gain an outline of the problem. Condition of failure Wort baing carried out 2 a 8 theltime Oof the ) m R failure Operating environment Past history,details of mintemma, etc.

---

Step 2 [Determining probable location of c a u q 1)Look at the troubleshooting section of the shop manual tofind locations of possible causes.

W T

rn76 3 i

:::E;?

lEWOO183

Repair

pboite

TEWOOlsI

Step 3 [Preparation of troubleshooting tools1

TEW00185

1) LDok at the table of troubleshooting tools in the shop manual and prepare the necessaTy 1001s. T-adapter Hydraulic pressuregaugekit,etc. 2) took in the parts book and prepare the necessary replacement

(step 7

1'-

Pinpoint locations of failure (carry out troubleshooting) Decide action to take

1) Before starting troubleshooting,locate and repair simple failures. Check before darting items Other check items 2) See the Troubleshooting Section of tha shop manual. select a troubleshooting flowchart that matches the symptoms, and carry out troubleshooting.

Step 6 [Reenacting failure] *

L Step 4

Drive and operate the machine to confirm the condition and judge if there is really a failure.

f-[

TEW189

F'C200-6Z

TEWWlE?

Was there anything strange about the machine before the failure occurred? Did the failure occur suddenly? Had any repairs bean carried out beforethe

20-203

TROUBLESHOOTING POINTS

TO REMEMBER WHEN CARRYING OUT MAINTENANCE

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

1. POINTS TO REMEMBER WHEN HANDLING

ELECTRIC EQUIPMENT

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

Main failures occurring in wiring harness @ Defectivecontact of connectors (defective contact between male and female) Problems with defective contact are likely to occur because the male connectoris not properly inserted into the female connector, or because one or both ofthe connectors is not correctly deformedorthepositionis aligned, or becausethereiscorrosion or oxidization of the contact surfaces.

w I

Improper insertion

TEwool92

TEW00193

@ Defective crimping or solderingof connectors The pins of the male andfemale connectors are in contactat the crimpedterminalor solderedportion, but if there is excessive the wiring, the platforce brought to bear on ing at the jointwill peel and cause improper connection or breakage.

70-7nA

TROUBLESHOOTING

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

3J Disconnections in wiring

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

a High-pressure water entering connector

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

3 1

1 s

? TEW00195

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 femalepins, the o i l will not let the electricity pass, so there will be defective contact. If there is oil orgrease stuck to the connector, wipe it off with a dry cloth or blowit dry with compressed air andspray it with a contact restorer. When wiping the mating portion of the connector, be careful not t o use excessive force or deform the pins. If there is oil or waterin the compressed air; the contactswill become even dirtier, so remove the oil andwater from the compressed air completely before cleaning with compressed air.

PC200-6Z

20-205

TROUBLESHOOTING

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

2) Removing, installing, and drying connectors and wiring harnesses 0

Disconnectingconnectors ( i J Hold the connectors when disconnecting. When disconnecting the connectors, hold the connectors and not the wires. For connectors 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. Never pull with one hand.

Press lightly when removing .ock *opper,

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

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

7n-70~

PC7m-67

TROUBLESHOOTING

POINTS TO REMEMBER WHEN CARRYING

OUT MAINTENANCE

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

@ Fix the connector securely.

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

@ Correct any protrusion of the boot and any

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

@ If the connector clamp has been removed, be sure to return it to its original position.

Check also that there are no loose clamps.

PC200-6Z

20-207

TROUBLESHOOTING

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

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

If water gets directly on the connector, do as follows. ( i J Disconnect the connector and wipe off the water with a dry cloth. If the connector is blown dry with compressed air, there is the risk that oil in the air may cause defective contact, so remove all oil and water from thecompressed air before blowing with air.

TEWOO196

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

@ 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 shortcircuitsbetweenpins caused by water. Aftercompletelydryingthe connector, blow it with contact restorer and reassemble.

20-208

PC200-6Z

TROUBLESHOOTING

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

3) Handling control box @ The control box containsamicrocomputer

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

@ Do not place objects on top of the control

box.

@ Cover the control connectors with tape or a

vinyl bag. Never touchthe connector contactswith your hand. @ During rainy weather, do not leave the control box in a place where it is exposed to rain.

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

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

2. Points to remember when troubleshooting electric circuits

1) Always turn the power OFF before disconnecting or connect connectors. 2) Before carrying out troubleshooting, check that all the related connectors are properly inserted.

* *

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

PC200-6Z

20-209

TROUBLESHOOTING

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

3. 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 circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary to be particularly careful. Be careful of the operating environment. Avoid adding hydraulic oil, replacing filters, or repairing the machine in rain or high winds, or places where there is a lot of dust. Disassembly and maintenance work in the field If disassembly or maintenance work is carried out on hydraulic equipment in the field, there is danger of dust entering theequipment. It is also difficult to confirmthe performance after repairs, so it is desirable t o use unit exchange. Disassemblyand main-tenance ofhydraulic equipment should be carried out in a specially prepared dustproofworkshop, and the performance should be confirmed with special test equipment.

Sealing openings After any piping or equipment is removed, the openings should be sealed with caps, tapes, or vinyl bags t o prevent any dirt or dust from 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.

Do not let any dirt or dust getin during refilling

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

20-2 10

TEW00209

PC200-6Z

TROUBLESHOOTING POINTS

TO REMEMBER WHEN CARRYING OUT MAINTENANCE

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

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

oil

TEwooZlO

7) Cleaningoperations After repairing the hydraulic equipment (pump, control valve,etc.) or whenrunningthe machine, carry out oil cleaning to remove the sludge or contaminants in the hydraulic oil circuit. The oil cleaning equipment is used t o remove ) that the filter the ultrafine (about 3 ~ particles built into thehydraulicequipmentcannot remove, so it is an extremely effective device.

PC200-6Z

20-211

TROUBLESHOOTING

TROUBLESHOOTING CHECKS BEFORE

CHECKS BEFORE TROUBLESHOOTING Item

Action

Check fuel level, type of fuel

Add fuel

Check for impurities in fuel

Clean, drain

3. Check hydraulic oil level

Add oil

Check hydraulic strainer

Clean, drain

Check swing machinery oil level

Add oil

Check engine oil level (oil pan oil level), type of oil

Add oil

Check coolant level

Add water

Check dust indicator for clogging

Clean or replace

Check hydraulic filter

Replace

Check for looseness, corrosion of battery terminal, wiring

Tighten or replace

Check for looseness, corrosion of alternator terminal, wiring

Tighten or replace

3. Check for looseness, corrosion of starting motor terminal, wiring

Tighten or replace

Check for abnormal noise, smell

Repair

Check for oil leakage

Repair

3. Carry out air bleeding 1.

Check battery voltage (engine stopped)

Check batteryelectrolytelevel

Bleed air 20

3. Check for discolored, burnt, exposed wiring 4.

Check for missing wiring clamps, hanging wiring

Check for water leaking on wiring (be particularly careful attention to water leaking on connectors or terminals)

6. Check for blown, corroded fuses

Check alternator voltage (engine running at 1/2 throttle or above)

Check operating sound of battery relay (when switch

20-2 12

- 30v -

is turned ON/OFF)

Replace Add or replace Replace Repair Disconnect connector and dry Replace

4fter running Replace for several minutes: 27.5 - 29.5 V

Replace

PC3CULh7

TROUBLESHOOTING

AND MOUNTING LOCATIONS

CONNECTOR TYPES

CONNECTOR TYPES AND MOUNTING LOCATIONS No. Connector Type of No. Dins

/Terminal

CO1

MIC

C05

~CO9 M

I C13

1 / /X / KESl

DO5

KESl

I KESl I

terminal BR

I R-8 1

M12

Fusible link

D-3

Pump prolix switch

G-2

M16

Terminal

Horn (high tone)

E-4

M17

Wiper motor

1-1

M18

Wiper switch

K-2

window washer circuit

K-4 For M I 9

For swing lock solenoid

K-4

/ Fortravel speed selector solenoidcircuit [ K-3 1

IM I

1 K-2 I

/ Wiper switch

M20 Terminal

Horn (low tone)

E-4

M21

Radio

K- 1

Horn switch

6-3

Horn switch speaker

G-4 H-4

SpeakerH-4

H-4

Air conditioner unit

F-7

Room lamp

G-4

~~~

I For heater

K-6

I K-3

1 Terminal I

I Heater

M22

M24

E l1

Address

M14

M23

IKESl /

Mounting location

e-2

ConNo. nector Type of No. I Dins I 1 -

Pump regulator

I Model selection connector I K-2 / 2 I Pump EPC solenoid valve I A-6 I

DO1

DO8

/ Battewrelay

I DO7 IKESl / I

Addres

Mounting location

M26

ZL,,,

:r&,,,

2ktDr1 M

M27

zLN

/ Electricalintakeairheaterrelay I P-7 I

E12

Alternator

P-1

M31

KESO

Wiper motor

E13

Terminal

Starting motor relay terminal 0-9

M31

ZA,,,

Option power source

Airconditionerunitpower source

M35

Air conditioner condenser

M36

M38

Travel Hi-Lo switch

M40

Additional right front lamp (opt) G-8

Additional left front lamp (opt) G-7

Additional rear lamp (option) A-8

E14 /Terminal E15 /Terminal

FO1 FB1 H02 H03 H05

X I

Box

1 1

1 Electricalintakeairheaterrelay

/ Electrical intake air heater

2 I

/ P-8 I I R-4 I E-5

Travel alarm (option)

1 I

Fuse box

IS (blue)/ 16 Left stand wiring harness

S (white1' 16 Right stand wiring harness

1-5

I 1-1 I I

H-2

M32

Right stand wiring harness

H-2

M41

H06

Right stand wiring harness

1-1

M42

M02

Starting motor relay

R-6

M43

M06

KESl

Heater switch

1-5

PO1

- 4

PO2 M08

Right front lamp

D-3

M09

Boom working lamp

A- 4

M10

Boom working lamp

E-3

M11

Fusible link

D-3

20-2 1 4

zk,

,!z%w 1 040

I KESl I

RE [Terminal

E-8

mode selector switch K-5 Kerosene

J-1

Option power source

E-4

Monitor panel

H-4

I Light switch

1 14-5 I

I Battery relay terminal B

I R-8 I PC200-6Z

TROUBLESHOOTING CONNECTOR

No. Connector Type of No. pins

I I

S11 lTerminaI1 I I

SO1

S12

S13 S14

I TO6 I

Zkr 1 %Lr1 2

(Terminal

TYPES AND MOUNTING LOCATIONS

ConNo. nector Type of No. pins

Addres

Mounting location

I Travel pressure switch (for travel alarm) I M-4 I I I Engine oil pressure switch I R-3 I I 1

PPC hydraulic lock switch

1-1

PPC hydraulic lock switch

J-1

PPC hydraulic lock switch

K-1

I I I

Address

Mounting location

1 - 1

1 1

I Starting switch (B)

I I

- ' I ~~~

PC200-6Z

20-2 15

wo Q CIJ

TO6 107

W26

TROUBLESHOOTING

PC200-6Z

CONNECTOR TYPES AND MOUNTING LOCATIONS

20-2 17

t d

TROUBLESHOOTING

CONNECTION FOR TABLE

CONNECTOR PIN NUMBERS

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS .k The terms male and female refer to the pins, while the terms male housing and female housing

refer to the mating portion of the housing.

No. of pins

X type connector Male (female housing)

Female (male housing)

BEH00148

8EH00149

2 2'

'2 moo221

TEwoo222

i I

TEWOO223

TNV00224

4 lEWW225

20-220

TEW00226

PC200-6Z

0 0 0 0 0

c--l

-1

TABLE FOR CONNECTOR PIN

TROUBLESHOOTING CONNECTION

M type connector

NO.

of pins

NUMBERS

Female (male housing)

Male (female housing) 2

3 â&#x20AC;&#x2DC;1

rrwoO243

TEWWZU

TEW00247

BLPOOOU)

20-222

TEW24S

TEWW246

TEW00248

BLpoooIl

PC200-6Z

, 3grn m

X o z 2 -"?

-1

TROUBLESHOOTING

No. of

pins

CONNECTIONFOR TABLE

CONNECTOR PIN NUMBERS

AMP040 type connector Male (female housing)

Female (male housing)

BLPOOOY

12 I

BLpDoo57

TEW00232

BLpooo58

PC200-6Z

TEWW234

20-225

'p,

5 0 C

n (P

w w

0 I 0 0

I 0

m rn

Ln 0

m rn

P.. z

No. of

pins

T-

PA connector Female (male housing)

Male (female housing)

BEH00157

PC200-6Z

8EH00156

20-229

METHOD OF USING TROUBLESHOOTING CHARTS

TROUBLESHOOTING

METHOD OF USING TROUBLESHOOTING CHARTS 1. Category of troubleshooting code number ~~

~~~~

Troubleshooting Code No.

Component

SO0

Troubleshooting of engine related parts

E-OO

Troubleshootingof electrical system

H-00

Troubleshooting of hydraulic, mechanical system

M-OO

Troubleshooting of machine monitor

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

20-230

PC200-6Z

OF USING TROUBLESHOOTING CHARTS

TROUBLESHOOTING METHOD

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

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

* * *

(4)

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

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

Divided into sections a) and b)

b) Remains actuated (safetu lock is not applied)

Remedy

Cause

4 YE5

Is voltage

- between S12and

Is voltage YES between V07 (1)

Is resistance YES between S12 and S13 asshown in Is resistance

between V07 (male) (1) and 12) normal? -Turn starting switch OFF. Disconnect V07.

-20-6oR

Table 17

and chassis normal?

*Turn starting

ON.

chassis normal?

-h

*Turn startingswitch

ON.

Smhg lock lever LOCK 20 30 V RELEASE: Max. 1 V

*Turn starting switch OFF. -Disconnect s12 NO and S13. * Check PPC oil pressure l o c k switch as individual part.

No 5 YE!

chassis normal? -Turn starting switch OFF. Disconnect S13. * Max.1 R

Table 1 Safety lock lever OFF LOCK

PC200-6Z

Defective contact or disconnection in wiring harness between V07 Ifemale) (2) HO2 (7) 514 (1)-S12

Repair or replace

Defective contact or disconnection in wiring harness between fuse 2 H06 (4) V07 (female) 11)

Repair or replace

Defective PPC oil pressure lock switch

Replace

Defective PPC oil pressure lock solenoid switch

Replace

-20-30V

Go to A

Go to H mode (H-3) Defective contact or disconnection in wiring harness between S13 S14 (2) H02 15) chassis ground

Repair or replace

Resistance value Max. 1 R Min. 1 M R

20-23 1

TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)

............................................................................................. Starting performance is poor (startingalways takes time) ..................................................

20-306

(1) Engine does not turn..........................................................................................................

20-307

Method of using troubleshootingcharts

ss-

1 2

Engine does not start

...............................................................................................................

(2) Engine turns but no exhaust smoke comes out (fuel is not being injected)

20-302 20-307

..............20-308

........... 20-309 Engine does not pick up smoothly (follow-up is poor) ........................................................ 20-310 Engine stops during operations .............................................................................................. 20-311 Engine does not rotate smoothly (hunting) ........................................................................... 20-312 (3) Exhaust smoke comes out. but engine does not start (fuel is being injected)

.s-4 s-

5 S- 6 s- 7 S- 8

s- 9

s-10 s-11 s-12 S-13 S-14 S-15 S-16

............................................................................................... 20-313 Exhaust smoke is black (incomplete combustion) ................................................................ 20-314 Oil consumption is excessive (or exhaust gas is blue) ......................................................... 20-315 Oil becomes contaminated quickly ......................................................................................... 20-316 Fuel consumption is excessive ................................................................................................ 20-317 Oil is in cooling water. or water spurts back. or water level goes down .......................... 20-318 Oil pressure caution lamp lights up (drop in oil pressure) .................................................. 20-319 Oil level rises (water. fuel in oil) ............................................................................................. 20-320 Water temperature becomes too high (overheating) ............................................................ 20-321 Abnormal noise is made .......................................................................................................... 20-322 Engine lacks output (no power)

Vibration is excessive ...............................................................................................................

20-323

PC200-6Z

20-301

TESTING AND ADJUSTING

METHOD OF USING TROUBLESHOOTING CHARTS

METHOD OF USING TROUBLESHOOTING CHARTS This troubleshooting chart is divided into three sections: questions, check items, and troubleshooting. Thequestions and check items are used to pinpoint high probability causes that can be located from thefailure symptoms or simple inspeciton without using troubleshooting tools. Next, troubleshooting tools or direct inspection are used to check the high probability causes to make final confirmation. [Questionsl Sections @ +@ I i n the I chart on the right corresponds to the items where answers can be obtained from the user. The items in @ are items that can be obtained from the user, depending on the user's level. [Check itemsl The serviceman carries out simple inspection to narrow down thecauses. The items under @ in the chart on the rightcorrespond to this. The serviceman narrows down the causes from information @ that he has obtained from the user and the results of @ that he has obtained from his own inspection. ITroubleshootingl Troubleshooting is carried out in the order of probability, starting with the causes that have been marked as having the highest probability from information gained from [Questions] and [Check items].

20-302

PC200-6Z

TESTING AND ADJUSTING

METHOD OF USING TROUBLESHOOTING CHARTS

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

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

PC200-6Z

20-303

TESTING AND ADJUSTING

METHOD OF USING TROUBLESHOOTING CHARTS

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

s 7 Exhaust gas is black (incomplete combustion) General causes why exhaust gas is black Insufficient intake of air Improperconditionoffuelinjection Excessive injectionoffuel

Legmd

20-304

PC200-6Z

METHOD OF USING TROUBLESHOOTING CHARTS

TESTING ADJUSTING AND

,,, lr

Five causes Step 1

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

t "

SteD 2

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

I I

PC200-6Z

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

20-305

TESTING AND ADJUSTING

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

a n +

-1

20Â°C 0"c

100% 90%

80% 1.24

75% 70% 1.26 1.22 1.23 1.28 1.23 1.24 1.25 1.27 1.29

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

20-306

PC200-6Z

s-2

TESTING

S-2 Engine does not start

(1) Engine does not turn

Causes

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

Legend 0:Possible causes(judging from Questions and check items)

~ : : p r & b l e c a u r c l c l o d g i f r w n ~ d c h e d r i l e m s ) :Possible causes dueto length of use (used for a long period)

0 :hems

toconfirm tho caw.

1 Confirm recent repair history

I Degree of useofmachine

I ODeratedfor long period

Condition of horn when

When starting switchis turned toSTART, pinion moves out, but

I 5m

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

-a

In1 InI I I I

Horn sounds

Speed is slow Makes grating noise Soon disengages again Makes rattlina noise anddoes not turn

When starting switch is turnedto START, pinion does not move out

101

When starting switch is turned to ON, there is no clicking sound

I I I I I

Batteryterminal is loose When batteryis checked, battery electrolyte is found to below Specificgravity of.electrolyte. voltage of battery is low

For the following conditions1) - 5). turn the starting switch OFF, connect the cord, and carry out troubleshootingONat

1) When terminal6 and terminal C of starting switch are

connected, engine starts

2) When terminal 6 and terminal C of starting motor are

connected, engine starts 3) When terminal 6 and terminal C of safety relay are

connected. engine starts 4)

Engine starts when safety switch terminal and starting motor B terminal is connected

5 ) There is no 24V between battery relay terminalM and

terminal E When ring gear is inspected directly. tooth surface is found to be chiooed

I :1 Remedy

PC200-6Z

20-307

TESTING AND ADJUSTING

s-2

(2)Engine turns but no exhaust smoke comes out (fuel is not being injected1

Check that the monitor panel does not display any abnormalityin the governor control system. General causes why engine turns but no exhaust smoke comes out Supplyoffuel impossible Supply of fuel is extremelysmall Improper selection of fuel (particularly in winter) f

Standards for use of fuel

20-308

PC200-6Z

TESTING AND ADJUSTING

s-2

(3)Exhaust smoke comes out but engine does not start (Fuel is being injected)

Ir General causes why exhaustsmokecomes out but engine does not start Lackof rotatingforcedue todefectiveelectrical system Insufficientsupplyoffuel Insufficientintake ofair Improper selection of fuel andoil

Legend 0 :Possiblemusets (judgingfrom Ouostho and check items)

PC200-6Z

20-309

TESTING AND ADJUSTING

s-3

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

causes

Gel

'I 1st

Legend

0:Possible causes (judging from Questions and check items) ~:~probabb~(iudgingfromoue+liomMdcheckitems)

:Possible causes due to length of use (used for a long period) :hems to confirmthe cause.

Rust and water are found when fuel tank is drained Dust indicator is red

Il0lol I I I I I I I I 0

Noise of interference is heard from around turbocharger

Engine pick-up suddenly becamepoor Color of exhaust gas

Blue under light load Black

I Clanging sound is heard from around cylinder head I Mud is stuck to fuel tank cap There is leakage from fuel piping

High idlingspeed underno load is normal, There is hunting from engine (rotation is irregular) When exhaust manifold is touched immediately after starting engine, temperature of somecylinders is low

I 20. Blowby gas is excessive

When aircleanerelement is inspected dirdy, it is found to be dogged

Speed does not change when operation

When control rack

of certain cylinders

is stopped

is pushed, it is found to be heavy, or does not return

When compression pressure is measured, is it

found to be lo\

I When turbocharger is rotated by hand, it is found to beheavy1 When fuel cap is inspected directly, is it

found to clogged be

When pump feed

too light or t w heavy

is operated, operation is

Remedy

20-310

000

00 I I I I l l o l I I I I I 0

I I I I I I I I I I I

mainerarrinspnteddirdy.meyarefoundtobeclossed _.

When feed pump strainer is inspested directly,it is found to be clogged

la1 I la1 I la1 I I lo I I I I l I I l a l I I I I I I I I I I I l 0 l I I 0

but speed suddenly drops when load is applied

When fudClter,

I I 1 1 1 .1 I I I I I

a , um s z c .

m ::2 5 E 5g xu

~x ~

a r0

~ z an a c

PC200-6Z

TESTING AND ADJUSTING

S-4

S-4 Engine stops during operations General causes why engine stops during operations Seized partsinside engie Insufficientsupplyoffuel overheating If there is overheating and the engine stops, carry out troubleshooting for overheating. Failure in main pistonpump If the engine stops because of a failure in the main piston pump, carry out troubleshooting for the hydraulic system (H MODE).

* *

When oil pan is removed and inspection is madedirectly, it is foundto be abnormal

co .E e

I-

When head cover is removed and inspection is made directly, it is found to be abnormal

When gear train isinspected, it does not turn When fuel filter, strainer are inspected directly, they are found to be clogged When feed pump nrainer is inspected directly,it is found to be clogged Inspect feed pump directly

When control rack is pushed, it is found to be heavy, or does not return 1

Remedy

PCZOO-6Z

20-31 1

TESTING AND

s-5

S-5 Engine does not rotate smoothly (hunting) General causes why engine does not rotate smoothly Air in fuel system Defectivegovernor mechanism Defectiveelectricgovernor mechanism Ir tf hunting does not occur when the rod between the governor motor and the injection pump is disconnected, troubleshoot by using the electrical system troubleshooting (E mode).

Causes

Rust, water are found when fuel tank is drained

;Iâ&#x201A;Ź

Leakage from fuel piping

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

2) No response, light, return is normal

Engine speed sometimes rises too far Engine i s sometimes difficult to stop

Seal on iniection oumo has come off

When governor lever is moved it isfound to be stiff

When injection pump istested, governoris found to be

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

does not return When fuel cap is inspecteddirectly, it is found to be clogged When feed pump strainer is inspected directly,it is found to

I I I Ie

be clogged When fuel filter. strainer are inspected directly, they are found to be clogged

Remedy

20-3 12

PC200-6Z

TESTING AND ADJUSTING

S-6

S-6 Engine lacks output (no power)

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

Causes

Legend 0 :Possible causes(judging from Questions and check i t e m s )

O:Mastprobsbkcaurer(judgiifrwnOuestionssndcheclritnns)

PCZOO-6Z

:Possible causes dueto length of use (used for a long period)

20-3 13

s-7

TESTING AND

S-7 Exhaust smoke is black (incomplete combustion)

Causes

General causes why exhaust smoke is black Insufficientintakeofair Impropercondition of fuelinjection Excessiveinjectionoffuel

Legend :Possiblecauses (judging from Questions and checkitems)

Q:Mostprobablecauses~udgingfrom&estiusandCheckinms) A :PossiMecauses due to length of use (usedfora long period) :kerns to confirm the cause.

Confirm recent repair history

1 1 1 1 1 1 1 1 1 1 1 1

Color of exhaust gas

excessive

Blow-by gas Engine pickup is

poor and combustion is irregular

When exhaustmanifold istouched immediately after starting engine, temperature of some cylinders is low

000

Timing block on fuel injection pump are out of alignment Clanging soundis heard from around cylinder head Muffler is crushed

20-3 1 4

PC200-6Z

TESTING AND ADJUSTING

S-8

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

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

Causes

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

When compression pressure is measured, it is found to be l o w When breather element is inspected. it is found to be clogged with dirty oil

.=E

There is external l e a b g e of oil from engine

Pressorbtightness test of oil cooler shows there is leakage

â&#x20AC;?c . Inspect rear seal directly

Excessive play ofturbocharger shaft

When intake manifoldis removed, dust is found inside When intake manifold is removed, insideis found to be dirty with oil

Remedy

PC200-6Z

20-315

Replace

Clean

Replace

Clean

Replace

I .

Carry out trout tshootina for EXHAU!

Troubleshooting Check items

Questions ~

ODOOB .. *.....

s-lo

TESTING AND ADJUSTING

S-10 Fuel consumption is excessive General causes why fuel consumption is excessive Leakage of fuel Improperconditionof fuelinjection Excessive injectionof fuel

Legend

0: Possible causes (judging from Questions and check items)

,~:ModprobabkcauseS(jUdgingfranQuestiomandChCdCitemJ) A :Possiblecauses due to length of use (used for a long period) 0 :hems to confirm the cause. Confirm recentrepair history Degree of use of machine C

Gradually increased Suddenly increased

I I

.E I

2 -m 0

Injection pump measurement shows that injection amount is excessive Speed does not changewhen operation of ceRaincylindersis

2= . Whencheckis ,O

I-

stopped

When control rack is pushed, it is found to be heavy, or does not return made, injeclion timing is found to

be incorrect

0 0

Remove head cover and inspect directly Remove feed pump and inspect directly

When engine speed is measured, low idling speed is found tobe high

PC200-6Z

20-3 17

s-I1

TESTING AND ADJUSTING

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

Legend

0 :Possible causes (judgingfrom Questions andcheck items1

~:MaaprobaMecSux*i(iudgingfromQwstiomandchsdcitems)

A:Possiblecauses due to lengthof use (usedfor a long

period)

:h e m to confirm the cause.

