SEBM024300 (General S&F) PDF

SEBM024300
PC200, 200LC-7
PC220, 220LC-7
MACHINE MODEL SERIAL NUMBER
PC200-7 00 200001 AND UP 00
PC200LC-7 00 200001 AND UP 00
PC220-7 00 60001 AND UP 00
PC220LC-7 00 60001 AND UP 00
• This shop manual may contain attachments and optional equipment that are not avail-
able in your area. Please consult your local Komatsu distributor for those items you may
require.
Materials and specifications are subject to change without notice
© 2001
All Rights Reserved 00-1
Printed in USA 09-01
CONTENTS
No. of page
01 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD. 10-1
20 TESTING AND ADJUSTING . . . . . . . . . . . . Will Be Issued 10-25-2001
30 DISASSEMBLY AND ASSEMBLY . . . . . . . . Will Be Issued 12-15-2001
90 OTHERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1
00
00-2
SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The service and
repair techniques recommended by Komatsu and described in this manual are both effective
and safe. Some of these techniques require the use of tools specially designed by Komatsu for
the specific purpose.
To prevent injury to workers, the symbol ¤ is used to mark safety precautions in this manual.
The cautions accompanying these symbols should always be followed carefully. If any danger-
ous situation arises or may possibly arise, first consider safety, and take the necessary actions
to deal with the situation.
GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

tools and removed parts. Always keep the tools
Mistakes in operation are extremely dangerous. and parts in their correct places. Always keep
Read the Operation and Maintenance Manual care- the work area clean and make sure that there is
fully BEFORE operating the machine. no dirt or oil on the floor. Smoke only in the areas
1. Before carrying out any greasing or repairs, read provided for smoking. Never smoke while work-
all the precautions given on the decals which are ing.
fixed to the machine.
2. When carrying out any operation, always PREPARATIONS FOR WORK
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons 7. Before adding oil or making any repairs, park the
missing. machine on hard, level ground, and block the
• Always wear safety glasses when hitting wheels or tracks to prevent the machine from
parts with a hammer. moving.
• Always wear safety glasses when grinding 8. Before starting work, lower blade, ripper, bucket
parts with a grinder, etc. or any other work equipment to the ground. If
3. If welding repairs are needed, always have a this is not possible, insert the safety pin or use
trained, experienced welder carry out the work. blocks to prevent the work equipment from fall-
When carrying out welding work, always wear ing. In addition, be sure to lock all the control
welding gloves, apron, hand shield, cap and levers and hang warning signs on them.
other clothes suited for welding work. 9. When disassembling or assembling, support the
4. When carrying out any operation with two or machine with blocks, jacks or stands before
more workers, always agree on the operating starting work.
procedure before starting. Always inform your 10.Remove all mud and oil from the steps or other
fellow workers before starting any step of the places used to get on and off the machine.
operation. Before starting work, hang UNDER Always use the handrails, ladders or steps when
REPAIR signs on the controls in the operator's getting on or off the machine. Never jump on or
compartment. off the machine. If it is impossible to use the
5. Keep all tools in good condition and learn the handrails, ladders or steps, use a stand to pro-
correct way to use them. vide safe footing.
00-3
SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK 19.Be sure to assemble all parts again in their origi-
nal places.
11. When removing the oil filler cap, drain plug or Replace any damaged parts with new parts.
hydraulic pressure measuring plugs, loosen • When installing hoses and wires, be sure
them slowly to prevent the oil from spurting out. that they will not be damaged by contact
Before disconnecting or removing components with other parts when the machine is being
of the oil, water or air circuits, first remove the operated.
pressure completely from the circuit. 20.When installing high pressure hoses, make sure
12.The water and oil in the circuits are hot when the that they are not twisted. Damaged tubes are
engine is stopped, so be careful not to get dangerous, so be extremely careful when install-
burned. ing tubes for high pressure circuits. Also, check
Wait for the oil and water to cool before carry- that connecting parts are correctly installed.
ing out any work on the oil or water circuits. 21.When assembling or installing parts, always use
13.Before starting work, remove the leads from the the specified tightening torques. When installing
battery. Always remove the lead from the nega- protective parts such as guards, or parts which
tive (–) terminal first. vibrate violently or rotate at high speed, be par-
14.When raising heavy components, use a hoist or ticularly careful to check that they are installed
crane. correctly.
Check that the wire rope, chains and hooks are 22.When aligning two holes, never insert your fin-
free from damage. gers or hand. Be careful not to get your fingers
Always use lifting equipment which has ample caught in a hole.
capacity. 23.When measuring hydraulic pressure, check that
Install the lifting equipment at the correct places. the measuring tool is correctly assembled before
Use a hoist or crane and operate slowly to pre- taking any measurements.
vent the component from hitting any other part.
24.Take care when removing or installing the tracks
Do not work with any part still raised by the hoist
of track-type machines.
or crane.
When removing the track, the track separates
15.When removing covers which are under internal suddenly, so never let anyone stand at either
pressure or under pressure from a spring, end of the track.
always leave two bolts in position on opposite
sides. Slowly release the pressure, then slowly
loosen the bolts to remove.
16.When removing components, be careful not to
break or damage the wiring. Damaged wiring
may cause electrical fires.
17.When removing piping, stop the fuel or oil from
spilling out. If any fuel or oil drips onto the floor,
wipe it up immediately. Fuel or oil on the floor
can cause you to slip, or can even start fires.
18.As a general rule, do not use gasoline to wash
parts. In particular, use only the minimum of
gasoline when washing electrical parts.
00-4
FOREWORD GENERAL
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judge-
ments. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are fur-
ther divided into the each main group of components.
STRUCTURE AND FUNCTION

This section explains the structure and function of each component. It serves not only to give an under-
standing of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and mainte-
nance standards.
TESTING AND ADJUSTING

This section explains checks to be made before and after performing repairs, as well as adjustments to
be made at completion of the checks and repairs.
Troubleshooting charts correlating "Problems" with "Causes" are also included in this section.
DISASSEMBLY AND ASSEMBLY

This section explains the procedures for removing, installing, disassembling and assembling each com-
ponent, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Use the specifications given in the book with the latest date.
00-5
FOREWORD HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL REVISED EDITION MARK
W h en a m an u a l is r e vis ed , a n e d itio n ma rk
VOLUMES
Shop manuals are issued as a guide to carrying out 123
( ....) is recorded on the bottom of the pages.
repairs. They are divided as follows:
Chassis volume: Issued for every machine model REVISIONS

Engine volume: Issued for each engine series
Each issued as one Revised pages are shown in the LIST OF REVISED
Electrical volume:
}
Attachments volume: · volume to cover all
models
PAGES next to the CONTENTS page.
SYMBOLS
These various volumes are designed to avoid dupli-
cating the same information. Therefore, to deal with So that the shop manual can be of ample practical
all repairs for any model , it is necessary that chas- use, important safety and quality portions are
sis, engine, electrical and attachment volumes be marked with the following symbols.
available.
DISTRIBUTION AND UPDATING

Any additions, amendments or other changes will be
sent to KOMATSU distributors. Get the most up-to- Symbol Item Remarks
date information before you start any work.
¤ Safety
Special safety precautions
are necessary when per-
forming the work.
FILING METHOD
1. See the page number on the bottom of the page. Special technical precau-
File the pages in correct order.
2. Following examples show how to read the page s Caution
tions or other precautions
for preserving standards
are necessary when per-
4
number.
forming the work.
Example 1 (Chassis volume):
Weight of parts of sys-
10 - 3 tems. Caution necessary
Weight when selecting hoisting
3
Item number (10. Structure and wire, or when working pos-
Function) ture is important, etc.
Consecutive page number for each
Places that require special
2
item. Tightening
attention for the tightening
torque
torque during assembly.
Example 2 (Engine volume):
Places to be coated with
5
12 - 5 Coat adhesives and lubricants,
etc.
Unit number (1. Engine) Places where oil, water or
6
Item number (2. Testing and Adjust- Oil, water fuel must be added, and
ing) the capacity.
Consecutive page number for each
item. Places where oil or water
Drain m u s t b e d r a i n e d , a nd
quantity to be drained.
3. Additional pages: Additional pages are indicated
by a hyphen (-) and number after the page
number. File as in the example.
Example:
10-4 12-203
10-4-1 12-203-1
Added pages
10-4-2 12-203-2
10-5 12-204
00-6
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
¤ Heavy parts (25 kg or more) must be lifted

Slinging near the edge of the hook may cause
the rope to slip off the hook during hoisting, and
4
with a hoist, etc. In the DISASSEMBLY a serious accident can result. Hooks have max-
AND ASSEMBLY section, every part imum strength at the middle portion.
weighing 25 kg or more is indicated clearly
with the symbol
• If a part cannot be smoothly removed from the

machine by hoisting, the following checks
should be made:
1) Check for removal of all bolts fastening the 100% 88% 79% 71% 41%
part to the relative parts. SAD00479
2) Check for existence of another part causing
3) Do not sling a heavy load with one rope alone,
interference with the part to be removed.
¤
but sling with two or more ropes symmetrically
wound onto the load.
WIRE ROPES
Slinging with one rope may cause turning
1) Use adequate ropes depending on the
of the load during hoisting, untwisting of
weight of parts to be hoisted, referring to
the rope, or slipping of the rope from its
the table below:
original winding position on the load, which
can result in a dangerous accident.
Wire ropes
(Standard "Z" or "S" twist ropes
without galvanizing) 4) Do not sling a heavy load with ropes forming a
wide hanging angle from the hook.
When hoisting a load with two or more ropes,
Rope diameter Allowable load the force subjected to each rope will increase
mm kN tons
with the hanging angles. The table below
shows the variation of allowable load kN {kg}
10 9.8 1.0 when hoisting is made with two ropes, each of
11.5 13.7 1.4 which is allowed to sling up to 9.8 kN {1000 kg}
12.5 15.7 1.6 vertically, at various hanging angles.
14 21.6 2.2 When two ropes sling a load vertically, up to
16 27.5 2.8 19.6 kN {2000 kg} of total weight can be sus-
18 35.3 3.6
pended. This weight becomes 9.8 kN {1000 kg}
20 43.1 4.4
22.4 54.9 5.6
when two ropes make a 120° hanging angle.
30 98.1 10.0 On the other hand, two ropes are subjected to
40 176.5 18.0 an excessive force as large as 39.2 kN {4000
50 274.6 28.0 kg} if they sling a 19.6 kN {2000 kg} load at a
60 392.2 40.0 lifting angle of 150°.
★ The allowable load value is estimated to be one-

sixth or one-seventh of the breaking strength of
the rope used.
2) Sling wire ropes from the middle portion of the

hook.
00-7
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
¤ Before carrying out the following work, release

the residual pressure from the hydraulic tank.
Type 1
For details, see TESTING AND ADJUSTING,

Releasing residual pressure from hydraulic
¤
tank.
Even if the residual pressure is released from

the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly,
prepare an oil receiving container.
Disconnection
1) Release the residual pressure from the hydrau-
lic tan k. Fo r d e tails , se e TES TIN G AN D
ADJUSTING, Releasing residual pressure from
hydraulic tank.
2) Hold adapter (1) and push hose joint (2) into

mating adapter (3). (See Fig. 1)
★ The adapter can be pushed in about 3.5
mm.
★ Do not hold rubber cap portion (4).
3) After hose joint (2) is pushed into adapter (3),

press rubber cap portion (4) against (3) until it
clicks. (See Fig. 2)
4) Hold hose adapter (1) or hose (5) and pull it out.

(See Fig. 3)
★ Since some hydraulic oil flows out, prepare
an oil receiving container.
Connection
1) Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3), aligning them with each
other. (See Fig. 4)
★ Do not hold rubber cap portion (4).
2) After inserting the hose in the mating adapter

perfectly, pull it back to check its connecting
condition. (See Fig. 5)
★ When the hose is pulled back, the rubber
cap portion moves toward the hose about
3.5 mm. This does not indicate abnormality,
however.
00-8
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 2 Type 3
1) Hold the mouthpiece of the tightening portion 1) Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end. the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn 2) Hold in the condition in Step 1), and push
lever (4) to the right (clockwise). until cover (3) contacts contact surface a of
the hexagonal portion at the male end.
Disassembly
3) Hold in the condition in Steps 1) and 2), and 3) Hold in the condition in Steps 1) and 2), and
pull out whole body (2) to disconnect it. pull out whole body (2) to disconnect it.
• Hold the mouthpiece of the tightening portion • Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end to con- the hexagonal portion at the male end to con-
nect it. nect it.
Connection
00-9
FOREWORD COATING MATERIALS
COATING MATERIALS
★ The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and assembly are listed below.
★ For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code Part No. Q'ty Container Main applications, featuresr
• Used to prevent rubber gaskets,

LT-1A 790-129-9030 150 g Tube rubber cushions, and cock plug
from coming out.
• Used in places requiring an imme-

diately effective, strong adhesive.
20 g Polyethylene Used for plastics (except polyeth-
LT-1B 790-129-9050
(2 pcs.) container ylene, polyprophylene, tetrafluor-
oet hl ene and vi nyl chl or ide) ,
rubber, metal and non-metal.
• Features: Resistance to heat and

LT-2 09940-00030 50 g Polyethylene chemicals
container • Used for anti-loosening and seal-
ant purpose for bolts and plugs.
Adhesive: • Used as adhesive or sealant for

790-129-9060 metal, glass and plastic.
(Set of 1 kg
Hardenin
LT-3 adhesive and Can
hardening g
agent:
agent)
500 g
Adhesives
Polyethylene • Used as sealant for machined

LT-4 790-129-9040 250 g holes.
container
Holtz • Used as heat-resisting sealant for

MH 705 790-126-9120 75 g Tube repairing engine.
• Quick hardening type adhesive

Three bond Polyethylene • Cure time: within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly for adhesion of met-
als, rubbers, plastics and woods.
• Quick hardening type adhesive

• Quick cure type (max. strength af-
Aron-alpha Polyethylene
201 790-129-9130 2g container ter 30 minutes)
• Used mainly for adhesion of rub-
bers, plastics and metals.
Loctite Polyethylene • Resistance to heat, chemicals

79A-129-9110 50 cc • Used at joint portions subject to
648-50 container
high temperatures.
• Used as adhesive or sealant for

LG-1 790-129-9010 200 g Tube gaskets and packing of power
train case, etc.
• Used as sealant for various

threads, pipe joints, flanges.
LG-5 790-129-9070 1 kg Can • Used as sealant for tapered
Gasket plugs, elbows, nipples of hydrau-
sealant lic piping.
• Features: Silicon based, resist-

ance to heat, cold
• Used as sealant for flange sur-
LG-6 790-129-9020 200 g Tube
face, tread.
• mab Used as sealant for oil pan,
final drive case, etc.
00-10
FOREWORD COATING MATERIALS
Category Komatsu code Part No. Q'ty Container Main applications, features
• Features: Silicon based, quick

hardening type
LG-7 790-129-9070 1g Tube • Used as sealant for flywheel
housing, intake manifold, oil an,
Adhesives thermostat housing, etc.
Three bond • Used as heat-resisting sealant for

790-129-9090 100 g Tube repairing engine.
1211
• Used as lubricant for sliding por-

LM-G 09940-00051 60 g Can
tion (to prevent from squeaking).
Molybdenum
disulphide • Used to prevent seizure or scuf-
lubricant fling of the thread when press fit-
LM-P 09940-00040 200 g Tube ting or shrink fitting.
• Used as lubricant for linkage,
bearings, etc.
SYG2-400LI • General purpose type