Confirm recent repair history

3a g

Pressure-tightness testof oil cooler shows there is leakage Pressuretightness testof cylinder head shows there leakage is

Remove cylinder head and inspect directly Remove oil panand inspect directly

20-318

PC200-6Z

TESTING AND ADJUSTING

s-12

S-12 Oil pressure caution lamp lights up (drop in oil pressure) General causes why oil pressure lamp lights up Leakage, clogging,wear of lubricating system Defective oil pressure control Improper oil used(improperviscosity) Deterioration of oil due to overheating

Standards for engine oil selection Ambient temperature

Type of oil

-4

86 104'F

Causes

Engine oil

Legend

Replacement of filters has not been carriedout according to Omration Manual ~~~

Non-specified oil is beins used Condition when oil pressure lamplights up

I I

Lights up at low idling Lights up at

low, high idling

Lightsuponslope Sometimes lights up

There is clogging, leakagefrom hydraulic piping (external)

When oil filter is inspected directly, it is found to be clogged

Remove oil pan and inspect directly

II)

Oil pump rotation is heavy, there is play

There is catching of relief valve or regulator valve, spring or

valve guide is broken

PCZOO-6Z

When oil pressure is measured, it is found to be within standard value

20-3 1 9

S-13

TESTING AND ADJUSTlNG

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

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

Causes

Pressure-tightness test of oil cooler shows there is leakage Pressure-tightness testof cylinder head shows there is leakage When compression pressure is measured, it is found to be low

1.1 I I le1

Remove rear seal and inspect directly

Remove injection pump and inspect directly Remove oil pan and check directly

20-320

PC200-6Z

S-14

TESTING AND ADJUSTING

S-14 Water temperature becomes too high (overheating) General causes why water temperature becomes too high Lack of cooling air (deformation, damage of fan) Drop in heatdissipation efficiency Defective coolingcirculation system

Causes

Temperature difference between top and bonom radiator tanks is excessive

~~~

Temperature difference between top and bonom radiator

-g .

I-

tanks is slight

When water filler port is inspected, core is found to be clogged

When function test is carried out onthermostat, it does not

open even at crackingtemperature When water temperature is measured, it is found to be normal When oil cooler is inspected directly, it is found to be clogged

cap tester, set When measurement is made with radiator Dressure is found tobe low

When compression pressure is measured, it is found to be low Remove oil pan and inspect directly Remedy

PC200-6Z

20-321

TESTING AND ADJUSTING

S-15 Abnormal noise is made

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

20-322

S-15

Causes

PC200-6Z

TESTING AND ADJUSTING

S-16

S-16 Vibration is excessive

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

PC200-6Z

20-323

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)

................................................ ..........................................................................................

Judgement table forelectrical, hydraulic, and mechanical systems Electrical circuit diagram for each system Failure codes

20-352 20-354

E-1 Abnormality in PC-â&#x201A;ŹPC control system a) Engine stops even when throttle lever is not returned to STOP position.

................................................................... 20-355 b) Lacks power when throttle lever is at FULL, work equipment speed is slow ............20-356 E-2 Abnormality in travel speed selector system (travel speed does not switch) ................... 20-358 When sudden load is applied, engine stalls.

E-3 Abnormality in swing holding brake solenoid system

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

.....................................

b) Remains actuated (swing cannot be locked) ................................................................... E-4 Abnormality in PPC oil pressure lock solenoid system

20-359 20-360 .

a) Solenoid is not actuated (safety lock is not canceled) ................................................... 20-361 b) Remains actuated (safety lock is not actuated) ............................................................... 20-362

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

PC200-6Z

20-364

20-351

JUDGEMENT TABLE FOR ELECTRICAL, SYSTEMS MECHANICAL ANDHYDRAULIC,

TROUBLESHOOTING

JUDGEMENT TABLE FOR ELECTRICAL, HYDRAULIC, AND MECHANICAL SYSTEMS Pump regulator

Solenoid valve Travel Hi-Lo solenoid

1. Insert T-adapter in pump regulator connector (CO1). 2. Turn starting switch to START. 3. Turn pump prolix switch

1. Insert T-adapter in Hi-Lo solenoid connector (V06). 2. Turn starting switch ON. 3. Is voltage between V06 (1) and chassis as shown in table below?

Parts causing failure

OFF.

4. Place all levers at HOLD. 5. Is voltage between CO1 (13) and (10) as shown in table below? (When normal)

Failure mode

Speeds of all work equipment, swing, travel are slow or lack power There is excessive droo in enaine soeed. or enaine stalls No work eauipment. travel, swina move Abnormal noise generated (around pump) Fine control ability is poor orresponse is poor Boom is slow or lacks power A r m is slow or lacks Dower Bucket is slow or lacks Dower Boom does not move Arm does not move Bucket does not move

Voltage At low idling At full

I 0.8 - 0.97 V I I 0.24 - 0.4 V I

High

- 30 V ov

Low

When swing holding brake is applied When swing holding brake

Troubleshooting No. for electrical system

20-352

0 0

Excessive hvdraulic drift Excessive time laa (enaine at low idlina) Cthev equipment moves when single circuit is relieved In compound operations, work equipment with larger load isslow In swing + boom (RAISE), boom is slow In swing + travel, travel speed drops excessively Excessive deviation during normaltravel Travel deviation Excessive deviation when startina Travel speed is slow Steering does not turn easily or lacks power Travel does not move (one side only) Travel soeed does not switch Both left and right Does not swing One direction onlv Swing acceleration is poor Both left and right or swing speed is slow One direction only Excessive overrun when Both left and right stopping swing One direction onlv Excessive shock when stomina swina (one direction onlv) Excessive abnormal noise when stopping swing Excessivehydraulic drift of swing

Hi-Lo switch

is canceled

E-1

E-2

PC200-6Z

JUDGEMENT TABLE FOR ELECTRICAL, HYDRAULIC, AND MECHANICAL SYSTEMS

TROUBLESHOOTING

Solenoid valve holding Swing

brake solenoid

1. Insert 1-adapter in swing holding brake connector solenoid (V04). 2. Turn starting switch ON. 3. Is voltage between V04 (1) and (2) as shown below?in table

normal)

(When

PPC hydraulic solenoid

1. Insert T-adapter in PPC hydraulic lock solenoid connector (V07). 2. Turn starting switch ON. 3. ISvoltage between V07 (1) and (2) as shown below? i n table

(When normal) measurement

Release

20-3ov

Release Lock

- 30 V ov

H-1 H-2 H-3 H-4 H-5 H-6 H-7 H-8

H-9 H-10 H-11 H-12 H-13 H-14 H-15 H-16 H-17 H-18 H-19 H-20 H-21 H-22 H-23 I

H-24 H-25

H-26 1

E-3

PC200-6Z

E-4

20-353

r--------1

0 V -4

TROUBLESHOOTING

E-1

E-1 Abnormality in PC-EPC control system

* * * *

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

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

Remedy

CaUSe

Is voltage

ON. Short circuit.dironnection, defective contact in wiring harness between fuse (2) Repair or HO6 14)- Cot (female)( 1 1 , ~ replace between COl (female)(8) and chassis ground

(female) (1) and (8)normal?

1 Does LED of pump regulator go out?

switch ON.

switch ON. Disconnect COT. -20-30V

LED of Pump - 1sregulator

NO flashing?

YES

I Is continuity YES between COI (female) 15) (10). (61 (10) normal? 3

* Turn staning

Replace or turn pump prolix switch

Troubleshooting of pump regulator

Turn Sartinp switch OFF. NO *DisconnectCot. No continuity between(5)and (10) -Continuity between(6) and (10)

Go t o H mode (H-2) Shon circuit, disconnection. or defective contact in wiring harness between CO1 (female) (5) -

(10). (6) (10)

5 YES

Is resistance

Turn starting switch ON. c

-Turn starringswitch OFF

Failure of solenoid

Replace

DisconnectC13.

-7-14R

Is resistance (female) (7) and (13) normal?

chassis normal? *

Disconnect CO1.

* Min. 1 Mi2

PC200-6Z

7 YES

Abnormality in pump regulator Disconnection in wiring harness between CO1 (female)(7)-COS (1) (3) C13 (female)(1). between C13 (female)12) COS (4) 12) CO1 (female)(13) Wiring harness betweenCO1 [female)( 7 ) C05 (11 (3) C13 (female)(1).or batween C13 (female)(2) COS (4) 12) CO1 ifernale) (13)shon :ircuiting with chassis around

Repair or replace

Replace or turn pump prolix switch 3N.

qepair or 'eplace

- -

qepair or 'eplace

20-355

TROUBLESHOOTING

E-1

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

Cause

Is resistance YES between CO1 (female) (3)and 2 (4) normal?

Is resistance YES between E07 (male) (1) and (2) normal? Turn starting switch OFF. Disconnect â&#x201A;Ź07. -500-1OOOR

Turn starting switch ON. Set throttle lever to,FULL.

Disconnect COl. -500-1OOOR

4 YES

Is continuin, befween COl (female)15) and (10). (61 and (101

normal?

Turn starting NO switch OFF. * Disconnect CO1. No continuity between (5) and (10) Continuity between (6) and (10)

20-356

starting - - Turn switch OFF.

-Is LED of pump regulator flashing?

3 YES

Troubleshooting of pump regulator Short circuit disconnection, or defective contact in wiring harness between CO1 (female) (3) and E07 (female) (1). or between CO1 (female) (41 and E07 (female)(2) Troubleshooting of speedtensor

Remedy

Replace

Repair or replace

Replace

Abnormality in pump regulator

Replace

Short circuit, disconnection, or defective contactin wiring harness between CO1 (female) (5) and (101, or between (6)and (10)

Repair or replace

PC200-6Z

E-2

TROUBLESHOOTING

E-2 Abnormality in travel speed selector system (travel speed does not switch)

* * *

Beforecarryingout troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to thenext step. YES Check that fuse 5 is normal. 3

Is voltage

; between VO6 (1)

Remedy

Go t o H mode (H-20)

4 YES Defective travel Hi-Lo

and chassis

, normal?

Does condition

Replace

relay

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

Disconnect VO6.

*20-60R

Defective travel Hi-Lo solenoid valve

HIGH

LOW

switch ON. *20-30V

Resistance value Max. 1 S2 Min. 1 MR

Defective contactor disconnection in wiring harness betweenfuse (5) H06 (8) H02 (9) M38 (female) 12). and between R05 (female) (5) - H03 (15)

chassis normal?

Tabte.1 Travel Hi-Lo switch

Replace

Defective contact or disconnection in wiring harness betweenM30 (female) (1) HO2 (1) H06 (2) R05 (female) (11

Is voltage

Replace

Repair or replace

Travel speed switch

E-2 Related electrical circuit diagram

V06 ( X 2 )

= a 3

007

-3 -3

20-358

- T r a v esl p e e d

solenoid v a l v e

TKPOlOlO

PC200-6Z

TROUBLESHOOTING

E-3

E-3 Abnormality in swing holding brake solenoid system

* * f

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

Is voltage and chassis Turn starting switch ON. Swing lock switch LOCK:

20-3ov

* Swing lock switch

CANCEL: Max. 1 V

1 * Turn $tatting

switch OFF.

switch OFF. Disconnect V04.

-20-60Q

GOto H-21 Defective contact or disconnection in wiring harness between V04 Repair or (female) (2) HO2 (3) replace X05 (female) (4, between X05 (female) (3) HOZ (5) chassis ground

Defective contact or disconnection in wiring harness betwean fuse 2 H06 (4) V04 (female) (1)

Repair or replace

Defective swing lock switch

Replace

Defective swing iock solenoid valve

Table 1 Swing holding brake switch CANCEL

LOCK

Replace

Resistance value Max. 1 B Min. 1 MR

E-3 a) Related electric circuit diagram Fuse

H06 (S8)

V04 ( X 2 1

BDP00258

PC200-6Z

20-359

E-3

TROUBLESHOOTING

b) Remains actuated (swing cannot be locked) Cause

I IS rm-stance

(female)(4) and

chassis normal7

Go to H Mode (H-21) Short ciucuit withchassis ground in wiring harness between VO4 (female) (2) Repair or replace H02 (3) X05 (female) (4)

Defective swing holding brake switch I

Turn starting

rm'tch OFF. Disconnect V04. -20-60n

Replace

' I Defective operation of swing holdingbrake Replace solenoid valve(short circuit with ground at (2))

Table 1 Swing holding brake switch CANCEL LOCK

Resistance value Max. 1 R Min. 1 MR

E-3 b) Related electric circuit diagram Fuse

H06 ( S 8 )

V04 ( X 2 1 S w i n eh o l d i n g brake solenoid

8DP00258

20-360

PCZOO-6Z

TROUBLESHOOTING

E-4

E-4 Abnormality in PPC oil pressure lock solenoid system

* * *

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

4 YEA

-YES 2 Is resistance

YE ; b e m e n s12 and

Is resistance

between V07 (male1 (11 and (2) Turn staning switch OFF. Disconnect V07. -20-60Q

st3 asshown in

Table 17

Is voltage between S f 2 and chassis normal?

Is voltage between V07 (1) and chassis normal?

- T u r n starting switch ON. -20-30V

Remedv

Defective contact or disconnection ,inwiring harness between'V07 (female) (2) H02 (71 S14 (1) S12

*Turn starting switch N(

ON.

Safety lofk lever LOCK: 20 30 V RELEASE: Max. 1 V

-Turn starting switch OFF. Disconnect S13. Max.1 f2

Table 1 Swing holding brake switch RELEASE LOCK

Repair or ceplace

Defective contact or disconnection in wiring harness between fuse 2 H06 (41 V07 (female) (11

Repair or replace

Defective PPC oil pressure lock switch

Replace

PPC oil I Defective pressure lock switch

Replace

-Turn starting switch OFF. NO -Disconnect S12 and S13. Check PPC oil pressure lock switch 8s individual part.

' Defective contact or

chassis normal?

Go to A

disconnection in wiring harness between S13 S14 (21 H02 (51 chassis ground

Repair or replace

Resistance value Max. 1 R Min. 1 MR -

E-4 a) Related electric circuit diagram Fuse

PPC o i l Dressure lock switch

SI3

PC200-6Z

S 1 4 (M2)

H06 (S8)

H02 (SI61

V07 (X021

I / I 1

L I

D20

BDPOO257

20-36 1

E-4

TROUBLESHOOTING

b) Remains actuated (safety lock is not actuated] Cause Short ciucuitwith chassis ground in wiring harness between V07 (female) (2) - H02 ( 7 )- S14 (1) and

1 YES Is resistance between S12 and S13 as shown in table 17

Turn starting switch OFF.

s12

Defective PPC oil pressure switch

Replace wiring harness

Replace

Disconnect SI2 and S13.

Table 1

Swing holding brake switch RELEASE LOCK

Resistance value Max. 1 R Min. 1 M R

E-4 b) Related electric circuit diagram Fuse

H06 6 8 )

V07 (X021

T 3 m A

PPC

oil pressure

lock s w i t c h

I /

PPC

oi I p r e s s u r e lock solenoid valve

8DP00257

70-1362

PC200-6Z

TROUBLESHOOTING

E-5

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

* * * *

When the starting motor does not turn. Check that fuse 1 is normal. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.

YES

Is there sound of starting motor pinion engaging?

Is voltage between

- terminal S and -

YES safety relay

Turn starting switch to START.

chassis normal?

3x- Same conditions Is voltage between as in Step 5. YES starting switch Iterminalcand chassis normal?

*Is voltage between-

When starting switch is turned

OFF. is sound heard

starting motor terminal B and chassis normal?

Turn starting switch toSTART. 2o 30

* Turn starting

from battery relay?

switch ON. -20-30V

* Turn starting

switch ON + OFF.

NO 12 YES

YES harnssbetwm

Is voltage and specific gravity of battery normal? ~~

*20-30V. Specific gravity: Min. 1.26

,, -

h resistance of wiring

there continuity - switch terminal B - Is

YES men starting Is voltage of starting switch NO terminal B normal?

* Connect ( 4 end

of tester to

battery terminal

(-1

starting switchBR and battery relay BR normal? Between starting

~ ~ ~ $ , ~ M ~ ~1 R ~ ~ & . :

and 0R7 Between wiring harness and chassis: Min.1 R Disconnect both endsof starting switch and battery relay. *Turn starting NO switch ON. -Remove terminal B.

-20-30V

20-364

PC200-6Z

E-5

TROUBLESHOOTING

Remedy

Cause

YES 7 Is voksge b a r n e n narring motor terminal C and chassis normal?

331 Same conditions as in Step5.

Is voltage between safew relay terminal C and chassis normal?

Q Same conditions

as in Step 5.

Is voltage

between M02 (female) 12) and chassis normal?

Defective starting motor (magnetic switch)

Rspair or replace

9 YES

Turn starting switch ON. Max. 13 V

Repair or replace

Defective contact or disconnection in wiring Repair or harness between safety replace relay terminal C T13 (1I -starting motor terminal

YES

Defective starting motor (motor proper)

Defective safety relay

Replace

Defective alternator

Replace

Defective contact or disconnection in wiring harness between startins switch terminal C H03 (3) M02 (1) safety relay terminal S

Repair or replace

Defective starting switch (between terminals E and Cl

Replace

Defective contactof wiring hemess betweenbattery terminal ( 4 battery relay terminal B -terminal M starting motor terminal B

Repair or replace

Defective battery relay

Replace

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

Repair wiring harness

Defective starting switch (between E and ER) Defective contact or dixonnecfion in wiring harness between banery relay terminal( 4 banery relay terminalB M11 (1). I2 H03 (2) -fuse 1 starting switch terminalB (including fusible link)

---

Lack of battery capacity

PC200-6Z

Replace

Repair wiring harness

Charge or replace

20-365

E-5

TROUBLESHOOTING

E-5 Related electric circuit diagram

S t a t t i n o switch

Fuse

Fusible l i n k

TKP0101 I

20-366

PC200-6Z

TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE) Table of failure modes and causes ...*.................................................................................................. 20-402 H-l Speeds of all work equipment, travel, swing are slow or lacks power.. ....................... 20-406 H-2 There is excessive drop in engine speed, or engine stalls .............................................. 20-408 H-3 No work equipment, travel, swing move ......................................................................................... 20-409 H-4 Abnormal noise generated (around pump) ....................................................................... 20-409 H-5 Fine control ability is poor or response is poor ................................................................ 20-409 H-6 Boom is slow or lacks power .............................................................................................. 20-412 H-7 Arm is slow or lacks power ................................................................................................. 20-414 H-8 Bucket is slow or lacks power ............................................................................................. 20-416 H-9 Work equipment (boom, arm, bucket) does not move (but travel and swing are normal) ...................................................................................... 20-416 H-10 Excessive hydraulic drift (boom, arm, bucket) .................................................................. 20-417 H-11 Excessive time lag (engine at low idling) .......................................................................... 20-418 H-12 Other equipment moves when single circuit is relieved .................................................. 20-418 H-13 In compound operations, work equipment with larger load is slow ............................. 20-418 H-14 In swing + boom RAISE, boom RAISE is slow .................................................................. 20-419 H-15 In swing + travel, travel speed drops excessively ............................................................ 20-419 H-16 Travel deviation ..................................................................................................................... 20-420 a) Deviation is excessive in normal travel ....................................................................... 20-420 b) Deviation is excessive when starting ........................................................................... 20-420 H-17 Travel speed is slow ............................................................................................................. 20-421 H-18 Steering does not turn easily or lacks power .................................................................... 20-422 H-19 Travel does not move (one side only) ................................................................................ 20-423 H-20 Travel speed does not switch .............................................................................................. 20-423 H-21 Does not swing ..................................................................................................................... 20-424 a ) Does not swing to either left or right .......................................................................... 20-424 b) Does not swing in one direction ................................................................................... 20-424 20-426 H-22 Swing acceleration is poor or swing speed is slow ......................................................... H-23 Excessive overrun when stopping swing ........................................................................... 20-428 a) One direction only .......................................................................................................... 20-428 b) Both directions ................................................................................................................ 20-428 .20-429 H-24 Excessive shock when stopping swing (one direction only). .......................................... H-25 Excessive abnormal noise when stopping swing ............................................................. 20-429 H-26 Excessive hydraulic drift of swing ...................................................................................... 20-430 a) When swing lock is ON ................................................................................................. 20-430 b) When swing lock is OFF ................................................................................................ 20-430

PC200-6Z

20-401

FAILURE TROUBLESHOOTING OF TABLE

MODES AND CAUSES

TABLE OF FAILURE MODES AND CAUSES (1/2) Piston pump

-e 9

z6i.% There is excessive drop in engine speed. or engine stalls

Speeds of all work equipment, swing, travel areslow or lack power

No work equipment, travel, swing move Abnormal noise generated (around pump) Fine control ability is poor or response is poor Boom is slow or lacks power Arm is slow or lacks power Bucket is slow or lacks power Boom does not m w e Arm does not m w e Bucket does not move Excessive hydraulic drift Excessive time lag (engine at l:,w idling)

f u-

I Other equipment moves when single circuit is relieved

operations, work equipment with larger load is slow I InIn-compound swing + boom (RAISE), boom is slow In swing

+ travel, travel speed drops excessively

Travel deviation

Deviation is excessive during normal travel Deviation is excessive when starting

Travel speed is slow Steering does not turn or lack power Does not move (one side only) Travel speed does not switch Both left and right Does not swing One direction only Swing acceleration is poor Both left and right One direction only or swing speed is slow Both left and right Excessive overrun when sttaaoina swino One direction onlv

Excessive shock when stopping swing (one direction only) Excessive abnormal noise when stopping swing Excessive hydraulic Whenbrake ON drift of swing When brake OFF

* In the failure modes, modes for compound operations are used when independent operations are normal

A: When there is an abnormality for both front and rear

20-402

PC200-6Z

;

Unload valve

b ~

~~~

< L

Swivel joint

M 5

-I

Swing PPC slow return valve

Travel PPC shuttle (built-in PPC valve)

PPC valve

Suction valve

Arm counterblance valve

LS circuit throttle

valveLS select

LS shuttle valve

LS circuit check valve

Main circuit check valve

Pressure compensation valve

Main relief valve

TROUBLESHOOTING

FAILURE OF

TABLE

MODES AND CAUSES

TABLE OF FAILURE MODES AND CAUSES (2/2) motor

Speeds of all work equipment, swing. travel are slow orlack power

.fs .E? There is excessive drop in engine speed, or engine stalls o x

-- .

55 E

s 5

U "

g'g 88

No work equipment. travel, swing move

Abnormal noise generated (around pump) Fine control ability is poor or response is poor Boom is slow or lacks power Arm is slow or lacks power Bucket is slow or lacks power Boom does not move Arm does not move Bucket does not move Excessive hydraulic drift Excessive time lag (engine at low idling) Other equipment moves when single circuit is relieved

Incompound operations, work equipment with larger load is slow In swing + boom (RAISE). boom is slow

In swing + travel, travel speed drops excessively Deviation is excessive during normal travel Travel deviation Deviation is excessive when starting Travel speed isslow Steering does not turn or lacks power D o e s not move (one side only) t Travel speed does not switch Both left and right Does not swing One direction only Swing acceleration is poor Both left and right One direction only $ or swing speed isslow Both left and right Z Excessive overrun 2; when stopping swing One direction only rn Excessive shock when stopping swing (one direction only) .$ v) Excessive abnormal noise when stopping swing

-55

Excessive hydraulic drift of swina

When brake ON When brake OFF

In the failure modes, modes for compound operations are used when independent operations are normal

A: When there is an abnormality for both front and rear

20-404

PC200-6Z

H-1

TROUBLESHOOTING

H-1 Speeds of all work equipments, travel, swing are slow or lacks

power

Check that there is no abnormal normal from the mainpump before starting troubleshooting. (If there is any abnormal noise, carry out Troubleshooting H-4.)

YES

4 Does condition

YES become normal

when PC valve is adjusted?

YES_ pressurerpprox. I R of main circuit pressure?

Engine at high idling Arm IN relieved

YES Is main pump

relief pressure normal?

ADJUSTING.

become normal when NZ P C v h assembly is -

replaced)

6 YES

Distribution NO between LS valve andpiston pump(servo piston).

YES l+ t

* Engine at high

relieved

Does condition become normal when main relief

a YES

become normal 30.4 33.8 MPa (310 345 NO when unload kslcmq â&#x201A;ŹWine at high idling

5 YES

replaced)

Check and measure circuit oil pressure. For details,see TESTING AND ADJUSTING.

TESTINGAND

Does become normal when NO LS valve assembly is

30.4 33.8 MPa (310 345 kglcm?

* For details, see

Is servo piston input

Does condition

valve is replaced?

-3.9 f 1.0 MPa

(40f 10 kg/cmâ&#x20AC;&#x2122;) * Arm INrelieved Engineat highidling Arm IN relieved

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

20-406

PC200-6Z

TROUBLESHOOTING

H-1

Cause

Defective adjustment of PC valve

Adjust

Defective PC valve assembly

Repair or replace

Defective piston pump

Repair or replace

Defective LS valve assembly

Repair or replace

Defective piston pump (servo piston)

Repair or reDlace

Defective adjustment of main relief valve

Adjust

Defective operation of unload valve

Replace

Defective operation of main relief valve

Replace

Defective hydraulic equipment in selfreducing pressure valve output circuit (For details, see TESTING AND ADJUSTING.)

PC200-6Z

Remedy

Adjust or replace

20-407

H-2

TROUBLESHOOTING

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

Check that the main relief pressure is normal. Cause

Remedy ~

servo or filter inside servo clogged?

Das condition become normal whenPCvalve assembly is replaced?

Is engine speed normal at arm % See below.

YES

Does condition become normal L when LS valve NO assembly is replaced?

Clogged throttle inside servo or filter inside

Clean Adjust or replace PC valve assembly

Servo Defective PC valve

Adjust or replace LS valve assembly

4 YES Defective LS valve

Replace (piston pump assembly)

NO Defective servo piston See troubleshooting for engine (S mode)