SYG2-350LI
G2-LI SYG2-400LI-A Various Various
SYG2-160LI
SYGA-160CNLI
SYG2-400CA • Used for normal temperature,

Grease SYG2-350CA light load bearing at places in con-
G2-CA SYG2-400CA-A Various Various tact with water or steam.
SYG2-160CA
SYGA-160CNCA
Molybdenum 400 g • Used for places with heavy load

disulphide SYG2-400M (10 per Belows type
lubricant case)
00-11
FOREWORD STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH)
★ In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in
the table below.
Thread diameter Width across

of bolt flats
mm mm Nm kgm
6 10 13.2 0 1.4 1.35 0 0.15

8 13 31 03 3.2 0 0.3
10 17 66 07 6.7 0 0.7
12 19 113 0 10 11.501
14 22 177 0 19 1802
16 24 279 0 30 28.5 0 3
18 27 382 0 39 39 0 4
20 30 549 0 59 56 0 6
22 32 745 0 83 76 0 8.5
24 36 927 0 103 94.5 0 10.5
27 41 1320 0 140 135 0 15

30 46 1720 0 190 175 0 20
33 50 2210 0 240 225 0 25
36 55 2750 0 290 280 0 30
39 60 3290 0 340 335 0 35
Thread diameter Width across

of bolt flats
mm mm Nm kgm
6 10 0
7.85 1.95 0.8 0 0.2
8 13 0
18.6 4.9 1.9 0 0.5
10 14 0
40.2 5.9 4.1 0 0.6
12 27 0
82.35 7.85 8.4 0 0.8
Sealing surface
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

★ In the case of flared nuts for which there is no
special instruction, tighten to the torque given in
SAD00483
the table below.
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
14 19 0
24.5 4.9 0
2.5 0.5
18 24 0
49 19.6 5 2 0
22 27 0
78.5 19.6 8 2 0
24 32 0
137.3 29.4 14 3 0
30 36 0
176.5 29.4 18 3 0
33 41 0
196.1 49 20 5 0
36 46 0
245.2 49 25 5 0
42 55 0
294.2 49 30 5 0
00-12
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

★ In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the
table below.
mm mm Nm kgm
10 14 0
65.7 6.8 0
6.7 0.7
12 17 112 9.80 11.5 1 0
16 22 279 290 28.5 3 0
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

★ Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.

Norminal No.
mm mm Nm kgm
02 14 0
34.3 4.9 3.5 0 0.5
03, 04 20 Varies depending 0
93.1 9.8 9.5 01
05, 06 24 on type of 0
142.1 19.6 14.5 02
10, 12 33 connector. 0
421.4 58.8 43 06
14 42 0
877.1 132.3 89.5 0 13.5
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

★ Unless there are special instructions, tighten the O-ring boss plugs to the torque below.

Norminal No.
mm mm Nm kgm
08 08 14 0
7.35 1.47 0.75 0.15 0
10 10 17 0
11.27 1.47 1.15 0.15 0
12 12 19 0
17.64 1.96 1.8 0.2 0
14 14 22 0
22.54 1.96 2.3 0.2 0
16 16 24 0
29.4 4.9 3 0.5 0
18 18 27 0
39.2 4.9 4 0.5 0
20 20 30 0
49 4.9 5 0.5 0
24 24 32 0
68.6 9.8 7 1 0
30 30 32 0
107.8 14.7 11 1.5 0
33 33 n 0
127.4 19.6 13 2 0
36 36 36 0
151.9 24.5 15.5 2.5 0
42 42 n 0
210.7 29.4 21.5 3 0
52 52 n 0
323.4 44.1 33 4.5 0
00-13
TIGHTENING TORQUE FOR 102 ENGINE SERIES (BOLT AND NUTS)

Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
mm Nm kgm
6 0
10 2 1.02 0 0.20
8 0
24 4 2.45 0 0.41
10 0
43 6 4.38 0 0.61
12 0
77 12 7.85 0 1.22
TIGHTENING TORQUE FOR 102 ENGINE SERIES (EYE JOINTS)

Use these torques for eye joints (unit: mm) of Cummins Engine.
mm Nm kgm
6 0
8 2 0.81 0 0.20
8 0
10 2 1.02 0 0.20
10 0
12 2 1.22 0 0.20
12 0
24 4 2.45 0 0.41
14 0
36 5 3.67 0 0.51
TIGHTENING TORQUE FOR 102 ENGINE SERIES (TAPERED SCREWS)

Use these torques for tapered screws (unit: inch) of Cummins Engine.
mm Nm kgm
1 / 16 0
3 1 0.31 0 0.10
1/8 0
8 2 0.81 0 0.20
1/4 0
12 2 1.22 0 0.20
3/8 0
15 2 1.53 0 0.41
1/2 0
24 4 2.45 0 0.41
3/4 0
36 5 3.67 0 0.51
1 0
60 9 6.12 0 0.92
00-14
FOREWORD ELECTRIC WIRE CODE
ELECTRIC WIRE CODE

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire
Norminal Cable O.D. Current
number Dia. of Cross (mm) rating Applicable circuit
Number of strands section (A)
strands
(mm2) (mm 2)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal

etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting
CLASSIFICATION BY COLOR AND CODE
Circuits
Priori- Charging Ground Starting Lighting Instrument Signal Other
ty Classi-
fication
Code W B B R Y G L
Pri-
1 mary
Color White Black Black Red Yellow Green Blue
Code WR n BW RW YR GW LW
2
Color White & Red n White & Black Red & White Rellow & Red Green & White Blue & White
Code WB n BY RB YB GR LR
3
Color White & Black n Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow
Code WL n BR RY YG GY LY
4 Auxi-
liary
Color White & Blue n Black & Red Red & Yellow
Yellow &
Green
Green &
Yellow
Blue & Yellow
Code WG n n RG YL GB LB
5
Color White & Green n n Red & Green Yellow & Blue Green & Black Blue & Black
Code n n n RL YW GL n
6
Color n n n Red & Blue Yellow & White Green & Blue n
00-15
FOREWORD CONVERSION TABLE
CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE

The Conversion Table in this section is provided to enable simple conversion of figures. For details of the
method of using the Conversion Table, see the example given below.
EXAMPLE
• Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
A
(1) Locate the number 50 in the vertical column at the left side, take this as , then draw a horizontal line
A
from .
B
(2) Locate the number 5 in the row across the top, take this as , then draw a perpendicular line down
B
from .
C
(3) Take the point where the two lines cross as . This point C gives the value when converting from mil-
limeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.
(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the
left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
B
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
C
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
A 50
60
1.969
2.362
2.008
2.402
2.047
2.441
2.087
2.480
2.126
2.520
2.165
2.559
2.205
2.598
2.244
2.638
2.283
2.677
2.323
2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
00-16
Millimeters to Inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to Pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-17
Liter to U.S. Gallon

l
1 = 0.2642 U.S. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
Liter to U.K. Gallon

l
1 = 0.21997 U.K. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
00-18
kgm to ft. lb
1 kgm = 7.233 ft. lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-19
kg/cm2 to lb/in2
1kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0

10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
00-20
Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Cen-
tigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface col-
umn of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 117.8

–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

–27.8 –18 –0.4 –8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
–27.2 –17 1.4 –7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
–26.7 –16 3.2 –7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
–26.1 –15 5.0 –6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
–25.6 –14 6.8 –6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

–25.0 –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
–24.4 –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
–23.9 –11 12.2 –4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
–23.3 –10 14.0 –3.9 25 77.0 15.6 0 140.0 35.0 95 203.0
–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

–22.2 –8 17.6 –2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
–21.7 –7 19.4 –2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
–21.1 –6 21.2 –1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
–20.6 –5 23.0 –1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
–20.0 –4 24.8 –0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

–19.4 –3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
–18.9 –2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
–18.3 –1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
–17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
–17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

–16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
–16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
–15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
–15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
–14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-21
FOREWORD UNITS
UNITS
In this manual, the measuring units are indicated with Internatinal System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.
Example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}
kW/rpm {HP/rpm}
g/kWh {g/HPh}
00-22
01 GENERAL
Specification Dimension Drawings

PC200-7, PC200LC-7 . . . . . . . . . . . 01-2
PC220-7, PC220LC-7 . . . . . . . . . . . 01-4
Specifications
PC200-7, PC200LC-7 . . . . . . . . . . . 01-6
PC220-7, PC220LC-7 . . . . . . . . . . . 01-8
Weight Table
PC200-7, PC200LC-7 . . . . . . . . . . 01-10
PC220-7, PC220LC-7 . . . . . . . . . . 01-12
Fuel, Coolant, And Lubricants. . . . . . . 01-14
PC200-7 01-1
GENERAL SPECIFICATION DIMENSION DRAWINGS
12
SPECIFICATION DIMENSION DRAWINGS
PC200-7, PC200LC-7
DIMENSIONS
WORKING RANGES
01-2 PC200-7
12
DIMENSIONS
Item Unit PC200-7 PC200LC-7
A Overall length mm 9,425 9,425
B Overall height mm 3,000 3,000
C Overall width mm 2,800 3,080
D Track shoe width mm 600 700
E Height of cab mm 3,000 3,000

F Tail swing radius mm 2,750 2,750
G Track overall length mm 4,080 4,450
H Length of track on ground mm 3,270 3,640
Min. ground clearance mm 440 440
WORKING RANGES
A Max. digging reach mm 9,875 9,875
B Max. digging depth mm 6,620 6,620
C Max. digging height mm 10,000 10,000
D Max. vertical wall depth mm 5,980 5,980

E Max. dumping height mm 7,110 7,110
F Min. dumping height mm 2,645 2,645
G Max. reach at ground level mm 2,645 2,645
PC200-7 01-3
PC220-7, PC220LC-7
DIMENSIONS
WORKING RANGES
01-4 PC200-7
12
DIMENSIONS
A Overall length mm 9,885 9,885
B Overall height mm 3,160 3,160
C Overall width mm 2,980 3,280
D Track shoe width mm 600 700
E Height of cab mm 3,015 3,015

F Tail swing radius mm 2,940 2,940
G Track overall length mm 4,250 4,640
H Length of track on ground mm 3,460 3,845
WORKING RANGES
A Max. digging reach mm 10,180 10,180
B Max. digging depth mm 6,920 6,920
C Max. digging height mm 10,000 10,000
D Max. vertical wall depth mm 6,010 6,010

E Max. dumping height mm 7,035 7,035
F Min. dumping height mm 2,530 2,530
G Max. reach at ground level mm 10,020 10,020
PC200-7 01-5
GENERAL SPECIFICATIONS
SPECIFICATIONS
PC200-7, PC200LC-7
Machine model PC200-7 PC200LC-7
Serial Number 200001 and up
Bucket capacity m³ 0.8 0.8
Operating weight kg 19,300 20,700
Max. digging depth mm 6,620 6,620

Working ranges
Max. vertical wall depth mm 5,980 5,980

Max. digging reach mm 9,875 9,875
Max. reach at ground level mm 9,700 9,700
Max. digging height mm 10,000 10,000
Max. dumping height mm 7,110 7,110
Max. digging force kN {kg} 138.3 {14,100} 138.3 {14,100}

Performance
(using power max. function) (149.1 {15,200}) (149.1 {15,200})
Swing speed rpm 12.4 12.4

Swing max. slope angle deg. 20 20
Travel speed km/h Lo: 3.0 ( Mi: 4.1) Lo: 3.0 ( Mi: 4.1)
Hi: 5.5 Hi: 5.5
Gradeability deg. 35 35
Ground pressure kPa {kg/cm²} 44.1 {0.45} 36.3 {0.37}

[standard shoe width] [mm] [600] [700]
Overall length (for transport) mm 9,425 9,425

Overall width mm 2,800 3,080
Overall width of track mm 2,800 3,080
Overall height (for transport) mm 3,000 3,000
Overall height to chassis mm 3,000 3,000
Dimensions
Ground clearance to bottom of upper structure mm 1,085 1,085

Tail swing radius mm 2,750 2,750
Min. swing radius of work equipment mm 3,040 3,040
Height of work equipment at min. swing radius mm 8,005 8,005
Length of track on ground mm 3,270 3,640
Track gauge mm 2,200 2,380
Height of machine cab mm 2,335 2,335
: The "Mi" mode is on the multi-monitor specification machine only.
01-6 PC200-7
12
Model SAA6D102E-2-A
Type 4-cycle, water-cooled, in-line, vertical, direct
injection, with turbo charger
No. of cylinders - bore x stroke mm 6 - 102 x 120
Piston displacement l {cc} 5.883 {5,883}
Flywheel horsepower kW/rpm {HP/rpm} 106.7/1,950 {143/1,950}

Performance
Engine
Max. torque Nm/rpm {kgm/rpm} 610.0/1,500 {62.2/1,500}

Max. speed at no load rpm 2,150
Min. speed at no load rpm 1,030
Min. fuel consumption g/kWh {g/HPh} 215 {160}
Starting motor 24V, 4.5 kW

Alternator 24V, 35 A
Battery 12V, 110 Ah x 2
Radiator core type Corrugated CWX-4
Carrier roller 2 on each side
Track roller 7 on each side 9 on each side

carriage
Under-
Assembly-type triple Assembly-type triple

Track shoe grouser, 45 on each grouser, 49 on each
side side
HPV95+95, variable displacement

Hydraulic
Type x No.
pump
Delivery
l/min Piston type: 214 x 2
Set pressure
MPa (kg/cm²) Piston type: 37.2 {380}
Control
Type x No. 6-spool type x 1

valve
Control method Hydraulic
Travel motor HMV110ADT-2, Piston type

Hydraulic
motor
(with brake valve, parking brake): x 2

Hydraulic system
Swing motor KMF125ABE-5, Piston type

(with safety valve, holding brake): x 1
Type Boom Arm Bucket

Hydraulic culinder
Double act- Double act- Double act-

ing piston ing piston ing piston
Inside diameter of cylinder mm 120 135 115

Diameter of piston rod mm 85 95 80
Stroke mm 1,334.5 1,490 1,120
Max. distance between pins mm 3,204.5 3,565 2,800
Min. distance between pins mm 1,870 2,075 1,680
Hrdraulic tank Closed box type

Hydraulic filter Tank return side
Hydraulic cooler CF40-1 (Air cooled)
PC200-7 01-7
PC220-7, PC220LC-7
Bucket capacity m³ 1.0 1.0
Operating weight kg 22,700 24,130
Max. digging depth mm 6,920 6,920

Working ranges
Max. vertical wall depth mm 6,010 6,010

Max. digging reach mm 10,180 10,180
Max. reach at ground level mm 10,020 10,020
Max. digging height mm 10,000 10,000
Max. dumping height mm 7,035 7,035
Max. digging force kN {kg} 158.9 {16,200} 158.9 {16,200}

Performance
(using power max. function) (171.6 {17,500}) (171.6 {17,500})
Swing speed rpm 11.7 11.7
Swing max. slope angle deg. 25 25
Travel speed km/h Lo: 3.1 ( Mi: 4.2) Lo: 3.1 ( Mi: 4.2)
Hi: 5.5 Hi: 5.5
Gradeability deg. 35 35
Ground pressure kPa {kg/cm²} 50.0 {0.51} 41.2 {0.42}

[standard shoe width] [mm] [600] [700]
Overall length (for transport) mm 9,885 9,885

Overall width mm 2,980 3,280
Overall width of track mm 2,980 3,280
Overall height (for transport) mm 3,160 3,160
Overall height to chassis mm 3,015 3,015
Dimensions
Ground clearance to bottom of upper structure mm 1,110 1,110

Tail swing radius mm 2,940 2,940
Min. swing radius of work equipment mm 3,450 3,450
Height of work equipment at min. swing radius mm 8,110 8,110
Length of track on ground mm 3,460 3,845
Track gauge mm 2,380 2,580
Height of machine cab mm 2,390 2,390
: The "Mi" mode is on the multi-monitor specification machine only.
01-8 PC200-7
Model SAA6D102E-2-C
Type 4-cycle, water-cooled, in-line, vertical, direct
injection, with turbo charger
No. of cylinders - bore x stroke mm 6 - 102 x 120
Piston displacement l {cc} 5.883 {5,883}
Flywheel horsepower kW/rpm {HP/rpm} 125/2,000 {167/2,000}

Performance
Engine
Max. torque Nm/rpm {kgm/rpm} 686/1,500 {70/1,500}

Max. speed at no load rpm 2,260
Min. speed at no load rpm 1,060
Min. fuel consumption g/kWh {g/HPh} 212 {153}
Starting motor 24V, 4.5 kW

Alternator 24V, 35 A
Battery 12V, 110 Ah x 2
Radiator core type Corrugated CF19-5
Carrier roller 2 on each side
Track roller 8 on each side 10 on each side

carriage
Under-
Assembly-type triple Assembly-type triple

Track shoe grouser, 47 on each grouser, 51 on each
side side
HPV95+95, variable displacement

Hydraulic
Type x No.
pump
Delivery
l/min Piston type: 214 x 2
Set pressure
MPa (kg/cm²) Piston type: 37.2 {380}
Control
Type x No. 6-spool type x 1

valve
Control method Hydraulic
Travel motor HMV110ADT-2, Piston type

Hydraulic
motor
(with brake valve, parking brake): x 2

Hydraulic system
Swing motor KMF125ABE-5, Piston type

(with safety valve, holding brake): x 1
Boom Arm Bucket

Type
Hydraulic culinder
Double act- Double act- Double act-

ing piston ing piston ing piston
Inside diameter of cylinder mm 130 140 130

Diameter of piston rod mm 90 100 90
Stroke mm 1,335 1,635 1,020
Max. distance between pins mm 3,205 2,235 2,625
Min. distance between pins
mm 1,870 3,870 1,605
Hrdraulic tank Closed box type

Hydraulic filter Tank return side
Hydraulic cooler CF40-1 (Air cooled)
PC200-7 01-9
GENERAL WEIGHT TABLE
12
WEIGHT TABLE
PC200-7, PC200LC-7
This weight table is for use when handling components or when transporting the machine.
Unit: kg
Serial Number 200001 and up 200001 and up
Engine assembly 749 749
• Engine 598 598
• Damper 6 6
• Hydraulic pump 145 145

Radiator oil cooler assembly 110 110
Hydraulic tank, filter assembly (excluding hydraulic oil) 123 123
Fuel tank (excluding fuel) 121 121
Revolving frame 1,729 1,729
Operator’s cab 278 278
Operator’s seat 35 35
Counterweight 3,735 3,735
Swing machinery 160 160
Control valve 263 263
Swing motor 60 60
Travel motor 98 x 2 98 x 2
Center swivel joint 36 36
Track frame assembly 4,194 4,712
• Track frame 2,179 2,534
• Swing circle 273 273
• Idler 99 x 2 99 x 2
• Idler cushion 130 x 2 135 x 2
• Carrier roller 16 x 4 16 x 4
• Track roller 36 x 14 36 x 18
• Final drive (including travel motor) 343 x 2 343 x 2
01-10 PC200-7
12
Unit: kg
Track shoe assembly
• Standard triple grouser shoe (600 mm) 1,215 x 2 1,325 x 2
• Wide triple grouser shoe (800 mm) 1,530 x 2 1,670 x 2
• Road liner (rubber pad type) (600 mm) 1,470 x 2 1,600 x 2
Boom assembly 1,408 1,408
Arm assembly 653 653
Bucket assembly 628 628
Boom cylinder assembly 172 x 2 172 x 2
Arm cylinder assembly 226 226
Bucket cylinder assembly 136 136
Link assembly (large) 81 81
Link assembly (small) 22 x 2 22 x 2
Boom pin 48 + 8 x 2 + 31 + 10 + 26 48 + 8 x 2 + 31 + 10 + 26
Arm pin 11 + 8 11 + 8
Bucket pin 20 x 2 20 x 2
Link pin 13 x 2 13 x 2
PC200-7 01-11
PC220-7, PC220LC-7
Unit: kg
Engine assembly 749 749
• Engine 598 598
• Damper 6 6
• Hydraulic pump 145 145

Radiator oil cooler assembly 119 119
Hydraulic tank, filter assembly (excluding hydraulic oil) 123 123
Fuel tank (excluding fuel) 121 121
Revolving frame 2,048 2,048
Operator’s cab 278 278
Operator’s seat 35 35
Counterweight 5,056 5,056
Swing machinery 237 237
Control valve 263 263
Swing motor 60 60
Travel motor 98 x 2 98 x 2
Center swivel joint 36 36
Track frame assembly 4,828 5,460
• Track frame 2,558 3,046
• Swing circle 293 293
• Idler 99 x 2 99 x 2
• Idler cushion 135 x 2 135 x 2
• Carrier roller 16 x 4 16 x 4
• Track roller 36 x 16 36 x 20
• Final drive (including travel motor) 362 x 2 362 x 2
01-12 PC200-7
12
Unit: kg
Track shoe assembly
• Wide triple grouser shoe (800 mm) 1,600 x 2 1,735 x 2
• Road liner (rubber pad type) (600 mm) 1,535 x 2 1,665 x 2
Boom assembly 1,825 1,825
Arm assembly 1,213 1,213
Bucket assembly 722 722
Boom cylinder assembly 195 x 2 195 x 2
Arm cylinder assembly 262 262
Bucket cylinder assembly 161 161
Link assembly (large) 82 82
Link assembly (small) 22 x 2 22 x 2
Boom pin 50 + 10 x 2 + 31 + 10 + 26 50 + 10 x 2 + 31 + 10 + 26
Arm pin 11 + 10 11 + 10
Bucket pin 20 x 2 20 x 2
Link pin 17 x 2 17 x 2
PC200-7 01-13
GENERAL FUEL, COOLANT, AND LUBRICANTs
12
FUEL, COOLANT, AND LUBRICANTS
KIND AMBIENT TEMPERATURE CAPACITY (l)

RESERVOIR OF -22 -4 14 32 50 68 86 104°F
FLUID Specified Refill
-30 -20 -10 0 10 20 30 40°C
SAE 30
SAE 10W
Engine oil pan 26.3 24
SAE 10W-30
SAE 15W-40
Damper case 0.75 —

Swing machinery case 6.6 6.6
Engine
Final drive case (each side) SAE 30 4.7 4.5
oil
Idler (1 each) 0.07-0.08 0.07-0.08
Track roller (1 each) 0.19-0.20 0.19-0.20
Carrier roller (1 each) 0.075-0.085 0.075-0.085
SAE 10W
SAE 10W-30
Hydraulic system 240 143
SAE 15W-40
Hydraulic
H046-HM (★)
oil
ASTM D975 No. 2

Diesel
Fuel tank 400 —
fuel
ASTM D975A
No.1
PC200, PC200,
PC200LC-7 PC200LC-7
22.4 22.4
Cooling system Coolant Add antifreeze
PC220, PC220,
PC220LC-7 PC220LC-7
30.9 30.9
★ For the H-046-HM, use the oil recommended by Komatsu.
01-14 PC200-7
10 STRUCTURE, FUNCTION, AND
MAINTENANCE STANDARD
1252
Engine Related Parts . . . . . . . . . . . . . .10-2 Hydraulic Cylinder
Radiator • Oil Cooler • Aftercooler . . .10-3 PC200-7, PC200LC-7 . . . . . . . . . 10-134
Power Train . . . . . . . . . . . . . . . . . . . . .10-4 PC220-7, PC220LC-7 . . . . . . . . . 10-136
Final Drive . . . . . . . . . . . . . . . . . . . . . .10-6 Work Equipment. . . . . . . . . . . . . . . 10-138
Swing Machinery Air Conditioner . . . . . . . . . . . . . . . . 10-146
PC200-7, PC200LC-7 . . . . . . . . . . . .10-8 Engine Control . . . . . . . . . . . . . . . . 10-147
PC220-7, PC220LC-7 . . . . . . . . . . .10-10 Electronic Control System . . . . . . . 10-155
Swing Circle Multi Monitor System . . . . . . . . . . 10-180
PC200-7, PC200LC-7 . . . . . . . . . . .10-12 7-Segment Monitor System . . . . . 10-202
PC220-7, PC220LC-7 . . . . . . . . . . .10-13 Sensor . . . . . . . . . . . . . . . . . . . . . . . 10-209
Track Frame • Recoil Spring . . . . . . .10-14
Idler. . . . . . . . . . . . . . . . . . . . . . . . . . .10-16
Carrier roller. . . . . . . . . . . . . . . . . . . .10-18
Track roller . . . . . . . . . . . . . . . . . . . . .10-19
Track Shoe . . . . . . . . . . . . . . . . . . . . .10-20
Hydraulic Equipment Layout Drawing
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-24
Hydraulic Tank . . . . . . . . . . . . . . . . . .10-26
Hydraulic Pump . . . . . . . . . . . . . . . . .10-28
Control Valve
PC200-7, PC200LC-7 . . . . . . . . . . .10-50
PC220-7, PC220LC-7 . . . . . . . . . . .10-64
CLSS . . . . . . . . . . . . . . . . . . . . . . . . . .10-80
Self Pressure Reducing Valve. . . . . .10-83
Swing Motor . . . . . . . . . . . . . . . . . . .10-86
Reverse Prevention Valve . . . . . . . . .10-91
Center Swivel Joint . . . . . . . . . . . . . .10-93
Travel Motor . . . . . . . . . . . . . . . . . . .10-94
Travel Junction Valve . . . . . . . . . . .10-103
Travel PPC Shuttle Valve . . . . . . . .10-105
Valve Control . . . . . . . . . . . . . . . . . .10-107
Work Equipment • Swing PPC Valve
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-108
Travel PPC Valve . . . . . . . . . . . . . . .10-112
Service PPC Valve . . . . . . . . . . . . . .10-121
Solenoid Valve. . . . . . . . . . . . . . . . .10-124
PPC Accumulator. . . . . . . . . . . . . . .10-126
Return Oil Filter . . . . . . . . . . . . . . . .10-127
Boom Hydraulic Drift Prevention Valve
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-128
Lift Check Valve . . . . . . . . . . . . . . . .10-131
Attachment Circuit Selector Valve .10-132
PC200-7 10-1
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ENGINE RELATED PARTS
12
ENGINE RELATED PARTS
1. Drive plate 5. Damper assembly OUTLINE

2. Torsion spring 6. Muffler
3. Stopper pin 7. Rear engine mount • The damper assembly is a wet type.
4. Friction plate 8. Front engine mount Oil capacity: 0.75 l
10-2 PC200-7
RADIATOR • OIL COOLER •
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD AFTERCOOLER
12
RADIATOR • OIL COOLER • AFTERCOOLER
SWP08671
1. Reservoir tank SPECIFICATIONS

2. Oil cooler
3. Radiator Radiator : CWX-4 (PC200-7, PC200LC-7)
4. Fan : CF19-5 (PC220-7, PC220LC-7)
5. Radiator inlet hose Oil cooler : CF40-1
6. Radiator outlet hose
7. Radiator cap
8. Net
9. Shroud
10. Aftercooler
PC200-7 10-3
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD POWER TRAIN
12
POWER TRAIN
1. Idler 7. Engine (SAA6D102E-2)

2. Center swivel joint 8. Travel speed solenoid valve
3. Control valve 9. Swing brake solenoid valve
4. Final drive 10. Swing motor (KMF125ABE-5)
5. Travel motor (HMV 110ADT-2) 11. Swing machinery
6. Hydraulic pump (HPV95+95) 12. Swing circle
10-4 PC200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD FINAL DRIVE
12
FINAL DRIVE
10-6 PC200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD FINAL DRIVE
12
1. Level plug
2. Drain plug
3. Cover
4. No. 2 sun gear (No. of teeth: 21)
5. No. 1 sun gear (No. of teeth: 10)
4. No. 1 planetary carrier
6. Cover
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:
 10 + 95   21+ 95 
− ×  + 1 = −57.00
 10   21 
Unit: mm
No. Check item Criteria Remedy
Backlash between No. 1 sun gear and Standard clearance Clearance limit
15
No. 1 planetary gear 0.15 - 0.49 1.00
Backlash between No. 1 planetary gear
16 0.17 - 0.57 1.10
and ring gear
Backlash between No. 1 planetary car-

17 0.06 - 0.25 —
rier and motor
Backlash between No. 2 sun gear and Replace

18 0.14 - 0.46 1.00
No. 2 planetary gear
Backlash between No. 2 planetary gear
19 0.17 - 0.57 1.10
and ring gear
Backlash between No. 2 planetary car-

20 0.38 - 0.66 1.00
rier and No. 1 sun gear
21 End play of sprocket shaft 0.00 - 0.10 —
22 Amount of wear on sprocket tooth Repair limit: 6

Rebuild or
Standard size Repair limit
23 Width of sprocket tooth replace
71 68
PC200-7 10-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING MACHINERY
12
SWING MACHINERY
PC200-7, PC200LC-7
10-8 PC200-7
12
1. Swing pinion (No. of teeth: 15)

2. Spacer
3. Case
5. No. 2 sun gear
6. Ring gear
7. No. 1 sun gear
8. Swing motor
9. Oil level gauge
10. No. 1 planetary gear
13. Drain plug
SPECIFICATIONS
Reduction ratio:
 17 + 58   18 + 58 
 ×  = 18.627
 17   18 
Unit: mm
Backlash between swing motor shaft and Standard clearance Clearance limit
14
No. 1 sun gear 0.18 - 0.28 —
Backlash between No. 1 sun gear and No. 1
15 0.16 - 0.50 1.00
planetary gear
Backlash between No. 1 planetary gear and
16 0.18 - 0.59 1.10
ring gear
Backlash between No. 1 planetary carrier
17 0.39 - 0.71 1.20
and No. 2 sun gear
Backlash between No. 2 sun gear and No. 2 Replace
18 0.16 - 0.50 0.90
planetary gear
19 0.18 - 0.59 1.00
ring gear
20 0.07 - 0.23 —
and swing pinion
Backlash between swing pinion and swing
21 0.22 - 1.32 2.00
circle
Clearance between plate and planetary car-
22 0.66 - 1.14 —
rier
Apply hard chrome
Wear of swing pinion surface contacting
23 0 plating, recondi-
with oil seal 115 — tion, or replace
-0.100
PC200-7 10-9
PC220-7, PC220LC-7
10-10 PC200-7
12
1. Swing pinion (No. of teeth: 13)