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

speedEngine

Min. 1900 rpm

20-408

Conditions ~~

~~~

~ _ _ _ _ _

Engine at high idling. With arm at end of stroke, move lever slowly to high idling and read engine speedat point where there is maximum drop in speed.

PC200-6Z

H-3, H-4

TROUBLESHOOTING

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

Cause

YES Is PFC l o c k

solenoid valve

2 YES When main pump pressure pickup plugisremoved, does oil come out?

* Crank with

starting

properly?

motor.

Defective self-reducing pressure valve or defective control circuit

Replace

Defective damper

Replace

working

Defective operation of

Hold outlethose by hand and operate l o c k lever.

Remedy

PPC lock solenoid valve

or safety lock lever

Adjust

H-4 Abnormal noise generated (around pump)

Cause

Remedy

Do bubbles engine is Improper hydraulic oil

- bubbles inside hydraulic tank?

YES Are there

Is hydraulic tank oil level normal?

PC200-6Z

YES

Is suction strainer clogged by _ Is.suctionstrainer 5 YE! NO external object?

.External object: Cloth, etc.

clogged with

metalpanicles or are metal particles stuck to drain plug?

Clogged by external object (cloth. etc.) (strainer)

Change hydraulic oil

Remove

Defect inside pump

Repair or replace

Operate for a short time and watch for any change in symptoms

Inspect again (depending on changes in symptoms)

Lack of hydraulic oil

Add hydraulic oil

20-409

H-5

TROUBLESHOOTING

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

F= Cause

Clogged throttle in LS circuit

Is throttle in LS circuit clogged?

DefectiveLS valve, or

defective servo piston

20-410

PC200-6Z

H-6

TROUBLESHOOTING

Cause

PC200-6Z

Remedy

Defective boom cylinder piston packing

Correct or replace

Defective operation of LS shuttle valve ( L s shuttle for R.H. travel or bucket)

Correct or replace

Defective safety & suction valve

Replace

Defective operation of boom regeneration valve

Correct or replace

Defective operation of pressure compensation valve or pressure compensation piston

Correct or replace

Defective operation of control vakre spool

Correct or replace

Defective PPC valve

Replace

20-413

TROUBLESHOOTING

H-7

H-7 Arm is slow or lacks power Ir When travel and swing speeds are normal.

IS YES ,-

Are relief pressure YES of F and R w m p

YES Does control YES vatve spoolfor arm move smoothly?

pressure of PPC valve normal? *

Min. 2.7 MPa {28.kg/cm? Engine at high idling

IS p I K I u n

companution VJIW

normal am, circuit is relieved?

toc

um~mul.ordoes P-recompbn-hn

30.4

- 33.8 MPa

Does LS shuttle - valve move -

smoothly?

6 YES

leakage from arm cylinder normal?

*Max.20cc/min NO Engine at high idling

Check Ls shuttle for LH. travel, NO boom, R.H. travel and bucket ~

(310-315 kg/cm2, NO * Engine at high Phil mOY* SllWMhb? idling * It is also possible to interchange with other NO compensation valve. See Note 1.

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

20-414

PC200-6Z

TROUBLESHOOTING

H-7

Cause

PC200-6Z

Remedy

Defective operation of arm regeneration valve or arm counterbalance valve

Correct or replace

Defective arm cylinder piston packing

Correct or replace

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

Correct or replace

Defective safety-suction valve for arm

Replace

Defective operation of arm pressure compensation valve or pressure compensation piston

Correct or replace

Defective operation of control valvespool

Correct or replace

Defective PPC valve

Replace

20-415

TROUBLESHOOTING

H-8, 9

H-8 Bucket is slow or lacks power

When travel and swing speeds are normal.

YES Is leakage from YE 2

Is output

pressure of PPC valve normal? Min. 2.7 MPa (28 kgkrn? Engine at high idling

Does control valve spool for bucket move smoothly?

does pressure lmmwnsationokton

1 rl

4 MS

Engine at high idlina

with other compensation valve. See Note 1.

Defective operation of safety-suction valvefor bucket

Repair or replace

Defective bucket cylinder

Repair or replace

NO pistonpacking

Defective operation of pressure compensation valve for bucket or pressure compensation

Repair or replace

piston Defective operation of control valve spool for bucket

Correct or replace

Defective PPC valve

Replace

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

H-9

Work equipment (boom, arm, bucket) does not move (but travel

and swing are normal)

Whenboom, pendently.

arm, andbucket

areeach

operated inde-

K Cause

Is output pressure of PPC valve normal?

Min. 2.7 MPa (28 kg/cm2) Engine at high idling

20-41 6

Defective control valve spool

-1 Defective PPC valve

Correct or replace

Replace

PC200-6Z

TROUBLESHOOTING

H-10

H-10 Excessive hydraulic drift (boom, arm, bucket) 1) Excessive hydraulic drift of boom

YES

1 1

Does speed of dcwnwardmovemeot becomefanerwhen lever is operated)

2 YES

'DOeSCOndition become normal when

See TESTING AND N ( j "'"W-sUcti" valve n mtefchanged? ADJUSTING. It is also possible NO to measure leakage of cylinder. Max. 20 c d m i n At relief Engine at high idling

Defective hydraulic cylinder piston packing

Replace

Defective operation of safety-suction valve

Replace

Defective operation of boom lock valve

Correct or replace

21 Excessive hydraulic drift of armor bucket Cause

'ES

downward mwement become faster when lever is operated? * See TESTING

---

AND ADJUSTING. It is also possible t o measure leakage of cylinder. Max. 20 c d m i n At relief Engine at high idling

YES

[Does condition become normal when safety-

-1

I compensation valve Or does pressure compensation piston move smoothly? * It is also possible to interchange with

other compensation valve. See Note 1.

Defective hydraulic cylinder piston packing

Replace

Defective operation of safety-suction valve

Replace

Defective control valve spool

Replace

Damaged slipper seal of pressure compensation valve, or defective operation of pressure compensation piston

ICorrect or

revlace

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

PC200-6Z

20-417

TROUBLESHOOTING

H-11, H-12, H-13

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

YE Bucket

it is also possible

to interchange .with other compensation valve. See Note 1.

Remedy

Defective safety-suction valve, or defective regeneration valve

Replace

Defective safety-suction valve

Replace

Defective omration of pressure compensation valve or pressure compeniation piston

Correct or replace

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

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

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

Replace

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

Remedy Defective operation of pressure Replace (replace pressure compensation compensation valve valve on side where load is lower) Combination of compound operation 1

Boom RAISE + arm IN

Boom RAISE + arm OUT

Boom RAISE + bucket CURL

A r m OUT

20-41 8

+ bucket CURL Boom LOWER + arm OUT

Side where load is larger Boom RAISE Arm OUT Boom RAISE Arm OUT Arm OUT

PC200-62

TROUBLESHOOTING

H-16

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

when starting)

a) Deviation is excessive in normal travel

I Cause Remedy

4YEE Defective travel motor

- control valve --

Does spool of

3move smoothly?

Does travel

YES pressure

k travel speed YES normal when rotating under no load?

For conditions

and standard values, see TESTING AND ADJUSTING.

- of

I5 output pressure self-reduu'ng

N 1 pressurevalve normal?

Min. 3.3 MPa (Min. 34 kg/cm') Engine athigh idling

compensation valva

individual pan.

Cause

Correct or replace

Defective operation of control valve spool

Correct or replace

Defective operation of travel pressure compensation valve

Correct or replace

Defective LS valve

Adjust or replace

Defective PPC valve

Replace

Defective self-reducing

pressure valve

b) Deviation is excessive when starting Remedy

Defective operation of travel counterbalance valve

Correct or replace

Clogged throttle inside servo of bottom or R pump

Correct or replace

20-420

rnovermoothly?

Check as

assembly

Replace

PC200-6Z

TROUBLESHOOTING

H-17

H-17 Travel speed is slow

Check that the spool of the travel PPC valve is moving the full stroke before carrying out troubleshooting.

Cau-

YES

YES n- V0 ma hu l , o r d w s pr.wrecDmpenvtion 2 pkmnmn YnooChb?

Does control YES valve spool move smoothly?

pressure normal?

between output pressure in FORWARD and

REVERSE:

Within 0.4 MPa (4 kglcm? Output pressure: Min. 2.7 MPa (28 kg/cm2} Engine at high idling * Relieve travel circuit

PC200-6Z

of self-reducing

e vNO la v;;;;~ :,

.Output pressure: Min. 3.3 MPa

become normal when suction valve is replaced?

Defective operation of control valve suction valve

Correct or replace

Defective travel motor assembly

Correct or replace

* It is also possible

5 YES

IS output pressure

4 YE!

Defective operation of pressure compensation to check by interchangingwith other NO compensation valve. valve or pressure compensation piston Note: After checking, alwaysreturn to original positions. Defective operation of NO control valve spool

right PPC valves normal. and is output

* Difference

Does condition

Remedy

Correct or replace Correct or replace

Defective PPC valve

Replace

Defective self-reducing pressure valve

Replace

(34kg/cmâ&#x20AC;&#x2122;)

* Engine at high

idling

20-421

H-18

TROUBLESHOOTING

H-18 Steering does not turn easily or lacks power Remedy

YES

normal y ~- become swhen suction valve Does condition

Is travel relief pressure normal?

3.8::;

MPa

(3551 ;: kglcmâ&#x20AC;&#x2122;b

Engine a t high idling

20-422

of control valve is intorchangod?

Defective control valve suction valve

3 YES

become n m a l when suaion valve and rightspools.NO of travel motor is interchanged?

* Interchange left

â&#x20AC;&#x2122;NO

Replace

Defective travel motor check valve

Correct or

Defective travel motor safew valve

Replace

Defective main relief va Ive

Replace

replace

PC200-62

TROUBLESHOOTING

H-19, H-20

H-19 Travel does not move (one side only)

k Cause

YES

Is any foreign

material found in oil drained from final drive?

Dosr condition

3 YES

y ~ become s nonnd when lehand right d o n 2

ISamount of oil drained from NO travel motor normal?

Max. 30 Umin Engine at high idling Relieve travel circuit.

valves con no^ valw ar0imerrh.ng.d’

Remedy

Defective final drive

Correct or replace

Defective operation of suction valve of control valve

Replace

Defective operation of counterbalance valveor travel motor safety valve

Replace

Defective travel motor

Replace

H-20 Travel speed does not switch Cause

2 YES

Is output pressure YES of travef speed

Is travel speed

- selector solenoid -

NO valve normal?

* Mi’. 2-7 MPa selector electrical - ’

circuit normal?

Disconnect connector V06. * Start engine. Set travel speed switch to Hi Use tester t o check that voltage at chassis wiring harness end of connector VO6 (1) is 21.5 - 29.5 V.

PC200-6Z

(28 kg/cmq Set travel speed selector switch toHi.

Remedy

Defective operation of travel motor speed selector servo piston

Replace

Defective operation of travel speed selector solenoid valve

Correct or replace

Defective travel speed selector switch or relay, chassis wiring harness

Correct or replace

20-423

TROUBLESHOOTING

H-21

H-21 Does not swing a) Does not swing to either left or right

Defective swing machinery

Is any

foreign

Cause

Remedy

Repair or replace

oil drained from of swing holding brake solenoid Ivatve normal?

Min. (28 kglcm? 2.7 MPa

Swing lock switch OFF

Defective swing holding motor brake or swing

â&#x20AC;&#x2DC;

solenoid holding brake Defective valve operation cancelof

Repair or replace

replace Or

b) Does.not swing in one direction

Does control swing move

Is PPC valve

outDut . .oressure normal? Min. 2.7 MPa

(28 kg/cm?

Cause

Remedy

Defective swing motor safety valve or suction valve

Replace

Defective operation of control valve spoolfor swing

Correct or replace

Defective PPC valve

Replace

* Swing lock

switch OFF

20-424

PC200-6Z

TROUBLESHOOTING

H-22

H-22 Swing acceleration is poor or swing speed is slow

If condition is normal when work equipment is operated independently.

2 YES

Both left and right

Does LS shuttle valve move srnoothty?

6 YES

acceleration poor in both directions or in one

- ai= -:ompenrat pressure

YES 3 Is PPC valve direction -output - One only pressure norral? (left or right) * Min. 2.7 MPa

(28 kg/cmz) Engine at high idling Swing lock switch OFF

Does control for swing move smoothly?

IDoerconamon 1 k m e normal YES when left and right safety vahres of 5 ming motor are interchanged?

YES for ming normel, don pressure 4 Compensationpiston

It is

possible to

measure relief prsuure ofnuin9 motor.

Relief pressure: 27.5 30.4 move moothlv? u80-310 k~mâ&#x20AC;&#x2122;l k is also possible to interchange NO *See Note 1. with other compensation valve. See Note 1.

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

20-426

PC200-6Z

H-22

TROUBLESHOOTING

Cause

Defective swing motor assembly Defective operation of LS

Replace

shuttle valve (all LS

Correct or replace

Defective operation of swing motor safety valve

Replace

Defective swing motor suction valve

Replace

Defective operation of pressure compensation valve or compensation piston

Correct or replace

Defective operation of control valve spool for swing

Correct or replace

Defective PPC valve

Replace

shuttles)

PC200-6Z

Remedy

20-427

TROUBLESHOOTING

H-23

H-23 Excessive overrun when stopping swing

a) One direction only

Cause

3 YES

Remedy

Defective swing PPC slow return valve

Correct or replace

Defective PPC valve

Replace

Defective swing motor safety valve

Replace

Defective operation of control valve spool for swing

I-eplace

returnvalves are

NO valve spool for swing move smoothly?

Zorrect or

b) Both directions Cause Defective swing motor

20-428

Remedy Repair or replace

PC200-6Z

H-24, H-25

TROUBLESHOOTING

H-24 Excessive shock when stopping swing (one direction only)

Remedy

Defective swing'PPC slow return v a l w k h e c k valve)

Correct or replace

Defective PPC valve

Replace

H-25 Excessive abrormal noise when stopping swing

Cause

1 Is output pressure of swing motor

solenoid valve

- 1

YES

become normal

Is foreign material found in

PC200-62

Remedy

Defective operation of swing motor safety valve

Replace

Defective swing motor suction valve

Replace

Defective swing machinery

Repair or replace

Defective back pressure valve

Correct or replace

20-429

H-26

TROUBLESHOOTING

H-26 Excessive hydraulic drift of swing

a) When swing lock is ON

Cause

Ls output pressure of swing holding

1 YES

brake solenoid

v a l v e normal?

Min 2.7 MPa 128 kglcrn? Turn swinglock switch OFF.

Remedy

Defective operation of swing holding brake

Repair or replace

Defective operation of swing lock solenoid va Ive

Correct or replace

b) When swing lock is OFF Cause

3 YE! Is problem reversed YES when lef! and right 2 satetyvalves are Is pressure interchanged? c~nsationvalveon ~~m$e-l*or N(

rdirection One

only

cwnpenwt'mpinon

,move rrnoothlv?

Is drain amount

- 1 0 Ulmin

-Engine at high idling -Relieve swing circuit

20-430

Remedy

Defective swing motor safety valve

Replace

Defective swing motor suction valve

Correct or replace

Defective pressure compensation valve, or defective operationof pressure compensation piston

Correct or replace

Defective control valve spool

Replace

Defective swing motor

Repair or replace

PC200-6Z

TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)

...........................................................................................

20-452 Monitor system electrical circuit diagram M- 1 When the starting switch is turnedON. no display is given (lamps do notlight up for 3 seconds) .............................................................................. 20-453 M- 2 When starting switch is turnedON. lamps light up f o r 3 seconds. but then do not go out 20-453 M- 3 When starting switch is turnedON, some lamps do not light up for 3 seconds ....... 20-454 a) No gauge lamps light up (caution lamps light up) 20-454 b) Swing lock. preheating lamps do not light up (all gauge lamps light up) 20-454 c) Charge caution lamp does not light up 20-454 20-454 d) Engine oil pressure caution lamp does not light up M- 4 When power is turned on (before engine isstarted). charge caution lamp does not light up 20-455 M- 5 When power is turned on (before engine isstarted), engine oil pressure caution lamp does not light up ......................................................................................... 20-455 M- 6 During preheating, preheating pilot lamp does notlight up ......................................... 20-456 M- 7 When switch is operated. swing lock lamp does not light up ...................................... 20-456 M- 8 Engine oil pressure caution lamp lightsup when engine is running 20-457 (engine oil pressure is normal)......................................................................................... M- 9 Charge caution lamp lightsup when engine is running................................................ 20-457 M-10 Abnormality in coolant temperature gauge.................................................................... 20-458 a) After engine is started, level stays at bottom (white range) and does not move.............................................................................................................. 20-458 b) After engine is started, level immediately rises Engine is not overheatingbut indicator enters red range....................................... 20-458 c) Coolant temperature gauge goes out ........................................................................ 20-458 M-11 Abnormality in fuel gauge ................................................................................................. 20-459 a) All fuel gauge segments go out ................................................................................. 20-459 b) Even when fuel level goes down, fuel gauge continues to show FULL ............... 20-459 c) Even when tank is filled, fuel gauge does not show FULL ..................................... 20-459 M-12 Defective operation of alarm buzzer ................................................................................. 20-461 a) Buzzer does not sound ................................................................................................ 20-461 b) Buzzer continues to sound and doesnot stop .......................................................... 20-461 M-13 Engine is running. but service meter does not move.................................................... 20-462 a) Charge caution lamp lights up ................................................................................... 20-462 b) Charge caution lamp does not light up ..................................................................... 20-462 M-14 Night lighting does not light up ........................................................................................ 20-463 20-463 a) Gauge lighting does not light up ............................................................................... b) Service meter lighting does not light up (service meter is working normally).... 20-463 M-15 Wiper does not move. or does not stop moving............................................................2 0.464 a) Wiper does not move when wiper switchis turned to ON ..................................... 20-464 b) Wiper moves even when wiper switch is not turned to ON ................................... 20-464 20-465 M-16 Heater does not work......................................................................................................... 20-465 a) Does not work at either Hi or Lo ................................................................................ b) Does not work at Lo only ............................................................................................ 20-465 20-465 c) Does not work at Hi only ............................................................................................

PC200-6Z

20-451

c m

L .

TROUBLESHOOTING

M-1, M-2

M-1 When the starting switch is turned ON, no display is gken (lamps doe not light up for 3 seconds)

* *

Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step. Cause

Defective monitor panel

'I I

I1s -age

Remedy

Defective contact or disconnection in wiring harness between Pol W 2 ) and fuse 2, or between PO1 (3)(4) H03 (11) - chassis ground

-20-30v

M-1

Blown fuse 2

Related electrical circuit diagram Moni t o r P a n e l

PO 1

(0401 6)

Replace

Repair or replace Replace fuse after inspecting and repairing cause of blown

I fuse

Fuse

VB VB

GND

H03 (St 6)

B O P O O ~

M-2 When starting switch is turned but then do not go out

* * *

ON, lamps light up for 3 seconds,

Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connectanydisconnectedconnectors before going on the next step. Check the fuses 2 before troubleshooting. Cause

Defective monitor panel

PC200-62

_i Remedy

Replace

20-453

M-3

TROUBLESHOOTING

M-3 When starting switch is turned ON, some lamps do not light up for,3 seconds

* * *

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

a) No gauge lamps light up (caution lamps light up) CaUSe

Remedy

Defective monitor panel

Replace

Blown bulb in lamp which does not light up

Replace

Defective monitor panel

Replace

Blown bulb of charge caution lamp

Replace

Blown bulb of engineoil presusure caution lamp

Replace

b) Swing lock, preheating lamps do not light up (all gauge lamps light up)

1 YES Is there disconnection in lamp whichdoes not lightup?

Check visually for NO blown bulb.

c) Charge caution lamp does not light up 1

Is there

disconnection in lamp?

YES

Check visually for NO blown buib:.?

GO to M-b.

dl Engine oil pressure caution lamp does not light up 1 YES

Is there disconnection in Check visually far blown bulb.

20-454

GO to M-5.

PC200-6Z

TROUBLESHOOTING

M I , M-5

M-4 When power is turned on (before engine is started), charge caution lamp does not light up

* *

Beforecarryingout troubleshooting, check thatall the related connectors are properly inserted. Always connect any disconnected connectors before going on the nextstep.

CaUSe

YES

Lamp bulb is blown

Is voltage between P O 1 (10) and PO1 (3).(4) normal? Turn starting

switch *O -SV

ON.

diagram circuit M-4 electric Related

ram circuit

7 between P O 1 NO (female) (10) -

Repbce

Defective contact or disconnection in wiring harness between PO1 (female) (10) H03 0)M02 (2) -E08 (1) E12 (1) -alternator terminal L

Repair or replace

Defective D l 4

Replace

Defective alternator

Replace

- -

3 YES (3). (4) normal? between Disconnect Wl. -Turn starting 0 - 1ov alternator Land chassis normal? switch ON. Max. 10 V -Turn starting NO switch ON. Disconnect P o l and D14. Max. 10 V

Remedy

Alternator

E l 2 (X21

TKP01013

M-5 When power .isturned on (before engine is started), engine oil pressure caution lamp does not light up

* * *

Beforecarryingout troubleshooting, check thatallthe related connectors are properly inserted. Always connect any disconnected connectors before going on the nextstep. Check for blown lamp bulb before starting troubleshooting. 2 YES

I IScontinuitv

aMax.0-5R

electric M-4 Related M o n i t o r oanel

=-I

PO1 (04016)

H03(SIGwhite)

Remedy

Defective monitor panel

Replace

Defective contact or disconnection in wiring harness between P o l (female) ( 9 )- H03 (10)E08 (male) ( 8 )

Repair or replace

Defective engine oil pressure sensor

Replace

Engine o i l Dressure s w i t c h

M-6, M-7

TROUBLESHOOTING

M-6 During preheating, preheating pilot lamp does not light up

t Before carrying out troubleshooting, check that all the related connectors are properly inserted.

* *

Always connect any disconnected connectors before going on the next step. If the lamps do not light up for3 seconds when the starting switch is turned ON, go to M-2.

ts voltage

betwean PO1 (13) and 13)(4) normal?

-Turn starting switch to HEAT. -20-30v

M-6

I Defective monitor panel

1YES

Defective contact or disconnection in wiring harness between PO1 (female) (13) and starting switch R1. or defective starting switch

Replace

Repair or replace

Related electrical circuit diagram

PO 1

Starting switch

M o n i t o r P a n e l (040 1 6 )

H03 6 1 6) BDP00266

M-7 When switch is operated, swing lock lamp does not light up

* *

Before carrying out troubleshooting, check that all the related connectors are properly inserted. A,lways.connect any disconnected connectors before going on the next step.

2 YES Is therecontinuity YES between PO1 1 (female) (12) and chassis normal?

between X05

* Disconnect Po1

Disconnect X=. -Turn swing lock switch ON.

M-7

~~~

Cause

Remedy

Defective monitor panel

Replace

Defective contact or disconnection in wiring harness between PO1 (female) (12) - H03 (9)HOZ (10) XOS (female) (1). or XOS (female) (2) H02 (5) - chassis ground

Repair or replace

Defective swing lock switch

Replace

Related eleccl- kat circuit diagram

20-456

PC200-6Z

I I

TROUBLESHOOTING

M-8, M-9

M-8 Engine oil pressure caution lamp lights up when engine is running

* *

(engine oil pressure is normal)

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

Remedy

CaUSe

YES

l t

Defective engine oil pressure sensor switch

Replace

Defective monitor p a n e l

Replace

Contact of chassis wiring harness with wiring harness between PO1 Ifemale) (9) H03 (10) E08 (mala) (8)

Repair or replace

Does engine oil

pressure caution

PO1 Ifemale) (9)

T~~~startingNO switch OFF.

terminal or E08. Start engine.

Check continuity between Wl (female) (9) and chassis ground. Min. 1 Mn

M-8 Related electric circuit diagram I

Wonitor P a n e l

POI (04016) I

Engine oil Pressure

Engine o i l Dressure s n i t c h

(SI6 w h i t e)

@ @

H03

TKP01014

M-9 Charge caution lamp lights up when engine is running

* *

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

YES

Is voltage YES between Po1 3 YES (female) (10) and Is rninance (3)(4) normal7 1 between alternator ~- Stan engine. terminal L (wiring Is Mkage &tween .20 - 30 v NO harness end), akernator terminal normal? L and chassis NO *Disconnect ground normal? alternator terminal Stan engine. 1 and Pol. -20-30V Min. 1 MR

charotnorate

Contact of chassis ground with wiring harness between PO1 (female)(10) H03 (7) - E08 (2) alternator terminal L

Repair or replace

Replace

Alternator

H03 (SI6 w h i t e )

Replace

Defective contact or disconnection in wiring harness between P O 1 (female) (10) H03 (7) E08 (2) -alternator terminal L Defective generation of electricity by alternator

M-9 Related electric circuit diagram PO I (04016)

Defective monitor panel

Mon i t o r Dane1

E 0 8 1( X) 9

TKPOIOIS

PC200-6Z

20-457

TROUBLESHOOTING

M-10

M-10 Abnormality in coolant temperature gauge f f

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

a) After engine is started, level stays at bottom (whiterange) and does not move Remedy ~~

YES

Defective coolant temperature sensor

1 1

pEGzGq one at a time and

Turn starting switch ON. Connect short connector to PO7 (female).

v 2 YES

one at a time and

N 6 findball

segments go out? ,.T ,, &aina switch ON. Short circuit P O 1 (6)and (3)(4).

Replace

Defective contactor disconnection in wiring harness betweenPO1 (female) ( 6 ) H03 (5) E08 (6) PO7 (female) (11, or between PO7 (female) (2) -chassis ground

Repair or replace

Defective monitor panel

Replace

Defective monitor panel

Replace

- -

b) After engine is started, level immediately rises Engine is not overheating but indicator enters red range 2 YES

k resistance

YES between m7

1 r (male) (1) and (2) I normal? J Defective coolant Replace

between P O 1

Start engine. Max. 0.1. V

-DisconnectPO7.

temperature sensor

cl Coolant temperature

gauge goes out

YES

light up?

Is resistance between PO1

Turn starting * Remove PO7

2 YES

(3)(4) normal?

Disconnect Pol. Resistance: Min. 1 lrll

M-10 Relatedelectricalcircuit Won i t o r p a n e l

PO 1 (0401 6)

Defective contact between PO1 (female) (3N4)- H03 (11) -chassis ground

After inspection, repair

Defective coolant temperature sensor

Replace

Defective monitor panel

Replace

Contact chassisground with wiringharness between P O 1 (female) (6) - H03 ( 5 ) E08 (6)- PO7 (female) (1). or leak

Repair or replace

diagram H03 (Sl6whi t e )

PO7 (X21

Enoine water t e m p e r a t u r e sensor

TKPOlOlB

20-458

f'C200-6Z

TROUBLESHOOTING

M-11

M-11 Abnormality in fuel gauge

* *

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

a) all fuel gauge segments go out

YES

Does fuel gauge give FULL display (all segments lighted up)? Turn starting switch ON. Connect PO6 (female) -Turn to chassis ground. Wait for approx. 1 minute.

Cause

2 YES

Defective fuel level sensor (failure in disconnection mode)

Replace

Defeaive contact or disconnection in wiring harness between PO1 (female) (7) H06 (6) -PO6 (female) (1)

Repair or replace

Defective monitor panel

Replace

Defective monitor panel

Replace

Contact chassisground with wiringharness between PO1 (female) (7) H06 ( 6 ) PO6 (female) (1)

Repair or replace

Defective fuel level sensor

Replace

Defective contactor disconnection in wiring harness between PO1 (female) (3)(4) H03 (11) -chassis ground

After inspection, repair

Defective monitor panel

Replace

Defective contactor disconnection in wiring harness between PO1 (female) (3)(4) H03 (11) -chassis ground

After inspection, repair

Defective fuel level sensor

Replace

Does fuel gauge give FULL display NO (all segments lighted up? starting NO

w&.h ON

Remedy

Short circuit PO1 (7) and (3). -Wait forapprox. 1 minute.

b) Even when fuel level goes down, fuel gauge continues to show FUL

- - Turn starting

YES fuel Is resistance of level sensor 1 Is voltage between PO1 (3)(4) and chassis !ground normal? ~

Start engine. * Max. 0.1 V

normal?

switch ON. Removesensor Wait for approx.1 minute. Movsfloatby NO hand and measure resistance betweenPO6 (male) and chassis ground. * F position : Max. approx. 12 R E position :Approx. 85 110 R

- :.

c ) Even when tank is filled, fuel gauge does not show FULL

1 Is resistance of fuel level sensor normal?

Measure resistance between PO6 (male) -chassis ground F position :Max. approx. 12 n

PC200-6Z

YES

2 YES Is voltage between PO1 (3)(4) and chassis ground normal? Start engine. Max. 0.1 V

20-459

-I

-l

I 5

TROUBLESHOOTING

M-12

M-12 Defective operation of alarm buzzer f f

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

a) Buzzer does not sound CaUSe

Does buzzer sound when PO1 (female) (15) and (3)are connected?

- -

Connect PO1 (female) (15) and (3). Turn starting switch ON.

YES

-.~6

between PO4 (2) and chassis ground normal? Turn starting switch ON. .20-3Ov

2 YES

Remedy

Defective monitor panel

Replace

Defective contact or disconneuion in wiring harnessbetween PO4 (female) (1) and P O 1 (female) (15). or defective buzzer

Repair or replace

Defective contact or disconnection in wiring harness between !use 2 and W4 (female) (2)

Repair or replace

b) Buzzer continues ?o sound and does not stop

M-12

Relatedelectricalcircuitdiagram

BDP0027 I

PC200-6Z

20-461

TROUBLESHOOTING

M-13

M-13 Engine is running,. but service meter does not move f Before carrying out troubleshooting, check that all the related connectors are properly inserted.

* Always connect any disconnectedconnectors before going on the next step. a) Charge caution lamp lights up

Remedy

Cause

YES

2 1

Defective monitor panel

Replace

Defective contactor disconnection in wiring harness betweenPol (10) H03 (7) E08 (2) alternator terminal L

Repair or replace

Start engine. -20-30v

terminal L and W1. Min. 1 MSI

Contact of chassis ground with wiring harness betweenP O 1 (female) (10) H03 (7) E08 (2) alternator terminal L Defective generationof electricity by alternator

Repair or replace

Replace

b) Charge caution lamp does not light up Cause

Defective monitor Dane1

M-13Related electrical circuit diagram

Replace

Alternator

20-462

PC200-6Z

TROUBLESHOOTlNG

M-14

M-14 Night lighting does not light up

* *

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

a) Gauge lighting does not light up

Bulb of night lifhting (inside monitor panel) blown Defective contact or disconnection in wiring harness between PO1 (female) (16) and PO2 (female) (3)

,YES

-Turn starting ON.

-20-3ov

between PO2 (3)

Is voltage Turn starting between PO2 (4) switch ON. N aand I:hassis Turn light switch-'-lground normal? ON.

-.u.

-20-30V

Replace

Repair or replace

Defective light switch

Replace

Disconnection in wiring harness between PO2 (female) (4) and fuse 4, or blown fuse

Repair or replace

b) Service meter lighting does not light up (service meter is working normally) Cause

Remedy

Defective monitor panel

Replace

M-14 Related electrical circuitdiagram

Monitor panel

PO 1

(04016)

PO2 (KES1, 4 ) To w o r k i n g

lam0

Lam0 s w i t c h

H03 ( S 1 6) Fuse BDP00272

f'C200-6Z

20-463

k' a

***

â&#x20AC;&#x2122;D

i i

TROUBLESHOOTING

M-16

M-I6 Heater does not work

* *

Before carrying out troubleshooting, check that allthe related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.

Remedy

a) Does not work at either Hi or Lo 2 YES

Go to troubleshooting of

I IS there continuity I I

heater

betmtntcnninals of M06 (male) as lshown in Table 17

Turn starting switch OFF.

Disconned M06.

*Turn starting switch OFF.

Defective contactor disconnection in wiring harness between M06 ffemale) (4)and chassis ground

Repair or replace

Defective heaterswitch

Replace

I ' NO

Table 1 Switch position Continuous terminal Lo Between (3) (4) Hi Be-n (2) (4)

Cause

b) Does not work at Lo only

Go to troubleshooting of heater

(female) (2) and chassis ground?

between M06

Disconnect M12. NO

-Turn NO switch OFF. Heater switch at Lo.

c) Does not work at Hi only

2 YES Is there continuity YES between M12

betmen M06 (male) 17'

[

(female)(3)and chassis ground?

Disconnect M06. Turn startina NO switch OFF* Heater switch at Si.

M-15 switch

Disconnect MIZ.

Defective contactor disconnection in wiring harness between M06 (female) (3) and M12 (female) (2)

Repair or replace

Defective heaterswitch

Replace

Go to troubleshooting of heater

Remedy

Defective contact or disconnection in wiring harness between M06 (female) (2) and M12 (female) (3)

Repair or replace

Defective heaterswitch

Replace

Heater switch at Hi.

Related electrical circuitdiagram Heater

H06 (KES14)

Heater H i H e a l e r Lo

1 Fuse

M l 2 (KES13)

Heater

H05 (L2)

BKP02453

20-466

PC200-6Z

30 DISASSEMBLY AND ASSEMBLY

. .

...................

METHOD OF USING MANUAL 30- 3 PRECAUTIONS WHEN CARRYING OUT OPERATION ............................................ 30- 4 SPECIAL TOOL LIST 30- 6 SKETCHES OF SPECIAL TOOLS ............... 30-10 STARTING MOTOR ASSEMBLY 30-11 Removal and Installation .................... ALTERNATOR ASSEMBLY 30-12 Removal and Installation .................... AIR CONDITIONER COMPRESSOR ASSEMBLY 30-13 Removal and Installation .................... CONDENSER ASSEMBLY Removal and Installation .................... 30-14 ENGINE OIL COOLER CORE ASSEMBLY 30-15 Removal and Installation .................... FUEL INJECTION PUMP ASSEMBLY Removal ................................................. 30-16 Installation ............................................ 30-19 WATER PUMP ASSEMBLY Removal and Installation .................... 30-21 NOZZLE HOLDER ASSEMBLY Removal and Installation .................... 30-23 TURBOCHARGER ASSEMBLY Removal and Installation .................... 30-24 THERMOSTAT ASSEMBLY Removal and Installation .................... 30-25 CYLINDER HEAD ASSEMBLY Removal ................................................. 30-27 Installation ............................................ 30-31 RADIATOR HYDRAULIC OIL COOLER ASSEMBLY 30-34 Removal ................................................. Installation ............................................ 30-36 ENGINE MAIN PUMP ASSEMBLY Removal ................................................. 30-37 Installation ............................................ 30-41 DAMPER ASSEMBLY Removal and Installation .................... 30-42 FUEL TANK ASSEMBLY Removal and Installation .................... 30-43

....................................

PC200-6Z

CENTER SWIVEL JOINT ASSEMBLY 30-44 Removal and Instaltation Disassembly and Assembly 30-46 FINAL DRIVE ASSEMBLY 30-47 Removal and Installation Disassembly 30-48 Assembly 30-51 SPROCKET Removal and Installation 30-56 SWING MOTOR. SWING MACHINERY ASSEMBLY 30-57 Removal and Installation Disassembly 30-59 Assembly 30-63 REVOLVING FRAME ASSEMBLY Removal 30-68 Installation 30-69 SWING CIRCLE ASSEMBLY Removal .................................................. 30-70 Installation 30-71 IDLER RECOIL SPRING ASSEMBLY Removal and Installation...................... 30-72 RECOIL SPRING ASSEMBLY Disassembly ........................................... 30-73 Assembly ................................................30-74 IDLER ASSEMBLY Disassembly ........................................... 30-75 Assembly ................................................ 30-76 TRACK ROLLER ASSEMBLY Removal and Installation...................... 30-78 Disassembly ........................................... 30-79 Assembly ................................................ 30-81 CARRIER ROLLER ASSEMBLY Removal and Installation...................... 30-83 Disassembly ........................................... 30-84 Assembly ................................................ 30-86 TRACK SHOE ASSEMBLY Removal and Installation...................... 30-88

.......... ................ .......... ........................................... ................................................ ...........

30-1

HYDRAULIC TANK ASSEMBLY Removal 30- 89 Installation 30- 90 MAIN PUMP ASSEMBLY Removal 30- 91 Installation 93 30MAIN PUMP INPUT SHAFT OIL SEAL Removal and Installation 30- 94 CONTROL VALVE ASSEMBLY Removal 30- 95 Installation 30- 97 Disassembly 30- 98 Assembly 30-103 MAIN RELIEF VALVE ASSEMBLY Disassembly and Assembty 30-109 PC VALVE ASSEMBLY Removal and Installation 30-110 LS VALVE ASSEMBLY Removal and Installation 30-172 PC-EPC VALVE ASSEMBLY Removal and Installation 30-1 13 SOLENOID VALVE ASSEMBLY Removal and Installation 30-114 WORK EQUIPMENT SWING PPC VALVE ASSEMBLY Removal and Installation 30-1 15 Disassembly 30-116 Assembly 17 30-1 TRAVEL PPC VALVE ASSEMBLY Removal and Installation 30-118 Disassembly and Assembly 30-119 BOOM LOCK VALVE ASSEMBLY Removal and Installation .......... 30-121

................................................

................

.......... .......... .......... ..........

.......... ......................................... .............................................. .......... ................

BOOM CYLINDER ASSEMBLY Removal ................................................ Installation ARM CYLINDER ASSEMBLY Removal Installation BUCKET CYLINDER ASSEMBLY Removal Installation HYDRAULIC CYLINDER ASSEMBLY Disassembly Assembly WORK EQUIPMENT ASSEMBLY Removal Installation BUCKET ASSEMBLY Removal Installation ARM ASSEMBLY Removal Installation BUCKET ARM ASSEMBLY Removal Installation BOOM ASSEMBLY Removal ................................................ Installation 44 OPERATOR'S CAB ASSEMBLY Removal and Installation COUNTERWEIGHT ASSEMBLY Removal and Installation MONITOR ASSEMBLY Removal and Installation

............................................ ................................................ ............................................ ................................................ ............................................ ....................................... .............................................. ................................................ ............................................ ................................................ ............................................ ................................................ ............................................ ................................................ ............................................ ............................................ .......... .......... ..........

30-122 30-123 30-124 30-125 30-126 30-127 30-128 30-131 30-135 30-136 30-137 30-138 30-139 30-1 40 30-1 41 30-142 30-143 30-1 30-145 30-146 30-147

PC200-6Z

I I

DISASSEMBLY AND ASSEMBLY

METHOD OF USING MANUAL

METHOD OF USING MANUAL 1. When removing or installing unit assemblies @ When removing or installing a unit assembly, the order of work andtechniques used are given for the removaloperation; the order of work for the installation operation is notgiven. @ Any special techniques applying only to the installation procedure are marked and the same mark is placed after the relevant step in the removal procedure t o indicate which step in the installation procedure it applies to.

(Example) REMOVAL OF 0000ASSEMBLY

............Title of operation Precautions related to safety when carrying out A ....................................................................... the operation

1. X X X X ( 1 ) ..................................................... 2.

................................................................... removing A A A A (2): ...............................................

00 00 assembly (3)

Stepinoperation Technique or important point to remember when XXXX (1). Indicates that a techniqueislisted for use during installation

............................................................ Quantity of oil or water drained INSTALLATION OF 0003 ASSEMBLY ....Title of operation Carry out installation in the reverse order to removal. .............................................................. Technique used during installation f ................................................................... Technique or important point toremember when installing A A A A (2). Adding water, oil ................................. Step in operation * ............................................................ Point to remember when adding water or oil @......................................................... Quantity when filling with oil and water

General precautions when carrying out installation or removal (disassembly or assembly) of units are given together as PRECAUTIONS WHEN CARRYING OUT OPERATION, so be sure to follow these precautions when carrying outthe operation.

3. Listing of special tools @ For details of the description, part number, and quantity of any .tools(AI, etc.) thdt agpear in the operation procedure, see the SPECIAL TOOLS LIST given in this manual.

PC200-6Z

30-3

WHEN CARRYING OUT OPERATION

PRECAUTIONS DISASSEMBLY AND ASSEMBLY

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 excessiveforce from being applied to the wiring, always hold theconnectors when disconnecting the connectors. DO not pull the wires. Fit wires and hoses with tags to show their installation position to prevent any mistake when installing. Check the number and thickness of the shims, and keep in a safe place. When raising components, be sure to use lifting equipment of ample strength. When using forcing screws to remove any components, tighten the forcing screws uniformly in turn. Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering after removal. Precautions when handling piping during disassembly Fit the following blind plugs into the piping after disconnecting it during disassembly operations. 1) Hoses and tubes using sleeve nuts

.. .

Nominal number

Plug (nut end)

02 03 04 05 06 10 12

07376-50210 07376-50315 07376-50422 07376-50522 07376-50628 07376-51034 07376-51234

Sleeve nut (elbow end) Use the two items below as a set 07221-20210 (Nut), 07222-00210 (Plug) 07221-20315 (Nut), 07222-00312 (Plug) 07221-20422 (Nut), 07222-00414 (Plug) 07221-20522 (Nut), 07222-00515 (Plug) 07221-20628 (Nut), 07222-00616 (Plug) 07221-21034 (Nut), 07222-01018 (Plug) 07221-21234 (Nut), 07222-01219 (Plug)

2) Split flange type hoses and tubes Nominal number

Split flange

Sleeve head (tube end)

Flange (hose end)

0737 1-30400 07378-10400 0737907371-30500 07378-10500 07379-00

04 05

3) If the part is not under hydraulic pressure, the following corks can be used. Nominal number 06 08 10 12 14 16 18 20 22 24 27

30-4

Part Number

Dimensions D l d I L 8 5 6 11 6.5 8 8.5 10 12 10 12 15 14 11.5 18 16 13.5 20 15 18 22 20 17 25 22 18.5 28 30 20 24 27 22.5 34 ~~

07049-00608 07049-0081 1 07049-01012 07049-01215 07049-01418 07049-01620 07049-01822 07049-02025 07049-02228 07049-02430 07049-02734

Taper 1/8

DEW401

f'C200-6Z

DISASSEMBLY AND ASSEMBLY PRECAUTIONS

WHEN CARRYING OUT OPERATION

2. Precautionswhen carrying out installation work

Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque. Install the hoses without twisting or interference. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts. Bend the cotter pins and lock plates securely. When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2 - 3 drops of adhesive. grease, check that there When coatingwith gasket sealant, clean the surface and remove all oil and is no dirt or damage, then coat uniformly with gasket sealant. Clean all parts, and correct any damage, dents, burrs, or rust. Coat rotating parts and sliding parts with engine oil. When press fitting parts, coat the surface with anti-friction compound (LM-P). After fitting snap rings, check that the snap ring is fitted securely in the ring groove. When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect securely. When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align the direction of the hook. When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side. When operating the hydraulic cylinders for the first time afterreassembling cylinders, pumps and other hydraulic equipment removed for repair, always bleed the air as follows: 1. Stan the engine and run a t low idling. 2. Operate thework equipmentcontrol lever to operate the hydrauliccylinder 4 - 5 times, stopping the cylinder 100 mm from the end of its stroke. 3. Next, operate the hydraulic cylinder 3 - 4 times t o the end of its stroke. 4. After doing this, run the engine at normal speed. Whenusingthe machine for thefirsttimeafterrepair or long storage, followthe same procedure.

3. Precautions when completing the operation

If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run the engine tocirculate the water through the system. Then check the water level again. If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. If the piping or hydraulic equipment have been removed, always bleed the air from the system after reassembling the parts. For details, seeTESTINGANDADJUSTING, Bleeding air. Add thespecified amount of grease (molybdenum disulphidegrease) to the work equipment parts.

PC200-6Z

30-5

LIST

DISASSEMBLY TOOL SPECIAL AND ASSEMBLY

SPECIAL TOOL LIST

* * * * * * *

Tools with part number790T-0000000cannot be supplied (they are items t o be locally manufactured). Necessity:

H: Cannot be substituted, shouldalwaysbeinstalled (used) 0: Extremely useful if available, can be substituted with commercially available part New/remodel:N: Tools with new part numbers, newly developed for this model. R: Tools with upgraded part numbers, remodeled from items already available for other models. Blank Tools already available for other models, used without any modification. Tools marked 0in the Sketch column are tools introducedin special sketches (See SKETCHES OF

SPECIAL TOOLS).

Symbol

Component Removal, installation of cylinder assembly Removal, insrallation of fuel injection pump assembly

Pan.No.

Part Name

790-331-1 110 Wrench

;ketchl

Nature of work, remarks

Tightening of cylinder head bolt Barring Removal of drive lgear

Removal, installation of nozzle holder assembly Engine, main pump assembly Radiator, hydraulic cooler assembly Control. pump assembly Main pump assembly', Removal, installation of. secvo valve assembly

796-460-1210

Oil stopper

-790-101-2520 -Screw ,791-112-1180 -Nut

Disassembly of center swivel joint assembly

,790-101-2540 .Washer ,790-101-2630 -Leg ,790-101-2570 -Plate 790-101-2560 -Nut

Disassembly,

as-:.r.mbly of swing m : . :cinery

! -

790-101-2650 (-Adapter

796-426-1120

Push tool

Press fitting of bearing

PC200-6Z

DISASSEMBLY SPECIAL AND ASSEMBLY

TOOL LIST

Component

Part No.

Symbol

Part Name

Wrench

796-427-1200

I I

NeCeSsiw Q'ty IreNmeoWd/ellSketch( Nature Of work* remarks Removal, installam 1 tion of round nut

796T-427-1221 Push tool

Block

790-101-2510

792-104-3940 ~~~

05180-11613

Disassembly, assembly of final drive assembly

01643-31645

Washer

01643-32060

Washer

790-105-2100

Jack

790-101-1 102 Pump

790-331-1110 Wrench

791-545-1510 Installer 791-600-2001

Compressor (A)

or 791-6858005

791-635-3160

Removal, installation of recoil spring assembty

Compressor (B)

w m

Extension

790-101-1600

Cylinder(b%.NOUtonl)

790-101-1102

Pump

Removal, installation of track shoe

Removal, installation of road liner (rubber pad w e )

1 1

-790-101-5021 -Grip

-01010-50816 -Bolt

79 1-63O-3OOO Remover & Installer

79C-101-1300 Cylii(980tN~lWtonll

790-101-1102

Pump

09007-01760

Hexagonal wrench

790-434-1630 Installer 790-101-1000

4-z K t

791-601-1000 Oil pump

790-331-1110 3 Tightening

K200-6Z

-790-201-1620 -Plate

790-434-1 640 Installer

Disassembly, assembly of track roller assembly

Commercialyavailablcsocket Hexagonal

Assembly of idler assembly

Wrench

Tightening of final drive cover mounting bolt Installation of floating seal

Removal, press fitting of master pin

790-201-1500 Push tool kit 2

Press fitting of bearing inner race

Removal, press fitting of master pin

1 17 rnm

Widthflats: across

17 mm Installation of floating seal Charging with oil,

111 1 m

Installation of dust seal on recoil spring piston

floating seal with Charging oil, ichecking for air leakage of track roller assembly mounting bolt

30-7

DISASSEMBLY TOOL SPECIAL AND ASSEMBLY

LIST

~~~

Component

Nature of work, remarks

Symbol

~~~

Removal, installation of nut Disassembly, assembly of carrier roller assembly

Press fitting of bearing

Installation of Roatina seal Charging with oil, hecking for air leakage

Installation of track roller

Replacement of pump shaft oil seal

Tightening of track roller bolt

lemoval. installation If piston assembly

3eplacement pin for wrench assembly Expansion of piston .ing

Disassembly, assembly of hydraulic cylinder

- 07281-01159

790-201-1702 Pushkit tool

*790-201-1831 -Push tool

.790-101-5021 .Grip

*01010-50816 .Bolt

790-201-1702 5

Clamp

Pushkit tool

.790-201-1930 .Push tool

~790-101-5021 .Grip

.01010-50816 .Bolt

790-201-1702

Push tool kit

7 Bucket

*790-201-1940 *Push tool

.790-101-5021 -Grip

,01010-50816 *Bolt

PCZOO-6Z

1 .

5.2

'00

-3

. I

Insertion of dust seal

W 0

DISASSEMBLY AND ASSEMBLY

SKETCHES OF SPECIAL TOOLS

SKETCHES OF SPECIAL TOOLS Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. G 2 Push tool

150 CKPO4076

MATERIAL TREATMENT HEAT

0000000000

30-10

PART NAME

PUSH TOOL

796T-427-1220

STKH13A

PC7 0 n - A 7

DISASSEMBLY AND ASSEMBLY

MOTOR

STARTING

REMOVAL OF STARTING MOTOR ASSEMBLY

A Disconnect the cable from the negative minal of the battery.

(-1 ter-

1. Openenginehood. 2. Disconnect 3 wires (1). 3. Remove 2 bolts (2). 4. Remove starting motor assembly (3).

CLPO3201

INSTALLATION OF STARTING MOTOR ASSEMBLY

Carry outinstallation removal.

in thereverseorderto

Starting motor mounting bolt : 43 6 Nm I4.38 2 0.61 kgm} Both faces of starting motor gasket : Gasket sealant (LG-1)

PC200-6Z

30-1 1

AND

DISASSEMBLY

ASSEMBLY

ALTERNATOR

REMOVAL OF ALTERNATOR ASSEMBLY

A Disconnect the cable from the negative (-) minal of the battery.

ter-

1. Open engine hood. 2.

Remove fan guard(1) and rightfan guard mounting bracket (2).

3. Disconnect wiring (3) and connector (41, and remove X-connector (5) from bracket.

CLPO3204

Using wrench@, raise tensioner ( 6 )and remove belt (7). Be extremely careful not to get your fingers caught when removing the belt.

I=1 5.

CLPO3205

Remove alter? ':,r mounting bolts (8) and (9), then remove L ' - rnator assembly (IO).

outin. re:-: val.

Car:

;tion in the reverse order to

PC200-6Z

DISASSEMBLY AND ASSEMBLY

AIR CONDITIONER COMPRESSOR

REMOVAL OF AIR CONDITIONER COMPRESSOR ASSEMBLY

Loosen the flangemountingbolts of theair conditioner hose, and release the refrigerant (R134a) slowly.

1. Open engine hood.

Remove fan guard (1).

3. Disconnectconnector (2). 4.

Disconnecthoses (3).

Loosen adjustment bolt (4) and remove belt (5).

Remove 4 mounting bolts (6).then remove compressor assembly (7).

INSTALLATION OF AIR CONDITIONER COMPRESSOR ASSEMBLY Carry outinstallationinthe removal.

* *

reverse order to

When installing the hoses, check that the 0rings are not damaged or deteriorated, then connect the hoses.

Adjust the belt tension. For details, see TESTING AND ADJUSTING, Testing and adjustingair conditioner belt tension. Fill with refrigerant (R-134a).

PCZOO-6Z

30-13

CONDENSER DISASSEMBLY AND ASSEMBLY

REMOVAL OF CONDENSER ASSEMBLY 1. Open engine hood (1) and side cover (2) at left

side of chassis.

2. Remove cover (3)on top of condenser.

I I

3. Disconnect air conditioner hose (41, thendisconnect hose (5)at receiver drier end and hose (6) at condenser end. Loosenhoses (41, (5) and (6) slightly and release the refrigerant (R-134a) completely before disconnecting hoses. Fit blind plugs into the condenser po'rt and hoses to prevent the entryof moisture, dust o r dirt.

I3803

Remove receiver drier (7) together with bracket.

Remove condenser assembly (8).

INSTALLATION OF CONDENSER ASSEMBLY Carryout removal.

p T J

installation in thereverseorderto

Check that the O-rings are not damaged deteriorated, then connect the hoses.

Fill withrefrigerant

30-1 4

(R-134a).

PC200-6Z

DISASSEMBLY AND ASSEMBLY

ENGINE OIL COOLER CORE

REMOVAL OF ENGINE OIL COOLER CORE ASSEMBLY 1. Open engine hood.

Remove adiabatic cover (1).

Remove turbocharger lubrication hose (2) and oil filter (3).

Disconnect connector (41 with alternator wiring, and remove connector bracket (5) of intermediate clamp.

5. Remove oil cooler cover assembly (6). 6.

Remove cooler core assembly (6).

(7) from oil cooler cover

CLPO3214

INSTALLATION OF ENGINE OIL COOLER CORE ASSEMBLY Carry outinstallationin removal.

the reverse orderto

w f

Sleeve nut (2) of turbocharger lubrication hose : 24 4 Nm {2.45 f 0.41 kgm} Oil filter (3): 13 2 Nm I1.33 0.20 kgm} Or bring the seal surface into contact, then tighten 314 turns.

I d â&#x20AC;&#x2122;

CLPO3228

Tighten in the order (1) - (14) as shown in the diagram. Mounting bolt (6)of oil cooler cover assembly : 24 = 4 lilm i2.45 = 0.41 kgm}

CLPO3715

PC200-6Z

30- 15

DISASSEMBLY AND ASSEMBLY

INJECTION FUEL

PUMP

REMOVAL OF FUEL INJECTION PUMP ASSEMBLY

A Disconnect the cable from, the negative (-1 minal of the battery.

ter-

1. Open engine hood.

k m o v e cover (1) on top of condenser, then remove stay (2) at counterweight.

3. Remove fan guard (3) and left bracket (4). 4.

Disconnect water temperature sensor connector (5).

Remove bracket (6)for compressor hose clamp. Tightentogether with thefuelinlet hose clamp.

7 . Disconnect governor motor rod ( 9 ) at governor

end. Ir Rotate the shaft of the governor motor and do not stop it suddenly. Always disconnect the guide motor connector before disconnecting the rod.

6. :'isconnect 6 deik ?-i tubes (10).

c ~

.,.- x. n n e c t fue! :.. -I.

-gel will li,: ..onnected, mes to p:

r $y hose (11) and returnhose when the hoses are diswooden plugs in the -:Ithe fuel from leaking.

:'3t

.nsert

CLPO3119

DISASSEMBLY AND ASSEMBLY

FUEL INJECTION PUMP

10. Disconnect tube clamp (15) (4 places) and tubes (13)and (14) between fuel filter and fuel injection pump.

11. Remove lubrication tube (16).

12. Remove mounting bolt (17) of support bracket at bottom of fuel injection pump.

13. Usingtool A 2 , rotateengine innormal direction, and push No. 1 cylinder compression top dead center positioning pin (18)into gear. f Push thepinlightly againstthegearand rotate the engine slowly. f After determining the TDC position, check if the meshing of the timing pinhas come out.

14. Remove 2 fan belts (19). then move fan tension pulley (20) and adjustment bar (21) towards fan shaft. f Loosen mounting bolt (23)of adjustment bolt bottom bracket.(22), then loosen adjustment bolt (24). 15. Turn cap (25)and remove.

CLP03226

16. Remove washer (27) and nut (26)inside case.

Be extremely careful not to dropthe nut and washer inside the case when removing.

PC200-6Z

30- 1 7

DISASSEMBLY FUEL AND ASSEMBLY

INJECTION PUMP

INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY Carry out installation in the reverse order to removal.

Adjust the governor lever. For details, see TESTING AND ADJUSTING, Adjusting governor motor lever stroke. Delivery tube sleeve nut (10) : 24 t 4 Nm 12.45 t 0.41 kgm}

Adjust the belt tension. For details, see TESTING AND ADJUSTING, Testing and adjusting fan belt tension. Drive nut (26) : 95 10 Nrn I9.7 t 1.01 kgrn}

Installthefuel injection pump assembly as follows. 1) Check that the No. 1 cylinder is at compression top dead center. For details, see RemovalStep13.

2) Remove plug (30), then remove timing pin (311.

3) Reverse the position of timing pin (31). align the timing pin groove with pointer (32)inside the pump, then temporarily tighten plug (30). If the toothof pointer (32) cannot be aligned with the timing pin hole, rotate the shaft of the fuel injection pump to align the pointer tooth.

CLPO3232

PC200-6Z

CLP03733

30-1 9

DISASSEMBLY INJECTION FUEL AND ASSEMBLY

PUMP

4) Align pump camshaft with pump drive gear

and install fuel injection pump assembly(29). then tighten nut (28). Nut (28) : 43 f: 6 Nrn 14.38 t 0.61 kgrn)

CLP03230

5) Assemble washer (271, and tighten nut (26) temporarily. Be extremely careful not to drop the nut and wash.er inside the casewhen installing. Temporary tightening of nut (26) : 12.5 t 2.5 Nm (1.27f: 0.25 kgm} This is not the final torque value. To prevent damage to the timing pin, be careful not to tighten the nut to more than the above tightening torque.

6) Remove meshing of engine timing pin (18).

I '

CLP03235

7) Remove plug (301, reverse position of timing pin (311, then assemble and install plug to fuel injection pump. Plug : 14.7 Nrn 11.5 kgrnl

8) Tighten nut (26) of fuel injection pump fully. Nut (26) : 95 t 10 Nm I9.7 t 1.01 kgm) 9) For remaining installation,carry out in reverse order to removal.

Bleeding air Bleed the air from fuel system.

30-20

CLPO3236

DP?fUlX7

AND

DISASSEMBLY

WATER PUMP

ASSEMBLY

REMOVAL OF WATER PUMP ASSEMBLY 1. Drain coolant.

Open engine hood.

3. Remove f a n guard (11, then remove left and right side covers (2) and (3)of fan guard mount.

Using wrench 0, raise tensioner (41, then remove belt (5). Be extremely careful not toget your fingers caught when removing the belt.

Loosen adjustment bar (7) of fan tension pulley

(6).then loosen fan belt ( 8 ) .

\ 6.

CLPO3240

Loosen mounting bolt (11) of fan pulley (10) and fan shaft (9) 2 - 3 mm, then move towards radiator.

PC200-6Z

30-2 1

, DISASSEMBLY AND ASSEMBLY

WATER PUMP

7. Remove water pump assembly (12).

INSTALLATION OF WATER PUMP ASSEMBLY Carry out installation in the reverse order to removal.

Adjust the belt tension. For details, see TESTING AND ADJUSTING, Testing and adjusting of fan belt tension.

Refilling with water Add water through the water filler to the specified level. Run the engine to circulate the water through the system. Then check the water level again.

30-22

DISASSEMBLY AND ASSEMBLY

NOZZLE HOLDER

REMOVAL OF NOZZLE HOLDER ASSEMBLY 1. Openengine hood. 2. Disconnect delivery tube (1) a t nozzle holder assembly end.

3. Remove spill tube (2). 4.

Remove nozzle holder assembly (3). If it is difficult to remove the nozzle holder assembly, use tool A4 to remove it. Be careful not to let dirt or dust get into the nozzle holder assembly mount.

* *

INSTALLATION OF NOZZLE HOLDER ASSEMBLY

CLPO3243

Carry out installation in the reverse orderto removal. CLP03244

Delivery tube sleeve nut : 30 2 5 Nm 13.06 2 0.51 kgm} Joint bolt :8

2 Nm I0.81

0.20 kgm}

Nozzle holder assembly : 60 t. 5 Nm I6.12 2 0.51 kgm} Nozzle holder assembly thread portion : Seizure prevention compound (Molycoat 1000) When assembling the nozzle holder, clean the nozzle holder mount, and checkthat there is no dirt or dust inside the sleeve before assembling.

PC200-6Z

30-23

DISASSEMBLY AND ASSEMBLY

TURBOCHARGER

REMOVAL OF TURBOCHARGER ASSEMBLY 1. Open engine hood, and remove adiabatic cover (1) of turbocharger assembly. 2.

Remove air cleaner intake connector (2) and air supplytube (3) between turbocharger and aftercooler.

3. Remove connector clamp (4). 4.

Removelubrication inlet tube (5) andlubrication return tube (61, then remove turbocharger assembly (7). Afterremovingthelubrication tube,close all the ports to prevent the entry of mud or dirt.

CL603245

CLPO3246

INSTALLATION OF TURBOCHARGER ASSEMBLY Carryoutinstallation removal.

in thereverseorder

Intake tube bandclip : 10 t: 2

11.02 t: 0.21 kgml

Lubrication inlet tube sleeve nut : 35 t: 5 Nm I3.6 t 0.5 kgml Lubrication return tube mountingbolt : 24 t: 4 Nm (2.45

t: 0.41

kgm}

Turbocharger assembly mounting nut :

I O 2 2 Nm 11.02 t: 0.20 kgm}

30-24

vr3nn-x7

THERMOSTAT DISASSEMBLY

ASSEMBLY

REMOVAL OF THERMOSTAT ASSEMBLY

Drain coolant.

Open engine hood, and remove fan guard (1) and right side guard mounting bracket (2).

3. Using wrench 0, raise tensioner (31,then re-

A Be extremely careful notto get your fingers move fan belt (4).

caught when removing the belt.

Remove .alternator assembly top mounting bolt (5) from bracket, then move alternator assembly ( 6 )towards partition plate end. Loosen the mounting bolts at the bottom of the alternator assembly.

I 5.

Disconnect radiator inlet hose (7)and aeration hose ( 8 ) .

Remove alternator bracket (9).

CLPO3250

^. 51

PC200-6Z

30-25

, THERMOSTAT DISASSEMBLY AND ASSEMBLY

Remove thermostat housing (10).

8. Remove thermostat (11).

CLP03253

INSTALLATION OF THERMOSTAT ASSEMBLY Carry out installation in the reverse order to removal. Thermostat housing mounting bolt : 24 t 4 Nm (2.45 2 0.41 kgm} Refilling with water Add water through the waterfiller to the specified level. Run the engine t o circulate thewater through the system. Then check the water level again.

30-26

pc3m-x7

DISASSEMBLY AND ASSEMBLY

HEAD

CYLINDER

REMOVAL OF CYLINDER HEAD ASSEMBLY

A Disconnect the cable from the negative (-1 minal of the battery.

ter-

1. Drain coolant.

2. Open engine hood. 3. Remove fan guard(1). then remove left and right side covers (2) and (3)of fan guard mount.

Remove turbocharger assembly. For details, see REMOVAL OF TURBOCHARGER ASSEMBLY.

5. Remove exhaust manifold cover (4).

Remove adiabatic plate mountingbracket (5) for turbocharger. In order t o remove mounting bolt (61, do as follows. 1) Remove muffler drain pipe. (main pump end) 2) Loosen muffler mounting U-bolt. Rotate connector (7) at the muffler end up slightly to a position where it is possible to remove the mounting bolts.

exhaust manifold 7. Remove

(8).

Disconnect electrical intake air heater wiring (91, water temperature sensor connector (101, and compressor connector (1 ).1

Remove mounting bracket (12) of intermediate at clampforwiring andairconditionerhose engine end.

10. Remove air conditioner belt (131, then remove compressor assembly(14) together with bracket, and move towards countenweight. 11. Remove mounting plate (16) and clamp (15) of

dipstick guide.

PC200-6Z

CLPO3258

30-27

DISASSEMBLY CYLINDER AND ASSEMBLY

HEAD

17. Remove intake connector (28).

18. Remove 6 deliverytubes (29).

19. Disconnect tubes (30) and (31) between fuel filter and fuel injection pump, then disconnect fuel return hose (32) at fuel filter end. EpJ 20. Remove fuel filter assembly (33) together with bracket.

CLPO3264

21. Remove intermediate clamps (34) (3 places) of fuelreturn hose (32). then removespilltube

(35).