2. Spacer
3. Case
5. No. 2 sun gear
6. Ring gear
7. No. 1 sun gear
8. Swing motor
9. Oil level gauge
13. Drain plug
SPECIFICATIONS
Reduction ratio:
 17 + 58   14 + 58 
 ×  = 22.689
 17   14 
Unit: mm
Backlash between swing motor shaft and Standard clearance Clearance limit
14
No. 1 sun gear 0.18 - 0.28 —
Backlash between No. 1 sun gear and No. 1
15 0.16 - 0.59 1.00
planetary gear
16 0.18 - 0.50 1.10
ring gear
17 0.39 - 0.64 1.20
and No. 2 sun gear
Backlash between No. 2 sun gear and No. 2 Replace
18 0.16 - 0.44 0.90
planetary gear
19 0.18 - 0.56 1.00
ring gear
20 0.08 - 0.23 —
and swing pinion
Backlash between swing pinion and swing
21 0.23 - 1.37 2.00
circle
Clearance between plate and planetary car-
22 0.58 - 0.62 —
rier
Apply hard chrome
Wear of swing pinion surface contacting
23 0 plating, recondi-
with oil seal 115 — tion, or replace
-0.100
PC200-7 10-11
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING CIRCLE
SWING CIRCLE
PC200-7, PC200LC-7
1. Swing circle inner race (No. of teeth: 110) SPECIFICATIONS

2. Ball
3. Swing circle outer race
Reduction ratio: 
110 
a. Inner race soft zone S position  = 7.333
 15 
b. Outer race soft zone S position
Amount of grease: 14.6 l (G2-LI)
Unit: mm
Axial clearance of bearing Standard clearance Clearance limit

4 Replace
(when mounted on chassis) 0.5 - 1.6 3.2
10-12 PC200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING CIRCLE
12
PC220-7, PC220LC-7
S*P09097
1. Swing circle inner race (No. of teeth: 92) SPECIFICATIONS

2. Ball
3. Swing circle outer race
Reduction ratio: −   = −7.077

92
a. Inner race soft zone S position
 13 
b. Outer race soft zone S position
Amount of grease: 15.8 l (G2-LI)

Unit: mm
Axial clearance of bearing Standard clearance Clearance limit

4 Replace
(when mounted on chassis) 0.5 - 1.6 3.2
PC200-7 10-13
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRACK FRAME • RECOIL SPRING
12
TRACK FRAME • RECOIL SPRING
1 Idler • The dimensions and the number of track rollers depend

2 Track frame on the model, but the basic structure is not different.
3 Carrier roller • Number of track rollers
4 Final drive
5 Track roller Model Q’ty
6 Track shoe
7 Center guard PC200-7 7
8 Recoil spring
9 Front guard PC200LC-7 9
PC220-7 8
PC220LC-7 10
10-14 PC200-7
12
Standard shoe
Model
PC200-7 PC200LC-7 PC220-7 PC220LC-7
Item
Shoe width 600 mm 700 mm 600 mm 700 mm
Link pitch 190 mm 190 mm 190 mm 190 mm
No. on track (one side) 45 (pieces) 49 (pieces) 47 (pieces) 51 (pieces)
Unit: mm
Standard
Tolerance Repair limit
size
10 Vertical width of idler guide
Track frame 107 Rebuild
or
Idler support 105
replace
Horizontal width of idler Track frame 250
11
guide Idler support 247.4
Free length Installation Installation Free Installation

Recoil spring x O.D. length load length load
12 108.8 kN 87.3 kN Replace

PC200-7 558 X 238 437 534
(11,100 kg) (8,900 kg)
PC200LC-7
126.5 kN 100.9 kN
PC220-7 603.5 X 239 466 576
(12,900 kg) (10,300 kg)
PC22LC-7
PC200-7 10-15
12
IDLER
10-16 PC200-7
12
Unit: mm

1 Outside diameter of protruding
538 —
2 Outside diameter of tread 500 488 Rebuild

or
3 Thickness of tread 26 20 replace
4 Total width 159 —
5 Width of tread 37.5 43.5
Standard Tolerance Standard Clearance

Clearance between shaft and size Shaft Hole clearance limit
6
bushing
-0.250 +0.074
65 0.214 - 0.424 1.5
-0.350 -0.036 Replace
Tolerance bushing
Standard Standard Interference
Interference between idler and size Shaft Hole interference limit
7
bushing
+0.089 -0.006
72 0.065 - 0.161 —
+0.059 -0.072
PC200-7 10-17
12
CARRIER ROLLER
Unit: mm

1 Outside diameter of flange
145 —
2 Outside diameter of tread 120 106
3 Width of tread 43 —
4 Thickness of tread 36.5 29.5
5 Width of flange 14 —
Standard Tolerance Standard Interference Replace

Interference between shaft size Shaft Hole interference limit
6
and bushing
-0.179 +0.284
40 0.339 - 0.474 —
-0.190 +0.169
Interference between roller -0.061 0

7 47 0.036 - 0.101 —
and bushing -0.036 -0.040
Standard clearance Clearance limit

8 Axial clearance of roller
0.44 - 0.76 —
10-18 PC200-7
12
TRACK ROLLER
Unit: mm

1 Outside diameter of flange
188 —
2 Outside diameter of tread 156 144
3 Thickness of tread 44.5 38.5 Rebuild

or
4 Overall width 225 — replace
5 Inside width 85 —
6 Width of tread 44.5 —
7 Width of flange 25.5 —
Standard Tolerance Standard Clearance

Clearance between shaft and size Shaft Hole clearance limit
8
bushing
-0.215 +0.195
60 0.215 - 0.510 1.5
-0.315 0 Replace
Tolerance bushing
Standard Standard Interference
Interference between roller size Shaft Hole interference limit
9
and bushing
-0.153 +0.030
67 0.023 - 0.153 —
-0.053 0
PC200-7 10-19
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRACK SHOE
12
TRACK SHOE
TRIPLE GROUSER SHOE, ROAD LINER, SWAMP SHOE, FLAT SHOE
★ P portion shows the link of bushing press fitting end.
1.Triple-grouser shoe 3.Swamp shoe

2.Road liner 4.Flat shoe
10-20 PC200-7
12
Unit: mm
No
Check item Criteria Remedy
.
1 Link pitch
190.25 194.25
Reverse
When turned or
Standard size replace
2 Bushing outside diameter Normal load Impact load
59.3 — 54.3

3 Link height
105 97 Repair or
replace
Thickness of link metal
4 28.5 20.5
(bushing press-fitting portion)
5 160.4
6 Shoe bolt pitch 62
7 18
8 Inside width 84.8
9 Link Overall width 45.4
10 Tread width 39.6
Regular 2.5 Adjust or

11 Protrusion of pin
Master 2.5 replace
Protrusion of Regular 4.85

12
bushing Master 0.0
Overall length of Regular 212

13
pin Master 212
Overall length of Regular 138.5

14
bushing Master 128.7
Standard 10.4 Reverse

Thickness of
15 When turned / or
bushing metal 5.4
Impact Load replace
16 Thickness of spacer —
17 Bushing 88.2 - 245 kN {9 - 25 ton}
18 Press-fitting Regular pin 127.4 - 274.4 kN {13 - 28 ton} —

force
Master pin 78.4 - 147 kN {8 - 15 ton}
19
: Dry type track link
PC200-7 10-21
12
Unit: mm
Tightening torque Additional tightening

(Nm {kgm}) angle (deg.)
490 ± 49
a. Regular link Triple shoe 120 ± 10
{50 ± 5}
Road liner 549 ± 59 Retighten

Shoe bolt —
20 (Rubber pad type) {56 ± 6}
Tightening torque Additional tightening Lower limit torque

b. Master link (Nm {kgm}) angle (deg.) (Nm {kgm})
— — —
PC200-7: 45, PC200LC-7: 49

No. of shoes (each side) —
PC220-7: 47, PC220LC-7: 51
Standard Tolerance Standard

Interference between size Shaft Hole interference
21
bushing and link
+0.304 +0.074
59 0.320 - 0.434
+0.394 0
Interference between +0.222 -0.138

22 38 0.300 - 0.422
regular pin and link +0.162 -0.200

Clearance between regular pin size Shaft Hole clearance
23
and bushing
+0.222 +0.902 Adjust or
38 0.180 - 0.740
+0.162 +0.402 replace

Interference between master size Shaft Hole interference
24 pin and bushing
+0.280 +0.062
37.8 0.188 - 0.280
+0.250 0

Clearance between master pin size Shaft Hole clearance
25 and bushing
-0.150 +0.902
38 0.552 - 1.252
-0.350 +0.402
Standard size Repair limit Lug welding,

Height of Triple-grouser rebuild or
26 16 replace
grouser
Road liner 70 25 Replace
: Dry type track link
10-22 PC200-7
12
TRIPLE GROUSER SHOE
SWAMP SHOE
Unit: mm

1 Height
26 16
2 Thickness 8.5
3 26
Length of base
4 19
5 20
Rebuild or replace
6 Length at tip 14
7 19

8 Thickness
34.5 24.5
9 Height 102.5 90.5
10 Thickness 17 5
PC200-7 10-23
HYDRAULIC EQUIPMENT LAYOUT
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD DRAWING
12
HYDRAULIC EQUIPMENT LAYOUT DRAWING
1. Bucket cylinder
2. Arm cylinder
3. Boom cylinder
4. Hydraulic tank
5. Hydraulic filter
6. R.H. travel motor
7. Swing motor
8. Hydraulic pump
9. Control valve
10. Oil cooler
11. L.H. travel motor
12. Multi-pattern selector valve
13. L.H. PPC valve
14. Safety lever (electric type)
15. Center swivel joint
16. R.H. PPC valve
17. Travel PPC valve
18. Attachment circuit selector valve
19. Holding valve
20. Accumulator
21. Solenoid valve assembly
21A PPC lock solenoid
21B Travel junction solenoid
21C Pump merge/divider solenoid
21D Travel speed solenoid
21E Swing brake solenoid
21F 2-stage relief solenoid
10-24 PC200-7
HYDRAULIC EQUIPMENT LAYOUT
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD DRAWING
12
PC200-7 10-25
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC TANK
12
HYDRAULIC TANK
1. Sight gauge SPECIFICATIONS

2. Hydraulic tank Tank capacity: 200 l
3. Oil filler cap Amount of oil inside tank: 143 l
4. Filter element Pressure valve
5. Strainer Relief cracking pressure:
6. Bypass valve 16.7 ± 6.9 kPa
7. Suction strainer {0.17 ± 0.07 kg/cm²}
Suction cracking pressure:
0 - 0.49 kPa
{0 - 0.005 kg/cm²}
Bypass Valve set pressure:
150 ± 30 kPa
{1.5 ± 0.3 kg/cm²}
10-26 PC200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
HYDRAULIC PUMP
HPV95 + 95
1. Front main pump IM : PC mode selector current PENR : Rear pump control pressure detec-
2. Rear main pump ISIG : LS set selector current tion port
3. LS valve PAF : Front pump delivery port PLSF : Front load pressure input port
4. PC valve PFC : Front pump delivery pres- PLSFC: Front load pressure detection port
5. LS-EPC valve sure detection port PLSR : Rear load pressure input port
6. PC-EPC valve PAR : Rear pump delivery port PLSRC: Rear load pressure detection port
PRC : Rear pump delivery pressure PS : Pump suction port
detection port PSIG : LS set selector pressure detection
PBF : Pump pressure input port port
PD1F: Case drain port PM : PC set selector pressure detection
PENF: Front pump control pressure port
detection port PEPC : EPC basic pressure input port
Outline
• This pump consists of 2 variable capacity swash plate
piston pumps, PC valve, LS valve, and EPC valve.
10-28 PC200-7
12
1. Shaft (Front) 7. Cylinder block

2. Cradle 8. Valve plate
3. Case (Front) 9. End cap
4. Rocker cam 10. Shaft (Rear)
5. Shoe 11. Case (Rear)
6. Piston 12. Servo piston
PC200-7 10-29
12
Function
• The rotation and torque transmitted to the • Rocker cam (4) has flat surface A, and shoe
pump shaft are converted into hydraulic (5) is always pressed against this surface
energy, and pressurized oil is discharged while sliding in a circular movement.
according to the load. Rocker cam (4) brings high pressure oil at cyl-
• It is possible to change the discharge amount inder surface B with cradle (2), which is
by changing the swash plate angle. secured to the case, and forms a static pres-
Structure sure bearing when it slides.
• Cylinder block (7) is supported to shaft (1) by • Piston (6) carries out relative movement in
a spline, and shaft (1) is supported by the the axial direction inside each cylinder cham-
front and rear bearings. ber of cylinder block (7).
• The tip of piston (6) is a concave ball, and • The cylinder block seals the pressure oil to
shoe (5) is caulked to it to form one unit. Pis- valve plate (8) and carries out relative rota-
ton (6) and shoe (5) form a spherical bearing. tion. This surface is designed so that the oil
pressure balance is maintained at a suitable
level. The oil inside each cylinder chamber of
cylinder block (7) is sucked in and discharged
through valve plate (8).
10-30 PC200-7
12
Operation
1) Operation of pump
i Cylinder block (7) rotates together with
shaft (1), and shoe (5) slides on flat surface
A.
When this happens, rocker cam (4) moves
along cylindrical surface B, so angle α
between center line X of rocker cam (4) and
the axial direction of cylinder block (7)
changes. (Angle α is called the swash plate
angle.)
ii Center line X of rocker cam (4) maintains
swash plate angle α in relation to the axial
direction of cylinder block (7), and flat sur-
face A moves as a cam in relation to shoe
(5).
In this way, piston (6) slides on the inside of
cylinder block (7), so a difference between
volumes E and F is created inside cylinder
block (7). The suction and discharge is car-
ried out by this difference F - E.
In other words, when cylinder block (7)
rotates and the volume of chamber E
becomes smaller, the oil is discharged dur-
ing that stroke. On the other hand, the vol-
ume of chamber F becomes larger, and as
the volume becomes bigger, the oil is
sucked in.
iii If center line X of rocker cam (4) is in line
with the axial direction of cylinder block (7)
(swash plate angle = 0), 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.
(In actual fact, the swash plate angle never
becomes 0.)
PC200-7 10-31
12
2) Control of discharge amount
• If the swash plate angle α becomes larger,
the difference between volumes E and F
becomes larger and discharge amount Q
increases.
• Swash plate angle α is changed by servo
piston (12).
• Servo piston (12) moves in a reciprocal
movement (↔) according to the signal
pressure from the PC and LS valves. This
straight line movement is transmitted
through rod (13) to rocker cam (4), and
rocker cam (4), which is supported by the
cylindrical surface to cradle (2), slides in a
rotating movement in direction of arrow.
• With servo piston (12), the area receiving
the pressure is different on the left and
the right, so main pump discharge pres-
sure (self pressure) PP is always brought
to the chamber receiving the pressure at
the small diameter piston end.
• Output pressure Pen of the LS valve is
brought to the chamber receiving the
pressure at the large diameter end. The
relationship in the size of pressure PP at
the small diameter piston end and pres-
sure Pen at the large diameter end, and
the ratio between the area receiving the
pressure of the small diameter piston and
the large diameter piston controls the
movement of servo piston (12).
10-32 PC200-7
12
LS VALVE
1. Plug PP : Pump port

2. Locknut PDP : Drain port
3. Sleeve PLP : LS control pressure output port
4. Spring PLS : LS pressure input port
5. Seat PPL : PC control pressure input port
6. Spool PSIG : LS mode selection pilot port
7. Piston
8. Sleeve
PC VALVE
PP1 : Pump port