22. Remove nozzle holder assembly (36).

23. Remove head cover (37).

PC200-6Z

30-29

HEAD DISASSEMBLY CYLINDER AND ASSEMBLY

24. Remove rocker arm assembly (38).

25 Remove pushrod (39).

26. Remove mabunting bolts of cylinder head in order shown in diagram. E3

CE100394

27. Lift off cylinder head assembly (40).

&I Cylinderheadassembly: 52 kg 28. Remove cylinder head gasket

(41).

f0 1x141

30-30

CLPO3269

PC200-6Z

HEAD DISASSEMBLY CYLINDER AND ASSEMBLY

INSTALLATION OF CYLINDER HEAD ASSEMBLY Carry out installation in thereverse removal.

orderto

Muffler mounting U-bolt : 12 t 2.5 Nm 1122 t 0.26 kgm)

Tighten the mounting bolts in the order @ @ shown in the diagram on the right. Exhaust manifold mounting bolt : 43 t 6 Nm 14.38 t 0.61 kgm}

CDW00396

Adjust the belt tension. For details, see TESTING AND ADJUSTING, belt tenTesting and adjusting air conditioner sion.

Pulley hub mounting bolt : 33 t 5 Nrn 13.37 t 0.51 kgm} Tensioner bracket mounting bolt : 24 2 4 Nm 12.45 t 0.41 kgm} Exhaust hose clamp : 10 2 Nm 11.02 t 0.20 kgm}

Sleeve nut at injection pump end : 24 t 4 Nm 4.45 t 0.41 kgm} Sleeve nut at nozzle holder end : 30 t 5 Nm 9.06 t 0.51 kgm}

Fuel tube joint bolt (301,(31) : 24 2 4 Nm 12.45 2 0.41 kgml Fuel hose joint bolt (32): . 30 2 5 Nm 13.06 2 0.51 kgm}

PC200-6Z

30-31

AND

DISASSEMBLY

p J

CYLINDER HEAD

Spill tube joint bolt: 8 t 2 Nm 10.81 t 020 kgml Nozzle holder assembly : 60 t 9 Nm 16.12 t 0.92 kgm} Head cover mounting bolt : 24 t 4 Nm 4.45 t 0.41 kgml

rn E

Install the rocker arm assembly and cylinder head assembly as follows. Check that there is no dirt or dust on the cylinder mount surface or inside the cylinder. 1) Setcylinder head gasket (41) t o cylinder block. Check that the gasket is aligned correctly with the holes in the block.

2) Raise cylinder head assembly (40) and set to cylinder block.

CLPO3269

3) Assemblepush rod (39). Add engine oil (15W-40) to the push

rod socket portion.

4) Fit rocker arm assembly (381,and tighten mounting bolts by hand. .k Check that the ball portion of the adjustment screw is fitted securely in thesocket portion of the push rod. 6 Put engine oil (15W-401 on the seat surface and thread of the 8 m m and 12 rnm diameter mounting bolts.

30-32

PC200-6Z

HEAD

DISASSEMBLY CYLINDER AND ASSEMBLY

5) Tighten cylinder head mounting bolts in order shown in diagram. 6 Put engine oil (15W-40) on the seat surface and thread of the mounting bolts. Cylinder head mounting bolt : 1st step: Tighten in order @ - @ to 90 t 5 Nm (9.18 t 0.51 kgml. 2nd step: Tighten in order 0,@, @, @, 0,@ to 120 t 5 Nm I12.24 t 0.51 kgm). 3rd step: i) When using tool A1 Using angle tightening wrench (tool A l l , tighten bolts a further SO" in order @ - @. iil When not using tool A1 Makematch marks with a felt pen on bolt andhead, then tighten bolt a further 90".

7) Adjustvalve clearance. For details, see TESTING AND ADJUSTING, Adjusting valve clearance.

Refilling with water Refill to the specifiedlevel,and run the engine to circulate the waterthrough the system. Then check the water level again.

f'C200-6Z

I 6 ) Tighten rocker arm assembly mounting bolts (diameter: 8 mm). Rocker a r m mounting bolt : 24 z 4 Nm 4.25 0.41 kgm)

CEW00394

CLPO4084

m a r k s on c r l l n d e r headan6 bolt Uake

DKP00485

30-33

RADIATOR DISASSEMBLY AND ASSEMBLY

REMOVAL OF RADIATOR, HYDRAULIC OIL COOLER ASSEMBLY

to the A Lower the work equipment completely loosenthe oil

. .

ground and stop the engine. Then filler cap slowly to release the pressure inside the hydraulic tank.

Remove the hydraulic tank strainer, and using tool B, stop the oil. When not using tool B, remove the drain plug,anddrain the oil from the hydraulic tank and inside the system. b

Hydraulic tank :Approx. 170

HYDRAULIC OIL COOLER

CLPO3276

Drain coolant.

1. Remove condenser assembly.

For details, see REMOVAL OF CONDENSER ASSEMBLY.

2. Remove undercoverat bottom of condenser and bottom of radiator. Set a container under the machine to catch the oil.

3. Disconnect hoses(1). then remove sub-tank (2). 4.

Remove sub-tank mounting bracket (3).

5. Disconnect oil cooler hoses (4) and (5).

30-34

P f7rx)-A7

DISASSEMBLY AND

8. 9.

ASSEMBLY RADIATOR

COOLER HYDRAULIC OIL

Remove f a n guard (10). Disconnect radiator upper hose (1 1).

10. Disconnectradiatorlower hose (12) andheater hose (131, then remove intermediate clamp (14) of radiator lower hose.

282

11. Remove 2 ctamps (16) of heater hose (15). 12. Disconnect left and right support rods radiator.

(17) of

13. Sling radiator and hydraulic oil cooler assembly (18), removebottommounting bolts, thenlift off radiator and hydraulic oil cooler assembly slowly. When raising the radiatorand hydraulic oil cooler assembly, be extremely careful n o t t o hit the fan.

PCZOO-6Z

Radiator hydraulic oil cooler assembly: 112 kg

30-35

DISASSEMBLY AND ASSEMBLY RADIATOR

HYDRAULIC OIL

COOLER

INSTALLATION OF RADIATOR, HYDRAULIC OIL COOLER ASSEMBLY Carry out installation in the reverse order to removal.

r q 1.1 [fl

Coupling : 16.7

2 Nm 11.7 2 0.2 kgm)

Radiator hose band clip : 8.83 f 0.98 Nm iO.9 t 0.1 kgm} Refilling with water Add water through the water filler to the specified level. Run the engine to circulate the water through the system. Then check the water levelagain.

Refilling with oil (hydraulictank) Add oil throughthe oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.

30-36

Pf7m-x7

ENGINE MAIN PUMP

DISASSEMBLY AND ASSEMBLY

REMOVAL OF ENGINE MAIN PUMP ASSEMBLY

A Disconnect the cable from the negative (-1 terminal of the battery. A Lower the work equipment completely to the

ground and stop the engine. Then loosen the oil filler cap slowly t o release the pressure inside the hydraulic tank. Remove the hydraulic tank strainer, and using tool B, stop the oil. Whennotusingtool B, remove thedrain plug, and drain the oil from thehydraulic tank and inside the system.

Hydraulic tank : Approx. 170 e

After disconnecting the piping, fit tags to distinguish the mounting position. Drain coolant. 1.

Remove engine hood (1).

I 2.

ICLPO3299

Remove main pump top cover (2).

3. Remove right side cover (3)together with cover mounting frame (4). Remove the cover a t the bottom of the main pump and the cover at the bottom of the engine, then set a container under the main pump t o catch the oil.

Remove connector (5) from bracket, then disconnect.

\\ \

PC200-6Z

CLPO3812

30-37

ENGINE PUMP MAIN

DISASSEMBLY AND ASSEMBLY

Disconnect F and R pump dischargehoses (6) and (7). F and R LS pressure hoses (8) and (9), and EPC basic pressure hose (10). Protect with the sleeve nut t o prevent damage to the nipple or elbow taper seal portion.

Disconnect pump servo pressure hose (11) and pump drain hose (121, and remove intermediate clamp (13) of hose. Protect with the sleeve nut t o prevent damage to the nipple or elbow taper seal portion.

7. Disconnect suction tube (14) at pump end. Cover the suction tube port portion with plastic.

, .

Removeenginepartition (17).

CcPOS814

plates (151, (161, and

9. Remove bracket (18) at counterweight end. I O . Remove fan guard

(191, then remove left and right side brackets (20)and (21) of fan guard mount.

30-38

pr7nn-x7

P 0

w N

DISASSEMBLY AND ASSEMBLY

ENGINE MAIN PUMP

INSTALLATION OF ENGINE, MAIN PUMP ASSEMBLY Carry outinstallation removal.

in the reverse orderto

Set the engine mount rubber as shown in the diagram, then install theengine and main pump assembly. Engine mount bolt : 277 2 32 Nm (28.3 t 3.3 kgm}

Refilling with water Add water through the waterfiller t o the specified level. Run the engine to circulate thewater through the system. Then check the water level again.

Enoine rear s l d e

Enoine front side

DKP00487

Refilling with oil(hydraulictank) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.

Bleeding air Bleed the air from the main pump. For details, see TESTING AND ADJUSTING, Bleeding air.

PC200-6Z

30-41

DISASSEMBLY AND ASSEMBLY

DAMPER

REMOVAL OF DAMPER ASSEMBLY

1. Removemain pump assembly. For details, see REMOVAL OF MAIN PUMP ASSEMBLY. 2.

Remove damperassembly (1).

INSTALLATION OF DAMPER ASSEMBLY Carry outinstallation removal.

30-42

in thereverseorder

PC200-6Z

TANK

DISASSEMBLY FUEL AND ASSEMBLY

REMOVAL OF FUEL TANK ASSEMBLY

A Disconnect the cable from the negative (-) minal of the battery.

1. Loosen drainvalve fuel. b

& 2.

(1) of fuel tank and drain

Fuel tank : Approx. 340

(when tank is full)

Disconnect fuel supply hose (2) and return hoses

(3)and (4).

Remove handrail (51,battery case (61, and cover

(7).

ter-

Battery case : 28 kg

Disconnect fuel sensor connector (81, then remove wiring from clamp.

5. Sling fuel tank assembly (91, then remove mounting bolts, and lift off fuel tank assemblv (9). I

Fuel tank assembly : 122 kg

INSTALLATION OF FUEL TANK ASSEMBLY Carry outinstallation removal.

in the reverse order to

Fuel tank mounting bolt : 277 2 3 2 N m (28.3 z 3.2 kgml

Refilling with fuel(fueltank) Add fuel.

PC200-6Z

30-43

CENTER SWIVEL JOINT

DISASSEMBLY AND ASSEMBLY

REMOVAL OF CENTER SWIVEL JOINT ASSEMBLY

A Release the remaining pressure in the hydraulic circuit. For details, see TESTING AND ADJUSTING, Releasing remaining pressure from hydraulic circuit. Mark all the piping with tags to prevent mistakes in the mounting position wheninstalling. 1. Disconnect hoses (1). (21, (31,and (4) between travel motor and swivel joint.

Remove elbow (5).

Disconnect drain hose (6). Disconnect hoses (7) and (8) between control valve and swivel joint. 5. Disconnect travel speed selector hose (9). 6. Disconnect plate (10).

3. 4.

7 . Remove center swivel joint assembly (11).

Center swivel joint assembly : 45 kg

I '

30-44

CLPO5177

PC200-6Z

DISASSEMBLY SWIVEL CENTER ,ANDASSEMBLY

JOINT

INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY Carry outinstallationin removal.

the reverse order to

Assemble the center swivel as shown in the diagram below. Refilling with oil (hydraulic tank) Add oil through the oilfiller to the specified level. Run the engine to circulatethe oil through thesystem. Then check the oil level again.

Bleeding air Bleed the air form the travel motor. For details, see TESTINGAND ADJUSTING, Bleeding air.

PCZOO-6Z

Center swivel. joint

Sprocket

QKP00488

30-45

CENTER SWIVEL JOINT

DISASSEMBLY AND ASSEMBLY

DISASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY 1. Removecover (1). 2.

Remove snap ring (2).

3. Using tool D, pull out swivel rotor (4) and ring (3)from swivel shaft (5). 4.

RemoveO-ring swivel rotor.

(6) and slipper seal ( 7 ) from

ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY 1. Assemble slipper seal ( 7 )and O-ring (6) t o swivel rotor.

2. Set swivel shaft (5) t o block, then using push tool, tap swivel rotor (4) with a plastic hammer t o install. Contact surface of rotor, shaft : Grease (G2-LI) -f When installing the rotor, be extremely careful not to damage the slipper seal and the O-ring.

5 I

CLPO384 1

3. Install ring (3) and secure with snap ring (2). 4.

Fit O-ring and install cover (1). Mounting bolt : 31.36 2 2.94 Nm 13.2

0.3 kgm)

30-46

CLPO3842

PC200-6Z

AND

DISASSEMBLY

ASSEMBLY

FINAL DRIVE

REMOVAL OF FINAL DRIVE ASSEMBLY 1. Remove sprocket. For details, see REMOVAL OF SPROCKET. Lower the work equipment completely to the ground and stop the engine. Then loosen the oil filler cap slowly t o release the pressure inside the hydraulic tank.

2. Remove cover (1).

3. Disconnect 4 travel motor hoses (21, and lift off final drive assembly (3). f

CLpol413

Be extremely careful not to damage the nipple tool surface of the hose mount. Final drive assembly : 300 kg Never use tap hole for cover when slinging final drive assembly.

& f

INSTALLATION OF FINAL DRIVE ASSEMBLY Carry outinstallation removal.

in the reverse order to

Final drive mounting bolt: 276.8 2 31.8 Nm 128.25 2 3.25 kgml

Bleeding air f Bleed the air from the travel motor. For details, see TESTING AND ADJUSTING, Bleeding air. Refilling with oil (hydraulictank) f Add oil through the oil filler to the specified level. Run theengine to circulatetheoil through the system. Then check the oil level again.

PC200-6Z

30-47

DRIVE AND

DISASSEMBLY FINAL

ASSEMBLY

DISASSEMBLY OF FINAL DRIVE ASSEMBLY 1. Draining oil

Remove drain plug and drainoil from final drive case. b

Final drive case : Approx. 4.2

Cover

Remove mounting bolts, then remove cover (1) using eyebolts 0. Ir When raising ring gear (12) and cover (1) a s o n e unit, tap the ring gear with a wooden hammer to remove thering gear.

12 CLPO1427

3. Spacer

Remove spacer (2).

CLPOI4l7

No. 1 carrierassembly 1) Remove No. 1 carrier assembly (3).

CLPO1418

2) Disassemble No. 1 carrier assembly a s follows. i) Push in pin (41, and pull outshaft (5)

from carrier (6). After removing the shaft, remove pin

(4). ii) Remove thrust washer (71, gear (8).bearing (91, and thrust washer (10).

O I

5 CLPOI4I9

30-48

K200-6Z

n n

DRIVE

DISASSEMBLY FINAL AND ASSEMBLY

11. Nut 1) Remove lock plate (241.

2) Using

tool G1, remove nut (25).

CLPO1433

12. Hub assembly 1) Using eyebolts 0,remove hub assembly (26) from travel motor.

26 CLPO1434

2) Disassemble hub assembly as follows.

i) Remove floating seal (27). ii) Remove bearings (28) and (29) from hub (30). When removing bearing (281, do not hit the resin retainer of the bearing.

28.

CLPO1435

3) Remove floating seal (31) from travel motor (32).

30-50

PC200-6Z

DISASSEMBLY FINAL AND ASSEMBLY

DRIVE

ASSEMBLY OF FINAL DRIVE ASSEMBLY

Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing.

1. Hub assembly 1) Using push tool, press fit bearings (28) and (29)t o hub (30).

'30

CLPO1435

2) Using tool 64, install floating seal (26). Remove all oil and grease from the 0ring and O-ring contact surface, and dry thepartsbeforeinstallingthefloating seal. Afterinstallingthefloating seal, check thattheangleofthefloatingsealis within 1 mm. After installing the floating seal, coat the sliding surface thinly with engine oil.

"'\

3) Usingtool 64, installfloating travel motor (32).

CKP03843

seal (31) to

The procedure forinstallation is the same as in Step 2) above.

CLPO1436

Using eyebolts @, set hub assembly (26) t o travel motor, then using push tool, tap t o press fit bearing portion.

PC200-6Z

CLPOI434

30-51

AND

DISASSEMBLY

FINAL DRIVE

ASSEMBLY

2. Nut

1) Install nut as follows. i) Using tool 62, push bearing inner race

portion. Do notheatthebearing with a burner, or directly push or hit the resin retainer. Pushing force: 8.82 - 12.74 kN (0.9 - 1.3 ton} Rotate t h e hub 2 - 3 times before applying the pushing forcetothe bearing inner race. Measure dimension a in the condition in Step i) above. Measure thickness b of nut itself. Calculate a - b = c. Using tool GI, tighten nut (25) to a point where dimension d is c$.,.

* * ii)

iii) iv) v)

CLPO3844

CLPOI437

vi) Using push-pull scale @, measure tangential force in direction of rotation of hub in relation to motor case. Tangential force : Max. 294 N (30kg1 The tangential force is the maximum force when starting rotation.

vii) Install lock plate (24).

30-52

PC200-6Z

DRIVE

DISASSEMBLY FINAL AND ASSEMBLY

Installthelock plate as shown inthe diagram. Thread of mounting bolt: Thread tightener (LT-21 Do not coatthetapportionofthe nut with thread tightener (LT-2).

BAD

there i s no c a s t i n rn o t c h . D late and s D I i n e B r i n el o c k

. .

3. No. 2 carrier assembly

1) Assemble No. 2 carrier assembly as follows. f Replace thrust washers (201, (23) and pin (17) with new ones. There are the remains ofthe caulking when the pin is insetted at the end face of hole h at the side of the carrier, so remove the caulked metal from the inside diameter of the hole before starting t o assemble. i) Assemblebearing (22) to gear (21). fit top and bottom thrust washers (20) and (231, andset gear assembly in carrier (19). ii) Align position of pin holes of shaft and carrier, then tap with a plastic hammer t o install shaft (18). When installing the shaft, rotate the planetary gear. Becareful not todamage the thrust washer. iii) Insert pin (17). After inserting the pin, caulk the pin portion of the carrier. Afterassemblingthe carrier assembly, check that gear (21) rotates smoothly.

CLPO1439

CLPO1440

2) Install No. 2 carrier assembly (16). Align the position so that the three tips of the gear shafts of carrierassembly (16) enter the three hollows in the end face of the motor case, then install.

CLPOI44I

K200-6Z

30-53

DISASSEMBLY AND ASSEMBLY

FINAL DRIVE

4. Thrustwasher Install thrust washer (15).

1 1.

No. 2 sun gear Install No. 2 sun gear (14).

6. Thrust washer Install thrust washer (13). 7.

No. 1 sun gear shaft Install No. 1 sun gear shaft (11). CLPOI442

No. 1 cam'er assembly 1) Assemble No. 1 carrier assembly as follows. f Replace thrust washers (71, (10) and pin (4) with new ones. Therearetheremainsofthecaulking when the pin is inserted at the endface of hole h at the side of the carrier, so remove the caulked metal from the inside diameter of the hole before starting to assemble. i) Assemble bearing (9) t o gear ( 8 ) , fit top and bottom thrust washers (7)and (lo), and set gear assembly in carrier (6).

ii) Align position of pin holes of shaft and carrier, then tap with a plastic hammer t o install shaft (5). When installing the shaft, rotate the planetary gear. Be careful not to damage the thrust washer. iii) Insert pin (4). After inserting the pin, caulk the pin portion of thecarrier. Afterassemblingthecarrier assembly, check that gear (8)rotates smoothly.

CLP01422

5' CLPO1423

2) Install No. 1 carrier assembly (3). 9.

Spacer Install spacer (2).

CLPO1443

30-54

PC200-6Z

FINAL DRIVE

DISASSEMBLY AND ASSEMBLY

10. Ring gear

Fit O-ring to hub end, then using eyebolts 0, align position of bolt holes of hub and ring gear (121, and install. f Remove all grease and oil from the mating surface of the ring gear and hub. f Do not put any gasket sealant on the mating surface of the ring gear and hub under any circumstances.

CLPO I444

11. Cover fit cover (11, thentighten Usingeyebolts 0, mountingbolts with angletighteningwrench 63. Mounting surface of cover : Gasket sealant (LG-6) Mounting bolt : 1st pass: 98 Nm {lo kgm) 2nd pass: Turn 80 90"

CLPO1445

12. Refilling with oil

Tighten drain plug and add engine oil through oil filler.

& *

Final drive case : Approx. 4.2 Carry out a final check of the oil level at the determined position after installing the final drive assembly to the chassis.

PC200-6Z

CLPOl446

30-55

DISASSEMBLY AND ASSEMBLY

SWtNG MOTOR AND

SWING MACHINERY

REMOVAL OF SWING. MOTOR, SWING MACHINERY ASSEMBLY

A Lower the work equipment to the ground and

stop the engine. Loosen the hydraulic tank oil filler cap slowly to release the pressure inside the hydraulictank. Then set the safety lock lever to the LOCK position.

1. Remove hose clamps (1) and (2) (2 places each). 2.

Disconnect swing motor inlet and outlet hoses (3)and (41, and disconnect suction hose (5).

3. Remove hose clamp (6). 4.

Disconnect drain hoses (7) and (81, then disconnect pilot hose (9).

Remove 12 mounting bolts (10) at swing machinery end, then lift off swing motor and swing machinery assembly (11). When removing the swing motor and swing machinery assembly, be careful not to damage the hoses, and lift off slowly. Swing motor, swing machinery assembly : 225 kg

e l

PC200-6Z

30-57

DISASSEMBLY AND ASSEMBLY

SWING MOTOR AND

SWING MACHINERY

INSTALLATION OF SWING MOTOR, SWING MACHINERY ASSEMBLY Carry out installation in the reverse order to removal. Swing machinery mounting bolt : 549 2 59 Nm (56 z 6 kgm) Refilling with oil (hydraulic tank) Add oil through the oil filler tothe specified level. Run the engine to circulate the oil through the system. Then check the oil level again.

Bleeding air Bleed the air from the swing motor. For details, see TESTING AND ADJUSTING, Bleeding air.

30-58

PC200-6Z

SWING MACHINERY

DISASSEMBLY AND ASSEMBLY

DISASSEMBLY OF SWING MACHINERY ASSEMBLY 1. Draining oil Loosen drain plug and drain oil from swing machinery case. b

Swing machinery case : Approx. 5.5

2. Swing motor assembly 1) Set swing motor and swing machinery assembly t o block @. 2 ) Remove mounting bolts, then remove swing motor assembly (1). 3.

No. 1 thrust washer

Remove No. 1 thrust washer (2).

\WWWl&A 4.

CLP02924

No. 1 sungear

Remove No. 1 sun gear (3).

CLPO2925

No. 1 carrierassembly 1) Remove No. 1 carrier assembly (4).

CLP07976

PC200-6Z

30-59

0 Y

N 4

0 V

D;'

-*,

DISASSEMBLY AND ASSEMBLY

Bolt Remove holder mounting bolt (13).

SWING MACHINERY

10. No. 2 carrier assembly 1) Remove No. 1 carrier assembly (14).

CL.PO2931

Disassemble No. 2 carrier assembty as follows. i) Push in pin (151, and knock shaft (16) out from carrier (17). Ir After removing the shaft, remove pin (15). ii) Remove thrust washer (181, gear (191, bearing (201, and thrust washer (21). iii) Remove plate (22).

'7,

/ l6

-1 5

CLPO2932

11. Shaft assembly 1) Remove mounting bolts (23). 2) Set shaft and case assembly to press, then using push tool @, remove shaft assembly (24) from case assembly (25).

Zj CLPO2933

3) Disassemble shaft assembly as follows. i) Usingpushtool @, removecover assembly (26) and bearing (27) from shaft (28). ii) Remove oil seal (29) from cover (30).

CLPO2934

CLP02935

PC200-6Z

CLPO2936

30-61

AND

DISASSEMBLY

ASSEMBLY

SWING MACHINERY

ASSEMBLY OF SWING MACHINERY ASSEMBLY

* 1.

Cleanallpartsand check fordirtor damage. Coat the slidingsurfaces of all parts with engine oil before installing. Bearing Using push tool0,press fit bearing (27)to case (32). CLPO2938

Cover assembly 1) Using push tool 0,press fit oil seal (29) to cover (30). Outside circumference of oil seal : Gasket sealant (LG-6) Be careful not to let the gasket sealant (LG-6) get on the oil seal lip when press fitting.

1 2) Fitcover

assembly (26) to case (32), and tighten mounting bolts (23). Cover mounting surface : Gasket sealant (LG-6) Q i 3 Mounting bolt : 66.2 t 7.4 N m i6.75 t 0.75 kgm) Lip. of oil seal : Grease (G2-LII

CLPO2939

26\

,2 3

CLP02940

Case Assembly Set case assembly (25) to shaft (28). then using press fit bearing inner race porpush tool 0, tion. When setting the case assembly to the shaft, be extremely careful not to damage the oil seal.

C l PO294 1

PC200-6Z

30-63

DISASSEMBLY AND ASSEMBLY

SWING MACHINERY

Bearing Using tool F, press fit bearing (31). Press the bearing inner race and outer race at the same time when press fitting.Do not press only the innerrace when press fitting. After press fitting the bearing, check that the case rotates smoothly.

* *

-11

CLP02942

5. No. 2 carrierassembly 1) Assemble No. 2 carrier assembly as follows. There are theremainsofthecaulking when the pin is inserted at the end face of hole h at the side of the carrier, so remove the caulked metal from the inside diameter of the hole before starting t o assemble. i) Assemble plate (22) t o carrier (17). ii) Assemblebearing (20) t o gear (191, fit top and bottom thrust washers (18) and (21) and set gear assembly to carrier(17). iii) Align with position of pin holes of shaft and carrier, then tap with a plastic hammer to install shaft(16). When installing the shaft, rotate the planetary gear, and be careful not to damage the thrustwasher. iv) Insert pin (15). After inserting the pin, caulk the pin portion of the carrier.

/I*

22-

CLPO.7943

/I6

2) Install No. 2 carrier assembly (14). 6.

Bolt

CLPO2944

Tighten bolt (13). Mounting bolt : Thread tightener ILT-2) Mounting bolt : 176.5 2 19.6 Nm I18 2 2.0 kgm)

L L PO2931

30-64

PC200-6Z

DISASSEMBLY AND ASSEMBLY

SWING MACHINERY

No. 2 sun gear Install No. 2 sun gear (12).

12930

No. 2 thrust washer Install No. 2 thrust washer (11).

12929

Ringgear Install ring gear (10). Case side mounting surface : Gasket sealant (LG-6)

10.

No. 1 carrier assembly

1) Assemble No. 1 carrier assembly as follows. There are the remains of the caulking at the end face of carrier side hole k made when inserting the pin, so remove the remainsofthecaulkingontheinside diameter of the hole before starting assembly. i) Assemble bearing ( 8 )t o gear (7).then fit top and bottom thrust washers (9)and set gear assembly to carrier.

PC200-6Z

CLPO2945

30-65

DISASSEMBLY AND ASSEMBLY

ii) Align pin holeposition of carrierand shaft, then tap with plastic hammer and install shaft (6). Rotate the planet gear when installing the shaft, and be careful not to damage the thrustwasher. iii) Insert pin (5). After inserting the pin, caulk the pin portion of the carrier.

SWING MACHINERY

6 CLP02946

iv) Install No. 1 carrier assembly (4).

CLPO2926

11. No. 1 sun gear Install No. 1 sun gear (3).

CLPO2925

12. No. 1 thrust washer Install No. 1 thrust washer (2).

CLPO2924

30-66

PC200-6Z

DISASSEMBLY AND ASSEMBLY

SWING MACHINERY

13. Swing motor assembly Install swing motor assembly (1). Ring gear side mounting surface : Gasket sealant ILG-6)

GLP02923

Coat the outside diameter of the hole only at the holein the ring gear where there is a distinguishing protrusion on the case. (See ?he diagram on the right.) Mounting bolt : 176.5 t: 19.6 Nm 118 2.0 kgm)

14. Refilling with oil Tightendrain plug andadd oil filler to specifiedlevel.

PC200-6Z

engine oilthrough

Path for I iauidoasket P r o j e c t i o nf o r identification

30-67

AND

DISASSEMBLY

ASSEMBLY

REVOLVING FRAME

REMOVAL OF REVOLVING FRAME ASSEMBLY 1. Remove 2 boom cylinder assemblies. For details, seeREMOVAL OF BOOM CYLINDERASSEMBLY.

Remove work equipment assembly. For details, see REMOVAL OF WORK EQUIPMENT ASSEMBLY.

Remove counterweightassembly. For details,see REMOVAL OF COUNTERWEIGHT ASSEMBLY.

Disconnect top mounting hoses (l), (21, and (3) of swivel joint assembly at swivel joint assembly end.

5. Remove stopper link (4).

Remove mounting bolts, then lift off revolving frame assembly (5). Leave 2 bolts @ each at the front and rear, use a lever block to adjust the balance of the revolving frame assembly to the front and rear, andleft and right,thenremovethe remaining bolts, and lift off. When removing the revolving frameassembly, be careful not to hit the center swivel joint assembly.

30-68

Revolving frame assembly: 5,200 kg

CLPO3849

PC200-6Z

AND

FRAME

DlSASSEMBLY REVOLVINGASSEMBLY

INSTALLATION OF REVOLVING FRAME ASSEMBLY Carry out installation in the reverse order to removal. Mating surface of swing circle : Gasket sealant (LG-1) Thread of revolving frame mounting bolt : Thread tightener (LT-2) Revolving frame mounting bolt : Mounting bolt

I PC200-6 I

20- 110

I I 32

1st: 294 (301 2nd: Tighten 60"

Refilling with oil (hydraulic tank) Ir Add oil throughthe oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.

Bleeding air Bleed the air.Fordetails, seeTESTING AND ADJUSTING, Bleeding air.

PC200-6Z

30-69

SWING CIRCLE

DISASSEMBLY AND ASSEMBLY

REMOVAL OF SWING CIRCLE ASSEMBLY 1. Remove revolving frame assembly. For details, see REMOVAL OF REVOLVING FRAME ASSEMBLY. 2.

Remove swing circle mounting bolts (11, leaving 1 bolt each in front and rear direction. .k Swingcircle assembly mounting bolts: 32 pcs.

3. Sling swing circle assembly (2) at three points, then remove remaining mounting bolts. 4.

I \

CLPO3850

Lift off swing circle assembly (2).

&I Swing circle assembly : 280 kg

30-70

PC200-6Z

AND

DSASSEMBLY

SWING CIRCLE

ASSEMBLY

INSTALLATION OF SWING CIRCLE ASSEMBLY Carry out installation in the reverse order to removal.

Thread of swing circle mounting bolt : Thread tightener (LT-2) Swing circle mounting bolt : 1st pass: Tighten to 191.2 t 19.6 Nm 119.5 t 2 kgm) 2nd pass: 1) Using the angle of the bolt head as the base, make start marks on the swing circle and socket. 2) Make an end mark at a point (on swing circle) 4 8 ~ 5 "from the start mark. 3) Tighten so thatthe startmark onthe socket is aligned with the end mark on the swing circle at the 484" position. Set the soft zone S mark on the inside ring of the inner race facing the right side as shown in the diagram, then install to the track frame. 6 Swing circle : Grease (G2-LII 211

B+

S u i n ec i r c l es t a r tm a r t Socket

start m a r t Sac t e t

48'f5

P o s i t i o n of s u i a ec i r c l e en4 aSa or kcskteatr t

mark

DKPO049 I

Innerrace zone

,soft

r race zone

PC200-6Z

DLP00492

30-71

DISASSEMBLY AND IDLER ASSEMBLY

SPRING RECOIL

REMOVAL OF IDLER.. RECOIL SPRINGlASSEMBLY 1. Remove track shoe assembly.Fordetails, REMOVAL OF TRACK SHOE ASSEMBLY.

see

2. Sling idler and recoil spring assembly (I), and pull out to the front toremove.

&IIdler

recoil spring assembly :275 kg

3. Disconnect recoil spring assembly (3)from idler assembly (2). & J

Idler assembly : 140 kg

Recoil spring assembly : 135 kg

INSTALLATION OF IDLER RECOIL SPRING ASSEMBLY Carry outinstallation removal.

in the reverse order to

CLPO3855

When installing the idler assembly and recoil spring assembly, assemble so that the position of the greasing plug on the idler is on the outside for the right side of the machine and on the inside for the left side of the machine.

30-72

PC20-67

DISASSEMBLY AND ASSEMBLY

RECOIL SPRING

Disassembly of recoil spring assembly 1) Set recoil spring assembly (1) to tool H1. The recoil spring is under large installed load, so be sure to set the tool properly. Failure to do this is dangerous. Installed load of spring

: 126.5 kN (12,900 kg)

* * *

Compress the spring to a point where the nut becomes loose. Release the'hydraulic pressure slowly and release the tension of the spring. Free length of spring : 603.5 mm

3) Remove yoke (6), cylinder (71, and dust seal ( 8 ) from spring (5). 3. Disassembly of piston assembly 1) Remove lock plate (10) from piston (9).then remove valve (11). 2) Remove snap ring (121,then remove U-packing (13) and ring (14).

PC200-6Z

30-73

DISASSEMBLY AND ASSEMBLY

RECOIL SPRING

ASSEMBLY OF RECOIL SPRING ASSEMBLY H2

1. Assembly of piston assembly 1)Assemble ring (14) andU-packing (13) to piston (9), and secure with snap ring (12). 2) Tightenvalve (11) temporarily,and secure with lock plate (10).

2. Assembly of recoil spring assembly 1) Using tool HZ, install dust seal (8)to cylinder (7). 2) Assemble cylinder (7) and yoke ( 6 ) t o spring (51, and set in tool H1. & Sliding portion of cylinder : Grease (G2-LI)

CLPO3858

3) Apply hydraulic pressure slowly tocompress

spring, and tighten nut ( 4 ) so that installed length of spring is dimension "a", then secure with lock plate (3). Installed length "a" of spring : 466 mm

4) Remove recoil spring assembly (1) from tool

H1.

3. Assemble piston assembly (2) to recoil spring

CLPO3859

assembly (1). xf_Ls Sliding portion of piston, wear ring: Grease (G2-LI) Assemble the cylinder assembly so that the mounting position of the valve is 90" t o the side. Fill the inside of the cylinder with 300 cc of grease (G2-LI), then bleed the air and check that grease comes out of the grease hole.

30-74

PC200-6Z

IDLER DISASSEMBLY AND ASSEMBLY

DISASSEMBLY OF IDLER ASSEMBLY 7

1. Remove dowel pin (11, then remove support (2).

Remove floating seal (3)from support (2) and idler (4).

3. Pull out idler (4) from shaft (5) and support (7) assembly. It is filledwith 80 cc. of oil, so drain the oil at this point or lay a cloth to prevent the area from becoming dirty.

2 CLPO3860

Remove floating seal ( 6 ) on opposite side from idler (4) and shaft (5)and support (7) assembly.

CLPO3861

Remove dowel pin (81, then remove support (7) from shaft (5).

Remove bushings (9) and (10) from idler (4).

CLPO3862

PC200-6Z

CLPO3863

30-75

DISASSEMBLY

IDLER

ASSEMBLY

ASSEMBLY OF IDLER ASSEMBLY

1. Press fit bushings (9) and (10) t o idler (4).

CLP022 IO

CLPO2209

Fit O-ring and install support(7)t o shaft (5)with dowel pin (8).

3. Using tool J1, install floating seal (6)to idler (4) and shaft (5) and support (7)assembly. Coat the sliding surface of the floating seal

with oil, and be carefd not to let any dirt or dust get stuck t o it. Remove all grease and oil from the contact surface of the O-ring and the floating seal.

CLPO3861

I I

CKP03867

Assemble shaft (5) land support (7) assembly to idler (4).

CLPO3868

30-76

Dr3M-X7

DISASSEMBLY AND ASSEMBLY

IDLER

Using tool J1, install floating seal (3)to idler (4) and support (2). .k Coat the sliding surface of the floating seal with oil, and be careful not tolet any dirt or dust get stuck t o it. Remove all grease and oil from the contact surface of the O-ring and the floating seal.

CLPO3869

CKP03870

Install O-ring, then install support ( 2 )with dowel pin (1).

7 . Add oil and tighten plug.

Oil : Approx. 80 cc (SAESO) Plug : 205.8

49 Nm (21 2 5 kgm)

2 CLPO3860

PC200-6Z

30-77

TRACK ROLLER

DISASSEMBLY AND ASSEMBLY

REMOVAL OF TRACK ROLLER ASSEMBLY 1. Lower work equipment,then loosen lubricator (11, and relieve track tension. The adjustment cylinder is under extremely high pressure. Never loosen the lubricator more than one turn. If the grease does not come out easily, move the machine backwards and forwards. 2. Remove mountingboltsof track roller, then swing work equipment 90". jack up machine, and remove track roller assembly (2) towards outside of machine.

CLP03872

Track roller assembly : 40 kg

INSTALLATION OF TRACK ROLLER ASSEMBLY Carry outinstallation removal.

* *

in the reverse order to

Adjustthe track tension. For details, see TESTING AND ADJUSTING, Testing and adjusting track tension. Place the plug on the outside of the chassis, andsetthetrackroller assembly inthe mounting position. Operate the work equipment levers to lower the machine slowly, then tighten the mounting bolts temporarily. Operate the work equipment levers to lower the machine completely tothe ground, then tighten the mounting bolts fully. Track roller assembly mounting bolt: 1st pass : Tighten to 196 t 19.6 Nm (20 t. 2 kgml 2nd pass : 1. Whenusingtool M. Using an angle tightening wrench, tighten bolt 90 2 5". 2. When not using tool M. 1) Using the angle of the bolt head as the base, make start marks on the track roller and socket. 2) Make an end mark at a point 90 2 5" from the start mark. 3) Tighten so that the start mark on the socket is aligned with the end markonthe track roller at the 9025" position.

33-78

M CLPO3871

Track r o l l e r s t a r t mark Socket start

Socket

t r a c kr o l l e r m a r ks t aeSrnotdc kme at r k

DLP00493

PC7CK)-A7

DISASSEMBLY AND ASSEMBLY

TRACK ROLLER

DISASSEMBLY OF TRACK ROLLER ASSEMBLY 1. Remove pin (11, then remove collar

(2).

CLP022 19

Remove floating seal (3)from collar (2) and roller (4).

CLPO2220

CLP0222 I

3. Pull out roller (4) from shaft (5).

It is filled with 190 - 215cc. of oil, so drain the oil at this point or lay a cloth to prevent the area from becoming dirty.

Remove floating seal ( 6 ) on opposite side from roller (4) and shaft (5).

5 4

CLPO2222

PC200-6Z

CLPO2223

30-79

0 I-

DISASSEMBLY AND ASSEMBLY

TRACK ROLLER

ASSEMBLY OF TRACK ROLLER ASSEMBLY 1. Using push tool (10) to roller (4).

0, press

fit bushings (9) and

2.' Assemble collar ( 8 ) t o shaft (51,and install pin

(7).

3. Using tool K1, install floating seal (6) to shaft (5).

When assembling the floatingseal, clean the contact surface of O-ring ( 6 c ) and floating seal (6a), remove all grease and oil, and dry it. Make sure that no dirt or dust sticks to the contact surface of the floating seal.

8 CLPOO803

Using tool K1, install floating seals (6) and (3) to roller (4). For details of the precautions when installing floating seals (6b) and (6d). and (3b) and (3d), see the precaution for Step3.

5. Assemble shaft (5) to roller (4). 6. Turn over roller (4) and shaft (5)assembly.

Using tool K I , install floating seal (3)to collar (2). For details of the precautions when installing floating seals (3a) and ( 3 ~ ) see . the precaution for Step 3.

CLPO2226

CLPO3885

CLPO3886

CL~ 0 3 ~ 8 8

PC200-6Z

CLP03889

30-81

r V 0 w

ROLLER DISASSEMBLY CARRIERAND ASSEMBLY

REMOVAL OF CARRIER ROLLER ASSEMBLY

1. Lower work equipment, thenloosenlubricator (1).relieve and track tension. The adjustment cylinder is under extremely high pressure. Never loosen the lubricator more than one turn. If the grease does not come out, move the machine backwards and forwards.

Using hydraulic jack 0,push up track to a position wherecarrierroller assembly canbe removed, then remove carrier roller assembly (2).

CLPO3872

INSTALLATION OF CARRIER ROLLER ASSEMBLY Carryoutinstallationin removal.

the reverse orderto

Adjustthetrack tension. For details, see TESTING AND ADJUSTING, Testing and adjusting track tension.

CLPO3894

Thread of carrier roller assembly mounting bolt: Thread tightener (LT-2)

PC200-6Z

30-83

ROLLERDISASSEMBLY CARRIER AND ASSEMBLY

DISASSEMBLY OF CARRIER ROLLER ASSEMBLY 1. Remove plug (1) anddrainoil. b

2. 3. 4.

Carrier roller assembly : 230

Set carrier roller assembly on stand Remove cover (2). Remove ring (3).

- 250 cc 0.

CLPO3896

CLPO3897

5. UsingtoolL1,remove

nut (4). Usingpushtool @, pull outshaftassembly (5) from roller ( 6 ) withpress, thenremoveinner race (7).

CLPO3898

Remove outer races ( 8 ) and (9)from roller ( 6 ) .

Disassembly of shaftassembly 1) Usingpuller @, removeinnerrace (10).

z9 CLPO3900

30-84

CLPO3899

CLPO3901

PC200-6Z

DISASSEMBLY AND ASSEMBLY

ROLLER

CARRIER

2) Remove floating seals (11). 3) Using push tool 0,remove collar (12) from shaft (13).

L +CLPO3903

PC200-6Z

30-85

DISASSEMBLY AND ASSEMBLY

CARRIER ROLLER

ASSEMBLY OF CARRIER ROLLER ASSEMBLY 1.

Using push tool @, press fit outer races ( 8 ) and (9) to roller (6).

Assembly of shaft assembly 1) Using push tool @, press fit collar (12) t o shaft (13). When press fitting, be careful that there is no scuffing. Fitting portion of shaft : SAE30 2 ) Using tool L3, assemble floating seals (11). When assembling the floatingseal, clean the contact surface of O-ring ( l l c ) and floating seal (lla), remove allgrease and oil, and dry it. Make sure that no dirt or dust sticks to the contact surface of the floating seal. 3) Assemble floating seals (111, then using tool L2, press fit inner race (10). For details of the precautions when installing floatingseals ( l l b )and (lld),see the precaution for Step 2).

* *

I CLPO3905

CLP03904

3. Assemble roller (6) t o shaft assembly (5). 4.

Using tool K, press fit inner race (7). W h e n press fitting the bearing, rotatethe fit t o a pointwherethe roller,andpress rotation becomes slightly heavier.

Using tool L1, tighten nut (4) to a point where drill hole in shaft is aligned with drill hole in nut.

Install ring (3).

Usingpush-pull smoothly.

CLPOI

448

CLP03898

scale @, check that it rotates

CtPO3909

30-86

CLP03897

PC200-6Z

DISASSEMBLY AND ASSEMBLY

8. Fit O-ring and

ROLLER

CARRIER

install cover (2).

CLPO3910

Usingtool L4, apply basic pressure to rolleroil filler port,and check for leakage of air from seal. Basic pressure : 0.1 MPa (1 kg/cm21 Methodof checking The basic pressure shall be maintained for 10 seconds and the indicator of the gauge shall not go down.

* *

I IO. Using tool L4, fill carrier roller assembly with

CLPO391 I

oil, then tighten plug (1).

Carrier roller oil : 230

- 250 cc (SAE30)

To o i l

DUHD

To vacuum t a n k

DLP00494

PC200-6Z

30-87

DISASSEMBLY AND ASSEMBLY

TRACK SHOE

REMOVAL OF TRACK SHOE ASSEMBLY 1. Stopmachine at a pointwheremaster pin is midway betweenidlerandcarrierroller,and where there is space to lay out track assembly on ground.

2. Lowerwork equipment, then loosenlubricator

A The adjustment cylinder is under extremely (11, and relieve track tension.

high pressure. Never loosen the lubricator more than one turn. If the grease does not come out, move the machine backwards and forwards. 3. Using tool I, pull out master pin (2). 4.

CLP03872

Remove tool I, and move machine forward so that position of temporary pin @ is at front of idler, and set block @ in position.

5. Remove temporary pin0,and remove dustseal, then drive machine in reverse to lay out track

(3).

INSTALLATION OF TRACK SHOE ASSEMBLY p g

* *

Adjustthe tracktension. For details, see TESTING AND ADJUSTING, Testing and adjusting track tension. Use tool I and press fit so that the protrusion of the master pin is dimension "a". Protrusion "a" of master pin : 4 2 2 m m

Whenassemblingthedust seal, coatthe bushing contact surface with grease (G2-LI). Replace the shoes with new ones when rubber pads get worn to the same height (or lower) as the heads of their mounting bolts. It is impossible to remove or install mounting bolts once the heads get damaged, crushed or deformed.

30-88

PC200-6Z

TANK

DISASSEMBLY HYDRAULIC AND ASSEMBLY

REMOVAL OF HYDRAULIC TANK ASSEMBLY 1.

Drain oil b

p g

from hydraulic tank. Hydraulic tank : Approx. 170

2. Remove engine hood (11, pump top cover (21, and control valve top cover (3).

Remove right side cover (4) together with cover mounting frame (5).

Remove engine partition plates ( 6 ) and ( 7 ) and mounting bracket for partition plate on hydraulic tank side.

Disconnect hydraulic oil return tube (8).

6. Remove pump suction tube (9) together with joint hose (10).

7 . Remove LS pressure hose clamp (11). 8.

Disconnect 7 hydraulic tank return hoses (12). After disconnecting the hoses, fit tags to distinguish them. Protect with the sleeve nut to prevent damage to the nipple or elbow taper seal portion.

* *

9. Sling hydraulic tank assembly (131, then remove mounting bolts, and lift off hydraulic tank assem bly.

Hydraulic tank assembly : 136 kg

CLP03670

PC200-6Z

30-89

DISASSEMBLY HYDRAULIC AND ASSEMBLY

TANK

INSTALLATION OF HYDRAULIC TANK ASSEMBLY Carry outinstallation removal.

in the reverse order to

Hydraulic tank drain plug : 68.5 t 10 Nm l6.98 z 1.01 kgm} Hydraulic tank mounting bolt : 277 232 Nm {28.3 t 3.2 kgm}

Refilling with oil (hydraulictank) Add oil through theoil filler to the specified level. Run the engine t o circulate the oil through the system. Then check the oil level again. Hydraulictank :Approx. 170

Bleeding air .k Bleed the air. For details, see TESTING AND ADJUSTING, Bleeding air.

30-90

PC200-6Z

DISASSEMBLY AND ASSEMBLY

PUMP

MAIN

REMOVAL OF MAIN PUMP ASSEMBLY

A Disconnect the cable from the negative (-1 terminal of the battery. A Lower the work equipment completely to the

ground and stop the engine. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Removethehydraulictank strainer, andusing tool B, stop the oil. Whennot using tool B, remove the drain plug, and drain the oil from the hydraulic tank and inside the system. b

CLPO3276

Hydraulic tank : Approx. 170

Drainoilfrom

damper case.

1. Remove engine hood cover (1).

Remove main pump top cover (2).

3. Remove right side cover (3) together with cover mounting frame (4).

Remove connector (5)from bracket and disconnect.

I 5.

\\ \

CLPO38 I2

Disconnect F and R pump discharge hoses ( 6 ) and (7).F and R LS pressure hoses ( 8 ) and (91, and EPC basic pressure hose (10). Protect with the sleeve nut to prevent damage to the nipple or elbow taper seal portion.

PC200-6Z

30-91

DISASSEMBLY AND ASSEMBLY

MAIN PUMP

6. Disconnect pump servo pressure hose (11) and pump drain hose (121, and remove intermediate clamp (13) of hose. Protect with the sleeve nut to prevent damage to the nipple or elbow taper seal portion.

Disconnect suction tube (14) at pump end. Cover the suction tube port portion with plastic.

8. Removeenginepartition (17).

plates (15), (161, and

Removemufflerdrainpipe mounting bracket (19).

(18) andclamp

03 8 1 6

10. Remove main p u m p assembly (20) as follows. 1) Leaving 2 - 3 mounting bolts, remove other mounting bolts. 2) Slingmain pump assemblyandinstall 2 guidebolts ( i J ondiametricallyopposite sides. 3) Remove remaining mounting bolts, then pull out slowly until main pump assembly separates from spline shaft. 4) Lift off main pump assembly.

30-92

Main pump assembly : 150 kg

/I7

PC200-6Z

DISASSEMBLY AND ASSEMBLY

MAIN PUMP

INSTALLATION OF MAIN PUMP ASSEMBLY Carry outinstallationin removal.

the reverse order t o

6 Involute spline of main pump :

Anti-friction compound (LM-G) Mating surface of main pump case : Gasket sealant ILG-6)

Refilling with oil (damper) Add engine oil through the oil filler to the specified level. Run the engine t o circulate the oil through thesystem. Wait for at least 15 minutes, then check the oil level again.

Damper :Approx. 0.7 Refilling with oil (hydraulictank) Add oil through the oilfiller to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.

Bleeding air t Bleed the air from main pump. For details, see TESTING AND ADJUSTING, Bleeding air.

PC200-6Z

30-93

DISASSEMBLY AND ASSEMBLY

INPUT PUMP MAIN

SHAFT OIL SEAL

REMOVAL OF MAIN PUMP INPUT SHAFT OIL SEAL 1. Remove main pump assembly. For details, see REMOVAL OF MAIN PUMP ASSEMBLY. 2.

Remove snap ring (11, then remove spacer (2).

3. Lever up oil seal (3) with a screwdriver to rep g move. Whenremovingtheoil seal, be extremely careful not to damage the shaft.

CLPO3916

INSTALLATION OF MAIN PUMP INPUT SHAFT OIL SEAL CarFy outinstallation removal.

in the reverse order to

a6 Lip of oil seal : Grease (G2-LI)

6 Coat the outside circumference of the oil

seal with grease (G2-LI) thinly, then Dress fit. Using tool N, press fit oil seal (3).

CLPO3917

30-94

PC200-6Z

CONTROL

ASSEMBLY DISASSEMBLY AND

REMOVAL OF CONTROL VALVE ASSEMBLY

A Run the engine at low idling, operate the cylin-

der to the end of its stroke without relieving the circuit, then lower the work equipment to the ground. For details, see TESTING AND ADJUSTING, ReIeasing pressure in hydraulic circuit. After stopping the engine, do as follows. Loosen theoilfillercap slowly t o release the pressure inside thetank. Operate thecontrol levers. Operate the control levers several times to release the pressure in the accumulator. Start the engine and run at low idling for approx. 5 seconds, then stop theengine and operate the control levers. f Repeat the above operation several times to release the remaining pressure completely.

1. Open engine hood, and remove valve top cover (1) and air deaner top cover(2). 2.

Removepartitionplate covers (3) and (4) between engine and control valve, move partition plate cover (5) under intake hose towards engine.

3. Disconnect pump discharge hoses (6) and (71, and remove hose clamp (8).

._-

Remove self-reducing pressure valve (9). The length of the mounting bolts is different. See below. Left side mounting bolts (2 bolts) : L = 120 mm Right side mounting bolts (2 bolts) : L = 125 m m

Disconnect hoses (10) between control valve and relay block, hose (1 1) between controlvalve and timing valve, travel valve pilot hose (12),2 boom valve pilot hoses (131, and 2 relief valve pilot hoses (14). After disconnecting the hoses, fit tags to distinguish them. Ir Protect with the sleeve nut to prevent damage t o the nipple or elbow taper seal portion.

PC200-6Z

30-95

CONTROL VALVE

DISASSEMBLY AND ASSEMBLY

6. Disconnect 2 travel valve junction hoses (15). 7.

Disconnect 2 LS pressure pilot hoses (16). f After disconnecting the hoses, fit tags to distinguish them.

Disconnect 10 hoses (19) connected t o each valve. f After disconnecting thehoses, fit tags to distinguish them. f Protect with the sleeve nut to prevent damage to the nipple or elbow taper seal portion.

I 9.

CLPO3828

Disconnect 2 each of bucket valve tube (20), boom valve tube (211, and arm valve tube (22).

10. Disconnect 2 each of right travel valve hose (23), swing valve hose (241, and left travel valve hose

(25).

11. Disconnect 2

LS select valve pilot hoses (26).

m?7% CLP03829

12. Sling control valve assembly (27), then remove mounting bolts, and lift off control valve assembly.

30-96

Control valve assembly : 170 kg

PC200-6Z

DISASSEMBLY AND ASSEMBLY

CONTROL VALVE

INSTALLATION OF CONTROL VALVE ASSEMBLY Carryoutinstallation removal.

in the reverse order to

Refilling with oil (hydraulic tank) Add oil through the oil filler tothe specified level. Run the engine to circulate the oil through the system. Then check the oil level again.

Bleeding air Bleed the airfrom thecircuitbetweenthe valve and the hydraulic cylinder. For details, see TESTING AND ADJUSTING, Bleeding air.

PC200-6Z

30-97

0 v

O T

-0

w \

DISASSEMBLY AND ASSEMBLY

COMROL VALVE

Bucket

RH t r a Boon

L-L

Swine

LH t r a Arm

8-8

79 24

25'

c-c J-J

AA-AA

DKP00528

30-100

PC200-6Z

CONTROL VALVE

The set pressure of the safety valve cannot be adjusted when it is installed on the machine, so do not disassemble. This section explains the procedure for the 6spool valve. 1. Main reliefvalve Remove main relief valve (2).

Unload valves, safety-suction valves.suction valves 1) Remove unload valves (1) and (17). 2) Remove safety-suction valves (23). (221,(271, (18). and (20). 3) Remove suction valves (251,(241,(211, (261, and (19).

3. Pressure compensation valves

Beforeremoving any pressure compensation valve, check and mark its mounting position. 1) Remove bucket DUMP pressure compensation valve (81, R.H. travel REVERSE pressure compensation valve (71, boom RAISE.pressurecompensation valve (61,rightswing pressure compensation valve (51, L.H. travel REVERSE pressure compensation valve (41, and arm OUT pressure compensation valve (3). 2) Remove bucket CURL pressure compensation valve (101, R.H. travel FORWARD pressure compensation valve (111, boom LOWER pressure cornpensation valve(121, left swing pressure compensation valve (131, L.H. travel FORWARDpressurecompensationvalve (741, and arm IN pressurecompensation valve (15). After removing the pressure compensation valves, remove check valve (35) from each pressure compensation valve mount.

LS select valve

Remove LS select valve (38).

f'C200-6Z

30-101

DISASSEMBLY AND ASSEMBLY

LS shuttle valves, pump merge/divider valve,

boom regeneration valve

1) Remove LS shuttle valves (79) and (81). 2) Remove block (80). then remove boom regenerationspring (61) and boom regeneration valve (62).

Remove covers (9) and (16).

7. Arm control valve 1) Remove case (701, then remove spring (74) and retainer (69). 2) Remove case (661, then remove spring (67) and retainer (78). 3) Remove spool assembly (68). Do not disassemble spool assembly (68).

CONTROLVALVE

10. Boom control valve 1) Remove case (571, then removespring (55) and retainer (60). 2) Remove case (641, thenremovespring (53) and retainer (63). 3) Remove spool assembly (54). Do not disassemble spool assembly (54).

11. Bucket control valve 1) Remove case (301, then removespring (31) and retainer (32). 2) Remove case (341, then remove spring (28) and retainer (33). 3) Remove spool assembly (29). Do not disassemble spool assembly (29).

8. Swing control valve 1) Remove case (401, then remove spring (39) and retainer (41). 2) Remove case (431, then remove spring (36) and retainer (42). 3) Remove spool assembly (37). Do not disassemble spool assembly (37).

RH. travel, L.H. travel control valves

1) Remove case (471, then remove spring

(46) and retainer (48). 2)Remove case(50). spring (44). and retainer (49). 3) Remove spool assembly (45). Do not disassemble spool assembly (45).

30-1 02

PC200-6Z

VALVE DISASSEMBLY CONTROL AND ASSEMBLY

ASSEMBLY OF CONTROL VALVE ASSEMBLY W3) I

DKP00526

FC200-6Z

30-103

c I

VALVEDISASSEMBLY CONTROL AND ASSEMBLY

Coat the sliding surfaces of all parts with engine oil before installing.