1. Servo piston assembly
PP2 : Pump pressure pilot port
2. Plug
PT : Drain port
3. Pin
PM : PC mode selector pressure pilot port
4. Spool
PPL : PC control pressure output port
5. Retainer
PLP : LS control pressure output port
6. Seat
7. Cover
8. Wiring
PC200-7 10-33
12
Function
(1) LS valve
The LS valve detects the load and controls the
discharge amount.
This valve controls main pump discharge
amount Q according to differential pressure
∆PLS (=PP - PLS) [called the LS differential
pressure] (the difference between main pump
pressure PP and control valve outlet port
pressure PLS).
Main pump pressure PP, pressure PLS {called
the LS pressure} coming from the control
valve output, and pressure Psig {called the
LS selector pressure} from the proportional
solenoid valve enter this valve. The relation-
ship between discharge amount Q and differ-
ential pressure ∆PLS, (the difference between
main pump pressure PP and LS pressure
PLS) (= PP - PLS) changes as shown in the
diagram at the right according to LS pressure
selector current isig of the LS-EPC valve.
When isig changes between 0 and 1A, the set
pressure of the spring changes according to
this, and the selector point for the pump dis-
charge amount changes at the rated central
valve between 0.69 ↔ 2.2 MPa {7 ↔ 22 kg/
cm²}.
(2) PC valve
When the pump discharge pressure PP1
(self-pressure) and PP2 (other pump pres-
sure) are high, the PC valve controls the
pump so that no more oil than the constant
flow (in accordance with the discharge pres-
sure) 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 during the opera-
tion becomes larger and the pump discharge
pressure rises, it reduces the discharge
amount from the pump; and if the pump dis-
charge pressure drops, it increases the dis-
charge 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 Q is
shown on the right, with the current given to
the PC-EPC valve solenoid shown as a param-
eter. The controller senses the actual speed of
the engine, and if the speed drops because of
an increase in the load, it reduces the pump the set value, the command current to the PC-
discharge amount to allow the speed to EPC valve solenoid from the controller
recover. In other words, when the load increases according to the drop in the engine
increases and the engine speed drops below speed to reduce the pump swash plate angle.
10-34 PC200-7
12
OPERATION
SDP08884
(1) LS valve At this point, spool (6) is pushed to the left,

1) When control valve is at neutral position and port C and port D are connected. Pump
• The LS valve is a three-way selector valve, pressure PP enters the large diameter end of
with pressure PLS (LS pressure) from the the piston from port K and the same pump
inlet port of the control valve brought to pressure PP also enters port J at the small
spring chamber B, and main pump discharge diameter end of the piston, so the swash plate
pressure PP brought to port H of sleeve (8). is moved to the minimum angle by the differ-
The size of this LS pressure PLS + force Z of ence in the area of the piston (11).
spring (4) and the main pump pressure (self
pressure) PP determines the position of
spool (6). However, the size of the output
pressure PSIG (the LS selection pressure) of
the EPC valve for the LS valve entering port G
also changes the position of spool (6). (The
set pressure of the spring changes).
• Before the engine is started, servo piston (11)
is pushed to the right. (See the diagram on
the right)
• When the engine is started and the control
lever is at the neutral position, LS pressure
PLS is 0 MPa {0 kg/cm²}. (It is interconnected
with the drain circuit through the control
valve spool.)
PC200-7 10-35
12
SDP08885
2) Operation in increase direction for pump • For this reason, the pressure at the large
discharge amount diameter end of servo piston (12) becomes
• When the difference between the main pump drain pressure PT, and pump pressure PP
pressure PP and LS pressure PLS, in other enters port J at the small diameter end, so
words, LS differential pressure ∆PLS, servo piston (12) is pushed to the right. There-
becomes smaller (for example, when the area fore, the swash plate moves in the direction
of opening of the control valve becomes to make the discharge amount larger. If the
larger and pump PP drops), spool (6) is output pressure of the EPC valve for the LS
pushed to the right by the combined force of valve enters port G, this pressure creates a
LS pressure PLS and the force of spring (4). force to move piston (7) to the left. If piston
• When spool (6) moves, port D and port E are (7) is pushed to the left, it acts to make the set
joined and connected to the PC valve. When pressure of spring (4) weaker, and the differ-
this happens, the PC valve is connected to the ence between PLS and PP changes when
drain port, so circuit D - K becomes drain ports D and E of spool (6) are connected.
pressure PT. (The operation of the PC valve is
explained later).
10-36 PC200-7
12
SDP08886
3) Operation in decrease direction for

pump discharge amount
• The following explains the situation if the • Main pump pressure PP also enters port J at
servo piston (12) moves to the left (the dis- the small diameter end of the piston, but
charge amount becomes smaller). When LS because of the difference in area between the
differential pressure ∆PLS becomes larger large diameter end and the small diameter
(for example, when the area of opening of the end of servo piston (12), servo piston (12) is
control valve becomes smaller and pump pushed to the left.
pressure PP rises), pump pressure PP • As a result, the swash plate moves in the
pushes spool (6) to the left. direction to make angle smaller.
• When spool (6) moves, main port pressure • If LS selection pressure PSIG enters port G, it
PP flows from port C and port D and from acts to make the set pressure of spring (4)
port K, it enters the large diameter end of the weaker.
piston.
PC200-7 10-37
12
SDP08887
4) When servo piston is balanced

• Let us take the area receiving the pressure at • At this point, the relationship between the
the large diameter end of the piston as A1, area receiving the pressure at both ends of
the area receiving the pressure at the small piston (12) is A0 : A1 = 1:2, so the pressure
diameter end as A0, and the pressure flowing applied to both ends of the piston when it is
into the large diameter end of the piston as balanced becomes PP : Pen = 2:1.
Pen. If the main pump pressure PP of the LS • The position where spool (6) is balanced and
valve and the combined force of force Z of stopped is the standard center, and the force
spring (4) and LS pressure PLS are balanced, of spring (4) is adjusted so that it is deter-
and the relationship is A0 x PP = A1 x Pen, mined when PP - PLS = 2.2 MPa {22 kg/cm²}.
servo piston (11) will stop in that position, and However, if PSIG (the output pressure of 0 ↔
the swash plate will be kept at an intermedi- 2.9 MPa {0 ↔ 30 kg/cm²} of the EPC valve of
ate position. (It will stop at a position where the LS valve) is applied to port G, the balance
the opening of the throttle from port D to port stop position will change in proportion to
E and from port C to port D of spool (6) is pressure PSIG between PP - PLS = 2.2 ↔
approximately the same.) 0.69 MPa {22 ↔ 7 kg/cm²}.
10-38 PC200-7
12
(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
➀ Movement of PC-EPC solenoid (1)
• The command current from the pump • the pressure (pressure of port C) output
controller flows to PC-EPC solenoid from the PC valve changes according to
(1).This command current acts on the PC- this position.
EPC valve and outputs the signal pres- • The size of command current X is deter-
sure. When this signal pressure is mined by the nature of the operation
received, the force pushing piston (2) is (lever operation), the selection of the
changed. working mode, and the set value and
• On the opposite side to the force pushing actual value for the engine speed.
this piston (2) is the spring set pressure of ★ Other pump pressure
springs (4) and (6) and pump pressure This is the pressure of the pump at the
PP1 (self pressure) and PP2 (other pump opposite end.
pressure) pushing spool (3). Piston (2) For the F pump, it is the R pump pressure
stops at a position where the combined For the R pump, it is the F pump pressure
force pushing spool (3) is balanced, and
PC200-7 10-39
12
SDP08889
➁ Action of spring
• The spring load of springs (4) and (6) in the • If the command circuit input to PC-EPC valve
PC valve is determined by the swash plate solenoid (1) changes further, the force push-
position. ing piston (2) changes, and the spring load of
• If piston (9) moves to the left, spring (6) is springs (4) and (6) also changes according to
compressed, and if it moves further to the left, the valve of the PC-EPC valve solenoid com-
spring (6) contacts seat (5) and is fixed in mand current.
position. In other words, the spring load is
changed by piston (9) extending or compress-
ing springs (4) and (6).
10-40 PC200-7
12
• Port C of the PC valve is connected to port E

of the LS valve (see (1) LS valve). Self pres-
sure PP1 enters port B and the small diame-
ter end of servo piston (9), and other pump
pressure PP2 enters port A.
• When pump pressures PP1 and PP2 are
small, spool (3) is on the left. At this point,
port C and D are connected, and the pressure
entering the LS valve becomes drain pressure
PT. If port E and port G of the LS valve are
connected (see (1) LS valve), the pressure
entering the large diameter end of the piston
from port J becomes drain pressure PT, and
servo piston (9) moves to the right. In this
way, the pump discharge amount moves in
the direction of increase.
• As servo piston (9) moves further, springs (4)
and (6) expand and the spring force becomes
weaker. When the spring force becomes
weaker, spool (3) moves to the right, so the
connection between port C and port D is cut,
and the pump discharge pressure ports B and
C are connected. As a result, the pressure at
port C rises, and the pressure at the large
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 the
pressures PP1 and PP2 acting on the spool
(3) are in balance.
PC200-7 10-41
12
b. When load on actuator is large and

pump discharge pressure is high
• When the load is large and pump dis- • If main pump pressure PP increases fur-
charge pressures PP1 and PP2 are high, ther and spool (3) moves further to the
the force pushing spool (3) to the left left, main pump pressure PP1 flows to
becomes larger and spool (3) moves to port C and acts to make the discharge
the position in the diagram above. When amount the minimum. When piston (9)
this happens, as shown in the diagram moves to the left, springs (4) and (6) are
above, part of the pressurized oil from compressed and push back spool (3).
port B flows out through port C where the When spool (3) moves to the left, the
LS valve is actuated to port D, and the opening of port C and port D becomes
pressurized oil flowing from port C to the larger. As a result, the pressure at port C
LS valve becomes approximately half of (= J) drops, and piston (9) stops moving
main pump pressure PP. to the left.
• When port E and port G of the LS valve • The position in which piston (9) stops
are connected (see (1) LS valve), the pres- when this happens is further to the left
sure from port J enters the large diameter than the position when pump pressures
end of servo piston (9), and servo piston PP1 and PP2 are low.
(9) stops.
10-42 PC200-7
12
• The relation of average pump pressure

(PP1 + PP2)/2 and the position of servo
piston (9) forms a bent line because of
the double-spring effect of springs (4)
and (6). The relationship between aver-
age pump pressure (PP1 + PP2)/2 and
pump discharge amount Q is shown in
the figure at the right.
• If command voltage X sent to PC-EPC

valve solenoid (1) increases further, the
relationship between average pump
pressure (PP1 + PP2)/2, and pump dis-
charge amount Q is proportional to the
pushing force of the PC-EPC valve sole-
noid and moves in parallel. In other
words, the pushing force of PC-EPC
solenoid (1) is added to the force push-
ing to the left because of the pump pres-
sure applied to the spool (3), so the
relationship between the average pump
pressure (PP1 + PP2)/2 and Q moves
from ➀ to ➁ in accordance with the
increase in X.
PC200-7 10-43
12
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, • At this point, port C is connected to the
turn emergency pump drive switch ON to drain pressure of port D, and the large
switch to the resistor side. In this case, the diameter end of the piston of servo piston
power source is taken directly from the (9) also becomes the drain pressure PT
battery. But if the current is used as it is, it through the LS valve. When this happens,
is too large, so use the resistor to control the pressure at the small diameter end of
the current flowing to PC-EPC valve sole- the piston is large, so servo piston (9)
noid (1). moves in the direction to make the dis-
• When this is done, the current becomes charge amount larger.
constant, so the force pushing piston (2)
is also constant.
• If the main pump pressure PP1 and PP2
are low, the combined force of the 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 posi-
tion to the left.
10-44 PC200-7
12
b. When main pump load is heavy

• In the same way as in the previous item, and discharge amount Q is determined as
when the emergency pump drive switch shown in the diagram for the valve of the
is ON, the command current sent to PC- current sent to the PC-EPC valve solenoid
EPC valve solenoid (1) becomes constant. through the resistor.
For this reason, the force of piston (2) The curve when the PC prolix switch is
pushing spool (3) is constant. ON is curve ➁, which is to the left of curve
• If main pump pressures PP1 and PP2 ➀ for when the pump controller is normal.
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 from port A
flows to port C, so servo piston (9) moves
to the left (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 emergency pump
drive switch is ON, the curve for the
pump pressure PP
PC200-7 10-45
12
LS(PC)-EPC VALVE
1. Body 5. Coil PSIG(PM) : To LS(PC) valve

2. Spool 6. Plunger PT : To tank
3. Spring 7. Connector PEPC : From self-reducing pressure valve
4. Rod
10-46 PC200-7
12O
FUNCTION
• The EPC valve consists of the proportional

solenoid portion and the hydraulic valve
portion.
• When it receives signal current i from the
pump controller, it generates the EPC out-
put pressure in proportion to the size of the
signal, and outputs it to the LS valve.
OPERATION
1. When signal current is 0 (coil deener-

gized)
• When there is no signal current flowing
from the controller to coil (5), coil (5) is
generalized.
• For this reason, spool (2) is pushed to the
right in the direction of the arrow by spring
(3).
• As a result, port PEPC closes and the pres-
surized oil from the main pump does not
flow to the LS valve.
At the same time, the pressurized oil from 08890
the LS valve passes from port PSIG(PM)
through port PT and is drained to the tank.
PC200-7 10-47
2. When signal current is very small (coil

energized)
• When a very small signal current flows to
coil (5), coil (5) is energized, and a propul-
sion force is generated which pushes
plunger (6) to the left.
• Push pin (4) pushes spool (2) to the left,
and pressurized oil flows from port PEPC
to port PSIG(PM).
• When the pressure at port PSIG(PM) rises
and the load of spring (3) + the force acting
on surface a of spool (2) becomes greater
than the propulsion force of plunger (6), 08891
spool (2) is pushed to the right. The circuit
between port PEPC and port PSIG(PM) is
shut off, and at the same time, port
PSIG(PM) and port PT are connected.
• As a result, spool (2) is moved up or down
until the propulsion force of plunger (6) is
balanced with the load of spring (3) + pres-
sure of port PSIG(PM).
• Therefore, the circuit pressure between the
EPC valve and the LS valve is controlled in
proportion to the size of the signal current.
3. When signal current is maximum (coil

energized)
• When the signal current flows to coil (5),
coil (5) is energized.
• When this happens, the signal current is at
its maximum, so the propulsion force of 08892
plunger (6) is also at its maximum.
• For this reason, spool (2) is pushed fully to
the left by push pin (4).
• As a result, the maximum flow of pressur-
ized oil from port PEPC flows to port
PSIG(PM), and the circuit pressure
between the EPC valve and LS valve
becomes the maximum.
At the same time, port PT closes and stops
the oil from flowing to the tank.
10-48 PC200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
12
CONTROL VALVE
PC200-7, PC200LC-7
1. 6-spool valve OUTLINE
2. Cover 1
3. Cover 2 • This control valve consists of a 6-spool
4. Pump merge-divider valve valve (unit type), 1 service valves, a pump
5. Back pressure valve merge-divider valve, a back pressure valve,
6. Boom lock valve and a boom hydraulic drift prevention
7. Service valve valve.
• Since all the valves are assembled together
with connecting bolts and their passes are
connected to each other inside the assem-
bly, the assembly is small in size and easy
to maintain.
• Since one spool of this control valve is
used for one work equipment unit, its struc-
ture is simple.
A1 : To bucket cylinder head P9 : From right travel PPC valve

A2 : To left travel motor P10 : From right travel PPC valve
A3 : To boom cylinder bottom P11 : From arm PPC valve
A4 : To swing motor P12 : From arm PPC valve
A5 : To right travel motor P-1 : From service PPC valve
A6 : To arm cylinder head P-2 : From service PPC valve
A-1 : To attachment BP1 : Boom RAISE PPC output pressure
B1 : To bucket cylinder bottom BP5 : From attachment circuit selector solenoid
B2 : To left travel motor valve
B3 : To bottom cylinder head PLS1 : To rear pump control
B4 : To swing motor PLS2 : To front pump control
B5 : To right travel motor PP1 : From rear main pump
B6 : To arm cylinder bottom PP2 : From front main pump
B-1 : To attachment PR : To solenoid valve, PPC valve, EPC valve
P1 : From bucket PPC valve PS : From pump merge-divider solenoid valve
P2 : From bucket PPC valve PST : From travel junction valve
P3 : From left travel PPC valve PX1 : From 2-stage solenoid valve
P5 : From boom PPC valve SA : Pressure sensor fitting port
P6 : From boom PPC valve SB : Pressure sensor fitting port
P7 : From swing PPC valve T : To tank
P8 : From swing PPC valve TS : To tank
TSW : To swing motor
10-50 PC200-7
12
7-spool valve
(6-spool valve + 1 service valves)
(1/9)
PC200-7 10-51
12
(2/9)
S*P09099
10-52 PC200-7
12
(3/9)
1. Unload valve 9. Pressure compensation valve (Service)

2. Pressure compensation valve (Arm OUT) 10. Pressure compensation valve (Bucket CURL)
3. Pressure compensation valve (Right travel 11. Pressure compensation valve (Left travel for-
Reverse) ward)
4. Pressure compensation valve (Left swing) 12. Pressure compensation valve (Boom LOWER)
5. Pressure compensation valve (Boom RAISE) 13. Pressure compensation valve (Right swing)
6. Pressure compensation valve (Left travel 14. Pressure compensation valve (Right travel
reverse) forward)
7. Pressure compensation valve (Bucket DUMP) 15. Pressure compensation valve (Arm IN)
8. Pressure compensation valve (Service) 16. Main relief valve
PC200-7 10-53
12
(4/9)
1. Spool (Arm) 6. Spool (Bucket)

2. Spool (Right travel) 7. Spool (Service)
3. Spool (Swing) 8. Unload valve
4. Spool (Boom) 9. Main relief valve
5. Spool (Left travel) 10. Spool return spring
Unit: mm

Free length x Installed Installed Free Installed
11 Spool return spring Outside diameter length load length load
416.5 N 333.2 N If damaged or
54.2 x 34.8 51.2 —
{42.5 kg} {34 kg} deformed, replace
spring
429.9 N 336.1 N
12 Spool return spring 54.6 x 34.8 51.2 —
{43.9 kg} {34.3 kg}
393 N 314.6 N
{40.1 kg} {32.1 kg}
10-54 PC200-7
12
(5/9)
1. Safety-suction valve (Arm OUT) 12. Safety-suction valve (Arm IN)

2. Suction valve (Right travel reverse) 13. LS shuttle valve (Arm)
3. Suction valve (Boom RAISE) 14. LS shuttle valve (Right travel)
4. Suction valve (Left travel reverse) 15. LS select valve
5. Safety-suction valve (Bucket DUMP) 16. LS shuttle valve (Boom)
6. Safety-suction valve (Service) 17. LS shuttle valve (Left travel)
7. Safety-suction valve (2-stage) (Service) 18. LS shuttle valve (Bucket)
8. Safety-suction valve (Bucket CURL) 19. LS shuttle valve (Service)
9. Suction valve (Left travel forward) 20. LS check valve
10. Safety-suction valve (Boom LOWER) 21. Pressure relief plug
11. Suction valve (Right travel forward)
Unit: mm

Free length x Installed Installed Free Installed If damaged or
22 Check valve spring Outside diameter length load length load deformed, replace
spring
1.5 N 1.2 N
11.5 x 4.6 8.5 —
{0.15 kg} {0.12 kg}
PC200-7 10-55
12
(6/9)
ARM CONTROL VALVE R. H. TRAVEL CONTROL

VALVE
1. Unload valve 5. Safety-suction valve
2. Main relief valve 6. Spool 12. Suction valve
3. Safety valve (Boom 7. Pressure compensation valve 13. Spool
RAISE) (OUT) 14. Pressure compensation valve
4. Lift check valve 8. LS shuttle valve (Reverse)
15. LS shuttle valve
9. Pressure compensation valve
16. Pressure compensation valve
(IN)
(Forward)
10. Safety-suction valve 17. Suction valve
11. Check valve for regeneration cir-
cuit
10-56 PC200-7
Unit: mm

18 Relief spring Outside diameter length load length load
406.7 N 325.6 N
30.7 x 9.6 25.9 —
{41.5 kg} {33.2 kg}
69.6 N 55.7 N
19 Valve spring 24.3 x 8 19.5 —
{7.1 kg} {5.7 kg}
70.6 N 56.4 N If damaged or
20 Unload spring 31.5 x 10.2 26.9 —
{7.2 kg} {5.8 kg} deformed, replace
spring
Regeneration valve 6.2 N 4.9 N
21 31.5 x 10.3 19 —
spring {0.6 kg} {0.5 kg}
17.5 N 14.0 N
22 Piston return spring 48.1 x 10.8 28 —
{1.8 kg} {1.4 kg}
79.4 N 63.5 N
{8.1 kg} {6.5 kg}
29.4 N 23.5 N
{3 kg} {2.4 kg}
PC200-7 10-57
(7/9)
BUCKET CONTROL VALVE SERVICE VALVE
1. Safety-suction valve 7. Safety-suction valve

2. Spool 8. Spool
3. Pressure compensation valve (DUMP) 9. Pressure compensation valve
4. LS shuttle valve 10. LS shuttle valve
5. Pressure compensation valve (CURL) 11. Pressure compensation valve
6. Safety-suction valve 12. Safety-suction valve
Unit: mm

13 Piston return spring Outside diameter length load length load If damaged or
17.5 N 14.0 N deformed, replace
48.1 x 10.8 28 — spring
{1.8 kg} {1.4 kg}
29.4 N 23.5 N
{3 kg} {2.4 kg}
10-58 PC200-7
12
(8/9)
SWING CONTROL VALVE BOOM CONTROL VALVE L. H. TRAVEL CONTROL

VALVE
1. Spool 5. Suction valve
2. Pressure compensation 6. Spool 13. Pump merge-divider valve
valve (Left) 7. Pressure compensation (Travel junction valve)
3. LS select valve valve (RAISE) 14. Return spring
4. Pressure compensation 8. Hydraulic drift prevention 15. Suction valve
valve (Right) valve 16. Spool
9. LS shuttle valve 17. Pressure compensation
10. Pressure compensation valve (Reverse)
valve (Lower) 18. LS shuttle valve
11. Safety-suction valve 19. Pressure compensation
12. Check valve for regeneration valve (Forward)
circuit 20. Suction valve
10-60 PC200-7
Unit: mm

21 Regeneration valve spring Outside diameter length load length load
6.2 N 4.9 N
31.5 x 10.3 19 —
{0.6 kg} {0.5 kg}
17.5 N 14.0 N
{1.8 kg} {1.4 kg}
29.4 N 23.5 N
{3 kg} {2.4 kg} If damaged or
428.3 N 343 N deformed, replace
24 Load spring 30.4 x 16.7 27 — spring
{43.7 kg} {35.0 kg}
3.0 N 2.4 N
25 Check valve spring 13.6 x 5.5 10 —
{0.3 kg} {0.25 kg}
35.3 N 28.2 N
26 Check valve spring 33.0 x 12.0 26 —
{3.6 kg} {2.9 kg}
13.7 N 11.0 N
27 Check valve spring 16.4 x 8.9 11.5 —
{1.4 kg} {1.1 kg}
50.0 N 40.0 N
28 Spool return spring 30.7 x 20.5 23 —
{5.1 kg} {4.1 kg}
PC200-7 10-61
12
(9/9)
1. Unload valve 9. LS bypass plug

2. Main relief valve 10. Screw
3. Pump merge-divider valve (Main) 11. Poppet
4. Return spring 12. Spring (Pressure reducing valve pilot)
5. Pump merge-divider valve (For LS) 13. Spring (Pressure reducing valve main)
6. Return spring 14. Valve (Pressure reducing valve)
7. Valve (Sequence valve) 15. Spring (Safety valve)
8. Spring (Sequence valve) 16. Ball
10-62 PC200-7
Unit: mm

17 Valve spring Outside diameter length load length load
69.6 N 55.7 N
24.3 x 8 19.5 —
{7.1 kg} {5.7 kg}
83.4 N 66.7 N
18 Unload spring 31.5 x 10.2 26 —
{8.5 kg} {6.8 kg}
1.5 N 1.2 N
19 Check valve spring 11.5 x 4.6 8.5 —
{0.15 kg} {0.12 kg} If damaged or
156.8 N 125.5 N deformed, replace
20 Spool return spring 46.6 x 21.8 3.3 — spring
{16.0 kg} {12.8 kg}
177.5 N 142.0 N
21 Spool return spring 64.5 x 32.3 63 —
{18.1 kg} {14.5 kg}
199.8 N 160.0 N
22 Sequence valve spring 70.9 x 18.0 59 —
{20.4 kg} {16.3 kg}
10.4 N 8.3 N
{1.1 kg} {0.8 kg}
430.2 N 344.2 N
24 Relief spring 34.7 x 10.4 32.3 —
{43.9 kg) {35.1 kg}
PC200-7 10-63
CONTROL VALVE
PC220-7, PC220LC-7
1. 6-spool valve OUTLINE
2. Cover 1
3. Cover 2 • This control valve consists of a 6-spool
4. Pump merge-divider valve valve (unit type), 1 service valves, a pump
5. Back pressure valve merge-divider valve, a back pressure valve,
6. Boom lock valve and a boom hydraulic drift prevention
7. Service valve valve.
• Since all the valves are assembled together
with connecting bolts and their passes are
connected to each other inside the assem-
bly, the assembly is small in size and easy
to maintain.
• Since one spool of this control valve is
used for one work equipment unit, its struc-
ture is simple.
A1 : To bucket cylinder head P9 : From right travel PPC valve

A2 : To left travel motor P10 : From right travel PPC valve
A3 : To boom cylinder bottom P11 : From arm PPC valve
A4 : To swing motor P12 : From arm PPC valve
A5 : To right travel motor P-1 : From service PPC valve
A6 : To arm cylinder head P-2 : From service PPC valve
A-1 : To attachment BP1 : Boom RAISE PPC output pressure
B1 : To bucket cylinder bottom BP5 : From attachment circuit selector solenoid
B2 : To left travel motor valve
B3 : To bottom cylinder head PLS1 : To rear pump control
B4 : To swing motor PLS2 : To front pump control
B5 : To right travel motor PP1 : From rear main pump
B6 : To arm cylinder bottom PP2 : From front main pump
B-1 : To attachment PR : To solenoid valve, PPC valve, EPC valve
P1 : From bucket PPC valve PS : From pump merge-divider solenoid valve
P2 : From bucket PPC valve PST : From travel junction valve
P5 : From boom PPC valve SA : Pressure sensor fitting port
P6 : From boom PPC valve SB : Pressure sensor fitting port
P7 : From swing PPC valve T : To tank
P8 : From swing PPC valve TS : To tank
TSW : To swing motor
10-64 PC200-7
12
7-spool valve
(6-spool valve + 1 service valves)
(1/9)
PC200-7 10-65
12
(2/9)
S*P09102
10-66 PC200-7
12
(3/9)
1. Unload valve 9. Pressure compensation valve (Service)

2. Pressure compensation valve (Arm OUT) 10. Pressure compensation valve (Bucket CURL)
3. Pressure compensation valve (Right travel 11. Pressure compensation valve (Left travel for-
Reverse) ward)
4. Pressure compensation valve (Left swing) 12. Pressure compensation valve (Boom LOWER)
5. Pressure compensation valve (Boom RAISE) 13. Pressure compensation valve (Right swing)
6. Pressure compensation valve (Left travel 14. Pressure compensation valve (Right travel
reverse) forward)
7. Pressure compensation valve (Bucket DUMP) 15. Pressure compensation valve (Arm IN)
8. Pressure compensation valve (Service) 16. Main relief valve
PC200-7 10-67
12
1. Spool (Arm) 6. Spool (Bucket)

2. Spool (Right travel) 7. Spool (Service)
3. Spool (Swing) 8. Unload valve
4. Spool (Boom) 9. Main relief valve
5. Spool (Left travel) 10. Spool return spring
10-68 PC200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MULTI MONITOR SYSTEM
METHOD OF CHECKING STATUS

MAINTENANCE ITEMS
★ Operate as follows when on the operator

screen.
1. Press maintenance switch (1) and switch to
the maintenance list display screen.
★ The maintencance items are displayed as
symbols on the screen.
2. Press control switch (2), or use the 10-key pad
to input the number (01 - 10) of the mainte-
nance item to select the item.
★ The cursor moves and the item is high-
lighted.
★ The display method is the same as
described on the previous page (relation-
ship between remaining time and caution
display). If the remaining time is less than
30 hours, the item is displayed in yellow,
and if it is less than 0 hours, it is displayed
in red.
MAINTENANCE OPERATION
1. After completing the selection, press input

confirmation switch (3).
The screen will change to the maintenance
reset screen.
2. Use the maintenance reset screen to check
the content, and if there is any problem, press
input confirmation switch (3) to move to the
check screen.
If the wrong item is selected, press return
switch (4) to return to the maintenance list
screen.
3. Check the content on the check screen, and if
there is no problem, press input confirmation
switch (3) to reset the maintenance time.
After the reset is completed, the screen
returns to the maintenance list display
screen. To check the remaining time, or if the
wrong item is selected, press return switch (4)
to return to the maintenance list screen.
★ The check screen shows the symbol for
the maintenance item and the set time in
large letters.
★ The background color of the symbol for
the item where the maintenance tiem was
reset is the same as the background of the
screen, so it is possible to check that it has
been reset.
PC200-7 10-195
BRIGHTNESS, CONTRAST ADJUSTMENT

FUNCTION
This function is used to adjust the brightness and

contrast of the display.
ADJUSTMENT METHOD

screen.
1. Press display brightness/contrast adjustment
switch (1) and switch to the adjustment
screen.
★ Relationship between menu symbol and con-
tent.
No. Symbol Content
01 Return mark Return
02 Contrast
03 Brightness

to input the number (00 - 02) to select either
contrast or brightness.
After completing the selection, press input
confirmation switch (3) and return to the
adjustment screen.
Then press return switch (4) or use the 10-key
pas to set to [00] and press input confirmation
switch (3) to return to the normal screen.
3. Press control switch (2) and adjust the bright-
ness and contrast as desired.
Control switch Actuation
Flow level bar graph

extends to the right

retracts to the left 08937
10-196 PC200-7
PASSWORD FUNCTION
• If a passport is input, the engine will not start

unless the password is input correctly when
starting.
• When setting this function or when changing 08941
the password, it is necessary to go from the
normal screen to the setting screen and input
the password.
This becomes posssible 10 minutes after the
starting switch is turned ON and the monitor
screen has changed to the normal screen.
METHOD OF SETTING, CHANGING