Bucket control valve spool 7 ) Assemble spool assembly (29) t o valve body. 2) Assembleretainer (33)and spring (281, then fit O-ring t o case (34) and install. Case mounting bolt : 30.87 t 3.43 Nm (3.15t 0.35 kgm} 3) Assembleretainer (32) and spring (31) to spool, then fit O-ring to case (30) and install. Case mounting bolt : 30.87 2 3.43 Nm 6.15 t 0.35 kgm}

2. Boom control valve spool 1) Assemble SPCOI assembly (54) to valve body. 2) Assembleretainer (63) and spring (53). then fit O-ring t o case (64) and install. QE3 Case mounting bolt : 30.87 3.43 Nm 13.15 t 0.35 kgm) 3) Assemblespring (56) and piston (591, then install plug (58). Plug : 107.8 14.7 Nm (11.0 1.5 kgm} 4) Assembleretainer (60) and spring (551, then install case (57). Case mounting bolt : 30.87 3.43 Nrn (3.15t 0.15 kgm}

3)Assembleretainer (41) and spring (39), then fit O-ring t o case (40) and install. Case mounting bolt : 30.87 t 3.43 Nrn {3.15t 0.15 kgm}

5. Arm control valve

1) Assemble spool assembly ( 6 8 ) to valve body. 2) Assembleretainer (78)andspring (67). then fit O-ring t o case (66) and install. Case mounting bolt : 30.87 t 3.43 Nm (3.15t 0.15 kgm} 3) Assembleretainer (69) andspring (741, then fit O-ring to case (70) and install. QE3 Case mounting bolt : 30.87 3.43 Nm 13.15 0.15 kgm}

3. R.H. travel, L.H. travel control valves

1) Assemble spool assembly (45) to valve body. 2) Assemble retainer (49) and spring (441, then fit O-ring t o case (50) and install. Case mounting bolt : 30.87 2 3.43 Nm 13.15 t 0.15 kgm} 3)Assemble retainer (48) and spring (46) to spool, then fit O-ring to case (47) and install. Case mounting bolt : 30.87 2 3.43 Nm 13.15 t 0.15 kgm}

Swing control valve spool 1) Assemblespool assembly (37) to valve body. 2) Assemble retainer (42) and spring (36), then fit O-ring to case (43) and install. Case mounting bolt : 30.87 2 3.43 Nm 13.15 t 0.15 kgml

30-1 06

PC200-6Z

DISASSEMBLY CONTROL AND ASSEMBLY

VALVE

6. Covers

1) Fit O-ring to cover (161, then install. 2) Fit O-ring to cover (91, then install. Mating surface of covers (161, (9) : Seal end 242 or equivalent Tighten the mounting bolts in the order shown in the diagram on the right. Mounting bolt : 166.6 t 9.8 Nm I17 1 kgm}

7. LS shuttle valves, pump mergejdivider valve,

boom regeneration valve 1) Assemble boom regeneration valve (62) and spring (61) to valve body, then install block (801. Tighten the mounting bolts in the order shown in the diagram on the right. Mounting bolt : 166.6 t 9.8 Nm (17 1 kgm} 2) Install LS shuttle valves (81) and (79). Mounting bolt : 66.15 t 7.35 Nm (6.75z 0.75 kgm}

CKpQo8M

8. LSselectvalve Install LS select valve (38). LS select valve :

127.4 = 19.6 Nm (13* 2 kgm}

9. Pressurecompensation valves Check themarksmade on each pressure compensation valve during disassembly, and install in the correct position. 1) Beforeinstallingpressurecompensation valves below, install check valve (35). 2) Fit O-ring, then install armIN pressure compensation valve (151,L.H. travel FORWARD pressure compensation valve(141, left swing pressurecompensationvalve (131, boom LOWER pressure compensation valve (121, R.H. travel FORWARD pressure compensation valve (11). and bucket CURL pressure compensation valve (10). Pressure compensation valves : 392 2 19.6 Nm I40 t 2 kgm} OUT pressure 3) Fit O-ring, theninstallarm compensation valve (31,L.H. travel REVERSE pressure compensationvalve (41, right swing pressurecompensationvalve 151, boom RAISE pressure compensation valve (61, R.H. travel REVERSE pressurecompensation valve (71, and bucket DUMP pressure compensation valve (8). Pressure compensation valves : 392 t 19.6 Nm I40 2 2 kgm)

PC200-6Z

30-107

VALVE DISASSEMBLY CONTROL AND ASSEMBLY

10. Unload valves,safety-suctionvalves,suction valves FitO-rings and install suction valves (191, (261, (211, (241, and (25). Suction valve : 147 2 9.8 N m I15 t 1 kgm} Fit O-rings and install safety-suction valves (18). (271,(221, and (23). Safety-suction valve : 147 t 9.8 Nm I15 t 1 kgm) Fit O-ringsand install unload valves(17)and (1). Unload valve assembly : 166.6 19.6 Nm I17 t 2 kgm}

u<woB20

11. Main relief valve

FitO-ring and install mainrelief valve assembly (2). Main relief valve : 53.9 t 4.9 Nm i5.5 t 0.5 kgm}

30-1 08

PC200-6Z

DISASSEMBLY AND ASSEMBLY

VALVE MAIN RELIEF

DISASSEMBLY OF MAIN RELIEF VALVE ASSEMBLY

CKPO39 I9

1. Loosenlocknut (91, removeplug (81, then remove retainer (6). 2. Locsenlocknut (101, then remove holder (71, spring (111, seat (121, and poppet (5). 3. Remove ring (11, thenremovevalve (3)and spring (4). If anyabnormalityisfoundinanypart after disassembly, replace the wholemain relief valve assembly.

ASSEMBLY OF MAIN RELIEF VALVE ASSEMBLY .-_

Coat the sliding surfaces with engineoil.

1. Assemble spring (4) and valve (31,then install ring (1). 2. Install seat (121, poppet (51, spring (111, and holder (71, and secure in position with locknut (10). Locknut : 53.9 2 4.9 Nm (5.5 2 0.5 kgm} 3. Fitretainer (61, then install plug ( 8 ) and secure in position with locknut (9). Locknut : 39.7 2 4.9Nm (4.0 0.5 kgm} After installing main reliefvalve to control valve assembly, adjustpressurereferring to section TESTING AND ADJUSTING, testing and adjusting hydraulic pressure in work equipment, swing, travel circuit.

PC200-6Z

30-109

PC VALVE

DISASSEMBLY AND ASSEMBLY

REMOVAL OF PC VALVE ASSEMBLY

Disconnect the cable from the negative (-1 terminal of the battery. Lower the work equipment completely to the ground andstop the engine. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank.

Remove the hydraulic tank strainer,and using tool B, stop the oil. When not using tool B, remove the drain plug, and drain the oil from the hydraulic tank and inside the system. b

J B

CLPO3276

Hydraulic tank : Approx. 170 fl

There are PC valve assernblies installed to both the front pumpand the rear pump, but the procedure for removal is the same.

1. Remove nut (11, then remove hoseassembly (2).

Installlocknut @ (708-2L-28290). Locknut : 100.5 2 12.5 Nm (10.25

1.25 kgm}

(3)in directionof loosening, then end. tighten at locknut (iJ Angle of turning for nut (3):Approx. 30"

3. Turnnut

Fit tool to widthacross flats (22 mm) of hexagonal portion of sleeve (41, then loosenandremove PC valve assembly (5).

a CKPO37 I9

30-1 10

PC200-6Z

PC VALVE

DISASSEMBLY AND ASSEMBLY

INSTALLATION OF PC VALVE ASSEMBLY Carry outinstallation removal. Nut (2): 100.5

* &

in the reverse order to

12.5 Nm t10.25

After installing the move locknut @.

1.25 kgm}

PC valve'assembly,re-

Adjust the PC valve assembly. For details, see TESTING AND ADJUSTING, Testing and adjusting PC valve output pressure (servo piston inlet pressure). Nut (3): 100.5 f 12.5 Nm (10.25 t 1.25 kgm}

Refilling with oil (hydraulic tank) Add oil through theoil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.

PC200-6Z

30-1 1 1

LS VALVE

DISASSEMBLY AND ASSEMBLY

REMOVAL OF LS VALVE ASSEMBLY

A Disconnect the cable from the negative (-1 terminal of the battery. A Lower the work equipment completely to the

ground and stop the engine. Then loosen theoil filler cap slowly to release the pressure inside the hydraulic tank. Remove thehydraulic tank strainer, andusing tool B, stop the oil. When not usingtool 6, remove the drain plug, and drain the oil from the hydraulic tank and inside thesystem. b

CLPO3276

Hydraulic tank :Approx. 170

There are LS valve assemblies installed to both the front pump and the rear pump, but the procedure for removal is the same.

1. Disconnecthose (1). 2.

Fit t o o l t owidth across flats (30mm) of hexagonal portion of sleeve, then loosen and remove LS valve assembly (2).

INSTALLATION OF LS VALVE ASSEMBLY Carry outinstallationinthe removal.

reverse order to

.A. Adjust the LS valve assembly.

For details, see TESTING AND ADJUSTING, Testing and adjusting LS valve output pressure (servo piston inletpressure) and LS differential pressure. Sleeve : 139.7 12.3 N m f14.752 1.25 kgm)

Refilling with oil {hydraulictank) t Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.

30-1 12

PC200-6Z

DISASSEMBLY AND ASSEMBLY

PCEPC VALVE

REMOVAL OF PC-EPC VALVE ASSEMBLY

A Disconnect the cable from the negative (-1 terminal of the battery. A Lower the work equipment completely to the

ground and stop the engine. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank.

1. Remove the main pump bottom cover. 2.

Disconnect wiring connectors (1) (2 places). After disconnecting the connectors, fit tags to distinguish them.

\\\

CLPO3831

3. Disconnecthose (2). 4.

Remove PC-EPC valve assembly (3).

INSTALLATION OF PC-EPC VALVE ASSEMBLY Carry out installation in the reverse order t o removal.

PC200-6Z

Hose sleeve nut :

24.5 t 4.9 Nm 4 . 5 t 0.5 kgm)

PC-EPC valve assembly mounting bolt : 13.3 2 1.5 N m {1.35 2 0.15 kgm)

30-1 13

AND ASSEMBLY SOLENOID DISASSEMBLY VALVE

REMOVAL OF SOLENOID VALVE ASSEMBLY Disconnect the cable from the negative (-) terminal of the battery. 1. Remove 3 solenoid wiring connectors (1) from clip and disconnect. Mark the male and female ends of each connector with tags to prevent mistakes when connecting.

Disconnect 2 hoses (2) installed to bottomof va Ive. After disconnecting the hoses, fit tags to distinguish them.

3. Disconnect 4 hoses (3)installed to top of valve.

After disconnecting the hoses, fit tags to distinguish them.

Remove mounting bolts, then remove solenoid valve assembly (4).

When removing solenoid valve as an individual Part i) When washing valve,loosen mounting bolt (5)and remove.

INSTALLATION OF SOLENOID VALVE ASSEMBLY

Bolt : 3.9 z 0.39 Nrn I0.4 t 0.04 kgm)

CKPO I453

30-1 14

PC200-6Z

EQUIPMENT SWING PPC VALVE

DISASSEMBLY AND ASSEMBLY WORK

REMOVAL OF WORK EQUIPMENT SWING PPC VALVE ASSEMBLY

A Lower the work

I /I

equipment completely to the ground andstop the engine. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank.

1. Remove control stand case. For details, see REMOVAL OF CONTROL STAND CASE.

2. Remove joint bolt(11, and disconnect hose (2).

p g

3. Remove mounting bolts, raise PPC valve assembly (31,then disconnect hoses (4) and (51, and

1121

remove. Before disconnecting the hoses, make match marks to show the connecting position.

INSTALLATION OF WORK EQUIPMENT SWING PPC VALVE ASSEMBLY -

Carry out installation in the reverse order to removal. Hose mount joint bolt: 29.4 t 4.9 Nm (3.0 t 0.5 kgm}

Hose mount joint bolt : 39.2 f 4.9 N m I4.0 t 0.5 kgm} If there is excessive play in the control levers, adjust the PPC valve. For details, see TESTING AND ADJUSTING, Adjusting PPC valve.

f'C200-6Z

30-1 15

DISASSEMBLY AND ASSEMBLY

WORK EQUIPMENT SWING PPC VALVE

DISASSEMBLY OF WORK EQUIPMENT SWING PPC VALVE ASSEMBLY 1. Remove nut (11, then remove disc (2) and boot

(3).

Remove bolts, then remove plate (5). Do notremove joint (4) unless it is to be replaced.

3. Remove seal (6) and collar ( 7 ) . 4.

Pull out piston (8). andremoveretainer (91, springs (10) and (111, and shim (12). Spring (10) consists of a set of two types of springs withdifferent installedloads, so check the mounting position (oil port) and mark with tags to prevent mistakes when installing.

5. Pull out valve (13) from body (14).

CLPO3924

30-1 16

PC200-6Z

WORK EQUPMENT SWING PPC VALVE

DISASSEMBLY AND ASSEMBLY

ASSEMBLY OF WORK EQUIPMENT SWING PPC VALVE ASSEMBLY 1. Assemble valve (13) to body (14).

2. Assemble shim (12) andspring (11) to valve (13). When assembling spring (111, set the end with the small coil diameter(insidediameter) at shim (12) end.

3. Assemble spring (101, retainer (91, and piston (8). The number of loops in the coil for spring (10) is different for each of thehydraulic ports below, so be careful when installing.

* *

Position of port

Free length of spring

P1, P2

44.4 mm

P3, P4

42.4 mm

The position of each port is marked on the bottom of the valve body. Piston : Grease (G2-LI) When assemblingpiston (81, coat the outside of the pistonand the inside of the hole in the body with grease.

Fit O-ring to collar(7)and (14). then install seal (6).

assemble in body

Install plate (5). Mounting bolt : 1323 t 1.47 Nm (1.35 t 0.15 kgm}

Install joint (4). Sliding portion of joint : Grease (G2-LII, 2 - 4 cc Female thread of body : Thread tightener (LT-2) Coat two places on the female thread with one drop each of Loctite as shown in the diagram. Joint : 44.1 t 4.9 N m (4.5 t 0.5 kgm} Keep strictly to the tightening torque.

Assemble boot (3)and disc (2). and tighten with nut (1). Contact surface of piston and disc : Grease (G2-LI1, 0.3 - 0.8 cc Nut : 112.7 = 14.7 N m (11.5 2 1.5 kgm} After assembling the disc, adjust the height of the disc. For details, see TESTING AND ADJUSTING, Adjusting PPC valve.

PC200-62

30-1 17

PPC VALVE

ASSEMBLY DISASSEMBLYTRAVEL AND

REMOVAL OF TRAVEL PPC VALVE ASSEMBLY

to the A Lower the work equipment completely loosen the oil ground andstop the engine. Then filler cap slowly to release the pressure inside the hydraulic tank.

1. Remove travel PPC valve undercover.

Removefloor mat.

3. Remove pedals (1) and levers (2). 4.

Removecover (3).

Remove covers (41,then remove springs (5).

Disconnect 6 PPC hoses (71,then remove travel p g PPC valve assembly (8).

CEP00427

INSTALLATION OF TRAVEL PPC VALVE ASSEMBLY Carryoutinstallation removal.

in the reverse order t o

Cover mounting bolt : 19.6 t 1.96 Nrn {2.0 t 0.2 kgrn} Hose mount joint bolt : (width across flats : 30 mm) :

39.2 t 4.9 Nrn 14.0 t 0.5 kgrn}

Hose mount elbow : (width across flats : 22 rnrn) : QECI

34.3 t 4.9 Nrn 13.5 t 0.5 kgm} Hose mount joint bolt : (width across flat : 17 m m ) : 24.5 4.9 Nrn I2.5 t 0.5 kgrn}

CEPW428

-8

CEP00429

30-1 18

PC200-6Z

DISASSEMBLYTRAVEL AND ASSEMBLY

PPC VALVE

DISASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY 1. Remove screws (1). then remove levers (2).

2. Remove mounting bolts (31, then remove case and shaft assembly (4).

3. Remove mounting bolts (51,then remove plate

* *

(6) and damper assembly (7) as one unit. Check the thickness and mounting position of washer (18). Never disassemble damper assembly (7).

Remove mounting bolts (81, then remove damper assembly ( 7 )from plate (6).

5. Remove seal (9) and collar (10).

Pull out piston (111, andremoveretainer (121, springs (13) and (141, and shims (15). Check the number and thickness of shims (15) for each mounting position, and keep in a safe place.

PUII out valve (16) from body (17).

CLPO3926

PC200-6Z

30-1 19

AND ASSEMBLY DISASSEMBLYTRAVEL

PPC VALVE

ASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY I. Assemble valve (16) in body (17).

2. Assembleshim

(15) andspring (14) to valve (16). thickness Assemblethesamenumberand of shim (15) as was removed during disassembly. Standard shim thickness : 0.3 m m top Spring (14) is not symmetricalatthe coil small the with and bottom, so assemble diameter (inside diameter) at the shim end.

Assemble spring (131, retainer (121, and piston (11). Outside circumference of piston, body hole : Grease (G2-LI)

Fit O-ring t o collar (10) and assemble in body (171, then install seal (9).

Install damper assembly (7) to plate (61, then tighten mounting bolts (8). Mounting bolt :Thread tightener (LT-2) Mounting bolt: 4.41 = 0.49 Nrn i0.45 f 0.05 kgm}

6. Install plate (6) and damper assembly (7) as one unit, then tighten mounting bolts(5). Check the thickness of washer (18) and assemble in the position checked during disassembly. Mounting bolt: 30.87 3.43 Nm I3.15 L 0.35 kgm}

7. Install case and shaft assembly (4). then tighten mounting bolts (3). Check thatthe out-of-parallel of shaft and damper assembly (7) of case and shaft assembly (4) is less than 0.5. Q Rocking portion of shaft, connection of lever and piston : Grease (G2-LI) Mounting bolt: 27.93 = 3.43 Nm 12.85 z 0.35 kgm)

CLPO3926

Install levers (2). then tighten screws (1). Adjust so that lever (2) can slightly move. Rocking portion of lever pin and plate : Grease (G2-LI) Screw : 8.82 z 0.98 N m IO.9 z 0.1 kgm}

30-1 20

PC200-6Z

DISASSEMBLY AND ASSEMBLY

BOOM LOCK VALVE

REMOVAL OF BOOM LOCK VALVE ASSEMBLY

A Lower the work equipment completely to the

ground, then release the remaining pressure in the hydraulic circuit. For details, see TESTING AND ADJUSTING, Releasing remaining pressure in hydraulic circuit.

1. Disconnect tube (1) and hoses (2).

Disconnect tube (3).

'CLPO3927

3. Remove mounting bolts of bracket (4). then remove boomlock valve (5) together with bracket (4).

INSTALLATION OF BOOM LOCK VALVE ASSEMBLY Carryoutinstallation removal.

in the reverse order to

Refilling with oil (hydraulictank) It Add oil through the oil filler to the specified level. Run theengine t o circulatethe oil through thesystem. Then check the oil level again.

CLPO3928

Bleeding air J, Bleed the air. For details, see TESTING AND ADJUSTING, Bleeding air.

PC200-6Z

30-121

BOOM CYLINDER

DISASSEMBLY AND ASSEMBLY

REMOVAL OF BOOM CYLINDER ASSEMBLY

Extend the armand bucketfully, lower the work equipment completely to the ground, and put the safety lock lever in the LOCK position.

1. Disconnect grease hose (1).

2. Sling boom cylinder assembly (2). and remove lock bolt (3). 3. Remove plate, then remove head pin (4). Ir Thereareshimsinstalled, so check the

number and thickness, and keep in a safe place.

4. Start engine, andretractpiston

rod, then tie piston rod with wire to prevent it from coming out. Setstand 0 underthecylinder assembly, and adjust the position for slinging. Release the remaining pressure in the hydraulic circuit. For details, seeTESTING AND ADJUSTING, Releasing remaining pressure in hydraulic circuit.

5. Disconnect hoses (5).

6. Remove plate, then using forcing screws 0,remove bottom pin (61, and remove boom cylinassembly der (2). Thereareshims installed, so check the number and thickness, and keep in a safe place.

&I Boom cylinder assembly : 205

30-1 22

PC200-6Z

DISASSEMBLY AND ASSEMBLY

BOOM CYLINDER

INSTALLATION OF BOOM CYLINDER ASSEMBLY Carry out installation in the reverse orderto removal.

When tightening thelocknut, tighten so that clearance a between the plate andnut is 0.5 1.5 mm.

A *

Inside surface of bushing when assembling pin : Anti-friction compound (LM-P) Greasing assembling after pin : Grease (LM-G) When aligning the position of the pin hole, never insert your fingers in the pin hole. Adjust the shim thickness so that clearance b between cylinder rod (7) and plate (8) is below 1 mm. Standardshim thickness : 0.8 mm, 1.5 mm

I CKP03932

A *

Inside surface of bushing when assembling pin : Anti-friction compound (LM-P) Greasing after assembling pin : Grease (LM-G) When aligning the position of the pin hole, never insert your fingers in thepin hole. Adjust the shim thickness so that clearance c between cylinder bottom (9) and bracket (10) is below 1 mm. Standard shim thickness : 0.8 mm, 1.5 rnm

CLPO3933

Refilling with oil (hydraulictank) Add oil through the oil filler to the specified level. Run theengine t o circulatetheoil through thesystem. Then check the oil level again.

CLPO3934

Bleeding air Bleed the air from the cylinder. For details, see TESTING AND ADJUSTING, Bleeding air from hydraulic cylinder.

PC200-6Z

30-1 23

DISASSEMBLY AND ASSEMBLY

LINDER

ARM CY

REMOVAL OF ARM CYLINDER ASSEMBLY

approx. 200 A Extend the arm cylinder piston rodcompletely to

mm, lower the work equipment the ground, then set the remaining safety lock lever to the LOCK position.

between arm cylinder and boom. 1. Set block (iJ

Remove plate, then remove head:pin (1).

3. Start engine, and retract piston rod, thentie

piston rod with wire to prevent it from coming out. Release the remaining pressure in the hydraulic circuit. For details,see TESTINGAND ADJUSTING, Releasing remaining pressure in hydraulic circuit.

CLPO3935

A 4.

Disconnect hoses (2).

Disconnect grease hose (3).

Raise arm cylinder assembly, remove plate, remove bottom pin (41, then remove a r m cylinder assembly (5). so check the Ir There areshimsinstalled, number and thickness,andkeep in a safe place.

30-124

Arm cylinder assembly : 265 kg

PC200-6Z

AND

DISASSEMBLY

ARM CYLINDER

INSTALLATION OF ARM CYLINDER ASSEMBLY Carry out installation in the reverse order to removal.

& Inside surface of bushing when

assembling pin : Anti-friction compound (LM-P) & Greasing after assembling pin : Grease (LM-G) When aligning the position of the pin hole, never insert your fingers in the pin hole.

CLP03936

- m

& Inside surface of bushing when

assembling pin : Anti-friction compound (LM-P) & Greasing after assembling pin : Grease (LM-G) When aligning the position of the pin hole, never insert your fingers in the pin hole. Adjust the shim thickness so that clearance a between cylinder bottom ( 6 ) and bracket (7)is below 1 mm. Standard shim thickness : 0.8 mm, 1.5 mm

A *

Refilling with oil (hydraulictank) Add oil through the oil filler tothe specified level. Run the engine to circulate theoil through the system. Then check the oil level again.

Bleeding air Bleed the air from the cylinder. For details, see TESTINGAND ADJUSTING, Bleeding air from hydraulic cylinder.

PC200-6Z

30-125

AND

DISASSEMBLY BUCKET

ASSEMBLY

CYLINDER

REMOVAL OF BUCKET CYLINDER ASSEMBLY

A Extend the bucket cylinder piston rod

approx. 200 mm, lower the work equipment completely to the ground, then set the safety lock lever to the LOCK position.

1. Set block @ under arm top. 2. Set block @ between link and arm, and block @ between bucket cylinder andarm. bolt Remove 3. lock (1). 4. Remove plate, then remove head pin (2). f Thereareshims installed, so check the number and thickness, and keep in a safe place. rod, then tie 5. Start engine, andretractpiston piston rod with wire to prevent it from coming out. Release the remaining pressure in the hydraulic circuit. For details, see TESTINGAND ADJUSTING, Releasing remaining pressure in hydraulic circuit. 6. Disconnect 2 hoses (3). 7 . Raise bucket cylinder assembly, remove plate, remove bottom pin(41, then remove bucket cylinder assembly (5). p J f Thereareshimsinstalled, so check the number and thickness, and keep i n a safe

CLPO3938

dace-

Bucket cylinder assembly : 165 kg

30-1 26

PC200-6Z

DISASSEMBLY AND ASSEMBLY

CYUNDER

BUCKET

INSTALLATION OF BUCKET CYLINDER ASSEMBLY Carry out installation in the reverse order to removal. f

When tightening the locknut, tighten so that clearance a between the plate and nut is 0.5 1.5 mm.

Inside surface of bushing when assembling pin : Anti-friction compound (LM-P) Grease after assembling pin : Grease (LM-G) When aligning the position of the pin hole, never insert your fingers in thepin hole. Adjust the shim thickness so that clearance b between link (6) and link ( 7 ) is below 1 rnm. Standard shim thickness : 0.8 rnm, 1.5 mm

I CKP03932

A *

I -

6 Inside surface of bushing when

assembling pin : Anti-friction compound (LM-P) 6 Grease after assembling pin : Grease (LM-GI When aligning the position of the pin hole, never insert your fingers in the pinhole. Adjust the shim thickness so that clearance c between cylinder bottom ( 8 ) and bracket ( 9 ) is below 1 mm. Standardshim thickness : 0.8 mm, 1.5 mm

CLP03939

Refilling with oil (hydraulictank) Add oil through the oilfiller to the specified level. Run the engine to circulate theoil through the system. Then check the oil level again.

CLPO3940

Bleeding air Bleed the air from the cylinder. For details, see TESTING AND ADJUSTING, Bleeding air from hydraulic cylinder.

Pc200-6Z

30-127

AND ASSEMBLY CYLINDERHYDRAULIC DISASSEMBLY

DISASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY 1. Piston rod assembly 1) Remove piping from cylinder assembly. 2) Remove mounting bolts and disconnect head assembly (1).

3) Pull out piston rod assembly (2). Place a container under the cylinder catch the oil.

CLPO3941

4) Disassemble piston rod assembly as follows. i) Set piston rod assembly (2) in tool 01.

ii) Remove stopper screw (3) of piston assembly. Common screw size for boom, arm, and bucketcylinder: M12 x Pitch 1.75

CLP03779

Ifthe caulking of screw (3)istoo strongand it cannot be removed, tighten the screw fully, then fit a tap to thethread and remove the screw.

30-1 28

DKP00498

PC200-6Z

CD L

0 I

MBLY

AND DISASSEMBLY

ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY

* *

Be careful notto damage the packings,dust seals, and O-rings. Do not try to force the backup ring into position. Warm it in warm water (50 60Â°C) before fitting

it.

1. Assembly of head assembly 1) Using tool 0 5 , press fit bushing (20). 2) Assemble buffer ring (19). 3) Assemble rod packing (18). 4) Using tool 06, install dust seal(171, and secure with snap ring (16). 5) Install backup ring and O-ring (15).

CLPO3786

CLPO3787

15 17

CLPO2322

Assembly of piston assembly 1) Using tool 03, expand piston ring (13). f Set the piston ring on tool 0 3 , and turn the handle 8 10 times to expand the ring. 2) Set tool 0 4 in position, and compress piston ring (13).

CKPO3788

CLPO3789

3) Install backup ring and O-ring (14). 4) Assemble wear ring (12).

5) Assemble ring (11). .k

Be careful not to open the endgap of the ring too wide. Ring groove : Grease (G2-LI)

I PC200-6Z

CLPO3784

30-131

DISASSEMBLY CYLINDERHYDRAULIC AND ASSEMBLY

3. Piston rod assembly

1) Set piston rod assembly (2) to tool 01.

2 ) Assemble head assembly (7).

3) Fit O-ring and backup ring to collar (61, then assemble. Boomandarm

cylinderonly

4) Assembleplunger (5). Boomandarm cylinderonly Check thatthere is a small amount of play at thetip of the plunger. Arm cylinderonly

5) Set cushion plunger (10) to piston rod, then assemble 12 balls (9) and secure with cap (8). Arm cylinderonly

CXPO3783

6) Assemble piston assembly (4) as follows. Whenusingrod and piston again: Ir Washthoroughly and removeall metal particles and dirt. i) Screw in piston assembly (41, then use tool 0 2 to tighten piston assembly (2) so thatposition of screw thread hole matches. Remove all burrs and flashes with a file. ii) Tighten screw (3). Screw (3) : 66.2 7.35 Nm (6.75 f: 0.75 kgml

30-132

OLP00499

PC200-6Z

BLY

AND

DISASSEMBLY

iii) Caulk thread at 2 places with punch.

When using a new part for either or both of rod or piston assembly (2) For therod with bottom cushion, mark the cushion plug position on the end face of the rod. Armcylinderonly

PunchI

DKP00500

i) Screw in until piston assembly (4) contacts end face of rod, then use tool 0 2 to tighten. Piston assembly (4): 294 t 29.4 Nm I30 t 3.0 kgm} After tightening the piston, check that there is play in plunger (5). Boom, arm cylinderonly

DKP00501

ii) Machine one of holes used to install screw (3). Align a drill horizontal with the V-groove of the thread of rod (2) andpiston (41, then carry out machining. For the cylinder with bottom cushion (arm cylinder), avoid the cushion plug position when machining. Screw machining dimension 4mm)

Drill

CLPO3792

iii) After machining, wash thoroughly to remove all metal particles and dust. iv) Tighten screw (3). Screw (3) : 66.2 2 7.35 Nm 16.75

0.75 kgm)

v) Caulk thread a t 2 places with punch. C I Po3779

PC200-6Z

30- 133

DISASSEMBLY CYLINDERHYDRAULIC AND ASSEMBLY

7) Assemble piston rod assembly (2). Seal portion : Grease (G2-Ll) Set the end gap of the ring horizontal (at side position), align axial center of cylinder tube, then insert. After inserting, check that the ring is not broken and has not come out, then push in fully.

DLP00502

8 ) Tighten head assembly (1) withmounting bolts. Mounting bolt :

Tightening torque

Cylinder Bucket Arm Boom

I I

9) Install piping.

30-134

270-+39Nm {27.5*4.0kgm) 373254Nm <38.0*5.5kgm) 27039Nm (27.5a4.Okgm)

CLPO394 1

PC200-6Z

WORK EQUIPMENT

DISASSEMBLY AND ASSEMBLY ._-

REMOVAL OF WORK. EQUIPMENT ASSEMBLY

A Extend the arm andbucket fully, lower the work equipment to the ground, and set the safety lock lever to theLOCK position.

1. Disconnect grease hose (1).

Sling boom cylinder assembly (21, and remove lock bolt (3).

3. Remove plate, then remove head pin (4) f

Thereareshims installed, so checkthe number and thickness, and keep in a safe place.