PASSWORD
1. Turn the starting switch ON, keep starting

switch (2) pressed, use the 10-key pad to input
7 → 2 → 9 → 7 → 2 → 9 in succession, and the
screen will change to the 8-digit numeral
input screen.
2. On the input screen, use the 10-key pad to

input an 8-digit number [19210513]. When the
final digit [number 3] is input, the screen will
change to the Valid/Invalid screen for the
password function.
PC200-7 10-197
3. Press control switch (1) or (2) to set to Valid/

Invalid.
The diagram on the right shows the screen
when control switch (1) is pressed and the
screen is set to [Valid].
If [Invalid] is selected and input confirmation

switch (3) is pressed, the password function
will be made invalid, and the screen will
return to the normal screen.
If [Valid] is selected and input confirmation
will be made valid, and the screen will change
to the screen for inputting the 4-digit number.
08942
4. Input a 4-digit number on the input screen

(the lock and key symbol are displayed), then
press input confirmation switch (3).
When the input confirmation switch is
pressed, you will be requested to input the
same 4-digit number again, so input the same
4-digit number, then press input confirmation
switch (3) to confirm the password.
Numerals 1 and 2 are displayed at the top
right corner of the screen to distinguish
between the 1st input screen and the 2nd
input screen.
When the password is confirmed, the screen
will return to the normal screen.
★ If the number input the second time is dif-
ferent from the number input the first
time, the password will not be confirmed
and the screen will return to the first
screen, so input the same 4-digit pass-
word 2 times in succession.
10-198 PC200-7
SERVICE METER CHECK FUNCTION
• When the starting switch is at the OFF posi-

tion, keep return switch (1) and control switch
(2) of the monitor pressed at the same time,
and the service meter is shown on the dis-
play.
• This display is shown only while the two
switches are being pressed. When the
switches are released, the display goes out.
Note that it takes 3 - 5 seconds after the
switches are pressed for the service meter
display to appear.
DISPLAY LCD CHECK FUNCTION
• On the password input screen or on the nor-

mal screen, if monitor return switch (1) and
working mode (A) switch are kept pressed at
the same time, all the LCD display will light 08943
up and the whole screen will become white,
so the display can be checked.
• If any part of the display is black, the LCD is
broken.
PC200-7 10-199
USER CODE DISPLAY FUNCTION
• If there is any problem in operating the

machine, the user code is displayed on the
monitor to advise the operator of the steps to
take.
This code display appears on the operator
screen.
• On the operator screen, the user code is dis-
played on the portion for the hydraulic oil
temperature gauge.
• If more than one user code is generated at the

same time, the user codes are displayed in
turn for 2 seconds each to display all the user
codes.
08945
10-200 PC200-7
• While the user code is being displayed, if the

input confirmation switch is pressed, the ser-
vice code and failure code can be displayed.
08946
• If there is more than one service code or fail-

ure code, the display switches every 2 sec-
onds and displays all the service codes/failure
codes that caused the user code to be dis-
played.
Even if service codes/failure codes have 08947
occurred, if they did not cause the user code
to be displayed, this function does not display
them.
• If the telephone number has been set using

the telephone number input on the service
menu, it is possible to switch on the service
code/failure code and display the telephone
symbol and telephone number.
For details of inputting and setting the tele- 08948
phone number, see SPECIAL FUNCTIONS OF
MONITOR PANEL in the TESTING AND
ADJUSTING section.
PC200-7 10-201
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD 7-SEGMENT MONITOR SYSTEM
7-SEGMENT MONITOR SYSTEM
SJP08775
OR
08931
• The monitor system monitors the condition • The monitor panel also has various mode
of the machine with sensors installed on vari- selector switches and functions to operate the
ous parts of the machine. It processes and machine control system.
immediately displays the obtained informa-
tion on the panel notifying the operator of the
condition of the machine.
The panel is roughly divided as follows.
1. Monitor section to output alarms when
the machine has troubles
2. Gauge section to display the condition
constantly (Coolant temperature, hydrau-
lic oil temperature, fuel level, etc.)
10-202 PC200-7
12
1. Monitor panel
OUTLINE INPUT AND OUTPUT SIGNALS

CN-P01 CN-P02
• The monitor panel has the functions to dis-
play various items and the functions to select Pin Pin
Signal neme Signal Name
No. No.
modes and electric parts.
1 Key switch (Battery) 1 Engine water temperature
The monitor panel has a CPU (Central Pro- 2 Key switch (Battery) 2 Fuel
cessing Unit) in it to process, display, and out-
3 Washer motor output 3 Radiator water level
put the information.
4 Key switch (Terminal C) 4 NC
The monitor display unit consists of LCD (Liq-
5 Wiper contact W 5 Air cleaner clogging sensor
uid Crystal Display) and LED (Light Emitting
6 GND 6 NC
Diode). The switches are flat sheet switches.
7 GND 7 Engine oil pressure sensor
8 VB + (24 V) 8 Engine oil level sensor
9 Wiper motor (+) 9 Network signal
10 Wiper motor (-) 10 Network signal
11 (Buzzer ON signal input) 11 Charge level
12 Wiper contact P 12 NC
13 GND (For analog signal)
14 NC
15 Wind limit switch
16 Buzzer cancel
17 Swing lock
18 Preheating
19 Limit switch
20 Network (GND)
PC200-7 10-203
Display section of monitor
1. Service meter display

2. Coolant temperature gauge
3. Coolant temperature caution
4. Digital meter display (Service code and user
code are displayed when trouble occurs
5. Fuel level caution
6. Fuel level gauge
7. Engine oil level caution lamp
8. Preheating pilot lamp
9. Swing holding brake pilot lamp
10. Oil maintenance pilot lamp
11. Battery charge caution lamp
12. Air cleaner clogging caution lamp
13. Engine oil pressure caution lamp
10-204 PC200-7
Monitored items and display

When engine is
Symbol Displayed item Display range While engine is running
stopped
Max. 1,500 rpm Lights when normal.
Max. 0.05 MPa (Goes off when
{0.5 kg/cm²} engine is started.) Flashes and buzzer
Engine oil pressure
Min. 1,500 rpm sounds when abnormal.
Max. 0.15 MPa
{1.5 kg/cm²}
Air cleaner clogging When clogged Goes off. Flashes when abnormal.
SAP00521
Lights when normal.

When charge is (Goes off when
Charge level engine is started.) Flashes when abnormal.
abnormal
Flashes when abnor-

Engine oil level Below low level Goes off.
SAP00523
mal.
When swing is Lights up when swing is locked. Flashes when

Packing (Swing lock)
locked swing holding brake release switch is turned on.
SAT00098
Oil maintenance See "OIL MAINTENANCE FUNCTION" on next page.
Lights up for 30 sec. when starting switch is set

Preheating When preheated to HEAT. Then, flashes for 10 sec. to indicated
SAP00526 completion of preheating.
Flashes at 102°C or higher. Flashes and

Coolant temperature
buzzer sounds at 105°C or higher.
Fuel level Flashes when below low level.
PC200-7 10-205
12
Oil maintenance function
1. Function and operation

At a set time after the engine oil is replaced, the
oil maintenance function is turned on to notify
the operator by the LED lamp on the monitor
panel that it is time to replace the oil. The func-
tion to indicate the phone number of the place to
make contact for service on the LCD unit is
installed, too.
1) Check of elapsed time

Nothing is displayed normally until point
B shown in the figure at right after this
function is reset. If the key is turned on
with the buzzer cancel switch processed
(for 2.5 seconds), however, the elapsed
time is displayed on the service meter
section.
2) Display of replacement of oil
If time passes point B after this function is
reset, the elapsed time is displayed on the
service meter section and the LED flashes
when the key is turned on.
2. Setting of time interval

1) The time interval is set in the interval set-
ting mode. It can be set to "125h", "250h",
"500h", "Not set", or "Demo-mode". The
default is "Not set".
2) To enter the interval setting mode, press
and hold the clock switch for 2.5 seconds.
3) If the buzzer cancel switch is pressed in
the interval setting mode, the clock dis-
play section changes to "—" → "125" →
"250" → "500" → " d" in order. ("—" corre-
sponds to "Not set" and " d" corresponds
to "Demo-mode".)
4) To save the time interval, set a desired
time (mode) on the monitor panel and
press and hold the clock switch for 2.5
seconds.
10-206 PC200-7
12
3. Timing and contents of display

1) When replacement of oil is displayed
The elapsed time is displayed for 10 sec-
onds after all segments are turned on.
Phone number is displayed for the next 10
seconds.
If the phone number has not been input,
however, the elapsed time is displayed for
20 seconds after all segments are turned
on.
2) When elapsed time is checked
4. Resetting elapsed time

1) When the replacement of oil and elapsed
time are displayed, press the buzzer can-
cel switch 10 seconds after all segments
are turned on (while the elapsed time is
displayed) and hold for 3 seconds. The
elapsed time is reset. After this operation,
"0h" is displayed for 1 second.
2) When the set time is changed, the elapsed
time is reset to "0h".
5. Demo-mode
1) In the demo-mode, the time is set to 250h,
the elapsed time is set to 240h, and
replacement of oil is displayed when the
key is turned on. The elapsed time does
not increase, however. The time can be
reset in this mode. Turn on the key 3
times in this mode, and the time interval
is automatically set to "Not set" at the 4th
time and after. The elapsed time is set to
"0h" and counting of elapsed time is
started.
PC200-7 10-207
12
Mode selector switches
1. Travel speed switch

2. Auto-deceleration switch
3. Wiper switch
4. Work mode selector switch
• There are 4 sets of the mode selector Operations table of switch section
switches on the switch section. Each time one
switch is pressed, the machine condition ★ The bold letters are the positions of the
changes. The current condition is indicated switches reset when the starting switch is
by the lighting of the LED above the switch. turned on.
• The initial setting of only the work mode after Item Operation
the starting switch is turned on can be
changed. Work mode A↔E↔B
★ For how to change the setting, see "Work Auto-deceleration ON↔OFF
mode default setting mode" in TROUBLE-
SHOOTING-Display and special functions of Wiper OFF↔Intermittent↔ON
monitor panel.
Travel speed Hi↔Lo
10-208 PC200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SENSOR
SENSOR
• The signals from the sensors are input to the
panel directly. Either side of a sensor of con-
tact type is always connected to the chassis
ground.
Sensor When When

Type of sensor
name normal abnormal
Engine oil ON OFF

Contact
level (Closed) (Open)
Engine oil OFF ON

Contact
pressure (Open) (Closed)
Hydraulic
oil tempera- Resistance — —
ture
Coolant
Resistance — —
temperature
Fuel level Resistance — —
Air cleaner OFF ON

Contact
clogging (Closed) (Open)
PC200-7 10-209
12
Engine oil level sensor
1. Connector
2. Bracket
3. Float
4. Switch
Engine oil pressure sensor (For low pressure)
1. Plug
2. Contact ring
3. Contact
4. Diaphragm
5. Spring
6. Terminal
Coolant temperature sensor

Hydraulic oil temperature sensor
1. Thermistor 4. Tube
2. Body 5. Wire
3. Tube 6. Connector
10-210 PC200-7
12
Fuel level sensor
1. Float
2. Connector
3. Cover
4. Variable resistor
Air cleaner clogging sensor
PC200-7 10-211
90 OTHERS
Hydraulic Circuit Diagram

PC200-7, PC200LC-7. . . . . . . . . . . . 90-3
PC220-7, PC220LC-7. . . . . . . . . . . . 90-5
Electrical Circuit Diagram (1/5)
PC200-7, PC200LC-7. . . . . . . . . . . . 90-7
PC220-7, PC220LC-7. . . . . . . . . . . . 90-9
Electrical Circuit Diagram (2/5). . . . . 90-11
Electrical Circuit Diagram For Air
Conditioner . . . . . . . . . . . . . . . . . . . . 90-19
PC200-7 90-1
OTHERS HYDRAULIC CIRCUIT DIAGRAM
HYDRAULIC CIRCUIT DIAGRAM

PC200-7, PC200LC-7
PC200-7 90-3

PC220-7, PC220LC-7
PC200-7 90-5
OTHERS ELECTRICAL CIRCUIT DIAGRAM (1/5)
ELECTRICAL CIRCUIT DIAGRAM (1/5)

FOR MULTI MONITOR
PC200-7, PC200LC-7
PC200-7 90-7

FOR MULTI MONITOR
PC220-7, PC220LC-7
PC200-7 90-9

FOR MULTI MONITOR
PC200-7, PC200LC-7
PC220-7, PC220LC-7
PC200-7 90-11

FOR MULTI MONITOR
PC200-7, PC200LC-7
PC220-7, PC220LC-7
PC200-7 90-13

FOR MULTI MONITOR
PC200-7, PC200LC-7
PC220-7, PC220LC-7
PC200-7 90-15

FOR MULTI MONITOR
PC200-7, PC200LC-7
PC220-7, PC220LC-7
PC200-7 90-17
OTHERS ELECTRICAL CIRCUIT DIAGRAM FOR AIR CONDITIONER
ELECTRICAL CIRCUIT DIAGRAM FOR AIR CONDITIONER
PC200-7 90-19
METHOD OF CHECKING STATUS

MAINTENANCE ITEMS

screen.
1. Press maintenance switch (1) and switch to
the maintenance list display screen.
★ The maintencance items are displayed as
symbols on the screen.
to input the number (01 - 10) of the mainte-
nance item to select the item.
★ The cursor moves and the item is high-
lighted.
★ The display method is the same as
described on the previous page (relation-
ship between remaining time and caution
display). If the remaining time is less than
30 hours, the item is displayed in yellow,
and if it is less than 0 hours, it is displayed
in red.
MAINTENANCE OPERATION
1. After completing the selection, press input

confirmation switch (3).
The screen will change to the maintenance
reset screen.
2. Use the maintenance reset screen to check
the content, and if there is any problem, press
input confirmation switch (3) to move to the
check screen.
If the wrong item is selected, press return
switch (4) to return to the maintenance list
screen.
3. Check the content on the check screen, and if
there is no problem, press input confirmation
switch (3) to reset the maintenance time.
After the reset is completed, the screen
returns to the maintenance list display
screen. To check the remaining time, or if the
wrong item is selected, press return switch (4)
to return to the maintenance list screen.
★ The check screen shows the symbol for
the maintenance item and the set time in
large letters.
★ The background color of the symbol for
the item where the maintenance tiem was
reset is the same as the background of the
screen, so it is possible to check that it has
been reset.
PC200-7 10-195
BRIGHTNESS, CONTRAST ADJUSTMENT

FUNCTION
This function is used to adjust the brightness and

contrast of the display.
ADJUSTMENT METHOD

screen.
1. Press display brightness/contrast adjustment
switch (1) and switch to the adjustment
screen.
★ Relationship between menu symbol and con-
tent.
No. Symbol Content
01 Return mark Return
02 Contrast
03 Brightness

to input the number (00 - 02) to select either
contrast or brightness.
After completing the selection, press input
confirmation switch (3) and return to the
adjustment screen.
Then press return switch (4) or use the 10-key
pas to set to [00] and press input confirmation
switch (3) to return to the normal screen.
3. Press control switch (2) and adjust the bright-
ness and contrast as desired.
Control switch Actuation

extends to the right

retracts to the left 08937
10-196 PC200-7
PASSWORD FUNCTION
• If a passport is input, the engine will not start

unless the password is input correctly when
starting.
• When setting this function or when changing 08941
the password, it is necessary to go from the
normal screen to the setting screen and input
the password.
This becomes posssible 10 minutes after the
starting switch is turned ON and the monitor
screen has changed to the normal screen.
METHOD OF SETTING, CHANGING

PASSWORD
1. Turn the starting switch ON, keep starting

switch (2) pressed, use the 10-key pad to input
7 → 2 → 9 → 7 → 2 → 9 in succession, and the
screen will change to the 8-digit numeral
input screen.
2. On the input screen, use the 10-key pad to

input an 8-digit number [19210513]. When the
final digit [number 3] is input, the screen will
change to the Valid/Invalid screen for the
password function.
PC200-7 10-197
3. Press control switch (1) or (2) to set to Valid/

Invalid.
The diagram on the right shows the screen
when control switch (1) is pressed and the
screen is set to [Valid].
If [Invalid] is selected and input confirmation

will be made invalid, and the screen will
return to the normal screen.
If [Valid] is selected and input confirmation
will be made valid, and the screen will change
to the screen for inputting the 4-digit number.
08942
4. Input a 4-digit number on the input screen

(the lock and key symbol are displayed), then
press input confirmation switch (3).
When the input confirmation switch is
pressed, you will be requested to input the
same 4-digit number again, so input the same
4-digit number, then press input confirmation
switch (3) to confirm the password.
Numerals 1 and 2 are displayed at the top
right corner of the screen to distinguish
between the 1st input screen and the 2nd
input screen.
When the password is confirmed, the screen
will return to the normal screen.
★ If the number input the second time is dif-
ferent from the number input the first
time, the password will not be confirmed
and the screen will return to the first
screen, so input the same 4-digit pass-
word 2 times in succession.
10-198 PC200-7
SERVICE METER CHECK FUNCTION
• When the starting switch is at the OFF posi-

tion, keep return switch (1) and control switch
(2) of the monitor pressed at the same time,
and the service meter is shown on the dis-
play.
• This display is shown only while the two
switches are being pressed. When the
switches are released, the display goes out.
Note that it takes 3 - 5 seconds after the
switches are pressed for the service meter
display to appear.
DISPLAY LCD CHECK FUNCTION
• On the password input screen or on the nor-

mal screen, if monitor return switch (1) and
working mode (A) switch are kept pressed at
the same time, all the LCD display will light 08943
up and the whole screen will become white,
so the display can be checked.
• If any part of the display is black, the LCD is
broken.
PC200-7 10-199
USER CODE DISPLAY FUNCTION
• If there is any problem in operating the

machine, the user code is displayed on the
monitor to advise the operator of the steps to
take.
This code display appears on the operator
screen.
• On the operator screen, the user code is dis-
played on the portion for the hydraulic oil
temperature gauge.
• If more than one user code is generated at the

same time, the user codes are displayed in
turn for 2 seconds each to display all the user
codes.
08945
10-200 PC200-7
• While the user code is being displayed, if the

input confirmation switch is pressed, the ser-
vice code and failure code can be displayed.
08946
• If there is more than one service code or fail-

ure code, the display switches every 2 sec-
onds and displays all the service codes/failure
codes that caused the user code to be dis-
played.
Even if service codes/failure codes have 08947
occurred, if they did not cause the user code
to be displayed, this function does not display
them.
• If the telephone number has been set using

the telephone number input on the service
menu, it is possible to switch on the service
code/failure code and display the telephone
symbol and telephone number.
For details of inputting and setting the tele- 08948
phone number, see SPECIAL FUNCTIONS OF
MONITOR PANEL in the TESTING AND
ADJUSTING section.
PC200-7 10-201
7-SEGMENT MONITOR SYSTEM
SJP08775
OR
08931
• The monitor system monitors the condition • The monitor panel also has various mode
of the machine with sensors installed on vari- selector switches and functions to operate the
ous parts of the machine. It processes and machine control system.
immediately displays the obtained informa-
tion on the panel notifying the operator of the
condition of the machine.
The panel is roughly divided as follows.
1. Monitor section to output alarms when
the machine has troubles
2. Gauge section to display the condition
constantly (Coolant temperature, hydrau-
lic oil temperature, fuel level, etc.)
10-202 PC200-7
12
1. Monitor panel
OUTLINE INPUT AND OUTPUT SIGNALS

CN-P01 CN-P02
• The monitor panel has the functions to dis-
play various items and the functions to select Pin Pin
Signal neme Signal Name
No. No.
modes and electric parts.
1 Key switch (Battery) 1 Engine water temperature
The monitor panel has a CPU (Central Pro- 2 Key switch (Battery) 2 Fuel
cessing Unit) in it to process, display, and out-
3 Washer motor output 3 Radiator water level
put the information.
4 Key switch (Terminal C) 4 NC
The monitor display unit consists of LCD (Liq-
5 Wiper contact W 5 Air cleaner clogging sensor
uid Crystal Display) and LED (Light Emitting
6 GND 6 NC
Diode). The switches are flat sheet switches.
7 GND 7 Engine oil pressure sensor
8 VB + (24 V) 8 Engine oil level sensor
9 Wiper motor (+) 9 Network signal
10 Wiper motor (-) 10 Network signal
11 (Buzzer ON signal input) 11 Charge level
12 Wiper contact P 12 NC
13 GND (For analog signal)
14 NC
15 Wind limit switch
16 Buzzer cancel
17 Swing lock
18 Preheating
19 Limit switch
20 Network (GND)
PC200-7 10-203
Display section of monitor
1. Service meter display

2. Coolant temperature gauge
3. Coolant temperature caution
4. Digital meter display (Service code and user
code are displayed when trouble occurs
5. Fuel level caution
6. Fuel level gauge
7. Engine oil level caution lamp
8. Preheating pilot lamp
9. Swing holding brake pilot lamp
10. Oil maintenance pilot lamp
11. Battery charge caution lamp
12. Air cleaner clogging caution lamp
13. Engine oil pressure caution lamp
10-204 PC200-7
Monitored items and display

When engine is
Symbol Displayed item Display range While engine is running
stopped
Max. 1,500 rpm Lights when normal.
Max. 0.05 MPa (Goes off when
{0.5 kg/cm²} engine is started.) Flashes and buzzer
Engine oil pressure
Min. 1,500 rpm sounds when abnormal.
Max. 0.15 MPa
{1.5 kg/cm²}
Air cleaner clogging When clogged Goes off. Flashes when abnormal.
SAP00521
Lights when normal.

When charge is (Goes off when
Charge level engine is started.) Flashes when abnormal.
abnormal
Flashes when abnor-

Engine oil level Below low level Goes off.
SAP00523
mal.
When swing is Lights up when swing is locked. Flashes when

Packing (Swing lock)
locked swing holding brake release switch is turned on.
SAT00098
Oil maintenance See "OIL MAINTENANCE FUNCTION" on next page.
Lights up for 30 sec. when starting switch is set

Preheating When preheated to HEAT. Then, flashes for 10 sec. to indicated
SAP00526 completion of preheating.
Flashes at 102°C or higher. Flashes and

Coolant temperature
buzzer sounds at 105°C or higher.
Fuel level Flashes when below low level.
PC200-7 10-205
12
Oil maintenance function
1. Function and operation

At a set time after the engine oil is replaced, the
oil maintenance function is turned on to notify
the operator by the LED lamp on the monitor
panel that it is time to replace the oil. The func-
tion to indicate the phone number of the place to
make contact for service on the LCD unit is
installed, too.
1) Check of elapsed time

Nothing is displayed normally until point
B shown in the figure at right after this
function is reset. If the key is turned on
with the buzzer cancel switch processed
(for 2.5 seconds), however, the elapsed
time is displayed on the service meter
section.
2) Display of replacement of oil
If time passes point B after this function is
reset, the elapsed time is displayed on the
service meter section and the LED flashes
when the key is turned on.
2. Setting of time interval

1) The time interval is set in the interval set-
ting mode. It can be set to "125h", "250h",
"500h", "Not set", or "Demo-mode". The
default is "Not set".
2) To enter the interval setting mode, press
and hold the clock switch for 2.5 seconds.
3) If the buzzer cancel switch is pressed in
the interval setting mode, the clock dis-
play section changes to "—" → "125" →
"250" → "500" → " d" in order. ("—" corre-
sponds to "Not set" and " d" corresponds
to "Demo-mode".)
4) To save the time interval, set a desired
time (mode) on the monitor panel and
press and hold the clock switch for 2.5
seconds.
10-206 PC200-7
12
3. Timing and contents of display

1) When replacement of oil is displayed
Phone number is displayed for the next 10
seconds.
If the phone number has not been input,
however, the elapsed time is displayed for
20 seconds after all segments are turned
on.
2) When elapsed time is checked
4. Resetting elapsed time

1) When the replacement of oil and elapsed
time are displayed, press the buzzer can-
cel switch 10 seconds after all segments
are turned on (while the elapsed time is
displayed) and hold for 3 seconds. The
elapsed time is reset. After this operation,
"0h" is displayed for 1 second.
2) When the set time is changed, the elapsed
time is reset to "0h".
5. Demo-mode
1) In the demo-mode, the time is set to 250h,
the elapsed time is set to 240h, and
replacement of oil is displayed when the
key is turned on. The elapsed time does
not increase, however. The time can be
reset in this mode. Turn on the key 3
times in this mode, and the time interval
is automatically set to "Not set" at the 4th
time and after. The elapsed time is set to
"0h" and counting of elapsed time is
started.
PC200-7 10-207
12
Mode selector switches
1. Travel speed switch

2. Auto-deceleration switch
3. Wiper switch
4. Work mode selector switch
• There are 4 sets of the mode selector Operations table of switch section
switches on the switch section. Each time one
switch is pressed, the machine condition ★ The bold letters are the positions of the
changes. The current condition is indicated switches reset when the starting switch is
by the lighting of the LED above the switch. turned on.
• The initial setting of only the work mode after Item Operation
the starting switch is turned on can be
changed. Work mode A↔E↔B
★ For how to change the setting, see "Work Auto-deceleration ON↔OFF
mode default setting mode" in TROUBLE-
SHOOTING-Display and special functions of Wiper OFF↔Intermittent↔ON
monitor panel.
Travel speed Hi↔Lo
10-208 PC200-7
SENSOR
• The signals from the sensors are input to the
panel directly. Either side of a sensor of con-
tact type is always connected to the chassis
ground.
Sensor When When

Type of sensor
name normal abnormal
Engine oil ON OFF

Contact
level (Closed) (Open)
Engine oil OFF ON

Contact
pressure (Open) (Closed)
Hydraulic
oil tempera- Resistance — —
ture
Coolant
Resistance — —
temperature
Fuel level Resistance — —
Air cleaner OFF ON

Contact
clogging (Closed) (Open)
PC200-7 10-209
12
Engine oil level sensor
1. Connector
2. Bracket
3. Float
4. Switch
Engine oil pressure sensor (For low pressure)
1. Plug
2. Contact ring
3. Contact
4. Diaphragm
5. Spring
6. Terminal
Coolant temperature sensor

Hydraulic oil temperature sensor
1. Thermistor 4. Tube
2. Body 5. Wire
3. Tube 6. Connector
10-210 PC200-7
12
Fuel level sensor
1. Float
2. Connector
3. Cover
4. Variable resistor
Air cleaner clogging sensor
PC200-7 10-211
90 OTHERS
Hydraulic Circuit Diagram

PC200-7, PC200LC-7. . . . . . . . . . . . 90-3
PC220-7, PC220LC-7. . . . . . . . . . . . 90-5
Electrical Circuit Diagram (1/5)
PC200-7, PC200LC-7. . . . . . . . . . . . 90-7
PC220-7, PC220LC-7. . . . . . . . . . . . 90-9
Electrical Circuit Diagram For Air
Conditioner . . . . . . . . . . . . . . . . . . . . 90-19
PC200-7 90-1

PC200-7, PC200LC-7
PC200-7 90-3

PC220-7, PC220LC-7
PC200-7 90-5

FOR MULTI MONITOR
PC200-7, PC200LC-7
PC200-7 90-7

FOR MULTI MONITOR
PC220-7, PC220LC-7
PC200-7 90-9

FOR MULTI MONITOR
PC200-7, PC200LC-7
PC220-7, PC220LC-7
PC200-7 90-11

FOR MULTI MONITOR
PC200-7, PC200LC-7
PC220-7, PC220LC-7
PC200-7 90-13

FOR MULTI MONITOR
PC200-7, PC200LC-7
PC220-7, PC220LC-7
PC200-7 90-15

FOR MULTI MONITOR
PC200-7, PC200LC-7
PC220-7, PC220LC-7
PC200-7 90-17
OTHERS ELECTRICAL CIRCUIT DIAGRAM FOR AIR CONDITIONER
ELECTRICAL CIRCUIT DIAGRAM FOR AIR CONDITIONER
PC200-7 90-19

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SEBM024300

PC200LC-7 00 200001 AND UP 00

PC220-7 00 60001 AND UP 00

PC220LC-7 00 60001 AND UP 00

10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD. 10-1

20 TESTING AND ADJUSTING . . . . . . . . . . . . Will Be Issued 10-25-2001

30 DISASSEMBLY AND ASSEMBLY . . . . . . . . Will Be Issued 12-15-2001

IMPORTANT SAFETY NOTICE

GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

HOW TO READ THE SHOP MANUAL REVISED EDITION MARK

Chassis volume: Issued for every machine model REVISIONS

DISTRIBUTION AND UPDATING

¤ Heavy parts (25 kg or more) must be lifted

• If a part cannot be smoothly removed from the

★ The allowable load value is estimated to be one-

2) Sling wire ropes from the middle portion of the

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

¤ Before carrying out the following work, release

For details, see TESTING AND ADJUSTING,

Even if the residual pressure is released from

2) Hold adapter (1) and push hose joint (2) into

3) After hose joint (2) is pushed into adapter (3),

4) Hold hose adapter (1) or hose (5) and pull it out.

2) After inserting the hose in the mating adapter

• Used to prevent rubber gaskets,

• Used in places requiring an imme-

• Features: Resistance to heat and

Adhesive: • Used as adhesive or sealant for

Polyethylene • Used as sealant for machined

Holtz • Used as heat-resisting sealant for

• Quick hardening type adhesive

• Quick hardening type adhesive

Loctite Polyethylene • Resistance to heat, chemicals

• Used as adhesive or sealant for

• Used as sealant for various

• Features: Silicon based, resist-

• Features: Silicon based, quick

Three bond • Used as heat-resisting sealant for

• Used as lubricant for sliding por-

SYG2-400LI • General purpose type

SYG2-400CA • Used for normal temperature,

Molybdenum 400 g • Used for places with heavy load

STANDARD TIGHTENING TORQUE

Thread diameter Width across

6 10 13.2 0 1.4 1.35 0 0.15

27 41 1320 0 140 135 0 15

Thread diameter Width across

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

Thread diameter Width across flat Tightening torque

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

Thread diameter Width across flat Tightening torque

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

Thread diameter Width across flat Tightening torque

TIGHTENING TORQUE FOR 102 ENGINE SERIES (BOLT AND NUTS)

Thread diameter Tightening torque

TIGHTENING TORQUE FOR 102 ENGINE SERIES (EYE JOINTS)

Thread diameter Tightening torque

TIGHTENING TORQUE FOR 102 ENGINE SERIES (TAPERED SCREWS)

Thread diameter Tightening torque