Start engine,and retract piston rod, thentie piston rod with wire to prevent it from coming out, and lower it onto block. f Disconnect the boom cylinder on the opposite side in the same way. Release the remaining pressure in the hydraulic circuit. For details, see TESTINGAND ADJUSTING, Releasing remaining pressure in hydraulic circuit.

A 5.

Disconnect hoses (51, and secure it to valve with rope. Hoses (6) are for machines equipped with an additional attachment circuit.

Disconnect wiring connector ( 6 ) forworking lamp.

7. Sling work equipment assembly, remove plate, then remove foot pin ( 7 ) using tool P, and removework equipment assembly (8). Thereareshims installed, so checkthe number and thickness, and keep in a safe place.

m II

CLPO4028

&I Work equipment assembly : 3,300 kg

CLP040?9

PC200-6Z

30-1 35

DISASSEMBLY AND ASSEMBLY

WORK EQUIPMENT

INSTALLATION OF WORK EQUIPMENT ASSEMBLY Carryoutinstallation removal. f

in the reverse order to

When tightening the locknut, tighten so that clearance a between the plate and nut is 0.5 1.5 mm.

e Inside surface of bushing when

A f

assembling pin : Anti-friction compound (LM-P) Grease after assembling pin : Grease (LM-G) When aligning the position of the pin hole, never insert your fingers inthe pin hole. Adjust the shim thickness so that clearance b between cylinder rod (10) and plate (11) is below 1 mm. f Standard shim thickness : 0.8 mm, 1.5 mm

a Inside surface of bushing when

A f

assembling pin : Anti-friction compound (LM-P) Grease after assembling pin : Grease (LM-GI When aligning the position of the pin hole, never insert your fingers in the pin hole. Adjust the shim thickness so that clearance c between boom (12) and bracket (13) is below l mm. f Standard shim thickness : 0.8 mm, 1.0 mm, 1.5 m m

Refilling with oil (hydraulic tank) Add oil through the oil filler to the specified level. Run the engine t o circulate theoil through the system. Then check the oil level again.

CKP03932

CLPO3947

+ C

CLPO3948

Bleeding air Bleed the air from the cylinder. For details, see TESTING AND ADJUSTING, Bleeding air from hydraulic cylinder.

30-1 36

PC200-6Z

DISASSEMBLY AND ASSEMBLY

BUCKET

REMOVAL OF BUCKET ASSEMBLY

lower A Set the back of the bucket facing down, the ground, the work equipment completely to and set the safety lock lever to the LOCK position.

1. Remove lock bolt (1). 2.

Removeconnecting pin (2) betweenlink and bucket. Thereare shims installed, so check the number and thickness, and keep in a safe place.

3. Start engine, andretractpiston rod, thentie piston rod with wire to prevent it from coming out.

Remove lock bolt (3).

Remove plate (41, the remove connectingpin (5) between arm and bucket. installed, so check the Thereareshims number and thickness, and keep in a safe place.

After raising work equipment, swing to disconnect bucket assembly (6).

Bucket assembly :650 kg

PC200-6Z

30-1 37

BUCKET

DISASSEMBLY AND ASSEMBLY

INSTALLATION OF BUCKET ASSEMBLY Carry outinstallation removal.

lfl

in the reverse order to

E l

A *

When tightening the locknut, tighten so that clearance a between the plate and nut is0.5 - 1.5 mm. Inside surface of bushing when assembling pin : Anti-friction compound (LM-P) Grease after assembling pin : Grease (LM-G) When aligning the position of thepin hole, never insertyour fingers in the pin hole. Adjust the shim thickness so that clearance b between bucketboss ( 7 ) and link ( 8 ) is below 1 mm. Standard shim thickness : 0.8 mm, 1.5 mm

- + - I a

CKP03932

E l

a Inside surface of bushing when

A * *

assembling pin : Anti-friction compound (LM-P) Grease after assembling pin : Grease (LM-G) When aligning the position of the pin hole, never insert your fingers in the pin hole. Set the O-ring at the end face of the bucket boss securely. Adjust the shim thickness so that clearance c between armtop (9) and spacer (IO) is 0.5 - 1.0 mm. Standardshim thickness : 0.5 mm, 1.0 mm

I I

CLPO3952

CLP03953

30-138

PC200-62

DISASSEMBLY

ASSEMBLY

ARM

REMOVAL OF ARM ASSEMBLY 1.

Remove bucket assembly. For details, see REMOVAL OF BUCKET ASSEMBLY.

Secure front link to arm with wire.

3. Pull in arm so that it is easy to remove pin at

arm cylinder head, then lower arm and bucket assembly (1) on to block 0. Set the safety lock lever to the LOCK position.

Set block @ between arm cylinder and boom.

Remove plate, then remove arm cylinder head pin (2).

cLP05 I8 I

6. Start engine, andretractpiston rod, thentie piston rod with wire to prevent it from coming out. Release the remaining pressure in the hydraulic circuit. For details, see TESTINGAND ADJUSTING, Releasing remaining pressure in hydraulic circuit.

7. Disconnect 2 hoses (3). Install blind plugs atthe male end and in the disconnected hoses.

Remove plate, thenremove connecting pin (4) between arm and boom. Ir Thereareshims installed, so check the number and thickness, and keep in a safe place.

After raising boom, swing to remove armand bucket cylinder assembly (1).

6 Arm, bucket cylinder

K200-6Z

assembly : 950 kg

30-139

ARM

DISASSEMBLY AND ASSEMBLY

INSTALLATION OF ARM ASSEMBLY Carry out installation in the reverse order to removal.

Inside surface of bushing when assembling pin : Anti-friction compound (LM-P) Grease after assembling pin : Grease (LM-GI When aligning the position of the pin hole, never insert your fingers in the pin hole.

I (

CLPO3955

Inside surface of bushing when assembling pin : Anti-friction compound (LM-P) 6 Grease after assembling pin : Grease (LM-G) When aligning the position of the pin hole, never insert your fingers in the pin hole. Adjust the shim thickness so that clearance a between boom top ( 6 ) and arm bottom (7) is below 1.0 mm. f Standard shim thickness : 0.8 mm

A *

Refilling with oil (hydraulic tank) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check theoil level again.

Bleeding air Bleed the air from the cylinder. Fordetails, Bleeding air see TESTING AND ADJUSTING, from hydraulic cylinder.

30-140

PC200-6Z

DISASSEMBLY BUCKET AND ASSEMBLY

ARM

REMOVAL OF BUCKET ARM ASSEMBLY

A Extend the arm cylinder piston rodapprox. 200

mm, lower the work equipment completely to the ground, thenset the safety lock lever to the LOCK position.

1. Set block @ between arm cylinder and boom. 2.

Remove plate, then remove arm cylinder head pin (1). pig

3. Startengine,and

retractpiston rod, thentie piston rod with wire to prevent it from coming out. Release the remaining pressure in the hydraulic circuit. For details, see TESTINGAND ADJUSTING, Releasing remaining pressure in hydraulic circuit.

CLPO3956

Disconnect hoses (2)and (3). Install blind plugs at themale end and in the disconnected hoses.

Raise bucket and arm assembly, remove plate, then remove connecting pin (4) betweenarm and boom, and remove bucket and arm assernbly (5). There are shims installed, so check the number and thickness, and keep in a safe place.

PCXX)dZ

Bucket, arm assembly : 1,650 kg

30-141

, DISASSEMBLY BUCKET AND ASSEMBLY

ARM

INSTALLATION OF BUCKET ARM ASSEMBLY Carry out installation in the reverse order to removal.

p g

Inside surface of bushing when assembling pin : Anti-friction compound (LM-P) 6 Grease after assembling pin : 'Grease (LM-GI When aligning the position of the pin hole, never insert your fingers i n the pin hole.

A *

CLPO3955

Inside surface of bushing when assembling pin : Anti-friction compound (LM-P) Grease after assembling pin : Grease (LM-G) When aligning the position of the pin hole, never insert your fingers in the pin hole. Adjust the shim thickness so that clearance a between boom top(6) and arm bottom ( 7 ) is below 1 mm. Standard shim thickness : 0.8 mm

Refilling with oil (hydraulictank) Add oil through the oil filler to the specified level.Run the engine to circulatethe oil through the system. Then checkthe oil level again.

Bleeding air Bleed the air from the cylinder. For details, see TESTING ANDADJUSTING, Bleeding air from hydraulic cylinder.

30-1 42

PC200-6Z

CAB

DISASSEMBLY AND ASSEMBLY

OPERATOR'S

REMOVAL OF OPERATORS CAB ASSEMBLY

A Disconnect the cable from the negative ( 4 terminal of thebattery.

1. Remove floor mat. 2.

Disconnect speaker wiring (11, room lamp wiring (2), antenna wiring (31,and washer hose (4). f Fit tags to mark the male and female ends of the connectors t o prevent mistakes when connecting.

3. Disconnect wiper motor wiring connector (5). 4.

Remove 9 cab mounting bolts. the chassis ground f Check thepositionof connection.

Lift off operator's cab asseembly (6).

Operator's cab assembly : 250 kg

CLPO4022

INSTALLATION OF OPERATOR'S CAB ASSEMBLY Carry outinstallation removal.

in the reverse order t o

CLP04023

PC200-6Z

CLPO4, 0 2 4

30-145

DISASSEMBLY AND ASSEMBLY

COUNTERWEIGHT

REMOVAL OF COUNTERWEIGHT ASSEMBLY I. 2.

Set eyebolts @ to counterweight assembly (11, and sling. Remove mounting bolts (2) and (3). Be careful not to lose the shimswhenremoving.

Lift off counterweight (1) horizontally with wire or chain block. f Be careful not to hit the engine, radiator and d o l e r assembly. Countenveight assembly : 3,430 kg

INSTALLATION OF COUNTERWEIGHT ASSEMBLY Carry out installation in the reverse order to removal.

p g

Thread of counterweight mounting bolt: Thread tightener (LT-2) Counterweight mounting bolt : 1,323 t 147 Nm t135 z 15 kgm) Installing andadjustingcounterweight 1) Sling counterweight with craneandset in position on frame. 2) Push counterweight and install shim and mounting bolts (2) and (3). and adjustto following dimensions. Clearance from revolving frame : 10 A 5 mm (left and right) Clearance from bodywork door : 10 A 5 mm (left and right) Steppeddifference b from revolving frame in left-to right direction : Max. 5 mm Steppeddifference a from bodywork door in left-to right direction : 10 k 4 m m Steppeddifference c from bodywork top cover in up-down direction : Max. 5 mm

30-146

/Door

U n i t :nn

Counterneioht

a = 1 Oi4

b=0i5

Revolvino frame

DKP00503

PC200-6Z

DISASSEMBLY AND ASSEMBLY

MONITOR

REMOVAL OF MONITOR ASSEMBLY

A Disconnect the cable from the negative minal of the battery.

(-) ter-

1. Removeboot (2) from cover ( l ) , raise t o top, then remove lever (3). Check the direction of the lever.

Disconnecthornwiring.

3. Remove cover (11, and disconnect 3 connectors

CLPO4025

(4).

Removemonitor assembly (5) from cover (1).

-I

INSTALLATION OF MONITOR ASSEMBLY Carry outinstallationinthe removal.

reverse order to I

I /I

CLPO4026

Mounting nut of monitor assembly : 8.33 2 0.49 Nm I0.85 2 0.05 kgm}

PC200-6Z

30-147

40 MAINTENANCESTANDARD ......................................... ................................................. .................................................... . ........................ ................................................................ ................................................ ................................................... .................................................... .......................................... ............................................... ................................................ ................................................

Swing machinery 40-2 Swing circle 40-4 40-6 Final drive 40-8 Track frame Recoil spring 40-10 Idler Carrier roller 40-12 40-13 Track roller 40-14 Track shoe 40-19 Hydraulic pump Control valve 40-20 40-27 Self-reducing pressure valve ...................... Swing motor 40-28 40-29 Travel motor Work equipment Swing PPC valve ..........40-30 40-31 Travel PPC valve .......................................... 40-32 Service PPC valve ........................................ 40-33 Center swivel joint Boom holding valve 40-35 Hydraulic cylinder 40-36 Work equipment 40-38 40-40 Dimension of work equipment

..................................... ..................................... ...................................... ......................................... .................

PC200-6Z

40-1

MAINTENANCE STANDARD

SWING MACHINERY

Unit: mm Check item

Remedy

Criteria Standard clearance

Backlash between swing motor shaft and No. 1 sun gear

Clearance limit

- 0.29

Backlash between No. 1 sun gear and No. 1 planetary gear

0.15 - 0.47

1.00

Backlash between No. 1 planetary gear and ring gear

0.17

- 0.55

1.10

Backlash between No. 1 planetary carrier and No. 2 sun gear

0.36

- 0.63

1.20

Backlash between No. 2 sun gear and No. 2 planetary gear

0.14

- 0.44

0.90

Backlash between No. 2 planetary gear and ring gear

0.16

- 0.51

1 .oo

0.09

- 0.20

0.22

- 1.32

0.68

- 1.12

Backlash between No. 2 planetary carrierswing pinion and Backlash between swing pinion and circle swina

Clearance between plate and planetary carrier Wear of swing pinion surface contacting with oil seal

0.18

I I

Standard size

lZ5-0.100

PC200-6Z

Replace

2.00

Repair limit 124.7

4pply hard :hrome dating .econdition. 3r reolace

40-3

MAINTENANCE STANDARD

SWING CIRCLE

------1.

1’/-.,

1 s t :294.2k29.4Nm

lst:191.3kl9.6Nm 2nd

(19.5k2koml :40+5’

(30t3koml

2nd:60+6‘

A-A SAP02736

Unit: m m

No.

’

Check i t e m Axial clearance of bearing (when mounted on chassis)

40-4

Criteria Standard clearance 0.5

- 1.6

Remedy Clearance limit

3.2

Replace

PC200-6Z

L -i .

j i j

7 m

U 3

D r

MAlNTrNANCE STANDARD

DRIVE

FINAL

Unit: mm

No.

Check item Backlash between No. 1 sun gear and No. 1 planetary gear

Clearance limit

Standard clearance 0.15

- 0.49

1-00

Backlash between No. 1 planetary gear and ring gear

0.17

- 0.57

1.10

Backlash between No. 1 planetary carrier and motor

0.06

- 0.25

Backlash between No. 2 sun gear and No. 2 planetary gear

0.14

- 0.46

1-00

Backlash between No. 2 planetary gear and ring gear

0.17

- 0.57

1.10

Backlash between No. 2 planetary carrier and No. 1 sun gear

0.38

- 0.66

1.oo

End play of sprocket shaft

Amount of wear on sprocket tooth

Remedy

Criteria

Width of sprocket tooth

PC200-6Z

Replace

- 0.10 Repair limit: 6

Standard size

Repair limit

Rebuild or replace

40-7

MAINTENANCE STANDARD

TRACK FRAME

TRACK FRAME SPRING RECOIL

RECOIL SPRING

SAPO2737

Unit: mm

No.

Check item

Remedy

Criteria Tolerance

Vertical width of idler guide

Track frame

'07

Idler support

105

Track frame

250

Rebuild or replace

Horizontal width of idler guide

40-8

Standard size Recoil spring

Repair limit

Free length x O.D.

Installation length

Installation load

'03.5 x 239

466

{12,900 kg}

126.5 kN

Free

length

576

installation load

Replace

100.9 kN {10,300 kg)

PC200-6Z

1 -

STANDARD

MAINTENANCE

IDLER

Unit: m m

Standard size

Repair limit

560

Outside diameter of tread

520

508

Width of protrusion

Total width

164

Outside diameter of protruding

Width of tread

Clearance between shaft and bushing 65

Clearance between shaft and support

Interference between idler and bushing

-0.250 -0.350 -0.250 -0.290

-1

+0.074

-0.036 -0.110 -0.220

Tolerance

+0.089 +0.059

-0.006 -0.072

1 I

45.5 Standard clearance

0.03 0.180

- 1.00

Rebuild or replace

Ck;raxe Replace bushing

1.5

Standard interference

Interference limit

0.065 0.161

Replace

Replace bushing

limit

Standard clearance Clearance 0.39

PC200-6Z

Tolerance

Standard size

Side clearance of idler (each)

39.5

I r;: tnd Sa

Remedy

Criteria

Check item

1.5

40-11

MAINTENANCE

STANDARD

TRACK

ROLLER

TRACK ROLLER .6Nm

SBP02740

No.

Unit: rnrn

Check item

Criteria

Outside diameter of flange (outside) ~

Standard size

Repair limit

188

Outside diameter of tread

156

144

Width of tread

44.5

Width of

Clearance bushing

F J I J - ~ I ?shaft ~

and

Tolerance

Standard size

-0.21 5 43-315

+0.030

- 1.0

Clearance limit

0.215 0.510

1.5

Standard interference

Interference limit

Replace bushing

0.023 0.153

Standard clearance Clearance 0.5

PC200-6Z

Standard clearance

+0.195 0

Interference between roller and bushing

Side clearance of : d e r

Tolerance

Standard

Rebuild or replace

25.5

,J?~z

. x -

Remedy

limit Seplace 1.5

40-1 3

'0 0

-I =R

MAINTENANCE STANDARD

No. -

TRACK SHOE

Unit: m m Remedy Check item ~~

Criteria ~~

194.25

Repair limit

190.25 When turned

- -

Standard size

Bushing outside diameter

Standard size

Link pitch

Reverse or replace

Impact load Normal load 59.3 Standard size

Link height

Thickness of link metal (bushing press-fitting portion)

Repair limit

Repair or replace

28.5

160.4

Shoe bolt pitch

Replace

Inside width

8 Overall 9

Link

84.8

width

Protrusion of pin

Protrusion of regular bushing

220

Overall length of pin

Overall length of bushing

128.7

Thickness of bGhing metal

10.4

Thickness of spacer

Bushing

4.85 ~

Press-fitting force

.x.

: Dry type track link

PC200-6Z

Repair or replace

40.3

45.5

88.2 127.4

Adjust or replace

- 245 kN (9 - 25 ton) - 274.4

kN {13

- 28 ton)

Master pim

78.4

- 147 kN (8 - 15 ton)

40-1 5

MAINTENANCE STANDARD

TRACK SHOE

* P portion shows the link of bushing

20,

SBP03974

press fitting end. i

40- 1 6

PC200-6Z

NDARD

MAINTENANCE

TRACK SHOE

~--

Unit mm

Check item

a. Regular link

Shoe bolt

b. Master link

Criteria Tightening torque (Nm IkgmH

Additinal tightening angle (deg.)

490*49 (50t5)

120*10

Tightening torque (Nm IkgmH

Additinal tightening angle (deg.)

No. of shoes (each side)

Interference between bushing and link - .

Interference between reaular Din and link

Clearance between regular pin and bushing

Interference between master pin and link

Ilearance between naster pin and bushing

f'C200-6Z

Standard interference

+0.304 +0.264

+0.074 0

0.190

- 0.314

+0.222 +0.072

-0.138 -0.200

0.210

- 0.422

Tolerance

Standard size

Standard clearance I

+0.222 +0.072

+0.902 +0.402

0.180

Tolerance

Standard size

+0*230 +0.200

+;'O6'

-0.200 -0.400

Adjust or replace

0.138

- 0.230

Standard clearance I

- 0.830

Standard interference

Tolerance

Standard size

-x- : Dry type track link

Retighten

Tolerance

Standard size

37.8

Lower limit torque (Nm fkgm))

Remedy

+0.902 +0.402

0.602

- 1.302

40- 17

TRACK SHOE

MAINTENANCE STANDARD

TRIPLE GROUSER SHOE

-..

SDDOl629

Unit: mrn

No.

2 3 1

__I

Check item

Height

Thickness

Length of base

Standard size

Repair limit

16 10

I I

27 22

Rebuild or replace

Remedy

Criteria

Length at tip

40- 1 8

14 19

PC200-6Z

W N VI 0

0 0

-0

CONTROL

VALVE

MAINTENANCE STANDARD

B-0

SAPO3976

Unit: mm

No. -

Check item

Criteria

.-~

Remedy Repair, limit

Standard size

return spring SPOOI

length

x O.D.

length

54.5

34.8

53.5

120.6 N (12.3 kg)

54.6

34.8

53.5

139.3 N (14.2 kg)

Installed 96.1 N (9.8 kg)

111.8 N (11.4 kg) ~

Spool return spring ~~

Spool return spring

PC200-6Z

54.2 x 34.0

53.5

85.3 N (8.7 kg}

Replace spring if any damages or deformations are found.

68.6 N {7 kg}

40-21

CONTROL

VALVE

MAINTENANCE STANDARD

392.3f I9.6Nm ( 4 0 t 2b.1

-6

;47.1 f9.8Nm (15flk.l

0-D

392.3t 19.6Nm

(40*2kpnl

E-E

392.3f 19.6Nm (40f 2k.l

392.3 f 19.6Nm (40f2ked

F-F

SAPO3253

40-22

PC200-6Z

MAINTENANCE STANDARD

VALVE

CONTROL

Unit: m m Check item

Criteria

Remedy

Standard size 1

Piston return spring

Installed length

Piston return spring

Load spring

6 -

Free length x O.D.

Repair limit Installed load

Installed load

17.6 N (1.8 kg)

13.7 N {1.4 kg)

428.3 N (33 (43.7 kg)

kg)

Check valve spring

13.6 x 5.5

Piston return spring

50.4 x 17

158.8 N (16.2 kg)

Piston return spring

40.8 x 22.4

17.6 N (1.8 kg)

PC200-6Z

Free length

(0.2 kg)

1.5N {0.15 kg)

Replace spring if any damages or deformations are found.

127.4N (13 kg}

13.7 N U.4 kg)

40-23

3 3

2 '

' Z

PW Oh.

I I

MAINTENANCE STANDARD

SAFETY-SUCTION VALVE -

VALVE

CONTFiOL

(FOR SERVICE VALVE)

SAP02748

Unit mm ~~

No.

Criteria

Check item

Remedy Repair limit

Standard size 1

Suction valve spring

Piston spring

40-26

Free length x 0 .D.

Installed length

Installed load

16.3 x 21.3

9.5

2.1 N (0.21 kg}

20 x 7

2.1 N (0.21 kg)

Free Installed length

load 1.6 N (0.16 kg1

Replace

1.6 N (0.16 kg}

i PC200-6Z

MAINTENANCE STANDARD

VALVEPRESSURE SELF-REDUCING

SELF-REDUCING PRESSURE VALVE

0-0 A- A

SAP03294

Unit: mm

Spring (safety valve)

PC200-6Z

16.1 x 7.8

13.4

61.7 N (6.3 kg)

58.0 N 16 kg)

40-27

o w

TRAVEL MOTOR

MAINTENANCE STANDARD

TRAVEL MOTOR HMVl lO-2

- -

c-c

8-0

SAP01750

No.

Criteria

Check item

Remedy limit

Standard size Repair 1

Check valve spring

Free length x O.D.

Installed length

31.6 x 6.5

24.2

Check valve spring

13.0 x 6.5

9.5

Return spring

58.43 x 30

42.6

PC200-6Z

Installed load

2.55 N (0.26 kg} 1.96 N [0.2 kg)

411 N i41.9 kg)

Free length

Installed load

Replace spring if

Io.â&#x20AC;&#x2122;

Zages or deformations are found.

2-06N

kg}

1.57 N {0.16 kg)

329 N (33.5 kg)

40-29

3!&

3 3

W I

sfz

W W

MAINTENANCE STANDARD

SERVICE PPC VALVE

SERVICE PPC VALVE -

Unit: m m Check item

No.

Criteria Repair limit

Standard size 1

Centering spring

Metering spring

40-32

Free length

Remedy

x 0 .D.

Installed length

Installed load

64.8 x 16.6

40.5

46.1 N (4.7 kg)

26.0 x 10.5

25.0

25.5 N {2.6 kg)

Free length

Installed load

(62.9)

44.1 N (4.5 kg)

(25'2)

24.5 N (2.5 kg}

Replace

spring if

any damages or deformations are found.

PC200-6Z

? G3

-4

BOOM HOLDING VALVE

MAINTENANCE STANDARD

BOOM HOLDING VALVE

For machine equipped with arm holding valve, the Maintenance Standard of arm holding valve is the same as this valve.

B-0

1 4/7 t lONm

( 1 5 * Ibrl

A-A

SDPO I354 Unit: m m Criteria

Check item

No.

Remedy Repair limit

Standard size 1

Pilot valve spring

Check valve spring

PC200-6Z

Free length

Installed length

26.5 x 11.2

25'0

37.2 x 16.2

30.0

O.D.

Installed load

4.7 N (0.48 kg) 35.3 N 13.6 kg)

Free length

Installed load

3.7 ( 0 . 3 kg)

28.4 (2.9 kg)

Replace spring if any damages or deformations are found.

40-35

STANDARD

CYLINDER

MAINTENANCE

Unit: mm

Remedy

Criteria

Check item

Cylinder

Clearance between piston rod and bushing

Clearance between piston rod support pin and bushing

PC200-6Z

+0.222 4.047

-0.030 -0.076

+0.258

0.078 -

-0.030 4.060

+0.457 4.370

0.400

-0.030 -0.076

4.457 4.370

0-400 0.533

-0.030 -0.076

+0.424 +0.350

0.380

-0.030 -0.060

4.451 +0.370

0.380

-0.030 -0.076

+0.457 +0.370

-0.030 -0.076

+0.424 +0.350

Bucket

Bucket z

-0.036 4.090

Arm

Bucket

Clearancebetwe,en cylinder bottom support pin and bushing

0.084

'1 .-

4.257

Boom

-0.036 -0.090

4.048

+0.048

0.347

0.3 12

0.500

0.484

0.400 0.523

0.380 0.500

0.434

0.334

0.517

0.412

Replace

1.0 1.0 1.o

1.0

Replace

pin or bushing

1.o

40-37

l o

B 0.

I n D -a

WORK EQUIPMENT

MAINTENANCE STANDARD

SEP02762

Unit: rnm

No.

Check item

Criteria

Clearance between connecting pin frame revolving ofbushing 1 and and boom

Shaft

Hole

Remedy

0.305

-0.036 +0.342 A 1.0n7'1 0.412 +0.269

-0.036 -0.071

+0.153 +0.097

0.133 0.224

1.0

Clearance between connecting pin and bushing of arm and link

-0.030 -0.076

+0.335 +0.275

0.305 0.41 1

1.0

Clearance between connecting pin and bushing of arm and bucket

-0.030

+0.337 +0.273

0.303 -0.076 0.413

1.0

Clearance between connecting pin and bushing of link and bucket

-0.030

+0.337 +0.273

0.303 -0.076 0.413

1.0

Clearance between connecting pin and bushing of link and link

-0.030

+0.335 +0.275

Clearance between connecting pin and bushing of boom and arm

PC200-6Z

-.-. .

0.303 -0.076 0.41 1

Replace

1.o

40-39

DIMENSION OF WORK EQUIPMENT

MAINTENANCE STANDARD

DIMENSION OF WORK EQUIPMENT 1. ARM PORTION

5 6

Y-Y

40-40

x-x

SAPO2764

PC200-6Z

OF WORK EQUIPMENT '

MAINTENANCE STANDARD DIMENSION

U n i t mm

PC200-6

090-0.036 -0.071

361.7t1

187.2a0.5

829.1t1

2,919

2,631.3a1

410al

640t0.2

600*0.5

458.1

1,486

080

326.5*1

080

Arm as individual pan

When pressfitting bushing

~ ~ ~ _ _ _ _ _ _ ~

311-0.5 325

Min.

1,680

Max.

2,800

PC200-6Z

40-41

DIMENSION OF WORK EQUIPMENT

MAINTENANCE STANDARD

Unit: mm

PC200-6Z 1

I I

M20 X 2.5mm thru, 4 holes equally spaced on 150.11 diameter between centers

326.14 327.66

022.35 Thru 0 38.10 Sprotface (after lineboring) 59.18

469.36 470.41 96.27

PC200-6Z

0110.01 - 110.21 Linebore Fit. front only

022.35 Thru 038.10 Spotface lineboring) (after

190.50 diameter

8 -

326.14 - 327.66

- 470.41

442.90 444.50

469.39

457.20 458.72

080.01 - 80.21 TYP. 1449.58 1370.08

40-43

90 OTHERS

Hydraulic piping drawing ........................................................................... go- 3 Hydraulic circuit diagram ........................................................................... go- 5 Actual electrical wiring diagram (1/2) ....................................................... go- 7 Actual electrical wiring diagram (2/2) 90-9 Electrical circuit diagram (1/2) ................................................................... 90-11 Electrical circuit diagram (2M)................................................................... 90-13 Operation of CLSS system as a whole 1 . When all work equipment is at neutral ......................................... 90-15 2. One side actuated. other side neutral ............................................90-17 3 A r m OUT. standard mode relief (cut-off controll) ........................ 90-19 4 . Bucket DUMP, power max. relief .................................................... 90-21 5 Boom RAISE...................................................................................... 90-23 6. Swing operated independently....................................................... 90-25 7 Tavel operated independently ........................................................ 90-27 8. Compound operation....................................................................... 90-29

.......................................................

. . .

PC200-6Z

90- 1

DataKom Publishing Corporation 440 North Fairway Drive Vernon Hills, IL 60061-8112 U S A . Attn: Service Publications Fax No. (847) 970-4186

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